58a447service Manual

REPAIR MANUAL
For 3 Cylinder Liquid Cooled Diesel Engines
FORM MS-1055-5/02
2002 BRIGGS & STRATTON DAIHATSU LLC
PRINTED IN U.S.A.
FOREWORD
The information, procedures and specifications provided in this repair manual are current as of the date of publication and subject to change without notice. Appropriate changes will be included in the next revision of this manual. Note: Manufacturing standards may vary from service specifications. Always refer to the service procedures and specifications in this manual when engine service is required.
GENERAL REPAIR INSTRUCTIONS

Before attempting a B&SD engine overhaul or a tune-up, it is necessary that your shop be equipped with proper tools, equipment and mechanics who are thoroughly familiar with Briggs & Stratton engine design and construction. With your shop thus equipped, this book will serve as a guide in performing the various steps necessary to do a complete and satisfactory job. Use only genuine replacement parts. Always use recommended service tools. This engine is designed and manufactured using metric dimensions. The English equivalents provided may have been rounded up or down to the closest numerical interpretation of the metric dimension. The terms Inspect, Check, Test and Replace are used as follows: INSPECT Visual inspection look for signs of wear, scoring, cracks, stripped threads, etc. CHECK Measure by means of plug gauges, micrometer, feeler gauges, scale, etc. TEST Analyze with proper test equipment. REPLACE This usually means to take off the old part and reassemble it or replace it with a new one.
Disassembly
As engine is being disassembled, mark parts which are part of an assembly, to prevent interchanging. Arrange parts in an orderly manner, keeping parts which are an assembly together. Visually inspect each part as it is removed look for signs of wear, scoring, cracks, stripped threads, etc.
Inspection and Measurement

Carefully check parts that can be reconditioned and/or reused. Replace any parts that are not within specification.
Clean parts to be reused

Clean or wash disassembled parts.
Assemble
Use a torque wrench to torque bolts and nuts to required specifications. Replace all gaskets, cotter pins, oil seals and O-rings.
ABBREVIATIONS
Abbreviation ASSY BDC DT EX ID IN LH MP Meaning Assembly Bottom Dead Center Diesel Turbocharger Exhaust Inside Diameter Intake Left Hand Multi-purpose OD OPT O/S RH SAE T/C TDC U/S Abbreviation Meaning Outside Diameter Optional Oversize Right Hand Society of Automotive Engineers Turbocharger Top Dead Center Undersize
Copyright " 2002 by Briggs & Stratton Corporation All rights reserved. No part of this material may be reproduced or transmitted, in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage and retrieval system, without permission in writing from Briggs & Stratton Corporation.
TABLE OF CONTENTS
See Pages II and III for Section Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1
CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2
TIMING GEARS AND GEAR CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3
FLYWHEEL AND REAR SEAL RETAINER . . . . . . . . . . . . . . . . . . . . . . . Section 4
CYLINDER BLOCK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5
CYLINDER BLOCK INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . Section 6
CRANKSHAFT, CAMSHAFT AND BEARINGS . . . . . . . . . . . . . . . . . . . . Section 7 PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 8 CYLINDER BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 9
FUEL SYSTEM AND RELATED COMPONENTS . . . . . . . . . . . . . . . . . Section 10
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 11
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 12
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 13 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 14
SECTION CONTENTS
Section 1
Section 6
GENERAL INFORMATION Engine Identification In The Interest Of Safety Engine Views Engine Specifications And Data Fastener Specifications Briggs & Stratton Numerical Number System Maintenance Schedule
CYLINDER BLOCK INSPECTION AND REPAIR Checking Cylinder Block Replacing Camshaft Bearing Replacing Camshaft Plug
Section 7
Section 2
CYLINDER HEAD AND VALVES Remove Cylinder Head Disassemble Cylinder Head Inspect And Repair Cylinder Head Valve Guides Valves Disassemble Rocker Arm Shaft Assemble Rocker Arm Shaft Assemble Cylinder Head Install Cylinder Head Adjust Valves
CRANKSHAFT, CAMSHAFT AND BEARINGS Checking Crankshaft Checking Main Bearing Clearances Checking Connecting Rod Bearing Clearances Checking Crankshaft End Play Checking Camshaft
Section 8
PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY Disassemble Piston And Connecting Rod Checking Piston And Rings Checking Piston Pin And Connecting Rod Assemble Piston And Connecting Rod Assemble Piston Rings To Piston
Section 3
TIMING GEARS AND GEAR CASE Remove Timing Gear Cover And Gears Checking Gears Remove Gear Case Replace Timing Gear Cover Oil Seal Assemble Timing Gear Case And Gears
Section 9
Section 4
FLYWHEEL AND REAR SEAL RETAINER Removing Flywheel And Rear Seal Retainer Replacing Oil Seal Installing Rear Seal Retainer And Flywheel Install Oil Pan
CYLINDER BLOCK ASSEMBLY Install Crankshaft Install Pistons And Connecting Rods General Assembly Oil Pickup Tube Rear Seal Retainer And Starter Motor Flywheel Install Timing Gear Case, Camshaft And Gears Install Oil Pan Install Alternator
10
Section 10
Section 5
CYLINDER BLOCK DISASSEMBLY Engine Stand Fixture Cylinder Block Disassembly
FUEL SYSTEM AND RELATED COMPONENTS General Information Injector Pump Timing Specifications Checking Injector Pump Timing
II
SECTION CONTENTS (contd)

Adjusting Injector Pump Timing Injectors Remove Injectors Checking Injectors Install Injectors Fuel Filter General Draining Water Collector Change Fuel Filter Fuel Shut-Off Solenoid Checking Fuel Shut-Off Solenoid Wiring Injector Pump Identification Engine Speed Identification Chart Adjust Idle Speed Adjust Top No Load Speed Test Equipment Testing Starter Starter Current Draw Test No Load Testing Starter (No Load) Starter Solenoid Equipment To Test Solenoid Testing Solenoid Remove Solenoid Check Pinion And Clutch Assembly Assemble Pinion And Clutch Assembly Install Solenoid Install Solenoid Contacts And Plunger Disassemble Starter Motor Inspect Armature Commutator Inspect Brushes Replace Brushes Assemble Starter Motor Wiring Diagrams 40 Amp Wiring Diagram 14 Amp Wiring Diagrams
11
Section 11
ELECTRICAL SYSTEMS Electrical System Components Glow Plug System Glow Plug Specifications Remove Glow Plugs Test Equipment Testing Glow Plug Preheat Timer And Glow Relay Testing Preheat Timer Testing Glow Relay Keyswitches Charging Systems 14 Amp Charging System Test Equipment Testing Alternator AC Output Testing Regulator-Rectifier DC Output Testing Charge Indicator Bulb And Wiring 40 Amp Charging System Test Equipment Testing Alternator DC Output Disassemble Alternator Checking Bearings Install Ball Bearing Check Brushes Check Regulator Check Rectifier Assemble Alternator Starter System Starter Current Draw Test Installed
12
Section 12
LUBRICATION SYSTEM Description Change Oil Change Oil Filter Check Oil Pressure Disassemble Gear Case Remove Oil Pump Assemble Gear Case Install Oil Pump
13
Section 13
COOLING SYSTEM General Information Checking Cooling System Pressure Testing Cooling System Testing Radiator Cap Changing Coolant Thermostat Removing Thermostat Checking Thermostat Installing Thermostat Water Pump Inspecting Water Pump Removing Water Pump Installing Water Pump
III
SECTION CONTENTS 14
Section 14 Turbocharger Pressure Control System Crankcase Bloeby Recirculating System Checking Waste Gate Actuator Servicing And Operating Information Remove Turbocharger Checking Turbocharger Install Turbocharger Installation Of Coolant Inlet Tube
TURBOCHARGER General Information Turbocharger Lubrication System Turbocharger Cooling System Turbocharger Waste Gate
IV
BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055)
Section 1 General Information

Section Contents Page ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 IN THE INTEREST OF SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ENGINE SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FASTENER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 BRIGGS & STRATTON NUMERICAL NUMBER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE IDENTIFICATION NUMBERS

The engine model and type number are located on the vale cover, Fig. 1. The serial number is stamped into the right side of the cylinder block, behind the intake manifold, Fig. 2.
MODEL AND TYPE NO.
SERIAL NO.
Fig. 1 Engine Model And Type Number
Fig. 2 Engine Serial Number
MAY 2002
GENERAL INFORMATION
IN THE INTEREST OF SAFETY

This safety alert symbol indicates that this message involves personal safety. Signal words danger, warning and caution indicate hazard degree. Death, personal injury and/OR property damage may occur unless instructions are followed carefully. WARNING: DO NOT 1. DO NOT run engine in an enclosed area. Exhaust gases contain carbon monoxide, an odorless and deadly poison. 2. DO NOT place hands or feet near moving or rotating parts. Keep all guards in place. 3. DO NOT place hands or feet near electric cooling fan (if equipped). Fan may start suddenly, depending on coolant temperature. 4. DO NOT store, spill, or use diesel fuel near an open flame, or devices such as a stove, furnace, or water heater which use a pilot light or devices which can create a spark. 5. DO NOT refuel indoors where area is not well ventilated. Outdoor refueling is preferred. 6. DO NOT fill fuel tank while engine is running. Allow engine to cool for 2 minutes before refueling. Store fuel in approved, correct color safety containers. 7. DO NOT remove fuel tank cap while engine is running. 8. DO NOT operate engine when smell of fuel is present or other explosive conditions exist. 9. DO NOT operate engine if diesel fuel is spilled. Move machine away from the spill and avoid creating any ignition until the spill has been wiped up. 10. DO NOT smoke when filling fuel tank. 11. DO NOT tamper with maximum speed set screw or full load set screw of the injector pump which may increase the governed engine speed. 12. DO NOT tamper with the engine speed selected by the original equipment manufacturer. 13. DO NOT operate engine with a damaged muffler or without muffler. Inspect periodically and replace, if necessary. If engine is equipped with muffler deflector(s), inspect periodically and replace, if necessary, with correct deflector(s). 14. DO NOT operate engine with an accumulation of grass, leaves, dirt or other combustible material in the muffler area. 15. DO NOT use this engine on any forest covered, brush covered, or grass covered unimproved land unless a spark arrester is installed on the muffler. The arrester must be maintained in effective working order by the operator. In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands.
16. DO NOT touch hot muffler(s) or cylinder(s) because contact may cause burns. 17. DO NOT remove the radiator cap while the engine is hot. To avoid scalding from hot coolant or steam blowing out of the radiator, use extreme care when removing the radiator cap. If possible, wait for engine to cool. If not possible, wrap a thick rag around cap while removing. To release pressure, slowly turn cap counter clockwise to the first stop. When all pressure has been released, press down on cap and continue turning. 18. DO NOT start or run engine with air cleaner or air cleaner cover removed. WARNING: DO 1. ALWAYS DO disconnect the negative wire from the battery terminal when servicing the engine or equipment, TO PREVENT ACCIDENTAL STARTING. 2. ALWAYS DO disconnect fuel shut off solenoid wire from injection pump before checking compression, TO PREVENT ACCIDENTAL STARTING. 3. DO wear eye protection when operating or repairing equipment. 4. DO keep governor parts free of grass and other debris which can affect engine speed. 5. DO examine muffler(s) periodically to be sure it is functioning effectively. A worn or leaking muffler(s) should be repaired or replaced as necessary. 6. DO check fuel lines and fittings frequently for cracks or leaks. Replace if necessary. CAUTION:
DO use clean fresh diesel fuel with a minimum of 40 cetane. DO NOT use kerosene. The injection pump requires diesel fuel for lubrication. Damage to the injection pump and/or engine may result if kerosene is used. NOTE: Use Original Briggs & Stratton-Daihatsu Service Replacement Parts when servicing your engine. Authorized Briggs & Stratton-Daihatsu Service Centers carry a stock of such parts. The use of Briggs & Stratton-Daihatsu parts preserves the original design of your engine. Imitation replacement parts may not fit or function as original Briggs & Stratton-Daihatsu parts and can expose the operator to potential personal injury. Contact any Authorized Briggs & Stratton-Daihatsu Service Center for Original Briggs & Stratton-Daihatsu Replacement Parts.
GENERAL INFORMATION ENGINE VIEWS

Diesel
1 2
13 12
1. 2. 3. 4. 5.
Thermostat Oil filler cap Electric starter Oil pan Alternator
11
6. 7. 8. 9. 10. 11. 12.
Injector nozzle Glow plug Oil drains 10 Oil filter Dipstick Injector pump 9 Engine Date code xxxxxxxx 13. Engine Model & Type number xxxxxx xxxx-xx
8
Turbo-charged Diesel
1. 2. 3. 4. 5. 6.
Thermostat Oil filler cap Turbocharger Electric starter Alternator Oil pan
7. 8. 9. 10. 11. 12. 13. 14. 15.
Injector nozzle Glow plug Oil drains Oil cooler (if equipped) Oil filter Dipstick Injector pump Engine Date code xxxxxxxx Engine Model & Type number xxxxxx xxxx-xx
GENERAL INFORMATION
ENGINE SPECIFICATIONS
Model Type Valve mechanism Bore x stroke mm (in) cc (cu in) 582447 @58A447 @588447 Diesel, 4-cycle, 3 cylinder, in-line, liquid cooled OHV, gear driven 68 x 64 68 x 78 72 x 78 (2.680 x 2.520) (2.680 x 3.070) (2.834 x 3.070) 697 (42.5) 850 (52.0) 952 (58.1) 1-2-3 (front, center, back) 24.0:1 25.0:1 24.4:1 @ 24.8:1 432447 522447 Bar (psi) 34.0 (498) @ 37 (526) Bar 30.0 29.0 30.5 (psi) (425) (412) (433) @ 27 (384) 26.5 19.5 23.6 @ 28.0 44.1 32.5 40.0 @ 49.2 434.4 x 442.9 x 548.4 441.8 x 440.4 x 434.4 x 442.9 x (17.1 x 17.44 x 21.59) 523.9 548.4 @ 434.4 x (17.4 x 17.34 x (17.1 x 17.44 x 447.5 x 559.0 20.6) 21.59) (17.1 x 17.62 x 22.01) 76 (168) 78 (172) 89 (196) 33.0 (469) 32.0 (455)
Piston displacement Firing order Compression ratio
Compression pressure (normal) @ 300 RPM Engine at operating temperature glow plugs removed Compression pressure (minimum) @ 300 RPM Engine at operating temperature glow plugs removed Gross HP @ 3600 RPM Gross Torque @ 2400 RPM
Dimensions (L x W x H) mm (in)
Dry weight
kg (lbs)
GENERAL INFORMATION
Cylinder Head Type Material Combustion Chamber Valve seat angle Intake Exhaust Single piece casting Cast Iron Swirl Type 45
45 Opens 10 BTDC Valve Intake Closes 45 ABDC Specifications Valve timing Opens 45 BBDC Exhaust Closes 10 ATDC Intake mm (in) 0.20 (.008 in) Valve clearance (cold) Exhaust mm (in) 0.20 (.008 in) Cylinder Block & Camshaft Cylinder block Camshaft Carbon steel
235 235
Mono-block, three cylinder, cast iron
Connecting rod Carbon steel Piston Pin Bearing Machined Piston pin, slip fit Crankpin Material aluminum alloy replaceable insert Connecting Bearing Rod & Piston Piston Heat resistant aluminum alloy Compression ring Two, chrome plated Piston ring Oil ring One, combination type, chrome plated One piece cast iron Crankshaft & Crankshaft Crankshaft Crankshaft main Material Replaceable insert aluminum alloy Bearing bearing
GENERAL INFORMATION LUBRICATING SYSTEM

Lubricating Method Oil Pump Oil Filter Oil Capacity Oil Pump Relief Valve Opening Pressure Lubrication Oil Type Drive Type Pressure lube Trochoid Gear drive Full flow, paper 3.3 ltr (3.5 qt) 4.6 Bar (65 psi) API SE/CD class or higher
COOLING SYSTEM
Cooling Method Coolant Capacity (engine only) Cooling System Pressure Pressure Cap Capacity Water Pump Thermostat Cooling Fan Type Drive Type Specification Drive Liquid cooled, forced circulation Approximately 1.8 ltr (1.9 qt) 1.0-0.75 Bar (15-11 psi) 0.9 Bar (13 psi) Centrifugal V-belt Wax pellet with bypass 82 C (180 F) V-belt V belt
FUEL SYSTEM
Fuel Requirements Type Injector Pump Injector Timing (Plunger stroke) #1 Cyl. TDC Nozzle Type Injector pressure Bar (psi) 140 (1,991) See Table 3, Page 7 Diesel fuel (Cetane number 40 or higher) Bosch VE (distributor type) See Tables 1 & 2, Page 6 Throttle type
Injector Nozzle Idle Speed RPM
ELECTRICAL SYSTEM
Battery Charging System Glow Plug Starter Voltage Capacity Alternator Regulator/rectifier Alternator {Optional} Voltage/Current V/A Voltage/Kilowatt V/K 12V (negative ground) 24 AH (28 AH cold) 28 Volt AC output Minimum 14 Amp DC output with charge indicator circuit 40 Amp DC output Internally regulated 11 Volts / 9.5 Amps Reduction gear type 12 Volts / 1.0 kw {12 Volts / 1.2 kw, optional}
GENERAL INFORMATION
TABLE 1 Injection Pump Timing Engine Date Code Before 99010100

Model/Type No. 432447-0150-E2 522447-0105-E2 522447-0106-E2 522447-0107-E2 522447-0108-E2 522447-0109-E2 582447-0105-E2 582447-0125-E2 582447-0130-E2 582447-0131-E2 Timing Specification 0.93 .03 mm (.0365 .001) 0.93 .03 mm (.0365 .001) 0.93 .03 mm (.0365 .001) 0.93 .03 mm (.0365 .001) 0.93 .03 mm (.0365 .001) 0.93 .03 mm (.0365 .001) 0.93 .03 mm (.0365 .001) 0.81 .03 mm (.032 .001) 0.93 .03 mm (.0365 .001) 0.81 .03 mm (.032 .001)
TABLE 2 Injection Pump Timing Engine Date Code After 98123100

Model Series 432447 All 522447 All 582447 All 58A447 All 588447 Timing Specification 0.90 .03 mm (.035 .001) 0.90 .03 mm (.035 .001) 0.81 .03 mm (.032 .001) 0.90 .03 mm (.035 .001)
INJECTOR PUMP IDENTIFICATION
IDENTIFICATION CODE
7 : 700 cc 8 : 850 cc 9 : 950 cc NAME PLATE IDENTIFICATION CODE
DESTINATION U : USA J : Japan X : Except for USA
SERIAL NUMBER
TABLE 3 Engine Speed Specification Chart

