12v140z-1 (JPN) All Shop

Shop CEBM002603
Manual
SA12V140Z-1 SERIES
SAA12V140ZE-2 SERIES
DIESEL ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
Copyright 2008 Komatsu

September 2008 DataKom Publishing Division 00-1 3
FOREWORD CONTENTS
CONTENTS
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
11 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . .11-1
12 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . 12-1
13 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 13-1
14 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
15 REPAIR AND REPLACEMENT OF PARTS . . . . . . . . . . . . . . 15-1
00-2 1
FOREWORD
The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. ● New page to be added Add
❍ Page to be replaced Replace
( ) Page to be deleted Discard
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
❍ 00-1 3 01-7 11-23 12-3 1
00-2 1 01-8 11-24 12-4 1
❍ 00-2-1 3 01-9 11-25 12-5 1
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FOREWORD
12-32 1 13-20 1 13-53 1 14-5
12-33 1 13-21 1 13-54 1 14-6
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12-40 1 13-28 1 13-61 1 14-13
13-29 1 13-62 1 14-14
13-1 1 13-30 1 13-63 1 14-15
13-2 1 13-31 1 13-64 1 14-16
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13-4 1 13-33 1 13-66 1 14-18
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● 13-6-3 3 13-38 1 13-71 1 14-23
● 13-6-4 3 13-39 1 ❍ 13-72 3 14-24
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13-12 1 13-45 1 13-74 1 15-1 2
13-13 1 13-46 1 13-75 1 15-2 2
13-14 1 13-47 1 13-76 1 15-3 2
13-15 1 13-48 1 15-4 2
13-16 1 13-49 1 14-1 15-5 2
13-17 1 13-50 1 14-2 15-6 2
13-18 1 13-51 1 14-3 15-7 2
13-19 1 13-52 1 14-4 15-8 2
00-2-2 3
FOREWORD
15-9 2 15-42 2
15-10 2 15-43 2
15-11 2 15-44 2
15-12 2 15-45 2
15-13 2 15-46 2
15-14 2 15-47 2
15-15 2 15-48 2
15-16 2 15-49 2
15-17 2 15-50 2
15-18 2
15-19 2
15-20 2
15-21 2
15-22 2
15-23 2
15-24 2
15-25 2
15-26 2
15-27 2
15-28 2
15-29 2
15-30 2
15-31 2
15-32 2
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15-35 2
15-36 2
15-37 2
15-38 2
15-39 2
15-40 2
15-41 2
00-2-3 3
FOREWORD
00-2-4 3
FOREWORD SAFETY
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and repair
techniques recommended and described in this manual are both effective and safe methods of operation. Some
of these operations require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cau-
tions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may
possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation are extremely dangerous. Read 7. Before adding oil or making repairs, park the
the OPERATION & MAINTENANCE MANUAL carefully machine on hard, level ground, and block the
BEFORE operating the machine. wheels or tracks to prevent the machine from mov-
ing.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are 8. Before starting work, lower blade, ripper, bucket or
fixed to the machine. any other work equipment to the ground. If this is
not possible, insert the safety pin or use blocks to
2. When carrying out any operation, always wear prevent the work equipment from falling. In addi-
safety shoes and helmet. Do not wear loose work tion, be sure to lock all the control levers and hang
clothes, or clothes with buttons missing. warning signs on them.
• Always wear safety glasses when hitting parts with
a hammer. 9. When disassembling or assembling, support the
• Always wear safety glasses when grinding parts machine with blocks, jacks or stands before start-
with a grinder, etc. ing work.
3. If welding repairs are needed, always have a 10. Remove all mud and oil from the steps or other
trained, experienced welder carry out the work. places used to get on and off the machine. Always
When carrying out welding work, always wear use the handrails, ladders or steps when getting on
welding gloves, apron, glasses, cap and other or off the machine. Never jump on or off the
clothes suited for welding work. machine. If it is impossible to use the handrails,
ladders or steps, use a stand to provide safe foot-
4. When carrying out any operation with two or more ing.
workers, always agree on the operating procedure
before starting. Always inform your fellow workers PRECAUTIONS DURING WORK
before starting any step of the operation. Before
starting work, hang UNDER REPAIR signs on the 11. When removing the oil filler cap, drain plug or
controls in the operator's compartment. hydraulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out. Before
5. Keep all tools in good condition and learn the cor- disconnecting or removing components of the oil,
rect way to use them. water or air circuits, first remove the pressure com-
pletely from the circuit.
6. Decide a place in the repair workshop to keep tools
and removed parts. Always keep the tools and 12. The water and oil in the circuits are hot when the
parts in their correct places. Always keep the work engine is stopped, so be careful not to get burned.
area clean and make sure that there is no dirt or oil Wait for the oil and water to cool before carrying
on the floor. Smoke only in the areas provided for out any work on the oil or water circuits.
smoking. Never smoke while working.
13. Before starting work, remove the leads from the
battery. ALWAYS remove the lead from the nega-
tive (-) terminal first.
00-3 1
FOREWORD SAFETY
14. When raising heavy components, use a hoist or 24. Take care when removing or installing the tracks of
crane. Check that the wire rope, chains and hooks track-type machines. When removing the track, the
are free from damage. Always use lifting equip- track separates suddenly, so never let anyone
ment which has ample capacity. Install the lifting stand at either end of the track.
equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the compo-
nent from hitting any other part. Do not work with
any part still raised by the hoist or crane.
15. When removing covers which are under internal

pressure or under pressure from a spring, always
leave two bolts in position on opposite sides.
Slowly release the pressure, then slowly loosen the
bolts to remove.
16. When removing components, be careful not to

break or damage the wiring, Damaged wiring may
cause electrical fires.
17. When removing piping, stop the fuel or oil from

spilling out. If any fuel or oil drips on to the floor,
wipe it up immediately. Fuel or oil on the floor can
cause you to slip, or can even start fires.
18. As a general rule, do not use gasoline to wash

parts. In particular, use only the minimum of gaso-
line when washing electrical parts.
19. Be sure to assemble all parts again in their original

places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they
will not be damaged by contact with other parts
when the machine is being operated.
20. When installing high pressure hoses, make sure

that they are not twisted. Damaged tubes are dan-
gerous, so be extremely careful when installing
tubes for high pressure circuits. Also check that
connecting parts are correctly installed.
21. When assembling or installing parts, always use

the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be particu-
larly careful to check that they are installed cor-
rectly.
22. When aligning two holes, never insert your fingers

or hand. Be careful not to get your fingers caught in
a hole.
23. When measuring hydraulic pressure, check that

the measuring tool is correctly assembled before
taking any measurements.
00-4 1
FOREWORD GENERAL
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accu-
rate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service work-
shop. For ease of understanding, the manual is divided into the following sections. These sections are further
divided into each main group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and
fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be
made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also
included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance
notice. Contact your distributor for the latest information.
00-5 1
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES REVISIONS
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows: Revised pages are shown at the LIST OF REVISED
PAGES between the title page and SAFETY page.
Chassis volume: Issued for every machine
model SYMBOLS
Engine volume: Issued for each engine series
So that the shop manual can be of ample practical use,
Electrical volume: Each issued as one to cover
important places for safety and quality are marked with
all models
the following symbols.
Attachment volume: Each issued as one to cover
all models
Symbol Item Remarks
These various volumes are designed to avoid duplica-
Special safety precautions
tion of information. Therefore to deal with all repairs for
Safety are necessary when perform-
any model, it is necessary that chassis, engine, electri-
ing the work.
cal and attachment be available.
Special technical precau-
DISTRIBUTION AND UPDATING tions or other precautions for
★ Caution preserving standards are
necessary when performing
Any additions, amendments or other changes will be
the work.
sent to your distributors. Get the most up-to-date infor-
mation before you start any work. Weight of parts or systems.
Caution necessary when
FILING METHOD Weight selecting hoisting wire or
when working posture is
1. See the page number on the bottom of the page. important, etc.
File the pages in correct order. Places that require special
2. Following examples show how to read the page Tightening
attention for tightening torque
number: torque
during assembly.
Example:
Places to be coated with
Coat
10 - 3 adhesives and lubricants etc.
Places where oil, water or

Item number (10. Structure and Function)
Oil, water fuel must be added, and the
capacity.
Consecutive page number for each item
Places where oil or water
3. Additional pages: Additional pages are indicated by Drain must be drained, and quantity
a hyphen (-) and numbered after the page number. to be drained.
File as in the example.
Example:
10-4
10-4-1
Added pages
10-4-2
10-5
REVISED EDITION MARK

When a manual is revised, an edition mark (123…) is
recorded on the bottom outside corner of the pages.
00-6 1
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS dent can result. Hooks have maximum strength at the
middle portion.
HOISTING
Heavy parts (25 kg or more) must be lifted

with a hoist etc. In the DISASSEMBLY AND
ASSEMBLY section, every part weighing 25
kg or more is indicated clearly with the symbol
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks should
be made: 3. Do not sling a heavy load with one rope alone, but
1. Check for removal of all bolts fastening the part to sling with two or more ropes symmetrically wound
the relative parts. on to the load.
2. Check for existence of another part causing inter-
face with the part to be removed. Slinging with one rope may cause turning of
the load during hoisting, untwisting of the rope,
or slipping of the rope from its original winding
WIRE ROPES position on the load, which can result in a dan-
1. Use adequate ropes depending on the weight of gerous accident.
parts to be hoisted, referring to the table below:
4. Do not sling a heavy load with ropes forming a
Wire ropes wide hanging angle from the hook. When hoisting a
(Standard “Z” or “S” twist ropes without galvanizing) load with two or more ropes, the force subjected to
each rope will increase with the hanging angles.
Rope diameter Allowable load The table below shows the variation of allowable
mm kN tons load (kg) when hoisting is made with two ropes,
each of which is allowed to sling up to 1000 kg ver-
10 9.8 1.0 tically, at various hanging angles. When two ropes
11.2 13.7 1.4 sling a load vertically, up to 2000 kg of total weight
can be suspended. This weight becomes 1000 kg
12.5 15.7 1.6 when two ropes make a 120° hanging angle. On
14 21.6 2.2 the other hand, two ropes are subject to an exces-
sive force as large as 4000 kg if they sling a 2000
16 27.5 2.8 kg load at a lifting angle of 150°.
18 35.3 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
★ The allowable load value is estimated to be 1/6 or

1/7 of the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the

hook.
Slinging near the edge of the hook may cause the rope
to slip off the hook during hoisting, and a serious acci-
00-7 1
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials prescribed in the shop manuals are listed below.
test
Category Code Part No. Quantity Container Main applications, features
• Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube cushions and cork plugs from coming
out
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene • Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and non-
metal.
• Features: Resistance to heat, chemi-
Polyethylene cals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purposes for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhe- • Used as adhesive or sealant for metal,
LT-3 Hardening Can
sive and hard- glass or plastic.
agent:
Adhesives
ening agent)
500 g
Polyethylene
LT-4 790-129-9040 250 g • Used as sealant for machined holes.
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive.
Three
Polyethylene • Cure time: within 5 sec. to 3 min.
bond 179-129-9140 2g
container • Used mainly for adhesion of metals,
1735
rubbers, plastics and woods.
• Quick hardening type adhesive.
Aron- • Quick cure type (max. strength after 30
Polyethylene
alpha 790-129-9130 50 g minutes).
container
201 • Used mainly for adhesion of rubbers,
plastics and metals.
• Features: Resistance to heat, chemi-
Loctite Polyethylene cals
79A-129-9110 50 cc
648-50 container • Used at joint portions subject to high
temperature.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Features: Resistance to heat
Gasket • Used as sealant for flange surfaces and
sealant bolts at high temperature locations;
used to prevent seizure.
LG-3 790-129-9070 1 kg Can
• Used as sealant for heat resistant gas-
ket for at high temperature locations
such as engine pre-combustion cham-
ber, exhaust pipe.
00-8 1
FOREWORD COATING MATERIALS
Category Code Part No. Quantity Container Main applications, features

• Features: Resistance to water, oil
• Used as sealant for flange surface,
thread.
LG-4 790-129-9020 200 g Tube • Also possible to use as sealant for
flanges with large clearance.
• Used as sealant for mating surfaces of
final drive case, transmission case.
• Used as sealant for various threads,
Polyethylene pipe joints, flanges.
LG-5 790-129-9080 1 kg
container • Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistant to
Gasket
heat, cold.
sealant
• Used as sealant for flange surface,
LG-6 09940-00011 250 g Tube
thread.
• Used as sealant for oil pan, final drive
case, etc.
• Features: Silicon based, quick harden-
ing type.
LG-7 09920-00150 150 g Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three
• Used as heat-resisting sealant for
bond 790-129-9090 100 g Tube
repairing engines.
1211
• Used as lubricant for sliding parts (to
LM-G 09940-00051 60 g Can
prevent squeaking).
Molybdenum
disulphide
lubricant
• Used to prevent seizure or scuffing of

the thread when press fitting or shrink
LM-P 09940-00040 200 g Tube fitting.
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various • General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
• Used for normal temperature, light load
SYG2-400CA-A
G2-CA Various Various bearing at places in contact with water
SYG2-160CA
Grease or steam.
SYG2-
160CNCA
disulphide lubricant
Molybdenum
400 g (10
SYG2-400M Belows type • Used for places with heavy load.
per case)
00-9 1
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of DIS-
ASSEMBLY AND ASSEMBLY.
Thread diameter of bolt Width across flats
mm mm Nm kgm
6 10 13.2 ±1.4 1.35 ±0.15
8 13 31.4 ±2.9 3.20 ±0.3
10 17 65.7 ±6.8 6.70 ±0.7
12 19 112 ±9.8 11.5 ±1.0
14 22 177 ±19 18 ±2.0
16 24 279 ±29 28.5 ±3
18 27 383 ±39 39 ±4
20 30 549 ±58 56 ±6
22 32 745 ±78 76 ±8
24 36 927 ±98 94.5 ±10
27 41 1320 ±140 135 ±15
30 46 1720 ±190 175 ±20
33 50 2210 ±240 225 ±25
36 55 2750 ±290 280 ±30
39 60 3280 ±340 335 ±35
Thread diameter of bolt Width across flats
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8
00-10 1
FOREWORD STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE OF HOSE NUTS

Use these torques for hose nuts.
Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm kgm
02 14 19 24.5 ± 4.9 2.5 ± 0.5
03 18 24 49 ± 19.6 5±2
04 22 27 78.5 ± 19.6 8±2
05 24 32 137.3 ± 29.4 14 ± 3
06 30 36 176.5 ± 29.4 18 ± 3
10 33 41 196.1 ± 49 20 ± 5
12 36 46 245.2 ± 49 25 ± 5
14 42 55 294.2 ± 49 30 ± 5
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.
mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3
TIGHTENING TORQUE FOR FLARED NUTS

Use these torques for flared part of nut.

mm mm Nm kgm
14 19 24.5 ±4.9 2.5 ±0.5
18 24 49 ±19.6 5 ±2
22 27 78.5 ±19.6 8 ±2
24 32 137.3 ±29.4 14 ±3
30 36 176.5 ±29.4 18 ±3
33 41 196.1 ±49 20 ±5
36 46 245.2 ±49 25 ±5
42 55 294.2 ±49 30 ±5
00-11 1
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code
table will help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current
Number of Dia. Of Cross sec- Applicable circuit
number (mm) rating (A)
strands strand (mm) tion (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE

Circuits
Priority Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Red & Yellow & Green &
Color — Blue & Red
Black Yellow Black Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Black & Red & Yel- Yellow & Green & Blue & Yel-
Color —
Blue Red low Green Yellow low
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-12 1
FOREWORD CONVERSION TABLES
CONVERSION TABLES
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method
of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
(a) Locate the number 50 in the vertical column at the left side, take this as 1, then draw a horizontal line from
1.
(b) Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from
2.
(c) Take the point where the two lines cross as 3. This point 3 gives the value when converting from millime-
ters to inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.

(a) The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to
convert it to 55 mm.
(b) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(c) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one
place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
2
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
3
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
1
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-13 1
Millimeters to Inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-14 1
Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-15 1
kgm to ft. lb. 1 kgm = 7.233 ft. lb.

0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-16 1
kg/cm 2 to lb/in2 1 kg/cm 2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-17 1
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of
figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to
convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit tempera-
tures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert
from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read
the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-18 1
PRODUCT PUBLICATIONS INFORMATION
Various product Parts and Service Publications are available to all KOMATSU construction equipment
owners, including operation and maintenance manuals, parts books and service manuals.
Special publications, such as service tool, air conditioning and turbocharger service manuals are also
available as well as selected Operation and Service manuals in foreign languages.
The Publications listed below are available for this particular machine(s).
DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER:

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application
PARTS BOOK - MICROFICHE:

OPERATION AND MAINTENANCE MANUAL:

SHOP MANUAL
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM002601
SAFETY MANUAL
Parts and Service Publications can only be acquired by authorized KOMATSU distributors using
the Komatsu America International Company Parts Inventory Processing System (PIPS).
If the PIPS system is not available at the distributor location, then the following Requisition for
Technical Service Publications and Service Forms can be used. Form KDC91E is shown on the
reverse side of this page.
pubinfok.fm 10/12/99
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM
AND RETURN TO < DataKom Publishing Corporation
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
PURCHASE ORDER NO.
SHIP TO <
ATTN.
STREET ADDRESS ORDER DATE

TYPE or PRINT
CITY, STATE, ZIP CODE
ONLY <
COUNTRY
PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE
SERIAL NUMBER MUST BE SHOWN.
PARTS BOOK
PUBLICATION
QTY. PUBLICATION FORM NO. P-Paper MODEL NUMBER SERIAL NUMBER
DESCRIPTION
M-Microfiche
KDC91D 022597 CURRENT PRICES WILL BE CHARGED

01 GENERAL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
GENERAL ASSEMBLY DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
VIEW FROM LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
VIEW FROM RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
VIEW FROM FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5
VIEW FROM REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
VIEW FROM LEFT SIDE (CUSTOM CONNECTIONS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
VIEW FROM TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
ENGINE PERFORMANCE CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
WA800-2LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
WA900-1LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
330M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11
01-1
GENERAL SPECIFICATIONS
SPECIFICATIONS
Engine model SA12V140Z-1
Applicable machine WA800-2LE WA900-1LC 330M
Number of cylinder 12
Bore x Stroke mm 140 x 165
Total piston displacement cc 30,480
Firing order R1 – LI – R5 – L5 – R3 – L3 – R6 – L6 – R2 – L2 – R4 –L4
Overall length mm 1887.7 1887.7 1887.7
Dimensions
Overall width mm 1320.1 1320.1 1320.1
Overall height mm 1658 1658 1658

(excluding exhaust pipe)
Flywheel horsepower kW(HP)/rpm 588(789)/2,000 636(853)/2,000 753(1010)/2,000
Gross horsepower kW(HP)/rpm 621(833)/2,000 669(897)/2,000 783(1050)/2,000
Maximum torque, gross N•m(lb/ft)/rpm 3806(2807)/1,400 4100(3024)/1,300 4628(3414)/1,400

Performance
Maximum torque, net N•m(lb/ft)/rpm 3279(2750)/1,400 4034(2975)/1,300 4560(3363)/1,400
High idling speed rpm 2,250±50 2,250±50 2,350±50

Low idling speed rpm + 50 + 50 + 50
650 650 650
–0 –0 –0
Minimum fuel consumption at full g/kW•h(lb/HP•h)
power 194 (.319) 193 (.317) 193 (.317)
Dry weight kg 3,271 3,271 3,271
Fuel injection pump BOSCH RP 39
Governor BOSCH RE 33
Lubricating oil amount (total system) l 148(39.1) 148(39.1) 148(39.1)
(minimum required) (US Gal) 132(34.9) 132(34.9) 132(34.9)
Coolant amount (engine only) l 85(22.4) 85(22.4) 85(22.4)
(total system) (US Gal) 310(81.9) 310(81.9) 228(60.2)
Alternator 24 V, 75 A 24 V, 75 A 24 V, 75 A
Starting motor 24 V, 11kW 50 MT 24 V, 11kW, 50 MT 24 V, 11kW, 50 MT
x1 x1 x1
Battery 12V 200 Ah x 4 12 V 200 Ah x 4 12 V 200 Ah x 4
Turbocharger H x 60 x 2 H x 60 x 2 H x 60 x 2
Air compressor Holset TC676 Holset TC676 Holset TC676
01-2
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING

VIEW FROM LEFT SIDE
01-3
VIEW FROM RIGHT SIDE
01-4
VIEW FROM FRONT
01-5
VIEW FROM REAR
01-6
VIEW FROM LEFT SIDE (CUSTOM CONNECTIONS)
01-7
VIEW FROM TOP
01-8
GENERAL ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE

WA800-2LC
Curves above represent gross engine performance capabilities obtained and corrected in accordance with SAE
J1995 conditions of 100 kPa (29.61 in. Hg) barometric pressure [91 m (300 ft.) altitude], 25°C (77°F) inlet air tem-
perature, and 1kPa (0.30 in. Hg) water vapor pressure with No. 2 diesel fuel. The engine may be operated without
changing the fuel setting up to 3048 m (10,000 ft.) altitude. For sustained operation at high altitudes, the fuel rate of
the engine will be adjusted to limit performance by 4% per 305 m (1,000 ft.) above 3048 m (10,000 ft.) altitude and
2% per 11°C above 38°C (1% per 10°F above 100°F).
01-9
WA900-1LC
01-10
330M
01-11
MEMORANDA
01-12
11 STRUCTURE AND FUNCTION
GENERAL STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

INTAKE AND EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
AFTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
ENGINE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Rocker arm housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Fuel injection nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Piston cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Liner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
MAIN REVOLVING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Connecting rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Front seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16
VALVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17
Valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18
FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19
Rear seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19
LUBRICATING OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20
Piston cooling, connecting rod, overhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21
Front gear train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23
FULL FLOW LUBRICATING OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24
LUBRICATING OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-25
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-25
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26
OIL COOLER BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27
Regulator valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27
LUBRICATING OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28
Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28
LUBRICATING OIL BYPASS FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29
LUBRICATING OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-31
11-1
STRUCTURE AND FUNCTION TABLE OF CONTENTS
FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-31
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32
RIGHT BANK PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-33
LEFT BANK PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34
FUEL INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-37
THERMOSTAT HOUSING FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-38
COOLING FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-39
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-41
CORROSION RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-42
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-42
ACCESSORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43
AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44
Unloader valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45
ALTERNATOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45
ALTERNATOR WITH REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-46
STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-47
ELECTRICAL INTAKE AIR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-48
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-48
11-2
STRUCTURE AND FUNCTION GENERAL STRUCTURE
GENERAL STRUCTURE
1. Front cover 9. Turbocharger 17. Connecting rod

2. Cylinder block 10. Cam follower 18. Connecting rod cap
3. Cylinder liner 11. Camshaft 19. Oil strainer
4. Rocker lever housing 12. Flywheel 20. Lubricating oil pump
5. Cylinder head cover 13. Flywheel housing 21. Crankshaft gear
6. Exhaust valve 14. Main bearing cap 22. Vibration damper
7. Intake valve 15. Crankshaft 23. Crankshaft pulley
8. Piston 16. Oil pan
11-3
STRUCTURE AND FUNCTION GENERAL STRUCTURE
24. Cylinder head 30. Aftercooler

25. Intake manifold 31. Nozzle holder
26. Electrical intake air heater 32. Push rod
27. Lubricating oil cooler 33. Piston cooling nozzle
28. Intake connector pipe
29. Rocker lever
11-4
STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM
INTAKE AND EXHAUST SYSTEM

INTAKE SYSTEM
1. Intake manifold (Right bank)

2. Electrical intake air heater
3. Aftercooler cover (Right bank)
4. Aftercooler cover (Left bank)
5. Intake manifold (Left bank)
A. Air intake
11-5
EXHAUST SYSTEM
1. Exhaust manifold (Left bank)

2. Exhaust manifold (Right bank)
3. Turbocharger (Right bank)
4. Turbocharger (Left bank)
11-6
TURBOCHARGER
1. V band clamp 15. Shaft and wheel

2. Turbine Housing 16. Turbo thrust bearing
3. Turbocharger heat shield 17. Turbo compressor impeller
4. Drive screw 18. Compressor housing
5. Lock nut 19. Turbo bearing housing
6. Split ring seal 20. Roll pin
7. Split ring seal 21. Retaining pin
8. Dataplate 22. Retaining ring
9. Regular hexagon nut 23. Turbocharger bearing
10. Thrust collar 24. Retaining ring
11. Oil slinger 25. O-ring seal
12. Oil seal plate 26. Oil control sleeve
13. V band clamp
14. Oil baffle
11-7
AFTERCOOLER
1. Aftercooler cover A. Intake air inlet (from turbocharger)

2. Aftercooler core B. Intake air outlet (to cylinder head)
3. Intake manifold C. Water inlet (to cylinder head)
D. Water outlet (to thermostat)
H The diagram above shows the right bank.
11-8
STRUCTURE AND FUNCTION ENGINE BODY
ENGINE BODY
CYLINDER HEAD
1. Fuel spill tube 7. Fuel injection nozzle holder B. Intake

2. Air vent tube assembly C. Exhaust
3. Rocker lever housing 8. Head cover mounting bolt d. To fuel tank
4. Cylinder head 9. Cylinder head mounting bolt e. To radiator
5. Head cover 10. Fuel inlet connector
6. Nozzle holder retainer
11-9
Specifications Valve seat

• Direct fuel injection type • Press fitted insert for intake and exhaust
• 4-valve
• Divided type (One cylinder head for one cylinder) Rocker arm housing cover
• Injection nozzle and fuel inlet connector assembled • Floating type seal
in rocker arm housing and cylinder head
• Cylinder head bolt: Tighten bolts by the plastic Fuel injection nozzle
range turning angle method • Mount: Dry type (without sleeve)
11-10
CYLINDER BLOCK
1. Cylinder block 7. Main bearing cap

2. Cylinder liner 8. Main bearing
3. Crevice seal 9. Piston cooling nozzle
4. Liner seal 10. Thrust bearing
5. Liner seal
6. Main bearing cap bolt
11-11
Specifications Cylinder liner

• Crankshaft: 7 bearings • Wet type
• Camshaft: 7 bearings • Treatment: Plateau honing finish
• Main bearing cap bolt: Tightening bolts by the Tuffride treated
plastic range turning angle method. Liner seal
Piston cooling • TOP:Crevice seal (Ethylene propylene
• With piston cooling nozzle rubber)
• MIDDLE: O-ring (Ethylene propylene
rubber)
• BOTTOM: O-ring (Silicon rubber)
11-12
MAIN REVOLVING SYSTEM
1. Piston 9. Crankshaft
2. Piston pin 10. Crankshaft gear (No. of teeth: 45)
3. Connecting rod bushing 11. Connecting rod bearing
4. Top ring 12. Connecting rod cap
5. Second ring 13. Connecting rod
6. Oil ring 14. Connection rod cap bolt
7. Crankshaft pulley
8. Vibration damper
11-13
Crankshaft
• Stamp forging Top ring Second ring Oil ring
• Journal and filet portion:
Induction hardening
Piston
• Ductile cast iron (FCD)
Connecting rod
Both faces key- Keystone inner M-shape steel
• Stamp forging:
stone. cut. ring.
With lubrication hole
Barrel face. Tapered face. Hard chrome
Hard chrome Hard chrome plating with coil
plating. plating. expander.
11-14
TIMING GEAR
H Circled numbers indicate spur gear. Other gears are helical.

