Oc t obe r 2 0 0 7 SERVICE M ANUAL SERVICE M ANUAL L2 A, L2 C, L2 E, L3 A, L3 C, L3 E Pub. No. Pub. No. 99619-16120 99619-16120 Printed in Japan L2 A, L2 C, L2 E L3 A, L3 C, L3 E Oc t obe r 2 0 0 7 Pub. No.
INTRODUCTION This service manual describes the specifications, maintenance and service procedures for Mitsubishi diesel engines. To maintain the performance of the engine for many years and to ensure safe operation, it is important to use the engine correctly and conduct regular inspection and maintenance, and also to take necessary measures which involves the disassembly, inspection, repair and reassembly of the engine and engine parts.
INTRODUCTION How to use this manual This service manual consists of several Groups, which are arranged so as to allow you to make reference quickly to specifications, maintenance standards, adjustment procedures and service procedures including methods for disassembly, inspection, repair and reassembly of the Mitsubishi Diesel Engine (standard model for land use).
INTRODUCTION Terms used in this manual Nominal means the rated (design) size or magnitude of a part to be measured. Standard means the quantitative requirement for dimension of a part, clearance between parts and performance. This is given in a form of tolerance. Therefore, the values shown are not in agreement with the design values. Limit means that, if this value is reached, the part must be repaired or replaced with a new part.
INTRODUCTION Safety Cautions :$51,1* Fire and explosion Keep flames away Care about fuel, oil and exhaust gas leakage Store fuel and engine oil in a well ventilated designated area. Make sure that the caps of fuel and engine oil containers are tightly closed. Do not use flames, do not smoke, and do not work near a heater or other fire hazard where fuel or oil is handled or when cleaning solvent is being used for washing parts. Wipe off spilled fuel, oil and LLC immediately and thoroughly.
INTRODUCTION :$51,1* Stay clear of all rotating and moving parts Install protective covers on rotating parts Lockout and Tagout Make sure the protective covers for engine rotating parts are properly installed as intended. Repair loose or damaged protective covers as necessary. Never remove the covers guarding personnel from rotating parts, when the engine is operating.
INTRODUCTION :$51,1* Be careful of burns Do not touch the engine during or immediately after operation Do not touch the engine during or immediately after operation to avoid risk of burns. To conduct maintenance and inspection work, wait until the engine has cooled sufficiently, checking the temperature gauge. Slowly and carefully open radiator cap Never attempt to open the radiator cap while the engine is running or immediately after the engine stops.
INTRODUCTION :$51,1* Be careful of falling down Lift engine correctly To lift the engine, always use a correct wire rope capable of withstanding the engine weight. Attach the wire rope to the lifting hangers provided on the engine using a correct sling. During lifting process, keep the engine in a well-balanced position by taking the center of gravity of the engine into consideration.
INTRODUCTION &$87,21 &$87,21 Service battery When abnormality occurs Handle the battery correctly Stop overheated engine after cooling run • Never use flames or allow sparks to generate near the battery. The battery releases flammable hydrogen gas and oxygen gas. Any flames or sparks in the vicinity could cause an explosion. • Do not use the battery the fluid level of which is lowered below the lower limit line. Sustained use of the battery could result in an explosion.
INTRODUCTION &$87,21 Other cautions Modification of engine prohibited Warming-up operation Unauthorized modification of the engine will void the manufacturer’s warranty. Modification of the engine may not only cause engine damage but also produce personal injuries. After starting the engine, run the engine at low idling speeds for 5 to 10 minutes for warming-up. Start the work after this operation is completed. Warm-up operation circulates the lubricant through the engine.
INTRODUCTION problems such as an increase of oil consumption, decrease of output, and starting difficulties. For effective removal of dust from intake air, conduct maintenance of the air cleaner according to the following instructions. • Do not conduct maintenance of the air cleaner/precleaner while the engine is operating. Engine operation without the air cleaner/precleaner in place allows foreign matters to enter the turbocharger, causing it to damage seriously.
INTRODUCTION &$87,21 About warning labels Maintenance of warning labels Make sure all warning/caution labels are legible. Clean or replace the warning/caution labels when the description and/or illustration are not clear to read. For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvents, gasoline or other chemicals to prevent the letters from getting blurred or the adhesion from being weakened. Replace damaged or fractured labels with new ones.
GENERAL CONTENTS Group Name Contents Group No.
GENERAL 1. External view...................................1-2 1.1 External view of L2A, L2C and L2E ......... 1-2 1.2 External view of L3A, L3C and L3E ......... 1-3 2. System flow diagrams .....................1-4 2.1 2.2 2.3 2.4 Fuel system - flow diagram ...................... 1-4 Lubrication system - flow diagram ........... 1-4 Cooling system - flow diagram................. 1-5 Inlet and exhaust system - flow diagram.. 1-5 3. Engine serial number location.........1-6 4.
GENERAL 1. External view 1.
GENERAL 1.
GENERAL 2. System flow diagrams 2.1 Fuel system - flow diagram Fuel leak-off pipe Fuel injection nozzle Fuel injection pipe To fuel tank From fuel pump Fuel filter Fuel injection pump Fuel system - flow diagram 2.
GENERAL 2.3 Cooling system - flow diagram Water pump Water bypass pipe Thermostat Radiator Cooling fan Cooling system - flow diagram 2.
GENERAL 3. Engine serial number location The engine serial number is stamped on the injection pump mount (upper side of tie rod cover) of the cylinder block. Engine serial number Stamp location of engine serial number 4. Indication of engine model and total displacement The engine type and displacement are stamped on the side of the injection pump mount of the cylinder block.
GENERAL 5. Specifications 5.1 Specifications of L2A, L2C and L2E Table 1-1 Specifications of L2A, L2C and L2E (1 / 4) Engine model L2A Type Main specifications L2C L2E Vertical type, water-cooled, 4 cycle diesel No. of cylinders 2 Combustion type Swirl chamber type Valve mechanism Overhead valve type Cylinder bore × stroke 65 × 70 mm [2.56 × 2.76 in.] Total displacement 0.464 L 0.538 L 0.635 L [0.126 U.S. gal.] [0.142 U.S. gal.] [0.168 U.S. gal.
GENERAL Table 1-1 Specifications of L2A, L2C and L2E (2 / 4) Engine model L2A Lubrication system Engine oil Lubrication system Speci fication API service category CF and CF-4 Capacity (engine total) Upper limit: 2.0 L [0.53 U.S. gal]/ Lower limit: 1.2 L [0.32 U.S. gal] (Upper limit: 2.5 L [0.66 U.S.gal]/ Lower limit: 1.7 L [0.45 U.S.
GENERAL Table 1-1 Specifications of L2A, L2C and L2E (3 / 4) Engine model L2A Voltage - polarity L2C L2E 12V - negative (-) ground, 24V - negative (-) ground Type Manufacturer Pinion engagement type M000T60481 Mitsubishi Electric Corporation Pinion shift (reduction type) Starter (1) Output 12V - 1.2 kW Number 1 Pinion/ring gear ratio Type Manufacturer Pinion engagement type 14/106 M001T68381 Mitsubishi Electric Corporation Pinion shift (reduction type) Starter (2) Output 12V - 1.
GENERAL Table 1-1 Specifications of L2A, L2C and L2E (4 / 4) Engine model L2A Working voltage Stop solenoid (1) Insulation resistance Stroke Ambient temperature for use Working voltage Stop solenoid (2) Insulation resistance Stroke Ambient temperature for use Electrical system Working voltage Stop solenoid (3) Insulation resistance Stroke Ambient temperature for use Working voltage Stop solenoid (4) Insulation resistance Stroke Ambient temperature for use 1-10 L2C L2E 12V - ETR: 8V or less 10
GENERAL 5.2 Specifications of L3A, L3C and L3E Table 1-2 Specifications of L3A, L3C and L3E (1 / 4) Engine model L3A Type Main specifications L3C L3E Vertical type, water-cooled, 4 cycle diesel No. of cylinders 3 Combustion type Swirl chamber type Valve mechanism Overhead valve type Cylinder bore × stroke 65 × 70 mm 70 × 70 mm [2.56 × 2.76 in.] [2.76 × 2.76 in.] 76 × 70 mm [2.99 × 2.76 in.] Total displacement 0.696 L 0.808 L [0.184 U.S. gal.] [0.213 U.S. gal.] 0.952 L [0.251 U.S. gal.
GENERAL Table 1-2 Specifications of L3A, L3C and L3E (2 / 4) Engine model Lubrication system Capacity (engine total) Lubrication system Type Oil pump Discharge rate Type Relief valve Valve opening pressure Oil filter Type Cooling system L3E API service category CF and CF-4 Upper limit: 3.1 L [0.82 U.S. gal]/ Lower limit: 1.8 L [0.48 U.S. gal] (Upper limit: 3.6 L [0.95 U.S. gal]/ Lower limit: 2.3 L [0.61 U.S. gal]) Upper limit: 4.2 L [1.11 U.S. gal]/ Lower limit: 3.0 L [0.79 U.S. gal] (Upper limit: 4.
GENERAL Table 1-2 Specifications of L3A, L3C and L3E (3 / 4) Engine model Voltage - polarity L3A L3C L3E 12V - negative (-) ground, 24V - negative (-) ground Type Manufacturer Pinion engagement type M000T60481 Mitsubishi Electric Corporation Pinion shift (reduction type) Starter (1) Output 12V - 1.2 kW Number 1 Pinion/ring gear ratio 14/106 Type Manufacturer Pinion engagement type M001T68381 Mitsubishi Electric Corporation Pinion shift (reduction type) Starter (2) Output 12V - 1.
GENERAL Table 1-2 Specifications of L3A, L3C and L3E (4 / 4) Engine model Working voltage Stop solenoid (1) Insulation resistance Stroke Ambient temperature for use Working voltage Stop solenoid (2) Insulation resistance Stroke Ambient temperature for use Electrical system Working voltage Stop solenoid (3) Insulation resistance Stroke Ambient temperature for use Working voltage Stop solenoid (4) Insulation resistance Stroke Ambient temperature for use 1-14 L3A L3C L3E 12V - ETR: 8V or less 100
GENERAL 6. Tips on disassembling and reassembling This service manual specifies the recommended procedures to be followed when servicing Mitsubishi engines. The manual also specifies the special tools that are required for the work, and the basic safety precautions to follow when working. Note that this manual does not exhaustively cover potential hazards that could occur during maintenance, inspection and service work of engine.
SERVICE DATA 1. Maintenance service data ...............2-2 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Engine general......................................... 2-2 Basic engine ............................................ 2-2 Fuel system.............................................. 2-5 Lubrication system ................................... 2-6 Cooling system ........................................ 2-6 Inlet/Exhaust system................................ 2-6 Electrical system ......................................
SERVICE DATA 1. Maintenance service data 1.1 Engine general Table 2-1 Maintenance service data table - Engine general Inspection point Nominal Maximum rotation speed (rated rotation speed used as reference) Standard Limit Unit: mm [in.] Remark (Varies depending on specification of destination) Adjusted by the governor. Minimum rotation speed 2.7 MPa {28 kgf/cm²} [398 psi] -1 Compression pressure (at 280 min ) Not acceptable at or below 2.2 MPa {22 kgf/cm²} [313 psi] 0.29 to 0.
SERVICE DATA Table 2-2 Maintenance service data table - Basic engine(2 / 4) Inspection point Valve seat angle Nominal Standard Unit mm [in.] Limit Remark 44° Seat width 0.5 [0.0197] Valve sinkage Valve seat and valve 0.4 to 0.6 [0.0158 to 0.0236] 1.0 [0.0394] Valve margin Valve guide mounting length 14 [0.5516] Valve margin 38.5 [1.516] ǰ ٌ Squareness Valve Valve sinkage seat angle 13.5 to 14.5 [0.5319 to 0.5516] 40 [1.57] Free length 0.5 [0.0197] Lf θ=2° Δ=1.4 [0.055] Lf=40 [1.
SERVICE DATA Table 2-2 Maintenance service data table - Basic engine(3 / 4) Inspection point L2A L3A Outside diameter L2C L3C L2E L3E Nominal Standard STD ø 65 [2.559] 64.919 to 64.939 [2.5559 to 2.5566] 0.25 OS ø 65.25 [2.569] 65.169 to 65.189 [2.5657 to 2.5665] 0.50 OS ø 65.50 [2.579] 65.419 to 65.439 [2.5755 to 2.5763] STD ø 70 [2.756] 69.913 to 69.933 [2.7525 to 2.7533] 0.25 OS ø 70.25 [2.766] 70.163 to 70.183 [2.7623 to 2.7631] 0.50 OS ø 70.50 [2.776] 70.413 to 70.433 [2.
