Model D4B

MODEL
D4B
SHOP MANUAL
(FOR INDUSTRIAL USE)
FORWORD
We would like to express our sincere gratitude to the patrons who have given us unwavering encouragement. This manual covers shop manual and parts catalog in one volume for an easy reference of parts list, as well as contains the accurate and efficient service procedures for HYUNDAI D4B industrial engine.
This manual includes specifications, troubleshooting, removal, installation, disassembly and assembly in each group and presents component illustrations and descriptions for an easy reference.
Accordingly, thoroughly read this manual, rapidly purchase the required parts and service the engine in proper methods to extend its life and benefit.
Improper service methods and procedures may shorten the engine life resulting from its low performance. Hyundai genuine parts are designed and built to provide the best performance in your engine. If your claim is caused by using non-Hyundai genuine parts or servicing at places not recommended, your warranty is not available.
Hyundai Motor Co., Inc. makes efforts to enhance quality and build better parts and service data for you. We want to assist you in every way possible with this manual and your purchase of HYUNDAI engine is highly appreciated.
March 2004
Hyundai Motor Co., Inc. Industrial Engine Development Team (TEL 82-52-280-8221~8223) O.E.M Parts Export Team (TEL 82-2-746-0291~0299)
NOTE: Contents and specifications are subject to change according to design changes without notice.
IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all engines as well as the personal safety during work. This manual provides general directions for the efficient service methods and procedures. There are numerous variations in procedure, techniques, tools and parts for servicing engines, as well as in the skill of the individual technician. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this manual must establish that he comprises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts.
NOTE, CAUTION, WARNING

NOTE : Information needed in reference to a repair service. CAUTION: Information about an activity that could cause damage to the vehicle. WARNING : Information about an activity that could cause injury or damage to the driver, occupants or repairman.
[SAFETY INFORMATION]
The following list contains some general warnings that you should follow when you work on an engine. Always wear safety glasses for eye protection. Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. Operate the engine only in a well-ventilated area to avoid the danger carbon monoxide poisoning. Keep yourself and your clothing away from moving parts when the engine is running, especially the drive belt. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. Do not smoke while working on an engine. To avoid injury, always remove rings, watches, loose hanging jewelry and loose clothing before beginning to work on an engine. Keep hands and other objects clear of the radiator fan. The fan can be operated with the ignition key in the OFF position. Therefore necessarily disconnect the radiator fan motor connector.
CONTENTS
1. 2. 3. 4. 5. 6. 7. GENERAL ENGINE MECHANICAL SYSTEM LUBRICATION SYSTEM COOLING SYSTEM INTAKE AND EXHAUST SYSTEM ENGINE ELECTRICAL SYSTEM FUEL SYSTEM 1-1 2-1 3-1 4-1 5-1 6-1 7-1
CHAPTER 1 GENERAL INFORMATION
1. GENERAL ............................................................................. 1- 1 2. ENGINE IDENTIFICATION NUMBER ..................................... 1- 6 3. TIGHTENING TORQUE OF STANDARD PARTS.................... 1- 7 4. RECOMMENDED LUBRICANTS AND CAPACITIES .............. 1- 8 5. SPECIFICATIONS .................................................................. 1- 9 6. TORQUE SPECIFICATIONS .................................................. 1- 13 7. SPECIAL TOOLS ................................................................... 1- 15 8. TROUBLESHOOTING ........................................................... 1- 18 9. CHECKING POINT ................................................................. 1- 20
GENERAL
1-1
1. OVERALL
1) ENGINE
Cylinder head is made of aluminum alloy and combustion chamber is a swirl type. Valve is a SOHC type and the camshaft is operated by the Cog type timing belt. Cylinder block is made of special cast iron and dry cylinder liner is press-fitted in the cylinder. Water jacket is a Siamese type and piston is made of aluminum alloy and connected with connecting rod by full floating piston pin. Oil ring no.1 of the piston ring is made of steel, no.2 of special cast iron, piston ring no.1 of barrel face, no.2 of taper face and oil ring of bevel cutter and coil expander is attached.
ENGINE ASSEMBLY
KD4BB01A
Crankshaft is made of forged steel and supported with main bearing. Pulley attached with torsional damper is installed in the front of crankshaft and flywheel in the rear of it. Silent shaft is installed to both ends of the cylinder block, operated with cog belt and rotated at a double speed of crankshaft.
1-2 Timming belt train
GENERAL
KD4BB02A
GENERAL
1-3
2) LUBRICATION SYSTEM
It is a forced lubrication system and the forced oil by the oil pump is sent to the engine compartment through the oil cooler and oil filter as shown in the illustration and directly operated by the crank shaft. Maximum oil pressure is controlled by the reducing valve.
Rocker arm shaft Camshaft Main passage
Oil filter To oil pan Left silent shaft
Reduing pressure Vaccum pump
Crank shaft Right silent shaft
Oil jet
KD4BB03A
1-4
GENERAL
Oil filter is a combined type and full flow filter and bypass filter are built in it. The bypass filter in the full flow filter uses a thick multi-fiber media to filter dirt (soot). If oil enters the oil filter, filtered oil from the full flow filter passes through the main passage and the filtered oil from the bypass filter returns to the oil pan.
Bypass filter Gasket Flow filter From oil pump Valve To oil pan To main passage
KD4BB04A
GENERAL
1-5
3) COOLING SYSTEM
Engine is cooled with the circulated coolant forced by the water pump. This illustration shows the flow of coolant.
Cold engine
From heater To heater Thermostat Water pump Water pipe
Hot engine
Thermostat Water pump
From heater Heater
Water pipe
KD4BB05A
1-6
ENGINE IDENTIFICATION NUMBER
2. ENGINE INDENTIFICATION NUMBER

1) ENGINE IDENTIFICATION NUMBER LOCATION
The engine identification number is stamped on the right front side of the top edge of the cylinder block.
Engine identification number
2) DESCRIPTION OF ENGINE IDENTIFICATION NUMBER

D 4 B B 2 0 0 0 0 0 0
KAXD010C
Engine fuel - D : diesel Engine range - 4 : In line 4 cycle 4 cylinder Engine development order - B : 4D56 Engine capacity - F : 2476 cc TC - H : 2476 cc TCI - B : 2607 cc NA Production year - 1 : 2001 - 2 : 2002 - 3 : 2003 - 4 : 2004 Engine production sequence number - 000000 ~ 999999
TIGHTENING TORQUE TABLE OF STANDARD PARTS
1-7
3. TIGHTENING TORQUE TABLE OF STANDARD PARTS

Bolt nominal diameter (mm) Torque (kg m) Pitch (mm) Head Mark 4 Head Mark 7
EADA010R
EADA010S
EADA010T
EADA010U
M5 M6 M8 M10 M12 M14
0.8 1.0 1.25 1.25 1.25 1.5
0.3 ~ 0.4 0.5 ~ 0.6 1.2 ~ 1.5 2.5 ~ 3.0 3.5 ~ 4.5 7.5 ~ 8.5
0.5 ~ 0.6 0.9 ~ 1.1 2.0 ~ 2.5 4.0 ~ 5.0 6~8 12 ~ 14
NOTE 1. The torques shown in the table are standard values under the following conditions. . Nuts and bolts are made of steel bar, and galvanized. . Galvanized plain steel washers are inserted. . All nuts, bolts and plain washers are dry. 2. The torques shown in the table are not applicable. . When spring washers, toothed washers and the like are inserted. . If plastic parts are fastened. . If self-tapping screws or self-locking nuts are used. 3. If you reduce the torques in the table to the percentage indicated below, under the following conditions, it will be the standard value. . If spring washers are used : 85% . If threads and bearing surfaces are stained with oil : 85%
1-8
LUBRICANTS CAPACITES
4. LUBRICANTS CAPACITES
Description Oil pan Oil filter Engine oil Oil cooler Total Coolant Capacities 0.7 l 0.5 l 9.5 l 0.7 l Antifreeze for aluminum Above API CD or SG (10W/30 or 1500W/40) Specified oil
CAUTION For the best performance and maximum protection of all types of operation, select only those lubricants which : 1. Satisfy the requirements of the API classification. 2. Have the proper SAE grade number for expected ambient temperature range.Lubricants which do not have both an SAE grade number and an API service clasification on the container should not be used.
SPECIFICATIONS
1-9
5. SPECIFICATIONS
Description Type Number of cylinders Valve system D4BB Total displacement 2607cc Cylinder bore General Cylinder stroke Comprssion ratio Intake valve - OPEN - CLOSE Valve timing Exhaust valve - OPEN - CLOSE 91.1 mm 100 mm 22 20 BTDC 48 ATDC 54 BTDC 22 ATDC 1-3-4-2 0.05 mm 0.15 mm 94.0 ~ 94.1 mm 0.2 mm 0.3 mm 2476cc 91.1 mm 95 mm 21 Specification Diesel engine 4 OHC D4BF, D4BH Limit
Firing order Flatness of gasket surface Flatness of manifold mounting surface Overall height Oversize of valve guide hole Cylinder head Rework dimensions (both intake and exhaust) Oversize rework dimensions of intake valve seat hole Oversize rework dimensions of exhaust valve seat hole Cam height Camshaft Journal O.D. Oil clearance End play I.D Rocker arm Rocker arm - to -guide clearance 0.05 0.25 0.50 0.30 0.60 0.30 0.60 Intake Exhaust
13.050 ~ 13.068 mm 13.250 ~ 13.268 mm 13.500 ~ 13.518 mm 43.300 ~ 43.325 mm 43.600 ~ 43.625 mm 37.300 ~ 37.325 mm 37.600 ~ 37.625 mm 37.05 mm 37.05 mm 29.935 ~ 29.950 mm 0.05 ~ 0.08 mm 0.1 ~ 0.2 mm 18.910 ~ 18.928 mm 0.012 ~ 0.050 mm 36.55 mm 36.55 mm
1-10
Description O.D. Rocker shaft Length
SPECIFICATIONS
Specification 18.878 ~ 18.898 mm 451.5 mm Intake Over length Exhaust Intake Stem diameter Valve Fage angle Thickness of valve head (Margin) Stem-to-guide clearance Free height Intake Exhaust Intake Exhaust Exhaust 136.5 mm 136.5 mm 7.960 ~ 7.975 mm 7.930 ~ 7.950 mm 45 ~ 45 3 0 2 mm 2 mm 0.03 ~ 0.06 mm 0.05 ~ 0.09 mm 49.1 mm 276/40.4 Max 2 71 mm 74 mm 8.000 ~ 8.018 mm 13.06 ~ 13.07 mm Ordinary temperature 45 0.9 ~ 1.3 mm 0.2 Right - Front - Rear Journal diameter 18.300 ~ 18.467 mm 42.975 ~ 42.991 mm 1.0 mm 1.0 mm Limit
Valve spring
Load/Installed height Over length
N kg/mm Out-of squareness Intake Exhaust I.D.
Valve guide O.D. Press temperature Seat angle Valve seat Valve contack widht Sinkage
Silient shaft
Left - Front - Rear Front Oil clearance Rear 18.959 ~ 18.980 mm 49.975 ~ 42.991 mm 0.02 ~ 0.06 mm 0.05 ~ 0.09 mm
SPECIFICATIONS
Description O.D. TC Piston-to cylinder clearance Piston Ring groove width No. 1 ring No. 2 ring Oil ring No. 1 ring End gap Piston ring Ring-to-ring groove clearance Piston pin O. D. Big end center-to small end center length bend Bend Connecting rod Twist Bing end side clearance End play Journal O.D. Pin O.D. Out of roundness of journal and pin Out-of taper of journal and pin Oil clelarance of journal Crank shaft Oil clearance of pin 0.25 U.S. Journal 0.50 U.S. 0.75 U.S. 0.25 U.S. Pin 0.50 U.S. 0.75 U.S. No. 2 ring Oil ring No. 1 ring No. 2 ring Oil ring 0.04 ~ 0.06 2.601 ~ 2.603 2.100 ~ 2.102 4.010 ~ 4.035 0.35 ~ 0.50 0.41 ~ 0.54 0.25 ~ 0.45 0.056 ~ 0.076 0.046 ~ 0.066 0.02 ~ 0.065 Specification 79.0 ~ 79.2 mm NA 0.03 ~ 0.05 2.02 ~ 2.04 2.07 ~ 2.09 3.01 ~ 3.035 0.25 ~ 0.40 0.45 ~ 0.60 0.20 ~ 0.40 0.03 ~ 0.07 0.08 ~ 0.12 0.02 ~ 0.065 Limit
1-11
0.8 mm 0.8 mm 0.8 mm 0.15 mm 0.15 mm 0.1 mm
28.994 ~ 29.000 mm 157.95 ~ 158.05 mm 0.05 0.1 0.1 ~ 0.25 mm 0.05 ~ 0.18 mm 66 mm 53 mm 0.05 mm less than 0.015 mm less than 0.02 ~ 0.05 mm 0.02 ~ 0.05 mm 65.735 ~ 65.750 mm 65.485 ~ 65.500 mm 65.235 ~ 65.250 mm 52.735 ~ 52.750 mm 52.485 ~ 52.500 mm 52.235 ~ 52.250 mm 0.1 mm 0.2 mm 0.3 mm
1-12
Description O. D. Cylinder block
SPECIFICATIONS
Specification 91.10 ~ 91.13 mm 0.05 mm 318.45 ~ 318.55 mm 0.13 mm Inner gear Tip clearnace Outer gear Oil pump Body clearnace Side clearance Outer gear Cooling system Drive Belt Water pump type Fan clutch type Thermo type Coolant temperature gauge unit Thermo switch(113C, A/con) 0.12 ~ 0.22 mm Water-cooled forced circulation system V Belt Centrifugal impeller Bimetal thermostat type Wax type Thermister type Thermister type 10 ~ 13 mm 76.5 2C / 82 2C 95C 8 or not less than 90.5 ~ 117.5 /70C 21.3 ~ 26.3 /115C 22.3 ~ 27.3k /-20C 2.92 ~ 3.58k /20C Paper filter type Expansion resonance type Side clearance Inner gear 0.12 ~ 0.22 mm 0.04 ~ 0.10 mm 0.03 ~ 0.09 mm 0.4 mm 0.15 mm 0.15 mm 0.30 mm 0.22 ~ 0.35 mm 0.13 mm 0.5 mm 0.1 mm Limit
Flatness of gasket surface Overall height
Flywheel
Run out
Cooling system
Drive belt Valve opening temperature Fulley opening temperature Repeat amount Coolant temperature gauge unit Resistance Coolant temperature gauge element Glow control element
Thermostat
Intake & Exhaust
Air cleaner Muffler
TORQUE SPECIFICATIONS
1-13
6. TORQUE SPECIFICATIONS
Deseription Crankshaft pulley bolt Crankshaft sprocket bolt Timing belt tensioner bolt Injection pump sprocket nut Silent shaft sprocket nut Timing belt tensioner B nut Rocer cover bolt Rocker arm shft bolt Cold engine Cylinder head bolt Hot engine Oil pan bolt Oil pan drain plug Front case bolt (upper, lower) Silent shaft driven gear bolt Silent shaft plug gap Silent shaft gear cover bolt Connecting rod cap nut Flywheel bolt Crankshaft bearing cap bolt Silent shaft chamber cover bolt Oil relief valve plug Oil pump cover bolt Oil pressure switch Oil filter bracket Oil cooler by-pass valve Oil jet check valve Water pump bolt Water pump pulley bolt 11.5 ~ 12.5 0.6 ~ 0.8 6~8 1.2 ~ 1.5 3.4 ~ 4.0 2.0 ~ 2.7 1.5 ~ 1.8 4.5 ~ 4.8 13 ~ 14 7.5 ~ 8.5 0.5 ~ 0.7 3.0 ~ 4.5 0.9 ~ 1.4 0.8 ~ 1.2 1.2 ~ 1.5 5.0 ~ 6.0 3.0 ~ 3.5 1.2 ~ 1.5 1.0 ~ 1.2 Standard (kg m) 17 ~ 19 6.5 ~ 7.5 2.2 ~ 3.0 8~9 3.4 ~ 4.0 2.2 ~ 3.0 0.5 ~ 0.7 1.9 ~ 2.1 10.5 ~ 11.5
1-14
Deseription Water outlet fitting attaching bolt Coolant tempeature gauge unit Thermo switch (113) Alternator brace bolt Adjust rocker arm Alternator support bolt nut Intake fitting bolt Intake manifold bolt
TORQUE SPECIFICATIONS
Standard (kg m) 1.0 ~ 1.3 3.0 ~ 4.0 0.9 1.2 ~ 1.5 1.2 ~ 1.5 2.0 ~ 2.5 1.0 ~ 1.3 1.5 ~ 2.0 M6 0.8 ` 1.0 1.2 ~ 1.5 0.8 ~ 1.0 5.0 ~ 7.0 5.0 ~ 7.0 1.5 ~ 2.0
Heat protector bolt M8 Oil return pipe bolt Exhaust fitting nut Turbo charger nut Exhaust manifold nut
SEALANTS
Description Half circle packing Oil pan gasket Coolant gauge unit Thermo switch (113, A/con) Sealants 3M ATR P/No. 8660 or equivalent 3M ATR P/No. 8660 or equivalent 3M nut rocking P/No. 4171 or equivalent Threebond No.2440 or equivalent Amount As required As required As required As required
SPECIAL TOOLS
1-15
7. SPECIAL TOOLS
Tool (Number and name) Silent shaft bearing puller (09212-43100) Illustration Use Removal of silent shaft rear bearing
B1243100
Silent shaft bearing installer (09212-43200)
Installation of silent shaft rear bearing
B1243200
Bearing installer stopper (09212-43300)
Removal of Right silent shaft rear bearing
B1243300
Crank shaft front oil seal installer (09214-32000)
Installation of crankshaft front oil seal
B1432000
Crankshaft front oil seal guide (09214 - 32100)
Guide for installation of crank shaft front oil seal
B1621100
Connecting - rod small - end busing replacement tool (09214-43000)
Replacement of connecting - rod small end bushing
B1443000
Camshaft oil seal installer (09221-21000)
Installation of camshaft oil seal
ECLA002I
1-16
Tool (Number and name) Cylinder head bolt wrench (09221-32000)
SPECIAL TOOLS
Illustration Use Loosening and tightening of cylinder head bolt
ECLA002A
Valve seat cutter pilot (09221-43200)
Correction of valve seat
ECLA002B
Valve seat cutter 45 (09221-43300)
ECLA002C
Valve seat cutter 65 (09221-43400)
ECLA002D
Valve seat cutter 30 (09221 - 43500)
ECLA002E
Valve spring compressor (09222-21000)
Compression of valve spring
B2221000
Valve stem seal installer (09222-32100)
Installation of valve stem seal
B2232100
SPECIAL TOOLS
Tool (Number and name) Valve guide installer (09222-32200) Illustration Use Removal and Installation of valve guide
1-17
ECLA002F
Silent shaft drive gear oil seal guide (09222-43200)
Installation of silent shaft drive oil seal
B2243200
Crankshaft rear oil seal installer (09232-32000)
Installation of crankshaft rear oil seal
B3132000
Oil pressure switch wrench (09260-32000)
Removal and Installation of oil pressure switch
B6032000
Injection pump sprocket puller (09314-43000)
Removal of injection of pump sprocket
C1443000
1-18
TROUBLESHOOTING
8. Troubleshooting
Symptom Low compression Probable cause Blown cylinder head gasket Worn or broken piston rings Warped or pitted valves Excessive run-out of valve seats on valve faces Noisy valves Incorrect of valve cleanrance Worn valve guides Connecting rod noise Excessive camshaft end play Insufficient oil supply Low oil pressure Remedy Install new head gasket Hone cylinder bores and install new rings Install new valve Reconditioning valve seats and valves Adjust as standard and valve Install new valves and/or new valve guides with O.S. Reconditioning valve seats and valve Correct end play Check engine oil level Check engine oil level Thin or diluted oil Excessive bearing clearance Connecting rod journals out-of-roundness Misaligned connecting rods Inspect oil relief valve and spring Change oil to correct viscosity Measure bearings for correct clearance Replace crankshaft or regrind journals Replace bent connecting rods Crankshaft Bearing noise Insufficient oil supply Low oil pressure Check engine oil level Check engine oil level Inspect oil relief valve and spring. Thin or diluted oil Excessive end play Crankshaft journal out-of-roundness worn Loosen flywheel Piston noise Excessive clearance due to cylinder wear Piston or piston pin worn Burnt piston Piston ring damaged Change oil to correct viscosilty Measure bearings for correct clearances Replace crankshft or regrind journals Tighten to correct torque Correct cylinder wear Replace piston Install new piston Install new rings
TROUBLESHOOTING
Symptom Oil leak Probable cause Oil pan drain plug loose Oil pan mounting bolt loose Oil pan gasket broken Crankshaft front oil seal defective Crankshaft front oil seal defective Rocker cover gasket broken Oil filter loose Oil filter gasket broken Oil consumption Worn, scuffed, or broken rings Carbon in oil ring slot Ring fitted too tight in grooves Tighten to torque Tighten to torque Install new oil seal Install new oil seal Install new oil seal Install new oil seal Tighten to torque Install new oil seal Hone cylinder bores and install new rings Install new rings Remove the rings. Check grooves. If groove width is not , proper width, replace pistion. Faulty valve stem seals Overheat Low oil level Slow idle speed Faulty oil pressure switch Colgged oil filter Worn parts in oil pump Thin or diluted oil Excessive bearing clearance Oil relief valve stuck Oil pump cover bent or cracked Oil screen loose or clogged Insufficent coolant Radiator leakage Loose or damage radiator hose, heater hose Themostat water pump leakage Radiator clogged Coolant dirty Damaged radiator cap High coolant tem- Damaged themostat perature Loose or broken belt Install new valve stem selas Check engine oil level Set idle speed to specification Install new switch Install new oil filter Replace worn parts or pump Change oil to correct viscosity Measure bearings for correct clearance Remove valve and inspect, clean and reinstall Install new oil pump Clean or replace screen Correct or replace Retighten or replace Retighten or replace Replenish Replace Replace Correct or replace Remedy
1-19
1-20
CHECKING POINT
9. CHECK POINT
CHECKING COOLANT RESERVIOR
1. Use an adapter to attach the cap to the tester. 2. Increase the pressure until the gauge stops moving. Check that the pressure level is maintained at or above the limit. Main valve opening pressure Main valve closing pressure 0.75 ~ 1.05 kgf/cm2 0.65 kgf/cm2
3. Replace the radiator cap if the reading does not remain at or above the limit. NOTE Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an incorrect reading.
CHECKING COOLANT
1. Check that the coolant level of the reservoir tank is between FULL and LOW marks. 2. Check that the coolant is not mixed with oil. 3. The standard coolant concentration range is as below. Standard 30 ~ 60% (normal range)
CAUTION If the concentration of coolant falls below 30% or above 60%, vapor corrosion is not inhibited, cooling is not efficient or the engine part could become damaged or not work properly.
3. Antifreeze ratio Coolant quantity (9.5l ) Freezing Delivery condition temperature(C) Mixture ratio(%) Antifreeze quantity(l) -15 40% -20 -25 30 35 40 10 2.45 2.80
CHECKING POINT
1-21
REPLACE COOLANT
1. Loosen and remove the drain plug. 2. Remove the reservoir tank and drain coolant. 3. After draining the coolant, pour water into the coolant reservoir cap and clean the coolant passage. 4. Securely tighten the radiator drain plug. 5. Install the reservoir tank. 6. Fill the reservoir tank up to FULL line with coolant. Coolant quantity 3.9l 9.5l Engine capacity Overall capacity including the reservoir tank and radiator
7. Securely install the coolant reservoir cap. 8. Check the coolant quantity after warming up the engine and add coolant. CAUTION Do not open the coolant reservoir cap when it is hot. Steam and scalding liquids released from a hot cooling system can burn you badly.
CHECKING ENGINE OIL LEVEL

