DIESEL ENGINE ISUZU 4JG2 Service Manual [PDF]

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INTRODUCTION GENERAL



The fuel injection pump has one plunger assembly that supplies fuel to the four fuel injectors. A mechanical governor controls the maximum engine speed. The operation of this governor is described in the Fuel System later in this section.



This section has the description and the repair procedures for the engine and the fuel system. Removal, disassembly, cleaning, assembly, installation, specifications and troubleshooting procedures are included.



The crankshaft has five main bearings. The main bearing in the center of the crankshaft is also the thrust bearing and has thrust washers (thrust bearings) on each side of the main bearing. The bearing journals have had a special process called “tufftrided” and can not be repaired by grinding.



DESCRIPTION The Isuzu 4JG2 diesel engine is a four–cylinder engine with a displacement of 3059 cm3 (186.7 in3). The firing order is 1–3–4–2. The No. 1 cylinder is toward the end of the engine with the fan. The serial number of the engine is on the side of the cylinder block near the No. 4 cylinder location.



The pistons have three piston rings. Each of the two compression rings have a special shape designed for its position on the piston. The third piston ring is the oil control ring. The cylinder liners are chrome plated.



This diesel engine has direct fuel injection. Diesel fuel is injected into the cylinder at the end of the compression stroke of the piston. A glow plug is also installed in the cylinder head for each cylinder. These glow plugs are cold start aids to make the diesel engine easier to start when the engine is cold.



The valves, valve guides, and valves seats can be replaced during engine repairs. 2



3



4



1



5



6



10



7



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



COOLING FAN THERMOSTAT HOUSING ENGINE OIL DIPSTICK FILL CAP FOR ENGINE OIL FUEL INJECTOR SERIAL NUNBER LOCATION FLYWHEEL DRAIN PLUG, ENGINE OIL FUEL INJECTION PUMP INTAKE MANIFOLD 9 8



FIGURE 1. ISUZU 4JG2 DIESEL ENGINE 1



REPAIRS WARNING Disconnect the battery cables before doing any disassembly and repair to the engine or parts of the electrical system. Put a “DO NOT OPERATE” tag in the operator’s area and on the battery connectors. The diodes and resistors in the electrical system can be damaged if the following cautions are not followed:



• Do not disconnect the battery when the engine is running. The voltage surge can damage the electronic devices in the circuit.



• Do not disconnect an electric wire before the engine is stopped and the switches are “OFF”.



• Do not cause a short circuit by connection of the electric wires to the wrong terminals. Make sure a correct identification is made of the wire before it is connected.



• Make sure a battery is the correct voltage and polarity before it is connected.



• Do not check for current flow by making a spark because the electronic devices in the circuit can be damaged.



REMOVAL AND INSTALLATION OF THE ENGINE NOTE: The removal and installation procedures for the engine are not included in this section. See the section, THE FRAME for the procedures to remove and install the engine.



engine has been removed from the lift truck, many of the following disconnections and removals will already be done. 1. Disconnect the battery cables at the battery. 2. Drain the cooling system. 3. Disconnect the air filter from the intake manifold. Remove the air filter and air duct. 4. Remove the fan guard from the radiator. Loosen the alternator support bracket and remove the drive belt. 5. Remove the cooling fan and spacer. Remove the pulley for the cooling fan and the drive belt. 6. Remove the alternator and its mount. 7. Remove the fuel lines between the fuel injectors and the fuel injection pump. If the engine must be completely disassembled for repairs, remove fuel injection pump as described in the procedure FUEL INJECTION PUMP, Removal. 8. Disconnect the exhaust manifold from the cylinder head. 9. Disconnect the hoses at the thermostat housing. Remove the clamps for the engine wiring that are on the thermostat housing and the side of the cylinder head. 10. Remove the glow plug connectors. Remove the glow plugs from the cylinder head. 11. Disconnect the fuel lines and remove the fuel injectors.



CYLINDER HEAD AND VALVE MECHANISM (See FIGURE 2.)



12. Remove the intake manifold.



Removal



14. Remove the rocker arm assembly. Remove the push rods. Keep the push rods in the correct order so that they will be installed in the same positions.



NOTE: The following procedure is for removal of the cylinder head when the engine is in the lift truck. If the



2



13. Remove the rocker arm cover.



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



VALVE COVER GROMMET CAPSCREW OIL FILL CAP BREATHER PCV VALVE HOSE CAPSCREW VALVE STEM SEAL WASHER VALVE GUIDE LIFTING EYE CYLINDER HEAD GLOW PLUG CONNECTOR GLOW PLUG



5 4 3 2



6



1 7



1 8



9 19



18



17



13



10 12



11 14



15



16



16. 17. 18. 19.



HEAD GASKET COMBUSTION CHAMBER INSERT VALVE SEAT, INTAKE VALVE SEAT, EXHAUST



FIGURE 2. CYLINDER HEAD ASSEMBLY 15. Loosen and remove the cylinder head bolts in several steps in the sequence shown in FIGURE 3.



6 2



14 10



15 18



7 11



3



16. Remove the cylinder head from the cylinder block. Remove the gasket. 1



NOTE: Keep all valve parts together so that they can be installed in the same positions.



5



9 13



17 16



12 8



4



FRONT OF ENGINE



FIGURE 3. LOOSENING SEQUENCE FOR REMOVAL OF THE CYLINDER HEAD 3



17. Put the cylinder head on a flat work surface. Use a wood surface or a pad to prevent damage to the cylinder head. Use a valve spring compressor to compress the valve springs and remove the retainers. See FIGURE 4. Release the valve spring compressor. Remove the valve spring cap, valve spring, seal, and seat washer. Remove the valve from the cylinder head. If the valve will be used again, make a mark on the valve head so that it can be installed again in the same position.



3. Check the surface of the cylinder head for distortion at the location for the intake and the exhaust manifold. If the amount of distortion is more an 0.20 mm (0.008 in), the cylinder head needs repair.



1. VALVE SPRING COMPRESSOR 1



9742



A E



F C



FIGURE 4. VALVES, REMOVAL AND INSTALLATION 18. Repeat step 17 to remove the other valves. Cleaning 1. Clean the surfaces of the cylinder head where the gaskets fit. 2. Clean the carbon from the combustion chambers and the valve ports. Be careful not to damage the combustion chamber inserts. Inspection And Repairs CYLINDER HEAD



D B



FIGURE 5. CHECK THE CYLINDER HEAD FOR DISTORTION 4. Use a straight edge and a thickness gauge to check the depth of the combustion chamber inserts. If the depth is more than 0.02 mm (0.008 in), the insert(s) must be replaced. An insert with cracks or other damage must also be replaced. Replace the combustion chamber inserts as follows: a. Use a hammer and rod to hit the insert and remove it from the cylinder head. See FIGURE 6. 1. COMBUSTION CHAMBER INSERT



1. Inspect the cylinder head for cracks in the exhaust ports, combustion chambers, combustion chamber inserts and external surfaces. If there are any cracks in the cylinder head, it must be replaced. 2. Check the surface of the cylinder head for distortion. Use a straight edge and a thickness gauge as shown in FIGURE 5. Do the measurement in the positions shown. If the amount of distortion is more than 0.2 mm (0.008 in), the cylinder head needs repair. If the height of the cylinder head is less than 91.55 mm (3.604 in), replace the cylinder head. 4



1



FIGURE 6. REMOVE THE COMBUSTION CHAMBER INSERT



b. Make sure the bore in the cylinder head is clean. Put the insert in the seat in the cylinder head and hit it with a plastic hammer.



less than 18.9 mm (0.744 inch), replace the rocker arm shaft. 9724



c. See FIGURE 7. Put a piece of metal on top of the combustion chamber insert. With a press, use 4500 to 5500 kg (9923 to 12,128 lb) of pressure to install the inserts. d. After installation, check that the insert is not loose. Hit the insert with a plastic hammer to check for looseness. See FIGURE 7. If the insert is above the surface of the cylinder head, grind the surface of the insert. The insert must not be above the surface of the cylinder head.



1. PRESS 2. COMBUSTION CHAMBER INSERT



1



FIGURE 8. CHECK THE ROCKER ARM SHAFT 3. Inspect the rocker arms for wear. The standard inside diameter of the rocker arm is 19.036 to 19.060 mm (0.7494 to 0.7503 in). Replace the rocker arm when the inside diameter is more than 19.100 mm (0.7519 in). Find the clearance between the rocker arm and the rocker arm shaft. The standard clearance is 0.01 to 0.05 mm (0.0004 to 0.002 in). When the clearance is more than 0.2 mm (0.008 inch), replace the rocker arm or the rocker arm shaft. Make sure the oil ports are clean. See FIGURE 9.



2 1



1



FIGURE 7. INSTALL THE COMBUSTION CHAMBER INSERT ROCKER SHAFT ASSEMBLY 1. Check the rocker arm shaft as shown in FIGURE 8. Rotate the shaft and make a note of the highest and the lowest reading on the dial indicator. If the difference between the readings is less very small, use a press to straighten the shaft. Do not apply heat to the shaft. If the difference between the readings is greater than 0.2 mm (0.008 inch), replace the shaft. 2. Check the rocker arm shaft for wear. Use a micrometer and measure the diameter of the shaft at the locations for the rocker arms. See FIGURE 8. The standard size of the rocker arm shaft is 18.98 to 19.00 mm (0.747 to 0.748 in). When the diameter at any of the locations is



1. OIL PORT



FIGURE 9. CHECK THE ROCKER ARM 4. Make sure the surfaces are not worn or damaged where the rocker arm pushes on the valve stem. Use an oil stone to remove minor wear patterns. A badly worn or damaged rocker arm must be replaced. VALVES AND GUIDES 1. Inspect the valves for burned or damaged areas in the seat surfaces. The correct valve face angle is 45°. Inspect for cracks and damaged or worn valve stems. 2. Check the diameter of the valve stems and inside diameter of the valve guides. Check the clearance of each valve stem in its valve guide. Use the following procedure: 5



a. Use a micrometer to measure the diameter of the valve stem in three places: top, center, and bottom. The correct measurements are shown in TABLE 1.



9727



TABLE 1. VALVE STEM SIZES VALVE Intake Exhaust



STANDARD



LIMIT



7.946–7.961 mm (0.3128–0.3134 in)



7.880 mm (0.3102 in)



7.946–7.961 mm (0.3128–0.3134 in)



7.850 mm (0.3091 in)



FIGURE 10. VALVE GUIDES, REMOVAL



A



b. Use a hole gauge to measure the bore in the valve guide. The correct measurements are shown in TABLE 2.



TABLE 2. VALVE GUIDE CLEARANCE VALVE



STANDARD



LIMIT



Intake



0.039–0.069 mm (0.0015–0.0027 in)



0.200 mm (0.0079 in)



Exhaust



0.064–0.093 mm (0.0025–0.0037 in)



0.250 mm (0.0098 in)



9743



DIMENSION “A” = 13 mm (0.512 in)



FIGURE 11. VALVE GUIDES, INSTALLATION c. If the clearance between the valve stem and its valve guide is greater than the specification, the valve and valve guide must be replaced as a set. Remove the valve guides with the special tool as shown in FIGURE 10. Special Tools: Valve guide tool (HYSTER Part No. 320910)



Use the special tool to install the valve guides as shown in FIGURE 11. Apply clean engine oil to the valve guide during installation. Install the valve guide so that it extends 13 mm (0.512 in) above the surface of the cylinder head.



6



VALVES AND VALVE SEATS 1. Check the valve seats for wear and damage. Before any work is done on the valve seats, make sure the valve guides are good. 2. Check the depth of the valve below the face of the cylinder head. See TABLE 4. If the measurement of the depth is more than the specification, replace the valve seat. 3. Check the width of the contact area on the valve seat. See FIGURE 13. and TABLE 3. 4. A correction for minimum wear and damage to the valve and valve seat can be done by a process called “lapping”. When the valve seats are “lapped”, keep the valve seat as narrow as possible. Make sure all of the lapping compound is removed from the valve and valve seat when the process is completed.



