SERVICE MANUAL MITSUBISHI DIESEL ENGINE 4 5
INDEX GENERAL MAJOR DATA AND SPECIFICATIONS 5 DISASSEMBLY 8 INSPECTION AND REPAIR .......................................... 16 REASSEMBLY 37 LUBRICATING SYSTEM 49 COOLING SYSTEM 52 FUEL SYSTEM 56 ELECTRICAL SYSTEM .............................................. 71 BENCH TEST 87 MAINTENANCE STANDARDS 89 SEALANT APPLICATION DATA 102 TIGHTENING TORQUE 103 .............................................
GENERAL 1. Major component parts 1-1 Left-hand side view 402500 1-Water pump 2-Fan 3-Fan belt 4-Fuel injection pump 5-Fuel feed pump 6-0il pipe 7-Fuel inlet connector 8-Fuel feed pipe 9-Fuel filter 10-Fuel injection nozzle 11-0il filler cap 12-Fuel injection pipe 13.
1-2 Right-hand side view 402501 l-Cylinder head 2-Crankcase 3-1 ndicator switch 4-Flywheel housing 5-Rocker cover 6-0il filter 7-Breather 8-0il filler 9-0il filler cap 10-Exhaust manifold ll-Elbow l2-Screw plug 13-Water pump 14-Fan l5-Fan belt 16-Alternator -2- l7-Alternator bracket 18-Timing gear case 19-0il level gauge 20-0il pipe 21-0il bypass alarm switch 22-0il pan 23-0il pipe
1-3 Longitudinal sectional view 402502 1-Rocker cover 2-Thermostat case 3-Thermostat 4-Exhaust valve 5-lntake valve 6-Water pump 7-Piston 8-Camshaft gear 9-Fan 10-Connecting rod 11-Cran kshaft pu lIey 12-Crankshaft gear 13-Timing gear case 14-Rocker shaft bracket 15-Rocker shaft 16-Valve push rod 17-Cylinder head 18-Cran kcase -3- 19-Tappet 20-Camshaft 21-Crankshaft 22-Flywheel 23-Flywheel housing 24-0il strainer 25-0il pan 26-Drain plug
1-4 Transverse sectional view 402503 1-Exhaust manifold 2-Piston 3-Valve push rod 4-Connecting rod 5-Tappet 6-Camshaft 7-0il level gauge 8-0il pump 9-0il strainer 10-Rocker arm 11-Rocker cover 12-Glow plug 13-Fuel injection nozzle 14-lntake manifold 15-Fuel injection pipe 16-Cylinder head 17 -Cran kcase 18-Fuel injection pump 19-Fuel feed pump 20-Starter 21-Cra n kshaft 22-0il pan -4- -------~------
MAJOR DATA AND SPECIFICATIONS Engine model 40Q5 Water-cooled, 4-stroke, swirl-combustion chamber type diesel Type No. of cylinders-arrangement 4-in line Bore x stroke mm (in.) 84 x 94 (3.307 x 3.701) Piston displacement cc(cuin.) 2084 (127.l) Compression ratio 21 : 1 kg/ cm 2 (p si) Compression pressure 1-3-4-2 Firing order Direction of rotation Counterclockwise as viewed from flywheel side Burns (fuel) Grade No.
Engine model 4DQ5 Type of nozzle tips ~ ~ ~ Fuel injection nozzles '1:l ""-= Spray hole diam Bosch ND-DNOSD21 mm (in.) 0° Spray angle Injection pressure kg/cm 2 (psi) Fuel filter e III >. '" '" = .sa Oil pressure 6) Trochoid Speed ratio to crankshaft ~ 120 +18 (1706 + 14 Paper-element type Type Oil pump 1 (0.04) 1/2 Capacity at oil temp. 50 ± 5°C (122 ± 9°F); liter (cu in.)/ pressure 3 kg/cm 2 min/rpm (42.7 psi) At duty run At idling kg/cm 2 (psi) Oil filter 8.37 (510.
Engine model 4DQ5 Working voltage volt 12 Negative (-) ground Polarity Type Glow plugs Sheathed Rated voltage current volt ampere Resistance at normal temperature ohm 10.5 - 8.3 1.26 M002T54172 Model = cv S .9- i Totally enclosed, drip-proof, pinion-shift type with overrunning clutch Type .... Manufacturer Starter Voltage-output co .l:t ....... Mi tsu b ishi-Electric volt kilowatt No. of pinion teeth/ No.
DISASSEMBLY (1) Drain the oil. (2) Remove the fan belt and alternator as follows: (a) Loosen bolt (1) securing fan belt adjusting plate and alternator, and remove fan belt (2). (b) Remove bolts (1) and (3) and remove alternator. (3) Remove the starter as follows: (a) Loosen attaching nuts (1). (b) Remove starter from rear plate. (4) Remove the fuel filter as follows: (a) Disconnect fuel feed pipes (1) (2). (b) Loosen attaching bolts (3) and remove fuel filter (4).
(5) Remove the injection pipes and injection nozzles as follows: (a) Loosen connectors (1) and disconnect injection pipes (2). (b) Remove fuel return pipe (3) by loosening union nut. (c) Loosen nuts (4) and remove fuel leak-off pipe (5). (d) Remove nozzle assemblies. (6) Remove the lube oil pipe from injection pump. (7) Remove the water pump pulley and crankshaft pulley as follows: (a) Loosen water pump shaft nut (1) and remove water pump pulley (2).
(10) Disconnect the water pump bypass hose and oil pipe. To disconnect bypass hose, displace thermostat elbow and water pump clamp. (I 1) Remove the water pump as follows: (a) Loosen attaching bolts (1). (b) Remove water pump assembly (2). (12) Remove the rocker shaft assembly as follows: (a) Loosen union nut (1). (b) Loosen short bolts (2) and long bolts (3). (c) Remove rocker shaft assembly (4). (d) Remove oil pipe (5) and "0" rings (2 pcs - to be replaced with new ones).
(14) Remove the oil pan and oil pump assembly as follows: (a) Loosen attaching bolts and remove oil pan (1) and gasket. (b) Loosen attaching bolts and remove oil pump (2) assembly. (15) Remove the timing gear train as follows: (a) Loosen idler gear bolt (1). (b) Remove thrust plate (2) and idler gear (3). (Draw idler gear while twisting it in the direction of its helix.) (c) Loosen injection pump drive gear nut (4). (d) Remove injection pump drive gear (5).
