4BD1 Workshop Manual 1

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DIESEL -ENGIN;E

4801, 4BD1- ~T MODELS . ,•.

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(FOR AUTON,IOT,IVE.USE)

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SECTION INDEX 'SECTION

NAME

ISUZU

1

GENERAl INFORMATION

WORKSHOP MANUAL

2

ENGINE ASSEMBlY

J!,

~

DIESEL ENGINE

4801 4801-T

FOREWORD lhis manual includes special notes, important points, service data, precautions.. etc. that are needed for the maintenance, ·adjustments. service, removal and i nstallation of components of the m odels titled.

-~

3

LUBRICATING SYSTEM I

4

COOliNG SYSTEM

5

FUEl SYSTEM

..

6

TURBOCHARGER

7

ELECTRICAL SYSTEM

~.

All information. illustrations and specifications contained in this m anual are based on the latest product information available at

the time of publication. The right is reserved to make changes at any time without notice. Arrange.ment of t he m aterial is shown by the tabl e of contents on the right·hand side of this page. Black spot on the first page of each section can be seen on the edge of the book below sec· tion title. Amore detailed table of contents precedes each sec-

'

8

AUXIliARIES (POWER STEERING OIL PUMP)

9

SPECIAL TOOL LIST

tion.

I

This manual applies to the 1986 year and later models.

I

.

10

TROUBLESHOOTING

11

CONVERSION TABLE

•··


.GJ;NERAL"INFORMATION 1- 1

SECTION 1

GENERAL INFORMATION PAGE

CONTENTS

General repair instructions. . ......... .. ..•...... •• . .. . . .... .....................•..•.. 1- 2 How. to use this manual .. . .·.... . ...........•............................. .. ... .. .... 1- 2 Main data and specifications . .. ........... .. .... .• .... .. ... . ..... .. ... .. ..... .. ... .. . 1- 5 Torque sp·e cifications .. .. ..... . ..... . ..... . ..... ...... .. .... ... . " · .... .. . · .......... 1- 7 How t"o tighten by angular tightening method .... . .... ... .. .. ..... . .... . ... .. . . ... .. . . .. 1- 8 Engine repair kit ..........•....•..............•.•............................ •. .• . . .•. 1-1? Servicing .. ..•.. • .. ..... . ..... . .... ... ..... . •.. ..•. .... . .. . ... .•.. ... .........• .. .. 1- 18 Recommended lubricants .. .. ....... ..... .. ... .... .. ... .. .... . ......... ... ..... . •... . 1-26 Engine oil viscosity chart .... .. ... ... .... .. .... .. ... .... .. . ......... ... ... . ..... .. .... 1-26 Adhesive for repairs ...•. ... . ..... ... ... . .... .. .. .•. .... .. ... •.... . . ... •.. ..... . .... 1-26

/


1-2 GENERAL IN FORMATION

GENERAL REPAIR INSTRUCTIONS 1. Before performing service operations, disconnect ground cable from the battery to reduce the chance of cable damage and burning due to short-circuiting. 2. The use of proper tools and special tools where specified, is Important for efficient and reliable service -operations. 3. Use genuine lsuzu pans. 4. Used cotter pins, gaskets. 0-rings, oil seals, lock washers and self Jock nuts should be discarded and new ones used as normal function of the parts can not be maintained if these pans are reused. 5.

To facilitate proper and smooth reassembly, keep disassembled parts neatly in groups. Keeping bolts and nuts separate is very important as they vary in hardness and design depending on posit ion of installation.

6. Clean the parts before inspection or reassembly. Also clean oil pons. etc. using compressed air to make cenain they are free from restrictions. 7. Lubricate rotating and sliding faces of the parts with oil or grease before installation. 8. When necessary, use a sealer on gaskets to prevent leakage. 9. Carefully observe all specifications for bolt and nut torques.

10. When service operation is completed, make a final check to be sure service has been done properly. 11. For assurance of saf ety, always release air pressure solely from the air tanks before disconnecting pipes, hoses or other parts from any unit under air pressure.

HOW TO USE THIS MANUAL 1. Find the applicable section by referring to the index. 2. This manual includes a "General information• section in which service data. maintenance items and specific· ations with torques are included. 3. Each section includes, disassembly, inspection and repair and reassembly. When the same service operation applies to more than one unit or equipment notice is inserted stating, "Refer to manual for other units or equip·

ment". 4.

In the removal and installation section. description of self-explanatory items such as removal of individual parts from the unit to be removed, is omitted and imponant operation such as adjustments. torque specifications. etc. are dealt with mainly.


GENERAL INFORMATION 1- 3 5.

Each service operation section begins with disassembled view of unit or equipment which is useful to find components, service procedure, availability and content of repair kits, etc.

* parts conta ined in repair kit MAJOR COMPONENT

Parts to be removed or installed as a unit

All units or parts within frame are to be considered as a "major component". Each unit or part within frame is to be considered as a "minor component!'.

,,

The number represents sequence of service operation.

,_.___,_~

Removal of the parts without number (excluding bolts. nuts. washers. gaskets. cotter pins. etc.) is unnecessary unless replacement is needed. Where parts replacement requires a specific note, instructions are given in "Inspection and repair".

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indicates repair kit availability.

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Name of parts listed in sequence of service operation.

• indicates important operation. Details of service operation are described in the paragra ph " Important operations".


1-4 GENERAL INFORMATION 6. The section following illustration(s) deals with important service.steps marked with • .a.". This section also includes "notes", "use of special tools", •service data", etc.

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Item shown in the illustration and marked with " .A ".

Clfi~IIN4fU-tll\'

Apply t '"'" CO
ll'-$ ¢yl01...... IW.:IQ o4rll

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Special tools are Identified with tool name and/or part number. The drawing illustrates how the tool is used.

Important note.

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The symbol indicates the step of service to be followed. Refer to the following paragraph for meaning of each symbol.

Service data and specifications are listed in table.

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7.

In this manual, the following symbols are used to indicate the type of service operations to be performed.

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Remove Install Disassemble Reassemble Align the marks Correct direction

[1!1

Inspect

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Take measurement

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Adjustment Clean Pay close attention -

important

Tighten to specified torque Use essential tool (s) Use available tool(s) Lubricate with oil Lubricate with grease

8. The service stand ard is indicated in term:s of "Standard" and "Limit". The "standard" means the assembly standard and standard range within which the parts are considered serviceable. "Limit" indicates the limit value (Correction or replacement is necessary when measurement is beyond this limit.) 9. In this manual, the components and parts are printed in singular form .


GENERALINFORMATION 1-5

MAIN DATA AND SPECIFICATIONS Items

I

Engine type

4801

4801 -T

Water-cooled, 4-cycle in line overhead valve Direct injection type

Combustion chamber type Cylinder liner type

Dry t'(pe (chomard liner)

Timing gear system

Gear drive

No. of piston rings

Compression ring 2, Oil ring 1

No. of cylinders - Bore x Stroke Total piston displacement Compression ratio

mm(in.)

4- 102 X 118

cc(cu.in.)

3856 (235.2)

(to 1J

17

Engine dimensions {length x width x height)

mm(in.)

795 X 701 X 720 (31 .3 X 27.6 X 28.3)

806 X 672 X 785 (31.7 X 26.5 X 30.9)

Engine weight : dry

kg(lbs.)

322.5 (711)

(Degree)

13"

327 (721) 10.

Fuel injection timing B.T.D.C.

1-3-4-2

Fuel injection order Type of fuel used

High-speed diesel fuel (SAE No. 2) (rpm)

Idle speed Compression pressure

kg/cm 2(psi)

Intake and exhaust valve clearance (at cold) mm(in.) Intake valve

Exhaust valve

555-605

31 (441) at 200 rpm

0.4 (0.016)

open at B.T.D.C. degree

28

close at A.B.D.C. degree

62

open at B.B.D.C. degree

70

close at A.T.D.C. degree

28

Injection pump type

575-625

1

BOSH in-line A type, with automatic timer

Governor type

RLD-K Mechanical type

Fuel feed pump type

KE Mechanical type

Injection nozzle type

Hole type (with 4 orifices)

Injection starting

pressure[qmkg/cm 2(psi)

Lubrication method

185 (2631) Pressurized circulation

Oil pump type

Trochoid

Oil filter type

Cartridge-paper element

Lubricating oil capacity

liters(imp.gal)

8.0 (1.8)

Oil cooler type

Pressuri.zed circulation

Cooling method

Water cooled

Cooling water capacity

liters (imp.gal)

14 (3.1)

Water pump type

Impeller type

Thermostat type

Waxpellet type (with jiggle valve)

Turbocharger type

RH·B6A

Compression type

Radial outward-flow


1- 6 GENERAL INFORMATION

4801

Maximum permissible speed (continuous)

(rpm)

130,000

Pressure ratio (Maximum)

2.8

* Exhaust gas temperature

750

Weight

kg(lbs.)

Manufacturer's name

*

4801-T

4.5 (9.9) lshikawajima-Harima Heavy lndistries Co., Ltd.

The exhaust gas temperatue meas maximum allowable temperature measured at turbocharger intake. ·

Note: The turbocharger uses bolts and nuts based on conventional inch system.


GENERAL INFORMATION 1-7

TORQUE SPECIFICATION STANDARD BOLTS The torque values given in the following table should be applied where a particular torque is not specified.

kg·m(ft.lbs.) Bolt Identification

Bolt diameter x pitch (mm)

6

X 1.0

8

X

1.25

G)

@

®

4T

7T

9T

(low carbon steel)

(High carbon steel)

(Alloy steel)

5.8)

0.5- 1.0 ( 3.6- 7.2)

-

5.8- 13.0)

1.2- 2.3! 8.7- 16.6)

1.7- 3.1 ( 12.3- 22.4)

0.4- 0.8 ( 2.90.8- 1.8 (

3.5 ( 15.2- 25.3)

2.8- 4.7 ( 20.3- 34.0)

3.8- 6.4 ( 27.5- 46.3)

2.0- 3.4 ( 14.5- 24.6)

2.8- 4.6 ( 20.3- 33.3)

3.7- 6.1 ( 26.8- 44.1)

12 X 1.25

5.o- 7.5 1 36.2- 54.21

6.2- 9.3 ( 44.8- 67.3)

7.7-11.6 ( 55.7- 83.9)

• 12 X 1.75

4.6- 7.0 ( 33.3- 50.6)

5.8- 8.6 ( 42.0- 62.2)

7.3- 10.9 ( 52.8- 78.8)

10 X 1.25 *10 X 1.5

2.1 -

1.5

7.8-11 .7 ( 54.6- 84.6)

9.5- 14.2 ( 68.7-102.7)

11.6- 17.4 ( 83.9-125.9)

*14 X 2.0

7.3-10.9 ( 52.8- 78.8)

9.o-13.4

1 65.1- 96.9)

10.9-16.3 ( 78.8-117.9)

14

X

10.6- 16.0 ( 76.7-115.7)

13.8-20.8 ( 99.8- 150.4)

16.3-24.5 (117.9- 177.2)

•16

16 X 1.5 X

2.0

10.2- 15.2 ( 73.8- 109.9)

13.2-19.8 ( 95.5-143.2)

15.6-23.4 (112 .8-169.3)

18

X

1.5

15.4- 23.0 (11 1.4-166.4)

19.9-29.9 (143.9- 216.3)

23.4-:35.2 (169.3-254.6)

20 X 1.5

21 .0- 31.6 (151 .9-228.6)

27.5-41 .3 (1 98.9-298.7)

32.3-48.5 (233.6-350.8)

22 X 1.5

25.6-42.2 (1 85.2- 305.2)

37.0-55.5 (267.6-401 .4)

43.3~.9

36.6-55.0 (264.7- 397.8)

43.9-72.5 (31 7.5-524.4)

56.5-84.7 (408.7-6 12.6)

24

X

2.0

(313.2-469.4)

The asteri~k *indicates that the bolts are used for female-threaded parts that are made of soft materials such as cast· ing, etc.


'·

1-8 GENERAL INFORMATION

HOW TO TIGHTEN BY ANGULAR TIGHTENING METHOD 1. Wash bolts and/or nuts clean to remove .oil, grease, etc. completely. 2. Apply a coat of molybdenum disulfide grease to threads

and setting face of bolts and/or nuts.

3. With a torque wrench tighten bolts and/or nuts to the specified torque (snug torque).

Center line-

Another line·

4. Draw a line (A-B) across the center of· each bolts.

5. On the face of parts to be clamped draw an another line (C-D) exteni;ling from the line (A-8).

->~ 6. On thefaceofthe parts to be clamped, draw a line (F-G) in direction at the specified angle (Q) to the line (A-B) across the center (E).


7. With

GENERAL IN FORMATION 1 9

a torn

partsc~m~ides

li~~ (~~~~l drawn the line (A·Bl on the

.,ue wren h · on the bolt head . c , tighten the b face of the with the o e clamped.

. . of t.19htemng . Example·· T urn of bolt (or nut) is direction

30°

1/12 of turn 1/6 of a turn 1/ 4 of a turn 1/2 of a turn

360°

One full turn


.


FIXING TORQUE CYLINDER HEAD AND COVER

kg·m(ft.lbs.)

2.0-3.0(14.5-21.7)

12.3-2.7(16.6-19.5) 1

Lubricate with engine oil 4B01

New

9.5-10.5 (68.7-76.0)

Reusoel 11.0-12.0 (79.5-86.8)

Lubricate with MOS2 grease 4BD1·T 1----- - - -- - --; 7 (50.6)- 9 (65.1) -90°-120°

...........

Rear

4.3-6.3(11.6-18.8)

MOS2 grease : Molybdenum disulfide grease


GENERAL INFORMATION 1- 11

INTAKE AND EXHAUST MANIFOLD kg-m(ft.lbs.)

2.1-3.1(1~.2-22.4)

4801- T ONLY 1

4801·TONLY

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4.3-6.3 (31.1-45.4) 1.9-2.3(13.7-16.6)



CYLINDER BODY AND OTHERS

kg-m(ft.lbs.)

12.5-15.5 (90.4-112.1)

/

/

/

1.1-2.1 (8.0-15.2) Lubricate with engine oil

123-25 (166.3-180.8) 1 Lubricate with engine oil

' 7-9 (51-65) '


GENERALINFORMATION 1- 13

CYLINDER BODY AND OTHERS kg·m(ft.lbs.)

2.1-3. 1 (15.2- 22.4 )

4.3-6.3 (31.1-45.5)

2.1-3.1 (15.2 - 22.4 )

~

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~-.__..,_

______,

1 1.6-2.6 (11.6-18.8) 1 4BD1 ·TONLY

1.6-2.6 (11.6-18.8)



CRANKSHAFT AND CAMSHAFT kg·m(ft.lbs.)

39-49 (282-354)

(Lubricate with engine oil)

114.5-17.5 (105-125) 1 (Lubricate with engine oil)

2.1 - 3.1 (15.2- 22.4)

12.5-15.5 (90-112)

1.

-

-

--

-

----


GENERALINFORMATION 1-15

- - -- - --

---F ,UEL SYSTEM


kg·m(ft.lbs.)

TURBOCHARGER



ENGINE REPAIR KIT

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Gasket ; cylinder head Gasket ; head cover bolt Gasket ; head cover Gasket ; drain cock Gasket ; relief valve Gasket ; tappet chamber cover Gasket ; tappet chamber bolt Gasket ; oa cooler Gasket ; oil pump cover Oil seal ; crankshaft rear Gasket ; retainer Gasket ; case to cylinder block Gasket ; gear case cover Gasket ; oil pan drain plug Gasket ; oil pan

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

Gasket ; oil filter Gasket ; oil pump pipe Gasket ; oil filter pipe Gasket ; injection oil pipe Gasket ; water pump Gasket ; outlet pipe Gasket ; thermostat housing Gasket ; intake manifold Gasket ; inlet pipe Gasket ; exhaust manifold Gasket ; leak off pipe Gasket ; fuel filter Oil seal ; crankshaft front Gasket ; injection pump bracket Gasket ; nozzle holder


1- 18 GENERAL INFORMATION

SERV ICING ENGINE OIL Draining

Drain from the engine crankcase completely by removing the drain plug on the lower part of the oil pan, main oil fil· ter and partiol flow oil filter w hilt: the engine is hot.

Refilling

Then fill into the engine crankcase from the filler pqrtwith new engine oil of the specified grade. When the engine crankcase is filled to the high level mark on the oil dipstick, start and let the engine idle for a few minutes. Stop the engine and recheck the oil level and replenish, if necessary. Engine oil capacity liter (Imp gallon)

8.0 (1.8)

Engine oil level and contamination

Pull out the oil level gauge rod (oil dipstick), wipe clean and reinsert it. Again pull it out and check that oil level is within high and low level marks. Also check oil on the gauge rod for contamination. If the engine has been operated, allow 5 minutes for oil to settle down before checking the oil level.

OIL FILTER 1. Loosen the oil filter by turning it counter-clockwise with a filter wrench. 2. With a rag wipe clean the fitting face of the oil cooler. so that new oil filter ca n be seated properly. • • 3. Lightly oil the 0-ring and turn in oil fiiter until sealing face is frtted against th e 0 -ring . Turn 1·1/4 turns further with the filter wrench.

FUEL FILTER Replacement

1. Loosen the fuel filter turning it counter-clockwise with a filter w rench . 2. With a rag w ipe clean the fitting face on the upper cover, so that new fuel filter can be seated properly.


3. Lightly oil the 0-ring. lnstall ·and turn in filter assembly clockwise carefully. to prevent ,fuel spillage until o~ring is fitted against sealing face of the f.ilter cover. Further turn filter assembly 1/3 to 2/3 of a turn with the filter wr.ench.

4. Loosen tbe loci< nut and the bleeder screw on the injection. pump. Operate the priming pump until the air bubles become invisible in the fuel flown out. Then tighten the bleeder screw and the lock nut.

VALVE CLEARANCE Inspection Check the rocker arm bracket bolts for looseness and retighten as necessary before adj'usting tlie valve clearances.

Torque

AdjustmentAdjust the valve clearances iri the fgllowing manner using a feeler gauge.

Standard clearance cold Intake and exhaust

m~T~(in.)

~'

.

'Turn the crankshaft in a clockwise direction to ·bring the piston in either No. 1 or No. 4 cylinder into To'p Dead Center (TDC) on compression stroke by aligning TDC line on the crankshaft pulley with the pointer. Hand-feel looseness of intake and exhaust valve push rods on the No. 1 cylinder.. When both pu_sh rods have a play, it indicates that the piston in No. 1 cylinder is at TDC on compression stroke. When the push tods have not play and,those ones on the No.4 have a play, it indicates that the piston in No. 4cylin· der is ·at TDC on compressio'n stroke.


1-20 GENERAL INFORMATION The same result can oe obtained by aligning the TDC line on the flywheel with the pointer on the flywheel housing.

...

Front

Adjust the valve clearances marked with arrow in the drawing. Rocker arm screw lock nut torque kg·m(ft.Jbs.)

... Front

2.3-2.7 (16.6-19,5)

After adjusting the valve clearances shown in the above drawing, turn the crankshaft one full turn in the clockwise direction and align the TDC line with the pointer, then adiustthe remaining valve :Jearances·shown in this drawing.

FEED PUMP STRAINER 1. Remove the joint bolt at the intake side of the feed pump. 2. Screw out the strainer counter-clockwise and clean it.

3. Install and tighten the strainer and the joint bolt. 4. Then operate the priming pt~mp on the injection pump to bleed the fuel system.


G!f)IERALINFORM~TION 1-21

INJECTION PRESSURE AND SPRAYING CONDITION . Preparation 1. 2. 3. 4.

Remove 4 injection pipes. Disconnect the leak off pipe. Remove 4 injection nozzles. Set each injection nozzle to the injection no7..zle tester.

Note:

*

On removal, mark. cylinder No. on the injection nozzles not to interchange. • Discard 0 -ring.and use new one.

Inspection Correct

Incorrect'

I ncorreet

-Ahk Restrictions

ttt orifices

Check the spray condition and injection pressure using a nozzle tester. Injection starting pressure:

kg/cm 2(psi)

185 (2630)

Dripping

Adjustment Adjust the injection starting pressure in the manner described below. · 1. Remove the cap nut. 2. Turn the adj usting screw to attain the correct injection starting pressure. 3. Tighten the cap nut to specified tor.que. Torque

kg·m(ft.lbs.)

6-8 (43-58)

Installation 1. lnstall4 injection nozzles to its home position, and tightenthe fixing to the specifi.e d torque. 2. Connect the leak off pipe. 3. Install 4 injection pipes and tighten to the specified torque. kg·m(ft.lbs.) Torque Nozzle fixing nut

2.1- 3.1 (1_5 .2-22.4)

Injection pipe •

2.9-3.2 (21.0- 23.1)



INJECTION TIMING Inspection

1. Check that notched line on the pump housing is in align· ment with that ofthe timer bracket. Also check the fixing nuts for looseness and ret'ghten if necessary.

