Daewoo Doosan D427 Diesel Engine 1550XL DSL702Skid Steer Loader Service Manual - PDF DOWNLOAD

SB4034E00 Jul. 2000

Engine For Skid Steer Loaders D427 Diesel Engine 1550XL(DSL702)

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Read and understand all safety precautions and warnings before operating or performing lubrication, maintenance and repair on this product.

Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety precautions are listed in the “Safety” section of the owner/operation/maintenance publication.

Specific safety warnings for all these publications are provided in the description of operations where hazards exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.

If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in this publication and on the product labels are identified by the following symbol.

WARNING Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. DAEWOO dealers have the most current information available.

Engine

1

2.1. General Information

Index Engine

Cooling System

Specifications ............................................................5 Troubleshooting Guide ..............................................6 Adjustment of Cylinder Head Valve Clearance/Idling....8 Adjustment of Valve Clearance .................................8 Idling Inspection..............................................................9 Adjustment ............................................................9 Injection Timing Inspection..............................................................9 Adjustment ..........................................................10 Checking of Compression Pressure........................10 Disassembly and Assembly.....................................11 Inspection and Adjustment Cylinder Head .....................................................21 Valve....................................................................24 Valve Spring ........................................................24 Push Rod ............................................................25 Tappet .................................................................26 Rocker Arm .........................................................26 Piston and Piston Ring........................................27 Connectng Rod ...................................................29 Connectng Rod Bearing......................................30 Crankshaft...........................................................31 Main Bearing .......................................................32 Cylinder Block .....................................................33 Cylinder liner .......................................................33 Camshaft.............................................................34 Gears ..................................................................35 Oil Seal................................................................36

Specifications ..........................................................42 Troubleshooting Guide ............................................42 Thermostat Removal ..............................................................43 Inspection............................................................43 Installation ...........................................................43 Water Pump On-Vehicle Inspection .........................................44 Removal and Inspection .....................................44 Disassembly and Assembly ................................44 Inspection............................................................45 V-Belt Inspection............................................................45

Fuel System Outline .....................................................................46 Structural View ....................................................46 Specifications ......................................................47 Troubleshooting Guide ............................................47 Fuel Filter Removal and Installation.....................................49 Air Bleeding.........................................................49 Water-Drain .........................................................50 Replacement .......................................................50 Injection pump Structural View ....................................................51 On-Vehicle Inspection and Adjustment ...............52 Removal ..............................................................53 Installation ...........................................................54 Air-Bleeding.........................................................54 Injection Nozzle Structural View ....................................................55 Removal ..............................................................55 Inspection and Adjustment..................................55 Assembly.............................................................57 Installation ...........................................................57

Lubrication System Outline Structural View ....................................................37 Specifications ......................................................38 Troubleshooting Guide ............................................38 Inspection Checking Oil Pressure ........................................39 Oil Pump Removal and Installation.....................................39 Disassembly ........................................................39 Inspection............................................................40 Assembly.............................................................41 Oil Pan Removal ..............................................................41 Installation ...........................................................41 Inspection............................................................41

Diesel Engine D427

3

Index

Engine Electrical System Specifications ..........................................................58 Troubleshooting Guide ............................................58 Starter On-Vehicle Inspection .........................................60 Removal ..............................................................60 Installation ...........................................................60 Free Running Test...............................................60 Disassembly ........................................................61 Inspection............................................................62 Alternator Circuit Diagram ...................................................65 Charging system cautions...................................65 On-Vehicle Inspection .........................................65 Checking No-Load Adjustment Voltage ..............66 Checking Output .................................................66 Removal ..............................................................66 Installation ...........................................................67 Disassembly and Assembly ................................67 Inspection............................................................69 Glow Plugs Checking Open Circuit of Glow plugs .................70 Removal and Installation.....................................70

Technical Data ..............................................72

Diesel Engine D427

4

Index

Engine Specifications Specifications Engine model

D427

Type

Diesel, four-cycle

Number and arrangement of cylinders

Four cylinders, in-line

Displacement

cc

Type of combustion chamber

Swirl floor type

Valve system

Over head valve(O.H.V)

Bore and stroke

mm X mm(in X in)

Compression ratio

Valve timing Exhaust valve

Open

BTDC 14˚

Closed

ABDC 44˚

Open

BBDC 48˚

Closed

ATDC 10˚

Injection Timing

ATDC 2˚ mm(in)

Intake

0.30(0.012)

Exhaust

0.30(0.012)

Idling speed

rpm

Firing order

Diesel Engine D427

92.0 X 101.6(3.62 X 4.00) 21.5 : 1

Intake valve

Valve clearance

2701

1100 L 25 1-3-4-2

5

Engine

Troubleshooting Guide Troubleshooting Guide Problem Insufficient power

Possible Cause Insufficient compression improper valve clearance Compression leakage from valve seat Seized valve stem Weak or broken valve spring Cracked or distorted cylinder head Sticking, damaged, or worn piston ring Cracked or worm piston Malfunction of fuel svstem

Excessive oil consumption

Remedy Adjust Repair (grind the valve seat) Replace Replace Replace Replace Replace Refer to Group 4

Oil working up Worn or sticking piston ring or piston ring groove Worn piston or cylinder Oil working down Bad valve seal Worn valve stem or guide Oil leakage

Replace Replace Refer to Group 2

Malfunction of engine-related components Burned valve Worn piston, piston ring, or cylinder Burned cylinder head gasket Malfunction of fuel system Malfunction of electrical system

Replace Replace or repair Replace Refer to Group 4 Refer to Group 5

Abnormal combustion

Malfunction of engine related components improper valve clearance Sticking or burned valve Weak or broken valve spring Carbon accumulation in combustion chamber Malfunction of fuel system

Adjust Replace Replace Eliminate the carbon Refer to Group 4

Poor idling

Malfunction of engine-related components Improper valve clearance Poor valve to valve seat contact Failure of cylinder head gasket Malfunction of fuel system

Adjust Repair or replace Replace Refer to Group 4

Difficult starting

Diesel Engine D427

6

Replace Replace or repair

Engine

Problem Engine noise

Diesel Engine D427

Possible Cause Crankshaft or bearing-related parts Excessive main bearing oil clearance Main bearing seized or heat-damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing seized or heat-damaged Piston-related parts Worn cylinder Worn piston or piston pin Seized piston Damaged piston ring Bent connecting rod Valves or related parts Excessive valve clearance Broken valve spring Excessive clearance between valve stem and guide Others Malfunction of water pump bearing Improper drive-belt tension Malfunction of alternator bearing Exhaust gas leakage Malfunction of timing belt tensioner

7

Remedy Replace or repair Replace Replace or repair Replace or repair Replace Replace of repair Replace Replace Replace Replace Adjust Replace Replace Replace Adjust Replace Repair Replace

Engine

Adjustment of Cylinder Head Valve Clearance/Idling

Adjustment of Valve Clearance

Adjustment of Cylinder Head

Fig 1-3

1. Remove the cylinder head cover.

Fig 1-2

2. With the No. 1 cylinder piston at TDC, check and adjust piston clearance as follows :

1. Remove the cylinder head cover.

2. Remove the head bolts.

Intake side : No.1, No.2 Exhaust side : No.1, No.3 Valve clearance(under cold engine condition) Intake & Exhaust : 0.30 mm (0.012in)

3. Tighten head bolts to the specified torque, in the numbered order shown in the figure. Use the torque wrench.

3. Set the No.1 cylinder to compression TDC by turning crankshaft, and then check and adjust piston clearance as follows :

Tightening torque(under cold engine condition) : 11.0 ~ 11.7 m•kg (78.6 ~ 84.6 ft•lb) 4. Adjust valve clearance when fixing bolts.

Intake side : No.3, No.4 Exhaust side : No.2, No.4 4. Assemble the cylinder head cover.

Diesel Engine D427

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Engine

Idling Inspection 1. Warm up the engine thoroughly.

2. Run the engine at idle.

Standard ldling speed : 1100 L 25 3. Adjust the idling speed if the speed is not within the specified range.

Fig 1-8

3. Set measuring instrument to injection pump. Make sure that the filler end of measuring device is in contact with plunger head.

Adjustment Adjust the idling speed by turning the idling adjusting bolt of the injection pump.

1. Remove the lock nut of the idling adjusting bolt.

2. Turn the idling adjusting bolt until the idling speed reaches standard valve.

3. Tighten the lock nut.

4. Run the engine for about 2-3 minutes and check if the idling speed is at standard value.

Fig 1-9

4. With the flywheel ring gear in proximity to BTDC 30˚ find the point where needle of dial gauge stands still, even when the flywheel is being turned.

Injection Timing

5. When it is confirmed that the needle of dial guage is not moving, then set the needle of the dial gauge to “O”

Inspection

Fig 1-7

Fig 1-10

1. Remove all injection pipes.

6. Turn the flywheel clockwise until it reaches TDC, lnjection timing is normal if dial gauge indicates 1.00mm at this point.

Adjust if more than 1.00mm.

2. Remove the head bolt and gasket from the distributor on the injection pump.

Cam lift for optimal injection timing : 1.00 mm (0.039 in) Diesel Engine D427

9

Engine

Adjustment

Checking of Compression Pressure

Injection timing is too early when cam lift value is more that 1.00mm, and too late when it is less than 1.00mm.

Fig 1-13 Fig 1-11

1. Warm up the engine thoroughly.

2. Remove the nozzle holders from all cylinders.

1. If injection timing is not right, then turn the injection pump until the dial gauge indicates 1.00mm.

(1) If cam lift value is less than 1.00mm, turn injection pump in direction of engine rotation to its maximum, and then adjust the cam lift value to 1.00mm, by turning it in counter direction.

(2) If cam lift value is more than 1.00mm, adjust it by turning injection pump in counter direction to engine rotation, until value reaches 1.00mm.