(18) Remove the flywheel and rear plate. (19) Remove the connecting rod bearing caps and bearings (lower shells) by loosening attaching bolts. (20) Remove the connecting rods and pistons. (21) Remove the main bearing caps by loosening attaching bolts.
(22) Remove the crankshaft. (23) Remove the main bearing shells. (24) Disassemble piston and connecting rod as follows: (a) Remove compression rings (1) and oil ring (2) by using piston ring tool (A). (b) Remove oil ring spring. (c) Remove snap rings (3) by using snap ring tool (B).
(d) Remove piston pin (4) by using drift (C). (e) Remove piston pin bushing and connecting rod bearing (upper). (25) Disassemble the rocker shaft assembly as follQws: (a) Remove snap rings on both ends (1). (b) Remove rocker assembly (2). (c) Remove rocker bracket (3). (d) Remove rocker assembly (4). (e) Remove spring (5). (26) Disassembly the cylinder head as follows: (a) Remove nozzle holders. (b) Remove glow plugs (l). (c) Loosen bolts (2) securing exhaust and intake manifolds.
(g) Remove valve cotters (6). (Depress valve spring by valve lifter.) (h) Remove retainer (7). (i) Remove valve spring (8). G) Take out valve (9). (k) Remove valve guide by using valve guide remover (A).
INSPECTION AND REPAIR Cylinder head (1) Inspection Check the gasketed surface of the cylinder head for flatness by using a straightedge and thickness gauge as in the case of checking the crankcase surfaces. This check is to be made with the precombustion chamber jets removed. Use a surface grinder to reface the cylinder head, as necessary, to the specified flatness. Specifications Item Warpage of gasketed surface of cylinder head Unit: mm (in.) Standard O.OS,max (0.0020) Repair limit 0.20 (0.
Valve guides and valve seats (1) Check each valve for carboning, burning, wear or other defect on head; also check cap end and stem for cracks. Replace the valve if damaged. (2) Check each valve guide for wear. Remember, the guide wears down more rapidly at its both ends than at any other parts. Measure the inside diameter of the guide at its ends and a t its middle part in two directions. Measure the outside diameter of each valve stem.
Valve refacer (a) Set a valve refacer to an angle of 45 degrees. (b) Grind the valve stock to a minimum and, if the margin is less than 1.2 mm (0.047 in.), replace the valve. Valve seat cutter Repair an excessively worn valve seat by using a valve seat grinder or valve seat cutter. (c) When using a valve seat cutter, exercise care so as to apply a uniform pressure to valve seat to prevent uneven cutting. After cutting, reface the seat by rotating the cutter with No.
'Valve springs Inspect each spring for cracks, and check it for squareness, free length and as-installed length against these specifications: Specifications Unit: mm (in.) Item Standard Repair limit Valve spring free length 48.85 (·1.9232) 47.6 (1.874) Valve spring squareness 1.5°, max Load compress spring to initial working lenfth [43 mm (1.69 in.) kg(lb) 19 ± 1 (41.9 ± 2.21) 15 (33.
Cylinder sleeves (1) Using a cylinder gauge, take ID measurements in two directions (parallel and transverse to crankshaft axis) on each cylinder sleeve, at three places indicated below. If wear reaches the repair limit, reb ore the sleeve to the next specifted oversize. Specifications Item Standard Unit: mm (in.) Repair limit Service limit I Taking ID measurements on cylinder sleeves 84 +0.035 Crlnkcase gaske,ed surfKe 0 +0.20 0.70 Cylinder sleeve ID (3.307 +g.00138) (+0.008) (0.
(4) When the sleeves are worn beyond the service limit, or when any cylinder bore is found to be defective, the sleeve should be replaced with a new one. When the inside surfaces of one of more cylinder bores in the crankcase are found to be defective, it is necessary to refinish the bores by boring. In this case, too, the liners should be replaced with new ones.
Pistons and piston rings (1) Pistons Inspect each piston for any abnormal wear of its sliding surface, for cracks at the crown and for evidence of melting or fusion. Examine the ring grooves for stepped wear and sloped wear. Replace pistons found in bad condition. (2) Measure the outside diameter of piston in two directions perpendicular to each other. If the diameter exceeds the service limit, replace the piston. Specifications Item Diameter (at skirt) Standard Unit: mm (in.
Front of engine (3) Replacing pistons Replace the piston with a new one if the measurement exceeds the service limit. Where any pistons have to be replaced, the variance in weight among the pistons must not exceed the limit. It is recommended that cylinder number be stamped on a piston selected to be used in a particular cylinder for convenience. When the cylinder sleeves are bored to the oversize, pistons and piston rings of the same oversize should be used.
(6) Replacing piston riDp If the rings are replaced, the gap width will exceed the standard value, but this is not a matter of concern, provided that the service limit is not exceeded. (7) Piston pin bosses Check the piston pin bosses by referring to the topic, Piston pins, piston pin bosses and piston pin bushings, which follows.
Connecting rod alignment and bearings (l) Check the connecting rod for evidence of cracks, especially cracks in the fillets of its small and big ends. Replace the rod if any cral:k is noted in the fillets. f t (2) Mount each connecting rod in the connecting rod aligner and check for bend and twist as shown below. In a twisted connecting rod, the bearing is not trued to the small end bushing. Such a rod must be corrected with the use of a press. <0.05 100 a.
(4) To ~he.:k the rod with a piston, pla~e the rod on the surfa~e plate as shown below, insert a round bar of the ~rankpin diameter into and through its big end bore, and take measurement at "A" and "B." The differen.:e between the two measurements tel1s the straighteness of the rod. When one or more, or all connecting rods are to be repla~ed, sele~t new rods so that the variance in weight among the rods is within the value given in the spedfication.
Specifications Item Standard Crankpin diameter 58 -0.035 -0.055 (2283 -0.00138) . -0.00217 Radial clearance between bearing and crankpin Unit: mm (in.) 0.035 ...., 0.100 (0.00138"'" 0.00394) Repair limit 0.20 (0.0079) To measure the inside diameter of the bearing, the bearing fitted to each connecting rod must be secured by tightening the cap bolts to 5.5 kg·m (39.8 lb·ft). Measure the diameter in two positions, 1 and 2, and in two directions D\ and D2, as shown below.
