Nanni Marine Diesel Engine T4.165 T4.180 T4.200 Workshop Manual 60300199

WORKSHOP MANUAL

Marine Diesel Engine T4.165 - T4.180 - T4.200

60300199

NOTICE TO READERS

This workshop manual has been designed to provide maintenance personnel with the information required for the operation, maintenance and repair of the T4.165, T4.180 and T4.200 Nanni engines. It is divided into three parts: "General", "Operation" and "Maintenance".

■ General This section provides information on the following topics: Engine description, technical specifications, line drawings, description of how to do the engine identification, general precautions, maintenance schedule, inspections and maintenance, and special tools.

■ Operation Information in this chapter have to be assimilate before proceeding with troubleshooting, disassembly, and maintenance.

■ Maintenance You will find information on troubleshooting, controls & settings, tightening torques, disassembly & reassembly and maintenance including procedures, precautions, plant specifications and eligible limits.

All information, illustrations and specifications contained in this manual are based on the latest product information available at the moment of creation.

We reserve the right to change any information at any time without prior notice.

Because this manual covers several engine models, information or illustrations used do not concern a specific engine.

April 2011

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SAFETY BEFORE ANYTHING This symbol, the « safety symbol» adopted by the industry, is used in this manual and on some stickers installed on the engine to inform the customers about danger likely to cause injuries. Please read these instructions and safety rules carefully before trying to repair the engine.

CAUTION: Indicates a highly dangerous situation, serious injury or death can occur if the situation is not avoided

DANGER: Indicates a highly dangerous situation, minor or serious injury can occur if the situation is not avoided.

IMPORTANT: Indicates a highly dangerous situation, serious injury or death can occur if the situation is not avoided

NOTICE : Provides useful information

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BEFORE ANY MAINTENANCE OR REPAIR 1) Read all general instructions and safety instructions of the manual and on the security stickers on the engine 2) Clean the work area and the engine 3) give the engine time to cool down before working on it 4) stop the engine and remove the key 5) disconnect the cable from the battery

START UP SECURITY 1) Do not start the engine by creating a short circuit between starters of the terminals 2) unauthorized modification to the engine may diminish or impair the operation and / or safety and durability of the engine

WORK SAFETY 1) Do not use the engine under the influence of alcohol, drugs or other similar substances, nor when tired.

2) Wear close-fitting clothing and appropriate safety equipment at work 3) Use tools for the job. Inappropriate tools, parts and procedures are not recommended.

4) When maintenance is performed at the same time by several people, be sure to carry out the work in safety.

5) Do not touch hot or rotating parts while the engine is running 6) Do not remove the cooler cap while the engine is running or immediately after stopping the engine. Otherwise hot coolant will flow out. Remove the cap only when the engine is cool enough to be touched bare handedly. Loosen the plug slowly until the first stop while releasing the pressure before removing it completely.

7) The leaking pressurized fluid (fuel or oil) can penetrate the skin, causing serious injury. Release pressure before detaching piping oil or fuel. Tighten all connections correctly before placing them under pressure.

8) Wear a protective device such as appropriate auditory soundproof headphones or hearing plugs to protect against loud noise.

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PREPARING FOR EMERGENCIES: 1) Always keep a first aid kit and a fire extinguisher within reach.

2) Keep emergency phone numbers of doctors, ambulance services, hospital and fire near the telephone.

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ENGINE DESCRIPTION

SUMMARY

GENERALITIES 1.

2.

3.

Images (side and back view) Images (side and front view) Technical data

8 9 10

MAIN PARTS IDENTIFICATION 1

Heat exchanger

13

Gear box

2

Coolant filling plug

14

Fuel filter

3

Exhaust mixer

15

Oil gauge

4

Engine support

16

Air cooler

5

Electric breakers

17

Oil filter

6

Engine Control Unit

18

Gear box oil cooler

7

Alternator

19

Gasoil cooler

8

Sea water pump

20

Timing gear belt cover

9

Air filter

21

Fresh water pump

10

Turbocharger

22

Fuse box

11

Trawling valve(if installed)

23

Automatic Alternator belt tensioner

12

Gearbox command

24

Oil filling plug

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DRAWING LINES SUMMARY 1.

2.

3.

4.

T4.180 — ZF 45A T4.165, T4.180, T4.200 — TTM40A T4.165, T4.180, T4.200 — TTM40A with sea-water filter T4.165, T4.180, T4.200 — ZF63IV

10

12 13 14 15

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GENERAL SUMMARY

GENERALITES 1. ENGINE IDENTIFICATION

16

[1.1] MODELE NAME AND SERIAL NUMBER [1.2] CYLINDERS ORDER

16 17

2. GENERAL PRECAUTIONS

17

3. MAINTENANCE SCHEDULE

18

4. CONTROLS AND MAINTENANCE

20

[4.1] OIL LEVEL CHECK [4.2] COOLANT LEVEL CHECK AND ADJUSTMENT [4.3] ELECTRIC PANELS: INDICATION CONTROLS AND ALARMS [4.4] OIL AND OIL FILTER REPLACEMENT [4.5] ALTERNATOR BELT CONTROL AND REPLACEMENT [4.6] FUEL FILTER REPLACEMENT [4.7] AIR FILTER CLEANING AND REPLACEMENT [4.8] ENGINE SUPPORT AND ALIGNMENT [4.9] CHECK AND REPLACEMENT OF THE ZINC ANODE [4.10] SCREW AND COLLAR TIGHTENING, HOSES CONTROL [4.11] SEA WATER PUMP IMPELLER REMPLACEMENT [4.12] COOLANT REPLACEMENT [4.13] PRESSURIZED PLUG REPLACEMENT [4.14] THERMOSTAT REPLACEMENT [4.15] HEAT EXCHANGER: INSPECTION, CLEANING and GASKETS REPLACEMENT [4.16] INTERCOOLER: INSPECTION, CLEANING and GASKETS REPLACEMENT [4.17] FUEL OIL and GEAR BOX OIL COOLER: INSPECTION, CLEANING. [4.18] TAPPET CLEARANCE:CONTROL [4.19] TURBOCHARGER LEVER: FREE MOVING AND GREASING

20 21 22 23 24 25 26 27 29 30 30 31 32 33 35 38 40 41 43

5. SPECIAL TOOLS

45

The pictures in this chapter are not contractual.

Equipment and accessories installed may vary depending on equipment level of the engine.

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[1.1]- ENGINE IDENTIFICATION On all correspondence, inquiries and orders for spare parts, it is imperative to mention the references written on the name plate of the engine and the gear box

.

ENGINE TYPE

T4.200

SERIAL NUMBER

TYBXXXXXXXX

SPECIFICATION

N4200E264JE01

IMPORTANT: Please write down the serial number and description of the model of the engine and transmission. Keep a copy of this information in a safe place

[1.2] ENGINE SERIAL NUMBER The engine serial number is composed of a combination of numbers and letters. It follows the model number of the engine. It indicates the month and year of manufacture as follows: TY

=

TOYOTA base

Letters

Engine Type

A

T4.180

B

T4.200

C

T4.165

The two first digits indicate the year of manufacture 07 = 2007, 08 = 2008, 09 = 2009, 10 = 2010, etc.

The next two digits indicate the month of manufacture 01= January, 02 = February, 03 = March, 04 = April, 05 = May, etc.

The last four digits indicate the chronological order of registration.

Example: The engine with the serial number: TYB07080001 TY B 07 08 0001

TOYOTA Base T4.200 Year of manufacture is 2007 Month of manufacture August This engine is the first one in the series of T4.200

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[1.2] CYLINDERS ORDERS The number of cylinders of the engine are designated as shown in the picture below.

The sequence of the “number of cylinders” is listed as No.1, No.2, No.3 and No. 4 from the timing belt cover (onwards)

[2] GENERAL PRECAUTIONS •

• • • • • • • (1) (2) (3)

Grease Force Place the cutting edge in the direction from which is coming the force.

(A) (B)

Retaining ring (extern) Retaining ring (interne)

17

During disassembly, carefully store disassembled parts in a clean place to avoid any confusion later.

Replace the screws, bolts and nuts in the same location in order to avoid mistakes during reassembly.

Where special tools are required, use the NANNI special tools.

Before removing or maintaining engine, always disconnect the ground cable from the battery first.

Remove oil and grease from the components before taking measurements.

Use only original NANNI INDUSTRIES spare parts in order to ensure proper running of the engine and safety.

Replace the gaskets and O-rings during reassembly.

Coat the newly greased seals / coat the new seals with grease before reassembly.

When refitting rushes off external or internal, place them with sharp edges in the opposite direction of the direction of the applied force.

Run the engine after repair or reassembly. Do not subject the engine to heavy load abruptly, because you may damage it.

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[3] MAINTENANCE SCHEDULE To maintain optimum performance in terms of life and security, perform regular inspections according to the maintenance schedule below.

OPERATIONS TYPE: C = Control / R = Replace / A = Adjust / N = clean Coolant level

Every day

1st visit of maintenance (20 H)

Every 100 Hours or every year (1)

Every 200 Hours or every year (1)

Every 400 Hours or every 2 years (1)

C/A

C/A

C/A

C/A

C/A

C/A

C/A

C/A

C/A

C/A

R*

Coolant replacement Engine oil level Engine oil replacement

R*

R*

R*

Engine oil filter

R*

R*

R*

C/A

C/A

Gear box oil level (2)

C/A

C/A

C/A

Gear box oil / Gear box oil filter (2)

R*

R*

R*

Fuel oil pre-filter (2)

R*

R

R

C/A

C/A

C/A

C/A

R*

R*

R*

R*

C/N

C/N

C/N

C/N

Air filter cleaning / Replacement

C

C

C/R/N*

C/R/N*

Alternator belt tension

C*

C*

C*

C*

R*

R*

C/A

C/A

Fuel oil pre-filter : oil drain (2)

C/A

Fuel oil filter Sea water filter / cleaning (2)

C/N

Sea water pump impeller C/A

C/A

C

C/A

A

C/A

C/A

screws and collars tightening

C/A

C/A

C/A

C/A

Engine support, mountings and alignment

C/A

C/A

C/A

Stuffing box (2)

Every 15 days

Batteries electrolysis level (2) General leakage check

Zinc Anode (if equipped) Electric panels : indications et alarms

C/A

C

Command : inspection Cables (accelerator / gear box and trolling) General greasing

C*

C/R*

C/R*

C/R*

C

C

C

C

C

C

C

C

Heat exchanger pressurized plug

R

Thermostat

R*

Heat exchanger : inspection , cleaning and gasket replacement

C/N*

Intercooler : inspection , cleaning and gasket replacement

C/N*

Gear box oil cooler : inspection - cleaning

C/N*

Fuel oil cooler: inspection—cleaning

C/N*

Injectors Pressure test / pulverisation

See specialist

Tappet clearance

1000 hours

Turbocharger: inspection— cleaning

See specialist

Turbocharger lever: free displacement et greasing

C/N

C/N* 1000 hours Or 2 ANS

Timing belt

• (1) (2)

C/N

*Operations performed according to instruction manual or workshop manuals of the engine.

Transactions must be made at the end of this to terms whichever comes first.

See concerned supplier manual

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WARNING • Before conducting a control or a replacement, stop the engine.

NOTE •

Lubricating Following the actual anti-pollution regulations, the lubricating oils CF-4 and CG-4 were developed for use with low sulphur fuels used in the engines of road vehicles. For off-road vehicles using fuels with high sulphur content, it is recommended to use lube oils CF, CD or CE with a high Total Base Number (IBT). If you use a lubricating oil CF-4 or CG-4 with fuel with a sulphur content higher, renew it at closer intervals.

•

Lubricating oil recommended with fuels with high / low sulphur.

Carburant

Rate suffers low

Rate suffers high

Remarks

Oil Class

O = recommended

X = not recommended

19

TBN = Total Base Number

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[4] CONTROLS AND MAINTENANCE [4.1] Oil level check WARNING •

Stop the engine before checking the oil level.

(1)

•

Make sure engine has no inclination.

•

To check the oil level, remove the dipstick (1), wipe it, reinsert it and remove it. Check to see if the oil level is between the two notches.

•

If the level is too low, add oil up to the specified level.

IMPORTANT When using an oil of a different brand or viscosity, drain the previous one. Never mix two different types of oil.

NOTICE •

Check the engine oil level when the engine is horizontal. If the engine has inclination,

(A)

the amount of oil can not be measured accu(B)

rately.

•

Keep the oil level between the upper and lower marks of the dipstick. A too high oil level will cause a decrease in performance, will affect exhaust emissions and may damage the engine. On the engine breather (sealed type) in which the oil vapours are sucked through a valve, excessive amounts of oil can cause compression in the crankcase. An insufficient amount of oil can cause jamming of moving parts.

Dipstick (A) Maximum (B) Minimum

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[4.2] Coolant level check and adjustment (1)

•

Remove the cap from the heat exchanger (1) and check if the coolant level is just below the filling hole between the lower level of the filler neck (2) and indicator finger (3), representing the minimum and maximum level of liquid.

•

If the coolant level is too low, find the reason why the liquid level has dropped.

CASE 1 If the liquid drop is due to evaporation, always top it with fresh water without limestone only.

CASE 2 If the liquid drop is due to leakage, always top off with a (3)

liquid of the same brand and type respecting the mixing

(2)

ratio (50% freshwater and 50% pure antifreeze).

If the brand of coolant is unknown, drain the remaining liquid and fill with a new mixture of coolant properly proportioned. (50% freshwater and 50% pure antifreeze).

WARNING •

Do not remove the cooler cap when the coolant temperature is too high. Then slightly loosen the cap to release the remaining pressure before complete removal.

•

When filling the coolant, bleed the cooling system at various locations.

•

Carefully close the heat exchanger cap. If the cap is loose or not closed, the coolant can escape and cause an engine to overheat.

•

Do not use antifreeze and anti-tartar additive at the same time.

•

Never mix different types or brands of coolant or antifreeze

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[4.3] Electric panel: Indications control and alarms The illustrated instruments often have safety lights.

So it is necessary to familiarize yourself with and do not hesitate to look at them when you turn on the power and use the engine.

The indicators are:

(1)

•

Tachometer with hour meter (1): The indication of the battery voltage is displayed when contact is made, and continues to be readable a few seconds after start-up).

•

Engine temperature indicator (2).

•

Engine oil pressure indicator (3).

•

A key to start and stop the engine (4).

•

A pre-heater and start-up button (5): the heating is done by pressing the button half-

(3)

(4)

(5)

(2)

way down, the indicator lights for heating as long as the intermediate pressure is performed. To start the engine, a full pressure on the switch must be performed Pre-heating (on tachometer) Turbocharger air pressure too high (on tachometer) Battery not charging (on tachometer).

Engine Diagnostic alarm (on tachometer) Water in fuel filter detected. (on tachometer) Coolant temperature too high (on the concerned indicator) Oil pressure alarm (on the concerned indicator)

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[4.4] Oil and oil filter replacement Engine oil Replacement

(1)

WARNING •

Stop the engine before changing oil.

•

Start the engine and let it warm for about 5 minutes.

•

Place a drain pan near the engine.

•

To drain the used oil, remove the drain pipe cover (1) and install an electric or manual drain oil pump.

•

Reinstall the drain pipe cover when the sump tank is empty.

•

Fill with oil to upper level of the dipstick (a).

IMPORTANT •

If you want to change the oil brand or viscosity, drain all the oil. (see page 19)

Capacity: • Drain and refill with oil filter change 7.4 liters (7.8 US qts, 6.5 lmp. qts) • Drain and refill without oil filter change 6.7 liters (7.1 US qts, 5.9 lmp. qts) • Dry fill 7.9 liters (8.3 US qts, 7.0 lmp. qts)

•

Never mix two different types of oil.

•

The engine oil must have the properties corresponding to the class CD / CE / CF / CF-4 / CG-4 classification API.

•

Use SAE 15W40 (Nanni recommendation)

Oil filter replacement •

Using Special Specific Tool (09228−07501), remove the oil filter.

IMPORTANT •

Put the oil drain container beneath the drain hose to receive the oil from the oil filter.

•

Wipe the installation surface of the oil filter of the engine side.

Apply clean engine oil to the gasket of a new oil filter (970313306) Install the oil filter to the engine, and screw it.

Finally, screw the oil filter with additional three−quarter (3/4) turn with Specific Special Tool.

(09228−07501)

• • •

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[4.5] Alternator belt control and replacement 1.

•

REMOVE GENERATOR BELT Remove the belt by rotating the tensioner pulley in clockwise direction to loosen its tension with pulley set bolt of the tensioner.

2.

•

INSTALL GENERATOR BELT Install the belt with a condition being rotated the tensioner pulley in clockwise direction with the pulley set bolt of the tensioner.

•

Make sure that the belt is set properly at each pulley.

Make sure that the indicator mark of the tensioner is within Range A (see picture).

NOTICE: •

A

3.

INSPECT DRIVE BELT

•

Visually check the belt for excessive wear, frayed cords etc.

HINT: • •

If any defect has been found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced.

•

Check that it fits properly in the ribbed grooves.

HINT: •

24

Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.

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[4.6] Fuel filter replacement

(1)

1.

• •

REMOVE FUEL FILTER COVER Loosen the bolt.(1) Remove the fuel filter cover.(2)

2.

• •

REMOVE FUEL FILTER ASSY Remove the 2 fuel hoses.

Disconnect each connector of the level warning switch from the fuel filter assy.

Remove the 2 nuts and fuel filter assy.

•

(2)

3.

•

DRAIN FUEL Loosen the fuel filter drain plug, and then drain the fuel from the fuel filter assy.

4.

REMOVE FUEL FILTER ELEMENT SUBASSEMBLY Remove the 2 bolts, and remove the metal cover.

Hold the fuel filter cap in a vice.

Using a water pump plier, remove the level warning switch and O−ring.

• • •

NOTICE: Be careful not to damage the level warning switch •

Using special tool, remove the fuel filter element.

5.

INSTALL FUEL FILTER ELEMENT SUB−AS SEMBLY Apply a bit of fuel to a new gasket, and then install the fuel filter element to the fuel filter cap.

•

NOTICE: Do not use a special tool to tighten up.

• • •

Install a new O−ring to the warning switch.

Apply fuel to the O−ring of the warning switch.

Install the level warning switch to a new fuel filter by hand.

•

Make sure that the fuel filter drain plug is within the range indicated in the illustration.

NOTICE: If the drain union is out of range, it will get difficult to drain water from the fuel filter after installation. The drain union may contact or hit a boat body when the fuel filter assembly is installed.

HINT: In case of a drain union is not within range, reset it by applying the range on the figure beside.

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•

Loosen the drain cock.

NOTICE: Be sure to close the drain cock in order to prevent fuel leakage.

(3)

•

Fasten the drain cock.

6. (a)

INSTALL FUEL FILTER ASSY Install the fuel filter assy with the 2 nuts.

Torque: 18 N m (178 kgf cm, 13 ft lbf) (b) (c)

Connect connector of the level warning switch to the fuel filter.

Install the 2 fuel hoses to the fuel filter cap.

7. ADD FUEL (a) Push the priming pump (3) several times to fill up the fuel filter with fuel.

8. CHECK FUEL LEAK

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[4.6] Air filter cleaning and replacement WARNING

(1)

(3)

•

Stop the engine before replacing the air filter.

1.

2.

3.

4.

Unscrew the nut (1) Unscrew the clamp (2) Remove the air filter element (3).

Use dry compressed air and clean inside the element. The air pressure must be less than 205 kPa (2.1 kgf/cm2, 30 psi). Maintain a reasonable distance between the nozzle and filter.

If the filter is too dirty, use the cleaning kit Reference: 970312809.

Replace the filter on the engine (3) Tight the clamp (2) Tight the nut (1).

(2)

5.

6.

7.

8.

NOTICE • • •

The air filter is a dry part. Do not lubricate it.

Do not run the engine without the filter Replace the filter once every year or every 200 running hours.

970312809

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[4.8] Engine support et alignment Engine support: On new engines, you must ensure that the front and aft flexible mounting are adjusted, or positioned at a maximum of 10mm (see photos).

Verify that the four flexible mountings are properly positioned, then tighten the flexible mounting.

Do not make any twists, or constraints on the rubber mounting, this is unacceptable.

WARNING • •

Do not use the flexible mounting for aligning the engine.

If the value exceeds 10mm , shims will have to be installed under the flexible mounting.

Engine alignment:

FIG.A

When checking the shaft alignment, it must be disconnected from the gearbox. It will be necessary to control if the radial offset value does not exceed 0.05mm (figure A) and the angular misalignment does not exceed 0.05mm (Figure B) for a 100mm coupling diameter.

FIG. B

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[4.9] Check and zinc anode replacement Figure A

Two differente type of exhaust mixer: •

Figure A: Exhaust mixer installed on the shaft line engine. The zinc anode should be checked at the first maintenance visit and later every 100 hours or every year.

•

Figure B: Exhaust mixer installed on the stern drive engine. The zinc anode should be checked at the first maintenance visit and later every 100 hours or every year. .

WARNING • Zinc anode •

The anode replacement should be performed if the anode reduction of volume is equal or over 50% of the initial zinc volume (original volume Ø 10mm L = 15mm).

If you have any doubt always replace the anode.

Zinc anode

Figure B

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[4.10] Screws and collars tightening, hoses control: •

Check if the hoses are properly attached at the first maintenance visit (20 hours or later than 45 days after the operation) and then every 100 hours of operation or annually, whichever comes first.

If the clamps are loose, put oil on threads and tighten them firmly.

If any doubts replace the clamps.

The hoses are in rubber and are getting old. It must be inspected and replaced if necessary or if cracks appear. Also, replace the clamp and tighten it firmly.

• • •

IMPORTANT •

To avoid serious damage to the engine, prevent dust from entering inside the hoses.

[4.11] Sea Water pump impeller replacement: WARNING

(2)

•

Before replacement of the seawater impeller pump, make sure the sea water suction valves are all closed and the engine is stopped.

• •

Close the suction and discharge seawater valve Unscrew and remove the 4 screws (1) and remove the pump cover (2) (Figure 1).

Remove the paper gasket and clean the contact surface.

Extract the sea water pump impeller (3) using pliers.

Reinstall a new rotor in a counter clockwise rotation (Figure 2).

Replace the cover with a new gasket.

Reinstall the four screws and tighten them.

Open the suction and discharge seawater valves, check for leakage.

Start the engine and check if the circuit is waterproof.

• • • • • • • (1)

Figure 1

3

Figure 2

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[4.12] Coolant replacement: 1.

DRAIN ENGINE COOLANT

(1)

WARNING •

To avoid the risk of burn injuries, do not remove the filling cap while the engine and heat exchanger are hot. It may result in heated fluid and steam being spewed by pressure, able result that heated fluid and steam are spewed by pressure inside the heat exchanger.

• •

Remove the heat exchanger filling cap (1).

Loosen the engine drain plug, and drain the coolant from the engine. (15.5 litres) Symbol for drain plug

•

Close the drain plugs.

Torque: 8 N m (82 kgf cm, 71 in. lbf)

(3)

(2)

2.

ADD ENGINE COOLANT

•

Fill the radiator with a coolant carefully through the filling cap.

IMPORTANT: • •

Use a mixture of 50% pure antifreeze with 50% demineralised water. The total volume of coolant is 15.5 litres.

If you prefer to use pre-mixed coolant its content ratio should be 50 % or up to 60 %.

Beyond that, 60 % and up would deteriorate the cooling effectiveness of the coolant.

NOTICE: •

Do not use an alcoholic coolant and plain (non-demineralised) water alone. Otherwise, it may cause damage to engine cooling system.

• • • •

Drain the air from the circuit (see procedure) Reset the heat exchanger filling cap.

Start the engine to circulate the coolant.

Wait until the coolant gets cold, then remove the filling cap again, and so check the coolant level inside the heat exchanger.

HINT: Refill the heat exchanger with the coolant if the coolant level is low.

3. INSPECT CHECK FOR ENGINE COOLANT

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WARNING (A)

Do not forget to drain the air correctly from the coolant circuit. Please follow the procedure below. a) b) c)

d) (B)

e) f) g)

Open the drain point at 2 different places: at the inlet water pipe (A) and at the turbo charger point (B) Start filling the heat exchanger When the coolant starts to flow out by point (A) close it and continue until the liquid starts to flow out by point (B). At this moment close the drain screw.

Complete the filling of the heat exchanger until the maximum point Run the engine for about 10 minutes Check the heat exchanger level and add some coolant if necessary Repeat phase (d) to (f) until the coolant level is stabilised.

[4.13] Pressurized plug replacement: WARNING • •

(1) • •

Before replacement of the pressurized plug, make sure the sea water suction valves are all closed and the engine is stopped.

To avoid the risk of burn injuries, do not remove the filling cap while the engine and heat exchanger are hot. It will probably result that heated fluid and steam are spewed by pressure, able result that heated fluid and steam are spewed by pressure inside the heat exchanger.

The pressurized plug (1) should be replaced, every 400 hours or 2 years at the end of one of the two occurrences.

The reference of the parts is 970314988

970314988

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[4.14] Thermostat replacement:

(1)

(2)

1.

DRAIN ENGINE COOLANT

•

Refer to the concern chapter page 32

2.

REMOVE ALTERNATOR CONNECTORS

•

Disconnect the 3 wires from the alternator (1 screw for the ground, 1 nut for the B+, 1 connector)

3.

REMOVE GENERATOR THE HOSE AND THE THERMOSTAT COVER

• • • •

loosen and remove collars (2) Remove the hose (3) Loosen and remove the 3 screws (4) on the thermostat cover Remove the thermostat cover (5)

4.

REMOVE THE THERMOSTAT

•

Remove the thermostat from the engine block (970312274)

(3)

(4)

(5)

970312274

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5.

INSTALL THE NEW THERMOSTAT

• •

Set a new gasket to the thermostat.

Install the thermostat while bring the jiggle valve into its right position described in the illustration.

Install the Thermostat cover with the 3 bolts.

•

Torque: 13 N m (133 kgf cm, 9.6 ft lbf) •

Install the wire harness with the bolt.

Torque: 8.0 N m (82 kgf cm, 71 in. lbf)

jiggle valve

6.

INSTALL GENERATOR CONNECTORS

•

Connect the 3 wires from the alternator (1 screw for the ground, 1 nut for the B+, 1 connector)

7.

FILL THE ENGINE WITH COOLANT

•

Refer to the concern chapter page 32

WARNING Do not forget to drain the air correctly from the coolant circuit. Please follow the procedure below. a) b) c)

d) e) f) g) 8.

34

Open the drain point at the 2 different places: at the inlet water pipe (A) and at the turbo charger point (B) Start filling the heat exchanger When the coolant starts to flow out by point (A) close it and continue until the liquid starts to flow out by point (B). At this moment close the drain screw.