3. Install the adapter set and use a pressure gauge of capacity greater than 30 kg/cm2 4. Remove the fuel cut solenoid wiring.

5. Crank the engine and measure compression pressure.

2. Install the bolts and gasket after adjusting.

CAUTION : Use new head bolts and gasket.

Compression pressure

kg/cm2 (lb•in2)-rpm

Standard

30(426)-200

Limit

27(384)-200

3. Install the injection pipes.

CAUTION : If the pressure does not come up to the specified pressure, check the engine speed.

At normal engine speed, if compression pressure is less or more than the standard, and the pressure differences in each cylinder are more than 3 kg/cm2, it is necessary to disassemble and readjust the engine.

Diesel Engine D427

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Engine

Disassembly and Assembly Disassembly and Assembly Disassemble in the following sequence. Assembly is the reverse order of disassembly.

1. Remove the Fuel pipes.

2. Remove the Starter motor.

3. Remove the Engine mounting bracket.

4. Remove coupler from the engine.

5. Set the engine on the engine hanger 6. Remove the following parts from the engine : (1) Alternator (7) Exhaust manifold (2) V-belt (8) Ventilation pipe (3) Crankshaft pulley (9) Injection pipe (4) Flywheel (10) Oil filter (5) End plate (11) Intake manifold (6) Water hose (12) Thermostat case

Diesel Engine D427

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Engine

7. Remove the cylinder head parts in the numbered order shown in the figure.

Fig 1-24 (1) Cylinder head cover. (2) Gasket. (3) Rocker arm. (4) Cylinder head. (5) Gasket. (6) Push rod. (7) Intake valve.

(8) Exhaust valve. (9) Valve guide.

Diesel Engine D427

12

Engine

8. Disassemble the piston and oil pan in the numbered order shown in the figure.

Fig 1-25 (1) Piston ring. (2) Piston. (3) Piston pin. (4) Connecting rod. (5) Connecting rod bearing set. (6) Oil pipe. (7) Set screw.

(8) Oil pump. (9) Oil level gauge. (10) Gasket. (11) Oil pan.

Diesel Engine D427

13

Engine

9. Disassemble the timing gear and the related parts in the numbered order shown in the figure.

Fig 1-26 (1) Timing case cover. (2) Gasket. (3) Oil deflector. (4) Injection pump cover. (5) Gasket. (6) Locking bolt.

(7) Thrust plate. (8) Idle gear. (9) Spindle. (10) Crankshaft gear. (11) Lock nut. (12) Lock plate.

(13) Cam gear. (14) Lock nut. (15) Lock plate. (16) Injection pump gear. (17) Timing case. (18) Oil seal

Diesel Engine D427

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Engine

10. Disassemble the crankshaft, cylinder block and the parts in the numbered order shown in the figure.

Fig 1-27 (1) Main bearing cap. (2) Bearing set. (3) Crankshaft. (4) Thrust plate. (5) Cam shaft. (6) Tappet. (7) Oil seal cap. (8) Gasket.

(9) Oil seal. (10) Cylinder liner. (11) Cylinder block.

Diesel Engine D427

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Engine

Fig 1-28

Fig 1-31

11. Disassemble the pulley lock bolts and crankshaft mounting bolts, preventing flywheel rotation prevent the flywheel from rotating and remove the pully lock bolts and crankshaft mounting bolts.

14. Remove the valve guide, pushing it towards combustion chamber by using the valve guide installer.

Fig 1-32 Fig 1-29

15. Assemble the valve guide in the following order.

12. Remove crankshaft pulley by using the taper ring remover

(1) Set valve guide on the opposite side of the combustion chamber and tap down by using the valve guide installer, until the height of the valve guide comes near to the level of the valve guide installer scale.

(2) Check the part of the valve guide protruding after assembling.

Standard Height of protruding part above the cylinder head : 16.5 mm (0.650 in)

Fig 1-30

13. Remove the taper sleeve after compressing the valve spring by using valve spring lifter and pivot

Diesel Engine D427

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Engine

Fig 1-33

Fig 1-36

16. Remove the piston pin by using the piston pin remover & installer.

19. Assemble the piston rings and oil rings onto piston as shown in the figure.

CAUTIONS : a) Gaps on the top ring and second ring must be placed on the opposite side of combustion chamber. b) Gap on the top ring should not face thrust side or counter thrust side. c) Gap on the top ring should be set on opposite side (180˚) of oil ring gap.

Fig 1-34

17. Assemble the piston and connecting rod, after inserting connecting rod into piston as shown in the figure.

Fig 1-37

20. Install the piston into cylinder block by using the piston ring compressor, and make sure that the piston is placed as shown in the figure. (Install the piston so that “F” mark on the piston faces the front side of the engine).

Fig 1-35

18. Assemble the piston rings after checking that the “Y” marked surfaces of the rings appear on the upper side of the rings.

Diesel Engine D427

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Engine

Fig 1-39

Fig 1-42

21. Adjust valve clearance after assembling. Oil pan gasket is composed of side, front and back gaskets as shown in the figure.

24. Remove the injection pump gear by using the extractor.

CAUTION : Use new oil pan gasket.

Fig 1-43

25. Install the idling gear with its reference mark (punched mark) meeting those of other pears.

Fig 1-40

22. Remove the timing gear by using the bearing puller set

Fig 1-44

26. Insert the oil seal, by using the oil seal puller & installer timing cover.

Fig 1-41

23. Remove the cam gear by using the timing gear case cover mounting bolts and bearing puller set.

Diesel Engine D427

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Engine

Fig 1-45 Fig 1-48

CAUTIONS a) Position the bearing cap and bearing according to their numbers. b) Line up thrust washers upright, and be careful not to alter bearing combination.

28. Install the cylinder liner, and measure cylinder inner diameter and height of liner protruding part.

Standard cylinder bore dia : 92.025 ~ 92.050 mm (3.623 ~ 3.624 in ) Protrusion height above cylinder block : -0.101 ~ 0 mm (-0.004 ~ 0 in)

Fig 1-46 Fig 1-49

27. Remove the cylinder liner, by using cylinder liner replacer and press.

29. Assemble the main bearing in reverse order of disassembly carefully not to apply oil on the back of the bearing.

Cylinder liner assembling pressure :1 ~ 3 tons

30. Apply the grease on crankshaft main journal and crank pin.

Fig 1-47

NOTES : a) If cylinder liner is difficult to remove, then bore the liner until it comes loose. b) Check for any damage or scratch on the cylinder bore wall after removing the liner and, if there is any defect, repair by using fine sandpaper.

Diesel Engine D427

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Engine

Fig 1-50

Fig 1-53

31. Assemble the main bearing cap, directing arrow mark on the top of the cap towards engine front.

35. Replacing valve seal (1) Remove the valve seal by using the suitable tools.

(2) Insert new seal into valve guide.

(3) Assemble the valve seal by using the valve seal pusher. Press valve seal pusher until the valve seal reaches the bottom of valve spring seat.

32. Assemble the thrust washers on both sides of center bearing, with their oil grooves facing outwards.

Fig 1-51

33. Apply engine oil to connecting rod bearing, and make sure that the weight marks on the connecting rod and bearing cap meet each other.

Fig 1-52

34. Check to make sure that the end of push rod is set at the hollow point of the tappet.

Diesel Engine D427

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Engine

Replacement of Insert

Inspection and Adjustment Cylinder Head Inspection of Cylinder Head

Fig 1-57

Inspect insert for damage and crack. If a problem is found, replace the part.

Fig 1-55

1. Inspect for distortion, damage and cracks. If a problem is found, repair or replace the part.

2. Measure cylinder surface (combustion chamber side) for distortion with straight edge and filler gauge.

Fig 1-58

1. Romove insert by hitting round steel rod with a hammer after inserting the round steel rod into glow plug hole or nozzle holder hole.

Fig 1-56

3. Measure cylinder head for distortion in the six directions shown in the figure. If cylinder head distortion exceeds the limit, replace the cylinder head.

Distortion limit : A, B : 0.1 mm (0.004 in) C, D, E, F : 0.25 mm (0.010 in)

Fig 1-59

2. Set the insert at the specified position on cylinder head, adjust so that it connects with welsh washer.

Set it facing towards cylinder head gasket and set the welsh washer at its original positon.

3. Tap the center of the welsh washer slightly, to fix it.

Diesel Engine D427

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Engine

Inspection of Valve and Valve Seat Contact Surface

Repair of Valve and Valve Seat Surface

Inspect contact surface of valve and valve seat as follows :

Fig 1-62

1. If the problem is slight, grind the valve with a valve grinder and compound.

Fig 1-60

1. Apply Prussian blue on contact area of valve seat.

2. Press down valve onto valve seat.

3. Check how Prussian blue adheres to the valve, and see if it is properly in contact with valve seat.

Inspection of Valve seat Contact Position Fig 1-63

Check the surface which contacts the valve face. The valve contact position in relation to the valve seat must be at the center of the circumference.

2. If the problem is a little serious, repair the valve seat to the specifid angle with a valve cutter.

Valve seat angle Intake valve : 45˚ Exhaust valve : 30˚ Valve seat contact with : Intake valve : 2.0 mm (0.079 in ) Exhaust valve : 2.0 mm (0.079 in )

Fig 1-61

Standard valve seat contact width : 2.0 mm (0.079 in)

Diesel Engine D427

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Engine

Fig 1-64

Fig 1-66

3. Grind the valve, with 3 valve grinder and compound.

4. Check lenght “L” before adjusting.

Projection Length of Valve Stem Above Cylinder Head(Length ÒLÓ) Measure the projection length of the valve stem above the cylinder head (lenght “L” ) and, if more than standard, adjust according to the following instructions :

Fig 1-67

(2) 0.5mm ~ 1.5mm long Place a washer (inner dia. 12.8mm, outer dia. 39 mm) under the lower spring seat. Adjust length “L” as standard valve.

Standard lenght “L” 48.05 mm (1.89 in)

(3) 1.5mm above Replace new one, and then measure length “L”.

