ENGINE MAIN PARTS

1. Cylinder Head and Valve Mechanism .......................................... 7 – 1

1.1 Disassembly ................................................................................... 7 – 1
1.2 Inspection........................................................................................ 7 – 3
1.3 Reassembly .................................................................................... 7 – 9
2. Flywheel ............................................................................................... 7 – 11
2.1 Disassembly .................................................................................... 7 – 11
2.2 Inspection........................................................................................ 7 – 13
2.3 Reassembly .................................................................................... 7 – 14
3. Damper, Timing Gears and Camshaft .......................................... 7 – 15
3.1 Disassembly .................................................................................... 7 – 15
3.2 Inspection........................................................................................ 7 – 19
3.3 Reassembly .................................................................................... 7 – 23
4. Pistons, Connecting Rods, Crankshaft, Crankcase and Tappets ...... 7 – 29
4.1 Disassembly .................................................................................... 7 – 29
4.2 Inspection........................................................................................ 7 – 32 7
4.3 Reassembly .................................................................................... 7 – 45
 ENGINE MAIN PARTS

1. Cylinder Head and Valve Mechanism

1.1 Disassembly

1 Replace.

10
9
4 8

Check threads for stripping.

Check push rod contact 3 Check for wear.
face for wear.
5
Check valve cap contact face for wear.
2 Check oil hole for clogging.
Check for wear or
clogged oil hole. 7
12
6 Check end faces for wear.
11
Check for bend.
Check for pitted or 15
fractured coils.
16
Check for crackes, or carbon
Replace. 17 or scale deposits.
20
Check for wear. 14
21
Replace.
13

Check for uneven wear.

Check stem for scratches

or scuff marks.

19
18

Disassembly sequence
1 Rocker cover 8 Exhaust valve rocker arm 15 Valve cotter
2 Adjusting screw 9 Rocker shaft spring 16 Valve retainer
3 Bolt (short) 10 Rocker shaft 17 Valve spring
4 Bolt (long) 11 Valve cap 18 Inlet valve
Remove 5 through 10 as an assembly. 12 Pushrod 19 Exhaust valve
5 Rocker shaft bracket 13 Cylinder head bolt 20 Valve stem seal
6 Snap ring Remove 14 through 20 as an assembly. 21 Cylinder head gasket
7 Inlet valve rocker arm 14 Cylinder head

7-1
ENGINE MAIN PARTS

(1) Removing rocker shaft assembly

Adjusting screw
(a) Loosen the adjusting screw one rotation.
(b) Loosen the bolts, short and long, that hold the rocker
shaft bracket to the cylinder head. Be sure to loosen
the short bolt first. Remove the rocker shaft
assembly from the cylinder head.

CAUTION
If the long bolt is loosened first, the rocker shaft
bracket might suffer damage. Removing rocker shaft assembly

(2) Disassembling rocker shaft assembly

Put a mark on the rocker arm and shaft so that the arm can
be installed on the same shaft position from which it was
removed.

Disassembling rocker shaft assembly

(3) Removing cylinder head

Cylinder head
(a) Remove the cylinder head bolts.
(b) Lift the head off the crankcase.

NOTE
(1) When removing the gasket from the crankcase, be
careful not to damage the gasket contact surface of
the crankcase
(2) If any cylinder head parts are faulty, check the
cylinder head bolts for torque with a torque Removing cylinder head
wrench before removing them.

(4) Remove valve and valve spring

Valve spring pusher
(a) Use valve spring pusher (30691 - 04500) to
compress the valve spring, then remove the valve
cotters.
(b) Remove the valves and valve springs.

NOTE
If the original valves are to be reused, mark them for
their locations to ensure the original location and
combinations of the valve, valve seat and valve guide. Removing valve and valve spring

7-2
 ENGINE MAIN PARTS

1.2 Inspection
Rocker arms, rocker bushings and rocker shaft
(1) Measuring rocker arm bushing and rocker shaft
Measure the inside diameter of the rocker bushing and the
diameter of the rocker shaft as shown in the illustration.
Determine the clearance between the bushing and shaft on
the basis of the measurements. If the clearance does not
exceed the repair limit, replace the rocker arm. If it exceeds
the repair limit, replace the shaft and rocker arm.
Unit: mm (in.)
Nominal Assembly Repair
Item
Value Standard Limit
Inside diameter of 19.010 to 19.030
— Measuring rocker arm bushing and
rocker bushings 19 (0.7484 to 0.7492)
rocker shaft
Diameter of (0.75) 18.980 to 19.000
—
rocker shaft (0.7472 to 0.7480)
Clearance
0.010 to 0.050 0.070
between rocker —
(0.0004 to 0.0020) (0.0028)
bushing and shaft

Valves, valve guides and valve seats

(1) Measuring valve stem
Measure the diameter of the valve stem as shown in the Measuring
diagram
illustration. If the stem is worn beyond the service limit or
unevenly worn excessively, replace the valve.
Unit: mm (in.)
Nominal Assembly Service
Item
Value Standard Limit
Inlet 7.940 to 7.955 7.900
Diameter valve 8 (0.3126 to 0.3132) (0.3110)
of value (0.31)
stem Exhaust 7.920 to 7.940 7.850
valve (0.3118 to 0.3126) (0.3091) Measuring valve stem

7-3
ENGINE MAIN PARTS

(2) Checking clearance between valve stem and valve

guide Measuring
diagram
The valve guide wears more rapidly at its both ends than at
any other parts. Measure the inside diameter of the guide at
its ends as shown in the illustration to determine the
clearance between the guide and stem. If clearance exceeds
the service limit, replace the valve or guide whichever is
excessively worn.
Unit: mm (in.)
Nominal Assembly Service
Item Measuring valve guide
Value Standard Limit
Clearance Inlet 0.065 to 0.095 0.150
between —
valve (0.0026 to 0.0037) (0.0059)
valve
stem and Exhaust 0.080 to 0.115 0.200
—
guide valve (0.0032 to 0.0045) (0.0079)
Height to top of 14 ±0.1
—
valve guide (0.55) (±0.004)

(3) Replacing valve guide

(a) Use the valve guide remover (32A91 - 00300), to Valve guide remover
remove the valve guide for replacement.

Removing valve guide

(b) To install a replacement guide, use valve guide

installer (32A91 - 00100).
Press Valve guide installer

CAUTION
The installation depth for the valve guide is 14±0.1 mm
specified; be sure to use the valve guide (0.55±0.004 in.)
installer to insure the correct depth.

Installing valve guide

7-4
 ENGINE MAIN PARTS

(4) Inspecting valve face

Coat the valve face lightly with red lead. Use the Valve
lapper to inspect the valve contacts with its seat. If the
contact is not uniform, or if the valve is defective or if the Valve lapper
repair limit is exceeded, repair or replace the valve and
valve seat.

NOTE
Red lead
(1) Inspect the valve face after the inspection or
replacement of the valve guide.
Inspecting valve face
(2) Do not rotate the valve when checking its contact.
(3) After refacing or replacing the valve or the valve
seat, be sure to lap the valve in the seat. (See (8)
Valve lapping.)

Unit: mm (in.)
Assembly Service
Item
Standard Limit
Good Bad
Angle 30° —
Inlet 0.4±0.1
Valve (0.016±0.004) 1.0 Valve contact pattern
Valve
Valve
sinkage Exhaust 0.5±0.1 (0.039)
seat
Valve (0.020±0.004)
Valve seat
1.4±0.14 1.8 width
Width
(0.055±0.0055) (0.071)
Up to 1.83
Valve margin 2.13 (0.0839) (0.0720) Valve seat
by refacing angle

Valve margin
Valve sinkage

Valve sinkage

(5) Refacing valve face

If the valve face is badly worn, reface it with a valve
refacer.