Crankcase (1) Inspect the outside and inside surfaces for evidence of cracking. VisuaUy examine the cylinder bores for scuffing, rusting, erosion or any abnormal wear. Using a straightedge, check the top face (for mating with cylinder head), front face (for mating with front plate) and rear face (for mating with rear plate) for flatness. (2) Make sure that the top face of the crankcase is flat within the standard specified below.
(l) Crankpins (a) Inspect each crankpin for surface flaws such as roughing, scratches, pitting and bums, and, as necessary, repair the crankpins by grinding to the next undersize or replace the crankshaft. (b) Mike each crankpin to take a total of four readings to determine the wear, out-of·round and taper. If any of the limits is exceeded, repair by grinding to the next undersize or replace the crankshaft.
(c) Grinding the crankshaft The crankshaft journals and crankpins must be refinished to a dimension smaller by 0.100 to 0.120 mm (0.00394 to 0.00472 in.) than the undersize of bearings to be used. Example: If 0.50-mm (0.01969-in.) undersize bearings are to be used: The journals must be refinished to 65 - 0.5 - (0.100 - 0.120) [2.55905 - 0.01969 - (0.003940.00472 in.)] The crankpins must be refinished to 58 - 0.5 - (0.100 - 0.120) [2.28346 - 0.01969 - (0.003940.00472 in.
(3) End play Check the crankshaft for end play, as shown, by using a thickness gauge at the thrust bearing. If the limit is reached replace the thrust plate. Specifications '\, Unit: mm (in.) '" Item Standard '---- Journal width for thrust bearing Repair limit 0.100-0.189 0.3 (0.00394 - 0.00744) (0.
(5) Main bearings Inspect each main bearing for evidence of wiping or fatigue failure, for scratches by dirt particles imbedded and for improper seating on the bore (bearing cap). On the basis of fmdings, determine whether the bearing should be replaced or not. Check each main bearing to be used in engine reassembly to see whether it will provide the specified radial clearance. This can be accomplished in this manner.
Specifications Standard Item Unit: mm tin.) Service limit 01: 46.916 ~gJ Intake cam profile Exhaust cam (DI - D1) W' D2 profile 01 - O:z = (1 84108 +0.00394) . -0.01181 6.184 (0.24346) 01 - 01 ,. 6.684 (0.26315) 01: 45.944 ~J 01 - O:z = 80882 +0.00394) 6.844 . -0.01181 (0.26945) 01 - Ol = 1.344 (0.28913) (1 (4) Check the camshaft for runout. Straighten the camshaft in a press or replace it, as necessary. Specifications Item Camshaft runout Unit: mm (in.) Standard Repair limit 0.02 (0.
Specifications Standard Repair limit 0.040 -- 0.090 (0.00157 --0.00354) 0.15 (0.0059) Item Fit of camshaft journals in holes (bushings) Unit: mm (in.) Unit: mm (in.) Specifications Item Service limit Standard 54H7 +0.030 No.l,2 Camshaft bushing inside diameter 0 (2.126H7 +g.00118) Miking camshaft hole ID 53H7 +0.030 0 No.3 (2.087H7 +g.00118) 54 -0.040 Camshaft journal outside diameter No.1,2 -0.060 (2 126 -0.00157) . No.3 -0.00236 53 -0.040 -0.060 ) (2.087 -0.00157 -0.00236 -0.1 (-0.
Flywheel (1) Check the flywheel for scoring or a sign of overheating of the friction surface, cracks, or any other damage. When any of these damages are presented, repair or replace the flywheel. ",:e" I t J Ifi Checking flywheel friction surface for warpage (2) Check the friction surface for warpage and/or face run out. When warpage or face runout exceeds the repair limit, repair or replace the flywheel.
Timing gears (1) Be sure that the backlash in each mesh is within the repair limit. If the limit is exceeded, reduce the backlash by replacing the worn gear. To measure backlash, use a thickness gauge: put the gauge squarely into between two gear teeth. Specifications Unit: mm (in.) Repair limit Standard Item 0.05 ~ 0.20 0.25 (0.0020 ~ 0.0079) (0.0098) Backlash (2) Check the radial clearance between idler bU5hing and shaft by miking.
Specifications Item Camshaft end play Standard Unit: mm (in.) Repair limit 0.05 - 0.112 0.3 (0.00197 - 0.00441) (0.012) (b) Injection pump drive gear Inspect the gear teeth for damage and also the mounting bolt holes for malcondition. Replace the gear if found in badly damaged condition. (c) Crankshaft gear Replace the gear if its teeth show signs of defective tooth contact, or are excessively worn or otherwise defective. (d) Idler gear Inspect the idler gear teeth and, as necessary, replace the gear.
(b) Heat piston with piston heater up to loooe to 1200 e (212° F to 248°F). Install small end of connecting rod into boss and connect piston and piston pin by slowly inserting piston pin into piston. Insert snap ring in one end in advance. Install connecting rod to piston so that the marking side of the connecting rod big end comes to the camshaft side. ...
(d) Install No.3 oil control ring (1) and expander (2) as shown below. CD J 8693 OIL CONTROL RING AND EXPANDER INSTALLED (2) Reassemble the crankcase as follows: (a) Drive three camshaft bushings (1) into camshaft holes in crankcase by using adapter (A). (If the fit exceeds the repair limit, machine the holes and install bushings.) Driving in DRIVING IN CAMSHAFT BUSHING (b) Drive idler shaft (2) into crankcase by using installer (B).
(c) Lightly apply engine oil to the crankpins and install main bearings (upper). Securely engage the bearings with the crankpins. (3) Install the piston assembly as follows: No.1 ring gap Install connecting rod bearing (upper) (1) into the big end of connecting rod_ Apply engine oil in the internal surface of bearing and on the external periphery of piston. Position piston rings so that ring gaps 0 lire located 90 in respect with each other as shown, and then insert piston assembly (2) into crankcase.
(4) Install the crankshaft as follows: (a) Install thrust plate (1) and two woodruff keys (2) to the crankshaft and drive in crankshaft gear (3) by using installer (A). (b) Install crankshaft to the crankcase. (5) Install the main bearing caps as follows: (a) Apply engine oil to the crankshaft journals and pms, and install the crankshaft in the crankcase securely.
