Nissan Bd30t Engine Service Manual

SERVICE DATA AND SPECIFICATIONS

INSPECTION AND ADJUSTMENT INJECTION AND FUEL SYSTEM
BASIC MECHANICAL SYSTEM Injection timing B.T.O.C./rpm

T027
Valve clearance (Hot)
mm Onl
Intake & Exhaust 0.35 (0.014) B030 6° /700
Fan belt deflection Idling rpm 700

mm On)/98 N (10 kg, 221b)
Used 11.13 (0.43 - 0.51) Max. engine speed under no-load rpm 2,600 - 2,700
...
New 9 - 11 (0.35 - 0.43) Initial injection pressure

kPa (bar, kg/cm', psi)
Engine oil capacity Q (US qt, Imp qt) 9,807
T027
(Without oil filter) (98.1, 100, 1,422)
T027 5.5 (5-7/8, 4.7/8)
15,691
B030
B030 7.5 (7-718,6.5/8) (156.9,160,2,275)
Water capacitY Q (US gal, Imp gal)

T027 10.8 (2-7/8,2.3/8)
B030 11.3 (3, 2-1/2)

TIGHTENING TORQUE
Radiator cap relief pressure
88 (0.88, 0.9,13)
kPa (bar, kg/cm' ,psi) N.m kg-m ft-lb
Cooling system leaking testing Cylinder head bolt*

147 (1.47,1.5,21)
pressure kPa (bar, kg/cm' , psi) 1st step 39 - 44 4.0 - 4.5 29 - 33
Compression pressure 2nd step 54-59 5.5-6.0 40-43
kPa (bar, kg/cm' , psi)/rpm
Intake manifold
2,942 T027 13.19
Standard 1.3 - 1.9 9 - 14
(29.4, 30, 427)/200
B030 14 - 18 1.4 - 1.8 10 - 13
2,452 Exhaust manifold 25 -29
Minimum 2.5 - 3.0 18 - 22
(24.5, 25, 356)/200
Oil drain plug 49 - 59 5.0 - 6.0 36 - 43
Difference between cylinders 294 (2.9, 3,43)/200
*: Then turn further 80° 100°.
ET-2
Inspection and Adjustment

COMPRESSION PRESSURE Valve guide
Unit: kPIl (bar, kg/em', psi)/rpm Unit: mm (in)
Standard 2,942 (29.4,30,427)/200 Standard Service
Minimum 2,452 (24.5, 25, 356)/200 12.033 • 12.044

Valve guide outside diameter (0.4737.
Differential limit between 0.4742)
294 (2.9, 3, 43)/200
cylinders
Valve guide inner diameter 8.000 - 8.015
CYLINDER HEAD Unit: mm (in) (Finished size) (0.3150 - 0.3156)
Limit 12.00 - 12.011

Cylinder head valve guide hole
(0.4724 -
diameter
Head surface distortion 0.2 (0.008) 0.4729)
Nominal cylinder head height 89.7 (3.531) 0.022.0.044

Interference fit of valve guide
(0.0009 - 0.0017)
VALVE Unit: mm (in) Standard Max. tolerance
T (Margin thickness) Stem to guide clearance

0.02.0.05
Intake (0.0008 - 0.15 (0.0059)
0.0020)
0.04.0.07
Exhaust (0.0016. 0.20 (0.0079)
0.0028)
Valve deflection Iim it

Intake 0.30 (0.0118)
- L -
SEM188 Exhaust 0.40 (0.0157)
Valve head diameter "0" Valve spring

Intake 43.5 (1.713) Free length mm (in) 46.8 (1.843)
42.3/123.6 - 330.5
Exhaust 38.0 (1.496) Assembled height
(42.3/12.6 - 33.7,
mm/N (mm/kg, in/lb)
1.665/27.8 - 74.3)
Valve length "L"
Intake Out of square mm (in) 2.0 (0.079)
117(4.61)
Exhaust
Valve stem diameter "d"
Intake 8.0 (0.315)
Exhaust 8.0 (0.315)
Valve seat angle "0/'

Intake
45°
Exhaust
Valve margin "T" limit 1.0 (0.039)
Valve stem end surface

0.2 (0.008)
grinding limit
Valve clearance (Hot)

Intake
0.35 (0.0138)
Exhaust
EM-2
Inspection and Adjustment (Cont'd)
VALVE LIFTER AND PUSH ROD CYLINDER HEAD TO VALVE DISTANCE
Unit: mm (in) Unit: mm (in)
Standard Limit
24.960. 24.970
Valve lifter outer diameter (0.9827 -
0.9831)
25.000 • 25.033
Cylinder block valve lifter
(0.9843 -
hole diameter
0.9855)
0.030.0.073
Valve Iifter to lifter hole
(0.0012. 0.20 (0.0079)
clearance
0.0029)
Lessthan SEM724C
Push rod bend (T.I.R.)* 0.5 (0.020)
0.3 (0.012)
Standard Limit
*: Total indicator reading
Intake
Rocker shaft and rocker arm 0.225 - 0.725
--------
Unit: mm (in) T027 (0.0089.
0.0285) 1.25
Standard Limit (0.0492)
0.725 - 1.225
B030 (0.0285 -
Rocker shaft
19.979 - 20.00 0.0482)
Outer diameter (0.7866 - -

Exhaust
0.7874)
0.255 - 0.745
T027 (0.0100.
Rocker shaft bend (T.I.R.I
0.0293) 1.75
0.06 0.10
T027 (0.0689)
(0.0024) (0.00391 0.755 - 1.245
B030 (0.0297.
0-0.3 0.60
B030 0.0490)
(0.0.0121 (0.0236)
Rocker arm
20.02 . 20.04
Inner diameter (0.7882 - -
0.7890)
Clearance between rocker

arm and rocker shaft
0.02.0.06
0.20
T027 (0.0008.
(0.0079)
0.0024)
0.014 - 0.056
B030 0.15
(0.0006 -
(0.0059)
0.0022)
EM-3
Valve seat CAMSHAFT AND CAMSHAFT BEARING
Unit: mm (in)
------
Camshaft journal to
bushing clearance
[Oil clearance]
Standard
0.020 • 0.109
10.0008 • 0.0043)
Unit:
Limit
mm (in)
0.15 10.0059)
Camshaft journal diameter

50.721 .50.740
Front -
0.9969 - 1.9976l
50.521 • 50.540
2nd -
11.9890. 1.9898)
SEM953C
50.321 - 50.340
3rd
11.9811 . 1.9819)
-
Intake
44.535 -44.545 50.121 - 50,140
Outer diameter "0, " 4th' -
(1.7533-1.7537) 11.9733-1.9740)
37.9.38.1 49.921 - 49.940

Inner diameter "D2 "
11.492 . 1.500)
Rear
11.9654 - 1.9661)
-
42.4 -42.6 Camshaft bend (Total Less than

Diameter of seat "D3 "
0.06 10.0024)
(1.669-1.677) indicator reading) 0.0210.0008)
Cylinder head valve seat 44.500-44.515 0.08 -0.28

Camshaft end play 0.5010.0197l
diameter 11.7520 • 1.7526) 10.0031 - 0.0110)
Valve seat face angle "</>" 89° . 91°
Exhaust
Outer diameter "0, "
39.535 • 39.545
Standard
(1.5565 • 1.5569)
0.210.008) 39.735-39.745
Oversize IService) (1.5644-1.5648)
0.4 10.016) 39.935 • 39.945 EM671

Oversize IService) 11.5722 • 1.5726)
Standard Limit
32.9 - 33.1
Inner diameter "D2 "
(1.295 . 1.303) Cam height "A"
41.88 - 41 .92 41.4
Intake
Diameter of seat "D3 "
36.90-37.10 11.6488 - 1.6504) (1.630)
11.4528 . 1.4606)
41.88 - 41.92 41.4
Exhaust
Cylinder head valve seat (1.6488. 1.6504) 11.630)
diameter
39.495-39.510
Standard
11.5549-1.5555)
39.695-39.710
0.2 10.008) Oversize
11.5628- 1.5634)
39.895-39.910
0.4 10.016) Oversize
11.5707 -1.5713)
Valve seat face angle "</>" 89° • 90°
Hino engine parts

Mitsubishi engine parts
Nissan engine parts
for heavy equipment
Contact: [email protected]
EM-4
Inspection and Adjustment (Cont' d)
CYLINDER BLOCK AND CYLINDER LINER Unit: mm (in)
Unit: mm (in)
2010.79)
SEM427
SEM950C Cylinder liner diameter "0" 96.050. 96.070

(service) * (3.7815 - 3.7823)
Surface flatness * Before installing in cylinder block

(Without cylinder liner)
Standard Lessthan 0.05 (0.0020)
Limit 0.2 (0.008)
Cylinder bore
Inner diameter
99.000 - 99.020
Standard
(3.8976 - 3.8984)
Cylinder bore
(With cylinder liner)
Inner diameter
Standard
96.000.96.010
Grade No.1
13.7795.3.7799)
96.010 96.020
Grade No.2
(3.7799 3.7803)
96.020 . 96.030
Grade No.3
(3.7803 - 3.7807)
Wear limit 0.20 (0.0079)
Out-of.round IX - y) Lessthan 0.040 (0.0016)
Taper (A - B) Lessthan 0.040 (0.0016)
Projection "S" 0.02.0.09 (0.0008 - 0.0035)
Division of each
Lessthan 0.05 10.0020)
cylinder "S"
Interference fit cylinder liner -0.01 to 0.03

to block (-0.0004 to 0.0012)
EM-5
PISTON, PISTON RING AND PISTON PIN
Available piston Unit: mm (in)
SEM778A
T027 B030
Piston skirt diameter "A"

Standard
Grade No.1 95.940.95.950 (3.7772 - 3.7776) 95.950 - 95.960 (3.7776 - 3.7779)
Grade No.2 95.950.95.960 (3.7776 - 3.7779) 95.960 - 95.970 (3.7779.3.7783)
Grade No. 3* 95.960 - 95.970 (3.7779 - 3.7783) 95.970 - 95.980 (3.7783 - 3.7787)
"a" dimension 70 (2.76) 63.5 (2.500)
Piston pin hole diameter 27.992 - 28.000 (1.1020. 1.1024) 29.997 - 30.005 (1.1810 - 1.1813)
Piston to cylinder liner clearance 0.05 - 0.07 (0.0020 - 0.0028)
* Grade No.3 piston is not provided as a service part.
Piston ring Piston pin

--------
Side clearance
Top
Standard
0.06 - 0.10
(0.0024 - 0.0039)
Limit
0.50 (0.0197)
Piston pin outer diameter
T027
B030
Piston pin to piston

27.993 - 28.000 (1.1021 - 1.1024)
29.993-30.000 (1.1808-1.1811)
0.04 -0.08 clearance

2nd 0.30 (0.0118) T027 -0.008 to 0.007 (-0.0003 to 0.0003)
(0.0016 - 0.0031)
B030 -0.003 to 0.D12 (-0.0001 to 0.0005)
0.02 - 0.06
Oil 0.15 (0.0059)
(0.0008 - 0.0024)
Piston pin to connecting
rod clearance
Ring gap
Standard 0.025 - 0.045 (0.0010 - 0.0018)
0.30 - 0.45
Top
(0.0118 - 0.0177)
Limit 0.15 (0.0059)
0.30 -0.45
2nd
(0.0118 - 0.Q177) 1.5 (0.059)
Oil (rail ring)

0.25 - 0.45
T027
(0.0098 - 0.0177)
0.20 -0.45
B030
(0.0079 - 0.Q177)
EM-6
CONNECTING ROD CRANKSHAFT
Unit: mm (in)
Unit: mm (in)
T027 B030
156.975 - 157.025
Center distance
(6.1801 - 6.1821)
Bend, torsion
[per 100 (3.94)]
Limit 0.05 (0.0020)
28.025 - 28.033 30.025 - 30.038

Piston pin bore dia.
/1.1033 -1.1037) (1.1821 -1.1826)
Side clearance
Standard 0.10 - 0.22 10.0039 - 0.0087) B
Limit 0.22 10.0087)

SEM100A
70.907 - 70.920
Journal diameter "A"
(2.7916 - 2.7921)
56.913 - 56.962
Pin diameter "B"
(2.2407 - 2.2426)
Center distance "S"

T027 46.00 (1.8110)
B030 51.00/2.0079)
Out-of-round X-V A B
TaperA-B ~
Qy
EM715
Taper of journal and pin "A-B"

Standard 0.01 10.0004)
Limit 0.02 (0.0008)
Out-of-round of journal and

pin "X-Y"
Standard 0.01 10.0004)
Limit 0.02 (0.0008)
Crankshaft bend
Standard 0- 0.03 (0.0.0012)
Limit 0.1010.0039)
Crankshaft end play

Standard
0.055 - 0.180
T027
10.0022 - 0.0071)
0.055 - 0.14
B030
(0.0022 - 0.0055)
Limit 0.40 (0.0157)
EM-7
AVAILABLE MAIN BEARING AVAILABLE THRUST WASHER
Bearing clearance Thrust washer undersize
------
Main bearing clearance Th rust washer th ickness

Standard 0.035-0.087 (0.0014-0.0034)
Standard
Limit 0.15 (0.0059) Stamped mark A 2.275 -2.325 (0.0896 -0.0915)
Connecting rod bearing B 2.300 .2.350 (0.0906 -0.0925)

clearance
Standard 0.035-0.081 (0.0014-0.0032) C 2.325.2.375 10.0915-0.0935)
Limit 0.15 (0.0059) Oversize

0.20 (0.0079) 2.475-2.525 (0.0974-0.0994)
0.40 (0.0157) 2.675-2.725 (0.1053 .0.1073)

Main bearing undersize
Unit: mm (in)
Crank journal diameter

MISCELLANEOUS COMPONENTS
Unit: mm (in)
Standard 70.907-70.920 (2.7916 . 2.7921)
Gear train
Undersize
Backlash of each gear 0.07 . 0.11 (0.0028. 0.0043)
0.25 (0.0098) 70.657 .70.670 (2.7818.2.7823)
Limit 0.20 (0.0079)
0.50 (0.0197) 70.407.70.420 (2.7719.2.7724)
Flywheel
0.75 (0.0295) 70.157.70.170 (2.7621 -2.7626)
Runout (Total
1.00 (0.0394) 69.907.69.920 (2.7522 . 2.7528) indicator reading)
TD27 Lessthan 0.15 (0.0059)
BD30 Lessthan 0.10 (0.0039)
Front plate
AVAILABLE CONNECTING ROD BEARING
Warpage limit 0.2 (0.008)
Connecting rod bearing undersize
------
Unit: mm (in)
Crank pin journal diameter
56.913-56.926
Standard
(2.2407-2.2412)
Undersize
56.663 . 56.676
0.25 (0.0098)
(2.2308-2.2313)
56.413 . 56.676
0.50 (0.0197)
(2.2210- 2.2313)
56.163-56.176
0.75 (0.0295)
(2.2111 -2.2116)
55.913-55.926
1.00 (0.0394)
(2.2013-2.2018)
EM-8
Tightening Torque
ENGINE OUTER PARTS ENGINE PARTS
Unit N,m kg-m ft-Ib Unit N'm kg-m ft.lb
Manifold nut Main bearing cap bolt 167. 177 17.0.18.0 123.130
Intake 15 - 20 1,5 - 2.0 11 - 14 Connecting rod big 78.83 8.0.8,5 58 - 61
Exhaust end nut
Without turbo- 25 29 2.5 -3.0 18 - 22 Crank pulley nut 294 -324 30.33 217 - 239
charger
With turbocharger 29-34 3.0 - 3.5 22.25 Flywheel bolt 147.167 15.0-17.0 108 -123
Injection pump nut 20.25 2.0 - 2.5 14 - 18 Timing gear casebolt 16.21 1.6.2.1 12 - 15
Injection pump to bracket 30 - 41 3.1.4.2 22.30 Timing gear casenut 16.21 1.6 - 2.1 12.15
bolt Front end plate bolt 10.13 1.0.1.3 7-9
Injection nozzle to 54.64 5.5 -6.5 40 -47 Camshaft gear bolt 44.49 4.5- 5.0 33- 36
cylinder head
Camshaft locating plate 4.6 0.4-0.6 2.9.4.3
Injection pump drive 59-69 6.0 -7.0 43 - 51 bolt
gear nut
Idler gear shaft bolt 25.35 2.6.3.6 19 - 26
Injection tube flare nut 20.25 2.0 - 2.5 14 - 18
Oil pan bolt 7.9 0.7 -0.9 5.1 - 6.5
Spill tube with cap nut 29-39 3,0 -4.0 22 - 29
Oil pan drain plug 54 59 5.5 -6.0 40-43
Alternator bracket bolt 30 - 41 3,1 - 4.2 22 -30
Cylinder head bolt Refer to installation of cylinder head.
Alternator to adjusting 16 - 21 1.6 - 2.1 12 - 15
bar bolt Glow plug 15.20 1.5 - 2.0 11 - 14
Rocker shaft bracket bolt 20 - 25 2.0 - 2.5 14 - 18
Rocker arm lock nut 15 -20 1.5 - 2.0 11 - 14
Rocker cover screw 1-2 0.1 -0.2 0.7.1.4
Head Bolt Tightening Sequence
Hino engine parts Mitsubishi engine parts Nissan engine parts

Engine parts for heavy equipment
EM-9
CHECKING COMPRESSION PRESSURE (On-vehicle service)
1. Warm up engine.
2. Remove glow plate and glow plugs (TD27 engine) or injec-
tion pipe and nozzle holder assembly (6030 engine).
~
SEM6188
3. F it compression gauge adapter to cylinder head.

