INDUSTRIAL DIESEL ENGINE 4LE2 MODEL
WORKSHOP MANUAL
©2003 ISUZU MOTORS LIMITED
FOREWORD This Workshop Manual is designed to help you perform necessary maintenance, service, and repair procedures on applicable Isuzu industrial engines. engines. Information contained in this Workshop Manual is the latest available available at at the tim e of publication. Isuzu reserves the right to make changes at any time without prior notice.
TABLE TABLE OF CON CONTEN TENTS TS SECTION 1.
GEN ER ERAL IN F FO ORM AT ATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
SECTION 2.
EN GIN E . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . .. .. .
27
SECTION 3.
LU BR BRICATIN G SY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79
SECTION 4. 4.
COOLIN G SY SYSTEM . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . .. .. . . . . . . . . .
83
SECTION 5. 5.
FU EL SYSTEM . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. .. . . . . . .
89
SECTION 6.
TROUBL UBLESHOOTING...... ..... ..... ..... .... ..... ..... .... 101
SECTION 7. 7.
SPECIAL TO TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
SECTION 8. 8.
CONVE NVERSION TA TABLE.... .... ..... ..... ..... ..... ..... ..... . 109
GENERAL INFORMATION 1
SECTION 1
GEN GEN ERAL INF IN FORM ORM ATION TABLE OF CONTENTS CON TEN TS
PAGE
GENER NERAL RE REPAIR INS INST TRUCT UCTIONS .... .... ..... ..... ..... ..... ..... ..... .... ..... ..... ..... ..... ..... ....
2
NOT NOTES ON ON TH THE FORMAT MAT OF OF THIS MANU MANUA AL ..... ..... ..... ..... ..... ..... ..... .... ..... ..... ..... .....
2
APPEARAN CE CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
MAI MAIN DATA AND AND SP SPECIFICATIONS.... NS.... .... ..... ..... ..... ..... ..... ..... .... ..... ..... ..... ..... ..... ....
6
TIGHTENING NING TORQUE SPECIFICATIONS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .
7
ANGUL NGULA AR NUT NUT AND AND BOLT TI TIGHTENING NING MET METHOD.... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
9
TIGHTENING NING TO TORQUE ON ON MAJ MAJOR CO COMPO MPONENT NENTS S ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 11 GASKET LOCATION ..... ..... ..... ..... ..... ..... ..... .... ..... ..... ..... ..... ..... ..... ..... ..... .... ..... . 17 M AI AIN T TE EN AN CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 RECOMMEND MMENDE ED LUBR UBRICATING OIL... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 25
2 GENERAL INFORMATION
GENERAL REPAIR INSTRUCTIONS 1. Before performing any service operation with the engine mounted, disconnect the grounding cable from the battery. battery. This will r educe the chance chance of cable cable damage and burni ng due to shor t circuiting. 2. Always use use the proper proper tool or too ls for the job at at hand. Where specified, specified, use the specially specially designed to ol or tools. 3. Use genuine ISUZU parts referri ng ISUZU PART PARTS S CATALOG CATALOG for t he engin es. 4. Never reuse cotter pi ns, gaskets, gaskets, O-ring O-ring s, lock washers, and self locking nuts. Discard Discard them as you remov e them . Replace eplace them w ith new ones. 5. Alw ays keep keep disass disassembled embled parts neatly neatly in gro ups. This wi ll ensure a smo smo oth reasse reassem m bly operation. It is especia especially lly i mp ortant t o keep keep fastening parts separate. separate. These These parts vary in hardn ess ess and design, depending on their installation position. 6. All parts should be carefully carefully cleaned before before inspection or reasse reassemb mb ly. Oil ports and other openings should be cleaned with compressed air to make sure that they are completely free of obstructions. 7. Rotating and slidi ng part surfaces should be lubr icated icated w ith oi l or gr ease ease before reasse reassem m bly. 8. If necessary, necessary, use a sealer sealer on g askets askets to prev ent leakage. 9. Nut and bolt torqu e specifications specifications should should be carefully carefully foll ow ed. 10. Alw ays release release the air pressure pressure from any m achine-mou achine-mou nted air tank(s) tank(s) before dismou nting t he engine or d isconnecting isconnecting pipes and hoses. 11. Alw ays check check and and recheck recheck your wo rk. No service operation is compl ete until y ou have done this. 12. Inform ation contained in the “ Main Data and and Specifications” Specifications” of the Workshop M anual and the InstrucInstruction Book may differ. In this case case,, the inform ation contained in the Instruction Instruction Book should be considered considered applicable.
N OTES OTES ON THE FORM ORM AT OF THIS MAN M ANU U AL This Workshop Workshop M anual is applicable to the 4LE2 4LE2 fam fam ily of in dustrial diesel diesel engines. Unless otherw ise specified, specified, these engines have comm on parts and com ponents as w ell as data and specifications. specifications. Illustrations used in this Wo rkshop M anual are based based o n th e 4LE 4LE2 engines. 1. Find th e applicable applicable section section by r eferring to t he Table Table of Contents Contents at the beginning of the M anual. 2. Common technical data such as general maintenance items, service specifications, and tightening torqu es are included in the “ General General Inform ation” section. section. 3. Eac Each h section is div ided in to sub-sections sub-sections d ealing ealing wi th disasse disassemb mb ly, inspection and repair, and reassembly. 4. When the same servicing operation is applicable to several different units, the manual will direct you to the approp riate page. 5. For the sake sake of brevity, self-explanatory self-explanatory r emoval and in stallation stallation p rocedures are are omi tted. Mo re complex pro cedures cedures are covered in detail.
GENERAL INFORMATION 3 6. Each ach service operation section section i n this Workshop M anual begins with an exploded view o f the applicable area.
(Example) Major components Figures in parentheses parentheses “ (
)” show the order of disasse disassemb mb ling or reasse reassem m bling .
Water Outlet Pipe (5) Packing (6) Thermostat (7)
Water pump ASM (8)
Pulley; Fan (4) Spacer (2) Fan; Cooling (1)
Belt; Fan (3)
Fig. 1
7. M easurement easurement criteria are defined by the term s “ standard” and “ lim it” . A m easurement easurement fallin g w ithin the “ standard” range indicates that the applicable part or parts are serserviceable. “ Limit ” should be thoug ht of as an an absolute value. A m easurement easurement w hich is outside the “ lim it” indicates that the applicable part part or p arts must be either repaired or replaced. replaced. 8. Com ponents and and parts are are listed listed in the singul singul ar form thr ougho ut the Manual.
4 GENERAL INFORMATION 9. The follow ing symbo ls appear appear throug hout this Worshop Manual. They tell you the type of service service operation operation or step step to perform.
...
Rem o v e
...
A d j u st m en t
...
In st al l at i o n In
...
Cl ean i n g Cl
...
Di sassem bl bl y
...
Im po po r t an t Op er at i o n Req u i r i n g Ex t r a Car e
...
Reassem bl bl y
...
Sp eci f i ed To r q u e (Ti g h t en )
...
A l i g n m en t (M ar ks)
...
Special Tool Use Required for Recommended (Isuzu Tool or Tools)
...
Di r ect i o n al In d i cat i o n
...
Com mercially Av ailable Tool Use Required Required or Recommended
...
In sp ect i o n
...
Lu b r i cat i o n (Oi l )
...
M easu r em en t
...
Lu b r i cat i o n (Gr ease)
...
Sealant lant
10. Direction Direction used in this M anual are are as follo ws: Front The cooling fan side of the engine viewed from the flyw heel. Right The injection injection p um p side of the engine. Left The exhaust exhaust manifo ld side of the engine. Rear The flywh eel side side of th e engine. Cylind er num bers are are counted from the front of the engine. The front m ost cylinder is No. 1 and and rear m ost cylinder is No. The engine’s engine’s direction of rot ation is counterclockwi counterclockwi se viewed fro m t he flyw heel.
GENERAL INFORMATION 5
APPEARANCE 1. MODE MODEL 4LE2 (1) (1) Left eft sid side e view view
Fig. 2
(2) (2) Right ight sid side e vie view w
Fig. 3
6 GENERAL INFORMATION
MAIN DATA AND SPECIFICATIONS 1. MODE MODEL 4LE2 Engine model(s)
4LE2
Item Ty p e
4-cy cl e, v er l i cal i n -l i n e, w at er co o l ed , OHV
Ti m i n g d r i v e sy st em
Gear d r i v e
No. of cylinders - bore
×
st r o k e
Di sp l acem en t
mm
4 – 85 × 92
L (ci d )
2.179 (133)
Co m p r essi o n r at i o
18 . 8 : 1
T y p e o f co m b u s t i o n Overall Overall lengt h
×
width
Di r ect i n j ect i o n ×
h ei g h t
mm
*
691 × 449 × 616
kg ( l b )
*
155 (342)
( w h e n at s t o p )
*
14°
Dr y w ei g h t Fu el i n j ect i o n t i m i n g (BTDC) Fi r i n g o r d er
1–3–4–2
Fuel
Highspeed diesel fuel (SAE No.2) m in -1
Idling speed speed Com pression pressure Valve clearance (cold (cold ) mm (in) (in)
Valve operating timing
*
M Pa(kg/cm a(kg/cm 2 /psi )
85 0 3 (31/440) or o r m or e/250 m in -1
In t ake
0.4 (0.0157)
Ex h au st
0.4 (0.0157)
Op en (BTDC)
15°
Cl o se (A BDC)
29°
Op en (BBDC)
40°
Cl o se (A TDC)
16°
Intake valve
Exhaust valve
In j ect i o n p u m p
Bo sch t y p e
Go v er n o r
M ech an i cal t y p e
N o zzl e
M u l t i -h o l e t y p e
Injection pressure
M Pa(kg/cm a(kg/cm 2 /psi )
*
17.7 (180/2560)
Oi l p u m p
Tr o ch o i d t y p e
Oi l f i l t er
Car t r i d g e t y p e
Lu br br ic ican t cap ac aci t y : In t o t al
L (q t s)
*
A b ou ou t 8.7 (9.2)
Gen er at o r o u t p u t
(V – A )
*
12 – 35
(V – KW )
*
12 – 2.0
St ar t er o u t p u t
These specifications specifications may b e subject subject to change with out notice. (Note) These Figures in the colum n w ith an asterisk asterisk (*) are dif ferent for each each m achine. achine. Refer Refer to t he specificaspecifications provi ded by machine manufacturers.
GENERAL INFORMATION 7
TIGHTENIN G TORQUE SPECIFIC SPECIFICA ATIONS TION S The tightening torque values given in the table below are applicable to the bolts unless otherwise specified.
STANDARD BOLT
N·m (kgf·m)
Bolt Identification
Bolt Diameter × pitch (mm) M6
×
1.0
003.9 00 3.9
007.8 00 7.8 {0 {00.4
00.8}
004.9 00 4.9
009.8 00 9.8 {0 {00.5
01.0}
M8
×
1.25
007.8 00 7.8 017.7 {0 {00.8
01.8}
011.8
022.6 {0 {01.2
02.3}
016.7
030.4 {0 {01.7 03.1}
M 10 × 1.25
020.6 034.3 {0 {02.1
03.5}
027.5
046.1 {0 {02.8
04.7}
037.3
062.8 {0 {03.8 06.4}
019.6 033.4 {0 {02.0
03.4}
027.5
045.1 {0 {02.8
04.6}
036.3 059.8 {0 {03.7 06.1}
M 12 × 1.25
049.1 073.6 {0 {05.0
07.5}
060.8
091.2 {0 {06.2
09.3}
075.5 75.5
114.0 114 .0 {07.7 7.7
11.6 11.6}}
* M 12 × 1.75
045.1 068.7 {0 {04.6
07.0}
056.9
084.4 {0 {05.8
08.6}
071.6 71.6 107. 107.0 0 {07.3 7.3
10.9 10.9}}
M 14 × 1.5
076.5 76.5
115.0 115 .0 {07.8 7.8
11.7 11.7}}
093.2 93.2
139.0 139 .0 {09.5 9.5
14.2 14.2}}
114.0 114 .0
171.0 171 .0 {11.6 11.6 17.4 17.4}}
* M 14 × 2.0
071.6 71.6
107.0 107 .0 {07.3 7.3
10.9 10.9}}
088.3 88.3
131.0 131 .0 {09.0 9.0
13.4 13.4}}
107.0 107 .0
160.0 160 .0 {10.9 10.9 16.3 16.3}}
* M 10 × 1.5
M 16 × 1.5
104.0 104 .0 157 157.0 .0 {10.6 {10.6 16.0} 16.0}
135.0 135 .0 204 204.0 .0 {13.8 {13.8 20.8} 20.8}
160.0 160 .0
240.0 240 .0 {16.3 16.3 24.5 24.5}}
* M 16 × 2.0
100.0 100 .0 149 149.0 .0 {10.2 {10.2 15.2} 15.2}
129.0 129 .0 194 194.0 .0 {13.2 {13.2 19.8} 19.8}
153.0 153 .0
230.0 230 .0 {15.6 15.6 23.4 23.4}}
M 18 × 1.5
151.0 151 .0 226 226.0 .0 {15.4 {15.4 23.0} 23.0}
195.0 195 .0 293 293.0 .0 {19.9 {19.9 29.9} 29.9}
230.0 230 .0
345.0 345 .0 {23.4 23.4 35.2 35.2}}
* M 18 × 2.5
151.0 151 .0 226 226.0 .0 {15.4 {15.4 23.0} 23.0}
196.0 196 .0 294 294.0 .0 {20.0 {20.0 30.0} 30.0}
231.0 231 .0
346.0 346 .0 {23.6 23.6 35.3 35.3}}
M 20 × 1.5
206.0 206 .0 310 310.0 .0 {21.0 {21.0 31.6} 31.6}
270.0 270 .0 405 405.0 .0 {27.5 27.5 41.3 41.3}}
317.0 317 .0 476 476.0 .0 {32.3 {32.3 48.5} 48.5}
* M 20 × 2.5
190.0 190 .0 286 286.0 .0 {19.4 {19.4 29.2} 29.2}
249.0 249 .0 375 375.0 .0 {25.4 {25.4 38.2} 38.2}
293.0 293 .0 440 440.0 .0 {29.9 {29.9 44.9} 44.9}
M 22 × 1.5
251.0 251 .0 414 414.0 .0 {25.6 {25.6 42.2} 42.2}
363.0 363 .0 544 544.0 .0 {37.0 {37.0 55.5} 55.5}
425.0 425 .0 637 637.0 .0 {43.3 {43.3 64.9} 64.9}
* M 22 × 2.5
218.0 218 .0 328 328.0 .0 {22.2 {22.2 33.4} 33.4}
338.0 338 .0 507 507.0 .0 {34.5 {34.5 51.7} 51.7}
394.0 394 .0 592 592.0 .0 {40.2 {40.2 60.4} 60.4}
M 24 × 2.0
359.0 359 .0 540 540.0 .0 {36.6 {36.6 55.0} 55.0}
431.0 431 .0 711 711.0 .0 {43.9 {43.9 72.5} 72.5}
554.0 554 .0 831 831.0 .0 {56.5 {56.5 84.7} 84.7}
* M 24 × 3.0
338.0 338 .0 507 507.0 .0 {34.5 {34.5 51.7} 51.7}
406.0 406 .0 608 608.0 .0 {41.4 {41.4 62.0} 62.0}
521.0 521 .0 782 782.0 .0 {53.1 {53.1 79.7} 79.7}
An asterisk asterisk (* ) indicates indicates that t he bolts are used used for female threaded parts that are made m ade of soft soft materials m aterials such as casting.
8 GENERAL INFORMATION
TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unless otherwise specified.
FLANGED HEAD BOLT
N·m (kgf·m)
Bolt Identification
Bolt Diameter × pitch (mm) M6
×
1.0
004.6 00 4.6
008.5 00 8.5 {0 {00.5
00.9}
006.6 00 6.6
012.2 {0 {00.6
01.2}
M8
×
1.25
010.5 0196 {0 {01.1
02.0}
015.3 028.4 {0 {01.6
02.9}
018.1
033.6 {0 {02.1
03.4}
023.1
038.5 {0 {02.4
03.9}
035.4 058.9 {0 {03.6
06.1}
042.3
070.5 {0 {04.3
07.2}
022.3
037.2 {0 {02.3
03.8}
034.5 057.5 {0 {03.5
05.8}
040.1
066.9 {0 {04.1
06.8}
M 12 × 1.25
054.9
082.3 {0 {05.6
08.4}
077.7 77.7
117.0 117 .0 {07.9 7.9
11.9 11.9}}
085.0 85.0
128.0 128 .0 {08.7 8.7
13.0 13.0}}
* M 12 × 1.75
051.0
076.5 {0 {05.2
07.8}
071.4 71.4
107.0 107 .0 {07.3 7.3
10.9 10.9}}
079.5 79.5
119.0 119 .0 {08.1 8.1
12.2 12.2}}
M 14 × 1.5
083.0 83.0
125.0 125 .0 {08.5 8.5
12.7 12.7}}
115.0 115 .0 172 172.0 .0 {11.7 {11.7
17.6} 17.6}
123.0 123 .0
185.0 185 .0 {12.6 {12.6 18.9} 18.9}
* M 14 × 2.0
077.2 77.2
116.0 116 .0 {07.9 7.9
11.8 11.8}}
108.0 108 .0 162 162.0 .0 {11.1 {11.1
16.6} 16.6}
116.0 116 .0
173.0 173 .0 {11.8 {11.8 17.7} 17.7}
M 16 × 1.5
116.0 116 .0 173 173.0 .0 {11.8 {11.8 17.7} 17.7}
171.0 171 .0 257 257.0 .0 {17.4 {17.4
26.2} 26.2}
177.0 177 .0
265.0 265 .0 {18.0 {18.0 27.1} 27.1}
* M 16 × 2.0
109.0 109 .0 164 164.0 .0 {11.2 {11.2 16.7} 16.7}
163.0 163 .0 244 244.0 .0 {16.6 {16.6
24.9} 24.9}
169.0 169 .0
253.0 253 .0 {17.2 {17.2 25.8} 25.8}
M 10 × 1.25
* M 10 × 1.5
A bolt w ith it h an asterisk (* ) is used used for female screws of soft mat erial such such as cast cast iron.
GENERAL INFORMATION 9
ANGU AN GUL LAR NUT NU T AND AN D BOL BOLT TIGHTEN TIGHTEN ING IN G M ETHOD
1. Carefully wash the nuts and bolts to remove all oil and g rease. rease.
2. Apply a coat coat of m olybdenum disulfide grease grease to the threads and setting setting faces faces of th e nuts and bo lts.
Fig. 4
3. Tighten the nuts and bolts to the specified torque (snug torque) with a torque wrench.
Snug torque
Fig. 5 Center Center li ne
Fig. 6
4. Draw Draw a line [A-B] [A-B] across across the cente centerr of each each bolt.
10 GENERAL INFORMATION 5. Draw Draw another another line [C-D [C-D]] on th e face face of each each of the parts to be clamp clamp ed. This line should be an extenextension of th e line [A-B]. [A-B].
Line
B
A
C
D
Fig. 7
6. Draw Draw another another line [F-G [F-G]] on the face of each each of the parts to be clamped. This line will be in the direcdirection of the specified angle [Q] across the center [E] of the nut or bolt.
E Specified angle (Q)
F Coinciding line
G
Fig. 8
7. Use a sock socket et wrench to tighten eac each h nut or b olt to the point w here the line [A-B] is aligned wit h the line [F-G].
Tighten
A C B
D
F
G Fig. 9
Exampl e: Specified Specified Angle and Tightening Rotation
A
Fig. 10
B C D E
A
30° 30°
1/12 1/1 2 of a tur n
B
60° 60°
1/6 of a turn
C
90° 90°
1/4 of a turn
D
180°
1/2 of a turn
E
360°
One full turn
GENERAL INFORMATION 11
TIGHTENING TORQUE ON MAJOR COMPONENTS 1. COOL OOLING ING FAN FAN AND WATE WATER R PUM P N·m (kgf·m/ (kgf·m/ ft. lb) 19 – 28 (1.9 – 2.9 / 14 – 21)
12 – 18 (1.2 – 1.8 / 9 – 13)
12 – 18 (1.2 – 1.8 / 9 – 13)
19 – 28 (1.9 – 2.9 / 14 – 21) To cylinder head
19 – 28 (1.9 – 2.9 / 14 – 21) To cylinder head
19 – 28 (1.9 – 2.9 / 14 – 21) 19 – 28 (1.9 – 2.9 / 14 – 21) 34 – 46 (3.5 – 4.7 / 25 – 34) Fig. 11
12 GENERAL INFORMATION
2. CYLINDER CYLINDER HEAD HEAD AND CYLINDER CYLINDER HEAD HEAD COVER COVER N·m (kgf·m/ (kgf·m/ ft. lb) 8 – 12 (0.8 – 1.2 / 6 – 9)
8 – 12 (0.8 – 1.2 / 6 – 8)
2–4 (0.2 – 0.4 / 1.4 – 2.9)
8 – 12 (0.8 – 1.2 / 6 – 9)
(Apply sealant.) sealant.)
83 – 93 (8.5 – 9.5 / 61 – 69) 60˚ – 90˚ 15 – 20 (1.5 – 2.0 / 11 – 14)
(Apply engine oil.)