SERVICE DATA Table 2-2 Maintenance service data table - Basic engine(4 / 4) Inspection point Nominal Standard Journal outside diameter (STD) ø 43 [1.69] 42.965 to 42.980 [1.6915 to 1.6921] Pin outside diameter (STD) ø 40 [1.57] 39.965 to 39.980 [1.5734 to 1.5740] Runout Crankshaft Unit mm [in.] Limit -0.70 [-0.0276] 0.06 [0.0024] or less 0.030 to 0.075 [0.0012 to 0.0030] 0.10 [0.0039] Clearance between connecting rod bearings 0.028 to 0.071 [0.0011 to 0.0028] 0.150 [0.0059] End play 0.
SERVICE DATA 1.4 Lubrication system Table 2-4 Maintenance service data table - Lubrication system Inspection point Unit: mm [in.] Nominal Standard Limit Remark Clearance between oil pump housing inside diameter and oil pump outer gear outside diameter ø 75.5 [2.972] 0.100 to 0.196 [0.0039 to 0.0077] 0.3 [0.012] Replace Clearance between oil pump outer gear width and oil pump housing 10 [0.04] 0.040 to 0.100 [0.0016 to 0.0039] 0.25 [0.
SERVICE DATA 1.7 Electrical system Table 2-7 Maintenance service data table - Electrical system(1 / 3) Inspection point Nominal 16.5 [0.650] 10.0 [0.394] 17.5 to 23.7 N {1.78 to 2.42 kgf} [3.92 to 5.34 lbf] 6.86 N {0.70 kgf} [1.54 lbf] Commutator radial runout 0.03 [0.0012] 0.10 [0.0039] Commutator outside diameter ø 29.4 [1.158] ø 28.8 [1.134] 0.5 to 1.0 [0.0197 to 0.0394] 0.2 [0.0079] or less Brush length 20.58 N {2.10 kgf} [4.
SERVICE DATA Table 2-7 Maintenance service data table - Electrical system(2 / 3) Inspection point Nominal 0.5 to 2.0 [0.0197 to 0.0787] Pinion gap 18 [0.709] 11 [0.4331] 28.9 to 39.1 N {2.95 to 3.99 kgf} [6.5035 to 8.7963 lbf] 20 N {2.04 kgf} [4.4974 lbf] Commutator radial runout 0.03 [0.0012] 0.10 [0.0039] Commutator outside diameter ø 32.0 [1.2598] ø 31.4 [1.2362] 0.4 to 0.6 [0.0158 to 0.0236] 0.2 [0.0079] or less Brush length 34 N {3.
SERVICE DATA Table 2-7 Maintenance service data table - Electrical system(3 / 3) Inspection point Nominal Clearance of stop solenoid to plunger rack Standard ETR ETS 0.3 to 0.7 [0.0118 to 0.0276] 0.15 to 0.20 [0.0059 to 0.0079] 12 V 0.2 Ω 24 V 4.5 Ω Resistance value of glow plug Unit: mm [in.
SERVICE DATA 2. List of tightening torque 2.1 Major bolts and nuts tightening torque 2.1.1 Basic engines Table 2-8 Tightening torque list - Basic engines Threads Dia × Pitch (mm) N·m kgf·m lbf·ft Main M10 × 1.25 73.5 to 83.4 7.5 to 8.5 54.2 to 61.5 Sub M8 × 1.25 19.6 to 29.4 2.0 to 3.0 14.5 to 21.7 Description Torque Remark Cylinder head bolt Rocker cover nut M6 × 1.0 4.9 to 6.9 0.5 to 0.7 3.6 to 5.1 Rocker stay bolt M8 × 1.25 14.7 to 21.6 1.5 to 2.2 10.8 to 15.
SERVICE DATA 2.1.3 Lubrication system Table 2-10 Tightening torque list - Lubrication system Threads Dia × Pitch (mm) N·m kgf·m lbf·ft Oil relief valve M18 × 1.5 39.2 to 49.0 4.0 to 5.0 28.9 to 36.2 Oil pan drain plug M18 × 1.5 49.0 to 58.8 5.0 to 6.0 36.2 to 43.4 Oil pressure switch PT1/8 7.85 to 11.8 0.8 to 1.2 5.8 to 8.7 M6 × 1.0 7.8 to 9.8 0.8 to 1.0 5.8 to 7.2 Description Oil pump 2.1.
SERVICE DATA 2.2 Standard bolt and nut tightening torque Table 2-14 Standard bolt and nut tightening torque Description Threads Dia × Pitch (mm) Width across flats (mm) [in.] Strength classification 7T 10.9 7 Metric automobile screw thread Metric course screw thread 10 N·m kgf·m lbf·ft N·m kgf·m lbf·ft M8 × 1.25 12 [0.47] 17 1.7 13 30 3.1 22 M10 × 1.25 14 [0.55] 33 3.4 24 60 6.1 44 M12 × 1.25 17 [0.67] 60 6.1 44 108 11.0 80 M14 × 1.5 22 [0.87] 97 9.9 72 176 17.
SERVICE DATA 2.3 Standard eyebolt tightening torque Table 2-15 Standard eyebolt tightening torque Threads Dia × Pitch (mm) Width across flats (mm) [in.] M8 × 1.25 Strength classification 4T N·m kgf·m lbf·ft 12 [0.47] 8±1 0.8 ± 0.1 6 ± 0.7 M10 × 1.25 14 [0.55] 15 ± 2 1.5 ± 0.2 11 ± 1.5 M12 × 1.25 17 [0.67] 25 ± 3 2.5 ± 0.3 18 ± 2.2 M14 × 1.5 19 [0.75] 34 ± 4 3.5 ± 0.4 25 ± 3.0 M16 × 1.5 22 [0.87] 44 ± 5 4.5 ± 0.5 32 ± 3.7 M18 × 1.5 24 [0.94] 74 ± 5 7.5 ± 0.5 55 ± 3.
SERVICE TOOLS 1. Basic tools .......................................3-2 2. Special tools ....................................
SERVICE TOOLS 1. Basic tools 1 5 2 3 4 Table 3-1 Basic tools list No. 3-2 Tool name Part No. Use - Tool set MM413900 Includes 1 to 5 1 Spanner MK96008010 Width across flats (8 mm × 10 mm) [0.32 × 0.39 in.] 2 Spanner MK96012014 Width across flats (12 mm × 14 mm) [0.47 × 0.55 in.] 3 Spanner MK96017019 Width across flats (17 mm × 19 mm) [0.69 × 0.75 in.
SERVICE TOOLS 2. Special tools Tool name Part No. Shape Use 30L91-00030 (L2A, L3A) Piston pin setting tool 30L91-00020 (L2C, L3C) For pulling out and press fitting piston pins 30L91-10010 (L2E, L3E) Compression gauge adapter ST332270 For measuring compression Oil pressure switch socket wrench (26) MD998054 For removing and installing oil pressure switch Piston ring pliers 31391-12900 Range applicable for removing and installing piston rings: 60 to 95 mm [2.36 to 3.74 in.
DETERMINATION OF OVERHAUL 1. Determining overhaul timing ...........4-2 2. Testing compression pressure ........
DETERMINATION OF OVERHAUL 1. Determining overhaul timing In most cases, the engine should be overhauled when the compression pressure of the engine becomes low. An increase in engine oil consumption and blow-by gas are also considered to evaluate the engine condition.
DETERMINATION OF OVERHAUL 2. Testing compression pressure &$87,21 (a) Be sure to measure the compression pressure for all the cylinders. It is not a good practice to measure the compression pressure for only one cylinder, and presume the compression for the remaining cylinder. (b) Also be sure to check engine speed when measuring the compression pressure, as compression pressure varies with engine speed. (c) Measuring the compression pressure at regular intervals is important to obtain correct data.
DISASSEMBLY OF BASIC ENGINE 1. Disassembling and inspecting cylinder head and valve mechanism ............5-2 1.1 1.2 1.3 1.4 1.5 1.6 Removing rocker shaft assembly............. 5-3 Disassembling rocker shaft assembly...... 5-3 Removing cylinder head bolt.................... 5-4 Removing cylinder head assembly .......... 5-4 Removing valves and valve spring .......... 5-5 Removing valve stem seal ....................... 5-5 2. Disassembling and inspecting flywheel .........................................
DISASSEMBLY OF BASIC ENGINE 1.
DISASSEMBLY OF BASIC ENGINE 1.1 Removing rocker shaft assembly (1) Loosen the rocker arm adjusting screw by about one turn. (2) Loosen the rocker stay bolts and remove the rocker shaft assembly. Note: When removing the rocker shaft assembly, remove it together with the rocker stay bolts, and keep them together for reassembling. Rocker shaft assembly Rocker stay bolt Removing rocker shaft assembly 1.2 Disassembling rocker shaft assembly (1) Pull out the grooved pin with a pair of pliers.
DISASSEMBLY OF BASIC ENGINE 1.3 Removing cylinder head bolt Loosen cylinder head bolts in the numerical order as shown in the illustration. Cylinder head bolt (main) Cylinder head bolt (sub) Loosening order of cylinder head bolt (L2) Cylinder head bolt (main) Cylinder head bolt (sub) Loosening order of cylinder head bolt (L3) 1.
DISASSEMBLY OF BASIC ENGINE 1.5 Removing valves and valve spring (1) Use a valve lifter to compress the valve spring and remove the valve lock. (2) Remove the retainer, valve spring and valve. Note: Put match marks for easy identification of the installing position if the valve is to be reused. When reassembling, do not change the combination of the valve and valve seat. Valve lifter Valve Valve lock Retainer Valve spring Removing valve and valve spring 1.
DISASSEMBLY OF BASIC ENGINE 2.
DISASSEMBLY OF BASIC ENGINE 2.1 Removing flywheel &$87,21 (a) Be careful not to cut yourself with the ring gear when pulling out the flywheel. Be careful not to drop or hit the flywheel when removing. (b) The personnel who holds the pulley must pay due attention to safety. Also, personnel must stay in close contact with each other during work. (1) One personnel must firmly hold the pulley with a wrench to prevent the flywheel from turning. (2) Remove one bolt from the flywheel.
DISASSEMBLY OF BASIC ENGINE 3.
DISASSEMBLY OF BASIC ENGINE 3.1 Removing tappet Remove the tappet from the cylinder block using the push rods. Note: If the camshaft is removed before the tappet, the tappet will fall in the oil pan. Pushrod Tappet Removing tappet 3.2 Removing gear pump housing (1) Remove the bolts and one stud (M8×1.25mm-15mm) shown in the illustration from the gear pump housing. (2) Screw a jack bolt into the stud threaded hole, and remove the gear pump housing. Stud (M81.
DISASSEMBLY OF BASIC ENGINE 3.5 Removing PTO gear Pull out the PTO gear together with two ball bearings from the gear case. PTO gear Ball bearing Removing PTO gear 3.6 Removing oil pump Remove the oil pump housing from the gear case, and then remove the oil pump outer gear and oil pump inner gear. Oil pump inner gear Oil pump housing Gear case Oil pump outer gear Removing oil pump 3.7 Removing relief valve (1) Remove the plug from the gear case.
DISASSEMBLY OF BASIC ENGINE 3.9 Measuring timing gear backlash Measure the backlash of the timing gears by using one of the following two methods; measure the gear play with the dial gauge plunger applied to a tooth flank on the pitch circle at a right angle to the tooth axis, or measure the clearance between gears by inserting a feeler gauge between the gears at the tooth-to-tooth contacting area. Replace the faulty gear pair if the limit is exceeded. Item Limit 0.010 to 0.136 mm [0.0004 to 0.0054 in.
DISASSEMBLY OF BASIC ENGINE 3.11 Removing camshaft &$87,21 Be careful not to cause damage to the cam lobe of the camshaft and the cam shaft hole of the cylinder block when removing the camshaft. (1) Remove the camshaft stopper washer. Camshaft stopper washer (2) Pull out the camshaft together with camshaft gear ball bearings.
DISASSEMBLY OF BASIC ENGINE 3.12 Removing fuel injection pump camshaft Sliding shaft &$87,21 When pulling out the fuel injection pump camshaft, be careful not to cause damage to the cam portion of the fuel injection pump camshaft and the cam hole of the cylinder block. (1) Remove the sliding shaft and the governor weight. Governor weight (2) Remove the camshaft stopper washer.
DISASSEMBLY OF BASIC ENGINE 3.13 Removing front plate (1) Remove the front plate bolts. (2) Remove the front plate from the crankcase. Note: If it is difficult to remove the front plate, lightly tap it with a plastic hammer.
