Service

Engine

Generator Set Models:

600REOZM
Engine Models:
D600

TP-6261 6/04
 California Proposition 65

WARNING
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.
 Table of Contents

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Section 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 External Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.2 Engine Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section 2 Engine Overhaul Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.1 Specific Bolt and Nut Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.2 Standard Bolt and Nut Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.3 Standard Eyebolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.4 Standard Union Nut Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.5 High-Pressure Fuel Injection Pipe Torque Values . . . . . . . . . . . . . . . . . . 13
2.3 Sealants and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Section 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Section 4 Overhaul Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 Overhaul Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Section 5 Component Adjustment and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1.1 Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1.2 Fuel System Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1.3 Fuel Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1.4 Idling Speed and Maximum Speed Setting . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1.5 Water Pump and Alternator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Bench Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2.1 Starting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2.2 Inspection After Starting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2.3 Bench Testing (Dynamometer) Conditions . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.4 Inspection and Adjustments After Bench Testing . . . . . . . . . . . . . . . . . . . 23
Section 6 Major Engine Component Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2 Major Engine Component Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.3 Major Engine Component Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3.1 Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3.2 Governor Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.3 Stop Solenoid and Start Rack Limit Solenoid . . . . . . . . . . . . . . . . . . . . . . 31
Section 7 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.1 Cylinder Heads and Valve Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.2 Cylinder Liners, Pistons, and Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.3 Torsional Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.4 Flywheel, Timing Gears, and Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.5 Crankcase, Crankshaft, and Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

TP-6261 6/04 Table of Contents

Table of Contents, continued

Section 8 Intake and Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

8.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.2 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.3 Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.4 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Section 9 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.2 Oil Pump and Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.3 Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.4 Oil Cooler and Oil Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
9.5 Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Section 10 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10.1 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10.2 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10.3 Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10.4 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10.5 Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Section 11 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
11.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
11.2 Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
11.3 Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
11.4 Fuel Injection Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Section 12 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
12.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
12.2 Engine Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Section 13 Disassembly and Reassembly Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
13.1 Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
13.2 O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
13.3 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
13.4 Lock Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
13.5 Split Pins and Spring Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Appendix B General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Appendix C Common Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Table of Contents TP-6261 6/04

 Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting Battery

Electromechanical equipment,
including generator sets and
accessories, can cause bodily harm WARNING WARNING
and pose life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE Accidental starting.
THESE INSTRUCTIONS. Can cause severe injury or death. Sulfuric acid in batteries.
Can cause severe injury or death.
This manual has several types of safety Disconnect the battery cables before
precautions and instructions: Danger, working on the generator set. Wear protective goggles and
Warning, Caution, and Notice. Remove the negative (--) lead first clothing. Battery acid may cause
when disconnecting the battery. blindness and burn skin.
Reconnect the negative (--) lead last
DANGER when reconnecting the battery.
WARNING
Danger indicates the presence of a Disabling the generator set.
hazard that will cause severe Accidental starting can cause
personal injury, death, or substantial severe injury or death. Before
property damage. working on the generator set or
connected equipment, disable the
Explosion.
generator set as follows: (1) Move the
WARNING Can cause severe injury or death.
generator set master switch to the OFF
Relays in the battery charger
position. (2) Disconnect the power to
cause arcs or sparks.
Warning indicates the presence of a the battery charger. (3) Remove the
hazard that can cause severe battery cables, negative (--) lead first. Locate the battery in a well-ventilated
personal injury, death, or substantial Reconnect the negative (--) lead last area. Isolate the battery charger from
property damage. when reconnecting the battery. Follow explosive fumes.
these precautions to prevent starting of
the generator set by an automatic Battery electrolyte is a diluted
CAUTION transfer switch, remote start/stop sulfuric acid. Battery acid can cause
switch, or engine start command from a severe injury or death. Battery acid
Caution indicates the presence of a remote computer. can cause blindness and burn skin.
hazard that will or can cause minor Always wear splashproof safety
personal injury or property damage. goggles, rubber gloves, and boots
when servicing the battery. Do not
NOTICE open a sealed battery or mutilate the
Notice communicates installation, battery case. If battery acid splashes in
operation, or maintenance information the eyes or on the skin, immediately
that is safety related but not hazard flush the affected area for 15 minutes
related. with large quantities of clean water.
Seek immediate medical aid in the case
Safety decals affixed to the equipment of eye contact. Never add acid to a
in prominent places alert the operator battery after placing the battery in
or service technician to potential service, as this may result in hazardous
hazards and explain how to act safely. spattering of battery acid.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.

TP-6261 6/04 Safety Precautions and Instructions I

Battery acid cleanup. Battery acid Engine Backfire/Flash Using engine starting fluid. A
can cause severe injury or death. sudden backfire can cause severe
Battery acid is electrically conductive Fire injury or death. Do not use starting
and corrosive. Add 500 g (1 lb.) of fluid or similar agents to start an engine
bicarbonate of soda (baking soda) to a WARNING equipped with air preheating (glow
container with 4 L (1 gal.) of water and plugs/starter element). The starter
mix the neutralizing solution. Pour the element may cause an explosion in the
neutralizing solution on the spilled inlet manifold.
battery acid and continue to add the
neutralizing solution to the spilled
Fire.
battery acid until all evidence of a
Can cause severe injury or death.
Engine Fluids and
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
Chemical Products
Do not smoke or permit flames or
water and dry the area. sparks near fuels or the fuel system.
WARNING
Battery gases. Explosion can cause
severe injury or death. Battery gases Servicing the fuel system. A flash
can cause an explosion. Do not smoke fire can cause severe injury or death.
or permit flames or sparks to occur near Do not smoke or permit flames or
a battery at any time, particularly when sparks near the fuel injection system,
it is charging. Do not dispose of a fuel line, fuel filter, fuel pump, or other
Handling caustic engine fluids and
battery in a fire. To prevent burns and potential sources of spilled fuels or fuel
chemical products.
sparks that could cause an explosion, vapors. Catch fuels in an approved
Can cause severe chemical burns,
avoid touching the battery terminals container when removing the fuel line
nausea, fainting, or death.
with tools or other metal objects. or carburetor.
Remove all jewelry before servicing the Most chemicals such as used engine
Servicing the air cleaner. A sudden
equipment. Discharge static electricity oil, antifreeze/coolant, rustproofing
backfire can cause severe injury or
from your body before touching agent, inhibiting oil, degreasing
death. Do not operate the generator
batteries by first touching a grounded agent, spray paint, and adhesives are
set with the air cleaner removed. hazardous to health. Read and follow
metal surface away from the battery. To
avoid sparks, do not disturb the battery Servicing the air cleaner on a the user information found on the
charger connections while the battery turbocharged engine. A sudden packaging. Avoid inhalation and skin
is charging. Always turn the battery engine backfire or turbocharger contact. Use only in well-ventilated
charger off before disconnecting the compressor failure can cause areas and use a protective mask
battery connections. Ventilate the severe injury or death. Do not when spraying. Store engine fluids
compartments containing batteries to operate the generator set with the air and chemical products in a locked
prevent accumulation of explosive cleaner removed. Burns from hot cabinet. Contact your local recycling
gases. turbocharger components may occur. center for disposal information and
Foreign objects sucked into the locations.
Battery short circuits. Explosion turbocharger can cause mechanical
can cause severe injury or death. damage and the potential for high
Short circuits can cause bodily injury velocity projectiles. WARNING
and/or equipment damage.
Disconnect the battery before Combustible materials. A fire can
generator set installation or cause severe injury or death.
maintenance. Remove all jewelry Generator set engine fuels and fuel
before servicing the equipment. Use vapors are flammable and explosive. Flammable engine solvents and
tools with insulated handles. Remove Handle these materials carefully to cleaners.
the negative (--) lead first when minimize the risk of fire or explosion. Can cause severe injury or death.
disconnecting the battery. Reconnect Equip the compartment or nearby area
the negative (--) lead last when with a fully charged fire extinguisher. Do not smoke or permit flames or
reconnecting the battery. Never Select a fire extinguisher rated ABC or sparks near flammable engine
connect the negative (--) battery cable BC for electrical fires or as solvents and cleaners. Read and
to the positive (+) connection terminal recommended by the local fire code or follow the user information found on
of the starter solenoid. Do not test the an authorized agency. Train all the packaging. Use only in well-
battery condition by shorting the personnel on fire extinguisher ventilated areas. Never use gasoline
terminals together. operation and fire prevention or low flash-point solvents as
procedures. cleaning agents.

II Safety Precautions and Instructions TP-6261 6/04

Leaking or accumulated engine Exhaust System Fuel System
fluids. A fire can cause severe injury
or death. Clean up engine fluids
including fuel, oil, grease, and coolant. WARNING WARNING
Determine the source of engine leaks
and correct before starting the
generator set. Keep the generator set
area clean and remove combustible
materials.
Carbon monoxide.
Used engine oil. Contact with used Can cause severe nausea, Explosive fuel vapors.
engine oil may cause severe skin fainting, or death. Can cause severe injury or death.
irritation. Repeated and prolonged
skin exposure may have other The exhaust system must be Use extreme care when handling,
health risks. Used engine oil is a leakproof and routinely inspected. storing, and using fuels.
suspected carcinogen. Avoid contact
with skin. Thoroughly wash your hands Generator set operation. Carbon
and nails with soap and water shortly monoxide can cause severe nausea, WARNING
after handling used engine oil. Wash or fainting, or death. Carbon monoxide
dispose of clothing or rags containing is an odorless, colorless, tasteless,
used engine oil. Dispose of used nonirritating gas that can cause death if
engine oil in a responsible manner. inhaled for even a short time. Avoid
Contact your local recycling center for breathing exhaust fumes when working
Avoid high pressure fluids.
disposal information and locations. on or near the generator set. Never
Can cause severe injury or death.
operate the generator set inside a
Fire-damaged or burned O-rings building unless the exhaust gas is Do not work on high pressure fuel or
may cause the formation of piped safely outside. Never operate hydraulic systems without protective
hydrofluoric acid. Contact with the generator set where exhaust gas gloves. Avoid the hazard by relieving
hydrofluoric acid may cause severe could accumulate and seep back inside pressure before disconnecting fuel
skin irritation and chemical burns. a potentially occupied building. injection pressure lines. Search for
O-rings and other fluoroelastomer
leaks using a piece of cardboard.
seals exposed to fire or temperatures Carbon monoxide symptoms.
Always protect hands and body from
above 316_C (600_F) (i.e., during Carbon monoxide can cause severe
high pressure fluids. If an accident
welding) may decompose forming nausea, fainting, or death. Carbon
occurs, seek medical attention
hydrofluoric acid. Avoid inhalation or monoxide is a poisonous gas present in immediately. Any fluid injected in the
skin contact. Do not incinerate O-rings. exhaust gases. Carbon monoxide skin tissues must be surgically
Dispose of O-ring waste material in a poisoning symptoms include but are removed within a few hours or
responsible manner. not limited to the following: gangrene may result.
D Light-headedness, dizziness
D Physical fatigue, weakness in
The fuel system. Explosive fuel
joints and muscles
vapors can cause severe injury or
D Sleepiness, mental fatigue,
death. Vaporized fuels are highly
inability to concentrate
explosive. Use extreme care when
or speak clearly, blurred vision
handling and storing fuels. Store fuels
D Stomachache, vomiting, nausea
in a well-ventilated area away from
If experiencing any of these symptoms
spark-producing equipment and out of
and carbon monoxide poisoning is
the reach of children. Never add fuel to
possible, seek fresh air immediately
the tank while the engine is running
and remain active. Do not sit, lie down,
because spilled fuel may ignite on
or fall asleep. Alert others to the
contact with hot parts or from sparks.
possibility of carbon monoxide
Do not smoke or permit flames or
poisoning. Seek medical attention if
sparks to occur near sources of spilled
the condition of affected persons does
fuel or fuel vapors. Keep the fuel lines
not improve within minutes of breathing
and connections tight and in good
fresh air.
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.

TP-6261 6/04 Safety Precautions and Instructions III

Fuel tanks. Explosive fuel vapors Hazardous Voltage/ Welding on the generator set. Can
can cause severe injury or death. cause severe electrical equipment
Gasoline and other volatile fuels stored Electrical Shock damage. Before welding on the
in day tanks or subbase fuel tanks can generator set perform the following
cause an explosion. Store only diesel DANGER steps: (1) Remove the battery cables,
fuel in tanks. negative (--) lead first. (2) Disconnect
all engine electronic control module
Draining the fuel system. Explosive (ECM) connectors. (3) Disconnect all
fuel vapors can cause severe injury generator set controller and voltage
or death. Spilled fuel can cause an regulator circuit board connectors.
explosion. Use a container to catch fuel Hazardous voltage. (4) Disconnect the engine battery-
when draining the fuel system. Wipe up Will cause severe injury or death. charging alternator connections.
spilled fuel after draining the system. (5) Attach the weld ground connection
Disconnect all power sources before
close to the weld location.
opening the enclosure.
Hazardous Noise Installing the battery charger.
Hazardous voltage can cause
WARNING severe injury or death. An
CAUTION ungrounded battery charger may
cause electrical shock. Connect the
battery charger enclosure to the ground
of a permanent wiring system. As an
alternative, install an equipment
Hazardous voltage. Moving rotor. grounding conductor with circuit
Hazardous noise. Can cause severe injury or death. conductors and connect it to the
Can cause hearing loss. Operate the generator set only when equipment grounding terminal or the
all guards and electrical enclosures lead on the battery charger. Install the
Never operate the generator set battery charger as prescribed in the
without a muffler or with a faulty are in place.
equipment manual. Install the battery
exhaust system. charger in compliance with local codes
and ordinances.
Engine noise. Hazardous noise can CAUTION
cause hearing loss. Generator sets Connecting the battery and the
not equipped with sound enclosures battery charger. Hazardous voltage
can produce noise levels greater than can cause severe injury or death.
105 dBA. Prolonged exposure to noise Reconnect the battery correctly,
levels greater than 85 dBA can cause positive to positive and negative to
permanent hearing loss. Wear hearing negative, to avoid electrical shock and
Welding the generator set.
protection when near an operating damage to the battery charger and
Can cause severe electrical
generator set. battery(ies). Have a qualified
equipment damage.
electrician install the battery(ies).
Never weld components of the
Servicing the day tank. Hazardous
generator set without first
voltage can cause severe injury or
disconnecting the battery, controller
death. Service the day tank electrical
wiring harness, and engine electronic
control module (ECM) as prescribed in
control module (ECM).
the equipment manual. Disconnect the
power to the day tank before servicing.
Grounding electrical equipment. Press the day tank ECM OFF
Hazardous voltage can cause pushbutton to disconnect the power.
severe injury or death. Electrocution Notice that line voltage is still present
is possible whenever electricity is within the ECM when the POWER ON
present. Open the main circuit light is lit. Ensure that the generator set
breakers of all power sources before and day tank are electrically grounded.
servicing the equipment. Configure the Do not operate the day tank when
installation to electrically ground the standing in water or on wet ground
generator set and related equipment because these conditions increase the
and electrical circuits to comply with risk of electrocution.
applicable codes and standards.
Never contact electrical leads or
appliances when standing in water or
on wet ground because these
conditions increase the risk of
electrocution.

IV Safety Precautions and Instructions TP-6261 6/04

Short circuits. Hazardous Hot Parts Servicing the exhaust system. Hot
voltage/current can cause severe parts can cause severe injury or
injury or death. Short circuits can death. Do not touch hot engine parts.
cause bodily injury and/or equipment WARNING The engine and exhaust system
damage. Do not contact electrical components become extremely hot
connections with tools or jewelry while during operation.
making adjustments or repairs.
Remove all jewelry before servicing the Servicing the engine heater. Hot
equipment. parts can cause minor personal
Hot coolant and steam. injury or property damage. Install the
Engine block heater. Hazardous Can cause severe injury or death. heater before connecting it to power.
voltage can cause severe injury or Operating the heater before installation
Before removing the pressure cap,
death. The engine block heater can stop the generator set and allow it to can cause burns and component
cause electrical shock. Remove the cool. Then loosen the pressure cap damage. Disconnect power to the
engine block heater plug from the to relieve pressure. heater and allow it to cool before
electrical outlet before working on the servicing the heater or nearby parts.
block heater electrical connections.
Testing live electrical circuits. WARNING Moving Parts
Hazardous voltage or current can
cause severe injury or death. Have
trained and qualified personnel take WARNING
diagnostic measurements of live
circuits. Use adequately rated test
Hot engine and exhaust system.
equipment with electrically insulated
Can cause severe injury or death.
probes and follow the instructions of the
test equipment manufacturer when Do not work on the generator set until Hazardous voltage. Moving rotor.
performing voltage tests. Observe the it cools. Can cause severe injury or death.
following precautions when performing
voltage tests: (1) Remove all jewelry. Operate the generator set only when
(2) Stand on a dry, approved electrically WARNING all guards and electrical enclosures
insulated mat. (3) Do not touch the are in place.
enclosure or components inside the
enclosure. (4) Be prepared for the
system to operate automatically. WARNING
(600 volts and under)
Hot engine oil.
Can cause severe injury or death.
Heavy Equipment Avoid skin contact with hot oil. Do not
start or operate the generator set with
WARNING the engine oil filler cap removed, as Rotating parts.
hot oil can spray out. Ensure that the Can cause severe injury or death.
lubrication system is not under
pressure when servicing. Do not Operate the generator set only when
work on the generator set until it all guards, screens, and covers are in
cools. place.

Unbalanced weight. Checking the coolant level. Hot

Improper lifting can cause severe
WARNING
coolant can cause severe injury or
injury or death and equipment death. Allow the engine to cool.
damage. Release pressure from the cooling
system before removing the pressure
Do not use lifting eyes.
cap. To release pressure, cover the
Lift the generator set using lifting bars
pressure cap with a thick cloth and then
inserted through the lifting holes on
slowly turn the cap counterclockwise to Airborne particles.
the skid.
the first stop. Remove the cap after Can cause severe injury or
pressure has been completely blindness.
released and the engine has cooled.
Check the coolant level at the tank if the Wear protective goggles and clothing
generator set has a coolant recovery when using power tools, hand tools,
or compressed air.
tank.

TP-6261 6/04 Safety Precautions and Instructions V

Tightening the hardware. Flying Notice NOTICE
projectiles can cause severe injury When replacing hardware, do not
or death. Loose hardware can cause NOTICE substitute with inferior grade
the hardware or pulley to release from Voltage reconnection. Affix a notice hardware. Screws and nuts are
the generator set engine and can cause to the generator set after reconnecting available in different hardness ratings.
personal injury. Retorque all the set to a voltage different from the To indicate hardness, American
crankshaft and rotor hardware after voltage on the nameplate. Order Standard hardware uses a series of
servicing. Do not loosen the crankshaft voltage reconnection decal 246242 markings, and metric hardware uses a
hardware or rotor thrubolt when making from an authorized service numeric system. Check the markings
adjustments or servicing the generator distributor/dealer. on the bolt heads and nuts for
set. Rotate the crankshaft manually in identification.
a clockwise direction only. Turning the NOTICE
crankshaft bolt or rotor thrubolt
Hardware damage. The engine and
counterclockwise can loosen the
generator set may use both American
hardware.
Standard and metric hardware. Use
Servicing the generator set when it the correct size tools to prevent
is operating. Exposed moving parts rounding of the bolt heads and nuts.
can cause severe injury or death.
Keep hands, feet, hair, clothing, and
test leads away from the belts and
pulleys when the generator set is
running. Replace guards, screens, and
covers before operating the generator
set.

VI Safety Precautions and Instructions TP-6261 6/04

 Introduction

This manual provides troubleshooting and repair The equipment service requirements are very important
instructions for 600REOZM generator set engines. to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Information in this publication represents data available Maintenance work must be performed by appropriately
at the time of print. Kohler Co. reserves the right to skilled and suitably-trained maintenance personnel
change this publication and the products represented familiar with generator set operation and service.
without notice and without any obligation or liability
whatsoever.

Read this manual and carefully follow all procedures

and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.

Service Assistance

For professional advice on generator power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric Fax: (86) 10 6518 7955

D Visit the Kohler Power Systems website at East China Regional Office, Shanghai
KohlerPowerSystems.com Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444 (91) 80 3366231
Fax: (91) 80 3315972
D Outside the US and Canada, call the nearest regional
office Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Fax: (813) 3440-2727
ZI Senia 122
Latin America
12, rue des Hauts Flouviers
Latin America Regional Office
94517 Thiais Cedex
Lakeland, Florida, USA
France
Phone: (863) 619-7568
Phone: (33) 1 41 735500
Fax: (863) 701-7131
Fax: (33) 1 41 735501
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 264-6422
Fax: (65) 264-6455

TP-6261 6/04 Introduction i

 Notes

ii Service Assistance TP-6261 6/04

 Section 1 General Information

1.1 Outline
1.1.1 External Views

3 4
2

15
6

14 7
13
8
12

11 10 9

1. Fan 5. Fuel feed pump 9. Oil level gauge 13. Water drain plug
2. Breather 6. Water drain petcock 10. Bypass oil filter 14. Oil cooler
3. Fuel filter 7. Turning gear 11. Oil filter 15. Water pump
4. Fuel injection pump (manual stop lever) 8. Oil fill 12. Vibration dampener

Figure 1-1 Engine, Left Side

2 3

4
1

8
5

6
7

1. Air cooler 3. Exhaust manifold 5. Engine alternator 7. Oil pan

2. Turbocharger 4. Thermostat 6. Nameplate 8. Starter

Figure 1-2 Engine, Right Side

TP-6261 6/04 Section 1 General Information 1

1.1.2 Engine Serial Number Location
The engine serial number is stamped on the nameplate
attached to the left side of the engine.

Example: Model Serial No.

D600 xxxxxxx

Rated output and speed are also stamped on the Figure 1-3 Engine Serial Number Location
nameplate. Figure 1-3 shows cylinder numbers.

1.2 General Specifications

Item Model D600
General
Water-cooled, 4-stroke cycle, turbocharged diesel
Type
Aftercooled
Cylinder, qty., arrangement 6 inline
Combustion chamber type Direct injection
Valve mechanism Overhead
Cylinder diameter x stroke, mm (in.) 170 x 180 (6.693 x 7.087)
Piston displacement, L (cu. in.) 24.5 (1495)
Compression ratio 14.0:1
Fuel Light oil (JIS K2204 special no. 1--3) or a heavy oil (use name brand fuel)
Firing order 1-5-3-6-2-4
Rotation direction Counterclockwise as viewed from flywheel side
Overall length 1722 (67.80)
Dimensions, mm (in.) Overall width 1050 (41.34)
Overall height 1498 (59)
Weight, Dry, kg. (lb.) 2300 (5072)
Engine Assembly
Cylinder liner Type Wet
Compression rings 2
Piston rings,
rings qty.
qty
Oil ring (w/expander) 1
Open BTDC 37°
Intake valve
Valve timing Close ABDC 44°
((when warm)) Open BBDC 57°
Exhaust valve
Close ATDC 24°
Engine support 4 point support
Starting system Electric motor starting
Intake and Exhaust Systems
Air cleaner Type Paper element or precleaner
Turbocharger Units, qty. 1
Air cooler Type Laminated fin-plate
Lubrication System
Type Pressure feed by gear pump
Specification Class CD oil or class CF oil (API service classification)
Engine oil
Capacity (engine), L (gal.) 100 (26.4), approx.
Type Gear pump
Oil pump
Delivery capacity, L (gal.)/min. 140 (83.2) at 1800 rpm engine
Type Piston valve
Relief valve
Valve opening pressure, MPa (psi) 0.46 (67)
Oil cooler Type Water-cooled multiplate (housed in the crankcase)
Full-flow oil filter Type Paper element (spin on)
Bypass oil filter Type Paper element (spin on)

2 Section 1 General Information TP-6261 6/04

Item Model D600
Lubrication System, continued
Type Piston valve, built-in electric contact points

Oil filter alarm Lamp fighting and valve opening

pressure (differential pressure), 0.15 +0.03/0 (21 +4/0)
MPa (psi)
Type Wax
Oil thermostat
Valve opening temperature, °C (°F) 80--84 (176--183)
Cooling System
Type Forced circulation
Capacity, engine, L (gal.) 50 (13.2), approx.
Type Centrifugal
Water pump
Delivery capacity, L (gal.) 800 (211.2) at 1800 engine rpm
Water pump and Type, qty. of belts Low-edge cog C-2
alternator drive belts Outer circumference, mm (in.) 1910 (75.2)
Type Wax
Thermostats
Valve opening temperature, °C (°F) 69--73 (156.2--163.4)
Radiator Type Plate fin or corrugated fin
Type Steel blade, circular arc
Cooling fan Blades, qty. 8
Outside diameter, mm (in.) 1010 (39.8)
Fuel System
Model PS 6 type
Plunger outside diameter, mm (in.) 17 (0.67)
Injection pump
Plunger lead, mm (in.) Left hand 35 (1.38)
Cam lift, mm (in.) 15 (0.59)
Feed pump cam lift, mm (in.) 12 (0.47)
Type Hole
Spray orifice, qty. 10
Injection nozzles Spray orifice inside diameter, mm (in.) 0.35 (0.0137), 0.325 (0.012), 0.31 (0.012) --160°
Spray angle 160°
Injection pressure, MPa (psi) 34.32--34.81 (4978--5049)
Fuel filter Type Paper element (spin on)
Electrical System
Voltage polarity 24V, negative (--) ground
Model 8-23000-6641
Type Pinion shift (reduction)
Starter Output, V-kW 24-7.5
Starters, qty. 1 or 2
Pinion/ring gear ratio 11/182
Type 3-phase with built-in IC regulator
Output 24--30
Alternator Rated output generated, rpm 5000 (at 27V, 30A)
Maximum speed, rpm 8000
Regulator adjusting voltage, V 28.5 ±0.5
Model 0-25000-7223
Nominal voltage, V 24
Allowable temperature, °C (°F) --30 to 40 (--22 to 104.0)
Safety
S f t relay
l (for
(f Rating, seconds 30
starter chattering)
330 (momentary)
Allowed contact current,
current A
50 (30 seconds)
Ground 2-wire system

TP-6261 6/04 Section 1 General Information 3

1.3 Disassembly and Reassembly 4. Pay attention to the marks on assemblies,
components, and parts for positions or directions.
This service manual covers recommended procedures Put on your own marks, if necessary, to aid
to be followed when servicing diesel engines. It also reassembly.
contains information on special tools required and basic
safety precautions. 5. Carefully check each part for faults during removal
or cleaning. Signs of abnormal wear will tell if parts
Read this manual and carefully follow all procedures or assemblies are functioning improperly.
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the 6. When lifting or carrying heavy parts, get someone
to help you if the part is too awkward for one person
Safety Precautions and Instructions section at the
to handle. Use jacks and chain blocks when
beginning of this manual. Keep this manual with the
necessary.
equipment for future reference.

