Engine: See The Attached Engine Manufacturer's SERVICE MANUAL

51.
ENGINE
TABLE OF CONTENTS
See the attached Engine manufacturer's SERVICE MANUAL
51
51-1
51. ENGINE
PREFACE
This manual explains the engine proper and is a faithful reproduction of Engine manufacturer's service manuals.
51-2
匡悶DuS耳R昏A虹
D臆S匡虹臣悶G畳悶臣
A-轟JG確
聞OD監L
FOREWORD
This Workshop Manual is desJ'gned to heJp you perform necessary

maJ'ntenance, Service, and Procedures on appJicabJe Jsuzu
･repaJr
l'ndustria] engJneS.
JnformatJ'on contal'ned in this Workshop ManuaI J's the latest
avaJ'JabJe at the tJ'me of publication.
Isuzu reserves the n'ght to make changes at any tJ-me without prror
notice.
This Workshop Manual is applicabFe to 1999 and Later models.
NOTICE
Before using this Workshop Manua一 to
you inassJ.St
performing engJne Service and maintenance operatI'ons,
J'tis recommended that you carefuHy read and throughJy
understand the I'nformatJlon contained in Section 1 -
under the headings ''GeneraI Repalr Jnstruction” and

JLNotes on The Format ofThJ's ManuaJ”
TABLE OF CONTENTS
SECTION 1. GENERALINFORMAT10N..‥=.‥‖‖..………‥.‥...‥ 1
SECT[ON2. MAJNTENANCE ”.......”...”.”....”.”””.”....... 17
SECTION3. ENGINEASSEMBLY川 29
(DISASSEMBLYI
SECTJON 4. ENG]NEASSEMBLY (2) 47
(JNSPECTION AND REPAIR)
SECT[ON5. ENGfNEASSEMBLY(3) ”””..””..””..”..””. 81

(REASSEMBu｢I
SECT10N 6. LUBFIJCATINGSYSTEM…‥‥…‥‥‥‥…....‥‥‥=.” 109
SECT10N 7. COOuNGSYSTEM ”””.””..”,,”...”””.”. 121
SECTION 8. FUELSYSTEM.....H‥‥….……‥…………‥…‥…‥ 127
SECTJON 9. ENGrNEELECTRJCALS...””””.”...,””..””.”... 141
SECTJON 10. TROUBLESHOOT[NG.”....”...””.””””.”.”.. 169
SECTIONll. SPECJALTOOLuST.......=…‥‥..……‥∴‥‥‥…‥. 195
SECTION 12. REPAIRSTANDARDS......……...”‥..‥…‥.……..” 199
SECT10N 13. CONVERS[ONTABLE.......”””.”........”......... 213

GENERAL INFORMAT]ON
SECTION 1
GENERAL fNFORMATJON
TABLE OF CONTENTS
ITEM PAGE
Generalrepairinstructions .......,............................,.......”.......” 2
Notesontheformatofthismanua[‥‥‥.‥‥‥‥‥‥‥‥‥‥‥‥‥...‥‥‥‥‥‥. 2
Maindataandspec;ficatjons.........”.................................”..””... 6
TlghtenjngtorquespecJ'ficatJ'ons ‥･.----･.‥..‥‥‥‥..‥‥‥‥.‥..‥‥‥.‥. 7
GENERAL JNFORMAT10N
GENERAL REPATFHNSTRUCT10NS
l･ Before performlng any Service with the engJne mounted, disconnect the
operation grounding cab一e
from the battery.
This vvilF reduce the chance ofcable damage and burnlng dueto short circuiting･
2. AJways usethe propertooJ athand.
ortoo[sforthejob
Where specified, use the speciaHy designed tool ortooJs.
3. Usegenuine ISUZU parts.
41 Never reuse cotter p)ns, gaskets, 0-rings･ lock vvashers･ and self 一ocking nuts･ Discard them as you
｢emove them. Rep一ace them with new ones.
5･ A一ways keep disassembled parts neatly in groups･ This win ensure a

smooth reassemb.y operatJ'on.
1t is especiaHy Important tO keep fastening parts separate･ These parts vary jn hardness design,
and
depending on their insta(lat壬on position.
6･ AI[ parts shouJd be carefuJJy cleaned before inspection or
reassembfy.
Oil ports and other open[ngs should be cJeaned with compressed air to make sure that they are
completely free of obstructions.
7･ Rotating and sliding part surfaces shou(d be (ubricated with oI'1or grease before reassembly.
8. 1f necessary, use a sealer on gaskets to prevent feakage.
9. Nut and bo[ttorque specifications should be carefuJly fo=owed.

10･ AJways re一ease the air pressure from any machine-mounted before dismounting the
airtank(s) engine
or disconnecting pIPeS and hoses･ To not do so is extreme[ydangerous.
11･ A一ways check and recheckyourwork. No service operation is complete until you have donethis.
NOTES ON THE FORMAT OF T川S MANUAL
This Workshop Manua[ is appJicab】e to ISUZU industrial eng)ne or engrnes which is or are in the
stated
title.
When more than two englne models are dealt in the manual, such engmes have common
parts and
components as we‖ as data and unless otherwise specified,
specifications,
1･ Find the appI7cab[e section by referr-ng to theTable of Contents beginnlng Ofthe ManuaL
atthe
2･ Common technl'cal data such as genera一 maintenance items, service specifications′ and tighten(ng
torques are included J'n the ”GeneraHnformation” section.
The section ENGINE ASSEMBLY is an
exception. This parts are divided in three sections to facilitates
indexing.
3･ Each section is divided into sub-sections dealing with disassembJy, inspection and repair, and
reassembJy.
GENERAL INFORMATION
4. When the same serv[ctng operation is applicable to several different units, the manual w‖ direct you
to the appropriate page.
5, Forthe sake of brevity, se(f-explanatory remova( and insta一lation procedures are omitted.
More procedures are in detaiI･

complex covered
6. Each service operation sectJ.On in this Workshop Manua[ begms with an
exploded view of the
area. A brief exp[anation of the notation used foIIows.
appricable
Parts marked with an asterisk (*) are
included in the repair kit.

/
/
甘ド
/`呈 Parts within a square frame are to be
I ････････-･
○
話; ㍗ removed and instaJ[ed as a smgJe unit,
J+ and their disassemb[y steps or reas-
1 2
し≡ sembly steps are shown in the
什8
埠
” irlustrations respectively.
/ r)
フ′/
＋OJ The number tells you the service oper-
3--T& ,f ♂
ation sequence.
.し寸㊨
QL譜
12
Removal of unnumbered parts is unne-
修髪
し
ll
cessary unFess rep[acement is.required.
㌔
♂
''*
The Repa)r Kit” indicates that a
repair kit is avaiJabJe.
di去
14サ席
de The parts J舌sted under ”DisassembJy
Steps′′ o｢ ”Reassemb-y Steps′′ 8re in
the service operation sequence.
Di9J与一●rrtbly St叩& ∼
2
1. Wz)t8r by･pJSS hose 10. CylJ'ndor h餌d g8宇ket

The or instaHation of parts
2. Thermostz)I hou5Jng ▲11, Crankshz)ft daTnpO( PUlrey wlth removal
A
3.
4.
W&ter pump
lnLt}ction nozz一e hoJdcr
dust s881
Timhg q8ar C8叩COVer
marked with'a triangle (▲=s an
Tlnling gear COVOr
5.
6.
Glow plug and glow plug ⊂onn8CtOr
CyJind即head亡OYOr Tlm7叩g帥r Important OPeratJ-on. Detai一ed infor-
Oi一pipo
Ftock8r arm Shaft and rockt)r Aml Jdler 9EI8( 'E)'8nd
▲ 7.
8. Push rod ldJBr g朗r ∼A'
shaft
mation is gIVen in the text.
▲ 9. CyrindEIr h8ad ld(8r ge8T 5hJ)托
lnyert8d 【ng事ne
GENERAL [NFORJV]ATJON
7. BeJow is a Manual･
sampleofthetextoftheWorkshop
This is the item shown in the iI[us-

tratT'on. ft is marked with a triangle
I. CJrTIfh■ft Tlrni叩G4＋r (▲)on the Major Components p89e.
1=nsta”.th｡thrust pI8tB ①
2) Apply th8 bolt thr88ds ㊨
臼
engLnB O･=o
3J JnstaJI the cBm5haft tin7lng gea( With the (lming Letters and numbers contained in a
mark stamp8d sido faclng out
回
as磯
Camshaft TImlng Gear Bolt Torque kgf･rnfTb f(JN･m)
circle refer to the刑ustration.
ll.0土10 (79,5土7.2/107.8士9.a)
T?.
国
Special too一s are identified by the
13. Crz[nbhJlft Re8r Oif So●I
too一 name and/or number.
LJ卓 l】 Apply OII to the
日
■■ ' engJne oJ'rsea=p clrCUmfer.
JI
i. J
ence and the oll s8al E)uler clrCurnf8renCC
21 Use The oll seahnstalre( to
The川ustr∂tion shows how the spe-
)nst8‖ the 0川sea7 to
医I
∼
th8 Cyhnder body
cial toot is to be used.
i
も卜
O†lSeal lnstz)LIwe･ 5･8840･0141.0
i..戸!
Jr
+ Symbols indicate the type of service

o｢ step to be
′
I
14･ FIywbee) HoLJSiq operation per-
l) Apply IJ-qua gasket to the 5h8dcld ar8a Shown l'n formed. A detai一ed explanatJ'on of
盟 the illus(ratiorl.
2)丁]ghten the flywheel housing bolts I(】 the SPeCl･ these symbo一s follows.
＼ミ ■′･
良 fled torque
shown Fn tho
a littJB8t a time
ll)LJStratrOrl.
ln the
sequence
I.1..1
も′ FJywhBeI HDU幻ng 8olt Torque kgトrn=b.∼./∼ ml
MIOX1 25 10.40×0.05) BE)I( 56土1 0 (40.5士7.2/ 549士981 Service data and specifications are
¶･ M12Xl.25 fO47×8 D5) 8olt 10 5土=〕け6 2/103.0士9.8I
0土7
given in this table.
M12X1 75 (047×0.07J BoJt 9.8±1 O f71.0士7.2/ 960±9.a)
8, The foJ[ow盲ng symbols appear throughout this Workshop Manual･ They teI[ you the type of service
or to perform.
operation step
■■
Ej Removal Adjustment
-
+l
■■l
･･-
-
巨] -･ JnstaHation
田-･･ Cleanlng
匡卜 Disassemb[y
∇- Important operation requJrLng extra Care
匡卜 Reassemb】y
国=+ Specified torque (tighten)
匡卦- 園--
Specia( toof use
required or
Ali9nment (marks)
recommended(lsuzu tool or too一s)
CommerciaHy
回･-
too一 use
回･･.I
Directional indication available
required or
recommended
団･- [nspection
日･- Lubrication (oil)
囲-. Measurement
E] Lubrication (grease)
････
団-･ Sealant app一ication

GENERAL [NFORMATION
9. Measurement criteria are defined bythe terms川standard.rand J'(亨mjt''.

A measurement fa川ng within the ▲`standard■- range indicates that the appLicabfe part or parts are
serviceabJe.
''Limit'lshould be thoughtofas an
absoJute vaJue･
A measurement which is outside the ''(imitl■

J'ndjcates that the appticabJe part or parts must be eJ'ther
repaired or replaced.
10. Components and parts are IJ'stedin the s[ngularform throughoutthe Manuaf,
ll, Directions used inthis Manual are asfoflows:

Front
The cooling fan side of the engJne Viewed from the flywheel.
RJ'ght
The right hand side viewed from the same position.
Left
The left hand side vJ'ewed from the same position.
Rear
The fJywheef side of the engJne.

Cylinde｢ numbers are
counted from the front of the en91ne.
The front mostcy[inder is Nor 1 and rear mostcylinder is thefinal cyJindernumber of the engJne･
The engJne's dJ'rection of rotation J-s counterclockwise viewed from the f[ywheeL
GENERAL JNFORMATfON
MAIN DAm AND SPECl円CAT10NS
EngineModeJ
A･4JGl
Item
Enginetype Watercooled′fouトCyCle.in-line.overheadvaTve
Combustionchambertype Directinjection
Cylinder=nertype Dry
No,ofcy[inders-BorexStrokemm(in､) 4-95.4xlO7
Totalpistondisplacement‖t(cJ'd) 3.059(186.7)
Compressionratio(Tol) 18.6
☆EngTnedimensionsmm(in.) 739x625x746
LengthxWidthxHeight (29.1x24.6x29.4)
*Engineweight(Dry)kg(]b.) 248(547)
Fuelinjectionorder 1-3-4-2
*FuelinjectiontJ.ming(B.T.D.C.)degrees 16
Specified fuel DieseJfueT
fnjectionpump ln-1inepZunger,BoschAtype
Governor VariabJespeedmechanicaltype
★Lowidlespeedmin-i B50-1′000
lnjectionnozzle Multi-ho(etype
fnjectionstartingpressureMPa(kgf/cm2/psi) 18.1(185/2630)
Fuelfiltertype Cartridgepapaerelement
Watersedimentor(ifsoequipped) Sediment/water]evelindicatingtype
CompressionpressureMPa(kgf/cm2/psi) 3.04(31/441)
Va]veclearance(atcold)[ntakemm(in.) 0.40(0.0157)
Exhau占tmm(in.) 0.40(0.0157)
Lubricationmethod Pressurizedcirculation
Oilpump Trochoidtype
Maino‖filtertype Cartridgepaperelement,fu‖flow
Partialoi[fi[ter NotequIPPed
*Lubricatingoilvolumerit.(qts) 7.6-9.6(Oilpan)
Oilcoo[er(ifsoequipped) Watercooledbuiltinoilfi[ter
Coo‖ngmethod Pressurizedforcedcirculation
Coo[antvolumelit.(qts) 5.0(5.3)
Waterpump Bertdriven,impel[ertype
Thermostattype WaxpeHettype
廿A[ternatorV-A 12-50
*StarterV-kVV 12-2.2
Spec汀ications marked with an asterisk (貴)w= vary according to engine application.

GENERAL INFORMATJON
TJGHTENING TORQUE SPECIFICATJONS
The tightening torque va[ues glVen in the table below are appJicabfe to the bolts unless otherwise
specified.
STANDARD BOLJ N･m (kgf.m)
Bolt
㊨ @@ ㊨
ldentifJ-cation
◎ ◎◎ 珍
Bolt
Diameterx
pitch(mm)
M6×1.0 3.9-7.8fO.4-0.8) 4.9-9.8(0.5-1.01
M8×1.25 7.8-17.7(0.8-1.8) ll.8-22.6(1.2-2.3) 16.7-30.4(1.7-3.1)
MIOxl.25 20.6-34.3(2.1-3.5‡ 27.5-46,l(2.8-4.7) 37.3-62.8(3.8-6.4)
＋MIOxl.5 19.6-33.4(2.0-3.4) 27.5-45.1(2.8-4.6) 36.3-59.a(3.7-6.1)
M12)く1.25 ヰ9.l-73.6(5.0-7.5) 60.a-91.2(6.2-9.3) 75.5-114.0(7.7-ll.6)
*M12×1.75 45.1-68,7(4.6-7.0〉 56.9-84,4(5.8-8.6) 7l.6-107.0(7.3-10.9)
M14×1.5 76.5-115.0(7.8-ll.7〉 93.2-139.0(9.5一-14.2) 114.0-171.a(ll.6-17.4I
書M14×2.0 71.6-107.0(7.3-10,9) 88.3-131.0(9.0-13.4) 107.0-160.0(10.9-16.3)
M16×1.5 104.0-157.0(10.6-16.0) 135.0-204.0(13.8-20.8) 160.0-240.0(16.3-24.5)
★M16×2.0 100.0-149.0(10.2-15.2) 129.O-194.0(13.2-19.8) 153.0-230.0(15.6-23.4)
M18×1.5 15l.0-226.0(15.4-23,0) 195.0-293,0(19,9-29.9) 230.0-345.0(23.4-35.2)
≠M18×2.5 151.0-226.0(15.4-23.0‡ 196.0-294.0(20.0-30.0) 231.0-346.0(23.6-35.3)
M20×1.5 206.0-310.0(21.0-31.6) 270.0-405.0(27.5-41.3) 317.0-476.0(32.3…48.5)
*M20×2.5 190.0-286.0(19.4-29.2) 249,0-375.0(25.4-38.2) 293.0-440.0(29.9-44.9)
M22×1.5 251.0-414.0(25.6-42.21 363.0-544.0(37.0-55.5〉 425.0-637.0(43,3-64.9)
*M22x2.5 218.0-328.0(22.2-33.41 338.0-507.0(34.5-5l.7) 394.0-592.0(40.2-60.4〉
M24x2.0 359.0-540.0(36.6-55.0) 431.0-711.0(43.9-72.5) 554.0-831.0(56.5-84.7)
★M24×3.0 338.0-507,0(34.5-51.7) 406.0-608.0(41.4-62.0) 521.O-782.0(53.1-79.7)
asterisk (i) indicates

An that the bolts are used for female threaded parts that are made of soft materiats
such as
casting.
GENERAL INFORMATION
T[GHTENJNG TORQUE SPECIF]CATJONS
The tightening torque vaJues glVen in the tab一e be[ow are

appJicable to the bolts un一ess otherwise
specified.
FLANGED HEAD 801J N･m (kgf･m)
Bolt
Identification
Bolt 4 ら 9
Diameterx
pitch(mm)
M6×1.0 4.6-8.5(0.5-0.9) 6.6-12.2(0.6-1.2)
MBxl.25 10.5-196(1.1-2.0) 15.3-28.4(1.6-2.9) 18.1-33.6(2.1-3.4)
MIOxl.25 23,1-38.5(2.4-3.9) 35,4-58.9(3.6-6.ll 42.3-70.5(4.3-7.2)
★MIOxl.5 22.3-37,2(2.3-3,8) 34.5-57.5(3.5-5.8) 40.1…66.9(4.1-6.8)
M12×1.25 54.9-82.3(5.6-8.4) 77.7-117.0(7.9-ll.9) 85.0-128.0(8.7-13.0)
書M12xl.75 51.0-76.5(5.2-7.8) 71.4-107.0(7.3-10.9) 79.5-119.0(8.1-12.2)
M14×1.5 83.0-125.0(a.5-12.7〉 115.0-172.0(ll.7-17.6) ■123.0-185.0(12,6-18.9)
★M14×2.0 77.2-116.0(7.9-ll.8) 108,0-162.0(1l.1-16.6) 116.0-173.0(ll.8-17.7)
M16×1.5 116.0-173.0(ll.8-17.7) 171.0-257.0(17.4-26.2) 177.0-265.0(18.0-27.1)
廿M16x2.0 109.0-164.0(ll.2-16.7) 163.0-244.0(16.6-24.9) 169.0-253.0(17.2-25.8)
A bolt with an asterisk (*) is used forfema[e screws as iron.

of soft materia一 such cast
GENERAL JNFORMATJON
国 SPECIAL PARTS FIXING NUTS AND BOu`s
cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket
N･m (k9f･m/lb.柑
8-18
感
(0.8- 1.8/5.8- 13)
!
(# 49-59
こ-
I/B#
(5.0 -
6.0/36- 43)
0
⑮
l
10-20
∩.0-2.0/7 -
141
冒
＼
(≡)
匂噂蹄
冒
U
i
l
Q鮮宗些
⊂)
7T
￠
くJ
磨 Q U
7T
e2
/
く⊃
U
訟
敬
＼こ)
勺
勺
G)
♂
F
勺
1st Step 2nd Step 3rd Step
44-54
60-75o 60-75o
(4.5 -
5.5/30 -
40I
Apply englne Oil to thread portion

GENERAL INFORMAT10N
国
■
Crankshaft Bearlng Cap, Connecting Rod BearJng Cap,

Crankshaft Damper Puf[ey, F[ywheel, and Oil Pan
N･m (kgf･m/fb.ft)
or ーて丁て一士
e5 盲
(3 症;弓
亡〉 ′
琶∈主友≦
;夢
m =t
2s5
辺 ”
幣
a に
113-123
∼
I ヽ
a (ll.5- 12.5/83-90)
27-31ぅ45o-Boo
関
(2.8 -3.2/20- 23I
Appfy OiJ to thread
%?
engTne portion
157-177
看ち
(16- 18/116- 130)
Apply engine oil to thread portion ＼
d a
＼
197-240
(20.1 -24.5/145 -
177) 〆ク
⑳
,VS
i:
ンら
壬哲
字空
宅才＼
”
鋼 Q
14-24
A (1.4- 2.4/4.4- 7.2)

a
10
GENERAL rNFORMATJON
国
■
Inning Gear Case･ FJywheeJ Houslng, Camshaft, 'Tlming Gear

and
N･m (kgf･m/1b,ft)
MIOxl.25 35-45 (3.6- 4.6/26-33)
M12xl.5 74191 (7.5-9.3/54-671
a
9
消
1
ウ ♂
/′
⊂) 勺
m6)Q)
○ a
14-24
∩.4-2.4/10 -
17)
⊂⊃
＼.
⊂⊃
＼ト
kS ♂
@
＼
t
♂
&
礼 /
r3
&
馳 SS
※
N
Q勺Q
恵〕
派
14-24
(1.4-2.I/10-17I
14-24
(1.4-2.4/10-17I
98-118
㊨
14-24
=0- 12/72-87)
(1.4-2.4/10- 17)
⑤ @
% @@◎
潤
♂
a
10-15
(1.0-1.5/7-ll) @@@ 98-118
(10- 12/72-87)
ll
GENERAL INFORMATJON
国 Cooling and Lubricating System
N･m (kgf･m/Ib.印
冒冒
14-24
句b
什4-2.4/10-17)
I
l
ー研一･愈
◎
L3
I
宏:
&@i&
L〉
lLt;
くJ
7T
･@& ○
q 蛋 Z2
L)
{qQi
14-24
∩.ヰー2.4/10-17)
(3
/二
＼ミ g#
リu
巳ゝ巳ノ基≠汚友≦
メ
ク房
r
ヽ a
SS
14-24
(1.4-2,4/10- 17) :b3
･愈
も､
_dク
ウ､､1
/
a 14-24
(10-17/10-17)
ン′
♂ 敏一/
14-24
∩.4-2.4/10-17I
12
GENERAL INFORMAT10N
国 Intake and Exhaust ManJ'fo[d
N[m (kgf･m/[b.ft)
14-24
(1.4-2.4/10- 171
@@%
a
Ct
∠〇
” 9
a
C2 ど
習E2
C!
5 rl
EB
a
C!
0
0
0
モ〕o
0
0 C2
pく
0
♂
￠ ○
＼ ♂
♂ □ 巨≡去 T7
♂ □ 毛:I
七)
% Q
@@
14-24
=.4-2.4/10･- 17I
13
Gt;NERAL ]NFORMATION
国
■
EngTne ElectrJ-cal
N･m (kgf･m/Ib.叫
14-24 15-20
(1^-2.4[10-17) ∩.5-2.0/ll
-14)
i
<%
14-24
(1.4-2.4/10- 17)
S しi3
@@
96
S #
@
ヽ
@%@>
66-86
(6.7 -8.7/49 63I

-
14
GENERAL INFORMAT10N
国 FueHnjection System
N･m (kgf･m/lb.柑
√､ _
∼
♂
@
√￣￣-････････-.
-
-
J
i
#
20-39
(2.0 -
4.0/14-29)
｢ー￣--- --
J
轡
@
@
♂ 象､
臥@
31-43
(3.2 4.4/23 32)

-
-
14-24
ll.4-2.4/10- 17)
㊤
14-24
什4-2.4/10- 17)
㊧
確執ク′
A /
?
/
ら F
+
”
14-2ヰ
(1.4-2.4/10- 17)
14-24
∩.4-2.4/10- 17)
14-24
∩.4-2.4/10- 17)
15
MEMO
=...--●,lJ=●>4●＋＋0.-JJ＋414＋PrP=●=●●◆rJ＋tI=I■=tDLILJ＋=●If▲pL44●＋4114r4=pJt=tO====●IAf4●lt=4f=●■=●Apt=14＋=trl”＋t4444=441=t41Jr■=■■=J4■◆JL●=●●fJ＋41＋=L*====▲=■-●-,--●...-.-...1-.....I.-I-●一●一-.1Jl10J-J-4tlrLJQf4J■=●■IJ4
..-....I.I..l..A41tP.-..-JI*＋4.l.1＋r-.＋1.1”.4”JA＋4It””J.4J.P＋＋-Ly”JT4.*J-＋＋＋tII”4JLtr＋L4＋I＋r””PLpft＋AL＋”.＋4r.IJPr..rr4＋ATJ..L*.LJ.LL＋＋＋1414..1＋4.I.I-.1..LJJ-.-.-.I..---.-....-I.I....-..........-.1-.1T..-.-.-.-I......I-II..1-4JLr＋＋”frrII
-■一---■●--I-■=■一●-==■●●=●●=l■===●==●=■●=■====■l=▼●●▼=●●●========■●=t■=●===●●●==■===■■■●=●=●●t===●==■==●●===●==●-一---●=●一=-■一一●-=●=■‥●----I-■■-‥●------=■=■=一===●==■=●
-.-I-‥=●●●=L-.4＋4JL.1J=■L4=L*=”*t4r*PJ141l＋J”J＋＋ILL＋rf>L4<dA=Ll●r＋=■If44▲●=ftQrOr4*■J14r＋=J＋PrJ*LrJt●fJ4LrJ=AAJ●r4rJDr■■=■lJ==■■●t4=14=●tr4＋-=PJLL＋rt4--=一●...-....---■--...I.....1I-.-.--一.I.-..1.--●●pJ14t■=4Jt●=●■■ppJllFJJrJ●
●==..--■I＋=●IJO.-..=J.==J-=■■=4J.==.ttL＋L＋tt=●....-4＋＋T1444r＋-.trI-■▲=4L■■r”r■-JJIIrLrJ”rlTL*=●ltJ＋Jt””JHdt”t■401＋J＋=JJf=r＋r●●1.=t＋=t.=l”J*.....--▲■-●●-●●●-...=●-.-.I1.■■■■-●..-▲●1-.--●-一■-I--.-一●-.●■JJtI■◆T＋Jr44
.111l..---.-.-”JL＋lA.1..-.L”4”J.tl..---4J444＋”Jrrr...””JJt＋4J＋＋41rL.”tt”JrJ””JJt4*＋＋lL＋t＋”t4J＋4＋t＋r*＋LPr＋＋＋l＋lTrJ4*JDtlt.L＋JIP＋＋4rtrL”＋.I-..A.4I4..-J4＋.I........-..1-...-...-.-...--.-.--....A...-LI.........-.-..---1..I.＋4r4AJL＋44L
●...I..=--●●●..1.ll-..●一....ll-.-.-､●1--I....-..11”4J.●●-.-.A.JJ.＋4..I--=-●▲J4rArP=■==L4>ll==●●JJLA14●4.=-=I■==●=■■.I.”=.Jt”-”.-.....I......-●●......I..---.---一■-▲..-■●-●.--●--.-=-.I...I-...=-一●一=一-...●●ll”T44L
■■J4====●=●Al●”4=AflrJ”＋■=LA=qA=L4=4J＋JJ”JL=●●41■14＋LrIP4JJrrL=LtL＋P＋tf==t””I-=●=fL=●●●●ITtJ=●fI＋4＋=14f4=■=●●＋4＋tJ4＋●●●Af=■■●tt=■=====●ft●====JJJ＋.1●-＋.-■==■-I-.一-●......=..-■1..-.-.......-......I.I-=4t＋A4LtJl
I”=4”1t14t4I=●rd■=●●=rrrL”J●=”IJ＋lJ=*4●●●==＋J===■●●J=●tI▼L4==●●J4t4t===4＋t*==L＋==●●f4ff>t=■PtrL=●Jr=＋It=●4t■=■■r”=4JIJ14＋＋P=●●●●==J”l-1.I...●--■I---.I--‥.........●●●--...-▼1..-●●...-...-t..=I■■”Lr4=●
一..--=.1-●-...■..-....●▲14tL＋=lt.I.--A....L>L◆=＋A....-=LJl■1I.=■●●l●一44At■■＋rrLt==●●LL=14*lr＋●●lrrp＋..=14J＋==●I4=＋1ll●=J＋4”TJ●●lt1....-.--.-.I......=■-.-■....■-一--.I1..-I--.---●==..---●=-■■●-●-...●-=--p.▲●●＋L
■=-=Jl=.I.-....--”.1==●=●4TJOITJJl＋=●=●===●p＋tt＋=JLl=I＋4141=●14=●=■=t4=●4L==●●414tt1=●●=■4-A4==●●=4P”tA●■4At4L4A＋JI=●4rI▼■=*-.＋4t.＋I.1＋JA1.-●--Il■■-.-=-I-..I-.........-●1.-.-=-.I.-....-..-..-I-.r-I.t===●=■
16
MAINTENANCE
SECT10N 2
MAINTENANCE
TABLE OF CONTENTS
ITEM PAGE
Modelidentjfication ‥…‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥”.‥‥‥‥‥.‥‖‖
18
JnJ'ectionpumpidentification.”....”..”....”...”....”.....”.,”...”.”.”.. 18
Lubricatingsystem ‥.‥‥‥‥‥…..‥.....‥‥‥‥‥‥=‥.‥‥.‥‥‥‥.‥‥..
18
Fuelsystem .......”.....”........,...............,..,...................,....
19
CooJingsystem ‥‥‥.‥.‥‥‥‥‥,.‥‥‥‥..‥‥‥‥‥‥.‥‥‥‥‥‥‥‥‥‥
22
Va[vecfearanceadjustment,.........”....,.....”.....,,.....”....”....,....” 23
■
JnjectionthJng･･...............”,”......”......,........”....”.....”..... 24
Compressionpressuremeasurement ”.......................”......”.”.”...”.
26
RecommendedJubricants.‥‥‥‥‥.,.‥….‥‥..‥..‥.‥‥‥‥‥‥‥,‥‥.‥.. 27
Enginerepajrkit -‥･‥‥‥‥‥‥･･‥‥･‥‥･‥‥‥‥‥‥‥‥‥‥‥..‥.‥‥‥”
28
17
MAINTENANCE
MAINTENANCE
Servicing refers to generar maintenance procedures to be performed by qualified service personnel･
Maintenance intervaf such as fuel or oil filter changes shou一d be refered to 'LINSTRUCTJON MANUAL”,
MODEL JDENT[FJCAT]ON
Engine Serial Number
The engfne number isstamped on the rear Left hand side

of the cy[inder body.
恒
○ k=
)NJECTLON PUMP ]DENT[FICATION
lnjection vo一ume be to
shourd adjusted after referring
the data app[icabre to the J-n)eCtion
adjustment pump
installed.
Pump No.
NP-P∈
The injection pump identification number (A) is stamped
(LICENCE BOSCH) on the injection pump identifications pJate.
Note:
④･･･ldentification
number
Always check the identificatJ'on number before beg(nn-
h-‖ne type
ing a
service operation.
App]icabJe servI-ce data will vary according to the ident-

ifJ'cation Use of the wrong service data w川
number,
resuJt in reduced engine performance and englne
dama9e.
MAKERyp ① ZEXEL (Manufacturer of the injectionpump) identifト

ASS'Y NO. ①
cation number
1NJ.PUMP
ASS'Y NO. ② ① lSUZU P∂什sNumbe｢
Distributor type
LUBRICATING SYSTEM
く=⊃
Main Oil F‖ter
Replacement Procedure
0
1. Loosenthedrain p)ugto drainthe englne OiL

＼.
2. Wait a few minutes and then retighten the drain
plし唱.
3. Loosen the used oi一fi[ter by turnlng it counterclock-
国 wise with
Filter VVrench
a f‖terwrench.
18
MAJNTENANCE
4. C一ean the oi( coolerfitting face.
四 This w川aIJowthe new oi川[terto seat properly1
5･ App一y a lightcoatofenglneOir tothe OィJ'ng.
冒 6･ Turn in the
fitted against
new oil fi[ter until
the sea‖ng face.
the filter 0-ring rs
7. Use a fi一ter wrench to turn in the filter
団
an
51(I
addJ'tionaf
l and 1/4ofaturn.
(ラ F‖ter Wrench
___ノ
ココL 8･ Checkthe englne Oi[ (eveJ and repJenish to the spec-
-2
ified (evef if required.
漂野丁､ 9･ Start the for oil (eakage from
囲
eng(ne and check the
main oil fi-ter.
FUEL SYSTEM
ヽ==⊃
Fuel F‖ter
Rep(acement Procedure
○
1. Loosen the fuef fi[ter by it counter-
回
used turning
cJockwise with the fitter wrench.
＼.
Filter VVrench
2. Clean the uppercoverfitting face.
田 This will afrowthe newfuef filterto seat properry.
SS
@ _.∠こ￣
3･ Apprya [ightcoatofengJne Oil tothe 0-ring.
Ej 4. Supply
ing.
fuel to the new fuel fjJter to facilitate bleed-
5･ Turn in the newfuel fi一teruntiJ thef‖ter 0-ring is fit-

ted against the searing face.
Po Be very carefu( to avoid fuel spil[age.

6. Use filterwrench to turn in the fuel fi[ter an
団
a addi-
tiona1 1/3to 2/3 ofaturn.
19
MAINTENANCE
Water Separator (Water Sedimentor)

申
磨 (Optiona] Equipment)
Check the water separator float ① 1eveI.

Jfthef[oat① has reached leve一 ②. Joosen the drain plug
@ (at the bottom side of the water separator) to drain
the water.
Drain PJug Torque N･m (kgf･m/Ib.ft)

固 9-15(0.9-1.5〝-ll)
Air B)eeding
1. For the eng(ne equlPPed with in-fine type

′￣
Injection
ヽ
PumP
1) Loosen the priming pump cap ① on the injection

A 9
PumP･
2) Loosen the fueいeturn eye bolt① on the fue=iJter.

-
1HFO
闇iB
3) Operate the priming pump un川the｢e are no more
bubb[es visib[e in the fueJ being

discharged from the
fue) return eye bolt on the fue( filter.
4) Retighten the fueJ return eye boTt on the fuel filter.
5) Loosen the bleeder bo一t ③ while operating the

pump prlming pump to check that the
lnjection air
has been bled completely.
6) Operate the priming pump several timesto check for

fue] leakage around the in)'ection pump and the fueJ
f‖ter.
2. For the englne equ[PPed with distributor type ]n)ec-

亡:頚F￣l川 tion
Air SCreW pump
○
○ 1) Loosen the bJeeder screw on the injection pump

overf)ow valve.
2) Operate the priming pump unti一 fue[ mixed with
0
foam f(ows from the bleeder screw.
3) Ti9hten the b一eeder screw.

○
(⊃
j匂
o)
D 盟｢ち○ 4) Operate the primin9
for fue一 leaka9e.
Pump SeVe｢a=imes and check
I
l I
i I
I
†
(㌔
′′
I
llfL.4･･.･ -∫
l`
ヽ_一
20
MAJNTENANCE
Injection NozzJe
Jnjection NozzJe Inspection
Use a nozzle tester to check the injection nozzle openJng

pressure and the spray condition.
復 1fthe openJng Pressure is above or below the specified
value, the nozzle must be
J'njection repfaced or
recondi-
t'10ned.
cctq rfthe spray

or
condition is bad, the injectionnozzle must be
replaced reconditioned.
JnjectionNozzJe OpenJng Pressure MPa (kgf/cm2/psi)
18.1 (185/2′630)
Spray Condition
① ④ ④
1 Co rrect
2 (ncorrect (Restrictions jn orifice)
3 ∫ncorrect (Dripping)
■l■
■■ lnJ'ection Nozzle Adjustment
イl
-
■■ 1. CJampthe hjection nozzle in a

vise.
21 Use a wrench to remove the injection nozzJe retain_
lng null
3･.nstaJJ the in)'ection nozz(e ① the push rod ①. the

㌔ ∫
sp｢in9 ③′and adjusting shin ④.

Retaining Nut Torque N･m (kgf･m/[b.ft)
39-49 (4.0-5.0/29-36)
国 4･ Attach the inJ'ection nozz(e holder to the injection

nozzle tester.
5･ AppTy pressure to the nozzfe tester to check that the

injectJ'onnozzle opens at the specified pressure,
(D
(喜妻∃ Jf the injection nozzle does not open at the specifJ'ed
pressure, instaJ( or remove the appropriate
I
number
of adjusting shims to it.
adjust
④ ④④ AdjustJ'ng shim Avaifabifity mm(in.)
Range 0･1 -
0.59 (0.0039-0.023)
WARNING:
TEST FLUID FROM THE JNJECTION NOZZLE TESTER
WILL SPRAY OUT UNDER GREAT PRESSURE.汀CAN
EASILY PUNCTURE A PERSON'S SKJN. KEEP YOUF!
HANDS AWAY FROM THE INJECTION NOZZLE TESTER
ATALL TIMES.
21
MAINTENANCE
COOLING SYSTEM
ち
Cooling Fan Dr;ve BeTt
C
Fan beJttension is adjusted by movlng the arternator.
A Crankshaft damper pulley

B Alternator puJIey
C Coolingfan drive pu‖ey
D Depress the drive belt mid-portion with a 98.N (10

kgf/22 [b.ft)force.
Drive Be一t DefJection
mm(in.)
10.0 (0.39)
Thermostat
Operat'Lng Test
1. CompleteFy submerge the thermostat in water.
2. Heatthe water.
Stir the water constantly to avoid direct heat being

to the thermostat.
applied
IA
3. Checkthe thermostat init7a] openlng temperature.

① 固 Thermostat lnitia[ Openlng Temperature oC(oF)
@ 82く180)
4. Checkthe thermostatfuH temperature.
囲
opemng
Thermostat Fu‖ Opening Temperature QC(oF)
SS ③
95 (203)
育 Valve Lift at Fu‖y Open Position
圃
mm(in.)
8.0 (0.315)
① Thermostat
② Agitatin白Rod
a Wooden Piece
22
MAINTENANCE
■■ VALVE CLEARANCE ADJUSTMENT

イl
JI
■■■
■l■
1. Retighten the arm shaft bracket bolts in

rocker
国 sequence as shown in the川ustration.
RockerArm Shaft Bracket Bo叶

Torque N･m (k9f･m/胤印
49-59 (5-6/36-43)
2, Bring the piston in eitherthe No. 1 cylinder or the

No. 4 cylinderto TDC on the compression stroke by
◎
1∴ TDC
turning
puJleyTDC
the crankshaft
一ine is a=gned
until
with
･the crankshaft
the timing pointer.
damper
A
諏
@
3. Check for play in the No. 1 intake and exhaustvalve
push rods.
If the No. 1 cylinder J'ntake and exhaust va)ve push

rods have pJay, the No. 1 piston is atTDC on the
compression stroke.
1fthe No. 1 cylinder intake and exhaust vafve push

rods are depressed, the No. 4 piston is atTDC on the
compression stroke.
JI<
l■■
Ad)lust the No. i or the No. 4 cy(inder vafve clearances
■■l
Jl
∼
■■ while their respective cvlinders are at TDC on the com-
pression stroke.
ヽ
/
＼モ
Valve Clearance mm(in.)
ヽ
ヽ
､､･コ
J%
′■■￣￣
0.40 (0.016)
ヽ
Loosen each valve clearance screw as shown
adjusti.ng
等 in the i‖ustration. (At TDC on the compression stroke of
the No. 1 cy‖nder)
Jnsert a fee一er gau.ge of the appropriate thickness
圃 between
4. Turn
the
the
rockerarm
va一ve cJearance
and the valve stem end.
adjusting screw
until a
slightd｢a9 Can be fe一ton thefeelergauge.
5. Tighten the rock nutsecurefy･
23
MAINTENANCE
Rotate the crankshaft 360o.
Rea‖gn the crankshaft damper pulJey TDC line w托h the

timlng POinter.
/ ヽ
ヽ
＼∋
for the remainJng

Adjust the cJearances VaJves as shown
;A in the i=ustration. (At TDC on the compression stroke of
the No. 4 stroke)
感熱
INJECTJON TJMfNG
0
Injection Timing Confirmation Procedure
0
□
1. ]n-‖netypeJnjection pump
◎
㊨
囲 1) Rotate
shaft gear
the crankshaft
timing mark
clockwise
”0” with
to align
the
the
timing
cam-
gear
⑥ case cover pointer.
The No. 1 cy=nderw川now be atthe poht where

nearly lnjectiontiming.
2) Removethe No. 1 fuel injection pipe.
3) Remove the de一ivery valve holder ① ∫ the deJivery
③.
(モミⅠ)
q=も valve spring ①′and the delive｢yvalve
CE:ち)
4) Tighten the delivery valve holder to the specified
qb
to｢que･
Delivery Valve Ho(der Torque N･m (kgf･m/1b.ft)
39-44 (4.0-4.5/29-33)
5) Operate the injection pump priming pump whi[e

(つ
l巨===-
哩
ヒ= f[ow-
sLowly rotating the crankshaft until fuel stops
@ C
[ng from the delivery valve hoJder･
17
6) Conform that the crankshaft damper pu[Jey notched
◎
囲 =ne is a[igned
pointer,
vvith the timing gear case cover
Injection TimJ'ng (Static BTDC)
65
鷲 16o
7) Remove the delivery valve ho(der.

