MODEL D4B

June 28, 2018 | Author: Torque | Category: Piston, Coolant, Cylinder (Engine), Motor Oil, Belt (Mechanical)
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MODELD4B SHOP MANUAL (FOR INDUSTRIAL USE) FORWORD We would like to express our sincere gratitude to the patrons who have given us unwavering encouragement. This manual covers shop manual and parts catalog in one volume for an easy reference of parts list, as well as contains the accurate and efficient service procedures for HYUNDAI D4B industrial engine. This manual includes specifications, troubleshooting, removal, installation, disassembly and assembly in each group and presents component illustrations and descriptions for an easy reference. Accordingly, thoroughly read this manual, rapidly purchase the required parts and service the engine in proper methods to extend its life and benefit. Improper service methods and procedures may shorten the engine life resulting from its low performance. Hyundai genuine parts are designed and built to provide the best performance in your engine. If your claim is caused by using non-Hyundai genuine parts or servicing at places not recommended, your warranty is not available. Hyundai Motor Co., Inc. makes efforts to enhance quality and build better parts and service data for you. We want to assist you in every way possible with this manual and your purchase of HYUNDAI engine is highly appreciated. March 2004 Hyundai Motor Co., Inc. Industrial Engine Development Team (TEL 82-52-280-8221~8223) O.E.M Parts Export Team (TEL 82-2-746-0291~0299) NOTE: Contents and specifications are subject to change according to design changes without notice. IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all engines as well as the personal safety during work. This manual provides general directions for the efficient service methods and procedures. There are numerous variations in procedure, techniques, tools and parts for servicing engines, as well as in the skill of the individual technician. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this manual must establish that he comprises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts. NOTE, CAUTION, WARNING NOTE : Information needed in reference to a repair service. CAUTION: Information about an activity that could cause damage to the vehicle. WARNING : Information about an activity that could cause injury or damage to the driver, occupants or repairman. [SAFETY INFORMATION] The following list contains some general warnings that you should follow when you work on an engine. Always wear safety glasses for eye protection. Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. Operate the engine only in a well-ventilated area to avoid the danger carbon monoxide poisoning. Keep yourself and your clothing away from moving parts when the engine is running, especially the drive belt. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. Do not smoke while working on an engine. To avoid injury, always remove rings, watches, loose hanging jewelry and loose clothing before beginning to work on an engine. Keep hands and other objects clear of the radiator fan. The fan can be operated with the ignition key in the OFF position. Therefore necessarily disconnect the radiator fan motor connector. . 2. GENERAL ENGINE MECHANICAL SYSTEM LUBRICATION SYSTEM COOLING SYSTEM INTAKE AND EXHAUST SYSTEM ENGINE ELECTRICAL SYSTEM FUEL SYSTEM 1-1 2-1 3-1 4-1 5-1 6-1 7-1 . 7. 3. 4. 5.CONTENTS 1. 6. ................... TROUBLESHOOTING ......15 8.1 2.. 1..... TORQUE SPECIFICATIONS ............................. CHECKING POINT ..................... 1.............................................CHAPTER 1 GENERAL INFORMATION 1..13 7......9 6...........7 4...... RECOMMENDED LUBRICANTS AND CAPACITIES .....6 3.....................................................8 5........ TIGHTENING TORQUE OF STANDARD PARTS............... 1........................................... GENERAL ........ 1....... 1....................... ENGINE IDENTIFICATION NUMBER ............................. 1......18 9.......... SPECIFICATIONS ...................... 1............ SPECIAL TOOLS .................20 .................................................. 1......... 1.... 1 of barrel face. no.2 of taper face and oil ring of bevel cutter and coil expander is attached. Silent shaft is installed to both ends of the cylinder block. ENGINE ASSEMBLY KD4BB01A Crankshaft is made of forged steel and supported with main bearing.2 of special cast iron. Oil ring no. Pulley attached with torsional damper is installed in the front of crankshaft and flywheel in the rear of it.1 of the piston ring is made of steel. piston ring no. OVERALL 1) ENGINE Cylinder head is made of aluminum alloy and combustion chamber is a swirl type. . Cylinder block is made of special cast iron and dry cylinder liner is press-fitted in the cylinder. operated with cog belt and rotated at a double speed of crankshaft. Water jacket is a Siamese type and piston is made of aluminum alloy and connected with connecting rod by full floating piston pin. no.GENERAL 1-1 1. Valve is a SOHC type and the camshaft is operated by the Cog type timing belt. 1-2 Timming belt train GENERAL KD4BB02A . Rocker arm shaft Camshaft Main passage Oil filter To oil pan Left silent shaft Reduing pressure Vaccum pump Crank shaft Right silent shaft Oil jet KD4BB03A .GENERAL 1-3 2) LUBRICATION SYSTEM It is a forced lubrication system and the forced oil by the oil pump is sent to the engine compartment through the oil cooler and oil filter as shown in the illustration and directly operated by the crank shaft. Maximum oil pressure is controlled by the reducing valve. Bypass filter Gasket Flow filter From oil pump Valve To oil pan To main passage KD4BB04A . The bypass filter in the full flow filter uses a thick multi-fiber media to filter dirt (soot). filtered oil from the full flow filter passes through the main passage and the filtered oil from the bypass filter returns to the oil pan.1-4 GENERAL Oil filter is a combined type and full flow filter and bypass filter are built in it. If oil enters the oil filter. Cold engine From heater To heater Thermostat Water pump Water pipe Hot engine Thermostat Water pump From heater Heater Water pipe KD4BB05A .GENERAL 1-5 3) COOLING SYSTEM Engine is cooled with the circulated coolant forced by the water pump. This illustration shows the flow of coolant. 1-6 ENGINE IDENTIFICATION NUMBER 2.000000 ~ 999999 .4 : In line 4 cycle 4 cylinder Engine development order . Engine identification number 2) DESCRIPTION OF ENGINE IDENTIFICATION NUMBER D 4 B B 2 0 0 0 0 0 0 KAXD010C Engine fuel . ENGINE INDENTIFICATION NUMBER 1) ENGINE IDENTIFICATION NUMBER LOCATION The engine identification number is stamped on the right front side of the top edge of the cylinder block.4 : 2004 Engine production sequence number .B : 2607 cc NA Production year .F : 2476 cc TC .2 : 2002 .3 : 2003 .D : diesel Engine range .H : 2476 cc TCI .1 : 2001 .B : 4D56 Engine capacity . 3 ~ 0. The torques shown in the table are standard values under the following conditions.5 0.6 1. . .25 1. and galvanized. If spring washers are used : 85% . . If you reduce the torques in the table to the percentage indicated below.0 1.9 ~ 1.5 ~ 3. .5 ~ 0. bolts and plain washers are dry.0 6~8 12 ~ 14 NOTE 1. TIGHTENING TORQUE TABLE OF STANDARD PARTS Bolt nominal diameter (mm) Torque (kg m) Pitch (mm) Head Mark 4 Head Mark 7 EADA010R EADA010S EADA010T EADA010U M5 M6 M8 M10 M12 M14 0.8 1. The torques shown in the table are not applicable. .5 4.25 1.2 ~ 1. it will be the standard value.5 0.5 7. Galvanized plain steel washers are inserted.5 2. toothed washers and the like are inserted.25 1.4 0. If self-tapping screws or self-locking nuts are used. 3. All nuts. When spring washers.0 ~ 5. If plastic parts are fastened.5 ~ 0. Nuts and bolts are made of steel bar.0 3. . under the following conditions.0 ~ 2. 2.1 2.5 ~ 8. If threads and bearing surfaces are stained with oil : 85% . .TIGHTENING TORQUE TABLE OF STANDARD PARTS 1-7 3.6 0.5 ~ 4. . LUBRICANTS CAPACITES Description Oil pan Oil filter Engine oil Oil cooler Total Coolant Capacities 0. select only those lubricants which : 1.5 l 9.Lubricants which do not have both an SAE grade number and an API service clasification on the container should not be used.5 l 0.7 l 0.7 l Antifreeze for aluminum Above API CD or SG (10W/30 or 1500W/40) Specified oil CAUTION For the best performance and maximum protection of all types of operation. Satisfy the requirements of the API classification. Have the proper SAE grade number for expected ambient temperature range. 2.1-8 LUBRICANTS CAPACITES 4. 05 mm 37.08 mm 0.CLOSE Valve timing Exhaust valve . SPECIFICATIONS Description Type Number of cylinders Valve system D4BB Total displacement 2607cc Cylinder bore General Cylinder stroke Comprssion ratio Intake valve .325 mm 37.50 0.0 ~ 94.050 mm 36.2 mm 0.935 ~ 29.CLOSE 91.012 ~ 0.15 mm 94.068 mm 13.325 mm 43.60 Intake Exhaust 13.2 mm 18.050 ~ 13.600 ~ 37.OPEN .05 ~ 0.05 0.250 ~ 13.1 mm 95 mm 21 Specification Diesel engine 4 OHC D4BF.910 ~ 18.518 mm 43.05 mm 0.500 ~ 13.30 0.928 mm 0. Oil clearance End play I.55 mm .625 mm 37.950 mm 0.1 mm 100 mm 22 20° BTDC 48° ATDC 54° BTDC 22° ATDC 1-3-4-2 0.1 mm 0.1 ~ 0.SPECIFICATIONS 1-9 5.55 mm 36.25 0. D4BH Limit Firing order Flatness of gasket surface Flatness of manifold mounting surface Overall height Oversize of valve guide hole Cylinder head Rework dimensions (both intake and exhaust) Oversize rework dimensions of intake valve seat hole Oversize rework dimensions of exhaust valve seat hole Cam height Camshaft Journal O.625 mm 37.3 mm 2476cc 91.D Rocker arm Rocker arm .600 ~ 43.OPEN .05 mm 29.30 0.268 mm 13.to -guide clearance 0.300 ~ 37.60 0.D.300 ~ 43. 2 Right .03 ~ 0.09 mm 49. Press temperature Seat angle Valve seat Valve contack widht Sinkage Silient shaft Left .959 ~ 18.06 mm 0.3 mm 0.975 ~ 42.05 ~ 0.991 mm 0.02 ~ 0.960 ~ 7.975 mm 7.9 ~ 1.975 ~ 42.Front .467 mm 42.5 mm Intake Over length Exhaust Intake Stem diameter Valve Fage angle Thickness of valve head (Margin) Stem-to-guide clearance Free height Intake Exhaust Intake Exhaust Exhaust 136.930 ~ 7.0 mm 1.991 mm 1.0 mm Limit Valve spring Load/Installed height Over length N kg/mm Out-of squareness Intake Exhaust I.1 mm 276/40.950 mm 45° ~ 45° 3 0 ” 2 mm 2 mm 0.000 ~ 8.06 mm 0.Rear Front Oil clearance Rear 18.980 mm 49.D.09 mm .300 ~ 18.898 mm 451.05 ~ 0.1-10 Description O.06 ~ 13.Front .4 Max 2° 71 mm 74 mm 8.5 mm 7.D.D.018 mm 13. Rocker shaft Length SPECIFICATIONS Specification 18. Valve guide O.Rear Journal diameter 18.878 ~ 18.5 mm 136.07 mm Ordinary temperature 45° 0. 0.95 ~ 158.04 2.D.8 mm 0.05 ~ 0.50 0.25 U.45 ~ 0.8 mm 0.601 ~ 2.046 ~ 0. Pin O.485 ~ 65.1 mm 0.1 0.3 mm .235 ~ 52.06 2. 0.0 ~ 79. 2 ring Oil ring 0.25 mm 0.250 mm 0.18 mm 66 mm 53 mm 0.8 mm 0.S.102 4.02 ~ 0.735 ~ 65. TC Piston-to cylinder clearance Piston Ring groove width No. 2 ring Oil ring No.75 U.735 ~ 52.035 0.S.15 mm 0.1 mm 28.100 ~ 2.750 mm 52.50 U.500 mm 52.000 mm 157.45 0.25 U. 1 ring No.25 ~ 0.15 mm 0. 1 ring End gap Piston ring Ring-to-ring groove clearance Piston pin O.D.12 0. 2 ring Oil ring No.08 ~ 0.25 ~ 0. Out of roundness of journal and pin Out-of taper of journal and pin Oil clelarance of journal Crank shaft Oil clearance of pin 0.04 ~ 0.50 U. 1 ring No.SPECIFICATIONS Description O.05 0.603 2.41 ~ 0.09 3.076 0.05 mm 65. 0.065 Limit 1-11 0.02 ~ 2.S.60 0.03 ~ 0.40 0.75 U.01 ~ 3.066 0.07 ~ 2.S. Journal 0.485 ~ 52. Pin 0.015 mm less than 0.065 Specification 79.05 2. No.20 ~ 0.S.500 mm 65.235 ~ 65.02 ~ 0.D.S.05 mm less than 0.2 mm NA 0.035 0.750 mm 65.02 ~ 0. D.056 ~ 0.1 ~ 0.05 mm 0.994 ~ 29.07 0.250 mm 52.03 ~ 0.02 ~ 0.54 0.40 0.2 mm 0.010 ~ 4. Big end center-to small end center length bend Bend Connecting rod Twist Bing end side clearance End play Journal O.35 ~ 0.05 mm 0. 13 mm 0.22 mm Water-cooled forced circulation system V Belt Centrifugal impeller Bimetal thermostat type Wax type Thermister type Thermister type 10 ~ 13 mm 76.1-12 Description O.4 mm 0.15 mm 0.45 ~ 318.55 mm 0.5 2°C / 82 2°C 95°C 8 or not less than 90.1 mm Limit Flatness of gasket surface Overall height Flywheel Run out Cooling system Drive belt Valve opening temperature Fulley opening temperature Repeat amount Coolant temperature gauge unit Resistance Coolant temperature gauge element Glow control element Thermostat Intake & Exhaust Air cleaner Muffler .58k /20°C Paper filter type Expansion resonance type Side clearance Inner gear 0.3 ~ 26.13 mm Inner gear Tip clearnace Outer gear Oil pump Body clearnace Side clearance Outer gear Cooling system Drive Belt Water pump type Fan clutch type Thermo type Coolant temperature gauge unit Thermo switch(113°C. Cylinder block SPECIFICATIONS Specification 91.35 mm 0.5 ~ 117.5 mm 0.13 mm 0.3 /115°C 22.04 ~ 0.92 ~ 3.3 ~ 27.12 ~ 0.05 mm 318.22 ~ 0.3k /-20°C 2.30 mm 0.10 mm 0.12 ~ 0. A/con) 0.22 mm 0.03 ~ 0.09 mm 0.10 ~ 91. D.5 /70°C 21.15 mm 0. 0 0.8 13 ~ 14 7.7 1.8 6~8 1.9 ~ 2.4 ~ 4.0 3.5 ~ 1. TORQUE SPECIFICATIONS Deseription Crankshaft pulley bolt Crankshaft sprocket bolt Timing belt tensioner bolt Injection pump sprocket nut Silent shaft sprocket nut Timing belt tensioner “ B ” nut Rocer cover bolt Rocker arm shft bolt Cold engine Cylinder head bolt Hot engine Oil pan bolt Oil pan drain plug Front case bolt (upper.5 ~ 4.5 .0 8~9 3.0 2.5 5.0 ~ 3.1 10.5 ~ 0.2 ~ 3.4 ~ 4.5 1.0 ~ 1.5 ~ 12.5 1.7 3.5 2.8 ~ 1.0 ~ 4.2 ~ 3.5 ~ 0.8 4.TORQUE SPECIFICATIONS 1-13 6.6 ~ 0.5 0.2 ~ 1.5 ~ 8.2 Standard (kg m) 17 ~ 19 6.0 2.2 ~ 1.2 1.5 3.0 ~ 2.9 ~ 1.4 0.5 0.5 ~ 11.5 ~ 7.5 0. lower) Silent shaft driven gear bolt Silent shaft plug gap Silent shaft gear cover bolt Connecting rod cap nut Flywheel bolt Crankshaft bearing cap bolt Silent shaft chamber cover bolt Oil relief valve plug Oil pump cover bolt Oil pressure switch Oil filter bracket Oil cooler by-pass valve Oil jet check valve Water pump bolt Water pump pulley bolt 11.0 ~ 6.7 1.2 ~ 1. 0 M6 0.3 1.0 5.9 1.0 ~ 1.5 2.0 1.5 ~ 2.1-14 Deseription Water outlet fitting attaching bolt Coolant tempeature gauge unit Thermo switch (113°) Alternator brace bolt Adjust rocker arm Alternator support bolt nut Intake fitting bolt Intake manifold bolt TORQUE SPECIFICATIONS Standard (kg m) 1.0 ~ 7.5 ~ 2. 4171 or equivalent Threebond No.0 ~ 4.0 ~ 1.0 1.2440 or equivalent Amount As required As required As required As required .0 5.0 0.0 ~ 7.2 ~ 1.5 0.8 ~ 1. A/con) Sealants 3M ATR P/No. 8660 or equivalent 3M ATR P/No.0 ~ 2.5 1.0 Heat protector bolt M8 Oil return pipe bolt Exhaust fitting nut Turbo charger nut Exhaust manifold nut SEALANTS Description Half circle packing Oil pan gasket Coolant gauge unit Thermo switch (113°.5 1.8 ` 1.3 3.2 ~ 1. 