(1) If sub-throttle is active: No. @) If sub-throttle is inactive: Yes. ‘After U0146 fail released, Remarks This DTC comes from only communication between i2 module and ECU. ‘TELEFLEX control head malfunction will detected as “Main Throttle Position Sensor Error’ Marine gear transmission control (shif) function is independent from throttle function. This means that shifting function should be controlled as i2 module function. (Ifi2 module is not powered, then UO146 occur and shift function may get inactive.) Back to normal communication after receiving data from i2 module. If sub- throttle is selected before communication get back to normal, main throttle will stay inactive, DTC/FMI Probable cause (1) Communication wire-harness (CAN) between ECU and Teleflex i2 module open or U0146/12 | connector not connected properly. (2) 2 module powered off or malfunction (1) Check if 2 module unit working (2) Check CAN communication cable between ECU and i2 module. (8) Check if 8320 is installed proper software and software setting, 1413. Troubleshooting 3.3.5 Diagnosis Procedure of Temperature Sensor (1) Temperature Sensor Diagnosis Procedure: PINE of PINE of pte | FMI ‘CONTENT eel eu P0115 3/4 | Water Temperature Sensor 37 35 P0180, 3/4 | Fuel Oil Temperature Sensor 28 35 P0195, 3/4 | Lubricant Temperature Sensor 39 35 4) Failure 4, Sensor Output Voltage “Use electric tester to check open / short circuit of wire hamess. *Make sure that all connectors (sensor and ECU) are connected. Measure voltage between sensor signal and GND. ([ECU_TH*] - [ECU_G_S}) Voltage ‘Status: Action (1) Replace wire hamess (ECU_THY nc “Wire hamess [ECU_TH"! short to ground earth <=02V (2 Replace temperature sensor. *Sensor failure <4aV condition | (Refer to "Sensor specification chart") (1) Replace wire hamess. ‘Wire hamess [ECU_TH"] open or short to “Sensor SV" a Ne "pattery+" (2) Replace temperature sensor. "Sensor failure (1) Check wire hamess if there is any damage or miss wiring. ae (2) Replace wire harness OK [Replace ECU Case2: When DTC is not active (logged status). “ECU stores the past DTC information and YDT indicate as logged DTC. If there is a possibility to have had failure situation such as disconnecting the connector, it may be the reason of logged DTc. (1). Checking wire harness, ‘Sway wire harness along the wire hamess between sensor and ECU. See if alarm tum on or not. “Recommendation: Before start this, it may be easier to clear DTC information by YDT, because the occurrence counter goes 0 and easily can identify when alarm occurred. DTC Contents ‘Appeared Check connector terminal, Change wire hamess. Not appeared No action 1443. Troubleshooting 3.3.6 Diagnosis Procedure of Pressure Sensor PIN# of PIN# of PIN# of Dre | FM CONTENT [ECU_VSEN] [ECU_PRS*] [ECU_G_S] 0235 | 3/4 | Boost Pressure Sensor 24 (SNS) | 40(PBST) | 5G) P0520 | 3/4 | Lubricant Oil Pressure Sensor (24 (SNS5) 27 (PLO) 35 (G_S) Pressure sonsor characterises Prose sear cou oto 180 1 24 sensor [SK85) 2 PLO27 38 1 ‘Signal out (EcU_P™ ‘ ignal output} Pestaol" ou ‘1 3 : sensor eno 2 35] ecu s) es | aa 3, i fect] £ : Lu bis ' an ay : c ‘ eup | Sensersv 30400 600 8001000 1200 4 Pressure [kpa] gal output * Power supply voltage at SV Signal output Toa aceuracy or sersor spec 5% sn Part code:119578-91300 vee hares Sects donsr SV wis hao pone Tse thet than ¥. Eachange Exchange | [exchange Eachange Exchange eeu tonsor| | wrohamess eeu weonamecs 1453. Troubleshooting “NOTE: THIS PRESSURE SENSOR GET DAMAGED IF SUPPLIED VOLTAGE OF SIGNAL OR SENSOR POWER EXCEEDED 6V. IN THIS CASE, SENSOR MAY GET OUT OF TUNE, AND HAS TO BE REPLACED. SENSOR POWER LINE IS COMMON TO ALL PRESSURE SENSOR, THUS REPLACEMENT SHOULD HAPPEN TO ALL PRESSURE SENSOR AT A TIME. “Before replacing wire harness, check also connectors of wire harness and ECU. Case: When DTC is ACTIVE. To distinguish (classify) the cause (wire-hamess, sensor failure, connector). 41. Checking sensor 5V output voltage. “Unplug connector from sensor. “Measure the voltage between terminals A and C of wire harness connector by electric tester. Terminals Vottage Expected status sy__| OK: Normal Wire hamess > Go to 2 “Check wire hamess open / short” connector 1-3 toy | Failure: in » Go to 4 “Check sensor 5V wire hamess open / short” NOTE: [ECU_SNS5] short to GND shall be detected by P1230/1 [ECU_SNS5] short to battery shall be detected by P1230/0. 2. Checking wire hamess open / short. *Disconnect ECU connector from ECU and unplug sensor connector. *Use electric tester to check open / short circuit of wire hamess. (Conductivity check) Terminals Conductivity Expected status (ECUP™|-B Good OK: Normal Bad | Failure: Open circuit of wire harness [ECU_SNS5]-C Good OK: Normal Bad Failure: Open circuit of wire hamess (ECU_G_S|-A7 Good (OK: Normal ee Bad Failure: Open circuit of wire harness [ECU_P™"]-A/C/ Bad | OK: Normal a Tete a Good Failure: Short circuit of wire harness [ECU_SNS5]-A7B/ Bad OK: Normal oe ae i Good | Failure: Short circuit of wire hamess [ECU_S_G]-B/C/ Bad OK: Normal joihen terminal Good Failure: Short circuit of wire hamess earth / Battery + = Replace wire hamess. Failure | «take a look on wiring hamess if there is any damage on hamess or wrong-wiring. (OK _ | Goto 3 *Check Sensor performance’ 1463. Troubleshooting 3. Checking sensor performance. “Connect ECU connector to ECU and plug in sensor, “Key on and supply battery voltage to ECU. “Use electrical tester to measure voltage. “Use breakout box. Check sensor signal out put and sensor 5V voltage. Breakout box a branch ames and connector from each pin of ECU fe tester probe can be inserted here, and the [8 shape of | waves between ECU each Terminals Expected value ‘A-B (Pressure sensor connector of wire hamess) 0.5V (at engine stopped) A-C (Pressure sensor connector of wire hamess) BV * Wire hamess is already checked at 1 Na | Replace pressure sensor. *Replace ECU if pressure sensor replacement does not make