Complete the filling of the heat exchanger until the maximum point Run the engine about for 10 minutes Check the heat exchanger level and add some coolant if necessary Repeat phase (d) to (f) until the coolant level is stabilised.

CHECK FOR ENGINE COOLANT LEAKAGES

04 /20110 indice A

[4.15] Heat exchanger (inspection, cleaning, gasket replacement): 1.

DRAIN THE COOLANT CIRCUIT

- Refer to concern chapter page 32

(7) (6) (2) (1)

(4) (5)

(3)

2.

REMOVE THE FRONT COMPONENT

• • • • • • •

Remove the drain pipe (1) Unscrew the hoses clamps(2) Remove the nuts (3) Remove the nut (4) Remove the water pipe (5) Remove the lifting bracket (6) Remove the fuse box support (7)

3.

REMOVE THE REAR COMPONENT

•

Unscrew the two hose clamps and remove the outlet see water hose (8) Remove the two bolts and the turbo charger cover (9) Unscrew the two hose clamps and remove the inlet see water hose (10)

(10) (8)

• •

(9)

35

04 /20110 indice A

(12) (11)

4.

DISMANTLING OF THE HEAT EXCHANGER

•

Unscrew and remove the 4 screws one the front side Remove the end cover Unscrew and remove the 4 screws one the rear side Remove the rear end cover Remove the screw cap(11) Remove the “alene” screw (12) with the gasket Push out the core assembly by the front side.

• • • • • •

WARNING

(10)

48418167 (8)

Joint 48418178

•

If you forgot to remove the “alene” screw, when pushing out the core you will damage it and will have to replace the parts

5.

CLEAN CORE AND HEAT EXCHANGER

• •

Clean the core by using a cleaner for cooling system. Follow the instructions for use the cleaning product.

Make sure all tubes are free from obstruction

6.

RE– BUILD OF THE HEAT EXCHANGER

• • • • • • • • •

•

Install 2 new O-rings (48418167) on the core Insert the core inside the heat exchanger body Install the front end cover and the four screws Install the first rear O-Ring (48418167) Install the intermediate plate Install the second rear O-Ring (48418167) Install the rear end cover and the four screws Install the “alene” screw (12) Tight the “alene” screw until you got a small resistance Put back the screw cap (11) with a new gasket (970312803) Tight all 8 screws fixing the end covers

7.

RE-INSTALLATION OF REAR COMPONENTS

•

Install the inlet see water hose (10) and tight the two hoses clamps Install the turbo charger cover (9) and tight the two bolts Install the outlet see water hose (8)and tight the two hose clamps

•

(9)

• (7)

•

(6)

(2)

8.

RE-INSTALL THE FRONT COMPONENTS

• • • •

Install the fuse box support (7) Install the front lifting bracket (6) Install the hose (2) with two clamps Install the front water pipe (5) with new O-Ring (48418178)

(5) 36

04 /20110 indice A

(1)

(4)

• •

Install and tight the nuts (4) and (3) Install the drain pipe (1) with four new copper gasket (970300430)

9.

REFILL THE CIRCUIT WITH COOLANT

•

refer to the concern chapter page 32

(3)

WARNING Do not forget to drain the air correctly from the coolant circuit. Please follow the procedure below. a) b) c)

d) e) f) g) 10.

37

Open the drain point at the 2 different places: at the inlet water pipe (A) and at the turbo charger point (B) Start filling the heat exchanger When the coolant starts to flow out by point (A) close it and continue until the liquid starts to flow out by point (B). At this moment close the drain screw.

Complete the filling of the heat exchanger until the maximum point Run the engine about 10 minutes Check the heat exchanger level and add some coolant if necessary Repeat phase (d) to (f) until the coolant level is stabilised.

CHECK FOR ENGINE COOLANT LEAKAGES

04 /20110 indice A

[4.16] Intercooler (inspection, cleaning, gasket replacement): WARNING

(A)

•

Before replacement of the impeller seawater pump, make sure the sea water suction valves are all closed and the engine is stopped.

1.

REMOVE THE EXTERNAL COMPONENT

•

• • •

Disconnect the air temperature sensor (A) and the air pressure sensor (B).

Unscrew the hoses clamps and remove the inlet sea water pipe (1) Unscrew the hoses clamps and remove the outlet sea water pipe (2) Unscrew the hoses clamps and remove the inlet air pipe (3) Unscrew the and remove the three nut (4) Unscrew the and remove the four nut (5) Remove the intercooler (6)

2.

INTERCOOLER INSPECTION

• • •

Unscrew and remove the eight bolts (7) on the end covers.

Remove the two end cover (8).

Remove the core.

3.

CLEAN INTERCOOLER CORE AND BODY

•

Clean the core by using a cleaner for cooling system. Follow the instructions for use the cleaning product.

Make sure all tubes on sea water side are free from obstruction.

(B)

(1)

• • • (3)

(4)

(6)

(5)

(1)

(3)

(7)

(8)

(2)

(5)

(8)

•

WARNING •

48418168

48418168

38

Make sure that the hole on the body bottom is free and open. This is where the air condensation water will be evacuated during engine working time

04 /20110 indice A

(6)

(4)

(1)

(3)

4.

INTERCOOLER RE-BUILD

•

Install one new O-Ring on the core (48418168) and put back inside the intercooler body.

Put back the end covers (8) and tight the eight bolts (7)

•

(9)

5.

REINSTALL THE INTERCOOLER

•

Put in place the intercooler (6) with a new O-ring (Mark 9, reference 970314072) Installed and tight the four nuts (5) Installed and tight the four nuts (4) Installed and tight the clamps of the air hose(3) Installed and tight the clamps of the sea water hose(2) Installed and tight the clamps of the sea water hose(1) Connect the air pressure sensor (B) Connect the air temperature sensor (A)

• • • •

(7)

• (8)

(2)

(5)

(8)

• • 5.

48418168

CHECK FOR ENGINE SEA WATER AND AIR LEAKAGES

48418168

39

04 /20110 indice A

[4.17] Gear box and Fuel cooler (inspection, cleaning): Fuel cooler

WARNING

Gear box oil cooler (B)

(A)

•

Before replacement of the impeller seawater pump, make sure the sea water suction valves are all closed and the engine is stopped.

1.

COOLER ASSEMBLY REMOVAL

•

Disconnect the 2 oil flexible hoses (A) and the 2 fuel oil cooler hose (B) Loose the collars and remove the hose (1) Loose the collars and remove the hose (2) Release the collars (3) and remove the coolers assembly including fuel oil cooler (4) and gear box oil cooler (5) Separate the two coolers by removal of the hose (6) after loosen the collars.

• • • • (2)

(1)

(3)

(4)

(6)

(5)

3.

CLEAN INTERCOOLER CORE AND BODY

•

Clean the core by using a cleaner for cooling system. Follow the instructions for use the cleaning product.

Make sure all tubes on sea water side are free from obstruction.

• 4.

COOLER ASSEMBLY REINSTALLATION

•

Reconnect the two coolers (4) and (5) with the hose (6) and tight the clamps.

Reinstalled the coolers on the support and tight the clamps (3) Reinstalled the hose (2) and tight the clamps Reinstalled the hose (1) and tight the clamps Reconnect the 2 oil flexible hoses (A) and the 2 fuel hose (B)

• • • • 5.

40

CHECK FOR ENGINE SEA WATER, FUEL AND OIL LEAKAGES

04 /20110 indice A

[4.18] TAPPET CLEARANCE (Control and adjustment): WARNING

(3) •

Before tappet inspection, make sure the fuel valves and sea water valves are all closed and secure. Make sure that engine power is OFF. Do not forget to install a panel to prevent risk of injuries.

1.

BEFORE INSPECTION

•

Drain the coolant circuit (see concern chapter page 32) Remove the plastic cover.

Disconnect the 4 injectors (1).

Remove the 4 injection pipes (2).

Unscrew the 4 screws and remove the 2 cover support (3) Unscrew the 2 banjo bolt and remove the water pipe (4) Unscrew the clamps and the 3 nuts and remove the water pipe (5) Unscrew the 2 clamps and remove the water pipe (6) Unscrew the 2 nuts and remove the sea water pump (7) Unscrew the 6 bolts and remove the timing belt cover (8) Unscrew the 12 bolts and remove the cylinder head cover (9).Be careful to the injectors seals.

• • • • (2)

(9)

•

(1)

• • • • • (4)

(5)

(8)

(6)

(7)

41

04 /20110 indice A

2.

INSPECT THE VALVE CLEARANCE

•

Lower the piston by rotating the crankshaft about 90 deg. counter clockwise from the TDC Align the timing mark of the camshaft timing pulley with the arrow mark of the timing belt No.2 cover.

Using a feeler gauge, measure the clearance between the valve lifter and camshaft, only on the valves indicated on illustration 1.

Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter if the values are out of limits.

• • •

EXHAUST

Valve clearance (engine cold): Intake: 0.20 to 0.30 mm (0.0079 to 0.0118 in.)

Exhaust: 0.35 to 0.45 mm (0.0138 to 0.0177 in.)

• • INTAKE FIGURE 1

EXHAUST

•

3.

RE-INSTALLATION

•

Re-install the cylinder head cover (9) with the 12 bolts. Be careful to the injectors seals.

Re-install the timing belt cover (8) with the 6 bolts.

Re-install the sea water pump (7) with the 2 nuts.

Re-install the water pipe (6)with 2 clamps.

Re-install the water pipe (5) with a new O-ring, the clamps and the 3 nuts.

Re-install the water pipe (4)with the 2 banjo bolt and 4 new copper rings.

Re-install the 2 cover supports (3) with the 4 screws.

Re-install the 4 injection pipes (2).

•

FIGURE 2

• • •

INTAKE

Turn the crankshaft 360 deg. to set the No.4 cylinder to the TDC position.

Check only the valves indicated in the illustration 2.

Measure the valve clearance (See procedure above).

• • •

Torque: 32 N m (326 kgf cm, 24 ft lbf) for use with Special Tool 35 N m (357 kgf cm, 26 ft lbf)

42

• • •

Re-connect the 4 injectors (1).

Re-install the plastic cover.

Fill the coolant circuit (see concern chapter page 32)

4.

CHECK FOR ENGINE SEA WATER, FUEL AND OIL LEAKAGES

04 /20110 indice A

[4.19] TURBO CHARGER INSPECTION: 1.

TURBOCHARGER SUB −ASSY

(a)

Inspect actuator and waste gate valve operation.

(1) Disconnect the actuator hose from the compressor housing.

(2) Using special tool 70804010, apply approx.

186 kPa (1.90kgf/cm 2, 26.6psi) pressure to the actuator.

(3) Move the actuator push rod, and check that the waste gate valve is open.

If the rod does not move, replace the actuator or turbocharger.

NOTICE: Never apply more than 216 kPa (2.20kgf/cm², 31.3 psi) or pressure to the actuator. (b)

Reconnect the actuator hose to the compressor housing.

2.

MAINTENANCE PRECAUTION

(a)

Do not stop the engine immediately after high speed driving. Idle the engine for 20 -120 seconds, depending on how hard the engine has been driven.

Avoid sudden acceleration or racing immediately after starting a cold engine.

If the turbocharger is found to be defective and must be replaced, check for the cause, and repair or replace the following items as necessary: (1) Engine oil level and quality (2) Conditions under which the turbocharger was used (3) Oil lines leading to the turbocharger Use caution when removing and reinstalling the turbocharger assembly. Do not drop it or bang it against anything or grasp it in the easily−deformed parts, when moving it.

Before removing the turbocharger, plug the intake and exhaust ports and oil inlet to prevent entry of dirt or other foreign material.

If replacing the turbocharger, check for accumulation of sludge particles in the oil pipes, and if necessary, replace the oil pipes.

Completely remove the gasket adhered to the lubrication oil pipe flange and turbocharger oil flange.

When replacing the bolts or nuts, use only authorized replacement parts to prevent breakage or deformation.

(b) (c)

Oil Pipe

(d)

(e) (f) (g) (h)

43

04 /20110 indice A

3.

ON−BOAT INSPECTION

A.

INSPECT INTAKE AIR SYSTEM

(a)

Check for leakage or clogging between the air cleaner housing and turbocharger inlet and between the turbocharger outlet and cylinder head.

(1) Clogged air cleaner… Clean or replace the air filter (2) Hoses collapsed or deformed...Repair or replace (3) Leakage from connections...Check each connection and repair (4) Cracks in components...Check and replace

B.

INSPECT EXHAUST SYSTEM

(a)

Check for leakage or clogging between the cylinder head and turbocharger inlet and between the turbocharger outlet and exhaust pipe.

(1) Deformed components...Repair or replace (2) Foreign material in passages...Remove (3) Leakage from components… Repair or replace (4) Cracks in components...Check and replace

C.

INSPECT TURBINE SHAFT ROTATION

(a)

Grasp the edge of the turbine shaft, and turn it.

Check that the turbine shaft turns smoothly.

If the turbine shaft does not turn or if it turns with a heavy drag, replace the turbocharger.

44

04 /20110 indice A

[5] SPECIAL TOOLS 70804010

Turbo Charger Pressure Gage

ECD SYSTEM

890000002

Diagnostics Kit

ECU SYSTEM

[5.1] SPECIAL TOOLS (MECHANICAL) Oil Pan Seal Cutter

PARTIAL ENGINE ASSEMBLY

Valve Guide bushing Remover & Replace Set

CYLINDER BLOCK ASSEMBLY

Valve Guide bushing Remover & Replace 6

CYLINDER BLOCK ASSEMBLY

970312764

Valve Stem Oil Seal Replacer

CYLINDER BLOCK ASSEMBLY

970312372

Valve Spring Compressor

CYLINDER BLOCK ASSEMBLY

(Attachment)

CYLINDER BLOCK ASSEMBLY

970312733

970312738

Crankshaft Pulley Replacer

970315565

Remove & Replacer

CYLINDER BLOCK ASSEMBLY

970315566

(Guide)

CYLINDER BLOCK ASSEMBLY

970315567

(Base)

PARTIAL ENGINE ASSEMBLY

970312742

Cover and Seal replacer

PARTIAL ENGINE ASSEMBLY

970312743

Oil seal & bearing Replacer

PARTIAL ENGINE ASSEMBLY

45

PARTIAL ENGINE ASSEMBLY

04 /20110 indice A

970315563

Oil seal & Bearing replacement

PARTIAL ENGINE ASSEMBLY

970312745

Crankshaft Oil seal Replacer

PARTIAL ENGINE ASSEMBLY

970314172

Differential Bearing Replacer

PARTIAL ENGINE ASSEMBLY

970313927

Front Hub Inner Bearing Cone Replacer

PARTIAL ENGINE ASSEMBLY

970312753

Puller B Set

PARTIAL ENGINE ASSEMBLY

(Hanger 200)

PARTIAL ENGINE ASSEMBLY

(Slide Arm)

PARTIAL ENGINE ASSEMBLY

(Centre bolt 200)

PARTIAL ENGINE ASSEMBLY

(Arm 25)

PARTIAL ENGINE ASSEMBLY

(Claw N°6)

PARTIAL ENGINE ASSEMBLY

(Attachment)

PARTIAL ENGINE ASSEMBLY

(Holder)

PARTIAL ENGINE ASSEMBLY

Puller C Set

PARTIAL ENGINE ASSEMBLY

970312374

(Hanger 150)

(Slide Arm)

46

PARTIAL ENGINE ASSEMBLY

PARTIAL ENGINE ASSEMBLY

04 /20110 indice A

(Centre bolt 150)

PARTIAL ENGINE ASSEMBLY

(Claw N°1)

PARTIAL ENGINE ASSEMBLY

Replacer Set

970315564

970312748

(Replacer 18)

CYLINDER BLOCK ASSEMBLY

(Replacer 20)

CYLINDER HEAD ASSEMBLY CYLINDER BLOCK ASSEMBLY

(Replacer 30)

CYLINDER HEAD ASSEMBLY

(Replacer 35)

CYLINDER HEAD ASSEMBLY CYLINDER BLOCK ASSEMBLY

(Replacer 40)

CYLINDER BLOCK ASSEMBLY

(Replacer 45)

CYLINDER BLOCK ASSEMBLY

(Replacer 48)

PARTIAL ENGINE ASSEMBLY

Handle set

PARTIAL ENGINE ASSEMBLY CYLINDER HEAD ASSEMBLY CYLINDER BLOCK ASSEMBLY

(Handle 100)

PARTIAL ENGINE ASSEMBLY CYLINDER HEAD ASSEMBLY

Variable Pin Wrench Set

970312754

47

PARTIAL ENGINE ASSEMBLY CYLINDER HEAD ASSEMBLY CYLINDER BLOCK ASSEMBLY

PARTIAL ENGINE ASSEMBLY

04 /20110 indice A

(Variable Pin Wrench Arm Assembly)

PARTIAL ENGINE ASSEMBLY

(Pin 6)

PARTIAL ENGINE ASSEMBLY

(Pin 10)

PARTIAL ENGINE ASSEMBLY

70804010

Turbocharger Pressure Gauge

PARTIAL ENGINE ASSEMBLY

970312770

Seal Packing Black or equivalent (FIPG)

PARTIAL ENGINE ASSEMBLY

970312769

“Adhesive 1324” THREE BOND 1324 or equivalent

CYLINDER BLOCK ASSEMBLY

SEALANT

Reamer Piston ring expander Micrometer Cylinder Gauge Dial indicator Feeler Gauge Torque wrench Vernier caliper Slide caliper V-Block Wooden block

Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools

48

04 /20110 indice A

[5.1] SPECIAL TOOLS (MECHANICAL / CONTINUATION) 70804009

Union Nut Wrench 17mm

CAMSHAFT SETTING OIL SEAL VALVE CLEARANCE CYLINDER HEAD GASKET PARTIAL ENGINE ASSEMBLY

970312736

Crankshaft Pulley Holding tool

CAMSHAFT SETTING OIL SEAL VALVE CLEARANCE CYLINDER HEAD GASKET PARTIAL ENGINE ASSEMBLY

970312743

Oil seal & Bearing Replacer

ENGINE REAR OIL SEAL

970312376

Crankshaft Front Oil Seal replacer

TIMING GEAR CASE OIL SEAL

Clutch Guide Tool

PARTIAL ENGINE ASSEMBLY

970312751

Oil Seal Puller

TIMING GEAR CASE

970312752

Combination Flange Holding Tool

ENGINE REAR OIL SEAL TIMING GEAR CASE OIL SEAL PARTIAL ENGINE ASSEMBLY CAMSHAFT CAMSHAFT SETTING OIL SEAL

970313927

Front Hub Inner Bearing Cone Replacer

VALVE CLEARANCE

(Hanger 150)

TIMING GEAR CASE OIL SEAL PARTIAL ENGINE ASSEMBLY

(Slide arm)

TIMING GEAR CASE OIL SEAL PARTIAL ENGINE ASSEMBLY

(Centre Bolt 150)

TIMING GEAR CASE OIL SEAL PARTIAL ENGINE ASSEMBLY

49

04 /20110 indice A

970315564

970312748

970312747

70804010

(Claw N°2)

TIMING GEAR CASE OIL SEAL PARTIAL ENGINE ASSEMBLY

(Attachment)

TIMING GEAR CASE OIL SEAL

Replacer Set

TIMING GEAR CASE OIL SEAL

(Replacer 35)

TIMING GEAR CASE OIL SEAL

Handle Set

ENGINE REAR OIL SEAL

(Handle 200)

ENGINE REAR OIL SEAL

Cylinder Compression Check Gauge Set

ENGINE

(N°4 attachment)

ENGINE

(Gauge assembly)

ENGINE

Turbocharger pressure gauge

VALVE CLEARANCE CYLINDER HEAD GASKET

Engine Sling Device

PARTIAL ENGINE ASSEMBLY

Seal Packing Black or equivalent (FIPG)

CAMSHAFT PARTIAL ENGINE ASSEMBLY ENGINE REAR OIL SEAL VALVE CLEARANCE CYLINDER HEAD GASKET

RECOMENDED TOOLS

SEALANT 970312770

50

04 /20110 indice A

STANDARD TOOLS Belt tension Gauge CO / CH Meter Chain block Compression gauge Dial indicator Feeler gauge Hexagonal wrench (10mm) Injection nozzle tester Micrometer Plastigage Precision straight edge Press Radiator cap tester Sandpaper #400 Slide caliper Steel square Electronic tachometer Timing light Torque wrench Vernier calipers

Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools

[5.2] SPECIAL TOOLS (LUBRICATION)

970312752

51

Clutch guide tool

TIMING GEAR CASE ASSEMBLY

Companion Flange Holding Tool

OIL COOLER ASSEMBLY TIMING GEAR CASE ASSEMBLY

Drive shaft Remover Attachment

TIMING GEAR CASE ASSEMBLY

Differential Side Gear Shaft Puller

TIMING GEAR CASE ASSEMBLY

(Shocker Set)

TIMING GEAR CASE ASSEMBLY

Ball Joint Puller

TIMING GEAR CASE ASSEMBLY

04 /20110 indice A

970312374

Puller C Set

TIMING GEAR CASE SUBASSEMBLY OIL COOLER ASSEMBLY TIMING GEAR CASE ASSEMBLY

(Hanger 150)

OIL COOLER ASSEMBLY TIMING GEAR CASE ASSEMBLY

(Slide )

OIL COOLER ASSEMBLY TIMING GEAR CASE ASSEMBLY

(Center bolt 150)

OIL COOLER ASSEMBLY TIMING GEAR CASE ASSEMBLY

(Claw N°1)

TIMING GEAR CASE ASSEMBLY

(Claw N°2)

OIL COOLER ASSEMBLY TIMING GEAR CASE ASSEMBLY

Seal Packing Black or equivalent (FIPG)

TIMING GEAR CASE ASSEMBLY

SEALANT 970312770

STANDARD TOOLS Feeler gauge Torque wrench Belt tension gauge Compression gauge CO / CH meter Dial indicator Hexagonal wrench (10mm) Press Radiator cap tester

Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools 52

04 /20110 indice A

Slide Calipper Steel square Electronic tachometer Timing light Torque wrench Verneer calippers

Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools

LUBRIFICATION FLUID Capacity Oil Grade 15W40

Classification API grade CF-4 or CD mini

Drain and refill with oil filter change

7.0 litres

Drain and refill without oil filter change

6.7 litres

Dry fill

7.0 litres

[5.2] SPECIAL TOOLS (COOLING) 70804009

Union Nut Wrench 17mm

970312770

Seal Packing Black or equivalent (FIPG)

WATER PUMP ASSEMBLY

SEALANT WATER PUMP ASSEMBLY

STANDARD TOOLS Feeler gauge Heater Hexagonal wrench (10mm) Press Radiator cap tester Slide Caliper Steel square Thermometer Torque wrench Vernier caliper

Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools

[5.3] SPECIAL TOOLS (INTAKE) STANDARD TOOLS Radiator cap tester Torque wrench

Standard tools Standard tools

53

04 /20110 indice A

[5.2] SPECIAL TOOLS (FUEL) INJECTORS ASSEMBLY FUEL HIGH PRESSURE PUMP ASSEMBLY COMMON RAIL

70804009

Union Nut Wrench 17mm

970312736

Crankshaft Pulley Holding tool

INJECTION OR HIGH PRESSURE PUMP ASSEMBLY

970313928

Fuel Filter Wrench

FUEL FILTER ELEMENT ASSEMBLY

970312752

Companion Flange Holding Tool

INJECTION OR HIGH PRESSURE PUMP ASSEMBLY

Sensor Socket Wrench

FUEL TEMPERATURE SENSOR

Puller C Set

INJECTION OR HIGH PRESSURE PUMP ASSEMBLY

(Hanger 150)

INJECTION OR HIGH PRESSURE PUMP ASSEMBLY

(Slide Arm)

INJECTION OR HIGH PRESSURE PUMP ASSEMBLY

Turbocharger pressure gauge

INJECTION OR HIGH PRESSURE PUMP ASSEMBLY

(Center Bolt 150)

INJECTION OR HIGH PRESSURE PUMP ASSEMBLY

(Claw N°2)

INJECTION OR HIGH PRESSURE PUMP ASSEMBLY

970312374

70804010

70804010

54

Turbocharger pressure gauge

INJECTIOR ASSEMBLY

04 /20110 indice A

SEALANT Seal Packing Black or equivalent (FIPG)

970312770

WATER PUMP ASSEMBLY

STANDARD TOOLS Belt tension gauge Clip Dial indicator Hexagonal wrench (10mm) Measuring flask Ohmmeter Press Radiator cap tester Service wire harness Steel square Stop watch Thermometer Torque wrench Vernier caliper

Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools Standard tools

55

04 /20110 indice A

ENGINE REPAIR SUMMURY ENTRETIEN 1.

SERVICE SPECIFICATION

57

[1.1] HOW TO DETERMINE BOLT STRENGHT [1.2] SPECIFIED TORQUE FOR STANDARD BOLTS [1.3] HOW TO DETERMINE NUT STRENGHT [1.4] ENGINE MACHANICAL SERVICE DATA [1.5] LUBRICATION SERVICE DATA [1.6] COOLING SERVICE DATA [1.7] FUEL SERRVICE DATA [1.8] STARTING & CHARGING SERVICE DATA [1.9] ENGINE CONTROLE SYSTEM SERVICE DATA

57 58 59 60 65 65 66 66 66

2.

TIMING BELT REPLACEMENT

67

3.

ENGINE OVERHAUL

72

[3.1] PARTIAL ENGINE ASSEMBLY COMPONENTS [3.2] ENGINE BLOCK OVERHAUL [3.3] OVERHAULD

72 75 77

4.

CYLINDER HEAD OVERHAUL [4.1] PARTIAL CYLINDER HEAD COMPONENTS [4.2] CYLINDER HEAD OVERHAULD

113 113 114

5.

CYLINDER BLOCK OVERHAUL [5.1] PARTIAL CYLINDER BLOCK COMPONENTS [5.2] CYLINDER BLOCK OVERHAULD

134 134 135

6.

COOLANT PUMP INSPECTION/REPLACEMENT [6.1] COOLANT PUMP PARTIAL COMPONENTS [6.2] COOLANT PUMPINSPECTION / REPLACEMENT

162 163 163

7.

TIMING GEAR OIL SYSTEM [7.1] TIMING GEAR OIL INSPECTION [7.2] TIMING GEAR OIL PUMP INSPECTION [7.3] CAMSHAFT OIL SEAL REPLACEMENT [7.4] REAR OIL SEAL REPLACEMENT [7.5] GEAR CASE OIL SEAL REPLACEMENT

164 164 174 175 177 179

8.

FUEL OIL SYSTEM [8.1] FUEL SYSTEM ON BOARD INSPECTION [8.2] INJECTORS REPLACEMENT [8.3] HIGH PRESSURE PUMP REPLACEMENT [8.4] FUEL TEMPERTURE REPLACEMENT [8.5] COMMON RAIL REPLACEMENT

181 181 182 188 191 191

9.