Pump Mfg. Part No. ID Code Model & Type No. Idle Speed (rpm) Top No Load (rpm)
22100-87801 22100-8713
7U1 7U2
22100 87802 22100-87802
9U1
22100-87806 22100-87807 22100 87807 22100-87809 22100 87809 22100-87810 22100-87815 22100-87817 22100-87811 22100-87818
9U2 8U1 8U2 8U3 8U4 8U5 9U4 9U5
432447-0105-E2 432447-0205-E2 582447-0105-E2 582447-0205-E2 582447-0130-E2 582447-0230-E2 582447-0219-E2 582447-0222E2 582447-0221-E2 582447-0225-E2 582447-0232-E2 582447-0125-E2 582447-0131-E2 582447-0231-E2 522447-0105-E2 522447-0108-E2 522447-0106-E2 522447-0109-E2 522447-0107-E2 522447-0107-E2 5224470107E2 58A4470205E2 5884470205E2 5884470216E2 5884470230E2 5884470225E2
120050 120050 120050 120050 160050 175050 105050 120050 185050 170050 120050 160050 185050 185050 152550 154050 154050 120050 120050 180050 160050 105050
385050 385050 385050 330050 360050 360050 385050 340050 342050 360050 385050 335050 342050 342050 277550 279050 279050 385050 385050 360050 360050 385050
GENERAL INFORMATION
Description Alternator Adjust. Bracket Alternator 14 Amp (to bracket) Alternator 40 Amp (to bracket) Alternator Bracket (to block) Camshaft Gear Camshaft Retainer Conn. Rod Nuts Crankshaft Pulley Cyl. Head Bolts (8 mm dia.) Cyl. Head Bolts (9 mm dia.) Cyl. Head Bolts (10 mm dia.) Exhaust Manifold Fan Pulley Flywheel Fuel Delivery Lines Fuel Return Line Glow Plug Idler Gear Injector Pump (mounting) Injector Pump Drive Gear Injector Pump Bracket Injector Nozzle Injector Pump Distributor Bolt Intake Manifold Main Bearing Screws Oil Drain Plug Oil Pan Oil Pressure Relief Valve Oil Pump Gear Oil Pump Pickup Rear Seal Support Rocker Arm Assy. Rocker Arm Adjustment Starter Starter Bracket Starter Solenoid Starter Motor Thru Bolts Timing Gear Case Timing Gear Cover (3 different lengths) Valve Cover Water Pump Wrench/Socket Size 12 mm 12 mm 12 mm 12 mm 17 mm 10 mm 12 mm 19 mm 12 mm 13 mm 14 mm 12 mm 10 mm 14 mm 17 mm 17 mm 12 mm Deep 12 mm 12 mm 19 mm 12 mm 21 mm Deep 14 mm 10 mm 14 mm 14 mm 10 mm 19 mm 12 mm 10 mm 10 mm 12 mm Deep 10 mm 14 mm 14 mm Phillips 10 mm 10 mm 10 mm 10 mm 12 mm Torque 19.0 Nm (170 in. lbs.) 19.0 Nm (170 in. lbs.) 61.0 Nm (45 ft. lbs.) 19.0 Nm (170 in. lbs.) 41.0 Nm (30 ft. lbs.) 8.0 Nm (70 in. lbs.) 36.0 Nm (320 in. lbs.) 88.0 Nm (65 ft. lbs.) 34.0 Nm (25 ft. lbs.) 43.0 Nm (32 ft. lbs.) 68.0 Nm (50 ft. lbs.) 19.0 Nm (170 in. lbs.) 7.0 Nm (60 in. lbs.) 47.0 Nm (35 ft. lbs.) 25.0 Nm (220 in. lbs.) 27.0 Nm (20 ft. lbs.) 17.0 Nm (150 in. lbs.) 25.0 Nm (220 in. lbs.) 19.0 Nm (170 in. lbs.) 61.0 Nm (45 ft. lbs.) 19.0 Nm (170 in. lbs.) 61.0 Nm (45 ft. lbs.) 17.0 Nm (150 in. lbs.) 8.0 Nm (70 in. lbs.) 58.0 Nm (43 ft. lbs.) 25.0 Nm (220 in. lbs.) 8.0 Nm (70 in. lbs.) 34.0 Nm (25 ft. lbs.) 19.0 Nm (170 in. lbs.) 8.0 Nm (70 in. lbs.) 6.0 Nm (50 in. lbs.) 19.0 Nm (170 in. lbs.) 11.0 Nm (95 in. lbs.) 40.0 Nm (30 ft. lbs.) 34.0 Nm (25 ft. lbs.) 9.0 Nm (80 in. lbs.) 9.0 Nm (80 in. lbs.) 8.0 Nm (70 in. lbs.) 8.0 Nm (70 in. lbs.) 6.0 Nm (50 in. lbs.) 19.0 Nm (170 in. lbs.)
GENERAL INFORMATION
BRIGGS & STRATTON DAIHATSU NUMERICAL NUMBER SYSTEM

All Briggs & Stratton Daihatsu engines have a unique numerical designation system. Each engine is identified by a Model, Type and Code/Serial number. Example: Model Type Code/Serial 432447 0125 01 020521145 This chart explains the numerical model designation system. It is possible to determine most of the important mechanical features of the engine by merely knowing the model number. Here is how it works.
FIRST DIGIT AFTER DISPLACEMENT CUBIC INCH DISPLACEMENT BASIC DESIGN SERIES SECOND DIGIT AFTER DISPLACEMENT CRANKSHAFT, CARBURETOR, GOVERNOR THIRD DIGIT AFTER DISPLACEMENT PTO BEARING, REDUCTION GEAR, AUXILIARY DRIVE, LUBRICATION FOURTH DIGIT AFTER DISPLACEMENT
TYPE OF STARTER
6 8 9 10 11 12 13 16 17 18 19 22 23 24 25 26 28 29 30 32 35 38 40 42 43 44 46 52 58
0 - Gas-Mechanical 1 - Natural Gas-Mechanical 2 - Diesel-Mechanical 3 - Gas-Electronic 4 - Natural Gas-Electronic 5 - Diesel-Electronic 6 7 8 - Diesel - Turbo 9 A - Diesel Turbo B to Z
0 - Horizontal Shaft Diesel Electronic or Mechanical Governor 1 - Horizontal Shaft Vacu Jet Carburetor Pneumatic Governor 2 - Horizontal Shaft Pulsa Jet Carburetor Pneumatic or Mechanical Governor 3 - Horizontal Shaft Flo Jet Carburetor Pneumatic Governor 4 - Horizontal Shaft Flo Jet Carburetor Electronic or Mechanical Governor 5 - Vertical Shaft Vacu Jet Carburetor Pneumatic or Mechanical Governor 6 - Vertical Shaft 7 - Vertical Shaft Flo Jet Carburetor Pneumatic or Mechanical Governor 8 - Vertical Shaft Flo Jet Carburetor Mechanical Governor 9 - Vertical Shaft Pulsa Jet Carburetor Pneumatic or Mechanical Governor
0 - Plain Bearing/DU Non Flange Mount 1 - Plain Bearing Flange Mounting 2 - Sleeve Bearing Flange Mounting Splash Lube 3 - Ball Bearing Flange Mounting Splash Lube 4 - Flange Mounting Pressure Lubrication on Horizontal Shaft 5 - Plain Bearing Gear Reduction (6 to 1) CW Rotation Flange Mounting 6 - Plain Bearing Gear Reduction (6 to 1) CCW Rotation 7 - Plain Bearing Pressure Lubrication on Vertical Shaft 8 - Plain Bearing Auxiliary Drive (PTO) Perpendicular to Crankshaft 9 - Plain Bearing Auxiliary Drive Parallel to Crankshaft
0 1 2 3
45678-
Without Starter Rope Starter Rewind Starter Electric Starter Only 120 Volt Gear Drive Electric Starter/Generator 12 Volt Belt Drive Electric Starter Only 12 Volt Gear Drive Alternator Only Electric Starter 12 Volt Gear Drive With Alternator Vertical Pull Starter or Side Pull Starter
The type number identifies certain unique features such as the crankshaft or governor spring used on an engine. The code/serial number identifies the assembly date of the engine and serial number. In some instances it is necessary to know the code/serial number as well as the model and type number when performing adjustments, repairs or ordering replacement parts for an engine. Here is how it works.
Example: 990521150
A. The first two digits, 02, indicate the calendar year, 2002. B. The second two digits, 05, indicate the calendar month, May. C. The third two digits, 21, indicate the calendar month day. D. The last three digits, 145, indicate the serial number.
10
GENERAL INFORMATION MAINTENANCE SCHEDULE

More frequent service is required when operating in adverse conditions (note 4 below). Every 50 hours Every 100 hours Every 200 hours Every 600 hours Every 800 hours
System
Maintenance Operation Check oil level
Daily D D
Yearly
Lubrication system
Check for oil leaks Change oil Change oil filter Check coolant
D1 D1 D
D2 D2
D5
Cooling system
Change coolant Check fan belt Service air cleaner D1 D D2, 4 D3, 4 D D D D6
Engine
Check cylinder head bolt torque Check valve clearance
Electrical system Fuel system
Check battery electrolyte Change fuel filter element
1 Perform first maintenance operation after 50 hours. 2 Then perform maintenance operation at this interval. 3 Replace after ever 600 hours of operation. 4 Service more often when operating under heavy load or in high temperatures. 5 Perform maintenance annually if operated less than 100 hours. 6 Follow manufacturers maintenance schedule if non-B&SD approved part is used.
11
Section 2 Cylinder Head and Valves

Section Contents Page
REMOVE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DISASSEMBLE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSPECT AND REPAIR Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DISASSEMBLE ROCKER ARM SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ASSEMBLE ROCKER ARM SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ASSEMBLE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALL CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ADJUST VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Overhead Valve Train
MAY 2002
CYLINDER HEAD AND VALVES REMOVE CYLINDER HEAD

ALWAYS disconnect fuel shut off solenoid wire from injection pump before checking compression, to prevent accidental starting. Drain cooling system and disconnect radiator hoses. 1. Remove the following parts from engine, Fig. 1-Fig. 5: a. Alternator adjusting bracket screw b. V-belt c. Fan (if equipped)
A
Fig. 1 Remove V-belt And Fan
Fig. 2: d. Water pump e. Exhaust manifold NOTE: Remove exhaust system before removing exhaust manifold.
D
Fig. 2 Remove Water Pump And Exhaust Manifold
Fig. 3: f. Valve cover Discard rubber seal.
Fig. 3 Remove Valve Cover
NOTE: Clean areas around fuel lines and injectors to prevent dirt entry. Fig. 4: g. Fuel delivery lines h. Fuel return line i. Glow plug wiring j. Breather tube and intake manifold
I J H
Fig. 4 Remove Fuel Lines
CYLINDER HEAD AND VALVES

Fig. 5: k. Fuel injector nozzles l. Glow plugs
Fig. 5 Remove Glow Plugs And Injectors
2. Set No. 1 piston at TDC, Fig. 6: a. Rotate crankshaft pulley until timing mark on pulley is aligned with reference point on timing cover. b. If intake and exhaust valves have clearance, No. 1 piston is at TDC compression stroke. c. If intake and exhaust valves do not have clearance, turn crankshaft pulley one complete revolution. Valves will then have clearance.
REFERENCE POINT
TIMING MARK
Fig. 6 Set Cylinder No. 1 At TDC
3. Remove rocker arm assembly and push rods, Fig. 7. a. Remove valve stem caps. NOTE: Mark push rods so that they may be reassembled in their original position.
VALVE STEM CAP
Fig. 7 Remove Rocker Arm Assembly And Push Rods
4. Remove cylinder head assembly, Fig. 8. a. Loosen cylinder head bolts in the order shown. NOTE: Current style head bolts are 9 mm diameter. Early style head bolts are 8 mm diameter. Torque specifications are different.
10 7 3 11 13
2 4 8
12 14 9
Fig. 8 Loosen Cylinder Head Bolts

3 5 4 6 9 10 8 1
DISASSEMBLE CYLINDER HEAD
11 7 2
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Cylinder Head Assembly Cylinder Head Gasket Valve Stem Cap Valve Spring Retainer Locks Valve Spring Retainer Valve Spring Valve Valve Spring Seat Valve Stem Seal Valve Guide Combustion Chamber
Fig. 9 Cylinder Head Components
Remove valves, Fig. 10. 1. Use valve spring compressor, Tool #19417, to compress valve springs. Remove the following parts, Fig. 9: a. b. c. d. e. Valve spring retainer locks 4 Valve spring retainer 5 Valve spring 6 IN and EX valve 7 Valve spring seats 8
Fig. 10 Remove Valves
2. Remove and discard valve stem seals, Fig. 11.
Fig. 11 Remove Valve Stem Seal
CYLINDER HEAD AND VALVES INSPECT AND REPAIR

1. Check cylinder head mounting surfaces, Fig. 12 and Fig. 13. Be sure all gasket material is removed from surfaces before checking. Use a gasket scraper if necessary. a. Inspect cylinder head for cracks or damage. b. Use a straight edge and check cylinder head lower surface for distortion.
STRAIGHT EDGE
Fig. 12 Check Cylinder Head For Distortion
Fig. 13: c. Check intake and exhaust manifold mounting surfaces. If mounting surfaces are distorted more than 0.1 mm (0.004 in.), the cylinder head must be replaced. It is not recommended that cylinder head mounting surfaces be resurfaced. NOTE: Intake manifold and exhaust manifold may be checked in the same manner. Use same specifications as cylinder head.
Fig. 13 Check Cylinder Head For Distortion
CHECK COMBUSTION CHAMBER

Engine Model 522000: combustion chambers are not replaceable. Engine Models 432000 and 582000 with date code after 990111007: combustion chambers are not replaceable. NOTE: Only Engine Models 432000 and 582000 with date code before 981225006 have replaceable combustion chambers. 1. Check combustion chamber, Fig. 14. a. Use a straight edge and feeler gauge. If combustion chamber protrudes more than 0.05 mm (.002 in.) above surface of cylinder head, it must be replaced. 2. Remove combustion chamber, Fig. 15. Insert a 10 mm brass rod through injector nozzle hole and drive out combustion chamber. NOTE: Do not damage threads in injector hole.
BRASS ROD COMBUSTION CHAMBER
COMBUSTION CHAMBER
Fig. 14 Check Combustion Chamber
COMBUSTION CHAMBER
Fig. 15 Remove Combustion Chamber

3. Install combustion chamber, Fig. 16. Align locating projection on combustion chamber with groove in cylinder head. Use a soft hammer and drive in new combustion chamber until it bottoms.
COMBUSTION CHAMBER
Fig. 16 Install Combustion Chamber
CHECK AND REPAIR VALVE GUIDES

1. Check valve guide bushings for wear using reject gauge, Tool #19382, Fig. 17. Remove if damaged or if reject gauge enters valve guide.
REJECT GAGE
Fig. 17 Check Valve Guide Bushing
2. Remove valve guide bushing if required, Fig. 18. a. Use bushing driver, Tool #19367, and press out valve guide bushing from combustion chamber side. b. Check valve guide bushing OD. Then see specifications below. Std. Bushing OD: 11.05 mm (.435 in.) Replacement Bushing OD: 11.08 mm (.4362 in.) c. If bushing OD measurement indicates that a replacement bushing has already been installed, the cylinder head must be replaced.
PRESSING OUT GUIDE
Fig. 18 Remove Valve Guide Bushing

3. Using bushing driver, Tool #19416, press in new valve guide bushing until tool bottoms on cylinder head, Fig. 19.
Fig. 19 Installing Valve Guide Bushing
VALVES AND SEATS

1. Valve faces may be resurfaced to 45. See Fig. 20 for dimensions for valves. Lap valves and seats with valve lapping Tool, #19258 and valve lapping compound, Tool #94150.
0.8 mm TO 1.2 mm (1/16 TO 3/64)
1.0 mm (.040) MINIMUM
SEATING AREA CENTERED ON VALVE FACE
Fig. 20 Valve Dimensions
2. Valve seats may be reconditioned using valve seat cutter, Tool #19446. NOTE: Check valve guide bushings first. If valve guides are worn, they must be replaced before refacing valve seats If valve seat is wider than dimension shown in Fig. 21, a narrowing cutter should be used to ensure that contact area of valve seat is centered on face of valve, Fig. 20. a. Use a 60 cutter to narrow seat from bottom and a 30 cutter to narrow seat from top, Fig. 21. NOTE: If valve seat is loose or cracked, replace cylinder head. 3. Measure valve stem diameter at specified distance from end of valve, as shown in Fig. 22. Replace IN if less than 5.927 mm (0.2333 in.). Replace EX if less than 5.923 mm (0.2332 in.).
0.8 mm TO 1.2 mm (1/16 TO 3/64)
45
VALVE SEAT DIMENSIONS
Fig. 21 Valve Seat Dimensions
Fig. 22 Measure Valve Stem Diameter

60 CUTTER

30 CUTTER
35 mm (1.38)

4. Inspect valve stem cap for wear, Fig. 23. Replace if cap is worn recessed.
Fig. 23 Check Valve Stem Cap
5. Check valve springs for squareness and free length, Fig. 24. Replace if out of square more than 1.0 mm (.040 in.). Replace if free length is less than 30.7 mm (1.209 in.).
Fig. 24 Check Valve Springs
DISASSEMBLE ROCKER ARM SHAFT
1. Remove snap rings from ends of rocker arm shaft. Remove set screw from center rocker arm support. Disassemble rocker arm assembly. Note position of all components, Fig. 25.
SET SCREW (1) SPRING (2) ROCKER ARM (6)
ROCKER ARM SUPPORT (3) ROCKER ARM SHAFT
SPACER (3)
SNAP RING (2)
Fig. 25 Rocker Arm Components

2. Check rocker arms and shaft, Fig. 26. a. Check rocker arm-bearing surface. Replace if greater than 10.03 mm (0.395 in.). b. Check rocker arm shaft Replace if less than 9.96 mm (0.392 in.). c. Check rocker arm studs for stripped threads and replace if required.
Fig. 26 Checking Rocker Arm And Shaft
ASSEMBLE ROCKER ARM SHAFT
1. Oil all components before assembling. Small grooves in rocker shaft next to oil holes must face down. Assemble rocker arm components, noting order of assembly as shown in Fig. 27. Note position of three thrust washers. Install set screw in center rocker arm shaft support.
SET SCREW (1) SPRING (2) ROCKER ARM (6)
ROCKER ARM SHAFT
OIL GROOVES DOWN
THRUST WASHER (3) ROCKER ARM SUPPORT (3)
SNAP RING (2)
Fig. 27 Rocker Arm Components
ASSEMBLE CYLINDER HEAD

12
3 5
11
6 9 10 8 13 1
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Cylinder Head Cylinder Head Gasket Valve Stem Cap Valve Spring Retainer Locks Valve Spring Retainer Valve Spring Valve Valve Spring Seat Valve Stem Seal Valve Guide Push Rod Rocker Arm Assembly Rocker Arm Stud
NOTE: When replacing rocker arm studs, torque to 20.0 Nm (180 in. lbs.).
Fig. 28 Cylinder Head Components
1. Install new valve stem seals, Fig. 29. Oil inner surface and lip of seal before installing. Press seal on to valve guide bushing until it bottoms.
VALVE STEM SEAL (CUTAWAY VIEW)
Fig. 29 Install Valve Stem Seals
10

2. Install valve spring seats, Fig. 30. NOTE: Lightly coat valve stems with Valve Guide Lubricant #93963 before installing valves. 3. Install valves.
VALVE SPRING SEATS
Fig. 30 Install Valve Spring Seats And Valves
4. Install valve springs with valve spring compressor, Tool #19417, Fig. 31. NOTE: After installing valve spring retainer locks, tap valve spring retainer lightly with a soft hammer to ensure locks are seated.
Fig. 31 Install Valve Springs
INSTALL CYLINDER HEAD