19 – 28 (1.9 – 2.9 / 14 – 21)
0.9 – 1.1 (0.09 – 0.11 / 0.6 – 0.8)
(Apply Locktite No.262 to this part.)
25 – 34 (2.5 – 3.5 / 18 – 25) 19 – 28 (1.9 – 2.9 / 14 – 21)
(Apply engine oil.)
Fig. 12
14 GENERAL INFORMATION
4. CYLINDER CYLINDER BLOC BLOCK K AND OTHER OTHER COM COMPO PONENTS NENTS (2) N·m (kgf·m/ (kgf·m/ ft. lb) 20 – 25 (2.0 – 2.5 / 15 – 18) 10 – 14 (1.0 – 1.4 / 7 – 10)
8 – 12 (0.8 – 1.2 / 6 – 9)
15 – 25 (1.5 – 2.5 / 11 – 18)
31 – 41 (3.2 – 4.2 / 23 – 30) 19 – 28 (1.9 – 2.9 / 14 – 21)
8 – 12 (0.8 – 1.2 / 5.8 – 8.7)
19 – 28 (1.9 – 2.9 / 14 – 21)
21 – 30 (2.1 – 3.1 / 15 – 22)
Positioning pin.
(Apply engine oil.)
8 – 12 (0.8 – 1.2 / 6 – 9)
69 – 88 (7.0 – 9.0 / 51 – 65)
19 – 28 (1.9 – 2.9 / 14 – 21)
19 – 28 (1.9 – 2.9 / 14 – 21) Fig. 14
GENERAL INFORMATION 15
5. CYLINDER YLINDER BLOC BLOCK K AND OTHER OTHER COM COMP PONENTS (3) N·m (kgf·m/ (kgf·m/ ft. lb)
Apply Locktite No.262 (2 locations).
8 – 12 (0.8 – 1.2 / 6 – 9) 12 – 16 (1.2 – 1.6 / 9 – 12)
8 – 12 (0.8 – 1.2 / 6 – 9)
Rotate 3/4 turn after contacted with sealing surface.
1.5 – 25 (1.5 – 2.5 / 11 – 18)
(With PTO PTO provided)
8 – 12 (0.8 – 1.2 / 6 – 9)
19 – 28 (1.9 – 2.9 / 14 – 21)
8 – 12 (0.8 – 1.2 / 6 – 9)
19 – 28 (1.9 – 2.9 / 14 – 21)
Fig. 15
41 – 55 (4.2 – 5.6 / 30 – 41) 8 – 12 (0.8 – 1.2 / 6 – 9)
16 GENERAL INFORMATION
6. TURB TURBOCHAR OCHARGE GER R N·m (kgf·m/ (kgf·m/ ft. lb)
19 – 28 (1.9 – 2.9 / 14 – 21)
Fig. 16
GENERAL INFORMATION 17
GASKE GAS KET T LOCA LOCATION TIO N 1. LOCA OCATIONS WHE W HERE RE GASKETS GASKETS ARE ARE USED
Packin; Packin; no zzle zzle ho lder Gasket; Gasket; no zzle zzle ho lder
Packin; ackin; join t bo lt
O-ring
Packin; Packin; h eadcover ( ) Sea Seala lant nt shou should ld not not b be e applied.
Gasket
Seal; valve
Packin; water outlet pipe
Gasket; cylinder head
Packin; idle spring set screw screw
O-ring; fuel cut lever
Packin; rear cover (PTO)
Packin; governor cover
Gasket; exhaust manifold
Oil seal; crankshaft rear
O-ring; control lever
O-ring; Oil strainer
O-ring; angleich cover Oil seal; crankshaft crankshaft fro nt
O-ring; Oil pump O-ring; Oil drain plug
Fig. 17
Gasket; exhaust silencer
18 GENERAL INFORMATION
2. LO LOC CATIONS WHER W HERE E SEAL SEALANT ANT IS APPL APPLIED IED Locat ion Name of part
Condit ion for use N am e of m at ing part
Object t o be sealed
Groove t o be applied
Name of sealant
1
Oi l p an
Cy l i n d er b l o ck
Engine oil (10W-30)
N o t p r o vi vi d ed
T B 12 0 7 C
2
Ro cker b r acket
Cy l i n d er h ead
Engine oil (10W-30)
Pr o v i d ed
TB1207B
3
A i r i n l et p i p e
Cy l i n d er h ead co v er
Ai r
Pr o v i d ed
TB 1207 C
4
Front plate (w i t h PTO p r o v i d ed )
Cylind er block
Engine oil (10W -30)
Pr o v i d ed
TB1207B
5
Timin g case case (with PTO p r o v i d ed )
Front plate
Engine oil (10W -30)
Pr o v i d ed
TB1207B
6
Timin g case case (with n o PTO p r o v i d ed )
Cylind er block
Engine oil (10W -30)
Pr o v i d ed
TB1207B
7
W at er p u m p A SM
Cy l i n d er b l o ck
Co o l i n g w at er
N o t p r o v i d ed
T B 1 20 7 C
8
Rear cover; water pump
Bo d y ; w at er p u m p
Co o l i n g w at er
Pr o v i d ed
TB1207B
9
Housing cover; i n j ect i o n p u m p
Cylind er block
Engine oil (10W -30)
Pr o v i d ed
TB1207B
10
So l en o i d ; f u el cu t
Cy l i n d er b l o ck
Engine oil (10W-30)
Pr o v i d ed
T B 1 2 07 C
11
Ret ai n er ; o i l seal
Cy l i n d er b l o ck
Engine oil (10W-30)
Pr o v i d ed
TB1207B
12
In d i cat o r ; ai r cl ean er
A i r cl ean er
Ai r
N o t p r o v i d ed
(Seal i n g t ap e)
Fig. 18
Cautions: 1. Always use use the above above brand brandnames names or an equivale equivalent nt as the seala sealant. nt. 2. Since Since Loc Loctit tite e FM FM D127 and Three-Bond Three-Bond 1386 are anaerobic anaerobic,, do not use use them in case case a gap exceeding exceeding 0.25 mm is occurring between the metallic mating surfaces since satisfactory effects cannot be expected. 3. Always use use the optimum quantity quantity of sealant. sealant. Observ Observe e the handling handling precautions precautions designa designated ted for respective respective products. When applying a sealant sealant : (1) (1) when applying a seala sealant nt over a surface surface where some some other liquid gaske gaskett w as used used previously, previously, thoroughly clean the reside sealant using a scraper and wipe the surface by waste cloth to remove oil, mo isture, dust, etc. etc. from the surface. surface. (2) (2) When When using using the gask gasket et remover remover “ Bundo 391D” 391D” made by Three-Bond (Isuzu’ (Isuzu’ s Part No. 1-8840-0542-0) to facilitate the “ cleaning work” work” , apply the remover and leave it as is for “ about 10 minutes” minutes” before starting starting t he removal w ork. (3) (3) Be care careful ful not to apply apply too much or too little. little. (4) How to use the TB1 TB120 207C 7C and TB120 TB1207B 7B Apply them with a line diameter diameter of 3 mm or m ore and for a thicknes thickness s of 1 ~ 2 mm. Apply them along the gluing groove w ithout interruptions and asse assemble mble the m ating structures structures with 5 minutes. Also, after finishing the assembly, leave the assembly as is for at least 2 hours and do not run the engine during this period.
GENERAL INFORMATION 19
Bolt hole
Determ ina tion
Dent
Apply onto the bore surface Dent
of the bolt hole. Specified Specified bead widt h (Reference) Anaerobic : 2 ~ 3 mm Others : 2 ~ 6 mm
Caution: Caution: When the t he application application method m ethod is being designated designated in t he repair manual, follow the designation.
3. Lockt ocktit ite e Types
Colors
W ork procedures 1.
Lo c t i t e 24 2
Bl u e 2.
Wipe the thoroughly thoroughly remove remove oil, oil, grea grease se and and moisture moisture from from the m ating surfaces such such as the bolt surface, surface, bolt hole, thread surface of th e nut. A pp pp ly ly Lo ck ckt it it e. e. Apply over the tip end surface, namely 1/3 of
Lo c t i t e 26 2
Lo c t i t e 27 1
Red
Red
the thr eaded section. section.
3. Tighte ighten n the the bolt bolt at the the “ specified specified tor que que”” . Caution: Caution: After t ightening the bolt, do not apply excessiv excessive e torque or vibrations for “about an hour” until the applied Loctite sets.
20 GENERAL INFORMATION
MAINTENANCE 1. VALVE VALVE CL CLEARANCE ARANCE AND ADJUSTM ENT
Note: The cylinder head bolts were previously tightened with th e “ Angular Tightening Method” Method ” . Therefore, Therefore, it is not necessary to retighten the cylinder head bolts before adjusting the valve clearance.
Fig. 19
1. Bring the piston in either either the No. 1 cylinder cylinder or the No. 3 cylinder to Top Dead Center on the compression stroke by turning the crankshaft until the TDC mark on the front cover cover aligns with the groove mark on th e cranksha crankshaft ft pu lley.
Groove mark TDC mark
2. Check to see if there is play in the No. 1 intake and exhaust valve rocker arms. imi ng gear (Tcase cover )
If the No. 1 cylinder intake and exhaust valve rocker arms have play, the No. 1 piston is at TDC on the compr ession ession stroke.
Crank pulley
Fig. 20
If the No. 1 cylinder intake and exhaust valve rocker arms are depressed, the No. 4 piston is at TDC on the comp ression ression stroke. Adjust the circle or double circle marked valves as shown in Fig. 22, while the No. 1 or the No.4 cylinder is at TDC on compression stroke. mm (in) (in) No.1 cylinder exhaust
No.1 cylinder intake
Valve arrangement
1 I
2 E
I
3 E
I
4 E
I
E
4. Insert Insert a 0.40 0.40 m m (0.015 (0.015 in) feeler feeler gauge between the rocker rocker arm and the valve stem end. 5. Turn the valve cleara clearance nce adjusting adjusting screw screw until a slight dr ag can can be belt on the feeler feeler gauge.
No. 1 cylinder TDC for compression
6. Tighten Tighten the lock lock nut sec securely. urely.
No. 4 cylinder TDC for compression I ; Int ake
0.40 0.4 0 ± 0.0 0.05 5 (0.015 (0.015 ± 0.00 0.002) 2)
3. Loosen Loosen each each valve clearanc clearance e adjusting adjusting screw as shown in the illustration. illustration.
Fig. 21 Cy l i n d er N o .
Intake and Exhaust Valve Clearance (cold)
7. Rotate the crank cranksha shaft ft 360° 360°. E ; Exhaust
Fig. 22
Realign the crankshaft pulley. 8. Adjust the cleara clearance nces s for the remaining valves as shown in the illustration. illustration.
GENERAL INFORMATION 21
2. LUBRIC UBRICA ATIN SYSTEM SYSTEM Cartridge (Spin-On) Type Cartridge
Removal Remover and Installer: Filter Wrench 1. Loosen Loosen the used used oil filter by turning it counterclock counterclock-wise with the filter w rench. rench. 2. Disca Discard rd the used used oil filter. filter.
Installation 1. Wipe the oil filter mounting face face with a clean clean rag. rag. Fig. 23
This wi ll allow th e new new oi l filter to seat seat properly. 2. Lightly Lightly oil oil the O-ring. O-ring. 3. Turn in the new new oil filter until the sea sealing ling face face is fitted against the O-ring. 4. Use the filter filter wrench to turn in the oil filter an an additional 3/4 of a turn or on e turn. 5. Check the engine oil level level and replenish replenish to the specispecified level if required. 6. Start Start the engine and and check check for oil leakage leakage from the oil filter.
3. COO OOL LING SYSTE SYSTEM M Cooling Fan Drive Belt Adjustment
Fan pulley 1 Depress here Cooling fan drive belt
About 10 mm Generator Generator pu lley 2
Crank pulley
Fig. 24
1. Check heck the cooling cooling fan drive belt for crack cracking ing and other damage. 2. Check heck the drive belt belt tension by exerting exerting a force of 98 N (10 kg) midw ay between the Fan Fan pul ley 1 and the Generator Generator pu lley 2. 3. Adjust the belt tension tension by loosening loosening the Genera Generator tor mounting bolt and the Generator adjusting bolt and pivoting the Generator. Be sure to retighten th e bolts after adjusting the belt tension. mm (in) (in) Co o l i n g Fan Dr i v e Bel t Def l ect i o n
7.5 – 8.5 – 8.5 (0.3 – 0.33) – 0.33)
22 GENERAL INFORMATION
4. INJE INJECTIO TION TIMING TIMING Note: Take care to avoid entry of dust or foreign particles into the pump interior when the timing adjustment is made. Delivery valve holder
Injection pump
Delivery spring
1.
Remove the inje inject ction ion pipe of the No. 1 cylinde cylinder. r.
2.
Remove the deli delive very ry valve valve holde holderr of the inje inject ction ion pump of the No. 1 cylinder, and then pull out the delivery spring.
3.
With the the spring spring left left removed, removed, instal installl the delive delivery ry valve holder.
4.
Slowly Slowly turn the cra cranks nkshaf haftt pulley pulley clockwis clockwise, e, at the sam sam e time, continue to feed the fuel. When the fuel fuel stop flowing out from the No. 1 delivery valve holder, stop tu rning the crankshaft. crankshaft.
Fig. 25
This crank angle position is the starting point of injection. 5. Groove mark TDC mark
In th the e condition condition at at Step Step (4) (4) abo above ve,, confirm confirm what degree the “ groove mark” mark” of the crank pulley is at, when seen by the “ timing mark” mark” , provided in the tim ing gear case case.. When the value is out of the range of the normal injection timing, adjust it accordingly.
(
Timi ng gear case cover
* In j ect i o n t i m i n g
)
Crank pulley
Injection Injection pum p Cylinder block Shim
Note: The injection timing varies according to the specifications of the machine.
Fig. 26
Identification mark
BTDC 14°
6.
Adjust Adjust the injecti injection on timing timing with a shim shim betwee between n the injection pum p and the cylind cylind er block. block. Shim i s available available in the follow ing 9 types, and and “ identification tification mark” mark” is stamped (or imprinted) on the top face.
Id en t if if i cat i o n m ar ar k o f sh sh i m an an d it it s t h i ckn ess Knock hole
Fig. 27
(m m )
M ar ark
Thickness
M ar ark
Thickness
M ar k
Thickn ess
2
0.2
5
0.5
8
0.8
3
0.3
6
0.6
10
1.0
4
0.4
7
0.7
12
1.2
Note: For each of the injection pumps of three cylinders, the shim adjustment is made at the same time. When a shim is missing while overhauling the engine and the shim thickness is unknown, assemble the engine with provisional shim inserted. After assembling the engine, check the injection timing and adjust the shim until the normal injection timing is obtained. Reference: To add the 0.1 mm shim thickness corresponds to the 1 degree of crankshaft angle advance.
GENERAL INFORMATION 23 Air bleeding from fuel (automatic air-bleeding system) 1.
For the the automatic automatic air-b air-blee leedin ding g sys system tem When the starter swit ch is set set to “ OPERATION” OPERATION ” , the electrom electrom agnetic pum p is activated to force-feed force-feed fuel to the fuel pipe and the leak-off pipe, and air in the fuel system system i s autom autom atically atically bl ed.
2. Injection Pump
Fig. 28
For non non-au -automatic tomatic air-b air-blee leedin ding g sys system tem While sending fuel by m eans eans of the for ce of the elecelectromagnetic pump, the fall from the fuel tank or the feed pump lever, bleed air out of the fuel pipe eye bolt of the No. 1 cylind cylind er injection pum p, the leak-off leak-off pipe eye bolt of the injection nozzle and the airbleeder plug of the fuel filter, starting with the one installed installed the lower m ost and upward.
5. COMP OM PRESSION SSION PRESSURE M EASUREM ASUREM ENT Compression gauge
1. Operate Operate the engine engine to warm-up until the coolant coolant temperature r eachs eachs to 75° 75°C (167° (167°F). 2. Remove all all of the glow plugs and and the injection injection pipes.
Adapter; gauge
3. Attach Attach a compression compression gauge gauge to the No. 1 cylinder cylinder glow plug installation threads.
Note: Compression pressure may be measured starting at any cylinder and in no particular parti cular cylinder order. How ever, it is very important that the compression pressure be measured in each cylinder. Therefore, Therefore, start start at the No. N o. 1 cylinder cylinder and w ork back. back. In this way, you will be sure to measure the compression pressure pressure in each cylinder. Fig. 29
Compressi ompression on Gauge Gauge
5-88 5-8840 40-2 -267 6755-0 0
Com pression pression Gauge Gauge Adapter 5-88 5-884040-90 9029 29-0 -0
4. Crank the engine with the starte starterr m otor and take take the compr ession ession gauge reading. MPa (kgf/cm 2 /psi ) at 250 m in -1 St an d ar d
Li m i t
3 (31/440)
2.5 (26/370)
5. Repe epeat at the procedure procedure (.Steps 3 and 4. 4.) for the remaining cylinders. Fig. 30
Compression pressure should be approximately the same same for each each cylinder. A variation exceeding exceeding 200 kPa (2.0 kg/cm 2 / .28 psi. psi .) is unacceptable. If the measured value exceeds the specified limit, the related parts must be checked.
24 GENERAL INFORMATION
6. FUEL UEL SYST SYSTE EM Fuel Filter Replacement Cartridge (Spin-On) Type Removal 1.
Loose Loosen n the fue fuell filter filter by turning it counte countercl rcloc ockwis kwise e wi th the filter wrench or your hand. hand. Discard Discard the used filter. Filter Wrench
2.
Wipe the fuel fuel filte filterr fitting face face clea clean n with a rag. rag. This will allow the new fuel filter to seat properly.
Fig. 31
Installation 1.
Apply a light coa coatt of engine engine oil to the O-ring. O-ring.
2.
Suppl upply y fue fuel to the the new new filte filter. This will f acilitate acilitate air bleeding.
3.
Turn Turn in the new new fuel filter filter until until the filter filter O-ring O-ring is fitted against the sealing face.
4.
Use Use the the filte filterr wrench wrench to turn in the fue fuell filter filter an addiadditional 2/3 of a turn .
Injection Injection nozzle
1
2
3
Check to see if the spray condition and the injection pressure are normal. Adjust them to the specified value respectively respectively wh en they don’ don ’ t m eet eet the standard valve.
Spray Condition (1) Correct (2) Incorrect (Restrictions in orifice) (3) Incorrect (Dipping) Fig. 32
MPa (kgf/cm 2 /psi ) In j ect i o n p r essu r e
17.7 (180/2560)
Using a no zzle tester, tester, adjust the i njection pr essure essure wi th a shim. Special too l: No zzle tester
Fig. 33
GENERAL INFORMATION 25
RECOMMENDED LUBRICATING OIL TYPE OF LU BRICAN TS (API)
DIESEL EN GIN E OIL; CC OR CD GRADE
ENGINE ENGIN E OIL VISCOSITY CHART CHART ENGINE OIL VISCOSITY GRADE – AM BIE BIENT NT TEMPERATURE TEMPERATURE
SAE 5W – 20 20 [Single grade]
SAE 40
SAE 20, 20W SAE 10W
Ambient temperature
25°C – 20 20°C – 15 15°C – 25 ( – 13 13°F) ( – 4°F) (5°F)
SAE 30 – 0°C (32°F)
15°C (59°F)
25°C 30°C (77°F) (86°F)
SAE 10W – 30 30 [Multi grade]
SAE 15W – 40, 40, 20W – 40 40
Fig. 34
MEMO
ENGINE 27
SECTION 2
ENGINE TABLE OF CONTENTS CON TEN TS
PAGE
DISASSEM BL BLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 8 INS NSP PECTION AND RE REPAIR .... ..... ..... ..... ..... ..... ..... .... ..... ..... ..... ..... ..... ..... ..... ..... .... 42 REASSEM BL BLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6
28 ENGINE
DISASSEM DISA SSEM BLY BLY 1. EXTER EXTERNAL PAR PARTS TS (Left (Left-hand -hand side) side)
(9)
(10)
(2)
(1)
(8) (3)
(5)
(11) (7) (4)
(6)
Fig. 35
(1) (1) Exhaus xhaustt silen ilenc cer (2) (2) Exhau xhaus st pip pipe e (3) Cooling ooling fan and spacer pacer (4) Fan belt (5) (5) Fan pull pulley ey (6) Genera erator tor (7) Star tarter ter (8) Exhaus xhaust manifold manifold and and gas gasket ket (9) Cylinder ylinder head head cover cover and and air intake intake pipe pipe (10) (10) Water outlet pipe and thermostat thermostat (11) Water pump asse assembly mbly
ENGINE 29
2. EXTERNAL XTERNAL PAR PARTS TS (Right-hand (Right-hand side) side)
(12)
(15)
(14)
(13)
(18)
(16)
(19)
(17)
(20)
Fig. 36
(12) Injection pipe . . . . . . . . . 4 pcs. pcs. (13) Fuel Fuel hose hose (14) Fuel Fuel leak off pipe pipe (15) Fuel Fuel pipe pipe (16) Engine stop solenoid solenoid (17) Injection Injection pum p housing cover cover (18) Injection Injection pump and shim . . . . . . . . . 4 set (19) Oil filter filter (20) Oil level level gauge gauge
30 ENGINE Leak Lea k off pi pe
Fuel Fuel pip e
Injection pipe Leak off pipe Fuel pipe
Eye bolt Injection pipe
1.