ELECTRIC SYSTEM [9.1] STARTING SYSTEM [9.2] CHARGING SYSTEM [9.3] PREHEATING SYSTEM [9.4] WIRING SYSTEM

193 193 194 197 199

56

04 /20110 indice A

1. SERVICE SPECIFICATIONS [1.1] STANDARD BOLT: HOW TO DETERMINE BOLT STRENGTH BOLT TYPE CLASS

HEXAGON HEAD BOLT NORMAL RECESS BOLT

DEEP RECESS BOLT

NO MARK

NO MARK

WITH MARK

WITH MARK

STUD BOLT

WELD BOLT

NO MARK

57

04 /20110 indice A

[1.2] STANDARD BOLT: SPECIFIED TORQUE FOR STANDARD BOLT SPECIFIED TORQUE CLASS

4T

5T

6T

7T

8T

9T

10T

11T

DIAMETER mm

PITCH mm

HEXAGONAL HEAD BOLT

HEXAGONAL FLANGE BOLT

N.m

kgf-cm

ft-lbf

N.m

kgf-cm

ft-lbf

6

1

5

55

48 in-lbf

6

60

52 in-lbf

8

1.25

12.5

130

9

14

145

10

10

1.25

26

260

19

29

290

21

12

1.25

47

480

35

53

540

39

14

1.5

74

760

55

84

850

61

16

1.5

115

1150

83

-

-

-

6

1

6.5

65

56 in-lbf

7.5

75

65 in-lbf

8

1.25

15.5

160

12

17.5

175

13

10

1.25

32

330

24

36

360

26

12

1.25

59

600

43

65

670

48

14

1.5

91

930

67

100

1050

76

16

1.5

140

1400

101

-

-

-

6

1

8

80

69 in-lbf

9

90

78 in-lbf

8

1.25

19

195

14

21

210

15

10

1.25

39

400

29

44

440

32

12

1.25

71

730

53

80

810

59

14

1.5

110

1100

80

125

1250

90

16

1.5

170

1750

127

-

-

-

6

1

10.5

110

8

12

120

9

8

1.25

25

260

19

28

290

21

10

1.25

52

530

38

58

590

43

12

1.25

95

970

70

105

1050

76

14

1.5

145

1500

108

165

1700

123

16

1.5

230

2300

166

-

-

-

8

1.25

29

300

22

33

330

24

10

1.25

61

620

45

68

690

50

12

1.25

110

1100

80

120

1250

90

8

1.25

34

340

25

37

380

27

10

1.25

70

710

51

78

790

57

12

1.25

125

1300

94

140

1450

105

8

1.25

38

390

28

42

430

31

10

1.25

78

800

58

88

890

64

12

1.25

140

1450

105

155

1600

116

8

1.25

42

430

31

47

480

35

10

1.25

87

890

64

97

990

72

12

1.25

155

1600

116

175

1800

130

58

04 /20110 indice A

[1.3] STANDARD BOLT: HOW TO DETERMINE NUT STRENGTH

PRESENT STANDARD HEXAGONAN NUT

NUT TYPE OLD STANDARD HEXAGON NUT COLD FORGING NUT

CUTTING PROCESSED NUT

NO MARK (WITH MARK)

NO MARK

CLASS

NO MARK

NO MARK (WITH MARK)

NO MARK

*: Nut with 1 or more marks on one side surface of the nut.

HINT: Use the nut with the same number of the nut strength classification or a number greater than the bolt strength classification number when tightening parts with a bolt and nut.

Example:

Bolt = Nut =

4T 4N or more

59

04 /20110 indice A

[1.4] ENGINE MECANICAL SERVICE DATA Cylinder block Balance shaft bearing inside diameter Balance shaft thrust clearance Warpage Cylinder bore diameter

Piston oil clearance

No. 1 No. 2 No. 3 STD Maximum Maximum STD Mark 1 STD Mark 2 STD Mark 3 Maximum STD Maximum

42.000 to 42.020 mm (1.6535 to 1.6543 in.)

41.000 to 41.020 mm (1.6142 to 1.6150 in.)

32.000 to 32.020 mm (1.2598 to 1.2606 in.)

0.065 to 0.140 mm (0.0026 to 0.0055 in.)

0.25 mm (0.0098 in.)

0.10 mm (0.0039 in.)

96.000 to 96.010 mm (3.7795 to 3.7799 in.)

96.010 to 96.020 mm (3.7799 to 3.7803 in.)

96.020 to 96.030 mm (3.7803 to 3.7807 in.)

96.23 mm (3.7886 in.)

0.070 to 0.090 mm (0.0028 to 0.0035 in.)

0.14 mm (0.0055 in.)

Cylinder head bolt Cylinder head bolt out diameter

STD Minimum

11.76 to 11.97 mm (0.4630 to 0.4713 in.)

11.60 mm (0.457 in.)

STD Maximum STD Maximum STD Maximum

0.06 to 0.11 mm (0.0024 to 0.0043 in.)

0.30 mm (0.0118 in.)

44.000 to 44.025 mm (1.7323 to 1.7333 in.)

43.955 to 43.990 mm (1.7305 to 1.7319 in.)

0.010 to 0.070 mm (0.0004 to 0.0028 in.)

0.20 mm (0.0079 in.)

0.02 to 0.15 mm (0.0008 to 0.0060 in.)

0.20 mm (0.0079 in.)

A B C D E Intake Exhaust

0.80 to 0.90 mm (0.0315 to 0.0354 in.)

0.85 to 0.95 mm (0.0335 to 0.0374 in.)

0.90 to 1.00 mm (0.0354 to 0.0394 in.)

0.95 to 1.05 mm (0.0374 to 0.0413 in.)

1.00 to 1.10 mm (0.0394 to 0.0433 in.)

0.20 to 0.30 mm (0.0079 to 0.0118 in.)

0.35 to 0.45 mm (0.0138 to 0.0177 in.)

Maximum STD O/S 0.05 Intake Exhaust

0.15 mm (0.0059 in.)

10.985 to 11.006 mm (0.4325 to 0.4333 in.)

11.035 to 11.056 mm (0.4344 to 0.4353 in.)

1.2 to 1.6 mm (0.047 to 0.063 in.)

1.6 to 2.0 mm (0.063 to 0.079 in.)

31.000 to 31.021 mm (1.2205 to 1.2213 in.)

0.024 to 0.055 mm (0.0009 to 0.0022 in.)

0.095 mm (0.0037 in.)

Timing gear Idle gear No.1 thrust clearance Idle gear No.1 inside diameter Idle gear shaft diameter Idle gear shaft oil clearance Gear backlash Cylinder head gasket New cylinder head gasket thickness

Valve clearance Cold Cylinder head Warpage Bush bore diameter Contact width Valve lifter bore diameter Valve lifter oil clearance

STD Maximum

60

04 /20110 indice A

[1.4] ENGINE MECANICAL SERVICE DATA Valve Valve stem diameter

Intake Exhaust

Valve face angle Margin thickness

Valve overall length

Valve stem oil clearance

STD Intake STD Exhaust Minimum Intake Minimum Exhaust STD Intake STD Exhaust Minimum Intake Minimum Exhaust STD Intake STD Exhaust Maximum Intake Maximum Exhaust

5.970 to 5.985 mm (0.2350 to 0.2356 in.)

5.960 to 5.975 mm (0.2346 to 0.2352 in.)

44.5° 1.1 mm (0.043 in.)

1.2 mm (0.047 in.)

0.6 mm (0.024 in.)

0.7 mm (0.028 in.)

105.15 to 105.75 mm (4.1398 to 4.1634 in.)

105.02 to 105.62 mm (4.1347 to 4.1583 in.)

104.65 mm (4.1201 in.)

104.52 mm (4.1150 in.)

0.025 to 0.060 mm (0.0010 to 0.0024 in.)

0.035 to 0.070 mm (0.0014 to 0.0028 in.)

0.08 mm (0.0031 in.)

0.10 mm (0.0039 in.)

Compression spring Deviation Maximum Free length Install tension at 33.1 mm (1.303 in.)

2.0 mm (0.079 in.)

46.5 mm (1.831 in.)

150 to 166 N (14.7 to 16.2 kgf, 33.7 to 37.3 lbf)

Valve guide bush Bush inside diameter Protrusion height

6.010 to 6.030 mm (0.2366 to 0.2374 in.)

10.3 to 10.7 mm (0.406 to 0.421 in.)

Valve lifter Lifter diameter

30.966 to 30.976 mm (1.2191 to 1.2195 in.)

Camshaft Circle run out Camshaft lobe height

Journal diameter Oil clearance Thrust clearance Camshaft backlash

Maximum STD Intake STD Exhaust Maximum Intake Maximum Exhaust STD Maximum STD Maximum STD Maximum

0.03 mm (0.0012 in.)

47.180 to 47.280 mm (1.8575 to 1.8614 in.)

48.070 to 48.170 mm (1.8925 to 1.8965 in.)

46.76 mm (1.8409 in.)

47.92 mm (1.8866 in.)

27.969 to 27.985 mm (1.1011 to 1.1018 in.)

0.025 to 0.062 mm (0.0010 to 0.0024 in.)

0.10 mm (0.0039 in.)

0.035 to 0.185 mm (0.0014 to 0.0073 in.)

0.25 mm (0.0098 in.)

0.035 to 0.089 mm (0.0014 to 0.0035 in.)

0.189 mm (0.0074 in.)

Connecting rod Thrust clearance Oil clearance Connecting rod bend Connecting rod twist Bush inside diameter

STD Maximum STD Maximum Maximum per 100 mm (3.94 in.)

Maximum per 100 mm (3.94 in.)

Mark A Mark B Mark C

61

0.100 to 0.300 mm (0.0039 to 0.0118 in.)

0.40 mm (0.0157 in.)

0.036 to 0.054 mm (0.0014 to 0.0021 in.)

0.10 mm (0.0039 in.)

0.03 mm (0.0012 in.)

0.15 mm (0.0059 in.)

34.012 to 34.016 mm (1.3391 to 1.3392 in.)

34.016 to 34.020 mm (1.3392 to 1.3394 in.)

34.020 to 34.024 mm (1.3394 to 1.3395 in.)

04 /20110 indice A

[1.4] ENGINE MECANICAL SERVICE DATA Crankshaft Thrust clearance Oil clearance Circle run out Main journal diameter Crank pin diameter Crank pin taper and out−of−round

STD Maximum STD Maximum Maximum Mark 1 Mark 2 Mark 3 Mark 1 Mark 2 Mark 3 Maximum

0.040 to 0.240 mm (0.0016 to 0.0094 in.)

0.30 mm (0.0118 in.)

0.030 to 0.048 mm (0.0012 to 0.0019 in.)

0.10 mm (0.0039 in.)

0.03 mm (0.0012 in.)

69.994 to 70.000 mm (2.75566 to 2.75590 in.)

69.988 to 69.994 mm (2.75543 to 2.75566 in.)

69.982 to 69.988 mm (2.75519 to 2.75543 in.)

58.994 to 59.000 mm (2.32259 to 2.32283 in.)

58.988 to 58.994 mm (2.32236 to 2.32259 in.)

58.982 to 58.988 mm (2.32212 to 2.32236 in.)

0.020 mm (0.0008 in.)

Idle speed 700 rpm ± 50 rpm Maximum speed 4,000 rpm Compression pressure at 250 rpm STD Minimum pressure Difference between each cylinder

2,700 kPa (27.5 kgf/cm2, 391 psi) or more 2,200 kPa (22.5 kgf/cm2, 320 psi) or more 500 kPa (5.0 kgf/cm2, 71 psi) or less

Valve clearance 0.20 − 0.30 mm (0.0079 − 0.0118 in.)

0.35 − 0.45 mm (0.0138 − 0.0177 in.)

Cold Intake Cold Exhaust Cylinder head set bolt STD Minimum outer diameter

11.76 − 11.97 mm (0.463 − 0.471 in.)

11.60 mm (0.457 in.)

Cylinder head gasket New cylinder head gasket thickness

A B C D E

62

0.80 − 0.90 mm (0.0315 − 0.0354 in.)

0.85 − 0.95 mm (0.0335 − 0.0374 in.)

0.90 − 1.00 mm (0.0354 − 0.0394 in.)

0.95 − 1.05 mm (0.0374 − 0.0413 in.)

1.00 − 1.10 mm (0.0394 − 0.0433 in.)

04 /20110 indice A

[1.4] ENGINE MECANICAL SERVICE DATA TORQUE VALUE Cylinder head system Part Tightened

N･m

Camshaft bearing cap × Cylinder head

19

Cover assembly, Cylinder head × Cylinder head

Bolt Nut

9 9 10

Bolt Nut

Common rail assembly × Cylinder head

29 29 38

Glow plug assembly × Cylinder head

13

Glow plug assembly × Glow plug connector

2.2

Clamp, nozzle holder × Cylinder head

21.6

Hanger, engine No.1 × Cylinder head

50

Hanger, engine No.2 × Cylinder head

32

Gauge assembly, water temperature sender × Cylinder head

19.6

Cap assembly, oil filler × Cover assembly, Cylinder head Intake manifold ×

Cylinder head

Cylinder block System Crank cap × Cylinder block

1rst step 2nd step

50 90° 26

Bolt Nut 1st step 2nd step Bolt Nut

Pan sub-assembly, oil × Drain plug

8 8 35 90° 16 16 34

Plug, oil pan × pan sub-assembly, oil

7

Tensioner assembly, V-ribbed belt × Cylinder block

21

Tensioner assembly, V-ribbed belt × Case assembly, timing gear

21

Tensioner assembly, V-ribbed belt × Bracket, alternator

21

Alternator × Bracket, alternator

21

Alternator × Tensioner assy, V-ribbed belt

62

Nozzle sub-assembly oil × Cylinder block Strainer sub-assembly, oil × Cylinder block Connecting rod cap × Connecting rod Pan sub-assembly, oil × Cylinder block

Pump assembly, water × Cylinder block Timing gear case assembly × Cylinder block Timing gear case assembly × Oil pump relief valve plug

Bolt Nut Bolt Union bolt Bolt

Cover, cylinder block side × Timing gear case assembly Cover, timing gear × Timing gear case assembly

13 13 13 16 44 29

Cover, timing gear × Crank position sensor

13 13 8.5

Cover, timing gear × Crank position sensor No.2

8.5

63

Bolt Nut

04 /20110 indice A

[1.4] ENGINE MECANICAL SERVICE DATA TORQUE VALUE Cylinder block System Cover, timing gear × Bracket, wiring harness clamp

13

Timing belt cover × Timing belt cover No.2

6

Plate, water seal × Cylinder block

8

Cylinder head × Cylinder block

1st 2nd 3rd

85 90° 90°

Rear end plate × Cylinder block

8

Engine rear oil seal retainer × Cylinder block

13

Oil cooler assembly, × oil cooler cover

16

Oil cooler cover sub-assembly, × Cylinder block

13

Drain cock × Oil cooler cover sub-assembly,

8

Oil filter × Oil cooler cover sub-assembly,

12

Water temperature sensor × Cylinder block

19.6

Plug, hole × Cylinder block

8

Cover, timing belt,No.2 × Cylinder head and Cylinder block and Timing gear case assembly Bracket, engine control computer,No.2 × Cylinder block Bracket, engine control computer,No.2 × ECU

Bolt Nut M8 M6

10 10 14 6 14

Hose clamp System Part Tightened

N･m

Hose, fuel No.3

2

Hose, fuel No.4

2

Exercise part System Part Tightened

N･m

Gear assembly, idle

35

Gear, balance shaft driven No.1 × Balance shaft No.1

36

Gear, balance shaft driven No.2 × Balance shaft No.2

36

Washer balance shaft thrust × Cylinder block

13

Gear, supply pomp drive × Pump assembly supply

64

Pulley sub-assembly crankshaft × Crankshaft

365

Flange camshaft timing pulley No.2 and Pulley, pump drive shaft × Gear, supply pump drive

31

Pulley camshaft timing No.1 × Camshaft sub-assembly No.1

98

Tensioner assembly, timing belt × Cover, timing gear

13

Idler sub-assembly timing belt × Cover, timing gear

35

Pulley × Pump assembly, water

23

Flywheel sub-assembly × Crankshaft

145 64

04 /20110 indice A

[1.4] ENGINE MECANICAL SERVICE DATA TORQUE VALUE Fuel System : Part Tightened

N･m

Pipe sub-assembly, injection No.1～4 × Injector assembly

35

Pipe sub-assembly, injection No.1～4 × Rail assembly common

35

Pipe sub-assembly, fuel inlet × Rail assembly common

35

Pipe sub-assembly, fuel inlet × Pump assembly supply

35

Clamp, injection pipe No.2 ×

Pipe sub-assembly, injection No.1and No.2

5

Clamp, injection pipe No.2 ×

Pipe sub-assembly, injection No.2and No.3

5

Clamp, injection pipe No.2 × Pipe sub-assembly, fuel inlet and Pipe assembly, nozzle leakage No.2 Clamp, injection pipe No.3 × Pipe sub-assembly, injection No.1and No.2 and No.3 Clamp, injection pipe × Intake manifold

5 5 5

Pump assembly supply × Timing gear case assembly

21

Pipe assembly, nozzle leakage,No.1 × Injector assembly Pipe assembly, nozzle leakage,No.1 × Cylinder head

Dry Wet Dry Wet

18 16 22 12.5

Pipe assembly, nozzle leakage,No.2 × Cylinder head

21

Pipe assembly, nozzle leakage,No.2 × Intake manifold

12.7

[1.5] LUBRICATION SERVICE DATA Oil pump Tip clearance Body clearance Side clearance

Standard Maximum Standard Maximum Standard Maximum

0.060 to 0.160 mm (0.0024 to 0.0063 in.)

0.21 mm (0.0083 in.)

0.100 to 0.170 mm (0.0039 to 0.0067 in.)

0.20 mm (0.0079 in.)

0.030 to 0.090 mm (0.0012 to 0.0035 in.)

0.15 mm (0.0059 in.)

Oil pressure At idle speed At 3000 rpm

29 kPa (0.3 kgf/cm², 4.3 psi) or more 245 kPa (2.5kgf/cm², 36 psi) or more

Supply pump drive shaft pulley Thrust clearance

0.15—0.55 mm (0.059—0.0217 in.)

[1.6] COOLING SERVICE DATA Thermostat Valve opening temperature Valve lifting at 95°C (203°F)

80°C—84°C (175°F—183°F) 10mm (0.39 in.) or more

65

04 /20110 indice A

[1.7] FUEL SERVICE DATA Injection or supply pump Resistance

SCV 1 SCV 2

1.5 Ω—1.7 Ω at 20°C (68°F) 1.5 Ω—1.7 Ω at 20°C (68°F)

Injectors Resistance at 20°C (68°F) Common rail

0.85 Ω—1.05 Ω

Resistance

2—3 1—2

3 kΩ or less 16.4 kΩ or less

[1.8] STARTING & CHARGING SERVICE DATA Starter (2.2kW type) Rated voltage and output power No load characteristics Starter relay

Current

Specified condition

1—2 3—5

12 volts 2.2 kW 120A or less at 11.5 volts Continuity No continuity

Battery Except maintenance free battery

1.25—1.29 at 20°C (68°F)

(standard specific gravity)

Voltage at 20°C (68°F) Glow plugs

12.5V—12.9V

Resistance at 20°C (68°F)

Approx. 0.72Ω

Glow plug relay Specified condition

1—2 3—4

Continuity No continuity

[1.9] ENGINE CONTROL SYSTEM SERVICE DATA Engine coolant temperature sensor Resistance

At 20°C (68°F) At 80°C (176°F)

2.21 kΩ—2.69 kΩ 0.287 kΩ—0.349 kΩ

At 20°C (68°F)

2.21 Ω—2.65 Ω

At cold At hot

1630 Ω—2740 Ω 2065 Ω—3225 Ω

At cold At hot

1630 Ω—2740 Ω 2065 Ω—3225 Ω

Inlet air temperature sensor Resistance Crankshaft position sensor Resistance Camshaft position sensor Resistance

66

04 /20110 indice A

2. TIMING GEAR BELT REPLACEMENT. WARNING •

67

• •

Please refer to the SAFETY instruction on pages 4 to 6 of this manual before doing any works.

Disconnect the engine from the batteries Close and secure sea water valves.

1)

DRAIN COOLANT

•

refer to concerned chapter

2)

REMOVE SEA PUMP

• • • •

Remove the suction hose Remove the discharge hose Unscrew and remove nut position 10 Be careful at the O-Rings 11 and 2 could fall down.

3)

REMOVE FRONT COOLANT PIPE

• • • •

Unscrew the clamp (29) Remove air drain pipe (34) Unscrew and remove the 3 nuts (21) Pull out the water pipe (24)

04 /20110 indice A

5)

REMOVE TIMING BELT COVER

•

Remove the 6 bolts and timing belt cover.

6)

REMOVE TIMING BELT

•

Turn the crankshaft in the clockwise direction and align the alignment as the illustration.

•

Uniformly, loosen the 2 bolts, remove the timing belt tensioner.

Remove the timing belt.

•

HINT: 1) 2)

68

When turning the camshaft while the timing belt is removed, turn the crankshaft 90 deg. counter clockwise.

When installing the timing belt, it is necessary to return the camshaft to the timing marks and then turn the crankshaft clockwise, it aligns with the timing marks as shown in the illustration.

04 /20110 indice A

7)

INSPECT TIMING BELT IDLER SUB−ASSY

(a)

Check that the idler pulley turns smoothly by hand.

Visually check the seal portion of the idler pulley has not grease.

(b)

NOTICE: 1) 2) 3) 4)

Do not bend, twist or turn the timing belt inside out.

Do not allow the timing belt and each pulley to come into contact with oil, water or steam.

Before installing, be sure to clean up each pulley with a rag.

Do not remove the timing belt idler No. 1, except for if it necessary.

8)

INSPECT CHAIN TENSIONER ASSY.

•

Visually check the seal portion of the tensioner for oil leakage.

HINT: 1) 2) 3) •

If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right.

If leakage is found, replace the tensioner.

In case of any doubt replace the tensioner.

Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn’t move. If the push rod moves, replace the tensioner.

NOTICE: Never hold the tensioner push rod facing downward.

•

Measure the protrusion of the push rod from the housing end.

Protrusion: 8.1− 8.9 mm (0.319 − 0.350 in.)

If the protrusion is not as specified, replace the tensioner.

NOTICE: The tensioner is included in the kit 970315355 69

04 /20110 indice A

Timing mark

Timing mark

9)

INSTALL TIMING BELT

•

Check that the timing marks are aligned as the illustration.

Install the timing belt to pump drive shaft pulley, camshaft timing pulley and timing belt idler in sequence.

Set the tensioner to the press up−right.

• •

NOTICE: 1) 2) 3) •

Do not allow the rod end to scratch and deform.

Press the tensioner rod.

Protect a tip of the push rod with a waste in order to prevent damage.

Using a press, slowly push in the push rod using 9,807 N (100 − 1,000 kgf, 220 − 2,205 lbf) of force.

NOTICE: Do not impose loads 9,807 N (100 − 1,000 kgf, 220 − 2,205lbf) or more on the push rod.

Timing mark

•

Align the holes of push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.

•

Temporarily install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.

Tighten the 2 bolts.

Timing mark •

Torque: 13 N m (133 kgf cm, 10 ft lbf) NOTICE: Uniformly tighten the 2 bolts and install the tensioner • •

70

Remove the 1.5 mm hexagon wrench from the tensioner.

Turn the crankshaft in the clockwise direction twice, check that the timing marks are aligned as

04 /20110 indice A

10) INSTALL TIMING BELT COVER •

Install the timing belt No. 1 cover with the 6 bolts.

Torque: 6 N m (61 kgf cm, 53 in. lbf) 11) REINSTALL COOLANT FRONT PIPE 12) REINSTALL THE SEA PUMP • • • •

Replace the O-Rings 11 and 2. (Make sure that they did not fall down during pump installation).

Tight the nuts 10 after installation of the washer 9 Install the suction hose Install the discharge hose

13) FILL THE ENGINE COOLANT •

refer to the concerned chapter.

14) CHECK FOR ENGINE COOLANT LEAKS

71

04 /20110 indice A

3. OVERHAUL [3.1] PARTIAL ENGINE ASSEMBLY COMPONENTS REMOVAL WARNING • • • •

Please refer to the SAFETY instruction on pages 4 to 6 of this manual before doing any works.

Disconnect the engine from the batteries Close and secure sea water valves.

Close en secure fuel valves

1)

DRAIN COOLANT

•

refer to concerned chapter

2)

DRAIN ENGINE OIL

•

Refer to concern chapter

3)

ELECTRIC WIRING REMOVAL

• • • • • • •

Disconnect all sensors from the engines Disconnect the injectors Disconnect the ECU Disconnect the EDU Disconnect the gear box neutral sensor Remove EDU RELAY and MAIN RELAY Remove starter and glows plug relay box

4)

FUEL FILTER ASSEMBLY REMOVAL

•

Disconnect fuel hoses from the filter (2 x screw 6) and from the fuel oil cooler (2 x screw 6) Remove the two supports (3 and 12) by unscrew the 5 bolts (1)

•

5)

ACCELARATOR SUPPORT REMOVAL

• • •

Unscrew and remove cable A Unscrew and remove nuts (8), (12) and bolt (7) Remove support with accelerator (2)

6) EDU SUPPORT REMOVAL • • • •

72

Unscrew and remove the 2 nuts (16) Unscrew and remove the 2 nuts (5) Disconnect the hose (17) from the outlet air of the intercooler.

Remove the support (2)

04 /20110 indice A

7)

INTERCOOLER REMOVAL

• • • • • •

Unscrew and remove the clamps (10) and (14) Remove the water hoses (7) and (8) Remove the air hose (3) Unscrew and remove nuts (9) and (22) Unscrew and remove nuts (6) Lift and remove the intercooler

8)

E.C.U. REMOVAL

•

Unscrew an remove 4 nuts (12) fixing the ECU (7), them remove the ECU Unscrew and remove 2 remaining nuts (12) and bolts 16, them remove the bracket (4)

•

NOTICE: take a particular look at the way the electric harness is installed , to be able to reinstall it correctly later on.

•

Unscrew the 2 remaining nuts (12) fixing the electric breaker support, them pull out the support (1).

NOTICE: Keep the breakers connected on the electric harness

9)

TURBO CHARGER REMOVAL

• • • • • • •

Remove turbocharger cover (not show) Unscrew and remove 2 nuts (5) Unscrew and remove hollow screw (6).