DISASSEMBLY OF BASIC ENGINE 4.
DISASSEMBLY OF BASIC ENGINE 4.1 Removing oil pan &$87,21 Do not insert a chisel or screwdriver between the oil pan and crankcase to remove the oil pan, as it could deform the oil pan flange. (1) Turn the engine around. (2) Remove bolts from the oil pan. (3) To remove oil pan, tap bottom corners of the oil pan with a plastic hammer. Removing oil pan 4.2 Removing oil screen Loosen the nut, and remove the oil screen and gasket. Oil screen Removing oil screen 4.
DISASSEMBLY OF BASIC ENGINE 4.4 Pulling out piston (1) Turn the crankshaft to bring the piston to the top dead center. (2) Using a piece of wood such a hammer handle, push the mating surface of the connecting rod cap, and pull the piston and connecting rod upward from the cylinder. Connecting rod Pulling out piston 4.5 Removing piston ring Remove the piston rings using piston ring pliers. Removing piston ring 4.6 Removing piston pin Remove the piston pin using a piston pin setting tool.
DISASSEMBLY OF BASIC ENGINE 4.7 Measuring crankshaft end play Measure the crankshaft end play (difference between the crankshaft thrust journal width and the width of the bearing cap assembled with thrust plates). Item Standard Limit Crankshaft end play 0.050 to 0.175 mm [0.0020 to 0.0069 in.] 0.500 mm [0.0197 in.] Measuring crankshaft end play 4.8 Removing main bearing cap (1) Remove the main bearing cap bolts. (2) Remove the main bearing caps.
INSPECTION AND REPAIR OF BASIC ENGINE 1. Inspecting and repairing cylinder head and valve mechanism .....................6-2 1.1 Measuring clearance between rocker arm and rocker shaft ....................................... 6-2 1.2 Measuring valve stem outside diameter and valve guide inside diameter ..................... 6-2 1.3 Replacing valve guide.............................. 6-3 1.4 Inspecting valve face ............................... 6-4 1.5 Refacing valve face..................................
INSPECTION AND REPAIR OF BASIC ENGINE 1. Inspecting and repairing cylinder head and valve mechanism 1.1 Measuring clearance between rocker arm and rocker shaft Measure the inside diameter of the rocker arm and outside diameter of the rocker shaft. Replace the rocker arm or rocker shaft if the clearance exceeds the limit. Item Nominal Standard Limit Rocker arm inside diameter ø 12 mm [0.47 in.] 12.013 to 12.035 mm [0.4730 to 0.4738 in.] - Rocker shaft outside diameter ø 12 mm [0.47 in.] 11.
INSPECTION AND REPAIR OF BASIC ENGINE 1.3 Replacing valve guide (1) Pull out the valve guide from the bottom to the top face of the cylinder head with a press using a blanking tool. Puller Puller 65 20 [2.56] [0.79] Ǿ6 [0.24] Ǿ10 [0.39] Unit mm [in.] Valve guide Ǿ12.5 [0.492] (Ǿ25) [0.98] (Ǿ12) [0.47] (Ǿ6.6+0.015 ) 0 [0.260 +0.00059 ] 0 14r0.5 [0.55r ] 14r0.1 [0.55r ] Pulling out valve guide (2) Using a stopper, press-fit the new valve guide from the top surface of cylinder head.
INSPECTION AND REPAIR OF BASIC ENGINE 1.4 Inspecting valve face Apply a thin coat of Shinmyoutan or equivalent lead-free coloring paste on the valve face, and strike the valve face against the valve seat using a valve lapper to check for contact condition. If the contact is not even, or any defects are found, or if the limit is exceeded, reface or replace the valve. Note: (a) Inspect the valve face after the valve guide is repaired or replaced.
INSPECTION AND REPAIR OF BASIC ENGINE 1.6 Measuring perpendicularity and free length of valve spring Measure the perpendicularity and free length of the valve spring. If the limit is exceeded, replace the valve spring with a new one. Item Free length ǰ Perpendicularity Set length/set force ٌ Lf Standard Limit 40 mm [1.57 in.] 38.5 mm [1.516 in.] θ = 2.0 °or less Δ (gap) = 1.4 mm [0.055 in.] or less Lf = 40 mm [1.57 in.] △ = 2.0 mm [0.079 in.
INSPECTION AND REPAIR OF BASIC ENGINE 1.8 Measuring distortion of the bottom surface of the cylinder head Measuring points &$87,21 Refacing of cylinder head should be kept to an absolute minimum. Excessive grinding of the cylinder head may result in defects such as defective combustion and stamping (contact between piston and valve). With a straight edge placed on the bottom face of the cylinder head, measure the bottom face distortion using a feeler gauge.
INSPECTION AND REPAIR OF BASIC ENGINE 2. Inspecting and repairing flywheel 2.1 Measuring flatness of flywheel Place the flywheel on a surface plate and move a dial gauge on the friction surface of the flywheel to measure the flatness. Grind the friction surface of the flywheel if the limit is exceeded. Item Flywheel flatness Standard Limit 0.08 mm [0.0031 in.] or less 0.50 mm [0.0197 in.] Measuring flatness of flywheel 2.
INSPECTION AND REPAIR OF BASIC ENGINE 3. Inspecting and repairing gear case, timing gear and camshaft 3.1 Measuring timing gear backlash Measure the backlash of the timing gears by using one of the following two methods; measure the gear play with the dial gauge plunger applied to a tooth flank on the pitch circle at a right angle to the tooth axis, or measure the clearance between gears by inserting a feeler gauge between the gears at the tooth-to-tooth contacting area.
INSPECTION AND REPAIR OF BASIC ENGINE 3.4 Measuring clearance between camshaft journal and cylinder block bore Calculate the clearance between the outside diameter of the camshaft journal and inside diameter of the cylinder block bore. Replace the camshaft or cylinder block if the clearance exceeds the limit. Note: Start measurement from the No.2 camshaft hole because the No.1 camshaft hole is for ball bearings. Item Standard Limit Clearance between camshaft journal and cylinder block bore 0.050 to 0.
INSPECTION AND REPAIR OF BASIC ENGINE 3.7 Inspecting tappet Inspect the cam contact surface of the tappets. Fit new tappets if the surface is excessively worn or damaged. Good Bad Bad Inspecting tappets 3.8 Measuring clearance between tappet and tappet guide hole Measure clearance between the tappet and tappet hole. Replace the tappet with a new one if the limit is exceeded. Item Standard Limit Clearance between camshaft journal and cylinder block bore 0.007 to 0.049 mm [0.0003 to 0.0019 in.] 0.
INSPECTION AND REPAIR OF BASIC ENGINE 4. Inspecting and repairing cylinder block, crankshaft, piston and oil pan 4.1 Measuring cylinder inside diameter Use a cylinder gauge to measure the inside diameter and cylindericity of the cylinder at three locations in the A and B directions as shown in the illustration. If any one of the cylinders exceeds the repair limit, bore all the cylinders and replace the pistons and piston rings with oversize ones. Replace the cylinder block if the limit is exceeded.
INSPECTION AND REPAIR OF BASIC ENGINE 4.2 Reboring cylinder Cylinders shall be rebored according to the following procedure. 4.2.1 Measuring piston outside diameter Using a micrometer, measure the piston outside diameter at the skirt perpendicular to the piston pins as shown in the illustration. Item Nominal Standard ø 65 mm [2.559 in.] 64.919 to 64.939 mm [2.5559 to 2.5566 in.] 0.25 OS ø 65.25 mm [2.569 in.] 65.169 to 65.189 mm [2.5657 to 2.5665 in.] 0.50 OS ø 65.50 mm [2.579 in.] 65.419 to 65.
INSPECTION AND REPAIR OF BASIC ENGINE 4.3 Measuring piston ring end gap &$87,21 (a) When replacing rings without boring (honing), measure the end gap at the bottom of the cylinder where the wear is minimum. (b) When replacing the ring, use the ring of the same size as the piston. Insert the piston ring into the cylinder bore and push it with the piston to achieve squareness. Then measure the end gap with feeler gauges. Replace the piston ring if the limit is exceeded. Item End gap of ring Standard No.
INSPECTION AND REPAIR OF BASIC ENGINE 4.5 Measuring piston pin bore diameter and piston pin outside diameter Measure the piston pin bore diameter and piston pin outside diameter. Replace if the limit is exceeded. Item Nominal Standard Limit L2A,L3A L2C,L3C ø 18 mm [0.71 in.] 18.001 to 18.007 mm [0.7087 to 0.7089 in.] - L2E,L3E ø 21 mm [0.83 in.] 21.002 to 21.005 mm [0.8269 to 0.8270 in.] - - 0.006 to 0.018 mm [0.0002 to 0.0007 in.] - 0.007 to 0.015 mm [0.0003 to 0.0006 in.
INSPECTION AND REPAIR OF BASIC ENGINE 4.7 Inspecting connecting rod bend and twist (1) Measure the dimensions of C and L in the illustration to check bend and twist of the connecting rod. Straighten the connecting rod with a press to meet the standard. If the standard is exceeded after correction, replace the connecting rod with a new one. (2) In general, a connecting rod aligner is used to check bend and twist. Note: Before checking bend, tighten the connecting rod cap to the specified torque.
INSPECTION AND REPAIR OF BASIC ENGINE 4.8 Measuring clearance between connecting rod bearing and crankpin &$87,21 Tightening torque 31.4 to 34.3 N㨯m {3.2 to 3.5 kgf㨯m} [23.1 to 25.3 lbf㨯ft] Measuring Measuring directions points When grinding crank pins, be sure to grind all the pins to the same size. Finish the fillet radius to the specified dimension. (1) Reassemble the bearing into the big end of the connecting rod. (2) Tighten the connecting rod cap bolts to the specified torque.
INSPECTION AND REPAIR OF BASIC ENGINE 4.9 Measuring clearance between main bearing and crankshaft journal Tightening torque 49.0 to 53.9 N㨯m {5.0 to 5.5 kgf㨯m} [36.2 to 39.8 lbf㨯ft] &$87,21 (a) When grinding crank journals, be sure to grind all the journals to the same size. (b) Finish the fillet radius to the specified dimension. (1) (2) (3) (4) (5) Reassemble main bearings. Tighten the main bearing caps to the specified torque. Measure the inside diameter of the main bearings.
INSPECTION AND REPAIR OF BASIC ENGINE 4.10 Measuring crankshaft runout Support the crankshaft at the front and rear journals with Vblocks, and measure the crankshaft runout at the center journal using a dial gauge. If the runout deviates from the standard only slightly, grind the crankshaft to repair. If the runout exceeds the standard considerably, straighten the crankshaft using a press. If the limit is exceeded, replace the crankshaft.
INSPECTION AND REPAIR OF BASIC ENGINE 4.12 Measuring distortion cylinder block top surface Measuring points and directions &$87,21 Refacing of cylinder head should be kept to an absolute minimum. Excessive grinding of the cylinder head may result in defects such as defective combustion and stamping (contact between piston and valve). Apply a straight edge to the top surface of the cylinder block and measure its distortion using a feeler gauge.
REASSEMBLY OF BASIC ENGINE 1. Reassembling cylinder block, crankshaft, piston and oil pan .........7-2 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 Installing main bearing ............................. 7-2 Installing crankshaft ................................. 7-2 Installing main bearing cap ...................... 7-3 Inserting side seal .................................... 7-3 Installing main bearing cap bolt ............... 7-4 Measuring crankshaft end play ................
REASSEMBLY OF BASIC ENGINE 1. Reassembling cylinder block, crankshaft, piston and oil pan 1.1 Installing main bearing (1) Install the main bearings (upper and lower) with aligning lug groove of the crankcase and main bearing cap. Note: Install the bearing (upper) with groove to the crankcase, and install the bearing (lower) without groove to the main bearing cap. (2) Install the flange main bearing to the rearmost crankcase mating surface. (3) Apply a small amount of engine oil to each bearing.
REASSEMBLY OF BASIC ENGINE 1.3 Installing main bearing cap &$87,21 The foremost and rearmost caps should be installed so that they are flush with the cylinder block surface. Sealant or lubricant Front (1) Apply sealant to the mating surface of the foremost and rearmost caps and the cylinder block mating faces before installing the main bearing caps.
REASSEMBLY OF BASIC ENGINE 1.5 Installing main bearing cap bolt (1) Tighten the main bearing cap bolts alternately and progressively to the specified torque. (2) Make sure that the crankshaft rotates smoothly. Tightening torque 49.0 to 53.9 N㨯m {5.0 to 5.5 kgf㨯m} [36.2 to 39.8 lbf㨯ft] Tightening main bearing cap bolt Checking crankshaft for rotation 1.6 Measuring crankshaft end play Attach a dial gauge to the end of the crankshaft to measure the end play.