1. Pull out the engine oil indicator(dipstick) and wipe it clean with clothing. 2. Insert the indicator into the oil level gauge guide. 3. Remove the indicator carefully and check that the oil level is between LOW and HIGH marks as shown in the illustration. CAUTION Make sure the vehicle is on a level ground. If the engine is running, turn the engine off and wait a few minutes before checking. 4. If the oil level is below the LOW mark, add enough recommended oil. Engine oil Diesel Above API CD SAE 10W30
LOW
Good
HIGH
KCMB018A
CAUTION Oil levels above the HIGH mark may cause engine damage. 5. After starting the engine, let it idle for a few minutes, stop the engine and recheck the engine oil level is within the normal range.
1-22
CHECKING POINT
REPLACING ENGINE OIL

CAUTION When replacing engine oil and oil filter, do not drop engine oil in the alternator. Engine oil placed in the alternator may harm the alternator.
Drain plug
1. After warming up the engine, remove the oil filler cap. 2. Remove the drain plug and drain oil. CAUTION Protect yourself from the hot oil.
Front
KD4B1001
3. Tighten the drain plug. 4. Add new oil to the oil filler.
CHECKING AND ADJUSTING DRIVE BELT TENSION

1. Inspect tension by pressing in the middle of belt with 10 kg f as shown in the illustration. Standard Alternator 10 ~ 13 mm
Belt
Water pump
Alternator
Crank shaft
KD4B1002
CHECKING AND ADJUSTING DRIVE BELT TENSION

CAUTION Inspect tension after rotating the engine to one turn counterclockwise.
Alternator
Alternator bolt
Alternator pully Alternator support bolt
Crankshaft pulley or pulley

KCMB020B
CHECKING POINT
1-23
BELT ADJUSTMENT
1. Loosen the alternator support nut. 2. Loosen the alternator brace bolt. 3. Move the alternator to increase the belt tension to the standard value. Standard 10 ~ 13 mm
Alternator brake bolt Water pump pully Alternator pully
Crank shaft pully

Alternator support bolt
KCMB020E
4. When using a tension gauge, move the alternator to the standard tension value.
10kg.m Water pump pully
Standard
50 ~ 70 kg Standard 40 kg
Crank shaft pulley Alternator pully
KCMB020F
VALVE CLEARANCE ADJUSTMENT

1. Warm up the engine until the coolant temperature reaches 80~90C.
2. Measure the valve clearance at arrow positions shown in the illustration.

NO.1 NO.2 NO.3 NO.4
Description Exhaust valve Intake valve
Hot engine 0.25 mm 0.25 mm

Intake valve Exhaust valve
KD4B1003
1-24
CHECKING POINT
3. If the measured value exceeds the standard, loosen the locker arm nut and adjust clearance with the adjust screw turning using a thickness gauge. 4. Tighten the lock nut to the specified torque with the adjusting nut fixed not to rotate using a screwdriver. 5. Rotate the crankshaft to 360 place the cylinder no.4 to the dead point.
Cygnus gauge
KD4B1004
6. Measure valve clearance at arrow positions shown in the illustration. ( ) : Cold engine Item Exhaust valve Intake valve Hot engine 0.25 (0.15) mm 0.25 (0.15) mm
NO.1
NO.2
NO.3
NO.4
Intake valve Exhaust valve

KD4B1005
7. If the measured value exceeds the standard, adjust it as the procedures (6)~(7). 8. Inspect clearance of the intake and exhaust valves and adjust it if required.
Feeler gauge
Standard
0.25 mm
KCMB020G
VALVE CLEARANCE ADJUSTMENT

1. Check the engine oil, starter and battery for normal operation. 2. Warm up the engine until the coolant temperature reaches 80~90C. 3. Engage the gauge adapter and install the preheat plug to the pressure gauge.
KCMB025A
Pressure gauge
CHECKING POINT
4. Crank the engine and measure the pressure. Limit (250rpm) 19.2 kg/cm2
1-25
5. Check that the measured value of each cylinder is within the limit. Limit 3.0 kg/cm2
CHECKING COMPRESSED PRESSURE

1. Disassemble the timing belt upper cover. 2. Rotate the crankshaft clockwise to place the cylinder no.1 to the dead point. Check that the timing mark on the sprocket is aligned.
Timing mark
No.1 cylinder dead point
KCMB026A
3. Loosen the spiral bolt to a turn and the groove nut to 1-2 turns.
Groove bolt
Spiral bolt
KCMB026B
4. Rotate the crankshaft clockwise to the second gear of the camshaft sprocket. 5. Fix the tensioner groove bolt and tighten the spiral bolt to the specified torque. Tightening torque 2.2 ~ 3.0 kg m
Cam shaft sprocket
Second gear
KCMB026C
1-26
CHECKING POINT
6. Rotate the crankshaft counterclockwise to align it to the timing mark. 7. Check the belt tension by pressing the middle of cam sprocket and injection pump sprocket with hand. Standard 4 ~ 5 mm
8. Assemble the timing belt upper cover.

ECLA005E
ADJUSTING TIMING BELT "B" TENSION

1. Disassemble the timing belt upper cover. 2. Rotate the crankshaft clockwise to place the cylinder no.1 to the dead point.
KCMB026F
3. Remove the access cover.
Access cover
KCMB026D
4. Loosen the spiral bolt to a turn and the groove nut to 1-2 turns. 5. First tighten the tensioner groove bolt and then the spiral bolt to the specified torque. Tightening torque Bolt Nut 6. Assemble the access cover. 7. Install the timing belt upper cover. 2.0 ~ 2.7 kg m 2.2 ~ 3.0 kg m
KCMB026E
Spiral bolt Groove nut
CHECKING POINT
1-27
CHECKING INJECTION TIMING

1. Stop the cold starting advance angle function. Insert a screwdriver into the lever lower groove and turn it as shown in the illustration. CAUTION Do not turn the lever too much.
Driver
ECLA005H
Accelerator lever
Spacer (10mm) Rod
2. Insert the spacer (thickness: 10mm) between the rod and adjusting screw. 3. Remove the screwdriver. CAUTION When checking and adjusting to replace the injection pump, stop the advance angle function not to result in lack of power.
WAX TYPE COLD STARTING EQUIPMENT

This unit is adopted at low temperature to properly correct the fuel injection timing according to the engine coolant temperature.
Wax type cold starting equipment
KCLA006A
1-28
CHECKING POINT
STRUCTURE
1. Wax is sealed in the cold starting equipment, so the piston rod is operated according to the engine coolant temperature.
Piston
Wax
KCLA006B
2. The lever is rotated by the piston and the roller puller is operated by pin(B) to control the injection timing in retard or advance. The torsion spring pushes the piston to the injection timing advance angle direction.
Timer Piston Adjusting bolt
Pin (A) Idle control bolt Pin (B) Spring Lever (1) Outut side lever Pump sie lever
KCLA006C
3. According to the engine coolant temperature except for the injection timing, the rod connected in the accelerator lever adjusts the engine idle speed.
Accelerator lever
Pin(A)
Lever (1)
KCLA006D
CHECKING POINT
1-29
ADJUSTING INJECTION TIMING

CAUTION Adjust the injection timing with the engine stopped. 1. Rotate the crankshaft to place the cylinder no.1 to the compression dead point.
Crank pully Notch Timing indicator
KCLA003G
2. Loosen the four union nuts in the injection pump side injection pipe and temporarily tighten them. Fix the distribution holder using a spanner not to be turned during loosening the union nut.
Distribution holder Nut
KCLA003H
3. Loosen the injection pump mounting nut and temporarily tighten it. Injection (4)
Bolt (2) Nut (2)

KCLA003I
4. Remove the timing check plug from the injection pump.
Timing check plug

KCLA003J
1-30
CHECKING POINT
5. Before installing the special tool, check that the push rod is jutted out about 10mm. Protrusion of the push rod is adjusted by the inner nut.
Push rod
Nut
09301-43000 09310 - 43000
10mm 10 mm
KCLA003K
6. Install the dial gauge by installing the special tool to the injection pump.
Dial gauge
KCLA003L
7. Align the crank pulley to 30 front of the cylinder no.1 compression dead point. 8. Set the dial gauge to read '0'. 9. Slightly move the crank pulley notch left and right and check that the pointer moves away from 0 position. If the pointer is unstable, realign the notch position to 30 front of the dead point
Approx 30 30
KCLA003M
10. Rotate the crankshaft to the right to place the pulley notch to 5. Normal injection timing ATDC 5
0.03 mm 1 10.03 mm
Recheck the dial gauge is within the standard. Standard 1 0.03 mm