(b) Tighten connecting rod clamping nuts to a torque of 5.5 kgm (39.771 lb.ft). (7) Install the retainers and gaskets as follows: (a) Install retainers (1) to the external peripheries of main bearing caps No.1 and No.3 with the flange facing the case inside. (b) Apply ThreeBond 1102 (adhesive) on both sides of oil pan gasket (2) and attach it to crankcase. Make sure that the gasket is completely attached in the grooves (A) in the caps.
(d) Install sleeve onto the rear end of crankshaft. Apply clean engine oil to the internal surface of oil seal (I) and secure it with bolts (2) by using oil seal aligner, (e) Apply Atomjet at the tip of bolts (3) as they fit into four through-bolt holes in the bearing cap. Tighten the bolts to a torque of 0.4 kgm (2.9 lb.ft). (8) Install the front plate as follows: (a) Apply ThreeBond 1102 to the both sides of front plate packing and attach the packing to the front face of crankcase.
(d) Tighten camshaft thrust plate to crankcase by using machining holes in camshaft gear. (9) Install the idler gear as follows: (a) Install idler gear by matching the timing mark on each gear. Timing gear match marks meeting each other 1-Camshaft gear 2-Cran kshaft gear 3-ldler gear 4-lnjection pump gear (b) Inspecting valve timing after installation of timing gears It is not necessary to check the valve timing, provided that all matching marks on the timing gears are aligned.
(10) Install the oil pump assembly as follows: (a) Install oil pump into the oil pump installation hole in the crankcase and mesh the pump drive gear with camshaft pump drive gear. (b) Tighten bolt and secure the oil pump. (11 ) Install the oil pan. (12) Install the rear plate and flywheel as follows: (a) Drive in dowel pin (1), and secure flywheel (2) complete with pilot bearing in place with bolts (4) and lock washers (3). (b) Bend lock washers properly to lock bolts.
Install stem seal (3) to the valve guide. Completely fit the breast of the seal in the guide groove. (b) Install valve (4), valve spring (5) and retainer (6) in this order. Compress the spring with a valve lifter to install valve cotter (7) securely. Install caps (8) when installing rocker shaft assembly. (c) Install thermostat, nozzle holders, glow plugs and exhaust manifold in the cylinder head.
(15) Install the push rods and rocker shafts as follows: (a) Insert the push rods (1) into the tappets. (b) Install rocker shaft assembly as follows: (c) Insert "0" rings (3) into oil pipe (2) and connect the oil pipe to the front and rear rocker shafts. Then temporarily install each bracket to the cylinder head. (d) Temporarily tighten two or three threads on the oil pipe union nut and connector.
(17) Install the rocker case. (18) Install the water pump assembly as follows: (a) Install water pump assembly. (b) Install bypass hose and oil pipe. (19) Install the timing gear case (1) to the front plate properly. Use copper packing for bolts (2) to prevent oil leakage. (20) Install the water pump pulley and crankshaft as follows: (a) Drive in water pump pulley (1) and crankshaft pulley (2) by using installers (A) and (B). (b) After driving in the crankshaft pulley, install washer and tighten nut.
LUBRICATING SYSTEM ® ® ®--~~-- ____~ L-__R-~--® I----------=~---~-==II ~u '-----------~.L=_=-=:;...'- - - G ) '-=---::------- Lubrication oil circuit 1. Lube oil circulation A trochoid rotary pump draws oil in the oil pan and delivers it under pressure to a full·flow oil nIter, from which the cleaned oil is forwarded into the oil gallery inside the crankcase. From the gallery, the oil is distributed to the various parts of the engine. The pump is driven from the camshaft.
2-2 Inspection (1) Running clearance between outer rotor and inner rotor Using a thickness gauge, check the clearance at various positions. If the reading exceeds the service limit; replace both rotors.. Specifications Item Unit: mm (in.) Service limit Standard Clearance between 0.013-0.15 0.25 inner rotor and (0.00051- 0.0059) (0.0098) outer rotor (2) Sliding clearance between rotors and cover This clearance is required to be not greater than 0.15 mm (0.00591 in.).
2-3 Reassembly (1) Install inner rotor to pump shaft with pin. (2) Place pump shaft in pump case. Install pump drive gear to the shaft with pin. (3) Place outer rotor in pump case, and install pump case cover complete with gasket and oil strainer. (NOTES] a) Ifpumpshaft or drive gear has been replaced, a new pin hole must be made by drilling through the gear mounted on the shaft. b) After putting on the cover, check to be sure that the match marb are correctly indexed.
COOLING SYSTEM 2}---+-....!....-~lt l-Thermostat 2-Water temperature! 3-8ypass hose 4-Radiator 5-Water jacket 6-Cylinder head 7-Crankcase 8-Drain plug 4 Direction of coolant flow 1. Coolant circuit Referring to the diagram, above, the coolant is set in forced recirculation by the water pump, which is a centrifugal pump driven by cooling-fan belt. The pump draws coolant from the lower tank section of radiator G) and forwards it to the water inlet of crankcase (1).
2-2 Inspection E E Clean the thennostat, place it in a hot-water tub, and test it for thennostatic action by heating the tub to raise the water temperature. The valve should start opening at 76.5 ± 2°C (169.7 ± 3.6°F) and be fully open at 90 ± 2°C (194 ± 3.6°F) with a valve lift of not less than 9 mm (0.35 in.). A thennostat whose valve fails to operate in this manner in the test must be replaced with a new one. ~ ., 9 > iii > 0 Tl: Temperature [76.5° ± 2°C (169.7°± 3.
(3) Remove snap ring (6) from the water pump shaft. (4) Pull shaft (8) off the pulley side on pump case and remove bearings (7) and (9) from the shaft. 3-2 Inspection (1) Examine the pump operation by slowly rotating it. If the pump is erratic in rotation, replace the bearings with new ones. (2) Visually check the impeller for corrosion or breakage. Replace a defective impeller. Also check the impeller for signs of rubbing. If such rubbing is evident, check for the cause.
3-3 Reassembly (1) Install bearings (2) on pump shaft (1) and install the shaft in pump case (3). (2) Install snap ring (4) in case on pulley side. (3) Install unit seal (5) in impeller (6) and secure the impeller to the shaft. (4) Install cover (7). (5) Rotate the shaft to check to see that the impeller does not interfere with cover.