Unscrew and remove 2 bolts (9) Remove oil pipe (3) Unscrew and remove 4 nuts (14) Remove turbo charger (1) with exhaust mixer

NOTICE: Gaskets (8), (7), (4), (2) need be to be replaced

73

04 /20110 indice A

10)

HEAT EXCHANGER REMOVAL

• • • • • •

Unscrew the 2 bolts Remove the bracket (7) Unscrew and remove clamp 37 Remove coolant hose (36) Unscrew and remove clamp (45) Unscrew and remove hollow screw (45) under the heat exchanger.

Remove the hose (41) Unscrew and remove clamp (43) Remove the sea water pipe (42) Unscrew and remove hollow screws (47) Remove the bleeding pipe (34) Unscrew and remove clamps (29) Unscrew the nut (28) Unscrew and remove nuts (21) Pull out coolant pipe (24) Remove the spacer (30) Unscrew and remove 4 bolts (9) and 4 bolts (10) Remove the heat exchanger (1)

• • • • • • • • • • • •

NOTICE: 1) 2)

74

Gaskets (48), (23), (46), should be replaced during reassembly.

All hoses should be checked and replaced if there is any cracks or doubt.

11)

TIMING BELT REMOVAL

•

See concerned chapter

04 /20110 indice A

[3.2] PARTIAL ENGINE ASSEMBLY COMPONENTS

75

04 /20110 indice A

76

04 /20110 indice A

[3.3] OVERHAUL

77

1)

REMOVE OIL FILLER CAP SUB-ASSY

•

Remove the oil filler cap from the cylinder head cover.

04 /20110 indice A

2)

REMOVE NOZZLE HOLDER SEAL

•

Pull out the 4 nozzle holder seals with a screwdriver.

3)

REMOVE CYLINDER HEAD COVER SUBASSY

•

Remove the 10 bolts, 2 nuts, cylinder head cover and gasket.

4)

REMOVE NOZZLE HOLDER CLAMP

•

Remove the 4 bolts, 4 washers and 4 nozzle holder clamps.

5)

REMOVE NOZZLE LEAKAGE PIPE ASSY

•

Remove the union bolt, 4 hollow screws, nozzle leakage pipe and 5 gaskets from the cylinder head and injector.

6)

REMOVE INJECTOR ASSY

•

Remove the 4 injectors from the cylinder head.

HINT: Remember the installed locations of each injector before removing them from the cylinder head. You will have to re-install them at the same locations.

78

04 /20110 indice A

7)

REMOVE CAMSHAFT TIMING PULLEY

•

Remove the bolt, the timing pulley and the set key while holding the hexagon portion of the camshaft with a monkey wrench.

•

Rotate the crankshaft about 90 deg. counter clockwise from the TDC position to lower the piston.

8)

REMOVE BACK TIMING BELT COVER

•

Remove the 4 bolts, nut and back timing belt cover

9)

REMOVE NO.2 CAMSHAFT

•

Uniformly loosen the 15 bearing cap bolts in the order indicated in the illustration and then remove them in the same order.

•

Remove the 5 bearing caps.

•

Remove the camshaft No.2.

camshaft No.2

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04 /20110 indice A

camshaft No.1

10)

REMOVE CAMSHAFT

•

Remove the camshaft from the cylinder head.

11)

REMOVE CAMSHAFT SETTING OIL SEAL

•

Remove the oil seal from the camshaft.

12) REMOVE CYLINDER HEAD SUB-ASSY •

Uniformly loosen the 18 cylinder head bolts in the order indicated in the illustration and then remove them in the same order.

NOTICE: Removing in the wrong order will cause the cylinder head to be warped.

•

Remove the cylinder head and cylinder head gasket from the cylinder block.

HINT: Prevent the removed cylinder head from being damaged.

13)

REMOVE WATER PUMP ASSY

•

Remove the 5 bolts, 2 nuts, water pump and gasket.

14) REMOVE TIMING GEAR CASE •

80

Remove the 14 bolts and 2 nuts.

04 /20110 indice A

81

16)

REMOVE TIMING BELT COVER OIL SEAL

•

Remove the oil seal with a slotted−screwdriver and hammer.

17)

REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1

•

Remove the crank angle sensor plate No.1

18)

REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

•

Using the special tool 970312374, remove the crankshaft timing gear.

19)

REMOVE IDLE GEAR THRUST PLATE

•

Remove the 2 bolts and idle gear thrust plate.

20)

REMOVE IDLE GEAR NO.1

•

Remove the idle gear No.1.

04 /20110 indice A

21)

REMOVE IDLE SUB GEAR NO.1

•

Set the idle gear No.1 and idle sub gear No.2 in a vice.

NOTICE: Be careful not to damage the gears.

•

Using the special tool 970312754, turn the idle sub gear No.1 clockwise and remove the service bolt.

•

Using snap ring pliers, remove the shaft snap ring.

• • • •

Remove the wave washer.

Remove the idle sub gear No.1.

Remove the idle gear spring.

Remove the idle gear No.1 from the vice.

22)

REMOVE IDLE SUB GEAR NO.2

•

Reverse the idle gear No.1 and reset it in the vice.

NOTICE: Be careful not to damage the gear.

82

04 /20110 indice A

83

•

Using snap ring pliers, remove the shaft snap ring.

• • •

Remove the wave washer.

Remove the idle sub gear No.2.

Remove the idle gear spring.

23)

REMOVE IDLE GEAR SHAFT NO.1

•

Remove the idle gear shaft No.1.

24)

REMOVE OIL PAN SUB −ASSY

•

Remove the 22 bolts and 2 nuts.

• •

Remove the oil pan sub−assembly.

Remove the oil pan gasket.

25)

REMOVE TIMING GEAR CASE ASSY

• •

Remove the 8 bolts and union bolt.

Using a plastic−faced hammer, tap out the timing gear case.

04 /20110 indice A

•

Remove the oil pump gasket.

•

Remove the stud bolt.

•

Remove the 2 O−rings.

26)

INSPECT NO.1 BALANCESHAFT SUB −ASSY

•

Using a dial indicator, measure the thrust clearance by moving the balancing shaft back and forth.

Standard thrust clearance: 0.065 to 0.140 mm (0.0026 to 0.0055 in.)

Maximum thrust clearance: 0.25 mm (0.0098 in.)

If the thrust clearance is greater than the maximum clearance, replace the balancing shaft thrust washer.

If the thrust clearance would still be greater than the maximum clearance, replace the balancing shaft.

84

27)

REMOVE NO.1 BALANCING SHAFT SUB −ASSY

•

Remove the 2 bolts and balancing shaft No.1.

04 /20110 indice A

28)

REMOVE BALANCESHAFT DRIVEN GEAR NO.1

•

Mount the balancing shaft in a vice.

NOTICE: Be careful not to damage the balancing shaft.

•

Remove the bolt, balancing shaft driven gear No.1 and balancing shaft thrust washer.

29. INSPECT NO.2 BALANCESHAFT SUB −ASSY •

Using a dial indicator, measure the thrust clearance by moving the balancing shaft back and forth.

Standard thrust clearance: 0.065 to 0.140 mm (0.0026 to 0.0055 in.)

Maximum thrust clearance: 0.25 mm (0.0098 in.)

If the thrust clearance is greater than the maximum clearance, replace the balance shaft thrust washer.

If the thrust clearance would still be greater than the maximum clearance, replace the balancing shaft.

30. REMOVE NO.2 BALANCING SHAFT SUB −ASSY •

Remove the 2 bolts and balancing shaft No.2.

31. REMOVE BALANCESHAFT DRIVEN GEAR NO.2 •

Mount the balancing shaft in a vice.

NOTICE: Be careful not to damage the balancing shaft.

•

Remove the bolt, balancing shaft driven gear No.2 and balancing shaft thrust washer.

32. REMOVE ENGINE REAR OIL SEAL RETAINER • •

85

Remove the 5 bolts.

Separate the engine rear oil seal retainer from the cylinder block with a slotted−screwdriver.

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33)

REMOVE ENGINE REAR OIL SEAL

•

Using a screwdriver and a hammer, tap out the oil seal.

34)

INSPECT CYLINDER HEAD SET BOLT

•

Using calipers, measure the outer diameter of the thread.

Standard outer diameter: 11.76 to 11.97 mm (0.4630 to 0.4713 in.)

Minimum outer diameter: 11.6 mm (0.457 in.)

If the outer diameter is less than the minimum, replace the bolt.

• • •

86

Check for damage to the threads of the cylinder head bolt.

Check for damage to the threads of the cylinder block.

Check that the 18 cylinder head bolts are installed to the cylinder block smoothly.

35)

INSPECT INJECTION GEAR

• •

Check the bearing condition.

Replace the bearing if it is worn.

36)

REPLACE INJECTION GEAR BEARING

•

Using the special tool 970312763, remove the bearing.

04 /20110 indice A

•

Using special tools 970312742—970312743— 970314172 and a press, press in a new bearing.

37)

INSPECT IDLE GEAR NO.1

•

Using a dial indicator, measure the thrust clearance.

Standard thrust clearance: 0.06 to 0.11 mm (0.0024 to 0.0043 in.)

Maximum thrust clearance: 0.30 mm (0.0118 in.)

If the thrust clearance is greater than the maximum clearance, replace the thrust plate. If the thrust clearance would still be greater than the maximum clearance, replace the idle gear and/ or idle gear shaft.

•

Using a cylinder gauge, measure the diameter of the idle gear.

Inside diameter of the idle gear: 44.000 to 44.025 mm (1.7323 to 1.7333 in.)

•

Using a micrometer, measure the diameter of the idle gear shaft.

Idle gear shaft diameter: 43.955 to 43.990 mm (1.7305 to 1.7319 in.)

•

Subtract the idle gear shaft diameter from the inside diameter of the idle gear.

Standard oil clearance: 0.010 to 0.070 mm (0.0004 to 0.0028 in.)

Maximum oil clearance: 0.20 mm (0.0079 in.)

If the clearance is greater than the maximum clearance, replace the gear and shaft.

87

04 /20110 indice A

88

•

Separate the timing gear case softly with a slotted−screwdriver.

•

Secure the idler sub−gears to the idler gear with a service bolt.

•

Remove the injection gear.

•

Remove the O−ring.

15)

REMOVE TIMING GEAR CASE OIL SEAL

•

Remove the oil seal with a slotted−screwdriver and hammer.

04 /20110 indice A

38) INSPECT BACKLASH •

Using a dial indicator, measure the backlash.

Standard gear backlash: 0.02 to 0.15 mm (0.0008 to 0.0060 in.)

Maximum gear backlash: 0.20 mm (0.0079 in.)

If the gear backlash is greater than the maximum backlash, replace the gears as a set.

Balancing shaft No.2 x high pressure fuel pump

Balancing shaft No.1 x Oil Pump

Crankshaft x Idler

Oil Pump x Crankshaft

High pressure fuel pump x Idler

39)

INSTALL ENGINE REAR OIL SEAL

•

Using the special tool SST 09223−15030, 970312748 and a hammer, tap in a new oil seal until its surface reaches the rear oil seal retainer.

Apply MP grease to the oil seal lip.

•

89

04 /20110 indice A

40)

INSTALL ENGINE REAR OIL SEAL RETAINER

•

Remove old seal packing (FIPG) from the rear oil seal retainer and cylinder block.

Apply seal packing to the specific places described in the illustration.

•

Seal packing: 970312770 or equivalent

NOTICE: Install the engine rear oil retainer within 3 minutes and tighten its bolts within 15 minutes after seal packing application is completed.

•

Install the retainer with the 5 bolts.

Torque: 13 N m (133 kgf cm, 10 ft lbf)

41)

INSTALL BALANCESHAFT DRIVEN GEAR NO.2

•

Mount the balancing shaft in a vice.

NOTICE: Be careful not to damage the balancing shafts.

•

Align the balancing shaft knock pin with the knock pin hole, and install the balancing shaft thrust washer and balancing shaft driven gear No.2.

Install and torque the bolt.

•

Torque: 36 N m (367 kgf cm, 27 ft lbf) 42)

INSTALL NO.2 BALANCESHAFT SUB −ASSY

•

Install the balancing shaft No.2 with the 2 bolts.

Torque: 13 N m (133 kgf cm, 10 ft lbf)

43)

INSTALL BALANCESHAFT DRIVEN GEAR NO.1

•

Mount the balancing shaft in a vice.

NOTICE: Be careful not to damage the balancing shafts.

• •

Align the balancing shaft knock pin with the knock pin hole, and install the balancing shaft thrust washer and balancing shaft driven gear No.1.

Install and torque the bolt.

Torque: 36 N m (367 kgf cm, 27 ft lbf)

90

04 /20110 indice A

44)

INSTALL NO.1 BALANCING SHAFT SUBASSY

•

Install the balancing shaft No.1 with the 2 bolts.

Torque: 13 N m (133 kgf cm, 10 ft lbf)

45)

INSTALL TIMING GEAR CASE ASSY

•

Install 2 new O-rings to the cylinder block.

•

Install the stud bolt.

New O−Ring

Torque: 8.0 N m (82 kgf cm, 71 in. lbf)

New Gasket

Width: 4 mm (0.16 in.)

Seal Packing

•

Place a new gasket into the groove of the timing gear case as shown in the illustration.

•

Remove old seal packing (FIPG) from the timing gear case and cylinder block.

Apply seal packing to the specific places described in the illustration.

•

Seal packing: Part No. 970312770 or equivalent

NOTICE: Install the timing gear case within 3 minutes and tighten its bolts within 15 minutes after seal packing application is completed.

91

04 /20110 indice A

•

Align the mark on the balancing shaft driven gear No.1 with the ”2” mark on the pump drive gear.

Align the mark on the oil pump drive gear with the mark on the timing gear case.

•

•

Install the 8 bolts and union bolt.

Torque: 13 N m (130 kgf cm, 9 ft lbf) for Bolt 16 N m (160 kgf cm, 12 ft lbf) for Union bolt

Seal Packing

46)

INSTALL OIL PAN SUB-ASSY

•

Remove old seal packing (FIPG) from the oil pan subassy and cylinder block.

•

Apply seal packing to the specific places described in the illustration.

Set a new oil pan gasket to the oil pan sub-assy.

•

Seal packing: 970312770 or equivalent

NOTICE: Install the timing gear case within 3 minutes and tighten its bolts within 15 minutes after seal packing application is completed.

Width: 4 mm (0.16 in.)

•

Install the oil pan with the 22 bolts and 2 nuts.

Torque: 15 N m (150 kgf cm, 11 ft lbf)

92

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47) INSTALL INJECTION GEAR • Remove the plug and gasket.

•

Pour approx. 50 cc (1.7 fl. oz) of engine oil into the oil pump.

•

Set a new gasket and install the plug.

Torque: 44 N m (449 kgf cm, 33 ft lbf)

• •

Install a new O-ring to the injection pump assy.

Fit the spline with the mark on the pump housing.

•

Temporarily install the supply pump assy with the 2 nuts.

Tighten the 2 nuts on the injection pump assy.

•

Torque: 21 N m (214 kgf cm, 16 ft lbf)

•

93

The marks on the balancing shaft driven gear No.2 should be aligned with the ”3” marks.

04 /20110 indice A

•

Install a new O−ring to the injection gear.

• •

Install the injection gear set nut.

Using the special tool 970312754, tighten the nut.

New O−Ring

Torque: 64 N m (653 kgf cm, 47 ft lbf)

970312754

48)

INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

•

The marks on the oil pump drive gear should be aligned with the ”1” marks.

Using the special tool 970312742 and a hammer, tap in the timing gear.

•

970312742

49) •

INSTALL IDLE GEAR SHAFT NO.1 Coat the idle gear shaft No.1 with engine oil as shown in the illustration.

•

Install the idle gear shaft No.1 to the cylinder block.

Engine Oil

94

04 /20110 indice A

50. INSTALL IDLE SUB GEAR NO.2 • Set the idle gear No.1 in a vice.

HINT: The cut−off mark of the idle gear faces down.

NOTICE: Be careful not to damage the gear.

Cut−off Mark Wave Washer

• • •

Idle Sub Gear No.2 Idle Gear Spring

Install the idle gear spring.

Install the idle sub gear No.2.

Install the wave washer.

HINT: Fit the pins on the gears to the spring ends.

970312754

•

Using snap ring pliers, install the snap ring.

•

Using the special tool 970312754, align the holes of the idle gear No.1 and idle sub gear No.2 by turning the idle sub gear No.2 clockwise, and install a service bolt.

Remove the idle gear No.1 from the vise and turn it upside down.

• Service Bolt

Upward

51)

INSTALL IDLE SUB GEAR NO.1

•

Set the idle gear No.1 and idle sub gear No.2 in a vice.

NOTICE: Be careful not to damage the gears.

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04 /20110 indice A

•

Remove the service bolt.

• • •

Install the idle gear spring.

Install the idle sub gear N°1.

Install the wave washer.

HINT: Fit the pins on the gears to the spring ends.

Service Bolt

•

Using snap ring pliers, install the snap ring.

•

Using the special tool 970312754, align the holes of the idle gear N°1 and idle sub gear No.1 by turning the idle sub gear N°1 clockwise, and install a service bolt.

52)

INSTALL IDLE GEAR N°1

•

Align mark ”4” of the idle gear No.1 with marks ”4” of the injection gear.

Align mark ”5” of the idle gear No.1 with marks ”5” of the crankshaft timing gear.

970312754 Upward

•

96

04 /20110 indice A

53)

INSTALL IDLE GEAR THRUST PLATE

•

Align the holes for the idle gear thrust plate set bolt .

•

Install the idle gear thrust plate with the 2 bolts.

Torque: 50 N m (510 kgf cm, 37 ft lbf)

54)

INSTALL CRANKSHAFT POSITION SENSOR PLATE N°1

•

Install the crankshaft position sensor plate N°1.

55)

INSTALL TIMING BELT COVER OIL SEAL

•

Using the special tool 970312745 and a hammer, tap in a new oil seal until its surface reaches the timing gear case.

•

Apply MP grease to the oil seal lip.

56)

INSTALL TIMING GEAR CASE OIL SEAL

•

Using the special tool 970312738 and a hammer, tap in a new oil seal until its surface reaches the timing gear case.

•

Apply MP grease to the oil seal lip.

970312745

970312738

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04 /20110 indice A

57)

INSTALL TIMING GEAR CASE

•

Remove the service bolt.

•

Install a new O-ring to the timing gear case.

•

Apply seal packing to the specific places described in the illustration.

Seal packing: 970312770 or equivalent

NOTICE: Install the timing gear case within 3 minutes and tighten its bolts within 15 minutes after seal packing application is completed.

•

Install the timing gear cover with the 14 bolts and 2 nuts.

Torque: 13 N m (133 kgf cm, 10 ft lbf)

58)

INSTALL WATER PUMP ASSY

•

Install the 5 bolts, 2 nuts, water pump and gasket.

Torque: 13 N m (133 kgf cm, 10 ft lbf)

98

04 /20110 indice A

59)

INSTALL CYLINDER HEAD SUB-ASSY

•

Check each piston head protrusion.

(1) Using a dial indicator, measure the amount of each piston head protrusion, between the top surfaces of each cylinder head and piston head.

(2) Perform the measurement at 2 places for each cylinder as shown in the illustration, making a total of 8 measurements.

(3) For the piston protrusion value of each cylin der, use the average of the 2 measurements of each cylinder.

Front

Protrusion: 0.005 to 0.255 mm (0.00020 to 0.01004 in.)

HINT: Measurement should be done at 2 locations, on the right and left sides of each piston head.

X = Measuring Point

Measuring Tip

Protrusion

•

Select an appropriate cylinder head gasket.

HINT: Each cylinder head gasket A to E has a unique notch position at its back−end, which helps you to identify an individual gasket.

(1) Find the maximum value among all the meas ured piston head protrusion length to select an appropriate cylinder head gasket from A to E. Gasket size

Piston protrusion in mm (in.)

A

0.005 to 0.054 (0.0002 to 0.00213)

B

0.055 to 0.104 (0.00217 to 0.00409)

C

0.105 to 0.154 (0.00413 to 0.00606)

D

0.155 to 0.204 (0.00610 to 0.00803)

E

0.205 to 0.255 (0.00807 to 0.01004)

Cylinder head gasket thickness:

99

Gasket size

Gasket thickness in mm (in.)

A

0.80 to 0.90 (0.0315 to 0.0354)

B

0.85 to 0.95 (0.0335 to 0.0374)

C

0.90 to 1.00 (0.0354 to 0.0394)

D

0.95 to 1.05 (0.0374 to 0.0413)

E

1.00 to 1.10 (0.0394 to 0.0433)

04 /20110 indice A

•

place a new cylinder head gasket in position on the cylinder block.

Lower the piston by rotating the crankshaft about 90° counter clockwise from the TDC position.

Install the cylinder head bolts.

• •

HINT: The cylinder head bolts are to be tightened in 3 progressive steps.

• •

Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

Step 1 (1) Install and uniformly tighten the 18 cylinder head bolts, in several passes in the sequence shown.

Torque: 85 N m (867 kgf cm, 63 ft lbf)

Step 2

Step 3

Front

•

Step 2 (1) Mark the front of the cylinder head bolt with paint.

(2) Retighten the cylinder head bolts 90° in the order shown.

•

Step 3 (1) Retighten the cylinder head bolts by an addi tional 90°.

(2) Check that the painted mark is now facing rearward.

60)

INSPECT VALVE CLEARANCE

•

Install the camshaft and camshaft N°2.

(1) Set the crankshaft and turn it 90° counter clockwise from the TDC position.

Painted Mark

Upward Key Groove (2) Place the camshaft to the cylinder head as shown in the illustration.

100

04 /20110 indice A

(3) Align the dot marks of the camshaft and cam shaft N°2 by meshing the 2 gears before placing the camshaft N°2.

Dot Mark

(4) Install the camshaft bearing cap as shown in the illustration.

(5) Tighten the 15 bolts for the camshaft bearing cap in the specified order described in the illustra tion.

Torque: 19 N m (194 kgf cm, 14 ft lbf)

•

Install the timing belt N°2 cover with the 4 bolts and nut.

Torque: 10 N m (102 kgf cm, 7 ft lbf)

•

Install the camshaft timing pulley.

(1) Install the set key to the key groove of the camshaft.

(2) Align the set key with the key groove of the timing pulley.

(3) Hold the hexagonal portion of the camshaft, and install the timing pulley with the bolt.

Torque: 98 N m (1,000 kgf cm, 72 ft lbf)

•

101

Inspect the valve clearance.

(1) Lower the piston by rotating the crankshaft about 90° counter clockwise from the TDC (2) Align the timing mark of the camshaft timing pulley with the arrow mark of the timing belt No.2 cover.

04 /20110 indice A

(3) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

(4) Record the out-of-specification valve clear ance measurements. They will be used later to determine the required replacement valve lifter.

Valve clearance (cold): Intake: 0.20 to 0.30 mm (0.0079 to 0.0118 in.)

Exhaust: 0.35 to 0.45 mm (0.0138 to 0.0177 in.)

(5) Turn the crankshaft 360° to set the N°4 cylinder to the TDC position.

(6) Check only the valves indicated in the illustra tion. Measure the valve clearance (See proce dure (C) above).

102

61)

ADJUST VALVE CLEARANCE

•

Set the crankshaft and turn it 90 deg. Counter clockwise from the TDC position.

•

Remove the camshaft timing pulley.

(1) Hold the hexagon portion of the camshaft with a monkey wrench, and remove the bolt, timing pulley and set key.

•

Remove the 4 bolts, nut and timing belt N°2 cover.

•

Remove the camshaft and camshaft N°2.

(1) Uniformly loosen the 15 bearing cap bolts in order indicated in the illustration and remove them in the same order.

(2) Remove the 5 bearing caps.

04 /20110 indice A

(3) Remove the camshaft N°2 from the cylinder head.

(4) Remove the camshaft from the cylinder head.

•

Adjust the valve clearance.

HINT: Determine the size of the valve lifter to be installed according to the following formula or charts: (1) Using a micrometer, measure the thickness of the removed lifter.

(2) Calculate the thickness of a new lifter so the valve clearance comes within the specified value.

A

Thickness of the new lifter

B

Thickness of the used lifter

C

Measured valve clearance Valve clearance: Intake A = B + (C - 0.25 mm (0.0098 in.))

Exhaust A = B + (C - 0.40 mm (0.0158 in.))

(3) Select a new lifter with a thickness as close as possible to the calculated values.

HINT: Valve lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

(4) Install the selected valve lifter.

103

04 /20110 indice A

104

04 /20110 indice A

105

04 /20110 indice A

62)

INSTALL CAMSHAFT

•

Install the camshaft and camshaft N°2.

(1) Set the crankshaft and turn it 90 deg. Counter clockwise from the TDC position.

Upward (2) Place the camshaft to the cylinder head as shown in the illustration.

Key groove

(3) Align the dot marks of the camshaft and cam shaft N°2 by meshing both of the two gears be fore placing the camshaft No.2.

Dot mark

(4) Remove old seal packing (FIPG) from the camshaft bearing cap and cylinder head.

(5) Apply seal packing to the specific places de scribed in the illustration.

Seal packing

Seal packing: 970312770 or equivalent Thickness: 1.0 mm (0.04 in.)

Oil Passage

NOTICE: • • Width •

106

Be careful not to stick seal packing to the oil passage of the bearing cap.

Install the timing gear case within 3 minutes and tighten its bolts within 15 minutes after seal packing application is completed.

Do not start the engine within 2 hours after the installation.

04 /20110 indice A

(6) Install the camshaft bearing cap as shown in the illustration.

(7) Tighten the 15 bolts for the camshaft bearing cap in the specified order described in the illustra tion.

Torque: 19 N m (194 kgf cm, 14 ft lbf)

63)

INSTALL CAMSHAFT SETTING OIL SEAL

•

Install the oil seal.

(1) Apply a small amount of MP grease to a new oil seal lip.

970313927

NOTICE: Keep the lip clean. Prevent dirt and dust from adhering to that area.

(2) Fit the oil seal using the special tool 970313927 and a hammer.

Oil seal depth from the flat - end surface : 0.5 to - 1.5 mm (0.020 to - 0.060 in.)

Width Seal packing

64)

INSTALL TIMING BELT N°2 COVER

•

Remove old seal packing from the timing gear case.

Apply seal packing to the specific places described in the illustration.

•

Seal packing: 970312770 or equivalent

NOTICE: Install the timing belt N°2 cover within 3 minutes and tighten its bolts and nut within 15 minutes after sealing packing application is completed.

•

Install the timing belt No.2 cover with the 4 bolts and nut.

Torque: 10 N m (102 kgf cm, 7 ft lbf)

107

04 /20110 indice A

63)

INSTALL CAMSHAFT TIMING PULLEY

•

Install the set key to the key groove of the camshaft.

Align the set key with the key groove of the timing pulley.

Hold the hexagon portion of the camshaft, and install the timing pulley with the bolt.

