SERVICE MANUAL MITSUBISHI DIESEL ENGINE L-SERIES L2A,L2C,L2E L3A,L3C,L3E APRIL 2001 MITSUBISHI HEAVY INDUSTRIES, LTD.FOREWARD This Service Manual, prepared for the benefit of service mechanics, describes the construc- tion and service procedures of the Mitsubishi diesel engine models L series (L2A, L2C, L2E, L3A, L3C and L3E). We hope that this manual will be helpful for you to make proper and fast service operations, ensuring that the engines are able to keep top performance over an extended period of time, This manual has been prepared on the basis of the latest engines in May 1997 and, therefore, does not contain possible changes in specification to which those engines are subject there- after, Pub. No, 99619-15180MITSUBISHI DIESEL ENGINE L MODELS CONTENTS GENERAL INFORMATION . ENGINE LUBRICATING SYSTEM FUEL SYSTEM .GOVERNOR SYSTEM oO IN |m | . COOLING SYSTEM -AIR CLEANER ELECTRICAL SYSTEM . SERVICE SPECIFICATIONS AND STANDARDSGroup oY? | GENERAL 01 ENGINE MODEL AND ENGINE NUMBER ~ 02 SECTIONAL VIEWS 03 FEATURES - 04 PERFORMANCE CURVES 05 ENGINE SPECIFICATIONS - 06 MAINTENANCE -- 07 TROUBLESHOOTING Tractor Application Excavator Application= G 0-01 ENGINE MODEL AND ENGINE NUMBER Engine Model and Engine Number 0, | Model, Classification, and Use (1) Engine model and Model [Application | Use La [1s Te~ | er For Aericarl vee | | ve |e = For austial La | ise [en = Fer eaport oni + we (2) The engine model number may be broken down as follows : ac-! A , “Lsusivisin of speciation Appliation Pegged 3 nl ieee eae) slider bore egg am.) Nonber of e's, (2: Two, 3: Three) Name of series (L: Lightwoight engine) gine model embossment and engine number stamp | (1) Embossment of engine model and cylinder vol ‘The engine model and cylinder volume are embos- sed on the side of injection pump mounting portion of the cylinder block, (2) Engine number stamp The engine number is stamped on the injection pump mounting portion of the cylinder block (on the upper side of the tie rod cover). It is a serial number beginning with 1001 as shown Number Engine model to01~ (ALL models) 3G L | 0.80 @ c ) Cc Engine Model and Cylinder Volume P SP SII Q 1001 ‘e—aull gine Number © LC e WwTow ACS we ca (eiOs 0-02 SECTIONAL VIEWS L Cross Section (L3C)ea = 0-02 GJ Sectional Views of Governor (L3C)Ne G 0-02 SECTIONAL VIEWS Oil Pump and Oil Filter.er nd 0-03 FEATURES 0-03 1. Aim of development The L series aim at the through going compact, lightweight engines which are suitable for super- seding gasoline engines to power lawn mowers, vehicles, etc, The high-speed (3600. rpm continuous) specification engines are also avail- able to apply them to the generators, welders, and marine use, The L series are, the smallest ‘and lightest water-cooled diesel engines in the world, 2, Features of the new series c }) Small and lightweight engine The new L series are 10 to 20% smaller in weight and 15 to 20% smaller in contour volume than the same class of engines of competitors, (2) Low noise and economical fuel consumption Low noise and economical fuel consumption are attained by the well designed cylinder block con- struction (having curved side faces), the rearranged combustion chambers, and the small sized fuel injection system, (3) Easy starting ‘The engine can be started instantly only by keep- ing the starting switch key in the ON position for about 6 seconds to allow automatic feeding of current to the glow plugs, eliminating the neces- _Iniection Pump sity of setting the key to the HEAT position, (For engines with the automatic glow plug system, ) The new governor mechanism also contributes to easy engine start, because it increases fuel injection and delays injection timing for ‘easy engine start without necessity of moving the throt- tle lever to the " full throttle” position,or GF 0-03 FEATURES (4) Multipurpose engine The L series engine can be equipped with various kinds of optional devices. Ex. Okey-OFF stop system (Fuel cutoff valve) Torque spring OManual stop lever Nozzle Holders and Return Pipeer vo. Gy 0-04 PERFORMANCE CURVES 0-04 Gy MLZ Series Performance Curves | = 1 he a BA I Mg 4 eee rpe 5 | a é La te ell | A] fl] fe | é | truant i |." Trerniene| cones : — 4] . 6 « | | : uo | eB i | | ir [tl Fi | : ; rr a ed One ae) Bae i ‘tgs sn om tobe toed om WA ae om 6270 = 2 Barometric pressure: 7 . Ti? ‘Ambient temperature: 20°C | E Vapor pressure + 10, Smmig " f i i Z| | amin conn | | § [em | T° foe “Se a8 a8 as oe roe eed om Lec= Gy 0-04 PERFORMANCE CURVES MIL3 Series Performance Curves b 7 SSS f LA e 5 a] yy sS i L g a [| / 8 LA 2 Weel $4 ' con | jo fio & Engine speed rpm = “ Ba ise 1 pwn 6270 ner | ioe he | Barometric pressure: 736mmHg t se | Ambient temperature: 20°C By Vapor pressure 10, 5mmHg * T 2" toxermfnent | i [continue AA — | € con! fr RE he © LETT 5 | se —10—Tas tee Nar Ne 0-05 ENGINE SPECIFICATIONS 0-05 Item ] ee tea} zc | ize | isa | usc | ose Engine type ‘eycle, water-cooled, vertical, diesel General | Compression ratio 2 Combustion chamber Swirl chamber Dry weight 61 5 | Number of cylinders 2 3 | cylinders | Bore x Stroke (mm) 85x70 | 70x70 | 76x70 | 65x70 | 70x70 | 76x70 Total displacement (2) | 0.464 | 0.538 | 0,635 | 0.696 | 0.808 | 0.952 Perfor. | Maximum power " Maximum torque See the engine performance curves, mance Specific fuel consumption List In every direction every 25° continuous 30'in a short time(within 30 min, ) ability | (to lower limit of oil level) Injection pump Bosch NC type Fuel System | Nozze Throttle type veer | Fuel IS No, 2 oF No, 3 diesel fuel Lubri- | Lubricating method Forced lubrication cation | oil filtration Paper-element filter (Full-flow type) system | ot eapciy 8) Upper timt/owe iit feces 0 bir ones) 24/14 3.0/1.5, 3.6/1.8 07 4.8/3.0 Cooling | Cooling method Forced water circulation with pressurized radiator system | S2elant capacity (2) te Ag si (except, rditor and hase) B A ‘Aiternator (V/A) 12/18 oF 12740 eves: : Starting motor (V//AW) 12/1,2 oF 12/1.6 sories Battery (an) 45 _or more 60_or more —n-CE] 0-06 MAINTENANCE MEEngine oil and oil filter 1, Checking