Manual Serviço Volvo D49 A MT

Workshop Manual H
2(0)
D49A MS, D49A MT
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Marine Engines
D49A MS/MT
Contents
Safety Information ................................................. 5 Group 22:Lubrication system

Warning labels ....................................................... 8 Oil Pump and Safety Valve
Disassembly ...................................................... 137
General Information ............................................ 10
Inspection .......................................................... 138
Presentation ........................................................ 16
Reassembly ....................................................... 140
Identification numbers ......................................... 18
Oil filter, Relief Valve,Left Cooler and Thermostat
Specifications ...................................................... 19
Disassembly ...................................................... 141
Maintenance Standards Table ............................. 22
Inspection .......................................................... 142
Tightening torques ............................................... 39
Reassembly ....................................................... 143
Sealants and Lubricants Table ............................ 45
Right Side Oil Cooler and Oil Thermostat
Special Tools ....................................................... 46 Disassembly ...................................................... 144
Determination of overhaul timing ...................... 49 Inspection .......................................................... 144
Reassembly ....................................................... 144
Adjustment and Benchtesting ............................ 50
Group 23:Fuel System
Engine auxiliaries removal ................................. 60
Fuel Filters
Engine auxiliaries installation ............................ 71 Disassembly ...................................................... 145
Reassembly ....................................................... 146
Group 21:Engine Body
Fuel Injectors
Cylinder heads and valve mechanism
Disassembly ...................................................... 147
Disassembly ........................................................ 75
Inspection and Adjustment ................................ 148
Inspection and Repair .......................................... 78
Reassembly ....................................................... 150
Reassembly ......................................................... 85
Fuel Injection Pump
Cylinder liners, Pistons and Connecting rods
Disassembly ...................................................... 151
Disassembly ........................................................ 89
Inspection .......................................................... 157
Inspection and Repair .......................................... 93
Reassembly ....................................................... 160
Reassembly ....................................................... 102
Adjustment of Injection Timing ........................... 169
Viscous damper and front gears
Feed Pump
Disassembly ...................................................... 106
Disassembly ...................................................... 171
Inspection and Repair ........................................ 109
Reassembly ....................................................... 172
Reassembly ....................................................... 111
Testing .............................................................. 172
Oil pan and Oil strainer ...................................... 113
PSG Woodward Governor and Drive
Flywheel, Timing gears, and Camshaft
Disassembly ...................................................... 173
Disassembly ...................................................... 115
Inspection .......................................................... 174
Reassembly ....................................................... 175
Reassembly ....................................................... 122
Crankcase, Crankshaft and Main bearings
Disassembly ...................................................... 126
Reassembly ....................................................... 135

Group 25:Inlet and Exhaust System Group 30:Electrical System
Air Cooler Starter
Disassembly ...................................................... 176 Disassembly ...................................................... 203
Inspection .......................................................... 177 Inspection and Repair ........................................ 206
Turbocharger ..................................................... 178 Reassembly ....................................................... 210
Disassembly ...................................................... 179 Alternator
Inspection .......................................................... 182 Disassembly ...................................................... 213
Reassembly ....................................................... 184 Inspection and repair ......................................... 214
Group 26:Cooling System Reassembly ....................................................... 214
Fresh Water Pump
Disassembly ...................................................... 191
Inspection .......................................................... 193
Reassembly ....................................................... 194
Thermostats ...................................................... 196
Heat Exchanger ................................................. 197
Raw Water Pump
Disassembly ...................................................... 198
Inspection .......................................................... 199
Reassembly ....................................................... 200

Safety information
Safety Information
Introduction
The Manual contains technical data, descriptions, and repair instructions for the designated Volvo Penta engines
or engine versions. Make sure that the correct workshop literature is used.
Read the following safety information and the General Information and Repair Instructions in the Workshop Man-
ual carefully before starting service work.
Important
The following special warning symbols are used in the Workshop Manual and on the engine.
WARNING! Warns of risk of bodily injury, serious damage to product or property, or that a serious malfunc-
tion can occur if the instructions are not followed.
IMPORTANT! Used to attract attention to things that can cause damage or malfunction to product or prop-
erty.
NOTE! Used to attract attention to important information, to simplify work procedures or handling.
The following list provides an overview of the risks and cautionary procedures that should always be observed.
Prevent the engine from being started by dis- Make sure that the warning or information de-
connecting the power with the main switch cals on the product are always clearly visible.
(switches) and locking it (them) in the discon- Replace labels that have been damaged or
nected position. Post warning signs stating painted over.
“Work in progress!” in every position from wich
the engine can be started. Never start the engine unless the air filter is fit-
ted. The rotating compressor wheel in the turbo
Maintenance and service should be performed can cause severe injury. Foreign objects in the
on a stationary engine. However, some proce- inlet pipe can also damage the machine.
dures, e.g. certain adjustments, require the en-
gine to be running. Approaching an engine that Never use starter spray or the like. Risk of in
is running is a safety risk. Remember that loose the inlet pipe. Risk of personal injury.
clothes or long hair can fasten in rotating parts
and cause severe injury. Avoid opening the coolant filler cap when the
A careless movement or dropped tool while engine is hot. Steam or hot coolant can spray
working in the vicinity of an engine that is runout, and built up pressure will be lost. Open the
ning, can in the worst case lead to injury. Ob- filler cap slowly and release the overpressure in
serve caution with hot surfaces (exhaust pipe, the cooling system if the filler cap or cock must
turbo, charge air pipe, starter element etc.) and be opened, or if a plug or coolant pipe must be
hot fluids in the lines and hoses of an engine removed when the engine is hot. Steam or hot
that is running, or has just been stopped. Refit coolant can flow out in an unpredicted direction.
all guards dismantled during service work be-
fore starting the engine.

Safety information
Hot oil can cause burn injuries. Avoid skin con- All fuels, as well as many chemicals, are inflam-
tact with hot oil. Make sure that the oil system is mable. Make sure no naked flames or sparks
not pressurised before working on it. Never can cause ignition. Petrol, certain thinners, and
start, or run the engine with the oil filler cap re- hydrogen from batteries are extremely inflam-
moved due to the risk of ejecting oil. mable and explosive when mixed with air.
Smoking is prohibited! Ventilate well and take
Stop the engine and close the bottom valve be- the necessary precautions before welding or
fore working on the cooling system. grinding in the immediate vicinity. Always have
a fire extinguisher handy in the workshop.
Only start the engine in a well-ventilated area.
Exhaust fumes and crankcase gases should be Make sure that rags drenched in oil and petrol,
bled out of the engine compartment or work- including old fuel and lubricant filters, are stored
shop when working in closed environments. safety. Oil drenched rags can in certain condi-
tions self-ignite. Old fuel and oil filters are envi-
Always use protective glasses for work where ronmentally hazardous waste, and together with
there is a risk of splintering, sparks, or splash- spent lubricant, contaminated fuel, paint resi-
ing of acid or other chemicals. The eyes are ex- due, solvent, degreasing agent and suds,
tremely sensitive, and an injury could cause should be handed in to a waste-handling unit for
blindness! destruction.
Avoid skin contact with oil! Prolonged or fre- Batteries must never be exposed to naked
quent skin contact with oil can degrease the flames or electrical sparks. Never smoke in the
skin, resulting in irritation, drying out, eczema, vicinity of batteries. Hydrogen develops when
and other skin complaints. Used oil is more batteries are charged, which in combination
dangerous than new oil from a health care point with air forms an explosive gas. This gas is
of view. Use protective gloves and avoid oil- highly inflammable and very explosive. One
drenched clothes and rags. Wash your hands spark from connecting the batteries incorrectly
regularly, especially before meals. Use special is sufficient to cause the battery to explode and
hand cream to counteract drying out, and to cause injury. Do not touch the connection when
simplify cleaning the skin. starting (risk of spark) and do not lean over the
batteries.
The majority of chemicals intended for the prod-
uct (e.g. engine and timing gear oils, glycol, Never confuse the plus and minus terminals
petrol and diesel oil) or chemicals for workshop when fitting the batteries. This can cause seri-
use (e.g. degreasing agent, enamels and sol- ous damage to the electrical equipment. Check
vents) are hazardous to health. Read the in- the wiring diagram.
structions on the pack carefully. Always follow
the given safety instructions (e.g. the use of Always use protective glasses when charging
breathing protection, protective glasses, or and handling batteries. The battery electrolyte
gloves, etc.) Make sure that other personnel are contains strongly corrosive sulphuric acid. Upon
not exposed to hazardous substances, e.g. by contact with the skin, wash with soap and plen-
inhaling the air. Make sure there is adequate ty of water. If battery acid gets into the eyes,
ventilation. Handle consumed and surplus rinse immediately with water, and contact a
chemicals in the prescribed manner. doctor without delay.
Observe extreme caution when tracing fuel Stop the engine and turn off the power with the
leaks in fuel systems and when testing fuel noz- main switch (switches) before working on the
zles. Wear protective glasses. The jet from a electrical system.
fuel nozzle has a very high pressure and pene-
trating force. The fuel can penetrate deeply into The clutch should be adjusted when the engine
bodily tissue and cause serious injury. Risk of is idle.
blood poisoning.

Safety information
Use the lifting hooks mounted on the engine/re- WARNING! The components in the electrical
versing gear when lifting the drive unit. Always system and fuel system on Volvo Penta prod-
check that the lifting equipment is in good con- ucts are designed and manufactured to mini-
dition and has the correct capacity for the lift mise the risks of explosion and fire. The engine
(weight of engine plus reversing gear and extra must not be run in environments surrounded by
equipment where appropriate). explosive media.
For safe handling, and to avoid damaging the Pressure pipes must not bent, turned, or ex-
components mounted on top of the engine, the posed to other strain. Replace damaged pres-
engine should always be lifted with a lifting bar sure pipes.
adjusted to the engine. All chains or wires
should run in parallel with each other and as Observe the following when cleaning with high-
perpendicular to the top of the engine as possi- pressure wash: Never point the jet of water at
ble. Special lifting equipment may be required to seals, rubber hoses, or electrical components.
ensure the right balance and safe handling if Never use the high-pressure function when
other equipment connected to the engine alters washing the engine.
its centre of gravity.
Always use Volvo Penta recommended fuel.
Never work on an engine supported only by lift- See the instruction manual. The use of inferior
ing equipment. quality fuel could damage the engine. The use
of inferior fuel in a diesel engine could cause
Never work alone when heavy components are the control rod to jam and the engine to over-
to be dismantled, even when safe lifting (e.g. speed, with the risk of personal injury or dam-
lockable block and tackle) equipment is used. In age to the machine. Inferior fuel can also lead
most cases, two persons are required even to higher maintenance costs.
when lifting equipment is used: one to handle
the equipment and one to make sure that com-
ponents are not damaged. When working on-
board a boat always make sure in advance that
there is sufficient space to allow dismantling in
situ, without the risk of personal injury or materi-
al damage.

Safety information
Warning labels D49A MS

The engine carries ‘Warning Labels’ at places where you are required to pay special attention. Please read them
carefully and make sure you understand the content of each label and the meaning of their position.
1. Make sure the labels are legible. If you find any letter or picture illegible in a label, remove soil from the label,
or replace it.
2. Clean the label with cloth and water or cleanser. Do not use organic solvent or gasoline, this would dissolve
the label’s adhesive and cause the label to fall off.
3. If any label is damaged, lost or illegible, replace it. When replacing a label, make sure the new label is
identical to the old one. For new labels, please contact your dealer.

8
Safety information
Warning labels D49A MT

The engine carries ‘Warning Labels’ at places where you are required to pay special attention. Please read them
carefully and make sure you understand the content of each label and the meaning of their position.
1. Make sure the labels are legible. If you find any letter or picture illegible in a label, remove soil from the label,
or replace it.
2. Clean the label with cloth and water or cleanser. Do not use organic solvent or gasoline, this would dissolve
the label’s adhesive and cause the label to fall off.
3. If any label is damaged, lost or illegible, replace it. When replacing a label, make sure the new label is
identical to the old one. For new labels, please contact your dealer.

9
General information
General Information
About the Workshop Manual
This Workshop Manual contains technical information, descriptions, and instructions for the standard versions of
the D49A MS and D49A MT engines. The engine designation and numbers are to be found on the engine identifi-
cation plate, refer to section “Identification numbers”. The motor designation and number should always be given
during all correspondence with Volvo Penta.
The Workshop Manual is primarily produced for Volvo Penta service workshops and their qualified personnel. It
is therefore assumed that persons using this manual have a basic knowledge of marine drive systems, and are
able to carry out the related mechanical and electrical nature. Volvo Penta is continuously developing their prod-
ucts. We therefore reserve the right to make changes. All the information contained in this book is based on
product data available prior to publication. Any essential changes or modifications in production or updated or re-
vised service methods introduced after publication will be communicated by means of Service Bulletins.
Spare parts
Spare parts for the electrical and fuel systems are subject to different national safety requirements, e.g. U.S.
Coast Guard Safety Regulations. Volvo Penta Genuine Spare Parts comply with these requirements. All types of
damage resulting from the use of non genuine Volvo Penta spare parts for the product in question will not be reg-
ulated by the warranty undertakings of Volvo Penta.
Certified engines
For service and repair on an engine certificated for any area where exhaust emissions are regulated by law, the
following is important:
Certification means that an engine type is inspected and approved by the authorities. The engine manufacturer
guarantees that all engines manufactured of that type correspond to the certified engine.
This places special requirements on maintenance and service as follows:
● The maintenance and service intervals recommended by Volvo Penta must be observed.
● Only genuine Volvo Penta replacement parts may be used.
● The service of injection pumps and injectors or pump settings must always be carried out by an authorized
Volvo Penta workshop.
● The engine must not be modified in any way except with accessories and service kits approved by Volvo
Penta.
● No modifications to the exhaust pipes and air supply ducts for the engine may be undertaken.
● Seals may only be broken by authorized personnel.

Otherwise the general instructions contained in the Operator’s manual concerning operation, service and mainte-
nance must be followed.
IMPORTANT! Neglected or deficient maintenance/service and the use of non-original spare parts will entail
Volvo Penta renouncing any responsibility for the engine corresponding to the certified version. Volvo Pen-
ta will not compensate for damage and/or costs arising from the above.
10

General information
Repair instructions
The working methods described in the Service Manual apply to work carried out in a workshop. The engine has
been removed from the boat and is installed in an engine fixture. Unless otherwise stated reconditioning work
which can be carried out with the engine in place follows the same working method.
Warning symbols occurring in the Workshop Manual (refer to section “Safety information”) are not in any way
comprehensive since it is impossible to predict every circumstance under which service work or repairs may be
carried out. For this reason we can only highlight the risks that can arise when work is carried out incorrectly in a
well-equipped workshop using working methods and tools developed by us.
All procedures for which there are Volvo Penta special tools in this Workshop Manual are carried out using
these. Special tools are developed to rationalize working methods and make procedures as safe as possible. It is
therefore the responsibility of any person using tools or working methods other than the ones recommended by
us to ensure that there is no danger of injury, damage or malfunction resulting from these.
In some cases there may be special safety precautions and instructions for the use of tools and chemicals con-
tained in this Workshop Manual. These special instructions should always be followed if there are no separate in-
structions in the Workshop Manual.
Certain elementary precautions and common sense can prevent most risks arising. A clean workplace and en-
gine eliminates much of the danger of injury and malfunction.
It is of the greatest importance that no dirt or foreign particles get into the fuel system, cooling system, lubrication
system, intake system, turbocharger, bearings and seals when they are being worked on. The result can be mal-
function or a shorter operational life.
Our joint responsibility

Each engine consists of many connected systems and components. If a component deviates from its technical
specification the environmental impact of an otherwise good engine may be increased significantly. It is therefore
vital that wear tolerances are maintained, that systems that can be adjusted are adjusted properly and that Volvo
Penta Genuine Parts as used. The engine Maintenance Schedule must be followed.
Some systems, such as the components in the fuel system, require special expertise and special testing equip-
ment for service and maintenance. Some components are sealed at the factory for environmental reasons. No
work should be carried out on sealed components except by authorized personnel.
Bear in mind that most chemicals used on boats are harmful to the environment if used incorrectly. Volvo Penta
recommends the use of biodegradable degreasing agents for cleaning engine components, unless otherwise
stated in a workshop manual. Take special care when working on-board, that oil and waste is taken for destruc-
tion and is not accidentally pumped into the environment with bilge water.
11

General information
How to Use This Manual Terms used in this manual

1. Parts in illustrations are numbered to correspond Before you read this manual, note that the following
with references to these numbers in text. special terms are used in dimensional and other
specifications.
2. Items or conditions to be inspected during disas-
sembly are listed in the disassembled views. Assembly standard
Indicates the dimension of a part, the dimension to be
3. Maintenance standards for inspection and repair attained at the time of reassembly or the standard
are described in text where relevant. For a quick performance.
summary of maintenance standards refer to sec-
tion “Maintenance Standards” of this manual. Norminal value
4. The sequence in which parts are to be reassem- Indicates the standard dimension of a part.
bled is summarized below each assembled view.
Repair limit
Such as:
A part which has reached this limit must be repaired.
Service limit
5. Tightening torque under wet conditions is indicat- A part which has reached this limit must be replaced.
ed as “(wet)” in text, drawings, and tables. When
so indicated, apply engine oil to the threaded por- Standard clearance
tion of the fastener. Unless indicated as (wet), the Indicates the clearance to be obtained between mat-
tightening torque should be dry. ing parts at reassembly.
12

General information
Disassembly and Reassembly

This service manual covers recommended procedures to be followed when servicing diesel engines. It also con-
tains information on special tools required and basic safety precautions.
It is the responsibility of service personnel to be familiar with these requirements, precautions, and potential haz-
ards and to discuss these points with their foreman or supervisor.
Study this manual carefully and observe the following general precautions to prevent serious personal injury and
to avoid damage to the engine, equipment, and parts.
WARNING! Use the correct tools and instruments. Serious injury or damage to the engine can result from
using the wrong tools and instruments
WARNING! When lifting or carrying heavy parts, get someone to help you if the part is too awkward for one
person to handle. Use jacks and chain blocks when necessary.
IMPORTANT! Use an overhaul stand or work bench if necessary.
IMPORTANT! Always read the Service Bulletins to learn about changes in procedures and/or technical data.
NOTE! Pay attention to the marks on assemblies, components, and parts for positions or directions. Put on your
own marks, if necessary, to aid reassembly.
NOTE! Carefully check each part for faults during removal or cleaning. Signs of abnormal wear will tell if parts or
assemblies are functioning improperly.
NOTE! Use assembly bins to keep the parts in order of removal and lay down disassembled or cleaned parts in
the order in which they were removed. This will save you time at reassembly
NOTE! Wash all engine parts, except oil seals, O-rings, rubber seals, etc. in cleaning solvent and dry them with
compressed air
NOTE! Use a torque wrench to tighten parts when specified tightening torques are required.
NOTE! Use only good quality lubricating oils and greases. Be sure to apply a coat of oil, grease, or sealant be-
fore reassembly, to parts as specified.
NOTE! Replace all gaskets and packing. Apply appropriate amount of adhesive or liquid gasket when required.
13

General information
Oil Seals
When installing oil seals, carefully observe the follow-

ing points.
Driving oil seals into housings
1. Check the seal lip for damage, and be sure to po-

sition correctly in the housing.
2. Apply a smear of grease to the surface of the oil

seal (to be fitted into the housing bore).
3. Use an oil seal driver shown to guide the seal lip

and drive the outer diameter squarely. To avoid
damage to the oil seal and leaking, never ham-
mer on it directly.
Driving oil seals onto shafts

1. Apply a smear of grease to the oil seal lip.
2. Use an oil seal guide of the type shown when

driving the oil seal over the stepped portion,
splines, threads, or key way to prevent damage
to the oil seal lip.
O-rings
Use an O-ring guide to install an O-ring over stepped
parts, splines, threads, or key way to prevent damage
to the ring. Apply a smear of grease to the O-ring be-
fore installation.
14

General information
Bearings
1. When installing a rolling bearing, be sure to push
the inner or outer race by which the bearing is fit-
ted. Be sure to use a bearing driver like the one
shown.
2. Whenever possible, use a press to minimize

shock to the bearing and to assure proper instal-
lation.
Lock Plates
Bend lock plates against the flats of the nuts or bolt
heads as shown.
Split Pins and Spring Pins

Generally, split pins are to be replaced once dis-
turbed. Insert the pin fully and spread it properly.
Drive each spring pin into position to hold it in place
after later installation of parts has been completed.
15

General information
Presentation D49 MS
D49A MS
1. Fuel filters
2. Oil cooler
3. Fuel injection pump
4. Governor oil filter
5. Manual stop lever
6. Governor
7. Stop solenoid
8. Oil dipstick
9. Fuel feed pump
10. Oil filler cap
11. Fresh water pump
12. Lifting eye
13. Intake air silencer
14. Turbocharger
15. Alternator
16. Oil filters
17. Engine oil drain pipe
18. Starter motor
19. Manual speed control knob
16

General information
Presentation D49 MT
D49A MT
1. Fuel filters
2. Oil cooler
3. Fuel injection pump
4. Governor oil filter
5. Manual stop lever
6. Governor
7. Stop solenoid
8. Oil dipstick
9. Fuel feed pump
10. Oil filler cap
11. Fresh water pump
12. Lifting eye
13. Intake air silencer
14. Turbocharger
15. Heat exchanger
16. Oil filters
17. Starter motor
18. Engine oil drain pipe
19. Sea water pump
20. Alternator
21. Manual speed control knob
17

General information
Identification numbers D49A

Type plates with identification numbers can be found on the engine and the transmission or generator. This infor-
mation must always be used as a reference when ordering service and spare parts.
Engine ........................................................................................................................................
Product designation ....................................................................................................................
Serial and basic engine number .................................................................................................
Product number ..........................................................................................................................
Certification, IMO ........................................................................................................................

Decal, part No. ...........................................................................................................................
Approval No. ...............................................................................................................................
Transmission / Generator ...........................................................................................................

Product designation ....................................................................................................................
Serial number .............................................................................................................................
Product number ..........................................................................................................................
18

General information
Specification D49A MS & MT

General specification
Model ........................................................................... Water-cooled,4-stroke, turbocharged diesel with air-cooled intercooler
No. of cylinders ............................................................ 12
Arrangement ................................................................ vertical V type
Combustion type .......................................................... Direct injection
Valve mechanism ........................................................ Overhead
Cylinder bore,mm [in.] .................................................. 170[6.70]
Cylinder stroke,mm [in.] ............................................... 180 [7.10]
Displacement, litres [U.S. gal] ..................................... 49.03 [12.95]
Compression ratio ........................................................ 14.0:1
Firing order ................................................................... 1-12-5-8-3-10-6-7-2-11-4-9
Rotational direction ...................................................... Counterclockwise as viewed from flywheel
Weight (Dry)(without marine gear), kg [lb] ................... MS: 4820[10626] MT: 5000 [11025]
Engine main parts

Cylinder liner type ........................................................ Wet type
Piston rings:
Compression rings, pcs ............................................... 2
Oil ring(w/expander), pcs ............................................. 1
Valve timing (when warm):
Inlet valve ..................................................................... open BTDC 37°
Inlet valve ..................................................................... close ABDC 44°
Exhaust valve .............................................................. open BBDC 57°
Exhaust valve .............................................................. close ATDC 24°
Engine support method ................................................ 4 point support
Fuel system
Fuel
JIS K2204 .................................................................... TYPE 1, TYPE 2, TYPE 3
ASTM. D975 ................................................................ No.1-D, No.2-D
BS2869 ........................................................................ CLASS-A1, CLASS-A2,
DIN51601 ..................................................................... DIESEL-FUEL
ISO8217 ....................................................................... DMX-CLASS
Injection pump
Model ........................................................................... PS6 type
Manufacturer ................................................................ Mitsubishi Heavy Industries, Ltd.
Plunger outside diam., mm [in.] ................................... 17 [0.67]
Plunger lead, mm [in.] .................................................. Counterclockwise, left-hand 35 [1.38] lead
Cam lift, mm [in.] .......................................................... 15 [0.59]
Fuel feed pump

Model ........................................................................... Zexel
Manufacturer ................................................................ Zexel
Cam lift, mm [in.] .......................................................... 12 [0.47]
Governor
Control system ............................................................. Woodward Hydraulic PSG
19

General information
Fuel system cont.

Fuel injector
Type ............................................................................. Hole type
Manufacturer ................................................................ Zexel
No. of spray holes ........................................................ 10
Spray hole diameter, mm [in.] ...................................... 0.325 [0.013]
Spray angle, deg. ......................................................... 160°
Injection press., Mpa(kgf/cm²)[psi] .............................. 34.32 to 34.81 (350 to 355) [4979 to 5050]
Fuel filter
Type ............................................................................. Paper element cartridge changeover, spin-on type
Oil system
Lubricating type ........................................................... Forced circulation type (pressure feed by oil pump)
Engine oil Standard ...................................................... CF oil (API service classification)
Engine oil volume:
Oil sump,liter [U.S. gal] ................................................ 200 [52.8] approx
Complete engine, liter [U.S. gal] .................................. 230 [60.8] approx
Oil pump
Type ............................................................................. Gear pump
Delivery capacity, liter [U.S. gal] .................................. 240 [63.4] (at engine speed 800 rpm)
Relief valve
Type ............................................................................. Piston valve type
Opening press., MPa(kgf/cm³)[psi] .............................. 0.51 +/-0.02 (5.2 +/-0.2) [73.97+/-2.84}
Oil cooler
Type ............................................................................. Water-cooled, multi-plate type (housed in the crankcase)
Full-flow oil filter

Type ............................................................................. Paper element changeover type (spin on)
Oil thermostat
Type ............................................................................. Wax type
Valve opening temp., °C [°F] ....................................... 80 to 84 [176 to 183.2]
Cooling system
Cooling type ................................................................. Water-cooled, forced circulation
Coolant capacity (whole engine), liter [U.S. gal] .......... MS: 125 [33.0] MT: 235 [62.1]
Fresh water pump

Type ............................................................................. Centrifugal
Pump capacity, liter [U.S. gal]/min. .............................. 1600 [423], Total head 0.20 MPa (20 mAq) (at 3292 rpm pump speed)
Thermostat
Type ............................................................................. Wax
Valve opening temp.,°C [°F] ........................................ 71+/-2 [159.8 +/- 3.6]
Raw water pump (only on MT)

Type ............................................................................. Rubber rotor
Pump capacity, liter [U.S. gal]/min. .............................. 800 [211], Total head 0.10 MPa (10 mAq)(at 1600 rpm pump speed)
Pump drive belt type .................................................... V-belt
Outside circumference, mm [in] ................................... 2085 [82] or 2115 [83]
20

General information
Inlet and exhaust system

Turbocharger
Type ............................................................................. MS: TD13 or TD15 MT: TD15
No. of units ................................................................... 2
Electrical system
Voltage-polarity ............................................................ 24V each float
Starter
Manufacturer ................................................................ Nikko Electric Industry
Pinion mesh type ......................................................... Pinion shift (Reduction type)
Output .......................................................................... V (kW) 24 (7.5)
No. of starters .............................................................. 2
No. of pinion tooth/ring gear tooth ............................... 15 / 182
Alternator
Type ............................................................................. 3-Phase alternating generator, Internal IC regulator
Manufacturer ................................................................ Mitsubishi Electric
Output .......................................................................... V-A 24-35
Rated generated .......................................................... min-1 5000 (at 27V, 35A)
Regulated voltrage ....................................................... V 28.5 +/- 0.5
Drive belt type .............................................................. V-belt
Outside circumference, mm [in.] .................................. 1000 [39.4]
21

Maintenance Standards
Maintenance Standards Table

General
Maximum rpm
Nominal Value ........... 5 – 10 % higher than rated rpm
Repair limit ................ Lower or 20 % higher than rated rpm
NOTE! Rated rpm stamped on the nameplate. Check governor setting.
Minimum rpm
Nominal value ........... 600 to 650 rpm
Compression pressure MPa (Bar) [psi]

Nominal Value ........... 2.85 (28.5) [263] minimum (at 120 rpm)
Repair limit ................ 2.30 (23.0) [185] or lower
NOTE! Oil and water temp. 20 to 30°C [68 to 86°F]
Lube oil pressure MPa (Bar) [psi]

Nominal Value ........... 0.20 – 0.29 (2.0 – 2.9) [28 to 43] at idling
Repair limit ................ 0.10 (1.0) [14] or lower
NOTE! Oil temp. 60 to 70°C [140 to 158°F]
Valve timing (2 mm[0.8 in.] clearance valve side, cold)
Nominal Value:
Inlet valve opens ....... 2.5° BTDC ±2° (crank angle)
Inlet valve closes ...... 13° ABDC ±2° (crank angle)
Exh. valve opens ...... 26° BBDC ±2° (crank angle)
Exh. valve closes ...... 10.5° BTDC ±2° (crank angle)
NOTE! Values are only for checking valve timing and are different from the actual ones.
Valve clearance (cold), mm [in.]