Compression gauge adapter:
~: 15 - 20 N.m
(1.5 - 2.0 kg-m, 11 - 14 ft-Ib)
4. Set no fuel injected condition.

Disconnect fuel cut solenoid wire.
5. Crank engine, then read gauge indication.
Engine compression measurement should be made as quickly as
possible.
Compression pressure:
Unit: kPa (bar, kg/cm2, psi)/200 rpm
Standard 2,942 (29.4, 30, 427)
Minimum 2,452 (24.5, 25, 356)
Differential limit between cylinders 294 (2.9, 3,43)
6. If cylinder compression in one or more cylinders is low, pour

a small quantity of engine oil into cylinders through the glow
holes and retest compression.
• If adding oil helps the compression pressure, chances are that
piston rings are worn or damaged.
• If pressure stays low, valve may be sticking or seating im-
properly.
• If cylinder compression in any two adjacent cylinders is low,
and if add ing oil does not help the compression, there is
leakage past the gasketed surface.
Oil and water in combustion chambers can result from this
problem.
EM-10
CYLINDER HEAD
,
!PJ9-11
~ (0.9-1.1,6.5.8.01
Adjusting screw
I
I
Rocker cover
Valve cotter
Cylinder head bolt
r
!PJ: Refer to "CYLINDER HEAD-
, '0''''''''00 (Oo.V.hl". So,,;,,)".
Lower seat
Cylinder head gasket~
Cylinder head
~ Always replace when disassembled
!PJ N.m (kg.m, ft.lbl
SEM693C
EM-12
CYLINDER HEAD
Removal (On-vehicle service)

1. Open top panel.
2. Remove rear floor board.
3. Remove battery.
4. Set NO.1 cylinder at T.O.C. on its compression stroke.
5. Drain engine coolant from drain plugs on cylinder block and
radiator.
6. Remove air cleaner and/or air duct.
7. Remove alternator adjusting bolt.
8. Disconnect exhaust manifold from front exhaust tube.
9. Disconnect radiator outlet hose and thermostat housing
water inlet hose.
10. Remove fuel injection tube assembly and spill tube.
11. Remove injection nozzle holder and top nozzle gasket using
deep socket wrench.
12. Remove rocker cover.

13. Remove rocker shaft with rocker arms.
14. Remove push rods.
EM-13
CYLINDER HEAD
Removal (On-vehicle service) (Cont'd)
15. Remove cylinder head bolts in numerical order and remove
cylinder head.
Head warpage or cracking could result from removing in in-
correct order.
Loosen in numerical order.
8030
Engine
front
SEM697C
Disassembly
1. Remove following parts:
• Intake manifold
• Exhaust manifold
• Thermostat housing
• Alternator adjusting bar & engine slinger
• Glow plate and glow plugs (TD27)
2. Remove valve component parts with Tool.
3. Remove valve oil seals with Tool.
KV1 01 07900
EM-14
CYLINDER HEAD
Disassembly (Cont'd)
4. Disassemble rocker shaft assembly.
a. Remove rocker shaft lock bolt.
b. Remove valve rocker and rocker shaft bracket.
If It Is difficult to remove rocker shaft bracket, Immerse rocker
shaft assembly In 011 of 70°C (158°F)for a few minutes and then
remove bracket.
Inspection
CYLINDER HEAD DISTORTION
Cylinder head distortion:
Limit
0.2 mm (0.008 in)
If beyond the specified limit, correct with a surface grinder.
Cylinder head height should be greater than 89.7 mm (3.531 in)
after surface has been ground.
VALVE GUIDE CLEARANCE

• Valve guide clearance should be measured parallel with
rocker arm. (Generally, a large amount of wear occurs In
this direction.)
Stem to guide clearance:
Limit
Intake 0.15 mm (0.0059 In)
Exhaust 0.20 mm (0.0079 In)
Maximum allowable deflection
(Dial Indicator reading)
SEM586A Intake 0.30 mm (0.0118 In)
Exhaust 0.40 mm (0.0157 In)
• To determine the correct replacement part, measure valve
stem diameter and valve guide Inner diameter.
Valve stem diameter: 8.0 mm (0.315 in)
Valve guide inner diameter:
8.000 • 8.015 mm (0.3150 • 0.3156 In)
EM030
EM-15
CYLINDER HEAD
Inspection (Cont'd)
2. Place new valve seats on dry ice and allow them to cool for
five minutes.
WARNING:
Do not touch cooled valve seats with bare hands.
3. Heat cylinder head to 80°C (176°F).
4. Install cooled valve seats on cylinder head with Tool.
5. Stake exhaust valve seat at five places with punch.

When staking valve seat, select different places than those
staked before.
6. Cut or grind valve seat using suitable tool at the specified

dimensions as shown in S.O.S.
7. After cutting, lap valve seat with a lapping compound.
8. Check contact condition of valve seat.
Hino engine parts

Nissan engine parts COMBUSTION CHAMBER [TD27]
for heavy equipment
Check combustion chamber for cracks and other damage. If
necessary, replace.
REPLACING COMBUSTION CHAMBER [TD27]

Usually combustion chamber should not be removed.
1. Remove combustion chamber so that cylinder head cannot
be damaged.
SEM633B
2. Install combustion chamber.

Identification of combustion chambers:
Identification mark Outer diameter

Engine
(on combustion chamber) "D" mm (in)
37 (1.46) TD27
Identificat ion
mark
SEM599C
EM-17
CYLINDER HEAD
Inspection (Cont'd)
2. Place new valve seats on dry ice and allow them to cool for
five minutes.
WARNING:
Do not touch cooled valve seats with bare hands.
3. Heat cylinder head to 80°C (176°F).
4. Install cooled valve seats on cylinder head with Tool.
5. Stake exhaust valve seat at five places with punch.

When staking valve seat, select different places than those
staked before.
6. Cut or grind valve seat using suitable tool at the specified

dimensions as shown in S.O.S.
7. After cutting, lap valve seat with a lapping compound.
8. Check contact condition of valve seat.
COMBUSTION CHAMBER [TD27]

Check combustion chamber for cracks and other damage. If
necessary, replace.
REPLACING COMBUSTION CHAMBER [TD27]

Usually combustion chamber should not be removed.
1. Remove combustion chamber so that cylinder head cannot
be damaged.
SEM633B
2. Install combustion chamber.

Identification of combustion chambers:
Identification mark Outer diameter

Engine
(on combustion chamber) "D" mm (in)
37 (1.46) TD27
Identificat ion
mark
SEM599C
EM-17
CYLINDER HEAD
Inspection (Cont'd)
(1) Cool combustion chamber with dry ice for approximately
5 to 10 minutes.
WARNING:
Do not touch cooled combustion chamber with bare hand.
Knock pin (2) Align combustion chamber knock pin with cylinder head
o Combustion chamber notch, and drive in combustion chamber with a soft hammer.
Align
3. Check amount of protrusion of combustion chamber.
Protrusion:
Standard
-0.05 to 0.10 mm (-0.0020 to 0.0039 in)
SEM634B
T (Margin thickness) VALVE DIMENSIONS

Check dimensions in eachvalve. For dimensions, refer to S.O.S.
When valve head has been worn down to 1.0 mm (0.039 in) in
margin thickness, replace the valve.
Grinding allowance tor valve stem tip is 0.2 mm (0.008 in) or
less.
VALVE SPRING SQUARENESS

Out-ot-square "S":
Lessthan 2.0 mm (0.079 in)
VALVE SPRING PRESSURE LOAD

Refer to S.O.S.
EM113
EM-18
CYLINDER HEAD
Inspection (Cont'd)
VALVE LIFTER AND PUSH ROD
Valve lifter
1. Check valve lifters for excessive wear on the face.
2. Replace with new ones if worn beyond repair.
a. Valve lifter end should be smooth.
b. Valve lifter to lifter hole clearance:
Standard
0.030 - 0.073 mm (0.0012 - 0.0029 in)
Limit
Valve lifter outer diameter "A":
25.960 - 25.970 mm (1.0220 - 1.0224 in)
Cylinder block valve lifter hole diameter liB":
26.000 - 26.033 mm (1.0236 - 1.0249 in)
Push rod
1. Inspect push rod for excessive wear on the face.
2. Replace if worn or damaged beyond repair.
3. Check push rod for bend using a dial gauge.
Maximum allowable bend
(Total indicator reading):
ROCKER SHAFT AND ROCKER ARM

1. Check valve rockers, brackets and rocker shafts for scoring,
wear or distortion. Replace if necessary.
EM-19
CYLINDER HEAD
Inspection (Cont'd)
2. Check clearance between valve rockers and rocker shaft. If
specified clearance is exceeded, replace affected valve rockers
or shafts.
Specified clearance:
Limit
TD27
Less than 0.20 mm (0.0079 in)
BD30
SEM027
Rocker shaft outer diameter "A":
Standard
19.979 - 20.000 mm (0.7866 - 0.7874 in)
Rocker arm inner diameter "B":
Standard
20.02 - 20.04 mm (0.7882 - 0.7890 in)
3. Check rocker shaft bend at its center. If bend is within

specified limit, straighten it; and if it is greater than specified
limit, replace rocker shaft.
Rocker shaft bend
(Total indicator reading):
Limit
TD27
BD30
SEM028
MEASURING CYLINDER HEAD TO VALVE DISTANCE
o Measure distance from cylinder head surface to intake and
exhaust valves. If specified distance is exceeded, replace valve(s)
or valve seat(s).
Specified distance:
Standard
Intake
TD27
)
0.225 - 0.725 mm
SEM026 "c (0.0089 - 0.0285 in)
BD30
0.725 - 1.225 mm
(0.0285 - 0.0482 in)
Exhaust
TD27
0.255.0.745 mm
(0.0100 - 0.0293 in)
BD30
0.755 - 1.245 mm
(0.0297 - 0.0490 in)
EM-20
CYLINDER HEAD
Inspection (Cont'd)
Limit
Intake and exhaust valves
Assembly
1. Assemble rocker shaft component parts.
Identification of rocker arms:

Identification mark
For use with
(on rocker arm)
B Intake
c Exhaust
SEM700C
2. Install valve component parts.

Identification of valves:
Identification mark
(on intake and exhaust valve)
Intake valve Exhaust valve
3 c
• Always use new valve 011 seal. (Refer to OIL SEAL
SEM926B
REPLACEMENT.)
• Install valve spring (uneven pitch type) with Its narrow pitch
side toward cylinder head side.
Wide pitch
Narrow pitch
•
Cylinder head side SEM638B
EM-21
CYLINDER HEAD
Installation (On-vehicle service)

1. Install cylinder head gasket.
Identification of cylinder head gaskets
Identification cut hole Inner diameter
Engine
(on cylinder head gasket) "d" mm (in)
97.5 (3.839) TD27
SEM600C a. When replacing only cylinder head gasket, install same grade
gasket as the one formerly used.
b. When replacing or repairing cylinder block, cylinder head,
piston, connecting rod and crankshaft, select gasket as
follows:
(1) Measure piston projection.

Measuring points • Set each piston at its Top Dead Center. With piston held in
that position, measure its projections at two points.
• Calculate the average value of the two measurements.
• Determine the amount of projection of the other three
pistons.
Front
(2) Select suitable cylinder head gasket which conforms to the
largest amount of projection of the four pistons.
T027 Unit: mm (in)
SEM640B
Gasket
8030 Average values piston projections Gasket th ickness
grade number
Less than 0.118 (0.0046) 1.30 (0.0512) 1
0.118 - 0.168 (0.0046 - 0.0066) 1.35 (0.0531) 2
More than 0.168 (0.0066) 1.40 (0.0551) 3
8030 Unit: mm (in)

,/L--, Engine
~ front Average values piston Gasket thickness
SEM702C Gasket grade number
projections (nominal dimension)
Less than 0.44 (0.0173) 1.20 (0.0472) 2
0.44 - 0.49 (0.0173 -
1.25 (0.0492) 3
0.0193)
More than 0.49 (0.0193) 1.30 (0.0512) 4
Make sure that No. 1 piston Is at T.O.C. on Its compression

stroke.
EM-22
CYLINDER HEAD
Installation (On-vehicle service) (Cont'd)
2. Install cylinder head.
Cylinder head identification mark:
Identification number
(on cylinder head) Engine
Float mark Punch mark
2 - T027
82 - 8030
3. Apply oil to the thread portion and seat surface of bolts and
tighten cylinder head bolts using Tool.
CAUTION:
Tightening procedure
1st: Tighten bolts to 39 - 44 N.m
(4.0 - 4.5 kg-m, 29 - 33 ft.lb)
2nd: Tighten bolts to 54 - 59 N.m
(5.5 - 6.0 kg-m, 40 - 43 ft-Ib)
Tighten in numerical order. SEM641 B 3rd:
(1) Mark exhaust side of cylinder head and cylinder
head bolts with paint asshown.
(2) Turn all bolts 90:!::10degreesclockwise.
Engine
front (3) Check that the paint mark of each bolt is facing
the front of the vehicle.
@(j)@@@@
Tighten in numerical order. SEM703C
4. Apply engine oil and install push rods.

5. Install rocker shaft assembly.
Rocker shaft bracket bolt:
~: 20 ~ 25 N'm
(2.0 - 2.5 kg-m, 14 - 18 ft-Ib)
Adjust intake and exhaust valve clearances temporarily.
Refer to section ET.
EM-23
CYLINDER HEAD
6. Install rocker cover with rocker cover plate (TD27).
• Be sure the "F" mark on rocker cover plate faces upward and
is at the front end.
• When replacing rocker cover gasket, bend slit of rocker cover
baffle plate a little to hold the gasket. Do not twist gasket.
Rocker cover gasket

SEM643B
8030
Rocker cover
SEM705C
7. Install glow plugs and glow plate (TD27).