and correcting the engine oil level, (1) Place the engine horizontally, (2) Check.the oil level with the oil level gauge, If the oil level has fallen to the lower limit, add cil up to the upper limit, (3) Check the oil level before (everyday) operation of the engine, Ca © Whenever added, check the oil level again after waiting for about 1 minute, © When adding oil, use only the same engine oil as used in the engine. ‘© When checking the oil level in an engine which has been long out of use, run the engine for several minutes, stop the engine, and check the oil level after a while, 2, Oil change intervals Change the oil after initial 50-hour operation of a new engine and, thereafter, every 100 hours of operation, Replace the oil filter after initial 50-hour operation of anew engine and, thereafter, every 200 hours of operation, 3, Engine oil to be used Engine oil must conform to the API classification and viscosity number specified in the table at right, Upper tit | [Normal eve) Lower iit (Checking Oil Level Olt Level Gauge PI classification | Atm, temperature Viscesity ‘Above 200 ‘SAE30 (lass C0 o better S200 ‘SAEZ0 Below 5 ‘SAE1OW-30 cise 09 tr 200 Ne speed speatea || Al seasons 1 tn ene =12-4, When replacing the oil filter, use only the genuine replacement filter. Filter 5. Changing the oil To change, oil, first warm up the engine and remove the drain plug to let oil drain completely. Put back the drain plug and refill the cil pan with fresh engine oll through the oil filler, © Oil pan drain plug tightening torque : 5.0 — 6.0 kfm [49 — 59 N-n} © Oil capacity (Upper limit//Lower limit) Le: 24071ae L3: Ordinary type 3.08//1.52 Deep type 3.62,/1.82 0 4.80,/3,08 (excluding 0.5 2 of oil filter capacity) 6. Replacing the oil filter (1) Remove the oil filter with a filter wrench or the like, (2) Thoroughly clean the filter mounting surface of the filter bracket, Install the new filter with the O-ring coated with engine oil and tighten secur- ely by hand, © Tightening torque 1.0 = 1.3 kofem [9.8 — 12.7 Nal (i Fite Wrenen Caution Be careful not to twist the O-ring. (3) Run the engine for several minutes and make ‘sure that no oil leaks, (4) After stopping the engine, check the oil level, necessary, add oil, =1B-G 0-06 MAINTENANCE © Tightening torque = io bolt ie 5 — 83.4 We al The rocker assembly (the rocker ‘arms, ‘shat, and stays) is to be kept removed when the cylinder (ylinger Head Bolt Tight ing Sequence (L2) 1.5 — 2.2 kofem (14,7 — 21.6 Nem MAdjusting the valve clearance Caution Be sure to retighten the ¢ adjusting the valve clearance, (1). Set the cylinder to be adjusted to the top dead center of compression stroke, © Valve clearance : 0,25 mm (cold) for both Intake and exhaust valves (2) The top dead center of compression stroke can be obtained by aligning the T.0.C. (Top Dead fer head bolts before Center) mark (notch) on the crankshaft pulley Adjusting Valve Clearence with the mark on the gear case. (3). First align the T.D,C, mark for the No, I cylin. der, Confirm that the valves do not move up and down when the crankshaft is turned about 20 in normal direction of rotation and in reverse direction, (4) When setting the top dead center for the No, 2 cylinder and that for the No.3 cylinder, perform as follows : -uea) L2 (Two-cylinder engine) From T.0,C, (Top Dead Center) for the No.1 cylinder, turn the crankshaft 180° clockwise, and the No, 2 cylinder is set to T.D.C, b) 13. (Three-cylinder engine) From T,D.C, for the No, | cylinder, turn the crankshaft 240° clockwise to set the No.3 cylinder T,D,C, Further, turn the crankshaft 240° clockwise, and the No, 2 cylinder is set to T.D.C., WMAdjusting the fan belt tension Move the alternator so that the belt may deflect about 10 mm deep when depressed by thumb force (about 10 kg) at a point mid- way between the alternator pulley and crankshaft pulley. MBleeding air from the fuel system (1) Loosen the air vent screw on the fuel filter, (2) For the engine without fuel pump, in which fuel drops spontaneously and enters the fuel filter, for fuel to overtiow the fuel filter, Then, tighten the air vent screw, (3) For the engine with the electromagnetic fuel pump, turn the starting switch key to the ON position to feed fuel to the fuel filter, Loosen the air vent screw on the filter and, after air escapes, tighten the air vent screw, (4) Loosen the air vent screw on the fuel injection pump to let air escape from the fuel pipe and fuel injection pump, (5) Air in the injection pipes and nozzles is driven out automatically by cranking up of the engine, Mark on eer case TDC mark on crankshaft pulley Timing mark Approx. 10mm (10g of thom force) Ajusting Fan Belt Tension Fuel Filter Air Bleeding Fuel injection Pump air Bleeding —15—tan Ne. 0-06 MAINTENANCE Replacing the fuel filter w (2) @) @ (o) Cartridge type Replace the cartridge type filter as an assembly if accumulation of dust or water in its element is evident, Regular replacement interval is every 400 hours of engine operation, Check the filter every 100 hours and, if necessary, replace early, Separate type filter with cock Close the filter cock, remove the ring aut, ‘and take out the element from the inside of filter, Clean or replace the element, Fuel pump ‘The foolowing three types of fuel pumps are available, Which type of pump is to be used for ‘an engine depends upon engine specification, Plunger type electromagnetic pump The plunger-type pumps are classified as the ‘common, large-sized pump having a filter element or as the compact, light-weight, low-priced pump without filter element, Regardless of classification, check the plun ger-type pump for normal function and make sure that it does not leak fuel, Only on the pump with filter element, remove the cover and clean orrepalce the filter element, Diaphragm type electromagnetic pump The diaphragm type electromagnetic pump should not be disassembled, Like the com- pact plunger-type pump mentioned above, check that the pump funcitons normally and does not leak fuel, Cartridge Type Fiter oS *y Plunger type (Common) Fuel Pump Plunger type (Compact) Fuel pump -16— Brae Magnet CoverNe. 