くヒこ王)
(ヒ:a 8) Instal一 the delivery valve ① ′ the de一ivery valve
q=こb
spring @ , and the deliveryva(ve ho]der@.
屯::ち
9) Tighten the delivery va一ve ho[der to the specified

to｢que-
10) lnstaJI the fue[ injection pipes and tighten them to

the specified torque.
･
Fuel hiection Pipe Torque N･m (kgf･m/Ib.ft)
国 20-39(2-4/15-29)
ll) Operation to airbreeding.
24
MAINTENANC∈
2. Distributortype injection pump

1) Rotate the crankshaft clockvvise to afign the cam-
○
shaft geartiming mark ''･0” with the timing gear
0
□
case cover pointer.
㊨
◎ The No. 1 cyJjnder w川now be atthe point vvhere
nearly injection tJlmJng･
㊨ 2) Remove
3) Fita d7aJgaugeand
inJ'ector pump
Top
set(iftto
distributor
1 mm
head plug.
(0･039 in).
Center
4) Set crankshaft damper pu=ey Dead mark
about 45o before Top Dead Center from the pointer.
5) Setdial gauge in the ``0” position.
MeasurJng device: 5-8840-0145-0
園
lO
6) Turn the a rittre rightwise and Jeftwise

⑳￠c?e crankshaft
and see if the pointeris stab一e in the ''0” position.
-v('Qfq5Sr- 7) Turn the crankshaft J-n the normaJ direction and read
the measunng device′s indication at TDC.
S'
監) Starting TimJng mm(in.)

)ーOo￣
0.5 (0.02)
jもfnl___ー∩._,(2]o≡○ CE)OESOO2
8) (fthe injection timing I-s outside the specified range,
continue with the foHowJng StePS･
9) Loosen the hjectlon pump fix-fng nuts and bracket
bolts.
珍
⑳ 8
10) Adjustthe injection pump setting angJe.
8 ⑳
｢･
ff injection timing vvI'H be advanced, move the
(つ
from
表露 tnjection pump away the eng[ne.

m ･ lfinjection timing wJ'lJ be retarded′ move the
ず/
injection pump toward the englne･
L-
○
Tighten the pump fixing nut, bolt and pump
○
adjust
○
distribution head pJug to the specified torque.
08O ∈S008
Pump Fixing Bo[t N･m(kgf･m/[b.ft)
19 (1.9/14)
Injection Pump
Distributor Head Plug N･m(kgf･m/Ib.ft)
17 (1.7/12)
25
MAINTENANCE
COMPRESS10N PRESSURE MEASUREMENT

野｢
1. Startthe it to for
/ engLne and a=ow run
severaJ
a minutesto warm it up,
2. Stopthe en∈‖ne and supp一y.

∼ cutthefuel
: ド7; 3. Remove alJ of the glowp]ugsfromthe engJne-
Compression Gauge :5-8840-2008-0
% 甲 /”
園 Adapter :518531-7001-0
4. Seta compression gauge tothe No1 1 cy=nderg)ow
p山9 hole.
5. Turn the eng)ne overwith the starter motor and take

the compression 9aし唱e reading,
Compression Pressure MPa (kgf/cm2/psりat 200 rpm
Standard Limit
3.04(31/441) 2.2(22/313)
26
MAINTENANCE
RECOMMENDED LUBRICANTS
ENGFNETYPE TYPESOFLUBRJCANTS
Dieseleng]neoiJ
W'rthoutturbocharger
CCorCDgrade
DJ'eselenglneOil
Withturbocharger
CDgrade
ENGINE O比VISCO$lTY CHART
ENGINE O比VISCOSITY GRADE -
AMB陀NT TEMPERATURE
【Single grade]
SA臣 20. 20W E.I

S.'Å40
1.pW. SAE 30
(TAemmbiee?三tu
〕
15oC 25oC 30oC
-30oC -15oC -OoC
,e ト22oF卜 (5oF) (32oF) (59oF) (77oF) (86oF)
[MuJti grade]
SA臣 IOⅥト30
SA臣 1 5W-40,
27
MAINTENANCE
ENG]NE REPAIR K[T
Alf of the numbered parts listed be(ow are included in the EngLne Repair Kit.
The gaskets marked with an asterisk (i) are
also inc[uded in theTop Overhau] Kit.
3 20
e2
℃㍑
D
e(
(つ
e-c(ll
87
♂哲紺
?
ヽJ
15 14
A
/
.A
13 0 lO
U
班 ” L3
E2
&
/I_F∠･プ
11
0 E2
&
…喪 0
J
t2 0
e
tin
U 19 格
0
Q
/レ
0
u e
ら I
○
･:,i
9
○
s)i 之≠
おプ
で
i/
く重〉一ー8
@
*
l
2
Cy=nde｢
Cy=nde｢
head
head
ョasket
cover gasket
.6}で 11
12
Water
Water
pump
outlet
gasket
pipe gasket
≠ *
3 Head cove｢cap nut gasket 13 Thermostat hou引ng gasket
*
4 Drain cock gasket 14 Intake manifold gasket
*
5 Crankshaft rear
oi一 sea一 15 Exhaust manifo[d gasket
6 Gear case gasket 16 Crankshafrfront oil sear
∼
7 Gear case cover
gasket 17 Nozz一e holder O-ri｢唱
求
8 Oil pan drain plug gasket ･18 Nozzle holder gasket
9 OiL pan gasket 19 Joint bolt gasket
10 Oil fitter gasket 20 Vacuum pump pIPe gasket
28
ENGINE ASSEMBLY ” )
SECT10N 3
ENGINE ASSEMBLY ” I
TABLE OF CONTENTS
ITEM PAGE
Generaldescr;ption‥.....,..‥.‥‥‥‥‥-･･---‥‥..･-･---.･‥‥‥‥‥. 30
Disass￠mbly.....-----------.--.--....---.-----.---... 31
29
ENGINE ASSEMBLY ‖ I
ENGINE ASSEMBLY
GENERAL DESCRIPT10N
This川ustration is based on the A-4JAl englne in 4J series.
i 4r
a
∩ L%
○ 皿
l ｢
千 iJ 抑 I
1
I
チド
E] ∼
+
▲=d･:･屯
ム
l 鼓し
訂
a
堤
○
㊨ □
0
◎ LJ
Fr.･･;
l
ド
J
【
J
Li
㍑
The 4J Series of industriaJ englneS features the umque lSUZU troidal square combustion chamber･ This
design provides superiorfue] economy for a wide ranged
Auto-thermatic pistons cast stee[ struts are

used to reduce thermal expansion and resulting engJne
with
noise when the englne is co一d.
chrome plated drytype cy(inder liners provide the highest durab=ty.
The laminated steef sheet cyJinder head gasket is very durabreL
This type of gasket eliminates cyIJ'nder head bolt retightening･
The tufftrided crankshaft has a long service life. Because it is tufftrided, it cannot be reground･
plated･ These bearings

The crankshaft beanngs
main and the connecting rod bearlngS are a(uminum are
especially sensitive to foreign materiaE such as metal scraps･ lt is very important that the oil ports and
parts be kept c(ean and free offore(gn materiaF･
other related
30
ENGINEASSEMBLY (1 )
回 DJSASSEMBLY
These disassembly steps are based on the A-4JGl engine.
18 17 16 78 5 12 ll 13 10
≡=よ
』+u
=払上==
皮 I
∩ l
ら.
1 t
ト
I
1 I ○
C! こ∋
l
十 I 1
ト
I
I ｢l 1 1
1
○ -”
CrしJ8
†二2
15 19 4 14 19
Disassenbly Steps I
1 Coo=ng fan and spacer 10 FueHeak off p'[pe

2 Cooling fan
drive be[t ▲ ll Fue) injection pJPe With clip
3 Coo=ng fan drive pu‖ey ▲ 12 )njection pump
4 Alternator and adjusting plate 13 lntake manifold
5 Fuel pJ'pe (Fuel filter to 14 Sta什er
injectionpump) 15 Oil fi)ter
6 Fuel pJ'pe (Fuel fiJterto feed pump) 16 Cooling water rubber hose
7 Fue一 pipe (Fue[ fi(ter Leak off) 17 Coo一ing water intake pfPe
8 Fuel fitter ▲ 18 Exhaust manifoJd
9 Oi一pipe (Injectionpump to cy‖nder 19 Stiffner (RH 良 LH)
body)
31
ENG(NEASSEMBLY (1 )
∇ ∫mportant OperatJlons (Disassembly Steps ･
1)
a
ご喝
〔)
E9
碍 0
ll, FueHnjection Pipe with CJip
1) Loosen the injection pipe sJeeve nuts atthe defivery

CI O O
vaJveside,
I
岩
Do not app[y excessive force to the injection
L p[pes.
2) Loosenthe in)'ection pipe c(ips.
3) Removethe injection pipes.
12. hJ'ection Pump
/ 1) Remove the six injection pump bracket bolts from

the cylinder bodytimlng gear Case.
2) Remove the injection pump rear bracket bolts from

the rear bracket.
過 3) Pu一l the injection pump wl'th the injection pump

timlng gear free from the rear.
Note:
P(ug the de=very hoJder the

J'njectionpump ports with
shipping caps (or the equivalent) to prevent the entry of
foreJgn material.
｡,愈
ノ′
＼
/
覇
酌￠ダ
L.dS
￠
18. Exhaust Manifold
Loosen the exhaust manifold bolts a litt!e at a time

in the numerica[ ordershown in the illustration.
① ① ㊨
32
ENGINE ASSEMBLY (1 I
/一1
9
/
申
/
｢
㍗
曾 6
★
-■■-O
I
1/ト｢
一l
猷
駅
/
冒
＼､ミ一′
1 2
㍗/
討
仁表
鴨
∩
男コ
㍗
め
0 フくこ>
ゝ 13
＼＼＼こ
10-★
⑳ d
♂ 翫 i.
4
52 ■▲
■l
♂
L上
∈主
/二
LJ
フ=≦
闘
＼ふ
I句
･≠二
SS
i
rlJt
♂/
★ Repair kit
Djsassembfy Steps I
1 Water by-pass hose 10. Cy=nde｢head gasket

2 Thermostat houslng ▲ ll. Crankshaftdamperpu=eywith
3 Water pump dust seal
▲ 4 lnjection nozzle ho(der 12 Timing 9ea｢ Case cover (Option)
5 G一ow p山9 and 9low p一ug connecto｢ 13 Timing gear cover
6 Cylinder head cover 14 Timlng gearOil pIPe

▲ 7 Rocker arm shaft and rocker arm 15 暮dJergear ”B''and shaft
8 Push rod ▲ 16 tdle｢ gear `′A′'
▲ 9 Cylinder head 17 ldler 9ear Shaft
Inverted Englne
ENGJNEASSEMBLY (1 )
15 4
A
捕 YQ
p随†-*-1
節
＼ヽ.
1i3
5
6 i
/
/ 10
12
/ ♂ 亡戸
節
ヾ㍗/ ke
i:
｢
I
∈∋ ll
＼＼
2a
''.I:
笹し＼
u 当紹
,
関醐
_工忘
7
負
___鷲且
1駈- 4
1a
メ
⊥
A
★ Repair kit
Disassembry Steps -
1, Oi(pan 8. Piston and connecting rod with

^ 2, Flywheel upper bearl咽
2a. ▲ 9. Crankshaft beari｢唱CaP With
RearfJywhee川fso equipped)
3. FlywheeJ houslng Lower beanng
4. OilpumpwithoiJpipe 10. Crankshaft thrust bean-ng
▲ 5. Camshaftwithcamshafttimlng 11. Crankshaft with crankshaft timJng gear
▲ 12. Crankshaft upper bearlng
宙ear and thrust p一ate
6 Timing case ▲ 13. Tappet
gear
▲ 7 Connecting rod cap with 14. Crankshaft rear
oil sea一
lower beanng 15. Cy一inder body
34
ENGINE ASSEMBLY = )
∇ [mportant Operations (Djsassembly Steps ∼
2)
4, JnJ'ection Nozzle Holder
l) Remove the nozz一e holder bracket nuts.
〟
百中
C2
㊨
A
2) Use the nozzle ho[der remover the s)iding
園
and
hammer to remove the nozzle holder together
with the ho(der bracket.
Nozzle Ho一der Remover: 5-8840-2034-0

SlidJ'ng Humme: 5-8840-0019-0
ヴ＼!6＼L か､
7. Rocker Arm Shaft and Rocker Arm
Loosen the rocker arm shaft bracket boJts -fn numer-
icaJ order a )ittJeat a time.
Note:
Fai[ure to loosen the rocker arm shaft bracket bolts in

numericaf order a IittEeat a time w川adversely effectthe
rocker arm shaft.
9. Cylinder Head
Loosen the cy‖nder head bolts in numerica一 order a
JittJeat a time.
腐空,dot4Qe5...7矧
0000
Note:
Fai[ure to loosen the head bo[ts in numerica一

1 cylinder
1 Jittle at time
order a a
w川adverseLy effect the cylinder
o占毛913′1612o,4 head暮ower surface.
u＼8
35
ENGINE-ASSEMBLY ” )
ll. Crankshaft Damper Pu[ley with Dust Seat
@ O
(揺ノb
C⑳
1) B(ockthe flywheel with a piece of wood to pre-
0 vent it from turnlng.
b
¶
Cn 2) Use the damper to the
回
pu‖ey remover remove
i亡7 ヽ damper pulley.

Dampe｢ Pu一ley Remover
16. 1dler Gear ``A′′
Measure the timing backlash′ the
園
camshaft gear
crankshaft tim∫ng gear backlash, and the idler gear
”A”
end play before removing the idler gear ''A”
and shaft.
TjmJ-ng Gear Backlash Measurement

0
o⊂⊃
0
1) Seta diaJ indicatorto thetiming gearto be mea-
sured.
HoTd both the gear to be checked and the

○
0
adjoin[ng
oトJO stationary.
0 gear
○
○ ㊨ 2) Move the bechecked
圃
gearto asfaras possibreto
A ○ both
Take
the right and
diaJ indicator
the 一eft.
O the
0
0 reading.
S)竺
S3 1f the measured value the fimit,
○
exceeds specified
thetim]ng gear must be rep一aced.
Tim[ng Gear Backlash
mm(in.)
GEAR Standard
CAM-[DLE(A) 0.032-0,060
CRANK-IDLE(A) 0.032-0.066
IDLE(A)-lDLE(B) 0-0.035
IDLE(B)-lNJ,PUMP 0-0.029
Jd(er Gear ''A” End P(ay Measurement
tさ
囲 Insert a
thrust co‖arto
feeler gauge
measure
between
the gap
the
and
idJer gear
determine
and the
the idler
宙ear end p一ay.
■
○
If the the limit,
# ○ measured value exceeds specified the
○
ヽヽ
○ thrust colla｢ must be replaced.

㌔ :/
勺l Idler Gear End play mm(in.)

Q 0
Standard Limit
こL 0.08-0.18(0.003-0.007) 0.30(0.012)
36
ENGINE ASSEMBLY ‖ I
∇ Jmportant Operations (Disassembly Steps -
3)
2. FJywheeJ
l) BJockthe flywheel with a piece of wood to pre-

疹;`≠ vent itf｢om turnlng.
2) Loosenthef(ywheel bolts a fittJe ata time jnthe

,<j order shown in the =ustratjon,
エ
numericaJ
診
臥
5. Camshaft with Camshaft Timzng Gear and Thrust

P)ate
l) Removethethrustpfate bolts.
a
2) Pu‖ the camshaft free along with the camshaft
timing gear and the thrust prate･
Note:
Be careful not to damage the camshaft )'ournaI, the cam,
and the camshaft during the disassembJy procedure.
7. Connecthg Rod Cap with Lower BearJng
Jfthe connecting rod Lower bearLngS are tO be rein-

staHed, mark their fitting positJ-ons by tag9Ing each
♂ bearJng VVith the cylinder number from whJ'ch it was
removed.
”
8. Piston and Connecting Rod with Upper BearJng
0 1) Remove carbon deposits from the upper portion

a ofthe cyljnder warr with a scraper before remov-
bQ@
Q
Q〟ト.＼ (ng the piston and connecting rod･

D 2) Move the piston to the
of the cy[indertop and
∩
tap it withhammergr(p
a or simi(ar object from
rod lowersideto drive it out,
/
the connecting
Q
q
)9
0 El
l
A:/pi91
ヽヽ
ら
rD
lfthe connecthg rod upper bearings are to be rein-

sta=ed′ mark their fitting positions by tagglng each
∈∋ bearing vvith the cylinder number from which it was
removed.
/cl
37
ENGJNEASSEMBLY (1 )
9. Crankshaft Bearlng Cap with Lower BearJng
l) Measure the crankshaft end play at the center
JOu｢nal of the crankshaft.
)
ll ∫
小 Do this before removing the crankshaft bear∫ng

∫
1
( ) CaPS.
rf the the
measured vaJue exceeds specifJ-ed
【 a
E limit, the thrust bearing must be

crankshaft
/ ｢￣
節 Crankshaft
repJaced.
End P一ay mm(in.)
Standard Lim)-t
0.10(0,0039) 0.30(0.0118)
2) Loosen the crankshaft bearing cap bo一ts in

a (ittle at a time.
10 numericaT order
ff the crankshaft bearings are to be reinstaJ[ed,
mark their fitting positions by tagglng
8 9 each
4 5 beanng the from it
○ with cyEinder number which
○
was removed.
12･ Crankshaft Upper Beartng
A lfthe crankshaft upper beanngs are to be reinstalled,

mark their fitting positions by tagglng each bearing
臥 with
removed.
the cylinder number from which it was
｢r)o
ooOo
13. Tappet
]f the tappets are to･be reinstaJled, mark their fitting
positions by tagglng each tappet with the cylinder

numberfrom vvhich itwas removed.
_A 1
巾｡.
14. Crankshaft Rear Oil Seal (Axial Type)

Remove the ftywheel houslr唱.
0 /､､
/､
With the oil seal pushed in deep, instal[ the special
tooL as shown in the ilJustration and remove the oiL
嶺｡
seaI.
eア Oi】 Sea一 Remover: 5-8840-2360-0
38
∈NGIN∈ ASSEMBLY ” )
国 DISASSEM8LY
SJNGLE UrWT
ROCKER ARM SHAFT AND ROCKER ARM
冒
◎
I 工 a;
丁モ己ゝ
さく
㊨
管!】
冒
U
C)
払
P)ド ;iLRIL”S
5
Disassembry Steps
▲ 1 Rocker arm shaft snap rLng 5. Rockerarm shaftsprlng

▲ 2 Rocker arm 6. Rockerarm sh8ftsnap ｢ln9
3 7. Rockerarm
▲ Rocker arm
shaft bracket shaft
4 Rocker arm
39
ENGINE ASSEMBLY I1 )
∇ Jmportant Operations
1. RockerArm ShaftSnap Ring
2. Ro￠kerArm
3. Rocker Arm Shaft Bracket
l) Use a pair of snap ring pliers to remove the

SnaP r]ngS･
2) Removethe rockerarms.
Removethe
3) rocker arm
shaft bracket,
]fthe rocker arms and rocker arm shaft brackets
are to be reinsta]led, mark their instaIJation
positions by taggFng each rocker arm

and rocker
arm shaft bracket with the cy=nder number from
which it was removed.
40
ENGJNE ASSEMBLY (1 )
CYLINDER HEAD
ec'
∈∋
日
U
⊂)
U
C1
玩
く⊃
O
岳5
/■ O
ヽ U
′＼く⊃
P
O
盟♂P E] e2
e
◎
I
( 0 e3
I
DisassembJy Steps
▲ 1 Sp.it collar 5. Valvestem oiJseaJ

2 Valve sprlng upper Seat 6. Valve sp｢Ing lowerwashe｢
3 Valve 7. Cy=nde｢head
sprJng
▲ 4 Intake and exhaust va一ves
41
ENGINE ASSEMBLY (1 )
∇ Important Operations
1. Split CoJJar
l) Place the cyJinder head on a flat wooden

surface.
2) Use the to the
園
spring compressor remove spJit
coHar.
宿 ○ 【)
○
0 ○
Do not to faJ[ from
allow the varve the cylinder
head.
⊂) -･-････
【⊂) O
⊂) ○
A Sp｢in9 Comp｢esso｢: 9-8523-1423-0
｢＼｢1 ∩
4. Intake and Exhaust Valve
lfthe intake and exhaust valves are to be reinsta=ed,

mark their insta‖ation positions by tagg[ng each
valve with the cylinder number from which it was
∼/a.ノ〟o1 removed.
1fthere is excessive va一ve wear or damage, the va(ve
fィFl ＼叫
must be replaced.
Referto Page 50 of ”Jnspection and Repair” for the

valve and va[ve seat insert procedure.
Note:
(f there is excessive va一ve guide wear or damage. the

valve guide must be rep(aced.
Refer to Page 49 of ”lnspection and Repair” for the va一ve
guide replacement procedure.
The va一ve and the valve guides must be replaced as a
⊂)
′
set. Never replace only one orthe other.
C〉し⊃ Cl
亡
2i
42
円STON AND CONNECTING ROD
∈∋
ノ
&6
C5
O
㌶､､ U
聖＼ ∼
D]'sassembFy Steps
▲ 1 Connecting rod beanng 5 Connectin9 rod

▲ 2 Piston nng ▲ 6 Piston pm snap rJng
▲ 3 Piston pln Snap nng ▲ 7 Piston
▲ 4 Piston pln
43
ENGINE ‖ )
･ASSEMBLY
∇ lmportant Operations
1. Connecting Rod Bearng

Tf the
connecting rod bearings are to be reinstalled,
∈∋
mark their fitting positions by tagg[ng each bear]ng
with the cylinder number from which it vvas
removed.
∼El1
2. Piston Ring
l) Clamptheconnecting rod inavise.

∈≡≡〉 damage
Take care notto the connecting rod.
2) Use
団
a piston pin replacer to remove the
i≧±言== piston
rings.
ゝ､ー
Piston Ring Rep[acer
Do not attempt to use some other tool to

remove the piston nngs･ Piston ring stretching
will result in reduced piston rlng tension.
3, Piston Pin Snap Ring
4. P;ston Pin Snap R盲n9
＼ー
隠 Use
Pln
a
Snap
palr
rlngS.
Of snap nng p[iers to remove the piston
5. Piston Pin
7. Piston
Tap the piston pLn OutWith a hammer and a brass

bar.
pistons are to be reinsta[Ied, mark

1f the their instaト
Iationposit'[ons by tagg(ng each piston with the
from it
虹 cy[inder which was
number removed.
/
44
CAMSHAF:T, CAMSHAF:T TJM(NG GEAR, AND THRUST PLATE
@1.
浴
港
;i;
RS
ES b
Disassemb)y Steps
▲ 1. CanlShafttiml｢唱9ea｢ 3 Feather key

▲ 2. Th｢ustplate 4 Camshaft
45
1. Camshaft Timing Gear
2. Thrust PIate
l) avise.
rCIampthecamshaftin
Take care notto damage the camshaft.
2) Usethe
園
uni.versa[ pu([ outthe
pu[JerOto
camshafttimln9
③ gear②.
Universal Pu[Ler: 5-8840-0086-0
,1､.
] 3) Removethethrustpfate@.
6T'1.E.J
①
46
SECT10N 4
TABLE OF CONTENTS
ITEM PAGE
rnspectionandrepaJr .‥‥‥.‥‥‥‥‥---L‥-‥...,.”..‥‥‥‥‥‥‥‥.‥.
48
47
囲 lNSPECT10N AND REPAIR
Make the necessary adjustments, repa[rs, and part replacements if excessive wear or damage is
dL'scovered during ]nspectllon.
CYLINDER HEAD
Cy[inder Head Lower Face Warpage

l･ Use a st｢ai9ht
圃 edge and a feeler gaし唱e tO measure
the four sides and the two diagonals of the cy一inder

head lowerface.
くJ
2. Re9｢ind
ら
head lowerface if the

随 the
cJ
⊂+
<⊥
cy=nder mea-
9
く.1
亡I
国
つ a L
sured values are greater than the specified 一imit but

敬
勺
@ less than the maximum grinding a‖owance,
i [f the measured vafues exceed the maximum grind･

⑪ lng al]owance, the cylinder head must be rep一aced.
Cylinder Head Lovver Face Warpage
mm(in)
1 MaximumGrinding
Standard Limit
A(1wance
E
A-/1 F
0.05
0.2(0.008) 0.3(0.012)
CD (0.002)orless
I-㌔-
ら
Ll Cyhrnder Head Height (Reference) mm(jn)
Standard
Limit￣1
91.95(3.620)-92.05(3.624) 91.65(3.60)
Note:
(fthe cylinder head lower face is reground, valve

depression must be checked.
Exhaust Manifold Fitting F:ace Warpage

Use
and a feeler gauge
囲
a straight edge to measure the
manifold cylinder head fitting face warpage･
Regn'nd the manifold cy(盲nder head fitting faces if the
0
- than
0 measured values are greater the specified Jimjt but
鞄 co& tess than the maximum grinding

0 a[]owance.
ooo
0 1f the measured vafues exceed the maximum
tQOO.6d
grinding
(
0
0
0 0
the cylinder head must
0
oooo aHowance, be replaced.
48
Manifofd FittJ'ng Face Warpage mm (in)

MaximumGrinding
Standard Limit
Allwance
0.05
0.2(0.008) 0.4(0.016)
(0.002)orless
VALVE GUIDE
Va[ve Stem Va一ve Guide Clearance
園
and
■
MeasurJng Method I
I
e)
l･ With the
va一ve stem inserted in the valve guide,
ア set
L
the dial indicator J'oW,
a
needJeto
2. MovethevaJve head from sideto side.
a
Read the dJ'a( indicator.
Note the highest dial indication.
Jf the measured values exceed the Hmit,

specified
the valve and the va一ve 9uide must be rep一aced as a
set.
Valve Stem clearance

mm(in)
Standard Limit
0.039-0.071 0.20
JntakeVa[ve
(0.0015-0.0028) (0.008)
0.064-0.096 0.25
ExhaustVa[ve
(0.0025-0.0037) (0.0098)
Measur]ng Method -
JI
塾 ◎ 固
1. Measurethe
Referto the
valve
Item
stem
hValve
outside
Stem
diameter.
Outside Diameter”.
2･ Use a caliper ca]ibrator or a telescoprng to
gauge
measure the valve guide inside diameter.
Valve Guide Replacement
Valve Guide Removal
回 Use a
the vaLve
hammer
and the va一ve guide replacerto drive
from the cy[inder head lower face.
out
guide
∈う
O
園 Valve Guide Repracer: 9-8523-1212-0
亡フ a
…雇夢
u
U
dJ
u
∩ ∈)
0
OIO
_彪
｢1 ∈)∩
49
Valve Guide JnstaJ[at盲on
回 1. App[y
enCe.
engJne Oi一 to the va一ve gu-1de outer circumfer-
___-･--一一ニー-′
田 2.
3.
Attach
Use a
the
hammerto
valve guide
drive
replacerto
the valve
the
guide
vafve
into
guide.
position
園 from
VaJve
the
Guide
cylinder
Replacer:
head upper
9-8523-1212-0
face.
密琶園
4. Measure the height of the va[ve g山de upper
圃
end
from the upper face of the cy[inder head.
Valve Guide Upper[nd Hei9ht (H)

I
(Reference) mm(in)
13.0 (0.512)
J
⑪
Note:
●●.-.I.....J
････.･･･.!/･･ ]fthe valve has been both the

●●▲ ●-●
guide removed, va一ve and

the va[ve guide must be replaced as a set.
VALVE AND VALVE SEAT INSERT

＋ /
一■一-
Va一ve Stem Outside Diameter
1J/ diameter
Measure the at three
圃
valve stem points.
Jfthe measured value is (ess than the specified JJ'mit, the
va[ve and the valve guide must be repJaced
ち
/
as a set.
Valve Stem Outside Diameter mm(in)

ら,こ
Standard Limit
7.946-7.961 7.88
lntakeValve (0.3128-0.3134) (0.3102)
7.921-7.936 7.88
ExhaustVaJve
(0.3118-0.3124) (0,3102)
Valve Thickness
Measure the va[ve thickness.
圃 1fthe
va[ve
measured
and the
value王s
valve guide
less than
must
the specified
be replaced as a
Iimit′the
set.
Intake and Exhaust Va一ve Thickness mm(in)

Standard Limit
lntakeVa]ve 1.79(0.070) 1.1(0.043)

ExhaustVa[ve 1.39(0.0547) 1.1(0.043)
50
Va)ve Depression
1. lnstalrthevaFve①tothecyrinderhead②.
2
+ Use depth
圃2.
gauge or a
孤
a straight edge wJ'th steel ru[e
from the cylinder
] )
_JIJ
to measure the valve depression

1II
I head lower surface.
①
i
t
If the
the vaJve
measured
seat insert
value
must
exceeds the specified
be replaced.
Jimit′
I Valve Depression mm(in)

Standard Limit
Jntake 0.65(0.026) 1.28(0.050)

Exhaust 1.10(0.043) 1.60(0.063)
VaJve Contact Width

1. Check the vaレve contact faces for rou9hness and
UneVenneSS.
JJl Jm
●●●
Make smooth the va一ve contact surfaces.
拙･:･･
｡I■
6:.A:軒
I
2. MeasurLe the valve conlactwidth.
i
l
圃 Jf the
the vafve
measured
seat insert
value
must
exceeds the
be repJaced.
specified limit′
I Valve Contact Width mm(in)

Standard Limit
lntake 1.7(0.067) 2.2(0,087)
Exhaust 2.0(0.079) 2.5(0.078)
Va[ve Seat Insert Replacement
④ Valve Seat Jnsert Removal

③＼
0 0
Ei) 1. Arc weld the
insert
entire inside circumference ① of the
@.
o
0 varve seat
財
○
insertto fora
④! 0
2. AHowthe va一ve seat cool few minutes.
This w‖ invite contraction and make removal of the

/ さ･､ ○
valve seat insert easier.
(か
51
3. Use a
screwdriver ③ to prythe valve seat insert
free.
Take care notto damagethe cy一inder head ①.
4. CarefuJ[y forelgn
E5]
remove carbon and other material
f｢om the cylinder head insert bore.
Va[ve Seat Insert Jnsta[Jation
___ゝ′
① Ej 1. Carefuf[y
outside
p[ace
diameter
the attachment
than the valve
0 (having
seat
a smaHer
insert) on the
① valve seat insert①.
1;1 Note:
㊨ The smooth side of the attachment must contact the

l valve seat insert.
I
ヽ
2. Use a bench press @ to gradual[y apply pressure to
the attachment and press the va一ve seat insert hto

ヽ
place.
Note:
Do not apply an excessive amount of pressure with the

bench press. Damage to the va[ve seat insert wi[l
result.
Valve Seat hsert Correction

/'' /[50' ∼--㌔
/ 固 1. Remove the carbon from the va一ve seat insert suト

/ face.
/
1 2. Use (15o, blades)
圃
a vafve cutter 45o, and 75o to
minimize scratches and other rough areas. This w=
bring the contactwidth backto the standard va[ue.
Remove onJy the scratches and rough areas. Do not
cut awaytoo much･ Take care ロotto cut away
unbJemished areas of the va一ve seat surface.
Valve Seat Ang一e 45o
Note:
Use
団
an cutter
adjustable va一ve pi一ot.
Do not allovv the valve cutter pi一otto vvobble inside the
valve guide.
52
3. App一y abrasive compound to the valve seat insert
＼ surface.
1L 4, lnsertthe valve into the vaJve guide.

⊂ノ 5･ Turn the valve whi一e tappJng Zt to fit the valve seat
C)
堰
insert.
⊂ノ /, ,
⊂ノ :ち 6. Checkthatthe valve contact width is correct.

C) C.) C
7. Check that the insert is
臼鮎
va.ve seat surface J'n contact
∩
with the entire circumference of the valve.
VALVE SPRING
Valve Spring Free Height
Use to the free
囲
a vern盲er caliper measure
valve spnng
height.
[fthe measured value is Jess than the Limit, the
specified
valve spring must be replaced.
Vafve Spring Free Height
mm(in)
Standard Limit
49.7(1.96) 48.2(1.90)
VaJve Spring Inclination

Use
囲
a surface p(ate and a to measure the
square valve
spnng lnC[ination.
(f the measured value exceeds the specified Hmit, the

valve sprlng must be rep[aced.
Valve Spring Jnc‖nation
mm(jn)
Standard Limit
1.5(0.06)orJess 2.5(0.098)
Square
Valve Spring Tension
Use teStertO the
囲
a sprlng measure tension.
valve sprJng
【fthe measured va[ue is 一ess than the limit′ the
specified
valve sprlng must be rep一ace.
Valve Spring Tension N(kgf/fb)

CompressedHeight Standard Limit
254 225
38.9mm(1.53in)
′ (25.9/57) (23/51〉
53
ENGINE ASSEMBLY (2 1
Rocker Arm Shaft Run･Out
1. Pf ace the rockerarm shaft on a V-b[ock.

Use dia一 indicator to the
囲2.
a measure rocker arm shaft
central portion run-out.
1f the run-out is very sTight, correct the rocker arm
帽 bench The
shaft run-out wL[th a press. rocker arm
must be at cofd condition.
[f the measured rocker arm shaft run-out exceeds

the specified limit, the rocker arm shaft must be
rep)aced.
Rocker Arm Shaft Run-Out mm(J'n)
Standard Limit
0.2(0.008) 0.6(0.024)
Rocker Arm Shaft Outside Diameter
to the fi吋ng
固
a measure rocker arm
･Use micrometer
portion outside diameter.
If the measured value is less than the specified limit, the
rocker arm shaft must be ｢eplaced.
Rocker Arm Shaft Outside Diameter mm(in)

Standard Limit
18.98-19.00(0.747-0.748) 18.85(0.742)
Rocker Arm Shaft and Rocker Arm C一earance
1. Use d舌af indicatorto
園
either a vernier ca‖per or a
measure the rocker arm bushing LnSide diameter.

Rocker Arm Bushing Inside Diameter mm(in)
Standard Limit
19.01-19.03(0.748-0.749) 19.05(0.750)
2. Measure diameter.
園
the rocker arm sha托outside
1f the measured value exceeds the specified limit,
repface eitherthe rocker arm or the rocker arm shaft.
RockerArm and Rocker Arm Shaft Clearance mm(in)
Standard L'rmit
0.01-0.05(0.0004-0.002) 0.2(0.008)
54
3. Check thatthe rocker arm

oi( port is free of obstruc-
tions.
1f necessary, use compress'ed air to clean the rocker

arm oil port.
′
Rocker Arm Correction
⇒
Jnspect the rocker arm valve stem contact surfaces for
一/一･③
step wear① and scorin∈I ②.
1f the contact surfaces have (ight step wear or sconng,
①
they may be honed with an oil stone.
1fthe step wearorsconng JS Severe, the rocker arm must
be ｢eplaced.
CYLINDER BODY
Cy)hder Liner Bore Measurement

Use a cylinder indicator to measure the cylinder bore
園
at
measuring in thethrust X-X and axiaJ Y-Y
y￠y
point①
directions of the crankshaft.
Measuring Point① : Maximum wear portion
ノ
【11-15mm(0.43-0.59in)】
①
lf the measured value exceeds the specified limit, the
表芸≧ニ cyrinder (iner
Cy一inder Liner
must be replaced.
Bore
mm(in)
Standard Limit
95.421-95.460(3.7567-3.7583) 95.5(3.7598)
Note:
The inside of the dry type cylinder Liner is chrome
prated. Jtcannot be rebored or honed.
Jf the inside of the cy[inder =ner is scored or

scorched,
the cylinder [iner must be replaced.
Cyrlnder Liner ProJ'ection lnspection
杏
① l･ Hold a
st｢ai9hted9e ① along the top edョe Ofthe
llmer to be measured.
ゝ､ cy=nder
2. Use fee[er ①to ‖ner
圃
a gauge measure each cylinder
projection.
弓J
⊂J
Cylinder Liner Proj'ection

mm(in)
冒
r Standard
②
那 0-0.10(0-0.0039)
The difference in the cylinder liner projection height

between any two cy一inders must not
adjacent
exceed 0.03 mm (0.0012 in).
55
CylJLnder Liner RepJacement
CyJinder Liner Removal
)＼＼＼回 1. Removethe cylinder body dowel.
2. Setthe cylinder nner removerto the cy=nder finer.
3. Check thatthe remover shaft ankle is firmly grJPPlng

the cylinde=iner bottom edョe.
4. SJowJy turn the remover shaft handle counterc[ock-

I-”
wise to pu一lthe cylinder liner free.

●l Lr
CyTinder Liner Remover Ankle: 5-8840-2304-0
園 Cyfinder Liner Remover: 9-8523-1 169-0
NOTE:
Take care not to damage the cylinder body upper during
the cylinder Liner removal procedure.
CyJinder Body Upper Face Warpage
圃 1.
2.
Remove
Removethe
the cylinder bodydovver.
rlrner.
cylinder
3. Use a
straightedge① and a
feeJergauge①to
冒 measure the four and the two diagonals
sides of the
cylinder body upper face.
@ rI*j=
/′■
Cylinder Body Upper Face Warpage

mm(in)
Standard Lim叶
0.05(0.002)orless 0.2(0.008)
lfthe measured value is more than the (古mit, the

A
cylinder body must be replaced.
F
E
CD
I-㌔_
B
ll
Cy=nder Body Height (Reference) mm(in)

Standard
272.945-273.105 (10.746- 10.752)
4. Reinsta‖ the cy=nder =ner.
Referto 'JCylinder Body Bore Measurement”.
5. ReinstaJl the cy一inder body dovvel.
56
Cylinder Liner Grade Selection

Measure the body inside diameter
@
cy‖nder and seJect
the proper cy=nder =ner grade'number corresponding to
the body inside diameter.
cyIJ'nder
Standard Fitting Interference (Reference) mm(in)
/1
0.001 -0.019 (0.00004-0.00075)
ー一--=ゴr
(f the =ner fitting interference is too smaFf,

､ヽ
cy=nder
ゝてアご eng(ne cooling efficiency wiJJ be adversely affected.
%. 1fthe cylinder [iner fitting interference盲s too large. it w川
be diffJ-cuJtto insert the cylinder liner into the cylinder
body.
The cylinder block deck has been marked during

イー production to indicate the correct liner sizes･ The =ner
grade (J'.e.1, 2, 3′ 4) is indicated in permanent ink.
rn the case of a questionab一e Jiner marking measure the

0
o&o. too oiEfo o&oi cyJinder body hside diameter･
e/mqSoo
0
10
0
0 ○ 0 0
Cylinder Body 8o柑Measurement
1. Take measurements at measuring point 0 across
圃 positions
Measun'ng Point①
(”W-W”),
: 98 mm
(”X-X”),
(3.86 in)
(Y-Y) and (Z-Z).
2.CalcuJate the average value of the four

measurements to determine the correct cylinder
9rade.
Cylhder Liner Grade
Nominal CyrinderBody
LinerGrade
I- Dimension BoreDiameter
” Z
97.001-97.010 l
Y
-∠y
_一＼
mO. 97.001-97.020 2
≠97
97.021-97.030 3
3 ”
x
C> 97.031-97.040 4
57
Cy)盲nder Liner Jnstallation
Ei] 1. Cy[inder Liner JnstalJation

kerosene
Using
diese一
The Specia[ TooT･
1) Use new or oil to thoroughfy
田 clean
2) Use compressed
the cy=nde=iners
air to
and bores.
b一ow-dry the cy=nde｢

Jiner and bore surfaces.
Note:
A= foreign material must be carefu][y removed from the

cylinder liner and the cy=nder bore before installation.
3) Jnsertthe cylinder [iner ① into the cy=nder body

③ ① from the top of the cylinder body.
①
②
謂
y,
r/
4) Setthe Liner I-nstaHer③ to thetop of the
園
cy[inder
cylinder liner.
③ 5-8840-2313-0
Cy=nder Line‖nsta‖er:
5) Position the cylinder body so that the instatler

r center @ is directly beneath the bench press
二=之ニ
shaft center ④.
0 D
i r)
ーIl r) r3
㍗ Note:
Check that the cylinder =ner is set perpendicular to the

Q ㊨ bench press and thatthere is no wobble.
force
6) Use the bench pressto app一y a seating of
500 kgf(1,102.5 [b/4,900 N) tothe cy[inder =ner.
7) Apply a force of 2′500 kgf (5,512.5 1b/24,500 N)
to fully seatthe cylinder liner.
8) After instaHing the cylinder finer, measure the
cylinder finer projection.