5. Damaged valve seats can be repaired with a cutter tool. See FIGURE 12. Repair the seats as follows: a. Use a cutter with 15°, 45°, and 75° blades. Install the correct cutter into the valve seat that is to be repaired. See FIGURE 12. Carefully turn the cutter in a clockwise direction. Remove only the minimum metal to repair the valve seat. Keep the valve seat as narrow as possible.



TABLE 3. VALVE CONTACT WIDTH VALVE Intake



STANDARD 1.70 mm (0.067in)



LIMIT 2.2 mm (0.087 in)



Exhaust



2.0 mm (0.079 in)



2.5 mm (0.098 in)



e. Check the valve depth. The correct valve depth is shown in TABLE 4. If the valve seat is badly damaged or worn, replace the valve seat as described in the following paragraphs. TABLE 4. VALVE DEPTH



1. CUTTER



1



VALVE Intake



STANDARD 1.1 mm (0.043 in)



LIMIT 1.6 mm (0.083 in)



Exhaust



1.1 mm (0.043 in)



1.6 mm (0.063 in)



6. If the valve seat can not be repaired so that the valve depth is within the specifications, the valve seat must be replaced. Replace the valve seat as follows:



FIGURE 12. CUTTER FOR VALVE SEATS



b. When the valve seat has been cut, remove the cutter and pilot. Clean the valve port area and remove any particles.



a. Use an electric welder and weld a small bead on the circumference of the valve seat. See FIGURE 14. Make sure that you do not weld between the valve seat and the cylinder head. b. Let the cylinder head cool for 5 to 15 minutes, then use a small prybar or a screwdriver to remove the valve seat.



3 1 1



1



2



2 15 0 45



1. CYLINDER HEAD 2. VALVE SEAT 3. VALVE CONTACT WIDTH



0



75 0



3



FIGURE 13. VALVE SEAT SPECIFICATIONS



1. WELD BEAD 2. VALVE SEAT 3. CYLINDER HEAD



1. USE A SCREWDRIVER TO REMOVE THE VALVE SEAT



FIGURE 14. VALVE SEAT REMOVAL c. Use the “lapping” process to make sure the valve and valve seat fit tightly together. d. Check the width of the valve contact area on the valve seat. See FIGURE 13. The correct contact width is shown in TABLE 3. Replace the valve seat when the width is more than specifications.



c. Clean the bore for the valve seat. d. Use a press to install a new valve seat. See FIGURE 15. e. Check the fit of the valve as described in the procedures above. 7



rect tension is 296 N (67 lbf). Replace the valve spring when the tension is less than 258 N (58 lbf).



1 2 3



4



1. PRESS 2. ADAPTER 3. VALVE SEAT



4. CYLINDER HEAD



FIGURE 15. VALVE SEAT INSTALLATION FIGURE 17. CHECK VALVE SPRING TENSION



VALVE SPRINGS 1. Check the valve springs for damage.



PUSH RODS



2. Measure the free length of the valve springs. See FIGURE 16. The standard length is 48.0 mm (1.89 in). Replace the valve spring when the length is less than 47.1 mm (1.86 in).



Put the push rod on a flat plate as shown in FIGURE 18. Roll the push rod on the flat plate and check the variation with a spacer gauge. If a push rod is more than 0.3 mm (0.012 in) from straight, it must be straightened or replaced.



3. Check the valve springs for being straight. Put the spring against a square as shown in FIGURE 16. Replace the valve spring when the measurement is more than 1.7 mm (0.067 in).



Check the ends of the push rod for wear and damage. Replace a worn or damaged push rod.



MEASURE HERE



FIGURE 18. CHECK FOR A BENT PUSH ROD Assembly



FIGURE 16. INSPECT THE VALVE SPRINGS 4. Use a valve spring tester to check the valve springs. A typical tester is shown in FIGURE 17. Check the tension at the installed height of 38.9 mm (1.5 in). The cor8



1. Use engine oil to lubricate the inner surface of the oil seal for the valve stem. A special tool is available to install the oil seal on the valve guide. Install the oil seal on the valve guide. See FIGURE 19. 2. Lubricate the valve stems with engine oil. Install the valves in their correct positions in the cylinder head.



4. Use the spring compressor to compress the valve spring. See FIGURE 21. Install the retainers that hold the valve spring assembly to the valve stem. Repeat step 2 through step 4 for all of the valves. 1



1. VALVE SEAL INSTALLATION TOOL



ISUZU PART NO. 5–8840–2033–0 FIGURE 19. INSTALLATION, OIL SEAL FOR THE VALVE STEM 3. Install the seat washer, valve spring, and valve spring cap on a valve stem. One end of the valve spring has a spot of paint. See FIGURE 20. This end of the valve spring must be installed next to the cylinder head.



FIGURE 21. INSTALL THE RETAINERS FOR THE VALVE SPRING 5. Assemble the parts of the rocker arm assembly as shown in FIGURE 22. Make sure the largest oil hole in the rocker arm shaft goes toward the fan end of the engine. Apply engine oil to the parts during assembly. Installation



1. PAINT SPOT 1



FIGURE 20. VALVE SPRING



1. Clean the surface of the cylinder head and the surface of the cylinder block. Clean the top of the pistons. 2. The correct head gasket is determined by measuring the fit of the piston to the cylinder block. Use the following procedures to choose the correct head gasket:



9



14



9



13 12



6



8



10



5 7 4 11 3 15 16 17



2 18



1



19



1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.



CAM FOLLOWER (TAPPET) PUSH ROD END PLUG SNAP RING ADJUSTMENT SCREW JAM NUT MOUNT, ROCKER SHAFT WASHER STUD ROCKER ARM WASHER SPRING ROCKER ARM SHAFT CAPSCREW VALVE KEEPER RETAINER VALVE SPRING EXHAUST VALVE INTAKE VALVE



FIGURE 22. ROCKER SHAFT AND VALVE ASSEMBLY a. Use a dial indicator to measure the distance that the piston extends above the cylinder block. Make four measurements at each bore as shown in FIGURE 23. b. Use the difference between the measurements (1



10



minus 2), and (3 minus 4) to calculate the average distance that the piston extends. Do these measurements for all four cylinders to obtain the maximum dimension.



the top. Carefully align the cylinder head gasket and cylinder head.



1



2 2



4. Lubricate the threads of the cylinder head bolts with engine oil. Install and tighten the bolts in three steps. Tighten the bolts to 49 N.m (36 lbf ft) in the sequence shown in FIGURE 24. Use the sequence again and tighten the bolts 60 to 75° more. Use the sequence a third time and tighten the bolts 60 to 75° more.



13



17



5 9



1. DIAL INDICATOR 2. MEASURING POINTS 12842



FIGURE 23. MEASURE THE PISTON HEIGHT c. Three different thicknesses or grades of head gaskets are available. To determine the correct gasket, use the specifications in TABLE 5. TABLE 5. CYLINDER HEAD THICKNESS GRADE MARK



AVERAGE PISTON HEIGHT



GASKET THICKNESS



0



0.658–0.713 mm (0.026–0.028 in)



1.60 mm (0.063 in)



00



0.713–0.759 mm (0.028–0.030 in)



1.65 mm (0.065 in)



000



0.759–0.814 mm (0.030–0.032 in)



1.70 mm (0.067 in)



4



10



12



16



8



6



14 18



1



2



3



7 11



15



FRONT OF ENGINE



FIGURE 24. TIGHTENING SEQUENCE FOR THE CYLINDER HEAD BOLTS 5. Lubricate the push rods with engine oil and then install them in the engine. 6. Install the rocker arm assembly. Loosen the screws for adjusting the valve clearance. Tighten the bolts for the rocker shaft mounts to 54 N.m (40 lbf ft). Tighten the bolts for the inner mounts first. 7. Install the glow plugs in the cylinder head. Tighten the glow plugs to 23 N.m (17 lbf ft). Install the glow plug connector. 8. Install the fuel injectors in the cylinder head. Tighten the injectors to 64 N.m (47 lbf ft). 9. Install a new gasket for the intake manifold. Install the gasket so that the end with the sharp corners is toward the fan end of the engine. Install the intake manifold.



GRADE MARKS



12842



NOTE: The difference between the highest and lowest measurements in piston heights must not be more than 1.00 mm (0.039 in). 3. Install the dowel pin in the cylinder block. Install the cylinder head on to the cylinder block, with the marks at



10. Install a new gasket for the exhaust manifold. Install the exhaust manifold. Tighten the capscrews for the exhaust manifold. Connect the exhaust pipe to the exhaust manifold. 11. Install the fuel lines. See FIGURE 25. Connect the fuel injection lines to the fuel injectors. NOTE: If the fuel injection pump is installed at this step, install the fuel lines. If the fuel injection pump is not installed, do this step after the fuel injection pump is installed. 11



Install the support clips in their original positions so that there is no stress on the fuel injection lines. A stress on the fuel injection line can cause a break during operation.



13. Install the coolant pump. Tighten the capscrews for the coolant pump to 19 N.m (14 lbf ft). 14. Install the coolant hoses to the thermostat housing and coolant pump. 15. Adjust the valves as described in CHECKS AND ADJUSTMENTS. 16. Install the rocker arm cover. 17. Install the front and rear engine lifting eyes. 18. Install the oil pipe from the fuel injection pump to the cylinder block.



FIGURE 25. INSTALLATION OF THE FUEL INJECTION LINES 12. Install the thermostat housing to the cylinder head. See FIGURE 26. 1. 2. 3. 4. 5. 6.



COVER GASKET THERMOSTAT GASKET HOUSING COOLANT TEMPERATURE SENDING UNIT 7. TEMPERATURE SENSOR, QUICK START



19. Install the alternator and its adjustment bracket. 20. Install a new engine oil filter. 21. Install the oil pressure switch if it was removed. 22. Connect the coolant hoses. Fill the cooling system with coolant.



1



23. Install the pulley for the cooling fan and the drive belt. Install the cooling fan. Adjust the drive belt to the correct tension.



2 3



24. Install and connect the air cleaner.



4



TIMING GEAR CASE 6



Removal (See FIGURE 27.) 7 5



FIGURE 26. THERMOSTAT HOUSING



12



The engine is normally removed from the lift truck to remove the timing gear case. There are separate covers on the timing gear case that can be removed to check the timing indicators.



5



3 4 2



1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.



OIL SEAL TIMING GEAR COVER SEAL DOWEL PIN TIMING GEAR CASE 1 GASKET INSPECTION COVER SHAFT, IDLER GEAR “A” IDLER GEAR “A” RETAINER CAPSCREW SHAFT, IDLER GEAR “B” IDLER GEAR “B” AND BEARING RETAINER CAPSCREW OIL PIPE WASHER SPECIAL CAPSCREW



6 9



7



10



8



17 17 12



18 16



11



13



15 14



FIGURE 27. TIMING GEAR ARRANGEMENT 1. Use a puller to remove the crankshaft pulley. See FIGURE 28. Use a block of wood next to the flywheel to prevent the crankshaft from turning.



2. Remove the capscrews that hold the timing gear cover to the timing gear case. Remove the timing gear cover. 3. Remove the capscrew and retainer for idler gear “B”. Remove the idler gear and its shaft. 4. Remove the oil pipe from the case and idler gear “A”. 5. Remove the capscrews and retainer for idler gear “A”. Remove the idler gear and shaft.



CAUTION Do not turn the camshaft or the crankshaft when the idler gears are removed and the valve mechanism is installed. If either shaft is turned, damage will occur to the valve mechanism. To prevent damage to the valve mechanism, remove the rocker arm assembly when working on the timing gears. FIGURE 28. REMOVE THE CRANKSHAFT DAMPER PULLEY



NOTE: Before removing the camshaft, the oil pump must be removed. See the procedures for the Oil Pump 13



6. Remove the capscrew for the the camshaft gear. Carefully pull the camshaft timing gear from the camshaft. Remove the capscrews and thrust plate from the cylinder block. Make sure the camshaft journal, lobes, and bearing surfaces are not damaged during disassembly. See the procedures for the Camshaft for additional information.