The equipment service requirements are very important 1.3.2 Reassembly

to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals. 1. Wash all engine parts, except oil seals, O-rings,
Maintenance work must be performed by appropriately rubber seals, etc. in cleaning solvent and dry with
skilled and suitably trained maintenance personnel compressed air.
familiar with engine/generator set operation and
2. Use only the correct tools and instruments.
service.
3. Use only good quality lubricating oils and greases.
1.3.1 Disassembly Be sure to apply a coat of oil, grease, or sealant to
parts as specified.
1. Use the correct tools and instruments. Serious
injury or damage to the engine can result from 4. Use a torque wrench to tighten parts when
using the wrong tools and instruments. specified tightening torques are required. See
Section 2.2, Tightening Torques.
2. Use an overhaul stand or workbench, if necessary.
Also use assembly bins to keep the engine parts in 5. Replace all gaskets and packing. Apply only the
order of removal. proper amount of quick-drying cement to gaskets
or packets when required.
3. Lay down disassembled or cleaned parts in the
order in which they were removed. This will save
you time at reassembly.

4 Section 1 General Information TP-6261 6/04

 Section 2 Engine Overhaul Specifications

2.1 Maintenance Standards

Nominal Assy Standard Repair Limit Service Limit
Inspection Point Value (Std. Clearance) (Clearance) (Clearance) Remarks
General
Compression pressure, Oil and water temp.
1.8 (263) min. at 120 rpm Faulty if 1.3 (185) or less
MPa (psi) 20°C--30°C (68°F--86°F).
0.5--0.64 (71--92.4) at rated rpm; Faulty if 0.4 (71) or less; Oil temp. 60°C--70°C
Lube oil pressure, MPa (psi)
0.2 (28) min. at idling faulty if 0.1 (14) or less (140°F--158°F).
Intake valve opens BTDC 2.5° Valves are only for
Valve timing with 2 mm (0.08 in.) Intake valve closes ABDC 13° checking valve timing and
clearance on valve side, cold Exhaust valve opens BBDC 26° are different from the
Exhaust valve closes ATDC 10.5° ±2° (crank angle) actual ones.
Valve Intake valves 0.6 (0.024)
clearance
clearance,
cold, (mm (in.) Exhaust valves 0.8 (0.031)
Varies according to
specifications. Refer to
Injection timing BTDC ±1° (crank angle)
Information plate on no. 1
rocker cover.
Engine Assembly
Rocker bushing 36.000--36.040 36.090
Rockers, inside diameter (1.41732--1.41889) (1.42086)
36 (1.42)
(1 42)
mm (in.) 35.966--35.991 35.940
Rocker diameter
(1.41598--1.41697) (1.41496)
Valve stem 9.940--9.960 9.910
Valves, diameter (0.39134--0.39213) (0.39016) The same for both intake
10 (39)
mm (in.) Valve guide 10.000--10.015 10.060 and exhaust valves.
inside diameter (0.39370--0.39429) (0.39606)
Valve seat angle 30° Seat width

Valve sinkage, --0.2 to 0.2

0 1.0 (0.039)
mm (in.) (--0.0079 to 0.0079)

Seat width, 2.15--2.45

2.3 (0.091) 2.8 (0.110) Valve
mm (in.) (0.0840--0.0965)
g
margin
Valve seats
and valves Refacing is
Valve margin, Valve Valve
3.0 (0.12) 2.8--3.2 (0.110--0.126) permissible up seat permissible
mm (in.) to 2.5 (0.098) angle sinkage
Cylinder head
bore inside
diameter and --0.070 to --0.130 Minus (--) indicates the
60 (2.36)
valve seat (--0.00276 to --0.00512) valve is closed.
diameter,
mm (in.)
Free length,
73 (2.87) 71 (2.80)
mm (in.)

n=2.2 mm
Squareness (0.087 in.) over
Valve springs the length

Length under
66.0/289--319
test force, mm/N
(2.598/64.9--71.8)
(in./lbf.)
Valve push
Runout 0.5 (0.020) maximum
rods, mm (in.)
Cylinder Warpage of
heads, gasketed 0.03 (0.0012) maximum 0.07 (0.0028) 0.50 (0.0197) Regrind slightly.
mm (in.) surface

TP-6261 6/04 Section 2 Engine Overhaul Specifications 5

 Nominal Assy Standard Repair Limit Service Limit
Inspection Point Value (Std. Clearance) (Clearance) (Clearance) Remarks
Engine Assembly, continued
170.000--170.040 170.200 170.500
Inside diameter 170 (6.69)
(6.69290--6.69447) (6.70588) (6.7126)
Out-of-roundness
0 02 (0.0008)
0.02 (0 0008) maximum
Taper
Cylinder Squareness with
liners, respect to lower 0.03 (0.0012) maximum
mm (in.) face of flange
Protrusion of
cylinder liner
0.11--0.20
flange above
(0.0043--0.0079)
gasketed
surface
Outside Measure diameter in the
169.76--169.80 169.66
diameter, 170 (6.69) direction transverse to pin
(6.6834--6.6850) (6.6795)
mm (in.) at piston skirt.
Variance in
weight among
20 (0.7), maximum
pistons per
Pistons engine, g (oz.)
Pin bore
70.002--70.015 70.040
diameter, 70 (2.76)
(2.75598--2.75649) (2.75958)
mm (in.)
Protrusion, 0.06--0.65
mm (in.) (0.0024--0.0256)
Cylinder head
As installed 1.77--1.83
gasket, 1.8 (0.071)
thickness (0.0697--0.0720)
mm (in.)
Clearance
Piston and
between piston 1.22--1.95
cylinder head,
top and cylinder (0.0480--0.0768)
mm (in.)
head
Top If g
gauge
g is not available,,
Piston
Pi t ring
i 0 6 0 8 (0.024--0.031)
0.6--0.8 (0 024 0 031) th generall value
the l can be b
Second 2.0 (0.079)
( )
gap mm (in.)
gap, (in ) obtained at the cylinder
Oil 0.30--0.45 (0.012--0.018) bore.
Piston pins, 69.987--70.000 69.970
Diameter
mm (in.) (2.7554--2.7559) (2.75472)
Bushing inside 70 (2.76)
70.020--70.040 70.070
diameter,
(2.75669--2.75747) (2.75866)
mm (in.)
Bend and twist, 0.05/100 (0.0020/3.9)
mm (in.) maximum
End play (crank
1.00076
pin and big end 67 (2.64) 0.2--0.6 (0.008--0.024)
(0.0394)
widths), mm (in.)
Connecting Variance in
rods weight among
connecting 40 (1.411) maximum
rods/engine,
g (oz.)
To be used in combination
Big end bore with bearing caps. Out-of-
131.000--131.025 131.050
diameter, 131 (5.16) roundness (largest
(5.15748--5.15847) (5.1594)
mm (in.) valve—smallest valve
<0.1 (0.0039).
Thickness of center:
2.972--2.985 2.930
Standard 3.000 (0.11811)
(0.11701--0.11752) (0.11535)
3.097--3.110 3.055
--0.25 (--0.0098) 3.125 (0.12303) Replace
p bearings
g if worn
Connecting (0.12193--0.12244) (0.12028)
rod bearing, 3.222--3.235 3.180 d
down to
t service
i limit.
li it
mm ((in.)) --0.50 (--0.0197) 3.250 (0.12795) Regrind crank pins and
(0.12685--0.12736) (0.12520)
use under/beyond service
3.347--3.360 3.305 limit.
--0.75 (--0.0295) 3.375 (0.13287)
(0.13177--0.13228) (0.13012)
3.472--3.485 3.430
--1.00 (--0.0394) 3.500 (0.13780)
(0.13669--0.13720) (0.13504)

6 Section 2 Engine Overhaul Specifications TP-6261 6/04

 Nominal Assy Standard Repair Limit Service Limit
Inspection Point Value (Std. Clearance) (Clearance) (Clearance) Remarks
Engine Assembly, continued
0.285 (0.01122)
Face runout
Flywheel, maximum
mm (in.) 0.127 (0.00500)
Radial runout
maximum
89.987--90.022
Drive case 90 (3.54)
(3.54279--3.54417)
bearing journal,
journal
inside diameter 99.987--100.022
100 (3.94)
(3.93649--3.93787)
89.985--90.000
90 (3.54)
Bearing outside (3.54272--3.54331)
IInjection
j ti diameter 99.985--100.000
pump 100 (3.94)
(3.93642--3.93701)
accessory
drive, 44.988--45.000
45 (1.77)
mm (in.) Bearing inside (1.77118--1.77165)
diameter 49.985--50.000
50 (1.97)
(1.96791--1.96850)
45.002--45.013
Drive shaft 45 (1.77)
(1.77173--1.77217)
bearing journal
outside diameter 50.002--50.013
50 (1.97)
(1.96858--1.96902)
Torsional Radial runout (at
periphery) 0.5 (0.020) or less 1.5 (0.059) Replace every 8000
dampener,
hours
hours.
mm (in.) Face runout
0.12--0.18
Backlash 0.30 (0.0118) 0.50 (0.0197) Replace gears.
(0.0047--0.0071)
Idler gear
50.000--50.025 50.060
bushing inside
Timing gears, (1.96850--1.96948) (1.97086)
diameter 50 (1.97)
mm (in.)
(in )
Idler gear shaft 49.950--49.975 49.900
diameter (1.96653--1.96752) (1.96456)
Idler gear end
0.2--0.4 (0.008--0.16) 0.6 (0.024)
play

9.247 9.197--9.297
Cam lift (A--B) 8.45 (0.3327)
(0.36405) (0.36209--0.36602)

Runout at center bushing

measured with both ends
Runout 0.05 (0.002) maximum 0.08 (0.0031)
supported. Repair or
Camshaft, replace.
mm (in.)
(in )
83.92--83.94
Journal diameter 83.87 (3.3020)
(3.3039--3.3047)
Camshaft inside 84 (3.31) Replace bushings and
diameter (as 84.000--84.035
84.10 (3.3110) ream them, if necessary, if
installed in (3.3071--3.3085) worn beyond service limit.
crankcase
0.10--0.25
End play 8 (0.31) 0.40 (0.016) Replace thrust plate.
(0.0039--0.0098)
Crank pin
125 (4.92)
diameter --0.050
0.050 to --0.070
0.070 --0.110
0.110
Crank pin (--0.00197 to --0.00276) (--0.0043)
140 (5.51)
journal diameter
Center to center
distance
90 (3.54) ±0.1 (±0.004)
between journal
Crankshaft, and crank pin
mm (in.) Parallelism
between 0.01 (0.0004) maximum
journals and at pin length
crank pins
0 03 (0.0012)
0.03 (0 0012)
Out-of-
roundness
0.01 (0.0004) maximum
between journal
and crank pins

TP-6261 6/04 Section 2 Engine Overhaul Specifications 7

 Nominal Assy Standard Repair Limit Service Limit
Inspection Point Value (Std. Clearance) (Clearance) (Clearance) Remarks
Engine Assembly, continued
Taper of journals
0.02 (0.0008) maximum 0.03 (0.0012)
and crank pins
Fillet radius of
7.0 0/--0.2
journals and 7 (0.28)
(0.276 0/--0.008)
crank pins
Hardness of
journals and Hv > 620
crank pins
Crankshaft
Crankshaft,
Angular error of
mm (in.), ±0° 20 ft.
continued crank pins
Runout 0.4 (0.0016) maximum 0.10 (0.0039) Repair or replace.
Replace thrust plate if
worn down to repair limit.
0.50 +1.18 Use oversize thrust plate if
End play (shaft 0.20--0.40 worn beyond repair limit.
66 (2.60) (0.0197
thrust width) (0.0079--0.0157) +0.25 (+0.0098)
+0.0465)
+0.50 (+0.0197)
+0.75 (+0.0295)
Thickness of
center:
3.467--3.480 3.425
Standard 3.5 (0.138)
(0.13650--0.13701) (0.13484)
3.592--3.605 3.550
Main --0.25 (--0.0098) 3.625 (0.14272) Replace
p bearings
g if worn
(0.14142--0.14193) (0.13976)
bearings
bearings, d
down to
t service
i limit.
li it
mm (in.) 3.717--3.730 3.675
--0.50 (--0.0197) 3.750 (0.14764) Regrind crank pins and
(0.14634--0.14685) (0.14468)
use undersize bearings if
3.842--3.855 3.800 worn beyond service limit.
--0.75 (--0.0295) 3.875 (0.15256)
(0.15126--0.15177) (0.14961)
3.967--3.980 3.925
--1.00 (--0.0394) 4.000 (0.15748)
(0.15618--0.15669) (0.15453)
Warpage of
gasketed 0.1 (0.004) maximum 0.2 (0.0079) Regrind slightly.
Crankcase, surface
mm (in.)
(in )
Main bearing 147.000--147.025 147.035
147 (5.79)
bore diameter (5.78739--2.78837) (5.78877)
Lubrication System
Oil pump
0.087--0.316
gear-to-idler 0.3 (0.012)
(0.0034--0.0124)
gear backlash
Drive and driven 0.10--0.20
0.20 (0.0079) 0.4 (0.016)
gear backlash (0.0039--0.0079)
Radical
0.100--0.196 Tip clearance
Oil pump, clearance of 60 (2.36)
(0.00394--0.00772) 0.35 (0.0138)
mm (in.) gear in case
End clearance 0.050--0.114
34 (1.34) 0.25 (0.0098)
of gears in case (0.00197--0.0049)
24.947--24.960 24.900
Shaft diameter
(0.98216--0.98268) (0.98031)
25 (0.98)
(0 98)
Bushing inside 25.000--25.021 25.100
diameter (0.98425--0.98508) (0.98819)
Opening
pressure, 1.37 ±0.10 (199 ±14)
MPa (psi)
Safety valve Safety valve
spring length
under test 67.3/39.2 (2.65/86.4)
force/test force,
mm/kgf (in./lbf.)
Pump idler gear-to-crankshaft 0.11--0.38
gear backlash, mm (in.) (0.0043--0.0150)
Relief valve opening pressure,
0.46 (66.86)
MPa (psi)

8 Section 2 Engine Overhaul Specifications TP-6261 6/04

 Nominal Assy Standard Repair Limit Service Limit
Inspection Point Value (Std. Clearance) (Clearance) (Clearance) Remarks
Lubrication System, continued
Temperature at
which valve 80--84 (176--183)
Oil starts opening
thermostat, Temperature at
°C (°F) which valve lift is
95 (203)
more than
11 mm (0.43 in.)
Lamp lighting
and valve
Bypass 1 mm (0.04 in.) shim
opening
alarm, 0.15 +0.03/0 (21 +4/0) changes, 0.007 MPa
pressure
MPa (psi) (1 psi).
(differential
pressure)
Oil jet nozzle, Opening
0.26--0.32 (38.4--45)
MPa (psi) pressure
Cooling System
79.988--80.018 80.025
80 (3.15)
Bearing bore (3.14913--3.15031) (3.15058)
inside diameter 89.987--90.022 90.025
90 (3.54)
(3.54279--3.54417) (3.54428)
79.985--80.000
80 (3.15)
Bear outside (3.14902--3.14961)
diameter 89.985--90.000
90 (3.54)
(3.54272--3.54331)
Water pump
pump,
mm (in.) Bearing inside 39.988--40.000
diameter (1.57433--1.57480)
Diameter of 40 (1.57)
shaft on which 40.002--40.013 39.995
bearing inner (1.57488--1.57531) (1.57492)
race is fitted
Vane front face
clearance in 0.72 (0.028) 0.5--1.3 (0.020--0.051)
pump case
Temperature at
which valve 69--73 (156.2--163.4)
starts opening
Thermostat, Temperature at Check at atmospheric
°C (°F) which valve lift is pressure.
more than 11 85 (185)
mm (0.43 in.),
minimum
Inside diameter 99.987--100.022
of bracket bore 100 (3.94)
(3.93649--3.93787)
in which bearing
outer races are 109.987--110.022
110 (4.33)
fitted (4.33019--4.33157)
99.985--100.000
100 (3.94)
Bearing outside (3.93642--3.93701)
diameter 109.985--110.000
Fan drive, 110 (4.33)
(4.33012--4.33071)
mm (in.)
(in )
44.988--45.000
45 (1.77)
Bearing inside (1.77118--1.77165)
diameter 49.985--50.000
50 (1.97)
(1.96791--1.96850)
Diameter of 45.002--45.013
45 (1.77)
shaft on which (1.77173--1.77216)
bearing inner 50.002--50.013
50 (1.97)
races are fitted (1.96858--1.96901)
Measure deflection by
pushing belt midway
Tension of water pump and between pulleys.
10--15 (0.39--0.59)
alternator drive belt, mm (in.)

TP-6261 6/04 Section 2 Engine Overhaul Specifications 9

 Nominal Assy Standard Repair Limit Service Limit
Inspection Point Value (Std. Clearance) (Clearance) (Clearance) Remarks
Fuel System
Valve opening
Fuel injection
pressure, 34.3 (4977)
nozzle
MPa (psi)
Check spray performance
with a hand tester [at fuel
oil temperature 20°C
Fuel injection
Spray angle 160° (68°F)]. Replace the
nozzle
nozzle tip if the spray
pattern is still bad after
washing in clean fuel oil.
Inside diameter
of case bore in
which drive shaft 51.988--52.018
side bearing (2.04677--2.04795)
outer race is 52 (2.05)
fitted
Drive shaft side
51.987--52.000
bearing outside
(2.04673--2.04724)
diameter
Drive shaft side
24.990--25.000
bearing inside
(0.98386--0.98425)
diameter
Outside 25 (0.98)
diameter of drive
25.002--25.011
shaft on which
(0.98433--0.98468)
Fuel injection bearing inner
drive, race is fitted
mm (in.) Inside diameter
in which idler
46.989--47.014
shaft side
(1.84996--1.85094)
bearing outer
race is fitted 47 (1.85)
Drive shaft side
46.988--47.000
bearing outside
(1.84992--1.85039)
diameter
Drive shaft side
19.990--20.000
bearing inside
(0.78701--0.78740)
diameter
Outside 20 (0.79)
diameter of idler
20.002--20.011
shaft on which
(0.78748--0.78783)
bearing inner
race is fitted
Electrical System
Pinion shaft
diameter and
bushing inside 18.90--18.94
19 (0.75)
diameter on (0.744--0.746)
front side,
mm (in.)
Pinion shaft
30.002--30.011
diameter on rear 30 (1.18)
(1.18118--1.18153)
side, mm (in.)
Armature shaft
diameter on 25.003--25.011
Starter 25 (0.98)
front side, (0.98433--0.98468)
mm (in.)
Armature shaft
13.941--13.968
diameter on rear 14 (0.55)
(0.549--0.550)
side, mm (in.)
Commutator
diameter, 43 (1.69) 42 (1.65)
mm (in.)
Runout of
0.100
commutator, 0.06 (0.0024) maximum
(0.00394)
mm (in.)

10 Section 2 Engine Overhaul Specifications TP-6261 6/04

 Nominal Assy Standard Repair Limit Service Limit
Inspection Point Value (Std. Clearance) (Clearance) (Clearance) Remarks
Electrical System, continued
Mica depth in
commutator, 0.7--0.9 (0.028--0.035) 0.21 (0.008)
mm (in.)
Height of
brushes, 21--22 (0.827--0.867) 13 (0.512)
Starter mm (in.)
Tension of brush
springs
44.13 (9.9) 39.23--49 (8.8--11) 39.23 (8.8)
(installed),
N (lbf.)
Front 19.000--19.033
19.000 19.033
19 (0.75)
(0 75)
Bearings, Pinion (0.74815--0.74933)
0 25 (0.0098)
0.25 (0 0098)
mm (in.) 14.000--14.027
Rear 14 (0.55)
(0.55118--0.55224)
Thrust gap, Armature 0.3--0.7 (0.012--0.028)
mm (in.) Pinion shaft 0.2--0.8 (0.079--0.031)
End play of
armature
0 2 0 6 (0.079--0.0236)
0.2--0.6 (0 079 0 0236)
End play of
pinion shaft
Diameter of 40.8--41.02
41 (1.61) 40.6 (1.598)
spring, mm (in.) (1.606--1.6150)
Alternator, Height of
mm (in.) brushes, 18.5 (0.728) 11.5 (0.453) Up to wear limit line.
mm (in.)
Tension of brush
3.7 (13.3) 3.1--4.3 (11.2--15.4) 1.96 (7)
springs, N (lbf.)
Tension of Push belt at midway
alternator drive between pulleys (force:
belt, N (lbt.) approx. 98--147 (22--33).
Distributor Valve height 21.5 ±0.1 20 (0.788)
valve, Shaft clearance 0.050--0.091
mm (in.) 0.300 (0.0112)
in bushing (0.002--0.004)
Valve clearance 0.16--0.52
15 (0.591) 0.100 (0.004)
Starter valve, in valve guide (0.0006--0.0204)
mm (in.) Valve spring free
36 (1.418) 34 (1.3396)
length

2.2 Tightening Torques

2.2.1 Specific Bolt and Nut Torque Values
Thread Dia.
x Pitch Torque,
Description (M-Thread) Nm (ft. lb.) Remarks
Cylinder head 22 x 2.5 539 (398) Apply engine oil to the threads of the nuts and bolts.
Two-step tightening method.
To tighten cylinder head bolts according to the angle method,
tighten to 294 Nm (217 ft. lb.), then turn 60° more.
Cylinder head nozzle glands (studs) 14 x 2.0 69--78(51--58)
Rocker case 12 x 1.25 108 (80)
Rocker shaft 14 x 2 147 (108)
Rocker arm locknuts 12 x 1.25 64 (47)
Bridge locknuts 10 x 1.25 55 (41)
Camshaft gear 12 x 1.25 127 (94)
Camshaft thrust plate 12 x 1.25 59(44)
Main bearing cap 22 x 1.5 490 (362) Apply engine oil to the threads of the nuts and bolts.
Tighten main bearing caps and side bolts as follows:
a. Tighten the cap bolts to the specified torque.
b. Tighten the side bolts on the right side of the engine.
c. Tighten the side bolts on the left side of the engine.

TP-6261 6/04 Section 2 Engine Overhaul Specifications 11

 Thread Dia.
x Pitch Torque,
Description (M-Thread) Nm (ft. lb.) Remarks
Hanger 12 x 1.25 108 (80)
Piston cooling nozzle 12 x 1.75 34 (25) Use a torque wrench to tighten check valves. Tightening
without the use of a torque wrench can result in excessive
tightening force causing valve malfunctions and lead to
seizing of pistons due to insufficient lubricating oil during
engine operation.
Timing gear case 16 x 1.5 216 (159)
Rear plate 12 x 1.25 108 (80)
Oil pan 12 x 1.25 59 (44)
Mounting bracket, front 12 x 1.25 108 (80)
Mounting bracket, rear 16 x 1.5 216 (159)
Connecting rod bearing cap 22 x 1.5 539 (398) Apply engine oil to the threads of the nuts and bolts.
Two-step tightening method.
To tighten connecting rod caps according to the angle
method, tighten to 245 Nm (181 ft. lb.), then turn 60° more.
Flywheel 22 x 1.5 539 (398) Apply engine oil to the threads of the nuts and bolts.
Torsional vibration dampener 22 x 1.5 490 (361)
Rear idler shaft 12 x 1.25 108 (80)
Rear idler shaft thrust plate 10 x 1.25 29 (22)
Exhaust manifold V-clamp nuts 6 x 1.0 9 (7)
Fuel injection pump/accessory drive case 12 x 1.25 108 (80)
Fuel injection pump gears (nuts) 30 x 1.5 392 (289)
Oil pump 12 x 1.25 108 (80) Apply LOCTITEr 262 or equivalent to screw threads. *
Oil pump idler gear (nut) 12 x 1.25 69 (51)
Water pump 12 x 1.25 59 (43)
Water pump pulley (nut) 24 x 1.5 245 (181) For alternator drive.
Fan drive camshaft gear (nut) 12 x 1.25 108 (80)
Fan drive shaft gear (nut) 30 x 1.5 392 (289)
Fan plate 12 x 1.25 108 (80)
Fuel injection pump bracket 12 x 1.25 108 (80)
Fuel injection pump 12 x 1.25 108 (80)
Fuel injection pump laminated plate 12 x 1.25 83--93 (61--69)
Fuel injection pump flywheel (nut) 24 x 1.5 235--255 (174--188)
Injection pump coupling shaft 14 x 1.5 167--177 (123--130)
Plunger assembly 12 x 1.25 78--83 (58--61)
Delivery valve holder 30 x 1.5 235--255 (174--188)
Fuel injection nozzle gland (nut) 14 x 1.5 98 (72)
Fuel injection nozzle tip retaining nut 28 x 1.5 177--196 (130--145)
Nozzle holder cap nuts 14 x 1.5 69--78 (51--58)
Fuel injection nozzle holder set screw nut 14 x 1.5 39--49 (29--36)
Fuel injection nozzle intake connector 16 x 1.5 64--74 (47--54)
Injection pipes 18 x 1.5 49--69 (36--51)
Fuel rack control lever 18 x 1.25 25 (18) Two-step tightening method.
Governor drive case 12 x 1.25 108 (80)
Starter 12 x 1.25 59 (43)
* LOCTITEr is a registered trademark of Henkel Loctite.