different. OK | Replace ECU Comment: Sensor signal out put range. Terminals Voltage Expected status below 0.5V_| Failure: just below | (1) Open circuit of wire hamess B- [ECU_P’ 0.5V may be | (2) Open circuit of wire hamess C- [ECU_SNSS] an error. _| (3) Short to GND circuit of wire harness B- [ECU_P**] Wire harnes osv< sconnector A - B [ECU_P™] | OK: Normal v<36v Failure: above 3.6V_ | (1) Short to battery of wire hamess C- [ECU_SNS5] (2) Short to battery of wire hamess B- [ECU_P"*'] 4. Checking sensor 5V wire harness. “Disconnect ECU connector from ECU and unplug sensor connector. “Use electric tester to check open / sort circuit of wire harness. (Conductivity check) earth / Battery + Terminals Conductivity Expected status Good [OK: Normal [ECU_SNS§]-C Bad Failure: Open circuit of wire hamess [ECU_SNSS]-A7B7 Bad OK: Normal other terminal / 7 Good Fallure: Short circuit of wire hamess 1473. Troubleshooting Case2: When DTC is not active (logged status). “ECU store the past DTC information and YDT indicate as logged DTC. If there is a possibility to have had disconnected the wire harness of sensor and turn on ECU, it may be the reason to have logged DTC *Clear DTC information first, then it become easy to identify when DTC comes on and also engine condition “Sway wire hamess around the pressure sensor and ECU. Check if DTC comes again. DTC Contents “Check the condition that DTC comes on Appeared Check connector terminal and wire hamess. Change wire harness. No action at this time. Not appeared “Wait and see if same DTC will come. 1483. Troubleshooting 3.3.7 Other Wiring Diagram “The following wiring diagram is listed 1. Air Heater 2. Rack Actuator, Rack Actuator Relay, Emergency SW 3. Rack Position Sensor 4, Sub-Throttle Indicator, Emergency Throttle Position Sensor 5. Starter Interlock RL, Starter, Alternator 6. Main RL, 1st Station RL, 2nd Station RL 7. NEUTRAL SW (1) Air Heater Heater relay Heater fuse hy ©] use veo oT Connector housing 82280"1 [| i] Seal 281994-2 Terminal 282110-1 7 SSK. scrow Terminals M6 Torque to 5 NM MAX. Fuse Batoy| + — Airnetorraay ecu P nl ‘8 Fuse uT 20 asoa_} Ae eater BAAN, 1T Airtotorrlay2 P nr ‘8 Fuse iT eB sin Aichestr2 AAW, 1T 1493. Troubleshooting (2) Rack Actuator, Rack Actuator Relay, Emergency SW Batty, ecu | fe Main olay Emergency FOP Actuator lay Stop Sw ou pat OA EMS rar QS} ____ 44 rag 8 FOP actuator SI RA 1503. Troubleshooting (3) Rack Position Sensor Battery [+ - Fuse 17 2A cou P. Maio iy Rack sensor AMP par 5H ou pes greg asdf dg FOP sens ary 1513. Troubleshooting (4) Sub-Throttle Indicator, Emergency Throttle Position Sensor boty se cou P tan oy Big? swotrate | nar cou sug? 2. dsr 2 a sete Poston sno L. os os 1523. Troubleshooting (8) Starter Interlock RL, Starter, Alternator satay [+ z pve 20a Fuse } 1A i | wan rey Star tock aay / Batok keys ‘sane cou sTro®. 216 sTR sto& + 8h sr tomato -w—9e R suaer roy 4 5 1” fal 77 sar a TIT Fu et 4 os s 1533. Troubleshooting (6) Main RL, 1st Station RL, 2nd Station RL G Fuse see a ic 1 ne eae faba : ° eI °° : : (7) NEUTRAL SW Fou -> nts Q?4 18) rs ub cpg 1544. Disassembly and reassembly 4. Disassembly and reassembly 4.1 Disassembly and reassembly precautions (1) Disassembly + Take sufficient time to accurately pin-point the cause of the trouble, and disassemble only those parts which are necessary. + Be careful to keep all disassembled parts in order. + Prepare disassembly tools. + Prepare a cleaner and a cleaning can. + Clear an adequate area for parts and prepare a container(s) * Drain cooling water (sea water, fresh water) and lube oil + Close the seacock (2) Reassembly + Sufficiently clean and inspect all parts to be assembled. * Coat sliding and rotating parts with new engine oil when assembling. + Replace all gaskets and O-rings, + Use a liquid packing agent as necessary to prevent oil / water leaks + Check the oil and thrust clearances. etc. of parts when assembling + Make sure you use the correct bolt / nut / washer. + Tighten main bolts / nuts to the specified torque. Be especially careful not to over tighten the aluminum alloy part mounting bolts. * Align match marks (if any) when assembling. Make sure that the correct sets of parts are used for bearings, pistons, and other parts where required 1554, Disassembly and reassembly 4.2 Disassembly and reassembly tools The following tools are required when disassembling and reassembling the engine. Please use them as instructed 4.2.1 General hand tools Name of tool Ilustration Remarks Wrench Size: 10x13 12x14 17x19 22x24 ‘Screwdriver ‘Steel hammer Local supply Copper hammer Local supply Mallet Local supply Nippers Local supply Pliers Local supply Offset wrench Local supply 1 set 1564. Disassembly and reassembly Name of tool lustration Remarks ‘Box spanner Local supply 1 set ‘Scraper Local supply Lead rod Local supply File Local supply 1 set I Rod spanner for Local supply hexagon socket Size: 6mm head screws 8mm 40mm ‘Staring pliers Local supply Hole type Shaf type 1574, Disassembly and reassembly 4.2.2 Special hand tools ‘small end bushing insertion / extraction tool Name of tool Illustration Remarks Piston insertion / a e extraction tool —l * _ (Extraction of piston pin) A B c D "1 20 80 35 f (Insertion of piston pi Connecting rod Intake and exhaust valve guide insertion extraction tool Lube oil fiter case remover 1584. Disassembly and reassembly Name of tool lustration Remarks Piston ring ‘compressor Piston ring replacer (for removal / insertion of piston ring) Valve lapping tool (Rubber cap type) Valve lapping powder Feeler gauge Cate Adjusting sore Pulley puller {Local supply) (Removing the coupling) 1594, Disassembly and reassembly Name of tool lustration Remarks ‘Stem seal insertion (for inserting stem seal) mm a [a] ds | 1 [te] is 16.2 | 22| 135 | 11.5 | 65 16.2 | 22| 135] 95 | 65 Yi Gj La Zama ts fff fs i 1604. Disassembly and reassembly 4.2.3 Measuring instruments (1) Application of tools Name of tool illustration ‘Application Vernier calipers 0.05 mm (0-150 mm, Micrometer 0.01 mm 0-25 mm. 25-50 mm, 50-75 mm, 75-100 mm. 100-125 mm 125-150 mm 0.01 mm 18-35 mm 35-60 mm, ‘50-100 mm. Cylinder gauge Thickness gauge 0.05-2 mm “Torque wrench 0-343 N oe (0-35 kgm) 0-49 MPa (0-500 kgf / cm?) Nozzle tester 1614, Disassembly and reassembly (2) Use of tools No. Name of tool Use. Tlustration 1 | Dial gauge Measures shaft bending, distortions of levelness, and gaps. 2. | Test indicator Measures narrow and deep places, which cannot be measured with dial gauge. 