KCLA003N
CHECKING POINT
11. If the pointer of dial gauge is out of the standard values, move the injection pump body left or right to correct and tighten the injection pump mounting nut and bolt to the specified torque. 12. After adjusting, repeat the procedures (7) and (10) to check that the adjustment is correct.
1-31
Front View
10.03 mm or more 10.03
10.03 mm or less 10.03
KCLA003O
13.Detach the dial gauge and special tool and install the gasket and plug. 14. Install the injection pipe nut. Fix the spanner not to turn the distribution holder together. 15. Install a new gasket and tighten the plug to the specified torque. Tightening torque 2.3 ~ 3.7 kg m
KCLA003P
Dial gauge Plug
CHECKING AND ADJUSTING ENGINE IDLE SPEED

CAUTION Only use the idle speed adjusting screw. 1. Before checking and adjusting Engine coolant temperature: 80~90C 2. Check the injection timing and valve clearance and adjust them if required. 3. Install the idle speedometer. 4. Measure the engine idle rpm. Standard 750 100 mm
Idle adjusting screw Speed up Accelerator lever Lock nut
KCLA004A
5. If the measure the value is out of the standard, loosen the lock nut and adjust it within the standard values by turning the adjusting screw. 6. After adjusting, tighten the lock nut.
CHAPTER 2. ENGINE MECHANICAL SYSTEM
1. CYLINDER HEAD ASSEMBLY .............................................. 2- 1 2. TIMING SYSTEM ................................................................... 2- 14 3. FRONT CASE ........................................................................ 2- 25 4. MAIN MOVING SYSTEM ....................................................... 2- 31 5. CYLINDER BLOCK ............................................................... 2- 41
CYLINDER HEAD ASSEMBLY
2-1
1. CYLINDER HEAD ASSEMBLY

1) LOCKER ARM & CAM SHAFT
COMPONENTS
0.5 ~ 0.7kgm 1
3 3.5 ~ 4.0kgm 4 10 6 9 8 13 1.9 ~ 2.1kgm 17 12 5 14 16 15 7
11
<Disassembly> 1. Breather hose 2. Oil filler cap 3. Rocker cover 4. Rocker cover gasket 5. Packing 6. Rocker shaft 7. Rocker arm, Intake 8. Rocker arm, Exhaust 9. Rocker shaft spring
10. 11. 12. 13. 14. 15. 16. 17.
Adjust screw Camshaft oil seal Camshaft bearing cap - Front Camshaft bearing cap No.2 Camshaft bearing cap No.3 Camshaft bearing cap No.4 Camshaft bearing cap - Rear Camshaft
KCMB800A
2-2 INSPECTION
CAMSHAFT
1. Visually inspect the camshaft journals and replace them if they are damaged and burned. If the camshaft journals have burned, check the cylinder head bearing for damage and the cylinder head oil passage for clogging.
Journal
KCMB810A
2. Measure the camshaft diameter and bearing inner diameter and if the oil clearance exceeds the limit value, replace the camshaft, cylinder head or both. Standard Limit 0.05 ~ 0.08 mm 0.13 mm
KCMB100H
3. Check the cam surface for abnormal wear or damage and replace it if required. Measure the cam height (bigger diameter) and replace it if it exceeds the limit. Standard Limit 37.05 mm 36.55 mm
ROCKER ARM
1. Check the contact surface with the cam and replace the rocker arm if it damaged and burned. 2. Visually check the inside for damage or burn and replace it if required. 3. Measure the inner and outer diameters and if the oil clearance exceeds the limit, replace the rocker arm, shaft or both. Standard Limit 0.01 - 0.04 mm 0.08 mm

ROCKER SHAFT
1. Check the oil passage for clogging and clean it if required. 2. Check the rocker arm assembly for damage or burn and replace it if required.
2-3
ASSEMBLY
CAM SHAFT
1. Measure A and B, calculate the end play, and if the value exceeds the limit, replace parts. B - A = End play Standard Limit 0.01 - 0.04 mm
A
0.08 mm
B
ECLA019C
2. Install the camshaft with the dowel pin upward to the cylinder head.
Dowel pin
Camshaft
KCMB820A
CAM SHAFT BEARING CAP

Assemble the camshaft bearing cap in sequence of the identification number engraving on the upper surface of bearing cap.
2-4
CAM SHAFT OIL SEAL
1. Using the special tool, press-fit a new camshaft oil seal to the front bearing cap portion. 2. Apply oil to the oil seal lip portion.
09221 21000 09221 --21000 Cam shaft
Oil seal
KCMB820B
ROCKER ARM (EXHAUST, INTAKE)

Take care not to make mistakes of the identification numbers.
ROCKER ARM SHAFT

1. Assemble the oil passage side shown in the illustration, facing it downward. 2. The shaft having one oil passage should be assembled in the front.
One oil passage Two oil passages
Front
KCMB820C
PACKING
Apply sealant to the marked portion in the illustration. Specified sealant 3M P/No. 8660 or equivalent
Apply sealanat
KCMB820D

ADJUSTING VALVE CLEARANCE
1. Rotate the crankshaft clockwise to align the camshaft sprocket with the timing mark.
Camshaft sprocket Timing mark
2-5
KCMB820E
2. Adjust the valve clearance at the arrow position shown in the illustration.
Ex. In.
In.
Ex.
KCMB280F
3. Loosen the adjusting screw mounting nut. 4. Adjust the valve clearance by turning the adjusting screw. Standard (Cold engine) Intake Exhaust 0.15 mm 0.15 mm
5. Fix the adjusting screw not to turn using a screwdriver and install the adjusting nut
ECLA019J
2-6
6. Rotate the crankshaft to one turn clockwise to place the cylinder no.4 to the compression dead point. 7. Follow the procedures (2), (3) and (4) to adjust the valve clearance. Standard (Hot-engine) Intake Exhaust 0.25 mm 0.25 mm
8. After installing the engine assembly to the vehicle, inspect the valve clearance with hot engine and adjust it if required.
Ex.
In. Ex. In.
KCMB280G
2-7
2) CYLINDER HEAD & VALVE

COMPONENTS
4 5 10 6 1 7 12 11 Cold engine : 10.5~11.5 kgm Hot engine : 11.5~12.5 kgm
14
13 8
[DISASSEMBLY] 1. Cylinder head bolt 2. Cylinder head 3. Cylinder head gasket 4. Valve spring retainer lock 5. Valve spring retainer 6. Valve spring 7. Spring seat 8. Intake valve 9. Exhaust valve
10. Valve stem seal 11. Intake valve guide 12. Exhaust valve 13. Intake valve seat 14. Exhaust valve
KCMB750A
2-8 DISASSEMBLY
CYLINDER HEAD BOLT
Using the special tool, Cylinder Head bolt Wrench (09221-32000), loosen 18 Cylinder head bolts and remove them. Loosen the bolts in the sequence shown and in two to three steps.
09221 - 32000
ECLA018B
6 1 5 10
14 18 13
16 12 15
8 4 7 3
17
11
KCDA052A
VALVE SPRING RETAINER LOCK

1. Using a valve spring compressor (09222 - 21000), compress the spring and fit the retainer lock in position. 2. The valve spring, if compressed excessively, causes the bottom end of retainer to be in contact with, and damages, the stem seal.
09222 - 21000
ECLA018D
INSPECTION
CYLINDER HEAD
1. Before cleaning the cylinder head, check for water and oil leaks, damage, or cracks. 2. Remove oil, scale, sealant, and carbon deposits completely. After cleaning the oil passages, apply compressed air to ensure that the passages are not clogged.

3. If there is gas leak from the cylinder head gasket surface, measure the surface flatness. If distortion exceeds the limit, replace the cylinder head. Standard value Limit L 0.05 mm less than 0.2 mm
2-9
4. Visually check the camshaft bearing internal surfaces for damage or seizure. If defects are evident, replace the bearing.
INTAKE VALVE, EXHAUST VALVE

1. If the valve stem develops wear (taper wear) or damaged, replace. If there is a dent in the stem end face (the surface in contact with the rocker arm adjust screw), replace. Contact
Margin
KCMB770A
2. Check the valve face for contact. If the contact is not proper, correct with a valve refacer. The contact pattern with the valve seat must be even at the center of valve face. 3. Replace if the margin (valve head thickness) exceeds the limit. Contact Standard value Limit 2.0 mm 1.0 mm
KCMB770A
Margin
VALVE SPRING
1. Measure the free height of spring and replace if the limit is exceeded. Standard value Limit 49.1 mm
Free height
48.1 mm
2. Measure the squareness of the spring and, if the limit is exceeded, replace.
KCMB100B
Standard value Limit
2 less than 4
2-10
VALVE GUIDE
Measure the valve guide to stem clearance and, if the measurement exceeds the limit, replace the valve guide or valve, or both. Exhaust Intake Intake Limit Exhaust 0.05 ~ 0.09 mm 0.03 ~ 0.06 mm 0.10 mm 0.15 mm
KCA9281D
Standard value
RECONDITIONING VALVE SEAT

1. When reconditioning the valve seat, inspect clearance between the valve guide and valve and replace the valve guide if required.
Special tool
2. Using the special tool or valve grinder, correct the seat width and angle to the specified value. VALVE SEAT CUTTER Cutter angle 45 65 30 Parts number 09221-43300 09221-43400 09221-43500
45 65 0.9 - 1.3 mm 65
Cutter
ECLA018E
3. Apply compound to the valve and seat.
VALVE SEAT REPLACEMENT PROCEDURE

1. Cut the valve seat to be replaced from the inside to thin the wall thickness. Then, replace the valve seat. 2. Rebore the valve seat hole in cylinder head to the oversize valve seat diameter. Intake valve seat ring hole diameter Exhaust valve seat ring hole diameter 0.30 O.S. 0.60 O.S. 0.30 O.S. 0.60 O.S. 43.300 ~ 43.325mm 43.600 ~ 43.625mm 37.300 ~ 37.325mm 37.600 ~ 37.625mm
KCMB100D
0.5 - 1mm
Cutting portion
0.5 - 1mm

3. Before fitting the valve seat, either heat the cylinder head up to approximately 250C (482F) or cool the valve seat in liquid nitrogen to prevent the cylinder head bore from abrasion. 4. After installation, recondition the valve seat.
Height of valve seat
2-11
Over size I.D.
KCMB100E
VALVE GUIDE REPLACEMEMT PROCEDURE

1. Using the push rod of Valve Guide installer (09222 - 32200) and apress, remove the valve guide forward cylinder block. 2. Rebore valve guide hole to the new oversize valve guide outside diameter. 0.05 O.S. 0.25 O.S. 0.50 O.S. 13.050 ~ 13.068 mm 13.250 ~ 13.268 mm 13.500 ~ 13.518 mm
CAUTION Do not reassemble the same size of valve guide.
3. Using Valve Guide Installer (09222-32200), press-fit the valve guide, working from the cylinder head top surface. CAUTION Take care not to change the exhaust and intake valve guides because both lengths are not equal.
Push rod Valve guide

09222 - 32200
Cylinder head
KCMB770C
Vavle guide (Intake valve)
Valve guide (Exhaust valve)
71mm
74mm
KCMB770D
2-12
4. After installing valve guides, insert new valves in them to check for sliding condition. 5. When replacing the valve guides, inspect valve contact and correct the valve seat if required.
Vavle guide (Intake valve)
Valve guide (Exhaust valve)
71mm
74mm
KCMB770E
INSTALLATION
VALVE STEM SEAL
1. Using Valve Stem Seal Installer (09222 - 32100), install the valve stem seal into the valve guide. CAUTION The valve stem seal must be not reused. The special tool must be used for the installation of the valve stem seal. Improper installation could result in oil consumption through valve guide.
Valve spring seat
09222 - 32100
KCMB780A
VALVE SPRING
Direct the valve spring end with identification color to the therocker arm.
Identification Spring
Retainer Stem seal

KCMB100F

VALVE SPRING RETAINER LOCK
Using a valve spring compressor (09222 - 21000), compress the spring and fit the retainer lock in position. CAUTION The valve spring, if compressed excessively, causes the bottom end of retainer to be in contact with, and damages, the stem seal.
2-13
09222 - 21000
ECLA018D
CYLINDER HEDA GASKET

1. Clean contact surfaces between the cylinder head and cylinder block gasket. 2. Assemble the gasket facing upward the marking portion in the illustration.
CYLINDER HEAD BOLT

1. Scrape off gasket adhered to cylinder head assembly. 2. Tighten in the numerical order indicated in the diagram in two or three groups with special tool. Specified torque
18 13 17 14 9 6 5 1 4 3 7 12 11 15 16
10
Limit Cold engine
11.5 ~ 12.5 kgm 10.5 ~ 11.5 kgm

KCMB780B
2-14
TIMING SYSTEM
2. TIMING SYSTEM
1) TIMING BELT
COMPONENTS
11 6.5 ~ 7.5kgm 2.2 ~ 3.0kgm
8 ~ 9kgm
12
5 17 ~ 19kgm 1 10 7
13
[DISASSEMBLY] 1. Crank shaft pully bolt 2. Washer 3. Crank shaft pully 4. Timing belt upper cover 5. Timing belt lower cover 6. Acess cover 7. Flange
8. 9. 10. 11. 12. 13.
Timing belt tensioner Tensioner speacer Timing belt Camshaft sprocket Injection pump sprocket Crank shaft sprocket
KCMB850A
TIMING SYSTEM
REMOVAL
TIMING BELT
1. Remove the cooling fan, water pump, crankshaft pulley and timing belt cover. 2. Turn the crankshaft to bring the piston in No. 1 cylinder to the top dead center on the compression stroke. 3. Mark an arrow on the back of the timing belt and timing belt B with a chalk to indicate the direction of rotation. This ensures that the belt is installed in the same direction for reuse.
2-15
CAUTION Stained belts with water or oils may be highly short enedtheir life. So, the removed timing belt, sprocket and tensioner should not be washed off, as well as not be stained with oils. If the belts are seriously stained, replace them.
ECLA020B
4. The piston in No. 1 cylinder is at the top dead center on the compression stroke when all timing marks at the three places are aligned as shown.
KCMB860A
5. Slightly loosen the two bolts securing the tensioner. Then, slide the tensioner toward the water pump and tighten the bolts temporarily to secure the tensioner in place.
Slide toward water pump
KCMB860B
2-16
CAMSHAFT SPROCKET
TIMING SYSTEM
1. Loosen the bolt securing the camshaft sprocket and remove the camshaft sprocket. 2. Remove the sprocket nut. CAUTION Use care not to give shock to the fuel injection pump shaft, as it could result in defective fuel injection pump. Using Injection Pump Sprocket Puller (09314 43000) or suitable tool, remove the sprocket from injection pump. 3. Remove the tensioner and tensioner spring.
KCMB860C
INSPECTION
TIMING BELT
Carefully inspect the belt and replace it with a new one if there are damages presented as below. 1. Hardened back surface of rubber Back surface is glossy, Non-elastic and so hard that, when your fingernail is pressed into it, no mark is produced.
ECA9200B
2. Cracked back surface of rubber 3. Cracked or separating canvas 4. Badly worn out teeth (initial stage)
Separation
Crack
Crack
5. Badly worn out teeth (last stage)
Crack
Crack
KCMB870A
TIMING SYSTEM
6. Side of belt cracked Normal belt should have precisely cut side as if produced by a sharp knife.
Separation Rounded belt side
2-17
Abnormal wear
KCMB100J
7. Cracked tooth bottom Initial state: Canvas worn (swollen canvas fiber, low quality of rubber, discolored with white, and bad clearness) Latter state: Canvas worn and rubber exposed (tooth width narrowed) 8. Missing tooth
Rubber exosed
Fiber exposed
KCMB100K
TIMING BELT TENSIONER

1. Check it for smooth rotation and abnormal noise and replace it if required. 2. Check it for clicking sound and rolling and replace it if required.
KCMB870B
TIMING BELT COVER

1. Check it for deformation and crack and replace it if required. 2. Check the seal for wear and damage and replace the timing belt if required.
2-18 INSTALLATION
CRANKSHAFT SPROCKET
TIMING SYSTEM
Crank shaft
1. Mount the crankshaft sprocket to the crankshaft noting the direction of the sprocket as well as the flange. 2. Mount the camshaft sprocket and tighten the flange bolts to specified torque. 3. Be careful of the flange installation direction.
Sprocket
Oil pump gear drive shaft
Sprocket B Flange
KCMB880A
TIMING BELT TENSIONER