1. Accessory drive gear (No. of teeth: 22) 10. Air compressor drive gear (No. of teeth: 30)
2. R-Sub-idler gear (No. of teeth: 50) 11. Crankshaft gear (No. of teeth: 45)
3. R-Idler gear (large) (No. of teeth: 75) 12. Oil pump drive gear (No. of teeth: 27)
4. R-Camshaft gear (No. of teeth: 60) 13. Water pump drive gear (No. of teeth: 25)
5. Idler gear (small) (No. of teeth: 45) 14. R-Fuel injection pump drive gear (No. of teeth: 60)
6. L-Camshaft gear (No. of teeth: 60) 15. Front seal
7. L-Idler gear (large) (No. of teeth: 75)
8. L-Sub-idler gear (No. of teeth: 50) R, L, A, B, B1, B2, C, D: Match marks for timing gears
9. L-Fuel injection pump drive gear (No. of teeth: 60)
11-15
Front seal
• Single lip with dust seal
11-16
VALVE SYSTEM
11-17
1. Camshaft gear 13. Locknut Valve timing

(No. of teeth: 48) 14. Crosshead
2. Thrust plate 15. Valve guide
3. Camshaft 16. Exhaust valve
4. Cam follower 17. Valve spring (outer)
5. Cam roller 18. Valve spring (inner)
6. Rocker arm shaft 19. Valve spring seat
7. Cam follower shaft (lower)
8. Rocker arm adjust- 20. Valve spring seat
ment screw (upper)
9. Lock nut 21. Intake valve
10. Push rod 22. Cam roller pin
11. Rocker arm
12. Crosshead adjust-
ment screw
Camshaft
• Drawn steel bar
• Journal and cam portion: Induction hardening
11-18
FLYWHEEL AND FLYWHEEL HOUSING
1. Ring gear (No. of teeth: 142) Rear seal

2. Flywheel • Dry type: Single lip oil seal
3. Flywheel housing • Wet type: Double lip oil seal
4. Crankshaft rear seal
A. Timing sensor pickup port
B. RPM sensor port
11-19
STRUCTURE AND FUNCTION LUBRICATING OIL SYSTEM
LUBRICATING OIL SYSTEM
1. Full flow filter head 11. Bypass filters

2. Full flow filter(s) 12. Oil cooler bypass valve
3. Lubricating oil pump 13. Bypass valve spring
4. High pressure regulator 14. Regulator valve
5. Suction tube 15. Regulator valve spring
6. Lubricating oil cooler 16. Valve body
7. Low pressure and lubricating oil cooler bypass reg- A. From main gallery (signal line)
ulator B. From oil cooler
8. Signal line C. To oil pan
9. Cold oil flow D. To oil filter
10. Hot oil flow
11-20
Piston cooling, connecting rod, overhead

1. Crankshaft oil drillings
2. Main oil drilling
3. Connecting rod wrist pin oil supply
4. Upper rocker lever oil supply
5. Piston cooling oil drilling
6. Cam follower oil drilling
7. Piston cooling nozzle
11-21
Front gear train

1. Right bank (large) idler gear
2. Right bank (small) idler gear
3. Piston cooling oil supply drillings
4. Left bank (large) idler gear
11-22
Turbocharger
1. Piston cooling oil supply drilling
2. Turbocharger oil supply
3. Turbocharger oil drain
11-23
FULL FLOW LUBRICATING OIL FILTERS
1. Oil supply
2. Oil drain
3. Full flow filters
11-24
LUBRICATING OIL PUMP
1. Pump body Specifications

2. Pump drive (No. of teeth: 27) • Type: Gear pump
3. Drive gear • Pump speed: Engine speed x 1.67
4. Driven gear
5. Pump cover
a. Suction (From oil pan)

b. Discharge (To oil cooler)
11-25
MAIN RELIEF VALVE
1. Valve spring
2. Main relief valve
3. Valve body
Specifications
• Cracking pressure:
8.5 ± 0.5 kg/cm2
121 ± 7 psi
11-26
OIL COOLER BYPASS VALVE

1. Oil cooler bypass valve
2. Bypass valve spring
3. Regulator valve
4. Regulator valve spring
5. Valve body
A. From main gallery
B. From oil cooler
C. To oil pan
D. To oil filter
Specifications
• Cracking pressure
(differential pressure)
2.3 ± 0.2 kg/cm2
3.3 ± 2.5 psi
Regulator valve
4.1 ± 0.5 kg/cm2
58 ± 7.1 psi
11-27
LUBRICATING OIL FILTER
1. Filter head
2. Filter connector
3. Cover
4. Cartridge
A. Oil inlet port

B. Oil outlet port
Specifications
• Filtering area:
3.6 m2
38.75 sq.ft.
Safety valve
2.0 ± 0.2 kg/cm2
28.44 ± 2.8 psi
11-28
LUBRICATING OIL BYPASS FILTER
1. Filter head Specifications

2. Cartridge • Filtering area: 2.8 m2 [30.1 sq. ft.]
A. Oil inlet port
B. Oil outlet port
11-29
LUBRICATING OIL COOLER
1. Oil cooler cover Specifications

2. Cooler element: 12 cores • Effective area:
0.986 m2
a. Oil inlet or outlet 10.61 sq. ft.
b. Oil inlet or outlet
c. Cooling water
11-30
STRUCTURE AND FUNCTION FUEL SYSTEM
FUEL SYSTEM
FLOW DIAGRAM
1. Fuel tank 7. Fuel injection pump D. Fuel gallery inlet

2. Prefilter 8. Fuel injection nozzle E. Fuel out to lift pump
3. Fuel connection block 9. Electronic governor F. Fuel in from fuel filter
4. Fuel lift pump A. Fuel supply (From tank) G. Fuel drain (to tank)
5. Fuel filter B. Fuel overflow valve
6. EHAB C. Fuel gallery outlet
11-31
FUEL INJECTION PUMP
Specifications
• Maker:BOSCH
• Type:RP39
11-32
RIGHT BANK PIPING
1. Fuel injection pipe (No. 6 cylinder) 10. Housing

2. Fuel injection pipe (No. 5 cylinder) 11. Coupling
3. Fuel injection pipe (No. 4 cylinder) 12. Air bleed plug
4. Fuel injection pipe (No. 3 cylinder) 13. Oil outlet pipe
5. Fuel spill tube 14. Fuel injection pump
6. Fuel injection pipe (No. 2 cylinder) 15. Adapter
7. Fuel injection pipe (No. 1 cylinder) 16. Feed pump
8. Pump drive gear (No. of teeth: 60) 17. Emergency stop valve
9. Pump drive shaft
11-33
LEFT BANK PIPING
1. Fuel injection pipe (No. 1 cylinder) 11. Feed pump

2. Fuel injection pipe (No. 2 cylinder) 12. Fuel injection pump
3. Fuel injection pipe (No. 3 cylinder) 13. Oil outlet pipe
4. Fuel spill tube 14. Hand priming pump
5. Fuel injection pipe (No. 4 cylinder) 15. Coupling
6. Fuel injection pipe (No. 5 cylinder) 16. Pump drive shaft
7. Fuel injection pipe (No. 6 cylinder) 17. Housing
8. Emergency stop valve 18. Pump drive gear (No. of teeth: 60)
9. Air bleed plug
10. Oil inlet pipe
11-34
FUEL INJECTION NOZZLE
1. Inlet connector Specifications

2. Nozzle holder • Type: Multi-hole type
3. Adjusting shim • Adjusting injection pressure: Shim adjusting type
4. Spring
5. Spring seat
6. Spacer
7. Nozzle
8. Retaining cap
9. Needle
10. #1 RB and #1 LB injector with needle lift sensor
a. Fuel inlet (From injection pump)

b. Injection (To cylinder)
c. Fuel return (To fuel tank)
11-35
FUEL FILTER
1. Filter head Specifications

2. Cartridge • Filtration area: 2.0 m2 (1.0 x 2 pcs)
a. Fuel inlet (From transfer pump)
b. Fuel outlet (To injection pump)
H Additional ports are marked indicating flow direc-

tion.
11-36
STRUCTURE AND FUNCTION COOLING SYSTEM
COOLING SYSTEM
1. Aftercooler 8. Bypass flow

2. Water outlet 9. Water filters
3. Aftercooler water inlet 10. Cylinder liner coolant cavity
4. Water pump impeller 11. Cylinder head coolant passage
5. Bypass flow 12. Oil coolers
6. Water outlet to block 13. Vent line flow
7. Water inlet
11-37
THERMOSTAT HOUSING FLOW
1. Thermostat
2. Water outlet
3. Coolant from block
4. Closed thermostat flow
5. Open thermostat flow
11-38
COOLING FAN BELT
1. Fan hub
2. Air crossover
3. Coolant temperature sensor
4. Oil pan
5. Fan idler tensioner
6. Water filters
7. Engine barring location
8. Full flow oil filters
11-39
WATER PUMP
1. Pump shaft Specifications

2. Water seal • Type: Centrifugal gear drive
3. Pump body • Pump speed: Engine speed x 1.80
4. Water pump drive gear (No. of teeth: 25)
5. Ball bearing
6. Oil seal
7. Impeller
8. Pump cover
a. From thermostat
b. From radiator (water inlet)
c. To oil cooler (water outlet)
11-40
COOLING FAN
1. Fan
2. Fan pulley Pulley outside diameter (mm)
3. Fan belt (poly V-belt)
4. Crank pulley Fan pulley Crank pulley Tension pulley
5. Tension pulley
405 203 150
6. Idler pulley
A. Wind direction
11-41
CORROSION RESISTOR
1. Head Specifications
2. Cartridge • Filtration area:0.373 m2 x 2
3. Element (Chemicals) 4.01 sq. ft. x 2
4. Valve
a. Water inlet
b. Water outlet
11-42
STRUCTURE AND FUNCTION ACCESSORY
ACCESSORY
AIR COMPRESSOR
1. Cylinder head a. Air inlet

2. Unloader valve b. Air outlet
3. Piston c. Unload pressure (from air governor)
4. Piston ring d. Oil inlet
5. Piston pin e. Water inlet or outlet
6. Cylinder f. Water inlet or outlet
7. Connecting rod g. Oil outlet
8. Crankcase
9. Crankshaft
10. Bushing
11. Cover
12. Thrust bearings
13. Unloading assembly
11-43
STRUCTURE AND FUNCTION ACCESSORY
Specifications Unloader valve

• Type: Water cooled, two cylinder • Governor controlled
• Unloader valve method: intake valve, open type • Max 125 psi
• Cylinder O.D. x stroke: 92.08 x 50.8 mm
• Discharge volume: 1352 cc/rev
• Weight: 33.5 kg
11-44
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
ALTERNATOR MOUNTING
1. Alternator
2. Adjustment molt
3. Alternator drive pulley
4. Alternator bracket
a. Alternator pulley
b. Alternator drive pulley
11-45
ALTERNATOR WITH REGULATOR
1. Alternator
2. Alternator pulley
11-46
STARTING MOTOR
DELCO 50MT 24V

1. Solenoid
2. Pinion gear
3. Starting motor
11-47
ELECTRICAL INTAKE AIR HEATER
1. Heater body Specifications

2. Heater coil • Rated voltage: 11V
3. Terminal • Rated current: 86A
11-48
12 TESTING, ADJUSTING AND
TROUBLESHOOTING
ADJUSTING VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
MEASURING COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
FUEL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
FUEL PUMP INSTALLATION AND TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
CHECKING INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
USING PROXIMITY SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
USING FUEL PUMP LOCK PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
SENSOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18
TIMING SENSOR (WITH FLYWHEEL TIMING HOLES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18
2ND DESIGN (FLYWHEEL TIMING LUGS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
FUEL OVERFLOW VALVE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20
ADJUSTING FUEL INJECTION PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-21
PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22
ENGINE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22
IN SERVICE RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22
ENGINE DYNAMOMETER RUN-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22
PORTABLE DYNAMOMETER OR LOAD BANK RUN-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22
INSITE SERVICE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22
FUEL FLOW MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23
MEASUREMENT OF FUEL CONSUMPTION RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-24
DYNAMOMETER WORKSHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-25
ENGINE DYNAMOMETER TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26
SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26
COOLANT PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26
GENERAL ENGINE TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26
ENGINE THROTTLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-27
TESTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28
ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . 12-28
FUEL INLET RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28
FUEL DRAIN LINE RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29
INTAKE MANIFOLD PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29
INTAKE AIR RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29
EXHAUST RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29
ENGINE BLOWBY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30
LUBRICATING OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32
COOLANT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32
LUBRICATING OIL TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32
AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-33
STARTING MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-33
ENGINE RUN-IN INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34
TEST LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34
TESTING AND ADJUSTING TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-37
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39
CHECKING FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39
12-1 1
TESTING AND ADJUSTING TABLE OF CONTENTS
330M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39
WA800/WA900. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39
ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39
CHECKING BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39
ADJUSTING BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-40
DRIVE BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-40
12-2 1
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
12
ADJUSTING VALVE CLEARANCE
★ Adjust clearance between crosshead and rocker arm.
Adjusting method of valve clearance
1. Remove the rocker arm housing cover
2. Rotate the crankshaft in a clockwise direction. While watch-

ing the movement of the intake valve of the R6 cylinder,
bring the R1 cylinder into the top dead center position of the
compression stroke and align the “R1.6 TOP” line on the
vibration damper (1) with the pointer (2).
★ Hold with a wrench in position B in the diagram on the right,

then crank the engine in the direction of the arrow.
★ When the R1 cylinder comes near the top dead center of
the compression stroke, the R6 intake valve will start to
move (open)
3. Loosen locknut (6) of adjustment screw (5) of R1 cylinder,

insert the feeler gauge A corresponding to the specified
clearance between crosshead (4) and rocker arm (3), and
adjust the clearance with the adjustment screw until the
thickness gauge can slide lightly.
★ Valve clearance (When engine is cold)

Intake valve: 0.43 mm
Exhaust valve: 0.80 mm
4. Tighten locknut in this position, secure adjustment screw.
Locknut: 58.8 ± 5.9 N•m (43.4 ± 4.4 lbf-ft)
5. Follow the same procedure to align the line with the pointer
and adjust the valve clearance of each cylinder according to
the firing order.
★ Firing order:
R1 – L1 – R5 – L5 – R3 – L3 – R6 – L6 – R2 – L2 – R4 – L4
★ The lines and marks shown in the diagram are on the out-
side circumference of the damper.
12-3 1
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
12
MEASURING COMPRESSION PRESSURE
Method of measuring compression pressure
Avoid touching the exhaust manifold or muffler when measuring compression. Be careful of rotating parts.
Do NOT wear loose fitting or torn clothing. Remove ALL jewelry when working.
★ Warm up the engine before measuring the compression pressure. (Oil temperature 40 - 60 °C)
1. Adjust valve clearance.
★ For details, see “ADJUSTING VALVE CLEARANCE” on page 12-3

2. Power to EHAB must be OFF.
3. Remove the nozzle holder assembly from the cylinder to be measured.
4. Install adapter A1 in the mount of the nozzle holder of the

cylinder to be measured, then secure with retainer (2).
Mounting bolt: 66.2 ± 7.4 N•m (48.8 ± 5.5 ft-lb)
5. Connect compression gauge A to the adapter.
6. Crank the engine with the starting motor and measure the
compression pressure.
★ Measure the compression pressure at the point where the

gauge indicator remains steady.
★ If the adapter mount is coated with a small amount of oil, it
will prevent leakage.
★ For details of the standard values for compression pressure,
see Standard value table.
12-4 1
TESTING AND ADJUSTING FUEL SYSTEM
12
FUEL SYSTEM
FUEL PUMP REMOVAL
★ Rotate the crankshaft to the engine timing specification
before removing the right bank fuel pump.
1. Install a protective cover to prevent any dirt or dust from get-

ting into the discharge port of the injection pump or the inlet
port of the nozzle connector. Clean the debris from around
the inline fuel injection pump.
2. Remove electrical connections (1) and fuel lines (2).

Remove all of the oil lines (3).
★ Right bank and left bank pumps are removed and installed
at the right bank timing location.
★ If the fuel pump is to be reused, remove the timing lock pin
and install in the locked position, as shown, to preserve the
pump timing.
3. Remove the four capscrews (1), washers and nuts holding

the pump to the drive housing.
4. Remove the injection pump bracket mounting bolts (2).
★ The right bank fuel pump bracket has six mounting bolts.
The left bank fuel pump bracket has three mounting bolts.
12-5 1
12
5. Move pump away from housing. Disengage the pump drive-
shaft gear from the spline coupling. Remove the pump from
the drive housing.
6. If pump is to be recalibrated, remove spline drive gear from

pump. Use spline coupling with bar attached to prevent
pump rotation while removing large nut. Use flange gear
puller to remove gear.
Remove locking pin to prevent damage.
7. Remove capscrews from mounting support and remove

support.
8. Install drive spline after repair. Remove locking pin.
Spine retaining nut:407 N•m (300 ft-lb)
9. Install locking pin and cap.
Locking pin and cap:27 N•m (20 ft-lb)
12-6 1
12
FUEL PUMP INSTALLATION AND TIMING
1. Rotate the engine clockwise until the crankshaft damper
pointer aligns with the specified engine timing, which is pro-
vided on the engine dataplate before TDC for the right bank
No. 1 cylinder on the compression stroke.
★ Right bank and left bank pumps are installed at the right
bank setting location.
2. Remove the No. 1 cylinder rocker cover and verify that the
No. 1 cylinder is at TDC, right bank.
3. Remove the fuel injection pump timing pin cap and verify
that the pump is locked.
4. Install the timing pin, plug, and sealing washer.
Timing pin plug:30 N•m (22 ft-lb)
5. Install the mounting bracket onto the fuel pump. Do NOT

tighten the capscrews.
6. Install the spline coupling onto the pump drive shaft gear
(1).
7. Install new o-rings.
12-7 1
12
I
If the pump does not align, do NOT force the pump and
drive into alignment. Forcing will result in fuel pump
damage.
8. Engage the spine coupling and install the pump drive shaft
gear into the drive housing. Install the flange mounting cap-
screws (1) and the fuel pump mounting capscrews (2).
★ The injection pump assembly MUST be at an angle to the

engine block.
★ If the pump does not align, remove fuel pump and the cover
plate on the front gear cover to gain access to the fuel pump
drive gear.
9. Loosen (2 to 3 turns) the large nut securing the two-piece

drive gear to the drive shaft. Using the barring tool to hold
the engine in position, remove the two opposing capscrews
securing the fuel pump drive gear to the hub.
10. Fabricate two jackscrews (M12x1.5) using bolts, Part No.

01011-31265. Remove 25mm of thread from the end of
each capscrew to form a 6mm diameter. The remaining 25
mm of thread will be used to install the jackscrews.
11. Install the two jackscrews.
12. Tighten the jackscrews through the gear and hub until mak-
ing contact with the thrust plate.
13. Tighten each capscrew with 1/4 turn until the two-piece gear
assembly pops off the drive shaft taper.
14. Remove the jackscrews.
12-8 1
12
15. Engage the spline coupling and install the pump drive shaft
gear into the drive housing. Install the flange mounting cap-
screw (1) and the fuel pump mounting screw (2).
★ The injection pump assembly MUST be at an angle to the

engine block.
16. Tighten the two pumps to bracket capscrews (1).
17. Tighten the four flange mounting capscrews (2).
18. Tighten the fuel pump mounting capscrews (3).
All capscrews:65 N•m (48 ft-lb)
19. Install large nut securing gear to shaft
Gear nut: 24 N•m (17 ft-lb)
20. Remove fuel pump locking pin.
★ If locking pin is difficult to remove, install metric capscrew

into end of pin to aid in removal.
12-9 1
12
21. Tighten large nut securing gear to shaft.
Large nut: 109 N•m (80 ft-lb)
22. Install and tighten two attaching bolts in gear.
Mounting bolt:14 N•m (84 ft-lb)
23. Rotate the engine clockwise until the crankshaft damper

pointer aligns with the specified engine timing, which is pro-
vided on the engine dataplate.
24. Install the injector pump lock pin. Verify the timing pin will
still engage.
25. Remove the lock pin.
26. Tighten the large nut securing the two-piece drive gear to
the drive shaft.
Large nut: 407 N•m (300 ft-lb)
27. Install the cover plate on the front gear cover.
28. Tighten the capscrews.
Capscrew: 65 N•m (48 ft-lb)
12-10 1
12
29. Install the electronic connections (1) and fuel lines (2) and
all the oil lines (3)
High pressure lines:24 N•m (17 ft-lb)
Low pressure lines:27 N•m (20 ft-lb)
30. Install the timing pin, cap and sealing washer in the
unlocked position.
Timing pin cap:30 N•m (22 ft-lb)
31. Pass the NBF connector through the hole in the rocker lever
cover.
32. Press fit the grommet into the rocker lever cover (3).
33. Install the valve cover and gasket (2).
Mounting bolt:7 N•m (62 in-lb)
34. Connect BF connector to ECM connection.
12-11 1
TESTING AND ADJUSTING CHECKING INJECTION TIMING
12
CHECKING INJECTION TIMING
USING PROXIMITY SENSOR
A Proximity Sensor and Lights Tool (Bosch # 0 986 612 174) is
the most accurate method of adjusting fuel pump timing. The
timing marks for the right bank are used to time both
pumps.
1. Remove the rocker cover of right bank cylinder 1. (The left

bank is illustrated.)
★ Before barring engine, make sure that the lock pins in both
of the fuel pumps are disengaged, to prevent damage to the
fuel pump.
★ If a lock pin is difficult to remove from its engaged position,

install a metric capscrew into the exposed end of the pin to
aid in its removal.
The normal direction of rotation for 12V140Z-1 engines is clock-

wise, when viewing from the front of the engine. A wrench may
be used to turn the engine from the center of the engine barring
location. (A).
If the front barring point is not readily accessible, the optional

barring tool may be used at the flywheel housing.
12-12 1
2. Rotate the engine to the R 1-6 mark on the crankshaft
damper.
3. Make sure that right bank cylinder 1 is at TDC of the com-

pression stroke by checking that both right bank cylinder 1
valve rocker levers are loose and the adjusting screws are
the same height. If not, then rotate the engi ne 360 °
4. Rotate the crankshaft counter-clockwise to approximately

40 degrees before TDC of the compression stroke for right
bank cylinder 1.
5. Remove the timing pin plug, the timing pin, and the sealing
washer from the pump to be timed.
12-13 1
★ Use only compressed air to clean the probe end of the sen-
sor to prevent damage.
6. Align the slot in the sensor with the slot in the fuel pump tim-
ing window. Securely hand tighten the sensor (A) and install
the ground clamp (B).
7. Slowly bar the engine in the normal direction of rotation.

One light on the service tool will illuminate as the pump
nears the injection point. It is not important if this is light A or
light B. The crank angle at which the second light first illumi-
nates is the current pump timing.
If timing does not meet specifications, refer to fuel pump timing

installation section.
8. Double check the pump timing, remove the sensor, and

install the lock pins in the disengaged position. Install the
timing pin plugs with sealing washers.
Timing pin cap:30 N•m (22 ft-lb)
9. Install needle lift sensor wire (3).
10. Install the rocker cover with a new gasket and tighten the
bolts to specification (The left bank is illustrated).
Mounting bolt:7 N•m (62 in-lb)
11. Connect needle lift sensor connector (1)
12-14 1
12
USING FUEL PUMP LOCK PIN
If a Proximity Sensor Lights Tool is not available, fuel injection
timing may be adjusted through the use of the fuel pump lock
pins. The timing marks for the right bank are used to time
both pumps.
1. Remove the rocker cover of right bank cylinder 1. (The left

bank is illustrated.)
★ Before barring the engine, make sure that the lock pins in
both of the fuel pumps are disengaged, to prevent damage
to the fuel pump.
★ If a lock pin is difficult to remove from its engaged position,

install a metric capscrew into the exposed end of the pin to
aid in its removal.
The normal direction of rotation for 12V140Z-1 engines is clock-

wise, when viewing from the front of the engine. A wrench may
be used to turn the engine from the center of the engine barring
location (A).
If the front barring point is not readily accessible, the optional

barring tool may be used at the flywheel housing.
12-15 1
2. Rotate the engine to the R 1-6 mark on the crankshaft
damper.
3. Make sure that the right bank cylinder 1 is at TDC of the

compression stroke by checking that both right bank cylin-
der 1 valve rocker levers are loose and the adjusting screws
are the same height. If not, then rotate the engine 360°.
4. Rotate the crankshaft clockwise to approximately 6.5

degrees before TDC of the compression stroke for right
bank cylinder 1.
5. Bar the engine back and forth near this point until the lock
pin can be installed in the engaged position.
12-16 1
If timing does not meet specifications, refer to fuel pump instal-
lation section.
12-17 1
TESTING AND ADJUSTING SENSOR INSTALLATION
12
SENSOR INSTALLATION
SPEED SENSOR
1. Bar engine to align tooth of flywheel ring gear with center of
sensor mounting hole.
2. Install sensor, hand tighten until contact.
3. Back out sensor 1/4 to 1 1/4 turn for alignment of mounting

capscrew hole.
4. Install capscrew.
Capscrew: 7 N•m (62 in-lb)
5. Connect pin connector to harness.
TIMING SENSOR (WITH FLYWHEEL TIM-

ING HOLES)
1. Bar engine and check alignment of reference hole in fly-
wheel through mounting hole. Reference hole should NOT
be visible.
12-18 1
TESTING AND ADJUSTING SENSOR INSTALLATION
2. Install sensor. Hand tighten until contact with flywheel sur-
face.
3. Back out 1/4 to 1 1/4 turn until alignment with mounting cap-
screw hole.
2ND DESIGN (FLYWHEEL TIMING LUGS)

1. Remove sensor mounting assembly.
2. Rotate 180° to place sensor over flywheel surface or bar

engine until one of seven timing lugs appear in sensor hole.
3. Install sensor. Hand tighten until contact.
4. Back out 1/4 to 1 1/4 turn until aligns with mounting cap-
screw hole.
6. Connect harness to sensor.
7. Install sensor cover into housing.
8. Connect harness from sensor to engine harness.
12-19 1
TESTING AND ADJUSTING FUEL OVERFLOW VALVE pressure
12
FUEL OVERFLOW VALVE PRESSURE
1. Install pressure gauge between lift pump outlet and fuel fil-
ter inlet.
★ Lift pump gauge installation will require modified capscrew

for hose connection.
1. Operate engine for 3 - 5 minutes or until pressure is stable.
Minimum: 245 kPa (35 psi)
Maximum: 280 kPa (40 psi)
If overflow valve is defective, fuel pump assembly must be reca-

librated with new valve.
If lift pump is defective, main pump calibration is not required.
Capscrew and fuel connection: 24 N•m (17 ft-lb)
12-20 1
TESTING AND ADJUSTING ADJUSTING FUEL INJECTION PRESSURE
12
ADJUSTING FUEL INJECTION PRESSURE
1. Remove retaining cap (8).
2. Confirm thickness of adjustment shim (3).
3. Insert correct shim (3) in response to the adjustment value

of injection pressure.
4. Tighten retaining cap (8), then confirm the fuel injection

pressure using nozzle tester.
Retaining cap:83.4 ± 4.9 N•m (61.5 ± 3.6 ft-lb)
★ Fuel injection racking pressure:

203
30 1.4 MPa (4350 psi)
–0 –0
★ Adjustment value per shim thickness of 0.025 mm:

0.34 MPa (49.3 psi)
★ Prepared shims: 0.5 to 1.975 mm

(at intervals of 0.025 mm)
★ Refer to the parts book for part numbers of the

prepared shims.
★ 0.031 x 7 hole cup 1600 PPH (725 kgH) flow
12-21 1
TESTING AND ADJUSTING PERFORMANCE TEST
12
PERFORMANCE TEST
ENGINE TESTING
This section outlines engine testing and engine run-in recom-
mendations for 12V140Z-1 engines. All engines must be run-in
after a rebuild or a repair involving the replacement of one or
more piston ring sets, cylinder liners or pistons.
Incorrect or insufficient break-in of the piston rings will

lead to early oil consumption or high blowby complaints.
Adherence to these run-in guidelines will allow the full
durability of new pistons, liners, and rings to be realized.
Before running the engine, make sure the engine is filled with
the proper coolant. Also, make sure the lubricating oil system is
filled and primed.
IN SERVICE RUN
The following in-service run-in guidelines are recommended for 12V140Z-1 engines after a repair involving
replacement of one or more of the piston ring sets, cylinder liners or pistons where engine or an engine dynamom-
eter and/or chassis dynamometer run-in cannot be performed.
The majority of heavy duty diesel applications will provide sufficient run-in under normal loaded operations. How-
ever, light load/high rpm operation must be avoided during the run-in period.
ENGINE DYNAMOMETER RUN-IN
This is the preferred method of run-in engines that have been rebuilt out-of-chassis. It is not practical, nor recom-
mended that an engine be removed from the application to conduct the run-in after a rebuild or cylinder repair has
been performed in-chassis. There is no requirement, nor is it recommended for an engine that has been run-in and
tested on an engine dynamometer to be run-in again after it has been reinstalled in the vehicle or equipment.
PORTABLE DYNAMOMETER OR LOAD BANK RUN-IN
When it is not possible to load an engine immediately after rebuild or repair, (example: a standby generator or fire
pump that cannot be operated because of customer restrictions, a fire truck that cannot be loaded with the water
pump, etc.), the engine must be run-in on a portable dynamometer or load bank following the recommendations
outlined in the attached procedures.
INSITE SERVICE TOOL
The preferred method of obtaining test information and determining corrective action is using service tool 3886188
to read fault codes and engine data. See INSITE information in this section.
12-22 1
12
FUEL FLOW MEASUREMENT
Accurate fuel flow measurement is important for evaluation of engine performance and troubleshooting on an
engine or chassis dynamometer. The only way accurate fuel flow measurement can be obtained is through proper
use of available equipment.
INSTALLATION
When installing the fuel measuring device, it is important to reduce the amount of air that can be introduced into the
system when the device is not in use. Therefore, the plumbing used must include non-restrictive shutoff valves,
such as ballcock valves, to contain fuel in the device after each use. Additional installation considerations are:
• A separate fuel supply for use on the dynamometer is recommended. All fuel used in the measuring device
must be clean for consistent operation.
• Care must be taken to reduce fuel line restriction to and from the engine. Minimum recommended hose sizes
are No. 10 for the engine fuel inlet, and No. 8 for the engine fuel drain. The length of either hose must not
exceed 15 feet.
• For accurate fuel consumption or flow measurement while testing on a chassis dynamometer, it is recom-
mended to use a fuel cooler to maintain inlet temperature to the fuel gear at 49°C (120°F) or below.
MEASUREMENT OF FUEL CONSUMPTION RATIO
1. Measure the length of time required for lowering of the fuel

level from A to B.
• Method for calculation of fuel consumption ratio.

g = (r•b)/(P•t) X 3600.
g = Fuel consumption ratio (g/kW•h(g/HP•h))
r = Specific gravity of fuel
b = Fuel consumption (cc) within measuring time
P = Shaft output (kW(HP))
t = Fuel consumption time (second)
• Typical measurement at test bench
12-23 1
• Simple measuring method
SPECIFICATIONS
Maintain the following limits during the engine test/run-in procedures:
Due to variations in ratings of different engine models, refer to the specific “Engine Data Sheet” for the particular
engine model being tested.
Intake restriction (Maximum at advertised horsepower)
• Clean air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 mm H2O (15 in H 2O)

• Dirty air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635 mm H2O (25 in H 2O)
Exhaust back pressure (Maximum at advertised horsepower) .................................................... 75 mm Hg (3 in Hg)
Blowby * (Maximum at advertised horsepower)
• New or rebuilt engines (Maximum 3600 hours). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Tables

• Used engines (Over 3600 hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Tables
Oil pressure (With 15W-40 oil at 107°C (225°F))
• Low idle (Minimum allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 kPa (20 psi)

• At 1200 RPM or torque peak (Minimum allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 kPa (36 psi)
Fuel inlet restriction measured at fuel pump inlet (Maximum at advertised horsepower)
• Clean fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 mm Hg (4 in Hg)

• Dirty fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 mm Hg (8 in Hg)
• Maximum allowable fuel inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71°C (160°F)
* Blowby checking tool, Part No. 3822566 - 0.302 inch orifice.
Blowby Limits
(using 0.302 inch diameter orifice at rated load and speed)
Engine HP (RPM Rating) New/Rebuilt Used Engine Limit
305 mm H2O 762 mm H2O
All ratings
(12 in H2O) (30 in H2O)
12-24 1
12
DYNAMOMETER WORKSHEET
Date: Repair Order No.: Operator:
ESN: CPL: Fuel Pump Code:
Complaint: SC Code:
PARAMETER CODE SPECIFICATIONS ACTUAL READING

Fuel Rate (lb/hr)
Intake Mfd. Pressure (in.Hg) See Fuel Pump Code
Intake Mfd. Temperature
*Intake Air Restriction 25 in H2O Maximum
*Exhaust Air Restriction 3 in Hg, Maximum
*Fuel Inlet Restriction 8 in Hg (Dirty Filter), Maximum
*Fuel Drain Line Restriction 3 psi, Maximum
Engine Blowby See Tables
* - Recorded at Maximum horsepower speed and full load
Road Speed Limit Engine High Speed Limit

Check Oil Level Low High OK Fuel Quality OK Not OK
Turbo Intake Lube HP

Engine Fuel Fuel Coolant Engine
Inlet Air Manifold Oil or
Speed *Rate/Press Temp Temp/Press Blowby
Temp Temp/Press Press Torque
* Be sure that the fuel rate is corrected for temperature.
Fuel Temperature Correction for Flow Rate Pressure Conversions
Less than 7°C (45°F) Flow meter not accurate

7 to 13°C (45 to 55°F) Subtract 2% from flow rate reading
13.0 to 20.0°C (55 to 68°F) Subtract 1% form flow rate reading 1 in. H2O = 0.074 in. Hg = 0.036 psi
20.0 29°C (68 to 85°F) No correction 1 in. Hg = 13.514 in. H 2O = 0.491 psi
29 to 42°C (85 to 108°F) Add 1% to flow rate reading 1 psi = 2.036 in. Hg = 27.7 in. H 2O
42 to 56°C (108 to 132°F) Add 2% to flow rate reading
56°C above (132°F) Flow meter not accurate
12-25 1
TESTING AND ADJUSTING ENGINE DYNAMOMETER TESTING
12
ENGINE DYNAMOMETER TESTING
SETUP
★ Be sure the dynamometer capacity is sufficient to permit
testing at 100 percent of the engine rated horsepower. If the
capacity is not enough, the testing procedure must be modi-
fied to the restrictions of the dynamometer.
1. Use engine lifting fixture, Part No. 3375109, to install the

engine to the test stand. Align and connect the dynamome-
ter. Refer to the manufacturer’s instructions for aligning and
testing the engine.
Refer to Service Bulletin No. 3666005, Dynamometer and Road Engine Testing, for detailed instructions on auxil-
iary aftercooling system attachment.
COOLANT PLUMBING
2. Connect the coolant supply to the water inlet connection.
3. Connect the coolant return to the water outlet connection.
4. Connect vent lines.
5. Install the drain plugs and close all of the water drain cocks.
GENERAL ENGINE TEST PROCEDURES
★ The lubricating oil system must be primed before operating

the engine after rebuild to avoid internal component dam-
age. Do not prime the system from the bypass filter as the
filter will be damaged.
6. Remove the large plug from the oil cooler housing.
7. Use a pump capable of supplying 205 kPa (30 psi) continu-

ous pressure. Connect the pump to the front of the engine
oil cooler as shown.
8. Use a supply of clean oil. Turn the pump to the ON position.