3 | Magnetic stand Keeps the dial gauge firmly in position, thereby permitting it to be used at various angles, 4 | Micrometer Measures the outer diameter of the crank shaft, piston, piston pin, ete. 5. | Cylinder gauge Measure the inner diameter of the cylinder liner and rod metal. 6 | Vernier calipers Measures various outer diameter, thickness, and width. 7 | Depth micrometer Measures sinking of valves. 8 | Square Measures distortion in position of springs and perpendicularity of parts. 9 | VBlock Measures shaft distortion. 1624. Disassembly and reassembly No. Name of tool Use Mlustration 10 | Torque wrench Used to tighten bolts and nuts to standard torque. Ep 71 | Thickness gauge ‘Measures the distance between the ring and ring groove, and between the shaft and shaft joint at time of assembling. 72 | Gap tester Check for leakage in the fresh water system. 13 | Battery current tester ‘Checks density of antifreeze and charging condition of battery fluid, 14 | Nozzle tester Checks the shape and pressure of spray emitted from the fuel injection valve at the time of injection. 15 | Digital thermostat Measures temperature of various parts, 1634, Disassembly and reassembly No. Name of tool Use Tustration 16 | Rotation [Contacttype | Measures rotation speed by using a : gauge reflector seal which is placed onthe | 4 i exterior of the revolving shaft Photoelectric | Measures rotation speed by using a type reflector seal which is placed onthe | Revolving shatt exterior of the revolving shaft. High pressure | Measures rotation speed without fuel pipe clamp | reference to revolving shaft center or type the exterior of the revolving shaft 17 | Circuit tester Measure the resistance, voltage, and continuity of the electric circuit. 1644. Disassembly and reassembly 4.2.4 Other material items Usual contents Features and application Liquid gasket [Three Bond | 200g Non-drying liquid gasket; solvent less type, easy to No.1 (1 kg also remove, superior in seawater resistance, applicable Ter101 available) to various mating surfaces. Three Bond | 200g Non-drying liquid gasket; easy to apply, superior in No.2 (1 kg also water resistance and oil resistance, especially 81102 available) superior in gasoline resistance. Three Bond | 150g Daying film, low viscosity and forming of thin film, No.3 appropriate for mating surface of precision parts. 781103 Three Bond | 200g ‘Semi-drying viscoelastic material, applicable to non- Not (1 kg also flat surface having many indentations and E1104 available) protrusions, superior in heat resistance, water resistance, and oil resistance. Three Bond | 100g Solvent-less type silicone-base sealant, applicable to No.10 high temperature areas. (-50 °C to 250) e121 Three Bond | 100g Silicone-base, non-fluid type, thick application 781212 possible. Adhesive Three Bond | 200g Prevention of loose bolts, gas leakage, and 81401 corrosion. Torque required to loosen bolt: 10 to 20% larger than tightening torque. Lock tight 50g Excellent adhesive strength locks bolt semi- SUPER permanently. Te1324 Seal Tape 5 mround tape | Sealing material for threaded parts of various pipes. Ambient temperature range: -150 °C to 200 °C. ‘O-ring kit @19x2m:1 | O-ring of any size can be prepared, whenever @24x2m:1 | required. @3.1x2m:1 _ | (Including adhesive, release agent, cutter, and jig) @3.5x2m1 25.7x2m1 EPlubricant |Brandname |50g For assembly of engine cylinders, pistons, metals, (molybdenum | (LOWCOL shafts, ete. disulfate) PASTE) Spray type facilitates application work, Brand name | 330g (PASTE SPRAY) Brand name [50g Prevention of seizure of threaded parts at high (MOLYPASTE) temperature. Applicable to intake and exhaust valves. (stem, guide, face) 1654, Disassembly and reassembly Features and application + The scale solvent removes scale in a shor time. (1 to 10 hours) + Prepare water (seawater is possible) in an amount that is about 10 times the weight of the solvent. Mix the solvent with water. + Just dipping disassembled part into removes scale, To shorten removal time, stir remover mixture. + If cleaning performance drops, replace remover mixture with new remover mixture. + Neutralize used mixture, and then dispose of it To Judge cleaning performance of mixture, put pH test paper into mixture. If test paper tums red, remover mixture is stil effective. ‘Add antirust to fresh water system at the cold area to engine operate. + The cleaning agent removes even carbon adhering to disassembled parts. + If'a cleaning machine is used, prepare 4 to 6% mixture of 60° to 80° to ensure more effective cleaning, ems Usual contents ‘Scale solvent [Scale solvent | 1 box (4 kg x4 removers) Neutralizer 1 box (caustic soda) | (2 kg x 4 neutralizers) pH test paper ‘Anti freeze Cleaning agent Cleaning agent for turbocharger [40 x4 180x1 1BSsets: 1, 500cc x6 Special cleaning agent that requires no water, specially designed for blower of turbocharger and intercooler. [NOTICE] It is recommended that the liquid gasket of Three Bond TB1212 should be used for service work Before providing service, observe the cautions below: 41) Build up each gasket equally 2) For a bolt hole, apply liquid gasket to the inside surface of the hole. 3) Conventionally, Three Bond TB1104(gray) or Three Bond TB1102(yellow) is used for paper packing though single use of one of these bounds is not effective. 