NOTE
(1) Set a valve refacer to an angle of 30°.
(2) The valve has a stellate facing. This facing will be
gone if the valve margin exceeds the service limit.
If the margin seems to be less than the service
limit when ground, replace the valve.
Refacing valve face

7-5
ENGINE MAIN PARTS

(6) Refacing valve seat

Use the valve seat cutter or valve seat grinder to reface the
valve seat. After refacing, grind the seat lightly using #400
grade sandpaper inserted between the cutter and valve seat.
Valve seat cutter

NOTE
(1) Cut or grind the valve seat only as needed for
refacing.
(2) Replace the valve seat if the seat width is more
than the repair limit as a result of wear or cutting.
Refacing valve seat

(7) Replacing valve seat

(a) Weld a stud to the valve seat. Insert a shaft into the
valve guide holder from the upper side of the Weld
cylinder head. Drive the seat off from the cylinder Shaft
head as shown. Valve seat

NOTE
When you weld the stud, do not to permit splatter to
come in contact with the machined surfaces of Stud
cylinder head.
Removing valve seat

(b) Before installing replacement valve seats in the Unit: mm (in.)

cylinder head, measure the bores in the cylinder head
(0.315±0.004)

(0.079±0.004)

(0.079±0.004)

(0.315±0.004)
for the valve seats.
8±0.1

2±0.1

2±0.1

8±0.1

46 +0.025
0 37 +0.025
0
+0.00098
45° (1.811 0 ) (1.457 +0.00098
0 ) 45°

Inlet valve Exhaust valve

seat bore seat bore

Valve seat dimensions

(c) Chill the valve seat in liquid nitrogen of –170°C

(–274°F) for more than 4 minutes with the cylinder Insert
head kept at normal temperature, or heat the cylinder caulking tool
head up to 80 to 100°C (176 to 212°F) with the valve
seat chilled in ether or alcohol containing dry ice.
(d) Using insert caulking tool, drive the seat into
position.
Special tool needed
Insert caulking tool
36791 - 00200
(for inlet valve seat)
Installing valve seat
Insert caulking tool
34491 - 03020
(for exhaust valve seat)
7-6
 ENGINE MAIN PARTS

(8) Lapping valve in valve seat

Be sure to lap the valve in the valve seat after the valve or
the seat have been replaced.
(a) Coat the valve face lightly with a lapping
compound.

NOTE Compound
(1) Do not permit the compound to come in contact
with the valve stem.
(2) Use a compound of 120 to 150 mesh for initial Coating valve with lapping compound
lapping and the compound finer than 200 mesh for
finish lapping.
(3) Mixing the compound with a small amount of
engine oil will facilitate coating.

(b) Using lapping tool, hold the valve against the seat
and rotate it only a part of a turn, then raise the
valve off the seat, rotating it to a new position. Then
Valve lapping toolx
press the valve against the seat for another part of a
turn. Repeat this operation until the compound
wears and loses it cutting particle.
(c) Wash off the compound with diesel fuel.
(d) Apply the valve face to the engine oil, and again lap
the valve.
(e) Check the valve face for contact.
Lapping valve in valve set

(9) Measuring valve spring perpendicularity and free

length
Measure the free length and perpendicularity of each valve Perpendicularity
spring. If the free length or perpendicularity exceeds the
service limit, replace the spring.
Unit: mm (in.) Free
length
Assembly Service
Item
Standard Limit
47.60
Free length 48.85 (1.92)
(1.87) Measuring valve spring perpendicularity
Perpendicularity 1.5° or less — and free length

Set length 43 (1.69) —

176 to 196 N 147 N
Set force (18 to 20 kgf) (15 kgf)
[40 to 44 lbf] [33 lbf]

7-7
ENGINE MAIN PARTS

Cylinder head, push rods and combustion jets

(1) Measuring cylinder head warpage
Using a heavy accurate straight edge and feeler gauge,
check the gasket contact surface for warpage in two
positions across the cylinder head width, two diagonal
measurements across the length and two at the outer edge
of the cylinder head, as shown in the illustration. If the
warpage exceeds the repair limit, reface the head with a
surface grinder.
Assembly Repair
Item
Standard Limit
Measuring cylinder head warpage
Warpage of gasket 0.05 mm (0.0020 in.) 0.20 mm
contact surface or less (0.0079 in.)

(2) Measuring valve pushrod deflection

Measure the pushrod deflection with a V-block and a dial
indicator as shown in the illustration. If the dial indicator
reading exceeds the assembly standard, replace the
pushrod.

Item Assembly Standard

Deflection (dial indicator reading) 0.3 mm (0.012 in.)
of valve pushrod or less
Measuring valve pushrod deflection

(3) Replacing Combustion Jet Round bar

Replace the combustion jets when they are cracked or

otherwise faulty.
(a) To remove the combustion jet, tap the jet off the
cylinder head with a 6 mm (0.24 in.) diameter round Combustion
jet
bar inserted through the glow plug hole as shown in
the illustration.

Removing combustion jet

(b) To install a replacement jet, position the jet so that

the orifice faces toward the center of the cylinder
Combustion
and drive it into position with a plastic hammer. jet

Orifice

Installing combustion jet

7-8
 ENGINE MAIN PARTS

1.3 Reassembly
(1) Installing valve and valve spring
Valve spring pusher
(a) Put the valve spring and retainer on the valve guide.
Using valve spring pusher (30691 - 04500),
compress the valve spring and install the valve
cotters.

Installing valve and valve spring

(b) Tap the valve stem top with a soft-faced hammer

several times to make sure the valve spring and
cotters are properly installed.

Installing valve cotters

(2) Installing cylinder head

(a) Put the gasket on the top of the crankcase, making Cylinder head
sure the two dowel pins enter their holes in the gasket.
(b) Put the cylinder head on the crankcase, making sure
Dowel pin
the two dowel pins enter their holes in the head.
Tighten the head bolts.

CAUTION
Do not use any sealant. Make sure the gasket
Dowel pin
contact surface of the crankcase is free from
any defects.
Installing cylinder head

(c) Tighten the cylinder head bolts to the specified

torque in the sequence shown in the illustration.

113 to 123 N·m Front

Tightening torque for
(11.5 to 12.5 kgf·m)
cylinder head bolts
[83 to 90 lbf·ft]

No. of bolts: 25

Cylinder head bolt tightening sequence

7-9
ENGINE MAIN PARTS

(3) Reassembling rocker shaft

Alignment mark
When reassembling the rocker arms, make sure that the
alignment marks on the shaft point forward the engine.
After reassembling the rocker shafts, make sure the rocker
arms move smoothly.

Reassembling rocker shafts

(4) Installing rocker shaft assembly

Short
(a) Install the valve caps in position. bolt
(b) Put the rocket shaft assembly on the cylinder head
and tighten the bolts to the specified torque.

Long
10.0 to 20.0 N·m bolt
Tightening torque for
(1.0 to 2.0 kgf·m)
rocker shaft bolts
[7.23 to 14.5 lbf·ft]

NOTE Installing rocker shaft assembly

Be sure to tighten the long bolt first.

(5) Adjusting valve clearance

(Refer to section 1.1 of Group 5.)

Adjusting valve clearance

7-10
 ENGINE MAIN PARTS

2. Flywheel

2.1 Disassembly

4
2

Replace gasket.

Check for cracks or

defective dowel hode.
Check for worn
or defective lip.

Check for cracks or Check for stripped

defective dowel hole. threads.

Disassembly sequence
1 Flywheel Remove 2 and 3 as an assembly. 4 Rear gasket
2 Rear plate
3 Oil seal

7-11
ENGINE MAIN PARTS

(1) Removing flywheel

Safety bar
(a) Remove one of the bolts that hold the flywheel to
the crankshaft.
(b) Run safety bar (M12 × 1.25) in the hole from which
the bolt was removed in Step (a). Remove the
remaining flywheel bolts.
(c) Remove the flywheel from the crankshaft by pulling
it straight.