Loosen Loosen the sleeve sleeve nuts on the nozz nozzle holder side side and and on the injection pump side, and then disconnect the injection pip es. es.
2.
Disconnect Disconnect the leak leak off pipe together wi th gaske gaskets. ts.
3.
Remove the eye bolt, and then then disconnect disconnect the fuel pipe.
Nozzle holder
Injection Injection pum p
Fig. 37
Solenoid ASM Remove th e solenoid ASM.
Solenoid ASM Fig. 38
Injection pump housing cover Stud bolt
1.
Remove the bolts and nut.
2.
Install Install the bolts (M8 x 1.25 1.25)) to the replace replacerr hole.
3.
Tighten Tighten the bolts, and then remove housing housing cover. cover.
Housing cover
Fig. 39 Housing cover
Mark : M8
1.25 1.25 for repla replace cerr
Fig. 40 Fuel cut cover Pin(6 φ)
Governor cover Fig. 41
Injection Injection pump 1.
Align the hole of the fuel fuel cut cut lever lever with the hole of the governor cover, and then insert a pin (6ø) into this hole to hold t he fuel cut cut lever.
2.
Check to see see if the pin groove of the control link is at the center center of the injection pum p.
3.
Remove the injection injection pum p, and and then take take out the shim.
ENGINE 31 NOTE: Injection pump center position
Control link
1.
Mark eac each injec injection tion pump pump as to w hic hich cyl cylind inder er it was removed from.
2.
Do not reus reuse e the shim, repla replac ce it with the same same thickness thickness that w as removed.
Injection pump rack pin Fig. 42 Injection pump ASM
Shim
* Stud Stud Cylinder block Fig. 43
Backlash of timing gear
mm (in) (in) STA N DA RD
LIM IT
CRA N K GEA R/ IDLER GEA R
0.04 (0.0017)
0.2 (0.0079)
CA M GEA R/ IDLER GEA R
0.03 (0.0012)
0.2 (0.0079)
IDLER GEAR END PLAY
mm (in) (in)
STA N DA RD
LIM IT
0.058 – 0.058 – 0.115 0.115 (0.0023 – (0.0023 – 0 0.0045)
0.2 (0.0079)
CRAN CR ANKSHAFT KSHAFT END PLAY PLAY
mm (in) (in)
STA N DA RD
LIM IT
0.058 – 0.058 – 0.208 0.208 (0.0023 – (0.0023 – 0 0.0082)
0.3 (0.0118)
32 ENGINE
3. INTER INTERNAL PAR PARTS TS Disassembly Steps (1) Rocker Rocker Bracket Bracket Assembly (2) Push Push Rods Rods (3) Rear Rear Hanger Hanger (4) Front Front Hanger Hanger (5) Cylinder Head Assembly Assembly (6) Cylinder Cylinder Head Gasket Gasket (7) Tappets Tappets (8) Oil Pan Pan (9) Oil Strainer Strainer (10) Oil Pipe Pipe (11) Crank Crank Pulley Pulley (12) (12) Flywheel (13) Flyw Flyw heel Housi Housing ng (14) Timing Gear Cas Case e (w ithout PTO) (15) Oil Pump Pump Asse Assembly mbly (16) Idler Gear Gear and Shaft (17) (17) Cam Gear (18) Camshaft Camshaft (19) Rear Rear Seal Retainer Retainer (20) Piston Piston Assemblies Assemblies (21) Cranks Crankshaft haft
ENGINE 33
Internal Parts Parts (1/ 3)
(14)
(1)
(3)
(2)
(5) (18) (17)
(7) (4)
(16) (15)
(6)
Fig. 44
34 ENGINE
Internal Parts Parts (2/ 3)
(20)
(13)
Do not pull out this bolt.
(9) (12)
(21)
(10) Rear
(19) (11)
(8)
Fig. 45
ENGINE 35
Internal Parts Parts (3/ 3) When provided provided w ith PTO
(14-2)
(14-1)
(15)
Fig. 46
36 ENGINE Rocker bracket
Install of nuts (6)
Push rod Install of bolts (5)
1.
Remove the roc rocke kerr bracke brackett asse assembly. mbly. (M 6 × 1 . . . . . 5 bol ts and 6 n uts)
2.
Pull out out the push push rods (8 pcs. pcs.). ). Marks : Thread hole (M8 x 1.25) for replacer of rocker bracket assembly
Rocker Bracket Fig. 47
Cylinder head assembly
Rear hanger Head bo lt Head (M12)
Cylinder head ASM
(M8)
Fig. 48
5
9
Remove the the re rear and and front hange hangers rs..
2.
When When removing the the cylinde cylinderr head head bolts, bolts, loos loosen en them slowly, a little at a time, starting with the outside, working in a circular pattern inward.
3.
Remove the cylinde cylinderr head head asse assembly mbly and the hea head d gasket.
4.
Pull out out the ta tappe ppett from the cyli cylinde nderr body. body.
Head gasket Front hanger
8
1.
1
4
3
2
12
15
11
13
14
Fig. 49
10
7
6
ENGINE 37
Cylinder Head Assembly
Glow plug (2) Connector (1) Seal; valve
Split collar (4) Guide; valve Spring seat (5) Studs are applied wi th sealing sealing agent. Do not pull them out. (5 locations)
Valve spring (6)
Nozzle holder (3)
Valve (7)
Hot plug
Seat; valve insert
Fig. 50
Valve mechanism 1.
Before efore disas disasse sembling mbling the valve valve mech mechani anism, sm, remove remove the connector, glow plug and nozzle holder assembly.
2.
Compressi ompressing ng the valv valve e spring, spring, remove remove the split split colcollar, spring seat, valve valve spring and valve.
38 ENGINE
Timing Gear
Bearing Wear Wear rin g
Cam shaft (8) Pin Bearing Snap ring (7) Cam Cam gear (6)
Fly weight ASM (5)
Shaft; idle gear (3) Lock nut Idle gear (2) Sleeve (4) Thrust collar Crankshaft Key
Crank gear Crank pulley (1)
Washer
Fig. 51
ENGINE 39 Timing gear 1.
Remove the idle idle gea gearr and the the idle idle gear gear shaf shaft. t.
2.
Pull out the slee sleeve ve from from the tip end end of the cam cam shaft. shaft.
3.
Remove the the lock lock nut of the cam cam shaft shaft gear gear,, and and then then remov e the flyweight assemb assemb ly and the cam cam gear.
Camshaft Crankshaft
Snap ring
Fig. 52
1.
Remove the the s sna nap p ring which which holds holds down down the front front bearing of the cam bearing cam shaft shaft from the ring groove of the cylinder blo ck. ck.
2.
Pull out the the cam cam sha shaft ft from the cylinde cylinderr block, block, together together w ith the bearing.
40 ENGINE
Piston and Connecting Rod
Piston r ing (4) Snap Pipe (5) Piston
Piston pin (6)
Bush (The drawing-out of the bush must be limited to only when replaced.
Con ’ rod bolt Con’ (The drawing-out ot the con’ con’ rod bolt must be limited to only when replaced.)
Connecting r od (7) Cap (6)
Cap nut (1)
Fig. 53
Piston Piston and connecting rod Piston
Connecting Connecting r od cap
1.
Turning Turning the the cra crank nks shaft, haft, po posi sition tion the piston piston to be remov ed at at the botto m dead center. center.
2.
Loose Loosen n the cap cap nu nutt of the conne connect cting ing rod, and and then then remove it.
3.
Give Give anothe anotherr rotation rotation to the crank cranksh shaf aftt to position position the piston at th e top dead center. center.
4.
With the the handle handle of a hamm hamm er plac placed at the bottom of the connecting rod, push the piston assembly upward out of the cylinder block.
Fig. 54
Notes: 1.
Before efore removin removing g the piston, piston, sc scrape rape the carbo carbon n deposit off the cylinder wall.
2.
When pus pushin hing g out the pis piston ton ass assembly, care shou should ld be taken not t o damage the cylinder cylinder w all.
3.
Attach Attach a tag tag with a cyl cylin inder der number number to the remov removed ed caps and bearings to keep them in order.
ENGINE 41 Piston Piston ring Remove the piston rin g wi th a ring pli ers. Pliers: piston rin g 1-85 1-8522 221-0 1-029 29-0 -0
Fig. 55 Brass bar
Piston Piston pin 1.
Remove the snap snap rings rings with a comm comm erci ercial ally ly ava availilable tool.
2.
With a brass brass bar atta attach ched ed to the the piston piston pin, push push it out by hammering it lightly.
Note: Keep the pistons, piston pins and connecting rods in order for each cylinder.
Piston pi n
Fig. 56
42 ENGINE
INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.
1. CYLINDER YLINDER BLOCK OCK Cylinder block Check the cylinder block for wear, damage or any other defects. Use the hydr aulic gauge to check check the w ater jacket jacket w ater pressure. Apply water pressure to the water jacket at 5 kg/cm 2 (71. (71.1 1 psi) for three m inutes.
Fig. 57
Cylinder bore Y X
X
Measur Mea sureme ement nt position: position: 13mm 13mm below below the top top (Measure in X-X and Y-Y directions.) (Near the No. 1 compression ring) mm (in) (in) St an d ar d
Fig. 58
ø 85
Li m i t
ø 85.2
Rep ai r m et h o d Perform boring and honing of the inner diameter.
Cylinder bore diameter and grade m ark Bore grade mark (Stamp position)
Fig. 59
The grade mark is stamped on the top surface of the cylinder block (on the mating face with the cylinder head).
ENGINE 43 mm (in) (in) En g i n e
4LE2
Bo r e Di am et er
Gr ad e
85.000 – 85.000 – 85.010 85.010 (3.3464 – (3.3464 – 3.3468) 3.3468)
A
85.011 – 85.011 – 85.020 85.020 (3.3468 – (3.3468 – 3.3472) 3.3472)
B
85.021 – 85.021 – 85.030 85.030 (3.3472 – (3.3472 – 3.3476) 3.3476)
C
Cylinder Body Upper Face Warpage 1
Use a straight edge 1 and a feeler gauge 2 to measure the four sides and the two diagonals of the cylinder body u pper face. face. Regrind the cylinder body upper face if the measured values are greater than the specified limit but less than the maximum grinding allowance. allowance. 2
Fig. 60
If the measured values exceed the maximum grinding allow ance, ance, the cylinder bod y m ust be replaced. replaced. Cy l i n d er Bo d y U p p er Face W ar p ag e A
St an d ar d
Li m i t
Maximum Grinding Grinding Allowance
0.075 (0.0029)
0.15 (0 (0.0059)
0.3 (0 (0.0118)
F
E C
D
m m (i n )
B
If the measured value is less than the limit, the cylinder body m ay be reground. reground. Fig. 61
Cylind er Body Height
H
Fig. 62
H (Ref er en ce)
En g i n e
St an d ar d
4LE2
307.94 – 307.94 – 308.06 308.06 (12.123 – (12.123 – 12.128) 12.128)
m m (i n )
44 ENGINE
2. CYLINDE YLINDER R HE HEAD AD Cylinder head inspection Remove carbon deposit on the bottom surface of the head with care care not t o dam age the valve sea seat. t. Leakage: ge: Wate Waterr pres pressure tes test
5kg/c g/cm 2 (for 3 minut es) es)
Fig. 63
Cylinder Head Lower Face Warpage 1.
Use Use a stra straight ight edge edge and and a feel feeler er gauge gauge to measu measure re the four sides and the two diagonals of the cylinder head low er face. face.
2.
Regrind egrind the cylinde cylinderr head head lower face face if the meameasured values are greater than the specified limit but less less than the m aximum grinding allowance. allowance.
Fig. 64
If the measured values exceed the maximum grinding allowance, the cylinder head m ust be replaced. replaced. Cy l i n d er Head Lo w er Face W ar p ag e A E
F C
D
m m (i n )
S t an d a r d
Li m i t
Maximum Grinding Grinding Allwance
0.075 (0.0029)
0.15 (0.0059)
0.3 (0.0118)
B
Fig. 65
Cylinder Head Height
H (Ref er en ce)
En g i n e
St an d ar d
4LE2
63.90 – 63.90 – 64.10 64.10 (2.515 – (2.515 – 2.523) 2.523)
m m (i n )
H
Note: If the cylinder head lower face is reground, valve depression depression m ust be checked. checked. Fig. 66
ENGINE 45
3. VALVE, VALVE, VALV VALV E SEAT SEAT INSER IN SERT T AND VALV VALV E SEAL Inspection Inspection of valve seat Cylinder head Valve
1.
A – C – Contact wid th
2.
B – Valve – Valve depression mm (in) (in)
A
S t an d a r d
Li m i t
2.0 (0.0787)
2.5 (0.0984)
IN
0.7 (0.0276)
1.2 (0.0427)
EX
0.9 (0.0354)
1.5 (0.0591)
Co n t act w i d t h B
Valve depression 45° Fig. 67
Valve thickness N o m i n al
Li m i t
IN
1.0 (0.03937)
0.7 (0.0276)
EX
0.8 (0.0315)
0.5 (0.0197)
Rep ai r m et h o d
Replace
Fig. 68
Valve Stem Outside Diameter M easure easure the valve stem stem d iameter at thr ee points. If the m easured easured value is less than the specified lim it, the valve mu st be replaced. replaced. Val v e St em Ou t si d e Di am et er
Fig. 69
m m (i n )
St an d ar d
Li m i t
Intake Valve
7.0 (0.2756)
6.85 (0.2697)
Exhaust Valve
7.0 (0.2756)
6.80 (0.2677)
46 ENGINE Valve Seat Insert Replacement 2
3
Valve Seat Insert Removal
4
1.
Arc weld the the entire entire inside inside circu circumfere mferenc nce e 1 of the valve seat insert 2.
2.
Allow the valve valve seat seat insert insert to cool cool for a few few m inutes. inutes. This will invite contraction and make removal of the valve seat insert easier.
1
3. Fig. 70
U se se a scr ew ew d ri ri ve ver 3 to pry the valve seat insert free. Take care not to damage the cylinder head 4.
4.
Carefu arefully lly remove remove carb carbon on and and other other foreign foreign materia materiall from the cylinder head head insert bore.
Valve Seat Insert Insert Installation Installation 3
1.
1
Carefu arefully lly place place the atta attachme chment nt 1 (having a smaller outside diameter than the valve seat insert) on the valve seat insert 2.
Note: 2
The smooth side of the attachment must contact the valve seat insert. 2.
Fig. 71
U se se a b en en ch ch p re ress 3 to gradually apply pressure to the attachment and press the valve seat insert into place. pl ace. 4,000 kg (8,819 (8,819 lbs.) lb s.)
Note: Do not apply an excessive amount of pressure with the bench bench press. press. Damage to the valve seat insert insert will result. Valve Seat Insert Correction
150° 90°
1.
Remove the car carbon bon from the valve valve sea seatt insert insert sursurface.
2.
Use Use a valve valve cutter utter (15°, 45° 45 °, and 75° 75° blades) to minim ize scratches scratches and other rough areas. areas. This w ill bring the contact contact w idth b ack ack to the standard standard value.
30°
m ) m i n . 0 8 2 . 0 0 . (
Remo ve only the scratches scratches and roug h areas. areas. Do not cut aw aw ay too mu ch. Take Take care not to cut away unblemished areas of the valve seat surface.
Fig. 72
Val v e Seat A n g l e
d e g r ee 45
Note: Use an adjustable valve cutter pilot. Do not allow the valve cutter pilot to wobble inside the valve guide.
Fig. 73
ENGINE 47
Fig. 74
3.
Apply abra abrasi sive ve compound compound to the valve valve sea seatt insert insert surface.
4.
Inse Insert rt the valve valve into the the valve valve guide. guide.
5.
Apply light pres pressu sure re to the valve valve while turning turning it it to fit t he valve seat seat insert.
6.
Check heck that that the valve valve conta contact ct width is corre correct ct..
7.
Check heck that that the valve seat seat insert insert surfac surface e is in contac contactt wi th the entire circumf erence erence of the valve.
8.
Clean lean the hea head d and valve valves s to remove the the abra abrasi sive ve compound and metal particles.
4. VA VAL LVE SPR SPRING Valve Spring Inclination Use a surface plate and a square to measure the valve spring inclination. If the measured value exceeds the specified limit, the valve spring m ust be replaced. replaced. mm (in) (in) Val v e Sp r i n g In cl i n at i o n
St an d ar d
Li m i t
1.8 (0.0709)
2.5 (0.0984)
Fig. 75
Valve Spring Tension Use a spring t ester ester to m easure easure the valve spring tension. If the m easured easured value is less than the specified lim it, the valve spring m ust be replaced. replaced. mm (in) (in) Valve Valve Sprin g Tension at 29.9 mm Set Length
St an d ar d
Li m i t
17.0 (37.479)
15.0 (33.069)
Fig. 76
Valve Spring Free Length Use a vernier caliper to measure the valve spring free length. If the m easured easured value is less than the specified lim it, the valve spring m ust be replaced. replaced. mm (in) (in)
Fig. 77
Exhaust an d Intake Valve Spring Free Length
St an d ar d
Li m i t
42.1 (1.6575)
40.0 (1.5748)
48 ENGINE
5. TAP APP PET (Cam (Cam Follow Follow er or Valve Valve Lifter) Lifter) AND AN D PUSH PUSH ROD TAPPET Inspect the tappets for excessive wear, damage and any abnormalities. Use a mi crom eter to measure the tappet tappet diam eter. mm (in) (in) Standard Tappet Diameter
20.967 – 20.967 – 20.980 20.980 (0.82547 – (0.82547 – 0.82598) 0.82598)
Fig. 78
Use a dial indicator to measure the clearance between the tappet and and cylinder bod y tappet travelling bore. mm (in) (in) Tappet and Tappet Travelling Travelling Bore Clearance
St an d ar d
Li m i t
0.020 – 0.020 – 0 0.054 (0.00079 – (0.00079 – 0 0.00213)
0.08 (0.003 00315)
Fig. 79
PUSH ROD Use a filler gauge to m easure easure the valve push rod run out. Roll the push rod along a smooth flat surface (illustration). mm (in) (in) Limit Pu sh Ro d Ru n -Ou t Fig. 80
0.3 (0.0118)
ENGINE 49
6. CAM SHAFT Inspection Inspection of cam shaft Check the journal and the cam for evidence of wear, damage or any oth er defect. defect.
Camshaft
Note: With the front and rear parts of camshaft pressed in with ball bearings, and with the cylinder block pressed in with roller bearings as the center bearing, check to see if the camshaft rotates smoothly with no play at each bearing. Fig. 81
M eas easurement urement of journal and cam cam 1.
Cam he hei gh gh t (A – B – B)
m m (i n )
St an d ar d
Li m it it
Rep ai r m et et h o d
Intake
6.13 5.83 (0.2 (0.241 413) 3) (0.2 (0.229 295) 5)
Replace
Exhaust
6.43 6.13 (0.2 (0.253 531) 1) (0.2 (0.241 413) 3)
Replace
Fig. 82
2.
I II I II
A' A
B' B
B'
3.
Cen t er j o u r n al d i am et er
m m (i n )
N o m i n al
Li m i t
Rep ai r m et h o d
52 ø (2.0472)
51.92 ø (2.0441)
Replace
U n ev en w ear o f j o u r n al
m m (i n )
A'
Fig. 83
4.
Fig. 84
N o m i n al
Li m i t
Rep ai r m et h o d
52 ø (2.0472)
0.05 (0.002)
Rep l ace
Ru n o u t o f cam sh af t
m m (i n )
N o m i n al
Li m i t
Rep ai r m et h o d
0.02 (0.008)
0.1 (0.004)
Rep l ace
50 ENGINE
7. ROCKE ROCKER R ARM ARM SHAFT SHAFT AND AN D ROCK ROCKER AR ARM M Inspect Inspect all disassembled disassembled parts for wear, damage and any abnormalities.
Fig. 85
Rocker Arm Shaft Outside Diameter Use a micrometer to measure the rocker arm outside diameter. If the m easured easured value is less less than the specified specified lim it, the shaft mu st be replaced. replaced. mm (in) (in) St an d ar d
Li m i t
Rocker Arm Shaft 11.9 11.935 35 – – 1 11.955 Di am et er (0.4699 – 0 – 0.4707)
Fig. 86
11.85 (0.4665)
Rocker Arm Shaft and Rocker Arm Clearance 1.
Use a vernier vernier cali caliper per to measure measure the rocke rockerr arm bushing inside diameter. mm (in) (in) Standard Rocker Arm Bushing In si d e Di am et er
Fig. 87
2.
11.960 – 11.960 – 11.980 11.980 (0.4709 – 0.4717) – 0.4717)
Measu Mea sure re the the rocke rockerr arm shaf shaftt outside outside diamete diameter. r. Replace eplace either the r ocker ocker arm or the rocker arm shaft if the clearance exceeds the specified limit. mm (in) (in)
Rocker ocker A rm Bushing and Rocker Rocker Ar m Shaft Clearance 3.