1. Place cylinder head gasket over alignment dowels on cylinder block, Fig. 32. NOTE: Make sure coolant, oil passages and head bolt holes are aligned.
ALIGNMENT DOWEL LOCATIONS
Fig. 32 Install Cylinder Head Gasket
2. Install cylinder head assembly, Fig. 33. Lubricate threads of cylinder head bolts with engine oil. Torque head bolts in 14.0 Nm (10 ft. lbs.) increments in sequence shown. NOTE: Current style head bolts are 9 mm diameter. Early style head bolts are 8 mm diameter. a. Torque 9 mm head bolts to 43.0 Nm (32 ft. lbs.). b. Torque 8 mm head bolts to 34.0 Nm (25 ft. lbs.). NOTE: Engine Models 58A447 588447 have 10 mm diameter head bolts. Torque head bolts to 68 Nm (60 ft. lbs.).
10 14
4 6 2
12 11 7
3 1 9 5
13
Fig. 33 Install Cylinder Head Assembly
11

3. Lubricate push rods with engine oil then install with recessed end up, Fig. 34.
RECESSED END UP
Fig. 34 Install Push Rods
4. Install valve stem caps on valve stems. Install rocker arm assembly, Fig. 35. Install washers and torque nuts to 19.0 Nm (170 in. lbs.). NOTE: Make sure rocker adjustment studs are seated in recessed end of push rods.
Fig. 35 Install Rocker Arm Assembly
5. Install intake manifold with new gasket, Fig. 36. a. Torque screws to 8.0 Nm (70 in. lbs.).
Fig. 36 Install Intake Manifold
6. Install Injectors, fuel lines and glow plugs, Fig. 37. a. Torque injectors to 61.0 Nm (45 ft. lbs.). b. Torque fuel return line to 27.0 Nm (20 ft. lbs.). c. Torque fuel delivery lines to 25.0 Nm (220 in. lbs.). d. Torque glow plugs to 17.0 Nm (150 in. lbs.).
Fig. 37 Install Glow Plugs And Injectors
12

7. Install exhaust manifold with new gasket, Fig. 38. a. Torque screws to 19.0 Nm (170 in. lbs.).
Fig. 38 Install Exhaust Manifold
GENERAL ASSEMBLY
1. Install water pump with new gasket, Fig. 39. a. Torque screws and nuts to 19.0 Nm (170 in. lbs.).
Fig. 39 Install Water Pump
2. Install water pump pulley, Fig. 40. 3. Install fan (if equipped). a. Torque screws to 7.0 Nm (60 in. lbs.).
Fig. 40 Install Water Pump Pulley And Fan
4. Install V-belt, Fig. 41. 5. Install alternator bolts A and B . Belt deflection limit is 1012 mm/10 kg (3/81/2 in/22 lbs.). a. Torque bolt A to 19.0 Nm (170 in. lbs.). b. Torque bolt B to 61.0 Nm (45 ft. lbs.).
BELT
HANDLE
3/8 1/2 Inch (10 12 mm) BELT MOVEMENT
Fig. 41 Adjusting V-belt
13
CYLINDER HEAD AND VALVES ADJUST VALVES

1. Before adjusting valves, make sure that No. 1 cylinder is at TDC compression stroke, Fig. 42.
REFERENCE POINT
TIMING MARK
Fig. 42 Set Cylinder No. 1 at TDC
a. Adjust valves and check, Fig. 43. Valve Clearance (cold) IN and EX 0.20 mm (0.008 in.) b. Torque adjusting screws and jam nuts to 11.0 Nm (95 in. lbs.).
Fig. 43 Adjust Valve Clearances
With No. 1 piston at TDC of compression stroke, check and adjust valve clearances for cylinders shown in chart at right. Rotate crankshaft one complete turn (360)" clockwise to check and adjust remaining valves.
Piston Position Cylinder No. 1 piston at TDC, of compression stroke Rotate Crankshaft 360 360 clockwise IN EX IN EX
1 l l
2 l l
3 l
2. Install valve cover with new rubber seal, Fig. 44. a. Torque cover nuts to 7.0 Nm (50 in. lbs.). NOTE: Make sure rubber seal is in groove in valve cover.
Fig. 44 Install Valve Cover
14
Section 3 Timing Gears and Gear Case

Section Contents Page REMOVE TIMING GEAR COVER AND GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CHECKING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REMOVE GEAR CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REPLACE TIMING GEAR COVER OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ASSEMBLE TIMING GEAR CASE AND GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MAY 2002
TIMING GEARS AND GEAR CASE REMOVING TIMING GEAR COVER AND GEARS
Make sure that #1 cylinder is at TDC, compression stroke. See Section 2, Fig. 6. Remove V-belt and fan (if equipped). Drain oil from engine. NOTE: Clean areas around fuel lines and injectors to prevent dirt entry. 1. Remove the following parts, Fig. 1. a. Glow plug wiring. b. Glow plugs. c. Injector pump bracket. d. Remove fuel delivery lines.
A B D
Fig. 1 Remove Fuel Delivery Lines
2. Remove the following parts, Fig. 2. a. Remove oil pan and discard gasket. b. Remove oil pick-up tube and strainer. Discard gasket.
OIL PICK-UP TUBE
Fig. 2 Removing Oil Pan
3. Remove bell housing adapter screw if equipped. and install flywheel holder, Tool #19418. 4. LEAVE TOOL INSTALLED. a. Remove crankshaft pulley using Tool # 19420, Fig. 3.
FLYWHEEL HOLDER
Fig. 3 Removing Crankshaft Pulley
5. Remove timing gear cover, Fig. 4. a. Discard timing gear cover gasket.
Fig. 4 Removing Timing Gear Cover
TIMING GEARS AND GEAR CASE

6. Remove oil pump drive gear, Fig. 5. a. Check oil pump drive gear for damaged teeth.
OIL PUMP GEAR
Fig. 5 Removing Oil Pump Gear
CHECKING GEARS
Inspect gear teeth for wear or damage. CHECK GEARS IN SEQUENCE SHOWN. 1. Check gear backlash between idler gear and crankshaft gear using dial indicator as shown in Fig. 6. a. Set tip of indicator on gear tooth, then rock idler gear back and forth noting indicator reading. NOTE: Crankshaft must not turn while checking.
IDLER GEAR CRANKSHAFT GEAR
Fig. 6 Checking Idler Gear Backlash
2. If backlash exceeds 0.2 mm (.008) check idler gear bearing and shaft for wear, Fig. 7. Reject Dimension: Idler Gear ID 34.17 mm (1.345) Idler Gear Shaft OD 33.91 mm (1.335) a. If idler gear bearing and shaft are within specification, replace with new idler gear and recheck. b. If backlash exceeds 0.2 mm (.008) with NEW idler gear, crankshaft gear is worn. NOTE: If crankshaft gear is worn the crankshaft must be replaced. 3. Hold idler gear as shown and check gear backlash between camshaft timing gear and idler gear using dial indicator, Fig. 8. Camshaft timing gear backlash must not exceed 0.2 mm (.008). NOTE: Idler gear must not turn while checking.
IDLER GEAR
IDLER GEAR SHAFT
Fig. 7 Checking Idler Gear And Shaft
CAMSHAFT TIMING GEAR
IDLER GEAR
Fig. 8 Checking Camshaft Timing Gear Backlash

4. Hold idler gear as shown and check gear backlash between injector pump timing gear and idler gear using dial indicator, Fig. 9. Injector pump timing gear backlash must not exceed 0.2 mm (.008). NOTE: Idler gear must not turn while checking. If gears are worn it is recommended that they be replaced as a set.
Fig. 9 Checking Injector Pump Timing Gear Backlash
REMOVE GEAR CASE

1. Remove injector pump timing gear with a three jaw puller, Fig. 10. a. Remove 2 nuts and injector pump. Discard O-ring.
O-RING
Fig. 10 Removing Injector Pump
2. Remove parts in sequence shown, Fig. 11. a. Remove 3 screws and camshaft retainer. b. Remove remaining 5 screws.
B
Fig. 11 Removing Timing Gear Case
3. Remove timing gear case and discard gasket, Fig. 12. a. Remove oil pump rotor from cylinder block.
ROTOR
Fig. 12 Remove Timing Gear Case
TIMING GEARS AND GEAR CASE REPLACE TIMING GEAR COVER OIL SEAL
1. Drive out oil seal. 2. Use seal driver, Tool #19423, to install new oil seal, Fig. 13.
Fig. 13 Replacing Oil Seal
ASSEMBLE TIMING GEAR CASE AND GEARS

1. Clean and lubricate oil pump rotor with engine oil and install in cylinder block, Fig. 14. a. ID mark on rotor must face cylinder block.
ID MARK
OIL PUMP ROTOR
Fig. 14 Installing Oil Pump Rotor
2. Install timing gear case with new gasket. Install camshaft retainer, Fig. 15. NOTE: It may be necessary to rotate oil pump drive to engage oil pump rotors. NOTE: Position camshaft retainer so that center hole does not interfere with camshaft. Note position, length and number of screws as shown. a. M6 x 28 mm (M6 x 1.1): 4 b. M6 x 18 mm (M6 x 0.7): 3 c. M6 x 16 mm (M6 x 0.6): 1 Torque screws to 8.0 Nm (70 in. lbs.). 3. Assemble injector pump to gear case with new O-ring and install nuts and support bracket screw finger tight, Fig. 16. NOTE: Pump must be able to rotate. a. Align timing mark on injector pump with timing mark on gear case. NOTE: See Section 10 for injector pump timing procedure.
Fig. 15 Installing Timing Gear Case
TIMING MARKS
Fig. 16 Install Injector Pump

4. Assemble idler gear shaft with arrow up, as shown in Fig. 17.
ARROW UP
Fig. 17 Installing Idler Gear Shaft
Engine models 432000 and 582000 after date code 990111007, and all engine models 522000 are equipped with right angle helical timing gears. Timing marks are identified by letters (A, AA, B, BB, etc.), instead of numbers. The timing procedure is the same. 5. With crankshaft key at 12 oclock position, assemble idler gear so that timing mark 11 (AA) is aligned with timing mark 1 (A) on crankshaft gear, timing mark 22 (BB) is aligned with timing mark 2 (B) on camshaft gear, and timing mark 33 (CC) is aligned with timing mark 3 (C) on injector pump gear, as shown in Fig. 18. a. Install oil pump gear.
CRANKSHAFT KEY 12 OCLOCK
Fig. 18 Aligning Timing Marks Typical
6. Torque screws as shown, Fig. 19. a. Camshaft Gear: 41.0 Nm (30 ft. lbs.) b. Idler Gear: 25.0 Nm (220 in. lbs.) c. Injector Pump Gear: 61.0 Nm (45 ft. lbs.) d. Oil Pump Gear: 19.0 Nm (170 in. lbs.)
Fig. 19 Torque Screws
7. Install timing gear cover with new gasket. Note position, length and number of screws as shown, Fig. 20. a. M6 x 55 mm (M6 x 2.5): 3 b. M6 x 45 mm (M6 x 2.1): 2 c. M6 x 30 mm (M6 x 1.1): 9 d. M6 nut: 2 Torque screws and nuts to 8.0 Nm (70 in. lbs.).
A A
Fig. 20 Installing Timing Gear Cover

8. Install crankshaft pulley with timing mark at 12 oclock position (#1 cylinder), Fig. 21. NOTE: Be sure alignment pin in crankshaft gear is seated in hole in pulley. a. Torque screw to 88.0 Nm (65 ft. lbs.). b. Remove flywheel holder.
Fig. 21 Installing Crankshaft Pulley
9. Install oil pick-up tube and strainer with new gasket. Torque to 8.0 Nm (70 in. lbs.). a. Apply a small bead of Permatex No. 2 or similar sealant to crankcase areas shown, Fig. 22. b. Install oil pan with new gasket. c. Torque screws and nuts to 8.0 Nm (70 in. lbs.).
SEALANT
Fig. 22 Installing Oil Pan
10. Install glow plugs, wiring and fuel delivery lines. a. Torque glow plugs to 17.0 Nm (150 in. lbs.). b. Torque fuel delivery lines to 25.0 Nm (220 in. lbs.), Fig. 23. 11. Install V-belt and fan (if equipped).
Fig. 23 Installing Fuel Delivery Lines
Section 4 Flywheel and Rear Seal Retainer

Section Contents Page REMOVING OIL PAN AND FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REMOVING REAR SEAL RETAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REPLACING OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INSTALLING REAR SEAL RETAINER AND FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INSTALL OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVING PAN AND FLYWHEEL

Drain oil from engine. 1. Remove oil pan screws and nuts. Remove oil pan and discard gasket Fig. 1.
2. Install flywheel holder, Tool #19418 a. Remove flywheel screws and flywheel, Fig. 2. Inspect flywheel for cracks or damage. Inspect flywheel ring gear for worn, chipped or cracked teeth. If ring gear is worn or damaged the flywheel must be replaced.
FLYWHEEL HOLDER
Fig. 2 Removing Flywheel
MAY 2002
FLYWHEEL AND REAR SEAL RETAINER REMOVE REAR SEAL RETAINER

Remove rear seal retainer and discard gasket, Fig. 3.
Fig. 3 Removing Seal Retainer
REPLACING OIL SEAL

1. Remove oil seal, Fig. 4.
Fig. 4 Removing Oil Seal
2. Lubricate outside diameter of oil seal. a. Using seal driver, Tool #19424 install new oil seal, Fig. 5.
Fig. 5 Installing Oil Seal
INSTALLING REAR SEAL RETAINER AND FLYWHEEL

1. Install rear seal retainer with new gasket, Fig. 6. a. Torque screws to 6.0 Nm (50 in. lbs.).
RETAINER
GASKET
Fig. 6 Installing Seal Retainer
FLYWHEEL AND REAR SEAL RETAINER

2. Install flywheel, Fig. 7. NOTE: Apply Permatex No. 2 or similar sealant to flywheel screws. a. Torque flywheel screws to 47.0 Nm (35 ft. lbs.). Remove flywheel holder.
Fig. 7 Installing Flywheel
INSTALL OIL PAN

1. Install oil pan with new gasket, Fig. 8. a. Apply a small bead of Permatex No. 2 or similar sealant to crankcase areas shown. b. Torque screws and nuts to 8.0 Nm (70 in. lbs.).
SEALANT
Section 5 Cylinder Block Disassembly

Section Contents Page ENGINE STAND FIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CYLINDER BLOCK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAY 2002
CYLINDER BLOCK DISASSEMBLY
ENGINE STAND
An automotive type engine stand is recommended when complete engine disassembly is required. See drawings below for dimensions to make an engine stand mounting fixture. The engine stand shown below is manufactured by Snap-On.
215 mm 65 mm 8-3/8 HOLES
80 mm
60 mm 65 mm 45 mm
45 mm
50 mm 107 mm
57 mm
39 mm
Mounting Plate
1/2 THICK
THRU HOLE 21/32 2 THRU HOLES 13/32
5/8
13
1-1/2 1-1/2 DIA.
Engine Stand Fixture
CYLINDER BLOCK DISASSEMBLY CYLINDER BLOCK DISASSEMBLY

1. Remove cylinder head. See Sec. 2. 2. Remove oil pan, oil pick up tube, timing cover, gears and gear case. See Sec. 3. 3. Remove flywheel and rear seal retainer. See Sec. 4. 4. Remove starter motor, Fig. 1.
STARTER MOTOR
Fig. 1 Removing Starter And Bracket
5. Remove alternator bracket and alternator, Fig. 2.

ALTERNATOR BRACKET
Fig. 2 Removing Alternator
6. Remove valve lifters, Fig. 3. a. Number lifters so that they may be re-installed in the same position.
VALVE LIFTER
Fig. 3 Removing Valve Lifters
7. Remove camshaft, Fig. 4. NOTE: Use care when removing camshaft to prevent damaging cam bearing, journals and lobes.
CAMSHAFT
Fig. 4 Removing Camshaft
CYLINDER BLOCK DISASSEMBLY

8. Remove connecting rod and piston assemblies, Fig. 5. NOTE: Remove carbon or ridge from cylinder and number connecting rod/piston assemblies before removing from cylinders. a. Remove connecting rod cap with lower bearing. b. Push connecting rod and piston out through top of cylinder. c. Reassemble connecting rod cap to connecting rod to prevent interchanging components.
Fig. 5 Removing Connecting Rod Assembly
9. Remove crankshaft main bearing caps, keeping main bearings with their respective caps, Fig. 6. NOTE: Main bearing caps are numbered 1 through 4.
Fig. 6 Removing Main Bearing Caps
10. Remove crankshaft, Fig. 7. a. Remove crankshaft thrust washers (#3 main bearing). b. Remove upper main bearings from saddles and place with respective bearing caps.
SHIMS #3 MAIN BEARING
Fig. 7 Removing Crankshaft
Section 6 Cylinder Block Inspection and Repair

Section Contents Page CHECKING CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REPLACING CAMSHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REPLACING CAMSHAFT PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKING CYLINDER BLOCK

Remove all traces of sealant and gasket material from mounting surfaces. Inspect cylinder block for damage, cracks and stripped threads. Inspect cylinder bores for damage or scores. 1. Check cylinder block deck for distortion, Fig. 1. Distortion Limit: 0.08 mm (.003)
Fig. 1 Checking Cylinder Block
2. If cylinder block exceeds limit shown, it may be resurfaced, Fig. 2. Cylinder Block Height Model Series 430000 Std: 229.20-229.80 mm (9.023-9.047) Minimum Dimension: 229.10 mm (9.019) (After Resurfacing) Model Series 520000 & 580000 Std: 238.70-239.30 mm (9.397-9.421) Minimum Dimension: 238.60 mm (9.3937) (After Resurfacing)
Fig. 2 Cylinder Block Height
MAY 2002
CYLINDER BLOCK INSPECTION AND REPAIR

3. Check cylinder bores for wear, Fig. 3. Standard Bore Size: Model Series 430000 & 520000: 68.00-68.030 mm (2.6770-2.6783) Model Series 580000: 72.00-72.030 mm (2.8346-2.8358) a. Measure cylinder bore in 6 points at right angles as shown, Fig. 3. b. If cylinder bore is worn more than 0.075 mm (.003) or more than 0.035 mm (.0015) out of round, it must be resized. Always resize to exactly .25 mm (.010) over standard bore size. If this is done accurately, the service oversize rings and pistons will fit perfectly and proper clearances will be maintained. 4. Check valve lifter bore, Fig. 4. Std. Dimension: 18.018 mm (.7094) Reject: 18.05 mm (.711) 5. Check valve lifter, Fig. 4. Std. Dimension: 17.98 mm (.708) Reject: 17.91 mm (.7051)
MEASURE CYLINDER BORE IN SIX POSITIONS SHOWN TO DETERMINE TAPER & OUT OF ROUND.
TOP OF RING TRAVEL (BELOW RIDGE) CENTER OF RING TRAVEL AREA OF NORMAL WEAR BOTTOM OF RING TRAVEL
Fig. 3 Checking Cylinder Bore
Fig. 4 Checking Valve Lifter And Bore
6. Check camshaft bearing, Fig. 5. Replace if greater than 36.06 mm (1.420).
Fig. 5 Checking Cam Bearing
REPLACING CAMSHAFT BEARING

1. Remove camshaft bearing, Fig. 6. a. Use camshaft bearing puller, Tool #19421.
Fig. 6 Removing Cam Bearing

2. Install camshaft bearing, Fig. 7. a. Use camshaft bearing driver, Tool #19422. NOTE: Notch on camshaft bearing must face out. Be sure oil hole in bearing is aligned with oil hole in cylinder block.
Fig. 7 Installing Cam Bearing
REPLACING CAMSHAFT PLUG