4) If conventional packing is used, do not use liquid packing Oil pan mating surface outside ( Inside of oil pan Buildup of T1212 1664. Disassembly and reassembly 4.3 Disassembly and reassembly 43.1 Disassembly + Preparation on a boat For engines mounted in an engine room of a ship, remove the piping and wiring connecting them to the ship. 1) Remove the electric wiring connecting the electronic control system and the engine. 2) Remove the wiring between the starting motor and the battery. 3) Remove the exhaust rubber hose from the mixing elbow. 4) Remove the rubber hose connecting the coolant recovery tank to the filer cap. 5) Remove the seawater inlet hose for the sea water pump (after making sure the seacock is closed) 6) Remove the fuel oil inlet rubber hose from the fuel feed pump. 7) Remove the body fit (reamer) bolts and disassemble the propeller shaft coupling and thrust shaft coupling, 8) If a driven coupling is mounted to the front drive coupling, disassemble. 9) Remove the flexible mount nut, lift the engine, and remove it from the engine base. (Leave the flexible mount attached to the engine base.) 1674, Disassembly and reassembly + Disassembling an engine in a workshop (1) Drain cooling water 1) Open two drain cocks to drain seawater. 2) Open two drain cocks to drain fresh water. {drain cock for seawater (2) Drain lube oil Remove the pipe coupling bolt, which holds the lube oil dipstick guide, and drain the lube oil from the engine, Note: I a lube oil supply / discharge pump is used for the engine, the intake hose is placed in the dipstick guide. (3) Removing electrical wiring Remove the wiring from the engine. (4) Removing the fuel filter & fuel pipe 1) Remove the fuel pipes (fuel filter- feed pump, fuel fiter-fuel pump and fuel nozzle-fuel fer) 2) Remove the fuel fiter from the engine. From tue nozzle To fuel pump Drain plug From fuel pump (Fuel fiter) 1684. Disassembly and reassembly (5) Removing the air silencer 1) Remove the breather hose from the air Intake air hose silencer. 2) Remove the air silencer from the turbocharger (6) Removing the mixing elbow 1) Remove the seawater rubber hose connecting to the mixing elbow. 2) Remove the mixing elbow from the turbocharger. (7) Removing the turbocharger 1) Remove the intake pipe —(turbine-intake manifold). 2) Remove the oil pan side rubber hose for the turbine lube oil retum pipe from the oil pan. 3) Remove the turbine lube oil pipe (lube oil Breatherhose _Airsencer cooler-turbine), oe 4) Remove the turbine, (8) Removing the intercooler 1) Remove the intake air hose. 2) Remove the seawater rubber hoses. (Heat exchanger-vintercooler>Lube oil cooler) 3) Remove the intercooler Lube ot cooler Intercooler’ Lube ci iter (9) Removing the starting motor Remove the starting motor from the flywheel housing, (10)Removing the alternator 1) Loosen the altemator adjuster bolt and Adiuster remove the V-belt. 2) Removing the adjuster from the fresh water pump, and remove the altemator from the gear case (with distance piece). rresh water pump Vet Atternator 1694, Disassembly and reassembly (11)Removing the cooling water pipe (seawater / fresh water) 1) Remove the seawater pipe (seawater pump- fresh water cooler). 2) Remove the fresh water pipe (fresh water pump-fresh water cooler, exhaust manifold- fresh water pump), 3) Remove the fresh water pipe (cylinder block- lube oil cooler, lube oil cooler-fresh water pump). (12)Removing the fresh water tank (exhaust manifold), fresh water cooler and fresh water pump. 1) Remove the fresh water tank and gasket packing. 2) Remove the fresh water cooler. 3) Remove the fresh water pump and gasket. (13)Removing the seawater pump Remove the seawater pump. (14)Removing the lube oil filter and lube oil cooler 1) Remove the lube oil filter. 2) Remove the lube oil cooler. 3) Remove the lube oil dipstick and guide. 170 Fresh water tank Fresh water cooler ‘seawater pump Intercooler Lube oil lier4. Disassembly and reassembly (15)Removing the electronic control devices Remove the cover and remove the electronic control unit, amplifier and fuse. (16)Removing the fuel injection pipe 1) Remove the fuel injection pipe retainer. 2) Loosen the cap nuts on both ends of the fuel injection pipe and remove the fuel injection Pipe (17)Removing the fuel injection nozzles Note: If the fuel nozzle seat stays in the cylinder head, make a note of the oylinder number and be sure to remove it when disassembling the cylinder head (18)Removing the fuel injection pump Refer to 6.1.5 for the procedure. (19)Removing the rocker arm shaft assembly 1) Remove the rocker arm cover. 2) Remove the bolts (s) for the rocker arm shaft support, and remove the entire rocker arm shaft assembly. 3) Pull out the push rods. (20)Removing the cylinder head 41) Loosen the cylinder head bolts in two steps in the illustrated order. Remove the cylinder head 2) Remove the cylinder head gasket. (21)Removing the marine gear box Loosen the bolts for the gear box case flange, and remove the gearbox assembly. (22)Removing the crankshaft damper and pulley Remove the crankshaft damper and the V-pulley. (23) Removing the gear case cover Loosen the gear case cover bolts, and remove the gear case cover from the gear case. 1 0.00.0.6 6, Flywheel side Gear case side Operating sido (Order of loosening cylinder head bolts)4, Disassembly and reassembly (24) Removing the flywheel and flywheel housing 1) Loosen the flywheel bolts and remove the flywheel 2) Remove the flywheel housing. Note: Be careful not to scratch the ring gear. (25)Turning the engine over Place a wood block on the floor, and lay the cylinder block upside down on it. Note: Make sure that the positioning pins on the cylinder block do not come in contact with the wood block. (26)Removing the oil pan and spacer Remove the oil pan and spacer. (27)Removing the connection rod big end cap 1) Loosen the rod bolts and remove the big end cap. 2) Tum the crankshaft and remove the big end cap for each cylinder. (28)Remove the lube oil pump (29) Loosening the main bearing bolts 1) Loosen the main bearing bolts and remove the main bearing bolts. 