Fig. 88
St an d ar d
Li m i t
0.005 – 0.005 – 0 0.045 (0.0002 – (0.0002 – 0 0.0018)
0.2 (0.0079)
Check heck tha thatt the rocke rockerr arm oil port is free free of obstruc obstruc-tions. If necessary, use compressed air to clean the rocker arm oil port.
ENGINE 51
8. PISTON, ISTON, PIST PISTON ON PIN PIN AND AN D PIST PISTON ON RING RING Clearance between piston and cylinder bore
About 64
1.
Measure Measur e the the outsi outside de diame diamete terr of the piston piston at at about about 64 mm from the top in a right angle to the piston pin (in the unit of 1/1,00 1/1,000 0 mm ).
2.
Calculate alculate the clea clearanc rance e base based d on the measure measurements ments of the cylinder bore and the outside diameter of the piston. mm (in) (in) Cl ear an ce
0.040 – 0.085 – 0.085 (0.0015 – (0.0015 – 0.0033) 0.0033)
Fig. 89
Outside diameter of piston and grade m ark The grade mark is stamped on the top surface of the piston in stalled stalled at the factory. The piston fo r service part doesn’ doesn’ t have the gr ade. mm (in) (in) M o d el
Ou t si d e d i am et er o f p i st o n
Gr ad e
4LE2
84.945 – 84.945 – 84.960 84.960 (3.3443 – (3.3443 – 3.3449) 3.3449)
NON
Fig. 90
Wear of piston pin (out side side diameter) mm (in) (in)
Fig. 91
N o m i n al
Li m i t
25.0 (0.9843)
24.97 (0.9831)
Rem ar ks Rep l ace i f w o r n b ey o n d l i m i t
52 ENGINE Clearance between piston pin and piston pin hole mm (in) (in) Standard 4LE2
0.007 – 0.007 – 0.017 0.017 (0.00027 – (0.00027 – 0.00067) 0.00067)
Piston ring gap With the ring inserted into the cylinder bore, push it in with the piston head so that it becomes a right angle to the cylinder, and then measure the gap of the piston ring. If worn b eyond the lim it, replace replace the rings. mm (in) (in) St an d ar d Fig. 92
1st co m pr pr es essi on on r in in g
0.2 – 0.2 – 0.35 0.35 (0.0079 – 0.0138) – 0.0138)
2n d co m p r essi o n ring
0.35 – 0.5 – 0.5 (0.0138 – 0.0197) – 0.0197)
Oil ring
0.2 – 0 0.2 – 0.4 (0.0079 – (0.0079 – 0 0.0157)
Li m i t 1.5 (0.0590) 1.0 (0.03937)
Clearance between piston ring groove and ring Measure clearance at several places on the circumference. If worn b eyond the lim it, replace replace the rings or piston. 4LE2
Fig. 93
m m (i n ) St an d ar d
Li m i t
1st co m pr p r es essi o n r in in g
0.085 – 0 – 0.105 (0.0033 – 0 – 0.0041)
0.2 (0.0078)
2n d co m pr p r es essi o n r in in g
0.050 – 0.085 – 0.085 (0.0020 – 0 – 0.0033)
0 . 15
Oil ring
0.030 – 0.030 – 0 0.070 (0.0011 – (0.0011 – 0.0027) 0.0027)
(0.0059)
ENGINE 53
9. CONNE ONN ECTING ROD AND CONN CONNE ECTING ROD BE BEAR ARING ING Torsion and parallelism of connecting rod If worn beyon d the limi t-repair or replace. replace. mm (in) (in) Per 100 m m (3.94)
St an d ar d
Li m i t
Torsion
0.05 (0.002)
0.2 (0.0079)
Parallelism
0.05 (0.002)
0.15 (0.0059)
Fig. 94
Clearance between small end pin hole of connecting rod and piston pin, inside diameter of bushing mm (in) (in)
Clearance In si d e d i am et er
St an d ar d
Li m i t
0.008 – 0.008 – 0 0.020 (0.0003 – (0.0003 – 0 0.0008)
0 . 05 (0.0020)
25 (0.9843)
—
Fig. 95
Connecting Rod Bearing Inspection 1.
Fit the connecti onnecting ng rod bear bearing ing lower lower half half into the the connecting connecting rod b earing earing cap. cap.
2.
Check heck the conne connect cting ing rod bearing bearing lower half half tens tension. ion. If the tension is insufficient, the bearing must be replaced.
3.
Tighte Tighten n the conne connect cting ing rod and and the bea bearing ring cap cap to to the specified specified t orque. N ·m (kgf· (kgf ·m/ft. lb)
Fig. 96
Ti gh gh te ten in in g t or or qu qu e
74 - 83 (7.5 - 8.5 / 54 - 61)
Clearance between bearing and crank pin, inside diameter with bearing installed and without. mm (in) (in)
Clearance
Fig. 97
St an d ar d
Li m i t
0.035 – 0.035 – 0 0.073 (0.0014 – (0.0014 – 0 0.0029)
0 . 10 (0.0039)
54 ENGINE
10.CRANKSHAFT AND AN D CRANKSHAFT BEARING BEARING Outside diameters of journal and pin If worn beyond the limits-replace Cr an k j o u r n al 4LE2
m m (i n ) St an d ar d
Li m i t
60.0 (2.3622)
59.86 (2.3567)
Cr an k p i n Fig. 98
m m (i n )
4LE2
St an d ar d
Li m i t
49.0 (1.9291)
48.87 (1.9240)
Note: When there occurs an uneven wear to the crankshaft, replace it with a new one without grinding it for reuse. Clearance between journal and bearing inside diameter with bearing installed and without mm (in) (in)
Clearance
St an d ar d
Li m i t
0.029 – 0.029 – 0 0.072 (0.0011 – (0.0011 – 0 0.0028)
0.11 (0.0043)
Fig. 99
Runout of crankshaft crankshaft Replace eplace if beyond lim it mm (in) (in) St an d ar d
Li m i t
0.025 (0.001)
0.05 (0.002)
Fig. 100
Crankshaft Crankshaft gear Check the crankshaft gear visually for damage and any other defects. defects.
Fig. 101
ENGINE 55 Oil seal Timi ng g ear case case
When the lip of an oil seal is found defective, replace it with a ne new w one. Installation Use the crankshaft front oil seal installer to install the crankshaft crankshaft front oil seal. seal.
Front oil seal seal
Fig. 102
11.FLYW 11.FLYWHEE HEEL L AND AN D RIN RING G GEAR G EAR Ring Gear Replacement Ring Gear Inspect Inspect the rin g gear. If the ring gear teeth teeth are broken or excessively excessively wo rn, the ring g ear ear m ust be replaced. replaced. Ring Gear Removal Strike around the edges of the ring gear with a hammer and chisel chisel to rem ove it. Fig. 103
Ring Gear Installation 1.
Heat eat the ring gear gear eve evenly nly with a gas burner burner to invite invite thermal expansion. Do not allow the temperature of the gas burner to exceed 200° 200°C (390° (390°F).
2.
Use Use a hamm hamm er to to instal installl the ring gear gear when when it is sufsufficiently h eated. eated.
Fig. 104
12.TIMIN G GEAR GEAR Uneven w ear of idle gear shaft shaft mm (in) (in) N o m i n al
Li m i t
45.0 (1.7717)
0.1 (0.0039)
Fig. 105
Clearance between idle gear bushing and shaft mm (in) (in)
Fig. 106
St an d ar d
Li m i t
0.025 – 0.025 – 0.085 0.085 (0.001 – (0.001 – 0 0.0033)
0.2 (0.0079)
56 ENGINE
REAS RE ASSEM SEM BLY BLY 1. CYLINDER YLINDER HE HEAD AD ASSEM ASSEM BLY Glow plug (7) Connector (8) Seal; valve (1)
Split collar (5) Guide; valve Spring seat (4) Apply Locktite Locktite No .262 .262 to this portion. (5 locations)
Valve spring (3)
Nozzle holder (6)
Valve (2)
Hot plug
Seat; valve insert Fig. 107
Important Operations Operations Valve Stem Oil Seal 1.
Lubricate Lubricate the oil sea seals ls and and valve stem stem sealing sealing area area with engine oil.
2.
Use Use a valve valve ste stem m oil seal seal insta installe llerr to install install the oil seal. Valve Stem Oil Seal Installer: 5-8840-9033-0
Fig. 108
Intake and Exhaust Valves 1.
Place lace the cylinde cylinderr head head on a flat wooden surfa surface ce..
2.
Lubric Lubricate ate valve valve stems stems with engine engine oil.
3.
Inst Install all the valve valves s to the intak intake e or exhau exhaust st guides guides.. Install Install th e valves to their o rigin al lapped valve seats. seats.
Fig. 109
ENGINE 57 Intake and Exhaust Valve Springs Install Install the valve springs w ith th eir painted end (the close pitched end) facing facing dow n.
Painted potio n Fig. 110 Spring compressor Split collar
Spring Seat Split Collar 1.
Use Use a spring spring compres compresso sorr to push push the val valve ve spring spring into position.
2.
Inst Instal alll the spring spring sea seatt split split colla collar. r.
3.
Set Set the spring spring sea seatt split split colla collarr by tapping tapping lightly lightly around the head of the collar with a rubber hamm er. Sprin g Com pressor: 5-88405-8840-903 9030-0 0-0
Fig. 111
Nozzle holder assembly Bolt Eye bolt
Before assembling the nozzle holder assembly, check to see if the spray condition and the spray pressure of the injection nozzle are appropriate, (Refer to “ INSPECTION AND SERVICE.” SERVICE. ” )
Bracket
Assemb Assemb le to t he cylinder head the g aske asket. t.
Nozzle holder ASM
Install Install th e nozz nozzle holder assemb assemb ly, and then t ighten i t to the specified specified tor que.
Gasket Fig. 112
N ·m (kgf· (kgf ·m/ft. lb) Ti g h t en i n g t o r q u e
31 - 41 (3.2 – 4.2 – 4.2 / 23 - 30)
Glow plug and connector Glow plug
Assemble the glow plug to the cylinder head, and then tight en it to the specified specified torq ue. Install the connector to the glow plug, and then tighten until snug. N ·m (kgf· (kgf ·m/ft. lb)
Connector
Fig. 113
Par t s
T i g h t en i n g t o r q u e
Gl o w p l u g
15 - 20 (1.5 – 2.0 – 2.0 / 11 - 14)
58 ENGINE
2. PISTON ISTON AND CONNEC CONNECTING TING ROD ROD
Piston r ing (5) Snap Pipe (4) Piston (1)
Piston pin (3)
Bush (2)
*
*
Rod bolt removed for clarity.
Connecting r od (2) Cap (7)
Cap nut (8)
Bearing (6)
Fig. 114
Important Operations Operations Conventional piston h eate eaterr
Piston Use a piston heater to heat the pistons to approximately 100° 100 °C (212° (212°F). Connecting Rod
Fig. 115 (Hot plug side)
Front mark
Engine front direction
Isuzu mark Cylinder number stamped side
Fig. 116
1.
Inst Install all the conne connect cting ing rod to the piston piston with sett setting ing the m arks as as illustrated.
2.
Inst Install all the the piston piston pin into the piston piston and and the conne connect ct-ing rod bushing.
ENGINE 59 Piston Pin Snap Ring 1.
Use Use a pair pair of sna snap p ring pliers pliers to ins insta tall ll the piston piston pin snap ring.
2.
Check heck that that the the pis piston ton moves smoothly on the piston piston pin.
Fig. 117
Piston Ring 1st
1.
Use Use a piston piston ring insta installe llerr to instal installl the three three piston piston rings. Piston Ring Installer
2nd
Install Install the piston rings in the follow ing order. (1) Oi l r in in g (2) 2nd compre compres ssion ring ring
Oil
(3) (3) 1st 1st c compres ompressi sion on ring The marked side of the two compression rings must be facing facing up .
Fig. 118
The undercut side of the second compression ring will be facing down. As the oil ring has no any facing facing m ark, it m ay face face in either direction. 2.
Lubric Lubricat ate e the piston piston ring surfa surface ces s with engine engine oil.
3.
Check heck that that the the p pis iston ton rings rotate rotate s smoothly moothly in the piston ring grooves.
60 ENGINE
3. INTER INTERNAL PAR PARTS TS Reassembly Steps (1) Cranks Crankshaft haft (2) Piston iston Asse Assembly mbly (3) Rear Rear Seal Retainer Retainer (4) Camshaft Camshaft (5) Cam Gear (6) Idler gear gear and Shaft Shaft (7) Oil Pump Pump Assembly Assembly (8) Timing Gear Cas Case e (Without PTO) (9) Flyw Flyw heel Hous Housing ing (10) (10) Flywheel (11) Crank Crank Pulley Pulley (12) Oil Pipe Pipe (13) (13) Oil Strainer Strainer (14) Oil Pan (15) (15) Tappets Tappets (16) Cylinder Head Gasket Gasket (17) Cylinder Head Assembly Assembly (18) Push Push Rods Rods (19) Rocker Rocker Bracket Bracket Assembly (20) Engine Hangers Hangers
ENGINE 61
Internal Parts Parts (1/ 3)
(2)
(9)
(13)
(10)
(1)
(12) Rear
(3) (11)
(14)
Fig. 119
62 ENGINE
Internal Parts Parts (2/ 3)
(8)
(19)
(20)
(18)
(17)
(4)
(5)
(15) (20)
(6) (7)
(16)
Fig. 120
ENGINE 63
Internal Parts Parts (3/ 3)
(8-1) (8-2)
(7)
Fig. 121
64 ENGINE Crankshaft bearing
With oil hole and groove (Upper)
Fit correctry
Note that there is an oil hole and an oil groove in the upper bearing (on the block side), but not in the lower bearing (on th e bearing cap side). side). Fit the bearing tang firmly into the slot machined on the cylinder bod y bearing arches.
No oil groove and hole (Lower) Fig. 122
Crankshaft and bearing Lubricate the bearings with engine oil, install the crankshaft, install the thrust bearings with the groove facing the crankshaft.
Thrust Bearing
Crankshaft
Bearing
Fig. 123 Arrow mark 10
6
5
9
4
5
3
2 3
7 2
1
1
4
Crankshaft Bearing Cap 1.
Lubric Lubricat ate e the the bear bearing ing cap cap bolts bolts with engine engine oil.
2.
Inst Install all the beari bearing ng caps caps to the cra cranks nksha haft. ft. The arrow m ark must be pointing to th e front of the engine.
8 Front
3.
Tighte Tighten n the beari bearing ng cap cap bolts to to the spec specifie ified d torque a little at a time in the numerical order shown in the illustration. N ·m (kgf· (kgf ·m/ft. lb)
Fig. 124
Crankshaft Bearin Bearin g Cap Bolt Torque 4.
83 - 93 (8.5 - 9.5 / 61 – 61 – 69) 69)
Check heck tha thatt the cra cranks nkshaf haftt turns smoothly by by manually rotating it.
ENGINE 65 Position the rings as shown making sure the ring gaps are away away fro m th e thrust side. 1st
2nd
Oil
Fig. 125
Piston Piston and Connecting Rod Special Special too l
Lubricate the piston, the piston rings, and the connecting rod bea bearings rings with engine oil. Front mark
Position the piston front mark towards the front of the engine. Use the piston ring compressor to compress the piston rings. Use a hammer grip to push the piston in until it makes contact with t he crank crank pin. At th e same same tim e, rotate the cranks crankshaft haft unti l the crankpin reaches reaches its highest poin t.
Fig. 126
Set Set the bearing cap cylinder n um ber m arks and the connecting rod cylinder number marks. The marks m ust be facing facing th e injection pum p side. N ·m (kgf· (kgf ·m/ft. lb) Cylinder No .
Ti g h t en i n g t o r q u e
74 - 83 (7.5 – 8.5 – 8.5 / 54 - 61)
Note: After installation, confirm that the crankshaft rotates smoothly. Fig. 127 6
Installation Installation of retainer
4
8
After applying engine oil to the lip of the oil seal, install the retainer. Apply sealant TB1207B to the retainer.
7
1
2
Tighten bolts on the retainer to the specified torque in the order as shown i n the figure left. N ·m (kgf· (kgf ·m/ft. lb) Ti g h t en i n g t o r q u e
3
5
Fig. 128
8 - 12 (0.8 - 1.2 / 6 - 9)
66 ENGINE Camshaft assembly 1.
Apply engine engine oil to the inside inside of the beari bearing ng of the cylinder block, and then install the camshaft assembly.
Note: When installing the assembly, care should be taken not to damage t he bearing. bearing. 2. Fig. 129
After After insta installa llation tion of the the sna snap p ring to the the outside outside of the front bearing, check to see if the camshaft rotates smoothly.
Cam gear and sleeve Cam Cam gear
1.
Inst Install all the the cam cam gear gear to the cams camshaf haftt so that that the timing point (a dot mark “ •“ ) com com es to the fro nt side.
2.
With the flyweight flyweight instal installe led, d, tighten tighten the cam cam gear gear with a lock lock nut. N ·m (kgf· (kgf ·m/ft. lb)
Timing point Sleeve
Ti gh gh te ten in in g t or or qu qu e Lock nut
Fly weight
69 - 88 (7.0 - 9.0 / 51 - 65)
3.
Apply engine engine oil to the shaft shaft of the slee sleeve ve and and the slide of the flyweight.
4.
With the lip of the slee sleeve ve pla place ced d in the cavity cavity of the flyweight, insert the shaft of the sleeve into the tip end of t he cam cam shaft.
Fig. 130
Note: Check to see if the sleeve moves smoothly. Idle Gear Idle gear
Install the idler gear shaft with the oil hole facing upward.
Timing point
Lubricate the shaft shaft w ith oil .
Thrust collar
Install Install t he idler g ear. ear. Idle gear shaft
Timing point
Align the tim ing m arks arks as shown in the illustration. illustration. Install the thrust collar and tighten the bolts to the specified specified t orque. N ·m (kgf· (kgf ·m/ft. lb)
Fig. 131
Ti g h t en i n g to to r q u e Cam Cam gear Timing point
Idle gear
Crank gear Fig. 132
21 - 30 (2.1 – 3.1 – 3.1 / 15 – 15 – 22) 22)
ENGINE 67 Oil pump assembly 1.
Cylinder block
When When PTO PTO is not provided, provided, install install the oil pump asse assemb mb ly to the cylinder bl ock.
PTO n o t p r o v i d ed Ti g h t en i n g t o r q u e
N ·m (kgf· (kgf ·m/ft. lb) 19 - 28 (1.9 – 2.9 – 2.9 / 14 – 14 – 21) 21)
Fig. 133
2.
When When PTO PTO is provided, provided, insta install ll the oil pump to the front plate.
PTO p r o v i d ed
Front plate
Ti g h t en i n g t o r q u e
N ·m (kgf· (kgf ·m/ft. lb) 8 - 12 (0.8 – 1.2 – 1.2 / 6 – 6 – 9) 9)
Fig. 134
Front Front plate (only for t hose hose provided w ith PTO) Front p late
Apply sealant to the front plate incorporated with the oil pump before installing it to the cylinder block. N ·m (kgf· (kgf ·m/ft. lb) Ti g h t en i n g t o r q u e
19 - 28 (1.9 – 2.9 – 2.9 / 14 – 14 – 21) 21)
(with PTO) Fig. 135
Front oil seal Timing gear case
Front oil seal seal
Install Install th e front o il seal seal to the tim ing g ear cas case. e. Installation is made according to the “ L” dimension shown in the figure. mm (in) (in) L dimension
Fig. 136
PTO n o t p r o v i d ed
60.2 – 60.8 – 60.8 (2.370 – (2.370 – 2.384) 2.384)
PTO p r o v i d ed
40.2 – 40.8 – 40.8 (1.582 – (1.582 – 1.606) 1.606)
68 ENGINE Timing gear case (with governor) Governor cover
Timing gear case
When not provided with PTO, install the timing gear case to the cylinder block. When provided with PTO, install it to the front plate. 1.
Put the link plate plate of of the governor governor incorpora incorporate ted d in the gear case through the connecting hole of the injection pump in advance.
2.
Apply engine engine oil to the bushes bushes provided provided on both ends of the main spring lever of the governor .
3.
Apply sea sealant lant to the gea gearr cas case, e, and then then install install it to the cylinder block or the front plate.
Front oil seal
N ·m (kgf· (kgf ·m/ft. lb) Case t ig ig ht ht en en in in g t or or qu qu e 4. Fig. 137
19 - 28 (1.9 – 2.9 – 2.9 / 14 – 21) – 21)
Ass Assemble the gaske gaskett and and the gove governor rnor cove coverr to the top of the gear case, and then tighten them to the specified specified to rque. N ·m (kgf· (kgf ·m/ft. lb) Co ve ver ti ti g h te ten i n g t o r qu qu e
8 - 12 (0.8 – 1.2 – 1.2 / 6 – 6 – 9) 9)
Flywheel housing Install the flywheel housing to the cylinder body. N ·m (kgf· (kgf ·m/ft. lb) Ti g h t en i n g to to r q u e
41 - 55 (4.2 – 5.6 – 5.6 / 30 – 30 – 40) 40)
Fig. 138
Flywheel Lubricate bolts with engine oil. Tighten a little at a time in the sequence shown in the illustration. N ·m (kgf· (kgf ·m/ft. lb) Ti g h t en i n g t o r q u e Apply engine oil Fig. 139
88 - 108 (9 – 11 – 11 / 65 – 65 – 80) 80)
ENGINE 69 Crank pulley Lubricate the lip of the fron t, seal seal wit h oil Crankshaft
Install the crank pulley, lock the crankshaft and tighten the front bolt. N ·m (kgf· (kgf ·m/ft. lb)
Crank pulley
Ti g h t en i n g to to r q u e
167 - 186 (17 – 19 – 19 /123 – /123 – 137) 137)
Washer
Front oil seal Fig. 140
Oil pipe and oil strainer To 2nd bearing cap
Oil strainer
1.
