This Manual is published for informational purposes only and the information so provided should not be considered as

all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation should be consulted.
Sale of product shown in this Manual is subject to Thermo King's terms and conditions including, but not limited to, the
THERMO KING LIMITED EXPRESS WARRANTY. Such terms and conditions are available upon request.
No warranties, express or implied, including warranties of fitness for a particular purpose or merchantability, or
warranties arising from course of dealing or usage of trade, are made regarding the information, recommendations,
and descriptions contained herein. Manufacturer is not responsible and will not be held liable in contract or in
tort (including negligence) for any special, indirect or consequential damages, including injury or damage caused
to vehicles, contents or persons, by reason of the installation of any Thermo King product or its mechanical failure.
Specifications
Disassembly
Inspection and Reconditioning
Reassembly
Fuel System
Electrical
TableofContents
f
~
1 SpecifICation
TK235 Di eselEngine Specifications .... . . . ... . ..,,. 2
TK353 Diesel EngineSpecifications ...,.........,, 5
TorqueChart ..., ........ . ...,,,.... .. ..,,. .8
2 Disassembly
Camshaft ...,,..... . ..... .. . . . ... ... . ... . ... 11
Crankshaft ...,,..... .. . ..... . . . ............ 11
Cylinder Li ners ..., ... ..... .,.. ..,..... . 12
Gear Housing ......,..................." , 11
Injection Pump ,,.. . ... . . . .,,..,. . . . ...., 10
RockerArm Assembly ...,..... ...,. . .......,,. .10
Ti ming Gear Lash ....... .,.... . ...,.......,...11
3 Inspection & Reconditioning
Camshaft ....,........,............ 20
Connecting Rods ... . . . .'......... ............ 16
Crankshaft ........., . . . . . .... ... .... . .,...... 17
Cyli nder Block ....,... .......... . ... . .... ...... 14
Cylinder Head . .. ............. ... . .... . ....... 21
Engine Lubri cation System ....,. . . . . ....... . . . .24
Li fters. ...,... .... . ..'..... . . ..... 24
Main Bearings ....,............................ 17
Oil Pump .. ...,,,. . . . . . . . . . . . . . ... .. . , .,.. 25
Pi stons ... .... ...... .., ... . ....',.....,15
Push Rods ....... ..., . ... . ...... . .. . 24
RockerArm ShaftAssembly ........ .......,. 23
Valves . ...... .,. ............ . . .. . ......,... 21
ValveGuides , ..... . ... .. ..... . ... . ... . .. 22
Valve Seats .... ......, ............. 23
Water Pump ...... ......., ....... ..., ......... 26
4 Reassembly
Camshaft ..... ...,......... . .... . . ... ..... ... 28
Connecting Rod ... . .... . . .,. . . . .,.. . . . .... 28,30
Crankshaft ......... . . .. .. .......... . ...,.... 29
Cylinder Head ....................,.....,,.... 31
Fl ywheel ..... ,....................... .29
GovernorSleeve ......... . ....,..... . ... ...,31
Injection Pump ......... . ... . ... .. . . . ... ... . . .31
Piston Installat ion ..... .. .... . ...... . ...." .... 29
Piston Ri ngs ................................ 29
Timi ng Gear Marks ........'.......... ... .... 30
5 Fuel System
Bleeding Fuel System ... . ..,,. ........... 35
InjectionNozzles ................... ... ...,.... 40
InjectionPumpAdj ustment ..... . . .... ... .42
Inject ion Pump Disassembly .,,........ . . . . .... . .37
Injection Pump Replacement .......,,. ....,..... 35
Inject ionPumpTi ming ..... ....... ..............35
Valve Clearance Adj ustment . ,... ............. 43
6 Electrical
Starter Overhaul '.............46
l'
Specifications
' .
Contents
TK235Diesel Engine Specifications ..............2
TK353 Diesel Engine Specifications ................ 5
Torque Chart .................................. 8
TK235 DIESEL ENGINE SPECIFICATIONS
The following standard (production) and allowable service limit specifications are given for a
standard engine. 0.25 mmundersize rod bearings are available.
GENERAL
No. ofCylinders
Bore
Stroke
Displacement
Horsepower
Fuel Injection Timing
Valve Clearance
Intake (coldl
Exhaust (coldl
Firing Order
Compression Ratio
Compression Pressure
High Speed
Low Speed
Oil Pressure
Nozzle Injection Pressure
Oil Base Capacity
VALVE SPRING AND GUIDE
Valve Spring
Free Length
Compressed Length/Pressure
Valve Guide I.D.
Intake
Exhaust
Valve Stem Diameter
Intake
Exhaust
Valve Stem Clearance
Intake
Exhaust
Valve Depth
Intake
Exhaust
Valve Seat Angle
Valve FaceAngle
Valve Seat Width
Valve Margi n
VALVE TRAIN
Tappet Diameter
Tappet Clearance to Block
Push Rod Length
Rocker Arm Bearing Inside Diameter
Rocker Shaft Diameter
Rocker Arm to Bearing Clearance
Standard
2
2.83 in. (72 mm)
2.83 in. (72 mm)
35.7 cu. in. (0.585 litrel
10.7 hp @ 2400 rpm
21 BTC
.0079 in. 10.2 mm)
.0079 in. 10.2 mm)
1,2
23:1
455 psi (3137 kPa) @ 320 rpm
2350 20rpm - KD-I
2450 50 rpm - MD-I
1300 20rpm
42.7-56.9 psi (294-392 kPa)
2275 psi (15,690 kPal
8 qts 17.57 litrel
1.44 in. (36.5 mml
1.15in./20.7 Ib 129.3 mm/9.4kgl
.2760-.2766 in. 17.01 -7.025 mml
.2762-.2768 in. 17.015-7.030 mml
.2740-.2744 in. 16.96-6.97 mml
.2740-.2744 in. 16.96-6.97 mml
.0016-.0026in. (0.040-0.065 mm)
.0018-. 0028in. (0.045-0.070mm)
.0374in. (0.95mm)
.0374in. 10.95 mml
45
45
.0697 in. 11.77 mml
.0295-.0453 in. (0.75- 1.15 mml
.3929-.3935 in. (9.98-9.995 mml
.0002-_0014 in. (0.006-0.035 mml
5.354-5.362 in. 1136.0-136.2 mml
.5518-.5525in. (14.016-14.034 mml
.5505-.5512 in. 113.982-14.0 mml
.0006-.0020 in . 10.016-0.052 mml
Service Limit
1.38in. (35.0 mml
1.15in_/16.5Ib
129.3 mml7.5 kgl
.2787 in. 17.08mml
.2787 in. (7.08mm)
.2717 in. (6.9 mm)
.2717 in. 16.9 mml
.005 in_10.13 mml
.005 in. (0.13 mml
.0492 in. (1.25 mml
.0492 in. (1.25 mml
.0276 in. (0.70 mml
.3917 in. (9.95 mml
.0039 in. (0.10 mml
5.335 in. (135.5 mml
.5551 in. (14_1 mml
.5472 in. 113.9mm)
.0059 in. (0.15mm)
~
'I
2
CAMSHAFT
Lobe Height
Intake and Exhaust Valves
Fuel Pump
Camshaft Bushing Inside Dia. (f lywheel end)
Journal Diameter (flywheel end)
Bushing toJournal Clearance (flywheel end)
Camshaft Bushing Outside Dia.
Camshaft Bushing Bore in Block
End Play
PISTON, PISTON RINGS
Pistons, Type
Piston Outside Diameter
Clearance to Cylinder Liner Wall
Piston Rings
Ring toGroove Clearance:
No.1 Compression - Barrel Face
No.2Compression - Tapered Face
No.3Oil Control with Expander
Ring End Gap
No.1
No.2
No. 3
PISTON PIN
Outside Diameter
Piston Pin Bearing Inside Diameter
Clearance to Bushing
CYLINDER LINER
Inside Diameter
Projection above Block
CONNECTING RODS
Rod Large End Bore (torqued wl o insert)
Rod Bearing Inside Diameter (torqued)
Allowable twist per 4in. (100 mm)
Allowable paralleli sm per 4 in. (100 mm)
Side Clearance to Journal
CRANKSHAFT
Main Bearing Inside Diameter
Flywheel end
Intermediate Bearing (torqued)
Gear End
Main Bearing Journal Diameter
Flywheel end
Intermediate
Gear end
Main Bearing Clearance
Flywheel end
Intermediate
Gear end
Rod Bearing Journal Diameter
Rod Bearing Clearance
Crankshaftend play
Standard
1.3780 in. (35.0 mm)
1.7717 in. (45.0 mm)
1.0626-1.0654in. (26.99-27.06mm)
1.0606-1.0614in. (26.94-26.96 mm)
.0012-.0048in. (0.031-0.122 mm)
1.1831-1.1845in. (30.05-30.085 mm)
1.1811 -1.1819 in. (30.0-30.02 mm)
None
Relief cast - full float pin
2.8312-2.8324 in. (71.913-71.943 mm)
.0022-.0046in. (0.057-0.117 mm)
.0026-.0039 in. (0.065-0.1 mm)
.0014-.0028 in. (0.035-0.070 mm)
.0008-.0022 in. (0.02-0.055 mm)
.008-.016 in. (0.2-0.4 mm)
.008-.016 in. (0.2-0.4 mm)
.008-.016 in. (0.2-0.4 mm)
.7870-.7874 in. (19.991-20.0 mm)
7884- .7889 in. (20.025-20.038 mm)
.001-.0019 in. (0.025-0.047 mm)
2.8346-2.8358 in. (72.0-72.03mm)
.0002- .0030 in. (0.005-0.075 mm)
1.6929-1.6935 in. (43.000-43.016mm)
1.5745-1.5762 in. (39.992-40.036 mm)
.0012 in. (0.03 mm)
.0012 in.(0.03 mm)
.0079-.0157 in. (O.2-DA mm)
2.3622-2.3639 in. (60.0-60.044 mm)
1.7323-1.7340in. 144.0-44.044mm)
1.7323-1.7340in. 144.0-44.044mm)
2.3602-2.3608in. 159.950-59.964mm)
1.7303-1 .7309 in. (43.950-43.964mm)
1.7303-1.7309in. (43.950-43.964mm)
.0014-.0037in. (0.036-0.094 mm)
.0014-.0037 in. 10.036-0.094 mm)
.0014-.0037 in. 10.036-D.094mm)
1.5728-1.5734in. (39.95-39.964 mm)
.0011-.0034 in. 10.028-0.086 mm)
.003-.007 in. (0.085-0.175 mm)
3
Service Limit
1.3543 in. 134.4 mm)
1.7520 in. (44.5 mm)
.0059 in. 10.15 mm)
2.8287 in. (71.85 mm)
.0118in. 10.3 mm)
.0079 in. 10.2 mm)
.0079 in. (0.2 mm)
.0059 in. 10.15 mm)
.059 in. (1.5mm)
.059in. (1.5 mm)
.059 in. (1.5mm)
.7866 in. 119.98 mm)
.7913 in. 120.1 mm)
2.8398 in. (72.13 mm)
.000 in. (0.00mm)
1.5795 in. (40.12 mm)
.0031 in. (0.08 mm)
.0031 in. 10.08 mm)
.0197in. 10.5 mm)
2.3669 in. 160.12 mm)
1.7370 in. 144.12 mm)
1.7370 in. (44.12 mm)
2.358in. 159.90 mm)
1.7283in. (43.90 mm)
1.7283 in. 143.90 mm)
.0059 in. (0.15 mm)
.0059 in. (0.15 mm)
.0059 in. (0.15 mm)
1.5717 in. (39.92 mm)
.0059 in. (0.15 mm)
.012 in. (0.3 mm)
CYLINDER BLOCK Standard Service Limit
Main Bearing Bore
Main bearing housing (flywheel end)
Intermediate bearing housing (torqued)
Gear end (block)
Push Rod Bore
Camshaft ball bearing bore (gear end)
TIMING GEARS
Timing Gear Backlash
Crank Gear to Pump Gear
Crank Gear to Cam Gear
LUBRICATION SYSTEM
Oil Pump
Oil Pump Type
Relief Valve Setat
Vane & Rotorto Cover Clearance
RotorTip to Vane Clearance
Vane to Body Clearance
FUEL SYSTEM
NozzleType
Injection Pressure
Tightening Torque
Injection Lines, O.D.
Injection Lines, I.D.
Injection Timed at
ELECTRICAL SYSTEM
Starter Motor (Nippondenso)
Voltage
Rotation - viewed from pinion end
Clutch
Method ofengagement
Periormance - NO LOAD"
Voltage
Current
RPM
Clearance
Commutator Original Diameter
Commutator Minimum Diameter
2.5591-2.5598 in. (65.0-65.019 mm)
1.8898-1.8904in. (48.0-48.016mm)
1.9291-1.9298in. (49.0-49.016 mm)
0.2421-0.2539 in. (6.15-6.45 mm)
.9841-.9846 in. (24.996-25.009mm)
.0034-.0051 in. (0.086-0.13 mm)
.0034-.0051 in. (0.086-0.13 mm)
Trochoid
42.7-56.9 psi 1294-392 kPa)
.0024-.0040 in. (0.06-0.1 mm)
.0020-.0040 in. (0.05-0.1 mm)
.0004-.0020 in. (0.01-0.05 mm)
YDN-OSDYDl
2276 psi (15,960 kPa)
18-20 ftllb(24.4- 27.1 N'm)
.236in. (6 mm)
.059 in. (1.5 mm)
21 BTC
12Vdc
clockwise
Over-running clutch
Magneticallyengaged sliding pinion
11V
180 amps @l1V
Over3500 rpm @11V
1.181 in. 130.0 mm)
1.142in.129.0mm)
f
.0118 in. (0.3 mm)
.0118 in. (0.3 mm)
.006in. (0.15 mm)
.006 in. (0.15 mm)
.003 in. (0.08mm)
'NOTE: Donotsupplymorethan11 voltstothestarterduringunloadedtestingtopreventoverspeeddamage.