12 Section 2 Engine Overhaul Specifications TP-6261 6/04

2.2.2 Standard Bolt and Nut Torque Values

Strength Classification
Thread Dia. x Pitch, mm (in.) Width Across Flats, mm (in.) 7T, Nm (ft. lb.) 10.9, Nm (ft. lb.)
ead

8 x 1.25 (0.31 x 0.049) 12 (0.47) 17 (12) 30 (22)

threa

10 x 1.25 (0.39 x 0.049) 14 (0.55) 33 (25) 60 (44)

ew th

12 x 1.25 (0.47 x 0.049) 17 (0.67) 60 (44) 108 (80)

scre

14 x 1.5 (0.55 x 0.059) 22 (0.87) 97 (72) 176 (129)

M tric s

16 x 1.5 (0.63 x 0.059) 24 (0.94) 145 (107) 262 (193)

Metr

18 x 1.5 (0.71 x 0.059) 27 (1.06) 210 (155) 378 (278)

20 x 1.5 (0.79 x 0.059) 30 (1.18) 291 (215) 524 (386)
22 x 1.5 (0.87 x 0.059) 32 (1.26) 385 (284) 694 (512)
24 x 1.5 (0.94 x 0.059) 36 (1.42) 487 (359) 878 (647)
27 x 3 (1.06 x 0.12) 738 (544) 1328 (980)
hread
w thr

10 x 1.5 (0.39 x 0.059) 14 (0.55) 32 (24) 58 (43)

crew

12 x 1.75 (0.47 x 0.069) 17 (0.67) 57 (42) 102 (75)

e scr

14 x 2 (0.55 x 0.079) 22 (0.87) 93 (69) 167 (123)

urse

16 x 2 (0.63 x 0.079) 24 (0.94) 139 (103) 251 (185)

cou

18 x 2.5 (0.71 x 0.098) 27 (1.06) 194 (143) 350 (258)

Metric c

20 x 2.5 (0.79 x 0.098) 30 (1.18) 272 (200) 489 (361)

Metr

22 x 2.5 (0.87 x 0.098) 32 (1.26) 363 (268) 653 (482)

24 x 3 (0.94 x 0.12) 36 (1.42) 468 (345) 843 (622)
27 x 3 (1.06 x 0.12) 41 (1.61) 686 (506) 1236 (911)
Notes: Table lists the tightening torque for the standard nuts and bolts. Numerical values are for use when using spring washers. Table
shows the standard values with a maximum tolerance value of ±10%. Except for special tables, use this table for tightening torques.
Do not apply oil to threads (dry state).

2.2.3 Standard Eyebolt Torque Values 2.2.4 Standard Union Nut Torque
Values
Strength
Thread Dia. (Dry) Width Across Classification, 4T, Nm
(ft. lb.) Nominal Width Across
x Pitch, mm (in.) Flats, mm (in.)
Diameter Cap Nut Flats, mm (in.) Nm (ft. lb.)
M8 x 1.25 (0.05) 12 (0.47) 8 ±1 (58 ±0.72)
63 M14 x 1.5 49 (1.93) 39 (29)
M10 x 1.25 (0.05) 14 (0.55) 15 ±2 (10.8 ±1.45)
80 M16 x 1.5 22 (0.87) 49 (36)
M12 x 1.25 (0.05) 17 (0.67) 25 ±3 (18.1 ±2.17)
100 M20 x 1.5 27 (1.06) 78 (58)
M14 x 1.5 (0.06) 22 (0.87) 34 ±4 (25.3 ±2.89)
120 M22 x 1.5 30 (1.18) 98 (72)
M16 x 1.5 (0.06) 24 (0.94) 44 ±5 (32.5 ±3.62)
150 M27 x 1.5 32 (1.26) 157( 116)
M18 x 1.5 (0.06) 27 (1.06) 74 ±6 (54.2 ±3.62)
180 M30 x 1.5 36 (1.42) 196 (145)
M20 x 1.5 (0.06) 30 (1.18) 98 ±10 (72.3 ±7.23)
200 M30 x 1.5 36 (1.42) 196 (145)
M24 x 1.5 (0.06) 36 (1.42) 147 ±16 (108.5 ±10.8)
220 M33 x 1.5 41 (1.61) 245 (181)
M27 x 1.5 (0.06) 41 (54.9) 226 ±20 (166.3 ±14.5)
254 M36 x 1.5 41 (1.61) 294 (217)

2.2.5 High-Pressure Fuel Injection Pipe

Torque Values

Cap Nut Nm (ft. lb.)

M12 x 1.5 39 ±5 (29 ±3.6)
M14 x 1.5 49 ±5 (29 ±3.6)
M18 x 1.5 59 ±10 (29 ±7.2)

TP-6261 6/04 Section 2 Engine Overhaul Specifications 13

2.3 Sealants and Lubricants
Group Application Point Application Point Sealant or Lubricant How to Use
Cylinder head sealing caps Rubber sealant Coat holes in crankcase.
Water outlet connectors (rocker case) Grease Grease O-ring joint.
Cylinder liners Engine oil Grease O-ring joint.
Front cover, gear case, oil pan, and crankcase Herdite Coat joint surfaces only.
Rear plate, gear case, oil pan, and crankcase Herdite Coat three-coat surfaces
only.
Crankcase taper plugs Thread-locking compound Apply to threads.
Engine Assembly Crankcase sealing cap Synthetic rubber sealant,
non-hardening
Oil pan and crankcase Herdite Coat joint surfaces only on
both sides of gasket.
Oil seal Engine oil Coat lip of each oil seal.
Rear plate and timing gear case Silicone liquid gasket Coat both sides of gasket.
Drive case Silicone liquid gasket Apply to flange surface.
Cylinder head gasket Silicone liquid gasket Apply to areas around
tappet chambers.
Oil pump Cover and case Synthetic rubber sealant, Coat both sides of gasket.
Lubrication system
non-hardening
Water pump Oil seal, unit seal Engine oil Coat lip of inner seal.
Cooling system
Fan drive Oil seal Engine oil Coat lip of oil seal.
Air cooler Between the element and Silicone sealant Fill the gap between the
Intake system
the side of plate element and the plate.
Taper plugs and petcocks not precoated with thread Vulcanized tape sealing Wrap threads with two
Others
sealants turns of tape.

14 Section 2 Engine Overhaul Specifications TP-6261 6/04

 Section 3 Special Tools

Part Order Kohler

Identification Part Number Tool Name Use Illustration

30091-08800 GM37286 Valve lapper Valve lapping

32191-03100 * Torque wrench

32591-02500 GM37291 Idler bushing puller Idler bushing removal/installation

33391-02100 * Compression gauge Compression pressure measurement

33591-04300 GM37307 Valve guide remover Valve guide removal

33591-04500 GM37308 Valve spring pusher Valve spring removal/installation

37191-01500 GM37322 Valve guide and seal installer Valve guide and valve stem installation

37191-03200 * Piston ring tool Piston ring removal/installation

37191-07100 * Piston installer Piston installation

Connecting rod bushing

37591-01010 GM37327 Connecting rod bushing installer
removal/installation

37591-02200 GM37328 Compression gauge adapter Compression pressure measurement

37591-02400 * Eye nut Cylinder head suspension

37591-02600 GM37329 Rocker bushing tool Rocker bushing installation/removal

37591-03100 GM37330 Water pump pliers For water pump cover snap ring

37591-03200 GM37331 Impeller remover Water pump impeller removal

37591-03500 * Socket

37591-04100 GM37332 Cylinder liner remover Cylinder liner removal

* Procure from your locat automotive or tool supplier.

TP-6261 6/04 Section 3 Special Tools 15

Part Order Kohler
Identification Part Number Tool Name Use Illustration

37591-05010 GM37333 Front seal installer assembly Front oil seal installation

37591-06010 GM37334 Rear seal installer assembly Rear oil seal installation

37591-06200 GM37336 Liner pusher Liner retainment

37591-06300 * Bolt

37591-06400 GM37337 Valve seat cutter shaft Valve seat contact surface adjustment

37591-06430 GM37338 Valve seat cutter

For use in angle-method tightening of

37598-08900 GM37339 Head bolt plate
head bolts

37598-09100 GM37340 Head bolt spacer

37598-09201 GM37341 Projection plate Crankcase ridge depth measurement

Flywheel and coupling clearance

37951-06100 GM37345 Injection coupling gauge
adjustment

Nozzle opening pressure

41091-01500 GM37346 Nozzle tester
measurement

For removal/installation of fan drive

58309-73100 * Socket
shaft gear, pulley cap nut

MM321420 * Piston remover Piston removal

* Procure from your locat automotive or tool supplier.

16 Section 3 Special Tools TP-6261 6/04

 Section 4 Overhaul Instructions

4.1 Overhaul Timing 4.2 Compression Pressure

Generally, when to overhaul the engine is to be Measure compression pressure on all cylinders. It is not
determined by taking into consideration a drop in a good practice to measure the compression pressure
compression pressure as well as an increase in on only two or three cylinders. Adjust the compression
lubricating oil consumption and excessive blow-by on the remaining cylinders.
gases.
Compression pressure varies with changes in engine
Low power or loss of power, increase in fuel rpm’s. Maintain engine rpm when measuring
consumption, drop in lubricating oil pressure, hard compression pressure.
starting, and excessive abnormal noise are also engine
problems. These problems, however, are not always 1. Remove injection nozzle from the cylinder where
the result of low compression pressure and give no valid the compression pressure is to be measured.
reason for overhauling the engine.
2. Attach adapter to cylinder and connect pressure
In most cases, overhaul the engine when the engine’s gauge to the adapter. See Figure 4-1.
compression pressure is low. Other factors indicating
3. Crank engine with starter motor, with fuel supply
an engine overhaul is required are as follows: shut off, and read compression gauge indication
while engine is running at the specified speed.
D Increased fuel consumption
D Hard starting 4. If the compression pressure is lower than the repair
D Increased lubricating oil consumption limit, overhaul the engine.
D Increased blow-by gas volume through breather due
to abrasion at the cylinder liner and piston ring Note: Measure the compression pressure with the
engine running at no load.
D Excessive blow-by due to poor seating of worn inlet
and exhaust valves
D Reduced power 2

D Increased noise from engine parts 1

D Abnormal color of exhaust gas from engine after
warmup

Any one or a combination of these symptoms may

indicate that engine overhaul is required; they may also
indicate other problems of nonrelated causes. Of the
items listed above, some directly relate to engine
1. Adapter (37591-02200)
deterioration while others do not. The first two items 2. Compression gauge (33391-02100)
above are more likely to be affected substantially by:
Figure 4-1 Checking Compression Pressure
D Injection volume of the fuel injection pump
D Fuel injection timing Assembly Repair
D Abrasion at the plunger Item Standard Limit
D Fitting of the injection nozzle Compression pressure, 1.8 (263.2) 1.3 (184.8)
MPa (psi) minimum maximum
D Condition of electrical equipment: battery, starter
motor, or engine alternator
Measure compression pressure at regular intervals to
Increased blow-by gas requires special consideration obtain correct data. Compression pressure will be
because decreased pressure due to abrasion at the slightly higher in a new or overhauled engine due to
cylinder liner and piston ring is one of the most obvious breaking in of piston rings, valve seats, etc. After the
signs that the engine requires overhauling. The most engine parts are broken in, the compression pressure
effective way to make a determination is testing the will drop slightly.
compression pressure; then other factors should be
considered.

TP-6261 6/04 Section 4 Overhaul Instructions 17

 Notes

18 Section 4 Overhaul Instructions TP-6261 6/04

 Section 5 Component Adjustment and Testing

5.1 Adjustments Note: If valve clearance between the bridge

and valve rotator is less than specified,
the valve cotters may come off. Maintain
5.1.1 Valve Clearance specified clearance (or more).
Inspect and adjust valve clearance when engine is cold.
See Figure 5-1. Assembly
Item Standard, mm (in.)
Note: The bridge-to-valve rotator clearance B should Intake valves 0.6 (0.024)
Valve clearance
be more than 1.5 min (0.059 in.) after adjusting Exhaust valves 0.8 (0.031)
the front and rear valve heights. If clearance is
too small, grind the bridge to obtain the specified Figure 5-1 Valve Clearance Values
clearance. See Figure 5-2.

1. Inspecting valve clearance.

a. Inspect the valve clearance in the firing order by

turning the crankshaft (120°) in the direction of
normal rotation to bring the piston to top dead
center of compression stroke.

Firing order: 1--5--3--6--2--4

Figure 5-2 Measuring Valve Clearance
Note: Set the turning gear at the run time
condition before you start the engine.

b. The top dead center on the compression stroke

of the piston is identified by the timing mark
(provided on the torsional vibration dampener)
aligned with the pointer. With the piston so
located, the intake and exhaust valve rocker
arms are not pushed up by their push rods. See
Figure 5-3.

c. Insert a feeler gauge in between the rocker arm

and bridge cap and inspect valve clearance.
Figure 5-3 Timing Mark (TDC)
2. Adjusting front and rear valve heights by the valve
bridge. See Figure 5-4.

a. Before adjusting the valve clearance, adjust the Rotate 10°

front and rear valve heights using the bridge
(bring bridge into contact with the valves). If the
valve seats are worn, valve heights will differ
causing variations between stem tops and
bridges.

b. To adjust valve height, loosen the locknut and

back off the adjusting screw. Figure 5-4 Adjusting Valve Height

c. Holding the rocker arm with your fingers, slowly

tighten the adjusting screw until it touches the
valve stem top. After looking into the hole of the
bridge to check that the screw is in contact with
the stem top, turn the screw approximately 10°
of one turn and tighten the locknut.

TP-6261 6/04 Section 5 Component Adjustment and Testing 19

 3. Adjusting valve clearance. See Figure 5-5.

a. Insert a feeler gauge between the rocker arm

and bridge cap and adjust the clearance by
turning the screw in either direction to the
extent that the gauge is gripped slightly
between the rocker arm and bridge cap.

b. After adjusting the clearance, tighten the

locknut. Inspect the clearance again and make
sure that it is correct.

Turning Gear Procedure Figure 5-5 Adjusting Valve Clearance

1. Loosen bolts. Remove the plate from the slot of the

RUN position CRANK position
shaft. Push the shaft until it reaches its limit. See 1
Figure 5-6.
2 4
2. Make the shaft turn by rotating it with the socket
3
and ratchet handle. 5

3. After completing the turn, pull out the shaft. Insert

the plate into the slot of the shaft. Tighten the bolts. 1
Check that the plate is inserted into the slot of the
shaft.
1. Bolt 3. Shaft 5. Ratchet handle
2. Plate 4. Socket
5.1.2 Fuel System Priming
Figure 5-6 Turning Gear Positions
Prime fuel filters and then prime fuel injection pumps.
1
1. Fuel filter.

a. Loosen the vent plug by turning approximately

1.5 turns. See Figure 5-7.

b. Unlock the priming pump handle by turning

counterclockwise. Operate the priming pump
by moving the handle up and down. See
Figure 5-8.

c. Tighten the air vent plug when fuel flows from 1. Vent plug
the vent hole without bubbles.
Figure 5-7 Fuel Vent Plugs

1. Priming pump handle

Figure 5-8 Priming Pump

20 Section 5 Component Adjustment and Testing TP-6261 6/04

 2. Fuel injection pumps. See Figure 5-9. c. Move the no. 1 cylinder intake and exhaust
valve rocker arms up and down to make sure
a. Loosen air vent plug by turning approximately they are not being pushed up by their push
two turns. rods.

b. Operate the priming pump handle. Note: Do not confuse top dead center on the
compression stroke for no. 1 cylinder
c. Tighten the air vent petcock when fuel flows with that for the no. 6 cylinder.
from vent hole without bubbles. Lock priming
pump by turning the handle clockwise while 3. Inspecting fuel injection timing.
pushing it down before tightening last vent plug.
a. Turn the crankshaft once approximately 60° in
Note: If the vent plugs are tightened before the the reverse direction. Turn it a little at a time in
priming pump handle is locked, fuel the normal direction to align the timing mark on
pressure acts on the feed pump, making the pump drive coupling with the pointer on the
it difficult to lock the handle. Use a cloth pump case. See Figure 5-10.
to absorb fuel spilled from vent hole.
b. Read the degrees of an angle (injection timing)
3. Tightening priming pump cap. on the scale on the vibration dampener,
indicated by pointer. Minus (--) mark on the
a. Tighten the priming pump gap by hand. Stop scale and information plate means before top
turning immediately after the tightening force dead center.
suddenly increases.

b. After step a, further turn the priming pump cap

by 120°--150° using a wrench. 1

Tighten the priming pump cap according to the specified

angle (120°--150°). If the priming pump cap is not
tightened firmly, engine operations can result in the wear
of internal threads. This can cause the priming pump 2
cap to eject and fuel to flow out. If the priming pump cap
1. Air vent plug
is tightened with excessive force (240° or more), the 2. Priming pump handle
head section of priming pump can become damaged.
Figure 5-9 Fuel Injection Pump

5.1.3 Fuel Injection Timing

1
1. Fuel injection timing and indication. The injection
timing is stamped on the information plate attached
to the no. 1 rocker cover. Verify timing by referring
to this information plate. The injection timing for 2
each engine model varies according to its output,
speed, and specifications.

2. Confirming the position of the no. 1 piston’s top 1. Pointer

dead center on the compression stroke. 2. Timing mark

a. Use the ratchet handle to turn in the normal Figure 5-10 Timing Mark and Pointer Alignment
direction.

b. Stop cranking the engine when the timing mark

(1.6) on the torsional vibration dampener is
aligned with the pointer.

TP-6261 6/04 Section 5 Component Adjustment and Testing 21

 4. Adjusting fuel injection timing. 5.2 Bench Testing
a. Make sure the timing mark for no. 1 cylinder on Performance test an overhauled engine on a
the dampener is aligned with the pointer. dynamometer. This test is also for breaking in the major
running parts of the engine. To test the engine, follow
b. Loosen two coupling (laminated plate) bolts
the procedures described in Section 5.2.1.
and displace the injection pump to align pointer
on pump case with timing mark on the flywheel.
Tighten one bolt to the specified torque and, 5.2.1 Starting Up
after turning the crankshaft, similarly tighten
the other. See Figure 5-11. 1. Inspect the levels in the radiator, oil pan, and fuel
tank. Prime the fuel and cooling systems to bleed
c. Again inspect the timing by cranking the engine air out.
for verification.
2. Crank the engine with the starter for approximately
15 seconds to permit lubricating oil to circulate
1 through the engine. For this cranking, do not
2 supply fuel to the engine.

3. Place the generator set master switch in the Run

position.

103--113 Nm 4. After the engine starts, let it run without load.

(76.0--83.3 ft. lb.)
3
5.2.2 Inspection After Starting Up

1. Pointer 3. Coupling bolts

After starting the engine, check the following points. If
2. Timing mark you find anything wrong, immediately stop the engine
and investigate the cause.
Figure 5-11 Adjusting Fuel Injection Timing
1. Lubricating oil pressure should be 490--637 kPa
5.1.4 Idling Speed and Maximum Speed (71--92.4 psi) at rated speed or over 196--294 kPa
Setting (28--42 psi) at idling speed.

Refer to TP-6330, Woodward ProAct II governor 2. Coolant temperature should be 70--90°C (158°F--
Installation and Operation Manual, 04121H, available 194°F).
for your generator set.
3. Lubricating oil temperature should be in the range
of 70°C--90°C (158°F--194°’F) when measured in
5.1.5 Water Pump and Alternator Drive the oil pan.
Belt
4. Leakage of oil, coolant, fuel, and oil leakage from
Apply thumb pressure to the belt midway between the turbocharger lubricating oil pipe connections.
pulleys to inspect belt tension. If the tension is incorrect,
5. Knocking should die away as coolant temperature
adjust using the turnbuckle. See Figure 5-12.
rises. No other defects should be found.
Note: Be sure drive belt tension is sufficiently tight.
6. Check exhaust color and abnormal odors.

Item Assembly Standard

Belt tension, mm (in.) 10--15 (0.39--0.59)

Figure 5-12 Belt Tension

22 Section 5 Component Adjustment and Testing TP-6261 6/04

5.2.3 Bench Testing (Dynamometer) 5.2.4 Inspection and Adjustments After
Conditions Bench Testing
Figure 5-13 summarizes bench testing conditions. 1. Adjusting valve clearance.

2. Adjusting injection timing.

Step Load Time, min.
1 No load 5 3. Retightening of exhaust manifold mounting bolts.
2 25% 10
3 50% 10
4 75% 30
5 100% 20
Varies according to specifications.

Figure 5-13 Bench Testing Conditions

TP-6261 6/04 Section 5 Component Adjustment and Testing 23

 Notes

24 Section 5 Component Adjustment and Testing TP-6261 6/04

 Section 6 Major Engine Component Removal and Installation

This section explains the procedures for removal and

installation of major engine components; the preliminary 1
process to go through for overhauling the engine.

WARNING
2
3
4

Hot engine oil.

Can cause severe injury or death.
Avoid skin contact with hot oil. Do not
start or operate the generator set with
the engine oil filler cap removed, as 1. Fan 3. Friction rubber
hot oil can spray out. Ensure that the 2. Spacer 4. Plate
lubrication system is not under Figure 6-1 Removing Fan
pressure when servicing. Do not
work on the generator set until it
cools.
1 2

6.1 Preparation
4
1. Shut off the fuel supply and disconnect the starting
system from the engine.

2. Loosen the drain petcocks on the left rear side of

3
crankcase and drain coolant.

3. Loosen the oil pan drain plug and drain engine oil.
The oil capacity is 100 L (26.4 gal.).
1. Exhaust pipe 3. Drain pipe
2. Turbocharger 4. Oil pipe
6.2 Major Engine Component
Figure 6-2 Removing Turbocharger
Removal
1. Remove the fan by unscrewing fan mounting bolts
and remove fan plate, friction rubber, and spacer. 1
See Figure 6-1.

2. Remove the turbocharger. See Figure 6-2.

a. Disconnect the turbocharger lubricating oil pipe

and drain pipe.

b. Remove turbocharger complete with exhaust

pipe. 2
3
3. Remove air cooler. See Figure 6-3.
1. Air cooler 3. Water pipes
a. Disconnect water pipes. 2. Air cooler cover

b. Remove the air cooler complete with air cooler Figure 6-3 Removing Air Cooler
cover.

TP-6261 6/04 Section 6 Major Engine Component Removal and Installation 25

 4. Remove the thermostat case complete with water
bypass pipe. See Figure 6-4. 1 2
3
5. Remove the exhaust manifolds. See Figure 6-5. 4

a. Remove insulator. 2

b. Remove couplings and joints.

c. Unscrew bolts securing manifolds and remove

the manifolds complete with gaskets. 2

d. Remove manifold complete with gasket. 5

Note: When installing the manifolds, place each 1. Insulator 3. Couplings 5. Gasket
gasket with its side marked as MANIFOLD 2. Manifold 4. Joints
facing the manifold. Figure 6-5 Removing Exhaust Manifolds
6. Remove the water pump. See Figure 6-6.
1
a. Remove belt cover.

b. Loosen tension pulley and remove water pump

drive belt.

c. Remove water pump by unscrewing mounting

bolts.
3
7. Remove the tension pulley by removing the tension
pulley mounting bolts. See Figure 6-7.
2

1. Belt cover 2. Water pump 3. Pump drive belt

Figure 6-6 Removing Water Pump

1
2
1

1. Tension pulley
1. Thermostat case 2. Bypass pipe

Figure 6-4 Removing Thermostat Figure 6-7 Removing Belt Tensioner

26 Section 6 Major Engine Component Removal and Installation TP-6261 6/04

 8. Remove the breather and oil filler. See Figure 6-8
and Figure 6-9. 1
2
a. Remove breather by unscrewing the mounting
bolts.

b. Remove oil filler by unscrewing mounting bolts.

9. Remove the fuel filters. See Figure 6-10.

a. Disconnect fuel pipes.

3 2
b. Remove fuel filter and filter bracket.

10. Remove the exhaust manifold. 1. Filter bracket 3. Fuel filter

2. Fuel pipe
a. Disconnect harness for the oil filter sensor.
Figure 6-9 Removing Oil Filter
b. Remove oil filter element and bypass oil filter
element.

c. Unscrew mounting bolts and remove oil filter

bracket. 1

Note: Before removing oil filter elements, punch or 4

drill a hole in the bottom of each element to
drain oil.