2. Disconnect the injection nozzle pipe on No. 1 cylinder.

t--"0'"'

B

3. Remove the delivery valve holder, delivery valve spring, delivery valve seat and delivery valve in the order mentioned.

B

4. Install and tighten the delivery valve holder and seat to

© -seat

~-Spring

~

Oeriyery valve

~

specified torque. Torque

kg·m(ft.lbs.)

4-4.5 (29-33)

5. Rotate the crankshaft w ith crankshaft turning wrench and stop when fuel starts to move at the top end of the deliv· ery valve holder.


GENERAL INFORMATION 1-23 6. Then eheck if notched. line on the crankshaft pulley aligned with specified mark. (degrees)

4801 4801-T Use of mirror is required to see timing marl
7. When injection timing is correct, re-install the delivery valve, spri ng and injection nozzle pipe. Delivery valve holder Torque

kg·m(ft.lbs.)

If injection timing is not c.orrect, follow· the nextprocedures without re-installation. ·

Injection timing adjustment procedure 1. :Adjust fuel injection timing by aligning notched line'on the or on the pulley With the specified mark (1o• or 13•) exactly. Use of mirror is requiretl to see timing marks from below.

2. Remove fuel pipe connecting fuel feed pump with fuel filter to get access. loosen the 4 nuts fixing injection pump housing. Then re-install fuel pipe connecting fuel feed pump with fuel filter. ·

3. While operating the priming pump, turn the injection pump housing in opposite direction of engine rotation, until fuel stops flowing from the delivery valve holder.


1-24 GENERAL INFORMATION 4. Blow out fuel remaining on the delivery valve holder and check that fuel is not being delivered as the priming pump is manually operated, then tighten fixing nut. Remove fuel pipe to get accessibility and tighten the residual fixing nuts.

Notched line

Fixing nuts

5. Re-install the fuel pipe, delivery valve, spring and nozzle pipe. Delivery valve holder: Torque

kg·m{ft.lbs.)

4-4.5 (29-33)

Over-tightening of the delivery valve holder and holder clip will invite malfunction of control rack.

COMPRESSION PRESSURE Preparation

1. Start and normalize the engine. Engine r.oolant temperature C(F•)

More than 75 {1 67)

2. Remove the following parts. • Glow plug connector • 4 glow plugs 3. Install adaptor and compression gauge. 4. Engage the starter and check that cranking speed is approximately 200 r.p.m. Measurement

Compression 90uge adaptor

1. Keep starter engaged until compression gauge needle reaches the maximum level and take reading of the gauge. 2. Repeat the test each cylinder. kg/ cm 2(psi) Standard 31 (441) at 200 rpm Limit 22 (313)

Compression gauge : 5-8840-2008-0 Adaptor : 5-8531 -7001-0



COOLING SYSTEM lsuzu Long life coo141nt 0 u :... - t 9 c -20 0 Q.

0

r- h..

7

i

An adequate amount of anti-free-ze solution should be

~"--f....

a~ded to the cooling system according to lowest temper-

....._

- 30

ature anticipated.

['.

c -40

.;:

Mixing ration

I

-~

60 - · 0

..s.

H

· 25 30 35 40 45 10 t 5· .·20

l .,o 55 60

Capacity liters (Imp gallon)

14 (3.1)

Mixing ration l%1

Fan belt Inspection Check that the belt gives a specified deflection when the intermediate part of the belt is depressed with finger (when pushed with a force of 10 kg (22 lbs.) Deflection

mm(in.)

8-1 2 (0.32- 0.47)

Adjustment 1. Loosen the fixing bolts of the generator and adjust.

J

2. Adjust belt tension by moving the generator. 3. Retighten the fixing bolts.



RECOMMENDED LUBRICANTS ENGINE TYPE

TYPES OF LUBRICANTS

Without turbocharger

Diesel engine oil CC or CD grade

W ith turbocharger

Diesel engine oil CD grade

ENGINE OIL VISCOSITY CHART ENGINE OIL VISCOSITY GRADE- AMBIENT TEMPERATURE (Single grado)

lTemper~turo)(-20°Fl IMulto·gradt[ SAE l OW-30 SAE l OW-40

\ SAt SW- 20

ADHESIVE FOR REPAIRS Liquid gasket, adhesives and other chemicals are used in various parts of the·engine to prevent leakage of oil, water and to prevent the bolts and nuts from loosening and these chemicals are available a; lsuzu M otors as lsuzu genuine parts. Wh en servicing th e engine, it is recommended to use lsuzu genuine parts or equivalent.

ITEMS

PARTS NAMES BELCOBOND NO. 4 BELCOBOND NO. 5

Liquid gasket

BELCOBOND No. 201 SEAL END NO. 242 THREE CEMENT SUPER THREE CEMENT

Adhesives and sealant

LOCKTITE 242 (Locktite Nutlock} LOCKTITE 262 (Locktite Studlock) LOCKTITE PRIM ER "N"


ENGINE ASSEMBLY 2-1

SECTION 2

ENGINE ASSEMBLY PAGE

CONTENTS

·General description . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- '2 Disassembly . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 3 Inspection and repair . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • . . . . . . . . . 2-t4 Reassembly . . . . • . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

' I

_./


2-2 ENGINE ASSEMBLY

GENERAL DESCRIPTION This illustration is based on the 4801-T model.

\


ENGINE ASSEMBLY 2-3

l•!•l

DISASSEMBLV

EXTERNAL PARTS This illustration is based on the 4BD1-T model.

Disassembly steps 1. Turbocharger related parts (480-T only) A. 2. Exhaust manifold assembly 3. Oil level gauge with guide tube 4. Starter motor S. Cooling fan 6. Generator 7. Cooling fan belt 8. Tappet chamber cover 9. Thermostat housing assembly 10. Rubber hose 11 . Water pump as.s embly A. 12. Cylinder head cover

• 13. 14. 1S. 16. • 17. 18. 19. 20. 21. 22. A. 23. 24.

Oil pan Fuel injection leak off pipe Fuel pipe Fuel injection pipe Injection nozzle holder Glow plug Fuel filter Intake manifold assembly Oil pipe Oil filter w ith bracket Injection pump assembly Oil cooler assembly


2-4 ENGINE A.SSEMBLY

Important operations 1. Turbochi!rger related parts

Parts removal steps are related as the following chart.

Heat protector

I

...

~~

\

E·x haust adaptor assembly Fuel cut bracket

Safety valve assembly

Boost (X)mpensator hose

2. Exhaust manifold assembly Loosen the exhaust manifold bolts in. numeri«al sequence.


ENGINE ASSEMBLY 2-5 12. Cylinder head cover Loosen the cylinder head cover bolts in numerical sequence.

17. Injection nozzle Keep the parts removed from each cylinder separate and handle the parts carefully so as not to cause damage to the nozzle end.

tttt

23. Injection pump assembly Remove the injection pump by loosening 6 through bolts and a nut. The through bolt A is hidden behind the hole cover. The nut B should be accessed from backward.

When the injection pump is removed, cap or tape the openings to prevent e~try of foreign matter into the delivery valve holder.

Caps

,--"---.

'


, 2-6 ENGINE ASSEMBLV

l•!•l

INTERNALPARTS

MAJOR COMPONENTS These illustrations are based on the 4BD1 model.

1

10

7

14

Disassembly steps ~

.. ~

~ ~

1. Rocker arm shaft assembly 2. Push rod 3. Cylinder head assembly 4. Cylinder head gasket 5. Flywheel 6. Flywheel housing 7. Rear oil seal assembly 8. Oil pump cover 9. Oil pump assembly 10. Piston and connecting rod assembly 11. Crankshaft front nut and washer

~

12. 13. 14 . 15.

16. ... 17. ~

18.

19. 20. • 21. 22.

Crankshaft pulley Gear case cover Idle gear Camshaft assembly Timing gear case Crankshaft beari ng cap and crankshaft bearing (Lower side) Thrust bearing Crankshaft asse:nbly Crankshaft bearing (Upper side) Tappet Oiling jet (4801-T only)


ENGINE ASSEMBLY 2...:_7

Important operations 1. Rocker arm shaft assembly Loosen the rocker arm shaft assembly bolts a little at a time in numerical sequen·ce as specified.

-

F (Ont

3. Cylinder head assembly Loosen·the·cylinder head bolts a little at a time in numerical sequence as specified. Upon removal of the cylinder head assembly with the rocker arm shaft assembly. use.a special-tool to loosen the· cylinder head bolts. Wrench: 1-8511-1003-0

5. Flywheel Loosen the flywheel bolts a little at a time in numerical sequence as specified.

10. Piston and connecting rod assembly With a scraper remove carbon deposits from the cylinder wall before removing the piston.

Bring the piston to top dead .center by turning the crankshaft, then push out the piston and c_onnecting rod assembly from the cylinder \.ISing the handle of a hammer or wood bar.

•'


2-8 ENGINE ASSEMBlY 11. Crankshaft front nut and washer Wrench : 4'1 mm

14. Idle gear Check the following poims before disassembly: Idle gear end play mm(in.) Standard

Limit

0.058- 0.115 (0.002 - 0.005)

0.2 (0.008)

Backlash in gears (Crankshaft gear, idle gear, camshaft gear). mm(in.) Standard Limit

0.10-0.17 (0.004 - 0.004)

0.3 (0.012)

~ 17. Crankshaft bearing cap and crankshaft bearing Check the crankshaft end play before disassembly. mm(in.) Standard Limit

0.15-0.33 (0.006 - 0.013)

0.45 (0.018)

Loosen the crankshaft bearing cap bolts in unmerical order.


ENGINE ASSEMBLY 2-9 18. Thrust bearing

Remove the thrust bearing using a wire.

Wire

21. Tappet

Ma'k eyli.~der No.

~-~ J

I

Ae"'

ic·

E!
Mark cylinder number on each tappet after removal.

~' ' \ I

I

'0' IN

.


2-10 ENGINE ASSEMBLY

,..: ..,

MINOR COMPONENTS

ROCKER ARM, BRACKET AND SHAFT ASSEMBLY 1

1

5

Disassembly steps 1.

Snap ring

2. Bracket 3.

4 . Spring 5. Rocker arm shaft

Rocker arm


ENGINE ASSEMBLY 2-11

l•!•l

CYLINDER HEAD ASSEMBLY

Disassembly steps &

1. Spring cap and split key 2. Spring 3. Valve

4.

Valve stem oil seal

5. Spring seat

Important operations Mark cylinder number on each part after removal.

• VALVE SPRING e VALVE • VALVESEAT

1. Spring cap and split key Valve spring compressor: 9-8523-14260



I•!..,

PISTON AND CONNE.CTING ROD ASSEMBLY

Disassembly steps • •

1. Piston ring 2. Snap ring

A

3. 4.

-·._________________

Pi ston pin, connecti ng rod and bearing Piston

--



Important operations Mark cylinder number on each part after removal.

• PISTON RING • PISTON e PISTON PIN • CONNECTING ROD

L_______________________

~

1. Piston ring Using a piston ring remover

2. Snap ring Using a snap ring remover.

3. Piston pin and connecting rod Drive out using a brass rod under normal temperature.



~ INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection.

CYLINDER HEAD AND BODY Distortion at mating face.

®

®

I

-

1'_,©

~-

I

------- ---

@ 0

I I

®

®

Check in six (6) different directions ( A straight edge and feeler gauge.

F ) using a

Distortion

mm(in.)

Standard

Limit

0.05 (0.020) or less

0.2 (0.08) or less

When the distortion exceecs specified limit, regrind the mating surface within specified limit. Regrind amount Limit

mm(in.)

0.30 (0.012)

VALVE, VALVE GUIDE AND VALVE SEAT INSERT Contact width mm(in.) Standard

Limit

1.5 (0.059)

2.0 (0.079)

~~~ Depr_e_s_s_io_n--------------~------------~~~ ~ mm(in.) Standard

Limit

1.0 (0.039)

2.5 (0.099)

D81>re.. ion



lt!fl.l

Valve seat angle

Valve seat insert replacement

Removal: Arc-weld excess metal around the inner face of insert and allow to cool off a few minutes, then pry off with a screw driver. Installation :

EJ

Press a new valve seat insert into the bore using a bench press.

After installation of the valve seat insert, grind finish the seating face with a seat grinder carefully noting the seating angle, contact width and depression. lap the valve and seat as the final step.

Valve seating angle

(degree) Intake valve

45.

Exhaust valve

45.

Valve head thickness

mm(in.) Standard

limit

1.5 (0.059)

1.0 (0.039)

/ ThicknM$



Itil!. I

i-

u

Valve stem diameter

mm(in.) Standard

Limit

Intake

8.946- 8.961 (0.352- 0.353)

8.88 (0.350)

Exhaust

8.921- 8.936 (0.351 -0.352)

8.88 (0.350)

Clearance between valve and valve guide. mm(in} Standard

Limit

Intake

0.039- 0.068 (O.OGlS-0.0027)

0.2 (0.008)

Exhaust

0.064- 0.093 (0.0025- 0.0037)

0.25 (0.010)

Valve guide replacement Remover and installer : 1-85220-001-0

The height of the valve guide top edge from the cylinder head upper face should be the specified figure .

13.9- 14.3 (0.547-0.563)

mm(in.)

Height

VALVE SPRING Free length and inclination

mm(in ) Standard

Limit

Inner

52.4 (2.065)

50.0 (1.970)

Outer

53.65 (2.11 2)

50.65 (1.994)

Inner

-

1.0 (0.039)

Outer

-

1.0 (0.039)

Free length

Inclination


ENGINE ASSEMBLY 2-1 7

~

Tensi on kg {lbs.)

Inner Outer

®G) Pitted

Crack

Set length

Standard

Limit

42.0mm {1 .65 in.)

10.9 {24.03)

9.9 (21.83)

44.0 mm

23.0

20.0

(1.73)

(50.72)

(44.10)

TAPPET Inspect tappets for wear, damage or other abnormal conditions. Normal ccntact

I'fi:l l ~

lt!tl

Diam eter

--------------------~------------~m~m~(in~.) Standard

Limit

27.97- 27.98 {1 01020 - 1.1 024i

(1 .1000)

27.92

Clearance between tappet and body. mm(in.) Standard

Limit

0.02- 0.054 (0.0007 - 0.0021)

0.1 {0.0039)



PUSH ROD Run-out Limit

mm(in.l

0.3 (0.012)

ROCKER ARM SHAFT ASSEMBLY Inspect all disassembly parts for wear, damage or other abnormal conditions.

Rocker arm shaft diameter mm(in.)

t·& ----.·-- ---· ~·--··~ ------.--- ...... ; ------ - - ------ J--- - ~------- --- -- · - ··

Standard

Limit

18.98- 19.00 (0.7478- 0.7486)

18.85 (0.7427)

Rocker arm diameter mm(in.) Standard

Limit

, 9.01 - 19.03 (0.7489 - 0.7497)

19.05 (0.7505)

Clearance between rocker arm shaft and rocker arm mm(in.) Standard

Limit

0.014- 0.062 (0.00055 - 0.0024)

0.2 (0.0079)


I --------------------------------------------------~E~N~GINEASSEMBLY 2-19

II

CAMSHAFT ASSEMBLY Inspect all disassembly parts for wear, damage or other abnormal conditions.

• CAMSHAFT • CAM GEAR e THRUST PLATE

li.

~~~ ~

~---------~~~ mm(in.)

End_p_la_v ____________ Standard

limit

0.050 - 0.114 (0.0002 - 0.0045)

0.2 (0.0079)

I

Camshaft journal diameter mm(in.)

I~

I

Standard

Limit

55.94 - 55.97 (2.2040 - 2.2052)

55.60 (2.1906)

Camshaft bearing inside diameter

Camshaft bearing

Standard

mm(in.)

- ------56.00 - 56.03

:

I

(2.2064-2.2076)

Clearance between camshaft journal and bearing mm(in.) Standard

limit

0.03-0.09 (0.0012 - 0.0035)

0.15 (0.0059)

I ,:

I

' '

; '·


2-20 ENGINE ASSEMBLY Camshaft bearing replacement Remover & intaller : 9-8523-1818-0

Align camshaft bearing oil ports with those in cylinder body. . No. 1 camshaft bearing (front side) has two oil ports while other have only one oil :Jort.

Run-out

I'

t

Limit

mm(in.)

0.1 (0.0039)

Camshaft gear If any abnormal conditions are found, or if the amount of back-lash measured at disassembly is excessive, replace the camshaft gear. · Refer to "DISASSEMBLY OF MAJOR COMPONENT" for the backlash measurement

Gear bolttorque

kg·m(ft.lbs.)

12.5-15.5 (9Q-11 2)

Gear and thrust plate replacement Removal : 5-8840-0086-0 Installation : Use a bench press ot a hammer.

lJ


Cam lobe height

mm(in.) Standard

Limit

47.7 (1.879)

46.5 (1.832)

IDLE GEAR AND IDLE GEAR SHAFT Shaft outside diameter

mm(in.) Standard

Limit

44.94-44.97 (1.7706-1.7718)

44.84 (1.7667)

Clearance between shaft and gear

mm(in.) Standard

Limit

0.009-0.060 (0.00035-0.0024)

0.2 (0.0019)

CYLINDER LINER Cylinder liner inside diameter

Measuring point: ApproXc. 20 mm below top end. mm(in.) Standard 102.021 - 102.060 (4.0196- 4.0212)

102.2 (4.0267)

Cylinder liner removal

Remover : 9-8523-1169-0 Remover ankle : 9·8523-2557-0


2-22 ENGINE ASSEMBLY Cylinder liner installation

Installer : 9-8523-2554-0 First., apply a load of 500 kg (1 103 lbs.) using a bench press. Do not use a hammer. Then, apply a final load of 2500 kg (5513 lbs.).

Standard fitting interference mm(in.)

0.001 - 0.019 (0.00004-0.00075)

The use of dry ice to cool the cylinder liner will invite contraction, facilitating smooth installation of the cylinder liner. ·

It!ll

Amount of projection

Standard

mm(in.)

0.03- 0.10 (0.001 2-0.0039)

Cylinder liner inside diameter

mm(in.) Minimum diameter

Piston grade required

102.021-102.040 (4.0196-4.0204)

A

102.041-1 02.060 (4.0204-4.0212)

c



PISTON, PISTON PIN AND PISTON RING Piston diameter mm(in.) Piston grade A

101.955-101.974 (4.0140-4.0147)

c

101 .975-101 .994 (4.0148- 4.0155)

Piston clearance

Standard

mm(in.)

0.057- 0.075 (0.0022- 0.0030)

Piston ring Clearance between piston ring and ring groove. 4801 model mm(in.) Standard

Limit

1st compression

0.085-0.11 (0.0033- 0.0043)

0.2 (0.008)

2nd compression

0.030-0.055 (0.0012-0.0022)

0.15 (0.006)

0.03-0.07 (0.001-0.003)

0.15 (0.006)

Oil

4801 -T model mm(in.) Standard

Limit

1st compression

0.105-0.13 (0.0041 - 0.0051)

0.2 (0.008)

2nd compression

0.040- 0.075 (0.001 6-0.0030)

0.15 (0.006)

0.03-Q.07 (0.001 -0.003)

0.1 5 (0.006)

Oil



I I ~

Piston ring gap mm(in)

Standard

Limit

1st compression

0.25- 0.45 (0.01 o-o.018)

1.5 (0.059)

2nd compression

0.2-0.4 (0.008-0.016)

1.5 (0.059)

Oil

0.2-0.4 (0.008-0.016)

1.5 (0.059)

Piston pin diameter mm(in.) Standard

Limit

35.000-35.005 (1.3790-1.3792)

(1.3~0)

34.95

Interference between piston pin and piston pin hole. Clearance

mm(in.)

0.005 (0.0002) or less

CONNECTING ROD AND BEARING Distortion or misalignment Connecting rod aligner. (per 100 mm)mm(in.) Standard

limit

0.05 (0.0002) or less

0.2 (0.0079)



It!!,J

Bushing inside diameter

mm(in.)

Standard

35.017- 35.025 (1.3797- 1.3800)

Clearance between piston pin and connecting-rod.

mm(in.) Standard

Limit

0.012-0.025 (0.00047-0.00098)

0.05 (0.0002)

Bushing replacement

Removal : Use a suitable bar and bench press or hammer. Installation : Use a suitable bar and bench press.

After installing a new bushing, finish the bushing bore with a pin hole grinder.

Bearing spread

Limit

mm(in.)

68.0 (2.68)


2- 26 ENGINE ASSEMBLY Tension Check to see if the bearing has enough tension, so that finger pressure is needed to fit the bearing into position.