8660 or equivalent 3M nut rocking P/No.2 ~ 1. rod small end bushing B1443000 Camshaft oil seal installer (09221-21000) Installation of camshaft oil seal ECLA002I . SPECIAL TOOLS Tool (Number and name) Silent shaft bearing puller (09212-43100) Illustration Use Removal of silent shaft rear bearing B1243100 Silent shaft bearing installer (09212-43200) Installation of silent shaft rear bearing B1243200 Bearing installer stopper (09212-43300) Removal of Right silent shaft rear bearing B1243300 Crank shaft front oil seal installer (09214-32000) Installation of crankshaft front oil seal B1432000 Crankshaft front oil seal guide (09214 .end busing replacement tool (09214-43000) Replacement of connecting .32100) Guide for installation of crank shaft front oil seal B1621100 Connecting .SPECIAL TOOLS 1-15 7.rod small . 1-16 Tool (Number and name) Cylinder head bolt wrench (09221-32000) SPECIAL TOOLS Illustration Use Loosening and tightening of cylinder head bolt ECLA002A Valve seat cutter pilot (09221-43200) Correction of valve seat ECLA002B Valve seat cutter 45° (09221-43300) Correction of valve seat ECLA002C Valve seat cutter 65° (09221-43400) Correction of valve seat ECLA002D Valve seat cutter 30° (09221 .43500) Correction of valve seat ECLA002E Valve spring compressor (09222-21000) Compression of valve spring B2221000 Valve stem seal installer (09222-32100) Installation of valve stem seal B2232100 . SPECIAL TOOLS Tool (Number and name) Valve guide installer (09222-32200) Illustration Use Removal and Installation of valve guide 1-17 ECLA002F Silent shaft drive gear oil seal guide (09222-43200) Installation of silent shaft drive oil seal B2243200 Crankshaft rear oil seal installer (09232-32000) Installation of crankshaft rear oil seal B3132000 Oil pressure switch wrench (09260-32000) Removal and Installation of oil pressure switch B6032000 Injection pump sprocket puller (09314-43000) Removal of injection of pump sprocket C1443000 . Troubleshooting Symptom Low compression Probable cause Blown cylinder head gasket Worn or broken piston rings Warped or pitted valves Excessive run-out of valve seats on valve faces Noisy valves Incorrect of valve cleanrance Worn valve guides Connecting rod noise Excessive camshaft end play Insufficient oil supply Low oil pressure Remedy Install new head gasket Hone cylinder bores and install new rings Install new valve Reconditioning valve seats and valves Adjust as standard and valve Install new valves and/or new valve guides with O. Thin or diluted oil Excessive end play Crankshaft journal out-of-roundness worn Loosen flywheel Piston noise Excessive clearance due to cylinder wear Piston or piston pin worn Burnt piston Piston ring damaged Change oil to correct viscosilty Measure bearings for correct clearances Replace crankshft or regrind journals Tighten to correct torque Correct cylinder wear Replace piston Install new piston Install new rings . Reconditioning valve seats and valve Correct end play Check engine oil level Check engine oil level Thin or diluted oil Excessive bearing clearance Connecting rod journals out-of-roundness Misaligned connecting rods Inspect oil relief valve and spring Change oil to correct viscosity Measure bearings for correct clearance Replace crankshaft or regrind journals Replace bent connecting rods Crankshaft Bearing noise Insufficient oil supply Low oil pressure Check engine oil level Check engine oil level Inspect oil relief valve and spring.S.1-18 TROUBLESHOOTING 8. clean and reinstall Install new oil pump Clean or replace screen Correct or replace Retighten or replace Retighten or replace Replenish Replace Replace Correct or replace Remedy 1-19 .Damaged themostat perature Loose or broken belt Install new valve stem selas Check engine oil level Set idle speed to specification Install new switch Install new oil filter Replace worn parts or pump Change oil to correct viscosity Measure bearings for correct clearance Remove valve and inspect. replace pistion. scuffed. Check grooves. or broken rings Carbon in oil ring slot Ring fitted too tight in grooves Tighten to torque Tighten to torque Install new oil seal Install new oil seal Install new oil seal Install new oil seal Tighten to torque Install new oil seal Hone cylinder bores and install new rings Install new rings Remove the rings. proper width. If groove width is not . heater hose Themostat water pump leakage Radiator clogged Coolant dirty Damaged radiator cap High coolant tem. Faulty valve stem seals Overheat Low oil level Slow idle speed Faulty oil pressure switch Colgged oil filter Worn parts in oil pump Thin or diluted oil Excessive bearing clearance Oil relief valve stuck Oil pump cover bent or cracked Oil screen loose or clogged Insufficent coolant Radiator leakage Loose or damage radiator hose.TROUBLESHOOTING Symptom Oil leak Probable cause Oil pan drain plug loose Oil pan mounting bolt loose Oil pan gasket broken Crankshaft front oil seal defective Crankshaft front oil seal defective Rocker cover gasket broken Oil filter loose Oil filter gasket broken Oil consumption Worn. 1-20 CHECKING POINT 9. Increase the pressure until the gauge stops moving. 3.05 kgf/cm2 0. Check that the coolant level of the reservoir tank is between FULL and LOW marks. 3. CHECK POINT CHECKING COOLANT RESERVIOR 1.5l ) Freezing Delivery condition temperature(°C) Mixture ratio(%) Antifreeze quantity(l) -15 40% -20 -25 30 35 40 10 2. cooling is not efficient or the engine part could become damaged or not work properly. Use an adapter to attach the cap to the tester.65 kgf/cm2 3.80 . vapor corrosion is not inhibited. since rust or other foreign material on the cap seal will cause an incorrect reading.75 ~ 1. CHECKING COOLANT 1. The standard coolant concentration range is as below. Check that the pressure level is maintained at or above the limit. Standard 30 ~ 60% (normal range) CAUTION If the concentration of coolant falls below 30% or above 60%. Check that the coolant is not mixed with oil. Antifreeze ratio Coolant quantity (9. Main valve opening pressure Main valve closing pressure 0. Replace the radiator cap if the reading does not remain at or above the limit.45 2. 2. NOTE Be sure that the cap is clean before testing. 2. Remove the reservoir tank and drain coolant. Loosen and remove the drain plug. . After starting the engine. 4. add enough recommended oil. CAUTION Do not open the coolant reservoir cap when it is hot. Pull out the engine oil indicator(dipstick) and wipe it clean with clothing. 2.5l Engine capacity Overall capacity including the reservoir tank and radiator 7. Remove the indicator carefully and check that the oil level is between LOW and HIGH marks as shown in the illustration. 8. • If the engine is running. 2. Check the coolant quantity after warming up the engine and add coolant. Engine oil Diesel Above API CD SAE 10W30 LOW Good HIGH KCMB018A CAUTION Oil levels above the HIGH mark may cause engine damage. CAUTION • Make sure the vehicle is on a level ground. Steam and scalding liquids released from a hot cooling system can burn you badly. Fill the reservoir tank up to FULL line with coolant.CHECKING POINT 1-21 REPLACE COOLANT 1. turn the engine off and wait a few minutes before checking. pour water into the coolant reservoir cap and clean the coolant passage. Coolant quantity 3. 5. stop the engine and recheck the engine oil level is within the normal range. After draining the coolant. Securely install the coolant reservoir cap. Install the reservoir tank. Securely tighten the radiator drain plug. 3. 4. 6. 3. 5. CHECKING ENGINE OIL LEVEL 1.9l 9. let it idle for a few minutes. Insert the indicator into the oil level gauge guide. If the oil level is below the LOW mark. 2. After warming up the engine. Front KD4B1001 3. do not drop engine oil in the alternator. Drain plug 1. Engine oil placed in the alternator may harm the alternator. Remove the drain plug and drain oil. CHECKING AND ADJUSTING DRIVE BELT TENSION 1. remove the oil filler cap. Add new oil to the oil filler. Tighten the drain plug.1-22 CHECKING POINT REPLACING ENGINE OIL CAUTION When replacing engine oil and oil filter. Inspect tension by pressing in the middle of belt with 10 kg f as shown in the illustration. Alternator Alternator bolt Alternator pully Alternator support bolt Crankshaft pulley or pulley KCMB020B . 4. Standard Alternator 10 ~ 13 mm Belt Water pump Alternator Crank shaft KD4B1002 CHECKING AND ADJUSTING DRIVE BELT TENSION CAUTION Inspect tension after rotating the engine to one turn counterclockwise. CAUTION Protect yourself from the hot oil. 10kg. Loosen the alternator brace bolt. Measure the valve clearance at arrow positions shown in the illustration.2 NO.25 mm 0. Loosen the alternator support nut.4 Description Exhaust valve Intake valve Hot engine 0. move the alternator to the standard tension value. Warm up the engine until the coolant temperature reaches 80~90°C.CHECKING POINT 1-23 BELT ADJUSTMENT 1. Move the alternator to increase the belt tension to the standard value.1 NO.3 NO. When using a tension gauge. 2.25 mm Intake valve Èí±â¹ëºê Exhaust valve ¹è±â¹ëºê KD4B1003 . NO. 2. Standard 10 ~ 13 mm Alternator brake bolt Water pump pully Alternator pully Crank shaft pully Alternator support bolt KCMB020E 4. 3.m · Water pump pully Standard 50 ~ 70 kg Standard 40 kg Crank shaft pulley Alternator pully KCMB020F VALVE CLEARANCE ADJUSTMENT 1. 4 to the dead point. KCMB025A Pressure gauge . loosen the locker arm nut and adjust clearance with the adjust screw turning using a thickness gauge. ( ) : Cold engine Item Exhaust valve Intake valve Hot engine 0. Feeler gauge Standard 0.15) mm NO. Inspect clearance of the intake and exhaust valves and adjust it if required.4 Intake valve Exhaust valveÈí±â¹ëºê ¹è±â¹ëºê KD4B1005 7. Rotate the crankshaft to 360° place the cylinder no. Measure valve clearance at arrow positions shown in the illustration. Check the engine oil.3 NO. 3. 4. 5. If the measured value exceeds the standard.1-24 CHECKING POINT 3. Tighten the lock nut to the specified torque with the adjusting nut fixed not to rotate using a screwdriver.25 (0. adjust it as the procedures (6)~(7).15) mm 0.25 (0. Engage the gauge adapter and install the preheat plug to the pressure gauge. Warm up the engine until the coolant temperature reaches 80~90°C. starter and battery for normal operation. Cygnus gauge KD4B1004 6.25 mm KCMB020G VALVE CLEARANCE ADJUSTMENT 1.1 NO. 2. If the measured value exceeds the standard. 8.2 NO. 1 to the dead point.CHECKING POINT 4. Disassemble the timing belt upper cover.0 kg m Cam shaft sprocket Second gear KCMB026C . Loosen the spiral bolt to a turn and the groove nut to 1-2 turns. Crank the engine and measure the pressure. Check that the timing mark on the sprocket is aligned. Rotate the crankshaft clockwise to the second gear of the camshaft sprocket.2 ~ 3.0 kg/cm2 CHECKING COMPRESSED PRESSURE 1. Rotate the crankshaft clockwise to place the cylinder no. Groove bolt Spiral bolt KCMB026B 4.2 kg/cm2 1-25 5. Timing mark No. 5. Fix the tensioner groove bolt and tighten the spiral bolt to the specified torque. Tightening torque 2. Limit (250rpm) 19. 2. Limit 3. Check that the measured value of each cylinder is within the limit.1 cylinder dead point KCMB026A 3. 2.1 to the dead point. 5. 2. Disassemble the timing belt upper cover.0 ~ 2.1-26 CHECKING POINT 6.0 kg m KCMB026E Spiral bolt Groove nut . KCMB026F 3. Assemble the timing belt upper cover. Check the belt tension by pressing the middle of cam sprocket and injection pump sprocket with hand. Loosen the spiral bolt to a turn and the groove nut to 1-2 turns. 7. Remove the access cover.2 ~ 3. Assemble the access cover. Tightening torque Bolt Nut 6. Rotate the crankshaft clockwise to place the cylinder no. Access cover KCMB026D 4. ECLA005E ADJUSTING TIMING BELT "B" TENSION 1. Standard 4 ~ 5 mm 8.7 kg m 2. Install the timing belt upper cover. First tighten the tensioner groove bolt and then the spiral bolt to the specified torque. 7. Rotate the crankshaft counterclockwise to align it to the timing mark. Wax type cold starting equipment KCLA006A . stop the advance angle function not to result in lack of power. CAUTION When checking and adjusting to replace the injection pump. WAX TYPE COLD STARTING EQUIPMENT This unit is adopted at low temperature to properly correct the fuel injection timing according to the engine coolant temperature. 3.CHECKING POINT 1-27 CHECKING INJECTION TIMING 1. CAUTION Do not turn the lever too much. Driver ECLA005H Accelerator lever Spacer (10mm) Rod 2. Remove the screwdriver. Stop the cold starting advance angle function. Insert a screwdriver into the lever lower groove and turn it as shown in the illustration. Insert the spacer (thickness: 10mm) between the rod and adjusting screw. Piston Wax KCLA006B 2. Wax is sealed in the cold starting equipment. The torsion spring pushes the piston to the injection timing advance angle direction. Accelerator lever Pin(A) Lever (1) KCLA006D . According to the engine coolant temperature except for the injection timing. The lever is rotated by the piston and the roller puller is operated by pin(B) to control the injection timing in retard or advance. the rod connected in the accelerator lever adjusts the engine idle speed. Timer Piston Adjusting bolt Pin (A) Idle control bolt Pin (B) Spring Lever (1) Outut side lever Pump sie lever KCLA006C 3.1-28 CHECKING POINT STRUCTURE 1. so the piston rod is operated according to the engine coolant temperature. Crank pully Notch Timing indicator KCLA003G 2. Distribution holder Nut KCLA003H 3. Loosen the injection pump mounting nut and temporarily tighten it. Loosen the four union nuts in the injection pump side injection pipe and temporarily tighten them. Rotate the crankshaft to place the cylinder no. Remove the timing check plug from the injection pump. Fix the distribution holder using a spanner not to be turned during loosening the union nut. Timing check plug KCLA003J . Injection (4) Bolt (2) Nut (2) KCLA003I 4. 1.CHECKING POINT 1-29 ADJUSTING INJECTION TIMING CAUTION Adjust the injection timing with the engine stopped.1 to the compression dead point. 1-30 CHECKING POINT 5. 9. Normal injection timing ATDC 5° ± 0. Set the dial gauge to read '0'.03 mm Recheck the dial gauge is within the standard.03 mm 1 10. Standard 1 0.03 mm KCLA003N . check that the push rod is jutted out about 10mm. Protrusion of the push rod is adjusted by the inner nut.43000 10mm 10 mm KCLA003K 6. Push rod Nut 09301-43000 09310 . Dial gauge KCLA003L 7. Rotate the crankshaft to the right to place the pulley notch to 5°. If the pointer is unstable.1 compression dead point. Slightly move the crank pulley notch left and right and check that the pointer moves away from 0 position. Install the dial gauge by installing the special tool to the injection pump. 8. Before installing the special tool. realign the notch position to 30° front of the dead point Approx 30° 30˚ 0 KCLA003M 10. Align the crank pulley to 30° front of the cylinder no. Fix the spanner not to turn the distribution holder together. 12. Check the injection timing and valve clearance and adjust them if required. Install the injection pipe nut. If the measure the value is out of the standard.03 1±0.CHECKING POINT 11. Install the idle speedometer. . 6. 15.03 mm or more 10. 1-31 Front View 1±0. Before checking and adjusting • Engine coolant temperature: 80~90°C 2. After adjusting. 