Refer to一`Cylinder Liner Projection lnspection′′.
2. Cylinder Liner lnstallation Using Dry [ce
回 lfthe
advisable
cylinder
to
=ner
use
is a chrome
dry Ice
p一ated drytype,
during the
it is
instaltation
procedure･
Cooling the cy一inder =ner with dry ice w‖ cause the
cyJinder Liner to contact, thus making insta‖at盲on
eaSler.
Note:
lt is important that the cy[inder liner be inserted to the
cy‖nder body immediately after it has been coo(ed.
･
58
WARNING:
DRY ICE MUST BE USED WITH GREAT CARE. CARE-

LESS HAND”NG OF DRY JCE CAN RESULT fN SEVERE
FROSTBITE.
Piston Selection
Se一ect the same

9rade number as the one for the
cylinder =ner I-ns亨dediameter.
Gradeofcyfinder
Gradeofpiston Combination
ins手dediameter
AX AX OK
CX CX OK
AX CX NG
CX AX NG
59
Piston Grade Selection
Measure finer bore. Then
画
the cyHnder select the
appropriate piston grade for the instaHed liner.
y!%fy
cylinder
1. Measure the cy[inder =ner bore.
ノ There ( ① and
aretwo measuring points ②).
l①
Liner
′
Measure the cyfinder bore in four different

_･一一戸丁二
′ ヽヽ i,@ direction (W-W. X-X, and Z-Z) at both mea-
噌ニー午 surlng POints.
% Ca[cufate the average va(ue of the eight measure-
ments to determ-[ne the correct cy=nder liner bore.
MeasurJ'ng pointsO : 20 mm (0,79 in)

①:160mm(6.30in)
Cy一inder Liner Bore mm(in)
Standard Limit
95.421-95.460(3.7567-3.7583〉 95.5(37598)
Relat7on between Lher Bore and Piston Grade mm(in)

LinerBoreDiameter PistonGrade
95.421-95.440
AX
(3.7567-3.7575)
95.441-95.460
CX
(3.7575-3.7583)
Note:
暮tis most important that the correct piston grade be

used. Fa‖ure to select the correct piston grade w川result
in engJne fai[ure.
2. Measure the pJ-ston outside diameter.
画 Piston Measuring Point① : 71 mm (2.79 in)

Piston Outside Diameter mm(J'n)
OutsideDiameter PistonGradeforService
95.365-95.384
a (3.7545-3.7553)
AX
95.385-95.404
CX
(3.7553-3.7561)
Cy=nder Liner and Piston Clearance mm(I'n)

0.037 (0.0015 -
0.0030)
-0.075
Note:
:Cy一inder (iner kit clearances are preset. However, the

cy一inder liner instaHation procedure may resu一t in s[ight
decreases in cylinder )iner clearances. A[ways measure
the cylinder finer c一earance after instaHation to be sure

that itis correct.
60
TAPPET AND PUSH ROD
○◎
.-.:.一･
■ t l1 VisuaT[y [nspect the tappet camshaft contact surfaces for
A.
I:･1.1'/ The
pitting, cracking, and other abnormal conditions.
● ● ■
tappet must be repJaced if any of these conditions are
Pr(∋Sent･
Referto the iHustration [eft.
￠
atthe
1 Pitting
2 Cracking
3 Norma一 contact
4 lrregular contact
5 lrreg山8r COntaCt
Note:
The tappet surfaces are spherJ'ca[. Do not attempt to
grindthem with an oil stone orsim‖artool in an
effortto
repair the tappet. Jf the tappet is damaged, it must be
rep一aced.
Tappet Outside Diameter
Measure the tappet diameter
囲
outside vvith a micrometer.
Ifthe measured value is Jess than the specified limit, the
tappet must be rep)aced.
∼ Tappet Outside Diameter
mm(in)
′
Standard Limit
12.97-12.99(0.510-0.511) 12.95(0.509)
61
Tappet and Cylinder Body Clearance
囲
mm(in)
W2i Standard Limit
0.03(0.0012) 0.1(0.0039)
⊂
こ⊃
#
こ⊃
く.⊃
茅妻芳
㍗I_⊥-⊂⊃
￣⊂⊃
Push Ftod Curvature
1. Laythe push rod on a

suげace plate.
2. RoJl the the
囲
push rod along surface plate and mea-
sure the push rod curvature with a thickness gauge,
If the measured the 一imit.
vaJue exceeds specified
the push rod must be rep一aced.
Push Rod Curvature mm(in)

LimJ't
0.3 (0.012)
3. Visua][y inspect both ends of the push rod for

excessive wear and damage. The push rod must be
repJaced if these conditions are discovered during
inspection.
CAMSHAFr
Visua‖y ins･pect the journa一s, the cams, the oi一 pump

drive gear, and the camshaft bearings for
excessive
wear and damage. The camshaft and the camshaft
bearings must be replaced if these conditions are
discovered dur'Ing mSPeCtion.
Camshaft Journal Diameter
Use a micrometer to journaF

圃
measure each camshaft
diameter in two directions ((X- X) and (Y-Y)). If the
measured value is 一ess than the limit, the
specified
yby
camshaft must be ｢eplaced.
Camshaft Journa( Diameter

mm(in)
Standard Limit
49.945-49.975 49.60
(1.9663-1.9675) (1.953)
62
ENGINEASSEMBLY (2 )
Cam Height
Measure the cam height (H) with a 1f the
囲
micrometer.
measured vafue is 一ess than the limit, the
specified
camshaft must be rep一aced.
I
H cam Height ⑪ mm(in)
Standard Limit
42.02(1.65) 41.65(1.64)
Camshaft Run･Out
i. Mountthe camshafton V-b.ocks.

○
2. Measurethe dial indicator.
圃
run10utWith a
Ff the measured value exceeds the specified limI't′

the camshaft must be ｢eplaced.
Camshaft Run-Out mm(in)

Standard Limit
0.02(0.0008) 0.10(0.004)
Camshaft and Camshaft Bear]ng
Use inside dial indicator
圃
an to measure the camshaft
bearJng diameter.
鉦+ ｡
_.o Camshaft
Inside
Bear[ng Inside Diameter
q C) mm(in)
&@yljo3
Standard Limit
50,0-50.03 50.08
(1.9685-1.9696) ∩.9716)
Jf the clearance between the camshaft bearlng Inside

diameter and the journal exceeds the Jimit′ the
specified
camshaft bearlng must be rep一aced.
Camshaft Bearlng Cle∂r∂nce mm(in)

Standard Limit
0.025-0.085
0.12(0.005)
(0,0010-0.033)
Camshaft Bear暮ng Rep一acement
Camshaft Bearlng Removal
町 Ei) 1. Remove the cylinder body pJug plate.

￠
2･ Use bearing
園
the camshaft repl∂cer to remove the
o
o旬
camshaft bea｢lng.
ノノ
屯
Beanng RepJacer: 5-884012038-0
(]?
＼㌔
a 一1∋
63
Camshaft Bear[ng lnsta[1at盲on
節r). /
少
日 l･ A=gn
ho】es.
the bearlng O‖ holes with the cylinder body oi一
∫
a
刀
一句 2. Use bearJng instalJer
周
I the camshaft reP[acer to instaH
;il
J
the camshaft bearing,
Beanng Repfacer: 5-8840-2038-0
Db･
∂
･Q
'^ ∂ 1
Camshaft End P一ay
l･ Before removin9 the camshaft gear ①′ push the

th｢ust prate ① as far as it w川go toward the
① 〟 cam-
shaft gear ①.
2. Use feeler
圃
a 9aUge tO measure the clearance
between the thrust plate and the camshaftjournal.
Jf the measured va[ue exceeds the specified (imit′
thethrust p一ate must be replaced.
④ Camshaft End P(ay
② mm(in)
Standard Limit
0.050-0.114(0.002-0.0044) 0.2(0.008)
Thrust Pfate Rep(acement

②
③ Thrust Plate Removal
⊥､回 1. Use
timing
the universa一 p山Ier ①to remove the camshaft
gear@.
園 2･
Universal
Removethethrust
Pu=er: 5-8840-0086-0
∫
① p(ate@.
冒 Lj
Thrust Plate lnstaIIat;on
Ej 1. Install thethrust p一ate.

2- Apply
E]
♂1 en9lne Oil to the bo一t setting face and the bolt
〈ク
threads.
3･ [nstal] the
響
camshaft gear.
国 Camshaft Gear Torque N･m(kgf･m/[b.ft)

98-118(10-12/72-87)
♂鷹
64
ENGINEASSEMBLY (2 )
CRANKSHAFT AND BEARING
Inspect the of the crankshaft journals

surface and
crankpins for excessive wear
and damage.
1nspect the oil seal fitting surfaces for excessive wear
and damage.
Inspect the oil ports for obstructJ'ons.
Note:
To increase crankshaft strength, tufftriding (Nitrizing

Treatment) has been appI盲ed. Because of this, it is not
possibJe to regrind the crankshaft surfaces.
Crankshaft Tufftriding Inspection
1. Use to
田
The portion to be tested an
organic c(eaner thorough一y clean, the
Jha‖ be he一d horizontal]y
Te卓t liq山d shou一d crankshaft. There must be no traces of oi一 on the
iOaS not tOlet the test
not be applied to
IOJution flovv. to be inspected.
th8 a(ea around the surfaces
oil port. 2･ Prepare a 5 10% solution of ammonium cuprous
-
The IIiding
打7
of the pin
cMorJ'de (dissolved in distJ'Hed
or
water).
J'ourn8L
3, Use a syrlnge tO aPPJythe solution to the surface to
ApproxILmateZy
Omm be inspected.
Hold the surface to be inspected perfect一y horizontaJ

to prevent the solution from runmng.
Note:
Do not alJowthe to come in contact

so[ut了on vvith the oil
ports and theJ-r surrounding area.
Judgment
1. Wait forth-IrtytO forty seconds.

ff there is
discoJoration
no after thirty or forty see-
onds′ the crankshaft is usable.
1f discoloration appears (the surface being tested

wiII become the color of copper), the crankshaft
must be ｢eplaced.
2･ Steam the immediately
E5]
clean crankshaft surface
afte｢ completing the test.
Note:
The ammonium cuprous chloride solution is highly cor-
rosive, Because of this, it is imperative that the surfaces

being tested be cleaned immediately after completing
the test.
65
Crankshaft Thrust CJearance
Setthe dia[盲ndicator as shown in the =ustration and

measure the crankshaft thrust c一earance.
[f the thrust clearance exceeds the specified Jimit′ re-
pracethethrust bearing as a set.
やや mm(in)
Standard Limit
ド
¶■ 0 J
○ 3V: 0.10(0.0039) 0.30(0.0118)
Crankshaft Run･Out
1. Set a dial indicator to the center of the crankshaft
/
/ ､′ ヽ
/ )ournaJ.
/
I(
ノ
ク
) ≠ 園
2. GentJyturn
rotation.
the crankshaft in the normal direction
of
Read the dial indicator as you turn the crankshaft.

1f the measured value exceeds the specified Limit,
+ the crankshaft must be repJaced.

Crankshaft Run-Out mm(in)
Standard Limit
0.05(0.002)orfess 0.08(0.0031)
Bearlng Tension
Checkto see ifthe bearJng has enough tension, so that a
good finger pressure is needed to fit the bearJng into
position.
∫-ノ
§;⊇=三≧≠
Crankshaft JournaL and Crankpin Diameter

③④
l･ Use to journa一
圃
a micrometer measure the crankshaft
や白
diameter across
po'[nts (”1 -
1”) and ('12-2'').

＼ 2. Use the micrometer to measure the crankshaft
＼'
＼
圃 3･
journaE diameteratthetwo
RepeatSteps 1 and 2to
points
measure
(@ and a
thecrankpin
).
diameter.
乙′
】fthe measured va(ues are less than the )imit, the
crankshaft must be replaced.
66
Crankshaft Journ∂l Diameter mm(in)

Standard Limit
69.917-69.932 69.910
(2.7526-2.7531) (2.7524)
Crankpin Diameter mm(in)

Standard Limit
52.915-52.930(2.0833-2.0839) 52.906(2.0829)
Crankshaft Journa[ and Crankpin

Uneven Wear mm(in)
Standard Limit
0.05(0.002)orJess 0,08(0.003)
Crankshaft Journal and Bearmg clearance
⑳冒圃
/
tf the c一earance between the measured bearing Inside
diameter and the crankshaft journal diameter
こ /
exceeds
the specified limit, the bearing and/or the crankshaft
t/
must be replaced.
⑳ Crankshaft Beanng Cap Bolt

＼
･＼ Torque N･m(k9f･m/lb.柑
∠ゝ ′
157-177(16-18/116-130)
♂
さ､. -iilttt
Crankshaft brg′ cap Bo什Torque
国 Crankshaft
Beamg
JournaJ
Clearance
and
mm(in)
Standard Limit
0.031-0.063(0.0012-0.0025) 0.ll(0.0043)
Connecting Rod BearJng lnside Diameter

1･ lnsta[l the bear[ngtothe connecting rod big end.
21 Tighten the bearfng the
国
CaPtO specified torque･
Connecting Rod Bearlng Cap Bolt

Torque N･m(kgf･m/)b.ft)
27-31 (2.8-3.2/20-23)一45o-60o
3. Use inside dial indicator to measure
圃
a
the connect-
]ng rod bearing Inside diameter.
67
Crankpin and Bearing Clearance
圃 Jf the
diameter
clearance
and the
between
crankpin
the measured
exceeds the
bearlng
specified
Inside
Limit,
the bearhg and/or the crankshaft must be replaced.
Crankp盲n and Beanng clearance mm(in)

Standard Limit
0.029-0.066(0.0011-0.0026) 0.10(0.0039)
clearance Measurements (With PJastigage)

0 9 o
Crankshaft Journal and Bearlng Cfearance
＼田
1. C一ean the cy(盲nder body,
surface, the bearlng Caps,

the
and
journal bearlng
the bearJngS.
fitting
2. Jnsta[1the bear]ngs to the cyl].nder body.

3. Carefu‖y place the crankshaft on the bea｢in9S.
◎
⊂〉
4. Rotate the crankshaft approximately 30o to seat the
○ bearln9.
5. place the PFastigage (arrow) over the crankshaft
)ournal acrossthe fun width of the beanng.

6. lnstaJlthe beanng caps with the bearJng.
7. Tighten the bea｢ln9 Caps tOthe specified torque.
国 Crankshaft
Torque
Beanng Cap Bo[t
N･m(kgf･m/[b,ft)
157-177(16-18/116-130)
n Do not arfow the crankshaft to turn during beanng

cap insta[Jation and tightening.
一￣
0
⑨ー 0 ○/の〔
8. Removethe bearJng Cap.
68
9. Compare the width of the Plastigage attached to
圃 either the
prJ'nted on
crankshaft orthe
the P[astJ'gage
bearing
container.
agaJnSt the scale
E2
でげthe measured
fo]lowlng
va山e exceeds
additional steps.
the limit, perform the
1) Use to the
回
a micrometer measure crankshaft
outside diameter.
0
2) Use an inside dia一 indicator to measure the

○
国 bea｢Ing
If the
JnSide diameter,
crankshaft journa( and bearJng clearance
exceeds the limit, the crankshaft and/or the

bearmg must be replaced.
Crankshaft Journal and BearJng clearance mm(in)

Standard Limit
0.ll
0.031-0.063
(0.0043)
Crankpin and Bearmg Clearance
1. Clean the
crankshaft′ the connecting rod, the bear-
1n9 Cap. and the bearln9S.
2. hsta‖ the bearing to the connecting rod and the

be∂｢lng Cap.
Do not aflow the crankshaftto move when instaHing

the beanng cap.
3. Prevent the connecting rod from movln9.
4. Attach the P[astigage to thre crankpin.
AppJy englne OH to the PJastigage to keep it from

fa[Jing.
5. Jnstarl the bearJng Cap and tighten itto the specJ-fJ-ed
国 torque･
Do not a‖owthe connecting rod to move when

insta川ng and tightening the bearrng cap.
Connecting Rod Bearing Cap Bo一t

Torque N.m(kgf･m/1b.ft)
27-31 (2.8-3.2/20-23卜◆45o-60o
6. Removethe bea｢lng Cap.
7, Compare the width of the Plastigage attached to
圃 eitherthe
printed on
crankshaft
the PlastJ'gage
or the beanng
container.
against the sca一e
1f the measured vaJue exceeds the specified limit′

perform the fo‖owlng additional steps.
1) Use to the
圃
a micrometer measure out-
c｢ankpin
side diameter,
2) Use inside dial indicator to the

圃
an measure
bearLng [nSide diameter.

1f the and bearing ctearance exceeds
crankpin
the lim7t, the crankshaft the
specified and/or
bearlng must be rep一aced.
Crankpin and Bearlng Clearance mm=n)

Standard Limit
0.029-0.066 0.10
(0,001l-0.0026) (0.0039)
69
CRANKSHAFT BEARING SELECTION

No.3
No2 Nod When insta=｢唱neW Crankshaft bearings or replacing
1 ｢
No.5
No''1 ｢ old bearings, referto the s(ection table below.

Se[ect and install the new crankshaft bearings, pay[ng
c一ose attention to the cy)盲nder body journal hole
0 0 ○
diameter size mark and the crankshaft journal diameter

a EEZ=
size mark.
ロE] E]E] E]
No.1 No.2 No.5
I ●
No.3 No.4
MainBearlng Crankshaft Cranksha冊

OifCfearance
BoreDiametermm(in.) MainJournalDiametermm(in.) Beanng
SizeMark InsideDiameter SizeMark OutsideDiameter mm(in.)
SizeMark
69.927-69.932 0.035∼0.061
1or- (2.7530-2.7532) Black (0.0014-0.0024)
73.987-.74.000 69.922∼69,927 O.O32∼.0.058
1 2or--
(2.9129-2.9134) (2,7528-2.7530) (0.0013-0.0023)
BJue
69.917∼69.922 0.037ー0.063
3or--
(2.7526-2,7528) (0.0015-0.0025)
69.927∼69.932 0.031-0.056
1or- (2.7530-2.7532) (0.0012←0.0022)
Green
73.975-73.987 69.922∼69.927 0.036∼0.048
2 2or--
(2.9124-2.9129) (2,7528-2.7530) (0.0014-0.0019)
69,917∼69.922 0.033-0.058
3or-- Black
(2.7526-2.7528) (0.0013-0.0023)
Crankshaft Timing Gear Rep(acement
① ｢ノ Crankshaft Timing Gear Remova]
Ej 1. Use the crankshaft ∈Iear remover ① to remove the

O
U
crankshaft gear②.
⊂)
2. Remove the crankshaft feather key.
r
ー､｢′ ∫/
園 Crankshaft Timlng Gear Remover: 9-8840-2057-0
7/ ㊨
し
Crankshaft Timing Gear ]nstaHation
) Ei] 1. (nstafT the crankshaft gear.
2･ Use the crankshaft gear instal(er ① to instaH the
園 crankshaft
The crankshaft
gea｢①.
gear timing mark (LLX -
X”) must be
♂ 任)
㊨
画 faci｢唱OutWard.
Crankshaft Gear lnstaller: 9-8522-0020-0

つDつ
70
CRANKSHAFT PILOT BEARING
Check the crankshaft piJot bearing for excessive wear
and damage and rep face jt if necessary.
Crankshaft Pilot BearJng Rep(acement
Crankshaft Pilot BearJng Removaf
￠
珍
匡l Use
ing.
the pilot bearJng remover tO remove the pilot bear-
匝I P‖ot Beanng
Sliding Hammer:
Remover: 5-8840-2000-0
518840-0019-O
Crankshaft Pnot BearJng lnstarration
巨] l･ P(ace
the
the
crankshaft
crankshaft
beanng
pilot beanng
jnstallation
horizontaJ[y
ho一e.
across
2･ Tap around the edges of the crankshaft pilot bearJng
園 outer
1ng into
races
the
with
crankshaft
aLbrass hammer
bearmg
to drive the bear-
instaJIation hole.
YS Note:
Pifot Beanng lnstaJJer: 5-8522-0024-0
Strike onry the crankshaft pi一ot bearlng outer races

VVith
the hammer･ Do not strike the bearing Inner races.
Bearlng damage and reduced beanng service Fife w=

result.
71
FLYWHEEL AND RING GEAR
① F)ywhee1
1. ∫nspect the fJywheeT friction surface for excessive

wear and heat cracks.
2. Measure the flywhee一 friction surface wear amount
(depth)
The fJywheeJ friction surface area actuar暮y making
contact with the crutch driven prate (the shaded area
in the川ustration) w川be smaFler than the originar

surface area.
mach盲ned
There will be a ridge on the fJywhee( surface area.
Be sure to measure the surface wear in the area
inside the ridge.

げthe measured va一ue is between the standard and
the specified (舌mit, the flywhee一 may be reground.
1f the measured value exceeds the specified ‖mljt,
the flywheel must be replaced.
Flywhee( Friction Surface Depth ① mm(in)

Limit
1.0 (0.04) o｢more
Note:
Because a
ridge is produced at the f[ywheef frictJ'on sur-
face as iHustrated, do not measure the friction surface
wea｢amount nonィidge at areathe but be sure to
measure it at the rear-friction surface which is shown in
the iIJustration by shaded area.
Ring Gear
Jnspectthe nng gear.

(fthe rmg gearteeth are broken or excessively worn, the
｢ln9 gear must be rep一aced.
RJ'ng Gear Rep(acement
Ei]
Ring Gear Removal
Strike around the edges of the nng gear with a hammer

/
it.
_
and diese( to remove
･二=石:::こ二コト-
衰㌍
{#
;ぎミき⊆ -･･ーマI
72
ENG[NE ASSEMBLY (2 )
Ring Gear lnsta=ation
顔 1. Heatthe
thermal
ring
expansion.
gearevenly with a gas burnerto invite
Do not the tempe｢atu｢e of the gas burner to

allow
♂ 2.
exceed
JnstaJJ the
200oC (390oF).
it js sufficiently heated.
ring gearwhen
The ring gear must be insta=ed with the chamfer
facing the cJutch.
Note:
to
Another method of heating the nng gear ]'nvite ther-
mal expansion is to soak a rag in diesel fuel, wrap the
diesel fue[ soaked rag around the rim of the rJng gear,
and then fightthe rag.
PISTON
Piston Grade Selection and CyHnder Liner Bore
Measurement
Refer to the Sect.ion ”CYLINDER BODY”, Item ”CyJinder
園 Liner
selection
Bore Measurement”
and cylinder
for
or liner bore
detaJ'1s on
measurement.
piston grade
PISTON RING
I Piston R;ng Gap
1. Jnsert the piston r[ng horizontaHy JLnTo the cyrinder

liner.
l
2. Use a piston 'lnSerted upside down to push the
/
piston ring into
cy[inder the liner untiHt reaches
either measuring point ① or measuring point ①,

Cy=nder liner diameter is the smallest at these two
y/
points.
Do allow the piston
not rJng tO Slantto one side or
the other. It must be perfectly horizontal.
変電 0
0
圃
3. Use afeelergaugeto
Measurl!ngPoint①‥
measurethe
10 mm (0･39 in)
piston
Or
rJng gap.
痩
MeasurJng Point@.- 120 mm (4.72 in)
Ifthe piston rlng gap exceeds the specified fimit′the

0
piston rmg must be rep(aced･
0
′
●一一-メ
♂ 0
73
Piston Ring Gap mm(in)

Standard L.[mit
0.2-0.35
1stCompressionRing
(O.008-0.014)
0.37-0.52 1.5
2ndCompressionRing
(0.015-0.020) (0.059)
0.2-0.4
OilRing
(0.008-0.016)
Piston Ring and Piston Ring Groove C一earance
Use feeler to the between
圃
a gauge measure clearance
6) the
points
piston
around
ring
the
and the
piston.
piston ring groove at severa[
If the clearance between the piston rlng and the piston

nng groove exceeds the specified ['(m舌t,the pEStOn rJng
must be replaced.
Piston Ring and PJ'ston Ring Groove
Clearance mm(in)
Standard Limit
0.09-0.130
1stCompressionRing
(0.003510.0051)
0.05-0.090 0.15
2ndCompressionRing (0.002-0.0035) (0.006)
0.03-0.07
OJ-[Ring
(0.0012-0.0028)
Visua一ly the piston. (f is
囲
Inspect a piston ring groove
damaged or distorted, the piston must be rep[aced.
74
PrSTON PJN
＼ ′
Piston
Use a
PJ'n Diameter
to measure the
micrometer
画
p】ston pJn OutSt'de
-一一{■ diameter at several points,
Jfthe measured value J's Less than the specified Jimit′the
piston p[n must be replaced.
Piston Pin Diameter mm(in)
誕± Standard
33.995-34.000(1.3384-1.3386)
Limit
33.97(l.3374)
Piston Pin and Piston CJearance

∈∋ Use inside diaI･indicator to the
圃
an measure
piston pln
hole (in the piston).
Piston Pin Ho一e
mm(in)
Standard
34.004-34.012 (1.3387- 1.3391)
Piston Pin and Piston Pin Hole

CJearance mm(in)
0.004 -
0.O17 (0.0002 -0.0006)

Piston Pin and Connecting Rod SmaIT End Bushing
Clearance
Use a caJiper ca=brator and a dial indicator to
㌔ measure
虻ゴ( 圃 the piston pln and connecting rod smaH end bushing
T clearance.
1fthe clearance between the piston pln and the connect-
mg smaH end bushing exceeds the specified h'mit,
rod
replace the piston pin and/or the connecting rod
a bushing.
Piston Pin and Connecting Rod Sma=

End Bushing Cfearance
mm(in)
Standard Limit
0.008-0.020 0.05
(0.0003-0.0008) (0.OO2)
Connecting Rod Bushing Replacement
Connecthg Rod Bushing Removal
E] 1. CJampthe
2. Use the
connecting rod J'n
bushing
dvise.
connecting rod to
団
remover remove
the connecti｢唱rOd bushin9.

Connectin9 Rod Bushing Replacer
75
Connecting Rod Bushing lnstaHation
巨) 1, CFamptheconnecting
2.
rod in av盲ce.
Use the rod bushing暮nSta‖er insta,I
団
connecting to
∼ the connecting rod bushhg.
Connecting Rod 巨ushing Repl∂cer:
3, Use a piston pin hole with

grinder①fitted a reamer
⊂= ①to ream the piston pin hole.

モ＼
墜
Inner Diameter ofSmaJJ End Bushing
mm(in)
＼
Standard
F= 34.008-34.015 (1.3389- 1.3392)
迄』
き謬
､･ー.==
_
､
-￣･●
I ′--･
'＼.ゝ-＼_
CONNECTING ROD
Connecting Rod A)ignment

iTq
Use a connecting rod a[jgner to measure the distortion
E7 ∩
圃 and
hole
the
and
paraHelism
theconnecting
between
rod
the
small
connecting
end hole.
rod big end
過
F:” a
Ll[ 1f either
the
the
specified
measured
limit, the
distortion
connecting
or
rod
para[FeJism
must
exceed
be rep(aced.
i Connecting Rod Alignment
J｢l
PerLength oflOO mm (3.94in) mm(in)

Standard Limit
0.20
Distortion
0.05orLess (0.008)
(0.002) 0.15
ParalleJJ'sm
(0.006)
76
ENGfNE ASSEMBLY (2 )
ConnectJrng Rod Side Face Clearance

1. hsta‖ the connecting rod tothe crankpin.
Use a fee(er gauge to measure the
園2`
clearance
betvveen the connecting rod big end side face and
the crankpJ'n side face.
Jf the measured value exceeds the specified Limit,

つ the connecting rod must be ｢eplaced.
Connecting Rod and Crankpin SJ'de Face

Clearance mm(in)
Standard Limit
0.175-0.290(0.0069-0.0114) 0,35(0.014)
JDLER GEAR SHAFT AND IDLER GEAR
ldrer Gear Shaft Outside Diameter
Use to the idler gear
圃
a measure
micrometer shaft out-
こ⊃
side diameter.
Jfthe measured vaJue is Less than the specified limit, the
idle｢ gear must be replaced.
rdfer Gear Shaft Outside Diameter

mm(in)
Standard Limit
44.95-44.98 44.90
(1.769-1,770) (1.767)
77
Jdler Gear ''A” ]nside Diameter
1. Use inside dia一 indic ator to measure the idJer
囲
an
gear
Jd]er Gear Inside Diameter mm(in)

Standard Lim)'t
45.0-45.03 45.10
(1.7717-1.7718) (1.7756)
If the between
clearance the id一er gear shaft outside
diameter and the id(er gear inside diameter exceeds the
limit, the id一ergear must be replaced･
[drer Gear Shaft and JdJer Gear

C一earance mm(in)
Standard Limit
0.025-0.085 0.2
(0.0010-0.0033) (0.008)
[d]er Gear ''B”
Bearing replacement
I
圃 Usea
Bearlng
suitable barand a
amount
bench press
be
orhammer.
within the
Pro)'ection shou[d spec-
⑦
] I
腔 ① ified height.
+_ mm(in)
Projection① 0.4-0.6(0.016-0,024)
Height② 23.7-24.0(0.933-0.945)
TIMING GEAR CASE COVER
Replace the crankshaft front oil sea一 if it is excessively

worn or damaged.
Crankshaft Front Oil Seat Rep一acement
OjJ Sea暮RemovaI
回 Use p一astic hammer

a and
the oi[ sear to free itfromthe
a
screwdriver
gearcase･
to tap around
∈‡∋
Take care not to damage the oi一 sea暮fitting surfaces.
潤
監萱薗
■■■ー...I
､ヾ苛
琶萄
78
OiI Seat InstaHation
回 l･ AppJyacoatofengfne
ference.
Oi一 to the oil sea川p circum-
○
I-ヽヾ
仏､
目 21 Use the
insertthe
oil searinstalfer and
oi一sea一 1 mm (0･039
the insta(Jer
in) intothe
gn'p to
front poト
園 tion of the timln9 gearCaSe.
敬S
OiJ Seal lnstafJer: 5-8840-2061-O
79
MEMO
-●●一●--..ll-.I一l-..I..-.●JL.I.I--...一●.I.-●■I-.-l●=●-●1.一....▲●●.＋●-.●...1＋-一-I.I.I-一■■●■●■■■一●llJ4.●■●●●●rJl＋tIJtPI＋l*r＋4＋●■■I==●●=●●■●●●■●●-●●●●●=▼●●■■●●-●■■●I-I-●●-■●■■1......L....▼一=■■一●■■■●●■..I..---■■-I-一●一I--一●■■●-●.4●T●■r4＋I41A
●--1.■-f4=■P..--●.I-.=I-..-一●.1I.-.-.JI..-.-.....--●●●-●--一●-●-L-●....ll-.I-●●●●..-●■■■I14＋==●l..t44JJ.-.-==lL=●●●●■■●r.r>J=.1.141＋=●●A＋=■●●◆=4-◆14-◆=■■■●-●-...1.-..＋●=..一=■.-I.-..--●.....--..I-=...●＋tr4r＋=t＋▲●＋JAtALl
=●--I-11=-●●-......I-I-●一.-.▼■-‥-1■=1...L=◆●-●tILJrJ=l=■■●●●”4JA＋1.I..-*=●●.rPfrrr*-4=>L4J●■■●■LA■=LtIIt41rITIJ=●LfrJ＋▼=AJ144tt4JftJ=▲■▲4tJ4>IJ=t■Ll”tJ4＋4-I=A4L=■I■■=4L4tJt”f=▲■●l＋●l--●.-....1....-.I-.-▼●---●●1-1-●r＋=lf=＋4
I...I.-.I-.=--....-.I.I.-●●--●--I-■●●1.I.-I-..●●●-.--..-...............Ill-.●=●●lI4●..-.1J.1t■■●-●＋[.1＋4I＋=l-JA●=●＋.1-.I■=●===.1■■■--I----.I-1....ll..I.--.--.-.----=.---I.--●l=1.I.I.-‥■一I.=1.I-l--.一●●-rLtJJ＋f
-一-...-.-.-I.--I-一一--.-I--.1●1.一-●..●....●=●一●...=●､●-.=...--●l-.--●I.-.I●‥-1.==-.-I.-●==●14＋r4l-▼■l●●rr..●-”＋1＋■=●=■■J＋=4J44J.-.=..-.--■■●●一...-...I...-I--Ill...l･--●..-..-...●▼●■一●●●..-...●■●I.-.I-=●●■●●T..-Tt■J”44D”＋A
..A...I.....A.-.-.....-.--..I..-.I.-.-.I..-....--..1-1＋LO4.-.IJ＋J..I..11＋4...I.J”.14＋4”””.rr＋JrTLIJfJfAI＋”LLJ”rtlf”rL＋＋ptrIJrr＋rp4pTPJ4I.IJrJl＋L1.441.,41.......1LL...1.ll...I..-J..,1....I.-...-..-1....--J-I.J-.-...-.I.I..Lll1...I-..pl.14-＋＋rl
---‥■--=●-●----I-●--●一●--■=--●●-一●-I-==●-●-I--●==●-■●--=●●●●---■■=-■■==-=■=■===▲==■=■======-●●--I--●●●=■●---I-●---▲-■■--‥●■■l-■■■=---一-I-------I-一■●一--●==l●■=●●
■..--‥-L●-●..--■一●●..”..---===●-●●.t＋..●e＋=J”.=●Irr.=●Jrr>l■■▲■===■I＋A■rr=●=●l＋l●=lJt4＋ltIJI＋=JJ＋r4J=r＋■t4JIJ=pr●●=▼==4＋J4r”JIHl*=JLJ4＋44r＋=▲J＋=I●-.-4=J4●●1.I-●14..1.=.＋--.L◆-All.-I.=■■■==....---1*tJl4＋4＋J＋
●●●1.-...-●I●-●I-..-.-●I..▲-I.A...■■■=■-.=●＋r＋.■=一■■■ヽ■lt*trfP”J==I＋==l=●===4tt=4rJAf●l●●●Jtt▲◆■==144q=●=”●=●=■■■●＋4=J＋=L4r=●■■●4tPILIrlq.4■●●=■L.-=■4J.Ill--.....●-.r=一●=▲4r-......-.....I.●●.-.●●-I-一-.=●==JrJf＋t=
-.l,-一---H‥‥L-.I.A-●==■一=-●====■.L.1‥●-.-=1.=..●1..I..J＋41r●●..=l◆IP■●=l＋lp■ILI＋tL=I＋==●=L=■=▲●＋JJ==●■==＋IP”J=●44JIAl●..=■....-=4.-.-=●---一4...--●=-.‥●一●●l-.-I.-.-..--.-.....I--.1.--●tt=■=JDJtrJ=4Lr4
..-..-----...-..-”-▲‥1--..■■●■■-..▲一-.I.-I..-..JL--.I-.■■■●..-..=.-.-......-=41=r-lL.J4-.-4J◆●f4...▲●=J＋..■●■●■■-..-●lrr-＋*=It＋4＋..-.-.Ill---●-.-.....一■一-●-I.-.-..I..-.I.I..‥●l-■I.-一.I..-l-●●.1■■●■■●.-”.-....-.I-●■■<●f4■”f＋
.--.-...---●---.-=■●---I....1=I.--..-I.....--‥-●-一●-●●●■一-I-..-...-.J.IIJ＋..,.==●=.I..J*-=4＋.1=-==●l---*4r.11t=●-A.-4..A-●..●..--I...●-..-■■1-▲--■-I..-=-●-I.---I-●...-..--..I--I--..,=●=1.--､●..-..rl■■
80
SECT10N 5
TABLE OF CONTENTS
JTEM PAGE
ReassembJy....-‥‥..---,....---------...------‥‥‥‥‥‥. 82
81
国 REASSEMBLY
SINGLE UNIT
3 2
冒 A
? 1
ni
トミ皇⊂i
kJ
冒
♂
㊨
@
”
匂払
P)ド
7
ReassembTy Steps
▲ 1 Rocker arm shaft 5. Rockerarm

2 Rocker arm shaft snap ring 6. Rockerarm shaftspnng
3 Rocker arm 7. Rockerarm shaftsnap ring
4 Rocker arm
shaft bracket
82
1. RockerArm Shaft
l) Position the rocker arm shaft with the large oil

hole (Dial 4 (0･136 in)) facingthefrontofthe
脚m㈹?
mm
en9Ine･
2) Jnsta[r the rocker-arm shaft together the

with
rocke｢ arm′ the ｢ocke｢ arm
shaft bracket′ and
the sp｢1ng.
｢￣￣ヽ
l￠q
83
CYLINDER HEAD
7
---------8
6一･J暫
3
---一･8
2
--一･･(亘)
f
冒
廼 U
C1
玩
O
く⊃
U
鮎
′
ヽ O
撫
′＼
P
莞轡
a;
e]
節
O
◎
I
t G) e3
I
Reass￠mbly Steps
1 Cylinder head 5. Va(vesprJng

2 Valve 6. Valvesprln9 uPPe｢Seat
sprl咽】owerwasher
▲ 3 VaJve stem oil seal 7. Splitcollar
▲ 4 Intake and exhaust valve
84
3. VaJveStem Oil Seal
l) AppJya coatengine oilto theoi[ seat inner face.
し_ J
′ 巨I 2) Use an oil sear
the va[ve guide.
instaHerto instaH the oil seal to
ノー--一一
園 Oil Seal lnstaI[er: 5-8840-2033-0
I一一-￣￣￣￣■ー一･･･一･一:I
零軍奈軍
コ≡守一
(A ｢[ ｢¶ 三野-
A. Intake and Exhaust Valve
l) App]yacoatofengine oil tovalvestem.
日 2) JnstaJI the intake and exhaustva]ves.
3) Turn the cylinder head up to盲nstaIJ the valve

SPrlngS.
Take care motto allow the installed va(ves to fa[(

free.
5. Valve Spring
l) Turn the cyrinder head up to install the va一ve
回 SPrJngS･
2) JnstaI‡ the va)ve springs with the fine

pitched
end (painted pink) facing down.
Take care notto the instafJed va)ves to faJ[
allow
free.
7. SpfitCo[Lar
l) Use the spring compressor to push the vaFve
園 sprng into position.
SprlJng Compressor: 9-852311423-0
2) 1nstallthe sp榊coIIa｢tothe va一ve stem.
3) Set the spfit col[ar by tapping around the bead
請
ク･■￣￣
ofthe collarwith a rubber hammer,
LS Ft C
qh
蔓豊ミ
85
PISTON AND CONNECTING ROD
∈∋
_ノ
C5
㌶､､
くっ
u
星＼ ∼
ReassembJy Steps
▲ 1 Piston 5 Piston pln Snap rmg

▲ 2 Piston pln Snap r[ng ▲ 6 Piston r[ng
▲ 3 Connectinョ rod ▲ 7 Connecting rod bea｢lng
▲ 4 Piston pJn
86
1. P;stoれ
∈≡∋ ■ t
2. P盲ston p]n snap rJng
3. Connecting rod
l) CJampthe connecting rod in a vise.
Take care ロotto dama9e the con=ectir唱rOd.
) 2) Use a pairofsnap instaffthe
団
ring p[iersto piston
pln Snap ring to the piston.
3) ]nstal] the piston to the connecting
回
rod.
①
The piston head front mark ① and the con-
necting rod I'fSUZU” casting mark @ must be

facing the same direction.
㊤
②
4. Piston pln
l) Apply a coatofengine
o‖ tothe piston pin and
the piston pin hoFe.
(S
2) Use your fingers to force the into the
日
piston pin
piston untit it makes contactwith the snap nng.
3) Use your fingers to force the piston pin snap

nng 'TntO the piston snap ring groove,
4) Check that the connecting rod moves

smoothly
onthe piston pm.
C]
87
6. P盲ston Ring
⑦ Use ring replacer to instal( the three
回1'
a piston
∈遜 piston rJngS.
/
/
Piston RJ'ng RepJacer:
さ､紛 [nstall the

piston nngs in the order shown in the
＼蒜
‖ustration.
① OJ-fring (Coil expandertype)
① 2nd compression ring (Taper undercut type)
③ 1st compression ring (Barrel face type)
Note:
Install the compression rings with the stamped side
回 facinョ
fnsert
uP.
the expander coif into the oiJ rlng groove SO that

there is no gap on eitherside of the expandercoir before
instal[ing the o盲I rLng.
2) Apply engine o‖ tothe piston ring surfaces.