1. Remove rear camshaft plug, Fig. 8. a. Use a wood dowel or brass rod to prevent damage to camshaft bearing.
Fig. 8 Removing Camshaft Plug
2. Install new camshaft plug using camshaft bearing driver, Tool #19422. a. Install camshaft plug flush with cylinder block, Fig. 9.
Fig. 9 Installing Camshaft Plug
If cylinder block is being resized, the following parts should be removed so that cylinder block may be thoroughly cleaned. 1. Remove oil pressure switch, water gallery plug and oil filter adapter, Fig. 10.
PLUG
ADAPTER
SWITCH
Fig. 10 Removing Oil Pressure Switch

2. Remove timing gear oil nozzle, Fig. 11.
OIL NOZZLE
Fig. 11 Removing Oil Nozzle
3. When re-installing oil nozzle, oil hole must be positioned at 45"angle, pointing towards idler gear, Fig. 12.
IDLER GEAR
Fig. 12 Installing Oil Nozzle
Section 7 Crankshaft, Camshaft and Bearings

Section Contents
Page CHECKING CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CHECKING MAIN BEARING CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CHECKING CONNECTING ROD BEARING CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CHECKING CRANKSHAFT END PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CHECKING CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHECKING CRANKSHAFT
Inspect crankshaft journals for grooves or signs of scoring. If found, crankshaft must be re-ground or replaced. 1. Check the main bearing and crankpin journals for wear and taper, Fig. 1. Standard size: Main 41.976-42.000 mm (1.6526-1.6535) Crankpin 36.976-37.000 mm (1.4557-1.4567) Maximum out of round and taper: 0.02 mm (0.0008). If crankshaft journals are not within specification, the crankshaft may be re-ground and .25 mm (.010) undersize bearings installed. See illustrated parts list for part numbers. 2. Check the crankshaft for run-out at #3 main bearing journal, Fig. 2. Maximum Run-out: 0.06 mm (0.0024) a. If run-out exceeds specification shown, the crankshaft must be replaced.
Fig. 1 Checking Journals
Fig. 2 Checking Run-out
MAY 2002
CRANKSHAFT, CAMSHAFT AND BEARINGS

3. Check crankshaft timing gear teeth for damaged teeth, Fig. 3. NOTE: See Section 3 for procedure to check crankshaft timing gear for wear. If crankshaft timing gear teeth are damaged or worn, the crankshaft must be replaced.
Fig. 3 Checking Timing Gear
CHECKING MAIN BEARING CLEARANCES

If main bearings show signs of flaking or scoring, bearings must be replaced. Main bearing saddles in cylinder block, main bearing caps, main bearings and crankshaft journals must be clean and free of oil. 1. With upper main bearings installed, install crankshaft. a. Lay a strip of plastigage lengthwise on journal, Fig. 4. Do not lay plastigage across oil hole in crankshaft journal. 2. Assemble main bearing cap with bearing and torque to 58.3 Nm (43 ft. lbs.), Fig. 5. DO NOT ALLOW CRANKSHAFT TO ROTATE.
PLASTIGAGE
Fig. 4 Install Plastigage
Fig. 5 Torque Bearing Cap
3. Remove the bearing cap. Measure the plastigage at its widest point, Fig. 6. If the clearance is not within specification, replace the bearings. Crankshaft Main Bearing Clearance: STD: 0.020-0.044 mm (0.0008-0.0017) Reject: 0.07 mm (0.0028) Repeat procedure for each main bearing.
Fig. 6 Measure Clearance
CRANKSHAFT, CAMSHAFT AND BEARINGS CHECKING CONNECTING ROD BEARING CLEARANCES

If connecting rod bearings show signs of flaking or scoring, bearings must be replaced. Connecting rod bearings and crankpin journals must be clean and free of oil. 1. With upper bearing assembled to connecting rod, install connecting rod. a. Lay a strip of plastigage lengthwise on journal, Fig. 7. Do not lay plastigage across oil hole in crankpin journal. 2. Assemble connecting rod cap with bearing and torque to 36.0 Nm (320 in. lbs.), Fig. 8. DO NOT ALLOW CRANKSHAFT TO ROTATE.
PLASTIGAGE
Fig. 7 Install Plastigage
Fig. 8 Torque Rod Cap
3. Remove the connecting rod cap. Measure the plastigage at its widest point, Fig. 9. If the clearance is not within specification, replace the bearings. Connecting Rod Bearing Clearance: STD: 0.020-0.044 mm (0.0008-0.0017) Reject: 0.07 mm (0.0028) Repeat procedure for each connecting rod.
Fig. 9 Measure Clearance
CHECKING CRANKSHAFT END PLAY

With thrust washers installed, check crankshaft end play at #3 main bearing as shown, Fig. 10. Crankshaft End Play: STD: 0.020-0.24 mm (0.0008-0.0094) Limit: 0.30 mm (0.012) If end play exceeds limit, .125 mm (.005) over size thrust washers are available. See illustrated parts list.
Fig. 10 Checking Crankshaft End Play
CRANKSHAFT, CAMSHAFT AND BEARINGS CHECKING CAMSHAFT

1. Measure camshaft lobe height, Fig. 11. If lobes are not to specification, replace the camshaft. Intake and Exhaust: STD: 30.065-30.135 mm (1.184-1.186) Reject: 29.965 mm (1.18)
Fig. 11 Checking Camshaft Lobes
2. Measure camshaft journals, Fig. 12. STD: Front 35.959-35.975 mm (1.4157-1.4163) Reject: 35.890 mm (1.413) STD: Center 35.910-35.955 mm (1.4138-1.4155) Reject: 35.84 mm (1.411) STD: Rear 35.910-35.955 mm (1.4138-1.4155) Reject: 35.84 mm (1.411)
Fig. 12 Checking Camshaft Journals
3. Measure camshaft run-out, Fig. 13. Maximum Run-out: 0.03 mm (0.0012). a. If run-out exceeds specification shown, the camshaft must be replaced.
Fig. 13 Checking Run-out
Section 8 Piston, Rings and Connecting Rod Inspection and Assembly

Section Contents Page DISASSEMBLE PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CHECKING PISTON AND RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CHECKING PISTON PIN AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ASSEMBLE PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ASSEMBLE PISTON RINGS TO PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISASSEMBLE PISTON AND CONNECTING ROD

1. Remove compression rings and oil ring using ring expander, Tool #19340, Fig. 1. a. Then remove coil expander.
PISTON
Fig. 1 Removing Piston Rings
2. Disassemble piston from connecting rod, Fig. 2. a. Remove piston pin retainers. b. Piston pin is a slip fit.
Fig. 2 Disassembling Piston/Connecting Rod
MAY 2002
PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY CHECKING PISTON AND RINGS
If the cylinder bore is to be resized there is no reason to check the piston as a new oversized piston will be used. If the cylinder is not going to be resized and the piston shows no signs of scoring, the piston should be checked. 1. Check side clearance of ring grooves using NEW rings, Fig. 3. If a 0.12 mm (0.005) feeler gauge can be inserted, the ring groove is worn. The piston must be replaced.
NEW PISTON RING
Fig. 3 Checking Ring Grooves
2. Check ring end gap, Fig. 4. a. Clean carbon from end of rings and using the piston, insert approximately 100 mm (3.9) into cylinder (below ring travel). Ring End Gap Reject Size Compression Rings 0.70 mm (0.028) Oil Ring 0.70 mm (0.028)
CHECK END GAP BELOW RING TRAVEL
Fig. 4 Checking End Gap
3. Check piston pin bore, Fig. 5. Engine Models: 432447, 522447, 582447 a. Replace if greater than 18.03 mm (0.710) or .01 mm (.0004) out of round. Engine Models: 58A447, 588447 b. Replace if greater than 21.03 mm (0.828) or .01 mm (.0004) out of round.
Fig. 5 Checking Piston Pin Bore
CHECKING PISTON PIN AND CONNECTING ROD

1. Check piston pin, Fig. 6. Engine Models: 432447, 522447, 582447 a. Replace if less than 17.98 mm (0.708) or .01 mm (.0004) out of round. Engine Models: 58A447, 588447 b. Replace if less than 20.98 mm (0.826) or .01 mm (.0004) out of round.
Fig. 6 Checking Piston Pin
PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY

2. Check piston pin bearing, Fig. 7. Engine Models: 432447, 522447, 582447 a. Replace if greater than 18.03 mm (0.710) or .01 mm (.0004) out of round. Engine Models: 58A447, 588447 b. Replace if greater than 21.03 mm (0.828) or .01 mm (.0004) out of round.
Fig. 7 Checking Piston Pin Bearing
3. Check crankpin bearing end of connecting rod for out of round, Fig. 8. a. With bearing inserts removed, assemble connecting rod cap and torque to 36.0 Nm (320 in. lbs.). Maximum out of round: 0.02 mm (0.0008) b. If out of round exceeds specification shown, the connecting rod must be replaced.
Fig. 8 Checking Crankpin Bearing End
4. Check for bent or twisted connecting rod, Fig. 9. NOTE: Thrust faces must be free of any burrs or nicks or connecting rod will not lay flat on surface plate. a. With connecting rod on a surface plate, any distortion will be evident by a rocking motion. b. If a 0.05 mm (0.002) feeler gauge can be inserted at piston pin end of connecting rod the rod must be replaced.
Fig. 9 Checking Connecting Rod
ASSEMBLE PISTON AND CONNECTING ROD

Assemble piston to connecting rod, Fig. 10. NOTE: Arrow on piston and ID mark on rod must face same side. 1. Lubricate piston pin with engine oil before assembly. a. Be sure retainers are seated properly in piston.
ID MARK
Fig. 10 Assembling Piston And Rod
PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY ASSEMBLE PISTON RINGS TO PISTON
1. Install piston rings using ring expander, Tool #19340, Fig. 11. a. Install oil ring coil expander making sure wire is inserted fully into coil. b. Install oil ring. c. Install center compression ring then, top compression ring with ID marks up.
WIRE
ID MARK
TOP ID MARK CENTER
OIL COIL EXPANDER
Fig. 11 Installing Piston Rings
2. Stagger ring end gaps as shown, Fig. 12.

OIL RING
TOP RING
SECOND RING
Fig. 12 Stagger Ring End Gaps
Section 9 Cylinder Block Assembly

Section Contents Page INSTALL CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INSTALL PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL ASSEMBLY Oil Pickup Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear Seal Retainer and Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTALL TIMING GEAR CASE, CAMSHAFT AND GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSTALL ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALL CRANKSHAFT
Install main bearings in cylinder block, Fig. 1. NOTE: Upper bearing has an oil groove and oil holes. 1. Install upper main bearings in their respective saddles. a. Be sure bearing is seated in saddle and tang in bearing is aligned with notch in saddle. b. Lubricate bearings with engine oil.
OIL HOLES
GROOVES
Fig. 1 Installing Upper Main Bearings
2. Install lower main bearings in bearing caps, Fig. 2. a. Be sure bearing is seated in bearing cap and tang in bearing is aligned with notch in bearing cap. b. Lubricate bearings with engine oil.
Fig. 2 Installing Lower Main Bearings
MAY 2002
CYLINDER BLOCK ASSEMBLY

3. Install crankshaft with gear facing front of cylinder block, Fig. 3. Take care not to damage journals or bearings. a. Install crankshaft shims on #3 main bearing web with grooves facing out. b. Lubricate journals with engine oil.
INSTALL SHIMS #3 MAIN BEARING
Fig. 3 Installing Crankshaft
4. Install main bearing caps, Fig. 4. Lubricate threads of screws with engine oil. a. Install bearing caps in their respective positions with arrows facing front. b. Starting with #3 bearing cap, torque bearing caps one at a time in sequence shown to 58.0 Nm (43 ft. lbs.). c. Recheck crankshaft end play. Crankshaft End Play: 0.025-0.24 mm (0.0008-0.0094) NOTE: After torquing bearing cap, make sure crankshaft rotates freely before proceeding to next bearing cap.
ARROW FRONT
#1
#2
#3
#4
FRONT
Fig. 4 Installing Main Bearing Caps
INSTALL PISTONS AND CONNECTING RODS

1. Install connecting rod bearings, Fig. 5. Be sure tang on bearing is seated in notch in connecting rod and cap. a. Install a piece of vinyl tubing over each connecting rod screw to prevent damage to screw threads or crankpin when installing piston and connecting rod.
ID MARK NOTCH
VINYL TUBING
Fig. 5 Installing Connecting Rod Bearings

Rotate crankshaft so that crankpin is at bottom of stroke. Then, lubricate cylinder walls, piston and rings, bearings and crankpins. 2. Using ring compressor, Tool #19070, install piston and connecting rod assemblies with arrow on piston facing front, Fig. 6. a. Install connecting rod cap with ID mark facing front. Lubricate threads and torque nuts to 34.0 Nm (320 in. lbs.). NOTE: After torquing rod cap, make sure crankshaft rotates freely before proceeding to next cylinder.
FRONT
ID MARK
Fig. 6 Installing Piston And Connecting Rod
GENERAL ASSEMBLY
1. Install gasket, oil pick-up tube and strainer, Fig. 7. a. Torque screws to 8.0 Nm (70 in. lbs.).
Fig. 7 Installing Oil Pick-Up
2. Install gasket and rear seal retainer, Fig. 8. a. Torque screws to 6.0 Nm (50 in. lbs.). 3. Install starter motor. a. Torque screws to 34.0 Nm (25 ft. lbs.).
REAR SEAL RETAINER
Fig. 8 Installing Rear Seal Retainer
4. Install flywheel, Fig. 9. a. Install flywheel holder, Tool #19418. b. Apply Permatex No. 2 or similar sealant to flywheel screws and torque to 47.0 Nm (35 ft. lbs.).
FLYWHEEL HOLDER
Fig. 9 Installing Flywheel
CYLINDER BLOCK ASSEMBLY INSTALL TIMING GEAR CASE, CAMSHAFT AND GEARS
1. Lubricate oil pump rotor with engine oil and install in cylinder block, Fig. 10. a. ID mark on rotor must face cylinder block.
ID MARK
OIL PUMP ROTOR
2. Install timing gear case with new gasket. NOTE: It may be necessary to rotate oil pump drive to engage oil pump rotors. Note position, length and number of screws as shown, Fig. 11. a. M6 x 28 mm (M6 x 1.1): 4 b. M6 x 16 mm (M6 x .6): 1 Torque screws to 8.0 Nm (70 in. lbs.).
B
Fig. 11 Installing Gear Case
3. Lubricate, then install camshaft in cylinder block, Fig. 12. Take care not to damage lobes or cam bearing. a. Install camshaft retainer. b. M6 x 18 mm (M6 x 0.7): 3 Torque screws to 8.0 Nm (70 in. lbs.). NOTE: Position camshaft retainer so that center hole does not interfere with camshaft.
RETAINER
Fig. 12 Installing Camshaft
4. Rotate crankshaft so that crankshaft key is at 12 oclock position as shown in Fig. 13.
Fig. 13 Rotate Crankshaft

5. Assemble injector pump to gear case with new O-ring and install nuts and support bracket screw finger tight, Fig. 14. NOTE: Pump must be able to rotate a. Align timing mark on injection pump with timing mark on gear case. NOTE: See Section 10 for injector pump timing procedure.
TIMING MARKS
6. Assemble idler gear shaft with ID mark up, as shown in Fig. 15.
ID MARK UP
IDLER GEAR SHAFT
Fig. 15 Assemble Idler Gear Shaft
Engine models 432000 and 582000 after date code 990111007, and all engine models 522000 are equipped with right angle helical timing gears. Timing marks are identified by letters (A, AA, B, BB, etc.), instead of numbers. The timing procedure is the same. 7. With crankshaft key at 12 oclock position, assemble idler gear so that timing mark 11 (AA) is aligned with timing mark 1 (A) on crankshaft gear, timing mark 22 (BB) is aligned with timing mark 2 (B) on camshaft gear, and timing mark 33 (CC) is aligned with timing mark 3 (C) on injector pump gear, as shown in Fig. 16. a. Install oil pump gear. 8. Torque screws as shown, Fig. 17. a. b. c. d. Camshaft Gear: 41.0 Nm (30 ft. lbs.) Idler Gear: 25.0 Nm (220 in. lbs.) Injector Pump Gear: 61.0 Nm (45 ft. lbs.) Oil pump Gear: 19.0 Nm (170 in. lbs.)
Fig. 16 Aligning Timing Marks

C A

9. Install timing gear cover with new gasket. Note position, length and number of screws as shown, Fig. 18. a. b. c. d. M6 x 55 mm (M6 x 2.5): 3 M6 x 45 mm (M6 x 2.1): 2 M6 x 30 mm (M6 x 1.1): 9 M6 nut: 2
Torque screws and nuts to 8.0 Nm (70 in. lbs.).
A A
Fig. 18 Installing Timing Cover
FLYWHEEL HOLDER
Fig. 19 Installing Pulley
INSTALL ALTERNATOR
1. Install alternator bracket and alternator, Fig. 20. a. Torque screws to 19.0 Nm (170 in. lbs.).
Fig. 20 Install Alternator
GENERAL ASSEMBLY
1. Lubricate tappets with engine oil and install in cylinder block. 2. See Section 2 for installation of cylinder head and related components.
10
Section 10 Fuel System and Related Components

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FUEL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INJECTION PUMP TIMING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INJECTOR PUMP Checking Injector Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Adjusting Injector Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INJECTORS Remove Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Checking Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 FUEL FILTER GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Draining Water Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Change Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FUEL SHUT OFF SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Checking Fuel Shut-Off Solenoid Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INJECTOR PUMP IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ENGINE SPEED IDENTIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Adjust Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Adjust Top No Load Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
The fuel system consists of a gear driven injector pump with fuel delivery and return lines and injector nozzles for each cylinder. Diesel fuel is drawn from the fuel tank through the fuel filter by the feed pump which is incorporated in the injection pump and delivers fuel to the injectors at a constant volume regardless of pump RPM. The feed pump also circulates fuel through the pump for lubrication purposes. A single pump plunger meters and distributes fuel in the correct firing order through an injector nozzle in each combustion chamber. Excess fuel from the injector nozzles and pump is returned to the fuel tank by way of the overflow valve and return line. This system of fuel circulation lubricates and cools the injection pump and also warms the fuel in the fuel tank to help prevent fuel waxing in cold weather. CAUTION: Always use clean fresh diesel fuel with a minimum of 40 cetane. DO NOT use kerosene. The injection pump requires diesel fuel for lubrication. Damage to the injection pump and/or engine may result if kerosene is used. Servicing the fuel injection system requires highly specialized equipment and procedures. Consult the Yellow Pages under Engines-Diesel-Fuel Injection Service & Parts for the nearest diesel fuel injection specialist if the injector pump or injector nozzles require servicing. See Section 3 for procedure for removing and installing injector pump.
MAY 2002
10
FUEL SYSTEM COMPONENTS
FUEL INJECTION SYSTEM COMPONENTS

FUEL FILTER FUEL RETURN LINE
FUEL DELIVERY LINE INJECTOR PUMP
INJECTOR
FUEL RETURN LINE
FUEL LINE
FUEL TANK
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INJECTOR PUMP
TABLE 1 Injection Pump Timing Engine Date Code Before 99010100

