Chapter 5 DISASSEMBLY OF BASIC ENGINE

2. Rear Mechanism - Disassemble and Inspect

Understanding of the current engine condition before disassembling is very important to find the cause of trouble and to per-
form efficient maintenance work.
Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with
any job.
Flywheel Face and Radial Runout - Measure
Timing Gear Backlash - Measure
Idler Gear and Camshaft End Play - Measure

Replace: Gasket, O-ring

Flaw, wear, 12 9
key groove defect

Flaw, wear
11
Oil hole clogging

Flaking, wear,
key way deformation and wear
9 9

14 Groove crack, wear

Electronic Oil pressure
governor spec governor spec 13 7 6
10 5
8 Wear, flaw,
deterioration

Non- Non-
Crack, dowel hole defect Hour meter spec attachment spec attachment spec
1
4
2
3

Crack, dowel hole defect,

Non- Non-
Tachometer spec attachment spec attachment spec Wear, flaw, deterioration flaw on gear, abnormal wear

Rear Mechanism - Disassemble and Inspect

Disassembling Sequence
1 Pick up (electronic governor spec) 9 Accessory drive (electronic governor spec)
2 Flywheel (Approx. 83 kg [183 lb]) Governor drive (Oil pressure governor spec)
3 Timing gear case (Approx. 43 kg [95 lb]) (Refer to the chapter "FUEL SYSTEM" for disassembly, in-
4 Oil seal spection and assembly.)
5 Oil seal slinger 10 Camshaft gear
6 Thrust plate 11 Thrust plate
7 Idler gear 12 Camshaft (Approx. 25 kg [55 lb.])
8 Fuel injection pump gear 13 Idler shaft
14 Rear plate (Approx. 21 kg [46 lb])

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2.1 Flywheel Face and Radial Runouts - Measure

Measure the face and radial runouts of the flywheel to check
the current condition.
For the measurement procedure, see "Flywheel Face and Face runout
measuring plane
Radial Runout - Measure" of "ENGINE BODY - ASSEM-
BLE." Radial runout
measuring plane

Flywheel Face and Radial Runouts - Measure

2.2 Flywheel - Remove
Sling

(a) Be careful not to drop or hit the flywheel. It can,

not only cause damage, but also may cause per-
sonnel injury.
(b) Be careful not to cut your hands with the ring gear
when pulling-out the flywheel.

Flywheel
Be sure to remove the pickups before removing the
Jack bolt (M12 × 1.25)
flywheel. Flywheel - Remove
(1) Attach a sling to the flywheel to prevent it from falling
off.
(2) Screw two jack bolts evenly into the bolt holes, and
remove the flywheel.

2.3 Timing Gear Case - Remove

Eyebolt
P/N:05930-00200
Be careful not to drop or hit the timing gear case. It (M12 × 1.25)
can, not only cause damage, but also may cause per-
sonnel injury.
(1) Attach a sling to the timing gear case to prevent it from
falling off.
(2) Lift the timing gear case to disengage the dowel pins,
and remove the timing gear case. Timing gear case
(3) Remove the oil seal from the timing gear case. Oil seal
Note: Replace the removed oil seal with a new one. Oil seal Timing Gear Case - Remove
cannot be re-used.

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

2.4 Timing Gear Backlash - Measure

Measure the timing gear backlash to check the current con-
dition.
For measurement procedure, see "Timing Gear Backlash -
Measure" of "ENGINE BODY - ASSEMBLE". Camshaft gear

Fuel injection
pump gear

Idler gear
Timing Gear Backlash - Measure
2.5 Idler Gear End Play - Measure
Measure the idler gear end play to check the current condi-
tion.
For measurement procedure, see "Idler Gear End Play -
Measure" of "ENGINE BODY - ASSEMBLE".

Idler gear
Idler Gear End Play - Measure
2.6 Camshaft End Play - Measure
Measure the camshaft end play to check the current condi-
tion.
For measurement procedure, see "Camshaft End Play -
Measure" of "ENGINE BODY - ASSEMBLE".

Camshaft gear
Camshaft End Play - Measure

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2.7 Idler Gear - Remove

The camshaft gear mounting nuts are left-hand

Socket
threaded. Be sure to turn them clockwise to loosen P/N : 32591-02800
them.
If the idler gear is removed first, the nut that fixes the cam-
shaft gear cannot be loosened because the camshaft gear
rotates. Thus, loosen the camshaft gear mounting nut before Camshaft gear
nut [Left-handed
removing the idler gear. screw]
(1) Remove the oil seal slinger from the crankshaft. Be Thrust plate Idler gear
careful not to scratch the crankshaft. Idler Gear - Remove
(2) Using a socket, loosen the camshaft gear mounting nut
(left-hand thread).
(3) Remove the thrust plate.
(4) Remove idler gears.

