DAIHATSU F73,F78 (F70, F75, F77) ENGINE MECHANICAL PRECAUTIONS .. TROUBLE SHOOTING .. EM- 3 ENGINE MAIN SPECIFICATIONS ... EM 5 ENGINE OUTLINE ENGINE TUNE-UP CYLINDER HEAD .. TIMING BELT COVER AND CASE PISTON AND CONNECTING ROD .. REMOVAL OF ENGINE ASSY INSPECTION OF COMPONENT: POSITIVE CRANKCASE VENTILATION (PCV) ... TURBO CHARGER SYSTEM POWER CONTROL SYSTEM . SST reese M73 EM-75 TIGHTENING TORQUE —M-77 ENGINE SERVICE SPECIFICATION ........ EM-79 THE ENGINE PROPER ‘SPECIFICATIONS .. EM-81 In the sections bearing “Kt” marks, the model codes “FTO, 75, 77" snould read as "F73 and F78" After checking the contents of the relevant sections of the F73, £78 manual, we found that the contents remeined the same. ‘Therefore, we are using the sections as they are inthis manual. NO. 9705ENGINE MECHANICAL PRECAUTIONS 1. Make sure that only the specified bolts and nuts are used. Also, where specified, be sure to employ a torque wrench to tighten bolts or nuts to specifications, 2. Use only genuine parts for every replacement operation. 3. Forincreased working efficiency and improved accuracy, utilized SSTs (Special Service Tools) effectively. 4. When both front and rear parts of the vehicle or only the rear part thereof is jacked up, make certain to place chocks at the wheels correctly in order to assure safe operations. 5. When the motor vehicle is jacked up, make sure to support the vehicle with safety stands positions at the specified jacking points. 8. Before any repair work is make on the electrical system or the en sure to disconnect the negative © terminal of the battery. 7. Disassembly. (1) When complicated parts are disassembled, put stamped marks or marks on suitable nonfunctional sections of the parts in order that the said parts may be easily assembled in the correct original positions. (2) Replacements of the cylinder block or crankshaft, ete should be carried out after the engine assembly has been removed from the motor vehicle. 8. Checks to the performed during disassembly. Each time a parts is removed, check conditions under which the part has been assembied. Also, check to see if the part exhibits any evidence of distortion, breakage, wear or scores, etc. 9. Arrangement of disassembled parts. Put disassembled parts in a good order. Moreover, divide disassembled parts into two groups: those parts to be replaced and those parts which can be reused. 10. Washing disassembled parts. As for those parts which can be reused, thoroughly clean or wash them, 11. Inspection and measurement. Those parts which are to be reused must be carefully inspected or measured, as required. 12. Assembly of parts. ‘Those satisfactory parts only should be assembled in accordance with the prescribed standards (e.g. specified adjustment values., tightening torque and so forth.) Furthermore, seal packing or grease should be applied, as required, Furthermore, in respect to packings, gaskets, cotter pins and similar items, be certain to install new parts. 18. Adjustments and checking of service operations, Service operations must be carried out correctly by means of gauges or testers, if the use of these instruments is required. ine is removed or Installed, first be stn EM2ENGINE MECHANICAL TROUBLE SHOOTING Problem, I Possibi2 cases Remedies Page Engine overnoat ‘Coalng system facty Trouble shost cooing system | Fuel system fauity Trouble shoot fuel system. Lubscation system faulty “rovble shoot lubrication system. Engine will not erank or crank | Starting system “Trouble shoot starting system. eon | Charging sysiem ‘Trouble shoot charging system. Engine wil not starflare 1 ear | Preheating device problem sree (Only cases where cranting by | Starter motor is normal} [+ Glow ptug Inspect glow plug. | + Glow ptug connector Inspect glow plug connector. | '*, Glow plug current sensor Inspect glow plug current sensor, Novel sumer Check fuel tank and fuel tne, Fus + Fuel tank + Fuel pipe + Foal fter «Injection pamp Inspect injection pump. | injection problem rua | Injection timing Reset injection ting, | + Injection nozzie (Check injection nozzle. | + injection ppe Rough idlerEngine stais | tecorest vale Gearance “Adjust valve clearance. EWR10 | inoorrect iste peed ‘Adjust idle speed. EM-13 Incorrect injoetion timing Reset injection ting, EMA Low compression ‘Check compression. M13 Fue! leakage (Check fue! tne rus + Injection ppe ‘Injection nozzle | + Setvery te | Turbo charger problem Ingpect turbo charger. M64 [ttiection pume probier Inspect injection pump. Fuss Lock of power | Full leakage ‘Check fuel five. FU-3 + Injection ppe Injection nezaie + Delivery vetve Incorect injection timing Reset injection timing) Event Turbo charger problem ‘Check turbo charger. EMA64 + Waste gate + Boost compensator ‘© Turbo chaiging pressure Injection pup problem Inspect injection pump. [rus EM-3ENGINE MECHANICAL ENGINE OUTLINE ra DL Engine Type DL engine is a water-cooled; 4-oylinder-inline diesel engine with a total displacement of 2765'cc. The DL engine comes in two types: One is the DL-42 (natural aspiration engine) type and the other is the DL-S2 (turbo charged engine) type. On the DL-52 engine, an air-cooled intercooler has been newly provided 80 as to increase the engine power. Moreover, for improved durability and reliability, the turbo charger employs a water-cooled type. ENGINE SECTIONAL VIEW DL-42 Engino] EM-6ENGINE MECHANICAL foubua zai EM-7ENGINE MECHANICAL ENGINE TUNE-UP 1. Inspection of engine coolant level (See page CO-7,) 2. Inspection of engine cil level 3. Inspection of air cleaner fitter element (1) Disconnect the air cleaner cap by loosen the three clamps. (2) Loosen the wing bolt retaining the element. Take out the element from the air cleaner element. (8) Visually inspect that the air filter element is not exces- sively dirty, damaged or oily. Replace the air filter element, if necessary. EM-8 aaa aoENGINE MECHANICAL (4) Clean the element with compréssed air. First, blow compressed air from irner side of the ele- ment thoroughly. ‘Then, blow off the outer side of the element. CAUTION: © The air pressure to be used this cleaning operation should not exceed 392. kPa (4.0 kef/em’). Replace the air filter element, if necessary. (6) Place the element in the air cleane- case. Secure the element with the wing rut. (6) Install the air cleaner cap to the air cleaner case. Secure the air cieaner cap by tightening the three clamps. 4. Inspection of battery (See the charging system section.) 5. Inspection of valve clearance (1) Warm up the engine completely (2) Remove the cylinder head cover by loosen the four attaching nuts. M9 Tae TRSENGINE MECHANICAL (3) Turn “the crankshaft until the recessed mark on crankshaft pulley is aligned with the indicator mark on timing gear cover. (4) Check to see if valve rocker arms of No. 1 cylinder are ree or are being push up. _ 4A According to the flowing table, check and/or adjust the valve clearance, using a thickness gauge. P| Valve Clearances (Hot condition) . por ‘DL-42 ‘DL-S2 Type Take ‘omy | 0252005 | 0252005 Exhaust (mm) | 0.2520.05 0.25 + 0.05, Tightening Torque: 19.6 - 24.5 Nm (2.0 - 25 kgf-m) ‘The “O” marks denote those valves that can be adjusted under that setting. finder errerert ee | eer e | eer era ea Rocker arm condition ‘When valve rocker arms of No. 1 Gyinder are free wl olo (Piston of No. 1 cylinder is at top dead center uncer compression stroke) [| EX | _O ° ‘When valve rocker arms of No. 4 eyinder are free: N I ofo (Piston of No.4 oylinder ist top dead center under compression stroke) [EX i) ° wero NOTE: + Before the adjusting bolts are tightened, apply engine oil to the lock nuts and rocker arm adjusting bolts. (6) Tum the crankshaft 360-degrees. Proceed to check andjor adjust the remaining valve clearance. EM-10(€) Wipe off the oil or dirt from the gasket surface of the cylinder head. (7) Install the cylinder head cover on the cylinder head. (8) Tighten the cylinder head cover nuts over two or three stages in sequence, unti they tightened to the specified torque. Tightening Torque: 54+ 7.5 Nm (0.55 = 0.15 kgl-m) Check and adjustment of injection timing 1. Remove the distributive head bolts on tne injection pump. Then, install the SST and set a dial gauge. SST: 09275-54010-000 NOTE: * Since there is a hole-shaped notch at the end of the plunger, the measuring pin of the dial gauge must con- ‘act the flat section of the plunger. + Make sure that no dust gets into the pump. 2. Release automatic cold starting system (ACSD eauipped vehicle only) (1) Turn the ‘automatic cold starting lever counterclockwise about 20° degree, using a screwdriver. (2) Put © metal plate 8.0 - 10.0 mm thick between the automatic cold starting lever and thermo wax plunger. 3. Align the top dead center mark on the crankshaft pulley with the top. dead center of the'No. 1 oylinder under the com- pression stroke. Then, back off crankshaft approx. 45° and align the pointer of the dial gauge with the zero position NOT! ‘+ Atthis time, tum slightly the crankshaft pulley to the right and left sides and make sure that the pointer is stable at the zero position. EMA ENGINE MECHANICAL TEE rt SO)ENGINE MECHANICAL 4, Tum the crankshaft in the normal direction and take the reading of the dial gauge when the top dead center mark on the pulley is aligned with the pointer. 1.07 - 1.13 mm Specified Valu (Injection Timing BTDC 1°) NOTE: + The gauge's reading of + 0.03 mm corresponds to the injection timing of + 0.5°. §.