1. Install the tensioner, tensioner spring and tensioner spacer. 2. The tensioner moved all the way to the water pump, temporarily tighten bolt. CAUTION When installing, face the short end of tensioner spring toward the water pump.
KCMB870B
TIMING BELT
1. Correctly line up timing marks on three sprockets. 2. While ensuring that the tension side of timing belt is not slack, install belt onto the crankshaft sprocket, injection pump sprocket, tensioner and camshaft sprocket, in that order.
Camshaft sprocket
Separation
Injection pump sprocket Tensioner
CAUTION When installing the belt onto the injection pump sprocket, keep the sprocket in position, as it tends to turn by itself at the timing mark alignment position. If the belt is to be reused, make sure that the arrow mark made during disassembly faces to the correct direction at reassembly.
Separation Crankshaft sprocket

KD4B2010
TIMING SYSTEM
3. Check if all timing marks are aligned correctly.
2-19
Bolt A
Bolt B
KCMB870B
4. Back off tensioner bolt A, that have previously been secured to the water pump side, one to two turns to give tension to the belt using tensioner spring tension. 5. Confirm that the timing belt is correctly engaged with three sprockets. CAUTION Turn crankshaft clockwise by the two teeth of the camshaft sprocket and keep the position.
Camshaft sprocket
Crank shaft
KCMB880C
6. Tighten bolt A. 7. Tighten bolt B. CAUTION If the bolt B is tightened first, the tensioner should be turned together, causing an undue tension to be applied to the timing belt. 8. Turn the crankshaft in the direction of backward rotation to line up timing marks. 9. In this condition, ensure that the deflection when the center of belt is pushed by the index finger. Standard 4 ~ 5 mm
Deflection
KCMB880E
2-20
FLANGE INSTALLATION
TIMING SYSTEM
Notch for timing adjustment Offset Flange
Note that bolt holes in the flange and those in the injection pump sprocket are offset positioned at one place. When assembling, position the jlange and sprocket as shown.
Sprocket
KCMB880F
TIMING SYSTEM
2-21
2) TIMING "B"
COMPONENTS
9 7 3.4 ~ 4.0kgm
3.4 ~ 4.0kgm 10 1 6
2.2 ~ 3.0kgm
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Flange Gasket Tensioner spacier Tensioner spring B Timing belt tensioner B Timing belt B Silent shaft sprocket-right Silent shaft sprocket-left Spacier Crank shaft sprocket B
KCMB900A
2-22 REMOVAL
TIMING BELT "B"
1. Remove the timing belt.
TIMING SYSTEM
2. Using chalk or the like, put an arrow on the back of the timing belt "B" to indicate the direction of drive.
ECLA021B
3. Slightly loosen the bolts and nuts securing the tensioner. Then, slide the tensioner toward the water pump and tighten the nuts to secure the tensioner in place temporarily. 4. Remove the timing belt "B". 5. Remove the crankshaft sprocket "B". 6. Remove the two silent shaft sprockets.
SILENT SHAFT SPROKCET(LEFT, RIGHT)

When loosening the nut and bolt for two silent shaft sprockets, be sure to lock the silent shaft as shown. CAUTION Water, oil, or grease on the belt shortens its life drastically. Use special care to ensure that the removed timing belt, sprockets, and tensioner are free from oil and grease.
Screw driver [shaft dia. 8 mm (0.31 in.) Wrench extension bar or similar size rod
Silent shaft, right Right side
Slient shaft, left
Remove this plugh and insert a screwdriver Remove cover and inseft bar
KCMB910A
TIMING SYSTEM
INSTALLATION
1. Mount the crankshaft sprocket "B"to the crankshaft, noting the direction of the sprocket "B".
Crank shaft
2-23
Oilpump gear drive shaft
Sprocket B
KCMB920A
2. The spacer must be installed with its chamfered end facing toward the silent shaft. If the spacer is installed in the wrong direction, damage to oil seal will result.
Spacier Silent shaft
Tapper
KCMB920B
TIMING BELT "B" TENSIONER

1. Install the tensioner spring and spacer, with the tensioner moved all the way to the water pump. 2. Tigh ten the nut. Tighten the bolt not fully put finger tight.
Water pump
Bolt
Nut
Spacier Tensioner Gasket Front lower case Tensioner spring B

KCMB920C
A-A
2-24
TIMING BELT "B"
TIMING SYSTEM
Timing mark
1. Line up timing marks on the crankshaft sprocket B, and right and left silent shaft sprockets. 2. With the timing belt B installed, ensure that its tension side is not slack. CAUTION If the belt is to be reused, make sure that the arrow mark made during disassembly faces to the correct direction at reinstallation.
Tensioner "B" Timing mark Tension Timing belt "B"
Crank shaft sprocket "B"

KCMB920D
3. With the tension side of timing belt B kept tight by pushing the slack side (indicated by A in illustration) with a finger, make sure that the timing marks are properly aligned with each other.
Timing mark Timing mark
Tension
Tension
KCMB920E
4. Back off tensioner B nut, that have previously been secured to the water pump side, one to two turns to give tension to the belt using tensioner spring tension. 5. First tighten the timing belt "B" tensioner mounting nut and then the bolt. CAUTION If the bolt is tightened first, the tension B should be turned together, resulting in reduced timing belt B tension.
Bolt Nut Tensioner spring "B"

KCMB920F
6. Ensure that the deflection is 4 to 5 mm (0.0394 to 0.1969 in.) when the belt is pushed by the index finger at the position indicated by and arrow. Belt deflection 4 ~ 5 mm
Silent
Belt deflection
Crank shaft sprocket "B"

KCMB920G
FRONT CASE
2-25
3. FRONT CASE
1) FRONT CASE, SLIENT SHAFT, OIL PAN
COMPONENTS
21 19 1.5 ~ 1.8kgm 11 3.4 ~ 4kgm 18 N 17 15 16
9 2.0 ~ 2.7kgm 20 12 14 4 19 1.2 ~ 1.5kgm 8N
13 N
21
2N 1.2 ~ 1.5kgm 7
[DISASSEMBLY] 1. Oil drain plug 2. Oil drani plug gasket 3. Oil pan 4. Oil screen 5. Oil screen gasket 6. Front upper case 7. Oil seal 8. Front upper case gasket 9. Plug Cap 10. O-ring 11. Flange bolt 12. Flange lower case 13. Flange lower case gasket 14. Front oil seal 15. Silent shaft gear cover
1 6 ~ 8kgm 0.6 ~ 0.8kgm 3
16. Silent shaft driven gear 17. Silent shaft driven gear 18. Oil seal 19. Silent shaft, right 20. Silent shaft, left 21. Bearing, rear [Remarks] Assembly is the reverse of disassembly. Do not reuse N marking parts.
KCMB150A
2-26 REMOVAL
OIL PAN
FRONT CASE
Remove the oil pan by tapping the oil pan bottom edge or drain plug with a soft hammer. CAUTION Do not insert a chisel or screwdriver between the oil pan flange and cylinder block to remove the oil pan. It may deform the oil pan flange surface.
ECLA007H
FLANGE BOLT REMOVAL

1. Remove the plug on the right side of the cylinder block.
Cylinder block right
Plug
KCMB160A
2. Insert a screwdriver (cross slotted) into the plug hole not to turn the silent shaft. 3. Remove the flange bolt.
Driver
Silent shaft right
KCMB160B
FRONT CASE
INSPECTION
SILENT SHAFT
1. The oil holes must be free from clogging. 2. Check journal for seizure, damage, and contact with the bearing. If defects are evident, replace the silent shaft, bearing, or front case assembly. 3. Check the silent shaft for oil clearance. If wear is excessive, replace the silent shaft bearing, silent shaft, or front case assembly. STANDARD VALUE Front left Front right Rear 0.02 ~ 0.6 mm 0.02 ~ 0.05 mm 0.05 ~ 0.09 mm
2-27
ECLA007K
FRONT UPPER CASE, FRONT LOWER CASE

Check them for damage and crack. Replace them if required.
OIL PAN
Check the gasket surface for deformation and replace it if required.
REPLACEMENT
SILENT SHAFT
1. Use Bearing Installer Stopper (special tool) only for removal and reinstallation of the right bearing.
09212-43300
ECLA008A
2-28
FRONT CASE
2. Using Bearing Installer Stopper and Silent Shaft Bearing Puller (09212 - 43300, 09212 - 43100), remove two rear bearings from the cylinder block.
09212 - 43100
Bearing
09212 - 43300
KCMB180B
3. Using Bearing Installer Stopper and Silent Shaft Bearing Puller (09212 - 43300, 09212 - 43100), remove two rear bearings from the cylinder block.
09212 - 43200
Bearing
09212 - 43300
Apply oil
KCMB180C
4. When press-fitting the right bearing, align the bearing oil hole with the cylinder block oil hole.
Bearing oil hole
Silent shaft bearing Plug Cylinder block Oil hole

KCMB180D
INSTALLATION
OIL SEAL
Install special tools in drive gear and apply to engine oil to drive gear shaft.
Socket
Oil seal
KCMB190A
FRONT CASE
SILENT SHAFT GEAR
1. Apply engine oil to the gear. 2. Align the mating marks on the silent shaft drive gear and driven gear and assemble them to the front lower case
Silent shaft Mating marks
2-29
KCMB190B
Front lower case
Drive gear
09222 - 43200
Oil seal
KCMB190C
FRONT LOWER CASE

When tightening the bolts, be sure to secure the silent shaft in position.
Front lower case
L = 55 L = 75 L = 25
L = 65 L = 55
L = 25 L = 65
L = bolt screw length (mm)

KCMB190D
FRONT OIL SEAL

1. Install the special tool guide to the crankshaft and apply engine oil to the outer surrounding. 2. Using the special tool, assemble the front oil seal to the case.
Crank shaft
Oil seal
Front lower case
Oil pump driver shaft
(Apply oil to outer surrounding) 09214 - 32100

KCMB190E
09214 - 32000
2-30
FLANGE BOLT
FRONT CASE
1. Insert a screwdriver (cross slotted) into the plug hole not to turn the silent shaft(right). 2. Assemble the flange bolt and tighten it to the specified torque.
KCMB190F
KCMB190G
OIL PAN
1. Remove the sealant attached in the cylinder block and oil pan gasket surface. 2. Apply sealant to the oil pan flange to the thickness of 4mm. 3. After applying sealant, assemble the oil pan and tighten the bolt to the specified torque in 15 minutes. Tightening torque 0.6 ~ 0.8 kgm
MAIN MOVING SYSTEM
2-31
4. MAIN MOVING SYSTEM

1) CRANK SHAFT & FLY WHEEL
COMPONENT
13 ~ 14 kgm 5 1
8 9
10
14 13
12 11
7.5 ~ 8.5 kgm
1. 2. 3. 4. 5. 6. 7.
Fly wheel assembly Rar plate Bell housing cover Oil sela case Gasket Oil separator Rear oil seal
8. Bearing cap 9. Crank shaft bearing-Lower 10. Crank shaft 11. Crank shaft bearing-Upper [Remarks] (1) Assembly is the reverse of disassembly (2) Do not reuse N marking parts.
KCMB200A
2-32 INSPECTION
CRANKSHAFT
MAIN MOVING SYSTEM
1. Visually inspect the journals and pins for damage and replace them if required. 2. Measure the journal O.D. and main bearing I.D. and if the clear ance exceeds the limit, replace the main bearing (and crank shaft if required). Or, grind the crankshaft to undersize and replace it with the undersize main bearing. Standard Limit 0.02 ~ 0.05 mm 0.01 mm
A 1 2 B
ECLA009B
KCMB210A
3. When grinding the crankshaft to undersize, ensure correct fillet radius dimensions in journals and pins.
2.5 mm R
2.5 mm R
2.5 mm R
KCMB210B
CRANKSHAFT OIL CLEARANCE (PLASTIGAGE METHOD)

1. Wipe crankshaft O.D. and bearing I.D. clean of oil. 2. Install the crankshaft. 3. Put a strip of Plastigage lengthwise in the center of the journal.
Plastic gauge
KCMB210C
MAIN MOVING SYSTEM

4. Replace the main bearing cap carefully and tighten bolts to specification. 5. Remove bolts and carefully remove the main bearing cap. 6. Using the scale printed on the bag of plastigage, measure the amount the Plastigage has been flattened (the widest point).
2-33
ECLA009F
CRANKSHAFT FRONT AND REAR OIL SEALS

1. Wear and damage in oil seal lips. 2. Deteriorated or hardened rubber. 3. Cracks or damage on oil seal case.
RING GEAR
1. If the ring gear teeth are worn, damaged, or broken, replace the ring gear. 2. If the teeth are damaged or broken, check the starting motor pinion. 3. To remove the ring gear for replacement, tap its outer rim one place after another. Heating the gear makes it impossible to remove. To install the ring gear onto the flywheel, heat it up to 260-280C (500-536C) : it is a shrink fit in the flywheel.
Fly wheel Ring gear
KCMB210D
FLYWHEEL
1. Visually inspect the flywheel clutch disc surface for wear and damage and replace it if required 2. If the clutch disc surface rolling exceeds the limit, replace it. Limit 0.13 mm
2-34
MAIN MOVING SYSTEM
DRIVE PLATE (AUTOMATIC TRANSAXLE)

Check the drive plate for deformation, damage and crack and replace it if required.
INSTALLATION
1. Install the upper crankshaft bearing to the cylinder block. There is oil hole in the upper crankshaft bearing. 2. Install the lower crankshaft bearings to each bearing cap and apply engine oil to the bearing surface.
Without oil hole
With oil hole
Lower bearing (No. 1. 2. 4. 5) (No. 1.2.4.5)
Upper bearing (No. 1. 2. 4. 5) Without oil hole

(No. 1.2.4.5)
Upper & lower bearning(middle)
KCMB220A
BEARING GAP
1. Install the main bearing to the cylinder block. Ensure the correct cap number and arrow mark direction.
Main bearing cap direction
Engine direction
Arrow (Display engine forward)

No.
Cap No.
KCMB220B
2. Check to ensure that the crankshaft turns smoothly and there is an adequate end play. Standard Limit 0.05 ~ 0.18 mm 0.25 mm
ECLA009J
MAIN MOVING SYSTEM

OIL SEAL CASE
Using special tool, press-fit a new crankshaft rear oil seal into the oil seal case.
2-35
09231 - 32000
KCMB210C
OIL SEPARATOR
Push oil separator into the oil seal case. Make sure that the oil hole in the separator comes at the bottom (indicated by an arrow in illustration.)
Oil hole
KCMB220C
2-36
MAIN MOVING SYSTEM
2) PISTON
COMPONENTS
6 7 8 11 9
10 5 13
12 4
[DISASSEMBLY] 1. Nut 2. Connect rod cap 3. Connect rod bearing 4. Piston & connecting rod assembly 5. Connect rod bearing 6. Bolt 7. Piston ring No.1 8. Piston ring No.2 9. Oil ring 10. Piston 11. Snapring 12. Piston rod 13. Connect rod 14. Bushing
1 4.5 ~ 4.8 kgm
[Remark] (1) Assembly is the reverse of disassembly

KCMB250A
MAIN MOVING SYSTEM

INSPECTION
PISTON
1. Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective. 2. Check that the piston pin fits in the piston pin hole. CAUTION Replace the piston and piston pin as an assembly. 3. Replace any piston and pin assembly that is defective. 4. The piston pin must be smoothly pressed by hand into the pin hole (at room temperature).
2-37
PISTON RING
1. Check each piston ring for breakage, damage and abnormal wear. Replace the defective rings. 2. When the piston requires replacement, its ring should also be replaced. Item Standard No.1 No.2 OIL No.1 No.2 OIL TC 0.056 ~ 0.076 0.046 ~ 0.066 0.02 ~ 0.065 0.15 0.15 0.1 NA 0.03 ~ 0.07 0.08 ~ 0.12 0.02 ~ 0.065
ECLA010B
imit
3. Measure the clearance between piston ring and ring home.