0-06 (c) Mechanical type fuel pump This type of fuel pump is installed with an adapter on the rear-end side of the fuel injection pump camshaft, As the camshaft rotates, the fuel pump cam pushes the tappet to actuate the diaphragm of the fuel pump, This type of fuel pump is provided with 2 priming lever to allow manual feed of fuel, Check the fuel pump for normal function and make sure that it does not leak fuel or make ‘abnormal sound, Adapter camenatt, foe injection pump Fuel Pump Priming lever Mechanical type Fuel Pump Pump type _| Delivery flow _| Shut-off pressure| "tino [887s moe | oan) Prager pe [e/a aoe | 8 ene Diaphragm type [0,371 /nin er mre) © t8t/ow Mechanical type [0,225/nin or more] (3 49t/em At 12V (electromagnetic pumps only) and at 20°C (4) Draining water from the water sedimenter For the engine provided with a water sedimenter, remove the filter ring nut involved and take out the cup, Wipe off water and dust accumulated in the cup, —17-0-06 MAINTENANCE MiChecking and adjusting injection timing To check and adjust injection timing, use the follow- ing procedure (1). Disconnect the No, | injection pipe, (2) Remove the No, | delivery valve from the injec- tion pump, Put back the valve holder only. Caution Be sure to shut off the fuel feed pipe before removing the delivery valve, (3) Remove the tie-rod cover and disconnect the tie rod from the control rack, (4) Set the control rack to a midway position in the working range, (5) Open the fuel feed pipe and make sure that fuel flows from the delivery valve holder. (6) Turn the crankshaft in the direction of normal rotation (clockwise) and find an instant that fuel stops flowing from the delivery valve hol: der, This instant is the real injection timing, Caution The standard injection timing differs with engine specification and engine speed. Check to see whether the real injection timing coincides with the standard injection timing (whether the IT mark on the crankshaft pulley isin alignment with the mark on the gear case). (7) If they do not coincide with each other, adjust thickness of the injection pump mounting shim, Increasing or decreasing thim thickness by 0, 1 mm causes the real injection timing to vary about I", -1 Removing Deliverry Valve Injection Timing Mark Adjusting Shim Thickness(8) To remove the injection pump, first disconnect, the injection pipes and fuel feed pipe from the injection pump, Then, remove the tie-rod cover and tie rod, Dismount the pump assembly. Installation of the pump is the reversal of removal, (9) In the dusty place or when the engine is dirty, removal of a delivery valve may cause intrusion fof dust into the injection pump, Under such circumstances leave the delivery valve installed and check injection timing using the following procedure : (2) Remove the tie-rod cover and disconnect the tie rod from the control rack, (b) Set the contro! rack to a midway position in the working range, Disconnect the injection pipe from the No, | nozzle, Turn the crank- shaft gradually in the direction of rotation Until swelling of fuel is found at the open end of the injection pipe, This instant is the real injection timing, which wi I" late than the standard injection timing, come approx, Adjusting the engine speeds To adjust engine speed, remove the cooling fan and install the safety cover over the fan to prevent getting hurt, For speed adjustment specification, see 8-05, (1) The upper limit of engine speed can be adjusted with the HIGH-SPEED stopper bolt, This stopper bolt has been set properly and sealed in the factory before shipping of the engine, Never tamper with the seal unless it is necessary, —19— © Removing injecto nt Pump Standard Injection Timing model le tom a Upto 2000 | sTOC IS" = ‘ver 2000~ 5 Under 3¢00_ | 87°C i" = over 3800 | TOC is =Caution ton Ne. 0-06 MAINTENANCE (2) The lower limit of engine speed can be adjusted with the LOW-SPEED stopper bolt, (3) Never remove the sealing cap unnecessarily to adjust the torque spring set, For the proper disassembling procedure, see 4-02, Low-sPeeD HIGH-SPEED Warm up the engine (until coolant temperature serbot rises up to 60°C or above) before adjusting engine speeds. HIGH-SPEED and LOW-SPEED Set Bolts (4) During running of the engine for speed adjust- ment, check the engine for gas leak, water leak, oll leak, and fuel leak, (5) After adjustment, perform engine acceleration and deceleration test to confirm that the engine is free from hunting and smoking, MiChecking and adjustment of nozzles To check and adjust the injection nozzles, use the following procedure = Injection start pressure Testing Inlection Start Pressure (1). Remove the nozzle assembly to be tested from the cylinder head and set the nozzle on the nozzle tester, Perform air bleeding by moving the tester han. dle up and down, (2) Operate the handle at a speed of 60 rpm or more and read the gauge pressure of fuel inject- ed from the nozzle, © Injection start pressure :140%:*kgf/em? (13.72! ° Wa] (3) If reading of gauge pressure is not within the specified range, disassemble the nozzle and vary thickness of the adjusting shim, Increasing or decreasing shim thickness by 0, 1 ‘mm will cause injection pressure to vary about 10 kgt/on? [0.98 MPal —29—(4) When installing the nozzle, use the following values of tightening torque : © Nozzle tightening (to cylinder head) torque : 5.0 — 6.0 kgf+m [49 — 59 Nem) © Nozzle retaining nut tightening torque : 3.5 — 4.0 kgf-m [34 — 39 Nea) © Nozzle union collar tightening torque 2.5 — 3.0 kgf-m [25 — 29 Nal 2, Chattering test Operate the tester handle at @ speed of about | stroke per second, (1). Needle valve oscilation Its consedered normal i the nozzle injects fuel mist, making intermittent sounds, and oscillations of the needle valve are transmitted to the handle, (2) State of fuel mist injection The nozzle should inject fuel mist straight in the direction ofits axis, A nozzle is defective if it does not inject steadily or it injects fuel in several separate stripes, ‘A