CRANKSHAFT AND BEARING Crankshaft pin outside diameter mm(in.) Standard

Limit

4801

63.932-63.944 (2.5189-2.5194)

63.000 (2.4803)

4801-T

63.924-63.944 {2.5167- 2.5175)

-

Procedure for measuring the clearance between crank shaft pin and connecting rod. Install bearings and cap Tighten the connecting rod bearing cap bolts to the specified angle. mm(in.) 1st step kg·m(ft.lbs.) 2nd step (degree) Torque

4.0 (29)

so·- so·

Inside d iameter Apply engine oil to bearing, then measure the connecting rod big end inside diameter. Nominal diameter

mm(in.)

64 'I> (2.52)

Clearance between crankshaft pin and connecting rod. mm(in ) Standard 4801

0.030-0.073 (0.001 2- 0.0029)

4801-T

0.030- 0.081 (0.0012-0.0032)

Limit

0.10 (0.004)


ENGINE ASSEMBLY 2-27 Crankshaft for 4601 -T engine can not be reground because it is finished with tufftride method. For the crankshaft on 4601-T, no attempt should be made to grind finish the faces of the journals and crankpins as they are tufftrided !Special hardening teatment). Therefore, the undersize bearings are not prepared.

IE

Except 4601-T mm(in.) Under size bearing availability for crankshaft regrinding mm(in.)

0.25, 0.50, 0.75, 1.00 (0.010, 0.020, 0.030, 0.040)

Crankshaft Tufftriding Ammoniun cuprous

chloride

Test liquid should not ;,e applied to area around oil

port

~7a

Inspection 1. Use an organic cleaner to thoroughly clean the crank· shaft. There must be no traces of oil on the surfaces to be inspected. 2. Prepare a 5 - 10% solution of ammonium cuprous chloride (dissolved in distilled water). 3. Use a spot glass rod to apply the solution to the surface to be inspected. . Hold the surface to be inspected perfectly horizontal to pre"ent the solution from running. Note: Do not allow the solution to come in contact with the oil ports and their surrounding area. Judgement 1. Wait for thirty to forty seconds. lfthere is no discoloration after thirty orforty seconds, the crankshaft is useable. If discoloration appears (the surface being tested will become the color of copper), the crankshaft must be replaced. 2. Clean the surface being tested with clean water of steam immediately after completing the test.

Note: The ammonium cuprous chloride solution is highly corrosive. Because of this, it is imperative that the surfaces being tested be cleaned immediately after completing the test.



ItgI

Crankshaft jo urnal o utside diameter mm(in ) Standard

Limit

4801

79.913-79.925 (3.1462-3.1467)

79.000 (3.1102)

4801 -T

79.905-79.925 (3.1459-3.1467)

-

Procduer for measuring the clearance between crank shaft journal and crankshaft bearing cap. Install bearings and cap Torque

kg·m(ft.lbs.)

23-25 (166-181)

Inside diameter Apply engine oil to bearing, then measure the main bearing cap inside diameter. Nominal diameter

mm(in.)

80 (3.15)

Clearance between crankshaft journal and bearing. mm(in.) Standard 4801

0.039-0.090 (0.0015-0.0035)

4801 -T

0.025- 0.076 (0.001 0-0.0030)

Limit

0.11 (0.0043)

Crankshaft for 4801-T engine can not be reground because it is finished with tufftride method. For the crankshaft on 4801 -T, no attempt should be made to grind finish the faces of the journals and crankpins as they are tufftrided (Special hardening teatment). Therefore, the undersize bearings are not prepared. Except 4801-T mm(in.) Under size bearing availability for crankshaft regrinding mm(in.)

0.25, 0.50, 0.75, 1.00 (0.010, 0.020, 0.030, 0.040)


ENGINE ASSEMBLY 2- 29

I'11:11 ~

Run-o ut

-------------------.--------------~m~m~(~in~.) Standard

Limit

0.05 (0.020) or less

0.30 (0.012)

If the crankshaft generated crack after repair, replace the cran ksh;~ft .

Crankshaft for 4801-Tengine can not be bench pressed. because it is finished with tufftride method.

Bearing spread Limit

mm(in.)

85.0 (3.35)

Tension Check to see if the bearing has enough tension, so that finger pressure is needed to fit the bearing into position.

"DISASSEM~

Crankshaft gear

If any abnormal condi:ions are found, or if the amount of backl ash measured at disassembly is excessive, replace the crankshaft gear.

Rot" to MAJOR COMPONENTS" fo · the backlash measurement.

_j Crankshaft gear replacement

Removal; Remover: 9-8521-0141-0


2-30 ENGINE ASSEMBLY Installation ; Installer : 9-8522-0033·0

Installe r

Pilot bearing replacement Removal; Remover: 9·8523-1812-0 Installation ; Installer : 5-8522-0024·0

FlYWHEEL AND HOUSING (REAR OIL SEAL) Thickness mm(in.)

Friction

face Crankshaft fitting face

Stand!!rd

limit

30.9-31 .1

30

(1.217- 1.225)

(1.182)

Ring gear replacement Removal ; Use a suitable brass rod and a hammer.

Installation ; With a gas burner, heatthe ring gear until heat expansion takes place, then install it using a hammer.


ENGINE ASSEMBLY 2-31 Oil seal replacement Removal ; pry off or pull out. Installation ; Installer : 9-8522-1254-0

---~-

-Oilseal

When the crankshaft face in contact with the oil seal is worn. the contact portion on the crankshaft can be changed by driving into the deeper position.

GEAR CASE COVER Oil seal replacement Removal ; pry off or pull out. Installation ; Installer : 9-8522-0034-0



l•!•l

REASSEMBLY

INTERNAL PARTS MINOR COMPONENTS PISTON AND CONNECTING-ROD ASSEMBLV

Reassembly steps • •

1. Piston 2. Piston pin, connecting-rod and bearing

• •

3. Snap ring 4. Piston ring


ENGINE ASSEMBLY 2- 33

Conventional piston heater

Important operations 1. Piston Heat the piston to about 60°C using a piston heater or equivalent.

2. Piston pin and connecting rod ~

Front

Piston head

Refer to the alignment hstructions given in the left figu re.

mark~

;

Put eylinder number

~~ ma~ked side in this

~

V

postt•on .

3. Snap ring Install the snap ring using a snap ring installer.

4. Piston ring Install the piston ring using a piston ring installer. The face w ith the mark #NPRM or ~OPh should be turned up for the 1st and 2nd compression rings.



l•!•l

CYLINDER HEAD ASSEMBLY

;'-:~--~--------5

a~:--,--J-

-4

~~·.----------------- 1

Reassembly steps 1. Spring seat 2. Valve stem oil seal .a. 3. Valve

•

.a. 4. Springs .a. 5. Spring cap and SPlit key

Important operations 2. Valve stem oil seal Install valve stem oil seals after lubricating them with clean engine oil. Installer: 1·85221·005·0

3. Valve lntak)valve

Exhauf valve

Install the intake and exhaust valves in the proper posi tions. Take care not to interchange the valves.

Oo Collated to support AULRO.com - Australia's premier Land Rover Website!

ENGINE ASSEMBLY 2-35 Springs Install the valve springs with their close pitched (painted side) end down.

5. Spring cap and split key Valve spring compressor : 9-8523-1426-0 When split keys are installed, tap on valve stem end lightly w ith a plastic hammer to insure correct seating of split keys.


2-36 ENGINE ASSEMBLY ROCKER ARM, BRACKET AND SHAFT ASSEMBLY

Reassembly steps "" 1. Rocker arm shaft 2. Spring 3. Rocker arm

4. Bracket 5.

Snap ring


l

!

ENGINE ASSEMBlY 2-37

tl

MAJOR COMPONENTS This illustration is based on the 4601-T model.

18

13

'I

8

I

Reassembly steps ... 1. 2. ... 3. ... 4. ... 5. ... 6. ... 7. A. 8. ... 9. ... 10. 11.

Oil jet (4801-T only) Tappet Crankshaft bearing (Upper side) Crankshaft Thrust bearing Cranksh aft bearin g cap and crankshaft bearing (Lower side) Timing gear case Camshaft assembly Piston and connecting rod assembly Oil pump assembly Oil pump cover

)

... 12. 13. 14. ... 15. ... 16. ... 17. ... 18. ... 19. ... 20. 21. A 22.

Idle gear .Timing gear case cover Crankshaft pulley Crankshaft front nut and washer Flywheel housing Rear oil seal assembly Flywheel Cylinder head gasket Cylinder head assembly Push rod Rocker arm shaft assembly

I

'

.....


r 2-38 ENGINE ASSEMBLY

Important operations 1. Oiling jet (4BD1· T only) Torque

With oil hole

.

~~ ~-

kg·m(ft.lbs.)

1.6-2.6 (11.5-18.8)

3. Crankshaft bearing (Upper side) Crankshaft bearing (Lower side) The center lower bearing is not provided with either oil groove or hole, while all other bearings have the oil groove and hole (upper side) or the oil groove (lower side).

f'!J)No oil9roove and hole ~(Center lower only) 4. Crankshaft The crankshaft should be installed, so that the end with the crankshaft gear is turned front of engine.

...,_ Front

5. Thrust bearing Thrust bearings should be installed so that their oil grooves are turned to the rotating face of crankshaft.

Arrowmark

(Po$ition No.

pu.:_:nc:;:hed;: l:--:-....r::--:-:--

6. Crankshaft bearing cap and crankshaft bearing (Lower side) Each bearing cap has a position number which is punched onto the arrow mark. The arrow mark should be pointed to the front of engine.

<::J Front



Tighten the crankshaft bearing cap bolts in the sequence specified. Torque

kg·m(ft.lbs.)

23- 25 (166.3-180.8)

7. T iming gear case Torque

kg·m(ft.lbs.)

2.1- 3.1 (15. 2-22.4)

8. Camshaft assembly Tighten the thrust plate bolts through the camshaft gear hole Torque

kg·m(ft.lbs.)

2.1-3.1 (15.2-22.4)

9. Piston and connecting rod assembly Set the piston ring to the recommended positions.

The piston front mark should be turned to the front of the block.

Piston ring compressor

Piston ring compressor: 9·8522-1251-0

From mArk


2- 40 ENGINE ASSEMBLV

Align the cylinder numbers marked on the cap and connecting rod.

Cylinder number

Tighten the connecting rod bearing cap bolts to the specified angle. mm(in.) 1st step kg·m(ft.lbs.) 2nd step (degree) Torque

r:::::t

L::J

60-90

10. Oil pump assembly

Install the oil pump after filling it with engine oil.

Torque

1. . 1

4.0 (29)

kg·m(ft.lbs.)

4.3-6.3•(31.1-45.5)

12. Idle gear Use thrust collar fixing bolts as guide. The oil port should be turned to the camshaft.


ENGINE ASSEMBLY 2-41 Align the timing marks ("A", "B" and "C") on the gears.

I nject ion P,u mp gear

Torque

kg·m(ft.lbs.)

I

4.3-6.3 (31.1-45.5)

The thrust collar should be installed so that the chamfer side is turned to the front.

~ 15. Crankshaft front nut Wrench : 41 mm Torque

kg·m(ft.lbs.)

39-49 (282-354)

16. Flywheel housing 17. Rear oil seal assembly Apply a liquid gasket Bel co Bond No.4 (or equivalent) to the shaded area in the drawing. kg·m(ft.lbs.) Torque Flywheel housing Rear oil seal assembly

12.5-15.5 (90.4- 112.1) 2.1-3.1 (15.2-22.4)