14. 3. 4. 1. move the injection pump body left or right to correct and tighten the injection pump mounting nut and bolt to the specified torque.03 KCLA003O 13. After adjusting. loosen the lock nut and adjust it within the standard values by turning the adjusting screw.Detach the dial gauge and special tool and install the gasket and plug. If the pointer of dial gauge is out of the standard values. Install a new gasket and tighten the plug to the specified torque. Measure the engine idle rpm. Tightening torque 2. repeat the procedures (7) and (10) to check that the adjustment is correct.7 kg m KCLA003P Dial gauge Plug CHECKING AND ADJUSTING ENGINE IDLE SPEED CAUTION Only use the idle speed adjusting screw.03 mm or less 10. Standard 750 100 mm Idle adjusting screw Speed up Accelerator lever Lock nut KCLA004A 5. tighten the lock nut.3 ~ 3. ..... 2............. FRONT CASE ...........14 3................................... CYLINDER HEAD ASSEMBLY .CHAPTER 2...................................... 2...................... CYLINDER BLOCK ....... TIMING SYSTEM ......41 ..................................25 4..31 5.. 2...................................................................................... 2...................1 2....... 2. ENGINE MECHANICAL SYSTEM 1.... MAIN MOVING SYSTEM ...................... Rocker arm. Intake 8.9 ~ 2. Oil filler cap 3. Packing 6. Rocker cover 4.4 Camshaft bearing cap .Front Camshaft bearing cap No. CYLINDER HEAD ASSEMBLY 1) LOCKER ARM & CAM SHAFT COMPONENTS 0.5 ~ 0.CYLINDER HEAD ASSEMBLY 2-1 1. Rocker shaft 7. Breather hose 2. 16.7kg·m 1 2 3 3. 12. 17. Adjust screw Camshaft oil seal Camshaft bearing cap .3 Camshaft bearing cap No. 13. Rocker arm. 15.2 Camshaft bearing cap No. Exhaust 9.1kg·m 17 12 5 14 16 15 7 11 <Disassembly> 1.0kg·m 4 10 6 9 8 13 1. 11. Rocker cover gasket 5.Rear Camshaft KCMB800A . 14.5 ~ 4. Rocker shaft spring 10. Standard Limit 0. shaft or both. Journal KCMB810A 2. Standard Limit 37.05 ~ 0.05 mm 36. Measure the cam height (bigger diameter) and replace it if it exceeds the limit. Check the cam surface for abnormal wear or damage and replace it if required.04 mm 0. Check the contact surface with the cam and replace the rocker arm if it damaged and burned.08 mm 0.0.13 mm KCMB100H 3.2-2 INSPECTION CAMSHAFT CYLINDER HEAD ASSEMBLY 1. Visually inspect the camshaft journals and replace them if they are damaged and burned. check the cylinder head bearing for damage and the cylinder head oil passage for clogging. Visually check the inside for damage or burn and replace it if required. Standard Limit 0. replace the camshaft.01 . replace the rocker arm. Measure the camshaft diameter and bearing inner diameter and if the oil clearance exceeds the limit value. If the camshaft journals have burned. Measure the inner and outer diameters and if the oil clearance exceeds the limit.55 mm ROCKER ARM 1.08 mm . 3. 2. cylinder head or both. 2. 2-3 ASSEMBLY CAM SHAFT 1. Check the rocker arm assembly for damage or burn and replace it if required.08 mm B ECLA019C 2. B .0.CYLINDER HEAD ASSEMBLY ROCKER SHAFT 1. calculate the end play. . Dowel pin Camshaft KCMB820A CAM SHAFT BEARING CAP Assemble the camshaft bearing cap in sequence of the identification number engraving on the upper surface of bearing cap. and if the value exceeds the limit.01 . Measure A and B. Check the oil passage for clogging and clean it if required.A = End play Standard Limit 0. Install the camshaft with the dowel pin upward to the cylinder head.04 mm A 0. replace parts. 09221 21000 09221 --21000 Cam shaft Oil seal KCMB820B ROCKER ARM (EXHAUST. The shaft having one oil passage should be assembled in the front.2-4 CAM SHAFT OIL SEAL CYLINDER HEAD ASSEMBLY 1. INTAKE) Take care not to make mistakes of the identification numbers. facing it downward. Specified sealant 3M P/No. Using the special tool. Assemble the oil passage side shown in the illustration. ROCKER ARM SHAFT 1. 2. 8660 or equivalent Apply sealanat KCMB820D . One oil passage Two oil passages Front KCMB820C PACKING Apply sealant to the marked portion in the illustration. 2. Apply oil to the oil seal lip portion. press-fit a new camshaft oil seal to the front bearing cap portion. Ex. Camshaft sprocket Timing mark 2-5 KCMB820E 2.CYLINDER HEAD ASSEMBLY ADJUSTING VALVE CLEARANCE 1. In. Loosen the adjusting screw mounting nut. Adjust the valve clearance by turning the adjusting screw. Ex. Adjust the valve clearance at the arrow position shown in the illustration.15 mm 0. KCMB280F 3. Standard (Cold engine) Intake Exhaust 0. 4.15 mm 5. In. Rotate the crankshaft clockwise to align the camshaft sprocket with the timing mark. Fix the adjusting screw not to turn using a screwdriver and install the adjusting nut ECLA019J . Follow the procedures (2). (3) and (4) to adjust the valve clearance.25 mm 8.25 mm 0. In. Ex.2-6 CYLINDER HEAD ASSEMBLY 6. After installing the engine assembly to the vehicle. KCMB280G .4 to the compression dead point. In. inspect the valve clearance with hot engine and adjust it if required. Ex. 7. Standard (Hot-engine) Intake Exhaust 0. Rotate the crankshaft to one turn clockwise to place the cylinder no. Intake valve 9. Intake valve guide 12.CYLINDER HEAD ASSEMBLY 2-7 2) CYLINDER HEAD & VALVE COMPONENTS 4 5 10 6 1 7 12 11 Cold engine : 10. Valve spring retainer lock 5.5~12. Valve stem seal 11. Intake valve seat 14. Valve spring retainer 6. Cylinder head 3. Spring seat 8. Exhaust valve KCMB750A . Exhaust valve 13. Valve spring 7.5 kg·m 2 3 14 13 8 9 [DISASSEMBLY] 1.5~11. Cylinder head bolt 2. Cylinder head gasket 4. Exhaust valve 10.5 kg·m Hot engine : 11. scale. Before cleaning the cylinder head.21000). damage. loosen 18 Cylinder head bolts and remove them. 09221 . the stem seal. 2. Cylinder Head bolt Wrench (09221-32000). causes the bottom end of retainer to be in contact with. 2. compress the spring and fit the retainer lock in position. or cracks. if compressed excessively. Using a valve spring compressor (09222 . check for water and oil leaks. sealant.32000 ECLA018B 6 1 5 10 14 18 13 16 12 15 8 4 7 3 2 9 17 11 KCDA052A VALVE SPRING RETAINER LOCK 1. 09222 .21000 ECLA018D INSPECTION CYLINDER HEAD 1. Remove oil. and carbon deposits completely. Loosen the bolts in the sequence shown and in two to three steps. and damages.2-8 DISASSEMBLY CYLINDER HEAD BOLT CYLINDER HEAD ASSEMBLY Using the special tool. . The valve spring. apply compressed air to ensure that the passages are not clogged. After cleaning the oil passages. The contact pattern with the valve seat must be even at the center of valve face. replace the bearing. Contact Standard value Limit 2. Replace if the margin (valve head thickness) exceeds the limit. Measure the free height of spring and replace if the limit is exceeded. replace. EXHAUST VALVE 1.1 mm 2. replace. Standard value Limit 49. if the limit is exceeded. measure the surface flatness.1 mm Free height ˚ 48.0 mm 1. If there is a dent in the stem end face (the surface in contact with the rocker arm adjust screw). If there is gas leak from the cylinder head gasket surface.2 mm 2-9 4. replace the cylinder head. Visually check the camshaft bearing internal surfaces for damage or seizure.CYLINDER HEAD ASSEMBLY 3. If the valve stem develops wear (taper wear) or damaged. If defects are evident. Check the valve face for contact. If distortion exceeds the limit.05 mm less than 0. KCMB100B Standard value Limit 2° less than 4° . If the contact is not proper. Contact Margin KCMB770A 2. replace.0 mm KCMB770A Margin VALVE SPRING 1. INTAKE VALVE. Standard value Limit L 0. 3. Measure the squareness of the spring and. correct with a valve refacer. Exhaust Intake Intake Limit Exhaust 0.600 ~ 37. 0.S.5 . Special tool 2. 0.1mm Cutting portion 0.2-10 VALVE GUIDE CYLINDER HEAD ASSEMBLY Measure the valve guide to stem clearance and.S.300 ~ 37. or both. 43. correct the seat width and angle to the specified value. inspect clearance between the valve guide and valve and replace the valve guide if required.300 ~ 43.9 .15 mm KCA9281D Standard value RECONDITIONING VALVE SEAT 1.09 mm 0. Cut the valve seat to be replaced from the inside to thin the wall thickness.60 O. 2.325mm 37.600 ~ 43.3 mm 65˚ Cutter ECLA018E 3. When reconditioning the valve seat. Rebore the valve seat hole in cylinder head to the oversize valve seat diameter.325mm 43.S. if the measurement exceeds the limit. Intake valve seat ring hole diameter Exhaust valve seat ring hole diameter 0. Apply compound to the valve and seat. VALVE SEAT CUTTER Cutter angle 45° 65° 30° Parts number 09221-43300 09221-43400 09221-43500 45˚ 65˚ 0. Then. VALVE SEAT REPLACEMENT PROCEDURE 1.S.05 ~ 0. 0.5 .625mm KCMB100D 0.1mm .06 mm 0. replace the valve seat.03 ~ 0. replace the valve guide or valve.625mm 37.10 mm 0. Using the special tool or valve grinder.30 O.30 O.60 O.1. press-fit the valve guide. Height of valve seat 2-11 Over size I.S.050 ~ 13. either heat the cylinder head up to approximately 250°C (482°F) or cool the valve seat in liquid nitrogen to prevent the cylinder head bore from abrasion.500 ~ 13. Push rod Valve guide 09222 . Using the push rod of Valve Guide installer (09222 . CAUTION Take care not to change the exhaust and intake valve guides because both lengths are not equal. 2.268 mm 13.518 mm CAUTION Do not reassemble the same size of valve guide. After installation. 13.D.S. Rebore valve guide hole to the new oversize valve guide outside diameter. recondition the valve seat.32200 Cylinder head KCMB770C Vavle guide (Intake valve) Valve guide (Exhaust valve) 71mm 74mm KCMB770D .068 mm 13. 3. remove the valve guide forward cylinder block.250 ~ 13. working from the cylinder head top surface.CYLINDER HEAD ASSEMBLY 3. 0. 0.50 O.05 O. Using Valve Guide Installer (09222-32200). 4. Before fitting the valve seat.25 O.32200) and apress. KCMB100E VALVE GUIDE REPLACEMEMT PROCEDURE 1. 0.S. • The special tool must be used for the installation of the valve stem seal. 5.32100). Improper installation could result in oil consumption through valve guide. After installing valve guides. inspect valve contact and correct the valve seat if required.2-12 CYLINDER HEAD ASSEMBLY 4. Valve spring seat 09222 . Using Valve Stem Seal Installer (09222 .32100 KCMB780A VALVE SPRING Direct the valve spring end with identification color to the therocker arm. insert new valves in them to check for sliding condition. Identification Spring Retainer Stem seal KCMB100F . Vavle guide (Intake valve) Valve guide (Exhaust valve) 71mm 74mm KCMB770E INSTALLATION VALVE STEM SEAL 1. When replacing the valve guides. install the valve stem seal into the valve guide. CAUTION • The valve stem seal must be not reused. Tighten in the numerical order indicated in the diagram in two or three groups with special tool.21000 ECLA018D CYLINDER HEDA GASKET 1.21000). the stem seal.5 kg·m 10. 2.5 ~ 11. Specified torque 18 13 17 14 9 6 5 1 4 3 7 12 11 15 16 10 2 8 Limit Cold engine 11. 2-13 09222 . 2. if compressed excessively. Scrape off gasket adhered to cylinder head assembly. CAUTION The valve spring. compress the spring and fit the retainer lock in position. and damages. Clean contact surfaces between the cylinder head and cylinder block gasket. Assemble the gasket facing upward the marking portion in the illustration.5 kg·m KCMB780B . causes the bottom end of retainer to be in contact with. CYLINDER HEAD BOLT 1.5 ~ 12.CYLINDER HEAD ASSEMBLY VALVE SPRING RETAINER LOCK Using a valve spring compressor (09222 . Crank shaft pully bolt 2. Crank shaft pully 4. Acess cover 7.2 ~ 3. Timing belt tensioner Tensioner speacer Timing belt Camshaft sprocket Injection pump sprocket Crank shaft sprocket KCMB850A . Flange 8. Timing belt lower cover 6.5 ~ 7. 10.2-14 TIMING SYSTEM 2. 11. 13.0kg·m 8 4 9 8 ~ 9kg·m 12 5 17 ~ 19kg·m 1 10 7 13 2 3 6 [DISASSEMBLY] 1. TIMING SYSTEM 1) TIMING BELT COMPONENTS 11 6. 12. Washer 3. 9.5kg·m 2. Timing belt upper cover 5. water pump. 3. slide the tensioner toward the water pump and tighten the bolts temporarily to secure the tensioner in place. as well as not be stained with oils. replace them. 1 cylinder is at the top dead center on the compression stroke when all timing marks at the three places are aligned as shown. Turn the crankshaft to bring the piston in No. KCMB860A 5. Slightly loosen the two bolts securing the tensioner. sprocket and tensioner should not be washed off. Remove the cooling fan. 1 cylinder to the top dead center on the compression stroke. Mark an arrow on the back of the timing belt and timing belt B with a chalk to indicate the direction of rotation. Then. 2-15 CAUTION Stained belts with water or oils may be highly short enedtheir life.TIMING SYSTEM REMOVAL TIMING BELT 1. ECLA020B 4. This ensures that the belt is installed in the same direction for reuse. The piston in No. the removed timing belt. 2. Slide toward water pump KCMB860B . If the belts are seriously stained. So. crankshaft pulley and timing belt cover. 2-16 CAMSHAFT SPROCKET TIMING SYSTEM 1. Using Injection Pump Sprocket Puller (09314 43000) or suitable tool. Non-elastic and so hard that. Loosen the bolt securing the camshaft sprocket and remove the camshaft sprocket. Hardened back surface of rubber Back surface is glossy. ECA9200B 2. 2. Remove the sprocket nut. KCMB860C INSPECTION TIMING BELT Carefully inspect the belt and replace it with a new one if there are damages presented as below. Badly worn out teeth (last stage) Crack Crack KCMB870A . as it could result in defective fuel injection pump. Cracked or separating canvas 4. Remove the tensioner and tensioner spring. CAUTION Use care not to give shock to the fuel injection pump shaft. 1. 3. remove the sprocket from injection pump. Badly worn out teeth (initial stage) Separation Crack Crack 5. Cracked back surface of rubber 3. no mark is produced. when your fingernail is pressed into it. Check it for smooth rotation and abnormal noise and replace it if required.TIMING SYSTEM 6. Separation Rounded belt side 2-17 Abnormal wear KCMB100J 7. Missing tooth Rubber exosed Fiber exposed KCMB100K TIMING BELT TENSIONER 1. Check it for clicking sound and rolling and replace it if required. Check the seal for wear and damage and replace the timing belt if required. . KCMB870B TIMING BELT COVER 1. Check it for deformation and crack and replace it if required. 2. low quality of rubber. discolored with white. and bad clearness) Latter state: Canvas worn and rubber exposed (tooth width narrowed) 8. Side of belt cracked Normal belt should have precisely cut side as if produced by a sharp knife. Cracked tooth bottom Initial state: Canvas worn (swollen canvas fiber. 2. CAUTION When installing. 