Model/Type No. 432447-0150-E2 522447-0105-E2 522447-0106-E2 522447-0107-E2 522447-0108-E2 522447-0109-E2 582447-0105-E2 582447-0125-E2 582447-0130-E2 582447-0131-E2 Timing Specification 0.93 .03 mm (.0365 .001) 0.93 .03 mm (.0365 .001) 0.93 .03 mm (.0365 .001) 0.93 .03 mm (.0365 .001) 0.93 .03 mm (.0365 .001) 0.93 .03 mm (.0365 .001) 0.93 .03 mm (.0365 .001) 0.81 .03 mm (.032 .001) 0.93 .03 mm (.0365 .001) 0.81 .03 mm (.032 .001)
TABLE 2 Injection Pump Timing Engine Date Code After 98123100

Model Series 432447 All 522447 All 582447 All 58A447 All 588447 Timing Specification 0.90 .03 mm (.035 .001) 0.90 .03 mm (.035 .001) 0.81 .03 mm (.032 .001) 0.90 .03 mm (.035 .001)
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INJECTOR PUMP Checking Injector Pump Timing

NOTE: Clean areas around fuel lines and injectors to prevent any dirt from entering injector nozzles or delivery valve ports when fuel delivery lines are removed. 1. Remove fuel delivery lines from injector pump and injector nozzles, Fig. 1.
Fig. 1 Removing Fuel Lines
2. Set No. 1 piston at TDC: a. Rotate crankshaft until timing mark on pulley is aligned with reference point on timing cover, Fig. 2. b. If intake and exhaust valves have clearance, No. 1 piston is at TDC compression stroke. c. If intake and exhaust valves do not have clearance, turn crankshaft pulley one complete revolution. Valves will then have clearance.
REFERENCE POINT
TIMING MARK
Fig. 2 Align Timing Marks
3. Remove distributor head screw with washer and install injector pump timing gage,dial indicator Tool # 19441, Fig. 3.
DIAL INDICATOR TOOL #19441
Fig. 3 Install Timing Tool
4. Slowly rotate crankshaft counter-clockwise until dial indicator needle just stops moving. Set dial indicator at 0, Fig. 4. NOTE: When indicator needle just stops moving, carefully rock crankshaft clockwise slightly, then counter-clockwise slightly to verify absolute 0.
Fig. 4 Setting Indicator
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INJECTOR PUMP
5. Slowly rotate crankshaft clockwise until timing mark on pulley aligns with reference point on gear case cover (TDC), Fig. 5. Note dial indicator reading. NOTE: Do not rotate crankshaft past TDC. If crankshaft is rotated past TDC rotate crankshaft back to 0 and repeat procedure. 6. Refer to timing specification tables on page 3 for correct specification by engine model and type or code number. If indicator reading is within specification, injector pump is properly timed. Proceed to step 6. If indicator reading is not within specification, see procedure for adjusting injector pump timing. 7. Remove timing gage and install distributor screw with new washer, Fig. 6. a. Torque screw to 17.0 Nm (150 in. lbs.). 8. Install fuel delivery lines. a. Torque to 25.0 Nm (220 in. lbs.).
METRIC INDICATOR SHOWN
Fig. 5 Checking Timing
DISTRIBUTOR SCREW
Fig. 6 Install Distributor Screw
Adjusting Injector Pump Timing

Refer to timing specification tables on page 3 for correct specification by engine model and type or code number. 1. Loosen injector pump mounting nuts and pump support bracket screw, Fig. 7. Rotate pump toward cylinder head as far as it will go. NOTE: Loosen nuts and screw only enough to allow pump to be rotated with some resistance. Perform Steps 2 through 4 as described in Checking Injector Pump Timing.
Fig. 7 Loosen Pump
2. Slowly rotate crankshaft clockwise until timing mark on pulley aligns with reference point on gear case cover (TDC), Fig. 8. NOTE: Do not rotate crankshaft past TDC. If crankshaft is rotated past TDC rotate crankshaft back to 0 and repeat procedure.
REFERENCE POINT
TIMING MARK
Fig. 8 Align Timing Marks
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INJECTOR PUMP
3. While observing dial indicator, slowly rotate injector pump away from cylinder head until indicator shows correct specification. Hold injector pump in this position and tighten outside pump mounting nut, Fig. 9. NOTE: Do not rotate pump past specification. If pump is rotated past specification, rotate pump back toward cylinder head and repeat procedure.
OUTSIDE MOUNTING NUT
Fig. 9 Adjusting Timing
4. To verify that timing is correct, rotate crankshaft counter-clockwise until dial indicator reads 0. Then rotate crankshaft clockwise until timing mark on pulley aligns with reference point on gear case cover (TDC). Indicator should be within specification, Fig. 10. 5. Torque injector pump mounting nuts and pump support bracket screw to 19.0 Nm (170 in. lbs.).
METRIC INDICATOR SHOWN
Fig. 10 Verify Timing
6. Remove timing gage and install distributor screw with new washer, Fig. 11. a. Torque screw to 17.0 Nm (150 in. lbs.). 7. Install fuel delivery lines. a. Torque to 25.0 Nm (220 in. lbs.).
DISTRIBUTOR SCREW
Fig. 11 Installing Distributor Screw
INJECTORS Remove Injectors

NOTE: Use care to prevent any dirt from entering injector holes or delivery valve ports when fuel delivery lines are removed. 1. Remove fuel delivery lines, Fig. 12. 2. Disconnect fuel return line hose. 3. Remove nuts and fuel return line. a. Discard fuel return line gaskets.
Fig. 12 Removing Fuel Lines
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INJECTORS
4. Remove injector nozzles, Fig. 13. a. Discard injector gaskets. NOTE: Handle injectors with extreme care. Do not drop! Always use new fuel return line and injector nozzle gaskets when servicing fuel system.
Fig. 13 Removing Injectors
Checking Injectors
Fuel injector nozzle testing requires highly specialized equipment and procedures. Consult the Yellow Pages under Engines-Diesel-Fuel Injection Service & Parts for the nearest diesel fuel injection specialist. The procedures and specifications listed are provided as an aid to the fuel injection specialist when testing injector nozzles. 1. With injector installed on a nozzle tester, operate the handle rapidly several times to clean off any carbon deposits on the injector port, Fig. 14. 2. Check pop off pressure of injector. Specification: 135 145 Bar (1955 2100 psi)
Fig. 14 Checking Injector
If injector is not within specification, the injector shim may be changed, Fig. 15. Replacement shims are available in .025 mm increments from .7 to 1.95 mm. NOTE: As the shim thickness increases or decreases by .025 mm, injection pressure will vary about 5 Bar (71 psi). Torque nozzle holder and injector body to 47.0 Nm (35 ft. lbs.).
SHIM
Fig. 15 Injector Shim
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INJECTORS
3. Check injector for leakage, Fig. 16. Maintain injector pressure at approximately 120 Bar (1707 psi), for about 10 seconds. Make sure there is no leakage from nozzle or retaining nut area.
Fig. 16 Checking Leakage
4. Check spray pattern of nozzle, Fig. 17. Operate tester handle rapidly while observing pattern. Spray pattern should be uniform and centered under nozzle. NOTE: A buzzing or chattering sound should also occur while operating handle. Nozzle should not drip between pump strokes.
Fig. 17 Checking Spray Pattern
Install Injectors
Install injectors and fuel return line with new gaskets, Fig. 18. Install fuel delivery lines. a. Torque injectors to 61.0 Nm (45 ft. lbs.). b. Torque fuel return line to 27.0 Nm (20 ft. lbs.). c. Torque fuel delivery lines to 25.0 Nm (220 in. lbs.).
Fig. 18 Installing Injectors
FUEL FILTER GENERAL

The fuel filter consists of a replaceable cartridge type filter with a water level sensor and priming pump, Fig. 19. Replace fuel filter cartridge every 800 hours of engine operation. The water collector contains a float type sensor that activates a warning lamp when it collects a minimum of 80 ccs (2.5 fl. oz.) of water.
PRIMER BUTTON
O-RING
VENT PLUG
FLOAT
DRAIN PLUG
FILTER
Fig. 19 Fuel Filter
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FUEL FILTER Draining Water Collector

When warning lamp comes on, drain water collector as follows: 1. Stop engine. 2. Place a drain pan under filter and loosen vent plug. 3. Loosen drain plug approximately 1 turn and drain water from filter until only fuel flows from filter. 4. Tighten drain plug and vent plug and wipe up any spills. 5. Start engine, making sure warning lamp goes out. Check for leaks.
Change Fuel Filter

1. Disconnect sensor wire and remove drain plug. Discard O-ring. 2. Remove fuel filter with a filter wrench. 3. Screw new filter on by hand until gasket contacts housing. Then tighten 1/3 turn more. 4. Install drain plug with new O-ring and connect sensor wire. 5. Activate primer button until resistance is felt. 6. Start engine and check for leaks.
Checking Float Sensor

The following test will be made with the meter in the Diode Test Position . Disconnect sensor wire from equipment harness and remove float sensor from fuel filter. 1. Attach a meter test lead to each terminal in connector. 2. While holding drain plug in vertical position, raise float to end of travel, Fig. 20. a. Meter should make a continuous tone. 3. Now lower float a. Meter should display OL. Replace drain plug and float sensor if not to specification.
Fig. 20 Checking Sensor
FLOAT
FUEL SHUT-OFF SOLENOID

When the ignition switch is turned to the On and Start position the fuel shut off solenoid valve opens allowing fuel to enter the fill port and pressure chamber. When the keyswitch is turned Off the solenoid closes shutting off the the fuel supply and the engine, Fig. 21. Solenoid is operating if a click is heard when keyswitch is turned On and Off. If solenoid does not click, problem may be in equipment wiring to solenoid.
Fig. 21 Fuel Shut-Off Solenoid
EQUIPMENT WIRING HARNESS CONNECTOR FUEL SHUT-OFF SOLENOID
Checking Fuel Shut-Off Solenoid Wiring

The following test will be made with the meter in the (DC Volts position). Turn keyswitch to Off position and disconnect equipment solenoid wire. 1. Attach BLACK meter test lead to a good ground. 2. Attach RED meter test lead to connector in equipment solenoid wire and turn keyswitch to On position. 3. Meter should display battery voltage, Fig. 22. a. If meter does not display battery voltage, check for broken solenoid wire, blown fuse (if equipped) or defective keyswitch.
Fig. 22 Testing Solenoid Wiring
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INJECTOR PUMP IDENTIFICATION
IDENTIFICATION CODE
NAME PLATE
7 : 700 cc 8 : 850 cc 9 : 950 cc
DESTINATION U : USA J : Japan X : Except for USA
SERIAL NUMBER
IDENTIFICATION CODE
TABLE 3 Engine Speed Specification Chart

Pump Mfg. Part No.
22100-87801 22100-8713
ID Code
7U1 7U2
Model & Type No.

432447-0105-E2 432447-0205-E2 582447-0105-E2 582447-0205-E2
Idle Speed (rpm)

120050 120050 120050 120050 160050 175050 105050 120050 185050 170050 120050 160050 185050 185050 152550 154050 154050 120050 120050 180050 160050 105050
Top No Load (rpm)

385050 385050 385050 330050 360050 360050 385050 340050 342050 360050 385050 335050 342050 342050 277550 279050 279050 385050 385050 360050 360050 385050
22100 87802 22100-87802
9U1
582447-0130-E2 582447-0230-E2 582447-0219-E2 582447-0222E2 582447-0221-E2 582447-0225-E2 582447-0232-E2 582447-0125-E2
22100-87806 22100-87807 22100 87807 22100-87809 22100 87809 22100-87810 22100-87815 22100-87817 22100-87811 22100-87818
9U2 8U1 8U2 8U3 8U4 8U5 9U4 9U5
582447-0131-E2 582447-0231-E2 522447-0105-E2 522447-0108-E2 522447-0106-E2 522447-0109-E2 522447-0107-E2 522447-0107-E2 5224470107E2 58A4470205E2 5884470205E2 5884470216E2 5884470230E2 5884470225E2
10
10
ENGINE SPEED ADJUST IDLE SPEED

Engine should be at operating temperature before adjusting idle speed. Make sure speed control lever contacts idle speed screw with engine at idle. 1. Loosen idle speed screw lock nut and adjust idle speed screw to obtain RPM specified by model and type number shown in chart, Fig. 23. NOTE: Do exceed RPM shown for specific model and type number. a. Torque lock nut to 6.0 Nm (50 in. lbs.).
IDLE SPEED SCREW
LOCK NUT
SPEED CONTROL LEVER
ADJUST TOP NO LOAD SPEED

Engine should be at operating temperature before adjusting idle speed. Temporarily disconnect speed control wire at control bracket on pump. 1. Remove and discard top no load wire and seal. 2. Loosen top no load speed screw lock nut. 3. Move speed control lever to FAST position and adjust top no load speed screw to RPM specified by model and type number shown in chart, Fig. 24. NOTE: Do exceed RPM shown for specific model and type number. 4. Stop engine and torque lock nut to 6.0 Nm (50 in. lbs.). 5. Reassemble speed control wire at bracket. a. Tighten screws securely. b. Make sure speed control lever contacts top no load screw when throttle lever is in FAST position.
TOP NO LOAD SPEED SCREW LOCK NUT
Fig. 23 Adjusting Idle Speed

SPEED CONTROL LEVER
Fig. 24 Adjusting Top No Load Speed
11
11
Section 11 Electrical System

ELECTRICAL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GLOW PLUG SYSTEM Glow Plug Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Testing Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PREHEAT TIMER AND GLOW RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Testing Preheat Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Testing Glow Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 KEYSWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 14 AMP CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Testing Alternator AC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Testing Regulator-rectifier DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Charging Indicator Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Testing Charging Indicator Bulb And Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 40 AMP CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Testing Alternator DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Checking Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Checking Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Check Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Check Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Check Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assemble Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
MAY 2002
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Section Contents (Continued) Page
STARTER SYSTEM GENERAL INFORMATION STARTER CURRENT DRAW TEST INSTALLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER CURRENT DRAW TEST NO LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Starter (No Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER SOLENOID Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Pinion And Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Pinion And Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assemble Pinion And Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install Solenoid Contacts And Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect Armature Commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAMS 14 AMP WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 AMP WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 17 18 18 18 19 19 20 20 21 21 22 22 24 24 24 25 26 27 28
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Electrical System Components

(Typical 40 Amp Alternator Shown)
FUEL FILTER
INJECTION PUMP
WATER INDICATOR LIGHT PREHEATING TIMER
1 2 3 4
KEYSWITCH PART NO. 493625
3 4
7 8 5
GLOW RELAY
1 6
GLOW LIGHT SOLENOID GLOW PLUGS
KEYSWITCH TERMINAL FUNCTION 2 4 5 ACCESSORY & PREHEAT TIMER SOLENOID & PREHEAT TIMER BATTERY
STARTER MOTOR IG TERMINAL CHARGE INDICATOR LIGHT
NOTE: TERMINALS 1, 3, 6 NOT USED
L TERMINAL
B TERMINAL
40 AMP ALTERNATOR
12 VOLT BATTERY
B TERMINAL
IG TERMINAL L TERMINAL
Fig. 1
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GLOW PLUG SYSTEM Glow Plug

The glow plug is a self regulating type, consisting of two metal heating element coils; a rush coil and a brake coil, Fig. 2. The rush coil provides rapid heating of the tip of the glow plug. The brake coil decreases current to the glow plug by increasing resistance as the temperature rises, regulating the temperature of the glow plug.
RUSH COIL
BRAKE COIL
Glow Plug Specifications Rated Voltage Rated Current Normal Resistance 11V 9.5A 1.0
Fig. 2 Glow Plug
Remove Glow Plug

Disconnect glow plug wiring from connector. 1. Remove glow plug connector nuts and connector. 2. Remove glow plugs, Fig. 3. Handle glow plugs with care. Do not drop. Do not scratch heater section.
Test Equipment
The digital multimeter, Tool #19390 is required to test the glow plug.
Fig. 3 Removing Glow Plugs
Testing Glow Plug

With meter selector switch in position, a continuous tone indicates continuity (complete circuit). No tone indicates no continuity (incomplete circuit). An incomplete circuit will be displayed as OL. 1. Check glow plug for continuity as shown, Fig. 4. a. If meter indicates NO continuity, replace glow plug.
Fig. 4 Testing Glow Plugs
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GLOW PLUG SYSTEM PREHEAT TIMER AND GLOW RELAY

The preheat timer and glow relay regulate current to the glow plugs for preheating and starting. When the keyswitch is turned to the On position, with the engine cold, the preheat timer activates the glow plugs. An indicator light lights and remains on while the glow plugs are preheating the combustion chamber. When the indicator light goes out, the engine may be started. When the keyswitch is in the Start position, the glow plugs and light are activated again as the engine is cranking. See Fig. 5 for terminal positions of the preheat timer and glow relay.
1 2 3 4
PREHEAT TIMER
7 8
GLOW RELAY
6 5
Fig. 5 Terminal Positions
Testing Preheat Timer

The following test will be made with the meter in the (DC Volts position), Fig. 6. Turn keyswitch to Off position. 1. Insert BLACK meter test lead probe into terminal #4. 2. Insert RED meter test lead probe into terminal #3. 3. Turn keyswitch to On position. a. Glow light should light. Meter should display 1.5 volts maximum. b. After 5 seconds (approximately), glow light should go out. Meter should display approximately battery voltage. 4. Replace preheat timer if not to specification. NOTE: If glow light does not light, replace bulb.
2 3 4
Fig. 6 Testing Preheat Timer
Testing Glow Relay

The following test will be made with the meter in the (DC Volts position), Fig. 7. Turn keyswitch to Off position. 1. Insert BLACK meter test lead probe into terminal #8. 2. Insert RED meter test lead probe into terminal #7. a. Meter should display battery voltage. 3. Turn keyswitch to On position. a. Glow light should light. Meter should display 0.5 volts maximum. b. After 5 seconds (approximately), glow light should go out. Meter should display approximate battery voltage. 4. Replace glow relay if not to specification.
Fig. 7 Testing Glow Relay
7 8 6 5
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GLOW PLUG SYSTEM KEYSWITCHES

Two types of keyswitches may be used on Briggs & Stratton Daihatsu diesel engines.
1+3+6 OFF
2+5 ON START 2 + 4 +5
Fixed Timer Preheat Keyswitch Part No. 493625

Keyswitch, Part No. 493625, is used with a preheat timer and glow relay, Fig. 8. With the keyswitch in the On and Start position, battery current is supplied to the preheat timer and glow relay. See keyswitch terminal positions and functions, Fig. 8. See Fig. 78 and Fig. 79 at end of section, for wiring diagrams for keyswitch No. 493625.
NOT USED ON
2 3 4 1 6 5 1 6 5
START
2 3 4
Test switch terminals for continuity with keyswitch in positions shown

2 4 5 Accessory & Preheat Timer Solenoid & Preheat Timer Battery NOTE: Terminals 1, 3, 6 Not Used
Fig. 8 Keyswitch Fixed Timer Preheat
Manual Preheat Keyswitch Part No. 825129