Piston
Thickness gauge
ECLA010C
2-38
MAIN MOVING SYSTEM
4. Place a piston ring in the cylinder bore and set it square by pushing it down with piston. Item Standard Limit No.1 No.2 OIL TC 0.30 ~ 0.50 0.41 ~ 0.54 0.25 ~ 0.45 0.8 NA 0.25 ~ 0.40 0.45 ~ 0.60 0.20 ~ 0.40
Piston ring Eng gap
KCMB260A
CONNECTING ROD BEARING

1. Check the bearing surfaces for uneven contact pattern, streaks, scratches, and seizure. If defects are evident, replace. If the surfaces are seriously nicked and seized, check also the crankshaft. If the crankshaft is also damaged, replace the crankshaft or grind to undersize for reuse.
ECLA010E
2. Measure the connecting rod bearing I.D. and crankshaft pin O.D. If the clearance (oil clearance) exceeds the limit, replace the bearing and, if necessary, the crankshaft. Or, grind the crankshaft to an undersize and, at the same time, replace the bearing with an undersize. Standard Limit 0.02 ~ 0.05 mm 0.1 mm
ECLA010F
CONNECTING ROD BUSHING

1. Pull out the bushing using the special tool.
Pull out
09214 - 43000
Pull out
ECLA010G
MAIN MOVING SYSTEM

2.. Press-fit the bushing using the special tool. At this time, align the busing with connecting rod small end oil hole.
09214 - 43000
2-39
Apply oil Align to the oil hole
Bushing Chamfer side
ECLA010H
3. Adjust the busing inner diameter within the standard values. Standard 29.015 ~ 29.025 mm
ECLA010I
CAUTION 1. Insert the piston pin, following the front mark.
Front mark
Front mark
KCMB260B
2. Install the snap ring in the following direction.
ECLA010K
2-40 INSTALLATION
MAIN MOVING SYSTEM
No. 1
PISTON RING INSTALLATION

No. 2
1. Install the oil ring expander and oil ring to the piston. 2. Then, install No.2 piston ring and No.1 piston ring, in that order. Make sure that the ring side, on which manufacturer and size marks are stamped, faces to the piston crown.
Oil
KCMB270B
PISTON & CONNECTING ROD ASSEMBLY

1. Apply engine oil to the piston surface, piston ring and oil ring. 2. Adjust gap between the piston ring and oil ring as shown in the illustration.
Upper side rail

No. 1
Piston pin
No. 2
Lower side rail

KMBC270B
3. Insert the piston and connecting rod assembly from above the top of cylinder. Ensure that the front mark on piston crown and that (ID mark) on the connecting rod face toward the front of engine (to the crank pulley side). 4. Clamp firm the piston rings with the ring band and install the piston assembly into cylinder. Do not strike it hard into the piston, as broken piston ring or damaged crank pin could result.
ECLA010N
5. When assembling, align the bearing cap with the connecting rod. If parts are new ones, align notches in the same direction. 6. Make sure the clearance of connecting rod big end side. Standard Limit 0.10 ~ 0.25 mm 0.4 mm
ECLA010O
CYLINDER BLOCK
2-41
5. CYLINDER BLOCK
1) CYLINDER BLOCK
COMPONENTS
4 ~ 5 kgm
N 2
5 ~ 6 kgm
0.5 ~ 0.7 kgm
[DISASSEMBLY] 1. Cover 2. Packing 3. Engine bracket, right 4. Engine bracket, left 5. Cylinder sleeve 6. Cylinder block
[Remarks] (1) Assembly is the reverse of disassembly (2) Do not reuse N marking parts
KCMB030A
2-42 INSPECTION
CYLINDER BLOCK
CAUTION Before inspection and repair, clean parts to remove dirt, oil, carbon, deposits, and scale. Before cleaning the cylinder block, be sure to check for evidences of water leaks and damage. Romove contaminants from oil holes with compressed air and, at the same time, make sure that they are not blocked.
CYLINDER BLOCK
1. Check for scratches, rust, and corrosion. Use also a flaw detecting agent for the check. If defects are evident, correct or replace. 2. Using a straightedge and thickness gauge, check the cylinder block top surface for flatness. Lay the straightedge longways and crossways as indicated by A, B,... in illustration. If flatness is not within the limit, replace the cylinder block. At measurement, ensure that the cylinder block top surface is free from any traces of gasket material. Standard Limit 0.05 mm 0.1 mm
A B
E F G
ECLA007B
3. Check cylinder wall for scratches and seizure. If defects are evident, correct (to oversize) or replace.
4. Using cylinder gauge, measure the cylinder bore. If it wears out excessively, bore the cylinder to oversize and replace the piston and piston rings. Measurement points are as shown. Standard 91.10 ~ 91.13 mm
Middle Bottom
KCMB040A
CYLINDER BLOCK
BORING OF CYLINDER
1. Using the maximum cylinder bore as a basis, determine the oversize piston to be used. There are four oversize pistons available : Size 0.25 mm(0.01 in.) O.S. 0.50 mm(0.02 in.) O.S. 0.75 mm(0.03 in.) O.S. 1.00 mm(0.04 in.) O.S. Identification mark 0.25 0.50 0.75 1.00
2-43
CAUTION Sizes are marked on the pistons.
2. Based on the piston O.D. measured, calculate the boring dimension. Boring dimension Piston O.D. + 0.04 to 0.06 mm (piston to cylinder clearance) - 0.02 mm (0.0008 in.) (honing margin).
Piston O.D.
4. Bore cylinders to obtain the calculated boring dimension.

KCMB040B
CAUTION To prevent thermal distortion due to temperature rise during boring operation, bore cylinders in the sequence of No. 2, 4, 1 and 3.
5. The cylinders must be honed to finish dimension. 6. Check clearance between piston and cylinder. TC Clearance 0.02 ~ 0.08 mm 0.03 ~ 0.05 mm NA
CAUTION 1. When boring cylinders, finish all of four cylin ders to the same oversize. 2. Don't bore only one cylinder to oversize.
2-44
CYLINDER BLOCK
2) REPLACING CYLINER SLEEVE

REMOVAL
1. Fix the cylinder block with a boring machine before centering. Centering should be done in the lower part of the cylinder sleeve where has little abnormal wear. 2. Bore the sleeve until the thickness is 0.5mm.
KD4B2001
Face the rounded side toward the block
Thin cylinder sleeve
3. Insert the processed screwdriver as shown in the illustration between the cylinder sleeve and cylinder block and remove the cylinder sleeve by tapping on the screwdriver slightly. Be careful not to damage the cylinder block wall.
Attach a round piece to the screwdriver
P
KD4B2002
INSPECTION
1. After removing the cylinder sleeve, inspect the cylinder block sleeve hole surface. 2. If there are damages, scuffing, abnormal wear and other defects, bore the cylinder block sleeve hole to oversize.
3. Measure the cylinder sleeve O.D. and cylinder block sleeve hole I.D. with a gauge placed as shown in the illustration. Measure D1, D2 and D3 in the directions of X and Y and if the average value is below 0.12mm, bore the sleeve hole to 0. 5mm oversize and press-fit the oversized sleeve into the sleeve hole. CAUTION Be sure when boring the cylinder, all sleeves should be removed from all cylinders not to make mistakes during rounding.
Y direction Xdirection
12mm Middle Bottom
D1 D2 D3
KD4B2003
CYLINDER BLOCK
PRESS-FIT
1. Without boring cylinder block sleeve hole 1) Apply press oil to the cylinder block sleeve hole surface and sleeve outer surface. 2) Put a flat rounded plate on the sleeve top end and pressfit it with a hydraulic press. Press-fit load 2200kg or more
Cylinder sleeve Hydraulic press
2-45
KD4B2004
3) Press-fit the sleeve until the sleeve top end surface is flush with the block top surface. Press-fit it toward the chamfer as shown in the illustration.
Upper part Lower part
KD4B2005
4) To prevent the cylinder sleeve and cylinder block top surfaces from roughness and bump, cut the cylinder block top surface. Difference between them should be '0' as possible. (The limit: 0.2mm)
No slice
Cylinder sleeve
Cylinder block
KD4B2006
5) Chamfer the cylinder sleeve top end as shown in the illustration.
1mm
Cylinder sleeve
30
KD4B2007
2-46
CYLINDER BLOCK
6) Cylinder sleeve I.D. is processed with 90.08~90.10mm, after press-fitting the sleeve, hone the bore to be within the standard value. Cylinder bore Honing surface formation Honing rendering angle (Cross-hatch) Cylinder bore perpendicularity 91.10~91.13mm 2~4 15~25 0.05mm
2. Boring cylinder sleeve hole 1. Prepare a 0.5mm oversized cylinder sleeve. 2. Hone the cylinder block sleeve hole to 94.025~94.050mm. 3. Press-fit the cylinder sleeve and render the bore. For press-fit and process procedures, refer to "Without boring block sleeve hole".
INSPECTION AFTER ASSEMBLY

1. After assembling the crankshaft and piston, inspect protrusion of the piston. If the protrusion is out of the limit, replace the piston inserted into thin one to be the protrusion within the limit. 2. After procedure 1, if the protrusion is not within the limit, replace the cylinder block. Limit 1.1 mm
Protrusion
Piston
Cylinder block
KD4B2008
CHAPTER 3. LUBRICATION
1. OIL FILTER ............................................................................ 3- 1 2. OIL PAN ................................................................................. 3- 5 3. OIL PUMP .............................................................................. 3- 7
OIL FILTER
3-1
1. OIL FILTER
COMPONENTS
1 1.2 ~ 1.5 kgm
4 3.0 ~ 4.5 kgm
2 5.0 ~ 6.0 kgm
3 0.8 ~ 1.2 kgm
[DISASSEMBLY] 1. Oil filter 2. Oil cooler by - pass valve 3. Oil pressure switch 4. Joint 5. Tapper plug 6. Oil filter bracket 7. Check valve 8. Gasket 9. Oil jet 10. Gasket [Remarks] (1) Assembly is the reverse of disassembly (2) Do not reuse N marking parts
10 9 8 7 3.0 ~ 3.5 kgm
KCUB050A
3-2 REMOVAL
OIL PRESSURE SWITCH
OIL FILTER
09260 - 32000
To remove the oil pressure switch, use Oil Pressure Switch Wrench (09260 - 32000). CAUTION During removal, use care to prevent damage to the sealant applied to threads.
ECLA013B
INSPECTION
OIL FILTER BRACKET
1. The oil filter mounting surface must be free from damage. 2. Check for cracks and oil leaks.
OIL PRESSURE SWITCH

1. Connect a tester ( range) between the terminal and the body of the switch to check for continuity. The switch is normal if there is continuity. If there is no continuity, replace the switch.
ECLA013C
2. Insert a thin rod in the oil hole of the switch and push it in lightly. The switch is normal if no continuity is detected (infinite resistance on the tester). If there is continuity, replace the switch.
Thin rod
KCDA052A
OIL FILTER
3. Apply a 0.5 kg/cm2 pressure to the oil hole. The switch is normal if there is no continuity. Also check for air leaks. If any air leaks are detected, the cause may be a broken diaphragm. Replace the switch if it leaks.
3-3
OIL JET, CHECK VALVE

1. Check the oil jet and check valve for clogging. 2. Check the oil jet for damage and deformation.
Engine oil
Oil jet Check valve assembly

KCMB520A
OIL COOLER BYPASS VALVE

1. Ensure that the dimension L measures the standard value under normal temperature and humidity. Dimension L 34.5mm
L
Valve
2. The dimension must be the standard value when measured after the valve has been dipped in 100C. Dimension L 40mm
KCMB520A
3-4 INSTALLATION
OIL JET
OIL FILTER
There are two types of oil jets installed: one for No. 1 and 3, and the other for No. 2 and 4. Make sure that the correct one is installed with correct direction as shown.
Oil jet (No.1, 3)
No.1.33 No.1, Cylinder
No.2, 4 No.2.4 Cylinder
Oil jet (No.2, 4)
Cylinder block knock pin Check valve Oil jet
KCMB530A
OIL JET SWITCH

1. Before installation, apply sealant to the switch threads. CAUTION The sealant must not get into the thread top surface. Use care not to torque excessively.
OIL FAN
3-5
2. OIL PAN
COMPONENTS
3.5~4.5 kg m
1 2
0.6~0.8 kg m
1. 1. 2. 3. 4. Drain plug Oil pan Oil screen Gasket

KD4B3001
3-6 REMOVAL
OIL FAN
OIL FAN
When the oil pan is stuck with the gasket, remove it by tapping the drain plug downward with a plastic hammer or equivalent.
KD4B3002
INSTALLATION
OIL FAN
1. Remove the gaskets attached in the oil pan and cylinder block using a scrapper, wire brush, etc.
KD4B3003
2. Cut the nozzle attached to the liquefied gasket as shown in the illustration. The liquefied gasket comes out with 4mm diameter. Semi-dry sealant MZ 100080 THREEBOND TB1212
Cutting part
KD4B3004
3. Squeeze the liquefied gasket from the tube and apply it to the oil pan as shown in the illustration.
Apply sealant
4mm Diameter Bolt hole

KD4B3005
OIL PUMP
3-7
3. OIL PUMP
COMPONENTS
7 6 7 4 3.0 ~ 4.5 kgm
0.9 ~ 1.4 kgm
1 2 3 8
1. Oil pump cover 2. Oil pump outer gear 3. Oil pump inner gear 4. Plug 5. Gasket 6. Relief plunger 7. Relief spring 8. Oil pump case [Remark] Do not reuse N marking parts.
KCMB550A
3-8 DISASSEMBLY
OIL PUMP
Inner rotor Marking
Before removing the oil pump outer and inner gears, mark the outer gear to make sure that it goes back to the position with correct direction.
Outer rotor
KCMB560A
INSPECTION
OIL PUMP ROTOR
1. Install the outer and inner gear into the front case and make sure that they turn smoothly with no excessive play between them. 2. Check the side clearance (the front case and oil pump cover surface). Standard Limit 0.04 ~ 0.10 mm 0.15 mm
3. Measure the body clearance and if the measure value ex ceeds the limit, replace the gear or case. Item Inner rotor Outer rotor Standard 0.22 ~ 0.35 mm 0.12 ~ 0.22 mm Limit 0.5 mm 0.4 mm
4. Check the oil pump cover rotor contact surface for wear and if there is bump, replace the cover. (If the individual part is not available, replace it as an oil pump case assembly).
OIL PUMP
INSTALLATION
OIL PUMP INNER ROTOR/OIL PUMP OUTER ROTOR
1. Apply engine oil to all rotor surfaces.
3-9
2. Install the gear in the same direction as markings represented during disassembly.
Inner rotor Marking
Outer rotor
KCMB560A
3. When air pressure of 0.5kg/cm is applied to the oil hole, if there is no continuity, it is normal. If air leakage is detected, replace the switch because the dia phragm may be damaged.
OIL JET, CHECK BELT

1. Check the oil jet and check valve for clogging. 2. Check the oil jet nozzles for damage or deformation.
3-10
OIL PUMP
OIL COOLER BYPASS VALVE

L
1. Standard value of 'L' at room temperature. Standard 34.5mm
2. Limit value of 'L' after coming out from oil of 100C.