11. Disconnect the fuel pipes (6 pcs) and leakoff pipes

(2 pcs). See Figure 6-11.
2
Note: Be sure to fit rubber caps to the openings of
3
injection pump and nozzle intake
connectors to prevent dust from getting 1. Filter bracket 3. Oil filter element
inside the fuel system. 2. Bypass oil filter element 4. Harness

Figure 6-10 Removing Fuel Filter

1
2 1

1. Breather 2. Oil filler

Figure 6-8 Removing Oil Fill and Breather

1. Leakoff pipes 2. Fuel pipes

Figure 6-11 Removing Fuel Injector Pump Pipes

TP-6261 6/04 Section 6 Major Engine Component Removal and Installation 27

12. Remove the fuel injection pump. See Figure 6-12. 1
2
a. Disconnect lube oil pipe.

b. Remove coupling cover.

c. Unscrew nut securing the coupling.

d. Unscrew bolts securing injection pump to the

engine. Remove pump complete with coupling
by prying it toward the front side of the engine 1. Oil cooler 2. Cover
with a bar. The weight is approximately 60 kg
(132 lb.). Figure 6-13 Removing Oil Cooler

e. Remove the bracket by unscrewing mounting

bolts. 1
2
13. Remove the oil cooler complete with cover. See
Figure 6-13.

14. Remove the alternator. See Figure 6-14.

a. Remove belt cover.

4
b. Disconnect the harness, remove the alternator 3
mounting bracket and belt adjusting turnbuckle,
and remove alternator.
1. Alternator mounting bracket 3. Harness
15. Remove the starter by unscrewing mounting bolts 2. Belt cover 4. Turnbuckle
and disconnecting harness. See Figure 6-15.
Figure 6-14 Removing Alternator

1
6
1
2

3
4 1. Starter 2. Harness

5 Figure 6-15 Removing Starter

1. Bolt 4. Lube oil pipe
2. Nut 5. Bracket
3. Coupling cover 6. Injection pump

Figure 6-12 Removing Fuel Injection Pump

28 Section 6 Major Engine Component Removal and Installation TP-6261 6/04

6.3 Major Engine Component
Installation
To install major engine components, use reverse of
removal procedures. After installing, service as follows:

1. Refill the engine with recommended oil up to the

specified level.

2. Refill the cooling system with coolant.

Figure 6-16 Timing Mark
3. Check each pipe connection for oil or coolant
leaks.

4. Prime the fuel system. 1

5. After installing the fuel injection pump, inspect and

adjust the injection timing. See Section 5.1.3, Fuel
Injection Timing.
2

6.3.1 Fuel Injection Pump

1. Turn the crankshaft in normal direction to align the
no. 1.6 timing mark on torsional viscous dampener
1. Pointer
with the pointer on the engine. See Figure 6-16. 2. Flywheel mark

2. Make sure the intake and exhaust valve rocker Figure 6-17 Timing Mark and Pointer Alignment
arms are not being pushed up by their pushrods.

3. Turn the crankshaft in reverse direction about 60°, 1

then slowly turn it in normal direction until the timing
mark on the dampener is aligned with the pointer.

Note: Ascertain in advance the beginning-of-

injection timing punched on the information
plate attached to the no. 1 cylinder rocker
cover.

4. Before installing the injection pump, align mark on

flywheel with pointer on the pump case. See 1. Pump drive-side coupling
Figure 6-17.
Figure 6-18 Pump Drive
5. Install one half of the pump drive side coupling to
the drive shaft, leaving the securing bolts loose.
See Figure 6-18.

6. Place the injection pump assembly on the bracket

3
and temporarily tighten bolts. See Figure 6-19. 1

7. Connect fuel pipe and lube oil pipes to the pump.

8. Temporarily tighten coupling nuts.

1 2

1. Coupling nut
2. Bolt, 167--177 Nm (123--130 ft. lb.)
3. Bolt, 108 Nm (80 ft. lb.)

Figure 6-19 Fuel Injection Pump

TP-6261 6/04 Section 6 Major Engine Component Removal and Installation 29

 9. Using injection coupling gauge (37591--16100), 6.3.2 Governor Link
adjust clearance between flywheel and coupling.
See Figure 6-20. 1. Check that the output shaft of the governor is
positioned on the side marked with 0 (no-injection
a. Insert the side of the gauge marked GO to side).
determine clearance between the flywheel and
coupling and tighten the bolt. 2. Install the governor lever at the angle shown in
Figure 6-21.
b. Make sure the side of the gauge marked NO
GO does not enter the gap. Only the side 3. Install links on the right and left side banks making
marked GO should fit into gap. The clearance sure the installation length is 62 ±0.07 mm (2.44
between flywheel and coupling is 49 ±0.25 mm. ±0.0028 in.). See Figure 6-22.

c. If the inspection in step b. shows that the

clearance is not 49 ±0.25 mm, loosen the bolt
and readjust the clearance.

10. After firmly tightening pump mounting bolt, check

that pointer on the pump case end face is aligned
with line on coupling. Then, tighten two connecting
nuts to the specified torque.

11. Tighten coupling shaft tightening bolt to specified

torque. See Figure 6-19.
Figure 6-21 Governor Lever
Note: Tighten the bolts of the coupling evenly to
specified torque to ensure secure mounting.
If the bolts are tightened with excessive
force or insufficient force, parts damage 1
and/or incorrect injection timing can result.

1. Bolt
2. Injection coupling gauge

Figure 6-20 Adjusting Clearance Coupling 1. Links

Figure 6-22 Checking Link Length

30 Section 6 Major Engine Component Removal and Installation TP-6261 6/04

 4. Install rod while adjusting length of rod to achieve a 6.3.3 Stop Solenoid and Start Rack
distance of 68 ±0.5 mm (2.68 ±0.020 in.) between Limit Solenoid
rack end surface and the pump case end surface.
See Figure 6-23.
Run-Off Solenoid Adjustment
Note: Make sure more than 8 mm (0.31 in.) of
1. Apply battery voltage to solenoid (contracted
threads of the rod and ball joint are engaged
condition). See Figure 6-24.
on both ends.
2. Loosen nuts.
5. Check that the rack stroke is approximately 2 mm
(0.08 in.) when stopper lever is pulled fully to the 3. Rotate rod to adjust clearance between lever and
STOP side. follower to between 0.5--1.0 mm (0.02--0.04 in.).

4. Tighten nuts.

Run-Off Solenoid Inspection

2
1 1. Disconnect battery voltage to solenoid (extended
condition). See Figure 6-24.

2. After adjusting exhaust temperature for the right-

and left side banks, operate the engine with full
load applied.

0.5--1.0 mm
1
1. Stopper lever
2. Rod

Figure 6-23 Stopper Lever 2

1. Lever 4. Rod
2. Follower 5. Solenoid
3. Nut

Figure 6-24 Run-Off Solenoid

TP-6261 6/04 Section 6 Major Engine Component Removal and Installation 31

 3. Apply battery voltage to solenoid (contracted
condition). See Figure 6-25.

4. After the engine stops completely, check that the

distance between the rack end surface and pump
case end surface is 68--69 mm (2.68--2.72 in.) on
both banks.

Note: Engine may not stop if the distance between

the rack end surface and pump case is more
than 70 mm (2.76 in.).

Note: When adjusting the adjusting rod, make

sure the rack moves without interference. If
rack does not move smoothly, governor
cannot operate properly.
1

1. Solenoid

Figure 6-25 Fuel Rack to Pump Case Adjustment

32 Section 6 Major Engine Component Removal and Installation TP-6261 6/04

 Section 7 Engine

7.1 Cylinder Heads and Valve Mechanism

2
1 4

5
27
6

9 7
26 8

14
25

24 10
23 15
13
16

11
17
12
22 18
21

20
19

1. Rocker cover 7. Gasket 14. Intake port gasket 21. Valve rotator
2. Cylinder head bolt 8. O-ring 15. Adjusting screw 22. Valve retainer
3. Nut, washer 9. Cylinder head 16. Rocker shaft 23. Rocker
4. Injection nozzle gland 10. Push rod 17. Bridge cap 24. Spacer
5. Injection nozzle 11. Tappet 18. Valve bridge 25. Bolt
6. Fuel intake connector 12. Cylinder head gasket 19. Stem seal 26. Rocker case
pipe 13. Valve 20. Valve spring 27. Water outlet connector

Figure 7-1 Cylinder Head and Valve Mechanism

TP-6261 6/04 Section 7 Engine 33

7.1.1 Disassembly 5. Removing the rocker case.

1. Removing fuel injection nozzles. a. Remove the snap ring of the water outlet
connector. Slide the connector toward the snap
a. Remove the fuel intake connector pipe and the ring. See Figure 7-5.
nozzle gland.
b. Loosen the rocker case mounting bolts and
b. Use the nozzle remover to remove the nozzle remove the rocker case from the cylinder head.
assembly. Take out the gasket left behind in the
cylinder head. See Figure 7-2.

c. Put away the nozzle and the intake connector 1

pipe where you can find them later. Do not
damage the nozzle tip.

2. Removing the rocker shaft assemblies.

a. Loosen the adjusting screw of each rocker.

See Figure 7-3.

b. Keep the shaft assembly and mounting bolts

together as a set.
1. Adjusting screw
3. Disassembling rocker shaft assemblies. Arrange Figure 7-3 Removing Rocker Shaft Assembly
the disassembled rockers in the order removed so
you can install them in that order at reassembly.
This will ensure the same rocker shaft clearance as
before. See Figure 7-4.

4. Removing the valve bridge. Remove the valve

bridge and bridge cap.

Note: Do not drop the bridge cap or other parts into

crankcase through the push rod hole.

Figure 7-4 Rocker Shaft Assembly

1

3
1
4
2

1. Gasket
2. Nozzle remover (33591-10101)
3. Injection nozzle gland
4. Fuel inlet connector pipe

Figure 7-2 Removing Fuel Injection Nozzle 1. Rocker case 2. Connector

Figure 7-5 Removing Rocker Case

34 Section 7 Engine TP-6261 6/04

 6. Removing cylinder head assemblies.
1
a. Each cylinder head is located relative to the
crankcase with the dowel pins. Use the eye nut
to lift the head off the crankcase. See
Figure 7-6. Approximate cylinder head weight
is 35 kg (77 lb.).

b. Remove the cylinder gasket.

Note: Do not damage the cylinder head or

crankcase surfaces when removing the
gasket with a screwdriver or other tool. 1. Eye nut (37591-02400)

7. Removing valves and valve springs. Use a valve Figure 7-6 Removing Cylinder Head Assembly
spring pusher to compress the valve spring
squarely and remove the valve retainers. See
1
Figure 7-7.

Note: If the valves are to be reversed, do not

change the combination of the valve seat
and valve guide.

8. Removing studs, guides, etc. Do not remove the

nozzle gland mounting studs or bridge guide from
cylinder head unless absolutely necessary. If any
of these parts have been removed, apply sealant to
the studded side threads of the part when installing 1. Valve spring pusher (33591-04500)
it to the cylinder head or install a new part. See
Figure 7-8. Figure 7-7 Removing Valve Spring

7.1.2 Inspection and Repair 1

2
Rockers, Rocker Bushings, Rocker Shaft
1. Measuring rocker bushing inside diameter and
rocker shaft diameter. If measurement exceeds
the service limit, replace the bushing or shaft. See
Figure 7-9 and Section 2, Engine Overhaul
Specifications.

1. Bridge guide 2. Stud

Figure 7-8 Bridge Guide and Stud Placement

Figure 7-9 Measuring Rocker Bushing and Rocker

Shaft

TP-6261 6/04 Section 7 Engine 35

 2. Replacing rocker bushings. Use a rocker bushing
puller to remove the rocker bushings for
replacement. See Figure 7-10.

a. Press a new bushing into the rocker from the

internally chamfered side of the bore.

b. Align the oil holes in the bushing and rocker.

c. After installing the bushing, measure the inside

diameter to make sure that it is to
specifications. See Section 2, Engine Figure 7-11 Measuring Valve Stem Diameter
Overhaul Specifications. If the diameter is not
within this tolerance, refinish to standard
tolerance by reaming to specifications with
3.2S cross hatch.

Valve Guide and Valve Stems

1. Measuring valve stem diameter and valve guide
inside diameter. The valve guide wears more
rapidly at the tooth end than at any other location.
Measure the inside diameter of the guide at the
ends and at the middle in two directions. If the
service limit is exceeded, replace the guide. See
Figure 7-12 Measuring Valve Guide Inside Diameter
Figure 7-11, Figure 7-12, and Section 2, Engine
Overhaul Specifications.

2. Replacing valve guides and stem seals. 1

a. Use the valve guide remover to remove the

valve guide for replacement. See Figure 7-13.

b. Use a valve guide seal installer to install slowly

a new guide with a press. See Figure 7-14.

2
1
1. Valve guide remover (33591-04300)
Align holes Figure 7-13 Removing Valve Guide
3

4
Removal Installation
1
1. Rocker bushing puller (37951-02600)
3
2. Bushing match marks
3. Chamfering
2
Figure 7-10 Replacing Rocker Bushing

1. Stem seal
2. Cylinder head
3. Valve guide
4. Valve guide seal installer (37191-01500)

Figure 7-14 Installing Valve Guide and Stem Seal

36 Section 7 Engine TP-6261 6/04

Notes: 2. Grinding the valve face. If the valve face is badly
worn, grind with a valve refacer. See Figure 7-17
1. The installation depth for the valve guide is and Figure 7-18.
specified, so use the valve guide seal installer to
secure the correct depth. a. Set a valve refacer at an angle of 30°.

2. Do not apply any oil or sealant to the surface of the b. Grind the valve stock to a minimum. If the
stem seal that comes in contact with the valve margin seems to exceed the repair limit as a
guide. When installing the stem seal, coat the seal- result of grinding, replace the valve.
rubbing surface of the stem with engine oil to
ensure initial lubrication of the stem seal lip. 3. Grinding valve seats.

3. Use a new stem seal. a. Use a valve seat cutter or valve seat grinder to
cut the valve seat. After cutting, grind the seat
lightly using #400 grit sandpaper inserted
Valves and Valve Seats between the cutter and valve seat. See
1. Inspecting the valve face. Coat valve face lightly Figure 7-19.
with red lead. Use valve lapper to inspect the valve
contact with its seat. If the contact is not uniform, if
the valve is defective, or if the repair limit is
exceeded, repair or replace the valve and valve
seat. See Figure 7-15 and Figure 7-16.

a. Inspect the valve face after the inspection or

replacement of the valve guide.

b. When pressing the valve coated with red lead Figure 7-17 Valve Seat Angle
into the valve seat, do not rotate the valve.

Figure 7-18 Grinding Valve

1. Valve lapper (30091-08800)
2. Red lead

Figure 7-15 Inspecting Valve Face

Figure 7-19 Refacing Valve Seat

Figure 7-16 Valve Contact with Seat

TP-6261 6/04 Section 7 Engine 37

 b. Lap the valve in the valve seat. Cut or grind the
valve seat only as needed for refacing.
Replace the valve seat if the seat width is more 1
than the repair limit as a result of wear or
cutting. Replace the valve seat if the valve 2
sinkage exceeds the repair limit after refacing. 3

4. Repairing valve seats.

a. Weld a stud to the valve seat. Insert a shaft into 1. Weld

2. Shaft 4
the valve guide holder from the upper side of 3. Valve seat
the cylinder head. Drive the seat off the head as 4. Stud, etc.
shown in Figure 7-20 and Figure 7-21. See
Section 2, Engine Overhaul Specifications. Figure 7-20 Removing Valve Seat

Note: When welding the stud, do not permit

splatter to come in contact with the Unit: mm (in.)
machined surfaces of the cylinder head.

b. Before inserting a new valve seat, measure the

inside diameter of the cylinder head bore and
the outside diameter of the seat to ensure Bore outside diameter
clearance (fit) is within clearance standards.
See Figure 7-21.
Seat outside diameter
Note: Negative (--) clearance valves indicate
interferences. Apply same dimensions
for intake and exhaust
c. Chill the valve seat in liquid nitrogen (about Figure 7-21 Valve Seat Dimensions
--170°C (--274°F) for more than 4 minutes with
the cylinder head kept at normal temperature,
or heat the cylinder head to 80°C--100°C
(176°F--212°F) with the valve seat chilled in
ether or alcohol containing dry ice.

d. Use the installer to install the valve seat. See

Figure 7-22.

5. Lapping valves in valve seats. Lap the valves in the

valve seats after replacing the seats.

a. Coat the valve face lightly with a lapping

compound. See Figure 7-23. Figure 7-22 Installing Valve Seat

Do not permit the compound to come in contact

with the valve stem. Use a compound of 120 to
150 mesh for initial lapping and a compound
finer than 200 mesh for finish lapping. Mixing
the compound with a small amount of engine oil
will facilitate coating.

1. Lapping compound

Figure 7-23 Coating Valve with Lapping Compound

38 Section 7 Engine TP-6261 6/04

 b. Use the valve lapper to lap the valve in the seat.
To lap, raise the valve off the seat and rotate the
valve only a partial turn and strike it against the
1
seat. See Figure 7-24.

c. Wash the compound with diesel fuel.

d. Coat the valve face with engine oil and lap the
valve again.

e. Check the valve face for contact.

Valve Springs: Measuring Squareness and 1. Valve lapper (30091-08800)

Free Length Figure 7-24 Lapping Valve in Valve Seat
Measure the free length and squareness of each valve
spring. If the free length or squareness exceeds the
service limit, replace the spring. See Figure 7-25 and
Section 2, Engine Overhaul Specifications.

Valve Bridges and Bridge Caps

Check the clearance between the bridge and the rotator
(cotter). See Figure 7-26.

1. If the clearance is less than 1.5 mm (0.059 in.), Figure 7-25 Measuring Valve Spring
check the valve stem top for cupping. When the
stem top is badly cupped, replace valve to obtain
more than 1.5 mm (0.059 in.) turn clearance.

2. Check the condition of the bridge cap. Replace if

badly worn.

Tappets and Push Rods

1. Inspecting cam contact face of tappets. Replace
the tappets if their cam contact faces are Figure 7-26 Checking Bridge-to-Rotor Clearance
abnormally worn. See Figure 7-27.

2. Inspecting valve push rods for runout. If the runout

exceeds the assembly standard, replace the push
rods. See Figure 7-28 and Section 2, Engine
Overhaul Specifications.

Figure 7-27 Cam Contact Face of Tappet

Figure 7-28 Measuring Valve Push Rod Runout

TP-6261 6/04 Section 7 Engine 39

Cylinder Head b. Place the gaskets on the crankcase assuring
the dowel pins enter their holes in the gaskets.
Use a straight edge and feeler gauge to measure
warpage on each cylinder head. If warpage exceeds the c. Install the cylinder head gasket by aligning
repair limit, reface the gasket surface with a surface holes with the dowel pins.
grinder. See Figure 7-29 and Section 2, Engine
Overhaul Specifications. D Application of Liquid Gasket

Apply a thin coat of silicone liquid gasket around

tappet holes and oil passage holes on both sides of
the head gasket. Install the gasket before the liquid
gasket dries.

Do not apply an excessive amount of liquid gasket

since it can press the head gasket O-ring and
cause deformation. Do not allow liquid gasket to
adhere around the bore; otherwise, gas leakage
can occur.

Figure 7-29 Measuring Head Gasket Warpage Before installation, wipe oil and grease from the
bottom face of the cylinder head, top face of the
7.1.3 Reassembly crankcase, and head gasket. Figure 7-32 and
Figure 7-33 show the areas and amounts of liquid
1. Installing tappets. Coat the tappets with engine oil gasket application.
and seat softly on camshaft. See Figure 7-30.
Apply liquid gasket to areas 5--8 mm
(0.20--0.31 in.) from the periphery of head gasket.
Apply liquid gasket to areas indicated in
Figure 7-32 and Figure 7-33. Apply liquid gasket
to both sides of head gasket.

Figure 7-30 Installing Tappets

2. Installing cylinder head gaskets. See Figure 7-31.

a. Clean the gasket surfaces of the cylinder head

Figure 7-32 Liquid Gasket Application on Head-
and crankcase thoroughly with a solvent or
Facing Side
degreasing solution.

Figure 7-33 Liquid Gasket Application on

1. Dowel pin Crankcase-Facing Side
Figure 7-31 Replacing Cylinder Head Gaskets
40 Section 7 Engine TP-6261 6/04
 Spread the liquid gasket with a finger to a thickness
of 0.2--0.5 mm (0.01--0.02 in.). Sections A and B
1
are very close to O-rings. Make sure there is no
large amount of liquid gasket on the edge at these
sections.

3. Reassembling the cylinder heads.

a. Coat the valve stems with engine oil and insert

them into the valve guides.

b. Install the valve springs and rotators to the

valve guides. Compress each valve spring with
the valve spring pusher and install the valve 1. Valve spring pusher (33591-04500)
retainers on the valve stem. See Figure 7-34.
Figure 7-34 Install Valve Springs
c. Lightly tap top of each valve stem with a soft
hammer to make sure valve spring and
retainers are properly installed. See
Figure 7-35.

4. Installing cylinder head assemblies.

a. Install eye nut to stud bolt and lift the cylinder

head assembly. Set head position to coincide
with the position of the dowel pin. Tighten head
bolts coated with engine oil. See Figure 7-36.

Note: When installing the connector, make

Figure 7-35 Checking Valve Spring Installation
sure the MANIFOLD mark on the gasket
faces the connector.
1
b. Install eye nut on the stud bolt. Attach a shackle
and wire rope to the eye nut and lift the cylinder
head assembly. Align the holes on the cylinder
head with the dowel pins and keep the head
assembly slightly lifted. Apply engine oil to the
threads of the head bolts and the bolt seats and
install the bolts into the head assembly. See
Figure 7-36.

c. Tighten cylinder head bolts with the specified

torque in the order shown in Figure 7-37. 1. Eye nut (37591-02400)

Note: To tighten cylinder head bolts according Figure 7-36 Installing Cylinder Head Bolts
to the angle method, tighten to 294 Nm
(217 ft. lb.) and turn an additional 60°.
539 Nm
(378 ft. lb.)
Note: Remove excess engine oil from cylinder wet
head bolts before installing. Before
installing the cylinder head assemblies,
measure the projection of pistons and
make sure the amount of projection is
correct.

Figure 7-37 Head Bolt Tightening Sequence

TP-6261 6/04 Section 7 Engine 41

 5. Installing the rocker case. See Figure 7-38.
108 Nm (80 ft. lb.)
a. Insert the water outlet connector fully into the
rocker case.

b. Install rocker case so it meets the dowel pins.

c. Insert water outlet connector by sliding it from

the next rocker case after coating the O-ring
with grease. Install the snap ring. Coat
with
grease
d. Tighten the rocker case mounting bolts to the
specified torque. Figure 7-38 Torquing Cylinder Head Bolts
6. Installing the valve bridges and caps. See
Figure 7-39.

a. Coat bridge guides with engine oil and install Coat bridge
the bridges to guides with the adjusting screw guide with
positioned on the exhaust manifold side. engine oil

b. Coat bridge contact face of the bridge caps with

engine oil. Install caps in position, being careful
not to let them fall into the crankcase through
the push rod holes.
Figure 7-39 Installing Bridge
7. Installing rocker shaft assembly. See Figure 7-40.

a. Align the notch of the rocker shaft with the bolt 147 Nm
hole of the rocker shaft bracket and insert the (108 ft. lb.) 1
bolt into the bolt hole.
Coat O-ring
b. Insert the long bolt for securing the head and with grease
rocker bracket with the O-ring through the bolt
hole of the rocker bracket into the cylinder
head.

Note: Move rocker arm up and down to make

sure the arm is free. While tightening the
bracket mounting bolts temporarily, 1. Spacer
install the bracket in place so the rocker
tip comes in contact with the bridge caps Figure 7-40 Installing Rocker Shaft Bolts
evenly. Tighten the long bolt securing
the head and rocker bracket first and 98 Nm
tighten the short bolt to the specified (70 ft. lb.)
torque. 1

8. Installing injection nozzle assemblies. See

Figure 7-41. 2
Coat gasket
a. Disconnect the fuel intake connector pipe from 63.7--73.5 Nm
with grease
(47--54 ft. lb.)
the nozzle assemblies.

b. Install three O-rings to the nozzle and coat with

grease.

c. Coat the gasket with grease and install the

1. Washer (spherical face on lower side)
gasket to the nozzle. Insert nozzle assembly
2. O-rings
into the cylinder head. Watch the center of the
connector installation hole. Figure 7-41 Installing Injection Nozzle Assembly

42 Section 7 Engine TP-6261 6/04

 d. Tighten the fuel intake connector pipe to the cylinder head before tightening to the specified
specified torque. torque. Install the gasket when installing the
nozzle assemblies.
e. Tighten nozzle gland mounting nut to the
specified torque. Maintain equal distances 9. Adjusting valve clearance. See Section 5.1.1,
between the fuel intake connector pipe and the Valve Clearance.