nozzle is defective if it spills fuel accumulated on the bottom of the nozzle after chattering test, However, a very small drop of fuel remaining on the tip of nozzle after chattering test may be regarded as normal, 3, Injection test Operate the tester handle at 2 speed of 4 to 6 strokes per second, © A nozzle should inject fuel mist uniformly in the shape of a cone, 4, Checking the compression pressure (1) Make sure of the following = (@)AII of the engine ol evel, air cleaner, starting motor, and battery are well-conditioned, (b)The engine is preferably warmed up (to a coolant temperature of 50°C or more), ~21- Installing Nozzle Assembly LI LI Good Bad Charttering Test Good Bad LJ Bad Atter-spiling Testing Compression Pressure0-06 MAINTENANCE (2) Measure the compression pressure using the following procedure : (@)Pull the stop lever to the position, (b)Remove the glow plug from the cylinder to be tested, Set the compression gauge adapter to that cylinder and install the gauge, (c)Crank the engine with the starting motor until a ‘non-injection™ stable reading of the compression gauge is obtained, (@after reading the gauge, sion gauge and adapter. plug. (€lCheck all cylinders using the procedure de. scribed above, remove the compres Put back the glow Engine speed 250 — 280 rpm | Compression presure 29 ~ 32 kg/em Pressure dterence between cylinders: Within 3 kg/cm —2—ae No 0-07 TROUBLESHOOTING son using the trouble-diagnosis chart ‘As for diesel engines, trouble symptoms and causes are often so complicated that it will be difficult to locate the root cause by judging from @ trouble symptom, For example, trouble symptoms caused by the faulty injection pump, faulty injection nozzles, and improper cylinder compression, respectively, Will be much the same, To pass judgment on such a case, very close examination of the existing trouble symptom is necessary, The trouble-diagnosis charts on the succeeding pages are prepared in such a way of beginning with the most possible or easiest-to-inspect item and then proceeding stepwise to less possible or more compli- cated items, Before troubleshooting you should have a ‘right understanding of the following features about the construction and fuel combustion in the diesel engines, No. 0-07 @Normal engine operation is accompanied by ‘combustion noise (diesel knocking sounds). @A heavy-loaded engine exhausts some black smoke, @When operated singly an engine may vibrate because of high cylinder compression and large ‘output torque, @When an engine is accelerated or decelerated some hunting may occur, quickly, CAUTION Do not attempt to readjust or disassemble the injection pump for the purpose of troubleshooting, without use of a pump tester which is indispensable to measure injection quantity for each cylinder, ‘©To check whether state of combustion in a desired loosen the injection pipe cylinder is normal or not, to cut fuel feed to that cylinder, and find the resulting slowdown of the engine, Compare the degree of slowdown by that cylinder with that by another cylinder, —23—0-07 TROUBLESHOOTING MiHard starting Matters to be checked before diagnosis © Clogging of air cleaner © Coagulation of engine oil © Use of poor-guality fuel Lowering of cranking speed 2, Diagnosis Does preheating Does current tlw in glow plug | 4, | Inspect key _swite, stem operate | N° | circut as soon as key ewitcnis | 8° | wiring, and glow srmally ? turned to” H” (ON). indicator. | 4 yes yess{ Inspect glow plug. Is electric wir. {bees fuel pump, if provided, operate when | jo | Inspect fuel pump ing normal? \key switch is turned to ON? = | and/or wiring tyes Does fuel flow in fuel| jo | Does fuel get out when fuel injection | No cp || 7 ° imp air vent screw is ned ? 7» ded line? ump air vent screw is loosened ? pees Byes | Injection timing » oo Is engine putin order ? { ‘Adjust engine properly. ae oreer and valve timing ° i Ree dyes De neton vas (State of ul mis inecton No [papect mjecton noses. | operate normally? and injection start pressure a Z dyes Inspect valves, Is elinder compression normal? | Ne | pistons, piston rings, and cylinder head gosket, 8 Inspect injection pump, eoNo 0-07 Miknocking Diesel engines are usually accompanied by fuel ‘combustion noise (diesel knocking sounds) because of structural feature, A trouble should be suspected only when the engine makes abnormally large sounds, |, Matters to be checked before diagnosis © Clogging of the air cleaner @Use of poor-quality fuel (Small cetane number fuel such as used for burning) 2, Diagnosis Is injection timing normal ? No ‘Adjust injection timin, (Check for premature injection, ) ° ee dyes Do injection nozzles operate normally 7 x (Check for lowering of injection start pressure 1° | Inspect injection nozzles. £ and improper state of fuel mist injection, ) Syes [in cyngor compression narmar? | No [inspect valves, pistons, piston rings, [1s einer compression norma? = land cylinder head gasket, yes Does injection pump operate normally ? (Check for uniformity of injection quantity. ) ayes Mechanical noise (Worn or damaged main moving parts) —25—0-07 TROUBLESHOOTING Moverheating Matters to be checked before diagnosis @Shortage of coolant and leakage © Clogging of muffler © Loosening of fan belt © Clogging of radiator fins © Too rich antifreeze solution 2, Diagnosis Is engine operating condition moderate? Find the cause of (Check for overload continu: overloat ‘ous running, ) ayes Is cooling system | through, water pump, water for malfunctioning. ) dyes (Check cylinder head gasket for blowing hose, in good order ? | radiator fins for clogging, and thermostat and © Stagnation of cooling air © Defective thermostat No 2 1s injection timing is normal? | NO [ Agjust injection timing, NOTE : Overheating is mostly caused by mis-matching load of the engine. If overheating arises only when the engine drives a load, measure coolant temperature under the working load condition (full open thermostat) to see whether the measurement exceeds a point 60° C higher than atmospheric temperature. If so, it is advised to