日 3) Check
the piston
that the piston
r]ng grooves.
rings rotate smoothly in
7. Connecting Rod Bearlng
Carefully w(pe any oil or other forelgn material from

the connecting rod bearing back face and the
connecting rod bearlng fitting surface.
88
CAMSHAFT, CAMSHAFT TJMJNG GEAR. AND THRUST PLATE
@1.
刀
港
RS
ES A
Reassembry Steps
l. Camshaft 3. Thrust p一ate

2. Feathe｢key 4. Camshafttiming gear
89
4. Camshaft TJ'm盲ng Gear
l) JnstaJJthethrust p]ateO.
2) App]yengineo‖tothe boltthreads①.
E] 3) lnsta‖ the camshaft
mark stamped side
timing
facing
gear
out.
with the timing
回
@&願
Camshaft Timing Gear Bo一t Torque N･m(kgf･m/Jb.ft)
98-118(10-12/72-87〉
90
MEMO
....-.-.-....-...AJIIJ.＋4.rlf4＋ILL41＋r＋QI＋lI＋＋4fPAIL＋＋＋I”t41＋rl＋＋4flAvttJAtltP＋IQLrtPt44””4dAJ4L14”LAJtt＋r＋.4＋t41t＋Ltll＋tt””””f4＋J”J4””I＋4f.Ll＋I”.I.JI-....I.-.-.-.-l--..I.--.-.-..-.-.-l1...-.....-..-.1.I-.---.-.,..I-41rlfflp*”1
.1I.1....I...-..-..1...-.--...J.4J.*tJL”.A.JI.Ad..--.Jl.”L441＋tJIJIJJ*PI＋-A..I....r.r.＋t.*.4A44＋OtL.＋”＋J.I-L.-l＋-I.I.-Ir.I,...-.A-..1JIJL....-..-I.....-.....-.1...I....-.-.I.....--.....-...--...-.I--.-J-...I-..I...........-.........4PJ＋r＋I44JJ＋
●--=●=■-●-●=t4＋.＋●●4*l=■tr”Jfr■●===▼J””■■■””””f4==4＋==T＋T4==J＋l＋=Lr=tlp1●●L＋=■●4*＋=lIAl■rt4”lrLrO414===●＋＋4”==r＋p4t4t4▼■=●●==●l.J=●JJ.JIJ.-==●=一=.-.-...-●...-......-.I-I-I-...-....-l===■4＋rpr=●■■■●4＋t
.-...I.l-I.J.I.J444I＋＋4l＋L4d4Lflfr14Jt””It＋4＋4＋lJrllL44＋”＋＋tlP＋PfrrtI＋ptJl＋*(lJl＋lr14”J141”II14”fPttfrJ”＋f＋14tl*t>p＋＋＋t4＋lpI＋”r＋t＋rt＋P144”JLLA＋AL”dIAl＋rJ＋4”L＋4PLl.1J*4.1＋4.JL4.＋＋h＋.IJ.I-*1-..-.....-.-...-.-..I.-I.......I.-r4t＋fLrJl44IL＋P4”lt
-.I..L.-4L＋fl＋J4＋IALrrP”JILJJ””4”IrJ-＋TrlP＋＋LIIJ4Att”41rLt＋441t441t”44JLLlfOlrl＋l＋LIAI”t14r”4＋”tT41r”＋r41JJ＋J4＋Jf4JA＋”dlr＋4J44＋l14tJfttttlrt44””Lr4r4I”II＋f＋JP10”JJIJP＋J＋＋Jt＋tPL*LAJ14JI-I.-4.I.I...ll.-.--.A....-........-.rr4＋p＋ffT＋＋rrJL441
----●-●●--■■--●==●-●●●====●==l=====●=●●=■●◆==●==■=●=●●=●==■====■■=■=■■=====●===▲=●==●==◆===-●=-=●--●=---一-”------■■-一---●-●■一●=-●■-------●-■■--●■●●一ーー-●===■■==
-●=-.-=--一.1..●...-..-=====＋”.”●.ll.I,.-=-I.L=■J”14tJl-41”＋t4rl”I＋Jr===■●=TP●=●IItL＋L＋4A▲■ttf44t＋t41fIQJJ＋41f■■r*＋”=●lt4▲.-I.IA＋A-...●1....J●●---..-.-.1-●-.-,-..--●●◆--●.....-.-.-●-..--I-●.....---=1-＋●14●●==
■●.I.-■1..-=●‥●-.-●4I4*”*JJ4===●41=4P4AJ＋)＋==●●=JIf＋＋4=fJP＋4＋*4r4=●●tt●==■”t▲▼■=▼●rIJ■■r4==●●●==■=■JI=●JILL■■r1[4J=144＋4r=●JJ4■f””l===4.--I.-.1=.-..I.-..-.=●-l--一●-I.‥■-..-I●-I-...-■●●-I.--lll1-.t＋=■■peJ＋==
.......-...I.Ill---...I.--1LALl”JI＋JtJ＋”I”JIr4t41＋＋14I＋L4J4J＋＋”Jlt*tJt*ttLI”fTPT4117J4”r14J＋J41tArr”4*”rPr4P”*4rrrT”I”444t4trt4＋4”r44＋A＋J.tt＋＋”＋PI.-414J14”＋＋JIJ＋J14t.∼--d.1.ll.-.ll...I.-..-.-..-I....I....1......--..-1...l1-QrltlP＋4
....-...-...I...I...--..,.＋*1.-＋..I-”tI＋LtPr＋J＋14”4”A＋4LLtALJ141JrAP4*Ipp＋＋＋＋*＋l＋14Jl＋1414JIDLf＋4II＋rtJt”Pf4PtPf14tt＋＋＋＋J4*4J4l＋r＋l＋＋Jf4＋＋f44P4*I4rL＋＋14.＋l*t.J..Jl14..-.,..1-..1I,.1I..-4..＋...I-.-.-.-...I.-.-.ll...--.-A.-I--.I.....IIL＋T＋P441＋＋＋A＋
1-...-....A-I.-I..I.r41.J.tLY-.J4fJIJ＋＋4ttPrJ14rL4t4f””1o”Jtfff4pfAt41＋41＋tLt4JLIJL”JOJI＋I＋Jrrfl14L＋lJI＋J＋Jt4J＋L＋>JIJrJ＋4414f414trlPILIJTtbAfAf＋I＋144Lt＋...”J-A......I--.....I...J.1＋lr＋r.＋＋Jll.JJ..I...I.I....1.I.-I.....-.........1111-tJt＋J4Jr*＋f4J
=-I..I.1.-.-...-.I---●1...4=●14＋=●■■●●t=l＋4fl●●J＋JJIJ=■=t4=14JJ4＋Jf”1rJII=■●41=●It4=”Jt＋=■*L4J[LA4=●ll”■■■■1.--A,--■▼●..▼●I-.I-....4JI.-..--●-.1I-----.-●--■--I1.11==-.一■■1-....-.-●●-I-..I...---■l■..1-.I--.I-■=lLJLrL＋AJJJ
.-.-.-I-...4””-”LJIJP”J＋Lf＋L＋*44Lr4tJ4”l＋”ILdtPr＋trtflflL41L14”＋t”D＋LtL4”lIJlr””rt4fr＋＋lQIAJ4*＋f”r＋r””lL＋l”J”＋AL4”L4LIp＋Jr4JJ4＋*＋Jt4＋trTJ”＋I-.-I-.--....-I.I-...t4..JJJl＋J4L14tt.I.I.....I.....-.1..1.-...-.......-I-.-.”OJlf4r＋l
.1I1.-I.....-.--...A..I.J..-.-.1J4＋l＋>4LPlt44＋4LJ＋L.44l＋<4LrJfJtLJt＋t4”tt”tL＋J””*A.DJJ.Art4Pf4P4rfPtt＋441＋IJfA1.J-All-.-.-.-.-1＋...I.A.LA,I-.......A...J.I---.ll-I...1..I...-..I-.1..-.-.-I..I.I-........I...-.-I.1.A...I.-.I-””4＋4t4t＋4A
●-●一I111..-●●..-●-●J.●1-I..P==●＋l＋=●■●=41L＋Jt=-■■=●=●●tPJtr4P=●J41tJI＋J4AtAJA4=●●JPlrIItt▼=LPILfT4t●=l●,●4＋4■●=■●●■”A■ll-J4=4P＋r●t＋t●■●=■=●t.J.J--J.1-1T-..---◆I.-.-,.1.I..-..--..I...一-A-一●●-■■●●●-一一一■-●....----■=>p●=＋lr＋
J-I.-J..I.-.-..-..-14-.I.--...-........-.-.--..--..I-.I--.I.-I..”4-*＋4LOLL”1.””LIJll＋LP4f4ILILJ＋llI/J4＋lJ4.A-.11L＋4L..I-.-A.”＋.1.-.-....--.--.........1.-...A.....-..1[.-........-..-...,..-...I--....-.........--....J-.I..-.-.--＋LIItLJOrLt
---.1........-.-=●-...▲-●--..-●▼●●-●-一●一-I.A,-..-I-.-..■-..-●-■1..A-●●=●I41●A..-I..A.144●●●=.A...I..-■●..-一●.-I-一●1......-.=■■I.●■....=●...-.●●●一-=一.-A...I-■●-...A...-I..●●●---●...-I-..-....-.--A......=44＋＋＋4pp”4==
.1...--.....I......--..＋.....1.-.....--＋l*l*.IILl.b1..I-.-...I..,1..”I.-4LIJ4J4.t44＋＋lJ＋41Jl”＋l”44I14PllA4.-...1..I....--...-.A.Ll-.J..4..-..............-..........1....JLA....1..-....-....-1--.---....---..-...-...-.-pT＋.4441rl”ltA4
.1I●●-■●..--1.f4f414J.=■,.t>4=J＋rJ＋4r4■=4＋tAl●=●Lr.JJI＋DJPIrLf=●f4Jr■＋L＋4=J■■●■=■44t4＋4■=”.pL4t■▲=■=■●●●●Jt=■”■■■■=-=”.▲-=＋*＋=.＋==■=t＋=＋J=●=▲▲4.1...-.I.-.-......I.-一-.I一...-●1..-J-..I-.A....-I=.--I...--.＋.=JJJ4=lt＋
..●.....=●...J.＋●L.＋.I-4＋IL4J＋41”Jtt”tJrl▲==1IJl”PT==■■■141J●lrJ＋trJ4JtJt4LJA＋Al●●●■●●Jt=J=rl=141r●*＋▲4J=r4”14AIJ4dJA”J.-rr=●●●L4f●I.I-I..■●●...I-.41.I.I..■■-.--.-.-一●1.-●--●1.-●1..---一■一.-.--I-.1‥■...-..●..-...-.fllIL14=141
.I-●..‥●=●●●.-.Ll4＋＋＋41rr14Dlf■▲●●ltLL●■●●J444r4●JItPrTtJrf■●LL”=●rL＋Ar4fJL＋4ILrJrl14JJ====●t4LtJt””4＋”■=AtLJ＋”L■■■-●r.4＋▼●●144P■*L>AIJ-41●●==＋J●●Lr1-.I....-.-....A.--...-..●.1......■●●一-I.I-.I-....1I1.L■-...一.-I--.1I--I--●tr＋lrI＋144
-.-...-.--●..‥■-...●●●＋.I.1.JJlfP＋4Itr=lf=J4==J4f4＋4=＋Ittttl＋J●●◆●4fJ4.＋L＋r＋rt●●L＋■===t4rJ＋=■■●”.14...■■=●●●=●==▲==＋4.●●■lIL4==A.”■-..1I-.-..-...-.1●=.I-I--●..-●..--...-●一.--.●-▼■..-.-....●-I..-.-I.--●●●=J＋lI141rL==
........-.-▲●‥●一■■....＋=..141PtfL●LL=●rJ=■●●=●14=fT4r4f4=■=4＋44P＋rL4t●=■＋V”d＋A＋t■■=1.r∼lf.f4=1＋”J4t＋=▲●●==Lf*”-”J...I--.I.”-.I.-..-=..L●1.L..I..I.-.A--▲■■--I.J1....-....-●.....-.‥-..●-■■■-一●l----●-L.■=-●-=1-*rJ4r141＋J
■■■一----...-一■●.J●●=一▲一JA=●●●●●●■=l=●=●=●●==4●●4J●=＋f●■●■I=■I■==tI＋=●rfrLr＋＋●JtJ4J44f＋r=●p14●=■rtr4J＋=fILr＋rf●=4JJ41＋=LJ●●==●lLI=●l=lJ.-..-.-..----.--.....◆==●A.=l●--..-..1.....■●●=.......-..-1-...-.-=■-J＋＋＋==●●LLL
●.--..-‖‥‥-I.t■.1==●●=＋14L4=>JttJT●●●■●●lJ＋144rfPT=＋4＋＋4t＋l●J4f4=●4rrr444r4Jld＋■I●=”Pp=■●＋444＋lL=JJIL=■lJJ●=”*■4”L＋L=bJr=Jl＋p＋＋4r44A＋●●=ttJ=●<JllJ-t..-.r-.-..I....＋=●●...1t1.l▲●■●1...-..-=.I..I.●1.....I..-....■●lt14=pttJ=44
●..--I-..I-0-.....▼●..I,●●t＋＋4”14=JftJJ4JJ”t14=JJJJrAPt＋=●=●●■=●●4J14”＋●●fL4LL”L=●●t”ftIL＋4＋＋L4＋■■●”t===”4Jo＋r44td4■=JJ=J4J4●=●-J.--＋...4.I.-....=-一-●-...-...I..一--I-=●-●●■T...-..1.-..-..-I--=●---.▲--...一●=4Lt
●--‥一●●‥●■●■==●==l●===■●●=l●●●●●●■=l==●●==●===●==●●■●●========■■===▲●==●●===●=●=■=■■=●=●●=●●●==■==●●==▲▲==■●=======●=■==●=●======●=▼------=----=●=●==●===●====■=
-●一一●1-.I...-..-I...＋.L●L4t=■■●＋IttlfI”T==LJ▼●●=●14==●JIJ444J4■●■J＋▲I”==●===■4ftJ=●一●一■●L”4=●●=▲41IJ*A=pI＋r4d=4”rJ■=●●fJ=t””tr4＋fIJr”L4t4bJ=LLI＋-●■=--...-I.I-I.4.----一●...-lL-一I■..-..I......-.-=●-●●■●●LII=r=＋J4r●■
.1-.........1A..-A.-....llI.f41tlrIIlpl＋L4＋llLI＋l＋Lrr＋l14tJt＋”fJfltt＋p＋p＋＋14>*Ir44plt＋44*4＋JIrr4rrJAr”4q＋t4pu”frJ＋tf”4f>rr＋＋＋et＋Jf4Jrf””LI＋pL＋A-1＋J44.A.＋＋＋＋＋r...J.r.＋.r.I..1.....-....-.-...A-1.I..-..-..-I....-.....1..-...I....-.ll,..＋rl.L-JJd4rJ4
▲■1.Ill-....一-....-.1-JJ==t41T＋4T＋LJJrJrt4”P=IPlrf=■JrO=●PLt＋L＋■■●■===■＋”J414”IJIP＋”P＋==41rt”J14tL■＋r＋■●●■t”IJ”I”41=＋J●141＋Q4J=■4J*J＋＋J4A＋J4＋＋=●●▲I..-.-..-...I-...A.-.-.●1-.一---●....I----●-I-.-..--●1.=●●-●J-●■rTP4＋
.I..I...I..=■●.1==●J=■A4===tflr=tLrtJ4r●==”＋=▼l●▲●●●=Ll●LJfJ4I▲l■”■4rrlfAJ=Jr●●=4tJ4==L4D●==●●●lIJ4tfLr=■■4●●＋”J●=●==●＋＋Jr4f=＋＋J4＋＋JrA=▲=●＋＋=f”tf====●=tt14=rJ●==IJ=-=--●.---......-..I...=●●＋＋===●●4LfJAr=
91
国 REASSEMBnr
2
ヽ
tQ
p電汁*-1
ヽ.
F=
冒/
8 13
A
14
/ 5
/ ♂′ ♂
㍗/ 節
L
｢
l Iヰa
笹
リ担i
10
醐
且
6頂
1垂虹 ll
16a
/
1
A
★ Repair kit
Reassembry Steps -
▲ 1. Cy=nde｢ body ▲ 10. Connecting rod capwith lower beanng
▲ 2. Tappet ▲ ll. OHpumpwithoi】 prpe

^ 3. Crankshaft upper bearln9 ▲ 12. Crankshaft rear oil seal
▲ 4. Crankshaft with crankshaft timlng gear ▲ 13, Flywhee=10uSln9
▲ 5. Crankshaft thrust bearlng ▲ 14. F】ywheel
▲ 6. Crankshaft bearing cap with 】owe｢ 14a Rear flywhee=げso equipped)
bea｢in;I ▲ 15. Oilpan
▲ 7. Timing gearcase
▲ 8. Camshaft with camshafttiming gear Inverted Engine
and thrust plate

▲ 9. Piston and connecting rod with upper
bearing
92
ENGtNE ASSEMBLY (3 )
/′1
/
?
e)
/ 冒
ド
㍗
曾 17
★ I
短ミ
------令
猷ン/
冒
ll
＼く
ヲ///
討
L-I;
10
”
( 遠野戸丁
チ+
L#3フ/二
琴モ O
亡)
O
o
8-★
★
a
♂
♂
読 ♂
琶∋
(J /
フ芸≦
ゝ､､
一≦:
rl
S
★ Repair kit
Reassembly Steps -
2
▲ 1. [dJer gear 10 Push rod

shaft
▲ 2. [d]er gear ''A” ▲ ll Rocker arm shaft and rocker arm
▲ 3. Idle｢ gear `甘′ ▲ 12 Water pump

4. Timlng gearOi) pJPe ▲ 13 Thermostat hou引咽
▲ 5. Timlng Case cover 14 Water by-pass hose
6. Timing gear case cover ▲ 15 Glow plug and g一ow p山g connector
▲ 7. Crankshaft damper pu[(ey with dust sea一
seal ▲ lnjection nozzle holder

▲ 8. Cylinder head gasket Cylinder head cover
^ 9. Cy一inder head
∇ Jmportant OperatJ'ons (ReassembJy Steps-1)
1, Cylinder Body
Use compressed air to thorougMy clean the inside

∈慧田
∼
∫
and outside surfaces of the cy一inder body, the oil

呈⊂二三
∈∋
こ∋
holes. and the water jackets.
ヽ. ∼
.Je
屯
∋クノ
一旬 L. d2
,Q
2. Tappet
l) Apply a coat of engine oi) to the tappet① and
日 bodytappet insert holes ①.
㌔
the cylinder
2) Locate the position mark applied at disassemb(y
(ifthe tappet is to be reused).
Note:
The tappet must be installed before the camshaft,
3. Crankshaft Upper Bear[ng
The crankshaft upper bearJngS have an

oi=10le and
U
an oil groove. The lower bear[ngs do not.
?
t) ∼ l■
亡 1) CarefuHy foreign from the
E5]
wJ'pe any materia[
し.
bearing
I
JJ すしべ . i/- c｢ankshaft upper and the crankshaft

beanng fitting surfaces.
# upper
a 令也 2) Locate the position mark applied at disassembry
U ifthe removed crankshaft upper bearJngS are tO
U
be reused.
4. Crankshaft with Crankshaft Tim;ng Gear
AppJy an ample coat of engine Oil to the crankshaft
E] )ournaFs
insta[Fing
and the crankshaft
the crankshaft.
bearfng Surfaces before
Note:
Do not apply eng∫ne Oil to the bear[ng back faces the
and
cylinder body bearJng fitting surfaces.
94
ENGINE ASSEMBLY ( 3､)
5. Crankshaft Thrust BearJ'ng
l) App一y anample coat of engine oiJ to the
日
/ crank-
shaft thrust beanngs.
て
./I-
2) Ensta= the crankshaft thrust bearhgs to the
回
一￣￣￣￣- -■･._.■-_
crankshaft center )ournal.

/
The crankshaft thrust bearing oil groove must
be facJ'ng the s=ding face.
ヽ.
!?I/ J
亡1
6. Crankshaft Bear∫ng Cap with Lower Bearlng

ヽヽ.__′
○ l) Apply searant TB 1207B or

equivaJant to the
-
body No･ 5 bearing fitting

6) ○
cy=nder cap surface
atthe points in the ilJustration.
shovvn
○ Note:
∈ Be sure that the beanng cap fittJ'ng surface is completeJy

也 ♂ free of oil before app[ying the silicon adhesive.
l■==■
三■ _一一
Do not allowthe to obstruct the cy[inder

siJicon､adhesive
thread holes and bearl咽S.
2) Jnsta(I the bearing caps.
0 O t〕
○ 回 The bea｢l｢唱CaP
f｢ont of the en91ne.
a｢｢OW marks must be facin9 the
The arrow mark J'ournaf number must corre-
spond to thejournaJ to which the beanng cap IS
installed.
ぐコ ⊂〉
＼ Note:
o O 0 0
2 3 Nile 5 The No. beanng does have

4journar cap not a number
stamped on it.
3) App一y a coat ofengjne oi一 to the bearJ-ng cap
メ. E] bolts.
4) Tighten the
crankshaft bearing cap bo[ts to the
㊨ ①
国 specified torque
shown
a =ttle
in the illustration.
at a tJ'me in the sequence
①
① ① Crankshaft Beanng Cap Torque N･m(kgf･m/Jb.ft)
157-177(16-18/116-132)
①①
① ⑩
○ 5) Check to see that the crankshaft turns
smoo仙y
by rotating it manua[[y.
7. Timing Gear Case

0
l) Tighten the timing gear case with timhg gear
国
○
璽窮璽ョasket to the specified

case torque.
0 o
0
Timlng Gear Case Bolt Torque N･m(kgf.m/Ib.ft)
き窃
○
軒
14-24(1.4-2.4/10-17)
り
0
軒
○
2) Cut away any excessive flash from the timing
0
0
0
● 0
gear gasket.
0
95
8. Camshaft wI'th Camshaft Timing Gear and Thrust

PJate
l) App一y a coat of engine oil to the camshaft and
巨I
○
the camshaft bearlngS.
㊨ OOO 2) 1nstal( the camshaftto the cyfinder body.
Take care not to damage the camshaft bearJngS.
3) Tighten the thrust to the torque.
国
⊂) plate specified
ql Cl
q 0
Thrust PJate Bo[t Torque N･m(kgf･m/fb.ft)
14-24(1.4-2.4/10-17〉
4) Check to see that the camshaft turns smoothly

by rotating it manual一y.
9. Piston and Connecting Rod with Upper Beanng
⑦ 10. Connecting Rod Bearing Cap with Lower Bearmg

■
1) Apply oi一 to the
占
a coat of engine circumference
日 ofeach piston rmg and piston.
2) Position the piston ring gaps as

shown in the
ll②
匡I ‖ustration.
① 1st
compressi?n riTg
@ 2nd compressJOn rlng
③Oi川咽
3) App(y a coat of molybdenum disulfide grease to
the two piston skirts.
This wilJ fac=tate smooth break-in when the

engine is first started after reassembJy･
③'yヽーJクも①
4) Apply a to the bearing
冒
coat of engine oH upper
surfaces.
Note:
E] Do notappryengJne
connecting rod
Oiltothe
bear[ng fitting
beanng
surfaces.
back faces
andthe
5) App[yacoatofengine oiJtothecy[inderwaJ[.
96
6) Position the piston head front mark so that it is

facing the front of the cylinder body.
I-i T
7) Use to
団
a piston compressor
3 a
ring compress the
pjston rings.
13
哲
刀 Tr一
l
PJ'ston Ring Compressor
8) Use a hammer grip to push the piston J'n until
⑦
00
〇 the connectin9 rod makes contact with the

}
O 戸モ crankpin.
At the same time, rotate th岳cran七s11aft until the
cr8nkpin is at BDC.
9) Instalr the connecting rod bearing

囲
I I ∼ caps.
′
∼＼ I The bearlng Cap front marks must be facJ'ng the

front of the englne.
磨
∫
The bearing cap (at the sJ'de
number of the
bearing cap) and the connecting rod number
β must bethe same.
l
∼
I
l Note:
o⊂ノO ノ [t is absolutely bearing
0
essential that the caps be
installed in the correct direction･ ReversJng the beanng
cap direction w‖ result in serious englne damage.
10) App一y oil to the threads
回
a coat of engine and
-一----I-I-
setting faces of each connecting rod cap bolt.
11) Tighten the connecting rod caps to the岳pecified
国 torque.
周刀I
Connecting Rod Cap Bolt Torque N･m(kgf･m/Ib.ft)
三J
= =
○
27-31 (2.8-3.2/20-23) -45c-Goo
■■
0 く】 0 ○
Q
壱
Cjj
○
′_ヽ
97
ll. OiJPumpwithOit Pipe

Jnsta‖ the oir pumpwith the oil pJPe and tighten the
bolts to the specified torque.
lI Oil Pump Bolt Torque N･m(kgf･m/Ib.ft)

14-24(1.4-2.4/10-17)
I
l
[ Note:
J i
-
O
J宮- L> ○
Take care not to damage the 0-rings when tightenFng

=JLt4Pnq the oil pfPe bo一ts.
12. Crankshaft Rear Oil Sea一 (AxiaT Type)
ド 12.5士0.3
1) Tighten the adapter
2 bolts.
to the crankshaft rear
and
section with
2) Jnsert the oil seal into the peripheraJ section of
adapter.
3) Insertthe s一eeve into the adapter section, and 1)
tighten itwith a bolt(M12x 1.75L=70) until the
adapter section hits the sleeve,
4) Remove the adapter and the s一eeve.
5) Withthesea[ pressed in, checkthe dimension of

the oil sear section.
Standard Dimension = 12.5 ± 0.3 mm
(0.492 ± 0.012 in)
OiJ SeaHnstaHer: 518840-2359-1
13. FIywhee=1ousJng
L5
6 勺
8 10 l) Apply sealant to the area in the
shaded shown
3
9
5
固 2)
i]Iustration.
Tighten the frywheer housing bolts to the speci-
国
匂
fied torque a Jitt】e at a time in the sequence
削
鰐
2
in the ilEustration.
7 〇 shown
Flywhee] Hous[ng Bo[t Torque N･m(kgf･m/1b.ft)
MIOxl,25 35-45(3.6-4.6/26-33〉
E) こ滋
4 M12xl,5 74-91(7.5-9.3/54-67)
98
14. FJywhee]
1) Blockthe flywhee( with a

piece of wood to pre-
vent it from turn'rng.
2) App(y a coat of eng'fne OI.Jto the threads of the

●ヽ
●
●一
8
E] 3)
ffywheeJ
Tighten
bolts.
the f[ywheel bo一ts in the numericaf
5@ 国 F(ywhee[
order shown
Bolt Torque
in the ‖ustration.
N･m(kgf･m/Jb.ft)
113-123 (ll.5-12.5/83-90)
15. OiJPan
l) App一y TB 1207B the

a
sealant
-
or equJ'va[antto
つ
a No. 5 beanng cap arches, the bear[ng grooves,
0
and the timlng gear Case arches atthe positions
○ ○ shovvn in the i[lustration.
･11
D
昏
○ ⊂ 也
らノ
()o()
2) Fitthe gasket rear =pped portion into the No. 5

bearJng Cap groove.
Be absoruteJy sure that the ripped portion is

∩ fitted snug一y in the groove.
01)00 t)dOocI
｢￣￣■￣￣￣￣丁･ヽ
_D oO
○
＼ C
○
I
4
l
D D D
､?
I
0
○
0
㌫ ○
0
3) TI'ghten the oil pan boJts to the specified torque
@
也
重要
軒＼ ○
①
a little at
=ustration.
a time in the sequence shown in the
Oj] Pan Bolt Torque N.m(kgf･m/fb.ft)

き孝＼
① il!
/ ”
14-24(1.4-2.4/10-17)
&＋ id
99
∇ Jmportant Operations (Reassembfy Steps-2)
1. [d)er Gear Shaft

J
/ ;3b(i
O :三=1
J
回 The idrergearshaftoil hole must be facing up.
〕
○
Ⅶ 3 つ
ノ
つ -
2. Id)erGear ”A'r
l) Apply engine oi一 to the idlergear① the
巨】
and
① ⑦
id[ergearshaft(致.
2) Position the idJer gear setthg marks ``X” and
回 ``Y′′so that they are facing the front

of the
⑳唱
englne.
3) A[ign the idler gear 'JX” setting the
国
mark with
一一Yl′
crankshafttiming ”X-X” setting mark.
gear③
珍 4) AIign idler gear
the ''Y” setting mark with the
㊨ 0
0
0 国 camshafttiming
5) Tighten the
gear④ 'JY Y” setting
id[er gear boJt
-
to the
mark.
specified
○ torque.
○ ヰ･
1dler Gear ”Ar'Bolt Torque N･m(kgf･m/7b.ft)

0
0
一■X'' 21-30(2.1 -3.1/15-22)
3
3. 1dlerGear ''Bw
l) Apply engine oil to the idler gear and the idler

gear shaft.
2) ATign the idler ”Z” setting
0 o (】
囲 gear⑤ markwith the

○ ○
idlergear① ''Z” setthg mark.
○
㊨
ldJer Gear ''B”BortTorque N.m(kgf･m/Jb.ft)
○顎
国
HZ'′
○
93-113(9.5-11】5/69-83)
○
100
5, Thing Case Cover
l) Before insta=ng the timing gearcase′ appJy a 3

mmx5mm (0･12 in xO.20 in) strip ofsealantto
馳､>､J ∼
Si
the
arrow
portion
in the
of the feather
iHustration.
key indJ-cared by the
2) Checkthatthe timing case cover O-ring is fJ'mlly
o?-63ゥ inserted into the gear

Tighten
case groove.
bolts
3) the timing to the
国
case cover speci-
fJ'ed torque.
TimJng Case Cover Bolt Torque N.m(kgf･m/Fb.ft)
M8xl.25 14-24(1.4-2.4/10-17)
○■
￣#&/(
Q.Q..---○
M12xl.25 65-85(6.7-8.7/48-63)
7. Crankshaft Damper Pu[rey with Dust Seal
1) BlockthefJywheel ring gearwith a piece of

wood to prevent it from turninョ.
2) Tighten the crankshaft damper puFley to the
国 Crankshaft
specified
Damper
torque.
Puf[ey Bo(t
Torque N･m(kgf･m/1b.ft)
197-240(20.1 -
177)
-24.5/145
Take care not to damage the crankshaft damper
pu=ey boss.
8. Cylinder Head Gasket
l･ Carefully deposits
圃
remove carbon and gasket
residue from the piston top face the
く=∋ and
t^/y
cylinder body upper surface.
∈∋
101
2. Use a dial indicatorto measure the piston head
○ projection at measuring.points ① and ③ on the

Ooo
也 0 0 piston head and measurLng POints ① and店) on
○
0 the cy=nde｢ body.
0
Do this for each cy=nder.
○
③ ●-- ① Notethe
3. highest measured value.
○
This w= determine the cylinder head gasket
○ ○
Oo thickness.
○ Piston Head Projection mm(in)
0.758-0,913 (0.0298-0.0359)
Piston head must be within the range

projection
shown in the abovetabJe.
4. Select a cy=nder head gasket of the appropriate

ぐコFront thickness.
TOP
The difference between the highest measured
head the Lowest
@
㊨ 'LtV<3工二:芳
珍 piston projection and measured
piston head must not exceed mm(in).
○ projection
Ej E3 mm(in〉
Grade Averagepiston Gasket
g5= mark projection

thickness
(Reference)
o;FIB
0 0 ○
A ZZZZZZ 0.758-0.812(0.0298-0.0319) 1.60
Grade mark
B Za 0,813-0.858(0.0320-0.0337) 1.65
C ZZa2ZZ 0.859-0.914(0.0338-0.0359) 1.70
5. The cylinder gasket ”TOP” mark must be facing
UP･
9. Cy一inder Head
l) A=gn the cylinder body dowels and the cy一inder
囲 head
CarefuETy
doweJ
set
ho)es.
the cyI'fnder head to the cylinder

head gasket.
2) App[y engine oil to the cylinder head fixing bolt
日 threads and setting faces.
3) Tighten the cy=nder head bolts to the specifJ'ed
国 torque
order shown
lLn
three steps
in the川ustration.
foHowJng the numerical
暦1o3｡9o5｡.o4 Cy=nder Head Bolt Torque N.m(kgf.m/1b.ft)
000
8き2恩
○ 1ststop
44-54
2ndstop
60-75o
3rdstop
60-75o
7Or15
苧o14Tlo｡′2o (4.5-5.5/64-78)
ll
u､63 Ll
102
ll. RockerArm Shaftand Rocker Arm
Tighten the rocker arm shaft bracket bolts in the
国 numericaJ
RockerArm Shaft
order shown
Bracket
in the ‖ustration.
Bo什Torque N･m(k9f･m/lb.印
49-59 (5.0-6.0/36-43)
eSi
B5;
Q)
12. Water Pump
l) Temporarily tighten the water pump bolt
marked with an arrow in the川ustration.

〇 This
0 boJt w川be tightened to the specified to
岱ヂ torque
instal[ed.
when the a[ternator adjusting plate is
@ ＼留
Cl
国 Water
2) Tiョhten the
fied torque.
Pump Bolt Torque
othe｢water pump bo一ts to the specト
N.m(kgf･m/1b.ft)
14-24(1.4-2.〟10-17〉
13. Thermostat Hous∫ng
l) lnstarl the thermostat housing.
2) Tighten the thermostat housing bolts to the
国 Thermostat
specified
Housrng
torque.
8o[t Torque Jリ･m(kgf･m/fb.ft)
14-24(1.4-2.4/10-17)
15. GJowP[ug and G[owPJug Connector
l〉 Tighten the gJovv pfugs to the specified torque.
国 G(ow Plug Torque N･m(kgf･m/Jb.ft)
15-20‖.5-2.0/ll-14)
2) 】nstall the ;‖ow plし唱COnneCtOrS.
16. lnjectionNozzle Holder
l) (nstall the hjection nozzle gasket ① and the O-

ring @to the injectionnozzle hofder@.
2) 1nsta[1 the nozzle holder ③ together with the
nozzle holder bracket①to the cylinder head.
3) Tighten the hoJder nuts with washer ⑤ to the
国 specified
Injection Nozzle
torque.
Holder Nut Torque N･m(kgf･m/[b.ft)

31 (3.2-4t4/23-32)
-43
103
㌍(磨
R
『意鮎C2
し覇気蘇議
i#
ミ一覧愈
104
ll 13 17 7 6
∩∩
⊂】
I
畠 I
I
l
し+
○
l I ○
.L･1
■￣○
C3 ○ 十I l
√･
+ l
:L･1
l
i
○ (
Oo( l
L
Lt
I
e :諺
ooEjo夢㌢
●
＼ゝ
15 16 20 12 14 18 19 102120
Reassembly Steps -
▲ 1 lntake manifo一d ▲ 10- Starter

▲ 2 fnjection pump ▲ ll. Exhaust manifo7d
▲ 3 Fue[ injectionpIPe With c(ip 12. Cooling water intake pJPe
4 Fuel Leak off pipe 13. CooHng water rubber hose
5 Oil pipe (Jn)'ectioりPumPtO Cylinder ▲ 14. Alternator and adjusting plate
body) ▲ 15. Oil fiJter
6 Fue一 filter 16. Oi一p｢essu｢e switch
7 Fuel pipe (Fuel filterto leakoff) 17. Cooling fan drive pu)rey
8 Fuel pipe (Fue[ filtertofeed 18. Cooling fan drive belt
pump)
9 Fue[ pipe (Fuel fi(terto injection 19. Cooli｢唱fan and space｢
pump) 20. Stiffner (RH a LH)
21. Air breather hose
105
ENGINE ASSEMBLY( 3 I
∇ Important Operations (ReassembTy Steps-3)
1. Intake Manifold
lnstall the intake manifo一d the end hav-
回
gasket with
ln9 the the front
sharp co｢nersfacin9 of the en91ne.
'1j. ⊃oouruo
Li)c,oーノO ooニ′OQQQ
oooぜ) -o-@9-teo碇eo雪害
乙::⊃
2. [nject;on PLJmP
l) Turn the crankshaftsfowlyclockw盲seto the
囲
a=gn
0
camshaft timing check ho[e pointer ① with the

0
□ camshafttiming gear ”ou

珍 mark@.
◎
㊨
2
0
2) JnstaTl the injection pump to the timing gear
#. CaSe.
A‖gn the injection timing hole
圃
○ pump check
モこ＼
O pointer③with thetiming 9ea｢”○′'mark④.
3) Temporari一y tighten the injection pump bracket
U
○ bolt⑤.
This bolt w川be final一y tightened injec-
after the
㊦ tion pump rear bracketbolts⑥.
4) Tighten the injectionpump rear bracket boJts to
固 the
InjectionPump
specified
Rear
torque
Bracket
@.
Bolt
Torque N.m(kgf･m/Lb.ft)
4
㌔
/
/
14-24(1.4-2.〟10-17)
5) Tighten the injection pump bracket boft⑤to the
specified torque. ､
#iLa
㌔
Injection Pump Bracket Bo一t Torque N･m(kgf･m/Zb.ft)
㊨
14-24(1.4-2.〟10-17)
106
6&
ン′二
＼
/
覇
酌￠ダ
`曲
3, Fuel JnJ.eCtion Pipe Clip

with
l) Temporarily tJ'ghten the injection pipe s[eeve
nut.
2) Setthe clip in the prescribed position.
Note:
Make absoZute】ysure thatthe clip JS COrreCtfy positioned.

An improperly pos'ltioned c一ip w川result in pJPe
Injection
breakage and fue一 pulsing noise.
3) Tighten the injection pIPe

国
Sleeve nutto the
specified torque.
Injection Pipe S[eeve NutTorque N･m(kgf･m/Ib.ft)

20-39 (2.0-4.0/14-29)
d@dF
I,./
g..･1.1t･配c.･:'/
10. Starter
Tighten the starter bolts to the torque.

specified
Starter Bo[t Torque N･m(kgf･m/Ib.ft)
65-85 (6.7-8.7/48- 63)
ll. Exhaust Manifo[d
Tighten the exhaust manifo一d bolts to the specified

国 torque
in the
a ljttleat a time in the numerica一 ordershown
iHustration.
Exhaust Manifold BoltTorque N,m(kgf.m/[b.ft)

⑦ ⑨ ㊨
14-24(1.4-2.〟10-17)
3
107
14, Alternator and AdJruSting plate
Tighten the bolts and the plate

alternator adjusting
国 bolts
Alternator
to the
Bolt Torque
specified to｢que･
N･m(kgf.m/lb･ft)
14-24(1.4-2.〟10-17)
Tighten the plate bolts to the specified

adjusting
国 torque
Adjusting
after cooling
Plate BoTt Torque
drive belt J'nsta[Jation.
N･m(kgf･m/Jb.ft)
14-24(1.4-2,4/10117)
15. Oil Filter
Tighten the oi=ilter bolts to the specified torque･
国 Oi==i[ter Bolt Torque N･m(kgf･m/]b.ft)
14-24(1.4-2.4/10-17)
Sofenoid
巨∃ l) lnstafl the so[enoid, connectthe fink rod vvith the
什 stop lever on the in)ection pump, and semi-
帖
-1.2mm tighten the fixing bo[t.
○
2) Adjust the soJenoid instarJation so that the gap

between the stop leve｢ and stopper on the
0
pump is broughttowithin 0.7- 1,2 mm
○
0 @ lnjection
○ when the soJenoid valve is energized on.
3) Tighten the solenoid fix'(ng bolts to the specified

torque.
l
4) With the engine running on trial, be sure that
solenoid 6) the englne is stopped, when the starter svvitch is
⊂1 turned to off position.
O ⊃
TVA
Fixing bo7t
108
LUBRICATING SYSTEM
SECT!ON 6
LUBRICATING SYSTEM
TABLE OF CONTENTS
ITEM PAGE
Maindataandspecjfications ‥..‥‥‥‥‥‥...‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥.. 110
Genera】description...‥‥‥･=‥‥...,.I.-----I---=‥-‥‥‥,.‥‥‥. 111
0iTpump-------.,--------･･･L･･･---.･‥-.-I,‥‥‥‥‥=.. 114
0ilfi[terwJ'thbu=t-inoi[coo)er...‥...‥‥‥‥‥‥,...‥.‥.‥‥‥‥‥‥.‥‥‥.,. 117
109
LUBRICATJNG SYSTEM
MAIN DATA AND SPECJFICAT10NS
Item 4JGl
Oi[pumptype Trochoid
DeLiveryvoJumeLjt(qts)/min･ 17.5(18.4)
Pumpspeed 1000
DeliverypressurekPa(kgf/cm2/psi) 392(4.0/57)
OiltemperatureoC(oF) 47-53･(116,6-127.4)
EnglneOi[ SAE30
Oirfi(tertype FuIZfJowwithcartridgepaperelement
ReguJatingvalvekPa(kgf/cm2/psi) 420-460(4.3-4.7/6l-67)
OPenlngPreSSure
RefiefvalveopenlngkPa(kgf/cm2/psi) 79-118(0.8-1.2/ll-17)
Pressure
OilcooJertype(ifsoequipped) VVater-cooled
safetyvalveopemngkPa(kgf/cm2/psi) 225-265(2.3-2.7/33-38)
Pressure
110
LUBRrCATJNG SYSTEM
GENERAL DESCRIPTJON
LUBR[CATING 0)L FLOVV

This iJlustration is based on 4J Series engine with oi. coo一er (option).
Lubricathg oil flow may vary according to the engJne specification.
L-Ba-”-er-y
Wa｢nlng
1
I
-
Light
Oil pressure switch
Cy=nder b一ock oil ga(Iery
ldFe gear
Oil fjJter shaft
∩
Filter cartridge
Vacuum
｢ [
Crank shaft Camshaft
be即m9 bearin9 Pump
Main flow
+ oi一fi一ter Oil pipe
] Rocker arm
shaft
Re[ief vaJve
Connecting
卜
(98±20kPa)
rod bea｢ln9
1lming Rocker arm
ge8｢S
OiI ≡烹1 (at;n g

vRaelgvUe
(441±20kPa)
Oi一 strainer
Oil pan
The 4J Series engJne lubricating system is a fu‖ forced circulation type.
Lubricatl-ng oiE is pumped from the oif pumpto the cylinder bodyoil gal]erythrough the oi一cooler and the
is
oiJ flfJter. It then delivered to the vital parts of the englnefrom thecy[inder body oil gaFlery.
111
LUBRICATING SYSTEM
0比PUMP
ク:
4J Series engine are

equ)pped with a trochoid type o盲Ipump･
112
LUBRICATING SYSTEM
MAIN O比円LTER
√て
ヾ
∫
OIL FllJER WITH BUILトIN OIL COOLER
疏
I
l 1l
I
一{
113
LUBRICATING SYSTEM
OIL PUMP
団 DISASSEMBnr
∈∋ 1
+//
5
＼丘
4＼垂 (⊃
⊂)
a ⊂)
lこ=ノ
a
Disassembly Steps
4. Vane
l.Oil pIPe
A 5･ Pump bodywith rotorand pinion
2. Strainer case
3. Pump cover
114
LUBRJCAT)NG SYSTEM
磨 lNSPECT10N AND REPAIR
Make the necessary ｢epal｢S′ and part replacements if excessive damage is dis-
adjustments. vvear or
covered duri｢唱lnSPeCtion.
Vane, Rotor, Cover CJearance
囲
and
Use a feele｢ gauge to measure the c一earance between
the vane′ the rotor, and the cover.
1f the clearance between the vane, the rotor, and the

the Limit. the (pin,
⊥ cover exceeds specified rotor set
shaft, rotor, and vane) must be replaced.
■■
Vane′ Rotor, and Cover Clea｢ance

mm=n)
Standard
Limit1
0.02-O.07(0.0008-0.0026) 0.15(0.006)
Rotor and Vane CJearance
圃 Use
the
a
rotor
fee一er gauge
and the vane.
to measure the c一earance between
Zf the clearance between the rotor and the exceeds the

specified limit, the rotor kit (shaft, rotor, and vane) must
be replaced.
Rotor and Vane CJearance

mm(in)
Standard Limit
0.14(0.006)orless 0.20(0.008)
Vane and Pump Body CJearaTLCe
圃 Use a fee一er gauョe tO measure the c一earance between
/ゝべ
thevaneandthe pump body.
Jfthe clearance between the vane and the pump body
exceeds the specified Jimit, the ent-Ere Pump assembly
must be ｢eplaced.
Vane and Pump Body C(earance
⊂〕 mm(in)
●
Standard Limit
■l
0.20-0.27(0.008-0.011) 0.40(0.016)
115
LUBRICATING SYSTEM
盟 REASSEMBⅣ
∈∋ 5
+//
1
----応
＼＼垂 ⊂)
⊂>
Q>
く⊃
ヾ=ン
a
Reassembly Steps
4. St柑iner case
l. Pump bodywith rotorand pinion
5.OiFpIPe
2. Vane
3. Pump cover
116
LUBRICATJNG SYSTEM
OIL FILTER WJTH BUILJ･[N OIL COOLER
団 DISASSEMBnl
⊂⊃
JF5
ノ⑳
Disassemb]y Steps
l. Drain p[ug 5. Safety va一ve

2. Cartridge filter 6. Re[iefvalve
oir
3. Oi一cooler 7. Oil filter body
4. 0-ring
117
LUBRICATING SYSTEM
囲 JNSPECTJON AND REPAIR
Make the necessary repalrS, and part replacements if excessive wear or damage is
adjustments,
discovered during JnSPeCtion,
Reguratjng Va[ve
l･ Attach an oil pressure gauge to the oil gallery near
the oiJ filter.