The manual preheat keyswitch, Part No. 825129, is equipped with four positions and six terminals, Fig. 9. The G1 terminal provides current to the glow plugs only when the switch is in the Heat position. When the keyswitch is turned to the Start position the G2 terminal provides current to the glow plugs while the engine is cranking. See keyswitch terminal positions and functions, Fig. 10. Symbols are shown as they appear on rear of keyswitch. Note that B terminal is connected to terminal below it, Fig. 10. Keyswitch will not function without connector. HEAT B S G2 B
Connector
B+B B+B+G1 HEAT OFF ON START B+B+S+M+G2 B+B+M
Fig. 9 Keyswitch Manual Preheat
See Fig. 80 and Fig. 81 for wiring diagrams for keyswitch No. 825129.
OFF G1 B S G2 B M
B+B
ON G1 B S G2 B M
B+B+M B S
START G1 B S G2 B M G1
M
B+B+G1
B+B+S+M+G2 Battery (2) Solenoid Glow Plug (Preheat) Glow Plug (Cranking) Accessory
Test switch terminals for continuity with keyswitch in positions shown.
G1 G2 M
Fig. 10 Terminal Positions And Functions
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CHARGING SYSTEMS 14 AMP CHARGING SYSTEM

The 14 amp charging system consists of two components: 1. The belt driven permanent magnet alternator produces AC voltage, Fig. 11. AC output will vary with engine RPM, from approximately 7 volts AC at 1000 RPM to 32 volts AC at 3000 RPM. NOTE: A loose V-belt will cause low AC output. Belt deflection limit is 9.5-11.5 mm/10 kg. (3/8-7/16 in./22 lb.).
Fig. 11 14 Amp Alternator
2. The regulator-rectifier converts the AC current to DC and regulates current to the battery, Fig. 12. The charging rate will vary with engine RPM. The regulator-rectifier is equipped with a charging indicator light circuit. NOTE: The regulator-rectifier requires a minimum battery voltage of 6 volts to function. There will be no charging output if battery voltage is below 6 volts. Fig. 78 and Fig. 80 at end of section, show wiring diagrams for typical 14 amp charging system.
CHARGE INDICATOR LIGHT
Fig. 12 Regulator-rectifier
Test Equipment
The digital multimeter, Tool #19464 and the DC shunt, Tool #19468, Fig. 13, are required to test the charging system. NOTE: The digital multimeter will withstand DC input of 10-20 amps for up to 30 seconds. To avoid blowing fuse in meter, the DC shunt is required. Replacement fuse is available from your Briggs & Stratton source of supply. Order Part No. 19449.
19464 19468
Fig. 13 Test Equipment
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CHARGING SYSTEMS Testing Alternator AC Output

The alternator output test will be performed with the meter in the V~ (AC volts) position, Fig. 14. Disconnect alternator wires at connector. Attach meter test leads to alternator output connectors BEFORE starting engine, Fig. 14. 1. With the engine running at 3300 RPM the output should be no less than 28 volts AC. a. If no output or low output is found, replace alternator. b. If alternator output is within specification, reconnect alternator wires and test regulator rectifier.
Fig. 14 Testing Alternator Output

ATTACH NEGATIVE BATTERY CABLE BLACK LEAD
Testing Regulator-Rectifier DC Output

The DC Shunt must be installed on the negative (-) terminal of the battery, Fig. 15. All connections must be clean and tight for correct amperage readings. Attach meter test leads BEFORE starting engine. The regulator-rectifier test will be performed with the meter in the position. 1. Attach RED meter test lead to RED post terminal on shunt. 2. Attach BLACK meter test lead to BLACK post terminal on shunt.
RED LEAD
NEGATIVE BATTERY TERMINAL
Fig. 15 DC Shunt Installation
3. With the engine running at 3300 RPM, the output should be: * 4 14 Amps * Depending upon battery voltage and/or current draw on system. 4. If no or low output is found, be sure that regulatorrectifier is grounded properly and all connections are clean and secure. If there is still no or low output, replace the regulator-rectifier.
11
CHARGING SYSTEMS Charging Indicator Circuit

The green wire from the regulator-rectifier is used to activate the charging indicator light. With the keyswitch in the ON position and the engine not running the charge indicator light should light, Fig. 16. With the engine running the light should go out, indicating that the battery is being charged. If the charge indicator light does not light when the keyswitch is in the ON position (engine not running), check the bulb and wiring.
Fig. 16 Charge Indicator Light
Testing Charging Indicator Bulb And Wiring

The following test will be made with the meter in the Diode Test Position , Fig. 17. With meter selector switch in position, a continuous tone indicates continuity (complete circuit). No tone indicates no continuity (incomplete circuit). An incomplete circuit will be displayed as OL.
Fig. 17 Meter Setting
Keyswitch must be in OFF position. 1. Disconnect output harness at regulator-rectifier. 2. Check continuity between charging indicator wire (green) and ground, Fig. 18. a. If meter indicates continuity, bulb and wiring are OK. Replace regulator-rectifier. b. If meter indicates NO continuity, replace bulb and re-test. c. If meter indicates NO continuity with new bulb, the problem must be a broken wire (open circuit) in the charging indicator circuit. If the charge indicator light remains on with the engine running, test the regulator-rectifier DC output. If output is within specification and charge indicator light remains on, replace the regulator-rectifier.
HARNESS CONNECTOR
LIGHT BLUE GREEN
BLACK
LIGHT BLUE RED
YELLOW
WIRE COLOR AND TERMINAL POSITION GREEN-CHARGE LAMP WIRE
Fig. 18 Testing Bulb And Wiring
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CHARGING SYSTEMS 40 AMP CHARGING SYSTEM

Fig. 1 shows wiring diagram for 40 amp charging system. The 40 amp charging system consists of a belt driven, internally regulated alternator, Fig. 19. The alternator contains a charge light circuit (L terminal). With the keyswitch in the ON position and the engine not running the charge indicator light should light. With the engine running the light should go out, indicating that the battery is being charged. If the charge indicator light does not light when the keyswitch is in the ON position (engine not running), check the bulb and wiring. Note: A loose V-belt will cause low DC output. Belt deflection limit is 9.5-11.5 mm/10 kg (3/8-7/16 in./22 lbs.).
Fig. 19 40 Amp Alternator
L TERMINAL
B TERMINAL
IG TERMINAL
TEST EQUIPMENT
The digital multimeter, Tool #19464 and the DC shunt, Tool #19468, Fig. 20, are required to test the charging system. Note: The digital multimeter will withstand DC input of 10-20 amps for up to 30 seconds. To avoid blowing fuse in meter, the DC shunt is required.
19464 19468
Replacement fuse is available from your Briggs & Stratton source of supply. Order Part No. 19449.
TESTING ALTERNATOR DC OUTPUT

The DC Shunt must be installed on the negative (-) terminal of the battery, Fig. 21. All connections must be clean and tight for correct amperage readings. Attach meter test leads BEFORE starting engine. The regulator-rectifier test will be performed with the meter in the position. 1. Attach RED meter test lead to RED post terminal on shunt. 2. Attach BLACK meter test lead to BLACK post terminal on shunt. 3. With the engine running at 2000 RPM, the output should be: * 4 20 Amps * Depending upon battery voltage and/or current draw on system. 4. If no or low output is found, be sure that all connections are clean and secure. 5. If all connections are OK, replace or repair the alternator. 10
NEGATIVE BATTERY TERMINAL ATTACH NEGATIVE BATTERY CABLE BLACK LEAD
RED LEAD
Fig. 21 DC Shunt Installation
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CHARGING SYSTEMS DISASSEMBLE ALTERNATOR

1. Remove pulley nut using tool #19491 and 10 mm deep socket as shown in Fig. 22. a. Remove pulley and spacer. Replace pulley if damaged or worn.
Fig. 22 Remove Pulley
2. Remove nut and insulator at B terminal. 3. Remove three screws and brush cover, Fig. 23.
B TERMINAL
Fig. 23 Remove Rear Cover
4. Remove two screws, assembly, Fig. 24.
then
brush
retainer
A 11.5 mm B 9.0 mm
Important: Length of brush retainer screws are different. Do not mix. Screw A: 11.5 mm Screw B: 9.0 mm
Fig. 24 Remove Brush Retainer
5. Remove three screws and regulator, Fig. 25.
Fig. 25 Remove Regulator
11
11
CHARGING SYSTEMS
6. Remove four stator lead screws from rectifier, Fig. 26. a. Carefully straighten stator leads. b. Remove rectifier.
STATOR LEADS
STATOR LEADS
Fig. 26 Remove Rectifier
7. Scribe or place a reference mark on drive end and brush end housing so that they may be re-assembled in original position. 8. Remove two nuts and two thru bolts. 9. Remove brush end housing being careful not to damage stator leads, Fig. 27.
Fig. 27 Remove Brush End Housing
10. Remove rotor from drive end housing, Fig. 28. Note: Stator is NOT removable.
ROTOR
Fig. 28 Remove Rotor
CHECKING BEARINGS
Ball bearings must rotate freely. If any rough spots are felt the ball bearing must be replaced. Note: Rotor and ball bearing are an assembly. If bearing is worn, replace rotor assembly.
19416 DRIVER
Remove Ball Bearing

1. Remove four screws and bearing retainer, Fig. 29. 2. Support drive housing on blocks. 3. Press out bearing from pulley side of drive end housing using driver #19416. DO NOT re-use ball bearings that have been removed from drive end housing. The bearing races are usually damaged during removal.
Fig. 29 Remove Bearing Retainer
12
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CHARGING SYSTEMS INSTALL BALL BEARING

1. Lightly lubricate bearing O.D. with engine oil. 2. Press in new bearing using bearing driver #19226, Fig. 30. 3. Install retainer and four screws.
19226 DRIVER
Fig. 30 Install Ball Bearing
CHECKING ROTOR
The following test will be made with the meter in the Diode Test Position . 1. Use digital multimeter and check for continuity between slip rings as shown, Fig. 31. a. Meter should make continuous tone (continuity). b. If meter displays OL, (no continuity) replace rotor. 2. Check for continuity between slip ring and rotor shaft. a. Meter should display OL, (no continuity). 3. Measure slip ring diameter, Fig. 32. STD: 14.4 mm (.567) Reject: 14.0 mm (.551) Slip rings may be cleaned with fine sandpaper (#300 500 grit).
Fig. 31 Check Rotor
1
Fig. 32 Check Slip Ring
CHECK BRUSHES
Measure length of brushes protruding from brush holder, Fig. 33. STD: 10.5 mm (.413) Reject: 8.0 mm (.315)
Fig. 33 Check Brushes
13
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CHARGING SYSTEMS CHECK REGULATOR

The following test will be made with the meter in the Diode Test Position . 1. Attach BLACK meter test lead to terminal A as shown, Fig. 34. 2. Contact terminal B with RED meter test lead, Fig. 34. a. Meter should beep once. b. If meter displays OL or makes a continuous tone, regulator is defective. Replace regulator.
Fig. 34 Check Regulator
CHECK RECTIFIER
The following test will be made with the meter in the Diode Test Position . 1. Attach BLACK meter test lead to B terminal, Fig. 35. Leave attached through Step 3. 2. Contact #1 terminal with RED meter test lead, Fig. 35. a. Meter should beep once. b. If meter displays OL or makes a continuous tone, diode is defective. Replace rectifier. 3. Repeat test at #2, #3 and #4 terminals. a. Results must be the same. 4. Attach RED test lead to one of the three rectifier mounting holes, Fig. 36. Leave attached through Step 6. 5. Contact #1 terminal with BLACK meter test lead, Fig. 36. a. Meter should beep once. b. If meter displays OL or makes a continuous tone, diode is defective. Replace rectifier. 6. Repeat test at #2, #3 and #4 terminals. a. Results must be the same.
#3 #2 #1 #4 B TERMINAL #3 #2 #1
#4
Fig. 35 Check Rectifier
Fig. 36 Check Rectifier
ASSEMBLE ALTERNATOR
1. Assemble rotor to drive end housing, Fig. 37. 2. Assemble spacer, pulley and nut to rotor shaft. a. Do not tighten nut at this time. b. Place pulley side down on work surface.
Fig. 37 Installing Rotor
14
11
CHARGING SYSTEMS
3. Assemble brush end housing to drive end housing with reference marks aligned, Fig. 38. Note: Do not damage stator leads. 4. Install thru bolts and nuts. a. Torque to 5.0 Nm (45 in. lbs.).
Fig. 38 Assemble Housings
5. Align stator wires with holes in rectifier and assemble rectifier to brush end housing, Fig. 39. 6. Carefully form a U bend in stator wires. a. Install screws and tighten securely.
RECTIFIER
Fig. 39 Install Rectifier
7. Install regulator with three screws shown, Fig. 40.
Fig. 40 Install Regulator
8. Assemble cover to brush holder, Fig. 41.
COVER
Fig. 41 Install Brush Cover
15
11
CHARGING SYSTEMS
9. Install brush holder. Important: Length of brush retainer screws are different. Install as shown, Fig. 42. Screw A: 11.5 mm Screw B: 9.0 mm
A 11.5 mm B 9.0 mm
Fig. 42 Install Brush Holder
10. Install rear cover and three screws, Fig. 43. a. Torque screws to 3.0 Nm (25 in. lbs.). 11. Install insulator and nut. a. Torque nut to 4.0 Nm (35 in. lbs.).
Fig. 43 Install Cover
Torque drive pulley using the following procedure, Fig. 44. 1. Hold nut with tool #19491. 2. With torque wrench, turn 10 mm deep socket COUNTERCLOCKWISE. a. Torque to 70.0 Nm (50 ft. lbs.).
TURN WRENCH COUNTERCLOCKWISE
HOLD NUT
Fig. 44 Torque Pulley
16
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STARTER SYSTEM
IDENTIFICATION NUMBER
IDENTIFICATION NUMBER
28100-87805
28100-87806
Fig. 45 1.0 Kw (Standard)
Fig. 46 1.2 Kw (Optional)
STARTER SYSTEM GENERAL INFORMATION

Two different starter motors are used on Briggs & Stratton Daihatsu diesel engines. The standard motor is rated at 1.0 Kw., Fig. 45. The optional starter is rated at 1.2 Kw., Fig. 46. The starters are identified by their identification numbers. The starters are similar enough that service procedures and specifications are the same. Where differences occur, they will be shown. Engine temperature should be at least 21 C (70 F). STARTER CURRENT DRAW TEST ALL Make sure battery and solenoid connections are clean (Starter Installed) and tight. Important: When making the starter current draw test NOTE: Battery voltage must not be below 11.7 make sure that all parasitic load is removed from the volts. engine and that engine has the correct viscosity oil.
Test Equipment
The following equipment is required to test current draw of starter, Fig. 47. 1. Digital multimeter, Tool #19464. 2. DC shunt, Tool #19468. 3. Two battery cables with alligator clips. 4. One jumper wire with alligator clips. 5. A fully charged 12 volt battery.
19390
19468
BATTERY CABLES
JUMPER WIRE
17
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STARTER SYSTEM Testing Starter All

NOTE: To prevent engine from starting, remove fuel shut off solenoid wire from injector pump. The starter current draw test will be performed with the meter in the position. The DC Shunt must be installed on the negative (-) terminal of the battery, Fig. 48. 1. Attach RED meter test lead to RED post terminal on shunt. 2. Attach BLACK meter test lead to BLACK post terminal on shunt. 3. Activate starter. a. Allow 3 seconds for meter reading to stabilize. 4. Current draw should not exceed 140 amps DC. If amperage draw exceeds specification, remove starter from engine and perform No Load starter current draw test.
Fig. 48 Starter Current Draw Test
NEGATIVE BATTERY CABLE
BLACK LEAD
RED LEAD
STARTER CURRENT DRAW TEST NO LOAD

Remove starter motor. To hold starter securely while testing, clamp starter mounting bracket in a vise. DO NOT clamp starter housing in a vise or field windings or magnets may be damaged.
NEGATIVE CABLE
BLACK LEAD
JUMPER WIRE
RED LEAD
Testing Starter (No Load)

The No Load starter current draw test will be performed with the meter in the position. The DC Shunt must be installed on the negative (-) terminal of the battery, Fig. 49. 1. Attach RED meter test lead to RED post terminal on shunt. 2. Attach BLACK meter test lead to BLACK post terminal on shunt. 3. Attach negative battery cable to a good ground such as drive housing. 4. Attach positive battery cable to battery terminal on solenoid. 5. Attach one end of jumper wire to solenoid tab terminal, Fig. 49. 6. Activate starter by contacting positive battery terminal with other end of jumper wire, Fig. 49. a. Allow 3 seconds for meter reading to stabilize. 7. Current draw should not exceed 90 amps DC. If amperage draw exceeds specification, replace starter.
Fig. 49 No Load Starter Current Draw Test
POSITIVE CABLE NEGATIVE CABLE JUMPER WIRE
18
11
STARTER SYSTEM
STARTER SOLENOID Test Equipment

The starter solenoid test is performed with the starter removed from the engine. The following equipment is recommended to test the solenoid. 1. One battery cable with alligator clips. Fig. 50. 2. A jumper wire. 3. A fully charged 12 volt battery.
JUMPER WIRE BATTERY CABLE
Testing Starter Solenoid

1. Attach one end of battery cable to negative battery terminal and other end of cable to a good ground such as drive housing. Fig. 51. 2. Attach jumper wire to tab terminal on solenoid. 3. Activate solenoid by contacting positive battery terminal with other end of jumper wire. a. Pinion must move outward quickly (engage). 4. Remove jumper wire from positive battery terminal. a. Pinion must return quickly (disengage). If pinion does not move, replace the solenoid.
Fig. 51 Testing Solenoid
1 DRIVE HOUSING 11 10 12 2 PINION AND DRIVE CLUTCH 3 DRIVE GEAR 4 RETAINER 5 ROLLER BEARINGS (5) 6 BALL 7 RETURN SPRING 8 SOLENOID 9 ARMATURE 10 STARTER HOUSING 11 BRUSH RETAINER 9 3 5 1 4 7 8 12 END CAP
JUMPER WIRE
EXPLODED VIEW OF STARTER TYPICAL
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STARTER SYSTEM Remove Solenoid

1. Remove nut and field coil wire from stud terminal on solenoid, Fig. 52.
FIELD COIL WIRE
Fig. 52 Removing Field Coil Wire
2. Remove through bolts and starter motor, Fig. 53. DO NOT remove armature from starter housing or it will be necessary to re-assemble brushes to armature.
Fig. 53 Removing Starter Motor
3. Remove two drive end cap screws. Hold starter in vertical position with drive housing down and separate solenoid housing from drive housing, Fig. 54. Note position of solenoid return spring and ball. NOTE: The solenoid must be replaced as an assembly.
DRIVE HOUSING DOWN
Fig. 54 Removing Solenoid
Remove Pinion And Clutch Assembly

1. Remove drive gear from bearing. Remove bearing retainer and five roller bearings, Fig. 55. 2. Remove pinion and clutch assembly from drive housing.
PINION AND CLUTCH
Fig. 55 Removing Pinion And Clutch
20
11
STARTER SYSTEM Check Pinion And Clutch Assembly

Check pinion and gear for damage, Fig. 56. Pinion and shaft must rotate in clutch in clockwise direction only. Bearings must turn freely. NOTE: The pinion and clutch must be replaced as an assembly.
CLOCKWISE
Fig. 56 Checking Pinion And Clutch
Assemble Pinion And Clutch Assembly