7.2 Cylinder Liners, Pistons, and Connecting Rods

1
2
3

7
8

9
10
11
12

1. Top compression ring 5. Piston pin 9. Connecting rod bearing (upper)

2. Second compression ring 6. Snap ring 10. Connecting rod bearing (lower)
3. Oil ring 7. Connecting rod 11. Connecting rod cap
4. Piston 8. Connecting rod bushing 12. Bolt

Figure 7-42 Cylinder Liners, Pistons, and Connecting Rods

7.2.1 Disassembly
1. Removing connecting rod caps. Loosen the cap
bolts from the inspection hole and remove the cap.
See Figure 7-43.

Do not damage the bearings or drop them into the

oil pan. Mark removed connecting rod bearings for
identification of cylinder numbers and for upper
and lower shells.
Figure 7-43 Removing Connecting Rod Caps

TP-6261 6/04 Section 7 Engine 43

 2. Preparing before piston removal. Use a cloth or oil
paper to remove all carbon deposits from the upper
areas of the cylinder liner. Carbon deposits will
make it difficult to pull a piston up. See Figure 7-45.

3. Removing pistons using a bar. See Figure 7-44

and Figure 7-46.

a. Turn crankshaft to bring the piston assembly

(from which the connecting rod has been
removed ) to top dead center (TDC).
Figure 7-45 Removing Carbon Deposits on Cylinder
b. Turn the crankshaft in normal direction until the Liner
crank pin comes off the connecting rod and the
joint of the rod is visible in the inspection hole on
the side of the crankcase.

c. Cover the turning bar with a cloth to protect it.

Put the tip of the bar under the bottom of the
large end of the connecting rod and pry the
piston assembly up a small amount using the 1
crank pin as a fulcrum. See Figure 7-47.

Note: Do not force turning bar to remove piston 2

assembly. Insert the bar so it protrudes 1. Bolt hole
about 10--20 mm (0.39--0.79 in.) from the 2. Crank pin
bottom end of the large end. Figure 7-46 Rotating Crankshaft Out Of Connecting
Rod
d. Turn the crankshaft in reverse direction just a
little at a time to raise the crank pin (fulcrum)
while pushing down on the outer end of the bar
to raise the piston assembly.

Note: Raise the piston assembly carefully so

the connecting rod will not damage the
piston cooling oil jet nozzle.

e. When piston oil ring comes out of cylinder liner, 1

lower piston a little and carefully rest oil ring on
10--20 mm
the edge of the cylinder liner. See Figure 7-48. (0.39--0.79 in.)

Note: To avoid damaging oil ring, lower piston

slowly and carefully. Do not rotate
piston.
1. Turning bar

Figure 7-47 Removing Piston Assembly

1
1
Cylinder
number
stamped
here

1. Pointer

Figure 7-44 Position Piston Assembly to TDC

1. Oil ring

Figure 7-48 Piston Rings Above Cylinder Liner

44 Section 7 Engine TP-6261 6/04

 f. While holding the compression ring portion of
the piston with your hands, carefully pull the 1
piston from the cylinder liner and rest the skirt
on the top of the crankcase. See Figure 7-49.

Note: Use gloves when handling the piston

assembly as the piston rings are sharp.

g. With your hands holding the piston pin portion

of the piston, lift piston assembly off the liner.

4. Using the piston remover.

1. Piston remover (MM321420)
a. Turn crankshaft to bring the piston assembly to
be removed to 50° before TDC. Figure 7-50 Installing Piston Remover

b. Attach piston remover to the top of the piston.

Grip the handle of remover and lift piston and 1
connecting rod off the liner. See Figure 7-50.

5. Removing the piston ring. Use the piston ring tool

to remove the piston rings. See Figure 7-51.

6. Removing piston pins from a piston.

a. Use ring pliers to remove the snap rings. See

Figure 7-52.

b. Remove the piston pin to separate the piston 1. Piston ring tool (37191-03200)
from the connecting rod.
Figure 7-51 Removing Piston Rings
c. If it is difficult to pull the pin out, heat the piston
with a piston heater, heat gun, or in hot water to
expand the pin bore. 1

1. Ring pliers (45191-08400)

Figure 7-52 Removing Snap Rings

Figure 7-49 Removing Piston Assembly from

Cylinder Liner

TP-6261 6/04 Section 7 Engine 45

7.2.2 Inspection and Repair

Cylinder Liners
1. Measuring cylinder liner inside diameter. Measure
the inside diameter of each liner in two directions,
parallel and transverse to the piston pin, at three
positions on top (ridged area). If measurements
exceed the service limit, replace the liner. See
Section 2, Engine Overhaul Specifications,
Figure 7-53, and Figure 7-54.

2. Measuring cylinder liner protrusion. Measure the Figure 7-53 Measuring Cylinder Liner
protrusion of each liner at the flange with dial
gauge. See Figure 7-55 and Section 2, Engine
Overhaul Specifications. If the protrusion is not
within the assembly standards, change the
position of the liner relative to the bore or use the
liner in another bore.

Note: If protrusion is less than assembly standard,

the gasket will fail to seal the bore resulting
in gas leakage.

D When cylinder head has just been removed: Figure 7-54 Measuring Cylinder Liner for Taper

D Clean the gasketed surface of the crankcase

and the top of the liners. 2
D Secure the top of the liner uniformly at four
places with liner pusher and bolt. See 1
Figure 7-55.

D Set the dial gauge at the top of the crankcase

and set the gauge pointer to 0.

D Measure the protrusion at four places on top

of liner. Take average of four measurements. 1. Liner pusher (37591-06200)
2. Bolt (37591-06300)
D If the average is less than the assembly
Figure 7-55 Measuring Cylinder Liner Protrusion
standard, insert a shim under the collar of the
cylinder liner.
1
D When cylinder liner is replaced, see item 3.

D Remove cylinder liner and study the cylinder

liner contacting surface of the crankcase.

D If the cylinder liner contacts the crankcase

only on one side, use a rotary grinder to grind
the surface to keep the differences of depth in
four directions (A, B, C and D) within
0.05 mm (0.002 in.) See Figure 7-56. 1. Rotary grinder

Figure 7-56 Using Rotary Grinder to Grind Cylinder

Head Surface

46 Section 7 Engine TP-6261 6/04

 D Measure the ridge depth of crankcase. Since
top surface of the crankcase may be slightly
distorted, use a projection plate to obtain
1
accurate measurements. See Figure 7-57 2
and Figure 7-58.

D Measure at four locations (A, B, C and D) and

obtain the average. See Figure 7-56.

D Measure thickness [standard measurement:

15 mm (0.59 in.)] of the projection plate using
a micrometer. Subtract the projection plate 1. Projection plate (37598-09201)
2. Ridge depth
thickness from the measured ridge depth to
obtain the actual ridge depth from the top Figure 7-57 Measuring Ridge Depth
surface of the crankcase.
Item Assembly Standard
D Measure thickness of the cylinder liner collar. 14 +0.05 (0.55 +0.002)
Crankcase ridge depth, mm (in.)
0
D Subtract crankcase ridge depth from cylinder Thickness of cylinder liner collar, 14 +0.20 (0.55 +0.008)
liner collar thickness. This value is the mm (in.) +0.16 (+0.006)
cylinder liner projection. Figure 7-58 Cylinder Liner Specifications
D If value is less than the assembly standard,
insert a shim under the collar of cylinder liner.

D Measuring cylinder liner projection.

D Place a dial gauge on the top surface of the

cylinder liner and set the indicator to 0. See
Figure 7-59.

D Measure the cylinder liner protrusion at four

locations and obtain the average.

D If average is less than the assembly standard

Figure 7-59 Measuring Cylinder Liner Projection
or if the protrusion has sectional chipping,
replace the cylinder liner. See item 3.

D Inserting cylinder liner shim.

D Remove cylinder liner. Insert a shim between

the cylinder liner and crankcase. See
Figure 7-60.
1
D From Figure 7-61, select appropriate shim
thickness to achieve the largest protrusion 1. Shim
within the assembly standard range. Figure 7-60 Installing Cylinder Liner Shim
D Clean the gasketed surface of the crankcase
Shim Thickness, mm (in.) Part No.
and the top of the liners.
0.05 (0.002)
D Secure the top of the liner uniformly at two 0.10 (0.004) See Parts Catalog
places with the clamps and bolts (M22 x 2.5). 0.15 (0.006)

D Set the dial gauge at the top of the crankcase

Figure 7-61 Cylinder Liner Shim Selection
and set the gauge pointer to 0.

D Measure the protrusion at four places on top

of the liner. Take average of four
measurements.

TP-6261 6/04 Section 7 Engine 47

 3. Replacing cylinder liners. Pistons
a. Use cylinder liner remover to remove cylinder Check the combustion chamber and inside surfaces of
liner from the crankcase for replacement. See the piston bosses. Replace piston if defects are found.
Figure 7-62.
1. Measuring piston diameter.
b. Attach O-rings to the new cylinder liner and
carefully insert the liner into the bore of the a. Using a micrometer, measure the diameter of
crankcase. See Figure 7-63. each piston in the transverse direction to the
piston pin (at position shown). If the diameter
Note: Before inserting liner, coat O-rings with exceeds the service limit, replace the piston. If
engine oil to prevent them from twisting. any pistons have to be replaced, select new
pistons so the variance in weight among
c. After inserting the liner into the bore, lightly tap pistons per engine is within assembly
it on the top with the installer so it rests on the standards. See Section 2, Engine Overhaul
flange in the counterbore formed by the Specifications, and Figure 7-64.
crankcase. After seating liner, tap on it several
times to be sure that it is properly installed. b. Piston weight is stamped on top of each piston.

After installing the liners on all bores, test the 2. Inspecting piston ring grooves. Check piston ring
liner joints for water tightness by applying water grooves for wear and damage and replace piston, if
under pressure. Check each liner to be sure necessary. Check the Ni-resist insert for cracks.
the protrusion is within assembly standards. Replace the piston if the insert is cracked. See
Figure 7-65.

1
1

3 2
1. Cylinder liner remover (37591-04100) 1. Part number
2. Piston weight
Figure 7-62 Removing Cylinder Liner 3. Direction mark

Figure 7-64 Piston Weight Stamp Location

1
2

3
1. Ni-resist insert
2. Top ring groove 4
3. Second ring groove
Figure 7-63 Installing O-Ring to Cylinder Liner 4. O-ring groove

Figure 7-65 Inspecting Piston Ring Grooves

48 Section 7 Engine TP-6261 6/04

 3. Measuring piston pin bore diameter. Using Piston Rings
calipers or a cylinder gauge, measure the piston
pin bore diameter. If the diameter exceeds the Measuring gaps. Place rings for the new master
service limit, replace the piston. See Section 2, cylinder liner and measure the gap of each ring. If gap of
Engine Overhaul Specifications, and Figure 7-66. any ring exceeds the service limit, replace all rings as a
set. See Figure 7-68, Figure 7-69, and Section 2,
4. Measuring piston protrusion. Measure protrusion Engine Overhaul Specifications.
of each piston. If not within standards for piston
protrusion measurement, inspect the clearance of Note: Use a piston to place the piston ring in the liner by
parts. See Figure 7-67. pushing it squarely.

a. Use a dial gauge to measure TDC of the Item Assembly Standard, mm (in.)
pistons. Master cylinder liner inside
170 ±0 mm (6.70 ±0 in.)
diameter
b. Set the dial gauge at the top of the crankcase.
Set the gauge pointer to 0. Figure 7-68 Piston Ring Specifications

c. Measure the protrusion at four places on the

piston head. Average the four measurements
to determine the protrusion. Subtract the piston
protrusion from the thickness of the cylinder
head gasket (as installed) to determine the
clearance between the piston top and cylinder
head. See Section 2, Engine Overhaul
Specifications.

Note: Keep piston protrusion within assembly

standard range to maintain high engine
performance and to prevent the valves Figure 7-69 Measuring Piston Rings
from interfering with piston.
Piston Pins
Measuring piston pin diameter. Using a micrometer,
measure the outside diameter of each piston pin. If the
outside diameter exceeds the service limit, replace the
pin. See Section 2, Engine Overhaul Specifications.

Connecting Rods, Connecting Rod Bearings,

and Small-End Bushings
1. Measuring small-end bushing inside diameter.
Using a cylinder gauge, measure the inside
Figure 7-66 Measuring Piston Bore Diameter diameter of each bushing. If the inside diameter
exceeds the service limit, replace the bushing. See
Section 2, Engine Overhaul Specifications, and
Figure 7-70.

Figure 7-67 Measuring Piston Protrusion

Figure 7-70 Measuring Connecting Rod Small-End
Bushing Inside Diameter

TP-6261 6/04 Section 7 Engine 49

 2. Replacing connecting rod small-end bushings. bolts to the specified torque. Use a feeler gauge to
measure the end play. If the end play exceeds the
a. Use a connecting rod small-end bushing service limit, replace the connecting rod. See
installer to remove the bushing for replacement Section 2, Engine Overhaul Specifications, and
as shown in Figure 7-71. Figure 7-75.

b. When installing a new bushing, align the oil

holes in the bushing and connecting rod.

c. After installing bushing, finish inside diameter

to 70 +0.040/+0.020 mm (2.75 +0.00157/
+0.00079 in.) oversize, 1.6S cross hatch and
parallel bushing with respect to the large-end
bearing to 0.05 mm (0.0020 in.) by reaming.

d. After installing the bushing, insert the piston pin

and make sure the pin rotates freely without
Figure 7-72 Connecting Rod Inspection
rattling.

Figure 7-71 Replacing Connecting Rod Bushing Figure 7-73 Inspecting Connecting Rod Installed on
Piston
3. Inspecting connecting rods for bend and twist.

a. Measure C and ᐛ. If the measurement at C is

larger than 0.05 mm (0.0020 in.) per 100 mm
(3.9 in.) of ᐛ, straighten the rod with a press. 1 2
See Figure 7-72.

Note: To inspect for bend, install the cap to the 3

connecting rod and tighten the cap bolts 1. Wiped overlay 2. Scratches 3. Seizure
to the specified torque.
Figure 7-74 Inspecting Connecting Rod Bearings
b. To inspect the rod installed to the piston, place
the piston on a surface plate, insert a round bar
the same diameter as the crank pin into the
large end bore, and measure heights A and B of
the bar. See Figure 7-73 and Section 2, Engine
Overhaul Specifications.

4. Inspecting connecting rod large-end bearings

metal shell for wiped overlay, scratching, seizure,
pitting, and other defects. If any defect is found,
replace the shell. See Figure 7-74. Figure 7-75 Measuring Connecting Rod End Play
5. Measuring connecting rod end play. Install the
connecting rod to the crank pin and tighten the cap

50 Section 7 Engine TP-6261 6/04

 6. Variance in weight among connecting rods per 7.2.3 Reassembly
engine. When replacing connecting rods, make
sure that the variance in weight among connecting 1. Reassembling pistons on connecting rods. See
rods per engine is within the assembly standards in Figure 7-77.
Section 2, Engine Overhaul Specifications.
a. Heat the piston with a piston heater, heat gun,
7. Measuring connecting rod large-end bore or with hot water.
diameter. Measure the connecting rod big-end
bore diameter in directions A, B, and C and at front b. Coat the piston pin with engine oil and insert it in
and rear positions 1 and 2 as shown in Figure 7-76. position through the connecting rod.
To obtain the out-of-roundness valve, subtract the
c. Install the connecting rod to the piston with the
smallest measured value from largest measured
matching marks on the large end on the
value. If the diameter exceeds the service limit,
camshaft side.
replace the connecting rod. See Section 2, Engine
Overhaul Specifications. d. Use ring pliers to install the snap rings in the
grooves of the pistons. Make sure that the rings
8. Inspecting serration on connecting rod big-end
are not fatigued and that they fit in the grooves
bore. Inspect the serration on connecting rod
properly. See Figure 7-78.
big-end bore by conducting a magnetic particle
test. It cracking or damage is found, replace the Note: Position the ends of both snap rings at
connecting rod. the bottom of the pin bore.
9. Measuring connecting rod bearing thickness. Use
a ballpoint micrometer to measure the center of 1
1
each bearing shell. If the thickness exceeds the
service limit on the upper or lower shell, replace
both shells as a set. See Section 2, Engine
Overhaul Specifications.
4
Note: Four sizes are available for the connecting 3
rod bearings. See Section 2, Engine
Overhaul Specifications. 2
View A

1. Piston weight 3. Matching marks

2. Part no. 4. Camshaft

Figure 7-77 Matching Marks on Connecting Rod

Figure 7-76 Measuring Connecting Rod Bore

1. Ring pliers (45191-08400)

Figure 7-78 Installing Snap Rings

TP-6261 6/04 Section 7 Engine 51

 2. Installing piston rings. 5. Inserting pistons.

a. Use the piston ring tool (37191-03200) to install a. Put the connecting rod in the cylinder liner and
the piston rings on the piston. See Figure 7-79. carefully rest the piston on top of the crankcase.
See Figure 7-84.
Note: Top and second piston rings are marked
RH and oil ring is marked R near gap on Note: Make sure the arrow mark CAM on top
side to be up when installed with this the piston points to the camshaft side.
mark down. Install piston rings this way When placing the connecting rod in the
to avoid excessive oil consumption and liner, keep it away from the oil jet nozzle
overheating. by observing rod through the crankcase
inspection hole and do not rotate piston.
b. Install the oil ring with the gap positioned at
180° to the coil spring. See Figure 7-80.
1
3. Preparation before installing pistons.

a. Turn the crankshaft in the normal direction until

the cylinder number (stamped on the
dampener) to which the piston is to be installed
is at the position of approximately 50° before
TDC. See Figure 7-81.

b. Clean the cylinder liner bore surface and crank 1. Cylinder no. stamp
pin by wiping with a cloth and coat it with engine Figure 7-81 Crankshaft Piston Markers
oil. See Figure 7-82.

4. Installing connecting rod bearing upper shells.

Install the upper shell of the bearing in the rod by
fitting the locking lip in the recess provided in the
rod. Coat the inside surface of the shell with engine
oil. Make sure the oil holes in the rod and bearing
are aligned. See Figure 7-83.

1 Figure 7-82 Preparing Cylinder Liner Bore

2
1
3
4
5
1. Up mark 4. Oil ring
2. Top compression ring 5. Coil spring
3. Second compression ring
1. Lug groove
Figure 7-79 Installing Piston Rings
Figure 7-83 Oiling Connecting Rod

1. Coil spring gap 2

2. Oil ring gap
Figure 7-84 Installing Pistons
Figure 7-80 Installing Piston Oil Ring
52 Section 7 Engine TP-6261 6/04
 b. Coat piston rings with engine oil and position
1 2
the ring gaps away from the axis of piston pin
and antithrust direction. See Figure 7-85.

c. With your hands, hold the compression ring

portion of the piston and carefully insert the
piston into the cylinder liner.

Note: Use gloves when handling the piston 4 3

assembly as the piston rings are sharp.
1. Coil spring gap 3. Oil ring gap
Note: Do not pinch your finger between the oil 2. Top compression ring gap 4. Second compression ring gap
ring and cylinder liner. Slowly insert the Figure 7-85 Piston Ring Position
piston to avoid damaging it.

d. After making sure that the piston ring gaps are 1

positioned properly, coat the rings with engine
oil and clamp them using the piston installer. At
this time, coat the inside surface of the installer
with engine oil. See Figure 7-86.

e. Lightly tap the piston head with a soft hammer

to insert the piston into the cylinder liner. If the
piston will not go into the liner, move the large
end of connecting rod back and forth through
the crankcase inspection hole. 1. Piston installer (37191-07100)

f. By inserting your hand through the crankcase Figure 7-86 Installing Pistons
inspection hole, make sure that the upper shell
of the bushing is properly positioned in the large
end of the connecting rod. See Figure 7-87.

6. Installing connecting rod cap bolts.

a. Coat the threads of the cap bolts and the inside

surface of the lower shells of the connecting rod
bearing with engine oil. See Figure 7-83.

b. Install each cap in position. With your hand, Figure 7-87 Checking Connecting Rod Bearing
hold the upper end of the cap and tighten the Position
bolt at the lower end first. This will help prevent
dropping the cap into the oil pan. Coat the
threads of the bolts with engine oil and tighten
the bolts temporarily. See Figure 7-88.

c. With the cap bolts tightened temporarily, touch

joint between the cap and rod. Make sure that
the cap is normally held in place and tighten the
bolts to the specified torque.

Note: Make sure matching marks on cap and Figure 7-88 Installing Connecting Rod Bolts
rod are on the same side and aligned.

d. Move the large end of this rod in the thrust

direction. Make sure that the rod has correct
end play. See Figure 7-88.

TP-6261 6/04 Section 7 Engine 53

 e. Tighten the cap bolts to the specified torque. Note: To tighten connecting rod cap bolts
See Figure 7-89. according to the angle method, tighten to
245 Nm (181 ft. lb.) and turn an
f. Use a feeler gauge to measure the end play of additional 60°.
the connecting rod. Make sure that the end
play is equal on both top and bottom sides of
crank pin. See Section 2, Engine Overhaul
Specifications, and Figure 7-90.

Figure 7-90 Checking End Play

539.4 Nm
(398 ft. lb.) wet

Figure 7-89 Torquing Connecting Rod Bolts

7.3 Torsional Dampener

1. Torsional dampener 2. Pulley (water pump and alternator drive) 3. Front cover, oil seal

Figure 7-91 Torsional Dampener Components

54 Section 7 Engine TP-6261 6/04

7.3.1 Disassembly 7.3.2 Inspection and Repair
1. Removing the torsional dampener. Inspecting torsional dampener. Check torsional
dampener for surface cracking, mirror plate swelling
a. Attach sling to torsional dampener. Remove and cracking, silicone oil leakage, paint discoloration
dampener mounting bolts. See Figure 7-92. caused by excess beating, and surface peeling.
Replace torsional dampener after 8000 hours of
b. To remove the dampener, install two jack bolts
operation regardless of whether the dampener has
[M12 x 1.24, 40 mm (1.57 in.)] in bolt holes and
loosen the bolts evenly while lifting dampener. surface flaw.
The approximate weight is 50 kg (110 lb.).
7.3.3 Reassembly
2. Removing front cover. Loosen the front cover
mounting bolts and remove the cover, being careful 1. Installing front cover.
not to damage the oil seal. See Figure 7-93.
a. Apply engine oil to the lip section of the oil seal.
Install the oil seal in the front cover making sure
that the oil seal is flush with the end face of the
oil seal installation hole of the front cover. See
Figure 7-94.

2
Figure 7-92 Removing Dampener Bolts

1. Front cover
2. Oil seal

Figure 7-94 Front Cover Oil Seal

Figure 7-93 Removing Front Cover

TP-6261 6/04 Section 7 Engine 55

 b. Apply sealant to front cover gasket mounting
surface of the crankcase, position the gasket
on the surface, and apply sealant on gasket.
Install the front cover.

c. If the dowel pins are worn or the cover has been

replaced, install new dowel pins.

d. Tighten the case mounting bolts evenly.

e. Check that the bottom surfaces of front cover

and crankcase are flush. Carefully remove
Figure 7-95 Removing Excess Gasket
excess gasket protruding from joined surfaces.
See Figure 7-95.

When pointer was removed or dislocated

accidentally. To determine the TDC of no. 1
piston in compression stroke, bring the mark on
the flywheel to the position where it is at the
equal distances from the two marks punched
on the timing gear case. When these mark are 1
positioned at an equal distance from one 1. Timing gear case 2
another, no. 1 and no. 6 pistons are at the TDC. 2. Flywheel
See Figure 7-96. Figure 7-96 Determining TDC
2. Installing pulley and torsional dampener. Tighten
the pulley and dampener mounting bolts to the
specified torque. See Figure 7-97.

490 Nm
(361.4 ft. lb.)

Figure 7-97 Installing Pulley and Torsional

Dampener

56 Section 7 Engine TP-6261 6/04

7.4 Flywheel, Timing Gears, and Camshafts

3
1

14

6
7
8
9

13
10

11
12

1. Fuel injection drive 6. Idler shaft 11. Flywheel

2. Camshaft 7. Camshaft gear 12. Timing gear case, oil seal
3. Thrust plate 8. Idler gear 13. Injection pump accessory drive
4. Nozzle plate 9. Thrust plate 14. Oil pan
5. Rear plate 10. Oil strainer, oil pipe, oil pump

Figure 7-98 Flywheel, Timing Gears, and Camshafts

7.4.1 Disassembly
1. Removing flywheel.

a. Attach a sling on the flywheel.

b. Remove the flywheel mounting bolts. See

Figure 7-99.

Figure 7-99 Removing Flywheel

TP-6261 6/04 Section 7 Engine 57

 c. Install two jack bolts (M12 x 1.25) in the holes
provided for flywheel removal and turn bolts
evenly to remove flywheel. Approximate
weight is 140 kg (309 lb.).

Note: Do not drop or hit the flywheel against a

hard object during the removal process.
The ring gear is bolted to the flywheel.
Do not remove the ring gear from the
flywheel unless it is replaced.

2. Removing fuel injection pump accessory drive.

Figure 7-101 Removing Timing Gear Case
Remove mounting bolts from fuel injection pump
accessory drive case. Remove fuel injection pump
accessory drive. Be careful not to damage the gear
teeth. See Figure 7-100.

3. Removing timing gear case. See Figure 7-101.

a. Attach slings to the timing gear case.

b. Remove the timing gear case mounting bolts.

c. Remove the timing gear case by pulling it away

from the engine block until the dowel pins are
out of the holes. Figure 7-102 Measuring Timing Gear Backlash and
End Play
In this step, keep timing gear case suspended
and be careful not to damage oil seal.
Approximate timing gear case weight is 85 kg
(187 lb.).