CAUTION
Removing flywheel
When removing the flywheel, wear heavy gloves
to avoid injury.

(2) Removing rear plate

Oil seal
Remove the bolts that hold the rear plate to the crankcase.
Remove the rear plate.

CAUTION
Do not cause damage to the oil seal.

Removing rear plate

7-12
 ENGINE MAIN PARTS

2.2 Inspection

Flywheel and ring gear

(1) Flatness (difference between lower and higher
measurements) of flywheel
Put the flywheel on the surface plate. Set a dial indicator at
one side of the friction surface and move it over to the
opposite side of that surface as shown in the illustration. If
the surface flatness is over the repair limit, regrind it.
Unit: mm (in.)
Assembly Repair
Item
Standard Limit
Flatness of flywheel 0.15 (0.0059) 0.50
friction surface or less (0.020) Measuring flywheel flatness

(2) Face runout of flywheel

Measure the runout of the flywheel installed on the
crankshaft. If the runout exceeds the assembly standard,
check for loose bolts or obstacles lodged between the
mounting faces of the flywheel and crankshaft.
Unit: mm (in.)
Assembly Repair
Item
Standard Limit
0.15 (0.0059) 0.50
Face runout of flywheel
or less (0.020)
Measuring flywheel runouts
(3) Ring gear replacement
Check the ring gear teeth and, if they are defective, replace
the gear as outlined below.

(Removal)
(a) Heat the ring gear evenly with an burner.
(b) Hit the ring gear all the way around with a bar and a
hammer to remove it.

(Installation) Removing ring gear

Heat a replacement ring gear up to 100°C (212°F) with a

heater, and install the gear to the flywheel placing the
unchamfered side of the teeth to the flywheel.

CAUTION
Do not heat the ring gear excessively.

7-13
ENGINE MAIN PARTS

2.3 Reassembly
(1) Installing oil seal
Apply a thin coat of grease to the oil seal and install the oil Rear plate
seal to the rear plate with an installer.
Make sure that the oil seal face is flush with rear plate. Engine side Flywheel side

NOTE
If the oil seal contact surface of the crankshaft is
Oil seal
excessively worn, use an oil seal with sleeve.

Installing oil seal

(2) Installing rear plate

(a) Apply engine oil to the oil seal lip. Apply engine oil.
(b) Aligning holes to the dowel pins on the crankcase,
install the rear plate and gasket together to the
crankcase.
(c) Tighten the rear plate mounting bolts to the specified
torque.

54.0 to 65.7 N·m

Tightening torque for
(5.5 to 6.7 kgf·m)
rear plate
[39.8 to 48.5 lbf·ft] Installing rear plate

(3) Installing flywheel

(a) Install the flywheel in place by using the dowel pins
Safety bar
on the crankshaft for alignment.
Flywheel
(b) Install the spring washers and bolts, and tighten the
bolts to the specified torque.
(c) Have someone hold the crankshaft pulley nut with a
wrench.
(d) Tighten the bolts that hold the flywheel to the
specified torque.

78.5 to 88.3 N·m Installing flywheel

Tightening torque for
(8.0 to 9.0 kgf·m)
flywheel bolts
[57.9 to 65.1 lbf·ft]

CAUTION
During installation, signal to each other to avoid
personal injury.

7-14
 ENGINE MAIN PARTS

3. Damper, Timing Gears and Camshaft

3.1 Disassembly

Replace O-ring.

Replace gasket.
11
Check for wear or damage.
8

13
12
Check teeth for wear,
nicks, burrs or chips.
Check keyway and
bushing for damage 7
or wear. 10

Replace
15 O-ring.

6
Check for wear.
5
9

Check for worn or Replace gasket.

damaged lip.
Check for cracks or
defective dowel holes.

Check for cracks or

defective dowel holes. Replace
2 O-ring.
3
Check for worn
belt grooves.

Check for stripped threads.

Disassembly sequence
1 Damper 6 Thrust plate Remove 11 through 13 as an assembly.
2 Crankshaft pulley 7 Idler gear 11 Camshaft
3 Gear case cover 8 Fuel injection pump 12 Camshaft gear
4 Timing gear case 9 Oil pan 13 Thrust plate
5 Oil pump gear 10 Oil strainer 14 Front plate
15 Oil pump

7-15
ENGINE MAIN PARTS

(1) Removing damper

(a) Install two safety bars (M12 × 1.25) in the rear end
of the crankshaft to hold the crankshaft.
(b) Remove the damper.

WARNING
Be sure to install the safety bars securely.

Removing damper

(2) Removing crankshaft pulley

Remove the pulley from the crankshaft as shown.

Removing crankshaft pulley

(3) Removing timing gear case assembly

Remove the timing gear case assembly as shown.

CAUTION
Do not cause damage to the oil seal.

Oil seal

Removing timing gear case assembly

(4) Measuring backlash and end play

Make a record of the backlash and end play measurements
to be referred to for reassembly. (Refer to section 3.2.)

Measuring backlash and end play

7-16
 ENGINE MAIN PARTS

(5) Removing oil pump gear

Loosen the nut and remove the gear.

Removing oil pump gear

(6) Removing idler gear

Remove the thrust plate and remove the gear as shown.

Removing idler gear

(7) Removing oil pan

Remove bolts to remove oil pan.

Bolt

Oil pan

Removing oil pan

(8) Removing oil strainer

Remove the oil strainer mounting bolt and then remove oil
strainer and stay.
Oil strainer
Stay

Bolt Bolt

Removing oil strainer

7-17
ENGINE MAIN PARTS

(9) Removing camshaft

(a) Turn the crankcase upside down.
(b) Position the camshaft gear so that its lightening
holes come to top and bottom. Remove the bolts
that hold the thrust plate. Remove the camshaft
from the crankcase.

CAUTION
Do not cause damage to the lobe faces of the
camshaft and the bushings.
Removing camshaft
(10)Removing camshaft gear
Remove the gear from the camshaft with a puller. Now the
thrust plate can be removed.

NOTE
Do not remove the camshaft gear and thrust plate
unless they are damaged to the extent of requiring
replacement.

Removing camshaft gear

(11) Removing front plate

Remove the bolts that hold the front plate to the crankcase.
Remove the front plate.

Front plate

Removing front plate

(12) Removing oil pump

Remove the oil pump mounting bolts and then remove oil
pump.

Bolt O-ring
Oil pump

Removing oil pump

7-18
 ENGINE MAIN PARTS

3.2 Inspection

Camshaft and camshaft bushings

(1) Measuring camshaft end play
Measure the camshaft end play as shown in the illustration.
If the end play exceeds the service limit, replace the thrust
plate.
Unit: mm (in.)
Assembly Service
Item
Standard Limit
0.10 to 0.25 0.30
End play of camshaft
(0.0039 to 0.0098) (0.0118)

Measuring camshaft end play

(2) Measuring cam lift

To find the cam lift, use the procedure that follows: Measuring diagram
(a) Measure lobe height A.
(b) Measure base circle B.
(c) Subtract base circle B from the lobe height A. The
difference is lobe lift C.
If the cam lift is less than the service limit, replace the
camshaft.
Unit: mm (in.)
Assembly Service Measuring cam lift
Item Nominal Value
Standard Limit
Inlet A = 46.916 +0.1
–0.3 6.684 6.184 C
+0.004
Cam lift valves (1.8471 –0.012 ) (0.2632) (0.2435)
C +0.1
Exhaust A = 46.880 –0.3 6.720 6.220
valves (1.8457 +0.004
–0.012 ) (0.2646) (0.2450)
A