REASSEMBLY OF BASIC ENGINE 1.7 Reassembling piston and connecting rod (1) With the identification mark of connecting rod facing upward, place the rod on the piston pin setting tool. Connecting rod Identification mark Piston pin setting tool P/N: 30L91-00030 for L2A, L3A ޓޓ30L91-00020 for L2C, L3C ޓޓ30L91-10010 for L2E, L3E Reassembling piston and connecting rod (1) (2) Set the piston pin push rod and guide to the piston pin.
REASSEMBLY OF BASIC ENGINE 1.8 Installing piston &$87,21 Every piston ring has a top mark such as “R” near the end gap. Install all piston rings with this mark facing upward. If the rings are installed upside down, it could cause malfunctions such as excessive oil consumption or an engine seizing. (1) Install the piston rings to the piston with a ring expander. (2) Install the oil ring with its end gap 180° away from the joint of the coil spring, as shown in the illustration. T Top face mark No.
REASSEMBLY OF BASIC ENGINE 1.10 Installing connecting rod cap (1) When the big end of the connecting rod comes into close contact with the crank pin, turn the crankshaft 180° while pressing the piston head. (2) Fit the connecting rod bearing (lower) to the rod cap with the lug aligned with the lug groove. (3) Install the cap to the connecting rod, aligning the mating marks made during disassembly.
REASSEMBLY OF BASIC ENGINE 1.11 Installing oil screen (1) Turn the engine upside-down so that the oil pan mounting surface is facing up. (2) Install the oil screen so that the tip of the screen does not contact the oil pan. Installing oil screen 1.12 Installing oil pan (1) Install new oil pan gasket. (2) Tighten oil pan bolts evenly and diagonally.
REASSEMBLY OF BASIC ENGINE 2. Reassembling gear case, timing gear and camshaft 2.1 (1) (2) (3) Installing front plate Clean the mounting surface of the gasket. Apply sealant to the gasket to prevent it from falling. With aligning to the dowel pin, install the gasket and the front plate. (4) Secure the front plate with mounting bolts. Fixing bolts of front plate: 7 Installing front plate 2.2 Rotating crankshaft (1) Install two bolts in the flywheel mounting holes of the crankshaft.
REASSEMBLY OF BASIC ENGINE 2.4 Installing camshaft &$87,21 Apply engine oil. Be careful not to damage camshaft journals, cams and camshaft holes during insertion. (1) (2) (3) (4) Apply engine oil to the camshaft journals and cams. Slowly insert the camshaft assembly. Install the camshaft stopper. Make sure that the camshaft rotates freely. Move the camshaft gear back and forth, and make sure there is end play.
REASSEMBLY OF BASIC ENGINE 2.6 Inspecting and adjusting timing gear after installation Be sure to inspect and adjust the timing gear when the timing gear has been reassembled. 2.6.1 Inspecting backlash Check backlash between each gear after installing the timing gears. Measuring timing gear backlash 2.7 Installing governor weights and sliding shaft Install the governor weights and sliding shaft on the fuel injection pump camshaft gear.
REASSEMBLY OF BASIC ENGINE 2.8 Installing speed control lever and governor shaft (1) Insert the governor shaft into the gear case with the governor lever and the tension lever positioned in place. (2) Drive the grooved pin into the gear case. (3) Drive new sealing cap into the gear case. (4) Thoroughly apply Alvania Grease #2 or #3 to the governor shaft cover. (5) Install new O-ring on the speed control lever and insert it into the gear case through the governor shaft.
REASSEMBLY OF BASIC ENGINE 2.11 Installing PTO gear Install ball bearings on both sides of PTO gear, and install the PTO gear into the gear case. PTO gear Ball bearing Installing PTO gear 2.12 Installing timing gear case (1) Apply sealant to the gasket to prevent it from displacing and install the gasket on the front plate. (2) Apply engine oil to the oil seal lip. (3) Install the timing gear case and tighten the bolts. Bolts on front: 8 pcs. Bolts on rear: 4 pcs.
REASSEMBLY OF BASIC ENGINE 2.14 Installing gear pump housing (1) Install the gear pump housing to the stud bolts on the gear case. (2) Tighten the gear pump housing bolt. (3) Install the last stud bolt to the gear pump housing. Stud (M81.25 mm-15 mm) Gear pump housing Bolt Installing gear pump housing 2.15 Installing tappet Coat the periphery of tappets with engine oil, insert them into the tappet holes and place them gently on the camshafts. Apply engine oil.
REASSEMBLY OF BASIC ENGINE 3. Reassembling flywheel 3.1 Installing oil seal case &$87,21 Be careful not to damage the oil seal. Oil seal case (1) Install the new oil seal gasket. (2) After applying engine oil to the entire circumference of the oil seal lips, install the oil seal case on the cylinder block. Installing oil seal case 3.2 Installing flywheel housing (1) Clean the mounting surface of the gasket. (2) Apply sealant to the gasket to prevent it from falling off. (3) Install the gasket.
REASSEMBLY OF BASIC ENGINE 3.3 Installing flywheel &$87,21 The person who holds the pulley must be very careful to assure safety by communicating with the person who is installing the flywheel. (1) One person must firmly hold the pulley with a wrench to prevent the crankshaft from turning. (2) Screw the guide bolt into the rear end of the crankshaft. (3) Align the bolt hole of flywheel with the guide bolt and install the flywheel to the crankshaft. (4) Temporarily tighten bolts.
REASSEMBLY OF BASIC ENGINE 4. Reassembling cylinder head and valve mechanism Reassemble the cylinder head and valve mechanisms in the reverse order of the disassembly procedures. 4.1 Cleaning cylinder head bottom surface Taking care not to damage the cylinder head bottom surface, remove residue of old gasket. Note: First, roughly scrape off residue of old gasket using a scraper. Then, grind off the remaining residue using an engine-oil immersed oil stone. Scraping gasket 4.
REASSEMBLY OF BASIC ENGINE 4.4 Installing valve lock &$87,21 Valve lock If valve spring is overcompressed, the lower end of the retainer comes into contact with the stem seal, and causes damage to the stem seal. Install the retainer on the valve spring. Compress the valve spring using a valve lifter, and install the valve locks. Installing valve lock 4.5 Installing cylinder head gasket &$87,21 Guide bolt Do not use liquid gasket.
REASSEMBLY OF BASIC ENGINE 4.7 Tightening cylinder head bolts In the numerical order as shown in the illustration, tighten cylinder head bolts progressively to the specified torque. Cylinder head bolt (main) 73.5 to 83.4N㨯m {7.5 to 8.5kgf㨯m}[54.2 to 61.5lbf㨯ft] Cylinder head bolt (sub) 19.6 to 29.4N㨯m {2.0 to 3.0kgf㨯m}[14.7 to 21.7lbf㨯ft] Tightening order of cylinder head bolts (L2) Cylinder head bolt (main) 73.5 to 83.4 N㨯m {7.5 to 8.5 kgf㨯m} [54.2 to 61.
REASSEMBLY OF BASIC ENGINE 4.9 Reassembling rocker shaft assembly Install the rocker shaft assembly in the reverse order of the disassembly sequence, observing the followings: (1) Apply engine oil to the rocker shaft. (2) Install the rocker shaft assembly in the same position as it was. Note: If the rocker shaft assembly is not installed in the same position, the clearance becomes different, and it may result in a defect such as wear increase.
REASSEMBLY OF BASIC ENGINE 4.11 Adjusting valve clearance Adjust the valve clearance. For adjusting procedures, refer to "Adjustment and Operation." Adjusting valve clearance Model Ignition order Rotation angle q q . . Mark on gear case side TDC mark on crankshaft pulley side Timing mark 4.12 Installing rocker cover (1) Make sure that the gasket is firmly installed into the rocker cover. (2) Tighten the rocker cover mounting nuts to the specified torque.
FUEL SYSTEM 1. Removing fuel system.....................8-2 1.1 Removing fuel pipe and fuel injection nozzle....................................................... 8-2 1.1.1 Removing fuel injection pipe ......................8-3 1.1.2 Removing fuel injection nozzle...................8-3 1.2 Removing fuel filter .................................. 8-4 1.3 Removing governor.................................. 8-5 1.3.1 Disconnecting tie rod from control rack ......8-6 1.3.
FUEL SYSTEM 1. Removing fuel system &$87,21 Cover the openings on the injection pipe, nozzle inlet connector and injection pipe to prevent dust from entering the fuel system. 1.1 Removing fuel pipe and fuel injection nozzle 3 2 1 4 Replace: Fuel return gasket 5 Replace: Holder gasket Removing fuel pipe and fuel injection nozzle Removing sequence 1 No. 1 fuel injection pipe 4 Fuel return pipe 2 No. 2 fuel injection pipe 5 Fuel injection nozzle 3 No.
FUEL SYSTEM 1.1.1 Removing fuel injection pipe Remove the fuel injection pipe and fuel return pipe. Removing fuel injection pipe 1.1.2 Removing fuel injection nozzle Using a wrench, loosen the nozzle, and remove the fuel injection nozzle and holder gasket. Note: Using a wire or screwdriver remove the holder gasket.
FUEL SYSTEM 1.
FUEL SYSTEM 1.
FUEL SYSTEM 1.3.1 Disconnecting tie rod from control rack (1) Remove the tie rod cover. (2) Remove the tie rod clip and disconnect the tie rod from the control rack. Tie rod clip Tie rod Control rack Disconnecting tie rod from control rack 1.3.2 Removing governor shaft and speed control lever (1) Remove the sealing cap from the side of the gear case. (2) Pull out the grooved pin A. (3) Remove the governor shaft, and remove tension lever and governor lever. (4) Remove the governor spring lever.
FUEL SYSTEM 1.4 Removing fuel injection pump 1 2 3 Removing fuel injection pump &$87,21 Check thickness of the fuel injection timing adjusting shim.
FUEL SYSTEM 2. Disassembling, inspecting and reassembling fuel system 2.
FUEL SYSTEM 2.1.1 Inspecting and adjusting fuel injection valve opening pressure Nozzle tester &$87,21 Never touch the injection nozzle tip during nozzle injection test. (1) Mount the nozzle on the nozzle tester. (2) Push down the handle at a speed of once a second and read the pressure when injection starts. Make adjustment if it is outside the standard. (3) To adjust the injection start pressure, remove the set screw on the nozzle holder, loosen the cap nut and turn the adjusting screw with a driver.
FUEL SYSTEM 2.1.2 Inspecting fuel spray pattern of fuel injection nozzle (1) When adjusting the nozzle opening pressure using the nozzle tester, check for nozzle hole condition, and fuel spray pattern. (2) Checking points of fuel spray are as follows: · Fuel is injected from all spray holes simultaneously. · Fuel is injected conically at the specified spray angle. · Fuel is injected in a spray of fine droplets. · Fuel is injected without after-dribbling.
FUEL SYSTEM 2.2 Reassembling fuel injection nozzles Tightening torque 34.3 to 39.2 N㨯m {3.5 to 4.0 kgf㨯m} [25.3 to 28.9 lbf㨯ft] Tightening torque 49.0 to 58.8 N㨯m {5.0 to 6.0 kgf㨯m} [36.2 to 43.
FUEL SYSTEM 2.3 Inspecting fuel injection pump on engine Do not disassemble the fuel injection pump unless it is absolutely necessary. If faulty, it is desirable to replace it as an assembly. Inspection item Inspection procedure Judgment Low idling Judgment by rotation speed (Varies depending on specifica tion) Exhaust color Observe exhaust color during sudden acceleration under no load. Observe exhaust color under load. No remarkable black smooke is emitted.
FUEL SYSTEM 2.4.1 Removing swivel nipple (1) Grab the plunger of the pump housing with a vise. (2) Remove the swivel nipple from the pump housing. Pump housing Swivel nipple Vise Removing swivel nipple 2.4.2 Removing tappets (1) Turn the pump housing upside down and grab the housing with a vise. (2) Remove the stop wire bracket and remove the control rack. (3) Push in the tappet and, pull out the tappet guide pin with tweezers. (4) Remove the tappet.
FUEL SYSTEM 2.4.4 Removing delivery valve &$87,21 (a) The delivery valve, plunger and plunger barrel are precision-machined parts. Do not smear or scratch them. (b) Keep the combination of the plunger barrel and plunger for each cylinder when removing. Do not mix the plunger barrel with the plunger of a different cylinder. (1) With pump housing faced up, grab the housing with a vise. (2) Remove outside lock plates first and remove center lock plate at the last. (3) Remove the delivery valve holder.