- Slacken the attaching sections of the’ ‘injection pump proper at the following points given below. Adjust the injection timing by moving the pump proper. * Injection pump attaching nuts Section A * Lower bracket attaching bolt Section B ‘+ Attaching nut of each high-pressure pipe (union nut) .. Section C 6. Perforrn the injection timing check again and ensure that the injection timing is proper. 7. When the injection timing is adjusted, make sure that the injection pump is in a pulled state toward you. If the injec- tion timing is adjusted with the injection pump in a pushed state toward the engine block side, the timing may be retarded. Tightening Torque: 18.1 + 3.4 Nm (1.85 + 0.35 kgf-m) NOTE: * Replace the copper washer the distributive head bolt with a new one. EM-12 ‘Approx. BIDCEG TDC — Species pe, Pump attaching?” Bi toward you en RS pun atachng ! l bot TS Within the ® ‘Specitied value L ne & —> Push towers the |G Deut toward block side odENGINE MECHANICAL Measurement of compression pressure 1. Warm up the engine 2. Remove all the glow plugs. 3. Position the attachment into the installation hole of the glow plug. Set the compression gauge in place. 4. With the throttle valve opened fully, crank the engine, using the starter 5. Cranking speed: 250 rpm Compression Pressure: STD 3138 kPa (32 kgt/cr) Limit 2158 kPa (22 kgticm*) Variation Between Cylinders: 196 kPa (2.0 kgficm’) Adjustment of idling speed 7. Warm up the engine. 2. Measure the idling speed. 38. Adjust the idling speed by tuming the idling adjusting bolt Specified Idling Speed: 650 + 25 pm EM-413 ‘Attachment Cy rao lolle set screw (01-43) Tae Seng ScrewENGINE MECHANICAL fouamen of maximum no-load revolution speed Fully when the accelerator pedal is depressed to the fullest extent. 2. Measure the maximum revolution speed at the time when the venturi opens fully because of the fully-depressed ac- celerator pedal. ‘Specified Maximum Revolution Speed: DL-42: 4500 rpm DLS2: 4500 mpm 3. Adjust the maximum no-load revolution speed by turning the maximum speed set screw. EM-14 Maximumt speed setting screw (01-82) odENGINE MECHANICAL CYLINDER HEAD COMPONENTS | TT 196228 Traen10 (2003) Valve rocker spon 8 va stra @ vate roe shat ® Oyiinger head bot © Gyiinder head © Gyinder head gasket @ Valve spring retainer lock © Vawve spring rexainer ae T1177 #98 (12,002 1.00) ® Compression soring @ Vatve stom ci seal ® Valve (XIN) Vatve quite buen ® Combustion chamber © Oylinder head cover Cylinder head cover gasket ® OF fler cap @ Valve stom cap + Nonreusable part + Tightening torque Unit? Nong) EM-15ENGINE MECHANICAL REMOVAL OF CYLINDER HEAD 1. Removal of battery (4) Disconnect the battery ground cable from the negative © terminal of battery (2) Remove the battery from the engine compertment by removing the battery holding clamp. 2. Removal of air cleaner assembly (1) Remove the air intake duct by loosen three attaching bolt and a clamp. (2) Remove the clutch cable attaching bolt at air cleaner case. (8) Remove the intake air pipe attaching bolt at air cleaner case. (4) Remove the air cleaner case by loosen two air cleaner bracket attaching nuts-and the air cleaner attaching bolt. 3. Drain the coolant. 4, Removal turbo charger. (See Turbo Charger System section) EM-6ENGINE MECHANICAL 5. Remove the water hoses. * Water outlet hose Water by-pass hose Heater hoses ‘Turbo charger cooling hose (DL-S2 engine only) ACSD water hose.(ACSD equipped vehicle only) 6. Remove water outlet housing. ~ 7. Remove the glow plug connector and glow plug. 8. Remove the accelerator cable from the injection pump. 9. "Removal of injection nozzle, using SST. (See page FU-14.) ‘SST: 09268-87310-000 NOTE: + Arrange the injection nozzie in order. EM-17 FETSENGINE MECHANICAL 10. Remove the cylinder head cor 11. Remove the vaive rocker-shaft with valve rocker arm by loosen valve rocker support bolts in sight figure. 12. Remove the push rods. NOTE: * Remove the parts in the sequence of cylinders. Store the removed parts properly so that they may not be mixed with each other. 13. Remove the cylinder head by loosen cylinder head bolts in right figure. 14. Remove the valve spring retainer lock and valve spring, using SST. SST: 09202-87001-000 15. Pull out the valve stem cil seal using pliers. NOTE: + Store the removed springs and valves in correct se- quence so that they may be installed in their original Positions on reassembly. EM-418 2 tO T oe oo 26 4 9 7 4 eRe WLLL SSeSoe ee TaeENGINE MECHANICAL 16. Removal of combustion chamber Drive out the combustion chamber by instaring an about 4 mm dia fod through the glow plug installation hole. INSPECTION OF CYLINDER HEAD 1. Cleaning of cylinder head (1) Remove any remaining gasket material from the cylinder head and manifold surfaces by using a gasket scraper. (2) Remove all carbon deposits from the combustion cham- bers by using a wire brush. CAUTION: + Be careful not to scratch the cylinder head gasket con- tact surfaces. (3) Clean all valve guide bushings by using valve guide brush and solvent. Using @ precision’ straight eage and thickness gauge, check the gasket surfaces contacting the cylinder block and manifolds for warpage Maximum Surface Warpage: Cylinder Block Side: 0.10 mm Intake Exhaust Manifold Side: 0.20 mm Replace the cylinder head, if surface warpage of the cylinder block side exceeds the maximum limit. EN-19 S= Cet “Manifold gasket surface WASTEENGINE MECHANICAL SSS 3. Inspection of valve stem-to-guide bush oil clearance (1) Using a caliper gauge, measure the inner diameter of the valve guide at six points. Record the measured values. Specified Value: IN: 9.010 - 9.030 mm EX: 9.010 -9.030 mm (2) Using a micrometer, measure the diameter of the valve stem at six points. Record the measured values. Specified Val IN: 8.968 - 8.984 mm EX: 8.934 - 8.950 mm (8) Calculate the valve stem-to-guide bush oil clearance from the measured results in the steps (1) and (2) above. a: Measured maximum value of guide bush b: Measured minimum value of valve stem a@=b = Oil clearance Oil Clearance: Specified Value: IN: 0.026 - 0.062 mm EX: 0.044 = 0.096 mm Allowable Limit: IN: 0.10 mm EX: 0.12mm 4, Inspection of intake and exhaust valve (1) Visually inspect the vaive stem for seizure or damage. NOTE: + If seizure or damage is found, replace the valve and valve guide bush a set. However, this. replacement should be performed only after the checks for the cylinder head have been finished. EM-20 wrens‘+ The valve guide bush hole must be used for refacing only valve seat. Hence , if the valve guide bush hole exhibits any rough- ness due to seizure, etc., rectify the hole with an adjus- table reamer. (2) Visually inspect the valve head for melting and damage. If the valve head exhibits any melting or damage, replace the valve. if the roughness on the contact surface can be cor- rected, grind the valve seat contact surface with a valve refacer. (8) Visually inspect the valve stem enc for abnormal wear. If the Valve stem end exhibits anormal wear, correct the stem end with valve refacer. However, this correction should be made within a limit from that of standard length. Standard Length: IN: 127.5 mm 127.5 mm Refacing of valve seats @® Apply 2 film of red iead to the valve seat. Then, let the valve drop on to the valve seat two or three times by its own weight. Care must be exercised not to tum the valve during this check. Specified Seat Width: 1.4 mm (0.055 inch) ® Cut the seat surface, using a 45-degree cutter. EM21 ENGINE MECHANICAL res ov0se | | Meting oF -4 Wear, { | We 14mm F¥ (6.088 inch)ENGINE MECHANICAL 5. Correction of seat position (1) If the seat position is too high, reface the valve seat, using 45-degree and 75-degree cutters. These valve seat cutters should be employed in the sequence as indicated by the illustration. (2) If the seat position is to 1ow, refaice the valve seat, using 45-degree and 15-degree cutters. These valve seat cut- ters should be employed in the sequence as indicated by the illustration. (8) After the valve seats havé been refaced, carry out hand grinding of the valves, using valve grinding compound. 6. Inspection of valve spring (1) Check the valve spring for squareness, using a steel square. Maximum Squareness: 1.6 mm If the squareness exceed the maximum limit, replace the valve spring. (2) Measure the valve spring for free length and spring tension, using a spring tester. inimum Free Length: 48 mm Minimum Tension Installation Height: 264.8 N (27.0 kgf/40.1 mm !f minimum free length andjor minimum tension is less than the minimum limit, replace the vaive spring. EM-22 TREENGINE MECHANICAL 7. Inspection of valve rocker arm and valve rocker shaft (1) Visually inspect the valve rocker armr for cracks, seizure or wear. Replace the valve rocker arm, if necessary. (2) Visually inspect the valve rocker shaft for cracks, seizure or wear. Replace the valve rocker shaft, if necessary. (3) Check valve rocker shait-to valve rocker arm ® Using a dial gauge, measure the inner diameter of the valve rocker arm in two directions, 90 degrees apart from each other Specified Value: 18.512 - 18.533 mm. ® Using a micrometer, measure tre outer diameter of valve rocker shaft Specified Value: 18.472 - 18.493 mm Oil Clearance: 0.022 - 0.733 mm Limit: 0.1 mm 8. Inspection of combustion ‘chamber (1) Visually inspect the combustion chamber for cracks or damage EM-23 restoreENGINE MECHANICAL 9. Inspection of intake and exhaust manifolds Using @ precision straight edge and thickness gauge, check the manifold gasket surface for warpage. INSTALLATION OF CYLINDER HEAD NOTE: + Prior to assembly, be certain to apply engine oil to the rotary sections or sliding sections of the parts. 