2. tensioner spring and tensioner spacer.2-18 INSTALLATION CRANKSHAFT SPROCKET TIMING SYSTEM Crank shaft 1. make sure that the arrow mark made during disassembly faces to the correct direction at reassembly. as it tends to turn by itself at the timing mark alignment position. KCMB870B TIMING BELT 1. Correctly line up timing marks on three sprockets. Mount the crankshaft sprocket to the crankshaft noting the direction of the sprocket as well as the flange. install belt onto the crankshaft sprocket. Be careful of the flange installation direction. tensioner and camshaft sprocket. While ensuring that the tension side of timing belt is not slack. Separation Crankshaft sprocket KD4B2010 . Mount the camshaft sprocket and tighten the flange bolts to specified torque. face the short end of tensioner spring toward the water pump. The tensioner moved all the way to the water pump. Camshaft sprocket Separation Injection pump sprocket Tensioner CAUTION • When installing the belt onto the injection pump sprocket. 3. injection pump sprocket. 2. 2. Sprocket Oil pump gear drive shaft Sprocket “ B ” Flange KCMB880A TIMING BELT TENSIONER 1. Install the tensioner. keep the sprocket in position. temporarily tighten bolt. • If the belt is to be reused. in that order. TIMING SYSTEM 3. one to two turns to give tension to the belt using tensioner spring tension. Check if all timing marks are aligned correctly. CAUTION Turn crankshaft clockwise by the two teeth of the camshaft sprocket and keep the position. 7. causing an undue tension to be applied to the timing belt. Camshaft sprocket Crank shaft KCMB880C 6. CAUTION If the bolt B is tightened first. 8. Standard 4 ~ 5 mm Deflection KCMB880E . Confirm that the timing belt is correctly engaged with three sprockets. 2-19 Bolt A Bolt B KCMB870B 4. 5. ensure that the deflection when the center of belt is pushed by the index finger. Back off tensioner bolt A. Tighten bolt A. 9. the tensioner should be turned together. In this condition. Tighten bolt B. that have previously been secured to the water pump side. Turn the crankshaft in the direction of backward rotation to line up timing marks. When assembling. Sprocket KCMB880F .2-20 FLANGE INSTALLATION TIMING SYSTEM Notch for timing adjustment Offset Flange Note that bolt holes in the flange and those in the injection pump sprocket are offset positioned at one place. position the jlange and sprocket as shown. 9.4 ~ 4. 3. 5.4 ~ 4. 10.2 ~ 3. 2.0kg·m 1.0kg·m 10 1 6 2.TIMING SYSTEM 2-21 2) TIMING "B" COMPONENTS 9 7 3. Flange Gasket Tensioner spacier Tensioner spring B Timing belt tensioner B Timing belt B Silent shaft sprocket-right Silent shaft sprocket-left Spacier Crank shaft sprocket B KCMB900A . 6. 4.0kg·m 8 2 3 4 5 3. 8. 7. 4. right Right side Slient shaft. slide the tensioner toward the water pump and tighten the nuts to secure the tensioner in place temporarily. put an arrow on the back of the timing belt "B" to indicate the direction of drive. oil. Use special care to ensure that the removed timing belt.31 in. Remove the timing belt. Using chalk or the like. SILENT SHAFT SPROKCET(LEFT. sprockets. Screw driver [shaft dia. Slightly loosen the bolts and nuts securing the tensioner. and tensioner are free from oil and grease. Remove the two silent shaft sprockets. 6. Remove the timing belt "B".2-22 REMOVAL TIMING BELT "B" 1. left Remove this plugh and insert a screwdriver Remove cover and inseft bar KCMB910A . 8 mm (0. TIMING SYSTEM 2. or grease on the belt shortens its life drastically. be sure to lock the silent shaft as shown.) Wrench extension bar or similar size rod Silent shaft. RIGHT) When loosening the nut and bolt for two silent shaft sprockets. 5. Remove the crankshaft sprocket "B". ECLA021B 3. Then. CAUTION Water. TIMING SYSTEM INSTALLATION 1. Mount the crankshaft sprocket "B"to the crankshaft, noting the direction of the sprocket "B". Crank shaft 2-23 Oilpump gear drive shaft Sprocket “ B ” KCMB920A 2. The spacer must be installed with its chamfered end facing toward the silent shaft. If the spacer is installed in the wrong direction, damage to oil seal will result. Spacier Silent shaft Tapper KCMB920B TIMING BELT "B" TENSIONER 1. Install the tensioner spring and spacer, with the tensioner moved all the way to the water pump. 2. Tigh ten the nut. Tighten the bolt not fully put finger tight. Water pump Bolt A Nut Spacier Tensioner Gasket Front lower case Tensioner spring “ B ” KCMB920C A-A 2-24 TIMING BELT "B" TIMING SYSTEM Timing mark 1. Line up timing marks on the crankshaft sprocket B, and right and left silent shaft sprockets. 2. With the timing belt B installed, ensure that its tension side is not slack. CAUTION If the belt is to be reused, make sure that the arrow mark made during disassembly faces to the correct direction at reinstallation. Tensioner "B" Timing mark Tension Timing belt "B" Crank shaft sprocket "B" KCMB920D 3. With the tension side of timing belt B kept tight by pushing the slack side (indicated by A in illustration) with a finger, make sure that the timing marks are properly aligned with each other. Timing mark Timing mark Tension Tension KCMB920E 4. Back off tensioner B nut, that have previously been secured to the water pump side, one to two turns to give tension to the belt using tensioner spring tension. 5. First tighten the timing belt "B" tensioner mounting nut and then the bolt. CAUTION If the bolt is tightened first, the tension B should be turned together, resulting in reduced timing belt B tension. Bolt Nut Tensioner spring "B" KCMB920F 6. Ensure that the deflection is 4 to 5 mm (0.0394 to 0.1969 in.) when the belt is pushed by the index finger at the position indicated by and arrow. Belt deflection 4 ~ 5 mm Silent Belt deflection Crank shaft sprocket "B" KCMB920G FRONT CASE 2-25 3. FRONT CASE 1) FRONT CASE, SLIENT SHAFT, OIL PAN COMPONENTS 21 19 1.5 ~ 1.8kg·m 11 3.4 ~ 4kg·m 18 N 17 15 16 9 2.0 ~ 2.7kg·m 20 12 14 4 19 1.2 ~ 1.5kg·m 8N 13 N 21 2N 1.2 ~ 1.5kg·m 7 6 [DISASSEMBLY] 1. Oil drain plug 2. Oil drani plug gasket 3. Oil pan 4. Oil screen 5. Oil screen gasket 6. Front upper case 7. Oil seal 8. Front upper case gasket 9. Plug Cap 10. O-ring 11. Flange bolt 12. Flange lower case 13. Flange lower case gasket 14. Front oil seal 15. Silent shaft gear cover 1 6 ~ 8kg·m 0.6 ~ 0.8kg·m 3 N 16. Silent shaft driven gear 17. Silent shaft driven gear 18. Oil seal 19. Silent shaft, right 20. Silent shaft, left 21. Bearing, rear [Remarks] Assembly is the reverse of disassembly. Do not reuse N marking parts. KCMB150A 3. Remove the plug on the right side of the cylinder block. It may deform the oil pan flange surface. Cylinder block right Plug KCMB160A 2. Insert a screwdriver (cross slotted) into the plug hole not to turn the silent shaft. Driver Silent shaft right KCMB160B .2-26 REMOVAL OIL PAN FRONT CASE Remove the oil pan by tapping the oil pan bottom edge or drain plug with a soft hammer. Remove the flange bolt. ECLA007H FLANGE BOLT REMOVAL 1. CAUTION Do not insert a chisel or screwdriver between the oil pan flange and cylinder block to remove the oil pan. FRONT CASE INSPECTION SILENT SHAFT 1. Use Bearing Installer Stopper (special tool) only for removal and reinstallation of the right bearing. replace the silent shaft. If defects are evident. Check the silent shaft for oil clearance. bearing.09 mm 2-27 ECLA007K FRONT UPPER CASE.05 mm 0. FRONT LOWER CASE Check them for damage and crack. and contact with the bearing. replace the silent shaft bearing. Replace them if required. or front case assembly.02 ~ 0. 09212-43300 ECLA008A . REPLACEMENT SILENT SHAFT 1.02 ~ 0. The oil holes must be free from clogging.6 mm 0.05 ~ 0. Check journal for seizure. or front case assembly. OIL PAN Check the gasket surface for deformation and replace it if required. If wear is excessive. silent shaft. 2. damage. STANDARD VALUE Front left Front right Rear 0. 3. 43300. 09212 .43300 Apply oil KCMB180C 4. When press-fitting the right bearing. 09212 . remove two rear bearings from the cylinder block.43100 Bearing 09212 . 09212 . Using Bearing Installer Stopper and Silent Shaft Bearing Puller (09212 .43300.43100).2-28 FRONT CASE 2. remove two rear bearings from the cylinder block. Using Bearing Installer Stopper and Silent Shaft Bearing Puller (09212 .43200 Bearing 09212 .43100). Socket Oil seal KCMB190A . Bearing oil hole Silent shaft bearing Plug Cylinder block Oil hole KCMB180D INSTALLATION OIL SEAL Install special tools in drive gear and apply to engine oil to drive gear shaft. 09212 .43300 KCMB180B 3. align the bearing oil hole with the cylinder block oil hole. Install the special tool guide to the crankshaft and apply engine oil to the outer surrounding. 2. assemble the front oil seal to the case.32000 . 2. Crank shaft Oil seal Front lower case Oil pump driver shaft (Apply oil to outer surrounding) 09214 . Front lower case L = 55 L = 75 L = 25 L = 65 L = 55 L = 25 L = 65 L = bolt screw length (mm) KCMB190D FRONT OIL SEAL 1. Using the special tool.43200 Oil seal KCMB190C FRONT LOWER CASE When tightening the bolts.32100 KCMB190E 09214 . Apply engine oil to the gear.FRONT CASE SILENT SHAFT GEAR 1. Align the mating marks on the silent shaft drive gear and driven gear and assemble them to the front lower case Silent shaft Mating marks 2-29 KCMB190B Front lower case Drive gear 09222 . be sure to secure the silent shaft in position. 6 ~ 0. Assemble the flange bolt and tighten it to the specified torque. Remove the sealant attached in the cylinder block and oil pan gasket surface. After applying sealant. Tightening torque 0. 3.8 kg·m . 2. KCMB190F KCMB190G OIL PAN 1. Insert a screwdriver (cross slotted) into the plug hole not to turn the silent shaft(right). Apply sealant to the oil pan flange to the thickness of 4mm.2-30 FLANGE BOLT FRONT CASE 1. assemble the oil pan and tighten the bolt to the specified torque in 15 minutes. 2. 7. Crank shaft bearing-Lower 10. Crank shaft 11. Bearing cap 9.MAIN MOVING SYSTEM 2-31 4. 2. Fly wheel assembly Rar plate Bell housing cover Oil sela case Gasket Oil separator Rear oil seal 8. 6. MAIN MOVING SYSTEM 1) CRANK SHAFT & FLY WHEEL COMPONENT 13 ~ 14 kg·m 5 1 8 9 10 7 6 14 13 12 11 7.5 kg·m 1. Crank shaft bearing-Upper [Remarks] (1) Assembly is the reverse of disassembly (2) Do not reuse N marking parts. 5. KCMB200A .5 ~ 8. 3. 4. 5 mm R KCMB210B CRANKSHAFT OIL CLEARANCE (PLASTIGAGE METHOD) 1. 2.D. Install the crankshaft. Put a strip of Plastigage lengthwise in the center of the journal.2-32 INSPECTION CRANKSHAFT MAIN MOVING SYSTEM 1. Measure the journal O. Wipe crankshaft O.D.05 mm 0. ensure correct fillet radius dimensions in journals and pins.D. Standard Limit 0. and bearing I. replace the main bearing (and crank shaft if required). When grinding the crankshaft to undersize. Or. Visually inspect the journals and pins for damage and replace them if required.5 mm R 2. Plastic gauge KCMB210C .D. and main bearing I. clean of oil.5 mm R 2. 3. and if the clear ance exceeds the limit.01 mm A 1 2 B ECLA009B KCMB210A 3. 2. grind the crankshaft to undersize and replace it with the undersize main bearing. 2.02 ~ 0. If the teeth are damaged or broken. 2. replace it. 5. To install the ring gear onto the flywheel. RING GEAR 1. Deteriorated or hardened rubber. Visually inspect the flywheel clutch disc surface for wear and damage and replace it if required 2. If the clutch disc surface rolling exceeds the limit. Limit 0. Fly wheel Ring gear KCMB210D FLYWHEEL 1. Remove bolts and carefully remove the main bearing cap. To remove the ring gear for replacement. If the ring gear teeth are worn. or broken.MAIN MOVING SYSTEM 4. 6. damaged. Using the scale printed on the bag of plastigage. 2. tap its outer rim one place after another. replace the ring gear. 3. heat it up to 260-280°C (500-536°C) : it is a shrink fit in the flywheel.13 mm . 3. Heating the gear makes it impossible to remove. 2-33 ECLA009F CRANKSHAFT FRONT AND REAR OIL SEALS 1. measure the amount the Plastigage has been flattened (the widest point). Wear and damage in oil seal lips. check the starting motor pinion. Replace the main bearing cap carefully and tighten bolts to specification. Cracks or damage on oil seal case. Cap No.2. 5) (No. Install the upper crankshaft bearing to the cylinder block. 2. 4.18 mm 0.05 ~ 0.5) Upper & lower bearning(middle) KCMB220A BEARING GAP 1.4. 2. 4. 5) Without oil hole (No. damage and crack and replace it if required. INSTALLATION 1. Without oil hole With oil hole Lower bearing (No. KCMB220B 2.5) Upper bearing (No. 1. Install the lower crankshaft bearings to each bearing cap and apply engine oil to the bearing surface. 1. Main bearing cap direction Engine direction Arrow (Display engine forward) No.2. Ensure the correct cap number and arrow mark direction. Standard Limit 0. 1.25 mm ECLA009J .2-34 MAIN MOVING SYSTEM DRIVE PLATE (AUTOMATIC TRANSAXLE) Check the drive plate for deformation. There is oil hole in the upper crankshaft bearing. Install the main bearing to the cylinder block. 2.4. Check to ensure that the crankshaft turns smoothly and there is an adequate end play. 1. ) Oil hole KCMB220C . 2-35 09231 . Make sure that the oil hole in the separator comes at the bottom (indicated by an arrow in illustration.MAIN MOVING SYSTEM OIL SEAL CASE Using special tool.32000 KCMB210C OIL SEPARATOR Push oil separator into the oil seal case. press-fit a new crankshaft rear oil seal into the oil seal case. Connect rod cap 3. Piston 11. Connect rod bearing 6.2 9. Piston rod 13.1 8. Nut 2.5 ~ 4. Oil ring 10.8 kg·m [Remark] (1) Assembly is the reverse of disassembly KCMB250A . Piston ring No. Bolt 7.2-36 MAIN MOVING SYSTEM 2) PISTON COMPONENTS 6 7 8 11 9 10 5 13 12 4 [DISASSEMBLY] 1. Connect rod bearing 4. Piston ring No. Piston & connecting rod assembly 5. Snapring 12. Connect rod 14. Bushing 3 2 1 4. Replace any piston and pin assembly that is defective.02 ~ 0. CAUTION Replace the piston and piston pin as an assembly. When the piston requires replacement.065 0.07 0. 2.MAIN MOVING SYSTEM INSPECTION PISTON 1. scoring. Measure the clearance between piston ring and ring home. wear and other defects. 2. its ring should also be replaced.02 ~ 0. 2-37 PISTON RING 1. Piston Thickness gauge ECLA010C .15 0.066 0. Replace the defective rings.08 ~ 0. Check that the piston pin fits in the piston pin hole. The piston pin must be smoothly pressed by hand into the pin hole (at room temperature). damage and abnormal wear.065 ECLA010B imit 3.2 OIL No. Check each piston for scuffing.12 0. Item Standard No.056 ~ 0.1 No. Replace any piston that is defective. Check each piston ring for breakage.1 NA 0.2 OIL TC 0.03 ~ 0. 3.046 ~ 0. 4.1 No.076 0.15 0. 40 0.02 ~ 0. the crankshaft. Check the bearing surfaces for uneven contact pattern.25 ~ 0. Standard Limit 0. and seizure. replace the bearing and. Place a piston ring in the cylinder bore and set it square by pushing it down with piston.2-38 MAIN MOVING SYSTEM 4.40 Piston ring Eng gap KCMB260A CONNECTING ROD BEARING 1.1 No.43000 Pull out ECLA010G . replace.45 ~ 0.30 ~ 0.20 ~ 0.D.50 0.54 0.25 ~ 0. check also the crankshaft. scratches. If the clearance (oil clearance) exceeds the limit. If the surfaces are seriously nicked and seized. replace the bearing with an undersize.2 OIL TC 0. If defects are evident. at the same time. grind the crankshaft to an undersize and. and crankshaft pin O. streaks. Item Standard Limit No.45 0.05 mm 0. Pull out the bushing using the special tool. ECLA010E 2. Measure the connecting rod bearing I.8 NA 0. replace the crankshaft or grind to undersize for reuse. Pull out 09214 . If the crankshaft is also damaged. Or.41 ~ 0.60 0.1 mm ECLA010F CONNECTING ROD BUSHING 1. if necessary.D. 43000 2-39 Apply oil Align to the oil hole Bushing Chamfer side ECLA010H 3.MAIN MOVING SYSTEM 2. At this time. Install the snap ring in the following direction. align the busing with connecting rod small end oil hole. Standard 29. Adjust the busing inner diameter within the standard values. Front mark Front mark KCMB260B 2.015 ~ 29.. Insert the piston pin. Press-fit the bushing using the special tool.025 mm ECLA010I CAUTION 1. 