Check the engine oil pressure gauge. When the gauge indi-
cates oil pressure, begin monitoring the oil level in the oil
pan.
12-26 1
9. Check the engine coolant level to be sure it is filled to the
proper level.
Check the coolant level only when the engine is

stopped. Wait until the coolant temperature is below
50°C (120°F) before removing the pressure cap. Failure
to do so can cause personal injury from heated coolant
spray.
Do not add cold coolant to a hot engine. This can cause

engine casting damage. Allow the engine to cool below
50°C (120°F) before adding coolant.
10. Check the engine lubricating oil level to be sure it is filled to

the proper level.
★ Use a known source of good quality No. 2 diesel fuel.
This is very important since No. 1 diesel fuels, along with most other alternate fuels, are lighter (lower specific grav-
ity, higher API gravity) than No. 2 diesel fuel. The lighter the fuel, the lower the energy content (BTU) per liter (gal-
lon).
ENGINE THROTTLE CONTROL

Engines that are run on the engine dynamometer require that
the engine harness be installed, and connected to the engine.
Additionally, a special engine dynamometer version of the OEM
wiring harness and throttle control must be installed.
A special wiring harness and throttle control has been devel-

oped to enable engine operation out of the chassis.
12-27 1
TESTING PROCEDURE
To properly monitor engine performance, record the following
parameters. To limit dynamometer operating time, instrument
the engine to make as many checks as possible.
• Engine speed rpm with a verified tachometer

• Fuel rate (Use service tool, Part No. 337637)
• Fuel temperature (if needed to correct fuel rate)
• Fuel inlet restriction
• Fuel drain line restriction
• Intake manifold pressure
• Intake air restriction

• Exhaust air restriction
• Coolant temperature
• Engine blowby
• Lubricating oil pressure
• Coolant pressure
• Inlet manifold air temperature
• Turbocharger inlet air temperature
ENGINE SPEED (RPM) WITH A VERIFIED

TACHOMETER
1. Use a digital optical tachometer, Part No. 3377462, to check

and verify speed.
FUEL INLET RESTRICTION
2. Measure the fuel inlet restriction. Install a vacuum gauge,

Part No. ST-434, between the primary fuel filter and the lift
pump inlet.
Do not measure fuel inlet restriction with the fuel measuring

device installed. This will not measure the inlet restriction of the
vehicle’s supply plumbing.
12-28 1
FUEL DRAIN LINE RESTRICTION
3. Use Pressure Gauge, Part No. ST-1273, to measure fuel

drain line restriction.
★ Do not measure fuel drain line restriction with the fuel mea-
suring device installed. This will not measure the drain line
restriction of the vehicle’s return plumbing.
INTAKE MANIFOLD PRESSURE
4. Measure the intake manifold pressure (turbocharger boost).

Install pressure gauge, Part No. ST-1273, in the intake
manifold crossover.
5. Observe the reading on the pressure gauge.
INTAKE AIR RESTRICTION
6. Measure the inlet air restriction. Install the vacuum gauge,

Part No. ST-434, or a manometer in the intake air piping.
★ The gauge adapter must be installed at a 90 degree angle

to the air flow in a straight section of pipe at a minimum of
one pipe diameter before the turbocharger.
EXHAUST RESTRICTION
7. Measure the exhaust air restriction. Install the pressure

gauge, Part No. ST-1273, or a manometer in the exhaust air
piping.
★ The gauge adapter must be installed near the turbocharger

in a straight section of pipe at the turbine outlet.
12-29 1
ENGINE BLOWBY
★ Excessive blowby indicates an air compressor, a turbo-

charger, or an engine malfunction, allowing combustion
gases or air to enter the crankcase and build a pressure
higher than normal.
This procedure describes how to measure crankcase pressure

and how to determine the component that is malfunctioning.
Use one of the three blowby tools and a water manometer, Part
No. ST-1111-3. Maximum gauge capacity is 1270 mm-H 2O (50
in-H2O).
The engine blowby tools are similar in design. The difference between the tools is in the size of the orifice.
Blowby Tool Part No. 382256: 0.302” orifice
8. Use a length of hose (1) to attach the blowby tool to one of

the crankcase breathers.
9. Plug all of the other breathers.
10. Attach a manometer to the location shown (2).
11. Operate the engine at rated rpm and full load (wide open
throttle) until a steady reading is obtained.
12. Compare the blowby readings to previous readings on the

engine. If previous readings for the engine are not avail-
able, compare the blowby reading to new engine specifica-
tions.
★ A sudden increase in blowby indicates a problem. A gradual

increase over a period of time is normal (due to wear of
internal engine components).
Blowby Limits
(using 0.302 inch diameter orifice at rated load and speed)
Engine HP (RPM Rating) New/Rebuilt Used Engine Limit
305 mm H2O 762 mm H2O
All ratings
(12 in H2O) (30 in H2O)
12-30 1
13. If the blowby is higher than normal, check the crankcase
breathers and breather tubes to see if they are plugged.
14. Check the engine oil level. If the level is too high it can
cause a higher than normal crankcase pressure.
15. Isolate the air compressor to determine if it is malfunctioning

and causing the high blowby pressure.
16. Relieve the air pressure on the first air tank in the system
after the air compressor (wet tank).
17. Disconnect the air inlet and outlet connections. Plug the
intake manifold or air piping where the inlet connection was
removed.
18. Operate the engine at rated speed and full load (wide open
throttle) until a steady blowby reading is obtained.
19. Compare the blowby readings to the previous value. If the

blowby is now acceptable, replace the air compressor.
12-31 1
A sudden increase in blowby or a high reading that is not steady
indicates that there is internal damage in the engine.
LUBRICATING OIL PRESSURE
20. Use a pressure gauge, Part No. 3375275, to measure lubri-

cating oil pressure.
21. Install the pressure gauge to the main oil rifle (1) or air filter
head (2).
138 kPa (20 psi)

207 kPa (30 psi)
COOLANT PRESSURE
22. Measure the coolant pressure at the water manifold (1).
241 kPa (35 psi)
LUBRICATING OIL TEMPERATURE
23. Drain oil and remove plug from oil pan. Install master
gauge. Fill pan with oil and operate engine. Compare tem-
perature of original and master gauge.
★ If defect is found, replace defective part.
12-32 1
AIR COMPRESSOR
All air compressors must be operating during the engine run-in.

During the performance check, all air compressors must be in
the unload or non-operating mode.
24. Connect a source of compressed air capable of producing

665 kPa (95 psi) to the air compressor unloader (1). This air
line must contain a valve between the source and the
unloader
★ The compressed air load in the accompanying illustration

must be attached to the air compressor outlet (2).
25. Use an air tank (2). Install an air regulator (3) capable of
maintaining 345 to 517 kPa (50 to 75 psi) air pressure at
both minimum and maximum engine rpm.
26. Install a steel tube or high temperature hose (1).
235°C (500°F)
27. Connect the tube or hose (1) to the air compressor outlet.
STARTING MOTOR
Always connect the negative (-) cable first to avoid arc-

ing that can ignite explosive battery gases.
28. Inspect the voltage rating on the starting motor before

installing the electrical wiring.
29. Install the electrical wiring to the starting motor and batter-
ies, if used.
★ If another method of starting the engine is used, follow the

manufacturer’s instructions to make the necessary connections.
12-33 1
12
ENGINE RUN-IN INSTRUCTIONS
TEST LOAD
Rated RPM Rated Horsepower Torque Rise Test Load

2100 1050 ALL 1157 N•m (854 ft-lb)
2100 950 ALL 1047 N•m (772 ft-lb)
2100 850 ALL 937 N•m (691 ft-lb)
2100 760 ALL 838 N•m (618 ft-lb)
The run-in test must be performed with the engine operating at torque peak rpm. Operate a generator set engine
at rated rpm.
Example: The test load for a 475 up engine rated at 2,000 rpm with a 15 percent torque rise is (300 ft-lb)
★ This chart assumes the dynamometer constant is 5,252. If the dynamometer constant is not 5,252, use the fol-
lowing formula to determine the correct test load:
Correct test load = (Dynamometer constant) x (Test load) \ 5,252.
Example: The dynamometer constant for testing the engine in the above example is 4,000.
Correct test load = (4,000 x 300) \ 5,252 = (228 ft-lb)
★ This chart assumes engine run-in on a chassis dynamometer.
Do not crank the starting motor for more than 30 sec-

onds. Excessive heat will damage the starter.
1. START the engine. If the engine does not begin operating

after 30 seconds, allow two minutes for the starting motor to
cool.
If the oil pressure is not within specifications, STOP the

engine immediately. Both low and high oil pressure will
cause engine damage.
Main oil rifle pressure at idle:
Minimum: 138 kPa (20 psi)
Maximum: 483 kPa (70 psi)
12-34 1
2. Operate the engine at the IDLE position. Check for leaks.
Do not operate the engine at IDLE for longer than spec-

ified. Excessive carbon formation will cause engine
damage.
3. Adjust the engine rpm to 1,200 rpm. Adjust the dynamome-

ter load to the test load as previously determined. Operate
the engine at this setting until the coolant temperature indi-
cates 70 °C (160°F).
4. Check for leaks. Fix all leaks.
5. Check all of the gauges and record the readings.
Do not proceed to the next step until the blowby becomes sta-
ble within specifications.
6. Adjust the engine rpm to the torque peak rpm. Adjust the
dynamometer load to equal two times the test load. Operate
the engine for two minutes.
7. Check all the gauges and record the readings.
8. Maintain the engine rpm at torque peak rpm. Increase the

dynamometer load to equal three times the test load.
9. Operate the engine at this load for 2 minutes.
12-35 1
11. Move the throttle lever to the FULL OPEN position. Increase
the load until the engine rpm is at torque peak rpm.
12. Operate the engine at this setting for 10 minutes or until the
blowby becomes stable within the specifications.
14. Decrease the dynamometer load until the engine rpm

increases to the rated rpm.
15. Operate the engine at this load for 5 minutes.
17. Decrease the dynamometer load completely.
Do not turn the engine OFF immediately. The engine

must be allowed to cool.
18. Move the throttle lever to the LOW IDLE position. Operate
the engine at this setting for 3 to 5 minutes. This will allow
the turbocharger and the other engine components to cool.
Do not operate the engine at IDLE longer than speci-

fied. Excessive carbon formation can cause engine
damage.
19. Turn the engine OFF.
12-36 1
TESTING AND ADJUSTING TESTING AND ADJUSTING TOOL LIST
12
TESTING AND ADJUSTING TOOL LIST
No. Testing and Measuring Item Tool Description Part Number
Hand Tachometer 3823782

1 Engine Speed
Digital Optical Tachometer 3377462
2 Battery Specific Gravity Specific Gravity Tester Commercially Available
3 Freezing Temperature of Coolant Fleetguard Coolant Test Kit CC2602
Water Temperature
4 Oil Temperature Digital Thermometer 3822666
Air Temperature
5 Exhaust Temperature Contact Pyrometer 3376336
Lubrication Oil Pressure
6 Fuel Pressure Pressure-Vacuum Meter 3824645
Intake Manifold Pressure
Exhaust Pressure
7 Blow-by Pressure Slack Tube Manometer ST1111-30
Intake Restriction
8 Compression Pressure Compression Gauge Commercially Available
9 Valve Clearance Feeler Gauges Commercially Available
10 Exhaust Gas Color Smoke Meter Commercially Available
11 Water and Fuel Content in Oil Engine Oil Testing Commercially Available
12 Fuel Injection Pressure and Pattern Nozzle Tester 3376946
13 Coolant quality, Molybdate and Nitrite Fleetguard Coolant Test Kit CC2602
14 Cooling Pressure Valve Function, Leakage Radiator Cap Tester Commercially Available
15 Radiator Wind Speed Anemometer Commercially Available
16 Engine Barring Barring Device 3201740
17 Electrical Circuit Testing Multimeter 3377161
Proximity Sensor and Lights Bosch # 0 986 612 174

18 Fuel Injection Timing
Fuel Pump Locking Pin Part of Pump Assembly
19 Performance Options Insite Service Tool 3886188
20 Alternator Belt Tension Tension Gauge ST1293
21 Fan Belt Tension Tension Gauge Burroughs BT-33-72B
12-37 1
TESTING AND ADJUSTING TESTING AND ADJUSTING TOOL LIST
12
Engine model 12V140Z-1
Applicable machine model 330M WA900 WA800
Classifi- Standard Permissible Standard Permissible Standard Permissible

Item Condition, etc. Unit
cation value value value value value value
High idling speed 2100 - 2200 2100 - 2200 2100 - 2200 2100 - 2200 2100 - 2200 2100 - 2200
Engine speed
Performance
rpm
(adjustable)
Low idling speed 600 - 700 600 - 700 650 - 700 650 - 700 650 - 700 650 - 700
0°C Min. 110 – Min. 110 – Min. 110 –

Necessary starting speed rpm
–20°C (with starting aid) Min. 100 – Min. 100 – Min. 100 –
Intake resistance At all speed mmH 2O Max. 380 635 Max. 380 635 Max. 380 635
Intake pressure At rated output mmHg 1321 – 1170 – 1016 –
Exhaust pressure
At rated output mmHg – – – – – –
Intake and exhaust system
(Turbine inlet pressure)
Exhaust temperature All speed

°C Max. 750 750 Max. 750 750 – –
(Turbine inlet temp.) (intake air temp.: 25°C)
Quick acceleration
Max. 5.0 7.0 Max. 5.0 7.0 5.0 7.0
(Low idling to High idling)
Bosch
Exhaust gas color
At rated output scale Max. 0.6 1.0 – – – –
At high idling Max. 0.6 1.0 Max. 1.0 1.5 1.0 1.5
Valve clearance Intake valve 0.43 – 0.43 – 0.43 –

(when engine is hot mm
or cold) Exhaust valve 0.80 – 0.80 – 0.80 –
Oil temperature: 40 – 60°C MPa

Compression pressure Min. 3.1 2.2 Min. 3.1 2.2 Min. 3.1 2.2
Engine body
(Engine speed:
(SAE30 oil)
160-200rpm) (kg/cm2) (Min. 32) (22) (Min. 32) (22) (Min. 32) (22)
At rated output
Blowby pressure mmH 2O
Water temperature: 305 635 305 635 305 635
(SAE30 oil)
Min. 70°C
0.3 – 0.44 0.21 0.25 – 0.39 0.18

At rated outputSAE30 oil – –
(3.0 – 4.5) (2.1) (2.5 – 4.0) (1.8)
0.25 – 0.39 0.18 0.20 – 0.34 0.13

SAE10W oil – –
Oil pressure (2.5 – 4.0) (1.8) (2.0 – 3.5) (1.3)
Lubrication system
MPa
(Oil temperature:
Min. 107°C (225°F)) (kg/cm2) Min. 0.1 0.07 Min. 0.1 0.07
At low idlingSAE30 oil – –
(Min. 1.0) (0.7) (Min. 1.0) (0.7)
Min. 0.1 0.07 Min. 0.1 0.07

SAE10W oil – –
(Min. 1.0) (0.7) (Min. 1.0) (0.7)
Oil temperature All speed (oil in oil pan) °C 80 – 110 120 80 – 110 120 80 – 110 120
At continuous rated output

Oil consumption ratio % Max. 0.5 1.0 Max. 0.5 1.0 – –
(Ratio of fuel consumption)
+1.0 +1.0 +1.0

30 - 0 30 - 0 30 - 0
Fuel system
MPa
Fuel injection pressure Nozzle tester – – –
(psi)
+200 +200 +200
4350 - 0 4350 - 0 4350 - 0
Fuel injection timing B.T.D.C. degree 6.5 6.5 ± 0.5 6.5 6.5 ± 0.5 6.5 6.5 ± 0.5
Cooling system
Opening pressure MPa 0.1 ± 0.015 0.1 ± 0.015 0.07 ± 0.01 0.07 ± 0.01
Radiator pressure valve – –
(Differential pressure) (kg/cm2) (1.0 ± 0.15) (1.0 ± 0.15) (0.70 ± 0.1) (0.70 ± 0.1)
Fan speed At rated engine speed rpm 1000 ± 30 – 1000 ± 30 – 1000 ± 30 –
Fan belt tension mm Autotension Autotension Autotension
★ The values given in the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.
12-38 1
TESTING AND ADJUSTING COOLING SYSTEM
COOLING SYSTEM
CHECKING FAN BELT TENSION
330M
1. Install belt tension gauge (Burroughs # BT-33-72B)
• New belt tension: 2660 N (600 lb)

• Used belt tension: 2220 N (500 lbF)
• Range: 1780 N (400 lbF)
2. If tension is below specifications, loosen nuts (1) and (2).

Tighten nut 2 until tension is correct.
Lock nut: 81 N•m (60 ft-lb)
WA800/WA900
Use same procedure for retension. New belt requires moving

lock nut (1) to end of rod and moving second idler to contact
belt. Tighten second idler and repeat new belt tensioning proce-
dure.
ALTERNATOR BELT
CHECKING BELT TENSION

Push belt (4) at mid-point between alternator and alternator
drive pulley with a force of approximately 58.8 N (1.3 lbf) and
measure the distance the belt moves.
12-39 1
TESTING AND ADJUSTING ALTERNATOR BELT
ADJUSTING BELT TENSION

Turn the lockout adjustment bolt (1) in the direction to extend
the belt (3). Adjust the belt to specifications. Tighten the lock
bolt (2) and the locknut.
Locknut: 55 N•m (40 ft-lb)
DRIVE BELT TENSION

SAE Belt Size Belt Tension Gauge Part No. Belt Tension New Belt Tension Range Used*
Click-type Burroughs N lbf N lbf
0.380 in 3822524 620 140 270 to 490 60 to 110
0.440 in 3822524 620 140 270 to 490 60 to 110
1/2 in 3822524 ST-1138 620 140 270 to 490 60 to 110
11/16 in 3822524 ST-1138 620 140 270 to 490 60 to 110
3/4 in 3822524 ST-1138 620 140 270 to 490 60 to 110
7/8 in 3822524 ST-1138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 110
5 rib 3822524 ST-1138 670 150 270 to 530 60 to 120
6 rib 3822525 ST-1293 710 160 290 to 580 65 to 130
8 rib 3822525 ST-1293 890 200 360 to 710 80 to 160
10 rib 3822525 3823138 1110 250 440 to 890 100 to 200
12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240
12 rib K section 3822525 3823138 1330 300 890 to 1070 200 to 240
★ This chart does not apply to automatic belt tensioners.

★ A belt is considered used if it has been in service for ten minutes or longer.
★ If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
12-40 1
13 DISASSEMBLY AND ASSEMBLY
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
WASHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
SETTING ENGINE STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
GENERAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Engine cooling water and engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Muffler assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Intake connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Turbocharger assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Intake manifold, aftercooler assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Exhaust manifold assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
Air compressor assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Fuel pump drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Water pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
Oil cooler assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
Rocker lever cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
Rocker lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
Cylinder head assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Cam follower assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15
Accessory drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15
Damper, crankshaft pulley assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16
Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16
Main relief valve, suction tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16
Front support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Gear case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-19
WASHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
WASHING CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
WASHING CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25
WASHING CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25
MEASURING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26
MEASURING CURVATURE OF CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26
MEASURING OUTSIDE DIAMETER OF JOURNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26
MEASURING OUT-OF-ROUNDNESS OF JOURNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26
MEASURING SURFACE ROUGHNESS OF OUTSIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-27
DIAMETER OF JOURNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-27
MEASURING DEPTH OF CYLINDER LINER COUNTERBORE . . . . . . . . . . . . . . . . . . . . . . . . . 13-27
MEASURING MAIN BEARING BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28
MEASURING CURVATURE OF CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28
MEASURING OUTSIDE DIAMETER OF JOURNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28
MEASURING HEIGHT OF CAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29
13-1 1
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
MEASURING PISTON RING GROOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29
MEASURING PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29
MEASURING OUTSIDE DIAMETER OF PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30
MEASURING LENGTH OF CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30
MEASURING INSIDE DIAMETER AT SMALL END OF CONNECTING ROD . . . . . . . . . . . . . . 13-31
MEASURING INSIDE DIAMETER AT BIG END OF CONNECTING ROD . . . . . . . . . . . . . . . . . 13-31
MEASURING CURVATURE, TWISTING OF CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . 13-31
STANDARD PRESSURE FOR PARTS PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 13-32
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-33
TIGHTENING BOLTS BY PLASTIC RANGE TURNING ANGLE METHOD . . . . . . . . . . . . . . . . 13-33
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-34
PREPARATORY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-34
GENERAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-35
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-35
Gear Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-47
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-53
Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-57
Front support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-58
Main relief valve, suction pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-58
Oil pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-58
Damper, crankshaft pulley assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-58
Accessory drive assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-59
Thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-60
Cam follower assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-60
Cylinder head assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-60
Rocker lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-63
Rocker lever cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-64
Oil cooler assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-65
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-67
Water pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-67
Fuel pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-68
Air compressor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-70
Fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-71
Exhaust manifold assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-71
Intake manifold, aftercooler assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-72
Turbocharger assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-73
Intake connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-74
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-74
General assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-75
13-2 1
DISASSEMBLY AND ASSEMBLY DISASSEMBLY
12
DISASSEMBLY
SPECIAL TOOLS
No. Part Number Part Description

A 3375960 Valve Spring Compressor
B 3823137 Piston Ring Expander
3376015
C Liner Puller
3375629
D 3823495 Protrusion Gauge
E 3825190 Fuel Injector Puller
WASHING
• Before disassembling the engine, check all parts for any
cracks or damage, then clean the whole engine carefully
with steam so that the disassembly work can be carried out
swiftly.
A) Before washing, remove starting motor assembly (1),
alternator assembly (2), and electric wiring.
B) Cover all the openings of the engine with tape.
C) Using a washing machine, clean engine.
★ Carefully wash all mating surfaces where mud tends to col-

lect
SETTING ENGINE STAND

• Prepare a stable engine stand that will prevent the engine
from falling over, then set the engine assembly on the stand
and secure it in position.
Engine assembly: Approx. 3,200 kg (7,056 lb)
(The weight differs according to the machine mounting the

engine.)
GENERAL DISASSEMBLY
Engine cooling water and engine oil
1. Drain engine cooling water and engine oil.
Engine oil: Approx. 147 L (39 gal) (The amount of oil differs according to the engine model.)
Government agencies have determined that used engine oil is toxic and carcinogenic. Avoid inhalation,
ingestion, and prolonged contact with used engine oil.
13-3 1
2. Filter
• Engine equipped with filters

A) Using filter wrench, remove corrosion resistor (1), oil fil-
ter (2), and fuel filter (3).
B) Remove bypass filter
C) Remove mounting brackets and filter head.
Muffler assembly
1. Disconnect komaclone tube (4), then remove muffler

assembly (5) and muffler bracket.
Fan
1. Using nylon sling, sling fan, then remove mounting bolts.
2. Remove fan (1).
Fan: 75 kg (165 lb)

(The weight differs according to the machine model.)
3. Fan belt
The fan belt idler is under tension. Do NOT place your

hands between the idler and the belt or the fan hub.
Personal injury can result.
A) Loosen locknuts (1) and (2).

B) Slowly remove nut (1) until the spring tension is relieved
and remove the belt.
13-4 1
4. Fan pulley assembly
A) Using nylon sling, sling fan pulley assembly, and

remove mounting bolts.
B) Remove fan pulley assembly (2)
Fan pulley assembly: 85 kg (187 lb)
Intake connector
1. Remove intake connectors. Loosen V-band clamp, slide O-

ring connector into crossover.
2. Remove capscrews and air crossover
Turbocharger assembly
1. Disconnect turbocharger oil supply tube (1) and drain tube

(2).
2. Remove turbocharger assembly (3).
13-5 1
IIntake manifold, aftercooler assembly for

SA12V140Z-1 Engine
1. Left bank
A) Remove tubes for aftercooler.

B) Remove heater relay wiring.
C) Disconnect air supply to air compressor.
D) Remove engine harness mount clamps.
E) Remove sensor connections.
2. Right bank
A) Remove tubes for aftercooler

B) Remove wiring of electrical intake air heater.
C) Remove sensors.
D) Remove engine harness clamps and engine harness
with mounting panel.
E) Sling intake manifold and aftercooler assembly (11),

and remove mounting bolts.
★ To prevent the electrical intake air heater from falling off,

install a guide bar in the mounting bolt hole of the intake
manifold below.
F) Remove intake manifold and aftercooler assembly.
Intake manifold, aftercooler assembly: 50 kg (110 lb)
3. Aftercooler core
A) Remove connector (12).

B) Remove cover (13).
C) Remove aftercooler core (14).
13-6 3
Intake manifold, aftercooler assembly for

SAA12V140ZE-2 Engine
1. Disconnect the engine harness from the coolant pressure

sensor. Remove the engine harness clamps.
2. Disconnect the coolant temperature sensor and the coolant

level sensor.
3. Cut the ties on the thermostat housing bracket, aftercooler

tube and fuel tube.
4. Disconnect the intake manifold temperature sensor.
13-6-1 3
5. Disconnect the ambient air pressure sensor (2) and the
intake manifold pressure sensor (1).
6. Disconnect the NBF injector lead from the wiring harness.
7. Remove the air compressor air inlet connection.
8. Loosen the outboard hose clamps on the hoses connecting

the turbocharger compressor outlet to the compressor outlet
duct.
9. Slide the hose clamps down toward the turbocharger.
13-6-2 3
10. Remove the four capscrews securing the turbocharger com-
pressor outlet duct to its support bracket.
11. Disengage the duct from the hose and remove it.
12. Remove the capscrews securing the charge air cooler

return duct to the intake manifold cover.
13. Remove the capscrews securing the charge air cooler

return duct to its bracket and remove the duct.
14. Remove wiring harness, intake manifold pressure sensor

and intake manifold air temperature sensor.
15. Remove two mounting capscrews. Install two 10 mm guide

studs.
Aftercooler assembly, intake manifold: 50 kg (110 lb)
16. Use a hoist, two 10 mm T-handles and a lifting sling. Attach

the T-handles, sling and hoist. Raise the hoist until there is
tension on the sling.
17. Remove the remaining capscrews and the air intake mani-
fold assembly.
18. Remove and discard the gaskets.
13-6-3 3
Clean
1. Clean the intake manifold to cylinder head surface.
2. Clean the intake manifold gasket surface.
Inspect for Reuse
1. Inspect the intake manifold for cracks or other damage.
★ When inspecting the intake manifold for oil or debris from an

air system failure, also inspect the intake ports in the cylin-
der head for oil and debris.
13-6-4 3
Exhaust manifold assembly

Remove exhaust manifold assembly (1).
Exhaust manifold assembly: 30 kg (66 lb)
Fuel Injector
1. Fuel injection spill pipe
A) Remove fuel injection pressure lines (1).

B) Remove drain tube (2).
★ Install a protective cover to prevent any dirt or dust from get-

port of the nozzle connector.
2. Fuel injection pump assembly
★ Rotate the crankshaft to the engine timing specification

before removing the right bank fuel pump.
★ Install a protective cover to prevent any dirt or dust from get-

port of the nozzle connector. Clean the debris from around
the inline fuel injection pump.
A) Remove electrical connections (1) and fuel lines (2).