4. Measuring backlash and end play. Measure the

backlash and end play of each gear to obtain data
to evaluate part replacement needs. See
Figure 7-102.

5. Removing idler gear. Align pointer with the mark for

TDC of piston no. 1 in compression stroke.
Remove the thrust plate mounting bolts and the
idler gear. See Figure 7-103. Figure 7-103 Removing Idler Gear

6. Removing idler shaft. Remove the idler shaft

mounting bolts. Install two jack bolts (M10x1.25) in
holes provided for shaft removal and loosen bolts
evenly to remove idler shaft. See Figure 7-104.

Figure 7-104 Removing Idler Shaft

Figure 7-100 Removing Fuel Injection Pump

Accessory Drive

58 Section 7 Engine TP-6261 6/04

 7. Removing camshaft gear. Remove camshaft gear 7.4.2 Inspection and Repair
mounting bolts and remove the camshaft gear.
See Figure 7-105. Flywheel and Ring Gear
8. Removing camshaft. Remove thrust plate mounting Measuring flywheel face and radial runouts. Measure
bolts. Remove camshaft from the crankcase. The the runouts with the flywheel installed on the crankshaft.
camshaft weight is approximately 32 kg (71 lb.). If the runouts exceed the assembly standard, check for
See Figure 7-106. loose bolts or obstacles lodged between the mounting
faces of the flywheel and crankshaft. See Section 2,
Note: When pulling out the camshaft, support it
with a bar-like tool inserted through the side Engine Overhaul Specifications, and Figure 7-107.
cover mounting section of the crankcase to
prevent damaging the cam surfaces and Fuel Injection Pump Accessory Drive
shaft bushings.
Inspecting fit of bearings. Inspect each bearing for
smooth rotation. Replace bearing if it rotates erratically
or hums. Inspect the fit of the bearing inner race on the
drive shaft and replace a part that is badly worn. Inspect
the fit of the bearing outer race in the drive case and
replace a part that is badly worn. Inspect drive shaft and
oil seal and replace a defective part. See Section 2,
Engine Overhaul Specifications, and Figure 7-108.

Figure 7-105 Removing Camshaft Gear

Figure 7-107 Measuring Flywheel Runout

Figure 7-106 Removing Camshaft

Figure 7-108 Drive Shaft and Oil Seal

TP-6261 6/04 Section 7 Engine 59

Timing Gears: Measuring Backlash b. Install a new bushing to the gear by pressing it
from the boss side of the gear until the end face
To measure backlash between the gears, set up a dial of the bushing is flush with that of the gear boss.
gauge so that it contacts the pitch circle of the gear to
measure. If a dial gauge is not available, measure the c. After installing the bushing, be sure the inside
backlash by inserting a feeler gauge between the gear diameter is within assembly standard. If less
teeth. If the backlash exceeds the service limit, replace than assembly standard, ream bushing to
the worn gear. The backlash between the crankshaft inside diameter of 50 +0.025/0 mm (1.97
gear and oil pump idler gear is 0.11--0.38 mm (0.0043-- +0.00098/0 in.) oversize, 1.6S cross latch.
0.150 in.). See Figure 7-109 and Section 2, Engine
Overhaul Specifications.

Note: The injection pump accessory drive is bolted

together with the timing gear case. This makes it
necessary to temporarily install them to rear plate
with bolts and nuts when measuring the backlash.

Figure 7-110 Measuring Idler Gear Bushing and Shaft

Figure 7-109 Measuring Timing Gear Backlash

Idler Gears, Idler Gear Bushing, and Idler

Gear Shafts
1. Measuring idler gear bushing inside diameter and
idler gear shaft diameter. If diameter exceeds the Figure 7-111 Measuring Idler Gear End Play
service limit, replace the bushing or shaft if either is
worn. See Figure 7-110 and Section 2, Engine
Overhaul Specifications.
1
2. Measuring idler gear end play. Measure the end
play with a feeler gauge or a dial gauge. If the end
play exceeds the repair limit, replace the thrust
plate. See Figure 7-111 and Section 2, Engine
Overhaul Specifications.

3. Replacing idler bushings.

a. Use an idler bushing puller to remove existing 1. Idler bushing puller

bushing. See Figure 7-112.
Figure 7-112 Replacing Idler Gear Bushing

60 Section 7 Engine TP-6261 6/04

Camshafts and Camshaft Bushings 4. Measuring camshaft bushing inside diameter. Use
a cylinder gauge to measure the inside diameter of
1. Measuring cam lift. Use a micrometer to measure the camshaft bushings fitted to the crankcase. If
the diameters of A and B on each cam to determine inside diameter exceeds the service limit, replace
the loss in cam lift. If the cam lift is less than the the bushings. See Section 2, Engine Overhaul
service limit, replace camshaft. See Section 2, Specifications, and Figure 7-116.
Engine Overhaul Specifications, and Figure 7-113.
5. Measuring camshaft end play. Use a dial gauge to
2. Measuring camshaft runout. If the runout exceeds measure the end play of the camshaft to which the
the repair limit, straighten camshaft with a press or camshaft gear is installed. If the end play exceeds
replace it with a new one. See Section 2, Engine the service limit, replace the thrust plate. See
Overhaul Specifications, and Figure 7-114. Section 2, Engine Overhaul Specifications, and
Figure 7-117.
Note: Set a dial gauge on the camshaft and turn
the camshaft. Take one half of the gauge
indication as the runout.

3. Measuring camshaft journal diameter. Use a

micrometer to measure each camshaft journal in
two directions at right angles to each other. If the
diameter exceeds the service limit, replace the
camshaft. See Section 2, Engine Overhaul
Specifications, and Figure 7-115.

Figure 7-115 Measuring Camshaft Journal Diameter

Figure 7-113 Measuring Cam Lift

Figure 7-116 Measuring Camshaft Inside Diameter

Figure 7-114 Measuring Camshaft Runout

Figure 7-117 Measuring Camshaft End Play

TP-6261 6/04 Section 7 Engine 61

 6. Replacing camshaft bushings. Install the bushings
in the crankcase and secure them in place with the
set screws. See Figure 7-118.

Before tightening the screws, be sure that the

screw holes in the bushings and crankcase are
aligned and that the oil holes in the bushings are
aligned with those leading to the oil gallery in the
crankcase. See Figure 7-119.

Use a wide bushing as the bearing for the rear

section and insert it in the correct direction. Figure 7-119 Checking Bushing and Crankcase Hole
Alignment
7.4.3 Reassembly
108 Nm
1. Installing rear plate. See Figure 7-120. (80 ft. lb.)

a. Apply sealant to rear plate mounting surface of

crankcase and place the gasket in position.
Apply same sealant to the gasket and install the
rear plate to the crankcase.

b. Replace the dowel pins if worn or if the rear

plate has been replaced.
Replace gasket
c. Make sure that the lower end of rear plate is
flush with the bottom of crankcase. Cut excess Figure 7-120 Installing Rear Plate
gasket neatly along the edge of the plate.

2. Rotating the engine. See Figure 7-121.

a. Install bolts (M22 x 1.5) in torsional dampener

mounting holes.

b. Put the bar to crankshaft, using the crankshaft

pulley mounting bolts, and turn the crankshaft
to bring no. 1 cylinder piston to TDC on
compression stroke.

3. Installing idler gear shaft. See Figure 7-122.

Figure 7-121 Rotating Engine
a. Drive the idler gear shaft in using a guide bolt.

b. Tighten the idler gear shaft mounting bolts to

the specified torque.

108 Nm
(80 ft. lb.)

Figure 7-122 Installing Idler Gear Shaft

Figure 7-118 Replacing Camshaft Bushings

62 Section 7 Engine TP-6261 6/04

 4. Installing camshafts. See Figure 7-123.

a. Insert the camshaft into the crankcase and

install the thrust plate. 127 Nm
(94 ft. lb.)
b. Tighten the thrust plate mounting bolts to the
specified torque.

c. Make sure that the camshaft rotates easily.

5. Installing camshaft gear. See Figure 7-124.

Figure 7-124 Installing Camshaft Gear
a. Install the camshaft gear to the camshaft with
the dowel pin entering its hole.

b. Tighten the gear mounting bolts to the specified

torque.

c. Make sure the camshaft rotates easily.

6. Installing fuel injection pump accessory drive. See 108 Nm

Figure 7-125. (80 ft. lb.)

392 Nm
a. Install the injection pump drive gear to the drive (290 ft. lb.)
shaft and tighten the mounting nut to specified
torque.
Figure 7-125 Installing Fuel Injection Pump
b. Fit the O-ring to the mounting flange of drive Accessory Drive
case and install the case to the rear plate.

c. Tighten the drive case mounting bolts to the

specified torque.

7. Installing idler gear.

a. Install idler gear by aligning the matching mark

with those on crankshaft gear, injection pump 29 Nm
gear, and camshaft gear and install the thrust (22 ft. lb.)
plate.
Figure 7-126 Installing Thrust Plate Mounting Bolts
b. Tighten the thrust plate mounting bolts to the
specified torque. See Figure 7-126.
1
c. Align the matching marks on the timing gears 2
as shown in Figure 7-127.

58.8 Nm
(43.4 ft. lb.) 1. Camshaft gear 3. Crankshaft gear
2. Idler gear 4. Injection pump gear

Figure 7-127 Timing Gear Train

Figure 7-123 Torquing Thrust Plate Mounting Bolts

TP-6261 6/04 Section 7 Engine 63

 8. Inspecting and adjusting timing gears after 9. Installing timing gear case.
installation. See Figure 7-128. After installing the
timing gears, inspect and adjust them as follows: a. Coat the oil seal lip with engine oil and insert the
seal into the bore of timing gear case until it is
Inspecting timing gear backlash and end play. flush with end face of case. See Figure 7-131.
After installing the timing gears, inspect backlash
between the gears in mesh and end play of each b. Apply sealant to the timing gear case surface.
gear. See Figure 7-109 and Section 2, Engine Place the gasket in position. Apply the sealant
Overhaul Specifications. on placed gasket. Cut excess gasket neatly
along the bottom surface of the crankcase.
Inspecting valve timing. It is not necessary to
inspect the valve timing provided that all matching c. Replace the dowel pins if worn or if the gear
marks on the timing gears are aligned. Inspect the case has been replaced.
timing for verification as follows:
d. Tighten the gear case mounting bolts evenly to
Using a 2 mm (0.08 in.) feeler gauge, set the the specified torque. See Figure 7-132.
clearance of the intake and exhaust valves of no. 1
cylinder to 2 mm (0.08 in.). Then insert a 0.05 mm TDC
(0.0020 in.) feeler gauge in between the bridge cap
and rocker. Slowly turn the crankshaft trying to find
a position where the feeler gauge is firmly gripped Direction of rotation
(valve starts opening) and where the gauge just
becomes free (valve starts closing). Check to
make sure that these positions coincide with the
angular positions shown in valve timing diagram
with 2 mm (0.08 in.) clearance added to the valves.
See Figure 7-129 and Figure 7-130.
BDC
Figure 7-130 Valve Timing Diagram with 2 mm
(0.08 in.) Clearance Added to Valves

Clearance: 1 mm (0.04 in.), approx.

3
1

2
Figure 7-128 Inspecting Timing Gears

TDC 1. Flush
Intake valve 2. Oil seal
opens 3. Timing gear case
Intake valve
closes Figure 7-131 Oil Seal Lip
Direction of rotation
Exhaust valve
opens
Exhaust valve
closes

BDC

Figure 7-129 Valve Timing Diagram

216 Nm
(159 ft. lb.)

Figure 7-132 Torquing Gear Case Bolts

64 Section 7 Engine TP-6261 6/04

10. Installing fuel injection pump drive. 12. Installing oil pump and oil strainer. Measure the
backlash between crankshaft gear and oil pump
a. Fit the O-ring to the mounting flange of drive drive gear and, if it is not within specifications,
case (to which the drive shaft and gear have make a shim adjustment. See Figure 7-135.
been installed) and install case to the rear plate.
13. Installing oil pan. See Figure 7-136.
b. Tighten the case mounting bolts to specified
torque. See Figure 7-133. a. Apply sealant to the joint surface of oil pan and
place the gasket on the oil pan. Apply the same
11. Installing flywheel. sealant to the gasket and install the oil pan to
the crankcase.
a. Install the flywheel making sure that the dowel
pins enter their holes. b. Tighten the oil pan mounting bolts uniformly to
the specified torque.
b. Coat threads and seats of flywheel mounting
bolts with engine oil and tighten bolts to
specified torque. Inspect the face and radial
runouts of the flywheel. See Figure 7-134.

108 Nm
(80 ft. lb.)
108 Nm
(80 ft. lb.)
Figure 7-135 Installing Oil Pump

Figure 7-133 Fuel Injection Pump Drive

58.8 Nm Replace gasket

(43.4 ft. lb.)
539 Nm
(400 ft. lb.), Figure 7-136 Installing Oil Pan
wet

Figure 7-134 Torquing Flywheel Bolts

TP-6261 6/04 Section 7 Engine 65

7.5 Crankcase, Crankshaft, and Main Bearings

12 2

11
3

4
10

3 6

8 7

1. Crankcase 4. Crankshaft gear 7. Bolt 10. Main bearing (upper shell)

2. Thrust plate 5. Crankshaft 8. Main bearing cap 11. Check valve
3. Slinger 6. Thrust plate 9. Main bearing (lower shell) 12. Piston cooling nozzle

Figure 7-137 Crankcase, Crankshaft, and Main Bearings

66 Section 7 Engine TP-6261 6/04

7.5.1 Disassembly
1. Turning the crankcase upside down. Use a hoist to
lay crankcase on the side. Attach strap or chains to
crankcase and turn it upside down. The crankcase
and crankshaft weight is approximately 1000 kg
(2205 lb.).

2. Removing the main bearing caps.

a. Loosen the cap bolts. Use a cap remover or a

crane (eye bolt M12 x 1.25) to remove the main
bearing caps. See Figure 7-137 and Figure 7-138 Removing Main Bearing Caps
Figure 7-138.
34.3 Nm
b. Remove thrust plates from the no. 7 bearing (25.3 ft. lb.)
cap. Do not damage the thrust plates.

3. Removing the crankshaft.

a. Remove the upper halves of the thrust plates

while rotating the crankshaft slowly.

b. Carefully lift the crankshaft off the crankcase,

keeping it horizontal.
Figure 7-139 Removing Oil Jet Nozzles
c. Remove the rear halves of the thrust plates in
the upper left of the crankcase.

4. Removing the oil jet nozzles. Remove the nozzles

only when the oil holes are clogged or defective.
See Figure 7-139.

Note: Tighten the oil jet nozzle to the specified

torque when reassembling.

7.5.2 Inspection and Repair

Figure 7-140 Measuring Crank Pin Diameter
Crankshaft
Measuring crank pin and journal diameters.

1. Using a micrometer, measure the crank pin and

journal diameters. See Figure 7-140. If the
diameter exceeds the repair limit, grind to the next
lower size:

--0.25 mm (--0.0098 in.)

--0.50 mm (--0.0197 in.)
--0.75 mm (--0.0295 in.)
--1.00 mm (--0.0394 in.).
Figure 7-141 Measuring Journal Diameter
2. Measure the crank pins and journals to determine
the amount of out-of-roundness and taper. See
Figure 7-141.

TP-6261 6/04 Section 7 Engine 67

 3. If the --1.00 mm (--0.0394 in.) undersize journals Generally the rear journal is likely to wear more
and crank pins exceed the repair limit, replace the rapidly than the front journal. This means that
crankshaft. See Section 2, Engine Overhaul replacement of rear thrust plates will generally
Specifications. be sufficient. See Section 2, Engine Overhaul
Specifications.
Grinding DImensions for Undersize
Crankshaft
If the crankshaft is refinished in compliance with any
grinding dimensions to the undersizes of the main
bearing and connecting rod bearing, and if the bearings
are replaced by undersized bearings, it is not necessary
to check the bearing contact pattern. See Figure 7-144.

When grinding crank pins and journals, produce same

fillet radius as original. They should have a hardness of
620 (Vickers hardness number). If necessary, reharden
crank pins and journals and inspect them for cracks by
Figure 7-142 Measuring Thrust Bearing Journal
conducting a magnetic particle test. After grinding,
Length
finish the journals and crank pins to 0.8S.

4. Measuring crankshaft end play. See Figure 7-142

and Figure 7-143.

a. Install the thrust plates in position and secure

the bearing cap. Under this condition, measure
end play. If the end play exceeds the standard
clearance, replace the thrust plates.

b. If the end play still exceeds the repair limit even

after the new thrust plates have been installed,
replace the plates with the next oversize plates.
There are three sizes for the thrust plates: Figure 7-143 Measuring Crankshaft End Play
+0.25 mm (+0.0098 in.)
+0.50 mm (+0.0197 in.)
+0.75 mm (+0.0295 in.)

Item Undersize Finishing Dimension Out of Roundness Taper

0.25 (0.0098) 124.68--124.70 (4.9087--4.9094)
0.50 (0.0197) 124.43--124.45 (4.8988--4.8996)
Crank pin diameter,
diameter mm (in.)
(in )
0.75 (0.0295) 124.18--124.20 (4.8890--4.8898)
1.00 (0.0394) 123.93--123.95 (4.8791--4.8799)
0 01 (0.0004),
0.01 (0 0004) max.
max 0 02 (0.0008),
0.02 (0 0008) max.
max
0.25 (0.0098) 139.68--139.70 (5.4992--5.5000)
0.50 (0.0197) 139.43--139.45 (5.4894--5.4901)
Journal diameter,
diameter mm (in.)
(in )
0.75 (0.0295) 139.18--139.20 (5.4795--5.4803)
1.00 (0.0394) 138.93--138.95 (5.4697--5.4705)

Figure 7-144 Crank Pin Journal Specifications

68 Section 7 Engine TP-6261 6/04

 5. Measuring crankshaft runout. Support crankshaft
1 3
on the journals in V-blocks and measure the runout
2
at the center journal with a dial gauge. Depending
on the amount of runout, repair the crankshaft by
grinding or straightening with a press. If the runout 4
exceeds the repair limit, replace the crankshaft.
See Section 2, Engine Overhaul Specifications,
and Figure 7-146.

6. Replacing the oil seal slinger. Replace the slinger if

it is pitted, scratched, or distorted enough to cause
oil leaks. See Figure 7-147.
1. Front cover 3. Timing gear case
Removing slinger. Use a gear puller to remove 2. Oil seal 4. Oil seal slinger
the slinger from the crankshaft. See Figure 7-148.
Figure 7-147 Oil Seal Slinger
Installing slinger.

a. Discriminate the front slinger from the rear one.

See Figure 7-149.

Note: Install front and rear slingers to the front

and rear sides of crankshaft respectively
or oil leakage will occur.

b. Using an installer, drive slinger heated above

110°C (230°F) onto the crankshaft. See
Figure 7-150.
Figure 7-148 Removing Crankshaft Slinger
c. Drive the rear slinger until it touches the gear.
Drive the front slinger until dimension shown in
Figure 7-149 is obtained.

d. If the installer gets stuck halfway, use a copper

hammer to tap the center or shoulder of the
installer.

Oversizes for Oversizes for

Journal or Journal and
Item Thrust Plates Thrust Plates Tolerance
+0.25 (+0.0098) 66.25
66.50 (2.62)
O.S., mm (in.) (2.6083)
+0.50 (+0.0197) 66.50 +0.030 Figure 7-149 Slinger Position
67.00 (2.64)
O.S., mm (in.) (2.6181) (+0.0012/0)
+0.75 (+0.0295) 66.75
67.50 (2.66)
O.S., mm (in.) (2.6279)

Figure 7-145 Crankshaft Journal Grinding

Specifications

Figure 7-146 Measuring Crankshaft Runout Figure 7-150 Installing Crankshaft Slinger

TP-6261 6/04 Section 7 Engine 69

 7. Replacing the crankshaft gear. Crankcase
Removing Gear. Note the direction of the gear 1. Measuring gasketed surface warpage. Measure
teeth and mark appropriately before removal. Use warpage with a straight edge and feeler gauge. If
a gear puller to remove gear from the crankshaft. warpage exceeds the assembly standard, reface
See Figure 7-148. the gasketed surfaces with a surface grinder. See
Section 2, Engine Overhaul Specifications, and
Note: Do not remove the gear by hitting it with a Figure 7-153.
hammer.
Note: Do not grind the crankcase more than
Installing Gear. See Figure 7-151. necessary to remove warpage. Excessive
grinding can cause the piston protrusion to
a. Before installing the crankshaft gear, measure exceed assembly standard. See Pistons,
the inside diameter of the crankshaft gear to be step 4, on page 49.
sure that the fit is 0.0106--0.171 mm (0.00417--
0.00673 in.). 2. Measuring main bearing bore diameter. Secure
the end bearing cap to the specified torque and
b. Heat the gear to 180°C--200°C (356°F--392°F). measure bore diameter in cross direction. See
Section 2, Engine Overhaul Specifications, and
c. Drive rear crankshaft gear onto the crankshaft Figure 7-154.
by tapping the end face of the gear lightly with a
copper hammer. Be sure the crankshaft dowel
pin enters the notch in the gear.
Scratches, corrosion,
Note: Install the gear to the crankshaft until it wiped overlap
touches the collar. Do not mistake the
direction of gear installation.

Align dowel pin and notch

Figure 7-152 Examining Main Bearings

Figure 7-151 Installing Crankshaft Gear

Main Bearing
Figure 7-153 Measuring Crankcase Gasketed
1. Inspect each bearing shell for abnormal contact Surfaces
such as scratching, corrosion, wiped overlay, etc.
Also check for signs of poor seating in the bore of 490 Nm (360 ft. lb.), wet
the crankcase or bearing cap. See Figure 7-152.

2. Measuring bearing thickness. Measure the center

of each bearing shell using a ballpoint micrometer.
If thickness exceeds service limit on any of upper or
lower shells, replace upper and lower shells as a
set. See Section 2, Engine Overhaul Specifications.

3. Replacing main bearings. If thickness exceeds the

service limit, either replace main bearings as
above, or refinish crankshaft and use undersize
bearings. If crankshaft is refinished in compliance Figure 7-154 Measuring Main Bearing Bore Diameter
with any of the undersizes, it is not necessary to
check the bearing contact pattern.

70 Section 7 Engine TP-6261 6/04

7.5.3 Reassembly 4. Installing main bearing caps. See Figure 7-157.

1. Installing the main bearing. See Figure 7-155. a. Fit lower shell of the bearing to each bearing
cap.
a. Install each upper shell of the main bearing in
the crankcase by fitting the locking lip in the b. Install the thrust plates to the no. 7 bearing cap
recess. The oil holes in bearings and with the oil groove side of the plates facing out.
crankcase will be aligned when bearings are
installed in this way. c. From the front side of the crankcase, bearings 1
to 7 are stamped on the caps. Install the caps
b. Lightly coat the inside surface of the shells with with these numbers on front of crankcase.
engine oil.
d. Coat the threads of the bearing cap bolts with
2. Installing thrust plates. See Figure 7-156. engine oil and temporarily install the bolts.

a. Install the thrust plates to the no. 7 bearing seat e. Use a soft hammer to evenly drive in bearing
of the crankcase with the oil groove side of the caps.
plates facing out.
5. Installing bearing cap bolts. See Figure 7-158.
b. After installing the crankshaft, install the inner
thrust plate with the oil groove facing inside the a. Temporarily tighten the bearing cap coated with
crankcase. engine oil. Tighten the four bolts alternately to
the specified torque.
3. Installing the crankshaft.
b. Make sure that the crankshaft rotates smoothly.
a. Wash the crankshaft with cleaning solvent and
dry it by applying a blast of pressurized air.
1
Note: After washing the crankshaft, make sure
the oil holes are clean and not clogged.

b. Use a hoist to hold crankshaft horizontally and

carefully put it on the crankcase.
2
c. Lightly coat the journals with engine oil.

1. FRONT mark
2. Cylinder no. 1-7

Figure 7-157 Installing Main Bearing Caps

1. Lug groove

Figure 7-155 Installing Main Bearings 490 Nm

(360 ft. lb.),
wet

Figure 7-158 Torquing Main Bearing Cap Bolts

Figure 7-156 Installing Thrust Plates

TP-6261 6/04 Section 7 Engine 71

 6. Measuring crankshaft end play. See Figure 7-159.

a. Tighten no. 1 through no. 6 bearing cap bolts,

mounting bolts to specified torque, with no. 7
cap bolt temporarily tightened, and measure
the end play.

b. After tightening the no. 7 cap bolts, make sure

end play is correct.

c. Confirm that all cap bolts are tightened to the

specified torque. See Section 2.2, Tightening
Torques. Figure 7-159 Measuring Crankshaft End Play

72 Section 7 Engine TP-6261 6/04

 Section 8 Intake and Exhaust Systems

8.1 Description 8.2 Air Cleaner

This section covers the air intake and exhaust systems. Note: When removing the air cleaner for service, stop
See Figure 8-1 for an overall view. See Figure 8-2 for a the engine and cover the air intake port to prevent
typical air cleaner assembly and Figure 8-3 for the air dirt from entering the engine.
cooler components.