09214 . following the front mark. ECLA010K . Oil KCMB270B PISTON & CONNECTING ROD ASSEMBLY 1.1 piston ring.25 mm 0. Standard Limit 0. 1 Piston pin No.4 mm ECLA010O . 2 Lower side rail KMBC270B 3. 4. 2 1. Upper side rail No. 1 PISTON RING INSTALLATION No.2-40 INSTALLATION MAIN MOVING SYSTEM No. as broken piston ring or damaged crank pin could result. piston ring and oil ring. align notches in the same direction. 2. install No. 2. in that order. Make sure the clearance of connecting rod big end side. Ensure that the front mark on piston crown and that (ID mark) on the connecting rod face toward the front of engine (to the crank pulley side). Clamp firm the piston rings with the ring band and install the piston assembly into cylinder. align the bearing cap with the connecting rod. Insert the piston and connecting rod assembly from above the top of cylinder. If parts are new ones. Install the oil ring expander and oil ring to the piston. on which manufacturer and size marks are stamped. Then. Make sure that the ring side. Apply engine oil to the piston surface. 6.10 ~ 0. When assembling. Adjust gap between the piston ring and oil ring as shown in the illustration.2 piston ring and No. faces to the piston crown. Do not strike it hard into the piston. ECLA010N 5. right 4.7 kg·m [DISASSEMBLY] 1. CYLINDER BLOCK 1) CYLINDER BLOCK COMPONENTS 4 ~ 5 kg·m 5 3 N 2 1 6 5 ~ 6 kg·m 4 0.CYLINDER BLOCK 2-41 5. left 5. Packing 3. Engine bracket. Engine bracket. Cylinder block [Remarks] (1) Assembly is the reverse of disassembly (2) Do not reuse N marking parts KCMB030A .5 ~ 0. Cylinder sleeve 6. Cover 2. .1 mm A B C D E F G ECLA007B 3. If flatness is not within the limit. check the cylinder block top surface for flatness.2-42 INSPECTION CYLINDER BLOCK CAUTION • Before inspection and repair. B. Standard 91.13 mm Middle Bottom KCMB040A . Use also a flaw detecting agent for the check. Check cylinder wall for scratches and seizure.. • Before cleaning the cylinder block. 2. 4. Lay the straightedge longways and crossways as indicated by A. and corrosion. If it wears out excessively. in illustration. If defects are evident.05 mm 0. Check for scratches. If defects are evident. correct (to oversize) or replace. carbon. clean parts to remove dirt.. At measurement. rust. measure the cylinder bore. ensure that the cylinder block top surface is free from any traces of gasket material. Measurement points are as shown. and scale. at the same time. be sure to check for evidences of water leaks and damage. bore the cylinder to oversize and replace the piston and piston rings. oil. deposits. Using cylinder gauge. Using a straightedge and thickness gauge. • Romove contaminants from oil holes with compressed air and.10 ~ 91. CYLINDER BLOCK 1. replace the cylinder block. Standard Limit 0. make sure that they are not blocked. correct or replace. 2.) (honing margin). • Boring dimension Piston O. 4.) O.) O.00 mm(0.04 to 0.75 1. + 0.0008 in. There are four oversize pistons available : Size 0.01 in.50 0. 0. 2. 2.S. The cylinders must be honed to finish dimension.08 mm 0.03 in.03 ~ 0. Check clearance between piston and cylinder. Piston O.D.04 in.02 ~ 0.25 mm(0. Bore cylinders to obtain the calculated boring dimension. 6. 1 and 3. 4. determine the oversize piston to be used. 5.0. 0. Don't bore only one cylinder to oversize.D.02 in.S.50 mm(0.75 mm(0.05 mm NA CAUTION 1. Using the maximum cylinder bore as a basis.) O. KCMB040B CAUTION To prevent thermal distortion due to temperature rise during boring operation. measured.S. bore cylinders in the sequence of No.) O.00 2-43 CAUTION Sizes are marked on the pistons.S.06 mm (piston to cylinder clearance) . 1. When boring cylinders.D. .25 0.CYLINDER BLOCK BORING OF CYLINDER 1.02 mm (0. finish all of four cylin ders to the same oversize. TC Clearance 0. Identification mark 0. Based on the piston O. calculate the boring dimension. Attach a round piece to the screwdriver P KD4B2002 INSPECTION 1. 2. 3. bore the sleeve hole to 0. 5mm oversize and press-fit the oversized sleeve into the sleeve hole. with a gauge placed as shown in the illustration. Measure the cylinder sleeve O.D. bore the cylinder block sleeve hole to oversize. Be careful not to damage the cylinder block wall. and cylinder block sleeve hole I. Fix the cylinder block with a boring machine before centering. Bore the sleeve until the thickness is 0. scuffing. CAUTION Be sure when boring the cylinder. After removing the cylinder sleeve.2-44 CYLINDER BLOCK 2) REPLACING CYLINER SLEEVE REMOVAL 1. all sleeves should be removed from all cylinders not to make mistakes during rounding. Measure D1. abnormal wear and other defects.5mm.12mm. inspect the cylinder block sleeve hole surface. KD4B2001 Face the rounded side toward the block Thin cylinder sleeve 3. D2 and D3 in the directions of X and Y and if the average value is below 0. Y direction Xdirection 12mm Middle Bottom D1 D2 D3 KD4B2003 . Insert the processed screwdriver as shown in the illustration between the cylinder sleeve and cylinder block and remove the cylinder sleeve by tapping on the screwdriver slightly. If there are damages. Centering should be done in the lower part of the cylinder sleeve where has little abnormal wear.D. 2. Difference between them should be '0' as possible.2mm) No slice Cylinder sleeve Cylinder block KD4B2006 5) Chamfer the cylinder sleeve top end as shown in the illustration. 1mm Cylinder sleeve 30 KD4B2007 . Without boring cylinder block sleeve hole 1) Apply press oil to the cylinder block sleeve hole surface and sleeve outer surface. Upper part Lower part KD4B2005 4) To prevent the cylinder sleeve and cylinder block top surfaces from roughness and bump. Press-fit load 2200kg or more Cylinder sleeve Hydraulic press 2-45 KD4B2004 3) Press-fit the sleeve until the sleeve top end surface is flush with the block top surface. cut the cylinder block top surface.CYLINDER BLOCK PRESS-FIT 1. 2) Put a flat rounded plate on the sleeve top end and pressfit it with a hydraulic press. Press-fit it toward the chamfer as shown in the illustration. (The limit: 0. after press-fitting the sleeve.050mm. if the protrusion is not within the limit. Limit 1.10mm. For press-fit and process procedures.1 mm Protrusion Piston Cylinder block KD4B2008 .10~91. After procedure 1.13mm 2~4 15~25° 0. Boring cylinder sleeve hole 1.5mm oversized cylinder sleeve. Press-fit the cylinder sleeve and render the bore. is processed with 90.05mm 2. If the protrusion is out of the limit.D. Prepare a 0. 2. hone the bore to be within the standard value. 2.2-46 CYLINDER BLOCK 6) Cylinder sleeve I. Hone the cylinder block sleeve hole to 94. inspect protrusion of the piston. INSPECTION AFTER ASSEMBLY 1. replace the piston inserted into thin one to be the protrusion within the limit. replace the cylinder block. refer to "Without boring block sleeve hole".08~90. After assembling the crankshaft and piston. Cylinder bore Honing surface formation Honing rendering angle (Cross-hatch) Cylinder bore perpendicularity 91.025~94. 3. . ......................... OIL PUMP .................. OIL FILTER ...........................CHAPTER 3... 3.... LUBRICATION 1.........7 ..................1 2.... 3........ OIL PAN ..........5 3.......................................................................... 3........................................... 5 kg·m 4 3.0 kg·m 5 3 0. OIL FILTER COMPONENTS 1 1.5 kg·m KCUB050A .pass valve 3. Gasket [Remarks] (1) Assembly is the reverse of disassembly (2) Do not reuse N marking parts 10 9 8 7 3.OIL FILTER 3-1 1.2 ~ 1. Tapper plug 6.0 ~ 4.8 ~ 1. Check valve 8. Oil pressure switch 4.0 ~ 6.5 kg·m 6 2 5.2 kg·m [DISASSEMBLY] 1.0 ~ 3. Oil filter 2. Oil jet 10. Joint 5. Gasket 9. Oil filter bracket 7. Oil cooler by . 32000). use care to prevent damage to the sealant applied to threads. The switch is normal if no continuity is detected (infinite resistance on the tester). The switch is normal if there is continuity. Thin rod KCDA052A . replace the switch. If there is continuity. use Oil Pressure Switch Wrench (09260 . CAUTION During removal.3-2 REMOVAL OIL PRESSURE SWITCH OIL FILTER 09260 . The oil filter mounting surface must be free from damage. Check for cracks and oil leaks.32000 To remove the oil pressure switch. ECLA013B INSPECTION OIL FILTER BRACKET 1. OIL PRESSURE SWITCH 1. replace the switch. ECLA013C 2. Connect a tester (Ω range) between the terminal and the body of the switch to check for continuity. Insert a thin rod in the oil hole of the switch and push it in lightly. If there is no continuity. 2. Check the oil jet and check valve for clogging. the cause may be a broken diaphragm. Check the oil jet for damage and deformation. The dimension must be the standard value when measured after the valve has been dipped in 100°C.OIL FILTER 3. If any air leaks are detected. Apply a 0. Dimension L 34. Ensure that the dimension L measures the standard value under normal temperature and humidity. CHECK VALVE 1. Dimension L 40mm KCMB520A .5mm L Valve 2. Engine oil Oil jet Check valve assembly KCMB520A OIL COOLER BYPASS VALVE 1. 3-3 OIL JET. The switch is normal if there is no continuity. Replace the switch if it leaks. 2.5 kg/cm2 pressure to the oil hole. Also check for air leaks. Cylinder No. 2 and 4. • Use care not to torque excessively.2. 4 No. 3) No. 4) Cylinder block knock pin Check valve Oil jet KCMB530A OIL JET SWITCH 1.2.1. Oil jet (No. . Make sure that the correct one is installed with correct direction as shown.2. 1 and 3.1. CAUTION • The sealant must not get into the thread top surface. apply sealant to the switch threads.3-4 INSTALLATION OIL JET OIL FILTER There are two types of oil jets installed: one for No.4 Cylinder Oil jet (No.1.33 No. Before installation. and the other for No. 3.5~4.8 kg ·m 1.6~0. OIL PAN COMPONENTS 3 4 3.5 kg ·m 1 2 0. 2. µ å 1. Drain plug Oil pan Oil screen Gasket KD4B3001 . 4.OIL FAN 3-5 2. Squeeze the liquefied gasket from the tube and apply it to the oil pan as shown in the illustration. etc. remove it by tapping the drain plug downward with a plastic hammer or equivalent. Apply sealant 4mm Diameter Bolt hole KD4B3005 . KD4B3002 INSTALLATION OIL FAN 1. Semi-dry sealant MZ 100080 THREEBOND TB1212 Cutting part KD4B3004 3. wire brush. Cut the nozzle attached to the liquefied gasket as shown in the illustration. The liquefied gasket comes out with 4mm diameter. Remove the gaskets attached in the oil pan and cylinder block using a scrapper.3-6 REMOVAL OIL FAN OIL FAN When the oil pan is stuck with the gasket. KD4B3003 2. OIL PUMP 3-7 3. Relief plunger 7. Oil pump inner gear 4.9 ~ 1.5 kg·m 0.4 kg·m 1 2 3 8 1. Plug 5. Oil pump outer gear 3. OIL PUMP COMPONENTS 7 6 7 4 3. Oil pump cover 2. KCMB550A . Gasket 6. Oil pump case [Remark] Do not reuse N marking parts. Relief spring 8.0 ~ 4. 22 mm Limit 0. replace the gear or case. Outer rotor KCMB560A INSPECTION OIL PUMP ROTOR 1.04 ~ 0. Item Inner rotor Outer rotor Standard 0.10 mm 0. 2.35 mm 0. replace the cover.3-8 DISASSEMBLY OIL PUMP Inner rotor Marking Before removing the oil pump outer and inner gears. Install the outer and inner gear into the front case and make sure that they turn smoothly with no excessive play between them.4 mm 4. Check the side clearance (the front case and oil pump cover surface). Check the oil pump cover rotor contact surface for wear and if there is bump.12 ~ 0. mark the outer gear to make sure that it goes back to the position with correct direction. .22 ~ 0. (If the individual part is not available. Standard Limit 0.15 mm 3.5 mm 0. Measure the body clearance and if the measure value ex ceeds the limit. replace it as an oil pump case assembly). Inner rotor Marking Outer rotor KCMB560A 3. Apply engine oil to all rotor surfaces.OIL PUMP INSTALLATION OIL PUMP INNER ROTOR/OIL PUMP OUTER ROTOR 1. When air pressure of 0. 2. Install the gear in the same direction as markings represented during disassembly. if there is no continuity. . it is normal. Check the oil jet nozzles for damage or deformation. If air leakage is detected. OIL JET. Check the oil jet and check valve for clogging. replace the switch because the dia phragm may be damaged.5kg/cm² is applied to the oil hole. 3-9 2. CHECK BELT 1. Limit value of 'L' after coming out from oil of 100°C. Standard 34. KCMB580B Limit 40mm not less than . Standard value of 'L' at room temperature.5mm 2.3-10 OIL PUMP OIL COOLER BYPASS VALVE L 1. . 1 2.... 4...........CHAPTER 4.......................................... 4.......... 4.................... THERMOSTAT .......8 4..... RADIATOR ... COOLING SYSTEM 1.................................................. WATER PUMP & WATER PIPE ...................... RADIATOR FAN MOTOR ...... 4...4 3..........................................................10 ............. WATER PUMP & WATER PIPE 4-1 1. WATER PUMP AND WATER PIPE COMPONENTS 10 1.2 ~ 1.5 kg·m 11 9 3.0 ~ 4.0 kg·m 14 2.0 ~ 2.5 kg·m 6 1.0 ~ 1.3 kg·m 7 8 12 13 1.2 ~ 1.5 kg·m 5 [DISASSEMBLY] 1. Drive belt (V belt) 2. Cooling fan 3. Fan clutch 4. Water pump pully (Power steering pump pully adhere) 5. Water pump pully 6. Water inlet fitting 7. water inlet fitting gasket 8. Thermostat 9. Coolant temperature gauge unit 10. Water inlet pipe 11. O-ring 12. Water pump 13. Water pump gasket 14. Thermostat assembly 1.0 ~ 1.2 kg·m [Remarks] (1) Assembly is the reverse of disassembly (2) Do not reuse N marking parts KCMB300A 4-2 INSTALLATION DRIVER BELT WATER PUMP & WATER PIPE Inspect the following items and replace them if required. 1. Loose belt 2. Damage, crack, and wear WATER PUMP & HOSE 1. Water pipe for crack, damage and clogging 2. Water hose for crack, damage and clogging WATER PUMP Check each part for cracks, damage or wear, and replace the water pump assembly if necessary. 1. Coolant leaks 2. Coolant leaks from A 3. Water pump body for damage and crack 4. Impeller for damage and crack 5. Bearing for damage A ECLA011B WATER PUMP & WATER PIPE ASSEMBLY WATER PUMP 1. Clean the gasket contact surfaces inserting between the water pump and cylinder block. 1 d 4-3 2. Bolt sizes are as below. No 1 2 3 Hardness category 4T 4T 7T dx1 4T 4T 7T Torque 1.2~1.5 kg·m 1.2~1.5 kg·m 2.0~2.7 kg·m Indication for hardness category L(Length) L 3 2 2 2 1 KCUB040A WATER PIPE & O-RING 1. Fit water pipe O-ring in the groove provided at water pipe end, wet the periphery of water pipe O-ring and insert water pipe. CAUTION Do not apply oil and grease to water pipe O-ring. O-ring KCMB320B 4-4 RADIATOR PAN MOTOR 2.7 kg·m 1. Cooling fan 3.0 ~ 1.0 ~ 1.2 kg·m 3 1 0. RADIATOR PAN MOTOR COMPONENTS 0.3 ~ 0.2 kg·m [DISASSEMBLY] 1.3 ~ 0.7 kg·m 2 1. Cooling fan clutch [Remark] (1) Assembly is the reverse of disassembly KCMB420A . Radiator upper shroud 2. 