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C 60/70/75/80 D

C 60/70/75 L

RATED CAPACITY : 6000– 8000kg

Part No. 8051043


Book No. SM 751
Aug. 2012
CONTENTS

CONTENTS

Group SA. Safe Maintenance Group 22. Wheels and Tires


Group PS. Periodic Service Group 23. Brake System
Group 00. Engine Group 25. Steering Column and Gear
Group 01. Engine Cooling System Group 26. Steer Axle
Group 02. Fuel System Group 29. Hydraulic Sump, Filters, and Pump
Group 03. Intake and Exhaust System Group 31. Hydraulic Control Valve (Daesung Nachi)
Group 07. Transmission-Diesel (3WG-94EC, New) Group 32. Tilt Cylinders
Group 08. Transmission-LPG (T12313) Group 34. Uprights
Group 13. Electrical system Group 38. Counterweight and Chassis
Group 20. Drive Axle - Diesel Group 40. Specifications
Group 21. Drive Axle - LPG

Group 34. Upright


Group 32. Tilt Cylinders
Group 13. Electrical System
Group 20/21. Drive Axle
Group 25. Steering Column and Gear
Group 23. Brake System

Group 07. Transmission-D (3WG-94EC) Group 31. Hydraulic Control Valve


Group 08. Transmission-L (T12313)

Group 02. Fuel System

Group 00. Engine


Group 29. Hydraulic Pump, Sump,
and Filters
Group 03. Intake System

Group 01. Cooling System

Group 22. Wheels and Tires

Group 26. Steer Axle


Group 38. Counterweight,
Sheet Metal, & Chassis

SM 751 CONTENTS-1
GROUP SA

GROUP SA

SAFE MAINTENANCE

Safety ................................................................... Section 1

Lifting, Jacking, and Blocking the Truck ....... Section 2

Towing................................................................. Section 3

SM 751 SA-0
Group SA, Safe Maintenance

Section 1

Safety

Safety Signs and Messages Safe Maintenance Practices


Safety signs and messages in this manual and on the lift The following instructions have been prepared from cur-
truck provide instructions and identify specific areas rent industry and government safety standards applicble to
where potential hazards exist and special precautions industrial truck operation and maintenance. These recom-
should be taken. Be sure you know and understand the mended procedures specify conditions, methods, and
meaning of these instructions, signs, and messages. Dam- accepted practices that aid in the safe maintenance of
age to the truck, death, or serious injury to you or other industrial trucks. They are listed here for the reference and
persons may result if these messages are not followed. safety of all workers during maintenance operations.
Carefully read and understand these instructions and the
NOTE
specific maintenance procedures before attempting to do
This message is used when special informa- any repair work.
tion, instructions or identification is re-
quired relating to procedures, equipment, When in doubt of any maintenance procedure, please con-
tools, pressures, capacities, and other spe-cial tact your local Clark dealer.
data. 1. Powered industrial trucks can become hazardous if
maintenance is neglected. Therefore, suitable
IMPORTANT mainte-nance facilities, trained personnel, and proce-
This message is used when special precau- dures must be provided.
tions should be taken to ensure a correct
action or to avoid damage to, or malfunc-tion 2. Maintenance and inspection of all powered industrial
of, the truck or a component. trucks shall be done in conformance with the manu-
facturer’s recommendations.
3. A scheduled planned maintenance, lubrication, and
! CAUTION inspection program shall be followed.
This message is used as a reminder of safety
4. Only trained and authorized personnel shall be per-
hazards that can result in personal injury if
mit-ted to maintain, repair, adjust, and inspect indus-
proper precautions are not taken.
trial trucks. Work should be performed in accordance
with the manufacturer’s specifications.
! WARNING 5. Properly ventilate work area, vent exhaust fumes,
This message is used when a hazard exists and keep shop clean and floor dry.
that can result in injury or death if proper 6. Avoid fire hazards and have fire protection equip-
precautions are not taken. ment present in the work area. Do not use an open
flame to check for level or leakage of fuel, electro-
! DANGER
lyte, oil, or coolant. Do not use open pans of fuel or
flammable cleaning fluids for cleaning parts.
This message is used when an extreme haz-
ard exists that can result in injury or death or 7. Before starting work on truck:
serious injury if proper precautions are not a. Raise drive wheels off of floor and use blocks or
taken. other positive truck positioning devices.
b. Disconnect battery before working on the electri-
The above terms have been adopted by Clark Material cal system.
Handling Company. The same terms may be used in dif- 8. Before working on engine fuel system of gasoline- or
ferent context in service literature supplied directly or diesel-powered trucks, be sure the fuel shut-off valve
indirectly by vendors of truck components. is closed.

SM 751 SA-1-1
Group SA, Safe Maintenance

9. Operation of the truck to check performance must be 19. Modifications and additions that affect capacity and
conducted in an authorized, safe, clear area. safe truck operation must not be done without the
manufacturer’s prior written approval. Capacity,
10. Before starting to drive truck:
operation and maintenance instruction plates, tags, or
a. Be in operating position.
decals must be changed accordingly. This is an
b. Be sure parking brake is engaged.
OSHA requirement.
c. Put direction control in neutral.
d. Start engine. 20. Care must be taken to assure that all replacement
e. Check functioning of direction and speed con- parts, including tires, are interchangeable with the
trols, steering, brakes, warning devices, and any original parts and of a quality at least equal to that
load handling attachments. provided in the original equipment. Parts, including
tires, are to be installed per the manufacturer’s proce-
11. Before leaving truck
dures. Always use genuine CLARK or CLARK-
a. Stop truck.
approved parts.
b. Put directional control in neutral.
c. Apply the parking brake. 21. Use special care when removing heavy components
d. Stop the engine by turning off the ignition circuit. from the truck, such as counterweight, seat deck,
e. Put blocks at the wheels if truck is on an incline. upright, etc. Be sure that lifting and handling equip-
ment is of the correct capacity and in good condition.
12. Brakes, steering mechanisms, control mechanisms,
Also, this removal may upset the stability of the
warning devices, lights, governors, guards, safety
truck. The frame must always be safely blocked for
devices, and frame members must be carefully and
major component removal.
regularly inspected and maintained in a safe operat-
ing condition.
NOTE
13. Special trucks or devices designed and approved for
hazardous area operation must receive special atten- You should also be familiar with additional
tion to ensure that maintenance preserves the origi- operating and maintenance safety instruc-
nal, approved, safe-operating features. tions contained in the following publica-
tions:
14. Fuel systems must be checked for leaks and condi-
tion of parts. Extra special consideration must be ANSI / ITSDF B56.1 : Operator Control-Industrial Tow
given in the case of a leak in the fuel system. Action Tractors (Safety Standard For Powered Industrial Trucks).
must be taken to prevent the use of the truck until the
leak has been corrected. NFPA 505: Fire Safety Standard for Powered Indus-trial
Trucks: Type Designations, Areas of Use, Mainte-nance
15. The truck manufacturer’s capacity, operation, and and Operation. Available from: National Fire Protection
maintenance instruction plates, tags, or decals must Assoc., Inc., Batterymarch Park, Quincy, MA 02269.
be maintained in legible condition.
General Industrial Standards, OSHA 2206: OSHA Safety
16. Batteries, motors, controllers, limit switches, protec- and Health Standards (29 CFR 1910), Subpart N-Mater
tive devices, electrical conductors, and connections als Handling and Storage, Section 1910.178 Powered
must be inspected and maintained in conformance Industrial Trucks. For sale by: Superintendent of Docu-
with good practice. Special attention must be paid to ments, U.S. Government Printing Office, Washington, DC
the condition of electrical insulation. 20402.
17. To avoid injury to personnel or damage to the equip-
ment, consult the manufacturer’s procedures in
replacing contacts on any battery connection.
18. Industrial trucks must be kept in a clean condition to
minimize fire hazards and help in the detection of
loose or defective parts.

SM 751 SA-1-2
Group SA, Safe Maintenance

Section 2

Lifting, Jacking, and Blocking the Truck

! WARNING
Lifting or jacking any large piece of equipment such as your fork truck presents obvious haz-
ards. It must be done with great care and forethought. Consult the truck weight tabulations
in Group 40, “Specifications” to ensure that your lifting equipment is of adequate capacity.

SM 751 SA-2-1
Group SA, Safe Maintenance

Safe Parking Raising Drive Wheels Off Floor


Before working on truck: This procedure uses the upright as a lever to lift the drive
wheels off the floor and prevent accidents due to inadvert-
1. Park truck on a hard, level, and solid surface, such as
ent powering of the drive wheels.
a concrete floor with no gaps or breaks.
1. Park truck safely as described in “Safe Parking.”
2. Put upright in vertical position and fully lower the
Block steer wheels.
forks or attachment.
2. Be sure upright trunnion bolts are tight. Bolt torques
3. Put all controls in neutral. Turn key switch OFF and
must be 75-80 Nm (55-59 ft-lb).
remove key.
3. Start the engine. Tilt the upright fully back. Adjust
4. Apply the parking brake and block the wheels.
upright height as necessary to put blocking under-
neath the lower end of the upright.
! WARNING
4. Put a solid 100 x 100 mm (4 x 4 in) hardwood block
Defective equipment can cause accidents. All under the front section of each upright rail. Put a 3-6
tools and lifting equipment must be in good mm (.125-.250 in) steel plate on top of each block.
condition, meet the load capacity require-
ments and have OSHA labels when required.
Tools with defects can have failures causing
severe injury or death.

Lifting, Blocking, and Jacking Points Steel


Plate
Use the following illustration to locate general lifting,
blocking, and jacking points on the truck. Read the proce-
dures for raising, blocking, or jacking specific compo-
nents of the truck to make sure you understand the correct, Block
safe procedures

5. Tilt upright fully forward. This raises the drive


wheels off the floor. Release the tilt control lever and
turn engine OFF.

Under Under Frame Under Upright


Steer
Axle Frame Mount

! WARNING
Do not attempt to lift the truck by the over-
head guard or the counterweight. Severe
injury may result and the truck can be dam-
aged.

SM 751 SA-2-2
Group SA, Safe Maintenance

6. Insert blocking under the frame behind the drive 3. To raise the front of the truck using the upright,
wheels or slip wheel cradles under the drive wheels. spread two chains on the outer rail tiebar of the
If using blocking, check for safe clearance between upright.
drive wheels and floor and blocks.
Place
chains
here

Rag

NOTE
When forks are raised as in illustration
above, use shop rags, paper, or bright tape on
fork tips to signal the danger of tripping.

7. Check for stable condition of the truck. Be sure that ! WARNING


the blocks are located securely under the truck frame Chain and hoist used to lift truck should be
before operating the drive or working on truck. checked to make sure they are of safe lifting
8. Lower the drive wheels to the floor and remove the capacity. See the truck data plate for infor-
blocks by reversing the above procedure. mation.

4. Slowly lift truck and lower drive wheels onto the cra-
dles or place blocking under frame prop points.
Raising Truck with A Hoist
When suitable equipment is available, the front of the
truck may be raised by means of a hoist, with wheel cra-
dles placed under the wheels or blocking placed under the
frame.

! CAUTION
When lifting the front of the truck watch
truck for signs of lateral instability. It may
tip sideways. You may have to support or
guide the side of the truck or overhead guard
to prevent tipping.

1. Park truck safely as described in “Safe Parking.” 5. When maintenance work is completed, lower the
Block rear steer wheels. truck to the floor by reversing the lifting procedure.
Check to be sure no tools or equipment are under the
2. Check trunnion bolts to make sure they are tightened
truck or wheels.
to correct torque. Bolt torques must be 75-80 Nm
(55-59 ft-lb).

SM 751 SA-2-3
Group SA, Safe Maintenance

Blocking the Upright In Raised


Position
Carriage
This procedure is used to safely provide clearance for
access from the front of truck to components on or near
the drive axle. Illustrations show upright with forks
removed however, fork removal is not necessary
1. Park truck safely as described in “Safe Parking.”
2. Put blocks in front of and behind drive wheels.
3. Put wooden support blocks conveniently near upright
rails before raising the upright. Use two 100 x 100 Inner Rail
mm (4 x 4 in) hardwood blocks or equal, of about
300 x 300 mm (12 in) and 600 x 600 mm (24 in) Outer Rail
length.
NOTE Short Block

For standard uprights, block may need


length cut to suit. For triple stage uprights, 7. Reverse the procedure to remove blocking.
the carriage may be blocked up, as shown.

4. Start engine and raise the upright carriage. Raising Rear of Truck
5. Hold the taller block against inner rail and lower the The truck may be raised at the rear by jacking and block-
upright until carriage rests on block. ing under the center of the frame member at either the
front or rear steer axle mounting, or under the center sec-
tion of the steer axle.
Refer to truck data plate for truck weights.

! WARNING
Carriage
An incorrectly installed counterweight can
move or fall unexpectedly. Never lift or block
a truck using the counterweight. Failure to
follow procedures outlined in this manual
can result in injury or death.

1. Park truck safely as described in “Safe Parking.” Put


blocks at front and rear of drive wheels.
Inner Rail

Outer Rail

Tall Block

6. Hold the shorter block against the outer rail and


lower the upright until inner rail rests on the block.

SM 751 SA-2-4
Group SA, Safe Maintenance

2. Put a floor jack under the steer axle mounting frame 6. When maintenance work is completed, lower the rear
member, centered between the two wheels. of truck to the floor by reversing the above procedure
and lowering each side of the truck 50 mm (2 in) at a
! WARNING time:
• Put jack under frame and raise truck.
Never lift the truck by the counterweight. • Carefully remove blocks and lower truck.
• Remove jack and blocks from drive wheels.

Raising Entire Truck


Refer to truck data plate for truck weights.
1. Park truck safely as described in “Safe Parking.”
Lower upright fully.
2. If necessary, drive truck onto boards to increase
underclearance.
NOTE
If there is insufficient clearance under frame
! WARNING
for your jack, the truck may first be driven SIDE-TO-SIDE TIPOVER. When jacking
onto shims, such as 25 x 150 x 300 mm (1 x 6 side of truck, be sure upright is lowered fully
x 12 in) pieces of board, to increase the truck and do not raise one side of the truck more
frame underclearance. than about 50 mm (2 in) higher than the
other, to avoid tipping truck over laterally.
3. Raise the truck only as high as necessary to perform
the maintenance work. END-TO-END TIPOVER. If the upright and
transaxle are removed while the truck is
4. Put blocks at both sides of the truck, fully under the blocked up, the truck will tip backwards due
frame main side structure. Put the blocks in front of to the heavy counterweight. Both upright and
but close to the counterweight and steer wheels for counterweight must be removed before
best truck stability. attempting to raise the truck for transaxle
removal. The back of the truck must be sup-
ported by blocking under the steer axle to
prevent movement.

The reverse is also true. If the counterweight


is removed while the truck is up on blocks,
the weight of the upright and transaxle will
cause the truck to tip on the front blocks and
fall forward.

Put an equal amount of blocks under each side of the truck


to provide a level working position.
5. Lower the truck onto the blocks and remove the jack.

! CAUTION
Before performing any maintenance work,
check the truck for stable condition on the
blocking.

SM 751 SA-2-5
Group SA, Safe Maintenance

3. Put the jack under side frame near the center of the
truck. ! CAUTION
Before performing any maintenance work,
check the truck for stable condition on the
blocking.

8. When maintenance work is completed, lower the


entire truck to the floor by reversing the lifting proce-
dure. Lower the truck one side at a time, while care-
fully removing the blocks. Check to be sure no tools
or equipment are under the truck or wheels.
NOTE
Jack truck Depending on jack height, shims under the
here tires may be needed for clearance to allow
removal of jack.
IMPORTANT
Be sure to put the jack squarely and fully
under the main side structure of the frame. Shipping Tie-Down Instructions
Do not put the jack under the outer covers 1. Front of Truck
which enclose the fuel and hydraulic sump a. With Upright and Carriage Installed
tanks. • Lower the carriage fully.
• Put a tie down (e.g., chain) between the carriage
4. Carefully raise the truck one side at a time, only as fork bars.
high as necessary to do the maintenance work and
not more than a maximum of 150 mm (6 in) total.
5. Put blocks under the side frame, at each side of the
jack. Spread the blocks close to the steer and drive
wheels for maximum stability.

b. Without an Upright and Carriage Installed


6. If using one jack, lower the truck onto the blocks and • Put a chain across the truck floor plate. Protect
move the jack to the opposite side. Repeat the lifting truck from chain damage by using covered chain
procedure. or protective material under the chain at contact
points.
7. Put the same size blocks under each side of the truck
so it will be level. 2. Rear of Truck
• Attach the tie down to pocket in bottom of coun-
terweight.

SM 751 SA-2-6
Group SA, Safe Maintenance

Section 3

Towing

If your truck is disabled but can be moved freely on its 4. Check that the counterweight bolts on both trucks are
own wheels without further damage, use the following in place and properly torqued to 440-490 Nm (325-
procedures to tow the truck safely to a repair area. 361 ft-lb). These bolts are made of special, high-ten-
sile steel and are not commercially available. When
! WARNING necessary, replace these bolts only with a genuine
Clark replacement part.
It is important for your safety and to the care
of your lift truck to use the proper equipment 5. Use an approved, solid metal tow bar with towing
and carefully follow these recommendations couplers that connect to the towing pins in the coun-
for safe towing. terweights.
Do not tow a lift truck if there is a problem
NOTE
with the brakes or tires, or if the steering
DOT-approved towing equipment is avail-
cannot be operated.
able from your Clark dealer.
Do not tow the disabled truck up or down
ramps or steep inclines.
6. Release the parking brake on the towed vehicle.
Do not attempt to tow the disabled truck if
Place directional control lever in neutral.
traction or weather conditions are poor.
7. Tow the disabled truck backwards. An operator must
1. Be sure to apply the parking brake or block the drive be on the disabled truck.
wheels on the disabled truck while working around
it. ! CAUTION
2. When possible, raise the carriage (forks) on the dis- The power steering will not operate on the
abled truck 300 mm (12 in) from the floor or ground. disabled truck when the engine is not run-
Secure the carriage on the upright with a chain. ning. The steering handwheel will be difficult
3. Use a truck for towing that is of equal or larger to turn.
capacity than the disabled truck. Carry a partial load
on the tow truck for improved traction. 8. Tow the truck slowly. Careful towing is necessary to
prevent injury to personnel or damage to the disabled
truck. The truck should be towed at a speed of less
than 8 kph (5 mph, or a moderate walking speed)
with a driver in place and steering the disabled truck.

Direction of towing for distances of


300 meters (325 yards) or less.
Disabled truck with Tow truck moving at 8 kilome-
driver in place to steer. ters-per-hour (5 mph) or less.

Solid-metal
tow bar Partial
load

SM 751 Towing • SA-3-1


Group SA, Safe Maintenance

IMPORTANT
Do not lift the disabled truck or any wheels
! WARNING
off the floor while the truck is being towed. Always engage the parking brake when
parking a lift truck. The truck can roll and
9. Park the disabled truck in authorized areas only. cause injury or death to personnel near it.
Fully lower the forks on the floor, leave the direc-
tional control in neutral, turn the ignition switch to
OFF, and engage the parking brake. Remove the
ignition key and, when necessary, block the wheels
to prevent the truck from rolling.

LIFT TRUCK PARKING

SA-3-2 • Towing SM 751


GROUP PS

GROUP PS

PERIODIC SERVICE

Maintenance Schedules ............................ Section 1

The Planned Maintenance Program ....... Section 2

SM 751 PS-0
Group PS, Periodic Service

Section 1

Maintenance Schedules

“Periodic Service” and “Planned Determining Maintenance Intervals


Maintenance” Time intervals on the charts on the next four pages and
The term “periodic service” includes all maintenance elsewhere in this manual relate to truck operating hours as
tasks that should be performed on a regularly scheduled recorded on the hourmeter, and are based on experience
basis. Clark has found to be convenient and suitable under nor-
mal operation. Standard operating condition classifica-
The term “Planned Maintenance” indicates a formalized tions are:
program of basic inspections, adjustments, and lubrica-
tions that the Clark service organization provides custom- Normal Operation: Eight-hour material handling, mostly
ers at a prescribed interval, usually 50-250 hours. The in buildings or in clean, open air on clean, paved surfaces.
recommended basic “Planned Maintenance” procedure is Severe Operation: Prolonged operating hours or constant
given in Section 2 of this Group. usage.
The current Section,“Maintenance Schedules,” specifies Extreme Operation:
all maintenance tasks—including Planned Maintenance
tasks—that should be performed periodically, and sug- • In sandy or dusty locations, such as cement plants,
gests intervals at which they should be performed. lumber mills, and coal dust or stone crushing sites.
• High-temperature locations, such as steel mills and
foundries.
• Sudden temperature changes, such as constant trips
from buildings into the open air, or in refrigeration
plants.
If the lift truck is used in severe or extreme operating con-
ditions, the maintenance intervals should be shortened
accordingly.

IMPORTANT
MAINTENANCE INTERVALS. If the lift
truck is used in severe or extreme operating
conditions, the maintenance intervals should
be shortened accordingly.

Since the operating environments of lift


trucks vary widely, the above descriptions
are highly generalized and should be applied
as actual conditions dictate.

SM 751 PS-1-1
Group PS, Periodic Service

Service Chart/Lubrication Points


A decal, similar to the illustration below, is located on the guide to periodic maintenance intervals and tasks. A more
underside of the truck’s engine cover. This decal is a basic detailed chart is supplied on the next page.

Every 8-10 Hours or daily


Every 50-250 Hours or monthly
Every 450-500 Hours or every 3 months
Every 900-1000 Hours or every 6 months
Every 2000 Hours or every year

Lift Chains
Brake Fluid

Upright Rollers Brake Operation

Brake Discs
Tilt Cylinder Pins
Lub All Wheel Lugs
Axle Mounting
Transmission Fluid
& Fasteners
(LPG)
Overhead Guard Transmission
Mounting Bolts Fluid (Diesel)

Transmission Fluid Diesel Eng-oil


Filter (LPG)
Fuel Filter
Transmission Fluid Diesel
Filter (Diesel)
Hydraulic oil
Battery Filter
Hydraulic oil
Engine Oil Filter
Diesel
V-Belts Air Cleaner

Radiator Coolant Engine Oil


and Core LPG
Steer Axle Steer Axle Wheel
Linkage Bearings
Counterweight Fuel Filter
Fasteners LPG
Overall Visual
Check
Check/Lubricate Check/Replace Clean/Air Clean

Check Monitor indicator on A/cleaner


Drain/Flush and Service as Required
A-Diesel Engine Oil : 15W40 B-Hydraulic Oil C-Engine Coolant D-EP2 Grease E-Transaxle Fluid F-Hydraulic Oil
Clark # 2776239 50/50 Mixture NLGI #2 Clark #2776236 used in Clark # 2776239
standard transaxle
LPG Engine Oil : 10W30
API,MORETHAN A CLASS SJ GRADE

Intervals refer to elapsed hour meter time and based on Clark's experience found to be suitable and convenient
under normal operating conditions.
Service and Maintain as per Service and Operator Manuals. Special or harsh conditions may need additional intervals.

Clark Material Handling Asia

SM 751 PS-1-2
Group PS, Periodic Service

Recommended Periodic Service Schedule


This chart lists maintenance tasks that should be done Apply as appropriate for diesel, gas, and LPG trucks.
periodically, the suggested time intervals, and the service Refer to Operator’s Manual for Daily Checks.
manual Group in which the task is covered.

Every 450- Every 900- Every 2000


Every
TASKS 1st 50 Hours 500 Hours 1000 Hours Hours
50-250 Hours
(or 3 months) (or 6 months) (or 1 year)
Group PS - Periodic Maintenance
Perform Planned Maintenance
inspections, lubrications, and •
adjustments
Group 00 - Engine
Exhaust smoke from gas engine -
inspect (blue-oil ; black-fuel)

Idle/governed rpm - check/adjust •
Mounts/brackets - inspect/tighten •
Oil change - drain/fill* • •
Oil filter cap & seal - clean/check •
Oil filter - replace • •
Oil level/condition - check • •
Stall rpm - check on standard
transaxle truck

Tune up - determine if needed by stall
check and/or functional test

Valve tappet adjustment - diesel engine •
Group 01 - Cooling System
Coolant level/condition - check/sample •
Coolant protection level - hydrometer test •
Coolant change - drain & flush •
Coolant hoses - inspect/replace • •
Fan blades - inspect loose/damaged •
Fan belt(s) - check tension, wear • •
Radiator cap - inspect/test • •
Thermostat - test/replace •
Water pump - check leaks/wear •
Group 02 - Fuel System
Carburetor idle/air - check/adjust •
CO level - check/adjust •
Diesel injectors/lines - clean/inspect •
Filler cap/screen - clean/inspect •
Fuel filter, diesel - replace • (500 Hr)
Fuel filter, LPG - replace • (400 Hr)
LPG lock-off valve filter - inspect/replace •

SM 751 PS-1-3
Group PS, Periodic Service

Every 450- Every 900- Every 2000


Every
TASKS 1st 50 Hours 500 Hours 1000 Hours Hours
50-250 Hours
(or 3 months) (or 6 months) (or 1 year)
LPG tank mounting/guard - inspect •
LPG tank shut-off valve - inspect/test •
LPG vaporizer/regulator/hoses - inspect •
Throttle linkage - check/adjust •
* Oil change interval may be determined by laboratory analysis

Group 03 - Air Intake & Exhaust


Air filter element - replace • (Diesel) • (Gas/LPG)
Air hoses/clamps - inspect •
Exhaust pipe/muffler - inspect •
Group 06 - Transmission
Charging pump - stall test standard
transmission

Clutch pack operation - stall test standard
transmission

Pressure checks •
Fluid change - drain/fill • •
Fluid filter - replace • •
Fluid level/condition - check/sample • •
Inching operation - check/test •
Oil cooler/lines - inspect •
Transmission strainer - clean on standard
transmission

Group 12 - Ignition System
Diesel cold starting plug - test •
Distributor cap/rotor - inspect •
Electronic ignition - test •
Ignition timing - check/adjust •
Ignition wiring - inspect •
Neutral start - check •
Parking brake interlock - check •
Spark plugs - regap/replace (GM LPG) •
Starter motor - inspect/test •
Starter solenoid - inspect/test •
Group 13 - Electrical System
Hourmeter - check •
Lamp check - at start-up •
Wiring harness - inspect •

SM 751 PS-1-4
Group PS, Periodic Service

Every 450- Every 900- Every 2000


Every
TASKS 1st 50 Hours 500 Hours 1000 Hours Hours
50-250 Hours
(or 3 months) (or 6 months) (or 1 year)
Group 20 - Drive Axle
Axle and lube - clean/repack •
Axle mounting bolts-inspect/tighten •
Oil change-drain/fill • •
Group 22 - Wheels And Tires
Wheel mounting bolts - tighten • •
Tire pressure/condition - check • •
Group 23 - Brake System
Operation - check •
Service brake - check wear •
Brake lines - check • •
Parking brake - check/adjust • •
Brake oil-check •
Brake oil change -drain/fill •
Group 26 - Steer Axle and Lines
Operation - check •
Power steering relief pressure - check •
Steer axle mounting - inspect •
Steer wheel bearings - check •
Steer wheel bearings - lubricate/adjust •
Steering cylinder seals - check leakage •
Steering linkage - lubricate •
Group 29 - Hydraulic Pump, Sump, and Filter
Hydraulic fluid level/condition -
check/sample

Hydraulic fluid change - drain/fill •
Hydraulic suction screen - clean •
Hydraulic fluid filter - replace • •
Hydraulic tank breather - clean/replace •
Group 30 - Hydraulic Valve & Linkage
Hydraulic system relief pressure -
test/adjust

Group 32 - Tilt Cylinders
Tilt cylinder adjustment - check/adjust •
Tilt cylinder drift - test •
Tilt cylinder mounting - check/tighten •
Tilt cylinder rod ends -
check/tighten/lubricate

Tilt cylinder rod/seals - check for leaks •

SM 751 PS-1-5
Group PS, Periodic Service

Every 450- Every 900- Every 2000


Every
TASKS 1st 50 Hours 500 Hours 1000 Hours Hours
50-250 Hours
(or 3 months) (or 6 months) (or 1 year)
Group 34 - Upright, Lift Cylinder, Carriage, Forks
Operation - check •
Carriage and lift chain - lubircate •
Carriage chain condition - inspect/adjust •
Forks, latches, stop pin -
inspect/check wear

Lift chain condition - inspect/adjust •
Load backrest •
Upright lift cylinder downdrift-test •
Upright rollers - check •
Upright mounting bolts - tighten •

SM 751 PS-1-6
Group PS, Periodic Service

Section 2

The Planned Maintenance Program

This Section defines a set of basic service procedures, known as the “Planned
Maintenance Program”, and describes systematic approach for performing
them.

SM 751 PS-2-1
Group PS, Periodic Service

Introduction to Planned Maintenance The Basic PM Procedures


A program of regular, routine inspections, lubrication, and The chart on the next page lists the basic PM tasks. The
other service tasks is important for the long life and trou- actual PM program may be modified to meet the specific
ble-free operation of the lift truck. needs of the truck application.
The Clark service organization offers customers a formal- The procedures beginning on page 4 outline a systematic
ized program—called Planned Maintenance, or PM—for approach to performing the PM tasks. These procedures
performing these tasks. consist of:
• External visual checks you make as you walk
PM Intervals around the truck with it turned off.

The PM inspections, adjustments, and lubrications are • Operational checks you make while operating the
typically performed on each covered truck at 50-250 hour truck.
intervals. (See Section 1, in this Group about defining ser- • Tests, adjustments, and lubrication you perform
vice intervals.) with the covers removed.

The PM Form
! CAUTION
As an aid to service technicians performing and docu-
• Do not make repairs or adjustments unless
menting PM inspections, Clark has prepared a “Gas, LPG
authorized to do so.
or Diesel Planned Maintenance Report” form. A black-
and-white copy of this form is inserted in Section 3 of this • Disconnect the battery ground cable (-) from
Group. the engine or frame before working on electrical
components.
We recommend that you use this form as a checklist and
• Always wear safety glasses.
to make a record of your inspection and truck condition.
This record can be used to inform the owner of needed • Wear a safety (hard) hat in industrial plants
repairs and help establish the optimal PM intervals. and in special areas where protection is neces-
sary or required.
When you have finished the PM inspections, be sure to
• Remove all jewelry (watch, rings, bracelets,
give a copy of the report to the person responsible for lift
etc.) before working on the truck.
truck maintenance.

SM 751 PS-2-2
Group PS, Periodic Service

The Recommended PM Task Chart

Listed by Service Manual Group

Group PS - The Basic PM Procedures Alternator - inspect/test


Visual inspection Alternator dirve belts - inspect/adjust
Functional performance check - test dirve Alternator output - test
Air cleaning of truck Battery condition - performance load test
Lubrication, filters, and fluid levels checks Battery electrolyte level - check/add
Critical fasteners torque check Battery terminals/cables - clean/tighten
Group 00 - Engine Neutral start - check
Exhaust smoke (blue-oil ; black-fuel) Starter cranking voltage - test
Idle RPM - check/adjust Group 22 - Wheels And Tires
Max no-load gov’d RPM - check/adjust Tire pressure/condition - check
Mounts/brackets - inspect/tighten Group 23 - Brake System
Oil filler cap & seal - clean/check Brake lines - check
Oil level/condition - check Check operation
Stall RPM - check Parking brake - check/adjust
Group 01 - Cooling System Service brake - check wear
Coolant hoses - inspect/replace Group 26 - Steer Axle & Lines
Coolant level/condition - check/sample Operation - check
Coolant protection level - hydrometer test Steer axle mounting - inspect
Fan belt(s) - check tension, wear Steer wheel bearings - check
Fan blades - inspect loose/damaged Steering cylinder seals - check leakage
Fan speed control - inspect Steering valve - check leakage
Group 02 - Fuel System & Exhaust Group 29 - Hydraulic Pump, Sump and Filter
Air hoses/clamps - inspect Hydraulic fluid level/condition - check/sample
Exhaust pipe/muffler - inspect Lines - check for leakage
LPG tank mounting/guard - inspect Group 30 - Hydraulic Valve & Linkage
LPG tank shut-off valve - inspect/test Hydraulic system relief pressure - test/adjust
LPG vaporizer/regulator/hoses - inspect Linkage and control handle operation - check
Throttle linkage - check/adjust Group 32 - Tilt Cylinders
Group 06~08 - Transmission Tilt cylinder mounting - check/tighten
Charging pump - stall test standard transmission Tilt cylinder rod ends - check/tighten
Clutch pack - stall test standard transmission Tilt cylinder rod/seals - check condition
Fluid level/condition - check/sample Group 34 - Upright, Lift Cylinders,
Inching operation - check/test Carriage, Forks
Oil cooler/lines - inspect Carriage/lift chain - lubricate
Group 12 - Ignition System Carriage chain condition - inspect/adjust
Distributor cap/rotor - inspect Forks, latches, stop pin - inspect/check wear
Ignition wiring - inspect Lift chain condition - inspect/adjust
Parking brake interlock - test Load backrest - inspect
Group 13 - Electrical System Operation of lift and tilt cylinder - check
Hourmeter - check Racking - check for
Indicator lights - check Upright mounting bolts - tighten
Wiring harness - inspect

SM 751 PS-2-3
Group PS, Periodic Service

Visual Inspection Carriage, Load Backrest, and Upright

First, perform a visual inspection of the lift truck and its (See Group 34 for detailed inspection procedure.)
components. Walk around the truck and take note of any Inspect the welds on the carriage, load backrest, and
obvious damage and maintenance problems. upright for cracks. Be sure that the mounting fasteners are
in place and tight.
Inspect the upright assembly: rails, carriage rollers, car-
riage fork bars, lift chains, and lift and tilt cylinders. Look
for obvious wear and maintenance problems and damaged
or missing parts. Check for any loose parts or fittings.
Check for leaks, any damaged or loose rollers and rail
wear (metal flaking). Carefully check the lift chains for
wear, rust and corrosion, cracked or broken links, stretch-
ing, etc. Check that the lift and carriage chains are cor-
rectly adjusted to have equal tension. Check that the lift
chain anchor fasteners and locking means are in place and
tight.
Be sure all safety guards and chain retainers are in place
Decals, Fasteners, and Leaks and not damaged. Inspect the carriage stops and cylinder
retainer bolts. Check all welded connections.
Check for loose fasteners and fittings.
Inspect all lift line hydraulic connections for leaks. Check
Check to be sure all capacity, safety, and warning plates the lift cylinder rods for wear marks, grooves and
and decals are attached and legible. scratches. Check the cylinder seals for leaks.
NOTE
Do not operate a lift truck with damaged or
missing decals and nameplates. Replace them Overhead Guard
immediately. They contain important infor-
mation. See Group 40 for decal locations.
Upright

Inspect the truck before and after starting engine for any
signs of external leakage: fuel, engine oil or coolant, Carriage
transmission fluid, etc.
Check for hydraulic oil leaks and loose fittings. DO NOT
USE BARE HANDS TO CHECK. Fork

! CAUTION
Hydraulic Fluid Pressure. Do not use your
hands to check for hydraulic leakage. Oil
may be hot or under pressure. Fluid under Forks
pressure can penetrate your skin and cause
serious injury. Inspect the load forks for cracks, breaks, bending and
wear as described in Group 34.
Overhead Guard
Be sure that the overhead guard and any other safety ! WARNING
devices are in place, undamaged, and attached securely. HEEL WEAR. If the fork blade at the heel is
Inspect welds and structural members for cracks or other worn down by more than 10 percent, the load
damage. Also check for loose or missing fasteners. capacity is reduced and the fork must be
replaced. See Group 34 for inspection proce-
dures.

SM 751 PS-2-4
Group PS, Periodic Service

Inspect the fork latches to ensure that they are in good Functional Tests
condition, operate freely, and lock correctly.
Be sure that:
Wheels and Tires • Parking brake is applied
Check the condition of the drive and steer wheels and • Directional control is in "N" (neutral).
tires. Remove objects that are embedded in the tread.
Inspect the tires for excessive wear or breaks or "chunking Test the horn, lights, and all other safety equipment. Be
out. sure they are properly mounted and working correctly.
Test all controls to ensure that they operate freely and
return to neutral properly.
Now prepare to start the truck and test its operation.

Starting System
A 3-position starter switch is standard equipment.
Check the neutral start function by placing the direction
control lever in forward or reverse and turning key switch
to “start” position. The starter must not engage until the
direction control lever is moved to “neutral” position.
Check all wheel lug nuts or bolts to be sure none are loose
or missing. Have missing bolts or lug nuts replaced and As you start the engine, check the instrument display. All
tightened to correct torque as explained in Group 22. indicator lights should come on for a 2-second lamp
check. The seat belt prompt light should remain on for 4
seconds, accompanied by a buzzer sound. The parking
brake light should remain on if the brake is set. If the truck
has a diesel engine, the glow plug preheat light should
remain on for 6 seconds. If the lights do not operate as
described, refer to Group 13 to diagnose the problem.
ON
OFF

Start

Engine Shut Down Mode


If the truck’s fault protection system detects low engine
! WARNING oil pressure, excessive transmission oil temperature, or
excessive engine coolant temperature, the truck will go
Check tire pressure from a position facing into “shutdown mode”—a buzzer will sound for 30 sec-
the tread of the tire, not the side. Use a long- onds, after which the truck will shut itself off. The truck
handled gauge to keep your body away. If may be restarted, but if the fault condition still exists, the
tires are low, the tire may require removal engine will again shutdown in 30 seconds.
and repair. Incorrect (low) tire pressure can
reduce truck stability. See “Specifications” in Parking Brake Interlock
Group 22 for proper inflation pressure.
The transmission should disengage when the parking brake
Brake and Inching Pedal Freeplay is on and reengage when the parking brake is released.

There should be no inching and 4~6mm braking pedal 1. Apply the parking brake.
freeplay. Both pedals should be at same the height. Adjust 2. Start the engine, if it is not already running.
as described in Group 23.
3. Place the direction control in forward or reverse.
Make sure the path is clear in the chosen direction.

SM 751 PS-2-5
Group PS, Periodic Service

4. Accelerate briefly. The truck should not move or put c. Depress the brake pedal and depress the accelera-
any strain on the parking brake if the interlock sys- tor pedal slightly, the truck should not move.
tem is OK.
5. Be sure the travel area is clear behind the truck.
5. Release the parking brake (and service brake). Truck Repeat steps 2 through 4 in the reverse direction.
should move slowly in selected direction. (On hydro-
6. Drive the truck and check that it accelerates and
static truck, depress accelerator pedal slightly.)
decelerates smoothly and stops properly.
Accelerator, Brake/Inching System, Direction 7. Depress the inching (left) pedal and depress the
Control, and Parking Brake accelerator to see if the transmission disengages
properly.
! WARNING 8. Check the function of the parking brake. Park the
Fasten your seat belt before driving the truck on a grade and apply the parking brake. The
truck. parking brake should hold a lift truck with rated load
on a 15% grade.
Make sure that you on a level surface, the travel area is
clear in front of the truck, the parking brake is release, and ! CAUTION
the truck is running.
If the service brake, parking brake, or inter-
1. Push the brake (right) pedal down fully and hold. lock is not operating properly, take the truck
The brakes should apply before the pedal reaches the out of service until it is repaired.
floorplate. If the pedal continues to creep downward,
report the failure immediately. Do not operate the Steering System
truck until the brakes are repaired.
Check the steering system by moving the steering hand-
2. Move the direction control lever from neutral to for- wheel in a full right turn and then in a full left turn. Return
ward. the steer wheels to the straight-ahead position. The steer-
ing system components should operate smoothly when the
3. For standard transaxle trucks: Release the brake
steering handwheel is turned. Hard steering, excessive
pedal and let the truck travel slowly forward. Then
play(looseness), or unusual sounds when turning or
push down on the brake pedal to stop the truck. The
maneuvering indicates a need for inspection or servicing.
brakes should apply smoothly and equally.
4. For hydrostatic transmission trucks:
a. Release the brake pedal. The transmission should
not engage and the truck should not move.
b. Accelerate briefly, then release the accelerator
pedal. Do not depress the brake pedal. The truck
should decelerate to a stop briefly after the accel- If the truck has a steering system fault, take the truck out
erator pedal is released. of service until it is repaired.

Lift Lever
Tilt Lever
Aux. Lever
Directional
Control
Brake Pedal

Accelerater Pedal
Inching Pedal

Operator’s Controls. Standard arrangment shown.

SM 751 PS-2-6
Group PS, Periodic Service

Lift Mechanisms and Controls Auxiliary Controls


(See Group 34 for detailed test procedure.) If the truck is equipped with an attachment, test the con-
trol lever for correct function and operate the attachment
1. Check the function of the lift system and controls
to check its function
with the engine running.
When you have completed the operational tests, park and
2. Pull back on the tilt control lever and hold until the
leave truck according to standard shutdown procedures.
upright reaches the full back tilt position. Push for-
Be sure to make a record of all maintenance and operating
ward on the lever to return the upright to the vertical
problems you find.
position. Release the lever.
If there is excessive play between rails and channels,
upright adjustment is required. If there is racking, Air Cleaning the Truck
adjustment of the cylinder rod yokes is required.
! CAUTION
! CAUTION
Wear suitable eye protection and protective
Be sure that there is adequate overhead clothing.
clearance before raising the upright.
Open the hood and remove the floorplate. Then air clean
3. Pull back on the lift control lever and raise the fork the following: upright assembly, drive axle, radiator from
carriage to full height. Watch the upright assembly as both counterweight and engine sides, engine and accesso-
it rises. All movements of the upright, fork carriage, ries, driveline and related components, and steer axle and
and lift chains must be even and smooth, without steer cylinder.
binding or jerking. Watch for chain wobble or loose-
ness; the chains should have equal tension and move Use an air hose with special adapter or extension that has
smoothly without noticeable wobble. Release the a control valve and nozzle to direct the air properly. Use
lever. clean, dry, low-pressure compressed air. Restrict air pres-
sure to 30 psi (207 kPa), maximum. (OSHA requirement).
It is important to maintain a lift truck in a clean condition.
Do not allow dirt, dust, lint or other contaminants to accu-
mulate on the truck. Keep the truck free from leaking oil
and grease. Wipe up all oil or fuel spills. Keep the controls
and floorboards clean, dry, and safe. A clean truck makes
it easier to see leakage, loose, missing, or damaged parts,
and will help prevent fires. A clean truck will run cooler.
The environment in which a lift truck operates determines
how often and to what extent cleaning is necessary. For
example, trucks operating in manufacturing plants which
have a high level of dirt, dust or lint, (e.g. cotton fibers,
paper dust, etc.) in the air or on the floor or ground,
require more frequent cleaning. The radiator, especially,
may require daily air cleaning to ensure correct cooling. If
air pressure does not remove heavy deposits of grease, oil,
etc., it may be necessary to use steam or liquid spray
cleaner.
If the maximum fork height cannot be reached, this
indicates there is low oil level in the hydraulic sump
or severe binding within the upright.
4. Push forward on the lift control lever. Watch the
upright as it lowers. If you suspect a problem with
lifting or lowering speeds, refer to Group 34 to diag-
nose the problem.

SM 751 PS-2-7
Group PS, Periodic Service

Truck Chassis Inspection and Lubrication Under-the-Hood Inspection


Lubrication requirements are given in the “Service Chart/ General Checks
Lubrication Points” chart in Section 1 of this Group. Also
Check all fluid levels and make sure that the following
see Lubricants and Shop Supplies” in Group 40 for parts
items are clean, secure, and in good condition:
information, and “General Specifications” in Group 40 for
lubricant specifications. • Hoses, lines, clamps, and fittings
Lubrication and inspection of truck chassis components • Wires, cables, and connectors
includes steer wheels, steer axle linkages, and steer wheel • Distributor, distributor cap, and rotor, coil, and
bearings, and drive wheel bearings. To check these items, plug wires (gas/LPG engine only)
the truck must be properly raised and blocked as described • Control linkages, pedals, and levers
in “Lifting, Jacking, and Blocking” in Group SA.
• Engine mounts
Check for play in wheel bearings by attempting to move • Fan and fan belts
the wheel side to side and up and down, by hand.
• Oil filler cap
Inspect the steering cylinder piston rods, seal, and fasten- • Steering gear (check for leaks).
ers for damage and leaks, and looseness.
Check linkages by observing whether the steer wheels lag ! CAUTION
when you turn the handwheel. To avoid the possibility of personal injury,
Lubricate the steer axle linkage rod ends and pivot points. never work in engine compartment with
Be sure to clean the grease fittings before lubricating. engine running except when absolutely nec-
Remove the excess grease from all points after lubricat- essary to check or make adjustments. Take
ing. Lubricate miscellaneous linkage as needed. extreme care to keep face, hands, tools, loose
clothing, etc., away from fan and drive belts.
Also, remove watches, bracelets, and rings.
Upright and Tilt Cylinder Lubrication Do not smoke.
Clean the fittings and lubricate the tilt cylinder rod end
bushings (forward end). Clean the fittings and lubricate Engine Air Cleaner
the tilt cylinder base rod end bushings (rear end). Clean Do not open the air cleaner to check the filter element.
and lubricate the upright trunnion bushings. The filter element should be replaced only at the specified
service interval or when the air filter light indicates that it
Lift Chain Lubrication is dirty.

Lubricate the lift chains as described in Group 34.