Glow plug:
~: 15 - 20 N.m (1.5 - 2.0 kg-m, 11 - 14 ft-Ib)
~
SEM618B
8. Install new top nozzle gasket and injection nozzle.

Injection nozzle holder:
~:44 - 49 N.m
(4.5 - 5.0 kg-m, 33 - 36 ft-Ib)
9. Install spill tube and injection tube.

Spill tube fixing nut:
COJ : 29 - 39 N.m
(3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
Injection tube flared nut:
~: 20 - 25 N.m
(2.0 - 2.5 kg-m, 14 - 18 ft-Ib)
EM-24
CYLINDER HEAD
10. Connect thermostat housing water inlet hose and radiator
hose.
11. After assembling all disassembled parts, fill radiator and
engine with new coolant up to filler opening.
EM-25
OIL SEAL REPLACEMENT (On-vehicle service)
OIL SEAL INSTALLING DIRECTION

When installing a new front or rear seal, make sure its mounting
direction is correct.
Engine. Engine
inside outside
CRANKSHAFT FRONT OIL SEAL

1. Remove counterweight.
2. Remove radiator shroud and radiator.
3. Remove muffler.
4. Remove cooling fan.
5. Remove drive belts.
6. Remove crank pulley.
7. Remove crankshaft oil seal.
Be careful not to damage sealing surfaces of crankshaft.
8. Coat new oil seal with engine oil and install it in place.
VALVE STEM OIL SEAL

1. Remove rocker cover.
2. Remove rocker shaft assembly.
3. Remove valve spring.
4. Remove valve oil seals.
EM-26
OIL SEAL REPLACEMENT (On-vehicle service)
5. Apply engine oil to valve oil seal and install it in place.
i /
Cylinder head or spring seat
SEM565E
EM-27
ENGINE OVERHAUL
Idler gear securing bolt

~ 25 - 35 (2.6 - 3.6, 19 - 26) (T027)
~23 - 30 (2.3 - 3.1,17 - 22) (8030)
Injection pump gear

Oil pump
Idler gear plate
Washer
Idler gear
Injection pump
gear securing nut Front plate ..-
~59 - 69
.~'"
(6.0 - 7.0,
43 - 51)
0"'''' p'''' ~
Dust cover
~~~
~ 13 - 19 0
(1'3-1~9'
9 - 14) f!;j
~ Key , " • Camshaft gear @i rl 2
~.crank.gear (PTO) ~ ~~---~ 4 - 6 (0.4 - 0.6, 2.9 - 4.3)
Front cover ~'

1""~\ \ •
~~...../011
Jet
Idler shaft securing bolt
~~ _ 49
(4.5 - 5.0,
~~~
~
Piston ring
a-ring ~ ~
,:\) Bearing i~~,
Snap ring; 1.
Bolt
Washer
33 - 36)
.
V.
Piston
l
Bolt Snap ring ~
~ " ~/Bolt ~ Connecting rod
1 9~ p ~
~
Washer ~ • 0
PTO i~ler gear ~ '\ ~ Piston pin
securing nut ,
Idler ear (PTO)~ Dummy (to be Connecting rod

go, , removed after bearing
~ O-ring installing oil
pump) Oil jet-~
Adapter (for hydraulic pump) ~ 29 - 39 ~
~c:~:y~~
~
, (3.0 - 4.0,
a-ring 22 _ 29)
Crankshaft
Bearing
(30 - 33, ~ .....\~

217 - 239) ~
~167 - 1n
(17.0 - 18.0,
123 - 130)
Oil pan
~7-9 ~
(0.7 - 0.9,
5.1 - 6.5) rn <Q>
.- .. 54 - 59~
~: N.m (kg-m, ft-Ib) (5.5 - 6.0,
D : Apply recommended sealant. 40 - 43)
(Nissan genuine part: KP610-00250) or equivalent.
~ : Always replace when disassembled,
l' : Keep in correct order.
FEM178
EM-28
ENGINE OVERHAUL
Disassembly
PISTON AND CRANKSHAFT
1. Remove oil filter.
2. Place engine on work stand.
SEM650B
Attachment installation hole
FEM179
3. Drain coolant and oil.

Coolant drain plug. D 4. Remove drive belts.
5. Remove cylinder head.
6. Remove oil pan.
=
FEM180
7. Remove crank pulley.
8. Remove water pump.

9. Remove front cover.
SEM652B
EM-29
ENGINE OVERHAUL
" the timing case Is hard to remove due to liquid gasket, pry It
off with a suitable tool at the cutout section.
SEM676B
10. Remove injection pump gear.
SEM653B
11. Remove idler gear and idler gear shaft.

12. Remove camshaft gear, camshaft and valve lifters.
SEM655B
13. Remove oil pump assembly.
EM-30
ENGINE OVERHAUL
14. Remove PTO gear, PTO idler gear and PTO crankshaft gear.
15. Remove crankshaft gear.

16. Remove flywheel and rear plate.
17. Remove connecting rod caps.
18. Remove pistons.
19. Remove rear oil seal retainer.
SEM6578
20. Remove bearing cap and crankshaft.

Place the bearings and caps in their proper order.
Loosen in numerical order.

SEM6588
EM-31
ENGINE OVERHAUL
Inspection and Replacement
1t~Qtt
---: Measuring point
CYLINDER BLOCK DISTORTION
If beyond the specified limit, replace it.
Cylinder block distortion:
~ Standard
Less than 0.05 mm (0.0020 In)
Limit
~-( 0.2 mm (0.008 In)
~({~
SEM038
CYLINDER LINER WEAR

1. Measure cylinder liner bore for out-of-round and taper with
a bore gauge. If beyond the limit, replace cylinder liner.
Inside diameter (With cylinder liner for factory):
96.000 - 96.030 mm (3.7795 - 3.7807 in)
Refer to S.O.S.
Inside diameter (WIth cylinder liner for service):
96.025 - 96.070 mm (3.7805 - 3.7823 in)
Wear limit:
Unit: mm (in) 0.20 mm (0.0079 In)
FEM182 Out-of-round (X - Y) limit:
0.040 mm (0.0016 in)
Taper (A - B) limit:
0.040 mm (0.0016 in)
2. Check for scratches or seizure. If seizure is found, replace
cylinder liner.
projectio~ 3. Check amount of projection of cylinder liner.

Cylinder liner projection:
Standard
0.02 - 0.09 mm (0.0008 - 0.0035 In)
Deviation of each cylinder:
CYLINDER LINER
Replacement
1. Remove cylinder liner with Tool.
SEM849
EM-32
ENGINE OVERHAUL
Inspection and Replacement (Cont'd)
2. Install cylinder liner with Tool.
3. Check amount of projection of cylinder liner.
SEM659B
PISTON TO CYLINDER WALL CLEARANCE

1. Measure piston and cylinder bore diameter.
Piston diameter "A":
Refer to S.O.S.
Measuring point "a" (Distance from the top):
T027
70 mm (2.76 In)
B030
63.5 mm (2.500 in)
SEM660B 2. Check that piston clearance is within the specification.
Piston clearance:
0.05 - 0.07 mm (0.0020 - 0.0028 in)
PISTON AND PISTON PIN CLEARANCE

Check clearance between pistons and piston pins.
Clearance (B - A):
Standard
-0.003 to 0.012 mm (-0.0001 to 0.0005 In)
Limit
SEM424
EM-33
ENGINE OVERHAUL
PISTON RING SIDE CLEARANCE
Side clearance:
Top ring
0.06.0.10 mm (0.0024.0.0039 In)
2nd ring
0.04 • 0.08 mm (0.0016.0.0031 In)
all ring
0.02 • 0.06 mm (0.0008 • 0.0024 In)
Max. limit of side clearance:
Top
0.5 mm (0.020 In)
2nd
0.3 mm (0.012 in)
all
0.15 mm (0.0059 in)
PISTON RING GAP

Install piston rings in grooves on cylinder liner within a range
of 20 mm (0.79 in), as shown, before measuring piston ring
gaps.
Ring gap (With cylinder liner for factory):
Top ring
0.30 • 0.45 mm (0.0118.0.0177 In)
2nd ring
~~Cl
Cylinder liner - 0.30 • 0.45 mm (0.0118 • 0.0177 in)
Unit: mm (in) Oil ring
SEM004E
T027
0.25 • 0.45 mm (0.0098 • 0.0177 in)
8030
0.20 • 0.45 mm (0.0079 • 0.0177 in)
Max. limit of ring gap:
1.5 mm (0.059 In)
Ring gap (With cylinder liner for service):
Top ring
0.40.0.60 mm (0.0157 • 0.0236 In)
2nd ring
8030
0.30 • 0.50 mm (0.0118 • 0.0197 In)
T027
0.60 • 0.80 mm (0.0236 • 0.0315 In)
Oil ring
0.40 • 0.65 mm (0.0157 • 0.0256 in)
Max. limit of ring gap:
1.5 mm (0.059 In)
EM-34
ENGINE OVERHAUL
MAIN BEARING CLEARANCE
Main bearing clearance:
Standard
0.035 . 0.087 mm (0.0014 . 0.0034 In)
Limit
1. Install main bearings to cylinder block and main bearing

cap.
2. Install main bearing cap to cylinder block.
Tighten all bolts In correct order and In two or three stages.
3. Measure inside diameter "A" of main bearing.
4. Measure outside diameter "Dm" of main journal in crank-

shaft.
5. Calculate main bearing clearance.

Main bearing clearance = A - Dm
CONNECTING ROD BEARING CLEARANCE

Connecting rod bearing clearance:
Standard
0.035 - 0.081 mm
(0.0014. 0.0032 In)
Limit
1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
EM-35
ENGINE OVERHAUL
Apply 011to the thread portion of bolts and seating surface of
nuts.
3. Measure inside diameter "A" of bearing.
4. Measure outside diameter "Op" of pin journal in crank-
shaft.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = A - Op
SEM507A
CONNECTING ROD BEND AND TORSION

Bend and torsion:
Limit
0.05 mm (0.0020 in)
per 100 mm (3.94 in) length
EM133
CONNECTING ROD SMALL END BUSHING CLEARANCE

1. Measure inside diameter "A" of connecting rod small end
bushings.
SEM781B
2. Measure outside diameter "0" of piston pin.

3. Calculate connecting rod small end bushing clearance.
Connecting rod small end bushing clearance = A - 0
Bushing clearance:
Standard
0.025 - 0.045 mm (0.0010 - 0.0018 In)
Limit
0.15 mm (0.0059 In)
EM-36
ENGINE OVERHAUL
REPLACEMENT OF CONNECTING ROD SMALL END
BUSHING
1. Drive in the small end bushing until it is flush with the end
surface of the rod.
Be sure to align the 011holes.
2. After driving in the small end bushing, ream the bushing.
Small end bushing Inside diameter:
Finished size:
T027
SEM062A 28.025 - 28.038 mm (1.1033.1.1039 in)
8030
30.025 . 30.038 mm (1.1821 - 1.1826 in)
Out-of-round X- Y CRANKSHAFT
Taper A - B
1. Check crankshaft journals and pins for score, bias, wear or
cracks. If faults are minor, correct with fine crocus cloth.
2. Check journals and pins with a micrometer for taper and
out-of-round.
Out-of-round (X - Y):
Standard
Limit
0.02 mm (0.0008 In)
EM715 Taper (A - B):
Standard
Limit
0.02 mm (0.0008 In)
3. Check crankshaft runout.

Runout [T.I.R. (Total Indicator Reading)]
Standard
0.0.03 mm (0 - 0.0012 In)
Limit
0.10 mm (0.0039 In)
SEM662B
ENGINE OVERHAUL
RESURFACING OF CRANKSHAFT JOURNAL AND
CRANK PIN
When using undersize main bearings and connecting rod
bearings, the crankshaft journals or crank pins must be finished
LLLL
O.K. N.G. N.G. N.G.
to match the bearings.
R: Crank Journal: 3.0 mm (0.118 In)
CAUTION:
Crank pin: 3.5 mm (0.138 In)
a. At the same time make sure that the surface width does not
SEF692A
increase.
b. Do not attempt to cut counterweight of crankshaft.
CRANKSHAFT PilOT BUSHING
Crankshaft pilot bushing replacement
1. Pull out bushing with Tool.
5.8 - 6.0 mm 2. Insert pilot bushing until distance between flange end and
(0.228 - 0.236 In) bushing is specified value.
Distance:
Approx. 5.8 • 6.0 mm (0.228 • 0.236 In)
FLYWHEEL RUNOUT
Runout (Total Indicator reading):
SEM059A
FRONT PLATE
Check front plate for warpage. If not within the limit, make flat
or "replace front plate.
Warpage limit:
0.2 mm (0.008 In)
SEM6688
EM-38
ENGINE OVERHAUL
GEAR TRAIN
Camshaft drive gear, injection pump drive gear, oil
pump gear, Idler gear and crankshaft gear
1. If gear tooth and key have scratches or are excessively
worn, replace gear and key.
2. Check gear train backlash before disassembling and after
assembling.
Method A (Using dial gauge)
Method B (Using fuse wire)
If beyond the limit, replace gear.
Backlash:
Standard
T027
0.07 . 0.11 mm (0.0028 - 0.0043 in)
B030
0.06 - 0.12 mm (0.0024.0.0047 in)
limit
0.20 mm (0.0079 in)
IDLER GEAR BUSHING CLEARANCE

1. Measure idler gear shaft outer diameter.
SEM666B
2. Measure idler gear bushing inner diameter.

3. Calculate idler gear bushing clearance.
Bushing 011 clearance:
Standard
0.025 • 0.061 mm (0.0010 • 0.0024 In)
Limit
0.20 mm (0.0079 In)
SEM705
IDLER GEAR END PLAY

Measure idler gear end play between gear plate and gear.
Idler gear end play:
Standard
0.03.0.14 mm (0.0012 • 0.0055 In)
Limit
EM-39
ENGINE OVERHAUL
REPLACEMENT OF IDLER GEAR BUSHING
1. Use a suitable tool to replace bushing.
2.. Ream idler gear bushing.
Finished size:
42.00 • 42.02 mm (1.6535 • 1.6543 in)
Idler gear shaft
Install idler gear shaft so that oil hole of shaft faces upward.
CAMSHAFT AND CAMSHAFT BUSHING

Camshaft bushing clearance
Measure inside diameter of camshaft bushing and outside
diameter of camshaft journal with a suitable gauge.
Clearance between camshaft and bushing (A - B):
Standard
0.020 • 0.109 mm
(0.0008 • 0.0043 in)
Limit
SEM669B Less than 0.15 mm (0.0059 In)
REPLACING CAMSHAFT BUSHING

1. Using Tool, remove camshaft bushings from the engine.
Some bushings must be broken in order to remove.
SEM106C
Cam bushing replacer set 2. Using Tool, install camshaft bushings as follows:
KV111045S0
Adapter
I1st bushing)
KV11104530
f ~D';h
ST15243000
SEM993B
(1) Install camshaft bushings in the order of "rear", "4th",

"3rd". "2nd" and "front". All bushings must be installed
Upward
from the front.
(2) Face the cutout upward and toward the front of the engine
during installation.
Q Front
5
Engine
front
SEM686B
EM-40
ENGINE OVERHAUL
(3) Rear camshaft bushing
a) Align the cutout of rear bushing with knock pin of replacer
bar before installation.
b) Insert rear bushing with replacer bar into the engine.