Fig 1-65

(1) 0 ~ 0.5mm long Use without adjusting.

Diesel Engine D427

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Engine

Valve

Clearance Between Valve Stem and Valve Guide

Checking Condition

Measure the clearance of max-wear piston between valve stem and valve guide with a dial gauge, by turning valve and moving valve stem horizontally.

Fig 1-68 Fig 1-70

Visually inspect the valve for even seating of valve seat with the center part of the valve, and check for defect. If any defective part is wide, replace valve and grind it if defective area is minor.

Clearance limit Intake : 0.127mm (0.0050 in) Exhaust : 0.127mm (0.0050 in) If the clearance exceeds the limit, replace valve and valve guide.

Dimensions of Valve

Valve Spring Checking Free Length Measure uncompressed length with calipers.

Fig 1-69 Fig 1-71

Thickness of head (valve verge) Standard : Intake : 1.7 mm (0.0669 in) Exhaust : 1.5 mm (0.0591 in) DIA. of valve stem : Standard: Intake : 8.955 ~ 8.980mm (0.3526 ~ 0.3535 in) Exhaust : 8.935 ~ 8.960mm (0.3518 ~ 0.3528 in) Limit : Intake : 8.904mm (0.3506 in) Exhaust : 8.884mm (0.3498 in) Diesel Engine D427

Uncompressed length limit Outer spring : 52.9 mm (2.083 in) Inner spring : 42.0 mm (1.654 in) Replace the spring if shorter than uncompressed length limit.

24

Engine

Checking Tension

Push Rod

Measure tension of assembled valve spring by using valve spring tester.

Checking Condition

Fig 1-74 Fig 1-72

1. Place valve spring on a valve spring tester.

Inspect both ends of push rod for wear or damage, and replace if necessary.

2. Compress the valve spring to assembled lenght.

(Compress several times).

Checking Deflection

3. Measure the spring tension when the spring is compressed longitudinally.

Spring

Assembled length

Standard, tension of assembled spring

Allowable tension

Outer spring 40.3 mm(1.587 in) 18.0 L 0.9kg(39.7 L 2.0 lb)

15.9kg(35.1 lb)

37.8 mm(1.488 in) 12.7 L 0.6kg(28.0 L 1.3lb)

11.3kg(24.9 lb)

Inner spring

Place the push rod on a plane surface, and measure the clearance between the plane surface and rod with feeler gauge.

Checking Perpendicular Place the spring on a surface, and measure the variation form perpendicular at the top of the spring.

Fig 1-75

Deflection limit : 0.19 mm (0.075 in) If the deflection exceeds the limit straighten or replace.

Fig 1-73

Angle limit Outter spring : 1.37mm (0.0539 in) Inner spring : 1.25 mm (0.0492 in)

Diesel Engine D427

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Engine

Tappet

Rocker Arm

Checking Condition

Checking Condition

Fig 1-78

Fig 1-76

Inspect tappet for crack or damage, and replace it if necessary. Inspect contact point with came, and replace it if it is worn out.

1. Inspect every part of rocker arm assembly for crack or damage, and replace it if necessary.

2. Inspect oil holes of rocker arm and shaft, and clean them if blocked.

Checking of Clearance Between Tappet and Tappet Guide Checking Clearance

Fig 1-77 Fig 1-79

Measure the clearance between tappet and tappet guide, and replace tapper or cylinder block if the clearance exceeds the limit.

Measure the clearance between rocker arm shaft and rocker arm bushing with a dial gauge.

Clearance limit : 0.07 mm (0.0028 in)

Clearance limit : 0.10 mm (0.0039 in)

Replace the rocker arm shaft and bushing, if the clearance exceeds the limit.

Diesel Engine D427

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Engine

Replacement of Rocker Arm Bushing

Piston and Piston Ring Checking Condition

Fig 1-80 Fig 1-82

1. Inspect sliding surface, ring groove, and other parts for crack or damage, and replace if necessary.

2. Inspect for breakage, burning, wear and other defects on the rings, and replace if necessary.

Fig 1-81

1. Remove the bushing by using press and round steel rod of proper diameter.

2. Press into the bushing by aligning the oil hole of rocker arm bushing.

3. Bore the bushing by using expansion reamer and pin hole grinder, in order to be within standard clearance between bushing and shaft after installing.

Standard clearance : 0.016 ~ 0.061 mm (0.0006 ~ 0.0024 in )

Diesel Engine D427

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Engine

Checking Clearance

Checking Piston Ring end Gap Measure piston ring end gap after inserting piston ring into a cylinder liner.

Fig 1-83

Fig 1-85

(1) When reusing the piston ring : Measure the gap, placing the ring at the point where the cylinder liner is most worn.

(2) When replacing the piston ring : Measure the gap, placing the ring at the point where the cylinder liner is least worn.

End gap limit : 1.5 mm (0.059 in)

Fig 1-84

Measure the clearance between piston and cylinder liner, and replace piston or cylinder liner if the clearance exceeds the limit.

Checking clearance Between Piston Ring Groove and Piston Ring

Piston and cylinder liner clearance limit : 0.044 ~ 0.070 mm (0.0017 ~ 0.0028 in) Measure the piston outer diameter in the thrust direction, 18mm (0.71 in) above the bottom of piston.

Standard piston outer diameter : 91.967 ~ 91.993mm (3.621 ~ 3.622 in)

Fig 1-86

1. Install the piston ring into the piston.

2. Measure clearance between piston ring groove and piston ring with a filler gauge. Replace piston or piston ring if the clearance exceeds the limit.

Clearance limit : 0.3 mm (0.012 in)

Diesel Engine D427

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Engine

Connecting Rod

Checking end Play of Big end

Checking Condition

Check end play of the big end of the connecting rod, and replace connecting rod or crankshaft if the play exceeds the limit.

Fig 1-87 Fig 1-89

Inspect connecting rod at both ends for crack of damage on the surface, and replace it if necessary.

1. Fit connecting rod to crankshsft.

2. Measure end play by using a dial gauge with magnetic base.

Checking for Bending & Torsion

End play limit : 0.40 mm (0.016 in)

Checking Clearance Between Piston Pin and Bushing

Fig 1-88

Check for banding or torsion of connecting rod by using connecting rod aligner, and modify the connecting rod with a press, replace it.

Bending limit : 0.05 mm (per 100mm)

Fig 1-90

Measure the clearance between piston pin and bushing as shown in the figure, and replace piston pin or bushing if the clearance exceeds the limit.

Clearance limit : 0.05 mm (0.002 in)

Diesel Engine D427

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Engine

Replacement of Small end Bushing

Fig 1-93

Fig 1-91

When grinding the bushing make sure that the reamer is precisely inserted to prevent a rough bushing surface always grind in the direction of cutting. Always be sure not to stop the reamer at same points. When repairing the small end bushing with a pin hole horning machine, the bushing hole tends to incline to one direction, so change the connecting rod position many times during the horning process until horning size reaches standard.

1. Replace the bushing by using a rod and press.

Connecting Rod Bearing Checking Condition Fig 1-92

2. Push the bushing with a press, confirming that the oil holes of connecting rod and bushing are in alignment with each other.

3. Adjust bushing hole with a reamer so that the clearance between piston pin and bush is within standard.

Standard clearance : 0.014 ~ 0.044 mm (0.0006 ~ 0.0017 in) Fig 1-94

Check connecting rod bearing for burning, melting and other damage, and replace if necessary.

Diesel Engine D427

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Engine

Checking Clearance

Crankshaft

Measure the oil clearance between crankshaft journal and connecting rod bearing with a plasti-gauge, in the follwing order.

Checking Condition

Fig 1-96 Fig 1-95

1. Inspect the crankshaft for crack, breakage, or other damage, and replace it if necessary.

1. Remove oil residue from joural and bearing.

2. Check if oil holes are clogged, and unblock them by using compressed air or a needle if clogged.

2. Set plasti-gauge to axial direction on a journal.

3. Install bearing cap and tighen to the specified torque.

Checking Wear

Cap bolt tightening torque : 7.6 ~ 8.3 m•kg (55.0 ~ 6.0 ft•lb) 4. Measure the clearance by using the plastigauge after removing the cap.

Oil clearance Standard : 0.059-0.090 mm (0.0023 ~ 0.0035 in) Limit : 0.12 mm (0.0047 in) If the oil clearance exceeds the standard value, grind the crank pin use undersized bearing.

Fig 1-97

1. Inspect the crankshaft for wear.

2. Inspect crankshaft pin and main journal in all directions (front and rear, diagonal directions), and if wear and tear of the crankshaft is beyond allowance limits, grind it to undersize and use undersized main bearing.

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31

Engine

Checking Deflection

Main Bearing Checking Condition

Fig 1-98 Fig 1-100

1. Place and secure both ends of the crankshaft on V-blocks.

Check the main bearing for wear, melting and other damage and replace it if necessary.

2. Measure the deflection by placing a dial gauge on the center of main journal and crankshaft slowly.

Replace crankshaft if the value exceeds the limit.

Read the maximum value on the dial gauge.

Checking Clearance

Deflection limit : 0.05 mm (0.002 in)

Checking end Play

Fig 1-101

Measure oil clearance between main journal and main bearing by using plasti-gauge.

Fig 1-99

Oil clearance Standard : 0.059 ~ 0.090 mm (0.0023 ~ 0.0035 in) Limit : 0.12 mm (0.0047 in)

Measure crankshaft end play by placing a dial gauge on crankshaft rear end and by moving crankshaft back and forth in the axial direction. If the value exceeds the limit, replace the thrust washer, which is inserted to the center bearing with 0.718 mm oversized one.

If oil clearance exceeds the limit, grind the main jounal and use the undersized bearing.