4
TK353 DIESEL ENGINE SPECIFICATIONS
The foll owing standard (production) and all owable service limit specifications are gi ven for a
standard engine. 0.25 mm undersize rod bearings are available.
GENERAL
No.of Cylinders
Bore
r Stroke
Displacement
Horsepower
Fuel Inj ectionTiming
Valve Clearance
IntakeIcold)
Exhaust Icold)
Firing Order
Compression Ratio
Compression Pressure
High Speed
Low Speed
Oil Pressure
Nozzle Injection Pressure
Oil Base Capacity
VALVE SPRING AND GUIDE
Valve Spring
Free Length
Compressed Length/Pressure
Valve Guide I.D.
Intake
Exhaust
Valve Stem Diameter
Intake
Exhaust
Valve Stem Clearance
Intake
Exhaust
Valve Depth
Intake
Exhaust
Valve Seat Angle
Valve Face Angle
Valve Seat Width
Valve Margin
VALVE TRAIN

Tappet Diameter
Tappet Clearance to Bl ock
Push Rod Length
Rocker Arm Bearing Inside Diameter
Rocker ShaftDiameter
Rocker Arm to Bearing Clearance
Standard
3
2.83 in. (72 mm)
2.83 in. (72 mm)
53.6 cu. in. 10.878 litre)
16.1 hp @2400 rp(Tl _
21 BTC
.0079 in. 10.2 mm)
.0079 in. (0.2 mml
1,3,2
23:1
455 psi (3137 kPa) @ 320 rpm
2350 20 rpm RD-I
1300 20 rpm
42.7-56.9 psi (294-392 kPa)
2275 psi 115,690 kPa ).
10 qts 19.46 litre)
ISw - 'to
1.44in. 136.5 mm)
1.15in.l20.71b129.3 mm/9.4kg)
.2760-.2766 in. 17.01-7.025 mm)
.2762-. 2768 in. 17.015-7.030 mm)
.2740-.2744 in. 16.96-6.97 mm)
.2740-.2744 in. 16.96-6.97 mm)
.0016-.0026 in. (0.040-0.065 mm)
.0018- .0028 in. 10.045-0.070nim)
.0374 in. 10.95 mm)
.0374 in. 10.95 mm)
45
45
.0697 in. 11.77 mm)
.0295-.0453 in. 10.75-1.15 mm)
.3929-.3935in. 19.98-9.995mm)
.0002-. 0014in. (0.006-0.035 mm)
5.354-5.362 in. 1136.0-1 36.2mm)
.5518-.5525 in. 114.016-14.034 mm)
.5505-.5512 in. 113.982- 14.0 mm)
.0006-. 0020 in. 10.016-0.052 mm)
5
Service Limit
1.38 in. 135.0 mm)
1.15in.! 16.5 Ib
129.3 mm17.5 kg)
.2787 in. 17.08 mm)
.2787 in. 17.08 mm)
.2717 in. 16.9 mm)
.2717in. 16.9 mm)
.005 in. (0.13 mm)
.005 in. (0.13 mm)
.0492in. 11.25 mm)
.0492 in. 11.25 mm)
.0276in. (0.70 mm)
.3917 in. (9.95mm)
.0039 in. (0.10 mm)
5.335 in. 1135.5 mm)
.5551 in. 114.1 mm)
.5472 in. 113.9 mm)
.0059 in . 10.15mm)
CAMSHAFT
Lobe Height
Intake and Exhaust Valves
Fuel Pump
Cam Journal Bore in Block (flywheel end)
Camshaft Journal Outer Diameter (flywheel end)
Bore toJournal Clearance (flywheel end)
End Play
PISTON, PISTON RINGS
Pistons, Type
Piston Outside Diameter
Clearance to Cylinder Liner Wall
Piston Rings
Ring to Groove Clearance:
No.1 Compression - Barrel Face
No.2Compression - Tapered Face
No.3Oil Control with Expander
Ring End Gap
No. 1
No. 2
No. 3
PISTON PIN
Outside Diameter
Piston Pin Bearing Inside Diameter
Clearance to Bushing
CYLINDER LINER
Inside Diameter
Projection above Block
CONNECTING RODS
Rod Large End Bore (torqued w/oinsert)
Rod Bearing Inside Diameter (torqued)
Allowable twist per4 in. (100 mm)
Allowable parallelism per4 in. (100 mm)
Side Clearance toJournal
CRANKSHAFT
Main Bearing Inside Diameter
Flywheel end
Intermediate Bearing (torqued)
Gear End
Main Bearing Journal Diameter
Flywheel end
Intermediate (flywheel & gearend)
Gear end
Main Bearing Clearance
Flywheel end
Intermediate (fywheel & gear end)
Gear end
Rod Bearing Journal Diameter
Rod Bearing Clearance
Crankshaft end play
Standard
1.3780 in. (35.0 mm)
1.7717 in. (45.0 mm)
1.1811-1.1819in. (30.0-30.02 mm)
1.1787-1.1795in. (29.94-29.96 mm)
.0016-.0032in.(0.040-0.082mm)
None
Relief cast - full float pin
2.8312-2.8324in. 01.913-71.943mm)
.0022-.0046 in. (0.057-0.117 mm)
.0026-.0039 in. (0.065-0.1 mm)
.0014-.0028 in. (0.035-0.070 mm)
.0008-.0022 in. (0.02-0.055 mml
.008-.016 in. (0.2-0.4 mm)
.008-.016in. 10.2-0.4 mm)
.008-.016in. 10.2-0.4 mml
.7870-.7874 in. (19.991-20.0 mm)
.7884-.7889 in. 120.025-20.038 mm)
.001-.0019 in. 10.025-0.047 mml
2.8346-2.8358in. (72.0-72.03 mm)
.0002-.0030in. (0.0050.075 mm)
1.6929-1.6935in. (43.000-43.016mm)
1.5745-1.5762in. (39.992-40.036 mm)
.0012 in. 10.03 mm)
.0012 in. 10.03 mm)
.0079-.0157 in. (0.2-0.4 mm)
2.3622-2.3639 in. 160.0-60.044 mm)
1.7323-1.7340in. 144.0-44.044 mml
1.7323-1.7340in. (44.0-44.044 mml
2.3602-2.3608 in. (59.950-59.964 mm)
1.73031.7309 in. 143.950-43.964 mm)
1.7303-1.7309in. 143.950-43.964 mm)
.0014-.0037 in. 10.036-0.094 mm)
.0014- .0037 in. (0.036-0.094 mm)
.0014-.0037 in. (O.036-0.094 mm)
1.57281.5734in. 139.95-39.964mm)
.0011-.0034 in. (0.028-0.086mm)
.003-.007 in. (0.085-0.175 mm)
6
Service Limit
1.3543 in. (34.4 mm)
1.7520 in. (44.5 mm)
.0059 in. (0.15 mm)
2.8287in. (71.85mm)
.0118in. (0.3 mm)
.0079 in. (0.2 mm)
.0079 in. (0.2 mm)
.0059 in. (0.15 mm)
.059 in. (1.5 mm)
.059 in. (1.5 mml
.059 in. (1.5 mm)
.7866 in. (19.98 mml
.7913 in. (20. 1mm)
\ ,
2.8398 in. (72.13 mm)
.000 in. (0.00 mm)
1.5795in. (40.12 mm)
.0031in. (0.08mm)
.0031 in. (0.08mm)
.0197 in. (0.5mm)
2.3669 in. (60.12 mm)
1.7370 in. (44.12 mm)
1.7370 in. (44.12 mm)
2.3583 in. (59.90 mm)
1.7283 in. (43.90 mm)
1.7283 in. (43.90 mm)
.0059in. (0.15 mm)
.0059 in. (0.15 mm)
.0059 in. (0.15 mm)
1.5717 in. (39.92 mm)
.0059 in. (0.15 mm)
.012 in. (0.3 mm)
CYLINDER BLOCK
Main Bearing Bore
Main bearing housing (flywheel end)
Intermediate bearing housing (torqued)
Gear end (block)
Push Rod Bore
Camshan ball bearing bore (gear end)
TIMING GEARS

Timing Gear Backlash

Crank Gearto Pump Gear
Crank Gear to Cam Gear
LUBRICATION SYSTEM
Oil Pump
Oil Pump Type
Relief Valve Set at
Vane & Rotor to Cover Clearance
RotorTip to Vane Clearance
Vane t o Body Clearance
FUEL SYSTEM
Nozzle Type
Injection Pressure
Tightening Torque
Injection Lines, 0 .0.
Injection Lines, 1.0.
Injection Timed at
ELECTRICAL SYSTEM
Starter Motor (Nippondenso)
Voltage
Rotation - viewed from pinion end
Clutch
Method ofengagement
Performance - NO LOAD'
Voltage
Current
RPM
Clearance
CommutatorOriginal Diameter
Commutator Minimum Diameter
Standard
2.5591-2.5598in. (65.0-65.019 mm)
1.8898-1.8904in. (48.0-48.016 mm)
1.9291-1.9298in. (49.0-49.016 mm)
0.2421-0.2539 in. (6.15-6.45 mm)
.9841-.9846 in. (24.996-25.009 mm)
.0034-.0051 in. (0.086-0.13 mm)
.0034-.0051 in. (0.086-0.13 mm)
Trochoid
42.7-56.9 psi 1294-392 kPa)
.0024-.0040 in. 10.06-0.1 mm)
.0020-.0040 in. (0.05-0.1 mm)
.0004-.0020 in. 10.01-0.05 mm)
YDN-OSDYOl
2276 psi (15,960 kPa)
18-20ft/lb (24.4- 27.1 N'm)
.236 in. 16 mm)
.059 in. 11.5 mm)
2FBTC
12V de
clockwise
Over-running clutch
Magnetically engaged sliding pinion
l1V
180 amps @llV
Over 3500 rpm @11V
1.181 in. (30.0 mm)
1.142in. (29.0mm)
Service limit
.0118in. 10.3 mm)
.0118 in. (0.3 mm)
.006 in. 10.15 mm)
.006in. 10.15 mm)
.003in. 10.08 mm)
"NOTE: Donotsupplymorethan11 voltstothestarterduringunloadedtestingtopreventoverspeeddamage.

7
TORQUEVALUES FOR TK235 & TK353 DIESEL ENGINE
Part No. Dia. (mm) Length (mm)
N'm ftllbs
Camshaft Retaining Screw 55-4635 8 10 15-16 11 -12
Clutch Mtg Bolt 55-4589 41 30
Connecting Rod Bolt 11-5042 7 22-27 16-20
Crankshaft Gear Nut 11 -5034 28 69-74 51-54
Crankshaft Pulley Nut 11-5035 18 58-68 43-50
Cylinder Head Stud 55-4595 12 34-39 25-29
Cylinder Head Nut 55-4597 12 22-27 16-20
Cylinder Head Mtg Bolt 55-4594 12 98-109 72-80
Cylinder Head Mtg Bolt 55-4596 8 22-27 16-20
Flywheel Mtg Bolt 11-5038 10 64-68 47-50
Fuel Cam and Cam Gear Nut 11 -5026 18 58-68 43-50
Gear Case Mtg Bolt 55-4648 8 85 24-27 18-20
Gear Case Mtg Bolt 55-1 141 8 45 24-27 18-20
Gear Case Mtg Bolt 5,5-4649 8 120 24-27 18-20
Gear Case Mtg Bolt 55-4647 8 75 24-27 18-20
Injection Nozzle Mtg Stud 55-4626 8 65 24-27 18-20
Injection Pump Mtg Stud 55-4620 8 24-27 18-20
Mounti ng Flange Bolt 55-4804 10 18 43-49 32-38
Intermediate Main Bearing Hsg Set Bolt 55-4618 10 45-49 33-36
Intermediate Main Bearing Hsg Bolts 55-4617 8 30-34 22-25
Oil Sump Mtg Bolt 55-4606 6 25 8-10 6-7
Oil Sump Mtg Bolt 55-4655 6 32 8-10 6-7
Oil Pan Mtg Bolt 55-4611 8 28 8-10 6-7
Oil Pan Mtg Bolt 55-4612 8 40 8-10 6-7
Oil Pump Mtg Screw 55-4637 6 22 10-12 7-9
Oil Fill Tube Mtg Screw 55-4749 8 25 24-27 18-20
Rear Main Bearing Hsg Mtg Bolts 55-1140 8 24-26 18-19
Rocker Arm Support Mtg Nut 55-4624 10 36-39 27-29
Starter Mtg Bolt 55-4677 10 35 45-49 33-36
Starter Mtg Bolt 55-4680 10 25 45-49 33-36
Thermostat Housing Mtg Bolt 55-4611 8 28 24-27 18-20
Thermostat Housi ng Mtg Bolt 55-4612 8 40 24-27 18-20
Water Pump Mtg Bolt 55-4646 8 85 24-27 18-20
Water Pump Mtg Bolt 55-4655 6 35 24-27 18-20
Water Pump Mtg Bolt 55-4654 8 90 24-27 18-20
Hollow Bolts (not specified) 8 12-16 9-12
10 19-30 14-22
12 24-34 18-25
Other Bolts (not specified) 4 3 2-2.5
6 8-10 6-7
8 24-27 18-20
10 43-49 32-36
12 68-73 50-54
8

Disassembly
Contents
Camshaft ......... ................ ..11
Crankshaft .................................. 11
Cylinder Liners ..... . .. . ... .. . ..... ......... 12
Gear Housing ........... ...... .....11
Inj ection Pump ..... ..... .. ....... ... ..... 10
RockerArm Assembly ............... .......... 10
Timing Gear Lash .............................. 11
9
Engine Disassembly
Fig.21 Assembled Engine
I. Removeclutchretaining boltand,with astandard
puller, removeclutch. Usecaretopreventdamage
toclutch assembly.