8. Remove the capscrews that hold the timing gear case to the cylinder block. Remove the timing gear case and gasket. 9. Remove the oil seal from the timing gear cover. See FIGURE 30. Installation



5



6



1. See FIGURE 27. Install the timing gear case (12) to the cylinder block. Use a new gasket during installation. Tighten the capscrews evenly to 20 N.m (15 lbf ft). 2. Install the key and the gear on the crankshaft. Make sure the timing marks “XX” are showing. Use a piece of tubing to push the gear completely against the shoulder.



4



3



1 1. 2. 3. 4. 5. 6.



2



CRANKSHAFT GEAR IDLER GEAR “A” IDLER GEAR “B” CAMSHAFT TIMING GEAR CAVITY FOR COOLANT PUMP OPENING FOR FUEL INJECTION PUMP



FIGURE 29. TIMING GEAR ARRANGEMENT



7. If the crankshaft gear must be removed, use a puller to remove the crankshaft gear. Remove the woodruff key from the crankshaft.



3. See Camshaft, Installation procedures to install the camshaft into the cylinder block. Install the thrust plate and tighten the capscrews to 18 N.m (13 lbf ft). Install the key and the camshaft timing gear. Make sure the timing marks “YY” are showing. Tighten the capscrew for the camshaft gear to 64 N.m (47 lbf ft).Check that the camshaft turns smoothly. Rotate the camshaft so that the “YY” mark on the camshaft timing gear is toward the center axis of idler gear “A”. 4. Install the idler gear shaft for idler gear “A”. Make sure the oil port is toward the top of the engine. 5. Turn the crankshaft so that the “XX” mark on the crankshaft gear is toward the top of the engine. 6. Lubricate idler gear “A” with engine oil. Install idler gear “A” so that the “X” and “Y” marks can be seen. As idler gear “A” is installed, align the “X” mark with the “XX” mark on the crankshaft gear, and align the “Y” mark with the “YY” mark on the camshaft timing gear. See FIGURE 31. 7. Install the retainer plate and the two capscrews for idler gear “A”. Tighten the capscrews to 20 N.m (15 lbf ft).



FIGURE 30. REMOVE THE OIL SEAL



14



8. See FIGURE 31. Lubricate idler gear “B” with engine oil. Install idler gear “B” on its shaft so that the “Z” and “ZZ” marks on both timing gears are aligned. Install the washer and capscrew on tining gear “B”. Tighten the capscrew to 76 N.m (56 lbf ft).



1



1. CASE 2. OIL SEAL



YY 2



4 1.0 mm (0.039 in)



2 3 7 2



6



XX 1



5



1. 2. 3. 4. 5.



CRANKSHAFT GEAR IDLER GEAR “A” IDLER GEAR “B” CAMSHAFT GEAR ALIGN X ON IDLER GEAR “A” WITH XX ON THE CRANKSHAFT TIMING GEAR 6. ALIGN Y ON IDLER GEAR “A” WITH YY ON THE CAMSHAFT TIMING GEAR 7. ALIGN Z ON IDLER GEAR “B” WITH ZZ ON IDLER GEAR “A”



FIGURE 31. ALIGNMENT OF THE TIMING GEARS



9. Install the oil pipe for the timing gear. Install the special capscrew and pipe to the retainer for idler gear “A” See FIGURE 27. Tighten the special capscrew to 13 N.m (9 lbf ft). 10. Install the crankshaft oil seal in the timing gear cover. Lubricate the lip of the oil seal with engine oil. Use the installation tool (Isuzu Part No. 5–8840–2061–0) to install the oil seal in the timing gear cover. Install the oil seal 1 mm (0.039 in) into the front of the timing gear cover. See FIGURE 32.



FIGURE 32. INSTALL THE CRANKSHAFT OIL SEAL 11. Install the O–ring in the groove in the timing case cover. Align the cover with the dowel pins, then install the cover. Tighten the capscrews to 19 N.m (14 lbf ft).. 12. Align the crankshaft damper pulley with the key and install the pulley. Be careful not to damage the seal. Use a block to prevent the crankshaft from turning. Install the capscrew and washer. Tighten the capscrew to 275 N.m (203 lbf ft).



CAMSHAFT AND CAM FOLLOWERS Removal See TIMING GEAR CASE, REMOVAL for information about removal of the camshaft from the cylinder block. Inspection And Repairs 1. Before the camshaft is removed, use a dial indicator to measure the amount of movement at the end of the camshaft. The standard clearance is 0.08 mm (0.0032 in). Replace the thrust plate when the movement is more than 0.20 mm (0.0079 in). 2. Remove the camshaft timing gear. Remove the capscrew and washer. Use a puller to remove the camshaft timing gear from the camshaft.



15



1 2



3 4



5



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



6 7



CAMSHAFT WOODRUFF KEY CAPSCREW (2) THRUST PLATE CAMSHAFT TIMING GEAR WASHER CAPSCREW



FIGURE 33. CAMSHAFT ASSEMBLY 3. Remove the capscrews and the thrust plate.



place the camshaft when the height of a lobe is less than 41.65 mm (1.6398 in).



1



5. Check the “run out” of the camshaft as shown in FIGURE 35. Rotate the camshaft and look at the dial indicator. The standard measurement for “run out” is 0.02 mm (0.008 in) or less. Replace the camshaft when the “run out” is more than 0.10 mm (0.004 in).



1. CAMSHAFT 2. LOBE 3. JOURNAL



A



9740



2 B 3



B A



12631



FIGURE 34. CAMSHAFT MEASUREMENTS 9748



4. See FIGURE 34. Use a micrometer to measure the camshaft journals. The correct measurement is 49.945 to 49.975 mm (1.9663 to 1.9675 in). Replace the camshaft when any of the journals are less than 49.60 mm (1.953 in). Measure the height of the camshaft lobes. The correct measurement is 42.02 mm (1.6543 in). Re16



FIGURE 35. CAMSHAFT INSPECTION 6. See FIGURE 36. Measure the inside diameter of the camshaft bearings. The standard measurement is 50.00 to 50.03 mm (1.9685 to 1.9696 in). Replace camshaft



bearings when the inside diameter is 50.08 mm (1.9716 in) or more. The maximum clearance between the bearings and the camshaft is 0,12 mm (0.005 in). See FIGURE 37. Replace the camshaft or bearings as necessary.



2. Measure the outside diameter of the cam followers as shown in FIGURE 38. The correct measurement is 12.97 to 12.99 mm (0.510 to 0.511 in). Replace a cam follower that has specifications less than 12.95 mm (0.0509 in). 3. Check the clearance between the cam follower and the bore in the cylinder block. Measure the diameter of the hole for the cam follower in the cylinder block as shown in FIGURE 39. The standard clearance is 0.03 mm (0.001 in). Install a new cam follower or cylinder block if the clearance is more than 0.10 mm (0.004 in).



FIGURE 36. CAMSHAFT BEARING INSPECTION



CAUTION During installation of the camshaft bearings, the oil ports in the bearing must be aligned with the oil ports in the cylinder block. If the ports are not correctly aligned, the bearing surfaces will not be lubricated and will fail.



FIGURE 38. CAM FOLLOWER INSPECTION



1



FIGURE 39. CAM FOLLOWER BORE INSPECTION 1. CAMSHAFT BEARING TOOL ISUZU PART NO. 5–8840–2038–0)



FIGURE 37. CAMSHAFT BEARING REPLACEMENT CAM FOLLOWERS (TAPPETS) 1. Keep the cam followers in an arrangement so that they will be installed again in the same position in the cylinder block. Inspect the contact surface of the cam follower for damage and wear. A cam follower will have a smooth ring where it rubs on the camshaft lobe. A cam follower with a damaged surface must be replaced. Replace a cam follower as necessary.



Installation 1. Lubricate the cam followers with engine oil and install them in the cylinder block. 2. Lubricate the camshaft and bearings and carefully install the camshaft. 3. Install the thrust plate fro the camshaft. Tighten the capscrews for the thrust plate to 18 N.m (13 lbf ft). Check that the camshaft rotates freely. 4. Align the camshaft timing gear with the woodruff key and install the timing gear on the camshaft. Make sure the timing marks (Y–Y) on the timing gear are showing. Tighten the capscrew to 64 N.m (47 lbf ft). 17



5. Check the alignment of the timing marks as described in the procedures for the Timing Case.



Oil Pump, Inspection 1. Remove the strainer assembly, the pump cover and the outer rotor.



LUBRICATION SYSTEM 2. If the oil pump is worn so that the performance is decreased, the oil pump must be replaced. Check the end clearance of the inner rotor. See FIGURE 41. If the clearance is greater than 0.15 mm (0.006 in), replace the rotor assembly.



Oil Pump, Removal And Disassembly (See FIGURE 40.) 1. Remove the dipstick. Drain the engine oil. 2. Remove the oil sump. 3. Remove the oil pump with the oil tube from the cylinder block



2 4 5 3



FIGURE 41. CHECK THE END CLEARANCES OF THE ROTOR 3. Check the clearances between the inner rotor and outer rotors. If the clearance is greater than 0.20 mm (.008 in), replace the rotor assembly. See FIGURE 42.



6



7 1



1. OIL TUBE ASSEMBLY 2. O–RING 3. OIL PUMP BODY 4. PINION 5. ROLL PIN 6. INNER ROTOR AND DRIVE SHAFT 7. OUTER ROTOR 8. COVER 9. STRAINER ASSEMBLY



8



9



FIGURE 40. OIL PUMP ASSEMBLY



18



FIGURE 42. CHECK THE CLEARANCE BETWEEN THE ROTORS 4. Check the clearances between the outer rotor and the pump body. See FIGURE 43. If the clearance is greater than 0.40 mm (.016 in), replace the oil pump.



3. Install the cover. 4. Install the strainer assembly. Install the oil tube so that it is loosely fastened to the oil pump.



FIGURE 43. CHECK THE CLEARANCE BETWEEN THE VANE AND PUMP BODY 5. Use a micrometer to measure the outer diameter of the drive shaft as shown in FIGURE 44. Measure the inner diameter of the pump body. If the clearance between the drive shaft and the pump body is greater than 0.20 mm (0.008 in), replace the oil pump.



FIGURE 45. INSTALLATION, OIL PUMP 5. Install the oil pump in the cylinder block. Use a new O–ring on the oil tube. Connect the oil tube and tighten the fittings. 6. Install the oil sump.



FIGURE 46. INSTALLATION, OIL SUMP FIGURE 44. CHECK THE ROTOR DRIVE SHAFT Oil Pump, Assembly And Installation (See FIGURE 45.) 1. Install the drive shaft and rotor into the pump body. 2. Install the pinion on the drive shaft. Use a 5 mm (0.20 in) drill to make an aligned hole through the pinion and drive shaft. Install the roll pin. Use a thread adhesive (Hyster Part No. 226414 or Locktite 271) to help hold the roll pin in the hole.



Oil Sump, Installation 1. Apply a liquid gasket to the arches of bearing cap No. 5 as shown FIGURE 46. Apply a liquid gasket to the arches of the timing gear case as shown in FIGURE 46. 2. Install the gasket for the oil sump. Make sure the gasket fits completely into the groove of bearing cap No. 5 and the corners where it joins the cylinder block. See FIGURE 47. 3. Install the oil sump and tighten the capscrews. Tighten the capscrews in a sequence beginning at the middle 19



and working toward each end of the oil sump. Tighten the capscrews to 19 N.m (14 lbf ft).



PISTONS AND CONNECTING RODS (See FIGURE 50.) NOTE: See the sections on Cylinder Liners for the selection and fitting of pistons to new cylinder liners. Removal 1. Remove the cylinder head as described in “Cylinder Head, Removal”. 2. Remove the oil sump. Remove the piston cooling pipe. 3. Clean the carbon from the top of each cylinder bore. 4. Remove the bearing caps from the connecting rods. Keep the bearings in their order in which they were installed. Keep each bearing cap with its connecting rod.