check for mis-matching of load, too. —26— ‘© Shortage of engine oil and deterioration Repair cooling system,0-07 WMBlack-smoky exhaust Matters to be checked before diagnosis, ‘© Clogging of air cleaner element ©Use of poor-quality fuel © Overload 2, Diagnosis Is smoke set of injection pump No ee NP | Adjust smoke set, Syes put in order ? (Check for excessive valve clearance and improper injec: tion timing, ) Adjust engine, yes Do injection nozzles operate normally ? (Check for improper state of fuel mist injection and for} NO [inspect injection nozzles, excessively large injection start pressure, ) dyes Inspect valves, cylinder head gasket, pistons, and piston rings, Is cylinder compression | No normal ? ° yes Inspect injection pump, 270-07 TROUBLESHOOTING ‘Munsteady 1 |. Matters to be checked before diagnosis ‘Faulty engine control system © To0 high engine oil viscosity © Use of poor quality fuel 2 Diagnosis Is engine adjusted properly ? (Check for idling speed, valve clearance, and injection | siming.) tL Syes | Do injection nozzles operate normally ? (Check for state of fuel mist injection and injection start pressure. ) dyes No 2 No Adjust engine, Inspect injection nozzles. 's cylinder compression normal ? (Check equality between cylinders. ) No 2 Inspect valves, pistons, and piston rings. Byes Inspect injection pump ‘and governor system, | Ca ~28—0-07 Mow output |. Matters to be checked before diagnosis ‘@Seizing of engine moving parts, _@ Clogging of air cleaner eleme! © Too viscous engine oi! © Use of poor-quality fuel 2, Diagnosis Is sufficient fuel flow in fuel line? dyes © Clogging of muffler nt (© Malfunctioning of drive system (Engine without fuel pump) Is spontaneous dropping of fuel nor- mal? (Engine with electromagnetic fuel pump) Does fuel pump feed fuel with key switch placed in ON ? — yes=| Inspect fuel pump, Is engine adjusted properly ? No ‘Adjust engi (Check for valve clearance and injection timing, ) * ——— Byes Do injection nozzles operate normally ? Inspect fuel filter, fuel pipe, and fuel tank, (Check for state of fuel mist iijection and injection start | N° [inspectinjection nozzles, | pressure.) TS Is cylinder compression normal ? yes 8 No * Inspect valves, cylinder head gasket, pistons, and piston rings, Inspect injection pump, —29—Gri coup e | ENGINE } 0 02 ROCKER ARMS AND ROCKER SHAFT 03 CYLINDER HEAD - 04 VALVES AND VALVE SPRINGS --- 05 INTAKE MANIFOLD AND EXHAUST MANIFOLD 06 GEAR CASE AND OIL PUMP «+--+ 07 TIMING GEARS- | GENERAL 08 CAMSHAFT (VALVE CAMSHAFT AND INJECTION PUMP CAMSHAFT) ---53 09 PISTON AND CONNECTING ROD 10 CRANKSHAFT - CYLINDER BLOCK. ~oe 1-01 GENERAL Specifications lem Model 1G B Oylinder head Material Special cast iron Combustion chamber type Swirl chamber Material of chamber Heat-resisting steel (press-fitted in cylinder head) Type of intake and exhaust por rts Cross-flow type | |Heat-resisting steel (3600 rpm spécification engines) Valve seats Material Special cast iron (3000 rpm or less engines) Face angle 4s Valves Intake IN Identification mark Exhaust | EX Valve springs Type Uniformly pitched, single Identification mark fhite paint at top (common to intake and exhaust vaives)| Cylinder head gasket Material Carbon sheet (Graphoil) Material Special steel Cylinder head bolts MIO x6 MIO x8 Size x Number of bolts MB x2 MB x3 Camshaft Valve cam Material Pump cam Carbon steel Arrangement — Drive Side ~ Gear driven Cylinder “block Cylinder bore aa [ee [tae [aA] se |e 5 | 70 | 76 | 65 70 | 76. Cylinder liner type Monoblock type Water jacket type A Full jacket, £: " Siamese” type Material ” Carbon steel Crankshaft Surface treatment Hardening (Induction) Main journal di, x Crankpin dia, 43 x 40 Type * Autothermic™ piston Joint to connecting rod Semi-floating Cooling Oit jet —32—e 1-01 Node hem 2 B om Semi-teystone ype Piston rings Noe Plain bpe jou ne With col expander Type | Gear pe out pump t Drive Direct arive by crankshaft Timing gears | Crankshaft gear Number of teeth : 26 Idle gear ” 240 | injection pump camshat gear ” 182 Valve camshaft gear ” 152 —33—No EI 1-01 GENERAL Special Tools Use Too! name | ‘Sketch Referential page Removal and installation | Piston pin | 56 ~ 58 of piston pin setting tool 7332400 Measurement of cylinder] Compression 20 compression gauge adapter 81332270 Removal and installation | Oil pressure 68 of oil pressure switch | switch socket wrench (26) ‘MD998054 Repair of valve seat | Valve seat | 37 ~ 38 eter ———- Valve seat cutter, 45° Valve seat \ cutter, 60° Nominal angle of eutter Valve seat cutter, 30° 34we ae ie ie EJ 1-02 ROCKER ARMS AND ROCKER SHAFT 1-02 EI Construction of Rocker System component Parts © il filler cap ® Rocker cover gasket ® Breather hose @® Rocker shaft @ Rocker cover © Rocker spring —35— @ Adjust screw ® Rocker arm @ Rocker stayRemoval and Installation Caution 1 2, After installing the rocker shaft, adjust valve clearance. | Minspection 1-02 ROCKER ARMS AND ROCKER SHAFT Be careful not to confuse proper direction of installation of the rocker shaft. @—— tghening toraue: Front dentif- {onthe valve ie) $3 hole 0.5 ~ 0.8 kgfim (4.9 — 7.8 Stay tightening torque: 1.5 — 2.2 ko tar — (2 @ pa Installing Recker Shaft and Recker Cover wal Nea] If any parts are found defective, replace them, Inspecting Rocker Shaft and Rocker Arms =36—te EJ 1-03 CYLINDER HEAD MConstruction a 1-03 ® ® Cylinder head _a cross section Cylinder Head Component Parts oO @ @ @ ® Cylinder head Valve guide Cylinder head boit (Main bolt) Cylinder head bolt (Sub-bolt) Seat ring (3600 rpm specification engine) eee0e8 —37— Water outlet fitting. Cylinder head gasket Mouth piece Thermostat Thermostat fittingio | 1-03 CYLINDER HEAD Removal (1) Remove the injection pipe assembly. Caution ‘© When disconnecting each injection pipe from the injection pump side delivery valve holder, grasp the holder with a wrench to prevent it from loosen- ing. After removing the pipe assembly, plug the nozzle holders and delivery valve holders to prevent intrusion of dust, (2) Disconnect the glow plug lead wire, (3) Loosen’ the alternator