Apply liquid gasket. (Cylinder body side only)

~~~

18.

-F-Iyw--h-ee-1----------~----------------Torque

1•1

kg·m(ft.lbs.)

14.5- 17.5 (105- 125)

19. Cylinder head gasket The "TOP" mark sho·Jid be up and the "FRONT" mark to the front.

Front

-..m------------~-------------------------

------------------------------------ ---------~


2-42 ENGINE ASSEMBLY 20. Cylinder head assembly 4801: Lubricate the head bolts with engine oil and tighten them in the following sequence in two steps.

-

kg·m(ft lbs J

Torque 1sJ step

Front

New

6.5-7.5 (47.0-54.2)

Reused

2nd ste.p 9.5- 10.5 (68.7-76.0) 11.0- 12.0 (7!:).5-86.8)

4801 -T: Lubricate the head bolts with Mos2 grease and ·t ighten them to the specified angle.

kg·m(ft.lbs.)

Torque 1st step

2nd 1>tep

7 (50.6)

9 (65;1)

3rd step

Note: There are two lengths of head bolts. The shorter ones must be used on injection pump side. 22. Rocker arm shaft assembly Tighten the rocker arm shaft bolts a little at a time in numerical sequence -as specified. Note that the bolt (black colored) witb lubricating oil groove should be installed to the front bracket.

-

Torque

kg·m(ft.lbs.)

.2.0-3;0 (14.5-21.7)

F ront

Adjust the valve clearance.

Refer to "Servicing of Section 1 General Information" for the valve clearance adjustment.


ENGINE ASSEMBLV 2--43

EXTERNAL PARTS These illustrations are based on the 4BD1-T model.

Reassembly steps • .6.

•

.A .A • • .6.

• .6.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11 . 12.

Oil pan Tappet chamber cover Starter motor Generator Oil cooler assembly Injection pump assembly Oil filter with bracket Glow plug lnjectior nozzle holder Cylinder head cover Thermostat housing assembly Water pump assembly

• 13. 14. .6. 15. 16. _. 11.

18. 19. 20. • 21. • 22. 23. • 24.

Cooling fan belt Cooling fan Intake manifold assembly Fuel filter Exhaust manifold assembly Oil level gauge with guide tube Rubber hose Oil pipe Fuel pipe Fuel injection pipe Fuel injection leak off pipe Turbo charger related parts (4801 -T only)


2-44 ENGINE ASSEMBlY

Important operations 1. Oil pan Apply liquid gasket to the specified portions between cyiinder body and oil pan install oil pan gasket, then install the oil pan. Bolt torque !
1.1-2.1 (8.0-15.2)

2. Tappet.camber cover Torque

kg·m(ft.lbs.)

1.6-2.6 (11.6-1 8.8)

3. Starter motor Torque

kg·m(ft.lbs.)

7.6- 9.6 (55.0- 69.4)

6. Injection pump assembly Torque

kg·m(ft.lbs.)

2.1- 3.1 (15.2-22.4)

Only the bolt with arrow mark should be accessed from b.ackward.

• = InJeCtion pump fixing bolts

7. Oil filter with bracket Torque

kg·m (ft.lbs.)

4.3-6.3 (31.1 - 45.5)


ENGINE ASSEMBLY 2--45 8. Glow plug

Torque

kg·m(ft.lbs.)

2.25- 2.75 (16.3- 19.9)

9. Injection nozzle holder. Adjust the injection starting pressure with the adjusting screw using a nozzle tester. Refer to "Servicing of Section 1 General Information" for the injection nqzzle starting pressure adjustment.

Use new gaskets and dust covers. The flange n·uts should be tightened after tightening the injection pipe sleeve nuts. Torque

kg·m(ft.lbs.)

2.25-2.75 (16.3- 19.9)

NolZie gasket

2~ 1

~

~ 10.

Cylinder head cover

® I

Bolt torque

kg·m(ft.lbs.)

1.6-2.6 (11 .6- 18.8)

Tighten the bolts in numerical sequence.

~ 11. Thermostat housing assembly


2-46 ENGINE ASSEMBLY 12. Water pump assembly

Apply.liquid gasket Belco Bond No.4 (or equivale'nt) to the gasket before installation.

13. Cooling fan belt

Adjust the fan belt tension. Refer to "Servicing of S·ection 1 General Information" for tne fan belt tension adjustment.

15. Intake manifold assembly Projection

The gasket sholud be installed, so tnat the side with the projection is positioned rearward and upward. Torque

kg·m(ft.lbs.)

1.6-2.6 (11.6-18.8)

~ 17. !=xhaust manifold assembly

4601 MODEL

The g&sket should be installed, so that the side with "TOP" mark is turned outside.

4BD1·T MODEL


ENGINE ASSEMBLY 2-47 Tighten the exhaust manifold bolts a little at a time in numerical sequence as specified. 5

1

4

8

~

Torque

kg·m(ft.lbs.)

1.6-2.6 (1 1.6-18.8)

Fuel pipe When installing the fuel pipes, avoid interchanging the check valve and joint bolts. Torque

kg·m(ft.lbs.)

2.0- 2.5 (14-18)

~ 22. Fu el injection pipe Torque

kg·m (ftlbs.)

2.9-3.2 (21 .0-23.1)

Over-tightening of the delivery valve holder, holder clip and injection pipe nut will invite malfunction of control rack. Delivery valve holder torque kg·m(ft.lbs.)

4.0-4.5 (29-33)


2-48 ENGINE ASSEMBlY 23. Turbo charger related parts Parts installation steps are refered as the following chart. Heat protector

Inlet rubber hose

~r:?

\

Fuel cut bracket

Safety valve assembly

Boost compensator hose

Oil drain pipe Torque

kg·m(ft.lbs.)

0.5- 1.0 (4- 7)

kg·m(ft.lbs.)

1.2-1.6 (8.7-11.6)

Oil feed pipe Torque


ENGINE ASSEMBLy 2-49

l"i\ I ~

Turbocha rger assembly

Torque kg·m(ft.lbs.)


LUBRICATING SYSTEM 3-1

SECTION 3

LUBRICATING SYSTEM CONTENTS

PAGE

Gene ral description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 2 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 3 Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 5

Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 6

---

--------------------------------~


3-2 LUBRICATING SYSTEM

LUBRICATING SYSTEM GENERAL DESCRIPTION

Full flow filter r-- -------- --., ~ - -

Benerv

I

I

Over flow valve (rel ief valve}

I

4B01·T only

I

I

I I

I I

pump

I I

Oil

I L-

Slr.ainer

l (

Orilice

. I - - - - - - - - -'

¢1.2mm (0.047in)

O il pan

OIL PUMP

OIL FILTER



OIL PUMP

1•:..11•!•1

DISASSEMBLY AND REASSEMBLY

Disassembly steps 1. Strain9r 2. Strainer case 3. Cover 4 . Relief valve assembly 5. Vane 6. Rotor assembly

Reassembly steps To reassemble, follow the disassembly procedures in reverse order.



INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage or any other abnormal conditions, are found through inspection.

Check the clearance i:>etween the vane, rotor and cover. If the measured value is beyond the specified value, replace the rotor set (pin, shaft, rotor, vane.)

Standard

mm(in.)

0.050-0.1 14 (0.0020-0.0045)

Check the clearance between the rotor and vane. If the measured value is beyond the standard value, replace the rotor set. Standard

mm(in.)

0.14 (0.0055) or less

Check the clearance between the vane and pump body. If the clearance is excessive, replace the entire pump assembly.

Standard

mm(in.)

0.20-0.30 (0:008- 0.Q12)

Check the clearance between the rotor shaft and pump body. If t he measured value is beyond the specified value, replace the entire pump assembly.

St
mm(in.)

0 .032- 0.070 (0.0013- 0.0028)



OIL FILTER

1++11++1

REMOVAL AND INSTALLATION

2

Removal steps 1. Main oil filter 2. Partial oil filter

Installation steps 2. Partial oil filter 1. Main oil filter



OIL COOLER

l•!•l

DISASSEMBLY

Disassem bly steps 1. Element 2. Bolt

INSPECTION AND REPAIR Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found through inspection.


LUBRICATING SYSTEM 3

l•!•l

REASSEMBLV

Reassembly steps A A

1. Element 2. Bull

Important operation - Installation 1. Element Torqu e

l
2 1-3.1 (1 5.2- 22.4)

2. Bolt Tighten the bolts in numerical sequence as specified.

T _ o_r_qu_e_ _ _ kg:..·_m.:...(l_tl_bs__:.)_L__::2.:_ .1_-~3. 1 (1 5.2- 22.4)


7

I

COOLING SYSTEM 4-1

SECTION 4

COOLING SYSTEM CONTENTS

PAGE

General descripti·on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 2 Water pump .......................................................................... 4-3 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

I

····-Collated to support AULRO.com - Australia's premier Land Rover Website!

4-2 COOLING SYSTEM

GENERAL DESCRIPTION

THERMOSTAT


WA~T~E;R~P:U:-:M-=-p----~CO~OJLILING SYSTEM 4 ---

l•!•l •

DISASSEMBLY

2*

*

Repair kit

Disassembl Y steps •

•

.... 5. Snap ring ... 6. Spindle. bearin 9 Seal ~mit and spacer .... 7. · washer and seal

1· Cover 2· Impel! er 34. 6ulley center · us1 throw er

lw I ~

Important operations 2· Impeller Remover : 9-RS?1-f.097-0


3

4-4 COOLING SYSTEM 3. Pulley center Use a bench press and a suitable rod.

5. Snap ring Remove the snap using a snap ring pliers.

6. Spindle, bearing and spacer Remove the spindle with bearings using a bench press and suitable remover.

7. Seal unit, washer and seal Remove the seal unit using a bench press and ·Suitable remover.


COOLING SYSTEM 4-5

IL'ii'l

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection.

Bearing replacement procedure

Removal: Use a bench press.

E1

w

Installation : Use a bench press for the front and rear bearings installation. The bearings should be so installed that their sealed side are turned outwards.

Seeled side outward


4-6 COOLING SYSTEM

l•!•l

REASSEMBLY

This illustration bassed on 4801 model.

*

Repair kit

Reassembly steps .A 1. .t. 2. 3. 4.

Spindle, bearing and spacer Washer, seal and seal unit Snap ring Dust thrower

.t. .t.

5. Pulley center 6. Impeller 7. Cover

Important operations Repack whh multipurpose type grease

1. Spindle, bearing and spacer Repack the bearings with multipurpose tvr>P. orease before installing into the pump body. Install the above asse-nbly using a bench press. Installer : 9-8522-1140-0 Sealed side outward


COOLING SYSTEM 4-7 2. Washer, seal and seal unit

Apply liquid gasket (Belco Bond No. 4) to the surface in contact with the pump body.

3. Snap ring Install the snap ring using a snap ring pliers.

5. Pulley center

Use a bench press. Press in until it stops.

6. Impeller Install the impeller using a bench press so that the clearance between the impeller and body is held within the specified value. Standard

mm(in.)

0.3- 0.8 (0.012- 0.031)


4-8 COOLING SYSTEM

THERMOSTAT

I'L•I


Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found through inspection.

Valveopeningtemperature

'C('F)

80-84 (176-183)

Valve lift

Standard

Approx. 10 mm at 95'C (0.4 in. at 203'F)'


FUEL' SYSTEM 5-1

SECTION 5

FUEL SYSTEM CONTENTS

PAGE

General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . • . . . . . . . . . . . . • . . . • . . . 5-

2

Injection pump . . • . . . • . . . . . . . . . . . . . . . . . . . . . • . • . • • • . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . • . 5- 3 Injection nozzle • . . • . • . . . . . • . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 0 Fuel filter . . . . . . . . . . . . . . . . . • . . • • . . . . . . • . . . • . . . . . . . . . . . . . . . . . • . . . . . • • . . . . . . . . . . . . . . . . 5-13


5-2 FUEL SYSTEM

GENERAL DESCRIPTION

l


FUEL SYSTEM 5- 3

INJECTION PUMP

1++11+.,1

REMOVAL AND INSTALLATION

.......

....... ' ·-.. .

......................•···

.···

,..-···

Remov al steps

1. 2. 3. 4.

5.

...

6. 7. 8.

9.

10. ... 1, . ... 12. 13. 14.

Engine stop Cllble Fuel leakoff pipe Fuel injection pipe Intake manifold Engine control cable Fuel pipe; feed pump to filter Fuel return pi~ Fuel pipe; filter to injection pump Hole cover Grommet Bolt; front ~iue (5i~) Bolt; rear side (one) Bracket Injection pump assembly

Install ation steps

14. 12. 11 . 10. 13. 8.

...

7. 6. 5. 4. 3.

2. 1. 9.

Injection pump assembly Bolt; rear side (one} Bolt; front side (six) Grommet Bracket Fuel pipe; filter to i njection pump Fuel return pipe Fu el pipe; feed pump to filte r Engine control cable Intake m anifold Fuel injection pipe Fuel leakoff ;>ipe Engine stop cable Hole cover


5-4 FUEL SYSTEM

Important operations - Removal 9. Hole cover

Align the notched line on the automatic timer with the arrow mark on the timing gearcase cover by rotating the crankshaft using the crankshaft turning wrench.

Crankshaft should not be rotated from this alignment for . ease of reinstallation.

11. Bolt; front si:cte (six) 12. Bolt; rear side (one) Remove the injection pump by loosening 6 through bolts and a nut The thro~h· bolt is hidden behind the hole cover. The nut @) should be accessed from backward.

®

w

D

Important operations - Installation 14. Injection pump

Install the injection pump assembly so that the notched line on the automatic timer align with the arrow mark on the timing gearcase cover.

If timing gear train gets misalignment, tu.rn the crankshaft in a clockwise direction to bring the piston in No. 1 cylinder into Top Dead Center (TDC) on compression stroke by aligning notched line on the crankshaft pulley with the specified mark exactly. After this adj ustment, install the injection pump assembly by following the procedure above.


FUEL SYSTEM 5

4. Inta ke manifold Torque

kg·m(ft.lbs.)

1.6-2.6 (11.6- 18.8)


5

5.-6 liUEL SYSTEM

INJECTION PUMP DATA

INJECTION VOLUME ADJUSTMENT Test condition lnj~ction

D.K.K.C. P.No. 105780-0000 Bosch type No. DN12SD12T

no;:;:le

D.K.K.C. P.No. 105780-2080 Bosch type No. EF8511 /9A 175 kg/cm2 (2489 psi)

Injection nozzle holder Injection starting pressure Injection line

Outside dia. 6mm (0.236 in.) x Inside dia. 2mm (0.078 in.) - Length 600 mm (24 in.)

Over flow valv.e opening pressure

1.6 kg/cm2 (23 psi)

Test oil

SAE standard test diesel fuel (SAE J967d, or IS04113)

Temperature of in use

35' - 45'C (95' - 113'F)

IDENTIFICATIONS PLATE AND NUMBER When .agjusting the volume of fuel delivery, use the correct data following the injection pump assembly number.

Pump No. 101 · · · · · · · · · · · · NP·PE 6A95--·· ··· ··· · · ··· · · ·· (LICENCE BOSCH l

@ · ·· IdentificatiOn number


-----------------------------

--

----

FUEL SYSTEM 5-7 Pre-stroke : No. 1 plunger 3.6

± 0.05 mm

INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM

Injection order : 1 - 3 - 4 - 2 (interval

so· ± 30")

4801 (Identification number : 101401-0290) ADR Spec.

Plun ger are numbered from the drive side Tappet clearance : More than 0.3 mm with all cylinder Adjusting Control rack point position (mm)

Injection Quantity

Pump speed (r.p.m.)

Strokes

11.3

950

1000

9.5

290

1000

11.3

950

1000

67.8- 69.8

B

10.95

1600

1000

67.0- 70.2

-

c

11.15

1300

1000

70.9- 74.1

-

Lever

0

11.05

650

1000

48.7 -

51.9

-

Lever

E

11.4

500

1000

49.9 -

53.9

-

Lever

A H

About

A

R1

Injection volume (cc/1 000 st.) 67.3 6.7-

Variance (%)

Fixed

Remarks Basic

70.3

± 2.5

Rack

9.3

± 14.0

Rack Lever Lever

Timing Advance Specification Pump Speed (rpm) Degree for Angl e of Lead (deg.)

1250

1350

below0.5

below 1.1

1400 below 1.6[

1600 0 5-1

" ~-----r----~'~,c -~ ( 1l401

l ~

s 1'

ll~XI

(!1 ~1

"

""'

,_.

•• !7 .,

I

11.'5 f~C...~ I I '

.,,

3) ~'\. IOO•t1S ~ ~' 1!.1 .~ . ( \1 ,1)';.) 12 .¢$


Basic

5-8 FUEL SYSTEM

INJECTION PUMP DATA INJECTION VOLUME ADJUSTMENT Test co ndition

D.K.K.C. P.No. 105780·0000 Bosch type No. DN1 2SD12T D.K.K.C. P.No. 105780·2080 Bosch type No. EF8511/9A 175 kg/cm 2 (2489 psi)

Injection nozzle Injection nozzle holder Injection starting pressure Injection line

Outside dia. 6mm (0.236 in.) x Inside dia. 2mm (0.078 in.) - Length 600 mm (24 in.)

Over flow valve opening pressure

1.3 kg/cm2 (18 psi)

Test oil

SAE standard test diesel fuel (SAE J967d, or 1504113)

Temperature of in use

40' - 45'C (1 04' - 113'Fl

IDENTIFICATIONS PLATE AND NUMBER Wh en adjusting th e volume of fuel delivery, use the cor· rect data following the injection pump assembly number.

] 0

I (A) I 3RG · · · • · • · · · • · · · • · ·

o

Pumo No 101 · · · • · • · • · · • · NP · PE 6A95 · · · · • · • · · · · • · · · · • · •

I LICENCE BOSCH )


FUEL SYSTEM 5-9 Pre-stroke : No. 1 plunger 3.4 ± 0.05 mm

INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM

Injection order :

1 - 3 - 4 - 2 (interval

go· ± 30N)

4801-T (Identification number : 101401-0660) with Boost compresator

Plunger are numbered from the drive side Tappet cleara nce: More than 0.3 mm with all cylinder Adju!:ting j Contro l racl< p oint position (mm )

-.

Pump speed (r.p.m.)

Stro kes

900

1000

290

1000

900

1000

11.3

A

H

About

A

R1

9.5 11 .2

I

i I

B

R1 -

o.2s

I

c

10.2

~

1

Injection volume (cc/1 000 st.)

Fixed

Remarks Basic

±14.0

Rack

72.2

-

Lever

Boost pressure Above 11 OmmHg

(49.7)

-

Lever

Boost pressure Above 11 OmmHg

-

Lever

70.2 -

I

'

9.3

I

1000

I

Rack

1000

(29.7)

1500

1000

78.0

150

1000

Above 90.0

-

-

(%)

± 2.5

6.7-

I

Variance

72.8

69.6 -

550

I

-0~ 02 I E

Injection Quantity

I I

1

-

-

'

Boost pressure Above 11OmmHg

Lever

I

Lever

Timing Advance Specification Pu m p Speed (rpm)

- - -- -- -- - - - -

11200- 1300

Degree fo r A n gle of Lead (d eg.)

Start 0

r,.ov!PNQ"'

j --.2_5~

I

Finish

3.0-4.0

l

AO.!\I~.(M(N T

I ,.:M,_,,.d td!li•lmt r.l

'

.... , • • ? ••

J>t-'ll·- - - -

'"' - ~ - -

P. l 0 1• '" - - - -

I _ _:' ;

" ~ ....:,......' ·--- ...

~i

1\

I

L..: -

- --

..

--- :.,

1

,' ' ..-' TI' - ::,;..; ' • ·- - - .. - --· ._ • ...,....

M 1 : -:.5>.....- - - - - ~

:

'" I

~

i

~1·- --

~

ll

, •

'

¥· : -I

'

,_-·

--- .,''

.. ·- -- -

___

'

'

'

- ,' .,- T1. .' - ·"J::·•

"""""~;:::: · 'f!CI •\f;:::.

J.· : .. }><..

•'#'lei)

J'~~-~"\""· ·

or: :.ct

'

l~~·~

·· ··~~" ' '"'.IJ' ltvtr Angh: t;(>O ~ T

E

COMPENSATO R ACJVSTM ENT

,

Ptr1Qtrm

.lt

SSO

f'O"'

iRI-O?"LT r ---- ----•

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SOO'H PI'C'\\ (mmHg)

-

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- - - - - - - - - - - - --- - -- - - -- -- -- - -


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5-10 FUEL SYSTEM

INJECTION NOZZLE

IL'4j'l

INSPECTION

Be sure to perform the following inspections before disassembly.

Nozzle opening pressure Measure the nozzle opening pressure using nozzle tester. Nozzle opening pressuire is 185 kg/cm 2 (2630 psi).

Check for leakage Using nozzle tester., maintain a pressure of 165 kg/cm 2 (2346 psi). if there is no leakage, the nozzle is satisfactory.

Correct

..

0.

.

~

0

:X:

~ I

Nozzle spray pattern

Incorrect

:ili ~ .

.

I

*

•,

.

I ·.

Turn the handle of tester clockwise until it is seated. Having moved the nozzle tester lever several times abruptly, check the spray pattern at a lever speed of 4-6 times per second or more .

Lj). .:

• I '

:

.

CAUTION: When using the nozzle tester, test flu id will spray out of injection nozzle at great pressure.w hich can easily puncture worker's skin. Since a defective injection nozzle and nozzle holder assembly may spray in any direction. make sure worker's hands are placed away from the nozle.outlet when using the nozzle-tester.


FUEL SYSTEM 5-11

DISASSEMBLY

i~ ~..:.Y

41 ·11 7---·-o

y~~ ~~~ @-

9

1

2 3 4

~--5

~

I

\ __ _j


4. 5.

6.

Cap nut

2. Gasket 3. Adjvstlng screw Washer Nozzle spring_

...

I.

Push rod Hetam 1ng nut

8 . Injection nozzle 9. Connector 10. Gasket

Important operation 8. Injection nozzle

Keep nozzle assembl•t removed from the nozzle body separate, from other ur-its to maintain proper needle valve and body combinations.


5 - 12 FUEL SYSTEM

IL'i'l


Make necessar y correction or parts replacemem if wear damage or any other abnormal conditions are f ound through inspection. Discard the used gaskets and install new one. Clean the nozzle and nozzle holder with clean diesel fuel. Check them for w orn out corrosion <'lnrl rlarnage, and replace if necessary. Carbon deposit on the tip end of the needle valve and injec tion holes should be cleaned using nozzle cleaning kit.

j-.:•1 REASSEMBlY

9 8

I 3

I !

4

7

•

6

l __ j

Disassembly steps

......

1. 2.

3. 4.

5.

Gasket Connector Injection nozzle Reta ining nut Push rod

6. Nozzle spring 7. Washer 8 . Adjusting screw 9. Gasket ... 10. Cap nut

...


FUEL SYSTEM 5-13

FUEL FILTER

l•!•l

DISASSEMBLY

2

Removal steps 1. Fuel filter cartridge

IL'itl

2.

Fuel filter body



l•!•l

REASSEMBLY

To reassemble, follow the disassembly procedure in reverse order.


5-14 FUEL SYSTEM

w

g

Important operations 3. Injection nozzle The locating pin on nozzle must be aligned w ith the hole in nozzle holder body.

4. Retaining nut Torque

kg·m(ft.lbs.)

6- 8 (43- 58)

8. Adjusting screw Make an adjustment after installation of the adj usting screw. Refer to Section 00 "General information" for the inject ion nozzle starting pressure adjustment.

Injection starting prcscure kg/cml(psi)

~~~

10.

185 (2630)

_c_a_p_n_u_t--------------~-----------------Torque

kg·m(ft.lbs.)

4-5 (29-36)


TURBOCHARGER 6-1

SECTION 6

TURBOCHARGER CONTENTS

PAGE

General description . . ............... ... .............. . . ... . . ........ . ..... . .. . ..... . .. 6- 2 Removal ..... ..... . .. . . ...... . . .. .. . . .. . .... . . . .. . .. . . ... . . .. . . .. , ..... . .. . . . . . . ... . . 6- 3 Inspection and repair .. . . .. .......... ...... .... . ........ ... . ........ . .. . . . . . . .. . ...... 6- 4 Installation .......... .... ........... . . ... ............ . .. . .. .. ............. . . . . .. .. .... 6- 5


6-2 TURBOCHARGER

GENERAL DESCRIPTION


TURBOCHARGER &-3

E]

REMOVAL

1. Intake duct 2. Intake rubber hose

3. Heat protector

4. Fixing nuts and bolts

5. Oil pipe


&-4 TURBOCHARGER

IL1i'l



1. Waste gate operation (1) Remove the hose at the actuator side. (2) Attach a pressure gauge to the actuator. (3) Use a pump to apply the specified pressure-to the actua.t or. Check the control rod operation. Note: The engine must be off (not running) during this procedure. Control rod operation

kg/cm 2(psi)

0.9 (12.8) (680 mmHg)

Pressure gauge : 5-8840·0075-0

2. Boost pressure (1)

Remove the hose·at the compressor blower side.

(2) Attach a pressure gauge to the compressor blower side. (3) Attach the tacilometer lead wire to the No. 1 nozzle holder head. (4) Measure the turbocharger pressure with the engine running at 3,000 rpm. mm(in.) Boost pressure (engine at no load) kg/cmZ

About 0.4 (5.7)

Engine speed (rpm)


3000

TURBOCHARGER &-5 3. Abnormal noise, excessive play, and oil leakage (1) Remove the intake duct. (2) Rotate the turbine shaft by hand to check for abnormal noise and excessive play. (3) Check each of the fl ange and oil pipe connections on the turbine, the center, and the compressor housing for oil leaks. Note: The engine must be off (not running) and cold during this inspection procedure.

1••1

INSTALLATION

To install the turbocharger, follow the removal procedure in the reverse order.


ELECTRICAL SYSTEM 7-1

SECTION 7

ELECTRICAL SYSTEM CONTENTS

PAGE

Starter motor ................ . .. . ... ....... ....... . . . . . .............. . . . .. .. .... . .. 7-

2

Alternator and regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 9 Vacuum pump . ...•. ..... .......... ....... .............. ...... ......... ......... . ... 7-32

Glow plugs ..... . ....................... . . . ............................ . . ...... .... 7-33 Control resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

I


r' ' '

7-2 ELECTRICAL SYSTEM

STARTER MOTOR IOENTIFICATION OF UNIT OR EQUIPMENT Nippondenso starter motor is identified with the name plate attached to the yoke as illustrated.

mI [

El

NIPPONOENSO CO. l TO A B C 0

: : : :

Dl

el l

l

I

lsuzu part no.

_j

A 8

1-81100-169-0

I

M anufacturer's code no.

!

0 28000-6640

JAPAN

lsuzu part number Manufacturer's code number Rated voltage Manufacturer's production mark

MAIN OATA AND SPECIFICATIONS

I

lsuzu part no. Manufacturer's code no .

028000-6561

Rated voltage Rated output Rating Direction of rotation As viewed from pinion side Type of clutch Terminal voltage: (No load) No-load current : Max. Number of revolutions : Min : (No-load)

'.

1-81100·169·0

(V) (kW)

(Sec.)

12 2.5 30 Clockwise Roller

{V)

(A) (rpm)

--~--~------~~~r-----

11

170 3,800

Pinion gear Module Number teeth Outside diameter Distance of travel

mm(in.) mm(in.)

11 40.5 (1.59) •) .81 (0.032)

Yoke Outside diameter

mm(in.)

90 (3.54)

Armature Outside diameter

mm(in.)

60 (2.36)

----------------------~-+----------------------------------

Number of poles

4

Brush length Standard limit

mm( in.) mm(in.)

20.5 (0.79) 13.0 {0.51)

Bush springs Standard fitting load

kg(lbs.) kg (lbs.)

3.4 (7.5)

Outside diameter Standard Limit

mm(in.) m m(in.)

36 {1.42) 35 (1.38)

Run-out Standard Li mit

mm(in.) mm(in.)

0:)5 (0.0020) 0.4 (0.016)

Depth of undercut mica Standard Limit

mm(in.) mm(in.)

0.5-0.8 (0.02-0.03) 02 (0.0078)

Com mutator

:'

------------------------r---------------------------

II., Collated to support AULRO.com - Australia's premier Land Rover Website!


TORQUE SPECIFICATIONS Manufacturer's code no. 028000·6561

kg·m(ft.lbs.)

0.27-0.47 (1.95-3.40)

J

.a.

T

0.7-1.2 (5.06-8.68)



RECOMMENDED LUBRICANTS

W

Grease of different types should never be blended, or characteri stics will be deteriorated.

Manufacturer's code no. 028000·6561

No.

Lubricating points

Recommended lubricant

Bilateral surface of drive pinion and idler and idler gear Teeth surface of gears Ball bearings 1 2 3 4 5

Felt washer Roller Retainer Steel ball Return spring

Nippondenso No. 50 grease Aeroshel l 1

(SHELL)

Aerosheii7A

(SHELL)

Beacon 325

!ESSO)



CIRCUIT ARRANGEMENT Manufacturer's code no. 028000·6561

BATTERY


7-6 ELECTRICAL SVSTEI\!I

!•l

f..

W

DISASSEMBLY

Note the following points when disassembling the starter motor:

1. To facilitate installation of the parts in original position, apply a setting mark across the yoke and magnetic switch body, and across the yoke and end frame. 2. When removing brush(+) on field coil side, raise brush spring, then remove the brush from holder. 3. Raise brush spring on brush holder side and pull the brush(- ) partway off the commutator and hold it in that position by setting brush spring against the brush. 4. If the housing, yoke or end frame is fitted tightly and does not come off easily, tap on the circumference of the parts lightly with a plastic hammer or soft-faced hammer.

Manufacturer!s code no. 028000-6561

13

~@

Disassembly steps 1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 11.

Nut Connecting lead Through bolt Screw End frame Covet Brush Brush holder Yoke Armature Felt washer

12. 13. 14. 15. 16. 17.

Lock plate Screw Housing Idler gear Retainer Roller 18. Clutch 19. Steel ball 20. Return spring 21 . Magnetic switch


---

--· ELECTRICAL SYSTEM 7-7

Important operation 21. Magnetic s witch (1) The hexagonal nuts on terminal bolts must not be loosened.

IL"ij'l


Make necessary correction or parts replacement if w ear, damage or any other abnormal condition are found through inspection.