2. Remove fuel and throttle solenoids and solenoid
brackets.
3. Removestarter.
4. Remove alternator and belt.
5. Remove water pump assembly including ther-
mostat housing, bypass coolant hose, idler pulley
andadjustmentassemblyandalternatormounting
bracket.
6. Di sconnectinjectionlines. Coverallinjectionlines
and fuellineswithplasticcovers ortape. Even the
smallest amount of dirt may damage the fuel
system.
Fig. 2-2 Removing Rocker ArmShaftAssembly
10
,
\Y
7. Disconnect the fuel return pipe from the injector
nozzles.
8. Remove theinjector nozzles.
9. Removethe valve cover.
10. Remove rocker arm shaft assembly (Fig. 2-2).
Loosen thebolts in progression.
II. Withdraw push rods and keep them in order if
they areto be reused.
12. Remove rocker arm oil tube.
13. Remove cylinder head bolts and removecylinder
head.
When removing or replacing the cylinder head,
graduallyloosenortighten thenutsin accordance
with the specified order to prevent head di stor-
tion.
Fig. 2-3 Removing Injection PumpAssembly
14. Remove the cover from the timing bearing hous-
ing. Remove the fuel injection pump assembly
(Fig. 2-3).
NOTE: Slowlywithdrawthefuelpumpfrom the
gear case, being careful not to damage Ihe rack.
Check the rack position through the viewing win-
dow in the gear housing.
15. Remove the crankshaft pulley and key. A puller
may be used ifneeded.
Arrange the connecting rods, bearing caps and
pistons in correct order if they are to be reused.
Theconnectingrodsandcapsarenumberedbythe
manufacturer. Marking will not normally be
needed.
22. Remove the flywheel. It is doweled and needs no
marking.
23. Remove rear main bearing housing bolts and in-
termediate main bearing housingset bolt.

24. Usingaplasticorsofthammeras adrift(Fig. 2-6),
drive the crankshaft free of the crank gear and
front and rear main bearings. Removecrankgear.
Carefully withdraw crankshaft through flywheel
endwith intermediateandrearmainbearinghous-
ings attached.
Fig. 24 Remove Gear Housing Assembly
Fig 25 Checking Gear Lash
16. Remove gear housingassembly(Fig. 2-4).
17. Check the timinggearlash at this point(Fig. 2-5).
If thelash is within specifications, thereis a good
possibility the gearsare reuseable.
Standard crankshaft gear to camshaft gear
backlash is .0034 to .0051 in. (0.086 to 0.13 mm) .
Standardoil pumptocrankshaftgearlashis .0034
to .0051 in. (0.086 to 0.13 mm).
If thelash is excessive, discard the gears.
18. Remove governor from crankshaft gear. Remove
governor sleeve. Remove gear nut and governor.
19. Remove oil pump assembly.
20. Remove oil pan dipstick and oil pan.
21. Remove connecting rod bearing caps. Withdraw
the piston and connecting rod up through the
cylinder bore afterchecking for a ring ridge.
CAUTION: DO NOT use an airwrench On the
rod cap bolls. Due to their close fit, the rapid
speed will seize them in thecap.
11
25. Removeintermediateandrearmainbearinghous-
ings from crankshaft.
26. Remove camshaft retainer screw (Fig. 2-7).
Remove the camshaft.
CAUTION: Be careful to avoid dalDaging the
calDshaftbearings.
Fig. 2-6 Crankshaft Removal
Fig. 2-7 Camshaft Retainer Screw
- - - - - -
.'
Fig. 2-8 Breaking Glaze on Cylinder Liner
27. Remove the tappets. Keep tappets with their
respective cylinders.
28. Thoroughly clean and inspectcylinder liner. Run
deglazer in and out of cylinder liner quickly to
remove varnish to improve heat transfer.
29. Check cylinder liners for wear, out-of-round,
pocketing, or any other problems that would
require replacement. The inside diameter of the
liner should not be greater than 2.8398 in. (72.13
mm) or .0024 in. (0.06 mm) out-of-round (Fig.
2-9).
30. Removecylinder liner with a suitable puller.
I
I' .
Ftg. 2-9 Cylinder Liner Measurement
12
Inspectionand Reconditioning
Contents
Camshaft ........... ........ ..... .......... ... 20
Connecting Rods ............................ 16
Crankshaft ............... .................... 17
CylinderBlock ................ ................ 14
Cylinder Head ................................ 21
Engine Lubrication System ............ ........ 24
Lifters ........................... ............ 24
Main Bearings .............................. 17
Oil Pump .....................................25
Pistons ....................................... 15
Push Rods ........ ... . ... ........... . .... ...24
RockerArmShaftAssembly .. .... ...... . ........ 23
Valves ....................................21
Valve Guides .................................22
Valve Seats ........ . .. . ........... ..... . ... . 23
Water Pump .............................. 26
13
Inspectionand Reconditioning
Now that the engine is disassembled, this section will
cover thecleaning, inspection, overhauland reassembly
ofindividualenginecomponents. The followingsecti on
of thi s manual describes the reassembly oftheengine.
After disassembling the engine, check the component
partsanddiscardunuseable partssuchas gaskets, burn-
ed valves, broken rings, etc. Items that may requi re
machineshopworkshould bechecked first so that this
work can be completed by the time theengine is ready
for reassembly.
CYLINDER BLOCK
I. Thoroughly clean t hecylinder boreandliners. [n-
spect the block and the outer surface of the
cylinder liner forevidence ofpittingorcorrosion.
If t he liner or cylinder bore ledge is erodedtot he
extentthatsealingis affected, thecylinderliner or
block must be replaced.
F"og. 3-1 Inspectand Clean Cylinder Bore and
ledge
2. Inspect thecylinder blockforcracks,damageand
distortion. Usinga straight edgeand feelergauge,
check theblock to head matingsurface. [f thereis
more than .0028 in. (0.070 mm) distortion on t he
two-cylinder engine block or .0039 in. (0.1 mm)
distor tion on the threecylinder block, resurface
the block.
3. Inspect the tappet bores in the block and check
tappet to bore clearance with a small hole gauge
and micrometer.Tappetclearanceshould be.0002
to .0014 in. (0.006 to0.035 mm). Thereisverylit-
tle, ifany, wear associated with these bores.
F"og. 3-2 Measuring BlockDistortion
4. Coat the exterior outer surface of the cylinder
liner with engine oi l. Insert the coated liner into
the cylinder block by hand. If the cyli nder liners
arereplaced,check thediameterandroundnessof
the new cylinder liner. Standard cylinder li ner
diameter is 2.83 in. (72.0 mm) and out-of-
roundness should be .001in. (0.025 mm).
5. Check the projection of the cyli nder liner above
the block head (Fig. 3-3). If the top edge oft he
cylinder li ner is below deck, theliner will notseal
properlyto thecylinderhead. Excessiveprojection
wi ll increase the top clearance and damage the
gasket. Cylinder liner projection should be flush
to .0030 in. (flush to 0.075 mm). If the cylinder
liner projection is below deck or excessive, try
another liner orfile it down.
Fig. 3-3 Measuring Sleeve Projection
14
PISTONS
I. Remove and discard the old piston rings.
2. Measure the piston diameter (Fig. 3-4). The
measurement should be taken .3543 in. (9.0 mm)
up from the bottom of the skirt and at a right
angletothepi stonpin. Pistondiametershouldnot
be less than2.8287 in. (71.85 mm).
NOTE: When working with a pislon and rod
assembly, do notclampitinasleeljawvise. Usea
softjawvise Or usesoftcoversover thesteeljaws.
Clamping the rod in a steel vise will put small
nicks in the rod. These become stress raisers and
can cause premature rod failure. Fig_ 3-5 Checking RingGrooveClearance
Fig. 3-4 Piston Measurement
3. Cleanthering grooves with a ringgroovecleaner,
being careful not to scrape any metal from the
piston. Ifitis notpossibleto obtaina ring groove
cleaner, a used ringcanbe broken and sharpened
to do the job.
4. Using a new set ofpiston rings, check the ring to
grooveclearancebyinserting a feeler gauge along
with the ring and roll it all the way around the
piston ring groove. Excessive side clearance re-
quirespistonreplacement.Donotinstallrings yet;
ring end gapwill need to bechecked.
5. Usea long.0010in. (0.025 mm) feeler gauge, and
check theclearancebetweenthecylinderlinerand
piston. Lay it against the piston vertically at a
position 90
0
from the wrist pin holes. This is the
widest partofthe piston. Nowcare fullytrytoin-
sertthe pistonalong with the feeler gaugeintothe
propercylinderbore.Thepistonandgaugeshould
beableto bepulledoutusinga I to3lb.(0.043 to
1.3 kg) pull. The clearance should not exceed
. 0118 in. (0.3 mm). Check top and bottom of
cylinder boreto make sure there is no taper.
Fig_ 3-6 PistonRing Identification
PISTON PINS
The wrist pin and bushing carries a great deal ofload
concentrated in a smallarea, and the fil is verycrilical.
Itis recommended thata qualified machineshopdothe
pin fitting when the engine is overhauled.
I. Because of the very close tolerances (.0010 to
.0019 in. [0.025 to 0.047 mm]) involved between
the wrist pin, piston bore and rod bushing,
measuring wear becomes verydifficult usingstan-
dard micrometers and small hole or telescopic
gauges.
If precision gauging equipment is not available,
the wrist pin tobushing fit can bechecked by oil-
ing the wrist pin and inserting it in the bore. It
should be snug and require at least a hand push
fit.
2. Measure the piston pins and replace any piston
pins that exceed .0010 in. (0.025 mm) wear (out-
side diameter less than .7866 in. [19.98 mm]).
15
Fig.3-7 Wrist Pin Measurement
CONNECTING RODS
Theproceduresfor reconditioningarod, honingthebig
end, fitting the wrist pin and straightening requires
varied and expensive equipment. If this equipment is
not available, most machine shops areable to recondi-
tion the rods to likenew specifications.
1. The connecting rods should, ifpossible, be glass
bead c1eaned, which in turn, st ress relieves them.
NOTE: A glassbeadcleanerdoes anexceptional
jobofcleaninga rod andis highly recommended.
Most machine shops offer this service and the
price is usually quite reasonable.
2. Use a rod alignment fixture to check for connec-
ting rod twi st or parallelism (Fig. 3-8 & 3.9). The
service limit is .0031 in. (0.08 mm) per 4 in. (100
mm). Iftherod is twi sted orbent beyond theser-
vice limit, therod will haveto bestraightened or
replaced.
3. Press out the piston pin bushing using a suitable
tool. Reinstall the new bushing, and ifa bushing
expandingtoolis available, expand thebushingin
the bore. Ream or hone the new bushing to the
fini shed size. Each bushing is usually fitted to its
own individual pin.
The inside diameter of the piston pin bearing
should be no greater than .7913 in. (20.1 mm).
4. The connecting rod and capshould be assembled
andtorquedto 16-20 ftllb(22 to 27 N'm)without
thebearing. Measurethebigendbore,andifthere
is more than .0010 in. (0.025 mm) out-of-round,
thebigendshould be reconditioned. Standardbig
end bore inside diameter is 1.6929 to 1.6935 in.
(43.000 to43.016 mm).
Fig. 3-8 Checking Rod Twist
Fig. 39 Checking Rod Parallelism
Fig. 310 Checking PistonPin Rod Bearing Bore
5. The connecting rod and capshould be assembled
with the bearingand torqued to 16 to 20 ftllb(22
to 27 Nm). If the inside diameter exceeds 1.5795
in. (40.12 mm) , replace the bearing.
16
Fig.3-11 MeasuringRod Bearing Inside Diameter
(torquedl
CRANKSHAFT
1. Remove the rear and intermediate main bearing
housings from the crankshaft.
2. Check the crankshaft journals, crankpins and oi l
seal surface forevidenceofwear, damageorclog-
ging of oil ports. Inspect the front (gear end)
shaft,sealsurfaceandcrankshaftgearfordamage
orwear. Check therear(flywheelend)sealsurface
for a groove left by the lip seal. If there are
grooves in the surface, the crankshaft should be
replaced or repaired.