Cam profile

7-19
ENGINE MAIN PARTS

(3) Measuring camshaft deflection

Support the camshaft on its front and rear journals in V-
blocks. With the dial indicator set at 0.00 mm (0.0000 in.)
at the center journal, turn the camshaft one full revolution
and read the indicator, as shown in the illustration. 1/2 of
the reading on the indicator is the deflection of the
camshaft. If deflection exceeds the repair limit, straighten
the camshaft by cold working, or replace it.
Unit: mm (in.)
Assembly Repair
Item Measuring camshaft deflection
Standard Limit
0.02 (0.0008) 0.05
Camshaft deflection
or less (0.0020)

(4) Clearance between camshaft journals and bushings

Measuring diagram
Measure the diameter of the camshaft journals and the
inside diameter of the bushings in the crankcase to check
the clearance between the journal and bushing. If the
clearance exceeds the service limit, replace the bushings.
Unit: mm (in.)
Nominal Assembly Service
Item
Value Standard Limit
No.1, 54 53.94 to 53.96 53.90
Diameters 2, 3 (2.13) (2.1236 to 2.1244) (2.1220)
of camshaft
journals 53 52.94 to 52.96 52.90 Measuring camshaft journals
No.4
(2.09) (2.0843 to 2.0850) (2.0827)

Unit: mm (in.)
Assembly Repair
Item
Standard Limit
Clearance between
0.040 to 0.119 0.15
camshaft journals and
(0.0016 to 0.0047) (0.0059)
bushing

Measuring camshaft bushings

7-20
 ENGINE MAIN PARTS

(5) Replacing camshaft bushings

Adaptor
Piece Bushing
(a) To replace or install bushings, use camshaft Bushing
Adaptor
bushings installer set (30691 - 00010).
(b) Install bushings with their oil holes aligned with the
holes leading to the oil gallery.

Rod
Rod Oil holes

Removal Installation

Replacing camshaft bushings

Timing gears
Backlash
Put a dial indicator on the gear along its pitch circle as
shown. Hold it tightly in place. Move one of the mating
gears back and forth to check the backlash. If the backlash
exceeds the service limit, replace the worn gears.
Unit: mm (in.)
Assembly Service
Item
Standard Limit
0.03 to 0.18 0.25 Measuring timing gear backlash
Backlash
(0.0012 to 0.0071) (0.0098)

NOTE
Install the injection pump drive gear to the front plate
in the state of being installed on the injection pump.

Idler gear, bushing and shaft

(1) Measuring idler gear end play
Measure the idler gear end play with feeler gauges or a dial
indicator as shown in the illustration. If the end play
exceeds the service limit, replace the thrust plate.
Unit: mm (in.)
Assembly Service
Item
Standard Limit
0.05 to 0.20 0.35
End play of idler gear
(0.0020 to 0.0079) (0.0138)

Measuring idler gear end play

7-21
ENGINE MAIN PARTS

(2) Measuring clearance between idler gear bushing and

shaft Measuring
diagram
Measure the inside diameter of the bushing and the
diameter of the shaft to determine the clearance between
the two. If the clearance exceeds the service limit, replace
the idler gear or shaft.
Unit: mm (in.)
Assembly Service
Item
Standard Limit
Clearance between idler 0.009 to 0.050 0.100
gear bushing and shaft (0.0004 to 0.0020) (0.0039) Measuring clearance between idler gear
bushing and shaft

(3) Removing idler gear shaft

Idler gear shaft puller
To remove the idler gear shaft for replacement, use idler
shaft puller (MH061077).

Removing idler gear shaft

Crankshaft pulley
Check the V-belt groove for wear. Wrap a new belt around
the pulley, pressing it in the groove as far as it goes, and
see if the top surface of the belt is above the top of the 1.6 mm
pulley. (0.06 in.)

If the top surface of the new belt is uniformly above the top
of the pulley all the way around, it is not necessary to
replace the pulley.
If the top surface of the new belt sinks into the groove more
Inspecting V-belt groove
than 1.6 mm (0.06 in.), replace the pulley.

7-22
 ENGINE MAIN PARTS

Damper
Check the damper for cracks, silicone oil leakage,
discoloration due to excessive heating, and flaking.
Replace the damper with a new part after 8000 service
hours, even when no defect is observed.
Measure the circular runout and face runout with a dial
gauge. If the runout exceeds the service limit, replace the
damper.
Unit: mm (in.) Inspecting damper
Assembly Service
Item Remark
Standard Limit
Circular runout Replace after
0.5 (0.020) 1.5
8000 service
Face runout or less (0.0591)
hours

Face runout

Circular runout

Inspection damper runout

3.3 Reassembly
(1) Installing oil pump
Install a new O-ring to the pump case and mount the oil
pump to the crankcase.

Bolt O-ring
Oil pump

Installing oil pump

(2) Installing front plate

(a) Put the gasket on the crankcase, making sure the
dowels enter the holes in the gasket.
(b) Tighten the bolts that hold the front plate to the
crankcase to the specified torque.

10.0 to 13.0 N·m

Tightening torque for
(1.0 to 1.3 kgf·m)
front plate bolts
[7.23 to 9.40 lbf·ft]

Installing front plate

(c) Cut off the excess of the gasket with a cutter.
7-23
ENGINE MAIN PARTS

(3) Installing camshaft gear and thrust plate

(a) Heat the camshaft gear for installation.
(b) Have the thrust plate installed in advance.

Thrust plate
Canshaft gear

Installing camshaft gear and thrust plate

(4) Installing camshaft

(a) Apply engine oil to the lobes and journals of the
camshaft.
(b) Carefully put the camshaft in the bore in the
crankcase.
(c) Tighten the bolts that hold the thrust plate to the
specified torque.

10.0 to 13.0 N·m

Tightening torque for
(1.0 to 1.3 kgf·m)
front plate bolts Installing camshaft
[7.23 to 9.40 lbf·ft]

CAUTION
Do not cause damage to the lobes and bushings.

(5) Installing oil strainer

Install the oil strainer.

Oil strainer
Stay

Bolt Bolt

Installing oil strainer

7-24
 ENGINE MAIN PARTS

(6) Installing fuel injection pump

Fuel injection Bracket
Mount the fuel injection pump with mounting bolts. pump

CAUTION
When reassembling separated fuel injection
pump assembly and flange plate, be sure to Bolt
align the marks placed on the flange before Gear Oil pipe
disassembly to ensure proper reassembly.
The same procedure must be followed when Bolt
installing a new fuel injection pump assembly.
Installing fuel injection pump

(7) Installing idler gear

(a) Install the idler gear by aligning its matching mark
with those on the crankshaft gear, injection pump
gear and camshaft gear and install the thrust plate.
(b) Tighten the thrust plate mounting bolts to the
specified torque.

29.0 to 39.0 N·m

Tightening torque for
(3.0 to 4.0 kgf·m)
thrust plate bolts
[21.7 to 28.9 lbf·ft]
Installing idler gear

(c) The marks on the gears will be aligned as shown

when the No.1 piston is at top dead center of Camshaft Idler gear

compression stroke.

Fuel injection
pump gear
Crankshaft
gear

Marks on timing gears

(8) Installing oil pump gear

(a) Install the gear to the oil pump shaft.
(b) Tighten the jam nut to the specified torque.

28.0 to 38.0 N·m

Tightening torque for
(2.9 to 3.9 kgf·m)
jam nut
[21.0 to 28.2 lbf·ft]

Installing oil pump gear

7-25
ENGINE MAIN PARTS

(9) Inspecting and adjusting after reassembly

Timing gear backlash and end play
After installing the timing gears, check the backlash and
end play and, if necessary, adjust them. (Refer to section
3.2.)