1. Install combustion chamber into cylinder head. Using a plastic hammer, drive the combustion chamber into position, making sure that the mate mark of the combustion chamber is aligned with that on the cylinder head side. 2. Measure the chamber projection height. ‘Specified Projection Height: 0 - 0.10 mm 3. Install the oil seal, using the following SST. SST: 09201-87702-000 NOTE: ‘© Once the valve has been removed, be sure to install new valve stem cil seal. * Be sure to apply engine cil to the lip section of the oil seal. EM-24 reso Mate mark wa — 09201-8702ENGINE MECHANICAL Assemble the parts given below, using the following SST. SST: 09202-87001-000 (1) Valve (2) Valve spring (8) Valve spring retainer (4) Valve spring retainer lock Install the cylinder head gasket with its “Top” mark facing upward. NOTE: * If the cylinder head gasket should be installed upside ‘down, it would cause the oll passages to be clogged, thereby causing engine seizure. + Be sure to replace the gasket with z new one. Install the cylinder head. (1) Apply engine cil to the threaded portion and seating ‘surface of each bolt. (2) Tighten the cylinder head bolts progressively in the ‘sequence as indicated by the illustration. Tightening Torque: 117.7 9.8 Nm (12.0 £ 1.0 kgt-m) Install the push rods. NOTE: * > Those valve push rods which have been stored inorder should be installed as a set to the original cylinder, respectively. EM-25ENGINE MECHANICAL 8. Installation of valve rocker shaft (1) Each of valve rocker arms and valve rocker supports bears an identification mark. They shouid be assembled as indicated in the right figure. Every valve rocker support is provided with a boss for identification purpose. The valve rocker support should be assembled in such a way the boss comes at the left side as viewed from the engine front side. (2) As for the tightening of the valve rocker supports, first apply engine oil to the threaded portion and seating surface of each bolt. Then, tighten the attaching bolts progressively as indicated in the right fi 9. ‘Initial setting of valve clearance IN: 0,30 mm [COLD] EX: 0.30 mm [COLD] NOTE: * After the engine has been assembled to the body, be sure to adjust the valve clearances again. * As for the adjusting procedure, see the section under "Valve Clearances”. 10. Install the intake and exhaust manifolds. Tightening Torque: Intake Manifold: 36.8 + 7.4 N-m (8.75 + 0.75 kgf-m) Exhaust Manifold: 46.6 + 7.4 N-m (4.75 + 0.75 kgf-m) NOTE: * Be sure to replace the gaskets with new ones. * On the turbo charged vehicle, be sure to install the turbo charger to the exhaust manifold before installing the exhaust manifold to the cylinder head. (See the section under “Turbo Charger system.") EM-26 No2 “No2 No2 No2 aoe Identification number| Boss or identicaton purpose | / Nozzle sice Identification number wera = Front of engine TBR,11. 12. 13. 14, 15. 16. 17. 18. install the water hoses. Water outlet hose Water by-pass hose Heater hoses Turbo charger cooling hose (DL. 52 engine only) ACSD water hose (ACSD equiped vehicle only) Install the injection nozzle seat in the direction as indicated in the right figure. NOTE: * Be sure to check the gasket before installing the nozzle holder. Install the injection nozzle. ‘SST: 09268-87310-000 Tightening Torque: 68.6 + 9.8 Nm (7.00 + 1.00 kgf-m) Install the injection pipe. Injection Pipe: Tightening Torque: 24.5 + 4.9 Nn (2.50 + 0.50 kgf-m) Install the glow plug connector and glow plug. Install the cylinder head cover. Install the water outlet housing, NOTE: + Be sure to replace the gasket with a new one. Install the water by-pass hose. EM-27 ENGINE MECHANICALENGINE MECHANICAL 19. 20. 21. 22. 24, 25. Fill the cootant. Fill the engine oil and check it. Install the battery in the engine compartment. Connect the battery ground cable to negative (-) terminal of battery. Install the engine hood. ‘Start the engine. Check the oil leakage and repair it. EM-28 wre. ev009ENGINE MECHANICAL TIMING BELT COVER AND CASE COMPONENTS General ‘specification A 128229 (1.30 + 0.30)} @ Timing batt cover @ Timing belt case Timing belt case gasket G Ventiation tube 2: Nonrousable part T_ = Tightening torque Unit: Nem (kgm) Tare EM-29ENGINE MECHANICAL REMOVAL OF TIMING BELT AND PULLEY 4. Remove the cco! air intake duct from air cleaner. 2. Remove the reserve-tank. 8. Temporary remove the fluid coupling with fan by loosen four nuts. 4. Remove the fan shroud and the fluid coupling withe fan. »._ Loosen the alternator attaching bolt.’ . Remove the fan pulley and V-belt. oe Remove the glow plug No. 1. Before pulling out the crankshaft pulley, position the piston No. 1 at the top dead center under the compression stroke. en 9. Remove the crankshaft pulley. NOTE: + Place the gear shift lever in the 5-th gear position so as to prevent the rotation of crankshaft. EM-30ENGINE MECHANICAL 40. Remove the timing belt cover 41. Slacken the timing belt tensioner. 12.~Mark the rotation direction on the back side of the timing ‘belt. Then, remove the timing belt. 18. Remove the crankshaft timing belt pulley, using the follow- ing SST in combination with M6 bolts. SST: 09213-31021-000 (M6 bolt) 14, Remove the timing belt tensioner and timing belt idler No. 2 TSR 15. Remove the injection timing belt pulley. SST: 08950-20017-000 TA EM-31ENGINE MECHANICAL, 16. Remove the valve lifters. NOTE: ‘+ Store the valve lifters in order. 17. Remove the camshaft timing belt pulley with camshaft. INSPECTION OF COMPONENTS, 1, Timing belt inspection CAUTION: ‘+ Do not bend, twist or tum the belt inside out. ‘* Donotallow the belt to come into contact with oil, water or steam. + Keep the belt clean. If there are defects, as shown in the figurés, check the ‘following points and replace the timing belt, if necessary. (1) Premature separation Check for proper installation. — Check the timing gear cover gaskets for damage and check for correct instailation. (2) IF the belt teeth are cracked or damaged, check to see if the camshaft is seized. (3) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on one side of the idler Pulley lock. WaT rdENGINE MECHANICAL (4) If there is wear or damage on only one side of the belt, check the pulley flange. (5) If there is noticeable wear on the belt teeth, check the timing cover gasket for damage and check for correct gasket installation. Check for foreign material on the pulley teeth Timing Belt Specifications: Waa Sree yee! oy aasz Copco ter a igh peripheral igh (em | 10287 NP MI VSI Pitch (mm) 9.525 ‘oe et i Nuriber oeeh 708 Saane)eaaee Belt width (ram) 318 Bett thich (mm) 54 2. “Timing Belt tensioner inspection + Check the timing belt tensioner for smooth turning. + Check the belt contact surface for damage. i necessary, replace the timing belt tensioner. CAUTION: * Never wash the timing belt tensioner. 3... Inspection of timing belt pulley. (1) Measure the maximum diameter of timing belt pulley, using vernier calipers. ‘Specified Value: ttem| Ourer | Pulley dame] ia | Neer Component (mr) | (mm) ‘Crankshaft timing puliey 507 | 33 20 Carat ing ply Te es | #8 iseion pur poly Tear | EM-33ENGINE MECHANICAL INSTALLATION OF TIMING BELT 1. Installation of camshaft with the camshaft timing belt pulley. (1) Install the camshaft, be carfull not to damage the cam= shaft bearings. (2) Install the vaive lifter. NOTE: * Those valve lifters which have been stord in oder should be installed as a set to original cylinders, respectively. (3) Instai! the push rod cover. Tightening Torque: 9.3 + 2.5 Nm (0.95 + 0.25 kgf-m) 2. Install the injection pumip timing belt pulley. Tightening Torque: . 83.4 + 4.9 Nm (8.50 + 0.52 kgm) EM-34 waar8. Install the timing belt idler No. 2 4, Temporarily install the timing belt tensioner. 5. Install the crankshaft timing belt pulley. NOTE: ‘+ The flange should be installed only in the correct install- ing direction. + Besureto install the crankshatt timing belt pulley in such a direction that the recessed mark stemped on the pulley comes at the front side. 6. Adjustment of timing bett tension (1) Align each of the three mating marks of the timing belt pulleys for the crankshaft, camshait and injection pump: with each corresponding mark of the three mating marks on the timing belt case. Under this condition, the piston No. 1 is set to about 30 degrees before the top dead center. (2) Assembling of timing belt ‘Assemble the belt in such a way thet the marks (yellow lines)'at the back and side of the timing belt may come at the same position on the front. NOTE: + Be sure to displace the front end surface of the timing belt about 2 mm toward the. timing belt case from the front end surface of each pulley. (3) Adjust timing belt tension: @ Insert 2 hexagonal wrench into the hexagonal hole of the timing tensioner. Tighter the bolt ® of the timing tensioner by applying tension to the wrench at about 90 degrees. Tension: 9.8 Nem (1 kgf-m) EM-35 ENGINE MECHANICAL Convex surface side 209 mark ics Mating marks Tension 1.0 kgi-mENGINE MECHANICAL ® Tum the crankshaft smocthly in the normal rotating direction. Stop the crankshait at the third tooth from the mating mark of the camshakt pulley. NOTE: © Before securely tightening the attaching bolt ofthe timing tensioner, under no circumstance should the crankshaft be tumed reversely. + Ifthe crankshaft should be turned reversely, back off the ‘crankshaft one turn, or advance the crankshaft two turns: and stop it at the normal position. @ Loosen the bolt @ of the timing tensioner. Perform the step (8) again. ® Tighten the bo't © of the timing tensioner. © To check that the timing belt tension meets the specification, measure the deflection of the timing ‘belt between the crankshaft timing belt pulley and the camshatt timing belt pulley when the specified pushing force is applied, ‘Specified Deflection: 1.8 mm Specified Pushing Force: 18.6:6.9N (1.94 0.7 kgf) Ifthe measured deflection and pushing force do not meet the specification, perform the steps @ through © repeatedly to obtain the specified deflection 7. Install the timing belt cover. Tightening Torque: 18.1 43.4 Nm (1.85 = 0.35 kgf-m) 8. Install the crankshaft pulley. Tightening Torque: 215.7 + 19.6 Nm (22.00 + 2.0 kgf-m) NOTE: ‘+ Place the gear shift lever in the 5-th gear position so as. to prevent the rotation of crankshaft. EM-36 Mating mark of timing belt case Mating mark of Thice tooth] camshatt tring pulley aeENGINE MECHANICAL 9. Install the radiator fan shroud. 