Inlet valves:
Standard Clearance .. 0.6 [0.024]
Exhaust valves:
Standard Clearance .. 0.8 [0.031]
Injection timing
Nominal Value ........... XX° BTDC ±1° (crank angle)
NOTE! XX varies according to specifications. Refer to caution plate on No. 1 rocker cover.
Engine main parts

Valves
Valve stem diameter, mm [in.]
Nominal Value ........... Ø10 [0.39]
Assembly Standard ... 9.940 to 9.960 [0.39134 to 0.39213]
Service Limit ............. 9.910 [0.39016]
NOTE! The same for both inlet and exhaust valves.
22

Valve guide inside diameter, mm [in.]

Nominal Value ........... Ø10 [0.39]
Service Limit ............. 10.060 [0.39606]
NOTE! The same for both inlet and exhaust valves.
Valve seat angle(A)

Nominal Value ........... 30°
Valve depth(B), mm [in.]

Nominal value ........... 0
Assembly Standard ... -2.0 – 0.2 [-0.008 – 0.008]
Repair Limit ............... 1.0 [0.039]
Seat width(C), mm [in.]

Nominal value ........... 2.3 [0.091]
Repair Limit ............... 2.8 [0.110]
Valve margin(D), mm [in.]

Nominal Value ........... 3.0 [0.12]
Assembly Standard ... 2.8 – 3.2 [0.110 to 0.126]
NOTE! Refacing permissible up to 2.5 [0.098]
Cylinder head bore and valve seat diameter, mm [in.]

Nominal Value ........... Ø60 [2.36]
Assembly Standard ... -0.070 – -0.130 [-0.00276 – -0.00512]
NOTE! - (minus) indicates interference
Valve push rods

Deflection, mm [in.]
Assembly Standard ... 0.5 [0.020] maximum
Service Limit ............. 0.5 [0.020]
Valve springs
Free length (A), mm [in.]
Assembly standard ... 73 [2.87]
Service limit .............. 71 [2.80]
Perpendicularity (B), mm [in.]

Service limit .............. 2.2 [0.087] (at end)
Length under test force, mm [in.]

Assembly standard ... 66.0 [2.6]
Test force, N (kgf) [lbf]

Assembly standard ... 289–319 (29.45 to 32.55) [65 to 72]
23

Rockers
Rocker bushing inside diameter, mm [in.]
Nominal Value ........... Ø36 [1.42]
Service Limit ............. 36.090 [1.42086]
Rocker shaft diameter, mm [in.]

Nominal Value ........... Ø36 [1.42]
Assembly Standard ... 35.966 to 35.991 [1.41598 to 1.41697
Service Limit ............. 35.940 [1.41496]Cylinder heads
Flatness of gasket surface, mm [in.]

Assembly Standard ... 0.03 [0.0012] or less
Repair Limit ............... 0.07 [0.0028]
Service Limit ............. 0.50 [0.0197]
NOTE! Reface if necessary
Thickness of gasket when tightened, mm [in.]

Nominal Value ........... 1.8 [0.07]
Cylinder liners
Inside diameter, mm [in.]
Nominal Value ........... Ø170 [6.69]
Repair Limit ............... 170.200 [6.70078]
Service Limit ............. 170.500 [6.71259]
Roundness, mm [in.]
Cylindricity, mm [in.]
Squareness of flange lower face to liner center line, mm [in.]

Protrusion of cylinder liner at flange, mm [in.]

Pistons and cylinderheads

Clearance between piston top and cylinder head, mm [in.]
Standard Clearance .. [1.22 to 1.95) ([0.0480 to 0.0768])
Pistons
Outside diameter, mm [in.]
Nominal Value ........... Ø170 [6.69]
Service Limit ............. 169.66 [6.6795]
NOTE! Meaure diameter perpendicular to pin at piston skirt.
24

Weight difference between pistons in one engine

Assembly Standard ... ±10 g [±0.35 oz]
Pin bore diameter, mm [in.]

Nominal Value ........... Ø70 [2.76]
Service Limit ............. 70.040 [2.75747]
Protrusion, mm [in.]
NOTE! From the cylinder block
Piston rings
Gaps Top ring, mm [in.]
Assembly Standard ... (0.6 to 0.8) ([0.024 to 0.031])
Service Limit ............. (2.0) ([0.079])
NOTE! If gauge is not available, the general value can be obtained at the cylinder bore.
Gaps Second ring, mm [in.]

Service Limit ............. (2.0) ([0.079])
Gaps Oil ring, mm [in.]

Service Limit ............. (2.0) ([0.079])
Piston pins
Diameter, mm [in.]
Nominal Value ........... Ø70 [2.76]
Service Limit ............. 69.970 [2.75472]
Connecting rods
Bushing inside diameter, mm [in.]
Nominal Value ........... Ø70 [2.76]
Service Limit ............. 70.070 [2.75866]
Bend and twist, mm [in.]

Assembly Standard ... 0.05/100 [0.0020/3.9] or less
End play (rod and crankpin widths), mm [in.]

Nominal Value ........... 60 [2.36] x 2
Service Limit ............. (1.4) ([0.055])
Weight difference between connecting rods in one engine

Assembly Standard ... ±30 g [±1.06 oz]
25

Big end bore diameter, mm [in.]

Nominal Value ........... Ø131 [5.16]
Service Limit ............. 131.050 [5.15944]
NOTE! To be measured in combination with caps. Roundness less than (0.1 mm [0.004 in.] - service limit)
Connecting rod bearings

Thickness of center, STD, mm [in.]
Nominal Value ........... 3.000 [0.11811]
Service Limit* ............ 2.930 [0.11535]
Thickness of center, –0.25 [–0.0098], mm [in.]

Nominal Value ........... 3.125 [0.12303]
Service Limit* ............ 3.055 [0.12028]

Nominal Value ........... 3.250 [0.12795]
Service Limit* ............ 3.180 [0.12520]

Nominal Value ........... 3.375 [0.12287]
Service Limit* ............ 3.305 [0.13012]

Nominal Value ........... 3.500 [0.13780]
Service Limit ............. 3.430 [0.13504]
*NOTE! Replace bearings if worn down to service limit. Regrind crankpins and use undersize bearings if necessary.
Oil pump drive

Cover bearing journal inside diameter, mm [in.]
Nominal Value ........... Ø110 [4.33]
Plate bearing journal inside diameter, mm [in.]

Nominal Value ........... Ø110 [4.33]
Bearing, Outside diameter, mm [in.]

Nominal Value ........... Ø110 [4.33]
Bearing, Inside diameter, mm [in.]

Nominal Value ........... Ø50 [1.97]
Gear shaft bearing journal diameter, mm [in.]

Nominal Value ........... Ø50 [1.97]
26

Flywheel
Face runout, mm [in.]
Assembly Standard ... 0.336 [0.0132] to less
Radial runout, mm [in.]

Injection pump accessory drive

Bearing bore inside diameter, mm [in.]
Nominal Value ........... Ø90 [3.54]
Assembly Standard ... 89.987 – 90.022 [3.54279 – 3.54417]

Nominal Value ........... Ø100 [3.94]
Assembly Standard ... 99.987– 100.022 [3.93649 – 3.93787]

Nominal Value ........... Ø90 [3.54]

Nominal Value ........... Ø100 [3.94]

Nominal Value ........... Ø45 [1.77]
Bearing, Inside diameter , mm [in.]

Nominal Value ........... Ø50 [1.97]
Drive shaft bearing journal diameter, mm [in.]

Nominal Value ........... Ø45 [1.77]
Drive shaft bearing journal diameter, mm [in.]

Nominal Value ........... Ø50 [1.97]
Damper
Radial runout (at periphery), mm [in.]
Service Limit ............. 1.5 [0.059]
Radial runout (at periphery), mm [in.]

Service Limit ............. 1.5 [0.059]
27

Front gears
Backlash, mm [in.]
Repair Limit ............... (0.30) ([0.0118])
Service Limit ............. (0.50) ([0.0197])
NOTE! Replace gears, if necessary
Idle gear shaft bushing inside diameter, mm [in.]

Nominal Value ........... Ø50 [1.97]
Service Limit ............. 50.060 [1.97086]
Idle gear shaft diameter, mm [in.]

Nominal Value ........... Ø50 [1.97]
Service Limit ............. 49.900 [1.96456]
Idle gear end play, mm [in.]

Service Limit ............. (0.6) ([0.024])
Timing gears
Backlash, mm [in.]
Repair Limit ............... (0.30) ([0.0118])
Service Limit ............. (0.50) ([0.0197])
Idle gear shaft bushing inside diameter, mm [in.]

Nominal Value ........... Ø65 [2.56]
Service Limit ............. 65.060 [2.56142]
Idle gear shaft diameter, mm [in.]

Nominal Value ........... Ø65 [2.56]
Service Limit ............. 64.900 [2.55512]
Idle gear end play, mm [in.]

Service Limit ............. (1.0) ([0.0397])
28

Camshaft
Cam lift (A-B), mm [in.]
Nominal Value ........... 9.247 [0.36405]
Service Limit ............. 8.45 [0.3327]
Repair Limit ............... 0.08 [0.0031]
NOTE! Deflection at center bushing measured with both ends supported. Repair or replace, if necessary.
Journal diameter, mm [in.]

Nominal Value ........... Ø84 [3.31]
Service Limit ............. 83.87 [3.3020]
Camshaft bushing inside diameter (as installed in crank case), mm [in.]

Nominal Value ........... Ø84 [3.31]
Service Limit ............. 84.10 [3.3110]
NOTE! Replace bushings and ream them, if necessary
End play, mm [in.]

Nominal Value ........... 8 [0.3]
Service Limit ............. 0.40 [0.0157])
NOTE! Replace thrust bearing, if necessary.
Crankshaft
Crankpin diameter, mm [in.]
Nominal Value ........... Ø125 [4.92]
Assembly Standard ... -0.050 – -0.070 [0.00197 – -0.00276]
Repair Limit ............... -0.110 [-0.00433]
Crankpin journal diameter, mm [in.]

Nominal Value ........... Ø170 [6.69]
Assembly Standard ... -0.060 – -0.080 [0.00236 – -0.00315]
Repair Limit ............... -0.110 [-0.00433]
Journal and crankpin center to center distance, mm [in.]

Nominal Value ........... 90 [3.54]
Assembly Standard ... ±0.1 [±0.004]
Parallelism between journals and crankpins, mm [in.]

Assembly Standard ... 0.01 [0.0004] or less at pin length
Repair Limit ............... 0.03 [0.0012]
Roundness of journals and crankpins, mm [in.]

Assembly Standard ... 0.01 [0.0004] or less in diameters
Repair Limit ............... 0.03 [0.0012]
Cylindricity of journals and crankpins, mm [in.]

Assembly Standard ... 0.02 [0.0008] or less in diameters
Repair Limit ............... 0.03 [0.0012]
29

Fillet radius of crankpins, mm [in.]

Nominal Value ........... 7 [0.28]
Fillet radius of journals, mm [in.]

Nominal Value ........... 8.5 [0.33]
Hardness of journals and crankpins

Assembly Standard ... Hv>590
Angularity
Assembly Standard ... ±0°20’
Repair Limit ............... 0.10 [0.0039]
NOTE! Repair or replace if necessary
Crankshaft end play, mm [in.]

Nominal Value ........... 67 [2.64]
Service Limit ............. 0.50 [0.0197] + 1.18[0.0465] (crank shaft width)
NOTE! Replace thrust bearings if worn down to service limit. Use oversize thrust bearings if worn beyond repair limit.
Main bearing
Thickness of center, STD, mm [in.]
Nominal Value ........... 4.500 [0.17717]
Service Limit ............. 4.425 [0.17421]
NOTE! Replace bearings if worn down to service limit. Regrind crankpins and use undersize bearings if worn beyond service limit.

Nominal Value ........... 4.625 [0.18209]
Service Limit ............. 4.550 [0.17913]

Nominal Value ........... 4.750 [0.18701]
Service Limit ............. 4.675 [0.18405]

Nominal Value ........... 4.875 [0.19193]
Service Limit ............. 4.800 [0.18898]

Nominal Value ........... 5.000 [0.19685]
Service Limit ............. 4.925 [0.19390]
30

Crankcase
Flatness of gasket surface, mm [in.]
Repair Limit ............... 0.2 [0.008]
NOTE! Reface if necessary
Main bearing bore diameter, mm [in.]

Nominal Value ........... Ø179 [7.05]
Service Limit ............. 179.045 [7.04900]
Inlet and exhaust system

Turbocharger TD13 (only on D49 MS)
Inside diameter of bearing-fitted housing section, mm [in.]
Nominal Value ........... 30 [1.18]
Service Limit ............. 30.006 [1.18134]
Bearing outside diameter, mm [in.]

Service Limit ............. 29.876 [1.17622]
Bearing inside diameter, mm [in.]

Service Limit ............. 18.050 [0.71063]
Bearing length, mm [in.]

Service Limit ............. 17.440 [0.68661]
Shaft journal diameter, mm [in.]

Nominal Value ........... 18 [0.709]
Service Limit ............. 17.996 [0.70850]
Shaft deflection, mm [in.]

Service Limit ............. 0.015 [0.00059]
Ring gap clearance, mm [in.]

Standard Clearance .. 0.05 to 0.25 [0.00197 to 0.00984]
Shaft & turbine wheel and turbine housing clearance, mm [in.]

Shaft end play, mm [in.]

Turbine backplate and turbine wheel clearance, mm [in.]

Turbocharger TD15
Inside diameter of bearing-fitted housing section, mm [in.]
Nominal Value ........... Ø34 [1.34]
Service Limit ............. 34.016 [1.33921]
31


Service Limit ............. 33.882 [1.33393]

Service Limit ............. 19.929 [0.78460]

Service Limit ............. 19.440 [0.76535]
Shaft journal, mm [in.]

Nominal Value ........... Ø20 [0.79]
Service Limit ............. 19.863 [0.78201]

Service Limit ............. 0.015 [0.00059]
Ring gap clearance, mm [in.]

Shaft & turbine wheel and turbine housing clearance, mm [in.]

Shaft end play, mm [in.]

Turbine backplate and turbine wheel clearance, mm [in.]

Lubrication system
Oil Pump
Backlash between drive gear and driven gear, mm [in.]
Assembly Standard ... (0.10 to 0.20) [0.0039 to 0.0079]
Service Limit ............. (0.4) [0.0157]
Drive gear and driven gear clearance, mm [in.]

Nominal Value ........... Ø60 [2.36]
Standard Clearance .. (0.100 to 0.148) [0.00394 to 0.00583]
Clearance .................. Tip clearance (0.35) [0.0138]
Gear and clearance in case, mm [in.]

Nominal Value ........... 72.5 [2.854]
Standard Clearance .. (0.040 to 0.116) [0.00157 to 0.00457]
Clearance .................. [0.21] [0.0083]
NOTE! Remove the cover packing (width of 0.04 [0.0016]) for mesurement.
Shaft diameter, Drive shaft, mm [in.]

Nominal Value ........... Ø30 [1.18]
Assembly Standard ... 29.887 to 29.000 [1.17665 to1.17717]
Service Limit ............. 29.840 [1.17480]
32

Shaft diameter, Driven shaft, mm [in.]

Nominal Value ........... Ø30 [1.18]
Service Limit ............. 29.900 [1.17716]

Nominal Value ........... Ø30 [1.18]
Assembly Standard ... 30.000 to 30.021 (1.18110 to 1.18193)
Service Limit ............. 30.055 [1.18327]
Safety valve
Valve opening pressure MPa (Bar) [psi]
Assembly Standard ... 1.27±0.13 (12.7±1.3) [185±18.5]
Spring set length/load mm [in.]/N (kgf) [lbf]

Assembly Standard ... 65.8 [2.59]/359 (36.6) [80.7]
Service Limit ............. 65.8 [2.59]/314 (32) [70.5]
Relief valve
Valve opening pressure, MPa (Bar) [psi]
Assembly Standard ... 0.5±0.02 (5±0.2) [71.1±2.84]
Oil thermostat
Temperature at which valve starts opening
Assembly Standard ... 80 to 84°C [176 to 183°F]
Temperature at which valve lift more than 11 mm [0.43 in.]

Assembly Standard ... 95°C [203°F]
Piston cooling nozzle

Valve opening pressure, MPa (Bar) [psi]
Assembly Standard ... 0.26 to 0.32 2.6 to 3.2 [38 to 47]
Cooling system
Fresh water pump
Nominal value ........... Ø120 [4.72]

Nominal value ........... Ø110 [4.33]
NOTE! Same as the bearing cover.

Nominal value ........... Ø120 [4.72]
33


Nominal value ........... Ø110 [4.33]

Nominal value ........... Ø55 [2.17]

Nominal value ........... Ø50 [1.97]
Shaft bearing journal diameter, mm [in.]

Nominal value ........... Ø55 [2.17]
Shaft bearing journal diameter, mm [in.]

Nominal value ........... Ø50 [1.97]
Vane front face clearance, mm [in.]

Nominal value ........... 1.04 [0.041]
Standard Clearance .. (0.58 to 1.5) ([0.023 to 0.059])
Thermostat
Temperature at which valve starts opening
Assembly Standard ... 71±2°C [159.8±3.6°F]
NOTE! Check in atmospheric pressure
Temperature at which valve lift is more than 11 mm [0.43 in.]

Assembly Standard ... 85°C [185°F]
NOTE! Check in atmospheric pressure
Sea water pump

Impeller
Repair Limit ............... Replace if cracked.
Pump seals
Repair Limit ............... Replace if water leaks.
Bearing
Repair Limit ............... Replace if worn excessively.
Holder bearing bore inside diameter, mm [in.]

Nominal value ........... Ø110 [4.33]
Service Limit ............. 110.030 [4.33188]
34


Nominal value ........... Ø110 [4.33]

Nominal value ........... Ø50 [1.97]
Shaft bearing journal, mm [in.]

Nominal value ........... Ø50 [1.97]
Service Limit ............. 50.000 [1.96858]
Fuel system
Fuel injector
Valve opening pressure, MPa (kgf/cm2) [psi]
Nominal value ........... 34.32 (350) [4977]
Assembly Standard ... 34.32 to 34.81 350 to 355 [4977 to 5048]
Spray cone angle

Nominal value ........... 160°
NOTE! Check nozzle with a hand tester (at fuel oil temperature 20°C [68°F]. Replace the nozzle if the spray pattern is still bad after
washing in clean fuel oil.
Injection pump
Overall clearance at tappet roller, mm [in.]
Service Limit ............. 0.2 [0.00787]
Wear of contact surface between tappet and plunger, mm [in.]

Service Limit ............. 0.2 [0.00787]
Outside diameter at contact surface of camshaft oil seal, mm [in.]

Nominal value ........... Ø35 [1.378]
Service Limit ............. 34.800 [1.37001]
Camshaft deflection, mm [in.]

Assembly Standard ... 0.05 [0.00197]
Repair Limit ............... 0.15 [0.00591]
35

Plunger Spring, mm [in.]

Free length (A), mm[in.]
Perpendicularity (B), mm[in.]
Service Limit ............. 1.8 [0.071]


Assembly standard ... 299–366 (30.5–37.3) [67.2–82.2]
Delivery valve spring, mm [in.]

Free length (A)
Assembly Standard ... 18 [0.71]
Perpendicularity (B)
Service Limit ............. 0.6 [0.024]


Assembly standard ... 51.6-61.4 (5.26–6.26) [11.60–13.80]
Camshaft thrust clearance, mm [in.]

Resistance in rack movement

Assembly Standard ... 500 g [1.102 lb]
NOTE! Make sure rack moves smoothly. Total rack stroke should be 36 mm [1.42 in.].
Injection start interval

Assembly Standard ... 60°±0.5°
NOTE! Camshaft angle
Nozzle valve opening pressure MPa (Bar) [psi]

Assembly Standard ... 34.3 (343) [4978.75]
Feed pressure MPa (Bar) [psi]

Assembly Standard ... 0.16 (1.6) [22.76]
Feed pump
Feed pump discharge start time
Assembly Standard ... 20 sec or less
Priming pump discharge start

Assembly Standard ... No. of pumping operations: 30 strokes or less
Feed pump feed rate (pump at 600 rpm)

Assembly Standard ... 900 cm3 [54.9 cu.in.]/15 sec
36

PSG governor drive

Diameter of case bore, drive shaft-side bearing section, mm [in.]
Nominal Value ........... 52 [2.05]
Assembly Standard ... 51.988–52.018 [2.04677–2.04795]
Drive shaft side bearing

Nominal Value ........... 52 [2.05]
Nominal Value ........... 25 [0.98]
Drive shaft diam., bearing section, mm [in.]

Nominal Value ........... 25 [0.98]
Case bore diam., idler shaft-side bearing section, mm [in.]

Nominal Value ........... 47 [1.85]
Assembly Standard ... 46.989–47.014 [1.84996 –1.85094]
Idler shaft side bearing diameter

Nominal Value ........... 47 [1.85]
Nominal Value ........... 20 [0.79]
Idler shaft diam., bearing section, mm [in.]

Nominal Value ........... 20 [0.79]
Electric system
Starter
Diameter of commutator, mm [in.]
Nominal Value ........... Ø43 [1.69]
Service Limit ............. Ø42 [1.65]
Runout of commutator, mm [in.]

Assembly Standard ... 0.06 [0.0024], or less
Service Limit ............. 0.10 [0.0039]
Mica depth in commutator, mm [in.]

Service Limit ............. 0.2 [0.0079]
Height of brushes, mm [in.]

Assembly Standard ... 21–22 [0.83–0.87]
Service Limit ............. 13 [0.51]
37

Tension of brush springs, N (kgf) [lbf]

Nominal Value ........... 44.13 [4.5] [10]
Assembly Standard ... 39.23–49.03 (4.0–5.0) [9–11]
Service Limit ............. 39.23 (4.0) [9], maximum
Armature shaft diameter (rear), mm [in.]

Nominal Value ........... Ø14 [0.55]
+0.25
Repair Limit ............... Ø10 +0.15 [0.39 +0.0098
+0.0059]
Armature shaft diameter (front), mm [in.]

Nominal Value ........... Ø25 [0.98]
Reapir Limit ............... Ø25 +0.25 +0.0098
+0.15 [0.98 +0.0059]
Armature shaft deflection, mm [in.]

Pinion shaft diameter (rear), mm [in.]

Nominal Value ........... Ø30 [1.8]
Reapir Limit ............... Ø30 +0.011 +0.0043
+0.002 [1.18 +0.0008]
Pinion shaft diameter (front), mm [in.]

Nominal Value ........... Ø19 [0.75]
Reapir Limit ............... Ø19 +0.06 +0.00236
+0.10 [0.75 +0.00394]
Metal, Pinion
Nominal Value ........... Ø19 [0.75]
Reapir Limit ............... Ø19 +0.033
0 [0.75 +0.00130
0 ]
Service Limit ............. 0.25 [0.0098]
NOTE! Clearance between shaft and metal.
End play of armature, mm [in.]

End play of pinion shaft, mm [in.]