Inspecting backlash and end play

(10) Inspecting valve timing TDC

30° 30°
It is not necessary to inspect the valve timing, provided that
all match marks on the timing gears are aligned. Inspect the Turning
timing for verification as explained below: direction
(a) Using a 3 mm (0.12 in.) thick smooth steel plate, Intake
Exhaust
add 3 mm (0.12 in.) clearance to the inlet and
exhaust valves of the No.1 cylinder.
(b) Put a 0.05 mm (0.0020 in.) feeler gauge between the 74°
50°
top of the valve cap and the rocker. BDC

(c) Slowly turn the crankshaft to find a position where Valve timing diagram
the feeler gauge is firmly gripped (the valve starts
opening) and a position where the gauge is just TDC
ungripped (the valve starts closing). 24° 18°
Turning
(d) Check to make sure these positions agree with the
direction
angular positions shown in the valve timing diagram Intake
with 3 mm (0.12 in.) clearance added to the valves. Exhaust

20°
2°
BDC

Valve timing diagram with 3 mm (0.12 in.)

clearance added

(11) Installing oil seal (if necessary)

Apply a small amount of grease to the oil seal and install it
to the timing gear case with an installer.

Installing oil seal

7-26
 ENGINE MAIN PARTS

(12) Installing timing gear case

(a) Put the gasket on the front plate, making sure the
dowels enter their holes in the gasket.
(b) Apply oil to the lip of the oil seal.
(c) Tighten the bolts that hold the timing gear case to
the specified torque.

17.0 to 20.0 N·m

Tightening torque for Oil seal
(1.7 to 2.0 kgf·m)
timing gear case bolts
[12.3 to 14.5 lbf·ft]
Installing timing gear case

(13) Installing oil pan

Put ThreeBond 1207C along heavy line.
(a) Clean the mounting surfaces of the crankcase,
timing gear case and oil pan.
(b) Squeeze out a 4 mm (0.2 in.) thickness of
ThreeBond 1207C (32A91 - 05100) from the tube
and put it on the oil pan flange.
(c) Install the oil pan to the crankcase within 5 minutes
after putting ThreeBond 1207C.
(d) Tighten the bolts to the specified torque.

10.0 to 13.0 N·m Oil pan flange to be coated with

Tightening torque for ThreeBond 1207C
(1.0 to 1.3 kgf·m)
oil pan bolts
[7.23 to 9.40 lbf·ft]

NOTE
To squeeze out a 4 mm (0.2 in.) thickness of
ThreeBond, cut the first node of the nozzle.
Cut nozzle here.

Nozzle for ThreeBond 1207C tube

7-27
ENGINE MAIN PARTS

(14) Installing crankshaft pulley

Install two safety bars (M12 × 1.25) to the rear end of the
crankshaft. Put a bar between the safety bars to hold the
crankshaft. Under this condition, install the crankshaft
pulley and tighten the nut to the specified torque.

480 to 500 N·m

Tightening torque for
(49 to 51 kgf·m)
crankshaft pulley nut
[354 to 369 lbf·ft]

Installing crankshaft pulley

WARNING
Be on standby to act if the safety bar comes off
inadvertently.

(15) Installing damper

Hold the crankshaft with safety bars and install the damper.

Installing damper

7-28
 ENGINE MAIN PARTS

4. Pistons, Connecting Rods, Crankshaft, Crankcase and Tappets

4.1 Disassembly

Check for wear, scoring, 4 Check for wear or damage.

cracking, damaged or
widened ring grooves, 5 Check for scale deposits,
clogged oil drain holes corrosion or other defects.
6 Check for fatigue.
or carbon deposits.
19
Check for wear.
8 Check for wear.
7
9 Check for wear
or cracking.
14
Check for wear or
clogged oil hole.
10

Check for
stripped thread.

3
Check for pitting, flaking,
17
chipping, cracking, loss
of overlay or signs of
overheating. 2
18
1

16

Check for cracking, scoring,

wear or clogged oil hole.
15

Check for nicking, chipping

or abnormal tooth contact.
14

13
12
14
Check for scratching, pitting, flaking,
chipping or loss of overlay.

NOTE: When replacing the crankcase, Check for stripped thread.

carefully remove the components Check for
(such as an oil pressure relief 11
cracking.
valve, etc.) to reuse them.

Disassembly sequence
1 Nut 7 Snap ring 14 Thrust plate
2 Connecting rod cap 8 Piston pin 15 Main bearing (lower half)
3 Connecting rod bearing 9 Piston 16 Crankshaft
Remove 4 through 10 as an assembly. 10 Connecting rod 17 Main bearing (upper half)
4 Top compression ring 11 Bearing cap bolt 18 Tappet
5 Second compression ring 12 Main bearing cap 19 Crankcase
6 Oil ring 13 Side seal

7-29
ENGINE MAIN PARTS

(1) Removing connecting rod cap

(a) Remove the nuts that hold the cap to the connecting
rod. Tap the bolts squarely and evenly with a
hammer and, after the cap comes off the reamer
bolts, remove the cap.
(b) Mark the bearings for cylinder number and location.

Removing connecting rod cap

(2) Preparation before removing pistons

(a) Lay the crankcase on its side.
(b) Use a cloth or oil paper to remove all carbon
deposits from the upper areas of the cylinder liner. If
any carbon deposits are present, this will make it
difficult to pull a piston upward.

Removing carbon from cylinders

(3) Removing piston
(a) Turn the crankshaft to bring the piston (from which
the connecting rod cap has been removed) to top
dead center.
(b) Put the handle of a hammer on the big-end of the
connecting rod and push the piston assembly off the
cylinder.

Removing piston

(4) Removing piston rings

Use piston ring plier (31391 - 12900) to remove the piston Piston ring plier

rings.

Removing piston rings

7-30
 ENGINE MAIN PARTS

(5) Removing piston pin

Using snap ring pliers, remove the snap rings from the
piston.
Remove the piston pin to separate the piston from the
connecting rod.
If it is difficult to pull out the pin, heat the piston with a
piston heater or in hot water to expand the pin bore.

Removing piston pin

(6) Removing main bearing caps

Remove the bolts that hold the cap to the crankcase.
Remove the cap with lower main bearing. To remove the
rearmost bearing cap, use a puller as shown in the
illustration.

NOTE
When removing the caps, do not cause damage to the
bearings. After removing the caps and bearings, mark
each combination of the cap and bearing for its
location so that it can be restored to the original Removing main bearing caps
position at reassembly.

(7) Removing crankshaft

Fasten a hoist to the crankshaft. Remove the crankshaft by
lifting it in a horizontal position.

Removing crankshaft
(8) Removing tappets
Remove the tappets.

NOTE
Put a mark on each tappet so that it can be installed in
the same position.

7-31
ENGINE MAIN PARTS

4.2 Inspection

Crankcase
(1) Gasket contact surface
Measure flatness of the gasket contact (top) surface with a
heavy accurate straight edge and feeler gauge, in three
positions across the crankcase width, two diagonal
measurements across the length and two at the outer edge
of the crankcase, as shown in the illustration. If flatness
exceeds the repair limit, grind the crankcase.
Unit: mm (in.)
Assembly Repair
Item
Standard Limit
Checking crankcase flatness
Flatness of gasket 0.05 (0.0020) 0.20
contact surface or less (0.0079)

(2) Inside diameter of cylinders Unit: mm (in.)

Measuring diagram
(a) Measure the inside diameter of the cylinder at the

80 (3.15)
11 (0.43)
top (ridged portion), middle and bottom, each in two
directions parallel and transverse to the crankshaft,
as shown in the illustration.

(5.91)
Unit: mm (in.)

Item
Assembly Repair Service 150
Standard Limit Limit
Inside diameter 94.000 to 94.035 94.200 94.700
of cylinder (3.7008 to 3.7022) (3.7087) (3.7283)
Measuring cylinder
0.01 (0.0004)
Circularity — —
or less
0.015 (0.0006)
Taper — —
or less

(b) If the cylinder has reached the repair limit, with the
wear far less than the service limit, bore it to 0.25
mm (0.0098 in.) or 0.5 mm (0.0197 in.) oversize.
(c) Hone the cylinder within an accuracy of 0.035 mm
(0.00138 in.), and use the piston and piston rings of
the same oversize.