• •

Torque: 98 N m (1,000 kgf cm, 72 ft lbf)

64)

INSTALL COMMON RAIL ASSY

•

Install the common rail with the 2 bolts.

Torque: 38 N m (387 kgf cm, 28 ft lbf)

•

Apply a light coat of engine oil to a new O-ring for each injector.

• •

Install 4 new nozzle seats to the cylinder head.

Install the injector to the cylinder head.

NOTICE: •

•

At this moment, insert the injector until it touches the nozzle sheet surface.

When installing the injector in the cylinder head, if the injector comes to float up with the reaction of O-ring, pull out the injector and install it again.

Do not exchange the injectors.

•

Temporarily install the 4 injection pipes.

•

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04 /20110 indice A

•

Before installing the nozzle leakage pipe, check that there is no scratch and deformation (dent) on the seal surface of the unions (at five positions) using a straight edge.

HINT: If there is any scratch or deformation, replace it to a new one.

• • •

• • •

Place the nozzle leakage pipe and 5 new gaskets.

Apply a light coat of engine oil to the 4 hollow screws and union bolt.

Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

Set the spring to each injector as shown in the illustration.

Set a new washer on the nozzle holder clamp as shown in the illustration.

Tighten the bolt.

Torque: 22 N m (220 kgf cm, 16 ft lbf)

NOTICE: •

•

• • • Union Bolt

Clip the injector at the fork portion with a clamp which is set on the head of the cam cap bolt. At this moment, check that the clamp does not hold the injector at the place where the spring is attached.

To tighten the clamp bolt, temporarily tighten it by hand until the bearing surface of the bolt touches the washer, then tighten to the specified torque.

When tightening to the specified torque, pay attention not to tilt the bolt and the clamp.

The washer can not be reused. If the washer is over tightened , replace it with a new one.

Tighten the 4 hollow screws from #1 to #4 in order.

Torque: 16 N m (163 kgf cm, 12 ft lbf)

NOTICE: If any of the screws are over tightened, replace the nozzle leakage pipe assy with a new one.

•

Tighten the union bolt.

Torque: 13 N m (130 kgf cm, 9 ft lbf)

Hollow screw

NOTICE: If the bolt is over tightened, replace the nozzle leakage pipe assembly with a new one.

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• •

Remove the 4 injection pipes.

Remove the 2 bolts and common rail.

65)

INSTALL CYLINDER HEAD COVER SUB-ASSY

• •

Remove old seal packing from the cylinder head.

Apply seal packing to the specific places described in the illustration.

Seal packing: 970312770 or equivalent

NOTICE: After applying the seal packing, parts must be assembled within 3 minutes, and then tightened within 15 minutes.

• •

Install the gasket to the cylinder head cover.

Install the cylinder head cover with the 10 bolts and the 2 nuts. Uniformly tighten the bolts and nuts.

Torque: 9.0 N m (92 kgf cm, 80 in. lbf)

110

66)

INSTALL NOZZLE HOLDER SEAL

•

Install 4 new nozzle holder seals.

67)

INSTALL OIL FILLER CAP SUB-ASSY

•

Install the oil filler cap to the cylinder head cover

04 /20110 indice A

68)

TIMING BELT REASSEMBLY

•

see concerned chapter

69)

HEAT EXCHANGE RE-INSTALLATION

•

Re-install the heat exchanger (1) with bolts (10) (9), washer (8) and a new gasket (48) Re-install spacer (30) Reinstall hose (34) with clamps (29) Re-install coolant pipe (24) with new o-ring (23) Tight the nuts (21) with washer and the clamps (29).

Re-install the bleeding pipe (34) with hollow screw (47) and new washers (46).

Re-install coolant pipe (41) with clamp (45) and hollow screw (17).

Re-install hose (36) with clamps (37).

Reinstall ECU support (7) with bolts (13).

Re-install Water hose (42) with clamps (43).

• • • • • • • • • 70)

TURBO CHARGER & MIXER REINSTALLATION

•

Re-install the lubrication pipe (3) with new gasket (4), (7) and (8).

Tight bolts (9) and hollow screw (6).

Re-install turbocharger (1) with new gasket (2).

Tight the nuts (14) with washers (15).

Re-install the turbo charger cover (not on the drawing).

• • • •

71)

ECU BRACKET AND ECU RE-INSTALLATION

•

•

Re-installation of the ECU support (4) with the 2 nuts (12), 2 bolts (16) and washers (15).

Re-installation of the breakers support (1) with 2 nuts (12).

Re-installation of the ECU with 4 nuts (12).

72)

INTERCOOLER RE-INSTALLATION

• • • • •

Re-install the intercooler (1) with new gasket (24).

Tight the nuts (6), (9) and (22).

Re-install the hose (7) with clamps (14) and (10).

Re-install the hose (3) with clamps (10) and (23).

Re-install the hose (8) with clamps (14).

•

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73)

EDU SUPPORT RE-INSTALLATION

• • • •

Install the support (2) Install and screw the 2 nuts (5) Install and screw the 2 nuts (16) Connect the hose (17) from the outlet air of the intercooler.

74)

ACCELARATOR SUPPORT REINSTALLATION

• • •

Install support with accelerator (2) Install and screw the nuts (8), (12) and bolt (7) Re-install and connect cable A

75)

FUEL FILTER ASSEMBLY RE-INSTALLATION

•

Disconnect fuel hoses from the filter (2 x screw 6) and from the fuel oil cooler (2 x screw 6) Remove the two supports (3 and 12) by unscrew the 5 bolts (1)

•

112

76)

ELECTRIC WIRING REMOVAL

• • • • • • •

Reconnect all sensors from the engines Reconnect the injectors Reconnect the ECU Reconnect the EDU Reconnect the gear box neutral sensor Remove EDU RELAY and MAIN RELAY Re-install starter and glows plug relay box

77)

REFILL ENGINE WITH OIL

•

Refer to concern chapter

78)

DRAIN COOLANT

•

Refer to concerned chapter

04 /20110 indice A

4. CYLINDER HEAD OVERHAUL [4.1] PARTIAL CYLINDER HEAD COMPONENTS

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[4.2] CYLINDER HEAD OVERHAULD HINT: - Thoroughly clean all parts to be assembled.

- Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.

- Replace all gaskets and oil seals with new ones.

1

REMOVE VALVE LIFTER

(a) Remove the valve lifters.

HINT: - Arrange the valve lifters in the correct order

970313372

2.

REMOVE INTAKE VALVE

(a)

Using special tool 970313372, compress the compression spring and remove the spring retainer lock.

Remove the spring retainer, compression spring, valve and plate washer.

(b)

HINT: - Arrange the valves, compression springs, plate washer and spring retainers in the correct order.

970313372 3.

REMOVE EXHAUST VALVE

(a)

Using the special tool 970313372, compress the compression spring and remove the spring retainer lock.

Remove the spring retainer, compression spring, valve and plate washer.

(b)

HINT: - Arrange the valves, compression springs, plate washer and spring retainers in the correct order.

114

4.

REMOVE VALVE STEM OIL SEAL

(a)

Using needle-nose pliers, remove the oil seal.

5.

REMOVE SEMICIRCULAR PLUG

(a)

Remove the semicircular plug from the cylinder head assembly.

04 /20110 indice A

6.

REMOVE W/HEAD STRAIGHT SCREW PLUG N°1

(a)

Using a 6 mm hexagon wrench, remove the screw plug.

NOTICE: •

If water leaks from the w/head straight screw plug No.1 or the plug corrodes, replace it.

7.

REMOVE STUD BOLT

(a)

Remove the stud bolt from the cylinder head assembly.

NOTICE: •

If the stud bolt is deformed or the threads are damaged, replace them.

8.

REMOVE RING W/HEAD PIN

(a)

Remove the ring pin from the cylinder head assembly.

NOTICE: •

It is not necessary to remove w/head pin unless it is being replaced.

9.

REMOVE RING PIN

(a)

Remove the ring pin from the cylinder head assembly.

NOTICE: •

It is not necessary to remove the ring pin unless it is being replaced.

10.

REMOVE TIGHT PLUG

(a)

Remove the tight plug from the cylinder head assembly.

NOTICE: •

If water leaks from the tight plug or the plug corrodes, replace it.

11.

CLEAN CYLINDER HEAD SUB-ASSY

(a)

Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.

NOTICE: •

115

Be careful not to scratch the cylinder block contact surface.

04 /20110 indice A

(b)

Using a valve guide bushing brush and solvent, clean all the guide bushes.

(c)

Using a soft brush and solvent, thoroughly clean the cylinder head.

12.

INSPECT CYLINDER HEAD SUB −ASSY

(a)

Inspect for warpage.

(1) Using a precision straight edge and feeler gauge, measure a warpage for the contact surface of the cylinder block and intake and exhaust mani folds.

Maximum warpage: 0.15 mm (0.0059 in.)

If the warpage is greater than the maximum, replace the cylinder head.

(b)

Inspect for cracks.

(1) Using a dye penetrant, check the combustion chamber, intake and exhaust ports and cylinder block surface for cracks.

If there is a crack, replace the cylinder head.

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13.

CLEAN INTAKE VALVE

(a) (b)

Using a gasket scraper, chip off any carbon from the valve head.

Using a wire brush, thoroughly clean the valve.

14.

INSPECT INTAKE VALVE

(a)

Using a micrometer, measure the outside diameter of the valve stem.

Valve stem diameter: 5.970 to 5.985 mm (0.2350 to 0.2356 in.)

(b)

Valve Face Angle

Check the valve face angle.

(1)

Grind the valve enough to remove carbon and eliminate pits.

(2)

Check that the valve is ground to the cor-rect valve face angle.

Valve face angle: 44.5 deg.

(c)

Check the valve head margin thickness.

Standard margin thickness: 1.1 mm (0.043 in.)

Minimum margin thickness: 0.6 mm (0.024 in.)

thickness

If the margin thickness is less than the minimum, replace the valve.

(d)

Check the valve overall length.

Standard overall length: 105.15 to 105.75 mm (4.1398 to 4.1634 in.)

Minimum overall length: 104.65 mm (4.1201 in.)

overall length

If the overall length is less than the minimum, replace the valve.

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(e)

Check the surface of the valve stem tip for wear

If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.

NOTICE: •

Do not grind off more than the minimum.

15.

CLEAN EXHAUST VALVE

(a) (b)

Using a gasket scraper, chip off any carbon from the valve head.

Using a wire brush, thoroughly clean the valve.

16.

INSPECT EXHAUST VALVE

(a)

Using a micrometer, measure the outside diameter of the valve stem.

Valve stem diameter: 5.960 to 5.975 mm (0.2346 to 0.2352 in.)

(b)

Valve Face Angle

Check the valve face angle.

(1) Grind the valve enough to remove carbon and eliminate pits.

(2) Check that the valve is ground to the cor-rect valve face angle.

Valve face angle: 44.5 deg.

(c)

Check the valve head margin thickness.

Standard margin thickness: 1.2 mm (0.047 in.)

Minimum margin thickness: 0.7 mm (0.028 in.)

thickness

If the margin thickness is less than the minimum, replace the valve.

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(d)

Check the valve overall length.

Standard overall length: 105.02 to 105.62 mm (4.1347 to 4.1583 in.)

Minimum overall length: 104.52 mm (4.1150 in.)

If the overall length is less than the minimum, replace the valve. (e)

Check the surface of the valve stem tip for wear.

If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.

NOTICE: •

Do not grind off more than the minimum.

17.

INSPECT INNER COMPRESSION SPRING

(a)

Using a steel square, measure the deviation of the spring.

Maximum deviation: 2.0 mm (0.079 in.)

If the deviation is greater than the maximum, replace the spring.

(b)

Using a vernier caliper, measure the free length of the spring.

Free length: 46.5 mm (1.831 in.)

If the free length is not as specified, replace the spring.

(c)

Using a spring tester, measure the tension of the valve spring at the specified installed length.

Installed tension (at 33.1 mm (1.303 in.)): 150.2 to 165.8 N (15.3 to 16.9 kgf, 33.7 to 37.3 lbf) If the installed tension is not as specified, replace the spring

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18.

INSPECT INTAKE VALVE GUIDE BUSH

(a)

Using a caliper gauge, measure the inside diameter of the guide bush.

Bush inside diameter: 6.010 to 6.030 mm (0.2366 to 0.2374 in.)

(b)

Subtract the valve stem diameter measurement (See step 14) from the guide bush inside diameter measurement.

Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0024 in.)

Maximum oil clearance: 0.08 mm (0.0031 in.)

If the clearance is greater than the maximum, replace the valve and guide bush (See steps 20 and 22).

19.

INSPECT EXHAUST VALVE GUIDE BUSH

(a)

Using a caliper gauge, measure the inside diameter of the guide bush.

(b)

Bush inside diameter: 6.010 to 6.030 mm (0.2366 to 0.2374 in.)

Subtract the valve stem diameter measurement (See step 16) from the guide bush inside diameter measurement.

Standard oil clearance: 0.035 to 0.070 mm (0.0014 to 0.0028 in.)

Maximum oil clearance: 0.10 mm (0.0039 in.)

If the clearance is greater than the maximum, replace the valve and guide bush (See steps 21 and 23).

20.

REMOVE INTAKE VALVE GUIDE BUSH

(a)

Using the special tool 970312733, 970312748 and a hammer, tap out the valve guide bushing from the combustion chamber.

21.

REMOVE EXHAUST VALVE GUIDE BUSH

(a)

Using special tool 970312733, 970312748 and a hammer, tap out the valve guide bushing from the combustion chamber.

SST

SST

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22.

INSTALL INTAKE VALVE GUIDE BUSH

(a)

Using a caliper gauge, measure the bush bore diameter of the cylinder head.

Select a new guide bush ((Standard (STD) or oversize 0.05 (O/S 0.05)).

(b)

Bush bore diameter mm (in.)

Bush size

10.985 to 11.006 mm (0.4325 to 0.4333 in.)

Use STD

11.035 to 11.056 mm (0.4344 to 0.4353 in.)

Use O/S 0.05

If the bush bore diameter of the cylinder head is greater than 11.006 mm (0.4333 in.), machine the bush bore to the dimension of 11.035 to 11.056 mm (0.4344 to 0.4353 in.).

If the bush bore diameter of the cylinder head is greater than 11.056 mm (0.4353 in.), replace the cylinder head. (c)

Using special tools 970312733, 970312748 and a hammer, tap in a new guide bush to the specified protrusion height.

Protrusion height: 10.3 to 10.7 mm (0.406 to 0.421 in.)

SST

(d)

Using a sharp 6.0 mm reamer, ream the guide bush to obtain the specified standard clearance (See step 18) between the guide bush and valve stem.

23.

INSTALL EXHAUST VALVE GUIDE BUSH

(a)

Using a caliper gauge, measure the bush bore diameter of the cylinder head.

Select a new guide bush (STD or O/S 0.05).

6.0 mm Reamer

(b)

Bush bore diameter mm (in.)

Bush size

10.985 to 11.006 mm (0.4325 to 0.4333 in.)

Use STD

11.035 to 11.056 mm (0.4344 to 0.4353 in.)

Use O/S 0.05

If the bush bore diameter of the cylinder head is greater than 11.006 mm (0.4333 in.), machine the bush bore to the dimension of 11.035 to 11.056 mm (0.4344 to 0.4353 in.).

If the bush bore diameter of the cylinder head is greater than 11.056 mm (0.4353 in.), replace the cylinder head.

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(c)

Using the special tools 970312783, 970312748 and a hammer, tap in a new guide bush to the specified protrusion height.

Protrusion height: 10.3 to 10.7 mm (0.406 to 0.421 in.)

SST

6.0 mm Reamer

(d)

Using a sharp 6.0 mm reamer, ream the guide bush to obtain the specified standard clearance (See step 19) between the guide bush and valve stem.

24.

INSPECT INTAKE VALVE SEATS

(a)

Using a 45° carbide cutter, resurface the valve.

Clean metal filings from the valve seats.

(b)

Check the valve seating position.

(1) Apply a light coat of Prussian blue (or white lead) to the valve face.

(2) Lightly press the valve against the seat. Do not rotate the valve.

Check the valve face and seat for the following: (1) If Prussian blue appears around the entire face, the valve is centred. If not, replace the valve.

(2) If Prussian blue appears around the entire valve seat, the guide and face are centred.

If not, resurface the seat.

(3) Check that the seat contacts in the middle of the valve face with the specified width.

(c) Width

Width: 1.2 to 1.6 mm (0.047 to 0.063 in.)

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25.

INSPECT EXHAUST VALVE SEATS

(a)

Using a 45° carbide cutter, resurface the valve seats. Clean metal filings from the seats.

(b)

Check the valve seating position.

(1) Apply a light coat of Prussian blue (or white lead) to the valve face.

(2) Lightly press the valve against the seat. Do not rotate the valve.

Check the valve face and seat for the following: (1) If Prussian blue appears around the entire face, the valve is concentric. If not, replace the valve.

(2) If Prussian blue appears around the entire valve seat, the guide and face are concentric. If not, resurface the seat.

(3) Check that the seat contacts in the middle of the valve face with the specified width.

(c)

Width: 1.6 to 2.0 mm (0.063 to 0.079 in.)

123

26.

REPAIR INTAKE VALVE SEATS

(a)

If the seating is too high on the valve face, use a 25° and 45° cutters to correct the seat.

(b)

If the seating is too low on the valve face, use 70° and 45° cutters to correct the seat.

04 /20110 indice A

(c) (d)

Hand rub the valve and valve seat with an abrasive compound.

After hand rubbing, clean the valve and valve seat.

27.

REPAIR EXHAUST VALVE SEATS

(a)

If the seating is too high on the valve face, use a 25° and 45° cutters to correct the seat.

(b)

If the seating is too low on the valve face, use a 75°and 45° cutters to correct the seat.

(c)

Hand rub the valve and valve seat with an abrasive compound.

After hand rubbing, clean the valve and valve seat.

(d)

28.

INSPECT VALVE LIFTER

(a)

Using a micrometer, measure the outside diameter of the lifter.

Lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.)

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(b)

Using a caliper gauge, measure the lifter bore diameter of the cylinder head.

Lifter bore diameter: 31.000 to 31.021 mm (1.2205 to 1.2213 in.)

(c)

Subtract the lifter diameter measurement from the lifter bore diameter measurement.

Standard oil clearance: 0.024 to 0.055 mm (0.0009 to 0.0022 in.)

Maximum oil clearance: 0.095 mm (0.0037 in.)

If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head.

29.

INSPECT CAMSHAFT

(a)

Inspect the circle run out.

(1) Place the camshaft on V-blocks.

(2) Using a dial indicator, measure the circle run out at the centre journal.

Maximum circle run out: 0.03 mm (0.0012 in.)

If the circle run out is greater than the maximum, replace the camshaft. (b)

Using a micrometer, measure the cam lobe height.

Standard cam lobe height: 47.180 to 47.280 mm (1.8575 to 1.8614 in.)

Minimum cam lobe height: 46.76 mm (1.8409 in.)

If the cam lobe height is less than the minimum, replace the camshaft.

(c)

Inspect the outside diameter of the journal of the camshaft.

(1) Using a micrometer, measure the outside diameter of the journal for the camshaft bearing.

Journal diameter: 27.969 to 27.985 mm (1.1011 to 1.1018 in.)

If the outside diameter of the journal is not as specified, check the oil clearance.

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(d)

Check the oil clearance.

(1) Clean the bearing caps and journals.

(2) Check the bearings for flaking and scoring.

If the bearings are damaged, replace the bearing caps and cylinder head as a set.

(3) (4) (5) (6) (7)

Install the bearings to the bearing caps and cylinder head.

Place the camshaft on the cylinder head.

Lay a strip of “Plastigage” across each of the journals.

Install the 5 bearing caps in their proper locations.

Install and uniformly tighten the 15 bearing cap bolts, in the order described in the il lustration.

Torque: 19 N m (194 kgf cm, 14 ft lbf)

NOTICE: •

Do not turn the camshaft.

(8) (9)

Remove the bearing caps.

Measure the “Plastigage” at its widest point.

Standard oil clearance: 0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Maximum oil clearance: 0.10 mm (0.0039 in.)

If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing cap and cylinder head as a set.

(10) (11) (e)

Completely remove the “Plastigage”.

Remove the camshaft.

Check the thrust clearance.

(1) Install the camshaft.

(2) Install the 5 bearing caps in their proper locations.

(3) Install and uniformly tighten the bearing cap bolts, in the order described in the illustration.

Torque: 19 N m (194 kgf cm, 14 ft lbf) (4)

Using a dial indicator, measure the thrust clearance by pushing the camshaft back and forth.

Standard thrust clearance: 0.035 to 0.185 mm (0.0014 to 0.0073 in.)

Maximum thrust clearance: 0.25 mm (0.0098 in.)

If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing cap and cylinder head as a set.

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(f)

Check the gear backlash.

(1) Install the 2 camshafts.

(2) Install the 5 bearing caps in their proper locations.

(3) Install and uniformly tighten the 15 bearing cap bolts, in the order described in the illustration.

Torque: 19 N m (194 kgf cm, 14 ft lbf)

(4)

Using a dial indicator, measure the backlash.

Standard backlash: 0.035 to 0.089 mm (0.0014 to 0.0035 in.)

Maximum backlash: 0.189 mm (0.0074 in.)

If the backlash is greater than the maximum, replace the 2 camshafts.

(5)

Remove the 2 camshafts.

30.

INSPECT N°2 CAMSHAFT

(a)

Inspect the circle run out.

(1) Place the camshaft on V−blocks.

(2) Using a dial indicator, measure the circle run out at the centre journal.

Maximum circle run out: 0.03 mm (0.0012 in)

If the circle run out is greater than the maximum, replace the camshaft. (b)

Using a micrometer, measure the cam lobe height.

Standard cam lobe height: 48.070 to 48.170 mm (1.8925 to 1.8965 in.)

Minimum cam lobe height: 47.92 mm (1.8866 in.)

If the cam lobe height is less than the minimum, replace the camshaft. (c)

Inspect the journal diameter of the camshaft.

(1) Using a micrometer, measure the journal diameter of the camshaft for the camshaft bearing.

Journal diameter: 27.969 to 27.985 mm (1.1011 to 1.1018 in.)

If the journal diameter is not as specified, check the oil clearance.

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(d)

Check the oil clearance.

(1) Clean the bearing caps and journals.

(2) Check the bearings for flaking and scoring.

If the bearings are damaged, replace the bearing caps and cylinder head.

(3) (4) (5) (6) (7)

Install the bearings to the bearing caps and cylinder head.

Place the camshaft on the cylinder head.

Lay a strip of “Plastigage” across each of the journals.

Install the 5 bearing caps in their proper locations.

Install and uniformly tighten the 15 bearing cap bolts, in the order described in the illustration.

Torque: 19 N m (194 kgf cm, 14 ft lbf)

NOTICE: •

Do not turn the camshaft.

(8) (9)

Remove the bearing caps.

Measure the “Plastigage” at its widest point.

Standard oil clearance: 0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Maximum oil clearance: 0.10 mm (0.0039 in.)

If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing cap and cylinder head as a set.

(10) (11) (e)

Completely remove the “Plastigage”.

Remove the camshaft.

Check the thrust clearance.

(1) Install the camshaft.

(2) Install the 5 bearing caps in their proper locations.

(3) Install and uniformly tighten the 15 bearing cap bolts, in the order described in the illustration.

Torque: 19 N m (194 kgf cm, 14 ft lbf) (4)

Using a dial indicator, measure the thrust clearance by pushing the camshaft back and forth.

Standard thrust clearance: 0.035 to 0.185 mm (0.0014 to 0.0073 in.)

Maximum thrust clearance: 0.25 mm (0.0098 in.)

If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing cap and cylinder head as a set.

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31.

INSTALL STUD BOLT

(a)

Install the stud bolts as shown in the illustration.

Torque: 5.0 N m (51 kgf cm, 44 in. lbf) for A 7.0 N m (71 kgf cm, 62 in. lbf) for B 15.0N m (153 kgf cm, 11 ft lbf) for C 5.0 N m (51 kgf cm, 44 in. lbf) for E Front Side:

Upper Side:

Intake Side:

Exhaust Side:

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04 /20110 indice A

32.

INSTALL RING PIN

(a)

Install the ring pin to the cylinder head.

33.

INSTALL RING W/HEAD PIN

(a)

Install the ring w/ head pin to the cylinder head.

34.

INSTALL TIGHT PLUG

(a)

Apply an adhesive around the tight plugs.

Adhesive: THREE BOND 1324 or equivalent

NOTICE: •

Do not start the engine within 1 hour after the installation.

(1)

Using special tools 970315564, 970312748, tap in the tight plug No.3 as shown in the illustration.

(2)

Using special tools 970315564, 970312748, tap in the tight plug No.4 as shown in the illustration.

(3)

Using special tools 970315564, 970312748, tap in the tight plug No.5 as shown in the illustration.

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Front Side:

Intake Side :

Tight Plug N°5

Tight Plug N°4

Tight Plug N°3 Tight Plug N°5

Tight Plug N°4

Tight Plug N°3

Tight Plug N°4

35.

INSTALL W/HEAD STRAIGHT SCREW PLUG N°1

(a)

Apply an adhesive to the end of the screw plug.

Tight Plug N°5

Adhesive: THREE BOND 1324 or equivalent (b)

Using a 6 mm hexagon wrench, install the screw plug.

Torque: 25 N·m (255 kgf·cm, 18 ft·lbf)

Adhesive

36.

INSTALL SEMI-CIRCULAR PLUG

(a)

Remove the oil seal packing (970312770).

(1) Using a gasket scraper and razor blade, remove the old seal packing from the contact surface of the semicircular plug and cylinder head, and clean them.

Apply seal packing to the semicircular plug.

(b)

NOTICE: • •

The semicircular plug must be installed within 3 minutes after seal packing application is completed.

Prevent FIPG from being stuck to the camshaft thrust groove.

(c)

Install the semicircular plug to the cylinder head.

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37.

INSTALL VALVE STEM OIL SEAL

(a)

Using Special tool 970312764, push in a new oil seal.

38.

INSTALL INTAKE VALVE

(a)

Install the valve, plate washer, compression spring and spring retainer.

Using special tool 970313732, compress the compression spring and place the spring retainer lock and the valve stem.

(b)

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04 /20110 indice A

(c) Using a plastic-faced hammer, tap in the valve stem tip until it fits properly.

NOTICE: •

Be careful not to damage the valve stem tip.

39.

INSTALL EXHAUST VALVE

(a)

Install the valve, plate washer, compression spring and spring retainer.

Using the special tool 970313372, compress the compression spring and place the spring retainer lock and the valve stem.

(b)

(c)

Using a plastic−faced hammer, tap in the valve stem tip until it fits properly.

NOTICE: •

133

Be careful not to damage the valve stem tip.