1. Lubricate the following components with silicone grease before assembly, Fig. 57. NOTE: See insert for correct assembly for type starter. a. Clutch gear. b. Bearing retainer and roller bearings. c. Drive gear. d. Pinion shaft bearings. e. Return spring ball. f. Return spring. 2. Assemble roller bearings and retainer to drive gear shaft, Fig. 58. NOTE: Roller bearings must face drive housing. Retainer must face solenoid housing.
1 KW
D E A D
1.2 KW
Fig. 57 Assembling Pinion And Clutch
ROLLER BEARINGS AND RETAINER
Fig. 58 Assembling Roller Bearings
3. Mesh drive gear with clutch gear. Install pinion and clutch assembly and drive gear into drive housing together, Fig. 59. Install return spring ball in clutch. Make sure roller bearings remain in position.
Fig. 59 Assembling Drive Housing
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STARTER SYSTEM Install Solenoid

1. Insert return spring into solenoid plunger. 2. Align pilot hole in solenoid with drive gear shaft and assemble solenoid to drive housing, Fig. 60. a. Torque screws to 9.0 Nm (80 in. lbs.).
DRIVE HOUSING DOWN
Fig. 60 Installing Solenoid
3. Assemble starter motor to drive housing. Align tab on starter with notch in drive housing, Fig. 61. a. Torque screws to 9.0 Nm (80 in. lbs.). 4. Install field coil wire. a. Torque nut to 8 Nm (70 in. lbs.).
Fig. 61 Installing Starter Motor
Replace Solenoid Plunger And Contacts

Place starter in a vise with cover plate up. 1. Remove three screws and cover plate. a. Discard gasket. 2. Remove plunger and spring.
Fig. 62 Remove Plunger
3. Replace contacts if burned or worn. Contacts and plunger must be replaced as an assembly. 4. Measure thickness of contact plates with calipers. Reject Dimension: 0.9 mm (0.035). Note:
WEAR
Fig. 63 Checking Contacts
22
11
STARTER SYSTEM
5. Remove two nuts with 14 mm wrench, Fig. 64. 6. Remove components in sequence shown, Fig. 65. Field Wire Terminal Side: (1) G (2) F (3) E (4) D (5) C (6) B (7) A
Fig. 64 Loosen Nuts
BEFORE 99010100: 1.0 KW / BEFORE 98083100: 1.2 KW
H I
(1.2 KW)
Battery Wire Terminal Side: Before 99010100: 1.0 KW / After 98123100: 1.0 KW Before 98083100: 1.2 KW / After 98090100: 1.2 KW (1) N (1) N (2) M (3) L (4) K (5) J (6) I (7) H (2) M (3) P (4) O (5) K (6) J (7) I (8) H 7. Install components in sequence shown, Fig. 65. Field Wire Terminal Side: (1) A (2) B (3) C (4) D (5) E (6) F (7) G Battery Wire Terminal Side: Before 99010100: 1.0 KW / After 98123100: 1.0 KW Before 98083100: 1.2 KW / After 98090100: 1.2 KW (1) H (1) H (2) I (3) J (4) K (5) L (6) M (7) N (2) I (3) J (4) K (5) O (6) P (7) M (8) N 8. Do not tighten terminal nuts at this time.
N M L K
J C
(1.0 KW)
B A
D E F G
AFTER 98123100: 1.0 KW / AFTER 98090100: 1.2 KW

H
I
(1.2 KW)
N M P
J C O K
(1.0 KW)
B A
D E F G
Fig. 65 Contact Assemblies
23
11
STARTER SYSTEM
9. Install new plunger and spring. 10. Place bearing driver, Tool #19422 on plunger and compress plunger to end of travel. Maintain pressure. a. Torque nuts to 17 Nm (150 in. lbs.). Note: This provides proper contact alignment with plunger and contact plates. 11. Clean contact plates and plunger contacts. 12. Install cover plate with new gasket. a. Torque screws to 4 Nm (35 in. lbs.).
Fig. 66 Aligning Contact Plates
DISASSEMBLE STARTER MOTOR

1. Remove starter motor from drive housing. 2. Remove screws and end cap. 3. Remove armature from motor housing, Fig. 67. If armature drive splines or armature bearings are damaged or worn, replace armature.
Fig. 67 Disassemble Starter Motor
Inspect Armature Commutator

The armature commutator may be cleaned with fine sandpaper. DO NOT use emery cloth. Commutator may be machined to no less than 29.0 mm (1.142), Fig. 68. NOTE: Minimum depth of slots between commutator bars after machining is 0.2 mm (.008). The armature should be checked for shorts with a growler.
29.0 mm
Fig. 68 Commutator Specifications
Inspect Brushes
Minimum brush dimension is shown below Fig. 69. 1.0 KW Starter: 9 mm (.350). 1.2 KW Starter: 10 mm (.400). If brushes are worn less than specification, replace as follows. 1.0 KW Starter: Replace brush retainer and brushes on starter housing. 1.2 KW Starter: Starter housing and brush retainer must be replaced as an assembly.
1.0 KW: 9 mm 1.2 KW: 10 mm
Fig. 69 Minimum Brush Dimension
24
11
STARTER SYSTEM
Use digital multimeter and check for continuity between field coil wire and brushes shown, Fig. 70. The following test will be made with the meter in the Diode Test Position . 1. Attach either meter test lead to field coil wire. 2. Contact first one positive brush, then opposite brush with other test lead as shown. a. Meter should make continuous tone (continuity). b. If meter does not make a tone, (no continuity) replace starter housing.
Fig. 70 Checking Brushes
3. Attach either test lead to brush retainer, Fig. 71. 4. Contact first one negative brush, then opposite brush with other test lead as shown. a. Meter should make continuous tone (continuity). b. If meter does not make a tone, (no continuity) replace brush retainer.
Fig. 71 Checking Brushes
Replace Brushes 1.0 KW Starter

1. Cut off brush lead wires at terminals as shown. 2. Use a fine file and carefully remove remaining lead wire from terminals. L: 2.3 2.7 mm (0.090 0.106) W: 6.5 7.5 mm (0.255 0.295)
L BRUSH LEAD WIRE CUT
Fig. 72 Clean Terminals
3. Crimp replacement brushes over terminals so that wires face in counterclockwise direction. 4. Solder brush lead wires to terminals. 5. Insert brushes into brush retainer.
COUNTERCLOCKWISE
Fig. 73 Install Brushes
25
11
STARTER SYSTEM ASSEMBLE STARTER MOTOR

For ease of assembly, clamp splined end of armature in a vise as shown. Use soft jaws to prevent damage to spline, Fig. 74. 1. Place green seal protector from Kit #19356 over commutator.
Fig. 74 Assemble Starter Motor
2. Using seal protector as a guide, slide motor housing with brush retainer into position, Fig. 75. Remove seal protector. a. Make sure brush wires are not grounding on brush retainer.
Fig. 75 Assembling Motor Housing And Brushes
3. Align notch in end cap with rubber seal and install end cap, Fig. 76. a. Make sure brush wires are not grounding on end cap. Tighten screws securely.
NOTCH
RUBBER SEAL
Fig. 76 Installing End Cap
4. Assemble starter motor to drive housing. Align tab on starter with notch in drive housing, Fig. 77. a. Torque screws to 9.0 Nm (80 in. lbs.). 5. Install field coil wire. a. Torque nut to 9.0 Nm (80 in. lbs.). 6. Install starter a. Torque screws to 34.0 Nm (25 ft. lbs.).
TAB
Fig. 77 Installing Starter Motor
26
11
STARTER SYSTEM
Wiring Diagram 14 Amp Alternator (Typical)

493625 Keyswitch With Fixed Preheat Timer and Glow Relay
FUEL FILTER
INJECTION PUMP
WATER INDICATOR LIGHT
PREHEATING TIMER
1
2 3 6 4
GLOW RELAY
3 4
1 6
KEYSWITCH TERMINAL FUNCTION 2 4 5
5
GLOW LIGHT
ACCESSORY & PREHEAT TIMER SOLENOID & PREHEAT TIMER BATTERY
SOLENOID
GLOW PLUGS

YELLOW GREEN
STARTER MOTOR RED REGULATOR RECTIFIER BLACK
LT. BLUE
12 VOLT BATTERY
14 AMP ALTERNATOR
LIGHT BLUE GREEN BLACK YELLOW LIGHT BLUE RED
Regulator Connector Fig. 78
27
11
STARTER SYSTEM

493625 Keyswitch With Fixed Preheat Timer and Glow Relay
FUEL FILTER
INJECTION PUMP
WATER INDICATOR LIGHT PREHEATING TIMER
1 2 3 4
3 4
7 8 5
GLOW RELAY
1 6
KEYSWITCH TERMINAL FUNCTION 2 4 5 ACCESSORY & PREHEAT TIMER SOLENOID & PREHEAT TIMER BATTERY
L TERMINAL
B TERMINAL 40 AMP ALTERNATOR
12 VOLT BATTERY
B TERMINAL
Fig. 79
28
11
STARTER SYSTEM

825129 Keyswitch Manual Preheat
FUEL FILTER
INJECTION PUMP
B B
G1 G2 M
GLOW LIGHT
KEYSWITCH TERMINAL FUNCTION B S BATTERY SOLENOID

SOLENOID
GLOW PLUGS
G1 GLOW PLUG (PREHEAT) G2 GLOW PLUG (CRANKING) M ACCESSORY

YELLOW
GREEN
STARTER MOTOR RED REGULATOR RECTIFIER BLACK
LT. BLUE
12 VOLT BATTERY
14 AMP ALTERNATOR
LIGHT BLUE GREEN BLACK YELLOW LIGHT BLUE RED
Regulator Connector Fig. 80
29
11
STARTER SYSTEM

825129 Keyswitch Manual Preheat
FUEL FILTER
INJECTION PUMP
KEYSWITCH PART NO. 825129 B B S G1 G2 M

KEYSWITCH TERMINAL FUNCTION B S BATTERY SOLENOID

G1 GLOW PLUG (PREHEAT) G2 GLOW PLUG (CRANKING) M ACCESSORY

B TERMINAL
L TERMINAL
40 AMP ALTERNATOR
12 VOLT BATTERY
B TERMINAL
Fig. 81
30
12
Section 12 Lubrication System

Section Contents Page DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CHANGE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CHANGE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CHECK OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DISASSEMBLE GEAR CASE Remove Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ASSEMBLE GEAR CASE Install Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ROCKER ARM SHAFT
CAMSHAFT
OIL NOZZLE CRANKSHAFT
OIL PUMP
Recommended SAE Viscosity Grades
F -30 C -34
-10 -23
STARTING TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
* A synthetic 5W-30 oil may be used. Use a high quality detergent oil classified For Service SE/CD or higher. Use no special additives with recommended oils.
MAY 2002

OIL STRAINER
OIL FILTER
*
10 -12 32 0 50 10 70 21 90 32 110 43
12
LUBRICATION SYSTEM
DESCRIPTION
Briggs & Stratton Daihatsu gasoline and diesel engines use a full pressure lubrication system with an oil filter. The gear driven oil pump draws oil from a screened oil pickup in the oil pan and pumps the oil through the oil filter. The filtered oil flows through oil galleries in the cylinder block and is distributed to the main bearings, connecting rod bearings, camshaft bearings and rocker arm shaft. A pressure relief valve limits the maximum oil pressure in the system.
CHANGE OIL
Change oil and filter after first 50 hours of operation. Thereafter, change oil every 100 hours of operation. Change oil filter every 200 hours of operation. Change oil and filter more often if engine is operated in dusty or dirty conditions or if engine is operated under heavy loads or high ambient air temperatures. Remove oil drain plug and drain oil while engine is still warm, Fig. 1. Check oil drain plug gasket and replace if necessary. Install and torque drain plug to 24.8 Nm (220 in. lbs.).
OIL FILTER
DRAIN PLUG
Fig. 1 Oil Drain Plug
Remove oil fill cap and refill with oil of recommended grade and viscosity. See Page 1. Oil Capacity: 3.3 liters (3.5 quarts) Fill to FULL mark on dipstick.
OIL FILL CAP
Fig. 2 Oil Fill Cap
CHANGE OIL FILTER

Change oil filter every 200 hours of operation. Before installing new filter, lightly oil filter gasket with fresh clean engine oil. NOTE: Hand tighten 1/2 turn after gasket contacts mounting surface.
1/2 TURN
Fig. 3 Replacing Oil Filter
12
LUBRICATION SYSTEM CHECK OIL PRESSURE

1. Oil level should be between the LOW and FULL marks on dipstick. If oil level is low, check for leaks and add to FULL mark.
OIL LEVEL SHOULD BE BETWEEN F AND L MARKS ON DIPSTICK.
Fig. 4 Oil Level
2. Remove oil pressure switch. 3. Install oil pressure gauge. 4. Start the engine and allow it to reach normal operating temperature. 5. Check oil pressure at 3000 RPM. Oil Pressure: 2.0 ~ 5.0 Bar (28 ~ 70 psi) See charts below for troubleshooting guide. Low Oil Pressure Engine RPM Too Low Wrong Viscosity or Diluted Oil Low Oil Level Broken Pressure Relief Spring Missing Pressure Relief Plunger Worn Bearings Damaged Or Defective Oil Pump High Oil Pressure Wrong Viscosity Oil Plugged Oil Galleries
OIL PRESSURE SWITCH
Fig. 5 Checking Oil Pressure
12
LUBRICATION SYSTEM
Exploded View DISASSEMBLE GEAR CASE Remove Oil Pump

Make sure that #1 cylinder is at TDC, compression stroke. See Section 2. Remove V-belt and fan (if equipped). Drain oil from engine. NOTE: Clean areas around fuel lines and injectors to prevent dirt entry. 1. Remove the following parts, Fig. 6. a. Glow plug wiring. b. Glow plugs. c. Injector pump bracket. d. Remove fuel delivery lines.
B D
Fig. 6 Remove Fuel Delivery Lines
12
LUBRICATION SYSTEM
2. Remove oil pan screws and nuts. a. Remove oil pan and discard gasket. b. Remove oil pick-up tube and strainer. Discard gasket, Fig. 7.
OIL PICK-UP TUBE
3. Remove bell housing adapter screw if equipped. and install flywheel holder, Tool #19418. LEAVE TOOL INSTALLED. a. Remove crankshaft pulley using Tool # 19420, Fig. 8.
FLYWHEEL HOLDER
Fig. 8 Removing Crankshaft Pulley
4. Remove timing gear cover, Fig. 9. a. Discard timing gear cover gasket.
Fig. 9 Removing Timing Gear Cover
5. Remove the following parts, Fig. 10. a. Camshaft timing gear. b. Oil pump gear. c. Injector pump nut. d. Idler gear.
Fig. 10 Removing Gears
12
LUBRICATION SYSTEM
6. Remove injector pump timing gear with a three jaw puller, Fig. 11. a. Remove 2 nuts and injector pump. Discard O-ring.
ORING
Fig. 11 Removing Injector Pump
7. Remove parts in sequence shown, Fig. 12. a. Remove 3 screws and camshaft retainer. b. Remove remaining 5 screws. c. Remove timing gear case and discard gasket.
A B
Fig. 12 Removing Timing Gear Case
8. Inspect rotors for wear or damage, Fig. 13. NOTE: If pump rotors are worn or damaged, replace the gear case.
OIL PUMP ROTORS
Fig. 13 Inspect Rotors
9. Remove and check pressure relief valve assembly, Fig. 14. a. Make sure plunger has no nicks or burrs. b. Check pressure relief valve spring free length. 10. Spring free length: 35.5 mm (1.400 .040)
WASHER
PLUNGER
SPRING SCREW
Fig. 14 Checking Pressure Relief Valve
12
LUBRICATION SYSTEM ASSEMBLE GEAR CASE Install Oil Pump

1. Lubricate oil pump rotor with engine oil and install in cylinder block, Fig. 15. a. ID mark on rotor must face cylinder block.
OIL PUMP ROTOR
ID MARK
2. Install timing gear case with new gasket. Install camshaft retainer, Fig. 16. NOTE: It may be necessary to rotate oil pump drive to engage oil pump rotors. NOTE: Position camshaft retainer so that center hole does not interfere with camshaft. Note position, length and number of screws as shown. a. M6 x 28 mm (M6 x 1.1): 4 b. M6 x 18 mm (M6 x 0.7): 3 c. M6 x 16 mm (M6 x 0.6): 1 3. Torque screws to 8.0 Nm (70 in. lbs.). 4. Assemble injector pump to gear case with new O-ring and install nuts and support bracket screw finger tight, Fig. 17. NOTE: Pump must be able to rotate. a. Align timing mark on injector pump with timing mark on gear case. NOTE: See Section 10 for injector pump timing procedure.
Fig. 16 Installing Timing Gear Case
TIMING MARKS
Engine models 432000 and 582000 after date code 990111007, and all engine models 522000 are equipped with right angle helical timing gears. Timing marks are identified by letters (A, AA, B, BB, etc.), instead of numbers. The timing procedure is the same. 5. With crankshaft key at 12 oclock position, assemble idler gear so that timing mark 11 (AA) is aligned with timing mark 1 (A) on crankshaft gear, timing mark 22 (BB) is aligned with timing mark 2 (B) on camshaft gear, and timing mark 33 (CC) is aligned with timing mark 3 (C) on injector pump gear, as shown in Fig. 18. a. Install oil pump gear.
Fig. 18 Aligning Timing Marks
12
LUBRICATION SYSTEM
6. Torque screws as shown, Fig. 19. a. Camshaft gear: 41.0 Nm (30 ft. lbs.) b. Idler gear: 25.0 Nm (220 in. lbs.) c. Injector pump gear: 61.0 Nm (45 ft. lbs.) d. Oil pump gear: 19.0 Nm (170 in. lbs.)
7. Install timing gear cover with new gasket. Note position, length and number of screws as shown, Fig. 20. a. M6 x 55 mm (M6 x 2.5): 3 b. M6 x 45 mm (M6 x 2.1): 2 c. M6 x 30 mm (M6 x 1.1): 9 d. M6 nut: 2 8. Torque screws and nuts to 8.0 Nm (70 in. lbs.).
A A
Fig. 20 Installing Timing Gear Cover
Fig. 21 Installing Crankshaft Pulley
10. Install oil pick-up tube and strainer with new gasket. Torque to 8.0 Nm (70 in. lbs.). a. Apply a small bead of Permatex No. 2 or similar sealant to crankcase areas shown, Fig. 22. b. Install oil pan with new gasket. c. Torque screws and nuts to 8.0 Nm (70 in. lbs.).
SEALANT
12
LUBRICATION SYSTEM
11. Install Glow plugs, wiring and fuel delivery lines. a. Torque glow plugs to 17.0 Nm (150 in. lbs.). b. Torque fuel delivery lines to 25.0 Nm (220 in. lbs.), Fig. 23.
Fig. 23 Installing Fuel Delivery Lines
12. Install V-belt, Fig. 24. 13. Install alternator bolts A and B . Belt deflection limit is 1012 mm/10 kg (3/81/2 in/22 lbs.). a. Torque bolt A to 19.0 Nm (170 in. lbs.). b. Torque bolt B to 61.0 Nm (45 ft. lbs.).
A
Fig. 24 Adjusting V-belt
13
Section 13 Cooling System

Section Contents
Page GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CHECKING COOLING SYSTEM Pressure Testing Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Testing Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CHANGING COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 THERMOSTAT Removing Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Checking Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installing Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 WATER PUMP Inspecting Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removing Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installing Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
THERMOSTAT CLOSED
THERMOSTAT OPEN
Briggs & Stratton Daihatsu gasoline and diesel engines use a pressurized, forced circulation cooling system. The water pump circulates coolant through the cylinder block, cylinder head and radiator. The thermostat maintains optimum engine temperature. The thermostat is equipped with a by-pass valve which permits coolant to re-circulate through the cylinder block and cylinder head. As the engine warms, the by-pass valve closes as the thermostat opens, permitting complete circulation through the radiator. Always maintain a 50% solution of phosphate free antifreeze at all times for adequate heat dissipation, lubrication and protection from freezing.
MAY 2002
13
COOLING SYSTEM CHECKING COOLING SYSTEM