Inst Instal alll the oil pipe pipe from the oil pump ass assembly embly to to the cylinder blo ck and and ti ghten th e sleeve sleeve nuts.
2.
Insta nstall ll the oil stra straine inerr to the oil oil pump, and and then then tighten the bracket of the strainer to the No. 2 bearing cap. N ·m (kgf· (kgf ·m/ft. lb) Ti g h t en i n g t o r q u e
Oil pipe
19 - 28 (1.9 – 2.9 – 2.9 / 14 – 14 – 21) 21)
Fig. 141
Oil pan 1.
Apply Apply sealant lant to the the oil pan. pan.
2.
Inst Instal alll the oil oil pan to the the cylinde cylinderr block block and and tighten tighten fixing bolts evenly. N ·m (kgf· (kgf ·m/ft. lb) Ti g h t en i n g t o r q u e
8 - 12 (0.8 – 1.2 – 1.2 / 6 – 6 – 9) 9)
Fig. 142
Tappet and head gasket 1.
Inst Instal alll the tappe tappett to the cylinde cylinderr block. block.
2.
When When insta installing lling the head head gask gasket et,, face face up the “ UP UP”” mark. Install Install the head gasket gasket o ver th e cylinder h ead ead l ocating dow els. els.
Fig. 143
70 ENGINE Cylinder head assembly 11 8
12
14
13
4
15
5
1
Lubricate the bolts with oil. 9
Tighten the bolts in the sequence shown in the illustration to t he specified specified torque. N ·m (kgf· (kgf ·m/ft. lb)
7
3
2
6
10
Bo l t si ze M 12 × 1.5 (8 each )
Ti g h t en i n g t o r q u e 83 – 93 – 93 (8.5 - 9.5 / 61 – 69) – 69)
M 8 × 1.25 (4 each )
Fig. 144
60° 60° 90° 90°
24 – 34 – 34 (2.5 - 3.5 / 8 – 25) – 25)
Push rod Install Install th e push rods. Rocker Rocker arm bracket assembly Apply liquid gasket to the the bottom of the rocker arm bracket assembly, being careful not to get any in the groove around the oil galley as shown in the illustration.
Rocker Rocker ar m Rocker spring
Install Install t he rocker rocker arm bracket bracket assembl assembl y m aking aking sure the push rods align with the rocker arms and tighten to the specified specified t orque. N ·m (kgf· (kgf ·m/ft. lb) Ti g h t en i n g t o r q u e Rocker Rocker arm bracket
Fig. 145 (Rocker bracket bottom surface) Apply stem of sealant
Avoid the application of sealant sealant to t his groove. Oil gallery Fig. 146
8 - 12 (0.8 – 1.2 – 1.2 / 6 – 6 – 9) 9)
ENGINE 71 Adjustment of valve clearance
Refer to Section “ General Information – Maintenance” Maintenance” (on p age 20). 20).
Front hanger and rear hanger Rear Rear han ger
Tighten them to the specified torque shown below. N ·m (kgf· (kgf ·m/ft. lb) Ti g h t en i n g t o r q u e
Front hanger
Fig. 147
19 - 28 (1.9 – 2.9 – 2.9 / 14 – 14 – 21) 21)
72 ENGINE
4. EXTERNAL XTERNAL PAR PARTS TS (Right-hand (Right-hand Side) Side)
(8)
(6)
(5)
(7)
(3)
(2)
(4)
(1)
Fig. 148
(1) (1) Dips Dipstic tick k (2) (2) Oil Oil Filter ilter (3) (3) Inje Injec ction tion Pump Pump (4) Injec Injection tion Pump Pump Hous Housing Cove Coverr (5) (5) Fuel uel Pip Pipe e (6) (6) Leak eak Off Off Pipe ipe (7) (7) Fuel uel Hose ose (8) (8) Inje Injec ction tion Pip Pipe e
ENGINE 73
5. EXTERNAL XTERNAL PAR PARTS TS (Left-hand (Left-hand Side)
(18)
(10)
(11)
(19)
(12) (17)
(15)
(9) (13) (16)
(14)
Fig. 149
(9) Water Pump Pump (10) Thermostat and Water Wat er Outlet Outlet Pipe (11) Cylinder Head Cover Cover (12) Exhaust xhaust Manifold M anifold (13) (13) Starter Starter (14) Generator Generator (15) Fan Fan Pulley Pulley (16) Fan Fan Belt Belt (17) Cooling Fan Fan (18) Exhaust xhaust Pipe (19) Exhaust xhaust Silencer Silencer
74 ENGINE Dipstick Dipstick
Cartridge
Oil filter (cartridge) 1.
Inse nsert the the dips dipstic tick k.
2.
Inst Install all the cartridge cartridge with a filte filterr wrench wrench (comm (comm ercially available).
(1) (1) Apply engine oil thinly to the gask gasket et of the cartridge. cartridge. (2) (2) Screw Screw in the cartridge cartridge until the gask gasket et comes comes into contact with the seal, and then tighten it by giving it about 3/4 turns. Fig. 150
Injection Injection pum p center position Control link
(Refere ferenc nce e: Tig Tighte hteni ning ng torqu torque e
12 to to 16 16 N· N·m (1.2 – (1.2 – 1.6 1.6 kgf· kgf ·m ))
Injection Injection pump Fuel cut lever Pin (6φ)
Align the two (2) holes in the fuel cut lever and the governor and lock into place wi th a pin. This will center and hold the control link for the installation of th e injection injection pumps.
Fig. 151 Injection pump ASM
Install a new shim with the same thickness as the one that was remov ed. (Refer (Refer to the maintenance sec section tion o n shim selection). selection).
Shim
Cylinder block Fig. 152
Injection pump center position
Install the injection pump making sure the rack pin is in the groove of the control rack before tightening the injection pump to the specified torque. N ·m (kgf· (kgf ·m/ft. lb)
Control link Rack pin
Ti g h t en i n g t o r q u e
19 - 28 (1.9 – 2.9 – 2.9 / 14 – 14 – 21) 21)
Remove the rack pin (6ø (6ø) which is inserted into the fuel cut lever, and then confirm that the fuel cut lever moves smoothly. Fig. 153
ENGINE 75 Injection pump housing cover Housing cover
After applying sealant (TB1207B) to the housing cover, install it to the cylinder block by the side of the injection pump. N ·m (kgf· (kgf ·m/ft. lb) Ti g h t en i n g t o r q u e
8 - 12 (0.8 – 1.2 – 1.2 / 6 – 6 – 9) 9)
Note: The areas of the housing cover to which liquid gasket is applied are about 4 mm in width from the cover edge and about 2 mm around the bolts.
Fig. 154 Housing cover
Apply potion of sealant
About 2mm around the bolt hole
About 4mm 4mm in width from the cover edge
Fig. 155
Solenoid assembly 1. Solenoid ASM
Apply seala sealant nt (TB1 (TB120 207C 7C)) to the surfac surface e (bite (bite groove) in w hich the solenoid is installed. installed.
Note: Avoid the application application of sealant t o the t he screw screw thread. 2.
Fig. 156
Ti g h t en i n g t o r q u e
Solenoid ASM Installed surface Apply surface of sealant sealant
Screw Screw thread Avoid the application of sealant Fig. 157
Screw crew in the solenoid olenoid from the rear rear of the cylinde cylinderr block (the rear rear of the No. 3 inj ection ection pum p rack), rack), and then tight en it to the specified specified torque. N ·m (kgf· (kgf ·m/ft. lb) 15 - 25 (1.5 – 2.5 – 2.5 / 11 – 11 – 18) 18)
76 ENGINE Fuel Fuel pi pe
Leak Lea k off p ipe
Fuel pipe Leak off pipe
Fuel hose
Nozzle holder
1.
Inst Install all the fue fuell pipe to the inject injection ion pump and the then n tight en it to the specified specified torq ue.
2.
Install Install the leak leak off pipe to the nozz nozzle holder holder and then tight en it to the specified specified torq ue. N ·m (kgf· (kgf ·m/ft. lb)
Injection pump
Tightening Tightening t orque Fig. 158
Fu el p i p e
20 - 25 (2.0 – 2.5 – 2.5 / 14 – 14 – 18) 18)
Leak o f f p i p e
10 - 14 (1.0 – 1.4 – 1.4 / 7 – 7 – 10) 10)
Note: When tightening it, hold the pipe securely by hand so that it w ill not not rotate. 3.
Connec onnect the ffuel uel pipe and and the lea leak k off pipe pipe with the fuel hose and fix them with clips.
Injection pipe
Injection pipe
Nozzle holder
Install the injection pipe to the injection pump and the nozzle nozzle holder and tig hten them up w ith sleeve nuts. N ·m (kgf· (kgf ·m/ft. lb) Ti g h t en i n g to to r q u e
Injection Injection pum p
15 - 25 (1.5 – 2.5 – 2.5 / 11 – 11 – 18) 18)
Note: Set t he thread of t he sleeve sleeve nut securely securely before tightening it up. Fig. 159
Water pump assembly assembly 1.
Put seal sealan antt on the wate waterr pump w here here it conta contact cts s the block and head.
2.
Tighte ighten to the spec pecified ified torque torque..
(L=60)
N ·m (kgf· (kgf ·m/ft. lb) Ti g h t en i n g to to r q u e
(L=40)
19 - 28 (1.9 – 2.9 – 2.9 / 14 – 14 – 21) 21)
Tighten together with adjusting plate Fig. 160
Thermostat Water outlet pipe
Thermostat
Gasket
Water outlet pipe Assemble the thermostat, install the gasket and the water outlet pipe, and then tighten it to the specified torque. N ·m (kgf· (kgf ·m/ft. lb)
Water pump
Fig. 161
Ti g h t en i n g to to r q u e
19 - 28 (1.9 – 2.9 – 2.9 / 14 – 14 – 21) 21)
ENGINE 77 Adjustment of valve clearance (Refer to Section “ GENERAL INFORMATION – MAINTE – MAINTENANCE.” NANCE.” ) Cylinder head cover Cylinder cover
1. Gasket
Rocker Rocker arm bracket
Inst Instal alll the gas gasket ket to the cylinde cylinderr head head cover. cover.
Notes: 1.
Much care should hould be taken taken for for the gas gasket ket not not to get dislocated or twisted when installing the head cover.
2.
Avoid Avoid the applic application ation of seal sealant ant to the rubber rubber gas gas-ket.
2.
Instal Installl the cylinde cylinderr head head cover cover to the rocke rockerr arm bracket, bracket, and and ti ghten it to th e specified specified torqu e.
Fig. 162
N ·m (kgf· (kgf ·m/ft. lb) Ti g h t en i n g t o r q u e
2 - 4 (0.2 – 0.4 – 0.4 / 1.4 – 1.4 – 2.9) 2.9)
Air inlet pipe Cylinder head cover
Air inlet pipe
1.
Apply seala sealant nt (TB1 (TB120 207C 7C)) to the surface surface in which the air inlet pip e is installed. installed.
2.
Inst Instal alll the air air inlet inlet pipe to the cylinde cylinderr head head cover, cover, and tighten it to t he specified specified torque. N ·m (kgf· (kgf ·m/ft. lb) Ti g h t en i n g t o r q u e
8 - 12 (0.8 – 1.2 – 1.2 / 6 – 6 – 9) 9)
Fig. 163
Exhaust manifold Gasket Exhaust manifold
Assemble the gasket to the cylinder head, install the exhaust manifold along the stud bolts and tighten it to the specified specified tor que. N ·m (kgf· (kgf ·m/ft. lb) Ti g h t en i n g t o r q u e
19 - 28 (1.9 – 2.9 – 2.9 / 14 – 14 – 21) 21)
Cylinder head Fig. 164
Starter Install the starter to the flywheel housing, and tighten it to the specified torque. N ·m (kgf· (kgf ·m/ft. lb) Ti g h te ten i n g t o rq rq u e Starter
Fig. 165
93 - 113 (9.5 – 11.5 – 11.5 / 69 – 69 – 83) 83)
78 ENGINE Generator Water pump
1.
Tighte Tighten n the adjus adjustt plate plate toge togethe therr with the wate waterr pump, and then install them temp orarily.
2.
Inst Install all the bottom of the alter alternat nator or to the timing gear gear case, and then tighten it temporarily with bolts and nuts.
3.
Inst Install all the fixing bolts bolts onto the top of the alte alterna rnator tor through the adjusting plate. (Temporary tightening)
Adjusting plate
Alternator Fig. 166
Fan pulley and fan belt Fan pulley
1.
Inst Install all the fan pulley pulley to the wate waterr pump and and then then tight en it up . (2 locations)
2.
Set the fan fan belt belt to ea each pulle pulley.
Water pump
Fan Fan b elt Fig. 167
Fan belt tension Adjust the alternator as specified and tighten to the specified specified t orque. mm (in) (in) Deflection amount (Press the belt at its center center betw een een the pu lleys w ith 98 N (10kg (10kg / 22 lbs.) for ce.)
7.5 to 8.5 (0.29 – (0.29 – 0.33) 0.33) mm (in) (in)
Fig. 168
Gen er at o r u p p er
1.9 – 2.9 – 2.9 (14.0 – (14.0 – 21.0) 21.0)
Gen er at o r l o w er
3.5 – 4.7 – 4.7 (25.0 – (25.0 – 34.0) 34.0)
A d j u st p l a t e
1.9 – 2.9 – 2.9 (14.0 – (14.0 – 21.0) 21.0)
Cooling fan Cooling fan
Spacer
Fig. 169
1.
Asse Assemble mble the spa space cerr before before tighten tightening ing the cooling cooling fan.
2.
Tighte Tighten n it to the spec specifie ified d torque. torque. (4 (4 locat locations ions))
LUBRICATING SYSTEM 79
SECTION 3
LUBRICATING SYSTEM TABLE OF CONTENTS CON TEN TS
PAGE
LU BRICATIN G OI OIL CIRCU LATION SY SYSTEM D DIIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 OIL PU M P. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 81
80 LUBRICATING SYSTEM
LUBRICATING OIL CIRCULATION DIAGRAM Valve opening pressure 98 kPa (1kgf/cm 2)
Oi l f i l t er
Valve opening pressure 440 kPa (4.5kgf/cm 2)
Oi l g al l er y
Main bearing
Idle gear bush
Cylinder head
Crankshaft
Timing gear
Rocker Rocker arm bracket
Connecting ro d
Governor
Rocker Rocker shaf t
Rocker Rocker arm
Oil pump
Injection pump
St r ai n er
Pi st o n Tap pe pet
Val ve ve st em em en d
Piston pin boss
Oil pan Pr essu r e f eed i n g
N o n p r essu r e f eed i n g
Fig. 170
LUBRICATING SYSTEM 81
OIL PUMP With PTO
Body; Oil pump Pin (common)
Withou t PTO PTO
Front p late (Body; integral structure)
Rotor; o uter Roter; inner O-ring O-ring (comm (comm on)
Relief valve
Pum p gear
Spring Plug Oil pump (common)
Common
Fig. 171
Inspection and replacement When there is wear, damages or any other defects found , repair repair or replace the rotor . Clearance between the outer rotor or inner rotor and the pum p cover cover mm (in) (in) St an d ar d
Li m i t
0.04 0.040 0 – 0.08 0.085 5 (0.00 (0.0016 16 – 0.0 0.003 033) 3)
0.15 0.1 5 (0.00 (0.0059 59))
Clearance between the periphery of the outer rotor and the pump body mm (in) (in) St an d ar d
Li m i t
0.10 0.10 – 0.18 0.185 5 (0.0 (0.003 039 9 – 0.00 0.0073 73))
0.4 0.4 (0.0 (0.015 157) 7)
Clearanc Clearance e betw een the inner rotor and the outer rot or mm (in) (in) S t an d a r d
Li m i t
0.17 (0.0067)
0.2 (0.0079)
MEMO
COOLING SYSTEM 83
SECTION 4
COOLING SYSTEM TABLE OF CONTENTS CON TEN TS
PAGE
COOLIN G WATER CIRCU LATION SYSTEM DI DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 WATER PU M P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 THERM OSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 87
84 COOLING SYSTEM
COOLING WATER CIRCULATION SYSTEM DIAGRAM Bottom bypass type thermostat Cyliner head
Cylinder block Radiator
(
Water Water pum p
Fig. 172
bypass circuit)
COOLING SYSTEM 85
WATER WATER PU M P DISASSEM DISA SSEM BLY BLY
Seal Seal un it
Impeller
Bearing unit
Fan center Cover
Body
Setscrew
Fig. 173
Fan center Cover
Setscrew
Fan center
Cover 1.
Loosen Loosen the set set screw. screw.
2.
Remove the cover. cover.
Note: The cover is applied with sealant (TB1207B). When removing the cover, much care should be taken not to deform it by applying an excessive force to it.
Fig. 174
Impeller Seal unit Bearing unit Bearing Bearing u nit Impeller Seal Seal u nit Fig. 175
86 COOLING SYSTEM
REASSEM BLY BLY Bearing unit Align holes Body Bearing Bearing un it
With a hole in the bearing unit set in line with one in the body, lock the bearing bearing unit w ith a setscrew. setscrew. N·m (kgf·m/ft. lb) Set s sc crew rew tighte tighteni ning ng ttorq orque ue
Fan center
8 - 12 ((0 0.8 – 1.2 – 1.2 / 6 – 6 – 9) 9)
Setscrew Fig. 176 Impeller
Seal unit Impeller 1.
Apply BE BELC LCO O bond bond No. 4 to the surfa surface ce where the seal seal unit com es into contact w ith th e body, and then assemble the seal unit.
2.
Press ress in the impeller with a press press until the cleara clearance nce between between the pum p im peller peller and the body gets to the specified value.
Seal Seal un it
Fig. 177
Cover Cover
1.
Apply sea sealan lantt to the surfa surface ce to which the the cove coverr is installed, and and t hen install th e cover.
2.
Apply Scre Screw-loc w-lock k to the cove coverr installa installation tion screws screws,, and then tighten them.
Fig. 178
Clearance, learance, play and t ightening allowance betw een parts 1.
Clear learanc ance e betwee between n the pump pump im pelle pellerr and the the body body mm (in) (in) St an d ar d
2.
0.53 – 2.17 – 2.17 (0.0209 – (0.0209 – 0.0854) 0.0854)
Play lay in the the wat water er pump ball ball bea bearing mm (in) (in) St an d ar d
Li m i t
0.008 – 0.008 – 0.010 0.010 (0.0003 – (0.0003 – 0 0.0004)
0.2 (0.0079)
3.
Tighte Tightening ning allowanc allowance e betwee between n the fa fan n cente centerr and the bearing shaft mm (in) (in) St an d ar d
0.026 – 0.061 – 0.061 (0.001 – (0.001 – 0.0024) 0.0024)
COOLING SYSTEM 87
THERM THERM OSTAT OSTAT Inspection and replacement Replace eplace the therm ostat wh en there is w ear, ear, damages or any other defects found . O p en i n g t em p .
80.5 – 83.5 – 83.5° °C (177 (177 – – 182 182° °F)
Valve lift mm (in.)
8mm o r more at 95 95°C (0.31 inch or more at 203° 203°F)
Thermometer
Agitating rod Thermostat Wooden piece
Fig. 179
MEMO
FUEL SYSTEM 89
SECTION 5
FUEL SYSTEM TABLE OF CONTENTS CON TEN TS
PAGE
FU EL CIRCU LATION SYSTEM DI DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 GOV ERN OR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 N OZZLE HOLDER ASSEM BLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
90 FUEL SYSTEM
FUEL CIRCULATION SYSTEM DIAGRAM
Fuel tank
Nozzle holder
Injection pump Nozzle
Fuel Fuel fi lter
Fig. 180
FUEL SYSTEM 91
GOVERNOR 1.
The adjustments of the governor -related -related parts parts requir requir e the engine perfor perfor mance test.
2.
Before Before disasse disassemb mb ling th e governor, measure the dimensions “ A” and “ B” given in th e structural structural drawi ng to ensure the same same dim ensions in reass reassembly embly .
3.
Do not disass disassemble emble the governor wh en the perform ance test cannot cannot be conducted after reass reassembly embly .