B) Remove all of the oil lines (3).
13-7 3
★ If the fuel pump is to be reused, remove the timing lock pin

and install in the locked position, as shown, to preserve the
pump timing.
C) Remove the four capscrews (1), washers and nuts hold-

ing the pump to the drive housing.
D) Remove the injection pump bracket mounting bolts (2).
★ The right bank fuel pump bracket has six mounting bolts.
The left bank fuel pump bracket has three mounting bolts.
E) Disengage the pump driveshaft gear from the spline

coupling.
F) Remove the pump from the drive housing.
Air compressor assembly
1. Remove air inlet, air outlet, water inlet, and water outlet con-
nections.
13-8 1
The component weighs more than 23 kg (50 lb). To

avoid personal injury, use a hoist or get assistance to lift
the component.
2. Remove the air compressor support mounting capscrews
(5).
3. Remove the capscrews (6) from the air compressor mount-

ing bracket.
4. Remove the air compressor. Remove the splined coupling

(1).
5. Remove and discard the gasket.
Fuel pump drive assembly
1. Remove the fuel pump drive gear cover plate on the front
gear cover.
2. Loosen (2 to 3 turns) the large nut securing the two-piece

drive gear to the drive shaft.
3. Remove the two opposing capscrews securing the fuel

pump drive gear to the hub.
4. Fabricate two jackscrews (M12x1.5) using capscrews, Part

No. 01011-31265. Remove 25 mm of thread form the end of
each capscrew to form a 6 mm diameter. The remaining 25
mm of thread will be used to install the jackscrews.
A) Install the two jackscrews.

B) Tighten the jackscrews through the gear and hub until
making contact with the thrust plate.
13-9 1
C) Tighten each capscrew with 1/4 turn until the two-piece
gear assembly pops off the drive shaft taper.
★ Check to make sure the drive gear assembly will be sup-

ported by the gear train. If NOT, use a wire to prevent it from
dropping into the oil pan.
D) Remove the jackscrews.

E) Remove the nut and washer.
5. Remove the four capscrews securing the flange mount

housing assembly to the rear gear cover.
6. Remove two capscrews from support bracket.
7. Remove the housing assembly.
8. Fuel pump drive disassembly
A) Remove retaining nut (1). (Use modified spline coupling

to hold shaft at spline (2).)
B) Remove shaft toward pump mount.
C) Remove spline retaining nut (3) (Use modified coupling
to hold shaft)
D) Use puller to remove spline coupling (2)

E) Drive bushing (4) from housing (5).
13-10 1
F) Fuel pump drive case assembly
i) Remove drive spline.

ii) Pull out drive shaft (3) towards portion A.
iii) Left bank: Short
Right bank: Long
iv) Remove oil seal (4).
v) Pull bushings (5) out from drive case (6).
Water pump assembly
1. Remove the water bypass connection and water transfer

tube.
2. Remove the four water pump mounting capscrews.
★ Two of the mounting capscrews are installed from the front

of the water pump and two from the back.
3. Remove the water pump assembly and gasket. Discard the

gasket.
Breather
1. Remove alternator bracket (1).
★ The alternator bracket is on the right bank only.

2. Remove clamp, then remove tube (2).
3. Remove breather (3).
13-11 1
Oil cooler assembly
1. Remove front oil cooler assembly (1).
2. Remove manifolds (2) and (3).
3. Remove rear oil cooler assembly(4).
4. Oil filter, oil level gauge
A) Remove bracket, then oil filler (1).

B) Remove oil level gauge guide (2).
★ Loosen the nut at the root of the level guide, then remove
the guide.
Rocker lever cover
1. Remove rocker lever cover (1).
2. Remove turbocharger oil supply tube (2) and drain tube (3).
3. Remove air vent tube (4).
4. Remove fuel drain line.
Remove fuel supply connection before removing injec-

tor to prevent damage to the rocker lever housing.
13-12 1
5. Nozzle holder, connection
A) Loosen locknut, and remove connection (1).

B) Remove holder (2).
C) Using tool E, remove nozzle holder (3).
★ Mark each nozzle holder with the cylinder number, keep it in

a safe place, and be careful not to damage the tip.
★ Check that the gasket is fitted to the tip of the nozzle holder.
Rocker lever
1. Remove rocker lever (1)
★ To prevent pressure on the push rod when installing, loosen

the locknut and turn the adjustment screw back 2 to 3 turns
before removing the rocker lever assembly.
2. Push rod
Remove push rod (2).
3. Crosshead
Remove crosshead (3).
4. Rocker lever housing
Remove rocker lever housing
13-13 1
Cylinder head assembly
1. Remove mounting bolts (1), then remove cylinder head

assembly (2).
2. Remove gasket (3) of each cylinder head.
3. Cylinder head disassembly
A) Using spring pusher A, compress valve spring, then

remove cotter (4).
B) Remove upper seat (5), outer spring (6), and inner
spring (7).
C) Remove seals.
D) Remove lower seat (8).

E) Raise cylinder head, and remove valve (9).
★ Use tags to mark the assembly portion of the valves of each

cylinder.
Cam follower assembly
1. Remove cover (1).
2. Remove mounting bolts (2), then remove cam follower

assembly (3).
★ The mounting bolt of the cam follower is a special bolt, so

keep it in a safe place and be careful not to lose it.
13-14 1
Thermostat housing
1. Remove connector tube (1).
2. Screw eyebolts (Thread dia. – 10 mm, Pitch – 1.5 mm)

[0.3937 in, P – 0.0591 in] into thermostat case (2), sling
thermostat case assembly (2), (3), then remove it.
3. Disconnect thermostat case (2) and thermostat housing.
4. Remove thermostat (4) from thermostat case.
5. Remove seal (5).
Accessory drive assembly
1. Remove pulley (1).
2. Remove drive assembly (2).
3. Accessory drive disassembly
A) Pull out hub (3), and remove thrust plate (4).

B) Remove shaft (5), thrust plate (6), and gear (7) as one
unit.
C) Remove gear (7) from shaft (5).
D) Pull out oil seal (9) and bushings (10) form housing (8).
13-15 1
Damper, crankshaft pulley assembly
1. Sling damper and crankshaft pulley assembly (1), and

2. Remove damper and crankshaft pulley assembly.
Damper, crankshaft pulley assembly: 56 kg (123 lb)
Do not use an impact wrench to loosen bolts, to prevent

possible damage to threads.
Oil pan
1. Raise cylinder block assembly, and set stand under flywheel

housing and front support.
2. Support oil pan with transmission jack, and remove mount-

ing bolts, then remove oil pan (1).
Oil pan: 45 kg (99lb)
Government agencies have determined that used

engine oil is toxic and carcinogenic. Avoid inhalation,
ingestion, and prolonged contact with used engine oil.
Main relief valve, suction tube
1. Remove main relief valve (2).
2. Remove bracket (3), then remove suction tube (4).
Front support
Raise cylinder block assembly and remove front support (1).
Sensors
Remove rpm (1) and timing (2) sensors.
13-16 1
Flywheel
1. Using eyebolts (3), (Thread dia. – 12 mm, Pitch – 1.75 mm)

[0.4724 in, P – 0.0689 in] sling flywheel (2), then remove
mounting bolts (1), and screw in forcing screws (4), (Thread
dia. – 12 mm, Pitch – 1.75 mm) [0.4724 in, P – 0.0689 in] to
remove flywheel (2).
Flywheel: 136 kg (300 lb)
Do not use an impact wrench to loosen bolts, to prevent

possible damage to threads.
2. Flywheel housing, rear seal
A) Remove 2 – 3 mounting bolts, then install guide bolts.

B) Sling flywheel housing (1), then remove remaining
mounting bolts, and remove flywheel housing (1).
★ Support the housing by hand when removing it to prevent it
from falling over.
Flywheel housing: 102 kg (225 lb)
C) Remove rear seal.
Gear case
1. Using eyebolts (1) (Thread dia. – 10 mm, Pitch – 1.5 mm)

[0.3937 in, P – 0.0591 in], sling gear case cover (1), then
remove mounting bolts, install guide bolts, and remove gear
case cover (1).
Gear case cover: 72 kg (159 lb)
2. Remove front seal.
3. Idler gear (large)
Remove mounting bolts, then remove plate (1) and idler gear
(large) (2).
13-17 1
4. Oil pump assembly
Remove oil pump assembly (1).
5. Idler gear (small)
Remove mounting bolts, then remove plate (1) and idler gear
(small) (2).
6. Camshaft assembly
Remove bolt from hole in cam gear, then pull out camshaft
assembly (1).
★ When removing the camshaft, rotate it while pulling it out to

prevent damage to the cam bushing.
7. Timing gear case
A) Using eyebolts (A) (Thread dia. – 10 mm, Pitch – 1.5

mm) [0.3937 in, P – 0.0591 in], sling gear case, then
B) Install guide bolts, and remove gear case (1).
Timing gear case: 65 kg (143 lb)
13-18 1
Cylinder Block
Remove mounting bolts, then remove each piston cooling noz-

zle (1).
★ Before removing the piston and connecting rod assembly,
remove the piston cooling nozzle.
★ Rotate 90° so that it does not contact the piston when it is
removed.
2. Piston and connecting rod assembly
A) Using dial gauge (1), measure connecting rod side

clearance to act as a guide when assembling.
★ Check the stamped number on the connecting rod cap.

(The cap number and cylinder number must match. The
number is stamped on the cam side.)
★ If there is no stamped mark, mark the cylinder No. with an
electric pen before removing. Do not stamp a mark.
B) Rotate the crankshaft so that the piston to be removed

is at bottom dead center.
C) Loosen connecting rod bolt (1) 5 – 6 turns.
If an impact wrench is used to loosen the bolts, there is

danger of damage to the thread, so loosen the bolts
with a hand tool.
D) Tap head of connecting rod bolt with a plastic hammer,

then disassemble connecting rod cap and connecting
rod.
E) Remove carbon from top wall of liner with fine sandpa-
per.
F) Rotate crankshaft, and align with top dead center, then
remove connecting rod cap (2).
G) Push in piston and connecting rod from oil pan end with
push bar (1), and support piston (3) at cylinder head
end while removing it.
★ Be careful not to damage the inside surface of the liner with

the corner of the connecting rod when removing it.
13-19 1
H) Remove other piston and connecting rods in the same

way.
★ Keep in a safe place and be careful not to damage the pis-

ton sliding surface and the bearing.
★ Assemble the connecting rod and cap temporarily and keep
together with the bearing to prevent mistakes when reas-
sembling.
I) Disassemble the piston and connecting rod assembly.
i) Remove snap ring (4).

ii) Support connecting rod (5) with hand, then pull out
piston pin (6), and disassemble piston (7) and con-
necting rod.
iii) If the piston pin is stiff and cannot be removed, heat
it in hot water (100°C [212°F], 5 min.) before remov-
ing it.
iv) Remove snap ring on the opposite side.
v) Using piston ring tool B, remove piston ring (8).

vi) Remove oil ring expander (9).
★ Keep the piston, connecting rod, connecting rod bearing,

piston ring, and piston pin in sets for each cylinder.
3. Crankshaft
A) Before removing the crankshaft, use dial gauge (1) to

measure end play of crankshaft, and use it as a guide
when assembling.
13-20 1
B) Remove mounting bolts (2) of main cap (1).
C) Insert bolt in hole of main cap, and move the main cap
from side to side to remove it.
★ Lower thrust bearing (3) is installed to the No. 7 main cap,

so after removing it, mark the assembly position.
D) Using wire, lift off crankshaft (4).
★ When raising the crankshaft, be careful not to hit it against

the cylinder block and damage it. After removal, keep it in a
safe place.
Crankshaft: 210 kg (463 lb)
E) Remove upper thrust bearing (5).

F) Remove upper bearing (6).
★ Use tags or a felt pen to mark the assembly position of the

main cap, main bearing, and thrust bearing, then keep them
in sets for each cap in a safe place.
13-21 1
4. Cylinder liner
A) Before removing cylinder liner, use tool D and dial indi-

cator (1) to measure protrusion of cylinder liner.
★ When measuring the protrusion of liner, tighten the liner with

a plate to prevent the liner from floating up on the O-ring.
Plate mounting bolt: 7 – 10 kgm (51 – 72 ft-lb)
B) Using liner puller C, pull out cylinder liner (1).
13-22 1
DISASSEMBLY AND ASSEMBLY WASHING
12
WASHING
Wear protective eyewear to prevent fluid from possible

contact with the eyes.
• When washing, divide the parts into small parts and large
parts, and wash the small parts in a bath like the one shown
on the right.
• Before washing disassembled parts, remove the gasket car-
bon with a wire brush.
• After washing, dry the washing fluid off completely with
compressed air.
• Make sure that no cleaning fluid remains in the bolt holes.
Bolts may not be properly tightened if fluid is present.
WASHING CYLINDER BLOCK

1. Before washing the cylinder block, remove the plugs of the
oil line in the cylinder block.
★ Timing case end: 7 places

★ Flywheel end: 5 places
2. Clean with a stiff wire brush to prevent any metal particles

from remaining in the oil line.
3. Use sandpaper to polish the O-ring contact surface smooth

at the bottom of the liner bore and to remove the burrs and
flashes from the liner bore.
4. Clean the oil line thoroughly with the jet cleaner nozzle of
the cleaning machine.
5. Dry off the cleaning fluid completely with compressed air.
★ Make sure that no cleaning fluid remains in the bolt holes.

Bolts may not be properly tightened if fluid is present.
13-23 1
12
6. Press fit plug with push tool.
Outer circumference of plug: Thread tightener (LT-2)
★ If the plug is bent when it is pushed in, it will cause leakage

of water, so be careful to insert it straight.
Unit: mm
Inside diameter ø30 ø40
of plug [1.1811 in] [1.5748 in]
0 0
29.5 –0.1
39.4 –0.1
øD
0 0
[1.1614 –0.0039 in] [1.15512 –0.0039 in]
0 0
26.5 –0.1
36.4 –0.1
ød
0 0
[1.0433 –0.0039 in] [1.4331 –0.0039 in]
6.4 ± 0.1 8.9 ± 0.1

H
[0.252 ± 0.0039 in] [0.3504 ± 0.0039 in]
1.0 1.0
t
[0.0394 in] [0.0394 in]
13-24 1
12
WASHING CRANKSHAFT
• If the engine is disassembled, wash the crankshaft before
inspecting.
1. Clean the crankshaft with a steam cleaner, then use a wire

brush like the one shown in the diagram on the right to clean
all the oil holes.
2. After washing, dry the cleaning fluid off thoroughly with com-
pressed air.
3. Use a small magnet to completely to completely remove all

the metal particles from the oil holes.
WASHING CONNECTING ROD

1. Clean the connecting rod with a steam cleaner, then use a wire brush to clean the oil holes.
2. If the inside surface of the hole at the big end of the connecting rod is black, but the problem is small and the
dimensions are still within the specified value, the connecting rod can be used as it is.
If the black portion is to be removed, use sandpaper (#800 – #1000) and polish lightly.
★ Polish lightly so that the original honing grain is not removed.

If the polishing removes the honing grain, and the wave on the inside surface exceeds the limit, the connecting
rod must not be used again.
3. Blow with air and use a cloth to remove all the dirt inside the big end of the connecting rod.
13-25 1
DISASSEMBLY AND ASSEMBLY MEASURING PARTS
12
MEASURING PARTS
• Before reassembling disassembled parts, check visually that there are no cracks, damage, or abnormal wear.
• Inspect for reuse.
• If no abnormalities are found during the visual inspection, use an accurate measuring device to measure the
specified position precisely.
• Action and judgement on whether the parts can be reused shall be in accordance with the maintenance stan-
dard.
MEASURING CURVATURE OF CRANK-

SHAFT
1. Support the center of both ends of the crankshaft with
lathes, put the indicator of the dial gauge perpendicularly in
contact with the journal at the center, and set it to 0.
★ If no lathe is available, support the No. 1 and No. 7 journals

in a V block.
2. Rotate the crankshaft one turn, and measure the difference

between the maximum reading and minimum reading of the
dial gauge.
★ Do not measure with both ends of the crankshaft supported

on V blocks. This method produces an error because of the
eccentric wear of the journal.
MEASURING OUTSIDE DIAMETER OF

JOURNAL
Using a micrometer, measure the outside diameter of the main
journal and pin journal in the X and Y directions.
MEASURING OUT-OF-ROUNDNESS OF
JOURNAL
Measure the outside diameter of the journal in the X and Y
directions and calculate the difference.
13-26 1
12
MEASURING SURFACE ROUGHNESS OF OUTSIDE
DIAMETER OF JOURNAL
Check the surface roughness using the surface roughness standard piece shown in the diagram below.
Part No.
Standard piece 790-101-8110
★ When measuring the surface roughness, compare the surface roughness of the journal with the standard
piece.
★ If there are any scratches or dents in the surface of the crankshaft journal, correct the surface roughness. How-
ever, if the outside diameter of the journal is close to the standard value and there is no margin for correction
(the scratches and dents cannot be removed by correcting the surface roughness), correct by grinding.
MEASURING DEPTH OF CYLINDER LINER

COUNTERBORE
1. Set the depth gauge (2) on gauge block (1), then set the
gauge indicator to 0.
2. Set the gauge block parallel with the top surface of the cylin-
der block, and measure the depth of the counterbore.
When doing this, slide the measurement portion and mea-
sure at several places.
★ Clean the counterbore and top surface of the cylinder block

before measuring.
13-27 1
MEASURING MAIN BEARING BORE

1. Install the main bearing cap to the cylinder block, and
tighten to the specified torque.
2. Using a dial bore gauge to inside micrometer, measure the

main bearing bore.
★ When measuring the main bearing bore, measure in two

directions (X and Y).
MEASURING CURVATURE OF CAMSHAFT

1. Support the center of both ends of the camshaft with lathes,
put the indicator of the dial gauge perpendicularly in contact
with the journal at the center, and set it to 0.
2. Rotate the camshaft one turn, and measure the difference

between the maximum reading and minimum reading of the
dial gauge.
MEASURING OUTSIDE DIAMETER OF

JOURNAL
Using a micrometer, measure the outside diameter of the cam-
shaft journal.
13-28 1
MEASURING HEIGHT OF CAM

Using a micrometer, measure cam height H for the intake and
exhaust.
MEASURING PISTON RING GROOVE

Special tools
No. Part No. Part Name Q’ty
A 795-901-1130 Wear gauge 1
1. Measuring keystone ring groove
Push piston ring wear gauge A lightly into the ring grooves of
the top ring and second ring, and measure the wear of the ring
groove.
★ If the shoulder of the wear gauge contacts the piston,

replace the piston.
★ Carry out the measurements at 8 places around the circum-
ference.
2. Measuring straight ring groove
Assemble the piston ring to the cylinder liner, push the piston
ring into the area of the cylinder where there is least wear, then measure the piston ring end gap with a feeler
gauge.
★ Insert the piston ring so that it is at right angles to the sliding portion of the liner.
MEASURING PISTON RING END GAP

Assemble the piston ring to the cylinder liner, push the piston
ring into the area of the cylinder where there is least wear, then
measure the piston ring end gap with a feeler gauge.
★ Insert the piston ring so that it is at right angles to the sliding

portion of the liner.
13-29 1
12
MEASURING OUTSIDE DIAMETER OF PIS-
TON
Use a micrometer to measure the dimension L at the piston skirt
(45 mm from bottom, at right angles from pin hole).
MEASURING LENGTH OF CONNECTING

ROD
1. Tighten the mounting bolts of the connecting rod cap to the
specified torque.
★ Check that the number at the rod and cap ends of the con-
necting rod are the same.
★ Do not assemble the connecting rod bearing.
2. Assemble a new piston ring pin in the hole at the small end
of the connecting rod.
★ Coat the piston with grease (G2-LI) before installing.
3. Support both ends of the piston pin on V blocks, and sup-

port both ends of the connecting rod on square blocks
4. Measure the distance A between the big end and small end
with a height gauge.
5. Measure the inside diameter of the big end and small end.
★ Calculate the value for the length B of the connecting rod as

follows.
Connecting rod dimension B
ID of big end + ID of small end

– -------------------------------------------------------------------------------- + A
2
★ If the value exceeds the permitted value, replace the connecting rod.
13-30 1
MEASURING INSIDE DIAMETER AT

SMALL END OF CONNECTING ROD
Use an inside micrometer to measure the dimension at positions
(a) and (b) in the X and Y directions.
★ If the value exceeds the permitted value, replace the bush-

ing.
MEASURING INSIDE DIAMETER AT BIG

END OF CONNECTING ROD
Use an inside micrometer to measure the dimension at positions
(c) and (d) in the X, Y, and Z directions.
★ If the value exceeds the permitted value, or if there are

scratches on the inside diameter at the large end, replace
the connecting rod.
★ Do not re-use any connecting rod if there has been seizure
of the bearing.
MEASURING CURVATURE, TWISTING OF CONNECTING ROD

1. Method for measuring curvature
A) Tighten the mounting bolts of the connecting rod to the

specified torque.
★ Do not assemble the connecting rod bearing.
B) Assemble a new piston pin in the hole at the small end

of the connecting rod, place V blocks on a flat surface,
then set both ends of the piston pin on the V block.
★ Coat the piston pin with grease (G2-LI) before installing.
C) Stand the connecting rod perpendicularly, and support

both sides of the big end with square blocks.
D) Set the indicator of height gauge (1) at the front of the hole at the big end, set it in contact with the bottom,
then set the gauge to 0.
E) Move the height gauge to the opposite side by a distance equal to the width of the big end, and read the
measurement of the gauge.
13-31 1
2. Method for measuring twisting
A) From the condition described above, remove the square

blocks, lay the connecting rod down, and support the
big end on the tip of a conical jack.
B) Measure the big end in the same way as when measur-

ing the curvature.
★ Calculate the value for the curvature and twisting as follows.
Curvature, twisting
Dimension A
– -------------------------------- ×Actual measured value
Dimension B
STANDARD PRESSURE FOR PARTS

PRESSURE TESTING
• Cylinder head: 3 – 3.5 kg/cm 2 (42.6 – 49.8 psi)

• Oil cooler element: 16 kg/cm2 (227.5 psi)
• Between oil cooler and cover: 2 kg/cm2 (28.4 psi)
• Aftercooler: 4 kg/cm2 (56.9 psi)
13-32 1
DISASSEMBLY AND ASSEMBLY ASSEMBLY
12
ASSEMBLY
TIGHTENING BOLTS BY PLASTIC RANGE
TURNING ANGLE METHOD
• The important bolts on the 12V140Z-1 series engine use the
plastic range turning angle method for tightening.
This method uses special bolts, and by tightening the bolts
to the load where the bolt starts to deform permanently
(plastic range), it is possible to get an accurate, high tighten-
ing force.
(Of the methods used for tightening bolts, the method using
checking of torque is the most common, but because of the
influence of friction factors, it is difficult to control the tight-
ening force accurately.)
• The tightening method using the plastic range turning angle method uses the initial tightening torque and the
turning angle to tighten the bolts.
• Bolts tightened with the plastic range turning angle method on the 12V140Z-1 series engine.
• Cylinder head mounting bolts
• Main cap mounting bolts
• Connecting rod cap mounting bolts
★ With the plastic range turning angle method, there is a permanent deformation remaining after tightening.
Therefore, there is a limit to the number of times that the bolt can be used, so please observe the following.
• After tightening, make one punch mark. If any bolt has more than 5 punch marks, do not use it again; replace
it with a new bolt.
• When tightening to an angle greater than the specified angle, loosen completely before tightening again. (In
this case, make two punch marks.)
• The target for the tightening angle should be the standard value ± tolerance.
13-33 1
12
SPECIAL TOOLS
No. Part Number Part Description

A 3375960 Valve Spring Compressor
B 3823137 Piston Ring Expander
D 3823495 Protrusion Gauge
E ST1229 Liner Driver
F 3822736 Piston Ring Compressor
G 790-331-1110 Wrench (Angle/Torque)
795-602-2200 Seal Installer (front)
H
795-602-2300 Seal Installer (rear)
• Wash all parts clean, and check that there are no dents, scratches, or casting defects. Check also that all oil or
water passages are clear before assembling
.
PREPARATORY WORK
Before inserting the cylinder liner, take the following action with
the cylinder block.
1. Remove the rust and scale from surfaces (A) and (B) with
sandpaper until the machining surface appears.
2. Polish portions (R) and (r) with #200 sandpaper so that the
R surface is smooth.
3. Polish potions (B), (R), and (r) with #200 sandpaper so that
they become smooth. If the corner of the R portion is sharp
or there are burrs, polish with a scraper or sandpaper. Be
sure to finish this surface particularly smoothly so that is
does not scratch the O-ring.
4. If surface (R) is pitted and rough, and cannot be corrected,

replace the cylinder block.
5. If surface (A) and portions (R) and (r) are pitted and rough,
finish them smoothly.
6. Inspect the counterbore, and remove any burrs or flashes.

If there are any metal particles or dirt on surface (C), the liner will not fit properly in close contact, and this may
cause problems such as leakage of water or protrusion of liner.
★ If there is any drooping, corrosion, or pitting left in the counterbore, carry out additional machining.
13-34 1
12
GENERAL ASSEMBLY
Cylinder block
1. Cylinder liner
★ Replace the liner O-ring and clevis seal with new parts immediately before assembling the liner.
A) Installing liner O-ring and clevis seal

i) Check the cylinder liner O-ring groove and outside circumference of the liner to confirm that there is no
rust or pitting.
★ If the surface is rough and pitted, it may cause leakage of water, so replace the liner.
ii) Coat the liner O-ring and clevis seal with soapy
water.
★ Oil causes the clevis seal and O-ring to swell and deterio-
rate, so do not leave them soaking in oil. If oil is used, coat
with a small amount of clean engine oil (SAE30) with a
brush immediately before assembly.
iii) Assemble the liner O-ring and clevis seal to the
liner as shown in the diagram on the right.
B) After installing the liner O-ring, check for twisting. If any

twisting is found, use a smooth bar (approx. ø 10) [ø
0.3937 in] to remove the twisting.
★ To prevent the clevis seal from twisting when it is installed,

press it around the whole circumference so that it fits into
the seal groove.
★ Assemble the clevis seal with the chamfered side facing
down.
13-35 1
C) Inserting cylinder liner.
i) Using a cloth, wipe off all the dirt and oil from the
contact surface of the liner lip and the cylinder block
counterbore.
ii) Coat the mating surface (a) of the cylinder block

and cylinder liner counterbore with silicon-based
gasket sealant (LG-6).
★ Width of gasket sealant: ø1.5 – 2.0 mm (0.0590 – 0.0787 in)
★ Make an overlap of 6 ± 6 mm (0 – 0.4724 in) at the begin-

ning and end when coating with gasket sealant LG-6.
13-36 1
D) When machining the bottom contact surface of the
counterbore liner lip and using a shim.
i) Coat the bottom of the shim thinly with gasket seal-
ant LG-6, then assemble the shim.
ii) Next, coat with gasket sealant LG-6 in the same
way as when not using a shim.
E) Coat the liner O-ring, clevis seal, and cylinder block

contact surface with a small amount of engine oil (SAE
#30) immediately before press fitting the liner.
★ Coat the contact surface of the cylinder block uniformly

around the whole circumference by hand.
★ There are two different types of pistons and cylinder liners.
Small piston Part No. 6212-31-2151 must be used with
small liner Part No. 6211-21-2230. Large piston Part No.
6212-31-2161 must be used with large cylinder liner Part
No. 6211-21-2240.
F) Set the “T” mark on the top surface of the liner facing
the front, then insert cylinder liner (1) into the cylinder
block, taking care not to damage the O-ring.
G) Use your weight and push the liner in with both hands.
★ If the liner does not go in smoothly when you apply your
weight, there is danger that the O-ring may be damaged, so
check the cylinder block for burrs or flashes.
H) Using a liner driver E, press fit cylinder liner (1) into the
cylinder block.
I) Using the following procedure, squeeze out the gasket

sealant coated on the counterbore.
i) Tighten the cylinder head temporarily with a used

head gasket.
★ Bolt (7) may be tightened partially.
13-37 1
ii) Remove the cylinder head, and wipe off gasket
sealant that comes out from between the cylinder
liner and cylinder block.
★ If the gasket sealant sticks to the head gasket grommet, the
grommet will be deformed. This will cause water leakage,
so be sure to wipe off all excess gasket sealant.
J) After press fitting the cylinder liner, use tool D to mea-

sure the protrusion of the cylinder liner.
★ When measuring the protrusion of the cylinder liner, hold
the cylinder liner down with plate (1) to prevent the cylinder
liner from being forced up by the elasticity of the O-ring dur-
ing measurement.
Measurement positions: (a), (b), (c), (d) (4 places)
Plate mounting bolt: 69 – 98 N•m (51 – 72 ft-lb)
★ Protrusion of cylinder liner: 0.080 – 0.185 mm (0.0031 –
0.0073 in)
★ If it is not within the standard value, take the action given in
the MAINTENANCE STANDARD.
2. Crankshaft
A) Align the protrusion of upper main bearing (6) with the

notch in the cylinder block, then assemble in the cylin-
der block.
★ Upper bearing: With oil hole
★ The bearing for No. 4 is wider than the other bearings, so be
careful not to mistake it when assembling.
★ Width a of bearing
No. 4 bearing: 52 mm (2.0 in)
Other bearings: 48 mm (1.9 in)
★ Check that there is no dirt at the rear face of the bearing

before tightening.
★ Do not coat the rear face of the bearing with oil.
B) Knock in roll pin so that protrusion from end face of

block is 2.7 – 3.4 mm (0.11 – 0.13), then install upper
thrust bearing (5).
★ Install the thrust bearing with the side with the groove on the
crankshaft side.
13-38 1
C) Coat inside surface of upper main bearing with engine
oil (SAE#30).
★ Check for the following before assembling the crankshaft.

• Abnormality in the front, rear side threaded portion
(The bolt must go in smoothly when turned by hand.)
• Scratches or dents on the pin or main journal portion.
• Dirt stuck to the inside of the oil hole.
D) Raise crankshaft (4), and assemble to the mounting

position, taking care not to hit the cylinder block.
E) Align the protrusion of lower bearing (5) with the notch

in the main cap, and install.
before tightening. Coat the inside surface of the bearing
with engine oil (SAE#30).
13-39 1
★ Lower bearing: No oil hole

★ The bearing for No. 4 is wider than the other bearings, so be
careful not to mistake it when assembling.
★ Width a of bearing
No. 4 bearing: 52 mm (2.0 in)
Other bearings: 48mm (1.9 in)
F) For No. 7 cap, knock in the roll pin so that the protrusion
from the end face of the cap is 2.7 – 3.4 mm, then install
lower thrust bearing (3) on both sides.
★ Install the thrust bearing with the side with the groove on the
crankshaft side.
G) Coat the journal surface of the crankshaft with engine
oil (SAE#30), check that the stamped number on each
main cap (2) matches the number on the cylinder block,
then install the main caps.
★ Assemble the main cap with the cast part number facing the
front of the engine.
H) Coat the washer and the mounting bolt thread of the

main cap with engine oil (SAE#30), then screw in the
bolts in turn to insert the main cap completely.
★ Do not use an impact wrench to tighten the bolts. This may
damage the threads. Always tighten with a hand tool.
I) When tightening, start from the center main cap and
work in order to the outside. Tighten the bolts to the
specified tightening torque using the following steps.
i) Tighten main cap mounting bolts in three steps, as

follows:
• Tighten both bolts to first torque value.
271 – 299 N•m (199 – 220 ft-lb)
• Tighten both bolts to second torque value.
559 – 579 N•m (413 – 426 ft-lb)
• Reference marks on the bolt and cap; then turn the bolt an
additional 90°.
13-40 1
ii) After tightening, make one punch mark on the bolt
head. If the bolt head has five punch marks, do not
reuse it. Replace the bolt with a new bolt.
J) After tightening bolts, rotate crankshaft, and check that

it rotates smoothly.
★ Starting torque of shaft: Max. 147 N•m (108.5 ft-lb)
K) Measure end play of crankshaft with dial gauge (1).