bracket bolts and dis- mount the alternator, (4) Disconnect the air breather hose, (5) Remove the rocker cover. (6) Remove the rocker shaft assembly, (7) Loosen the cylinder head mounting bolts in the ‘numerical order illustrated at right and remove the cylinder head assembly (including the intake and exhaust manifold), (8) Remove the cylinder head gasket, Clean the cylinder head and the cylinder block surface from which the gasket has been removed, (9) Remove the nozzle holder assemblies and glow plugs from the cylinder head, (i) Remove the intake manifold and exhaust manifold from the cylinder head, (1) Remove the valve retainers, valve springs, and valves from the cylinder head, Caution ‘© When removing each valve retainer, depress the retainer against the valve spring and remove the retainer lock, Identify each valve by putting a mark indicating the number of cylinder from which the valve is removed, (12) Remove the valve stem seals, Sequence for Loosening Cylinder Head Belts (L2) Removing Valves a38—‘No. 1-03 Minspection and Repair CChack cylinder head surface for warpage between Bolt Roles: within 0. 08mm Cchack guide for ware and damage. Check for valve contac, Check foc cracks, domege, ‘wear, damage, ond sink of seat face. water leak and remove ol sudge Sealant deposit, carbon deposit Inspection of Cylinder Head MReplacement of Valve Guide 1, Removal (96.6738) Press the guide at its upper end and pull it out to the valve seat side, 2, Installation (Press-fitting) Fress-fit the guide from the upper side of the cylinder head to a height of 14 0,5 mm from the valve spring seat face, Pressfitting Valve Guide —39—No. EJ 1-03 CYLINDER HEAD MRepair of Valve Seat Ia valve seat is found defective, reface it or replace the cylinder head, [ Valve sinkage Sinkage of valve Standard Serviee lit 0.5 mm 1.5 mm Caution ‘® When checking valve sinkage, the valve guide must be in the normal condition, ‘@Resurface the valve seat so that it contacts the mid-portion of the valve face, Minstallation Installation of the cylinder head is in the reverse order of removal, Pay attention to the following : (1). Renew the cylinder head gasket, No application of sealant is necessary, On the upper froht of, the gasket is engine model to which that gasket is applicable, gasket for other engine model, (2) tighten the cylinder head bolts in the numerical order shown in the figure at right, going through that order two or three times, Tighten each bolt a little at a time until all are tightened Be careful not to confuse with a to the specified torque, (3) When connecting the injection pipe assembly, loosen the pipe clamp, ‘When tightening the nut at each end of pipe, ‘grip the nozzle holder or delivery valve holder with @ wrench to prevent it from being turned together with the nut, Also, take care not to allow dust to enter the fuel line, Invertace and weer Checking Valve Sinkage Wath of valve contact: 1'3-1.8mm Sequence for Tightening Cylinder Head Bolts (L2) Sequence for Tightening Cylinder Head Bolts (L3) 40se a i in EJ 1-04 VALVES AND VALVE SPRINGS 1-04 | Construction GQ been: Aastra Valve System Component Parts © Valve stem cap @® Valve stem seal © Retainer lock ® Valve spring @ Valve spring retainer ® Vabve —u—om No EJ 1-04 VALVES AND VALVE SPRINGS MRemoval (1) Dismount the cylinder head assembly, (2) Depress the valve retainer (to compress the valve spring) and remove the retainer lock, (3) Remove the valve. Removing Valve and Valve Spring inspection and Repair If any parts are found defective, repair or replace them, ‘Wear and damage (Without for agrcutrat ° 68 8 aoe 0 | ants and waar | + ridge and damage Inspection of Valve and Valve Spring [ Valve fatigue and damage = Iepeston tem | __Standard Serie iit Free length (ee) 40,5 =I H Load te/am) | 5.98/35,5 = 15% Seusrenes z ¥ Margin (na) 1.0 0.5 Valve Spring Tester 4g"es E a Repair of valve face If the valve face is found worn down, resurface with a valve refacer, If margin of the resurfaced valve exceeds service limit, replace the valve, 2, Repair of valve stem end If the valve stem end has been indented by wear, flatten with an oil stone, Inspecting Valve installation (1) Install the valves and valve springs, referring to notes shown in the figure below, (2) Mount the cylinder head assembly, (3) Adjust the valve clearances, Wa eave ees Yo compress ‘ohng, ea Pres tis tte tere oc ey | [ rt t Diving in Instaling sping Intating sing evier Installation of Valve Spring Caution Be careful not to damage the spring and stem seal by excessively compressing the spring wher ling the valve spring, =43—vor EJ 1-05 INTAKE MANIFOLD AND EXHAUST MANIFOLD Construction Tightening torave 1.5 = 2.2 kofem [14.7 — 21.6 Nea) Manifold Component Parts © Intake pipe © Intake manitotd gasket ® Intake cover ® Exhaust manifold gasket @ _ Exhaust manifold —u-No 1-05 inspection Check the following matters, If any defect is found, repair or replace the manifold, (1) Check the mounting surfaces to the cylinder head for flatness, The surfaces must be flat within 0, 15 mm, (2) Check the manifolds for corrosion, damage and cracks, Caution Check the interior of the Intake manifold for dust and dirt, If any dust is found, check the joints to the air cleaner and intake pipe for sealed condition, —45—a We E| 1-06 GEAR CASE AND OIL PUMP Construction Common to L2 and L3 Gear Case Component Parts © Bushings © Relief plunger ® Plug ®© Relief spring ® Gear case ® Oil pump inner gear ® Front oil seal ® il pump outer gear ~46— eeee Oil pump housing Gear case gasket High-pressure pump gear housing Housing gasketMRemoval (1) Remove the crankshatt pulley, (6) Remove the water pump assembly, (2) Remove the fan and fan belt, (7) Remove the alternator. (3) Remove the tie-rod cover from the side face of __—_-(8)_ Remove the pump housing. the injection pump. (9) Remove the gear case assembly. (4) Remove the tie rod and tie rod and tie-rod “spring. Be careful not to let the spring fal into the case, (5) Remove the governor cover assembly. Minspection Check the removed parts. If any parts are