3. Measure the crankshaft main journals. The
diameterofthe main journal should be2.3583 to
2.3608 in. (59.90 to 59.964 mm) on the flywheel
end journal. The diameter should be 1.7283 to
1.7309 in. (43.90 to 43.964 mm) on the in-
termediateand gear end journals.
Ifthereis more than .0010in. (0.025 mm) out-of-
round or taper wear onany ofthe main journals,
replace the crankshaft.
4. Measure therodjournals. Thediametershould be
1.5717 to 1. 5732 in. (39.92 to 39.96 mm). Ifthere
is morethan .0010in. (0.025 mm)out-of-round or
taper wear on any ofthe rodjournals, replace the
crankshaft.
5. Inspect the main bearingsand main beari ng hous-
ings. Measure the inside diameter ofthe flywheel
andgearendcrankshaftmain bearings. Theinside
diameter of the fl ywheel end bearing should be
2.3622 to 2.3669 in. (60.0 to 60. 12 mm). The in-
sidediameterofthegearend main beari ng should
be 1.7323 to 1.7370 in. (44.0 to 44.12 mm). The
main bearinginside diametershould be measured
twice, 90 to each other. Ifthe wear exceeds the
service limit or the bearing is out-of-round,
replace the bearing.
Fig. 3-12 MainBearing CoverAssembly
6. Use the special insertion and extraction tool to
remove the main bearings from the flywheel end
main bearing housing and the gear end of the
engine block.
NOTE: Tbe main bearing housing must be in-
stalled on the cylinder block to replace eUher the
geareodorflywheel end main bearing.The inser-
tion and extraction tool is designed to utilize one
end main bearing as a guide whil e tbe other end
main bearingis removed or instaUed.
7. Toremovethegearend(front)mainbearingfrom
cylinder block, assemble special insertion/extrac-
tion tool in the cyli nder block as shown in Fig.
3-13. RefertoFig. 3-14 to seeclearlythe position
and relationship of the pieces assembled in the
block in Fig. 3-13.
Fig.3-13 InsertionandExtractionTool
AssembledinBlockforGearend
MainBearingRemoval
17
Nut& Ratwasher
Gear end main hA"rirln:::"
Insertion/extraction
FlvwhAAI end main bearing
Insertion/extraction piece
Fig.3-14 ProperArrangementof Insertion &
ExtractionTool Piecesfor GearEnd
Main BearingRemoval
Firstpositionthegearend(small) mainbearingin-
sertion/extractionpiecein thegearendmain bear-
ingfrom theoutsideoftheblock. Theninstall the
flywheel end insertion/extraction piece in the
flywheel end main bearing from the inside ofthe
block. Insert the 5/8 inch diameter bolt through
both insertion/extraction pieces and install drive
plate on flywheel endagainst main bearing hous-
ing. Install flatwasher and nuts and tighten in
place. Pull gear end bearing into engine block
cavity by tighteningnuton flywheel endofblock.
8. Toinstall the gear end (front) mainbearingin the
cylinder block, assemble the special insertion/ex-
tractiontoolinthecylinderblockas shown inFig.
3-15.
First install the flywheel end insertion/extraction
piecein theflywheelendmainbearingfromthein-
side ofthe block.
Fig.3-15 Insertion& ExtractionTool
Assembled in Blockfor GearEnd
Main BearingInsertion
18
Nextinsertthelongthreadendofthe5/8inchbolt
through the flywheel end insertion/extraction
piece and partway into the engine block cavity.
Install a nutand flatwasher onthebolt. Placethe
bearingon thegear endinsertion/extractionpiece
and position in gear end boreinside the block.
CAUTION: Make sure the oil hole in the bear-
ing and block are aligned. Also be sure tbe
chamfered lip of the bearing faces into tbe bore.
Lubricate the outer surface of the bearing for
easierinstallation.
Slide bolt through gear end insertion/extraction
piece. Placethedriveplate,washerandnutonthe
bolt. Tighten nutand washer againstgearendin-
sertion/extraction piece inside theblock. Tighten
the nut and washer against the drive plate on the
outside ofthe block topullthebearinginto bore.
The bearing should slide in smoothly without
binding or pinching.Tightennutuntil thebearing
contacts the drive plate. Remove tool.
9. Toremove flywheel end main bearing from main
bearing housing, assemble special insertion/ex-
tractiontoolinthecylinder blockas shownin Fig.
3-16. Refer to Fig. 3-\7tosee clearly the position
and relationship of the pieces assembled in the
block in Fig. 3-16.
Fig. 3-16 Insertion & ExtractionTool
Assembledin Blockfor Rywheel
End Main Bearing Removal
First position the flywheel end insertion/extrac-
tion piece in the flywheel end main bearing from
theoutsideoftheblock. Next installthegearend
insertion/extraction piece in the gearend bearing
frominsidetheblock. Insertthe5/8inchcUameter
bol! through bothinsertion/extraction pieces and
install drive plate on gear end against block sur-
face. Install flatwashers and nuts and tighten in
place. Pull flywheel endbearingintoengineblock
cavity by tightening nut ongear end ofblock.
Lubricate the outer surface of the bearing for
N)Jt& Flatwas'!er",-""?"\
easier installation.
Slide bolt through flywheel end insertion/extrac-
tion piece. Place the drive plate, washer and nut
on the bolt. Tighten the nut and washer against
the flywheel end insertion/extraction piece inside
the block. Tightenthe nutandwasher againstthe
drive plate on the outside ofthe main housing to
pull thebearingintothe bore.Thebearingshould
slide in smoothly without binding or pinching.
Tighten nut until the bearing contacts the drive
Drive I \ ' .
plate. Remove tool.
II. Assemble the intermediate bearing housings
main Flywheel main h..,uir,';
together with the new bearing inserts and torque
Insertion/extraction piece InsertionI extraction piece
thehousingboltsto33 to36 ft/lb. (45 to49Nm).
Fig. 3-17 Proper ArrangmentofInsertion& Theinsidediameterofthebearinginsertshouldbe
ExtractionToolPiecesforFlywheelEnd 1.7323 to 1.7370 (44.0 to44.12 mm).
MainBearingRemoval
Measure thebearinginsidediametertwice, 90
0
to
each other.
10. To install the flywheel end main bearing in the
main bearing housing, assemble thespecial inser-
tion/extractiontoolinthecylinderblockas shown
in Fig. 3-18.
Fig. 3-19 IntermediateMainBearing
12. Placeapieceofplasticgaugeoneachintermediate
Fig. 3-18 Insertion& ExtractionTool
main crankshaft journal. Disassemble in-
AssembledinBlockforRywheelEnd
termediatemain bearingsandinstall bearingsand
Main Bearing Insertion
housing on crankshaft. The "F" on the body of
themainbearingmustfacetheflywheelendofthe
Firstinstallthegearendinsertion/extractionpiece
crankshaft. Make sure the marks on the top and
inthegearendmainbearingfrom theinsideofthe
bottom of the bearings also match (Fig. 3-19).
block.
Tighten the housing bolts to 33 to 36 ftllb (45 to
Nextinsertthelongthreadendofthe5/8inchbolt
49 Nm). Remove caps and check the bearing
through the gear end insertion!extraction piece
clearance.
andpartway intotheengineblockcavity. Installa
CAUTION: Inlermediale bearinginserts can be
nut and flatwasher on the bolt. Place the bearing
inslalled upside down. Checkoil hole alignmenl.
on the flywheel end insertionandextractionpiece
and position the piece inside the block in the 13. Reassemble bearings on crankshaft and torque
flywheel end bore in the main bearing housing. housing bolts to33 to 36 ftllb (45 to49 Nm).
CAUTION: Make surethe oil hole in the bear- CAUTION: The"F"onIhebodyofIhebearing
ing and housing are aligned. Also be sure the housing musl face Ihe flywheel end of the
chamfered lip of Ihe bearing faces inlo the bore. crankshaft.
19
diameter for the 3-cylinder engine should be
1.1787 to 1.1795 in. (29.94 to 29.96 mm).
4. Inspect and measure the inside diameter ofcam-
shaft bushing in the flywheel end of the cylinder
block (TK235 engine ONLY). The standard
bushing inside diameter is 1.0626 to 1.0654 in.
(26.99 to27.06 mm). Replacethe bushingorcam-
shaft when the bushing to journal clearance ex-
ceeds .0059 in. (0.15 mm).
Removewornbushingswith specialbushinginser-
tion/extraction tool. Drive old bushing through
bore into cylinder block cavity. Using special in-
sertion/extraction tool, insert new bushing with
bushingnotch ontop, facing in(Fig. 3-22). Drive
bushing in until the rear face of tool's collar is
flush with the block surface(Fig. 3-23).
Fog. 3-20 TorqueHousing Boltson Crankshaft
CAMSHAFT
I. Check the journals and cam lobes for wear or
damage.
2. Measure the cam lobe height (Fig. 3-21) . The
height ofthe intakeorexhaustvalvecamsshould
be 1.3543 to 1.3780 in. (34.4 to 35.0 mm). The
heightoftheinjectionpumpcamshouldbe1.7520
to 1.7717 in. (44.5 to 45.0 mm).
Fig. 3-21 CamshaftLobe Measurement
Check the lobe faces for damage. Clean up slight
imperfections .
If the valve cam lobe wear exceeds the limit, the
camshaft should be replaced. If injection pump
Fig. 3-23 Proper Installation Depth -
camwear exceeds thelimit, pressoffthecamshaft
Back ofTool Collar Flush
gear and injection pump cam. Reinstall camshaft
with Block Surface
gear and new injection pump cam.
5. Inspect camshaft ball bearing for excessive play
3. Measure the flywheel end camshaft journal andfree rotation. Inspectcamshaft gear for wear
diameters. The flywheel end journal diameter for and damage. Press off camshaft gear and injec-
the 2-cylinder engine should be 1.0606 to 1.0614 tion pump cam to replace camshaft gear or ball
in.(26.94to26.96 mm). Theflywheel endjournal bearing.
20
Fig. 3-22 CamshaftBusing Installation
CTK235 onlyl
6. Measurecamshaftdeflection (TK353 engineonly)
with a dial indicatorand a set of"V" blocks. Set
the dial indicator on the gear end intermediate
journal and zero the dial indicator. Rotate the
camshaft one full turn and note the highest
reading. The camshaft deflection is 50'7. of this
figure. Replace the camshaft if there is morethan
.002 in. (0.051 mm) defl ection.
7. Inspect oil passages and oil bleed holes for
obstructions.
CYLINDER HEAD
DisassemblyandInspection
I. Drive out the front precombusion chamber
assembly and packing very carefully with a soft
punch.
2. Witha valve spring compressor, remove thevalve
spring assembly and valves from the head (Fig.
3-24).
NOTE: When you remove the valves from the
cylinder head, besuretoMARK thecylindersand
keep the parts of each intake and exhaust valve
SEPARATE.
3. Remove valvestem seals and discard.
Fog. 3-24 Valve Removal
4. Inspect cylinder head for cracks, damage and
distortion (Fig. 3-25). Use a straight edge and
feeler gaugetomeasuredistortion. Ifthereismore
than .0028 in. (0.070 mm) distortion on the two-
cylinderengineheador.0039in. (0.10mm)distor-
tion on the three-cylinder head, resurface or
replace the head.
Fog. 3-25 CheckHead Distortion
MeasuringHeadDistortion
ValveSprings
Check valve spring for squareness, free length, com-
pressed length and pressure, and tilt. Ifthe spring ex-
ceeds the service limits for free length, compressed
length and pressure, tiltorsquareness, replace the spr-
ing.
Valves
I. Inspect and measure the valve stems. Standard
size is .2740 to .2744 in. (6.96 to 6.97 mm).
Replace valves that are worn to .2717 in. (6.9
mm).
2. Checkthe valve margin. Ifthereisless than .0276
in. (0.70 mm) margin left, replace the valves.
3. Check for bent valves in the grinding machine.
There should not be more than .0012 in. (0.03
mm) deflection.
4. Regrind thevalve face angle to 45.
21
Valve Guide
I rvli"rl,, Head
Fig. 327 MeasuringValve ShaftDiameter
Valve Margin Measurement
.040 in. 11.0) Standard
Fig. 328 Valve Margin
Valve Guides
I. Useavalveguidecarboncleanertoremovecarbon
from the guides. Check the valve stem to valve
guide clearance. Replacevalves in their respective
seatsandraisethe valve3/8in. (9.53 mm). Check
lateral deflection in four directions. Lateral
deflectionshouldnotexceed .0250in. (0.635 mm).
If the valve guide wear (lateral deflection) is ex-
cessive, replace the guides.
If the engine has accrued a great many hours of
runningtime. it is agoodideatoreplacetheguides
as they are usually worn. Because the valve seat
grinding procedure is piloted offofthe guides. a
new straight guide wilt ensure an accurate valve
seat.
2. RemovethevalveguideswithapressorlOol. driv-
ing the valve guides out from the top of the
cylinder headdown.
3. Reinstall the new valveguides usingapress. Press
theguidesin fromthelOp ofthecylinderhead. In-
sert the guides umil the outer groove reaches the
cylinder head surface (Fig. 3-29).
22
CAUTION: Be sure not to mix intake and ex-
haustvalveguides.Theexhaustvalvesguideshave
a specialgss groove on theirinsidesurface.