1
5
6
1
4 2

2
3

5
2
4 3

1. Cover 3. Element 5. Distortion, damage

2. Wing nut 4. Air cleaner body 6. Dust indicator

Figure 8-2 Air Cleaner, Typical

1. Exhaust duct 3. Air heater 5. Air intake
2. Air cooler 4. Turbocharger

Figure 8-1 Air Intake/Exhaust System

8.3 Air Cooler

8.3.1 Disassembly

Fill space between

element and plates with
silicone sealing compound
1
2
3
1

Replace gasket

Every 2000 hours; clean element

1. Gasket 3. Element
2. Plate 4. Air cooler case

Figure 8-3 Air Cooler Components

TP-6261 6/04 Section 8 Intake and Exhaust Systems 73

8.3.2 Inspection 8.4 Exhaust Manifold
1. Cleaning air coolers.
The exhaust system is shown in Figure 8-4.
a. Remove dirt buildup from air cooler by directing
high pressure air of 296.5--489.5 kPa (43-- Note: Place each gasket with the MANIFOLD mark on
71 psi) maximum in the direction opposite to air the exhaust manifold side. If one of the gaskets
flow. Inspect the cooler for corrosion and requires replacement, replace all the cylinder
cracks. gaskets at the same time.

b. Wash the water pipes in water and caustic soda

lime to remove scale deposits.

2. Inspecting air coolers for air tightness. Immerse

the air cooler in water and apply high pressure air of
393 kPa (57 psi) to the coolant side to inspect for air
leaks.

2 3 4 5
Replace gasket

Cracks, damage,
distortion

1. Insulator 4. Exhaust manifold

2. Flexible joint 5. Gasket
3. Coupling

Figure 8-4 Exhaust System

74 Section 8 Intake and Exhaust Systems TP-6261 6/04

 Section 9 Lubrication System

9.1 General Description

This section covers the lubrication system. See
Figure 9-1 for an illustration of the lubrication system.

2 3
1 4

5
20
6
19

18 8

17 10
15 13
16 14 12 11

1. Piston 5. Oil thermostat 9. Injection pump 13. Oil strainer 17. Crankshaft
2. Rocker shaft 6. Oil cooler 10. Oil pump 14. Oil filter 18. Water pump
3. Turbocharger 7. Timing gear 11. Safety valve 15. Filter bypass 19. Fan drive
4. Camshaft 8. Governor 12. Bypass oil filter 16. Relief valve 20. Oil jet

Figure 9-1 Lubrication System Components

9.2 Oil Pump and Safety Valve

9.2.1 Disassembly
Note: Before removing the gears, measure backlash of
each pair of gears. If the measurement exceeds
the service limit, replace the gears.

9.2.2 Inspection
1. Inspecting oil pump gear backlash. If the backlash Figure 9-2 Measuring Pump Gear Radial
exceeds the service limit, replace the gears. See Clearance
Section 2, Engine Overhaul Specifications.

2. Measuring pump gear radial clearance. Using a

feeler gauge, measure the radial clearance. If the
clearance exceeds the service limit, replace the
gears or case, whichever is badly worn. See
Section 2, Engine Overhaul Specifications, and
Figure 9-2.

TP-6261 6/04 Section 9 Lubrication System 75

 5

6
3
4

3
2

9
1 3
10

11

13
12

1. Support 4. Oil pump case 7. Idler gear 10. Oil pump cover 12. Oil strainer
2. Drive gear 5. Oil pump gear 8. Nut 11. Safety valve 13. Oil pipe
3. Bushing 6. Spindle 9. Driven gear

Figure 9-3 Oil Pump Components

3. Measuring oil pump gear end clearance. Using a

dial gauge, measure end clearance. If the
clearance exceeds service limit, replace the gears
or case, whichever is badly worn. See Figure 9-4
and Section 2, Engine Overhaul Specification.

4. Measuring drive and driven gear shaft and bushing

diameters. See Figure 9-5.

a. Check the gear teeth and replace gears, if

defective.
Figure 9-4 Measuring Oil Pump Gear Clearance
b. If diameter exceeds the service limit, replace
the gears. Nominal Standard Service
Item Value Clearance Limit
5. Measuring spindle diameter and idler gear bushing Spindle diameter, 24.947--24.960 24.900
inside diameter. Measure spindle diameter and the mm (in.) (0.98216--0.98268) (0.98031)
25 (0.98)
(0 98)
inside diameter of bushing to determine clearance. Bushing, inside 25.000--25.021 25.100
diameter, mm (in.) (0.98425--0.98508) (0.98819)
If clearance exceeds the service limit, replace the
bushing. See Figure 9-5. Figure 9-5 Oil Pump Specifications

76 Section 9 Lubrication System TP-6261 6/04

 6. Replacing oil pump bushings.

a. Use oil pump bushing tool to remove bushings.

If it is difficult to remove the bushings, replace
the bushings and related parts as an assembly.
See Figure 9-6.

b. The press-in depths of the bushings are shown

in Figure 9-7.

c. After installing each bushing, ream the inside

diameter to 25H7 mm [+0.0021/0 oversize]
(0.98H7 in. [+0.00083/0 oversize]).

d. When installing bushings to the oil pump case Figure 9-7 Bushing Press-In Depths
and pump cover, align the bushing ends with oil
grooves. See Figure 9-8.

7. Inspecting the safety valve.

a. Replace valve spring if it is fatigued, worn, or

broken. See Figure 9-5.

b. Adjusting backlash between crankshaft gear

and oil pump idler gear. After installing the oil
pump to the crankcase, measure the backlash.
If the measurement exceeds the assembly
standard, adjust the backlash by inserting
shim(s). See Figure 9-5 and Figure 9-9.
Figure 9-8 Installing Oil Pump Case Bushings
9.2.3 Reassembly
See Figure 9-10 and Figure 9-11 for oil pump
reassembly.

Note: Coat pump parts with engine oil before assembly.

Apply a thick coat of engine oil to the threads and
seating faces of nuts (except for flange nuts) and
bolts before assembly.

1
108 Nm
(80 ft. lb.)

Figure 9-9 Adjusting Crankshaft Backlash

1. Oil pump bushing tool

Figure 9-6 Replacing Oil Pump Case Bushing Figure 9-10 Reassembling Sequence

TP-6261 6/04 Section 9 Lubrication System 77

 (gear)
Backlash: (bushing)
0.087--0.316 mm
(0.0034--0.0124 in.)

68.6 Nm
(50.6 ft. lb.)

33 ±6.7 Nm
(24.59 ±6.67 ft. lb.)
Backlash:
0.10--0.20 mm
After degreasing nut and (0.0039--0.0079 in.)
spindle apply LOCTITEr 262
to threads and tighten to the Section A-A
specified torque.

Figure 9-11 Oil Pump Reassembly

9.3 Relief Valve

9.3.1 Disassembly
See Figure 9-12 for relief valve components.

8
7 2
6
5
4

3
1. Pressuring adjusting shim 3. Oil pipe, O-ring 5. Spring 7. Sleeve
2. Drain from main bearing 4. Stopper 6. Relief valve 8. Plate

Figure 9-12 Relief Valve Components

LOCTITEr is a registered trademark of Henkel Loctite.

78 Section 9 Lubrication System TP-6261 6/04

9.3.2 Inspection 9.3.3 Reassembly
Testing relief valve setting. See Figure 9-13. To reassemble, follow the disassembly sequence in
reverse. Install new O-rings during reassembly.
1. Remove the taper plug at the top of oil filter bracket
and attach a pressure gauge.

2. Warm up the engine until the oil temperature rises

to 70°C--90°C (158°F--194°F).

3. Measure the engine oil pressure at no load and at

full load.

4. If the relief valve setting is below the assembly

standard, remove the oil pipe, and adjust the
setting by inserting shims into between the oil pipe
and spring. See Figure 9-14. Figure 9-13 Testing Relief Valve Setting
Note: Oil pressure may rise beyond assembly Item Assembly Standard
standard when oil temperature is low but will
Relief valve setting, at
come down to assembly standard as the 0.49--0.64 MPa (71.1--92.4 psi)
maximum speed
temperature rises. Relief valve opening pressure 0.41 MPa (59.7 psi)

5. If the setting does not vary after adjustment has Figure 9-14 Relief Valve Specifications
been made, replace the relief valve and spring.

9.4 Oil Cooler and Oil Thermostat

9.4.1 Disassembly
Note: Replace the gaskets and O-rings with new
components at reassembly.

Clogging, rupture, cracks

Replace O-ring

Replace gasket

Figure 9-15 Oil Cooler and Oil Thermostat

TP-6261 6/04 Section 9 Lubrication System 79

9.4.2 Inspection 9.4.3 Reassembly
1. Inspecting oil cooler element. Test the element for To reassemble, follow the disassembly sequence in
tears or other defects by applying an air pressure of reverse.
1.5 MPa (213 psi) and replace it if leakage occurs.
1. Install new gaskets and O-rings during
2. Inspecting oil thermostat. See Figure 9-16. reassembly.

a. Inspect the oil thermostat seal for deterioration 2. Clean oil passages in the oil cooler cover and other
or tears and replace, if defective. parts with cleaning solution. Blow compressed air
to remove dust and cleaning solution before
b. Install the seal correctly as shown. reassembly.
3. Testing oil thermostat. Place the thermostat in a
water tub and test for thermostat action by heating 9.5 Oil Filters
the tube to raise the water temperature. In the test,
measure the temperature at which the valves starts The oil filter components are shown in Figure 9-18.
opening and at which the valve lift is more than
10 mm (0.39 in.). If temperature measurements
are out of assembly standard, replace thermostat. 9.5.1 Disassembly
See Section 2, Engine Overhaul Specifications, See Figure 9-18 for the oil filter components.
and Figure 9-17.

Note: Stir the water in the tub with a stick to 1

maintain its temperature uniform during test.
Be sure to place each thermostat in correct
position by ascertaining the valve opening
temperature stamped on the side face of the
thermostat valve at reassembly. Clogging, cracks
5 Every 250 hours, replace

4 2

3
3
1. Thermostat
1. Oil filter alarm 4. Oil filter (cartridge type)
2. Bypass filter 5. Filter bracket
Figure 9-16 Oil Thermostat Valve 3. Full-flow filter

Figure 9-18 Oil Filter Components

Figure 9-17 Testing Oil Thermostat Valve

80 Section 9 Lubrication System TP-6261 6/04

9.5.2 Inspection
1. When replacing paper element, investigate by
sampling about 500 cm3 (30.5 in.3) of the oil. If any
metallic particles or other foreign matter is found,
unfold the pleats or the removed element and
inspect the element for colors and shapes of 1
1. Shim
metallic particles trapped in the pleats to locate the
cause. See Figure 9-19. Figure 9-20 Oil Pressure Sensor

2. Inspecting oil pressure sensor. Item Assembly Standard

Oil sensor pressure 1.5 MPa (21.3 psi)
a. Using a tester, test the sensor for insulation and
continuity. Disassemble and repair sensor, if Figure 9-21 Oil Pressure Sensor Specifications
defective with respect to insulation or
continuity. Replace sensor if the resin and
9.5.3 Reassembly
rubber insulators are deteriorated or damaged.
See Figure 9-20. To reassemble, follow the disassembly sequence in
reverse.
b. If the valve opening pressure is out of the
assembly standard, adjust it by inserting shims. 1. Install new gaskets and O-rings during
A 1 mm (0.04 in.) shim thickness corresponds reassembly.
to a change in pressure of 1.5 MPa (1.00 psi).
See Figure 9-21. 2. Clean oil passages in the oil filter bracket and other
parts with cleaning solution. Blow compressed air
to remove dust and cleaning solution before
reassembly.

3. Mount the oil filter element on the bracket before

installation.

Figure 9-19 Oil FIlter Inspection

TP-6261 6/04 Section 9 Lubrication System 81

 Notes

82 Section 9 Lubrication System TP-6261 6/04

 Section 10 Cooling System

10.1 Cooling System

1
See Figure 10-1 for the cooling system. 2

10.2 Water Pump 6

3
Figure 10-2 shows the water pump components.

4
5

1. Thermostat 4. Oil cooler

2. Water outlet (locker case) 5. Water pump
3. After cooler 6. Radiator

Figure 10-1 Cooling System with Radiator

6 4

7
2
6
5
4
3
Wear, damage,
2 deterioration of lip
1
Rotation
Wear, damage

Wear, damage,
deterioration of lip

5
8
9
10 Corrosion, feathering
11 due to rubbing
Wear, damage
of belt groove

Corrosion, cracks, damage

12

1. Nut, washer 4. Oil seal 7. Water pump shaft 10. Impeller

2. Water pump pulley, key 5. Snap ring 8. Cover 11. Unit seal
3. Spacer, O--ring 6. Bearing 9. O--ring 12. Water pump housing

Figure 10-2 Water Pump Components

TP-6261 6/04 Section 10 Cooling System 83

10.2.1 Disassembly
1. Inspecting the wear pump on engine. Check the
drain port located at the bottom center of pump. If
the port contains fluid, inspect the condition of the
unit seal. If it contains fluid, the oil seal is defective.
See Figure 10-3.

2. Removing the impeller.

a. Remove the snap ring and cover from the rear

of the water pump. See Figure 10-4. Figure 10-3 Touching Drain Port

b. Using a puller, remove the impeller from the

shaft. See Figure 10-5. 1

3. Removing water pump shaft. Remove the snap

ring from the front bearing. Using a press or soft
hammer, drive out the pump shaft assembly with
the bearing toward the gear side. Be careful not to
damage the water pump shaft and impeller during 2
removal of the impeller from the shaft. 3
1. Puller
2. Cover
10.2.2 Inspection 3. Snap ring
Using a cylinder gauge, measure inside diameter of the Figure 10-4 Removing Water Pump Snap Ring
pump case bore to which the bearing outer race is fitted.
If the case is excessively worn or damaged, replace the 3 1
case and/or bearing. See Section 2, Engine Overhaul
Specifications, for specifications.
2

1. Impeller remover
2. Shaft
3. Impeller

Figure 10-5 Removing Water Pump Impeller

84 Section 10 Cooling System TP-6261 6/04

10.2.3 Reassembly
See Figure 10-6 for the reassembling sequence and
Figure 10-7 for an illustration of the assembled water Figure 10-6 Reassembling Sequence
pump.

Note: Replace O--rings, oil seals, and unit seal during

reassembly. Install the ball bearings to the pump
shaft with their side plates on the oil seal side.

245 Nm
(181 ft. lb.)

Flush

Apply grease to lubricate seal lip.

Apply sealant to outside surface of
unit seal.
Apply antifreeze solution to floating
portion of unit seal at two places when
pressing the seal into impeller

Figure 10-7 Water Pump Assembled

TP-6261 6/04 Section 10 Cooling System 85

10.3 Thermostats
See Figure 10-8 for thermostat components.

1 Deteriorated, worn,
2 cracked
3
4
5

Replace gasket

Worn, cracked

1. Case cover 3. Snap ring 5. Thermostat seal

2. Gasket 4. Thermostat 6. Thermostat case

Figure 10-8 Thermostat Components

10.3.1 Disassembly Assembly

Item Standard, °C (°F)
Temperature where valve should
10.3.2 Inspection 69--73 (156.2--163.4)
start opening
Valve lift of 11 mm (0.43 in.)
Place the thermostat in a water tub and test it by heating 83--87 (181.4--188.6)
minimum
water to raise water temperature. Test the temperature
where the valve should start opening and where the Figure 10-9 Thermostat Specifications
valve shaft should be; 11 mm (0.43 in.) or more. If valve
falls to operate properly, replace the thermostat. See
Figure 10-9 and Figure 10-10.

Note: Stir heated water during test to maintain an even

temperature.

During reassembly, confirm that the temperature value

stamped on the thermostat mounting flange matches
specifications. Some thermostats have a notch or arrow
indicating the correct mounting position.
Figure 10-10 Testing Thermostat

86 Section 10 Cooling System TP-6261 6/04

10.4 Radiator 2. Check the rubber hose and hose clamp. Replace if
damaged or deteriorated.
1. Inspect radiator for dirt, scale, or rust in water
passages. Clean, if necessary. See Figure 10-11.

Figure 10-11 Radiator Components

TP-6261 6/04 Section 10 Cooling System 87

10.5 Fan Drive If the bearing inner race is fitted. If the bearing,
shaft, or bracket is worn, replace it.

10.5.1 Disassembly 2. Check the fan bushing for wear and damage and
replace if anything abnormal is found.
Note: If one fan blade is broken, the fan will vibrate
excessively making the opposite blade fragile. 3. Check the friction rubber for deterioration, cracks,
Keeping this in mind, carefully inspect each blade or damage. Replace it if necessary. See Section 2,
for cracks and distortion. See Figure 10-12. Engine Overhaul Specifications.

4. Inspect the fan bushing for wear or damage, and

10.5.2 Inspection
replace it if defective.
1. Measure inside diameter of the bracket to which
the bearing outer race is fitted. Measure diameter 5. Inspect the friction rubber for deterioration, fatigue,
of the shaft to which the bearing inner race is fitted. cracks or other defects, and replace it if defective.

3 4
1
2

12

6 5
7
15
16 11 3

1
8
9
13
12

10
11

1. Bearings 5. Camshaft gear 9. Sleeve 13. Spacer, grommet

2. Snap ring 6. Gasket 10. Bushing 14. Fan
3. Fan drive gear, key 7. Fan drive case 11. Friction rubber 15. Camshaft gear
4. Nut, washer 8. Oil seal 12. Plate 16. Fan drive shaft

Figure 10-12 Fan Drive Components

88 Section 10 Cooling System TP-6261 6/04

10.5.3 Reassembly

Apply engine oil

to oil seal lip
108 Nm (80 ft. lb.)

392 Nm (289 ft. lb.)

108 Nm (80 ft. lb.)

Figure 10-13 Fan Drive Reassembly

Figure 10-14 Reassembly Sequence

TP-6261 6/04 Section 10 Cooling System 89

 Notes

90 Section 10 Cooling System TP-6261 6/04

 Section 11 Fuel System

11.1 Description
See Figure 11-1 for the fuel system components. Cracks,
damaged
threads

1 2
1

Replace
3 every
1000 hours
2

4
6
1. Fuel filter bracket
5 2. Element

Figure 11-2 Fuel FIlters

1. Injection nozzle 4. Injection pump
2. Leakoff pipe 5. Feed pump
3. Return pipe 6. Fuel filter Air vent plug
7.8--9.8 Nm
Figure 11-1 Fuel System Components (5.8--7.8 ft. lb.)
Apply
fuel oil

11.2 Fuel Filters

11.2.1 Disassembly and Inspection

See Figure 11-2 for fuel filters.

11.2.2 Reassembly
See Figure 11-3 and Figure 11-4 for the fuel filter
reassembly. To install the cartridge, clean the mounting
surface and apply fuel oil to the gasket. After bringing
the gasket into contact with the sealing surface of the Figure 11-3 Fuel Filter Assembly
bracket, manually tighten cartridge approximately 1/2--
3/4 turn.

Note: After installing the fuel filter on engine, start the

engine and verify that the filters are not leaking. Figure 11-4 Reassembly Sequence

TP-6261 6/04 Section 11 Fuel System 91

11.3 Fuel Injection Nozzles

11.3.1 Disassembly
See Figure 11-6 for the fuel system nozzle components.
9
1
11.3.2 Inspection and Adjustment
4 2
WARNING
8
3
7

Avoid high pressure fluids. 6

Can cause severe injury or death.
5
Do not work on high pressure fuel or
hydraulic systems without protective
gloves. Avoid the hazard by relieving 4
pressure before disconnecting fuel
injection pressure lines. Search for 1. Fuel inlet connector
leaks using a piece of cardboard. 2. Cap nut, gasket
Always protect hands and body from 3. Adjusting screw
high pressure fluids. If an accident 4. O-ring
occurs, seek medical attention 5. Retaining nut
immediately. Any fluid injected in the 6. Nozzle tip
skin tissues must be surgically 7. Spacer
8. Pushrod, nozzle spring, spring seat
removed within a few hours or 9. Nozzle holder
gangrene may result.
Figure 11-6 Fuel Injection Nozzle Components
1. Injection pressure.

a. Install the nozzle on tester. Operate the handle

2
of the tester at a rate of about 1 stroke/second
to observe the pressure at which fuel is being
injected. If pressure is out of standard, adjust
nozzle pressure. See Figure 11-5 and
Figure 11-7.

b. To adjust the injection pressure, remove the

cap nut from the nozzle holder, loosen jam nut,
and turn the adjusting screw in either direction
1. Tester
with a screwdriver. See Figure 11-8.
Figure 11-7 Injector Spray Pattern
c. After completing adjustment, tighten the jam
nut and cap nut to the specified torque.

d. Recheck the injection pressure to be sure it is 39--49 Nm

(29--36 ft. lb.)
correct.
1
Increase
Assembly injection
Decrease
Item Standard, MPa (psi) pressure
injection
Injection pressure (valve opening pressure 2
34.3--34.8 (4977--5048)
pressure)

Figure 11-5 Fuel Injection Pressure Specifications

1. Cap nut
2. Adjusting screw

Figure 11-8 Fuel Injector Pressure Adjustment

92 Section 11 Fuel System TP-6261 6/04

 2. Spray pattern. See Figure 11-9. Note: New nozzle tips are coated with
petroleum jelly to preserve them. Wash
a. When testing injection pressure, inspect each them twice, first in gasoline and then in
nozzle for clogged spray holes and fuel leaks diesel fuel before you install them.
from the holes. Also examine the spray pattern.
If nozzle is faulty, wash or replace nozzle tip.
11.3.3 Reassembly
b. When tested on the nozzle tester, the nozzle
should spray fuel from ten holes at the same For reassembly, see Figure 11-12 and Figure 11-13.
time in a straight cone of 160 degrees. The
Note: Tighten the retaining nut only as far as the
spray should consist of finely atomized fuel
specified torque. If there is excessive torque on
particles without any large droplets. The spray
the retaining nut, the needle will not operate
should terminate with no dripping at the tip.
smoothly causing discoloration of exhaust gas
3. Washing or replacing the nozzle tip. and sticking. See Figure 11-10.

a. The nozzle tip is spring loaded. Remove cap

nut and use a screwdriver to loosen adjusting
screw until it can be loosened by hand.

b. Loosen the retaining nut, remove the nozzle tip, 1 2

and wash the needle valve and body. See
Figure 11-10.

Note: When pulling the nozzle tip out, do not 1. Needle valve
2. Body
damage the tip.
Figure 11-11 Cleaning Nozzle Tip
c. Wash the nozzle tip in clean cleaning oil. After
washing, assemble the needle valve and body
in clean diesel fuel. 34--44 Nm
(25--32 ft. lb.)
Note: The needle valve and body are finely 38--49 Nm
finished and should be treated as a (28--36 ft. lb.)
matched set. Do not change combination
of valve and body. See Figure 11-11.

d. Tighten the retaining nut to specified torque.

64--74 Nm
e. If the spray pattern is still bad after the nozzle (47--54 ft. lb.)
has been adjusted and cleaned, replace the
nozzle tip.

177--196 Nm
Good Large angle After drip Intermittent Whirling (130--145 ft. lb.)

Figure 11-9 Spray Pattern Comparison

2
Figure 11-12 Fuel Injector Nozzle Assembly

Figure 11-13 Reassembly Sequence

1. Tip 2. Retaining nut

Figure 11-10 Removing Nozzle Tip

TP-6261 6/04 Section 11 Fuel System 93

11.4 Fuel Injection Pump Drive 11.4.2 Inspection
Rotate each bearing to check for rotation. Replace a
11.4.1 Disassembly bearing that fails to rotate smoothly. Check fit of
bearings on drive shaft and idler shaft. Replace badly
See Figure 11-14 for fuel injection pump drive
worn shaft or bearings. Check the fit of bearings in the
components.
drive case and replace a worn part. See Section 2,
Engine Overhaul Specifications.

5
4

7
11
3 9

10
2
7 6
1 8

9
7

1. Fuel injection pump 4. O-ring 7. Snap ring 10. Washer, bolt

2. Gasket 5. Idler gear 8. Drive shaft 11. Idler shaft
3. Drive case 6. Drive gear 9. Bearings

Figure 11-14 Fuel Injection Pump Drive Components

94 Section 11 Fuel System TP-6261 6/04

11.4.3 Reassembly
See Figure 11-15 and Figure 11-16 for fuel injection
pump drive reassembly. Figure 11-15 Reassembly Sequence

1. Using the turning gear, turn engine until one tooth

of the ring gear aligns with the center of the pickup
mounting hole. See Figure 11-17.

2. Gently turn the pickup. When the tip of the pickup

contacts the tooth of ring gear, unscrew the pickup Shrinkage fit
at 200°C
slightly by turning 1/4 turn and secure it in position (392°F)
using the locknut. maximum

Backlash
0.12--0.18 mm
(0.0047--
0.0071 in.)

Shrinkage fit
at 200°C
(392°F)
maximum

108 Nm
(80 ft. lb.)

Figure 11-16 Fuel Injection Pump Drive Assembly

3
1. Timing gear case
2. Locknut
3. Ring gear (193 teeth)

Figure 11-17 Magnetic Pickup Adjustment

TP-6261 6/04 Section 11 Fuel System 95

 Notes

96 Section 11 Fuel System TP-6261 6/04

 Section 12 Electrical System

12.1 Starter 2. Unscrew the through bolts and brush holder

mounting screws and remove the rear bracket.
See Figure 12-3 for starter motor components. See Figure 12-2.