FIGURE 47. INSTALLATION, OIL SUMP Oil Filter Assembly (See FIGURE 48.) Replace the oil filter as described in the section, PERIODIC MAINTENANCE. Change the oil filter at the same time engine oil is changed. Use the correct oil according to the specifications. Install a new filter cartridge. Apply clean oil to the gasket of the new filter cartridge. Turn the filter until the gasket touches, then tighten 1/2 to 3/4 turn with your hand. Start the engine. Check the area around the oil filter for leaks.



1



5. Push the piston and connecting rod assembly from the top of the cylinder. Keep the piston and connecting rod assemblies in an arrangement so that they can be installed in the engine again in the same order from which they were removed. Disassembly (See FIGURE 50.) 1. During disassembly of the piston and connecting rod assemblies, keep each set of parts with its assembly. Put a piston and connecting rod assembly in a vise with soft jaws. Be careful that the assembly is not damaged in the vise. 2. Use a piston ring expander to remove the piston rings. 3. Use snap ring pliers to remove the snap rings at each end of the piston pin. Use a hammer and a brass driver to remove the piston pin as shown in FIGURE 49.



6 2



9736



3



4



5 1. FILTER CARTRIDGE 2. BODY, OIL FILTER 3. O–RING 4. PLUG



5. REGULATOR VALVE 6. GASKET



FIGURE 48. OIL FILTER ASSEMBLY 20



FIGURE 49. PISTON PIN, REMOVAL



NOTE: If the cylinder liner is worn or damaged, check the clearance between the piston and the cylinder liner after the cylinder liner has been replaced.



6 5 1



Piston Rings, Inspection



4



1. Measure the end clearance of each piston ring as shown in FIGURE 51. Install the piston ring into the cylinder where it will be used. Use a thickness gauge to measure the end clearance. Make sure the piston ring is perpendicular to the cylinder wall when the end clearance is measured. For the correct end clearance of the piston rings, see TABLE 6. If the end clearance for any of the piston rings is greater than the specifications, replace the piston ring.



3 2 1



7



TABLE 6. PISTON RING END CLEARANCE 8 RING



STANDARD



LIMIT



1st (Top)



0.20–0.35 mm (0.0079–0.0138 in)



1.5 mm (0.0591 in)



2nd



0.37–0.52 mm (0.0146–0.0224 in)



2.0 mm (0.0787 in)



3rd



0.20–0.40 mm (0.0079–0.0157 in)



1.6 mm (0.0630 in)



9739



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



10



8



SNAP RING PISTON PIN PISTON OIL CONTROL RING COMPRESSION RING NO. 2 COMPRESSION RING NO. 1 CONNECTING ROD BEARING HALF BEARING CAP NUT



FIGURE 50. PISTON AND CONNECTING ROD ASSEMBLY



Pistons, Inspection And Repair Visually inspect the pistons for wear and cracks. Replace a piston that is worn or damaged.



FIGURE 51. CHECK THE END CLEARANCE OF THE PISTON RING



2. Measure the clearance between the piston ring and the groove in the piston as shown in FIGURE 52. For the correct clearance of the piston rings in their grooves, see TABLE 7. 21



Connecting Rods, Inspection And Repair



TABLE 7. PISTON RING GROOVE CLEARANCE RING



STANDARD



LIMIT



1st (Top)



0.09–0.13 mm (0.003–0.005 in)



0.15 mm (0.0059 in)



2nd



0.03–0.07 mm (0.0012–0.0028 in)



0.15 mm (0.0059 in)



0.03–0.07 mm (0.0012–0.0028 in)



0.15 mm (0.0059 in)



1. Clean and inspect the parts for wear and damage. Check the alignment of the connecting rods (bend and twist) with a test fixture. See TABLE 8. TABLE 8. CONNECTING ROD ALIGNMENT



3rd



STANDARD



LIMIT



Bend per 100 mm (3.94 in)



0.08 mm (0.0031 in) or less



0.20 mm (0.0079 in)



Twist per 100 mm (3.94 in)



0.05 mm (0.0020 in) or less



0.15 mm (0.0059 in) 1



9738



1. ALIGNMENT TOOL



FIGURE 52. CLEARANCE BETWEEN THE PISTON RING AND THE GROOVE Piston Pins, Inspection And Repair 1. Inspect the piston pins for cracks and wear. Measure the diameter of the pin. The correct measurement is 33.995 to 34.000 mm (1.3384 to 1.3386 in). If the diameter of the piston pin is less than 33.970 mm (1.3374 in) replace the piston pin. 2. Measure the inside diameter of the piston pin hole in the connecting rod. The standard clearance is 0.008 to 0.020 in (0.0003 to 0.0008 in). If the clearance between the piston pin and bushing is more than 0.05 mm (0.0020 in), replace the bushing or pin. If the bushing is worn, use a press to remove the bushing from the connecting rod. Use the press to carefully install a new bushing, making sure the oil ports are aligned. Use a reamer to increase the inner diameter of the bushing to the standard size for the piston pin. 3. Install the piston pin into the piston. If the pin rotates smoothly, the clearance is normal. If there is resistance, check the clearance. The standard clearance is 0.002 to 0.004 mm (0.0008 to 0.0016 in). If the clearance between the piston pin and piston is more than 0.04 mm (0.0016 in), replace the worn parts. 22



2. Check the clearance between the bushing in the connecting rod and the piston pin as described in the procedures for the Piston Pins. If the bushing is worn, use a press to remove the bushing from the connecting rod. Use the press to carefully install a new bushing. Use a reamer to increase the inner diameter of the bushing to the standard size for the piston pin.



9730



FIGURE 53. CHECK THE CLEARANCE BETWEEN THE CONNECTING ROD AND THE CRANKSHAFT 3. Install the connecting rod in its position on the crankshaft. Check the axial clearance between the connecting rod and the crankshaft as shown in FIGURE 53. The standard clearance is 0.230 mm (0.0091 in). Replace the



connecting rod when the clearance is more than 0.35 mm (0.0144 in).



Pistons And Connecting Rods, Assembly And Installation



New Pistons, Selection



Special Tools: Piston ring expander Piston installation tool (piston ring compressor)



CAUTION The correct piston grade must be selected to keep the clearances correct between the cylinder liner and piston or the engine will be damaged. If a new piston must be installed because of damage or a new cylinder liner was installed, the following procedure must be used to select the correct piston: a. Measure the outside diameter of the piston as shown in FIGURE 54. The measurement is made on the piston skirt approximately 71 mm (2.8 in) below the top of the piston. The piston sizes are shown in TABLE 9.



71 mm (2.8 in)



FIGURE 54. MEASURE THE PISTON



CAUTION The engine will be damaged if the pistons and connecting rods are installed in the wrong direction. 1. Assemble the connecting rod and the piston. Make sure that the connecting rod is installed in the piston as shown in FIGURE 55. Hold the connecting rod in a vise while the piston is installed. 1 1. THE PISTON MUST BE INSTALLED IN THE ENGINE WITH THE NOTCH MARK TOWARD THE COOLANT PUMP 2. THE “ISUZU” CAST MARK MUST BE INSTALLED IN THE SAME DIRECTION AS THE NOTCH MARK ON THE PISTON.



2



FIGURE 55. PISTON AND CONNECTING ROD ARRANGEMENT



WARNING Hot parts. Wear protective clothing and gloves to prevent burns.



TABLE 9. PISTON SIZES GRADE MARK



OUTSIDE DIAMETER



A



95.365–95.374 mm (3.7545–3.7549 in)



B



95.375–95.384 mm (3.7549–3.7553 in)



C



95.385–95.394 mm (3.7553–3.7557 in)



D



95.395–95.404 mm (3.7557–3.7561 in)



b. See the procedures for Cylinder Liners to make sure the piston is installed in the correct bore.



2. Use snap ring pliers to install one of the snap rings in the piston. Heat the piston in an oil bath to approximately 77°C (170°F) for easier installation of the piston pin. Push the piston pin into the piston and connecting rod. Install the other snap ring. Check that the connecting rod moves smoothly on the piston pin. 3. Use a piston ring expander to install the piston rings as shown in FIGURE 56. During installation, make sure the mark on the piston rings is toward the top of the piston. Make sure there is no gap on either side of the expander coil before the oil control ring is installed. Make 23



sure the piston rings will move smoothly in their grooves after they are installed.



CAUTION The number on the bearing cap must be the same number as the connecting rod. The arrow marks of all the bearing caps must point toward the fan end of the engine. NOTE: See the section “How To Check The Clearance Between The Crankshaft Bearings And Their Journals” when the bearing for the connecting rod is installed. 7. Install the bearing in the bearing cap for the connecting rod. Apply clean engine oil to the bearing surface and then install the bearing and bearing cap on the connecting rod. Tighten the nuts 29 N.m (22 lbf ft). For the second step, rotate the nuts 45 to 60° more. Rotate the crankshaft to make sure it moves freely.



1. OIL CONTROL RING 2. COMPRESSION RING NO. 2 3. COMPRESSION RING NO.1



FIGURE 56. ASSEMBLY OF THE PISTON RINGS 4. Apply clean engine oil to the piston rings and the journals for the connecting rods. When a piston is installed into its cylinder, arrange the gaps in the piston rings so that they are 120° part from each other. See FIGURE 57. FAN END OF ENGINE



C



8. Install the piston cooling pipe. See FIGURE 58. Tighten the relief valve to 29 N.m (22 lbf ft). Tighten the M8 capscrews to 19 N.m (14 lbf ft). Tighten the M6 capscrews to 8 N.m (69 lbf in).



CAUTION After installation of the oil pipes, check that there is clearance between the oil pipes and the pistons. Rotate the crankshaft slowly to check the clearances



A



1 2 3



4 B A = GAP FOR OIL CONTROL RING B = GAP FOR COMPRESSION RING NO. 2 C = GAP FOR COMPRESSION RING NO.1



4



FIGURE 57. ARRANGEMENT OF THE PISTON RINGS ON THE PISTON 5. Install the upper half of the bearing in the connecting rod. Make sure the parts are clean. Rotate the crankshaft so that the bearing journal for piston being installed is at BDC. 6. Apply a thin coat of molybdenum disulfide grease to the piston skirts. Use a piston ring compressor and install the piston assemblies into their correct cylinders. During installation, the small mark on the top of the piston must be toward the end of the engine with the cooling fan. See FIGURE 55. or FIGURE 57. 24



1. 2. 3. 4.



RELIEF VALVE OIL PIPE CYLINDER BLOCK CAPSCREW



FIGURE 58. ARRANGEMENT FOR COOLING OIL PIPES



9. Install the oil pump. See “Oil Pump, Assembly And Installation” and FIGURE 45. 10. Install the oil sump. See “Oil Sump, Installation” and FIGURE 46. 11. Install the cylinder head as described in “Cylinder Head, Installation”.



4. Remove the bearing caps for the connecting rods. 5. Remove the capscrews for the main bearings caps as shown in the sequence in FIGURE 60.



3 7



CRANKSHAFT AND MAIN BEARINGS (See FIGURE 59.) 4



8



6



10



9



5



2



1



Crankshaft, Removal 1. Remove the flywheel and flywheel housing. See “Flywheel, Removal”. 2. Remove the timing gear case as described in “Timing Gear Case, Removal”.



7 6 8 5



3



FIGURE 60. REMOVE THE CRANKSHAFT 6. Before removing the crankshaft, measure the clearance between the crankshaft and thrust bearings at the middle main bearing location. See FIGURE 61. Move the crankshaft fully forward before making the measurement. The standard clearance is 0.10 mm (0.0039 in). The maximum amount of clearance (axial clearance) is 0.30 mm (0.0118 in). If the amount of axial clearance is greater than the specification, install new thrust bearings.



4 1



2



9 7



10 1. 2. 3. 4. 5. 6.