2) Remove the main bearing cap and lower main bearing metal Note The thrust metal (lower) is mounted to the base main bearing cap. (30)Removing the crankshaft Remove the crankshaft Note: 1. The thrust metal (upper) is mounted to the standard main bearing, 2. Remove the main bearing metal (upper) from, the cylinder block, (31) Removing the connecting rod & piston assy 1724. Disassembly and reassembly 4.3.2 Reassembly + Clean all parts Clean all parts using by the cloth and diesel oil (or cleaning agent) before reassembly. Note: 1. If the dust remain with the parts, engine may cause the seizing or damage. 2. The cleaning agent removes even carbon adhering to disassembled parts. (1) Cylinder block Completely clean each oil hole. After cleaning, check that no scaling remains on cylinder block. Place a wood block on the floor and put the cylinder block upside down (with the cylinder head mounting surface facing down). (2) Inserting the tappets Check that each tappet is fitted to appropriate cylinder and valve (exhaust or intake) Before fitting, apply engine oll to each tappet. After fitting, check that each tappet operates smoothly. (3) Fitting piston cooling nozzle Fit each piston cooling nozzle. Check that nozzle end is positioned on piston head side. Also check that nozzle does not touch cylinder block. Tightening torque: 19.6N+m (2.0kgf+m) 173 Cylinder block, (Piston cooling nozzle)4, Disassembly and reassembly (4) Fitting cam shaft bearing 1) Fit each cam shaft bearing as follows: a) Apply lube oil to outer surface of each bearing and fitting area of cylinder block, and then press-fit metal into its position using driving tool. Check the position of each oil hole. More than 2/3 area of a hole should be aligned. Anti-flywheel side: A=2 Intermediate position: A=1.5 Flywheel side: A=0.5 b) After press-fitting, check each bearing for distortion by measuring inner diameter of bearing. mm Inner diameter after press-fiting | _57+0.05/-0.02 Note: To remove cam shaft bearing 1) Attach plate to cam shaft bearing, and tap off bearing using copper hammer. 2) Completely clean each bearing hole on cylinder block before press-fitting each bearing (5) Mounting the crankshaft 1) Apply engine oil fo each crank journal hole of cylinder block and each block side main bearing Bearings having an oil groove should be positioned on upper side (block side). Fit thrust metal so that oil grooves are respectively positioned outside 2) Apply engine oil to each crank pin and crank journal, and fit each journal to main bearing 3) Fitting bearing caps @) Apply engine oil to both surfaces of each cap side main bearing, and then fit each main bearing to the cap. b) Apply lube oil to bolt holes of each bearing cap. Fit each bearing cap to each joumal of crankshaft, and apply the specified torque to tighten each bearing cap bolt. Check that each bolt is equally tightened ‘Bearing cap bolt (M15, 14 bolts) tightening torque 235210Nem (24:1kgfm) 174 Bearing QS = omaoner UO ; of (Fitting of upper bearings)4. Disassembly and reassembly (Fitting of bearing cap) ssa oe Note: Check that the arrow marked on each bearing cap faces flywheel direction, and the match mark on each cylinder is correctly aligned. 1754, Disassembly and reassembly ©) Check that crankshaft rotates smoothly. d) Set a dial indicator on the cylinder block and measure side clearance of crankshaft Set cial ingicator mm ‘Side clearance of crankshaft | 0.132-0.223 (6) Fitting lube oil pump 1) Fit lube oil pump idle gear and shaft to main bearing cap. Side clearance 0.40 0.30 mm : 64=2Nm Tightening torque (65202 Kgem (Fitting of lube oil pump idle gear) su... 2) Fit lube oil pump while adjusting the position of positioning pin, Secure pump by tightening 3 bolts of M10 x 55 mm. 3) Measure gear backlash between lube oil pump and idle gear, and check that backlash satisfies value specified below: Gear backlash 0.12 20.04 mm. Lube oi pump. oe (Fitting of ube olf pump) asus 1764. Disassembly and reassembly (7) Gear case Apply liquid gasket to gear case, and then fit gear case to cylinder body while adjusting position of dowel pin Secure gear case by tightening bolt listed below: 1. MB x 45 mm bolt...... 4 pes. 2. M8 x 80 mm bolts... 2 pes. (8) Camshaft 1) Apply lube oil to bearing of camshaft, and then fit camshaft 2) Fit thrust plate, and secure it by tightening 2 bolts of MB x 16 mm mm Side clearance 0.05-0.20 Note: If cam gear is removed from camshaft, fit thrust metal before fitting gear. Heat cam gear to between 180 °C and 200 °C, and then press-fit it Interference: 0.023 to 0.060 mm. (Fitting of camshaft) (9) Piston assembly 1) Fit connecting rod to each piston while = Fualijocton checking direction of piston. (See the right = Sy pump side camsnan (( C=) ) ) figure.) on Note FW" mark Coat engine lube oil on piston pin and insert it into piston if it is hard to insert piston pin into piston. 2) Fit piston rings and oil ring to each piston while checking that cutouts of rings are offset 120° from each other. 3) Apply engine oil to sleeve, outer surface of piston, and rod metal. 4) Adjust crankshaft pin of corresponding piston to top position. 5) Check direction of piston. 6) Insert piston into cylinder using piston insertion tool 7) After insertion, remove tool Then rotate crankshaft by pressing piston edge using hammer until piston reaches bottom dead center. 8) Install cap on big end while checking match marks, and then tighten rod bolts. Before tightening rod bolts, apply lube oil to bolt bearing surface. Note: Selectively fit each piston and sleeve. 