End play Standard : 0.14 ~ 0.39 mm (0.0055 ~ 0.0154 in) Limit : 0.4 mm (0.016 in)

Diesel Engine D427

32

Engine

Cylinder Block

Cylinder Liner

Checking Condition

Checking Wear Measure the inner diameter of cylinder liner, and check for wear, and its extent. Measure the inner diameter at 3 positions, of top, middle and buttom at sections X-X, and Y-Y, as shown in the figure

Fig 1-102

1. Inspect the cylinder block for crack, breakage, damage or other defects, and repair or replace if necessary.

Fig 1-104

2. Check if oil holes and coolant passages are clogged, and pierce with compressed air or needles as necessary.

Wear limit Wear=Measured highest value-Standard highest value Standard cylinder liner : 92.025 ~ 92.050 mm (3.623 ~ 3.624 in)

Checking Distortion

Fig 1-103 Fig 1-105

Measure the distortion of top surface of the cylinder block, and repair or replace if the distortion exceeds the limit.

If the wear exceeds 2.0 mm ( 0.079 in), replace the cylinder liner.

Distortion limit A B : 0.10 mm (0.004 in) C D : 0.25 mm (0.010 in)

Diesel Engine D427

one-sided wear limit One-sided wear=Measured highest value Measured lowest valve If the one-sided wear exceeds 2.0mm (0.079 in), replace the cylinder liner.

33

Engine

Camshaft

Checking The Cam Journal Wear

Checking Condition

Check the cam jounal for wear, and replace the cam shaft if the wear exceeds the limit.

Inspect camshaft for crack, breakage, damage of other defects, and replace it necessary.

Fig 1-108

Fig 1-106

Journal Diameter 1. Repair for replace if necessary.

No.1

2. Be careful not to change the original shape of the cam when repairing.

51.910-51.940mm 2.044 - 2.045 in)

No.2

51.660-51.690mm (2.034-2.035 in)

No.3

51.410-51.440mm (2.24-2025 in)

No.4

51.160-51.190mm (2.014~ 2.015)

Checking Height

Wear limit

0.008mm (0.0003 in)

Checking Deflection

Fig 1-107

Check the height of the cam, and replace if lower than minimum height.

Cam height limit : (42.478 mm) (1.672 in) Fig 1-109

Minor cam surface defects can be repaired by using a fine abrasive compound, but be careful not to change the original of the cam when repairing.

Support both ends of the camshaft with V-blocks.

Measure in deflection with dial gauge on journal by turning the camshaft slowly. If the deflecetion exceeds the limit, replace the camshaft.

Deflection limit : 0.8 mm (0.032 in)

Diesel Engine D427

34

Engine

Checking end Play

Gears(Cam Shaft Gear, Idling Gear, Cam Gear, Injection Pump Gear) Checking Condition

Fig 1-110

Measure the end play, and replace thrust plate if the value exceeds the limit.

Fig 1-113

1. Mount thrust plate and camshaft gear on camshaft.

Replace gear if the gear teeth have been cracked or damaged.

2. Tighten the lock bolt to the specified torque.

Checking Backlash

Bolt tightening torque : 6.2 ~ 7.0 m•kg (44.8 ~ 50.6 ft•lb) End play limit : 0.3 mm (0.012 in)

Measure backlash between idling gear and other gears with a dial gauge.

Backlash Standard : 0.10 ~ 0.17 mm (0.004 ~ 0.007 in) Limit : 0.3 mm (0.012 in)

Checking Journal Oil Clearance

Checking Idle Gear end Play

Fig 1-111

Check the oil clearance by measuring inner diameter of camshaft bearing, and outer diameter of cam journal. If the oil clearance exceeds the limit, replace the camshaft or cylinder block.

Fig 1-114

Measure the end play by inserting a filler gauge bewteen idling gear and thrust.

Oil clearance limit : 0.145 mm (0.006 in)

Standard end play : 0.15 ~ 0.28 mm (0.006 ~ 0.011 in)

Diesel Engine D427

35

Engine

Checking Oil Clearance Between Idling Gear and Spindle

Oil Seal (Timing Gear Cover Oil Seal, Rear Oil Seal) Checking

Fig 1-115

Measure the oil clearance by checking inner diameter of idling gear and outer diameter of spindle. If the oil clearance exceeds limit, replace idling gear bushing and spindle.

Fig 1-116

Oil clearance Standard : 0.034 ~ 0.048 mm(0.001 ~ 0.003 in) Limit : 0.15 mm (0.06 in)

Fig 1-117

Inspect oil seals for wear, breakage and damage, and replace defective oil seals.

Diesel Engine D427

36

Engine

Lubrication System Outline Structural View

Fig 2-1

Diesel Engine D427

37

Lubrication Systems

Specifications Lubrication System Oil pump

Force-feed type Type

Trochoid type 3.8 kg/cm2(56.9 lb/in2)

Oil pressure control valve opening pressure Oil Filter

Type

Full-flow type, paper filter

Oil filter relief valve opening pressure Oil cooler

0.8~1.2kg/cm2(11.4~17.1 lb/cn2)

Type

water cooled type 0.2~0.4kg/cm2(2.8~5.7 lb/in2)

Oil warning lamp activation pressure

Troubleshooting Guide Preblem

Possible Cause

Remedy

OIl leakage

Loose drain plug Faulty seal oil and cylinder block Damaged cylinder head cover Loose oil pump body bolt, cylinder head cover bolt, or oil pan bolt Damaged front housing gasket, or cylinder head gasket Faulty oil seal(s) Loose oil filter Loose or damaged oil pressure switch

Tighten or replace Replace Replace Tighten Replace Replace Tighten Tighten or replace

Oil pressure drop

Oil leak Insufficient oil Worn and/or damaged oil pump gear Worn plunger(inside oil pump) or weak spring Clogged oil strainer Excessive lubrication clearance between main bearing and connecting rod bearing

As described above Add oil Replace Replace Clean it

Oil pressure drop Malfunction of oil pressure switch Problem in electrical system

As described above Repair Repair

Warning lamp illuminates while engine running

Diesel Engine D427

38

Refer to Group 1

Lubrication Systems

Inspection

Oil Pump

Checking Oil Pressure

Rremoval and Installation Remove each part in the following order, lnstallation is the reverse order of removal.

1. Drain engine oil.

2. Remove the oil pan.

3. Remove the oil pipe.

4. Remove the oil pump.

Fig 2-2

Disassembly 1. Remove the oil pressure switch.

Disassemble in the following sequence : 2. Mount the oil pressure gauge on the cylinder block hole where oil pressure switch had been installed.

3. Start the engine and warm it up to an appropriate temperature.

4. Read the gauge, holding the engine speed steady(High idle).

Oil pressure limit : 3.8kg•cm2 (54.1 lb•in2) IF the oil pressure exceeds the limit, each part and repair if necessary.

FIG 2-3 (1) Oil pump body. (2) Set screw. (3) Nut. (4) Plunger.

(5) Spring. (6) Plug. (7) Drive shaft. (8) Outer rotor (9) Inner rotor. (10) Cover. (11) Oil strainer. (12) Oil pipe

Diesel Engine D427

39

Lubrication Systems

Clearance Between Outer Rotor and Pump Doby

Inspection Checking Condition Check all parts visually, and replace if necessary.

Carefully check the sliding surface of the pump cover, and replace if significantly of the pump cover, and replace if significantly defective (Repair minor defects by grinding with grinding compound).

Clearance Between Pump Body And Shaft Fig 2-7

Measure clearance between outer rotor and pump body with a leaf gauge. If the clearance exceeds the limit, replace the rotor or pump body.

Clearance limit : 0.3 mm (0.012 in)

Clearance Between Rotor and Pump Cover Fig 2-5

Measure the clearance with a dial gauge and magnetic base.

Clearance limit : 0.1 mm (0.004 in) If the clearance exceeds the limit, replace the pump drive shaft, inner rotor, pump body and drive gear.

Fig 2-8

Clearance Between Inner and Outer Rotor

Check the end float of the rotor. Place a flat ruler across the pump body and measure the clearance between ruler and rotor. If the clearance exceeds the limit, replace the drive gear, drive shaft, inner rotor, outer rotor and pump body.

Clearance limit : 0.15 mm (0.006 in)

Free Length of Plunger Spring Check wear of relief valve plunger and spring defect.

Fig 2-6

Free length of spring : 40 mm (1.57 in)

Measure the clearance with a leaf gauge. Replace both rotors if the clearance exceeds the limit.

Clearance limit : 0.3 mm (0.012 in)

Diesel Engine D427

40

Lubrication Systems

Assembly

7. Remove the gasket.

8. Remove the level switch from the oil pan (if installed).

9. Remove oil level gauge pipe from the oil pan upper bock.

Installation Install in the reverse order of removal Fig 2-9

CAUTION : Install oil pan upper block with its assembly surface conforming to the cylinder block under part.

Assemble in reverse order of disassembly.

CAUTION : When assembling the rotor on the body, confirm that the matching marks are in the front of the cover.

Replace the oil pan gasket with a new one. Apply a thin coating of engine oil to gasket between the cylinder block and the oil pan. Tighten the oil pan bolts and nuts on the cylinder block to the specified torque.

Cover tightening torque : 0.8 ~ 1.2 m•kg (5.79 ~ 8.68 ft•lb)

Tightening torque : 1.6 ~ 2.3 m•kg (11.6 ~ 16.6 ft•lb)

Oil Pan Inspection

Removal

1. Remove dust and chips from oil pan.

2. Inspect the oil pan for cracking, and check the drain plug spiral part for damage. Check bolt hole for any damage due to excessive tightening.

Repair such damaged part, and replace if difficult to repair.