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 ENGINE MAIN PARTS

(d) If any cylinder is unevenly worn, determine the

oversize on the basis of the maximum wear noted to
ensure perfect roundness in the oversized bore.

NOTE
(1) Refinish all cylinders to the same oversize.
(2) If the cylinder is found in good condition, with the
wear far less than the repair limit, replace the
piston ring and ream off “ridge” at the top of the
cylinder. Hone the bore if necessary.
Ridge-reaming cylinder

Pistons and piston rings

(1) Measuring piston diameter
Measuring
(a) Measure the diameter of the piston at skirt in the diagram
direction transverse to the piston pin with a
micrometer, as shown in the illustration. If the
piston is worn beyond the service limit, replace it.
Unit: mm (in.)
Assembly Service
Item
Standard Limit
93.955 to 93.985 93.770
Standard
(3.6990 to 3.7002) (3.6917)
Outside Measuring piston diameter
0.25 (0.0098) 94.205 to 94.235 94.020
diameters
oversize (3.7089 to 3.7100) (3.7016)
of pistons
Front
0.50 (0.0197) 94.455 to 94.485 94.270
oversize (3.7187 to 3.7199) (3.7114) FRONT mark
Piston weight difference 5 g (0.18 oz) WEIGHT mark
—
per engine or less

(b) When installing the piston, make sure the weight

difference of the piston per engine is in the assembly
standard.

WEIGHT mark on piston

7-33
ENGINE MAIN PARTS

(2) Measuring end gap of piston ring

Put the piston ring in the gauge or a new cylinder sleeve Feeler gauge
(crankcase) and measure the end gap with a feeler gauge as
shown in the illustration. If the clearance exceeds the Gauge

service limit, replace all piston rings.

+0.035 +0.001 38
Inside diameter of gauge: 94 0 mm (3.70 0 in.)

End gap
NOTE
Use the piston to put the ring in the cylinder sleeve Measuring end gap of piston ring
squarely.

Unit: mm (in.)
Assembly Service
Item
Standard Limit
End gap (No.1, No.2 0.30 to 0.50 1.50
and oil rings) (0.0118 to 0.0197) (0.0591)

(3) Measuring clearance between groove and piston ring

Put a new piston ring in the groove. Measure the clearance
between the groove and piston ring with a straight edge and
feeler gauges as shown in the illustration. If the clearance
exceeds the service limit, replace the piston.
Unit: mm (in.)
Assembly Service
Item
Standard Limit
No.1 0.135 to 0.157 0.200
ring (0.0053 to 0.0062) (0.0079)
Clearance Measuring clearance between groove and
No.2 0.045 to 0.085 0.150 piston ring
between groove
ring (0.0018 to 0.0033) (0.0059)
and piston ring
Oil 0.025 to 0.065 0.150
ring (0.0010 to 0.0026) (0.0059)

7-34
 ENGINE MAIN PARTS

(4) Measuring clearance between piston pin and bore

Measure the inside diameter of the piston pin bore and the
diameter of the pin as shown in the illustration to check the
clearance between the piston and pin. If the clearance
exceeds the service limit, replace the pin or piston
whichever is excessively worn.
Measureing diagram
Unit: mm (in.)
Nominal Assembly Service
Item
Value Standard Limit
Diameter of 30 29.994 to 30.000
— Measuring clearance between piston pin
piston pin (1.18) (1.1809 to 1.1811)
and bore
Clearance
0.000 to 0.016 0.050
between piston —
(0.0000 to 0.0006) (0.0020)
pin and bore

(5) Measuring piston protrusion

If the piston protrusion is not correct, check the various
parts for clearance. Measure the piston protrusion as
outlined below.
(a) Measure the top dead center of the pistons with a
dial gauge.
(b) Install the dial indicator on the top of the crankcase.
Set the indicator to read 0.0 mm (0.000 in.).
(c) Measure the piston protrusion at least three locations
on the top of the piston and average the three
Measuring piston protrusion
measurements to check the protrusion. Subtract the
projection from the compressed thickness of the
cylinder head gasket to check the clearance between
the piston top and the cylinder head.

Item Assembly Standard

−0.25 to 0.15 mm
Piston protrusion
(−0.0098 to 0.0059 in.)
Compressed thickness of 1.2±0.05 mm
cylinder head gasket (0.05±0.002 in.)

CAUTION
Incorrect piston protrusion affects engine
performance and causes valve interference with
the piston.

7-35
ENGINE MAIN PARTS

Connecting rods, connecting rod bearings and

connecting rod bushings
(1) Clearance between connecting rod bearing and
49.0 to 59.0 N·m
crankpin Measuring diagram (5.0 to 6.0 kgf·m)
[36.2 to 43.4 lbf·ft]
Measure the diameter of the crankpin and the inside
diameter of the connecting rod bearing as shown in the
illustration to check the clearance between the two. If the
clearance exceeds the service limit, replace the bearing. If
the crankpin is badly or unevenly worn, grind the crankpin
and use an undersize bearing.
0.25 mm (0.0098 in.), 0.50 mm (0.0197 in.) and 0.75 mm
(0.0295 in.) undersize connecting rod bearings are available
for service. Measuring connecting rod bearing

NOTE
To measure the inside diameter of the connecting rod
bearing, install the upper and lower halves in the
connecting rod and tighten the cap bolts to the
specified torque.

Unit: mm (in.)
Nominal Assembly Service
Item
Value Standard Limit
Diameter of 58 57.955 to 57.970 57.800
crankpin (2.28) (2.2817 to 2.2823) (2.2756)
Clearance between
connecting rod 0.030 to 0.090 0.200
—
bearing and (0.0012 to 0.0035) (0.0079)
crankpin

(2) Clearance between connecting rod bushing and piston

pin
Measure the inside diameter of the connecting rod bushing
and the diameter of the piston pin as shown in the
illustration to check the clearance between the two. If the
clearance exceeds the service limit, replace the pin or
bushing whichever is badly worn. Measuring
diagram
Unit: mm (in.)
Nominal Assembly Service
Item
Value Standard Limit
Inside diameter of Measuring connecting rod bushing
30 30.020 to 30.045
connecting rod —
(1.18) (1.1819 to 1.1829)
bushing
Clearance between 0.020 to 0.051 0.080
—
pin and bushing (0.0008 to 0.0020) (0.0031)

7-36
 ENGINE MAIN PARTS

(3) Installing connecting rod bushing

Matching mark
(a) Use connecting rod bushing puller (32A91 - 00500)
to install the connecting rod bushing.
(b) When installing a new bushing, align the oil holes in
Oil hole
the bushing and connecting rod. Position the ends
of the bushing as shown in the illustration.
(c) After installing the bushing, put the piston pin in
position and make sure the pin rotates freely. Ends of bushing

Installing connecting rod bushing

(4) Inspecting connecting rods for bend and twist

Unit: mm (in.)
(a) Measure C and L. If the measurement at C is more C 0.05 (0.0020)
<
L 100 (3.94)
than 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) of C 0.05 (0.0020)
<
L, straighten the rod with a press. C L 100 (3.94)

L L
Unit: mm (in.)
Piston pin C
Assembly Repair
Item
Standard Limit
Twist
Bend or twisting of 0.05/100 0.15
connecting rod (0.0020/3.94) or less (0.0059) Bend

Measuring connecting rod bend and twist

(b) A connecting rod aligner is generally used for

checking the connecting rod bend and twist.