174, Disassembly and reassembly (10) Oil pan spacer Apply liquid gasket to oil pan spacer, and then fit spacer, Secure spacer by tightening 2 bolts of M8 x 35mm and 2 bolts of MB x 30mm, (11) Lube oil intake pipe and delivery pipe 1) Fit lube oil delivery pipe first, and then intake pipe. ‘Secure delivery and intake pipes by tightening bolts listed below: MB x 25 mm, 2 bolts MB x 16 mm, 2 bolts 2) Insert other end of lube oil delivery pipe into oil pan spacer. ‘Secure pipe by tightening bolts of MB x 25 mm. (12) Oil pan Apply liquid gasket to oil pan, and then fit oil pan. ‘Secure oil pan by tightening bolts listed below: MB x 25 mm, 4 bolts MB x 120 mm, 26 bolts MB x 190 mm, 2 bolts MB x 90 mm, 2 bolts (13) Oil seal (Flywheel housing) Insert the oil seal into the flywheel housing, (Use the special tool for insertion.) Grease the outer circumference of the lip portion of the oil seal. mm ‘Spigot joint runout of flywheel housing 028 1784. Disassembly and reassembly (14) Flywheel housing ; . Fit flywheel housing while adjusting position of 2 : parallel pins. Secure housing by tightening bolts listed below: 4, M10 x 30 mm, 9 bolts 2. M10 x 35 mm, 5 bolts (15) Seawater pump Fit seawater pump to gear case. Secure pump by tightening bolts and nuts listed below: M8 x 20 mm, 2 bolts MB, 2 nuts Goar case Cynder block \ seawater pump (Fitting of seawater pump) (16) Idle gear Mark positioned on top 1) Fit idle gear and shaft, and secure them by tightening 2 bolts of M8 x 25 mm, 7 2) Measure side clearance of idle gear, and /o SA check that clearance satisfies value specified O“% ere ce er a4, Disassembly and reassembly (17) Lube oil pressure regulating valve Fit lube oil pressure regulating valve assembly, and secure it by tightening bolts listed below: M8 x 45 mm, 3 bolts M8 x 50 mm, 1 bolt Lube oil pressure 0.45 + 0.050 MPa (at 3300min") (4.605 kghom?) Lube oi prossure regulating valve (Fitting of regulating valve) sso. n» (18) Cooling water passage cover Apply liquid gasket to cooling water passage cover, and then fit cover. eres eencarmmcned (19) Fuel injection pump 1) Before assembling a fuel injection pump gear, keep the crankshaft at 20° before ; compression top dead center of the No.6 oylinder. [NOTICE] Be careful not to adjust a crankshaft to exhaust stroke. The exhaust and intake valves don't move during compression stroke. farking-off ine of gear case cover Marking-ot ine of pulley et 1804. Disassembly and reassembly 2) While adjusting the mark (0) of the fuel injection pump gear and mark (B) of the idle gear, insert the pump gear to the timer flange. At29° before top dead center Refer to 6.1.5. (20) Flywheel Fit the flywheel while adjusting the position of dowel pin. It is convenient to use 2 bolts of M10 x 1.5 for lifting the flywheel. Apply engine oil to thread and flange of bolt. Secure flywheel by tightening 6 bolts of M16 x 47 mm. The tightening order of 6 bolts is shown in right figure. 294 = 10Nem Tightening torque G02 1 kgtm) (21) Cylinder head assembly 1) Correctly fit head gasket Thickness t= 1.3 mm Check that each positioning pin is properly inserted into pin hole. 2) Fit cylinder head, into which intake / exhaust valves were assembled, to cylinder block while checking that each positioning pin is properly inserted into pin hole. 3) Apply lube oil to thread and flange of bolt. + Sequentially tighten bolts in order of ascending number. * Loosely tighten bolts twice, and then finally tighten them Note: 1. The total length of the head bolts for operation side is different from those for non 8 s operation side. = : M14-139mm (13 pes.)...... Operation side 3 8 M14-149mm (13 pes)... Non operation side a 5 2. Be careful because the tightening torque = ° differs in the new bolts and the used bolts. Operating side Nem (kafemm) 1%time | 2° time | 3° time 108 167 | 206210 Used bots | ay a | ete [18 177 | 226210 New bots | azo) | 80) | @321) 1814, Disassembly and reassembly 4) Measure the top clearance by using fuse wire. Refer to 5.2.7, Note: 1. Check that cylinder head surface fitting fon cylinder block is clean. Also check inside of each cylinder for dust, dirt, and 0 on. 2. Head identification No. is marked on upper surface on flywheel side.4. Disassembly and reassembly (25) Push rod and rocker arm shaft assembly 41) Check condition of each push rod. If there is 1no abnormality, properly fit push rod to tappet. 2) Fit rocker arm shaft assembly. Do not forget to fit valve cap. Secure rocker arm tightening bolts and nuts shaft assembly by Rocker arm shaft support tightening torque (M8) 26 +3Nem (2.6 + 0.3 kgf) 3) Measure valve clearances, and check that they satisfy values specified below: (at normal temperature) Refer to 2,2.4(2) for the procedure. Valve Tnlake valve [0220.05 mm Clearance Exhaust valve [0.5 = 0.05mm After adjusting valve clearances, apply lube oil to each rocker arm (both sides of valve and push rod), and then fit rocker arm cover, 4) Fit rocker arm cover, and secure it by tightening 10 bolts of M8 x 25 mm. 5) Fit liting eye bolts to gear and flywheel sides of rocker arm cover, (26) Fresh water pump 1) Apply liquid gasket to both sides of gasket. 2) Fit fresh water pump to fitting surface on cylinder head. Then secure pump by tightening bolts, Note: Before tightening bolts, attach O-ring to area connected to cooling water passage cover. 183 Exhaust rocker arm ' & Pace ma nan (Rocker arm shaft assembly) Packing, Thermostat \, From cylinder head From coolant tank Gasket To cylinder boty o-ring, Flange Frosh wator pump assy4, Disassembly and reassembly (27) Gear case cover 1) Apply liquid gasket to gear case, and then fit gear case cover to gear case while adjusting Position of 2 parallel pins, 2) Tighten gear case cover with bolts listed below. 1. MB x 45 mm (washer based boll)... 9 pcs. 2. M8 x 80mm (washer based bolt).... 5 pes. (28) Crank V-pulley and damper 4) Fit crank V-pulley, and secure it by tightening crank pulley bolt. Crank pulley bolt (M16) 226 +10 Nem tightening torque (23 + tkafm) Note: While fitting crank pulley, take care not to attach dust or dirt to tapered area of crankshaft and tapered hole of V-pulley. 