Install guide plate with bolt holes (on the 'TO" mark side)
facing upper side of cylinder block. Tighten bolts.
c) Drive replacer bar until the alignment mark on replacer bar

is aligned with the end of replacer guide.
Remove replacer set.
After installation, check that oil holes in camshaft bushings
are aligned with oil holes in cylinder block.
EM-41
ENGINE OVERHAUL
Alignment mark to Rear bushing

Guide plate @ surface
Knock pin
Replacer bar
Engine
front
SEM601C
(4) 4th. 3rd and 2nd camshaft bushings

Install in the same manner as rear camshaft bushing.
Alignment mark to
@ surface
Engine
front
Alignment mark to
@ surface
SEM602C
EM-42
ENGINE OVERHAUL
Inspection and Replacement (Co nt' d)
(5) Front camshaft bushing
Using 1st bushing adapter. position front camshaft bushing
so that oil hole in cylinder block is aligned with oil hole in
bushing.
3. Check camshaft bushing clearance.
4. Install new welch plug with a drift.

Apply liquid sealer.
Liquid sealer
When setting 4th through 2nd bushings on replacer bar,

tape the bar to prevent movement.
SEM999B
EM-43
ENGINE OVERHAUL
CAMSHAFT ALIGNMENT
1. Check camshaft journal and cam surface for bend, wear or
damage.
If fault is beyond limit, replace.
2. Check camshaft bend at center journal.
If bend is greater than specified limit, repair or replace
camshaft.
Camshaft bend
(Total Indicator reading):
Standard
SEM670B Less than 0.02 mm (0.0008 In)
Limit
3. Measure camshaft end play between locating plate and

gear. If beyond the specified limit, replace camshaft locat-
ing plate.
Camshaft end play:
Standard
0.08 - 0.28 mm (0.0031 - 0.0110 In)
Limit
4. Measure camshaft cam height. If beyond the specified limit,

replace camshaft.
OJ cam
height
earn height:
Standard
Intake
41.88 - 41.92 mm (1.6488 - 1.6504 in)
Exhaust
41.88 - 41.92 mm (1.6488.1.6504 in)
Limit
SEM037 Intake
Exhaust
SO camshaft identification
SEM717C
EM-44
ENGINE OVERHAUL
1D27 Leaf type Assembly

combustion
chamber
PISTON
Assemble pistons, piston pins, snap rings and connecting rods.
Grade mark a. Numbers are stamped on the connecting rod and cap cor-
(Left direction)
Engine
responding to each cylinder. Care should be taken to avoid
front a wrong combination Including bearing.
Matching mark
(Cylinder No.)
SEM672S
8D30
Grade mark
Engine
front
c::?
Matching mark
(cylinder No.)
SEM718C
b. When Inserting piston pin In connecting rod, heat piston

with a heater or hot water [approximately 60 to 70°C (140
to 158°F)] and apply engine 011 to pin and small end of con-
necting rod.
c. After assembling, ascertain that piston swings smoothly.
SEM292
Install piston assembly.

CAUTION:
a. Stretch the piston rings only enough to fit them In the pis-
ton grooves.
b. Be sure the manufacturer's mark faces upward.
c. Identification of top piston ring and second piston ring.
White paint""/ Punch mark side up

identification mark (Both top and second
(2nd piston ring only) piston rings)
SEM005E
EM-45
ENGINE OVERHAUL
Assembly (Cont'd)
TD27 Ring gap direction d. Install No.1 piston ring In such a way that Its gap faces the
direction of the piston pin; and then Install piston rings so
that their gap positioned at 180 to one another.
0
8D30
Identification
mark
Top and
oil ring
2nd ring
Engine
front
Piston grade number
SEM719C
CRANKSHAFT
1. Install crankshaft.
(1) Set main bearings in the proper position on cylinder block.
a. If either crankshaft, cylinder block or main bearing Is
reused again, It Is necessary to measure main bearing
clearance.
b. Upper bearings have 011 hole and 011 groove, however
lower bearings do not.
(2) Apply engine oil to crankshaft journal and pin and install
crankshaft.
(3) Install main bearing caps.
Engine a) Install main bearing cap with the number facing the front of
front vehicle.
b) Apply engine oil to main bearing cap and cylinder block
contact surfaces.
c) Install rear oil seal assembly. Apply engine oil to contact
surface of rear end oil seal and crankshaft.
SEM6748
(4) Install crankshaft thrust washer at the 4th journal from

front.
Install thrust washer so that 011 groove can face crankshaft.
SEM057
EM-46
ENGINE OVERHAUL
Assembly (Cont'd)
(5) Tighten bearing cap bolts gradually in stages, starting from
two to three separate stages, from center bearing and mov-
ing outward in sequence.
Tighten in numerical order. SEM675B
(6) Measure crankshaft free end play at No.4 bearing.

Crankshaft free end play:
Standard
0.055.0.180 mm (0.0022.0.0071 In)
Limit
0.4 mm (0.016 In)
If beyond the limit, replace No.4 main bearing thrust washer.
Refer to S.O.S.
SEM063
2. Install pistons with connecting rods.

(1) Install them into corresponding cylinder using Tool.
• Be careful not to scratch cylinder wall with connecting rod.
Engine • Apply engine 011 to cylinder wall, piston and bearing.
front • The leaf type combustion chamber on piston head must be
at right side of engine.
SEM453
(2) Install connecting rod bearing caps.
Hino engine parts

Nissan engine parts
for heavy equipment
SEM678B
EM-47
ENGINE OVERHAUL
Assembly (Cont'd)
3. Measure connecting rod side clearance.
Connecting rod side clearance:
Standard
0.10.0.22 mm (0.0039.0.0087 In)
Limit
0.22 mm (0.0087 In)
If beyond the limit, replace connecting rod and/or crankshaft.
GEAR TRAIN
Idler gear 1. Set NO.1 piston at its top dead center.
2. Align each gear mark and install gears.
SEM665B
TIMING GEAR CASE

Installation
1. Before installing timing gear case, remove all traces of liq~
uid gasket from mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of
front plate.
SEM680B
2. Apply a continuous bead of liquid gasket to mating surface

of timing gear case.
SEM681B
EM-48
ENGINE OVERHAUL
Assembly (Cont'd)
----- Application portion SEM682B
• Be sure liquid gasket Is 2.5 to 3.5 mm (0.098 to 0.138 In)

wide.
• AUach timing gear case to front plate within 10 minutes
Cut here after coating.
.~-----J Liqu id gasket

•
•
Walt at least 30 minutes before refilling engine coolant or
starting engine.
Use Genuine Liquid Gasket or equivalent.
SEM683B
EM-49
SPECIAL SERVICE TOOLS
': 5pecial tool or commercial equivalent

Tool number Engine application
Tool name Description
TD27 BD30
5T05015000' Disassembling and

Engine stand assembly assembling
(1) 5T05011000
Engine stand
@ 5T05012000 x x
Base
KV10106500'
Engine attachment
x x
KV11103200'
Engine sub-attachment
X X
~~
KV10109250 Q) Disassembling and

(1) KV10109210' assembling valve compo-
Valve spring com- nents
pressor X
X
@ KV10111200'
Adapter
~
KV10107900' Disassembling valve oil
Valve oil seal puller seal
X X
KV11103400 Installing valve oil seal

Valve oil seal drift
X X
5T11033000' Removing valve guide

Valve guide drift
X X
KV11103900' Installing valve guide

Valve gUide drift
X X
EM-50
*: Special tool or commercial equivalent

Description
Tool name TD27 BD30
ST11032000' Reaming valve guide

Valve guide reamer
8.0 mm (0.315 in) dia. X X
G) KV11101110 Removing valve seat

X X
Valve seat remover
@ KV11103510
CD
Adapter (Intake) 2 @@@@CV
@ KV11103520
Adapter (Exhaust)
@ KV11104910
Adapter (Intake)
@ KV11104920
Adapter (Exhaust)
@ KV11103610
X X
Adapter (Intake)
(f) KV11103620
X X
Adapter (Exhaust)
G) ST15243000 Installing valve seat X X
Valve seat drift
@ KV11103710 @@
Adapter (Intake)
@ KV11103720
Adapter (Exhaust)
@ KV11103810 ~ X X
Adapter (Intake)
@ KV11103820 X X
Adapter (Exhaust)
~
@@
G) KV11104010 Removing and installing X X

Cylinder liner tool cylinder liner
@ KV11104020
Adapter for remov-
ing
@@@
@ KV11104700
Adapter for remov-
ing
@ KV11104110
tJ,@ X X
Adapter for remov-
ing
@ KV11104030
Adapter for install-
ing
d X X
EM03470000' Installing piston into cylin-

Piston ring compressor der
X X
~
EM-51
*: Special tool or commercial equivalent

Description
Tool name TD27 8030
KV111033S0 Preventing crankshaft from

Engine stopper rotating
G) KV11103310
Stopper plate
@ KV10105630 x x
Stopper gear
ST16610001' Removing pilot bushing

Pilot bushing puller
x x
KV111045S0 Removing cam bushing or

eam bushing replacer installing cam bushing
set
G) KV11104510
Replacer bar
@ KV11104520
Guide plate
@ KV11104530
Adapter
x x
(1st bushing)
@ ST15243000
Drift
KV10109300' Preventing drive gear

Injection pump drive from rotating (VE-type)
gear holder
x
KV11103000' Removing drive gear (VE-

Injection pump drive type)
gear pUller
x
WS39930000' Pressing the tube of liquid

Tube presser gasket
x x
EM-52

Description
Tool name
TD27 8D30
ED19601000 Checking compression
Compression gauge pressure
x x

adapter (for glow plug
hole)
x

adapter (for injector
hole)
x

adapter (for injection
hole) x
DK57914010 Removing and installing

Socket wrench (For injection pump assembly
timer round nut)
x
KV11226582 Removing injection pump

Timer extractor assembly
EM-53
Engine Lubrication System
OIL PRESSURE CHECK TIGHTENING TORQUE
Engine Approximate discharge pressure Unit N'm kg-m ft-Ib

rpm kPa (bar, kg/em' , psi)
Oil pump fixing bolt 13 -19 1.3 -1.9 9 -14
Idle speed 98 (0.98, 1.0, 14) Oil cooler securing bolt 16 - 21 1.6 -2.1 12 -15
3,000 294 - 441 (2.94 - 4.41,3.0 - 4.5, 43 - 64)
Oil filter bracket fixing 16 -21 1.6 - 2.1 12 - 15
bolt
Oil jet bolt (for piston) 29 -39 3.0 -4.0 22 - 29

Oil pump relief valve 29 - 49 3.0 - 5.0 22 - 36
OIL PUMP INSPECTION Oil cooler short valve 29 -49 3.0 - 5.0 22 - 36
Unit: mm (in)
Regulator valve 29 -49 3.0 - 5.0 22 - 36
Gear side clearance 0.05 - 0.13 (0.0020 - 0.0051 )
Gear backlash 0.07. 0.11 (0.0028 - 0.0043)
Oil pump bushing clearance Less than 0.15 (0.0059)
Oil pump bushing inside 13.012 -13.098 (0.5123 -0.5157)

diameter
Drive gear shaft outside 12.974 - 12.992 (0.5108 - 0.5115)

diameter
Engine Cooling System
THERMOSTAT TIGHTENING TORQUE
Valve opening temperature Unit N'm kg-m ft-lb

82 (180)
°c (0 F)
Water pump
Max. valve lift
8/95 (0.31/203) M8 16 - 21 1.6 -2.1 12 - 15
mmtc (intF)
Ml0 30 -41 3.1 -4.2 22 - 30
Thermostat housing bolt 16 - 21 1.6.2.1 12 -15
Water outlet bolt 16 - 21 1.6 -2.1 12 -15
Fan securing bolt 7 -9 0.7 -0.9 5.1 - 6.5

RADIATOR Cylinder block drain plug 20 - 29 2.0 - 3.0 14 - 22
Unit: kPa (bar, kg/em', psi)
Water temperature sensor 20 - 29 2.0 - 3.0 14 - 22
78 -98
Cap relief pressure
(0.78 - 0.98, 0.8 -1.0, 11 -14)
Leakage test pressure 98 (0.98, 1.0, 14)
LC-2
ENGINE LUBRICATION SYSTEM
Lubrication Circuit
Oil cooler assembly
Oil jet (for piston & cylinder)

Oil jet (for gear train)
Note: ~ Oil gallery in cylinder block
-4- -- - By-pass passage
-l
~ Oil passage
________ Return to oil pan
Engine oil cooler

------j Regulator valve "--I
I
I
Oil strainer Oil pan

_lJ
FEL030
LC-5
011 Pressure Check (On-vehicle service)

WARNING:
a. Be careful not to burn yourself, as the engineand oil may
be hot.
b. Oil pressure check should be done in "Neutral" gear posi-
tion.
1. Check oil level.

2. Remove oil pressure switch.
3. Install pressure gauge.

4. Start engine and warm it up to normal operating tempera-
ture.
5. Check oil pressure with engine running under no-load.
Approximate discharge pressure

Engine rpm
kPa (bar, kg/cm2 , psi)
Idle speed 98 (0.98, 1.0, 14)
294.441
3,000
(2.94 . 4.41, 3.0 . 4.5, 43 . 64)
If difference is extreme, check oil passage and oil pump for

011 leaks.
6. Install oil pressure switCh.
Use proper liquid sealant.
Oil pressure switch:
~ : 10 • 13 N.m (1.0 - 1.3 kg-m, 7 - 9 ft-Ib)
LC-6
ENG INELU BRI CATION SYSTEM
Oil Pum
Oil pump-
SLC020A
OIL PUMP INSPECTION

1. Insf?ect pump body, gears and drive shaft for wear and
damage.
2. Using a feeler gauge and fuse wire, check the following
clearances.
Gear side clearance:
0.05 - 0.13 mm (0.0020 - 0.0051 in)
Gear backlash:
0.07 - 0.11 mm (0.0028 - 0.0043 in)
SLC967
3. Measure inside diameter "A" of bushing.