1. STRUCT STRUCTURA URAL L DRAWING DRAWING OF GOVE GOVER RNOR (1) (1)
Idle speed screw Idle (sub) spring Start spring Fuel cut cover A
Link plate
Governor shaft
Set Set spri ng
Control link
Governor cover Injection Injection pum p Guide lever
Main spring lever Main spring
Timing gear case
Floating lever B
Camshaft
Tensioner lever
Angleich Full l oad stopper
Sleeve
Flyweight Shifter
Fig. 181
92 FUEL SYSTEM
2. STRUCT STRUCTURA URAL L DR DRAWING OF GOVE GOVER RNOR (2) (2) Start spring Set Set sprin g
Control link
Snap pin
Guide lever Floating lever
Link plate
A Cap nu t
Guide piece Shifter
Setscrew Shaft (floating (floating ) Fuel cut lever
Return spri ng
Main spring
B
Fuel cut sh aft
Shifter shaft
Tensioner lever
O-ring Idle spring
Lever; main spring
Bracket; start spring
Speed control screw Angleich Return spring
O-ring
A Shaft
Lever bush
Sleeve
B
Lever bush
Full load setscrew
Contro l lever
Timing gear case
Fig. 182
Cam gear Flyweight
FUEL SYSTEM 93
3. RE REASSEM ASSEMBL BLY OF CON CONTROL TROL LEVER LEVER REL RELA ATED PAR PARTS TS (1) (1) Put the lever lever (main spring) through the hole of the timing g ear ear case case lever. lever. Note: Before hammering in the bushes, put both shafts of the lever through the holes of the timing gear case lever respectively. (2) (2) Put the return spring spring of the control lever lever through th e shaft shaft of the lever lever (main (main spring). (3) (3) Asse Assemble mble the bushes bushes.. Assemb Assemb le the bush of the lever (main spring) fir st, and and then th e contr contr ol lever bush. Note: When assembling the bushes, apply Loctite (#601) to the periphery of the bushes.
Bush Apply Loctite No.601 No.601 to the peniphery
Lever; Lever; Main sprin g Protrusion
Pin
Return spring
Timin g g ear ear case
Bush Apply Loctite No.601 No.601 to the peniphery
Fig. 183
(4) (4) Hook both ends of the return spring (control (control lever) sec securely urely to the protrusion and the pin of the lever lever (main sprin g) respectively. respectively.
94 FUEL SYSTEM (6) (6) Asse Assemble mble the control control leve lever. r. Assemble Assemble th e O-ring O-ring to t he groov e of the bu shes (contro (contro l lever) first, and then assemb assemb le the w ashers ashers and the contro contro l lever before before tightenin g up the control lever with a nut. N ·m (kgf· (kgf ·m/ft. lb) Contro ontroll leve leverr tight tighte ening ning torque torque
12 - 18 (1 (1.2 – 1.8 – 1.8 / 9 – 9 – 13) 13)
Contro l lever
O-ring Bush
Spring w asher asher Washer
Groove
Fig. 184
Notes: 1.
Tighten Tighten the control control lev lever er after after locking locking the control control lev lever er firmly. firmly. (Do not t ighten t he control lever after locking locking the main spring lever.) lever.)
2.
After as assembly, confirm onfirm that the control control lever lever moves smoothly.
Nu t
FUEL SYSTEM 95
4. Rea eas ssembly embly of of shi shifter fter (1) (1) Assemble Assemble the shifter shifter to the guide lever, lever, put the shaft shaft through it, and and then asse assemble mble the snap snap ring. (2) (2) After ass assembly, embly, confirm confirm that the shaft shaft moves smoothly. (3) (3) Also, confirm that the shifter shifter shake shakes s smoothly. smoothly.
Guide lever
Shifter Snap ring
Shaft Fig. 185
96 FUEL SYSTEM
5. Reas eass sembly of gove governo rnorr cove coverr Assemble Assemble th e related related parts such as the fuel cut lever and th e idle spring to the governor cover.
[Stop]
Governor cover
2 2
Return spri ng
(Bent-up (Bent-up p art)
[Operate] °
Thrust washer
O-ring Shaft
2 2 2° °
Governor
Z
Nu t
Idle spring
Spring w asher asher (Notched groove)
Fuel cut l ever
Z
Fig. 186
Cap Cap nut Packing Lock nut (
)
Gasket Idle screw
A
Governor lever Tensioner lever
Washer
Idle spring Washer
Snap ring
(Z view of the drawing above) Fig. 187
(1) (1) When ass assembling embling the shaft, shaft, apply engine engine oil to the sliding portion w ith the governor cover. cover. (2) (2) Set Set both ends of the return return spring sec securely urely to the notched groove at the bottom of the cover and the bent-up arm of th e lever respectively. respectively. (3) (3) After reas reasse sembling mbling the governor cover, cover, confirm that the governor moves smoot smoot hly. (4) (4) When ass assembling embling the timing gear gear case case to the govergovernor cover, tighten the “ A ” dimension shown in the illustration illustration to 2 – 3 – 3 mm temporarily. The parts given in the square indicated by (* ) are ass assemembled after perform ance test. mm (in) (in) “ A ” dimension
(When assembling temporarily) 2 – 3 – 3 (0.0787 – (0.0787 – 0.0118) 0.0118)
FUEL SYSTEM 97
6. Reas eass sembly of fullfull-loa load d stoppe stopperr Install Install the full-load stopper to the tim ing gear case case,, and and then tigh ten it wi th a nut temp orarily.
Timing gear case case
Full load stopper
Nut; setscrew
Fig. 188
98 FUEL SYSTEM
7. Reas eass sembly of of govern governor or lever related components Assemble Assemble each lever and spring to t he tim ing gear case case..
Main spring lever
Lever shaft
Tensioner lever Link plate Main spring
Eye; start spring
Set spring
Guide piece Start spring Guide lever
Snap pin Plug
Floating lever Shaft; floatong lever
Fig. 189
8. Notes when as assembling embling gover governor nor related related compon components ents (1) When asse assem m bling com ponents, apply apply engin e oil to each each slide (such (such as the end face face of the lever, lever, the hole in t he shaft, and and th e periphery of the shaft). (2) (2) Install Install the set set spring sec securely urely to the groove of the pin connecting connecting the floating lever, lever, with m uch care care to its asse assem m bling direction. (3) (3) Confirm that each each lever lever moves by its dead dead w eight before installing installing the start start spring. (4) (4) After ass assembly, embly, confirm confirm that each each lever lever moves smoothly. And also confirm that each each spring o perates properly .
FUEL SYSTEM 99
N OZZLE OZZ LE HOLDER HOLDER ASSEMB ASSEM BLY DISASSEM DISA SSEM BLY BLY
Push rod Bolt Spacer Gasket Gasket
Nozzle
Nozzle holder
Retainer nut Adjusting shim
Spring
Fig. 190
N OZZLE ASSEM BLY BLY Inspection and replacement Place the remo ved nozzle nozzle in the clean clean ligh t oil, disassemble it into the nozzle body and the needle valve and clean them thoroughly. Then check to see if the valve moves smooth smooth ly in the body. When it does not move smoothly, repair or replace the nozzle. Light oil Fig. 191
Adjustment For the adjustment of the injection pressure and the spray condition of fuel, refer to Section 1 “ INSPECTION AND SERVICE.” SERVICE. ”
MEMO
TROUBLESHOOTING 101
SECTION 6
TROUBLESHOOTING Engine does not start
Starter does not run
Engin e starts but does not run continuously.
Starter Starter runs but does not start
Check battery Engine Battery in discharging (Charge)
Fu el sy st em
Fu el i n j ect ed
No fuel injected
Fuel i njected
Air mixed in fuel pump
OK Check compression ratio
( )
*
Check wiring
Loosened connector connector or broken wire (Retighten or replace replace w ith new wiring)
OK
Low compression ratio
OK
Check for air mixing
Defective valve, spring, gasket, etc. (Overhaul)
Air mixed (Retighten it, replace packing, bleed air)
Check starter swi tch
Defective (Replace)
Check preheating circuit
Check if fuel comes to fuel pump
OK
OK
Check magneti c switch ( )
*
Defective (Replace)
OK
OK
Normal operation of glow plug control resistance OK
Abnormal (Adjust)
OK
Disordered idling
Adjust idling
Check injection timing
Check fuel filter
Clogged (Clean)
Poor operation of glow plug control resistance (Replace)
OK
Retighten, replace packing, bleed air
OK
OK
Check nozzle Check engine stop solenoid return
Defective (Repair or replace)
Check starter bush
OK
Check solenoi d
Poor contact (Repair or replace)
OK
Defective Defective starter (Bring it to a specialty shop for repair)
Stuck solenoid or poor operation (Repair (Repair o r r eplace)
OK
Defective injection pump (Bring it to a specialty shop for repair)
Note: “ Bring it to a specialty specialty shop” means that that defective defective parts of the injection injection pum p and electricals must be brought to a specialty shop for repair. (This note is applicable applicable to all the foll owin g pro cedures. cedures.))
102 TROUBLESHOOTING Unstable engine rotation
Unstable engine idling
Idling speed too high
Unstable rotation at medium speed speed (Hunting)
Unstable rotation at high speed
Engin e does not change change from hi gh to low rotation rotation
Defective idling adjustment
Defective control lever adjustment
Governor spring deteriorated
Check fuel for air mixing
Check accelerato r pedal
Defective valve return (Adjust)
OK
Check high pressure pipe for cracking, clogging or bending
Cracked, clogged or bent (Replace)
OK
OK
Check cyli cyli nder fo r uneven com pression pression pressure
Uneven compression pressure (Adjust)
OK
Defective injection pump (Bring it to a specialty shop for repair)
Air mixed (Bleed air)mixing
Check fuel pip e for crash
Crash (Replace)
OK
OK
OK
Defective injection pump (Bring it to a specialty shop for repair)
Pedal sticking sticking or hitching (Clean (Clean o r replace)
OK
Check fuel filt er for clogging
Clogged (Clean or replace)
OK
Check uneven fuel injection
Check nozzle
Defective (Repair or replace)
Defective (Repair or replace)
Uneven (Adjust)
OK
Check valve clearance adjustment
Poor adjustment (Adjust)
OK
Defective injection pump (Bring it to a specialty shop for repair)
Defective injection pum p (Bring (Bring it to a specialty specialty shop for repair)
TROUBLESHOOTING 103
Insufficient out put
Fuel system
Check fuel for air mixing
Air mixed (Bleed air)
Overheat
Mechanical system
Check engine control
Cooling system
Check coolin g water level
Insufficient
OK Poor adjustment
OK
OK
Handling
Check fan belt for slip
Slipping (Adjust)
OK
(Adjust) Check fuel fi lter or fuel hose for clogging
Clogged (Clean or Replace)
Check inlet air temperature
Temperatu re too high (Improve ventilation)
OK
OK
Check injectio n timing
Abnormal (Adjust)
Check therm ostat
Malfunction (Replace)
OK
Leak to external
Leak to internal
Repair
Repair or replace
Insufficient Insufficient inlet air
Air cleaner cleaner stained (Clean (Clean o r replace)
OK
Check nozzle
Defective (Repair or replace)
Check fo r leakage
OK
Check valve clearance and cam cam lif t
Abnormal (Adjust or replace)
OK
Check compression pressure
Low Defective injection injection pum p (Bring (Bring it to a specialized specialized shop for repair)
Low Excessive blow-by gas (Overhaul)
Gas leak from valve and gasket gasket (Repair (Repair o r replace)
Care must be taken when replenishing (Replace)
OK
OK Engine rotation too high
OK
Check hig h pressure pipe for clogging or bending
Clogged or bent (Replace)
Replenish
Check if oi l used is inferior quality, or engine oil is too much
Overloaded
Check coolin g system system for stain, and radiator for clogging Temperature abnormally high Stained or clogged (Clean)
OK
Improve ventilation
104 TROUBLESHOOTING Abnormal exhaust gas
Check if fuel used is of inferior quality
OK
Change fuel
Check if engine oil is too much
White smoke too much
Black smoke too much
Check fuel for water mixing
Check nozzle
Water mixed (Change (Change fuel)
OK
Defective (Repair or replace)
Air cleaner clogged
OK
Replace ai r cleaner element
OK
Check air hose for crash
Check injection injection tim ing Check injection injection tim ing Advanced Advanced too m uch
Delayed (Adjust)
OK
(Adjust)
OK
Check injection pump Check com com pression rati o
Low
Excessive blow-by gas (Overhaul)
Gas leak from valve and gasket (Repair or replace)
OK
OK
Defective Defective injection pum p (Bring it to a specialty shop for repair)
Check up and down movement of oil
1.Disordered 1.Disordered valve tim ing 2.Broken 2.Broken piston ring or misassembly 3.Worn camshaft camshaft 4.Worn v alve or insert insert (Overhaul)
Stuck (Overhaul)
Over-discharge of battery Battery
Wiring
Regulator and generator
Check electrolyt e level
Check terminals for warp, deformation or corrosion
Check belt for slip or damage
Low
OK
Battery Natural case consumpt cracked io n (Replace) (Replenish)
Poor contact (Repair (Repair o r r eplace) Over charge
Note: Improper m aintenance aintenance
Check for broken wire (Repair (Repair o r replace)
OK
Slipping or damaged (Repair (Repair or repl ace) ace)
Test Test charging conditio n
Abnormal
Bring it to a battery shop Check specific specific g ravity Low
Recharge
Recharging impossible
Bring it to a battery specialty specialty shop
OK
OK
TROUBLESHOOTING 105
Oil pressure t oo low
Oil consum pt ion t oo m uch
Oil consum pt ion t oo m uch
Ch eck o i l l ev el
Ch eck f o r o i l l eakag e
Ch eck f o r o i l l eakag e
Low (Replenish) (Replenish)
OK
OK
Leaking (Retight Leaking (Retight en, replace packing seal)
Leaking (Retight Leaking (Retight en, replace packing seal)
OK
Check cooling water temperature Check nozzle
Check oil quality
OK
High (See “ Overheat” )
OK
Defective (Repair (Repair o r r eplace)
Poor quality (Change (Change to specified o il)
OK
Check oil in crankcase Ch ec eck i nj nj ec ect io io n t im im i ng ng Improper viscosity
OK A b n o r m al (A d j u st )
Water or fu el m ixed. Check Check fuel system system and cooling system system
Low OK
Defective (Repair (Repair o r r eplace)
Oil pump malfunction malfunction Loosened Loosened or crack cracked ed pipe Wear Wear of sliding part Oil pump clogged clogged (Overhaul)
OK
Gas leak from valve and gasket gasket (Repair or replace)
1. 2. 3. 4. 5.
Oil pump malfunction malfunction Loosened Loosened or cracke cracked d pipe Wear Wear of sliding part Oil pump clogged clogged Defectiv Defectiv e valve stem seal seal (Overhaul)
(*) Wo rn bore,and bore,and worn or b roken ring (Measure (Measure com pression pression pressure, and check entrance of dust)
Engine knocking Mechanical system
Fuel system
Ch ec eck u p m o ve vem en en t o f o ilil
Ch ec eck i nj nj ec ect io io n t im im i ng ng
Oi l st ai n ed (Ov er h au l )
OK
Ch eck co m pr pr essi o n p r essu r e
Low
OK
A b n o r m al al (A d j u st )
OK
Ch eck n o zzl e
Defective (Repair (Repair o r r eplace)
OK
To fuel system Note: Fuel Fuel used is of p oor q uality. Excessive blow-by gas (Overhaul)
Gas leak from valve and gasket gasket (Repair or replace)
OK
Chec heck up and down down move moveme ment nt of oil oil
Defective Defective injection pum p (Bring it to a specialty shop for repair)
Excessive blow-by gas
Cl o g g ed (Cl ean )
OK
Chec heck compre compres ssion ratio ratio
Check relief valv e
1. 2. 3. 4.
Ch ec eck b le leed er er f or or cl og og gi gi ng ng
MEMO
SPECIAL TOOLS 107
SECTION 7
SPECIAL TOOLS The alphanum eric codes codes in parenthese parentheses s “( No.
Il l u st r at i o n
)” are part num bers ass assigned igned by special special tool m anufacturers. anufacturers.
Par t N u m b er
Par t N am e
Pag e
1.
5-8840-2675-0
Co m p r essi o n g au g e
23
2.
5-8840-9029-0
Co m p r essi o n g au g e ad ap t er
23
3.
5-8840-9016-0 (J-28829)
N o zzl e t est er
24
4.
5-8840-9015-0 (JKM-9004)
Oi l f i l t er w r en ch
—
5.
5-8840-9030-0
Val v e sp r i n g co m p r esso r
57
6.
1-85221-029-0
Pi st o n r i n g p l i er s
41
7.
5-8840-9018-0 (J-8037)
Pi st o n r i n g co m p r esso r
—
8.
5-8840-9031-0
Fr o n t o i l seal i n st al l er
—
9.
5-8840-9032-0
Rear o i l seal i n st al l er
—
10 .
5-8840-9034-0
Cam sh af t b ear i n g i n st al l er
—
11 .
5-8840-9035-0
Val v e g u i d e i n st al l er
—
12 .
5-8840-9033-0
Val v e st em seal i n st al l er
—
MEMO
CONVERSION TABLE 109
SECTION 8
CONVERSION TABLE TABLE OF CONTENTS ITEM
PAGE
LEN GTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 109 AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 111 V OLU M E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 111 M ASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1 13 PRESSU RE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1 14 TORQU E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 115 TEM PERATU RE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 116 LENGTH M ILLIM ETERS TO IN CHES mm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
i n. 0.0394 0.0787 0.1181 0.1575 0.1969 0.2362 0.2756 0.3150 0.3543 0.3937 0.4331 0.4724 0.5118 0.5512 0.5906 0.6299 0.6693 0.7087 0.7480 0.7874 0.8268 0.8661 0.9055 0.9449 0.9843
mm 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
i n. 1.0236 1.0630 1.1024 1.1417 1.1811 1.2205 1.2598 1.2992 1.3386 1.3780 1.4173 1.4567 1.4961 1.5354 1.5748 1.6142 1.6535 1.6929 1.7323 1.7717 1.8110 1.8504 1.8898 1.9291 1.9685
mm 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
IN CHES TO M ILLIM ETERS
i n.
mm
in .
2.0079 2.0472 2.0866 2.1260 2.1654 2.2047 2.2441 2.2835 2.3228 2.3622 2.4016 2.4409 2.4803 2.5197 2.5591 2.5984 2.6378 2.6772 2.7165 2.7559 2.7953 2.8346 2.8740 2.9134 2.9528
76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
2.9921 3.0315 3.0709 3.1102 3.1496 3.1890 3.2283 3.2677 3.3071 3.3465 3.3858 3.4252 3.4646 3.5039 3.5433 3.5827 3.6220 3.6614 3.7008 3.7402 3.7795 3.8189 3.8583 3.8976 3.9370
i n.
mm 1/64
1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32
101 102 103 104 105 106 107 108 109
3.9764 4.0157 4.0551 4.0945 4.1339 4.1732 4.2126 4.2520 4.2913
111 112 113 114 115 116 117 118 119
4.3701 4.4094 4.4488 4.4882 4.5276 4.5669 4.6063 4.6457 4.6850
121 122 123 124 125 126 127 128 129
4.7638 4.8031 4.8425 4.8819 4.9213 4.9606 5.0000 5.0394 5.0787
131 132 133 134 135 136 137 138 139
5.1575 5.1969 5.2362 5.2756 5.3150 5.3543 5.3937 5.4331 5.4724
27/64 7/16 29/64 15/32 31/64 1/2
0.3969 0.7938 1.1906 1.5875 1.9844 2.3813 2.7781 3.1750 3.1750 3.5719 3.9688 4.3656 4.7625 5.1594 5.5563 5.9531 6.3500 6.3500 6.7469 7.1438 7.5406 7.9375 8.3344 8.7313 9.1281 9.5250 9.5250 9.9219 10.3188 10.7156 11.1125 11.5094 11.9063 12.3031 12.7000
i n.
mm 33/64
17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 1
13.0969 13.4938 13.8906 14.2875 14.6844 15.0813 15.4781 15.875 15.8750 0 16.2719 16.6688 17.0656 17.4625 17.8594 18.2563 18.6531 19.050 19.0500 0 19.4469 19.8438 20.2406 20.6375 21.0344 21.4313 21.8281 22.225 22.2250 0 22.6219 23.0188 23.4156 23.8125 24.2094 24.6063 25.0031 25.4000
110 CONVERSION TABLE LENGTH FEET FEET TO M ETERS f t.
0
1
2
3
4
5
6
7
8
9
m
m
m
m
m
m
m
m
m
m
––– ––– 10 20 30 40 50 60 70 80 90 100
––– ––– 0 3.048 6.096 9.144 12.192 15.240 18.288 21.336 24.384 27.432 30.480
0.305 3.353 6.401 9.449 12.497 15.545 18.593 21.641 24.689 27.737 30.785
0.610 3.658 6.706 9.754 12.802 15.850 18.898 21.946 24.994 28.042 31.090
0.914 3.962 7.010 10.058 13.106 16.154 19.202 22.250 25.298 28.346 31.394
1.219 4.267 7.315 10.363 13.411 16.459 19.507 22.555 25.603 28.651 31.699
1.524 4.572 7.620 10.668 13.716 16.764 19.812 22.860 25.908 28.956 32.004
1.829 4.877 7.925 10.973 14.021 17.069 20.117 23.165 26.213 29.261 32.309
2.134 5.182 8.230 11.278 14.326 17.374 20.422 23.470 26.518 29.566 32.614
2.438 5.486 8.534 11.582 14.630 17.678 20.726 23.774 26.822 29.870 32.918
2.743 5.791 8.839 11.887 14.935 17.983 21.031 24.079 27.127 30.175 33.223
ft . ––– 10 20 30 40 50 60 70 80 90 100
M ETERS TO FEET FEET m ––– ––– 10 20 30 40 50 60 70 80 90 100
0
1
2
3
4
5
6
7
8
9
ft .
f t.
f t.
ft.
ft .
f t.
ft.
ft .
ft .
f t.