Fluid Checks
Battery
Inspect the battery for any damage, cracks, leaking condi-
tion, etc. If the terminals are corroded, clean and protect
them with CLARK Battery Saver (available from your
Clark dealer). If the battery has removable cell caps,
check to be sure the cells are all filled. If necessary, refill
with distilled water.

SM 751 PS-2-8
Group PS, Periodic Service

Engine Cooling System Fill the oil level above the LOW mark on the dipstick by
adding only the hydraulic fluid prescribed in Group 29.
Check coolant level in the coolant recovery bottle and in
DO NOT OVERFILL.
the radiator as described in Group 01.

! CAUTION
Low Full

STEAM. Do not remove the radiator cap


when the radiator is hot. Steam from the
radiator will cause severe burns.
Transaxle Fluid Level
Coolant should be checked on a daily basis in high-cycle Check the transaxle fluid level with the engine running, as
applications. explained in Group 06.

Engine Oil Fill to the FULL mark on the dipstick, using the transaxle
fluid specified in Group 06.
Oil Level: With the truck level and the engine shutdown
for at least 5 minutes, check the engine oil level.
Locate the engine oil dipstick. Pull the dipstick out, wipe
it with a clean wiper and reinsert it fully into the dipstick
tube. Remove the dipstick and check oil level.

FULL

Stall Test
ADD
On standard transaxle trucks, perform the stall test
described in Group 00 to determine engine and transaxle
condition.

Cranking Voltage Test


It is normal to add some oil between oil changes. Keep the To determine battery condition, check the cranking volt-
oil level above the ADD mark on the dipstick by adding age as described in Group 14.
oil as required. Use only the oil specified in Group 00.
Oil Change: Change oil as described in Group 00. Critical Fastener Torque Checks
Diesel Engine Oil Filter:Replace as described in Group
For safety it is important that the correct torque be main-
00.
tained on all critical fasteners of components which
directly support, handle or control the load and protect the
Hydraulic Fluid Level
operator.
Check the hydraulic sump tank fluid level as described in
Check torque of critical items, including:
Group 29. Correct fluid level is important for proper sys-
tem operation. Low fluid level can cause pump damage. • Drive axle mounting
Overfilling can cause fluid leakage. • Drive and steer wheel mounting
Hydraulic fluid expands as its temperature rises. There- • Counterweight mounting
fore, it is preferable to check the fluid level at operating • Overhead guard mounting
temperature (after approximately 30 minutes of truck
• Operator’s cell mounting
operation).
• Tilt cylinder mounting and yokes
• Upright mounting and components.
Critical fastener torque specifications are given in the gen-
eral specifications Section of Group 40.

SM 751 PS-2-9
Group PS, Periodic Service

SM 751 PS-2-10
GROUP 00 (D-IVECO)

GROUP 00 (D-IVECO)

DIESEL ENGINE

General specifications .............................. Section 1

Fuel .............................................................Section 2

Duty - Industrial applications


Mechanical injection Engines ...................Section 3

Overhaul and technical specifications ......Section 4

Tools.............................................................Section 5

Engine Replacement...................................Section 6

PREFACE TO USER’S GUIDELINE MANUAL


Section 1 describes the NEF engine illustrating its features and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty and is divided in four separate parts:
1. Mechanical part, related to the engine overhaul, limited to those components with different characteristics based
on the relating specific duty.
2. Electrical part, concerning wiring harness, electrical and electronic equipment with different characteristics
based on the relating specific duty.
3. Maintenance planning and specific overhaul.
4. Troubleshooting part dedicated to the operators who, being entitled to provide technical assistance, shall have
simple and direct instructions to identify the cause of the major inconveniences.
Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to exe-
cute such operations.

SM 751 00(D-IVECO)-0
Group 00, Engine(D-IVECO)

Section 1

GENERAL SPECIFICATIONS

LUBRICATION From the pan, the lubrication oil flows to the driving shaft,
to the camshaft and to the valve drive.
Lubrication by forced circulation is achieved through oil
rotary expansion pump, placed in the front part of the Lubrication involves the heat exchanger (2,3), the turbob-
basement, driven by the straight-tooth gear splined to the lower for turbocompressed versions, and for any com-
shaft’s bar hold. pressed air system.
All these components may often vary according to the
specific duty.

Fi
gure1

Routing of oil under pressure


Routing of oil return by gravity
to sump
Introduction of oil

3 4

003237t

LUBRICATION SYSTEM LAYOUT (4 cyl. engines)


1. Lubrication oil pipe to supercharger - 2. Heat exchanger body - 3. Heat exchanger - 4. Oil rotary expansion pump -
5. Oil filter

SM 751 00(D-IVECO)-1-1
Group 00, Engine(D-IVECO)

OIL VAPOUR RECIRCULATING SYS- The remaining non-condensed vapours shall be properly
TEM conveyed through the breather pipe (2), by suction as an
example (connection towards these vapours shall be
On the tappet cap (3) there is a valve (1) whose duty is to designed by the Engineer).
condense oil vapour inducing these to fall down because
of gravity, to the Tappet cap underneath.
Fi
gure3

003240t

1. Valve - 2. Breather pipe - 3. Tappet Cap

SM 751 00(D-IVECO)-1-2
Group 00, Engine(D-IVECO)

COOLING SYSTEM Visc pusher fan, having the duty to increase the heat
dissipating power of the radiator. This component as
The engine cooling system, closed circuit forced circula- well will be specifically equipped based on the
tion type, generally incorporates the following compo- engine’s development.
nents: Heat exchanger to cool the lubrication oil: even this
Expansion tank; placement, shape and dimensions are component is part of the engine’s specific equipment.
subject to change according to the engine’s equipment. Centrifugal water pump, placed in the front part of the
Radiator, which has the duty to dissipate the heat sub- engine block.
tracted to the engine by the cooling liquid. Also this Thermostat regulating the circulation of the cooling
component will have specific peculiarities based on liquid.
the equipment developed, both for what concerns the The circuit may eventually be extended to the com-
placement and the dimensions. pressor, if this is included in the equipment.

Figure 4
TO RADI ATO R

FROM RADIATOR

W ater comingout from thermostat


003241t

W ater recirculating in engine

W ater coming into pump

COOLIN G SYSTEM LAYOU T (4 cyl. engines)

SM 751 00(D-IVECO)-1-3
Group 00, Engine(D-IVECO)

AIR INDUCTION BOOST DIAGRAM The above mentioned air is then cooled by the radiator
and flown through the piston induction collector.

Description The turbocharger is equipped with a transforming valve to


regulate the pressure , that is located on the exhaust col-
The turbocharger is composed by the following main lector before the turbine and connected by piping to the
parts: induction collector.
one turbine, one transforming valve to regulate the boost It’s duty is to choke the exhaust of the emissions , releas-
feeding pressure , one main body and one compressor. ing part of them directly to the exhaust tube when the
boost feeding pressure, over the compressor, reaches the
During engine working process, the exhaust emission
prescribed bar value.
flow through the body of the turbine, provoking the tur-
bine disk wheel’s rotation. The cooling process and the lubrication of the turbo-
charger and of the bearings is made by the oil of the
The compressor rotor, being connected by shaft to the tur-
engine.
bine disk wheel, rotates as long as this last one rotates,
compressing the sucked air through the air filter.

Figure 6

AIR FILTER TU RBO CHARGE R

EX HAUST

RADI ATO R
74195

SM 751 00(D-IVECO)-1-4
Group 00, Engine(D-IVECO)

Section 2

Fuel

INJECTION FEED SYSTEM BY - Fuel pre-filter (if available, it is usually placed close
to the engine on the machine frame)
MECHANICAL ROTARY PUMP Priming pump, assembled to the engine and driven by
the camshaft
4 cylinder engines General information Fuel filter (assembled to the engine in different posi-
tions according to equipment application and duty)
Fuel feed system is composed by: Fuel feed rotary pump
Fuel tank (placed on the machine) Injector feed pipeline (from fuel feed pump to injec-
Fuel delivery and back-flow to tank tors)
Injectors.
Fi
gure1

2
1
4

1. Injector feed pipes - 2. Fuel exhaust pipes from injectors - 3. Fuel feed rotary pump - 4. Connector for LDA pressure
gauge pipe within suction collector - 5. KSB thermal bulb - 6. Electro-valve - 7. Injector
74168

SM 751 00(D-IVECO)-2-1
Group 00, Engine(D-IVECO)

Description of working principles Transfer pump is placed inside the feed pump, and is
bladed type; its duty is to increase fuel pressure in corre-
Fuel is sucked from the fuel tank by the priming pump. spondence with the increase of the number of revolutions.
This last one is placed on the engine basement and is
driven by the camshaft. The fuel arrives therefore to the valve gauging the pres-
sure inside feed pump.
Throughout the filter/s, the fuel is piped to the union fit-
ting vacuum chamber of the transfer pump. (For applica- The distribution plunger further increases this pressure
tions to be equipped in cold climate areas, the fuel filter is and delivers fuel throughout the delivery pipe fitting to the
provided with heater). injectors.
The fuel drawing from the injectors is recovered and
delivered to the tank again.

Fi
gure2

3
2

75807

SM 751 00(D-IVECO)-2-2
Group 00, Engine(D-IVECO)

FEED PUMP E = Pump dimensions


4= 4 cylinders engine
The rotary type pump is driven by a gear mating the cam- 12 = Distribution plunger in mm.
shaft’s one. 1150 = No. of pump revolutions per minute
LV = Left direction of rotation
Example of identification
V= Distribution rotary plunger

Fi
gure3

1
15

2
14
3

5
13
12

7
8

9
11
10

Injection pump longitudinal section


1. Diagram - 2. Locking nut - 3. Pivot - 4. Drive lever - 5. Speed gauge - 6. Transfer pump - 7. Drive shaft - 8. Cam disk - 30454
9. Advance converter - 10. Distribution plunger - 11. Delivery pipe fitting - 12. Hydraulic head - 13. Drive plate -
14. Gauge pin - 15. Counteracting spring.

SM 751 00(D-IVECO)-2-3
Group 00, Engine(D-IVECO)

PRIMING PUMP
This pump has the specific duty to prime the fuel available
in the tank and convey it to the feed pump inlet. It is
assembled to the engine block and driven by the camshaft.

Fi
gure4

2 3246t

1. Priming pump - 2. Camshaft.

Fi
gure5

88209

1. Priming pump - 2. Drive lever - 3. Camshaft.

SM 751 00(D-IVECO)-2-4
Group 00, Engine(D-IVECO)

FUEL FILTER On the filter cartridge base there is a water dump screw,
throughout which it is possible to provide regular drain-
The filter is assembled close to the feed and priming pump age; on the bearing for those equipment applications
and has the specific duty to provide barrier to the impuri- requiring it (cold climate areas), there can be a heater
ties and separation of water from fuel. assembled to and a temperature sensor. On some versions,
a water presence sensor is present at filtering cartridge
base.

Fi
gure7

88210

1.Fuelfi
ltersupport-2.Filtering cartridge-3.W aterdrainscrew .

SM 751 00(D-IVECO)-2-5
Group 00, Engine(D-IVECO)

Section 3

DUTY - INDUSTRIAL APPLICATION

GENERAL INFORMATION ter will follow and comply with all


installation prescriptions provided by Iveco
Motors.
Version equipped with mechanical feed pump Furthermore, the expanders assembled by
the Setter must always comply with couple,
NEF engines have been designed and developed by Iveco
power and number of revolutions based on
Motors specifically for transportation by land and farming
which the engine has been designed.
equipment in general.
They are characteristed by diesel cycle 4 stroke atmo- The section herein described is composed or four directo-
spheric or supercharged 4 and 6 cylinders each with 2 ries:
valves.
directory of mechanical overhaul prescribed in accor-
Feed is provided by rotary mechanical pump or on line dance to the engine’s specific duty, illustrating all nec-
according to the equipment application. essary operations to remove and assembly the external
components of the engine, including cylinder heads,
It differs from other applications because of the provision
gearbox of the timing system and of the front part
of different power, power take-off for the different collec-
cover;
tor configuration, priming pump, oil pan and boost tur-
electrical directory, describing the connections of the
bine.
different components, of the pre-post heating gearbox
NOTE (only for some versions) and of the sensors assembled
The picture shows application designed for 4 to the engine;
cylinders version, 2 valves per cylinder, hav- troubleshooting directory;
ing fuel feed mechanical pump. directory of preventive and regular maintenance oper-
ations, providing instructions for the execution of the
NOTE main operations.
Data, technical specifications and perfor-
mances granted shall be valid only if the Set-
Figure
1

03220

SM 751 00(D-IVECO)-3-1
Group 00, Engine(D-IVECO)

Clearance data - 4 cyl.

Type
IVEC O F4G E9454C

Compression ratio 17.5 : 1


Max. output kW 67
HP 91

rpm 2300
Max. torque Nm 389
kgm 38.9

rpm 1300
Loadless engine
idling rpm 850
Loadless engine
peak rpm 2300
Bore x stroke mm 104 x 132
Displacement cm3 4500
SUPERCHARGING without intercooler
Direct injection

Turbocharger type HOLSET HX25W

LUBRICATION Forced by gear pump, relief valve single action


oil filter

Oil pressure (warm engine)


bar
- idling bar 0.70
- peak rpm bar 3.50

COOLING By centrifugal pump, regulating thermostat, heat


exchanger, intercooler
Water pump control Through belt
Thermostat
- start of opening ºC 81 ± 2

FILLING

15W 40 ACEA E3 engine sump* liters 13

engine sump + filter* liters 14


* First filling operation

NOTE Furthermore, the users assembled by the set-


Data, features and performances are valid ter shall always be in conformance to couple,
only if the setter fully complies with all the power and number of turns based on which
installation prescriptions provided by Iveco the engine has been designed.
Motors.

SM 751 00(D-IVECO)-3-2
Group 00, Engine(D-IVECO)

OVERHAUL OF THE 4 CYLINDER NOTE


ENGINE PROVIDEDWITH MECHANI- For some versions, the oil filter (3) is directly
assembled on to the heat exchanger:in such
CAL ROTARY PUMP case it shall be disassembled using tool
99360076.
Preface Warning: the oil filter contains inside aprx. 1
kg. of engine oil. Provide for oil recovery and
Part of the operations illustrated within this section can be disposal in compliance with the law and reg-
partially executed while the engine is assembled on the ulations in force.
vehicle, depending on the room available for access to the
Fi
gure2
engine and on the equipment application as well.
2
NOTE
With regard to the engine disassembly opera-
tions, please apply for information consulting
the specific manual. All operations of engine
disassembly operations as well as overhaul
operations must be executed by qualified
engineers provided with the specific tooling
and equipment required.

The following information relate to the engine overhaul 3 1


operations only for what concerns the different compo- 75670

nents customising the engine, according to its specific


duties. Only for turbocompressed versions

NOTE disassemble lubrication oil exhaust pipe from the


For specific application exigencies, some turbo-blower:
units can be assembled to the engine in dif- Underneath the turbo-blower loosen the two screws
ferent positions. (2), loosen the screw (3) fixing the pipe throughout the
stop collar (4) fixing the block; finally loosen and
Within ”General overhaul” section, all the operations of remove the union (5) fromthe block; plug the pipe
engine block overhaul have been contemplated. Therefore ends and the exhaust of the turbo-blower.
the abovementioned section is to be considered as follow- Fi
gure3
ing the part hereby described.

Engine setting operations for the assembly


on turning stand 2

Figure relevant to turbocompressed versions


In order to apply the brackets 99361037 to the engine
block to fix it on to the stand 99322205 for the overhaul, it
3
is necessary to perform the following operations:
4
On the right hand side:
disassemble pipes (1) from the union (2) fitting the
lubrication oil filter (assembled on the opposite side): 1
unlock the nuts fixing the pipes (1) and remove them
5
from the union (2); drain the oil eventually still inside
the pipes and plug them properly in order to avoid
impurity inlet. 75671

SM 751 00(D-IVECO)-3-3
Group 00, Engine(D-IVECO)

Disassemble the starter; Assemble the second bracket 99361037 throughout


Properly hold the starter (1) and loosen the two fixing the screw-threaded ports (1).
screws (2); assemble the bracket bearing 99361037 Lift the engine using the rocker arm 99360595 and put
using the four screw threaded ports (3). Drain the oil through the cap underneath the plug.
Fi
gure4 NOTE
Warning: avoid contact of engine oil with the
3 skin:
in case of skin contamination, rinse in run-
ning water. Engine oil is highly pollutant:
provide for disposal in compliance with the
law and regulations in force.
Fi
gure6
2
1

1
75672

On the left hand side:


Disassemble oil filter (1) and bracket aswell (for ver-
sions with engine oil filter not directly assembled on to
the exchanger);
Using tool 99360076 operate on oil filter;
Loosen the screws (3) removing the bracket together
with the filter bearing (4 and 5).
75674
NOTE
Warning: the oil filter contains inside aprx. 1
kg. of engine oil. Disassembly of application components
Provide tank with sufficient capacity to con-
For turbocompressed versions
tain the liquid.
Warning: avoid contact of engine oil with the proceed disassembling the supercharger:
skin: in case of skin contamination rinse in
loosen the fixing nut (1) and remove the lubrication
running water.
pipe from the supercharger. Analogously carry out the
Engine oil is highly pollutant: provide for
same operation on the other end of the pipe and
disposal in compliance with the law and reg-
remove it from the upper part of the heat exchanger.
ulations in force.
Loosen the screw nuts fixing the supercharger on the
exhaust manifold.
Remove the oil level rod together with guide pipe (2);
Hold up the supercharger and after lifting it remove
(loosen the guide pipe disassembling from the block);
the gasket.
properly pipe the screw-threaded port to avoid inlet of
foreign matters. Fi
gure7
Fi
gure5 1

3
4

2
75673 75675

SM 751 00(D-IVECO)-3-4
Group 00, Engine(D-IVECO)

Place a container under the fuel filter and screw out Disconnect the LDA pipe (1) from the head and from
the condense drain faucet underneath said filter. Carry the feed pump. Pipe the ends of the pipelines as well as
out complete drainage of the fuel contained therein. the feed pump and the engine head.
Screw out completely the faucet and, using equipment Fi
gure10
99360076 disassemble oil filter (1).
Disconnect fuel pipelines (2 and 3) respectively from
priming pump to filter bearing and from this last one
to the feed pump.
Remove the fuel filter bearing (4) from the bracket
fixed to the engine head.
Fi
gure8

75677

90502

NOTE
To disconnect fuel pipelines (2 and 3, Figure
8), in low pressure from the relating pipe fit-
tings, it is Necessary to press the locking fas-
tener (1) as shown in picture B.
After having disconnected the pipeline, reset
the locking fastener (1) in lock position as
shown in. picture A, to avoid any possible
deformation of the fastener itself.
Fi
gure9

70126

SM 751 00(D-IVECO)-3-5
Group 00, Engine(D-IVECO)

Figure 11

3
7

4
6 5

1. Rear bracket fixing screw (on suction collector plate) - 2. Fuel recovery pipeline to pump - 3. Rotary feed pump -
4. Connection nut to pumping elements - 5. Injector - 6. Bracket fixing screw to injection pump side-
7. Front bracket fixing screw (on suction collector plate).

Disconnect the pipelines (1) and (2) that provide feed Loosen the two fixing screws and disassemble priming
and fuel recovery between pump and injectors; screw pump.
out the nuts fixing the pipes to the pumping elements; Fi
gure13
loosen the fuel recovery pipe collar on the injection
pump; operate on the nuts assembled to the injectors
and loosen the screws fixing the fuel recovery pipe-
line; loosen the screws holding the fixing brackets of
such pipelines (1,6, and 7, Figure 11); pipe the pipe-
1
line ends.
Disassemble the injectors and remove them from their
slot: remove the gaskets.
Fi
gure12

1 1
2

75678

75679

SM 751 00(D-IVECO)-3-6
Group 00, Engine(D-IVECO)

Remove tappet caps: Disassemble rocker arm bearings; loosen the two fix-
Loosen the four fixing screws (1) and lift the caps (2); ing screws (2) and remove the complete rocker arm-
remove the gaskets. bearing; withdraw tappet rods. Repeat the operation
for all the remaining rocker arm bearings.
NOTE
Disassemble water temperature transmitter (1).
In the picture, the front cap has already been
removed. Fi
gure16
On the central cap there is a blow-by valve
2
for the lubrication oil vapours.
All the gaskets shall always be replaced dur-
ing assembly.
Fi
gure14
1 2

75683

For applications with automatic belt stretcher


Remove the belt tightener(2).
Remove the belt (4) of the ancillary members by act-
ing on the alternator fixing bracket (1).
Remove the alternator (3), the water pump (6), the fan
pulley (5) and the jockey pulley (7).
Remove the pulley support (8).
Remove the engine block cooling system connector
(3).
Fi
gure17
75681

Disassemble suction and exhaust manifolds: loosen


the 8 screws (1) fixing the suction manifold plate to
the cylinder head (two of them have already been
screwed-out since fixing the pipe brackets to the injec-
tors); from the exhaust manifold side;
loosen the (2) fixing screws; remove the gaskets.
Fi
gure15
2

86571

1
75682

SM 751 00(D-IVECO)-3-7
Group 00, Engine(D-IVECO)

Remove belt tensioner (3). Disassemble thermostat unit; loosen the three fixing
Remove belt (5) for auxiliary members operating on screws (1) and disassemble the thermostat unit (2)
bracket (1) securing the alternator. together with the bracket (3); remove the gasket (4)
Remove alternator (2), water pump (4), fan pulley (7) and the thermostat (5).
and guide pulleys (6). Assemble the bracket in the original position fixing
take support off pulley (8). itwith the screws of the thermostat unit.
Fi
gure18 Fi
gure20

5
2

3
75685

Properly hold the alternator (1) separating it from its


90503
bearing by loosening the screw (2); remove screw nut
For applications with traditional belt stretcher and washer.
Fi
gure21
Loosen screw (1) and relevant nut on belt stretcher
bracket (3). 1 2
Loosen screw (2, Figure 20) in order to slide out
POLY-V belt (2).
Remove the belt stretcher bracket (3).
Disassemble the driven pulleys and the guide rollers.
Fi
gure19

75686

88089

SM 751 00(D-IVECO)-3-8
Group 00, Engine(D-IVECO)

Loosen the screws (1) and withdraw the alternator Disassemble cylinder head;
bearing (2). loosen the screws (1) and (2) fixing the cylinder head
(3); hook the brackets with metal ropes and, through-
NOTE
out a hoist withdraw cylinder head from the block.
The shape and the dimensions of the support
of the alternator vary according to the use of Fi
gure24
the engine. The relevant pictures provide a
general guide of the procedure that is to be 1
carried out. The procedures described are
2
always applicable.
Fi
gure22
3

4
75688

Use the tool 99360339 (2) to operate on the flywheel


cover box (1) in order to block flywheel rotation (3).
(Utilise starter holding down studs and fixing screw-
88091
nuts).
Loosen the flywheel fixing screws (4) to engine drive
Loosen the screws (4) and disassemble the oil pres- shaft.
sure/temperature sensor (3) (if fitted).
Loosen the screws (1) and disassemble the oil filter/ NOTE
heat exchanger bearing (2), interlayer plate (6) and In some versions there is provided 99360351
relating gaskets. tool checking the flywheel.
Disassemble oil level sensor (5) (whether provided). Fi
gure25
Disassemble injection pump (see specific procedure)
and the power take-off underneath.
2
Fi
gure23

4 75692

75810

SM 751 00(D-IVECO)-3-9
Group 00, Engine(D-IVECO)

- Loosen the screws (1) and disassemble the pulley (2). Using the specially provided tie rod (3) for the tool
Fi
gure26 99363204 and the lever (4), withdraw the external
holding ring (2) from the front cover (1).
Fi
gure28

00904
90504
Loosen the screws (1) and remove the front cover (2).
Remove the engine drive shaft fixing ring from the
front cover. Use the tool 99340055 (4) to operate on NOTE
the front tang (2) of the engine drive shaft. Throughout Take note of the screw (1) assembly position,
the tool guide ports, drill the internal holding ring (1) since the screws have different length.
using Ø 3,5 mm drill for a 5mm depth. Fix the tool to
Fi
gure29
the ring tightening the 6 screws specially provided.
Proceed withdrawing the ring (1) tightening the screw
(3).
Fi
gure27

70149

Loosen the screws (1) and remove oil pump (2).


Fi
gure30

78256

75811

SM 751 00(D-IVECO)-3-10
Group 00, Engine(D-IVECO)

Screw out the opposite screws (1) fromthe portswhere Remove the flywheel cover box fixing ring using the
the withdrawal pins shall be introduced (see picture tool 99340056 (3) to operate on the back tang (5) of
following). the engine drive shaft. Throughout the tool guide
Loosen remaining flywheel fixing screws (3) to the ports, drill the internal holding ring using Ø 3,5 mm
engine drive shaft (4). drill for a 5mm depth.
Remove the flywheel block tool (2). Fix the tool 99340056 (3) to the ring (1) tightening the
6 screws specially provided (4).
Fi
gure31
Proceed with drawing the ring (1) tightening the screw
2 (2).
1
Using the specially provided tie rod (3) for the tool
99363204 and the lever (4), withdraw the external
holding ring of the flywheel cover box.
Fi
gure33

3
75691

Screw up two medium length screws in the ports (4) to


sling the flywheel with a hoist.
Throughout two guide pins (2) previously screwed up
into the engine drive shaft ports (3) control the engine
flywheel withdrawal by means of a hoist.
Fi
gure32
00903
1 4
Loosen the screws (2) and remove the flywheel cover
box (1).
2 NOTE
Take note of the screw (1) assembly position,
since the screws have different length.
3 Fi
gure34

75690

70153

SM 751 00(D-IVECO)-3-11
Group 00, Engine(D-IVECO)

Turn the engine upside-down. Version with suction rose type B


Loosen the screws (2), disassemble the plate (3) and
Remove the screws (1) and (4) and disassembled the
remove the oil pan (1).
suction rose (5).
NOTE Remove the screws (2) and disassemble the stiffening
The shape and dimensions of the pan and of plate (3)
the rose pipe may vary according to the Fi
gure37
engine application. The relating illustrations
provide general guidelines of the operation to
be performed. The procedures described are
applicable anyway.
Fi
gure35

86601

By means of pin (1) lock the additional masses (2) in the


P.M.S. Loosen the fixing screws (3) and remove the addi-
tional masses (2).
Fi
gure38

88046

Version with suction rose type A


Loosen the screws (1) and disassemble the oil suction 86578

rose pipe (3).


Loosen the screws (2) and remove the stiffening plate
(4).
Fi
gure36

70155

SM 751 00(D-IVECO)-3-12
Group 00, Engine(D-IVECO)

Loosen the screws (1) and disassemble the gear from Version with reduced distribution
the camshaft (2).
Loosen the screws (2) and remove the flywheel cover
Fi
gure39 box (1).
NOTE
Take note of the screw (1) assembly position,
since the screws have different length.
Figure 40/1

87422

Remove the gear (1) transmitting motion to the igni-


tion pump and the relevant support.
Figure 40/2
90505

Loosen the screws (2) and disassemble the timing


gearbox (1).
NOTE
Take note of the screw (2) assembly position,
since the screws have different length.
Fi
gure40

87655

70157

SM 751 00(D-IVECO)-3-13
Group 00, Engine(D-IVECO)

Remove the screws (1) and disassemble the gears (3) Reassemble to box (1) to the engine block.
and (4) from the camshaft (2). Tighten the fixing screws in the same position as
Figure 40/3 found out during disassembly and fix the screws to the
locking couples listed here below, following the order
as shown in the picture.
Screws M12 ........................ 65~89 Nm
Screws M8 ......................... 20~28 Nm
Screws M10 ....................... 42~52 Nm
NOTE
Before assembly, always check that the
threads of the ports and of the screws have
no evidence of tear and wear on dirt.
Figure 42
87424 1
9 10
Installation of rear components
Accurately clean the timing gearbox (1) and the 6 8
engine block.
4 3
NOTE
It is necessary and essential to clean the sur-
face to be sealed in order to achieve a per- 2
fectly tight seal. 1
Apply sealing LOCTITE 5205 on the box in
order to form a bead of a few mm. diameter. 7 5
It must be uniform (no crumbs), with no air
blisters, thinner or irregular zones.
Any eventual imperfection should be cor-
75711
rected as soon as possible.
DIAGRAM SHOWING SCREW
Avoid using material in excess to seal the
TIGHTENING TO FIX REAR GEARBOX
joint. Too much sealing material would drop
out on both sides of the joint and obstruct
lubricant passages. With a penmarker,mark the tooth (1) of the driving
Couplings must be assembled within 10 min- gear assembled to the engine drive shaft with (2) ()
timing notch.
utes after completing the sealing operation.
NOTE
Figure 41
Screw up two pins to facilitate operation of
engine drive shaft rotation.
Fi
gure43

1
75712

DIAGRAM SHOWING SEALING LOCTITE 5205


APPLICATION WITHIN GEARBOX AREAS
70211

SM 751 00(D-IVECO)-3-14
Group 00, Engine(D-IVECO)

Orient engine drive shaft (3) and camshaft (4) taking - Tighten the screws (1) fixing the gear to the camshaft
care that in phase of assembly of the driving gear (2) (3) and lock them to the prescribed couple.
to the camshaft, the notches marked on the gears (1 Fi
gure46
and 2) shall match.
Fi
gure44

90508

Position comparator (1) on timing system gear (2) and


check that the clearance between gears (2) and (3) is
within 0.076 0.280 mm range.
Fi
gure45

90507

SM 751 00(D-IVECO)-3-15
Group 00, Engine(D-IVECO)

NOTE NOTE
It is necessary and essential to clean the sur- Before assembly, always check that the
face to be sealed in order to achieve a per- threads of the ports and of the screws have
fectly tight seal. no evidence of tear and wear or dirt.
Apply sealing LOCTITE 5205 on the box in Fi
gure48
order to form a bead of a few mm. diameter.
It must be uniform (no crumbs), with no air
1
blisters, thinner or irregular zones.
16 15
Any eventual imperfection should be cor-
rected as soon as possible. 8 14 7
17
Avoid using material in excess to seal the
joint. Too much sealing material would drop 6
18 13
out on both sides of the joint and obstruct 5
lubricant passages. 19 12
Couplings must be assembled within 10 min- 11
utes after completing the sealing operation. 20
2 1
Fi
gure47 21

4 9 10 3

75709

Apply to engine drive shaft rear tang (6), the detail (5)
of the tool 99346252, fix it tightening the screws (4)
and key the new holding ring on it (3).
Place detail (1) on detail (5), tighten the screw nut (2)
until complete assembly of the fixing ring (3) into the
flywheel cover box (7).
Fi
gure49

1
75708

Reassemble the box (1) to the engine block, tighten the


fixing screws in the same position as found out during
disassembly and fix the screws to the locking couples
listed here below, following the order as shown in the
picture.
Screws M12 ....................... 75 ~ 95 Nm
Screws M10 ....................... 44 ~ 53 Nm

0901t

In case of engine coupling with mechanical gears in


presence of friction, verify surface status of the fly-
wheel and eventually work it out to maintain rated
engine flywheel thickness, which is 49,6 ± 0,13 mm.

SM 751 00(D-IVECO)-3-16
Group 00, Engine(D-IVECO)

NOTE on the latter, the marks printed on the gears (1 and 2)


Check the conditions of the rim teeth (2). If coincide.
tooth breakage or excessive wear is detected, Figure 50/2
disassemble the rim from the engine flywheel
using a common driver and replace with a
new one, previously heated to 150 ଇ degrees
for 15 ~ 20; seconds; bevelling must be made
towards engine flywheel direction.
Fi
gure50

1 2

87652

Place the dial gauge (1) on the timing gear (2) and
check that the slack between the gears (2) and (3) is
included in the range between 0,076 ~ 0,280 mm.
Figure 50/3

75696

Installation of rear components with reduced


distribution
With a penmarker,mark the tooth (1) of the driving
gear assembled to the engine drive shaft with (2) ()
timing notch.
NOTE
Screw in two pins to facilitate operation of
87653
engine drive shaft rotation.
Figure 50/1
Fit the screws (1) fastening the gears (2) to the cam-
shaft (3) and tighten them to the prescribed pair.
Figure 50/4

70211

Orient the engine drive shaft (3) and the camshaft (4) 87654

ensuring that while assembling the conveyed gear (1)

SM 751 00(D-IVECO)-3-17
Group 00, Engine(D-IVECO)

Spline the gear (1) transferring motion to the ignition Couplings must be assembled within 10 min-
pump. utes after completing the sealing operation.
Figure 50/5 Figure 50/7

87657
87655

DIAGRAM SHOWING SEALING LOCTITE 5205


APPLICATION
Fit the power take-off gear (2) (if available) into the
specially provided housing and fasten the screws (1), Re-assemble the box (1) to the engine basement.
Figure 50/6 Tighten the fastening screws (2) to the same position
detected before disassembly.
NOTE
Before assembly, always check that the
threads of the ports and of the screws have
no evidence of tear and wear or dirt.
Figure 50/8

87656

NOTE
It is necessary and essential to clean the sur-
face toG be sealed in order to achieve a per-
fectly tight seal.
Apply sealing LOCTITE 5205 on the box in
87658
orderGto form a bead of a few mm diameter.
It mustG be uniform (no crumbs),with no air
blisters, thinnerGor irregular zones. Apply to the rear tongs hold (3) of the engine drive
Any eventual imperfection should be cor- shaft the part (6) of the tool 99346253, fix it with the
rected as soonGas possible. screws (1) and spline the new tight ring to it (2).
Avoid using material in excess to seal the
joint. TooGmuch sealing material would drop
out on bothG sides of the joint and obstruct
lubricant passages.

SM 751 00(D-IVECO)-3-18
Group 00, Engine(D-IVECO)

Place the part (5) on the part (6), tighten the nut (4) on the flywheel cover box (1) to block engine flywheel
until tight ring assembly (2) into the flywheel box is rotation.
completed. Fi
gure52
Figure 50/9 2

4 75692

Tighten the engine flywheel (1) fixing screws (2) in two


phases:
87659 1st phase; tightening by means of dynamometric
wrench to couple 30 ± 4 Nm;
2nd phase, 60° ±5° angle dwell
Flywheel installation
NOTE
Screw up two hooks or trail rings in the flywheel (1) Angle dwell shall always be performed using
threaded ports (4) for handling . 99395216 tool.
Using a hoist, handle the flywheel to place it in its Before assembly, always check that the
housing inside the flywheel cover box. threads of the ports and of the screws have no
Screw up to pins (2) having appropriate length, in the evidence of tear and wear or dirt..
shaft ports (3) and using them as guide, assemble the
engine flywheel (1) properly placing it inside the fly- Fi
gure53
wheel cover box.
1
Fi
gure51
1 4
2

3 75695

75690

Installation of front components


Tighten the screws (4) fixing the engine flywheel (3) Assemble oil pump (1).
to the engine shaft. Use tool 99360339 (2) to operate

SM 751 00(D-IVECO)-3-19
Group 00, Engine(D-IVECO)

Tighten fixing screws (2) and lock themto the pre- Remove the fixing ring (2) from the front cover (1),
scribed couple. accurately clean the plug surface.
Fi
gure54 Fi
gure57

70223

70220
Accurately clean the contact surface of engine block
Apply to the water pump (1) a new fixing ring (2). and apply sealing LOCTITE 5205 on it in order to
form a uniform and continuous bead with no crumbs.
Fi
gure55 Fi
gure58

70221

Assemble the water pump (1).


75710

Tighten the screws (2) and lock them to the prescribed Assemble the front cover (2) to the block and tighten
couple. the screws (1) fixing them to the prescribed couple.
Fi
gure56
Fi
gure59

76112 75812

SM 751 00(D-IVECO)-3-20
Group 00, Engine(D-IVECO)

Apply on engine drive shaft front tang (6) the detail Assemble the plate (3), the suction rose (5) and tighten
(4) of the tool 99346252, fix it with the screws (5) and the fixing screws (1, 2 and 4) to the prescribed torque.
key the new holding ring on it (7). Fi
gure62
Place the detail (2) on the detail (4), screw-up the
threaded nut until carrying out the complete assembly
of the holding ring (7) to the front cover.
Fi
gure60

86601

00902

Assemble the plate (1), the rose pipe (2), tighten the
fixing screws (3) and fix them to the prescribed cou-
ple.
Fi
gure61

87260

SM 751 00(D-IVECO)-3-21
Group 00, Engine(D-IVECO)

Assembly of additional masses


Fit the additional masses (2) and tighten the screws (3) on
the engine block.
Remove the lock pin (1) of the additional masses.
Fi
gure63

Timing of additional masses


Version with reduced distribution
Match the signs (A) engraved on the gears for timing,
insert the pin in the hole (B) on the balancing mass.
86578

Figure 64

1. Injectionpump gear 2. Camshaft control gear 3. Injection pump control gear(reduced distribution)
4. Additional masses.

SM 751 00(D-IVECO)-3-22
Group 00, Engine(D-IVECO)

Provide for new gasket replacement (1) of the oil pan Assemble the pulley (1) to the engine drive shaft , and
(2). the distance ring (3).
Tighten the fixing screws (2) and lock them to the 68
NOTE
±7 Nm couple.
The pictures illustrating the pan and of the
Fi
gure67
rose pipe may not correspond to the ones of
your model. However the procedures
described are applicable anyway.
Fi
gure65

Assemble oil pan (1), apply the plate over it (2).


Tighten the screws (2) and lock them to the prescribed
couple.
1 2
NOTE
75697
Before assembly, always check that the
threads of the ports and of the screws have Assemble the following elements to the block: new
no evidence of tear and wear or dirt. gasket (1), heat exchanger (2), new gasket (3), oil filter
bearing (4).
Fi
gure66 Tighten the screws (5) and lock them to the prescribed
couple.
NOTE
Before assembly, always check that the
threads of the ports and of the screws have
no evidence of tear and wear or dirt.
Fi
gure68

75814
88046

SM 751 00(D-IVECO)-3-23
Group 00, Engine(D-IVECO)

- Lubricate the fixing ring (2) using engine oil and NOTE
place it on the oil filter (3). Before assembly, always check that the
- Manually start the oil filter (3) on the bearing union threads of the ports and of the screws have
(1) until counter-boring, further screw up the oil filter no evidence of tear and wear nor dirt.
(3) by 3/4 turn.
Fi
gure70
- Place a new fixing ring on the block housing (6).
- Apply, (if needed) new fixing ring on the oil temper-
ature/pressure sensor (4) and assemble it to the bearing
(1) tightening the fixing screws to the prescribed cou-
ple.
NOTE
In some applications, the bearing of the
exchanger shall be assembled to a screw
threaded union connected to the filter on the
opposite side of the engine, throughout two
pipelines (see picture 2).
Fi
gure69 76114

Connect the alternator (1) to the support.


Tighten the screw without locking it (2).
Fi
gure71

1 2

76113

NOTE
The shape and the dimensions of the alterna-
tor support vary according to the use of the 75686

engine. Therefore the relevant pictures pro-


vide a general guideline of the procedures Place the gasket (1) over the block.
that are to be carried out. However the pro- The choice of the gasket’s thickness shall be made in
cedures described are applicable. consideration of the cylinder protrusion measured with
respect to the block’s upper surface.
- Assemble the alternator bearing (1) ensuring that the
NOTE
pins (3 and 4) are against the engine block.
- Tighten the screws (2) and lock them to the pre- Verify that the engine block stand is clean.
scribed couple. Do not grease the gasket. It is recommended
to keep the gasket inside packaging until
assembly to the cylinder head.
Gasket assembly shall be made following the
direction of wording printed on the gasket

SM 751 00(D-IVECO)-3-24
Group 00, Engine(D-IVECO)

itself so that this will be readable as indicated M12 x 180 ...............70 Nm + 180 deg’s
in the picture. Fi
gure74
Fi
gure72

10 4 1 5 11

13 7 2 8 14
9 3 6 12

76115

Carry out the assembly of the rocker arms after previ-


ous check of the components..
87759
Figure 75
Place the head (3) over the block and insert screws (1)
and (2). 4

NOTE 1
If the valves have been removed from the 3
head, it is necessary to assemble them before
assembling the head itself on the engine 2
block. 2
Fi
gure73 3
1

1 75705

2 ROCKER ARM UNIT COMPONENTS:


1. Elastic ring - 2. Spacer- 3. Rocker arms-
4. Support
3
Check the coupling surfaces of bearing and shaft: no evi-
dence of excessive wear shall be detected or damages.
Replace if necessary.
Figure 76
4
75688

18.975
18.963
Lubricate cylinder head bolts and install to head.
Bolts must be torqued using stitching pattern starting
with the centre bolts and moving out. Bolts to be
torqued in stages: all bolts torqued to snug torque, then
90 degrees rotation for all bolts. Then a further 90
degrees for the M12 x 140 and M12 x 180.
M12 x 70 .................50 Nm + 90 deg’s
M12 x 140 ...............40 Nm + 180 deg’s 19.000 19.000
19.026 19.026
75704

SHAFT AND ROCKER ARM BASIC DATA

SM 751 00(D-IVECO)-3-25
Group 00, Engine(D-IVECO)

If unscrewed, check adjustment quota. Tighten the screws (2) to the prescribed couple and
Tighten the screw-threaded nut (1) to the i 0.4 - 0.6 Nm assemble water temperature sensor (1).
couple. Fi
gure80
Fi
gure77
2

19.00
16.00
75702

ROCKER ARM ADJUSTMENT SCREW


1
Before executing assembly, check the Rocker Arm driv- 75683
ing rods: these shall not be deformed; the spherical ends in
contact with the Rocker Armadjustment screw and with Adjust the slack between rocker arms and valves using
the tappet (arrows) shall not present evidence of seizure socket wrench (1), point wrench (3) and feeler gauge (2).
orwear: in case of detection proceed replacing them. Correct slack is:
The rods driving the intake and exhaust valves are identi- suction valves 0.25 ±0.05 mm
cal and therefore interchangeable. exhaust valves 0.50 ±0.05 mm.
Fi
gure78
NOTE
In order carry out a quicker adjustment of
the working slack between rocker arms and
valves, proceed as following: Rotate the
engine drive shaft, balance the valves of cyl-
inder 1 and adjust the valves identified by
star symbol, as indicated in the following
table:
Cylinder No. 1 2 3 4
Suction - - * *
Exhaust - * - *
32655

Insert the tappet driving rods and the Rocker Arm unit. NOTE
Before using the fixing screws again,measure themt- Rotate the engine drive shaft., balance the
wice as indicated in the picture, checking D1 and D2 valves of cylinder 4 and adjust the valves
diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again;
if D1 - D2 > 0,1 mm the screw must be replaced;
Fi
gure79

D2 D1

75703

SM 751 00(D-IVECO)-3-26
Group 00, Engine(D-IVECO)

identified by star symbol, as indicated in the In suchG case provide for replacement with
following table: new nods.
Cylinder No. 1 2 3 4 Fi
gure83
Suction * * - -
Exhaust * - * - 1 2
Fi
gure81

2 1

75806

Assemble injectors after having replaced the sealing


gasket (1).
NOTE
During assembly of injectors, verify that the
injector sphere is correctly positioned on the
head housing. 75681

Fi
gure82
Assemble exhaust manifold (1) providing new gaskets
(2).
NOTE
The illustration of exhaust manifold may be
notG matching your model. Anyhow,
describedGprocedure is applicable.
Fi
gure84

1
1
75707

Assemble cylinder covers (2) with the respective gas-


kets;
Fit the seal nods and tighten the screws fixing them to
the prescribed couple.
2
NOTE
Always replace the gaskets using new ones. 75808

Check the threads of the fixing screws: there


shall beG no evidence of wear or dirt deposit. Assemble thermostat unit (2) including thermostat (5)
Seal nods shall have no visible deformation. and gasket (4).