40. Install the fan pulley and V-belt. 14. Install the fluid coupling with fan. 7 Specified V-belt Tension: New belt; 10-13 mm Used belt: 8-11 mm {With a force of 98 N (10 kgf) applied} 12. Install the glow plug. Tightening Torque: 1282.9 Nm (1.30 + 0.3 kgtm) 13. Install the cool air intake duct in the air cleaner. EM-37ENGINE MECHANICAL PISTON AND CONNECTING ROD COMPONENTS 793225 (0.95 0.25) @ Oilpan ® Connecting rod ® Connecting rod bearing @ Snap ring @ Piston pin © Piston © Piston ring © Piston wieonnecting roa T= Tightening torque Unit : Nam (kgf-m) EM-38 TaENGINE MECHANICAL REMOVAL OF ENGINE ASSY 1 2. P85 eax Drain the coolant and engine oil Remove the battery. Remove the éngine hood. Remove the air cleaner sub-assy. Remove the water hoses, radiator and cooling fan. Disconnect the fuel pipes and choses. Disconnect the engine hamess. Disconnect the exhaust pipe and temporary remove it. Remove the transmission attaching bots. Disconnect the engine mounting. Remove the engine assy by using chaine block. EM-39ENGINE MECHANICAL DISASSEMBLY OF CYLINDER BLOCK 1. Remove the cylinder head with intake and exhaust mani- fold. (See page EM-60.) 2. Remove the alternator. 3. Remove the timing belt cover and the timing belt. (See page EM-80.)= a Rettiove the injection pump. - (See page FU-6.) Removal of the camshat. (1) Remove the push rod cover. (2) Remove the push rod arid the valve lifter. NOTE: + Remove the parts in the sequence of cylinders. * Store the removed parts properly so that they may not to be mixed with each other. (3) Remove the thrust plate attaching bolts. (4) Remove the camshaft with the camshaft timing belt pul- ley. 3. Remove the water pump by loosen four bolts. EMa1 ENGINE MECHANICALENGINE MECHANICAL 7. Remove the oil filter bracket with oil filter. 8, Remove the oil pan by loosen 20 bolts and 4 nuts. 9. Remove the oil pipes. 10. Remove the clutch cover. 11. Remove the clutch disc. 12. Remove the bearing, using the SST. SST: 09303-35011-000 cscosesdts Le TAS EM15. 16. ENGINE MECHANICAL Remove the flywheel. Remove the rear end plate. Remove the rear oil seal retainer. Remove the oil seal. Remove the connecting rod bearing cao, Pull out the piston toward the cylinder head side. NOTE: * When pulling out the piston, be very careful not to scratch the cylinder liner. EM43ENGINE MECHANICAL 19. Store the pistons and conhecting fod caps in correct se- quence without changing the correct combination of these Parts. 20. Remove the timing belt case. 21. Remove the crankshaft bearings. Remove the crankshaft. Place the removed crankshaft bearings in the correct se quence so that they may not be mixed with each other. 22. Clean cylinder block. (1) Remove all the gasket material from the top of the block. (2) Blow carbon and oil from the bolt holes. WARNINGS scree ies 28. Disconnect the connécting rod from piston. (1) Remove the snap ring, using needlenose pliers.(2) Gradually heat the piston t bout 60°C to 70°C. (8) Proceed to tive the piston pin by tapping it lightly, using a plastic hummer in combination with the follow- ing SST. SST: 09221-87601-000 NOTE: + The piston and pin are a matched set. + Keep the piston, pin, rings and connecting rod together for each cylinder. EM-45, ENGINE MECHANICAL WareENGINE MECHANICAL INSPECTION OF COMPONENTS INSPECTION OF CYLINDER BLOCK 1. Remove all gasket materials from cylinder block. 2. Clean the cylinder block, using a soft brush and cleaning solvent. 8. Ihispection of top surface of cylinder block Using a precision straight edge and thickness gauge, check the surface contacting the oylinder head gasket for warpage in the six directions. Allowable Wapage: 0 - 0.1 mm If the warpage exceeds the allowable limit, replace the cylinder liner. 4. Measurement of cylinder liners (1) Measure the bore diameter of each cylinder liner at six points, shown in the right figure. Ensure that the difference between the maximum and minimum bore diameters of each cylinder is within 0.1 mm. If the difference between the maximum and minimum values exceeds 0.1 mm, perform boring for the cylinder liner bore or repiace the cylinder liner. (2) Measure the bore diameter of each cylinder at point shown in right figure. The measured value is regarded as cylinder bore diameter. Specified Bore Diameter: $2.00 - 92.03 mm INSPECTION OF CAMSHAFT 1. Visually inspect the camshaft for wear or damage. Replace the camshatt if the cam surface and/or joural section exhibits any wear and damage. Q Trust direction @ Longitucinal direction aS Q Thnst direction ® Longitudinal Girestion, waeENGINE MECHANICAL 5. Inspection camshaft for rlinout ‘Support the camshaft at its both ends with V-shaped blocks. Set a dial gauge to mid-point of center journal section of camshaft. Tum the camshaft one turn, making sure that camshaft will not move in the axial direction. Take a reading on dial ‘gauge during the turning. Calculate the maximum runout, ie. the difference between the maximum and minimum readings. Maximum Runout:” 0.05 mm inspection of cam lobe height Measure the cam lobe height, using a micrometer. ‘Specified Cam Lobe Height IN-EX: 37.717 - 37.817 mm Inspection of journal section. Measure the camshaft journal section diameter, using a micrometer. 46.559 - 46.575 46.259 - 46.275 45.959 - 45.975 4th journal: 45.659 - 46.675 Sth journal: 45.359 - 45.375, Inspection of camshaft thrust clearance (1) Measure the camshaft thrust clearence. Specified Value: 0.10 - 0.19 mm NOTE: + Prior to the measurement of the camshaft thrust clearance, tighten thé camshaft timing belt pulley to the camshaft to the specified torque. (2) If the camshaft thrust clearance exceeds the limit, replace the camshaft thrust plate. Inspection of valve push rod (1) Visually inspect the valve push rod ‘or damage or wear. EM~47 TaN WaTENGINE MECHANICAL (2) Inspect the valve push rod for bend. Bend Limit of Push Rod: 0.4 mm 7. Inspection of value lifter (1) Visually inspect the value lifter for wear or damage. (2) Measure the oil clearance of vaiue lifter. Specified Oil Clearance: 0.015 - 0.049 mm Limit: 0.1 mm. 8 Inspection of crankshaft (1) Measure the crankshaft for runout. Take a reading on dial gauge during the turning. Runout Limit: 0.05 mm (2) Visually inspect the crankshaft main journals and crankpin journals for wear or damage. EM~48 TTS aaaENGINE MECHANICAL (3) Measure the diameter of crankshaft main journal and crankpin journal. Specified Value: Main Journal: 67.955 - 67.970 Crankpin Journal: 55.075 - 5.990 (4) Measure the thrust clearance of the crankshaft. ‘Specified Value: 0.050 - 0.159 mm Limit: 0.25 mm NOTE: ‘+ Tighten the crankshaft bearing cap to the specified torque in advance. Tightening Torque: 103.0 + 6.9 Nm (10.50 + 0.70 kgf-m) (5) Measure the oil cléarance of the main journal of the crankshaft, using a plastigage. Specified Value: No.1-and No.5 joumais: 0.028 - 0.060 mm No.2, No.3 and No.4 joumals: 0.030 --0.065-mm Limit: 0.12 mm If the oil clearance exceeds the lirit, replace the bear- ing. NOTE: Wipe off the oil-or the like getting to the main journal section in advance. + Tighten the crankshaft bearing cap to the specified torque. Tightening Torque: 103.0 + 6.9 Nm (10.50 + 0.70 kgf-m) 9. Inspection of piston (A) Visually inspect the piston for wear or damage. (2), Measure the piston outer diameter in thrust direction at @ point about 24 mm above from lower edge of the piston skirt ‘Then, calculate the piston clearance. Specified Value: Piston Outer Diameter: DL-42: 91.93 - 91.96 mm DL-62: 91.92 - 91.95 mm Piston Clearanes DL-42: 0.06 - 0.08 mm DL-S2:_ 0.07 - 0.09 mm EM-49 WaTENGINE MECHANICAL 10. (@) Measure the groove width of piston rings No. 1, No. 2, No. 3 with a thickness gauge. Due DLs2 'No. 1 piston ring groave wath 255-257 | 7* key stone 'No. 2 piston ring groove with 208-205 | 206-208 'No. 8 piston ring groove width 401-408 | 401-405 Inspection of piston ting a) @ Inspect the piston ring width Specified Value: Free! p42 oLs2 Component Compression ring No. 1 25 | Tkey stone ‘Compression ring No. 2 20 3B 20 38 ‘ilning 408 40 38 Inspect the piston ring thickness. Di42 DLs2 ‘Compression ring No, + ssto1 | 882012 ‘Compression ring No. 2 38201 | 8820.10 (8) Caiculate the piston ring side clearance. (4) Specified Value ee DLs2 [Germonon tana | bie-010 | — Compression ring No. 2 08-008 | 007-011 (Oil ing No. 8 o2-006 | 002-006 where very little wear exists. Specified Val Mesure the piston ring end gap. Place the piston ring in the cylinder bore at lower part Measure the end gap of the piston ring. Die DL52 ‘Compression ring No. 1 020-045 | 035-050 ‘Compression ring No. 2 020-045 | 090-045 ‘Olt ring No.3 : 090-050 | 090-080 EM-50ENGINE MECHANICAL 11. “Ingpection of piston pin (1) Measure the length of piston pin. Specified Value: L = 74.8 - 75.0 TRE (2) Measure the diameter of piston pin. Specified Value: D = 27.998 - 28.000 (8) Visually inspect the piston pin for wear or damage. 