FUEL SYSTEM 1-Air vent plug 2-Fuel filter 3·Air vent plug 4-Air vent plug 5-Fuel 6-Fuel 7-Fuel a-Fuel injection pump feed pump injection pipe injection nozzle Fuel circuit 1.
2. Priming the fuel system (1) Unlock the priming pump by turning its knob counterclockwise. (2) Loosen the air vent plugs, and operate the pump until overflowing fuel no longer carries air bubbles. (3) Tighten the air vent plugs while pressing the pump knob downward. (4) Lock the pump by turning the knob clockwise while pressing it downward. 3. Adjusting the injection timing The engine with RUV governor (1) Alignment marks (line marks) are provided on the pump body and flange plate.
The engine with RSV governor The injection timing for each model of the engine varies according to its output, speed and specification. Be sure to verify the timing by referring to the specifications of each model. (1) Bringing No.1 piston to top dead center on compression stroke (a) Using turning bar (30691-11800) at the crankshaft pulley, turn the crankshaft in normal direction (clockwise as viewed from the front side of the engine).
(b) One graduation of the scale on the injection pump coupling changes the timing by 6° in terms of crank angle. 4. Fuel filter The fuel filter uses a special paper element having high flltering performance and large capacity. 4-1 Inspection (1) Filter case and cover Check for cracks, distortion or other damage and also for stripped threads. Replace the case and cover if found in defective condition. (2) Connector bolts and plug Check for defective threads, replacing them if damaged.
5. Injection nozzles The injection nozzle provides a means of spraying into the precombustion chamber the fuel oil delivered under pressure from the injection pump. It sprays oil out in a conical pattern consisting of finely atomized droplets of oil. The mating surfaces of the nozzle holder body, distance piece and nozzle are precision.finished to form an oil·tightness. The injection pressure adjustment may be made by means of adjusting washer.
(3) Remove nozzle tip (3), distance piece (4), pressure pin (5), spring (6) and washer (7) from nozzle holder. (4) All the parts disassembled should be washed in clean kerosene and dried with compressed air. Decarbon the nozzles removed with a wooden scraper and clean them thoroughly in gasoline.
5-4 Testing and adjustment (1) Injection pressure The pressure at which the needle valve unseats itself against the force of the pressure spring is referred to as "valve opening pressure" or "beginning-of-injection pressure," but will be called here "injection pressure' for short. The value 01 this pressure is specified; it is checked and adjusted as follows: (a) Install the injection nozzle in the nozzle tester, and operate the manual pumping handle of the tester several strokes to prime the nozzle.
(a) Initial throttled spray When the nozzle is producing only this spray, atomization is generally poor and the pattern is rather straight than conical, there being more or less after-dribble, that is, fuel dribbling after injection. All these are due to the fact that the fuel being injected is being throttled by the pintle prptruding from the valve.
5-5 Reassembly Assemble injection nozzles in the reverse order of disassembly. Be sure to assemble nozzle assembly in kerosene. \\hen using new needle vavles, remove sealing cover (synthetic resin) from the valves and wash them in kerosene to remove rust and corrosion inhibitor sprayed over them by sliding the valves in the nozzles immersed in kerosene.
6-1 Disassembly (1) Remove valve holder (1) and priming pump (2) and take out check valve (3). Priming pump cannot be disassembled as the cylinder and valve holder are adhered with adhesives. (2) Loosen piston chamber plug (4) and pull out piston spring (5) and piston (6). (3) Remove ring (7) and take out tappet (8) and push rod.
6-2 Inspection (1) Check valve Inspect the seating faces of the check valve for wear, and replace parts found in abnormally or excessively worn condition. (2) Tappet wear Mike the tappet and tappet hole to determine their diametral wear. Replacement is necessary if the amount of wear noted in comparison with the standard diameter is 0.1 mm (0.004 in.) otmore. Specifications Unit: mm (in.) Item Standard Service limit Tappet OD 20 (0.78) 0.1 (0.004) Tappet hole ID 20 (0.78) 0.1 (0.
6-3 Testing The feed pump IS m satisfactory condition when it meets all of the test requirements hereunder enumerated: (1) Suction perfODnllJlee The pump should be capable of starting to deliver fuel in 45 seconds of its starting at 150 rpm. (2) Delivery preauae Run the feed pump at 600 injection-pump rpm, with the discharge side of the feed pump fully closed. Under this condition, the delivery pressure should be anywhere between 1.S kg/cm 2 (25.6 psi) and 2.2 kg/cm2 (31.3 psi).
7. Fuel injection pump , -Bearing cover 2-Tapered roller bearing 3-Governor housing 4-Tapered roller bearing 5-Screw plug 6-Pump housing 7-Delivery valve spring 8-Delivery valve 9-Alr vent screw , O-Delivery valve seat gasket -Tappet '2-Cover l' The pump body is an aluminum alloy casting IDCl houses all the moving parts of pump elements and the camshaft. The governor housing is attached to one end of the pump body. The camshaft is supported by two tapered roDer bearings.
The delivery valve, through which a shot of fuel is forced out into the injection pipe by each upward motion of the plunger, is essentially a check valve having a special function of qUickly reducing the line pressure the moment the plunger begins to descend. This quick relief of line pressure is necessary to prevent the injection nozzle from dribbling at the end of each injection. How this is accomplished will become clear. Tabulated data Cam lift 8 mm (0.315 in.) Plunger diameter 6.5 mm (0.256 in.
The governor is an all-speed governor operating in response to changes in engine speed to actuate the control rack in order to maintain engine speed at a constant level proportional to the set position of the accelerator. This governor function is in sharp contrast to that of a minimum-speed maximumspeed governor, whose control action is to limit the lowest and highest speeds of the engine, leaving the control of intermediate speeds to the operator.
ELECTRICAL SYSTEM 1. General Model Starter Manufacturer MOO2T54172 Mitsubishi Electric Alternator AOO1T25070 Mitsubishi Electric Glow plugs Sheathed type Hiyoshi Electric Battery charge lamp Glow plug indicator Starter switch Glow plugs Wire sizes s - 40 ODd 5 ODd - - 1.25 ODd - - 0.