04 /20110 indice A

5. CYLINDER BLOCK ASSEMBLY OVERHAULD [5.1]

CYLINDER BLOCK ASSY COMPONENTS

134

04 /20110 indice A

[5.2]

CYLINDER BLOCK ASSEMBLY OVERHAUL HINT: • •

Thoroughly clean all parts to be assembled.

Before installing the parts, apply new engine oil to all the sliding and rotating surfaces.

Replace all the gaskets, O-rings and oil seals with new ones.

• 1.

REMOVE CYLINDER BLOCK OIL ORIFICE

(a)

Remove the cylinder block oil orifice from the cylinder block.

2. INSPECT CYLINDER BLOCK OIL ORIFICE (a)

Check the oil orifice for damage or clogging.

If necessary, replace the oil orifice.

3.

INSPECT CONNECTING ROD THRUST CLEARANCE

(a)

Using a dial indicator, measure the thrust clearance by moving the connecting rod back and forth.

Standard thrust clearance: 0.100 to 0.300 mm (0.0039 to 0.0118 in.)

Maximum thrust clearance: 0.40 mm (0.0157 in.)

If the thrust clearance is greater than the maximum clearance, replace the connecting rod assembly. If necessary, replace the crankshaft.

4.

INSPECT CONNECTING ROD OIL CLEARANCE

(a)

Check that the connecting rod and cap are assembled properly by looking over the match marks.

Remove the 2 connecting rod cap bolts.

Using the 2 removed connecting rod bolts, pry off the connecting rod cap.

(b) (c)

HINT: • (d) (e)

Keep the lower bearing inserted in the connecting rod cap.

Clean the crank pin and bearing.

Check the crank pin and bearing for pits and scratches.

If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

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04 /20110 indice A

(f) (g)

Lay a strip of “Plastigage” across the crank pin.

Install the connecting rod cap with the 2 bolts (See step 39).

NOTICE:

136

•

Do not turn the crankshaft.

(h)

Remove the 2 bolts, connecting rod cap and lower bearing (See the procedures (b) and (c) mentioned above).

04 /20110 indice A

(i) Measure the “Plastigage” at its widest point.

Standard oil clearance: 0.036 to 0.054 mm (0.0014 to 0.0021 in.)

Maximum oil clearance: 0.10 mm (0.0039 in.)

If the oil clearance is greater than the maximum clearance, replace the bearings.

HINT: •

If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, add together the numbers imprinted on the crankshaft and connecting rod, then select the bearing with the same number as the total. There are 5 sizes of standard bearings, marked 2, 3, 4, 5 and 6 accordingly. item

Number mark

Connecting rod cap

1

2

3

Crankshaft

1

2

3

1

2

3

1

2

3

Use bearing

2

3

4

3

4

5

4

5

6

EXAMPLE: Connecting rod cap ”3” + Crankshaft ”1” = Total number 4 (Use bearing ”4”) Reference Connecting rod big end inner diameter: Mark 1

62.014 to 62.020 mm (2.4415 to 2.4417 in.)

Mark 2

62.020 to 62.026 mm (2.4417 to 2.4420 in.)

Mark 3

62.026 to 62.032 mm (2.4420 to 2.4422 in.)

Crankshaft pin diameter: Mark 1

58.994 to 59.000 mm (2.3226 to 2.3228 in.)

Mark 2

58.988 to 58.994 mm (2.3224 to 2.3226 in.)

Mark 3

58.982 to 58.988 mm (2.3221 to 2.3224 in.)

Standard sized bearing center wall thickness:

(j)

137

Mark 2

1.486 to 1.489 mm (0.0585 to 0.0586 in.)

Mark 3

1.489 to 1.492 mm (0.0586 to 0.0587 in.)

Mark 4

1.492 to 1.495 mm (0.0587 to 0.0589 in.)

Mark 5

1.495 to 1.498 mm (0.0589 to 0.0590 in.)

Mark 6

1.498 to 1.501 mm (0.0590 to 0.0591 in.)

Completely remove the “Plastigage”.

04 /20110 indice A

5.

REMOVE PISTON AND CONNECTING ROD

(a)

Using a ridge reamer, remove all the carbon from the top of the cylinder.

Push the piston, connecting rod assembly and upper bearing.

(b)

HINT: •

Keep the bearings, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in the correct order.

•

6.

REMOVE W/PIN PISTON SUB-ASSY

(a)

Check the fitting condition between the piston and piston pin.

(1) Try to move the piston back and forth on the piston pin.

If any movement is felt, replace the piston and pin as a set. (b)

Remove the piston rings.

(1) Using a piston ring expander, remove the 2 compression rings and oil ring.

(2) Remove the coil rails by hand.

HINT: •

Arrange the piston rings in the correct order.

(c) Disconnect the connecting rod from the piston.

(1) Using a screwdriver, pry off the snap ring from the piston.

(2)

138

Gradually heat the piston to approx. 80°C (176 F).

04 /20110 indice A

(3)

• •

Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and pin and remove the connecting rod.

HINT: The piston and pin are a matched set.

Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

7. INSPECT CRANKSHAFT THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while prying the crankshaft with a screwdriver.

Standard thrust clearance: 0.040 to 0.240 mm (0.0016 to 0.0094 in.)

Maximum thrust clearance: 0.30 mm (0.0118 in.)

If the thrust clearance is greater than the maximum clearance, replace the thrust washers as a set.

Thrust washer thickness: STD

2.430 to 2.480 mm (0.0957 to 0.0976 in.)

O/S 0.125

2.555 to 2.605 mm (0.1006 to 0.1026 in.)

O/S 0.250

2.680 to 2.730 mm (0.1055 to 0.1075 in.)

8.

INSPECT CRANKSHAFT OIL CLEARANCE

(a)

Uniformly loosen the 10 main bearing cap bolts in order described in the illustration, and remove the bolts in the same order.

(b)

Using the removed crankshaft bearing cap bolts, pry the cap, and remove the crankshaft bearing caps, lower crankshaft bearings and lower thrust washers (No.5 crankshaft bearing cap only).

HINT: Keep the lower bearing and crankshaft bearings cap together.

• Arrange the thrust washers in correct order.

•

(c) •

HINT: Keep the upper crankshaft bearings and upper thrust washers together with the cylinder block.

(d)

139

Lift out the crankshaft.

Clean each main journal and bearing.

04 /20110 indice A

(e)

Check that there is no pits and scratches for the main journal bearing.

If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft. (f) (g)

Place the crankshaft on the cylinder block.

Lay a strip of “Plastigage” across each journal.

(h)

Install the 5 crankshaft bearing caps with the 10 bolts (See step 38).

NOTICE: Do not turn the crankshaft. (i)

140

Remove the 10 bolts and 5 crankshaft bearing caps (See the procedures (a) and (b) mentioned above).

04 /20110 indice A

(j) Measure the “Plastigage” at its widest point.

Standard oil clearance: 0.030 to 0.048 mm (0.0012 to 0.0019 in.)

Maximum clearance: 0.10 mm (0.0039 in.)

If the oil clearance is greater than the maximum clearance, replace the bearings.

HINT: If replacing the cylinder block sub assembly, the bearing standard clearance will be: 0.030 to 0.048 mm (0.0012 to 0.0019 in.)

HINT: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, add together the numbers imprinted on the cylinder block and crankshaft, then select the bearing with the same number as the total. There are 5 sizes of standard bearings, marked 2, 3, 4, 5 and 6 accordingly.

EXAMPLE: item

Number mark

Cylinder block

1

2

3

Crankshaft

1

2

3

1

2

3

1

2

3

Use bearing

2

3

4

3

4

5

4

5

6

Cylinder block ”2” + Crankshaft ”1”= Total number ”3” (Use bearing ”3” reference) (k)

Completely remove the “Plastigage”.

Cylinder block main journal bore diameter: Mark 1

75.000 to 75.006 mm (2.9528 to 2.9530 in.)

Mark 2

75.006 to 75.012 mm (2.9530 to 2.9532 in.)

Mark 3

75.012 to 75. 018 mm (2.9532 to 2.9535 in.)

Crankshaft journal diameter: Mark 1

69.994 to 70.000 mm (2.7557 to 2.7559 in.)

Mark 2

69.988 to 69.994 mm (2.7554 to 2.7557 in.)

Mark 3

69.982 to 69.988 mm (2.7552 to 2.7554 in.)

Standard sized bearing center wall thickness:

9. (a) (b)

Mark 2

2.482 to 2.485 mm (0.0977 to 0.0978 in.)

Mark 3

2.485 to 2.488 mm (0.0978 to 0.0980 in.)

Mark 4

2.488 to 2.491 mm (0.0980 to 0.0981 in.)

Mark 5

2.491 to 2.494 mm (0.0981 to 0.0982 in.)

Mark 6

2.494 to 2.497 mm (0.0982 to 0.0983 in.)

REMOVE CRANKSHAFT Lift out the crankshaft.

Remove the upper bearings and upper thrust washers from the cylinder block.

HINT: Arrange the main bearing caps, bearings and thrust washers in the correct order.

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10.

REMOVE SUB-ASSY OIL NOZZLE NO.1

(a)

Remove the 4 check valves and oil nozzles.

11. INSPECT OIL CHECK VALVE SUB-ASSY (a) Push the valve with a wooden stick to check if it is stuck.

If stuck, replace the check valve.

12. (a)

INSPECT SUB−ASSY OIL NOZZLE NO.1 Check the oil nozzles for damage or clogging. If necessary, replace the oil nozzle.

13. (a)

REMOVE STUD BOLT Remove the stud bolt from the cylinder block assy.

NOTICE: If the stud bolt is deformed or the threads are damaged, replace it.

14. (a)

REMOVE STRAIGHT PIN Remove the straight pin from the cylinder block assy.

NOTICE: If the straight pin is damaged, replace it.

15. (a)

REMOVE RING PIN Remove the ring pin from the cylinder block assy.

NOTICE: It is not necessary to remove the ring pin unless it is being 16. (a)

REMOVE TIGHT PLUG Remove the tight plug from the cylinder block assy.

NOTICE: If water leaks from the tight plug or the plug corrodes, replace them.

17. (a) (b)

CLEAN CYLINDER BLOCK ASSY Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

Using compressed air, blow carbon and oil from the bolt holes.

CAUTION: Protect your eyes when using high pressure compressed air.

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04 /20110 indice A

18.

INSPECT CYLINDER BLOCK ASSY

(a)

Inspect warpage.

(1) Using a precision straight edge and feeler gauge, measure the warpage of the con tact surface of the cylinder head cap.

Maximum warpage: 0.10 mm (0.0039 in.)

If warpage is greater than the maximum, replace the cylinder block.

(b) Visually check the cylinder for vertical scratches.

If necessary, replace the cylinder block.

(c) Inspect the cylinder bore diameter.

HINT: There are 3 sizes of standard cylinder bore diameter, marked 1, 2 and 3 accordingly. The mark is stamped on the lower left rear of the cylinder block.

Mark 1, 2 or 3

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04 /20110 indice A

(1) Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions Standard diameter: Mark 1

96.000 to 96.010 mm (3.7795 to 3.7799 in.)

Mark 2

96.010 to 96.020 mm (3.7799 to 3.7803 in.)

Mark 3

96.020 to 96.030 mm (3.7803 to 3.7807 in.)

Maximum diameter:

Standard

Thrust Direction

96.23 mm (3.7886 in.)

If necessary, replace the cylinder block.

Axial Direction

(d)

Remove the cylinder ridge.

If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.

Ridge Reamer

144

19. (a)

CLEAN W/PIN PISTON SUB-ASSY Using a gasket scraper, remove the carbon from the piston top.

(b)

Using a groove cleaning tool or broken ring, clean the piston ring grooves.

04 /20110 indice A

(c)

Using solvent and a brush, thoroughly clean the piston.

NOTICE: Do not use a wire brush.

20. (a)

INSPECT W/PIN PISTON SUB-ASSY Inspect the piston oil clearance.

HINT: There are 3 sizes of standard piston diameter, marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the piston top.

(1) Using a micrometer, measure the piston diameter at right angles to the piston pin centre line, 63.0 mm (2.4803 in.) from the piston head.

Standard diameter: Mark 1 95.920 to 95.930 mm (3.77637 to 3.77676 in.)

STD Mark 2 95.930 to 95.940 mm (3.77676 to 3.77716 in.)

Mark 3 95.940 to 95.950 mm (3.77716 to 3.77755 in.)

Front

(2)

Measure the cylinder bore diameter in the thrust directions (See step 18).

(3)

Subtract the piston diameter measurement from the cylinder bore diameter measurement.

Standard oil clearance: 0.070 to 0.090 mm (0.0028 to 0.0035 in.)

Maximum oil clearance: 0.14 mm (0.0055 in.)

If the oil clearance is greater than the maximum, replace all the 4 pistons. If necessary, replace the cylinder block.

Front Mark

Mark 1, 2 or 3

145

HINT: Use a piston with the same number as the cylinder bore diameter marked on the cylinder block.

04 /20110 indice A

(b)

Inspect the piston pin fit.

(1)

Heat the piston to approx. 80 deg. C, and push the piston pin into the piston pin hole.

If the pin can be installed at a lower temperature, replace the piston and pin as a set.

(c) Using a micrometer, measure the piston pin diameter.

Piston pin diameter: Mark A

33.996 to 34.000 mm (1.33842 to 1.33858 in.)

Mark B

34.000 to 34.004 mm (1.33858 to 1.33874 in.)

Mark C

34.004 to 34.008 mm (1.33874 to 1.33889 in.)

Mark A, B or C

N°1 ring

21. (a)

New Piston Ring

INSPECT PISTON RING SET Inspect the piston ring groove clearance.

(1)

N°1 ring: Install a new No.1 piston ring to the piston.

Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove.

Ring groove clearance (N°1): 0.091 to 0.135 mm (0.0036 to 0.0053 in.)

Feeler Gauge

(2) N°2 ring Feeler Gauge

No.2 and oil ring: Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove.

Ring groove clearance (No 2 and oil ring):

New Piston Ring

N°2

0.090 to 0.135 mm (0.0036 to 0.0053 in.)

Oil

0.030 to 0.075 mm (0.0012 to 0.003 in.)

If the clearance is greater than the maximum, replace the piston.

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04 /20110 indice A

b)

Inspect the piston ring end gap.

(1) (2)

(3)

Insert the piston ring into the cylinder bore.

Using a piston, push the piston ring a little beyond the bottom of the ring travel, 120 mm (4.72 in.) from the top of the cylinder block.

Using a feeler gauge, measure the end gap.

Standard end gap:

N°1

0.27 to 0.39 mm (0.0106 to 0.0154 in.)

N°2

0.55 to 0.70 mm (0.0217 to 0.0276 in.)

Oil

0.20 to 0.40 mm (0.0079 to 0.0157 in.)

Maximum end gap: N°1

0.85 mm (0.0335 in.)

N°2

1.07 mm (0.0421 in.)

Oil

0.77 mm (0.0303 in.)

If the end gap is greater than the maximum, replace the piston ring.

22.

INSPECT CONNECTING ROD SUB-ASSY

(a)

Using a rod aligner and feeler gauge, check the connecting rod alignment.

(1)

Check for bend.

Maximum bend: 0.03 mm (0.0012 in.) per 100 mm (3.94 in.)

If the bend is greater than the maximum, replace the connecting rod sub−assembly.

(2)

Check for twist Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

If the twist is greater than the maximum, replace the connecting rod sub-assembly.

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04 /20110 indice A

(b)

Inspect the piston pin oil clearance.

(1) Using a caliper gauge, measure the inside diameter of the connecting rod bush.

Bush inside diameter:

Mark A

34.012 to 34.016 mm (1.3391 to 1.3392 in.)

Mark B

34.016 to 34.020 mm (1.3392 to 1.3394 in.)

Mark C

34.020 to 34.024 mm (1.3394 to 1.3395 in.)

(2)

Subtract the piston pin diameter (See step 20) from the bush inside diameter.

Standard oil clearance: 0.012 to 0.020 mm (0.0005 to 0.0008 in.)

Maximum oil clearance: 0.03 mm (0.0012 in.)

If the oil clearance is greater than the maximum, replace the bush. If necessary, replace the piston and piston pin as a set.

23.

REMOVE CONNECTING ROD SMALL END BUSH

(a)

Using special tools 970315565 and 970315567 and a press, press out the bush.

24.

INSPECT CONNECTING ROD BOLT

(a)

Using caliper, measure the constricted portion of the connecting rod bolt.

970315565

970315567

Elongated

Standard diameter: 8.500 to 8.600 mm (0.3346 to 0.3385 in.)

Minimum diameter: 8.30 mm (0.3268 in.)

Measuring Point

If the diameter is less than the minimum, replace the bolt.

25.

INSPECT NO.1 BALANCESHAFT SUB-ASSY

(a)

Using a cylinder gauge, measure the inside diameter of the balance shaft bearing.

Bearing inside diameter:

148

N°1

42.000 to 42.020 mm (1.6535 to 1.6543 in.)

N°2

41.000 to 41.020 mm (1.6142 to 1.6150 in.)

N°3

32.000 to 32.020 mm (1.2598 to 1.2606 in.)

04 /20110 indice A

(b)

Using a micrometer, measure the outside diameter of the balance shaft main journals.

Main journal diameter:

(c)

N°1

41.941 to 41.960 mm (1.6512 to 1.6520 in.)

N°2

40.931 to 40.950 mm (1.6115 to 1.6122 in.)

N°3

31.941 to 31.960 mm (1.2575 to 1.2583 in.)

Subtract the outside diameter of the balance shaft main journal from the inside diameter to the balance shaft bearing.

Standard oil clearance: N°1

0.040 to 0.079 mm (0.0016 to 0.0031 in.)

N°2

0.040 to 0.079 mm (0.0016 to 0.0031 in.)

N°3

0.050 to 0.089 mm (0.0020 to 0.0035 in.)

Maximum oil clearance: N°1

0.18 mm (0.0071 in.)

N°2

0.19 mm (0.0075 in.)

N°3

0.18 mm (0.0071 in.)

If the clearance is greater than the maximum, replace the cylinder block and balance shaft.

26.

INSPECT NO.2 BALANCESHAFT SUB-ASSY

(a)

Using a cylinder gauge, measure the inside diameter of the balance shaft bearing.

Bearing inside diameter:

(b)

N°1

42.000 to 42.020 mm (1.6535 to 1.6543 in.)

N°2

41.000 to 41.020 mm (1.6142 to 1.6150 in.)

N°3

32.000 to 32.020 mm (1.2598 to 1.2606 in.)

Using a micrometer, measure the outside diameter of the balance shaft main journals.

Main journal diameter:

(c)

N°1

41.941 to 41.960 mm (1.6512 to 1.6520 in.)

N°2

40.931 to 40.950 mm (1.6115 to 1.6122 in.)

N°3

31.941 to 31.960 mm (1.2575 to 1.2583 in.)

Subtract the outside diameter of the balance shaft main journal from the inside diameter to the balance shaft bearing.

Standard oil clearance:

149

N°1

0.040 to 0.079 mm (0.0016 to 0.0031 in.)

N°2

0.040 to 0.079 mm (0.0016 to 0.0031 in.)

N°3

0.050 to 0.089 mm (0.0020 to 0.0035 in.)

04 /20110 indice A

Standard oil clearance: N°1

0.040 to 0.079 mm (0.0016 to 0.0031 in.)

N°2

0.040 to 0.079 mm (0.0016 to 0.0031 in.)

N°3

0.050 to 0.089 mm (0.0020 to 0.0035 in.)

If the clearance is greater than the maximum, replace the cylinder block and balance shaft.

27.

INSPECT CRANKSHAFT

(a)

Inspect for circle run out.

(1) Place the crankshaft on V-blocks.

(2) Using a dial indicator, measure the circle run out at the centre journal.

Maximum circle run out: 0.03 mm (0.0012 in.)

Centre journal

If the circle run out is greater than the maximum, replace the crankshaft.

(b)

Inspect the main journals.

(1)

Using a micrometer, measure the outside diameter of each main journal.

Main journal diameter:

150

Mark 1

69.994 to 70.000 mm (2.75566 to 2.75590 in.)

Mark 2

69.988 to 69.994 mm (2.75543 to 2.75566 in.)

Mark 3

69.982 to 69.988 mm (2.75519 to 2.75543 in.)

04 /20110 indice A

(c)

Inspect the crank pins.

(1) Using a micrometer, measure the outside diameter of each crank pin.

Main journal diameter: Mark 1

69.994 to 70.000 mm (2.75566 to 2.75590 in.)

Mark 2

69.988 to 69.994 mm (2.75543 to 2.75566 in.)

Mark 3

69.982 to 69.988 mm (2.75519 to 2.75543 in.)

If the diameter is not as specified, check the oil clearance (See step 4). If necessary, grind or replace the crankshaft.

(2)

Check each crank pin for taper and out-ofround as shown. maximum taper and out-of-round: 0.020 mm (0.0008 in.)

If the taper and out-of-round is greater than the maximum, replace the crankshaft.

Measuring Point

28.

INSPECT CRANKSHAFT BEARING CAP BOLT

(a)

Using vernier calipers, measure the minimum diameter of the compressed thread at the measuring point.

Standard diameter: 13.500 to 14.000 mm (0.5315 to 0.5512 in.)

Minimum diameter: 12.60 mm (0.4961 in.)

If the diameter is less than the minimum, replace the bolt.

29.

Adhesive

INSTALL TIGHT PLUG

(a) Apply an adhesive around the tight plugs.

Adhesive: THREE BOND 1324 or equivalent NOTICE: Do not start the engine within 1 hour after the installation.

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04 /20110 indice A

(1) (2) (3) (4) (5) (6) (7)

Using special tool 970315564 and 970312748 , tap in the tight plug No.1 as shown in the illustration below Using special tool 970315564, and 970312748, tap in the tight plug No.2 as shown in the illustration below.

Using special tool 970315564 and 970312748, tap in the tight plug No.3 as shown in the illustration below.

Using special tool 970315564, and 970312748, tap in the tight plug No.4 as shown in the illustration below.

Using special tool 970315564, and 970312748, tap in the tight plug No.5 as shown in the illustration below.

Using special tool 970315564, and 970312748, tap in the tight plug No.6 as shown in the illustration below.

Using a 8 mm deep socket wrench, tap in the tight plug No.7 as shown in the illustration below.

Front Side:

Exhaust Side: Tight Plug N°2

Tight Plug N°5

Tight Plug N°6

Rear Side:

Inlet Side: Tight Plug N°4

Tight Plug N°1 Tight Plug N°6

Tight Plug N°3

Tight Plug N°1

Tight Plug N°4

Tight Plug N°7

Tight Plug N°2

Tight Plug N°5

152

Tight Plug N°3

Tight Plug N°6

Tight Plug N°7

04 /20110 indice A

(a)

Install the stud bolts as shown in the illustration.

Torque: 7.0 N·m (71 kgf·cm, 62 in. lbf) for bolt A and B 8.0 N·m (82 kgf·cm, 71 in. lbf) for bolt C 4.0 N·m (41 kgf·cm, 35 in. lbf) for bolt D and E Front Side:

Intake Side:

Lower Side:

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04 /20110 indice A

31.

INSTALL STRAIGHT PIN

(a)

Install the straight pin as shown in the illustration.

Front Side:

Lower Side

32.

INSTALL RING PIN

(a)

Install the ring pin as shown in the illustration.

Rear Side:

Upper Side:

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04 /20110 indice A

33. INSTALL SUB-ASSY OIL NOZZLE N°1 (a) (b)

Align the oil nozzle pin with the pin hole of the cylinder block.

Install the oil nozzle with the check valve. Install the 4 oil nozzles and check valves.

Torque: 26 N·m (265 kgf·cm, 19 ft·lbf)

Round File

34.

INSTALL CONNECTING ROD SMALL END BUSH

(a)

Using a round file, lightly file the small end of the connecting rod.

(b)

Install the bushing to special tool 970315566 with the ball of special tool facing inside the oil hole of the bushing.

(c)

Align the oil holes of a new bushing and the connecting rod.

(d)

Using special tool 970315565, 970315566, 970315567 and a press, press in the bushing.

Oil Hole

Ball 970315566

Align

970315565

970315566

970315567

155

04 /20110 indice A

Piston Pin

Front Mark (Arrow)

Front Mark (Protusion)

156

(1)

Using a pin hole grinder, hone the bush to obtain the standard specified clearance (See step 22) between the bush and piston pin.

(2)

Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

35.

INSTALL W/PIN PISTON SUB −ASSY

(a)

Assemble the piston and connecting rod.

(1)

Using a screwdriver, install a new snap ring on one side of the piston pin hole.

(2)

Gradually heat the piston to about 80°C (176°F).

(3) (4)

Coat the piston pin with engine oil.

Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

04 /20110 indice A

(b)

(5)

Check that the piston and piston pin are fitted by pushing the piston back and forth.

(6)

Using a screwdriver, install a new snap ring on the other side of the piston pin hole.

Install the piston rings.

(1) Install the coil by hand.

HINT: Face the end gap of the oil ring in the opposite direction of the coil joint.

Coil Joint

Oil Ring Ends (2)

Using a piston ring expander, install the oil ring.

(3)

Using a piston ring expander, install the No.1 and No.2 piston rings with the code mark facing upward.

Code marks:

Code Mark

157

N°1

NKD

N°2

N

04 /20110 indice A

(4) Oil

Position the piston rings so that the ring ends are as shown.

NOTICE: Do not align the ring ends.

Front Mark

Coil

Bearing Claw

Bearing Claw

36. (a)

INSTALL CONNECTING ROD BEARING Align the bearing claw with the groove of the connecting rod or connecting cap.

(b)

Install the bearings in the connecting rod and connecting rod cap.

37.

INSTALL CRANKSHAFT BEARING

HINT: Upper bearings have an oil groove and oil hole, but lower bearings do not.

Bearing groove

158

(a)

Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.

(b)

Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings

04 /20110 indice A

Thrust Washer

Oil Groove

38.

INSTALL CRANKSHAFT

(a) (b)

Place the crankshaft on the cylinder block.

Install the 2 upper thrust washers to the No.5 journal position of the cylinder block.

(1) Push the crankshaft toward the front (rear) side.

(2) Install the 2 thrust washers with the oil grooves facing outward.

(c)

Install the 2 thrust washers on the No.5 bearing cap with the grooves facing outward.

(d)

Install the 5 crankshaft bearing caps in their proper locations.

(e)

Install the crankshaft bearing cap bolts.

Cylinder Block

Oil Groove

HINT: The main bearing cap bolts are tightened in 2 progressive steps (steps (b) and (d)).

• If any one of the main bearing cap bolts is broken or deformed, replace it.

•

(1) (2)

Apply a light coat of the engine oil to the threads and under the bolt heads of the main bearing caps.

Install and uniformly tighten the 10 bolts of the main bearing caps, in several passes, in the sequence shown in the order indicated in the illustration.