KCMB580B
Limit
40mm not less than
CHAPTER 4. COOLING SYSTEM
1. WATER PUMP & WATER PIPE ............................................ 4- 1 2. RADIATOR FAN MOTOR ...................................................... 4- 4 3. THERMOSTAT ...................................................................... 4- 8 4. RADIATOR ............................................................................ 4- 10
WATER PUMP & WATER PIPE
4-1
1. WATER PUMP AND WATER PIPE

COMPONENTS
10 1.2 ~ 1.5 kgm 11 9 3.0 ~ 4.0 kgm
14 2.0 ~ 2.5 kgm 6 1.0 ~ 1.3 kgm 7 8 12 13
1.2 ~ 1.5 kgm
[DISASSEMBLY] 1. Drive belt (V belt) 2. Cooling fan 3. Fan clutch 4. Water pump pully (Power steering pump pully adhere) 5. Water pump pully 6. Water inlet fitting 7. water inlet fitting gasket 8. Thermostat 9. Coolant temperature gauge unit 10. Water inlet pipe 11. O-ring 12. Water pump 13. Water pump gasket 14. Thermostat assembly
1.0 ~ 1.2 kgm
[Remarks] (1) Assembly is the reverse of disassembly (2) Do not reuse N marking parts
KCMB300A
4-2 INSTALLATION
DRIVER BELT
Inspect the following items and replace them if required. 1. Loose belt 2. Damage, crack, and wear
WATER PUMP & HOSE

1. Water pipe for crack, damage and clogging 2. Water hose for crack, damage and clogging
WATER PUMP
Check each part for cracks, damage or wear, and replace the water pump assembly if necessary. 1. Coolant leaks 2. Coolant leaks from A 3. Water pump body for damage and crack 4. Impeller for damage and crack 5. Bearing for damage
A
ECLA011B

ASSEMBLY
WATER PUMP
1. Clean the gasket contact surfaces inserting between the water pump and cylinder block.
1 d
4-3
2. Bolt sizes are as below. No 1 2 3 Hardness category 4T 4T 7T dx1 4T 4T 7T Torque 1.2~1.5 kgm 1.2~1.5 kgm 2.0~2.7 kgm
Indication for hardness category
L(Length) L
KCUB040A
WATER PIPE & O-RING

1. Fit water pipe O-ring in the groove provided at water pipe end, wet the periphery of water pipe O-ring and insert water pipe. CAUTION Do not apply oil and grease to water pipe O-ring.
O-ring
KCMB320B
4-4
RADIATOR PAN MOTOR
2. RADIATOR PAN MOTOR

COMPONENTS
0.3 ~ 0.7 kgm
1.0 ~ 1.2 kgm
0.3 ~ 0.7 kgm
1.0 ~ 1.2 kgm
[DISASSEMBLY] 1. Radiator upper shroud 2. Cooling fan 3. Cooling fan clutch [Remark] (1) Assembly is the reverse of disassembly
KCMB420A
RADIATOR PAN MOTOR

INSPECTION
COOLING FAN
1. Check the blades for damage and cracks. 2. If any portion of fan is damaged or cracked, replacecooling fan.
4-5
FAN CLUTCH
1. Check the case joint and seal for oil leakage from the pan clutch. 2. Oil leakage may cause overheating the engine resulting from the pan speed decrease. 3. Check the bimetal strip for damage
Bimetal
KCMB430A
4-6 COMPONENTS
RADIATOR PAN MOTOR
2 (1.0~1.2 kgm)
1 (1.0~1.4 kgm)
[DISASSEMBLY] 1. Whter temperature gauge unit 2. Thermo switch (113C) (For A/C equipped vehicle)
KCMB450A
RADIATOR PAN MOTOR

INSPECTION
WATER TEMPERATURE GAUGE UNIT
1. Put the sensor in water and increase the water temperature measure the resistance.
4-7
ECLA012E
2. If the measurement radically deviates from specification, replace. 3. Measure the resistance across terminal (A) and body for water temperature gauge element and across terminal (B) and body for glow control element. Standard Terminal (A) (For coolant temp) Terminal (B) (For preheat plug) 0.4 / 70C 23.8 / 115C 24.8 / -20C 3.25 / 20C
KCMB460A
Terminal (A)
Terminal (B)
THERMO SWITCH (FOR A/CON)

1. After inserting the coolant temperature switch into oil, heat the oil. 2. Check that the coolant temperature switch is turned OFF when the oil temperature reaches the standard. Standard Coolant temperature at A Coolant temperature at B 113 3C
ECLA012G
106C
CAUTION Only engine oil is available and stir the oil during heating. Do not overheat.
4-8
THERMOSTAT
3. THERMOSTAT
COMPONENTS
2 3 N6
4 7 9 10 N 11 12
4 N8 9 12
1.1 kgm 1.2~1.5 kgm 2.4 kgm N5
1.2~1.5 kgm 1.2~1.5 kgm 2.4 kgm 1.2~1.5 kgm
[THERMOSTAT DISASSEMBLY] 1. Radiator lower hose 7. Water inlet fitting 8. Gasket 9. Themostat
[WATER PUMP DISASSEMBLY] 1. Radiator lower hose 2. Power steering oil hose 3. Power steering oil pump bracket 4. Water pump & thermostat 5. Water pump gasket 6. O-ring 10. Thermostat housing 11. Thermostat housing gasket 12. Water pump
KCUB040C
THERMOSTAT
INSPECTION
1. Check that valve closes tightly at room temperature. 2. Check for defects or damage.
4-9
3. Immerse thermostat in container of water. 82 Opening valve temperature 76.5 2C 2C

Water temperature gauge
KCMB310A
ASSEMBLY
Assemble the thermostat in the direction shown in the illustration.
Thermostat brush
Thermostat housing
Thermostat
KCUB040E
4-10
RADIATOR
4. RADIATOR
COMPONENTS
1 5 0.8 ~ 1.1 kgm 3
7 6
0.3 ~ 0.7 kgm
4 9 2
0.8 ~ 1.1 kgm 0.8 ~ 1.1 kgm 8
[DISASSEMBLY] 1. Radiator cap 2. Drain plug 3. Over flow tube 4. Reserve tank 5. Radiator upper hose 6. Radiator lower hose
7. Radiator upper shroud 8. Radiator lower shroud 9. Radiator [Remark] (1) Installation is the reverse of removal.
KCMB400A
RADIATOR
INSPECTION
1. Check between the radiator pins for foreign material. 2. Check the radiator pins for bending or damage. 3. Check the radiator for contamination, damage or rust. 4. Check the radiator hose for crack, damage or deformation. 5. Check the reservoir tank for damage. 6. Check the radiator cap spring for damage. 7. Check the radiator cap packing for damage or crack.
4-11
CHAPTER 5. INTAKE AND EXHAUST SYSTEM
1. INTAKE AND EXHAUST MANIFOLD ................................... 5- 1 2. TURBO CHARGER (TC)....................................................... 5- 3 3. AIR CLEANER ...................................................................... 5- 8
INTAKE AND EXHAUST MANIFOLD
5-1
1. INTAKE AND EXHAUST MANIFOLD

COMPONENTS
6.0 kgm
1 5
6.0 kgm 4 6
6.0 kgm 3
1. 2. 3. 4. 5. 6. 7.
Exhaust fitting Gasket Oil return pipe Oil return pipe gasket Exhaust manifold Turbo charger gasket Turbo charger assembly
KCMB600A
5-2 ASSEMBLY
TURBO CHARGER ASSEMBLY
Remove the heat protector.
INTAKE AND EXHAUST MANIFOLD
CAUTION Be careful of foreign material not to come in the oil passage during cleaning.
ECLA015C
EYE BOLT
Before installing the oil pipe eyebolt (turbocharger upper part), fill the turbocharger with clean engine oil. After full filling, check that the turbine and compressor wheel are rotating smoothly.
ECLA015D
TURBO CHARGER [TC]
5-3
2. TURBO CHARGER (TC)

COMPONENTS [D4BF]
3 0.4 ~ 0.5 kgm 2.9 ~ 3.6 ft.lbs.
[DISASSEMBLY] 1. Hose clip 2. Hose 3. Coupling 4. Turbine housing 5. Snap ring 6. Compressor cover 7. O-ring 8. Cartridge assembly
KCUB060A
5-4 DISASSEMBLY
TURBINE HOUSING
TURBO CHARGER [TC]
Before removal, make the mating mark on compressor cover bearing housing and turbine housing. CAUTION Be sure not to damage the compressor and turbine wheel blade.
Mating mark
KCMB660A
SNAP RING
Remove the snap ring using snap ring filler. Snap ring
KCLA016C
CARTRIDGE ASSEMBLY
Remover by tapping the compressor cover of cartridge assembly with plastic hammer. NOTE O-ring installed around the cartridge assembly may cause tight installation sometimes. CAUTION Use a heavy duty carbon solvent to loosen the carbon from the parts. Do not use caustic solutions, wire brushes, or wire wheels to remove carbon deposits from any turbo charger part.
Cartridge assembly
KCMB660C
TURBO CHARGER [TC]

INSPECTION
TURBINE HOUSING
1. Check the inner housing contacting turbine wheel for crack, pitching and other damages caused by overheat. Contacting surface
5-5
KCMB670A
2. Make sure that the waste gate valve lever operates freely by hands.
COMPRESSOR COVER
Make sure there are no damages on the inner housing surface contacting compressor wheel.
C ARTRIDGE ASSEMBLY
1. Turbine wheel and shaft assemblies with cracks in the blades or broken blades can not be used again. If the blades are slightly bent, it can be used again but severely bent blades can not be reused. 2. Check if there are foreign materials disturbing the oil flow in the oil passage of cartridge assembly.
KCMB670B
Compressor Oil passage Turbine wheel wheel
OIL PIPE AND OIL RETURN PIPE

Check the oil pipe and oil return pipe for clogging and deformation. Repair or replace them if required.
5-6
WASTE GATE INSPECTION
TURBO CHARGER [TC]
Check the waste gate rod operation under the pressure below. Pressure TCI engine Approx. 0.80kg/cm2
ECLA016J
ASSEMBLY
O-RING ASSEMBLY
Apply engine oil to the new O-ring thinly and assemble the cartridge assembly. O-ring CAUTION Take care not to damage the O-ring.
KCMB670C
COMPRESSOR COVER/CARTRIGE ASSEMBLY

1. Install the cartridge assembly to the compressor cover with them mating as marked when disassembling. 2. When replacing it with a new one, install it as shown in the left illustration. CAUTION When installing the cartridge assembly to the compressor cover, take care not to damage the compressor wheel blade. Mating mark
KCMB670D
SNAP RING
Install the snap ring with the compressor cover downward. CAUTION Install the snap ring with the chamfer upward.
Snap ring
Chamfer
Cartridge assembly
Compressor cover
KCMB670E
TURBO CHARGER [TC]

TURBINE HOUSING
Install the cartridge assembly to the compressor cover with them mating as marked when disassembling. CAUTION Take care not to damage the compressor wheel blade.
5-7
5-8
AIR CLEANER
3. AIR CLEANER
COMPONENTS
Case assembly
Air cleaner element
Wirng nut Air cleaner cover assembly Dust pan assembly

T : 0.15 ~ 0.25
kgm TORQUE : kgcm
KCYB720A
CHAPTER 6. ENGINE ELECTRICAL
1. GENERAL ............................................................................. 6- 1 2. SPECIFICATIONS ................................................................. 6- 2 3. SERVICE SPECIFICATIONS ................................................ 6- 3 4. TIGHTENING TORQUE ......................................................... 6- 3 5. TROUBLESHOOTING .......................................................... 6- 4 6. ALTERNATOR....................................................................... 6- 11 7. STARTER MOTOR ................................................................ 6- 17 8. GLOW PLUG......................................................................... 6- 26
ENGINE ELECTRICAL SYSTEM
6-1
1. GENERAL
STARTER MOTOR
Starter motor is a reduction drive type.
KD4B6001
ALTERNATOR
Alternator is electronic voltage regulator built-in type.
KD4B6002
6-2 GLOW PLUG

Glow plug uses AGS.
Coil
Identification mark
AGS
KD4B6003
2. SPECIFICATIONS
ALTERNATOR
Item Type Rated output Motor speed Voltage regulator type Regulator setting voltage Temperature compensated Specification Battery voltage sensing 12V / 50A 1,000 ~ 10,000 rpm Electronic voltage regulator, with vacuum pump 14.4 0.3V -10 3 mV/C Remark
STARTER MOTOR
Item Output 24V / 5KW (Bus aircon) Number of pinion teeth No-load characteristics Terminal voltage Amperage 13 11V 30A Specification 12V / 2.2KW (Generator, Excavator, Loader) Remark
GLOW PLUG
Item Identification mark Type Auto glow Y-115T Sheathed type
6-3
3. SERVICE SPECIFICATIONS
ALTERNATOR
Item Brush length Slip ring O.D. Rotor coil resistance (at 20C) 33mm 2.75 0.2 Standard Limit Wear limit 32.2mm
STARTER MOTOR
No-load characteristics voltage (Bus aircon) Amperage (Bus aircon) Revolution number (Bus aircon) Pinion gap Commutator O.D. Undercut Outer round Brush length 11V (23V) 130A (95A) 4500rpm (3300rpm) 0.5~2.0mm 29.4mm 0.5mm 0.05mm 28.4mm 0.2 mm 0.1mm Wear limit
GLOW PLUG
0.5 (Generator, Excavator, Loader) Resistance AGS 10 (Bus aircon)
4. TIGHTENING TORQUE
Item Lock bolt Generator support bolt nut Eye bolt Starter motor attaching bolt Glow plug Glow plug plate attaching nut Torque (kg.m) 1.2 ~ 1.5 2.0 ~ 2.5 1.4 ~ 1.9 2.7 ~ 3.4 1.5 ~ 2.0 0.1 ~ 0.15 Remark
6-4
5. TROUBLESHOOTING
STARTING SYSTEM
Trouble symptom Starter spins but engine will not crank Probable cause Starter motor faulty Remedy After removing the starter motor, check the drive for crack and wear Replace flywheel ring gear or torque converter Engine will not crank Battery cables loose, corroded or worn out Battery charge low Cables loose or cables wear Starter motor faulty Engine cranks slowly Battery cables loose, corroded or worn out Battery charge low Starter motor faulty Repair or replace cables Charge or replace battery Tighten or replace cables Repair or replace starter motor Repair or replace cables Charge or replace battery Repair or replace starter motor
Flywheel ring gear teeth broken
CHARGING SYSTEM
Trouble symptom Low battery Probable cause Wiring connection loose Overload Remedy Tighten loose connections Check and remove the accessories if required Replace battery Repair or replace Replace voltage regulato Check the battery or replace, if necessary
Worn battery Generator faulty Electronic voltage regulator faulty Battery faulty

GLOW CONTROL SYSTEM
Trouble symptom Engine will not start below 50C Probable cause Wiring connection loose or bad wiring ECT sensor malfunction Glow plug malfunction Glow plug control unit failed After first combustion, engine stall or rough idle below 50C Wiring connection loose or bad wiring Glow plug malfunction Remedy Repair or replace wiring Replace ECT sensor Repair or replace glow plug Replace glow control unit Repair or replace wiring
6-5
Check the resistance of glow plug and replace, if necessary Check the relay and replace, if necessary Check the control unit and replace, if necessary Replace lamp Repair or replace wiring Repair or replace wiring Replace control unit, if necessary
Glow plug relay malfunction Glow plug control unit failed Yellow glow lamp will not turn-ON
Open lamp Wiring connection loose or bad wiring Shorted wiring Glow plug control unit failed
6-6
VEHICLE INSPECTION
SPECIFICATIONS
B Diode trio L L R R D.Power transistor Starter coil F C D Field coil Tr E Voltage regulator R Battery R Charge lamp
Alternator
KD4B6004
NOTE Register with diode According to battery voltage detective type alternator adoption, when the charge warning lamp is short, to get the charging function, the continuity circuit of the L terminal (field coil) is installed parallel with the circuit of the charge warning lamp.