Alternator
Output current (27 V), 2500 rpm
At 2500 rpm:
Assembly Standard ... 30 A or higher when cold
At 5000 rpm:
Assembly Standard ... 35 A or higher, when hot
Regulator adjusting voltage (alternator at 5000 rpm, load at 5 A or lower)

Assembly Standard ... 28.5±0.5 V
Field coil resistance (at 20°C [68°F])

Assembly Standard ... 7.3 to 8.6 W
38

General information
Tightening torques D49A MS

Thread Torque
Description Diam.xPitch Nm kpm lbf.ft Notes
(M-Thread)
Cylinder Head 22 x 2,5 539 55 398 (a) (b) (c)
Cylinder head nozzle gland (studs) 14 x 2,0 69-78 7-8 51-58
Rocker case 12 x 1,25 108 11 80
Rocker shaft 14 x 2,0 147 15 108
Rocker arm lock nuts 12 x 1,25 64 6,5 47
Bridge lock nuts 10 x 1,25 55 5,6 40
Camshaft gear 12 x 1,25 108 11 80
Camshaft thrust plate 12 x 1,25 59 6 43
Main bearing caps 22 x 2,5 588 60 434 (a)
Main bearing cap side bolts 20 x 2,5 392 40 289
Hanger 12 x 1,25 392 40 289
Hanger 16 x 1,5 216 22 159
Piston cooling nozzle 12 x 1,75 34 3,5 25 (d)
Timing gear case 16 x 1,5 255 26 188
Rear plate 12 x 1,25 108 11 80
Rear plate 16 x 1,5 216 22 159
Oil pan 12 x 1,25 59 6 43
Front mounting bracket 20 x 1,5 392 40 289
Rear mounting bracket 20 x 1,5 392 40 289
Connecting rod metal caps 22 x 1,5 539 55 398 (a) (e)
Flywheel 22 x 1,5 539 55 398 (a)
Balance weight 22 x 1,5 490 50 362
Viscous damper 22 x 1,5 490 50 362
Ring gears 10 x 1,25 59 6 43
Rear idler shaft 20 x 1,25 392 40 289
Rear idler shaft (nuts) 18 x 1,5 196 20 145
Front gear case 12 x 1,25 59 6 43
Front plate 12 x 1,25 59 6 43
Front idler shaft 12 x 1,25 108 11 80
Front idler gear thrust plate 10 x 1,25 29 3 22
Exhaust manifold V-clamp nuts 6 x 1,0 9 0,9 6,5
Exhaust manifold mounting bolts 10 x 1,5 98 10 72
Fresh water pump 12 x 1,25 108 11 80

Fresh water pump shaft pulley (nuts) 30 x 1,5 392 40 289 For alternator drive.
(a) Wet , apply lubrication oil to the threads of the nut and bolt.
(b) 2-step tightening method
(c) Tighten cylinder head bolts according to the angle method, tighten to 294 Nm [30 kpm; 217 lbf.ft], then tighten 60° more.
(d) Extremely important to use torque wrench in tightening the piston cooling nozzles. Failure to do so may result in excessive tightening
torque, which may cause valve malfunctions that could lead to seizing of pistons due to insufficient lubrication.
(e) Tighten connecting rod caps according to the angle method, tighten to 245 Nm [25 kpm; 181 lbf.ft], then tighten 60° more.
39

General information
Tightening torques D49A MS

Thread Torque
(M-Thread)
Oil pump 12 x 1,25 108 11 80
Oil pump cover 10 x 1,25 26,3-39,7 2,7-4,1 18-32
Oil & Water pump mounting plates 12 x 1,25 59 6 43
Bearing cover (oil & water pump) 12 x 1,25 108 11 80
Injection pump 12 x 1,25 108 11 80

Injection pump bracket 12 x 1,25 108 11 80
Injection pump drive case 12 x 1,25 108 11 80
Injection pump gear (nuts) 30 x 1,5 392 40 289
Injection pump laminate plate 12 x 1,25 103-113 10,5-11,5 76-83
Injection pump flywheel (nuts) 24 x 1,5 392 40 289
Injection pump coupling shaft 14 x 1,5 167-177 17-18 123-130 Tighten the slit part.
Injection pump plunger assembly 12 x 1,25 78-83 8-8,5 58-61
Injection pump delivery valve holder 30 x 1,5 235-255 24-26 174-188
Injection nozzle gland (nut) 14 x 1,5 98 10 72
Injection nozzle chip (nut) 28 x 1,5 177-196 18-20 130-145
Nozzle holder cap nuts 14 x 1,5 69-78 7-8 51-58
Injection nozzle set screw 10 x 1,5 34-44 3,5-4,5 25-33
Injection nozzle inlet connector 16 x 1,5 64-74 6,5-7,5 47-54
Injection pipes 18 x 1,5 49-69 5-7 36-51
Fuel filter air vent plug – 7,8-9,8 0,8-1,0 5,8-7,2

Fuel rack control lever 8 x 1,25 25 2,5 18 (b)
Governor drivecase 12 x 1,25 108 11 80
Starter 12 x 1,25 59 6 43
Turbocharger compressor wheel (nut) 11 x 1,0 – – – TD13(f)(g)(h)

Turbocharger V-clamp – 7,8-9,8 0,8-1,0 5,8-7,2 TD13 (g)
Turbocharger compressor wheel (nut) 1/2 x 20 – – – TD15UNF(f)(i)
Turbocharger turbine housing 10 x 1,5 25-28 2,6-2,9 19-21 TD15 (g)
(b) 2-step tightening method,
(d) Extremely important to use torque wrench in tightening the piston cooling nozzles. Failure to do so may result in excessive
tightening torque, which may cause valve malfunctions that could lead to seizing of pistons due to insufficient lubrication.
(f) Left-handed thread.
(g) Apply Moly Disulfide to thread.
(h) Tighten the lock nut to 49 Nm [5 kpm; 36 lbf.ft] firs, then loosen it completely. Retighten to 14,7 Nm [1,5 kpm; 0,8 lbf.ft],
then tighten 80±3° more.
(i) Tighten the lock nut to 69 Nm [7 kpm; 51 lbf.ft] then loosen it completely. Apply Loctite No. 962T to the threads.
Retighten to 9,8 Nm [1 kpm; 7,2 lbf.ft], then tighten 90±3° more.
40

General information
Tightening torques D49A MT

Thread Torque
(M-Thread)
Cylinder Head 22 x 2,5 539 55 398 (a) (b) (c)
Cylinder head nozzle gland (studs) 14 x 2,0 69-78 7-8 51-58
Rocker case 12 x 1,25 108 11 80
Rocker shaft 14 x 2,0 147 15 108
Rocker arm lock nuts 12 x 1,25 64 6,5 47
Bridge lock nuts 10 x 1,25 55 5,6 40
Camshaft gear 12 x 1,25 108 11 80
Camshaft thrust plate 12 x 1,25 59 6 43
Main bearing caps 22 x 2,5 588 60 434 (a)
Main bearing cap side bolts 20 x 2,5 392 40 289
Hanger 12 x 1,25 392 40 289
Hanger 16 x 1,5 216 22 159
Piston cooling nozzle 12 x 1,75 34 3,5 25 (d)
Timing gear case 16 x 1,5 255 26 188
Oil pan 12 x 1,25 59 6 43
Front mounting bracket 20 x 1,5 392 40 289
Rear mounting bracket 20 x 1,5 392 40 289
Connecting rod metal caps 22 x 1,5 539 55 398 (a) (e)
Flywheel 22 x 1,5 588 60 434 (a)
Balance weight 22 x 1,5 490 50 362
Viscous damper 22 x 1,5 490 50 362
Ring gears 10 x 1,25 59 6 43
Rear plate 12 x 1,25 108 11 80

Rear plate 16 x 1,5 216 22 159
Rear idler shaft 20 x 1,25 392 40 289
Rear idler shaft (nuts) 18 x 1,5 196 20 145
Front plate 12 x 1,25 59 6 43
Front idler shaft 12 x 1,25 108 11 80
Front idler gear thrust plate 10 x 1,25 29 3 22
Exhaust manifold V-clamp nuts 6 x 1,0 9 0,9 6,5

Exhaust manifold mounting bolts 10 x 1,5 98 10 72
Water pump 12 x 1,25 108 11 80

Water pump shaft pulley (nuts) 30 x 1,5 392 40 289 For alternator drive.
(b) 2-step tightening method
(d) Extremely important to use torque wrench in tightening the piston cooling nozzles. Failure to do so may result in excessive tightening
torque, which may cause valve malfunctions that could lead to seizing of pistons due to insufficient lubrication.
41

General information
Tightening torques D49A MT

Thread Torque
(M-Thread)
Oil pump 12 x 1,25 108 11 80
Oil pump cover 10 x 1,25 26,3-39,7 2,7-4,1 18-32
Oil & Water pump mounting plates 12 x 1,25 59 6 43
Bearing cover (oil & water pump) 12 x 1,25 108 11 80
Sea water pump cam (screw) 10 x 1,25 15,7-21,6 1,6-2,2 11,6-15,9

Sea water pump casing 8 x 1,25 7,4-9,8 0,75-1,0 5,42-7,23
Sea water pump cover 8 x 1,25 7,4-9,8 0,75-1,0 5,42-7,23
Sea water pump drive gear (nut) 24 x 3,0 191-201 19,5-20,5 141-148
Injection pump 12 x 1,25 108 11 80

Injection pump bracket 12 x 1,25 108 11 80
Injection pump drive case 12 x 1,25 108 11 80
Injection pump gear (nuts) 30 x 1,5 392 40 289
Injection pump laminate plate 12 x 1,25 103-113 10,5-11,5 76-83
Injection pump flywheel (nuts) 24 x 1,5 392 40 289
Injection pump coupling shaft 14 x 1,5 167-177 17-18 123-130 Tighten the slit part.
Injection pump plunger assembly 12 x 1,25 78-83 8-8,5 58-61
Injection pump delivery valve holder 30 x 1,5 235-255 24-26 174-188
Injection nozzle gland (nut) 14 x 1,5 98 10 72
Injection nozzle chip (nut) 28 x 1,5 177-196 18-20 130-145
Nozzle holder cap nuts 14 x 1,5 69-78 7-8 51-58
Injection nozzle set screw 10 x 1,5 34-44 3,5-4,5 25-33
Injection nozzle inlet connector 16 x 1,5 64-74 6,5-7,5 47-54
Injection pipes 18 x 1,5 49-69 5-7 36-51
Fuel filter air vent plug – 7,8-9,8 0,8-1,0 5,8-7,2

Fuel rack control lever 8 x 1,25 25 2,5 18 (b)
Governor drivecase 12 x 1,25 108 11 80
Starter 12 x 1,25 59 6 43
Turbocharger compressor wheel (nut) 1/2 x 20 – – – TD15UNF(f)(i)

Turbocharger turbine housing 10 x 1,5 25-28 2,6-2,9 19-21 TD15 (g)
(b) 2-step tightening method,
(d) Extremely important to use torque wrench in tightening the piston cooling nozzles. Failure to do so may result in excessive
tightening torque, which may cause valve malfunctions that could lead to seizing of pistons due to insufficient lubrication.
(f) Left-handed thread.
(g) Apply Moly Disulfide to thread.
(h) Tighten the lock nut to 49 Nm [5 kpm; 36 lbf.ft] firs, then loosen it completely. Retighten to 14,7 Nm [1,5 kpm; 0,8 lbf.ft],
then tighten 80±3° more.
(i) Tighten the lock nut to 69 Nm [7 kpm; 51 lbf.ft] then loosen it completely. Apply Loctite No. 962T to the threads.
Retighten to 9,8 Nm [1 kpm; 7,2 lbf.ft], then tighten 90±3° more.
42

General information
Standard Bolts and Nuts

Fine threads
Thread Strength classification
diameter x pitch 7T 10.9
mm [in.] Nm kpm lbf.ft Nm kpm lbf.ft
M10 x 1,25 [0.39 x 0.049] 33 3,4 25 60 6,1 44
M12 x 1,25 [0.47 x 0.049] 60 6,1 44 108 11,0 80
M14 x 1,5 [0.55 x 0.059] 97 9,9 72 176 17,9 129
M16 x 1,5 [0.63 x 0.059] 145 14,8 107 262 26,7 193
M18 x 1,5 [0.71 x 0.059] 210 21,4 155 378 38,5 278
M20 x 1,5 [0.79 x 0.059] 291 29,7 215 524 53,4 386
M22 x 1,5 [0.87 x 0.059] 385 39,3 284 694 70,8 512
M24 x 1,5 [0.94 x 0.059] 487 49,7 359 878 89,5 647
M27 x 3 [1.06 x 0.12] 738 75,3 544 1328 135,5 980
Coarse threads
M8 x 1,25 [0.31 x 0.049] 17 1,7 12 30 3,1 22
M10 x 1,5 [0.39 x 0.059] 32 3,3 24 58 5,9 43
M12 x 1,75 [0.47 x 0.069] 57 5,8 42 102 10,4 75
M14 x 2 [0.55 x 0.079] 93 9,5 69 167 17,0 123
M16 x 2 [0.63 x 0.079] 139 14,2 103 251 25,6 185
M18 x 2,5 [0.71 x 0.098] 194 19,8 143 350 35,7 258
M20 x 2,5 [0.79 x 0.098] 272 27,7 200 489 49,9 361
M22 x 2,5 [0.87 x 0.098] 363 37,0 268 653 66,6 482
M24 x 3 [0.94 x 0.12] 468 47,7 345 843 86,0 622
M27 x 3 [1.06 x 0.12] 686 70,0 506 1236 126,0 911
Standard eyebolts
Thread Strength classification
diameter x pitch 4T
mm [in.] Nm kpm lbf.ft
M8 x 1,25 [0.31 x 0.049] 8±1 0,8±0,1 5,8±0,72
M10 x 1,25 [0.39 x 0.049] 15±2 1,5±0,2 10,8±1,45
M12 x 1,25 [0.47 x 0.049] 25±3 2,5±0,3 18,1±2,17
M14 x 1,5 [0,55 x 0.059] 34±4 3,5±0,4 25,3±2,89
M16 x 1,5 [0.63 x 0.059] 44±5 4,5±0,5 32,5±3,62
M18 x 1,5 [0.71 x 0.059] 74±5 7,5±0,5 54,2±3,62
M20 x 1,5 [0.79 x 0.059] 98±10 10,0±1,0 72,3±7,23
M24 x 1,5 [0.94 x 0.059] 147±15 15,0±1,5 108,5±10,8
M27 x 3 [1.06 x 0.12] 226±20 23,0±2,0 166,3±14,5
(Dry)
43

General information
Standard union nuts

Cap nut size Strength classification Nominal
diameter x pitch diameter
M14 x 1,5 [0.55 x 0.059] 39 4 29 63
M16 x 1,5 [0.63 x 0.059] 49 5 36 80
M20 x 1,5 [0.79 x 0.059] 78 8 58 100
M22 x 1,5 [0.87 x 0.059] 98 10 72 120
M27 x 1,5 [1.06 x 0.059] 157 16 116 150
M30 x 1,5 [1.18 x 0.059] 196 20 145 180
M30 x 1,5 [1.18 x 0.059] 196 20 145 200
M33 x 1,5 [1.30 x 0.059] 245 25 181 220
M36 x 1,5 [1.42 x 0.059] 294 30 217 254
(Dry)
High pressure fuel injection pipes

Cap nut size Strength classification
diameter x pitch
M12 x 1,5 [0.49 x 0.059] 39±5 4±0,5 29±3,6
M14 x 1,5 [0.55 x 0.059] 49±5 5±0,5 36±3,6
M18 x 1,5 [0.71 x 0.059] 59±1 6±1,0 43±7,2
(Dry)
44

General information
Sealants and Lubricants Table

Engine main parts Lubrication system
Cylinder head sealing caps Oil pump, Cover and case

Sealant ...................... refer to parts catalogue Sealant ...................... refer to parts catalogue
How to use ................ Coat holes in crankcase How to use ................ Coat both sides of packing
Water outlet connectors (Rocker case) Cooling system

Lubricant ................... Grease
Fresh water pump, Oil seal
How to use ................ Grease O-ring joint
Lubricant ................... Engine oil
Cylinder liners How to use ................ Coat lip of inner seal
Sealant or lubricant ... Engine Oil

Fresh water pump, Unit seal
How to use ................ Grease O-ring joint
Lubricant ................... Coolant
Front plate, gear case, oil pan, and crankcase How to use ................ Coat floating seat
Sealant ...................... refer to parts catalogue

Sea water pump, Unit seal
How to use ................ Coat three face-mating portions only
Rear plate, gear case, oil pan, and crankcase How to use ................ Apply to surface that contacts bushing

Sea water pump, Oil seal
Crankcase plugs How to use ................ Apply to hollow part and lip of oil seal
Sealant ...................... Loctite Inlet system

How to use ................ Apply to threads
Air Cooler, between elements, both sides of plate

Oil pan and crankcase
How to use ................ Fill gap between element and plate.
Front plate, front gear case and timing gear case

Oil Seals
Lubricant ................... Engine oil
How to use ................ Coat lip of each oil seal
Drive case
How to use ................ Apply to flange surface
Cylinder head gasket

How to use ................ Apply around tappet chambers
45

Special tools
Special Tools
885423 Rocker bushing tool 885452 Ring pliers

885422 Cylinder head lifting 885425 Cylinder liner remover
885391 Valve spring pusher 885414 Piston ring tool
885410 Valve guide remover 885396 Idler bushing puller
885413 Valve guide and seal installer 885443 Piston installer
885386 Valve lapper 885420 Connection rod bushing installer
46

Special tools
885421 Compression gauge adaptor 885455 To remove oil and water pump plate and
885409 Compression gauge flywheel
885445 To remove/install injection pump gear 885451 Nozzle tester
and waterpump shaft pulley nut. 885439 To remove and install snap ring
885447 Tool for lifting piston 885441 To remove and install snap ring
885446 Waterpump pliers 885440 To remove and install snap ring
885424 Impeller remover 885428 Injection coupling gauge
47

Special tools
885426 To install front oil seal 885429 Bolt for liner pusher
885435 To installa rear oil seal 885432 Spacer for liner pusher head bolt
885430 Valve seat cutter shaft 885450 To measure crankcase counter bore
885431 Valve seat cutter depth
885448 Liner pusher 885449 To tighten cylinder head bolts
48

Overhaul Instructions
Determination of overhaul timing

In most cases the engine should be overhauled when the engine’s compression pressure is low. Other factors
that indicate the necessity of engine overhaul are:
A. Decreased power
B. Increased fuel consumption
C. Increased engine oil consumption
D. Increased blow-by gas volume through the breather due to abrasion of liner and piston rings
E. Gas leakage due to poor seating of inlet and exhaust valves
F. Starting problems
G. Increased noise from engine parts
H. Abnormal color of exhaust gas after warm-up
Anyone or a combination of these symptoms may indicate that engine overhaul is required. Some items listed
above are not directly related to the need of an engine overhaul. B and F are more likely to be affected substan-
tially by
● Injection volume of the fuel injection pump
● Fuel injection timing
● Wear of injection-pump plunger
● Fitting of the injection nozzle
● Condition of equipment: battery, starter, or alternator
Item D above, however, requires special consideration because decreased pressure, due to wear of the cylinder
liner and the piston rings, is one of the most obvious signs that the engine requires overhauling. Test the com-
pression pressure.
Testing the compression pressure

Measure the compression pressure at regular inter-
vals to obtain correct data. If the compression pres-
sure is lower than the repair limit, overhaul the en-
gine.
1. Remove the injector from the cylinder to be mea-

sured. Attach the compression gauge adapter (A)
to the adapter and connect compression gauge
(B).
2. Crank the engine. Read the compression pres-

sure with the engine running at specified speed.
Compression pressure, Mpa (Bar) [psi]

Assembly Standard ... 2.85 (28.5) [263] min.
Repair Limit ............... 2.30 (23.0) [185] max.
IMPORTANT! Measure the compression pres-

sure on all cylinders.
NOTE ! Compression pressure varies with engine

speed. Measure the compression pressure at 120
rpm
NOTE ! The compression pressure will be slightly
higher on new or overhauled engines. Pressure will
drop gradually by wear of parts.
49

Adjustments and Benchtesting
Adjustment and Benchtesting

Valve Clearance
Check and adjust the valve clearance on a cold en-
gine. The valve height is adjusted first, and then the
clearance of the rocker arm.
IMPORTANT! The engine must under no circum-

stances be running when checking and adjust-
ing the valve clearance since the valves can
knock against the pistons and cause serious
damage.
IMPORTANT! Make sure that the stop lever is

pulled out and the starter key switched off.
Top dead center on compression stroke

1. Turn the engine in the normal direction to align
the timing mark [1 .6] on the damper with the
pointer as shown.
2. Remove the cylinder cover and make sure the in-

let and exhaust valves have some clearance. If
the timing mark [1 .6] is aligned with the pointer,
either the No. 1 or No. 6 piston is at top dead
center on the compression stroke.
Adjust valve height

IMPORTANT! Clearance between valve yoke
and rotator should be min. 1.5 mm [0.059 in.]. If
not, interference will occur and cause the valve
cones to get out of place. If clearance is less
than 1.5 mm [0.059 in.] after valve adjustment,
consult your dealer.
NOTE! If the valve seats are worn, one valve will dif-
fer from another in height, increasing the clearance
between the valve stem and yoke, leading to an in-
creased valve clearance.
1. Unscrew lock nut and adjusting screw on the

valves so that there is clearance between the
yoke and the valve stem.
2. Press the valve yoke down.Turn the adjusting

screw until it touches the valve stem. Turn an ad-
ditional 10 degrees. Lock the adjusting screw
with the lock nut.
50

Valve clearance inspection

1. Check the valve clearance with feeler gauges in-
serted between the rocker arm and yoke cap.
Valve Clearance:
Inlet valve .................. 0.6 mm [ 0.024 in.]
Exhaust valve ........... 0.8 mm [ 0.031 in.]
2. The clearance is correct if feeler gauge is slightly

gripped between the rocker arm and the yoke
cap. If the feeler does not fit into the clearance
exactly, perform adjustments as described below.
Adjust valve clearance

1. Loosen the lock nut of the adjusting screw.
2. Turn the adjusting screw in either direction until

the feeler gauge is slightly gripped between the
rocker arm and yoke cap.
3. After adjusting the clearance, tighten the lock nut

of the adjusting screw.
Firing order
Check and adjust the valve clearance in the firing order (injection sequence), turning the engine with each cylin-
der piston at top dead center on compression stroke.
Firing order 1 12 5 8 3 10 6 7 2 11 4 9
(Example): After checking and adjusting the cylinder No.1, turn the engine 60° and check and adjust the cylinder
No. 12.
Cylinder No. 1 12 5 8 3 10 6 7 2 11 4 9
Timing ( ° ) 0 60 120 180 240 300 360 420 480 540 600 660
51

How to use the Turning Gear

1. Loosen the two bolts securing the shaft lock plate
and remove the plate from the shaft (groove).
2. Push in the shaft all the way to the TURN posi-

tion.
3. Put a socket to the hexagonal end of the shaft

and turn the shaft with a ratchet handle for turn-
ing.
4. After turning the engine, pull the shaft back to the

RUN position, secure the shaft with the locking
device and tighten the plate bolts. Make sure the
plate is secured properly.
WARNING! Before starting the engine, make

sure the turning gear is in the RUN position and
is locked.
52

Fuel system bleeding

Prime the fuel filters and fuel injection pump in the fol-
lowing sequence:
Bleeding the Fuel filter

1. Put the fuel filter switching cock in the left filter
bleed position and loosen the left air vent plug.
2. Turn the priming pump plunger counterclockwise

to unlock the mechanism.
3. Move the plunger up and down until fuel free of

air flows out, then tighten the air vent plug.
4. Put the fuel filter switching cock in the neutral po-

sition and repeat the procedure with the other fuel
filter.
53

Bleeding the fuel injection pump

1. Loosen the air vent cock on the fuel injection
pump about 1.5 turns.
2. Pump the priming pump to start the flow of fuel

through the system.
3. When fuel without visible bubbles comes out of

the air vent cock, lock the priming pump cap
while holding it down. Tighten the air vent cock.
NOTE! Be sure to lock the priming pump cap before
tightening the air vent plugs and cock. If not, the cap
will not return to the original position due to pressure
in the priming pump.
4. Tighten the priming pump cap by hand until the

tightening force increases, normally this occurs
after approximately 70 to 90 degrees. Mark this
position on the priming pum.
5. Tighten the priming pump cap an additional 120

to150 degrees using a wrench.
IMPORTANT! If the priming pump cap is tight-

ened too much (more than 240 degrees in to-
tal), the top of the pump might be damaged.
IMPORTANT! If the pump cap is not tightened

properly, engine vibration may cause excessive
wear to the internal threads of the pump. This
may cause the priming pump cap to eject and
oil to flow out leading to engine failure and dam-
age to the installation.
54

Fuel injection timing

The injection timing is indicated on the caution plate
attached to the No. 1 rocker cover. Check it before
inspection. Bring the piston for No. 1 cylinder to top
dead center on compression stroke as follows:
1. Turn the engine in the normal direction to align

the timing mark [1 .6] on the damper with the
pointer as shown.
2. Remove the No. 1 rocker cover and make sure

the inlet and exhaust valves for No. 1 cylinder
have some clearance. If these valves have no
clearance, turn the engine once again to align the
timing mark [1 .6].
NOTE! Do not confuse the No. 1 cylinder with No. 6.
When the piston for the No. 1 cylinder is in the above-
mentioned position, its inlet and exhaust valve are
seated, presenting some clearance.
3. Turn back the engine approximately 60 degrees,

and turn it in the normal direction slowly until the
specified timing (indicated on the caution plate)
aligns with the pointer.
4. To ensure proper injection timing, make sure that

the timing mark (B) on the coupling flywheel
aligns with the pointer (A) on the fuel injection
pump.
55

Adjust fuel injection timing

1. Make sure the timing mark (indicated on the cau-
tion plate) is aligned with the pointer, with the pis-
ton for the cylinder at top dead center on com-
pression stroke.
2. Loosen the bolts(C) for the fuel injection pump

coupling.
3. Turn the coupling flywheel until the timing mark(B

on the coupling flywheel aligns with the pointer(A)
on the fuel injection pump.
4. Tighten the one nut for fuel injection pump cou-

pling. Turn the engine to tighten the other side
nut.
5. Turn the engine (two turns) to recheck the injec-

tion timing for verification.
56

Speed setting
IMPORTANT! When working with speed set-
tings, stand by to stop the engine manually to
avoid engine overspeed.
NOTE! The idling speed and maximum speed are set

at factory bench testing, and the set bolts are sealed.
These settings are to be inspected and adjusted at
Volvo Penta Workshops only.
NOTE! After adjusting the governor be sure to seal
the stopper. Whether the seals are intact or not has
bearing on the validity of claims under the warranty.
NOTE! Prior to inspection and adjustment, run the
engine until coolant and oil temperature is 70°C
[158°F] or higher.
PSG Governor
Check and adjust idling speed setting
1. Make sure the speed control lever is in idling po-
sition, measure engine rpm.
2. If idling speed is out of the specified range, reset

with the adjust screw (1).
Check and adjust no-load max. speed setting

1. Move speed control lever to max. speed, mea-
sure engine rpm.
2. If max. speed is out of the specified range, reset

with the governor set bolt (2).
3. Manually change the engine speed to test the

governor response, its ability to sense changes in
speed and adjust it promptly to nominal speed.
Correcting hunting
1. If the engine hunts, adjust with the needle valve
(3). Open the needle valve (counterclockwise, 2
to 3 rotations) until the engine hunts. Keep it
hunting for 30 seconds, until air is vented from
the governor.
2. Slowly close the valve until the hunting stops.