Torque: 50 N·m (510 kgf·cm, 37 ft·lbf)

If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.

159

04 /20110 indice A

(3) (4) (5) Painted Mark

Mark the front of the main bearing cap bolt with paint.

Retighten the main bearing cap bolts 90° in the order shown above.

Check that the painted mark is now at a 90° angle to the front.

(f) (g)

Check that the crankshaft turns smoothly.

Check the crankshaft thrust clearance (See step 7).

39.

INSTALL PISTON AND CONNECTING ROD

(a)

Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.

(b)

Place the connecting rod cap on the connecting rod.

(1) Match the numbered connecting rod cap with the connecting rod.

(2) Align the pins of the connecting rod cap with the pin holes of the connecting rod, and install the connecting rod cap.

Front Mark (Arrow)

(3)

Check that the front mark of the connecting rod cap is facing forward.

Front Mark (Protusion)

(c)

Install the connecting rod cap bolts.

HINT: The connecting rod cap bolts are tightened in 2 progressive steps (steps (2) and (4)).

• If any connecting rod bolts is broken or deformed, replace it.

•

(1)

160

Apply a light of engine oil to the threads and under the heads of the connecting rod cap bolts.

04 /20110 indice A

(2)

Install and alternately tighten the bolts of the connecting rod cap in several passes.

Torque: 35 N·m (357 kgf·cm, 26 ft·lbf)

Front

If any of the connecting rod cap bolts does not meet the torque specification, replace the cap bolts.

Painted Mark

(3)

Cylinder Block Oil Orifice

Injection pump

Gasket Spacer

(d) (e)

Mark the front of the connecting rod cap bolts with paint.

(4) Retighten the connecting rod cap bolts 90° as shown in the illustration.

(5) Check that the painted mark is now at a 90° angle to the front.

Check that the crankshaft turns smoothly.

Check the connecting rod thrust clearance (See step 3).

40.

INSTALL CYLINDER BLOCK OIL ORIFICE

(a)

Install the cylinder block oil orifice to the cylinder block.

41.

REMOVE CYLINDER BLOCK SIDE COVER

(a)

Remove the 2 nuts, spacers, cylinder block side cover and gasket.

42. (a)

INSTALL CYLINDER BLOCK SIDE COVER Install the new gasket, cylinder block side cover, 2 spacers and 2 nuts.

Torque: 29N·m(302kgf·m, 22ft·lbf)

NOTICE: Do not reuse the gasket.

Nut

Cylinder block side cover

161

04 /20110 indice A

6. COOLANT PUMP INSPECTION & REPLACEMENT [6.1]

COOLANT PUMP ASSY COMPONENTS

162

04 /20110 indice A

[6.2]

COOLANT PUMP ASSEMBLY INSPECTION—REPLACEMENT 1.

INSPECT WATER PUMP ASSY

(a)

Visually check the water hole for coolant leakage.

If leakage is found, replace the water pump. (b)

Turn the pulley and check that the water pump bearing moves smoothly and quietly.

If necessary, replace the water pump.

2.

WATER PUMP REPLACEMENT

A. B. C. D. E. F.

DRAIN ENGINE COOLANT REMOVE GENERATOR BELT REMOVE TIMING BELT COVER N°1 REMOVE TIMING BELT REMOVE GENERATOR ASSY REMOVE IDLE PULLEY ASSY (a) Remove the bolt and idle pulley assy.

REMOVE INJECTION PIPE REMOVE CYLINDER HEAD COVER SUB−ASSY REMOVE CAMSHAFT TIMING PULLEY REMOVE TIMING BELT IDLER SUB−ASSY N°1 REMOVE TIMING BELT COVERN°2 REMOVE WATER PUMP ASSY (a) Remove the 5 bolts and 2 nuts, and re move the water pump assy.

INSTALL WATER PUMP ASSY (a) Set a new gasket and install the water pump assembly with the 5 bolts and 2 nuts.

G. H. I. J. K. L. M.

Torque: 13 N m (133 kgf cm, 10 ft lbf) N. O. P. Q. R. S.

INSTALL TIMING BELT N°2 COVER INSTALL TIMING BELT IDLER SUB−ASSY N°1 INSTALL CAMSHAFT TIMING PULLEY INSTALL CYLINDER HEAD COVER SUB−ASSY INSTALL INJECTION PIPE INSTALL IDLE PULLEY ASSY (a) Install the idle pulley with the bolt.

Torque: 45 N m (459 kgf cm, 33 ft lbf)

T. U. V.

INSTALL GENERATOR ASSY INSTALL TIMING BELT INSTALL TIMING BELT NO.1 COVER (a) Install the timing belt cover No. 1 with the 6 bolts.

Torque: 6.0 N m (61 kgf cm, 53 in. lbf) (b) (c)

Install the wire harness clamp.

Install the water hose clamp with the bolt.

Torque: 18 N m (184 kgf cm, 13 ft lbf) W. X. Y. Z. 163

INSTALL GENERATOR BELT ADD ENGINE COOLANT CHECK FOR ENGINE COOLANT LEAKS CHECK FUEL LEAK 04 /20110 indice A

7. TIMING GEAR OIL SYSTEM [7.1]

TIMING GEAR OIL PUMP ASSEMBLY INSPECTION 1.

TIMING GEAR CASE ASSEMBLY COMPONENTS

164

04 /20110 indice A

2.

TIMING GEAR CASE ASSEMBLY INSPECTION

165

04 /20110 indice A

1.

2.

3.

4.

5.

6.

7.

8.

DRAIN COOLANT DRAIN ENGINE OIL REMOVE ALTERNATOR BELT REMOVE TIMING BELT COVER REMOVE TIMING BELT REMOVE ALTERNATOR ASSY REMOVE IDLE PULLEY ASSY REMOVE ALTERNATOR BRACKET (a) Remove the bolt and alternator bracket.

9.

10.

11.

12.

13.

14.

15.

REMOVE WATER PUMP ASSY REMOVE FUEL INLET PIPE SUB−ASSY REMOVE INJECTION PIPE REMOVE CYLINDER HEAD COVER SUB−ASSY REMOVE CAMSHAFT TIMING PULLEY REMOVE TIMING BELT IDLER SUB−ASSY NO.1 REMOVE TIMING BELT COVER 16.

REMOVE PUMP DRIVE SHAFT PULLEY

(a)

Remove the 4 bolts, camshaft timing pulley flange No. 2 and pump drive shaft pulley.

(b)

With holding the crankshaft using special tools 970312736 and 970312752, remove the nut and O−ring.

17.

18.

REMOVE CRANKSHAFT PULLEY REMOVE CRANKSHAFT POSITION SENSOR

(a)

Disconnect the crankshaft position sensor connector, and then remove the bolt and crankshaft position sensor.

19.

REMOVE CAMSHAFT POSITION SENSOR

(a)

Disconnect the camshaft position sensor connector, and then remove the bolt and camshaft position sensor.

166

04 /20110 indice A

20.

REMOVE TIMING GEAR CASE

(a) (b) (c)

Remove the wire harness clamp.

Remove the 14 bolts and 2 nuts.

Separate its cover from the timing gear case softly using a slotted screwdriver.

HINT: There are some tiny slots that allow you to insert the slotted screwdriver tip for separating the timing gear case and its cover. Refer to the illustration for these slot locations. (d)

Remove the case cover and O−ring.

CAUTION: Be careful not to damage each jointing face of timing gear case and its cover in the aforementioned separating and removing steps.

21.

FIX IDLE GEAR NO.1

(a)

Fix the sub idle gears to the idle gear No. 1 with the service bolt.

Torque: 8 N m (82 kgf cm, 71 in. lbf) HINT: This is for eliminating a torsional force caused by the idle gear springs (which are set in between the idle gear No. 1 and each sub idle gear). Such a torsional force will cause the sub idle gear’s tooth to be out of alignment from the gear tooth of idle gear N°1.

Service Bolt

NOTICE: If a screw hole of the rear sub idle gear is not at its correct position, correct it by rotating the crankshaft in counter clockwise direction, and then screw the service bolt.

167

22.

REMOVE CRANKSHAFT TIMING GEAR

(a) (b)

Remove the crankshaft sensor plate.

Install the service bolt to the crankshaft.

(c)

Remove the crankshaft timing gear with special tool 970312374

04 /20110 indice A

23.

REMOVE IDLE GEAR NO.1

(a)

Remove the 2 bolts, idle gear thrust plate and idle gear No. 1.

(b)

Remove the idle gear shaft No. 1.

24.

REMOVE INJECTION GEAR

(a)

Remove the injection gear with the special tool 970312374

25.

REMOVE SUPPLY PUMP ASSEMBLY

(a)

Remove the 2 nuts, supply pump assembly and its O-ring.

26.

REMOVE FLYWHEEL SUB−ASSEMBLY

27.

REMOVE REAR END PLATE

(a)

Remove the bolt and rear end plate.

28.

REMOVE OIL LEVEL GAGE SUB −ASSEMBLY

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04 /20110 indice A

29. REMOVE OIL PAN SUB-ASSEMBLY (a)

Remove the 22 bolts and 2 nuts.

(b)

Remove the oil pan sub−assembly

NOTICE: • •

Do not use SST for the oil pump body side and rear oil seal retainer.

Be careful not to damage the oil pan flange.

(c)

Remove the oil pan gasket.

30.

REMOVE TIMING GEAR CASE ASSY

(a)

Remove the nut, and remove the vacuum transmitting pipe No. 1.

(b)

Remove the 8 bolts and union bolt, and then remove the timing gear case and its 2 O−rings.

NOTICE: Beware of dropping the oil pump rotor.

O−Ring

169

31.

INSTALL TIMING GEAR CASE ASSEMBLY

(a)

Set the 2 O−rings to the cylinder block.

04 /20110 indice A

Width: 5mm (0.20 in.)

Gasket

(b)

Remove old seal packing (FIPG) from the timing gear case and cylinder block.

Set a new oil pump gasket to the timing gear case.

Apply a seal packing to the specific places described in the illustration.

(c) (d)

Seal packing black: 970312770 or equivalent

NOTICE:

Seal Packing

•

Install the timing gear case within 3 minutes and tighten the bolts within 15 minutes after seal packing application is completed.

Do not start the engine until 2 hours after the installation.

• (e) (f)

With matching the match marks of the balance shaft driven gear No. 1 and oil pump drive gear, install the timing gear case to the cylinder block.

Tighten the 8 bolts and union bolt.

Torque: 13 N m (130 kgf cm, 9 ft lbf) for bolt 16 N m (160 kgf cm, 12 ft lbf) for union bolt

(g)

Make sure that the oil pump drive gear rotates smoothly.

NOTICE: If this failed, loosen the 8 bolts and union bolt to release the oil pump drive gear, and retighten all these bolts again. (h)

Install the vacuum transmitting pipe No. 1 with the nut.

Seal Packing

Torque: 8 N m (82 kgf cm, 71 in. lbf) 32.

INSTALL OIL PAN SUB −ASSEMBLY

(a)

Remove old seal packing from the oil pan sub−assembly and cylinder block.

Apply a seal packing to the specific places described in the illustration.

Seal packing black: 970312770 or equivalent

(b) Width: 5mm (0.20 in.)

NOTICE: • •

Install the timing gear case within 3 minutes and tighten the bolts within 15 minutes after seal packing application is completed.

Do not start the engine until 2 hours after the installation.

(c) (d)

Set a new oil pan gasket to the oil pan sub−assy.

Install the oil pan with the 22 bolts and 2 nuts.

(e) (f)

Set a new gasket, and install the oil strainer with 2 nuts. Torque: 8 N m (82 kgf cm, 71 in. lbf) Connect the engine oil level sensor connector.

33.

INSTALL REAR END PLATE

(a)

Install the rear end plate with the bolt.

34.

INSTALL FLYWHEEL SUB−ASSEMBLY

170

Torque: 15 N m (148 kgf cm, 11 ft lbf)

Torque: 8 N m (82 kgf cm, 71 in. lbf)

04 /20110 indice A

35. INSTALL SUPPLY PUMP ASSEMBLY (a) (b)

Remove the plug shown in the illustration, and then pour engine oil with 50 cc (3.05 cut in) into there.

Set a new gasket and reset the plug.

Torque: 44 N m (449 kgf cm, 33 ft lbf)

(c) (d) (e)

Set a new O−ring to the supply pump.

Temporarily install the supply pump with the 2 nuts and supply pump stay with the 4 bolts.

Tighten the 2 nuts for the supply pump.

Torque: 21 N m (214 kgf cm, 16 ft lbf)

(f)

Tighten the 2 bolts for the pump stay at the pump side first, and then rest the 2 bolts at cylinder block side likewise.

Torque: 21 N m (214 kgf cm, 16 ft lbf)

36.

INSTALL INJECTION GEAR

(a)

With matching the match marks of the injection gear and balance shaft driven gear No. 2, install the injection gear.

NOTICE: Fit key (protrusion) of the supply pump to its key −slot on the injection gear. (b)

Set a new O−ring, and then temporarily install the nut. Under this condition, check a thrust clearance for the supply pump drive shaft by pushing the injection gear in back and forth direction with your hand.

Thrust clearance: 0.15 − 0.55 mm (0.0059 − 0.0217 in.)

HINT: If there is no thrust clearance, remove the injection gear again and re−install it.

171

37.

INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

(a)

With matching the match marks of the crankshaft timing gear and oil pump drive gear using special tool 970312742, install the crankshaft timing gear.

38.

INSTALL IDLE GEAR NO.1

(a)

Apply engine oil to specific place described in the illustration, install the idle gear shaft No. 1 to the cylinder block.

04 /20110 indice A

(b)

(c)

With matching the match marks of the idle gear No. 1 for the match mark of the crankshaft timing gear and injection gear and install the idle gear No. 1.

Fix the idle gear No. 1 with the idle gear thrust plate and 2 bolts.

Torque: 50 N m (510 kgf cm, 37 ft lbf)

(d)

Remove the service bolt.

39.

INSTALL CRANKSHAFT POSITION SENSOR PLATE

(a)

Install the crank angle sensor plate No. 1.

40.

INSTALL TIMING GEAR CASE

(a)

Set a new O−ring to the timing gear case.

Service Bolt

O−Ring

172

04 /20110 indice A

(b) Remove old seal packing (FIPG) from the timing gear case. (c) Apply a seal packing to the specific places described in the illustration.

Seal packing: 970312770 or equivalent

NOTICE: o Install the timing case cover within 3 minutes and tighten its bolts and nuts within 15 minutes as soon as when applying FIPG is completed. o Do not start the engine 2 hours after the installation. (d)

Install the timing case cover with the 14 bolts and 2 nuts.

41.

INSTALL CAMSAFT POSITION SENSOR

(a) (b)

Apply engine oil to the O−ring.

Install the crank position sensor No. 2 with the bolt.

42.

INSTALL CRANKSHAFT POSITION SENSOR

(a) (b)

Apply engine oil to the O−ring.

Install the crank position sensor with the bolt.

43.

INSTALL CRANKSHAFT PULLEY

Torque: 13 N m (133 kgf cm, 10 ft lbf)

Torque: 8 N m (82 kgf cm, 71 in. lbf)

Torque: 8 N m (82 kgf cm, 71 in. lbf)

44.

INSTALL PUMP DRIVE SHAFT PULLEY

(a) Hold the crankshaft with special tools 970312736 and 970312752 to tighten a nut. (b) Set the O−ring, and tighten the nut.

Torque: 103 N m (1050 kgf cm, 76 ft lbf) (c) Install the camshaft timing pulley flange No. 2 and pump drive shaft pulley with the 4 bolts.

Torque: 31 N m (316 kgf cm, 23 ft lbf) (d) Check a thrust clearance for the supply pump drive shaft by pushing the camshaft timing pulley flange No. 2 in back and forth direction with your hand.

Thrust clearance: 0.15 − 0.55 mm (0.0059 − 0.0217)

NOTICE: The notch of the crankshaft pulley must be located 30° counter clockwise from the TDC.

HINT: If there is no thrust clearance, disassemble the parts to remove the timing gear case again, and reassemble them.

45.

46.

47.

48.

49.

50.

INSTALL TIMING BELT COVER INSTALL TIMING BELT IDLER SUB−ASSEMBLY INSTALL CAMSHAFT TIMING PULLEY INSTALL CYLINDER HEAD COVER SUB−ASSEMBLY INSTALL INJECTION PIPE INSTALL FUEL INLET PIPE SUB−ASSEMBLY

NOTICE: Replace the fuel inlet pipe with a new one when replacing the timing gear case assy.

173

04 /20110 indice A

48.

49.

INSTALL WATER PUMP ASSEMBLY INSTALL ALTERNATOR BRACKET

(a)

Temporarily install the alternator bracket with the bolt

NOTICE: Tighten that bolt after the alternator assembly installation.

50.

51.

52.

53.

INSTALL IDLE PULLEY ASSEMBLY INSTALL ALTERNATOR ASSEMBLY INSTALL TIMING BELT INSTALL TIMING BELT COVER

(a)

Install the timing belt cover with the 6 bolts.

Torque: 6.0 N m (61 kgf cm, 53 in. lbf) 54.

55.

56.

57.

58.

59.

INSTALL ALTERNATOR BELT ADD ENGINE OIL ADD ENGINE COOLANT CHECK FOR ENGINE OIL LEAKS CHECK FOR ENGINE COOLANT LEAKS CHECK FUEL LEAK

[7.2]

TIMING GEAR OIL PUMP INSPECTION 1.

REMOVE OIL PUMP RELIEF VALVE

(a)

Remove the plug, gasket, spring and relief valve from the timing gear case assy.

2.

INSPECT OIL PUMP RELIEF VALVE

(a)

Coat the valve with engine oil and check that the relief valve falls smoothly into the valve hole by its own weight. If it doesn’t fall smoothly, replace the relief valve. If the problem still continues, replace the oil pump assembly.

3.

INSPECT TIMING GEAR CASE ASSY

(a)

Inspect the rotor tip clearance.

(1) Using a feeler gauge, measure the clearance between the drive and driven rotor tips.

Standard tip clearance: 0.060 to 0.160 mm (0.0024 to 0.0063 in.)

Maximum tip clearance: 0.21 mm (0.0083 in.)

If the tip clearance is greater than the maximum, replace the timing gear case. (b)

Inspect the rotor body clearance.

(1) Using a feeler gauge, measure the clearance between the driven rotor and body.

Standard body clearance: 0.100 to 0.170 mm (0.0039 to 0.0067 in.)

Maximum body clearance: 0.20 mm (0.0079 in.)

If the body clearance is greater than the maximum, replace the timing gear case.

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04 /20110 indice A

(c)

Inspect the rotor side clearance.

(1) Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge.

Standard side clearance: 0.030 to 0.090 mm (0.0012 to 0.0035 in.)

Maximum side clearance: 0.15 mm (0.0059 in.)

If the side clearance is greater than the maximum, replace the timing gear case.

4.

INSTALL OIL PUMP RELIEF VALVE

(a)

Install the relief valve and spring to the timing gear case.

Install a new gasket and plug.

(b)

Torque: 44N m (449kgf cm, 33ft lbf)

[7.3] 1.

2.

3.

4.

5.

6.

7.

8.

CAMSHAFT OIL SEAL REPLACEMENT

DRAIN ENGINE COOLANT REMOVE ALTERNATOR BELT REMOVE TIMING BELT COVER REMOVE TIMING BELT REMOVE INJECTION PIPE REMOVE CYLINDER HEAD COVER SUB−ASSEMBLY REMOVE CAMSHAFT TIMING PULLEY REMOVE TIMING BELT IDLER SUB−ASSEMBLY 9.

REMOVE TIMING BELT COVER 10. REMOVE NOZZLE HOLDER CLAMP (a) Remove the bolt and washer, and remove the nozzle holder clamp.

11.

REMOVE CAMSHAFT SETTING OIL SEAL

(a) Uniformly loosen the 3 bolts, and remove the camshaft bearing cap. (b) Remove the oil seal.

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04 /20110 indice A

Seal Packing

8 mm (0.31 in.)

Oil passage

12.

INSTALL CAMSHAFT SETTING OIL SEAL

(a)

Remove old seal packing (FIPG) from the camshaft bearing cap.

Apply a seal packing to the specific places described in the illustration.

(b)

Seal packing: 970312770 or equivalent Thickness: 1 mm (0.039 in.)

Width: 4 mm (0.16 in.)

NOTICE: • •

• (c)

Beware not to stick seal packing in the oil passage of the bearing cap.

Once the seal packing application is completed, install the camshaft bearing cap within 3 minutes and tighten its bolts within 15 minutes.

Do not start the engine until 2 hours after the installation.

Uniformly tighten the 3 bolts, and fix the camshaft bearing cap.

Torque: 19 N m (194 kgf cm, 14 ft lbf)

(d)

Apply a bit of MP grease to a new oil seal’s lip.

NOTICE: Keep the lip clean. Do not bring dirt or dust on that area. (e) Fit the oil seal by using special tool 970313927 and a hammer.

Oil seal depth from flat end face: 0.5 to −1.5 mm (0.020 to −0.060 in.)

NOTICE: Install the oil seal straight.

13.

INSTALL NOZZLE HOLDER CLAMP

(a)

Set a washer in between a bolt and the nozzle holder clamp, and install the nozzle holder clamp by tightening the bolt.

Torque: 22 N m (220 kgf cm, 16 ft lbf)

NOTICE: Beware not to install a washer upside −down.

14.

15.

16.

17.

18.

19.

176

INSTALL TIMING BELT COVER INSTALL TIMING BELT IDLER SUB−ASSEMBLY INSTALL CAMSHAFT TIMING PULLEY INSTALL CYLINDER HEAD COVER SUB−ASSEMBLY INSTALL INJECTION PIPE INSTALL TIMING BELT

04 /20110 indice A

[7.4] 1.

REAR OIL SEAL REPLACEMENT

REMOVE TRANSMISSION ASSEMBLY

3.

REMOVE REAR END PLATE

(a)

Remove the bolt and rear end plate.

2.

REMOVE FLYWHEEL SUB −ASSEMBLY

(a) (b)

Fix the crankshaft with Special tool 970312736 + 970312752.

Remove the 8 bolts and flywheel.

4.

REMOVE ENGINE REAR OIL SEAL RETAINER

(a)

Remove the 7 bolts and engine rear oil seal retainer.

5.

REMOVE ENGINE REAR OIL SEAL

(a)

Remove the oil seal with a slotted screwdriver in the manner shown in the illustration.

HINT: Put a protection material around sharp−end of the screwdriver to protect the oil seal retainer. (b)

Remove oil seal packing (FIPG) from the engine rear oil seal retainer.

6.

INSTALL ENGINE REAR OIL SEAL

(a)

Using Special tools 970315563 + 970312748 and a hammer, tap in a new oil seal.

970315563

Acceptable depth from the top −flat −face of the oil seal retainer: 0 to −0.8 mm (0 to −0.020 in.)

NOTICE: Be sure to have the oil seal a horizontal when embedded. (b)

Apply a bit of MP grease to the oil seal’s lip.

NOTICE: Keep the lip clean. Do not bring dirt or dusts on that 177

04 /20110 indice A

Seal Packing

7.

INSTALL ENGINE REAR OIL SEAL RETAINER

a)

Remove oil seal packing (FIPG) from oil pan and cylinder block.

Apply a seal packing to the specific places described in the illustration.

b)

Seal packing: 970312770 or equivalent

NOTICE: •

Install the engine rear oil seal retainer within 3 minutes and tighten its bolts within 15 minutes after seal packing application is completed.

Do not start the engine 2 hours after the installation.

•

Seal Packing Width: 5 mm (0.20 in.) (c)

Install the engine rear oil seal retainer with the 7 bolts.

Torque: 13 N m (133 kgf cm, 9.6 ft lbf) for bolt A 16 N m (163 kgf cm, 12 ft lbf) for bolt B

9.

8.

INSTALL FLYWHEEL SUB−ASSEMBLY

INSTALL REAR END PLATE

(a) Install the rear end plate with the bolt.

Torque: 8 N m (82 kgf cm, 71 in. lbf)

(a) (b) (c)

Clean up the bolt and its hole.

Apply a bit of an adhesive to the 8 bolts tip.

Adhesive: THREE BOND 1324 or equivalent

NOTICE: Do not start the engine until 1 hour after the installation. (c) (d)

Fix the crankshaft with special tools 970312736 and 970312752.

Install the flywheel with the 8 bolts.

Torque: 178 N m (1815 kgf cm, 132 ft lbf)

10.

178

CHECK FOR ENGINE OIL LEAKS 04 /20110 indice A

[7.5] 1.

2.

GEAR CASE OIL SEAL REPLACEMENT

DRAIN COOLANT REMOVE ALTERNATOR BELT 970312736 + 970312752

3.

REMOVE CRANKSHAFT PULLEY

(a)

Remove the bolt with holding the crankshaft using 970312736 and 970312752.

Insert the service bolt.

(b)

970312374

(c) Remove the crankshaft pulley with special tool 970312374.

NOTICE: Apply grease on thread and tip of special tool (Center bolt) prior to use it.

4.

REMOVE TIMING GEAR CASE OIL SEA

(a)

Remove the oil seal with special tools 970312751, 970312374 and 970315564

NOTICE: Make sure that there is no damage like scratch on the inner− joint −face of the crankshaft after the oil seal removal. If it is found, please make the surface smooth by a sandpaper (#400).

970312751 970312374 970315564

5.

INSTALL TIMING GEAR CASE OIL SEAL

(a)

Apply a bit of MP grease to a new oil seal’s lip.

NOTICE: Keep the lip clean. Do not bring dirt and dust on that area. (b) Fit the oil seal by using special tool 970312376 and a hammer.

970312376

Acceptable depth from the top −flat −face of the timing gear case cover: 0 to −0.5 mm (0 to −0.020 in.)

NOTICE: Be sure to have the oil seal properly positioned when embedded.

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04 /20110 indice A

6.

INSTALL CRANKSHAFT PULLEY

(a)

Tighten the bolt with holding the crankshaft pulley using special tools 970312736 and 970312752 Torque: 365 N m (3722 kgf cm, 270 ft lbf)

7.

8.

9.

10.

INSTALL ALTERNATOR BELT ADD ENGINE COOLANT CHECK FOR ENGINE COOLANT LEAKS CHECK ENGINE OIL LEAK

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04 /20110 indice A

8. FUEL OIL SYSTEM [8.1] 1.

FUEL SYSTEM ON−BOAT INSPECTION

CHECK FUEL LEAK

WARNING • •

During ACTIVE TEST mode, engine speed and combustion noise increase, so pay attention.

During ACTIVE TEST mode, fuel pressure increases, so take care not to expose your eyes, hands, or body to the escaped fuel. (a) (b) (c) (d) (e) (f) (h) (i)

Check that there are no leaks from any part of the fuel system at the engine stops. If there is fuel leakage, replace these parts.