found defective, repair or replace them, Cracks anc damage Wear and damage Wear, damage, and clearance Spring fatigue ‘Smooth movement “Thoroughly clean oi lin. Seal surface nterteence Inspection of Gear Case and Oil Pump Oi! Pump Performance Speed, rem | 1000 2000 Description Pressure.kgf/on'twPel [1.500.181 | 2.0 [0.20] Discharge [tow rateé /ain Bor more | 17 of wore ‘Cracking pressure Ko/enwPal | 3.0 10.28) = Relief valve cioingpresurekat/atiral | — | (0,49) or below ‘0/1 used : SAEBO, 100-5 —a7—1-06 GEAR CASE AND OIL PUMP MReplacement of Front Oil Seal (1) Remove the front oil seal, (2) Presscfit the new front oil seal, Cation, a aaa © Apply thin coat of engine oll to the circumference and lip of the oil seal. WReplacement of Governor Shaft Bushings (1) Remove the expansion plug and draw the bush- ings out. (2). Press-fit the new bushings into positions shown in the figure at right, ayy ‘Tobe tush with “To bein contact this plane wth bottom Pressfitting Governor Shaft Bushing inspection of Governor System: Check the governor system parts. If any parts are found defective, repair or replace them, (cheek spines for fatigue gf @ | | PE. Check siding sleeve join for weat and demage. Check weight for wear and damage, =4g—Ne 1-08 MDisassembly and Reassembly of Governor Levers cere ol ener Expansion plug Grooved pin Proition (1) Remove the expansion plug, taking care not to ‘spprex. 2mm scratch the gear case a (2) Pull out the grooved pin. 2, Installation of shaft (1) Install the shaft in the reverse order of removal, Secton Ak (2) After installing the shaft, press-fit the expan- sion plug into the shaft hole in the gear case. Minstallation of Gear Case Assembly —49— Gear case Installing Governor Shaft Tightening torque 0.8 1.0 kof (7.8 = 9.8 Tightening torque: x 4 5 kofm (99 — 49 Hea] ‘Taper plug ghtening torque’ 1.8 = 2.2 kofem (14.7 — 21.6 Wea] ‘Sealant: HERMESEA HY or THREE-BOND 1948 Gear Case Assembly Installing Gear Case Assemblymie 1-07 TIMING GEARS Construction Timing Gear Component Parts © Crankshaft gear @® Camshaft gear @ dle gear ® Injection pump camshaft gear ~50—Removal (1) Pry the snap ring out and remove the idle gear. (2) Remove the valve camshaft and injection pump camshaft on which the respective gears are press-fitted, Remove the gears from the shafts, (3) Remove the crankshaft, Remove the gear from the crankshatt, inspection Check the removed gears, If any gear is found defective, replace it, Idle gear bushing Descrigtion Standard vale | Service limit Carne baween bat! 93 — 0,07 on seas . . . Backlash between gears in mesh Description Standard vale | Service limit (Crankshat-ile Ide-Camstatt | 0,01 = 0,14 0.3 Iee-Fel pump Gear Nor 1-07 Removing Camshaft Gear Injeoton pump camsnah goer Check tooth faces land end surfaces for vat and damage, Valve camshaft gear | Crankshaft gear Inspecting Timing Gears —s1—‘Ne. EJ 1-07 TIMING GEARS installation of Timing Gears (1) Press-fit the crankshaft gear onto the shaft, (2) Press-fit the valve camshaft gear and injection pump camshaft gear onto the respective shafts, (3) Install the gears in the following sequence (2) Turn the crankshaft to set the No, | cylinder to top dead center on compression stroke, (b) Install the vaive camshaft and injection pump camshaft, (c) Install the idle gear so that timing marks on it are in alignment with marks on other gears, (d) Confirm that timing gears are in alignment with each other, Timing Gears in Alignment with Each Other —52—a tas tie te EI 1-08 CAMSHAFTS (Valve and Pump) 1-08 EJ Construction | . os Camshaft Component Parts © Camshaft (Valve) ® Tappet ® Camshaft gear ® Push rod @® Ball bearing ® Camshaft (injection pump) ® Woodrutt key @ Camshatt gear © Sunk key @ Ball bearing (Rear) © Camshaft stopper ® Snap ring @ Bolt —53—Ea 1-08 CAMSHAFTS (Valve and Pump) Removal of Valve Camshaft |, When it is necessary to remove only the valve 2, camshaft, use the following procedure : (1) Dismount the cylinder head assembly, (2) Pull out the push rods, (3) Pull out the tappets, (4) Remove the gear case assembly, (5) Remove the camshaft stopper bolt, (6) Draw the camshaft assembly out, Removal of the injection pump camshaft (1) Disconnect the injection pipes, (2) Remove the injection pump assembly, (3) Remove the gear case assembly, (4) Remove the shaft rear cover. (5) Remove the stopper bolt, (6) Pull out the shaft to the front side, Removing Injection Pump Camshaft 54No. 1-08 ssc 8 2 Ge -S] se: Som, | Each ball a ene hams coupling Wear cam lobe-Weee apd eamage Inspection of Camshafts Major diameter of injection pump cam Major diameter of valve cam ‘Standard value 30 ‘Standard value 2.37 Serviee ti it 0.7 Service limit 1.0 —55—om No. cI 1-08 CAMSHAFTS (Valve and Pump) installation When installing the camshafts, give care to the following (1) Coat the bearings and cam lobes with oil, (2) Install the camshafts in the reverse order of removal, (3) Position the timing marks on the gears in align- ment with the marks on the idler gear. Refer to 1-07 TIMING GEAR, (4) After installation, check and adjust fuel injec- tion timing and vaive clearances, Installing Valve Camshett —56—an oa No No | 1-09 PISTON AND CONNECTING ROD. 1-09 MConstruction cI @—o Piston and Connecting Rod Component parts © Piston ring No. | © Piston pin ® Connecting rod cap ® Piston ring No.2 ©® Connecting rod ® Connecting rod bott ® Oi ring D Connecting rod bearing ® Connecting rod nut ® Piston —s7—1-09 PISTON AND CONNECTING. ROD Removal (1) Remove the cylinder head assembly. (2) Remove the oil pan, (3) Remove the oil screen, (4) Chalk the cylinder number on the side face of big end of each connecting rod to prevent confusion of connecting rods. (5) Remove the connecting rod cap from each piston-and-rod assembly, and draw the assem. bly upward from the cylinder, Take care not to allow the connecting rod to ‘scratch the crankshaft pin and cylinder, Keep the removed parts (connecting rod, rod cap, piston, etc.) classified by cylinders, (6) Remove the rings from each piston with the piston ring pliers, (7) Using the piston