12. Inspection of connecting rod (1) Visually inspect the connecting rod for damage. Ed (2) Check the connecting rods alignment using a rod alig- ner. IF the rod is bend or twisted, replace the connecting rod. ‘Specified Value: Bend Limit: 0.05 mm Twist Limit: 0.05 mm EM-51ENGINE MECHANICAL (@) Measure the inner diameier of connecting rod small end. Specified Value: D = 28,005 - 28.020 (4) Calculate the oil clearance of piston pin to piston pin bush. ‘Specified Clearance: 0.005 - 0.027 mm Limit. 0.05 mm If the clearance is not within the specification, replace the connecting rod bush. (8) Measure the crankpin journal oil clearance. © Place plastigauge on the crankpin journal in parallel with the crankshaft. @ Tighten the bearing cap bolts to the specified torque. Specified Torque: 68.6 + 4.9 N-m (7.0 + 0.5 kgf-m) NOTE: * Be sure not to turn the crankshaft or connecting rod during this crankpin journal oil clearance measurement. @ Measure the largest width of flattened plastigauge. ‘Specified Value: 0.030 - 0.065 mm Limit: 0.012 mm 18. Inspection of flywheel (1) Install the flywheel and measure the runout, using a dial gauge. Tightening Torque: 11.5 - 14.0 kg-m (83 - 101 ftb) Runout Limit: 0.2 mm (0.0079 inch) (2) Check the flat plane of the flywheel for roughness, EM-52 wrest 99 aENGINE MECHANICAL (8) Bearing Rotate the bearing, while applying force to the bearing by your finger. If you do not feel ary binding, it means that the bearing is satisfactory. REPLACEMENT OF CYLINDER LINER 1. Remove the cylinder liner by using SST. SST: 09221-87301-000 2. Combination of cylinder liners and cylinder bores. Each cylinder bore bears a mate number stamped on the top surface of the cylinder block. Likewise, each liner dears a mate number stamped at the side of the liner. When a liner is press-ftted into a cylinder bore having the same number as the liner, you can get a proper combination of liner and bore. Relationship Between Stamped Numbers and Cylinder Liner & Cylinder Block mm Dimensions} cylinder iner | cyinder biock bore ‘Stamped numbe? outer diameter | inner diameter 1 96.025 - 96.040 | 96.000 - 96.015 2 96.040 - 96.055 | 96.015 - 96.030 3 96.085 - 96.070 | 96.080 - 96.045 NOTE: + After new cylinder liners have beer press-fitted, boring machining and honing operation should be carried out for each bore’in accordance with the STD piston outer diameter. 3. Apply engine oil o the outer circumference of each cylinder liner. Then, press each cylinder liner irto position, using a press. Force to be applied for press-fitting: 24518 N (2500 kgf) EM-63 Numerals (1, 2,8)ENGINE MECHANICAL 4. After new cylinder liners have been press-fitted, measure the projection height of each cylinder liner. Specified Projection Height: 0.01 - 0.12 mm REPLACEMENT OF CAMSHAFT BEARING 1. Removal of camshaft bearing (1) Remove the expansion plug by using SST and a hum- mer. SST: 09215-87601-000 (2) Remove the camshaft bearings by using SST: SST: 09215-87601-000 2. installation of camshaft bearing (1) Install new bearings in their proper location. (2) Align the oil holes of the bearing and cylinder block. EM-54 0.01 -0.12 TSR waneENGINE MECHANICAL (8) Install the camshaft bearings by using SST. SST: 09215-87601-000 3. Check the camshatt oil clearance. 4. Instaltation’of the expaiision plug (1) Apply liquid sealer to expansion pug surface of the cylinder block. (2) Install the’ expansion ‘plug into’ the cylinder block -by using @ hummer. ASSEMBLY OF CYLINDER BLOCK 4. Install the crankshaft bearing (1) Prior to the installation, thoroughly wipe the backside or each bearing so as to remove ary cil (2) Apply a thin film of engine oil to the rotery section of each bearing EM-55ENGINE MECHANICAL 2. Install the crankshaft. 3, Install the bearing caps in the sequence of numbers with the arrow-headed mark on each bearing cap faced toward the front direction. Tighten the bearing cap bolts in the sequence as indicated in the illustration. After the bearing cap bolts have been tightened, make sure that the crankshaft can be turned lightly by hands. Cap Bolt Tightening Torque: 103.0 + 6.9 Nm (10.50 + 0.7 kgm) NOTE: to the assembly, apply engine oil to the threaded Portion and bearing section of each cap bolt.” 4. Install the timing belt case. Tightening Torque: 18.1£3.4Nm (1.85 + 0.35 kgf-m) 5. Drive the oil seal into position, using the SST. SST: 09608-87302-000 6. Prior to the installation, apply a small amount of MP grease to the lip-section of the oil seal. EM-56 Front mark (Artowsheaced mark) Taree waeaesoN ENGINE MECHANICAL Install the oil seal retainer. Install the rear end plate. Install the flywheel. Tightening Torque: 125.0+ 12.3 Nem (12.78 + 1.25 kgf-m) . Drive the bearing into position, using the SST. SST: 09304-12012-000 - Install the clutch disc and clutch cover, using the SST. SST: 09301-22020-000 Install the ciutch cover. Tightening Torque: _ 19.6 + 4.9 Nm — (2.00 + 0.50 kgf-m) EMS7 TaENGINE MECHANICAL 13. Assemble the piston in the connecting rod, using the SST. SST: 09221-87601-000 NOTE: ‘= Prior to the piston pin insertion, be sure to heat the piston at about 60°C, using a piston heater 14. Make sure that the front mark in the piston and the “D” mark on the connecting rod come on the same side. 15. Instali hole snap rings securely in position. 16. Install piston rings on each piston, using a piston ring ex pander. The piston rings should be installed in the se- quence of the oil ring, No. 2 ring and No. 1 ring. NOTE: + Be certain to install piston rings in such a way that the stamped mark at the end section of each ring faces upward: EM-58ENGINE MECHANICAL 17. 18. 19. at. Set the piston rings in such a way ‘hat their end gaps assume the respective positions as shown in the illustration. Install the ‘pistons in the cylinder block using the SST. SST: 09217-87001-000 NOTE: ‘+ When installing the pistons, make sure that the front mark of each piston faces toward the front of the engine. Install the connecting fod bearing cap. Tightening Torque: 68.6 4.9 Nem (7.00 + 0.50 kgf-m) NOTE: ‘+ Tighten the connecting rod bearing cap with the front mark facing forward. ‘+ Prior to the assembly, coat the inside of each bearing with a film of engine oil. ‘+ Also, apply engine oil to the threaded portion of each bolt and the bearing section of each nut Install the oil pan. When installing the oil pan, apply bond sealer to the gasket installation surface on the cylinder block side. Tightening Torque: 9.3 + 2.5 Nm (0.95 + 0.25 kgf-m) Install the camshaft, using care not to damage the camshaft bearings. EM-59 Oil ringENGINE MECHANICAL 22. install the valve lifter. NOTE: + Those valve lifters which have been stored in order should be installed as a set to the original oylinders, respectively. 23. Install the push rod cover. 24, Install the alternator.ENGINE MECHANICAL INSTALLATION OF ENGINE ASSY 1 ep mae 8. 11. 12. 18. 44. Place the engine assy into engine compartment by using chain block. Connect the engine mounting. Install the transmission into the engine installation part and tighten attaching bolts. Connect the exhaust pipe. Connect the engine hamess. Connect the fuel pipes and hoses. Connect the water hoses. Install the radiator and cooling fan, Install the air cleaner sub-assy. Install the battery. Fill the coolant and engine cit Install the engine hood. Start the engine, Check and tune up the engine. EM-61ENGINE MECHANICAL POSITIVE CRANKCASE VENTILATION (PCV) To combat with air pollution problems, the engine is equipped with a sealed type PCV system in order to Prevent blow-by gases generated inside the crankcase from being released into the atmosphere. Biow-by gases generated inside the crankcase pass the side of the camshaft and push rod in the cylinder block and fiow into the cylinder head. The biow-by gases which entered the cylinder head is introduced into the intake manifold (the entrance of the turbo cherger in the case of type DL-52 engine) through the cylinder head cover and blow-by gas hose. Then, the blow-by gases are sucked into the combustion chamber and burnt there together with intake air. When blow-by gases pass through the cylinder head cover, oil mist component is separated at the oil separator section provided at the cylinder head cover. in this way, the oil carrying-out is reduced and the intake manifold is prevented from being contaminated. DL-42 Engine i DL-42 Engine Positive crankcase ventilation system Heag Cover 08 seperator — Crenk-cese Gases EM-62ENGINE MECHANICAL DL-52 Engine Positive crankcase ventilation system Head Cover ll separator Blow-by Gas Hose Testo cherger — crankcase Gases > Fresh Air Inspection of PCV Hose & Connection Visual inspection of hose and connection Check the hose for improper connections, cracks, leak ér damage. Check the oylinder block to oil pan and eylinder head cover contact surface for leak or damage. Replace or repair any part which exhibits defects. EM-63ENGINE MECHANICAL TURBO CHARGER SYSTEM Because of the newly employment of the intercooler, intake pipes have been provided newiy and the air cleaner and coo! air intake duct have been changed. Consequently, volumetric efficiency has been improved and also the maximum output power has been increased from 67 KW to 75 KW. Furthermore, for enhanced durability and reliability, the cooling water is circulated in the turbo charger housing so as to coo! the floating metal Cool air intake duct Intercooler Ware EM-64ENGINE MECHANICAL COMPONENTS: 1% 1 Nomreusable part ® Cool air intake duct S/A @ Water bypass pipe No. 2 @ Ke cleaner Ay Welement ® Water bypass pipe No. 1 @ Air hose No. 1 Nut @ Exnaust manifold cover Turbo charger outet pipe SIA, @ Intake maniold No. 2 ® Turbo charger inlet pipe SIA @ Air intake No.1 ® Exraust manifod ® Exnaust manifois heat inguletor No. + Turbine outlet elbow @ Turbo cherger stay ® Turbo charger SIA © Air hose No. 2ENGINE MECHANICAL SERVICING INSTRUCTIONS FOR TURBOCHARGER 1. Never disassemble the turbocharger, because it is a Precision component whose assembly requires utmost care. 2. Alter the turbocharger has been removed, affix gum tapes, etc. to the inletfoutlet ports of the oil and those of the intake/exhaust gases so that no dirt or foreign matter may enter. 