2. Start the engrne to check the regulating va(ve
0 openin9 Pressure.
Relief Valve Open[ng Pressure kPa(kgf/cm2/psi)

421 (4.3-4.7/61
-462 -67)
Oil Cooler
/
Water Leakage At Water Pass;唱e
l･ Plug one side of the oiJ coo[erwater passage.

芦三戸￣￣￣￣￣=￣
2. Submerge the oil cooEer in water.
3･ App[y compressed air (196 kPa (2 kgf/cm2/28 to

psi￣))
the other side of the oi) coolerwater passage.
[f air bubb[es rise to the surface, there is water (ea-
kage.
∨
118
LUBRICATING SYSTEM
国 REASSEMBLY
⊂⊃
JF3
′⑳
Reassemb[y Steps
l. Oi川Iter body ▲ 5.Oi]cooler

▲ 2. Reliefvalve ▲ 6･ 0'r[ fJ'rter cartridge
▲ 3. Safetyvalve A 7.Drainp[ug
4. 0-ring
119
LUBR[CATJNG SYSTEM
∇ Jmportant Operations
2. Regu[ating Vale
A. 園
Tighten the reJiefva(ve to the specified torque.
* a Regu(ating Valve Torque

25-34 (2.5-3.5/18-25)
N･m(kgf.mnb.ft)
t@S 5. 0;[ Coofer
l)Align the oil fi)ter ho一es with the body knock
pJnS at instaHation.
∼/壁 2) Tighten the oi一cooJerto the specified torque.
%Ql 一⑳ 国 Oi] Coo一er Torque
25-34 (2.5-3.5/18-25)
N･m(kgf.m/Ib.ft)
6. Oi[ Filter Carl:ridge
l)AppJyengine o‖tothe 0-ring.

⊂⊃ 1●■ 巨I 2)Turn
1ng face
in the cartridge oi( filter untiJ the filter sea[-
makes contact with the 0-ring.
%Ql 3)Turn in the cartridge

l/4 ofa turn.
oi】filteran additionaf 1 and
7. Dra;nP山9
Tighten the drain plug to the specified
国
torque.
⊂⊃
Drain PIug Torque N.m(kgf.m/Jb.ft)
20-30 (2.0-3.0/14-22)
%Q≠
120
COOLING SYSTEM
SECT!ON 7
COOLING SYSTEM
TABLE OF CONTENTS
IJTEM PAGE
MaindataandspecificatJLons............””･･･L･････,.”･････.･.･”......”..”. 122
GeneraldescrJ-ption‥‥‥‥‥..‥‥‥....‥‥‥----‥.‥--‥‥‥‥‥‥..‥ 123
Thermostat.‥‥‥‥‥‥‥‥‥‥‥‥‥.‥...‥‥‥‥‥‥‥‥‥=‥‥‥...‥‥‥ 125
121
COOLING SYSTEM
MAIN DAm AND SPECIFICATIONS
[tem
Waterpumptype CentrifugalimpeHer
Pumptocrankshaftspeedratio(Tol) 1.1
De=veryvo[umeLit(qts)/m舌n. 100(105.5)
Tola[headkPa 60
Pumpspeedat3000rpm
Watertemperatureat30oC(86oF)
Pumpbearingtype Doub!erowshaft
Thermostattype Waxpefletwithjigglevarve
Valveinitia[openJngtemPeratureoC(oF) 82(180)
Valvefu‖open[ngtemperatureoC(oF) 95(203)
Valveliftatfu=yopenpositionmm(in.) 8.0(0.31)
122
COOLING SYSTEM
GENERAL DESCRIPTION
COOLANT FLOW
●
●
●
- ー
+ + + J
The englne COOh'ng system consists of the radiator, the water pump, the cooling fan, and the thermostat.
To hcrease co)d englne COOJanttemperature for smooth engine operation, the coolant is
quickly circu(ated
by the water pump and thermostat through the by-pass hose and back to the cy】inde｢ body･ The coolant
does not circulate through the radiator.
When the coolant temperature reaches 82oC (180oF), the thermostat wiJ[ begin to open and a graduaHy
increasJng amount Of coolant w川circu(ate through the radiator･
The thermostat win be fuJJy open when the temperature reaches 95oC (203oF). A(I of the coolant is
coolant
now circulating through the radiator for effective engJne COOIant･
123
COOLING SYSTEM
VVATER PUMP
J
T†
lF
I( O
ヽノ
0
A
A centrifugal type water pump forcefuT[y circulates the coolant through the coo=ng system･
124
COOLING SYSTEM
THERMOSTAT
囲 INSPECT10N AND REPAIR
Make the necessary repaJrS, and part rep[acements if excessive wear or damage is
adjustments,
discovered du｢ing JnSPeCtion.
Operating Test
1. Completely submerge the thermostat in water.
2. Heatthewater.
Stir the water constantly to avoid direct heat being
appried to the thermostat.
LZ
3. Checkthethermostat initial open[ng temperature.
/① 固 Thermostat lnitia1 0penlng Temperature oC(oF)

@ 82 (180)
4. CheckthethermostatfuFE opening temperature.
SS
囲 Thermostat Full 0penrng Temperature
95 (203)
oC(oF)
帯 Va一ve Lift at Ful[y Open Position mm(in.)
圃 8.0 (0.315)
① The｢mostat
① Agitathg Rod
@ WoodenPiece
125
MEMO
126
FUEL SYSTEM
SECT!ON 8
FUEL SYSTEM
TABLE OF CONTENTS
ITEM PAGE
Maindataandspecifications ･･--------･･----.---･･---･L--･･ 128
Genera[description‥,‥‥----･=-----･･--∴------=----･ 129
lnJ'ectionnozzJe ‥‥=･･--I-----･･･-=-I--------･･･----. 132
137
Jnjectionpumpcaribrationdata---･--･･-I-･････--･･.I---=････---
127
FUEL SYSTEM
MAIN DAm AND SPECIFICAT10NS
Item
lnjectionpumptype BoschAtype
P[ungeroutsidediametermm(in.) 9.0(0.35)
Governortype RSVvariabJespeedmechanicaFtype
FueJfeedpumptype Singfeaction
fnjectionnozzJetype HoJetype
Numberofinj'ectionnozzleorifjces 5
lnjectionnozzleorificeinsidediametermm(”.) 1.0(0.039)
lnjectionnozzleopeningpressureMPa(kg/cm2/psi) 18.1(185/2,630)
MaJ'nfueZfirtertype Cartr'Idgepaperelement
128
FUEL SYSTEM
GENERAL DESCRIPTION
FUEL FLOW
Fue.
filter
Noz2Ie
Water seperator
廿巨 lnJ'ection punlP
Fue[ tank
The fuel system of the fue一 tank′ the water separator (if so equipped). the fuel filter, the injection
consists
pump, and the injection nozzle･
The fuel from the fuel tank passes through the water separator and the fuel fi[terwhere water particles and
other forelgn materia一 are removed from the fuel.
Fuel, fed bythe injection pump plunger, is del'Nered to the injection nozzle in the measured volume atthe
optimum timlng for efficient engine operation･
129
FUEL SYSTEM
JNJECTJON NOZZLE
I
∫
i
J [
I_J
”OZZ [e holder
Ad■Ju sting shirn
I
Spring
Spring seat
リ
fq'ection nozzle R eta lng nut
A hole (with 5 orifices) type injection nozzle is used. 1t consists of the nozz[e body and the need[e valve
assembly.
The in)'ection nozz[e sprays pressurized fueJ from the injection pump into the combustion chamber
through the nozzle body in)'ection orifjce･
130
FUEL SYSTEM
FUEL FILJER AND WATER SEPARATOR
圭
l
Drain Lever
# -`●(44
●
I-r.
■● ●●●●●■一
I
●●●一●
●●●●●･
Acartridge type fue[ fi(ter and a water separator are used･
As inside of the injectionpump

the lubricated bythe IS fue一 which it is pumptng, the fuel must be perfectly
fuel fitter and the water separator remove water partic[es and other forelgn material from the
clean二The
fueE before it reaches the hjection pump.
The water separator has an hterna) float･ When the float reaches the drain level, remind you to drain the
water from the water separator.
131
FUEL SYSTEM
INJECT10N NOZZLE
団 DISASSEMBLY
C)
Disassemb]y Steps
1 Retaining nut 5 Spring

▲ 2 Injection nozzfe 6 Adjusting shim
3 Space｢ 7 Nozzle ho一der
4 Spring seat
132
FUEL SYSTEM
Performance this test before disassembJing the injection

1｢ nozz一e.
㌧ノ 1) Insta‡1the injection nozzle to the nozzletester.
2) Use the nozzle tester to apply compressed fuel at
18LI MPa (185 kgf/cm2/2,630 psi) to the injectT'on
托
nozzle.
固 3) Check
teakage.
the area around the nozzle seat for fueJ
cot: 1f there is fue一一eakage, the injection nozzle and the
Jnject盲onbody must be replaced as a set.
2. lnjection Nozzle
1) Remove the inJ'ection nozzles from the nozz(e
holders,
The nozzfe needle valve and nozzle body
combinations must be interchange.
2) Fmmerse the injection nozzfes in a tool tray fiJled
with clean diesel fuel to protectthem from dust.
133
FUEL SYSTEM
囲 lNSPECT10N AND REPAIR
Make the necessary adjustments, repa(rs, and part replacements if excessive wear or damage is
discovered during [nspection.
InjectionNozz一e Needle lnspection

l･ Removethe nozzle needlefromthe nozzle body.
2. Carefu[1y wash the nozz-e and the nozzle

need[e
body in clean diese一 fuel.
3. Checkthatthe nozzle need一e moves smoothty暮nSide

□ the injection nozzle body.
Jfthe nozzle needle does not moves

smooth[y, it
must be repaired (See ''Nozzre Lapping Procedure”
below.)
Nozzle LappJng Procedure

1. Lapthe nozzle nozzle body@by
needleOandthe
app[y(ng a compound chrome
of oxidized and
animaJ oil ③.
Note:
Do not app[y an excessive amount of the oxidized

to the
chrome and animal oi一 compound injection needle
valve seat area.
① 2･ CarefulJywash the needfevalve and the nozzle body
E5] Nozz)e
in c[ean
Body
diesel fuel after Fapp]ng.
Inspect‡on
and Need一e Valve
Checkthe nozzle body and the need(eva[ve fordamage

and deformation.
The nozz一e and body must be replaced ifeitherofthese

two conditions are discovered during Inspection.
134
FUEL SYSTEM
国 REASSEMBn｢
汁 ⊂)
Reassemb[y Steps
1 Nozz一e holder 5. Spacer

▲ 2 Adjustng sh盲m 6. 1njection nozzle
3 Spring ▲ 7. Retainin9nut
4 Spring seat
135
FUEL SYSTEM
Important Opera胡ons
31 AdjustShim
Adjust Shim Ava‖abiFity mm(in.I
Ran9e 0.10-0.59 (0.0039-0.0232)
7. RetainingNut
Tighten
国
to the retaining the torque.
nutto specified
Retaけ‖ng Nut Torque N･m(k9f･m/lb.印
29-39 (3-4/22-29)
-
InJ'ect;on Nozzle Adjustment
-
J∼
∼
-
l･ Attach the injection nozzle ho一der to the injection
nozzle tester.
2. Apply pressure to the testerto that the

nozzle check
現 injection nozz一e opens at the specified pressure.
[fthe injection nozz[e does not open at the specified

pressure, instal[ or remove the appropriate number
of adjusting shims to
adjust it.
cctt WARNING:
TEST FLUID FROM THE ]NJECT[ON NOZZLE TESTER

WILL SPRAY OUT UNDER GREAT PRESSURE. ]T CAN
EAS)LY PUNCTURE A PERSON'S SKIN. KEEP YOUR
HANDS AWAY FROM THE mJECT10N NOZZLE TESTER
AT ALL TIMES.
136
FUEL SYSTEM
lNJECTrON PUMP CALIBRATrON DATA
lDENT肝1CAT10N PLATE AND PRODUCT

SERIAL NUMBER
I 1 Injection pump and reparr should be
MADE TN adjustment
･ZEXEL
.
JAPA N
made by the nearest ZEXEL CORPORATION or
ROBERT BOSCH Authorized Service Out[et.

○ ○
Pump No. 2. When you ask such authorllzed service outlet the
NP-PE the identification Prate
･--･-････--=
or repair, and
ad)'ustment
(UCENCE BOSCH)
Product Seria一 Number w= gNe them a necessary
to get technicaJ data distributed by the
㊨･･･Jdentif7cation number c[ue
manufacturers prev壬ous[y.
Without this data, the Service Outret w川be unab[e

to effectively service your lnJeCtJ-on pump.
Jf you are unab)e to locate the data appricabre to
your pump, please contact [SUZU MO一

Injection
丁ORS LTD throu9h your machine supp=e｢.
3. Do not remove the [dentification Pfate and Product
Serial Number from the injection pump.
Keep the Identification Plate and Product Seria一

Numberc(ean atalltimes. Do notallow itto rust or
become illegible.
Examples data are as foIJows･

Note: of test conditions and calibration
TEST CONDmONS REQUJRED FOR THE FUEL JNJECT)ON AMOUNT ADJUSTMENT
Nozzle *ZEXEL No.: 105780-0000

Injection
Bosch Type No.: DN12SD12T
ZEXEL No.: 105780-2080

Injection Nozzle Ho一der
Bosch Type No∴ EF8511/9
Pressure 17.2 (175)
Jnjection Starting MPa(k9〃cm2)
injection Line Dimensions mm(in.)
lnside Diameter 2.0 (0.079)
Outside Diameter 6.0 (0.236)
Len9th 600.0 (23.6)
Transfer Pump Pressure 1.6 (22.75)
Testing Diesel Fuel ISO4113 or SAE Standard Test Oil (SAEJ967D)
Operating Tempe｢atu｢e oC(oF) 40-45(104-113)

Pump Rotation Direction CIockwise (Vievved from the drive side)
137
FUEL SYSTEM
rNJ. PUMP CAuBRATION DATA Ass'y No. 000000-0000

Date : 2
ENGINE MODEL 4JBIPAVV-01 Company : JSUZU
N o. 0-00000-000-0
Injection pump : PES4A Governor : EP/RSV Tim]ng device :
OOOOOO-0000 000000-0000
1. Test Conditions :
Pump rotation :
ctockwJ'se (Viewed from drive side)
Nozzle : 000000-0000 N･∼- 1rder : 00OOOO-0000

(BOSCH Type No. DN12SD12T) (BOSCH Type No. EF8511/9A)
Nozzle openhg pressure : 175 kgf/cm2 Pump Pressure : 1.6 kgf/cm2
メ.tjr
hjectionpipe:
Test Oil : lSO4113
lnnerDia.
orSAE
2
Standard
mrrl
銀牌漣ゝr'ヽl''
J967d)
mJ
mm-Length 600
Oi( Temp∴
mm
40'5oc
.JAE
OverfJow valve opening pressure : 1.b kgf/cm2
2. lnJ'ection llming :
Pre-stroke: No. 1 P[unger 3.3±0.05mm Note : Adjustwith control rod position of mm
[njectionorder: 1 3′1 4.1 2

90o±30′ 1 80o±30` 270o±30′
Q±
(interva一 : 30')
PJungersarenumberedfromthe Driver
side.
Tappetclearance: Boltadjustmenttype ,-
Morethan 0.3 mmforaII cylinders.
Shim ; Manua‖y rotate the camshaft 2-3 times confirm that
adjustmenttype and
it rotates smoothly.
4. lnjection Quantity :
Rod Pump Max.var

Adjust- In).ectionQ'ty
Position Speed bet.cy[ Fixed Remarks
ingpoint (cc/1000strokes)
(mm) くr.p.m) (%)
A 8.3 1,5Oo 64-65 ±2.5 Lever Basic
Approx.
C 500 9.5-13.5 ±15 Rack
6.6
D Above14.0 100 (70-85) Lever
鉢弼 pl丘
5. Timing advance specification :
PumpSpeed
(｢.p.m)
Advance
Angle(deg.)
I
= EX EL zEXsEeLN.?eODRePp?nRmAello”享-eTl(.K
Japan
138
FUEL SYSTEM
GOVERNOR ADJUSTMENT
Full Adjustment
Above 14.0
ldJe･sub sprJng Setting
13.0
Governor sprJng Setting
9.3
9.1±0.1
■■■■■
8.3
≡
7.8±0. 1
呈
⊂
0
500
's
'a
＼
O
6.3 ＼
a.
&
O 4.3±0.4
l■
丘:
l
I
l
I
L_
160±30 250 500 (610I ‖535)1545 1610
Pump speed (rpm)
Speed L.ever Angle
35o±3o 1 2o士5凸
Stop
25 o士58
139
MEMO
140
ENGINE ELECTRICALS
SECTION 9
ENGINE ELECTRICALS
TABLE OF CONTENTS
ITEM PAGE
Starter.‥‥‥..‥‥‥‥‥.”..=.‥‖‖..”‥‥‥‥‥‥.‥‥‥‥.‥‥=‥‥‥. 142
Afternator‥‥‥‥‥‥‥‥‥..‥‥‥.....‥‥‥‥....‥.‥‥‥‥‥‥‥‥”.=.. 157
141
ENGINE ELECTRICALS
STARTER
STARTER rDENT(FICAT[ON
MJTSUB)SHJ
A EL[CTRIC COR戸, +APAN 24V MfTSUE31SHI
to
starter
the
motor is identified by name
pJate
attached yoke.川山stration)
TYPE ①
NO. ① Manufacturer`stype
② @ Jsuzupartnumber
③ ③ Barcode
Note:
A一ways check the identification before beg[n-

number
nlng a Service operat]1on.
App]icabJe service data will vary to the ident･

according
ification number･ Use of the data
wrong service w川
result in starter damage.
142
ENGINE ELECTRICALS
MAJN DATA AND SPECJFICAT(ON
lsuzuPartNo.
89720471301897137-478.
Mitsubl'shicodeNo.
L
RatedvortageV 1224
RatedoutputkVV 2.23.2
RatJ'ngsec 30
Directionofrotation
(VJ'ewedfromthepinionside) C一ockwise
CJutchtype RoIJer
TerminaJvoltage(No.Load)V 1123
Minimumcurrent(No.Load)A 14080
Startermotorminimumoperatingspeed
(No･Load)rpm 38003750
Piniongear
Modu)es 2.75
Numberofteeth ll
Outsidediametermm(”.) 38.5(15.2)
Yokeoutsidediametermm(in.) 81.6(3.21)
Brushlength
Standardmm(in.) 18(0.71)
Limitmm(in.) ll(0.43)
Brushspnngstandardfitting)oadN(kgf) 26.7-36.1(2.7-3.7〉
Commutator
Outsidediameter
Standardmm(in.) 32(1.26)
Limitmm(in.) 31.4(1.23)
Depthofundercutmica
Standardmm(in.) 0.5(0.02)
Limitmm(in.) 0.2(0.008)
143
ENGJNE ELECTR]CALS
･GENERAL DESCRIPTION
Magnetic switch Lever sp｢】ng
Lever
Rear bracket
OverrunnJng C(utch
Brush C(utch shaft
Front bracket
Beanng
a /
Oi[ seal
+
Pinion
Bal[ Gear Bearing

shaft
Armature Yoke ASM

Jnternal gear
円anetary gear
144
ENGINE ELECTRICALS
団 DISASSEMBLY
Disassembly Diagram: Disassembre in numer了cal orders.
3 13 15
㌔廷〕
○
rT17
4) (4)∩) 19
ll
9
蛋 / ㊨
罪 ○
⊂:=7
12
『 20
14 16 17 21 18
Disassembly Steps
1 Nut : MTermina( 14. Prate&packing

2 Screw 15. LeverASM
3 Magnetic switch (1) Lever
4 Pinion (2) Packing (notdescribed)
5 Bo一t (3) Plate (not described)
6 Screw (4) Leversprin9
7 Rear bracket 16. P[anetarygear
8 Yoke ASM 17. Gearshaft
9 Brush sprlr唱 18. C山tch
10 Brush 19. Bracket
ll Brush holderASM 20. hternalgea｢
12 Armature ASM 21. Washer
13 Bal)
Assemb一y: Assemble in reverse

procedure to the disassembly.
145
ENGINE ELECTRICALS
∇ DisassembJy
When disassembJing the starter motor, to
make
easier, to match the magnet
reassembfing mark switch
and the yoke.
Magnetic 1. Nut (MtermhaI)

switch
Nut Remove JIM” terminal
the nut of the magnet switch
and then the cab一e.
Yoke
2. Screw
Remove the screw.
sc
rev/AA& 3. Magnet
Remove
Switch
the magnet switch and the plunger.
4. Phion
Removlng the p)nion requires simp[e too一s. A set

consists of3 parts (1 bolt, 1 nut and 1 smaH tJLn
pJate).
These too一s are not used during assemb一y. The
pln10n is assemb一ed uslng the pu=er.
･
Pul[thelever with the boltinstead
of the
plunger and push out where to
the plnion can
be moved forward. Jn orderto fixthe (ever and

the pln暮On,fixthe bolttothe smaII p一ate.
146
ENGINE ELECTRICALS
Soket Hold the adjustable socket on the stop ring. Hit

Snap rlr唱 the socket with a hammer and remove the stop
Stop ring, expose the snap ring, then remove the

nng
Pinion snap ring, the stop ring, the pinion′ and the
plnion snap rJng.
円∩'ron spnng
The snap rlng lS not ｢euSable.
5. Bo一t
Screw
6. Screwand Brush holder
＼滋 Remove the bolt and the screw.
5 7. Rear bracket
Remove the rear bracket.
Rear bracket
8. YokeASM
HoJd the socket (maJ'or diameter 32mm) on the

a｢mature commutator and remove the yoke ASM
⊂) 8S
you slide the brush onto the socket.
Removlng this
･
way makes reassembring easier

and inspection of the brush rotation can be
brush from
貞迎 conducted with the removed the
socket.
＼
Yoke ASM
9. Brush sprJng
lO. Brush
Pu= upthe brush sprJng and remove the brush.
ll. Brush holder
After removlng the brush, remove the brush holder.
Brush holder
Brush
12. Armature ASM
:g&
P=ll out the a｢m8ture from
the planetary ヨear and
remove the bearlng With the puJler.
Armature
147
ENGINE ELECTRICALS
13. Bal∫
Be careful motto (osethe balL
14. P[ate
Lever packinョ -､
Remove the plate and the packin9.
逮
ヽ Leve｢sprln9 plate
15. LeverASM
Remove the
lever spnngs.
lever packing. the p(ate and the two
Lever
16. Planetary gear

Remove the four packing, the pLate the two
and
a @珍
lever sprlngS.
Gear shaft g
腎
17. Gearshaft
Q
Planet8ry 9ear
18. C[utch; Overrun
19. Bracket; Front
Put the gear shaft′ the overrunnlr唱C山tch and the

lever together, then from
remove them the front
bracket.
Overrun clutch
20. lnternal gear

21. Washer
When the two E type washers are removed, it

divides into the overrunning clutch, the internal
@
9ear′ the washer and the gear shafts.
rnterna( gear
148
ENGINE ELECTRICALS
囲肌ISPECT10N AND REPAIR
Make the necessary repaJrS, and part replacements if excessive wear damage is dis-
adjustments, or
covered during Inspection.
ARMATURE
Armature Short Circuit Test

6) l･ place the armature on a
growJertesterO.
2, Hold a hack saw blade ① againstthe armature core
wh‖e slowly rotating the armature.

h
Jfthe armature is short circuited, the hack savv blade
w‖ vibrate and wiH be attracted to the armature
COre.
A short circuited armature must be replaced.
Armature Winding Ground Test
Check for
囲
continuity across the commutator segments
and the core.
rfthere is continuity′ the armature is interna[Iy grounded

due to insulation failure and must be repZaced.
Armature Winding Continuity Test
Check for conthuity the
E2] 圃
across commutator segment.
)f there is
continuity′ the coif is open
no armature and
must be replaced.
⊃○｡
+ 二___
149
ENGINE ELECTRICALS
Commutator Run･Out Test
闘 Use dJ'a! indicator V-bJockto the
圃
a a measure com-
and
mutator ｢unout.
Jf the measure
va[ue exceeds the limit, the commutator
must be replaced.
Commutator Run-Out mm(in.)
Standard Limit
0.02(0.0008) 0.O5(0.002)
Commutator Outs)'de Diameter Measurement
Use to the
圃
a vernier caliper measure commutator out-
一`､勺 side diameter.
Jf the measured value exceeds the limit′ the armature

L? C
c
must be repfaced.
Commutator Outside Diameter mm(in.)
Standard Limit
32(1.26) 31.4(1.24)
Segment Mica Depth Measurement
Use depth depth.
圃
a gaugeto measurethe segment mica
1f the va(ue exceeds the limit, the segment

measured
mica must be undercut.
Segment Mica Depth mm(in.)

Standard Limit
0.5
0.2(0.008)
(0.02)
Bearing Inspection
Visuafly bear]ng.
匝
JnSPeCtthe
Ifthe beanng ISWOrn Or damaged, it must be repJaced.
150
ENGINE ELECTRICAL.S
YOKE
Field Winding Ground Test
Use a circuittesterto checkthe field winding ground.

1. Touch one probeto the brush field winding end.
2. Touch the other probe to the bare surface of the

yoke body.
There should be no
continuity.
Zfthere is continuity, the field windings are grounded.
RepaJr Or
replace the fiefd windings,
Fie[d Winding Continuity Test
〟
Use a circuittesterto checkthe fJLe[dwinding continuity.
1. Touch one
probetothefield winding leadwire.
2. Touch the other probetothe brush.
There should be continuity.
1fthere is no
continuity, the field windings are open.
Repa[r or replace the field windings.
BRUSH AND BRUSH HOLDER
Brush Length Measurement
囲 Use a verniercafiperto measure the brush length.
l千the measured value exceeds the 一imit. the brush

and/
orthe yoke must be replaced.
Brush Len9th mm(in.)

Standard Limit
18(0.71) ll(0.43)
151
ENGINE ELECTRtCALS
Brush Spring Inspection
l VJ'suaHy
ing.
check the brush sprJng for weakness and rust-
Replacethe brush sprlng if it is weakor rusted.
Use a spnng ba[ancerto measurethe sprlng tension.
1fthe measured valve exceeds the limit,the brush spnng

must be rep一aced.
Brush Holder [nsuJat]1on Test
Use a circuittesterto checkthe brush hofder insulation.
1. Touch one
probetothefieJd winding read vvire.
2. Touch the other probetothe brush.
There should be no
continuity.
Ifthere is continuity, the brush ho[der must be
or replaced.
repaired
MAGNETJC SWITCH
圃 Check for continuity across the magnetic ''S”

switch
産室 termina(
coil is open
and
and
coi) case.
shou[d
ff no
be
continuity
replaced,
exists, the shunt
Check for continuity across magnetic svvitch 'LS” termト
==二二==
囲 nat
are
and
open
`′M”terminaJ.
and shou一d be
[f no
replaced.
continuity exists, series coir
152
ENGLNE ELECTRJCALS
OVERRUNrVJNG CLUTCH AND PJNJON GEAR
Hold the overrunn(ng clutch housing and turn the

pJnion
by hand. Jf it turns one
resist声nCe but
way with s=ght
not the other, the condition is normal. [f not, reprace the
overrunning crutch. 1f abrasions or damage is found

during JnSPeCtion of the pJnion, rep face it.
･ The inside of the overrunning clutch isf=ed
w汁h grease, There may be a danger ofsp‖ing
the grease when washed with detergent used
for cJeanlng Off oil and kerosene.
FRONT BRACKET
lf any oil sp川age or damage is found during JnSPeCt盲on

of the bearJng and the oil seat, rep一ace with front bracket
assembJy (including bearing and oil seaり.
lNT∈RNAL GEAR AND PLANETARY GEAR
lfany abrasions or damage is found durJ'ng lnSPeCtion of

the gear tooth. replace the internal gear or the pZanetary
gear･
LEVER
Lightlypushthehead of the
overrunnlngCIutchsh aft
fnspect both ends (where it touches the overrunning
backbyhand
of the lever for abrasion. Jncomplete
clutch)
蘇
engagement may result if the 一ever is worn, making the
pJnion ineffective･
When the projection position of the plmOn is outside the
reference value, adjustment cannot be made, so

replace
the fever.
Rangeofshaftrnov ement
ProJ'ection Position of the Pinion mm(in.)
0.5-2.0
153
ENGINE ELECTRICALS
国 ASSEMBn｢
AIthough is done盲n the reverse procedureto disassemb[y, some

points need to be expJained･
assembly
l. Oiljng section and t言ghtening torque
Referto the specifications attached. (P.155)

･
Recommended 9reaSe is MUL TEMP#6129
(Kyodo Yushi), Mo[ykote RAG-650 (Dow
Corning) or equivalent.
2. Tightening torque
Referto the specif.[cations attached. (P.155)
●
●
3. lnspectjon of the proJreCtion position of the pln10n
A什er reassemblir唱the cranking motor. inspect the

Sw;tch projection position of the pJnLOn.
守 Position Pinion
Projection of the mm(in.)
0.5-2.0
Battery
Sta rter
motor
Measurlng method
Lightlypushtheh ead of the
overrunnmgc[utc h shaft As shown in the diagram, connect the starter motor to
backbyhand
the battery.
When the switch isturned
蘇
･
on′the plnion w=
move forward to the cranking position. At this
time, the armatures･may aLso turn, so care is
needed.
･
Light[y push the head of the overrunnTng Clutch
Rangeofshaft movement by hand
shaft and measure the movement
(return) of the c[utch shaft.
Lfthe value is within 0.5-2.0, it is in the normal

position. Jf it is outside the Limit, replace the
Jever.
154
ENGINE ELECTRICALS
OJL[NG SECTION AND TJGHTENJNG TORQUE
4.9-8.8N･m
(0.5-0.9k9f･ml
8.8一-13N･m (0.9-1.3kgf･ml
㌔
顎ヽ
e[
2.4-4.4N･m
b a
(1.25-0,45k9f･m)
7･8-13N･m (0.8-1.3k9f･m〉
OiFingSection Brandname
a S】eaveBearJngandBaJ[ MolycoatRAG-650
b SIeaveBeanng Mo[ycoatRAG-650
C OverrunnlngClutchandBear[ng MolycoatRAG-650
d GearShaftSp[ine MoJycoatRAG-650
e SJidingpartbetweenleverandoverrunnlngCIutch MULTEMP#6129
f Armatureshaftgear,Jnterna[gear,PJanetarygear Mo[ycoatRAG1650
g PIungersurface MULTEMP#6129
h lnternaJandexternaJsidesurfaceofarmaturebearlng MULTEMP#6129
I Oi(seal MULTEMP#6129
155
ENGJNE ELECTRICALS
PERFORMANCE TEST
Performance Test
The starter motor characteristics are

sJgnificantry
inf[uenced by the capac-rty of the battery. Therefore, test
by using a battery of the designated capacity.
Since a large amount of current w川fJow. conduct the

test quickly.
No Load Test
A Turn Load
under no and measure the rotationaF speed
Ammeter Switch
and vo托age orcurrent.
No-road characteristics (Standard vafue)

V Vo[tmeter Voltage 23V
Battery
Current 80Amax
Starte r
motor Numberofrotations 3′750rpmmin
156
ENGINE ELECTRICALS
AIJERNATOR
ALTERNATOR IDENTJFJCATJON
HJTACH[
Hitachi MfTSUBJSHI identified
=*=
or alternators are by
name
p一ate attached to the rear
cover.川山stration)
=*= ① lsuzu part number
I ② Manufacturer′s code number
田 HITACH[ _@= ③ Rated voltage
01
0 Isuzupartnumber
MITSUBISHL Manufacturer`s
② name
⊂=二 ① 二二=] ③ RatedvoZtage
=二 ① 二=コ @ Barcode
□ =③:=] ⊂コ Note:
｢｢ A一ways
I
④ I check the J'dentificatjon number before begJn-
+ a
nJ'ng service operation.
_+
AppJJ'cabJe service data w川vary according to the ident-
ificat'fOn number･ Use of the wrong data
service vv川
resu[t alternator damaged.
157
ENGINE ELECTRICALS
MAIN DATA AND SPECJF[CATJON
EnglneModehobeEqulPPed 4JSeries
ManufacturerLsname HITACHJ MITSUB)SHr
897201-2810
】suzuPartNo. 897228-3180 897023-2631 897182-2892
Manufacturer'sCodeNo. LR150 LR240-388 AOO2TA8383
12
RatedvoJtageV 字4 24
RatedoutputA 50 40 30
Operat盲ngspeedrpm 1200-18000 1000-13500 1200-18000
RatedoutputatrpmAN/rpm 47/13.5/5000 38/27/5000 -/-/5000

No-loadoutputatOamperesV/rpm 13.5/1200or[ess 27/1000orJess 27/1000orJess
Directionofrotation(viewedfromthe C一ockwise Clockwise･
pu‖eyside)
Po(aritygrounded Negative Negative
Pulleydiameter(P.C.D.)mm(in･) 82(3.23) 80(3.15)
Coilresistanceat20oC
Rotorcoilf2 2.6 12.5 6.5-7.8
Statorcoiln 0.101 0.14
Brushlength
Standardmm(in.) 22(0.86) 25(0.98) 18.5
Limitmm(in.) 6(0.24) 6(0.24) 5.0
SliprJngdiameter:
Standardmm(in.) 27(1.06) 31.6(1.24) 22.7(0.89)

Limitmm(in.) 26(1.02) 30.6(1.20) 22.1(0.87)
Shaftdiameter
Frontmm(in.) 17(0.67) 17.0(0.67) 17(0.67)
Rearmm(in.) 10(0.39) 12.0(0.47) 8(0.31)
Regu[ator(s)appI7cabJe Bu主(t-J'n
JsuzuPartNo. 897184-6290 897184-6280
Manufacturer(s)codeNo. TR2Z-47 A866X42272
158
ENG[NE ELECTRICALS
GENERAL DESCRIPT10N
(
1_
Based on LR240
The alternator consists of the front cover, the rotor, the stator, the built-in (C regulator (some engines use a
TirreTl alternator with separate regulator), and the rear cover.
This smaH size and 一ightweight aJternator provides excelfent re‖ability. Jts simp一e construction makes it
very easyto service. The bui一t-in lC regulator mJ'nimizes circuit wiring.
159
ENGINE ELECTRICALS
団 DISASSEMBn｢
These disassembfy steps are based on the bui一t-in [C regulator type･
J事
Q
a O
I
Jb
○
?
ヽヽ
C)
@ @ 4
＼､､
/一一㍍′′ ♂宣惑
1
Disassemb[y Steps
1 Through bolt 7 Ball bearln9

2 Rear cover
and stator 8 Front cover
▲ 3 Pulley and fan ▲ 9 Stator

▲ 4 Spacer collar ▲10 Rectifier with brush holder
5 Rotor with bearJng 11 IC regulator
6 BearJng retainer 12 Rear cover
160
ENG[NE ELECTR[CALS
3. Puueyand Fan
凸==コ Clampthe
(1) rotorshaftin a
softjawvise.
(2) Loosenthe pu‖eyJocknut①.
(カ (3) Removethe pu‖ey ① alon9 With帥e spacer
collar.
5Q
③ チ
r/r ヽ
4. Rotor and Bearlng
凸 (1) Use a p一astic hamme｢or a

press①to remove
the roto｢from the front cover ①.

ーー/
①
(2) Remove the space｢co‖ar.
＼ .ノづクー
ヽ
｢や
②
bd
[i
8. Front Cover
Use to the front from

screwdrivers pry cover
① the
stator @.
戯 Note:
Do not attempt to prythe coil wires from the stator.
9. Stator
10. Rectifier with Brush Holder
Use a soldering iron ①and a long

-
pairof nose
pliers
①to remove the rectifiers.
@
Note:
㊨ ③
㊨ Hold the
G) rectifier leads between the rectifier and the
ニーく soldering Iron With the 一ong nose p‖ers. This w川

protect the rectifier from the heat,
161
ENGINE ELECTR]CALS
囲 lNSPECT10N AND REPAtR
Make the necessary repalrS, and part replacements if excessive wear or damage is dis-
adjustments,
covered during lnSPeCtion･
ROTOR AND BEARING
Check the face of the slip nngs for contamination and

rouョhness. 1ffound to be ｢ou9hened′ dress with a fine
sand paper (#500 -
600). [f found to be contaminated,

clean with a cfoth saturated with alcohol.
BaJf Bearng
Check thatthe ball bearmgs rotate smooth[y.
1fthe ball beanngs are noisy, they must be replaced.
〟
/
Use a vernier ca]iper to measure the slip ring outside
園 diameter.
1f the measured va[ue exceeds the Omit, the rotor must
G be ｢eplaced.
/遡 S=p Fung Outside Diameter
Limit
mm(in.)
Standard
31.6(1.24) 30.6(1.20)
162
ENG[NE ELECTRJCALS
Rotor CoJ'[ Continuity Test
:I-辛圃
Use an
1･ Touch
circuittesterto
both
testthe
circuittester
rotor
probes
coiJ continuity.
to the rotor coir s=p
恩￣ 2.
rings.
Note the circuittester reading.
The circuit tester should register approximately 9

ohms.
3, 1fthe circuit tester does not show continuity, check

the connections between the lead wire and the slip
rings.
[f breaks are founded, repaJr and repeat the rotor

coil continuity test.
Ifthere is st川no rotor coil continuity, the rotor must

be replaced.
Rotor Coi[ Ground Test
Use an circuittesterto testthe rotor co‖ for grounding.

G喜ヨ / 1･ Touch of the circuit tester to the
圃
one
作 probes rotor
○
shaft.
㊨ 2･ Touch
rir唱S.
the other circuit tester probe to one of sfip
3. Note the circuittester reading.

4･ Touchthe circuittester probe to the other s一ip nng.
5. Notethe circuittester readhg.
The circuit tester should show infinity (no need(e
movement) at both measurin9 Points.
Jfthe tester does not show infinity (the need(e
circuit
at both measuring points, the rotor is
moves)
grounded and must be rep[aced.
STATOR CO]L
Stator CojJ Continu;ty Test
Use an
circuit tester to testthe stator coil conthuity.
1L]
1. Touch the circuit tester to two of the bare
圃
probes
stator wires.
鵡貫 2. Note the circuittester reading.