★ End play: 0.140 – 0.32 mm (0.0056 – 0.0125in)
★ Lever the center portion of the counterweight and measure
the end play.
★ If it is within the standard value, take the action given in the
maintenance standard.
3. Piston, connecting rod assembly
A) Assemble piston and connecting rod.

i) Fit oil ring expander (9) in oil ring groove.
ii) Using piston ring tool B, assemble oil ring, second
ring, and top ring in order.
★ Assemble each piston ring as shown in the diagram.

★ Set each ring with the stamped mark facing up, then assem-
ble to the piston.
★ When assembling the oil ring, first take out the expander
and fit it to the piston, then assemble the oil ring. When
doing this, check that the expander is fitted completely into
the ring groove.
★ The end gap of the expander coil must be at 180° to the end
gap of the oil ring.
13-41 1
B) Install snap ring (10) on one side.
There are two different connecting rods. The left bank

uses connecting rod, Part No. 6215-31-3200 (small pis-
ton) ONLY. The right bank uses connecting rod, Part
No. 6215-31-3100 (large piston) ONLY. Using the wrong
part will cause engine failure.
C) Set piston (7) and connecting rod (5) in position. Align

the casting mark [EX ‹— F] on the piston with the cham-
fered side of the hole at the big end of the connecting
rod when assembling.
D) Coat the piston pin boss and the inside of the connect-
ing rod bushing with engine oil (SAE#30), face the con-
necting rod in the position described above, then insert
piston pin (6).
E) Install snap ring (4) on the opposite side.
★ Rotate the left and right snap rings to check that the snap
rings are completely fitted into the ring groove.
★ Check that the connecting rod moves smoothly.
F) Align the protrusion of connecting rod upper bearing

(11) with the notch in the connecting rod, then install
before assembling.
★ Check that the hole in the bearing at the big end and the
bushing at the small end of the connecting rod are aligned
with the oil hole in the connecting rod.
★ Before assembling the connecting rod, check that there is
no dirt stuck inside the connecting rod oil hole.
G) Align the protrusion of connecting rod lower bearing

(12) with the notch in the connecting rod cap, then
install.
before assembling. When assembling, do not coat the rear
face with engine oil.
13-42 1
H) Coat cylinder liner with engine oil (SAE#30).
★ Coat the whole circumference uniformly with engine oil by
hand.
I) Rotate the crankshaft and set pin journal of cylinder for

insertion at top dead center
★ There are two different types of pistons and cylinder liners.
Small piston Part No. 6212-31-2151 must be used with
small liner Part No. 6211-21-2230. Large piston Part No.
6212-31-2161 must be used with large cylinder liner Part
No. 6211-21-2240.
J) Check number of piston and connecting rod assembly,

and insert in cylinder at position shown in the diagram
on the right.
★ Set the cylinder block so that the cylinder faces the side in
order to prevent the piston and connecting rod assembly
from entering the cylinder suddenly when it is inserted.
K) Original engine assembly has large piston and liner on one bank. The small piston and liner are on the
other bank.
★ Piston assembly position
13-43 1
12 L) Align end gap of each piston ring in the position shown in the diagram below
M) Coat piston ring uniformly with engine oil (SAE#30).
N) Tighten piston ring with piston ring holder F, then push

in piston head with wooden bar.
O) Using connecting rod pulling tool shown in the diagram

on the right, pull connecting rod, and fit it in close con-
tact with pin journal.
★ Check that the connecting rod bearing is correctly in posi-
tion.
★ To make a connecting rod pulling tool, weld a bar to an old
connecting rod bolt.
P) Coat crankshaft pin journal with engine oil (SAE#30).
13-44 1
Q) Rotate crankshaft 180° while pulling connecting rod.
R) Coat connecting rod lower bearing (12) with engine oil

(SAE #30), check cap number, then align with dowel
pin, and install connecting rod cap (2).
★ When coating with engine oil, spread the oil with a finger
over the whole part.
★ When assembling a new connecting rod, mark the cylinder
number with an electric pen. (Do not make a stamped
mark) Do not change combination of connecting rod and
cap under any circumstances.
S) Coat thread and washer of connecting rod bolt with

engine oil (SAE #30).
T) Tighten connecting rod bolts (1) in turn until connecting

rod cap is in tight contact.
If an impact wrench is used to tighten the bolts, there is

danger of damage to the thread, so tighten the bolts
with a hand tool.
13-45 1
U) Rotate crankshaft 180°, and insert piston and connect-
ing rod assembly of other bank using procedure in
Steps H) – T).
★ Tighten the connecting rod bolts as follows.
★ If impact wrench is used to tighten bolts quickly, there is
danger of damage to thread, so tighten the bolts with hand
tool.
1st step:
Tighten to 69 – 78 N•m (51 – 57 ft-lb) in order
shown in diagram.
2nd step:
Tighten again to 69 – 78 N•m (51 – 57 ft-lb) in order
shown in diagram.
3rd step:
+30°
Using wrench G, turn 90 0 °to tighten.
★ When not using wrench G, tighten as follows.
• Tighten bolts.
69 – 78 N•m (51 – 57 ft-lb)
• Place reference marks on bolt and cap, then tighten the bolt
an additional 90°.
• After tightening, make one punch mark on the bolt head. If

the bolt head has five punch marks, so not reuse it.
Replace the bolt with a new bolt.
• After assembling the connecting rod, check that the crank-
shaft rotates smoothly.
V) Using dial gauge (1), measure side clearance on con-

necting rod.
★ Standard for side clearance:
0.3 – 0.454 mm (0.0119 – 0.0178 in)
★ If the connecting rod does not move, remove the connecting
rod cap and check that there is no mistake in assembly, and
that there are no burrs, or dirt caught anywhere.
13-46 1
A) Install cooling nozzle (1).
Mounting bolts:34 – 74 N•m (26 – 54 ft-lb)
★ Before installing, check for cracks in the nozzle, and check

that there is no clogging inside the nozzle.
• Face the tip of the nozzle to the side with the mounting hole
at the top, insert into the piston, taking care that it does not
hit the piston, then turn 90° to install.
• Before installing, check for cracks in the nozzle, and
check that there is no clogging inside the nozzle.
B) Rotate crankshaft slowly and check that there is no

interference between piston cooling nozzle and piston,
crankshaft.
Gear Case
1. Timing gear case
Fit gasket and install timing gear case (1).

★ Coat the gasket thinly in several places with gasket sealant
and stick it in position to prevent it from coming off.
Exercise caution when inserting the camshaft, to pre-

vent injury to fingers.
2. Camshaft assembly
A) Coat cam bushing with engine oil (SAE#30).

B) Install camshaft assembly (1), then align with mounting
hole of thrust plate, and tighten nylock bolts.
★ Replace the nylock bolts with new parts.
• Tighten nylock bolts.

Nylock Bolts:54 – 122 N•m (40 – 90 ft-lb)
★ When inserting the cam shaft, rotate it while inserting it in

order to prevent damage to the cam bushing.
13-47 1
3. Idler gear (small)
A) Align match mark “D” of cam gear and idler gear (2),
and install idler gear.
B) Fit plate (1) and tighten mounting bolts.
4. Oil pump assembly
Fit O-ring, set oil pump assembly (1) in mounting position, then
tighten mounting bolts.
Mounting Bolts:34 – 74 N•m (26 – 54 ft-lb)
5. Idler gear (large) (right bank)
A) Align match mark of gear and install idler gear (large).

i) Align mark “D” of cam gear (1) and idler gear
(small) (2).
ii) Align mark “A” of idler gear (small) (2) and sub-idler
gear (3).
iii) Align mark “R” of idler gear (larger) (3) and crank-
shaft gear (5).

★ Set plate (6) with the OUT mark facing the outside, then
assemble.
★ Check that match marks “D”, “A”, and “R” at four
places are aligned.
13-48 1
6. Idler gear (large) (left bank)
A) Align match of gear and install idler gear (large).

i) Align mark “C” of cam gear (1) and sub-idler gear
(2).
ii) Align mark “L” of idler gear (large) (2) and crank-
shaft gear (4).

★ Set plate (5) with the OUT mark facing the outside, then
assemble.
★ Check that match marks “C” and “L” at three places are
aligned.
★ After assembling each gear, check the timing mark of the

gear again.
7. Measuring backlash of gear
A) Fit gear (1) to rear compressor and install temporarily.
B) Install water pump assembly (2) temporarily.
• Measure the backlash and end play of each gear with a dial
gauge.
13-49 1
12
• Standard value for backlash of each gear
Standard
Position Judgement position
mm in
A•A Right idler gear (small) 0.130 – 0.390 0.0052 – 0.0153

and right sub-idler gear
B1 • B1 RIght sub-idler gear and right 0.051 – 0.469 0.0021 – 0.0184

injection pump gear
B1 • B1 Left sub-idler gear 0.051 – 0.469 0.0021 – 0.0184

and left injection pump gear
C•C Left sub-idler gear 0.129 – 0.391 0.0051 – 0.0153

and left cam gear
D•D Right idler gear (small) 0.129 – 0.391 0.0051 – 0.0153

and right cam gear
E•E Right idler gear (large) 0.052 – 0.481 0.0021 – 0.0189

and water pump drive gear
F•F Right idler gear (large) 0.137 – 0.421 0.0054 – 0.0165

and oil pump gear
Left injection pump gear and

G•G 0.106 – 0.381 0.0042 – 0.0150
compressor gear
Right cam gear and accessory

H•H 0.085 – 0.492 0.0034 – 0.0193
drive gear
Crankshaft gear and right idler

L•L 0.141 – 0.425 0.0056 – 0.0167
gear (large)
Crankshaft gear and right idler

R•R 0.141 – 0.425 0.0056 – 0.0167
gear (large)
• Standard value for end play of each gear
Posi- Part Name Standard

tion
mm in
1 Idler gear (large) 0.07 – 0.18 0.0027 – 0.0070
2 Idler gear (small) 0.07 – 0.18 0.0027 – 0.0070
3 Injection pump drive gear 0.07 – 0.20 0.0028 – 0.0078
4 Oil pump drive gear 0.03 – 0.088 0.0012 – 0.0034
5 Accessory drive gear 0.1 – 0.4 0.004 – 0.0157
6 Crankshaft gear 0.14 – 0.32 0.0056 – 0.0125
7 Camshaft gear 0.10 – 0.25 0.004 – 0.098
8. Front oil seal, sleeve
Take the following action according to the wear of the crankshaft

seal contact surface.
A) If crankshaft is new, or if there is no wear of surface in
contact with seal oil.
★ Measure dimension of portion (b) of front cover and check

for a bolt hole in the end face of the cover. Then use the
table below and press fit the oil seal to press-fitting depth a.
13-50 1
Press-fitting
Dimension of Bolt hole depth a for oil
portion b1 6 – 12 x 1.75 seal
109 mm No 13 – 14 mm
114 mm Yes 18 – 19 mm
B) If there is wear of oil seal contact on the surface of

crankshaft, and it is possible to correct by moving
mounting position of oil seal.
★ Push in a new oil seal and install it at a point where the lip of
the oil seal does not reach the wear groove on the crank-
shaft.
★ Use plastic sleeve supplied with seal to guide seal over
nose of crankshaft.
C) If crankshaft has already been corrected in Step B).

★ Install sleeve to crankshaft, then install oversize oil seal.
D) Install sleeve as follows.

i) Remove all rust from sleeve press-fitting portion of
crankshaft (range of 60 mm from tip).
ii) Coat whole of inside surface of sleeve with gasket
sealant (LG-7).
13-51 1
iii) Using a plastic hammer, tap end face of sleeve
around circumference and install sleeve (1) parallel
to crankshaft.
★ The sleeve is symmetrical, so it can be installed in either
direction.
iv) Using tool H1, press fit sleeve (1) to specified posi-
tion.
★ Tighten the bolts uniformly.
★ After press fitting the sleeve, wipe off the gasket sealant that
has been squeezed out. (If the gasket sealant that has been
squeezed out gets on the seal lip, it will cause oil leakage.)
E) Using tool H1, install front oil seal (2).

★ Tighten the mounting bolts uniformly.
★ The press-fitting depth for the oil seal differs according to
the condition of the crankshaft.
Select one of the following three types.
i) When crankshaft is new, or there is no wear on seal

contact surface, insert spacer (1) of 1.8 – 2.8 mm
between installer and oil seal, then install.
ii) When changing mounting position of oil seal to

install, install oil seal with installer H1.
iii) When using sleeve on crankshaft, fit one washer

between the installer and crankshaft and install.
★ Before assembling the oil seal, clean the outside circumfer-
ence of the crankshaft, then coat the whole circumference
with engine oil (SAE#30).
iv) Use plastic sleeve supplied with seal to guide seal
over the nose of the crankshaft.
13-52 1
9. Gear case cover
Using eyebolts (A),

(Thread dia. – 10 mm, Pitch – 1.5 mm) [0.3937 in, P – 0.0591 in]
sling then fit gasket and install gear case cover.
Flywheel
1. Rear oil seal, sleeve
Take the following action according to the wear of the crankshaft

seal contact surface.
A) If crankshaft is new, or if there is no wear of surface in
contact with seal oil.
i) Install at the standard dimension from the end face
of the crankshaft.
ii) Use plastic sleeve supplied with seal to guide seal
over the nose of the crankshaft.
B) If there is wear of oil seal contact surface of crankshaft,

and it is possible to correct by moving mounting position
of oil seal.
★ Push in a new oil seal and install it at a point where the lip of
the oil seal does not reach the wear groove on the crank-
shaft.
13-53 1
C) If crankshaft has already been corrected in Step B).
★ Install sleeve to crankshaft, then install oversize oil seal.
D) Install sleeve as follows.

i) Remove all rust from sleeve press-fitting portion of
crankshaft (range of 60 mm from tip).
ii) Coat whole of inside surface of sleeve with gasket
sealant (LG-7).
iii) Using a plastic hammer, tap end face of sleeve

around circumference and install sleeve (1) parallel
to crankshaft.
★ The sleeve is symmetrical, so it can be installed in either
direction.
iv) Using tool H2, press fit sleeve (1) to specified posi-
tion.
★ Tighten the bolts uniformly.
★ After press fitting the sleeve, wipe off the gasket sealant that
has been squeezed out. (If the gasket sealant that has been
squeezed out gets on the seal lip, it will cause oil leakage.)
13-54 1
E) Rear oil seal
Using tool H2, install rear oil seal (2).
★ Tighten the mounting bolts uniformly.
★ The press-fitting depth for the oil seal differs according to

the condition of the crankshaft. Select one of the following
three types.
i) When crankshaft is new or there is no wear on seal

contact surface, insert two washers between
installer and crankshaft.
ii) When changing mounting position of oil seal to

install, do not use any washer between the installer
and crankshaft.
iii) When using sleeve on crankshaft, fit two washers in

the same way as in Step i).
F) After installing flywheel housing, using dial gauge (1) to

measure face runout and radial runout.
• SAE No. 00: Max. 0.30 mm (0.012 in)
• SAE No. 0: Max. 0.25 mm (0.010 in)
13-55 1
2. Flywheel
A) Using guide bolt, install flywheel (1).

B) Align dowel hole in crankshaft with dowel hole in fly-
wheel. This will establish timing position of flywheel.
Coat the thread and washer of the bolt with engine oil
(SAE #30).
C) Tighten bolts in turn until flywheel is in tight contact.

danger of damage to the thread, so loosen the bolts
with a hand tool.
D) Secure flywheel with housing (1).
★ One capscrew has a large shoulder to prevent movement.

Install capscrew next to timing hole.
★ Tighten the mounting bolts as follows.
Flywheel mounting bolt

Target Range
Step
kgm ft-lb kgm ft-lb
1st 10 72 8 – 12 58 – 86
2nd 30 217 28 – 32 203 – 231
3rd 55 398 53 – 57 384 – 412
13-56 1
E) Using dial gauge (1), measure face runout and radial
runout.
• Face runout: Max. 0.30 mm (0.0118 in)
• Radial runout: Max. 0.30 mm (0.0118 in)
★ For speed and timing sensor installation information, refer to

section 12.
3. Flywheel housing
Fit gasket, raise flywheel housing (2), then install and tighten
bolts (1).
★ Tighten the flywheel housing mounting bolts in the order

shown in the diagram using the following procedure.
Flywheel housing mounting bolt
Step Procedure
1st Tighten to 345 ± 49 N•m (255 ft-lb)
2nd Loosen completely.
3rd Tighten to 411 ± 20 N•m (303 ft-lb)
Sensor
Install RPM (1) and timing (2) sensors.
13-57 1
12
Front support
Fill oil groove of front support (1) with grease and install.
★ Amount of grease: Approx. 20 cc (1.2 cu.in)
Groove of front mount: Coat with G2-LI
★ Lower the cylinder block assembly on the stable stand.
Main relief valve, suction pipe
1. Fit gasket and install main relief valve (2).
2. After fitting O-ring, fit suction pipe (4), install bracket (3), and
secure in position.
Oil pan
1. Stick gasket to oil pan.
2. Support oil pan (1) with transmission jack, set in mounting

position, then tighten bolts.
Damper, crankshaft pulley assembly
1. Raise crankshaft pulley and damper assembly (1), then

align dowel pin of crankshaft and install.
Coat the thread and washer of the bolts with engine oil
(SAE #30).
2. Tighten bolts in turn until damper and crankshaft pulley are

in tight contact.

danger of damage to the threads, so loosen the bolts
with a hand tool
13-58 1
A) Tighten crankshaft pulley mounting bolts as follows:
i) Tighten bolts to first torque value.

54 – 93 N•m (40 – 68 ft-lb)
ii) Tighten bolts to second torque value.

225 – 264 N•m (167 – 195 ft-lb)
iii) Tighten bolts to third torque value.

725 – 764 N•m (536 – 564 ft-lb)
iv) Tighten damper mounting bolt.

97 – 117 N•m (73 – 86 ft-lb)
Accessory drive assembly
1. Assemble accessory drive.
A) Press fit bushings (10) and oil seal (9) to housing (8).
★ Press fit the bushing 2 mm (0.0787 in) below the end face.
Inside surface of bushing: Engine oil (SAE #30)
★ Press fit the oil seal 1.5 mm (0.0591 in) below the end face.
Lip of seal: Grease (G2-LI)

★ Fill 50 – 80% of the space at the lip.
B) Press fit gear (7) to shaft (5).

C) Assemble thrust plate (6) to shaft and gear assembly, then insert from rear of housing.
D) Assemble thrust plate (4) to shaft, and press fit hub (3).
★ Be careful not to damage the seal lip.
2. Fit O-ring and install drive assembly (2).
3. Install pulley (1).
13-59 1
Thermostat housing
1. Press fit seal (5) to thermostat case (2).
2. Make sure that the seal is not at an angle when press fitting.
3. Assemble thermostat (4) in thermostat case.
4. Fit gasket, then install thermostat case (2) to thermostat

housing (3), and tighten mounting bolts.
5. Screw eyebolts (Thread dia. – 10 mm, Pitch – 1.5 mm)

[0.3937 in, P – 0.0591 in] into thermostat case, and sling.
6. Fit gasket and install thermostat case assembly (2), (3) to

cylinder block.
7. Fit gasket and install connector tube (1).
Cam follower assembly
1. Install cam follower assembly (3), then tighten mounting

bolts (2) and secure in position.
44 – 58 N•m (33 – 43 ft-lb)
2. Fit gasket and install cover (1).
34 – 44 N•m (26 – 32 ft-lb)

★ Fit the seal washers to 4 bolts under the cover and tighten.
Cylinder head assembly
1. Assemble cylinder head
A) Coat valve stem and inside surface of valve guide with

engine oil (SAE #30), and assemble valve (9).
B) Raise cylinder head, and assemble lower seat (8).
★ Check part number of valve for proper location.
13-60 1
C) Install a stem seal to valve (5). Knock in until bottom
surface a of the jig contacts lower seat (795-130-1720).
★ Assemble and install valve springs with closed coils down.

D) Fit inner spring (7) and outer spring (6), and assemble
upper seat (5).
E) Using spring pusher A, compress valve spring, then
assemble valve cotter (4).
★ Tap the valve stem with a plastic hammer, and check that
the cotter is fitted securely in the valve stem groove.
2. Check that there is no dirt or dust inside cylinder and mount-

ing surface of cylinder head, and set cylinder head gasket
(3) in position.
★ When installing the gasket, check that the grommet has

been fitted and has not come out of position.
★ The grommets in the head gasket may become deformed
by swelling, so do not coat them with gasket sealant.
13-61 1
3. Install cylinder head assembly (2), and tighten mounting
bolts (1).
Coat under the bolt head with SAE 140 and coat the
bolt thread with SAE 30 lubricant.
★ Tighten cylinder head mounting bolts 1-6 as follows:

• Tighten bolts to first torque value.
137 – 157 N•m (102 – 115 ft-lb)
• Tighten bolts to second torque value.

210 – 220 N•m (156 – 162 ft-lb)
• Tighten bolts an additional 90°±30°.
★ Tighten bolt 7.
59 – 73 N•m (44 – 54 ft-lb)
★ After tightening, make one punch mark on the bolt head.

★ If the bolt head has five punch marks, do not reuse it.
Replace it with a new bolt.
13-62 1
Rocker lever
1. Rocker lever housing
Fit gasket and install rocker lever housing (2).

Tighten mounting bolts.
44 – 50 N•m (33 – 43 ft-lb)
2. Crosshead
A) Install crosshead (3).

★ Adjust the crosshead as follows.
i) Loosen locknut, and turn back adjustment screw.
ii) Hold top surface of crosshead lightly, and screw in
adjustment screw.
iii) After adjustment screw contacts valve stem, screw
in a further 20°.
iv) Tighten locknut to hold in position.
53 – 65 N•m (39 – 47ft-lb)
3. Push rod
Install push rod (2).

★ Check that the push rod is fitted in the cam follower.
4. Rocker lever
Assemble rocker cover.
A) Using push tool, align oil hole of bushing, and knock in

rocker lever (2).
B) Assemble adjustment screw (3) and locknut (4) to

rocker lever.
13-63 1
C) Coat rocker shaft with engine oil (SAE #30), set side
with plug facing exhaust rocker lever, then insert rocker
shaft.
★ Exhaust end rocker lever: Long
★ Intake end rocker lever: Short
D) Install rocker lever (1)

★ Install with the wide end face of the rocker lever shaft facing
down.
★ Check that the ball of the adjustment screw is fitted securely
into the socket of the push rod, then tighten the mounting
bolts.
93 – 103 N•m (68 – 75 ft-lb)
Rocker lever cover
1. Nozzle holder, connection
★ Check that there is no dirt or dust inside the nozzle holder

sleeve.
A) Fit O-ring (7) and coat with engine oil (SAE #30).
★ Check that there are no scratches on the O-ring.
B) Install gasket (6) to nozzle holder.
C) Align with mounting hole of connection of nozzle holder

(5), and insert nozzle holder.
★ Align the match mark, and make sure that the inlet connec-
tor tap hole (nozzle holder end) and inlet connector insertion
hole (rocker housing end) do not move out of position.
D) Insert connection (2) in rocker arm housing, and tighten

temporarily.
E) Fit holder (4), then fit spherical washer to mounting bolt

(3), and tighten.
★ Set one holder on top of the head of the rocker housing
mounting bolt, and tighten it.
13-64 1
12 F) Tighten connection (2), then tighten locknut (1).
Mounting bolt: 63 – 73 N•m (44 – 54 ft-lb)
Connection: 34 – 40 N•m (26 – 29 ft-lb)
Locknut: 34 – 44 N•m (26 – 32 ft-lb)
★ No. 1 injector is equipped with timing control. Lead wire must NOT be pinched.
2. Adjusting valve clearance
Adjust valve clearance.

For details, see TESTING AND ADJUSTING, Adjusting valve clearance.
3. Head cover, turbocharger lubrication tube
A) Fit gasket and install air vent tube (4).
B) Fit gasket and install turbocharger drain tube (3), then

install oil supply tube (2).
C) Fit gasket and install head cover (1).
D) Install fuel drain tubing

Mounting bolt: 5 N•m (48 in-lb)
Fuel drain mounting banjo capscrew:9 N•m (80 in-lb)
Oil cooler assembly
1. Oil level gauge, oil filler
A) Install oil level gauge guide (2).

★ Fit the O-ring and tighten the nut at the root of the level
gauge guide to secure it in position.
50 N•m (38 ft-lb)
B) Fit O-ring and install oil filler (1), then secure with
bracket.
13-65 1
2. Oil cooler installation
A) Install oil coolers
B) Tighten capscrews
Capscrews:66 N•m (49 ft-lb)
C) Install the o-rings into the back of the oil transfer con-
nection.
D) Install the oil transfer connection and capscrews onto

the cylinder block. Tighten the capscrews
E) Install the lubricating oil bypass valve with gasket.

Tighten the capscrews.
F) Install the O-rings on the aluminum oil transfer connec-

tion.
G) Install the connection to the cylinder block and the other

oil transfer connection.Tighten the capscrews.
13-66 1
Breather
1. Breather with O-ring groove
A) Fit O-ring and install breather (3).

B) Fit tube (2), then tighten with clamp.
C) Install alternator bracket (1).
★ The alternator bracket is installed to the right bank only.
2. Breather with no O-ring groove.
A) Install breather (3).
Breather mounting surface: Gasket sealant (LG-7)

Breather:25 – 29 N•m (18.0 – 21.5 ft-lb)
B) Install tube (2), and secure with clamp.
C) Install alternator bracket (1).
Water pump assembly
1. Lubricate the O-ring with soapy water and install on the

water pump.
2. Install the water pump into the gear case.
★ Make sure that the threaded plug has been installed into the
water pump.
3. Install the four mounting capscrews.
★ Two of the capscrews install from the back side.

13-67 1
5. Use vegetable oil and lubricate the O-ring on the bypass
tube.
6. Install the bypass tube.
7. Install the bypass connection gasket.
9. Install water connection from water pump to block.
Water connection:40 N•m (30 ft-lb)
10. Install water filter head and new O-rings.
Filter head:40 N•m (30 ft-lb)
Fuel pump drive
1. Fuel pump drive assembly
A) Assemble bushings (4) into housing (5) with press and

mandrel.
B) Align oil hole in bushing with oil hole in housing.
C) Coat bushings with engine oil.
D) Lubricate shaft (7) and thrust washer (4).
E) Insert shaft through housing (5) with thrust washer (4),

washer (6), spline (2), and retaining nut (3).
13-68 1
F) Install thrust washer (5), washer (6), and retaining nut
(8) on end of shaft.
G) Use fabricated tool to secure spline coupling (2) while

torquing retaining nut (3) and retaining nut (8).
Nut (3): 406.7 N•m (300 ft-lb)
Nut (8): 542.3 N•m (400 ft-lb)
H) Install injection pump drive case.
I) Install new O-rings on front of housing.
J) Install upper support capscrews and four flange mount

capscrews.
K) Install ECM mount on both sides (1).
2. Injection pump drive gear
A) Install assembled hub and gear (1) and (2) on taper

shaft.
B) Hand tighten large nut (3) and (4). Do not torque until
pump timing is set.
Hub to gear capscrews:
114 N•m (84 ft-lb)
13-69 1
Air compressor assembly
1. Install the gasket and the cover plate (support bracket) on

the compressor. Do not tighten the six capscrews. The
support must be adjusted.
★ Do not install the splined coupling or the mounting gasket.
2. Install the compressor on the rear of the front gear cover.
3. Install the four capscrews (6). Do not tighten. The com-

pressor must be turned to align the support bracket.
The support MUST be flat against the block. Rotate the

compressor until the support is aligned properly against
the block. If the support is NOT flat, the compressor will
fail.
4. Tighten the four capscrews (6).
60 N•m (45 ft-lb)
★ The bracket must remain flat against the block. Tighten the
support capscrews (7) that are accessible.
45 N•m (35 ft-lb)
5. Remove the four capscrews (6). Remove the compressor.
6. Tighten the two remaining support to compressor cap-

screws.
45 N•m (35 ft-lb)
13-70 1
7. Install the splined coupling (1), the gasket, and the com-
pressor.
The support MUST be flat against the block. Rotate the

compressor until the support is aligned properly against
the block. If the support is NOT flat, the compressor
and/or accessory will fail.
8. Install the four capscrews (6) and two capscrews (5).
Capscrew (6): 60 N•m (45 ft-lb)

Capscrew (5): 45 N•m (35 ft-lb)
9. Install the lubricating oil inlet line to the air compressor.
10. Install the air inlet and outlet connections to the air compres-
sor. Tighten the clamps.
Clamp: 6 N•m (50 in-lb)
11. Install water inlet and outlet tubes.
Fuel injection pump

For details on fuel injection pump installation and timing, refer to section 12.
Exhaust manifold assembly
1. Fit gasket and install exhaust manifold assembly (1).
44 – 54 N•m (33 – 40 ft-lb)
★ Fit a spacer to the bolt before tightening.
2. Tighten the mounting bolts in the order shown in the dia-

gram.
13-71 3
Coat the thread of the bolt and the bottom of the bolt
head with anti-friction compound (LM-P) before tighten-
ing.

SA12V140Z-1 Engine
1. Install aftercooler core as follows.
A) Fit gasket and install aftercooler core (14).