INSPECTION
Check the following items before inspecting voltage regulator adjusting voltage alternator output current. 1. Alternator installation 2. Alternator drive belt tension 3. Battery specific gravity and voltage 4. Fusible link 5. Abnormal noise from alternator durng operation NOTE Use fully charged battery to obtain the standard value.
6-7
PREPARATION
1. Turn ignition switch to "OFF." 2. Disconnect the battery ground cable. 3. Connect a digital voltmeter between the "S(L)" terminal of the alternator and ground. Connect the (+) lead of the voltmeter to the "S(L)" terminal of the alternator. Connect the (-) lead to good ground or the battery (-) terminal. 4. Disconnect the alternator output wire from the generator "B" terminal. 5. Connect a DC ammeter (0 to 100A) in series between the "B" terminal and the disconnected output wire. Connect the (-) lead wire of the ammeter to the disconnected output wire. 6. Attach the engine tachometer and connect the battery ground cable.
REGULATED VOLTAGE TEST

1. Set the special tool wiring connector, voltmeter and ammeter as following.
Load Ignition switch(IG)
Alternator
Red
Yellow
Battery Voltmeter Amperemeter
Regulated voltage test

KD4B6005
6-8
2. Check as the following procedures. No. 1 Check item Voltage between L terminal and earth
Operation Ignition switch: OFF Ignition switch: ON
Determination Normal 0V Abnormal Voltage arises
Cause Abnormal wiring or alternator
Remedy Correct wiring or repair alternator
2~5V
0V Battery voltage Faulty ALTR Shor t wiring or fusable link Repair ALTR Correct wiring or replace fusable link
Voltage between S terminal and earth
Ignition switch: OFF Ignition switch: ON
Battery voltage
0V
Voltage between S terminal and earth (regulator adjust voltage)
Run the engine and keep the engine at 2000~3000rpm.
14.4 0.5V (At 20C)
Highly exceed the standard value Below the standard value
Abnormal IC regulator If the output current is 5A or more If the output current is 5A or less, the alternator is abnormal.
Repair ALTR
fully charge the battery.
Repair ALTR
NOTE Adjust voltage becomes slightly low in proportion to the output current, so it is inspected with low output current (approx. 5A or less) of IC regulator. Adjust voltage varies according to the IC regulator surrounding temperature, so refer to the characteristics as shown in the left figure. If the battery may be discharged or the head lamp is overloaded, the current reads 5A or more. Recheck the battery lamp this time.
16
Adjust voltage V
14.6V
15 14 13 25C -40 -20 0 20 40 60 80 IC regulator surface temperature(C)

KD4B6006
14.0V

CURRENT OUTPUT TEST
1. Remove battery ground cable. 2. Remove alternator outlet line from alternator "B" terminal. Connect 0-100A test ammeter DC between "B" terminal and remove outlet line in series. 3. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. 4. Attach an engine tachometer. 5. Check that the values on voltmeter and battery are the same. 0V is caused by a disconnected wire between the alternator "B" terminal and battery (+), or a blown fusible link, or defective ground. 6. With headlamp switch ON, start engine. Set headlamps at high beam and heater blower switch to HIGH. Increase engine speed to 2500 rpm and read the maximum output current on the ammeter. Limit 70% of nominal output current
Battery
80A 30A
6-9
Load
Ignition switch
Charge warning lamp
L S B
Relay with diode
Voltmeter
Amperemeter
KD4B6007
NOTE Read the maximum value quickly as charged current drops repidly. Nominal output current value is indicated on a plate on the alternator. 7. The value on the ammeter should be over the limit value. When the value is under the limit and the alternator outlet wiring [between alternator "B" terminal and battery (+) terminal] is normal, remove the alternator for inspection.
NOTE Having headlamps on when checking alternator output current increases the load. Standard current is generated at low speed of alternator. However, output current is stabilized at about 4000rpm alternator speed. Therefore, the output current at 2500 rpm engine speed exceeds the standard value, and the alternator can be considered as near normal. 8. Alternator output current changes due to load. Therefore, the standard output current may not be obtained due th small electric load despite the charging system being normal. In this case, increase the load and recheck.
6-10 RESULT
1. After output current test, bring engine speed to idle. Turn ignition switch OFF. 2. Remove battery ground cable. 3. Remove ammeter, voltmeter and engine tachometer. 4. Connect alternator output line to alternator "B" terminal. 5. Connect battery ground cable.
6-11
6. ALTERNATOR
COMPONENTS
4 5 1
T=1.2~1.5 kgm
T=2.0~2.5 kgm
1. 2. 3. 4. 5.
Lock bolt Nut Support bolt Alternator assembly Alternator brace

KD4B6008
INSTALLATION
ALTERNATOR ASSEMBLY
1. For belt tension, refer to Chapter 5 Engine-Service adjustment procedures.
6-12 COMPONENTS
4 2 5
6 8 7
1 13
3 11 10
12
[DISASSEMBLY] 1. Pulley 2. Fan 3. Seal 4. Rotor & fan assembly 5. Rear bearing 6. Bearing retainer 7. Front bearing 8. Front bracket 9. Stator assembly 10. Plate 11. Regulator & brush holder 12. Rectifier assembly 13. Rear bracket
[Remarks] Assembly is the reverse of disassembly

KD4B6009

DISASSEMBLY
FRONT BRACKET
1. With a screwdriver blade inserted between the front bracket and stator core, pry it to separate the stator and the front bracket. 2. If they are hard to separate, lightly strike the bracket with a plastic hammer while prying with the screwdriver.
6-13
KD4B6010
CAUTION Do not insert the screwdriver too deep as the stator core could be damaged.
STATOR ASSEMBLY, RECULATOR AND BRUSH HOLDER

1. When removing the stator, unsolder the three stator leads from the main diodes. 2. When removing the rectifier from the brush holder, unsolder two soldered points. CAUTION When soldering or unsoldering, use care not to expose the diode to soldering iron heat for extended time. Complete soldering or unsoldering in as short a time as possible. Do not overstress the diode leads.
Rectifier
Soldering
Plate "L"
Plate "B"
KD4B6011
6-14 INSPECTION
ROTOR
1. Check the rotor coil continuity. Make sure that there is continuity between slip rings. Measure the rotor resistance. If it is excessively small, it indicates a shorted rotor, If without continuity or shorted, replace the rotor assembly. Standard value 3 - 5 ohms
KD4B6012
2. Check the rotor coil grounding. Make sure that there is no continuity between the slip ring and core. Replace the rotor assembly if there is continuity.
KD4B6013
STATOR
1. Check the stator continuity. Make sure that there is continuity between coil leads. Replace the stator assembly if there is no continuity.
KD4B6014

2. Check the coil grounding. Make sure that there is no continuity between the coil and core. Replace the stator assembly if there is continuity.
6-15
KD4B6015
RECTIFIER
1. Inspection of (+) Heat Sink Assembly Using a circuit tester, check continuity between the (+) heat sink and the stator coil lead connection terminals. If there is continuity in both directions, the diode is shorted. Then, replace the rectifier assembly.
KD4B6016
2. Inspection of (-) Heat Sink Assembly Check continuity between the (-) heat sink and the stator coil lead connection terminals. If there is continuity in both directions the diode is shorted. Then, replace the rectifier assembly.
KD4B6017
3. Inspection of Diode Trio With a circuit tester connected to both ends of each diode, check continuity of the three diodes. If there is continuity or no continuity in both directions, the diode is damaged. Then, replace the rectifier assembly.
KD4B6018
6-16
BRUSH
1. The brush must be replaced if worn to the wear limit line.
Wear limit line

KD4B6019
2. Unsolder the brush lead wires, and the brush and spring will come out.
Solder
KD4B6020
3. When installing a new brush, push the brush into the holder as illustrated and solder the leads. 04570
3314
KD4B6021
REASSEMBLY
ROTOR ASSEMLY
1. Before installing the rotor on the rear bracket, thread a steel wire through the small hole provided in the rear bracket to lift up the brush. After rotor installation, remove the steel wire.
Brush
Rear bracket Wire
KD4B6022
6-17
7. STRATER MOTOR
COMPONENTS
1. Starter motor 2. Nut 3. Bolt
3
KD4B6023
REMOVAL
Remove the starter at the engine room lower portion.
S Battery M B
INSPECTION
PINION GAP ADJUSTMENT
1. Disconnect the field coil wire from the terminal M of the magnetic switch. 2. Connect at 12V battery the terminal S and the terminal M. CAUTION This test must be performed quickly within 10 seconds to prevent the switch coil from burning. 3. When the battery is connected, the pinion moves out. Now, push back the pinion with a finger and measure the pinion stroke (the travel along which the pinion is pushed back). This is the pinion gap. 4. If the pinion gap is not up to specification, adjust by adding or removing fiber washers between the magnetic switch and front bracket. Using more washers makes the gap smaller. Pinion gap 0.2 ~ 2.0 mm
Disconnect connector
Starter motor
KD4B6024
Pinion
Pinion gap
KD4B6025
6-18
PULL-IN TEST OF MAGNETIC SWITCH

The pull-in coil is in good condition if the plunger is pulled in to cause the pinion to move out when a battery is connected between the terminals S and M of the magnetic switch. If the pinion does not move out, replace the magnetic switch. CAUTION The connector must be disconnected from terminal M for this test. The test must be finished within 10 seconds.
S Battery 12V B
Starter motor
KD4B6026
HOLD-IN TEST OF MAGNETIC SWITCH

With a battery connected between the terminal S and body of magnetic, manually pull the pinion up to the pinion stopper. The hold-in coil is in good condition if the pinion remains out when releasing it. CAUTION This test must be completed with 10 seconds.
+ S Battery 12V
Starter motor
KD4B6027
RETURN TEST OF MAGNETIC SWITCH

With a battery connected between the terminal M and body of the magnetic switch, manually pull the pinion out to the pinion stopper. Body coils are fully operational if the pinion returns immediately when releasing it. CAUTION This test must be completed with 10 seconds.
M+ Battery
Starter motor
KD4B6028
NO-LOAD TEST
1. Set up a circuit as shown which connects a starter motor, battery, ammeter, voltmeter, and variable resistance. 2. The starting motor should be in good condition if it turns smoothly and steadily when the switch is turned ON with a maximum variable resistance value. Adjust the variable resistor so that the voltmeter reads 11.5V. If the current and rpm are out of specification after this adjustment, troubleshoot according to the table below and take remedial action as required.
Variable resistor Ammeter A Starter motor Battery 12V
Voltmeter
KD4B6029

Symptom Large current with low rpm (torque also being small) Possible cause Contaminated bearing Armature coil rubbing pole piece Armature coil shorting Large current with no rotation Solenoid switch grounding Armature and field coil grounding Seized bearing No current flowing with no rotation Broken armature and field coils Broken brush and pigtail Improper contact between brush and commutator Improper field coil connection (Note, however, that open or improperly connected shunt coil only will result in high rpm.) Shorted field coil
6-19
Small current with low rpm (torque also being small) Large current with high rpm (torque being small)
6-20 COMPONENTS
2 3
18 19 23 29 20 12 14 1 16 4 21 22 17 28 5 27 25 26 24 11 9 10 8 7 6 13 15
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Screw Magnetic switch Fiber washer Screw Screw Rear bracket Brush holder assembly Yoke assembly Armature Front bearing Rear bearing Screw Cover Snap ring Washer Plate
17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
Screw Center bracket Packing Lever spring Washer Gear Lever Snap ring Stop ring Pinion gear Spring Pinion shaft assembly Front bracket

KD4B6030

DISASSEMBLY
MAGNETIC SWITCH
Remove the field coil wire from the terminal M of magnetic.
Magnetic switch Terminal S Terminal M
6-21
Terminal B Field coil wire
KD4B6031
SNAP RING
Pinion shaft
Plate
Measure the pinion shaft end play using the feeler gauge for the purpose of reassembly.
Snap ring
Washer
KD4B6032
SNAP RING AND STOP RING

1. Using an adequate socket, push the stop ring over the snap ring.
Socket Pinion gear Stop ring
KD4B6033
2. Remove the snap ring with a screwdriver, then, remove the stop ring.
Snap ring Stop ring Pinion gear
KD4B6034
6-22
CLEANING THE STARTER MOTOR PARTS

1. Do not immerse parts in cleaning solvent. Immersing the yoke and field coil assembly and/or armature will damage the insulation. Wipe these parts with a cloth only. 2. Do not immerse the drive unit in cleaning solvent. The overrun clutch is pre-lubricated at the factory and solvent will wash lubrication from the clutch. 3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.
INSPECTION
CHECKING THE COMMUTATOR
1. Place the armature on a pair of V-blocks, and check the run out by using a dial gauge. Standard value Limit 0 ~ 0.03mm 0.1mm
KD4B6035
2. Check the outer diameter of the commutator. Standard value Limit 32 0.1mm 31.4mm
KD4B6036
3. Check the depth of the undercut between segments. Standard value Limit 0.5mm 0.2mm
Segment
Under cut
Mica
KD4B6037

FIELD COIL OPEN-CIRCUIT TEST
Check for condinuity between field brushes. There must be continuity.
6-23
Yoke
KD4B6038
FIELD COIL GROUND TEST

Check for continuity between the field coil brush and yoke. There must be no continuity.
Field brush
Yoke
KD4B6039
BRUSH HOLDER
Check for continuity between brush holder plate and brush holder. There must be no continuity.
Brush holder
KD4B6040
OVERRUNNING CLUTCH
1. Ensure that the pinion locks when turned counterclockwise and turns freely when turned clockwise. 2. Check the pinion for wear and damage.
KD4B6041
6-24
BURSHES
1. Check the brush surface in contact with the commutator for surface roughness. Check also the brush length. Limit Wear limit line
Wear limit line
2. If the surface has been refaced or brush has been replaced, wrap sand paper around the commutator to correct its surface. 3. When removing a worn brush by breaking with pliers, use care to prevent damage to the pigtail. 4. Polish the pigtail end for battery soldering with sand paper. 5. Insert the pigtail into the hole in a new brush and solder. Make sure that the brush surface is free from excess solder.
Pigtail
KD4B6042
New brush Soldering (Brush surface is free from excess solder)
Mark
KD4B6043
ARMATURE COIL SHORT TEST

1. Place the armature on a growler. 2. Slowly turn the armature while a thin metal is held above it. The armature coil is not shorted if the metal does not vibrate. CAUTION Before this test, ensure that the armature surface if free from foreign substances.
Growler
KD4B6044
ARMATURE COIL GROUND TEST

Check for insulation between the commutator segment and armature coil core. There must be no continuity.
Growler
KD4B6045

ARMATURE COIL OPEN-CIRCUIT TEST
Check for continuity between segments. There must be continuity.
6-25
KD4B6046
INSTALLATION
STOP RING AND SNAP RING
Using a puller of adequate type, pull the stop ring over the snap ring.
Stop ring
Pinion gear
KD4B6047
6-26
8. GLOW PLUG
COMPONENTS
1
T=1.5~2.0 kgm T=1.5~2.0 kgm 3
1. Connector 2. Glow plug plate 3. Glow plug

KD4B6048
REMOVAL
GLOW PLUG
Especially ceramic part of glow plug is so fragile that the screw should be removed with the hand after unscrewing it several turns with a tool.

INSPECTION
1. Check for rust on glow plug plate. 2. Check glow plug for damage. NOTE Do not use the plug dropped at the height of 10cm or higher.
6-27
3. Check the continuity between the terminal and body as illustrated. Replace if discontinuity or with large resistance. Standard value 500(20C)
NOTE Remove oil from plug before measuring as glow plug resistance is very small.
KD4B6049
INSTALLATION
GLOW PLUG
Especially ceramic part of glow plug is so fragile that the screw should be removed with the hand after unscrewing it several turns with a tool.
CHAPTER 7. FUEL SYSTEM
1. GENERAL ............................................................................. 7- 1 2. INJECTION NOZZLE ............................................................ 7- 8 3. INJECTION NOZZLE HOLDER ............................................ 7- 10 4. INJECTION PUMP ................................................................ 7- 12 5. TROUBLESHOOTING .......................................................... 7- 15
GENERAL
7-1
1. GENERAL IMFORMATION
OVERALL
A distribution-type fuel injection pump is installed in the front upper case and is driven by the timing belt. The fuel is drawn from the fuel tank by a pump inside the fuel injection pump and sent to the injection pump through a filter which contains a water separator. The fuel under pressure enters the pump chamber, where the fuel pressure is regulated by a regulating valve. From the pump chamber, the fuel is sent through the distributor head passage and then the inlet port in the barrel to the high pressure chamber above the plunger. The plunger pumps the fuel and the highly pressurized fuel is injected from the nozzle in accordance with the injection sequence. The excess fuel in the pump housing chamber is returned through the overflow valve and the overflow pipe to the fuel tank. The injection pump is cooled and lubricated by means of fuel circulation. The excess fuel at the nozzle holder is also returned through the overflow pipe with unions on the injection pump to the fuel tank. Since the injection pump is lubricated by fuel, water in the fuel will shorten the pump life to a great degree. Therefore, special care must be taken to prevent the entry of water, dust, etc. into the system.
High speed adjust bolt Low speed adjust bolt
Control lever
Hole rodadjust screw
Fuel cut solenoid Drive shaft Plunger
Feed pump Roller holder Cam disc Timer Plunger spring Delivery valve
EFLB001A
7-2 SPECIFICATIONS
Item Fuel filter type Fuel injiction pump Type Turning direction Injection sequence Governor type Feed pump type Injection nozzle Nozzle type Holder type
GENERAL
Specification Cartridge paper filter element type Distribution type Clockwise as viewed from drive side 1-3-4-2 Half All Speed Vane type Throttle type Screw-on type
Remark
SERVICE SPECIFICATIONS
Item Injiction pump Injection timing Cam lift Plunger diameter Delivery valve opening pressure Fuel cut solenoid Injiction Injection orifice (Number-diameter) Pressure Opening pressure Adjust pressure Idle speed Standard ATDC 5 2.2mm 10mm 21.5kg/cm2 12V/8 1 ~ 1.02mm 120kg/cm2 125 ~ 135kg/cm2 820 ~ 880rpm 110kg/cm2 Limit
GENERAL
TOQUE SPECIFICATIONS
Item Injection pipe clamp bolts Injection pipe union nuts Pump bracket-to-cylinder block bolts Injection pump-to-pump bracket bolts Injection pump mounting nuts Fuel return pipe nuts Injection nozzle ning nut-to-nozzle body Pump sprocket nut Torque (kg.m) 0.4 ~ 0.6 2.3 ~ 3.7 1.8 ~ 2.5 2.0 ~ 2.7 1.5 ~ 2.2 3.0 ~ 4.0 5.0 ~ 6.0 3.0 ~ 5.0 8.0 ~ 9.0
7-3
SPECIAL TOOLS
Tool (Number and name) 09310-43000 Prestroke measuring adapter Illustration Use Injection timing adjustment
D1043000
09314-43100 Nozzle holder socket wrench
Removal of nozzle holder
D1443100
09314-43000 Injection pump sprocket puller
Removal of injection pump sprocket
C1443000
7-4 INSPECTION AND ADJUSTMENT