3. Move one of the circuittester a third wire.
probesto
163
ENGJNE ELECTRJCALS
4･ Note the circuittester reading.

1fthe two readings (Steps 2 and 4) are identical, the
stator coif has continuity.
If the two circuit tester readings are different, there

is no st8tOr COntinuity.
5. Checkthe neutral junction (arrow mark) forbreaks.
Jf breaks are found, repalr repeat the stator
and coif
continuity test.
1f there is stilt no stator coir continuity, the stator
must be repl8Ced.
Stator CoiJ Ground Test

7:
Use for grounding･
囲
an circuittesterto testthe statorcoiF
I_Q
1･ Touch one bear

circuit tester probe to the metal
sur†ace of the stator.
2･ Touch the other circuit tester probe to a bare stator
･
74
′ ＼
lead vvire.
3･ Note the circuittester reading.
The circuit tester shou一d show infinity (no need一e

movement).
1fthe circuit tester shows a value other than infinity
(the needle moves)∫ the stator is grounded and must
be rep[aGed.
RECTIF旺R
0 Rectifier (Positive DiodeI Cont;nuity Test

I｢｢ l ◎
BAD GOOD
○
rum
○
Use circuit tester to test
囲
○ an rectifier continuity･
Oo
oO
空＼ 1･ Touch the circuit tester positive probe to the rectjf7er

○ A
holder,
⑮
○
玩 i@
2･ Touch the cjrcuittester negative to each
書ヨ
probe of the
diodeterminats 'rn
turns.
164
ENGINE ELECTRrCALS
3. Note the meter reading foreach diode terminaL

AJl of the diode shou[d showcontinuity.
Jfa diode shows no continuity, it is open circuit. The

｢ectifier assembly must be replaced.
4. Touch the circuit tester negative probe to the recti-

fier holder.
GOOD BAD
∈) 5. Touch the circuittester positive probe to each of the
憾
0
od 0 a diodeterminals in turn.
oO
n 6. Note the meter foreach diode termina一.
○ a reading
㊨
0
None of the diodes should showcontinuity.
@
(f a diode shows continuity, it is shorted. The recti-
fie｢ assemb一y must be replaced.
Rectifier (Negative Diode) ContJ'nuity Test
￣￣
｢ l Use a circuit testerto test the rectifier continuity.
圃
f ｢
BAD GOOD ◎ 0
○ 0
1. Touch the circuit tester negative probe to the rectト
fier holder.
-0.
Oo
oO
@;
2. Touch the circuJ't tester positive probe to each of the
diode terminals in turn.
⑳i
3. Note the meter reading foreach diode terminal.
AJJ of the diode should shovvcontinuity.

1fa diode shows no
continuity, it is open. The rec-
tifier assembly must be rep faced.

4. Touch the circuit tester positive probe to the rectifier
GOOD
hoJder.
BAD ◎ (∋
5. Touch to
0 0 the circuittester negative probe each of the
a diodeterminals盲n
wm.旦＼ ○
Oo
0 ○
6, Notethe
turn.
foreach diodeterminal.
meter reading
㊨ & None of the
1f a diode shows
fi即aSSemb】y must
diode should
continuity, it is shorted.
be rep一aced.
show continuけy.
The rect]'-
RectifJ'er Assembly Replacement Procedure

①
Use the Rectifier Service Kit to rep[ace the rectifier
壷L 圃 assembly in the foHow]ng

1. Connectthethree inside
steps.
(Cad wires to the ''N” termト
na)s①.
2. Connect the three outside Lead wires ② to the out-
side terrninals.
/ 3. lead
Wind the stator wires around the rectifier read
@ w7res (inc一uded in the RectJ-fier Service Kit) and soI-
derthem.
165
ENGINE EL.E:CTRJCALS
Note:
1･ The be
圃
stato=ead wires must cut to the proper
(ength before they are connected to the rectifier
Jead wZres･ lf the stator lead wires are too long or
[￣二 Stator
too short,
Lead
troub(e
Wire Length
may occur.
mm(in.)
33.5 (1.32)
2･ Take care not to damage the rectifier paint surfaces.
BRUSH
囲 Use a verniercaliperto measurethe brush.

(fthe measured va)ue exceeds the limit, the brush must
be replaced.
Brush Length mm(in.)

Standard Limit
897201-2810 22(0.86) 6(0.24)

897023-2631 25(0.98) 6(0.24)
Brushes are provided with a line whJ.Ch indicates the

[imJ't of usage.
166
ENGINE ELECTRICALS
国 REASSEMBLY
ll
メl
○
∼
i 4G
○
?
＼ ■
@ 噂タ
10
■′-
/
//
ーー/一一∴ #
rt-:g十表しン-
Steps
-
/
_′
一■
)一一一1
Reassemb[y
1 Rear cover ▲ 7 Bal=)ea｢lng

2 (C regulator 8 Beanng retainer
▲ 3 Rectifl'er with brush holder 9 Rotor with bearJng
▲ 4 Stator 10 Spacer co‖ar
5 Rear cover and stator ▲11 P山1ey and fan
6 Front cover 12 Through bo一t
167
ENGINE ELECTRICALS
3. RectifJ'er with Brush HoJder

/ 4. Stator
When connecting stator and diode Jeads

coiHeads
using soJder, use [ong-nose pfiers and finish the
work as
quickJy as possib[e to prevent the heat from
being transferred to the diodes.
ll. Pu‖eyandFan
Tighten.the fan to the specified torque.
国
Fつ
pu=ey and
Pu一ley and Fan NutTo｢que N･m(k9f･m/Ib.柑
⊂⊃
49-64 (5.0-6.5/36- 48)
⊂⊃
⊂>
歩行
/′=
168
TROUBLESHOOTING
SECT10N IO
TROUBLESHOOTJNG
TABLE OF CONTENTS
JTEM PAGE
Hardstartt'ng -...----.,..--------------･･-･--.-....--. 171
UnstableidJJ'ng..‥‥-----.･.---I--L･-‥-..I..‥..‥‥‥‥=‥,.=‥ 175
[nsufFicientpower ‥‥.‥‥‥‥‥‥‥‥.‥..-.‥”･-･･=･”‥‥.･”.‥‥‥..‥ 178
ExcessivefueJconsumptJ'on‥‥.‥‥‥‥‥..‥･･･.‥-‥‥..‥‥.-‥‥.,‥‥‥‥ 182
ExcessiveojJconsumption...........･1...”.････.･･-””,.1･.....･･･..”,.”... 184
Overheating-------.,･-----･･----･･･-----.I.-･.----.. 185
Whiteexhaustsmoke ‥.‥.‥..‥‥‥‥‥‥‥‥‥‥.‥‥‥..‥‥‥‥...‥‥.‥‥ 187
Darkexhaustsmoke ...”..”.......”..............,......”.......,,....””.. 188
Oi[pressuredoesnotrise.,..‥‥..,.‥‥-I--‥･...‥･=‥‥‥..,....‥...‥‥ 189
■
AbnormalengJnenOise,.....,....･”....････････････.･･･････”.I.”...A..,...... 191
169
TROU8LESHOOTING
TROUBLESHOOTING
Referto this Section to diagnose repa(r eng(ne

quickly and problems.
Each troubleshooting chart has three headings arranged from leftto right.
(1) Checkpoint (2) TroubleCause (3) Countermeasure
This Section is divided into ten sub-sections:

1. HardSta｢ting
l) Starter inoperative
2) Starteroperates but engine does notturn over
3) Engineturnsoverbutdoes notstart
2. Unstableld=ng
3. Insufficient Power
4･ Excessive Fuel ConヲumPtion
5. Excessive Oil Consumption
6. Overheating
7. VVhiteExhaustSmoke
8. DarkExhaustSmoke
9. OiJPressure DoesNotRise
10. Abnorma)Eng盲neNoise
170
TROUBLESHOOTING
1. HARDSTARTING
1. STARTER JNOPERATJVE
Checkpoht l†ouble Cause Countermeasure
NG NG
Neutral switch (Jf so Defective neutral switch RepI8Ce the
equipped) neutra一 switch
NG Loose battery cable termina一s NG CJean the bat-

and/or retighten
B∂tte｢y
Poor connections due to rusting tery cable termina(s
NG NG
Battery discharged or weak Recharge or rep(ace the battery
NG NG
Fan be一t loose or broken AdJ'ust or rep)ace the fan belt
OK
NG NG
Fusible 一ink Fusible Fink shorted Replace the fusJ'b[e ”nk
OK
NG Defective starter swJ'tch or NG Replace the starter or

Starter switch
switch
starter relay the starter re)ay
OK
NG Defective magnetic or NG RepaJr the

Starter sw['tch Or replace magnetJ'c
starter re一ay switch
OK
NG NG
Starter Defective starter Repair or repFacethe starter motor
171
TROUBLESHOOTING
1. HARDSmRTING
2. STARTER OPERATES BUT ENGINE DOES NOTTURN OVER
Checkpoint Trouble Cause Countermeasure
NG Loose battery cab)e terminals NG clean the bat-

Battery and/or retighten
Poor connections due to rusting tery cab一e terminaLs
NG NG
Battery discharged or weak Recha｢9e Or ｢ePl8Ce the battery
NG NG
Fan be(t Loose or broken Adjust or replace the fan belt
OK
NG NG
Starter Defective pinion 9ea｢ Replace the pln10n gear
NG NG Repa汀0｢ rep一ace the magnetic

Defective magnetI'c switch
switch
NG Brush we∂｢ NG Rep一ace the brush and/orthe

Weak brush sprJng brush sprJng
OK
NG Piston, crank bearJng Seizure, NG RepalrOr replace the re一ated

Engine
o｢ other damaョe Parts
172
TROUBLESHOOTING
1. HARD STARTlrUG
3. ENGJNE TURNS OVER BUTDOES NOTSTART
Checkpoht TroubJe Cause Countermeasure
DefectiveengJneStOPmeChanism Replacetheeng[nestop
NG NG
Enginestopmechanism mechanism
controlwireimproper[yadjusted
(JnJJ'nepump) Ad)'ustthecontrorwJ're
NG DefectJ'vefuefcutsoJenoJ-dvaJve NG ReplacethefuelcutsoJenoid
(VEpump) valve
FUEL TS NOT BEING DEuVERED TO THE (NJECT10N PUrV]P
NG NG
Fuel FueJ tank is empty F川thefueZ tank
OK
Repa[r or rep[ace the fueHl'nes

NG CIog9ed or damaged fue川nes NG
Fue一 pIPlng Retighten the fuel h'ne
Loose fuel line connections
connections
OK
NG Fuel fi(ter overfJow valve does NG RepaJr Or replace the fuel fJ'(te[
Fuef filter
not close overfJovv valve
NG RepTace the fue( fi一terelement or

NG fuel fitter element
C(ogged
the fuel fi一ter carl｢id9e
OK
NG NG
Fuel Ai( in the fuel system 別ee° the air from the fue一 system
system
Continued on the next page
173
TROUBLESHOOTJNG
1. HARDSTARTJNG
3. ENG.NE TURNS OVER BUT DOES NOTSTART
FUEL IS BEING DELIVERED TO THE INJECT10N PUMP
Checkpojnt ■什ouble Cause Countermeasure
Continued from the previous page
OK
hjectl'on nozzle injection startfng

NG NG Adjust or repJace the
l'njection
”)'ect]'on nozz[e pressure too row
nozzle
Improper spray condJ'tion
OK
Defective fuel injection nozzle

NG NG
fuel drippage Replace the deJivery
Jnjection pump resultJ'ng I'n after valve
fuel injection
NG Defective inJ'ection pump controf NG Repair or replace the injection

rack ope｢8tion pump control rack
NG NG Replace the injection pump

Jnjection pump plunger worn or
stuck plunger assembly
OK
NG lnjectionpump drive NG RepJace the drive

(VE pump)
shaft J'njectionpump
InjectI'onpump or damage
seizure other shaft
NG Injection pump governor spnng NG Replace the in).ection pump

SelZU｢e governor SPrJng
174
TROUBLESHOOTING
2. UNSTABLE JDLJNG
Checkpoht Trouble Cause Countermeasure
NG NG
Idring system [d=ng the id=ng
JmPrOPerly adjusted Adjust
OK
NG Defective fast id=ng speed NG RepaJr Or replace the fast idling

Fast J'd‖ng speed control device
control device speed control device
OK
NG Accelerator contro一 system NG Adjust the accelerator control

Acce[erator control system
imp｢oper【y System
adjusted
OK
NG NG
Fuel system Fue( system leakage or blockage Repa[r or replace the fuel system
NG NG
AJ-r in the fuel system B!eed the air from the fue( system
NG NG
Water particles J'n the fuel system Changeth白fuel
OK
NG NG Repf ace the fuer fJlter eJement or

Fuel付te｢ Crogged fue( filter e一ement
the fue一 fi一terca｢trid9e
Continued on the next paョe
175
TROUBLESHOOTING
2. UNSTABLE IDLING
Checkpoint Troub一e Cause Countermeasure
Contl'nued from the prevL'ous page
oKi
NG NG Repa[rorrepfacethegovernor
[njectJ-onpump DefectivegovernorJeveroperatron
lever
NG Regu[atorvalveimproper[y NG AdJ'ustorrep)acetheregulator
adjusted(VEpumponJy) valve
NG NG
Brokenplungersprlng RepJacethep[ungerspr-ng
NG NG
WornpFunger ReplacethepJungerassembry
NG NG
Worncamshaft(ln-nlePumPOnly) Replacethecamshaft
NG Wornro[Jertappet(ln-=nepump NG
Replacetherollertappet
on一y)
NG NG
Worncamdisc(VEpumponly) Rep[acethecamdisc
176
TROUBLESHOOT-NG
2. UNSTABLE IDLING
ContJ'nued from the prevf'ous page
OK
NG Va[ve clearance improperly NG

Valve cJearance Ad)Lust the valve clearance
adjusted
OK
BJown out cyIFnder head gasket

Worn cylinder ‖ner
NG NG
Compression pressure PI'ston nng sticking or broken Replace the reTated parts
lmproper seating between the
va)ve and the va[ve seat
177
TROUBLESHOOTJNG
3. 1NSUFFICIENT POWER
CheckpoJ'nt Troub(e Cause Countermeasure
NG NG Clean or rep一ace the air cleane｢

Air c一eaner Clogged air c一eaner e一ement
e一ement
OK
NG NG
Fue一 Water particles in the fue一 Replace the fue(
OK
NG NG Replace thefuef fJ'rter element or

Fuel fnter C[ogged fuel filter element
the fuel futer cartridge
OK
NG NG Repair or replace the fuef feed

Fue一 feed pump Defective fuel feed pump
Pump
OK
NG NG
InJ'ection Replace the injection nozzJe
Jnjection nozzle nozzle sticking
Injectionnozz一e in)'ection startJ'ng

NG NG Adjust or repTace the injection
pressure too low
nozz一e
Improper spray condition
OK
NG Fuel in)'ection pLPeS damaged or NG

Fuel injectionp]pes Rep[ace the fueh'n)'ection pIPeS
obstructed
178
TROUBLESHOOTJNG
3. JNSUFFJCJENT POWER
OK
NG Defectiveregu7atJlngvaZve NG Repa]rorrepracetheregufatJ-ng
Injectionpump (VEpumponfy) vaFve
NG NG
DefectivedeJiveryvaJve Repracethede‖veryvalve
NG NG
Defectl.Vetimer Repairorrep[acethetJ'mer
NG NG
Worncamdisc(VEpumponry) Rep[acethecarndisc
NG NG Adjustorreplacethecontrol
lmpropercontrorleveroperation
Jever
AdjusttheinjectJ'ontiming
NG NG
DefectiveinjectiontI-ming RepalrOrrePlacetheFnjection
pumptimer
NG NG
Weakgovernorspnng Replacethegovernorsprlng
ContJLnued on the next page
179
TROUBLESHOOTING
3. 1NSUF円CIENT POWER
oKf
NG NG
lnJ'ectionpump Wornplunger Replacetheplungerassembly
NG NG
Worncamshaft(ln-=nepumpon[y) Replacethecamshaft
NG Wornronertappet(I什Iinepump NG
RepracetheroIIertappet
only)
NG NG
Worncamdisc(VEpumponry) RepLacethecamdisc
OK
NG BoostercompensatorpIPe NG Replacetheboostercompen-
brokenorcracked SatOrPIPe
Exhaustgasleakagefromthe
NG NG RepaJrOrrePJacethereJated
exhaustsystem
Parts
AJ'rleakagefromtheintakesystem
NG NG Repa(rorreplacethepovverecho
Defectjvepowerechogate
gate
180
TROUBLESHOOTING
3. 肌ISUF円C陀NT POWER
Checkpoint TroubTe Cause Countermeasure
OK
NG NG
Turbocharger Defective turbocharger assembly Replace the turbocharger assembly
OK
B一own out cy=nde｢ head !IaSket

Worn cylinder h'ner
NG NG
Compression pressure Piston or broken Replace
ring sticking the related parts
Jmproper seatJ'ng between the
va一ve and the v∂lve seat
OK
NG Valve c一earance improper一y NG

V8lve c一earance Adjust the vafve clearance
adjusted
OK
NG NG
Va一ve spnng Va[ve sprrng vveak or broken Rep face the valve sprlng
OK
NG NG
Exhaust system Exhaust pipe clogged Cfean the exhaust pipe
OK
NG Open and improper(y set NG Adjust and reseal the

Fun load screw seal adjusthg
adjusting screw sea.
adjusting SCreW
181
TROUBLESHOOTING
4. EXCESSIVE FUEL CONSUMPTION
Checkpoint TroubJe Cause Countermeasure
NG NG Repalr Or ｢ePlace the fue一 system

Fuel system Fuel leakage
｢elated parts
OK
NG NG Clean or replace the air c(eaner

AJ'r c)eaner clogged air cleaner element
elemenl:
OK
NG NG
ld=ng Poorly idring speed Adjustthe id口ng speed
speed adjusted
OK
1njection nozzre hjection starting

NG in)'ection
NG Adjust or replace the
Injection nozzle pressure too row
nozzle
Improper spray condition
OK
NG Fuel injectiontiming LmPrOPer]Y NG

Fuel Adjust the fue( injectl'ontiming
injectiontiming
adjusted
OK
Defective de[ivery va一ve resuJting

NG NG
is fuel drippage fuel Replace the deJive,ry
Injection pump after valve
l'njection
OK
NG Ai‖eakage from the turbocharger NG Repai｢ the turbocharger intake

Tu｢bocha｢ger
intake side side
Continued on the next p89e
182
TROUBLESHOOTJNG
4. EXCESS(VE FUELCONSUMPTION
Checkpoint 1†ouble Cause Countermeasure
ContJ'nued from the previous page
OK
NG NG
Turbocha｢9e｢ Defective turbocharger assembly Replace the turbocharger assemb)y
OK
NG Valve clearance improperly NG

Valve clearance Ad)Lust the valve clearance
adjusted
OK
B[own out cylinder head gasket

Worn Finer
NG
cyh'nder NG
Compression pressure Piston nng sticking or broken Replace the related parts
Jmproper seating between the
valve and the vaJve seat
OK
NG NG
VaTve spnng Va[ve spnng weak or broken F!ep(ace the vaJve spnng
183
TROU8LESHOOTING
5. EXCESSIVE O比CONSUMPT10N
CheckpoI'nt TroubJe Cause Countermeasure
NG Engine ol-1unsu7table NG Rep一ace the engine oH

Engine oil Too much englne OI.I Correctthe engJne Oil vo[ume
OK
NG Oil leakage from the ol'(seat NG Replace the oJ'lsea一 and/or the
Oil sea一 and gasket
the gasket gasket
and/or
OK
NG NG
AT'r breather Clogged af'r breather CJean the air breather
OK
Defective valve seals

Fnlet and exhaust va一ves NG NG Rep(ace the va(ve seals, the
Worn v8lves stems and valve
Valve sea一s varves, and the valve guides
guides
OK
NG Piston nngs worn, broken or NG Replace the piston nngs or

Piston r(ngs
J-mproperly JlnstaJled properJy insta(J
OK
NG Cylinder Lines scored or NG

Cy臼nder [J'ners Replace the cyHnder =ners
WOrn
184
TROUBLESHOOTmG
6. OVERHEATING
NG NG
CooHn9 Water Insufficient coo=ng water Replenish the water
cooJJ'ng
OK
NG NG
Fan coupIJ'ng (ifso ○‖eakage from the fan coup=∩9 Rep face the fan
equJ'pped) coupJing
OK
NG Fan be(I (oose or cracked causing NG

Fan be一t Rep一ace the fan be一t
s‖pp;唱e
OK
NG DefectJ've radiator cap or clogged NG RepJace the or

Radiator radJ'ator cap c(ean
radial:or core the radiator core
OK
NG NG
Water pump Defective water pump RepaJr Or the
rep(ace water pump
OK
Cylinder head
and cylinder body NG Defective sea(ing cap resulting ln NG
RepJace the seaJjng cap
se∂‖n9 Cap water leaka9e
OK
NG NG
Thermostat Defective thermostat Rep一ace the thermostat
185
TROUBLESHOOTJNG
6. OVERHEATING
ContJ'nued from the prevJ'ous page
OK
NG Coo=∩9 System C】099ed by NG Clean the forelgn maten'ar from

Cooling system
fore唱n materia一 the coo(ing system
OK
NG Fue一 J'n)'ection timing JmPrOPerly NG

Fue( J'nJeCtI'on timing Ad)lust the fuel injection tl'ming
adjusted
186
TROUBLESHOOTING
7. WHITE EXHAUSTSMOKE
NG NG
Fue一 Water partic[es l'n the fuel RepJace the fue(
OK
NG NG
Fue( injectiontiml-ng Delayed fu白( in)'ectJ'on tFmlng AdJ'ust the fueJ injection tJlming
OK
BJown out cylinder head gasket

Worn cylinder liner
NG NG
Compressl'on pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the va)ve seat
OK
NG NG
Turbocha｢9er Defective turbocharger Replace the turbocharger
OK
Defective vafve seals

Inlet and exhaustvalves NG NG Rep[ace the va(ve seaJs, the
Worn valves stems and vaJve
Valve seats valves, and the valve guides
guides
OK
NG Piston rln9S WOrn′ broken or NG RepJacethe piston nn9S Or

Piston rl咽S improperly insta[led properJy J'nstalJ
OK
NG Cylinder nnes scored or NG

Cylinder Liners Replace the cyhlnder ”-ners
WOrn
187
TROU8LESHOOTING
8. DARKEXHAUSTSMOKE
NG NG CleanorrepJacetheal'rcreaner
AJ'rcleaner Cloggedaircreanerelement
element
OK
fnjectionnozz]einjectionstarting NG
NG Adjustorreplacetheinjection
1njectionnozzle pressuretoolow
nozz[e
lmproperspraycondition
OK
NG NG
FuelinjectiontimingJmPrOPerJy
Fue[injectiontimhlg AdjustthefuelinjectJLontiming
adjusted
OK
Defectivedeliveryvalveresufting
NG NG
infueldrippageafterfuel Replacetheddiveryvafve
)njectjonpump
Jnjection
NG NG
Excessivehjectionvolume Adjusttheinjectionvolume
188
TROUBLESHOOTING
9. 0[LPRESSURE DOES NOTRISE
NG Lmproper viscosity englne Oil NG Replace the en91ne Oi一

En9ine oi一
Too much eng[ne oi一 Correct the engJne Oil vo(ume
OK
Defective oil pressure gauge or Repa[r or rep一ace the oi[ pres-

OJ'J pressure gauge or unJ't NG NG
unit sure 9aU;】e Or Unit
Oil pressure indicator Light
Defective indl'cator =ght Rep一ace the indic8tO川ght
OK
NG NG Replace the o‖ filter eJement or

Oil fi[ter Clogged oJ'JfL'[tereFement
the ou filter cartridge
OK
NG ReJiefvalve sticking weak NG Rep(ace the

Re[ief by-pass and/or relief valve and/or
valve and valve
by-pass valve sprln9 the by-pass va(ve sprlng
OK
NG NG
Oi一 pump C一ogged oil pump strainer Clean the oil pump strainer
NG NG Rep[ace the
Worn oil pump related
oi[ pump reJated parts
Pa ｢tS
OK
NG NG
Rocker arm shaft Worn rocker arm bushing F!eplace the bushhlg
rocker arm
Continued on the next paョe
189
TROUBLESHOOTtNG
9. OILPRESSURE DOES NOTRISE
Checkpoint Troubfe Cause Countermeasure
OK
NG Worn and NG Rep(ace the camshaft and the

camshaft camshaft
Camshaft
bean'ng camshaft be8rhgs
OK
NG NG Rep(ace the crankshaft

beanngs Worn bea｢ln9S and/or
Crankshaft and c柑nkshaft and
the bearings
190
TROUBLESHOOTING
10. ABNORMALENGINE NOISE
l･ EngJneKnocking
Checkpo]'nt 一打ouble Cause Countermeasure
Checkto see thatthe engine has been thoroughly warmed before beginnJ'ng the troubJeshooting
up procedure.
NG NG
Fuef Fuel unsuI'tab[e RepLace the fuel
OK
NG Fue一 hjection timJ'ng improperly NG

Fuef
(InjectiontimJng Adjust the fuel
J'njectiontllmJng
adjusted
OK
NG ∫mproper injectJ'onnozzle NG
starting Adjust or replace the
l'njection
Injection nozzle
pressure and spray condition nozz一e
OK
NG B一own out head 9aSket NG Repl8Ce the head 9aSket orthe

Compression pressure
Broken piston rln9 pJtStOn ring
2･ GasLeaka9￠Noise
Tightentheexhaustpipe
NG LooseFyconnectedexhaustpipes NG
Exhaustpipes connections
BrokenexhaustpJ'pes
Replacetheexhaustpipes
OK
Rep[acethewashers
lnjectionnozzlesand/orgJow NG Looseinjectionnozz[esand/or NG
TightentheinjectJ'onnozzJes
pfugs g[owp(ugs
and/ortheglowpJugs
Continued on the next pa9e
191
TROUBLESHOOTfNG
10. ABNORMAL ENGINE NOISE
2. GasLeakageNoise
Checkpoint Troub[e Cause Countermeasure
Continued from the prevJ'ous page
OK
NG Loose一y connected exhaust mani- NG TJ'ghten the exhaust

Exhaust maniford
manifoJd fold gfow plugs connections
and/or
OK
NG NG
Cy一inder head 9aSket Damaged cylinder head gasket Rep一ace the cyfhder head gasket
3. ContinuousNoise
NG NG
Fanbert Loosefanbe(t
ReadjustthefanbeLttension
OK
NG NG
Coo[J-ngfan Loosecoo=ngfan Retightenthecoo=ngfan
OK
NG Wornordamagedwaterpump NG
VVaterpumpbearLng Repracethevvaterpumpbeanng
beanng
OK
NG DefectiveaJternatororvacuum NG RepaJrOrrePJacethealternator
AIternatororvacuumpump
Pump orthevacuumpump
OK
NG VarvecJearancel'mproperly NG
Va[vecJearance Adjustthevalvec(earance
adjusted
192
TROUBLESHOOTING
10. ABNORMAL ENGINE NOISE

■
4. SZapplngNoise
Checkpoint TroubTe Cause Countermeasure
NG Valve cJearance improperly NG

VaJve clearance Adjust the valve c一earance
adjusted
OK
NG NG
Rocker arm D∂ma9ed rocker arm Rep一ace the rocker arm
OK
NG NG
FJywheel Loose fZywheeJ bolts Reti9hten the fJywhee=)olts
OK
NG Worn or damaged crankshaft NG Rep一ace the crankshaft the

Crankshaft and thrust bearJngS and/or
and/or thrust bearings thrust bearmgs
OK
Crankshaft and connecting rod NG Worn or d8ma9ed c｢8nkshaft NG Rep一ace the crankshaft and/or the
bearln9S and/or connecting rod bearings connecting rod bearJlngs
OK
Connecting rod bushing and NG Worn or damaged connectJ.ng NG Rep(ace the connectJ'ng rod
piston pJn rod bushing and piston pln hushing piston
and/orthe pf-n
OK
Worn or damaged piston and

NG NG Replace the piston and the
Piston ‖ner cy(in-
and cylinde｢ =ner cy=nder
der Hner
Fo｢elgn materia一 in the cy一inder
193
MEMO
194
SPECIAL TOOL LIST
SECT10N ll
SPECIAL TOOL UST
195
SPECIAL TOOL LIST
SPECIAL TOOL LIST
JTEMNO. JLLUSTRATJON PARTNO. PARTSNAME PAGE
l /ul･ 5-8840-0145-0 MeasurlngDevice 25
2 5-8840-2008-0 CompressionGauge 26
3 5-8531-7001-0 CompressionGaugeAdapter 26
35
4 5-8840-0019-0 S=di.ngHammer
71
/
/A NozzleHotder
5 5-8840-2034-0 35
Remover
匂'i
42
6 9-8523-1423-0 VaZveSpringCompressor
85
旺〆〆
Q
CamshaftTim[ngGear 46
7 5-8840-0086-0
C
Un]'versa[PuJler 64
49
#
8 9-8523-1212-0 ValveGuideRe-placer
50
節
9 5-8840-2313-0 Cy[inderLiner[nstalrer 58
63
10 C3 5-8840-2038-0 CamshaftBear)ngReplacer
64
196
SPECIAL TOOL LJST
rTEMNO. 1LLUSTRATJON PARTNO. PARTSNAME PAGE
I
CrankshaftT盲mingGear
ll 9-8840-2057-0 70
Remover
I-(
CrankshaftTimingGear
12
電霜謎 9-8522-0020-0
(nstaller
70
鶴
CrankshaftPilotBeanng
13 5-8840-2000-0 71
Remover
CrankshaftPiFotBeanng
14 5-8522-0024-0 71
:I lnstaller
15
0 5-8840-2061-0 .CrankshaftFrontOilSea[
JnstaHer
79
J土l ValveStemOi[Seaf
16 5-8840-2033-0 85
lnstaller
■■■
17
匡∋ 5-8840-2304-0 CylinderLinerRemoverAnk[e 56
18
管 9-8523-1169-0 CylinderLinerRemover 56
19 5-8840-2360-0 RearOilSeaIRemover 38
OHSea[lnsta‡ler
20 5-8840-2359-1 98
e9② (AxiaJType)
197
MEMO
198
REPAZR STANDARDS
SECT10N 12
REPAIR STANDARDS
TABLE OF CONTEJqTS
汀EM PAGE
Generalrdes......”.”””..””...”..”...”.””..”””.”..,.........””....”....”.”....”199
Repairstandardschart
‥…‥‥‥‥…=…...”…‥………‥‥…‥‥….=……‥‥‥‥……‥‥….200
Genera一 Ru∫卓s
1･ Thesetab[es provide diese一 engine,･

standards relating the repaJr Ofthefol[owing
ModeJ A-4JG1
2･ These RepairStandards are based on inspection items, togetherwith dimensions,

assembly standards,
limit values, and repalr Procedures.
(1) Nominal dimensions arethe standard production values.
(2) Assembly standards considered to be the values used as during the
objectives assemb)y
procedures which foHow repafrS･･ aS a result, they may be somewhat at van'ance with the assembly
dimensions ofa new eng[ne.
(3) Limitvalues referto the measured vaJues resulting from wear, etc., beyond a must
which part not
be Jf a measured value fans beyond the ‥mit value, the part involved be repaired
used･ must or
｢eplaced.
(4) 'IRepair Procedures” indicates repair methods.
normaf
(5) Unless otherwise the unit of numerical in tables be taken to to
stated, values should refer
m=imeters′ mm (in).
3. Explanation of Terms Used inTables

''wear”
(1) The dimension of refers to the dJ'fference between the dimensions of a part which is not
worn (orthe ``nomina[ dimension” of a
partwithout wear) and the dimension of the part suffering
from the most wear (the dimensl'on of the vvorn part).
(2) Uneven wear meansthe difference between the maximum and minimum wearvarues.
41 When repaJrS are requested on the overall engJne･ first perform bench tests to determine what parts
require repalrS･ then perform the minimum disassembry and repafrS required to correct the problems.
When repalrS On a Part are tO be in reference
specific englne requested, repalrS made to the relevant
items in accordancewith the repair standards [isted in this manuaL
199
REPAIR STANDARDS
I ∽
⊂ L
○ ≡
i_
○
3ぎ tて)
旨喜萱g
′■■ヽ
+∼
∽ Nてコ a)a) C)∼
＋一
a)て)⊂ CL〔 .⊆き->c;
⊂
也)
⊂むq) C)コ ⊂誤写
a ⊂u)
.?J3S註召
嘗邑芸書
E
卦菖
●8)詔
蓋喜暮雲
≡
O 忘,盟 [卜･
U ∈cQ'
重苦星空篭 ⊂】n⊂⊂
也)
zg空夢＋Jq)
竺諾占
＋J
∽
コ
ヰ･J
(〟
+
○
L
≡
+
⊃
妄5-&董
コ (ロ
て】て】 ⊂ ≡ 1
a) ⊂ 0 ■ヽ C)
応 +
O q)
I一一
○ + U
盲召
4L
a_
_c)2 .賀=
竜骨
馳
コC)
+ .巴-
○⊂
1
何 C〕C) 左記嘗BO euoE
也) 詔.t= c)ど
q)a
ぷB
+也)
CE: (ロ(ロ En ーL
のn Oc)
E5LO ∽.0 zo.DQ)
3CLB･!･m9 ,Jg旨
Lo一一
■ー■
”
一-■■.
求㌔
.ヒ
3恵
O
寸
⊂)
⊂)
絹吊sco
.巨
_J N
}
▼■■}■ N
芸d O⊂; ー
V
コ J■■ー {
の N
言>76 OM
r⊂〉
O∽
Ou)
■一■■■ヽ
富岳
遷毒
o'? ーc;_4)
L
JO
go
ヽ■_■■
⊂〉l
⊂〉
＋一
} く:〉
∽
⊂:
寸
76.E2
′l-l
●一■■■-･
▼￣
⊂∽ 寸寸求演 Ln(【〉
0)Ln
'g旨 O寸
･､
⊂)
⊂)
O
⊂) ･r｢
Mr ▼■■- Y-
M
} .空M
⊂)ー一`
zo芸
== _=
■ー
,⊂: q)
∽
a
コ ⊃･ロ)
∽
1
ヽ､ヽー
【ロ N
a
L
≡
一口
⊂
0 ⊂⊃
<
≧ 豊
ロ)
E p∼-
也) 上
C) a. O ”)ヽ･-
蔓NOL
a.-￣一
L5o篭
＋J くロ
≡
嘗蛋
q･-
⊂ コ L
○ ∽ 4)
(ロ
.喜≦
⊂
∽ ⊂:
ち O CL ∈
①
a.
q)
L
a
O
-a
1
U
豆召J J
コ
”
∽ Lコ
E ○ O ＋J
.萱+
4)∽
E ■■J
⊂ し) ○ ∽
○ コロ) ⊂O3< q)
a)
O 帆 ⊂ ■●-■ヽ＋J
_...C) O _〔】
L
⊂ q)
⊂≡
＋J +
+
C) (ロ也 L
O ○ a
て) O U てココ
+ i- ∽
⊂ `こ q ⊂
q) く乃
= 也)
.Q C) ⊂ q)
> ココ >
き
+
U LL + J U a.
Q)亡也)
岳Lq
青書喜
^pogJaPu‖^〇
Zち
盲選言
>
++
昔S, ^po日au16uヨ
∑届 .F
U
200
REPAIR STANDARDS
tS 巴8
Ra?
誘雀
∽
芝電
〟
Q)寸
三岳毒
⊂
a)
E
U
○
≡ 冒.!芸
む∽コ
星盲
Lロ.
三石B 也)”
>Q至uJX 苦言
L
＋J
(ロ ○
q)
也) q) +
+ ∽
付
コ .ロ
書3
4) 1
'O
也) 0
L
O t: ,2
q
=上
○ >
C)
盲点
L
∽
EL
･≡富
⊂ .J=
＋J
.妻
L
c3UE
音p訂
(ロ a)
CL O L Lq)
+
(ロ ●■-■L
也) (でQ) (ロ
CE: .itO)_NO
空言き
a
a
也) Cユ
CE:
,rol･嘗
L
.JVmen
■■■￣■■■ ■-■■■
′■-I ■■ヽ一-ヽ
J'^
∩ 卜､ α) CO OO
司書
.∼_
∼ LL)
E o'○
I-o' rIC2O cJC2⊂〕ぐJq⊂) c;○⊂) ⊂)
+ ヽ■.1...■■′
} } } ーー
T￣
C)
コ LL) ▼￣ a) ′一ヽ
く亡〉 -U ∼ N
主要 O一-.
q)
:P苗
q)
冨r= 冒詔 8設
毒害雷
一一■■.
遷喜 ∽N ∽卜､く⊂)
貞B
遍毒
o'R
o,S忘
ー′
.1一⊂)
ヱ貞写生吋⊂〉
苫旨 g旨 }
◆J
也)
⊂
(ロ
+= _st:≡
⊂ー
,⊂:､-■一
LJJ
⊂) ⊂)
×
∽
u+
雪･:BO
■巨忘
芸芸
′-■■ヽ
-てコ ∽
lE)
L 1
ヽ､
< a
ロ)
N
てコ
(∈j3 O-
iJ
(ロ
⊂ L∼-
⊂
⊂
選巨
q) コこ>
く乃コ ⊂lコ)
≡ o>ぎ O
d)
ーl
Er)= ①
>
ti-｡--
○= E 'E皇
一口 ∽コ mO3 a_
'D
盲≡-魂
⊂ >
警EO
) J上
O O ∽
th
ヰ■J .⊂ q)
豊誓言<些妄宣言
ーヽ■■一 ●4I-
くJ .t: ⊂ ･∼
C) ≧ (ロ也)
a .空d3
I-U L
∽ J=
＋･J ･uq_” ≡ コ
⊂: てコ ⊂+ 叫-I ∽
∽
qc) O
lき q)
d) L
量重曹
＋J CL
誓遷
O ∫
L■
(ウ
ヰ･J O
◆･J
⊂ くロ
○
U 芳m= ≧
①亡
喜ELn
ZL6 ,-!芸}豊玉岩音蔦喜 peaHJaPu!J^○
+ど
音v& ^po日au!6u]
∑7;
U
201
REPAIR STANDARDS
⊂む
て)
也)
J=
O
∽
音鰯
＋J
⊂
A)
毒苫
E き:
也)0
E
宣言
○
U
q)
+
コ L
⊂
てフ ⊂) a L L ∽
C) O ○ 伯
U ⊂ ⊂
”) 帆
〔)
L ＋J
⊂) ○
＋一ロ) CD ≧
∽ ∽ ⊂ ⊂ α)
CL ＋J
a `= 一= ⊂
L a.⊆
Q) C) (D ①
(ウ c)1 C) O
O U O
a_
q) 諾5 一口【ロ (ロ ⊂)
∼
【エ:
S･.g CL
,fPO5 a
(D
CL
q) .B2O5
計.q
rー
C)
on.ち
＋■l
仁:CL EE: CZ:a 凸: D: CE:a <
串言 Cr)
′■■ヽ
′■■ー一■■ー′■■ヽ
ごヒ M卜･
t9.≡軍書軍書
LE)LO
≡ mm
∩
Tic?⊂〉 Oo 0⊂⊃ Oo
J ー } ーヽ■■■■
.空.I:
⊂〕ー
三言
′■■ヽ. ′-■･ヽ ′一ー {
C) (D ⊂)く⊂〉也
■-lヽ
{ { ▼￣一ー■
寸 ∼
コ卜･⊂〉 ⊂)00 ⊂) ⊂)LL) ⊂)” ⊂〉N
l妻∽TeOm ⊂)M Lnt■■￣ NN Ln一.I LL){ M⊂) Ol`=〉卜､⊂)
言空 a)'宍C!○
r⊂〉
琵琶
′-■･ヽ
⊂)⊂) M⊂) LL)⊂) drL･. I-･⊂) く⊃O ⊂〉⊂)

J門 m'耳くロCq
”(ロ⊂)⊂〉 ⊂)⊂) Mt- ⊂)⊂〉 ⊂〉⊂) ⊂)⊂) NN ▼■■■■■￣T￣ J.I)tn ⊂〉⊂) く⊃O ⊂>⊂⊃
I I( ll lI ll ll ]J ll lI ll ll rl
粘
卜､(D ⊂)r OLL) ON
寸N
⊂)⊂)
LE)寸
O)CO
⊂)CO
NO
トーLL)
mr 琵琶 LL)r rr
I-∼
寸< のM LL)⊂⊃
⊂〉N
mt-
⊂)⊂) Cr)” ヽ■lllll■■■
O⊂) O⊂⊃ OO
<5毒
q o'⊂モ c5q c;⊂) r･･} r--一一
O⊂⊃
＋一 oO. 寸O? ⊂〉 ⊂〉 ⊂) o⊂モ ⊂〉q
∽ O ⊂) m▼￣
l- } ー ⊂〉 }
⊂)
ヽ■■′■ ー ■■-
} }
⊂
O.∼
'6.望
⊂∽
-E-a,C 畠呂
EE;CY
芸芸 a-=
′一ーロ) 訊 O) ロ) ロ) C)
【: ⊂ ⊂ ⊂ ⊂ ⊂ ⊂
●■llllll■
+ + L + + i
くロ ⊂
⊂ ⊂ CT) ⊂ ⊂ ロ) ⊂ O)
Q)rT O O 0
UN a) ⊂ ⊂ ⊂
＋J＋'-￣
で.2 小J1￣＋J●-
･u.望
≡.壷
(ロー + '= ■こ:
0
E
也)
J⊂
⊂ -w望 N=冨+
a
L
1
○ -m冨ゝ_
a
+
(ユ.
○ -w望兵器 +
1
L
1
○
E ∈ ≡ E E E
適量真
＋J a.
⊂ ⊂ 0 ○ ○ ○ 0 ○
0 U O U O U ⊂
○ ○
0
=F[ ＋J
◆J ∽ 's
O
q) 旨B 1 a
(ロ
J■■■■■
lヰ･･･
O)
⊂
何
＋J
a てJ ⊂
毒.萱
O
∽ ⊂ u .上∠ 0
⊂ 【ロ
}
6;Q) ■⊂
ロつ ≡ ._⊂
,■ヒ ○
也)の ⊂① ⊂ ⊂ むn'=
oO
l■llllll■
【ユ.
⊂n ■己2 1 CE: ⊂
○
(ロ
⊂: ロ)
巴Q) ⊂和 ⊂
O U)
○
d3てI
也)(ロ
B旨＋J
∽
＋J
∽ 【:
ロ)
⊂
∽q)
■￣-
(D
--i
a: DL_ ト Uエl'=ロ)
_g蓋喜書
Uロ) Lu 【⊂
d3亡
岳a: SuOIS!d 6u!臼uOIS!cF

z盲
>
++
含蓄
≡盲
slJed6u!1eJE)dou!e州
202
REPAIR STANDARDS
C)
O
(ロ
∽Lt:
L
ヒ誘
.!'喜
の
G)吉
＋J
⊂ =n芯
① B2
E ∼o'妻 ⊂+=
誉ぷ
(ロ＋J
E
U
0
至.=o'
(OL
tjQ)a)1
ED+
＋Jの
g眉
∽丁-
rE).
蓋zo
DOg音量
5巴
＋･J
○
⊂
帆
く乃
L
5LC,
⊂ (ロむ
'j=一口 D) .j=屯
品ちB 旦4,U
(ウ
UO ⊂
C3 O
L_ '= ⊂∽n･
コ .巴c)
0.上∠
∽
ロ)
(ロ (⊃,if
一亡
てコ
a)
LIB.tf ⊂ A) (ロ o髭巴邑空芸
ロつ ⊥凸ロ)
冨≡嘉
U 'ヽl＋- L .⊂ Iヽ
め
⊂ ⊂
O 王2c) (ロ＋一
”) .⊂oむ
盲至芸
..さ∠ +
I_ L■ q⊃
L 一章LG'で (ロコ
L
⊂
一口
(ロ
音■を喜
く乃 .⊂】
I_
C) + C)
也) .⊂
＋J O
宏邑宅
望豊玉
.【コ ∼ .⊂l
rO
む V a) C) q)
a
●至召
蓋毒盲
U O O O U
C)
5O星空
” (ロ q)∽ (ロ (ロ【ロ
EE:
CL a て】コ a a. iユ.
空言書
a) q) ⊂む C) q) C〕
【こ亡E: =),D n: α:
Bv苫gL 亡:
■-■ ■■l■l■ll■■
4'J■】ヽ ■■一■ヽ ′■ー一-■
＋J Ln ” ∝) t■■■ 0)
琶巨
I- T- I-
⊂〉⊂〉 r⊂) mt- ⊂)⊂) ▼-⊂)