Fig 2-10

1. Drain engine oil.

2. Remove the hose between the vacuum pump and the oil pan upper block.

3. Remove the oil level gauge pipe from the rubber hose.

4. Remove the oil level switch coupler (if installed).

5. Remove the oil pan.

6. Remove the gasket.

Diesel Engine D427

41

Lubrication Systems

Cooling System Specifications Cooling Method

Water-cooled Type

Wax type(2 stage)

Opening temp

82 L 1.5˚C

Full-open temp

95˚C

Full-open lift

8.0mm (0.31 in) or more

Water pump type

Type

Centrifugal, timing belt driven

Radiator

Type

Corrugated 1.0 L 0.15 kg/cm2(14.2 L 2.1 lb/in2)

Cap valve opening pressure

Troubleshooting Guide Preblem

Possible Cause

Remedy

Water leakage

Damaged radiator core seam Leakage from radiator hose or heater hose Leakage from water temperature switch Leakage from water seal (water pump) Damaged or loose thermostat cover or gasket Loose cylinder head bolt Damaged cylinder block Cracked cylinder head

Replace Repair or replace Repair or replace Replace Repair or replace Tighten Replace Replace

Corrosion

Impurities in coolant

Clean

Overheating

Water passage clogged Thermostat malfunction Radiator fins clogged Water pump malfunction Insufficient coolant Thermo - modulated cooling fan malfunction Radiator cap malfunction

Clean Replace Clean Repair or replace Add Replace Replace

Diesel Engine D427

42

Cooling System

Inspection

Thermostat Removal Remove the thermostat in the following sequence.

Fig 3-11

Put the thermostat and a thermometer in water, heat the water temperature gradually and raise the temperature, both when the thermostat valve starts to open and when it is fully open. If the temperature values are lower than the specified values, replace the thermostat.

Fig 3-9

Opening temp

Full-open temp

Full-open lift

82˚C L 1.5˚C

95˚C

8mm(0.3in) or more

Installation Install the thermostat in the reverse order of removal.

Notes Fig 3-10

1. Remove the coolant. Drain the coolant until the coolant level drops below the thermostat case.

2. Remove the radiator upper hose.

3. Remove the thermostat.

Fig 3-12

a) Replace the gasket whenever installing the thermostat cover. b) Set the thermostat with its air hole on top. c) After installing the thermostat, fill the coolant, start the engine, and check for any leakage.

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43

Cooling System

Disassembly and Assembly

Water Pump

Disassemble in the numbered sequence shown in the figure, and assemble in reverse order of disassembly.

On-Vehicle Inspection

Fig 3-13

Check the water pump for leakage, noise and looseness to the shaft or bearing. Clattering noise, when the fan blades are pushed up and down, indicates that the bearing is worn-out and defective, in the hole of pump body is leaking, disassemble hole of the pump and replace the seal.

Fig 3-15

Removal and Installation

(1) Nut & washer. (2) Bearing housing. (3) Gasket.

(4) Pulley boss. (5) Snap ring.

(6) Shaft, spacer & bearing ass'y. (7) Impeller. (8) Seal ass'y.

(9) Bearing. (10) Spacer. (11) Bearing. (12) Baffle plate.

(13) Dust seal. (14) Snap ring.

Remove the water pump in the numbered order.

Installation is the reverse order of removal.

Fig 3-14 Fig 3-16

1. Drain the coolant.

1. Remove the pump pulley boss with the fan pulley boss puller and press.

2. Remove the radiator cowling.

3. Remove the cooling fan.

4. Remove the V-belt.

5. Remove the cooling fan pulley.

6. Remove the water hose.

7. Remove the water pump.

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44

Cooling System

Inspection

Fig 3-17

2. Remove the impeller and the shaft from bearing housing by using the support block and press.

Fig 3-20

1. Disassemble scale from within the pump body.

Clean removed parts.

2. Inspect all pump parts, and replace any part which is cracked or damaged.

3. Check the water pump for noise and looseness, and replace if necessary.

4. Always use a new water seal after disassembling the water pump. Replace the impeller if there are defects in water seal and impeller contact surface.

Fig 3-18

V-belt 3. Remove the snap ring by using snap ring pliers, and push out the water pump shaft from the bearing.

Inspection

Fig 3-21 Fig 3-19

1. Check the V-belt for breakage or wear, and replace if necessary.

4. Apply or inject grease to the following parts : CAUTIONS : a) Fill 1/3 of the bearing space with lithium grease (NLGI NO2). b) Apply grease on water seal surface contacting the impeller.

2. If there is any noise, check tension of the belt and alignment of the pulleys.

3. V-belt should depress by a given amount when 10kg power is applied to it.

Belt deflection New belt : 10 ~ 12 mm (0.39 ~ 0.47 in) Used belt : 13 ~ 16 mm (0.51 ~ 0.63 in)

Diesel Engine D427

45

Cooling System

Fuel System Outline Structural View

Fig 4-1

Diesel Engine D427

46

Fuel Systems

Specifications Item

Specification

Injection pump

Injection nozzle

Type

VE type

Injection timing

ATDC 2˚

Turning direction

Clockwise

Idling speed

1100 L 25

Nozzle type

Throttle type

Orifice Dia. XNo.

8mm (0.032 in.)X1

Injection pressure

135~140 kg/cm2

Air cleaner

Filter paper element type

Fuel Filter

Cartridge type with water-detector

Injection order

1-3-4-2

Troubleshooting Guide Preblem Hard starting

Possible Cause

Remedy

Clogged fuel filter Air in fuel filter Faulty fuel cut valve Faulty injection timing Air in injection pump Trouble inside of injection pump Seized needle valve of injection nozzle Fuel dripping from injection nozzle Faulty cold start device

Replace Air-bleed Replace Adjust Air-bleed Replace Clean or replace Adjust Adjust or replace

Rough idling

Clogged fuel filter Air in fuel filter Faulty fuel cut valve Faulty injection timing Air in injection pump Trouble inside of injection pump Seized needle valve of injection nozzle Faulty injection starting pressure Improper mounting to nozzle holder Leakage at gasker Crack in injection pipe Leaking from injection pipe joint improper idling speed

Replace Air-bleed Replace Adjust Air-bleed Replace Clean or replace Adjust Disassemble and assemble or replace Replace Replace Retighten or replace Adjust

Engine knocking

Faulty injection timing Low quality fuel Faulty injection starting pressure Seized needle valve of injection nozzle Fuel dripping from injection nozzle

Adjust Replace Adjust Clean or replace Replace

Engine knockin

Faulty injection timing Low quality fuel Faulty injection starting pressure Seized needle valve of injection nozzle Fuel dripping from injection nozzle

Adjust Replace Adjust Clean or replace Replace

Diesel Engine D427

47

Fuel Systems

Preblem

Possible Cause

Remedy

High fuel consumption

Faulty injection timing High idling speed Faulty injection starting pressure Fuel dripping from injection nozzle Leakage of gasket Leaking from injection pipe joint Clogged fuel filter Clogged air cleaner

Adjust Adjust Adjust Replace Replace Retighten or replace Replace Clean or replace

Poor acceleration

Clogged air cleaner Seized needle valve of injection nozzle Fuel dripping form injection nozzle Faulty fuel cut valve Faulty injection timing Air in injection pump Trouble inside of pump Crack of injection pipe Leaking from injection pipe joint Air in fuel filter Clogged fuel filter

Clean or replace Clean or replace Replace Replace Adjust Air-bleed Replace Replace Retighten or replace Air-bleed replace

Excessive exhaust smoke

Clogged air cleaner Improper injection timing Faulty injection nozzle

Clean of replace Adjust Adjust or replace

Diesel Engine D427

48

Fuel Systems

Fuel Filter

Air Bleeding

Fig 4-7

Fig 4-9

The fuel filter is installed between the fuel tank and the injection pump, and it filters out all impurities from the fuel system.

Removal and Installation

Fig 4-10

1. Loosen the air breather on the fuel filter.

2. Operate the priming pump in the fuel filter until the pure fuel comes out.

3. After bleeding all the between fuel tank and fuel filter, fuel comes out.

Fig 4-8

4. Loosen the overflow pipe of injection pump.

Remove as the following sequence. Install the filter in the reverse order of removal.

5. Supply fuel to pump compartment in the injection pump by operating the priming pump.

1. Drain fuel from the filter.

6. Start the engine, and bleed air in the injection pump.

2. Remove the element, sealing, 0-ring and bow downwards from the body.

7. Tighten the overflow pipe connector.

NOTE: Apply fuel to the sealing (top & base) and 0ring-before installing.

8. Loosen the injection pipe on injection nozzle side.

9. Start the engine and check whether fuel us is being ejected from injection pipe

After installing the filter, remove the air breather screw in order to remove air with the priming the filter, remove the air with priming pump, and after starting the engine, check for leakage

Diesel Engine D427

49

Fuel Systems

Water-Drain

Replacement 1. When removing the fuel filter, be careful not to spoil the fuel by holding the fuel filter upright.

Fig 4-11

Drain water when indicating lamp comes on or when float level reaches standard level.

1. Loosen the drain plug.

2. Loosen the air breather if water does not come out easily.

3. After draining water, supply fuel by operating the priming pump on the filter.

4. DO air-bleeding.

Fig 4-12 (1) Adapter. (2) Cartridge. (3) Level sensor. (4) Drain plug (5) Air breather.

2. Apply a small amount of diesel on the packing.

3. Install the cartridge to adapter and tighten securely by hand.

4. Install the sensor and drain plug to the cartridge.

5. Bleed air in the filter.

6. Start the engine and check whether there is any leakage.

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50

Fuel Systems

Injection Pump If the inside of the injection pump is disassembled for maintenance, be sure to properly use the checking device such as the injection tester, and carefully inspect each component.

Structural View

Fig 4-13

Diesel Engine D427

51

Fuel Systems

Checking Injection Timing

On-Vehicle Inspection and Adjustment Checking Idling Speed 1. Warm up the engine.

2. Put the tachometer 3. Idle the engine.

4. Check the engine speed.

Fig 4-17

5. Adjust the idling-speed if the idling speed a with the specified range.

1. Disconnect the fuel injection pipes from the injection pump.

Standard idling speed : 1100 L 25

2. Remove the bolt and gasket from distributor head of the injection pump.

Adjusting Idling Speed

Fig 4-18 Fig 4-16

3. Mount the measuring device on the injection pump. Make sure that the tip of the tester feeler needle touches the plunger end of pump.