setting tool, pull out the piston pin from each piston, Miinspection Inspect the removed parts, If any parts are found defective, replace or repair them, FRONT ark arom Removing Piston Pin Wear, seizure, and steaks “Clearance between piston and cylinder Standard: 0.07~0.115mm = Wear of piston ring grooves 2 Damage, weer, and ring gap — ——— “ Big'end pay Standard: 0.1 ~0.25mm He Fs —— “Faking and fon + Ol cearanee & Standard 6022~0,052mm @ —— damage. Inspection of Piston and Connecting Rod —58—Inspection of piston ring gaps Put each piston ring into the cylinder bore and push the ring with piston to position the ring on. ‘square with the-cylinder wall, Measure the ring gap with a feeler gauge, If the measurement exceeds service limit, replace that piston ring, Caution ‘© When only the replacement of rings is to be made, without reboring (honing) of the cylinder, position the ring to be measured at the least worn place of cylinder skirt. © When replacing rings, install the new rings having. the same size as the piston, ‘© Piston rings available for servicing are sized into three classes : STD, 0.25 0S, and 0,50 OS, 2, Inspection of ring groove in piston Measure the side clearance for each piston ring set in the ring groove in the piston, If the service limit is exceeded, If the clearance still exceeds the service limit, replace the piston with new one, replace the ring with new one, installation When reassembling the piston and connecting rod and installing the piston-and-rod assemblies in the cylinder block, pay attention to the following (1) Reassembling the piston and connecting rod Using the Piston Pin Setting Tool, press the piston pin in to the set position, Description Standard Pin press-fitting force 500k (at a normal temperature) 1000+ 500kg —59— No 1-09 Pion © I cinder —J Ring Ring gees Measuring Ring Gap Ring Standard | Service limit All ings 0, 15~0, 40 1s Measuring Ring Side Clearance Ring Standard | Service limit No. = 0.3 No.2 0. 05~0,08 02 oil 0,03~0,07 a2 Note : No, I ring is of the semi-key stone ype, Installation of Piston and Connecting RodNo. 1-09 PISTON AND CONNECTING. ROD EI Pe FRONT motk (oro) Bese plug Connecting kod th tod Identtication mark LA reer vy Guid "LA" 1920): for 28, L98 Sti “Le 8.80) fo Lae, Le Gee Pressing in Piston Pin (2). Installation of piston rings FRONT mark Fd front mark Align notches accurately with tach other Tightening torque: 3.2 — 3.5 kofm (31 — 34 “Tack an Ring set postions: 2 0S sae mark Not ng, fies ae a ee eyeee ae Color of discrimination: STE 0.25= White 0150-818 Installation of Piston Rings and Connecting Rod Cap —60—No. 1-09 @) (a) 6) Set the piston ring gaps to the proper positions {as shown in the figure at right. Coat the rings and cylinder wall with oil, Using a piston-ring compressor to compress the rings into the grooves, push the piston-and-rod assembly down into the cylinder. Be careful not to break the rings by excessively knocking the head of piston, Note that the front marks on the piston and connecting rod are toward the engine front, Coat the bearing surface of the connecting rod caps with engine oil, Fit each cap to the connecting rod using match marks put before removal as a guide, In the case of a new rod which does not such a match mark, position the notches (provided for preventing the bear- ing from rotating) on the same side. a Front <— 0 ng eo SY 1 fing 929 ‘expander of ot ‘ing Proper Arrangement of Ring Gaps Fitting Cap to Connecting RodNo. EJ 1-10 CRANKSHAFT MConstruction é Crankshaft Component Parts © Key © Washer © Rear oil seal case @® Crankshaft ® Spring washer ® Gasket ® Crankshaft gear © Flywheel @ Flywheel bott ® Crankshaft pulley @® Ring gear ® Nut @ Rear oil seal aRemoval (1) Loosen the flywheel bolts and remove the fiywheel, (2) Loosen the crankshaft pulley nut and remove the pulley. (3) Remove the rear oll seal case assembly. (4) Remove the main bearing caps. Keep each set of bearings removed together with its bearing cap. (5) Take out the crankshaft. Removing Wain Bearing Cap Minspection Inspect the removed parts. If any parts are found defective, repair or replace them, Dameged to tooth face | Damage to en ace Wear and damage Wobble of puley Inspection of Crankshaft and Flywheel —63—id 1-10 CRANKSHAFT Checking the crankshaft for wear To check the crankpins and main journals for tapering wear and out-of-round wear, diameter of each crankpin or main journal should be measured at two places along the crankpin or main journal, in two directions ” A” and” 8” each place, as shown in the figure at right, If necessary, regrind the crankpins and main jour- nals to the next under size, If any crankpin or ‘main journal has been worn out beyond the service limit, replace the crankshaft, Checking Crankshaft for Wear Diameter of crankpin and main journal (mm) Under-size diameters (mm) T Description Standard | Service limit Description Main journal Crankpin, fee 43 0,70 0.25US — |42,715~42, 730] 39, 715~39, 730 Crankpin dia, 40 =0.70 0,50 Us | 42, 465~42, 480|39, 465~39, 480 —64—2, Inspection of crankshaft oll clearance Oil clearance is calculated by subtracting the diameter of main journal or crankpin from the inside diameter of main bearing or rod bearing, To check the main bearings and rod bearings for tapering wear and out-of-round wear, inside diameter of each main bearing or rod bearing should be measured, after its bearing-cap is fastened to the specified torque, at two places along the bearing, in two directions" A” and” B” each place, as shown in the figure at right, If necessary, replace the worn bearing with new one, If oil clearance still exceeds the service limit, regrind the crankshaft to the next under size and replace the bearing with one of the corresponding under size, Caution ‘© A crankshaft which has been sized cannot be re- ground to any under size, Measuring Wain Bearing |. D. Tightening torque kat-m [om] Oil clearance (mm) Description Standard Description. Service limit Main bearing cap bolt so sste~ 9) Main bearing [oto Rod bearing cap nut a2 3soi— 90 Rod bearing 0.15 —65—