NOTE! If the needle is closed too far, speed regula-
tion with respect to changes in load will be delayed.
Keep the valve backed off at least 1/4 rotation from
the fully closed position.
4. Seal all set bolts.
57

Measure V-belt deflection

Measure the deflection of the belt. Apply approxi-
mately 98 to 147 N (10 to 15 kgf) [22 to 33 lbf] force
midway between the pulleys. The deflection should
be approximately 10 to 15 mm [0.4 to 0.6 in.]. Adjust
the belt if the deflection is not correct.
Alternator
1. Remove the V-belt cover.
2. Loosen the mounting bolts (1) of the alternator

and the adjusting rod(2).
3. Loosen the upper- and lower-side lock nuts (3) of

the adjusting rod.
NOTE! Turn the nut below the adjusting rod to the left
to tighten.
4. Set the tension of the V-belt properly by turning

the adjusting rod (2).
5. After setting the tension, tighten the upper- and

lower-side lock nuts.
6. Tighten the mounting bolts to fix the alternator.
7. Set the belt cover and front cover properly.
Raw water pump

1. Remove the front belt cover.
2. Loosen the tension pulley bracket(1) mounting

bolts(2).
3. While loosening lock nut(3), turn the adjusting

bolt(4) and set the tension of belt properly.
4. While maintaining this condition, tighten lock nut

and the mounting bracket bolts.
5. Set the front belt cover properly.
58

Bench testing Bench test (dynamometer) conditions

Summary table of bench testing conditions.
An overhauled engine should be performance tested
on a dynamometer. This test is also for breaking in
Step 1
the major running parts of the engine. To test the en-
gine, follow these procedures: Speed (rpm) .............. Idling
Load .......................... No load
Start Up Time (min.) ................ 5
1. Check levels in radiator, oil pan, and fuel tank. Step 2

Prime the fuel and cooling systems. Speed (rpm) .............. 1000
2. Crank the engine for about 10 seconds to permit Load .......................... No load
lubricating oil to circulate through the engine. Time (min.) ................ 5
NOTE! Do not supply fuel to the engine, place the Step 3

stop lever in stop position.
Speed (rpm) .............. 1200
3. Move the speed control lever slightly in the direc- Load .......................... No load
tion of increasing fuel injection, turn the starter Time (min.) ................ 10
switch to START to start the engine. Do not move
the control lever to “full fuel injection” position. Step 4
4. After the engine starts, let it idle under no load by Speed (rpm) .............. Rated*
operating the speed control lover. Load .......................... 25%
Time (min.) ................ 10
Inspection after Start Up
Step 5
After starting up the engine, check the following
Speed (rpm) .............. Rated*
points. If you find anything wrong, immediately stop
Load .......................... 50%
the engine and investigate the cause.
Time (min.) ................ 10
1. Lubricating oil pressure should be 0.49 to 0.64
Mpa (5 to 6.5 kgf/cm2) [71 to 92 psi] at rated Step 6
speed or over 0.20 to 0.29 Mpa (2 to 3 kgf/cm2) Speed (rpm) .............. Rated*
[28 to 43 psi] at idling speed. Load .......................... 75%
2. Coolant temperature should be 71 to 85°C [165 Time (min.) ................ 30
top 185°F].
Step 7
3. Check for leakage of oil, coolant, fuel, especially Speed (rpm) .............. Rated*
oil pipe connections for turbocharger lubrication. Load .......................... 100%
4. Knocking should die away as coolant tempera- Time (min.) ................ 20
ture rises. No other defective noise should be *Rated speed: Varies according to specifications.
heard.
After Bench Testing
5. Check exhaust color and for abnormal odors.
1. Adjust valve clearance
2. Adjust injection timing
3. Re-tighten external bolts and nuts
59

Auxiliaries removal and installation
Engine auxiliaries removal and installation

This section explains the procedures and tips for removal and installation of the accessories – the preliminary
process to go through for overhauling the engine.
Preparation
1. Shut off the fuel supply, and disconnect the starting system from the engine.
2. Loosen the drain cocks, on the left rear side of crankcase, and drain coolant.
3. Loosen the oil pan drain plug, and drain engine oil.
Oil capacity: 230 l [60.8 U.S. gals] (Whole engine)
WARNING! Hot engine oil can cause personal injury if it contacts the skin. Be careful when draining the oil.
Engine Auxiliaries Removal

Removing the belt cover and tension pulley
1. Remove the front belt cover (1) and (2).
2. Loosen the adjusting bolt of the tension pulley

(3), then remove the V-belts.
3. Unscrew each mounting bolt of the tension pul-

ley, then remove the tension pulley.
Removing the expansion tank

1. Remove the right- and left-hand couplings (1),
then disconnect the connection from the thermo-
stats.
2. Unscrew the mounting bolts of the expansion

tank (2), then remove the expansion tank.
3. Remove the tank bracket (3).
60

Removing the thermostat housing

1. Remove the coupling (1).
2. Remove the bypass pipes (2) and

(3).
3. Remove the right- and left-hand

thermostat housings (4).
4. Remove the thermo-brackets (5)

and (6).
Removing the raw water pump

1. Remove couplings (1), (2) and (3).
2. Remove raw water pipes (4), (5),

(6), (7), (8), (9), (10) and (11).
3. Unscrew the raw water pump (12)

mounting bolts, and remove it.
Raw water pump weight:
approx. 35 kg [77.2 lb]
4. Remove the pump bracket (13).
5. Remove the bracket (14).
6. Remove the pipe stays (15) and

(16).
61

Removing the air duct

1. Remove the air duct (1).
Removing the exhaust manifolds

1. Remove the couplings (1) and the joints (2).
2. Unscrew the manifold mounting bolts, then re-

move the manifolds (3) and the gaskets (4).
NOTE! When installing the manifold, place each gas-
ket with its side marked as “MANIFOLD” facing the
manifold.
Removing the turbochargers and the exhaust

pipe
1. Remove the turbocharger oil pipes
1 Stay
2 Oil pipe
3 Oil pipe
4 Drain connector
62

2. Unscrew each mounting bolt of the turbocharger

(5), then remove the turbochargers.
Turbocharger weight: approx. 48 kg [105.8 lb]
3. Remove the exhaust pipe joints (6), then remove

seal rings (7).
4. Unscrew each mounting bolt of the exhaust pipe

(8), then remove the exhaust pipe.
Exhaust pipe weight: approx. 30 kg [66.1 lb]
5. Remove the brackets (9).
6. Remove the turbocharger brackets (10).
7. Remove the exhaust pipe stays (11).
Removing the air cooler

1. Remove the sea water pipe (1).
2. Remove the connectors (2) and (3).
3. Unscrew two bolts (M12 x 1.75 mm [0.47 x 0.069

in.] on the upper-side of the air cooler cover (4),
then using eye-bolts, slide the air cooler cover to-
wards the front to remove.
4. Using thread (4 locations) M8 x 1.25 mm [0.31 x

0.049 in.]) on the upper-side of the air cooler,
slide the air cooler element (7) towards the front
and remove.
Air cooler element weight: approx. 60 kg [132 lb]
5. Remove the plates (8) and (9) at the front med

rear.
6. Slide the air cooler case (10) towards the front

and remove.
7. Using thread (4 locations) (M8 x 1.25 mm [0.31 x

0.049 in.]) on the air cooler element, slide the air
cooler element (11) towards the front and re-
move.
8. Remove the plates (12) and (13) at the front and

rear.
63

Removing the alternator

1. Remove the belt covers (1) and (2).
2. Loosen belt adjustment turnbuckle (3), and re-

move V-belt (4).
3. Remove bracket (5), and dismount alternator (6).
Removing the water pump

1. Remove the nut (1) at the end of the water pump
shaft. Remove the alternator driving pulley (2).
2. Remove the water pump (3) by unscrewing the

bolts and nuts.
Weight: approx. 33 kg [73 lb]
Removing the oil pump

1. Remove the connection stay(1) from the oil pipe
located under the oil pump.
2. Unscrew the oil pump mounting bolts, then re-

move the oil pump(2).
Removing the speed control

1. Remove the lock nut from the governor lever (1)
to disconnect the control cable (2) from the gov-
ernor lever.
2. Remove the control bracket (3) and the speed

control knob as a set.
64

Removing the governor oil filter

1. Remove the oil pipes (1), (2) and (3).
2. Remove the governor oil filter (4).
3. Remove the bracket (5) and the oil tank stay (6).
Removing the governor

1. Remove the drain pipe (1).
2. Disconnect the governor link (2).
3. Remove the governor (3).
65

Removing the fuel control linkage
1. Remove each control link (1) from the right- and 5. Remove each bearing cover (10) on both right-
left-hand injection pumps. and left-side.
2. Remove the R. H. link (2) and the L. H. link (3). 6. Remove the snap ring (11), the pipe (12), and the
control shaft (13).
3. Remove the link lever (6) and the L. H. lever (7)
on the left side. 7. Remove the R. H.0 lever bracket (14) and the L.
H. lever bracket (15).
4. Remove the spring (8) and the L. H. lever (9).
Removing the stop solenoid

1. Disconnect the linkage (1).
2. Remove the stop solenoid (2).
3. Remove the stop solenoid bracket (3).
66

Removing the fuel pipes (right- and left-hand) (Follow the same procedure for both sides)
1. Remove leak-off pipe(1) connecting the right- and 4. Remove six leak connectors(4).
left-side injection pumps.
WARNING! Cover the openings of the injection
2. Remove leak-off pipe(2) from the injection pump. pump and nozzle inlet connectors with rubber
caps to prevent dust from entering the system.
3. Remove six fuel pipes(3) as a set.
67

Removing the fuel leak-off pipes
1. Disconnect the fuel leak-off pipes (1),(2), and (3). 2. Remove all fuel leak-off pipes (4) on both sides.
Removing the fuel filters (right- and left-hand) (Follow the same procedure for both sides)
1. Disconnect the fuel pipe (1). 3. Remove the fuel filter (5).
2. Remove the fuel pipes (2), (3), and (4). 4. Remove both fuel filter brackets (6) and the pipe
stay (7).
68

Removing the fuel injection pumps (right- and left-hand)
1. Remove the oil pipes (1) and (2), and the drain 4. Remove pump mounting bolts (6) and (7).
pipe (3) of the right-side.
5. With the coupling attached to the injection pump
2. Remove the coupling cover (4). (leave the laminated plate on the drive shaft), lift
the injection pump to dismount.
3. Remove two coupling connecting bolts (5).
Weight: approx 60 kg [132 lb]
Removing the sea water pipes

1. Remove the couplings (1) and (2).
2. Remove the sea water pipes (3), (4), and (5).
3. Unscrew the bracket mounting bolts, and remove

the bracket (8).
69

Removing the right oil cooler

1. Remove oil pipes (1) and (2).
2. Remove the clip, and dismount the oil pipe (3).
3. Unscrew the oil cooler mounting bolts, then re-

move the oil cooler (4).
Removing the left oil filter and oil cooler

1. Remove four oil filter elements (1).
2. Disconnect the oil pipes (2).
3. Unscrew the oil cooler inlet connector mounting

bolts, and disconnect the connector (3).
4. Remove the oil thermostat (4).
5. After unscrewing the oil filter bracket mounting

bolts, remove the filter bracket (5) complete with
the oil cooler.
Removing the oil filler and the oil level gage

1. Remove oil filler (1) by unscrewing mounting
bolts.
2. Remove the oil level gauge (2) and the stay (3).
Removing the starters

Remove starters (1) by unscrewing the starter mount-
ing bolts.
70

Engine Auxiliaries Installation

To install the engine auxiliaries, follow the removal procedures in reverse. After installation, service them as fol-
lows:
1. Refill the engine with the recommended oil up to the specified level.
2. Refill the cooling system with coolant.
3. For easy engine starting, pour engine oil for the governor into the oil filter from its vent plug.
4. Check each pipe connection for oil or coolant leaks.
5. Prime the fuel system.
6. Installation of the fuel injection pump is described below. After installing the fuel injection pumps, be sure to
inspect and adjust the injection timing. (Refer to Section 1.3 of Chapter 5, “Adjustments and Bench Testing.”
Fuel Injection Pump Installations:

Right Injection pump
1. Turn the crankshaft in normal direction to align
the timing mark “1 6” on the viscous damper
●
with the pointer.

NOTE! Verify the injection timing by referring to the
caution plate attached to the No. 1 rocker cover.
2. Move the No. 1 cylinder inlet and exhaust valve

rocker arms to make sure that they are not being
pushed up by the push rods.
3. Turn the crankshaft about 60° in reverse. Turn it

a little at a time in the normal direction to align the
timing mark on the damper with the pointer.
4. Install the coupling to the injection pump, then

align the pointer (1) on the pump case with mark
(2) on the coupling.
71

5. Connect the pump drive coupling (3) to the drive

shaft. Loosen the coupling mounting bolts.
6. Put the pump case on the pump bracket, then

tighten the mounting bolts (4) temporarily.
7. Connect the fuel pipe and the oil pipe to the injec-
tion pump.
8. Tighten the two coupling bolts (5) temporarily.
9. Insert the side of the Injection coupling gauge (A)

marked with “GO” to determine clearance (B) be-
tween the flywheel and coupling, then tighten the
bolts to specified torque.
NOTE! Only the side marked with “GO” should fit into
the gap. If not, loosen the bolt and readjust the clear-
ance.
Flywheel and coupling clearance, mm[in.]

Standard clearance ... 49±0.25 [1.93±0.010
10. Tighten the pump mounting bolt (4) firmly. Be

sure that the coupling mark (B) aligns with the
pump case pointer (A). Tighten the two connect-
ing nuts (5) to specified torque.
11. Tighten the shaft tightening bolt (6) of the cou-

pling to specified torque.
NOTE! Coupling damage or wrong injection timing
can be caused by improper tightening of bolts.
72

Fuel Injection Pump Installation:

Left Injection Pump
1. Align the timing marks “7 12” on the viscous
●
damper with the pointer. Make sure that bolt inlet

and exhaust valves of the No. 7 cylinder piston is
at top dead center of the compression stroke.
2. Follow the procedures described for the right in-

jection pump.
Adjust injection quantities of pumps

1. Check to make sure the output shaft of the gover-
nor is positioned on the side marked with “0” (no-
injection side).
2. Install governor lever (1) at an angle of 20°.
3. Install links (2) on the right- and left-hand banks,

making sure that the installation length is 62±0.7
mm [2.4±0.028 in.].
4. Install the link (3) on the right-hand bank.

NOTE! Link (3) has a fixed length of 239 [9.3 in.].
73

5. Install the link (4) on the left-hand bank, length

should be 239 mm [9.4 in.] (same as for the right-
hand bank).
6. Install the rod (5) and adjust the length of the rod
to a distance of 68±0.5 mm [2.68±0.020 in.] be-
tween the rack end surface and the pump case
end surface.
NOTE! More than 8 mm [0.35 in.] of threads of the
rod and ball joint should be engaged on both ends.
7. The rack stroke should be approximately 2 mm

[0.08 in.] when the stop lever (6) is pulled fully to
the STOP side.
RUN-OFF solenoid
Adjustment
1. Supply power to solenoid (1) (contracted).
2. Loosen nuts (2) and (3).
3. Rotate rod (4) to adjust the clearance between le-

ver (5) and follower (6) to be from 0.5 to 1.0 mm
[0.020 to 0.039 in.].
4. Tighten nuts (2) and (3).
Inspection
1. Cut off power to solenoid (1) (extended).
2. After adjusting the exhaust temperature, run the

engine at high idling speed.
3. Supply electric current to solenoid (1) (contracted

condition).
4. After the engine stops completely, check to make

sure the distance between the rack end surface
and pump case end surface is 68 to 69 mm [2.68
to 2.72 in.] on both banks.
NOTE! It should be noted that the engine may not
stop if the distance between the rack end surface and
pump case is 70 mm [2.76 in.] or more.
NOTE! When adjusting the adjusting rod, make sure

the rack moves without interference. If the rack does
not move smoothly, the governor cannot operate
properly.
74

Group 21 Engine Body

Cylinder heads and valve mechanism
Disassembly: Look for:

1. Rocker cover 15. Push rod A. Cracks, oil leaks, deterioration
2. Fuel inlet connector 16. Rocker case B. Cracks, damage, carbon and scale deposits
3. Nut, washer 17. Water outlet connector C. Wear
4. Injection nozzle gland 18. Cylinder head bolt D. Damaged threads
5. Injection nozzle 19. Cylinder head E. Wear, clogged oil hole
6. Gasket 20. Inlet port packing F. Distortion, cracks
7. O-ring 21. Exhaust connector G. Matching, wear
8. Adjusting screw 22. Valve cotter H. Worn stem or face, corrosion, damage, or carbon deposits
9. Bolt 23. Valve rotator I. Cracks, damage, deterioration, rubber parts cracked
10. Rocker 24. Valve spring J. Worn ends, distortion
11. Spacer 25. Stem seal K. Worn cam contact face or sliding surface
12. Rockershaft 26. Valve L. Replace gasket
13. Bridge cap 27. Cylinder head gasket
14. Valve bridge 28. Tappet
75

Removing fuel injector assemblies

1. Remove the fuel inlet connector and the nozzle
gland
2. Use the Nozzle remover to remove the injector
assembly. Take out the gasket if it is left behind
in the cylinder head.
3. Store the injector and the inlet connector as a set
to avoid swapping. Pay attention not damage the
nozzle.
Removing the rockershaft assemblies

1. Loosen the adjusting screw of each rocker.
2. Store the shaft assembly and mounting bolts to-
gether as a set.
Disassembling rockershaft assemblies

Arrange the disassembled rockers in the order re-
moved, so you can install them in that order at reas-
sembly. This will ensure the same rockershaft clear-
ance as before.
Remove the valve bridge

Remove the valve bridge and bridge cap.
NOTE! Do not drop the bridge cap or other parts into

the crankcase through the push rod hole.
76

Removing the rocker cases

1. Remove the snap ring of the water outlet connec-
tor. Slide the connector towards the snap ring.
2. Unscrew the rocker case mounting bolts, then re-
move the rocker case from the cylinder head.
Removing cylinder head assemblies

1. Each cylinder head is located relative to the
crankcase with dowel pins. Use the Eye nut to lift
the head off the crankcase at a slant.
Cylinder head weight: approx. 35 kg (77 lb)

2. Remove the cylinder head gasket
IMPORTANT! Do not damage the cylinder head

or crankcase surfaces when you remove the
gasket with a screwdriver or other tool.
Removing valves and valve springs

Use the valve spring pusher to compress the valve
spring squarely, then remove the valve cotters.
NOTE! If the valves are to be reused, do not change

the combination of the valve seat and valve guide.
Removing studs, guides, etc.

Do not remove the nozzle gland mounting studs or
the bridge guide from the cylinder head unless abso-
lutely necessary. If any of these parts have been re-
moved, apply thread adhesive to the threads when in-
stalling it or a new part to the cylinder head.
77

Inspection and Repair

Rocker Bushings and Rockershaft
1. Measuring rocker bushing inside diameter and
rockershaft diameter. If the measurement ex-
ceeds the service limit, replace the bushing or
shaft.
Rocker bushing inside diameter, mm [in]

Normal Value ............ Ø36 [1.42]
Service limit .............. 36.090 [1.42086]
Rockershaft diameter, mm [in]

Normal Value ............ Ø36 [1.42]
Service limit .............. 35.940 [1.41496]
Replacing rocker bushings

Use the Rocker bushing tool to remove the rocker
bushings for replacement.
NOTE! Press a new bushing into the rocker from the

chamfered side(1) of the bore.
NOTE! Align the oil holes in the bushing and rocker.
NOTE! Check bushing joint mark(2)
78

Valve Guide and Valve Stems

Measure valve stem and valve guide.
The valve guide wears more rapidly at its ends than
at any other location. Measure the inside diameter of
the guide at its ends in two directions. If the service
limit is exceeded, replace the guide.
Valve stem diameter, mm [in]

Normal Value ............ Ø10 [0.39]
Service limit .............. 9.910 [0.39016]
Valve guide inside diameter, mm [in]

Normal Value ............ Ø10 [0.39]
Service limit .............. 10.060 [0.39606]
Replacing valve guides and stem seals

1. Use the Valve guide remover to remove the valve
guide for replacement.
2. Use the Valve guide seal installer to install slowly
a new guide with a press.
IMPORTANT! The installation depth for the

valve guide is specified, so use the Valve guide
seal installer to secure the correct depth.
IMPORTANT! Do not apply any oil or sealant to

the surface of the stem seal that comes in con-
tact with the valve guide. When installing the
stem seal, apply lub oil to valve stem to ensure
initial lubrication of the stem seal lip.
IMPORTANT! Use a new stem seal whenever

removed.
79

Valves and Valve Seats

Inspecting the valve
Coat the valve face lightly with red lead. Use the
Valve lapper to inspect the valve contact with its seat.
If the contact is not uniform, or if the valve is defec-
tive, or if the repair limit is exceeded, repair or replace
the valve and valve seat.
NOTE! Inspect the valve face after the inspection or

replacement of the valve guide.
NOTE! When you press the valve coated with red
lead into the valve seat, do not rotate the valve.
A. Good contact
B. Bad contact
Valve seat, mm [in]

Angle (A)
Assembly Standard ... 30°
Valve sinkage (depth)(B)
Assembly Standard ... -0.2–0.2 [-0.008–0.008]
Repair limit ................ 1.0 [0.039]
Width (C)
Repair limit ................ 2.8 [0.110]
Valve margin (thickness)(D), mm [in]

Repair limit(refacing) . 2.5 [0.098]
80

Refacing the valve face

If the valve face is badly worn, reface it with a valve
refacer
NOTE! Set a valve refacer at an angle of 30°.
NOTE! Grind the valve as little as possible. If the
margin seems to exceed the repair limit as a result of
grinding, replace the valve.
Refacing valve seats

1. Use the Valve seat cutter or a valve seat grinder
to reface the valve seat. After refacing, grind the
seat lightly using #400 grade sandpaper inserted
between the cutter and valve seat.
2. Lap the valve in the valve seat.
NOTE! Cut or grind the valve seat only as needed for

refacing.
NOTE! Replace the valve seat if the seat width is
more than the repair limit as a result of wear or cut-
ting.
NOTE! Replace the valve seat if the valve sinkage
exceeds the repair limit after refacing.
Replacing valve seats

1. Weld a stud(1) to the valve seat(2). Insert a
shaft(3) into the valve guide holder from the up-
per side of the cylinder head. Drive the seat off
the head as shown.
NOTE! When you weld the stud, do not permit splat-

ter to come in contact with the machined surfaces of
the cylinder head.
81

2. Before inserting a new valve seat, measure the

inside diameter of the cylinder head bore and the
outside diameter of the valve seat to make sure
that clearance (fit) is within clearance standards.
Valve seat dimensions, mm [in.]

Cylinder head bore diameter (A)
Nominal value ........... 60.000-60.030 [2.36220-2.36338]
Valve seat diameter (A)
Nominal value ........... 60.100-60.130 [2.36614-2.36732]
Cylinder head bore / Valve seat clearance
standard clearance* .. -0.070 – -0.130 [-0.00276 – -0.00512]
B
Nominal value ........... 3.6 [0.142]
C
Nominal value ........... 8.0 [0.315]
D
Nominal value ........... 11.6–11.7 [0.4567–0.4606]
*A minus (–) indicates interference.
3. Chill the valve seat in liquid nitrogen -70°C

[-274°F] for more than 4 minutes with the cylinder
head kept at normal temperature, or heat the cyl-
inder head to 80 to 100 °C [176 to 212 °F] with
the valve seat chilled in ether or alcohol contain-
ing dry ice.
4. Use the Installer to install the valve seat.
82

Lapping valves in valve seats

Be sure to lap the valves in the valve seats after the
seats has been replaced.
1. Coat the valve face lightly with a lapping com-
pound.
2. Lap the valve in the seat using the valve lapper.
Raise the valve off the seat, then rotate the valve
only a partial turn and strike it against the seat.
3. Wash off the compound with diesel fuel.
4. Coat the valve face with engine oil, then lap the
valve again.
5. Check the valve face for contact.
NOTE! Do not permit the compound to come in con-

tact with the valve Stern.
NOTE! Use a compound of 120 to 150 mesh for initial
lapping and a compound finer than 200 mesh for fin-
ish lapping.
NOTE! Mixing the compound with a small amount of
engine oil will facilitate coating.
Valve spring clearance and free length

Measure the free length and clearance of each valve
spring. If the free length or clearance (perpendiculari-
ty) exceeds the service limit, replace the spring.
Free length (A), mm [in.]

Assembly standard ... 73 [2.87]
Service limit .............. 71 [2.80]
Perpendicularity (B), mm [in.]

Service limit .............. 2.2 [0.087] (at end)


Assembly standard ... 289–319 (29.45 to 32.55) [65 to 72]
83

Bridge-to-rotator clearance
1. When clearance is less than 1.5 mm [0.059 in.],
check the valve stem top for cupping. If the stem
top is badly cupped, replace the valve to obtain
more than 1.5 mm [0.059 in.] clearance.
2. Check the condition of the bridge cap. Replace it
if it is badly worn.
Tappets and Push Rods

Inspecting tam contact faces of tappets
Replace the tappets if their tam contact faces are ab-
normally worn.
Measuring valve pushrod deflection

If the deflection exceeds the assembly standard, re-
place the push rods.
Push rod deflection, mm [in.]

Assembly standard ... Less than 0.5 [0.020] max.
Cylinder Head
Measuring head gasket flatness of surface
Use a straight edge and feeler gauges to measure
warping on each cylinder head. If warping exceeds
the repair limit, reface the gasket surface with a sur-
face grinder.
Flatness, mm [in.]
Assembly standard ... <0.03 [0.0012]
Repair limit ................ 0.07 [0.0028]
Service limit .............. 0.50 [0.0197]
84

Reassembly
Reassembly sequence:
Reverse the order of disassembly.
Installing tappets
Insert tappets coated with engine oil into the tappet
holes and make them seat softly on the camshaft.
Installing cylinder head gaskets

1. Clean the gasketed surfaces of the cylinder head
and crankcase thoroughly with a solvent or de-
greasing solution.
2. Apply a thin coat of Three Bond 1211 to areas 5
to 8 mm [0.197 to 0.315 in.] from the periphery of
the head gasket, around tappet holes and oil pas-
sage holes, on both sides of the head gasket (to
areas indicated in the diagram on the right).
Spread the liquid gasket with a finger to a thick-
ness of 0.2 to 0.5 mm [0.008 to 0.020 in.].
NOTE! Liquid gasket should be applied to areas indi-

cated in the diagram on the right. Do not apply an ex-
cessive amount of liquid gasket, since it can press
the head gasket O-rings and cause deformation.
NOTE! Do not allow liquid gasket to adhere within an

area of 10 mm [0.394 in] around the cylinder bore (A),
this may cause gas leakage. Sections B and C are
very close to O-rings. Make sure that there is no large
amount of liquid gasket on the edge at these sec-
tions.
2. Install the gasket before the liquid gasket dries.