1-1 Starter (1) Tabulated data Model M002T54172 Type Pinion-shift type with overrunning clutch Voltage 12V Output 2 kW Armature winding Series Yoke diameter 80 mm (3.15 in.) Rating 30 seconds Rotation Clockwise as viewed from pinion side Weight 5.8 kg (12.8 lb), approx. Performance item Specification Condition No-load characteristics Voltage: 11 V Current Speed 130 A, max. 4000 rpm, min. Locked characteristics Voltage: 3 V Current Torque 1000 A, max. 2.8 kg·m (20.3 lb·ft), min.
tated into the free state by the springs to unlock the inner and outer races. This allows the pinion to spin independently of, or overrun, the remainder of the clutch. (2) Reduction gear train and overrunning clutch The inner end of armature shaft carries a drive gear which is in mesh with a driven gear splined to the pinion shaft to provide speed reduction. The pinion shaft is fitted loosely to the outer race of overrunning clutch through helical spline engagement.
1-2 Alternator 1-Rotor 2-Bearing 3-Pulley 4-Stator 5-Front bracket 6-Rear bracket (1) Tabulated data of alternator (2) Construction of alternator Model designation AOOIT25070 Nominal output 12V-35A Polarity of ground Negative Outside diameter 114 mm (4.48 in.) Direction of rotation Weight Regulator Voltage regulation 7-IC regulator a-Rectifier 9-Bearing This alternator has a built-in IC regulator. The rotary parts are: rotor, ball bearings, fan and pulley.
(3) Alternator operation (a) Starter switch in M position ....._..JI~'--_Fuse box -- Alternator t Ie regu lator ,······1.-" Battery .... (b) Starter switch in S position and starter operates '--_....JJ7f\..l'--_ Fuse box ,······1.-" Battery -75 - ....
(c) Engine starts and alternator charges battery ~----------------~B~------------------~ IC regulator ..............-otl····· ·1, Battery ":" (d) Alternator charges battery excessively ~~--------------~B~----------------~~ Fuse box IC regulator ......--tII······I..-,. Battery When output voltage has sufficiently dropped, zener diode Dz permits no current to flow. Now transistor Ql turns off and transistor Q2 turns on and, consequently, the field current increases and output voltage rises again.
2. Starter removal and installation (1) Disconnect wire (1) between the battery and starter and wire (2) between the starter and starter switch. (2) Unscrew mounting nuts (1), and remove starter assembly (2) from the engine. To install, follow the reverse of removal procedure.
3. Starter disassembly and reassembly 13 16 15 14 8 10 1-Switch 2-Rear bracket 3-Brush holder 4-Yoke 5-Armature 6-Ball bea(ing 7-8all bearing a-Cover set 9-Center bracket 10-Gear 11-Spring set 12-Lever 13-Pinion set 14-Pinion shaft 15-0il seal 16-8all bearing 17-Front bracket (The parts are numbered in the sequence of removal for disassembly. To reassemble, follow the reverse of disassembly procedure.) (1) Loosen the nut on the switch terminal (M), and remove the connector.
(3) Remove two brushes on the positive side, and take off the brush holder. (6) Remove the center bracket by unscrewing two bolts. Remove washers (several pieces) for adjusting the pinion shaft axial play. (4) Remove the yoke, and pull off the armature. (7) Remove the snap ring holding the pinion, and remove the pinion. [NOTE] (8) Remove the lever springs (large and small), lever, reduction gears, pinion shaft, etc. Replace rubber packings fitted to the ends of yoke with new ones.
4. Alternator removal and installation (1) Pull the three through bolts, and break the alternator into the rotor (complete with front bracket and pulley) and stator (complete with rear bracket). (1) Disconnect wire (1) between the alternator and relay and ground harness, unscrew the adjusting plate bolts, and remove the fan belt. (2) Unscrew bolts (2) securing the alternator bracket, and remove alternator assembly (3) from the engine.
Do not jump into a conclusion that th.e starter is in trouble when the engine refuses to fire up upon cranking: the engine could be in trouble. 6. Preheating system Removal and installation of glow plugs (1) Before removing glow plugs from the engine, be sure to disconnect battery terminals. (b) No-load test (2) Disconnect cable (1) from No.4 cylinder glow plug. Loosen glow plug connection plate attaching nut (2) and remove connection plate (3).
Starter troubleshooting guide Symptom Possible cause 1) Bearings are dirty, or need lubrication. Large current and low speed 2) Rotor (armature core) is rubbing the pole pieces. 3) Grounded coil in the armature or in the field. 4) Short-circuit in the armature coils. 670202 1) Magnetic switch is grounded and is not working. Large current but no speed (b) A growler is generally used to test armature for short circuit in its Winding.
(d) Brushes and brush springs Pinion gap 1) Measure brush length. Replace brush if the length exceeds the service limit. Battery 12 V Pinion Specifications Item 670208 Pinion gap Specifications Item Brush length I Assembly standard 0.5 (0.020 ~ ~ 2.0 0.079) Unit: mm (in.) Assembly standard Service limit 18 (0.71 ) 11 (0.43) I Unit: mm (in.) [NOTE] To adjust pinion gap, increase or decrease thickness of washers used between mating faces of magnetic switch and front bracket.
(2) Regulator voltage test (a) Test on a test bench (3) Alternator inspection after disassembly (a) Inspection of each diode Use a fully charged battery. Close the switch, and gradually increase the alternator speed. Make sure that the current is below 5 amperes and the voltage is 14.1 to 14.7 volts when the alternator speed reaches 5000 rpm. If this requirement is nor met, replace the regulator assembly. It is impossible to reset the regulator voltage.
(3) Inspection of brushes and commutator (a) Check the brushes for wear. A brush worn down excessively should be replaced by a new one. When the brush is replaced, grind the brush against the commutator surface by using #250 sandpaper so that it makes a full-face contact with the commutator. (b) Check the mica insulation for condition, It should be "undercut," that is, the segment between two adjacent mica should be slightly proud of the mica surface, as viewed in the cross section.
(c) Armature inspection 7-3 Battery Alternatively check four wire leads of the armature coil for continuity with a tester as shown: Check the electrolyte level in the battery cells, making sure that it is 10 mm (5/16 in.) above cell plates. Check the specific gravity of electrolyte. If it is below 1.260 at 20°C (68°F), prepare an electrolyte of 1.260 specific gravity and add it to the battery. A specific gravity below 1.190 means that the battery is half discharged; in such a case recharge the battery.