––– ––– 00 00 32.8084 65.6168 98.4252 131.2336 164.0420 196.8504 229.6588 262.4672 295.2756 328.0840
3.2808 36.0892 68.8976 101.7060 134.5144 167.3228 200.1312 232.9396 265.7480 298.5564 331.3648
6.5617 39.3701 72.1785 104.9869 137.7953 170.6037 203.4121 236.2205 269.0289 301.8373 334.6457
9.8425 42.6509 75.4593 108.2677 141.0761 173.8845 206.6929 239.5013 272.3097 305.1181 337.9265
13.1234 45.9318 78.7402 111.5486 144.3570 177.1654 209.9738 242.7822 275.5906 308.3990 341.2074
16.4042 49.2126 82.0210 114.8294 147.6378 180.4462 213.2546 246.0630 278.8714 311.6798 344.4882
19.6850 52.4934 85.3018 118.1102 150.9186 183.7270 216.5354 249.3438 282.1522 314.9606 347.7690
22.9659 55.7743 88.5827 121.3911 154.1995 187.0079 219.8163 252.6247 285.4331 318.2415 351.0499
26.2467 59.0551 91.8635 124.6719 157.4803 190.2887 223.0971 255.9055 288.7139 321.5223 354.3307
29.5276 62.3360 95.1444 127.9528 160.7612 193.5696 226.3780 259.1864 291.9948 324.8032 357.6116
7
8
9
––– 10 20 30 40 50 60 70 80 90 100
MILES TO KILOMETERS m i l es
0
1
2
3
4
5
6
km
km
km
km
km
km
km
km
km
km
––– ––– 10 20 30 40 50 60 70 80 90 100
––– ––– 00 00 16.093 32.187 48.280 64.374 80.467 96.560 112.654 128.747 144.841 160.934
1.609 17.703 33.796 49.890 65.983 82.076 98.170 114.263 130.357 146.450 162.543
3.219 19.312 35.405 51.499 67.592 83.686 99.779 115.872 131.966 148.059 164.153
4.828 20.921 37.015 53.108 69.202 85.295 101.388 117.482 133.575 149.669 165.762
6.437 22.531 38.624 54.718 70.811 86.904 102.998 119.091 135.185 151.278 167.371
8.047 24.140 40.234 56.327 72.420 88.514 104.607 120.701 136.794 152.887 168.981
9.656 25.749 41.843 57.936 74.030 90.123 106.216 122.310 138.403 154.497 170.590
11.265 27.359 43.452 59.546 75.639 91.732 107.826 123.919 140.013 156.106 172.199
12.875 28.968 45.062 61.155 77.248 93.342 109.435 125.529 141.622 157.715 173.809
14.484 30.577 46.671 62.764 78.858 94.951 111.044 127.138 143.231 159.325 175.418
––– 10 20 30 40 50 60 70 80 90 100
KILOMETERS TO MILES km ––– ––– 10 20 30 40 50 60 70 80 90 100
0
1
2
3
4
5
6
7
8
9
m i l es
m i l es
m i l es
m i l es
m i l es
m i l es
m i l es
m i l es
m i l es
m i l es
––– ––– 0 6.214 12.427 18.641 24.855 31.069 37.282 43.496 49.710 55.923 62.137
0.621 6.835 13.049 19.262 25.476 31.690 37.904 44.117 50.331 56.545 62.758
1.243 7.456 13.670 19.884 26.098 32.311 38.525 44.739 50.952 57.166 63.380
1.864 8.078 14.292 20.505 26.719 32.933 39.146 45.360 51.574 57.787 64.001
2.485 8.699 14.913 21.127 27.340 33.554 39.768 45.981 52.195 58.409 64.622
3.107 9.321 15.534 21.748 27.962 34.175 40.389 46.603 52.816 59.030 65.244
3.728 9.942 16.156 22.369 28.583 34.797 41.010 47.224 53.438 59.652 65.865
4.350 10.563 16.777 22.991 29.204 35.418 41.632 47.845 54.059 60.273 66.487
4.971 11.185 17.398 23.612 29.826 36.039 42.253 48.467 54.681 60.894 67.108
5.592 11.806 18.020 24.233 30.447 36.661 42.875 49.088 55.302 61.516 67.729
––– 10 20 30 40 50 60 70 80 90 100
CONVERSION TABLE 111 AREA SQUARE INCHES TO SQUARE CENTIMETERS in 2 ––– ––– 10 20 30 40 50 60 70 80 90 100
0
1
2
3
4
5
6
7
8
9
cm 2
cm 2
cm 2
cm 2
cm 2
cm 2
cm 2
cm 2
cm 2
cm 2
––– ––– 00 00 64.516 129.032 193.548 258.064 322.580 387.096 451.612 516.128 580.644 645.160
6.452 70.968 135.484 200.000 264.516 329.032 393.548 458.064 522.580 587.096 651.612
12.903 77.419 141.935 206.451 270.967 335.483 399.999 464.515 529.031 593.547 658.063
19.355 83.871 148.387 212.903 277.419 341.935 406.451 470.967 535.483 599.999 664.515
25.806 90.322 154.838 219.354 283.870 348.386 412.902 477.418 541.934 606.450 670.966
32.258 96.774 161.290 225.806 290.322 354.838 419.354 483.870 548.386 612.902 677.418
38.710 103.226 167.742 232.258 296.774 361.290 425.806 490.322 554.838 619.354 683.870
45.161 109.677 174.193 238.709 303.225 367.741 432.257 496.773 561.289 625.805 690.321
51.613 116.129 180.645 245.161 309.677 374.193 438.709 503.225 567.741 632.257 696.773
58.064 122.580 187.096 251.612 316.128 380.644 445.160 509.676 574.192 638.708 703.224
8
9
i n2 ––– 10 20 30 40 50 60 70 80 90 100
SQUARE CENTIMETERS TO SQUARE INCHES cm 2
0 in
––– ––– 10 20 30 40 50 60 70 80 90 100
2
––– ––– 0 1.550 3.100 4.650 6.200 7.750 9.300 10.850 12.400 13.950 15.500
1 in
2
0.155 1.705 3.255 4.805 6.355 7.905 9.455 11.005 12.555 14.105 15.655
2 in
2
0.310 1.860 3.410 4.960 6.510 8.060 9.610 11.160 12.710 14.260 15.810
3 in
2
0.465 2.015 3.565 5.115 6.665 8.215 9.765 11.315 12.865 14.415 15.965
4 in
2
0.620 2.170 3.720 5.270 6.820 8.370 9.920 11.470 13.020 14.570 16.120
5 in
2
0.775 2.325 3.875 5.425 6.975 8.525 10.075 11.625 13.175 14.725 16.275
6 in
2
0.930 2.480 4.030 5.580 7.130 8.680 10.230 11.780 13.330 14.880 16.430
7 in
2
in
2
in
cm 2
2
1.085 2.635 4.185 5.735 7.285 8.835 10.385 11.935 13.485 15.035 16.585
1.240 2.790 4.340 5.890 7.440 8.990 10.540 12.090 13.640 15.190 16.740
1.395 2.945 4.495 6.045 7.595 9.145 10.695 12.245 13.795 15.345 16.895
––– 10 20 30 40 50 60 70 80 90 100
VOLUME CUBIC INCHES TO CUBIC CENTIMETERS in 3 ––– ––– 10 20 30 40 50 60 70 80 90 100
0
1
2
3
4
5
6
7
8
9
cm 3(cc)
cm 3(cc)
cm 3(cc)
cm 3(cc)
cm 3(cc)
cm 3(cc)
cm 3(cc)
cm 3(cc)
cm 3(cc)
cm 3(cc)
––– ––– 00 00 163.871 327.741 491.612 655.483 819.353 983.224 1147.094 1310.965 1474.836 1638.706
16.387 180.258 344.128 507.999 671.870 835.740 999.611 1163.482 1327.352 1491.223 1655.093
32.774 196.645 360.515 524.386 688.257 852.127 1015.998 1179.869 1343.739 1507.610 1671.481
49.161 213.032 376.902 540.773 704.644 868.514 1032.385 1196.256 1360.126 1523.997 1687.868
65.548 229.419 393.290 557.160 721.031 884.901 1048.772 1212.643 1376.513 1540.384 1704.255
81.935 245.806 409.677 573.547 737.418 901.289 1065.159 1229.030 1392.900 1556.771 1720.642
98.322 262.193 426.064 589.934 753.805 917.676 1081.546 1245.417 1409.288 1573.158 1737.029
114.709 278.580 442.451 606.321 770.192 934.063 1097.933 1261.804 1425.675 1589.545 1753.416
131.097 294.967 458.838 622.708 786.579 950.450 1114.320 1278.191 1442.062 1605.932 1769.803
147.484 311.354 475.225 639.095 802.966 966.837 1130.707 1294.578 1458.449 1622.319 1786.190
i n3 ––– 10 20 30 40 50 60 70 80 90 100
CUBIC CENTIMETERS TO CUBIC INCHES cm 3(cc) ––– ––– 10 20 30 40 50 60 70 80 90 100
0
1
2
3
4
5
6
7
8
9
in 3
in 3
in 3
in 3
in 3
in 3
in 3
in 3
in 3
in 3
––– ––– 0 0.6102 1.2205 1.8307 2.4409 3.0512 3.6614 4.2716 4.8818 5.4921 6.1023
0.0610 0.6713 1.2815 1.8917 2.5019 3.1122 3.7224 4.3326 4.9429 5.5531 6.1633
0.1220 0.7323 1.3425 1.9527 2.5630 3.1732 3.7834 4.3937 5.0039 5.6141 6.2243
0.1831 0.7933 1.4035 2.0138 2.6240 3.2342 3.8444 4.4547 5.0649 5.6751 6.2854
0.2441 0.8543 1.4646 2.0748 2.6850 3.2952 3.9055 4.5157 5.1259 5.7362 6.3464
0.3051 0.9153 1.5256 2.1358 2.7460 3.3563 3.9665 4.5767 5.1870 5.7972 6.4074
0.3661 0.9764 1.5866 2.1968 2.8071 3.4173 4.0275 4.6377 5.2480 5.8582 6.4684
0.4272 1.0374 1.6476 2.2579 2.8681 3.4783 4.0885 4.6988 5.3090 5.9192 6.5295
0.4882 1.0984 1.7086 2.3189 2.9291 3.5393 4.1496 4.7598 5.3700 5.9803 6.5905
0.5492 1.1594 1.7697 2.3799 2.9901 3.6004 4.2106 4.8208 5.4310 6.0413 6.6515
cm 3(cc) ––– 10 20 30 40 50 60 70 80 90 100
112 CONVERSION TABLE VOLUME GALLONS (U.S.) TO LITERS U .S. g al . ––– ––– 10 20 30 40 50 60 70 80 90 100
0
1
2
3
4
5
6
7
8
9
U .S.g al .
l i t er s
l i t er s
l i t er s
l i t er s
l i t er s
l i t er s
l i t er s
l i t er s
l i t er s
l i t er s
––– ––– 00 00 37.8543 75.7085 113.5628 151.4171 189.2714 227.1256 264.9799 302.8342 340.6884 378.5427
3.7854 41.6397 79.4940 117.3482 155.2025 193.0568 230.9110 268.7653 306.6196 344.4739 382.3281
7.5709 45.4251 83.2794 121.1337 158.9879 196.8422 234.6965 272.5507 310.4050 348.2593 386.1136
11.3563 49.2106 87.0648 124.9191 162.7734 200.6276 238.4819 276.3362 314.1904 352.0447 389.8990
15.1417 52.9960 90.8502 128.7045 166.5588 204.4131 242.2673 280.1216 317.9759 355.8301 393.6844
18.9271 56.7814 94.6357 132.4899 170.3442 208.1985 246.0528 283.9070 321.7613 359.6156 397.4698
22.7126 60.5668 98.4211 136.2754 174.1296 211.9839 249.8382 287.6925 325.5467 363.4010 401.2553
26.4980 64.3523 102.2065 140.0608 177.9151 215.7693 253.6236 291.4779 329.3321 367.1864 405.0407
30.2834 68.1377 105.9920 143.8462 181.7005 219.5548 257.4090 295.2633 333.1176 370.9718 408.8261
34.0688 71.9231 109.7774 147.6317 185.4859 223.3402 261.1945 299.0487 336.9030 374.7573 412.6115
––– 10 20 30 40 50 60 70 80 90 100
l i t er s
LITERS TO GALLONS (U.S.) l i t er s ––– ––– 10 20 30 40 50 60 70 80 90 100
0
1
2
3
4
5
6
7
8
9
g al .
g al .
g al .
g al .
g al .
g al .
g al .
g al .
g al .
g al .
––– ––– 00 00 2.6417 5.2834 7.9252 10.5669 13.2086 15.8503 18.4920 21.1338 23.7755 26.4172
0.2642 2.9059 5.5476 8.1893 10.8311 13.4728 16.1145 18.7562 21.3979 24.0397 26.6814
0.5283 3.1701 5.8118 8.4535 11.0952 13.7369 16.3787 19.0204 21.6621 24.3038 26.9455
0.7925 3.4342 6.0760 8.7177 11.3594 14.0011 16.6428 19.2846 21.9263 24.5680 27.2097
1.0567 3.6984 6.3401 8.9818 11.6236 14.2653 16.9070 19.5487 22.1904 24.8322 27.4739
1.3209 3.9626 6.6043 9.2460 11.8877 14.5295 17.1712 19.8129 22.4546 25.0963 27.7381
1.5850 4.2268 6.8685 9.5102 12.1519 14.7936 17.4354 20.0771 22.7188 25.3605 28.0022
1.8492 4.4909 7.1326 9.7744 12.4161 15.0578 17.6995 20.3412 22.9830 25.6247 28.2664
2.1134 4.7551 7.3968 10.0385 12.6803 15.3220 17.9637 20.6054 23.2471 25.8889 28.5306
2.3775 5.0193 7.6610 10.3027 12.9444 15.5861 18.2279 20.8696 23.5113 26.1530 28.7947
7
8
9
––– 10 20 30 40 50 60 70 80 90 100
GALLONS (IMP.) TO LITERS Im p g al . ––– ––– 10 20 30 40 50 60 70 80 90 100
0
1
2
3
4
5
6
l i t er s
l i t er s
l i t er s
l i t er s
l i t er s
l i t er s
l i t er s
l i t er s
l i t er s
l i t er s
––– ––– 00 00 45.4590 90.9180 136.3770 181.8360 227.2950 272.7540 318.2130 363.6720 409.1310 454.5900
4.5459 50.0049 95.4639 140.9229 186.3819 231.8409 277.2999 322.7589 368.2179 413.6769 459.1359
9.0918 54.5508 100.0098 145.4688 190.9278 236.3868 281.8458 327.3048 372.7638 418.2228 463.6818
13.6377 59.0967 104.5557 150.0147 195.4737 240.9327 286.3917 331.8507 377.3097 422.7687 468.2277
18.1836 63.6426 109.1016 154.5606 200.0196 245.4786 290.9376 336.3966 381.8556 427.3146 472.7736
22.7295 68.1885 113.6475 159.1065 204.5655 250.0245 295.4835 340.9425 386.4015 431.8605 477.3195
27.2754 72.7344 118.1934 163.6524 209.1114 254.5704 300.0294 345.4884 390.9474 436.4064 481.8654
31.8213 77.2803 122.7393 168.1983 213.6573 259.1163 304.5753 350.0343 395.4933 440.9523 486.4113
36.3672 81.8262 127.2852 172.7442 218.2032 263.6622 309.1212 354.5802 400.0392 445.4982 490.9572
40.9131 86.3721 131.8311 177.2901 222.7491 268.2081 313.6671 359.1261 404.5851 450.0441 495.5031
Im p g al . ––– 10 20 30 40 50 60 70 80 90 100
LITERS TO GALLONS (IMP.) l i t er s ––– ––– 10 20 30 40 50 60 70 80 90 100
0
1
2
3
4
5
6
7
8
9
g al .
g al .
g al .
g al .
g al .
g al .
g al .
g al .
g al .
g al .
––– ––– 00 00 2.1998 4.3996 6.5994 8.7992 10.9990 13.1988 15.3986 17.5984 19.7982 21.9980
0.2200 2.4198 4.6196 6.8194 9.0192 11.2190 13.4188 15.6186 17.8184 20.0182 22.2180
0.4400 2.6398 4.8396 7.0394 9.2392 11.4390 13.6388 15.8386 18.0384 20.2382 22.4380
0.6599 2.8597 5.0595 7.2593 9.4591 11.6589 13.8587 16.0585 18.2583 20.4581 22.6579
0.8799 3.0797 5.2795 7.4793 9.6791 11.8789 14.0787 16.2785 18.4783 20.6781 22.8779
1.0999 3.2997 5.4995 7.6993 9.8991 12.0989 14.2987 16.4985 18.6983 20.8981 23.0979
1.3199 3.5197 5.7195 7.9193 10.1191 12.3189 14.5187 16.7185 18.9183 21.1181 23.3179
1.5399 3.7397 5.9395 8.1393 10.3391 12.5389 14.7387 16.9385 19.1383 21.3381 23.5379
1.7598 3.9596 6.1594 8.3592 10.5590 12.7588 14.9586 17.1584 19.3582 21.5580 23.7578
1.9798 4.1796 6.3794 8.5792 10.7790 12.9788 15.1786 17.3784 19.5782 21.7780 23.9778
l i t er s ––– 10 20 30 40 50 60 70 80 90 100
CONVERSION TABLE 113 MASS POUNDS TO KILOGRAMS l b s.
0
1
2
3
4
5
6
7
8
9
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
––– ––– 10 20 30 40 50 60 70 80 90 100
––– ––– 0 4.536 9.072 13.608 18.144 22.680 27.215 31.751 36.287 40.823 45.359
0.454 4.989 9.525 14.061 18.597 23.133 27.669 32.205 36.741 41.277 45.813
0.907 5.443 9.979 14.515 19.051 23.587 28.123 32.658 37.194 41.730 46.266
1.361 5.897 10.433 14.968 19.504 24.040 28.576 33.112 37.648 42.184 46.720
1.814 6.350 10.886 15.422 19.958 24.494 29.030 33.566 38.102 42.637 47.173
2.268 6.804 11.340 15.876 20.412 24.947 29.483 34.019 38.555 43.091 47.627
2.722 7.257 11.793 16.329 20.865 25.401 29.937 34.473 39.009 43.545 48.081
3.175 7.711 12.247 16.783 21.319 25.855 30.391 34.926 39.462 43.998 48.534
3.629 8.165 12.701 17.236 21.772 26.308 30.844 35.380 39.916 44.452 48.988
4.082 8.618 13.154 17.690 22.226 26.762 31.298 35.834 40.370 44.905 49.441
l b s. ––– 10 20 30 40 50 60 70 80 90 100
KILOGRAMS TO POUNDS kg ––– ––– 10 20 30 40 50 60 70 80 90 100
0
1
2
3
4
5
6
7
8
9
l b s.
l b s.
l b s.
l b s.
l b s.
l b s.
l b s.
l b s.
l b s.
l b s.