CAPSCREW WASHER PULLEY TIMING GEAR KEY MAIN BEARING (UPPER) 7. THRUST BEARING



8. CRANKSHAFT 9. MAIN BEARING (LOWER) 10. MAIN BEARING CAP



9749



FIGURE 61. CHECK THE CLEARANCE BETWEEN THE CRANKSHAFT AND THRUST BEARINGS



FIGURE 59. CRANKSHAFT ARRANGEMENT



7. Remove the crankshaft. Keep the main bearings for the crankshaft in their correct order.



3. Remove the oil sump. Remove the oil pump. Remove the cooling oil pipes.



8. If necessary. use a puller to remove the crankshaft timing gear as shown in FIGURE 62. Remove the woodruff key from the crankshaft. 25



d. Wait approximately 30 to 40 seconds. If the test area becomes the color of copper, the nitrided surface is worn and the crankshaft must be replaced. If the test surface does not change color, the nitrided surface is good. 1. Carefully apply a drop of the test solution to the surface of the bearing journal or other surface to be inspected. 2. Do not apply the test solution to any surface within approximately 10 mm (0.4 in) of an oil port. 1



FIGURE 62. CRANKSHAFT TIMING GEAR, REMOVAL



2



Crankshaft, Inspection And Repair 1. Carefully clean the crankshaft. There must not be any oil on the surfaces to be inspected. 2. Visually inspect the crankshaft for wear, cracks or other damage. Replace the crankshaft if it has cracks. Inspect the oil seal surfaces for wear and damage NOTE: The surface of the crankshaft has been hardened by a process called “tufftrided” (a nitriding treatment) to increase its surface strength. Worn or damaged journal surfaces of the crankshaft can not be repaired by grinding. 3. The following procedure can be used to check the nitrided surface of the crankshaft: a. Prepare a test solution of 5 to 10% solution of ammonium cuprous chloride dissolved in distilled water.



FIGURE 63. CHECK THE NITRIDED SURFACE OF THE CRANKSHAFT e. Use steam to clean the test solution immediately after the test. The test solution will cause corrosion and damage the crankshaft if it is not removed immediately after the test. 4. Check the crankshaft as shown in FIGURE 64. Rotate the crankshaft one turn and check the reading on the dial indicator. The standard reading is 0.05 mm (0.002 in). If the difference between the highest and the lowest reading is more than 0.08 mm (0.0031 inch), repair or replace the crankshaft.



b. This procedure will not give correct results if there is any oil on the surfaces to be inspected. Hold the surface to be tested as level as possible to prevent the test solution from flowing from the small test area. c. See FIGURE 63. Carefully apply a drop of the test solution to the surface to be inspected. Do not apply the test solution to any surface within approximately 10 mm (0.4 in) of an oil port.



26



9734



FIGURE 64. CRANKSHAFT INSPECTION



No. 1



No. 2



No.3



No.4



No.5



1. When installing new main bearings for the crankshaft, be sure to check the size marks. There are size marks on the cylinder block that indicate the bore size for the main bearings. There are also size marks on the crankshaft to indicate the bearing journal diameters. For the location of these marks, see FIGURE 65. For the dimensions of the size marks, see TABLE 11.



1 2 1 1 2 MAIN BEARING BORE SIZE MARKS No. 1



No. 2



Crankshaft Bearing Selection



No.5



2. Use a micrometer to measure the journals for the bearings of the crankshaft. Make the measurements at the positions shown in FIGURE 66. The correct measurements are shown in TABLE 10. TABLE 10. CRANKSHAFT JOURNAL SIZES



1



2



2



No.3



3



1



ITEM



STANDARD



LIMIT



MAIN JOURNAL



69.917–69.932 mm (2.7526–2.7532 in)



69.91 mm (2.7524in)



ROD JOURNAL



52.915–52.930 mm (2.0833–2.0839 in)



52.90 mm (2.0843 in)



WEAR LIMIT



0.05 mm (0.0020 in)



0.08 mm (0.0031 in)



No.4



MAIN JOURNAL DIAMETER SIZE MARKS



FIGURE 65. CRANKSHAFT SIZE MARKS



TABLE 11. CRANKSHAFT SIZE MARKS MAIN BEARING BORE DIAMETER SIZE MARK



1



2



INSIDE DIAMETER



73.987–74.000 mm (2.9129–2.9134 in)



73.975–73.987 mm (2.9124–2.9129 in)



MAIN BEARING JOURNAL SIZE SIZE MARK



OUTSIDE DIAMETER



1 or



69.927–69.932 mm (2.7530–2.7532 in)



2 or



69.922–69.927 mm (2.7528–2.7530 in)



CRANKSHAFT BEARING G SIZE S MARK



CLEARANCE BETWEEN BEARING G AND JOURNAL



BLACK



0.035–0.061 mm (0.0014–0.0024 in)



BLUE



0.032–0.058 mm 0.0013–0.0023 in)



3 or



69.917–69.922 mm (2.7526–2.7528 in)



0.037–0.063 mm 0.0015–0.0025 in)



1 or



69.927–69.932 mm (2.7530–2.7532 in)



0.031–0.056 mm (0.0012–0.0022 in)



2 or



69.922–69.927 mm (2.7528–2.7530 in)



3 or



69.917–69.922 mm (2.7526–2.7528 in)



GREEN



0.036–0.048 mm 0.0014–0.0019 in) BLACK



0.033–0.058 mm 0.0013–0.0023 in)



27



ened to their final torque or there will be an error in the measurement. 6. Remove the main bearing cap. The Plastigage will be compressed and wider and will adhere to either the main bearing or its journal. See FIGURE 68. Use the scale on the envelope for the Plastigage to measure the width of the plastic at its widest point. The scale will indicate the clearance in millimetres or thousandths of an inch. 1 1. MEASURING POINTS



1



1



1



1



1



FIGURE 66. CRANKSHAFT MEASUREMENTS How To Check The Clearance Between The Crankshaft Bearings And Their Journals 1. Use Plastigage or equivalent to check the clearance. The procedure is similar for both connecting rod bearings and main bearings. If the engine has been removed from the lift truck put the engine so that the crankshaft is up. The weight of the crankshaft must be against the upper bearing half so that the total clearance can be measured correctly. If the engine is still in the lift truck, the crankshaft must have a support to remove any additional clearance between the upper bearing half and its journal. 2. All main bearing caps must be installed and their capscrews tightened to the specifications. 3. Check the rear main bearing first. Remove the cap for the rear main bearing. The procedure for checking the clearance of the other bearings is similar. 4. Clean the oil from the bearing half and journal to be checked. Put a piece of Plastigage across the full width of the bearing journal as shown in FIGURE 67. Do not rotate the crankshaft when the Plastigage is between the main bearing and its journal. 5. Install the main bearing cap and tighten the capscrews to 167 N.m (123 lbf ft). The capscrews must be tight28



FIGURE 67. PLASTIGAGE ON A BEARING JOURNAL 7. If the clearance is greater than the specifications, select a new a bearing set and install it. Measure the clearance again. If the clearance can not meet specifications the crankshaft must be replaced.



FIGURE 68. MEASURE THE PLASTIGAGE ON A BEARING JOURNAL 8. See TABLE 11. If the clearance is within specifications, lubricate the bearing with engine oil and install the main bearings and bearing caps. Tighten the capscrews on the main bearing caps to the correct specifications. 9. Turn the crankshaft to make sure it rotates smoothly. Crankshaft, Installation 1. Before installation of the crankshaft, make sure all the passages for oil in the crankshaft are clean.



NOTE: See the following section “How To Check The Clearance Between The Crankshaft Bearings And Their Journals” when the crankshaft is installed. 2. Clean the main bearings. Install the main bearings in the cylinder block. The upper main bearings have an oil passage and an oil groove. The lower bearing half has a smooth surface. Apply clean engine oil to the surface of the bearings. 3. Carefully install the crankshaft.



so that the oil grooves are toward the thrust surface of the crankshaft. 5. Install the main bearings into the bearing caps. Apply clean engine oil to the surface of the bearings and install the bearing caps. The arrow marks of all the bearing caps must point toward the fan end of the engine. 6. Install the gasket and apply silicon adhesive to the cylinder block at the No. 5 main bearing as shown in FIGURE 70.



4. Install the thrust bearings at the No. 3 main bearing location. Make sure that the oil grooves in the thrust bearings are toward the crankshaft. See FIGURE 69. Push one end of the thrust bearing until both ends are even with the surface of the crankcase.



FIGURE 70. APPLY SEALANT FOR THE NO. 5 MAIN BEARING 2



2 1



7. During installation, adjust the position of the No. 1 and No. 5 main bearing caps. The outer surface of each bearing cap must be even with the surface of the cylinder block. Tighten the capscrews in several steps in the sequence shown in FIGURE 71. Tighten the capscrews for the bearing caps to 167 N.m (123 lbf ft).



8



1. THRUST BEARING 2. OIL GROOVES (THE OIL GROOVES MUST BE INSTALLED TOWARD THE THRUST SURFACE OF THE CRANKSHAFT)



FIGURE 69. INSTALLATION OF THE THRUST WASHERS



CAUTION It is very important that the thrust bearings are installed correctly. If they are installed wrong, the crankshaft will be damaged because it will not receive correct lubrication. Install the thrust bearings



7



4



3



1



2



5



6



9



10



FIGURE 71. INSTALL THE CRANKSHAFT 8. Install the oil seal in the groove of the No. 5 main bearing cap. Use a tool to push the seal into position as shown in FIGURE 72. After installation, check that the seal is fully against its seat. 9. Install the key in the crankshaft. Align the slot in crankshaft timing gear with the key. Install the crankshaft timing gear. Make sure the timing marks X–X are toward the outside. 29



2. Remove the flywheel housing and the braces. 12.2–12.8 mm (0.480–504 in)



4



Ring Gear, Replacement



WARNING Wear eye protection for this operation to prevent eye injury from metal chips. You will be using a hammer and chisel to break the ring gear. 3 1 1. OIL SEAL



2



2. CRANKSHAFT 3. ADAPTER 4. TOOL



Before the ring gear is removed, check the position of the chamfer on the teeth.



FIGURE 72. INSTALL REAR SEAL 10. Install the timing gear case as described in “Timing Gear Case, Installation”.



1. See FIGURE 73. Use a hammer and chisel to break the ring gear. Make sure that you do not damage the flywheel.



11. Install the connecting rods as described in “Connecting Rods, Assembly And Installation”. 12. Install the oil pump as described in “Oil Pump, Assembly And Installation”. Install the oil sump as described in “Oil Sump, Installation”. 13. Install the flywheel housing and the flywheel.



FLYWHEEL AND RING GEAR Flywheel, Removal (See FIGURE 74.) 1. Remove the capscrews for the flywheel, then remove the flywheel.



FIGURE 73. RING GEAR REMOVAL



2 5 3



5



1 4



FIGURE 74. FLYWHEEL AND HOUSING



30



1. 2. 3. 4. 5.



FLYWHEEL HOUSING FLYWHEEL SUPPORT PLATE DRIVE PLATE BRACE



4



3



1



3 2



4 4



1. FLYWHEEL HOUSING 2. SPECIAL BOLT AND NUT, 46 N.m (34 lbf ft) 3. CAPSCREWS TO cylinder block (M10), 55 N.m (41 lbf ft) 4. CAPSCREWS TO cylinder block (M12), 94 N.m (69 lbf ft) TIGHTENING SEQUENCE



12767



5 5 5



5 6



5. CAPSCREWS TO BRACES, 98 N.m (72 lbf ft) 6. FLYWHEEL CAPSCREWS, 120 N.m (89 lbf ft)



FIGURE 75. FLYWHEEL AND HOUSING 2. The ring gear must be heated before it can be installed on the flywheel. Use an oven that has a temperature control. Make sure that the ring gear is not heated to more than 200°C (390°F).



WARNING



en the capscrews to 120 N.m (89 lbf ft) as shown in the sequence in FIGURE 75.



CYLINDER BLOCK AND CYLINDER LINERS (See FIGURE 76.)



Hot parts. Wear protective clothing and gloves to prevent burns.



Cylinder Liners, Inspection



3. Install the ring gear on the flywheel. Make sure that the chamfer on the teeth is in the correct direction toward the starter.