12.1.1 Disassembly
1. Remove the lead wire and starter solenoid. See
Figure 12-1.

Figure 12-2 Removing Starter Motor Through Bolts

Figure 12-1 Removing Starter Solenoid

1 2

9 10
3 4 5
6

8
7

1. Lever assembly 4. Yoke assembly 7. Armature assembly 9. Pinion clutch assembly

2. Starter solenoid 5. Brush hold assembly 8. Front bracket 10. Pinion case
3. Center bracket 6. Rear bracket

Figure 12-3 Starter Motor Components

TP-6261 6/04 Section 12 Electrical System 97

 3. Remove brushes from the brush holder assembly
and remove the yoke. See Figure 12-4.

4. Pull out the armature assembly. See Figure 12-5.

5. Remove the center bracket. See Figure 12-6.

6. Remove the lever pin, inner housing, and shift lever

from the pinion case. See Figure 12-7.

7. Using a jig, remove pinion stopper and overrunning

clutch from the pinion shaft. See Figure 12-8.
Figure 12-8 Removing Pinion Stopper and Clutch
Note: To remove shaft bearing for replacement,
use a bearing puller like the one shown in
Figure 12-9.

Figure 12-4 Removing Brushes Figure 12-9 Pinion Shaft Bearing Puller

12.1.2 Inspection and Repair

Starter Solenoid
1. Testing the starter solenoid coil.

a. Test pressure coil and holding coil for an open

Figure 12-5 Removing Armature circuit. The coils are open-circuited if there is
no continuity between M terminal of the starter
solenoid and the case.

Resistance: 1.16 ohms (approximate)

b. Apply voltage of 24 volts between M terminal of

starter solenoid and case. Now push plunger in
by hand. When you release, the plunger should
not be attracted.
Figure 12-6 Removing Center Bracket
2. Testing starter switch contact points. Measure the
load current flowing through starter. If the voltage
drop between terminals B and M exceeds 0.3 volts/
100 amperes, clean or replace the contact points.

Note: If the starter switch is turned to OFF during

voltage measurement, the battery voltage is
directly applied to the voltmeter. This can
damage the voltmeter. Always turn the
Figure 12-7 Removing Lever Pin starter switch to ON before measuring the
voltage and turn it OFF after measuring the
voltage. Under no circumstances should
only the starter solenoid be tested.

98 Section 12 Electrical System TP-6261 6/04

Armature Brushes
1. Measuring the armature shaft for runout. Measure 1. Inspecting for wear. If the brushes are unevenly
runout with a dial gauge. If the runout exceeds the worn or roughened, recondition them. See
assembly standard, repair or replace the armature. Figure 12-14 and Section 2, Engine Overhaul
See Figure 12-10 and Figure 12-11. Specifications.

2. Inspecting the commutator. 2. Testing brush spring tension. See Section 2,

Engine Overhaul Specifications.
a. Check condition of the commutator surface. If
rough, polish with #400--#600 sandpaper. Assembly Service
Check commutator for runout with a dial gauge. Item Standard Limit
Replace the commutator if the runout exceeds Armature shaft 0.05
—
the service limit. See Section 2, Engine runout, mm (in.) (0.0020)
Overhaul Specifications. Figure 12-10 Starter Motor Specifications
b. Measuring the mica depth. Use a depth gauge
to measure the depth of each mica undercut. If
the depth exceeds the repair limit, recondition
the mica. See Figure 12-12 and Section 2,
Engine Overhaul Specifications.

3. Testing the armature.

a. Use a Meggarr to test the armature for short Figure 12-11 Measuring Armature Shaft Runout
circuits. If a short circuit exists, replace or
repair the armature.

b. If there is continuity between the commutator

and shaft, replace or repair the armature.

Field Coil
Testing for open circuits. If there is no continuity
between the M terminal of the field coil and the lead wire
Figure 12-12 Measuring Mica Depth
on the brush side, replace the field coil.

Overrunning Clutch
The clutch is in good condition if it rotates freely in one
direction when turned by hand. Check the pinion teeth
for wear or damage. If they are damaged, replace the
pinion. See Figure 12-13.

Note: Do not immerse the overrunning clutch in Figure 12-13 Testing Overrunning Clutch
cleaning solvent to clean it. Immersion in
cleaning solvent will cause grease inside the
clutch to run out, causing clutch parts to seize
when operating.

Figure 12-14 Brush Wear Limits

Meggarr is a registered trademark of Biddle Instruments.

TP-6261 6/04 Section 12 Electrical System 99

12.1.3 Reassembly
Use the illustration in Figure 12-15 and Figure 12-20 to
assemble the starter motor.

1. Install the center bracket, overrunning clutch, and

pinion stopper to the pinion shaft. Insert the shaft in
position by tapping it with a plastic hammer. See
Figure 12-16.

2. Install the shift lever and pinion shaft to the front Figure 12-17 Installing Shift Lever and Pinion Shaft
bracket by aligning the matching mark on the shift
lever. See Figure 12-17.

3. Install the armature and yoke to the center bracket,

making sure that the dowel pin enters its hole. See
Figure 12-4.

4. Install the brushes and brush holders. See

Figure 12-18.

Note: Install the positive (+) side brush and

negative (--) side brush as shown. See
Figure 12-19. Figure 12-18 Installing Brushes

Figure 12-15 Reassembly Sequence

Figure 12-19 Installing Side Brushes

Figure 12-16 Installing Shaft

Figure 12-20 Starter Motor Reassembly Order

100 Section 12 Electrical System TP-6261 6/04

 5. Install rear bracket to yoke by aligning the matching
marks. Secure brush holders with bolts and tighten
the through bolts. See Figure 12-21.

6. Measure the end play of the armature. If the end

play exceeds the assembly standard, adjust it on
the rear side. Test the motor to make sure that the
voltage is below 24 volts and the current below
90 amperes. See Figure 12-10 and Figure 12-22.

7. Liberally coat the internal gear with grease and Figure 12-21 Aligning Rear Bracket and Yoke Marks
install the pinion shaft to the gear.

8. Measure the end play of the pinion shaft. If the end

play exceeds assembly standard, adjust it on the
internal gear side. See Figure 12-10.

9. Install the starter solenoid. Apply a voltage of

24 volts between the C and E terminals. Connect
the lead wire and energize the circuit between the
M and E terminals (within 1 sec.). After the pinion
has shifted, measure how much the pinion returns.
If measurement is not 1.5--5 mm (0.06--0.20 in.), Figure 12-22 Measuring Armature End Play
use the starter solenoid adjusting screw to make
adjustments. See Figure 12-1.
12.2 Engine Alternator
10. Secure the lead wire.
See Figure 12-23 for engine alternator components.

Dirty, burned slip rings, worn oil 3

seal contact surface of shaft
Rotation
2

4
Rotation

7
Brush movement
9
10
8

1. Screw 5. Rear bracket 8. Stator

2. Front bracket assembly 6. Rectifier assembly 9. Pulley
3. Rotor assembly 7. Regulator assembly 10. Nut, washer
4. Nut set

Figure 12-23 Engine Alternator Components

TP-6261 6/04 Section 12 Electrical System 101

12.2.1 Disassembly

12.2.2 Inspection and Repair

1. Stator. See Figure 12-24.

a. Testing the stator coil for open circuits. If there

is no continuity among the four lead wires, Figure 12-24 Testing Stator
replace the stator.

b. Testing the stator coil for grounding. If there is

continuity between the coil and core, replace
the stator.

2. Rotor. See Figure 12-25.

a. Testing the rotor coil for open circuits. If there is

no continuity between the slip rings, replace the
rotor. Figure 12-25 Testing Rotor

b. Testing the rotor coil for grounding. If there is

continuity between the slip rings and shaft (or
core), replace the rotor.
18.5
c. Using calipers, measure the outside diameter (0.728)
Wear
of each slip ring. If the diameter exceeds the limit line 7.0 (0.28)
service limit, replace the slip ring. See
Section 2, Engine Overhaul Specifications.
Figure 12-26 Inspecting Brush Wear
3. Brushes.
Trio-diodes
a. Inspecting for wear. See Section 2, Engine Heat sink (--)
Overhaul Specifications, and Figure 12-26.

b. Testing spring tension.

4. To check individual diodes, measure resistance

between diode lead wire and heat sink. Connect
the positive (+) test lead wire to diode and measure
resistance. Then, connect negative (--) test lead
wire to the diode to measure resistance again. If Heat sink (+)
Diode lead wires
both measured values are infinite, diode circuit is
open. If both measured values are close to 0, the Figure 12-27 Inspecting Rectifier Diodes
circuit is shorted. If the diode has an open circuit or
is shorted, it is defective and the rectifier must be
replaced. See Figure 12-27.

102 Section 12 Electrical System TP-6261 6/04

12.2.3 Reassembly
Use Figure 12-28 and Figure 12-29 to assemble the
engine alternator. Figure 12-29 Reassembly Sequence
Use a wire to install the brushes in the brush holder as
shown in Figure 12-30. Install the rotor. Be sure to
remove the wire when you are finished. 2

1. Wire 2. Brushes 3. Rotor

Figure 12-30 Using Wire to Hold Brushes During

Reassembly

Figure 12-28 Engine Alternator Reassembly

TP-6261 6/04 Section 12 Electrical System 103

 Notes

104 Section 12 Electrical System TP-6261 6/04

 Section 13 Disassembly and Reassembly Practices

13.1 Oil Seals 13.2 O-Rings

When installing oil seals, carefully observe the following Use an O-ring guide to install an O-ring over stepped
points: parts, splines, threads, or keyway to prevent damage to
the ring. Apply a thin coat of grease to the O-ring before
1. Driving oil seals into housings. See Figure 13-1. installation. See Figure 13-3.
a. Check the seal lip for damage and position
correctly with respect to the oil compartment. 13.3 Bearings
b. Apply a small amount of grease to the surface 1. When installing a rolling bearing, be sure to push
of the oil seal to be fitted into the housing bore. the inner or outer race by which the bearing is fitted.
Use a bearing driver as shown in Figure 13-4.
c. Use an oil seal driver to guide seal lip squarely.
To avoid damage to the oil seal and leaking, 2. Whenever possible, use a press to minimize shock
never hammer on it directly. to the bearing and to assure proper installation.
See Figure 13-5.
2. Driving oil seals onto shafts. See Figure 13-2.

a. Apply a thin coat of grease to the oil seal lip.

b. Use an oil seal guide of the type shown when

driving the oil seal over the stepped portion,
splines, threads, or keyway to prevent damage
to the oil seal lip.

Figure 13-3 Using O-Ring Guide

Figure 13-1 Installing Oil Seal Using Driver

Figure 13-4 Using Bearing Driver

Figure 13-2 Installing Oil Seal Using Guide

Figure 13-5 Installing Bearing With Press

TP-6261 6/04 Section 13 Disassembly and Reassembly Practices 105

13.4 Lock Plates
Bend lock plates against the flats of the nuts or bolt
heads as shown in Figure 13-6.

13.5 Split Pins and Spring Pins

Generally, split pins are to be replaced at disassembly.
Insert the pin fully and spread it properly. Drive each
spring pin into position to hold it in place after later
installation of parts has been completed.

Figure 13-6 Bending Lock Plates

106 Section 13 Disassembly and Reassembly Practices TP-6261 6/04

 Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.
A, amp ampere cfh cubic feet per hour etc. et cetera (and so forth)
ABDC after bottom dead center cfm cubic feet per minute exh. exhaust
AC alternating current CG center of gravity ext. external
A/D analog to digital CID cubic inch displacement F Fahrenheit, female
ADC analog to digital converter CL centerline fglass. fiberglass
adj. adjust, adjustment cm centimeter FHM flat head machine (screw)
ADV advertising dimensional CMOS complementary metal oxide fl. oz. fluid ounce
drawing substrate (semiconductor) flex. flexible
AHWT anticipatory high water cogen. cogeneration freq. frequency
temperature com communications (port) FS full scale
AISI American Iron and Steel coml commercial ft. foot, feet
Institute Coml/Rec Commercial/Recreational
ALOP anticipatory low oil pressure ft. lbs. foot pounds (torque)
conn. connection ft./min. feet per minute
alt. alternator cont. continued
Al aluminum g gram
CPVC chlorinated polyvinyl chloride ga. gauge (meters, wire size)
ANSI American National Standards crit. critical
Institute gal. gallon
(formerly American Standards CRT cathode ray tube gen. generator
Association, ASA) CSA Canadian Standards genset generator set
AO anticipatory only Association GFI ground fault interrupter
API American Petroleum Institute CT current transformer
Cu copper GND, ground
approx. approximate, approximately
cu. in. cubic inch gov. governor
AR as required, as requested
cw. clockwise gph gallons per hour
AS as supplied, as stated, as
suggested CWC city water-cooled gpm gallons per minute
ASE American Society of Engineers cyl. cylinder gr. grade, gross
ASME American Society of D/A digital to analog GRD equipment ground
Mechanical Engineers DAC digital to analog converter gr. wt. gross weight
assy. assembly dB decibel HxWxD height by width by depth
ASTM American Society for Testing dBA decibel (A weighted) HC hex cap
Materials DC direct current HCHT high cylinder head temperature
ATDC after top dead center DCR direct current resistance HD heavy duty
ATS automatic transfer switch deg., ° degree HET high exhaust temperature,
auto. automatic high engine temperature
dept. department
aux. auxiliary hex hexagon
dia. diameter
A/V audiovisual Hg mercury (element)
DI/EO dual inlet/end outlet
avg. average HH hex head
DIN Deutsches Institut fur Normung
AVR automatic voltage regulator e. V. HHC hex head cap
AWG American Wire Gauge (also Deutsche Industrie HP horsepower
AWM appliance wiring material Normenausschuss) hr. hour
bat. battery DIP dual inline package HS heat shrink
BBDC before bottom dead center DPDT double-pole, double-throw hsg. housing
BC battery charger, battery DPST double-pole, single-throw HVAC heating, ventilation, and air
charging DS disconnect switch conditioning
BCA battery charging alternator DVR digital voltage regulator HWT high water temperature
BCI Battery Council International E, emer. emergency (power source) Hz hertz (cycles per second)
BDC before dead center EDI electronic data interchange IC integrated circuit
BHP brake horsepower EFR emergency frequency relay ID inside diameter, identification
blk. black (paint color), block e.g. for example (exempli gratia) IEC International Electrotechnical
(engine) EG electronic governor Commission
blk. htr. block heater EGSA Electrical Generating Systems IEEE Institute of Electrical and
BMEP brake mean effective pressure Association Electronics Engineers
bps bits per second EIA Electronic Industries IMS improved motor starting
br. brass Association in. inch
BTDC before top dead center EI/EO end inlet/end outlet in. H2O inches of water
Btu British thermal unit EMI electromagnetic interference in. Hg inches of mercury
Btu/min. British thermal units per minute emiss. emission in. lbs. inch pounds
C Celsius, centigrade eng. engine Inc. incorporated
cal. calorie EPA Environmental Protection ind. industrial
Agency int. internal
CAN Controller Area Network
CARB California Air Resources Board EPS emergency power system int./ext. internal/external
CB circuit breaker ER emergency relay I/O input/output
cc cubic centimeter ES engineering special, IP iron pipe
engineered special ISO International Organization for
CCA cold cranking amps ESD electrostatic discharge Standardization
ccw. counterclockwise est. estimated J joule
CEC Canadian Electrical Code E-Stop emergency stop
cert. certificate, certification, certified

TP-6261 6/04 Appendix A-1

JIS Japanese Industry Standard m/sec. meters per second RHM round head machine (screw)
k kilo (1000) MTBF mean time between failure rly. relay
K kelvin MTBO mean time between overhauls rms root mean square
kA kiloampere mtg. mounting rnd. round
KB kilobyte (210 bytes) MW megawatt ROM read only memory
kg kilogram mW milliwatt rot. rotate, rotating
kg/cm2 kilograms per square µF microfarad rpm revolutions per minute
centimeter N, norm. normal (power source) rps revolutions per second
kgm kilogram-meter NA not available, not applicable RS right side
kg/m3 kilograms per cubic meter nat. gas natural gas RTV room temperature vulcanization
kHz kilohertz NBS National Bureau of Standards SAE Society of Automotive
kJ kilojoule NC normally closed Engineers
km kilometer NEC National Electrical Code scfm standard cubic feet per minute
kOhm, kΩ kilo-ohm NEMA National Electrical SCR silicon controlled rectifier
kPa kilopascal Manufacturers Association s, sec. second
kph kilometers per hour NFPA National Fire Protection SI Systeme international d’unites,
kV kilovolt Association International System of Units
kVA kilovolt ampere Nm newton meter SI/EO side in/end out
kVAR kilovolt ampere reactive NO normally open sil. silencer
kW kilowatt no., nos. number, numbers SN serial number
kWh kilowatt-hour NPS National Pipe, Straight SPDT single--pole, double--throw
kWm kilowatt mechanical NPSC National Pipe, Straight-coupling SPST single--pole, single--throw
L liter NPT National Standard taper pipe spec, specs
LAN local area network thread per general use specification(s)
L x W x H length by width by height NPTF National Pipe, Taper-Fine sq. square
lb. pound, pounds NR not required, normal relay sq. cm square centimeter
lbm/ft3 pounds mass per cubic feet ns nanosecond sq. in. square inch
LCB line circuit breaker OC overcrank SS stainless steel
LCD liquid crystal display OD outside diameter std. standard
ld. shd. load shed OEM original equipment stl. steel
manufacturer tach. tachometer
LED light emitting diode OF overfrequency
Lph liters per hour TD time delay
opt. option, optional TDC top dead center
Lpm liters per minute OS oversize, overspeed
LOP low oil pressure TDEC time delay engine cooldown
OSHA Occupational Safety and Health TDEN time delay emergency to
LP liquefied petroleum Administration normal
LPG liquefied petroleum gas OV overvoltage TDES time delay engine start
LS left side oz. ounce TDNE time delay normal to
Lwa sound power level, A weighted p., pp. page, pages emergency
LWL low water level PC personal computer TDOE time delay off to emergency
LWT low water temperature PCB printed circuit board TDON time delay off to normal
m meter, milli (1/1000) pF picofarad temp. temperature
M mega (106 when used with SI PF power factor term. terminal
units), male
ph., ∅ phase TIF telephone influence factor
m3 cubic meter
PHC Phillips head crimptite (screw) TIR total indicator reading
m3/min. cubic meters per minute
PHH Phillips hex head (screw) tol. tolerance
mA milliampere
PHM pan head machine (screw) turbo. turbocharger
man. manual
PLC programmable logic control typ. typical (same in multiple
max. maximum PMG permanent-magnet generator locations)
MB megabyte (220 bytes) pot potentiometer, potential UF underfrequency
MCM one thousand circular mils ppm parts per million UHF ultrahigh frequency
MCCB molded-case circuit breaker PROM programmable read-only UL Underwriter’s Laboratories, Inc.
meggar megohmmeter memory UNC unified coarse thread (was NC)
MHz megahertz psi pounds per square inch UNF unified fine thread (was NF)
mi. mile pt. pint univ. universal
mil one one-thousandth of an inch PTC positive temperature coefficient US undersize, underspeed
min. minimum, minute PTO power takeoff UV ultraviolet, undervoltage
misc. miscellaneous PVC polyvinyl chloride V volt
MJ megajoule qt. quart, quarts VAC volts alternating current
mJ millijoule qty. quantity VAR voltampere reactive
mm millimeter R replacement (emergency) VDC volts direct current
mOhm, mΩ power source VFD vacuum fluorescent display
milliohm rad. radiator, radius VGA video graphics adapter
MOhm, MΩ RAM random access memory
megohm VHF very high frequency
RDO relay driver output W watt
MOV metal oxide varistor ref. reference
MPa megapascal WCR withstand and closing rating
rem. remote w/ with
mpg miles per gallon
Res/Coml Residential/Commercial w/o without
mph miles per hour
RFI radio frequency interference wt. weight
MS military standard
RH round head xfmr transformer

A-2 Appendix TP-6261 6/04

 Appendix B General Torque Specifications

Use the following torque specifications when service oiled threads. Increase values by 15% for nonplated
literature instructions give no specific torque values. threads. All torque values are +0%/--10%.
The charts list values for new plated, zinc phosphate, or

American Standard Fasteners Torque Specifications

Assembled into Cast Iron or Steel Assembled into
Torque Aluminum
Size Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5
8-32 Nm (in. lb.) 1.8 (16) 2.3 (20) — 1.8 (16)
10-24 Nm (in. lb.) 2.9 (26) 3.6 (32) — 2.9 (26)
10-32 Nm (in. lb.) 2.9 (26) 3.6 (32) — 2.9 (26)
1/4-20 Nm (in. lb.) 6.8 (60) 10.8 (96) 14.9 (132) 6.8 (60)
1/4-28 Nm (in. lb.) 8.1 (72) 12.2 (108) 16.3 (144) 8.1 (72)
5/16-18 Nm (in. lb.) 13.6 (120) 21.7 (192) 29.8 (264) 13.6 (120)
5/16-24 Nm (in. lb.) 14.9 (132) 23.1 (204) 32.5 (288) 14.9 (132)
3/8-16 Nm (ft. lb.) 24.0 (18) 38.0 (28) 53.0 (39) 24.0 (18)
3/8-24 Nm (ft. lb.) 27.0 (20) 42.0 (31) 60.0 (44) 27.0 (20)
7/16-14 Nm (ft. lb.) 39.0 (29) 60.0 (44) 85.0 (63) —
7/16-20 Nm (ft. lb.) 43.0 (32) 68.0 (50) 95.0 (70) —
1/2-13 Nm (ft. lb.) 60.0 (44) 92.0 (68) 130.0 (96) —
1/2-20 Nm (ft. lb.) 66.0 (49) 103.0 (76) 146.0 (108) —
9/16-12 Nm (ft. lb.) 81.0 (60) 133.0 (98) 187.0 (138) —
9/16-18 Nm (ft. lb.) 91.0 (67) 148.0 (109) 209.0 (154) —
5/8-11 Nm (ft. lb.) 113.0 (83) 183.0 (135) 259.0 (191) —
5/8-18 Nm (ft. lb.) 128.0 (94) 208.0 (153) 293.0 (216) —
3/4-10 Nm (ft. lb.) 199.0 (147) 325.0 (240) 458.0 (338) —
3/4-16 Nm (ft. lb.) 222.0 (164) 363.0 (268) 513.0 (378) —
1-8 Nm (ft. lb.) 259.0 (191) 721.0 (532) 1109.0 (818) —
1-12 Nm (ft. lb.) 283.0 (209) 789.0 (582) 1214.0 (895) —

Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)

Assembled into Cast Iron or Steel Assembled into
Aluminum
Size (mm) Grade 5.8 Grade 8.8 Grade 10.9 Grade 5.8 or 8.8
M6 x 1.00 5.6 (4) 9.9 (7) 14.0 (10) 5.6 (4)
M8 x 1.25 13.6 (10) 25.0 (18) 35.0 (26) 13.6 (10)
M8 x 1.00 21.0 (16) 25.0 (18) 35.0 (26) 21.0 (16)
M10 x 1.50 27.0 (20) 49.0 (35) 68.0 (50) 27.0 (20)
M10 x 1.25 39.0 (29) 49.0 (35) 68.0 (50) 39.0 (29)
M12 x 1.75 47.0 (35) 83.0 (61) 117.0 (86) —
M12 x 1.50 65.0 (48) 88.0 (65) 125.0 (92) —
M14 x 2.00 74.0 (55) 132.0 (97) 185.0 (136) —
M14 x 1.50 100.0 (74) 140.0 (103) 192.0 (142) —
M16 x 2.00 115.0 (85) 200.0 (148) 285.0 (210) —
M16 x 1.50 141.0 (104) 210.0 (155) 295.0 (218) —
M18 x 2.50 155.0 (114) 275.0 (203) 390.0 (288) —
M18 x 1.50 196.0 (145) 305.0 (225) 425.0 (315) —

TP-6261 6/04 Appendix A-3

Appendix C Common Hardware Identification

Screw/Bolts/Studs Nuts Hardness Grades

Head Styles Nut Styles American Standard

Hex Head or Machine Head Hex Head Grade 2

Hex Head or Machine Head

Lock or Elastic Grade 5
with Washer

Flat Head (FHM) Square Grade 8

Grade 8/9 (Hex Socket

Round Head (RHM) Cap or Acorn
Head)
Metric
Pan Head Wing
Number stamped on 5.8
Hex Socket Head Cap or Washers hardware; 5.8 shown
Allent Head Cap
Washer Styles
Hex Socket Head or Allent
Head Shoulder Bolt Plain

Sheet Metal Screw Split Lock or Spring

Stud Spring or Wave

Drive Styles
External Tooth Lock
Hex
Internal Tooth Lock
Hex and Slotted
Internal-External Tooth Lock
Phillipsr

Slotted

Hex Socket

Allent head screw is a trademark of Holo-Krome Co.

Phillipsr screw is a registered trademark of Phillips Screw Company.

Sample Dimensions
American Standard (Screws, Bolts, Studs, and Nuts) Plain Washers
1/4-20 x 1 9/32 x 5/8 x 1/16
Length In Inches (Screws and Bolts) Thickness
Threads Per Inch External Dimension
Major Thread Diameter In Fractional Inches Or Screw Number Size Internal Dimension
Metric (Screws, Bolts, Studs, and Nuts)
M8-1.25 x 20 Lock Washers
Length In Millimeters (Screws and Bolts) 5/8
Distance Between Threads In Millimeters Internal Dimension
Major Thread Diameter In Millimeters

A-4 Appendix TP-6261 6/04

TP-6261 6/04