3. When disassembling the intake, exhaust and lubricating systems; care must be taken so that no dirt or foreign matter may enter. 4. Never rotate the engine when the intake manifold No. 2, intake air connector and turbine outlet elbow, etc. are dis- connected (so as to prevent foreign matters from entering). 5. Use the specified attaching set bolts and nuts of the tur- bocharger since they have under-gone the heat-resistant treatment, 6. After the turbocharger has been replaced, keep the engine idling for more than ten seconds after it starts. If the revolu- tional speed is increased sharply, the bearings of the tur- bocharger may be damaged. In addition, make sure that no oil leaks from the oll pipe. 7. Replace the removed gasket and seal, etc. with new ones. Moreover, tighten the Section to the specified torques so that no leakage takes place. 8. Do not hold the waste gate valve rod section. 9. Since the turbocharger is a precision part, do not drop it. 10. Do not remove the residual! oil completely from the bearing section. (The residual oil refers to'such an amount of ol that remains on the surface after the oil has flown naturally.) 11. Do not place the turbocharger vertically. Under such condition, the cil in the shaft section flows to the impeller room and this may be mistakenly regarded as an cil leakage. EM-66 ‘Tape affixing Section os = BC BUD Do not crop S * turbocharger1. Checking operation of turbocharger weste gate valve (1) Remove the waste gate actuator hose at the actuator side. (2) Connect the turbocharger pressure gauge. Ensure that the rod and link operate when a pressure of 92.2 kPa (0.94 kgf/cm?) is applied and that ‘he valve retums to the. original position smoothly when the pressure is released. ‘Specified Value: Shaft Stroke: About 2 mm With a pressure of 92.2 KPa (0.94 kgl/en?) NOTE: * Ifthe pressure exceeding 117.7 kPa (1.2 kafiom*) should be applied to the waste gate actuator, the diaphragm may be damaged. (3) Check the hose for crack and damage. 2. Checking air-tightness of boost compensator (1) Connect the turbocharger to the boost compensator. (2) Apply a positive pressure of 133.4 kPa (1.36 kat/em*) and measure the time required for the pressure to drop. to 130.4 kPa (1.33 kgficm’) ‘Specified Value: Not less than 10 seconds 8 . Check of supercharging pressure (running test) To obtain total evaluation, perform a running test and measure the supercharging pressure. The running test must be carried out al a place where the Vehicle can be accelerated safely with full throttle of the accelerator pedal in the second gear. One person drives @ vehicle and the other person performs measurement. (Two persons aboard) (1) Connect a turbo charger pressure gauge to the vacuum hose of the intake manifold with a three-way joint inter- posed. Place the gauge in the vehicle interior. ~ (2) Aiter the engine has warmed up, accelerate the vehicle at full throttle up to 8,500 rpm with the second gear. EM-67 ENGINE MECHANICAL Waste gate Sciustor Were => Fullthrotte TERSENGINE MECHANICAL (3) Measure the maximum supercharging pressure generated while the vehicle is accelerated up to 3,500 rpm. ‘Specified Value: 49.0 - 78.5 kPa (0.50 - 0.80 kgf/cm’) If the measured value is less than the specified value, most likely there exists the following malfunction. @® Leakage at waste gate valve @® improper increase in injection amount of boost com- pensator or bent vacuum hose @ Leakage at intake or exhaust system @ Air cleaner, muffler, fuel fiter and so forth restricted © Turbo charger matfunction © The engine proper faulty If the measured value exceeds the specified value, most likely there exists the following malfunction. ® Malfunctioning injection pump REMOVAL OF TURBO CHARGER 1. Disconnect the engine ground cable from the negative (-) terminal of the battery. 2. Drain the cooling water. 3. Removal of air cleaner (1) Remove the cool air intake duct subassembly by loosening the three screws. (2) Disconnect the air hose No.1 (8) Remove the air cleaner assembly by loosening the four ait cleaner attaching bolts. 4, Remove the exhaust manifold cover by loosening the two attaching bolts. 5. Remove the intake manifold No.2 by loosening the two attaching bolts and two attaching nuts. NOTE: # Never reuse the removed gasket. EM-68 3,500 rpm 490-785 kPa,ENGINE MECHANICAL . Disconnect the following hoses from che eir intake No.1. Then, remove the air intake No.1 from the turbo charger. ° PCV hose © PCS hose © Turbo charger actuator hose Remove the exhaust manifold heat insulator No.1 by loosen- ing the two bolts. . Remove the two attaching bolts of the turbo charger stay and turbine outlet elbow, 2. Disconnect the air hose No.2 from the turbo charger. NOTE: ‘+ Seal the suction port with a tape or Ike so as to prevent ust from entering the turbo charger. Disconnect the water by-pass hose No.2. NOTE: + Never reuse the removed gasket. EM-69 Tees Wate byness pee Nez LS oF i fri WZ la TO d) yENGINE MECHANICAL 4 12. 18. 14, 15, 16. Disconnect the water by-pass hose No.1 NOTE: + Never reuse the removed gasket. Disconnect the oil inlet pipe of the turbo charger. Remove the two attaching bolts of the oil outlet pipe at the turbo charger side. NOTE: Never reuse the removed gasket. Move the front exhaust pipe downward by removing the three attaching nuts of the front exhaust pipe. Remove the exhaust manifold together with the turbo charger by loosening the six attaching nuts of the exhaust manifold NOTE: + Never reuse the removed gasket. Removal of turbo charger (1) Remove the turbine outlet elbow from the turbo charger bby loosening the two bolts and two nuts. (2) Remove the turbo charger from the exhaust manifold by toosening the four attaching nuts. NOTE: ‘+ Never reuse the removed gasket. ‘+ Never hold the actuator rod section during the removal of the turbo charger. Affix a tape or the like so as to prevent any foreign ~~“matters from entering each of water port and oil port of the turbo charger. EM-70ENGINE MECHANICAL INSTALLATION OF TURBO CHARGER 4. Clean each gasket installing surface of the turbo charger. 2. Install the exhaust manifold to the turbo charger. Tightening Torque: 24.5: 4.9N-m 2.5 + 0.5 kgt-m) 3. Insfall the turbine outlet elbow to the turbo charger. Tightening Torque: 24.5 + 4.9N-m (2.5 + 0.5 kgf-m) NOTE: ‘+ Be very careful not to deform the turbo charger actuator rod. ‘+ Never disassemble the turbo charger or tighten the bolts further. + Use a new gasket. 4. Temporarily install the exhaust manifold together with the turbo charger to the engine. NOTE: +. Use anew gasket. 5. Corinect the oil outlet pipe to the turbo charger. Tightening Torque: 7.4 + 1.5 Nm (0.75 £0.15 kef-m) 6. Connect the oi! inlet pipe of the turbo charger. Tightening Torque: 17.2 + 2.5 Nm (1.75 + 0.25 kef-m) NOTE: Use a new gasket. 7. Fully tighten the exhaust manifold. Tightening Torque: 46.6% 4.9 Nem (4.75 + 0.75 kgt-m} 8. Install the front exhaust pipe. Tightening Torque: 49.04 4.9 Nm (6.00 = 0.50 kgf-m} EM-71ENGINE MECHANICAL 9.” Install the water by-pass vaive No.1 Tightening Torque: 29.4 + 4.9 Nm (8.00 + 0.50 kgf-m) 10. Install the water by-pass valve No.2. Tightening Torque: 29.4 + 4.9 Nm (8.00 + 0.50 kgf-m) NOTE: ¢- Use a new gasket. 14. Connect the air hose No.2. 12, Tighten the turbo charger stay and turbine outlet elbow. Tightening Torque: 18.1 +3.4 Nm (1.85-+ 0.35 kgtm) 13. Install the exhaust manifold heat insulator No.1. 14. Install the air intake No.1 to the turbo charger. 15. Insert the following hoses into the air intake No.2. Attach clips. + PCV hose + PCS hose + Turbo charger actuator hose 16._ Install the intake manifold No.2. EN-T217. Insiall the exnaust manifold cover. 18. Installation of air cleaner (1) Install the air cleaner assembly. (2) Connect the air hose No.1 between the air cleaner and the turbo charger. 8) Install the cool air duct. 19. Fill cooling water. 20. Connect the ground cable to the negative (-) terminal of the battery. EM-73 ENGINE MECHANICALENGINE MECHANICAL POWER CONTROL SYSTEM When the transmission is set to the first gear, this system controls the surge tank pressure by means of the transmission switch, VSV and by-pass valve, thereby controlling the supercharging pressure. In this easy, the power control system controls the output power by reducing the boost compensator pressure of the injection pump and by reducing the fuel injection amount. vsv Transmission switch O By-pess valve ross, Yeon pane Sa Supercharging pressure t 3 S Injection pump ‘oest compensator Shift position Transmission switch vsv By-pess vale First gear OFF OFF Open Reverse and second a ‘gear through fith gear at a EM-741. Inspection of power control system (1) Connect a vacuum gauge between the by-pass valve and the VSV with the three-way interposed. (2) Start-the-engine and-cepress the clutch pedal. When the shift lever is placed in R, 2, 3, 4 and § positions, ensure that the pointer of the vacuum gauge registers zero. (2) Start the engine and depress the clutch pedal. When the shift lever is set to the 1st position, ensure that negative pressure is applied to the vacuum gauge. 