While cranking or start the engine, check that there are no leaks from any part of the fuel sys tem. If there is fuel leakage, replace these parts.

Disconnect the return hose from the common rail.

While cranking the engine, check fuel leaks from the return pipe. If there is fuel leakage, re place the common rail assembly.

Connect the Engine Diagnosis Tool.

Start the engine and start the Engine Diagnosis Tool.

If you have no Engine Diagnosis Tool, open the throttle quickly and fully to increase the engine speed at maximum and keep it for 2 seconds. Repeat this operation several times.

Check that there are no leaks from any part of the fuel system.

NOTICE: However, if the leakage from the return pipe is less than 10 cc (0.6 cu in.) in a minute, it is acceptable. If there is fuel leakage, replace these parts. (j)

Reconnect the return hose to the common rail.

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[8.2]

INJECTORS REPLACEMENT

8.21

INJECTORS ASSEMBLY COMPONENTS

182

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8.22

INJECTORS REPLACEMENT NOTICE: When removing the injection pipes, clean them up with a brush and compressed air.

1.

REMOVE INJECTION PIPE

NOTICE: • •

(a)

(b)

183

After removing the fuel pipe, affix the gum tape to outlets on the common rail to prevent dust from coming in.

After removing the fuel pipe, put a vinyl bag and rubber band to keep foreign objects from the injectors inlet.

Remove the injection pipe No. 1, No. 2 and No. 3.

(1) Remove the 2 bolts and injection pipe clamp No. 3.

(2) Remove the bolt and injection pipe clamp No. 2.

(3) Using the special tool 70804009, remove the injection pipe No. 1, No. 2 and No. 3.

Remove the injection pipe No. 4.

(1) Remove the bolt and disconnect the injecttion pipe clamp No. 1.

(2) Using the special tool 70804009, remove the injection pipe No. 4.

2.

REMOVE CYLINDER HEAD COVER.

(a) (b)

Remove the 4 nozzle holder seals.

Disconnect the ventilation hose .

(c)

Remove the 10 bolts, 2 nuts and cylinder head cover

04 /20110 indice A

Union Bolt

3.

REMOVE INJECTOR ASSEMBLY

(a)

Remove the nozzle leakage pipe assembly.

(1) Remove the union bolt, hollow screw and nozzle leakage pipe assembly.

NOTICE: • Hollow screw

• • (b)

Put a vinyl bag to keep foreign substances from over the injector.

When removing the return pipe, place a shop rag around the pipe.

Pay attention not to deform or scratch the union seal surface.

(c)

Remove the nozzle holder clamp.

(1) Remove the bolt, washer and nozzle holder clamp.

Remove the injector.

4.

INSTALL INJECTOR ASSY

NOTICE: Be sure to install the injector, nozzle holder clamp, washer and bolt to the removed cylinder. (a) (b)

Install a new injection nozzle sheet to the cylinder head.

Install a new O-ring and injector.

HINT: Apply a light coat of engine oil on the O−ring. (c)

Temporarily install the 4 injection pipes.

NOTICE:

O−ring

If the injector is replaced, the injection pipe must also be replaced.

HINT: Tighten the nut of injection pipe manually until fully screwed.

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(d) Union Bolt

(e)

Apply a light coat of engine oil on hollow screw and union bolt.

Temporarily install a new gasket and nozzle leakage pipe assy.

NOTICE:

Hollow screw

•

At this moment, insert the injector until it touches the nozzle sheet surface.

When installing the injector to the cylinder head and in case the injector comes to float up with the reaction of O −ring, pull out the injector once, and install it again.

After equipping the head cover and before installing the injection pipe, install protection from irregular objects.

Do not exchange the injector cylinder.

•

• •

HINT: Tighten the hollow screw and union bolt manually until fully screwed. (f)

Set the spring to each injector as shown in the illustration.

(g)

Install new washer and nozzle clamp with the bolt.

Nozzle clamp holder

Torque: 22 N m (220 kgf cm, 16 ft lbf)

NOTICE: • •

• • •

185

Clip the injector at the fork portion with a clamp which is set on the head of the cam cap bolt.

To fasten the clamp bolt, temporarily torque it manually until the bearing surface of the bolt touches the washer, then tighten by the specified torque.

When tightening by the specified torque, pay attention not to tilt the bolt and the clamp.

The washer can not be reused.

If the washer is tightened with too much torque, replace it with a new one.

04 /20110 indice A

Union Bolt

(h)

Tighten the 4 hollow screws from #1 to #4 in order.

Torque: 16 N m (163 kgf cm, 12 ft lbf)

NOTICE: In case of over −torque, replace the nozzle leakage pipe assembly with a new one.

Hollow screw

(i)

Tighten the union bolt.

Torque: 12.5 N m (127 kgf cm, 9 ft lbf)

NOTICE: In case of over −torque, replace the nozzle leakage pipe assembly with a new one.

5.

INSPECT FOR FUEL LEAKS

HINT: Check that there are no leaks from the nozzle leakage pipe assy. (a) (b)

(d)

Remove the fuel hose.

Apply a light coat of soapy water (any fluid to detect fuel leakage) on the nozzle leakage pipe assembly N°2 connection.

Using special tool 70804010 (turbocharger pressure gauge), apply the special tool to the fuel return side of the nozzle leakage pipe assembly N° 2, and maintain 100 kPa (1.0 kgf/cm2, 14.5 psi) of pressure for 60 seconds to check that there are no bubbles from applying the soapy water place.

Connect the fuel hose.

6.

INSTALL CYLINDER HEAD COVER

(a) (b)

Remove old seal packing from the cylinder head.

Apply a seal packing to the specific places described in the illustration.

(c)

Seal packing: 970312770 or equivalent

Seal Packing

NOTICE: • • •

186

After applying the seal packing, parts must be assembled within 3 minutes, and then tightened within 15 minutes.

Otherwise the material must be removed and reapplied.

Do not start the engine until 2 hours after the installation.

04 /20110 indice A

(c)

Install the cylinder head cover with 10 bolts and 2 nuts.

Torque: 9 N m (92 kgf cm, 80 in. lbf)

(d)

Install a new nozzle holder seal.

7.

INSTALL INJECTION PIPE

NOTICE: •

When replacing the injector, replace the injection pipe as well.

Keep the joint of the injection pipe clean .

• (a)

Install the injection pipe No. 1, 2 and 3.

(1) Temporarily install the injection pipes.

(2) Attach the injection pipe clamp No. 2 and No. 3.

Torque: 5 N m (51 kgf cm, 44 in. lbf)

HINT: •

Make sure to install the injection pipe clamps N°2 and N°3 in the correct position indicated by the painted marks on injection pipe N°2.

If the painted marks on injection pipe N°2 are erased, install the injection clamp N°2 and N°3 as shown in the illustration on page 184.

•

(3)

Fasten the unions sequentially, from the injection pipe common rail to the injector, using a union nut wrench (17 mm).

Torque: 32 N m (326 kgf cm, 24 ft lbf) for use with SST 35 N m (357 kgf cm, 26 ft lbf) (b)

Install the injection pipe No. 4.

(1) Temporarily install the injection pipe.

(2) Install a new injection pipe clamp No. 1.

Torque: 5 N m (51 kgf cm, 44 in. lbf)

NOTICE: • • Injection Pipe Clamp No. 1 (3)

Make sure the inner −rubber fits inside the clamp.

When installing the pipe, check that the inner −rubber and the clamp are in proper position.

Fasten the unions sequentially, from the injection pipe common rail to the injector, using a special tool 70804009 Torque: 32 N m (326 kgf cm, 24 ft lbf) for use with SST 35 N m (357 kgf cm, 26 ft lbf)

8.

187

CHECK FUEL LEAKS

04 /20110 indice A

[8.3]

HIGH PRESSURE PUMP REPLACEMENT

8.31

HIGH PRESSURE PUMP ASSEMBLY COMPONENTS

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8.32 1.

2.

3.

4.

5.

HIGH PRESSURE PUMP REPLACEMENT DRAIN ENGINE COOLANT REMOVE ALTERNATOR BELT REMOVE TIMING BELT COVER REMOVE TIMING BELT REMOVE FUEL INLET PIPE SUB−ASSEMBLY 6.

REMOVE SUPPLY PUMP ASSEMBLY

(a) (b)

Remove the 4 bolts first.

Remove both the camshaft timing pulley flange N°2 and pump drive shaft pulley

(c)

Remove the supply pump gear set nut and O−ring while holding the crankshaft pulley by using special tools 970312736 and 970312752.

(d)

Remove the 3 connectors from the supply pump first, as well as, disengage the 3 fuel hoses.

(e)

Loosen the 2 nuts shown in the illustration.

(f)

Disengage the supply pump from the supply pump gear by using special tools 970312374 Remove the 2 nuts and supply pump from the engine component.

Remove the O−ring.

970312736 and 970312752

970312374 (g) (h)

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8.

INSTALL SUPPLY PUMP ASSEMBLY

(a)

Confirm the supply pump gear in the timing gear case that moves in back−and−forth direction smoothly.

Install a new O−ring to the injection pump.

As fitting its projecting edge of the supply pump head to the key−slot of the supply pump gear, install the pump to the timing gear case.

With hold the supply pump by a hand, push the supply pump gear in rear side direction to joint the pump gear and drive shaft.

Temporarily install the supply pump with the 2 nuts.

(b) (c) (d) (e) (f) (g)

(h) (i)

970312736 and 970312752

Fix the crankshaft by special tools 970312736 and 970312752.

Set a new O−ring before tightening the supply pump gear set nut.

Torque: 64 N m ( 653kgf cm, 47ft lbf) Temporary install the supply pump stay with the 2 bolts on the engine block side.

Tighten the 2 nuts for the injection pump.

Torque: 21 N m (214 kgf cm, 16 ft lbf)

(j)

Fit the supply pump stay to the engine block, and install the 2 bolts for the supply pump side.

Torque: 21 N m (214 kgf cm, 16 ft lbf)

(k)

Fasten the supply pump stay on the engine block side.

Torque: 21 N m (214 kgf cm, 16 ft lbf)

(l)

Install the camshaft timing pulley flange N°2 and pump drive shaft with the 4 bolts.

Torque: 31 N m (316 kgf cm, 23 ft lbf)

(m)

Push the pump drive shaft pulley into back and forth to see a thrust clearance of the injection pump drive shaft.

Thrust clearance: 0.15 − 0.55 mm (0.0059 − 0.0217 in.)

NOTICE: Make sure the crankshaft pulley ’s notch is 30° counter clockwise from TDC position.

HINT: If there is no thrust clearance, disassemble and reassemble the injection pump and pump drive shaft pulley.

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9.

INSTALL FUEL INLET PIPE SUB−ASSEMBLY

NOTICE: • • •

Also, if the supply pump is replaced, the fuel inlet pipe must be replaced.

Beware of sticking dusts, dirt or any other materials onto the joint area of the fuel inlet pipe.

Use special tool 70804009

10.

11. (a)

INSTALL TIMING BELT INSTALL TIMING BELT COVER Install the timing belt cover with the 6 bolts.

Torque: 6 N m (61 kgf cm, 53 in. lbf)

12.

13.

14.

15.

INSTALL GENERATOR BELT ADD ENGINE COOLANT CHECK FOR ENGINE COOLANT LEAKS CHECK FUEL LEAK

[8.4]

FUEL TEMPERATURE SENSOR REPLACEMENT

1.

REMOVE FUEL TEMPERATURE SENSOR

(a) (b)

Disconnect the connector from the fuel temperature sensor.

Remove the temperature sensor using the special tool 970313928.

2.

INSTALL FUEL TEMPERATURE SENSOR

(a) (b)

Set a new O−ring to the fuel temperature sensor.

Install the temperature sensor using special tool 970313928.

Torque: 22 N m (225 kgf cm, 16 ft lbf)

(c)

Connect the connector to the temperature sensor.

3.

CHECK FUEL LEAK

[8.5]

COMMON RAIL REPLACEMENT

NOTICE: When removing the injection pipes and fuel inlet pipe, clean them up with a brush and compressed air.

1.

REMOVE OIL FILTER SUB−ASSEMBLY 2.

REMOVE FUEL INLET PIPE SUB−ASSEMBLY (a) Remove the fuel inlet pipe using the special tool 70804009

NOTICE: After removing the fuel pipe, affix gum tape on the pump, common rail, and the whole injector installation area of the cylinder head cover to prevent dust from coming into them.

3.

191

REMOVE INJECTION PIPE

04 /20110 indice A

4.

REMOVE NOZZLE LEAKAGE PIPE ASSY N°2

(a) (b)

Pull out the fuel hose.

Remove the check valve, bolt and union bolt, before remove the nozzle leakage pipe assembly N°2.

5.

REMOVE COMMON RAIL ASSEMBLY

(a) (b)

Pull out the fuel pressure sensor connector, and remove the 3 bolts.

Remove the common rail.

NOTICE: • •

Do not remove the pressure limiter.

Do not reuse the fuel pressure sensor.

6.

INSTALL COMMON RAIL ASSEMBLY

(a)

Install the common rail and tighten the bolts.

Torque: 38 N m (387 kgf cm, 28 ft lbf)

(b)

Connect the black connector of the fuel pressure sensor.

NOTICE: Do not connect the white connector. The white connector is the throttle sensor connector.

The fuel pressure sensor connector is shown in black in the ELECTRICAL WIRING DIAGRAM. The throttle sensor connector is shown in the natural colour in the ELECTRICAL WIRING DIAGRAM.

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9. ELECTRIC SYSTEM [9.1]

STARTING SYSTEM 1.

Terminal C

STARTER ASSEMBLY INSPECTION

NOTICE: These tests must be done within 3 to 5 seconds to avoid burning out the coil. (a)

Terminal 50

(b)

Disconnect Terminal C

(c)

(d) Terminal 50

Disconnect

Do pull−in test.

(1) Disconnect the field coil lead wire from terminal C. (2) Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward.

Do holding test.

(1) With battery connected as above with the clutch pinion gear out, disconnect the negative (−) lead from terminal C. Check that the pinion gear remains out.

Inspect clutch pinion gear return.

(1) Disconnect the negative (−) lead from the switch body. Check that the clutch pinion gear returns inward.

Perform the operation test without load.

(1) Connect the field coil lead wire to terminal C. Torque: 2.2 kw 5.9 N m (60 kgf cm, 52 in. lbf) (2) (3) (4)

Grip the starter with a vice.

Connect the battery and ammeter to the starter as shown.

Check that the ammeter reads the specified current.

Specified current: 2.2kw 120 A or less at 11.5 V

Terminal 50

Disconnect

2. STARTER RELAY ASSEMBLY Terminal 30

(a)

Terminal 50

Continuity inspection.

(1) Using an ohmmeter, check that there is continuity between each terminal.

Specified condition: Between terminals Specified condition

1 − 2 Continuity 3 − 5 No continuity

(2)

Using an ohmmeter, check that there is continuity between terminals 3 and 5 when the between voltage is applied across terminals 1 and 2.

Specified condition: Continuity

193

04 /20110 indice A

3.

STARTER ASSEMBLY REPLACEMENT

A) B)

DISCONNECT BATTERY NEGATIVE TERMINAL REMOVE STARTER ASSEMBLY (a) (b) (c)

C)

Disconnect the terminal 50 connector from the starter assembly.

Remove the nut, and remove the terminal 30 wire.

Remove the bolt and 2 nuts as well as the starter assy.

INSTALL STARTER ASSY (a) Install the starter assembly with the bolt and 2 nuts.

Torque: 68 N m (694 kgf cm, 49 ft lbf) (b)

Install the terminal 30 with the nut.

Torque: 9.8 N m (100 kgf cm, 7 ft lbf) for 2.2 kW

(c) D)

Connect the terminal 50 connector to the starter assembly.

CONNECT BATTERY NEGATIVE TERMINAL

[9.2]

CHARGING SYSTEM INSPECTION

WARNING 1.

2.

3.

4.

5.

Check that the battery cables are connected to the correct terminals.

Disconnect the battery cables when the battery is given a quick charge.

Do not perform tests with a high voltage insulation resistance tester.

Never disconnect the battery while the engine is running.

Check that the charging cable is tightened on terminal B of the generator and the fuse box.

ON−BOAT INSPECTION 1.

CHECK BATTERY ELECTROLYTE LEVEL (a) Check the electrolyte quantity of each cell (Maintenance−Free Battery).

(1) If under the lower level, replace the battery (or add distilled water if possible) and check the charging system. (b) Check the electrolyte quantity of each cell (Except Maintenance−Free Battery).

(1) If under the lower level, add distilled water.

2. (a)

CHECK BATTERY SPECIFIC GRAVITY (Except Maintenance −Free Battery) Check the specific gravity of each cell.

Standard specific gravity: 1.25 - 1.29 at 20°C(68°F)

HINT: If the specific gravity is lower than specified, charge the battery.

3. (a)

(b) (c)

CHECK BATTERY VOLTAGE After having driven the engine and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlight, blower motor etc.) for 60 seconds to remove the surface charge.

Turn the ignition switch OFF and turn off the electrical systems.

Measure the battery voltage between the negative (−) and positive (+) terminals of the battery.

Standard voltage: 12.5 - 12.9 V at 20°C (68°F) 194

04 /20110 indice A

HINT: If the voltage is lower than specified value, charge the battery. (d)

Check the indicator as shown in the illustration.

HINT: • • •

Blue: OK White: Charging Necessary Red: Insufficient Water

4. (a) (b)

CHECK BATTERY TERMINALS AND FUSES Check that the battery terminals are not loose or corroded.

Check the H- fuses and fuses for continuity.

5.

INSPECT DRIVE BELT

(a)

Visually check the belt for excessive wear, frayed cords etc…

HINT: • •

If any defect is found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced.

(b)

Check that it fits properly in the ribbed grooves.

HINT: Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.

6. (a)

VISUALLY CHECK ALTERNATOR WIRING Check that the wiring is in good condition.

7.

LISTEN FOR ABNORMAL NOISES FROM ALTERNATOR Check that there is no abnormal noise from the generator while the engine is running.

(a) 8. (a) (b)

INSPECT CHARGE WARNING LIGHT CIRCUIT Turn the ignition switch ON. Check that the charge warning light comes on.

Start the engine. Check that the light goes off.

HINT: If the light does not operate as specified, troubleshoot the charge warning light circuit.

9. (a) (b)

195

INSPECT CHARGING CIRCUIT WITHOUT LOAD If a battery/generator tester is available, connect the tester to the charging circuit as per manufacturer’s instructions.

If a tester is not available, connect a voltmeter to the charging circuit as follows.

(1) Disconnect to the wire from terminal B of the generator and connect it to the negative (−) lead of the ammeter.

04 /20110 indice A

Ammeter Disconnect Wire (c) from Terminal B

Alternator

2) Connect the positive (+) lead of the ammeter to terminal B of the alternator.

(3) Connect the positive (+) lead of the voltmeter to terminal B of the alternator.

(4) Ground the negative (−) lead of the voltmeter.

Check the charging circuit.

(1) With the engine running from idle to 2,000 rpm, check the reading on the amp meter and voltmeter.

Standard current: 10 A or less Standard voltage: 13.2 − 14.8 V

HINT:

Volt meter

•

If the voltmeter reading is over the standard voltage, replace the voltage regulator.

If the voltmeter reading is lower than the standard voltage, check the voltage regulator and generator as follows:

•

10. (a) (b)

INSPECT CHARGING CIRCUIT WITH LOAD With the engine running at 2,000 rpm, turn on the switch with “Hi” load.

Check the reading on the amp meter.

Standard current: 30 A or more

HINT: • • 11.

ALTERNATOR REPLACEMENT

A) B) C) D) (a)

DISCONNECT BATTERY NEGATIVE TERMINAL DRAIN ENGINE COOLANT REMOVE ALTERNATOR BELT REMOVE ALTERNATOR ASSEMBLY Disconnect the connector from the generator assembly.

Remove the nut, and remove the terminal B. Remove the 2 bolts and generator assembly.

(b) (c)

196

If the ammeter reading is lower than standard current value, repair the alternator.

When battery is fully charged, the indication may be lower than standard current value

12. (a)

INSTALL ALTERNATOR ASSEMBLY Install the generator assembly with the 2 bolts.

Torque: 62 N m (632 kgf cm, 46 ft lbf) (M10) 21 N m (214 kgf cm, 16 ft lbf) (M8)

(b)

Install the terminal B with the nut.

Torque: 9.8 N m (100 kgf cm, 7 ft lbf)

(c)

Connect the connector to the generator assembly.

13.

14.

15.

16.

INSTALL ALTERNATOR BELT ADD ENGINE COOLANT CHECK FOR ENGINE COOLANT LEAKS CONNECT BATTERY NEGATIVE TERMINAL

04 /20110 indice A

[9.3]

PREHEATING SYSTEM

9.31

GLOW PLUGS REPLACEMENT 1.

DISCONNECT BATTERY NEGATIVE TERMINAL REMOVE EDU SUPPORT SUB-ASSEMBLY REMOVE CYLINDER HEAD COVER REMOVE GLOW PLUG N°1 CONNECTOR Remove the screw grommet, nut and wire harness.

Remove the 4 screw grommets, 4 nuts and glow plug connector N°1.

2.

3.

4. (a) (b) 5. (a)

REMOVE GLOW PLUG ASSEMBLY Using a 12 mm deep socket wrench, remove the grow plug assembly.

6. (a)

INSTALL GLOW PLUG ASSEMBLY Using a 12 mm deep socket wrench, install the grow plug assy.

Torque: 13 N m (133 kgf cm, 10 ft lbf)

7. (a)

INSTALL GLOW PLUG N°1 CONNECTOR Temporarily install the glow plug connector N°1 with the 4 nuts, and then install it securely.

Torque: 2.2 N m (22 kgf cm, 19 in. lbf)

(b) (c)

Install the 4 screw grommets.

Install the wire harness with the nut.

Torque: 2.6 N m (27 kgf cm, 23 in. lbf)

(d)

Install the screw grommet.

8.

9.

10.

INSTALL CYLINDER HEAD COVER INSTALL ECU SUPPORT SUB-ASSEMBLY CONNECT BATTERY NEGATIVE TERMINAL

9.32 PREHEATING INSPECTION NOTICE: Turn the ignition switch OFF for 60 seconds before performing this inspection.

1. (a)

GLOW PLUG (SUB) RELAY ASSEMBLY Continuity inspection.

(1) Using an ohmmeter, check that there is continuity between each terminal.

Specified condition: Between terminal

Specified condition

1−2

No continuity

3−4

Continuity

(2)

197

Using an ohmmeter, check that there is continuity between terminals 1 and 2 when the battery voltage is applied across terminals 3 and 4.

Specified condition: Continuity 04 /20110 indice A

Lighting time (sec)

2. (a)

INSPECT LIGHTING TIME OF GLOW INDICATOR LIGHT Turn the ignition switch ON, and measure the lighting time. Glow indicator lighting time: Refer to the chart graph

Engine Water Temperature °C (°F)

Pre−heating Time (sec)

3. (a)

Battery Voltage [V]

Engine coolant temperature

Pre−Heating time

40°C or more

1 sec

40°C or less

Refer to the chart graph (15 sec at the longest)

(b) (c)

Turn the ignition switch STA, check the battery voltage is applied to the glow plugs.

While cranking the engine, measure the time when the battery voltage is applied to the glow plugs.

Pre−Heating time:

Engine coolant temperature

Pre−Heating time

40°C or more

1 sec

40°C or less

Refer to the chart graph (15 sec at the longest)

4. (a)

After Glow Time (sec)

INSPECT PRE−HEATING Turn the ignition switch ON, measure the time when the battery voltage is applied to the glow plugs.

Pre−Heating time:

INSPECT AFTER GLOW TIME After the engine starting, measure the time when the battery voltage is applied to the terminal SREL of the ECU. After glow time: Refer to the chart graph

Engine Water Temperature °C (°F)

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04 /20110 indice A

[9.4]

WIRING SYSTEM

9.41

ENGINE WIRING

199

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ENGINE WIRING SPARES PARTS 674435 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27)

29) 30)

Connected to the alternator ?

Fuel pressure sensor Fuel temperature sensor Fuel control valve E.D.U. outlet E.D.U. Inlet Control discharge valve Injector N°1 Injector N°2 Injector N°3 Injector N°4 Water temperature sensor (ECU) Air temperature sensor Air pressure sensor Starter solenoid Crankshaft position sensor Camshaft position sensor Accelerator Upper ECU connector Lower ECU connector Diagnostic box EDU relay support MAIN relay support Starter and Glow plug relays box Fuses box Water in fuel filter sensor

31) 32) 33) 34) 35)

Water temperature sensor (PANEL) Oil sensor (WK): remark: the connector should be modified Connector 32 on wire SW1 Connector 31 engine harness Panel 674455 or interface 940200007 Panel 674455 or interface 940200007 Panel 674455 or interface 940200007

H27) Oil sensor (G) P48 P4A P42

25A breaker 120A breaker 80A breaker

E1/E2/E3

Alternator ground

J08

Glow plug connectors

Masse

Ground above HP fuel pump

M15 Gear box neutral switch position sensor M16 Gear box neutral switch position sensor

200

04 /20110 indice A

ENGINE WIRING SPARE PARTS 674435

32 To connector 31 on the engine harness SW1 To battery switch

Q01 P49 P49A P49B P4A P71

To starter 120A breaker 80A breaker 25A breaker 120A breaker B+ Alternator

P49

P4A

P49B P48

P49A

P42

201

04 /20110 indice A

H27

J08

9

10

11

6 7

30

12

15 23

24

Masse

17

18

5

4

8

3

13

15

14

202

04 /20110 indice A

22

26 E1/E2/E3

970313326

1 P71

970313325

203

04 /20110 indice A

9.42

INTERFACE WIRING WARNING Since the January 2010, the engines are supplied with an interface reference 940200007. this interface is necessary to connect the engine with the new C4 panels reference 940100006.

204

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9.43

SENSORS AND RELAIS POSITIONS

WARNING •

If you need more information concerning the electronic parts please refer to the manual N° 60300183

970311309

970311310 22

Diagnostic connector

E.C.U. adapted to the engine 970311311 26

Fuse box

20

21

E1/E2/E3 29

P71

970314776 17

970314125 205

04 /20110 indice A

970314079

3

8

970314069 970314085 19 13

27

M15

M16 970312242

H27

30

18

48201143

4

970314124

970314088 970315393 5

970314051

206

04 /20110 indice A

970314079

970314089 7

19

6

970314155 23

24

970314084 15

14

970314086

970314123

207

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Nanni Industries S.A.S. 11, Avenue Mariotte ‐ Zone Industrielle 33260 La Teste France Tel : + 33 (0)5 56 22 30 60 Fax : +33 (0)5 56 22 30 79 E‐mail : contact@nannidiesel.com

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