SM 751 00(D-IVECO)-3-27
Group 00, Engine(D-IVECO)

Tighten the screws to the prescribed couple. For applications with traditional belt stretcher
NOTE In order to connect the POLY-V belt carry out the
The screws (1) have been have been utilised operations described on page _ vice versa.
to fixGthe bracket (3).
NOTE
Disassemble the bracket and reassemble
For belt stretching turn the alternator as
components from 1 to 5 as shown in the pic-
ture. indicated inGthe figure, tighten screw (1) and
The gasket must be new. the bolt that fixesG the alternator to the sup-
port.
Fi
gure85
NOTE
1 If the old belt is to be reassembled examine it
carefully in order to see if there may be inci-
4 sions orGevident signs of yielding.
Fi
gure87

2 5

75685

Assemble the pulley fan bearing tightening the screws


toGthe prescribed couple.
Assemble the alternator tensioning bracket.
Mount pulley (3) and secure it to support through
screws (2). 88090
Assemble the transmission pulley (1).
Fi
gure86
For applications with automatic belt tensioner
2 Assemble belt Poli-V (4) on the pulley (5) of the engine
shaft,Gon the jockey pulley (2), on the water pump (6) and
on theG alternator (3), tighten (syn.: tension) the belt by
means of theGautomatic belt tensioner.
Fi
gure88

75687
86571

SM 751 00(D-IVECO)-3-28
Group 00, Engine(D-IVECO)

Mount Poly-V belt (4) on pulley (7), engine shaft pul- Also assemble the brackets (1) fixing the fuel pipe-
leyG(5), guide pulleys (6), water pump (3) and alterna- linesG to the injectors: use the same screws (2) fixing
tor (1);Gstretch the belt by operating on automatic belt theGmanifold plate as shown in the picture.
tensionerG(2). Fi
gure91
Fi
gure89

90509

Apply on the surface joining the suction manifold


plateG(1) a sufficient coat of Loctite 5999 and provide.
fixingGthe screws to the prescribed couple.
If the pipe (6) of the suction manifold plate (1) has
75700
beenG removed, reassemble it after having fit a new
gasket (5).
Tighten the screws (7) to the prescribed couple. Assemble priming pump (1) providing new gasket and
tighten the screws (2) to the prescribed couple.
NOTE Also assemble feed pump (see specific procedure) and
For the versions provided with heater, also the power take-off underneath.
assembleGcomponents (3) and (4).
NOTE
Fi
gure90
Pump mounting requires specific procedure
contained in this section.
1 7 Fi
gure92
2
6

5
1
4

3
75701

2
75678

SM 751 00(D-IVECO)-3-29
Group 00, Engine(D-IVECO)

Figure 93

3
7

4
6 5

1. Rear bracket fixing screw (on suction collector plate) 2. Fuel recovery pipeline to pump 3. Rotary feed pump
4. Connection nut to pumping elements 5. Injector - 6. Bracket fixing screw to injection pump side
7. Front bracket fixing screw (on suction collector plate)

Assemble the pipes (1) and (2) providing fuel feed and Fix the LDA pipeline (1) to the engine head and to the
recovery between pump and injectors; feed pump.
Screw up the locking nuts and tighten the screws fix- Fi
gure95
ingG the fuel recovery manifold; fix the pipes to the
injectorsG throughout the brackets previously assem-
bled.
Fi
gure94

1 1

75677

- Assemble the fuel filter bearing (4) to the bracket


fixedGto the engine head.
- Connect the fuel pipelines (2 and 3) respectively
75679
fromGpriming pump to filter bearing and from this last
one toGfeed pump.
- Using 99360076 equipment assemble fuel filter (1).

SM 751 00(D-IVECO)-3-30
Group 00, Engine(D-IVECO)

NOTE - Tighten the lubrication pipe fixing ring. Operate in


The filter shall be priory filled with fuel to theGsame way on the other end of the pipe. Connect it
facilitateGfeed system bleed operations. toGthe upper part of the heat exchanger.
Fi
gure96 To complete engine assembly it is necessary to remove it
from the turning stand.
- Using rocker arm 99360595 hold the engine and
loosenG the screws fixing the brackets to the turning
standG99322205.
- Disassemble the brackets from the engine after hav-
ingGproperly put it on a wooden bearing.
Fi
gure98

90502

NOTE
To connect fuel pipelines (2 and 3, Figure 96)
in lowGpressure from the relating connection
unions it isGnecessary to press the locking fas-
tener (1) as shownGin picture B.
75675
After having connected the pipeline, reset the
fastener (1) into block position as shown in
pictureGA. Completion of the engine
Fi
gure97
On the right hand side:
reassemble the pipes (1) from the union (2) to the
lubrication oil filter (placed on the opposite side):
tightenG the pipe rings (1) and connect them to the
union
NOTE
In some cases, the oil filter (3) is directly
placed onG the heat exchanger: in this case it
shall be assembledGusing tool 99360076.
Fi
gure99

70126 2

For turbocompressed versions


proceed assembling the turbocharger:
- Hold the turbocharger and place it on the exhaust
manifold after having interposed the gasket.
- Screw up the fixing nuts of the turbocharger to the
exhaust manifold tightening them to the prescribed 3 1
couple.
75670

SM 751 00(D-IVECO)-3-31
Group 00, Engine(D-IVECO)

For turbocompressed versions On the left hand side:


Reassemble the lubrication oil exhaust pipeline (1) Assemble oil filter (1) together with bracket (for the
fromG the turbocharger: from underneath the turbo- versions with engine oil filter not directly assembled
chargerG tighten the two screws (2); tighten the screw toG the exchanger); tighten the screws (3) assembling
(3) fixingGthe pipeline to the block throughout the fix- theGbracket (4) including filter bearing (5).
ing collar (4)Gto the block; finally tighten the union (5) Using tool 99360076 screw up oil filter;
to the block. Assemble oil level rod togetherwith guide pipe (2).Fill
Figure 100
upGengine oil.
Install the engine on the machine (for installation
operations please apply to specific issue).
Figure 102

2
3
4

3 1
4
2
75673

75671

Reassemble the starter; properly hold the starter (1)


and tighten the fixing screws to the prescribed couple.
Figure 101

1
75717

SM 751 00(D-IVECO)-3-32
Group 00, Engine(D-IVECO)

Rotary feed pump disassembly and assembly The following procedure analyses this second hypothesis
since it is the more complex.
procedure
Figure 104
NOTE
This procedure prescribes that:
 The fuel pipelines (from pumping ele-
ments toG injectors, bleeding recovery 2
pipes from injectorsGto pump, LDA pipe-
line and feed provided byGpriming pump)
shall all be disassembled. 1
 Electrical connection to feed pump shall
beGdisconnected.
 Accelerator cable shall be disconnected.
Engine versions with tool (99360330)
75714
Disassemble the starter fromthe flywheel box and use tool
99360330 (2) to rotate the flywheel.
Find the top dead centre with the tool (99395097) -
Figure 103
False injector
Remove the rocker covers of the 1st cylinder; remove the
1st injector and place the tool (1) to set the 1st cylinder top
dead centre position (end-of-compression phase). Pre-
load the gauge.
The searched condition is obtained by rotating the engine
shaft properly until you find the maximum value on the
comparator and then checking that the intake and exhaust
valves are both closed.
Once PMS has been obtained, lock the flywheel by means
of tool 99360339 (Figure 104).
1
Figure 105 (Demonst
ration)
88140

Engine versions with tool (99360339)


Disassemble the starter from the flywheel box (1) and use
tool 99360339 (2) to rotate the flywheel.
In case feed pump replacement is necessary, this shall be
supplied pre-set already as spare part.
On the other hand, in case the pump shall be disassembled
and reassembled later on without being repaired it will be
necessary to pre-set it while it is still assembled to the
engine and disassemble it only afterwards.
1

88141

Unscrew the side screw that locks the pump shaft par-
tially (1) and remove spacer (2). This must be kept on

SM 751 00(D-IVECO)-3-33
Group 00, Engine(D-IVECO)

a side (we recommend to fix it on the pump with a NOTE


wire or a clip). Hold the pump driving gear to avoid inter-
Tighten the lateral screw (1) blocking rotation of the ference or crawling during timing gear rota-
pump shaft. tion.
Figure 106 Figure 108

2 1

75694
75721

From timing side, remove the cover (2) loosening the Assemble the pump pre-set in its housing on the
screws (1) in order to have access to the union fixing engine, fitting the shaft into the gear port (not provided
nut (3) to the pump driving gear. with wrench).
Loosen the fixing nut (3) and remove the relating Tighten the fixing nuts (1) locking the pump flange in
washer. the slot centre.

Figure 107 NOTE


The gasket removed during pump disassem-
1 4 bly shall not be utilised again.
Always use original spare parts.
Figure 109

2 3
75693

From the pump side, loosen the fixing nuts (1) without
removing them in order to enable moving the pump
75694
backwards using 99340035 extractor.
Assemble the 99340035 extractor throughout the two
threaded ports (4, Figure 107) and withdraw the gear
from the pump shaft.
Properly hold the feed pump and loosen completely
the fixing nuts.
Withdraw the pump from the studs, together with the
gasket.
When the supply pump is to be assembled on the engine
the P.M.S. conditions at compression end stage cylinder
No. 1 must be carried out.

SM 751 00(D-IVECO)-3-34
Group 00, Engine(D-IVECO)

On the timing side, throughout the specially appointed With the injection pump inserted in relating seat and
port, fit the washer and screw up the fixing nut (3) to securing screws loosened, mount comparator
the pump shaft. Lock the nut to the 90-95 Nm couple. 99395603 (2) and 99395100 gauge tool (1), preloading
Figure 110 the rod by 2.5 mm.
Rotate the engine drive shaft to shift from the condi-
1 4 tion of the first cylinder to TDC end of compression
phase. Reset the dial gauges and rotate the engine
drive shaft condition of the 1st cylinder to TDC in
phase of compression (see Figure 105).
From this position on the comparator applied on the
pump it must be possible to read the value listed on the
pumping element pre-lift table. Section 4.
Rotate the pump in anti-clockwise direction if the
stroke is shorter or in clockwise direction if the stroke
is longer, until obtaining the stroke prescribed.
2 3 Checking these conditions, lock the pump by tighten-
75715 ing the relevant nuts to the prescribed pair.
Figure 112 (Demonst
ration)
Loosen screw (1) that prevents pump shaft rotation
and insert spacer (2). Tighten screw (1)so that it locks
spacer (2): in this way the supply pump shaft will be
able to rotate freely.
Assemble the cover (2, Figure 110) including gasket
and tighten the screws (1, Figure 110).
Disassemble the flywheel rotation/locking tool
99360339 or 99360330; arrange the starting motor in
its seat.
Connect all pipelines (from pumping elements to
injectors, bleeding recovery pipes from injectors to
pump, LDA pipeline and feed provided by priming 87720
pump).
Connect electrical connections to electro-magnets on
the hydraulic head and on KSB.
NOTE
In case pump removal has been carried out
while the engine was assembled, connect
acceleration cable.
Figure 111

1 2

75721

Ignition pump control and timing

SM 751 00(D-IVECO)-3-35
Group 00, Engine(D-IVECO)

Feed system bleed procedure Power take-off disassembly and assem-


Version with A type fuel filter bly procedure
In case any operation has been executed on the compo- Where designed, there is a power take-off able to transmit
nents of the feed circuit, it is necessary to execute bleed- motion to different auxiliary parts.
ing of air within the system. Disassembly of such mechanism shall be executed as fol-
Loosen the bleeder vent screw (3) on the fuel filter (1) lowing:
and keep working on the bleed lever of the priming Loosen the two screws (3) and after having removed
pump (2). the cover (1) with a specially provided extractor, with-
Continue executing this operation until when fuel draw the power take-off (2).
drains from the bleeder vent screw. The two gaskets (4) shall be replaced in phase of reas-
Tighten the bleeder vent screw (3). semble.
Figure 113 Vary out the assembly fitting the power take-off in its
housing, providing new gasket and checking the
sprocket gear meshing.
Assemble cover and gasket and tighten the screws to
the prescribed couple.
Figure 115

1 4 3

76211

Version with B type fuel filter


Disconnect the fuel pipe (1) of the filter and repeat
working on the drain lever (2) of the priming pump.
Continue the operation until when fuel outflows.
Connect the (1) to the filter. 2 75720

Figure 114

87751

SM 751 00(D-IVECO)-3-36
Group 00, Engine(D-IVECO)

Checks and controls


NOTE
The following tests shall be made after engine
assembly to the vehicle.
Preventively check that the liquid levels have
been correctly restored.

Start the engine, let it run at revolution regimen slightly


higher than idling and wait that the cooling liquid temper-
ature reaches the value enabling thermostat opening, then
check that:
There is no water bleeding from the manifolds con-
necting engine cooling circuit pipelines and cabin
internal heating, eventually providing to further
tighten the locking rings.
Carefully check the fuel connection pipes to the
respective unions.
There is no oil leakage from the lubrication circuit of
the various pipelines connecting cover and cylinder
head, oil pan and bearing, oil filter and heat exchanger
as well as relating housings.
There is no fuel leakage from fuel pipelines.
There is no blow-by from pneumatic pipes (if pro-
vided).
Verify correct working of the lighting leds of the dash-
board containing the tools as well as of the equipment
that was disconnected during engine disconnection.
Check and blow by with care the engine cooling sys-
tem, carrying out frequent drainage.

SM 751 00(D-IVECO)-3-37
Group 00, Engine(D-IVECO)

ELECTRICAL EQUIPMENT
ELECTRICAL COMPONET LAYOUT (4 CYL. ENGINESWITH ROTARY POMP)
Below there are listed the electric components which are 4. Electromagnets assembled to feed pump:
present on NEF F4BE04--- and F4GE04--- engines. (A) on hydraulic head unit
(B) on KSB;
1. Cooling liquid temperature sensor;
5. Fuel heater;
2. Starter;
6. Oil pressure sensor;
3. KSB Water temperature sensor;
7. Resistance for cold start up (where provided for);
8. Alternator;

Figure
340

3 4
2

A
1

B
8

7 5

75724

Cooling liquid temperature sensor Bulb side on engine: .......-40 ~ +140 ଇ


Working tensions: ...........6 ~ 28 V
It is a component integrating a temperature sensor. Settings:
It is assembled to the engine head close to the thermostat 80 ଇ ..........................0.304 ~ 0.342 ໰
unit and its duty is to detect engine cooling liquid temper-
ature.
Specifications:
Range of working temperatures:
Connection side ...............-40 ~ +150 ଇ for < 10 min.

SM 751 00(D-IVECO)-3-38
Group 00, Engine(D-IVECO)

20 ଇ ........................... 2.262 ~ 2.760 ໰ KSBWater temperature sensor


-10 ଇ .........................8.244 ~ 10.661 ໰
Figure341
It is assembled to the cylinder head on the engine left hand
side.
Specifications:
Working tensions: 12 ~ 24 V
Electrical Power load: 2.5 A (induction)
5.0 A (resistance)
Setting: 32±2ଇ Contact opening upon
increasing temperature 22±2
ଇ Contact closure upon
decreasing temperature
Figure
343

A B

A C
B
75718

Starter
Starter is usually driven by starting unit placed on the
vehicle dashboard and provides positive tension to the
75719
tele-switch assembled to the starter itself.
Specifications: BOSCH 3 kW - 12V
Electromagnets assembled to feed pump
Figure
342
Figure 344

1 2
75724a
75717

1. Hydraulic head Electro-magnet


2. KSB Electro-magnet

SM 751 00(D-IVECO)-3-39
Group 00, Engine(D-IVECO)

Oil pressure sensor Alternator


It is assembled to the block on the engine’s left hand side. It is place front view on the right hand side of the engine,
and is driven by tooth belt.
Specifications:
Specifications:
Working tensions: ............................12 ~ 24 V
Working tension: ..................... 12 V
Contact closure Current delivered: .................... 90A (at 6000 rpm)
upon lower pressure: ........................0.2 bar Absorption in stand-by: UUUUUUUUUUU ˺ 1mA
Contact opening Sense of rotation: ..................... clockwices
upon higher pressure: .......................0.9 bar Figure
347
Fig
ure 345

75722
75725

Fuel filter Pre-post heating resistor


On the fuel filter bearing there is the temperature sensor
It is a resistor assembled to the suction collector and is
and the fuel filter heating resistor connection.
utilised to heat the air during pre-post heating operations.
Figure
346
It is fed by a tele-switch usually placed very close to the
engine.
Specifications:
Working tension: 12 V
Maximum possible
air flow: 2 cc / min
(pressure 138 kPa)
2 Figure348

75716

1 - Fue l t e mp e ra t u re s e n s o r;
2 - R es i s t o r f o r f i l t e r h e a t i n g ;

75723

SM 751 00(D-IVECO)-3-40
Group 00, Engine(D-IVECO)

Pre-post heating unit Operating temperature: ..........................-40ଇ ~ 85ଇ


Maximum current in the GH line: .........0.3A
Legend
F= Fuse
R= Pre-post heating resistance
T= Remote control switch
GHC = Pre-post heating unit
Figure
349

+0 30

F 15 7
4
6 GH F
30 50 5
NTC 10 T
31 8
N31
1 3 FB

1.2W R

88153

Electrical diagram pin out


PIN Description
1 “Cold start” warning indicator light output
2 Not connected
3 Feedback signal input from pre-post heating resis-
tance (FB)
4 Started engine signal input (D)
5 Start-up signal input (50)
6 Pre-post heating resistance supply remote control
switch output (GH)
7 Supply positive (15)
8 Supply negative (31)
9 Not connected
10 Temperature analogue signal input (NTC)

This unit operates, bymeans of the remote control switch,


the pre-post heating resistance according to the engine
coolant temperature.
Features:
Nominal voltage: ................................... 12 V
Operating voltage: ................................. 7 V ~ 16V

SM 751 00(D-IVECO)-3-41
Group 00, Engine(D-IVECO)

TROUBLESHOOTING
ANOMALY POSSIBLE CAUSE REMEDY NOTE

The engine does not start Battery flat or faulty. Check and recharge battery.
Replace battery if necessary.

Connections to battery termi- Clean, examine and tighten the nuts


nals corroded or loose. on the battery terminals. Replace
the cable terminals and the nuts if
excessively corroded.

Incorrect timing of injection Check and correctly time the injec- See your Iveco dealer.
pump. tion pump.

Deposits or water in the fuel Disconnect the hoses and clean Drain feed system.
tank. them using a jet of compressed air.
Dismantle and clean the injection
pump.
Remove water from tank and
refuel.

No fuel in tank. Refuel.

No power supply. Overhaul or replace the fuel or


transfer pump.

Air bubbles in the fuel lines Check the hoses to ensure that air is
or injection pump. in fact present and also check the
fuel pump.
Eliminate the air from the injection
pump by unscrewing the cap and
working the fuel pump by hand.

Faulty starter motor. Repair or replace the starter motor.

The engine does not start Fuel system clogged with Replace the fuel with fuel suitable
at low temperatures paraffin crystals forming due for use at low temperatures.
to the use of unsuitable fuel. Replace the fuel filters.

K.S.B. device for cold spark Check or replace the injection See your Iveco dealer.
advance control operating pump.
incorrectly.

SM 751 00(D-IVECO)-3-42
Group 00, Engine(D-IVECO)

ANOMALY POSSIBLE CAUSE REMEDY NOTE

The engine cuts out. Idle rpm too low. Adjust with adjustment screw.

Irregular flow of injection Adjust flow. See your Iveco dealer.


pump.

Impurities or water in the fuel Disconnect the hoses and clean Drain feed system.
lines. them using a jet of compressed air.
Dismantle and clean the injection
pump. Remove water from fuel
tank and refuel.

Clogged fuel filter. Dismantle and replace if necessary.

Presence of air in the fuel and Check that the hoses are not
injection system. cracked or the unions loose.
Replace worn parts, remove the air
from the hoses and deaerate the
injection pump and fuel filter by
unscrewing the caps and working
the primer pump by hand.

Broken injection pump con- Replace the faulty parts.


trols.

Abnormal clearance between Adjust clearance by replacing


camshaft cams and tappets. shims.

Burnt, corroded or chalky Replace the valves, rectify or


valves. replace the cylinder head seatings.

The engine overheats Faulty water pump. Check the unit and replace if neces-
sary. Replace the gasket.

Malfunctioning thermostat. Replace the thermostat.

Fouling in coolant openings Wash following the standards spec-


in the cylinder head and cyl- ified for the type of descaling prod-
inder groups. uct used.

Water pump drive belt slack. Check and adjust the tightness of On applications provided
the belt. with automatic tensioner,
check corret worching of
such device.

Coolant level too low. Top-up radiator with coolant.

Incorrect engine timing. Check timing and tune correctly.

Incorrect calibration of injec- Correct the delivery rate of the See your Iveco dealer.
tion pump. pump on a bench so that the injec-
tion is at the specified rate.

Dry air cleaner blocked. Clean the air filter or replace if nec-
essary.

SM 751 00(D-IVECO)-3-43
Group 00, Engine(D-IVECO)

ANOMALY POSSIBLE CAUSE REMEDY NOTE

Engine operation is irreg- Incorrect timing of injection Check timing and correctly set
ular and lacks power pump. pump.

K.S.B. automatic cold Check or replace injection pump.


advance device malfunction-
ing.

Excessive piston wear. Check or replace injection pump.

Incorrect calibration of speed Check and correctly calibrate the See your Iveco dealer.
regulator. regulator.

Engine operation is irreg- Partial blockage of nozzles or Clean the nozzles of the atomisers
ular and lacks power faulty operation of injectors. using the appropriate tools and
completely overhaul the injectors.

Impurities orwater in the fuel Carefully clean the system and If necessary drain feed
and injection system. refuel. system.

Incorrect play between cam- Check and correct play


shaft cams and tappets.

Faulty turbocharger. Replace complete unit.

Air cleaner blocked. Clean or replace air cleaner.

Faulty operation of L.D.A. Check that the diaphragm is not See your Iveco dealer.
device perforated, that the counter spring
is suitable and that it has the correct
loading (check on test bench).
Check that there is adequate air
pressure inside the intakemanifold
in relation to the engine rpm under
full-load conditions.

Tie rods between accelerator Adjust the tie-rods so that the com-
pedal and regulation lever mand lever can be moved to the full
incorrectly adjusted. delivery position.

Engine running with Faulty operation of injectors. Replace all injectors.


abnormal knocking
Fuel lines blocked. Dismantle the hoses, clean them
and replace those that are seriously
dented.

Incorrect set-up of injection Correct the set-up of the pump so See your Iveco dealer.
pump. that injection occurs at the speci-
fied angle.

SM 751 00(D-IVECO)-3-44
Group 00, Engine(D-IVECO)

ANOMALY POSSIBLE CAUSE REMEDY NOTE

Engine running with Knocking of crankshaft caus- Rectify the pins of the crankshaft
abnormal knocking ing excessive play on one or and install smaller bearings.
more main or rod bearings or Replace the thrust halfrings.
excessive play on shoulders.

Crankshaft unbalanced. Check alignment of crankshaft.

Loosening of screws securing Replace the loosened screws and


flywheel. tighten all the screws to the speci-
fied torque.

Misalignment of rods. Replace the rods.

Noise from piston journals Replace the piston journal and/or


due to excessive play of pis- the piston and rod bushing.
ton hubs and in the rod bush-
ing.
Loose bushings in the rod Replace with new bushings.
seatings.

Noisy timing. Adjust the play between camshaft


cams and tappets and check that
there are no broken springs, that
there is no excessive play between
the valve stems and the valve
guides, tappets and seatings.
The engine smokes Excessive maximum pump Disconnect the pump and adjust See your Iveco dealer.
abnormally. Black or dark output. delivery in accordance with the
grey smoke. data given in the calibration table.

K.S.B. device out of calibra- Check operation by a tester and


tion or malfunctioning. adjust correctly as described in the
manual.

There is an excessive delay Correct the set-up.


on the injection pump.

SM 751 00(D-IVECO)-3-45
Group 00, Engine(D-IVECO)

ANOMALY POSSIBLE CAUSE REMEDY NOTE

The engine smokes The injection pump has an Correct the set-up.
abnormally. Black or dark excessive advance.
grey smoke.
The holes in the atomisers (or Replace the injectors with a series
some of them) are partially or of new injectors or clean and rec-
entirely blocked. tify the original ones using suitable
equipment.

Air cleaner blocked or deteri- Clean or replace the filter element.


orated.

Loss of compression in the Overhaul the engine or limit the


engine due to: interventions to the relative parts.
stuck or worn flexible rings;
worn cylinder liners;
valves deteriorated or badly
adjusted.

Unsuitable injectors, differ- Replace or calibrate the injectors.


ent types of injectors or
incorrectly calibrated.

Injection hoses with an Check conditions of the end or


unsuitable internal diameter, unions and where necessary replace
end of hoses pinched due to the hoses.
repeated blocking.

Blue, grey-blue, grey Excessive delay in injection Correct the set-up of the pump. See your Iveco dealer.
smoke tending to white. pump.

K.S.B. automatic cold Check or replace injection pump. See your Iveco dealer.
advance device malfunction-
ing.

Faulty injector. Replace the injector.

Leaking of oil from the pis- Overhaul the engine.


ton rings caused by glued or
worn rings or wearing of cyl-
inder liner walls.

Engine oil passing through Recondition the cylinder head.


the intake guides-valves fol-
lowing wearing of guides or
valve stems.

Engine too cold (thermostat Replace the thermostat.


blocked or inefficient).

SM 751 00(D-IVECO)-3-46
Group 00, Engine(D-IVECO)

MAINTENANCE PLANNING
MAINTENANCE PLANNING

Recovery
To ensure optimisedworking conditions, in the following pageswe are providing instructions for the overhaul control
interventions, checks and setting operations that must be performed on the engine at due planned dates.
The frequency of themaintenance operations is just an indication since the use of the engine is the main characteristic to
determine and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary
maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested
by common sense and by the specific conditions in which the engine is run.

Planning of controls and periodical intervention


Controls and periodical intervention Frequency (hours)
Visual check of engine ................................................................................................. Daily
Check presence of water in fuel filter or pre-filter ........................................................ Daily
Check of belt wear status ............................................................................................. -
Check and setting of tappet clearance .......................................................................... 4000
Replacement of engine’s oil and filter .......................................................................... 500
Replacement of fuel pre-filter ...................................................................................... 1000
Replacement of fuel filter ............................................................................................. 500
Replacement of belt ...................................................................................................... 1500
NOTE
The frequency of the maintenance operations is just an indication since the use of the engine is the main
characteristic to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescrip-
tions provided by Iveco Motors.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and
number of turns based on which the engine has been designed.

Checks not included in maintenance planning-daily checks


It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid
inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s
drivers.
 Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
Verify absence of noise or unusual rattle during engine working.
Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
Visual check of fumes (colour of exhaust emissions)
Visual check of cooling liquid level, in the expansion tank.

SM 751 00(D-IVECO)-3-47
Group 00, Engine(D-IVECO)

MAINTENANCE PROCEDURES full compliance with the law and regulations


in force.
Fig
ure 371
Checks and controls
Engine oil level check.
The check must be executedwhen the engine is discon-
1
nected and possibly cool.
The check can be made using the specially provided flexi-
ble rod (1).
Draw off the rod fromits slot and check that the level is
within the etched tags of minimum and maximum level.
Whether it should be difficult tomake the evaluation, pro-
ceed cleaning the rod using a clean cloth with no rag
grinding and put it back in its slot. Draw it off again and
check the level.
In case the level results being close to the tag showing 2
minimum level, provide filling lubrication of the engine’s
components. 75749

Figure
370
Check of fuel system
The check must be executed both when the engine discon-
MA X nected and when it is running.
The check operation consists in examining the fuel pipe-
lines running from the tank to the pre-filter (if provided in
the specific equipment), to the filter, to the injection pump
and to the injectors.
M IN
Cooling system check
The check must be executed both when the engine discon-
1 nected and when it is running.
75748 Check the pipelines from the engine to the radiator, from
the expansion tank and vice-versa. Find out any blow-by,
To provide filling, operate through the upper top (1) or
verify the status of the pipes specially close to the holding
through the lateral top (2). During filling operation, the
strips.
tops must be removed as well as the rod in order to make
the oil flow easier”. Verify that the radiator is clean, the correct working of the
fan flywheels, the presence of any leakage from the con-
Some applications are equipped with a level transmitter nectors, from the manifold and from the radiating unit.
alerting dashboard instruments in case of insufficient
lubrication oil within the pan. NOTE
Due to the high temperatures achieved by the
NOTE system, do not operate immediately after the
The engine oil is highly polluting and harm- engine’s disconnection, but wait for the time
ful. deemed necessary for the cooling.
In case of contact with the skin, rinse well Protect the eyes and the skin from any even-
with water and detergent. tual high pressure jet of cooling liquid.
Adequately protect the skin and the eyes,
operate in full compliance with safety regula-
tions.
Disposal must be carried out properly, and in

SM 751 00(D-IVECO)-3-48
Group 00, Engine(D-IVECO)

The density of the cooling liquid must be checked any Some applications are equipped with an automatic ten-
how every year before winter season and be replaced in sioner that provides correcting belt tensioning.
any case every two year.
Check of belts tear and wear status
NOTE
Carefully verify the belts surface in order to detect any
In case of new filling, proceed bleeding sys- sign of incision, crack, excessive wear in correspondence
tem, through the bleeds on the engine. of toothing; check end and surface grinding.
If bleeding of the system is not carried out,
serious inconvenience might be caused to the
engine due to the presence of air pockets in
! DANGER
the engine’s head. Danger: if the engine is switched off but is
still hot, unexpected motion of the belt may
Lubricating system check occur.
Wait for engine temperature cooling as a
The check must be executed both when the engine
precaution in order to avoid serious danger
disconnected and when it is running. injury.
Verify the presence of any oil leakage or blow-by from
the head, from the engine pan of from the heat exchanger. Check and setting of tappet clearance
NOTE Adjust clearance between rockers and valves using set-
The engine oil is highly polluting and harm- screw wrench (1), box wrench (3) and feeler gauge (2).
ful.
Clearance shall be as follows:
In case of contact with the skin, rinse well
with water and detergent. intake valves 0.25 0.05 mm
Adequately protect the skin and the eyes, exhaust valves 0.50 0.05 mm.
operate in full compliance with safety regula- Figure372
tions.
Disposal must be carried out properly, and in 2 1
full compliance with the law and regulations
in force.
3
Check of water presence within fuel filter or pre-filter
NOTE
The components of the system can be dam-
aged very quickly in presence of water or
impurity within the fuel.
Timely proceed operating on the pre-filter
(not available on the engine block) to carry 75806

out the drainage of the water within the feed


circuit. NOTE
Fuel filter is equipped with pump screw-valve to drain the In order to more quickly perform the operat-
water eventually mixed with fuel (some applications of 6 ing clearance adjustment for rocker arms —
cylinders engines will be equipped with two fuel filters, valves, proceed as follows:
both provided with drainage. rotate the drive shaft, balance cylinder 1
valves and adjust the valves marked by the
Place a container underneath the filter and slightly loosen
asterisk as shown in the table:
the screw. Drain the water eventually contained in the fil-
ter’s bottom.
cylinder n. 1 2 3 4
Lock the screw (max 0.5 Nm locking couple) as soon as
fuel starts bleeding. intake - - * *
exhaust - * - *
Check of drive belt tensioning

SM 751 00(D-IVECO)-3-49
Group 00, Engine(D-IVECO)

Rotate the drive shaft, balance cylinder 4 valves and Check the level through the dipsick until when the fill-
adjust the valves marked by the asterisk as shown in the ing is next to the maximum level notch indicated on
table: the dipsick.

cylinder n. 1 2 3 4 Whereas you replace the lubrication oil, it is necessary to


intake * * - - replace the filter.
According to the application the filter can be located in
exhaust * - * -
different positions: the following procedure is a valid
guide for all applications.
Oil motor and filter replacement The filter is composed by a support and a filtering car-
tridge. For the cartridge replacement use the 9936076-
! WARNING tool.
Warning: We recommend to wear proper
protection because of high motor service ! WARNING
temperature. Warning: the oil filter contains inside a
The motor oil reaches very high tempera- quantity of oil of about 1 kg.
ture: you must always wear protective gloves. Place properly a container for the liquid.
Warning: avoid the contact of skin with the
Due to the several applications, the pan shape and the oil motor oil: in case of contact wash the skin
quantity can change slightly. However, the following with running water.
operations are valid for all applications. The motor oil is very pollutant: it must be
Werecommend to carry out the oil drainage when themo- disposed of according to the rules.
tor is hot.
Replace the filtering cartidge with a new one and
Place a proper container for the oil collecting under screw manually until when the gasket is in contact
the pan connected with the drain plug. with the support.
Unscrew the plug and then take out the control dipsick Tigthen by means of the 99360076-tool of three fourth
and the inserting plug to ease the downflowof the turn.
lubrication oil. Operate the motor for some minutes and check the
NOTE level through the dipsick again. If it is necessary, carry
out a topping up to compensate the quantity of oil used
The oil motor is very pollutant and harmful.
for the filling of the filtering cartridge.
In case of contact with the skin, wash with
much water and detergent.
Protect properly skin and eyes: operate Fuel filter replacement
according to safety rules.
Dispose of the residual properly following the NOTE
rules. During this operation don’t smoke and don’t
use free flames.
After the complete drainage, screw the plug and carry Avoid to breathe the vapors coming from fil-
out the clean oil filling. ter.
NOTE
NOTE
Use only the recommended oil or oil having
After filters replacement the supply equip-
the requested features for the corrrect motor
ment deaeration must be carried out.
functioning.
In case of topping up, don’t mix oils having
According to the applications the filters position and the
different features.
quantity can change.
If you don’t complywith theses rules, the ser-
vice warrantyis no more valid. However the following operations are valid for all appli-
cations.

SM 751 00(D-IVECO)-3-50
Group 00, Engine(D-IVECO)

Drain the fuel inside the filter by operating the water For applications with automatic belt stretcher
release screw. Collect the fuel in a container without
Unscrew the screws which fix the belt guard (2) to the
impurities.
support and dismount it.
Unscrew the cartridge by using the 99360076-tool.
Operate on the tightener (1) and withdraw the belt (3)
Collect the eventual fuel inside the filtering cartridge.
from the alternator and water pumps from pulleys and
Clean the gasket seat on the support and oil slightly
from the returns pumps.
the gasket on the new filtering cartridge.
Replace the worn belt with a new one.
Screw manually the new filtering cartdrige until when
Place the belt on the pulleys and the guide rollers.
the gasket is completely on its seat.
Place the automatic tightener in order to key the belt in
Tigthen through the 99360076-tool at 10-5 Nm torque.
the functioning position.
Alternator belt replacement
Further adjustments are not required.
Due to several applications the belt run can change very- Fig
ure 374
much.
We describe the replacement of a belt mounted on a 4-cyl- 1
inders motor with traditional belt tension and a 6-cylin-
ders motor with an automatic screw coupling.

! WARNING
Warning: with switched off motor (but still
hot) the belt can operate without advance
notice. 2 3
Wait for the motor temperature lowering to
avoid very serious accidents.

For applications with traditional belt stretcher 74171

Loosen screw (1) and the relevant nut on belt stretch-


ing bracket (3).
Loosen the bolt that fixes the alternator to the support.
Fit the new belt on the pulleys and guide rollers.
Stretch POLY-V belt (2).
Lock screw (1) and the bolt that fixes the alternator to
the support
Run the engine for a few hours and check proper belt
stretching.
Figure
373

88089

SM 751 00(D-IVECO)-3-51
Group 00, Engine(D-IVECO)

Section 4

OVERHAUL AND TECHNICAL SPECIFICATIONS

GENERAL SPECIFICATIONS

Type 4 CYLINDERS 6 CYLINDERS

Cycle Four-stroke diesel engine


Power See properties described in Section 3
Injection Direct

Number of cylinders 4 in-line 6 in-line

Bore mm 104/102 ( . )

Stroke mm 132/120 ( . )

+ + +..= Total displacement cm 3 4485/3922 ( . ) 6728/5883 ( . )

TIMING

start before T.D.C. A 15°


end after B.D.C. B 35°

start before B.D.C D 69°


end after T.D.C C 21°

Checking timing
mm -
X
mm -
X
Checking operation
mm 0.25 ± 0.05
X
mm 0.50 ± 0.05

FUEL FEED

Type: rotary Bosch VE 4/12 F VE 6/12 F


in Bosch line PES 6A

Injectors
Nozzle type
DSLA 145 P

Injection sequence 1-3-4-2 1-5-3-6-2-4

bar
Injection pressure bar
-

( . ) Valid for F4BE--- engines only.

SM 751 00(D-IVECO)-4-1
Group 00, Engine(D-IVECO)

CLEARANCE DATA

Type 4 CYLINDERS 6 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm


1

Cylinder barrels 1 104.000to 104.024 / 102,01 to 102,03(• )


X

Sparepistons
1 type:
X Size X 55.9 / 61 (• )
Outsidediameter 1 103.730 to103.748/ 101.757to 101.775(• )
2 Pinhousing 2 38.010to38.016/ 40.006 to40.012 (• )

Piston— cylinder barrels 0.252 to 0.294/ 0.235to 0.273(• )

Pistondiameter 1 0.4,0.5,0.8

X
Pistonprotrusion X 0.28 to 0.52

3 Pistonpin 3 37.994to38.000 /39.994 to40.000(• )

Pistonpin— pin housing 0.010 to 0.022 /0.006to 0.018(• )

(• ) Valid for F4BE---enginesonly.

SM 751 00(D-IVECO)-4-2
Group 00, Engine(D-IVECO)

Type 4 CYLINDER 6 CYLINDER

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm


X1 2,705to 2,735 / 2,690*(• ) / 2,700*(• )
X1 Split ring slots X2 2,440to 2,460 / 2,425 to 2,445(• ) / 2,740*(• )
X2 X3 4,030 to 4,050/ 4,040 to 4,060(• )
X3 * measured on a of
98.75÷ 99.00 mm
S 1 S1 2.560to 2.605/ 2.310 to 2.340(• ) / 2.567to 2.618(• )
S 2 Split rings S2 2.350 to 2.380/ 2.560 to 2.605(• )
S 3 S3 3.970 to 3.990/ 3.975 to 4.000 (• )

1 0.100 to 0.175/ - (• )
Split rings- slots 2 0.060 to 0.110/ 0.115 to 0.180(• )
3 0.040 to 0.080/ 0.040 to 0.085(• )

Split rings 0.4, 0.5(• ), 0.8

X1 Split ringend opening


X 2 in cylinderbarrel:
X1 0.30 to 0.40/ 0.25to 0.55(• )
X3
X2 0.60 to 0.80/ 0.40to 0.70(• )
X3 0.30 to 0.55/ 0.25to 0.55(• )

1
Smallend bush
housing 1 40.987to 41.013 /43.279 to43.553(• )
Bigend bearing
housing 2 72.987 to 73.013
2

3 Smallend bush diameter


Outside 4 40.987to 41.013/ 43.279to 43.553(• )
Inside 3 38.019to 38.033/ 40.019to 40.033(• )
S Sparebig endhalf
bearings S 1.955to 1.968

Small end bush—housing 10.266 to 0.566(• )

Pistonpin —bush 0.019 to 0.039

Big end half bearings 0.250 to 0.500

(•) Validfor F4BE---enginesonly.

SM 751 00(D-IVECO)-4-3
Group 00, Engine(D-IVECO)

Type 4 CYLINDERS 6 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm


X
Size X --

Max. tolerance
on connecting rod
axis alignment --

Journals 1 82.99 to 83.01


Crankpins 2 68.987 to 69.013
1 2

Main half bearings S1 2.456 to 2.464


Big end half bearings S2 1.955 to 1.968

S 1 S 2

Main bearings
3 No. 1 - 5 3 87.982 to 88.008
No. 2 - 3 - 4 3 87.977 to 88.013

Half bearings . Journals


No. 1-5 / 1-7 0.064 to 0.095 / 0.041 to 0.119 (•)
No. 2-3-4 / 2-3-4-5-6 0.059 to 0.100 / 0.041 to 0.103 (•)
Half bearings - Crankpins 0.064 to 0.090

Main half bearings + 0.250 to + 0.500


Big end half bearings

1 37.350 to 37.650
Shoulder journal X1 37.475 to 37.545
37.475 to 37.545 (•)

X 1

Shoulder main bearing X2 31.730 to 32.280 / 25.980 to 26.480 (•)

X 2

X 3
Shoulder half-rings X3 37.28 to 37.38

Output shaft shoulder 0.095 to 0.270 / 0.068 to 0.410 (•)

(•) Valid for F4BE--- engines only.

SM 751 00(D-IVECO)-4-4
Group 00, Engine(D-IVECO)

Type 4 CYLINDERS 6 CYLINDERS

CYLINDER HEAD . TIMING SYSTEM mm


1

Valveguide seats on
cylinder head 1 8.019 to 8.039

4 Valves
:

4 7.943 to 7.963
60º

4 7.943 to 7.963
45º
Valve stem and guide 0.056 to 0.096
Housing on head for
valve seat:

1 46.987 to 47.013

1 1 43.637 to 43.663

Valve seat outside diameter;


valve seat angle on cylinder
2
head:
2 47.063 to 47.089
60º

2 43.713 to 43.739
45º

X 0.356 to 1.102

X Sinking X 0.104 to 0.840

0.050 to 0.102
Between valve seat
andhead 0.050 to 0.102

Valve seats -

(•) ValidforF4BE---engines only.

SM 751 00(D-IVECO)-4-5
Group 00, Engine(D-IVECO)

Type 4 CYLINDERS 6 CYLINDERS

CYLINDER HEAD . TIMING SYSTEM mm


Valve spring height:

free spring H 63.50


H H1 under a load equal to:
H 2 329 N H1 49.02
641 N H2 38.20

Injector protrusion X -
X

Camshaft bush
59.222 to 59.248
housings No. 1-5
Camshaft housings
54.089 to 54.139
No. 2-3-4
1 2 3 4 5
2
Camshaft journals:
1 5
1 7 53.995 to 54.045

1 3

Camshaft bush outside


diameter: . 59.222 to 59.248

Bush inside
diameter . 54.083 to 54.147

Bushes and housings


on block -

Bushes and journals 0.038to 0.162


Cam lift:

H H 11.02

H 10.74

SM 751 00(D-IVECO)-4-6
Group 00, Engine(D-IVECO)

Type 4 CYLINDERS 6 CYLINDERS

CYLINDER HEAD - TIMING SYSTEM mm


1
Tappet cap housing
on block 1 -

2
3 Tappet cap outside
diameter: 2 15.924 to 15.954
3 15.965 to 15.980
2
Between tappets and housings -

Tappets -

1
Rocker shaft 1 18.963 to 18.975

Rockers 2 19.000 to 19.026

2
Between rockers and shaft 0.025 to 0.063

SM 751 00(D-IVECO)-4-7
Group 00, Engine(D-IVECO)

INJECTION PUMP PUMPING ELEMENT PRE-LIFT TABLE


Technical Code Commercial Code Pre-lift (mm)
4 CYLINDER ENGINES F4BE0454A*D601 1 · 0.05
F4BE0454B*D601 1 · 0.05
F4BE0454B*D602 1 · 0.05
F4BE0484D*D608 1 · 0.05
F4BE0484E*D601 1 · 0.05
F4BE0484E*D602 1 · 0.05
F4BE0484E*D605 1 · 0.05
F4BE0484E*D607 1 · 0.05
F4BE0484F*D606 1 · 0.05
F4GE0404A*D6.. N45 MNA - MSA 1.15 · 0.05
F4GE0404B*D6.. 1.15 · 0.05
F4GE0454A*D6.. N45 MNS - MSS 1 · 0.05
F4GE0454B*D6.. 1 · 0.05
F4GE0454E*D6.. 1 · 0.05
F4GE0454G*D6.. 1 · 0.05
F4GE0454H*D6.. 1 · 0.05
F4GE0484C*D650 1 · 0.05
F4GE0484C*D6.. N45 MNT - MST 1 · 0.05
F4GE0484G*D6.. N45 MST 1 · 0.05

NOTE The following operations are relating to the 4 cylinders


INJECTION PUMP CALIBRATION engine but are analogously applicable for the 6 cylinders.
Overhaul and calibration interventions are Remove the screws (1) fastening the connecting rod caps
up to BOSCH assistance network. (2) and remove them.
The contract technical specification contain-
ing the data to calibrate thepump at the- Withdrawthe pistons including the connecting rods
benchis identified by the code shown on fromthe top of the engine block.
injection pump body and is available at NOTE
BOSCH technical assistance network.
Keep the half-bearings into their housings
Otherwise, refer to IVECO MOTORS Tech-
since in case of use they shall be fitted in the
nical Assistance Service.
same position found at removal.
Fi
gure1

ENGINE OVERHAUL

ENGINE REMOVAL AT THE BENCH


The following instructions are prescribed on the under-
standing that the engine has previously been placed on the
rotating bench and that removal of all specific compo-
nents of the equipment have been already removed as
well. (See Section 3 of the manual herein).
The section illustrates therefore all the most important 70158

engine overhaul procedures.

SM 751 00(D-IVECO)-4-8
Group 00, Engine(D-IVECO)

Remove the screws (1) and the main bearing caps (2). Remove the main half-bearings (1).
Fi
gure2
Remove the screws (2) and remove the oil nozzles (3).
Fi
gure5

70159

The second last main bearing cap (1) and the relevant sup-
70162
port are fitted with shoulder half-bearing (2).
NOTE Remove the screws (1) and disconnect camshaft (3)
retaining plate (2).
Take note of lower and upper half-bearing
assembling positions since in case of reuse NOTE
they shall be fitted in the same position found Take note of plate (2) assembling position.
at removal.
Fi
gure6
Fi
gure3

70163

70160 Withdraw carefully the camshaft (1) from the engine


block.
Use tool 99360500 (1) and hoist to remove the output
Fi
gure7
shaft (2) from the block.
Fi
gure4

70164

70161

SM 751 00(D-IVECO)-4-9
Group 00, Engine(D-IVECO)

Withdraw the tappets (1) from the engine block. Measurements shall be performed on each cylinder, at
Fi
gure8 three different heights in the barrel and on two planes per-
pendicular with each other: one parallel to the longitudinal
axis of the engine (A), and the other perpendicular (B).
Maximum wear is usually found on plane (B) in corre-
spondence with the first measurement.
Should ovalisation, taper or wear be found, bore and grind
the cylinder barrels. Cylinder barrel regrinding shall be
performed according to the spare piston diameter over-
sized by 0.5 mm and to the specified assembling clear-
ance.
Fi
gure10

70165

REPAIR OPERATIONS(CYLINDER
UNIT)

Checks and measurements


70167
Once engine is disassembled, clean accurately the cylin-
der-block assembly. s

Use the proper rings to handle the cylinder unit.