★ Install with the welded aftercooler core at the top.
B) Fit gasket and install cover (13).
C) Fit gaskets and install connectors (12).
D) Tighten high pressure fuel line clamps.
2. Fit gaskets to both ends of electrical intake air heater and

install aftercooler and intake manifold assembly (11).
★ To prevent the electrical intake air heater from falling out, fit
a guide bar into the bottom mounting bolt hole of the intake
manifold when installing.
Mounting bolt: 59 – 73 N•m (44 – 54 ft-lb)
★ Tighten the mounting bolts in the order shown in the dia-

gram.
A) Install electronic control modules
B) Install wiring harness and manifold sensors.
C) Install harness support clamps and connectors.
13-72 3
3. Right bank
A) Install electrical intake air heater wiring (10).

B) Fit O-ring and install tube (8).
4. Left bank
A) Install clamp (1) of fuel injection tubes and secure injec-

tion tubes.
B) Install heater relay wiring (5).

C) Install tube (3) for aftercooler.
D) Install tubes (1) and (2) for air compressor.
E) Install harness supports, ground connections, and con-
nect sensors.

SAA12V140ZE-2 Engine
Left and Right Banks:
★ The spacers or grid heaters are installed with the part num-
ber facing the aftercooler and arrow pointing toward the cyl-
inder head.
★ Use guide studs long enough to protrude beyond the
installed part.
13-72-1 3
1. Install 12 guide studs in the upper row of capscrew holes in
the intake manifold mounting holes.
2. Install the gaskets on the studs with the word UP toward the
top and facing the cylinder head.
★ The 8 mm straight-thread O-ring plug is installed on the bot-

tom of the aftercooler housing (number 2 right-bank and
number 5 left-bank). If not, install and tighten.
O-ring plugs: 6 N•m (53 in-lb)
3. Install the spacer and the second gasket with the word UP
toward the top and facing the cylinder head.
★ On some engines, an electric grid heater is required. The

heater must be installed in place of the spacer.
Intake manifold, aftercooler assembly: 50 kg (110 lb)
4. Install the aftercooler assembly using guide pins. Install the

bottom row of capscrews. Tighten the capscrews only
enough to hold the part.
★ All gaskets, spacers and heaters must be properly posi-

tioned before tightening the capscrews.
5. Remove the guide studs and install the top row of cap-
screws. Some capscrews will be used for the wiring harness
brackets.
6. Use the sequence shown and tighten the capscrews.
7. Install intake manifold pressure sensor and intake manifold

air temperature sensor. Connect wiring harness.
13-72-2 3
8. Install the charge air cooler return duct support bracket onto
the intake manifold cover.
9. Use a new gasket and install the charge air cooler return
duct.
10. Loosely install the capscrews securing the duct to the intake
manifold cover and the support bracket.
11. Tighten intake manifold cover capscrews and support

bracket capscrews.
12. Install the compressor outlet duct.
13. Slip the duct into the compressor side of the compressor
outlet hose attached to the compressor side of the turbo-
charger.
14. Align the duct with the support bracket and install the four
capscrews.
15. Move the hose clamp into its correct position and tighten.
Clamp: 8 N•m (71 in-lb)
17. Fill the cooling system (and lubricating system also, if nec-
essary). Operate the engine to normal operating tempera-
ture and check for air leaks.
13-72-3 3
Aftercooler Water Transfer Connection

1. Install gaskets on the two large water transfer connections
and the two small water transfer connections.
2. Lubricate the water transfer connections with vegetable oil;

this will aid in assembly.
3. Install the small transfer connections in the top aftercooler

port in each bank; install the large transfer connections in
the lower aftercooler port in each bank.
4. Press firmly to slide connections in place.
5. Install the gasket and the water transfer connection on the

lower aftercooler port on the right bank.
★ Check that a pipe plug is installed in the water transfer con-

nection. If not, install the pipe plug using Loctite 592 and
tighten.
Aftercooler Water Tubes

1. Install an O-ring on the right-bank end of the aftercooler
supply tube. Use vegetable oil to lubricate the O-ring.
2. Install a gasket to the right-bank end of the aftercooler

return tube.
3. Install gaskets on the left-bank ends of the aftercooler sup-

ply and return tubes. Tighten capscrews.
★ Check that the two pipe plugs are installed in the left-bank
aftercooler supply tube flange. If not, install the pipe plugs
using Loctite part number 3375066 and tighten.
Pipe plugs: 7 N•m (62 in-lb)
13-72-4 3
4. Use vegetable oil to lubricate the O-rings. Install the O-rings
on both ends of the aftercooler supply tube.
5. Install the aftercooler supply tube.
★ If the tube does not align, loosen the joining hose and rotate
the tubes to fit.
Aftercooler Return Tubes

1. Install O-rings on the ends of the aftercooler return tubes.
Lubricate the O-rings with vegetable oil.
2. Install the tubes into the thermostat housing.
★ The short tube is for the right bank and the long tube is for
the left bank.
3. Install the clamping plates.
Clamping plates: 65 N•m (48 ft-lb)
4. Install the gasket on the water return tube flanges. Tighten

capscrews.
Turbocharger assembly
1. Install turbocharger assembly (3).
Capscrew: 44 – 54 N•m (32.6 – 39.7 ft-lb)

★ When installing the turbocharger mounting bolts, install
each connection, then align the center and tighten fully.
2. Fit gasket and connect turbocharger drain tube (2).
3. Connect turbocharger oil supply tubes (1).
13-73 3
Intake connector
Fit gaskets and O-rings at each end, then install intake connec-
tor (1).
★ Rotate offset connector for alignment
Fan
1. Fan pulley assembly
Using a nylon sling, sling fan pulley assembly (2), set in mount-
ing position, then tighten mounting bolts.
★ Check that the fan pulley rotates smoothly.
2. Fan belt
For details on fan belt installation, refer to section 12.
3. Fan
Using a nylon sling, sling fan (1), set in mounting position, then
tighten mounting bolts.
13-74 1
12
General assembly
1. Filter
A) Install bypass filter (4).
B) Install fuel filter (3), oil filter (2), and corrosion resistor
(1).
★ Install each filter as follows.
• Coat seal portion and thread portion of filter cartridge thinly
with engine oil (SAE #30).
• Tighten until packing surface contacts seal surface of filter
holder, then tighten further by hand as follows:
Bypass filter: 3/4 – 1 turn
Oil filter: 3/4 – 1 turn
Fuel filter: 1/2 – 3/4 turn
Corrosion resistor: 2/3 turn
2. Alternator assembly
A) Install alternator assembly (4), tighten lock bolt (2) and

adjustment bolt (1) temporarily, then install belt (3).
B) Set so that locknut of adjustment bolt (1) faces in direc-

tion of extension of belt (3), then adjust so that deflec-
tion is approx. 15 mm when belt (3) is pressed at mid-
point with a force of approx. 6kg. After adjusting,
tighten lock bolt (2) and locknut of adjustment bolt.
3. Starting motor assembly
Fit gasket and install starting motor (1)
13-75 1
12
13-76 1
14 MAINTENANCE STANDARD
INTAKE AND EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
ENGINE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
VALVE, VALVE SPRING AND VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
ROCKER ARM AND SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
CROSSHEAD AND GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8
CYLINDER LINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-10
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
CAM FOLLOWER AND PUSH ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
PISTON, PISTON RING AND PISTON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-21
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-24
OIL COOLER BY-PASS VALVE, REGULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-25
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-26
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-26
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-27
14-1
MAINTENANCE STANDARD INTAKE AND EXHAUST SYSTEM
INTAKE AND EXHAUST SYSTEM

TURBOCHARGER
Unit: mm [in]
No Check item Criteria Remedy
1 End play (Play in axial direction) Standard Repair limit Replace
0.03 [0.001] 0.10 [0.004] thrust parts
2 Radial play (Play in radial direction) at compressor 0.15 [0.006] 0.46 [0.018] Replace
wheel bearing
3 Radial play (Play in radial direction) at turbine wheel 0.20 [0.008] 0.53 [0.021] parts
4 Tightening torque of blower impeller locknut 41 N•m [362 in-lb] Tighten
5 Tightening torque of turbocharger mounting bolt 61 N•m [540 in-lb]
6 Tightening torque of V band locknut 8 N•m [70 in-lb]
14-2
MAINTENANCE STANDARD ENGINE BODY
ENGINE BODY
CYLINDER HEAD
Tightening order of cylinder head mounting bolts
Unit: mm [in]
1 Distortion of cylinder head Standard Repair limit Repair by
mounting surface 0 - 0.06 [0 - 0.023] 0.09 [0.0035] grinding or
replace
2 Protrusion of nozzle Standard: 4.65 – 5.65 [0.183 – 0.222] Replace
nozzle or
cylinder
head
3 Tightening torque of cylin- Bolt no. Order Target Range Tighten bolts
der head mounting bolt 1st step0 15 kgm 4 -16 kgm in accor-
(Coat the thread areas and [108.5 ft.lb] [101.3 - 115.7 dance with
bearing surface with ft.lb] bolt No.
molybdenum disulfide) 2nd step 22 kgm 21.5 - 22.5 kgm
¨?± [159.1 ft.lb] [155.5 - 162.7
ft.lb]
3rd step Retighten with 90° – 120°
90°
- 7 kgm 6 – 7.5 kgm
ð [50.6 ft.lb] [43.4 – 54.2
ft.lb]
4 Tightening torque of nozzle Target Range Retighten
holder mounting bolt 6.8 kgm [49.2 ft.lb] 6 – 7.5 kgm [43.4 – 54.2 ft.lb]
5 Tightening torque of fuel 3.8 kgm [27.5 ft.lb] 3.5 – 4.1 kgm [25.4 – 29.6 ft.lb]
inlet connector
6 Tightening torque of con- 4.0 kgm [28.9 ft.lb] 3.5 – 4.5 kgm [25.4 – 32.5 ft.lb]
nector pipe locknut
7 Tightening torque of cylin- 0.5 kgm [3.6 ft.lb] 0.4 – 0.6 kgm [2.9 – 4.3 ft.lb]
der head cover mounting
bolt
14-3
VALVE, VALVE SPRING AND VALVE GUIDE
14-4
Unit mm[in]
1 Amount of valve sinking Valve Standard size Tolerance Repair limit Replace
Intake valve 0 ± 0.10 0.70 valve or
[± 0.0039] [0.0275] valve seat
Exhaust valve 0 ± 0.10 0.70
[± 0.0039] [0.0275]
2 Thickness of valve lip Valve Standard size Repair limits Replace
Intake valve 2.4 [0.094] 1.9 [0.075] valve
Exhaust valve 2.15 [0.085] 1.6 [0.063]
3 Valve seat angle H Valve Standard size Repair limits Repair or
Intake valve 60° ±0°15´ replace
Exhaust valve 45° ±0°15´ valve and
valve seat
4 Outside diameter of valve Intake valve 10 [0.394] -0.045[-0.0017] Replace
stem -0.060[-0.0023] valve
Exhaust valve 10 [0.394] -0.074[-0.0029]
-0.089[-0.0035]
Inside diameter of valve Before inserting 10 [0.394] +0.011[+0.0004] Replace
guide -0.011[-0.0004] valve guide
After inserting 10 [0.394] +0.011[+0.0004]
-0.011[-0.0004]
Clearance between valve Valve Standard clearance Clearance limit Replace
guide and valve stem Intake valve 0.034-0.071 0.22 valve or
[0.0013-0.0027] [0.0086] valve guide
Exhaust valve 0.063-0.100 0.24
[0.0025-0.0039] [0.0094]
Bend of valve stem Repair limit: 0.02 [0.0007] (total indicated runout for 100 [3.937] Replace
valve
5 Protrusion of valve guide Standard size Tolerance Repair
23 [0.906] ± 0.2 [± 0.0078]
6 Valve spring Valve Standard size Repair limit Replace
spring Free Installed Installed Free Installed valve spring
length length load length load
Outer 81.7 51.0 43.3±2.2 38.7 kg
(Large) [3.22] [2.01] kg [85.3 lb]
[95.45±
9.7 lb]
Inner 72.0 46.0 22.0±1.5 19.7 kg
(Small) [2.84] [1.81] kg [43.4 lb]
[48.5±6.6
lb]
Squarence of valve spring Repair limit: 2° (for both ends)
H The intake valve cannot be reground. It must be replaced with a new part.
H If the exhaust valve has been used for more than 10,000 hours, replace with a new part.
14-5
ROCKER ARM AND SHAFT
Unit: mm [in]
No. Check item Criteria Remedy
1 Outside diameter of rocker Standard size Tolerance Replace
arm shaft 32.0 [1.26] ± 0.0065 [± 0.0002] rocker arm
shaft
Inside diameter of rocker 32.0 [1.26] + 0.087 [+0.0034] Replace
arm bushing + 0.035 [+0.0013] rocker arm
Clearance between rocker Standard clearance Clearance limit Replace
arm shaft and rocker arm 0.0285 – 0.0935 0.13 [0.0051] rocker arm
bushing [0.0012 – 0.0036] or rocker
arm shaft
2 Valve clearance (When Valve Standard size Tolerance Adjust
engine cold) Intake 0.43 [0.0169] ± 0.02 [0.0007]
Exhaust 0.80 [0.0315] ± 0.02 [0.0007]
3 Tightening torque of rocker Target Range Tighten
arm adjustment screw 6 kgm [43.4 ft.lb] 5.4 – 6.6 kgm [39.1 – 47.7 ft.lb]
locknut
14-6
CROSSHEAD AND GUIDE
Unit: mm [in]
1 Depth of crosshead stem Standard size Tolerance Repair limit Replace
6.2 [0.244] +0.3 [+0.0118] 6.71 [0.264]
0 [0]
2 Inside diameter of cross- 11 [0.433] +0.06 [+0.0023] 11.17 [0.440]
head +0.02 [+0.0007]
Outside diameter of cross- 11 [0.433] +0.11 [+0.0043] 10.95 [0.431]
head guide 0 [0]
3 Protrusion of crosshead 49.0 [1.929] ± 0.25 [± 0.0098] - Repair
guide
4 Tightening torque of cross- 6 ± 0.6 kgm [43.4 ± 4.3 ft-lb] Tighten
head locknut
14-7
CYLINDER BLOCK
14-8
Unit: mm [in]
1 Distortion of cylinder head Standard size Repair limit Repair by
mounting surface 0 – 0.09 [0 – 0.0035] 0.135 [0.0053] grinding or
replace
2 Inside diameter of main Standard size Tolerance Replace or
bearing hole 157 [6.18] + 0.025 [+ 0.001] repair main
– 0.010 [– 0.0004] bearing cap
Surface roughness of main Within 10 S Correct
bearing mount hole
Out-of-roundness of mount Service limit: 0.005 [0.0002]
hole
Thickness of No.4 4.5 [0.177] – 0.050 [– 0.0019] Replace
main bearing only – 0.060 [– 0.0023] main bear-
Except 4.5 [0.177] – 0.065 [– 0.0026] ing
No.4 – 0.075 [– 0.0030]
3 Inside diame- Journal Standard size Tolerance Repair limit
ter of main No.4 148 [5.827] + 0.175 [+ 0.0068] 148.23 [5.835]
bearing only + 0.130 [+ 0.0051]
Except 148 [5.827] + 0.145 [+ 0.0057] 148.20 [5.834]
No.4 + 0.100 [+ 0.0039]
4 Inside diameter of cam- 69 [2.717] + 0.025 [+ 0.0009] – Repair or
shaft bushing hole 0 [0] replace cyl-
inder block
5 Inside diameter of cam- 65 [2.559] + 0.040 [+ 0.0016] 65.15 [2.565] Replace
shaft bushing 0 [0] camshaft
bushing
6 Tightening torque of main Order Target Range Retighten
bearing cap bolt (Coat 1st step 29 kgm [209.8 ft.lb] 27.5 – 30.5 kgm
thread area with engine oil) [198.9 – 220.6 ft.lb]
2nd step 58 kgm [419.5 ft.lb] 57.0 – 59.0 kgm
[412.3 – 426.7 ft.lb]
3rd step Retighten with 90° 90 – 120°
– Tightening torque of oil pan Target Range
mounting bolt 6.7 kgm [48.5 ft.lb] 6 – 7.5 kgm [43.4 – 54.2 ft.lb]
– Difference of face between Repair limit: 0.14 [0.0055] Replace by
cylinder block and front reassem-
cover bling
H The main cap bolt can be tightened a maximum of 12 times. Make a punch mark on the bolt head each time it
is tightened.
14-9
CYLINDER LINER
Unit: mm [in]
1 Protrusion of cylinder liner Permissible range: 0.08 – 0.185 [.0031 – .0073] Repair cylin-
der liner or
repair or
replace cyl-
inder block
2 Inside diameter of cylinder Rank Standard size Tolerance Repair limit Replace cyl-
liner S 140 [5.512] +0.020 140.12 [5.516] inder liner
[+0.0008] (Only L is
0 [0 ] supplied)
L 140 [5.512] +0.040 140.14 [5.517]
[+0.0015]
+0.021
[+0.0008]
3 Outside diameter of cylin- Standard size Tolerance
der liner 170.2 [6.692] 0 [0 ]
(Counter bore) –0.10 [–0.0039]
Clearance between cylin- Standard: 0 – 0.163 [0 – 0.0064] Replace cyl-
der liner and block inder liner or
(Counter bore) cylinder
block
4 Outside diameter of cylin- Standard size Tolerance Replace cyl-
der liner 161.2 [6.346] +0.090 [+0.0035] inder liner
(Counter bore bottom) +0.050 [+0.0019]
Interference between cylin- Standard interference Interference limit Repair cylin-
der liner and block 0.02 – 0.12 [0.0008 – 0.0047] 0.02 – 0.12 [0.0008 – 0.0047] der liner or
(Counter bore bottom) repair or
replace cyl-
inder block
5 Outside diameter of cylin- Standard size Tolerance Replace cyl-
der liner 158 [6.22] –0.024 [–0.0009] inder liner
(O-ring part) –0.049 [–0.0019]
Clearance between cylin- 0.024 – 0.094 [0.001 – 0.0037] Replace cyl-
der liner and block (O-ring inder liner or
part) cylinder
block
14-10
CRANKSHAFT
Unit: mm [in]
1 End play Standard size Repair limit Repair by
0.140 – 0.315 0.50 [0.0196] using over
[0.0056 – 0.0124] size thrust
bearing or
replace
2 Outside diameter of main Standard size Tolerance Repair limit Repair by
journal STD 148.00 [5.827] 0 147.98 [5.825] using over
0.25 U.S. 147.75 [5.817] –0.020 147.73 [5.816] size bearing
[0.0098] [0] or replace
0.50 U.S. 147.50 [5.807] [–0.0008] 147.48 [5.787]
[0.0197]
0.75 U.S. 147.25 [5.797] 147.23 [5.796]
[0.0295]
1.00 U.S. 147.00 [5.787] 146.98 [5.786]
[0.0394]
Roundness of main journal Repair limit
0 – 0.010 [0– 0.0003]
Clearance of Journal Standard clearance Clearance limit Correct by
main journal No. 4 only 0.130 – 0.195 0.25 [0.0099] using under
[0.0051 – 0.0076] size bearing
Except 0.100 – 0.165 [0.004 – 0.0064] 0.22 [0.0087] or replace
No.4 main bear-
ing
Surface roughness of main 0.8 S (Surface roughness at R portion: 3.2 S) Correct sur-
journal face rough-
ness of
crankshaft
journal
14-11
3 Outside diameter of crank Standard size Tolerance Repair limit Repair by

pin journal STD 100.00 [3.937] 0 99.88 [3.932] using over
0.25 U.S. 99.75 [3.927] –0.020 99.63 [3.922] size bearing
[0.0098] [0] or replace
0.50 U.S. 99.50 [3.917] [–0.0008] 99.38 [3.913]
[0.0197]
0.75 U.S. 99.25 [3.907] 99.13 [3.903]
[0.0295]
1.00 U.S. 99.00 [3.897] 98.88 [3.893]
[0.0394]
Roundness of crank pin Repair limit
journal 0 – 0.010 [0 – 0.0003]
Clearance of crank pin Standard clearance Clearance limit Replace
journal 0.046 – 0.116 0.17 [0.0067] connecting
[0.0019 – 0.0045] rod bearing
Surface roughness of 0.8 S (Surface roughness at R portion: 3.2 S) Correct sur-
crankshaft pin journal face rough-
ness of
crankshaft
journal
4 Straightness of all main Standard size Repair limit Replace
journal within 0 – 0.09 [0 – 0.0035] 0.09 [0.0035]
Straightness of two main within 0 – 0.05 [0 – 0.0019] 0.05 [0.0019]
journal
5 Crank pulley mounting bolt Target Range Tighten bolts
1st step 7.5 kgm 5.5 – 9.5 kgm [39.8 – 68.7 ft.lb] in accor-
[54.2 ft.lb] dance with
2nd step 25.0 kgm 23.0 – 27.0 kgm bolt No.
[180.8 ft.lb] [166.4 – 195.2 ft.lb]
3rd step 76.0 kgm 74.0 – 78.0 kgm
[549.7 ft.lb] [535.3 – 564.1 ft.lb]
6 Tightening torque of vibra- 11 ± 1.0 kgm [79.6 ± 7.2 ft.lb]
tion damper mounting bolts
Judgement standards for judging if crankshaft can be used again
If it is impossible to measure all the items in the MAINTENANCE STANDARD (including roughness), use the fol-
lowing conditions to judge if the crankshaft can be used again.
1. If more than 60% of the overlay of the pin bearing has been lost after about 4000 hours of operation due to the
entry of dust, the crankshaft journal surface has probably become rough, so grind again or replace.
2. On engines where the oil filter may have be-come clogged because of deterioration of the oil or entry of water
into the oil pan, there are probably scratches or increased roughness on the journal surface caused by dirt, so
grind again or replace.
3. If the main journal or pin journal has seized, the crankshaft hardness will have been lost because of the high
temperature and the strength may have dropped, so do not use such parts again. (There is danger that the
crankshaft may break.)
14-12
CAMSHAFT
Unit: mm [in]
1 End play Standard size Repair limit Replace
0.1 – 0.25 [0.0039 – 0.0098] 0.36 [0.0142] thrust plate
2 Outside diameter of cam- Standard size Tolerance Replace
shaft journal 65 [2.559] –0.016 [–0.0006] camshaft
–0.036 [–0.0014]
Clearance of camshaft Standard clearance Clearance limit Replace
journal 0.016 – 0.096 0.15 [0.0059] camshaft
[0.0007 – 0.0037] bushing
3 Bend of camshaft Repair limit: 0.04 [0.0016] (Total indicated runout) Replace
4 Cam height Cam Standard size Tolerance Repair limit camshaft
Intake 55.48 [2.184] ± 0.1 55.08 [2.168]
[± 0.0039]
Exhaust 55.75 [2.195] ± 0.1 55.35 [2.179]
[± 0.0039]
14-13
CAM FOLLOWER AND PUSH ROD
Unit: mm [in]
1 Outside diameter of cam Standard size Tolerance Repair limit Replace
follower shaft 22 [0.866] –0.021 [–0.0008] 21.92 [0.864]
–0.034 [–0.0013]
Inside diameter of cam fol- 22 [0.866] +0.021 [+0.0008] 22.07 [0.870]
lower shaft 0[0]
2 Outside diameter of cam 31.7 [1.248] +0.05 [+0.0019] 31.5 [1.240]
roller +0.02 [+0.0007]
3 Inside diameter of cam 12.7 [0.500] +0.038 [+0.0015] 12.78 [0.503]
roller +0.013 [+0.0005]
Outside diameter of cam 12.63 [0.497] ± 0.006 [± 0.0002] 12.56 [0.494]
roller pin
4 Radius of push rod ball end Standard size Tolerance
12.7 [0.500] 0[0]
–0.20 [–0.0078]
5 Radius of push rod socket 13.4 [0.528] 0[0]
end –0.20 [–0.0078]
6 Bend of push rod Repair limit: 0.3 [0.0118] (Total indicated runout)
7 Tightening torque of cam 4.5 – 6.0 kgm [32.6 – 43.3 ft.lb] Tighten
follower mounting bolt
14-14
TIMING GEAR
14-15
Unit: mm [in]
Measuring
Gears Standard size Repair limit
point
Crankshaft gear and R-main 0.141-0.425
a 0.6 [0.0236]
idler gear (Large) [0.0056-0.0167]
R-main idler gear (Small) and 0.130-0.390
b 0.6 [0.0236]
R-sub idler gear [0.0052-0.0153]
*b 0.6 [0.0236]
R-sub idler gear [0.0049-0.0143]
c 0.6 [0.0236]
R-camshaft gear [0.0051-0.0153]
*c 0.6 [0.0236]
R-camshaft gear [0.0049-0.0143]
R-camshaft gear and acces- 0.085-0.492
d 0.6 [0.0236]
sory drive gear [0.0034-0.0193]
R-camshaft gear and acces- 0.138-0.354
*d 0.6 [0.0236]
sory drive gear [0.0054-0.0139]
e 0.6 [0.0236]
R-injection pump drive gear [0.0021-0.0184]
Backlash of each gear R-main idler gear (Small) and 0.125-0.363
– *e 0.6 [0.0236] Replace
(* : Between spur gears) R-injection pump drive gear [0.0049-0.0143]
f 0.6 [0.0236]
water pump drive gear [0.0021-0.0189]
g 0.6 [0.0236]
oil pump drive gear [0.0054-0.0165]
Crankshaft gear and L-main 0.141-0.425
h 0.6 [0.0236]
idler gear (Large) [0.0056-0.0167]
L-main idler gear (Small) and 0.129-0.391
i 0.6 [0.0236]
L-camshaft gear [0.0051-0.0153]
*i 0.6 [0.0236]
L-camshaft gear [0.0049-0.0143]
j 0.6 [0.0236]
L-injection pump drive gear [0.0021-0.0184]
*j 0.6 [0.0236]
L-injection pump drive gear [0.0049-0.0143]
L-injection pump drive gear 0.106-0.381
k 0.6 [0.0236]
and air compressor drive gear [0.0042-0.015]
L-injection pump drive gear 0.138-0.354
*k 0.6 [0.0236]
and air compressor drive gear [0.0054-0.0139]
Standard Tolerance Standard Clearance
Clearance between main size Shaft Bushing clearance limit
1 idler gear bushing and +0.055
shaft (R and L bank) -0.016 [-0.0006] 0.016 - 0.084 0.20 Replace
56 [2.205] [+0.0021]
-0.029 [-0.0011] [0.0006 - 0.0032] [0.0078]
0[0] bushing
Clearance between sub +0.055
-0.016 [-0.0006] 0.016 - 0.084 0.20
2 idler gear bushing and 56 [2.205] [+0.0021]
-0.029 [-0.0011] [0.0006 - 0.0032] [0.0078]
shaft 0[0]
End play of main idler Standard size Repair limit
3
gear 0.07 – 0.18 [0.0028 – 0.0071] 0.4 [0.0157]
4 End play of sub ider gear 0.06 – 0.14 [0.0024 – 0.0055] 0.4 [0.0157]
End play of injection Replace
5 0.09 – 0.51 [0.003 – 0.020] 0.63 [0.024] thrust
pump drive gear
End play of oil pump bearing
6 0.03 – 0.088 [0.0012 – 0.0034] 0.4 [0.0157]
drive gear
End play of accessory
7 0.10 – 0.40 [0.004 – 0.0157] 0.4 [0.0157]
drive gear
14-16
PISTON, PISTON RING AND PISTON PIN
14-17
Unit: mm [in]
1 Outside diameter of piston Rank Standard size Tolerance Repair limit Replace pis-
(at right angles to boss) S 140 [5.512] –0.070 [–0.0027] 139.85 [5.510] ton (only S is
–0.085 [–0.0033] supplied)
L 140 [5.512] –0.070 [–0.0027] 139.85 [5.510]
–0.085 [–0.0033]
2-4 Clearance at piston ring No. Measurement Standard clear- Clearance limit Replace pis-
end gap location ance ton ring
2 Top ring 0.42-0.57 1.0 [0.0394]
[0.0166-0.0224]
3 Second ring 0.42-0.57 1.0 [0.0394]
[0.0166-0.0224]
4 Oil ring 0.37-0.52 1.0 [0.0394]
[0.0146-0.0204]
Clearance between piston No. Measure- Standard Tolerance Stan- Clear- Replace pis-
ring groove and piston ring ment size dard ance ton ring or
location
Ring Piston
clear- limit piston
ance
2 Top 2.4 –0.015 Judge with groove wear
ring [0.0945] [-0.0005] gauge
–0.035
[–0.0013]
3 2nd 2.4 –0.010 Judge with groove wear
ring [0.0949] [–0.0003] gauge
–0.035
[–0.0013]
4 Oil ring 4 –0.010 +0.030 0.02-0.06 0.14
[0.157] [–0.0004] [+0.0012] [0.0008- [0.0055]
–0.030 +0.010 0.0024]
[–0.0012] [+0.0004]
5 Clearance between piston Standard Tolerance Standard clear- Clear- Replace pis-
and piston pin size ance ance ton ring or
Shaft Hole
limit piston pin
52 0 [0 ] +0.045 [+0.0017] 0.035-0.051 0.10
[2.047] –0.006 +0.035 [+0.0013] [0.0014-0.0020] [0.0039]
[–0.0023]
- Piston portion B Carbon deposit (Thickness: 1mm [0.0394] or more) Replace pis-
ton (if thick-
ness is less
than 1 mm
[0.0394], it is
possible to
clean off car-
bon at A and
B and use
again
14-18
CONNECTING ROD
14-19
Unit: mm [in]
1 Inside diameter of connect- Standard size Tolerance Repair limit Replace
ing rod small end bushing 52 [2.047] +0.049 [+0.0019] 52.09 [2.051] bushing
+0.030 [+0.0011] (supplied as
semi-fin-
ished prod-
uct)
Clearance between con- Standard clearance Clearance limit Replace
necting rod small end 0.030 – 0.055 0.11 [0.0043] bushing or
bushing and piston pin [0.0012 – 0.0021] piston pin
2 Inside diameter of mount- Standard size Tolerance Replace
ing hole of connecting rod 57.4 [2.260] +0.030 [+0.0011] connecting
small end bushing 0[0] rod (not per-
mitted to
correct)
3 Inside diameter of connect- Standard size Tolerance Repair limit Replace
ing rod big end bearing 100 [3.937] +0.096 [+0.0037] 100.15 [3.946] bearing
(crankshaft pin journal) +0.046 [+0.0018]
4 Inside diameter of connect- 106 [4.173] +0.026 [+0.0010] — Replace
ing rod big end hole (no –0.004 [–0.0002] connecting
bearing, X, Y, Z directions) Tighten connecting rod cap to specified torque, then measure rod (not per-
mitted to
correct)
5 Thickness of connecting 3.0 [0.118] –0.025 [–0.0009] — Replace
rod bearing –0.035 [–0.0013] bearing
6 Parallelism, twisting of Standard Repair Replace
connecting rod limit connecting
Parallel- 0-0.10 0.15 rod bushing
ism [0- 0.0039] [0.0059] or connect-
Twisting 0-0.25 0.30 ing rod
[0- 0.0098] [0.0118]
7 Tightening torque for con- Procedure Target Range Tighten in

necting rod cap mounting 1st 7.5 kgm [54.2 ft.lb] 7 – 8 kgm order shown
bolt (coat nut seat face at [50.7 – 57.8 ft.lb] in diagram
bolt head with engine oil) 2nd Tighten 90° 90° + 30
0
8 Inside diame- Rough- 3.2 S Replace
ter of connect- ness
ing rod big end Wave 0.004 [0.00015] (Whole width)
H The connecting rod bolt can be tightened a maximum of 5 times. Make a punch mark on the bolt head each
time it is tightened.
14-20
FLYWHEEL AND FLYWHEEL HOUSING
Unit: mm [in]
1 Face runout of flywheel Repair limit: 0.25 [0.0098] Repair
housing
2 Radial runout of flywheel Repair limit: 0.25 [0.0098]
housing
3 Face runout of flywheel Repair limit: 0.30 [0.0118]
4 Radial runout of flywheel Repair limit: 0.13 [0.0051]
5 Tightening torque of fly- Order Target Range Tighten bolts
wheel housing mounting 1st step 35 kgm [253 ft.lb] 30 – 40 in accor-
bolts (Coat thread areas [217 – 289 ft.lb] dance with
and bearing surface with 2nd step 42 kgm [304 ft.lb] 40 – 44 bolt No.
engine oil) [289 – 318 ft.lb]
6 Tightening torque of fly- Order Target Range
wheel mounting bolts (Coat 1st step 10 kgm [72 ft.lb] 8 – 12
thread areas and bearing [58 – 86 ft.lb]
surface with engine oil) 2nd step 30 kgm [217 ft.lb] 28 – 32
[203 – 231 ft.lb]
3rd step 55 kgm [398 ft.lb] 53 – 57
[384 – 412 ft.lb]
14-21
MAINTENANCE STANDARD LUBRICATION SYSTEM
LUBRICATION SYSTEM
OIL PUMP
Unit: mm [in]
1 Axial clearance of pump Standard Tolerance Standard Clearance Replace
gear size Gear Housing clearance limit gear
thickness width
54 0[0] +0.067 0.040-0.097 0.040-0.097
[2.128] -0.030 [+0.0026] [0.0016- [0.0016-
[-0.0012] +0.040 0.0038] 0.0038]
[+0.0015]
2 Radial clearance of pump Standard Tolerance Standard Clearance
gear size Gear O.D. Housing clearance limit
I.D.
54.99 -0.15 +0.06 0.15-0.27 0.15-0.27
[2.167] [-0.0059] [+0.0023] [0.0059- [0.0059-
-0.21 0[0] 0.0106] 0.0106]
[-0.0082]
3 Interference between Standard Tolerance Standard Interference Replace
driven shaft and pump size Shaft Hole interference limit
cover 18 +0.090 +0.040 0.030-0.068 –
[0.709] [+0.0035] [+0.0015] [0.0012-
+0.070 +0.022 0.0027]
[+0.0027] [+0.0008]
4 Interference between 21 +0.090 +0.035 0.030-0.090 –
driven shaft and driven [0.827] [+0.0035] [+0.0013] [0.0012-
+0.070 0[0] 0.0035]
gear bushing [+0.0027]
14-22