––– ––– 00 00 22.046 44.092 66.139 88.185 110.231 132.277 154.323 176.370 198.416 220.462
2.205 24.251 46.297 68.343 90.389 112.436 134.482 156.528 178.574 200.620 222.667
4.409 26.455 48.502 70.548 92.594 114.640 136.686 158.733 180.779 202.825 224.871
6.614 28.660 50.706 72.752 94.799 116.845 138.891 160.937 182.983 205.030 227.076
8.818 30.865 52.911 74.957 97.003 119.049 141.096 163.142 185.188 207.234 229.280
11.023 33.069 55.116 77.162 99.208 121.254 143.300 165.347 187.393 209.439 231.485
13.228 35.274 57.320 79.366 101.413 123.459 145.505 167.551 189.597 211.644 233.690
15.432 37.479 59.525 81.571 103.617 125.663 147.710 169.756 191.802 213.848 235.894
17.637 39.683 61.729 83.776 105.822 127.868 149.914 171.960 194.007 216.053 238.099
19.842 41.888 63.934 85.980 108.026 130.073 152.119 174.165 196.211 218.257 240.304
7
8
9
kg kg ––– 10 20 30 40 50 60 70 80 90 100
KILOGRAMS TO NEWTON kg
0
1
N
N
––– ––– 10 20 30 40 50 60 70 80 90 100
––– ––– 0 98.07 196.13 294.20 392.27 490.34 588.40 686.47 784.54 882.60 980.67
9.81 107.87 205.94 304.01 402.07 500.14 598.21 696.28 794.34 892.41 990.48
2 N 19.61 117.68 215.75 313.81 411.88 509.95 608.02 706.08 804.15 902.22 1000.28
3
4
N 29.42 127.49 225.55 323.62 421.69 519.76 617.82 715.89 813.96 912.02 1010.09
5
6
N
N
N
N
N
N
39.23 137.29 235.36 333.43 431.49 529.56 627.63 725.70 823.76 921.83 1019.90
49.03 147.10 245.17 343.23 441.30 539.37 637.44 735.50 833.57 931.64 1029.70
58.84 156.91 254.97 353.04 451.11 549.18 647.24 745.31 843.38 941.44 1039.51
68.65 166.71 264.78 362.85 460.91 558.98 657.05 755.12 853.18 951.25 1049.32
78.45 176.52 274.59 372.65 470.72 568.79 666.86 764.92 862.99 961.06 1059.12
88.26 186.33 284.39 382.46 480.53 578.60 676.66 774.73 872.80 970.86 1068.93
kg kg ––– 10 20 30 40 50 60 70 80 90 100
NEWTON TO KILOGRAMS N ––– ––– 100 200 300 400 500 600 700 800 900 1000
0
10
20
30
40
50
60
70
80
90
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
––– ––– 00 00 10.197 20.394 30.592 40.789 50.986 61.183 71.380 81.578 91.775 101.972
1.020 11.217 21.414 31.611 41.809 52.006 62.203 72.400 82.597 92.795 102.992
2.039 12.237 22.434 32.631 42.828 53.025 63.223 73.420 83.617 93.814 104.011
3.059 13.256 23.454 33.651 43.848 54.045 64.242 74.440 84.637 94.834 105.031
4.079 14.276 24.473 34.670 44.868 55.065 65.262 75.459 85.656 95.854 106.051
5.099 15.296 25.493 35.690 45.887 56.085 66.282 76.479 86.676 96.873 107.071
6.118 16.316 26.513 36.710 46.907 57.104 67.302 77.499 87.696 97.893 108.090
7.138 17.335 27.532 37.730 47.927 58.124 68.321 78.518 88.716 98.913 109.110
8.158 18.355 28.552 38.749 48.947 59.144 69.341 79.538 89.735 99.933 110.130
9.177 19.375 29.572 39.769 49.966 60.163 70.361 80.558 90.755 100.952 111.149
N ––– 100 200 300 400 500 600 700 800 900 1000
114 CONVERSION TABLE PRESSURE POUNDS POUN DS PER SQUARE SQU ARE INCHES TO KILOGRAM KILOGRAM S PER PER SQUARE CENTI CENTIM M ETERS ETERS lb/in 2
0
1
2
3
4
5
6
7
8
9
l b /i n2
(p si )
kg /cm 2
kg/cm 2
kg/cm 2
kg/cm 2
kg/cm 2
kg/cm 2
kg/cm 2
kg/cm 2
kg/cm 2
kg/cm 2
(psi)
––– ––– 10 20 30 40 50 60 70 80 90 100
––– ––– 0 0.7031 1.4061 2.1092 2.8123 3.5154 4.2184 4.9215 5.6246 6.3276 7.0307
0.0703 0.7734 1.4764 2.1795 2.8826 3.5857 4.2887 4.9918 5.6949 6.3979 7.1010
0.1406 0.8437 1.5468 2.2498 2.9529 3.6560 4.3590 5.0621 5.7652 6.4682 7.1713
0.2109 0.9140 1.6171 2.3201 3.0232 3.7263 4.4293 5.1324 5.8355 6.5386 7.2416
0.2812 0.9843 1.6874 2.3904 3.0935 3.7966 4.4996 5.2027 5.9058 6.6089 7.3119
0.3515 1.0546 1.7577 2.4607 3.1638 3.8669 4.5700 5.2730 5.9761 6.6792 7.3822
0.4218 1.1249 1.8280 2.5311 3.2341 3.9372 4.6403 5.3433 6.0464 6.7495 7.4525
0.4921 1.1952 1.8983 2.6014 3.3044 4.0075 4.7106 5.4136 6.1167 6.8198 7.5228
0.5625 1.2655 1.9686 2.6717 3.3747 4.0778 4.7809 5.4839 6.1870 6.8901 7.5932
0.6328 1.3358 2.0389 2.7420 3.4450 4.1481 4.8512 5.5543 6.2573 6.9604 7.6635
––– 10 20 30 40 50 60 70 80 90 100
KILOGRAMS PER SQUARE CENTI CENTIM M ETERS ETERS TO POUNDS POUN DS PER SQUARE SQU ARE INCHES kg/cm 2 ––– ––– 10 20 30 40 50 60 70 80 90 100
kg /cm 2
0
1
2
3
4
5
6
7
8
9
2
lb/in (psi (psi))
2
lb/in lb/in (psi (psi))
2
lb/in lb/in (psi) psi)
2
lb/in lb/in (psi) psi)
2
lb/in lb/in (psi (psi))
2
lb/in lb/in (psi (psi))
2
lb/in lb/in (psi) psi)
2
lb/in lb/in (psi (psi))
2
lb/in lb/in (psi (psi))
2
lb/in lb/in (psi)
––– ––– 00 00 142.23 284.46 426.69 568.92 711.15 853.38 995.61 1137.84 1280.07 1422.30
14.22 156.45 298.68 440.91 583.14 725.37 867.60 1009.83 1152.06 1294.29 1436.52
28.45 170.68 312.91 455.14 597.37 739.60 881.83 1024.06 1166.29 1308.52 1450.75
42.67 184.90 327.13 469.36 611.59 753.82 896.05 1038.28 1180.51 1322.74 1464.97
56.89 199.12 341.35 483.58 625.81 768.04 910.27 1052.50 1194.73 1336.96 1479.19
71.12 213.35 355.58 497.81 640.04 782.27 924.50 1066.73 1208.96 1351.19 1493.42
85.34 227.57 369.80 512.03 654.26 796.49 938.72 1080.95 1223.18 1365.41 1507.64
99.56 241.79 384.02 526.25 668.48 810.71 952.94 1095.17 1237.40 1379.63 1521.86
113.78 256.01 398.24 540.47 682.70 824.93 967.16 1109.39 1251.62 1393.85 1536.08
128.01 270.24 412.47 554.70 696.93 839.16 981.39 1123.62 1265.85 1408.08 1550.31
––– 10 20 30 40 50 60 70 80 90 100
KILOGRAMS PER PER SQUARE SQUA RE CENTIM CENTIM ETERS ETERS TO KILO PASCAL kg/cm 2 ––– ––– 10 20 30 40 50 60 70 80 90 100
kg /cm 2
0
1
2
3
4
5
6
7
8
9
KPa
KPa
KPa
KPa
KPa
KPa
KPa
KPa
KPa
KPa
196.1 1176.8 2157.5 3138.1 4118.8 5099.5 6080.2 7060.8 8041.5 9022.2 10002.8
294.2 1274.9 2255.5 3236.2 4216.9 5197.6 6178.2 7158.9 8139.6 9120.2 10100.9
392.3 1372.9 2353.6 3334.3 4314.9 5295.6 6276.3 7257.0 8237.6 9218.3 10199.0
490.3 1471.0 2451.7 3432.3 4413.0 5393.7 6374.4 7355.0 8335.7 9316.4 10297.0
588.4 1569.1 2549.7 3530.4 4511.1 5491.8 6472.4 7453.1 8433.8 9414.4 10395.1
686.5 1667.1 2647.8 3628.5 4609.1 5589.8 6570.5 7551.2 8531.8 9512.5 10493.2
784.5 1765.2 2745.9 3726.5 4707.2 5687.9 6668.6 7649.2 8629.9 9610.6 10591.2
882.6 1863.3 2843.9 3824.6 4805.3 5786.0 6766.6 7747.3 8728.0 9708.6 10689.3
800
900
––– ––– 00 00 980.7 1961.3 2942.0 3922.7 4903.4 5884.0 6864.7 7845.4 8826.0 9806.7
98.1 1078.7 2059.4 3040.1 4020.7 5001.4 5982.1 6962.8 7943.4 8924.1 9904.8
––– 10 20 30 40 50 60 70 80 90 100
KILO PASCAL TO KILOGRAM KILOGRAM S PER SQUARE CENTI CENTIM M ETERS ETERS KPa
0 kg/cm
––– ––– 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
100 2
––– ––– 00 00 10.197 20.394 30.592 40.789 50.986 61.183 71.380 81.578 91.775 101.972
kg/cm
200 2
1.020 11.217 21.414 31.611 41.809 52.006 62.203 72.400 82.597 92.795 102.992
kg/cm
300 2
2.039 12.237 22.434 32.631 42.828 53.025 63.223 73.420 83.617 93.814 104.011
kg/cm
400 2
3.059 13.256 23.454 33.651 43.848 54.045 64.242 74.440 84.637 94.834 105.031
kg/cm
500 2
4.079 14.276 24.473 34.670 44.868 55.065 65.262 75.459 85.656 95.854 106.051
kg/cm
600 2
5.099 15.296 25.493 35.690 45.887 56.085 66.282 76.479 86.676 96.873 107.071
kg/cm
700 2
6.118 16.316 26.513 36.710 46.907 57.104 67.302 77.499 87.696 97.893 108.090
kg/cm
2
7.138 17.335 27.532 37.730 47.927 58.124 68.321 78.518 88.716 98.913 109.110
kg/cm
2
8.158 18.355 28.552 38.749 48.947 59.144 69.341 79.538 89.735 99.933 110.130
kg/cm
KPa 2
9.177 19.375 29.572 39.769 49.966 60.163 70.361 80.558 90.755 100.952 111.149
–––0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
CONVERSION TABLE 115 TORQUE FOOT POUNDS TO KILOGRAM KILOGRAM M ETERS ETERS f t . l b s. ––– ––– 10 20 30 40 50 60 70 80 90 100
0
1
2
3
4
5
6
7
8
9
kg -m
kg -m
kg -m
kg -m
kg -m
kg -m
kg -m
kg -m
kg -m
kg -m
––– ––– 0 1.383 2.765 4.148 5.530 6.913 8.296 9.678 11.061 12.443 13.826
0.138 1.521 2.903 4.286 5.669 7.051 8.434 9.816 11.199 12.582 13.964
0.277 1.659 3.042 4.424 5.807 7.190 8.572 9.955 11.337 12.720 14.103
0.415 1.797 3.180 4.563 5.945 7.328 8.710 10.093 11.476 12.858 14.241
0.553 1.936 3.318 4.701 6.083 7.466 8.849 10.231 11.614 12.996 14.379
0.691 2.074 3.457 4.839 6.222 7.604 8.987 10.370 11.752 13.135 14.517
0.830 2.212 3.595 4.977 6.360 7.743 9.125 10.508 11.890 13.273 14.656
0.968 2.350 3.733 5.116 6.498 7.881 9.263 10.646 12.029 13.411 14.794
1.106 2.489 3.871 5.254 6.636 8.019 9.402 10.784 12.167 13.549 14.932
1.244 2.627 4.010 5.392 6.775 8.157 9.540 10.923 12.305 13.688 15.070
f t l b s. ––– 10 20 30 40 50 60 70 80 90 100
KILOGRAMM KILOGRAMM ETERS ETERS TO FOOT POUN DS kg -m ––– ––– 10 20 30 40 50 60 70 80 90 100
0
1
2
3
4
5
6
7
8
9
f t . l b s.
f t . l b s.
f t . l b s.
f t . l b s.
f t . l b s.
f t . l b s.
f t . l b s.
f t . l b s.
f t . l b s.
f t . l b s.
––– ––– 0 72.33 144.66 216.99 289.32 361.65 433.98 506.31 578.64 650.97 723.30
7.23 79.56 151.89 224.22 296.55 368.88 441.21 513.54 585.87 658.20 730.53
14.47 86.80 159.13 231.46 303.79 376.12 448.45 520.78 593.11 665.44 737.77
21.70 94.03 166.36 238.69 311.02 383.35 455.68 528.01 600.34 672.67 745.00
28.93 101.26 173.59 245.92 318.25 390.58 462.91 535.24 607.57 679.90 752.23
36.17 108.50 180.83 253.16 325.49 397.82 470.15 542.48 614.81 687.14 759.47
43.40 115.73 188.06 260.39 332.72 405.05 477.38 549.71 622.04 694.37 766.70
50.63 122.96 195.29 267.62 339.95 412.28 484.61 556.94 629.27 701.60 773.93
57.86 130.19 202.52 274.85 347.18 419.51 491.84 564.17 636.50 708.83 781.16
65.10 137.43 209.76 282.09 354.42 426.75 499.08 571.41 643.74 716.07 788.40
kg kg -m ––– 10 20 30 40 50 60 70 80 90 100
KILOGRAMM KILOGRAMM ETERS ETERS TO N EWTONM ETERS ETERS kg -m ––– ––– 10 20 30 40 50 60 70 80 90 100
0
1
2
3
4
5
6
7
8
9
N -m
N -m
N -m
N -m
N -m
N -m
N -m
N -m
N -m
N -m
––– ––– 00 00 98.07 196.13 294.20 392.27 490.34 588.40 686.47 784.54 882.60 980.67
9.81 107.87 205.94 304.01 402.07 500.14 598.21 696.28 794.34 892.41 990.48
19.61 117.68 215.75 313.81 411.88 509.95 608.02 706.08 804.15 902.22 1000.28
29.42 127.49 225.55 323.62 421.69 519.76 617.82 715.89 813.96 912.02 1010.09
39.23 137.29 235.36 333.43 431.49 529.56 627.63 725.70 823.76 921.83 1019.90
49.03 147.10 245.17 343.23 441.30 539.37 637.44 735.50 833.57 931.64 1029.70
58.84 156.91 254.97 353.04 451.11 549.18 647.24 745.31 843.38 941.44 1039.51
68.65 166.71 264.78 362.85 460.91 558.98 657.05 755.12 853.18 951.25 1049.32
78.45 176.52 274.59 372.65 470.72 568.79 666.86 764.92 862.99 961.06 1059.12
88.26 186.33 284.39 382.46 480.53 578.60 676.66 774.73 872.80 970.86 1068.93
kg kg -m ––– 10 20 30 40 50 60 70 80 90 100
NEWTON M ETERS ETERS TO KILOGRAM KILOGRAM M ETERS ETERS N -m ––– ––– 100 200 300 400 500 600 700 800 900 1000
0
10
20
30
40
50
60
70
80
90
kg -m
kg -m
kg -m
kg -m
kg -m
kg -m
kg -m
kg -m
kg -m
kg -m
––– ––– 00 00 10.197 20.394 30.591 40.788 50.985 61.182 71.379 81.576 91.773 101.970
1.020 11.217 21.414 31.611 41.808 52.005 62.202 72.399 82.596 92.793 102.990
2.039 12.236 22.433 32.630 42.827 53.024 63.221 73.418 83.615 93.812 104.009
3.059 13.256 23.453 33.650 43.847 54.044 64.241 74.438 84.635 94.832 105.029
4.079 14.276 24.473 34.670 44.867 55.064 65.261 75.458 85.655 95.852 106.049
5.099 15.296 25.493 35.690 45.887 56.084 66.281 76.478 86.675 96.872 107.069
6.118 16.315 26.512 36.709 46.906 57.103 67.300 77.497 87.694 97.891 108.088
7.138 17.335 27.532 37.729 47.926 58.123 68.320 78.517 88.714 98.911 109.108
8.158 18.355 28.552 38.749 48.946 59.143 69.340 79.537 89.734 99.931 110.128
9.177 19.374 29.571 39.768 49.965 60.162 70.359 80.556 90.753 100.950 111.147
N -m ––– 100 200 300 400 500 600 700 800 900 1000
116 CONVERSION TABLE TEMPERATURE FAHRENHEIT TO CENTIGRADE °F
°C
°F
°C
°F
°C
°F
°C
°F
°C
°F
°C
°F
°C
°F
°C
-60 -58 -56 -54 -52 -50 -48 -46 -44 -42 -40 -38 -36 -34 -32 -30 -28 -26 -24 -22 -20 -18 -16 -14 -12 -10 -8 -6 -4
-51.1 -50.0 -48.9 -47.8 -46.7 -45.6 -44.4 -43.3 -42.2 -41.1 -40.0 -38.9 -37.8 -36.7 -35.6 -34.4 -33.3 -32.2 -31.1 -30.0 -28.9 -27.8 -26.7 -25.6 -24.4 -23.3 -22.2 -21.1 -20.0
-2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54
-18.9 -17.8 -16.7 -15.6 -14.4 -13.3 -12.2 -11.1 -10.0 -8.9 -7.8 -6.7 -5.6 -4.4 -3.3 -2.2 -1.1 0.0 1.1 2.2 3.3 4.4 5.6 6.7 7.8 8.9 10.0 11.1 12.2
56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112
13.3 14.4 15.6 16.7 17.8 18.9 20.0 21.1 22.2 23.3 24.4 25.6 26.7 27.8 28.9 30.0 31.1 32.2 33.3 34.4 35.6 36.7 37.8 38.9 40.0 41.1 42.2 43.3 44.4
114 116 118 120 122 124 126 128 130 132 134 136 138 140 142 144 146 148 150 152 154 156 158 160 162 164 166 168 170
45.6 46.7 47.8 48.9 50.0 51.1 52.2 53.3 54.4 55.6 56.7 57.8 58.9 60.0 61.1 62.2 63.3 64.4 65.6 66.7 67.8 68.9 70.0 71.1 72.2 73.3 74.4 75.6 76.7
172 174 176 178 180 182 184 186 188 190 192 194 196 198 200 202 204 206 208 210 212 214 216 218 220 222 224 226 228
77.8 78.9 80.0 81.1 82.2 83.3 84.4 85.6 86.7 87.8 88.9 90.0 91.1 92.2 93.3 94.4 95.6 96.7 97.8 98.9 100.0 101.1 102.2 103.3 104.4 105.6 106.7 107.8 108.9
230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286
110.0 111.1 112.2 113.3 114.4 115.6 116.7 117.8 118.9 120.0 121.1 122.2 123.3 124.4 125.6 126.7 127.8 128.9 130.0 131.1 132.2 133.3 134.4 135.6 136.7 137.8 138.9 140.0 141.1
288 290 292 294 296 298 300 302 304 306 308 310 312 314 316 318 320 322 324 326 328 330 332 334 336 338 340 342 344
142.2 143.3 144.4 145.6 146.7 147.8 148.9 150.0 151.1 152.2 153.3 154.4 155.6 156.7 157.8 158.9 160.0 161.1 162.2 163.3 164.4 165.6 166.7 167.8 168.9 170.0 171.1 172.2 173.3
346 348 350 352 354 356 358 360 362 364 366 368 370 372 374 376 378 380 382 384 386 388 390 392 400 410 420 430 440
174.4 175.6 176.7 177.8 178.9 180.0 181.1 182.2 183.3 184.4 185.6 186.7 187.8 188.9 190.0 191.1 192.2 193.3 194.4 195.6 196.7 197.8 198.9 200.0 204.4 210.0 215.6 221.1 226.7
CENTIGRADE TO FAHRENHEIT °C
°F
°C
°F
°C
°F
°C
°F
°C
°F
°C
°F
°C
°F
°C
°F
-50 -49 -48 -47 -46 -45 -44 -43 -42 -41 -40 -39 -38 -37 -36 -35 -34 -33 -32 -31 -30 -29 -28 -27 -26 -25 -24 -23 -22 -21 -20 -19
-58.0 -56.2 -54.4 -52.6 -50.8 -49.0 -47.2 -45.4 -43.6 -41.8 -40.0 -38.2 -36.4 -34.6 -32.8 -31.0 -29.2 -27.4 -25.6 -23.8 -22.0 -20.2 -18.4 -16.6 -14.8 -13.0 -11.2 -9.4 -7.6 -5.8 -4.0 -2.2
-18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13
-0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 51.8 53.6 55.4
14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77
114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6
78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109
172.4 174.2 176.0 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 213.8 215.6 217.4 219.2 221.0 222.8 224.6 226.4 228.2
110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141
230.0 231.8 233.6 235.4 237.2 239.0 240.8 242.6 244.4 246.2 248.0 249.8 251.6 253.4 255.2 257.0 258.8 260.6 262.4 264.2 266.0 267.8 269.6 271.4 273.2 275.0 276.8 278.6 280.4 282.2 284.0 285.8
142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173
287.6 289.4 291.2 293.0 294.8 296.6 298.4 300.2 302.0 303.8 305.6 307.4 309.2 311.0 312.8 314.6 316.4 318.2 320.0 321.8 323.6 325.4 327.2 329.0 330.8 332.6 334.4 336.2 338.0 339.8 341.6 343.4
174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 210 220 230 240 250
345.2 347.0 348.8 350.6 352.4 354.2 356.0 357.8 359.6 361.4 363.2 365.0 366.8 368.6 370.4 372.2 374.0 375.8 377.6 379.4 381.2 383.0 384.8 386.6 388.4 390.2 392.0 410.0 428.0 446.0 464.0 482.0
Copyright reserved for this manual may not be reproduced or copied, in whole or in part, without the written consent of ISUZU MOTORS LIMITED.
WORKSHOP WORKSHOP MAN UAL (INDU STRIAL) STRIAL) 4LE2 (IDE-2330) Issued by
ISUZU M OTORS OTORS LIMITED Pow ertrain Service & Parts Pow ertrain Operations 6-26-1, Minami-oi, Shinagawa-ku,Tokyo, 140-8722, Japan TEL 03-5471-1111 Fi r st ed i t i o n Sep ., 1999
107-02K
IDE-2330
PRINTED IN JAPAN