2. Check the by-pass vaive. (1) Connect a MityVac to the by-pass valve. When a nege- tive pressure of 56.0 kPa (420 mmHg) or more is ap- plied, ensure that air continuity exists between the ports AandB. 3. Check the VSV. (1) When the battery voltage (12V) is applied between the terminals, confirm the following items. Between A and B: Air continuity exists. Between A and C: No air continuity exists. (2) When no battery voltage (12V) is applied between the terminals, confirm the following items. Between A and B: No ait continuity exists. Between A and C: Air continuity exists. (3) Measure the resistance between the terminals: ‘Specified Value: 37.- 400 (at 20°C) EM-75, ENGINE MECHANICALENGINE MECHANICAL SsT ‘Shape Part number & name Remark (09032-00100-000 il Pan Seal Cutter Used for removing ol! pan (09201-60011-000 Valve guide bush remover & replacer Used for removinghteplace valve guide bush (09201-87703-000 Valve ster ol seal repiacer Used for replace valve stem oil seal (09202-87002.000 Valve cutter remover & repiacer Used for removerrepiace valve spring (09210-87701-000, Fywheel holder Prevent crankshaft from turning 09218.81021-000 Crankshaft pulley puller Used for remove crankshatt ring pulley (08214-60010-000, TS Crenkshatt pulley gear replacer Used for replace crankshaft timing a pulley @ (09216-87601-000 9 es Camshaft bearing remover & repiacer_| Used for removelteplace camshatt ~8Ge bearing )9221-87301-000 Cylinder tiner remover & replecer Used for removesreplace oylinder Ener (09281-87601-000 Piston pin remover 8 replacer Used for removeireplace piston pin Connecting rod bush remover & 09222-87308-000 | | replacer | I Used for removerreplace connecting ros bush (09255-00030-000, T Plog set Piuged uber hose (09258-87201-000 Crankshaft bearing Not inner race replacer Used for press fit seal set (99268-87310-000 Nozzle holder wrench Used for remove/replace injection nozzle EM-76ENGINE MECHANICAL Shape Part number & name Remark (08275-8770%-000 (98807-20020-000 <= tact ide tn Used for assemble ckth eae (98808-85017-000 em ‘put shat ront bearing puller less eetaauie wea (8808-12912.000 Inputhatt ont bearing epizcer | 05 ter preset fywhee! bearing oe (00950-20017-000 Universal puller | Used for remove injection pump timing pulley (08217-87001-000 | Piston ring compressor | Used for guide piston inset | (08810-8730-000 | q Counter shaft rear Dearing repiacer Used for pressfit crankshaft front oll seal '09606-87302-000 = O BELL. Drive pinion bearing tool set Used for pressfit crankshaft rear oil seal | ‘08808-10010-000 | Oil see puler Used for remove crankshaft cearfront | oil seal a wrestENGINE MECHANICAL TIGHTENING TORQUE Tightening component ee Remar Na kghm feb Oyinder head x Oylinder head cover ~saets | Oss2015° | 40zia 2x Intake mantold sess74 | s752075 | arvess x Echeust manifold ases74 | 4752075 | aaes4 % Gow plug wsz29 | 150x000 | oaz22 > Injector pipe bracket werzs4 | iessoas | tates x Water temperature senda zeizes | e2szozs | teaet8 Cylinder block x Cylinder head | a77ies. | 12002100 | ee8a72 | Wet x Crankshaft bearing cap waotea | 10502070 | 759251 | Wet > Push red cover 93425 | ossto2 | eorte xOllpan ss25 | os+025 | sez1e xEngine mounting bracket front) | s6s274 | s75z075 | ar1zs4 xCamshattretainer x bet case | 181234 | tesz0as | ta4z25 xO! hose Not vases | 1752028 | sa7s18 x Oil hose No2 225x025 | 183218. | x Oil pump inet pipe tesz0ss | 13425 | x Oil pump outlet pipe 4502075 | s2s¥54 x ide shaft 350£050°| 25s#36 —} wet Injection pump verss2 | te5s025 | 124225 | x Timing bet cover rest2s | 130030 | o4e22 | XO] pump inet pipe weisde | 152038 | 124225 Ol pump ole pipe wisse | tass0as | sa4s2s x Oil pump reef plug ge2iae | soos0s0 | 259236 x Oil fier bracket gese74 | a76e075 | a7tass Gonneciing 0d x Connecting rod cap ees49 | rooz0s0 | soesa6 | Wer Crankshat x Flywheel vesox123 | 12752125 | 9282900 | Wet Crankshat x Crarkshaft pulley zis72196 | 22004200 | 15912145 | Wet Camshatt x Camshat pulley a774 | sasz07s | s0ses4 Rocker arm > Adjusting sorew reex29 | 200090 | tase22 | wet Valve rocker shat x Valve rocker support se#10 | ososo1 | 4szo7 Oi ter beacket x TIC of inlet pipe rasa20 | 1208090 | esse Oiler bracket x Oil cooler aoxas | soozt100 | seze72 Oit fier bracket Oil pressure valve 4002050 | 29236 wie XTIG oi outet pipe 7aeis | o75£015 | s4ztt Oil fiter x Oil fiter bracket ssex20 | 2002020 | usz15 EM-78ENGINE MECHANICAL Tightening component — Remark Nar geen fb 7 Injection pump Injection pump déve pulley ganas | e50z0s0 | 615296 > Injection pipe zase49 | 2sosos0 | 121296 x Delivery valve holder - 4ooz49 | soososo | se2ea6 x Nozzle leakage No.2 sese25 | 3754025 | a7te18 > Union (uel return) paseas-| 2soe050 | 181236 : x Urion zase49-| 2s0t050 | 1a1236 x Disbibutive head bolt foi72e29 | 4754090 | 127222 x Sorew Ay overtow 74215 -| 0752015 | S4a14 Nozzle holder > Oylinder head easzos | 700e100 | soss72 x Injection pipe zaseae | 250 18.1236 x Nazzle leakage No.t aaize9 | asososo | a25238 Alterator x Altemator beiaket sese74 | s75s075 | 271254 Vaowurn pump. - Oil hose No.t sr2zes-| 1752025 | ta7s18 x Oil hose No2 zeixes-| 2a5xo2s | 163218 xUrion zizes | 2assc2s | 163218 Aternator > Agjusting bar zaxs9 | soosos | 217243 Oitpan x Drain plug sasz49 | ss0s050 | 253208 we x Exhaust manifold 245249 | 2502050 | 962456 x Outlet elbow zase49 | 250x050 | 362438 Glow plug x Giow plug connector 15-29 | 015-090 | 141-22 Crankshaft pulley x Crankshaft pulley No2 vess34 | testoas | 134225 Radiator E es+is7 | 10418 | 724116 Radiator x Fan shroud s4ais | sss | 40214 Exhaust manifold. x Exheust manifold cover we7see | 19403 | 94x22 Aircleaner | 729 | 13208 94222 Inter cooler waisaa | teseoas | ia4s25 Fue fiter tange | teres4 | 1ass035 | tas25 x Fuel fiter | we1xse | 1esz0ss 1see25 x Union 368274 | 27x84 Glow plug connector | 018-029 | oors-oceo | 011-022 ‘Clamp injection pipe zaszas | 2508050 | 181496 Ol pressure swich wastes | ssoe110 | 2se+80 Wes EM-79ENGINE MECHANICAL ENGINE SERVICE SPECIFICATION Lae Ouse item Olinger capacity 2785 King Diesel, 4 cycle Syfinder number an arrangmment 4 oyindersivine, mounted longitudinally Combusion chamber ype Swirl chamber Pe Valve mechanism Bett Drive OHV Bore x Stoke mm 92x 104 Comoression ratio 212 Comoression | STO 3150 (329250 pressure Mii ee a wn 2150 (@2)250 Difference Between oyiindars 490 (5/250 Engine proper | Maximum Power KiWimm | SAE OSE —— = ON 5448800 7/8400 Z 7 = Maximum Torque Nrvrpm | SAE Ret lds ON 17012200 245/1800 Engine dimensions . Ce age) mm| 763548696 763x811 x 728 ‘Service engine weight g 236 250 a 2° BTDC Value Tiring ieleed kaise 7 60" BBDC exhaust OPP Close 20° ATOS intake mm 0.25 005 Valve clearance Bihaust mam 025% 0.05 035% 005 Iole speed em 650 25 Blow-by gas recirculating ‘Closed Type Lubricating metiod Fully forced feed method Lubricating siete | Ol pump pe Trochoid Type Oil capacity on ea Costing method Water cooled, V-bett ype Coating : system Coolant capacity (with reserve tank) om 708 Thermostat type wax type EM-80ENGINE MECHANICAL Eraine ype owe ouse tem | Air ceaner type Gyelone pe, paper tr ype Fuel tank capacity dm? 60 as remo | : Ijecon Timing (high ator sooo) | aToe i Punget Garter tm 30 Injection pump a oo Cami mn 22 Governor typ> Centrifugal type Timer ape ira pressars ype Nez retainer We injection nears [Necae of injector a Wisofon eS emt) | 10780: 1079110210) (43070) votese v 7 (negative ground) ing order 13-42 Engine - Tipe Sheathestyee ‘electrical ‘Glow plug a yr Seem Vorage cures VA| __105-85,70-85 70-85 Banery Type NiO or SEERA Aerator OapuvA 72-48 ‘Starter ‘Output V-KW 12-22 EM-81ENGINE MECHANICAL THE ENGINE PROPER SPECIFICATIONS NOTE: '¢ The entry figures are those values at a temperature of 20°C. Cylinder r outer diameter x Cylinder block bore diameter mm Tem finer ne yiner boc i ‘Combination ‘outer diameter Dore diameter amerlerees, ioe" 1 [96.028 - 96.010 196.000 - 98.015 0.01 0.04 2 | 96.040 - 96.055 96.015 - 96.030 0.01 - 0.04 g $65 -86070 00-805 Soros ‘Cylinder liner inner diameter x Piston outer diameter (DL-42) mm om a cine ine er rir Fison outer ater Saba iter x Ba-BE Sass o186, 8 92.01 - 92.02 91.94 - 91.95, =e 200-8004 EE oma Cylinder liner inner diameter x Piston outer diameter (DL-52) mm Ten Hen inde ner dareter Pion cute eter phates eter ‘A Boe Baas 3 wer -e202 onaeco138 e e200 2201 ona 8188 ae Cylinder block x Crankshaft x Crankshaft bearing mm Te cant cymeerticckmen | canteen veaing | Cranste rain jal aber Suratieraamnetee | Oe Sa danas cane | 7 aoe TaGie | 1888-2000 Teo Novas | eon | groe0-srers 2 72010-72020 | _2000-2.005 Bleck] 7 7 72.000 - 72. | 4.985 - 2.000 [Brown] Sanat Bere _| ce 67385-67970 2 72.010 - 72.020 | 2,000 - 2.005 {Biack) EM-82Connecting rod large end x Crankshaft x Connecting rod bearing ENGINE MECHANICAL Connecting'rod large end ‘Connecting roc bearing Conoieinnn | Somesiglags es | cnet ann aanaer =r 1 8,000 - 580% a | 5 ‘O10 ee 120 [Blown i I 58.010 - 58.020 -490 - 1.495 [Black] warmest Piston pin x Connecting rod small end x Piston pin hole mm) om ee ‘Connecting rod small end J ‘ Poe Piston pin outer clamete sing fod smal Fision pin hole inner diameter 27.983 - 26.000 28.005 - 28.020 | 27.985 - 27 995 E wae Valve lifter x Cylinder block mn ‘Valve lifter outer diameter Cylinder block valve lifer inner diameter 25872 -23.585 24.000 - 24.021 wane Valve stem x