NOTE: The cylinder block was marked at the factory to indicate the correct liner sizes. Check for the marks during inspection.



Flywheel, Installation (See FIGURE 75.)



Inspect the cylinder liner for wear and damage. Measure the inside diameter of each cylinder liner to find the amount of wear. Do the measurement of the liner at the area that is approximately 20 mm (0.8 inch) below the surface of the cylinder block. See FIGURE 77. Measure the diameter in a minimum of two directions: (X—X) perpendicular to the axis of the crankshaft and (Y—Y) parallel to the axis of the crankshaft. The correct liner sizes are shown in TABLE 13. If the inside diameter of the cylinder liner is more than the specifications, replace the cylinder liner.



1. Install the flywheel housing and flywheel as follows: a. If the flywheel housing was removed, install it on the engine. Install the capscrews and bolt. Tighten the special bolt (2) and nut first. Tighten the nut to 46 N.m (34 lbf ft). Tighten the other capscrews as shown in FIGURE 75. b. Install the flywheel on the crankshaft. Apply an adhesive sealant on the threads of the capscrews, then install the capscrews for the flywheel. Tight-



31



1. CYLINDER LINER 2. CYLINDER BLOCK



1



1 2



1. CYLINDER LINER REMOVER, ISUZU PART NO. 5–8840–2304–0 9732



FIGURE 78. CYLINDER LINER REMOVAL



FIGURE 76. CYLINDER BLOCK AND LINERS



Replacement Of A Cylinder Liner NOTE: The cylinder liners have a chrome surface. Do not try to repair a cylinder liner that has damage. A damaged cylinder liner must be replaced.



2. Before installation of the cylinder liners, check the surface of the cylinder block for distortion. Make the measurements at the positions shown in FIGURE 79. If the amount of distortion is more than 0.2 mm (0.008 in), replace the cylinder block.



20 mm (0.80 in)



9744



A E



F C



D B



FIGURE 77. MEASURE THE BORE OF THE CYLINDER LINER Special Tools: Cylinder liner removal tool, Isuzu Part No. 5–8840–2304–0 Cylinder liner installation tool, Isuzu Part No. 5–8840–2313–0 1. To remove the cylinder liner, install the remover tool as shown in FIGURE 78. Rotate the handle to pull the liner from the cylinder block. 32



FIGURE 79. CHECK THE SURFACE OF THE CYLINDER BLOCK FOR DISTORTION 3. Measure the inside diameter of the cylinder block where the replacement cylinder liner will be installed. A grade of cylinder liner will be selected according to this measurement. Measure the diameter at W—W, X—X, Y—Y, and Z—Z as shown in FIGURE 80. Make the measurements at approximately 98 mm (3.9 in) below the surface of the cylinder block. Calculate the average value of the four measurements to find the correct cylin-



der bore. This measurement will be used with the measurement in step 4 to select the correct grade of cylinder liner.



5. Carefully clean the bore in the cylinder block where the cylinder liner will be installed. Make sure the tools and press are ready before installation of the cylinder liner is begun. TABLE 12. CYLINDER LINER



FIGURE 80. MEASURE THE CYLINDER BLOCK DIAMETER 4. Make an X—X and Y—Y measurement at three points on the cylinder liner as shown in FIGURE 81. The following measuring points are below the upper surface of the cylinder liner: point 1 = 20 mm (0.79 in) point 2 = 90 mm (3.54 in) point 3 = 160 mm (6.30 in)



LINER GRADE



BORE DIAMETER (AVERAGE)



LINER DIAMETER (AVERAGE)



A



97.001–97.010 mm (3.8189–3.8193 in)



97.011–97.020 mm (3.8193–3.8197 in)



B



97.011–97.020 mm (3.8193–3.8197 in)



97.021–97.030 mm (3.8197–3.8201 in)



C



97.021–97.030 mm (3.8197–3.8201 in)



97.031–97.040 mm (3.8201–3.8205 in)



D



97.031–97.040 mm (3.8201–3.8205 in)



97.041–97.050 mm (3.8205–3.8209 in)



6. Insert the cylinder liner in its bore in the cylinder block. Use a press and the special installation tool to install the cylinder liner. See FIGURE 82. Make sure the alignment between the cylinder liner and the cylinder block is correct during installation. Use the press to apply 4900 N (1100 lbf) to install the cylinder liner in the bore. Use the press to apply 24 500 N (5513 lbf) to finish installation of the cylinder liner in the cylinder block.



1



1. INSTALLATION TOOL, ISUZU PART NO. 5–8840–2313–0



9731



FIGURE 82. CYLINDER LINER INSTALLATION FIGURE 81. MEASURE THE OUTSIDE DIAMETER OF THE CYLINDER LINER



Calculate the average value of the six measurements to find the correct grade of cylinder liner. The grades of cylinder liners are shown in TABLE 12.



7. Measure the position of the cylinder liner. The cylinder liner can extend 0.10 mm (0.004 in) above the surface of the cylinder block. See FIGURE 83. The difference in the height of adjacent cylinder liners must be less than 0.03 mm (0.0012 in). 33



Coolant Pump, Disassembly (See FIGURE 84.)



CAUTION Do not use a hammer to disassemble parts of the coolant pump. Some parts are cast iron and can be broken if they are hit with a hammer. 1. Remove the cover (10) and gasket (9) from the pump body (5). 9728



FIGURE 83. MEASURE THE CYLINDER LINER POSITION



2. Use a press and adapter or a special puller (Hyster Part No. 368758) to remove the hub (1). 3. Remove the set screw (7) that holds the bearing unit in the pump body. 4. Use a press to push the shaft from the impeller (4) and the seal (6).



8. Measure the bore of the cylinder liner after it is installed. Make the measurements at a point 20 mm (0.80 in) from the top of the cylinder block. Make measurements in two directions; in line with the crankshaft and in the thrust direction. See FIGURE 77. Use these measurements when choosing pistons. TABLE 13. CYLINDER LINER SIZES GRADE MARK



INSIDE DIAMETER (PISTON BORE)



A



95.421–95.430 mm (3.7567–3.7571 in)



B



95.431–95.440 mm (3.7571–3.7575 in)



C



95.441–95.450 mm (3.7575–3.7579 in)



D



95.451–95.460 mm (3.7579–3.7583 in)



Coolant Pump, Assembly And Installation (See FIGURE 84.) 1. Install the bearing unit (2) so that the holes for the set screw are aligned. Install the set screw (7). 2. Install the seal (4). Apply a thin coat of liquid sealant to the outer circumference of the seal during installation. 3. Use a press to install the impeller (8). The clearance between the impeller and the pump body must be 0.3 to 0.6 mm (0.012 to 0.024 inch). 4. Install the gasket and cover (10).



COOLING SYSTEM (See FIGURE 84.) Coolant Pump, Removal



5. Install the hub (1). Use a press to push the hub on the shaft. 6. Install the coolant pump and gasket on the cylinder block. Tighten the capscrews to 20 N.m (15 lbf ft). 7. Adjust the tension of the drive belt as described in the section PERIODIC MAINTENANCE. Thermostat, Replacement (See FIGURE 84.)



1. Drain the cooling system 2. Remove the drive belt, the fan, and the pulley.



1. Drain the cooling system so that the coolant level is below the thermostat position and disconnect the top hose from the outlet connection.



3. Remove the hoses from the coolant pump.



2. Remove the capscrews and remove the outlet connection.



4. Remove the coolant pump from the engine.



3. Remove the thermostat.



34



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



HUB BEARING UNIT DEFLECTOR SEAL PUMP BODY WASHER SETSCREW IMPELLER 5 GASKET COVER 2



3



11



12



10 7



8



9 15



6 16 17



4 13



1



18 19 14



11. 12. 13. 14. 15.



SCREW GASKET FITTING PLUG OUTLET



16. 17. 18. 19. 20.



THERMOSTAT HOUSING DRIVE BELT PULLEY SPACER



20



FIGURE 84. COOLING SYSTEM 4. Make sure that the surfaces for the joint in the outlet are clean. Install a new thermostat in the housing.



FUEL SYSTEM



The solenoid valve is controlled by the ignition switch. When the ignition switch is turned to ON, the coil in the solenoid valve is energized. The solenoid valve opens to permit fuel to flow into the pressure chamber for the plunger (2). When the ignition switch is turned to OFF, the solenoid valve closes and stops the flow of fuel. The solenoid valve permits the engine to be stopped quickly when the ignition switch is turned to OFF.



NOTE: Special tools and training are needed to repair the fuel injection pump. A fuel injection pump is normally sent to an authorized repair station if repairs are necessary. Fuel injectors also require special equipment and training for repair. Most users have a special repair service do this work. The repair of the fuel injection pump and the fuel injectors is not described in this section.



The drive shaft (2) is turned by the gear train in the engine. The fuel pump (3) is a rotary vane pump that pulls fuel from the fuel tank through the water separator. The pressure of the fuel oil from the fuel pump increases when the speed of the drive shaft increases. The regulator valve controls the pressure of the fuel oil to the specifications set by the manufacturer.



5. Use a new gasket and install the outlet connection. Tighten the capscrews to 20 N.m (15 lbf ft). 6. Connect the top hose and fill the cooling system.



Description And Operation (See FIGURE 85.) The parts of the fuel system include the fuel tank, injection pump and governor, fuel filter, and fuel injectors. A basic diagram of the fuel system is shown in FIGURE 85.



The overflow valve (6) in the injection pump is a by– pass valve that permits some fuel oil to return to the fuel tank. The overflow valve keeps the fuel oil at a constant pressure in the plunger chamber so that the fuel flow to the fuel injectors is even. 35



5 6 4 1. FUEL INJECTION PUMP 2. DRIVE SHAFT 3. FUEL PUMP (OUT OF POSITION) 4. FUEL FILTER 5. THROTTLE LEVER 6. OVERFLOW VALVE 7. FUEL INJECTOR 8. SOLENOID VALVE 9. FUEL TANK



7



8 3



2



1



9 12627



FIGURE 85. FUEL SYSTEM A control sleeve slides on the plunger and partially opens a passage in the plunger to control the amount of fuel oil sent to the fuel injectors. This control sleeve is controlled by both the control lever (5) and the mechanical governor. The control lever (5) is connected to the throttle pedal for the lift truck.



FUEL INJECTION PUMP



from the timing gear case so that the drive gear is disengaged from the timing gear train. Installation NOTE: The timing gears must be correctly installed in the engine before the fuel injection pump is installed. If the timing gear cover is removed, check the timing marks as shown in FIGURE 86.



Removal 1. Disconnect the battery cables at the battery. 1



2. Remove clamps as necessary so that the fuel lines are not bent. Remove the fuel line between the fuel filter and the fuel injection pump. 3. Remove the fuel lines from the fuel injection pump and the fuel injectors that returns fuel to the fuel tank. 4. Disconnect the throttle cable from the control lever on the fuel injection pump. 5. See FIGURE 89. Remove the access cover for the timing of the fuel injection pump on the timing gear cover. Rotate the engine to align the “O” mark (2) on the gear with the pointer (1). 6. Remove the six capscrews that hold the fuel injection pump to the engine. Move the fuel injection pump away 36



2



1. TIMING GEAR, FUEL INJECTION PUMP 2. IDLER GEAR “B”



FIGURE 86. ALIGNMENT OF TIMING GEARS



CAUTION Do not turn the crankshaft or the camshaft if the timing gears have been removed and the valve mechanism is installed. If either shaft is turned, damage will occur to the valve mechanism. To prevent damage to the valve mechanism, remove the rocker arm assembly when working on the timing gears. 1



NOTE: If the engine is installed in the lift truck, the letters on the timing gears can be difficult to see to align the position of the gears. Some service people use a light and a mirror to see the letters on the timing gears.



1. See FIGURE 87. Remove the access cover for the camshaft timing on the timing gear cover. Slowly turn the crankshaft clockwise. Align the pointer (1) with the “O” mark (2) on the camshaft gear.