Exhaust Intake
Valve Guide Valve Guide
Valve
Guide
Bore
GasGroove
Fig. 329 ValveGuide InsertPosition
Valve Depth
A very critical dimension for most diesel engines is the
depth that the valvesare set down into the head (valve
depth). Iftheyareset toodeep(theresultofvalvegrind-
ing). the combusion chamber volume enlarges and the
compression ratio drops. This, in turn, results in hard
starting. Itis veryimportanttocheckvalvedepthbefore
any valve or seat grinding is attempted. Ifthis dimen-
sion is alreadyatthelimit. the cylinder head may have
to be replaced.
1. To check valve seat depth, reinstall the valves in
their respective seats and check the depth (Fig.
3-30). Valve seat depth should be .0374 to .0492
in. (0.95 to 1.25 mm).
2. If the depth has not exceeded thespecified limit.
gri nd the valves and recheck the depth.
3. If the limit sti ll has not been exceeded, go ahead
and grind the seats.
4. If the depth figure is now beyond specifications.
thevalve will have to be replaced.
Fig. 330 CheckingValve Depth
Valve SeatGrinding
I. If the valve depthis not excessive, grind theseats
toa 45"angle. Thevalveguideboreis .2760in. (7
mm) in diameter.
If the seat width becomes excessive (more than
.0697 in. [1.77 mm]), 15" and 70 stones may be
used to narrow and also raise or lower theseat.
Astheseat isbeingground, periodicallycheck the
seatingofthevalvewithPrussianBlueorasimilar
type ofdye, making sure the seat is contactingas
close to the middle ofthe valve face as possible.
Fig. 3-31 Using Valve Seat Grinding Equipment
Fig. 3-32 Seat Width Measurement
2. After all valve seats have been ground, thevalves
may be lapped. Put a small amount ofa medium
grit compound on each valve face and, usi ng a
valve lapping tool , spin the valve against the seat
forashortperi od.Thenliftthe valveandrotateit
about a quarter ofaturn. Drop thevalve backin-
to theseat and continuelapping. Repeatthis pro-
cedureuntil thecompound isused up. Removeall
traces ofgrind compound with a thorough dean-
ing.
Fig. 3-33 Valve Seat Angle
RockerArm ShaftAssembly
I. To disassemble, remove the clips at both ends of
the rocker arm shaft. Then remove the springs,
rocker arms and brackets. Arrange the rocker
arms in the sequence of disassembly to ensure
ready reassemblyintocorrect position.
NOTE: The intake and exhaust valve rocker
armsdifferin shapeandsize.Whendisassembling
and reassembling. be sure to carefully identify
them.
2. Measure and inspect the rocker arm shaft and
bushings.Theoutsidediameteroftheshaftshould
be.5472to .5512in.(13.9to 14.0mm) .Theinside
diameter ofthe bushingshould be .5518 to .5551
in. (14.016 to 14.108 mm) . Replace worn or
damaged parts. Remove the bushingwith a press.
Pressthenewbushingin and honetosize(.5518to
.5525 in. [14.016 to 14.034 mm]).
3. Check wear on rocker face. Recondition or
replace.
4. Reassemble the rocker shaft . stands, rockerarms.
springs,etc.. Besuretoloosenallthevalvelashad-
justment screws.
Fig. 3-34 Rocker Arm Shaft Assembly
23
Cylinder Head Reassembly
I. After all cylinder head components have been
reconditioned, reground or replaced, the head is
readyfor reassembly.
2. Install new valve stem seals.
NOTE: New seals should always be used.
ValveStemSeal
ValveGuide
CylinderHead
Fig. 3-35 Valve Stem Seal
3. Coat valve stem with oil and install valves in
cylinderhead. Oilcoatingpreventsstemfromseiz-
ing in new valve stem oil seal.
4. Install valve springs and retainers.
5. Afterthevalvesareinstalled, placethe head onits
side and fill up the exhaust ports with diesel fuel.
Check the exhaust valves for leakage. Repeat the
procedure for the intake valves. Only a slight
seepageshouldbenoticedcomingfrom thevalves.
NOTE: If the leakage seems excessive, Ihe leak-
ing valve will have to be removed and lapped
again.
Fog.3-36 Testing Sealing Ability of Valves
6. "Install hardcapson valvesandgrease topofcaps.
Install valve rocker arm supports and rocker arm
assemblies on cylinder head.
24
PUSH RODS
1. Check thepush rods for bending and wear at the
ends. Roll the push rod on a flat surace. Replace
the rods that donotroll smoothly.
LIFTERS
1. Inspect the face of the tappet s for wear or
damage. Place a straight edge on the tappet face
and hold in front ofa light. Tappet face should
have a slight crown (convex surface) or be flat.
Replace worn tappets. Measure the outside
diameter of the lifter with a micrometer, and
replace those that exceed the wear limit. Lifter
diameter should be .3917 to .3935 in. (9.950 to
9.995 mm).
Fig. 3-37 Measuring Valve Tappets
ENGINE LUBRICATION SYSTEM
The TK235 and TK353 diesel engines have a pressure
lubrication system. Oil is circulated by a trochoid gear
type oil pump"driven offa gear on thecrankshaftand
hasseveraltimesthecapacityrequiredby theengine.the
excess being returned to the crankcase. Oil is supplied
by a suction t ube with a screened inlet which picks up
clean oil withoutanyresiduewhich mayhavesettled in
the bottom ofthe pan.
From theoil pump, theoil is forced througha pressure
regulatortoafull-flow filter, then totheoilgallery. Oil
from the gallery flows to camshaft journals.
Connecting rod bearings are supplied through drilled
passages in the crankshaft. Tappets and cylinder walls
arelubricated by oi lthrown from connectingrod bear-
ingsas t he crankshaftrevolves. Fromtherearcamshaft
bearing passageway, oil is piped outside the engine to
the rockerarm shaftwhere thesurplusdrainsbackinto
thecrankcase.Oil pressureisautomaticallyregulatedto
43 to 57 psi (294 to 392 kPa) by a spring-loaded reli ef
valve. Oil pressure may exceed this settingwhen the oil Oil Pump
is cold.
Oil pressureisaffectedbyoil temperature,viscosity and I. Visuall y inspect the vane, rotor and pump body
engine speed. Subnormalpressures usuallymaybetrac- for scratches or other damage. Reassemble t he
edtolackofoil, faulty pressure control valve, loose oil vanein the pump body.
connections or worn bearings .
2. Check for excessive clearance between the vane
(outer rot or) and pump body.
3. Thevane to pump bodyclearanceshould be.0004
to .002in.(0.01to0.05 mm). If clearanceexceeds
.003 in. (0.08 mm) , repl ace the oil pump.
4.
Crankshaft
Crank pin
bearing
journal
beari ng


5.
Fig. 3-39 TK353 Engine Lubrication System
25
L O. con trof valve
T appet
Crankshaft
Crank pin
beanng
Crank jou rnal
'---c:i:-::t- beari ng
L.O. inlet pipe
Fog. 3-38 TK235 Engine Lubrication System
Tappel
Fig. 3-40 Oil Pump Vane to Body Clearance
Check for excessive clearance between the rotor
and vane with a feeler gauge. The vane to rotor
clearanceshould be .0020to .0040 in. (0.05 to 0. 1
mm). Ift heclearanceexceeds0.006in .(0. 15mm),
replace the oil pump.
Fig. 3-41 Oil Pump Vane to Rotor Clearance
Check for excessive clearance between t he pump
cover and the vanerotorwith a straightedgeand
feelergauge. If theclearance exceeds.006in.(0.15
mm), replace t he oil pu mp.
WATER PUMP
CAUTION: Shaft must be supported or snap
ring or bearing may be damaged when pressing
Inspection
impellerorpulley mounting flange ontoshaft.
J. Make sure the pumpshaft rotates smoothly.
2. Check to makesurethereis noplayon the pump
shaft. Ifthere is any play, replace the pump.
3. Inspecttheimpeller for damageor corrosion.
4. Check thesealholeforsignsofleakage.If coolant
leaks from the hole, disassemble the pump and
replace the mechanicalseal.
Fig. 3-42 WaterPump
Disassembly
I. Remove the impeller using a gear puller.
2. Remove mechanical seal.
3. Remove pulley flange from shaft with a gear
puller.
4. Remove snap ring.
5. Press pump shaft and bearing assembly out the
pulley side ofthe housing.
6. Check housing for cracks, wear or external
damage. Clean thoroughly.
7. Discard the impeller, bearing unit and seal
assembly because these parts are contained in a
new repair kit.
Reassembly
1. Press new shaft and bearing into pump housing
from pulley side ofpump until the snap ring can
be inserted.
2. Insertsnap ring in housing.
4. Install mechanicalsealonshaft.
5. Press impeller on shaft.
SnapRing
Pulley
BearingandShaft
Fig.3-43 WaterPumpAssembly
r
3. Presspulley flange on shaft.
26
Reassembly _
Contents
Camshaft ................................... 28
Connecting Rod ...........................28,30
Crankshaft ..................................29
Cylinder Head ....... . . ................ . ..... .31
Flywheel ................................29
Governor Sleeve ..............................31
Injection Pump . ........ . . . . . . ... . .... .. .. .. 31
Piston Installation ............................. 29
Piston Rings .................................. 29
TimingGearMarks ......... ...... . . . . . . .... ...30
27
4. Use plastigauge to check crank pin to rod bearing
Engine Reassembly
oil clearance.Cleantheinsidesurfaceofthecrank
pinbearing. Fittheconnectiononthecrankpinof
thecrankshaft. Placea piece ofplastigaugeonthe
After the major components of the engi ne have been
crank pin along the full length ofthe bearingsur-
disassembled, repaired and reassembled, you are ready
face. Coat bolts with oil. Install rod end cap and
to reassemble theengine. During reassembly, it is very
tighten bolts in steps to 16 to 20 ftllb (22 to 27
importanttokeep theengineasdeanaspossible. Dirt is
Nm).
oneofthemajorfactorsinthefailureofrebuiltengines.
CAUTION: 00 not rotate the crankshal't when
Do not reassembletheengineinanarea whereany type
tightening the end cap rod bolts.
of grinding is done. Keep your workbench, tools and
your hands dean. Keep sub-assemblies covered until
Loosen bolts and measure clearance. Standard
they are needed. If you have to leave the engine for
clearance should be .0011 to .0059 in. (0.028 to
morethana short period oftime, coverthe engineunW
0.15 mm).
you return.
Make sure you carefully follow the reassembly order
thatis given becausecertainparts, ifnotinstalledin the
correct order, will requiretheenginetobedisassembled
again so they can be installed.
Check all assembly tolerances such as end play,
gearlash,etc., carefully. Neglectingthese tolerancescan
cause serious problems later in theengine' s life.
I. Install thestarter mounting flange and alignment
pins on the flywheel end of the cylinder block.
Tighten the mounting bolt to 32 to36 flllb(43 to
49 Nm) .
2. Coat tappet barrels and faces with engine
assembly compound orengine oil and install tap-
pets.
NOTE: This MUSTBEDONEbeforecamshaft
is installed.
3. Apply oil to thecamshaftball bearingand gently
install and tap shaft into place in cylinder block
(Fig. 4-1). Install and lighten camshaft screw.
Fig. 4-2 Checking Rod BearingClearance
5. Replace connecting rod on crank pin. Using a
feeler gauge, check rod side clearance. If the
clearanceisless than .0079 to.0197 in. (0.2 to0.5
mm), therodsidefacescanbelappedona lapping
board. Remove rod from crankshaft.
Fig. 4-3 Checking ConnectingRod Side
Clearance
Fig. 4-1 CamshaftInstallation
28
6. Placetheengine onits sideona wooden base. In-
sertcrankshaft.Aligntheintermediatemain bear-
ingset bolt holes (Fig. 4-4). Installand tightenin-
termediate bearingset boJt(s) to 22 to 25 ftllb(30
to 34 Nm).
CAUTION: Makesurecentermainbearingalign-
ment is correct. Refer to page 19.
7. Install new oil seal in main bearing housing.
Coattheinsideofthesealwith light grease. RTV
compound may be used onouterdiameter only.
Install main bearing housing on crankshaft and
tighten mounting bolts to 18 to 19 ftl lb (24 to 26
Nm).
8. Using a dial indicator, check the crankshaft end
play. It should be .0030to .0120 in. (0.085 to0.30
mm). If theclearanceis excessive, the crankshaft,
the intermediate main bearing (flywheel end in-
termediatebearingonTK353 engine) orbothmay
have to be replaced.
Fig. 4-4 Aligning SetBoh Holes
-
Fig. 4-5 Checking Crankshaft Endplay
9. Install the flywheel and torque mounting bolts to
47 to 50 f!llb (64 to 68 Nm). Measure flywheel
end runout. Should be within .0039 in. (0.1 mm).
Fig. 4-6 Checking Aywheel Runout
10. Check ring end gaps by placing ring in respecti ve
cylinderbore.Slidering tobottomofcylinderand
square up with piston. Measure gap with feeler
gauge. File to adjust as necessary.
No. I top .008 to.016in. (0.2to0.4mm)
No.2 .008to.016 in. (0.2to0.4mm)
No.3 bottom .008 to.016in. (0.2to0.4mm)
Fig. 4-7 Piston Ring Identification
11. Heat the pistons in hotwater (ISO to200 F [65 to
93 C]). Coatpistonpinwith oilandinstallpinsin-
to pistons and rods and installlock ring.