A: 13.012 - 13.098 mm (0.5123 - 0.5157 in)
LC-7
ENGINE LUBRICAT.lON SYSTEM
Oil Pump (Cant'd)
4. Measure outside diameter "8" of drive gear shaft.
B: 12.974 - 12.992 mm (0.5108.0.5115 in)
5. Calculate oil pump bushing clearance.
Oil pump bushing clearance: A - B
SLC969
If it exceeds the limit, replace oil pump bushing or entire oil

pump assembly.
SLC965
LC-8
Oil Filter Bracket
@
III
all pump """"" /@(, .~(~".. ~""k:;~tM b~k"

(For loading pump lubrication) ... ~ / ~
~
~
Bolt (6)
16.19 (1.6.1.9.12.14)
: Always replace after every disassembly.
! ;ket
Oil filter
~ : N.m (kg-m, ft-Ib)

FEL031
OIL PUMP RELIEF VALVE INSPECTION

1. Visually inspect components for wear and damage.
2. Coat relief valve with engine oil and check that it falls
smoothly into the valve hole by its own weight.
If damaged, replace oil pump relief valve set.
OIL FILTER RELIEF VALVE INSPECTION

Inspect oil filter short valve for movement, cracks and breaks
by pushing the ball.
If damaged, replace oil filter bracket assembly.
LC-9
Oil Cooler
Regulator valve-
- Oil cooler elel'T)ent
~ : N.m (kg-m, ft.lb) SLC973
OIL COOLER RELIEF VALVE INSPECTION

Inspect oil cooler relief valve for movement, cracks and breaks
by pushing the ball.
If damaged, replace oil cooler relief valve set.
REGULATOR VALVE INSPECTION

1. Visually inspect components for wear and damage.
2. Coat regulator valve with engine oil and check that it falls
smoothly into the valve hole by its own weight.
If damaged, replace regulator valve set.
LC-10
Oil Jet
INSPECTION
Gear train
Make sure that the holes are not clogged. Clean them with a wire
if necessary.
Oil jet has to be installed with oil hole facing crank gear and
idler gear.
Piston
1. Blow through outlet of oil jet and make sure that air comes
out of inlet.
2. Push cut-off valve of oil jet bolt with a clean resin or brass
rod and make sure that cut-off valve moves smoothly with
proper repulsion.
When installing oil jet, align oil jet's boss with hole on cylinder
block.
Oil jet bolt:
~: 29-39N.m
(3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
Dimension "0":
12 mm (0.47 in)
SLC325A
LC-11
COOlIN6,SYSTEM
Cooling Circuit
Water pump assembly
Radiator
t
Thermostat
housing
t
•
Water pump Water outlet
{7
Engine oil cooler Cylinder block Thermostat
t
Cylinder head
<$' 1 Under cold conditions
LC..12
COOLING SYSTEM
Cooling System Inspection

CHECKING HOSES
Check hoses for proper attachment, leaks, cracks, damage, loose
connections, chafing and deterioration.
CHECKING RADIATOR CAP

Apply pressure to radiator cap by means of a cap tester to see if
it is satisfactory.
Radiator cap relief pressure:
78.98 kPa
(0.78 .0.98 bar, 0.8 . 1.0 kg/cm2 , 11 . 14 psi)
CHECKING COOLING SYSTEM FOR LEAKS

Apply pressure to the cooling system by means of a tester to
check for leakage.
Testing pressure:
98 kPa (0.98 bar, 1.0 kg/cm2
, 14 psi)
CAUTION:
Higher than the specified pressure may cause radiator damage.
SMA990A
LC-13
COOLING SYSTEM
Water Pump
REMOVAL AND INSTALLATION
Drain coolant from drain plugs on cylinder block and radiator.
Cylinder block drain plug
(Use proper sealant):
~: 20 - 29 N.m
(2.0 - 3.0 kg-m, 14 - 22 ft-Ib)
Nut (2)
t"J 26 - ,. "_7 - 3.7. 20 - 27' ~
,~ Water pump gasket ~
\8011151
~ 13.19 (1.3.1.9, 9.14)
~ : Always replace after every disassembly"

~ : N.m (kg-m, ft-Ib)
FCD024
CAUTION:
a. When removing water pump assembly, be careful not to get
coolant on drive belt.
b. Water pump cannot be disassembled and should be replaced
as a unit.
c. Always replace with new gasket.
d. After installing water pump, connect hose and clamp secure.
Iy, then check for leaks using radiator cap tester.
LC-14
COOLING SYSTEM
Water Pump (Cont'd)
INSPECTION
1. Check for badly rusted or corroded body assembly and vane.
2. Check for rough operation due to excessive end play.
FCD025
3. Check fan coupling for rough operation, oil leakage or bent

bimetal.
The water pump and fan coupling cannot be disassembled and
should be replaced as a unit.
Water Outlet and Thermostat

Bolt
Harness Clamp~tDJ'3- 19 (1.3 ,'.9, 9.14)
Water outlet~YBOIt (2)

tDJ13 - 19 (1.3 - 1.9,9 - 14)
F1f.
~Ga"" 0 ///1I OPT :~";"'~
~
Therm~:~~~ostat
Bolt
tDJ 13 - 19 (1.3 - 1.9,
housing
'/
()XJ/ Cylinder head
9 - 14) Washer
Bolt _ () ()
Bolt
9 - 14)
A13-'911_3-'_9.9-141~<¥'
@i7t~ Y0~...
~-'
\-.,
<", •••
>. • Q tDJ 15-25
(1.5-2.5,1'-'8)
~ : Always replace after every disassembly. b 1...1

/1
i ~It. (2)
Thermal transmitter
tDJ 15-20 (1.5-2.0, '1-14)

Prl'I : N.m (kg-m, ft.lb) Rub er sea Prl'I 13.19 (1.3.1.9,9 - 14)
.-J .-J FCD026
• After installation, run engine for a few minutes, and check

for leaks.
• Be careful not to spill coolant over engine compartment.
Place a rag to absorb coolant.
LC-15
COOLING SYSTEM
Water Outlet and Thermostat (Cont'd)
INSPECTION
1. Check for valve seating condition at ordinary temperatures. It
should seat tightly.
2. Check valve opening temperature and maximum valve lift.
Valve opening temperature °c (oF) 82 (l80)
Max. valve lift mmtC (intF) 8/95 (0.31/203)
SLC343
3. Then check if valve closes at 5°C (9° F) below valve opening
temperature.
Radiator
WARNING:
To avoid serious personal injury, never remove radiator cap
quickly when engine is hot. Sudden release of cooling system
pressure is very dangerous.
If it is necessary to remove radiator cap. when radiator is hot,
cover the cap with waste cloth and turn cap slowly counterclock-
wise to the first stop. After all pressure in the cooling system
is released, turn cap passing the stop and remove it.
INSPECTION
Checking radiator cap
Checking cooling system for leaks

LC-16
Tool number
Description
Tool name
ST25051001
Oil pressure gauge
a
ST25052000 Adapting oil pressure gauge
Hose to cyl inder block
uI
EG17650301 Adapting radiator cap tester
Radiator cap tester to rad iator fi lIer neck
adapter
LC-17
Inspection and Adjustment

Injection timing
Dimension '~K" mm (in) 3.2 - 3.4 (0.126 - 0.134)
Engine Plunger lift mm (in)
0.632 - 0.672 (0.0249 - 0.0265)

TD27
. (equivalent to 5° B.T.D.C.)
1.20 - 1.24 (0.0472 - 0.0488)

BD30
(equivell!ll'1ttq6° B.T.D.C.)
UK"
SEF639
Adjusting shim ("B" position)
Thickness Thickness
Part number Part number
mm(in) mm (in)
16884.V0700 1.92 (0.0756) 16742-R8100 1.96 (0.0772)

16884-V0701 2.00 (0.0787) 16742-R8101 2.04 (0.0803)
16884-V0702 2.08 (0.0819) 16742-R8102 2.12 (0.0835)
~
= 16884-V0703 2.16 (0.0850) 16742-R8103 2.20 (0.0866)
SEF016A 2.28 (0.0898)
16884.V0704 2.24 (0.0882) 167 42-R81 04
16884-V0705 2.32 (0.0913) 16742.R8105 2.36 (0.0929)
16884-V0706 2.40 (0.0945) 16742-R8106 2.44 (0.09611
16884-V0707 2.48 (0.0976) 16742-R8107 2.52 (0.0992)
Use of adjustment value and adjusting shim 16884-V0708 2.56 (0.1008) 16742-R8108 2.60 (0.1024)
when installing injection pump. 16884-V0709 2.64 (0.1039) 16742.R8109 2.68 (0.1055)
16884-V0710 2.72 (0.1071) 16742.R8110 2.76 (0.1087)
Dimension "KF" mm (in) 5.7 - 5.9 (0.224 - 0.232) 16884-V0711 2.80 (0.1102) 16742-R8111 2.84 (0.1118)
16884- V0712 2.88 (0.1134)
_D_ie_m_n_si_on_"L_'_' m_m_(_in_)_1 1.5 - 2.0 (0.059 - 0.079)
"L"
"KF" SEF638
Adjusting shim ("A" position)
Part number Thickness mm (in)
16882-V0700 0.5 (0.020)

SEF500
16882.V0701 0.8 (0.031)
16882-V0702 1.0 (0.039)
16882.V0703 1.2 (0.047)
16882-V0704 1.5 (0.059)
16882-V0705 1.8 (0.071)
16882-V0706 2.0 (0.079)
EF-2
Axial play of flyweight (")
0.15 . 0.35 (0.0059. 0.013S)
holder "L" mil) In
. /
Flyweight holder
~~ SEF047A
Adjusting shim
Part number Thickness mm (in)
1920S.V0700 1.0510.0413)
19208.V0701 1.25 (0.0492)
19208.V0702 1.4510.05711
1920S-V0703 1.65 (0.0650)
19208.V0704 1.S5 (O.072S)
Dimension "MS" mm (in) 0.9. 1.1 (0.035 .0.043)
SEF856
Adjusting closing plug
Part number Length mm (in)
1626S.RS100 3.1010.1220)
1626S.RS101 3.30 (0.1299)
1626S.RS102 3.50 1O.137S)
1626S.RS103 3.7010.1457)
1626S-RS104 3.90 (0.1535)
1626S.RS105 4.10 (0.1614)
1626S.RS106 4.3010.1693)
1626S-RS107 4.50 (0.1772)
EF-3
S,~,RVICEDATA ANI;>$PECIFICATIONS
Inspection" and AdJustment (Cont'd)
BD30 ENGINE MODEL
I njection pump assembly No. 104741.4241 Pump rotation: Clockwise-viewed from drive side]
,Part No. 16700-45K01 [ Pre-stroke: -
Cherge air press Difference in del ivery
Pump speed
1. Setting Settings kPa mQ
rpm
(mbar, mmHg, inHg) (US fl OZ, Imp fl oz)
1.1 Timing device travel 900 1.6 • 2.0 mm (0.063 .0.079 in) -
1.2 Supply pump pressure 900 235 .294 kPa (2.35 .2.94 bar,
-
2.4 .3.0 kg/cm' , 34 .43 psi)
1.3 Full.load delivery 800 53.6.54.6 mQ (1.81 . 1.85 US fl OZ, 4.0 (0.14, 0.14)
1.89. 1.92 Imp fl oz)
-
1.4 Idle sPeedregulation 350 6.5 - 10.0 mQ (0.22 .0.34 US fl OZ, 2.0 (0.07,0.07)
0.23.0.35 Imp fl oz)
1.5 Start 100 75.85 mQ (2.5 .2.9 US fl oz,
-
2.6.3.0 Imp fl oz)/1,OOO st
1.6 Full.load sPeedregulation 1,350 11.1 . 17.1 mQ (0.38.0.58 US fl OZ, -
0.39 .0.60 Imp fl oz)
2. Test specIf ications
2.1 Timing device N = rpm 700 900 1,100 1,300 1,350

mm lin) 0.2.1.0 1.6.2.0 2.6.3.4 3.6.4.5 3.6.4.5
10.008.0.039) 10.063 . 0.079) 10.102.0.134) 10.142.0.177) 10.142.0.177)
2.2 Supply pump N = rpm 700 900 1,100 1,200

kPa (bar, 186.245 235.294 275.333 294.353
kg/cm' , psi) (1.86.2.45, (2.35.2.94 (2.75.3.33 (2.94.3.53,
1.9.2.5,27.36) 2.4 . 3.0, 34 .43) 2.8.3.4,40.48) 3.0.3.6,43.51 )
2.3 Overflow del ivery N = rpm 900

mQ IUS fl OZ, 210.470
Imp fl oz)/ (7.1 - 15.9,
10 sec. 7.4.16.5)
2 .4 Fuel del iveries
Fuel delivery Difference in 3. Dimensions

Charge air press
Pump speed mQ IUS fl OZ, delivery
Speed control lever kPa Imbar,
rpm Imp fl oz)/ mQ (US fl OZ, K 2.7 - 2.9 mm (0.106.0.114 in)
mmHg, inHg)
1,000 st Imp fl oz) 4.9. 5.1 mm (0.193 . 0.201 in)
KF
End stop 800 53.6.54.6 MS 1.6.1.8 mm 10.063.0.071 in)
11.81 .1.85,
1.89.1.92)
8CS -
300 38.8 Control lever angle
n.31,1.37)
25.4 degree
500 36.1.42.1 "
(1.22 . 1.42, Ya
1.27 . 1.48)
700 50.3 {3 37.5 degree
11.70,1.77) 8
1,000 54.8 - 57.8
11.85.1.95, "Y -
1.93.2.03) - - C -
1,200 58.3.61.3
11.97.2.07,
2.05.2.16)
1,250 58.3
11.97,2.05)
1,300 40.2
11.36.1.42)
1,350 11.1.17.1
(0.38.0.58,
0.39.0.60)
1,500 Below 5.0
(0.17,0.18)
Switch OFF 350 010,0) - -

Idle stop 350 5.3.9.3
10.18.0.31,
0.19.0.33)
- -
450 Below 3.0
10.10,0.11)
2.5 Solenoid Max. cut.in voltage: 8V

Test voltage: 12.14V
EF-6
S~"V'CE DATA AND SPECIFICATIONS
Control lever angle measurement position
Measure control lever angles (a,~) at hole "A".
FEF167
If there is no designation in the specifications for the solenoid timer's ON-OF F position, then the position
should be regarded as OFF.
INJECTION NOZZLE ASSEMBLY

Adjusting shim for injection pressure
Thickness mm (in)
T027 6030
Initial injection pressure
kPa (bar, kg/cm2 , psi) 16,182.17,162 T027 6030
10,297 - 11,278
(103.0. 112.8, (161.8.171.6,
New 0.1 (0.004)
105. 115, 165.175,
1,493 . 1,635) 2,346 - 2,489) 0.2 (0.008)
0.3 (0.012)
9,807 15,691
Used (98.1,100, (156.9,160, 0.4 (0.016)
1,422) 2,275) 0.5 (0.020) 0.5 (0.020) to 1.5 (0.059)
[Every 0.025 (0.0010)]
0.52 (0.0205)
0.54 (0.0213)
0.56 (0.0220)
0.58 (0.0228)
0.8 (0.031)
EF-7
SERVICE DATA ANDSP£CIFICATIONS
Tightening Torque
Unit N'm kg-m ft-Ib
Distributor head to 10 -14 1.0 - 1.4 7 -10

pump housing
Plug to distributor head 59 - 78 6.0 -8.0 43 - 58
Del ivery valve to 44 - 54 4.5 - 5.5 33 - 40

distributor head
Pivot. pin to pump 10 - 13 1.0 -1.3 7-9
h04-sing
Regulating valve to 10 - 13 1.0 - 1.3 7-9
pump housing
Control shaft to control 7 -10 0.7 - 1.0 5.1 - 7.2
lever
Injection pump drive 59 - 69 6.0 -7.0 43 - 51
gear nut
Injection pump fixing bolt 20 -25 2.0 -2.5 14 - 18
Injection pump to 25 - 35 2.6 -3.6 19 - 26

mounting bracket
Injection nozzle to 54 - 64 5.5 - 6.5 40 -47
cy Iinder head*
Injection tube flare nut 20 - 25 2.0 - 2.5 14 - 18
. Spill tube nut 29 - 39 3.0 - 4.0 22 - 29
Feed pump cover to 2-3 0.2 -0.3 1.4 - 2.2

pump housing
Speed timer cover to 6-8 0.6 -0.8 4.3 - 5.8
pump housing
Governor shaft lock nut 17 - 22 1.7 - 2.2 12 - 16
Overflow valve 20 - 29 2.0 - 3.0 14 - 22
Maximum and idle speed 6-9 0.6 -0.9 4.3 -6.5
adjusting screw lock nuts
Full-load adjusting screw 7-9 0.7 -0.9 5.1 -6.5
lock nut
Fuel cut solenoid valve 15 - 25 1.5 - 2.5 11 - 18
Plug bolt 14 - 20 1.4 - 2.0 10 - 14
Adjusting rod bushing 25 - 34 2.5 - 3.5 18 - 25

lock nut
*. Part No. of injection nozzle: 16600-43G02
EF-8
INJECTION PUMP
Removal
1. Remove injection tube.
Cover the injection nozzle assembly with a plug to prevent dust
entry.
2. Remove fuel cut solenoid wire.