1



2



3 2 1. ADAPTER PLATE 2. FUEL INJECTION PUMP 3. ALIGNMENT MARKS



FIGURE 88. FUEL INJECTION PUMP ALIGNMENT 3. See FIGURE 89. Remove the access cover for the timing of the fuel injection pump on the timing gear cover. Put a thin coat of liquid sealant on both surfaces of the gasket that is installed between the adapter for the fuel injection pump and the timing gear case. Install the fuel injection pump on the timing gear case. Align the “O” mark (2) on the gear with the pointer (1) as the fuel injection pump is installed. 1



1. POINTER 2. MARK, CAMSHAFT TIMING GEAR



FIGURE 87. ALIGNMENT, CAMSHAFT TIMING GEAR



2. If removed, install the injection pump on the adapter plate. Make sure the marks are aligned. See FIGURE 88. Tighten the capscrews to 19 N.m (14 lbf ft).



2



1. POINTER 2. MARK, GEAR FOR FUEL INJECTION PUMP



FIGURE 89. ALIGNMENT, GEAR FOR THE FUEL INJECTION PUMP



37



4. Install the capscrews that fasten the adapter to the timing gear case. Tighten the capscrews to 19 N.m (14 lbf ft).



1. Carefully clean the parts of the fuel injector in a mineral oil solvent. The parts are specially fitted. Do not use an abrasive on the fitted areas of the nozzle.



5. Install the fuel lines from the fuel injection pump and the fuel injectors that returns fuel to the fuel tank.



2. Carefully check all parts for wear and damage. See FIGURE 90. The nozzle assembly (8) must be replaced if there is any wear or damage. Hold the nozzle in a vertical position. Pull the nozzle upward approximately 1/3 of its length and release it. The nozzle must lower smoothly into its seat by its own weight. If the nozzle does not pass this test, it must be replaced.



6. Install the clamps as necessary so that the fuel lines are not bent. Install the fuel line between the fuel filter and the fuel injection pump. 7. Connect the throttle cable to the control lever on the fuel injection pump. 8. If installation and alignment of the timing gears is complete, install the access covers for the camshaft gear and the gear for the fuel injection pump.



1 2



9. See the procedure “Remove Air From The Fuel System” before starting the engine.



FUEL INJECTORS (See FIGURE 90.)



8



3



The engine will run roughly if a fuel injector is damaged or dirty. To find which fuel injector has a problem, operate the engine at approximately 1000 rpm. Loosen and tighten the connection to the inlet of each fuel injector in a sequence. When the connection to the fuel injector with a problem is loosened, there will not be a change in the engine speed.



9 4 5 10



6 7



WARNING Do not put your hands on fuel lines under pressure. Fuel oil can be injected into your body by the hydraulic pressure. Removal 1. Disconnect the fuel lines at the fuel injector. Do not bend the fuel lines.



1. 2. 3. 4. 5.



RETAINING NUT GASKET NOZZLE HOLDER SHIM SPRING



6. 7. 8. 9. 10.



SPRING SEAT SPACER NOZZLE ADJUSTER RETAINER



FIGURE 90. FUEL INJECTOR



2. Remove the fuel injectors. See FIGURE 90. Inspection NOTE: The inspection and repair of fuel injectors require special tools and training. Many users have a special repair service make repairs on fuel injectors. Fuel injector nozzles that have damage or are dirty will cause black smoke in the exhaust, a decrease in engine power, and an increase in engine noise. 38



3. The operation of the fuel injector must be checked with an injection tester. See FIGURE 91. Follow the instructions by the tester manufacturer. 4. Check the spray pattern of the nozzle. See FIGURE 91. If the spray pattern is not correct, clean or replace parts as required.



Installation



WARNING Make sure that the nozzle of the injector is away from the operator during a test. Test oil can be injected into your body by the hydraulic pressure. 5. Use an injector tester to check the pressure at which the nozzle operates. The correct pressure is 14.93 MPa (2133 psi). 6. See FIGURE 90. To change the pressure at which the nozzle operates, add or subtract shims (4). Shims are available in thicknesses of 0.10 to 0.80 mm (0.004 to 0.031 in). 1. INJECTOR TESTER 2. FUEL INJECTOR



1. Install the fuel injector in the cylinder head. Tighten the injector to 64 N.m (47 lbf ft). 2. Connect the fuel lines and tighten the fittings. Install the line clamps if they were removed. 3. Remove the air from the fuel system. See “Remove Air From The Fuel System”. 4. When the engine can be operated, check for fuel leaks.



FUEL FILTER NOTE: There is a water separator in the bottom of the fuel filter. A sender unit in the bottom of the fuel filter illuminates an indicator light on the instrument panel if there is water in the water separator. Filter Replacement



2 1



1. See FIGURE 92. Disconnect the two sender wires from the bottom of the fuel filter. Remove the fuel filter from its mount. Remove the parts that include the sender unit from the bottom of the fuel filter. 2. Install the parts that include the sender unit in the new fuel filter. Use a new O–ring between the fuel filter and the sender unit. Lubricate the O–ring with diesel fuel when it is installed. When the engine can be operated, check for leaks.



PATTERN NOT CORRECT



4°



FIGURE 91. CHECK THE FUEL INJECTORS



Remove Air from the Fuel System NOTE: The fuel injection pump will normally remove small amounts of air from the fuel system when the engine is started. If the fuel pump, fuel injection pump, or the fuel filter is empty, it is necessary to remove air from tha system as described below. 1. See FIGURE 92. Loosen the vent screw on the fuel filter housing. Use the hand pump to pump fuel from the vent until there are no air bubbles in the fuel. Hold down on the hand pump and close the vent screw.



39



4. Start the engine and check for leaks. 1



1. 2. 3. 4.



2



5



3



4



5. 6. 7. 8. 9. 10. 11.



6



9



HAND PUMP HOUSING VENT SCREW INLET (FROM FUEL TANK) OUTLET (TO INJECTION PUMP) FILTER CAP SENSOR AND FLOAT O–RING WIRE CONNECTOR DRAIN VALVE AND HOSE



Check the Water Sensor (See FIGURE 93.) 1. Check the operation of the sensor for the fuel filter as follows: a. Drain the fuel from the filter. Disconnect the wires at the sensor. Remove the sensor and float assembly from the filter. b. Connect a continuity tester between the two wires for the sensor. Lift on the float. There is continuity when the float is raised. There is no continuity when the float is lowered.



8 7 10 11 12609



FIGURE 92. FUEL FILTER WITH A WATER SEPARATOR 2. Loosen the fitting for the return line on the injection pump. Operate the hand pump until there is fuel at the injection pump. Rotate the engine until the fuel at the fitting is free of air bubbles. Tighten the fitting. 3. Loosen the supply line at each fuel injector. Rotate the engine until the fuel at the fittings is free of air bubbles. Tighten the fittings.



FIGURE 93. TEST THE WATER SENSOR



CHECKS AND ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT NOTE: Before you check the clearance of the valves, check the torque of the bracket bolts for the rocker arm assembly. The correct torque is 54 N.m (40 lbf ft). Number 1 cylinder is at the end of the engine with the cooling fan. An intake valve is the first valve in the sequence. The valve clearance is measured between the top of the valve stem and the rocker arm as shown in FIGURE 94. Valve clearance (cold): 40



INTAKE = 0.40 mm (0.016 in) EXHAUST = 0.40 mm (0.016 in) 1. Remove the valve cover. Rotate the crankshaft until the NO. 1 piston is at TDC on the compression stroke as indicated by the timing marks on the crankshaft pulley. See FIGURE 95. In this position, both rocker arms for the number 1 cylinder will be loose. 2. Adjust the valves that are marked “A” in the table of FIGURE 94. Do the adjustments when the engine is cold. The correct valve clearance for all valves is 0.40 mm (0.016 in).



3. Rotate the crankshaft 360° until the TDC timing mark is aligned again as shown in FIGURE 95. At this position, the NO. 4 piston will be at TDC on the compression stroke. Adjust the valves that are marked “B” in the table of FIGURE 94.



TDC



FIGURE 95. TIMING MARKS



3 9723



CYLINDER ARRANGEMENT NO. 1



NO. 2



NO. 3



NO. 4



IN



EX



IN



EX



IN



EX



IN



EX



A



A



A



B



B



A



B



B



A – Adjust these valves when No. 1 piston is at TDC on the compression stroke B – Adjust these valves when No. 4 piston is at TDC on the compression stroke



FIGURE 94. VALVE CLEARANCE ADJUSTMENT



CHECK THE TIMING OF THE FUEL INJECTION PUMP 1. Remove the capscrew from the center of the distributor head (1). See FIGURE 96. Use a dial indicator so that the movement of the plunger can be measured. The movement of the plunger can be measured through the hole in the distributor head where the capscrew was removed. 2. Rotate the crankshaft until the number one piston is at TDC on the compression stroke. Read the mark for timing on the crankshaft pulley that is aligned with the indicator on the gear case shown in FIGURE 95. Rotate the crankshaft before and after TDC to find the maximum movement of the plunger toward the end of the distributor head.



1 1. DISTRIBUTOR HEAD 2. PLUNGER 3. DIAL INDICATOR



2



FIGURE 96. FUEL INJECTION PUMP 3. Rotate the crankshaft counterclockwise approximately 30°. Now rotate the crankshaft clockwise slowly. 4. Stop rotating the crankshaft when the plunger is 0.50 mm (0.020 in) less than its maximum movement found in step 2. 5. Read the mark for timing on the crankshaft pulley that is aligned with the indicator on the gear case. See FIGURE 95. The correct timing for injection is 6° BTDC. 6. If the timing is not correct, loosen the fuel injection pump and rotate it as necessary. Repeat the procedure described in step 5 until the timing is correct. 7. Remove the dial gauge and install the capscrew in the distributor head. 8. Remove the air from the fuel system. The procedure is described in “Remove the Air From the Fuel System”. 41



THROTTLE LINKAGE, ADJUSTMENT (See FIGURE 97. and FIGURE 98.)



leased. Make sure the control lever is against the maximum speed screw when the pedal touches the floor.



NOTE: Each time the throttle linkage is disassembled, it is important to adjust the throttle cable. Adjust the throttle linkage when the engine is running at idle speed and at normal operating temperature.



MONOTROL PEDAL SHOWN 2



1



1. Disconnect the throttle cable at the control lever on the injection pump. 3



2. Adjust the idle speed of the engine. The idle adjustment screw on the injection pump controls the idle speed. The correct idle speed is 725 ± 25 rpm. Be sure to use a tachometer that will work for a diesel engine.



4 5 4



3. Check that the engine speed with the throttle wide open and no load is 2100 to 2200 rpm. Use the maximum speed screw on the injection pump for to set the engine speed at wide open throttle. 1



2 3 4 4 6



6



5



12845



1. RETURN SPRING 2. CONTROL LEVER 3. IDLE ADJUSTMENT SCREW



4. THROTTLE CABLE 5. INJECTION PUMP 6. MAXIMUM SPEED SCREW



FIGURE 97. THROTTLE LINKAGE 4. Make sure the throttle linkage at the pedal assembly is in the correct position. Hold the throttle pedal against the floor plate. Hold the control lever in the wide open position. Adjust the position of the cable by using the jam nuts on the bracket at the intake manifold. Adjust the cable so that the rod end fits into the control lever 5. Adjust the stop for the throttle pedal so that the control lever is completely closed when the pedal is released. 6. Operate the throttle pedal. Make sure the control lever is against the idle speed screw when the pedal is re42



1. 2. 3. 4. 5. 6.



4



PEDAL FRAME PEDAL PAD STOP CORRECT HOLES FOR THE LINKAGE LINK CRANK



FIGURE 98. THROTTLE PEDAL AND LINKAGE



CHECK THE ELEMENTS FOR THE COLD START AID SYSTEM Check the condition of the glow plugs for the cold start aid system. See the section THE ELECTRICAL SYSTEM for more information.