+ d⊂モ o'q ⊂) c;C? dC? o'q
O
}
⊂>c; l■■■■■
ー }
⊂> ⊂)
ー
O
一■■ヽ
J■ー
q) LE)
コく.D
MN { くロN
>.一石 (D⊂〉 ∼ て凸O
云> ⊂)(=〉 ′■ー
⊂〉O
:qB
G)
⊂)⊂〉 ⊂)” ⊂)O
遷毒
ll r⊂) ー
J(
r-N
d? O)r
mr
⊂〉く⊃
⊂)
} g旨 Nr
⊂)⊂)
⊂)
(/)
＋･J
o-早⊂〉 dC?
⊂〉
ー■′ }
一-■l■
亡D
⊂
l.∩
-g.呂卜､
N E2雷
'E忘
ヽ-
○ 占C?
rヽ
(ロ岩巴
zo･aE ⊂⊃
ロ)
⊂
'= ⊂
ロ) > (ウ CL
E ⊂
忘.5<
何
忘.冒. ＋J a)
a) `= CL コ ∫)
●J
勺くロむL- o⊂
ロ) O
て)
毒眉毒召g
⊂ q〉 ⊂ 'C; ⊂
⊂ +
J】 ⊂ O
0 -≡ コ L
コ ⊂ q) L
'P O てコ rロ
忘妄言
･D･ロ O)
U ￣■つ a. ⊂ 4) ヰごギ
4)⊂ + C
q) 可 Oくロ J=0 ” (ロ (ロ
∽ ∼ 'P
冨'ip
1 += 4)
-■-
⊂__ .=
蔓≡雪息≡召旨∈
”) (ウ∽ の ∽
(ウ(ウロ)
⊂ ⊂+
Bo書
,if .ゝ亡
⊃て)
i.C) ⊂ ⊂ ロ) 旨⊂●=
芸窒息冨
(ロ (ロ ⊂
a)コ ⊂ Q)⊂巧
OQ. O L L
｢∽ tj.9. ｢⊃ U U D=
-uooB
c)亡
岳￡叫eLJSlue+〇 spo臼6u!l〇auuOO
Zち
Lご
音vg, slJed6u!leJadou!e州
≡盲
U
203
REPAIR STANDARDS
て】
§宣
OJ】
董卓
J⊂
∽
.亡品=?
き⊂
一トJ
⊂
￠也)○
∈ L=-･･
no冨
＋･J
善書喜
ぐロの
0
≡ O'u-
7;ど
2琵
書芸
U
一E5n
昔喜
C)+=CD
if§
裏書妻
トo B呈
+
てフ
0 【=
0
a) ○ a i_
+ 【ユ.節 + ロ)
コ
O ⊂
て】
O
王5 ロ) ◆J
C)
O
a)
O
#
(ロロ)
'F
rロ
'妻■喜 U
くJ ⊂ (で (ロ ⊂ J=
① .⊂ く乃
○ ∽ '=
L J⊂ ⊂ a CL
星書
Dl ”) ⊂ a) 0 ≡ (ロ ∈
+ ⊃ 0 L ー吋也) (ロ
J〕 O L I_ O O
くロ .工】
O ○ 色) C) 也
① C)
1
q) 8ち O
(で
O
くっ
+ O
(ロ
O
吋
くJ
(ウ
DE
(ロ(ウ .t=
t訂何
一己= CL a a 1 CL
q)
a CL
q) a) 也也) 也) 4)
遥8 〔Z: CE: lエ: 凸:: α: ⊂亡亡亡
′■■■ ′■■ヽ
⊂)
ノーヽ一ー■ ′■■■■
く0-ー
′■■ヽ
∞ 卜･
LOO N寸
賀og 司≡ 竿… 賀≡ dO.
.tf
≡ Mr r⊂〉
+ OoL
`■-■■J
c;q ⊂) ⊂)d
ー
Oo'
}
Oo
ー
I
⊂)
ー
<oi冨
■
(ロr
}
⊂】
}
■■■■■
l^
a) ノ■ヽ ′■ー
LOLL)
○:)
コトト
OO
司…弓z3 準星
′-■ヽ ■■■■ヽ
>￣石 N⊂⊃ N ∼ の(∫)

云> ⊂)⊂〉
⊂⊃⊂〉 ⊂⊃c; 弓設 Od
o3O?
寸t-
遷毒
Il Il ⊂).壁 ⊂〉,望
}
Jz ll
ー
COM LL?M
＋J
O⊂〉
⊂〉⊂) 堅rlogLo
.⊂) ⊂)
g旨
⊂〉
呂喜寸く亡)
CT)(D
Oo' ⊂⊃o' cr)'0?
∽ c;q 寸r
⊂)
ー
ーー
ー
⊂
76.9
⊂∽
訳富宗奮宗奮
'E一忘 dC2 dC? Q'o).
b一巴 E5ニ a-ニ
zo･B A) a)
ロつ
=o盲
⊂
⊂
て)
⊂ ●= LC'盲
lug で∈
L
(ウ
(ロて) O
≡ 1 ⊂可
忘呂忘呂
a)
＋J ⊂⊂
+ピ q)ロ)
A)⊂
也)
.工】
5> (ロ =r■￣ =r￣
き忘.E'
￠)L
【:
竜Bn
て】
召五
(ロL くロL
貞萱長NC' P5
⊂ 0 q)
岳旦
+
>
喜∈旦
○ L
L￣ロ rO
'P q)
U 1コ) ⊂ ･凸て) q)
○
⊃ Q)⊂ き
2?･邑
q) ＋J ＋J∽ O(ロ
LS⊂
nB雪盲 B昔
1 ⊂._
てコ
”)
⊂
岩●変 ⊂ 召亘 (ロ
⊂
和(ロ
の
⊂
⊂￠ C)76 L
旨E L■
蓋･2
⊂'O ココ
C)コ
○⊂ ○ O
Uコ .P完
【□CL ｢ E5.9. ｢
uB慧皇
u!雪盲
a)亡
量宅 spoヒI6u!1〇auuOO 対eLJSLueつ
+と･
昔旨 sIJed6u暮IeJadouT.e州
≡7S
U
204
REPAIR STANDARDS
IO
⊂聖
○■蒜
∽
＋一
喜Le-
⊂ ≧o
q)
a.･凸
E
U
E
O 軍um=○∽
.⊆∈
≡3
q) q)
+ ＋一
コくロ
ヰゴ ■亡
'C; (ロ (ロ a
q)
I-〟
U .⊂ _⊂
∽ の ∽
O
コ
+
≡ E +
a_ q CE)
L O O +=
＋･J
(ロ也) 4) a)
U O O
a.
(ロくっ (ロ
q)
【E: 【1 a 1
q) 也) ①
CE: a: 凸:
■ー■
′､
,i:
≡ 軍書
r-I 買言司og
コ ○⊂; Oo'
寸= ー }
q) ′■■ヽ
コ ■-■■■
寸
CO 寸寸
書>76 ⊂) r-O
I-⊂)
≡選 ⊂⊃⊂〉
届書
l[
ー+
NO LL)N
O O⊂)
●･J O dCZ
∽ ⊂)
-′
⊂
-”.望
⊂∽
'E忘軍曹
等土
zo削
E
q)
＋J
=式
⊂
O
.I- >
(ロ
U ＋一
q) コ 1
CL O
∽ ⊂ て】
⊂ コ ⊂
i1 i_ 也)
.J=
ロつ #
■亡
(ロ (ロ
a)
.J= _⊂
∽ ,=
帆
≡ ≡ E
(ロ吋 (ウ
U U U
a)亡
岳a: 叫eLZSuJeつ
Z15
>
LL
.R邑
(ロq)
sリed6u!1eJadou!E2州
∑忘
U
205
REPAIR STANDARDS
E
⊂
B∽ a)･-
(乃⊂ >u) q〕
コ
雪ew
”)
＋･J
⊂
也)
B:a o1
【ロ
>
E
∈
≡邑
Ld) 'i完
＋Jて】 a)
O
⊂
O コq) 也)
∽L- >Q) L
U q)
(ロ..⊂ ￣己ヨー
q)十J ①
∑7; %孟 ∝
L
+
也) L
① 也)
L 0
コ
'U
む
召竜 qロ) 苫音
匂ロ)
ロ)
⊂ L
O ① C)
J=
巷毒
上∠
巷毒
O > ∽ O
L
コ
(ロ
CL
> 2#
_⊂)
C) C) 也)”
.ヒ
吋
1
O
一口
ei孟 8孟 O O_⊂
(ロ(刀
呈2V
昔2: 夏雲A,n巨
a)
CE: CL
む
α:: 【こくロ
EEC'買江:>
′■■･■ ′■ー{
め-∼ ′■■■■
” ⊂〉CO ■■■■ヽ
＋■′
寸 =O)0)
■-l■
CO
一■■･■
＋･J CON CO 帆 CO LL)∼

LL)の O O
l∈ r<2
N⊂) NO
⊂〉
宍聖ー
▼■■￣
⊂)
N⊂〉
d⊂!
【ロCO寸
,三
+ dCr! c;C2⊂) o'⊂モ
⊂)
}
▼￣￣ N!3 N
ー
Ln
て)
< ⊂〉 t5空orT
a-望
} ー
} }
■■■■■■■
CO
▼■■■ 寸 ”
一■ー {
韓罵声
■■-∼
CO ∞ N
■-ヽ.
r･･･■N (工〉M ⊂〉CO

ト⊂) 0)⊂> ⊂)寸
g弓
′■■■ヽ
′■￣■
ト LL) ■一■一ヽ
卜･rr) トm O⊂) ⊂)⊂) ■■■■■ヽ
ト 0).■卜･
_>｢コ
■■-■■ヽ
∝) ⊂) ⊂〉
d⊂)
■■
lo'
盲点B ld
等[ 岩l
00
lL
O⊂〉
I[
N⊂)
O⊂)
⊂)
■-
⊂〉
}
寸聖
L∫)0)
軍害 Jl n5rO I
⊂
也)(ロ
のの 0)00 O?LL) 寸Ln ⊂〉C2 の O
NLn･ Ool
E5よト
B男> m▼￣く.DN ⊂) ト ” N ヽ■■■■
の寸
r<f3 r==
om
ー I }
⊂)O O⊂〉 ⊂)⊂)
占門占m. dC!
r■ r￣
c6卜:
o'q ⊂〉 r⊂) }
占望 a-望 ⊂〉
ー
⊂)
ー
■ヽ-
■-■
一■■ー ■■l■ヽ
⊂ N N ′■ヽ
(P
13.9 r r■
望B
■-■l
O)
⊂∽. 03LD LO LL)
▲丁￣
Z 〉く O
▼一■
'E忘 ⊂〉ヽ-■■′
qm
l-J LIJ
} } IV
O ⊂) ド
C)望 LL?呂
墨書
I
a)
∩ ∩ ▼■￣
▼￣ T￣
寸
〟
∽
＋J
コ
q) (ロ E ≡
也) C)
≡ E
■■■■ヽ
⊂ J･J
'tコ .王=
× ∽
q)
.≧ rロコ u+ コ E
> 一っ) (ロ L_
＋J rO
.≧
” ∽ 4) O .j=
〉く L
> 之
1_二棚c6
＋J
コ
E +
付てコ
a) q)
潔
(ロ＋一 q
d) C) .1
＋J q) > O i_
I
-⊂ 〉ゝゝ
× ＋･J ○ (ロ
⊂
L
(ちき ⊂q)
0 ⊂ a) +
q〕
至嘗書雪
一￣てコ q)
○ a) E ⊂ き
毒萱 FRrltlll
⊂ i=
｢F
O
也)
き q)
＋J
∽
喜'a a)
￠
.⊂
ヽ■J■■
也
a)ロつ
q)⊂
t亡
(ウ
≡ 主_S B遥 ⊂
鳥篭
■l･･J U
CL
め 4) q) O 2｢コ【⊃) O ⊂ .⊂
∽
B葵 B孟
●一 > ⊂ ＋J
⊂ q
nB
∽
空室苫屋宰
■⊂: q) (ロ
a)
(ロト
⊂
L
【ロ ≡
> L
空言
∽
書芸賀冨
q) a) 【ロ
∽
＋J ￠ U
.≧
一口の L'-
q) ＋一打￠
L
⊂
U L_
> コ 4)> LL a)
L L
tO c)5 .+=c)て) む冨 +.ど 1
●J
q) ①てさヱo l●l■-I-J- U
C)o
空旦
,=
芸名 E5芯豊島盲
〉く ○
⊂ But,Jd ∂∧ e∧
>Q蓋 ⊂⊂
uB-:
uJ
_=忘
①亡
岳疋 Sa^lP∧
zち
>
+し
音So, LualS^sa^le∧
∑忘
U
206
REPAIR STANDARDS
〔巴
∽
＋一
.t=Q'=
奄壱
⊂
C)
≡ 旨完
E
○ 76∈
U
S3∈
nO
∽Lt:
也)
+
:⊃
て】
O ＋+ ＋J
O 也) 也)
O CL a
L_ CL 1
EL 【ロ rロ
＋J -■■J
+
C) C)
和 O O
a (ロくロ
CE: 1 a
a) q)
a: 凸::
′-ヽ
′■■■.
O)
⊂〉M LLIO)
.tt
O?⊂〉
E r⊂〉
NLn.
+ dO
⊂) T￣⊂) }
ー
I-■
O)r￣
Cr)r
′■ll■■
_>,o ∼ rJLQ
盲点3V
a)⊂【t)
Mr-
⊂)⊂)
丁････⊂)
ll
c;q O ト⊂〉
設∼n3> } Cr)r
<∽
rjLE2
t￣⊂⊃
ー
⊂
局.望
i=く乃
'巨忘
zoz5E
q) 亡:
･P O
A)
＋J :t=
≡ q) E てコ
CL (ロ
C) ⊂
ナJ
【1 0
てコ
(ロ O
⊂ I-∫ ●J
◆･J
O ⊂ ￣コ
○
●■lllll■l
◆･J
q) C)
O
q)
q) E
毒舌
1 a)
+
⊂ 0
ぐロ
言B
L
① (”
き ⊂
⊂- ＋J (ロ
也)
巴u> q)
1 O
遥召 CL
くロ
L
U和ト <
a)亡
+OueaP
岳LD 19dde⊥
+!∀
Zt6
>
L+
LualS^s LualS^s
.9.a
(ロ4)
a^le^ 8qeluf
≡盲
U
207
REPAIR STANDARDS
∽
＋-∫
⊂
(D
E
≡
O
U
q) i
L 也)
コ > ヰ･J
てコ q)
⊂) (D O
也) 0 ∽ 【ロ
O L L
0 ○ a
L ○
L_
＋一 C)
L ○
L
+
O L +
ヰ■J
C) O 也
e3LO
(ウ
O L O
a
(ロ (ロ
a) (ロ
α: -Qc)I
n⊂ a a a
a)和 q) q) C)
亡:> ∝ 【⊂ ∝
′-･ヽ ■■■ヽ
′■ヽ
′■■■■
Jヒ
冨寧軍書司og 軍≡ ∩
E t■￣■
rN Oo' Oo'
ー ○⊂;
.J ー I- ヽ■■■′
ノへ
① く工) ■一-■■■■■
:コ ∼. ′■■ヽ
r
ト⊂) (D トr
>￣亮
冒s雷
′-■･■
⊂)⊂〉 NO
云>
弓拐
甘LF)勺･
亡D<くロ ⊂〕⊂) O⊂)
遷毒
llJ l( ⊂).聖
l■■■■■
Il !lI
N∝〉 ⊂)OO
宍巴等ーー
⊂⊃⊂) きoL I
N⊂〉
olq
冨買･蔓
- c;冒 ⊂)
⊂)
∽ ⊂〉
}
ヽ■一′
⊂
局.9
⊂∽
'E忘
zee;E
′一■ヽ ′■■■■■
′■ー●■■￣ ⊂_A____
∫-■〔 ∽
∈邑 E L 凸.
ヽ･ヽ
也)
a) ⊃
請
-rヽ
> ヰ･一
U
⊂ て) i=
一石E
【ロ ○ ′-■l■
≡ rロ)
､■一一.ユ∠
(ロ
也) d3
.エ】
1
∽
a
○
0
.⊆豊
[望
rロ
CD
O
C)
＋J
c)●■-￣
i.くっ
U ⊂ E ト正 ◆一
}･･(ロ
L_ (ロ ⊃ C) OLL
:⊃L
雪zsNhFEu?
L
⊂ ∽+さ∠ 也 a. ロ)
付 a dl.&
0 u) > +
む ⊂
O
ヰー
O
也)
L O O q) E コ
也)
望ぎ
(ウ
a) 1
てコ 0 て】
a.
⊂ ⊂ aC) L
∽ ○ (ロ (ロ 'Q
邑76
豊善書蓋冨
⊂ ⊂ >
ロ) L >
.a 【ロ CDt>
⊂ ○
てコ ⊂q)
∈≡
ヰJ
＋･J ⊂ ロ) ■■■■■J■■■￣
○ ⊂
(ロ
U
+
ヽ
和
ロ)
玉奄
旨冒邑買電
L
'= q) L> ⊃L
○ ロ)
,a
コ
⊂
くロ
＋-∫
B召 ○ ロ)a)
＋J
+ > 〔Z: U伯 EL-I--I---■-I U 【こiF
a)ど
aJnSSaJd
岳￡ I..0 a^Je∧1a![a臼PuedLund川0+al[!‖!0
z75
Lと
%S, uJ∂lS^s6u!1e3!+qn1
≡忘
U
208
REPAIR STANDARDS
ヒち
芯巴
一一■･■
Z ＋J L q)
CO
O) 岩oc a
帆､ー
∼
∼
⊂
J〕
巨･⊆ a)
① c).盟ロ)
3C? 'U
≡ O ∼ 吉 ⊂
●=
⊂ N
≡ ヒ
8･B巴
}
C)
O + ヽトーロ
U U
蓋ぎ盲
Nq
CL a)
也) Q.
･._.. ド q) ∝ ○
∽ ￠
葺葛≡
①
L
コ
て】
a)
･= EIp (D
U
号音SI
rt:
U
0 a
昔著書
L Q〕
a_ L_
L L
0
(ロ q) Q)
U ヰ･J J U
CL
LO毒害 ∽
(ロ rO
q) の 4) > コ一口
CE: a a. CLて】 1 a
q) こす q) C)
正 < CE: 【⊂
cEC'.冒,DO
{
O)
Jヒ
rlB
⊂〉 ⊂)
.巨
+
ー
⊂)
C) N
コ r 一■■ヽ
′-■･ヽ
∪_
LE) ｢ヽ
言要 M
r
⊂〉
⊂) fj a
寸 S) gr)
勺･ 0〕 u
■l■■■ヽ
y一
⊂〉
旨冨
CO r
l l (
岳琵
⊂〉
I I
I- l
M CO
∞㌫ ⊂〉 (D ー
<忘 c;I ⊂⊃
∝)卜､
▼■■■■■
●■･J ⊂) ー
ー
∽ ⊂)
ー
【:
局.9 ′-■■
⊂ ∽ u計
.巨忘岳声
茎･c,E ■■_-
一一-■
⊂
⊂ L
'E L[ q) u)
空[
}
+
L_ q)
q) ⊃ q)
≡ コ
∼
(1
■■■- ●
ヽ
i: I
≡ L
(ロ
CL巴
音 0
L_
(ロ .±ご
ざ巴 ≧
_【: ロ)
α)
a. Js ロ)
,t,a
+
O ∽
2 C) ⊂ ⊂
≡
-ヽ
a ∽
∈ L>
ロ) LILL- 4) ロ) I ■■■■ ll■■-
o
ロ)
≡ ⊂
悪運
d) ⊂
L
q) a)
紬喜
J一 EL LF+ .j= m
岩32
＋J
●こコ
⊂ O
⊂ (ウ 1
0 4)
旨冨 q) H u
'=
U
J3
= 一--
芸ジ聖 ⊂
q) JJ くゎ
a
0
_0
○
てコ ⊂
､ ◆J
⊂
l
q)
芸盲
墨書
書書芸
q) ⊂
如意
【ロ
a
∽
A 0
￠
コ ≡
2盲
I- 一一一 C)
＋一1
⊂
夏空
n3
I_
ロ)
む 1 ⊂ 右B 重雪
∽ q)
O cL ∽ a)
L
＋J 0
0
重量萱
至芸
一￣
要望
星章芦
旨.19
eg星
空召
B電 a
∈
コ
CL
-■■■■■■一■---I
⊂t=
の
u_
q)
て)
:{ E
-一-
の
⊂
-
n
①
∈冨
声量
=P品
I-
'6 E
コ(ウ
L+ てコ
(ロ
a)亡
岳n_” t4-o
dun° +∂1e州 '〇18 J6u!d!d
≡
>､
+ L■
昔S, LU81S^s 6u‖ooつ UJE)1S^s 一an+

∑7G
U
209
REPAIR STANDARDS
a)I
_ゝ:＋J
U
q)
+= _='E6
∽
･トJ
買巨
⊂ Q)O
!o毒書萱
a)
≡
墨B=毒
喜書董.i芸mgv皇
≡
O
.盟_>き
U
ヒ.望LQ)
D=S長2L3
著書著書
q)
L
コ
て〕 ∽ q)
L一
C) ロ)
コ
U ⊂ ＋J
O +
'= 一口
L_
○
L I-∫
C〕
(ロ
≡
L
○ L
L_ ⊥】 (ロ
Et]
也) a) 4) C3 Q)
CL + O U + U + くJ U L
･E'冨雪盲
q) rロ Et] (ロ (ロ C3
伯くっ rO 一口
【こ
蓋書芸竜
a 1 a a 1 1 a CL (1
(D 0 也) C) q) a) q) C) C)
α: 【亡【⊂: CE: a: 亡E: 〔亡 CE: ∝
′■￣ヽ ′■■ヽ
の N 寸
一■■･■
M∽ m ■へ
▼￣■ ■■■■ヽ ′■ー J■■■ヽ
(⊃u) 寸 ∝〉
.■ヒく⊃q) ⊂) ”
㌫完 N⊂)
o'L ⊂)
ー琵琶 (凸r1
⊂〉
⊂)
ー
o'q
.E ､-+ T■■■ くっー
+ ヽ-･′ } ▼￣ ⊂)
”
■一■'■■■ヽ一■一
rO
ヽ■■■■■
r 〔⊃
⊂) ⊂〉
′■■ヽ
_>で T■■■■■￣ N{
盲虐男
{
卜 mくD
LE?eel
C)⊂何
⊂〉
ー I i Q'
■N
Oo'
I-r
∞ ⊂)ー
■■■■■
<g讃>
⊂
7S.9 ′一■ヽ ′■■ヽ
⊂∽
'巨忘㌫写
zoE5E
r
ヽ■一′
記望ヽ■.■一■
て)
q)
【⊃つ
伯
E +
(ロ +=
■て) L
也 { I-J
i; a
≡
+
0
イ･J
コ
q)
i: ”
+=
C;
ー一■■ 垂 a)
て】
O (ロ
⊂ ∽ 0 ._￠也)
q) ●-∫ ⊂ J⊂ OO =U
＋一
ヰー 0 ,⊂
＋J
コ
ココ O q) O⊂ ○⊂
●･J O L
ロ) O
⊂ ロ) て) ⊂ O(ロp〟 L
【ロ
也
●■T
○ O ⊂ 節 C)
拐cn t亡
a,o'苫
蓋.萱
'F q l=
+
+ ■='- '1コ
て】
＋J c)I
帆 a) ⊂
O o.≡ (ロ
月芦
＋一
⊂ ー⊂: =)
む
CL
⊂.ヒ ∽ q) コ
L
q) c;
∽ 1 琵き【□
_⊂ ∈ ＋一 ■-･■
Oo ト
E +
⊂ (ロ ⊂ ■⊂:
【
LL
＋J
○＋J O 0
(ロコロ) ＋J
てコ (ロ
+⊂ ○ ⊂ UCO くD ＋J
ロ) 00 ロコ
⊂ ー=■￣J･J ⊂
≡ 也) 'Pーコ
1くっ ≡
曇毒萱
一= C)
⊂ ∽ I+=
帆
≡
真書
I,_
くっ CL O コ
0 L O
き +010とJ ∽ LISnJg + 也 U
A)亡 UO!1eつ!Pu!
(oL8乙-LOZL68!LPel!H) (OCLL-サ0乙L68!uS!qnSl!Vu)
岳￡ ∂6)eu3S旧 6u!J!仙
∀o!;'^zLJOIPuJalJ∀
zち /a6+叫つ仙qZIZ'^ZLJaUelS
>
L+
音旨 [eO!･JIO∂I]
≡忘
U
210
REPAIR STANDARDS
′■ー
u_ q)
O
⊂
くJ)
∽ 卜･
指
ー r
4) q)
⊂
ヽ■■■■■■
⊂ 1=
0 U
ロ) ロ) r
E ⊂ ⊂ q)帆
E
貢ぎ萱
a) 0 ⊂'￣
＋J
○
U ≡ E ⊂コ
L L むn
【ロ (ロ
きき毒害
也) ロ)
L
q)
⊂て】 L_
コ l=⊂ 0
●lコ
d3
O
O
'∼i3∈ L
O
+ コd)
EL
+
ご旨
''-∼(〟
め
0
＋･J
(ロコ＋J ＋J
CL ⊂ O O
＋･J
Bo主
I- ∽
C) q) O
a: n∽ ∈ a a
コ
Jl■■lヽ
く乃 ∽ てコ
4)L ⊂〉
⊂ ⊂
lエTo ∩ <
∽
′■ー ∽
” a)
.i:
rq.品 L_
O
Nさ寸
.巨
.J N
ー■■■一求
LL)
￠ ′■■■■
コ寸 C) ∽
(⊂) L ∽
言>7S 寸勺･
′■■ヽ.
｢冒l
寸m
0
E
也)
L_
届書
⊂)寸 + ○
l､ Iミ O
Mr 勺･LL?
” U)勺･
㌔
ー
Nl
求 ⊂)
a r■■
◆一の r
∽ ∩
ー
⊂
局.望
⊂∽
一巨忘
zee;E
■一■･..I ■l■￣■■
{
∽ ∽ く乃
CL 1 1
､ー､ー
＼
∼ N
芸蓋
≡ ≡
くJ O
⊂t> t>CD
ロ)
E
q〕
＋J
⊂
○
星空 O上亡
'訪､一
∽.(ロ
a)-
Iit .i:
U
遠望
也)
⊂ ＋J むCL +=
和 O
○
旨暑≡邑
L
･L喜≦
l= 4) ∽ a) ⊂
+
くJ CL q) CL O
q)
○ 'F
a.
∽ ⊂ 邑邑
∈L ○ lit
a
⊂ ■T ⊂=L U E
○⊂) ロ)
Ol
⊂
コ O⊂) 'c'-o>8 ⊂
a) コ
∽
コ .⊂
O
L_ 'F
蓋雲n=
LN ⊂
①＋J 何＋J
O
CL Q) O
⊂ ■｢ロココ ⊃ U
きロ)
⊂○ ○ L CL
＋J
∫)
O
⊂ =i宅･-q)ro ⊃
○
コ q)
コ
u LU U 〔⊃J〕 LL
...+
a)亡
+ale8Ll
岳cLm-∂Jd
Zち
uo!10adsulLt2u!ヨ
>
しL
7eO!J-
昔旨 1〇aJj
≡盲
U
211
MEMO
212
CONVERSION TABLE
SECTION 13
CONVERSION TABLES
INDEX
CONTENTS PAGE
Length.･,･-･･･････････.･･････-････-･･.･-.････････.･･･-I..･･f-..-･･･････ 213
Area..‥‥‥.=..‥‥..‥‥.‥‥..‥‥‥‥‥.‥‥..‥‥...‥‥.‥‥‥‥‥‥... 215
VoJume ..”...”......................””..................”..”............ 215
Mass ‥‥‥‥‥‥‥..‥‥.‥‥‥‥‥‥‥‥‥‥.‥‥‥..‥...---..‥‥‥‥‥ 217
Pressure -----------------･.--------------- 218
Torque.....,.･･.”･･･..･･･.I-,･･･-･･･････････････････････...,････-･････-･.･ 219
Temperature‥･---I--･･---------I.---･･-I----･･･.-I-･･ 220
LENGTH
M]LLJMETERS TO [NCHES INCHES TO MILLIMETERS
mm in. mm in. mm in. mm in. in. mm in.mm
1 0.0394 26 1.D236 51 2.OO79 76 2.9921 1/64 0.3969 33/6413.0969

2 0.0787 27 1.0630 52 2.0472 77 3.0315 1/32 0.7938 17/32 13.4938
3 0.1181 28 1.1024 53 2.0866 78 3.0709 3/64 1.1906 35/64 13.8906
4 0.1575 29 1.1417 54 2.1260 79 3.1102 1/16 1.5875 9/16 14.2875
5 0.1969 30 1.1811 55 2.1654 80 3.1496 5/64 1,9844 37/64 14.6844
6 0.2362 31 l.2205 56 2.2047 81 3.189O 3/32 2.3813 19/32 15.0813
7 0.2756 1.2598 57 2.2441 82 3.2283 7/64 2.7781 39/64 15.4781

-32
8 0.3150 33 1.2992 58 2.2835 83 3.2677 1/8 3.1750 5/8 15.8750
9 0.3543 34 1.3386 59 2.3228 84 3.3071 9/64 3.5719 41/64 16.2719
10 0.3937 35 1.3780 60 2.3622 85 3.3465 5/32 3.9688 21/32 16.6688
ll 0.4331 36 1.4173 61 2.4016 86 3.3858 ll/64 4.3656 43/64 17.0656
12 0.4724 37 1.4567 62 2.4409 87 3.4252 3/16 4.7625 ll/16 17.4625
13 0.5118 38 1.4961 63 2.4803 88 3.4646 13/64 5.1594 45/64 17.8594
14 0.5512 39 1.5354 64 2.5197 89 3.5039 7/32 5.5563 23/32 18.2563
15 0.5906 40 1.5748 65 2.5591 90 3.5433 15/64 5.9531 47/64 18.6531
16 0.6299 41 1.6142 66 2.5984 91 3.5827 1/4 6.3500 3/4 19.O500
17 0.6693 42 1.6535 67 2.6378 92 3.6220 17/64 6.7469 49/64 19.4469
18 O.7087 43 1,6929 68 2.6772 93 3.6614 9/32 7.1438 25/32 19.8438
19 D.7480 44 1.7323 69 2.7165 94 3.7008 19/64 7.5406 51/64 20.2406
20 0.7874 45 1.7717 70 2.7559 95 3.7402 5/16 7.9375 13/16 20,6375
21 0.8268 46 1.8110 71 2.7953 96 3.7795 21/64 8.3344 53/64 21.0344
22 0.8661 47 1.850ヰ 72 2.8346 97 3.8189 ll/32 8.7313 27/32 21.4313
23 0.9055 48 1.8898 73 2.8740 g8 3.8583 23/64 9.1281 55/64 21.8281
24 0.9449 49 1.9291 74 2.9134 99 3.8976 3/8 9.5250 7/8 22.2250
25 0.9843 50 1.9685 75 2.9528 100 3.9370 25/64 9.9219 57/64 22.6219
13/32 10.3188 29/32 23.0188
01 3.9764 1 4.3701 21 4.7638 31 5.1575 27/64 10.7156 59/64 23.4156
02 4.0157 2 4.4094 22 4.8031 32 5.1968 7/16 ll.1125 15/16 23.8125
03 4.0551 3 4.4488 23 4.8425 33 5.2362 29/64 1l.5094 61/64 24.2094
04 4.0945 4 4.4882 24 4.8819 34 5.2756 15/32 ll.9063 31/32 24.6063
05 4.1339 5 4.5276 25 4.9213 35 5.3150 31/64 12.3031 63/64 25.0031
06 4.1732 6 4,5669 26 4.9606 36 5.3543 1/2 12.700D 1 25.4000
07 4.2126 7 4.6063 27 5.0000 37 5.3937
08 4.2520 8 4.6457 28 5.0394 38 5.4331
09 4.2913 9 4.6850 29 5.0787 39 5.4724
213
CONVERSJON TABLE
LENGTH
FEET TO METERS
ft. 0 1 2 3 4 5 6 7 8 9 ft.
rTl m m m m m m m m m
0.305 0,610 0.914 1,219 1.524 l.829 2.134 2.438 2.743
10 3.048 3.353 3.658 3,962 4.267 4.572 4.877 5.182 5.486 5.791 10
20 6.096 6.40l 6.706 7-010 7.315 7.62D 7.925 8.230 8.534 8.839 20
30 9.144 9.449 9.754 10.058 10.363 10.668 10.973 ll.278 ll.582 1l.887 30
40 12.192 12.497 12.802 13.106 13.411 13.716 14.D21 14.326 14.63O 14.935 40
50 15.240 15,545 15.85O 16.154 16.459 16.764 17.069 17.374 17.678 17.983 50
60 18.288 18.593 18.898 19.202 19.507 19.812 20.117 20.422 20,726 21.O31 60
70 2l.336 21.641 21.946 22.250 22.555 22.860 23.165 23.470 23.774 24.079 70
80 24.384 24.689 24,994 25.298 25.603 25.908 26.213 26.518 26,822 27.127 80
90 27.432 27.737 28.042 28.346 28.651 28.956 29.261 29.566 29.870 30.175 90
100 30.480 30.785 31.090 31.394 31.699 32.004 32.309 32.614 32.918 33.223 100
METERS TO FEET
rn 0 l 2 3 4 5 6 7 8 9
ft. f[. f[. ft. ft. ft. f(. ft. ft. ft.
3.28O8 6.5617 9.8425 13.1234 16.4042 19,6850 22.9659 26.2467 29.5276
1O 32,8084 36.0892 39.3701 42.6509 45.9318 49.2126 52.4934 55.7743 59.0551 62.3360 10
2O 65.6168 68.8976 72.1785 75.4593 78.7402 82.0210 85.3018 88.5827 91.8635 95,1444 2O
30 98.4252 101.7060 104.9869 108.2677 111.5486 114.8294 118.1102 121.3911 124.6719 127.9528 30
40 131.2336 134.5144 137.7953 141.0761 144,3570 147.6378 150.9186 154.1995 157.4803 160.7612 40
50 164.0420･ 167.3228 lワo.6037 173.8845 177.1654 180.4462 183.7270 187.0079 190.2887 193.5696 50
60 196.8504 200.1312 203.4121 206.6929 209.9738 213.2546 216.5354 219.8163 223.0971 226.3780 60
70 229.6588 232.9396 236.2205 239.5013 242.7822 246.0630 249.3438 252.6247 255.9O55 259.1864 70
80 262.4672 265.7480 269.0289 272.3097 275.5906 278.8714 282.1522 285.4331 288.7139 291,9948 80
90 295.2756 298.5564 301,8373 305.1181 308.3990 311.6798 314.9606 318.2415 321.5223 324.8032 90
100 328,0840 331.3648 334.6457 337.9265 341.2074 344.4882 347.7690 351.0499 354.3307 357.6116 100
MILES TO K比OMETERS
0 l 2 3 4 5 6 7 8 9
rniFes
km km km km km km km km km km
1.609 3.219 4.828 6.437 8.047 9.656 ll.265 12.875 14.484
1O 16.093 17.703 19.312 20.921 22.531 24.140 25.75O 27.359 28.968 30.578 10
20 32.187 33.796 35.406 37.015 38.624 40.234 41.843 43_452 45.062 46.671 20
30 48.280 49.890 5l.499 53.108 54.718 56.327 57.936 59.546 61.155 62.764 30
40 64.374 65.983 67.592 69.202 7O.811 72.420 74.030 75.639 77.249 78.858 40
50 80.467 82.077 83.686 85.295 86.905 88.514 90.123 91.733 93.342 94.951 50
60 96.561 98.170 99.779 101,389 102.998 104.607 106.217 107.826 109,435 lll.045 60
70 112.654 114.263 115.873 117.482 119.091 120.701 122.310 123.919 125.529 127.138 70
80 128.748 130.357 131.966 133.576 135.185 136.794 138.404 140.013 141.622 143.232 80
90 144.841 146.450 148.060 149.669 15l.278 152.888 154,497 156.106 157.716 159.325 90
100 160.934 162.544 164.153 165.762 167.372 168.981 170.590 172.200 173.809 175.418 100
K)LOMETERS TO JVTrLES
km 0 1 2 3 4 5 6 7 8 9
mJ'Jes m‖es mites miles mJ'1es miles mi一es miles miles mHes
0.62l 1.243 1.864 2.485 3.107 3.728 4.350 4.971 5.592
10 6.214 6.835 7.456 8.078 8.699 9.321 9.942 10.563 ll.185 ll.806 10
20 12.427 13.049 13.670 14.292 14.913 15,534 16.156 16.777 17.398 18.020 20
30 18.641 19.262 19.884 20.505 21.127 21.748 22.369 22.991 23.612 24.233 30
40 24.855 25.476 26.098 26.719 27.340 27.962 28.583 29.204 29.826 30,447 40
50 31.069 31.690 32.all 32.933 33.554 34,175 34.797 35.418 36.039 36,661 50
60 37.282 37.904 38.525 39.146 39.768 40.389 41.010 41.632 42.253 42.875 60
70 43.496 44.117 44,739 45.360 45.981 46.6(〕3 47.224 47.845 48.467 49.088 70
80 49.710 50.33l 50.952 51.574 52.195 52.816 53.438 54,059 54.681 55.302 80
90 55.923 56.545 57.166 57.787 58.409 59.030 59.652 60,273 60.894 61.516 90
100 62.137 62.758 63.380 64.001 64.622 65.244 65.865 66.487 67.108 67.729 100
214
CONVERSION TABLE
AREA
SQUARE JNCHES TO SQUARE CENTJMETERS
in2 0 1 2 3 4 5 6 7 8 9 in2
cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2
6.452 12.903 19.355 25.806 32.258 38.71O 45.161 51.613 58.064
10 64.516 70.968 77.419 83.871 90.322 96.774 103.226 109.677 116.129 122.58O 10
20 129.032 135.484 141.935 148.387 154,838 161.290 167.742 174.193 180.645 187.096 20
30 193.548 200,000 206.451 212.903 219.354 225.806 232.258 238.709 245.161 251.612 30
40 258.064 264.516 270.967 277.419 283.870 290.322 296.774 303.225 309.677 316.128 40
50 322.580 329.032 335.483 341.935 348.386 354.838 361.290 367.741 374.193 380.644 50
60 387.096 393.548 399.999 406.451 412.902 419.354 425,806 432.257 438.709 445.160 60
70 451.612 458,064 464.515 470.967 477.418 483.870 490.322 496.773 503.225 509.676 70
80 516.128 522.580 529.031 535.483 541.934 548.386 554.838 561.289 567.741 574.192 80
90 580.644 587.096 593.547 599.999 606.450 612.902 619,354 625.805 632.257 638.708 90
100 645.160 651.612 658.063 664.515 670.966 677.418 683.870 690.321 696.773 703.224 100
SQUARE CENTJMETERS TO SQUARE JNCHES
cm2 O' l 2 3 4 5 6 7 8 9 cm2
J'n2 ['n2 in2 in2 in2 7'n2 in2 in2 11n2 J'n2
0.155 0.310 0.465 0.620 0.775 0.930 1.085 1.240 1.395
10 1.550 1.705 l.860 2.015 2.17O 2.325 2.480 2.635 2.790 2.945 1O
20 3.100 3.255 3.410 3.565 3.720 3.875 4.030 4.185 4.340 4.495 20
3O 4.65O 4.805 4.960 5.115 5.270 5.425 5.580 5,735 5.890 6.045 3O
4O 6.200 6.355 6.510 6.665 6.820 6.975 7.130 7.285 7.440 7.595 40
5O 7.750 7.905 8.060 8.215 8.370 8.525 8.680 8.835 8,990 9.145 5O
60 9.300 9.455 9.610 9.765 9.920 l().075 10.23O 10.385 10.540 10.695 60
70 10.850 ll.005 ll.160 ll.315 ll.470 ll.625 ll,780 ll.935 12.090 12.245 70
80 12.400 12.555 12.710 12.865 13.020 13.175 13.330 13.485 13.640 13.795 80
90 13.950 14.105 14.260 14.415 14.570 14.725 14.880 15.035 15.190 15.345 90
loo 15.500 15.655 15.810 15.965 16.120 16.275 16.430 16.585 16.740 16.895 100
VOLUME
CUBtC INCHES TO CU別C CENTIMETERS
in3 0 1 2 3 4 5･ 6 7 8 9 Jln3
cm3(cc) cm3(cc) cn13(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) crn3(cc)
16.387 32.774 49.161 65.548 81.935 98.322 114.709 131.097 147.484
1D 163,871 180.258 196.645 213.032 229.419 245.806 262,193 278.580 294.967 311.354 10
20 327.741 344.128 360.515 376.902 393.290 409.677 426.064 442.451 458.838 475.225 20
30 491.612 507.999 524.386 540.773 573.547 589.934 606.321 622.708 639.095 30