3. Remove accelerator wire and disconnect spill hose, fuel
inlet hose and fuel return hose.
FEF157
4. Separate flare nut at injection pump.
5. Remove dust cover and loosen injection pump drive gear nut.
6. Confirm that No.1 piston is set at T.D.C. on its compression

stroke.
Make sure that "Z" marks are aligned.
EF-9
INJECTION~UMP
Removal (Cont'd)
7. Remove rocker,oover and observe the intake and exhaust
valve positions, and make sure that the matchmarks on front
cover and crank pulley are aligned.
8. Remove injection pump drive gearby using puller.
9. Make sure that marks on injection pump and pump bracket

are aligned, then remove injection pump.
Do not turn crankshaft after removing injection pump.
Installation and Adjustment

1. Confirm that No. 1 piston is set at T.D.C. on its compres-
sion stroke, and temporarily set injection pump so that the
flange of pump is aligned with aligning mark on front cover.
2. Make sure that "Z" marks are aligned.
EF-10
INJECTION PUMP ~
Installation and Adjustment (Cont'd)
3. Install injection drive gear.
~: 69 - 69 N.m (6 - 7 kg-m, 43 - 61 ft-Ib)
Make sure that the key does not fall into the front cover.
F EF159
PLUNGER LIFT ADJUSTMENT

1. Loosen injection pump mounting nuts and mounting bracket
bolt.
2. Remove plug bolt from distributor head and install dial
gauge.
3. Plunger lift measurement and adjustment.
(1) Turn crankshaft counterclockwise 20 to 25 degrees from
No.1 piston at T.O.C.
=:;::;-- (2) Find dial gauge's needle rest position at step (1) set position,
SEF016A then set the gaugeto zero.
(3) Turn crankshaft clockwise until No.1 piston is set at T.O.C.
(4) Read dial gauge indication.
TD27:
0.632 - 0.672 mm (0.0249 - 0.0266 in)
(equivalent to 6° B.T.D.C.)
BD30:
1.20 - 1.24 mm (0.0472 - 0.0488 in)
(equivalent to 6° B.T.D.C.)
(5) If it is not within the above range, turn pump body until it
comes within standard range.
a. If indication is smaller than the specified value, turn pump
body counterclockwise.
b. If indication is larger than the specified value, turn pump
body clockwise.
4. Tighten injection pump securely.
Injection pump fixing bolt:
~: 20 - 26 N.m (2.0 - 2.6 kg-m, 14 - 18 ft-Ib)
Injection pump to mounting bracket:
~: 26 - 36 N.m (2.6 - 3.6 kg-m, 19 - 26 ft-Ib)
5. Disconnect dial gauge and reinstall plug bolt with new washer.
~: 14 - 20 N.m (1.4 - 2.0 kg-m, 10 - 14 ft-Ib)
6. Connect injection tubes.
Flare nut:
2 ~: 20 - 26 N.m (2.0 - 2.6 kg-m, 14 - 18 ft-Ib)
7. Bleed air from fuel system.
3
SEF852
EF-11
INJECTION PUMP
Installation and Adjustment (Cont'd)
IDLE AND MAXIMUM SPEED ADJUSTMENT
Idle adjustment
1. Warm up engine.
2. Install tachometer after removing clamp.
Idling speed: 700 rpm
3. Loosen accelerator wire adjusting nut.

4. Make sure that idle adjusting screw and accelerator control
lever contact each other.
5. Adjust idling speed by turning idle adjusting S(;,rew.
6. Tighten accelerator adjusting nut.
Maximum speed adjustment

Maximum speed adjusting screw is retained by sealing wire and
need not be adjusted under normal circumstances. However, if
it becomes necessary to adjust it, the following procedure should
be followed:
1. Start engine and warm it up until coolant temperature indi-
cator points to middle of gauge.
2. Connect tachometer's pick-up to No.1 fuel injection tube.
To obtain accurate reading of engine rpm, remove clamps that
secure No.1 fuel injection tube.
3. Depress accelerator pedal fully under no load and, at this
point, read the tachometer indication.
Maximum engine speed (Under no load):
2,600 - 2,700 rpm
Sealing wire
4. If indication is lower than specified maximum engine speed,
Sealing cap
turn maximum speed adjusting screw counterclockwise 1 or
2 rotations. Then depress accelerator pedal to floor under no
~ load and, at this point, read indication.
5. If indication is still lower than specified speed, repeat step 4
above until specified engine speed is reached.
6J SEF5561
6. After adjustment, tighten lock nut securely.
7. Seal with a sealing wire or install a sealing cap.
EF-12
INJECTION PUMP
Disassembly
PREPARATION
• Before performing disassembly and adjustment, test the
fuel injection pump and note test results.
• Prior to beginning disassembly of fuel injection pump, clean
all dust and dirt from its exterior.
• Disconnect overflow valve and drain fuel.
• Clean work bench completely, removing all foreign matter.
• Collect only those service tools necessary for disassembling
and reassembling.
• Be careful not to bend or scratch any parts.
EF-13
INJ.ECTION PUMP
Disassembly (Cont' d)
Without high altitude compensator
..
CIl
..
CIl
;
5l
Cl
c
"5-
CIl
>
:0
E
51
II>
'"
...
Il'i
UI .~ Cl
C'i Cl C
..... j
I 'i:
~
(J
:S
o E
Itl
8 '"
u
....
..
CIl
.s::
...
'"
:1:
., ~....-
.... 0
'0'"
0"':1
... - ....
~~/~
o .
.......
":8
~ SEF333F
EF-14
INJECTION PUMP
With high altitude compensator
..
ijj'
q'
M
_Gi ..
N
q
,...
q
~
CJlN ..
... ...,...'
N
,..: NN Lti
'M
10, •
q
!e
~~ ..,...
q'
.. -..
t:iq
'
CJl;:
2
..
o
E
Z
>-
:0 N
..
E
Q> N
'"Q.
E
:;,
..
..,.
~'
Q.
'"
Q>
:2
o
.J::.
~'"
..,
~ ~ e
!ai '"..
Q>
l:l
0
N • Eo
.. c:
';:;
:;,
~~ CJl '5'
....,
N
i'"
0 5 ~ ~ ..E
8.
tIlO
M
j
8.
f
...
:;,
E
.2N E Q>
'x ~
"'-
>CJl
o
U
~
:a '"
::E ..0
:1:N 'tl Cl E
0 '0 tIl
;;=0
"'N
~~ ~
~~ <.!!
~'"
..
SEF384F
EF-15
INJECTION PUMP
. Block gauge (With high altitude compensator) KVl1229752
'<c~~:.~~~~3~,
. 1;
Block gauge.fO.
r "MS" adjustment .~ 8'O'k
g'"" (WI," high',,,.. d. oomp,"~,"" KVI1229762
ft.
KVl1229110
• ~ert device KVl1229072
o • Adjusting device
~~ \ ~ (For governor shaft)
KVl1215842
Dammy shaft
~
KVl1241920
KVl1229830
::\.
Adjusting device
Socket wrench (For delivery valve holder)----==z

e
.8- Socket wrench

IFor
. regulating valve)
..KV11214260
KVl1214110 (J.)
~
~ Oil sealgUide
(For drive shaft)
~ KVl1222090
C0aJ
~
l Feed pump holder
KVl1229542
Socket wrench (For pivot bolt)
Socket :;:Ch ~ KVl1214270
(For head plug) Dial gauge
~
KVl1214250 (For measuring plunger lift on car) KVl1229352 SEF5571
1. Remove pump cover.

(1) Remove nut, spring washer, spring seat and spring from con-
trol lever.
(2) Draw aligning marks on control lever and control shaft.
(3) Remove compensator cover.
EF-16
INJECTION PUMP
(4) Remove bellows and adjusting shim.
(5) Remove E-ring, then remove spring seat and spring.
(6) Loosen nut.
(7) Remove governor cover plugs.
(8) Remove governor cover.

a. Remove sealing wire and idle and maximum speed adjusting
screws.
EF-17
INJECTION PUMP
b. Remove governor cover fixing bolts and screws.
Use hexagon wrench.
c. Remove full-load adjusting screw.

d. Remove governor cover, by holding control shaft with Tool
(KV11229072) and lifting governor cover.
Do not tap control shaft with a hammer.
(9) Remove high altitude compensator parts.

a. Remove plugs.
b. Remove lever pin and lever using a suitable drift and a
plastic mallet, by tapping it from the right-hand side (viewed
from the drive side).
c. Remove plug and pin.
d. Remove retainer, sleeveand washer.

Use a suitable screwdriver to remove retainer.
EF-18
INJECTION PUMP
e. Remove nut and adjusting rod.
f. Remove bushing.

(1) Remove nut, spring washer, spring seat and spring from
control lever.
(2) Check aligning marks on control lever and control shaft.
(3) Remove pump cover.

Lift and separate governor cover from control shaft, while
holding control shaft with Tool (KV11229072).
Do not tap control shaft with a hammer.
EF-19
INJECTION PUMP
2. Remove control shaft from tension lever.
3. Remove governor shaftwith Tool (KV11215842).

Loosen lock nut by turning it counterclockwise.
4. Remove governor sleeve, washer and flyweight, along with

flyweight holder, then remove washer and shims.
5. Remove plug with special service tool.
EF-20
INJECTION PUMP ~
DisasS$mbly (Cont'd)
6. Remove delivery valve holder, spring, delivery valve and
gasket.
Distributor head has letters (A, B, C, D) stamped on it. Remove
lettered parts in alphabetical order and arrange neatly.
, SEF034A
7. Remove fuel-cut solenoid valve.

Be careful not to drop the spring and armature.
8. Remove distributor head.

Be careful not to drop the two support springs and guide pins.
9. Remove plunger assembly.

Lift plunger, along with control sleeve,shim, spring seat, plunger
spring, washer and shim.
10. Loosen left and right governor pivot bolts.
EF-21
INJECTIQN .PUMP
Disassembly' (Cont' d)
11. Remove governor pivot bolts and lever assembly.
Avoid pulling on start spring and start idle spring.
12. Remove shim, cam disc, spring and driving disc.
G;r--Shirn
earn disc
I--spring
~ Drivingdisc
SEF478
13. Remove clip and pin.
14. Move adjusting pin to center of roller holder, as shown.
EF-22
INJECTION PUMP
Disassembly (Cant'd)
15. Lift out roller holder with rollers without tilting.
Be careful not to drop rollers.
16. Remove drive shaft.

a. Rotate drive shaft until keyway faces the top of injection
pump.
b. Remove drive gear side key.
c. Attach oil seal guide (KV11222090) onto drive shaft to
prevent keyway from damaging oil seal.
d. Be careful not to scratch inner surface of fuel injection pump
body.
e. Be careful not to drop the key.
17. Remove speed,timer cover, O-rin~, shims, spring, piston and

slider.
SEF513
18. Remove regulating valve with special service tool.
19. Loosen the two screws from feed pump cover.
EF-23
INJECTION PUMP [ill
20. Remove cover and feed pump assembly as a unit.
1) Insert feed pump holder (KV11229542) into fuel injection
pump housing.
2) Turn injection pump upside down, as shown.
3) Remove cover and feed pump assembly as a unit.
KV11229542
a. If cover and feed pump assembly are hard to remove or
stuck midway, strike the pump body lightly.
b. Do not change positions of vanes.
SEF487
Inspection
1. Wash all parts completely.
2. Replace worn or damaged parts.
3. Control edge of plunger must be sharp and contact surfaces
must not exhibit any noticeable running tracks. If the con-
dition is not good, replace plunger.
4. Check for height of all rollers.
Difference in maximum and minimum roller height should be
lessthan 0.02 mm (0.0008 in).
SEF504
Assembly
Always replace the following service parts as assembly units.
• Distributor head, control sleeveand plunger
• Feed pump assembly (pump impeller and vanes with eccen-
tric ring)
• Plunger spring kit
• Roller assembly
• Flyweight kit
• Governor lever assembly
PREPARATION
Larger side Smaller side
Dip all movable parts and O-rings in test oil, then clean.
B 1. Set feed pump cover, rotor with vanes, and ring on Tool
(KV11229542).
1) Align the three holes in feed pump cover and ring.
"--. Feed pump 2) Do not change positions of vanes.
cover 3) Holes A and B in ring are not equally spaced to inner wall
of ring.
SEF505
2. Install feed pump cover, rotor with vanes, and ring to pump
housing.
Be careful to install ring correctly. If left and right are reversed,
fuel will not be discharged from feed pump.
SEF341F
EF-24
INJECTION PUMP ~
Assembly (Cont' d)
When fuel injection pump rotates in direction "R"
The. following description applies to fuel injection pumps that
rotate in direction "R".
0
3. Turn fuel injection pump 180 , and remove Tool
(KVl1229542). Tighten screw to retain pump cover.
a. When tightening screws, be careful not to scratch inner wall
of pump housing.
b. After tightening screws, make sure that rotor with vanes
moves smoothly.
SEF507
4. Make sure that drive shaft and gear are assembled properly,
as shown.
Applied
grease
~ Side view of gear

[p::::c:[]
5. Install drive shaft to housing while, key in drive shaft engages

with key groove in rotor.
a. Before installing drive shaft, attach oil seal guide
(KV11222090) onto drive shaft.
b. Be careful not to scratch oil sealsand inner wall of housing.
6. Set drive shaft's nail parallel to timer.

7. Install roller and holder.
a. Do not interchange roller positions. If they are interchanged,
refer to Inspection for correction.
b. Make sure that washer is situated outward of rollers.
8. Align holder and timer adjusting pin holes.
EF-25
INJECTION, PUMP ~
Assembly (Cont' d)
9. Install timer piston and slider as a unit.
a. Make sure that hole in slider faces towards roller holder.
b. Make sure that concave hole in piston is on same side as
return hole.
10. Insert timer adjusting pin into timer piston slider, and secure
with retaining pin and clip.
Make sure that timer piston moves smoothly.
11. Install timer, using a 0.6 mm (0.024 in) thick shim, then
install timer spring, shim, G-ring, and cover, in that order.
a. Use at least one shim on each side of timer spring.
~~.~,m b. Use shims that were selected during bench test.
J
l\e~
in~~~
, ' ::;;;; O-ri ng

50"';
SEF513
12. Install regulating valve.