2.8 Fuel Injection Pump Gear - Remove

Using a puller, remove the fuel injection pump gear.
Threaded holes
(M10 × 1.25)

Fuel injection pump gear

Puller
Fuel Injection Pump Gear - Remove
2.9 Governor Drive and Fuel Injection Pump Accessory Drive - Remove
Remove the governor drive (oil pressure governor spec) and
fuel injection pump accessory drive from the rear plate. Accessory drive

(See "FUEL SYSTEM" for disassembly, inspection, and

assembly.)
Electronic
governor spec Governor drive

Oil pressure
governor spec
Governor Drive and Fuel Injection Pump Accessory
Drive - Remove

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

2.10 Camshaft Gear - Remove

(1) Remove the nut (left-hand thread).
(2) Remove the camshaft gear with the puller using the
threads in the gear. Threaded holes
(M10 × 1.25)

Camshaft gear Puller

Camshaft Gear - Remove
2.11 Camshaft - Remove

Remove the camshaft by lifting from Crankcase top Thrust plate

face, paying attention not to damage the Crankcase
and camshaft.
(1) Remove the thrust plate.
(2) Lift the camshaft with a sling fitted to the top of the
crankcase and remove the camshaft to the rear of the
engine. Camshaft

Camshaft - Remove (1)

Sling
Camshaft bush

Cam

Camshaft
Crankcase
Camshaft - Remove (2)
2.12 Idler Shaft - Remove
Screw two jack bolts evenly into the jack bolt holes, and
Jack bolt (M10 × 1.25)
remove the idler shaft.

Idler Shaft - Remove

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2.13 Rear Plate - Remove

Remove the rear plate from the crankcase.

Dowel pin

Rear Plate - Remove

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

3. Front Mechanism - Disassemble and Inspect

Understanding of the current engine condition before disassembling is very important to find the cause of trouble and to per-
form efficient maintenance work.
Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with
any job.

Fan attachment spec Oil pipe

1

3
2

4 Replace

Replace

Belt groove wear

With pulley (ribbed belt) Double installation spec

6
5 10 (Slinger portion)

4 10 (Seal lip portion) 9 Crack, dowel hole defect

8
With pulley (V-belt)

7
4
Crack, oil leak

Front oil seal assembly in the form of a cassette combing an seal lip and slinger.
With cranking pulley Front oil seal should be replaced whenever the front cover is removed.
Front Mechanism - Disassemble and Inspect
Disassembling Sequence
1 Fan (Approx. 41 kg [90 lb]) (with fan spec) 6 Spacer (double damper spec)
2 Fan bracket assembly (with fan spec) 7 Damper (Approx. 56 kg [123 lb.])
3 Belt (with fan spec) 8 Crankshaft pulley
4 Front pulley 9 Front cover
5 Damper (Approx. 56 kg [123 lb]) (double damper spec) 10 Oil seal (cassette type)

Note:(a) The shape of fan differs in accordance with the customization and specification.
(b) The consisting parts of the damper differ in accordance with the customization and specification.

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

3.1 Fan, Fan Bracket Assembly, and Belt - Remove

(Fan equipped type)
Remove the fan, fan bracket assembly, and belt.

3.2 Front Pulley, Damper and Crankshaft Pulley - Remove

Raise using a rope, etc.

Be careful not to drop or bump the pulley and damper.
It can, not only cause damage to parts, but also lead Jack bolt
(M12 × 1.75)
to personnel injury.
(1) Install the guide bolt to damper mounting thread on the
crankshaft.
(2) Hitch a rope or the like to the groove of front pulley to
support. Screw two jack bolts evenly into the jack bolt
holes, and remove the pulley. Guide bolt pulley
Front Pulley - Remove
(3) While supporting the damper with a sling, screw two
jack bolts evenly into the jack bolt holes, and remove
the damper. Double installation Guide bolt
spec

Spacer Jack bolt

(M12 × 1.25)
Damper - Remove
(4) Screw two jack bolts evenly into the jack bolt holes,
and remove the crankshaft pulley from the crankshaft.

Jack bolt
(M12 × 1.25)

Crankshaft pulley

Crankshaft Pulley - Remove

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3.3 Front Cover - Remove

When removing the oil seal (slinger portion), be careful Pointer

not to damage the crankshaft.If the crankshaft has a

flaw, oil will leak from its flaw even if new oil seal is Bolt
installed.
(1) Screw two jack bolts evenly into the jack bolt holes,
Front cover
and remove the front cover from the crankcase,
(2) Remove the oil seal (seal lip portion) from the front Oil seal Jack bolt
cover. (M10 × 1.5)

(3) Remove the oil seal (slinger portion) from the crank- Front Cover - Remove
shaft by tapping lightly or prying it.

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