The engine block shall not show cracks.
Check operating plug conditions and replace them in case
of uncertain seal or if rusted.
Inspect cylinder barrel surfaces; they shall be free from-
seizing, scores, ovalisation, taper or excessive wear.
Inspection of cylinder barrel bore to check ovalisation,
taper and wear shall be performed using the bore dial
gauge (1) fitted with the dial gauge previously set to zero
on the ring gauge (2) of the cylinder barrel diameter.
NOTE
Should the ring gauge be not available, use a
micrometer for zero-setting.
Fi
gure9

SM 751 00(D-IVECO)-4-10
Group 00, Engine(D-IVECO)

NOTE Checking head supporting surface on cylin-


In case of regrinding, all barrels shall have der unit
the same oversize (0.5 mm).
When finding the distortion areas, replace the cylinder
Check main bearing housings as follows: unit.
fit the main bearings caps on the supports without Planarity error shall not exceed 0.075 mm.
bearings;
Check cylinder unit operating plug conditions, replace
tighten the fastening screws to the specified torque;
use the proper internal gauge to check whether the them in case of uncertain seal or if rustedU
housing diameter is falling within the specified value. Fi
gure12
Replace if higher value is found.
Fi
gure11
±

70168

80585

SM 751 00(D-IVECO)-4-11
Group 00, Engine(D-IVECO)

TIMING SYSTEM if they show any traces of seizing or scoring replace the
camshaft and the bushes.

Camshaft
Camshaft pin and cam surfaces shall be absolutely
smooth;

Fi
gure 13

70169

CAMSHAFT MAIN DATA (4 CYL.)


Specified data refer to pin standard diameter

Checking cam lift and pin alignment BUSHES


Set the camshaft on the tailstock and using a 1/100 gauge Camshaft bushes (2) shall be pressed into their housings.
setG on the central support, check whether the alignment Internal surfaces must not show seizing or wear.
errorG is not exceeding 0.04 mm, otherwise replace the Use bore dial gauge (3) to measure camshaft front and
camshaft. rearGbush (2) and intermediate housing (1) diameter.G
Measurements shall be performed on two perpendicular
Check camshaft (2) pin diameter using micrometer (1) on
axes.
two perpendicular axes.
Fi
gure16
Fi
gure15

70172

70171

SM 751 00(D-IVECO)-4-12
Group 00, Engine(D-IVECO)

Figure 17
Sec.A-A

* 70173

CAMSHAFT BUSH AND HOUSING MAIN DATA


* Value to be obtained after driving the bushes.

Bush replacement Tappets


To replace front and rear bushes (1), remove and refit Fi
gure20
themG using the beater 99360362 (2) and the handgrip
99370006G(3).
NOTE
When refitting the bushes (1), direct them to
makeG the lubricating holes (2) coincide with
the holes onGthe block housings.
Fi
gure19

84053

MAIN DATA CONCERNING THE TAPPETS AND THE


RELEVANT HOUSINGS ON THE ENGINE BLOCK

70174

SM 751 00(D-IVECO)-4-13
Group 00, Engine(D-IVECO)

Fitting tappets — camshaft Check camshaft end float (1).


It shall be 0.23 · 0.13 mm.
Lubricate the tappets (1) and fit them into the relevant
Fi
gure24
housings on the engine block.
Fi
gure21

70179

Fit nozzles (2) and tighten the fastening screws (1) to the
70176
specified torque.
Fi
gure25
Lubricate the camshaft bushes and fit the camshaft (1)
takingGcare not to damage the bushes or the housings.
Fi
gure22

70180

70164
OUTPUT SHAFT

Set camshaft (3) retaining plate (1) with the slot facing the Measuring journals and crankpins
top of the engine block and the marking facing the opera-
tor,Gthen tighten the screws (2) to the specified torque. Grind journals and crankpins if seizing, scoring or exces-
Fi
gure23 siveG ovalisation are found. Before grinding the pins (2)
measureG them with a micrometer (1) to decide the final
diameter toGwhich the pins are to be ground.
NOTE
It is recommended to insert the found values
in theGproper table.
See Figure 27.

Undersize classes are:


NOTE
Journals and crankpins shall always be
70238
ground to theGsame undersize class.

SM 751 00(D-IVECO)-4-14
Group 00, Engine(D-IVECO)

Journals and crankpins undersize shall be For undersized crankpins and journals: let-
marked onGthe side of the crank arm No.1. ters MB
For undersized crankpins: letter M Fi
gure26
For undersized journals: letter B

70182

82.99
83.01

68.98
69.01

FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES

SM 751 00(D-IVECO)-4-15
Group 00, Engine(D-IVECO)

Figure 28

measured on > 45.5 mm radius


between adjacent journals 70183

OUTPUT SHAFT MAIN TOLERANCES

TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL


Roundness
SHAPE / /
Cilindricity
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality O

Circular oscillation
OSCILLATION Total oscillation
Taper
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL
CRITICAL C

IMPORTANT
SECONDARY

MAIN BEARING ON TIMING INTERMEDIATE MAIN FIRST MAIN BEARING


SYSTEM CONTROL SIDE BEARINGS ON FRONT SIDE

70237

SM 751 00(D-IVECO)-4-16
Group 00, Engine(D-IVECO)

Replacing oil pump control gear Finding journal clearance


Check that gear teeth (1) are not damaged or worn,Gother- Refit the output shaft (2).
wise remove it using the proper puller (3). Check the backlash between output shaft main journals
When fitting the new gear, heat it to 180ଇ for 10 minutes andGthe relevant bearings as follows:
in an oven and then key it to the output shaft. Fi
gure34
Fi
gure32

70161

clean accurately the parts and remove any trace of oil;


position a piece of calibratedwire (3) on the output
70184
shaftG pins (4) so that it is parallel to the longitudinal
axis;
Fitting main bearings fit caps (1), including the half bearings (2) on the rele-
vantGsupports.
NOTE Fi
gure35
Refit the main bearings that have not been
replaced,G in the same position found at
removal.

Main bearings (1) are supplied spare with 0.250 — 0.500


mmGundersize on the internal diameter.
NOTE
Do not try to adapt the bearings.

Clean accurately the main half bearings (1) having the


lubricating hole and fit them into their housings. 70186

The second last main half bearing (1) is fitted with shoul-
derGhalf rings.
Fi
gure33

70185

SM 751 00(D-IVECO)-4-17
Group 00, Engine(D-IVECO)

Tighten the pre-lubricated screws (1) in the following Remove caps from supports.
threeGsuccessive stages: The backlash between the main bearings and the pins is
found by comparing the width of the calibrated wire (2) at
1st stage, with torque wrench to 50 · 6 Nm.
2nd stage, with torque wrench to 80 · 6 Nm. the narrowest point with the scale on the envelope (1)
containing the calibrated wire.
Fi
gure36
The numbers on the scale indicate the backlash in mm.
Replace the half bearings and repeat the check if a differ-
entGbacklash value is found. Once the specified backlash
isG obtained, lubricate the main bearings and fit the sup-
ports byG tightening the fastening screws as previously
described.
Fi
gure38

70187

3rd stage, with tool 99395216 (1) set as shown in the


figure, tighten the screws (2) with 90 ¶ · 5 ¶ angle.
Fi
gure37

70189

Checking output shaft shoulder clearance


This check is performed by setting amagnetic-base dial
gaugeG (2) on the output shaft (3) as shown in the figure,
standardGvalue is 0.068 to 0.41.

70188
If higher value is found, replace main thrust half bearings
ofGthe second last rear support (1) and repeat the clearance
check between output shaft pins and main half bearings.
Fi
gure39

70190

SM 751 00(D-IVECO)-4-18
Group 00, Engine(D-IVECO)

CONNECTING ROD — PISTON Remove split rings (1) from piston (2) using pliers
99360183G(3).
ASSEMBLY
Fi
gure41
NOTE
Pistons are supplied spare with 0.5 mm over-
size.

Figure 40

32613

Piston pin (1) split rings (2) are removed using a scriber
(3).
Fi
gure42
CONNECTING ROD, PISTON ASSEMBLY
COMPONENTS
1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -
6. Half bearings - 7. Connecting rod - 8. Bush.

32614

Figure 43

87760
MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS

SM 751 00(D-IVECO)-4-19
Group 00, Engine(D-IVECO)

PistonsOMeasuring piston diameterP The clearance between the piston and the cylinder barrel
canG be checked alsowith a feeler gauge (1) as shown in
Using a micrometer (2), measure the diameter of the pis-
the figure.
tonG(1) to determine the assembly clearance.
Fi
gure45
NOTE
The diameter shall be measured at 12 mm
from theGpiston skirt.
Fi
gure44

70192

32615

FOR F4BE--- ENGINES

Application with Intercooler

Fi
gure46

90530

MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS

SM 751 00(D-IVECO)-4-20
Group 00, Engine(D-IVECO)

Application without Intercooler

Fi
gure47

86471

MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS

Piston pins Conditions for proper pin-piston coupling


To measure the piston pin (1) diameter use the micrometer Lubricate the pin (1) and its seat on piston hubs with
(2). engineG oil; the pin shall be fitted into the piston with a
Fi
gure48 slight fingerGpressure and shall not be withdrawn by grav-
ity.
Fi
gure49

18857

32619

SM 751 00(D-IVECO)-4-21
Group 00, Engine(D-IVECO)

Split rings In this position, use a feeler gauge to check the clearance
(X)Gbetween ring and slot: found value shall be the speci-
Use a micrometer (1) to check split ring (2) thickness. fied one.
Fi
gure50 Fi
gure52

16552

41104

Check the clearance between the sealing rings (3) of the DIAGRAM FOR MEASURING THE CLEARANCE X
2ndG and 3rd slot and the relevant housings on the piston BETWEEN THE FIRST PISTON SLOT AND THE
TRAPEZOIDAL RING
(2), usingGa feeler gauge (1).
Fi
gure51 Use feeler gauge (1) to measure the clearance between the
ends of the split rings (2) fitted into the cylinder barrel (3).
Fi
gure53

32620 70194

Since the first sealing ring section is trapezoidal, the clear- Connecting rods
anceG between the slot and the ring shall be measured as Fi
gure54

follows:G make the piston (1) protrude from the engine


block so thatGthe ring (2) protrudes half-way from the cyl-
inder barrel (3).

87762

SM 751 00(D-IVECO)-4-22
Group 00, Engine(D-IVECO)

NOTE Material removal is not allowed.


The surface of connecting rod and rod cap Fi
gure56
are knurled to ensure better coupling.
Therefore, it is recommended not to smooth
the knurls.
Fi
gure55

CONNECTING ROD BODY

CONNECTING CONNECTING
ROD BODY ROD BODY *

* *
*

CONNECTING ROD BODY

CONNECTING ROD BODY CONNECTING ROD BODY CONNECTING ROD BODY


-

70196

Bushes
86472
Check that the bush in the connecting rod small end is free
MAIN DATA FOR CONNECTING ROD, BUSH, PISTON from scoring or seizing and that it is not loosen. Otherwise
PIN AND HALF BEARINGS replace.
* Value for inside diameter to be obtained after driving in Removal and refitting shall be performed using the proper
connecting rod small end and grinding.
beater.
** Value not measurable in released condition
When refitting take care to make coincide the oil holes set
NOTE on the bush with those set on the connecting rod small
Every connecting rod is marked as follows: end. Grind the bush to obtain the specified diameter.
On body and cap with a number showing their cou-
pling and the corresponding cylinder. Checking connecting rods
In case of replacement it is therefore necessary to
mark the new connecting rod with the same num- Check that the axes of the connecting rods (1) are parallel
bers of the replaced one. using tool 99395363 (5) as follows:
On body with a letter showing theweight of the con- fit the connecting rod (1) on tool 99395363 (5) spindle
necting rod assembled at production: and lock it with screw (4);
• V, 1820 to 1860 (yellow marking);
• W, 1861 to 1900 (green marking);
• X, 1901 to 1940 (blue marking);
Spare connecting rods are of theWclass with green mark-
ing *.

SM 751 00(D-IVECO)-4-23
Group 00, Engine(D-IVECO)

set the spindle (3) on V-blocks by resting the connect- Checking bending
ing rod (1) on the stop bar (2).
Check connecting rod (5) bending by comparing two
Fi
gure57 points C andD of the pin (3) on the vertical plane of the
connecting rod axis.
Position the vertical support (1) of the dial gauge (2) to
rest the latter on pin (3), point C.
Move the connecting rod forwards and backwards to find
pin top position, then in this condition reset the dial gauge
(2).
Move the spindle with the connecting rod (5) and repeat
the check of the top point on the opposite side D of the pin
(3). The difference between point Cand pointDshall not
exceed 0.08 mm.
Fi
gure59

61696

Checking torsion
Check connecting rod (5) torsion by comparing two points
(A and B) of pin (3) on the horizontal plane of the con-
necting rod axis.
Position the dial gauge (2) support (1) to obtain a preload
of approx. 0.5 mm on the pin (3) in point A and then set
the dial gauge (2) to zero. Move the spindle (4) with the
connecting rod (5) and compare any deviation on the
opposite side (B) of the pin (3): the difference between A 61695

and B shall not exceed 0.08 mm.


Fi
gure58 Fitting connecting rod-piston assembly Con-
necting rod-piston coupling
The piston crown is marked as follows:
1. Part number and design modification number;
2. Arrow showing piston assembling direction into cyl-
inder barrel, this arrow shall face the front key of the
engine block;
3. Marking showing 1st slot insert testing;

61694

SM 751 00(D-IVECO)-4-24
Group 00, Engine(D-IVECO)

4. Manufacturing date. the cylinder barrel and the numbers (5) marked on the
Fi
gure60 connecting rod (5) are read as shown in the figure.
Fi
gure62

70198
70199
On piston crown, following references are printed:
1. Spare part number and design modification number; Fi
gure63

2. Manufacturing date.
3. Writing indicating the mounting mark of the piston
in the cylinder barrel; this writing must face block
front side;
Fi
gure61

84104

Position the piston (1) on the connecting rod according to


the diagram shown in the figure, fit the pin (3) and stop it
by the split rings (2).
Fi
gure64

84103

Connect piston (2) to connecting rod (4) with pin (3) so


that the reference arrow (1) for fitting the piston (2) into

72705

Fitting split rings


Use pliers 99360183 (3) to fit the split rings (1) on the pis-
ton (2).

SM 751 00(D-IVECO)-4-25
Group 00, Engine(D-IVECO)

Split rings shall be fitted with the marking “TOP” facing Fitting connecting rod-piston assembly into
upwards and their openings shall be displaced with each
cylinder barrels
other by 120 ¶ .
Lubricate accurately the pistons, including the split rings
NOTE
and the cylinder barrel inside.
Split rings are supplied spare with the follow-
ing sizes: Use band 99360605 (2) to fit the connecting rod-piston
- standard, yellow marking; assembly (1) into the cylinder barrels and check the fol-
- 0.5 mm oversize, yellow/green marking; lowing:
Fi
gure65 the number of each connecting rod shall correspond to
the cap coupling number.
Fi
gure67

32613

70201

Fit half bearings (1) on connecting rod and cap.


- Split ring openings shall be displaced with each other
NOTE
by 120 ¶ ;
Refit the main bearings that have not been
- connecting rod-piston assemblies shall have the same
replaced, in the same position found at
weight;
removal. Do not try to adapt the half bear-
- the arrowmarked on the piston crown shall be facing
ings.
the front side of the engine block or the slot obtained
Fi
gure66 on the piston skirt shall be corresponding to the oil
nozzle position.
Fi
gure68

70200

70202

DIAGRAM FOR CONNECTING ROD-PISTON


ASSEMBLY FITTING INTO BARREL

SM 751 00(D-IVECO)-4-26
Group 00, Engine(D-IVECO)

Finding crankpin clearance Apply tool 99395216 (1) to the socket wrench and
tighten screws (2) of 60 ¶ .
To measure the clearance proceed as follows:
Fi
gure71
- clean the parts accurately and remove any trace of
oil;
- set a piece of calibrated wire (2) on the output shaft
pins (1);
- fit the connecting rod caps (3) with the relevant half
bearings (4).
Fi
gure69

70205

Remove the cap and find the existing clearance by


comparing the calibrated wire width (1) with the scale
on the wire envelope (2).
Fi
gure72

70203

Lubricate the screws (1) with engine oil and then


tighten them to the specified torque using a torque
wrench (2).
Fi
gure70

70206

If a different clearance value is found, replace the half


bearings and repeat the check.
Once the specified clearance has been obtained, lubricate
the main half bearings and fit them by tightening the con-
necting rod cap fastening screws to the specified torque.
NOTE
70204 Before the final fitting of the connecting rod
cap fastening screws, check that their diame-
ter measured at the centre of the thread
length is not < 0.1mm than the diameter mea-
sured at approx. 10 mm from screw end.

SM 751 00(D-IVECO)-4-27
Group 00, Engine(D-IVECO)

Check manually that the connecting rods (1) are sliding CYLINDER HEAD
axially on the output shaft pins and that their end float,
measured with feeler gauge (2) is 0.250 to 0.275 mm.
Removing the valves
Fi
gure73
Intake (1) and exhaust (2) valves have heads with differ-
ent diameter.
NOTE
Should cylinder head valves be not replaced,
number them before removing in order to
refit them in the same position.
A = intake side
Fi
gure75

70207
2

Checking piston protrusion


Once connecting rod-piston assemblies refitting is over,
use dial gauge 39395603 (1) fitted with base 99370415 (2) A
to check piston (3) protrusion at T.D.C. with respect to the
top of the engine block.
75750
Protrusion shall be 0.28 to 0.52 mm.
Fi
gure74
Valve removal shall be performed using tool 99360268
(1) and pressing the cap (3) so that when compressing the
springs (4) the cotters (2) can be removed. Then remove
the cap (3) and the springs (4).
Repeat this operation for all the valves.
Overturn the cylinder head and withdraw the valves (5).
Fi
gure76

1 2
70208 3
4

75751

Sealing rings (1) for intake valves are yellow.

SM 751 00(D-IVECO)-4-28
Group 00, Engine(D-IVECO)

NOTE Distortion found along the whole cylinder head shall not
Sealing rings (2) for exhaust valves are green. exceed 0.20 mm.
Remove sealing rings (1 and 2) from the If higher values are found grind the cylinder head accord-
valve guide. ing to values and indications shown in the following fig-
Fi
gure77 ure.
The rated thickness A for the cylinder head is 95 · 0.25
mm, max. metal removal shall not exceed thickness B by
2 1 mm.
NOTE
After grinding, check valve sinking. Regrind
the valve seats, if required, to obtain the
specified dimensions.
Fi
gure79

1 D

0,4 C
0,0
25 /¯25,4

75752

A B
Checking cylinder head wet seal
This check shall be performed using the proper tools.
0,4 TO TAL C
Use a pump to fill with water heated to approx. 90ଇ and 2 0,0
1 /¯50

to 3 bar pressure.
75756
Replace the cup plugs (1) if leaks are found, use the
proper beater for their removal/refitting.
NOTE
Before refitting, smear the plug surfaces with
water-repellent sealant.

Replace the cylinder head if leaks are found.


Fi
gure78

75753

Checking cylinder head supporting surface

SM 751 00(D-IVECO)-4-29
Group 00, Engine(D-IVECO)

VALVES Check the valve stem (1) using a micrometer (2), it shall
be 7.943 to 7.963.
Figure 80
Fi
gure82
EX H A UST IN TA KE
VA LVE VA LVE

18882

42.13 45.13
41.87 44.87
Checking clearance between valve stem and
70326
valve guide and valve centering
INTAKE AND EXHAUST VALVE MAIN DATA Use a magnetic base dial gauge (1) set as shown in the fig-
ure, the assembling clearance shall be 0.056 0.096 mm.
Removing carbon deposits, checking and Turn the valve (2) and check that the centering error is not
grinding valves exceeding 0.03 mm.
Fi
gure83
Remove carbon deposits from valves using the proper
metal brush.
1
Check that the valves show no signs of seizing, scoring or
cracking. 2
Regrind the valve seats, if required, using tool 99305018
and removing as less material as possible.
Fi
gure81

75757

18625

SM 751 00(D-IVECO)-4-30
Group 00, Engine(D-IVECO)

VALVE GUIDE VALVE SEATS


Use a bore dial gauge to measure the inside diameter of
the valve guides, the read value shall comply with the Regrinding — replacing the valve seats
value shown in the figure.
Check the valve seats (2). If slight scoring or burnout is
Fi
gure84 found, regrind seats using tool 99305014 (1) according to
the angle values shown in Figure 86.
Fi
gure85

INTAKE EXH AU ST
84046 75754

Should valve seats be not reset just by regrinding, replace them with the spare ones. Use tool 99305019 (Figure 85) to
remove as much material as possible from the valve seats (take care not to damage the cylinder head) until they can be
extracted from the cylinder head using a punch.
Heat the cylinder head to 80ଇ- 100ଇ and using the proper beater, fit the new valve seats, previously cooled, into the cyl-
inder head.
Use tool 99305019 to regrind the valve seats according to the values shown in Figure 86.
Figure 86

29.5º 36.5º
30.5º 37.5º

60º
45º
74.5º
75.5º
59.5º
60.5º

4.64 4.06
4.38 4.32
INTAKE EXHAUST
VALVE SEAT MAIN DATA 75755

SM 751 00(D-IVECO)-4-31
Group 00, Engine(D-IVECO)

After regrinding, check that valve (3) sinking value is the FITTING CYLINDER HEAD
specified one by using the base 99370415 (2) and the dial
gauge 99395603 (1). Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fi
gure87
Fit the sealing rings (2 and 3) on the valve guide.
NOTE
1 Sealing rings (2) for intake valves are yellow
and sealing rings (3) for exhaust valves are
2
green.
3 Fi
gure89

3 1

75758

1
VALVE SPRINGS
2
Before refitting use tool 99305047 to check spring flexi-
bility. Compare load and elastic deformation data with
75759
those of the new springs shown in the following table.
Fi
gure88
Position on the cylinder head: the spring (4), the upper cap
(3); use tool 99360268 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
Fi
gure90

1 2
3
4

50676
6
MAIN DATA TO CHECK INTAKE AND EXHAUST
VALVE SPRINGS
5
Height Under a load of
75751
H (free) 63.50 N

H1 49.02 329 Refitting the cylinder head


H2 38.20 641 Check cleanness of cylinder head and engine block cou-
pling surface.
75759 Take care not to foul the cylinder head gasket.
75751 Set the cylinder head gasket (1) with the marking “N. of
component” (1) facing the head.
Figure 89

SM 751 00(D-IVECO)-4-32
Group 00, Engine(D-IVECO)

The arrow shows the point where the gasket thickness is NOTE
given. Before re-utilising the bolts for the cylinder
Fi
gure91 head, verify there is no evidence of wear or
deformation and in that case replace them.

87759

There are two types of head seals,for thethickness(1.25mm


Type A and1.15 mm Type B) take the followingmeasures:
- for each piston detect, as indicated on Figure 92, at a
distance of 45 mm from the centre of the piston
overhandings S1 and S2 in relation to the engine base
upper plane then calculate the average:

Scil1 = S1+ S2
2
For 4 cylinder versions:
Repeat theoperation for pistons2,3and4 and calculate the
average value.
Scil1 + Scil2 + Scil3 + Scil4
S=
4
For 6 cylinder versions:
Repeat the operation for pistons2,3,4,5 and6 andcalculate
the average value.
Scil1 + Scil2 + Scil3 + Scil4 + Scil5 + Scil6
S=
6
If Sis > 0,40 mm use sealtype A.
If Sis < 0,40 mm use sealtype B.

Figure 92

88775

SM 751 00(D-IVECO)-4-33
Group 00, Engine(D-IVECO)

TIGHTENING TORQUE (FOR 4 AND 6 CYL.)


TORQUE
COMPONENT
Nm kgm
Cooling Nozzles (M8x1.25x10) 15± 3 1.5 ± 0.3
Main bearing cap 1st stage 50 ± 6 5.0 ± 0.6
2nd stage 80 ± 6 8.0 ± 0.6
3rd stage 90º± 5º
Rear gear housing assembly 2.4 ± 0.4
(M8x1.25x40) 24± 4
2.4 ± 0.4
(M8x1.25x25) 24± 4
(M10x1.5) 4.9 ± 0.5
49 ± 5
Oil pump (M8x1.25x30) 8± 1 0.8 ± 0.1
Front cover assembly
(M8x1.25x45) 24± 4 2.4 ± 0.4
(M8x1.25x30) 24± 4 2.4 ± 0.4
Connecting rod bolts (M11x1.25) 1st stage 30 ± 3 3.0 ± 0.3
2nd stage 60 ± 5 6.0 ± 0.5
3rd stage 60º± 5º
Ladder frame assembly (M10x1.25x25) 43 ± 5 4.3 ± 0.5
Oil rifle plugs
(M10x1) 6± 1 0.6 ± 0.1
(M14x1.5) 11± 2 1.1 ± 0.2
Assemble oil suction tube (M8x1.25x20) 24± 4 2.4 ± 0.4
Oil pan assembly
(M8x1.25x25) 24± 4 2.4 ± 0.4
(M18x1.50) 60 ± 9 6.0 ± 0.9
Set timing pin 5±1 0.5 ± 0.1
Fuel pump assembly
M8 screw 24± 4 2.4 ± 0.4
M6 screw 10 ± 1 1.0 ± 0.1
M6 nut 10 ± 1 1.0 ± 0.1
M10x1.5 flange head nuts pre-torque 10 -15 1.0 -1.5
Final torque 50 -55 5.0 -5.5
Fuel pump gear (drive gear nut) Snug torque 15-20 1.5 -2.0
Final torque 85 -90 8.5 -9.0
Timing pin cap of fuel pump 30 -35 3.0 - 3.5
Rocker assys (M8) 24± 4 2.4 ± 0.4
Cylinder head bolts
(M12x70) 50 + 90º 5.0 + 90º
(M12x140) 40 + 180º 4.0 + 180º
(M12x180) 70 + 180º 7.0 + 180º
Assy rocker covers (M8x1.25x25) 24± 4 2.4 ± 0.4
Intake manifold (M8x1.25) 24± 4 2.4 ± 0.4
Assy air intake connection (M8x1.25) 24± 4 2.4 ± 0.4
Oil bypass valve into lube filter head (M22x1.5x10) 80 ± 8 8.0 ± 0.8
Plug (M12x1.5x12) 10 ± 1 1.0 ± 0.1
Exhaust manifold (M10x1.5x65) 43 ± 6 4.3 ± 0.6
Water pump (M8x1.25x25) 24± 4 2.4 ± 0.4
Water outlet connection
(M8x1.25x35) 24± 4 2.4 ± 0.4
(M8x1.25x70) 24± 4 2.4 ± 0.4
Fan support (M10x1.5x20) 33± 5 3.3 ± 0.5
Fan pulley
(M6) 10 ± 2 1.0 ± 0.2

SM 751 00(D-IVECO)-4-34
Group 00, Engine(D-IVECO)

TO RQ U E
COMPONENT
Nm kgm
Rear lifting bracket (M12x1.75x30) 77 ± 12 7.
7 ± 1.2
Crankshaft pulley (M12x1.75x10.9) 110 ± 5 11.0 ± 0.
5
Flywheel housing
(M12x120) 85 ± 10 8.
5 ± 1.
0
(M12x80) 85 ± 10 8.
5 ± 1.
0
(M10x80) 49 ± 5 4.
9 ± 0.
5
(M10x40) 49 ± 5 4.
9 ± 0.
5
Flywheel housing (M12x1.25) 1st stage 30 ± 4 3.
0 ± 0.
4
2nd stage 60º± 5º
Assy rear cover plate to flywheel housing (M8x1.25x16) 24 ± 4 2.4 ± 0.4
Fuel injectors 60 ± 5 6.0 ± 0.5
Fuel lift pump 24 ± 4 2.4 ± 0.4
Turbocharger to exhaust manifold (M10) 43 ± 6 4.3 ± 0.6
Oil feed to oil filter head 24 ± 4 2.4 ± 0.4
Oil feed to turbocharger (M12x1.5) 35 ± 5 3.5 ± 0.5
Oil drain (M8x1.25x16) 24 ± 4 2.4 ± 0.4
Alternator to alternator support (M8x1.25x30) 24 ± 4 2.4 ± 0.4
Alternator to water inlet conn. assy (M8x1.25x30) 24 ± 4 2.4 ± 0.4
Lower alternator mounting (M10x1.25x25) 24 ± 4 2.4 ± 0.4
Alternator upper pivot to support (M10) 49 ± 5 4.9 ± 0.5
Alternator mounting hardware (M12x1.75x120) 43 ± 6 4.3 ± 0.6
Alternator wiring (M6x1.0 nut) 10 ± 2 1.0 ± 0.2
Starter motor to gear case (M10) 49 ± 5 4.9 ± 0.5
Screw M8 for fastening cylinder barrel lubricating nozzles 15 ± 3 1.5 ± 0.3
Screw M12 for fastening output shaft caps 1ststage 50 ± 6 5 ± 0.6
2nd sa
stage 80 ± 6 8 ± 0.6
3rd stage 90º± 5º
Screw M8 for fastening camshaft longitudinal retaining plate 24 ± 4 2.4 ± 0.4
Screw M8 for fastening camshaft gear 36 ± 4 3.6 ± 0.4
Screw M11 for fastening connecting rod caps 1st stage
a 60 ± 5 6 ± 0.5
2nd stage 60º± 5º

SM 751 00(D-IVECO)-4-35
Group 00, Engine(D-IVECO)

Section 5

TOOLS

TOOLS
TOOL NO. DESCRIPTION

99305019 Kit for valve seat regrinding

99305047 Spring load tester

Revolving stand for overhauling units (700 daN/m capacity, 120


99322205 N/m torque)

99340035 Injection pump gear extractor.

99340055 Tool to remove output shaft front gasket

99340056 Tool to remove output shaft rear gasket

SM 751 00(D-IVECO)-5-1
Group 00, Engine(D-IVECO)

TOOLS
TOOL NO. DESCRIPTION

99340205 Tool to remove injectors

99346252 Tool for fitting output shaft front gasket

99346253 Tool for fitting output shaft rear gasket

99360076 Tool to remove oil filter (engine)

99360183 Pliers for removing/refitting piston rings (65 . 110 mm)

99360268 Tool for removing/refitting engine valves

SM 751 00(D-IVECO)-5-2
Group 00, Engine(D-IVECO)

TOOLS
TOOL NO. DESCRIPTION

99360330 Flywheel crank handle (*)

99360339 Tool for stopping the engine flywheel (**)

99360344 Adapter, cylinder compression test (use with 99395682)

99360351 Tool for flywheel holding (***)

99360362 Driver for removing/refitting camshaft bushes (to be used with


993700069)

99360500 Tool for lifting the output shaft

SM 751 00(D-IVECO)-5-3
Group 00, Engine(D-IVECO)

TOOLS
TOOL NO. DESCRIPTION

99360595 Lifting rig for engine removal/refitting

99360605 Band for fitting piston into cylinder barrel (60 . 125 mm)

99361037 Brackets for fastening engine to revolving stand 99322205

99363204 Tool to remove gaskets

99365195 Comparator holder tool for injection pump timing


(to be used with 99395604) (*****)

99367121 Tool to remove gaskets

SM 751 00(D-IVECO)-5-4
Group 00, Engine(D-IVECO)

TOOLS
TOOL NO. DESCRIPTION

9999370006 Interchangeable willow handgrip

99370415 Gauge base for different measurements (to be used with


99395603)

99395097 Tool to check top dead centre (use with 99395604)

99395100 Dial gauge holder for rotary injection pump timing (use with
99395603)

99395216 Pair of gauges with ½ ”and ¾ ”square head for angle


tightening

99395220 All-purpose goniometer/Inclinometer

SM 751 00(D-IVECO)-5-5
Group 00, Engine(D-IVECO)

TOOLS
TOOL NO. DESCRIPTION

99395363 Complete bush testing square

99395603 Dial gauge (0 . 5 mm)

99395604 Dial gauge (0 . 10 mm)

99395682 Diesel fuel engine cylinder compression control device

SM 751 00(D-IVECO)-5-6
Group 00, Engine(D-IVECO)

APPENDIX
SAFETY PRESCRIPTIONS Ensure that hands and feet are dry and execute work-
ing operations utilizing isolating foot-boards. Donot
Particular attention shall be drawn on some precautions carry out working operations if not trained for.
that must be followed absolutely in a standard working Do not smoke nor light up flames close to batteries
area and whose non fulfillment will make any other mea- and to any fuel material.
sure useless or not sufficient to ensure safety to the per- Put the dirty rags with oil, diesel fuel or solvents in
sonnel in-charge of maintenance. anti-fire specially provided containers.
Be informed and inform personnel as well of the laws in Do not execute any intervention if not provided with
force regulating safety, providing information documenta- necessary instructions.
tion available for consultation. Do not use any tool or equipment for any different
operation from the ones they’ve been designed and
Keep working areas as clean as possible, ensuring ade- provided for: serious injury may occur.
quate aeration. In case of test or calibration operations requiring
Ensure that working areas are provided with emer- engine running, ensure that the area is sufficiently aer-
gency boxes, that must be clearly visible and always ated or utilize specific vacuum equipment to eliminate
provided with adequate sanitary equipment. exhaust gas. Danger: poisoning and death.
Provide for adequate fire extinguishing means, prop-
erly indicated and always having free access. Their
efficiency must be checked on regular basis and the During maintenance
personnelmust be trained on intervention methods and Never open filler cap of cooling circuit when the
priorities. engine is hot. Operating pressure would provoke high
Organize and displace specific exit points to evacuate temperature with serious danger and risk of burn. Wait
the areas in case of emergency, providing for adequate unit the temperature decreases under 50C.
indications of the emergency exit lines. Never top up an overheated engine with cooler and
Smoking in working areas subject to fire danger must utilize only appropriate liquids.
be strictly prohibited. Always operate when the engine is turned off: whether
ProvideWarnings throughout adequate boards signal- particular circumstances require maintenance inter-
ing danger, prohibitions and indications to ensure easy vention on running engine, be aware of all risks
comprehension of the instructions even in case of involved with such operation.
emergency. Be equipped with adequate and safe containers for
drainage operation of engine liquids and exhaust oil.
Prevention of injury Keep the engine clean from oil tangles, diesel fuel and
or chemical solvents.
Do not wear unsuitable cloths for work, with fluttering Use of solvents or detergents during maintenance may
ends, nor jewels such as rings and chains when work- originate toxic vapors. Always keep working areas
ing close to engines and equipment in motion. aerated. Whenever necessary wear safety mask.
Wear safety gloves and goggles when performing the Do not leave rags impregnated with flammable sub-
following operations: stances close to the engine.
filling inhibitors or anti-frost Upon engine start after maintenance, undertake proper
lubrication oil topping or replacement preventing actions to stop air suction in case of run-
utilization of compressed air or liquids under pressure away speed rate.
(pressure allowed: ˺ 2 bar) Do not utilize fast screw-tightening tools.
Wear safety helmet when working close to hanging Never disconnect batteries when the engine is running.
loads or equipment working at head height level. Disconnect batteries before any intervention on the
Always wear safety shoeswhen and cloths adhering to electrical system.
the body, better if provided with elastics at the ends. Disconnect batteries from system aboard to load them
Use protection cream for hands. with the battery loader.
Change wet cloths as soon as possible After every intervention, verify that battery clamp
In presence of current tension exceeding 48-60 V ver- polarity is correct and that the clamps are tight and
ify efficiency of earth andmass electrical connections. safe from accidental short circuit and oxidation.

SM 751 00(D-IVECO)-5-7
Group 00, Engine(D-IVECO)

Do not disconnect and connect electrical connections be aerated, far from heat sources and not exposed to
in presence of electrical feed. fire danger.
Before proceeding with pipelines disassembly (pneu- Handle the batteries with care, storing them in aerated
matic, hydraulic, fuel pipes) verify presence of liquid environment and within anti-acid containers. Warning:
or air under pressure. Take all necessary precautions battery exhalation represent serious danger of intoxi-
bleeding and draining residual pressure or closing cation and environment contamination.
dump valves. Always wear adequate safety mask or
goggles.
Non fulfillment of these prescriptions may cause seri-
ous injury and poisoning.
Avoid incorrect tightening or out of couple. Danger:
incorrect tightening may seriously damage engine’s
components, affecting engine’s duration.
Avoid priming from fuel tanks made out of copper
alloys and/or with ducts not being provided with fil-
ters.
Do not modify cable wires: their length shall not be
changed.
Do not connect any user to the engine electrical equip-
ment unless specifically approved by Iveco.
Do not modify fuel systems or hydraulic system unless
Iveco specific approval has been released. Any unau-
thorized modification will compromise warranty assis-
tance and furthermore may affect engine correct
working and duration. For engines equipped with elec-
tronic gearbox:
Do not execute electric arc weldingwithout having pri-
ory removed electronic gearbox.
Remove electronic gearbox in case of any intervention
requiring heating over 80ºC temperature.
Do not paint the components and the electronic con-
nections.
Do not vary or alter any data filed in the electronic
gearbox driving the engine. Any manipulation or alter-
ation of electronic components shall totally compro-
mise engine assistance warranty and furthermore may
affect engine correct working and duration.

Respect of the Environment


Respect of the Environment shall be of primary impor-
tance: all necessary precautions to ensure personnel’s
safety and health shall be adopted.
Be informed and inform the personnel as well of laws
in force regulating use and exhaust of liquids and
engine exhaust oil. Provide for adequate board indica-
tions and organize specific training courses to ensure
that personnel is fully aware of such law prescriptions
and of basic preventive safety measures.
Collect exhaust oils in adequate specially provided
containers with hermetic sealing ensuring that storage
is made in specific, properly identified areas that shall

SM 751 00(D-IVECO)-5-8
Group 00, Engine(D-IVECO)

Section 6

Engine Replacement

Engine Replacement 6. Set the engine onto the mounting isolators. Set
mounting bolts in place but do not tighten. The
Before beginning engine replacement, make sure the truck engine may have to be shifted to line up with the
parked with the parking brake applied and wheels transmission.
chocked. To replace the engine:
1. Make sure the hoist and chains or engine stand you
are using is of adequate capacity to safely lift the
engine.
2. Hook the hoist chains to the engine lifting eyes.

7. Connect the engine to the transaxle (or hydrostatic


3. Slowly lift the engine and move it into place over the transmission pump) .
truck frame.
8. Torque engine mounting bolts to 170-190 Nm (125-
4. Make sure there are no wires, cables, hoses, or other 140 ft-lb).
equipment in the way of lowering the engine into the
9. Align and connect the exhaust pipe to the engine ter-
frame.
bocharge manifold using.
5. Slowly begin lowering the engine into the frame. V-type Clamp

! WARNING Exhaust manifold


Never use your hands to move the engine in
the frame. Always use a pry bar to gently
shift or hold the engine in place. After the
engine is in place, keep the hoist chains
attached and keep slack out of the chains.
Remove the chains only when the engine is
securely mounted in the truck frame and
remounted with the transmission.

SM 751 00(D-IVECO)-6-1
Group 00, Engine(D-IVECO)

10. Reconnect the radiator hoses between the radiator 14. Check the engine air cleaner and hoses. See Group 3
and the water pump and the thermostat of the engine, for complete details. Set the aircleaner and hoses in
as described in Group 01. Before reinstallation, place and align before tightening clamps and mount-
check that hoses are in good condition with no dry- ing nuts. Torque the base-mounting nuts to 20-25
ing, cracking, or splitting. Nm (14.8-18.5 ft-lb); torque hose-to-engine clamp
to 1.9-2.9 Nm (1.4-2.1 ft-lb).
11. Uncap and reconnect the fuel line at the fuel tank.
Make sure the hose is in good condition with no dry- 15. Check the battery and reconnect the cables to the bat-
ing, cracking, or splitting evident. Torque band tery posts and to the starter and ground.
clamp to 0.8-1.0 Nm (0.6-0.73 ft-lb).

Negative cable
grounded to frame

Battery cable
A Neg.
VIEW A Battery x2

Positive cable to
starter solenoid

To engine From battery Side


frame LH

Fuel hose

Band clamp Engine starter


Battery cable positive
motor

12. Reconnect the wiring. See Group 13 for drawings


that show the wiring harness and component connec-
a. Torque the terminal nuts at the battery posts to
tion points on the engine.
14-20 Nm (10.3-14.8 ft-lb).
13. On the standard transaxle truck, reconnect the accel- b. Torque the nut on the starter terminal to 10-12
erator linkage and adjust length using the adjustment Nm (90-110 in-lb; 7.5-9.1 ft-lb).
nuts. See Group 02 for throttle linkage adjustments. c. Install covers over cable ends after assembly.
16. Assembly the rear hood according to the procedures
in Group 38.
17. Close engine drain valve and fill radiator according
to the prodedures presented in “Engine Cooling Sys-
tem Testing and Maintenance” in Group 01. Check
inlet and outlet hoses for leaks.
18. Restart the engine and check all truck electrical,
Accelerator hydraulic, and mechanical components for proper
Cable Bracket operation before returning the truck to service.
Throttle Lever

SM 751 00(D-IVECO)-6-2
GROUP 00(D-Kubota)

GROUP 00(D-Kubota)

ENGINE

(Kubota)

General ..................................................... Section 1

Check and Maintenance ........................... Section 2

Mechanism ................................................. Section 3

Servicing ..................................................... Section 4

00(D-Kubota)-0-1
Group 00(D-Kubota), Engine

Section 1
GENERAL
1. SPECIFICATIONS
Model V3800DI-T-E2B (Tier2) V3800DI-T-E3B (Tier3)
Number of Cylinder 4
Type Vertical, water-cooled, 4-cycle DI diesel engine
Bore × Stroke 100 × 120 mm (3.94 × 4.72 in.)
Total Displacement 3769 cm3 (230 cu.in.)
61.3 kW / 2600 min-1(rpm)
ISO Net Continuous
(82.2 HP / 2600 min-1 (rpm))
70.6 kW / 2600 min-1 (rpm)
ISO / SAE Net Intermittent
(94.6 HP / 2600 min-1 (rpm))
72.8 kW / 2600 min-1 (rpm)
SAE Gross Intermittent
(97.6 HP / 2600 min-1 (rpm))
Maximum Bare Speed 2800 min-1 (rpm)
Minimum Bare Idling Speed 775 to 825 min-1 (rpm)
Combustion Chamber Reentrant Type, Center Direct Injection Type (E-CDIS)
Fuel Injection Pump Bosch Type Mini Pump
Governor All sp eed mechanical governor
Direction of Rotation Counter-clockwise (Viewed from flywheel side)
Injection Nozzle Bosch P Type
Injection Timing 0.23 rad (13.0 °) before T.D.C. . rad ( 6.0 °) before T.D.C.
010
Firing Order 1-3-4-2
Injection Pressure 1st stage 18.6 MPa (190 kgf/cm2, 2702 psi), 2st stage 23.5 MPa (240 kgf/cm2, 3414 psi)
Compression Ratio 19.0
Lubricating System Forced lubrication by trochoid pump
Oil Pressure Indicating Electrical Type Switch
Lubricating Filter Full Flow Paper Filter (Cartridge Type)
Cooling System Pressurized radiator, forced circulation with water pump
Starting System Electric Starting with Starter
Starting Motor 12 V, 3.0 kW
Starting Support Device Intake Air Heater in Intake Manifold

External EGR
EGR NONE (EGR Cooler + Mechanical EGR
Valve + Reed Valve)

Battery 12 V, 136 AH, equivalent


Charging Alternator 12 V, 540 W
Fuel Diesel Fuel No. 2-D (ASTM D975)

Lubricating Oil Class CF lubricating oil as per API classification is recommended.

Lubricating Oil Capacity 13.2 L ( 3.49 U .S.g al s)


Weight (Dry) 257 kg (566.6 lbs) 288 kg (635 lbs)
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

00(D-Kubota)-1-1
Group 00(D-Kubota), Engine

2. DIMENSIONS

6KGT

=8&+6'$?6KGT

00(D-Kubota)-1-2
Group 00(D-Kubota), Engine

Section 2
CHECK AND MAINTENANCE

1. MAINTENANCE CHECK LIST


To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following
the table below.
Service Interval
Item Every Every Every Every 1 Every Every Every
Initial Every Every
50 hrs 50 hrs 250 500 1000 or 2 1500 3000 1 year 2
hrs hrs hrs months hrs hrs years
Changing engine oil
Replacing oil filter cartridge
*Checking fuel hoses and clamps
*Cleaning air filter element
(Replace the element after 6 times cleanings)
*Cleaning fuel filter
Checking battery electrolyte level
Checking radiator hoses and clamps
*Checking intake air line
Checking fan belt tension and damage
*Replacing fuel filter cartridge
Replacing fan belt
Cleaning radiator interior
Checking valve clearance
Recharging battery
*Checking injection nozzle condition
*Checking turbocharger
Checking fuel injection pump
*Checking injection timing (spill timing)
*Replacing air filter element
Changing radiator coolant (L.L.C.)
Replacing radiator hoses and clamps
*Replacing fuel hoses and clamps
*Replacing intake air line
Replacing battery
* The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S.EPA
nonroad emission regulation.
As the engine owner, you are responsible for the performance of the required maintenance on the engine according
to the above instruction.