12. Install piston rings on piston with align "mark"
facing topofpiston(Fi g. 48). Alternateringend
gaps 120
0
to be sure no ring end gaps are in line
29
Manufacturer's Mark
Fig. 4-8 Manufacturer's Ring Mark
2ndRing 1stRing
to7 ftllb (8 to 10 Nm).
with piston pin hole(Fig. 4-9). Whenthesethings 13. Fittherodbearingon thecrankpin andinstallrod
havebeen checked,coatthecylinder linerandthe endcap. Torqueboltsinstepsto 16 to20ft/lb(22
piston and rings with engine oil. Using a ring to27 Nm).
compressor, install the piston assemblies.
14. Installcover onoil pan. Tightenoilpanboltsto6
Oi/Ring
FI9. 4-11 Torquing Connecting Rod End Cap
15. Install crankshaft gear on crankshaft and align
crankshaft and camshaft gear timing marks. In
stall governor weight supportandweights. Install
crankshaftgearmountingnutandtighten to51 to
54 ftllb (69 to74 Nm).
Install governorsleeve.
FI9. 4-10 Installing Pistonand Ring Assembly
30
FI9. 4-9 Piston Ring Gap location
Fig. 4-12 AlignTiming Marks
16. Install oil pumpandtightenmountingboltsto7to
9 ftllb (10 to 12 Nm).
17. Install gear COver gasket. Install oil seal in gear
case cover.
Coattheinside oftheseal with light grease. RTV
compound may beused on outer diameter only.
Installgearcoveronengineandtorqueto18 to20
ft / lb (24 to27 Nm).

Nm). Install water hose from water pump to
engine bl ock.
Fig. 4-13 GovernorSleeve Installation
18. InstallVpulleyassemblyandlocknut.Torquenut
to 43 to 50 ftllb(58 to 68 N'm)
19. Clean injection pumptimingshimsinsuitablesol-
vent. Reinstalloncylinderbody. Lookingthrough
the timing gear window, align the governorlever
with the rack pin ofthe pumpand install pump.
Tighten mounting nuts to 18 to20 ftllb(24 to27
Nm). See Section 5 for injectionpump timing or
repair.
Fig. 4-14 Injection PumpInstallation
20. Install cylinder head gasket and place cylinder
head on block. Torque12mmdiameterhead bolts
to 72 to 80 ftllb (98 to 109 N'm) and 8 mm
diameter head boIts to 16 to 20 ft/lb (22 to 27
N'm) in steps per torque sequence shown.
21. Connect lube oil line to cylinder head.
22. Install gasket and water pump assembly on
cyli nder head. Tighten to 18 to 20 ftl lb (24 to 27
Fig. 4-15 Governor Leverand Rack PinAlignment
6 2 4
TK 235 Flywheel End
5A 6A
3

5
Fig.4-16 TK235 Cylinder HeadTorqueSequence:
1-2-3-4-5-5A-UA
5 3 7
TK 353 Flywheel End
+-
2A 1 A 3A
8 2 4 6
Fig. 4-17 TK353 CylinderHeadTorqueSequence:
1-1A-2-2A-3-3A4-5-6-7-8
23. Insert push rods in cylinder body.
24. Install rocker arm assembly on cylinder head.
Make sure that the valve adjusting screws have
been loosened and backed out before tightening
the rocker stand locking nuts.
CAUTION: Tightening down the rocker shaft
with the valve lash adjustments in the original
position may bend the push rods.
Tightenlockingnutsin sequenceto27 to29 ft llb
(36 to 39 N'm) to keep the assembly as level as
possible.
CAUTION: Do not use an air wrench to install
rockerstand bolts. Thetilting of the rockershaft
31
I
assembly along with the speed of the air wrench
will gall the bolls to the aluminum rocker stands.
25. Adjustthe valvesto .0079 in. (0.20mm) .Referto
valve adj ustment procedure, Section 5.
26. Install rocker arm gasket and cover on cylinder
head. Insert combustion chambers and gaskets.
Install nozzle insulatorandinjecti onnozzle. Con-
nect the hi gh pressurefallIineto inj ectionnozzles
and tighten nozzle holder assembly to 18 to 20
ftl lb (24 to 27 N m).
27. Connect fuel return pipe.
28. Check and adjust the governor li nkage. Refer to
governoradjustment procedure,Section5. Install
timing gear cover on gearcase.
29. Fill crankcase with engine oil.
30. Check injection pump timing. Refer to injection
pump timing procedure, Section 5.
I!
I'
32
Fuel System
Contents
Bleeding Fuel System ..... . ... . .. . ....... . ... 35
Injecti onNozzles ....... ... ...... . . ...... ...... 40
Injecti onPumpAdjustment .... .. .. .... ......... 42
Injection PumpDisassembly ..... . .. .. ...... 37
Injecti on Pump Replacement .... . . ........ . .... 35
Injection Pumpnming ...... . ... . . . . . .... ...... 35
Valve Cl earanceAdjustment .... . . ... . . . . . ... ..43
33
Fuel System
The fuel injection system used on the Thermo King
TK235 and TK353 diesel engines is manufactured by
Yanmar. It is a high pressure system used in conjunction
with a prechamber or swirl chamber.
The components of the fuel system are:
I. Fuel tank (may be the truck fuel tank).
2. Prefilter.
3. Electric fuel pump.
4. Fuel filter assembly.
5. Injection pump.
6. Injection nozzles.
Two 7 psi (48.3 kPa) electric fuel pumps (connected in
series) pull fuel from the fuel tank through a prefilter
and push it through the fuel filters to the injection
pump. The injection pump requires a positive inlet
pressure of about I psi (7 kPa).
The injection pump plungers are activated by a fuel
pump cam extension on the engine camshaft. The gover-
nor sleeve and weight assembly is mounted on the end of
Filter Assembly
Supply Line
Bleed S c r e w ~ ~
Injectors
Fig. 5-1 Typical Fuel System
34
the crankshaft, relaying the governor's speed re-
quirements to the injection pump through a linkage ar-
rangement located in the front timing cover. The injec-
tion pump raises the pressure of the fuel and feeds the
correct amount of fuel to the nozzle at the correct time.
The increased fuel pressure lifts the spring loaded valve
in the nozzle admitting fuel into the combustion
chamber.
The most common cause of fuel system problems is con-
tamination. It cannot be stressed enough that the fuel
must be clean, and fuel tanks must be free from con-
taminants.
Fuel filters must be changed regularly, and whenever the
fuel system is opened up. All possible precautions
should be taken to keep dirt from entering the system.
This means all fuel lines should be capped when open.
The work should be done in a relatively clean area, if
possible, and the work should be completed in the
shortest time possible.
We recommend that any major injection pump or noz-
zle repairs be done by a quality diesel injection service
specialty shop. The investment in equipment and
facilities to service these components is quite high.
Therefore, this equipment is not found in most repair
shops.
Return Line
Thefollowing procedures can be done under field con-
ditions:
I. Bleeding fuel system free ofair.
2. Maintenance involving the fuel tank and filter
system.
3. Speed and governor adjustments.
4. Electric transfer pump replacement or repair.
5. Injection line replacement.
6. Pumptiming.
7. Nozzle spray pattern testing and adjustment.
8. Minor rebuildingofnozzles.
BLEEDINGTHE FUEL SYSTEM
Iftheenginerunsoutoffuel or repairsaremadeto the
fuel system, or air gets into the system for any other
reason, the fuel system will have to have the air bled
out.
NOTE: BESURE to keep the fuel tank ventopeu_ If
the venl becomesclogged, a partialvacuumdevelopsin
Ibe tank, andthisincreases Ihe tendency forair10 enter
Ihesyslem_
Proceed as follows:
I. Loosen theair bleedscrew onthe injection pump
banjo bolt.
2. The electric fuel pumps do notenergize when the
on-off switch is turned on. They receive current
from the 8D circuit after the unit is running and
hasbuiltenoughoilpressuretoengage thelow oil
pressure relay. The pumps can ilowever be
energized by holding the Preheat-Start switch in
thePreheatposition. The pumpsareconnected to
the Preheat-Start switch to ensure fuel is bei ng
pumpedtotheengine beforeandduringstartup.
Thi scircuitcanbeutilizedtoturnonthepumpsto
bleed thefuel system. Run thepumpsuntil aclear
flow offuelisnotedattileairbleedscrew. Tighten
the screw.
3. Loosen the injection nozzle boxnuts atthe injec-
tion nozzles.
4. Cranktileengineuntilfuel appearsatthenozzles.
Tightentheinjectionnozzleboxnuts andstartthe
engine.
NOTE: Fuel will nol appear at the nozzles by
merely energizing the eleclric fuel pumps. Tbe
engine mnst be cranked.
INJECTION PUMPREPLACEMENT
NOTE: Tbe procedureontlinedwill assumeIhe pump
is being removed and replaced on Ihe engine_ Iftbe
pump is notremoved, only the last portion ofthe pro-
cedure is used.
PumpRemoval
I. Remove the fuel supply line and the four nuts
holding pump to timing cover.
2. Removeinspection plateon thesideofthetiming
cover.
3. Centertherackinthepumpbody,thenremovein-
jection pump from timingcover. Thetimingshim
will usuallystayattached to the pump.
CAUTlON:Iftberack is notpositionedcorrectly,
the pump will notcome outoftbe timing cover.
Fig. 5-2 InjectionPumpRemoval
PumpInstallation
I . Remove small inspection plate on front timing
cover. Replace the shim gasket on the injection
pump if it has been damaged during pump
removal. Newshimsaresuppliedinsets. Selectthe
same thickness shim that was removed from the
pump.
NOTE: Do not pulgaskelsealer on the shim or
pump unlil Ihe injection timing of tbe pump bas
been checked_ Tbe shim may have to be replaced
wilh one ofa different thickness_
2. Center the rackin the pump body and insert the
pumpin thetiminggearcover. Therack pin must
be indexed with thegovernorarm as thepump is
beinginserted.
3. Installthewashersandnuts_Torquethenutsto18
to 20 ft/ lb (24 to27 Nm).
4. Install the fuel lineon the pump.
INJECTION PUMPTIMING
TimingtheInjectionPumptotheEngine
Thereare twodifferenttypes oftimingproceduresused
on the TK235 and TK353 engines. One procedure in-
35
vol ves checking to make sure that both cylinders are
timedcorrectlytoeachother, and thesecondprocedure
times the injection pump correctly to theengine. If the
cylinders are not timed correctly to each other, it is of
no value to time the injection pump to the engine
becauseoneofthe two cylinders would beoutoftime.
Theindividualplungersintheinjectionpumparetimed
toeachotherbythe use ofspacersin thepumpplunger
base. It is rarethataninjecti onpumpwould changein-
dividualcylindertimingunlessithadbeenthr oughsome
typeofrepairprocess, butifallotherpossibleproblems
with a rough running engine have been checked, and
especially if the engine' s injection pump has been
replaced Or repaired recently, it may be beneficial to
checkindividualcylindertiming.Becausethepossibility
ofincorrectindividualcylindertimingissominimal, the
procedure for timing the pump to the engine will be
covered first.Theprocedureforindividualcylindertim-
ing isverysimilar totimingtheinjectionpumpso itwill
becovered last.
NOTE: The cylinders on the engine are numbered
from the rtywheel end to the water pump end. The
number1cylinderis nextto theflywheel. Thenumber2
(or 3) cylinder is next to the water pump. The timing
marks on the flywheel arematched to this system.
1. Rotate the engine in the direction of rotation
(clockwise as viewed from the water pump end)
until thenumber I cylinder(closest toflywheel) is
at approximately dead center ofthe compression
stroke. The valve cover should be removed to
identify the compression stroke. Both valves of
the number I cylinder will be loose. Check the
position ofthe timing marks in relation to the il-
lustration.
Fig. 5-3 FlywheelTiming Marks
CAUTION: The cylinders have timing marks
stampedontheflywheel (180 or120)apart.Top
deadcentermarksareidentified bythenumberof
the cylinderstamped next to them. Injection tim-
36
ing marks are unmarked. The tinting marks are
most easily viewed through the curbside door.
2. Remove thehigh pressure linefromthenumber I
injector on the injection pump. Remove the
delivery valve holder, delivery valve and spring.
Care must be taken to prevent dirt fromentering
the fuel injection system. Replace the delivery
valve holder.
3. Installa drip tube on the nozzle holder.
4. Activate the run solenoid by turning the unit
switch on. Makesure the Diesel-Electricswitch is
in the Diesel position. Use a jumper wire to ac-
tivate the electri c fuel pump. Jumper number 2
wire to SF wi re attheroadsidecontrolpanel.
CAUTION: Loosen the box nut on the high
pressureline ofthe number2 cylinderto prevent
any possibility oftheenginefiring.
5. Theengine should be close tothetop dead center
positionwiththeplungerportinthepumpclosed.
No fuel should flow from the drip tube.
6. Turntheenginebackwardspasttheinjection tim-
ing mark until fuel flows from thedrip tube.
7. Slowly rotate the engine in the direction ofrota-
tion while watching the drip tube. When the fuel
flow slows to approximately one drip every 10 to
15 seconds, check thetimingmarks. Theyshould
be lined up.
NOTE: A diesel injection timing light is
availableand may also beused totime theengine.