W

l•!•l

REASSEMBLY


1. When installing rotating or sliding parts, check to make sure they operate smoothly before proceeding to the following steps. 2. When installing brush holder, exercise care so as not to cause damage to the brusht::>. 3. Properly align the setting marks applied to the yoke or end frame at disassembly before tightening. 4. Tighten fixing bolts, screws and nuts to the specified torques.

Manufacturer's code no. 028000-6561

17

Reassembly steps 1. Magnetic switch

12. Armature

2. Return spring

13. Yoke 14. Brush holder 15. Brush 16. Cover 17. End frame 18. Screw 19. Through bolt 20. Connecting lead 21 . Nut

3. Steel ball 4. Clutch 5. Roller 6. Retainer 7. Idler gear 8. Housing 9. Screw 10. Lock plate 1 1. Felt washer


----


ALTERNATOR AND REGULATOR

r

i

IDENTIFICATION OF UNIT OR EQUIPMENT ALTERNATOR Hitachi alternator is identified with the name plate attached to the rear end frame as illustrated.

~~~==~8==~11

II

D

'e'l

A

I ~

I

c

I

I~

I

lsuzu part no.

Manufacturer's code no.

5-81200-132-0

100210-1150

8-94175-448-1

LR170-401

IC REG BUILT IN Hitachi Ltd Japan A :

I

lsuzu part number

8 : Manufacturer's code number C : Rated voltage D : Manufacturer's production mark

REGULATOR 11

Hitachi regulator is identified with the mark printed on the cover as illustrated.

A

lsuzu part no.

Manufacturer's code no.

8 -94202-581-0

026000-2510

B

c II o e A: 8 : C: D:

lsuzu part number Manufacturer's code number Rated voltage Manufacturer's production mark

II



MAIN DATA AND SPECIFICATIONS ALTERNATOR Engine model

4801

4BD1T

lsuzu part no.

5-81200-132-0

8-94175-448-1

100210·1 150

LR170-401

12 40 850-10000 5000

12 70 1000· 11,000 5000

40/14/3500 14/820-1020

67/13.5/5000 13.5/1250

Clockwise

Clockwise

mm(in.)

Negative 90 (3.54)

Negative 82 (3.23)

l!l)

4.0 (0.16)

3.8 (0.15}

Brush length Standard Limit

mm(in.) mm(in.)

12.5 (0.49) 5.5 (0.22)

20.0 (0.79) 14.0 (0.55)

Slip ring diameter Standard Limit

mm(in.) mm(in.)

42.0 (1.65) 41 .6 (0.16)

34.6 (1.36) 33.6 (1.32)

8-94202·581 ·0 026000-2510

-

Manuf.,ctur er's code no. Rated voltage Rated output Operating speed Rated speed Rated output at r.p.m. No-load output at o Amp Direction of rotation as viewed from pulley side Polarity grounded Pulley diameter Coil resistance at 20'C Rotor coil

(Vl (A) (rpm) (rpm) (Amp.Nolt/rpm) (Volt/rpm)

Regulator's applicable lsuzu part no. Manufocturer'$ no.

REGULATOR Engine model

4801

lsuzu part no.

8·94202·581-0

Voltage regulator Regulated voltage Yoke gap Core gap Point gap

mm(in.) mm(in.) mm(in.)

13.7 - 14.3 0.2 (0.0078) 0.3 (0.0118) 0.3-5.6 (0.0118-0.220)

Relays Yoke gap Core gap Point gap

mm(in.) mm(in.) mm(in.)

0.1-1.0 (0.0039-0.039) 0 0.4- 1.2 (0.0016-0.0472)

M



Manufactuer's code no. Alternator

100210·1150

Combined regulator

026000·251 0

Alternator indicator light

I'

F

..,..

rI

N

_ _ ,_ j

E

Regulator

I

I

I I _L

l!

Manufactuer's code no. Alternator

LR1 70-401

_

0 .5J.IF

T I

_L

E I

E



TORQUE SPECIFICATIONS ALTERNATOR Manufacturer's c.o de no. 100210-1150 kg-m(ft.lbs..)


ELECTRICAL SVSTEM 7-13

Manufacturer's cod e no. LR170-401



SECTIONAL VIEW ALTERNATOR Manufacturer's code no. 100210-1150

l•!•l

DISASSEMBLV

GENERATOR

W


1. To facilitate installation of the parts in original position, apply a setting mark across the drive end f rame and rear end frame. 2. Clamp the rotor in vise when removing pulley nut. Use a soft-jawed vise to prevent to prevent damaging rotor assembly. 3. Keep insulation washers neatly in sequence of removal to avoid installing them in wrong position. 4. When disconnecting stator coil leads from rectifiers using a soldering iron, melt solder quickly and use long-nose pliers or equivalent to allow for heat dissipation.


ELECTRICAL SYSTEM· 7- 15



2. 3. 4. 5. 6. 7.

Pulley Pulley and fan Key Through bolt Rea r end frame Screw Retainer plate

....

8. 9. 10. 11. 12. 13. 14 .

Bearing lock nut Rotor Ball bearing Screw Cord cli p Nut Insulator

15. 16.

17:

18. 19. 20.

Terminal Drive end frame Stator Brush holder Insulator Rectifier

Impo rtant operation 8 . Bearing lock nut Remove b earing lock nut by turning clockwise. The loci< n ut has left-hand t hread.



n~l


Make necessary correction or parts replacement if wear, damage or any other abnormal condition are found through inspection.

l•!•l

REASSEMBLY

ALTERNATOR

w

Note the following points when reassembling the alternator:

1. When connecting stator coil leads to recti~ier using a soldering iron, solder quickly and use long-nose pliers or equivalent to l!llow for heat dissipation. 2. When installing terminal bolts and rectifier fixing nuts, be sure insulation washers are in place.

3: When fitting the rotor slip ring under the brushes hold the brushes in raised position by fitting a piece of hard wire into guide-holes in the drive and frame or rear end frame. 4. Install a guide bar through holes in drive end frame and rear end frame for alignment of setting marks, then install through bolts. 5. Tighten fixing bolts, screws and nuts to the specified torques.




..

I

Reassembly steps 1. 2. 3. 4. 5. 6.

7. 8. 9. 10.

Rectifier Insulator Brush holder Stator Drive end fram;! Terminal Insulator Nut Cord clip Screw

Ball bearing Rotor Bearing Jock nut Retainer plate Screw Rear end frame Through bolt 18. Key 19. Pulley and fan 20. Pulley nut

11 . 12. 13. 14. 15. 16. 17.


7-18 ELE€TRICAL SYSTEM

SECTIONAL VIEW ALTERNATOR Manufacturer's code no. LR170-401

l•!,.l

DISASSEMBLY

GENERATOR

W


1. To facilitate installation of the parts in original position, apply a setting mark across the drive end frame and rear end frame . 2. Clamp the rotor in vise when removing pulley nut. Use a soft-jawed vise to prevent to prevent damaging rotor assembly. 3. Keep insulation washers neatly in sequence of removal to avoid installing them in wrong position. 4. When disconnecting stator coil leads from rectifiers using a soldering iron, melt solder quickly·a nd use long-nose pliers or equivalent to allow for heat dissipation.


ELECTRICAL SYSTEM 7- 19

l•!•l

DISASSEMBLY

Manufacturer's code no. LR170·401

3

------~...----

14

==""""?I==® 4

2

Disassembly steps ..t. 1. ..t. 2. ..t. 3. ..t. 4. ..t. 5.

6. 7. 8. 9.

Vacuum pump assembly Through bolt Pulley and rotor assembly Rear cover and stator assembly Pulley nut Pulley Fan Spacer Rotor

10. 11 . 12. 13. ...t. 14. ..t. 15. ..t. 16. 17.

Rear ball bearing Bearing retainer Front ball bearing Front cover Rear cover Stator and diode assembly Diode assembly Stator


7- 20 ELECTRICAL SYSTEM

Important operations 1. Va cuum pump assembly Rem ove the vacuum pump fixing bolts. Hold the center plate and remove the vacuum pump in direction in line with the rotor shaft.

Remove the center plate by t urning it, then remove t he rotor and vane in the order mentioned.

2. Through bolt

I

i t(

Remove the through bolts and separate the body into front and rear sections. When separating, exercise care so as not to allow stator coils to come off the rear cover.

I 3. Pulley and rotor assembly 4 . Rear cover and stator assembly

Take care not to damage the oil se al when removing the rear cover. Taping the splines will provide some protection.

5. Pulley nut Clamp the rotor assem bly in a vise and rem ove th e pulley nut, then remove the pulley, front cover and rotor.

-


ELECTRICAL SYSTEM 7-21 14. Rear cover 15. Stator and diode assembly Remove the nuts fixing the B terminal and diode holder, then remove the screw inside the stator. Separate the stator and rear cover. Note. the position of insulation washers to insure reassembly into original position.

16. Diode assembly Separate the diodes from the stator by melting away solder on stator coil, diode and "N" terminal leads. When melting solder, hold the lead wire with longnose pliers to prevent heat from being transferred to the diodes.



INSPECTION AND REPAIR Make necessary correction or parts re!'llacement if wear, damage or any other abnomal condition a·r.e found through inspection.

ROTOR ASSEMBLY Visual check Make necessary correction or parts replacement if wear, damage or any other abnomal condition are found through inspection.

Measure the outside diameter of the slip rings. mm(in.) Standard

Limit

34.6 (1 .362)

33.6 (1.323)

Continuity test Check the rotor coil resistance across the slip rings. If no continuity exists, replace the rotor.

Ground test Check for continuity across the slip ring and rotor core or shaft. If a continuity exists, the parts should be replaced. Check front and rear ball bearings for abnormal noise and binding. Replace as necessary.



STATOR COIL ASSEMBLY Continuity test Check for continuity across the stator coils. If no continuity exists. replace the coils.

Ground test Check for continuity across one of the stator coils and stator core. If a continuity exists. replace the coil.

L_ BRUSH Measure length of brushes. Brush length mm(in.) St andard

Limit

20 (0.787)

6 (0.24)

Brushes are provided with a line whrch indicates the limit of usage.

DIODE Check for continuity across the terminals (example: across BAT and U). If a continuity exists the dio.de is in satisfactory co.ndition. If no con tinuity exists the diode is defective. Make a test wi th the polarities reversed. If no con tinuity exists the diode is in satisfactory condition. If a continuity exists at any point, the diode is defective and should be replaced. Auxiliary diodes are not provided with the terminal and a continuity test should be made across the terminals of the conventional diodes.


7-24 ELECTRICAL SYSTEM U. V.W. indicate stator coil Jesd terrninols

Across terminals Tester pin v.v.w. Positive side Negative side

B.A.T. (Positive side(+) diodes) Positive side Negative side No continuity Continuity

Across terminals Tester pin Positive side V.V.W. Negative side

E (Negative side(-) diodes) Positive side Negative side Continuity No continuity

O ire<:t10n of

flow of current

IC REGULATOR Measuring instruments to be prepared.

MN.wtfno i:tlstn~tnen~ lO o. pteoetW

Battery standard voltage

12V • Anluor noon. 3W) . .. . ... . , . . . R, • Vtritblt' r•sin or

•o- 3000, 12Wl .

Rv

12V, 2 pes

•atntry (12V. 2.ocd ........ , . . .. 8AT 1 • 8AT1 • OCYOIQ9t~1., (0 ..: SOV) .. .. V 1 •

v,

20V- 26V

Take the following measurements with the instruments connected as shown in the illustration. V2: Measure the voltage across the terminals E- Fwhile

varying resistance gradually from zero using variable resistor. Then check that abrupt voltage increase from less to more aro und 2V. If increase in voltage is interrupted at any point, replace the regulator. V1: Measure the voltage across the terminals LIS - E

w hile varying resistance gradually. from zero using variable resistor. Then check it when voltage increase abruptly by 2 6V.

Standard voltage at 2o·c (68"FJ (V)

14.4-15.0

If measured value deviates from the standard, replace the regulator.


ELECTRICAL SYSTEM 7-25 Change connection of the instruments as illustrated. V1: Measure the voltage across the terminals B/L - E while varying resistance gradually from zero using variable resistor. Then check it when voltage increases abruptly. Standard voltage at zo•c (68.F) (V)

14.9-16.5

If measured voltage deviates from the standard value, replace the regulator.

VACUUM PUMP Visual check

Inspect the following parts for wear, damage or other abnormal conditions.

Measure the length of vanes. Standard

mm(in.)

12.5- 13.5 (0.492-0.531)

Measure the inside diameter of housing. Standard

mm(in.)

Js7.0- 57.1 (2.2440-2.2441)


7-26 ELECTRICAl SYSTEM

CHECK VALVE Apply a light pressure onto the valve with a screw driver and check that valve operates smoothly.

OIL SEAL Inspection

Che9k inner face of the rear cover for traces of oil leakage. Also check inner face of the oil seal for wear or damage. Replacement

1. Using a screw driver, remove oil seal from rear cover side.

2. Install a new oil seal using oil seal installer.

Oil seal



l•!•l

REASSEMBLY

ALTERNATOR

W

Note the follow ing points when reassembling the alternator:

1. When connecting stator coil leads to rectifier using a soldering iron, solder quickly and use long-nose pliers or equivalent to allow for heat dissipation. 2. When installing terminal holts and rectifier fixing nuts, be sure insulation washers are in place. 3. When fitting the rotor slip ring under the brushes hold the brushes in raised position by fitting a piece of hard wire into guide holes in the drive and frame or rear end frame. 4. Install a guide bar through holes in drive end frame and rear end frame for alignment of setting marks, then install through bolts. 5. Tighten fixing bolts, screws and nuts to the specified torques.



l•!•l

REASSEMBLY

Manufacturer's code no. LR170-401

15

14

16

Reassemply steps

...

... ...

,.

Stator 2. Diode assembly 3. Starter and diode assembly 4. Rear cover 5. Front cover 6. Front ball bearing 7. Bearing retainer 8. Rear ball bearing 9. Rotor

10. 11 . 12. ... 13. ... 14.

Spacer Fan Pulley Pulley nut Rear cover and stator assembly ... 15. Pulley and rotor assembly .... 16. Through bolt 4 17. Vacuum pump assembly



Important operations 1. Stator

2 . Diode assembly When connecting stator coil leads and diode leads using solder, use lohg-nose pliers and finish .t he work as quickly as possible to prevent the heat from being transferred to the diodes.

8. Rear ball bearing

The dowel of the rear side bearing protrudes from the outer ring, as the ring is mounted on the eccentric groove of the outer ring. Upon assembling, rotate the ring to.a position where this protrusion is at. a m inimum. then assemble the ring. Limit

mm(in.)

0.65 (0.0256)

In addition, inspect the bearing of the rear cover. Should any irregularity be present, replace the rear cover at the same time.

13. Pulley nut Clamp the rotor in a vise and install the pulley nut. Torque

kg•m(ft.lbs.)

4.5-6.0 (33- 43)

14. Rear cover and stator assembly 15. Pulley and rotor assembly Position the projected portion of ring on the bearing so that the projection becomes minimum.


7-30 ELECTRICAL SYSTEM Install the. pulley and rotor assembly holding the brush pushed-in with a pin. Then remove the taping of splines:

16. Through bolt Place a guide bar through the holes in front cover and rear cover flange for alignment, them install the through bolts.

17. Vacuum pump assembly Position the rotor, with the serrated boss turned up, on the center plate and housing. Align the holes in center plate and rotor. Install vanes into slits in rotor. The vanes should be 'nstalled with round side turned outward.

After installation of O·ring, install the center plate by turning it.

If the holes in housing and center plate are not in alignment, adjust by turning the housing slowly.


ELECTRICAL SYSTEM 7-31 Install and fix the housing to the generator using 3 volts. Pour engine oil (pee or so) in through the filler port, then check that generator pulley can be turned smoothly with hand.


7-32 ElECTRICAL SYSTEM

VACUUM PUMP GENERAL DESCRIPTION This illustration is based on the 4801 engine.

Rotor

Vane

\ MAIN DATA AND SPECIFICATONS Engine model Pump type

Oil-cooled vane type pump

Theretical derively Maximum allowable speed Direction of rotation Weight

4BD1T

4801

cc/rev.(in3 / rev.) (rpm)

31 (1.89)

10,000

30 (1.83)

·I

11,000

Clockwise as viewed from coupling side kg(lbs.)

2.2 (4.85)

0.9 (1.98)



GLOW PLUGS MAIN DATA AND SPECIFICATIONS lsuzu part no.

5-81410-023-0

Rated voltage Rated current Time taken before

8oo·c is reacned

(V) (A) (n)

10.5 6 - 7.5 1.8

(Sec.)

20-25

CONTROL RESISTOR MAIN DATA AND SPECIFICATIONS lsuzu part no. Rated voltage Rated current Internal resistance

9-8253-0041-0 (V} (A) (n)

12

26 0.028- 0.032

Time taken before 8oo•c is reached

{Sec.)

20 - 25

lnsulaton resistance Saturation temperature

{Mn)

1 or higher 1000 or lower

("C)


AUXILIARIES 8-1

SECTION 8

AUXILIARIES (POWER STEERING OIL PUMP)

CONTENTS

PAGE

General description ........................................... . ....................... 8-2 Main data and specification ............................................................ 8-2 Disassembly .......................................... . ....... . ....................... 8-3 Inspection and repair ... . ..... . . ...... .. .. ..... ...... .................................. 8-4 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5


8-2 AUXILIARIES

GENERAL DESCRIPTION

MAIN DATA AND SPECIFICATION Item Pump type

(V)

Theoritical delivery volume

cc/rev.(in 3 /rev)

Relief valve preset pressure

kg/ cm 2 (psi)

Preset delivery volume

liter/min.(UK gallon/ min)

Centifugal vane 12.2 (0.732)

85 (1208) 8 (1.8)

at 200 r pm Pump operating speed Pump to crankshaft speed ratio to 1 W eight (dry)

(rpm)

450-4000