Valve guide bush mm Valve stom outer ameter Valve guide bush inner diameter intake valve 8.968 - 8.984 01-808 Exhaust vave 8.934 -€.950 901-908 eae Valve rocker shaft x Valve rocker arm mm Valve rocks" shatt autor diameter Valve rocker arm inner diameter 78472 16.498 18512-18599 Connecting rod x Crankshatt mm Connecting od large end thickness Crankshaft in Jounal thieves 3880-88.95 3410 -38.15 TEE Pre combustion chamber x Cylinder head mm re combustion chamber (jjinder head pre combustion chamber : outer diameter inner diameter eeetareee| 37.080~ 87.048 87.000 - 97.080 09-0085 Valve guide bush'x Cylinder head - mim Vane guide bush outer diameter sores Nae eaten oui ae Interference 14088-14088 14000-14918 0.018 - 0.058 weroENGINE MECHANICAL Camshaft bearing x Cylinder block mm Camshat bearing over diameter | QOS as csametor Interference Not 50.675 - 60.77 £50,600 - 60.825 0.050- 0.175 No.2 50.875 60.418 50.300 - 50.325 0.050- 0.118 Nos 5007S 60.115 501000 - 500085 0050-0115 No.4 49775-49815 39,700 49.725 0.050- 0.175 Nos 50075 - 60.175 "50.000 - 50.025 0.0507 0.118 Valve guide bush x Valve stem oil seal mam ‘Valve guide bush outer diameter Valve stem oli seal inner Giameter | Interference 14025 - 14081 1891-1889 0.024 0.134 Valve rocker shaft x Valve rocker support mm Valve rocker shaft outer diameter ‘Vaive rocker suppom inner diameter No. 1, 2, 3,4 Taare 16405 ‘| 18500" 18521 ‘Camshaft x Camshaft bearing mm Camshaft journal outer diameter ‘Camshaft bearing inner diameter Not 46559 - 46.575 46.600 - 46.825 Neve 46259-46275 46.900 - 46.525 Ne 45.969 - 45.975 5 "46.000 - 45.025 Ne. 4 45.659 - 45.575, E 5.700 45.725 No.5 25.559 - 45375 “45.400 - 45.405 e wero Piston ring x Piston (DL42) cam Piston Fag thicwness Piston fing groave thickness “Compression ring NO. 1 247-249 [ 255-257 Compression ring No.2 187-199 208-205 Oliag [ 397-899 401-408 7 Piston ring x Piston (DL-52) mm Piston ing thickness Piston ring groove thickness Compression ring No. 1 7° Keystone ring 7 Keystone ring Compression ring No. 2 197-198 2.06 - 2.08 Oiling 397-399 407-408 ot EM-84Connecting rod x Connecting rod small end bush ENGINE MECHANICAL EM-85 mm Connecting od swallend | __ Connecting rod small end bush ‘inner diameter ‘outer diameter Imerference it 31.070 — 81.000 37.025 01085-07710 nee Cylinder liner x Cylinder block upper gasket surface mm Onder fines lange Depth of eyincer block ‘section thickness flange section feneeet ot Preanitet 301-308 292-300 001-012 wreraoe Valve x Cylinder head lower gasket surface 7 mmm ‘Vale recession ariount intake vaive 100-170 Exhaust vane 100-170 weber Camshaft x Camshaft timing belt pulley mm Camshaft oer dameter Camshaft ering bet puley inertorence 2008-26021 28.000 - 28.021 “D7 - 0081 Precombusion chamber x Cylinder head lower gasket surtace mm ae, Depth of oyinder head section ‘Amount of protrusion 6.000 - 6005 5950-0 0-000 : aero Cylinder Head Gyjinder head lower gasket surface distortion mm on Manioid gasket surtace distortion mm 02 intake ta ‘Seat width mm Valve seat ie aad Intake 75,48, 75 Correction angle . Exnanst 15, 45,75 Guide bush srking temperature : °C | _Nommal temperature weraENGINE MECHANICAL Valve Spring item ‘Specified valve ‘Aliowable lint Free length ram 460 a7 ‘engin installed z een aon = “Tension a8 installed NOG 2648 (270) 2256 (30) ‘Ohofsquareness Ea = 16 Valve Lifter, Push Rod He tem Specified Valve ‘Allowable limit Vale Iter oll clearance mm 0018-0049) oa Push rod bend mm = Oa = weraee Valve Rocker Arm & Shaft item Species value ‘Alowatie iit Oil clearance en (0.018-0.061 or earners Valve Guid Bush Protrusion rom oylinder head (IN & EX) mm 760 were Valve ‘Specified value i — 0026 a = intake 0.026 0.062 O10 Exhaust 0.044-01086 012 Head stock tices a Sens ce Exhaust (090-130 05 H e. WREST ENS, Camshaft & Bearing tem Specified value allowable rit Rurout ca 7 08 “Tht eleerance rar 010-038 030) Bearing oil clearance ‘me | No. 1 to.No. 5 0.025 - 0.066 0.10 Cam lobe height mm Intake ells iad | Exhaust 37.767 1.0 EM-86ENGINE MECHANICAL Valve Rocker Arm & Shaft item Spectiog value ‘Allowable tit Top gasket suriace distorion mm = on Weer mm = 018 tmreerneee (Out roundness taper mm = 0.02 Promusion mm 001-072 = Pressing force NUS) 24516 (2500) = Connecting Rod Trem Specified value ‘Allowable lint Big end thas clearance mm 018-025, 0.80 Bearing oll cearance Ea (0.080 - 0.088 018 Piston pin oll cearance Ea 0005-0027 = | 0.05 Bend lit mm = 0.05 Twist it rm = [ 0.05 waraee Crankshaft tem ‘Spectied value ‘Allowable tnt Ronoat E mm 7 — 005 Thrust eteamace rm 0.050 0.189 025 TUsSfirisned dameted mm {02 | NenS 65.460- 68 Zs errr 6855 65.470 NOtS E710 68.725 us 075 - No2.3.4 (68.705 "68.720 bE 1 7 Nea. 8.960 68.975 | UiS 1.00 = = - 1 ‘NO-2, 3, 4 (68.955 - 68.970 1 ‘No.1, 5. 0.025 - | ‘Stem oil clearance mm geccb O15 No.2, 3.4 0.080- 0.088) [sto | ‘54.975 - 54.990 = [Us 025 Bares-54700 | a Crankpin diameter (UPS finished diameter] mm | US 0.50 84.475 - 54.490 I = us076 | $4225 - BaD = Us £00 ‘55.575 - 58300 = weno EM-87ENGINE MECHANICAL Flywheel iter ‘Specified value ‘Allowable init Rune ram = 02 Intake; Exhaust Manifold hem Spectied value ‘Allowable iit c = 3 Gasket sstace dizorion nm [0 7 [Bihaust = 4 wares Piston,PistonRing rem ‘Speciied value STD) 9188-9156 = Piston mm 1S 1.00 92.83 - 8256 = 9.060 = 0.080) 072, Piston oil clearance mm. | O82 | a DLs2 | 0.070 - 0.080 072 Not (035-050 = Piston ring end gap om Noe 0307045 = ‘OIL (030-650 = Tea POE | 0.06 “0.10 = - DLs2 7 Keystone er = Piston ring side clearance Saou! ee mom F Dia 0.04 - 0.08 = No.2 DLse 007-071 = [ow 0.02 - 0.06 = Piston pin insaling temperature 0-70 = weno Camshaft timing pulley, Crankshaft timing pulley, Injection timing pulley em | _Speciied value ‘Alowabie tit ‘Camshaft timing pulley 119.95 - 120.07 119.90 Timing pulley diameter mm | Crankshaft ting pulley 59.87 - 58.47, 69.20 EE 7 Injection pump tiring puley 119.904 120.084 119.86 i wresres Oipump is : __tere ‘Spectied valve ‘Alowable init Rel valve opening pressure Wa (kgiiom) | 4413-899.4(@5-55) Bs Side clearance mm 0.08 - 0.085 015 ‘Body clearance mm 01-046 040 vere ese EM-88ENGINE MECHANICAL Radiator tem Speced wave Aiwa a Radiator cap relief valve opening pressure kPa (kgtiom’) | 73.6 - 108.0 (0.75 - 1.05) 58.8 (0.60) Radiator leak test pressure kPa (kgtfom®) 417.7 (4.2) _ anaes Waterpump en T Specifedvave | Mtonabi i oarng Fatalng tatpore eT 0-80 | = Grearance between body and tor om oS = an Thermostat item | ‘Specified valve Allowable iimit Valve opening terperature (Start to open at) °C 80-84 62 Vane fi opening emoereure “val O | pipe ooe wo e Valve opening travel mn 10 60 — Waste gate valve, Turbo indicator lamp = Spectied vate Checking turbo incicator lamp Winen pressure exceeds 23.5 kPa (0.84 kgtiem") Turbo ingicator lamp goes on. When pressure is below 19.6 kPa (0.20 kaffer?) Turbo indicator iamp goes of. Checking operation of waste gate valve Shaft stroke: About 2mm (With a pressure of 89.2 KPe (0.91 kaffor) applied) (Checking supercharging pressure (Running test) 58.9 - 89.4 kPa (0.55 - 0.85 katiem*VAt S400 rpm Starter Tn ‘Specfed valve ees 12V ype Nominal eet iw = Voltage v us Novload characteristics Current A ead Rewduion speed pm Gres me 100e, EM-89ENGINE MECHANICAL Alternator tern Specified valve ‘Type 2V type Maxinu output A as Cutout revolution speed om (Not more than $500 ory Alternator Regulator em Specified value Regulating vokage v 138-748 ‘Voltage relay actuating voltage Vv 40-58 | Injection Nozzle, Nozzle Holder Iter Specified value ‘Alowable'tiit Nozzle opening pressure kPa (kgifem’) | 10297 - 11278 (105 - 115) fe EN ee ei : 20 sizes in 0.05 mm (0.002 inch) increment EM-90ENGINE MECHANICAL INJECTION PUMP La DLS sD OFT General | Aas, Seiterland PlangerGameter 2 5 5 ; Cam it mam 22 22 22 22 Pump specifications | Sscgonveuuar oa rm? 0 « 375 375 Injection orcer ABCD ABCD ABCD ABCD ["Govemorspedicaiors | Al speeds Al'speeds ‘All speeds All speeds (Overfiow amount inom | 21-477i900 | 2t-a7r900_| 17-a7700_|_17-S7/1700 Increase amount ‘curing staring 6 - 85/100 66 - 85/100 e6-ssy00 | 68-85/100 esiod mnmfstipm Injection rae cmisurpm | 418~50.5/400 | 415 -50.5/400 | 50-58/350 50 - 881350 eee 2i5- GESTION | S82-AOraTTIO0 | 6S7S-erTSTOD | eS 7S-Er TENT Fullload 38-agis00 | 95.1-40.1800 | 42:7-45.71500 | 42:7-45.71500 mevietrom | 44 ag;taso | a14-aetraso | 51-54)680 51-S44680 | 40.5-44srig00 | 36.6-a3.6n900 | 65-7070 | €5-70/1700 a wae | 183 285250 [17S Da.8ia080 [MATTE ZATSRO | MITTS aT aD ‘om specs irom | 245-225/2100 | 35-aaI2100 | 565-645/1800 | 565-645/1600 Governor Zorlessyas00 | Zorless‘24s0 | 2oriessi2500 | 2 orless/2500 i ae 65-115850 | 65- 115850 | “65-115850 | “65-11.5R50 Character Zortess/S00_| 2orkess¥600 | 2ortess/500_| 2 or ess/500 — ‘0- 1.0700 098700 | “o7-1.7700 | “06-18750 ee rmimipm | 29°80/1100 | 185-185/1100 | 25-a9'1100 | 22-s21100 37-47naso | 35-4s/4s0 | 4.1-8.1/1500 | 34-4.4/1500 5.7-657250 | 616-s.05/2060 | 49-57/1760 | 4.1-4:91600 fangs compensate = BS-AC TIO) | on a (N= 1100 rpm wit iever ‘osttioned at full stroke positon) - eee tener a | re \ ren‘JotkPa (rnmtig) = 503-S87/707 (2) a = = = 27-4970 | 427-4870 Boost compensator - - | s12-627240 (160) | 512-55.27240 (160) (No = 1100 rpm) as 7 £5855 506/883 (250) | 55 - 506/083 (250) mimikPa (mmHg) - - 75 - 61 25/667 (S00)6SS- 67251087 (00) - - 65 oc ee/t067(90)|665 or se08,7 (800 = = = 153- | Load sension timer mnnvmerfist | etae rare = = = 3.38- 4.38/Ful a = = = 2.0510 Addomatc col stat deve a fe A asisieanas oe s 7 o1as “": Characteristics when Po = 68.7 KPa (500 mmHg) * Characteristics when Pb = 0 kPa (O mm) EM-91