S. If the timing marks did not line up, a shim or
shimswill have tobeaddedorsubtractedfromthe
injection pump. Adding shims will retard the in-
jection timing, subtracting shims will advance the
timing. Increasingordecreasingshim thickness by
.004in. (0.1 mm) will change the timing by 10.
9. After shims have been added or subtracted,
recheck the timing.
10. Whentheinjectionpumphasbeencorrectlytimed
to the engine, remove the pump and put a light
coatofsiliconegasketsealerontheshim packand
pump.
11. Reinstall the pump and torque the nuts to 18-20
ft!lb (24-22 N m).
12. Reinstalldeliveryvalveandspring.Torquedelivery
valve holder to 30 ft/lb (40.7 Nm) .
13. Reinstall high pressure lines, bleed air from
nozzles and test [un engine.
Timing Individual Cylinder Injection
This procedure should be used when a poor running
engine has had all possible problems checked butcon-
tinues to run badly. If the injection pump has been
repaired or replaced, the chance of individual cylinder
timing problems occurring is greater.
To check indi vidual cylinder timing, follow the pump
riming procedure but instead ofchanging shims to ad
justpump timing ifit is incorrect, check the timing of
number 2 (and 3) injector to the engine after checking
number J. All cylinders should time on theirrespective
flywheel timing marks.
If theinjection pumpplungersarenotcorrectlytimed to
each other the pump must be removed and sent toa
diesel injection equipment shop for calibration.
If the cylinder injection timing of all cylinders is not
uniform, make them uniform by adding a plunger
stroke adjusting shim to the "timingdelayed" partor
extracting the shim from the "timingadvanced" part.
Fuel Injection PumpCheck
Ifthe fuel controlrack has excessive sliding resistance,
undesirableengineconditionssuch as irregular running
orhunting(bursts) ofenginespeed occurs.Tocheckthe
fuel controlrackfor freedomofmovement ,laythefuel
control rack upright. If therack smoothlymoves down
byitsown weightalongthe full lengthofthepumpside,
its free movement is good.Turn it upside down to test
its downward movement.
When thecontrolrack hashighslidingresistance, possi-
blecauses are:
I. Therotaryslidingsectionofthe plungerassembly
offers high resistance.
2. The delivery valve holder has excessively been
tightened (as a result the plunger barrel is
distorted).
3. The fuel control rack, gear segment of the fuel
control brush or the outside of the fuel control
rackhasbeen scratched; ordirthas stucktothese
parts. As a result , the fuel control rack cannot
movesmoothly.
4. The fuel control rack hole of the fuel injection
pumpbody has been scratched.
5. The plunger barrel packing is improperly fitted,
and as a resulttheplunger barrel is distorted. (In
this case, the fuel oil will leak into the crankcase
and dilute the lubricating oil. This demands
careful attention .)
In the above case, disassemble the fuel injection
pump and rinse or recondition it.
If the rack sticks, the injection pump will have to be
disassembled and inspected.
FUEL INJECTION PUMP DISASSEMBLY
In the eventthatcompletedisassemblyofthefuel pump
is necessary, prepare containers to keep the vari ous
parts of each cyli nder in order to ensure correct
reassembl y. Do notmixthepartsfromonecylinderwith
another.
Fig. 5-4 RemovePlungerGuide Stopper Pin
o
Fig. 55 RemovePlungerGuide
J. Remove the plunger guide stopper pin.
2. Remove the plungerguide.
CAUTION: Whenremoving theplungerguides,
keep the plunger stroke adjusting shims with the
properguide.
3. Remove the plunger, plunger spring lower seat,
plunger spring and plunger prestroke adjusting
shim.
37
4. Remove the upperseat and pinion.
5. Remove thecontrol rack.
6. Remove the delivery valve holder and spring,
delivery valve packing and delivery valve
assembly.
7. Remove the plunger barrel.
Fig. 5-8 Remove Delivery Valve Assembly
Fig_ 5-9 Remove Plunger Barrel
glass, for excessive wear or possible
chips onthe helix.
If there is any chipped area on the lead helix, it
will notbe indicated in any ofthe tests.
Fig. 5-7 Remove Upper Seat and Pinion a. Inspect the plunger. Ifthe plunger is chipped,
replace theplungerandbarrel assembly.
b. Inspecttheoutsidediameteroftheplunger.Ex-
amine the surface with a magnifying glass.
Inspection of Major Components
Even theslightestimperfection will prevent the
plunger from operating properly. Check for
I. Inspection ofthe Plunger and Barrel
burrs, nicks, erosion, cracks, chipping and ex-
Due to the close tolerance(.0004 in. [0.001 mm])
cessive wear. If necessary, replace the plunger
oftheplungerandbarrelassembly, makesureitis
and barrel assembly.
free from excessive scratches, wear, chips and
c. Free fall ofthe plungerand barrel.
foreign material. Also, the free fall ofthe plunger
Afterthoroughly cleaning theplungerand bar-
shouldbe smooth.
rel, tilt them about 60'. Plunger should slide
The plunger should be checked visually, under a down slowly (Fig. 5-10)
38
Fig. 5-6 Remove Plunger Assembly
Fig.5-10 Plunger and Barrel Free-Fall Test
Repeatthis test several times while rotating the
plunger. Ifit slidesdown too fastorifit sticks
halfway, correct(lap or clean) or replace it.
2. Delivery Valve Inspection
a. Inspect thedelivery valve, and replace itifthe
suction collar or seat is scratched, dented or
shows signs ofwear.
b. Thoroughly clean the delivery valve. After
cleaning, press the lower end down with your
finger to close it. Remove your finger, and it
shouldspringback.If itdoesnotspringback, it
should be replaced because the suction collar
section is probably badly worn.
Fig.5-11 Delivery Valve Spring Back Test
3. Inspection of the Control Sleeve and Control
Rack
Check that the control sleeveandcontrol rackdo
nothave anyabnormalgearcontact, scratchesor
foreign matter on them. Any abnormal gear
engagement will increase the friction resistance of
the control rack and may cause engine trouble.
4. Inspection of the Delivery Spring and Plunger
Spring
Check for any abnormal contact/damageon the
springs and deforma tion ofthesprings.
5. Plunger Guide Inspection
There should notbe any "play" between the pin
and the inside/outsi de roller pin. Also be sure
there is no "pitching" on the surface ofthe out-
sidewheel ofthe roller.
Fuel Injection Pump Assembly
Donot mix thevariouspartsofeach valve.If onevalve
part is defective, replace all the valves . During
assembly, keeptheparts in clean fueloil and match the
"matching marks".
1. Place the left plunger barrelgasketin position.
2. Install the left plunger barrel.
3. Install the left deliveryvalve assembly and gasket
together.
4. Install the left delivery valve spring. Tighten the
left delivery valve holder with a torque wrench.
Torqueshould be29-32 ft. lb. (39.3 to43.4Nm).
5. Install the fuel control rack.
6. Install the left fuelcontrol sleeve.
7. Install the upper seatofthe leftplungerspring.
8. Install theleft plunger spring.
9. Install the left plunger.
10. Install the lower seatofthe leftplungerspring.
11. Install theplunger location adjusting shim.
12. Install the left plungerguide.
13. Install the left plungerguidestop. Setthestopby
pressing the plunger by hand. (Press the plunger
guidebymovingtheracksothattheplungercollar
can be fixed intothegrooveoftheregulatinggear
tooth.)
14. Placeonly therightfuel controlgear toothin the
pumpbody.
15. Apply the procedures given in steps I to 4 to the
right unit.
16. Insert the right fuel control sleeve in the pump
body. Check that the "matching lines" of both
the regulating ring and regulating gear tooth
match.
17. Repeatsteps 7 to 13 on the right unit.
39
18. Repeat steps 15 through 17 on the right unit for
theinjection pump on theTK353 engine.
19. Set theplungerguide checking pin.
20. Repeat fuel coutrol rack free movement test.
FIg.5-12 Fuel Rack Free Movement Test
INJECTION NOZZLES
The nozzles areYanmarthrottletype with 1mm inJec-
tion orifice. Injection angle is 0 degrees. Injection
pressureis 2,200 psi (15,168 kPa) .
Fuel, under high pressure from the lnJection pump
enters theannulargroovein thetopofthenozzlebody,
flows through the fuel ducts into the pressurechamber
abovethevalveseatandacts onthedifferentialareaof
the nozzle valve. When the hydraul ic pressure exceeds
the force exerted by the pressure adjusting spring, the
valve is lifted off its seat and fuel is forced from the
orifice into the spray hole chamber and combustion
chamber. Any fuel thatleaks pasttheneedle and pintle
returnstothetankpastthestem,springandthroughthe
hollow adjustment to the return line.
Thevalve returns to its "normall yclosed" position on
the valve seat when the hydraulic pressure in the
pressurechamber drops below theforce exerted onthe
valve by the pressureadjusting spring.
Testing Injection Nozzle
Install nozzle in nozzle tester PartNo. 204-290.
NOTE: Tube 204-451 is available separately. This
tube should be bent to fit the nozzle. Only clean,
filtered, diesel fuel must be used in tbe nozzle tester.
CAUTION: Keep hands away from sprayingnozzles.
The pressure of the fnel spraying from tbe nozzle can
penetrateintotbefleshdestroyingtissuesandmaycause
blood poisoning.
Fig. 5-13 Nozzle Tester
Buzzirlg
Close the hand valve and operate the handle several
times rapidly and with a fulI stroke. If the nozzle is
operating properly, there will be a buzz and a high
whistle.
NOTE: If thepumpingspeedis increased, thebuzzing
slops and tbe oil then leaves Ihe nozzle with bissing
noise.
Opening Pressure
Testopeningpressure.Openthehandvalvesothegauge
will regi ster. Slowly force the handle down and deter-
mine the opening pressure. The nozzle should buzz
distinctly during spraying.
Openingpressurefornozzlesinnew conditionshouldbe
2,275 to2,350 psi (15,684 to 16,201 kPa).
Minimum opening pressurefor used nozzles is 2200 psi
(15, 167 kPa) .AU nozzles in theengineshould bewithin
70 Ib (483 kPa) . Adjust as necessary to bring nozzle to
correctopening pressure. Adjustmentisaccomplishedby
removingthenozzle spring retainerandaddinga nozzle
springadjustingshim.Anadjustingshimof.004in. (0.1
mm) increases injection pressure by approximatel y 142
psi (981 kPa).
Pattern
Check the spray pattern. Close the hand valve and
operatethepump. Operatepumpatabout4to6strokes
persecondandobservespray. Thespraypatternshould
bealmostsymmetricalaroundtheaxisofthenozzleand
without side jets.
40
A B
Good Incorrect
1. Lowinjection
pressure
2. Valve sticking
3. Nozzle spring bent
C
Incorrect
1. Scratch ordirt in
the nozzle hole
2. Carbon depositin
the hole
D E
Incorrect Incorrect
1. Injection holeworn 1. Improperly sealed
2. Carbon deposit in injection valve
the hole 2. Damaged orworn
injection hole
3. Carbon deposit in
the hole
Fig. 514 NozzleSprayPattern
Dripping
Open hand valve and operate pump slowly to build
pressure up to within 300 psi (2,068 kPa) of opening
pressure.
NOTE: Thereshouldbe no drippinguntil thepressure
gets within 300 psi (2,068 kPa) of opening pressure or
less.
Leakage
Duringthetestingprocedure, thereshouldbeverylittle
ifany fuel flowing from the returnfuel port.Ifenough
fuel is leaking past the nozzle valve and body to cause
flowdownthesideofthenozzleduringtesting,thenoz-
zle shouldbe repaired or replaced.
NozzleRepair
1. Secure the nozzle in a vise andremove thespring
nut.
2. Remove spring nut packing and adjusting shims,
spring, springretainer and spindle.
3. Secureholderin vise with nozzle up. Loosen noz-
zle nut and then remove carefully to avoid drop-
ping nozzle. When removing the nozzle, use care
tokeepneedlevalvefromfalling out.Nozzlebody
and pintle valvecanbereconditioned with special
care, skill and equipment. Body andvalve can be
purchased separately and installed in holder but
should be tested and set for opening pressure.
4. Submergenozzleneedleand nozzleheadseparate-
ly in filtered diesel fuel. Put the needle into the
head while holding head vertical. The nozzle nee-
41
NozzleSpring Nut
Packingfor Nozzle SpringNut 2
Shimfor NozzleSpringAdjustment 3
NozzleSpring 4
NozzleSpringRetainer
5 - ~ c . I
InterSpindle
Nozzle Holder Body
NozzleValve
6
8--0
Nozzle Body
9---tj
Nozzle Nut
10-tJ
Fig.5-15 ExplodedViewofInjection Nozzle
die, when pulled out approximately 1/3 of its
length must slide to its seat by its own weight.
Turn the needle and repeat the procedure in
several different positions.
NOTE: Ifthe needle does not seat in all posi-
tions, replace nozzle and needle.
S. Thoroughlyrinseallpartsand assemblethenozzle
holder.
NOTE: Ifnew nozzle and needle are installed,
they mustfirst bethoroughlycleaned insolvent to
remove the anti-rustcompound.
6. Cleanallcomponents. Reinstallspindle,springre-
tainer and spring. Replace adjusting shims and
spring nut packing. Install nozzle spring nut, but
donottighten. Leavethenutlooseaturnortwo.
7. Install nozzle assembly and tighten. Then tighten
nozzle spring nut.