5 Clearance between driven Standard Tolerance Standard Clearance Replace
shaft and driven gear size Shaft Hole clearance limit bushing
bushing 18 +0.090 +0.147 0.032-0.077 0.032-0.077
[0.709] [+0.0035] [+0.0057] [0.0013- [0.0013-
+0.070 +0.122 0.0030] 0.0030]
[+0.0027] [+0.0048]
6 Clearance between driven 18 +0.090 +0.129 0.012-0.059 0.012-0.059
shaft and body [0.709] [+0.0035] [+0.005] [0.0005- [0.0005-
+0.070 +0.102 0.0023] 0.0023]
[+0.0027] [+0.004]
7 Clearance between drive 18 +0.106 +0.173 0.040-0.085 0.040-0.085
shaft and pump body bush- [0.709] [+0.0041] [+0.0068] [0.0016- [0.0016-
+0.088 +0.146 0.0033] 0.0033]
ing [+0.0034] [+0.0057]
8 Interference between drive Standard Tolerance Standard Interference Replace
gear and drive shaft size Shaft Hole interference limit
18 +0.106 +0.063 0.025-0.078 –
[0.709] [+0.0041] [+0.0024] [0.001-0.003]
+0.088 +0.028
[+0.0034] [+0.0011]
9 Interference between drive 21 +0.090 +0.021 0.044-0.090 –
shaft bushing and pump [0.827] [+0.0035] [+0.0008] [0.0017-
+0.065 0[0] 0.0035]
cover [+0.0025]
10 Interference between drive 18 +0.106 +0.065 0.023-0.059 –
shaft and oil pump drive [0.709] [+0.0041] [+0.0025] [0.0009-
+0.088 +0.047 0.0023]
gear [+0.0034] [+0.0018]
11 Tightening torque of pump 3.15 ± 0.35 kgm [20.3 – 25.3 ft.lb]
cover mounting bolt
14-23
MAIN RELIEF VALVE
Unit: mm [in]
1 Clearance between main relief Standard Tolerance Standard Replace
valve and body size Valve O.D. Body I.D. clearance valve or
28 [1.1024] –0.020 [–0.0008] +0.033 [+0.0012] 0.020 – 0.086 body
–0.053 [–0.0021] 0[0] [0.0008 – 0.0033]
2 Main relief valve spring Standard size Repair limit Replace
Free length Installed Installed load Installed load spring
length
72.4 60.5 [2.3819] 40 kg [88.1 lb] 36 kg [79.2 lb]
[2.8504]
3 Main relief valve set pressure 8.5 ± 0.5 kg/cm2 [113.8 – 127.9 psi] Adjust or
replace
spring
14-24
OIL COOLER BY-PASS VALVE, REGULATOR VALVE
Unit: mm [in]
1 Clearance between regula- Standard size Tolerance Standard Replace
tor valve and body Valve O.D. Body I.D. clearance valve or
22 [0.8661] –0.020 [–0.0008] +0.033 [+0.0012] 0.020-0.074 body
–0.041 [–0.0017] 0[0] [0.0008-0.0029]
2 Regulator valve spring Standard size Repair limit Replace
Free length Installed Installed load Installed load spring
length
111.5 [4.3898] 75 [2.9528] 13.87 kg 24.4 kg
[30.6 lb] [53.8 lb]
3 Regulator valve set pres- 4.1 ± 0.5 kg/cm2 [51.2 – 65.4 psi] Adjust or
sure replace
spring
4 Clearance between oil Standard Tolerance Standard Replace
cooler by-pass valve and size Valve O.D. Body I.D. clearance valve or
body 28 [1.1024] –0.020 [–0.0008] +0.033 [+0.0012] 0.020-0.086 body
–0.053 [–0.0021] 0[0] [0.0008-0.0033]
5 Oil cooler by-pass valve Standard size Repair limit Replace
spring Free length Installed Installed load Installed load spring
length
125.8 [4.921] 89.8 [3.5381] 19 kg [41.9 lb] –
6 Oil cooler by-pass valve 4.0 ± 0.2 kg/cm2 [56.9 ± 2.8 psi] Adjust or
set pressure replace
spring
14-25
MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
WATER PUMP
Unit: mm [in]
1 Interference between Standard size Tolerance Standard Replace.
impeller and shaft Shaft Hole interference Usually,
19.0 [0.748] +0.018 –0.025 [-0.001] 0.031-0.068 replace
[+0.0007] –0.050 [-0.002] [0.0012-0.0027] impeller
+0.006 (there is
[+0.0002] almost no
change in
outside
diameter of
shaft)
2 Interference between drive 30 [1.181] +0.021 –0.012 [–0.005] 0.020-0.060 Replace
gear and shaft [+0.0008] –0.039 [–0.015] [0.0008-0.0024] (usually,
+0.008 replace
[+0.0003] gear)
3 Clearance between impel- Standard clearance: 0.25 – 1.02 (Including end play) Replace
ler and body (0.0099 – 0.0401)
4 Abrasion of 4a. seal Surface roughness: Max. 0.8 S
seal ring in ring
water seal 4b. water Surface roughness: Max. 1.2 S
seal
14-26
THERMOSTAT
Unit: mm [in]
1 Lift of thermostat valve Min. 10 mm [0.394] (Check after immersion in a hot water bath
of 90°C [194°F] for 4 or 5 minutes.)
2 Opening and closing of Valve must be closed fully when immersed in a hot water bath
valve in thermostat (71°C) [159.8°F] for 4 or 5 minutes after being immersed in a hot
water bath (90°) [194°F] to fully open the valve.
14-27
MEMORANDA
14-28
15 REPAIR AND REPLACEMENT OF PARTS
TABLE OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
CYLINDER AND MOUNTING FACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
REPLACING VALVE SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
PRESSURE TEST OF CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
REPLACING VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12
REPLACING CROSSHEAD GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12
GRINDING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
METHOD OF CHECKING INSIDE DIAMETER OF MAIN BEARING MOUNTING HOLE
USING ALIGNMENT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
CORRECTING CYLINDER BLOCK TOP SURFACE, COUNTERBORE . . . . . . . . . . . . . . . . . . . 15-18
REPLACING MAIN BEARING CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-25
REPLACING CAM BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-27
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-29
CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTION . . . . . . . . . 15-31
GRINDING CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-35
CORRECTING FRONT SEAL CONTACT SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-42
CORRECTING REAR SEAL CONTACT SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-44
CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-46
REPLACING CONNECTING ROD SMALL END BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-48
REPLACING CRANKSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-49
REPLACING CAMSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-50
REPLACING FLYWHEEL RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-50
15-1 2
REPAIR AND REPLACEMENT OF PARTS TABLE OF SPECIAL TOOLS
TABLE OF SPECIAL TOOLS

Operation Tool description Part Number
Puller adapter, Intake valve 3377396
Puller adapter, Exhaust valve 3376617

Replacing valve seat
Valve seat grinder, 110 volt ST685A
Valve seat grinder, 220 volt ST685C
Valve guide puller 3824919

Replacing valve guide
Valve guide installer 3824918
Cross head guide puller ST1134

Replacing cross head guide
Cross head guide installer 3824920
Grinding valve Tool kit Commercially available
Fuel injector removal Fuel injector puller 3825190
Checking ID of main bearing bores Alignment bar Commercially available
Machining counterbore Tool kit Commercially available
Measure liner protrusion Protrusion gauge 3823495
Replacing cam bushing Tool kit Commercially available
Correcting surface roughness of crank journal Standard piece 790-101-8110
Measure crankshaft thrust Indicator gauge 3823495
Connecting rod bend/twist Gauge mandrel kit 3825185
Sleeve installer 795-502-2220

Mount front seal
Seal installer 795-502-2210
Sleeve installer 795-502-2120

Mount rear seal
Seal installer 795-502-2110
Replacing connecting rod small end bushing Use ReCon rod
Bearing puller 790-101-2800

Replacing crankshaft gear
Push puller 790-101-2300
Cup plug driver, 30 mm 3376796

Install cup plug
Cup plug driver, 40 mm 3824895
Engine revolution Barring device 3201740
15-2 2
REPAIR AND REPLACEMENT OF PARTS CYLINDER HEAD
CYLINDER HEAD
1. Cylinder head
2. Cross head guide
3. Valve guide
4. O-ring
5. Push rod tube
6. Valve seat (intake side)
7. Valve seat (exhaust side)
15-3 2
Unit: mm
Symbol Inspection item Judgement standards Remedy
• Check for cracks (external color check)
Cracks, leakage from • Check for water leakage with air pressure test Correct by welding
A
cylinder head (3.0 – 3.5 kg/cm2, 30 sec.) or replace
• Water pressure test (3.5 – 4.0 kg/cm2, 10 minutes)
Distortion of top, bottom Tolerance Repair limit

B Grind to correct
surface of cylinder head 0 – 0.06 0.09
Protrusion of injection
C Permissible range: 4.65 – 5.65
nozzle
Do not grind
intake valve.
• Pitting of valve contact surface
Damage to valve contact Correct valve
• Check contact of valve contact surface
D surface of valve seat, contact surface
• Airtightness test
loosening of valve seat of valve seat or
• Tap cylinder head and check for looseness
replace valve
seat
Sinking of valve (both Standard value Repair limit Replace valve or

E
intake and exhaust) 0 ± 0.1 0.7 valve seat
• Thickness of valve head
Standard value Repair limit
Intake value 2.4 Replace

1.9
Exhaust value
1.6
2.15
F Thickness of valve head
• Angle of valve seat contact

surface
–
Intake valve: 30°
Exhaust valve: 45°
15-4 2
Unit: mm
• Check if head has become concave
• Check for cracks or pitting of valve seat contact surface
• Airtightness test
Replace
G • Check for play in cotter pin when new cotter pin is
inserted in cotter groove.
• Check for uneven wear or curvature of valve stem
• Check for hollow in tip of valve stem Correct
• Outside diameter
Valve Standard size Standard value Repair limit
Outside diameter of valve
H Intake valve 10 9.940 – 9.955 – Replace
stem
Exhaust valve 10 9.911 – 9.926 –
Value Standard size Standard value Repair limit

Sinking of valve (both
E Intake valve 10 9.989 – 10.011 –
intake and exhaust)
Exhaust valve 10 9.989 – 10.011 –
Replace
J Protrusion of valve guide Permissible range: 23 ± 0.2
Outside diameter of cross Standard size Standard value Repair limit

K
head guide 11 11.000 – 11.011 10.95
Protrusion of cross head

L Permissible range: 49 ± 0.25 Correct
guide
15-5 2
CYLINDER AND MOUNTING FACE
WARNING! Wear protective eye wear to prevent fluid from possible contact with the eyes.
1. Grinding
A. Remove valve seat. For details, see "REPLACING VALVE SEAT" on page 15-7.
B. Grind cylinder head to remove deformation or rust. Do

not exceed repair limit of cylinder head height "a". Stamp
[R] on left side of cylinder head.
★ Standard dimension for height of cylinder head "a":
105 ± 0.05 mm
★ Repair limit after grinding: 0.10 – 0.15 mm
★ Surface roughness of grinding surface: Within 6S
★ Flatness (deformation): Within 0.05 mm
★ Grinding limit: 0.3 mm
★ Difference in head height per unit: Within 0.15 mm
C. Press fit one size larger over size valve seat. For details,
see "REPLACING VALVE SEAT" on page 15-7.
2. Checking after completion of grinding

• Check that sinking of valve is within standard value. Carry out adjustment and modification if necessary.
★ Sinking of valve: Standard: 0 ± 0.1 mm
15-6 2
REPLACING VALVE SEAT
WARNING! Wear protective eye wear to prevent

fluid from possible contact with the
eyes.
1. Removal of seat
A. When removing with a valve seat puller
1) Install grindstone (5) to grinder (1).
2) Align the groove of sleeve (3) with holder (2), and
insert.
★ Adjust the position of the grinder with set screw
(4).
3) Adjust the position of the grinder so that the center of
grindstone (5) is at the center of valve seat (1), then
tighten the set screw to fix the grinder in place.
4) Rotate the grindstone and move it slowly until it
contacts valve seat (1).
5) Press the grindstone lightly against the inside face of
the valve seat and make a groove around the whole
circumference of the inside face of the valve seat.
★ Depth of groove: Approx. 1 mm
6) Push the three claws (6a) of puller head (6) of tool A

inwards by hand, and fit into valve seat (1).
7) Tighten screw (8) to push the three claws into the
groove on the inside face of the valve seat.
★ When the claws are completely in contact with
the groove, stop tightening.
8) Insert bridge (9) on the outside of the puller head, set
plates (10) and (11) on top of the bridge and tighten
nut (12) to pull out the valve seat.
15-7 2
B. When welding a bar to the valve seat to remove
1) Weld bar (2) (length: 0.1 – 0.5 mm shorter that inside
diameter of valve seat, diameter: approx. 10 mm) to
inside of valve seat (1).
★ Be careful not to deposit any of the welding metal
on the head itself.
2) When the temperature of the weld has dropped to
around room temperature, insert a used valve (3) in
the opposite direction, and hit the face of the valve
with a small hammer to remove the valve seat.
★ Be careful not to hit too hard, as any excessive
shock may cause the weld to break off.
2. Press fitting valve seat

A. When not grinding and correcting press-fitting surface of
valve seat
1) Using tools B1 and B2, or tools B1 and B3, press fit
standard valve seat (1) with a press.
★ Do not use a hammer to press fit.
★ Press-fitting force for valve seat;
Intake side: Approx. 1.5 ton
Exhaust side: Approx. 1.5 ton
2) Check the insertion depth a of valve seat from the

bottom surface of cylinder head.
★ Insertion depth a of valve seat;
Intake side: 2.2 mm
Exhaust side: 2.4 mm
3. Over size machining of mounting hole for valve seat insert.

A. Using tools C1 and C2, grind the hole to one level larger
over size.
★ Machine within an over size range of 1.0 mm
(0.0394 in). If it is more than 1.0 mm (0.0394 in),
replace the cylinder head.
15-8 2
• Method of machining valve seat and mounting hole Unit: mm
Valve seat Valve seat Valve seat mounting hole
Valve
size d1 c1 d2 d3 c2
+0.100 0 +0.019 0
Intake 55.0 +0.090 8.8 –0.1 55.0 0 58.00 ± 0.2 11 –0.1
S.T.D.
+0.080 0 +0.019 0
Exhaust 52.0 +0.070 8.6 –0.1 52.0 0 55.00 ± 0.2 11 –0.1
+0.100 0 +0.019 0
Intake 55.25 +0.090
8.8 –0.1
55.25 0
58.25 ± 0.2 11 –0.1
0.25 O.S.
+0.080 0 +0.019 0
Exhaust 52.25 +0.070 8.6 –0.1 52.25 0 55.25 ± 0.2 11 –0.1
+0.100 0 +0.019 0
Intake 55.5 +0.090 8.92 –0.1 55.5 0 58.50 ± 0.2 11.12 –0.1
0.50 O.S.
+0.080 0 +0.019 0
Exhaust 52.5 +0.070
8.72 –0.1
52.5 0
55.50 ± 0.2 11.12 –0.1
+0.100 0 +0.019 0
Intake 55.75 +0.090 9.05 –0.1 55.75 0 58.75 ± 0.2 11.25 –0.1
0.75 O.S.
+0.080 0 +0.019 0
Exhaust 52.75 +0.070 8.85 –0.1 52.75 0 55.75 ± 0.2 11.25 –0.1
+0.100 0 +0.019 0
Intake 56.0 +0.090 9.18 –0.1 56.0 0 59.00 ± 0.2 11.38 –0.1
1.00 O.S.
+0.080 0 +0.019 0
Exhaust 53.0 +0.070 8.98 –0.1 53.0 0 56.00 ± 0.2 11.38 –0.1
★ Roughness of inside surface: Within 6.3S

★ Roughness at bottom of mounting hole: Within 12.5 S
★ Concentricity with valve guide inside surface: Within 0.03 mm (0.0012 in) (TIR)
15-9 2
4. Finishing valve seat contact surface
A. Using tools C1, C3, and C4, finish surface of the valve
contact surface of valve seat to dimensions shown in
diagram on the right.
★ When selecting tool C5 to insert into the valve guide,
choose one that gives no clearance.
B. Rub the valve seat contact surface with compound.
C. Concentricity of valve guide and valve seat:

Within 0.05 mm (TIR)
D. Width of finished surface of valve seat at exhaust side,

and width of contact with valve.
Exhaust Intake
6210-11-1320 (S.T.D.) 6210-11-1321 (S.T.D.)

6210-19-1320 (0.25 O.S.) 6210-19-1321 (0.25 O.S.)
6210-18-1320 (0.50 O.S.) 6210-18-1321 (0.50 O.S.)
Part No.
6210-17-1320 (0.75 O.S.) 6210-17-1321 (0.75 O.S.)
6210-16-1320 (1.00 O.S.) 6210-16-1321 (1.00 O.S.)
Width of finished surface e: 47.1 f: 1.5 e: 45.7 f: 2.5
Width of contact with valve (when

g: 1.5 ± 0.2 g: 2.5 ± 0.2
using master valve)
5. Final inspection
A. Coat valve seat contact surface of the new valve thinly
with red lead (minimum), insert it in the valve guide, push
lightly against valve seat surface, and rotate 10°. Check
valve seat contact surface, and confirm that the contact is
uniform without any breaks.
or
15-10 2
B. Make marks with a pencil on valve seat contact surface
of the new valve as shown in diagram on the right, insert
it in the valve guide, push lightly against valve seat
surface, and rotate 10°. Check that pencil marks have
been erased uniformly around the whole circumference.
PRESSURE TEST OF CYLINDER HEAD

• When corrections have been made around the cylinder head,
test pressure as follows.
1. Water pressure test

A. Assemble tool E and tool F, and connect the hose to
flange (1).
B. Apply water pressure at 3.5 – 4.0 kg/cm2 (50 – 57 psi) for
approx. 10 minutes. Check that there is no leakage from
around cylinder head.
★ When carrying out this test, heat the whole cylinder
head and carry out test with hot water 82 – 93°C (180
- 200oF).
2. Air pressure test

A. Connect the air compressor hose to flange (1).
B. Put cylinder head in a container of water, apply air pressure 3.0 – 3.5 kg/cm2 (43 – 50 psi) for approx. 30
seconds. Check that there is no air leakage into the water.
★ If the above test shows any cracks around the plate plugs of the cylinder head, replace cylinder head.
15-11 2
REPLACING VALVE GUIDE

1. Removal of valve guide
• Using tool G1, remove the valve guide.
2. Press fitting valve guide

A. Press fit the valve guide until tip of tool G2 contacts the
cylinder head.
B. Measure protrusion of the valve guide and check that it is
within standard range.
★ Protrusion of valve guide
Tolerance: 23 ± 0.2 mm (0.9 ± 0.007 in)
REPLACING CROSSHEAD GUIDE

1. Removal of cross head guide
• Using tool H1, remove the cross head guide.
A. As shown in the diagram grip cross head guide with collet

(5) of puller.
B. Tighten collet with bolt (1), and lock sleeve (2).
C. Turn nut (3), and pull out cross head guide.
D. Remove any burrs or flashes from the cross head guide
mount.
2. Press fitting cross head guide

A. Using tool H2, insert the cross head guide into cylinder head, and use a copper bar or plastic hammer to
press fit until protrusion is within the permitted tolerance.
★ Protrusion of cross head guide
Tolerance: 49 ± 0.25 mm (1.9 ± 0.01 in)
15-12 2
GRINDING VALVE
WARNING! Wear protective eye wear when

grinding to prevent injury to eyes
from grinding material.
1. Grinding valve seat contact surface

• Using tool I (valve refacer), grind the valve seat contact
surface.
★ Valve seat contact surface angle (α)
Intake valve: 60° ± 0°15’ (DO NOT GRIND)
Exhaust valve: 45° ± 0°15’
2. Checking after grinding

• Check thickness of the valve head, amount of sinking of
the valve, and contact of the valve seat contact surface,
and confirm that it is within the standard value.
★ Repair limit for thickness a of valve head
Intake valve: Min. 1.9 mm (standard dimension:
2.15 mm)
Exhaust valve: Min. 1.6 mm (standard dimension:
2.15 mm)
★ Sinking of valve
Standard: 0 ± 0.1 mm
Repair limit: 0.7 mm
★ Use dial gauge (1) to measure face run out (TIR) of

valve seat contact surface.
Intake valve: 0.045 mm
Exhaust valve: 0.030 mm
★ Use one of the following methods to check contact of
the valve seat contact surface.
• Coat the valve seat contact surface of ground valve thinly

with red lead (minimum), insert it into valve guide, push
lightly against the valve seat, and rotate 10°. Check the
valve seat contact surface, and confirm that contact is
uniform without any breaks.
• Make marks with a pencil on valve seat contact surface

of the ground valve as shown in diagram, insert it into the
valve guide, push lightly against valve seat, and rotate
10°. Check that pencil marks have been erased uniformly
around the entire circumference.
15-13 2
REPAIR AND REPLACEMENT OF PARTS CYLINDER BLOCK
CYLINDER BLOCK
1. Cylinder liner
2. Clevis seal
3. Cylinder liner O-ring
4. Cylinder block
5. Main bearing cap bolt
6. Main bearing cap
(No. 1, 2, 3, 5, 6 are common)
7. Camshaft bushing
15-14 2
Unit: mm
Check for cracks (external collar check)

A Cracks Replace
Cylinder head bolt hole portion, etc.
Correction of contact at
B Replace
packing portion
Replace
cylinder
Clearance from cylinder
C liner or
liner
cylinder
block
Inside diameter of Replace

D
camshaft bushing bushing
Replace
cylinder
liner or
E Protrusion of liner
correct
cylinder
block
Depth of counterbore Repair by

F and corrosion of bottom machining,
surface add shim
Distortion, wear of
Repair by
G cylinder head mounting
machining
surface
15-15 2
Inside diameter of main

bearing mounting hole
• Tighten main bearing
cap bolt to specified
H torque
• Measure main bearing
cap mating surface
within up-and-down
range of 10°
Replace
Fitting of main bearing cap

I
and cylinder block
Replace
cylinder
liner
Inside diameter of counter-
J bore, outside diameter of
cylinder liner flange
Correct
cylinder
block
sleeve
15-16 2
METHOD OF CHECKING INSIDE DIAMETER OF MAIN BEARING MOUNTING

HOLE USING ALIGNMENT BAR
• When checking inside diameter of the main bearing mounting hole using an alignment bar, do as follows.
Unit: mm
Tool J (alignment bar) Standard dimension
–0.014
Diameter 157–0.039
Roundness 0.005
Straightness 0.010
Length Min. 1300
1. Set cylinder block on a stand with main bearing cap mount at the top.
2. Coat inside surface of main bearing hole of the cylinder block with engine oil.
3. Remove main bearing cap.
4. Set tool J (alignment bar) in main bearing hole of the cylinder block.
5. Install the main bearing cap, then tighten mounting bolts to specified torque.
6. Check that tool J moves smoothly.
15-17 2
CORRECTING CYLINDER BLOCK TOP SURFACE, COUNTERBORE

Flow for correction procedure
★ When removing, installing, disassembling, or assembling the engine, see "DISASSEMBLY AND ASSEMBLY"
section for details.
★ If judgement for Item 9 is NO, go to (A). If the answer is NO again, go on to (B).
15-18 2
15-19 2
WARNING! Wear protective eye wear when grinding to prevent injury to eyes from grinding
material.
Grinding
• If there is strain or corrosion of top surface of the cylinder block, grind the top surface.
• If there are blackened portions on the cylinder liner contact surface of the counterbore (particularly in front-to-
rear direction), or there is speckled wear, and these portions extend over more than half of the contact surface,
or if grinding has been carried out on the top surface, correct the counterpower.
1. Grinding top surface of cylinder block

A. Measure wear and strain of top surface of the cylinder
block, and if it is over the repair limit, grind top surface of
the cylinder block within the repair limit for height "d" of
the cylinder block.
★ Guideline for grinding to surface of cylinder block
• When wear and corrosion on top surface of
cylinder block are the same shape as mark left
by the head gasket
• When wear amount "a" is more than 0.15 mm
Table 1 Unit: mm
Standard Repair
dimension limit
Flatness of cylinder block (for one

0.05 0.10
cylinder)
Height of cylinder block "d" 471.5 ± 0.04 471.0
Roughness of top surface of

Within 12.5 S
cylinder block
When grinding with grindstone (reference)

• Grindstone speed: 1650 – 1950 m/min
• Table speed: 15 – 30 m/min
• Amount of grinding for one pass: 0.025 mm
• Cross feed for one pass: 1 – 2 mm
• Grindstone: A461V
• Grinding fluid: Water soluble grinding fluid
2. Grinding counterbore
• After grinding top surface of the cylinder block, measure
depth of the counterbore. If necessary, correct the
counterbore depth "f" within the repair limit.
★ Guideline for correcting counterbore
• If it is not within standard dimension.