Be carefu I not to scratch O-rings.
13. Install driving disc with its concave side facing up.
EF-26
INJECTION PUMP ~
Assembly (Cont' d)
14. Measurement of plunger spring set length (dimension "KF")
Dimension "KF" is the distance between the end face of the
distributor barrel and the end face of the plunger.
(1) Install distributor head, as shown.
• Do not insert shim into" A" portion before measuring.
1 Spring seat
2 Plunger spring
3 Guide pin
4 Distributor head
5 Distributor barrel
6 Spring seat
7 Washer
8 Shim
9 Plunger
SEF362F
(2) Set dial gauge so that it can cOQ1press0 to 10 mm (0 to

0.39 in), and reset to zero.
KV11229042
SEF419
(3) Apply force (not enough to compress plunger spring) to

plunger's bottom in axial direction, and measure dimension
"KF" with dial gauge, as shown.
(Shim is inserted,)
SEF855
(4) Determine the shim to be used by calculating difference

between standard and measured dimensions.
Standard dimension "KF":
Refer to S.O.S.
[Example]
When measured (dial gauge reading) value is 5.2 mm,
5.7 mm - 5.2 mm = 0.5 mm (shim thickness~o be used)
EF-27
INJECTION PUMP ~
Assembly (Cont~d)
a. When there are no shims available of a thickness which
matches specified dimensions, use slightly thicker shims.
b. Use seleetedshim with distributor head in step 14-(3) above.
c. Use the same size shim on each side of distributor head.
d. Shims are available in seven different thicknesses.
Thickness
Part number
mm (in)
16882-V0700 0.5(0.020)
16882.V0701 0.8 (0.031)
16882-V0702 1.0 (0.039)
16882.V0703 1.2 (0.047)
16882-V0704 1.5 (0.059)
16882-V0705 1.8 (0.071)
16882-V0706 2.0 (0.079)
15. Adjustment of plunger dimensions ,(Measurement of dimen-

sion "K")
Dimension "K" is the distance from the end face of the distri-
butor barrel to the end face of the plunger top, when the plunger
is at the bottom dead center position.
(1) Install parts as shown.
a. Do not install "spring" on driving disc.
b. When inserting plunger and shim into cam disc, make sure
that drive pin is situated in groove at bottom of plunger.
1 Drive shaft 7 Spring seat

2 Driving disc 8 Shim
3 Shim 9 Distributor barrel
4 Spring seat 10 Washer
5 Plunger spring 11 Shim
6 Guide pin 12 eam disc
SEF370F
(2) Using a dial gauge, measure dimension as shown.

a. Rotate drive shaft so that plunger is set at bottom dead
KV11229042
center.
b. Securely mount distributor head with screws.
SEF044A
EF-28
INJECTION PUMP
Assembly (Cont'd)
(3) Determine shim to be used by calculating difference between
measured (dial gauge reading) value and standard dimension
"K", and position that shim on plunger's bottom.
"K": Refer to S.O.S.
a. When measured value is greater than standard dimension

"K", use a thicker shim.
b. After shim has been positioned, measure dimension again to
ensure that it is correct.
SEF519
c. Shims are available in 25 different thicknesses.
Thickness Thickness
Part number Part number
mm (in) mm (in)
16884.V0700 1.92 (0.0756) 16742.R8100 1.96 (0.0772)
16884.V0701 2.00 (0.0787) 16742.R8101 2.04 (0.0803)
16884.V0702 2.08 (0.0819) 16742.R8102 2.12 (0.0835)
16884.V0703 2.16 (0.0850) 16742.R8103 2.20 (0.0866)
16884.V0704 2.24 (0.0882) 16742.R8104 2.28 (0.0898)
16884. V0705 2.32 (0.0913) 16742.R8105 2.36 (0.0929)
16884. V0706 2.40 (0.0945) 16742-R8106 2.44 (0.0961)
16884. V0707 2.48 (0.0976) 16742.R8107 2.52 (0.09'92)
16884- V0708 2.56 (0.1008) 16742-R8108 2.60 (0.1024)
16884. V0709 2.64 (0.1039) 16742.R8109 2.68 (0.1055)
16884- V071 0 2.72 (0.1071) 16742-R8110 2.76 (0.1087)
16884.V0711 2.80 (0.1102) 16742-R8111 2.84 (0.1118)
--------- ---------
16884.V0712 2.88 (0.1134)
16. Install spring in top of driving disc, then install cam disc
and shim.
Make sure cam disc drive pin and drive shaft key way face
upwards.
EF-29
INJECTION PUMP
Assembly (Con,l' d)
17. Install governor lever.
Avoid pulling on start spring and start idle spring.
~ /'
. ,(~10.13N.m
~\r 11.0.1.3 kg-m.
7 - 9 ft.lb)
SEF521
18. Install plunger assembly.

a. Make sure control sleeve is installed with its small hole
facing spring seat side.
b. Insert ball pin for governor lever into hole in control sleeve
(shown by arrow).
19. Apply a coat of grease to guide pin, shim and spring seat,
and attach these parts to distributor head.
20. Install distributor head.

a. Always face support spring toward governor lever.
b. Be careful not to drop spring.
c. Make sure that ball pin for governor lever is inserted pro-
perly into hole in control sleeve.
d. After installing distributor head, make sure that plunger
spring is at guide pin in spring seat.
EF-30
INJEC"FION PUMP
Assembfy,(Cont'd)
21. Tighten distributor head.
Distributor head bolts:
~: 10 - 14 N.m (1.0 -1.4 kg-m, 7 -10 ft-Ib)
22. Attach flyweight assembly.