2) When fitting viscous-type dampers for crank shaft and fuel injection pump, position the caution labels on the viscous dampers outside, Tighten bolts for dampers. 184 (Crank Vepulley) usu ‘Damper (Crank shaft) ‘Damper (Fuel injection pump)4. Disassembly and reassembly (29) Fuel injection nozzle 1) Fit O-ring to fuel injection nozzle, and apply lube oil to outside of O-ring Note: Replace O-ring with new one every time when fuel injection nozzle is disassembled. 2) Insert nozzle seats into cylinder head and fit fuel injection nozzles to cylinder head, Note: Replace nozzle seal with new one every time when fuel injection nozzle is disassembled. 3) Apply lube oil to fuel nozzle retainer and fuel nozzle bolt (see the right figure). Fit retainer and bolt to fuel injection nozzle. Fasten the bolt by hand while shaking the retainer back and forth and making the position of the retainer be stable. Note: When fixing retainer to cylinder head, be careful to take the gap A in more than 1.5mm between retainer and intake rocker arm and the gap B in more than 1mm between fuel nozzle and retainer. 185 ~ Nozzle relainer — Fuel injection nozzle Lube of ~ Washer Retainer \ Intake rocker arm4, Disassembly and reassembly 4) Insert pipe seal for fuel injection pipe into cylinder head and connect fuel injection pipe to fuel nozzle. Tighten the fuel injection pipe nut. Tightening torque 24.542Nm (nozzle & pump sides) (25 +0.2kgfm) aS Fuel inoetion pipe nut 5) Finally tighten the retainer bolt for fuel injection nozzle to the specified torque. 31422Nm 8.2 0.2 kgfm) Tightening torque 1864. Disassembly and reassembly (30) Fresh water cooler 1) Apply silicone grease to two O-rings and fit the O-rings to both sides of cooler core and insert the core into cooler body. Flywheel side Goar case side ‘Separalar packing : Fresh water tank B77 ip suck Fresh water cooler ‘seawater pump Note: Align the cooler core notch with @2 hole of cooler body (see the right figure). 2) Fit separator packing to both side covers (gear case side & flywheel sides). (See the above figure.) Fit side covers to fresh water cooler. (31) Coolant tank (fresh water) 1) Fit rubber packing to thermostat and insert the thermostat to coolant tank. 1874, Disassembly and reassembly 2) Secure the coolant tank securely with bolts. (32) Lube oil cooler 1) Apply silicone grease to two O-rings and fit the O-rings to both sides of cooler core and insert the core into cooler body. Note: Align re-setting marks of cooler core and case 2) Fit separator packing to side cover of flywheel side. (See the right figure.) Fit side covers to lube oil cooler. 3) Fit lube oil cooler to engine. Note: After fitting intercooler and filter bracket to engine and tightening lube oil tube, fit lube oil cooler. (33) Lube oil filter 1) Apply lube oil to rubber packing of lube oil filters, 2) Install lube oil filter of full flow manually to filter bracket by tuming it clockwise until its tubber packing comes into contact with ‘mounting surface, and tighten it further to 3/4 of a tum with filter wrench. Install lube oil fiter of bypass manually to fiter bracket by tuming it clockwise unti its rubber packing comes into contact with mounting surface, and tighten it further to one tum with filter wrench 188 Flywhee! side Pour coolant ater, fasioning here Fitbrackets Tocyinder block ~~ (Cooler core Gear case side ‘Soparator packing ncsa-acn Lube of ter (Qu tow) Fiterbracket Lube olfiter (eypass)4. Disassembly and reassembly (34) Cooling water pipes 1) Fit bend A to fresh water cooler and joint the bend and seawater pump with hose. 2) Fit bend B to intercooler and joint intercooler and fresh water cooler with hose. 3) Apply hose clamps to seawater inlet & outlet of fresh water cooler and seawater inlet & outlet of lube oil cooler. Note: Apply two hose clamps to each four places shown in the right and below figures to prevent the pulling-out of hoses. Fresh water cooler Fresh water cooler _—- “Hay Intorcooter WS Z seawater pump Se (Seawater line) a Og Lib ot cooler 1894, Disassembly and reassembly (35) Air duct 1) Fitair duct to outlet of turbine by V-clamop. 2) Fit air duct to inlet of intercooler by hose and clamps. (36) Turbocharger 1) Install the turbocharger and the attached lube oil pipe. 2) Fit bracket A & bracket B (bridging) and fasten bolts lightly. Tighten bolts in order of 1,2,3 shown in the below figure. Turbocharger \ Mixing elbow Air silencor ‘Turbocharger: 1904. Disassembly and reassembly 3) Defat the silencer, turbocharger and inside of hose sufficiently. If oil is stuck on those parts, they may come off during engine running. Install the silencer and hose to the turbocharger and tighten hose bands to the specified torque. 320.5 Nem Tightening torque (0.3:0.05kghm) (37) Mixing elbow Install the mixing elbow to turbocharger. + Structure of exhaust outlet and V-Band (right figure) (38) Lube oil pipes for fuel injection pump Connect lube oil pipe to fuel injection pump. * Fit lube oil pipe A connected between pressure regulating valve, timer and fuel injection pump. Fit three steady braces to the places shown in the right figure. + Tighten overflow valve for both lube oil pipe A & Bat timer inlet + Apply seal washers to pipe joint bolts. 191 Detat ot ene Gasket Turbocharger A Tebig sbow ia det ea oe Steady brace & MB bolts vertiow valve4, Disassembly and reassembly (39) Alternator 1) Mount adjuster on the fresh water pump and install alternator. 2) Adjust V-belt tension with the adjuster, and tighten the adjuster bolt. (40) Starting motor Fit starting motor to fiywhee! housing, 192 Frosh water pup Adjustor bot \ : Deflation Veet e-10mm Aerator Push5. Inspection and servicing of basic engine parts 5. Inspection and servicing of basic engine parts 5.1 Cylinder block The cylinder block is a thin-skinned, (low-weight), short skirt type with rationally placed ribs. The side walls are shaped to maximize rigidity for strength and low noise. 