00(D-Kubota)-2-1
Group 00(D-Kubota), Engine

CAUTION
• When changing or inspecting, be sure to level and stop the engine.
NOTE
Engine Oil :
• Refer to the following table for the suitable American Petroleum Institute (API) classification of engine oil
according to the engine type (with internal EGR, external EGR or non-EGR) and the Fuel Type Used :
(Low Sulfur, Ultra Low Sulfur or High Sulfur Fuels).
Engine oil classification (API classification)
Fuel Type Engines with non-EGR
Engines with external EGR
Engines with internal EGR
CF
High Sulfur Fuel
(If the "CF-4, CG-4, CH-4, or CI-4" engine
[0.05 % (500 ppm) ≤
oil is used with a high-sulfur fuel, change –
Sulfur Content <
the engine oil at shorter intervals.
0.50 % (5000 ppm)]
(approximately half))
Low Sulfur Fuel
[Sulfur Content <
CF or CI-4
0.05 % (500 ppm)] or
CF, CF-4, CG-4, CH-4 or CI-4 (Class CF-4, CG-4 and CH-4 engine oils
Ultra Low Sulfur Fuel
cannot be used on EGR type engines.)
[Sulfur Content <
0.0015 % (15 ppm)]
EGR : Exhaust Gas Re-circulation

• CJ4 classification oil is intended for use in engines equipped with DPF (Diesel Particulate Filter) and is Not
Recommended for use in E3 specification engines.
• Oil used in the engine should have API classification and Proper SAE Engine Oil Viscosity according to
the ambient temperatures where the engine is operated.
• With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils have been developed
for use with low sulfur fuels, for On-Highway vehicle engines. When a Non-Road engine runs on high
sulfur fuel, it is advisable to use a "CF or better" classification engine oil with a high Total Base Number
(a minimum TBN of 10 is recommended).
Fuel :
• Cetane Rating : The minimum recommended Fuel Cetane Rating is 45. A cetane rating greater than 50 is
preferred, especially for ambient temperatures below −20 °C (−4 °F) or elevations above 1500 m (5000 ft).
• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable
emission regulations for the area in which the engine is operated.
• Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly recommended.
• If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to 1.0 % (10000 ppm)) is used as a diesel fuel, change
the engine oil and oil filter at shorter intervals. (approximately half)
• DO NOT USE Fuels that have sulfur content greater than 1.0 % (10000 ppm).
• Diesel fuels specified to EN 590 or ASTM D975 are recommended.
• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313
JUN87)
• Since Our diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards,
the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these engines, when operated in US EPA
regulated areas. Therefore, please use No.2-D S500 or S15 diesel fuel as an alternative to No.2-D, and use
No.1-D S500 or S15 diesel fuel as an alternative to No.1-D for ambient temperatures below −10 °C (14 °F).

1) SAE : Society of Automotive Engineers


2) EN : European Norm
3) ASTM : American Society of Testing and Materials
4) US EPA : United States Environmental Protection Agency
5) No.1-D or No.2-D, S500 : Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%
No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%
00(D-Kubota)-2-2
Group 00(D-Kubota), Engine

2. CHECK AND MAINTENANCE


[1] DAILY CHECK POINTS
Checking Engine Oil Level
1. Level the engine.
2. To check the oil level, draw out the dipstick (1), wipe it clean,
reinsert it, and draw it out again.
Check to see that the oil level lies between the two notches.
3. If the level is too low, add new oil to the specified level.
IMPORTANT
• When using an oil of different maker or viscosity from the
previous one, drain old oil. Never mix two different types of
oil.
NOTE
• Be sure to inspect the engine, locating it on a horizontal
place. If placed on gradients, accurately, oil quantity may
not be measured.
• Be sure to keep the oil level between upper and lower limits
of the dipstick. Too much oil may cause a drop in output or
excessive blow-by gas. On the closed breather type engine
in which mist is sucked through port, too much oil may
caused oil hammer. While too little oil, may seize the
engine’s rotating and sliding parts.
(1) Dipstick (a) Maximum
(b) Minimum

00(D-Kubota)-2-3
Group 00(D-Kubota), Engine

Checking and Replenish Coolant


1. Without recovery tank :
Remove the radiator cap (1) and check to see that the coolant
level is just below the port.
With recovery tank (2) :
Check to see that the coolant level lies between FULL (A) and
LOW (B).
2. If coolant level is too low, check the reason for decreasing
coolant.
(Case 1)
If coolant is decreasing by evaporation, replenish only fresh, soft
water.
(Case 2)
If coolant is decreasing by leak, replenish coolant of the same
manufacture and type in the specified mixture ratio (fresh, soft
water and L.L.C.). If the coolant brand cannot be identified, drain
out all of the remaining coolant and refill with a totally new brand
of coolant mix.

CAUTION
• Do not remove the radiator cap until coolant temperature is
below its boiling point. Then loosen the cap slightly to
relieve any excess pressure before removing the cap
completely.
IMPORTANT
• During filling the coolant, air must be vented from the engine
coolant passages. The air vents by jiggling the radiator
upper and lower hoses.
• Be sure to close the radiator cap securely. If the cap is loose
or improperly closed, coolant may leak out and the engine
could overheat.
• Do not use an antifreeze and scale inhibitor at the same time.
• Never mix the different type or brand of L.L.C..
(1) Radiator Cap A: FULL
(2) Recovery Tank B: LOW

00(D-Kubota)-2-4
Group 00(D-Kubota), Engine

[2] CHECK POINTS OF INITIAL 50 HOURS


Changing Engine Oil
#
CAUTION
• Be sure to stop engine before changing engine oil.
1. Start and warm up the engine for approx. 5 minutes.
2. Place an oil pan underneath the engine.
3. To drain the used oil, remove the drain plug (1) at the bottom of
the engine and drain the oil completely.
4. Screw the drain plug (1).
5. Fill new oil up to upper line on the dipstick (2).

<A> ; V3800DI-T-E2B Engine (Tier2)


<B> ; V3800DI-T-E3B Engine (Tier3)

IMPORTANT
• When using an oil of different maker or viscosity from the
previous one, remove all of the old oil.
• Never mix two different types of oil.
• Engine oil should have properties of API classification CF
$
5GG.WDTKECVKPI1KN
• Use the proper SAE Engine Oil according to ambient
temperature.
SAE 30 or SAE 10W-30
Above 25 °C (77 °F)
SAE 10W-40
SAE 20 or SAE 10W-30
0 °C to 25 °C (32 °F to 77 °F)
SAE 10W-40
SAE 10W or SAE 10W-30
Below 0 °C (32 °F)
SAE 10W-40

13.2 L
Engine oil capacity
3.49 U.S.gals

(1) Drain Plug (2) Dipstick

Replacing Oil Filter Cartridge

CAUTION
• Be sure to stop the engine before changing filter cartridge.
1. Remove the oil filter cartridge (1) with the filter wrench.
2. Apply a slight coat of oil onto the new cartridge gasket.
3. To install the new cartridge, screw it in by hand. Over tightening
may cause deformation of rubber gasket.
4. After the new cartridge has been replaced, the engine oil
normally decrease a little. Thus see that the engine oil does not
leak through the seal and be sure to read the oil level on the
dipstick. Then, replenish the engine oil up to the specified level.
IMPORTANT
• To prevent serious damage to the engine, replacement
element must be highly efficient. Use only a KUBOTA
genuine filter or its equivalent.
(1) Engine Oil Filter Cartridge

00(D-Kubota)-2-5
Group 00(D-Kubota), Engine

Fan Belt Tension


1. Measure the deflection (A), depressing the belt halfway between
the fan drive pulley and alternator pulley at specified force 98 N
(10 kgf, 22 lbs).
2. If the measurement is not within the factory specifications, loosen
the alternator mounting screws and relocate the alternator to
adjust.
10 to 12 mm
Deflection (A) Factory spec.
0.394 to 0.472 in.

(A) Deflection

[3] CHECK POINT OF EVERY 50 HOURS


Checking Fuel Hose and Clamp Bands
1. If the clamp (2) is loose, apply oil to the threads and securely
retighten it.
2. The fuel hose (3) is made of rubber and ages regardless of the
period service.
Change the fuel pipe together with the clamp every two years.
3. However, if the fuel hose and clamps are found to be damaged
or deteriorate earlier than two years, then change or remedy.
4. After the fuel hose and the clamps have been changed, bleed the
fuel system.

CAUTION
• Stop the engine when attempting the check and change
prescribed above.
(When bleeding fuel system)
1. Fill the tank with fuel and open the cock.
2. Loosen the air vent coupling bolt of fuel filter a few turns.
3. When there is no more air bubbles in the fuel coming out of this
coupling bolt, tighten the coupling bolt.
4. Open the air vent cock (1) on the top of fuel injection pump.
5. If equipped electrical fuel feed pump, turn the key on AC position
and pump the fuel up for 10 to 15 seconds.
If equipped mechanical fuel feed pump, set the stop lever on stop
position and crank the engine for 10 to 15 seconds.
6. Close securely the air vent cock (1) after air bleeding.
IMPORTANT
• Except when venting the air, be sure to keep closed the air
vent coupling bolt of the fuel injection pump. Otherwise, the
engine may stall.
(1) Air Vent Cock (3) Fuel Hose
(2) Clamp

00(D-Kubota)-2-6
Group 00(D-Kubota), Engine

[4] CHECK POINTS OF EVERY 250 HOURS


Fan Belt Tension
1. Measure the deflection (A), depressing the belt halfway between
the fan drive pulley and alternator pulley at specified force 98 N
(10 kgf, 22 lbs).
2. If the measurement is not within the factory specifications, loosen
the alternator mounting screws and relocate the alternator to
adjust.
10 to 12 mm
Deflection (A) Factory spec.
0.394 to 0.472 in.

(A) Deflection

Fan Belt Damage and Wear


1. Check the fan belt for damage.
2. If the fan belt is damaged, replace it.
3. Check if the fan belt is worn and sunk in the pulley groove.
4. If the fan belt is nearly worn out and deeply sunk in the pulley
groove, replace it.
(A) Good (B) Bad

Cleaning Air Cleaner Element


1. Remove the air cleaner element.
2. Use clean dry compressed air on the inside of the element.
Pressure of compressed air must be under 205 kPa (2.1 kgf/cm2,
30 psi).
Maintain reasonable distance between the nozzle and the filter.
NOTE
• The air cleaner uses a dry element. Never apply oil to it.
• Do not run the engine with filter element removed.
• Change the element once a year or every 6th cleaning.

00(D-Kubota)-2-7
Group 00(D-Kubota), Engine

Cleaning Fuel Filter (Element Type only)


1. Close the fuel cock (3).
2. Unscrew the retaining ring (6) and remove the filter cup (5), and
rinse the inside with kerosene.
3. Take out the element (4) and dip it in the kerosene to rinse.
4. After cleaning, reassemble the fuel filter, keeping out dust and
dirt.
5. Bleed the fuel system.
IMPORTANT
• If dust and dirt enter the fuel, the fuel injection pump and
injection nozzle will wear quickly. To prevent this, be sure
to clean the filter cup (5) periodically.
(1) Cock Body (4) Filter Element
(2) Air Vent Plug (5) Filter Cup
(3) Fuel Cock (6) Retaining Ring

Checking Radiator Hoses and Clamp Bands


1. Check to see if the radiator hoses are properly fixed every 250
hours of operation or every six months, whichever comes first.
2. If the clamp is loose, apply oil to the threads and retighten it
securely.
3. The water hose is made of rubber and tends to age. It must be
replaced every two years. Also replace the clamp and tighten it
securely.
(1) Upper Hose (2) Lower Hose

Checking Battery Electrolyte Level


1. Check the battery electrolyte level.
2. If the level is below than lower level line (2), and the distilled water
to pour level of each cell.
(1) Upper Level Line (2) Lower Level Line

Checking Intake Air Line


1. Check to see if the intake air hose(s) are properly fixed every 250
hours of operation.
2. If the clamp is loose, apply oil to the threads and retighten it
securely.
3. The intake air hose(s) is made of rubber and tends to age. It must
be change every two years. Also change the clamp and tighten
it securely.
IMPORTANT
• To prevent serious damage to the engine, keep out any dust
inside the intake air line.
(1) Intake Air Hose (2) Clamp

00(D-Kubota)-2-8
Group 00(D-Kubota), Engine

[5] CHECK POINTS OF EVERY 500 HOURS


Changing Engine Oil
#
CAUTION
• Be sure to stop engine before changing engine oil.
1. Start and warm up the engine for approx. 5 minutes.
2. Place an oil pan underneath the engine.
3. To drain the used oil, remove the drain plug (1) at the bottom of
the engine and drain the oil completely.
4. Screw the drain plug (1).
5. Fill new oil up to upper line on the dipstick (2).

<A> ; V3800DI-T-E2B Engine (Tier2)


<B> ; V3800DI-T-E3B Engine (Tier3)

IMPORTANT
• When using an oil of different maker or viscosity from the
previous one, remove all of the old oil.
• Never mix two different types of oil.
• Engine oil should have properties of API classification CF
$ (See Lubricating Oil)
• Use the proper SAE Engine Oil according to ambient
temperature.
SAE 30 or SAE 10W-30
Above 25 °C (77 °F)
SAE 10W-40
SAE 20 or SAE 10W-30
0 °C to 25 °C (32 °F to 77 °F)
SAE 10W-40
SAE 10W or SAE 10W-30
Below 0 °C (32 °F)
SAE 10W-40

13.2 L
Engine oil capacity
3.49 U.S.gals

(1) Drain Plug (2) Dipstick

Replacing Oil Filter Cartridge

CAUTION
• Be sure to stop the engine before changing filter cartridge.
1. Remove the oil filter cartridge (1) with the filter wrench.
2. Apply a slight coat of oil onto the new cartridge gasket.
3. To install the new cartridge, screw it in by hand. Over tightening
may cause deformation of rubber gasket.
4. After the new cartridge has been replaced, the engine oil
normally decrease a little. Thus see that the engine oil does not
leak through the seal and be sure to read the oil level on the
dipstick. Then, replenish the engine oil up to the specified level.
IMPORTANT
• To prevent serious damage to the engine, replacement
element must be highly efficient. Use only a KUBOTA
genuine filter or its equivalent.
(1) Engine Oil Filter Cartridge

00(D-Kubota)-2-9
Group 00(D-Kubota), Engine

Replacing Fuel Filter Cartridge (Cartridge Type)


Water and dust in fuel are collected in the filter cartridge. So,
change the filter cartridge every 500 hours service.
1. Remove the used filter cartridge with filter wrench.
2. Apply a thin film of fuel to the surface of new filter cartridge gasket
before screwing on.
3. Then tighten enough by hand.
4. Loosen the air vent plug to let the air out.
5. Start engine and check for fuel leakage.
(1) Fuel Filter Cartridge

Replacing Fan Belt


1. Remove the alternator.
2. Remove the fan belt (1).
3. Replace new fan belt.
4. Install the alternator.
5. Check the fan belt tension.
10.0 to 12.0 mm / 98 N
Deflection (A) Factory spec. 0.394 to 0.472 in. / 98 N
(10 kgf, 22 lbs)

(1) Fan Belt (A) Deflection

Cleaning Water Jacket and Radiator Interior

CAUTION
• Do not remove the radiator cap when the engine is hot. Then
loosen cap slightly to the stop to relieve any excess
pressure before removing cap completely.
1. Stop the engine and let cool down.
2. To drain the coolant, open the radiator drain plug (2) and remove
the radiator cap (1). Then radiator cap (1) must be removed to
completely drain the coolant. And open the drain cock of engine
body.
3. After all coolant is drained, close the drain plug.
4. Fill with clean water and cooling system cleaner.
5. Follow directions of the cleaner instruction.
6. After flushing, fill with clean water and anti-freeze until the coolant
level is just below the port. Install the radiator cap (1) securely.
7. Fill with coolant up to “FULL” (A) mark on the recovery tank (3).
8. Start and operate the engine for few minutes.
9. Stop the engine and let cool. Check coolant level of radiator and
recovery tank (3) and add coolant if necessary.
IMPORTANT
• Do not start engine without coolant.
• Use clean, fresh, soft water and anti-freeze to fill the radiator
and recovery tank.
• When the anti-freeze is mixed with fresh, soft water, the anti-
freeze mixing ratio must be less than 50 %.
• Securely tighten radiator cap. If the cap is loose or
improperly fitted, water may leak out and the engine could
overheat.
(1) Radiator Cap A : Full
(2) Drain Plug B : Low
(3) Recovery Tank

00(D-Kubota)-2-10
Group 00(D-Kubota), Engine

Anti-Freeze
• There are two types of anti-freeze available: use the permanent
type (PT) for this engine.
• Before adding anti-freeze for the first time, clean the radiator
interior by pouring fresh, soft water and draining it a few times.
• The procedure for mixing water and anti-freeze differs according
to the make of the anti-freeze and the ambient temperature.
Basically, it should be referred to SAE J1034 standard, more
specifically also to SAE J814c.
• Mix the anti-freeze with fresh, soft water, and then fill into the
radiator.
IMPORTANT
• When the anti-freeze is mixed with fresh, soft water, the anti-
freeze mixing ratio must be less than 50 %.
Vol % Freezing point Boiling point*
anti-freeze ୅ ୅
එ එ
40 –24 –11.2 106 222.8
50 –37 –34.6 108 226.4
* At 1.013 × 100000 Pa (760 mmHg) pressure (atmospheric). A
higher boiling point is obtained by using a radiator pressure cap
which permits the development of pressure within the cooling
system.
NOTE
• The above data represents industrial standards that
necessitate a minimum glycol content in the concentrated
anti-freeze.
• When the coolant level drops due to evaporation, add fresh,
soft water only to keep the anti-freeze mixing ratio less than
50 %. In case of leakage, add anti-freeze and fresh, soft
water in the specified mixing ratio.
• Anti-freeze absorbs moisture. Keep unused anti-freeze in a
tightly sealed container.
• Do not use radiator cleaning agents when anti-freeze has
been added to the coolant.
(Anti-freeze contains an anti-corrosive agent, which will
react with the radiator cleaning agent forming sludge which
will affect the engine parts.)

00(D-Kubota)-2-11
Group 00(D-Kubota), Engine

[6] CHECK POINT OF EVERY 1000 HOURS


Checking Valve Clearance
IMPORTANT
• Valve clearance must be checked and adjusted when engine
is cold.
1. Remove the high pressure pipes and the head cover.
2. Align the 1TC mark of flywheel and the convex of flywheel
housing timing windows so that the first piston (gear case side)
comes to the compression top dead center.
3. Before adjusting the valve clearance, adjust the bridge evenly to
the valve stem.
4. Loosen the lock nut (2) and adjust with screw (1).
5. Slightly push the rocker arm with your fingers and screw in the
adjusting screw slowly until you feel the screw touch the top of
valve stem, then tighten the lock nut.
6. Loosen the lock nut (4) of adjusting screw (3) (push rod side) and
insert the feeler gauge between the rocker arm and the bridge
head. Set the adjusting screw to the specified value, then tighten
the lock nut.
0.23 to 0.27 mm
Valve clearance Factory spec.
0.0091 to 0.0106 in.

NOTE
• After adjusting, tighten the lock nut (4) securely.
Valve arrangement
Adjustment cylinder IN. EX
Location of piston
1st

When No.1 piston is at 2nd


compression top dead center 3rd
4th
1st

When No.1 piston is at 2nd


overlap position 3rd
4th

6.9 to 11.3 N·m


Cylinder head cover screw 0.7 to 1.15 kgf·m
5.1 to 8.32 ft-lbs
19.6 to 24.5 N·m
Tightening torque V3800DI 2.0 to 2.5 kgf·m
-T-E2B
14.5 to 18.1 ft-lbs
Injection pipe
retaining nut 23 to 36 N·m
V3800DI
-T-E3B
2.3 to 3.7 kgf·m
17 to 26 ft-lbs

(1) Adjusting Screw (3) Adjusting Screw


(2) Lock Nut (4) Lock Nut

00(D-Kubota)-2-12
Group 00(D-Kubota), Engine

[7] CHECK POINTS OF EVERY 1 OR 2 MONTHS


Recharging

CAUTION
• When the battery is being activated, hydrogen and oxygen
gases in the battery are extremely explosive. Keep open
sparks and flames away from the battery at all times,
especially when charging the battery.
• When charging battery, remove battery vent plugs.
• When disconnecting the cable from the battery, start with
the negative terminal first. When connecting the cable to the
battery, start with the positive terminal first.
• Never check battery charge by placing a metal object across
the posts.
Use a voltmeter or hydrometer.
1) Slow Charging
1. Add distilled water if the electrolyte level is low. When charging,
the amount of electrolyte should be slightly lower than the
specified level to prevent overflow.
2. Connect the battery to the charging unit, following the
manufacture’s instructions.
3. As the electrolyte generates gas while charging, remove all port
caps.
4. The electrolyte temperature must not exceed 40୅ (104එP
during charging.
If it exceed 40୅ (104එ), decrease the charging amperage or
stop charging for a while.
5. When charging several batteries in series, charge at the rate of
the smallest battery in the line.
2) Quick Charging
1. Determine the proper charging current and charging time with the
tester attached to the quick charger.
2. Determine the proper charging current as 1/1 of the battery
capacity. If the battery capacity exceeds 50 Ah, consider 50 A as
the maximum.
Precaution for Operating a Quick Charger
• Operate with a quick charger differs according to the type.
Consult the instruction manual and use accordingly.

00(D-Kubota)-2-13
Group 00(D-Kubota), Engine

Battery Specific Gravity


1. Check the specific gravity of the electrolyte in each cell with a
hydrometer.
2. When the electrolyte temperature differs from that at which the
hydrometer was calibrated, correct the specific gravity reading
following the formula mentioned in (Reference).
3. If the specific gravity is less than 1.215 (after it is corrected for
temperature), charge or replace the battery.
4. If the specific gravity differs between any two cells by more than
0.05, replace the battery.
NOTE
• Hold the hydrometer tube vertical without removing it from
the electrolyte.
• Do not suck too much electrolyte into the tube.
• Allow the float to move freely and hold the hydrometer at eye
level.
• The hydrometer reading must be taken at the highest
electrolyte level.
(Reference)
• Specific gravity slightly varies with temperature. To be exact, the
specific gravity decreases by 0.0007 with an increase of 1 °C
(0.0004 with an increase of 1 °F) in temperature, and increases
by 0.0007 with a decreases of 1 °C (0.0004 with a decrease of 1
°F).
Therefore, using 20 °C (68 °F) as a reference, the specific gravity
reading must be corrected by the following formula :
- Specific gravity at 20 °C = Measured value + 0.0007 x
(electrolyte temperature : 20 °C)
- Specific gravity at 68 °F = Measured value + 0.0004 x
(electrolyte temperature : 68 °F)
Specific Gravity State of Charge
1.260 Sp. Gr. 100 % Ch ar ged
1.230 Sp. Gr. 7 5 % C ha r g e d
1.200 Sp. Gr. 50 % Charg ed
1.170 Sp. Gr. 25 % Charg ed
1.140 Sp. Gr. Very Little Useful Capacity
1.110 Sp. Gr. Discharged
At an electrolyte temperature of 20 °C (68 °F)
(a) Good (c) Bad
(b) Bad

00(D-Kubota)-2-14
Group 00(D-Kubota), Engine

[8] CHECK POINTS OF EVERY 1500 HOURS


CAUTION
• Check the injection pressure and condition after confirming that there is nobody standing in the direction
the spray goes.
• If the spray from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning
may be caused.
Nozzle Spraying Condition
1. Attach the injection nozzle to the nozzle tester, and check the
nozzle spraying condition.
2. If the spraying condition is defective, replace the injection nozzle
assembly or repair at Denso service shop.
(a) Good (b) Bad

Checking Nozzle Injection Pressure


1. Attach the injection nozzle to the nozzle tester.
2. Slowly move the tester handle to measure the pressure at which
fuel begins jetting out from the nozzle.
3. If the measurement is not within the factory specifications,
replace the injection nozzle assembly or repair at Denso service
shop.
NOTE
• Injection nozzle gasket must be replaced when the injection
nozzle is removed for checking.
18.63 to 19.61 MPa
Factory 1st
Injection pressure 190 to 200 kgf/cm2
spec. stage
2702 to 2845 psi

Valve Seat Tightness


1. Attach the injection nozzle to the nozzle tester.
2. Raise the fuel pressure, and keep at 16.67 MPa (170 kgf/cm2,
2418 psi) for 10 seconds.
3. If any fuel leak is found, replace the injection nozzle assembly or
repair at Denso service shop.
No fuel leak at
16.67 MPa
Valve seat tightness Factory spec.
170 kgf/cm2
2418 psi

00(D-Kubota)-2-15
Group 00(D-Kubota), Engine

[9] CHECK POINTS OF EVERY 3000 HOURS


Checking Turbocharger
(Turbine Side)
1. Check the exhaust port (3) and inlet port (5) side of turbine
housing (1) to see if there is no exhaust gas leak.
2. If any gas leak is found, retighten the bolts and nuts or replace
the gasket (2) / (4) / (6) with new one.
(Compressor Side)
1. Check the inlet hose (9) of the compressor cover (10) to see if
there is no air leak.
2. If any air leak is found, change the clamp (8) and / or inlet hoses.
3. Check the intake hose (7) and the clamp to see if there is not
loose or crack.
4. If any loose or crack is found, tighten the cramp or change the
hose to prevent dust from entry.
(Radial Clearance)
1. If the wheel contact to the housing, replace the turbocharger
assembly with new one.
(1) Turbine Housing (6) Gasket
(2) Gasket (7) Intake Hose
(3) Exhaust Port (8) Clamp
(4) Gasket (9) Inlet Hose
(5) Inlet Port (10) Compressor Cover

00(D-Kubota)-2-16
Group 00(D-Kubota), Engine

Injection Timing
1. Make sure of matching the injection timing align mark (1) of the
injection pump unit and the plate (gearcase), as shown in the
illustration.
2. Remove the injection pipes.
3. Remove the stop solenoid.
4. Turn the flywheel counterclockwise (viewed from flywheel side)
until the fuel fills up to the hole of the delivery valve holder (2) for
No.1 cylinder.
5. After the fuel fills up to the hole of the delivery valve holder for
No.1 cylinder, turn back (clockwise) the flywheel around 1.57 rad
(90 °).
6. Turn the flywheel counterclockwise to set at around 0.35 rad
(20 ) before T.D.C..
7. Slowly turn the flywheel counterclockwise and stop turning when
the fuel begins to come up, to get the present injection timing.
8. Check to see the degree on flywheel.
The flywheel has mark “1TC”, “10” and “20” for the crank angle
before the top dead center of No.1 piston.
9. If the injection timing is not within the specification, rotate the
injection pump unit to adjust the injection timing.
IMPORTANT
• When installing the injection pump unit to the engine body,
follow the correct procedure.
See the “Injection Pump Unit”.
0.21 to 0.24 rad (12  to
Injection timing Factory spec.
14 ) before T.D.C.

19.6 to 24.5 N·m


Injection pipe retaining nut 2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs
Tightening torque
17.7 to 20.6 N·m
Injection pump unit
1.8 to 2.1 kgf·m
mounting nut
13.0 to 15.2 ft-lbs

(1) Injection Timing Align Mark (a) Injection Timing Advanced


(2) Delivery Valve Holder (b) Injection Timing Retarded

00(D-Kubota)-2-17
Group 00(D-Kubota), Engine

Checking Injection Pump


(Fuel Tightness of Pump Element)
1. Remove the engine stop solenoid.
2. Remove the injection pipes.
3. Install the injection pump pressure tester to the injection pump.
4. Install the injection nozzle (2) jetted with the proper injection
pressure to the injection pump pressure tester (1). (Refer to the
figure.)
5. Set the speed control lever to the maximum speed position.
6. Run the starter to increase the pressure.
7. If the pressure can not reach the allowable limit, replace the
pump with new one or repair with a Kubota-authorized pump
service shop.
(Fuel Tightness of Delivery Valve)
1. Remove the engine stop solenoid.
2. Remove the injection pipes.
3. Set a pressure tester to the fuel injection pump.
4. Install the injection nozzle (2) jetted with the proper injection
pressure to the injection pump pressure tester (1).
5. Run the starter to increase the pressure.
6. Stop the starter when the fuel jets from the injection nozzle. After
that, turn the flywheel by the hand and raise the pressure to
approx. 18.63 MPa (190 kgf/cm2, 2702 psi).
7. Now turn the flywheel back about half a turn (to keep the plunger
free). Maintain the flywheel at this position and clock the time
taken for the pressure to drop from 18.63 to 17.65 MPa (from 190
to 180 kgf/cm2, from 2702 to 2560 psi).
8. Measure the time needed to decrease the pressure from 18.63 to
17.65 MPa (from 190 to 180 kgf/cm2, from 2702 to 2560 psi).
9. If the measurement is less than allowable limit, replace the pump
with new one or repair with a Kubota-authorized pump service
shop.
18.63 MPa
Fuel tightness of pump
Allowable limit 190 kgf/cm2
element
2702 psi
10 seconds
18.63 ˧ 17.65 MPa
Factory spec.
190 ˧ 180 kgf/cm2
Fuel tightness of 2702 ˧ 2560 psi
delivery valve 5 seconds
18.63 ˧ 17.65 MPa
Allowable limit
190 ˧ 180 kgf/cm2
2702 ˧ 2560 psi

NOTE
• Never try to disassemble the injection pump assembly. For
repairs, you are strongly requested to contact a Kubota-
authorized pump service shop.
(1) Injection Pump Pressure Tester (3) Protection Cover for Jetted Fuel
(2) Injection Nozzle

00(D-Kubota)-2-18
Group 00(D-Kubota), Engine

[10] CHECK POINTS OF EVERY 1 YEAR


Changing Engine Oil
#
CAUTION
• Be sure to stop engine before changing engine oil.
1. Start and warm up the engine for approx. 5 minutes.
2. Place an oil pan underneath the engine.
3. To drain the used oil, remove the drain plug (1) at the bottom of
the engine and drain the oil completely.
4. Screw the drain plug (1).
5. Fill new oil up to upper line on the dipstick (2).
<A> ; V3800DI-T-E2B Engine (Tier2)
<B> ; V3800DI-T-E3B Engine (Tier3)

IMPORTANT
• When using an oil of different maker or viscosity from the
previous one, remove all of the old oil.
• Never mix two different types of oil.
• Engine oil should have properties of API classification CF

5GG.WDTKECVKPI1KN
$ • Use the proper SAE Engine Oil according to ambient
temperature.
SAE 30 or SAE 10W-30
Above 25 °C (77 °F)
SAE 10W-40
SAE 20 or SAE 10W-30
0 °C to 25 °C (32 °F to 77 °F)
SAE 10W-40
SAE 10W or SAE 10W-30
Below 0 °C (32 °F)
SAE 10W-40

13.2 L
Engine oil capacity
3.49 U.S.gals

(1) Drain Plug (2) Dipstick

Replacing Air Cleaner Element


1. Remove used air cleaner element.
2. Replace new air cleaner element.
NOTE
• The air cleaner uses a dry element. Never apply oil to it.
• Do not run the engine with filter element removed.

00(D-Kubota)-2-19
Group 00(D-Kubota), Engine

[11] CHECK POINTS OF EVERY 2 YEARS


Replacing Fan Belt
1. Remove the alternator.
2. Remove the fan belt (1).
3. Replace new fan belt.
4. Install the alternator.
5. Check the fan belt tension.
10.0 to 12.0 mm / 98 N
Deflection (A) Factory spec. 0.394 to 0.472 in. / 98 N
(10 kgf, 22 lbs)

(1) Fan Belt (A) Deflection

Changing Radiator Coolant (L.L.C.)

CAUTION
• Do not remove the radiator cap when the engine is hot. Then
loosen cap slightly to the stop to relieve any excess
pressure before removing cap completely.
1. Stop the engine and let cool down.
2. To drain the coolant, open the radiator drain plug (2) and remove
the radiator cap (1). Then radiator cap (1) must be removed to
completely drain the coolant. And open the drain cock of engine
body.
3. After all coolant is drained, close the drain plug.
4. Fill with clean water and cooling system cleaner.
5. Follow directions of the cleaner instruction.
6. After flushing, fill with clean water and anti-freeze until the coolant
level is just below the port. Install the radiator cap (1) securely.
7. Fill with coolant up to “FULL” (A) mark on the recovery tank (3).
8. Start and operate the engine for few minutes.
9. Stop the engine and let cool. Check coolant level of radiator and
recovery tank (3) and add coolant if necessary.
IMPORTANT
• Do not start engine without coolant.
• Use clean, fresh, soft water and anti-freeze to fill the radiator
and recovery tank.
• When the anti-freeze is mixed with fresh, soft water, the anti-
freeze mixing ratio must be less than 50 %.
• Securely tighten radiator cap. If the cap is loose or
improperly fitted, water may leak out and the engine could
overheat.
(1) Radiator Cap A : Full
(2) Drain Plug B : Low
(3) Recovery Tank

00(D-Kubota)-2-20
Group 00(D-Kubota), Engine

Changing Radiator Coolant (L.L.C.) (Continued)


(Anti-freeze)
• There are two types of anti-freeze available: use the permanent
type (PT) for this engine.
• Before adding anti-freeze for the first time, clean the radiator
interior by pouring fresh, soft water and draining it a few times.
• The procedure for mixing water and anti-freeze differs according
to the make of the anti-freeze and the ambient temperature.
Basically, it should be referred to SAE J1034 standard, more
specifically also to SAE J814c.
• Mix the anti-freeze with fresh, soft water, and then fill into the
radiator.
IMPORTANT
• When the anti-freeze is mixed with fresh, soft water, the anti-
freeze mixing ratio must be less than 50 %.
Vol % Freezing point Boiling point*
anti-freeze ୅ එ ୅ එ
40 –24 –11.2 106 222.8
50 –37 –34.6 108 226.4
* At 1.013 × 100000 Pa (760 mmHg) pressure (atmospheric). A
higher boiling point is obtained by using a radiator pressure cap
which permits the development of pressure within the cooling
system.
NOTE
• The above data represents industrial standards that
necessitate a minimum glycol content in the concentrated
anti-freeze.
• When the coolant level drops due to evaporation, add fresh,
soft water only to keep the anti-freeze mixing ratio less than
50 %. In case of leakage, add anti-freeze and fresh, soft
water in the specified mixing ratio.
• Anti-freeze absorbs moisture. Keep unused anti-freeze in a
tightly sealed container.
• Do not use radiator cleaning agents when anti-freeze has
been added to the coolant.
(Anti-freeze contains an anti-corrosive agent, which will
react with the radiator cleaning agent forming sludge which
will affect the engine parts.)

Replacing Radiator Hoses and Clamp Bands

CAUTION
• Do not remove the radiator cap when the engine is hot. Then
loosen cap slightly to the stop to relieve any excess
pressure before removing cap completely.
1. Drain the coolant.
2. Loosen the clamp bands.
3. Remove the upper hose (1) and lower hose (2).
4. Replace new upper / lower hose (1), (2) and clamp bands.
5. Tighten the clamp bands.
6. Fill with clean water and anti-freeze until the coolant level is just
below the port. Install the radiator cap securely.
(1) Upper Hose (2) Lower Hose

00(D-Kubota)-2-21
Group 00(D-Kubota), Engine

Replacing Fuel Hose and Clamp Bands


1. Loosen the clamp (2) and remove the fuel hose (3).
2. Replace new fuel hose (3) and new clamp (2).
3. Tighten the clamp (2).
CAUTION
• Stop the engine when attempting the check and change
prescribed above.
(When bleeding fuel system)
1. Fill the tank with fuel and open the cock.
2. Loosen the air vent coupling bolt of fuel filter a few turns.
3. When there is no more air bubbles in the fuel coming out of this
coupling bolt, tighten the coupling bolt.
4. Open the air vent cock (1) on the top of fuel injection pump.
5. If equipped electrical fuel feed pump, turn the key on AC position
and pump the fuel up for 10 to 15 seconds.
If equipped mechanical fuel feed pump, set the stop lever on stop
position and crank the engine for 10 to 15 seconds.
6. Close securely the air vent cock (1) after air bleeding.
IMPORTANT
• Except when venting the air, be sure to keep closed the air
vent coupling bolt of the fuel injection pump. Otherwise, the
engine may stall.
(1) Air Vent Cock (3) Fuel Hose
(2) Clamp

Replacing Intake Air Line


1. Loosen the clamp (2).
2. Remove the intake air hose (1) and clamp (2).
3. Replace new intake air hose (1) and new clamp (2).
4. Tighten the clamp (2).
NOTE
• To prevent serious damage to the engine, keep out any dust
inside the intake air line.
(1) Intake Air Hose (2) Clamp

Replacing Battery
CAUTION
• When the battery is being activated, hydrogen and oxygen
gases in the battery are extremely explosive. Keep open
sparks and flames away from the battery at all times,
especially when charging the battery.
• When charging battery, remove battery vent plugs.
• When disconnecting the cable from the battery, start with
the negative terminal first. When connecting the cable to the
battery, start with the positive terminal first.
• Never check battery charge by placing a metal object across
the posts.
1. Disconnect the negative terminal and positive terminal.
2. Remove the battery holder.
3. Remove the used battery.
4. Replace the new battery.
5. Tighten the battery holder.
6. Connect the positive terminal.
7. Connect the negative terminal.

00(D-Kubota)-2-22
Group 00(D-Kubota), Engine

Section 3
Mechanism
1. ENGINE BODY
[1] CYLINDER BLOCK This engine employs separate type crankcases - the
crankcase 1 (1) with combustion part and the crankcase
2 (2) which supports the crankcase 1 (1) and reduces
noise.
Since it is a hanger type, you can easily assemble /
disassemble it. The cylinder is a linerless type which
enables good cooling operation, less strain and good
abrasion resistance.
(1) Crankcase 1 (3) Oil Pan
(2) Crankcase 2

[2] HALF-FLOATING HEAD COVER


The rubber packing is fitted in to maintain the head
cover 0.5 mm (0.02 in.) or so off the cylinder head. This
arrangement helps reduce noise coming from the
cylinder head.
(1) Cylinder Head Cover (2) Rubber Packing

00(D-Kubota)-3-1
Group 00(D-Kubota), Engine

[3] CYLINDER HEAD


This engine employs four valve system, the cylinder
head is provided with double intake passenge in order to
ensure appropriate air suction and give an optimum
swirl.
(1) Intake (2) Exhaust

[4] CENTER DIRECT INJECTION SYSTEM (E-CDIS)


V3 series DI engine adopts the Center Direct Injection
System (E-CDIS), in which the injection nozzle is
positioned upright at the center of the cylinder.
This system serves to inject fuel directly at the center
of the cylinder. By so doing, injected fuel and suction air
can be mixed more uniformly, leading to more stable,
higher combustion performance. In other words, cleaner
emission, higher power output, lower fuel consumption,
lower operating noise and higher start-up performance
have been achieved.
(1) Exhaust Valves (3) Injection Nozzle
(2) Piston (4) Intake Valves

V3 series DI engine has two intake valves and two


exhaust valves per each cylinder.
The rocker arm (1) contacts a bridge arm (2) instead
of the valves stem tip.
The bridge arm then contacts both intake valves or
both exhaust valves and causes two valves to open
simultaneously.
(1) Rocker Arm (2) Bridge Arm

00(D-Kubota)-3-2
Group 00(D-Kubota), Engine

[5] PISTON
Piston’s skirt is coated with molybdenum disulfide ,
which reduces the piston slap noise and thus the entire
operating noise.

Molybdenum disulfide (MoS2)


The molybdenum disulfied serves as a solid lubricant,
like a Graphite or Teflon. This material helps resist metal
wears even with little lube oil.
(1) Molybdenum Disulfide

[6] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY)


Engine are sure to vibrate by piston’s reciprocation.
Theoretically, three-cylinder engines are much less
prone to cause vibration than four-cylinder ones (second
inertia, etc.). However, any engine has many moving
parts in addition to its pistons and cannot be completely
free from vibration.
The four cylinder engine is fitted with balance weight
on crankcase to absorb the second inertia mentioned
above and reduce vibration.

00(D-Kubota)-3-3
Group 00(D-Kubota), Engine

2. LUBRICATING SYSTEM
[1] OIL COOLER
V3 series engine has a water-cooled oil cooler that
not only cools hot oil, but also warms the cool engine oil
shoftly after start up.
As shown in the figure, the oil flows inside the
connected cooler plate, whereas coolant is kept
circulating outside the cooler plate, thereby cooling down
or warming the oil.
(A) Oil Inlet Port (a) Coolant Inlet Port
(B) Oil Outlet Port (b) Coolant Outlet Port

00(D-Kubota)-3-4
Group 00(D-Kubota), Engine

3. COOLING SYSTEM
[1] THERMOSTAT
Conventional thermostatically-controlled valves
(outlet water temperature control type) open against the
flow of coolant. In this design, the pressure (steam
pressure + water pump’s discharge pressure) affects the
open/close performance of such valve. In other words,
the valve may be delayed in opening at a preset opening
temperature opening suddenly, above the preset
temperature. This is called the overshoot phenomenon.
The overshoot problem invites the undershoot
phenomenon too. Too much water cooled by the radiator
flows through the water passage, which suddenly closes
the valve below the thermostat’s preset valve closing
temperature.
A repeated cycle of such overshoot and undershoot
phenomena is called the water temperature hunting.
This hunting problem may adversely affects the cooling
system parts, and also the engine and its related
components.
To cope with this trouble, the V3 series engine is
equipped with the flow control thermostat. The valve has
a notch to control the coolant flowrate smoothly in small
steps.
(1) Coolant Temperature (A) Valve Lift Versus Flowrate
(2) Time (B) Flowrate
(3) Overshoot (C) At Short Valve Lift
(4) Notch (D) At Medium Valve Lift
(E) At High Valve Lift
(F) Valve Lift

00(D-Kubota)-3-5
Group 00(D-Kubota), Engine

[2] BOTTOM BYPASS SYSTEM


Bottom bypass system is introduced in V3 series for
improving the cooling performance of the radiator.
While the temperature of coolant in the engine is low,
the thermostat is held closed and the coolant is allowed
to flow through the bypass pipe and to circulate in the
engine.
When the temperature exceeds the thermostat valve
opening level, the thermostat fully opens itself to prevent
the hot coolant from flowing through the bypass into the
engine.
In this way, the radiator can increase its cooling
performance.
(1) Thermostat (A) Bypass Opened
(B) Bypass Closed

00(D-Kubota)-3-6
Group 00(D-Kubota), Engine

4. FUEL SYSTEM
[1] GOVERNOR
The engine employs the separated fuel injection
pump in combination with Kubota’s own small multi-
function mechanical governor, which enables more
dependability.
It also employs the torque limiting mechanism to
control the maximum peak torque so that it complies with
the regulations of exhaust gas.
This mechanism maintains engine speed at a
constant level even under fluctuating loads, provides
stable idling and regulates maximum engine speed by
controlling the fuel injection rate.
This engine uses a mechanical governor that controls
the fuel injection rate at all speed ranges (from idling to
maximum speed) by utilizing the balance between the
flyweight’s centrifugal force and spring tension.
A governor shaft for monitoring engine speed is
independent of the injection pump shaft and rotates at
twice the speed of conventional types, providing better
response to load fluctuation and delivering greater
engine output.

At Start
The stop solenoid (energized-to-run type) is powered
to release the stop lever.
As no centrifugal force is applied to flyweight (2), low
tension of start spring (1) permits control rack to move
the starting position, supplying the amount of fuel
required to start the engine.
(1) Start Spring (2) Flyweight

00(D-Kubota)-3-7
Group 00(D-Kubota), Engine

At Idling
Turn the speed control lever (6) clockwise to idle the
engine. It tensions the governor spring (3) to pull the fork
lever 2 (1).
When the fork lever 2 is pulled, it moves the torque
spring pin (7) and the fork lever 1 (5) in the direction of
the arrow A to restrain the weight. In combination with
the start spring tension, it is balanced with the centrifugal
force of flywheel weight to keep idling.
(1) Fork Lever 2 (5) Fork Lever 1
(2) Start Spring (6) Speed Control Lever
(3) Governor Spring (7) Spring Pin
(4) Flyweight

At rated speed with full load and overload


As the speed control lever is changed from the middle
speed to high speed, the governor spring tension
increases to compress the torque spring and move the
fork lever 1 in the direction of the arrow A.
The fork lever 2 moves until it reaches the output
limiting bolt to keep rated rotation and rated output.
When the engine is overloaded, the engine rotating
speed decreases and the centrifugal force of flywheel
weight decreases. Then the torque spring moves the
fork lever 1 in the direction of arrow A.
The control rack moves in the direction that increases
fuel supply to increase the output. It is balanced with the
centrifugal force of the flywheel weight to produce low-
speed output (torque output).
(1) No-load Maximum Rotation (3) Torque Limiting Bolt
(2) Output Limiting Bolt (4) Idling Adjusting Bolt

00(D-Kubota)-3-8
Group 00(D-Kubota), Engine

To stop engine
When the stop solenoid is turned off, the spring
tension of the solenoid is released, the rod extrudes and
the stop lever moves the control rack in the direction of
the arrow B which stops the engine.
To stop the engine manually, move the external stop
lever to the left.