FUEL SYSTEM 2.5 Reassembling fuel injection pump 3.2 to 4.0 N㨯m {0.3 to 0.4 kgf㨯m} [2.2 to 2.9 lbf㨯ft] 4.9 to 6.9 N㨯m {0.5 to 0.7 kgf㨯m} [3.6 to 5.1 lbf㨯ft] 34.3 to 38.2 N㨯m {3.5 to 3.9 kgf㨯m} [25.3 to 28.2 lbf㨯ft] 9.8 to 14.7 N㨯m {1.0 to 1.5 kgf㨯m} [7.2 to 10.8 lbf㨯ft] 3.2 to 4.0 N㨯m {0.3 to 0.4 kgf㨯m} [2.2 to 2.9 lbf㨯ft] Reassembling fuel injection pump 2.5.
FUEL SYSTEM 2.5.2 Assembling delivery valve &$87,21 (a) Do not reuse the O-ring. (b) Install a new O-ring so that it is not cut with threads of the valve holder. Delivery valve holder O-ring Delivery valve spring Assemble the delivery valve, delivery valve gasket and delivery valve spring. Then with the O-ring installed, temporarily tighten the delivery valve holder. Delivery valve gasket Delivery valve Assembling delivery valve 2.5.
FUEL SYSTEM 2.5.5 Installing tappet (1) Install the tappet shim plate. (2) Install the tappet so that its groove is positioned to face the tappet guide pin hole. Groove Tappet Tappet shim plate Tappet guide pin hole (3) Push down the tappet, and install the tappet guide pin. Installing tappet Tappet Tappet guide pin Installing tappet guide pin 2.5.6 Installing control rack (1) Align the control sleeve position so that the protrusion of the control sleeve fits into the fork of the control rack.
FUEL SYSTEM 2.5.7 Tightening delivery valve holder (1) Place the pump housing upright, and grab the housing with a vise. (2) Tighten the delivery valve holder to the specified torque. 34.3 to 38.2 N㨯m {3.5 to 3.9 kgf㨯m} [25.3 to 28.2 lbf㨯ft] Delivery valve holder Pump housing Tightening delivery valve holder 2.5.8 Inspecting control rack for smooth operation (1) Remove the pump housing from the vise and check the control rack for smooth movement.
FUEL SYSTEM 2.6 Disassembling and inspecting governor cover Fatigue and crack Replace: O-ring Disassembling and inspecting governor cover Disassembling sequence 1 Set bolt 4 Stop lever 7 Lever 2 Set bolt 5 Return spring 8 Governor lever 3 Jam nut 6 Grooved pin 2.
FUEL SYSTEM 2.8 Disassembling and inspecting torque spring set (Single spring type) Fatigue and crack (Double spring type) Fatigue and crack Disassembling and inspecting torque spring set Disassembling sequence 1 Locknut 4 Spring stopper 2 Adjusting screw 5 Torque spring (2 spring type) 3 Torque spring 6 Torque spring case 2.9 Reassembling torque spring set Approx. 2mm [0.08in.] (Single spring type) 7.8 to 11.8N㨯m {0.8 to1.2kgf㨯m} [5.8 to 8.7lbf㨯ft] (Double spring type) Approx.
FUEL SYSTEM 2.9.1 Torque spring set, single spring type Reassemble the torque spring set of the single spring type as described in the following: (1) To lightly tighten adjusting screw, turn the adjusting screw with a screwdriver until you feel resistance. At the position where you feel resistance, secure the adjusting screw lightly using lock nut. (2) Set the scale to zero. Turn the torque spring case until the scale reading reaches the load value “A” g in the table below.
FUEL SYSTEM 2.9.2 Reassembling torque spring set, double spring type Reassemble the torque spring set of the double spring type as described in the following. (1) Screw in the adjusting screw so that the end of the spring stopper protrudes from the torque spring case as the protrusion table below. (2) Then, tighten the locknut to the specified torque to secure the adjusting screw.
FUEL SYSTEM 2.10 Inspecting fuel pump The fuel pump is available in 3 types and the type differs based on engine specifications. (1) Electromagnetic plunger-type fuel pump For this pump, a large-sized pump of normal type with a filter element and a small-sized pump of compact type without a filter element are available. In either type, apply the specified voltage, and check for operation and fuel leakage. For the type with filter element, remove the cover and clean or replace the filter element.
FUEL SYSTEM 2.
FUEL SYSTEM 2.
FUEL SYSTEM 3. Installing fuel system 3.
FUEL SYSTEM 3.2 Installing governor Replace Replace 14.7 to 24.5N㨯m {1.5 to 2.5kgf㨯m} [10.8 to 18.
FUEL SYSTEM 3.2.1 Installing speed control lever and governor shaft (1) Insert the governor shaft into the gear case while placing the governor lever and the tension lever. (2) Drive the grooved pin A into the gear case. (3) Drive new sealing cap into the gear case. (4) Thoroughly apply Alvania Grease #2 or #3 to the governor shaft cover. (5) With governor shaft cover installed on speed control lever, install a new O-ring on the speed control lever and insert it into the gear case.
FUEL SYSTEM 3.2.3 Installing torque spring set (Single spring, double spring) For installation and adjustment &$87,21 The torque spring set is properly adjusted at the factory before shipment. Do not work on the torque spring set unless absolutely necessary. Adjust and reassemble the torque spring set as described in the following. (1) Adjust the speed control lever with the high speed set bolt. After setting it at the high idle engine speed, secure it by nut.
FUEL SYSTEM 3.2.5 Installing rack set screw &$87,21 Torque set nut The rack set screw are properly adjusted at the factory before shipment. Do not work on the rack set screw unless absolutely necessary. Adjust and reassemble the rack set screw as described in the following. (1) Adjust the speed control lever with the high speed set bolt. After setting it to the high idle engine speed, secure it by nut. (2) Screw in the rack set screw at rated engine speed, set it to the rated engine power.
FUEL SYSTEM 3.
FUEL SYSTEM 3.4 Installing fuel pipe and fuel injection nozzles 24.5 to 29.4 N㨯m {2.5 to 3.0 kgf㨯m} [18.1 to 21.7 lbf㨯ft] 20.6 to 24.5 N㨯m {2.1 to 2.5 kgf㨯m} [15.2 to 18.1 lbf㨯ft] Installing fuel pipe and fuel injection nozzles 3.4.1 Installing fuel injection nozzle (1) Clean the nozzle holder hole of cylinder head. (2) Install the gasket to the nozzle tip and tighten the fuel injection nozzle. 49.0 to 68.6 N㨯m {5.0 to 6.0 kgf㨯m} [36.2 to 43.4 lbf㨯ft] Installing fuel injection nozzles 3.4.
LUBRICATION SYSTEM 1. Removing lubrication system ..........9-2 1.1 Removing oil filter, relief valve and oil pressure switch ................................... 9-2 1.1.1 Removing oil filter.......................................9-3 1.1.2 Removing relief valve .................................9-3 1.1.3 Removing oil pressure switch ....................9-3 1.2 Removing oil pump, oil pan and oil screen9-4 1.2.1 Removing oil pump ....................................9-4 2.
LUBRICATION SYSTEM 1. Removing lubrication system 1.
LUBRICATION SYSTEM 1.1.1 Removing oil filter (1) Place a drip pan under the oil filter. (2) Remove the oil filter using a filter wrench. Oil filter Removing oil filter 1.1.2 Removing relief valve Remove the plug from the gear case and take out the relief spring and relief plunger. Relief plunger Gear case Relief spring Plug Removing relief valve 1.1.3 Removing oil pressure switch Using an oil pressure switch socket wrench, remove oil presssure switch.
LUBRICATION SYSTEM 1.2 Removing oil pump, oil pan and oil screen Replace Flaking and wear Replace Removing oil pump, oil pan and oil screen Removing sequence 1 Oil pump housing 3 Oil pump inner gear 2 Oil pump outer gear 4 Oil pan Removing oil pump (1) Remove the oil pump housing from the gear case. (2) Remove the oil pump outer gear and oil pump inner gear from the oil pump housing. 5 Oil screen 1.2.
LUBRICATION SYSTEM 2. Disassembling, inspecting and reassembling lubrication system 2.1 Inspecting oil pump 2.1.1 Measuring clearance between oil pump housing inside diameter and oil pump outer gear outside diameter Measure the clearance using thickness gauges. Replace the gear or housing if the limit is exceeded. Item Standard Limit Clearance between oil pump housing inside diameter and oil pump outer gear outside diameter 0.100 to 0.196 mm [0.0039 to 0.0077 in.] 0.3 mm [0.012 in.
LUBRICATION SYSTEM 2.2 Inspecting relief valve (1) Check the relief valve and its seat for contact. Check the spring for fatigue and damage. If faulty, replace the relief valve with new one. (2) Measure the relief valve opening pressure. If the pressure does not fall within the standard range, replace the relief valve with new one. Item Relief valve opening pressure Oil pump housing Oil pump inner gear Relief spring Standard 0.29 ± 0.029 MPa {3.0 ± 0.3 kgf/cm²} [43 ± 4.
LUBRICATION SYSTEM 3. Installing lubrication system 3.1 Installing oil pump, oil pan and oil screen Replace 7.8 to 9.8N㨯m {0.8 to 1.0kgf㨯m} [5.8 to 7.2 lbf㨯ft] Replace Installing oil pump, oil pan and oil screen 3.1.1 Installing oil pump Install the oil pump inner gear, oil pump outer gear and oil pump housing, and tighten the bolts to the specified torque. Oil pump inner gear Oil pump housing 7.8 to 9.8 N㨯m {0.8 to 1.0 kgf㨯m} [5.8 to 7.
LUBRICATION SYSTEM 3.2 Installing oil filter, relief valve and oil pressure 7.85 to 11.8 N㨯m {0.8 to 1.2 kgf㨯m} [5.8 to 8.7 lbf㨯ft] 39.2 to 49.0 N㨯m {4.0 to 5.0 kgf㨯m} [29 to 36 lbf㨯ft] Installing oil filter, relief valve and oil pressure 3.2.1 Installing oil pressure switch &$87,21 Do not allow sealant to squeeze out at the thread end. Do not overtighten. (1) Using an oil pressure switch socket wrench, tighten the oil pressure switch to the specified torque.
LUBRICATION SYSTEM 3.2.3 Installing oil filter (1) Apply a light coating of engine oil to the filter gasket. (2) Screw the filter in by hand. When the filter gasket contacts the mounting surface, screw the filter in another turn. Tighten the oil filter by hand. Installing oil filter (1) Apply engine oil.
COOLING SYSTEM 1. Removing cooling system .............10-2 1.1 Removing cooling fan, fan pulley, V-belt, thermostat, thermoswitch and water pump ............................................ 10-2 2. Disassembling, inspecting and reassembling cooling system ........10-3 2.1 Disassembling and inspecting thermostat10-3 2.2 Inspecting thermostat............................. 10-3 2.3 Reassembling thermostat ...................... 10-4 2.4 Inspecting thermoswitch ........................ 10-4 2.
COOLING SYSTEM 1. Removing cooling system 1.
COOLING SYSTEM 2. Disassembling, inspecting and reassembling cooling system 2.1 Disassembling and inspecting thermostat 1 Replace 2 3 Disassembling and inspecting thermostat Disassembling sequence 1 Thermostat cover 2 Thermostat 3 Thermostat case 2.2 Inspecting thermostat &$87,21 Stir hot water well. Be careful of burns or a fire when measuring temperature, as it involves a high-temperature and open flame. To test the thermostat operation, immerse the thermostat in a container filled with water.
COOLING SYSTEM 2.3 Reassembling thermostat 8 to 10 N㨯m {0.8 to 1.0 kgf㨯m} [5.8 to 7.2 lbf㨯ft] Reassembling thermostat 2.4 Inspecting thermoswitch &$87,21 Both water and the thermoswitch become hot. Pay attention to prevent burn and fire. Immerse the temperature-senser in oil and measure the resistance while raising the oil temperature. If the resistance extremely deviates from the standard, replace the thermoswitch. Temperature Standard 120°C [248°F] 30 mΩ Inspecting thermostat 2.
COOLING SYSTEM 3. Installing cooling system 3.1 Installing cooling fan, fan pulley, V-belt, thermostat, thermoswitch and water pump Replace Replace Replace 19.6 to 29.4 N㨯m {2.0 to 3.