8. Test and adjust nozzle to proper pressure by ad-
dingorremoving adjustmentshims. Addshimsto
increase pressure or remove shims to decrease
pressure.
NOTE: Iffurther work is needed, it is recom-
mendedthatthenozzlebesenttoadieselinjection
serviceshop. Forreconditioning in an emergency
situation,thepintlevalveand holdercan beclean-
ed with Part No. 204-283 nozzle cleaning kit.
Refer to Service BulletinTK4190.
NOTE: All replacement springs should be
visually checked before installation.
INJECTIONPUMPANDGOVERNOR
ADJUSTMENTS
Todeterminethecorrectspeedsettings for a particular
Thermo King unit model, see "Specifications" section
or consult the maintenancemanual for that model.
When the diesel engine fail s to maintain the correct
enginespeeds, check the following beforeadjustingthe
speed:
I. Check the prefilterscreen. Recheck the speed.
2. Bleed air out of the fuel system. Recheck the
speed.
3. Bleed air outofthenozzles. Recheck the speed.
Maketheenginespeedadjustmentswiththeenginefully
warmed up.
The engine has two solenoids mounted on one bracket
attached totheexhaustmanifoldsideoftheengine.The
upper solenoid controlshigh speed .. Thelower solenoid
is a combination on-off and low speed solenoid. The
speed of the engine should be checked with a hand
tachometer, TK Part204-220, on the crankshaftpulley
boltorby theuseofastroboscopetachometer, TK Part
204-436.
CAUTION: DONOTtrytoadjustthefuellimitscrew
onthefrontofthetimingcover.Thefuellimitscrewisa
FACTORY SET smoke and power controller. Itdoes
notcontrolanypbaseoftbeenginespeed,anditisnota
sensitivityscrew. Thefuel limitscrewsbouldnotbead-
justed ortampered with in tbe field.
IDLE STOP AND THROTTLE SOLENOID
ADJUSTMENTS
NOTE: Refer to appropriate unit maintenance
manual forhighandlowspeed throttlesolenoidadjust-
meot procedure.
Fuel Limiting Screw
The fuel limiting screw is located on the front ofthe
timinggearcover. Thisscrewispresetatthefactoryand
SHOULD NEVER need adjustment. The engine has
enough reserve horsepower and torque to preclude the
governorlever fromcomingup againstthefuel limiting
screw and its internal torque spring. There is the
possibility however that an inexperienced mechanic
might try to adjust the screw to cure some unrelated
engine problem makingit necessarytoreadjust the fuel
limiting screw. Indications that the fuel limiting screw
has been moved are excessive black smoke when the
engine changesspeeds or theengine havingdifficultyin
pi cking upspeed.
CAUTION: Be sure the fuel limitingscrewHASbeen
tampered with before attempting to readjust it. Ifthe
engine is simply having difficulty in picking up speed,
theengine has afuel supply problem(weak ordefective
eleclric fuel pump, air leak in fuel line, clogged lines,
filters or nozzle, or injection pump problems). Mis.d-
justmentofthe fuellimitingscrewcanseriouslydamage
lhe engine.
Fig. 5-16 Fuel Limiting ScrewAdjustment
42
1. Remove all solenoid linkages.
2. Removethesideinspectionfrom thetimingcover.
3. Remove the fuel limiting screw cover and loosen
the jam nut.
NOTE: The two small 8mm nutsfixiug thetor-
que spring adjustment cannot be accurately field
adjusted. If they have been tampered with, they
can be reset hy unlocking tbem and then setting
the outer nut approximately2-112 to 3 tbreads in
from the end of theshaft.
4. Lightlymovethecontrollever forward, butdonot
compress the fuel limit screw torque spring.
Watchthetwonutsthatprojectfrom thefuellimit
screw. Ifthenutsstartto move, thetorquespring
is beingcompressedandthecontrolleverhasbeen
pull ed too far back.
5. Usea pencilorsimilaritemtogentlypushtherack
control lever back towards the engine While still
holding thecontrol lever up against the fuel limit
screwtorquespringwithoutcompressingit. Asthe
rack controllever is being pushed back, it will en-
counter a resistance ata certain point. From that
pointon,anyfurthermovementtotheleftwill put
tension on the governor spring and will cause the
control lever to begin to move. Repeat this pro-
cedure two or three times until the rack control
lever can be moved too and stopped at the
resistance point without causing a movement of
the control lever.
Fig. 517 Fuel Limiting ScrewRack Alignment
6. There is a punch mark on the rack shaft which
should now align with the edge ofthe machined
area ofthe injection pump. If the pump mark is
outofalignment, adjustthe fuel limitingscrewin
or out until the punch mark is aligned. Movethe
rack control lever back and forth a few times to
recheck thepunchmarkalignment. A stronglight
source may be needed becauseofthedifficultyin
seeing the punch mark.
7. Tighten the fuel limit screw jamnut and reinstall
the cover nut.
ADJUST ENGINE VALVE CLEARANCE
1. Remove valve cover. Torque 12 mm diameter
head bolts prior to adjusting valves: 80 ftllb
(108.5 Nm). Valve clearance should be checked
after the first 500 hours ofengine operation and
after2000 hoursmaximum ofoperation. It is very
important that valves be adjusted to the correct
specifications for satisfactory engine operation.
Insufficient valveclearancewill resultin compres-
sion loss and misfiring of cylinders resulting in
burnedvalves and seats.Excessivevalveclearance
will result in noisy valve operation and abnormal
wear of the valves and rocker arms. The intake
and exhaust valves are adjusted with the valve in
the closed position.
Fig. 5-18 Intakeand Exhaust Valve Clearance
2. Theintakevalveandexhaustvalveareadjustedto
.0079 in. (0.2 mm) with the temperature at70 F
(21 C).
Turn the engine by using the belt on the
crankshaft pulley. Rotate the engine in thedirec-
tion of rotation (clockwise as viewed next to
flywheel) from the water pump end.
CAUTION: Make sure fnel rack is off to pre-
ventengine from starting.
a. Turn engine so No. I cylinder is on compres-
sionwithpistonatTDe.Bothpushrodsshould
turn freely. Adjust both valves on No. I
cylinder.
43
b. On theTK235 engine, revolvecrankshaft 180
to TOe mark ofNo.2cylinder. Adjust both
valves. On the TK353 engine, revolve the
crankshaft 240 to TOe mark of No. 3
cylinder, and adjust both valves.
c. On TK353 engine, turn thecrankshaft240 to
align TOe mark of No.2cylinder and adjust
both valves.
d. BE SURE to tighten lockingnut while holding
the ball head screw in position.
e. Install valvecovermakingsurethatgasketisin
position.
44
Electrical
Contents
Starter Overhaul .... .. . . . . . . . . ..... ...... . 46
45
it in that position while cranking. It also serves to
Electrical
releasethepinionaftertheenginestarts, simultaneously
STARTER
Construction and Operating Principles
The starterconsists ofthe motorthatdevelopsstarting
torque, amagneticswitchthatengagesthemotor, anda
pinion that engages the flywheel gear to transfer the
starting torque.
Fog. 6-1 StarterMotorPull-in Pictorial
Fog. 6-2 StarterMotorOperatirog Pictorial
Motor
Thestarting motoris a highoutputserieswound motor
in which the armature coil and field are connected in
series.
Magnetic Switch
Themagneticswitch actuates the shiftlever that forces
thepinionintoengagementwiththeringgearandholds
bringingthemotorto a stop.
Pinion
The pinion shaft is driven by an over-running clutch
assembly. When the engine is started and the flywheel
gearturnsfasterthanthe pinion, thepinionturnsfreely
to prevent damageto the othercomponents.
Starter Disassembly
I. Disconnectthe lead wire from the terminal ofthe
magnetic switch.
2. Remove two through bolts from drive end hous-
ing. Then separate the starting motor from
magnetic switch.
3. Remove screws from drive housing, and separate
the drive housing from magnetic switch housing.
4. Pull out the overrunning clutch, and remove the
steel balland return spring.
NOTE: Be careful not to lose tbe steel ball and
springlocated between magneticswitch and over-
running clutch.
5. Remove the idle gear, roller and retainer from
magneticswitch.
6. Remove the brushes frombrushholder, then pull
outthe armature from yoke.
NOTE: The clutch gear assembly and magnetic
switch are not repairable, and the mechanic must
use his judgement as to reuse or replace these
parts.
Starter Inspection andReassembly
1. Thefollowingmagneticswitchtestsshouldbeper-
formed with the specified voltage applied. The
starter must beassembled withoutthe motor.
NOTE:
a. 00 not attempt 10 disassemble the
magnetic switch. It cannol be repaired and
must be replaced if defective.
b. Perform each test as quickly as possible
(3-5 seconds) to prevent thecoilsfromburn-
ing.
a. Pull-inTest
When the negative battery (-) terminal is con-
nected to magnetic switch body and "e" ter-
minal, and the positive (+) terminal to the
"50" terminal, the pinion should extend out.
46
RETAINER
OVERRUNNING
CLUTCH
BALL
MAGNETIC
SWITCH
Fig. 6-3 Cutaway View of Starter
C"
Fig. 6-4 Pullin Test
b. HoldinTest
Withthesameconnection as in thepullintest,
disconnect the "e" terminal. The pinion
shouldremain extended.
c. ReturnTest
Withthesameconnectionasintheholdintest,
connectpositive(+ ) jumperwire from battery
to lie" terminal. At this time, disconnect "50"
terminaljumperwire.Thepinionshouldreturn
47
Fig 6-5 HoId-in Test
quickly (Fig. 66).
d. Remove plunger cover and plunger from
starter. Inspect switch contactor points. If the
points are roughened or corroded, dress them
as necessary.
2. Make a good visual inspection ofarmature com
mutator for thrown solder, deformed windings,
signs of overheating, and shaft damage on
bushingends orcenter carrier.
~ _ c ~
Depth to Mica
Incorrect
Fig.6-8 UndercuttingofMica
F'9 6-7 InspectSwitchContactor
3. Check the commutator for roughness, corrosion
and outofround. Commutatorshould notbeout
ofround by more than .0157 in. (0.4 mm).
a. If necessary, dress with a fine sandpaper.
b. Turnthecommutatorinalatheifdamageisex-
cessive. Outside diameter of commutator
should be 1.1417 to l.lSI I in. (29.0 to 30.0
mm). Replace armatureifcommutatorexceeds
service limit.
c. After commutator is turned, check and recut
mica if necessary.
d. Test thearmaturecoil for a short. Positionthe
armature on a growler tester and slowly turn
the armature with a piece ofiron attached to
lhe core. If lhe iron piece is attracted by the
magnetic force or it vibrates, it indicates that
thearmaturecoil is shorted. If such is thecase,
repair or replace the coil.
e. Armature coil continuity test. With the ohm-
meter, check continuity between the segments
onthecommutator. If thereis no continuity, it
indicates the coil circuit is open and necessary
repair or replacement of the coil should be
made.
48
Fig 6-6 RetumTest
.020in. to .032In.
0.50to0.80mm
Fig.6-9 Armature ContinuityTest
Fig. 6-10 Armature GroundTest
f. Armature coi l insulation test. With the ohm-
meter, check the insulation between the com-
mutator(coil)andcore. Ifthereis continuity, it
indi catesthatthecoilinsulationisdefectiveand
the coil should be repaired orreplaced.
4. Inspectfield windingfor wearordamage. Allcon-
nections should be clean and tight.
a. Using an ohmmeter, check for continuity bet-
ween the field coil brush lead and power feed
wire ("C" terminal).
~ I Q 6-11 Field Winding ContinuityTest
b. Check for a ground between the field coiland
thecase.Makenecessaryrepairsifgrounded.If
thereisstillcontinuity, thefieldwindingshould
be replaced.
5. a. Brush holders can also be tested with an ohm-
meter. Touchoneprobetoholder plateand the
otherprobepositivebrushholder.Thereshould
be no continuity. Ifthere is continuity, repair
or replace the brush holder.
~ I Q 6-12 Brush Holder InsulationTest
49
b. Measure the brush length and replace if the
brush is reduced to .397 in. (10 mm).
NOTE: Ifthe negative side brushes mounted
onthebrushholderareworn, replace(heentire
brush holder. Ifthe positive side brushes con-
nected to field winding are worn, replace the
entire field yoke assembly.
c. Check brush springtension. Inspect brush spr-
ings for overheating or deformation and
replace if necessary.
6. Inspect bearings for wear and damage. Check pi-
nion teethforwear. Thepinionshouldturn freely
in direction ofrotation and belocked in opposite
direction ofrotation.
~ I Q 6-13 Inspect Bearings,Pinion Teethand Clutch
7. Startercan now bereassembled usinglight grease
for lubrication of spline, pinion gear, idle gear,
roller retainer, coil spring and ball, and clutch
gear. Do not forget to assemble thesteel ball and
spring.
NOTE: Points to be noted when assembling the
startermotor to theengine.
a. Use care not to damage and get oil on the
brushes when assembling them.
b. Securely tighten the starting motor to the
engineasagreatloadis imposedonthestarting
motor when cranking theengine.
c. Check to make sure all the connections are
tight. Otherwise the increase in contact
resistance will lead to starting failure.
8. Perform No Load Performance Test. Clamp
starterfirmlyinvice. Apply 1Jvolttostarter.The
startershouldshowsmooth steadyoperationwith
current draw of 180A maximum and speed of
3,500 rpm.