00(D-Kubota)-3-9
Group 00(D-Kubota), Engine

[2] MECHANICAL TIMER WITH COLD START ADVANCE FUNCTION


(V3800DI-T-E3B Engine)

This device makes the fuel injection timing advanced


by engine oil temperature and engine rpm in order to
improve the engine cold start-ability and reduce the blue
white smoke.

Thermal control
When the engine rpm is low and engine oil
temperature is under 30 °C, the fuel injection timing is
max. advanced.
When the engine rpm is low and engine oil
temperature is higher than 70 °C, the fuel injection timing
advance is 0 degree.
The fuel injection timing advance by engine oil
temperature is controlled with shape memory (storage)
spring.
(1) Timer Flyweight (a) No Gap Between Timer and
(2) Injection Pump Gear Injection Pump Gear
(3) Fuel Camshaft (b) Spring Force
(c) Advanced Injection Timing
[A] At Cold (d) Gap Between Timer and
[B] At Hot Injection Pump Gear
(e) Advanced Injection Timing
(degree)
(f) Engine Oil Temperature

00(D-Kubota)-3-10
Group 00(D-Kubota), Engine

Speed control
If the engine rpm is higher than a certain rpm, the fuel
injection timing advance by engine oil temperature does
not work. At that time, the quantity of advance timing is
variably changed by centrifugal force of the timer
flyweights which meets engine rpm.
(1) Timer Flyweight (a) No Gap Between Timer and
(2) Injection Pump Gear Injection Pump Gear
(3) Fuel Camshaft (b) Centrifugal Force
(c) Advanced Injection Timing
[A] At Low rpm (d) Gap Between Timer and
[B] At High rpm Injection Pump Gear
(e) Rotation
(f) Advanced Injection Timing
(Degree)
(g) Engine rpm

00(D-Kubota)-3-11
Group 00(D-Kubota), Engine

[3] 2 STAGE DI NOZZLE


Exhaust and noise regulations are becoming
increasingly strict, particularly in regard to the reduction
of NOx (nitrogen oxides) and particulates.
The two-spring nozzle holder has been developed to
reduce NOx (nitrogen oxides) and particulates from
direct injection diesel engine exhaust.
Features
The two-spring nozzle holder limits needle valve lift at
initial valve opening to throttle the injection quantity.
Main injection occurs when the in-line pressure has
increased sufficiently to move the needle valve through
its full lift.
This gives the following features.
• Improved engine stability at low and intermediate
speeds.
• Decreased engine hunting and surge.
• Decreased noise at idling.
• Decreased idling speed because of improved engine
stability.
• Stabilized fuel injection characteristics from the
injection pump and nozzle system, and easier
matching of governor characteristics to engine
demand.
(1) Nozzle Holder Body (7) Second Spring
(2) 1st Stage Injection Pressure (8) Pre-lift Adjusting Spring Seat
Adjusting Shim (9) Chip-packing
(3) First Spring (10) Max-lift Adjusting Washer
(4) Pressure Pin (11) Retaining Nut
(5) Spring Seat (12) Nozzle
(6) 2nd Stage Injection Pressure
Adjusting Shim

00(D-Kubota)-3-12
Group 00(D-Kubota), Engine

A-B : First Spring’s Set Force


B-C-D : Combined Force of
First and Second Springs
P1 : First Opening Pressure
P2 : Second Opening Pressure

L : Full Needle Valve Lift


l : Needle Valve Pre-lift

X1 : Cam Angle ()


Y1 : Injection Rate (mm3/)
X2 : Needle Valve Lift (mm)
Y2 : In-line Pressure

First opening pressure


The force of the high pressure fuel delivered by the injection pump acts to push the needle valve up. When this
force exceeds the set force of the first spring, the nozzle’s needle valve pushes the first pushrod up and the valve
opens. (First opening pressure is represented by point E in the bottom left hand figure, and point A in the above
figure.)
Second opening pressure
When the first pushrod has been lifted through the pre-lift, it contacts the second pushrod. As the set force of the
second spring is acting on the second pushrod, the combined forces of both the first spring and the second spring then
act on the needle valve, which will not lift unless these forces are overcome.

[4] INJECTION PUMP WITH F.S.P.


The fuel injection pump with F.S.P. (Fine Spill Port)
mechanism is equipped with two functions: speed timer
function and injection rate control function.
The former function works like this. As the rpm is low,
the injection timing gets delayed. This helps cut down on
NOx and operating noise.
The latter function serves to keep down the initial
injection rate and keep up the later injection rate, which
cuts down on NOx and PM as well.
(1) Fine Spill Port (F.S.P.) (5) Plunger
(2) Plunger Chamber (6) F.S.P. Stroke
(3) Main Port (7) Leaking Fuel at Initial Fuel
(4) Cylinder Pressure-Feed Stage

00(D-Kubota)-3-13
Group 00(D-Kubota), Engine

5. TURBOCHARGER SYSTEM
[1] BOOST COMPENSATOR
The boost compensator is controlled by the boost
pressure of the control mechanism which controls
transient smoke caused by oversupply of fuel when the
engine starts and accelerates.
When the boost pressure is lower than working
pressure of the boost actuator (1), it prevents oversupply
of fuel to reduce transient smoke.
When the boost pressure is higher than working
pressure of the boost actuator (1), it controls the supply
of fuel to the equivalent of maximum power / rated speed
output.
The boost compensator adjusting screws (2) are set
and tamper-proof capped in factory, so never take off the
tamper-proof cap and readjust the screws.
(1) Boost Actuator (2) Boost Compensator Adjusting
Screw

6. INTAKE SYSTEM
[1] INTAKE AIR HEATER
The intake air heater is introduced in order to further
improve the starting performance and to reduce the
white smoke at cold starting.
The intake air heater is mounted on the intake
manifold. In this new construction, there is no need to
arrange any glow plug on the cylinder head. This means
that a multi-valve design can be implemented and that
the starting performance and serviceability are
enhanced.

00(D-Kubota)-3-14
Group 00(D-Kubota), Engine

7. EXHAUST GAS RECIRCULATION (EGR) SYSTEM


(V3800DI-T-E3B Engine)

[1] GENERAL
In order to meet with the strict emission regulations, this engine has adopted the EGR
The nitrogen oxide (NOx) which is a hazardous component in exhaust gas is generated by oxidation of nitrogen in the
air, due to rise of the combustion temperature in cylinders. The EGR is a system in which the exhaust gas with lean
oxygen is cooled and returned to cylinders again in order to lower the combustion temperature. As a result, NOx can be
decreased.

(1) External / Mechanical EGR

(1) Thermo Valve (4) Intake Manifold (a) Boost Pressure (f) Cooled EGR Gas Merges
(2) Mechanical EGR Valve (5) Exhaust Manifold (b) Coolant Temperature with Fresh Air
(3) Reed Valve (6) EGR Cooler (c) Cooled EGR Gas (g) Exhaust
(d) To The Intake Manifold (h) Coolant Inlet
(e) Fresh Air (i) Coolant Outlet

External / Mechanical EGR consists of water cooled EGR cooler, mechanical EGR valve, reed valve and thermo
valve.
When the coolant temperature is getting higher, thermo valve is open and the boost pressure of intake manifold
gets to reach the diaphragm of mechanical EGR valve.
If the coolant temperature is high, but the boost pressure is low, the EGR valve does not open. If coolant
temperature is high, boost pressure is also high, EGR valve is open and cooled EGR gas through the water cooled
EGR cooler flows into the intake manifold. And the reed valve between EGR valve and intake manifold prevents the
fresh air flowing into EGR system.

00(D-Kubota)-3-15
Group 00(D-Kubota), Engine

(A) EGR Cooler

The EGR (Exhaust Gas Recirculation) cooler is used


to lower combustion temperature and efficiently cool
EGR gas, with the aim of reducing the NOx that is in the
exhaust gas of diesel engine.
The EGR cooler is placed between the exhaust
manifold and the intake manifold of the engine and
returns the cooled exhaust gases to the engine suction
side.
The EGR cooler has resistant to clogging up,
compact and efficient tubes internally.
(1) Pipe A Coolant Inlet Port
(2) EGR Cooler B Coolant Outlet Port
(3) Exhaust Manifold
(4) Flange
(5) Tube

(B) Thermo Valve


Thermo valve controls boost pressure “ON / OFF” for
the EGR valve.
If the coolant temperature is low, thermo valve is
closed, so that boost pressure does not reach to the EGR
valve.
If the coolant temperature is high, thermo valve is
open, so that boost pressure reaches to the EGR valve.
(1) Thermo Valve (a) Boost Pressure From Intake
(2) Coolant Temperature Manifold
(b) Boost Pressure To EGR
Valve
(c) Open
(d) Close

00(D-Kubota)-3-16
Group 00(D-Kubota), Engine

(C) Mechanical EGR Valve


Mechanical EGR valve controls the flow of cooled
EGR gas to the intake manifold.
If the boost pressure is low, EGR valve is closed, so
cooled EGR gas does not flow to the intake manifold.
If the boost pressure is getting higher, EGR valve is
opening and cooled EGR gas is flowing to the intake
manifold.
(1) Mechanical EGR Valve (a) Boost Pressure From Intake
(2) EGR Valve Lift Manifold
(3) Boost Pressure (b) Cooled EGR Gas
(c) Cooled EGR Gas To The
Intake Manifold
(d) Open
(e) Close

(D) Reed Valve


The reed valve is provided at the confluence of
exhaust gas after passing the EGR valve, and intake air.
It operates by the pressure difference between inside of
the crankcase and the atmosphere, and prevents back
flow of the mixture of exhaust gas and intake air
generated by the piston and valves. It is used as the
secondary air introduction device for the
countermeasure against exhaust gas of four-cycle
engines.
(1) Valve (3) Stopper
(2) Case (4) Screw

00(D-Kubota)-3-17
Group 00(D-Kubota), Engine

Section 4
Servicing

1. TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
Engine Does Not No fuel Replenish fuel
Start Air in the fuel system Vent air
Water in the fuel system Change fuel and –
repair or replace fuel
system
Fuel hose clogged Clean or replace
Fuel filter clogged Replace
Excessively high viscosity of fuel or engine oil at Use specified fuel or
low temperature engine oil
Fuel with low cetane number Use specified fuel
Fuel leak due to loose injection pipe retaining nut Tighten retaining nut
Incorrect injection timing Adjust
Fuel camshaft worn Replace
Injection nozzle clogged Repair or replace
Injection pump malfunctioning Repair or replace
Seizure of crankshaft, camshaft, piston, cylinder Repair or replace –
or bearing
Compression leak from cylinder Replace head
gasket, tighten
cylinder head screw
and nozzle holder
Improper valve timing Correct or replace
timing gear
Piston ring and cylinder worn Replace

Excess ive valv e clearance A djust


Stop solenoid malfunctioning Replace
Starter Does Not Run Battery discharged Charge
Starter malfunctioning Repair or replace

Key sw itch malfunct ioning Replace –


Wiring disconnected Connect –

00(D-Kubota)-4-1
Group 00(D-Kubota), Engine

Reference
Symptom Probable Cause So l u t i o n
Page
Engine Revolution Is Fuel filter clogged or dirty Replace
Not Smooth Air cleaner clogged Clean or replace
Fuel leak due to loose injection pipe retaining nut Tighten retaining nut
Injection pump malfunctioning Repair or replace
Incorrect nozzle opening pressure Repair or replace
Injection nozzle stuck or clogged Repair or replace
Governor malfunctioning Repair
Turbocharger bearing worn out Replace the
turbocharger
assembly
Turbocharger shaft bent Replace the
turbocharger
assembly
Turbocharger fin or other part damaged due to Replace the
foreign matters turbocharger
assembly
Either White or Blue Excessive engine oil Reduce to specified
Exhaust Gas Is level
Observed Piston ring and cylinder worn or stuck Repair or replace

Incorrect injection timing Adjust


Oil Leak into Exhaust Waste oil pipe clogged or deformed Repair or replace
Pipe or Suction Pipe Turbocharger’s piston ring seal faulty Replace the
turbocharger
assembly
Either Black or Dark Overload Reduce the load –
Gray Exhaust Gas Is Low grade fuel used Use specified fuel
Observed
Fuel filter clogged Replace
Air cleaner clogged Clean or replace
Deficient nozzle injection Repair or replace
nozzle

00(D-Kubota)-4-2
Group 00(D-Kubota), Engine

Reference
Symptom Probable Cause Solution
Page
Deficient Output Incorrect injection timing Adjust
Engine’s moving parts seem to be seizing Repair or replace –
Injection pump malfunctioning Repair or replace
Deficient nozzle injection Repair or replace
nozzle
Compress ion l eak Check the
compression
pressure and repair
Gas leak from exhaust system Repair or replace
Air leak from compressor discharge side Repair or replace
Air cleaner dirty or clogged Clean or replace
Compressor wheel turning heavily Replace the turbo-
charger assembly
Excessive Lubricant Piston ring’s gap facing the same direction Shift ring gap
Oil Consumption direction
Oil ring worn or stuck Replace
Piston ring groove worn Replace piston
Valve stem and valve guide worn Replace
Crankshaft bearing and crank pin bearing worn Replace
Oil leaking due to defective seals or packing Replace –
Fuel Mixed into Injection pump’s plunger worn Repair or replace
Lubricant Oil Deficient nozzle injection Repair or replace
nozzle
Injection pump broken Replace
Water Mixed into Head gasket defective Replace
Lubricant Oil Cylinder block or cylinder head flawed Replace
Low Oil Pressure Engine oil insufficient Replenish
Oil strainer clogged Clean
R el i e f val v e s tuck w i th di rt C le a n
Relief valve spring weaken or broken Replace
Excessive oil clearance of crankshaft bearing Replace
Excessive oil clearance of crankpin bearing Replace
Excessive oil clearance of rocker arm Replace
Oil passage clogged Clean –
Different type of oil Use specified type of
oil
Oil pump defectiv e R eplace

00(D-Kubota)-4-3
Group 00(D-Kubota), Engine

Reference
Symptom Probable Cause So l u t i o n
Page
High Oil Pressure Different type of oil Use specified type of
oil
Relief valve defective Replace
Engine Overheated Engine oil insufficient Replenis h
Fan belt broken or elongated Replace or adjust
Coolant insufficient Replenis h
Radiator net and radiator fin clogged with dust Clean –
Inside of radiator corroded Clean or replace
Coolant flow route corroded Clean or replace
Radiator cap defective Replace
Overload running Reduce the load –
Head gasket defective Replace
Incorrect injection timing Adjust
Unsuitable fuel used Use specified fuel
Battery Quickly Battery electrolyte insufficient Replenish distilled
Discharged water and charge
Fan belt slips Adjust belt tension or
replace
Wiring disconnected Connect –
Rectifier defective Replace
Alternator defective Replace
Battery defective Replace

00(D-Kubota)-4-4
Group 00(D-Kubota), Engine

2. SERVICING SPECIFICATIONS
ENGINE BODY
Item Factory Specification Allowable Limit
Cylinder Head Surfac e F l atness – 0.05 mm
0.0020 in.
Top Clearance 0.72 to 0.90 mm –
0.0283 to 0.0354 in.
Compression Pressure

3.47 MPa / 2.56 MPa /


250 min-1 (rpm) 250 min -1 (rpm)
V3800DI-T-E2B
V3800DI-T-E3B 2
35.4 kgf/cm / 26.1 kgf/cm2 /
250 min -1 (rpm) 250 min -1 (rpm)

503 psi / 371 psi /


250 min -1 (rpm) 250 min -1 (rpm)

Variance Among Cylinders – 10 % or less


Valve Seat Angle (Intake) 1.047 rad –
60 °

Angle (Exhaust) 0.785 rad –


45 °

Width (Intake) 1.6 to 2.0 mm –


0.0630 to 0.0790 in.

Width (Exhaust) 2.3 to 2.6 mm –


0.0906 to 0.1024 in.
Valve Face Angle (Intake) 1.047 rad –
60 °

Angle (Exhaust) 0.785 rad –


45 °
Valve Recessing Intake 0.6 to 0.8 mm 1.2 mm
0.0236 to 0.0315 in. 0.0472 in.

Exhaust 0.85 to 1.05 mm 1.2 mm


0.0335 to 0.0413 in. 0.0472 in.

00(D-Kubota)-4-5
Group 00(D-Kubota), Engine

ENGINE BODY (Continued)


Item Factory Specification Al l o w a b l e L i m i t
Valve Stem to Valve Guide Clearance 0.055 to 0.085 mm 0.1 mm
(Intake) 0.0022 to 0.0033 in. 0.0039 in.

Valve Stem O.D. (Intake) 6.960 to 6.975 mm –


0.2740 to 0.2746 in.

Valve Guide I.D. (Intake) 7.030 to 7.045 mm –


0.2768 to 0.2774 in.

Valve Stem to Valve Guide Clearance 0.055 to 0.085 mm 0.1 mm


(Exhaust) 0.0022 to 0.0033 in. 0.0039 in.

Valve Stem O.D. (Exhaust) 6.960 to 6.975 mm –


0.2740 to 0.2746 in.

Valve Guide I.D. (Exhaust) 7.030 to 7.045 mm –


0.2768 to 0.2774 in.
Valve Clearance (Cold) 0.23 to 0.27 mm –
0.0091 to 0.0106 in.
Intake Valve Timing Open 0.24 rad (14ȋP –
before T.D.C.

Close 0.61 rad (36ȋP –


after B.D.C.
Exhaust Valve Timing Op en 0.79 rad (45ȋP –
before B.D.C.

Close 0.29 rad (17ȋP –


after T.D.C.
Valve Spring Free Length 35.1 to 35.6 mm 34.6 mm
(Intake) 1.3819 to 1.4016 in. 1.3622 in.

Free Length 35.1 to 35.6 mm 34.6 mm


(Exhaust) 1.3819 to 1.4016 in. 1.3622 in.

Tilt – 1.0 mm
0.039 in.
Valve Spring Setting Load / 63.547 N / 31.5 mm 45.864 N /
Setting Length 6.48 kgf / 31.5 mm 31.5 mm
(Intake) 14.256 lbs / 1.2401 in. 4.68 kgf / 31.5 mm
10.296 lbs /
1.2401 in.

Setting Load / 63.547 N / 31.5 mm 45.864 N /


Setting Length 6.48 kgf / 31.5 mm 31.5 mm
(Exhaust) 14.256 lbs / 1.2401 in. 4.68 kgf / 31.5 mm
10.296 lbs /
1.2401 in.

00(D-Kubota)-4-6
Group 00(D-Kubota), Engine

ENGINE BODY (Continued)


Item Facto ry Specification Allowable Limit
Rocker Arm Shaft to Rocker Arm Clearance 0.016 to 0.045 mm 0.15 mm
0.0006 to 0.0018 in. 0.0059 in.

Rocker Arm Shaft O.D. 15.973 to 15.984 mm –


0.6289 to 0.6293 in.

Rocker Arm I.D. 16.000 to 16.018 mm –


0.6299 to 0.6306 in.
Valve Arm Bridge and Valve Arm Bridge Clearance 0.018 to 0.042 mm 0.15 mm
Shaft 0.0007 to 0.0017 in. 0.0059 in.

Valve Arm Bridge I.D. 9.050 to 9.065 mm –


0.3563 to 0.3569 in.

Valve Arm Bridge Shaft O.D. 9.023 to 9.032 mm –


0.3552 to 0.3556 in.
Push Rod Alignment – 0.25 mm
0.0098 in.
Tappet to Tappet Guide Clearance 0.020 to 0.062 mm 0.07 mm
0.0008 to 0.0024 in. 0.0028 in.

Tappet Guide Bore I.D. 24.000 to 24.021 mm –


0.9449 to 0.9457 in.

Tappet O.D. 23.959 to 23.980 mm –


0.9433 to 0.9441 in.
Camshaft Side Clearance 0.07 to 0.22 mm 0.30 mm
0.0028 to 0.0087 in. 0.0118 in.

Alignment – 0.01 mm
0.00039 in.
Cam Height Intake 37.63 mm 37.13 mm
1.4815 in. 1.4618 in.

Exhaust 38.96 mm 38.46 mm


1.5338 in. 1.5141 in.
Camshaft Oil Clearance 0.050 to 0.091 mm 0.15 mm
0.0020 to 0.0036 in. 0.0059 in.

Camshaft Journal O.D. 45.934 to 45.950 mm –


1.8084 to 1.8091 in.

Camshaft Bearing I.D. 46.000 to 46.025 mm –


1.8110 to 1.8120 in.

00(D-Kubota)-4-7
Group 00(D-Kubota), Engine

ENGINE BODY (Continued)


Item Factory Specification Al l o w a b l e L i m i t
Timing Gear
Idle Gear 1 to Crank Gear Backlash 0.049 to 0.193 mm 0.22 mm
0.0019 to 0.0076 in. 0.0087 in.
Idle Gear 1 to Cam Gear Backlash 0.049 to 0.189 mm 0.22 mm
0.0019 to 0.0074 in. 0.0087 in.
Idle Gear 1 to Idle Gear 2 Backlash 0.044 to 0.185 mm 0.22 mm
0.0017 to 0.0073 in. 0.0087 in.
Idle Gear 2 to Injection Pump Gear Backlash 0.044 to 0.177 mm 0.22 mm
0.0017 to 0.0070 in. 0.0087 in.
Cam Gear to Balancer Gear 1 Backlash 0.047 to 0.182 mm 0.22 mm
(Balancer Model Only) 0.0018 to 0.0072 in. 0.0087 in.
Idle Gear 1 to Balancer Gear 2 Backlash 0.044 to 0.183 mm 0.22 mm
(Balancer Model Only) 0.0017 to 0.0072 in. 0.0087 in.
Idle Gear Shaft 1, 2 to Idle Gear 1, 2 Oil Clearance 0.050 to 0.091 mm 0.10 mm
Bushing 0.0020 to 0.0036 in. 0.0039 in.

Idle Gear 1, 2 Bushing I.D. 45.025 to 45.050 mm –


1.7726 to 1.7736 in.

Idle Gear 1, 2 Shaft O.D. 44.959 to 44.975 mm –


1.7700 to 1.7707 in.
Idle Gear Side Clearance 0.15 to 0.30 mm 0.9 mm
0.0059 to 0.0118 in. 0.0354 in.
Balancer Shaft (Balancer Model Only) Side Clearance 0.070 to 0.22 mm 0.3 mm
0.0028 to 0.0087 in. 0.0118 in.
Balancer Shaft (Balancer Model Only) Alignment – 0.02 mm
0.0008 in.
Balancer Shaft (Balancer Model Only) Oil Clearance 0.070 to 0.159 mm 0.2 mm
0.0028 to 0.0063 in. 0.0079 in.

Balancer Shaft Journal O.D. 50.92 to 50.94 mm –


2.0047 to 2.0055 in.

Balancer Bearing I.D. 51.01 to 51.08 mm –


2.0083 to 2.0110 in.
Piston Pin Bore I.D. 30.000 to 30.013 mm 30.05 mm
1.1811 to 1.1816 in. 1.1831 in.
Top Ring to Ring Groove Clearance 0.05 to 0.09 mm 0.15 mm
0.0020 to 0.0035 in. 0.0059 in.
Second Ring to Ring Groove Clearance 0.093 to 0.120 mm 0.20 mm
0.0037 to 0.0047 in. 0.0079 in.
Oil Ring to Ring Groove Clearance 0.020 to 0.060 mm 0.15 mm
0.0008 to 0.0023 in. 0.0059 in.

00(D-Kubota)-4-8
Group 00(D-Kubota), Engine

ENGINE BODY (Continued)


Item Factory Specification Allowable Limit
Piston Ring Gap Top Ring 0.30 to 0.45 mm 1.25 mm
0.0118 to 0.0177 in. 0.0492 in.

Second Ring 0.30 to 0.45 mm 1.25 mm


0.0118 to 0.0177 in. 0.0492 in.

Oil Ring 0.25 to 0.45 mm 1.25 mm


0.0098 to 0.0177 in. 0.0492 in.
Connecting Rod Alignment – 0.05 mm
0.0020 in.
Piston Pin to Small End Bushing Clearance 0.020 to 0.040 mm 0.15 mm
0.0008 to 0.0016 in. 0.0059 in.

Piston Pin O.D. 30.006 to 30.011 mm –


1.1813 to 1.1815 in.

Small End Bushing I.D. 30.031 to 30.046 mm –


1.1823 to 1.1829 in.
Crankshaft Side Clearance 0.15 to 0.31 mm 0.50 mm
0.0059 to 0.0122 in. 0.0197 in.

Alignment – 0.02 mm
0.00079 in.
Crankshaft Journal to Crankshaft Bearing Oil Clearance 0.018 to 0.062 mm 0.20 mm
0.0007 to 0.0024 in. 0.0079 in.

Crankshaft Journal O.D. 74.977 to 74.990 mm –


2.9518 to 2.9524 in.
Crank Pin to Pin Bearing Oil Clearance 0.018 to 0.051 mm 0.20 mm
0.0007 to 0.0020 in. 0.0079 in.

Crank Pin O.D. 52.977 to 52.990 mm –


2.0857 to 2.0862 in.
Cylinder Bore I.D. 100.000 to 100.022 mm 100.15 mm
3.9370 to 3.9379 in. 3.9429 in.
Cylinder Bore (Oversize) I.D. 100.500 to 100.522 mm 100.65 mm
3.9567 to 3.9576 in. 3.9626 in.

00(D-Kubota)-4-9
Group 00(D-Kubota), Engine

LUBRICATING SYSTEM
Item Factory Specification Al l o w a b l e L i m i t
Engine Oil Pressure At Idle Speed – 49 kPa
0.5 kgf/cm2
7 psi

At Rated Speed 196 to 392 kPa 147.1 kPa


2.0 to 4.0 kgf/cm2 1.5 kgf/cm2
28 to 57 psi 21.3 psi
Engine Oil Pressure Switch Working Pressure 39.2 to 58.8 kPa –
0.4 to 0.6 kgf/cm2
5.6 to 8.4 psi
Inner Rotor to Outer Rotor Clearance 0.04 to 0.16 mm 0.3 mm
0.0016 to 0.0063 in. 0.0118 in.
Outer Rotor to Pump Body Clearance 0.100 to 0.184 mm 0.3 mm
0.0039 to 0.0072 in. 0.0118 in.
Inner Rotor to Cover Clearance 0.025 to 0.075 mm 0.225 mm
0.0010 to 0.0030 in. 0.0089 in.
Relief Valve Working Pressure 885 kPa –
9.04 kgf/cm2
129 psi

COOLING SYSTEM
Thermostat Valve Opening 74.5 to 78.5 °C –
Temperature 166.1 to 173.3 °F

Valve Opening 90 °C –
Temperature 194 °F
(Opened
Completely)
Radiator Water Tightness Water tightness at –
specified pressure
137 kPa
1.4 kgf/cm2
G 20 psi
Radiator Cap Air Leakage 10 seconds or more –
88 ˧G59 kPa
0.9 ˧G0.6 kgf/cm2
13 ˧G9 psi
Fan Belt Tension 10.0 to 12.0 mm / 98 N –
0.394 to 0.472 in. / 98 N
(10 kgf, 22 lbs)

00(D-Kubota)-4-10
Group 00(D-Kubota), Engine

FUEL SYSTEM
Item Factor y S pecification Allowable Limit

0.21 to 0.24 rad



V3800DI-T-E2B (12 to 14 °)
Injection Timing before T.D.C.
0.0917 to 0.117 rad
V3800DI-T-E3B (5.25 to 6.75 °) –
before T.D.C.
Pump Element Fuel Tightness – 18.63 MPa
190 kgf/cm2
2702 psi
Delivery Valve Fuel Tightness 1 0 seconds 5 seconds
18.63 ˧G17.65 MPa 18.63 ˧G17.65 MPa
190 ˧G180 kgf/cm2 190 ˧G180 kgf/cm 2
2702 ˧G2560 psi 2702 ˧G2560 psi
Fuel Injection Nozzle Injection Pressure 18.63 to 19.61 MPa –
(1st stage) 190 to 200 kgf/cm2
2702 to 2845 psi

Injection Pressure 23.54 to 24.52 MPa –


(2nd stage) 240 to 250 kgf/cm2
3414 to 3556 psi

Valve Seat When the pressure is –


Tightness 16.67 MPa
(170 kgf/cm2, 2418 psi),
the valve seat must be
fuel tightness.

ELECTRICAL SYSTEM
Commutator O.D. 32 mm 31.4 mm
1.2598 in. 1.2362 in.
Mica Undercut 0 .5 mm 0.2 mm
0.0197 in. 0.0079 in.
Brush (Starter) Length 18.0 mm 11.0 mm
0.7086 in. 0.4331 in.
Alternator No-load Voltage 14 V at –
4000 min-1 (rpm)
Rotor Coil Resistance 2.8 to 3.3 ȳ –
Slip Ring O.D. 22.7 mm 22.1 mm
0.894 in. 0.870 in.
Brush (Alternator) Length 18.5 mm 5.0 mm
0.728 in. 0.197 in.
Intake Air Heater Resistance –
Approx. 0.3 ȳ
(at cold occasion)

00(D-Kubota)-4-11
Group 00(D-Kubota), Engine

3. CHECKING, DISASSEMBLING AND SERVICING


[1] CHECKING AND ADJUSTING
(1) Engine Body
Compression Pressure
1. After warming up the engine, shut it down and remove the air
cleaner, the muffler, high pressure pipes, cylinder head cover,
overflow pipe, all nozzle holders and all nozzle gaskets.
2. Install a compression tester (Code No: 07909-30208) and nozzle
adaptor for diesel engines to nozzle holder hole.
3. After making sure that the stop lever is set at the stop position
(Non-injection), run the engine at 200 to 300 min1 (rpm) with the
starter.
4. Read the maximum pressure. Measure the pressure more than
twice.
NOTE
• Check the compression pressure with the specified valve
clearance.
• Always use a fully charged battery for performing this test.
• Variances in cylinder compression values should be under
10 %.

Factory 3.47 MPa / 250 min-1 (rpm)


spec. 35.4 kgf/cm2 / 250 min-1 (rpm)
503 psi / 250 min-1 (rpm)
Compression
pressure

2.56 MPa / 250 min-1 (rpm)


Allowable
26.1 kgf/cm2 / 250 min-1 (rpm)
limit
371 psi / 250 min-1 (rpm)

17.7 to 20.6 N·m


Nozzle holder clamp nut 1.8 to 2.1 kgf·m
13.0 to 15.2 ft-lbs
9.8 to 11.3 N·m
Overflow pipe assembly
1.0 to 1.15 kgf·m
retaining screw
7.23 to 8.32 ft-lbs
Tightening torque
6.9 to 11.3 N·m
Cylinder head cover screw 0.7 to 1.15 kgf·m
5.1 to 8.32 ft-lbs
19.6 to 24.5 N·m
Injection pipe retaining nut 2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs

00(D-Kubota)-4-12
Group 00(D-Kubota), Engine

Checking Valve Clearance


IMPORTANT
• Valve clearance must be checked and adjusted when engine
is cold.
1. Remove the high pressure pipes and the head cover.
2. Align the 1TC mark of flywheel and the convex of flywheel
housing timing windows so that the first piston (gear case side)
comes to the compression top dead center.
3. Before adjusting the valve clearance, adjust the bridge evenly to
the valve stem.
4. Loosen the lock nut (2) and adjust with screw (1).
5. Slightly push the rocker arm with your fingers and screw in the
adjusting screw slowly until you feel the screw touch the top of
valve stem, then tighten the lock nut.
6. Loosen the lock nut (4) of adjusting screw (3) (push rod side) and
insert the feeler gauge between the rocker arm and the bridge
head. Set the adjusting screw to the specified value, then tighten
the lock nut.
0.23 to 0.27 mm
Valve clearance Factory spec.
0.0091 to 0.0106 in.

NOTE
• After adjusting, tighten the lock nut (4) securely.
Valve arrangement
Adjustment cylinder IN. EX
Location of piston
1st

When No.1 piston is at 2nd


compression top dead center 3rd
4th
1st

When No.1 piston is at 2nd


overlap position 3rd
4th

6.9 to 11.3 N·m


Cylinder head cover screw 0.7 to 1.15 kgf·m
5.1 to 8.32 ft-lbs
Tightening torque
19.6 to 24.5 N·m
Injection pipe retaining nut 2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs

(1) Adjusting Screw (3) Adjusting Screw


(2) Lock Nut (4) Lock Nut

00(D-Kubota)-4-13
Group 00(D-Kubota), Engine

(2) Lubricating System


Engine Oil Pressure
1. Remove the oil switch and set a pressure tester (Code No.
07916-32032).
2. Start the engine. After warming up, measure the oil pressure of
both idling and rated speeds.
3. If the oil pressure is less than the allowable limit, check the
following.
• Engine oil insufficient
• Oil pump defective
• Oil strainer clogged
• Oil filter cartridge clogged
• Oil gallery clogged
• Excessive oil clearance
• Foreign matter in the relief valve
(When reassembling)
• After checking the engine oil pressure, tighten the engine oil
pressure switch to the specified torque.
49 kPa
At idle Allowable
0.5 kgf/cm2
speed limit
7 psi
196 to 392 kPa
Factory
Engine oil pressure 2.0 to 4.0 kgf/cm2
spec.
At rated 28 to 57 psi
speed 147.1 kPa
Allowable
1.5 kgf/cm2
limit
21.3 psi

14.7 to 19.6 N·m


Tightening torque Oil switch taper screw 1.5 to 2.0 kgf·m
10.8 to 14.5 ft-lbs

(3) Cooling System


Fan Belt Tension
1. Measure the deflection (A), depressing the belt halfway between
the fan drive pulley and alternator pulley at specified force 98 N
(10 kgf, 22 lbs).
2. If the measurement is not within the factory specifications, loosen
the alternator mounting screws and relocate the alternator to
adjust.
10 to 12 mm
Deflection (A) Factory spec.
0.394 to 0.472 in.

(A) Deflection

00(D-Kubota)-4-14
Group 00(D-Kubota), Engine

Fan Belt Damage and Wear


1. Check the fan belt for damage.
2. If the fan belt is damaged, replace it.
3. Check if the fan belt is worn and sunk in the pulley groove.
4. If the fan belt is nearly worn out and deeply sunk in the pulley
groove, replace it.
(A) Good
(B) Bad

CAUTION
•When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down.
Otherwise, hot water may gush out, scalding nearby people.
Radiator Cap Air Leakage
1. Set a radiator tester on the radiator cap.
2. Attach a radiator tester.
Apply the specified pressure of 88 kPa (0.9 kgf/cm2, 13 psi).
3. Check if the pressure drop to less than 59 kPa (0.6 kgf/cm2, 9 psi)
in 10 seconds.
4. If the pressure is less than the factory specification, replace it.

Radiator Water Leakage


1. Pour a specified amount of water into the radiator.
2. Attach a radiator tester.
Increase water pressure to the specified pressure of 137 kPa (1.4
kgf/cm2, 20 psi).
3. Check the radiator for water leaks.
4. When water leakage is excessive, replace the radiator. If water
leakage is caused by a small pinhole, correct the radiator with
radiator sealant.

00(D-Kubota)-4-15
Group 00(D-Kubota), Engine

Thermostat Valve Opening Temperature


1. Push down the thermostat valve and insert a string between the
valve and the valve seat.
2. Place the thermostat and a thermostat in a container with water
and gradually heat the water.
3. Hold the string to suspend the thermostat in the water. When the
water temperature rises, the thermostat valve will open, allowing
it to fall down from the string.
Read the temperature at this moment on the thermometer.
4. Continue heating the water and read the temperature when the
valve has risen by about 8 mm (0.315 in.).
5. If the measurement is not acceptable, replace the thermostat.
Thermostat’s valve 74.5 to 78.5 ୅
Factory spec.
opening temperature 166.1 to 173.3 එ
Temperature at which
90 ୅
thermostat completely Factory spec.
194 එ
opens

00(D-Kubota)-4-16
Group 00(D-Kubota), Engine

(4) Fuel System (V3800DI-T-E2B Engine)


Injection Timing
1. Make sure of matching the injection timing align mark (1) of the
injection pump unit and the plate (gearcase), as shown in the
illustration.
2. Remove the injection pipes.
3. Remove the stop solenoid.
4. Turn the flywheel counterclockwise (viewed from flywheel side)
until the fuel fills up to the hole of the delivery valve holder (2) for
No.1 cylinder.
5. After the fuel fills up to the hole of the delivery valve holder for
No.1 cylinder, turn back (clockwise) the flywheel around 1.57 rad
(90 °).
6. Turn the flywheel counterclockwise to set at around 0.35 rad
(20 °) before T.D.C..
7. Slowly turn the flywheel counterclockwise and stop turning when
the fuel begins to come up, to get the present injection timing.
8. Check to see the degree on flywheel.
The flywheel has mark “1TC”, “10” and “20” for the crank angle
before the top dead center of No.1 piston.
9. If the injection timing is not within the specification, rotate the
injection pump unit to adjust the injection timing.
IMPORTANT
• When installing the injection pump unit to the engine body,
follow the correct procedure.
See the “Injection Pump Unit”.
0.21 to 0.24 rad (12  to
Injection timing Factory spec.
14 ) before T.D.C.

19.6 to 24.5 N·m


Injection pipe retaining nut 2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs
Tightening torque
17.7 to 20.6 N·m
Injection pump unit
1.8 to 2.1 kgf·m
mounting nut
13.0 to 15.2 ft-lbs

(1) Injection Timing Align Mark (a) Injection Timing Advanced


(2) Delivery Valve Holder (b) Injection Timing Retarded

00(D-Kubota)-4-17
Group 00(D-Kubota), Engine

(5) Fuel System (V3800DI-T-E3B Engine)

Injection Timing
1. Remove the timer gear lubricating pipe (1).

2. Remove the gear case cover (2).

3. Set the timer 0 ° restoring jig (4) to the timer gear(3).

4. Make sure of matching the injection timing align mark (5) of the
injection pump unit and the plate (gear case), as shown in the
illustration.
5. Remove the injection pipes.
6. Remove the solenoid.
(1) Timer Gear Lubricating Pipe
(2) Gear Case Cover
(3) Timer Gear
(4) Timer 0 ° Restoring Jig
(5) Injection Timing Align Mark

[A] for V3800DI-T-E3B Engine

(a) Injection Timing Advanced

(b) Injection Timing Retarded

00(D-Kubota)-4-18
Group 00(D-Kubota), Engine

Injection Timing (Continued)


7. Turn the flywheel counterclockwise (viewed from flywheel side)
until the fuel fills up to the hole of the delivery valve holder (6) for
No.1 cylinder.
8. After the fuel fills up to the hole of the delivery valve holder for
No.1 cylinder, turn back (clockwise) the flywheel around 1.6 rad
(90 °).
9. Turn the flywheel counterclockwise to set at around 0.35 rad
(20 °) before T.D.C..
10.Slowly turn the flywheel counterclockwise and stop turning when
the fuel begins to come up, to get the present injection timing.
11.Check to see the degree on flywheel.
The flywheel has mark “1TC”, “10” and “20” for the crank angle
before the top dead center of No.1 piston.
12.If the injection timing is not within the specification, rotate the
injection pump unit to adjust the injection timing.
IMPORTANT
• When installing the injection pump unit to the engine body,
follow the correct procedure.
See the “Injection Pump Unit”.

0.0917 to 0.117 rad


Factory V3800DI-T-E3B,
Injection timing (5.25 ° to 6.75 °) before
spec.
T.D.C.

23 to 36 N·m
Injection pipe retaining nut 2.3 to 3.7 kgf·m
17 to 26 lbf·ft
Tightening torque
18 to 20 N·m
Injection pump unit
1.8 to 2.1 kgf·m
mounting nut
13 to 15 lbf·ft

(6) Delivery Valve Holder

00(D-Kubota)-4-19
Group 00(D-Kubota), Engine

Fuel Tightness of Pump Element


1. Remove the engine stop solenoid.
2. Remove the injection pipes.
3. Install the injection pump pressure tester to the injection pump.
4. Install the injection nozzle (2) jetted with the proper injection
pressure to the injection pump pressure tester (1). (Refer to the
figure.)
5. Set the speed control lever to the maximum speed position.
6. Run the starter to increase the pressure.
7. If the pressure can not reach the allowable limit, replace the
pump with new one or repair with a Kubota-authorized pump
service shop.

Fuel tightness of pump 18.63 MPa


Allowable limit 190 kgf/cm2
element
2702 psi
NOTE
• Never try to disassemble the injection pump assembly. For
repairs, you are strongly requested to contact a Kubota-
authorized pump service shop.
(1) Injection Pump Pressure Tester (3) Protection Cover for Jetted Fuel
(2) Injection Nozzle

Fuel Tightness of Delivery Valve


1. Remove the engine stop solenoid.
2. Remove the injection pipes.
3. Install a pressure tester to the fuel injection pump.
4. Install the injection nozzle (2) jetted with the proper injection
pressure to the injection pump pressure tester (1).
5. Run the starter to increase the pressure.
6. Stop the starter when the fuel jets from the injection nozzle. After
that, turn the flywheel by the hand and raise the pressure to
approx. 18.63 MPa (190 kgf/cm2, 2702 psi).
7. Now turn the flywheel back about half a turn (to keep the plunger
free). Maintain the flywheel at this position and clock the time
taken for the pressure to drop from 18.63 to 17.65 MPa (from 190
to 180 kgf/cm2, from 2702 to 2560 psi).
8. Measure the time needed to decrease the pressure from 18.63 to
17.65 MPa (from 190 to 180 kgf/cm2, from 2702 to 2560 psi).
9. If the measurement is less than allowable limit, replace the pump
with new one or repair with a Kubota-authorized pump service
shop.
10 seconds
18.63 ˧G17.65 MPa
Factory spec. 190 ˧G180 kgf/cm2
Fuel tightness of 2702 ˧G2560 psi
delivery valve 5 seconds
18.63 ˧G17.65 MPa
Allowable limit 190 ˧G180 kgf/cm2
2702 ˧G2560 psi

NOTE
• Never try to disassemble the injection pump assembly. For
repairs, you are strongly requested to contact a Kubota-
authorized pump service shop.
(1) Injection Pump Pressure Tester (3) Protection Cover for Jetted Fuel
(2) Injection Nozzle

00(D-Kubota)-4-20
Group 00(D-Kubota), Engine

CAUTION
• Check the nozzle injection pressure and condition after confirming that there is nobody standing in the
direction the spray goes.
• If the spray from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning
may be caused.
Nozzle Spraying Condition
1. Attach the injection nozzle to the nozzle tester, and check the
nozzle spraying condition.
2. If the spraying condition is defective, replace the injection nozzle
assembly or repair at Denso service shop.
(a) Good
(b) Bad

Checking Nozzle Injection Pressure


1. Attach the injection nozzle to the nozzle tester.
2. Slowly move the tester handle to measure the pressure at which
fuel begins jetting out from the nozzle.
3. If the measurement is not within the factory specifications,
replace the injection nozzle assembly or repair at Denso service
shop.
NOTE
• Injection nozzle gasket must be replaced when the injection
nozzle is removed for checking.
18.63 to 19.61 MPa
Factory 1st
Injection pressure 190 to 200 kgf/cm2
spec. stage
2702 to 2845 psi

Valve Seat Tightness


1. Attach the injection nozzle to the nozzle tester.
2. Raise the fuel pressure, and keep at 16.67 MPa (170 kgf/cm2,
2418 psi) for 10 seconds.
3. If any fuel leak is found, replace the injection nozzle assembly or
repair at Denso service shop.
No fuel leak at
16.67 MPa
Valve seat tightness Factory spec.
170 kgf/cm2
2418 psi

00(D-Kubota)-4-21
Group 00(D-Kubota), Engine

(6) Electrical System

CAUTION
• To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the
negative cable is attached to the negative terminal.
• Never remove the battery cap while the engine is running.
• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely
with water immediately.
• Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen
becomes very explosive.
IMPORTANT
• If the machine is to be operated for a short time without battery (using a slave battery for starting), use
additional current (lights) while engine is running and insulate terminal of battery. If this advice is
disregarded, damage to alternator and regulator may result.
Battery Voltage
1. Stop the engine.
2. Measure the voltage with a circuit tester between the battery
terminals.
3. If the battery voltage is less than the factory specification, check
the battery specific gravity and recharge the battery.
Battery voltage Factory spec. More than 12 V

(1) Positive Terminal


(2) Negative Terminal

00(D-Kubota)-4-22
Group 00(D-Kubota), Engine

Battery Specific Gravity


1. Check the specific gravity of the electrolyte in each cell with a
hydrometer.
2. When the electrolyte temperature differs from that at which the
hydrometer was calibrated, correct the specific gravity reading
following the formula mentioned in (Reference).
3. If the specific gravity is less than 1.215 (after it is corrected for
temperature), charge or replace the battery.
4. If the specific gravity differs between any two cells by more than
0.05, replace the battery.
NOTE
• Hold the hydrometer tube vertical without removing it from
the electrolyte.
• Do not suck too much electrolyte into the tube.
• Allow the float to move freely and hold the hydrometer at eye
level.
• The hydrometer reading must be taken at the highest
electrolyte level.
(Reference)
• Specific gravity slightly varies with temperature. To be exact, the
specific gravity decreases by 0.0007 with an increase of 1 °C
(0.0004 with an increase of 1 °F) in temperature, and increases
by 0.0007 with a decreases of 1 °C (0.0004 with a decrease of 1
°F).
Therefore, using 20 °C (68 °F) as a reference, the specific gravity
reading must be corrected by the following formula :
- Specific gravity at 20 °C = Measured value + 0.0007 x
(electrolyte temperature : 20 °C)
- Specific gravity at 68 °F = Measured value + 0.0004 x
(electrolyte temperature : 68 °F)
Specific Gravity State of Charge
1.260 Sp. Gr. 100 % Charged
1.230 Sp. Gr. 75 % Ch ar ged
1.200 Sp. Gr. 50 % Char ged
1.170 Sp. Gr. 25 % C h ar ged
1.140 Sp. Gr. Very Little Useful Capacity
1.110 Sp. Gr. Discharged
At an electrolyte temperature of 20 °C (68 °F)
(a) Good
(b) Bad
(c) Bad

00(D-Kubota)-4-23
Group 00(D-Kubota), Engine

Motor Test

CAUTION
• Secure the starter to prevent it from jumping up and down
while testing the motor.
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter C terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starter’s body
and the battery negative terminal (3).
7. If the motor does not run, starter is failure.
Repair or replace the starter.
NOTE
• B terminal : It is the terminal which connects the cable from
the battery to the starter.
• C terminal : It is the terminal which connects the cable from
the motor to the magnet switch.
(1) C Terminal (3) Negative Terminal
(2) Positive Terminal

Magnetic Switch Test


1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter S terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starter’s body
and the battery negative terminal (3).
7. If the pinion gear does not pop out, the magnetic switch is failure.
Repair or replace the starter.
NOTE
• B terminal : It is the terminal which connects the cable from
the battery to the starter.
• S terminal : It is the terminal which connects the cable from
the starter switch to the magnet switch.
(1) S Terminal (3) Negative Terminal
(2) Positive Terminal

Magnet Switch Continuity Test


1. Check the continuity across the C terminal (1) and the B terminal
(2) with a circuit tester, pushing in the plunger.
2. If not continuous or if a certain value is indicated, replace the
magnet switch.
(1) C Terminal (2) B Terminal

00(D-Kubota)-4-24
Group 00(D-Kubota), Engine

Alternator on Unit Test


(Before testing)
• Before alternator on unit test, check the battery terminal connec-
tions, circuit connection, fan belt tension, charging indicator lamp,
fuses on the circuit, and abnormal noise from the alternator.
• Prepare full charged battery for the test.
NOTE
• Be careful not to touch the rotating engine parts while
engine is running.
Keep safety distance from the engine rotating parts.
1. Start the engine.
2. When the engine is operating measure the voltage between two
battery terminals. If the voltage is between 13.8 V and 14.8 V,
the alternator is operating normally.
3. If the results of alternator on unit test are not within the
specifications, disassemble the alternator and check the each
component part for finding out the failure. See the
“DISASSEMBLING AND ASSEMBLING” and “SERVICING” for
alternator.
Regulating voltage at no 13.8 to 14.8 V at 25 °C
Factory spec.
load (77 °F)

Intake Air Heater


1. Disconnect the lead.
2. Measure the resistance between + terminal (1) and intake air
heater body (2).
3. If the resistance is infinity, the intake air heater is faulty.
Intake air heater Approx. 0.3 Ω
Factory spec.
resistance (At cold occasion)

(1) + Terminal (2) Intake Air Heater Body

Engine Stop Solenoid


1. Remove the engine stop solenoid from the engine.
2. Connect the jumper leads from the pulling coil P terminal to the
switch (3), and from switch (3) to the battery positive terminal.
3. Connect the jumper leads from the holding coil H terminal to the
switch (4), and from switch (4) to the battery positive terminal.
4. Connect the jumper leads from the engine stop solenoid body to
the battery negative terminal.
5. When switch (4) is turn on, the plunger pull into the solenoid body
and then turn off the switch (4), the plunger comes out.
6. Turn on the switch (3) then turn on the switch (4), the plunger pull
into the solenoid body and it keep in holding position after turn off
the switch (4).
7. If the plunger is not attracted, the engine stop solenoid is faulty.
IMPORTANT
• Never apply the current for pulling coil more than two
seconds when inspecting.
(1) Connector P : Terminal for Pulling Coil
(2) Battery H : Terminal for Holding Coil
(3) Switch for Holding Coil
(4) Switch for Pulling Coil

00(D-Kubota)-4-25
Group 00(D-Kubota), Engine

(7) Turbocharger
Turbine Side
1. Check the exhaust port (3) and inlet port (5) side of turbine
housing (1) to see if there is no exhaust gas leak.
2. If any gas leak is found, retighten the bolts and nuts or replace
the gasket (2) / (4) / (6) with new one.
(1) Turbine Housing (4) Gasket
(2) Gasket (5) Inlet Port
(3) Exhaust Port (6) Gasket

Compressor Side
1. Check the inlet hose (1) of the compressor cover (3) to see if
there is no air leak.
2. Check for loose connections or cracks in the suction side of the
intake hose.
3. If any air leak is found, change the clamp (2) and or inlet hoses.
(1) Inlet Hose (3) Compressor Cover
(2) Clamp

Radial Clearance
1. If the wheel contact to the housing, replace the turbocharger
assembly with new one.