ACCELERATOR CABLE
1. Warm engine until stabilized at idle. 2. Confirm idle rpm is at prescribed rpm. 3. Stop engine.
GENERAL
4. Confirm there are no sharp bends in accelerator cable. 5. Check inner cable for correct slack. 6. If there is too much slack, adjust slack by the following procedures. 1) Loosen adjusting nut. Fully close throttle lever. 2) Tighten adjusting nut until throttle lever just starts moving. Return 1 turn and lock with lock nut. This adjusts accelerator cable play to standard value. Standard value approx. 1 mm (0.04 in.)
Lock nut
EFLB07A
Adjusting nut
3) Adjust so that accelerator pedal stopper touches pedal arm when throttle lever is fully opened. 4) After adjusting, confirm that throttle level fully opens and closes by operating pedal.
EVACUATION OF AIR FROM FUEL LINE

1. When fuel is drained and re-filled for service. 2. When fuel filter is replaced. 3. When main fuel line is removed. 1) Loosen fuel filter air plug. 2) Place rags around air plug hole. Operate hand pump repeatedly until no bubbles come from plug hole. Tighten air plug. 3) Repeat until hand pump operation becomes stiff.
GENERAL
EVACUATION OF WATER FROM FUEL FILTER
Water is in the filter when fuel filter indicator lights. Evacuate water by the following procedures. 1. Loosen drain plug. 2. Drain water with hand pump. Finger-tighten drain plug.
Drain plug
7-5
EFLB009A
INJECTION NOZZLE
INJECTION START PRESSURE
1. Set injection nozzle in nozzle tester and check the following. 2. Move nozzle tester handle at about one stroke per second. 3. The pressure gauge pointer rises slowly and swings when injection is made. Read the position at which the pointer started to swing. Check the injection start pressure is the standard value. Standard value Opening pressure Adjust preesure Limit 120kg/cm2 125~135kg/cm2 112kg/cm2 or more
EFLB010A
4. If the nozzle is faulty, disassemble and adjust injection start pressure to the standard value by changing the shim thickness. Injection pressure increases by approx. 1,000 kPa (10 kg/ cm2,142 psi) as shim thickness is increased by 0.1 mm (0. 0039 in.). CAUTION When disassembling nozzle holder, be careful not to allow entry of dirt or water.
7-6
GENERAL
5. If the injection start pressure can not be adjusted by changing the shim thickness, replace nozzle assembly.
Shim
EFLB011A
INJECTION STATUS
Move nozzle tester handle at about 1 stroke per second.
Good
Not good Large injection Direction Split Intermittent angle imbalance injection injection
EFLB012A
NEEDLE VALVE VIBRATION

Inject on is normal if the characteristic intermittent sound is heard as the handle is operated, and vibration of the needle valve is felt at the handle.
GENERAL
SPRAY
1. Check that the spray is good, as illustrated in the figure, in the test, the spray may be bolt shaped with a course mist and fuel may remain. This is phenomenon common in this type of inspection, and the nozzle function is normal. 2. Move nozzle tester handle at 4 to 6 strokes per second. 3. Confirm the spray is cone shaped with an angle of about 15. This indicates a good condition.
7-7
EFLB013A
4. If the injection is not good, disassemble nozzle and replace nozzle tip or entire assembly. 5. Confirm fuel does not drip after injection. 6. If dripping, disassemble injection nozzle and replace nozzle tip or entire assembly.
NOZZLE OIL-SEAL
1. Maintain internal nozzle pressure (pressure gauge indication value) with the nozzle tester at 10,000-11,000 kPa (100-110 kg/cm2, 1,422-1,565 psi). Check for fuel leaking from nozzle tip in this condition.
EFLB014A
2. If there is leakage, disassemble injection nozzle and replace nozzle tip or entire assembly.
7-8
INJECTION NOZZLE
2. INJECTION NOZZLE
COMPONENTS
0.4 ~ 0.6 1 2
3.0 ~ 4.0 5 6 7 8 9 3 2.3 ~ 3.7
0.4 ~ 0.6
5.0 ~ 6.0
1 2 3 4 5
Injection pipe clamp Injection pipe Fuel return hose Nut Fuel return pipe
6 7 8 9
Fuel return pipe gasket Nozzle holder Holder gasket Nozzle gasket
TORQUE : kgm
EFLB015A
REMOVAL
1. Injection pipe When loosening the union nuts, hold delivery valve holder on fuel injection pump head or hexagon nut of fuel return pipe with a wrench to prevent it from rotating along with the union nut. CAUTION Because VE type injection pipe is different from DPC type injection pipe, be careful when you install. (VE type injection pipe is coated yellow)
Delivery holder Nut
EFLB016A
INJECTION NOZZLE
2. Fuel return pipe When removing the fuel return pipe nut, hold the fuel return pipe by the hexagon nut with a wrench. CAUTION If you remove the hexagon nut without holding the fuel return pipe nut, the pipe might be damaged. So you must remove the hexagon nut with holding return pipe.
Nut
7-9
Fuel return pipe
EFLB017A
3. Return holder Using a deep socket wrench, loosen the injection nozzle and remove.
09314-43100
CAUTION Write the number of the cylinder on the injection nozzle that has been removed. Cover the opening with an appropriate cap to prevent entry of dust, water and foreign material into the fuel passage land combustion chamber.
EFLB018A
INSTALLATION
NOZZLE HOLDER
1. Clean nozzle holder installation area of the cylinder head. CAUTION Gasket groove may cause lack of idle RPM.
Holder gasket Nozzle gasket
EFLB019A
2. Fit a new nozzle gasket and holder gasket into the nozzle holder hole in the cylinder head.
7-10
INJECTION NOZZLE HOLDER
3. INJECTION NOZZLE HOLDER

COMPONENTS
3 7
6 3.5 ~ 4.0 5 1
1 2 3 4 5 6 7
Retaining nut Nozzle tip Distance piece Retaining pin Pressure spring Shim Nozzle holder body
TORQUE : kgm
EFLB020A
DISASSEMBLY
RETAINING NUT
1. Retaining nut Lightly clamp the retaining nut with a cushion bracket . 2. Hold the retaining nut with a box wrench, and loosen the nozzle holder body using a deep socket wrench.
EFLB021A
Deep socket wrench
INJECTION NOZZLE HOLDER

NOZZLE TIP
1. Check the nozzle tip for carbon deposits: Scrape off carbon deposits with a piece of wood land clean each part with patrol. After cleaning, keep parts submerged in diesel fuel. Take particular care to protect the nozzle tip needle valve from damage. 2. While the nozzle tip is submerged in diesel fuel, check that the needle valve slides smoothly. If the needle valve does not slide smoothly, replace the nozzle tip. When replacing the nozzle tip, completely wash off the anticorrosive oil from the new nozzle tip with clean diesel fuel before using it. 3. Check plunger tip "A" for deformation and breakage. If "A" is damaged or broken replace it. Check the surface in contact with the nozzle holder body by using minimum. Check spring for weakness and breakage.
7-11
Plunger Nozzle tip
EFLB022A
RETAINING NUT
1. Finger-tighten the nozzle holder body. 2. clamp the retaining nut in a vise with cushion plates. 3. While holding the retaining nut with a box wrench, tighten the nozzle holder body to the specified torque with a deep socket wrench.
Deep socket wrench
EFLB021A
7-12
INJECTION PUMP
4. INJECTION PUMP
COMPONENTS
1.0 ~ 1.2 2.3 ~ 3.7
0.4 ~ 0.6 8.0 ~ 9.0
0.4 ~ 0.6
1.5 ~ 2.2
2.0 ~ 2.7
[REMOVAL] 1 Fuel injection pump connector 1A Electrical system connector 2 Fuel hose 3 Accelerator cable 4 Fuel injection pipe 5 Upper timming cover
6 7
Fuel injection pump sprocket Fuel injection pump
TORQUE : kgm
EFLB024A
INJECTION PUMP
REMOVAL
FUEL INJECTION PIPE
To remove the fuel injection pipe, refer to Injection nozzle
7-13
EFLB025A
FUEL INJECTION PUMP SPROCKET

1. Rotate the crankshaft to place it to the first cylinder piston compression dead point. 2. Place the belt tensioner to the full loose position of timing belt.. 3. After removing the sprocket mounting nut, remove the sprocket from the pump drive shaft using the special tool or equivalent puller. CAUTION Do not tap on the pump drive shaft with a hammer.
09314-43000
EFLB026A
4. Leave the sprocket in the timing belt lower cover with the timing belt engaged. CAUTION Do not burden the timing belt with twist, bend, etc. After removing, do not rotate the crank shaft. When holding the injection pump, do not pull down the accelerator lever or fast idle lever. Do not these levers. It may cause malfunction of the injection pump.
7-14
INJECTION PUMP
INSTALLATION OF FUEL INJECTION PUMP SPROCKET

When installing the sprocket to the injection pump, be sure the timing mark is aligned and tighten the nut to the specified torque. CAUTION After installing the sprocket, adjust the belt tension. (Refer to Timing belt of EM group)
No.1 TDC
EFLB027A
Timing mark
TROUBLESHOOTING
7-15
5. TROUBLESHOOTING
FUEL TANK AND FUEL LINE
Symptom Engine fault caused by low fuel supply Probable cause Bend and twist of fuel pipes and hoses Fuel pipes and hoses clogged Fuel filter clogged Water in fuel filter Air in fuel filter Fuel tank inside damaged and rusted Fuel pump fault Remedy Correct or replace Clean or replace Replace Drain water from the fuel filter Bleed the fuel filter Clean or replace Replace
7-16 FUEL INJECTION SYSTEM

Symptom Engine does not start
TROUBLESHOOTING
Probable cause No voltage at fuel cut-off solenoid on injection pump Fuel cut-off solenoid on injection pump loose or faulty
Remedy Check for voltage with test light. If necessary, replace fuse or faulty wires. Tighten solenoid. Check that solenoid clicks when key is turned OFF and ON. Replace faulty solenoid. If test light shows no voltage at bus with key at "O" position, test relay and wiring. Test and, if necessary, replace glow plug. Bleed fuel system. If no fuel emerges from a looseness injection pipe during cranking, check timing belt and fuel supply from filter. Connect pipes in correct location Adjust injection timing. Check and, if necessary, repair or replace nozzles. Try to start engine with new pump installed. If necessary, replace pump permanently. Check and, if necessary, adjust the idle speed. Check that lever on pump is not loose, then adjust accelerator cable. Replace hose or secure with clamps, bleed air from system. Inspect and, if necessary, replace lines and hoses or replace fuel filter.
No voltage at glow plug bus
Glow plug faulty Air in fuel system Injection pump not delivering fue
Injection pipes misconnected Injection timing incorrect Faulty injection nozzles
Faulty injection pump
Idle speed incorrect or idle rough irregular
speed incorrectly adjusted Accelerator control binding
Loose fuel hose between filter and injection pump Inadequate fuel supply owing to clogged fuel filter, or fuel return line and injection pipes leaking, dirty, kinked, or squeezed at connections Air in fuel system Faulty injection nozzles Injection timing incorrect Faulty injection pump
Bleed fuel system. Check and, if necessary, repair or replace injection nozzles. . Adjust injection timing. Try engine at idle with new pump installed. If necessary, replace pump permanently.
TROUBLESHOOTING
Symptom Smoky exhaust (black, blue or white) Probable cause Maximum rpm incorrect Remedy
7-17
Check and if necessary, replace injection pump. Check and, if necessary, repair or replace injection nozzles. Adjust injection timing. Observe exhaust with new pump installed if necessary, replace pump permanently. Tighten lever, check that accelerator pedal travel is not restricted, then adjust accelerator cable. Check and, if necessary, replace injection pump. Inspect and, if necessary, replace lines and hoses, replaced fuel filter.
Faulty injection nozzles Injection timing incorrect Faulty injection pump Poor power output, slow acceleration (speedometer accurate, clutch not slipping) Injection pump accelerator lever loose or not reaching maximum rpm adjusting screw
Maximum rpm incorrect Inadequate fuel supply owing to clogged fuel filter, or fuel return line and injection pipes leaking, dirty, kinked, or squeezed at connections Air in fuel system Ice or solidified wax in fuel lines. (winter time only) Faulty injection nozzles Injection timing incorrect Faulty injection pump
Bleed fuel system. Move car to a warm garage until ice or wax has become liquid, then bleed fuel system. Check and, if necessary, repair or replace injection nozzles. Adjust injection timing. Check acceleration and speed with new pump installed. If necessary, replace pump permanently. Check and, if necessary, replace or tighten all pipes, hoses and connections. Check return line for kinks and dents. Replace faulty lines. If line is clogged, blow it out with compressed air, then bleed fuel system. Check and, if necessary, adjust idle speed or replace injection pump. Check and, if necessary, repair or replace injection nozzles. Check fuel consumption with new pump installed, if unnecessary, replace pump permanently.
Excessive fuel consumption
Fuel leaks Return pipe and hose blocked
Idle speed too fast or maximum rpm too high Injection timing incorrect
Faulty injection pump

Model D4B

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MODEL

IMPORTANT SAFETY NOTICE

NOTE, CAUTION, WARNING

CHAPTER 1 GENERAL INFORMATION

1-2 Timming belt train

Rocker arm shaft Camshaft Main passage

Oil filter To oil pan Left silent shaft

Reduing pressure Vaccum pump

Crank shaft Right silent shaft

From heater To heater Thermostat Water pump Water pipe

From heater Heater

ENGINE IDENTIFICATION NUMBER

2. ENGINE INDENTIFICATION NUMBER

2) DESCRIPTION OF ENGINE IDENTIFICATION NUMBER

TIGHTENING TORQUE TABLE OF STANDARD PARTS

3. TIGHTENING TORQUE TABLE OF STANDARD PARTS

M5 M6 M8 M10 M12 M14

0.8 1.0 1.25 1.25 1.25 1.5

0.5 ~ 0.6 0.9 ~ 1.1 2.0 ~ 2.5 4.0 ~ 5.0 6~8 12 ~ 14

Load/Installed height Over length

N kg/mm Out-of squareness Intake Exhaust I.D.

0.8 mm 0.8 mm 0.8 mm 0.15 mm 0.15 mm 0.1 mm

Flatness of gasket surface Overall height

Intake & Exhaust

Air cleaner Muffler

Silent shaft bearing installer (09212-43200)

Installation of silent shaft rear bearing

Bearing installer stopper (09212-43300)

Removal of Right silent shaft rear bearing

Crank shaft front oil seal installer (09214-32000)

Installation of crankshaft front oil seal

Crankshaft front oil seal guide (09214 - 32100)

Guide for installation of crank shaft front oil seal

Connecting - rod small - end busing replacement tool (09214-43000)

Replacement of connecting - rod small end bushing

Camshaft oil seal installer (09221-21000)

Installation of camshaft oil seal

Valve seat cutter pilot (09221-43200)

Correction of valve seat

Valve seat cutter 45 (09221-43300)

Correction of valve seat

Valve seat cutter 65 (09221-43400)

Correction of valve seat

Valve seat cutter 30 (09221 - 43500)

Correction of valve seat

Valve spring compressor (09222-21000)

Compression of valve spring

Valve stem seal installer (09222-32100)

Installation of valve stem seal

Silent shaft drive gear oil seal guide (09222-43200)

Installation of silent shaft drive oil seal

Crankshaft rear oil seal installer (09232-32000)

Installation of crankshaft rear oil seal

Oil pressure switch wrench (09260-32000)

Removal and Installation of oil pressure switch