INLET AND EXHAUST SYSTEMS 1. Removing inlet and exhaust systems ...........................11-2 1.1 Removing inlet cover and exhaust manifold.................................... 11-2 2. Disassembling, inspecting and reassembling inlet and exhaust systems ...........................11-3 2.1 Inspecting inlet cover and exhaust manifold.................................... 11-3 2.2 Measuring distortion of inlet and exhaust manifold.................................... 11-3 3.
INLET AND EXHAUST SYSTEMS 1. Removing inlet and exhaust systems 1.
INLET AND EXHAUST SYSTEMS 2. Disassembling, inspecting and reassembling inlet and exhaust systems 2.1 Inspecting inlet cover and exhaust manifold Crack, damage, contamination, dirt adhesion and corrosion Crack, damage and corrosion Crack, damage and corrosion Crack, damage, contamination, dirt adhesion and corrosion Inspecting inlet cover and exhaust manifold 2.
INLET AND EXHAUST SYSTEMS 3. Installing inlet and exhaust systems 3.1 Installing inlet cover and exhaust manifold Replace 7.8 to 9.8N㨯m {0.8 to 1.0kgf㨯m} [6 to 7 lbf㨯ft] Replace Replace Replace Replace Replace 7.8 to 9.8N㨯m {0.8 to 1.0kgf㨯m} [6 to 7 lbf㨯ft] Replace Replace 14.7 to 21.6N㨯m {1.5 to 2.2kgf㨯m} [11 to 16 lbf㨯ft] Installing inlet cover and exhaust manifold 11-4 14.7 to 21.6N㨯m {1.5 to 2.
ELECTRICAL SYSTEM 1. Removing electrical system ..........12-2 1.1 Removing starter.................................... 12-2 1.2 Inspection before removing alternator (A007TA0171B (12V-40A), A007TA8271A (24V-25A)) ..................... 12-3 1.2.1 Inspecting alternator operation.................12-3 1.2.2 Handling precaution .................................12-3 1.2.3 Inspecting regulated voltage ....................12-4 1.2.4 Inspecting output ......................................12-4 1.
ELECTRICAL SYSTEM 2.8.15 Inspecting continuity of magnetic switch (between M terminal and case) .............12-33 2.8.16 Inspecting insulation of magnetic switch (between M terminal and B terminal) .....12-33 2.9 Reassembling starter (M002T66071 (24V-3.2kW)) ................ 12-34 2.9.1 Applying grease .....................................12-34 2.9.2 Installing lever and pinion shaft ..............12-35 2.9.3 Installing pinion ......................................12-35 2.9.
ELECTRICAL SYSTEM 1. Removing electrical system 1.
ELECTRICAL SYSTEM 1.2 Inspection before removing alternator (A007TA0171B (12V-40A), A007TA8271A (24V-25A)) 1.2.1 Inspecting alternator operation Locate the cause of faulty charging from malfunctions described below. Do not remove the alternator for inspection and repair unless inspection cannot be performed with the alternator installed on the engine. Adjusted value of voltage regulator is high. Overcharge Faulty battery. Low adjusted value of voltage relay. Faulty alternator output.
ELECTRICAL SYSTEM 1.2.3 Inspecting regulated voltage (1) Disconnect the battery (+) terminal, and connect an ammeter. (2) Connect a volt meter to terminal L ground line. (3) Make sure that the volt meter indicates 0 when the starter switch is OFF position. Make sure that the volt meter indicates much lower voltage than battery voltage when the starter switch is ON position. (4) Disconnect the terminal of ammeter, and start the engine. (5) Measure the adjusting voltage with volt meter.
ELECTRICAL SYSTEM 1.3 Removing alternator 1 6 3 4 2 5 Removing alternator Removing sequence 1 Harness 3 Generator brace 5 Washer 2 Flange bolt 4 Bolt 6 Alternator 1.
ELECTRICAL SYSTEM 1.
ELECTRICAL SYSTEM 2. Disassembling, inspecting and reassembling electrical system 2.1 Inspection before disassembling starter (M000T60481 (12V-1.2kW), M001T68381 (12V-1.7kW)) 2.1.1 Inspecting pinion clearance &$87,21 Do not apply current continuously for longer than 10 seconds. (1) Connect the starter to the circuit as shown in the illustration. (2) When the switches SW1 and SW2 are turned ON, the pinion springs out to the cranking position and the armature rotates.
ELECTRICAL SYSTEM 2.1.2 Inspecting magnetic switch Perform the inspection as described below. If faulty, replace the magnetic switch with a new one. Disconnect the connector. &$87,21 Do not apply current continuously for longer than 10 seconds. (1) Disconnect the connector of M terminal. (2) Pull-in test Connect the starter to the circuit as shown in the illustration. The magnetic switch is normal if the pinion springs out when the switch is turned ON.
ELECTRICAL SYSTEM 2.1.3 No load test &$87,21 Use as thick a wire as possible and firmly tighten each terminal. When detecting the rotation at the tip of the pinion, be careful, as the pinion pops out during operation. (1) Connect the starter to the circuit as shown in the illustration. (2) In normal condition, the pinion pops out when the switch is turned ON, and the starter rotates at or more the specified rotation speed.
ELECTRICAL SYSTEM 2.2 Disassembling and inspecting starter (M000T60481 (12V-1.2kW), M001T68381 (12V-1.
ELECTRICAL SYSTEM 2.3 Preparation before disassembling Mark the mating marks on magnetic switch, front bracket, center bracket, yoke and rear bracket to each other for reassembly. Preparatory work before disassembly 2.3.1 Removing pinion set &$87,21 SW1 The starter generates heat if it is left with current being applied. Remove the pinion within 10 seconds. (1) Connect the starter to the circuit as shown in the illustration.
ELECTRICAL SYSTEM 2.3.3 Removing rear bracket Remove the through bolts and screws of the brush holder, and then remove the rear bracket. Rear bracket Screw Through bolt Removing rear bracket 2.3.4 Removing brush holder and brush assembly Apply a socket (of the same diameter as the commutator) to the commutator of the armature. Remove the brush holder and brush assembly by sliding on the socket. Socket Brush holder Brush assembly Removing brush holder and brush assembly 2.3.
ELECTRICAL SYSTEM 2.3.6 Removing overrunning clutch Pull out the internal gear, gear shaft, overrunning clutch and lever as an assembly from the front bracket, and remove the lever. Lever Overrunning clutch Internal gear Gear shaft Front bracket Removing overrunning clutch 2.3.7 Removing gear shaft (1) Remove the stopper ring and then the stopper. (2) Separate the overrunning clutch, internal gear and gear shaft.
ELECTRICAL SYSTEM 2.4 Inspecting and repairing starter (M000T60481 (12V-1.2kW), M001T68381 (12V-1.7kW)) 2.4.1 Inspecting brushes for wear Measure the length of the brushes. If the measured value is less than the limit, replace both the brush holder assembly and the brush assembly with new ones. Item Standard Limit Brush length 16.5 mm [0.650 in.] 10.0 mm [0.394 in.] Measure the length of the brush. Replace if the length is equal to or less than the limit. Inspecting brushes for wear 2.4.
ELECTRICAL SYSTEM 2.4.4 Measuring commutator radial runout (1) Inspect the commutator surface. If the surface is rough, polish it using a 400 to 600 grit sandpaper. (2) Measure the commutator radial runout with a dial gauge. If the measured value exceeds the limit, replace the armature with a new one. Item Commutator radial runout Standard Limit 0.03 mm [0.0012 in.] 0.10 mm [0.0039 in.] Commutator Measuring commutator radial runout 2.4.
ELECTRICAL SYSTEM 2.4.7 Checking armature coil (1) Inspect the armature coil using a growler. Hold a piece of iron plate against the armature core. If the iron plate vibrates, replace the armature with a new one. Growler tester Iron plate Inspecting armature coil for short circuit (2) Check that there is no continuity between the commutator and the shaft (core). If any continuity is observed, replace the armature with a new one.
ELECTRICAL SYSTEM 2.4.9 Inspecting overrunning clutch &$87,21 Do not clean the overrunning clutch in wash oil. Make sure that, when attempting to turn the overrunning clutch, it locks in one direction and rotates smoothly in the opposite direction. Inspecting overrunning clutch 2.4.10 Inspecting pinion Check the pinion for wear and damage. If faulty, replace the pinion with a new one. 2.4.11 Inspecting front bracket The ball bearing should rotate smoothly without abnormal noise.
ELECTRICAL SYSTEM 2.5 Reassembling starter (M000T60481 (12V-1.2kW), M001T68381 (12V-1.7kW)) 4.1 to 7.6 N㨯m {0.42 to 0.77 kgf㨯m} [7 to 9 lbf㨯ft] 8.8 to 12.7 N㨯m {0.90 to 1.30 kgf㨯m} [7 to 8 lbf㨯ft] 4.4 to 7.1 N㨯m {0.45 to 0.72 kgf㨯m} [7 to 9 lbf㨯ft] Apply Multemp PS2 (Kyodo Yushi made) or equivalent. Apply Multemp PS2 (Kyodo Yushimade) or equivalent. 2.4 to 4.4 N㨯m {0.24 to 0.45 kgf㨯m} [7 to 9 lbf㨯ft] Apply Molykote RAG650 (Dow Corning Asia made) or equivalent. Reassembling starter (M000T60481 (12V-1.
ELECTRICAL SYSTEM 2.5.2 Installing pinion &$87,21 Before assembling, apply grease to the inner race groove of the front bracket bearing. Be sure to use a new stopper ring. Do not reuse the stopper ring that has been removed. (1) Put the overrunning clutch through the front bracket. (2) Fit the internal gear into the gear shaft. (3) Put the gear shaft through the overrunning clutch and install the stopper on it. (4) Install the stopper ring firmly to the shaft groove of overrunning clutch.
ELECTRICAL SYSTEM 2.5.4 (1) (2) (3) (4) (5) Installing yoke and armature Install the planetary gears on the gear shaft. Install the packing on the internal gear. Packing Plate Install the plate and packing. Install the yoke on the front bracket. Apply grease to the armature shaft end and install a ball on it. Armature Yoke Packing Ball Planetary gear (6) Install the armature. Note: The adjustment of play in the axial direction of the armature shaft is not necessary. Installing yoke and armature 2.
ELECTRICAL SYSTEM 2.5.8 Inspecting pinion clearance &$87,21 Do not apply current continuously for longer than 10 seconds. (1) Connect the starter to the circuit as shown in the illustration. (2) When the switches SW1 and SW2 are turned ON, the pinion springs out to the cranking position and the armature rotates. (3) Turn the switch SW2 OFF to stop the rotation of the armature.
ELECTRICAL SYSTEM 2.6 Inspection before disassembling starter (M002T66071 (24V-3.2kW)) 2.6.1 Inspecting pinion clearance &$87,21 Do not apply current continuously for longer than 10 seconds. (1) Connect the starter to the circuit as shown in the illustration. (2) When the switches SW1 and SW2 are turned ON, the pinion springs out to the cranking position and the armature rotates. (3) Turn the switch SW2 OFF to stop the rotation of the armature.
ELECTRICAL SYSTEM 2.6.2 Inspecting magnetic switch Perform the inspection as described below. If faulty, replace the magnetic switch with a new one. 㧿 &$87,21 㧹 Do not apply current continuously for longer than 10 seconds. (1) Disconnect the connector of M terminal. (2) Pull-in test Connect the starter to the circuit as shown in the illustration. The magnetic switch is normal if the pinion springs out when the switch is turned ON.
ELECTRICAL SYSTEM No load test 59 &$87,21 Use as thick a wire as possible and firmly tighten each terminal. When detecting the rotation at the tip of the pinion, be careful, as the pinion pops out during operation. (1) Connect the starter to the circuit as shown in the illustration. (2) In normal condition, the pinion pops out when the switch is turned ON, and the starter rotates at or more the specified rotation speed.
ELECTRICAL SYSTEM 2.7 Disassembling and inspecting starter (M002T66071 (24V-3.
ELECTRICAL SYSTEM 2.7.1 Preparation before disassembling Mark the mating marks on magnetic switch, front bracket, center bracket, yoke and rear bracket to each other for reassembly. Preparation before disassembling 2.7.2 Removing magnetic switch Disconnect the leads, and remove the magnetic switch. Connector Magnetic switch Mounting screw Removing magnetic switch 2.7.3 Removing rear bracket Remove the through bolts and screws of the brush holder, and then remove the rear bracket.