00(D-Kubota)-4-26
Group 00(D-Kubota), Engine

[2] EGR SYSTEM


(1) Checking the function of EGR system (V3800DI-T-E3B Engine)
1. Check the coolant temperature and monitor the coolant
temperature while checking 1) and 2).
2. If the coolant temperature is already 55 °C (131 °F), cool down
the engine.
3. Start the engine and go to check 1) immediately.
4. After completing checking 1), arrange the coolant temperature is
getting over 70 °C (158 °F).
5. If the coolant temperature is over 70 °C (158 °F), go to check 2).
(a) Measuring Place of EGR Pipe
Surface Temperature

1) If the coolant temperature is under 55 °C (131 °F), the surface temperature of EGR pipe must be under
50 °C (122 °F).

00(D-Kubota)-4-27
Group 00(D-Kubota), Engine

2) If the coolant temperature is over 70 °C (158 °F), the surface temperature of EGR pipe must be over
100 °C (212 °F).

00(D-Kubota)-4-28
Group 00(D-Kubota), Engine

[3] DISASSEMBLING AND ASSEMBLING


(1) Draining Oil and Coolant
Draining Engine Oil
# 1. Start and warm up the engine for approx. 5 minutes.
2. Place an oil pan underneath the engine.
3. Remove the drain plug (1) to drain oil.
4. After draining, screw in the drain plug.
(When refilling)
• Fill the engine oil up to the upper line on the dipstick (2).
IMPORTANT
• Never mix two different types of oil.
• Use the proper SAE Engine Oil according to ambient
temperature.
(1) Drain Plug (2) Dipstick

<A> ; V3800DI-T-E2B Engine (Tier2)


<B> ; V3800DI-T-E3B Engine (Tier3)

$

Draining Coolant

CAUTION
• Never remove radiator cap while operating or immediately
after stopping. Otherwise, hot water will spout out from the
radiator. Wait for more than ten minutes to cool the radiator,
before opening the cap.
1. Prepare a bucket. Open the coolant drain cock.
(1) Coolant Drain Cock

(2) External Components


Air Cleaner, Muffler and Others
1. Remove the air cleaner and muffler.
2. Remove the fan, fan belt, alternator and starter.
(When reassembling)
• Check to see that there are no cracks on the belt surface.
IMPORTANT
• After reassembling the fan belt, be sure to adjust the fan belt
tension.
• Do not confuse the direction of the fan. Attach the fan with
its “1C010” marking facing frontward (toward the radiator).

00(D-Kubota)-4-29
Group 00(D-Kubota), Engine

(3) Turbocharger (V3800DI-T-E2B Engine)

CAUTION
• While the engine is running and or just after it stops, the turbocharger is hot, be careful not to touch the
turbocharger.
NOTE
• When detaching and attaching the turbocharger assembly, be very careful not to allow dust, dirt and other
foreign matter in the oil pipes.
• When the turbocharger assembly has been replace, pour fresh engine oil through the oil filler port of the
turbocharger.
• Before starting the engine, make sure that air cleaner is in position.
Oil Pipe
1. Remove the joint bolt (5) and clamp (4) and take off the pipe 1 (2).
2. Remove the bolts (1) and release the clamp (6).
3. Disconnect the oil pipe 2 (7) and pipe 4 (3).
(When reassembling)
• Pour fresh engine oil through the oil filler port of the turbocharger.
• Replace the gasket with new one.
• Be careful not to allow dust, dirt and other foreign matters in the
oil pipes.
NOTE
• Tape or plug all openings to prevent foreign matters from
damaging the oil cavities in the turbocharger.
(1) Bolt (5) Joint Bolt
(2) Oil Pipe 1 (6) Clamp
(3) Oil Pipe 4 (7) Oil Pipe 2
(4) Clamp

Turbocharger
1. Remove the screw (1) and bolt (3).
2. Take off the turbocharger assembly (2).
(When reassembling)
• Replace the gasket with new one.
(1) Screw (3) Bolt
(2) Turbocharger Assembly

00(D-Kubota)-4-30
Group 00(D-Kubota), Engine

(4) Turbocharger (V3800DI-T-E3B Engine)


CAUTION
• While the engine is running and or just after it stops, the turbocharger is hot, be careful not to touch the
turbocharger.
NOTE
• When detaching and attaching the turbocharger assembly, be very careful not to allow dust, dirt and other
foreign matter in the oil pipes.
• When the turbocharger assembly has been replace, pour fresh engine oil through the oil filler port of the
turbocharger.
• Before starting the engine, make sure that air cleaner is in position.
Oil Pipe
1. Remove the cover (8)
2. Remove the joint bolt (5) and clamp (4) and take off the pipe 1 (2).
3. Remove the bolts (1) and release the clamp (6).
4. Disconnect the oil pipe 2 (7) and pipe 4 (3).

(When reassembling)
• Pour fresh engine oil through the oil filler port of the turbocharger.
• Replace the gasket with new one.
• Be careful not to allow dust, dirt and other foreign matters in the
oil pipes.
NOTE
• Tape or plug all openings to prevent foreign matters from
damaging the oil cavities in the turbocharger.
(1) Bolt (6) Clamp
(2) Oil Pipe 1 (7) Oil Pipe 2
(3) Oil Pipe 4 (8) Cover
(4) Clamp
(5) Joint Bolt

Turbocharger
1. Remove the turbocharger flange (1).
2. Remove the inlet hose (2).
3. Remove the turbocharger assembly (3).
(When reassembling)
• Replace the gasket with new one.

(1) Turbocharger Flange


(2) Inlet Hose
(3) Turbocharger Assembly

00(D-Kubota)-4-31
Group 00(D-Kubota), Engine

(5) Exhaust Gas Recirculation (EGR) (V3800DI-T-E3B Engine)


EGR Pipe
1. Remove the EGR pipe (1).
(When reassembling)
• Replace the gaskets with new ones.
(1) EGR Pipe

EGR Cooler
1. Remove the EGR cooler (1).
(When reassembling)
• Replace the gaskets with new ones.
(1) EGR Cooler

EGR Cooler Flange


1. Remove the EGR cooler flange (2).
(When reassembling)
• Replace the gaskets with new ones.
(1) Gasket
(2) EGR Cooler Flange

EGR Valve
1. Remove the EGR valve (1).
(When reassembling)
• Replace the gaskets with new ones.
(1) EGR Valve

Reed Valve
1. Remove the reed valve (2) from the EGR valve (1).
(When reassembling)
• Replace the gasket with new ones.
(1) EGR Valve
(2) Reed Valve

00(D-Kubota)-4-32
Group 00(D-Kubota), Engine

Thermo Valve (If necessary)


1. Disconnect hoses (1), (2).
2. Remove the thermo valve (3).
NOTE
• If you drop the thermo valve (3), replace the thermo valve (3)
with new one.
(When reassembling)
• Securely connect the hoses (1), (2).
30 to 39 N·m
Tightening torque Thermo valve 3.0 to 4.0 kgf·m
22 to 28 lbf·ft

(1) Hose to EGR Valve (a) Boost Pressure from Intake


(2) Hose from Intake Manifold Flange Manifold
(3) Thermo Valve (b) Boost Pressure to EGR Valve

00(D-Kubota)-4-33
Group 00(D-Kubota), Engine

(6) Cylinder Head and Valves


Cylinder Head Cover and Nozzle Holder
1. Remove the injection pipes (2).
2. Remove the cylinder head cover (1).
3. Remove the over flow pipe (3).
4. Remove the nozzle holder clamps (4), nozzle holder assembly
(5) and nozzle gaskets.
(When reassembling)
• Check to see that the cylinder head cover gasket is not defective.
• Be sure to place the nozzle gaskets.
• Tighten the head cover mounting bolts to specified torque.
• Mount the check valve with the  mark toward the tank.
17.7 to 20.6 N·m
Nozzle holder clamp nut 1.8 to 2.1 kgf·m
13.0 to 15.2 ft-lbs
9.8 to 11.3 N·m
Overflow pipe assembly
Tightening torque 1.0 to 1.15 kgf·m
retaining screw
(V3800DI-T-E2B) 7.23 to 8.32 ft-lbs
6.9 to 11.3 N·m
Cylinder head cover screw 0.7 to 1.15 kgf·m
5.1 to 8.32 ft-lbs
19.6 to 24.5 N·m
Injection pipe retaining nut 2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs

18 to 20 N·m
Nozzle holder clamp nut 1.8 to 2.1 kgf·m
13 to 15 lbf·ft
9.8 to 11.2 N·m
Overflow pipe assembly
Tightening torque 1.0 to 1.15 kgf·m
joint screw
(V3800DI-T-E3B) 7.24 to 8.31 lbf·ft
6.9 to 11.2 N·m
Cylinder head cover screw 0.70 to 1.15 kgf·m
5.1 to 8.31 lbf·ft
23 to 36 N·m
Injection pipe retaining nut 2.3 to 3.7 kgf·m
17 to 26 lbf·ft

(1) Head Cover (4) Nozzle Holder Clamps


(2) Injection Pipe (5) Nozzle Holder Assembly
(3) Overflow Pipe

00(D-Kubota)-4-34
Group 00(D-Kubota), Engine

Rocker Arm and Push Rod


1. Remove the rocker arm (3) as a unit.
2. Remove the push rods (1).
3. Remove the bridge arm (4).
(When reassembling)
• When putting the push rods onto the tappets (2), check to see if
their ends are properly engaged with the grooves.
IMPORTANT
• After reassembling the rocker arm, be sure to adjust the
valve clearance.
49.0 to 55.9 N·m
Tightening torque Rocker arm bracket screw 5.0 to 5.7 kgf·m
36.2 to 41.2 ft-lbs

(1) Push Rod (3) Rocker Arm


(2) Tappet (4) Bridge Arm

Injection Nozzle Oil Seal (if necessary)


1. Remove the injection nozzle oil seal (2) from cylinder head cover
(1).
(When reassembling)
• When installing the injection nozzle oil seal, use new one.
(1) Cylinder Head Cover (2) Injection Nozzle Oil Seal

00(D-Kubota)-4-35
Group 00(D-Kubota), Engine

Cylinder Head and Tappet


1. Loosen the pipe band, and remove the water return pipe (1).
2. Disconnect the fuel pipe (2) first and then the fuel filter (3).
3. Remove the IN. / EX. Manifold.
4. Remove the cylinder head screw in the order of (18) to (1), and
remove the cylinder head.
5. Remove the cylinder head gasket.
6. Remove the tappets (4) from the crank case.
(When reassembling)
• Replace the head gasket with a new one.
• Before installing the tappets (4), apply engine oil thinly around
them.
• When mounting the gasket, set it to the knock pin hole. Take
care not to mount it reversely.
• The cylinder head should be free of scratches and dust.
• Take care for handling the gasket not to damage it.
• Install the cylinder head.
• Tighten the cylinder head screw gradually in the order of (1) to
(18) after applying engine oil.
• Be sure to adjust the valve clearance. See the “Valve
Clearance”.
• It is not necessary to retighten the cylinder head screw after
running the engine for 30 minutes.
IMPORTANT
• When replacing a piston, piston pin bush, connecting rod or
crankpin bearing, select the cylinder head gasket thickness
to meet with the top clearance refer to the “Selecting
Cylinder Head Gasket”.
NOTE
• Mark the cylinder number to the tappets to prevent
interchanging.
98.1 to 107.9 N·m
Cylinder head mounting
Tightening torque 10.0 to 11.0 kgf·m
screw
72.3 to 79.6 ft-lbs

(1) Return Pipe A : Gear Case Side


(2) Fuel Pipe B : Flywheel Side
(3) Fuel Filter
(4) Tappet

00(D-Kubota)-4-36
Group 00(D-Kubota), Engine

Selecting Cylinder Head Gasket


Replacing the Cylinder Head Gasket
1. Make sure to note the notch (a), (b) or (c) of cylinder head gasket
(1) in advance.
2. Replace the same notch (a), (b) or (c) as the original cylinder
head gasket (1).
Selecting the Cylinder Head Gasket
• Select the cylinder head gasket (1) thickness to meet with the top
clearance when replacing the piston, piston pin bush, connecting
rod or crankpin bearing.
1. Measure the piston head’s protrusion or recessing from the
crankcase cylinder face 4 spots per each piston and (average of
four pistons) using the dial gauge as shown in figure.
2. Select the suitable cylinder head gasket refer to the table below.
Thickness of cylinder Piston Head’s
Notch of head gasket protrusion or
Cylinder recessing from the
Part Code
Head Before After level of crankcase
Gasket tightening tightening cylinder face.
(average of 4 pistons)
2 notches 0.90 mm 0.80 mm -0.07 to +0.049 mm
1G514-03310
(a) 0.0354 in. 0.0315 in. -0.0028 to +0.0019 in.
1 notch 1.00 mm 0.90 mm +0.050 to +0.149 mm
1G514-03600
(b) 0.0394 in. 0.0354 in. +0.0020 to +0.0058 in.
Without 1.05 mm 0.95 mm +0.150 to +0.20 mm
1G514-03610
notch (c) 0.0413 in. 0.0374 in. +0.0059 to +0.0078 in.

(1) Cylinder Head Gasket (a) 2 Notches


(2) Measuring Point (b) 1 Notch
(A) Gear Case Side (c) Without Notch
(B) Flywheel Side

Valve
1. Remove the valve spring collets (1) after compressing the valve
spring (3) with the valve spring retainer (2).
(When reassembling)
• Install the valve spring with its small-pitch end downward (at the
head side).
• Wash the valve stem and valve guide hole, and apply engine oil
sufficiently.
• After installing the valve spring collets, lightly tap the stem to
assure proper fit with a plastic hammer.
(1) Valve Spring Collet (7) Large Pitch
(2) Valve Spring Retainer (8) Smaller Pitch
(3) Valve Spring (9) Install the spring with its smaller-
(4) Valve Stem Seal pitch end downward (at the head
(5) Arm Bridge side)
(6) Valve

00(D-Kubota)-4-37
Group 00(D-Kubota), Engine

(7) Thermostat
Thermostat Assembly
1. Remove the thermostat cover mounting screws, and remove the
thermostat cover (1).
2. Remove the thermostat assembly (3).
(When reassembling)
• Apply a liquid gasket (Three Bond 1215 or equivalent) only at the
thermostat cover side of the gasket (2).
• Attach the thermostat with its hole facing toward the air suction
side.
(1) Thermostat Cover (3) Thermostat Assembly
(2) Thermostat Cover Gasket (4) Hole

00(D-Kubota)-4-38
Group 00(D-Kubota), Engine

(8) Injection Pump Unit


Injection Pump Unit (V3800DI-T-E2B Engine)
(Removing the fuel injection pump unit)
1. Detach the gear cover for the fuel injection pump unit from the
gearcase.
2. Place the piston of the 4th cylinder at the top dead center in the
compression stroke. Fix the flywheel with the flywheel stopper.
IMPORTANT
• Look for the align mark on the idle gear 2. Using a white
marking pen or the like, put an align mark on the engaged
tooth of the idle gear. This helps to reassemble these gears
in mesh later.
NOTE
• When the already existing align marks align with each other,
there is no need to put another align mark.
3. Unscrew the two plugs (3) of the injection pump unit.
4. Tighten the upper fuel cam shaft lock screw (5) until it comes into
contact with the fuel cam shaft. Make sure the cam shaft does
not move any longer.
5. Tighten the lower fuel cam shaft lock screw (5) until it comes into
contact with the fuel cam shaft.
NOTE
• Never overtighten the lock screws when they have come into
contact with the cam shaft. Otherwise the injection pump
itself may get damaged.
• Use of a socket set screw (dog point type) in recommended
for best results. Such screw can be constructed as shown
in figure (a).
6. Loosen the injection pump gear mounting nut. Using the specific
gear puller, take out the gear (6).
NOTE
• Be careful not to drop the key.
7. Disconnect the lubricating oil pipe (4).
8. Loosen the three injection pump unit mounting nuts (2).
9. Remove the injection pump unit support (1) and take out the
injection pump unit.
A M8  Pitch 1.25
B 5 mm dia. (0.197 in. dia.)
C 4 mm (0.157 in.)
D 45 mm (1.772 in.)
E 10 mm (0.39 in.) : Conspicuously Painted

(1) Injection Pump Unit Support (4) Lubricating Oil Pipe


(2) Injection Pump Unit Mounting Nut (5) Fuel Cam Shaft Lock Screw
(3) Plug (Socket Set Screw Dog Point Type)
(6) Injection Pump Gear

00(D-Kubota)-4-39
Group 00(D-Kubota), Engine

Injection Pump Unit (V3800DI-T-E2B Engine) (Continued)


(Reassembling the fuel injection pump unit)
1. Place the piston of the 4th cylinder at the top dead center in the
compression stroke. Fix the flywheel with the flywheel stopper.
2. Place the injection pump gear (1) back into the gear case
position. Make sure of aligning the align marks of the injection
pump gear (1) and the idle gear 2 (3).
3. Install the injection pump unit to the injection pump gear (1).
NOTE
• When installing the injection pump unit to the injection
pump gear, make sure that the key is fit in the keyway of
injection pump gear.
4. Temporarily tighten the injection pump gear mounting nut by
hand.
5. Fix the injection pump unit and tighten the injection pump gear
mounting nut to the specified torque.
6. Take off the fuel cam shaft lock screws (4) and tighten the plugs
(5) for plugging.
7. Loose the injection pump unit mounting nuts (7) for aligning the
injection timing.
8. Moving the injection pump unit clockwise (viewed from gear case
side), align the injection timing marks (6) on the injection pump
unit and on the gear case.
9. Tighten the injection pump unit mounting nut (7) to the specified
torque.
10.Reconnect the lubricating oil pipe (8) and place the injection
pump unit support and the gear cover of the injection pump unit.
11.Remove the flywheel stopper.
12.Check the injection timing. (See the “Injection Timing”.)
13.If the injection timing is not within the specification, repeat (7) to
(12) again.
73.6 to 83.4 N·m
Injection pump gear
7.5 to 8.5 kgf·m
mounting nut
54.2 to 61.5 ft-lbs
Tightening torque
17.7 to 20.6 N·m
Injection pump unit
1.8 to 2.1 kgf·m
mounting nut
13.0 to 15.2 ft-lbs

(1) Injection Pump Gear (5) Plug


(2) Align mark of the Injection Gear (6) Align Mark
(3) Idle Gear 2 (7) Injection Pump Unit Mounting Nut
(4) Fuel Cam Shaft Lock Screw (8) Lubricating Oil Pipe
(Socket Set Screw Dog Point Type)

00(D-Kubota)-4-40
Group 00(D-Kubota), Engine

Injection Pump Unit [V3800DI-T-E3B Engine]


(Removing)
1. Removing the timer lubricating pipe (1).
2. Remove the injection pump gear cover (2).
3. Set the timer 0 ° restoring jig (4) to the timer gear (3).

4. Turn the flywheel counter-clockwise slowly.

5. Set the flywheel 1 TC mark to align T.D.C. mark on flywheel


housing or rear end plate in order to set the No.4 piston at
compression top dead center.

IMPORTANT
• If the flywheel 1 TC mark passes T.D.C., Turn back the
flywheel clockwise around 90 degree, and try to set T.D.C.
again. (go back to the procedure 4..)
• If you set the T.D.C. by turning flywheel clockwise, the gears
backlash becomes maximum.
6. Check the injection pump gear timing mark.
If the injection pump gear / timer gear timing mark (5) meshes to
the idle gear teeth, No.4 piston is at compression top dead
center.
If not so, turn the flywheel 360 degree counter-clockwise.
(go back to the procedure 4..)
7. Fix the flywheel not to turn.
8. Put the temporary mark (6) on the idle gear teeth, which the
injection pump gear / timer gear timing mark (5) meshes, with
white marking pen.
It is very helpful to reassemble the injection pump gear / timer
gear later.
(1) Timer Lubricating Pipe
(2) Injection Pump Gear Cover
(3) Timer Gear
(4) Timer 0 ° Restoring Jig
(5) Injection Pump Gear / Timer Gear
Timing Mark
(6) Temporary Mark

00(D-Kubota)-4-41
Group 00(D-Kubota), Engine

Injection Pump Unit [ V3800DI-T-E3B Engine] (Continued)

9. Remove the plugs (1).


NOTE
• When you tighten the fuel camshaft lock screw, the
tightening order (upper / lower) is different in the engine
model.
• Recommend you use a socket set screw (dog point type) as
a fuel camshaft lock screw for preventing the damage of
screw hole tread. (See the figure (a))
A M8 x Pitch 1.25
B 5.0 mm dia. (0.20 in. dia.)
C 4.0 mm (0.16 in.)
D 45 mm (1.8 in.)
E 10 mm (0.39 in.) : Conspicuously Painted
• Do not overtighten the fuel camshaft lock screws.

10.Tighten the upper fuel camshaft lock screw (2) securely.

IMPORTANT
• When tighten the lock screw at this moment, the timing
gears backlash becomes “0” (Zero).
11.Tighten the lower fuel camshaft lock screw (2) securely.

12.Remove the imer gear mounting nut and washer.

13.Set the timer gear puller (4).


14.Pull out the timer gear.
(1) Plug
(2) Fuel Camshaft Lock Screw
(4) Timer Gear Puller

00(D-Kubota)-4-42
Group 00(D-Kubota), Engine

Injection Pump Unit [ V3800DI-T-E3B Engine) (Continued)

15.Disconnect the governor lubricating pipe (6).

16.Remove the injection pump unit support (7).

17.Hold the injection pump unit not to drop.

18.Remove the injection pump unit mounting nuts (5).

19.Remove the injection pump unit.


(5) Injection Pump Unit Mounting Nut
(6) Governor Lubricating Pipe
(7) Injection Pump Unit Support

00(D-Kubota)-4-43
Group 00(D-Kubota), Engine

Injection Pump Unit [ V3800DI-T-E3B Engine) (Continued)


(Reassembling)
1. Make sure that No.4 piston is at compression top dead center.
2. Set the timer 0 ° restoring jig (5) to the timer gear (4).
3. Set the timer gear (4) into the gear case position.

4. Make sure that the timing marks between


timer gear (4) align correctly.
5. Install the injection pump unit to the
timer gear (4) as aligning key of fuel camshaft and key way of
timer gear (4).
6. Set the injection pump gear mounting nut / timer gear mounting
nut and washer temporarily.
7. Tighten the injection pump unit mounting nuts securely.
8. Tighten the injection pump gear mounting nut / timer gear
mounting nut securely.
9. Set the governor lubricating pipe.
10.Set the injection pump unit support.
11.Remove the timer 0 ° restoring jig (5).
12.Set the injection pump gear cover.
13.Set the timer gear lubricating pipe.

14.Remove the fuel camshaft lock screws (6).

IMPORTANT
• Make sure that you remove the fuel camshaft lock screws.
Otherwise, injection pump unit housing case can get a
damage.
15.Set the plugs.
16.Remove the flywheel stopper.
17.Check the injection timing. (See the “Injection Timing”.)

(4) Timer Gear


(5) Timer 0 ° Restoring Jig
(6) Fuel Camshaft Lock Screw

00(D-Kubota)-4-44
Group 00(D-Kubota), Engine

Governor Housing Assembly


1. Remove the injection pump unit from the engine. (See the
“Injection Pump Unit”.)
2. Remove the governor lubricating pipe (3).
3. Remove the stop solenoid (1).
4. Detach the sight cover (2) from the injection pump unit.
5. Unhook the start spring (7) from the rack pin (6) of injection pump
assembly.
6. Remove the nut (5).
NOTE
• Be careful not to drop the nut inside.
7. Slide off the governor connecting rod (4) from the rack pin of
injection pump assembly.
8. For convenient sake, temporarily hook the start spring on the
rack pin hole of the governor connecting rod.
9. Remove the governor housing mounting screws.
10.Detach the governor housing assembly (8) from the injection
pump unit.
(When reassembling)
• When reassembling the inside parts, put the oil on each inside
part slightly.
• After sliding on the governor connecting rod to the rack pin,
tighten the nut with the specified torque with using the jig for
keeping the governor connecting rod horizontal. (See the
Replacing Injection Pump Assembly.)
• After tightening the nut, hook the start spring on the rack pin.
• Check the movement of control rack of injection pump assembly
by the stop lever.
NOTE
• When installing the governor housing assembly to the
injection pump unit, be careful not to damage O-ring (9).
• When linking the governor connecting rod to the rack pin of
injection pump, use the jig for keeping the governor
connecting rod horizontal. Otherwise the control rack may
be stuck, and causes to be difficult to start the engine or
hunting of governor. (See the Replacing Injection Pump
Assembly.)
9.8 to 11.3 N·m
Governor housing
1.00 to 1.15 kgf·m
mounting screw
7.23 to 8.32 ft-lbs
Tightening torque
2.8 to 4.0 N·m
Anti-rotation nut 0.29 to 0.41 kgf·m
2.1 to 3.0 ft-lbs

(1) Stop Solenoid (6) Rack Pin


(2) Sight Cover (7) Start Spring
(3) Governor Lubricating Pipe (8) Governor Housing Assembly
(4) Governor Connecting Rod (9) O-ring
(5) Anti-Rotation Nut

00(D-Kubota)-4-45
Group 00(D-Kubota), Engine

Governor Fork Lever Assembly


1. Pull off the governor fork lever shaft (1) with the extra bolt (Dia :
4 mm, Pitch : 0.7 mm, Length : more than 25 mm) (2).
2. Unhook the governor spring (3) at the governor fork lever (4)
side.
3. Remove the governor fork lever assembly from the governor
housing (5).
(When reassembling)
• After reassembling the governor housing assembly, check the
movement of the governor fork lever assembly, the speed control
lever and the stop lever.
NOTE
• When assembling the inside parts, put the oil on each inside
part slightly.
• Be careful not to deform the start spring.
(1) Governor Fork Lever Shaft (3) Governor Spring
(2) Extra Bolt (4) Governor Fork Lever
(Dia : 4 mm, Pitch : 0.7 mm, (5) Governor Housing
Length : more than 25 mm)

Boost Arms (If equipped Boost Compensator)


1. Remove the boost actuator (1).
2. Remove the cir-clip (2).
3. Remove the boost arms (3) and the boost spring (4) from the pin
(5).
39.2 to 45.1 N·m
Tightening torque Boost actuator 4.0 to 4.6 kgf·m
28.9 to 33.3 ft-lbs

(1) Boost Actuator (4) Boost Spring


(2) Cir-clip (5) Pin
(3) Boost Arm

00(D-Kubota)-4-46
Group 00(D-Kubota), Engine

Governor Lever
1. Remove the speed control lever (1) and the return spring (2).
2. Remove the governor lever assembly (4) from the governor
housing.
3. Remove the start spring (5) and the stop spring (3).
(1) Speed Control Lever (4) Governor Lever Assembly
(2) Return Spring (5) Start Spring
(3) Stop Spring

Stop Lever
1. Remove the stop lever (1) and the return spring (2).
2. Remove the stop lever shaft (3).
(1) Stop Lever (3) Stop Lever Shaft
(2) Return Spring

00(D-Kubota)-4-47
Group 00(D-Kubota), Engine

Fuel Camshaft and Governor Weight


1. Separate the governor housing assembly from the injection
pump unit. (See the “Injection Pump Unit”.)
2. Remove the governor sleeve (1).
3. Remove the injection pump assembly (2).
4. Remove the fuel camshaft lock screws.
5. Fix the fuel camshaft with open end wrench (3), and remove the
governor weight mounting nut and the governor weight (4).
6. Loosen the fuel camshaft stopper mounting screws and remove
the fuel camshaft stopper (5).
7. Pull out the fuel camshaft (8) and bearings (6) together.
8. Remove the spacer (V3800DI-T-E3B Engine)
9. After removing the bearing’s cir-clip (7), press out the bearings.

NOTE
• Do not use the fuel camshaft lock bolts, when removing the
governor weight mounting nut. Otherwise, the lock bolts or
injection pump housing might get damage.

(When reassembling)
• Press the bearings into the fuel camshaft.
• Set the cir-clip at the gear side’s bearing.
• Install the fuel camshaft and bearings to the injection pump
housing.
• Attach the fuel camshaft stopper and tighten the fuel camshaft
stopper mounting screws with the specified torque.
• Attach the governor weight to the fuel camshaft and tighten the
governor weight mounting nut with specified torque.
23.5 to 27.5 N·m
Injection pump mounting
2.4 to 2.8 kgf·m
screw
17.4 to 20.3 ft-lbs
Tightening torque
17.7 to 20.6 N·m
Injection pump mounting
1.8 to 2.1 kgf·m
nut
13.0 to 15.2 ft-lbs

(1) Governor Sleeve (6) Bearing


(2) Injection Pump Assembly (7) Cir-clip
(3) Open End Wrench (22 mm) (8) Fuel Camshaft
(4) Governor Weight (9) Key Way of Fuel Camshaft
(5) Fuel Camshaft Stopper

00(D-Kubota)-4-48
Group 00(D-Kubota), Engine

Fuel Camshaft and Governor Weight (Continued)


(When reassembling)
• Fix the fuel camshaft with lock bolts as the key way of fuel
camshaft (9) is upward.
• Install the injection pump assembly to the injection pump
housing.
• Attach the O-ring and the cover and tighten the cover mounting
bolts.
• Install the governor sleeve to the fuel camshaft.
• Check the movement of the governor sleeve.
NOTE
• Be careful not to damage the O-ring.
• Be careful the direction of the governor sleeve.
• When reassembling the inside parts, put the oil on each
inside part slightly.
7.9 to 9.3 N·m
Fuel camshaft stopper
0.80 to 0.95 kgf·m
mounting screw
5.8 to 6.9 ft-lbs
Tightening torque
62.8 to 72.6 N·m
Governor weight mounting
6.4 to 7.4 kgf·m
nut
46.3 to 53.5 ft-lbs

(1) Governor Sleeve (6) Bearing


(2) Injection Pump Assembly (7) Cir-clip
(3) Open End Wrench (22 mm) (8) Fuel Camshaft
(4) Governor Weight (9) Key Way of Fuel Camshaft
(5) Fuel Camshaft Stopper

00(D-Kubota)-4-49
Group 00(D-Kubota), Engine

Replacing Injection Pump Assembly (If necessary)


• The injection pump can be replaced with the crankshaft in
whatever position.
1. Disconnect all injection pipes (1).
2. Disconnect the fuel hose (6) and fuel overflow pipe (4).
3. Disconnect the connector (2) from the stop solenoid. Then
remove the stop solenoid (3).
4. Detach the sight cover (7) from the injection pump unit.
5. Unhook the start spring (10), and remove the anti-rotation nut (9).
6. Just loosen the injection pump assembly mounting screws and
nuts like the figure, which the injection pump assembly keeps
tilted.
7. Slide off the governor connecting rod (8) from the rack pin of
injection pump assembly.
8. Remove the injection pump mounting screws and nuts, and take
out the injection pump assembly (5).
NOTE
• Be careful not to drop the anti-rotation nut (9).
• Be careful not to deform the start spring.
• When taking out the injection pump assembly, be careful not
to hit it against the governor connecting rod.
(When reassembling)
• Install the new injection pump according to the installing
procedure.
(1) Injection Pipe (6) Fuel Hose
(2) Connector (7) Sight Cover
(3) Stop Solenoid (8) Governor Connecting Rod
(4) Fuel Overflow Pipe (9) Anti-Rotation Nut
(5) Injection Pump Assembly (10) Start Spring

00(D-Kubota)-4-50
Group 00(D-Kubota), Engine

Installing Procedure of Injection Pump Assembly


1. Install the fuel injection pump assembly (1) in its unit (2), and
tighten the mounting screws and nuts like the figure, which the
injection pump assembly (1) keeps tilted.
2. Hook the governor connecting rod (4) to the rack pin of the
injection pump assembly (1).
3. Tighten the mounting screws and nuts with the specified torque,
not to slide off the governor connecting rod (4) from the rack pin.
4. Place the service jig (3) in the stop solenoid mounting hole of the
fuel injection pump unit.
5. Make sure the permanent magnet at the tip of the service jig is
attracted to the governor connecting rod (4). To do this, turn the
jig a little clockwise and counterclockwise and look into the fuel
injection pump unit sight hole to see if the governor connecting
rod (4) moves right and left accordingly.
6. Slightly tighten the anti-rotation nut of the governor connecting
rod.
7. Holding down the service jig (3) by hand, tighten up the anti-
rotation nut (5) to the specified torque.
8. Hook the start spring (6) to the rack pin (7).

(1) Fuel Injection Pump Assembly (5) Anti-rotation Nut


(2) Fuel Injection Pump Unit (6) Start Spring
(3) Service Jig (7) Rack Pin
(4) Governor Connecting Rod

00(D-Kubota)-4-51
Group 00(D-Kubota), Engine

Installing Procedure (Continued)


1. Move the stop lever (1) and visually check to see if the fuel
injection pump control rack comes smoothly back to the start
position by the counter force of the start spring.
2. If the control rack fails to move back smoothly, remove the start
spring and the anti-rotation nut, take the above steps from 2 of
the former page again.
3. Finally fit the sight cover and the stop solenoid back into place.
2.8 to 4.0 N·m
Anti-rotation nut 0.29 to 0.41 kgf·m
2.1 to 3.0 ft-lbs
23.5 to 27.5 N·m
Injection pump mounting
Tightening torque 2.4 to 2.8 kgf·m
screw
17.4 to 20.3 ft-lbs
17.7 to 20.6 N·m
Injection pump mounting
1.8 to 2.1 kgf·m
nut
13.0 to 15.2 ft-lbs

(1) Stop Lever (2) Sliding Point between Governor Fork


Lever and Governor Connecting Rod

Fan Drive Pulley


1. Set the stopper to the flywheel.
2. Remove the crankshaft screw (2).
3. Draw out the fan drive pulley (1).
(When reassembling)
255.0 to 274.6 N·m
Tightening torque Crankshaft screw 26.0 to 28.0 kgf·m
188.1 to 202.5 ft-lbs

(1) Fan Drive Pulley (2) Crankshaft Screw

00(D-Kubota)-4-52
Group 00(D-Kubota), Engine

(9) Water Pump and Oil Cooler


Water Pump
1. Remove the pipe band and the water pipe (1).
2. Remove the water pump (2).
(When reassembling)
• When mounting the water pump, take care not to forget mounting
the O-ring and not to let it out of position.
(1) Water Pipe (2) Water Pump

Oil Cooler
1. Remove the water pipe (1).
2. Remove the oil filter cartridge (2) and the oil cooler joint screw
(3).
3. Remove the oil cooler (4).
39.2 to 44.1 N·m
Tightening torque Oil cooler joint screw 4.0 to 4.5 kgf·m
28.9 to 32.5 ft-lbs

(1) Water Pipe (3) Oil Cooler Joint Screw


(2) Oil Filter Cartridge (4) Oil Cooler

00(D-Kubota)-4-53
Group 00(D-Kubota), Engine

(10) Gear Case and Timing Gears


Gear Case Cover
1. Remove the gear case cover.
(When reassembling)
• Confirm that the liquid gasket coating surface is free of water,
dust and oil in order to maintain sealing effect.
• Carefully apply the adhesive evenly. (Refer to the figure on the
left.)
NOTE
• When mounting the adhesive-applied parts, take care to fit
them to the mating parts.
• Assemble the adhesive-applied parts within ten minutes.
• Apply a liquid gasket (Three Bond 1217D) to the gear case
cover.
23.5 to 27.5 N·m
Gear case cover
2.4 to 2.8 kgf·m
mounting screw (7T)
Tightening torque 17.4 to 20.3 ft-lbs

Gear case cover 33 to 36 N·m


3.3 to 3.7 kgf·m
mounting screw (10T)
24 to 26 lbf·ft

(1) Liquid Gasket

Relief Valve
1. Remove the relief valve retaining screw (1).
2. Remove the relief valve (2), the spring (3) and the packing (4).
68.6 to 78.4 N·m
Relief valve retaining
Tightening torque 7.0 to 8.0 kgf·m
screw
50.6 to 57.9 ft-lbs

(1) Relief Valve Retaining Screw (3) Spring


(2) Relief Valve (4) Packing

Idle Gear and Camshaft


1. Remove three set screws of the idle gear and draw out the idle
gear 1, 2.
2. Remove two set screws of the camshaft stopper and draw out the
camshaft.
(When reassembling)
• Set the crankshaft at the top dead center of No. 1 and 4 cylinder
and the camshaft key to the top position and align the marks of
idle gear 1 (3) and idle gear 2 (2) to assemble them. (Refer to the
figure on the left.)
• Mount the injection pump gear (1) after installing the gear case.
23.5 to 27.5 N·m
Camshaft set screw 2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
Tightening torque
23.5 to 27.5 N·m
Idle gear mounting screw 2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs

(1) Injection Pump Gear (4) Cam Gear


(2) Idle Gear 2 (5) Crank Gear
(3) Idle Gear 1

00(D-Kubota)-4-54
Group 00(D-Kubota), Engine

Idle Gear 1 and Idle Gear 2 (for Balancer Model)


1. Remove the idle gear mounting screw (1).
2. Draw out the idle gear (2) and (3).
(When reassembling)
• When installing the idle gear (2) and (3), be sure to place the 4th
cylinder piston at the top dead center in compressio then, align
all mating marks on each gear to assemble the timing gears, set
the idle gear last.
23.5 to 27.5 N·m
Tightening torque Idle gear mounting screw 2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs

(1) Idle Gear Mounting Screw (3) Idle Gear 2


(2) Idle Gear 1

Camshaft and Balancer Shaft (for Balancer Model)


1. Remove the camshaft set screws and draw out the camshaft (1).
2. Remove the balancer shaft 1 set screws and draw out the
balancer shaft 1 (2).
3. Remove the balancer shaft 2 set screws and draw out the
balancer shaft 2 (6).
(When reassembling)
• When installing the balancer shaft 1 and 2, be sure to place the
4th cylinders piston at the top dead center in compression then,
align all mating marks on each gear to assemble the timing
gears, set the idle gear last.
23.5 to 27.5 N·m
Camshaft set screw 2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
Tightening torque
23.5 to 27.5 N·m
Balancer shaft set screw 2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs

(1) Camshaft (4) Crank Gear


(2) Balancer Shaft 1 (5) Idle Gear 2
(3) Idle Gear 1 (6) Balancer Shaft 2

00(D-Kubota)-4-55
Group 00(D-Kubota), Engine

Plate (Gear Case)


1. Remove the three plate mounting screws(1). Detach the plate
(2).
(When reassembling)
• Apply Three Bond 1217D adhesive or equivalent over the
shaded zones on both sides of the gasket that will be sandwiched
between the crankcase and plate.
• Be sure to fix the O-rings (3).
23.5 to 27.5 N·m
Tightening torque Plate mounting screw 2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs

(1) Plate Mounting Screw (4) Gasket


(2) Plate (5) Liquid Gasket
(3) O-ring

(11) Piston and Connecting Rod

Oil Pan and Oil Strainer


1. Unscrew the oil pan mounting screws and remove the oil pan (1).
2. Unscrew the oil strainer mounting screw, and remove the oil
strainer (2).
(When reassembling)
• Install the oil strainer, using care not to damage the O-ring.
• Apply liquid gasket (Three Bond 1217D) to the oil pan as shown
in the figure.
• Confirm that the liquid gasket coating surface is free of water,
dust and oil in order to maintain sealing effect.
• Carefully apply the adhesive evenly.
NOTE
• When mounting the adhesive-applied parts, take care to fit
them to the mating parts.
• Assemble the adhesive-applied parts within ten minutes.
• To avoid uneven tightening, tighten mounting screws in
diagonal order from the center.
• After cleaning the oil strainer, install it.
• Attach the oil pan with its central drain plug facing toward
the air suction side.
(1) Oil Pan (3) Liquid Gasket
(2) Oil Strainer

00(D-Kubota)-4-56
Group 00(D-Kubota), Engine

Connecting Rod Cap


1. Remove the connecting rod screws (1) from connecting rod cap.
2. Remove the connecting rod caps.
(When reassembling)
• Align the marks (a) with each other. (Face the marks toward the
injection pump.)
• Apply engine oil to the connecting rod screws and lightly screw it
in by hand, then tighten it to the specified torque.
If the connecting rod screw won’t be screwed in smoothly, clean
the threads.
If the connecting rod screw is still hard to screw in, replace it.
• When using the existing crank pin metal again, put tally marks on
the crank pin metal and the connecting rod in order to keep their
positioning.
• Fit the crank pin metal in place : its centrally groove side toward
the connecting rod, and the non-grooved side toward the cap.
78.5 to 83.4 N·m
Tightening torque Connecting rod screw 8.0 to 8.5 kgf·m
57.9 to 61.5 ft-lbs