Place the gaskets on the crankcase, making sure
that the dowel pins enter their holes in the gas-
kets.
85

Reassembly of the cylinder heads

1. Coat the valve Stems with engine oil, then insert
them into the valve guides.
2. Install the valve springs and rotators to the valve
guides. Compress each valve spring with the
Valve spring pusher, then install the valve cotters
on the valve Stem.
3. Lightly tap on the top of each valve stem with a
soft-faced mallet to make sure that the valve
spring and cotters are properly installed.
Install cylinder head assemblies
IMPORTANT! Before you install the cylinder

head assembly, measure the protrusion of each
piston. Make sure that the protrusion is correct.
1. Install the exhaust connector to the cylinder

head, while pushing down the exhaust connector
so it touches the edge of the bolt hole.
NOTE! Place the gasket so its ”MANIFOLD” printed

side aligns with the connector side.
2. Install the Eye nut to the stud bolt, and lift up the
cylinder head assembly. Locate the head aligning
its holes with the dowel pins, and keep the head
being slightly separated from the cylinder. Apply
engine oil to the threads and bearing surfaces of
head bolts, then wipe off the excessive oil before
tightening.
3. Tighten the cylinder head bolts with the specified
torque in the order shown in the drawing.
86

Tightening cylinder head bolts

1. Place the Head bolt plate on the cylinder head.
2. Tighten each head bolt to 294 Nlm (30 kgflm)
[217 lbflft] torque (initial torque).
3. The head bolt plate has graduations at 30° inter-
vals. Place a reference point mark on each head
bolt.
4. Tighten each bolt 30°. After tightening all bolts,
turn each bolt another 30° (totally 60°).
Installing the rocker case

1. Insert the water outlet connector fully into the
rocker case.
2. Install the rocker case so it meets the dowel pins
3. Tighten the rocker case mounting bolts to the
specified torque.
4. Insert the water outlet connector by sliding it from
the next rocker case after coating the O-ring with
grease. Install the snap ring.
Installing valve bridges and caps

1. Coat the bridge guides with engine oil (A), then
install the bridges to the guides with the adjusting
screws positioned on the exhaust manifold side.
2. Coat the bridge contact face of the bridge caps
(A) with engine oil. Install the caps in position, be-
ing careful not to let them fall into the crankcase
through the push rod holes.
Installing rocker shaft assemblies

1. Install the spacer (A) on the rocker shaft and
mount the rockers on both sides.
2. Align the pin hole of the rocker shaft with the po-
sitioning pin, and install the rocker shaft assem-
bly to the rocker case. Move the rocker arm up
and down to make sure that the arm is free.
NOTE! While tightening the bracket mounting bolts
temporarily, install the bracket in place so the rocker
tip comes in contact with the bridge caps evenly.
NOTE! Tighten the long bolt securing the head and
rocker bracket first, then tighten the short bolt to the
specified torque.
87

Install fuel injector

1. Disconnect the fuel inlet connector from the
injector assembly.
2. Put three O-rings on the injector and coat them
with grease.
3. Coat the gasket with grease and attach it to the
injector. Insert the injector assembly into the cyl-
inder head aligning its connector hole with the
rocker case hole.
IMPORTANT! The grease must be high temp.

resistant and must not cover the nozzle holes.
4. Tighten the fuel inlet connector to the specified

torque.
5. Tighten nozzle gland mounting nut to the speci-
fied torque
NOTE! Maintain equal distances between the fuel in-
let connector and the cylinder head before tightening
the gland to the specified torque.
88

Cylinder liners, Pistons and Connecting rods

1. Bolt A. Wear, scratches, damage
2. Connecting rod cap B. Fatigue
3. Connecting rod bearing (lower shell) C. Scratches, cracks, damage, wear,
4. Top compression ring carbon deposits on outside surface
5. Second compression ring D. Cracks, clogged oil hole
6. Oil ring E. Scratches, wear on inside surface,

rust on outside surface
7. Snap ring
F. Damage
8. Piston pin
G. Wear, scratches, discolored inside surface
9. Piston
H. Scratches, seizure, wiping out of overlay on
10. Connecting rod both sides
11. Connecting rod bushing I. Damaged threads
12. Connecting rod bearing
89

Removing connecting rod caps

Open the inspection hatches, remove the connecting
rod caps. For identification, mark the removed con-
necting rod bearing with cylinder number and upper
or lower shell.
IMPORTANT! Handle bearings with care.
Removing pistons
Preparations
Use a cloth or oil paper to remove all carbon deposits
from the upper areas of the cylinder liner.Carbon de-
posits make it difficult to pull the piston out.
Removing pistons in right bank cylinders

1. Turn the crankshaft to bring the piston assembly
(from which the connecting rod cap has been re-
moved ) to top dead center.
2. Turn the crankshaft in reverse until the crank pin
comes off the connecting rod and the bolt hole of
the rod is visible through the inspection hatch on
the side of the crankcase.
1. 2.
3. Cover a bar with a cloth for protection. Put the tip

of the bar under the bottom of the big end of the
connecting rod and pry the bar slightly down-
wards using the crank pin as a fulcrum. This will
push the piston assembly upwards.
NOTE! If you insert the turning bar too far, you may
not be able to pry the piston assembly upwards. In-
sert the bar 10 to 20 mm [0.39 to 0.79 in.] beyond the
big end.
90

4. Turn the crankshaft a little at a time to raise the

crank pin (fulcrum), while pushing the outer end
of the bar, to further raise the piston assembly.
IMPORTANT! Raise the piston assembly care-
fully so that the connecting rod don’t interfere with
the oil jet nozzle for piston cooling.
5. When the oil ring of the piston comes out of the

cylinder liner, lower the piston a little and carefully
rest the oil ring on the edge of the liner.
NOTE! To avoid damage to the oil ring, lower the pis-

ton slowly and carefully. Do not rotate the piston.
6. Holding the compression ring portion of the piston

and carefully pull the piston from the cylinder lin-
er. Rest its skirt on the top of the crankcase.
7. Hold the piston pin portion of the piston, and lift
the piston assembly off the liner.
Removing pistons in left bank cylinders

Removal procedure is the same as that for removing
pistons in right bank cylinders. The only difference is
that the position of the crank pin and the direction of
the crankshaft rotation for removal are reversed.
91

Using the Piston remover

1. Turn the crankshaft to bring the piston assembly
to 50° after top dead center for the left bank.
2. Attach the Piston remover to the top of the piston.
Grip the handle of the remover, then lift the piston
and the connecting rod off the liner.
IMPORTANT! Do not damage the piston when

you pull it out from the cylinder liner. Do not let
it hit the connecting rod with its skirt. Support
the connecting rod to avoid the cylinder liner
bore from scratching.
Removing the piston ring

Use the Piston ring tool to remove I the piston rings.
Removing piston pins

1. Use the Ring pliers to remove the snap rings.
2. Remove the piston pin to separate the piston
from the connecting rod.
3. If it is difficult to pull out the pin, heat the piston
with a piston heater or in hot water to expand the
pin bore.
92


Cylinder Liners
Inside diameter
Measure the inside diameter of each liner in two di-
rections, parallel and transverse to the piston pin, at
three positions, top (weared position), middle and
low. If measurements exceed the service limit, re-
place the liner.
Cylinder liner side diameter, mm [in.]

Normal value ............. Ø170 [Ø6.69]
Assembly standard ... 170.000–170.040 [6.69290–6.69447]
Service limit .............. 170.500 [6.71259]
Measuring cylinder liner protrusion

Measure the protrusion of each liner at its flange with
a dial gauge.
NOTE! The method of measuring the protrusion of an
used liner differs from that of newly installed one.
Cylinder liner protrusion at flange (A), mm [in]

IMPORTANT! If the protrusion is less than the

assembly standard, the gasket will fail to seal
the bore resulting in gas leakage.
When cylinder head has just been removed

1. Clean the gasketed surface of the crankcase and
the top of the liners.
2. Secure the top of the liner uniformly at four plac-

es with the Liner pusher and the Bolts.
NOTE! Use the Head bolt spacers when tightening
the Line pushers using head bolts.
3. Set up the dial gauge at the top face of the crank-

case, then set the gauge pointer to zero (0).
4. Measure the protrusion at four places at the

flange of the liner. Take the average of the four
measurements.
5. If the average is less than the assembly stan-

dard, insert a shim under the collar of the cylinder
liner.
93

When replacing cylinder liner
1. Remove the cylinder liner (Refer to section Re-

place cylinder liners) and observe the cylinder
liner contacting surface to the crankcase.
2. If the cylinder liner contacts the crankcase only

on one side, use a rotary grinder to grind the
surface to keep the differences of depth in four
positions within 0.05 mm [0.0020 in.].
3. Use the Projection plate (B) and measure the

counter bore depth of the crankcase in four po-
sitions and obtain the average.
4. Subtract the Projection plate thickness from the

measured counter bore depth to obtain the ac-
tual counter bore depth from the top surface of
the crankcase.
Crankcase counter bore depth (A), mm [in]

5. Measure the thickness of the cylinder liner collar.
Thickness of cylinder liner collar, mm [in]

7. Subtract the crankcase ridge depth from the cyl-

inder liner collar thickness. This value is the cylin-
der liner protrusion.
8. If the value is less than the assembly standard,

insert a shim under the collar of the cylinder liner.
Measuring step height of cylinder liner collar

1. Place a dial gauge on the rim of the liner collar,
and set the indicator to 0 (zero).
2. Measure the cylinder liner step at four locations,

and obtain the average.
Cylinder liner step height, mm [in]

3. If the average is less than the assembly standard

or if the step has sectional chipping, replace the
cylinder liner.
94

Cylinder liner shim

Insert a shim between the cylinder liner and the
crankcase.
NOTE! Select the shim that achieves the largest pro-
trusion within the assembly standard range.
Replace cylinder liners

1. Use the Cylinder liner remover to remove the cyl-
inder liner from the crankcase.
2. Coat the O-rings with engine oil to prevent twist-

ing and attach them to the new cylinder liner.
A – black o-ring
B – red o-ring
Carefully insert the liner into the bore of the

crankcase.
3. Lightly tap liner on the top with the installer so it

rests on its flange on the counterbore in the
crankcase. After seating the liner, tap on it sever-
al times more to secure the proper seating.
IMPORTANT! After installing the liners on all

bores, test the liner fitting for water tightness by
applying water under pressure.
NOTE! Check all liners to be sure its protrusion is

within assembly standards.
95

Pistons
Inspecting the piston outside surfaces
Check the combustion surfaces and inside surfaces
of the pin bosses. Replace the piston if any defects
are found.
Measuring piston diameter

Measure the diameter of each piston perpendicular
(A) to the piston pin and 30 mm [1.18 in.] below the
center of the piston pin (B). If the service limit is ex-
ceeded, replace the piston. If any pistons have to be
replaced, select new pistons so that weight difference
in an engine is within assembly standards.
Piston diameter, mm [in.]

Normal value ............. Ø170 [Ø6.69]
Service limit .............. 169.66 [6.6795]
Weight difference in an engine, g [oz]

Assembly standard ... +/- 10g [+/- 0.35 ] max.
Information stamped on top of each piston:

A – Part no.
B – Engine front side mark
C – Piston weight
Measuring piston pin diameter

Using a micrometer, measure the outside diameter of
each piston pin. If the measurement exceeds the ser-
vice limit, replace the pin.
Piston pin outside diameter, mm [in]

Nominal value ........... Ø70 [2.76]
Service limit .............. 69.970 [2.75472]
96

Measuring piston pin bore diameter

Using calipers or a cylinder gauge, measure the pis-
ton pin bore diameter. If the service limit is exceeded
replace the piston.
Piston pin bore diameter, mm [in.]

Normal value ............. Ø70 [Ø2.76]
Service limit .............. 70.040 [2.75747]
Measuring piston protrusion

Measure the protrusion (height from cylinder head to
piston head) of each piston at top dead center. If it is
not within standards for piston protrusion measure-
ment, inspect the clearance of the parts.
1. Set the dial gauge to zero (0) on top of the crank-

case and measure the protrusion at four places
on top of the piston head. Average the four mea-
surements to determine the protrusion.
2. Subtract the piston protrusion from the thickness

of the cylinder head gasket (as installed) to deter-
mine the clearance between the piston top and
cylinder head.
Piston protrusion, mm [in]

Assembly standard ... 0.06 60 0.065 [0.0024 to 0.0256]
Cylinder head gasket thickness, mm [in]

Assembly standard ... 1.77 to 1.83 [0.0697 to 0.0720]
Piston top and cylinder head clearance, mm [in]

Assembly standard ... 1.22 to 1.95 [0.0480 to 0.0768]
IMPORTANT! Keep the piston protrusion within

assembly standard range to prevent the valves
from stamping on the piston and to maintain
high engine performance.
Inspecting piston ring grooves

Check the piston ring grooves for wear and damage,
replace the piston if necessary. Pay special attention
to the Ni-resist insert in the top groove (A) for cracks.
97

Piston Rings
Measuring piston ring gaps
Place the rings in the new or master cylinder liner.
Measure the gap of each ring. If the service limit is
exceeded, replace all the rings on that piston.
NOTE! Use a piston to place the piston ring in the lin-
er by pushing it squarely.
Piston ring gap, Top ring, mm [in]

Standard clearance ... 0.6–0.8 [0.024–0.031]
Service limit .............. 2.0 [0.079]
Piston ring gap, Second ring, mm [in]

Service limit .............. 2.0 [0.079]
Piston ring gap, Oil ring, mm [in]

Standard clearance ... 0.3–0.45 [0.012 –0.018]
Service limit .............. 2.0 [0.079]
98

Connecting Rods, Bearings, and

Bushings
Measuring connecting rod bushing inside
diameter
Measure the inside diameter of each bushing in two
directions and on two locations(see picture). If the
service limit is exceeded, replace the bushing.
Connection rod bushing inside diameter, mm [in.]

Normal value ............. Ø70 [2.76]
Service limit .............. 70.070 [2.75866]
Replacing connecting rod bushings

1. Use the Connecting rod bushing installer(A) to re-
move(1) the bushing for replacement as shown.
2. When installing a new bushing(2), align the oil

holes in the bushing and connecting rod.
3. After installing the bushing, measure it and ream

to correct size if necessary. Insert the piston pin,
and make sure that the pin rotates freely without
rattling.
Connecting rods bend(1) and twist(2)

Measure C and L. If the measurement at C is larger
than 0.05 mm [0.0020 in.] per 100 mm [3.9 in.] of L,
straighten the rod with a press
NOTE! To inspect for bend and twist, install the cap
to the connecting rod, then tighten the cap bolts to the
specified torque.
To inspect the rod bend when assembled with the

piston, place the piston on a surface plate. Insert a
round bar of the same diameter as the crank pin into
the big end bore, then measure heights A and B of
the bar.
Connecting rod bend C/D, mm [in]

Assembly standard ... 0.05/100 max. [0.0020/3.9]
99

Inspecting connecting rod large-end bearings

Inspect each bearing shell for flaking, scratching, sei-
zure, pitting, and other defects. If any defects are
found, replace the shell.
Measuring connecting rod end play

Install the connecting rod to its crank pin, then tighten
its cap bolts to the specified torque. Use feeler gaug-
es to measure the end play. If the end play exceeds
the service limit, replace the connecting rod.
Connecting rod end play*, mm [in]

Nominal value ........... 60 x 2 [2.36 x 2]
Standard clearance ... 0.4 to 0.9 [0.016 to 0.035]
Service limit .............. 1.4 [0.055]
* Axial play over crankpin
Weight difference of connecting rods in an engine

When replacing connecting rods, make sure that the
weight difference of connecting rods in an engine is
within the assembly standards below.
Weight difference of connecting rods, g [oz]

Assembly standard ... +/- 30 [+/-1.06]
Big end bore diameter

Measure the connecting rod big-end bore diameter in
directions 3, 4 and 5 and at front and rear positions 1
and 2, as shown in the drawing. To obtain the round-
ness value, subtract the smallest measured value
from the largest measured value. If the diameter ex-
ceeds the servi
Big end bore diameter, mm [in]

Nominal value ........... Ø131 [5.16]
Service limit .............. 131.050 [5.15944]
Service limit* ............. 0.100 [0.0039]
*Roundness
100

Serration on connecting rod big-end.

Inspect the serration on connecting rod. big-end by
conducting a Magnaflux (magnetic particle) test. If
cracking or damage is found, replace the connecting
rod.
Connecting rod bearing thickness

Use a ball-point micrometer to measure the center of
each bearing shell. If the thickness exceeds the ser-
vice limit on the upper or lower shell, replace both
shells as a set.
Connecting rod bearing thickness STD, mm [in]

Nominal value ........... 3.000 [0.11811]
Assembly standard ... 2.9 72–2.985 [0.11701–0.11752]
Service limit .............. 2.930 [0.11535]
Bearing thickness –0.25 [-0.0098], mm [in]

Nominal value ........... 3.125 [0.12303]
Service limit .............. 3.055 [0.12028]

Nominal value ........... 3.250 [0.12795]
Service limit .............. 3.180 [0.12520]

Nominal value ........... 3.375 [0.13287]
Service limit .............. 3.305 [0.13012]

Nominal value ........... 3.500 [0.13780]
Service limit .............. 3.430 [0.13504]
101

Reassembly
Reassembly is done in the reverse order of disas-
sembly.
Pistons and connecting rods

1. The piston pin is clearance-fitted to the piston. To
facilitate pin insertion, heat the piston with a pis-
ton heater or in hot water.
2. Coat the piston pin with engine oil, then insert it in

position through the connecting rod.
3. Install the connecting rod to the piston with the

matching marks on the large end on the camshaft
side.
4. Use the Ring pliers to install the snap rings in the

grooves of the piston. Make sure that the rings
are not fatigued and that they fit in the grooves
properly.
NOTE! Position the ends of both snap rings at the
bottom of the pin bore.
Piston rings
1. Use the Piston ring tool to install the piston rings
on the piston
IMPORTANT! The top piston ring and second
piston ring are marked “RH”, and the oil ring is
marked “R” near the gap. Install the rings with these
marks upwards. Faulty mounting will cause excessive
oil consumption and overheating.
2. Install the oil ring with its gap positioned at 180°

from the coil spring joint.
102

Preparation before installing pistons

Clean the cylinder liner bore surface and crank pin by
wiping with a cloth, then coat it with engine oil.
Pistons for right bank cylinders

Turn the crankshaft in the normal direction until the
number (stamped on the damper)(A) of the cylinder to
which the piston is to be installed is at the position of
approximately SO* before top dead center.
Pistons for left bank cylinders

Turn the crankshaft in the normal direction until the
number of the cylinder to which the piston is to be in-
stalled is at the position of about 50° after top dead
center.
Connecting rod bearing upper shells

Install the upper shell of the bearing in the rod by fit-
ting its locating lug in the lug groove of the rod(A).
Coat the inside surface of the shell with engine oil.
Make sure the oil holes in the rod and bearing are
aligned.
Inserting pistons
1. Put the connecting rod in the cylinder liner, and
carefully rest the piston on top of the crankcase.
IMPORTANT! Make sure the arrow mark above

the “CAM-arrow”(A) on top of the piston points
towards the camshaft(B).
IMPORTANT! When placing the connecting rod

in the liner, have another service man to ob-
serve the rod through the inspection hole to
keep it away from the oil cooling nozzle. Do not
rotate the piston.
103

2. Coat the piston rings with engine oil, then position

the ring gaps as shown:
A – Joint of coil spring
B – Gap of top compression ring
C – Gap of second compression ring
D – Gap of oil ring
3. Hold the compression ring portion of the piston,

and carefully insert the piston into the cylinder lin-
er.
NOTE! Do not pinch your fingers between the oil ring
and cylinder liner.
Insert the piston slowly not to damage the oil ring.
4. Coat the rings with engine oil and clamp them,

using the Piston installer. Coat the inside surface
of the installer with engine oil.
5. Lightly tap on the piston head with a soft-head

mallet to insert the piston into the cylinder liner. If
the piston will not go into the liner, move the large
end of the connecting rod back and forth through
the crankcase inspection hole.
6. Make sure that the upper shell of the bearing is

properly positioned in the big end of the connect-
ing rod.
Installing connecting rod cap bolts

1. Place the connecting rod bearing on the connect-
ing rod, fitting its lug in the lug groove. Coat the
threads of the cap bolts and the inside surface of
the lower shells of the connecting rod bearing
with engine oil.
2. Install each cap in position. Hold the upper end of

the cap, then tighten the bolt at the lower end
first. This will help prevent the cap from dropping
into the oil pan. Coat the threads and bearing sur-
faces of the bolts with engine oil, then tighten the
bolts temporarily.
104

3. Touch the joint between the cap and rod. Make

sure that the cap is fit in place, and tighten the
bolts to the specified torque.
IMPORTANT! Make sure that the matching

marks on the cap and rod are on the same side
and show the same number.
4. Install the other connecting rod to the crank pin.

Temporarily tighten the cap bolts of the rod in-
stalled later, then press it squarely toward the rod
already installed by tapping. Move the large end
of this rod in the thrust direction. Make sure that
the rod has correct end play (insert feeler gauges
while tightening).
5. Tighten the cap bolts to the specified torque.

NOTE! Tighten connecting rod cap bolts according to
the angle method. Tighten to 245 N.m (25 kgf.m) [181
lbf.ft], then 60° more.
6. Use feeler gauges to measure the end play of the

connecting rod. Make sure that the end play is
equal on both top and bottom sides of the crank
pin.
IMPORTANT! Before installing the cylinder head,

measure the protrusion of the piston. Make sure
that the measurement is correct.
105

Viscous damper and front gears

1. Viscous damper, damper spacer A. Worn seal lip
2. Plate B. Roughness in rotation
3. Oil pump gear C. Wear, nicking, chipping, defective splines
4. Front gear case D. Wear
5. Water coupling E. Wear, nicking, chipping, abnormally worn bushing
6. Water pump bearing cover F. Clogged oil hole, wear
7. Oil pump bearing cover G. Cracking, defective dowel pin hole
8. Thrust plate H. Cracking, defective dowel pin hole
9. Idle gear I. Worn, lip, nicking, deterioration
10. Idler shaft J. Cracking, oil leakage
11. Front plate
106

Viscous damper
1. Attach a sling to the viscous damper. Unscrew
the mounting bolts.
2. Screw the jack-bolts (M14x1.5-40 mm [0.55 x
0.059 - 1.57 in.]) into the threads evenly, then re-
move the viscous damper.
Weight: Approx. 50 kg [110 lb]
Oil pump and water pump mounting plate

Remove the plate by screwing the two jack-bolts (A)
(885455: M12 x 1.25 mm [0.47 x 0.049 in.]) evenly
into the plate.
Oil pump gear

Remove the oil pump gear with the bearing.
Front gear case

1. Attach a sling to the front gear case.
2. Unscrew the front gear case mounting bolts. Re-
move the lifted gear case by sliding it until the
gear case comes apart from the positioning dow-
el pin. Be careful not to damage the oil seal, or
bend the pointer by hitting it.
107

Oil pump and water pump bearing cover

Unscrew the bearing cover mounting bolts, and re-
move the bearing cover.
Measure backlash and end play of the

idler gear
Measure the backlash and end play of the idler gear
to obtain the data for replacement. (Refer to chapter
“Maintenance Standards Table”)
Idler gear
Unscrew the thrust plate mounting bolt and remove
the idler gear.
Idler shaft
Do not remove the idler shaft unless it is needed.
When needed, remove it by unscrewing the mounting
bolts and screwing the two jack-bolts (A) (Ml0 x 1.25
mm [0.39 x 0.049 in.]) evenly.
108


Viscous damper inspection
Check the viscous damper for cracks, deformations
or cracks in the mirror plate, leakage of silicone oil,
discolored or peeling paint due to excessive heat. Re-
place it with a new one after 8000 to 12000 hours of
service, even when no defect is observed.
NOTE! Damper may also be sent to authorized Volvo
Penta workshop for inspection.
Measure backlash
Set up a dial gauge so that it contacts with the pitch
circle of the gear to measure the backlash between
the gears. If the dial gauge is not available, measure
the backlash by inserting feeler gauges between the
teeth of the gears. If the backlash exceeds the ser-
vice limit, replace the worn gear.
Backlash,mm [in]
Service limit .............. 0.50 [0.0197]
Oil pump drive

Diameters of bearings and bearing-fitted sections
Rotate the bearing, and replace it if it is not smooth.
Check the fittings of following items and replace them
if they show any evidence of excessive wear.
●
Drive shaft and bearing
●
Drive case and bearing
●
Drive shaft and oil seal
Cover bearing bore, mm [in]

Nominal value ........... Ø110 [4.33]
Plate bearing bore, mm [in]

Nominal value ........... Ø110 [4.33]
Bearing outside diameter, mm [in]

Nominal value ........... Ø110 [4.33]
Bearing inside diameter, mm [in]

Nominal value ........... Ø50 [1.97]
Gear shaft bearing bore, mm [in]

Nominal value ........... Ø50 [1.97]
109

Idler gears, bushings, and shafts

Measuring idler gear bushing inside diameter and
idler gear shaft diameter. If the service limit is ex-
ceeded, replace the bushing or shaft (whichever is
worn).
Idler gear bushing inside diameter, mm [in]

Nominal value ........... Ø50 [1.97]
Service limit .............. 50.060 [1.97086]
Idler gear shaft diameter, mm [in]

Nominal value ........... Ø50 [1.97]
Service limit .............. 49.900 [1.96456]
Idler gear end play

Measure the end play with feeler gauges or dial
gauge. If the idler gear end play exceeds the service
limit, replace the thrust plate.
Idler gear end play, mm [in]

Service limit .............. 0.6 [0.024]
Replace idler bushing

1. Use the Idler bushing puller to remove the bush-
ing.
2. Install a new bushing to the gear by pressing it

until the end face of the bushing is 1 mm [0.04
in.] (A) recessed from that of the gear boss.
3. After installing the bushing, make sure that its in-

side diameter is within the assembly standard. If
not, ream the bushing to the correct diameter (0.4
Ra).
110

Reassembly
sembly.
Installing the front plate

1. Apply sealant to the front plate mounting surface
of the crankcase, then place the packing in posi-
tion. Apply the same sealant to the packing, then
install the front plate.
2. Replace the dowel pins if worn, or if the front

plate has been replaced.
3. Make sure that the lower end of the front plate is

flush with the bottom of the crankcase. Cut off the
excess of the packing neatly along the edge of
the plate.
Installing the idler shaft

1. Insert the idler shaft using the guide bolts.
2. Tighten the shaft mounting bolts to the specified

torque.
Installing the idler gear

1. Insert the idler gear into the shaft, and install the
thrust plate.
2. Install the thrust plate, then tighten the mounting

bolts to the specified torque.
Installing the oil pump and water pump

drive bearing cover
1. Insert the bearing cover into the front plate, then
tighten the cover mounting bolts to the specified
torque
111

Installing the front gear case and pointer

1. Apply a sealant to the front gear case packing
mounting surface, then mount the packing. Apply
sealant to the packing, then install the front gear
case.
2. Mount the water coupling of the front plate and

the gear case to the crankcase. Apply grease to
the O-rings and O-ring grooves. Do not damage
the O-rings when installing the gear case.
3. Replace the dowel pins if worn, or if the front cov-

er has been replaced.
4. Tighten the front cover mounting bolts evenly to

the specified torque.
5. Make sure that the lower end of the front cover is

flush with the bottom of the front plate. Cut off the
excess packing along the edge of the cover.
6. Install the oil seal(2) to the front gear case(1).
7. Apply engine oil to the lip of the oil seal.
8. Insert the oil seal to the slinger(3) to a distance of

15.7 – 16.3 mm [0.588 – 0.612 in.](A) using the
special tool (Front seal installer assembly).
When the Pointer is out of place

To determine the top dead center on the compression
stroke of No. 1.6 cylinder, for example, bring the mark
on the flywheel to where it is at an equal distance be-
tween the marks stamped on the timing gear case.
Oil pump gear and mounting plate

1. Insert the oil pump gear.
2. Install the oil and water pump mounting plate,

then tighten the bolts to the specified torque.
Installing the viscous damper

Tighten the damper mounting bolts to the specified
torque.
112

Oil pan and Oil strainer

1. Oil pipe A. Clogs
2. Oil pan B. Replace
3. Oil pan packing C. Cracks
4. Oil strainer
113

Reassembly
sembly.
1. Fit the O-ring to the oil passage of the oil pan

mounting surface.
2. Fit the packing to the oil pan by applying sealant

to the 4 separated sections.
114

Flywheel, Timing gears, and Camshaft

1. Flywheel A. Clogged oil hole
2. Idler shaft thrust collar B. Damage, wear
3. Timing gear case, oil seal C. Rough bearing rotation, damaged seal
4. Injection pump drive D. Flaking or wear
5. Idler gear E. Clogged oil, wear
6. Idler shaft F. Cracks, damaged dowel holes
7. Camshaft gear G. Wear, damaged or deteriorated lip
8. Thrust plate H. Damaged threads
9. Camshaft I. Cracks, defective dowel holes, worn ring gear
10. Rear plate
11. Nozzle plate
12. Cover
115

Remove the flywheel

1. Attach a sling to the flywheel.
2. Unscrew the mounting bolts.
3. Screw the two jack-bolts into the holes in the fly-
wheel evenly, then remove the flywheel.
IMPORTANT! When you remove the flywheel,

do not drop it or bump it against a hard object.
IMPORTANT! The ring gear is bolt mounted to

the flywheel. Do not remove the gear except
when it has to be replaced.
Remove the idler shaft collar

1. Unscrew the cover mounting bolts, then remove
the cover.
2. Unscrew the idler shaft thrust collar mounting
nuts. Mark the collar position.
3. Screw bolts (M6 x 1.0 mm [0.24 x 0.039 in.])
through the thrust collar removing bolt holes and
pull the thrust collar from the gear case.
NOTE! Place marks to identify the right and left col-
lars to ensure proper backlash and end play in rein-
stallation.
Remove the timing gear case

1. Attach slings to the timing gear case.
2. Unscrew the timing gear case mounting bolts.
3. Remove the timing gear case by lifting it up until it
separates from the dowel pin. Do not damage the
oil seal.
Measure backlash and end play

Measure the backlash and end play of each gear to
obtain the data for parts replacement.
116

Fuel pump drive gears (left and right)

Unscrew the injection pump drive case mounting
bolts, then remove the pump drive. Do not damage
the gear teeth.
NOTE! Remove the No. 12 cylinder cam cover before
removing the pump drive case of the left side.
Remove idler gears

1. Remove the slinger of the crankshaft.
NOTE! When the slinger is removed, install a new
slinger during reassembly.
2. Remove the idler gears (left and right).
Remove the idler shaft

Do not remove the idler shaft unless you need to re-
pair it. To remove, install the sliding hammer to the
idler shaft removing screw hole (M22 x 1.5 mm [0.87
x 0.059 in.]).
Remove camshaft gears

Unscrew the camshaft gear mounting bolts, then re-
move the camshaft gear.
Remove camshafts
Unscrew the thrust plate mounting bolts, then pull out
the camshaft from the crankcase.
Weight: Approx. 45 kg [l00 lb]
IMPORTANT! When pulling out the camshaft,

support it with a bar inserted through the cam-
shaft inspection hole of the crankcase to pre-
vent damage to the cam surfaces and bush-
ings.
117


Flywheel face and radial runouts
Measure the runouts of the flywheel installed on the
crankshaft. If the runouts exceed the assembly stan-
dard, check for loose bolts or obstacles lodged be-
tween the mounting faces of the flywheel and crank-
shaft.
Flywheel face runout, mm [in]

Assembly standard ... 0.336 [0.0132] max.
Flywheel radial runout, mm [in]

Injection pump drive and bearing

1. Measure inside and outside diameters of bearing-
fitted sections of injection pump drive.
2. Check bearings, drive shaft, and oil seal. Replace

if not running smoothly or if otherwise defective.
3. Check the fit of the drive shaft in the bearing and

the fit of the bearing in the drive case. Replace
excessively worn parts.