ELECTRICAL SYSTEM 2.7.4 Removing brushes, brush holder, yoke and armature While lifting the two brushes, remove the yoke and brush holder assembly. Then, pull out the armature. Brush Brush holder Yoke Armature Removing brushes, brush holder, yoke and armature 2.7.5 Removing ball bearing Remove the bearings from both ends of the armature using a puller. Rear bearin Front bearing Armature Removing ball bearings 2.7.6 Removing cover set Remove the cover, and pull out the snap ring and the washer.
ELECTRICAL SYSTEM 2.7.7 Removing center bracket Remove the screw, then remove the center bracket. Once the center bracket is removed, the adjusting washer that adjusts the pinion shaft end play can be removed. Center bracket Adjusting washer Screw Removing center bracket 2.7.8 Removing reduction gear and spring set (1) Remove the reduction gear from the pinion shaft. (2) Remove the packing and lever spring from the lever.
ELECTRICAL SYSTEM 2.8 Inspecting and repairing starter (M002T66071 (24V-3.2kW)) 2.8.1 Inspecting brushes for wear Measure the length of the brushes. If the measured value is less than the limit, replace both the brush holder assembly and the brush assembly with new ones. Item Brush length Standard Limit 18 mm [0.709 in.] 11 mm [0.4331 in.] Measure the length of the brush. Replace if the length is equal to or less than the limit. Inspecting brushes for wear 2.8.
ELECTRICAL SYSTEM 2.8.4 Measuring commutator radial runout (1) Inspect the commutator surface. If the surface is rough, polish it using a 400 to 600 grit sandpaper. (2) Measure the commutator radial runout with a dial gauge. If the measured value exceeds the limit, replace the armature with a new one. Item Commutator radial runout Standard Limit 0.03 mm [0.0012 in.] 0.10 mm [0.0039 in.] Commutator Measuring commutator radial runout 2.8.
ELECTRICAL SYSTEM 2.8.7 Checking armature coil (1) Inspect the armature coil using a growler. Hold a piece of iron plate against the armature core. If the iron plate vibrates, replace the armature with a new one. Growler tester Iron plate Checking armature coil for short circuit (2) Check that there is no continuity between the commutator and the shaft (core). If any continuity is observed, replace the armature with a new one.
ELECTRICAL SYSTEM 2.8.8 Inspecting continuity of yoke assembly Check that there is continuity between M terminal of field coil and the lead wire for the brush. If no continuity is observed, replace the yoke assembly with a new one. Checking field coils for breaks 2.8.9 Inspecting insulation between yoke body and brush Check that there is no continuity between yoke body and brush. If continuity is observed, replace the yoke assembly with a new one. Checking field coils for grounding 2.8.
ELECTRICAL SYSTEM 2.8.11 Inspecting overrunning clutch &$87,21 Do not clean the overrunning clutch in wash oil. Make sure that, when attempting to turn the overrunning clutch, it locks in one direction and rotates smoothly in the opposite direction. Inspecting overrunning clutch 2.8.12 Inspecting pinion Check the pinion for wear and damage. If faulty, replace the pinion with a new one. 2.8.13 Inspecting front bracket The ball bearing should rotate smoothly without abnormal noise.
ELECTRICAL SYSTEM 2.9 Reassembling starter (M002T66071 (24V-3.2kW)) 4.1 to 7.6N㨯m {0.42 to 0.77kgf㨯m} [3 to 6lbf㨯ft] 8.8 to 12.7N㨯m {0.90 to 1.90kgf㨯m} [7 to 14lbf㨯ft] Apply Multemp PS2 (Kyodo Yushi made) or the equivalent. Apply Multemp PS2 (Kyodo Yushi made) or the equivalent. 2.2 to 4.4N㨯m {0.24 to 0.45kgf㨯m} [2 to 3lbf㨯ft] 4.4 to 7.1N㨯m {0.45 to 0.72kgf㨯m} [3 to 5lbf㨯ft] Apply Molykote RAG650 (Dow Corning Asia made) or the equivalent. Reassembling starter (M002T66071 (24V-3.2kW)) 2.9.
ELECTRICAL SYSTEM 2.9.2 Installing lever and pinion shaft Reassemble the lever to the pinion shaft and insert them into the front bracket. Front bracket Pinion shaft Lever Installing lever and pinion shaft 2.9.3 Installing pinion (1) Install the spring, pinion and pinion stopper on the pinion shaft. (2) Install a stopper ring into the ring groove on the pinion shaft. Using a puller, pull the pinion stopper until its groove engages with the stopper ring.
ELECTRICAL SYSTEM 2.9.6 Adjusting pinion shaft end play Adjust the end play (thrust gap) to 0.5 mm [0.0197 in.] or less by inserting adjusting washers between the center bracket and reduction gear. (1) Install the pinion shaft, reduction gear, washer and snap ring onto the center bracket. (2) Measure the pinion shaft end play by moving the shaft in the axial direction. If the measured value exceeds 0.5 mm [0.0197 in.], make an adjustment by adding adjusting washer(s).
ELECTRICAL SYSTEM 2.9.9 Installing rear bracket Install the rear bracket to the yoke, and tighten the through bolt and the brush holder screws. Through bolt 4.4 to 7.1N㨯m {0.45 to 0.72kgf㨯m} [3 to 5lbf㨯ft] Screw 2.4 to 4.4N㨯m {0.24 to 0.45kgf㨯m} [2 to 3lbf㨯ft] Installing rear bracket 2.9.10 Installing magnetic switch (1) Install the magnetic switch and tighten the screws. (2) Connect the lead to the terminal M and secure it with the fixing nut. Connector Magnet switch Terminal M 8.8 to 12.7N㨯m {0.
ELECTRICAL SYSTEM 2.
ELECTRICAL SYSTEM 2.10.1 Separating front bracket from stator &$87,21 Rear bracket Do not disassemble the alternator unless the repair is necessary. Do not insert the screwdrivers too deep, as it can damage the stator. (1) Remove the through bolts. (2) With two flat-head screwdrivers inserted between the front bracket and stator, pry them apart. Stator core Front bracket Separating front bracket from stator 2.10.
ELECTRICAL SYSTEM 2.10.5 Removing stator &$87,21 Unsoldering must be finished as quickly as possible. Extended heating will damage the diodes. Cut off the joint of the stator and remove the stator from the rectifier. Stator core Rectifier Soldering Removing stator 2.10.6 Removing regulator assembly Remove the screws of the regulator assembly and then remove the regulator assembly. Screws Regulator assembly Removing regulator assembly 2.10.
ELECTRICAL SYSTEM 2.11 Inspecting and repairing alternator 2.11.1 Inspecting rectifier Check that diodes in a rectifier function properly. To check, measure both negative (-) and positive (+) resistance alternately twice. If both infinite negative and infinite positive resistances are observed, the diode is opencircuited. If measured value is close to 0 Ω, the diode is short-circuited. In either case, replace the rectifier with a new one. Note: Use a wide measuring range as much as possible.
ELECTRICAL SYSTEM 2.11.3 Inspecting stator (1) Checking continuity between lead wires Check that there is continuity between a pair of lead wires. Also check that there is no continuity between a pair of lead wires and other pair of lead wires. If defective, replace the stator. Checking for continuity between leads (2) Checking insulation between lead wire and core Check that there is no continuity between each lead wire and the stator core. If continuity is observed, replace the stator.
ELECTRICAL SYSTEM 2.11.5 Replacing brushes (1) To remove the brush and the spring, unsolder the brush lead. Soldering Brush holder Replacing brushes (2) To install a new brush, push the brush into the brush holder as shown in the illustration, and then solder the lead to the brush.
ELECTRICAL SYSTEM 2.
ELECTRICAL SYSTEM 2.12.1 Installing rectifier assembly and regulator assembly Install the rectifier assembly and regulator assembly on the rear bracket. Regulator assembly Regulator assembly Installing rectifier assembly and regulator assembly 2.12.2 Installing stator &$87,21 Soldering must be finished as quickly as possible. Extended heating will damage the diodes. Install the stator and solder the leads of the stator to the rectifier. Stator core Rectifier Soldering Installing stator 2.12.
ELECTRICAL SYSTEM 2.12.4 Installing rear bearing Press-fit the rear bearing to the rotor. Rotor Rear bearing Installing rear bearing 2.12.5 Installing pulley (1) Insert the rotor into the front bracket. Apply a cloth to the rotor and set it in a vise. (2) Install the spacer and pulley, and secure the pulley with a nut. Pulley Front bracket Rotor Installing pulley 2.12.
ELECTRICAL SYSTEM 2.13 Inspecting glow plug Check continuity between the terminal and the body as shown in the illustration. If no continuity is indicated, or the resistance is large, replace the glow plug with a new one. Item Standard 12 V 0.2 Ω 24 V 4.
ELECTRICAL SYSTEM 3. Installing electrical system 3.1 Installing glow plug 0.98 to 1.47 N㨯m {0.10 to 0.15 kgf㨯m} [0.72 to 1.08 lbf㨯ft] 14.7 to 19.6 N㨯m {1.5 to 2.0 kgf㨯m} [10.8 to 14.5 lbf㨯ft] Installing glow plug 3.2 Installing stop solenoid ETR type ETS type 39.2 to 49.0N㨯m {4.0 to 5.0kgf㨯m} [28.9 to 36.
ELECTRICAL SYSTEM 3.3 Installing stop solenoid (ETR type) These areas must be free from sealants. Control rack Cylinder block Nut 39.2 to 49.0 N㨯m {4.0 to 5.0 kgf㨯m} [28.9 to 36.2 lbf㨯ft] Approx. 0.3 to 0.7 mm [0.012 to 0.028 in.] Stop solenoid Threaded portion: Apply sealant. Rod Installing stop solenoid (ETR type) 3.3.1 Procedure for installing stop solenoid (ETR type) (1) Apply a sealant to the threaded portion of the stop solenoid.
ELECTRICAL SYSTEM 3.4 Installing stop solenoid (ETS type) These areas must be free from a sealant. Control rack Nut Cylinder block 39.2 to 49.0N㨯m {4.0 to 5.0kgf㨯m} [28.9 to 36.2lbf㨯ft] Do not allow wash fluid to enter the inside of the solenoid from the clearance. 㧭 Rubber cap 0.15 to 0.20mm [0.00591 to 0.00788 in.] Stop solenoid Threaded portion: Apply a sealant. UP PUSH TO STOP Shaft Water drain hole Installing stop solenoid (ETS type) 3.4.
ELECTRICAL SYSTEM 3.4.2 Verification after reassembly (ETS type) (1) After starting the engine, turn the starter switch key to the OFF position, and make sure that the solenoid activates and the engine stops. (2) During engine start, turn the starter switch key to the ON position, and make sure that the solenoid activates and the engine enters a stopped state. (3) Turn the starter switch key from the OFF position to ON, and then to START position.
ELECTRICAL SYSTEM 3.5 Installing alternator Installing alternator 3.
ADJUSTMENT AND OPERATION 1. Inspection and adjustment of engine ...........................................13-2 1.1 Inspecting and adjusting valve clearance13-2 1.1.1 Preparation for valve clearance inspection13-2 1.1.2 Inspecting valve clearance .......................13-3 1.2 Inspecting fuel injection timing ............... 13-4 1.3 Adjusting fuel injection timing................. 13-5 1.4 Inspecting and adjusting low idle speed and high idle speed................................ 13-6 1.4.1 Preparation...
ADJUSTMENT AND OPERATION 1. Inspection and adjustment of engine 1.1 Inspecting and adjusting valve clearance 1.1.1 Preparation for valve clearance inspection (1) Inspect and adjust the valve clearance when the engine is cold. (2) Slightly loosen cylinder head bolts and tighten them to the specified torque in the order as shown in the illustration. Note: Be careful that the tightening torque of cylinder head bolts is different between main bolts and sub bolts. Cylinder head bolt (main) 73.5 to 83.4N㨯m {7.
ADJUSTMENT AND OPERATION 1.1.2 Item Model . . Ignition order Rotation angle q q Inspecting valve clearance (1) Set No. 1 cylinder to the top dead center in compression stroke. This position is where the TDC mark on the crankshaft pulley aligns with the mark on the gear case. Note: The compression top is where the rocker arm does not move when the crankshaft is rotated in the forward and backward direction by both 20°approx.
ADJUSTMENT AND OPERATION 1.2 Inspecting fuel injection timing Valve &$87,21 (1) Remove the No. 1 fuel injection pipe. (2) Remove the No.1 delivery valve holder of the fuel injection pump. (3) Pull out the spring and delivery valve. Then do not remove the delivery valve seat. (4) Install the delivery valve holder. (5) Remove the tie rod cover. (6) Disconnect the tie rod from the control rack. (7) Set the control rack to the medium position of the operating range.