5.1.1 Inspection of parts Make a visual inspection to check for cracks on engines that have frozen up, overtumed or otherwise been subjected to undue stress. Perform a color check on any portions that appear to be cracked, and replace the cylinder block if the crack is not repairable. 5.1.2 Cleaning of oil holes Clean all oil holes, making sure that none are clogged up and the blind plugs do not come off. Color check kit ‘Quantity Penetrant 1 Developer 2 Cleaner 3 193 Pug 65m / Pug 4omm Cf Plug 18 mm jeetomm Pug 40 mn —~ S @ Presse g Pg 25 mn \ \ ou rug 6mm 8 I |5._Inspection and servicing of basic engine parts 5.1.3 Color check procedure (1) Clean the area to be inspected (2) Color check kit The color check test kit consists of an aerosol cleaner, penetrant and developer. (3) Clean the area to be inspected with the cleaner. Either spray the cleaner on directly and wipe, or wipe the area with a cloth moistened with cleaner. (4) Spray on red penetrant After cleaning, spray on the red penetrant and allow 5~10 minutes for penetration. Spray on more red penetrant if it dries before it has been able to penetrate. (5) Spray on developer Remove any residual penetrant on the surface after the penetrant has penetrated, and spray on the surface after the penetrant has penetrated, and spray on the developer. If there are any cracks in the surface, red dots or a red line will appear several minutes after the developer dries. Hold the developer 300~400mm away from the area the surface uniformly. (©) Clean the surface with the cleaner. Note: Without fail, read the instructions for the color check kit before use. 1945. Inspection and servicing of basic engine parts 5.1.4 Replacement of plugs Description Procedure Tool or material used 1 Remove the plug using by a screw | « Screw driver Cylinder block Hammes driver and hammer. +Hammer . Hit the plug by screw driver and Sy hammer tap lightly obliquely from the5._Inspection and servicing of basic engine parts 5.1.5 Cylinder bore measurement Especially clean head surface, cylinder bores and oll holes, and check the below items after removing any carbon deposit and bonding agent. (1) Appearance inspection Check if there is any discoloration or crack. Ifcrack is suspected, perform color check. Suficiently clean the oil holes and check they are not clogged. (2) Cylinder bore and distortion Measure at 20 mm below the crest of the liner, at 20 mm from the bottom end and at the center in two directions A and B as shown in the below figure. Direction A means crank shaft center line. Roundness Roundness is found as follows though it is the simple method, Measure cylinder diameters of the A direction and the B direction on each section of a, b and, Roundness is the maximum value among those difference values Cylindrcity Cylindricity is found as follows though it is the simple method. Measure cylinder diameters of a, b and c sections in the A direction, and calculate the difference in maximum value and minimum value of the measured diameters, In the same way measure and calculate the difference in the B direction. Cylindricity is the maximum value between those difference values mm tem ‘Standard Limit [Cylinder bore diameter] 105.900-105,930) 105.950 Cylinder roundness | 0.03 or less 5 [Cylindricity 0.02 or less = 196 { Measure into decors Ue 7, Rare tron neo F F20 mm (Cylinder bore measurement positions)5. Inspection and servicing of basic engine parts 5.2 Cylinder head The cylinder head is of 6-cylinder integral construction, mounted with 26 bolts. Special alloy stellite with superior resistance to heat and wear is fitted on the seats, and the area between the valves is cooled by the water jet Breather retum hose ‘Breather hose ‘rom gear case s Exhaust rocker arm Rocker arm spring Rocker arm shaft Intake rocker arm ef Bridge seat Coter—3, z Valve retainer Aw vawve sera) vate bao & Vavestemsesi—o © Rocker arn support 6 Gear dave side Exhaust valve: Intako vane 1975._Inspection and servicing of basic engine parts 5.2.1 Inspecting the cylinder head The cylinder head is subjected to very severe operating conditions with repeated high pressure, high temperature and cooling. Thoroughly remove all the carbon and dirt after disassembly and carefully inspect all parts. (A) Distortion of the combustion surface Carefully check for cylinder head distortion as this leads to gasket damage and compression leaks. 1) Clean the cylinder head surface. 2) Place a straight-edge along each of the four sides and each diagonal. Measure the clearance between the straight-edge and combustion surface with a feeler gauge. mm ‘Standard ‘Wear limit Cylinder head Siaaiee 0.05 or less 0.20 (2) Checking for cracks in the combustion surface Remove the fuel injection nozzle, intake and exhaust valve and clean the combustion surface. Check for discoloration or distortion and conduct a color check test to check for any cracks. (3) Checking the intake and exhaust valve seats Check the surface and width of the valve seats. If seat width is too wide, or if the surface is rough, correct to the following standards: Tntake 20° Seat angle Exhaust 90° Seat width| _ Standard Limit Intake 1071.24 | 1.74 Exhaust 124145 | 1.94 1985. Inspection and servicing of basic engine parts 5.2.2 Valve seat correction procedure The most common method for correcting unevenness of the seat surface with a seat grinder is as follows: (1) Use a seat grinder to make the surface even, As the valve seat width will be enlarged, first use a 70° grinder, then grind the seat to the standard dimension 45° by using the seat grinder with a 15° chanfer. Intake valve 45 deg 45 deg Seat angle 6 Exhaust valve Note: When seat adjustment is necessary, be sure to check the valve and valve guide. Ifthe clearance exceeds the tolerance, replace the valve or the valve guide, and then grind the seat, (2) Knead valve compound with oil and finish the valve seat with a lapping tool Lapping tool Use a rubber cap type lapping tool for valves without a lapping tool groove slit. 199 £4