0.89 \25/28) kg(lbs.)

4.3 (9.48)


AUXIUARIES 8-3

l•!•l

DISASSEMBLY

5

Disassembly steps 1. Outer connector and 0-ring

10. Side plate

2. Plug and 0-ring

11. 0 -rings 12. Spring 13. Snap ring 14. Shaft with bearing 15. Snap ring 16. Collar 17. Oil seal 18. 0 -ring 19. Body

3. Relief valve 4. Spring 5. Gear 6. Cover 7. 0-ring 8. Cartridge assembly 9. Knock pin


8-4 AUXILIARIES

Important operations 14. Shaft with ball bearing Use a mallet for remov.al.

17. Oil seal Use a suitable brass drift.

IL'O'I INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection.

Bearing replacement procedure Removal: Remove the snap ring and then, remove the bearing using a bench press and a suitable rod:

Installation: Use a bench press and a suitable rod .


AUXILIARIES 8-5

j..!.-j REASSEMBLV

Reassembly steps 1. .2. 3. 4. 5. 6. 7. 8. 9.

Body 0 -ring Oil seal Collar Snap ring Shaft with bearing Snap ring Spring Oil seals 10. Side plate

11 . 12. 13. 14. A 15. 16. 17. 18. 19.

Knock pin Cartridge assembly 0-ring Cover Gear Spring Relief valve Plug and 0-ring Outer connector and 0 -ring


8-6 AUXILIARIES

Important operation 15. Gear Torque

kg·m(ft.lbs.)

8- 10 (58- 72)


SPECIAL TOOL LIST 9-1

SECTION 9

SPECIAL TOOL LIST CONTENTS

PAGE

Special tool list ..... .. . .. . . .... . ... ............... .... . .......... ... .... ............. 9-2

I


9-2 SPECIAL TOOL LIST

ITEM NO.

!

ILLUSTRATION

i

PART NO. I

... -·

I

;

~

f.~' -::~

1

i 2

PART NAME

9-8523-1426-6 JKM-1033

:/ .

I

/

3

I

Valve guide remover & installer '

,,

~

4

Valve spring compressor

! 1-8522-0001-0 JKM-1019

.

!

I I

-.

--··

9-8523-1169-0 JKM-1021

Cylinder liner remover

9-8523-2557-0 +(EN-8) JKM-1022

Cylinder liner remover ankle

-

- -~~,,,,

9-8523-2554-0 JKM-1024

~

5

:

:;.1 'III

:

(%

6

9 -852 1 -0141~0

+ (OT-3) JKM -1026

try'

I

(Cg;;;)

7

Cylinder liner installer

Crankshaft gear remover

9·8522·0033·0 JKM-1027

Crankshaft gear installer

5-8840 -2000-0 + (OT·6) JKM-1026

Crankshaft pilot ::>earing remover

5-8522-0024-0 JKM-3035

Crankshaft gear installer

9·8522·1254·0 JKM-1028

Crankshaft rear oil seal installer

1

~

8

~. "'

I

.

~.

9

10

I

(~\ ! •, , • I'· J I ~t

l

i

-

~

'

I



ITEM NO.

ILLUSTRATION

11

@(]-.

12

~

13

w~

PART NO.

PART NAME

9-8522-0034-0 JKM-1029

Cronkshaft front oil seal installer

5-8840-0086-0 J KM-1035

Camshaft gear remover

9-8521-0063-0 JKM-3222

Crankshaft pulley remover

Crankshaft pulley remover

14

w~

9-8521-Q063-0 JKM-3222

15

~

1-85221 -005·0 JKM-1 030

Valve stem oil seal installer

9-8522-1251 ·0 JKM-1 102

Piston ring compressor

9-8521-0097-Q J KM-1031

Water pump impeller remover

a=-a

9-8522-1140-0 JKM -1032

Water pump bearing installer

51 JJ

1-85111-0030 JKM-1002

Cylinder head bolt wrench

~~

5-8840-2008-0 J-29762

Compression gauge

16

17

18

19

20

~

~


9-4 SPECIAL TOOL UST

I

ITEM NO.

ILLUSTRATION

PART NO.

·:

PART NAME

~

t II I~

21

5-8531 -7001.,.0 JKM-1018

lbl••

Compression gauge adapter

Ir

j

r.

~

l 22

1

9-8511-3703..() J KM-1017

Injection pump wrench

J-33895

ACG checker (Built-in IC regurator)

5-85253-001 -0 J-24547

Clutch pilot aligner

5·8840-2000-0 + (OT-7) J-5822

Crankshaft pilot bearing remover

5·8522-0024-0 JKM-3035

Crankshaft pilot bearing installer

5-8840-2058-o JKM-20580

Servo unit support plate

9-8523-1733-0 JKM-3250

Handle

9·8511-4307 -0 JKM-3146

Handle

5-8840-0Q1 9·0 J-23907

Sliding hammer (Small)

T~1 23

~1IJ

I; 1:

24

I

~

!·u• na ~.-.,

~I . I

25

I

26

I I··

27

'

28

'

~

~ 0

~ 0

i'

OT-3

/

1[:

::

OT-6

,~


.l

II


ITEM NO.

ILLUSTRATION

OT-7

~

PART NO.

PART NAME

5·8840·0084-0

Sliding hammer

J-2619-01

(Big)


TROUBLESHOOTING 10-1

SECTION 10

TROUBLESHOOTING CONTENTS

PAGE

Engine assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-

2

Lubricating system .. ...... ..... ........... . .......... ..... ... . .......... . ....... . . 10- 11

I


10-2 TROUBLESHOOTING

ENGINE ASSEMBLY HARD-STARTING Difficulty will not be experienced in starting a diesel engine provided sufficient power is supplied for cranking, compression pressure is sufficiently high, preheating system is operating normally and an appropriate volume of fuel is supplied. As an initial step for checking the cause of hard-starting, loosen the pipe joint at the nozzle end and see if fuel is being supplied. In some instances, il may be necessary to check nozzle spray conditions and fuel injection timing. If these checks do not disclose any problems, measure the compression pressure to determine the condition of valves and piston rings .. If the engine starts but stalls sudde,ly and can not be restarted, presence of air in the fuel system is likely. Engine startability is more or less affected by the environmental temperature conditons.

IHard-starting Checl< level of fuel in fuel tank against fuel gauge.

Check notched line on injection pump flange for proper alignment.

Check to see if fuel is reaching injection nozzles.

YES

NO

I

.c:> Chect< operation of pre· heating circuit.

0 Connections of fu$
Check injection nonles.

Fuel spray ~attern Fuel injection Slatting Pfeuure: 185kg/cm' (2631 psi)

CheCk valve clearances.

Intake valves: 0.40mm (0.016in.) Exhaust vallles: 0 .40mm (0.016in.l

I

Check to see if air in fuel filter has t>Hn removed eompletely.

Check to see if air is being drawn into fuel line· through leakage in pipe joints.

I Check operation o; en9ine S'Cop motor .

Check fuel filtel' element for restrictions. Check compreS$iOn pres· sure in eac.h cylinder.

Standard value: 31kg/cm' (441psi) Value indicating need for servicing:

22-23k em' (313-327

psi)

Check t1ming gears.

I Check fuel p1pes for restrictions. I Check delivery valv! for sticking.

Replace or readjust setting• of injection pump.



ENGINE IDLING ROUGH Lack of engine· power may be caused by insufficient injection volume, insufficient volume of intake air, lowered com pression pressure, etc. If the trouble is due to lack of volume of fuel injection, check fuel filter element for restrictions and fuel system for presence of air. If the above checks do not disclose any troubles, make a test on the fuel injection pump and governor, using a pump tester.* If the volume of intake air is inoufficient, check air cleaner element for restrictions and exhaust pipe(s) for clogging.

I

Lack of engine power

j

0 Check air cleaner !or restrictions.

Cheek accelerator el.lntrol cable for binding or twisting.

Checl< seal• on max;mum speed stop bolt and full load adjust bolt.

Check to see if accelerator control lever is in contaCt with maximum weed stOP bolt.

Check exhaust muffler and oip" for r~trict ions.

Chec1< to see if air has been removed eomoletely from fuel filter.

Check fuel p;pes for being collapse or loose connect;ons.

Check fuel tank breather for restrictions.

Check to tee if fuel in use i.s

l

i nferi~

Check injection timing.

in Quality .

I Fuel spray patterns Fuel injection start;ng pr8$sure: 185kg/cm' (263 1 psil

I Check injection nozzles.

Inta ke valves: 0.40mm (0.011S ;n.J Exhaust valves : 0.40mm 10.016 ;n.J

Check valve clearances.

Standard valut: 31 kg/em' (441ps;) Check compression pressure in each cylinder.

Value indieating need for setVicing :

22-23kg/cm 2 (3 13-327 psi)

Check delivery vatve for sticking,

J

: Readjust• or replace injection pump. l



ENGINE LACKS POWER Rough engine idling can cause engine surging and sudden engine stalling at quick deceleration. If the engine operates normally at medium and high speeds, perform diagnostic checks on the injection pump and related components, then check engine idling speed. Engine hunting may be caused by too low an idling speed, rough plunger operation, over-tightened delivery valve holder, etc. If the engine stalls at quick deceleration, idling speed might have been cot too low.

j Engine idling unstable

I

Check to see if idle speed Is lower than specified range.

On moclels with air conditioning. check operatton of fast idle control device.

Check accelerator control cable for binding or twisting.

I.

Check setting of accelerator lever for looseness.

! Chec:k to see if air or water in fuel filter has been removed eompletely.

Check notched line on injection pump fla1ge for proper alignment .

Check engine mounting for loosening or cracks.

J

Check injection noxa les.

I

I

Nozzle spray pattern Injection starting pressure: 185kg/cm' (2631 psi)

0 Check valve clearances.

!

Intake valves: 0.40mm (0.016 in.) Exhaust valves : 0.40mm (0.016 in.)

Chec\< variance in compression preuure in eylinders.

I

Standard value: 31kgfcm' (441psi) Value indicating need for servicing: 22- 23k

Check: timing gear train for faults.

I Check delivery vatve for sticking, j Readjust'• or raptace injection pump.



DARK OR WHITE EXHAUST SMOKE A considerable amount of dark smoke in the exhaust gases is due to incomplete fu el combustion caused by excessive volume of fuel injection, insufficient volume of intake air, poor spray condition, excessively advanced injection timing, etc. To determine the cause, check seals on the injection pump, check compression pressure, condition of air cleaner and injection nozzle spray conditons, then check fuel injection timing.

Cheek to see if engine is thoroughly wormed up.

I Check air cleaner for restrictions. I

Check to see if air or water has been removed completely from fue l filter.

Check sealing on fu11 load adjust bolt.

Check exhaust muffler and pipes for restrict ions.

Cheek to see if fuel in use

i~

inferior in Quahty.

~eck injection timing.

D J

Check injection noz.z tes.

j

<....>

.---- -- - - - . Check valve clearances.

Fuel spray pattern

Injection starting p.e.,..re : 185kg{crn7 (2631 psi)

l

,.------ ·------~

I

Intake valves : O.«lmm (0.0 16 in .I Exhaust va1ves:0.40mm (0.016 in.)

C~ck compression pressure in each cylinder. I

Standard value : 3 1 kg/em' (441 psi) Value indicating nood for servicing :

22- 23
Tim ing gear installat ion. )

Check delivery valve for stick ing ,

Ch.:;;·eondition of valve guodes and sea ls.

Rcadjus-:. • or

repl~e injectio n pu mp.

I

I


10-6 TROVBLESHOOTING

ENGINE OVERHEATING When lpcating :the cause of engine overheating, it is necessary to find whethef the engine is actually overheating or the· temperature gauge is giving a false indication. To determine the true cause, measure the temperature of engine coolant at the upper part of the radiator with the engine running and compar.e the measured value with the reading of the temperature gauge on the instrument panel to check the accuracy of gauge indication. Then check the following causes. sterting with the item which can be checked easily. Common causes of engine overheating will be as follows when listed in sequence of frequency: Leakage of coolant from water pump, radiator and hoses which causes a reduction in coolant level,. defective-thermostat, formation of scales in water passages. etc. Leakage of gases into cooling water circuit due to defective gasket, excessive volume of fuel injection, incorrect injection timing, deposit of carbon within the combustion chambers are but some of-the causes of engine overheating which are often overlooked.

I Engine overheating j 0

I Check le""l of coolant in radiator. 0 I

Contamination. ratio of anti-freeze in water.

Check condition of coolant.

Leakage of oil into coolant.

0

I Check h05es for leakage. I

Deteriorated hoses. loosened cliPS.

0 I Check water pump for teakage.

0

I Check cylinder head gasket for damage. I

I

I

0 Check fan belt tension.

I I

0 Check operation of fan clutch.

Deflection : Approximately li:>mm .jQ,4 in.)

I

0

I Valve opening temperature: 82-:. C f

I Check ope ration of ther.moStat. I I

Check injection ·timing.

Notched line, O.Smm 10.02 in.) on measuring dev ice• at 10 degrees: BTDC except California model or 6· degrees BTOC for·Califomia model.

I

0

Fuel spray pattern

I Check injection nozzles. I

Injection starting pre$$ure: 185kg/cm• (2631 PSil

0 I

Check condition of water pump impeller. !

Check quality of oil in P.ngi nt!.

I

0

Readjust • or re,;:>lace injection pump.



ENGINE NOISY Abnormal noise of engine includes knocking sound, piston slap, etc. Engine knocking is a result of rapid fuel combustion and is due mainly to excessively advanced fuel injection timing or detriorated fuel spray conditions. Engine may produce slight knocking immediately after starting which normally diminishes as the engine temperature increases. If engine produces a continuous noise, systematic checks are usually periormed to determine the source of the noise, and noise from the auxiliaries such as generator, water pump, etc. can be shut-off by removing the belt to make checks on the engine easier. If the engine produces slapping noise such as piston slap, piston pins and connecting-rod bearing noise, cylinder from which the noise comes can be checked by interrupting flow of fuel with the injection pipe joints loosened in sequence. Engine crankshaft noise can be dia~nosed by moving the clutch pedal in and out. If noise is caused by crankshaft movement, noise will change as the clutch is operated.

Abnormal engine noite

I

~-----------~ Noi M i ndiceting ges leekege

Entine knoekini

I

I

-o

I

I

Continuout f\oi•

I

-o

0

Check to -

if engine has been thoroughly warmed up.

ICheek injection timlng.

Check exhaust pipes for loose eonnec~ons

I

0

Check fan belt tension,

Check valve elearnnc:es.

Deflection: Appro•imately 10 rnm (0.04 i n.)

Intake valves: 0.40mm (0.016 in ,) exhaust valves: 0.40rnm f0.016 in.)

or leakage.

Check installation of nozzle$ and glow olugs . j Check cooling fan for looseness.

0

Cf'ledc injcc.tion nou·le$,

Check cylinder head gasket lor damage

Fuel spray pattern

I Check rocker arm$ tor damage,

-o

Injection starting pre$Sure: 185kg/cm1 (263 1P
Check flywheel fixing bolts for

1oos.eneu.

Check compression pressure in each eytindttr. Stenderd value: 31kg/em' (441P
tntak.e " atv~s : 0.40mm 10.016 in .) Exh3'Ust va tves: 0.40mm (0.016 in.)

Chedt operat•on of generator and vacuum oumP.

Check crankshafts and thru•t bearing for wear or damege. Cheek valve clearances.

Check compress1on pressure in each cylinder.

Intake valves: 0.40mrn

Check main bearing oil c lear-

10.016 in.l

ances

Exhaust valves: 0.40mm

(0.016 in.) Check to see tf fuel in use i.s in fertor in quality,

4

Rt:adju.st• or replace injection pump.

Standard value : 31kg/cm' (441psil Value indicating need for servi~· ing: 22-23kg/em 1 (313-327 psi)

Check eoronecting·rod beO
oil clearances.

Check wnnecting.rod bushing

oil ctearanees.

Ch~ek

clearance be~n pistons

and cylinder walls.



EXCESSIVE ENGINE OIL CONSUMPTION It is necessary to find under which driving conditions the rate of fuel consumption is registered before f ollowing the diagnosis procedure since the fueJ.consumption varies greatly w ith the driving habits, load the vehicle carries and general condition of the roads and streets. As a first step check the air clean er and exhaust muffler for restrictions, then check the compression pressure in the cylinders. Road test the vehicle to see if the engine operate.s normally, giving reasonable acceleration. If the results of road t est are satisfactory, trouble in the fuel system is suspected. To determine th e condition of the fuel system, check fuel spray condition and inje(;tiun :starling pr~ssure using a n ozzle tester.

Fuel consumption excessive

[

C~~c~ air cle<;Jncr for n~str~c~SJ ,---,

....;....__,...>' ·~

Ch~t:k s~il l CHt lu ll

load <)Cjust in; b oJt .

J

-Q I Check tuel~ipes for 1~

,0

L

Check

en~ine idling $peed,

I

~J. jcht!ck. to see if

fut:110-~-~e )S in1erior in -~:~~itv. ·(..) ..

r-C~'eck

injection t iming.l

D ~inJecti~ nOZlleS. I

,c;.

I Cneck vaJve clearances j

F-uei .SJ)ray Pat tern

lniection .starting pressure: 185Kg,•'C'n° (263rps.·)

---

- - - - - - -- ,

Intake valves: 0.40mrn (0.016 mJ E)(haust valves : 0.40mm (0.016 in.)

I Cneck c:ompressi~~-~~-;n-.,-.a-c_h_c_y_lin_d_e_r.'] 0

Standard value: 31 i
22- 23kgjcm' (313-327 psi)

Chec:;k dcliv~ry valve for sttck ,ng.

I

Readjust• or replace injection pump. ,



EXCESSIVE FUEL CONSUMPTION M ajor causes of excessive oil consumption include external oil leakage, oil buming and internal leakage of oil past the piston can be detected with relative ease through visual checks. To find whether oil is burning or leaking past the piston, start and let the engine idle for a few minutes, then check with the cylinder head removed. Oil burning is indicated by the traces of oil around the circumference of pistons. A trace of oil is normally found around the valve head£is localized to :hat area when internal oil leakage is present.

I

Oil consumption excessive

0

I

Oil !eating