Nominal value ........... Ø90 [3.54]
Assembly standard ... 89.985–90.000 [3.54272]

Nominal value ........... Ø100 [3.94]

Nominal value ........... Ø45 [1.77]

Nominal value ........... Ø50 [1.97]
Drive shaft bearing diameter, mm [in]

Nominal value ........... Ø45 [1.77]
Drive shaft bearing diameter, mm [in]

Nominal value ........... Ø50 [1.97]
118

Timing gear backlash

To measure the backlash between the gears, set up
a dial gauge so that it contacts the pitch circle of the
gear to measure. If a dial gauge is not available, mea-
sure the backlash by inserting feeler gauges between
the gear teeth. If the backlash exceeds the service
limit, replace the worn gears.
Timing gear backlash, mm [in]

Repair limit ................ 0.30 [0.0118]
Service limit .............. 0.50 [0.0197]
Idler gears, bushings, and shafts

Measuring idler gear bushing inside diameter and
idler gear shaft diameter. If the service limit is ex-
ceeded, replace the bushing or shaft (whichever is
worn).
Idler gear bushing inside diameter, mm [in]

Nominal value ........... Ø65 [2.56]
Service limit .............. 65 [2.56142]
Idler gear shaft diameter, mm [in]

Nominal value ........... Ø65 [2.56]
Service limit .............. 64.900 [2.55512]
Idler gear end play

Measure the end play with feeler gauges or dial
gauge. If the idler gear end play exceeds the service
limit, replace the thrust plate.
Idler gear end play, mm [in]

Service limit .............. 1.0 [0.0397]
Replace idler bushing

1. Use the Idler bushing puller to remove the bush-
ing.
2. Install a new bushing to the gear by pressing it

until the end face of the bushing is 1 mm [0.04
in.] (A) recessed from that of the gear boss.
3. After installing the bushing, make sure that its in-

side diameter is within the assembly standard. If
not, ream the bushing to the correct diameter (0.4
Ra).
119

Camshafts and Camshaft Bushings

Measure cam lift
Use a micrometer to measure the diameters of “A”
and “B” on each cam to determine the reduction in
cam lift. If the cam lift is less than the service limit, re-
place the camshaft.
Cam lift (A-B), mm [in]

Service limit .............. 8.45 [0.3327]
Measuring camshaft deflection

If the deflection exceeds the repair limit, straighten
the camshaft with a press, or replace it with a new
one.
IMPORTANT! Set up a dial gauge on the cam-

shaft, then turn the camshaft. Take one-half of
the gauge indication as the deflection.
Camshaft deflection, mm [in]

Assembly standard ... 0.05 [0.0020] max
Repair limit ................ 0.08 [0.0031]
Measuring camshaft journal diameters

Use a micrometer to measure each camshaft journal
in two directions at right angles to each other. If the
diameter exceeds the service limit, replace the cam-
shaft.
Camshaft journal diameter, mm [in]

Nominal value ........... Ø84 [3.31]
Service standard ....... 83.87 [3.3020]
Measuring camshaft bushing inside diameter

Use a cylinder gauge to measure the inside diameter
of the camshaft bushings fitted to the crankcase. If
the inside diameter exceeds the service limit, replace
the bushings.
Camshaft bushing inside diameter, mm [in]

Nominal value ........... Ø84 [3.31]
Assembly standard ... 84.000–84.035 [3.30708 –3.30846]
Service limit .............. 84.10 [3.3110]
120

Measuring camshaft end play

Use a dial gauge to measure the end play of the cam-
shaft to which the camshaft gear is installed. If the
end play exceeds the service limit, replace the thrust
plate.
Camshaft end play, mm [in]

Service limit .............. 0.40 [0.0157]
Replacing camshaft bushings

Install the bushings in the crankcase, then secure
them in place with the set screws. Before tightening
the screws, be sure that the screw holes in the bush-
ings and crankcase are aligned and that the oil holes
in the bushings are aligned with those leading to the
oil gallery in the crankcase. Use a wide bushing as
the bearing for the rear section, and insert it in the
correct attitude.
121

Reassembly
Install the rear plate
1. Apply sealant (HERDITE) to the rear plate
mounting surface of the crankcase, then place
the packing in position. Apply the same sealant to
the packing, then install the rear plate.
2. Replace the dowel pins if worn, or if the rear plate

has been replaced.
3. Make sure that the lower end of the rear plate is

flush with the bottom of the crankcase. Cut off the
excess of the packing neatly along the edge of
the plate.
Crank the engine

1. Install the bolts (M22 x 1.5 mm [0.87 x 0.059 in.])
to the viscous damper mounting holes.
2. Using these bolts, turn the crankshaft with a bar

to bring the No. 1 cylinder piston to the top dead
center.
Install idler gear shafts

Fit the O-ring to the idler shaft. Apply grease to the O-
ring to insert the idler shaft into the crankcase. At this
time. In this step, make sure the “TOP” mark on the
shaft is located at the top (oil passage in vertical di-
rection).
Install camshafts (left and right)

1. Insert the camshaft into the cylinder block, then
install the thrust plate.
2. Tighten the thrust plate mounting bolts to the

specified torque.
3. Check and make sure that the camshaft turns

smoothly.
NOTE! Do not mix the two different camshafts when
you reassemble the engine.
122

Installing camshaft gears

1. Install the camshaft gears to meet the dowel pin.
2. Tighten the camshaft gear mounting bolts to the

specified torque.
3. After installing the camshaft gear, check that the

gear rotates smoothly.
Installing idler gears

1. Install the idler gear by aligning its matching mark
with that on the crankshaft gear and camshaft
gear. Tighten the idler gear mounting bolts to the
specified torque.
2. Insert the slinger to the crankshaft.
3. Confirm that the matching marks of the timing

gears are as the drawing shown on the right.
Installing the injection pump drive

1. Install the injection pump gear to the drive shaft,
then tighten it to the specified torque. 392 N.m
(40 kgf.m) [289 lbf.ft]
2. Fit the O-ring to the installation surface of the

drive case. Apply a thin coat of ThreeBond 1212
on the flange surface.
3. Install the injection pump drive to the rear plate

by aligning its matching mark to that of the idler
gear.
4. Tighten the drive case mounting bolts to the

specified torque. 108 N.m (11 kgf.m) [80 lbf.ft]
123

Inspect and adjust timing gears

After installing the timing gears, be sure to inspect
and adjust them as follows.
Inspect timing gear backlash and end play

After installing the timing gears, inspect the backlash
between the gears in mesh, and the end play of each
gear.
Inspect Valve Timing

It is not necessary to inspect the valve timing, provi-
ded that all match marks on the timing gears are
aligned. Inspect the timing for verification as ex-
plained below.
Valve timing diagrams
A. Standard
B. with 2 mm [0.08 in.] valve clearance added

1. Inlet valve opens
2. Inlet valve closes
3. Exhaust valve opens
4. Exhaust valve closes
Use a feeler gauge 2 mm [0.08 in.] thick, add 2 mm
[0.08 in.] clearance to the inlet and exhaust valves of
the No. 1 cylinder. Then insert a feeler gauge 0.05
mm [0.020 in.] thick between the bridge cap and rock-
er. Slowly turn the crankshaft to find the position
where the feeler gauge is firmly gripped (the valve
starts opening) and the position where the gauge is
released (the valve starts closing). Check that these
positions coincide with the angular positions shown in
the valve timing diagram B.
Install the timing gear case

1. Apply sealant to gear case surface. Mount the
packing. Apply sealant to packing.
2. Replace dowel pins if worn, or if gear case has

been replaced.
3. Tighten gear case mounting bolts evenly to the

specified torque. Cut off excess packing along
the edge of the crankcase.
4. Apply engine oil to the oil seal lip. Insert seal (2)
into timing gear case(1).
5. Fit oil seal to slinger (3) to a distance of 15.7 –

16.3 mm [0.588 – 0.612 in.](A) using the Rear
seal installer.
124

Install the idler shaft thrust collars

1. Apply grease to the thrust collars, and insert the
collars in the timing gear case.
In this step, make sure the “TOP” mark is located

at the top and that the right and left collars are in-
stalled in their original positions.
2. Tighten the thrust collar mounting nuts to the

specified torque.
3. Install the cover, and tighten the mounting bolts

to the specified torque.
Installing the flywheel

1. Install the flywheel. Check that all dowel pins en-
ter their holes.
2. Coat the threads and the bolt bearing surface of

the flywheel mounting bolts with engine oil. Tight-
en the bolts to the specified torque. Inspect the
face and radial runouts of the flywheel.
Installing the pickup

1. Rotate the engine using the turning gear until a
tooth of the ring gear is positioned at the center of
the pickup mounting hole.
2. Screw the pickup gently into the hole. When the

tip of the pickup contacts the tooth surface of the
ring gear, loosen the pickup 1½ turn, then tighten
the lock nut to secure the pickup in place.
NOTE! Installing the pickup too close to the teeth of
the ring gear may result in too strong a signal.
125

Crankcase, Crankshaft and Main bearings

1. Main bearing cap bolt A. Scale damage, cracks, clogged oil holes
2. Side bolt B. Wear scratching pitting, scoring
3. Main bearing cap C. Stripped threads
4. Main bearing (lower) D. Wear
5. Thrust bearing E. Clogged oil hole
6. Crankshaft F. Check valve movement
7. Main bearing (upper) G. Scoring, pitting, flaking, chipping,
8. Thrust bearing cracks, corrosion
9. Slinger (front) H. Wear, chipping, abnormal tooth contact
10. Crankshaft gear (front) I. Wear
11. Slinger (rear) J. Cracking
12. Crankshaft gear (rear) K. Stripped threads
13. Check valve

14. Piston cooling nozzle
15. Crankcase
126

Turning the crankcase upside down

Use such lifting tool as a chain block and shackles to
play the crankcase on its side. Then add slings to the
crankcase, and turn it upside down.
Removing the main bearing caps

1. Unscrew the cap bolts and side bolts. Remove
the main bearing cap using cap removers (injec-
tor remover) or a chain block (use 2 eye bolts,
M27 x 1.5 mm [1.06 x 0.059 in.]).
2. Remove the thrust bearings from the No. 9 bear-
ing cap. Do not damage the thrust bearings.
Removing the crankshaft

1. Remove the front upper halves of the thrust bear-
ings by rotating them slowly.
2. Carefully lift the crankshaft off the crankcase,
keeping it horizontal.
3. Remove the rear upper halves of the thrust bear-
ings on the crankcase
Removing the piston cooling nozzles

Do not remove the nozzles unless such defects as
clogging are observed.
NOTE! Tighten the piston cooling nozzle to the speci-
fied torque when reassembling.
127


Crankshaft
Crank pin and crank journal diameters
1. Using a micrometer, measure the crank pin(A.)
and crank journal (B.) diameters. If the repair limit
is exceeded, grind them to the next lower size:
-0.25 mm [-0.0098 in.],-0.50 mm [-0.0197 in.],

-0.75 mm [-0.0295 in.], or -1.00 mm [-0.0394 in.].
NOTE! If the –1.00 mm [0.0394 in.] undersize jour-
nals and crank pins exceed the repair limit, replace
the crankshaft.
2. Measure the crank pins and journals to determine

the roundness and cylindricity
Crank pin diameter (A), mm [in]

Nominal value ........... Ø125 [4.92]
Assembly standard ... -0.050– -0.070 [-0.00197– -0.00276]
Repair limit ................ -0.110 [-0.00433]
Crank journal diameter (A), mm [in]

Nominal value ........... Ø170 [6.69]
Assembly standard ... -0.060– -0.080 [-0.00236– -0.00315]
Repair limit ................ -0.110 [-0.00433]
Pin & Journal roundness, mm [in]

Assembly standard ... Dia. diff. 0.01 [0.0004] max.
Repair limit ................ 0.03 [0.0012]
Pin & Journal cylindricity, mm [in]

Assembly standard ... Dia. Diff. 0.02 [0.0008] max.
Repair limit ................ 0.03 [0.0012]
Pin fillet radius mm [in]

Nominal value ........... 7 [0.28]
Assembly standard ... 7.0 0 / -0.2 [0.276 0 / -0.008]
Journal fillet radius journal, mm [in]

Nominal value ........... 8.5 [0.33]
Assembly standard ... 8.5 0 / -0.2 [0.335 0 / -0.008]
Pin & Journal hardness

Assembly standard ... Hv>590
128

Grinding dim. for undersize crankshaft

Crankpin diam. undersize 0.25 [0.0098], mm [in]
Finishing dimension .. 124.68–124.70 [4.9087–4.9094]
Roundness ................ Dia. Diff. 0.01 [0.0004] max
Cylindricity ................ Dia. Diff.e 0.02 [0.0008] max

Finishing dimension .. 124.43–124.45 [ 4.8988–4.8996]
Cylindricity ................ Dia. Diff. 0.02 [0.0008] max


Journal diam. undersize 0.25 [0.0098], mm [in]




Grinding the crankshaft

Refinish the crankshaft according to the dimensions
of the undersize main bearing and connecting rod
bearing.
When grinding the crank pins and journals, be sure to
produce the same fillet radius as the original. They
should have a hardness of 590 (Vickers Hardness
Number). If necessary, re-harden the crank pins and
journals, and inspect them for cracks by conducting a
Magnaflux (magnetic particle) test. After grinding, fin-
ish the journals and crank pins to 0.2 Ra.
129

Measuring crankshaft end play

1. Install the thrust bearings in position, then secure
the bearing cap. Under this condition, measure
the end play. If the end play exceeds the stan-
dard clearance, replace the thrust bearings.
2. If the end play still exceeds the repair limit even

after the new thrust bearings have been installed,
replace the bearings with the next oversize bear-
ings. There are three sizes for the thrust bear-
ings:
+ 0.25 mm [+0.0098 in]
+ 0.50 mm [+0.0197 in]
+ 0.75 mm [+0.0295 in]
NOTE! Generally the rear journal is likely to wear
more rapidly than the front journal. This means that
replacement of the rear thrust bearings will generally
be sufficient.
Thrust bearing journal length (A), mm [in]

Nominal value ........... 67.000–67.030 [2.6400–2.64118]
Crankshaft end play, mm [in]

Standard Clearance .. 0.20–-0.40 [0.0079–0.0157]
Service limit .............. 0.50 [0.0197]
Crankshaft Journal grinding dimensions

(oversize thrust bearings)
+0.25 [0.0098] , mm [in]

Oversizes for Journal or Thrust bearings 67.25 [2.6476]
Oversizes for Journal and Thrust bearings 67.50 [2.6575]
Tolerance .................. +0.03 / 0 [+0.0012 / 0]
+0.50 [0.0197] , mm [in]

Tolerance .................. +0.03 / 0 [+0.0012 / 0]
+0.75 [0.0295] , mm [in]

Tolerance .................. +0.03 / 0 [+0.0012 / 0]
130

Measuring crankshaft deflection

Support the crankshaft on its journals in V-blocks,
then measure the deflection at the center journal with
a dial gauge. Depending on the amount of deflection,
repair the crankshaft by grinding or straightening with
a press. If the deflection exceeds the repair limit, re-
place the crankshaft.
Crankshaft deflection, mm [in]

Repair limit ................ 0.10 [0.0039]
Replace the oil seal slinger

Replace the slinger if it is pitted, scratched, or distort-
ed enough to cause oil leaks.
Remove the Slinger

Use a gear puller to remove the slinger from the
crankshaft.
Install the Slinger

1. Identify the front slinger and the rear slinger, and
pay attention to their attitudes
A.Front
B.Rear
1. Front cover
2. Timing gear case
3. Oil seal
4. Slinger
2. Use a slinger installer to install the heated (above

110 °C [230 °F]) slinger to the crankshaft until it
contacts the gear.
IMPORTANT! If the slinger has stopped before it

touches the gear, tap the center or shoulder of
the installer with a copper hammer.
131

Replace the crankshaft gear

Remove the Gear
Use a gear puller to remove the gear from the crank-
shaft.
NOTE! Do not remove the gear by hitting it with a
hammer.
Install the Gear

1. Before installing the crankshaft gear, measure
the inside diameter of the crankshaft gear. to be
sure that the fit is within the specified value.
Front side .................. 0.106–0.171 mm [0.00417–0.00673 in]
Rear side ................... 0.274–0.358 mm [0.01079–0.01409 in]
2. Heat the gear to the range 180 to 200 °C

[356 to 392 °F. (Do not heat the gear above 200
°C [392 °F].)
3. Drive the rear crankshaft gear onto the crank-

shaft by tapping the end face of the gear lightly
with a copper hammer. Be sure the crankshaft
dowel pin enters the notch in the gear.
IMPORTANT! Install the gear to the crankshaft

until it contacts the collar.
IMPORTANT! Do not mistake the direction of

gear installation
132

Main Bearing
Bearing surfaces
Inspect each bearing shell for abnormal contact such
as scratching, corrosion, flaking, etc. Also check for
signs of poor seating in the bore of the crankcase or
bearing cap.
Bearing thickness
Use a ball point micrometer to measure the center of
each hearing shell. If the service limit is exceeded on
any of the shells, replace the upper and lower shells
as a set.
Main bearing thickness (center) STD, mm [in]

Nominal value ........... 4.500 [0.17717]
Service limit .............. 4.425 [0.17421]
Main bearing thickness (center) –0.25 [0.0098],

mm [in]
Nominal value ........... 4.625 [0.18209]
Service limit .............. 4.550 [0.17913]

mm [in]
Nominal value ........... 4.750 [0.18701]
Service limit .............. 4.675 [0.18405]

mm [in]
Nominal value ........... 4.875 [0.19193]
Service limit .............. 4.800 [0.18898]

mm [in]
Nominal value ........... 5.000 [0.19685]
Service limit .............. 4.925 [0.19390]
NOTE! Four undersizes are available for the main

bearings; -0.25 mm [-0.0098 in], -0.50 mm [-0.0197
in], -0.75 mm [-0.0295 in] and –1.00 mm [-0.0394].
Replace main bearings.

If the thickness exceeds the service limit, either re-
place the main bearings as above, or refinish the
crankshaft and use undersize bearings.
133

Crankcase
Flatness of gasket surface
Measure flatness with a straight edge and feeler
gauges. If the warpage exceeds the assembly stan-
dard, reface the gasketed surfaces with a surface
grinder.
Crankcase gasket surface flatness, mm [in]

Assembly standard ... 0.1 [0.004] max
Repair limit ................ 0.2 [0.008]
NOTE! Do not grind the crankcase more than neces-

sary to remove warpage. Excessive grinding can
cause the piston protrusion to exceed assembly stan-
dard.
Main bearing bore diameter

Secure the end bearing cap to the specified torque,
and measure the bore diameter in the three direc-
tions.
Main bearing bore diameter, mm [in]

Nominal value ........... Ø179 [7.05]
Service Limit ............. 179.045 [7.04900]
134

Reassembly
sembly.
Main bearing
1. Install each upper shell of the main bearing in the
crankcase by fitting its locating lug in the lug
groove. The oil holes in the bearings and crank-
case Will be aligned when the bearings are in-
stalled in this way.
2. Lightly coat the inside surface of the shells with

engine oil.
Installing thrust bearings

1. Install the thrust bearings to the No. 9 bearing
seat of the crankcase, with the oil groove side of
the bearings facing out.
2. After installing the crankshaft, install the inner

thrust hearing with the oil groove facing inside the
crankcase.
Crankshaft
1. Wash the crankshaft with cleaning solvent, and
dry it by air blow.
NOTE! After washing the crankshaft, make sure that
the oil holes are clean and not clogged.
2. Hold the crankshaft horizontally with a hoist, then

carefully put it on the crankcase.
3. Lightly coat the journals with engine oil.
135

Main bearings
Main bearing caps
1. Fit the lower shell of the bearing to each bearing
cap.
2. Install the thrust bearings to the No. 7 bearing

cap, with the oil groove side of the bearing facing
out.
3. From the front side of the crankcase, hearings

No. 1 to No. 7 are stamped on the caps. Install
the caps with these numbers and “FRONT” mark
on the front of the crankcase.
4. Coat the threads of the metal cap bolts with en-

gine oil, then temporarily tighten the bolts.
5. Use a softhead mallet to drive in the metal caps

evenly.
Bearing cap bolts

1. Temporarily tighten the bearing cap coated with
engine oil. Tighten the four bolts progressively
and evenly to the specified torque.
2. Tighten the left and right side bolts progressively

and evenly to the specified torque.
3. Make sure that the crankshaft rotates smoothly.
Crankshaft end play

1. Tighten No. 1 through No. 6 bearing cap bolts
and side bolts to the specified torque, with the
No. 7 cap bolt temporarily tightened, then mea-
sure the end play.
2. After tightening the No. 7 cap bolts, make sure

that the end play is correct.
3. Confirm that all cap bolts and side bolts are tight-
ened to the specified torque.
136

Group 22 Lubrication System
Group 22 Lubrication system

Oil Pump and Safety Valve
Disassembly Look for:

1.Oil pump cover A. Fatigue, break, wear
2.Safety valve assy B. Cracks, other damage
3.Bushing C. Worn, broken spline
4.Drive gear D. Damage, wear
5.Driven gear E. Replace packing
6.Driven gear F. Damage wear
7.Bushing G. Damage, wear
8.Oil pump case H. Cracks, other damage
137

Inspection
Measuring gear backlash
If the backlash exceeds the service limit, replace the
gears.
Drive gear and driven gear backlash, mm [in.]

Standard Clearance .. 0.10–0.20 [0.039–0.0079]
Service Limit ............. 0.4 [0.0157]
Measuring gear clearance

Use feeler gauges to measure the clearance. If the
clearance exceeds the service limit, replace the gears
or case, whichever is badly worn.
Drive gear and driven gear clearance, mm [in.]

Nominal Value ........... Ø60 [2.36]
Service Limit
Tip clearance: ........... 0.35 [0.0138]
Measuring pump gear end clearance

Use a dial gauge to measure thr clearance. If the
clearance exceeds the service limit, replace the gears
or case, whichever is badly worn.
Pump gear end clearance, mm [in.]

Nominal Value ........... 72.5 [2.854]
Service Limit ............. 0.21 [0.0083]
NOTE! Remove the cover mounting packing (0.04

mm [0.0016 in.] thick) when measuring.
138

Measuring shaft and bushing diameters

1. Check the gear teeth. Replace gears if they are
defective.
2. Measure the gear shafts and bushings using a
dial gauge. If the diameter exceeds the service
limit, replace the parts.
Drive shaft diameter, mm [in.]

Nominal Value ........... Ø30 [1.18]
Service Limit ............. 29.840 [1.17480]
Driven shaft diameter, mm [in.]