1. Confirm the accelerator cable deflection. If the deflection is not suitable, adjust it by turning accelerator cable lock nuts.

2. Loosen the lock nut of the idle adjusting bolt and adjust the idling speed by turning the idle adjusting bolt.

NOTE : Idle speed will increase when the adjusting bolt is turned clockwise and decrease when turned counter-clockwise.

3. After adjusting, press the accelerator pedal 2 ~ 3times, and check the return of the accelerator cable

Fig 4-19

4. Set the flywheel ring gear BTDC 30˚ and find a position where the pointer of dial gauge fixed.

5. After confirming the stability of the dial gauge pointer, set the dial gauge pointer to “O” point.

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52

Fuel Systems

Removal

Fig 4-20

6. Turn the flywheel clockwise until indicator pointer comes to TDC. The injection timing is right if the pointer is increased 1mm.

Fig 4-22

Cam lift at optimal injection timing : 1.00 mm (0.039 in) 7. Adjust injection timing if the cam lift exceeds 1mm.

Adjusting Injection Pump

Fig 4-23

1. Remove the (+) (-) terminals from the battery.

2. Remove the upper cover and the cooling fan.

3. Disconnect the air hose.

4. Disconnect the fuel pipe and the injection pipe.

5. Remove the accelerator cable from the injection pump.

Fig 4-21

1. If the injection timing is not correct, turn the injection pump, and set at a position where the dial gauge pointer indicates 1.00 mm (0.039 in).

6. Remove the fuel-cut solenoid wire.l 7. Remove the injection pump cover.

• If the cam lift value is more than 1mm, adjust so that the cam lift becomes 1.00mm, by turning the injection pump one full turn clockwise(in direction of engine rotation) and counter-clockwise it as necessary again.

• If the cam lift is less than 1mm, adjust the cam lift by turning the injection pump counterclockwise.

8. Loosen the lock nut.

9. Remove the plane washer. Be sure not to drop the washer into the gear case by using a wire.

10. When checking the shaft key of the injection pump, turn the flywheel through the timing hole on the clutch cover until the key arrives at the position.

2. After adjustment, install the gasket and tighten the head bolt.

NOTE : When adjusting, use a new head bolt and gasket.

Diesel Engine D427

53

Fuel Systems

Installation Install the injection pump in the reverse order of removal, paying attention to the following points :

Fig 4-24

11. Remove the bolt on the auxiliary bracket, which fixes the lower part of the injection pump.

12. Remove the injection pump mounting nut. Also remove the spring washer and flat washer.

Fig 4-26

1. Before installing the key on the drive shaft of injection pump, tap the key hole slightly until the key is inserted into the key hole completely.

13. Remove the pump shaft and the gear.

• Set the extractor and use M marked side of it.

• Disconnect the shaft and the gear by tightening extractor bolt.

2. Remove air after installing the injection pump.

Drive gear tightening torque : 4.0 ~ 7.0 m•kg (28.9 ~ 50.6 ft•lb)

Air-Bleeding Make sure to bleed the air replacing the fuel filter or cleaning the sedimenter.

1. Loosen the air bolt on fuel filter.

2. Pump with feed pump until fuel comes out.

Fig 4-25

3. Tighten the air bolt with pressing the feed pump.

14. Remove the injection pump. Remove the injection pump in turn by pushing other pump gear near to it, being careful not to drop the key into gear case.

15. Remove the extractor.

Diesel Engine D427

54

Fuel Systems

Removal

Injection Nozzle(KCA Type)

Remove the injection nozzle in the following order :

Structural View

Fig 4-28

1. Fuel injection pipe 2. Fuel leak pipe lock nut 3. Fuel leak pipe 4. Injection nozzle 5. Washer

Inspection and Adjustment Checking Injection starting pressure

Fig 4-27 (1) Nozzle holder body. (2) Pressure Pin. (3) Pressure Spring.

(4) Retaining Nut. (5) Distance Piece. (6) Shim. (7) Washer.

(8) Nut. (9) Nozzle.

Fig 4-29

1. Set the nozzle on the nozzle tester.

2. Bleed the air by pumping the nozzle tester handle several times.

3. Slowly lower the nozzle tester handle, and check the value shown on the pressure gauge when injection is started.

Injection starting pressure : 135 ~ 140 kg•cm2 (1920 ~ 1991 lb•in2) Diesel Engine D427

55

Fuel Systems

Checking Atomizing Condition

Fig 4-30

Fig 4-32

4. If the injection starting pressure is not within the specified range, adjust the starting pressure with the shim. The shim has 20 different thicknesses for every 0.05mm (0.0020in.) to 1.95mm (0.0768in.). As 0.05mm (0.0020in.) is added, approx. 5kg•cm2 (71.12 lb•in2) of injection pressure increases.

1. Set the injection nozzle on a nozzle tester.

2. Bleed the air by operating the nozzle tester handle several times.

3. Keeping the pressure gauge of the nozzle tester in the non-functioning condition, quickly lower the handle several times (lower the handle as quickly as possible so that a pulsation whistling sound can be heard) and check the atomizing condition.

Checking Tightness of Valve Seat

(1) Fuel is atomized uniformly and properly.

(2) The injection angle and direction are normal. If the atomizing condition is incorrect, it is necessary to disassemble, wash and recheck the injection nozzle, or to replace it.

Checking Nozzle Valve and Needle Valve Fig 4-31

Apply a pressure of 115kg•cm2 (1635.3 lb•in2), and check for fuel leaks from the nozzle injection hole. If fuel leaks, it is necessary to disassemble, clean and recheck the injection nozzle or replace it.

Fig 4-33

1. Check and ensure that the valve seat of the needle valve and other parts are not damaged.

2. Make sure that the nozzle body is not damaged.

Hold the nozzle body upright and insert approximately two thirds of the needle valve and see if the needle valve drops to the valve seat by its own weight.

Diesel Engine D427

56

Fuel Systems

Assembly Pay attention to the following matters when assembling injection nozzle.

Fig 4-34

CAUTIONS : a) After assembling the injection nozzle, check the injection starting pressure and atomizing condition. b) Tighten the nozzle body on the nozzle holder to the specified torque.

Nozzle tightening torque: 8 ~ 10 m•kg (58 ~ 72 ft•lb)

Installation Install in reverse order of removal.

Fig 4-35

CAUTIONS : a) The gasket and corrugated gasket and not be reused. b) Tighten the injection nozzle on the cylinder head to the specified torque.

Nozzle tightening torque : 6 ~ 7 m•kg (43 ~ 52 ft•lb)

Diesel Engine D427

57

Fuel Systems

Engine Electrical System Specifications Item

Specification

Voltage

12V, Negative Ground Type

Alternator

Alternating

Output

12V-60A

Regulator Type Starter

Transistorized(built-in IC regulator)

Type

Electromagnetic push-in-type

Output

12V-2.5kW

Type Glow plug

Sheathed type

Voltage

11V

Amperage

52A

Troubleshooting Guide Preblem

Possible Cause

Remedy

Starter does not turn at all, or its turning speed is too slow to start the engine.

Battery and related parts Poor contact of battery terminals Clean and tighten Poor grounding of negative cable Clean and repair Voltage drop caused by discharged battery Recharge Insufficient voltage caused by battery malfunction Replace Magnetic switch and related parts Loose wiring and / or connectors Repair Burnt magnetic switch contact plate or improper contact Replace Broken wire in magnetic switch contact plate or improper contact Replace plate or improper contact Broken wire magnetic switch holding coil Replace Starter and related parts Adjust contact or replace Poor contact of brushes Fatigued brush spring Replace Poor grounding of field coil Replace Poor soldering of field coil Repair Commutator malfunction Repair Grounded armature Replace Worn parts Replace

Starting problem

Insufficient battery capacity

Recharge

Starter turns but pinion gear does not mesh with ring gear

Tip of overrunning pinion is worn Fatigued overrunning clutch drive spring Overrunning clutch races Improper sliding of spline Worn bushing Worn ring gear

Replace Replace Replace Adjust contact and repair Replace Replace

Starter turns continuously (does not stop)

Sticking contact place of magnetic switch Layer shorting of coil magnetic switch

Replace Replace

Diesel Engine D427

58

Engine Electrical System

Preblem

Possible Cause

Remedy

Misfiring of motor

Malfunction of wiring, or poor wiring contact

Replace

Discharging of battery

Loose drive belt Grounded or broken stator coil Broken rotor coil Poor contact of brush and slip ring Malfunction or rectifier Malfunction of IC regulator Insufficient or unsuitable battery electrolyte Malfunction of battery electrode(internal short-circuit) Poor contact of battery terminals Excessive electric load

Adjust Replace Replace Clean or replace Replace Replace Adjust Replace Clean and tighten Check power consumption

Overcharging of battery

IC regulator malfunction Operating in extremely high temperature

Replace Repair

Diesel Engine D427

59

Engine Electrical System

Removal

Starter

1. Disconnect the battery (-) and (+) terminals.

On-Vehicle Inspection

2. Disconnect the wiring from the starter.

3. Remove the fixing bolts and remove the starter.

Installation Install the start in the reverse order of removal, taking care of the following.

1. Tighten terminals B and M to the specified torque.

Fig 5-5

Tightening torque : 8.0 ~ 10.0 m•kg (57.9 ~ 72.3 ft•lb)

1. Turn off the ignition switch and place the gear shift lever to neutral position before inspection.

Free Running Test

2. Directly connect the battery terminal B and starter terminal M. 3. The starter is functioning properly if it turns smoothly, without abnormal noise.

WARNING Be specially careful, when the starter is operated, the engine may start.