BENCH TEST When the engine is overhauled, it is advisable to conduct the bench tests for checking the engine performance. The purpose of bench tests is to make sure that each major component has been properly serviced. (f) The relationship between the load and runningin period is as follows: After running-in the engine, check the valve clearance. 1.
760 - 11.
MAINTENANCE STANDARDS Unit: mm, (in.) ---- Group Nominal dimension Item Maximum rpm (no-load) Assembly standard Repair limit [Standard clearance] [Clearance] Varies according to customers' specifications. 2 Compression pressure . Engine oil pressure QJ Valve timing In take valves [3mm (0.12irt) added to valve Exhaust valves side 1 20 kg/cm 2 (284 psi) 3 -4 kg/cm 2 (43 -57 psi) (at 1500 rpm) 2 kg/cm 2 (28.4 psi) kg/cm 2 0.5 kg/cm 2 (7.
Unit: mm (in.) Nominal dimension Item Group Clearance on crankshaft journal (in two directions at right angles 10 each other with bearing in place) ~c. ~ a U 1) Replace crankcase and bearing cap as an assembly. 2) Upper bearing shells have oil groove. /1--[\ 0 E9rH I--- \ '- ,l:l .S oS ::;; ; .:.= 0.Q35-0.100 [(0.00138~0.00394 )1 Replace bearing if repair limit is reached. Regrind crankshaft journals and use undersize bearings 0.25 (0.0098), 0.50 (0.0197) or 0.75 (0.
Unit: mm (in.) ... "'to" .. "'" .c: Warpage of gasketed surface Regrind' if warpage is minor . 0.20 (0.0079) ,0.05 (0.0020), max ,,--W'@."Y--er,*-o-~o~,-G I -, , ", ~ 00 ,OO!0Q,oq B-~~&-~~-()-.!~c::.:~~ , I ~- I I C -~ I -'r I 0 E :§ >. U As-installed thickness of gasket Diameter of valve stem "C '" Go> ..c: .. .::'"to :> 1.35 (0.0531) Intake 8 (0.315) Exhaust Clearance of Intake valve stem in guide Exhaust Valve sinkage 8 (0.315) 0.8 (0.031) ±o.OS (± 0.0020) -0.
Unit: mm (in.) Group Item Valve clearance Nominal dimension Assembly standard [Standard clearance] Repair limit [Clearance] Service limit [ Clearance] Remedy Remarks 0.25 (0.009S) clearance may also be obtained by warm setting if intake and exhaust valves are at the same temperature. 0.25 (0.009S) (cold setting) Inside diameter IS (0.709) +g.061 tg.00240) Diameter of rocker shaft IS (0.709) -0.016 CO.00063) -0.034 -0.00134 "0 to .. .. U .c '" u 7j :§ IX: "0 0 G Fit on shaft IS (0.
Unit: mm (in.) . .::: .<: ~ c: r! U Center-to-center dimension between journals and crankpins c: E '" ii: (0.0004), max as runout Standard 83.90(3.3031) :a. 0.25 (0.0098) oversize 84.15(3.3130) ~ 0.50 (0.0197) oversize 84.40(3.3228) is 0.75 (0.0295) 84.65 (3.3328) B..... CJ E ., oversize ± 0.05 (± 0.0020) om ParaUelism between crank pins and journals --. . 47 (1.850) e---± 0.015 (± 0.00059) Measure in the direction transverse to piston pin. -0.2 (-0.008) • ------~--~-.
Unit: mm (in.) Item Group Nominal dimension Assembly standard [Standard clearance] Repair limit [Clearance] Service limit [Clearance] Remedy Remarks Compress rings to 84 (3.31) dia. [ Gap 0.30 - 0.50 \ (0.0118 -0.0197) I~~ [ 1.5 \ (0.059) oo~C o c . ~ .;:: .: 0 t:: iC ..., > 0 0 to No.1 compression ring 2.5 (0.098) No_ 2 compression ring 2.0 (0.079) 0.050 - 0.085 [(0.00197 - 0.00335)] [ 0.20 \ (0.0079) Replace rings if service limit is reached.
Unit; mm (in.) . "CI g ...!a'" ~ DO s:: .;;: OIl [ End play .§ 0.15 ~ 0.35 ) (0.0059 ~ 0.0138) [ 0.50 ) (0.0197) Replace connecting rods. ., u I: I: 0 , u Difference in weight among rods per engine ., Flatness ±25g (iO.88 oz) ~ 0 E .5 ~ :g Grind or replace. '" ..c:: 0.5 (0.020) 0.15 (0.0059), max ~ >. r;::: Replace flywheel. Runout Intake +0.1 DI 46.916_ 0 . 3 +0.00394 (1.84708_0.01181 ) Exhaust ... .E: u ..c:: Vl .... +0.00394 DI - D2 = 6.844 (0.26945) (J .
Unit: mm (in.) Item Nominal dimension Assembly standard [Standard clearance) Thrust journal width in boss 26 (1.024) 0.05 -0.15 ] 1(Q0020 - 0.0059) Fit of shaft in holes in crankcase 30 (1.181) 0.09T ~0.045T [(O.0035T -0.0018T) J Group ] . § ~OIl .f! .5 t-< 0.05 (0.0020 Gear backlash ...e ~ \0 '"I = .9 ~0.0079) Sliding clearance between outer rotor and cover 24 (0.9449) Clearance between outer rotor and body 40.5 (1.5945) Outside diameter of rOlor shaft 13 (0.5118) 1 0.04 -0.
Unit: mm (in.) 900 cc (55 cu in.)/min, min Delivery capacity p. Air-tightness E "p. " ~ Check displacement with injection pump operated at 1000 rpm with a discharge pressure of 1.5 kg/ cm 2 (21 psi). 600 cc (37 Cll in.)/min, min Close pump discharge port with a plug. Apply an air pressure of 2 kg/cm 2 (28 psi) to the pump, and keep the pump immersed in diesel fuel longer than 1 minute. Not greater than 50 ee (3.1 eu in.)/min (with bubbles not larger than 2 rom (0.08 in.) in size.) ""Cl "0 " [.