Nominal Value ........... Ø30 [1.18]
Assembly Standard ... 29.947–29.960[1.17901–1.17953]
Service Limit ............. 29.900 [1.17716]

Nominal Value ........... Ø30.1 [1.19]
Service Limit ............. 30.155 [1.18720]
Replacing oil pump bushings

1. Remove the oil pump bushing as needed. If the
oil pump busing insertion is too tight to remove it,
replace it with the case or cover assembly.
2. When you install the pump cover bushing, place
the bushing joint positions as shown in the right
drawing. (Do not align with the lubrication oil
groove.)
3. Using the oil pump bushing installer A, insert the
bushing to the position shown in the right draw-
ing.
4. After you press a new bushing into position, finish
its inside diameter to Ø30H7+0.021/0 mm [1.18+0.0008/0
in.] 0.8 Ra.
139

Inspecting the safety valve

1. Check the valve spring of the oil pump safety
valve for fatigue. If excessive fatigue, wear or
break is found, replace the valve spring.
2. Measure the valve opening pressure. If the pres-
sure is higher or lower than the assembly stan-
dard, increase or decrease the thickness of shim
inserted between the spring and spring cap nut.
For the thickness of a shim, 1 mm [0.04 in.] cor-
responds to a change in pressure of 0.10 MPa (1
kgf/cm2) [14.2 psi].
Safety valve opening press., MPa (kgf/cm2) [psi]

Assembly Standard ... 1.27±0.13 (13±1.3 ) [185±18.5]
Safety valve spring set length/set force, mm/N

(in/kgf) [lbf]
Assembly Standard ... 65.8/359 (2.59/36.6) [80.7]
Service Limit ............. 65.8/314 (2.59/32.0) [70.5]
Reassembly
Reassembly sequence
1 3
8 7 4 5 6 2
140

Oil Filter, Filter Alarm, Relief Valve,

Left Side Cooler and Thermostat

1. Full flow oil filter element A. Holes clogging, cracks
2. Filter bracket assy B. Replace packing
3. Adaptor A assy C. Replace O-rings
4. Adaptor B assy D. Replace O-rings
5. Oil cooler element E. Fatigue, break, wear of spring
6. Relief valve assy F. Deterioration, wear, cracks
7. Connector G. Wear, cracks
8. Oil thermostat
9. Thermostat seal
10. Body assy
11. Cover
12. Cover
13. Drain cock
141

Inspection
Inspecting the oil filter
When you replace the paper element, sample about
500 cm3 [30.5 in3.] of oil and check for metal particles.
If any metal particles are found, unfold the pleats of
element and check the color and shape of the parti-
cles trapped in the pleats to identify the cause.
Measuring relief valve pressure

1. Remove the taper plug (PT US) on the upper
side of the filter bracket, and attach a pressure
gauge.
2. Warrn up the engine until the oil temperature ris-
es to 70–90°C [158–194°F].
3. Measure oil pressure at idling speed and maxi-
mum speed.
4. If the measured oil pressure is lower than the
specified value, adjust the valve opening pres-
sure by inserting shims. For shim thickness, 5
mm [0.2 in.] corresponds to a change in pressure
of approximately 0.1 MPa (1 kgf/cm2) [14 psi].
Set pressure (max. speed), MPa (kgf/cm2) [psi]

Assembly Standard ... 0.49–0.64 (5.0–6.5) [71.12–92.46]
Relief valve opening pressure

Assembly Standard ... 0.50 ±0.02 (5.0±0.2) [71.10 ±2.84]
NOTE! The measured oil pressure might be above

the set pressure when oil temperature is low, but it re-
turns to the set pressure when oil temperature rises.
5. If adjustment with shims is not effective, replace
the relief valve and spring.
IMPORTANT! A dirty oil cooler will increase the
oil temperature and consequently lower the oil
pressure.
142

Inspecting the left side oil cooler

Test the oil path with compressed air of 1.47 MPa (15
kgf/cm2) [213 psi] for damage or cracks in the ele-
ment. If there is any leakage, replace the element.
Inspection the left side thermostat

1. Inspect the oil thermostat seal for deterioration
and cracks. If any are found, replace the seal.
2. Refer to the drawing on the right that shows the
correct direction for seal installation.
3. Operation testing
Immerse the thermostat in engine oil, then measure
the temperature where the valve opens, then mea-
sure it again when the valve lift is 11 mm [0.43 in.].
Replace the thermostat if temperatures are not within
standard.
Temperature for valve opening, °C [°F]

Assembly Standard ... 80–84 [176–183.2]
Temp. for 11 mm [0.43 in.] valve lift, °C [°F]

Assembly Standard ... 95 [203]
IMPORTANT! Stir the oil to maintain even tem-

peratures during the test.
IMPORTANT! At reassembly, confirm the valve
opening temperature stamped on its mounting
flange.
Reassembly
Reassembly is the reverse procedure of disassembly.
1. Replace packing and O-rings for reassembly.
2. Before reassembly, clean the oil paths of the oil
filter bracket, etc. by flushing them with oil and
blowing them with air.
3. Install the oil filter element with its bracket.
143

Right Side Oil Cooler and Oil Thermostat

1. Connector A. Holes clogged, cracking
2. Oil thermostat B. Deterioration, wear, cracks
3. Oil cooler C. Wear, cracks
4. Oil cooler element D. Replace packing
5. Thermostat
Inspection Reassembly
Follow the same inspection procedure as that for the Reassembly is the reverse procedure of disassembly.
left side oil cooler and oil thermostat. If any deteriora- 1. Replace packing and O-rings for reassembly.
tion is found, replace them.
2. Before reassembly, clean the oil paths of the oil
cooler cover, etc. by flushing them with oil then
blowing them with compressed air.
144

Group 23 Fuel System

Fuel Filters
Disassembly Look for

1. Filter element A. Cracks, damaged threads
2. Bolt
3. Cover
4. O-ring
5. Pin
6. Cock
7. Fuel filter bracket
8. Packing
9. Air vent plug
145

Reassembly
7 5 4 6 8 3 2 1
To install the filter, clean the mounting surface and apply fuel oil to the gasket. After bringing the gasket into con-
tact with the sealing surface of the bracket, tighten the filter with your hand about one-half to three quarters of a
full tum. Bleed the filter.
NOTE! After installing the fuel filter on the engine start the engine and look for leaks.
146

Fuel Injectors

1. Cap nut, gasket A. Fatigue, damage, length
2. Adjusting screw B. Wear, damage
3. O-ring C. Carbon deposits, clogged spray
4. Retaining nut hole, sticking needle valve
5. Nozzle
6. Spacer
7. Pushrod, nozzle spring,
spring seat
8. O-ring
9. Nozzle holder
10. Fuel inlet connector
147

Inspection and Adjustment

Injection pressure
1. Install the nozzle on the nozzle tester. Operate
the handle of the tester at a rate of about 1 stroke
per setond to observe the pressure at which fuel
is being injected. If the pressure is out of stan-
dard, adjust it.
Injection pressure, MPa (kgf/cm2) [psi]

Assembly Standard ... 34.32–34.81(350–355)[4979–5050]
WARNING! Never touch the spray hole of the in-

jection nozzle during injection testing.
2. To adjust injection pressure, remove the set

screw from the nozzle holder, loosen the cap nut,
and then turn the adjusting screw. To increase
the injection pressure, tighten the screw. To de-
crease the injection pressure, loosen the screw.
3. After completing the adjustment, tighten the set
screw and the cap nut to the specified torque.
4. Re-check the injection pressure to be sure that it
is correct.
Spray pattem
1. When you are testing the injection pressure, in-
spect each nozzle for clogged or leaking holes.
Also examine the spray pattem. If the nozzle is
faulty, wash or replace it.
2. When tested on the nozzle tester, the nozzle
should spray fuel from all ten holes at the same
time in a straight cone of 160 degrees. The spray
should tonsist of finely atomized fuel particles
without large droplets. The spray should termi-
nate without dripping at the top.
148

Washing or replacing the nozzle

1. The nozzle is spring loaded. Remove the set
screw and loosen the adjusting screw until it can
be loosened by hand.
2. Loosen the retaining nut, remove the nozzle and
wash the needle valve and body.
IMPORTANT! When pulling out the nozzle, do

not damage the tip.
3. Wash the nozzle in clean diesel fuel oil. After
washing, assemble the needle valve and body in
clean diesel fuel.
NOTE! The needle valve and body are finely finished.

Do not change the pairing of needle valve and body
when cleaning more than one nozzle at the time
4. Tighten the retaining nut to the specified torque.

5. If the spray pattem is still bad after the nozzle has
been adjusted and cleaned, replace the nozzle.
NOTE! New nozzle tips are coated with vaseline to

preserve them. Wash them in diesel fuel before you
install them.
NOTE! Avoid getting “Copa slip” or “Molycote” on the
needle.
149

Reassembly
Reassembly Sequence:
9 3 8 7 6 5 4 10 2 1
IMPORTANT! Tighten the retaining nut to the specified torque. Excessive torque on the retaining nut will
cause sticky movement of the needle and will result in exhaust smoke or the needle stick.
NOTE! Always replace all o-rings at reassembly.
150

Fuel Injection Pump

1. Drain plug 23. Barrel shim A. Damage of threads
2. Rack set cap 24. Bellows B. Fatigue
3. Sealing washer 25. Set screw C. Wear and cracks on teeth, wear of sliding sur-
4. Jam nut 26. Control rack faces
5. Bolt 27. Tappet D. Ridges caused by abrasion, cracks
6. Spring case 28. Front cover, O-ring, bearing outer race E. Wear, scratches
7. O-ring 29. Bolt F. Erosion
8. Self locking nut 30. Camshaft G. Cracking
9. Return spring 31. Center bearing H. Damage and scratches on bushing contact
10. Coupling 32. Bearing inner race surfaces, cracks
11. Laminated plate 33. Rear cover, oil seal, bearing outer race I. Rotation condition
12. Cross coupling 34. Shim J. Pitching, roller surface roughness
13. Laminated plate 35. Lower spring seat K. Scratches wear
14. Flywheel 36. Plunger L. Damage and scratches on key grooves and
15. Feed pump 37. Plunger spring seal contact surfaces, wear of cam surface
16. Valve holder 38. Upper spring seat M. Rack sliding resistance, wear of teeth
17. Spring seat 39. Pinion N. Wear
18. Delivery valve spring 40. O-ring O. Wear, scratches, discoloration, corrosion, ero-
19. Delivery valve assembly 41. Barrel sion
20. Deflector bolt 42. Pump case P. Contact surface
21. Barrel bolt, washer 43. Rack bushing Q. Seat contacting surface
22. Plunger assembly
NOTE! The fuel injection pump may be serviced by an Authorized Bosch workshop.
151

Preparing for disassembly

1. Hold the pump assembly stand with a vice.
2. Remove the drain plug from the bottom of the
pump and drain oil from the case.
3. Clean the outer surface of the injection pump,

and mount the pump on the pump assembly
stand.
4. Remove the rack set cap and the sealing washer.

5. Unscrew two jam nuts, and remove the spring
case.
152

6. Unscrew the self-locking nut, and remove the re-

turn spring.
NOTE! Do not reuse the self-locking nut.
7. Remove the couplings, laminated plates, cross

coupling, flywheel and feed pump.
NOTE! When removing the flywheel mounting nut, in-
sert turning bar into the turning bar hole located at the
flywheel periphery, in order for the flywheel to avoid
slipping.
Removing delivery valves

Remove delivery valve holders. Remove the spring
seat, delivery valve spring, delivery valve and valve
seat from each valve holder.
NOTE! Place each pair of delivery valve and valve

seat in clean diesel fuel. Do not swap the original
combinations of delivery valves and valve seats.
153

Removing plunger assemblies

1. Position the tam at the bottom dead center in the
cylinder from which the plunger assembly is re-
moved.
2. Remove the deflector bolt located on the back
side of the pump case.
IMPORTANT! Be sure to remove the deflector

before removing the plunger assembly. If the
plunger assembly is removed without removing
the deflector bolt first, damage results in the de-
flector bolt and plunger assembly.
3. Screw the Plunger holder (48291-00301) in the

threaded hole on the upper end of the plunger.
4. Loosen two barrel bolts altemately, and lift the
plunger assembly and remove.
Removing the control rack

1. Dislodge the bellows from the grooves of the con-
trol rack and rack bushing installed in the pump
case, and remove the bellows.
2. Remove the set screw from the back side of the
pump case, and pull out the control rack.
NOTE! After removing the set screw, conduct a color

check or magnaflux inspection to make sure there are
no cracks.
NOTE! Do not remove the rack bushing unless nec-
essary.
154

Removing tappets
Hook a wire to two small holes (4-mm (0.16 in.) dia.)
on the upper side of the tappet, and pull out the tap-
pet.
Removing the camshaft

1. Unscrew four front cover mounting bolts, and re-
move the front cover and bearing outer race.
2. Tilt the pump case sideways, and remove two
center bearing mounting bolts.
3. Strike the camshaft on the drive-side end with a
soft hammer to remove the camshaft and center
bearing.
4. Remove the bearing inner races from both ends
of the camshaft.
Removing the rear cover

Remove the rear cover mounting bolts. Insert the tips
of screwdrivers into the notch located on the side of
the rear cover, and pry out. Remove the shim.
155

Disassembling plunger
1. Mount the plunger assembly on the plunger
spring compression jig (4829 1-00200).
2. Press the knob on the jig to tompress the plunger
spring, then remove the plunger holder jig.
3. Loosen the compression of the plunger spring
gradually, and remove the lower spring seat,
plunger and plunger spring from the barrel.
IMPORTANT! Handle plungers carefully to pre-

vent damage and scratches.
IMPORTANT! Place the removed plungers in a

tray with clean diesel fuel, do not change the
original combinations of plungers and barrels.
4. Remove the barrel from the plunger spring com-

pression jig, then remove the upper spring seat,
pinion and O-ring.
156

Inspection
NOTE! After disassembly, wash parts in clean diesel
oil. Replace defective or damaged parts.
Plungers and barrels

1. Inspect the lead section and tip of each plunger
for wear, scratches, discoloration, and erosion.
2. After washing with clean diesel fuel, check each
plunger by tilting approximately 15’ and lifting it
approximately 30 to 35 mm [ 1.18 to 1.38 in.], as
shown in the diagram. The plunger must fall
smoothly on its own weight. Change the plunger
position by turning it slightly and check again. Re-
peat this test two or three times for each plunger.
3. If the plunger falls too quickly or sticks before it
reaches the bottom, replace the plunger and bar-
rel as a set.
Delivery valves
1. In each delivery valve, inspect the valve seat and
sliding surfaces for scratches and check contact-
ing surface to the barrel.
2. Wash parts with clean diesel oil. Lift the valve
and let it fall, making sure that it slides down
smoothly to the valve seat.
3. If the valve sticks, replace the delivery valve and
valve seat as a set.
Tappets
1. Check each tappet roller, roller bearing and
tappet pin for flaking, lotal wear and scratches.
2. Check overall clearance of tappet, taper roller,
roller bearing and tappet pin. If the measurement
exceeds the service limit, replace with a new as-
sembly.
Overall clearance of tappet roller, mm [in.]

Service Limit ............. 0.2 [0.00787]
3. Inspect the plunger contact surface of each tap-

pet. If the amount of wear exceeds the service
limit, replace with a new assembly.
Tappet wear of plunger contact area, mm [in.]

Service Limit ............. 0.2 [0.00787]
157

Camshaft
1. Check the key and key groove for excessive
play. Also check the tapered section for scratch-
es, and the tam surfaces for flaking, local wear
and scratches. If damage is found, replace the
camshaft.
2. Check the oil seal contacting surface for wear. If
the amount of wear exceeds the service limit, re-
place with a new part.
Camshaft diam. at oil seal contact area, mm [in.]

Service Limit ............. 34.800 [1.37001]
3. Support the camshaft with V blocks, and mea-

sure runout at the center bearing section using a
dial gauge. If the amount of runout exceeds the
repair limit, correct with a press or replace with a
new part.
Camshaft deflection, mm [in.]

Repair Limit ............... 0.15 [0.00591]
Bearing
Check the bearing for flaking, abnormal abrasion and
noise. If damage is found, replace with a new part.
158

Plunger and delivery valve springs

1. Check the surface of each spring for scratches
and rust.
2. Using a square, measure the perpendicularity
(gap, B) at the upper end of the spring.
If the measurement exceeds the service limit, re-
place the spring.
Plunger Spring, mm [in.]

Free length (A)
Service Limit ............. 1.8 [0.071]


Assembly standard ... 299–366 (30.5–37.3) [67.2–82.2]
Delivery valve spring, mm [in.]

Free length (A)
Assembly Standard ... 18 [0.71]
Service Limit ............. 0.6 [0.024]


Assembly standard ... 51.6-61.4 (5.26–6.26) [11.60–13.80]
Valve holders
1. Check the contacting surfaces of injection pipe
and delivery valve on each valve holder for
scratches.
2. If the contact surfaces are scratched, replace the
valve holder since surface scratches can cause
fuel leakage.
Pump case
Check the pump case for surface scratches, dents,
cracks and damage. If critical flaws are found, re-
place with a new part.
O-rings and bellow

Replace O-rings, gaskets and below with new ones
once disturbed.
159

Reassembly
43 42 28 30 31 32 29 34 33 27 26 25 22 23 21 20 19 18 17 16 21 15 14 13 12
41 40 39 38 37 36 35 11 10 9 8 7 6
5 4 3 2 1
NOTE! The reassembly of the jam nut (4) and subsequent steps should be performed after the parts are mount-
ed on the engine and adjusted properly.
160

Assembling the bearing and front cover

1. Install the O-ring and bearing outer race on the
front cover.
2. Install the front cover on the pump case by strik-
ing with a hammer.
3. Tighten the front cover mounting bolts.
Assembling the camshaft center bearing

1. Install the bearing inner race on the camshaft by
striking with a hammer.
2. Lay the pump case on its side.

3. Place the center bearing on the camshaft, and in-
sert the shaft into the pump case.
4. Slowly rotate the camshaft and align the bolt hole

in the center bearing with the bolt hole in the
pump case, then tighten the mounting bolt.
161

Assembling the rear cover

1. Install the bearing outer race on the rear cover.
2. Install the O-ring and shim on the rear cover, and
install the rear cover on the pump case.
Camshaft thrust clearance

1. Set a dial gauge on the end surface of the cam-
shaft, and measure end play using the Cam
thrust ejector.
Camshaft thrust end play, mm [in.]

2. If the measured clearance deviates from the as-

sembly standard, increase or decrease the shim
thickness to make adjustment.
3. Tum the camshaft to make sure if it rotates
smoothly.
Installing tappets
1. Install the tappet roller and roller bearing in each
tappet, and insert the tappet pin in each assem-
bly.
2. Apply lubricating oil to each part.
3. After the assembly, make sure the roller rotates
smoothly without sticking.
4. Install tappets in the pump case by positioning
each tappet so the falt faces of the tappet engag-
es securely with the stopper pin.
162

Assembling plunger assemblies

NOTE! Wash each part with clean diesel fuel before
assembly. Use new O-rings and apply grease to the
O-rings to prevent damage during assembly. Install
the O-rings in the sequence of A, B and C.
1. Install three O-rings on each barrel.

2. Install the pinion and upper spring seat on each
barrel by tapping with a hammer. Make sure the
pin inserted in the barrel is positioned at the
notch of the upper spring seat.
3. Set the assembly of the barrel, pinion, upper

spring seat on the plunger spring compression
jig. Insert the jig stopper in the pinion tooth sec-
tion (missing tooth section). This stopper posi-
tions the missing tooth section (for prevention of
incorrect engagement with rack) of the pinion to
the center of the inspection hole in the upper
spring seat.
163

4. Align the flange section of the plunger properly

with the plunger seating section of the pinion us-
ing a screwdriver.
5. Press down the knob of the jig to insert the plung-

er into the plunger seating section of the pinion,
then screw the plunger holder to the threaded
section of the plunger head.
Installing the control rack

1. Insert the control rack in the pump case, making
sure the “F” mark on the end surface or the
threaded section is positioned on the driven side,
then tighten the set screw to 21 Nom (2.1 kgf-m) [
15 lbf-ft].
2. Look through the cylinder from the upper side of

the pump case, and move the control rack so the
thick tooth (three times thicker than other teeth
for prevention of incorrect engagement with pin-
ion) is positioned at the center of the cylinder in
the pump case.
164

Installing plunger assemblies

1. Position the cam at the bottom dead center in the
cylinder to which the plunger assembly is in-
stalled.
2. Place the Stopper plate (1) on top of the pump
case to prevent damage to the pinion and control
rack during the installation of the plunger assem-
bly.
NOTE! If the stopper plate is not used during plunger

assembly installation, the teeth on the pinion hit the
teeth on the rack, causing rough edges that hinder
smooth rack movement.
3. Hold the flange of the barrel with both hands and

press down the plunger assembly until the bot-
tom side of the flange contacts the stopper plate.
4. Remove the stopper plate, and lower the plunger
assembly by serching the correct meshing slow-
ly. Do not apply excessive forte to press down
the plunger assembly. If the plunger assembly is
jammed, turn the flange by jiggling back and
forth, then press down.
5. Insert standard barrel shims (thickness: 1.0 mm

[0.04 in.] ) under each barrel flange, and align the
reference mark on the barrel flange with the
alignment mark (1.5-mm [0.06 in.]diameter hole)
on the pump case.
IMPORTANT! In each cylinder, insert barrel

shims of the same thickness, one in front and
one in back. (Do not use two or more shims at
one location.) If the shim thickness varies in the
front and back of a cylinder, the rack may not
move smoothly, causing hunting or other prob-
lems.
6. Install washers on the barrel bolts, and screw the

bolts snug. Then, using a torque wrench, tighten
the bolts progressively and evenly to 78 to 83
N*m (8.0 to 8.5 kgf m) [58 to 61 Ibf ft].
165

7. Remove the Plunger holder. Make sure the con-

trol rack slides and strokes smoothly.
IMPORTANT! Move the rack after installing each

plunger assembly to make sure it moves
smoothly (sliding resistance: 4.9 N (0.5 kgf) [
1.10 IbfJ or less). At the same time, check to
make sure the total rack stroke is 36 mm [ 1.42
in.].
Control rack sliding resistance

1. After the pump assembly is completed, attach a
spring balancer to the control rack and make sure
the control rack moves smoothly over the entire
stroke.
Control rack sliding resistance, N (kgf) [lbf]

Assembly Standard ... 4.9 (0.5) [1.10] or less
2. After making sure the rack sliding resistance is

lower than the standard value, install the deflector
bolts on the pump case to 41 N*m (4.2 kgfem)
[30 lbf.ft].
Assembling delivery valves

1. In each barrel, install delivery valve, valve spring,
spring seat and valve holder in that order.
2. Apply grease to a new O-ring to prevent 0; ring
from damage, then install the O-ring on each
valve holder.
3. Using a torque wrench, tighten the valve holders
to 235 to 255 N*m (24 to 26 kgfam) [174 to 188
lbfaft].
166

Installing the bellows

Insert the protrusions on the bellows into the grooves
on the control rack and rack bushing and install the
bellows.
Installing the flywheel

Install the flywheel, making sure it aligns with the
woodruff key of the camshaft, then tighten the jam nut
to 329 N*m (40 kgf-m) [289 lbf&].
Installing the coupling assembly

1. Install sets of short bushings, short bolts and cou-
pling washers in two diagonally located holes in
the laminated plate.
WARNING! If the coupling washer is installed in

the wrong direction, the laminated plate can
break. When the laminated plate breaks, bolt
damage occurs and can result in a serious acci-
dent.
NOTE! Set the side of the coupling washer with a ra-

diused outer edge on the laminated plate.
2. While making sure that the short bolts and cou-

pling washers installed on the laminated plate re-
main in place, install the laminated plate to the
cross coupling by screwing short bolts with long
bushings and coupling washers in the remaining
two holes in the laminated plate from the opposite
side. Tighten the short bolts to 103 to 113 N-m
(10.5 to 11.7 kgf-m) [76 to 83 lbf-ft].
NOTE! Use a spanner-type torque wrench to tighten

the short bolts.
167

3. Tighten the two remaining short bolts on the lami-

nated plate mounted with the cross coupling to
install the laminated plate securely to the fly-
wheel. Tighten the bolts to 103 to 113 N-m (10.5
to 11.5 kgf-m) [76 to 83 lbf-ft].
NOTE! When tightening the short bolts be sure not to
drop the coupling washers.
4. Install short bushings, long bolts and coupling

washers to two diagonally located holes in the
other laminated plate.
5. Install the laminated plate to the coupling on the
drive side using the wide coupling washers.
Tighten the flange nuts to 103 to 113 Nrn (10.5 to
11.5 kgf-m) [76 to 83 lbf ft].
6. Install sets of long bushings and coupling wash-

ers to the laminated plate, and install the laminat-
ed plate to the cross coupling with short bolts.
Tighten the short bolts to 103 to 113 N-m (10.5 to
11.5 kgf-m) [76 to 83 lbf ft].
NOTE! Make sure the coupling on the drive side is
positioned so that the key groove of the drive cou-
pling faces the black line on the flywheel, as shown in
the diagram.
Installing the control rack retum spring

1. Install the retum spring, plain washer and spring
washer to the control rack, and install and tighten
a new self-locking nut.
NOTE! After tightening the self-locking nut, flatten the
cylinder section.
2. Install the spring case.
The two jam nuts installed at the tip of the control
rack hold the control rack at the maximum injec-
tion position. Therefore, after the injection pump
is installed to the engine, make adjustments on a
test bench. Do not conduct the following assem-
bly procedure on the dismounted injection pump.
168

Adjustment of Injection Timing

Adjustment of the prestroke
After the pump assembly is completed, place it on an
injection pump tester, and make the following adjust-
ments.
1. Remove the deflector bolt from the back side of
the pump case.
2. Remove the valve holder from cylinder No. 1
(counter-drive side), then remove the spring seat,
valve spring and delivery valve.
3. Set the measuring tip of a dial depth gaugeon the
head of the plunger. Rotate the camshaft by hand
to bring the plunger to the bottom dead center by
reading the indication on the depth gauge. Set
the depth gauge indicator to “0”.
4. Tum the camshaft in the normal operating direc-
tion until the dial depth gauge indicates 5 mm [0.2
in.].
5. With the camshaft in this position, check to make
sure the pointer located on the pump case end
surface aligns with the stamped line on the fly-
wheel. If they are not aligned, stamp a new line
on the flywheel at the pointer position.
6. Point a flashlight from the top of the pump case,

and look through the deflector bolt hole and
check the position of the upper end of the plung-
er.
7. Rotate the camshaft until the upper end of the

plunger closes the barrel suction hole. With the
camshaft in this position, the pointer should align
with the stamped line on the flywheel. If not,
change the shims so the pointer aligns with the
line.
NOTE! Increase of shim thickness retards injec-

tion timing and decrease of shim thickness ad-
vances injection timing
IMPORTANT! Never use more than one shim on

each side. Use shims of the same thickness on
both sides of the cylinder.
169

Adjustment of injection intervals

1. For cylinder No. 2 and subsequent cylinders, use
the injection start timing of cylinder No. 1 as the
reference point and check the injection start inter-
vals on the angle scale on the pump tester ac-
cording to the injection sequence.
2. If the injection intervals deviate from the specifi-
cation, make adjustment by adjusting the thick-
ness of the barrel shims in the same way for pre-
stroke adjustment.
NOTE! Injection start intervals 60°±0.5°
Adjustment of Injection Volume

1. Install a fuel hose and the specified fuel pipe to
the fuel injection pipe.
Adjustment conditions.
Nozzle holes Ø(10) ... 0.31 mm [0.012 in.]
Nozz. opening press. 34.32 MPa (350 kgf/cm2) [4979 psi]
Feed pressure
MPa(kgf/cm2)[psi] ...... 0.3±0.05 (3±0.5) [42.7±7.1]
Fuel pipe dimensions
outØ x inØ x L ........... (7x2.8x817mm) [0.28x0.11x32.2 in.]
Test fuel .................... JIS Class 2 diesel fuel
Test fuel temp. .......... 40±10°C [104±18°F]
3. To adjust the injection volume, loosen barrel bolts

and slowly turn the barrel.
4. After adjustment, tighten the barrel bolts alter-
nately to 78 to 83 N m (8 to 8.5 kgf m) [58 to 61
● ●
lbf ft] torque.

●
170

Feed Pump

1. Priming pump A. Scuffing, rust on piston and cylinder
2. Spring B. Fatigue
3. Valve C. Dust particles Gauze filter: Wash
4. Plug with diesel fuel
5. Spring D. Cracks, damage of threads
6. Valve E. Wear of seat
7. Plug
IMPORTANT! Do not disassemble
8. Spring
the gauge filter if it is clogged, the
9. Piston filter may become twisted and
10. Puch rod damaged. Remove as much dust
as possible through the small
11. Snap ring
holes, then disassemble the gauge
12. Tappet filter with a screwfriver.
13. Adapter
14. Pump housing
171

Reassembly
14 13 12 11 10 9 8 7 6 5 4 3 2 1
Testing
Airtightness test
Plug the discharge port. Apply air pressure of 0.2
MPa (2 kgf/cm2) [28.4 psi] to the suction port, im-
merse the pump in diesel fuel, and check for air leak-
age (bubbles).
Feed pump test

Testing conditions
Fuel pipe, mm [in.]
Outside diameter ...... 15 mm [0.59 in.]
Inside diameter ......... 13 mm [0.51 in.]
Length ....................... 2000 mm [78.7 in.]
Cam, mm [in.]
Lift per revolution ...... 12 mm [0.47 in]
Run the pump under the above conditions, and mea-
sure the discharge start time.
Feed pump discharge start at 100 rpm, sec

Assembly Standard ... 20 sec or less
Priming pump suction capacity

Discharge fuel completely from the feed pump in the
testing conditions described in the feed pump test.
Then, operate the priming pump at a rate of 60 to 100
strokes per minute, and count the number of pumping
operations required for fuel to reach the pump.
Priming pump discharge start, strokes

Assembly Standard ... 30 or less
Feed rate test

Open the valve on the discharge side in the testing
conditions described in the feed pump test. Operate
the pump and measure the amount of oil fed during
the first 15 seconds.
Feed rate at 500 rpm, cm3 [cu.in.]/15 sec.

Assembly Standard ... 1100 [67.1] or more
172

PSG Woodward Governor and Drive

1. PSG governor A. Rotation
2. Packing B. Wear
3. Drive case C. Wear of teeth
4. O-ring D. Wear of spline
5. Idler gear
6. Snap ring
7. Idler shaft
8. Washer, bolt
9. Bearings
10. Drive gear
11. Snap ring
12. Drive shaft
13. Snap ring
14. Bearings
173

Inspection
Inspection of bearings
Rotate each bearing to check for rotation. Replace a
bearing which fails to rotate smoothly. Check the fit of
bearings on the drive shaft and idler shaft. Replace
the shaft or bearings whichever are badly worn.
Check the fit of bearings in the drive case, and re-
place a worn part.
Case bore diam., drive shaft-side, mm [in.]

Nominal Value ........... 52 [2.05]
Drive shaft side bearing, mm [in.]

Outside diameter
Nominal Value ........... 52 [2.05]
Inside diameter
Nominal Value ........... 25 [0.98]
Drive shaft diam., mm [in.]