WARNING: The cooling system is pressurized. Do not remove the radiator cap while the engine is hot. To avoid scalding hot coolant or steam blowing out of the radiator, use extreme care when removing the radiator cap. If possible, wait for engine to cool. Wrap a thick rag around cap while removing. To release pressure, slowly turn cap counter clockwise to the first stop. When all pressure has been released, press down on cap and continue turning.
Pressure Testing Cooling System

1. Remove radiator cap and make sure coolant is at correct level. a. Coolant level must be no more than 25 mm (1) below bottom of filler neck. 2. Install cooling system pressure tester on radiator and pressurize system to 0.75 Bar (11 psi). 3. Check the following for any signs of leaking. NOTE: System must maintain pressure during test. a. Hoses and connections (also check hoses for excessive bulging). b. Radiator. c. Water pump. d. Freeze plugs (cylinder block and cylinder head). If system does not maintain pressure and no leaks are evident externally, check for an internal leak such as a blown head gasket, warped cylinder head or cylinder block.
DRAIN PLUG
Fig. 1 Draining Coolant
Testing Radiator Cap

Make sure that rubber seal on radiator cap is not damaged or distorted. Rubber seals must be clean and free of debris to seal properly. 1. Install radiator cap on pressure tester and pressurize the cap. Specification: 1.03 ~ 0.76 Bar (15 ~ 11 psi) Replace cap if not within specification shown. NOTE: Recommended pressure cap capacity is 0.9 Bar (13 psi).
25 mm (1)
CHANGING COOLANT
Coolant should be changed once a year. Change coolant with engine cold. 1. Remove radiator cap. Remove radiator drain plug and drain the system, Fig. 1. 2. Tighten drain plug. NOTE: Follow state or federal laws regarding the proper procedure for disposing of antifreeze. 3. Fill radiator with 50% solution of phosphate free antifreeze. 4. Start and run engine until thermostat opens (when coolant level drops, thermostat is open). 5. Check coolant level in radiator and add coolant as required, Fig. 2.
Fig. 2 Adding Coolant
13
COOLING SYSTEM THERMOSTAT Removing Thermostat Engine Cold

1. 2. 3. 4. Drain engine coolant. Remove screws and coolant outlet housing. Remove locating screw and thermostat, Fig. 3. Remove all traces of gasket material.
THERMOSTAT
COOLANT OUTLET
LOCATING SCREW
Fig. 3 Removing Thermostat
Checking Thermostat
A thermometer capable of reading 100 C (210 F) or more is required. 1. Check to make sure thermostat valve is fully closed. 2. Immerse thermostat in water and heat water gradually, Fig. 4. 3. Note temperature when thermostat starts to open. a. 81 ~ 84 C (178 ~ 183 F) 4. Note temperature when thermostat is fully open. a. 95 C (203 F) 5. Remove thermostat from water and allow to cool. a. Thermostat should close fully.
Fig. 4 Checking Thermostat
Installing Thermostat
1. Insert thermostat in housing and install locating screw, Fig. 5. 2. Install coolant outlet housing with new gasket. 3. Torque screws to 8.0 Nm (70 in. lbs.). Refill with coolant.
LOCATING SCREW
Fig. 5 Installing Thermostat
13
COOLING SYSTEM WATER PUMP Inspecting Water Pump

Inspect water pump for signs of leaking at vent holes, mounting surfaces and water pump pulley shaft, Fig. 6. 1. Remove V-belt, alternator adjustment bracket, fan (if equipped) and water pump pulley. a. Replace pulley if bent or damaged.
VENT HOLES
Fig. 6 Inspecting Water Pump
2. Check water pump bearings by rotating pulley flange by hand, Fig. 7. a. Make sure pulley rotates smoothly. If water pump shows evidence of leaking or bearings are rough, replace the water pump. NOTE: Most water pump and cooling system failures result from using straight water as a coolant. Without water pump lubricant and corrosion inhibitors, the water pump will fail prematurely.
Fig. 7 Checking Bearings
Removing Water Pump

Drain engine coolant. 1. Disconnect radiator hoses, Fig. 8.
Fig. 8 Remove Hoses
Remove the following parts, Fig. 9. 2. Temperature gauge wire (if equipped). 3. Coolant outlet. 4. Coolant inlet. 5. Water pump. Clean all traces of gasket material from mounting surfaces and inspect mounting surfaces for damage.
4 1
Fig. 9 Removing Water Pump
13
COOLING SYSTEM Installing Water Pump

1. Install water pump with new gasket, Fig. 10. a. Torque screws and nuts to 19.0 Nm (170 in. lbs.). After installing water pump make sure pump rotates smoothly.
Fig. 10 Installing Water Pump
2. Install coolant inlet with new gasket, Fig. 11. a. Torque screws to 8.0 Nm (70 in. lbs.). 3. Install thermostat and coolant outlet with new gasket, Fig. 11. a. Torque screws to 8.0 Nm (70 in. lbs.). 4. Install temperature gauge wire (if equipped). 5. Install radiator hoses.
Fig. 11 Installing Coolant Inlet And Outlet
6. Install fan (if equipped) and water pump pulley, Fig. 12. a. Torque screws to 8.0 Nm (70 in. lbs.).
Fig. 12 Installing Fan And Pulley
7. Install V-belt, Fig. 13. a. Belt tension adjustment: 10-12 mm/10 kg (3/8-1/2 in./22 lbs.). 8. Refill cooling system.
BELT
HANDLE
Fig. 13 Install V-Belt
14
Section 14 Turbocharger
Section Contents Page GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Turbocharger Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Turbocharger Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Turbocharger Waste Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Turbocharger Pressure Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Crankcase Blow-by Recirculating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CHECKING WASTE GATE ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SERVICING AND OPERATING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 REMOVE TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CHECKING TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALL TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION OF COOLANT INLET TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
MAY 2002
14
950 CC DIESEL TURBOCHARGED ENGINE General Information

Models 588447 and 58A447 are turbocharged equipped diesel engines.
Turbocharger Lubrication System

Lubricating oil for the turbocharger is supplied from the rear of the cylinder head to the turbocharger via the oil inlet line. The oil supply is regulated by the inlet port diameter of the oil inlet line. The oil inlet line is installed with union screws at the cylinder head and the turbocharger. Oil returns to the cylinder block via the oil outlet line.
UNION SCREW (M8) AT TURBOCHARGER
UNION SCREW (M12) AT CYLINDER HEAD
OIL INLET LINE
OIL OUTLET LINE
Fig. 1 Lubricating System of Turbocharger
Full Floating Bearing

The turbine shaft for the turbocharger is equipped with a full floating bearing lubricated by engine oil.
OIL TURBINE SIDE COMPRESSOR SIDE
FLOATING BEARING
Fig. 2 Full Floating Bearing
14
TURBOCHARGER
Turbocharger Cooling System
Coolant for the turbocharger is supplied from the rear right of cylinder block and returns to the water pump inlet.
COOLANT OUTLET LINE
COOLANT INLET LINE
Fig. 3 Cooling System of Turbocharger (1)
COOLING WATER TO WATER PUMP INLET
COOLING WATER FROM CYLINDER BLOCK
Fig. 4 Cooling System of Turbocharger (2)
14
TURBOCHARGER
Turbocharger Waste Gate
The turbocharger is equipped with a waste gate to control turbocharger pressure.
WASTE GATE VALVE
WASTE GATE ACTUATOR
Fig. 5 Turbocharger
Turbocharger Pressure Control System

As pressure in the turbocharger rises, the actuator for the waste gate valve opens allowing some of the exhaust gases to bypass the turbocharger.
EXHAUST
WASTE GATE VALVE
TURBOCHARGED INTAKE AIR
WASTE GATE VALVE
WASTE GATE VALVE SECTION
WASTE GATE ACTUATOR
AIR CLEANER TURBOCHARGER INTAKE AIR
Fig. 6 Turbocharger Pressure Control System
14
TURBOCHARGER
Crankcase Blow-by Recirculating System
Crankcase blow-by is recirculated as shown in Fig. 7
CRANKCASE BREATHER TUBE
A/C
IN
EX
FRESH AIR
BLOW-BY GASES
T/C
EXHAUST GASES
Fig. 7 Crankcase Blow-by Recirculating System
CHECKING WASTE GATE ACTUATOR

1. Disconnect the waste gate actuator hose at the actuator. 2. Connect pressure/vacuum pump, Tool #19493. 3. Apply pressure of 14.2 psi (0.9 bar) and ensure that the rod and link operate. 4. When pressure is released rod and link must return to original position. NOTE: DO NOT apply pressure more than 21.3 psi (1.5 bar) to the waste gate actuator or the diaphragm will be damaged. 5. If the actuator hose is damaged or cracked it must be replaced.
Fig. 8 Checking Waste Gate Valve
14
TURBOCHARGER SERVICING AND OPERATION INFORMATION

1. DO NOT disassemble the turbocharger. 2. When removing and installing turbocharger: a. Handle the turbocharger carefully. DO NOT drop. b. When removing the air intake system or lubrication system, be careful not to get dust or foreign matter into the turbocharger. c. Use tape to cover the oil inlet and outlet ports, coolant ports, air intake and exhaust port to prevent the turbocharger from getting dust or debris into it. d. After the turbocharger has been replaced, run the engine a minimum of 15 seconds at idle. If the engine speed is raised rapidly, it may cause damage to the turbocharger bearing. e. Check oil and coolant lines for leaks. f. Special heat treated mounting fasteners are used on the turbocharger. Do not substitute.
POINTS TO BE COVERED WITH TAPE
Fig. 9 Cautions on Handling Turbocharger (1)
ALLOW THE ENGINE TO IDLE FOR 15 SECONDS MINIMUM
3. DO NOT lift or carry turbocharger by the waste gate actuator rod.
CARRY TURBOCHARGER BY ACTUATOR ROD
DO NOT
4. DO NOT remove residual oil from turbocharger. 5. DO NOT touch the turbocharger when the engine is running. 6. DO NOT run the engine with the intake pipe removed. 7. DO NOT place the turbocharger in a vertical position.
DO NOT
DROP
14
TURBOCHARGER REMOVE TURBOCHARGER

1. Remove the muffler or exhaust pipe from the turbocharger. 2. Lift tab on tie strap and remove tie strap. Then remove crankcase breather tube at air intake tube.
TIE STRAP
TAB
Fig. 13 Remove Clamp
3. Disconnect the air intake tube at the turbocharger. 4. Disconnect the air intake tube from the air intake pipe.
AIR INTAKE TUBE
Fig. 14 Disconnecting Air Intake Tube
5. Remove the two nuts, and remove the air intake pipe from turbocharger.
AIR INTAKE PIPE
Fig. 15 Removing Air Intake Pipe
6. Remove the coolant inlet hose from coolant inlet line.
COOLANT HOSE
Fig. 16 Removing Coolant Hose
14
TURBOCHARGER
7. Remove coolant outlet hose.
OUTLET HOSE
Fig. 17 Disconnect Coolant Hose
8. Remove coolant inlet line bracket screw.
BRACKET
Fig. 18 Remove Clamp
9. Remove two nuts, then remove coolant line assembly from turbocharger .
Fig. 19 Removing Coolant Line
10. Remove oil inlet line union screw at turbocharger. Discard the washer.
Fig. 20 Removing Union Screw
14
TURBOCHARGER
11. Remove oil inlet line union screw at rear of cylinder head. Discard washers.
Fig. 21 Removing Union Screw
12. Remove oil inlet line bracket screw at the exhaust manifold.
Fig. 22 Removing Bracket Bolt
13. Remove two screws from turbocharger and pull out the oil outlet tube from the cylinder block. Discard O ring and gasket.
Fig. 23 Removing Oil Outlet Tube
14. Remove screws (2) and nuts (3) and remove turbocharger mounting bracket. Discard gasket.
Fig. 24 Removing Turbo Charger Bracket
14
TURBOCHARGER
15. Remove nuts (3), and remove the turbocharger assembly from the exhaust manifold.
Fig. 25 Removing Turbocharger Assembly
NOTE: When removing the turbocharger assembly, DO NOT lift or carry turbocharger by the waste gate actuator rod. Use tape to cover the oil inlet and outlet ports, coolant ports, air intake and exhaust port.
Fig. 26 Removing Turbocharger Assembly
CHECKING TURBOCHARGER
1. Check blades of turbine and compressor for damage. 2. Rotate the blades by hand, and ensure that they turn freely without contacting the housing. 3. Check that oil is not leaking at the turbine side. 4. Check oil inlet union screws for dirt or debris. If the union screw is clogged, clean it using compressed air as shown below. NOTE: If union screws are clogged, clean or replace the oil inlet line. 5. Check each part for damage or cracks. Replace defective parts.
TURBINE SIDE COMPRESSOR SIDE
Fig. 27 Checking Turbocharger Assembly
PLUG OPPOSITE SIDE HOLE WITH FINGER
AIR GUN
Fig. 28 Cleaning Union Screw
10
14
TURBOCHARGER INSTALL TURBOCHARGER

1. Install the turbocharger assembly with new gasket. a. Torque nuts (3) to 25 Nm (18.0 ft.-lb).
Fig. 29 Installing Turbocharger Assembly
2. Install the turbocharger bracket with new gasket. a. Temporarily tighten the nuts and bolts until the flange surfaces of the turbocharger, exhaust manifold and turbocharger stay in contact each other. b. First torque nuts to 34.0 Nm (25.0 ft.-lb) c. Then torque screws to 29.0 Nm (20.0 ft.-lb)

Fig. 30 Installing Turbocharger Bracket
3. Install oil outlet line. a. Insert the oil outlet tube into the cylinder block with new O ring. b. Assemble to turbocharger with new gasket. c. Torque screws to 8.0 Nm (70.0 in-lb).
OIL OUTLET LINE
Fig. 31 Installing Oil Outlet Tube
11
14
TURBOCHARGER
4. Install oil inlet line. a. Temporarily install the union screw with washers at the cylinder head. b. Temporarily install the union screw with washer at the turbocharger. c. Temporarily install the inlet line bracket screw. d. Then torque union screws and bracket screw. Union screws: Cylinder head side Turbocharger side 44.0 Nm 18.0 Nm (170 in-lb) (32.0 ft.-lb)
Fig. 32 Installing Oil Inlet Line
Bracket screw: 19.0 Nm (170. in-lb)
Fig. 33 Installing Bracket Screw
5. Install Coolant Line at turbocharger with new gasket. a. Torque nuts to 8.0 Nm (70 in. lbs.).
Fig. 34 Installing Coolant Line
6. Install bracket screw. a. Torque screw to 19.0 Nm (170 in. lbs.).
TURBO WATER PIPE CLAMP
Fig. 35 Install Bracket Screw
12
14
TURBOCHARGER
7. Install coolant outlet hose from turbocharger to coolant inlet housing as shown, Fig. 36. Install clamps with tabs as shown.
Fig. 36 Install Coolant Outlet Hose
8. Install coolant inlet hose over inlet tube up to yellow mark on tube. Install clamps with tabs as shown.
B A
YELLOW MARK
Fig. 37 Install Coolant Inlet Hose
9. Install air intake pipe. a. Torque nuts to 13.0 Nm (115 in. lbs.).
AIR INTAKE PIPE
Fig. 38 Installing Air Intake Pipe
10. Align the match marks (white paint), and install the air intake hose onto the air intake pipe. Installation direction of clamps:
A Install the clamp so that tabs face rear of

engine.
B Install the clamp so that tabs face out. A B

Fig. 39 Installing Air Intake Hose
13
14
TURBOCHARGER
11. Install breather tube as shown. 12. Install muffler or exhaust pipe. 13. Connect the air hose connecting the air cleaner to the turbocharger.
PIPE
PULL
BREATHER TUBE
Fig. 40 Installing Clamp
INSTALLATION OF COOLANT INLET TUBE

1. Apply sealer to the portion of tube that is to be installed in cylinder block. 2. Align the center of tube with the center of M10 thread at the rear end of the cylinder block. 3. Press-in tube until flange contacts the cylinder block.
ALIGN THIS POINT
M10 THREAD
CENTER OF M10 THREAD
CYLINDER BLOCK
Fig. 41 Installing Tube
14

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What are the main steps for disassembling an engine?

What are the main steps for disassembling an engine?

What are the main steps for inspecting and measuring engine parts?

What are the main steps for inspecting and measuring engine parts?

REPAIR MANUAL

For 3 Cylinder Liquid Cooled Diesel Engines

2002 BRIGGS & STRATTON DAIHATSU LLC

GENERAL REPAIR INSTRUCTIONS

Inspection and Measurement

Clean parts to be reused

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1

CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2

TIMING GEARS AND GEAR CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3

FLYWHEEL AND REAR SEAL RETAINER . . . . . . . . . . . . . . . . . . . . . . . Section 4

CYLINDER BLOCK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5

CYLINDER BLOCK INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . Section 6

FUEL SYSTEM AND RELATED COMPONENTS . . . . . . . . . . . . . . . . . Section 10

ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 11

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 12

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 13 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 14

CYLINDER BLOCK DISASSEMBLY Engine Stand Fixture Cylinder Block Disassembly

SECTION CONTENTS (contd)

Section 1 General Information

ENGINE IDENTIFICATION NUMBERS

MODEL AND TYPE NO.

Fig. 1 Engine Model And Type Number

Fig. 2 Engine Serial Number

IN THE INTEREST OF SAFETY

GENERAL INFORMATION ENGINE VIEWS

Thermostat Oil filler cap Electric starter Oil pan Alternator

6. 7. 8. 9. 10. 11. 12.

7. 8. 9. 10. 11. 12. 13. 14. 15.

Piston displacement Firing order Compression ratio

Mono-block, three cylinder, cast iron

GENERAL INFORMATION LUBRICATING SYSTEM

Injector Nozzle Idle Speed RPM

TABLE 1 Injection Pump Timing Engine Date Code Before 99010100

TABLE 2 Injection Pump Timing Engine Date Code After 98123100

INJECTOR PUMP IDENTIFICATION

7 : 700 cc 8 : 850 cc 9 : 950 cc NAME PLATE IDENTIFICATION CODE

DESTINATION U : USA J : Japan X : Except for USA

TABLE 3 Engine Speed Specification Chart

22100 87802 22100-87802

9U2 8U1 8U2 8U3 8U4 8U5 9U4 9U5

BRIGGS & STRATTON DAIHATSU NUMERICAL NUMBER SYSTEM

GENERAL INFORMATION MAINTENANCE SCHEDULE

Maintenance Operation Check oil level

Check cylinder head bolt torque Check valve clearance

Electrical system Fuel system

Check battery electrolyte Change fuel filter element

Section 2 Cylinder Head and Valves

Overhead Valve Train

CYLINDER HEAD AND VALVES REMOVE CYLINDER HEAD

Fig. 1 Remove V-belt And Fan

Fig. 2 Remove Water Pump And Exhaust Manifold

Fig. 3: f. Valve cover Discard rubber seal.

Fig. 3 Remove Valve Cover

Fig. 4 Remove Fuel Lines

CYLINDER HEAD AND VALVES