NOTE
To check for bending, install the bearing cap to the
connecting rod and tighten the cap nuts to the 49.0 to
59.0 N·m (5.0 to 6.0 kgf·m) [36.2 to 43.4 lbf·ft].

Checking connecting rod on a

connecting rod aligner

(c) To check the rod complete with the piston, put the
piston on the surface plate, put a round bar identical D
with the crankpin in diameter in the big end bore C
and measure the heights A and B of the bar with a
dial indicator.
A B

Measuring connecting rod

7-37
ENGINE MAIN PARTS

(5) Inspecting connecting rod bearings

Check each bearing for flaking of overlay, scratching,
burning, pitting or other defects. Replace defective bearings
if any.
Flaking of Scratching
overlay

Failure due to
poor seating

Checking connecting rod bearings

(6) Measuring connecting rod side clearance

Install the connecting rod to the mating crankpin by
tightening the cap nuts to the specified torque. Measure the
side clearance with a feeler gauge as shown in the
illustration. If the side clearance exceeds the service limit,
replace the connecting rod.
Unit: mm (in.)
Assembly Service
Item
Standard Limit
Side clearance of 0.15 to 0.35 0.50
connecting rod (0.0059 to 0.0138) (0.020) Measuring connecting rod side clearance

(7) Replacing connecting rods

When replacing connecting rod, use replacement part
of the same weight ranking.

Matching
mark
Weight mark

Replacing connecting rods

7-38
 ENGINE MAIN PARTS

Crankshaft
(1) Measuring journal diameter
Measuring diagram
Measure the journal with a micrometer as shown in the
illustration to check wear, circularity, taper and clearance
between the bearing and journal. If any measurement
exceeds the repair limit, grind the crankshaft to an
undersize. If it exceeds the service limit, replace the
crankshaft.
Unit: mm (in.)
Nominal Assembly Repair Service
Item
Value Standard Limit Limit
Journal 78 77.955 to 77.970 77.850 77.100 Measuring journals
diameter (3.07) (3.0691 to 3.0697) (3.0650) (3.0354)
Circularity 0.01 (0.0004) 0.03
— —
Taper or less (0.0012)

(2) Measuring crankpin diameter

Measuring diagram
Measure the crankpin with a micrometer as shown in the
illustration to check wear, circularity, taper and clearance
between the bearing and crankpin. If any measurement
exceeds the repair limit, grind the crankshaft to an
undersize, or replace the crankshaft.

Unit: mm (in.)
Nominal Assembly Repair Service
Item
Value Standard Limit Limit
Crankpin 58 57.955 to 57.970 57.800 Measuring crankpins
diameter (2.28) (2.2817 to 2.2823) (2.2756)
Circularity 0.01 (0.0004) 0.03
— —
Taper or less (0.0012)

7-39
ENGINE MAIN PARTS

(3) Grinding crankshaft

3 mm 3 mm
When grinding the crankpins and journals, be sure to (0.118 in.) (0.118 in.)
produce the same fillet radius as the original one. They
should have a hardness of 550 or more in terms of Vickers
Hardness Number. If necessary, re-harden the crankpins
and journals, and inspect them for cracks by conducting a 3 mm
magnalux (magnetic particle) test. (0.118 in.)

After grinding, finish the journals and crankpins to 3 mm

(0.118 in.).

Crankshaft grinding dimensions Finished size of fillet radius

Unit: mm (in.)
Undersize Grinding dimension
0.25 77.705 to 77.720
(0.0098) (3.0593 to 3.0598)
0.50 77.455 to 77.470
(0.0197) (3.0494 to 3.0500)
Journal
0.75 77.205 to 77.220
(0.0295) (3.0396 to 3.0402)
0.25 57.705 to 57.720
(0.0098) (2.2719 to 2.2724)
0.50 57.455 to 57.470
(0.0197) (2.2620 to 2.2626)
Crankpin
0.75 57.205 to 57.220
(0.0295) (2.2522 to 2.2528)

(4) Measuring crankshaft end play

31 +0.039
0 mm
(a) With the thrust plates installed in the front and rear (1.22 +0.00154
0 in.)
of a journal and all bearing caps tightened to the
specified torque, measure the end play (the
difference in width between the journal and thrust
plate). If the end play exceeds the repair limit,
replace the thrust plates.
(b) If the end play still exceeds the repair limit even
after the new thrust plates have been installed,
replace the thrust plates with the oversize ones. 0.15
mm (0.0059 in.) and 0.30 mm (0.0118 in.) oversize Crankshaft journal width
thrust plates are available for service. Generally the
rear journal is likely to wear more rapidly than the
front journal. This means that replacement of the
rear thrust plates will generally be sufficient.

7-40
 ENGINE MAIN PARTS

Unit: mm (in.)
Assembly Repair
Item
Standard Limit
0.100 to 0.264 0.300
Crankshaft end play
(0.0039 to 0.0104) (0.0118)

Crankshaft grinding dimensions for

oversize thrust plates
Unit: mm (in.)
Oversize for Oversize for
Oversize Measuring crankshaft end play
front or rear front and rear
0.15 +0.039
0 31.15 +0.039
0 31.30 +0.039
0
+0.00154 +0.00154 +0.00154
(0.0059 0 ) (1.2264 0 ) (1.2323 0 )
0.30 +0.039
0 31.30 +0.039
0 31.45 +0.039
0

(0.0118 +0.00154
0 ) (1.2323 +0.00154
0 ) (1.2382 +0.00154
0 )

(5) Measuring crankshaft deflection

Support the crankshaft on its journals in V-blocks, then
measure the deflection at the center journal with a dial
gauge. Depending on the amount of deflection, repair the
crankshaft by grinding or straightening with a press. If the
deflection exceeds the repair limit, replace the crankshaft.
Unit: mm (in.)
Assembly Repair
Item
Standard Limit
0.02 (0.0008) 0.05
Crankshaft deflection Measuring crankshaft deflection
or less (0.0020)

(6) Replacing crankshaft gear

(a) Use gear puller to remove the gear from the
crankshaft.

CAUTION
Do not remove the gear by tapping with a
hammer.

Replacing crankshaft gear

7-41
ENGINE MAIN PARTS

(b) Heat a replacement gear up to 100°C (212°F) with a

gear heater. Put the gear on the crankshaft with its
keyway aligned with the key and tap the end face of To be aligned
the gear with a hammer.

Installing crankshaft gear

(7) Checking oil seal running surface

Check the oil seal running surface of the crankshaft for
wear. If the crankshaft is badly worn, replace the oil seal
complete with oil seal sleeve. Oil seal

Oil seal
running
surface

Checking oil seal running surface

(a) Installing oil seal sleeve

Apply oil to the inside of an oil seal sleeve and, using Sleeve
installer
oil seal sleeve installer set (30691 - 13010), install the
sleeve in position, as shown in the illustration.
Guide
(30691 - 13100)
CAUTION
Be careful not to cause damage to the sleeve
when installing it.
Installer
(30691 - 13200)
The oil seal sleeve will be worn in the course of time.
In such a case, replace both the oil seal and sleeve. Installing oil seal sleeve

Oil seal

Oil seal
sleeve

Checking oil seal running surface

7-42
 ENGINE MAIN PARTS

(b) Removing oil seal sleeve

Hold a flat chisel at right angles to the sleeve and cut
the sleeve at three places to loosen it, as shown in the
illustration. If it is impossible to remove the sleeve in
this method, hold the chisel in the axial direction and
lightly tap the sleeve to loosen it.