CHECK THE COMPRESSION PRESSURE (See FIGURE 99.) 1. Operate the engine until it is at normal operating temperature. 2. Remove the glow plugs from the cylinder head. Disconnect the wire at the fuel shut off solenoid on the injection pump. Disconnect the wire for the temperature switch at the thermostat housing.



3. Install a compression gauge in the number 1 cylinder. Make sure the gauge has a minimum range of 3.5 MPa (500 psi).



d. If the compression pressure increases to a normal reading, the low pressure was caused by worn or damaged piston rings. The cylinder bore can also be damaged.



4. Use the starter to crank the engine at least six (6) revolutions. Check the pressure reading and release the pressure. Repeat the test again and make a note of the highest pressure. Do this test for each cylinder.



e. If the compression reading does not increase, the low pressure was caused by worn valves, valve seats or valve guides.



5. The standard pressure reading is 3.0 MPa (427 psi). The minimum reading is 2.7 MPa (384 psi). The maximum variation between cylinders is 0.3 MPa (43 psi).



f. If the low pressure readings are in two cylinders next to each other, the cylinder head can be leaking. 1. ADAPTER



6. If the readings are lower than the minimum reading, there is a problem with the valves, piston rings or cylinder head gasket. Do the following tests to find the problem:



1



a. Add approximately 30 ml (1.0 oz) of engine oil to each cylinder at the glow plug port. b. Crank the engine approximately ten revolutions to distribute the oil. c. Install the compression gauge and do the same tests as described in step 3.



FIGURE 99. CHECK THE COMPRESSION PRESSURE



43



ENGINE SPECIFICATIONS ITEM



SPECIFICATION



Engine Type



In–Line, Four Cylinders



Bore x Stroke



95.4 mm x 107.0 mm (3.76 in x 4.21 in)



Firing Order Displacement Compression Ratio Idle Speed Governed Speed (No Load)



1–3–4–2 3059 cm3 (186.7 in3) 20.5:1 725 ± 25 2100–2200 rpm



Compression Pressure



2944 kPa (427 psi) @ 250 rpm



Injection Pump Timing



6° BTDC



Oil Pressure @ 2000 rpm



294 kPa (43 psi)



Thermostat Starts to Open Fully Open



76.5°C (170°F) 90°C (194°F)



Camshaft Camshaft Lobes Camshaft Lobes – Minimum Height Bearing Journals Service Limit Clearance Between Journals and Bore End Clearance (Maximum) Connecting Rods Small End Bore Clearance Between Piston Pin and Bore Service Limit Clearance Between Crankshaft Journals and Rod Bearings Crankshaft Distortion Service Limit Main Bearing Journal Diameter Service Limit Clearance Between Journals and Main Bearings Connecting Rod Journal Diameter Service Limit Thrust Bearing Clearance Service Limit Cylinder Block and Liners Sizes Cylinder Head Height Distortion Limit 44



42.02 mm (1.6543 in) 41.65 mm (1.66398 in) 49.945–49.975 mm (1.9663–1.9675 in) 49.60 mm (1.953 in) 0.12 mm (0.005 in) 0.20 mm (0.0079 in) 21.943–21.961 mm (0.8639–0.8646 in) 0.012–0.039 mm (0.0005–0.0015 in) 0.05 mm (0.002 in) 0.037–0.076 mm (0.0015–0.0030 in) 0.05 mm (0.002 in) 0.08 mm (0.0031 in) 69.917–69.932 mm (2.7526–2.7532 in) 69.91 mm (2.7524 in) See TABLE 11 52.915–52.930 mm (2.0833–2.0839 in) 52.90 mm (2.0843 in) 0.10 mm (0.0039 in) 0.30 mm (0.0118 in) See TABLES 12 and 13 91.55 mm (3.604 in) 0.20 mm (0.008 in)



ENGINE SPECIFICATIONS ITEM



ENGINE MODEL



Oil Pump Clearance Between Shaft and Body (Maximum) Clearance Between Inner and Outer Rotors (Maximum) Clearance Between Outer Rotor and Body (Maximum) End Clearance Between Rotors and Housing (Maximum)



0.2 mm (0.008 in) 0.2 mm (0.008 in) 0.4 mm (0.016 in) 0.15 mm (0.006 in)



Pistons Diameter Clearance in Groove for Piston Rings Piston Ring End Clearance



See TABLE 9 See TABLE 7 See TABLE 6



Piston Pins Diameter Service Limit



33.995–34.000 mm (1.3384–1.3386 in) 33.970 mm (1.3374 in)



Rocker Shaft Assembly Rocker Shaft Diameter Service Limit Rocker Arm, Inside Diameter Service Limit



18.98–19.00 mm (0.747–0.748 in) 18.90 mm (0.744 in) 19.036–19.060 mm (0.7494–0.7503 in) 19.100 mm (0.7519 in)



Valve Mechanism Clearance in Guide (Intake) Service Limit Clearance in Guide (Exhaust) Service Limit Diameter of Valve Stem (Intake) Service Limit Diameter of Valve Stem (Exhaust) Service Limit Valve Seats Valve Face Angle (Intake and Exhaust) Spring, Free Length Service Limit



0.039–0.069 mm (0.0015–0.0027 in) 0.200 mm (0.0079 in) 0.064–0.093 mm (0.0025–0.0037 in) 0.250 mm (0.0098 in) 7.946–7.961 mm (0.3128–0.3134 in) 7.880 mm (0.3102 in) 7.946–7.961 mm (0.3128–0.3134 in) 7.850 mm (0.3091 in) See FIGURE 13 45° 48.0 mm (1.89 in) 47.1 mm (1.86 in)



45



TORQUE SPECIFICATIONS ITEM



SPECIFICATION



Camshaft Gear



64 N.m (47 lbf ft)



Camshaft Thrust Plate



18 N.m (13 lbf ft)



Cooling Fan



20 N.m (15 lbf ft)



Coolant Pump



19 N.m (14 lbf ft)



Connecting Rod Cap Crankshaft Pulley Cylinder Head Engine Mount to Engine Exhaust Manifold Flywheel



See Text 275 N.m (203 lbf ft) See Text 55 N.m (41 lbf ft) 18 to 22 N.m (13 to 16 lbf ft) 120 N.m (89 lbf ft)



Flywheel Housing



See FIGURE 75



Fuel Injection Pump Drive Gear



64 N.m (47 lbf ft)



Fuel Injection Pump To Adapter Plate



19 N.m (14 lbf ft)



Fuel Injector



64 N.m (47 lbf ft)



Glow Plug



23 N.m (17 lbf ft)



Intake Manifold Main Bearing Cap



16 to 24 N.m (12 to 17 lbf ft) 167 N.m (123 lbf ft)



Oil Pump



19 N.m (14 lbf ft)



Oil Sump



19 N.m (14 lbf ft)



Rocker Shaft Brackets



54 N.m (40 lbf ft)



Starter



88 N.m (65 lbf ft)



Thermostat Housing



19 N.m (14 lbf ft)



Timing Gear Case



20 N.m (15 lbf ft)



Timing Gear Cover



19 N.m (14 lbf ft)



46



TROUBLESHOOTING PROBLEM The engine will not start.



POSSIBLE CAUSE 1. 2. 3. 4. 5. 6. 7. 8.



The engine rotates but will not start.



The engine does not idle smoothly.



The engine does not have normal power.



The engine uses too much fuel.



Fuel tank is empty. Starter does not operate. Cold start aid does not operate. Neutral start circuit does not operate correctly. Engine has internal damage. Fuel shut–off solenoid does not operate correctly. Battery is not fully charged. Battery cables dirty or loose.



1. Fuel tank is empty. 2. Fuel injector(s), or fuel injection pump does not operate correctly. 3. Cold start aid does not operate. 4. Fuel lines have a restriction. 5. Fuel shut–off solenoid does not operate correctly. 1. Air is in the fuel system. 2. Fuel injector(s), or fuel injection pump does not operate correctly. 3. Fuel lines have a restriction. 4. Fuel filter has a restriction. 5. Water in the fuel system. 6. Valves are not adjusted correctly. 7. Compression pressure is too low. 1. Air filter has a restriction. 2. Fuel injector(s), or fuel injection pump does not operate correctly. 3. Fuel lines have a restriction. 4. Fuel filter has a restriction. 5. Water in the fuel system. 6. Valves are not adjusted correctly. 7. Compression pressure is too low. 8. Valve springs are worn or broken. 9. Exhaust pipe has a restriction. 1. Air filter has a restriction. 2. Fuel injector(s), or fuel injection pump does not operate correctly. 3. Valves are not adjusted correctly. 4. Compression pressure is too low. 5. Valve springs are worn or broken.



PROCEDURE OR ACTION 1. 2. 3. 4.



Fill fuel tank. Check starter and circuit. Check circuit for glow plugs. Check wiring and switches.



5. Check and repair. 6. Check wiring and solenoid. 7. Charge the battery. 8. Clean and tighten battery terminals. 1. Fill fuel tank. 2. Clean or repair. 3. Check circuit for glow plugs. 4. Repair fuel lines. 5. Check wiring and solenoid. 1. Remove air. 2. Clean or repair. 3. 4. 5. 6. 7.



Repair fuel lines. Install a new filter element. Drain water from filter. Adjust the valves. Repair engine.



1. Clean or install a new filter. 2. Clean or repair. 3. 4. 5. 6. 7. 8. 9.



Repair fuel lines. Install a new filter element. Drain water from filter. Adjust the valves. Repair engine. Replace springs. Clean exhaust pipe.



1. Clean or install a new filter. 2. Clean or repair. 3. Adjust the valves. 4. Repair engine. 5. Replace springs.



47



TROUBLESHOOTING PROBLEM Engine oil pressure is too low.



The engine uses too much oil.



POSSIBLE CAUSE 1. Too much oil in the engine, or the wrong type of oil. 2. Oil filter has a restriction. 3. Oil strainer has a restriction. 4. Oil pump is worn. 5. Rocker arm bushings are worn. 6. Camshaft or bearings are worn. 7. Crankshaft or bearings are worn. 1. Too much oil in the engine, or the wrong type of oil. 2. Oil leaks from seals or gaskets. 3. Seals for valve guides are worn. 4. Piston rings are worn or broken. 5. Cylinder liners are worn or damaged. 6. Oil lines or oil filter is loose.



The engine operating temper- 1. Coolant level is too low. ature is too high. 2. Drive belt for fan and water pump is loose or missing. 3. Radiator has a restriction. 4. Water pump is worn or damaged. 5. Cylinder head gasket leaks. 6. Thermostat does not operate. 7. Leaks in the cooling system. 8. Fuel injection timing is not correct. White exhaust smoke.



1. 2. 3. 4. 5. 6.



There is water in the fuel. Fuel injection timing is not correct. Compression pressure is too low. Seals for valve guides are worn. Piston rings are worn or broken. Cylinder liners are worn or damaged.



Black exhaust smoke.



1. Air filter has a restriction. 2. Fuel injector is dirty or pressure is too low 3. Fuel injection timing is not correct.



PROCEDURE OR ACTION 1. Use correct amount and type of oil. 2. 3. 4. 5. 6. 7



Install a new oil filter. Clean oil strainer. Install a new oil pump. Install new bushings. Install a new camshaft or bearings. Install a new crankshaft or bearings.



1. Use correct amount and type of oil. 2. 3. 4. 5.



Install new seals or gaskets. Install new valve guide seals. Install new piston rings. Install new liners.



6. Check for loose fittings or filter. 1. Check coolant level. 2. Install drive belt and adjust tension. 3. 4. 5. 6. 7. 8.



Clean or repair radiator. Install a new water pump. Install a new head gasket. Install a new thermostat. Repair leaks. Check and adjust timing.



1. 2. 3. 4. 5. 6.



Drain water at fuel filter. Check and adjust timing. Repair engine. Install new valve guide seals. Install new piston rings. Install new liners.



1. Clean or install a new filter. 2. Clean and adjust injectors. 3. Check and adjust timing.



TECHNICAL PUBLICATIONS 600 SRM 553 48



1/94 Litho in U.S.A.