Locknut~
When installing governor shaft, be careful not to scratch O-rings.
7
--A~ -ring
Governor
shaft
~~~Shim
~~ l"--- Washer
~.~ Flyweight
~L ~
assembly
Shim
~ Governor sleeve
SE F5621
23. Adjust dimension "L".
1.5 - 2.0 mm (0.059 - 0.079 in)

Lock nut:
~: 17.22 N.m (1.7 - 2.2 kg-m, 12 - 16 ft-Ib)
EF-31
INJECTI;QNPUMP ~
Assembly (Cont' d)
24. Measure axial play of flyweight holder. If it is not within
specified range, adjust it by means of shims.
ilL" :
0.15 - 0.35 mm (0.0059 - 0.0138 in)
Shims are available in 5 different thicknesses.
Thickness
Part number
mm (in)
19208-V0700 1.05 (0.0413)
19208- V0701 1.25 (0.0492)
19208. V0702 1.45 (0.0571)
19208-V0703 1.65 (0.0650)
19208-V0704 1.85 (0.0728)
25. Measurement of dimension "MS" (for determining starting

amount of fuel injection)
Dimensions "MS" is the distance between closing plug and start
lever.
Collector
lever
SEF856
(1) Remove lock nut and governor shaft with Tool

(KV11215842).
SEF5611
EF-32
INJECTION PUMP ~
Assembly (Cont'd)
(2) Install special service tool (dummy shaft) at governor shaft
position.
(3) Install special service tool (dial gauge) with rod.
SEF049A
(4) Install special service tool (block gauge) to pump housing.

KV11229752 is for pump with high altitude compensator.
SEF424A
KV11229110 is for pump without high altitude compensator.
SEF050A
(5) Push governor sleeve against flyweight. Hold governor sleeve

in that position and set dial gaugeto zero.
EF-33
INUECTION PUMP ~
Assetnbly( (;:ont' d)
(6) Push tension lever until it touches stopper pin. Back governor
sleeve up until start lever touches tension lever. At this point
read dial gauge.
MS: Refer to S.O.S.
(7) If dial gauge indication is not within this range, replace

closing plug and adjust dimension "MS" to that range.
Closing plugs are available in 8 different lengths.
Locking cap
Push
.....•.•.•.••.•
CI"~Jl Part number
16268-R8100
Length
mm (in)
3.10 (0.1220)
16268-R8101 3.30 (0.1299)
SEF538 16268-R8102 3.50 (0.1378)
16268-R8103 3.70 (0.1457)
16268-R8104 3.90 (0.1535)
16268-R8105 4.10 (0.1614)
16268-R8106 4.30 (0.1693)
16268-R8107 4.50 (0.1772)
26. Install control lever shaft.

Apply a coat of greaseto lever shaft end.
27. InstaII governor cover.

(1) Position adjusting rod bushing so that its height above
upper surface of governor cover is with in specified range.
L: 20.5:tO.5 mm
(O.807:tO.020 in)
Ensure that holes in adjusting rod bushing and governor cover are
aligned properly.
EF-34
INJECTION PUMP CY!J
Assembly (Cont'd)
(2) Install adjusting rod.
(3) Install washer and nut.
(4) Tighten nut.
Adjusting rod bushing lock nut:
~: 25 - 34 N.m (2.5 - 3.5kg-m, 18 - 25 ft-Ib)
a. Prevent adjusting rod bushing from rotating by locking its
nut.
b. If nut and bushing rotate together, bushing height above
upper surface of governor cover is insufficient.
(5) Install washer, sleeve and retainer.
(6) Install pin.

Ensure that pin moves smoothly when adjusting rod is moved
up or down.
(7) Install lever.

Use a suitable bar as a guide to properly install lever.
EF-35
INJECTION PUMP
Assembly (Cont'd)
Ensure that lever moves smoothly when adjusting rod is moved
up or down.
(8) Check clearance between block gauge and lever.

If not within specifications, change the pin.
Clearance:
0.1 mm (0.004 in)
Pin
Length
Part number
mm (in)
19276-02NOO 24.6 (0.969)
19276-02N01 24.8 (0.976)
19276-02N02 25.0 (0.984)
19276-02N03 25.2 (0.992)
19276-02N04 25.4 (1.000)
(9) InstaII governor cover.
(10) Install control lever.

Align aligning marks of speed control lever and control lever
shaft.
EF-36
INJECTION PUMP
Assembly (Cont'd)
I (
(11) Install spring seat, spring and E-ring.
(12) Install adjusting shim and bellows.
(13) Install compensator cover.
SEF438A

(1) Install pump governor cover.
(2) Install speed control lever assembly.

Align aligning marks of speed control lever and control lever
shaft.
28. Install plug with new G-ring.

Always replace plug with a new one.
Plug:
~: 59 - 78 N.m (6.0 - 8.0 kg-m, 43 - 58 ft-Ib)
29. Install plug bolt with a new gasket.
SEF055A
~44 .54 N'm 30. Install fuel cut solenoid valve.

(4.5 . 5.5 kg.m,
31. Install del ivery valve.
33 - 40 ft-Ib)
a. Always usenew washers.
b. Make sure that delivery valve is reinstalled in its original
position.
EF-37
INJECTION PUMP
Test
PREPARATION
Nozzle KV11257800
Nozzle holder KV11257802
Nozzle starting pressure kPa (bar, kg/cm2, psi) 14,711 -15,201 (147.1 -152.0, 150 -155,2,133 - 2,204)
Nozzle tube
Inner dia. x outer dia. x length KV11205032
mm (in) 2.0 x 6.0 x 840 (0.079 x 0.236 x 33.07)
Fuel feed pressure kPa (bar, kg/cm2 , psi) 20 (0.20, 0.2, 2.8)
Fuel (test oil) ISO 4113 or SAE Standard Test Oil (SAE J967d)
Fuel temperature °c (OF) 45 . 50 (113 - 122)
Rotating direction Right (observed from the drive shaft)
Injection sequence 1-3-4-2
1. Prepare necessaryservice tools.
Insert device ~
KVl1229522
M
U
Nozzle holder
KVl1257802
Injection pipe
KVl1205032 Measuring device for pump timer stroke
KVl1282815
~ SEF057A
2. Pour test oil into fuel injection pump.

Test oil should be ISO 4113, SAE Standard Test Oil (SAE J967d)
or its equivalent.
SEF950
EF-38
INJECTION PUMP
Test (Cant'd)
3. Install fuel injection pump to pump tester.
4. Connect necessarypiping.
1 Fuel supply inlet from pump tester

2 Overflow valve
3 Coupling
4 Fixing stand
SEF378F
L 5. Make sure that governor shaft is properly installed.

Adjust dimension "L".
ilL ":
~,""'h'" 1.5 - 2.0 mm (0.059.0.079 in)
l . Governor shaft lock nut:
~ : 17 - 22 N.m (1.7.2.2 kg-m, 12 .16 ft-Ib)
SEF500
6. Run fuel injection pump as follows:

(1) Maintain test oil in tank at 45 to 50°C (113 to 122°F).
(2) Set control lever at "full speed" using a spring.
Set maximum speed adjusting screw in position shown, by turn.
ing it counterclockwise.
(3) Furnish specified voltage of 12 volts to fuel-cut solenoid
valve to activate it.
8.9mm (4) Rotate fuel injection pump by hand to see if it moves
(0.31 - 0.35 in)
L Maximum speed adjusting screw smoothly.
SEF569 (5) Rotate fuel injection pump at 300 rpm to make sure that all
air inside pump chamber is discharged through overflow
valve.
(6) Set feed oil pressure at 20 kPa (0.20 bar, 0.2 kg/cm2, 2.8 psi).
(7) Run fuel injection pump at 1,000 rpm for ten minutes.
If fuel leakage, fuel injection failure or unusual noise is noticed,
immediately stop pump tester operation and check fuel injection
pump for abnormalities.
EF-39
INJECTION PUMP ~
Test (Cont'd)
ADJUSTMENT
Preadjust full-load delivery
If equipped with high altitude compensator, remove high altitude
compensator cover, bellows and adjusting shim.
1. Set control lever at "full speed" using a spring.
Set maximum speed adjusting screw in position shown, by turn-
ing it counterclockwise. Refer to step 6-(2) in Preparation.
2. Furnish specified voltage of 12 volts to activate fuel-cut
solenoid valve.
3. Rotate fuel injection pump at 1,100 rpm, and measure
amount of fuel injection.
Standard fuel injection:
Refer to S.O.S.
4. If fuel injection is less than standard, adjust it with fu II-load

Full-load
adjusting screw adjusting screw.
Turn adjusting screw clockwise to increase fuel injection.
Adjustment of feed pump pressure

1. Repeat steps 1 and 2 outlined under "Preadjust Full-Load
Delivery" heading.
2. Measure feed pump pressure at specified fuel injection pump
rpm.
Refer to S.O.S.
a. When measured pressure is lower than specifications.

Push in plug that is driven into regulating valve body.
Be careful not to push plug in too far.
EF-40
INJECTION PUMP ~
Test (Cont'd)
b. When measured pressure is higher than specifications.
Spring-.
! (1) Remove regulating valve from fuel injection pump, and
disassemble regulating valve using Tool (KV11229462).
Piston -0
Spring----
ring
SEF572
(2) Drive plug out until it is flush with end face of regulating
Plug valve.
Install spring, piston and spring ring, in that order, to re-
gu lating valve.
Make sure that spring ring is flush with end face of regulat-
ing valve body when it is pushed in.
SEF573
(3) Attach regulating valve to fuel injection pump.

Regulating valve:
~: 10 - 13 N.m (1.0 - 1.3 kg.m, 7 - 9 ft-Ib)
(4) Adjust supply pump pressure to specifications. Refer to step
2-a.
Spring ring
Regulating valve
SEF637
Adjustment of speed timer

1. Repeat steps 1 and 2 outlined under "Preadjust Full-Load
Delivery" heading.
2. Remove cover from high-pressure side (side without spring)
of timer, and attach Tool (KV11282815) to that side.
3. Measure timer piston strokes at specified fuel injection pump

rpm indicated below.
Refer to S.O.S.
EF-41
INJECTION PUMP ~
Test (Cont'd)
4. If timer piston stroke is not within specified range, remove
cover from low-pressure side of timer and adjust piston
stroke by adding shim(sl.
a. Shims (service parts)

Thickness
Part number
mm (in)
16880-V0700 0.6 (0.024)
16880-V0701 0.7 (0.028)
16880-V0702 0.9 (0.035)
16880-V0703 1.0 (0.039)
16880-V0704 1.2 (0.047)
b. Make sure that at least one shim is used on each side of timer
spring.
Adjustment of fuel injection under full-load

1. Set control lever at "full speed" using a spring.
solenoid valve.
3. Measure fuel injection at each specified fuel injection pump
rpm.

Refer to S.O.S.
4. If fuel injection is not within standard range, adjust it using

full-load adjusting screw.
Adjustment of fuel injection during idle

1. Pull spring until control lever touches idle speed adjusting
screw.
solenoid valve.
3. Measure fuel injection at specified fuel injection pump rpm.

Refer to S.O.S.
EF-42
INJECTION PUMP ~
Test (Cont'd)
4. If fuel injection is not within specified range, adjust using
Idle speed adjusting screw
idle speed adjusting screw.
a. Tightening this screw will increase fuel injection amount.

b. Make sure that control lever angle (a) is set at the specified
range.
a: Refer to S.O.S.
If control lever angle is not within specified range, adjust it
by repositioning control lever on control shaft. (One serra-
tion pitch: 15°)
After control lever has been repositioned, be sure to measure
amount of fuel injection at idle speed again.
SEF379F
Adjustment of fuel injection during start

1. Set control lever at "fu II speed" by pu lling spring.
solenoid valve.
3. Measure fuel injection at specified fuel injection pump rpm.
Refer to S.O.S.
4. If fuel injection is lower than standard, check, "MS" dimen-

sion. Refer to step 25 for Injection Pump Assembly.
Adjustment of fuel injection at maximum pump rpm

1. Set control lever at "full speed" by pulling spring.
solenoid valve.
3. Measure fuel injection at specified fuel injection rpm.
Refer to S.O.S.
4. If fuel injection is not within standard range, adjust using

maximum speed adjusting screw.
EF-43
INJECTION PUMP
Test (Cant'd)
a. Tightening screw will decreasefuel injection.
b. Make sure that control lever angle (/3) is within the specified
range.
/3: Refer to S.O.S.
Measurement of overflow amount

1. Set control lever at "full speed" by pulling spring.
2. Furnish specified voltage of 12 volts to activate fuel cut
solenoid valve.
3. Measure fuel overflow at specified fuel injection rpm.
Fuel overflow:
Refer to S.O.S.
Operation check .of fuel-cut solenoid valve

When engine is idling and fuel cut solenoid valve current is OF F,
be sure there is no injection. This check has to be done for
approx. 5 seconds.
EF-44
INJECTION NOZZLE
Removal and Installation

1. Remove injection tube assembly.
2. Remove spill tube assembly.
To prevent spill tube from breaking, remove it by gripping nozzle
holder.
3. Remove injection nozzle assembly using deep socket wrench.

4. Install injection nozzle in the reverseorder of removal.
Injection nozzle to cylinder head:
~: 54-64 N.m
(5.5 - 6.5 kg-m, 40 - 47 ft-Ib)
Nozzle support bolt (B030):
~: 44.49 N.m
(4.5 - 5.0 kg-m, 33 - 36 ft-Ib)
Spill tube nut:
~: 29 - 39 N.m
(3.0 . 4.0 kg-m, 22 . 29 ft-Ib)
Injection tube flare nut:
~: 20-25 N.m
(2.0. 2.5 kg-m, 14 - 18 ft-Ib)
a. Nozzle gaskets should always be replaced.
b. To prevent spill tube from breaking later, spill tube nuts
should be tightened gradually in sequence.
5. Bleed air from fuel system.
Refer to BLEEDING FUEL SYSTEM.
EF-45
I NJECTION NOZZLE
Disassembly
1. Loosen inlet connector while keeping nozzle top from
turning.
Inlet connector 2. Arrange all disassembled parts in order shown at left.

Adjusting shim,
N~zzle Spring~\ I
Spring seat ~ ',~

spacer~~
Nozzle~, ~
needle "lf1
Nozzle
} assembly
~ ~
V' Nozzle body
~ Nozzle holder
~~- Nozzle washer
Nozzle gasket
SEF425F
8030
Pin
Nozzle needle
Nozzle assembly
Retaining ~29 - 39 N.m
nut (3.0 - 4.0 kg-m, 22 - 29 ft-lbJ SEF843M
Inspection
Thoroughly clean all disassembled parts with fresh kerosene or
solvent.
• If nozzle needle is damaged or fused, replace nozzle assembly
with a new one.
• If end of nozzle needle is seized or excessively discolored,
replace nozzle assembly.
• Check nozzle body and distance piece for proper contact. If
excessively worn or damaged, replace nozzle assembly or
nozzle holder assembly.
• Check distance piece and nozzle holder for proper contact. If
excessively worn or damaged, replace nozzle holder assembly.
• Check nozzle spring for excessive wear or damage. If exces-
sively worn or damaged, replace nozzle holder assembly.
EF-46
INJECTION NOZZLE
Cleaning
1. Clean nozzle assembly using the Nozzle Cleaning Kit.
2. Portions which should be cleaned are indicated in the left

T027
figure.
In let con nector Adjusting shim
Nozzle holder
Nozzle spring
~Nozzle needle
Nozzle body
SEF426F
8030
Adjusting shim
Nozzle spring
Spring seat
Spacer
Nozzle needle
Nozzle assembly
Retaining nut
3. Remove any carbon from exterior of nozzle body (except

wrapping angle portion) by using Tool.
EF-47
INJECTiON NOZZLE
Cleaning (Cont'd)
T027 4. Clean fuel sump of nozzle body using Tool.
KV11290632
SEF831
8030
KV11290122
SEF6391
T027 5. Clean nozzle seat by using Tool.

This job should be performed with extra precautions, since effici-
ency of nozzle depends greatly on a good nozzle seat.
SEF832
8030
KV11290150
Cleaning area
SEF6401
T027 6. Clean spray hole of nozzle body by using Tool.

To prevent spray hole from canting, always clean it by starting
with inner side and working towards outside.
KVl1290220
SEF833
EF-48
INJECTION NOZZLE
Cleaning (Cont'd)
7. Decarbon nozzle needle tip by using Tool.
TD27 8. Check needle for proper position.

(1) Pull needle about halfway out from body and then release it.
(2) Needle should sink into body very smoothly from just its
own weight.
(3) Repeat this test and rotate needle slightly each time.
If needle fails to sink smoothly from any position, replace both
needle and body as a unit.
SEF835
SEF641 I
EF-49
INJECTION NOZZLE
Assembly
Assemble in the reverse order of disassembly.
Inlet connector to nozzle holder (TD27):
A: 34 - 54 N.m
KVl1292210
(3.5 - 5.5 kg-m, 25 - 40 ft-Ib)
Retaining nut to nozzle holder (BD30):
toJ: 29 - 39 N.m
If{ (3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
SEF967
Test and Adjustment

WARNING:
When using nozzle tester, be careful not to allow fuel sprayed
from nozzle to come into contact with your hand or body, and
make sure that your eyes are properly protected with goggles.
INJECTION PRESSURE TEST

1. Install nozzle to injection nozzle tester and bleed air from
flare nut.
EF791A
2. Pump the tester handle slowly (one time per second) and
watch the pressure gauge.
3. Read the pressure gauge when the injection pressure just
starts dropping.
Initial injection pressure:
Unit: kPa (bar, kg/cm2, psi)
TD27 8D30
9,807 15,691
Used
(98.1, 100, 1,422) (156.9, 160,2,275)
10,297 - 11,278 16,182 - 17,162

New (103.0 - 112.8, 105 - 115, (161.8-171.6,165-175,
1,493 - 1,635) 2,346 - 2,489)
New nozzle is required to always check initial injection pressure.
EF-50
INJECTION NOZZLE
Test and Adjustment (Cont'd)
4. To adjust injection pressure, change adjusting shims.
a. Increasing the thickness of adjusting shims increases initial
injection pressure. Decreasing thickness reduces initial pres-
Adjusting shim
sure.
b. A shim thickness of 0.04 mm (0.0016 in) corresponds approx-
imately to a difference of 471 kPa (4.71 bar, 4.8 kg/cm2 , 68
psi) in initial injection pressure. (TD27)
c. A shim thickness of 0.010 mm (0.0004 in) corresponds
approximately to a difference of 147 kPa (1.47 bar, 1.5
SEF427F
kg/cm2 , 21 psi) in initial injection pressure. (8030)
Thickness mm (in)
TD27 8030
0.1 (0.004)
0.2 (0.008)
0.3 (0.012)
0.4 (0.016)
0.5 (0.020) 0.5 (0.020) to 1.5 (0.059)
0.52 (0.0205) [Every 0.025 (0.0010)]
0.54 (0.0213)
0.56 (0.0220)
0.58 (0.0228)
0.8 (0.031)
LEAKAGE TEST
1. Maintain the pressure at about 981 to 1,961 kPa (9.8 to 19.6
bar, 10 to 20 kg/cm2, 142 to 284 psi) below initial injection
pressure.
2. Check that there is no dripping from the nozzle tip or around
the body.
3. If there is leakage, clean, overhaul injection nozzle or replace
it.
Good Faulty
SEF674A
TD27 SPRAY PATTERN TEST

1. Pump the tester handle one time per second.
2. Check the spray pattern.
3. If the spray pattern is not correct, clean injection nozzle or
.. .
• replace it .
I
Good Wrong
EF794A
EF-51
INJECTION NOZZLE
Test and Adjustment (Cont'd)
8030
Good >Wrong
> FEF.156
EF-52
BLEEDING FUEL SYSTEM
Bleeding Fuel System (Engine on vehicle)

Air should be bled out of fuel system wh~n injection pump is
removed or fuel system is repaired.
Protect pump and engine mounts from fuel splash with rags.
If engine will not start after bleeding air, loosen injection tubes
at nozzle side and crank engine until fuel overflows from injec-
tion tube. Tighten injection tube flare nutS.
If the engine does not operate smoothly after it has started, race
it two or three times.
WITHOUT AIR VENT SCREW

Up and down
Method A
Move the priming pump up and down until there is suddenly
more resistance in the movement.
SEF429F
Method B
1. Loosen injection pump bleeder screw/or disconnect return
hose and priming.
2. Make sure that fuel overflows at bleeder screw/tube end,
then tighten it/connect hose.
SEF958
WITH AIR VENT SCREW

Up and down
Method A
1. Loosen the air vent screw CD.
2. Move the priming pump @ up and down until no further air-
bleed comes out of the air vent screw CD .
3. Tighten the air vent screw CD.
4. Move the priming pump @ up and down until there is
suddenly more resistance in the movement.
SEF430F
Up and down
Method B
1. Loosen the air vent screw CD.
t 2. Move the priming pump @ up and down until no further air-
bleed comes out of the air vent screw CD.
3. Tighten the air vent screw CD.
SEF431 F
EF-53
BLEEDING FUEL SYSTEM
Bleeding Fuel System (Engine on vehicle) (Cont'd)
4. Loosen injection pump bleeder screw/or disconnect return
PUSh~ hose and priming.
5. Make sure that fuel overflows at bleeder screw/tube end,
fI------... Fuel filter
then tighten it/connect hose.
SEF958
Checking Priming Pump

Before checking priming pump, make sure that fuel filter is
filled with fuel.
1. Disconnect fuel return hose.
Place a suitable container beneath hose end.
2. Pump priming pump and check that the fuel overflows
from the hose end. If not, replace priming pump.
EF-54
SPECIAL ..SERVICE. TOOLS
Injection Pump
ADJUSTING DEVICE ON CAR
Tool number
Description
Tool name
KVl1229352
Measuring device
(Set length of
plunger spring)
G) KVl1229350
Holder
@ KV 11229360
Nut
CID KV 11229370
Pin
@) KVl1254410
Dial gauge
DISASSEMBLING AND ASSEMBLlNG TOOLS
G) KVl1244852
Universal vise
@ KVl1244872
Bracket
CID KVl1244792
Bracket
KV11229072
Insert device
KVl1214110
Socket wrench for
delivery valve co
I(Vl1214270
Socket wrench for
governor pivot bolt
EF-55
Injection Pump (Cont'd)
Tool number
Description
Tool name
KV11214260
Socket wrench for
regulating valve g D
KV11214250
Socket wrench for
distributor head plug
KV11215842
Governor shaft
adjusting device
KV11229542
Feed pump holder
"MS" measuring
device set
CD KV11229110
Block gauge
@ KV11241920
Dummy shaft
@ KV11229830
Rod
KV11229752
Block gauge
(For high altitude
compensator)
KV11229762
Block gauge
(For high altitude
compensator)
KV11229042
"K" & "KF"
measuring device
KV11222090
Oil seal guide
(For drive shaft)
EF-56
Injection Pump (Cont'd)
ADJUSTING DEVICE ON PUMP TESTER
Tool number
Tool name I 0"";0';0"
KVl1281036
Fixing stand
~
KVl1242442
Coupling
KVl1282815
Measuring device
(Timer advance angle) ({l ~
r
KVl1205032
Injection pipe
[840 mm (33.07 in)]
KVl1229462
Extractor
(Disassembling of
regulating valve)
.~
KVl1229522
Insert device
(Assembling of
regulating valve) U
KVl1257802
Nozzle holder
(Bosch type
EF8511.9A)
~
KVl1257800
Nozzle
(Bosch type
DN12SD12T)
t1
ADJUSTING DEVICE FOR POTENTIOMETER
KVl1229882
Voltage check harness
(F or potentiometer)
KVl1244582
Voltage adjusting
harness
(F or potentiometer)
EF-57

Nissan Bd30t Engine Service Manual

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SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS

BASIC MECHANICAL SYSTEM Injection timing B.T.O.C./rpm

Fan belt deflection Idling rpm 700

New 9 - 11 (0.35 - 0.43) Initial injection pressure

Water capacitY Q (US gal, Imp gal)

B030 11.3 (3, 2-1/2)

Cooling system leaking testing Cylinder head bolt*

Inspection and Adjustment

Standard 2,942 (29.4,30,427)/200 Standard Service

Minimum 2,452 (24.5, 25, 356)/200 12.033 • 12.044

Limit 12.00 - 12.011

Nominal cylinder head height 89.7 (3.531) 0.022.0.044

VALVE Unit: mm (in) Standard Max. tolerance

T (Margin thickness) Stem to guide clearance

Valve deflection Iim it

Valve head diameter "0" Valve spring

Valve stem diameter "d"

Intake 8.0 (0.315)

Exhaust 8.0 (0.315)

Valve seat angle "0/'

Valve margin "T" limit 1.0 (0.039)

Valve stem end surface

Valve clearance (Hot)

Outer diameter (0.7866 - -

Clearance between rocker

Camshaft journal diameter

37.9.38.1 49.921 - 49.940

42.4 -42.6 Camshaft bend (Total Less than

Cylinder head valve seat 44.500-44.515 0.08 -0.28

Valve seat face angle "</>" 89° . 91°

0.4 10.016) 39.935 • 39.945 EM671

Valve seat face angle "</>" 89° • 90°

Hino engine parts

SEM950C Cylinder liner diameter "0" 96.050. 96.070

Surface flatness * Before installing in cylinder block

Limit 0.2 (0.008)

Wear limit 0.20 (0.0079)

Out-of.round IX - y) Lessthan 0.040 (0.0016)

Taper (A - B) Lessthan 0.040 (0.0016)

Projection "S" 0.02.0.09 (0.0008 - 0.0035)

Interference fit cylinder liner -0.01 to 0.03

Piston skirt diameter "A"

Grade No.2 95.950.95.960 (3.7776 - 3.7779) 95.960 - 95.970 (3.7779.3.7783)

"a" dimension 70 (2.76) 63.5 (2.500)

Piston to cylinder liner clearance 0.05 - 0.07 (0.0020 - 0.0028)

* Grade No.3 piston is not provided as a service part.

Piston ring Piston pin

Piston pin to piston

0.04 -0.08 clearance

Oil (rail ring)

28.025 - 28.033 30.025 - 30.038

Limit 0.22 10.0087)

Center distance "S"

Taper of journal and pin "A-B"

Limit 0.02 (0.0008)

Out-of-round of journal and

Limit 0.02 (0.0008)

Crankshaft end play