Nominal Value ........... 25 [0.98]
Case bore diam., idler shaft side, mm [in.]

Nominal Value ........... 47 [1.85]
Assembly Standard ... 46.989 to 47.014 [1.84996 to
1.85094]
Idler shaft side bearing diameter, mm [in.]

Outside diameter
Nominal Value ........... 47 [1.85]
Inside diameter
Nominal Value ........... 20 [0.79]
Idler shaft diam., mm [in.]

Nominal Value ........... 20 [0.79]
174

Reassembly
3 9 7 8 6 5 14 12 13 11 10 2 1 4
175

Group 25 Inlet and Exhaust System

Air Cooler

1. Air cooler cover A. Replace packing
2. Packing
3. Air cooler element
4. Plate
5. Packing
6. Air cooler case
7. Packing
8. Air cooler element
9. Plate
10. Packing
176

Inspection
Cleaning air cooler
1. Remove dirt built up from the air cooler by direct-
ing high pressure air of {max press. 0.29 to 0.49
MPa (3 to 5kgf/cm2) [43 to 71 psi]} in the opposite
direction of the air flow. Inspect the cooler for cor-
rosion and cracks.
2. Wash the fresh water or salt water pipes in water
and caustic soda lime, then remove scale depos-
its by inserting a 3 mm [ 1/8 in.] bar into each
pipe.
Inspecting air cooler for air tightness

Immerse the air cooler in water, then apply high pres-
sure air {max press. 0.39 MPa (4 kgf/cm2) [57 psi]} to
the coolant side to inspect for air leaks.
NOTE! Keep record of the water/air
temperatures(using infrared temp. gun) to determine
when the cooler needs cleaning.
177

Turbocharger

1. V-clamp 14. Thrust bearing A. Wear
2. Compressor cover 15. Thrust ring (turbo) B. Thrust face wear
3. Diffuser 16. Bolt C. Vane distortion, damage, rubbing contact on back face and
4. O-ring 17. Turbine housing gas erosion
5. Lock nut 18. Shaft and turbine wheel D. Rubbing contact with compressor wheel
6. Compressor wheel 19. Piston ring E. Rubbing contact with turbine wheel, cracks and distortion
7. Snap ring 20. Turbine backplate F. Vane distortion, damage, rubbing contact on back face and
8. Insert 21. Bearing gas erosion and damage to ring grooves
9. Finger sleeve 22. Snap ring G. Rubbing contact with turbine wheel and damage
10. Piston ring 23. Snap ring H. Damage to bearing bore, gas erosion and distortion of tur-
11. O-ring 24. Bearing bine side flange
12. Oil deflector 25. Snap ring
13. Thrust ring (compressor) 26. Bearing housing
178

Disassembly
Preparing for disassembly
Mount the turbine housing In a vice by clamping at
the flange.
IMPORTANT! Clamp the flange securely to pre-

vent the turbine housing from loosening or mov-
ing during work.
Removing the compressor cover

The compressor cover, bearing housing and
turbine housing must be reassembled in correct
orientation. Therefore, put alignment marks with
a punch or marker.
1. Loosen the V-clamp using a socket wrench.
2. Lightly tap around the compressor cover with a
soft-faced hammer to remove the cover.
Removing the diffuser

1. Lightly tap around the diffuser with a soft faced
hammer to remove the diffuser.
2. Remove O-ring from the bearing housing.
179

Removing the compressor wheel

IMPORTANT! Handle the compressor wheel and
turbine wheel with care during disassembly and
assembly. Vanes can easily bend when
dropped or hit.
1. While holding the boss of the shaft & turbine
wheel remove the lock nut fastening the com-
pressor wheel.
2. While holding the turbine wheel with one hand,
turn the compressor wheel lightly with the other
hand and remove.
Removing the snap ring

NOTE! Use only snap ring pliers to remove snap
rings.
NOTE! Put your thumb on the snap ring to prevent it
from flying out in case the pliers lose grip.
180

Removing the insert and oil deflector

1. Using two screwdrivers, gently pry out the insert
from the bearing housing.
2. Separate the finger sleeve together with the pis-
ton ring from the insert.
3. Remove the o-ring, the oil deflector, the compres-
sor thrust ring, the thrust bearing, and the turbo
thrust ring from the bearing housing.
Removing the shaft & turbine wheel

1. Remove the bolts and lock plates.
2. While gripping the shaft of the shaft & turbine
wheel with one hand, hold the bearing housing
with the other hand and slowly remove the shaft
& turbine wheel from the turbine housing.
3. Turn the bearing housing (turbine wheel face up)

and place it on the compressor cover. Remove
the shaft and turbine wheel, the piston ring, the
turbine backplate and the bearing(compressor
side).
Removing the snap ring and bearing

IMPORTANT! Remove the snap ring with care
and make sure not to damage the inside sur-
face of the bearing house or the seal (turbine
side) of the piston ring.
Place the bearing housing on a workbench with the
compressor side face up. Then remove the 3 snap
rings and the bearing.
181

Inspection
Bearing housing
Measure inside diameter of bearing-fitted section
If the measured diameter exceeds the service limit,
replace the bearing housing.
Inside diam. bearing-fitted section, mm [in.]

Service Limit ............. 34.016 [1.33921]
Bearing
Measure bearing outside diameter
If the measured diameter is less than the service limit,
replace the bearing.

Service Limit ............. 33.882 [1.33393]
Measure bearing inside diameter

If the measured diameter exceeds the service limit,

Service Limit ............. 19.929 [0.78460]
Measuring bearing length

If the measured length is less than the service limit,

Service Limit ............. 19.44 [0.76535]
182

Shaft & turbine wheel

Measure journal diam. of shaft & turbine wheel
If the measured diameter is less than the service limit,
replace the shaft & turbine wheel.
Shaft journal diameter, mm [in.]

Service Limit ............. 19.863 [0.78201]
Measure shaft deflection

1. Set a dial gauge at a location next to the thread-
ed section of the shaft, and measure shaft deflec-
tion. If the deviation indicated by the dial gauge
exceeds the service limit, replace the shaft & tur-
bine w heel.
IMPORTANT! If the shaft is bent, replace.

Do not attempt to correct the bend.
2. If the surface of the shaft journal is rough, mount

the shaft on a lathe, and gently polish the surface
using #400 sandpaper and engine oil while rotat-
ing at 300-600 min-1.

Service Limit ............. 0.015 [0.00059]
Insert
Measure piston ring end gap
Install a new piston ring squarely in the insert then
measure the piston ring end gap. If the end gap devi-
ates from the assembly standard, replace the insert.
Ring end gap, mm [in.]

183

Reassembly
26 25 23 24 22 20
21 15 14 11 13 12
19 18 7 6 5 17 16 4 3 2 1
10 9 8
NOTE! Always replace the following parts at disassembly:

4. O-ring
9. Piston ring
11. O-ring
19. Piston ring
IMPORTANT! If vanes are damaged or cracked, do not reuse the part.
IMPORTANT! After reinstalling the overhauled turbocharger, crank the engine to lubricate moving parts of
the turbo.
184

Install shaft & turbine wheel and bearing

1. Install the bearing housing, the snap rings and
the bearing on the turbine side, and the snap ring
on the compressor side.
NOTE! Use only snap ring pliers to install snap rings.
After installing the snap ring, rotate it with a finger to
make sure it rotates smoothly.
NOTE! Apply engine oil to the outside and inside sur-
faces of the bearing before installation.
2. Place the bearing housing on the compressor

cover, and install the turbine backplate.
3. Insert the piston ring into the groove on the shaft

& turbine wheel
4. When installing the shaft & turbine wheel mount-

ed with the piston ring in the bearing housing, po-
sition the ring on the shaft so that there is a small
space (A) at the ring end gap side (B) and a large
space (C) on the other side. Then insert the shaft
& turbine wheel while rotating.
IMPORTANT! Do not expand the piston ring ex-

cessively or twist the ends when installing on
the shaft & turbine wheel.
IMPORTANT! Do not apply excessive forte with-

out tentering the shaft properly during the instal-
lation of the shaft & turbine wheel.
NOTE! After installing the piston ring in the ring
groove, apply Moly Disulfide to the ring before as-
sembly.
5. Hold the shaft end and tum the assembly over so

the compressor side faces up. Install the bearing
on the compressor side and then mount the bear-
ing housing on the turbine housing and fasten
the bolt temporarily.
185

Installing the thrust bearing

Apply engine oil to both sides of the thrust ring and
thrust bearing. To install the thrust bearing, align the
notch with the groove pin.
Installing the O-ring

Apply grease to the O-ring and install.
Installing the oil deflector

Apply engine oil to both sides of the thrust ring and in-
stall. Then install the oil deflector with the baffle fac-
ing down.
186

Assembling the insert sub-assembly

1. Install the finger sleeve and the piston ring in the
insert.
IMPORTANT! Do not expand the piston ring ex-

cessively or twist the ends when installing on
the finger sleeve.
IMPORTANT! Apply Moly Disulfide to the piston

ring installed on the finger sleeve, then install
on the insert carefully so as to avoid piston ring
damage.
2. After installing the above parts, irrstall the sub as-

sembly in the bearing housing 26.
Installing the snap ring

Install the snap ring with the tapered side face up in
the bearing housing. Make sure you install the snap
ring correctly!
NOTE! Lightly drive both ends of the snap ring using

a screwdriver and hammer to securely insert the ring
into the groove on the bearing housing. Make sure
the screwdriver does not hit the bearing housing.
187

Turbine wheel and housing clearance

Set a dial gauge on the end face of the shaft & turbine
wheel. Read the dial gauge indication while moving
the shaft & turbine wheel in the axial direction.
If the dial gauge indication deviates from the assem-
bly standard, disassemble and locate the cause of the
problem.
Clearance turbine wheel and housing, mm [in.]

Installing the compressor wheel

Install the compressor wheel. Tighten the lock nut to
the specified torque.
Lock nut tightening method

1. Tighten the lock nut to torque of 69 N m (7 kgf m)
● ●
[51 lbf ft], then loosen it completely.

●
2. Apply Loctite No. 962T to the threads.

3. Retighten to a snug torque of 9.8 N m (1 kgf m)
● ●
[7.2 lbf ft], then turn another 90±3°.

●
Shaft & turbine wheel axial play

Set a dial gauge on the end face of the shaft & turbine
wheel. Measure the amount of play while moving the
compressor wheel in the axial direction.
If the measured play deviates from the standard val-
ue, disassemble and locate the cause of the problem.
Shaft & turbine wheel axial play, mm [in.]

188

Turbine wheel and backplate clearance

Remove the turbine housing from the bearing housing
and install the compressor cover. Measure the clear-
ance between the turbine backplate and the back
side of the turbine wheel using feeler gauges.
NOTE! Use two feeler gauges, and measure at vane
tips.
If the clearance deviates from the assembly standard,
disassemble and locate the cause of the problem.
Turbine wheel and turbine backplate

clearance, mm [in.]
Installing the turbine housing

1. Check the mounting direction of the turbine hous-
ing, then install on the bearing housing.
2. Apply Moly Disulfide to the threads of the bolt,
and tighten to the specified torque.
Installing the diffuser

1. Apply grease to the diffuser and install the bear-
ing housing.
2. Install the diffuser.
189

Installing the compressor cover

Check the mounting direction of the compressor cov-
er, then install.
Installing the V-clamp

Install the V-clamp 1 to the compressor cover 2 and
tap around it with a soft-faced hammer for more than
3 times and tighten to the specified torque.
190

Group 26 Cooling System

Fresh Water Pump

1. Snap ring A. Rotation
2. Cover B. Wear, deterioration of lip
3. Water pump impeller C. Corrosion, chafing
4. Ring D. Crack, damage
5. Unit seal E. Wear, damage
6. Oil seal sleeve
7. Bearing
8. Water pump gear
9. Bearing
10. Water pump shaft
11. Oil seal
12. Pump case
191

Fresh water pump

Touch the drain port located at the bottom of the
pump with your finger. If the port is leaking water,
check the condition of the unit seal. If it is leaking oil,
the oil seal is defective.
Remove the impeller

1. Remove the snap ring the water pump pliers then
remove the cover.
2. Remove the impeller with the impeller remover.
Remove the water pump shaft

1. Remove the oil seal sleeve.
2. Remove the gear and the bearing with the gear
puller.
3. Remove the snap ring of the impeller side ball
bearing
4. Inset the two rings (A) of the ring remover be-
tween the unit seal and the pump case.
5. Fit the outer ring (B) to the outside of the half
rings to prevent them from falling down.
6. Support the pump case and push out the shaft
from the impeller side by pushing with a hand
press .
192

Inspection
Water pump
Measure the inside diameter of the pump case bore
to which the bearing outer race is fitted. Measure the
diameter of the pump shaft on which the bearing in-
ner race is fitted. If the bearing, case, or shaft is worn,
replace it
Inside diameter of pump case bearing, mm [in.]

Norminal value .......... Ø120 [4.72]
Assembly standard ... 119.987–120.022 [4.72389–
4.72527]
Pump case bore diameter, mm [in.]

Norminal value .......... Ø110 [4.33]
Assembly standard ... 110.005–110.040[4.33090–4.33227]
Bearing Diameter, mm [in.]

Norminal value .......... Ø120 [4.72]
Assembly standard ... 119.985–120.000[4.72381–4.72441]
Bearing Diameter, mm [in.]

Norminal value .......... Ø110 [4.33]
Assembly standard ... 109.985–110.000 [4.33012–
4.33071]
Bearing Inside diameter, mm [in.]

Norminal value .......... Ø55 [2.17]
Bearing Inside diameter, mm [in.]

Norminal value .......... Ø50 [1.97]
Diameter of pump shaft, mm [in.]

Norminal value .......... Ø55 [2.17]
Diameter of pump shaft, mm [in.]

Norminal value .......... Ø50 [1.97]
193

Reassembly
NOTE! Replace all O-rings, unit seals and oil seals at
reassembly.
12 11 5
8 7 6 4 3 2 1
10 9
1. Use the oil seal installer to drive in the oil seal.

Apply engine oil to seal lip.
2. Use the unit seal installer to drive in the unit seal.

Replace the unit seal once disturbed.
NOTE! Install the unit seal after coating the outer ring
with sealant.
3. Press the impeller-side of the pump shaft, com-

plete with ball bearings, into the case. Install the
snap ring with its gap down.
4. Press in the unit seal ring with the unit seal float-
ing seat using the ring installer .
NOTE! Before installation coat the floating seat at two
locations with LLC solution (anti- freeze).
194

5. Insert the gear into the shaft by aligning the key.

Press in the ball bearing on the nut side.
6. Press in the impeller to the depth where impel-

ler’s boss end face is flush with the shaft end.
7. Mount the cover on the impeller side, and secure

it in place with the snap ring.
8. After installing the water pump assembly, install
the alternator pulley and tighten the nut to the
specified torque.
195

Thermostats

1. Thermostat cover A. Deteriorated, worn, cracked
2. Packing B. Replace packing
3. Snap ring C. Worn, cracked
4. Thermostat
5. Thermostat seal
6. Thermostat case
Inspection
Heat the thermostat in water. Measure the tempera-
ture when the valve opens. Measure it again when
the valve lift is 11 mm [0.43 in.]. Replace if not within
standard.
Opening temp., °C [°F]

Assembly standard ... 71±2 [159.8±3.6]
Valve lift 11 mm [0.43 in.] temp., °C [°F]

Assembly standard ... 85 [185]
NOTE! Stir the water to maintain even temperatures

during the test.
NOTE! Confirm the valve opening temperature
(stamped on its mounting flange).
196

Heat Exchanger

1. Cover A. Pipes clogged, leaks
2. Packing B. Change if less than 50%
3. Cover remains
4. O-ring
5. Zinc rod
6. Element
7. Body
Inspection
Cleaning of element
1. While pouring running water onto the outer sur-
face of the element, clean with a wire brush.
Check the element for corrosion and tears.
2. Insert a stick into the pipe and remove deposits.
197

Raw Water Pump(standard rubber impeller)
Disassembly
1. Cover, O-ring
2. Impeller
3. Casing, gasket, plate, gasket
4. Bushing, unit seal
5. Slinger
6. Nut, spring washer
7. Pulley
8. Snap ring
9. Shaft, key
10. Bearing
11. Oil seal
12. Holder
13. Cam
IMPORTANT! The rubber impeller is not resistant to anti-freeze or cooling water conditioner.
198

Inspection
Bearing dimensions
Measure the dimensions of the bearing installation
sections of the sea water pump holder and shaft. If
excessive wear or damage is observed, replace the
bearing, holder and shaft.
Inside diameter at bearing position, mm [in.]

Nominal value ........... Ø110 [4.33]
Service limit .............. 110.030 [4.33188]

Nominal value ........... Ø110 [4.33]
Assembly standard ... 109.985–110.000 [4.33011–.3307]

Nominal value ........... Ø50 [1.97]
Shaft diam. at bearing position, mm [in.]

Nominal value ........... Ø50 [1.97]
Service limit .............. 50.000 [1.96858]
199

Reassembly
12 11 9 8 5 4 3 2 1 7 6
10 13
200

1. Install the cam to the casing, and tighten the

screw to the specified torque. The contact surfac-
es must be coated with ThreeBond 1102.
2. Install the unit seal to the bushing by striking with

a hammer, making sure the unit seal remains
square to the bushing during installation. The
contact surface must be coated with ThreeBond
1102
NOTE! Be sure to replace the unit seal with a new
part
3. Using a jig and a hammer, install the bearing to

the shaft, making sure the bearing remains
square to the center line of the shaft.
4. Install the slinger (A) to the holder. Install the

bushing (B) with unit seal to the holder. Clean the
sliding surface (C) on the seat side of the unit
seal with ethyl alcohol, then coat with turbine oil.
Install the seat side (D) onto the shaft, and fasten
with the snap ring (E).
201

5. Install the casing to the holder via the plate. The

contact surface must be coated with ThreeBond
1102. Tighten the bolts to 7.4 to 9.8 N*m (0.75 to
1.0 kgf*m) [5.42 to 7.23 lbf*ft].
6. Install the impeller to the shaft by striking with a

hammer.
NOTE! Make sure the impeller vane tips are pointed
in the direction opposite to the rotational direction.
7. Install the O-ring to the casing, and mount the

cover. Tighten the bolts to the specified torque.
8. Tighten the nut to secure the pulley in place
(tightening torque: 196 N*m (20 kgf*m) [144.7
lbf*ft])
202

Group 30 Electrical System

Starter

1. Safety switch A. Wear of gear, damage
2. Magnetic switch assembly B. Play and unsmooth rotation
3. Rear bracket C. Adhesion of brush particles, irregular
4. Brush holder assembly wear, brush movement in holder
5. Yoke assembly D. Wear of gear
6. Armature assembly E. Surface roughness, seizure, wear

and damage
7. Center bracket
8. Shift lever assembly
9. Front bracket
10. Pinion case
11. Pinion clutch assembly
203

1. Remove the safety switch, wires and cables and

the magnetic switch assembly.
2. Unscrew the through bolts and the brush holder

mounting screws. Remove the rear bracket.
3. Remove the brushes from the brush holder as-

sembly and then remove the yoke.
4. Pull out the armature assembly
204

5. Remove the center bracket.
6. Remove the lever pin, inner housing, and shift le-

ver from the pinion case.
7. Using a jig, remove the pinion stopper, then re-

move the overrunning clutch from the pinion
shaft.
NOTE! To remove the shaft bearing for replacement,

use a bearing puller as shown in the drawing.
205


Magnetic Switch
Testing the magnetic switch coil
1. Test the pressure coil and holding coil for an
open ciruit. The coils are open-circuited if there is
no continuity between the M terminal of the mag-
netic switch and the case.
Resistance: 1.4 ohms (approx.)
2. Apply voltage of 24 volts between the M terminal

of the magnetic switch and the case. Now push in
the plunger by hand. When you release your
hand, the plunger should not be attracted.
Testing magnetic switch contact points

Measure the load current flowing through the starter.
If the voltage drop between terminals B and M ex-
ceeds 0.3 volts per 100 amperes, clean or replace
the contact points.
If the starter switch is tumed to OFF during voltage
measurement, the battery voltage is directly applied
to the voltmeter. This can damage the voltmeter. Al-
ways turn the starter switch to ON before measuring
the voltage, then turn it OFF after measuring the volt-
age.
IMPORTANT! Do not apply 24 V on terminals to

test the magnetic switch movement.
206

Armature
Measuring the armature runout
Measure the runout with a dial gauge. If the deflection
exceeds the assembly standard, repair or replace the
armature.
Armature deflection, mm [in.]

Inspecting the commutator

1. Check the condition of the commutator surface. If
it is rough, polish it with #400 to #600 sandpaper.
Check the commutator for runout with a dial
gauge. Replace the commutator if the deflection
exceeds the service limit.
Commutator deflection, mm [in.]

Assembly Standard ... 0.06 [0.0024] maximum
Service Limit ............. 0.10 [0.0039]
2. Measure the mica depth. Use a depth gauge to

measure the depth of each mica undercut. If the
depth exceeds the repair limit, re-condition the
mica.
Commutator mica depth, mm [in.]

Assembly Standard ... 0.7 to 0.9 [0.028–0.035]
Repair Limit ............... 0.2 [0.0079]
Testing the armature

1. Use a growler to test the armature for short cir-
cuits. If the hacksaw blade vibrates against the
core, replace the armature.
2. If there is continuity between the commutator and

shaft, replace the armature.
207

Field coil
Testing for open circuits
1. If there is no continuity between the M terminal of
the field coil and the lead wire on the brush side,
replace the field coil.
Overrunning Clutch
The clutch is in good condition if it rotates freely in
one direction when tumed by hand.
Check the pinion teeth for wear or damage. If they
are damaged, replace the pinion.
IMPORTANT! Do not immerse the overrunning

clutch in cleaning solvent to clean it. Immersion
in cleaning solvent Will cause grease inside the
clutch to run out, causing clutch parts to seize
when operating.
Brushes
Inspecting for wear
B Brush height, mm [in.]
A
Assembly Standard ... 21–22 [0.83–0.87](A)
Service Limit ............. 13 [0.51](B)
Testing brush spring tension
Brush spring tension, N (kgf) [lbf]

Assembly Standard ... 39.23–49.03 (4.0–5.0 [9–11]
Service Limit ............. 39.23 (4.0 [9] maximum
208

Safety Switch
R
Connect the safety switch as shown, and check the
starter and safety switch operations.
1. Connect the R terminal to the battery minus (-)

side.
2. Turn the switch on, and check that the starter

tums.
3. After step (2) above is completed, if you remove

the R terminal from the battery minus (-) side, or
if you connect the terminal to the battery plus (+)
side after removal, make sure you stop the start-
er operation.
IMPORTANT! When you are making con-

nections, pay special attention to the bat-
tery’s polarity.
209

Reassembly
Reassembly sequence: 9 8 10 7 6 5 4 3 2 1
1. Install the center bracket, overrunning clutch, and

pinion stopper to the pinion shaft. Insert the shaft
in position by tapping it with a soft-head mallet.
2. Install the shift lever and pinion shaft to the front

bracket by aligning the matching mark on the shifi
lever.
3. Install the armature and yoke to the center brack-

et, making sure that the dowel pin enters its hole.
4. Install the brushes and brush holders.
210

NOTE! Install the positive (+) side brush and negative

(-) side brush as shown.
5. Install the rear bracket to the yoke by aligning the

matching marks. Secure the brush holders with
bolts, then tighten the through bolts.
6. Measure the end play of the armature. If the end

play exceeds the assembly standard, adjust it on
the rear side.
Armature end play, mm [in.]

7. Liberally coat the internal gear with grease, then

install the pinion shaft to the gear.
211

8. Measure the end play of the pinion shaft. If the

end play exceeds the assembly standard, adjust
it on the internal gear side.
Pinion shaft end play, mm [in.]

9. Install the magnetic switch. Apply a voltage of 24

volts between the C and E terminals. Connect the
lead wire and energize the circuit between the M
and E terminals (within 1 setond). After the pinion
has shifted, measure retraction length of the pin-
ion. If the measurement is not within 2.5 to 5.5
mm CO.098 to 0.22 in.], use the magnetic switch
adjusting screw to make adjustments.
10. Secure the lead wire.
11. Install the safety switch.
212

Alternator
Disassembly
1. Nut, washer
2. Pulley assembly
3. Set screw
4. Front bracket assembly
5. Rotor assembly
6. Field coil
7. Stator
8. Rear bracket
9. Regulator assembly
10. Rectifier assembly
11. Terminal assembly
213

Inspection and repair

Stator
1. Testing the stator coil for open circuits
If there is no continuity among the three lead
wires, replace the stator.
2. Testing the stator coil for grounding
If there is continuity between the coil and core,
replace the stator.
Field coil
Measure resistance between the terminals of the field
coil. If the measured resistance deviates from the
standard value, replace the coil.
Field coil resistance, Ω

Assembly Standard ... 7.3–8.6
Inspecting rectifier
To check individual diodes, measure resistance be-
tween the diode lead wire and heat sink. Connect the
positive (+) test lead wire to the diode and measure
resistance. Then, connect the negative (-) test lead
wire to the diode and measure resistance again. If
both measured values are close to 0 (zero), the cir-
cuit is shorted.
NOTE! If the diode has an open circuit or is shorted, it
is defective, and the rectifier must be replaced.
Reassembly
Reassembly sequence
8 9 10 11 7 6
3
4 5 2 1
WARNING! The alternator requires no grease.

Keep the bearing box free of oil and grease since oil
and grease can cause creeping of the bearing on the
rear side.
WARNING! Heat the bearing box of the rear
bracket for assembly.
214

02– 2003
7742852-2 English

Manual Serviço Volvo D49 A MT

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Workshop Manual H

D49A MS, D49A MT

Plus d'informations sur : www.dbmoteurs.fr

Safety Information ................................................. 5 Group 22:Lubrication system

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Plus d'informations sur : www.dbmoteurs.fr

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Warning labels D49A MS

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Warning labels D49A MT

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● Only genuine Volvo Penta replacement parts may be used.

● Seals may only be broken by authorized personnel.

Plus d'informations sur : www.dbmoteurs.fr

Our joint responsibility

Plus d'informations sur : www.dbmoteurs.fr

How to Use This Manual Terms used in this manual

Plus d'informations sur : www.dbmoteurs.fr

Disassembly and Reassembly

Plus d'informations sur : www.dbmoteurs.fr

When installing oil seals, carefully observe the follow-

Driving oil seals into housings

1. Check the seal lip for damage, and be sure to po-

2. Apply a smear of grease to the surface of the oil

3. Use an oil seal driver shown to guide the seal lip

Driving oil seals onto shafts

2. Use an oil seal guide of the type shown when

Plus d'informations sur : www.dbmoteurs.fr

2. Whenever possible, use a press to minimize

Split Pins and Spring Pins

Plus d'informations sur : www.dbmoteurs.fr

3. Fuel injection pump

4. Governor oil filter

5. Manual stop lever

9. Fuel feed pump

10. Oil filler cap

11. Fresh water pump

12. Lifting eye

13. Intake air silencer

16. Oil filters

17. Engine oil drain pipe

18. Starter motor

19. Manual speed control knob

Plus d'informations sur : www.dbmoteurs.fr

3. Fuel injection pump

4. Governor oil filter

5. Manual stop lever

9. Fuel feed pump

10. Oil filler cap

11. Fresh water pump

12. Lifting eye

13. Intake air silencer

15. Heat exchanger

16. Oil filters

17. Starter motor

18. Engine oil drain pipe

19. Sea water pump

21. Manual speed control knob