2. 3. 2. Check the case joint and seal for oil leakage from the pan clutch. If any portion of fan is damaged or cracked. 4-5 FAN CLUTCH 1. Check the bimetal strip for damage Bimetal KCMB430A . Check the blades for damage and cracks.RADIATOR PAN MOTOR INSPECTION COOLING FAN 1. replacecooling fan. Oil leakage may cause overheating the engine resulting from the pan speed decrease. 4-6 COMPONENTS RADIATOR PAN MOTOR 2 (1.0~1.2 kg·m) 1 (1. Whter temperature gauge unit 2.0~1. Thermo switch (113°C) (For A/C equipped vehicle) KCMB450A .4 kg·m) [DISASSEMBLY] 1. RADIATOR PAN MOTOR INSPECTION WATER TEMPERATURE GAUGE UNIT 1. If the measurement radically deviates from specification. 4-7 ECLA012E 2. Measure the resistance across terminal (A) and body for water temperature gauge element and across terminal (B) and body for glow control element.8Ω / -20°C 3. After inserting the coolant temperature switch into oil.8Ω / 115°C 24. 2. . replace. 3.25Ω / 20°C KCMB460A Terminal (A) Terminal (B) THERMO SWITCH (FOR A/CON) 1.4Ω / 70°C 23. Check that the coolant temperature switch is turned OFF when the oil temperature reaches the standard. Put the sensor in water and increase the water temperature measure the resistance. heat the oil. Standard Terminal (A) (For coolant temp) Terminal (B) (For preheat plug) 0. Standard Coolant temperature at A Coolant temperature at B 113 3°C ECLA012G 106°C CAUTION Only engine oil is available and stir the oil during heating. Do not overheat. 2~1. Water pump KCUB040C . Power steering oil pump bracket 4.5 kg·m [THERMOSTAT DISASSEMBLY] 1.5 kg·m 1. Power steering oil hose 3.2~1. THERMOSTAT COMPONENTS 2 3 N6 4 7 9 10 N 11 12 1 7 4 N8 9 12 1. Water pump & thermostat 5. Radiator lower hose 2.4 kg·m N5 1. Gasket 9. Thermostat housing 11. Water inlet fitting 8. Thermostat housing gasket 12.4 kg·m 1.2~1.5 kg·m 2. Water pump gasket 6. Themostat [WATER PUMP DISASSEMBLY] 1.2~1. Radiator lower hose 7.4-8 THERMOSTAT 3.1 kg·m 1. O-ring 10.5 kg·m 2. 4-9 3. 2.THERMOSTAT INSPECTION 1. Thermostat brush ˚ Thermostat housing Thermostat KCUB040E .5 2°C 2°C Water temperature gauge KCMB310A ASSEMBLY Assemble the thermostat in the direction shown in the illustration. Immerse thermostat in container of water. Check for defects or damage. 82 Opening valve temperature 76. Check that valve closes tightly at room temperature. 4-10 RADIATOR 4. RADIATOR COMPONENTS 1 5 0.8 ~ 1.1 kg·m 3 7 6 0.3 ~ 0.7 kg·m 3 4 9 2 0.8 ~ 1.1 kg·m 0.8 ~ 1.1 kg·m 8 [DISASSEMBLY] 1. Radiator cap 2. Drain plug 3. Over flow tube 4. Reserve tank 5. Radiator upper hose 6. Radiator lower hose 7. Radiator upper shroud 8. Radiator lower shroud 9. Radiator [Remark] (1) Installation is the reverse of removal. KCMB400A RADIATOR INSPECTION 1. Check between the radiator pins for foreign material. 2. Check the radiator pins for bending or damage. 3. Check the radiator for contamination, damage or rust. 4. Check the radiator hose for crack, damage or deformation. 5. Check the reservoir tank for damage. 6. Check the radiator cap spring for damage. 7. Check the radiator cap packing for damage or crack. 4-11 CHAPTER 5. INTAKE AND EXHAUST SYSTEM 1. INTAKE AND EXHAUST MANIFOLD ................................... 5- 1 2. TURBO CHARGER (TC)....................................................... 5- 3 3. AIR CLEANER ...................................................................... 5- 8 6.0 kg·m 3 1. 4. 7. INTAKE AND EXHAUST MANIFOLD COMPONENTS 2 6. Exhaust fitting Gasket Oil return pipe Oil return pipe gasket Exhaust manifold Turbo charger gasket Turbo charger assembly KCMB600A .INTAKE AND EXHAUST MANIFOLD 5-1 1. 5.0 kg·m 7 1 5 6. 3.0 kg·m 4 6 6. 2. After full filling. INTAKE AND EXHAUST MANIFOLD CAUTION Be careful of foreign material not to come in the oil passage during cleaning.5-2 ASSEMBLY TURBO CHARGER ASSEMBLY Remove the heat protector. fill the turbocharger with clean engine oil. ECLA015D . check that the turbine and compressor wheel are rotating smoothly. ECLA015C EYE BOLT Before installing the oil pipe eyebolt (turbocharger upper part). TURBO CHARGER (TC) COMPONENTS [D4BF] 1 4 5 2 8 7 6 3 0.5 kg·m 2. Hose clip 2. Turbine housing 5.4 ~ 0.9 ~ 3. Hose 3. [DISASSEMBLY] 1.lbs.6 ft. O-ring 8.TURBO CHARGER [TC] 5-3 2. Coupling 4. Snap ring 6. Compressor cover 7. Cartridge assembly KCUB060A . Cartridge assembly KCMB660C . CAUTION • Use a heavy duty carbon solvent to loosen the carbon from the parts. Snap ring KCLA016C CARTRIDGE ASSEMBLY Remover by tapping the compressor cover of cartridge assembly with plastic hammer. Mating mark KCMB660A SNAP RING Remove the snap ring using snap ring filler. make the mating mark on compressor cover bearing housing and turbine housing. NOTE O-ring installed around the cartridge assembly may cause tight installation sometimes.5-4 DISASSEMBLY TURBINE HOUSING TURBO CHARGER [TC] Before removal. wire brushes. CAUTION Be sure not to damage the compressor and turbine wheel blade. or wire wheels to remove carbon deposits from any turbo charger part. • Do not use caustic solutions. Make sure that the waste gate valve lever operates freely by hands. COMPRESSOR COVER Make sure there are no damages on the inner housing surface contacting compressor wheel. Turbine wheel and shaft assemblies with cracks in the blades or broken blades can not be used again. C ARTRIDGE ASSEMBLY 1. If the blades are slightly bent. Repair or replace them if required.TURBO CHARGER [TC] INSPECTION TURBINE HOUSING 1. Check the inner housing contacting turbine wheel for crack. Check if there are foreign materials disturbing the oil flow in the oil passage of cartridge assembly. KCMB670B Compressor Oil passage Turbine wheel wheel OIL PIPE AND OIL RETURN PIPE Check the oil pipe and oil return pipe for clogging and deformation. Contacting surface 5-5 KCMB670A 2. pitching and other damages caused by overheat. 2. it can be used again but severely bent blades can not be reused. . When replacing it with a new one. O-ring CAUTION Take care not to damage the O-ring. 2. 0. take care not to damage the compressor wheel blade. Snap ring Chamfer Cartridge assembly Compressor cover KCMB670E . Pressure TCI engine Approx.80kg/cm2 ECLA016J ASSEMBLY O-RING ASSEMBLY Apply engine oil to the new O-ring thinly and assemble the cartridge assembly. install it as shown in the left illustration. Install the cartridge assembly to the compressor cover with them mating as marked when disassembling. CAUTION When installing the cartridge assembly to the compressor cover. CAUTION Install the snap ring with the chamfer upward. KCMB670C COMPRESSOR COVER/CARTRIGE ASSEMBLY 1. Mating mark KCMB670D SNAP RING Install the snap ring with the compressor cover downward.5-6 WASTE GATE INSPECTION TURBO CHARGER [TC] Check the waste gate rod operation under the pressure below. CAUTION Take care not to damage the compressor wheel blade.TURBO CHARGER [TC] TURBINE HOUSING Install the cartridge assembly to the compressor cover with them mating as marked when disassembling. 5-7 . 15 ~ 0. AIR CLEANER COMPONENTS Case assembly Air cleaner element Wirng nut Air cleaner cover assembly Dust pan assembly T : 0.25 kg·m TORQUE : kg·cm KCYB720A .5-8 AIR CLEANER 3. . ................... TROUBLESHOOTING ........................... 6................. SERVICE SPECIFICATIONS ......................CHAPTER 6..................... TIGHTENING TORQUE ......................... GLOW PLUG.................... 6............ 6. 6................. 6.................. 6...3 4............................................................................. STARTER MOTOR .....2 3. ENGINE ELECTRICAL 1....4 6...... GENERAL .........................................................17 8........ 6.......26 ..........................................................................3 5....1 2...... SPECIFICATIONS . 6..........................11 7..................... ALTERNATOR................................ KD4B6001 ALTERNATOR Alternator is electronic voltage regulator built-in type.ENGINE ELECTRICAL SYSTEM 6-1 1. KD4B6002 . GENERAL STARTER MOTOR Starter motor is a reduction drive type. Excavator.4 ± 0.3V -10 ± 3 mV/°C Remark STARTER MOTOR Item Output 24V / 5KW (Bus aircon) Number of pinion teeth No-load characteristics Terminal voltage Amperage 13 11V 30A Specification 12V / 2. Loader) Remark GLOW PLUG Item Identification mark Type Auto glow Y-115T Sheathed type . with vacuum pump 14. SPECIFICATIONS ALTERNATOR Item Type Rated output Motor speed Voltage regulator type Regulator setting voltage Temperature compensated Specification Battery voltage sensing 12V / 50A 1.2KW (Generator.000 rpm Electronic voltage regulator.6-2 GLOW PLUG Glow plug uses AGS.000 ~ 10. ENGINE ELECTRICAL SYSTEM Coil Identification mark AGS KD4B6003 2. 4 1.9 2.5~2. Excavator.75 ± 0.D.4 ~ 1.D. Undercut Outer round Brush length 11V (23V) 130A (95A) 4500rpm (3300rpm) 0.5 2. Rotor coil resistance (at 20°C) 33mm 2.7 ~ 3.ENGINE ELECTRICAL SYSTEM 6-3 3.1 ~ 0.4mm 0. SERVICE SPECIFICATIONS ALTERNATOR Item Brush length Slip ring O.2 mm 0.5 ~ 2.0mm 29.0 ~ 2.5mm 0.m) 1.0 0.1mm Wear limit GLOW PLUG 0.4mm 0.5Ω (Generator.2 ~ 1.15 Remark . TIGHTENING TORQUE Item Lock bolt Generator support bolt nut Eye bolt Starter motor attaching bolt Glow plug Glow plug plate attaching nut Torque (kg.5 1.05mm 28.2mm STARTER MOTOR No-load characteristics voltage (Bus aircon) Amperage (Bus aircon) Revolution number (Bus aircon) Pinion gap Commutator O. Loader) Resistance AGS 10Ω (Bus aircon) 4.2Ω Standard Limit Wear limit 32. TROUBLESHOOTING STARTING SYSTEM Trouble symptom Starter spins but engine will not crank Probable cause Starter motor faulty Remedy After removing the starter motor. check the drive for crack and wear Replace flywheel ring gear or torque converter Engine will not crank Battery cables loose.6-4 ENGINE ELECTRICAL SYSTEM 5. corroded or worn out Battery charge low Starter motor faulty Repair or replace cables Charge or replace battery Tighten or replace cables Repair or replace starter motor Repair or replace cables Charge or replace battery Repair or replace starter motor Flywheel ring gear teeth broken CHARGING SYSTEM Trouble symptom Low battery Probable cause Wiring connection loose Overload Remedy Tighten loose connections Check and remove the accessories if required Replace battery Repair or replace Replace voltage regulato Check the battery or replace. if necessary Worn battery Generator faulty Electronic voltage regulator faulty Battery faulty . corroded or worn out Battery charge low Cables loose or cables wear Starter motor faulty Engine cranks slowly Battery cables loose. if necessary Replace lamp Repair or replace wiring Repair or replace wiring Replace control unit.ENGINE ELECTRICAL SYSTEM GLOW CONTROL SYSTEM Trouble symptom Engine will not start below 50°C Probable cause Wiring connection loose or bad wiring ECT sensor malfunction Glow plug malfunction Glow plug control unit failed After first combustion. if necessary Glow plug relay malfunction Glow plug control unit failed Yellow glow lamp will not turn-ON Open lamp Wiring connection loose or bad wiring Shorted wiring Glow plug control unit failed . engine stall or rough idle below 50°C Wiring connection loose or bad wiring Glow plug malfunction Remedy Repair or replace wiring Replace ECT sensor Repair or replace glow plug Replace glow control unit Repair or replace wiring 6-5 Check the resistance of glow plug and replace. if necessary Check the control unit and replace. if necessary Check the relay and replace. to get the charging function. the continuity circuit of the L terminal (field coil) is installed parallel with the circuit of the charge warning lamp. when the charge warning lamp is short. .Power transistor Starter coil F C D Field coil Tr E Voltage regulator R Battery R Charge lamp Alternator KD4B6004 NOTE Register with diode • According to battery voltage detective type alternator adoption.6-6 ENGINE ELECTRICAL SYSTEM VEHICLE INSPECTION SPECIFICATIONS B Diode trio L L R R D. ENGINE ELECTRICAL SYSTEM INSPECTION Check the following items before inspecting voltage regulator adjusting voltage alternator output current. Connect a DC ammeter (0 to 100A) in series between the "B" terminal and the disconnected output wire." 2. voltmeter and ammeter as following. 4. REGULATED VOLTAGE TEST 1. Abnormal noise from alternator durng operation NOTE Use fully charged battery to obtain the standard value. Alternator drive belt tension 3. Connect the (-) lead wire of the ammeter to the disconnected output wire. Alternator installation 2. Fusible link 5. Set the special tool wiring connector. Connect the (+) lead of the voltmeter to the "S(L)" terminal of the alternator. Disconnect the alternator output wire from the generator "B" terminal. Turn ignition switch to "OFF. Connect the (-) lead to good ground or the battery (-) terminal. Disconnect the battery ground cable. Attach the engine tachometer and connect the battery ground cable. 3. Battery specific gravity and voltage 4. Load Ignition switch(IG) Alternator Red Yellow Battery Voltmeter Amperemeter Regulated voltage test KD4B6005 . 6. Connect a digital voltmeter between the "S(L)" terminal of the alternator and ground. 1. 5. 6-7 PREPARATION 1. • If the battery may be discharged or the head lamp is overloaded. the current reads 5A or more. Recheck the battery lamp this time. 16 Adjust voltage V 14. Repair ALTR NOTE • Adjust voltage becomes slightly low in proportion to the output current.0V . the alternator is abnormal. • Adjust voltage varies according to the IC regulator surrounding temperature.6V 15 14 13 25°C -40 -20 0 20 40 60 80 IC regulator surface temperature(°C) KD4B6006 14. so refer to the characteristics as shown in the left figure.6-8 2. Check as the following procedures.5V (At 20°C) Highly exceed the standard value Below the standard value Abnormal IC regulator If the output current is 5A or more If the output current is 5A or less. No. 14. Repair ALTR fully charge the battery. 5A or less) of IC regulator. so it is inspected with low output current (approx.4 ±0. 1 Check item Voltage between L terminal and earth ENGINE ELECTRICAL SYSTEM Operation Ignition switch: OFF Ignition switch: ON Determination Normal 0V Abnormal Voltage arises Cause Abnormal wiring or alternator Remedy Correct wiring or repair alternator 2~5V 0V Battery voltage Faulty ALTR Shor t wiring or fusable link Repair ALTR Correct wiring or replace fusable link 2 Voltage between S terminal and earth Ignition switch: OFF Ignition switch: ON Battery voltage 0V 3 Voltage between S terminal and earth (regulator adjust voltage) Run the engine and keep the engine at 2000~3000rpm. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Limit 70% of nominal output current Battery 80A 30A 6-9 Load Ignition switch Charge warning lamp L S B Relay with diode Voltmeter Amperemeter KD4B6007 NOTE Read the maximum value quickly as charged current drops repidly. the output current at 2500 rpm engine speed exceeds the standard value. Set headlamps at high beam and heater blower switch to HIGH. 7. Remove battery ground cable. Nominal output current value is indicated on a plate on the alternator. Increase engine speed to 2500 rpm and read the maximum output current on the ammeter. 0V is caused by a disconnected wire between the alternator "B" terminal and battery (+). Therefore. and the alternator can be considered as near normal. the standard output current may not be obtained due th small electric load despite the charging system being normal. or a blown fusible link. Check that the values on voltmeter and battery are the same. Therefore. When the value is under the limit and the alternator outlet wiring [between alternator "B" terminal and battery (+) terminal] is normal. . In this case. 5. Attach an engine tachometer. start engine. increase the load and recheck. remove the alternator for inspection. NOTE Having headlamps on when checking alternator output current increases the load. 8. With headlamp switch ON. The value on the ammeter should be over the limit value. 4. 2. Standard current is generated at low speed of alternator. However. Remove alternator outlet line from alternator "B" terminal. output current is stabilized at about 4000rpm alternator speed. Connect 0-100A test ammeter DC between "B" terminal and remove outlet line in series. or defective ground. 6. 3.ENGINE ELECTRICAL SYSTEM CURRENT OUTPUT TEST 1. Alternator output current changes due to load. Connect battery ground cable. 3.6-10 RESULT ENGINE ELECTRICAL SYSTEM 1. 4. 2. Turn ignition switch OFF. bring engine speed to idle. After output current test. Connect alternator output line to alternator "B" terminal. Remove ammeter. 5. Remove battery ground cable. voltmeter and engine tachometer. . refer to Chapter 5 Engine-Service adjustment procedures. 4.0~2. ALTERNATOR COMPONENTS 4 5 1 T=1. For belt tension. 5.ENGINE ELECTRICAL SYSTEM 6-11 6.2~1.5 kg·m 3 T=2. . Lock bolt Nut Support bolt Alternator assembly Alternator brace KD4B6008 INSTALLATION ALTERNATOR ASSEMBLY 1. 2.5 kg·m 2 1. 3. Rear bearing 6. Pulley 2. Regulator & brush holder 12. Rotor & fan assembly 5. Front bracket 9. Bearing retainer 7. Front bearing 8. Seal 4.6-12 COMPONENTS ENGINE ELECTRICAL SYSTEM 4 2 5 6 8 7 3 1 13 3 11 10 12 9 [DISASSEMBLY] 1. Stator assembly 10. Fan 3. Plate 11. Rear bracket [Remarks] Assembly is the reverse of disassembly KD4B6009 . Rectifier assembly 13. If they are hard to separate. 2. STATOR ASSEMBLY. Rectifier Soldering Plate "L" Plate "B" KD4B6011 . use care not to expose the diode to soldering iron heat for extended time. 2. 6-13 KD4B6010 CAUTION Do not insert the screwdriver too deep as the stator core could be damaged.ENGINE ELECTRICAL SYSTEM DISASSEMBLY FRONT BRACKET 1. Complete soldering or unsoldering in as short a time as possible. • Do not overstress the diode leads. unsolder two soldered points. When removing the rectifier from the brush holder. pry it to separate the stator and the front bracket. lightly strike the bracket with a plastic hammer while prying with the screwdriver. RECULATOR AND BRUSH HOLDER 1. When removing the stator. unsolder the three stator leads from the main diodes. CAUTION • When soldering or unsoldering. With a screwdriver blade inserted between the front bracket and stator core. Check the stator continuity. it indicates a shorted rotor. Make sure that there is no continuity between the slip ring and core. KD4B6014 . If it is excessively small. Make sure that there is continuity between slip rings. Check the rotor coil continuity. replace the rotor assembly. Replace the stator assembly if there is no continuity. Measure the rotor resistance. Make sure that there is continuity between coil leads. Check the rotor coil grounding.6-14 INSPECTION ROTOR ENGINE ELECTRICAL SYSTEM 1.5 ohms KD4B6012 2. Replace the rotor assembly if there is continuity. If without continuity or shorted. KD4B6013 STATOR 1. Standard value 3 . KD4B6018 . Check the coil grounding. replace the rectifier assembly. check continuity of the three diodes. Inspection of (+) Heat Sink Assembly Using a circuit tester. Inspection of (-) Heat Sink Assembly Check continuity between the (-) heat sink and the stator coil lead connection terminals.ENGINE ELECTRICAL SYSTEM 2. Then. KD4B6016 2. the diode is damaged. Make sure that there is no continuity between the coil and core. If there is continuity in both directions. check continuity between the (+) heat sink and the stator coil lead connection terminals. replace the rectifier assembly. Then. replace the rectifier assembly. 6-15 KD4B6015 RECTIFIER 1. Inspection of Diode Trio With a circuit tester connected to both ends of each diode. Then. If there is continuity in both directions the diode is shorted. KD4B6017 3. Replace the stator assembly if there is continuity. If there is continuity or no continuity in both directions. the diode is shorted. Unsolder the brush lead wires. Solder KD4B6020 3. After rotor installation. When installing a new brush. thread a steel wire through the small hole provided in the rear bracket to lift up the brush.6-16 BRUSH ENGINE ELECTRICAL SYSTEM 1. 04570 3314 KD4B6021 REASSEMBLY ROTOR ASSEMLY 1. Before installing the rotor on the rear bracket. Brush Rear bracket Wire KD4B6022 . and the brush and spring will come out. Wear limit line KD4B6019 2. The brush must be replaced if worn to the wear limit line. remove the steel wire. push the brush into the holder as illustrated and solder the leads. Starter motor 2. Bolt 3 KD4B6023 REMOVAL Remove the starter at the engine room lower portion. adjust by adding or removing fiber washers between the magnetic switch and front bracket. Using more washers makes the gap smaller. the pinion moves out. push back the pinion with a finger and measure the pinion stroke (the travel along which the pinion is pushed back).0 mm Disconnect connector Starter motor KD4B6024 Pinion Pinion gap KD4B6025 . Connect at 12V battery the terminal S and the terminal M. This is the pinion gap.2 ~ 2. 4. If the pinion gap is not up to specification.ENGINE ELECTRICAL SYSTEM 6-17 7. 2. Nut 3. Disconnect the field coil wire from the terminal M of the magnetic switch. CAUTION This test must be performed quickly within 10 seconds to prevent the switch coil from burning. Now. Pinion gap 0. S Battery M B INSPECTION PINION GAP ADJUSTMENT 1. STRATER MOTOR COMPONENTS 2 1 1. 3. When the battery is connected. and variable resistance. voltmeter. CAUTION This test must be completed with 10 seconds. + S Battery 12V Disconnect connector Starter motor KD4B6027 RETURN TEST OF MAGNETIC SWITCH With a battery connected between the terminal M and body of the magnetic switch. manually pull the pinion up to the pinion stopper. troubleshoot according to the table below and take remedial action as required. CAUTION This test must be completed with 10 seconds. If the pinion does not move out.5V. CAUTION • The connector must be disconnected from terminal M for this test. S Battery 12V B Disconnect connector Starter motor KD4B6026 HOLD-IN TEST OF MAGNETIC SWITCH With a battery connected between the terminal S and body of magnetic. Body coils are fully operational if the pinion returns immediately when releasing it. 2. Adjust the variable resistor so that the voltmeter reads 11. Variable resistor Ammeter A Starter motor Battery 12V V Voltmeter KD4B6029 . M+ Battery Disconnect connector Starter motor KD4B6028 NO-LOAD TEST 1. Set up a circuit as shown which connects a starter motor. The starting motor should be in good condition if it turns smoothly and steadily when the switch is turned ON with a maximum variable resistance value.6-18 ENGINE ELECTRICAL SYSTEM PULL-IN TEST OF MAGNETIC SWITCH The pull-in coil is in good condition if the plunger is pulled in to cause the pinion to move out when a battery is connected between the terminals S and M of the magnetic switch. replace the magnetic switch. If the current and rpm are out of specification after this adjustment. manually pull the pinion out to the pinion stopper. • The test must be finished within 10 seconds. The hold-in coil is in good condition if the pinion remains out when releasing it. ammeter. battery. ) • Shorted field coil 6-19 Small current with low rpm (torque also being small) Large current with high rpm (torque being small) .ENGINE ELECTRICAL SYSTEM Symptom Large current with low rpm (torque also being small) Possible cause • Contaminated bearing • Armature coil rubbing pole piece • Armature coil shorting Large current with no rotation • Solenoid switch grounding • Armature and field coil grounding • Seized bearing No current flowing with no rotation • Broken armature and field coils • Broken brush and pigtail • Improper contact between brush and commutator • Improper field coil connection (Note. however. that open or improperly connected shunt coil only will result in high rpm. 18. 2. 21. 22. 16. Screw Magnetic switch Fiber washer Screw Screw Rear bracket Brush holder assembly Yoke assembly Armature Front bearing Rear bearing Screw Cover Snap ring Washer Plate 17. 27. 13. 4. 29. 7.6-20 COMPONENTS ENGINE ELECTRICAL SYSTEM 2 3 18 19 23 29 20 12 14 1 16 4 21 22 17 28 5 27 25 26 24 11 9 10 8 7 6 13 15 1. 5. 6. 10. 3. 9. 14. 12. 23. 19. 25. 26. 15. Screw Center bracket Packing Lever spring Washer Gear Lever Snap ring Stop ring Pinion gear Spring Pinion shaft assembly Front bracket [Remarks] Assembly is the reverse of disassembly KD4B6030 . 11. 8. 28. 20. 24. Using an adequate socket. then. push the stop ring over the snap ring.ENGINE ELECTRICAL SYSTEM DISASSEMBLY MAGNETIC SWITCH Remove the field coil wire from the terminal M of magnetic. Snap ring Stop ring Pinion gear KD4B6034 . Snap ring Washer KD4B6032 SNAP RING AND STOP RING 1. Remove the snap ring with a screwdriver. Socket Pinion gear Stop ring KD4B6033 2. remove the stop ring. Magnetic switch Terminal S Terminal M 6-21 Terminal B Field coil wire KD4B6031 SNAP RING Pinion shaft Plate Measure the pinion shaft end play using the feeler gauge for the purpose of reassembly. Standard value Limit 32 ±0.4mm KD4B6036 3. 2. Standard value Limit 0 ~ 0. Do not immerse the drive unit in cleaning solvent.03mm 0. Check the depth of the undercut between segments. Do not immerse parts in cleaning solvent.5mm 0. INSPECTION CHECKING THE COMMUTATOR 1. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth. Place the armature on a pair of V-blocks.2mm Segment Under cut Mica KD4B6037 . The overrun clutch is pre-lubricated at the factory and solvent will wash lubrication from the clutch.1mm KD4B6035 2.6-22 ENGINE ELECTRICAL SYSTEM CLEANING THE STARTER MOTOR PARTS 1. Check the outer diameter of the commutator.1mm 31. Immersing the yoke and field coil assembly and/or armature will damage the insulation. Standard value Limit 0. and check the run out by using a dial gauge. Wipe these parts with a cloth only. 3. ENGINE ELECTRICAL SYSTEM FIELD COIL OPEN-CIRCUIT TEST Check for condinuity between field brushes. 6-23 Yoke KD4B6038 FIELD COIL GROUND TEST Check for continuity between the field coil brush and yoke. Brush holder KD4B6040 OVERRUNNING CLUTCH 1. KD4B6041 . Ensure that the pinion locks when turned counterclockwise and turns freely when turned clockwise. There must be continuity. Check the pinion for wear and damage. There must be no continuity. 2. Field brush Yoke KD4B6039 BRUSH HOLDER Check for continuity between brush holder plate and brush holder. There must be no continuity. Pigtail KD4B6042 New brush Soldering (Brush surface is free from excess solder) Mark KD4B6043 ARMATURE COIL SHORT TEST 1. 2. CAUTION Before this test. Check the brush surface in contact with the commutator for surface roughness. Slowly turn the armature while a thin metal is held above it. use care to prevent damage to the pigtail. If the surface has been refaced or brush has been replaced. Limit Wear limit line Wear limit line 2. Check also the brush length. Growler KD4B6044 ARMATURE COIL GROUND TEST Check for insulation between the commutator segment and armature coil core. Insert the pigtail into the hole in a new brush and solder. There must be no continuity. Polish the pigtail end for battery soldering with sand paper. 3. Make sure that the brush surface is free from excess solder. The armature coil is not shorted if the metal does not vibrate. ensure that the armature surface if free from foreign substances. Growler KD4B6045 .6-24 BURSHES ENGINE ELECTRICAL SYSTEM 1. wrap sand paper around the commutator to correct its surface. 5. Place the armature on a growler. When removing a worn brush by breaking with pliers. 4. There must be continuity. pull the stop ring over the snap ring. 6-25 KD4B6046 INSTALLATION STOP RING AND SNAP RING Using a puller of adequate type. Stop ring Pinion gear KD4B6047 .ENGINE ELECTRICAL SYSTEM ARMATURE COIL OPEN-CIRCUIT TEST Check for continuity between segments. Glow plug plate 3.6-26 ENGINE ELECTRICAL SYSTEM 8. Glow plug KD4B6048 REMOVAL GLOW PLUG Especially ceramic part of glow plug is so fragile that the screw should be removed with the hand after unscrewing it several turns with a tool. Connector 2. GLOW PLUG COMPONENTS 1 2 T=1.5~2. .0 kg·m 3 1.0 kg·m T=1.5~2. NOTE Do not use the plug dropped at the height of 10cm or higher. 2.ENGINE ELECTRICAL SYSTEM INSPECTION 1. 6-27 3. Check glow plug for damage. Check the continuity between the terminal and body as illustrated. Standard value 500Ω(20°C) NOTE Remove oil from plug before measuring as glow plug resistance is very small. Replace if discontinuity or with large resistance. Check for rust on glow plug plate. . KD4B6049 INSTALLATION GLOW PLUG Especially ceramic part of glow plug is so fragile that the screw should be removed with the hand after unscrewing it several turns with a tool. ......................................... FUEL SYSTEM 1........................1 2............ INJECTION NOZZLE ............. GENERAL .............. 7........................CHAPTER 7......... 7.. 7.............8 3.... INJECTION PUMP .10 4....15 ................... 7....................... 7........................................................ INJECTION NOZZLE HOLDER .......12 5........................ TROUBLESHOOTING ......................... water in the fuel will shorten the pump life to a great degree. dust. special care must be taken to prevent the entry of water. into the system. From the pump chamber. High speed adjust bolt Low speed adjust bolt Control lever Hole rodadjust screw Fuel cut solenoid Drive shaft Plunger Feed pump Roller holder Cam disc Timer Plunger spring Delivery valve EFLB001A . The excess fuel at the nozzle holder is also returned through the overflow pipe with unions on the injection pump to the fuel tank. The excess fuel in the pump housing chamber is returned through the overflow valve and the overflow pipe to the fuel tank. etc. The injection pump is cooled and lubricated by means of fuel circulation. The plunger pumps the fuel and the highly pressurized fuel is injected from the nozzle in accordance with the injection sequence. the fuel is sent through the distributor head passage and then the inlet port in the barrel to the high pressure chamber above the plunger.GENERAL 7-1 1. Since the injection pump is lubricated by fuel. Therefore. where the fuel pressure is regulated by a regulating valve. The fuel under pressure enters the pump chamber. GENERAL IMFORMATION OVERALL A distribution-type fuel injection pump is installed in the front upper case and is driven by the timing belt. The fuel is drawn from the fuel tank by a pump inside the fuel injection pump and sent to the injection pump through a filter which contains a water separator. 5kg/cm2 12V/8Ω 1 ~ 1.7-2 SPECIFICATIONS Item Fuel filter type Fuel injiction pump Type Turning direction Injection sequence Governor type Feed pump type Injection nozzle Nozzle type Holder type GENERAL Specification Cartridge paper filter element type Distribution type Clockwise as viewed from drive side 1-3-4-2 Half All Speed Vane type Throttle type Screw-on type Remark SERVICE SPECIFICATIONS Item Injiction pump Injection timing Cam lift Plunger diameter Delivery valve opening pressure Fuel cut solenoid Injiction Injection orifice (Number-diameter) Pressure Opening pressure Adjust pressure Idle speed Standard ATDC 5° 2.2mm 10mm 21.02mm 120kg/cm2 125 ~ 135kg/cm2 820 ~ 880rpm 110kg/cm2 Limit . 7 1.7 1.0 ~ 6.GENERAL TOQUE SPECIFICATIONS Item Injection pipe clamp bolts Injection pipe union nuts Pump bracket-to-cylinder block bolts Injection pump-to-pump bracket bolts Injection pump mounting nuts Fuel return pipe nuts Injection nozzle ning nut-to-nozzle body Pump sprocket nut Torque (kg.0 ~ 4.5 2.3 ~ 3.8 ~ 2.0 5.2 3.0 7-3 SPECIAL TOOLS Tool (Number and name) 09310-43000 Prestroke measuring adapter Illustration Use Injection timing adjustment D1043000 09314-43100 Nozzle holder socket wrench Removal of nozzle holder D1443100 09314-43000 Injection pump sprocket puller Removal of injection pump sprocket C1443000 .5 ~ 2.0 ~ 9.m) 0.0 8.6 2.0 ~ 2.0 3.0 ~ 5.4 ~ 0. 2. . 4) After adjusting. EVACUATION OF AIR FROM FUEL LINE 1. 5. 3. If there is too much slack. 2) Tighten adjusting nut until throttle lever just starts moving. Operate hand pump repeatedly until no bubbles come from plug hole.04 in. Return 1 turn and lock with lock nut. When fuel is drained and re-filled for service. 2. Confirm there are no sharp bends in accelerator cable.) Lock nut EFLB07A Adjusting nut 3) Adjust so that accelerator pedal stopper touches pedal arm when throttle lever is fully opened. Warm engine until stabilized at idle. confirm that throttle level fully opens and closes by operating pedal. adjust slack by the following procedures. 2) Place rags around air plug hole. 1) Loosen adjusting nut. Standard value approx. Stop engine. 3. Fully close throttle lever. When main fuel line is removed. Confirm idle rpm is at prescribed rpm. GENERAL 4. 1 mm (0.7-4 INSPECTION AND ADJUSTMENT ACCELERATOR CABLE 1. 3) Repeat until hand pump operation becomes stiff. When fuel filter is replaced. Tighten air plug. This adjusts accelerator cable play to standard value. Check inner cable for correct slack. 6. 1) Loosen fuel filter air plug. Move nozzle tester handle at about one stroke per second. Read the position at which the pointer started to swing. 0039 in. 3. 2. Loosen drain plug.142 psi) as shim thickness is increased by 0. be careful not to allow entry of dirt or water. Drain plug 7-5 EFLB009A INJECTION NOZZLE INJECTION START PRESSURE 1.1 mm (0. Standard value Opening pressure Adjust preesure Limit 120kg/cm2 125~135kg/cm2 112kg/cm2 or more EFLB010A 4. CAUTION When disassembling nozzle holder. Check the injection start pressure is the standard value. If the nozzle is faulty. disassemble and adjust injection start pressure to the standard value by changing the shim thickness.000 kPa (10 kg/ cm2. 2. 1. Injection pressure increases by approx. Finger-tighten drain plug. . Drain water with hand pump.).GENERAL EVACUATION OF WATER FROM FUEL FILTER Water is in the filter when fuel filter indicator lights. 1. Set injection nozzle in nozzle tester and check the following. The pressure gauge pointer rises slowly and swings when injection is made. Evacuate water by the following procedures. and vibration of the needle valve is felt at the handle.7-6 GENERAL 5. replace nozzle assembly. Good Not good Large injection Direction Split Intermittent angle imbalance injection injection EFLB012A NEEDLE VALVE VIBRATION Inject on is normal if the characteristic intermittent sound is heard as the handle is operated. . If the injection start pressure can not be adjusted by changing the shim thickness. Shim EFLB011A INJECTION STATUS Move nozzle tester handle at about 1 stroke per second. EFLB014A 2. NOZZLE OIL-SEAL 1. 5. disassemble injection nozzle and replace nozzle tip or entire assembly. 2. disassemble nozzle and replace nozzle tip or entire assembly. If there is leakage. disassemble injection nozzle and replace nozzle tip or entire assembly. Maintain internal nozzle pressure (pressure gauge indication value) with the nozzle tester at 10.422-1. Confirm the spray is cone shaped with an angle of about 15°. Check for fuel leaking from nozzle tip in this condition. 7-7 EFLB013A 4.565 psi). If the injection is not good. in the test. the spray may be bolt shaped with a course mist and fuel may remain.000-11.GENERAL SPRAY 1. and the nozzle function is normal. as illustrated in the figure. This is phenomenon common in this type of inspection. 3. This indicates a good condition. 6.000 kPa (100-110 kg/cm2. 1. Check that the spray is good. . Confirm fuel does not drip after injection. If dripping. Move nozzle tester handle at 4 to 6 strokes per second. 4 ~ 0. CAUTION Because VE type injection pipe is different from DPC type injection pipe. (VE type injection pipe is coated yellow) Delivery holder Nut EFLB016A .6 1 2 3. be careful when you install.0 ~ 6.0 1 2 3 4 5 Injection pipe clamp Injection pipe Fuel return hose Nut Fuel return pipe 6 7 8 9 Fuel return pipe gasket Nozzle holder Holder gasket Nozzle gasket TORQUE : kg·m EFLB015A REMOVAL 1.4 ~ 0.6 5. INJECTION NOZZLE COMPONENTS 4 0.0 ~ 4.3 ~ 3. Injection pipe When loosening the union nuts. hold delivery valve holder on fuel injection pump head or hexagon nut of fuel return pipe with a wrench to prevent it from rotating along with the union nut.7 1 0.0 5 6 7 8 9 3 2.7-8 INJECTION NOZZLE 2. the pipe might be damaged. CAUTION If you remove the hexagon nut without holding the fuel return pipe nut. Holder gasket Nozzle gasket EFLB019A 2. Return holder Using a deep socket wrench. . 09314-43100 CAUTION Write the number of the cylinder on the injection nozzle that has been removed. Fuel return pipe When removing the fuel return pipe nut.INJECTION NOZZLE 2. hold the fuel return pipe by the hexagon nut with a wrench. CAUTION Gasket groove may cause lack of idle RPM. Clean nozzle holder installation area of the cylinder head. EFLB018A INSTALLATION NOZZLE HOLDER 1. So you must remove the hexagon nut with holding return pipe. Cover the opening with an appropriate cap to prevent entry of dust. Fit a new nozzle gasket and holder gasket into the nozzle holder hole in the cylinder head. loosen the injection nozzle and remove. Nut 7-9 Fuel return pipe EFLB017A 3. water and foreign material into the fuel passage land combustion chamber. 2.5 ~ 4. Hold the retaining nut with a box wrench. EFLB021A Deep socket wrench . INJECTION NOZZLE HOLDER COMPONENTS 3 7 2 6 3.0 5 1 1 2 3 4 5 6 7 Retaining nut Nozzle tip Distance piece Retaining pin Pressure spring Shim Nozzle holder body 4 TORQUE : kg·m EFLB020A DISASSEMBLY RETAINING NUT 1. and loosen the nozzle holder body using a deep socket wrench.7-10 INJECTION NOZZLE HOLDER 3. Retaining nut Lightly clamp the retaining nut with a cushion bracket . Take particular care to protect the nozzle tip needle valve from damage. Check the surface in contact with the nozzle holder body by using minimum. 2. While holding the retaining nut with a box wrench. When replacing the nozzle tip. After cleaning. Deep socket wrench EFLB021A . 2. tighten the nozzle holder body to the specified torque with a deep socket wrench. If "A" is damaged or broken replace it. Check spring for weakness and breakage. While the nozzle tip is submerged in diesel fuel. 3. 7-11 Plunger Nozzle tip EFLB022A RETAINING NUT 1.INJECTION NOZZLE HOLDER NOZZLE TIP 1. Check plunger tip "A" for deformation and breakage. check that the needle valve slides smoothly. completely wash off the anticorrosive oil from the new nozzle tip with clean diesel fuel before using it. Check the nozzle tip for carbon deposits: Scrape off carbon deposits with a piece of wood land clean each part with patrol. Finger-tighten the nozzle holder body. If the needle valve does not slide smoothly. replace the nozzle tip. 3. clamp the retaining nut in a vise with cushion plates. keep parts submerged in diesel fuel. 7 0.6 1.0 ~ 2.6 8.3 ~ 3.4 ~ 0.2 2.0 ~ 9.0 0.7 [REMOVAL] 1 Fuel injection pump connector 1A Electrical system connector 2 Fuel hose 3 Accelerator cable 4 Fuel injection pipe 5 Upper timming cover 6 7 Fuel injection pump sprocket Fuel injection pump [Remarks] Assembly is the reverse of disassembly TORQUE : kg·m EFLB024A . INJECTION PUMP COMPONENTS 1.2 2.0 ~ 1.5 ~ 2.7-12 INJECTION PUMP 4.4 ~ 0. INJECTION PUMP REMOVAL FUEL INJECTION PIPE To remove the fuel injection pipe, refer to Injection nozzle 7-13 EFLB025A FUEL INJECTION PUMP SPROCKET 1. Rotate the crankshaft to place it to the first cylinder piston compression dead point. 2. Place the belt tensioner to the full loose position of timing belt.. 3. After removing the sprocket mounting nut, remove the sprocket from the pump drive shaft using the special tool or equivalent puller. CAUTION Do not tap on the pump drive shaft with a hammer. 09314-43000 EFLB026A 4. Leave the sprocket in the timing belt lower cover with the timing belt engaged. CAUTION • Do not burden the timing belt with twist, bend, etc. • After removing, do not rotate the crank shaft. • When holding the injection pump, do not pull down the accelerator lever or fast idle lever. Do not these levers. It may cause malfunction of the injection pump. 7-14 INJECTION PUMP INSTALLATION OF FUEL INJECTION PUMP SPROCKET When installing the sprocket to the injection pump, be sure the timing mark is aligned and tighten the nut to the specified torque. CAUTION After installing the sprocket, adjust the belt tension. (Refer to Timing belt of EM group) No.1 TDC EFLB027A Timing mark TROUBLESHOOTING 7-15 5. TROUBLESHOOTING FUEL TANK AND FUEL LINE Symptom Engine fault caused by low fuel supply Probable cause Bend and twist of fuel pipes and hoses Fuel pipes and hoses clogged Fuel filter clogged Water in fuel filter Air in fuel filter Fuel tank inside damaged and rusted Fuel pump fault Remedy Correct or replace Clean or replace Replace Drain water from the fuel filter Bleed the fuel filter Clean or replace Replace replace glow plug. Check that solenoid clicks when key is turned OFF and ON. test relay and wiring.7-16 FUEL INJECTION SYSTEM Symptom Engine does not start TROUBLESHOOTING Probable cause No voltage at fuel cut-off solenoid on injection pump Fuel cut-off solenoid on injection pump loose or faulty Remedy Check for voltage with test light. if necessary. Connect pipes in correct location Adjust injection timing. Inspect and. bleed air from system. Tighten solenoid. if necessary. Try engine at idle with new pump installed. If necessary. If no fuel emerges from a looseness injection pipe during cranking. replace pump permanently. if necessary. . if necessary. repair or replace nozzles. Replace hose or secure with clamps. replace fuse or faulty wires. then adjust accelerator cable. Check and. Try to start engine with new pump installed. dirty. or squeezed at connections Air in fuel system Faulty injection nozzles Injection timing incorrect Faulty injection pump Bleed fuel system. replace lines and hoses or replace fuel filter. Check and. kinked. replace pump permanently. If test light shows no voltage at bus with key at "O" position. If necessary. if necessary. If necessary. repair or replace injection nozzles. check timing belt and fuel supply from filter. or fuel return line and injection pipes leaking. . Test and. Bleed fuel system. Check and. No voltage at glow plug bus Glow plug faulty Air in fuel system Injection pump not delivering fue Injection pipes misconnected Injection timing incorrect Faulty injection nozzles Faulty injection pump Idle speed incorrect or idle rough irregular speed incorrectly adjusted Accelerator control binding Loose fuel hose between filter and injection pump Inadequate fuel supply owing to clogged fuel filter. adjust the idle speed. Replace faulty solenoid. Check that lever on pump is not loose. Adjust injection timing. Check and. then bleed fuel system. (winter time only) Faulty injection nozzles Injection timing incorrect Faulty injection pump Bleed fuel system. replace injection pump. or squeezed at connections Air in fuel system Ice or solidified wax in fuel lines. Adjust injection timing. Check and. replace or tighten all pipes. if necessary. Tighten lever. Observe exhaust with new pump installed if necessary. replace pump permanently. repair or replace injection nozzles. if necessary. Check acceleration and speed with new pump installed. Faulty injection nozzles Injection timing incorrect Faulty injection pump Poor power output. if necessary. replace pump permanently. kinked. Check fuel consumption with new pump installed. if necessary. or fuel return line and injection pipes leaking. Check and. replace injection pump. replace lines and hoses. Move car to a warm garage until ice or wax has become liquid. repair or replace injection nozzles. then adjust accelerator cable. hoses and connections. If line is clogged. Check return line for kinks and dents. if necessary.TROUBLESHOOTING Symptom Smoky exhaust (black. slow acceleration (speedometer accurate. dirty. Adjust injection timing. check that accelerator pedal travel is not restricted. Inspect and. replaced fuel filter. Excessive fuel consumption Fuel leaks Return pipe and hose blocked Idle speed too fast or maximum rpm too high Injection timing incorrect Faulty injection pump . Replace faulty lines. then bleed fuel system. clutch not slipping) Injection pump accelerator lever loose or not reaching maximum rpm adjusting screw Maximum rpm incorrect Inadequate fuel supply owing to clogged fuel filter. if unnecessary. if necessary. If necessary. replace pump permanently. blue or white) Probable cause Maximum rpm incorrect Remedy 7-17 Check and if necessary. Check and. if necessary. adjust idle speed or replace injection pump. Check and. Check and. repair or replace injection nozzles. blow it out with compressed air.


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