Fig 5-7

Measure the current when the start begins to run constantly connecting the battery, starter and ammeter as shown in the figure.

Current : 200 A or less Voltage : 11 V

Fig 5-6

4. If starting is slow, if the starter doesn’t turn, or if abnormal noise is heard, remove the starter and check it, but be sure to check the following matters before removing it.

A. Charging condition of battery B. Looseness or corrosion of battery terminal C. Condition of ignition switch E. Locked engine.

Diesel Engine D427

60

Engine Electrical System

Disassembly

Fig 5-8

Diesel Engine D427

61

Engine Electrical System

Inspection Checking the Armature

Fig 5-11

5. Measure the shrinkage of the mold between segments. If the value is 0.2mm (0.008 in) or less, undercut by 0.5 to 0.8mm (0.02 ~ 0.03 in).

Fig 5-9

1. Check insulation between all segments and core of the armature coil.

Field Coil

2. It is normal if there is no continuity.

3. Check for continuity between all segments. It is normal if there is continuity.

Fig 5-12

1. Check for continuity between the yoke and the field terminal by using a circuit tester. It is normal if there is continuity.

Fig 5-10

2. Check for continuity between leads by using a circuit tester. It is normal if there is continuity.

4. Check for short circuit with a glower tester. The armature is shorted if an iron piece, when placed on the core while the armature is rotated, is attracted or vibrates. In that case, replace the core.

Diesel Engine D427

62

Engine Electrical System

Checking the Brush Holder

Replacement the Brush

Fig 5-13

Fig 5-15

Check for continuity between brush holder (+) line and brush holder frame with a circuit tester. It is normal if there is no continuity.

Checking for Brush Wear

Fig 5-16

1. Pull out the brush and brush lead wire from the brush holder.

2. Remove the brush from the brush lead wire by crushing the brush.

Fig 5-14

3. Replace a new brush in the brush lead wire. Clean the brush lead wire. Fix the brush lead by inserting the lead through the small tapered hole on the brush.

Check the brush for any damage or wear.

Wear limit : 14 mm (5.51 in)

4. Solder the brush brush lead wire together. Use a soldering iron of more than 200W.

Diesel Engine D427

63

Engine Electrical System

Checking the Magnetic Switch

Return Test

Attraction Test

Fig 5-19 Fig 5-17

1. Disconnect the lead wire between the terminal and the starter.

1. Disconnect the lead wire between terminal M and starter terminal.

2. Connect battery power to terminal M of magnetic switch and its body.

2. It is normal if the plunger is pulled in and the pinion jumps out when power is supplied to the magnetic switch S and the terminal M.

3. Pull and release the pinion. It is normal if the pinion returns quickly to its original position ; but, if it does not return, replace the magnetic switch.

CAUTION : Do not supply power for more than 10 seconds.

Pinion Jumping-out Condition Attraction-holding Test

Fig 5-20 Fig 5-18

1. Disconnect the wire from the terminal M.

1. Disconnect the lead wire between the terminal M and starter.

2. The pinion jumps out when battery power is supplied to terminal S and to starer body. Measure the clearance between the pinion and stopper.

2. Supply battery power to S terminal of magnetic switch and switch body, and then pull the pinion by hand.

Standard Pinion clearance : 0 ~ 2.0mm (0 ~ 0.078 in)

3. It is normal if the pinion does not return to its original position when the pulled-out pinion is released.

Diesel Engine D427

CAUTION : Do not supply power to starter for more than 20 seconds.

64

Engine Electrical System

Alternator

On-Vehicle Inspection

Circuit Diagram

Inspection of Charging System

Fig 5-21

Fig 5-23

Charging System Cautions

1. Make current and voltage connections as shown in the figure.

2. Turn the ignition switch OFF.

1. Be sure battery connections are not reversed, because this will damage the rectifier.

3. Read the voltage between the L terminal and ground. The alternator is bad if the reading is not 0 V.

2. Do not use high-voltage testers, such as a Megger, because they will damage the rectifier.

4. Turn the ignition switch ON and read the voltmeter.

If the reading is 0 V, there is a malfunction of the alternator or wiring.

3. Remember that battery voltage is always applied to the alternator’s B terminal.

4. Do not ground the L terminal while the engine is running.

5. Do not start the engine while the coupler is disconnected from the L and R terminals.

Diesel Engine D427

65

Engine Electrical System

Checking No-Load Adjustment Voltage

Checking Output

Fig 5-25 Fig 5-24

1. Disconnect the negative battery cable.

1. Check to be sure that the battery is fully charged.

2. Connect an ammeter and a voltmeter as shown in the figure.

2. Connect an ammeter and a voltmeter as shown in the figure. Be sure that the voltmeter reading is 0 V.

3. Connect the negative battery cable.

3. Turn the ignition key to ON, and then check to be sure that the voltmeter reading is significantly lower than the battery voltage(1 ~ 3V). If the voltmeter reading is the same as the battery voltage, there may be a malfunction in the alternator.

4. Start the engine.

5. Apply a increase the engine speed. and read the output current. If the voltage is higher than the battery voltage and there is an output current, there is no problem.

4. Short circuit the terminals of the ammeter, and then start the engine. After starting, discontinue the short circuiting.

Removal

NOTE : Be careful, when starting the motor, that the current of the starter doesn’t flow to the ammeter.

5. Under no-load conditions, increase the alternator speed to 5,000 rpm (engine speed of 2,000 ~ 2,500 rpm).

6. Read the indication shown by the voltmeter and the ammeter.

Ammeter : 5A or less Vlotemter (adjustment voltage) : 14.7 L 0.3 V (at 20˚C (68˚F))

Fig 5-26

1. Lift the seat cushion and fasten is with the strap.

2. Remove the driver’s seat cushion.

3. Disconnect the negative battery cable.

4. Remove the drive belt.

5. Disconnect the wire from the B terminal of the alternator and coupler from the L and R terminals, and disconnect the wire harness from the clip.

6. Disconnect the vacuum hose and oil hose.

Diesel Engine D427

66

Engine Electrical System

Fornt Bracket and Rotor

Installation Installation is the reverse order of removal. Note the following points.

Fig 5-30

Fit a flat-tipped - screwdriver between the front bracket and the stator core, and than separate the stator and rotor by tapping the screwdriver with a nylon hammer.

Fig 5-27

1. Install the drive belt so that the V fits into the grooves of each pulley.

CAUTION : Be careful not to force the screwdriver too far in, because the coil may become scratched.

2. Adjust the drive belt tension.

LOCK NUT

Disassembly and Assembly Disassemble in numbered order shown in the figure.

Assembly is the reverse order of disassembly.

Fig 5-31

Fig 5-32

Secure the rotor in a vise, and loosen the pulley nut.

Fig 5-28 (1) Front bracket. (2) Fan and pulley. (3) Rotor.

(4) Rear bracket. (5) Stator coil. (6) Brush holder.

(7) Rectifier.

Diesel Engine D427

67

Engine Electrical System

Stator

Brushes

Fig 5-33

Fig 5-35

Use a soldering iron to disconnect the stator lead wiring.

CAUTION : Do the disconnecting quickly, using the soldering iron no more than about 5 seconds, because the rectifier may become damaged if the inside is overheated.

Brush Holder and ic Regulator Assembly Fig 5-36

When the rotor is to be attached to the rear bracket, insert a wire through the hole in the rear bracket so that the brushes are at the specified position

Seal Washers

Fig 5-34

Use a soldering iron to disconnect the brush holder and IC regulator assembly from the rectifier.

Fig 5-37

Insert a seal washer at each end of the front bracket.

Diesel Engine D427

68

Engine Electrical System

Inspection

Rotor

Fig 5-38

Fig 5-40

Inspect the following parts, and repair or replace if a problem is found.

1. Use a circuit tester to check for continuity between the core and each slip ring.

No-continuity is the normal condition.

Stator 1. Use a circuit tester to check for continuity between the core and each lead wire. No continuity is the normal condition.

Fig 5-41

2. Use an ohmmeter to check the resistance between each slip ring. Resistnace : 3 ~ 4 Ω

Fig 5-39

2. Use a circuit tester to check for continuity between lead wires. Continuity is normal condition.

Diesel Engine D427

69

Engine Electrical System

Rectifiers

Bearings

Fig 5-42

Fig 5-44

Use a continuity tester to check the continuity of each rectifier. There should be high resistance in one direction and low resistance in the other direction.

There is a short-circuit if the resistance is low in both directions, and there is a broken wire if the resistance is high in both directions. In either instance, replace the rectifier.

Check the front and rear bearings for improper rotation and/or abnormal noise. Replace if an abnormal condition is discovered.

Glow Plugs

Brushes and Spring

Checking Open Circuit of Glow Plugs

Fig 5-43

Fig 5-45

Check the continuity between the positive terminal of the glow plug and cylinder head block with a circuit tester. If there is no continuity, replace the glow plug.

1. Check the force of the brush spring. Measure the force of the brush spring by using a spring pressure gauge, and push the brush into the brush holder until the tip projects 2mm (0.079 in).

Limit : Less than 210 g (7.4 oz) 2. Check for burnt or worn brushes.

Limit : 6.5 mm (0.256 in)

Diesel Engine D427

70

Engine Electrical System

Removal and Installation

Fig 5-46

Remove in the following order : 1. Glow plug connector attaching nut. Use a suitable wrench.

2. Glow plug connector 3. Glow plug NOTE : Turn the glow plug counterclockwise and remove it.

To install the glow plug, reverse order of removing.