ADJUSTMENT AND OPERATION 1.3 Adjusting fuel injection timing &$87,21 When using the shim, apply sealant to both side of the shim to prevent oil leakage. (1) If the fuel injection timing does not meet the specified value, increase or decrease the thickness of the fuel injection pump adjusting shim to adjust the timing. (adjusting value: standard value ± 1.5) Note: A change in thickness of the shim by 0.1 mm [0.004 in.] results in a change in the fuel injection timing by approx 1°.
ADJUSTMENT AND OPERATION 1.4 Inspecting and adjusting low idle speed and high idle speed &$87,21 (a) The minimum no-load speed (low idle speed) and the maximum no-load speed (high idle speed) of each engine have been checked on test bench and then their setting bolts have been sealed by sealing cap at the factory. Only the service shops designated by Mitsubishi are authorized to perform checking and adjustment of these settings.
ADJUSTMENT AND OPERATION 1.5 Bleeding fuel system :$51,1* Completely wipe off any spilled fuel from air vent plug with a cloth, as spilled fuel can cause a fire. Bleeding of the fuel system must be started from the place closest to the fuel tank: the fuel filter the first and the fuel injection pump the last. Bleeding air from fuel filter (1) Cartrige type paper element Loosen the air vent screw marked by the letter "1." Tighten the air vent screw when fuel does not show air bubbles.
ADJUSTMENT AND OPERATION 1.5.2 Bleeding air from fuel injection pump Loosen the air vent screw of pump to discharge air in the fuel pipe and fuel injection pump. Note: Air in the fuel injection pipe and fuel injection nozzle is automatically discharged by cranking of the engine.
ADJUSTMENT AND OPERATION 1.6 Adjusting V-belt tension (1) Loosen the adjusting bolt and fixing bolt of the alternator. Loop the V-belt over the water pump pulley, alternator pulley and crankshaft pulley. (2) With the alternator pushed toward the V-belt tension side, tighten the adjusting bolt at an appropriate position. (3) Inspect the V-belt tension to make sure it is within the specified value. Belt tension (with pushing force of approx.
ADJUSTMENT AND OPERATION 2. Break-in operation After the engine is overhauled, couple the engine to the dynamometer, and run the engine for break-in operation and inspection. 2.3 Break-in operation time The relationship between the load in break-in operation and the operation time is as shown below. 2.1 Starting up (1) Before starting the engine, check the levels of coolant, engine oil and fuel. Bleed air from the fuel and cooling systems.
ADJUSTMENT AND OPERATION 3. Performance test (JIS standard) The following describes the procedures specified in "Earth moving machinery - Engines - Part 1: Test code of net power (JIS D0006-1)" and "Earth moving machinery Engines - Part 2: Standard format of specifications and testing methods of diesel engines (JIS D0006-2)." Other test items may be required in some applications. All test results should be evaluated comprehensively in order to determine the engine performance. 3.
ADJUSTMENT AND OPERATION 3.4.2 Calculation of corrected power Multiply the measured brake power or torque by the calculated diesel engine correction factor to obtain a corrected value. If the applicable range of the correction formula is exceeded, indicate the corrected values and record the test conditions on the test record.
TROUBLESHOOTING 1. Troubleshooting ............................14-2 1.1 Before troubleshooting........................... 14-2 1.2 Starting trouble....................................... 14-3 1.2.1 Check items before troubleshooting.........14-3 1.2.2 Problem: Starting trouble ........................14-3 1.3 Knocking ................................................ 14-4 1.3.1 Check items before troubleshooting.........14-4 1.3.2 Problem: Knocking ..................................14-4 1.4 Overheating .....
TROUBLESHOOTING 1. Troubleshooting 1.1 Before troubleshooting &$87,21 (a) For the fuel injection pump, the injection quantity of each cylinder can be measured only with a pump tester. Do not adjust or disassemble the fuel injection pump even during troubleshooting unless absolutely necessary.
TROUBLESHOOTING 1.2 Starting trouble 1.2.1 Check items before troubleshooting (1) Clogging of air cleaner element (2) Coagulation of engine oil (3) Use of poor quality fuel (4) Drop in cranking speed 1.2.
TROUBLESHOOTING 1.3 Knocking The diesel engine rotates producing unique combustion noise (diesel knock) due to its combustion system. This knock noise is normal unless it is especially loud. (2) Use of poor quality fuel (low cetane number fuel such as kerosene) 1.3.1 Check items before troubleshooting (1) Clogging of air cleaner element 1.3.
TROUBLESHOOTING 1.4 Overheating 1.4.1 Check items before troubleshooting (1) Quantity and leakage of coolant (2) Loosening of fan belt (3) Clogging of radiator fins (4) Concentration of LLC (5) Clogging of muffler (6) Quantity and degradation of engine oil (7) Swirling of cooling air (8) Thermostat malfunction 1.4.2 Problem: Overheating Overheat often occurs by engine load mismatching when the engine is set up.
TROUBLESHOOTING 1.5 Excessive black smoke 1.5.1 Check items before troubleshooting (1) Clogging of air cleaner element (2) Use of poor quality fuel (3) Overload 1.5.
TROUBLESHOOTING 1.6 Idling malfunction 1.6.1 Check items before troubleshooting (1) Engine control system malfunction (2) Viscosity of engine oil too high (3) Use of poor quality fuel 1.6.
TROUBLESHOOTING 1.7 Low output 1.7.1 Check items before troublshooting (1) Seizure of engine moving parts (2) Viscosity of engine oil too high (3) Use of poor quality fuel (4) Clogging of air cleaner element (5) Clogging of muffler (6) Powertrain malfunction 1.7.
SUPPLEMENT INSPECTION RECORD SHEET（L-SERIES） No.1 Measurement of Cylinder Inside Diameter ····························································Supplement- 2 No.2 Measurement of Valve Guide Inside Diameter and Valve Stem Outside Diameter···································································································Supplement- 3 No.3 Measurement of Valve Seat Angle, Valve Sinkage and Valve Margin ···················Supplement- 4 No.
No.1 INSPECTION RECORD SHEET L Engine Model Company Date Serial No. Inspection Point Measurement of Cylinder Inside Diameter Unit mm [in.] Measuring Positions Standard Cylinder Inside Diameter Nominal Value Standard L2A, L3A φ65 [2.56] 65.00 to 65.03 [2.5591 to 2.5602] L2C, L3C φ70 [2.76] 70.00 to 70.03 [2.7559 to 2.7571] L2E, L3E φ76 [2.99] 76.00 to 76.03 [2.9921 to 2.9933] Limit Remarks +0.7 [+0.0276] Repair. limit: +0.20 [+0.
No.2 INSPECTION RECORD SHEET L Engine Model Company Inspection Point Date Serial No. Measurement of Valve Guide Inside Diameter and Valve Stem Outside Diameter Measuring Positions Unit mm [in.] Standard Nominal Value Standard Limit Inlet φ6.6 [0.260] 6.600 to 6.615 [0.2598 to 0.2604] – Exhaust φ6.6 [0.260] 6.600 to 6.615 [0.2598 to 0.2604] – Inlet φ6.6 [0.260] 6.565 to 6.580 [0.2585 to 0.2591] 6.500 [0.2559] Exhaust φ6.6 [0.260] 6.530 to 6.550 [0.2571 to 0.2579] 6.500 [0.
No.3 INSPECTION RECORD SHEET L Engine Model Company Date Serial No. Measurement of Valve Seat Angle, Valve Sinkage and Valve Margin Inspection Point Measuring Positions Unit mm [in.] Standard Standard Limit Valve Seat Angle 44° – Valve Sinkage 0.4 to 0.6 [0.0158 to 0.0236] – Valve Margin 1.0 [0.0394] 0.5 [0.0197] Measured Values Part Name Valve Seat Angle No.
No.4 INSPECTION RECORD SHEET L Engine Model Company Date Serial No. Measurement of Distortion of Cylinder Head Bottom Surfaces Inspection Point mm [in.] Unit Standard Measuring Positions 㧭 㧮 㧯 Distortion of Cylinder Head Bottom Surfaces 㧰 㧱 Standard Limit 0.05 or less [0.0020] 0.10 [0.0039] 㧲 㧳 Measured Values Distortion of Cylinder Head Bottom Surfaces Part Name No.
No.5 INSPECTION RECORD SHEET L Engine Model Company Date Serial No. Measurement of Clearance Between Connecting Rod Bearing Inside Diameter and Crankshaft Pin Outside Inspection Point Unit mm [in.] Measuring Positions Ԙԙ X X Y Y Z Ԙԙ Standard Nominal Value Standard Limit Connecting Rod Bearing Inside Diameter φ40 [1.57] 40.008 to 40.036 [1.5751 to 1.5762] – Crankshaft Pin Outside Diameter φ40 [1.57] 39.965 to 39.980 [1.5734 to 1.5740] -0.70 [-0.
No.6 INSPECTION RECORD SHEET L Engine Model Company Date Serial No. Inspection Point Measurement of Rocker Arm Inside Diameter and Rocker Shaft Outside Diameter mm [in.] Unit Standard Measuring Positions Nominal Value Standard Limit Rocker Arm Inside Diameter φ12 [0.47] 12.013 to 12.035 [0.4730 to 0.4738] – Rocker Shaft Outside Diameter φ12 [0.47] 11.470 to 11.984 [0.4516 to 0.4718] – Clearance between Rocker Arm and Shaft – 0.029 to 0.065 [0.0011 to 0.0026] 0.200 [0.
No.7 INSPECTION RECORD SHEET L Engine Model Company Inspection Point Date Serial No. Measurement of Piston Pin Bore Diameter and Piston Pin Outside Diameter Measuring Positions 㧮 㧭 mm [in.] Standard Nominal Value 㧭 Unit Piston Pin Bore Diameter Piston Pin Outside Diameter 㧮 㨄 㨄 Limit L2A, L3A L2C, L3C φ18 [0.71] 18.013 to 18.019 [0.7092 to 0.7094] – L2E, L3E φ21 [0.83] 21.014 to 21.017 [0.8273 to 0.8274] – L2A, L3A L2C, L3C φ18 [0.71] 18.001 to 18.007 [0.7087 to 0.
No.8 INSPECTION RECORD SHEET L Engine Model Company Inspection Point Date Serial No. Measurement of Valve Clearance mm [in.] Unit Standard Measuring Positions Standard Inlet 0.25 [0.0098] Exhaust 0.25 [0.0098] Valve Clearance (Cold Setting) Measured Values Valve Clearance No.
No.9 INSPECTION RECORD SHEET L Engine Model Company Inspection Point Date Serial No. Measurement of Valve Opening Pressure of Fuel Injection Nozzle Measuring Positions MPa Unit {kgf/cm2} [psi] Standard Valve Opening Pressure Nominal Value Standard 13.73 {140} [1992] 13.73 to 14.73 {140 to 150} [1992 to 2134] Measured Values Valve Opening Pressure Valve Opening Pressure No.
No.10 INSPECTION RECORD SHEET L Engine Model Company Inspection Point Date Serial No. Measurement of Camshaft Journal Outside Diameter to Cylinder Block Camshaft Bore Clearance (L2) Measuring Positions 㨅 Unit mm [in.] Standard Nominal Value Standard Limit No.2 φ34 [1.34] 33.925 to 33.950 [1.3356 to 1.336] – No.3 φ33 [1.30] 32.925 to 32.950 [1.2963 to 1.2972] – No.2 φ34 [1.34] 34.000 to 34.025 [1.3386 to 1.3396] – No.3 φ33 [1.30] 33.000 to 33.025 [1.2992 to1.3002] – No.2 No.
No.11 INSPECTION RECORD SHEET L Engine Model Company Inspection Point Date Serial No. Measurement of Camshaft Journal Outside Diameter to Cylinder Block Camshaft Bore Clearance (L3) Measuring Positions Unit mm [in.] Standard 㨅 Nominal Value Standard Limit No.2 φ34 [1.34] 33.925 to 33.950 [1.3356 to 1.336] – No.3 No.4 φ33 [1.30] 32.925 to 32.950 [1.2963 to 1.2972] – No.2 φ34 [1.34] 34.000 to 34.025 [1.3396 to 1.3396] – No.3 No.4 φ33 [1.30] 33.000 to 33.025 [1.2992 to 1.
No.12 INSPECTION RECORD SHEET L Engine Model Company Inspection Point Date Serial No. Measurement of Crankshaft End Play Unit mm [in.] Measuring Positions Standard Crankshaft End Play Standard Limit 0.050 to 0.175 [0.0020 to 0.0069] 0.500 [0.