.557.160
40 655.483 671.87O 688.257 704.644 721.031 737.418 753.8O5 770.192 786.579 802.966 40
50 819.353 835.740 852.127 868.514 884.901 901.289 917.676 934,063 950.450 966,837 50
6O 983.224 999.611 1015.998 1032.385 1048.772 1065.159 1081.546 1097.933 1114.320 1130.707 60
70 1147.094 1163.482 1179.869 1196.256 1212.643 1229.030 1245.417 1261.804 1278.191 1294.578 70
80 1310.965 1327.352 1343.739 1360.126 1376.513 1392.900 1409.28B 1425.675 1442.062 1458.449 80
90 1474.836 1491.223 1507.610 1523.997 1540,384 1556.771 1573.158 1589.545 1605.932 1622.319 90
100 1638.706 1655.093 1671.481 1687.868 1704.255 1720.642 1737.029 1753.416 1769.8O3 1786.190 loo
CUBIC CENTrMETERS TO CUB]C rNCHES
0 1 2 3 4 5 6 7 8 9
cm3(cc) cm3(cc)
in3 in3 in3 l'n3 in3 in3 J'n3 jn3 in3 in3
0.0610 0.1220 0.1831 0.2441 0.3051 0.3661 0.4272 0.4882 0.5492
10 0.6102 0.6713 0.7323 0.7933 0.8543 0,9153. 0.9764 1.D374 1,0984 1.1594 10
20 1.2205 l.2815 1.3425 1.4035 1.4646 1.5256 1.5866 1.6476 1.7086 1.7697 20
30 1.8307 1.8917 1.9527 2.0138 2.O748 2.1358 2.1968 2.2579 2.3190 2.3799 30
40 2.4409 2.5020 2.5630 2.6240 2.6850 2.7460 2.8071 2.8681 2.9291 2.9901 40
50 3.0512 3.1122 3.1732 3.2342 3.2952- 3.3563 3.4173 3.4783 3.5393 3.6004 50
60 3.6614 3.7224 3.7834 3.8444 3.9055 3.9665 4.0275 4.0885 4.1496 4.2106 60
70 4.2716 4.3326 4.3937 4.4547 4.5157 4.5767 4.6377 4.6988 4.7598 4.8208 70
80 4.8818 4.9429 5.0039 5.0649 5.1259 5.1870 5.2480 5.3090 5.3700 5.4310 80
90 5.4921 5.5531 5.6141 5.6751 5.7362 5.7972 5.8582 5.9192 5.9803 6.0413 90
loo 6.1023 6.1633 6.2243 6.2854 6.3464 6.4074 6.4684 6.5295 6.5905 6.6515 100
215
CONVERSION TABLE
VOLUME
GALLONS (U.S.I TO LITERS
U.S.gal. 0 1 2 3 4 5 6 7 8 9 U.S.gal.
Jiters 一iters =ters )iters [J'ters liters 一iters I)'ters liters 一iters
3.7854 7,5709 ll.3563 15.1417 18.927l 22.7126 26.4980 30.2834 34.0688
10 37.8543 41.6397 45.425l 49.2105 52.9960 56.7814 6O.5668 64.3523 68.1377 7l.9231 10
20 75.7085 79.4940 83.2794 87.0648 90.8502 94.6357 98.4211 102.2065 105.9920 109.7774 20
30 113.5628 117.3482 121.1337 124.9191 128.7045 132.4899 136.2754 140.0608 143.8462 147.6316 30
40 151.4171 155.2025 158.9879 162.7734 166.5588 170.3442 174.1296 177.9151 181.7005 185.4859 40
50 189.2713 193.0568 196.8422 200.6276 204.4131 208.1985 211.9839 215.7693 219.5548 223.3402 50
60 227.1256 230.9110 234.6965 238.4819 242.2673 246.0527 249.8382 253.6236 257.4090 261.1945 6O
70 264.9799 268.7653 272.5507 276.3362 280.1216 283.9070 287.6924 291.4779 295.2633 299.0487 70
80 302.8342 306.6196 310.4050 314,1904 317.9759 321.7613 325.5467 329.3321 333.1176 336.9030 80
90 340.6884 344.4738 348.2593 352.0447 355.8301 359.6156 363.4010 367.1864 370.9718 374.7573 90
100 378.5427 382.3281 386.1135 389.8990 393.6844 397.4698 40l.2553 405.0407 408.8261 412.6115 100
LrrERS TO GALLONS (U.S.)
拙ers 0 1 2 3 4 5 6 7 8 9 ”-ters
gaJ. gaJ. ga一. gal. gaL gal, gal. gal. ga一. gal,
0.2642 0.5283 0.7925 1.0567 1.3209 1.5850 1.8492 2.1134 2.3775
10 2.6417 2.9059 3.1701 3.4342 3.6984 3.9626 4.2268 4.4909 4.7551 5.0193 10
20 5.2834 5.5476 5.8118 6.0760 6.3401 6.6043 6.8685 7.1326 7.3968 7.6610 20
30 7,9252 8.1893 8.4535 8.7177 8.9818 9.2460 9.5102 9.7744 10.0385 10.3027 30
40 10.5669 10.8311 ll.0952 ll.3594 ll.6236 ll.8877 12.1519 12.4161 12.6803 12.9444 40
50 13.2O86 13.4728 13.7369 14.0011 14.2653 14.5295 14.7936 15.0578 15.3220 15.5861 50
60 15.8503 16.1145 16.3787 16.6428 16.9070 17.1712 17,4354 17,6995 17.9637 18.2279 60
70 18.4920 18.7562 19.0204 19.2846 19.5487 19.8129 20.0771 20.3412 20.6054 20.8696 70
80 21.1338 21.3979 2l.6621 21,9263 22.1904 22.4546 22.7188 22.983O 23.2471 23.5113 80
90 23.7755 24.0397 24.3038 24.5680 24.8322 25.0963 25.3605 25.6247 25.8889 26.1530 90
100 26.4172 26.6814 26.9455 27.2097 27.4739 27.7381 28.0022 28.2664 28.5306 28.7947 100
GALLONS (IMP.) TO UTERS
fmpga(. 0 1 2 3 4 5 6 7 8 9 FmpgaJ.
lFters liters liters 一iters liters liters liters Liters (iters liters
4.5459 9.0918 13.6377 18.1836 22.7295 27.2754 31.8213 36.3672 40.9131
1O 45.4590 50.0049 54.5508 59.0967 63.6426 68.1885 72.7344 77.2803 8l.8262 86.3721 10
2D 90.9180 95.4639 100.0098 104.5557 109.1016 113.6475 118.1934 122.7393 127.2852 131.8311 20
30 136.3770 140.9229 145.4688 150.0147 154.5606 159.1065 163.6524 168.1983 172.7442 177.29Ol 30
40 181.8360 186.3819 190.9278 195.4737 200.O196 204.5655 209.1114 213.6573 218.2032 222.7491 40
50 227.2950 231.8409 236.3868 240.9327 245.4786 250.0245 254,5704 259.1163 263.6622 268,2081 50
60 272.7540 277.2999 281.8458 286.3917 290.9376 295.4835 300.0294 304.5753 309,1212 313.6671 60
70 318.213O 322.7589 327.3048 331.8507 336.3966 340.9425 345.4884 350.0343 354.5802 359.1261 70
80 363.6720 368.2179 372.7638 377.3097 381.8556 386.4015 390.9474 395.4933 400.0392 404.5851 80
90 409.1310 413.6769 418.2228 422,7687 427.3146 431.8605 436.4064 440.9523 445.4982 450.0441 90
100 454.5900 459.1359 463.6818 468.2277 472.7736 477.3195 481,8654 486,4113 490.9572 495.5031 loo
UTERS TO GALLONS ()MP.)
liters 0 1 2 3 4 5 6 7 8 9 Hters
9aL gaL ga一. gal. gaL gal. gal. 9aE. gal. ga[.
0.2200 0.4400 0.6599 0.8799 l.0999 1.3199 1.5399 i.7598 l.9798
10 2.1998 2.4198 2.6398 2.8597 3.0797 3.2997 3.5197 3.7397 3.9596 4.1796 10
20 4.3996 4.6196 4.8396 5.0595 5.2795 5.4995 5.7195 5.9395 6.1594 6.3794 20
30 6.5994 6,8194 7.0394 7.2593 7.4793 7,6993 7.9193 8.1393 8.3592 8.5792 30
40 8.7992 9.0192 9.2392 9.4591 9.6791 9.8991 10.1191 10.3391 10.5590 10.7790 40
50 10.9990 1l.2190 ll.4390 ll.6589 ll.8789 12.0989 12,3189 12.5389 12.7588 12.9788 50
60 13.1988 13.4188 13.6388 13.8587 14.0787 14.2987 14.5187 14.7387 14.9586 15.1786 60
70 15.3986 15.6186 15.8386 16.0585 16.2785 16.4985 16.7185 16.9385 17.1584 17.3784 70
80 17.5984 17.8184 18.0384 18.2583 18.4783 18.6g83 18.9183 19.1383 19.3582 19.5782 80
90 19.7982 20.O182 20.2382 20.4581 20.6781 20.8981 21.1181 21.3381 2l.5580 21.7780 90
100 21.9980 22.2180 22.4380 22-6579 22.8779 23,0979 23.3179 23.5379 23.7578 23.9778 loo
216
CONVERS10N TABLE
MASS
POUNDS TO KILOGRAMS
(bs. 0 l 2 3 4 5 6 7 8 9 lbs.
kg kg kg kg kg kg kg kg kg kg
0,454 0.907 1.361 i.814 2.268 2.722 3.175 3.629 4.082
1O 4.536 4,990 5.443 5.897 6.35O 6.804 7.257 7.711 8.165 8.618 10
20 9.072 9.525 9.979 10.433 10.886 ll.340 1l.793 12.247 12.701 13.154 20
30 13.6O8 14,061 14.515 14.970 15.422 15.876 16,329 16.783 17.237 17.690 30
40 18.144 18.597 19.051 19.504 19.958 20.412 20.865 21.319 2l.772 22.226 40
50 22.680 23.133 23.587 24,Oho 24.494 24.948 25.401 25.855 26.308 26.762 50
60 27.216 27.669 28.123 28.576 29,030 ■29.484 29.937 30.39l 30.844 31.298 6O
70 3l.751 32.205 32.659 33.112 33.566 34.019 34.473 34.927 35,38O 35.834 70
80 36.287 36.741 37.195 37.648 38,102 38.555 39.009 39.463 39.916 40.370 BO
90 40.823 41.277 41.731 42.184 42.638 43.091 43.545 43.998 44.452 44.905 90
100 45.359 45.813 46.267 46.720 47.174 47.627 48.O81 48.534 48.988 49.442 100
KILOGRAMS TO POUNDS
kg 0 1 2 3 4 5 6 7 8 9 kg
Jb5. lbs. lbs. Jbs. fbら. rbs. Ibs. Jbs. lbs. lbs.
2.205 4.409 6,614 8.818 ll.023 13.228 15.432 17.637 19.842
10 22.046 24.251 26.455 28.660 30,865 33.069 35.274 37.479 39.683 41.888 10
2O 44.092 46.297 48.502 50.706 52.911 55.116 57.320 59.525 61.729 63.934 20
3O 66.139 68.343･ 70.548 72.753 74.957 77.162 79.366 81.571 83.776 85.980 30
40 88.185 90.390 92.594 94.799 97,003 99.208 101.413 103.617 105.822 1O8.026 40
50 110.231 112.436 114.640 116,845 119.050 121.254 123.459 125.663 127.868 130.073 50
6O 132,277 134.482 136.687 138.891 141.096 1ヰ3.300 145,505 147.710 149.914 152.119 60
70 154.324 156.528 158.733 160.937 163.142 165.347 167.551 169.756 171.960 174.165 70
80 176.370 178.574 180.779 182.984 185.188 187.393 189.597 191.802 194.007 196.211 80
90 198.416 200.621 202,825 205.030 207.234 209.439 211.644 213.848 216.053 218.258 90
100 220.462 222.667 224,871 227.076 229.281 231.485 233.690 235.895 238.099 240.304 100
KILOGRAMS TO NEWTOrU
kgf 0 1 2 3 4 5 6 7 8 9 kgf
N N N N N N N N N N
9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26
10 98.07 107.87 117.68 127.49 137.29 147.10 156.gl 166.71 176.52 186.33 10
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333,43 343.23 353.04 362.85 372.65 382.46 30
40 392.27 4O2_07 411.88 421.69 431.49 441.3O 45l.ll 460,91 470,72 480.53 40
50 490.33 500.14 509.95 519.75 529.56 539.37 549.17 558.98 568.79 578.59 50
60 588.40 598.21 608.Ol 617.82 627.63 637.43 647.24 657.05 666.85 676.66 60
70 686.47 696.27 706.08 715.89 725.69 735.50 745,31 755.ll 764.92 774,73 70
80 784.53 794.34 804.15 813.95 823,76 833.57 843.37 853.18 862.99 872.79 80
90 882.60 892.41 902.21 912.02 921.83 931.63 94l.44 951.25 961,05 970.86 90
100 980.67 99O.47 1000.2B 1010.08 1019.89 1029.70 1039.50 1049.31 1059.12 1068.92 loo
NEWTON TO K(I.OGRAMS
N O 10 20 30 40 50 60 70 80 gO N
kgf kgf kgf kgf kgf kgf kgf kgf kgf kgf
i.020 2.039 3.059 4.O79 5.099 6.118 7.138 8.158 9.177
100 10.197 ll.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 100
200 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 200
300 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38,749 39.769 300
4(】0 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 400
500 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 500
600 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 600
700 71.380 72.400 73.420 74.44D 75.459 76.479 77.499 78.518 79.538 80.558 700
800 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 800
900 91.775 92.795 93.814 94,834 95.854 96.873 97.893 98.913 99.933 100.952 900
1000 1Ol.972 102.992 104.011 105.031 106.051 107.071 108.090 log.110 110.130 111.149 1000
217
CONVERS10N TABLE
PRESSURE
POUNDS PER'SQUARE INCHES TO KILOGRAMS PER SQUARE CENTIMETERS
Jb/in2 0 1 2 3 4 5 6 7 8 9 lb/J'n2
(psi) kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/crn2 kgi/cm2 kgf/cm2 kgf/cm2 kgf/cm2 (psJ')
0.0703 0.1406 0.2109 0.2812 0.3515 0.4218 0.4921 0.5625 0.6328
10 0.7031 0.7734 0.8437 0.9140 0.9843 1.0546 1.1249 l.1952 1.2655 1.3358 10
20 1.4061 1.4764 1.5468 1.6171 1.6874 1.7577 1,8280 l.8983 1.9686 2.0389 20
30 2.1092 2.1795 2.2498 2.3201 2.3904 2,4607 2.5311 2.6014 2.6717 2.7420 30
40 2.8123 2.8826 2.9529 3.0232 3.0935 3.1638 3.2341 3.3044 3,3747 3.4450 40
50 3.5154 3.5857 3.6560 3.7263 3.7966 3.8669 3.9372 4.0075 4.0778 4.1481 50
60 4.2184 4.2887 4.3590 4.4293 4.4996 4.5700 4.6403 4.7106 4.7809 4.8512 60
70 4.9215 4.9918 5.0621 5.1324 5.2027 5.2730 5.3433 5.4136 5.4839 5.5543 70
80 5.6246 5.6949 5.7652 5.8355 5.9058 5.9761 6.0464 6.1167 6.1870 6.2573 80
90 6.3276 6.3979 6.4682 6.5386 6.6089 6.6792 6.7495 6.8198 6.8901 6.9604 90
100 7.0307 7.101O 7.1713 7.2416 7.3119 7.3822 7.4525 7.5228 7.5932 7.6635 100
KILOGRAMS PER SQUARE CENTIMETERS TO POUNDS PER SQUARE INCHES
kgf/cm2 0 1 2 3 4 5 6 7 8 9 kgf/cm2
Jb/l'n2(psi) Ib伽2(pst) Ib/in2(psi) Fb/in2(psi) Ib/in2(psり tb/in2(psり lb/in2(psi) lb/in2(psi) Ib/fn2(ps7) Jb/in2(psi)
14.22 28.45 42.67 56.89 71.12 85.34 99.56 113.78 128.Ol
10 142.23 156.45 170.68 184.90 199.12 213.35 227.57 241.79 256.01 270.24 10
20 284.46 298.68 312.91 327.13 341.35 355.58 369.80 384.02 398.24 412.47 20
3O 426.69 440.91 455.14 469.36 483.58 497.81 512.03 526.25 540.47 554.70 30
40 568.92 583.14 597.37 611.59 625.81 640.04 654.26 668.48 682.70 696.93 40
50 71l.15 725.37 739.60 753.82 768,04 782.27 796.49 810.71 824.93 839.16 50
60 853.38 867.60 881.83 896.05 910.27 924.50 938,72 952.94 967.16 98l.39 60
70 995,61 1009.83 1024.06 1038.28 1052.50 1066.73 1080.95 1095.17 1109.39 1123.62 70
80 1137.84 1152.06 1166.29 1180.51 1194.73 1208.96 1223.18 1237.40 1251.62 1265.85 80
90 1280.07 1294,29 1308.52 1322､74 1336.96 1351.19 1365.41 1379.63 1393.85 1408.08 90
100 1422.30 1436.52 1450.75 1464.97 1479.19 1493.42 1507.64 1521.86 1536.08 1550.31 100
KILOGRAMS PER SQUARE CENT)METERS TO K]L.0 PASCAL
kgf/cm2 0 1 2 3 4 5 6 7 8 9 kgf/cm2
KPa KPa KPa KPa KPa KPa KPa KPa KPa KPa
98.1 196.1_ 294.2 392.3 490.3 588,4 686.5 784.5 882.6
10 980.7 1078,7 1176.8 1274.9 1372.9 1471.0 1569,1 1667.1 1765.2 1863.3 10
20 1961.3 2059.4 2157.5 2255.5 2353,6 2451.7 2549.7 2647.8 2745.9 2843.9 20
30 2942.0 3040.1 3138.1 3236.2 3334.3 3432.3 3530.4 3628.5 3726.5 3824.6 30
40 3922.7 4020.7 ヰ118.8 4216.9 4314.9 4413.0 4511.l 46O9.1 4707.2 4805.3 40
50 4903.4 5001.4 5099.5 5197.5 5295.6 5393.7 5491.8 5589.8 5687.9 5785.9 50
60 5884.0 5982.1 6080.1 6178.2 6276.3 6374.4 6472.4 6570.5 6668.6 6766.6 60
70 6864.7 6962.7 7060.8 7158.9 7256.9 7355.0 7453.1 7551.1 7649,2 7747.3 70
80 7845.3 7943.4 8041,5 8139.5 8237.6 8335.7 8433.7 8531.8 8629.9 8727.9 80
90 8826.0 8924.1 9022.1 9120.2 9218.3 9316.3 9414.4 9512.5 9610.5 9708.6 90
100 9806.7 9904.7 lOOO2.8 10100.8 10198.9 10297.0 1O395.1 10493.1 10591.2 10689.2 100
K]LO PASCAL TO KLLOGRAMS PER SQUARE CENT)METERS
KPa 0 100 200 ョoo 400 500 600 700 800 900 KPa
kgf/cm2 kgf/crn2 kgt/cm2 kgt/cm2 kgf/cm2 kgf/cm2 kgt/cm2 kgf/cm2 kgf/cm2 kgf/cm2
1.020 2.O39 3.059 4.079 5.099 6.118 7.138 8.158 9.177
1000 10.197 ll.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 1000
2000 20.394 21.414 22,434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 2000
30DO 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 3000
40OO 40,789 41.809 42.828 43,848 44.868 45.887 46.907 47.927 48.947 49.966 4000
5000 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60,163 5000
6000 61.183 62.203 63.223 64.242 65.262 66.282 67,302 68,321 69.341 70.361 6000
7000 71.3白o 72.400 73.420 74.44O 75.459 76.479 77.499 78.518 79,538 80.558 7000
8000 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 8000
9000 9l.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 9000
10000 10l.972 102.992 104.011 105,031 106.O51 107.071 108.090 109.110 110.130 111.149 10000
218
CONVERSION TABLE
TORQUE
FOOT POUNDS TO KILOGRAMMETERS
ft.1bs. 0 l 2 3 4 5 6 7 8 9 ftJbs.
kgf-rn kgf-m kgf-m kgf･m kgf-m kgf･m kgf･m kgf-m kgf-m kgf-m
0.138 0.277 0.415 0.553 0.691 0.830 0.968 1.106 1.244
10 1.383 1.521 l.659 1.797 l.936 2.074 2.212 2.350 2.489 2.627 10
20 2.765 2.9O3 3.042 3.180 3.318 3.456 3.595 3.733 3.871 4.OO9 20
30 4.148 4.286 4.424 4.562 4.701 4.839 4.977 5.115 5.254 5.392 30
40 5.530 5.668 5.807 5.945 6.083 6.221 6.360 6.498 6.636 6.774 40
50￣ 6.913 7.051 7.189 7.328 7.466 7.604 7.742 7.881 8.019 8.157 50
60 8.295 8.434 8.572 8.710 8.848 8.987 9.125 9.263 9.401 9.540 60
70 9.678 9.816 9.954 10.093 10.231 10.369 10.507･ 10.646 10.784 10.922 70
80 ll.060 ll.199 ll.337 1l.475 ll.613 1l.752 ll.890 12.028 12.166 12.305 80
90 12.443 12.581 12.719 12.858 12.996 13.134 13.272 13,ヰ11 13.549 13.687 90
loo 13.826 13.964 14,102 14.240 14.379 14.517 14.655 14.793 14.932 15.070 100
KILOGRAMMETERS TO FOOT POUNDS
kgf-m 0 1 2 3 4 5 6 7 8 9 kgf-m
f[.Jbs. fLlbs. fLlbs. ft.1bs. ft.1bs. ft.Jbs. ft.1bs. ft.rbs, f[.1bs. ft.Jbs.
7.23 14.47 21.70 28.93 36.17 43.40 50.63 57.86 65.10
10 72.33 79.56 86.80 94.03 101.26 108.50 715.73 122.96 130.19 137.43 10
20 144.66 151.89 159.13 166.36 173.59 180.83 188.06 195,29 202,52 209.76 20
30 216.99 224.22 231.46 238,69 245.92 253.16 260.39 267.62 274.85 282.09 30
40 289.32 296.55 303-79 311.02 318.25 325.49 332.72 339.95 347.18 354.42 40
50 361.65 368.88 376,12 383.35 390.58 397.82 405.05 412.28 419.51 426.75 5O
60 433.98 441.21 448.45 455.68 462.91 470.15 477.38 484.61 49l.84 499.08 60
70 506.31 513.54 520.78 528.01 535.24 542.48 549.71 556.94 564.17 571.41 70
80 578.64 585.87 593.ll GOO.34 607.57 614.81 622.04 629.27 636.50 643▲74 80
90 650.97 658.20 665.44 672.67 679.90 687.14 694.37 701.60 7O8.83 716.07 90
loo 723.30 730.53 737.77 745.00 752.23 759.47 766.70 773.93 781.16 788.40 100
KILOGRAMMETERS TO NEWTONMETERS
kgf･m 0 1 2 3 4 5 6 7 8 9 kgfィn
N-m N-m N･m N-m N･m N-m N-m N-m N-rTl N-m
9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26
10 98.07 107.87 117,68 127,49 137.29 147.10 156.91 166.71 176.52 186.33 1O
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.Ol 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 3O
4O 392.27 402.07 411.88 421.69 431.4g 44l.30 451.ll 460.91 470.72 480.53 40
5O 490.33 50O.14 509.95 519.75 529.56 539.37 549.17 558.98 568.79 578.59 50
60 588.40 598.21 608.01 617.82 627.63 637.43 647.24 657.05 666.85 676.66 60
70 686.47 696.27 706.08 715.89 725.69 735.50 745.31 755.ll 764.92 774.73 70
80 784.53 794.34 804.15 813.95 823.76 833.57 843.37 853.18 862.99 872.79 80
90 882.60 892.41 902.21 912.02 921.83 931.63 941.44 951,25 961.O5 970.86 90
一oo 980.67 990.47 1OOO.28 1010.08 1019.89 1029.70 1039.51 1049.31 1059.12 1068.93 loo
NEWTONMETERS TO KILOGRAMMETERS
N･m 0 10 20 30 40 50 60 70 80 90 N-rn
kgf-m kgf-m kgf-r71 kgf-m kg†-m kgf-m kgf-m kgf-m kgf-m kgfィTl
1.020 2.039 3.059 4,879 5.099 6.118 7.138 8.158 9.177
100 10.197 ll.217 12.236 13.256 14.276 15.296 16.315 17.335 18.355 19.374 100
200 20.394 21.414 22.433 23.453 24.473 25.493 26,512 27.532 28.552 29.571 200
300 30.591 31.611 32.630 33.650 34.670 35.690 36.709 37.729 38.749 39.768 300
4OO 40.788 41.808 42.827 43.847 44.867 45.887 46.906 47.926 48.946 49.965 400
500 50.985 52.005 53.024 54.044 55.064 56.084 57,103 58.123 59.143 60.162 500
600 61.182 62.202 63.221 64.241 65.261 66.281 67.300 68,320 69.340 70.359 600
700 71.379 72.399 73.418 74.438 75.458 76.478 77.497 78.517 79.537 80.556 700
800 81.576 82.596 83.615 84.635 85.655 86.675 87.694 88.714 89.734 90,753 800
900 91.773 92.793 93.812 94.832 95.852 96.872 97.891 98.911 99.931 100.950 900
1000 101.970 102.990 104.009 105.029 106.049 107.069 108.088 log.108 110.128 lil.147 1000
219
CONVERSION TABLE
TEMPERATURE
FAHRENHEIT TO CENTIGRADE
oF ロC ロF oC oF oC oF c'C oF oC cF oC oF oC t)F oC
56 13.3 114 45.6 172 77.8 230 110.0 288 142.2 346 174,4
-60 151.1 -2 -18.9
0 58 14,4 116 46.7 174 78.9 232 lll.1 290 143.3 348 175.6
-58 -50.0 ,17.8
2 ･16.7 60 15,6 118 47.8 176 80.0 234 112.2 292 144.4 350 176.7
-56 -48.9
4 62 16.7 120 48.9 178 81.i 236 113.3 294 145.6 352 177.8
-54 -47.8 -15.6
6 ･14.4 64 17.8 122 50.0 180 82.2 238 114.4 296 146.7 354 178.9
-52 -46.7
8 66 18.9 124 51.1 182 83.3 24O 115.6 298 147.8 356 180.0
-50 -45.6 ･13.3
10 68 20.0 126 52.2 184 84.4 242 116.7 300 148.9 358 181.1
-48 144.4 -12.2
12 70 21.1 128 53.3 186 85.6 244 117.8 302 150.0 360 182.2
-46 -43.3 -ll.1
14 72 22.2 130 54.4 188 86.7 246 118.9 304 151.1 362 183.3
･44 -42.2 ･10.0
16 74 23.3 132 55.6 190 87.8 248 120.0 3O6 152.2 364 184.4
-42 -41.1 -8.9
18 76 24.4 134 56.7 192 88.9 250 121.i 308 153.3 366 185.6
-40 -40.0 -7.8
20 78 25.6 136 57.8 194 90.0 252 122.2 310 154.4 368 186.7
-38 ･38.9 -6.7
22 80 26.7 138 58.9 196 91.1 254 123.3 312 155,6 370 187.8
･36 ･37.8 -5.6
24 82 27,8 140 60.0 198 92.2 256 124.4 314 156.7 372 188.9
-34 -36.7 ･4.4
26 84 28.9 142 61.1 200 93.3 258 125.6 316 157.8 374 190,0
-32 -35.6 ･3,3
28 86 30.0 144 62.2 202 94.4 260 126.7 318 158.9 376 191.i
-30 -34.4 -2.2
30 88 3l.1 146 63.3 204 95.6 262 127.8 320 160.0 378 192.2
･28 -33.3 -1.1
32 0.0 90 32.2 148 64,4 206 96.7 264 128.9 322 161.1 380 193.3
-26 ･32.2
34 1.1 92 33.3 150 65.6 208 97.8 266 130.0 324 162.2 382 194.4
･24 -31.1
36 2.2 94 34.4 152 66.7 210 98.9 268 131.1 326 163.3 384 195.6
･22 -30.0
38 3.3 96 35.6 154 67,8 212 100.0 270 132.2 328 164.4 386 196.7
-20 -28.9
40 4.4 98 36.7 156 68.9 214 10l.1 272 133.3 330 165.6 388 197.8
-18 -27.8
42 5.6 100 37,8 158 70.0 216 102.2 274 134.4 332 166.7 390 198.9
･16 ･26.7
44 6.7 102 38.9 160 71.1 218 103.3 276 135.6 334 167.8 392 200.0
-14 -25.6
46 7.8 104 40.0 162 72.2 220 104.4 278 136.7 336 168.g 400 2O4.4
･12 ･24.4
48 8.9 106 41.1 164 73.3 222 105.6 280 137,8 338 170.0 410 210.0
-10 -23.3
50 10.0 108 42.2 166 74.4 224 106.7 282 138.9 340 171.1 420 215.6
-8 -22.2
52 ll.1 110 43.3 168 75.6 226 107.8 284 140.0 342 172.2 430 221.1
-6 ･21,1
54 12.2 112 44.4 170 76.7 228 108.9 286 14l.1 344 173.3 440 226.7
-4 -20.0
CENTIGRADE TO FAHRENHEIT
c'C oF oC oF oC oF cC oF oC E'F oC cF oC oF oC oF
14 57.2 46 114.8 78 172.I 110 230.0 142 287.6 174 345.2

･50 -58.0 -18 -0.4
1.4 15 59.0 47 116.6 79 174.2 111 231.8 143 289.4 175 347.0
-49 ･56.2 ･17
3.2 16 60.8 48 118.4 80 176.0 112 233.6 144 291.2 176 348,8
-48 -54.4 ･16
5.0 17 62.6 49 120.2 81 177,8 113 235.4 1ヰ5 293.0 177 350.6
-47 -52.6 -15
6.8 18 64.4 50 122.0 82 179.6 114 237.2 146 294.8 178 352.4
-46 -50.8 -14
8.6 19 66.2 51 123.8 83 18l.4 115 239.0 147 296.6 179 354.2
-45 -49.O ･13
10.4 20 68.0 52 125.6 84 183.2 116 240.8 148 298.4 180 356.0
･44 ･47.2 -12
12.2 21 69.8 53 127,4 85 185.O 117 242.6 149 300.2 181 357.8
-43 -45.4 -ll
14.O 22 71.6 54 129.2 86 186.8 118 244.4 150 302.0 182 359.6
-42 -43.6 ･10
15.8 23 73.4 55 131.0 87 188.6 119 246.2 151 303.8 183 361.4
-41 ･41.8 -9
17.6 24 75.2 56 132.8 88 190.4 120 248.0 152 305.6 184 363.2
-40 -40.0 -8
19.4 25 77.0 57 134.6 89 192.2 121 249.8 153 307.4 185 365.0
-39 ･38.2 -7
21.2 26 78.8 58 136.4 90 194.0 122 251.6 154 309.2 186 366.8
-38 ･36.4 -6
23.0 27 80.6 59 138.2 91 195.8 123･ 253.ヰ 155 311.0 187 368.6
-37 ･34.6 15
24.8 28 82.4 60 140.0 92 197.6 124 255.2 156 312.8 188 370.4
-36 ･32.8 -4
26.6 29 84.2 61 14l.8 93 199.4 125 257.0 157 314.6 189 372.2
-35 -31.O -3
28.4 30 86.0 62 143.6 94 201.2 126 258.8 158 316.4 190 374.0
134 -29.2 ･2
30.2 31 87.8 63 145.4 95 203.0 127 260,6 159 318,2 191 375.8
-33 -27.4 ･1
0 32.0 32 89.6 64 147.2 96 2O4,8 128 262.4 leo 320,0 192 377.6
-32 ･25.6
1 33.8 33 91,4 65 149.0 97 206,6 129 264.2 161 321.8 193 379.4
-31 ･23.8
2 35.6 34 93.2 66 150.8 98 208.4 130 266.0 162 323.6 194 38l.2
･30 ･22.0
3 37.4 35 95.0 67 152.6 99 21O.2 131 267.8 163 325.4 195 383.0
-29 -20.2
4 39.2 36 96.8 68 154.4 100 212.0 132 269.6 164 327.2 196 384.8
128 ･18.4
5 41.0 37 98.6 69 156.2 101 213.8 133 27l.4 165 329.0 197 386.6
-27 ･16.6
6 42.8 38 10(】.4 70 158.0 102 215.6 134 273.2 166 330.8 198 388.4
-26 ･14.8
7 44.6 39 102.2 71 159.8 103 217.4 135 275,0 167 332.6 199 390.2
-25 ･13.0
8 46.4 40 104.0 72 161.6 104 219.2 136 276.8 168 334.4 200 392.0
-24 -ll.2
9 48.2 41 105.8 73 163.4 105 221.0 137 278.6 169 336.2 210 410.0
･23 -9.4
10 50.0 42 107.6 74 165.2 106 222.8 138 280.4 170 338.0 220 428.0
-22 -7.6
ll 51.8 43 109.4 75 167.0 107 224.6 139 282.2 171 339.8 230 446.0
-21 -5.8
12 53.6 44 111.2 76 168.8 108 226.4 140 284.0 172 341.6 240 464.0
-20 -4.0
13 55.4 45 113.0 77 170.6 log 228.2 141 285.8 173 343.4 250 482.0
119 .-2.2
220
Copyright reserved for this manual may not be
reproduced or copied, in whore or in part,. without the

written consent of FSUZU MOTORS UMITED,
WORKSHOP MANUAL (lNDUSTRtALI
A-4JG I
(lDE-2320)
Jssued by
ISUZU MOTORS LIM汀ED

POVVERTRAJN SERV[CE a PARTS
POVVERTRA[N OPERATIONS
6-26･1. Minahli-of, Shinagawa･ku.Tokyo, 140-8722, Japan
TEL 03-547ト1111
First edition Aug., 1999 907-01K

Engine: See The Attached Engine Manufacturer's SERVICE MANUAL

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Engine: See The Attached Engine Manufacturer's SERVICE MANUAL

Enviado por

Direitos autorais:

Formatos disponíveis

51.

See the attached Engine manufacturer's SERVICE MANUAL

This Workshop Manual is desJ'gned to heJp you perform necessary

under the headings ''GeneraI Repalr Jnstruction” and

SECT[ON2. MAJNTENANCE ”.......”...”.”....”.”””.”....... 17

SECT[ON5. ENGfNEASSEMBLY(3) ”””..””..””..”..””. 81

SECT10N 6. LUBFIJCATINGSYSTEM…‥‥…‥‥‥‥…....‥‥‥=.” 109

SECT10N 7. COOuNGSYSTEM ”””.””..”,,”...”””.”. 121

SECTION 8. FUELSYSTEM.....H‥‥….……‥…………‥…‥…‥ 127

SECTJON 9. ENGrNEELECTRJCALS...””””.”...,””..””.”... 141

SECTJON 10. TROUBLESHOOT[NG.”....”...””.””””.”.”.. 169

SECTIONll. SPECJALTOOLuST.......=…‥‥..……‥∴‥‥‥…‥. 195

SECTION 12. REPAIRSTANDARDS......……...”‥..‥…‥.……..” 199

SECT10N 13. CONVERS[ONTABLE.......”””.”........”......... 213

3. Usegenuine ISUZU parts.

5･ A一ways keep disassembled parts neatly in groups･ This win ensure a

completely free of obstructions.

9. Nut and bo[ttorque specifications should be carefuJly fo=owed.

NOTES ON THE FORMAT OF T川S MANUAL

More procedures are in detaiI･

Parts marked with an asterisk (*) are

included in the repair kit.

し≡ sembly steps are shown in the

Removal of unnumbered parts is unne-

repair kit is avaiJabJe.

1. Wz)t8r by･pJSS hose 10. CylJ'ndor h餌d g8宇ket

This is the item shown in the iI[us-

+ Symbols indicate the type of service

団-･ Sealant app一ication

9. Measurement criteria are defined bythe terms川standard.rand J'(亨mjt''.

A measurement which is outside the ''(imitl■

ll, Directions used inthis Manual are asfoflows:

The right hand side viewed from the same position.

The left hand side vJ'ewed from the same position.

The fJywheef side of the engJne.

MAIN DAm AND SPECl円CAT10NS

Spec汀ications marked with an asterisk (貴)w= vary according to engine application.

TJGHTENING TORQUE SPECIFICATJONS

STANDARD BOLJ N･m (kgf.m)

M6×1.0 3.9-7.8fO.4-0.8) 4.9-9.8(0.5-1.01

M8×1.25 7.8-17.7(0.8-1.8) ll.8-22.6(1.2-2.3) 16.7-30.4(1.7-3.1)

MIOxl.25 20.6-34.3(2.1-3.5‡ 27.5-46,l(2.8-4.7) 37.3-62.8(3.8-6.4)

＋MIOxl.5 19.6-33.4(2.0-3.4) 27.5-45.1(2.8-4.6) 36.3-59.a(3.7-6.1)

M12)く1.25 ヰ9.l-73.6(5.0-7.5) 60.a-91.2(6.2-9.3) 75.5-114.0(7.7-ll.6)

*M12×1.75 45.1-68,7(4.6-7.0〉 56.9-84,4(5.8-8.6) 7l.6-107.0(7.3-10.9)

M14×1.5 76.5-115.0(7.8-ll.7〉 93.2-139.0(9.5一-14.2) 114.0-171.a(ll.6-17.4I

書M14×2.0 71.6-107.0(7.3-10,9) 88.3-131.0(9.0-13.4) 107.0-160.0(10.9-16.3)

M16×1.5 104.0-157.0(10.6-16.0) 135.0-204.0(13.8-20.8) 160.0-240.0(16.3-24.5)

★M16×2.0 100.0-149.0(10.2-15.2) 129.O-194.0(13.2-19.8) 153.0-230.0(15.6-23.4)

M18×1.5 15l.0-226.0(15.4-23,0) 195.0-293,0(19,9-29.9) 230.0-345.0(23.4-35.2)

≠M18×2.5 151.0-226.0(15.4-23.0‡ 196.0-294.0(20.0-30.0) 231.0-346.0(23.6-35.3)

M20×1.5 206.0-310.0(21.0-31.6) 270.0-405.0(27.5-41.3) 317.0-476.0(32.3…48.5)

*M20×2.5 190.0-286.0(19.4-29.2) 249,0-375.0(25.4-38.2) 293.0-440.0(29.9-44.9)

M22×1.5 251.0-414.0(25.6-42.21 363.0-544.0(37.0-55.5〉 425.0-637.0(43,3-64.9)

*M22x2.5 218.0-328.0(22.2-33.41 338.0-507.0(34.5-5l.7) 394.0-592.0(40.2-60.4〉

M24x2.0 359.0-540.0(36.6-55.0) 431.0-711.0(43.9-72.5) 554.0-831.0(56.5-84.7)

★M24×3.0 338.0-507,0(34.5-51.7) 406.0-608.0(41.4-62.0) 521.O-782.0(53.1-79.7)

asterisk (i) indicates

T[GHTENJNG TORQUE SPECIF]CATJONS

The tightening torque vaJues glVen in the tab一e be[ow are

FLANGED HEAD 801J N･m (kgf･m)

M6×1.0 4.6-8.5(0.5-0.9) 6.6-12.2(0.6-1.2)

MBxl.25 10.5-196(1.1-2.0) 15.3-28.4(1.6-2.9) 18.1-33.6(2.1-3.4)