• If there are blackened portions on cylinder liner contact
surface of counterbore (particularly in front-to-rear
direction), or there is speckled wear, and these portions
extend over more than half of the contact surface.
15-20 2
• After correcting, if the counterbore depth is within 14.05 –
15.525 mm, combine with shims and adjust so that liner
protrusion is 0.07 – 0.15 mm.
Table 2 Unit: mm
Standard Repair
dimension limit
counterbore depth f 11 +0.05 12.52 S
Cylinder liner protrusion e --- 0.080 - 0.185
Roughness of counterbore Within 12.5 S
In accordance with diagram on right

Machined shape
(detail diagram for portion b)
• For the machining amount for counterbore depth "f", decide

an amount that will bring protrusion "e" of cylinder liner within
the standard value.
• When grinding within repair limit in cases where counterbore
depth "f" exceeds standard dimension, set machining
amount so that one shim can be used for each cylinder as
shown in the table below.
Table 3
Adjustment shims for counterbore depth Unit: mm
Part No. T t Weight (kg) Remarks
6210-29-2260 1.50 0.025 0.023
6210-29-2250 0.08 0.025 0.012
6210-29-2240 0.50 0.025 0.008
6210-29-2230 0.26 0.025 0.004
6210-29-2220 0.20 0.020 0.003

6210-29-2210 0.16 0.016 0.002
15-21 2
Use tool K when grinding the counterbore.
3. Checking and distinguishing after grinding and

correcting
• After grinding and correcting, check for scratches on the
flat surface around the water and oil holes in the cylinder
block top surface.
• Remove all burrs and flashes completely.
• After grinding the top surface, if cylinder block height "d"
exceeds the standard dimension, but it within repair limit
(471.0 – 471.4 mm), always use an over size head
gasket.
Table 4 Unit: mm
Head gasket Part No. Plate thickness
S.T.D. 6210-11-1812 2.0
Over size 6210-19-1813 2.4
★ To distinguish, the letters [OS] are stamped on the

plate.
• After correcting, stamp top surface of cylinder block (rear

of left bank) according to the nature of correction as
shown in table below.
Table 5
Over size head gasket Shim Stamp
– – Not needed
Parts used for
correction
X – OS
– X SH
X X WS
(Size of letters: 5 - 10 mm)
15-22 2
4. Procedure for coating cylinder block top surface deck
with gasket sealant
• When pulling out the cylinder liner and press fitting it
again, coat cylinder block top surface deck (cylinder liner
flange contact surface of the cylinder block) with gasket
sealant (LG-6) as follows.
★ Use the same procedure when using a shim for the

deck.
A. Use a cloth to wipe off all dirt and oil from cylinder block
top surface deck and cylinder liner flange contact
surface.
B. Coat position marked in the diagram with LG-6.
• Diameter of line of gasket sealant: 2 – 3 mm
• Overlap of beginning and end of sealant: 6 ± 6 mm
★ When using shims for deck
• After coating bottom of the shim thinly with
LG-6, install it to left portion of the cylinder
block.
• Next, coat with LG-6 in same way as when
not using shims.
C. Press fit liner into the cylinder block.

When doing this, coat the cylinder block contact surface
of seal and O-ring with a small amount of engine oil
(SAE30) immediately before press fitting the liner.
★ Do not coat with engine oil until immediately before
press fitting the cylinder liner.
D. After setting the cylinder liner into the cylinder block,

assemble a used head gasket and temporarily tighten the
cylinder head. When doing this, tighten in the tightening
order shown in diagram on the right.
137 - 157 Nm (101 – 115 lbf ft)
15-23 2
E. Loosen cylinder head mounting bolts, remove cylinder
head, then wipe off excess gasket sealant that has come
out from the counterbore.
★ The gasket sealant that comes out may cause
deformation of head gasket grommet, so always
carry out Steps 4) and 5) without fail.
★ After carrying out Steps 4) and 5), use a new head
gasket to install the cylinder head.
5. Standard for rebuilding cylinder liner O-ring portion of

cylinder block
• If the bushing of cylinder liner O-ring of the cylinder block
has been corrected, make the finishing dimensions as
follows.
★ Concentricity of (6) in relation to standard (A):
Max. 0.05 mm
Table 6 Unit: mm
No. Finishing dimensions
ø 167 see "REPLACING MAIN BEARING CAP"

(1)
on page 15-25.
(2) ø 161.45 ± 0.25
(3) ø 160.67 ± 0.064
(4) 176 ± 0.25
(5) 184.94 ± 0.18
+0.040
(6) ø 158
0
(7) ø 159.03 (Gauge diameter)
15-24 2
REPLACING MAIN BEARING CAP

• When replacing the main bearing cap, machine semi-finished product to the following dimensions, then install.
Correction parts
Part Number Part Name
6215-29-1210 Main bearing caps other than No. 4, 7

6215-29-1230 Main bearing cap No. 4
6215-29-1250 Main bearing cap No. 7
1. Machining inside diameter of main bearing cap

A. Remove the cylinder liner.
B. Install replacement main bearing cap to the cylinder block, and tighten to specified torque.
Main bearing cap mounting bolt:Coat seat face of threaded potion with engine oil.
Main bearing cap mounting bolt:
Order Target Range

1st step 2.9 kgf m (21 lbf ft) 2.8 - 3.1 kgf m (20 - 23 lbf ft)
2nd step 5.9 kgf m (43 lbf ft) 5.8 - 6.0 kgf m (42 - 44 lbf ft)
3rd step Tighten 90° further 90°+30°

0
★ Align cylinder block and main bearing cap notch.
C. Set a cylinder block mounting jig on table of a horizontal

boring machine, fit cylinder liner mounting hole of the
cylinder block to standard line on the jig, and install the
cylinder block.
D. Of the main bearing caps to be used again, take one with

longest pitch and put a dial gauge in contact with inside
diameter at two places to align center of the boring
machine arbor.
15-25 2

E. Check machined inside diameter of bearing cap (1) and

grind a little at a time.
★ Grind until the bit touches inside surface of cylinder
block (2).
★ Inside diameter of cap main bearing cap
1) Machining dimension
Tolerance: 157 +0.025
0 mm
2) Inside diameter of cap when main bearing cap is
tightened to specified torque after machining
Tolerance: 157 +0.025
-0.010 mm
(Up-down range of 10° at mating surface of main bearing cap)
★ Finishing roughness: Within 10 S
★ Do not grind inside face of cylinder block.
2. Machining width of main bearing cap

(Only when machining No. 7 main bearing cap)
A. Insert cast iron bushing (1), then pass arbor (2) through.
B. Install facing bit (3) to arbor.
C. Grind cap (4) until bit touches cylinder block face.
D. Grind opposite side in the same way.
★ Roughness of thrust bearing mounting surface:
Within 12.5 S
★ Do not grind cylinder block
★ Width of main bearing cap
0
Tolerance: 52 -0.030 mm
15-26 2
REPLACING CAM BUSHING

★ When replacing the cam bushing, first remove blind plug at
rear of cylinder block.
1. Removal of No. 1, 7 bushings

A. As shown in diagram, assemble push tool L2, collar L3,
and push bar L1 of push tool L, then hit the push bar to
knock bushing (2) out from cylinder block (1).
2. Removal of No. 2, 6 bushings

A. Assemble push bar L1, push tool L2, collar L3, and guide
L4 of push tool L, then hit the push bar to knock bushing
(3) out from cylinder block (1).
3. Removal of No. 3, 4, 5 bushings

A. Assemble push bar L1, push tool L2, collar L3, and guide
L4 of push tool L, then hit the push bar to knock bushing
(4) out from cylinder block(1).
B. After removing bushing, remove any burrs or dirt, and

clean mounting hole of the bushing.
15-27 2
4. Press fitting No. 3, 4, 5 bushings
A. Assemble bushing (4) to tool L, and press fit the bushing
until oil hole of cylinder block (1) matches oil hole of the
bushing.
5. Press fitting No. 2, 6 bushings

bushing.
6. Press fitting No. 1, 7 bushings

bushing.
7. Measuring after press fitting bushing

A. Using inside gauge (1), measure inside diameter of
bushing.
B. Check clearance between bushing and shaft, and if the
clearance is not within specified range, or shaft does not
move smoothly, correct inside diameter of bushing with a
reamer.
• When inside diameter of bushing has been corrected
with a reamer, clean all metal particles from the oil
hole and oil groove.
★ Inside diameter of cam bushing:
ø 65 +0.06
0 mm
★ Clearance of camshaft journal:
0.016 – 0.096 mm
15-28 2
REPAIR AND REPLACEMENT OF PARTS CRANKSHAFT
CRANKSHAFT
1. Crankshaft.
2. Main bearing (upper)
(common except for No. 4).
3. Main bearing (lower)
(common except for No. 4).
4. Thrust bearing
(Top x 1, bottom x 2, all common).
Unit: mm
A. Cracks Use a magnetic flaw detector to check for cracks Replace

If damage is slight,
Scratches, correct with an oil-
Check for damage to journal portion: Seizure, stone or correct by
B. Damage Discoloration lapping. Replace if
there is seizure.
Damage to threaded hole at front and rear end of crankshaft

Correct
C. Clogging of oil hole Check for clogging of oil hole
Standard value Repair limit Replace thrust

bearing or
D. End play of crankshaft
0.140 – 0.320 0.50 correct with
over size
15-29 2
Unit: mm
Size Standard size Tolerance Repair limit
STD 4.000 3.79

Replace thrust
Thickness of thrust 0.25 OS 4.125 3.92 bearing or correct
E. –0.07
bearing 0.50 OS 4.250 4.04 crankshaft with
–0.12 over size
0.75 OS 4.375 4.17
1.00 OS 4.500 4.29
STD 100.00 99.88
Outside diameter of 0.25 US 99.75 99.63

F. 0
crankshaft pin journal 0.50 US 99.50 99.38 Correct with
–0.020 under size or
0.75 US 99.25 99.13 replace
1.00 US 99.00 98.88
Roundness of Standard Repair limit

G.
crankshaft pin journal 0 – 0.010 0.010
Correct with under
Clearance of crankshaft size or replace
H. 0.046 – 0.116 0.260
pin journal connecting rod
bearing
STD 148.00 147.98
Outside diameter of 0.25 US 147.75 147.73

I. 0
main journal 0.50 US 147.50 147.48 Correct with
–0.020 under size or
0.75 US 147.25 147.23 replace
1.00 US 147.00 146.98
Roundness of main Standard Repair limit

J.
journal 0 – 0.010 0.010
No. 4 only 0.130 – 0.195 0.250 Correct with

Clearance of main under size or
K. Other than
journal 0.100 – 0.165 0.220 replace main
No. 4 bearing
Standard Repair limit
Total coaxially of
Curvature of crankshaft Within 0.09 0.09
main journal
L. (total run out of Replace
indicator) Coaxially of
neighboring jour- Within 0.05 0.05
nals
15-30 2
CORRECTING SURFACE ROUGHNESS OF

CRANKSHAFT JOURNAL PORTION
If roughness of crankshaft journal portion does not fulfill standard,
and there are scratches or dents on outside diameter which it is
possible to correct, then correct the surface roughness
A. Cleaning and blowing with air

Before polishing, brush oil holes and blow with air.
B. Correcting surface roughness of journal portion.
1. When correcting with special polishing machine

Use a special polishing machine as shown in diagram on the
right.
A. Set rotating speed for polishing machine at 40 – 50 rpm.

When correcting, use sandpaper (belt type), and move
sandpaper once up and down entire journal width for
each journal.
★ Use #320 sandpaper (belt type).
★ Move sandpaper smoothly and do not stop at any
point.
★ Do not use honing oil.
B. Next, replace with #500 sandpaper, coat journal surface with honing oil, and move handle of machine to
the left and right by amount of play to give fine movement. Use this movement to move once up and down
entire width of the journal.
★ Move sandpaper smoothly and do not stop at any point
C. Using tool M (standard gauge), check surface roughness.

★ When measuring surface roughness, compare
surface roughness of journal portion with tool M
(standard piece). Standard value for surface
roughness (pin journal, main journal):
Journal portion: Max. 0.8 S

R portion: Max. 3.2 S
D. Check surface roughness, and if it is not within standard,

polish again once up and down the width of journal with
#500 sandpaper.
★ Check that there are no scratches or dents in journal portion or fillet portion.
If there are any scratches or dents, polish again and follow procedure from Step 1).
15-31 2
2. When a special polishing machine is not available, use a
polishing jig such as shown in diagram to right.
A. Use a crankshaft grinding machine and rotate crankshaft
to polish.
★ Sandpaper: #800
★ Machining oil: Honing oil (or diesel oil)
★ Work speed: 40 rpm
B. Move polishing jig the amount of play of journal width

(approx. 5 mm), and move up and down journal in axial
direction to carry out polishing.
★ Polishing time for one journal is approx. 6 minutes.
After completing honing of one journal, replace
sandpaper with new.
★ When honing the pin journal, carry out work with pin
journal at rotation center.
3. Assembly of polishing jig and method of use

A. Assemble polishing jig for pin journal and main journal as
shown in diagram to the right.
B. Cut out a piece of #800 sandpaper with shape shown in

diagram to the right.
C. Take 2 pieces of sandpaper, align with slit of jig plate (1),

then insert and fix in position with tape.
D. Fit journal in jig plate (1), and fix ends of jig lever (2) with
a rubber band.
15-32 2
Polishing jig
Make a polishing jig according to diagram below.
Polishing jig (for pin journal)

Plate (1) [2 are used for each jig]
Lever (2) [2 are used for each jig]
15-33 2
Polishing jig (for main journal)
Plate (1) [2 are used for each jig]
Lever (2) [2 are used for each jig]
15-34 2
GRINDING CRANKSHAFT

• When grinding crankshaft to correct wear, light seizure or

damage, grind to any of the following under size dimensions.
Under size: 0.25, 0.50, 0.75, 1.00 mm
• If there is curvature or uneven wear of the crankshaft, it is

preferable to replace crankshaft and not repair it. (A high
level of skill is required.)
• Be particularly careful when finishing the fillet portion R, shoulder r, and R around the hole.
Finishing dimension for fillet: Unit: mm

Finishing Surface
dimension roughness
R1 4+0.4
0 3.2 S
Pin journal
r1 5 ± 0.5 12.5 S
0
R2 3.5–0.5 3.2 S
Main journal
r2 6 ± 0.5 12.5 S
Finishing dimensions for oil holes in main journal and pin journal
are as shown in diagram to the right.
Main journal portion
15-35 2
Pin journal portion
• Surface roughness for outside diameter of the pin journal and main journal shall be 0.8 S or less.
★ Necessary equipment and jigs for grinding

1. Magnet flaw detector
2. Shore hardness gauge
3. Etching kit
4. Crankshaft mill
5. Crankshaft polisher
6. Roughness gauge
7. Fillet R measurement ball gauge
1. Inspecting before grinding
A. Visual inspection Check for cracks, damage, discoloration caused by seizure, and wear, and judge if it is
possible to correct by grinding.
B. Inspecting hardness of journal surface

Standard value: 63 – 69 Hs
If it is below repair limit, discard the part.
15-36 2
2. Inspection during grinding and after grinding
A. Inspecting fillet R.
• Check that fillet R is connected smoothly to shoulder
of the journal.
• Use a fillet R measurement ball gauge to check that
R dimension is between the dimension for minimum
value gauge and the dimension for maximum value
gauge
Unit: mm
Fillet R Min. radius Max. radius
Main journal 4.0 4.4
Pin journal 3.0 3.5
B. Checking for traces of seizure using etching

• After grinding, carry out an etching test to confirm that there is no grinding seizure.
• If any traces of seizure are found, grind approx. 0.02 mm and correct again to the next under size
dimension.
• After inspection, neutralize and wash inspection surface, then coat with rust prevention oil.
C. Magnetic flaw detection

• Carry out a magnetic flaw detection of the corrected
crankshaft before use and check that there are no
cracks.
• Be particularly careful to check journal fillet portion
entering watch danger zone of the crankshaft.
• After carrying out magnetic flaw detection, always
carry out demagnetization.
C. Measuring curvature (measuring alignment)

• Measure the curvature of crankshaft after grinding and check that it is within standard value.
• Check curvature (alignment) at the following four places:
1) Total length of alignment

Tolerance: Max. 0.09 mm
2) Neighboring alignment
3) Tip alignment
4) Rear end alignment
15-37 2

3. Grinding main journal

• Grind each main journal to same under size dimension.
• When grinding, leave a tolerance of 0.007 – 0.008 mm
for finishing.
• Mark under size dimension on the ground crankshaft as
shown in the diagram to prevent any mistake in the size
when assembling the bearing.
Main journal under size dimension Unit: mm

Size Standard size Tolerance
S.T.D. 100.000
0.25 US 99.750
0
0.50 US 99.500
–0.020
0.75 US 99.250
1.00 US 99.000
Roundness, cylindricity (TIR), surface roughness of main journal.

Surface roughness: Max. 0.8 µm
4. Grinding thrust surface

• There is no particular need to grind front and rear thrust
surface to same under size dimension.
• Mark under size dimension on ground crankshaft as
shown in diagram to prevent any mistake in the size
when assembling thrust bearing.
• If thrust surface has been ground, check that end play of
crankshaft is within the permitted range.
(For details, see overall assembly in "DISASSEMBLY
AND ASSEMBLY" section.)
15-38 2
Thrust surface over size dimension Unit: mm
Rear thrust surface
STD. 0.25 O.S. 0.50 O.S.
Standard size 59 +0.050 +0.050 +0.050

0 59.25 0 59.5 0
STD.
Repair limit 59.060 59.310 59.560
Front Standard size 59.25 +0.050

59.5 +0.050
59.75 +0.050
0.25 0 0 0
thrust
O.S.
surface Repair limit 59.310 59.560 59.810
Standard size +0.050 +0.050 +0.050

0.50 59.50 0 59.75 0 60 0
O.S.
Repair limit 59.560 59.810 60.050
Squareness of thrust surface (TIR)

Tolerance: 0.02 mm
material.
5. Grinding pin journal

• Grind each pin journal to same under size dimension.
• When grinding, leave a tolerance of 0.007 – 0.008 mm
for finishing.
• Mark under size dimension on ground crankshaft as
shown in diagram to prevent any mistake in size when
assembling bearing.
Pin journal under size dimension Unit: mm

Size Standard size Tolerance
S.T.D. 100.000
0.25 US 99.750
0
0.50 US 99.500
–0.020
0.75 US 99.250
1.00 US 99.000
Roundness, cylindricity (TIR), surface roughness of main journal.

Surface roughness: Max. 0.8 µm
15-39 2
6. Grinding main journal width and pin journal width
• When correcting wear surface of main journal and pin
journal, correct using minimum amount of grinding.
• Crankshaft pin journal width
★ When grinding one side only
Standard: 92 +0.054
0 mm
★ Squareness (TIR) of thrust surface

7. Correcting grindstone
• Carry out dressing for grindstone for each journal
• Adjust grindstone correction device and correct grindstone to a dimension matching arc of the fillet.
• When checking and correcting grindstone edge, grind a wooden test piece and check with a ball gauge.
8. Prevention of grinding seizure

• Use plunge grind method when grinding.
• Use whole width of grindstone
★ Avoid grinding boss surface as far as possible.
• Direct an ample supply of cooling oil
• When crankshaft speed is 40 rpm, make standard grinding speed at circumference of grindstone
2000 m/min.
9. Finishing surface
See section on "Surface Roughness".
• Surface roughness standard (pin journal, main journal)
Journal face: Max. 0.8 S
Thrust surface: Max. 1.6 S
Tip taper portion, pin, journal boss portion, fillet portion: Max. 3.2S
• Allowance for polish finishing: 0.007 – 0.008 mm
10. Action after grinding

• Check again that each dimension is as specified.
• Wash each part thoroughly and coat it with rust prevention oil.
• When storing for a long period, support at three points or fit a lifting tool and stand upright.
11. Balancing (reference)

As far as possible, do not carry out repairs that will affect balance of the crankshaft.
• Service limit for imbalance: 10 g•cm
• Limitations for accurate reading of balance
Crankshaft curvature: 0.05 mm (TIR)
Crankshaft rotation speed: Max. 325 rpm
• To correct balance, make a drill hole in the counterweight or carry our grinding.
Direction of drill hole: Radial direction
Hole diameter: Max. 13 mm
Hole depth: Max. 50 mm
No. of holes: Max. total of 6 for one counterweight
Center of hole: Align with center of counterweight (deviation shall not exceed 0.5 mm)
Distance between holes: Min. 5 mm
15-40 2
12. Procedure for measuring curvature of crankshaft and
outside diameter of journal
A. Support center of both ends of crankshaft with lathes. Put
probe of a dial gauge perpendicularly in contact with the
center journal (No. 4) and set dial to 0 at the peak. Then
rotate one turn and read minimum and maximum values.
• If no lathes are available, support No. 1 and No. 7
journals on a V block.
B. Measure outside diameter of the main journal and

outside diameter of the pin journal with a micrometer
or air micrometer.
• Locations for measuring journal

Pin journal: X and Y directions, 5 places
Main journal: X and Y directions, 3 places
15-41 2
CORRECTING FRONT SEAL CONTACT SURFACE

Correction parts
Komatsu Part No. Part Name
6215-29-4320 Sleeve, front seal assembly
6215-29-4340 Sleeve
6215-29-4330 Front seal
• If there is wear or damage to the front seal contact surface of

crankshaft (1), use correction oil seal (2) and sleeve (3) to
correct.
• Remove crankshaft pulley and damper.
• Remove front seal (2).
★ Be careful not to damage surface of the crankshaft.
1. Press fitting sleeve

A. Use sandpaper to remove any dust or mud from the
sleeve press-fitting portion of crankshaft (1), then clean
the part.
• 60 mm range (hatched portion) from end face of the
crankshaft.
B. Coat the whole inside of the sleeve thinly with sealant

(LG-7).
C. Using a plastic hammer or wooden hammer, tap edge of

sleeve (3) around the circumference to install sleeve (3)
uniformly to end face of crankshaft (1).
• Do not use a metal hammer. If a metal hammer is

used, burrs or flashes will be made at end face of the
sleeve, and this will damage the lip surface of oil
seal.
• The sleeve is symmetrical, so it can be installed in
either direction.
D. Using sleeve press-fitting tool N1, press fit until inside of

the press-fitting tool is in contact with end face of the
crankshaft.
• Tighten mounting bolts in turn to press fit. (Do not hit

with a hammer to press fit.)
• Press fit sleeve to a position 5 mm from front face of
the crankshaft.
E. After press fitting the sleeve, wipe off all sealant that is
squeezed out.
• If sealant sticks to lip of the oil seal, it will cause leakage
of oil.
15-42 2
• If a sleeve is already being used
F. Using a puller, remove sleeve (3).
• If no puller is available, make a cut in the sleeve with a cutter, hit with a chisel to release force holding
the sleeve, then remove sleeve.
G. After removing the old sleeve, clean surface of crankshaft and polish with emery cloth.
The remaining procedure is same as for Steps A thru E above.
2. Press fitting front seal
A. Use plastic sleeve to install seal over end of crankshaft
B. Using sleeve press-fitting tool N2, press fit until the inside of press-fitting tool is in contact with end face of
the crankshaft.
• Tighten mounting bolts in turn to press fit. (Do not hit with a hammer to press fit.)
• Press fit front seal to a position 13 mm from front face of the crankshaft.
C. Install damper and crankshaft pulley.
15-43 2
CORRECTING REAR SEAL CONTACT SURFACE

Correction parts
Komatsu Part No. Part Name
6215-29-4220 Sleeve, rear seal assembly
6215-29-4240 Sleeve
6215-29-4230 Rear seal
• If there is wear or damage to rear seal contact surface of

crankshaft (1), use correction oil seal (2) and sleeve (3) to
correct.
• Remove flywheel.
• Remove rear seal (2).
★ Be careful not to damage surface of crankshaft.
1. Press fitting sleeve

A. Use sandpaper to remove any dust or mud from sleeve
press-fitting portion of crankshaft (1), then clean the part.
• 60 mm range (hatched portion) from end face of the
crankshaft.
B. Coat entire inside of sleeve thinly with sealant (LG-7).
C. Using a plastic hammer or wooden hammer, tap edge of

sleeve (3) around circumference to install sleeve (3)
uniformly to the end face of crankshaft (1).
• Do not use a metal hammer. If a metal hammer is

used, burrs or flashes will be made at end face of the
sleeve, and this will damage lip surface of the oil
seal.
• The sleeve is symmetrical, so it can be installed in
either direction.
D. Using sleeve press-fitting tool O1, press fit until inside of

the press-fitting tool is in contact with end face of the
crankshaft.
• Tighten mounting bolts in turn to press fit.

(Do not hit with a hammer to press fit.)
• Press fit sleeve to a position 14 mm from front face of
the crankshaft.
E. After press fitting the sleeve, wipe off all sealant that is
squeezed out.
• If sealant sticks to lip of the oil seal, it will cause leakage
of oil.
15-44 2
• If a sleeve is already being used
F. Using a puller, remove sleeve (3).
• If no puller is available, make a cut in the sleeve with a cutter, hit with a chisel to release force holding
the sleeve, then remove sleeve.
G. After removing the old sleeve, clean surface of crankshaft and polish with emery cloth.
The remaining procedure is same as for Steps A thru E above.
2. Press fitting rear seal
A. Use plastic sleeve to install seal over end of crankshaft
B. Using sleeve press-fitting tool O2, press fit until inside of the press-fitting tool is in contact with end face of
the crankshaft.
• Tighten the mounting bolts in turn to press fit. (Do not hit with a hammer to press fit.)
• Press fit front seal to a position 21 mm from front face of the crankshaft.
C. Install flywheel.
15-45 2
REPAIR AND REPLACEMENT OF PARTS CONNECTING ROD
CONNECTING ROD
1. Connecting rod bolt
2. Washer
3. Cap
4. Dowel pin
5. Bearing (lower)
6. Bearing (upper)
7. Rod
8. Bushing
Unit: mm
A Cracks Check for cracks with a color check or magnetic flaw detector
Replace
B Curvature, twisting
Standard Tolerance Standard Clearance Replace bushing,

Clearance between size clearance limit roughness of
Shaft Hole
C connecting rod bushing inside surface
and piston pin 0 +0.049 0.030 – of bushing:
52 0.11 Max. 3.2 S
–0.006 +0.030 0.055
• Inside diameter of hole at Standard

Tolerance
big end size
• Without bearing
• Roughness of inside surface of +0.026
106
hole at big end: +0.006
Max. 3.2 S
Standard Clearance
Inside diameter of hole • Clearance from crankshaft pin
clearance limit
D at big end of journal (with bearing) Replace
connecting rod • Localized wear of big end 0.046 –
internal circumference: 0.26
0.116
Max. 0.004 (whole width)
Even if each part is within
repair limit, if it is above
the clearance limit, replace
the part (bearing etc.)
STD. 3.000 2.91
0.125 US 3.125 3.04

E Thickness of bearing –0.025 Replace
0.250 US 3.250 –0.035 3.16
0.375 US 3.375 3.29
0.500 US 3.500 3.40
15-46 2
Replace bearing
Scratches on inside
(replace
F surface of bearing, Check for scratches or seizure
connecting rod
seizure
also)
Distance between holes Standard size Tolerance

G at big end and small 0 Replace
end 305
– 0.05
Scratches at I shape Check for scratches in horizontal

portion of connecting direction in area A Replace
rod
H Replace if there
Check for grinder grain in horizontal
direction in area A are any dents,
Dents
regardless of
size.
Check for fretting of mating surface Replace if

Fretting of mating
I Roughness of mating surface: Max. 6.3 S fingernail catches
surface of cap
Back contact of mating surface: Min. 70% in fretting
Correct with
Scuffing of cap bolt seat surface
oilstone
J Scuffing of bolt surface
Scuffing of bolt seat surface Replace bolt
Scuffing of washer surface Replace washer
Deformation of dowel Check for deformation of dowel pin

K Replace
pin Check for deformation of dowel pin hole
Check for cracks, damage to bolt thread

L Damage to bolt Replace bolt
Check for curvature of bolt
★ It is impossible to measure all items in this judgement standard (in particular, the localized wear of big internal
circumference) after machining and rebuilding the connecting rod, do not carry out any rebuilding. The reason
for this is that it is impossible to confirm the precision after machining and rebuilding the hole at connecting rod
big end.
★ When deciding on whether to reuse or discard the connecting rod, if honing grain can be observed on hole
surface at big end, measurement of big end hole surface toughness and wave is unnecessary.
15-47 2
REPLACING CONNECTING ROD SMALL END BUSHING

1. Removal of connecting rod bushing
A. Set connecting rod on tool P3.
B. Using tools P1 and P4, remove connecting rod bushing

with a press.
• After removing bushing, remove any burrs or dirt,
and clean mounting hole of the bushing.
2. Press fitting connecting rod bushing
A. Set the connecting rod on tool P3.
B. Assemble connecting rod bushing to tool P1, then set

tool P2 and secure with tool P4 so that it does not move.
• Align connecting rod bushing oil hole and connecting
rod oil hole.
C. Push tool P1 with a press and press fit connecting rod bearing.
• Bushing is a semi-finished product, and inside diameter is small, so piston pin will not fit.
• After press fitting the bushing, machine inside diameter of bushing with a reamer or honing machine in
accordance with the MAINTENANCE STANDARD.
★ After machining, remove all metal particles from the oil hole and oil groove.
★ Surface roughness of inside diameter after machining bushing: Within 3.2 S
15-48 2
REPLACING CRANKSHAFT GEAR

1. Removal of gear
• Make a scratch in surface at root of teeth with a grinder,

then assemble tools Q1 and Q2 and turn nut (1) to
remove gear.
★ If gear cannot be removed in this way, make a
scratch in surface at root of teeth with a grinder, then
heat gear with a gas burner and knock gear out with
a copper rod.
★ Be careful not to damage crankshaft.
2. Press fitting gear
A. Check gear mounting surface, key groove, and flange

surface, and if there are any scratches, correct them with
an oilstone.
B. Knock a new key into key groove of the shaft.
C. Heat gear for specified time at the specified shrink-fitting temperature.

• Gear shrink-fitting temperature: 200°C
Heating time: Min. 30 minutes
D. Put timing mark of gear on outside, then use a hitting tool to press fit until the side face of gear is in close
contact with crankshaft flange.
• Knock in quickly before gear becomes cool.
15-49 2
REPLACING CAMSHAFT GEAR
WARNING! Use care when placing camshaft assembly to prevent injury to fingers.
1. Removal of gear
Set camshaft assembly on press stand, then push camshaft to

remove gear.
A. Check gear mounting surface, key groove, and flange

surface, and if there are any scratches, correct them with
an oilstone.
B. Knock a new key into groove of the shaft.
C. Assemble the thrust plate.
D. Heat gear for the specified time at specified shrink-fitting temperature.

• Gear shrink-fitting temperature: 200 – 240°C (392 - 464oF)
E. Put timing mark of gear on the outside, then use a hitting tool to press fit until side face of gear is in close
contact with the camshaft flange.
• Knock in quickly before gear becomes cool.
REPLACING FLYWHEEL RING GEAR
material.
1. Removal of gear
• Make a scratch in surface at root of the gear teeth with a grinder, then split with a chisel to remove.
A. Check gear mounting surface, and if there are any scratches, correct them with an oilstone.
B. Heat gear for specified time at the specified shrink-fitting temperature.

• Gear shrink-fitting temperature: Max. 200°C
C. Set chamfered face of gear facing the flywheel, and press fit until side face of gear is in close contact with
the flywheel.
15-50 2

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Shop CEBM002603

Copyright 2008 Komatsu

11 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . .11-1

12 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . 12-1

13 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 13-1

14 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

15 REPAIR AND REPLACEMENT OF PARTS . . . . . . . . . . . . . . 15-1

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