I

I

I

I

I

Oil burning

0

I

Check oil le""l.

ICh~ck I

0 Check Quality of oil in engine.

I

drain plug for looseness.

Check oil p ipos for leak-.

I

I

I ChKk

Check valve stem oil seals.

valve guides and vatve stems for wear.

Check oil seal retainer and oil filter seat gasket for 1eakage.

I Cheelc setting of pi.ston rings.

Check rubber gaskets in cylinder head cover, oil pan and oil pump for leakage.

I

I

Check piston rings for wear.

Check cylinder head gasket for leakage.

I

Check o il seal for leakage.

l

Check piston ring grooves in pirtons f()( wear.

I

O>eck cylinder walls for wear o r scuffs.


I

I


LUBRICATING SYSTEM Cause

Complaint Oil consumption too high

Oil pressure too low

Oil deteriorates quickly

Oil does not reach valve system

Correction

Use of w rong oil

Drain and refill with specified oil

One-way valve leakage in PCV system

Clean or ·eplace one-way valve

Oil seals for gaskets defective

Correct

Piston rings or ring grooves worn

Replace piston rings or pistons

Piston rings sticking

Replace piston rings or pistons

Valve stem oil seals, valve guides or valve stems worn

Replace oil seals, valves or valve guides

Cylinder bores worn

Rebore cylinders

Use of wrong oil


Relief valve sticking

Replace relief valve

Obstruction in oil pump gauze filter

Clean or replace gauze filter

Oil pump driven and drive gear worn

Replace oil pump assembly

Oil pipe cracked, broken or loosely connected

Correct or replace

Oil pump defective

Replace oil pump assembly

Crankshaft bearings or connecting-rod Bearings worn excessively

Replace

Oil pressure gauge defective

Correct or replace

Obstruction in oil filter

Replace filter cartridge

Gases lea(ing

Replace piston rings or rebore cylinders

Use of wrong oil


Oil ports in cylinder block and cylinder head clogged

Clean or correct

Oil ports in rocker arm shaft clogged

Clean or correct

Oil ports in rocker arm shaft brackets clogged

Clean or correct

Oil ports in rocker arms clogged

Clean or correct



COOLING SYSTEM Complaint

Cause

Correction

Cooling water level too low

Replenish, check for leakage and correct as necessary

Radiator cap pressure valve spring weakened

RepiGice filler cGip assem bly

Fan belt loosened or broken

Adjust or replace fan belt

Fen belt slipping

Replace fan belt

Thermostat defective (valve not opening)

Replace thermostat assembly

Water pump defective

Replace water pump assembly

Obstructions in water passages due to accumulation of scale

Clean radiator and water passages

Injection timing incorrect

Adjust injection timing correctly

Obstructions in radiator core

Clean exterior of radiator

Gases leaking into water jacket due to broken cylinder head gasket

Check cylinder head and replace gasket

Engine over-cooling

Thermostat defective (valve not closing completely)

Replace thermostat

Frequent replenishment is needed

Radiator leaking

Correct or replace

Radiator hoses loosely connected or damaged

Retighten clips or replace hoses

Radiator cap valve spring weakened

Correct or replace filler cap assembly

Water pump leaking


Heater hoses loosely connected or broken

Retighten or replace hoses

Cylinder head gasket leaking

Check cylinder head and replace gasket

Cylinder head or cylinder block cr acked

Replace cylinder head or cylinder block

Water pump bearing defective


Fan loosely fitted or bent

Retighten or replace fan assembly

Fan out of balance

Replace fan assembly

Engine overheating

Cooling system noisy

Fan belt defective

.

Replace fan belt


CONVERSION TABLES 11-1

SECTION 11

CONVERSION TABLE PAGE

CONTENTS

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 Volume ....... " ............ . ........ .. ..... . ... ....... ... . ....................... . 11-3 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

LENGTH MILLIMETERS TO INCHES mm 1 2 3 4 5 6 7 8 9 10

,,

12 13 14 IS

16 17 18 19 20 21 22 23 24 25

in.

0 .0 394 0.0 787 0 .1181 0.1575 0.1 969 0.2362 0 .2756 0 .3150 0.3543 0.3937 0.4331 0.4724 0.5 118 0.55 12 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

so

INCHES TO MILLIMETERS

mm

in.

mm

ln.

1.0236

51

l ,OtiJV

52

53 54 55 56 57 58 59 60 61 62 63 64

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

1.1 0 24 1,1417 1.1811 1.2205 1.2598 1.2992 1.3386 1.3780 1.4 173 1.4567 1.4961 1.5354 1.5748 1.8142 1.6535 1.6929 1.732 3 1.7717 1.8110 1.8504 1.8898 1.9291 l ,9665

2.0079 2.0472 2.0866 2.1 260 2. 1654 2 .2047 2 .2441 2.2835 2.-3228 2.3622 2.4016 2.4409 2.4803 2.5 197 2.559 1 2.5984 2.6378 2 .6772 2.7165 2 .7559 2.7953 2.8346 2.8740 2.9134 2.9528

in.

6! 6~

67

68 69 70 71 72

73 74 75

1/64 1/ 32

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

3164 1{16 S/ 64 3/32 7/64 1!8 9/64

101

3.9764 <1.0 ·1S7

103 104

4.0551 4.0945 4 .1339 4,1732 4.2126 4.2520 4 .2913

lOS

106 107 108 109

fll 11 2

113 114

11 5 116 117 118 119

4.3701 44094 4 ,4488 4.4882 4.527G 4.5669 4.6063 4.6467 4.6850

121 122 123 124 1 ~5

1~6

127 128 129

4.7638 4.8031 4 .8425 4 .8819 4.9213 4.9606

s.oooo 5.0394 5.0787

131 132 I 33 134 135 136 137 138 139

5 .1575 5,1968 5.2362 5.2756 5.3 150 5 3543 5.3937 5 .433 1 5.4?24

11/84 3i16 13/64 15/64 1/4 17/ 64 9/32 19/ 64 5116 21164 11/32 23/64 318 25164 27164 7118

5 . ~ 594 5.S563 5.9531 6.3500 6,7469 7.1 4 38

17132 35164 9.'16

37164 19/32 39/64 5!8 41 / 64

29/64

11.50~4

31/64

1 UI063 12.3031 14.7000

15132

21132 43/ 64 11116 45164 23132 47.'64

3 14 49/64 25/ 32 5 1/64

7.~406

7.3375 83344 8.7313 9.1281 95250 99219 10.3188 10.7156 11 .1125

mm

33/64

4.$656 4.7625

7132

1/2

0.3969 o .7n8 1,1306 1.5675 1.9844 2.3813 2.7781 3.1750 3.5719 3 .~688

5/32

13132 102

...

mm

in.

13116 53164 27132 56/ 64 718 5716" 29132 59/6<1 15/ 16 0 1/ 04

24.2094

63/54

24.6063 25.0031 25.4000

31!32

,

13.0'9 69 13.4938 13.8906 14.2875 14.6844 15.0813 15.4781 15.8750 16:271 9 16.6688 17.0656 17.4625 17.8594 18.2563 18.6531 19.0500 19.4469 19.8438 20.2406 20.6375 21.0344 21.4313 21.8281 22.2250 22.6219 23.0 188 23.4156 23.8125


11-2 CONVERSION TABLES LENGTH FEET TO METERS ft.

0

1

2

3

4

5

6

7

8

9

m

m

m

m

m

m

m

m

m

m

3.048 6 .006 9. 144 12.192 15.240 18.288 21.336 24.384 2 7.432 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 2 1.946 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

1.2 19 4 .267

1 .524 4.572 7.620 10.668 13.716 16.764 19.812 22.860 25.908 28.956 32.004

2.134 5.182 13.230 11.278 14.326 17.374 20.422 23.470 26.518 29.566 32.614

2 .438 5.486 13.!134 11.582 14.630 17.678 20.726 23.774 26.822 29.870 32.9 18

7

8 ft. 26.2467 59.0551 91 .8635 124.6719 175.4803 190.2887 223.0971 255.9055 288.7139 321.5223 354.3307

10 20 30 40 50 60 70 80 90 100

I

7.31S

10.363 13.411 16.459 19.507 22.555 25.603 28.651 31 ,699

1.829 4.877 7 .925

10.973 14.02 1 17.069 20. 117 23.165 26.213 29.261 32.309

2.743 5.791

ft.

-10

11 .887 14.935 17.983 21.031 24.079 27.127 30. 175 33.223

20 30 40 50 60 70 80 90 100

9

m

6 .1339

METERS TO FEET m

0

1

2

3

4

5

ft.

ft.

ft.

ft.

ft.

ft.

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 10 1.7060 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 141.076 1 173.8845 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 49.21 26 82.0210 114.8 294 147.6378 180.4462 213.2546 246.0630 278.8714 311 .6798 344.4882

10 20 30 40

so 60 70 80 90 100

6 ft. 19.6850 52.4934 85.3018 118.1102 150.9186 183.7270 216.5354 249.3438 282.1522 314.9606 347.7690

ft.

22.9659 55.7743 88.5827 121 .3911 154.1995 187.0079 219.8163 252.6247 285.4331 318.2415 3 51.0499

ft.

-

29.5276 62.3360 95.1444 127.9528 160.7612 193.5696 226.3780 259. 1864 291 .9948 324.8032 357.6116

10 20 30 40 50 60 70 80 90 100

miles

MILES TO KILOMETERS miles

0

1

2

3

4

5

6

7

8

9

km

km

km

km

km

km

km

km

km

km

16.093 32.187 48.280 64.374 80.4 67 96.561 112.654 128.748 144.841 160.934

1.609 17.703 33.796 49.890 65.983 82.077 98.170 114.263 130.357 146.450 162.544

3.219 19.312 35.406 51.499 67.592 83.686 99.779 1 15.873 131.966 148.060 164.153

4 .828 20.921 37.015 53.108 69.202 85.295 101 .389 11 7.482 133.576 149.669 165.762

6 .437 22.531 38.624 54.718 70.811 86.905 103.000 119.091 135.185 151.278 167.372

8.047 24. 140 40.234 56.327 72.420 88.514 104.607 120.700 136.794 152.888 168.981

9.656 25.750 41 .8 4 3 57.936 74,030 90.123 106.217 122.3 10 138.404 154,497 170.590

11.265 27.359 43.452 59.546 75.639 91 .733 107.826 123.919 140.013 156.106 172.200

12,875 28.968 45.062 61 .155 77.249 93.342 109.435 125.529 141 .622 157.716 173.809

14.484 30.578 46.671 62.764 78.858 94.951 1 11.045 127. 138 143.232 159.325 175.418

10 20 30 40 50 60 70 80 90 100

km

10 20 30 40 50 60 70 80 90 100

-

KILOMETERS TO M ILES km

-

10 20 30

40

50 60 70 80 90 100

0

1

2

3

4

5

6

7

8

9

miles

miles

miles

miles

mites

miles

miles

miles

miles

miles

6.214 12.427 18.641 24.855 3 1.065 37.282 43.496 4 9.71 1 55.923 62.137

0.62 1 6.835 13.049 19.2.62 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 57.1 66 63.380

1.86 4 8.078 14.292 20.505 26.719 32.933 39. 14 6 45.360 51 .574 57.187 64.00 1

2.485 8.699 14.91 3 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..370 28.583 34.797 4 1.010 47.224 53.438 59.652 65.865

4.350 10.563 16.777 22.990 29.204 35.418 41.632 47.845 54.059 6o.273 66.487

4,971 11 '185 17.398 23.612 29.826

5.592 1 1.806 18.020 24.233 30.447 36.661 42.875 49.088 55.302 61.516 67.729

36.0~9

42.253 48467 54.681 60.894 67. 108


-10 20 :10

40 50 60 70 80 90 100

CONVERSION TABLE S 11 - 3 AREA SQUARE INCHES TO SQ UARE CENT IMETERS in2

-

10 20 30 40 50 60 70 80 90 100

0

1

2

3

om'

om•

em'

em%

64.5 16 129.032 193.548 258.004 322.580 387,096 451 .612 516.126 580.644 645.160

6.452 70.966 135.484 200.00) 264.515 329.032 393.548 458.064 522.580 587.096 651 .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 53 5.483 599.999 664.515

4 em' 25.806 90.322 154.838 219.354 ;a3.870 348.386 412.902 477.4 18 541.934 606.450 670.966

in1

5

6

7

8

em'

em'

cm1

em•

9 em'

32.258 96.774 161.290 225.806 290.322 354.838 419.354 483.870 548.386 612.902 677.4 18

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 43 2.257 496.773 561.289 625.805 690.312

51 .613 116.129 180.645 245.161 309.677 374.193 438.709 503.225 567.741 632.257 696.773

58.064 , 22.5 80 187.096 251.612 316.128 380.644 445 .16 0 509.678 574. 192 638.708 703.224

9 in2 1.395 2.945 4.495 6.0 45 7.595 9.145 10.695 12.245 1 3.795 1 5.345 16.895

em'

inl

-10 20 30 40 50 60 70 80 90 100

SQUARE CENTIM ETERS TO SQUARE INCHES em'

-10 20 30 40 50 60 70 80 90 100

0

1

4

5

8

in2

in:

in2

6 in2

7

in'

2 in 7

3

ina

in 1

in:

1.550 3. 100 4.650 6.200 7.750 9.300 10.850 12.400 13.950 15.600

0.1 55 1.705 3.255 4.805 6.355 7.905 9.455 11.005 12.555 14.105 15.656

0.310 1.860 3.410 4 .960 6.510 8.060 9.610 11. 160 12.71 0 14.260 15.810

0.465 2.015 3.565 5.115 6.665 8.215 9.765 11.3 15 12.865 14.415 15.965

0 .620 2.170 3.720 5.270 6.820 8.370 9.9 20 11.470 13.020 14.570 16. 120

0 .775 2.325 3.875 5.425 6.9 75 8.52 5 10.075 11.625 13. 175 14.725 16.275

0.930 2.480 4.030 5.580 7.130 8.680 10.230 11.780 13.330 14.880 16.430

1.085 2.635 4.185 5.735 7.285 8.835 10.385 11.935 13.485 15.035 16.583

1.240 2.790 4.340 5.890 7.440 8.990 10.540 12.090 13.640 15.190 16.740

10 20 30 40 50

so

70 80 90 100

VOLUME CUBIC INCHES TO CUBIC CENTIMETERS in-l

10 20 30 40 50 60 70 80 90 100

0

1

2

3

4

5

cm'lec)

cm'(ccl

em21ce)

cm' lce)

cm' (cc)

cm1 (cc)

163.871 327.741 491 .612 655.483 819.353 983.224 1147.094 1310.965 147 4.836 1638.706

16.387 180.258 344.128 507.999 671 .870 835.740 999.6 11 11 63.482 1327.352 1491 .223 1655.093

32.774 196.645 360.51 5 524.386 688.257 852.127 1015.998 1179.869 1343.739 1507.6 10 1671 .48 1

49.161 213.032 376.902 540.773 704.644 868.514 103.2,385 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 .935 245.806 209.677 573.547 737.418 901.289 1065.159 1229.030 1392.900 1556.771 1720.642

6 cml(cc: 98.322 262.1 93 426.064 589.934 753.8C5 917.676 1081 .546 1245.417 1409.288 1573.158 1737.029

7

8

9

em•(ce)

em 'Ieel

cm'(cc)

114.709 278.580 442.4 5 1 606.321 770. 192 934.0.6 3 1097.933 1261.804 1425.675 1589.5 4 5 1753.416

131 .097 294.967 458.838 622.708 786.579 950.450 111 4.320 1278.191 1442.062 1605 .932 1769.803

147.484 311.35 4 475.225 639.095 802.966 966.837 1130.707 1294.578 1458.449 1622.319 1786.190

10 20 30 40 50 60 70 80 90 100

9

cm'(cc)

-

CUBIC CENTIMETERS TO CUBIC INCHES

cm' lecl

-10 20 30 40

so sa 70

so 90 100

0

1

in'

in3

2 ini

0 .6102 1.2205 1.8307 2.4409 3.0512 3.6614 4.2716 4.8818 5.4921 6.1023

0 .0610 0 .67 13 1.28 15 1 .8917 2.5020 3.11 22 3.7224 4.3326 4.9429 5.5531 6. 1633

o:1220 0.7323 1.3425 1.9527 2.5630 3.1 732 3.7834 4.3937 5.0039 5.6 141 6.2243

3 in3 0.1831 0.7933 1.4035 2.0138 2.6240 3.2342 3.8444 4.4547 5.0649 5.6751 6.2854

4

5

6

7

in 3 0.2441 0 .8543 1.4646 2.0748 2.6850 3.2952 3.9055 4.5157 5.1259 5.7362 6.3464

in' 0 .3051 0 .9153 1.5 256 2. 1358 2.7 460 3.3563 3.9665 4.5767 5.1870 5.7972 6.4074

in ~

in 31

0.3661 0 .9764 1.5866 2.1968 2.8071 3,4173 4.0275 4.6377 5.2480 5.8582 6.4884

0 .4272 1.0374 1.6476 2.2579 2.8681 3.4783 4.0885 4.6988 5.3090 5.9 192 6.5295

8 in3 0.4 882 1.0984 1.7086 2.1389 2.9291 3.5393 4.1496 4.7598 5.3700 5.9803 6.5905


in'-

0.549 2 1. 1594 1.7697 , ~79Sl 2.9901 3.6004 4.2106 4.8208 5.4310 6.0413 6.65 15

-

10 20 30 40 50 60 70 80 90 100

r

11-4 CONVERSION TABLES 11

VOLUME GALLONS (U. S.) TO LITERS

LE

u.s g~_o_t _

---=--1

113 5629

40

1

_3_

1_

_4

_j_

t1ters

5

1 _6_ ~,

lit;;s-J

fi ters

·

ftte(S

u.s

1 9 8 liW$11 ---:I:-itet-S- ~

f

t" "1 .4l71 189 2713 1227.1256 1 264,979 9 302,8342 3.:0 6884 ) 378.5 4 27

50 60 70 80 90 100

2

I

7!>.7085

!

!

3.78[>4 1 7.5709 11.3563 , 15. 1417 18927 1 1 22.71 26 26.4980 1 30.2834 1· 3 4.0633 41 6 397 45.425 1 49.2105 1 s2.9960 56.7814 \ 60.5668 \ 64 35 23 J 68.13 77 7 1.9 231 '/ 9 4940 83.2794 87.0648 1 90. 8 5 02 94 6357 9 8.421 1 102.2065 105 9920 109. 7774 117.3482m1 . 1337 124.9191 128.7045 >32.4801 13ts. n54 11 40.06081~62 14'76316 l 155.2025 158.9879 162.7734 166.55881170 .341.2 1741296 1177.9151 . 181,7005 1 185.4859 ! 193.0 568 196.84221200.6276 204 4 131 20 8.1985 211 .9839 215 7693 1219.5548 223.34021 230.9110 Z34 6965 ! 238.4819 1 242.2673 1 2 46.0527 2 49.838 2 253.6 236 257.4090 261 19 45 268.7653 272.5507 276.33621280. i 2 16 283.9070 287.6924 129 1 47791295.263: 129'9 0 487 1 306.6196 310.4050131 4.1 904 31 7.9 759 321.7613 3 2 5 5467 329.3321 333.1 176 336.9030 344.4738 3~8.2593 1 352.0447 1 355.8 301 359.61 5 6 363.4010 1367. 18 64 1370 9 71 8 ! 374.7573 382 3 281 386 1135 389 8990 393 6844 397.4 698 40 1.2553 405 0 4071408.8 26 1 41 2.611 s

I 3 7.8!>43

10 20 30

1_

~ Tfue~lltcrs

liters

1

i

I

i

i

9•1.

10 20 30 40 50 60 70 80 90 100

LITERS TO GALLONS (U.S.)

-~~ __o_ I 931

_

_;__-;-- ..:.'--+- .....:.3_ 4 5 6 a 9 liters gal. g&l gal gal gal. ~ o•L gol. ~ L_ __ - - -' o.2642 _ o.;:.5_2_B_3-+-o"' .,-9-25 \ 1.0567 1.3?09 1 58SO ~ -1-".8::-4:-:g:-:,-+-=2"-.1"01-=3..,.4-+- 2 .3775 ~ 10 2.9059 3. 1701 3.43 42 3.6984 4,2268 44909 47551 5.0193 10 20 5.2834 5.5476 ~.8118 6.0760 6.3401 6.6043 6.8685 7. 1326 7.3968 7.66 10 20 _ __ 3:;.0::__.;.._,;. 7:.:;: .9.::; 25 2 8.1 893 : 8.4 5 3 s 8.71 77 8 981 ~400 .:::9.:.: .5:.,:1.;::0:.:;2, + -.:;.9:.:, .7..:.7_4,;:.3_,:_.;..10 ~073875;;..;.'--,;,.; 1 0:-:·;.30::;2~7-+1 _....;:. 30=--40 \ 10.5669 10.8311 11.0952 3 5 9t. 11.62 361 f1.B8 77 12 1519 12 416 1 1 12.6803 12.9444 I! 40 so \ 13.2086 13.4728 11~.7369 . 14.0011 1 14.265 3 1 14.529 5 1' 4.7936 15.0578 15 32 20 15.5861 so 60 15.8503 16.1 145 1€.3787 16.6428 1 1690~. 1711 1 17,4354 1769.::9.;;5-+l.:-1.;7..;;9.;:,6;. 3~7--'-=18;:·.;;2;;:.2, 7 9;....:--.;;6.;,.0_ _ - --,;;;o:--1'-;-1:;, 8.'4':;:;9.;;,20;:--!-~T8;,:..,;.75~6,:.;2;-,.l....,1"'9"'.o';2~o:-;4+-o1.;;,9:.;: .2;,;8~4::,a ~87 1 t9"iil2'91 20.011;-~12 · 20.6054 ·I 208696 1 70 +1 _

J_

2.641~7 I

I I I,

I

I

80 90 100

21.1338 1 213979 1 23.7755 24.039 7 264172 26.6814

i

lmp g•l.

0

-

1

2

Jitets

4 5459 45.4590 50.0049 90 9 180 95.4639 136.3770 140.9229 11 8 1.8360 186.3819 227.2950 1231 8 409 l 272.7540 277.2999 3 18.2 130 3 22.7589 36 3.6720 368.21 79 409 1310 413.6769 45 4.5900 459.1359

10 20 30 40 50

GO 70 80 90 100

I

I

21.9263 ! 22.190 4 [ 22.4546 1 22.7188 24.5680 24.8321 2!>.0963 25 3605 21.zo 91 27 4739 2 7.7381 28 .oo22

22.98 30 25 6 24 7 28.2664

2 3.24 71 123.5113 1 25 688 9 26.1 5 30 28.5306 26.7947

so 90 1oo

GALLONS (IMP.l TO LITERS

.

liter s

1

21 .6621 243038 269455

3.9~26

I

:

li1ers

90918 545508 100.0 098 145.4688 190.9278 236.3868 ' 281 .all 58 327.3048 3 72 7638 418.2228 463.6818

4

3

5

6