Diesel Engine D427

71

Engine Electrical System

Technical Data Engine Item Type

Diesel, four-cycle

Number and arrangement of cylinders

Four cylinders, in-line

Type of combustion chamber

Swirl floor type mm B mm(in*in)

Bore and Stroke Total piston displacement

cc

Compression ratio

92.0 B 101.6 (3.62 B 4.00) 2701 21.5 : 1

Valve system

Over head valve(0•H•V)

Valve timing Intake valve Exhaust valve

Open(BTDC)

14˚

Closes(ABDC)

44˚

Open(BBDC)

48˚

Closes(ATDC)

10˚

Firing order

1-3-4-2

Idling speed

1075 ~ 1125

Cylinder head Valve clearance(cold)

mm(in)

Intake

0.30(0.012)

Exhaust

0.30(0.012)

Cylinder head distortion limit

mm(in)

0.10(0.0040)

Valve seat Seat sinking

mm(in)

Intake

(Length “L”) Exhaust Seat angle Seat contact width Valve stem

mm(in)

mm(in) Intake

standard

48.05(1.892)

Limit

49.05(1.931)

Standard

48.05(1.892)

Limit

49.05(1.931)

Intake

45˚

Exhaust

30˚

Intake

2.0(0.079)

Exhaust

20(0.079)

Standard

8.995 ~ 8.989(0.3526 ~ 0.3535)

Limit Exhaust

8.904(0.3506)

Standard

0.038 ~ 0.085(0.0015 ~ 0.0033)

Limit Valve stem to guide clearance

Intake

mm(in)

0.127(0.0050)

Standard

0.038 ~ 0.085(0.0015 ~ 0.0033)

Limit Exhaust

0.127(0.0050)

Standard

0.058 ~ 0.105(0.0023 ~ 0.0041)

Limit

Diesel Engine D427

0.127(0.0050)

72

Technical Data

Tappet Standard outer diameter

mm(in)

14.218 ~ 14.223(0.5598 ~ 0.5600)

Standard tappet hole diameter

mm(in)

14.288 ~ 14.319(0.5625 ~ 0.5637)

Clearance between tappet

mm(in)

hole and outer

Standard

0.055 ~ 0.101(0.0022 ~0.0040)

Limit

0.10(0.0040)

Camshaft Cam height

mm(in)

Intake Exhaust

Journal

mm(in)

Standard

42.580(1.6764)

Wear limit

42.478(1.6724)

Standard

42.580(1.6764)

Wear limit

42.478(1.6724)

Elliptical limit Diameter

0.008(0.0003) 1

51.910 ~ 51.940(2.044 ~ 2.045)

2

51.660 ~ 51.690(2.034 ~ 2.035)

3

51.410 ~ 51.440(2.024 ~ 2.025)

4

51.160 ~ 51.190(2.014 ~ 2.015)

Camshaft deflection limit Camshaft end play

mm(in) mm(in)

Standard

0.8(0.00079 ~ 0.000709) 0.02 ~ 0.18(0.00079 ~ 0.000709)

Limit

0.3(0.0118)

Connecting rod and connecting rod bearing Piston pin to small and bushing clearance

Standard mm(in)

Connecting rod side clearance

0.014 ~ 0.44(0.0006 ~ 0.0017)

Limit

0.05(0.0020)

Standard mm(in)

0.239 ~ 0.330(0.0094 ~ 0.00130)

Limit

Undersize connecting rod bearing

0.4(0.0157) mm(in)

0.254(0.010), 0.508(0.020), 0.762(0.030)

Crankshaft and main bearing Crankshaft deflection limit Crank pin diameter

mm(in) mm(in)

Standard

57.112 ~ 57.125(2.2485 ~ 2.2490)

Limit

0.05(0.0020)

Grinding limit Standard Main journal diameter Main journal bearing

mm (in) mm(in)

oil clearance

65.812~69.825(2.7485~2.7490) 0.008(0.0003)

Grinding limit

69.14(2.7220)

Standard

0.059 ~ 0.090(0.0023 ~ 0.00035)

Limit

0.12(0.0047) mm(in)

mm(in)

Standard

0.254(0.010), 0.508(0.020), 0.762(0.030) 0.14 ~ 0.39(0.0055 ~ 0.0154)

Limit

Diesel Engine D427

56.35 (2.2185)

Limit

Undersize bearings Crankshaft end play

0.05(0.002)

0.4(0.0157)

73

Technical Data

Cylinder block, piston and piston ring Distortion limit

0.10(0.0040)

Cylinder liner inner diameter

mm(in)

A : 92.025 ~ 92.037(3.6230 ~ 3.6235) B : 92.037 ~ 92.050(3.6235 ~ 3.6240)

Cylinder to cylinder liner clearance limit

mm(in)

0.021 ~ 0.078(0.0008 ~ 0.0031)

Cylinder liner wear limit

mm(in)

0.20(0.0079)

Piston standard outer diameter (Diameter measured at 90˚ to pin bore axis and 19 mm(0.75 in) below the oil ring groove) Ring groove width

mm(in)

Piston ring thickness

mm(in)

Clearance between piston

mm(in)

ring and ring groove

mm(in)

Top

2.433 ~ 2.453(0.0958 ~ 0.0966)

Second

2.423 ~ 2.443(0.0954 ~ 0.0962)

Oil

4.793 ~ 4.813(0.1887 ~ 0.1895)

Top

2.363 ~ 2.383(0.0930 ~ 0.0938)

Second

2.363 ~ 2.383(0.0930 ~ 0.0938)

Oil

3.97 ~ 3.99(0.1563 ~ 0.1571)

Top

0.05 ~ 0.09(0.0020 ~ 0.0035)

Second

0.04 ~ 0.08(0.0016 ~ 0.0032)

Oil

0.830 ~ 1.043(0.0316 ~ 0.0411)

Wear limit Piston ring end gap mm(in)

A : 91.967 ~ 91.980(3.6207 ~ 3.6213) B: 91.980 ~ 91.993(3.6213 ~ 3.6218)

0.3(0.0118)

Top

0.35 ~ 0.55(0.0138 ~ 0.0217)

Second

0.35~ 0.55(0.0138 ~ 0.0217)

Oil

O.35 ~ 0.55(0.0138 ~ 0.0217)

Wear limit

0.3(0.0118)

Piston pin diameter

mm(in)

Tightening torque

m ¥ kg(ft-lb)

Cylinder head(cold engine) Manifold

31.744 ~ 31.749(1.2498 ~ 1.2500)

11.0 ~ 11.7(80 ~ 85) Intake

1.6 ~ 2.4(12 ~ 17)

Exhaust

2.7 ~ 3.3(20 ~ 24)

Crankshaft pulley

3.5 ~ 4.0(25 ~ 29)

Camshaft thrust plate

1.6 ~ 2.4(12 ~ 17)

Connecting rod bearing caps

7.6 ~ 8.3(55 ~22)

Cooling fan

1.6 ~ 2.4(12 ~ 17)

Injection pipe

2.5 ~ 3.0(18 ~ 22)

Oil pan

1.6 ~ 2.3(12 ~ 17)

Main bearing cap

11.0 ~ 11.7(80 ~ 85)

Idle gear

2.3 ~ 3.2(17 ~ 23)

Rear oil seal

1.5 ~ 2.0(11 ~ 14)

Water pump

1.6 ~ 2.3(12 ~ 17)

Camshaft gear

6.2 ~ 7.0 (45 ~ 51)

lnjection pump gear

4.0 ~ 7.0(29 ~ 51)

Diesel Engine D427

74

Technical Data

Lubrication System Item

Specification

Lubricating method

Force-fed type

Oil Pump Type

Trochoid type kg/cm2(lb/in2)

Oil pressure Outer rotor and body

mm(in)

clearance

Standard

0.14 ~ 0.25(0.0055 ~ 0.0098)

Limit

Pump shaft and body

mm(in)

clearance

3.8(54) or more 0.3(0.0118)

Standard

0.06 ~ 0.15(0.0024 ~ 0.0059)

Limit

0.1(0.0039)

Tightening torque

m•kg (ft-lb)

Oil filter

By hand + 1/2 turn

Oil pan

1.6 ~ 2.3(12 ~ 17)

Oil pipe

0.8 ~ 1.2(6 ~ 9)

Oil pressure switch

1.2 ~ 1.8 (9 ~ 13)

Cooling System Item

Specification

Fan belt tension

New belt

10 ~ 12(0.39 ~ 0.47)

(10kg force

Used belt

13 ~ 16(0.51 ~ 0.63)

mm(in)

Fan

Type

Blower

Number of blades Outer diameter

6 mm(in)

430(16.93)

Item Thermostat

Specification

Opening temp ˚C(˚F)

82 L 1.5(179.6 L 34.7)

Full-open temp ˚C(˚F)

95(203)

Full-open lift mm(in)

8.0(0.31)

Water pump

Type

Centrifugal, timing belt driven

Radiator

Type

Corrugated 1.0 L 0.15(14.2 L 2.1)

Cap valve opening Pressure kg/cm2(lb/in2)

Diesel Engine D427

75

Technical Data

Fuel System Item

Specification 1100 L 25

Idle speed rpm Injection timing

ATDC 2˚ 2

Injection pressure

2

kg/cm (lb/in ) Tightening torque

135 ~ 140(1920 ~ 1991) m¥kg (ft-lb)

Injection pump gear

4.0 ~ 7.0(29 ~ 51)

Injection nozzle holder

6.0 ~ 8.0(43 ~ 58)

Injection pipe

2.5 ~ 3.0(18 ~ 22)

Engine electrical system Item

Specification

Charging system Alternator

Type Voltage capacity

Alternating V-A

Regulated voltage

V

12 - 60 14.4 L 0.3

Starting system Starting motor

Type

Electromagnetic push-in type

Voltage

V

12

kW

2.5

Voltage

V

11

Current

A

200 or less

Speed

rpm

3000 or more

Output Free running test

Tightening torque

m¥kg (ft-lb)

Starting motor

8.9 ~ 12.0(64 ~ 87)

Alternator

1.8 ~ 2.7(13 ~ 20) Tightening torque

m¥kg (ft-lb)

Flywheel Housing

3.3 ~ 4.8(23 ~ 34)

Flywheel

Diesel Engine D427

13.1 ~ 13.8(94 ~ 99)

76

Technical Data