CAUTION
Be careful not to cause damage to the crankshaft
when removing the sleeve.
Removing oil seal sleeve

Main bearings
(1) Inspecting the main bearing surface
Inspect each bearing shell for abnormal contact such as
scratching, corrosion, flaking, etc. Also check for signs of
Scratching, corrosion
poor seating in the bore of the crankcase or bearing cap. or flaking

Inspecting main bearing surface

(2) Clearance between bearing and journal

Install the bearings to the crankcase and bearing cap.
Tighten the cap to the specified torque. Measure the inside
diameter of the bearing in two positions lengthwise and
three crosswise as shown in the illustration to take an
average. Check the clearance between the bearing and
journal on the basis of this measurement.
Unit: mm (in.)
Assembly Repair 98 to 108 N·m
Item (10.0 to 11.0 kgf·m)
Standard Limit
[72 to 80 lbf·ft]
Clearance between 0.050 to 0.110 0.200
bearing and journal (0.0020 to 0.0043) (0.0079) Measuring main bearing

(3) Replacement
If the clearance between the bearing and journal exceeds
the repair limit, replace the bearings, or grind the
crankshaft and use undersize bearings. If the crankshaft
has been grounded, it is also necessary to check the bearing
contact.

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ENGINE MAIN PARTS

Tappets
(1) Inspecting cam contact face of tappet
Replace the tappets if there cam contact faces are
abnormally worn.

Good Bad Bad

Cam contact face of tappet

(2) Measuring clearance between tappet and tappet bore

Measuring diagram
Measure the diameter of the tappet and the inside diameter
of the bore for the tappet, as shown in the illustration, to
check the clearance between the two. If the clearance
exceeds the repair limit, replace the tappet.
Unit: mm (in.)
Assembly Repair Service
Item
Standard Limit Limit
Inside diameter of 14.000 to 14.018 14.100
—
tappet bore (0.5512 to 0.5519) (0.5551)
Clearance between Measuring clearance between tappet and
0.016 to 0.052 0.08 tappet bore
tappet and tappet —
(0.0006 to 0.0021) (0.0031)
bore

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 ENGINE MAIN PARTS

4.3 Reassembly
(1) Installing main bearings
(a) Install each upper shell of the main bearing to the
crankcase so that the bearing lug fits into the notch
Oil grooves
in the crankcase. The oil hole in the bearing and
crankcase will be aligned when the bearing is so
installed.
(b) Apply a small amount of engine oil to the bearings.
(c) Install the thrust plate to the rear face of the
crankcase with oil grooves toward the outside as
shown in the illustration.
Installing main bearings

(2) Installing crankshaft

(a) Wash the crankshaft with cleaning solvent, and dry
it by air blow.
(b) Hold the crankshaft in a horizontal position by using
a hoist, and carefully put it in the crankcase.
(c) Lightly coat the journals with engine oil.

Installing crankshaft

(3) Installing main bearing caps

ThreeBond No. 1212
(a) Apply engine oil to the bearings and install the
bearings to the caps.
(b) Apply ThreeBond 1212 to the corners of the rear
bearing cap and install the cap to the crankcase so
that the rear face of the cap is even with the rear face
of the crankcase.

ThreeBond No. 1211

Installing main bearing caps

(c) Apply ThreeBond 1211 to the side seals and put the
seals in the groove in each bearing cap with rounded Crankcase
Bearing cap Side seal
side toward outside. Push them into position with
the blade of a screwdriver or the like, taking care not
to bend or twist them.
(d) Apply ThreeBond 1211 to and around the side seals.

Rounded side
NOTE
Install the main bearing caps in number sequence.
Installing side seals
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ENGINE MAIN PARTS

(4) Installing main bearing cap bolts

Apply engine oil to the bolts and tighten them to the
specified torque.

98 to 108 N·m
Tightening torque for
(10.0 to 11.0 kgf·m)
main bearing cap bolts
[72 to 80 lbf·ft]

Installing main bearing cap bolts

(5) Measuring crankshaft end play

After installing the bearing caps, check the end play of the
crankshaft. (Refer to section 4.2.)

Measuring crankshaft end play

(6) Assembling piston and connecting rod

View A A
(a) Assemble the piston and the connecting rod with the
WEIGHT mark of the piston and the MATCHING
mark of the rod on the same side.
(b) Apply engine oil to the piston pin and insert the pin
into position. WEIGHT mark MATCHING
FRONT mark mark

Assembling piston and connecting rod

(c) Install each snap ring in the snap ring groove of the
piston with snap ring pliers. Make sure the snap ring
fits in the groove properly.

NOTE
Install the snap ring with the ends toward the bottom
of the piston.

Installing snap rings

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 ENGINE MAIN PARTS

(7) Installing piston rings

Top mark
(a) Put the compression rings and oil ring in the ring
grooves of the piston with piston ring pliers (31391 -
12900). No. 1
compression ring
NOTE No. 2
Install the compression rings on the piston with “RN” compression ring

or “R” mark toward the top of the piston.

Oil ring

Installing piston rings

(b) Install the oil ring with the joint of the coil spring
180° apart from those of the ring gap. Joint of coil spring

180°

Ends of oil ring

Ends of oil ring and coil spring

(8) Preparation before installing pistons

(a) Lay the crankcase on its side
(b) Clean the cylinder bores with a clean rag and apply
engine oil to the bore surfaces.
(c) Put the connecting rod cap bolts in the big end of the
connecting rod so that the flats of their heads fit to
the rod properly.

Preparation before for piston installation

(d) Install the upper half of the connecting rod bearing

Tab and groove
to the big end of the connecting rod, making sure the
locating lug fits into the notch in the rod. Apply
engine oil to the bearing.

Connecting rod and bearing

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ENGINE MAIN PARTS

(9) Inserting pistons Thrust Camshaft side

(a) Apply engine oil to the piston rings. Install the rings direction
on the piston with the ring ends positioned as shown 180° End gap of
No.1 com-
in the illustration. pression ring

End gap of
No.2 com-
pression ring End gap of
60° 60° oil ring

Anti-thrust Combustion
direction chamber side

Configuration of piston ring ends

(b) Turn the crankshaft to bring a crankpin to install the

piston and connecting rod assembly top dead center.
Using piston installer (34491 - 00200), put the
assembly in the cylinder, with FRONT mark ( ) on
the piston toward the front of the engine.
(c) After resting the big-end of the connecting rod on
the crankpin, turn the crankshaft 180° while pushing
FRONT mark
the piston head to bring the big-end to a position
where the cap can be installed easily. Piston installer

Installing piston and connecting rod assembly

(10)Installing connecting rod cap

(a) Install the lower half of the connecting rod bearing
to the cap, making sure the locating lug fits into the
notch in the cap. Apply engine oil to the bearing.
(b) Install the cap to the rod and tighten the cap nuts to
the specified torque.

49.0 to 59.0 N·m

Tightening torque for
(5.0 to 6.0 kgf·m)
cap nuts
[36.2 to 43.4 lbf·ft]
Installing connecting rod cap

CAUTION
Make sure the matching mark on the cap is on
the same side as the mark on the connecting rod.

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 INLET AND EXHAUST SYSTEM

1. Description ......................................................................................... 8 – 1
2. Exhaust Manifold .............................................................................. 8 – 1
Inspection .............................................................................................. 8 – 1

8
 INLET AND EXHAUST SYSTEM

1. Description

Exhaust manifold Inlet manifold

CAUTION
When replacing parts, make sure to use OEM designated parts. If OEM parts are not used, the
exhaust emission’s warranty will be voided. New parts may be updated due to improvement. Fuel and
Exhaust system repairs should only be conducted by an authorized Mitsubishi forklift dealer.
Tampering or adjusting the fuel system components will void the warranty and could be in violation of
the EPA regulations. The fuel injection pump must be replaced as an assembly.

2. Exhaust Manifold

Inspection
(1) Check the flanges for cracking.
(2) Check the flanges for warpage as shown in the
illustration. If the warpage exceeds the assembly
standard, repair the flanges.

Item Assembly Standard

Warpage of exhaust 0.2 mm (0.008 in.),
manifold flange maximum
Checking exhaust manifold flange for warpage

8-1