Unit: mm (in.) Group Item Inside diameter of tappet holes in pump housing Nominal odimension Repair limit Assembly standard [Standard clearance] [Clearance] Service limit [Clearance] Remedy Remarks -0.15 (-0.0059) 24 (0.945) Axial play of camshaft bearing 0.03 ~ 0.05 I 1(0.0012 ~ 0.0020) Fit of tappet pin in tappet (hole) 0.013 ~0.050 1(0.00051 ~0.00197)1 Adjust by means of shim. [ 0.1 ] (0.004) 7 (0.276) 0.033 ~0.078 1(0.00 130 ~ 0.
Unit: mm (in.) Slip torque of gear complete 0.4 (2.9 ~0.6 ~4.3 kg-m Ib-ft) Adjust by means of shim. 0.006 ~0.059 [(0.00024 ~0.00232)1 Fit of governor sleeve on governor shaft Fit of governor sleeve groove on sliding piece [ 0.03~0.\3 (0.0012 ~0.0051) I [0.15 I (0.0059) [0.18 J (0.0071 ) Replace sliding piece. - Replace floating lever or bolt. Fit of floating lever on bolt 6 (0.236) [ Fit of floating lever on pin 0.01 (0.00039 ~0.052 ~0.00205) ) Replace floating lever or pin. [ 0.
Unit: mm (in.) ., 120 kg/cm 2 (1706.4 psi) I njection pressure 2 110 kg/cm + 19 kg/cm 2 t146·2 psi) (1564.2 psi) N ...e 4) til >, til Cl ;:::s ~ 0 Spray of fuel oil should be uniform and consists of fine droplets. No dribbling should be observed after each injection. "Throttle injection" should occur when the tester lever is operated slowly. Replace nozzle tip when needle surface is scratched or scored.
Unit: mm (in.) Item Nominal dimension Assembly standard [Standard clearance] Repair limit (Clearance] Commutator runout 0.05 (0.0020) 0.03 (0.0012) 0.1 (0.004) Group Service limit [ Clearance] 18 (0.71) Height Remedy 11 (0.43) Brush Spring pressure ... 2 kg (4.4 lbf) 3.5 kg (7.7Ib) Pinion-to-stopper clearance [ 0.5~2.0 (0.D20 ~ 0.079) I ~ ...
SEALANT APPLICATION DATA Where to apply Mating face or parts Crankcase Oil pan gasket Sealant Remarks ThreeBond 1102 Apply to bottom face for oil pan. Atmojet Apply to both sides of cork packing. ThreeBond 1207C Apply to periphery of rubber packing. Front/rear attaching faces Main oil gallery plug Crankcase Hermeseal H-l Apply to hole in crankcase and also to plug after installing. Crankcase screw plug Crankcase Hermeseal H-I Apply to threaded portion. Apply when reassembling temporarily.
TIGHTENING TORQUE Important bolts and nuts Unit: k9·m (lb-ft) Item Torque Cylinder head bolts 12.0 ± 0.5 (86.8 ± 3.6) Main bearing cap bolts 8.5 ± 0.5 (61.5 ± 3.6) Connecting rod cap bolts 5.5±0.5 (39.8 ± 3.6) Rocker shaft bracket bolts 1.5 ± 0.5 (10.8 ± 3.6) Front plate bolts 1.0 .± 0.5 «7.2 ± 3.6) Timing gear case bolts 1.0 ± 0.5 Camshaft thrust plate bolts 1.8 ± 0.5 (13.0 ± 3.6) Idler thrust plate bolt 3.5 ± 0.5 (25.3 ± 3.6) Crankshaft pulley nut 40.0:t 0.5 (~89.3 ± 3.6) (7.2 ± 3.
General bolts and nuts (2) The values listed below have a tolerance of ±10%. (I) The values listed in this chart are for standard bolts. For other bolts, nuts and screws, refer to the related sections in this manual. Screw thread When an impact wrench is used, a torque up to and including 14 'kg-m (10 I Ib-ft) has a tolerance of ±20% and a torque above 14 kg-m (101 Ib-ft) has a tolerance of ± 15%.
SPECIAL SERVICE TOOLS Unit: mm Tool No. Qt. Drawing or sketch Tool name Used for: Installing valve guides I lC A 30691-10200 Valve guide installer 55 Material: S53C l-Valve guide installer 2-Valve guide 3-Cylinder head A-Guide length outsi de hole Removing valve guides • ~~ 31391-10500 Valve guide remover O.
Unit: mm Tool No. Tool name Drawing or sketch Qt. Used for: Connecting pressure gauge to engine for compression measurement 30691·11100 Adaptor Placing pistons in crankcase 30691-52100 Piston guide Removing idler shaft MH061077 n t:I ~"~i Idler shaft puller I \ " 'II Rotating crank pulley for engine cranking 30691- 21800 Cranking handle Installing camshaft thrust plate 34491.
Unit: mm Tool No. Tool name Drawing or sketch Qt.
Unit: mm Tool No. Tool name Drawing sketch Qt.
TROUBLESHOOTING Engine lacks power Engine will not start Abnormal exhaust smoke Engine hunts Engine turns over but does not start Complaint -,- Possible cause Insufficient fuel supply to injection pump o o Greater variance of injection quantity - - 0 o o o o 0-000 Defective injection pump seals Insufficient injection quantity o o o Excessive injection quantity o Improper fuel spray from injection nozzles E ~ o Excessive fuel return from injection nozzles o o o o 0-000 o o
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Engine hunts Abnormal exhaust smoke Complaint Possible cause Engine is too cold.
( • For detailed information refer to the separate chart.) ,:: ,:: "0 .g " .;l" ~ " ...'" "0. Q) ~ Q) ..c:: " .~ u .!
< ... <8 0 on'" 0.. on 1;l ,:: 2 E ~ $l on ...'" on ,:: 0 "0.. ... 0 0 B " 3 0.. on "0 0 on on > ... ",:: ,:: '" ,:: ,:: "'ED 'ED 0 'ED >, ~ 0) 0) 0) 0) 0) Q);':: .~ <:: ~ ,:: ~ 0 ~ ,:: ~ 0 "" ...'" ,:: ~.D ·Bu .:= " "0 1;l ... "...> " Defective lubrication system ,:: Abnormal water temperature rise ,:: .9 0.. .9 0..
Dec . '85 Printed in J apan Pub. No .