hte~li1ers 13.6377 18. 1836 22.7295 2 7 2 754 59.0967 63.6426 68. 188 5 1 n. 7344 10 4.55 5 7 109. 1016 113 6475 118.1931. 1 50 .01 4 7 i 154.5 606 15 9. ' os 5 \ t 6 3.65 2 4 195.4 737 200.0196 1204. 565 5 209.1 1 14 240.9327 24 5.4786 250 0245 254.5704 286.39 17 290.93 761295.4835 300.0294 331.8507 336.8966 340. 9425 3 4 5.4884 37 7.3097 381.8556 386.40 15 390.9474 4 22.7687 42!.3146 431.8 605 436.406 4 468.2277 472.7736 4 77.3195 48 1.8 654 liters

liters

7 8 9 liters iters liters 3 1.8213 36.3672 40.9131 77.280 3 81 .8 262 86.3721 122.7393 127.2852 13 1.8 311 1 68.1983 1172.7442 ' 177.2901 2 1 3,6573 2 18.203 2 222 .7 491 25V 163 263.6622 268.2081 304.5753 309. 12 12 3 13.6671 35 C.0343 t 354.5802 359.1261 395.4933 400.0392 404.585 1 440 9523 445.4982 4500441 48 6.41 13 ! 49 0.9 5 72 495.5031

Imp gal.

-

10 20 30

tT 50 60 70 80 90 TOO

LITERS TO GALLONS (IMP.)

H

htCr$

-10

2. 1998 4,3996 6.5 994 8.7992 10.99QO 13. 1988 15.3986 17 5984 19 798 2 21 .9980

20 30 40 50 so 70 80 90 100

\...

__ -

1

gat

aL

-

-

-

-

I I

0.2200 2.4198 4 6 196 6.8 194 9.0 192 11.21!)0 13.4 188 15.6 186 17.81841 20 0182 22.2180

-

- -

2 ga 0.4<00 2.6398 4.8~96

7.0394 9.239 2 , 1.4390

13.6388 15.8336 1 8.0334 20.2382 22.4380

-

3 gal. 0 .6599 2.8 5 97 5.0595 7.2593 9.t.591 11.6590 13.8587 16.0585 18.2583 20.4581 22.65 79

4

5

6

gal. 0.8799 3.0797 5.2795 7.4 793 9 6791 1 1.8789 14.0787 16.2 78 5 , 8.4783 20.6781 22.8 779

gal

g al.

7 9•1.

1,0999 3.2997 5.4995 7.6993 98991 12.098 9 14 2987 164985 18.698 3 20.8981 23.0979

1.3199 3.5197 5. 7195 7.9193 101191 12.3189 14.51 8 7 16.7185 18.9183 21 . 118 1 23 .3179

1 .E399 3.7397 5.9395 8. 1393 10.3391 12,5389 14.7387 16.9385 19, 1383 21 .3381 23.5379

' 9 8 gal. gal. 1.7598 1.9798 4.1796 3.9596 6 1594 1 6 .3794 8.3592 8 .579 2 10.!559U 10.7790 12 7588 12.9788 14.9586 15.178 6 17., 584 17.378 4 19.3582 19.5782 2 1.5 580 21.7780 23 7578 23.9778

-------- -


liter

10 20 30_ _ 40

I

50 60 70 80

90 100

CONVERSION TABLES 11 - 5 MASS POUNDS TO KILOGRAMS lbs.

10 20 30 40 50 60 70 80 90 100

1

0 kg

kg

4.536 9.072 13.608 18.1 44 22.680 27.216 3 I. 751 36.287 40.823 45.359

0.454 4.990 9525 14.061 18.597 23.133 27.669 32.205 36.741 41 .277 45.813

2 kg 0.9:>7 5.443 9979

14.515 19.051 23.537 28.123 32.659 37.H5 41 .731 46.266

3

4

kg

kg

1.361 5.897 10 4:l:l 14.969 19.504 24.040 28.576 33.112 37.648 42.184 46.720

1.814 6.350 10886 15.422 19.958 24.494 29.030 33.566 38.102 42.638 47.174

5 kg 2.268 6.804 11 340 15.876 20.41 2 24.948 29.484 34.019 38.555 43.091 47.627

6 kg 2.722 7.257 11 793 16.329 20.8 65 25.401 29.937 34.473 39.009 43.545 47.081

7 kg 3.175 7.>11 12,47 16.>83 21.319 25.855 30.391 34.927 39.4.6 3 43.998 48.534

8 kg 3.629 8.165 12 701 17.237 21.772 26.308 30.844 35.380 39.916 44.452 48.988

lbs.

9 kg 4 .082 8 .618 13.164 17.690 22.226 26.762 31 .298 35.834 40.370 44.906 49.442

30 40 50 60 70 80 90 100

kg

10 20

KILOGRAMS TO POUNDS kg

-10 20 30 40 50 60 70 80 90 100

0

1

2

3

4

5

6

7

8

9

lbs.

lbs.

lbs.

lbs.

lbs.

l bs.

lbs.

lbs.

lbs.

lbs.

22.046 44.092 66.139 88.185 110.231 132.277 154.324 176.370 198.416 220.462

2.205 24.251 46.297 68.343 90.390 112.436 134.482 156.528 178.574 200.621 222.667

4.409 26.455 48.!02 70.:48 92.:94 114.640 136.687 158.732 180.780 202.825 224.87 1

6.614 28.660 50.706 72.753 94.799 116.845 138.891 160.937 182.984 205.030 227.076

8.818 30.865 52.911 74.957 97.003 119.050 141.096 163.142 185.188 207.234 229.281

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 81.571 103.617 125.633 147.710 169.756 191 .802 213.848 235.895

17.637 39.683 6 1.729 83.776 105.822 127.868 149.914 171.961 194.007 216.053 238.099

19.842 4 1.888 63.934 85.980 108.026 130.073 152.119 174.165 196.211 218.258 240.304

10 20 30 40 50 60 70 80 90 100

kg

-

KILOGRAMS TO N EWTON kg

-

0

1

2

3

N

N

N

N

19.61 117.68 215.7 5 3 13.81 411 .88 509.95 608.01 706.08 804.15 902.21 1000.28

29.42 127,4g 225.55 323.62 421.69 519.75 617.82 7 15.89 813.95 912.02 1010.08

-

10 20 30 40 50 60 70 80 90 100

9.81 107.87 205.94 304.01 402.07 500.14 598.21 696.27 794.34 892.41 990.47

98.07 196.13 294.20 392.27 490.33 558.40 686:47 784.53 882.60 980.67

l

4

5

6

;

8

9

N

N

N

N

N

N

39.23 137.29 235.36 333.43 431 .49 529.56 627.63 725.69 823.76 921 .83 1019.89

49.03 147.10 245. 17 343.23 441 .30 539.37 637 .43 735.50 833.57 931 .63 1029.70,

58.84 156.91 25497 353.04 451.11 549.17 647.24 745.31 843.37 941.44 1039.50

68.65 166.71 264.78 362.85 460.91 558.98 657.05 755.1 1 853. 18 951.25 1049.31

78.45 176.52 274.59 372.65 470.72 568.79 q66.85 764.92 862.99 961.05 1059.12

88.26 186.33 284.39 382.46 480.53 578.59 676.66 774.73 872.79 970.86 1068.92

-10 20 30 40 50 60 70 80 90 100

NEWTON TO KILOGRAMS N

I

0 kg

100 200 300 400 500 600 700 800 900 1000

10.197 20.394 30.59·2 40.789 50.986 61.183 71.380 81.578 91.775 101.972

I

10 kg 1.020 11 .217 21.414 31 .611 41 ,809 52.006 62.203 72.400 82.597 92.795 102.992

20 kS

2.039 12.237 22.434 32.631

42.828 53.025 63.223 73.420 83.617 93.814 104.011

30 kg 3.059 13.256 23.453 33.661 43.848 54.045 64.242 74,440 84.637 94.834 105.031

40 kg

4.079 14.276 24.473 34.670 44.868 55.065 65.262 75.459 85.656 95.854 106.051

50 kg 5.099 15.296 25.493 35.690 45.887 56.085 66.282 76.479 86.676 96.873 107.071

60 l<.g

6.118 16.316 26.513 36.?10 46.907 57.104 67.302 77.499 87.696 97.893 108.090

go 80 kg kg k~ 9.177 7138 8.158 19.375 17 335 18.355 27532 28.552 i 29.572 38.749 39.769 37730 47927 48.947 49.966 59.144 60.163 58124 6g_34i 70.361 68321 79.538 78.518 80.558 88.716 89.735 90.755 98.913 99.933 100.952 109. 110 1 110. 130 111,149 70


N

100 200 300 400 500 600 700 800 900 1000

11 - 6 CONVERSION TABLES PRESSURE POUNDS PER SQUARE INCHES TO KILOGRAM S PER SQUARE CENTIMETERS lb/in2 (psi)

10 20 30 40 50 60 70 80 90 100

0 kg/em• 0.7031 1.4061 2.1092 2.8123 3.51 54 4.2184 4.9215 5.6246 6. 3276 7.0307

1 kg/em' 0.0703 0.7734 1.4 764 2.1795 2.8826 3 .5857 4.2887 4.9918 5.6947 6.3979 7.1010

2 kg/ em' 0. 1406 0.8437 1.5468 2.2498 2 .9529 3 .6560 4 .3sgo 5.0621 5.7652 6.4682 7.1713

3 kg/ em' 0.:.!10~

I

0.9140 1.6171 2.3201 3.0232 3.7263 4 .4293 5. 1324 5.8355 6.5386 7.2416

4

5

kg /em' 0.:.!812 0.9843 1.6874 2.3904 3.0935 3.7966 4 .4996 5.2027 5.9058 6.6089 7.3119

kg/em2 0.3515 1.0546 1.7577 2.4607 3.1638 3.8669 4.5700 5.2730 5.9761 6.6792. 7.3822

6 kg/em' 0 .4218 1 .1249 1.8280 2.5311 3.2341 3.9372 4.6403 5.3433 6.0464 6.7495 7.4525

7 kg/em' 0 .4921 1.1952 1.8983 2.6014 3.3044 4.0075 4.7106 5.4136 6.1167 6.8198 7.5228

8 kg/ crnz

0.5625 1 .2fi!i!i 1.9686 2.6717 3.3747 4.0778 4.78 09 5.4839 6.1 870 6.8901 7.5932

9 kg/em' 0.6328 1.3358 2.0389 2.7420 3.4450 4.1481 4.8512 5.5543 6.2573 6.9604 7.6635

lb/in' IpsO

10 20 30 40 50 60 70 80 90 100

KILOGRAMS PER SQUARE CENTIMETERS TO POUNDS PER SQUARE INCHES kglcm'

10 20 30 40 50 60 70 80 90 100

i
0

1

2

3

4

5

6

7

8

9

lb/in•(psil

lblin' (psi)

lb/in'(psi)

lb/in'lpsil

lb/in 21psi)

lb/ln2 (psi)

lbfin>(psil

lb/in'(psi)

lb/in'(psil

lblin2 (psil

142.23 284.46 426.69 568.92 711.16 853.38 995.61 1137.84 1280.07 1422.30

14.22 156.45 298.68 440.91 583.14 725.37 867.60 1009.83 1152.06 1294.20 1436.52

28.45 170.68 3 12.91 455.14 597.37 739.60 881 .83 1024.06 1166.27 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 1 194.73 1336.96 1479.1jl

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 5 12.03 654.26 795.49 998,72 1080.95 1223.18 1365.41 1507.64

99.56 241 .79 384.02 526.25 668.48 810.71 952.94 1095.1 7 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 15!iO:l1

10 20 30 40 50 60 70 80 90 100

kg/em'

-

KILOGRAMS PER SQUARE CENTIMETERS TO KILO PASCAL kg/em'

-10 20 30 40 50 60 70

80 90 100

0

1

2

3

4

5

6

7

8

9

KPa

KPa

KPa

KPa

KPa

KPa

KPa

KPa

KPa

KPa

980.7 1961 .3 2942.0 3922.7 4903.3 5584.0 6864.7 7845.3 8826.0 9806.7

98.1 1078.7 2059.4 3040. 1 4020.7 5001 .4 5982.1 6962.7 7943.4 8924.1 9904.7

196.1 1176.8 2157.5 3138. 1 4118.8 5099.5 6080.1 7060.8 8041 .5 9022,1 10002.8

294.2 1274.9 2255.5 3236.2 42 16.9 5197.5 6178.2 7158.9 8139.5 9120.2 10100.8

392.3 1372.9 2353.6 3334.3 4314.9 5295.6 6276.3 7256.9 8237.6 921 8.3 10198.9

490.3 1471.0 245 1.7 3432.3 4413.0 5393.7 6374,3 7355.0 8335.7 9316.3 10297.0

588.4 1569.1 2549.7 3530.4 4511.1 5491-7 6472.4 7453.1 8433.7 9 414.4 10395.0

686.5 1667.1 2647.8 3628.5 4609. 1 5589.8 6570.5 7551 . 1 8531.8 9512.5 10493.1

784.5 1765.2 2745.9 3726.5 4707.2 5687.9 6668.5 7649.2 8629.9 9610.5 10591 .2

882.6 1863.3 2843.9 9824.6 4805.3 5785.9 6766.6 7747.3 8727.9 9708.6 10689.2

10 20 30 40

so 60 70 80 90 100

KILO PASCAL TO KILOGRAMS PER SQUARE CENTIMETERS

KPa

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

0 kg! em•

-

10.197 20.394 30.592 40.789 50.986 61 .183 71 .380

suns

91 .775 101.972

100 kg/em• 1.020 11.217 2 1.414 31 .61 1 41 .809 52.006 62.203 72.400 82.597 92.794 102.992

200 kg/em' 2.039 12.237 22.434 32.631 42.828 53.025 63.223 73,420 83.617 93.814 104.011

300 kg /em~

3.059 13.256 23.453 33.651 43.848 54.045 64.242 74.440 84.637 94.834 105.031

400 kg/em• 4.079 14.276 24.473 34.67.0 44.868 ' 55.065 65.262 75.459 85.656 95.854 106.051

500 kg/em' 5.099 15.296 25 4!'!3 35.690 45.887 56.085 66.282 76.47 9 86.676 96.873 107.071

600 kg/em ' 6.118 16.316 26.513

36.7 10 46.907 57.104 67.302 77.499 87.696 97.893 108.090

700 kg/em' 7.138 17.335 27.532 37.730 47.927 58.124 68.321 78.5 18 88.716 98.9 13 109.110

800 kg/em' 8 .158 18.355 28.552 38.749 48.947 59.144 69.341 79.538 89.735 99.933 110.130

900 kg/em2 9.177 19.375

KPa

29.572

2000

39.769 49.966 60.163 70.361 80.558 90.755 100.952 111.149

3000 4000 5000 6000 7000 8000 9000 10000


1000

CONVERSION TABLES 11-7 TORQUE FOOT POUNDS TO KILOGRAMMETERS ft. lbs.

0

1

2

3

4

5

6

7

8

9

kg·m

k9·m

kg·m

kg·m

kg-m

kg·m

kQ·m

kg·m

kg·m

kg-m

1.383 2.765 4. 148 5.530 6.9 13 8.295 9.678

0.138 1.521 2.903 4.286 5.668 '7.051 8.434 9.816

0.277 1.6S9 3.0"-2 4.424 5.807 7.1E9 8.572 9.954 11.337 12.719 14.102

0.415 1.797 :3-180 4.562 5.945 7.328 8.710 10.093 11.475 12.858 14.240

0.553 1,936 3.318 4.700 6.083 7.466 8.848 10.231 1 1.613 12.996 14.379

0 .691 2.074 3.456 4 .839 6.221 7.604 8.987 10.369 11 .752 13. 134 14.517

0.830 2.212 3.595 4.977 6.360 7.742 9.125 10.507 11.890 13.272 14.655

0.958 2.350 3.733 5.11 5 6.498 7.881 9.263 10.646 12.028 13.4: 0 14 .793

1 '106 2.489 3.871 5.253 6.636 8.019 9.401 10.784 12. 166 13.549 14.932

-

10 20

30

40 50 60 70 80 90 100

11.060 111.199 12.442 12.581 13.826 13.964

1.244 2.627

ftlbs.

-10

4 ,009

20

5.392 6.774 8. 157 9.540 10.922 12.305 13.687 15.070

30 40 50 60 70 80 90 100

9 ft. lbs. 65.10 137.43 209.76 282.09 354.42 426.75 499.08 571.41 643.74 716.07 788.40

kg·m

kg ·m

KILOGRAMMETERS TO FOOT POUNDS kg· m

-10 20 30 40 50 60 70 80 90 100

0

1

ft.lbs.

ft. lbs.

72.33 144.66 217.00 289.32 361.65 433.98 506.31 578.64 650.97 723.30

7.23 79.56 151.89 224.22 296.55 368.88 441.21 513.54 585.87 658.20 730.53

2 ft. lbs. 14.47 86.80 159. 13 231 .46 303.79 376.12 448.45 520.78 593.1 1 665.4"737.71

4

3 ft.lbs.

ft. lbs.

5 ft lbs.

21 .70 94.03 166.36 238.69 311.02 383.35 455.68 528.Ql 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

6 11. lbs. 43.40 115.73 188.06 260.39 332.72 405.05 477.38 549.71 622.04 694 ..37 766.70

7

8

ft. lbs.

ft lbs.

50.63 122.S6 195.29 267.62 339.95 412.28 484.61 556.94 629.27 701 .6:> 773.93

57.86 130.19 202.52 274.85 347. 18 419.5 1 491 .84 564.17 636.50 708.83 781.16

-10 20 30 40 so 60 70 80 90 100

KILOGRAMMETERS TO NEWTONMETERS kg·m

-10 I 20 30 40

so 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

9.81 107.87 205.94 304.01 402.07 500. 14 598.21 696.27 794.34 892.41 990.47

19.61 1 17.68 215.75 313.81 411 .88 509.95 608.o· 706.08 804. 15 902.21 1000.28

29.42 127.4 9 225.55 323.62 42 1.69 519.75 617.82 715.89 813.95 912.02 10 10.08

39.23 137.29 235.36 333.43 431.49 529.56 627.63 725.69 823.76 921.83 1019.89

49.03 147.10 245.17 343.23 441 .30 539.37 637.43 735.50 833.57 931 .63 1029.70'

58.84 156.91 254.97 353.04 451 .1 1 549.17 647.24 745.31 843.37 941.44 1039.50

68.65 166.7 1 264.78 362.85 460.9 1 558.98 657.05 755.11 853.1 s 951.25 1049.31

78.45 176.52 274.59 372.65 470.72 568.79 666.85 764.92 862.99 961 .05 1059.1 2

88.26 186.33 284.39 382.46 480.53 578.59 676.66 774.73 872_79 970.86 1068.92

60 70 80 90 100

N·m

98.07 196.1 3 294.20 392.27 490.33 588.40 686.41 784.53 882.60 980.67

-10 20 30 40

so

NEWTONMETERS TO KILOGRAMMETERS N-m

-

100 200 300 400

500 60Q 700

soo

90() 1000

0 kg·!"

-

10.197 20.394 30.591 40.7&9 50.986 61 .183 71 .380 81.57] 91.774 101.972

10 k9-m 1.020 11.217 21 .414 3).61 1 4].!108 52.005 62.202 72.399 82.596 92.793 102.990

20

30

40

so

60

70

80

90

kg-m

kg·m

kg·m

kg-m

kg·m

kg·m

kg· m

kg-m

2.039 12.236 22.433 32.630 42.827 53.024 63 .221 73.418 83.61 5 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 86.67 5 96.872 107 069

6.118 16.315 26.512 36.710 46.906 57. 103 67.300 77.497 87.694 97.891 108.088

7.138 17.335 27.532 37 7?9 47.926 58.123 68.320 78.51i 88.714 98.911 109.10E

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 30.768 49.965 60.162 70.359 80.556 90. 753 100.950 11 1.1 4 7

l


-

100 200 300 400 500 600 700 800 900 1000

11 -8 CONVERSION TABLES TEMPERATURE FAHRENHEIT TO CENTIGRADE

I ..

I;

•f

•c

-60 -58 -56 -54 -52

-51..1 -50 -48.9 -47.8 - 46.7

-SO

- ~&. 6

-48 -46 -44 -42 -40 -38 -36 -34 -32 -30 -28 - 26 -24 -22 - 20 -18 -16 -14 -12 -10 -8 -6 -4

Of

•c

•f

- 18.9 -17.8 - 16.7 -1 5.6 -14.4

-44.4 -43.3 -42.2 - 41.1 -40.0 -38.9 -37 8 -36.7 -35.6 -34.4 -3 3.3 -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

56 58 60 62 64 00 68 70

·c

•F

-50

-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 -3 4.6 - 32.8 -31.0 -29.2 -27.4 - 25.6 - 23.8 -22.0 - 20.2 -18.4 - 16.6 · 14.8 · 13.0 -1 1.2 -9.4 -7.6 -5.8 -4.4 -2.2

•c

Of

•c

Of

1~.3

114 116 11 8 120 122 124 126 128 130 132 134 136 138 140 14 2 144 146 148 150 !52 !54 156 158 160 162 164 166 168 170-

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 2 10 2 12 21 4 2Hi 218 220 22 2 224 226 228

•c 77.8 78.9 80.0 81.1

•f

•c

Of

•c

•F

•c

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 11 3.3 114.4 115.6 11 6.7 11 7.8 118.9 1 20.0 12 1.1 122.2 123.3 1 24.4 125.6 •126.7 127.8 128.9 130.0 1s 1. 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 31 4 316 3 18 3 20 322 324 326 328 330 332 334 336 338 340 342 344

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 3 48 350 352 356 358 360 362 364 366 368 370 372 374 376 378 380 382 384 386 388 390 392 400 4 10 420 430 440

174.4 175.6 176.7 177.8 , 78.9 180.0 181 . 1 182.2 183.3 184.4 185.6 186.7 187.8 188.9 190.0 191.1 192. 2 193.3 194.4 195.8 196.7 197.8 198.9 200.0 204.4 210.0 215.6 221 .1 226.7

2.2 3.3 4.4 5.6 6.7 7.8 8.9 10.0 11. 1 12. 2

74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 1 12

14.4' 15.6 16.7 17.8 18.9 20.0 21 .1 22.2 23.3 2; .9 25.6 26.7 27.8 28.9 30.0 31.1 32.2 33.3 34.4 3S.6 36.7 37.8 38.9 40.0 41.1 42.2 43.3 44.4

•c

•f

•c

•F

•c

Of

•c

•f

•c

•f

•c

Of

•c

•f

- 18 - 17 -1 6 - 15 -14 -1 3 -12 · 11 - 10 -9 -8 -7 -6 -5 -4

- 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 5 1.8 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

46 47 48 49 50 51 52 53 54 55 56 57 58

114.8 1 16.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154:4 156.2 158.0 159.8 161.6' 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 2 12.Q 213.8 2151\ 217.4 219.2 221.0 222.8 224.6 226.4 228.2

110 111 112 113 11 4 115 1 16 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141

230.0 231 .8 233.6 235.4 237.2 239.0 240.8 242.6 244.4 246.2 248.0 2 49.8 251.6 253.4 255.2 257.0 258.8 260.6 262.4 264.2 266.0 267.8 269,6 271.4 273.2 275.0 276.8 278.6 280.4 282.2 284.0 285.8

142 143 144 145 146 147 148 149 150 151 152 153 1S4 155 156 157 168 159 160 16 1 162 1E3 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 3 2 1.8 323.6 325.4 327.2, 329.0 330.8 332.6 334.4 336.4 338.Q 339.8 341.6 343,4

174 175 176 177 178 179 180 181 182 183 184 185 188 187 188 189 190 191 192 193 19 4 195 196 197 198 199 200 210 220 230 240 250

345.2 347.0 348.8 350.6 352.4 354.2 356.0 357.8 359.6 361.4 363.2 365.0 386.8 368.6 370.4 372.2 374.0 375.8 377.6 379.4 381 .2 383.0 384.8 388.6 388.4 390.2 392.0 410.0 4 28.0 446.0 464.0 482 .0

- 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 1.1

72

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

~54

CENTIGRADE TO FAHRENHEIT

-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

-3

-2 -1 0 1 2 3 4 5 6 7

8 9 10 11 12 13

6~.6

64.4 6E.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82 4 842 86.0 87.8 89.6 91.4 932 95.0 96.8 98.6 100.4 102.2 104.>) 105.8 107.6 109.4

111 .2 113.0

69 60 61 62 63 64 65 66 67 68 69 70 71 72

73 74 75 76 77


4BD1 Workshop Manual 1

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