(1) Connecting Rod Screw (a) Mark

Piston
1. Completely clean carbon in the cylinders.
2. Turn the flywheel and set a piston to the top dead center.
3. Pull out the piston upward by lightly tapping it from the bottom of
the crankcase with the grip of a hammer.
(When reassembling)
• Before inserting the piston into the cylinder, apply enough engine
oil to the cylinder.
• When inserting the piston into the cylinder, face the mark (3) on
the connecting rod to the injection pump.
IMPORTANT
• Do not change the combination of cylinder and piston.
Make sure of the position of each piston by marking. For
example, mark “1” on the No. 1 position.
• When inserting the piston into the cylinder, place the gap of
each pison ring like the figure.
• Carefully insert the pistons using a piston ring compressor
(1). Otherwise, their chrome-plated section of piston rings
may be scratched, causing trouble inside the liner.
• When inserting the piston in place, be careful not to get the
molybdenum disulfide coating torn off its skirt. This coating
is useful in minimizing the clearance with the cylinder liner.
Just after the piston pin has been press-fitted, in particular,
the piston is still hot and the coating is easy to peel off. Wait
until the piston cools down.
(1) Piston Ring Compressor (A) Top Ring Gap
(2) Molybdenum Disulfide Coating in (B) Second Ring Gap
piston skirt (C) Oil Ring Gap
(3) Mark (D) Piston Pin Hole
(a) 0.79 rad (45 ) (E) Injection Pump Side

00(D-Kubota)-4-57
Group 00(D-Kubota), Engine

Piston Ring and Connecting Rod


1. Remove the piston rings using a piston ring tool.
2. Remove the piston pin (8), and separate the connecting rod (7)
from the piston (6).
(When reassembling)
• Be sure to fix the crankpin bearing and the connecting rod are
same I.D. colors.
• When installing the ring, assemble the rings so that the
manufacture’s mark (12) near the gap faces the top of the piston.
• When installing the oil ring on to the piston, place the expander
joint (10) on the opposite side of the oil ring gap (11).
• Apply engine oil to the piston pin.
• When installing the piston pin, immerse the piston in 80୅ (176
එ) oil for 10 to 15 minutes and insert the piston pin to the piston.
• Assemble the piston to the connecting rod with the ˦ mark (5)
and the connecting rod numbering mark (9) facing same side.
• The end faces of the oil ring are plated with hard chrome. In
putting the piston into the cylinder, be careful not to get the oil ring
scratched by the cylinder. Use the piston ring fitter to tighten up
the oil ring. If the ring’s planting is scratched, it may get stuck on
the cylinder wall, causing a serious trouble.
IMPORTANT
• Mark the same number on the connecting rod and the piston
so as not to change the combination.
(1) Top Ring (10) Expander Joint
(2) Second Ring (11) Oil Ring Gap
(3) Oil Ring (12) Manufacture’s Mark
(4) Piston Pin Snap Pin
(5) Mark (˦) (A) Connecting Rod ID Color : Blue
(6) Piston or without Color
(7) Connecting Rod (B) Crankpin Bearing ID Color : Blue
(8) Piston Pin or without Color
(9) Numbering Mark

00(D-Kubota)-4-58
Group 00(D-Kubota), Engine

(12) Flywheel and Crankshaft


Flywheel
1. Install the stopper to the flywheel so that the flywheel does not
turn.
NOTE
• Do not use an impact wrench. Serious damage will occur.
2. Detach the flywheel screws.
3. Remove the flywheel.
(When reassembling)
• Apply engine oil to the flywheel screws.
• Before fitting the flywheel and the crankshaft together, wipe oil,
dust and other foreign substances off their mating faces.
• The flywheel and the crankshaft are fitting together in just one
position. Make sure they are tightly fit and drive the bolts.
98.1 to 107.9 N·m
Tightening torque Flywheel screw 10.0 to 11.0 kgf·m
72.3 to 79.6 ft-lbs

Bearing Case Cover


NOTE
• Before disassembling, check the side clearance of
crankshaft. Also check it during reassembly.
1. Remove the bearing case over mounting screws.
2. Screw two removed screws into the screw hole (2) of bearing
case cover to remove it.
(When reassembling)
IMPORTANT
• In case of replacing the oil seal, use caution when installing
the seal in the bearing case cover as not to install it tilted.
The seal should be flush with the cover.
• Confirm that the liquid gasket coating surface is free of
water, dust and oil in order to maintain sealing effect.
• Apply liquid gasket (Three Bond 1217D) to the bearing case
cover as shown in the figure.
• Before installing the bearing case cover / oil seal assembly,
lube the seal to be careful not to damage the seal while
installing the assembly.
Install the bearing case cover / oil seal assembly to position
the casting mark “UP” on it upward.
• Tighten the bearing case cover mounting screws with even
force on the diagonal line.
NOTE
• When mounting the adhesive-applied parts, take care to fit
them to the mating parts.
• Assemble the adhesive-applied parts within ten minutes.
23.5 to 27.5 N·m
Bearing case cover
Tightening torque 2.4 to 2.8 kgf·m
mounting screw
17.4 to 20.3 ft-lbs

(1) Top Mark “UP” (3) Liquid Gasket


(2) Screw Hole

00(D-Kubota)-4-59
Group 00(D-Kubota), Engine

Flywheel Housing
1. Remove the flywheel housing.
(When reassembling)
• Tighten the flywheel housing mounting screws with even force on
the diagonal line.
• Make sure the crank cases 1 and 2 are clean. Install them in
position, referring to the flywheel housing’s contoured face.
77.5 to 90.2 N·m
Flywheel housing
Tightening torque 7.9 to 9.2 kgf·m
mounting screw
57.1 to 66.5 ft-lbs

(1) Flywheel Housing

Crankcase 2
1. Remove the crankcase 2 (1).
(When reassembling)
IMPORTANT
• Make sure the crankcase 1 and 2 are clean.
• Apply liquid gasket (Three Bond 1217D) to the crankcase 2
as shown in the figure.
• Tighten the crankcase 2 mounting screws with even force on
the diagonal line.
• Confirm that the liquid gasket coating surface is free of
water, dust and oil in order to maintain sealing effect.
• Carefully apply the adhesive evenly.
NOTE
• When mounting the adhesive-applied parts, take care to fit
them to the mating parts.
• Assemble the adhesive-applied parts within ten minutes.
49.0 to 55.9 N·m
Crankcase 2 mounting
Tightening torque 5.0 to 5.7 kgf·m
screw
36.2 to 41.2 ft-lbs

(1) Crankcase 2 (2) Liquid Gasket

Crankcase 1 and Crankcase 2


(When reassembling)
• Match the crankcase 1 and 2, referring to the flywheel housing’s
contoured face.
• Tighten the crankcase 2 mounting screws loosely.
• Tighten up the jig to the specified torque same as the flywheel
housing screw. This helps to minimize the level difference
between the crankcase 1 and the crankcase 2 (at the flywheel
side). Possible gap must be 0.05 mm (0.0020 in.) or smaller.
49.0 to 55.9 N·m
Crankcase 2 mounting
5.0 to 5.7 kgf·m
screw
36.2 to 41.2 ft-lbs
Tightening torque
77.5 to 90.2 N·m
Flywheel housing
7.9 to 9.2 kgf·m
mounting screw
57.1 to 66.5 ft-lbs

(1) Crankcase 1 (4) Crankcase 2


(2) Gap to be smaller than 0.05 mm (5) Jig
(0.0020 in.)
(3) Flywheel Housing

00(D-Kubota)-4-60
Group 00(D-Kubota), Engine

Crankshaft
1. Remove the main bearing case.
2. Remove the crankshaft.
(When reassembling)
• Reassemble the main bearing case having the same number as
the one engraved on the crankcase, and set the casting mark “F
/ W SIDE” on the main bearing case facing towards the flywheel
side.
• Reassemble the thrust bearing (2), with the oil groove facing
outside, into both side of the fourth main bearing case (1).
• Apply oil to the bearing case screws and tighten them to the
specified torque.
137.3 to 147.1 N·m
Tightening torque Main bearing case screw 14.0 to 15.0 kgf·m
101.3 to 108.5 ft-lbs

(1) 4th Main Bearing Case (3) F / W SIDE Mark


(2) Thrust Bearing

00(D-Kubota)-4-61
Group 00(D-Kubota), Engine

(13) Intake Air Heater


Intake Air Heater (V3800DI-T-E2B Engine)
1. Remove the inlet hose.
2. Disconnect the lead.
3. Remove the flange and the intake air heater.
NOTE
• When assembling the intake air heater at the side of intake
manifold, assemble the intake air heater as the heater lines
are vertical. Otherwise, it may be short-circuited.
(1) Intake air heater (2) Flange

Intake Air Heater (V3800DI-T-E3B Engine)


1. Remove the inlet hose.
2. Disconnect the lead.
3. Remove the flange (1).
4. Remove the intake air heater (2).
(1) Flange (2) Intake air heater

(14) Starter
Disassembling Motor
1. Disconnect the solenoid switch (3).
2. Remove the 2 through screws (9) and the 2 brush holder lock
screws. Take out the rear end frame (13) and the brush holder
(12).
3. Disconnect the armature (10) and the yoke (11). Remove also
the ball (7) from the tip of the armature.
4. Remove the set of packings (8), the 4 planetary gears and
another packing.
5. Take out the shaft assembly. Take note of the position of the
lever.
IMPORTANT
• Before disconnecting the yoke, put tally marks on the yoke
and the front bracket.
• Take note of the positions of the set of packings and the
setup bolt.
• Apply grease to the gears, bearings, shaft’s sliding part and
ball.
NOTE
• Do not damage to the brush and commutator.
(When reassembling)
• Apply grease (DENSO CO. No.50 or equivalent) to the parts
indicated in the figure.
(1) Gear (8) Set of Packings
(2) Front Bracket (9) Through Bolt
(3) Solenoid Switch (10) Armature
(4) Overrunning Clutch (11) Yoke
(5) Internal Gear (12) Brush Holder
(6) Planetary Gear (13) Rear End Frame
(7) Ball

00(D-Kubota)-4-62
Group 00(D-Kubota), Engine

(15) Alternator
Front Bracket
1. Remove the 4 screws (3).
2. Separate the front bracket (1) and the rear bracket (2) from each
other.
IMPORTANT
• Put a tally line on the front bracket and the rear bracket for
reassembling them later.
(1) Front Bracket (3) Screw
(2) Rear Bracket

Pulley
1. Hold the rotor (base of the claw) in a vise. Loosen the lock nut
using a M24 box wrench.
58.3 to 78.9 N·m
Tightening torque Pulley nut 5.95 to 8.05 kgf·m
43.0 to 58.2 ft-lbs

Rotor
1. Remove the 4 screws and detach the bearing retainer.
2. Temporarily install the nut on the pulley screw, and detach the
rotor.

Brush
1. When the rotor is detached, the 2 brushes are found to stretch
out of the shaft hole.

00(D-Kubota)-4-63
Group 00(D-Kubota), Engine

Reassembling the Brush


1. Fit the brush with its sliding face in the clockwise direction when
viewed from front.
IMPORTANT
• Be sure to keep the 2 brushes deep in the brush holder.
Otherwise the rotor and the rear section can not be fitted
into the position.
• Use a 4 mm hex. wrench to push the brushes into place.
• Using a pin-pointed (2 mm) punch, keep the brushes from
popping out.
2. Match the tally line of the front section with that of the rear
section.
3. Tighten the 4 screws, and draw out the pin-pointed punch out of
the brush holder.
(1) Marking

Bearing at Slip Ring Side


1. Lightly secure the rotor (1) with a vise to prevent damage, and
remove the bearing (2) with a puller (3).
(1) Rotor (3) Puller
(2) Bearing

00(D-Kubota)-4-64
Group 00(D-Kubota), Engine

[4] SERVICING
(1) Cylinder Head
Top Clearance
1. Remove the cylinder head (remove the cylinder head gasket
completely).
2. Bring the piston to its top dead center fasten 1.5 mm dia. 5 to 7
mm long fuse wires to 3 to 4 spots on the piston top with grease
so as to avoid the intake and exhaust valves and the combustion
chamber ports.
3. Bring the piston to its middle position, install the cylinder head,
and tighten the cylinder head screws to specification. (Head
gasket must be changed to new one).
4. Turn the crank shaft until the piston exceeds its top dead center.
5. Remove the cylinder head, and measure squeezed fuse wires for
thickness.
6. If the measurement is not within the specified value, check the oil
clearance of the crankpin journal and the piston pin.
0.72 to 0.90 mm
Top clearance V3800DI-T-E2B 0.0283 to 0.0354 in.
(Factory spec)
0.701 to 0.930 mm
V3800DI-T-E3B 0.0276 to 0.0366 in.

98.1 to 107.9 N·m


Cylinder head mounting
Tightening torque 10.0 to 11.0 kgf·m
screw
72.3 to 79.6 ft-lbs

(1) Fuse

Cylinder Head Surface Flatness


1. Clean the cylinder head surface.
2. Place a straightedge on the cylinder head’s four sides (A), (B),
(C) and (D) and two diagonal (E) and (F) as shown in the figure.
Measure the clearance with a feeler gauge.
3. If the measurement exceeds the allowable limit, correct it with a
surface grinder.
IMPORTANT
• Be sure to check the valve recessing after correcting.
Cylinder head surface 0.05 mm
Allowable limit
flatness 0.0020 in.

00(D-Kubota)-4-65
Group 00(D-Kubota), Engine

Cylinder Head Flaw


1. Prepare an air spray red check.
2. Clean the surface of the cylinder head with the detergent (2).
3. Spray the cylinder head surface with the red permeative liquid
(1). Leave it five to ten minutes after spraying.
4. Wash away the red permeative liquid on the cylinder head
surface with the detergent (2).
5. Spray the cylinder head surface with the white developer (3).
6. If flawed, it can be identified as red marks.
(1) Red Permeative Liquid (3) White Developer
(2) Detergent

Valve Recessing
1. Clean the cylinder head, the valve face and seat.
2. Insert the valve into the valve guide.
3. Measure the valve recessing with a depth gauge.
4. If the measurement exceeds the allowable limit, replace the
valve.
If it still exceeds the allowable limit after replacing the valve,
replace the cylinder head.
(recessing)
Intake
0.6 to 0.8 mm
valve
Factory 0.0236 to 0.0315 in.
spec. (recessing)
Exhaust
Valve recessing 0.85 to 1.05 mm
valve
0.0335 to 0.0413 in.
(recessing)
Allowable
1.2 mm
limit
0.0472 in.

(1) Cylinder Head Surface (A) Recessing


(B) Protrusion

Valve Lapping
1. Apply compound evenly to the valve lapping surface.
2. Insert the valve into the valve guide. Lap the valve onto its seat
with a valve flapper or screwdriver.
3. After lapping the valve, wash the compound away and apply oil,
then repeat valve lapping with oil.
4. Apply prussian blue to the contact surface to check the seated
rate. If it is less than 70 %, repeat valve lapping again.
IMPORTANT
• When valve lapping is performed, be sure to check the valve
recessing and adjust the valve clearance after assembling
the valve.
(1) Correct (3) Incorrect
(2) Incorrect

00(D-Kubota)-4-66
Group 00(D-Kubota), Engine

Clearance between Valve Stem and Valve Guide


1. Remove carbon from the valve guide section.
2. Measure the valve stem O.D. with an outside micrometer.
3. Measure the valve guide I.D. of the cylinder head at the most
wear part as shown in the figure below with a small hole gauge.
And calculate the clearance.
4. If the clearance exceeds the allowable limit, replace the valves.
If it still exceeds the allowable limit, replace the valve guide.
Intake 0.055 to 0.085 mm
Factory valve 0.0022 to 0.0033 in.
Clearance between spec. Exhaust 0.055 to 0.085 mm
valve stem and guide valve 0.0022 to 0.0033 in.
0.1 mm
Allowable limit
0.0039 in.

Intake 6.960 to 6.975 mm


Factory valve 0.2740 to 0.2746 in.
Valve stem O.D.
spec. Exhaust 6.960 to 6.975 mm
valve 0.2740 to 0.2746 in.

Intake 7.030 to 7.045 mm


Factory valve 0.2768 to 0.2774 in.
Valve guide I.D.
spec. Exhaust 7.030 to 7.045 mm
valve 0.2768 to 0.2774 in.

Replacing Valve Guide


(When removing)
1. Using a valve guide replacing tool, press out the used valve
guide.
(When installing)
1. Clean a new valve guide, and apply engine oil to it.
2. Using a valve guide replacing tool, press in a new valve guide
until it is flush with the cylinder head as shown in the figure.
3. Ream precisely the I.D. of the valve guide to the specified
dimension.
IMPORTANT
• Do not hit the valve guide with a hammer, etc. during
replacement.
(A) When Removing (B) When Installing

00(D-Kubota)-4-67
Group 00(D-Kubota), Engine

Correcting Valve and Valve Seat


NOTE
• Before correcting the valve and seat, check the valve stem
and the I.D. of valve guide section, and repair them if
necessary.
• After correcting the valve seat, be sure to check the valve
recessing.
1) Correcting Valve
1. Correct the valve with a valve refacer.
1.047 rad
IN.
Factory 60 °
Valve face angle
spec. 0.785 rad
EX.
45 °
2) Correcting Valve Seat
1. Slightly correct the seat surface with a 1.047 rad (60 °) (intake
valve) or 0.785 rad (45 °) (exhaust valve) valve seat cutter.
2. Resurface the seat surface with a 0.523 rad (30 °) valve seat
cutter to intake valve seat and with a 0.262 rad (15 °) valve seat
cutter to exhaust valve seat so that the width is close to specified
valve seat width.
1.6 to 2.0 mm
IN.
Factory 0.0630 to 0.0790 in.
Valve seat width
spec. 2.3 to 2.6 mm
EX.
0.0906 to 0.1024 in.
3. After resurfacing the seat, inspect for even valve seating, apply a
thin film of compound between the valve face and valve seat, and
fit them with valve lapping tool.
4. Check the valve seating with prussian blue. The valve seating
surface should show good contact all the way around.
1.047 rad
IN.
Factory 60 °
Valve seat angle
spec. 0.785 rad
EX.
45 °

(1) Valve Seat Width (A) Check Contact


(2) Identical Dimensions (B) Correct Seat Width
(C) Check Contact
(a) 0.262 rad (15 °) or 0.523 rad (30 °)
(b) 0.785 rad (45 °) or 1.047 rad (60 °)
(c) 0.523 rad (30 °) or 0.262 rad (15 °)

00(D-Kubota)-4-68
Group 00(D-Kubota), Engine

Free Length and Tilt of Valve Spring


1. Measure the free length (B) with vernier calipers. If the
measurement is less than the allowable limit, replace it.
2. Put the spring on a surface plate, place a square on the side of
the spring, and check to see if the entire side is contact with the
square. Rotate the spring and measure the maximum (A). If the
measurement exceeds the allowable limit, replace.
3. Check the entire surface of the spring for scratches. Replace it,
if any.
1.0 mm
Tilt (A) Allowable limit 0.039 in.

Intake 35.1 to 35.6 mm


Factory valve 1.3819 to 1.4016 in.
spec. Exhaust 35.1 to 35.6 mm
valve 1.3819 to 1.4016 in.
Free length (B)
Intake 34.6 mm
Allowable valve 1.3622 in.
limit Exhaust 34.6 mm
valve 1.3622 in.
(A) Tilt (B) Free length

Valve Spring Setting Load


1. Place the valve spring on a tester and compress it to the same
length it is actually compressed in the engine.
2. Read the compression load on the gauge.
3. If the measurement is less than the allowable limit, replace it.
Intake 63.547 N / 31.5 mm
valve 6.48 kgf / 31.5 mm
Factory 14.256 lbs / 1.2401 in.
spec. 63.547 N / 31.5 mm
Exhaust
valve 6.48 kgf / 31.5 mm
Setting load / setting 14.256 lbs / 1.2401 in.
length 45.864 N / 31.5 mm
Intake
valve 4.68 kgf / 31.5 mm
Allowable 10.296 lbs / 1.2401 in.
limit 45.864 N / 31.5 mm
Exhaust
4.68 kgf / 31.5 mm
valve
10.296 lbs / 1.2401 in.

Oil Clearance between Rocker Arm Shaft and Bearing


1. Measure the rocker arm bearing I.D. with an inside micrometer.
2. Measure the rocker arm shaft O.D. with an outside micrometer,
and then calculate the oil clearance.
3. If the clearance exceeds the allowable limit, replace the rocker
arm and measure the oil clearance again. If it still exceeds the
allowable limit, replace also the rocker arm shaft.
0.016 to 0.045 mm
Factory spec.
Oil clearance of rocker 0.0006 to 0.0018 in.
arm shaft and bearing 0.15 mm
Allowable limit
0.0059 in.

15.973 to 15.984 mm
Rocker arm shaft O.D. Factory spec.
0.6289 to 0.6293 in.
16.000 to 16.018 mm
Rocker arm I.D. for shaft Factory spec.
0.6299 to 0.6306 in.

00(D-Kubota)-4-69
Group 00(D-Kubota), Engine

Push Rod Alignment


1. Place the push rod on V blocks.
2. Measure the push rod alignment.
3. If the measurement exceeds the allowable limit, replace the push
rod.
0.25 mm
Push rod alignment Allowable limit 0.0098 in.

Oil Clearance between Tappet and Tappet Guide Bore


1. Measure the tappet O.D. with an outside micrometer.
2. Measure the I.D. of the tappet guide bore with a cylinder gauge,
and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit or the tappet is
damaged, replace the tappet.
0.020 to 0.062 mm
Factory spec.
0.0008 to 0.0024 in.
Oil clearance between
tappet and guide bore 0.07 mm
Allowable limit
0.0028 in.

23.959 to 23.980 mm
Tappet O.D. Factory spec.
0.9433 to 0.9441 in.
24.000 to 24.021 mm
Tappet guide bore I.D. Factory spec. 0.9449 to 0.9457 in.

00(D-Kubota)-4-70
Group 00(D-Kubota), Engine

(2) Timing Gears


Timing Gear Backlash
1. Set a dial indicator (lever type) with its tip on the gear tooth.
2. Move the gear to measure the backlash, holding its mating gear.
3. If the backlash exceeds the allowable limit, check the oil
clearance of the shafts and the gear.
4. If the oil clearance is proper, replace the gear.
Factory spec. 0.049 to 0.193 mm
Backlash between crank 0.0019 to 0.0076 in.
gear and idle gear 1 0.22 mm
Allowable limit
0.0087 in.

Factory spec. 0.049 to 0.189 mm


Backlash between idle 0.0019 to 0.0074 in.
gear 1 and cam gear 0.22 mm
Allowable limit
0.0087 in.

Factory spec. 0.044 to 0.185 mm


Backlash between idle 0.0017 to 0.0073 in.
gear 1 and idle gear 2 0.22 mm
Allowable limit
0.0087 in.

0.044 to 0.177 mm
Backlash between idle Factory spec.
0.0017 to 0.0070 in.
gear 2 and injection
pump gear Allowable limit 0.22 mm
0.0087 in.

Factory spec. 0.047 to 0.182 mm


Backlash between cam 0.0018 to 0.0072 in.
gear and balancer gear
1 Allowable limit 0.22 mm
0.0087 in.

Factory spec. 0.044 to 0.183 mm


Backlash between idle 0.0017 to 0.0072 in.
gear 1 and balancer
gear 2 Allowable limit 0.22 mm
0.0087 in.

Idle Gear Side Clearance


1. Set a dial indicator with its tip on the idle gear.
2. Measure the side clearance by moving the idle gear to the front
and rear.
3. If the measurement exceeds the allowable limit, replace the idle
gear collar.
Factory spec. 0.15 to 0.30 mm
0.0059 to 0.0118 in.
Idle gear side clearance
Allowable limit 0.9 mm
0.0354 in.

Camshaft Side Clearance


1. Set a dial indicator with its tip on the camshaft.
2. Measure the side clearance by moving the cam gear to the front
and rear.
3. If the measurement exceeds the allowable limit, replace the
camshaft stopper.
Factory spec. 0.07 to 0.22 mm
0.0028 to 0.0087 in.
Side clearance 0.30 mm
Allowable limit
0.0118 in.

00(D-Kubota)-4-71
Group 00(D-Kubota), Engine

Camshaft Alignment
1. Support the camshaft with V block on the surface plate and set a
dial indicator with its tip on the intermediate journal at right angle.
2. Rotate the camshaft on the V blocks and get the misalignment
(half of the measurement).
3. If the misalignment exceeds the allowable limit, replace the
camshaft.
0.01 mm
Camshaft alignment Allowable limit
0.00039 in.

Cam Height
1. Measure the height of the cam at its highest point with an outside
micrometer.
2. If the measurement is less than the allowable limit, replace the
camshaft.
Intake 37.63 mm
Factory valve 1.4815 in.
spec. Exhaust 38.96 mm
Intake and exhaust cam valve 1.5338 in.
height Intake 37.13 mm
Allowable valve 1.4618 in.
limit Exhaust 38.46 mm
valve 1.5141 in.

Oil Clearance of Camshaft Journal


1. Measure the camshaft journal O.D. with an outside micrometer.
2. Measure the cylinder block bore I.D. for camshaft with an inside
micrometer.
3. If the clearance exceeds the allowable limit, replace the
camshaft.
0.050 to 0.091 mm
Factory spec.
Oil clearance of 0.0020 to 0.0036 in.
camshaft journal 0.15 mm
Allowable limit
0.0059 in.

45.934 to 45.950 mm
Camshaft journal O.D. Factory spec.
1.8084 to 1.8091 in.
46.000 to 46.025 mm
Camshaft bearing I.D. Factory spec.
1.8110 to 1.8120 in.

00(D-Kubota)-4-72
Group 00(D-Kubota), Engine

Oil Clearance between Idle Gear Shaft 1, 2 and Idle Gear 1, 2


Bushing
1. Measure the idle gear shaft O.D. with an outside micrometer.
2. Measure the idle gear bushings I.D. with an inside micrometer,
and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
bushing.
0.050 to 0.091 mm
Oil clearance between Factory spec.
0.0020 to 0.0036 in.
idle gear 1, 2 shaft and
idle gear 1, 2 bushing 0.10 mm
Allowable limit
0.0039 in.

Idle gear 1, 2 bushing 45.025 to 45.050 mm


Factory spec.
I.D. 1.7726 to 1.7736 in.
44.959 to 44.975 mm
Idle gear 1, 2 shaft O.D. Factory spec.
1.7700 to 1.7707 in.

Replacing Idle Gear Bushing


(When removing)
1. Using an idle gear bushing replacing tool, press out the used
bushing.
(When installing)
1. Clean a new idle gear bushing and idle gear bore, and apply
engine oil to them.
2. Using an idle gear bushing replacing tool, press in a new bushing
(service parts) to the specified dimension. (See figure.)
(A) When Removing (B) When Installing

Balancer Shaft Side Clearance


1. Set a dial indicator with tip on the balancer shaft.
2. Measure the side clearance by moving the balancer shaft to the
front and rear.
3. If the measurement exceeds the allowable limit, replace the
balancer shaft.
0.070 to 0.22 mm
Factory spec.
0.0028 to 0.0087 in.
Side clearance
0.3 mm
Allowable limit
0.0118 in.

Balance Shaft Alignment


1. Support the balancer shaft with V blocks on the surface plate and
set a dial indicator with its tip on the intermediate journal at high
angle.
2. Rotate the balancer shaft on the V block and get the
misalignment (half of the measurement).
3. If the misalignment exceeds the allowable limit, replace the
balancer shaft.
Balancer shaft 0.02 mm
Allowable limit
alignment 0.0008 in.

00(D-Kubota)-4-73
Group 00(D-Kubota), Engine

Oil Clearance of Balancer Shaft Journal


1. Measure the balancer shaft journal O.D. with an outside
micrometer.
2. Measure the cylinder block bore I.D. (A), (B) for balancer shaft
with an inside micrometer.
3. If the clearance exceeds the allowable limit, replace the balancer
shaft.
0.070 to 0.159 mm
Factory spec.
Oil clearance of 0.0028 to 0.0063 in.
balancer-shaft journal 0.2 mm
Allowable limit
0.0079 in.

Balancer-shaft journal 50.92 to 50.94 mm


Factory spec.
O.D. 2.0047 to 2.0055 in.
Balancer-shaft bearing 51.01 to 51.08 mm
Factory spec.
I.D. (A), (B) 2.0083 to 2.0110 in.

(A) Balancer-shaft Bearing I.D. (B) Balancer-shaft Bearing I.D.

(3) Piston and Connecting Rod


Piston Pin Bore I.D.
1. Measure the piston pin bore I.D. in both the horizontal and
vertical directions with a cylinder gauge.
2. If the measurement exceeds the allowable limit, replace the
piston.
30.000 to 30.013 mm
Factory spec.
1.1811 to 1.1816 in.
Piston pin bore I.D.
30.05 mm
Allowable limit
1.1831 in.

Oil Clearance between Piston Pin and Small End Bushing


1. Measure the O.D. of the piston pin where it contacts the bushing
with an outside micrometer.
2. Measure the I.D. of the piston pin bushing at the connecting rod
small end with a cylinder gauge.
Calculate the oil clearance.
3. If the clearance exceeds the allowable limit, replace the bushing.
If it still exceeds the allowable limit, replace the piston pin.
0.020 to 0.040 mm
Oil clearance between Factory spec.
0.0008 to 0.0016 in.
piston pin and small end
bushing 0.15 mm
Allowable limit
0.0059 in.

30.006 to 30.011 mm
Piston pin O.D. Factory spec.
1.1813 to 1.1815 in.
30.031 to 30.046 mm
Small end bushing I.D. Factory spec.
1.1823 to 1.1829 in.
W1065897

00(D-Kubota)-4-74
Group 00(D-Kubota), Engine

Replacing Small End Bushing


(When removing)
1. Press out the used bushing using a small end bushing replacing
tool.
(When installing)
1. Clean a new small end bushing and bore, and apply engine oil to
them.
2. Insert a new bushing onto the tool and press-fit it with a press so
that the seam (1) of bushing position as shown in the figure, until
is flash with the connecting rod.
(1) Seam (A) When Removing
(B) When Installing
(C) 0.26 rad (15 °)

Connecting Rod Alignment


NOTE
• Since the I.D. of the connecting rod small end bushing is the
basis of this check, check the bushing for wear beforehand.
1. Remove the piston pin from the piston.
2. Install the piston pin in the connecting rod.
3. Install the connecting rod on the connecting rod alignment tool.
4. Put a gauge over the piston pin, and move it against the face
plate.
5. If the gauge does not fit squarely against the face plate, measure
the space between the pin of the gauge and the face plate.
6. If the measurement exceeds the allowable limit, replace the
connecting rod.
Connecting rod 0.05 mm
alignment Allowable limit 0.0020 in.

Piston Ring Gap


1. Insert the piston ring into the lower part of the liner (the least worn
part) with the piston.
2. Measure the ring gap with a feeler gauge.
3. If the gap exceeds the allowable limit, replace the piston ring.
Factory spec. 0.30 to 0.45 mm
Top ring and second 0.0118 to 0.0177 in.
ring 1.25 mm
Allowable limit
0.0492 in.

Factory spec. 0.25 to 0.45 mm


0.0098 to 0.0177 in.
Oil ring 1.25 mm
Allowable limit 0.0492 in.

00(D-Kubota)-4-75
Group 00(D-Kubota), Engine

Clearance between Piston Ring and Groove


1. Remove carbon from the ring grooves.
2. Measure the clearance between the ring and the groove with a
feeler gauge or depth gauge.
3. If the clearance exceeds allowable limit, check the new ring since
compression leak and oil shortage result.
4. If clearance still exceeds the allowable limit after replacing the
ring, replace the piston.
0.05 to 0.09 mm
Top ring
0.0020 to 0.0035 in.
0.093 to 0.120 mm
Factory spec. Second ring
0.0037 to 0.0047 in.
0.020 to 0.060 mm
Oil ring
0.0008 to 0.0023 in.
0.15 mm
Top ring
0.0059 in.
0.20 mm
Allowable limit Second ring
0.0079 in.
0.15 mm
Oil ring
0.0059 in.

(4) Crankshaft
Crankshaft Side Clearance
1. Set a dial indicator with its tip on the end of the crankshaft.
2. Measure the side clearance by moving the crankshaft to the front
and rear.
3. If the measurement exceeds the allowable limit, replace the
thrust bearings.
4. If the same size bearing is useless because of the crankshaft
journal wear, replace it with an oversize one referring to the table
and figure.
0.15 to 0.31 mm
Factory spec.
Crankshaft side 0.0059 to 0.0122 in.
clearance 0.50 mm
Allowable limit
0.0197 in.
(Reference)
• Oversize dimensions of crankshaft journal.
0.2 mm 0.4 mm
Oversize
0.008 in. 0.016 in.
169.1 to 169.15 mm 169.2 to 169.25 mm
Dimension A
6.6575 to 6.6594 in. 6.6614 to 6.6634 in.
29.20 to 29.25 mm 29.40 to 29.45 mm
Dimension B
1.1496 to 1.1515 in. 1.1574 to 1.1594 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension C
0.1102 to 0.1260 in. radius 0.1102 to 0.1260 in. radius
(0.8S)
The crankshaft journal must be fine-finished to higher than ೚೚೚೚

00(D-Kubota)-4-76
Group 00(D-Kubota), Engine

Crankshaft Alignment
1. Support the crankshaft with V block on the surface plate and set
a dial indicator with its tip on the intermediate journal at right
angle.
2. Rotate the crankshaft on the V block and get the misalignment
(half of the measurement).
3. If the misalignment exceeds the allowable limit, replace the
crankshaft.
0.02 mm
Crankshaft alignment Allowable limit
0.00079 in.

Oil Clearance between Crankpin and Crankpin Bearing


1. Clean the crankpin and crankpin bearing.
2. Put a strip of plastigage on the center of the crankpin.
3. Install the connecting rod cap and tighten the connecting rod
screws to the specified torque, and remove the cap again.
4. Measure the amount of the flattening with the scale, and get the
oil clearance.
5. If the oil clearance exceeds the allowable limit, replace the
crankpin bearing.
6. If the same size bearing is out of specifications because of the
crankpin wear, replace it with an undersize one referring to the
table and figure.
NOTE
• Never insert the plastigage into the crankpin oil hole.
• Be sure not to move the crankshaft while the connecting rod
screws are tightened.
52.977 to 52.990 mm
Crankpin O.D. Factory spec.
2.0857 to 2.0862 in.

0.018 to 0.051 mm
Oil clearance between Factory spec.
0.0007 to 0.0020 in.
crankpin and crankpin
bearing 0.20 mm
Allowable limit
0.0079 in.

00(D-Kubota)-4-77
Group 00(D-Kubota), Engine

Oil Clearance between Crankpin and Crankpin Bearing


(Continued)
IMPORTANT
• STD size crankpin bearing.
To replace it with a specific STD service part, make sure the
crankpin bearing has the same ID color as the connecting
rod.
Connecting rod Crankpin bearing
ID Color
Large-end in. dia. Class Part code Center wall thick
56.01 to 56.02 mm 1.496 to 1.501 mm
Blue L 1C020-22311
2.2051 to 2.2055 in. 0.0589 to 0.0591 in.
Without 56.00 to 56.01 mm 1.491 to 1.496 mm
S 1C020-22331
color 2.2047 to 2.2051 in. 0.0587 to 0.0589 in.

(Reference)
• Undersize dimensions of crankpin
0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension A
0.1102 to 0.1260 in. radius 0.1102 to 0.1260 in. radius
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.0394 to 0.0591 in. relief 0.0394 to 0.0591 in. relief
52.777 to 52.790 mm dia. 52.577 to 52.590 mm dia.
Dimension C
2.0778 to 2.0783 in. dia. 2.0700 to 2.0705 in. dia.
(0.8S)
The crankpin must be fine-finished to higher than ೚೚೚೚
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.0394 to 0.0591 in.) relief.

(1) ID Color (3) Center Wall Thick


(2) Crankpin Bearing

00(D-Kubota)-4-78
Group 00(D-Kubota), Engine

Oil Clearance between Crankshaft Journal and Crankshaft


Bearing
1. Clean the crankshaft journal and crankshaft bearing.
2. Put a strip of press gauge on the center of the journal.
IMPORTANT
• Never insert the press gauge into the oil hole of the journal.
3. Install the main bearing case and tighten the screws to the
specified torque, and remove the cases again.
4. Measure the amount of the flattening with the scale and get the
oil clearance.
5. If the clearance exceeds the allowable limit, replace the
crankshaft bearing.
74.977 to 74.990 mm
Crankshaft journal O.D. Factory spec.
2.9518 to 2.9524 in.

0.018 to 0.062 mm
Oil clearance between Factory spec.
0.0007 to 0.0024 in.
crankshaft journal and
crankshaft bearing 0.20 mm
Allowable limit
0.0079 in.
(Reference)
• Undersize dimensions of crankshaft journal.
0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension A
0.1102 to 0.1260 in. radius 0.1102 to 0.1260 in. radius
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.0394 to 0.0591 in. relief 0.0394 to 0.0591 in. relief
74.777 to 74.790 mm dia. 74.577 to 74.590 mm dia.
Dimension C
2.9440 to 2.9445 in. dia. 2.9361 to 2.9366 in. dia.
(0.8S)
The crankshaft journal must be fine-finished to higher than ೚೚೚೚
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.0394 to 0.0591 in.) relief.

Replacing Crankshaft Sleeve


1. Remove the used crankshaft sleeve (2).
2. Set the sleeve guide (3) to the crankshaft (1).
3. Heat a new sleeve to a temperature between 150 to 200୅G(302
to 392 එ), and fix the sleeve to the crankshaft as shown in figure.
4. Press fit the sleeve using the auxiliary socket for pushing (4).
NOTE
• Mount the sleeve with its largely chamfered surface facing
outward.
(1) Crankshaft (3) Sleeve Guide
(2) Crankshaft Sleeve (4) Auxiliary Socket for Pushing

00(D-Kubota)-4-79
Group 00(D-Kubota), Engine

(5) Cylinder
Cylinder Wear
1. Measure the I.D. of the cylinder at the six positions (see figure)
with a cylinder gauge to find the maximum and minimum I.D.’s.
2. Get the difference (Maximum wear) between the maximum and
the minimum I.D.’s.
3. If the wear exceeds the allowable limit, bore and hone to the
oversize dimension. (Refer to “Correcting Cylinder”.)
4. Visually check the cylinder wall for scratches. If deep scratches
are found, the cylinder should be bored. (Refer to “Correcting
Cylinder”.)
100.00 to 100.022 mm
Factory spec.
3.9370 to 3.9379 in.
Cylinder Bore I.D.
100.15 mm
Allowable limit
3.9429 in.

(A) Top (a) Right-angled to piston pin


(B) Middle (b) Piston pin direction
(C) Bottom (Skirt)

Correcting Cylinder (Oversize)


1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
100.500 to 100.522 mm
Cylinder I.D. (2) Factory spec.
3.9567 to 3.9576 in.
100.65 mm
Maximum wear Allowable limit
3.9626 in.
Hone to 1.2 to 3.0 Ɇm Rz
Finishing
(0.000087 to 0.00012 in. Rz) ೚೚೚
2. Replace the piston and piston rings with oversize 0.5 mm (0.0197
in.) ones.
NOTE
• When the oversize cylinder is worn beyond the allowable
limit, replace the cylinder block with a new one.
(1) Cylinder I.D. (Before Correction) (2) Oversize Cylinder I.D.
(6) Oil Pump
Rotor Lobe Clearance
1. Measure the clearance between lobes of the inner rotor and the
outer rotor with a feeler gauge.
2. If the clearance exceeds the allowable limit, replace the oil pump
rotor assembly.
0.04 to 0.16 mm
Clearance between Factory spec.
0.0016 to 0.0063 in.
inner rotor and outer
rotor 0.3 mm
Allowable limit
0.0118 in.

00(D-Kubota)-4-80
Group 00(D-Kubota), Engine

Clearance between Outer Rotor and Pump Body


1. Measure the clearance between the outer rotor and the pump
body with a feeler gauge.
2. If the clearance exceeds the allowable limit, replace the oil pump
rotor assembly.
0.100 to 0.184 mm
Clearance between Factory spec.
0.0039 to 0.0072 in.
outer rotor and pump
body 0.3 mm
Allowable limit
0.0118 in.

Clearance between Rotor and Cover


1. Put a strip of plastigage onto the rotor face with grease.
2. Install the cover and tighten the screws with the specified torque.
3. Remove the cover carefully, and measure the amount of the
flattening with the scale and get the clearance.
4. If the clearance exceeds the allowable limit, replace oil pump
rotor assembly and the cover.
0.025 to 0.075 mm
Factory spec.
Clearance between rotor 0.0010 to 0.0030 in.
and cover 0.225 mm
Allowable limit
0.0089 in.

7.9 to 9.3 N·m


Tightening torque Oil pump cover screw 0.80 to 0.95 kgf·m
5.8 to 6.9 ft-lbs

(7) Starter
Overrunning Clutch
1. Inspect the pinion for wear or damage.
2. If there is any defect, replace the overrunning clutch assembly.
3. Check that the pinion turns freely and smoothly in the
overrunning direction and does not slip in the cranking direction.
4. If the pinion slips or does not rotate in the both directions, replace
the overrunning clutch assembly.

00(D-Kubota)-4-81
Group 00(D-Kubota), Engine

Commutator and Mica


1. Check the contact face of the commutator for wear, and grind the
commutator with emery paper if it is slightly worn.
2. Measure the commutator O.D. with an outside micrometer at
several points.
3. If the minimum O.D. is less than the allowable limit, replace the
armature.
4. If the difference of the O.D.’s exceeds the allowable limit, correct
the commutator on a lathe to the factory specification.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct if with a saw
blade and chamfer the segment edges.
32 mm
Factory spec.
1.2598 in.
Commutator O.D.
31.4 mm
Allowable limit
1.2362 in.

0.5 mm
Factory spec.
0.0197 in.
Mica under cut
0.20 mm
Allowable limit
0.0079 in.

(1) Segment (a) Good


(2) Depth of Mica (b) Bad
(3) Mica

Brush Wear
1. If the contact face of the brush is dirty or dusty, clean it with emery
paper.
2. Measure the brush length (A) with vernier calipers.
3. If the length is less than the allowable limit, replace the yoke
assembly and brush holder.
18.0 mm
Factory spec.
0.7086 in.
Brush length (A)
11.0 mm
Allowable limit
0.4331 in.

(A) Brush Length

Brush Holder
1. Check the continuity across the brush holder and the holder
support with an ohmmeter.
2. If it conducts, replace the brush holder.
Brush holder –
Resistance Infinity
Holder support

00(D-Kubota)-4-82
Group 00(D-Kubota), Engine

Armature Coil
1. Check the continuity across the commutator and armature coil
core with an ohmmeter.
2. If it conducts, replace the armature.
3. Check the continuity across the segments of the commutator with
an ohmmeter.
4. If it does not conduct, replace the armature.
Commutator –
Infinity
Resistance Armature coil core
Commutator segment 0Ω

Field Coil
1. Check the continuity across the lead (1) and brush (2) with an
ohmmeter.
2. If it does not conduct, replace the yoke assembly.
3. Check the continuity across the brush (2) and yoke (3) with an
ohmmeter.
4. If it conducts, replace the yoke assembly.
Lead (1) – Brush (2) 0Ω
Resistance
Brush (2) – Yoke (3) Infinity

(1) Lead (3) Yoke


(2) Brush

(8) Alternator
Bearing
1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.

00(D-Kubota)-4-83
Group 00(D-Kubota), Engine

Rotor
1. Measure the resistance across the slip rings with an ohmmeter.
2. If the resistance is not the factory specification, replace it.
3. Check the continuity across the slip and core with an ohmmeter.
4. If infinity is not indicated, replace it.
Resistance Factory spec. 2.8 to 3.3 Ω

Slip Ring
1. Check the slip ring for score.
2. If scored, correct with an sand paper or on a lathe.
3. Measure the O.D. of slip ring with vernier calipers.
4. If the measurement is less than the allowable limit, replace it.
22.7 mm
Factory spec.
0.894 in.
Slip ring O.D.
22.1 mm
Allowable limit
0.870 in.

Brush Wear
1. Measure the brush length (A) with vernier calipers.
2. If the measurement is less than allowable limit, replace it.
3. Make sure that the brush moves smoothly.
4. If the brush is defective, replace it.
18.5 mm
Factory spec.
0.728 in.
Brush length (A)
5.0 mm
Allowable limit
0.197 in.

(A) Brush Length

00(D-Kubota)-4-84
GROUP 00(L)

GROUP 00(L)

ENGINE (GM V6 4.3L)

ENGINE REMOVAL AND REPLACEMENT ................... Section1

4.3 LITER V6 ENGINE REPAIR PROCEDURES............. Section2

COOLING SYSTEM.......................................................... Section3

SM 751 00(L)-0
Group 00(L), ENGINE

Section 1

ENGINE REMOVAL AND REPLACEMENT

ENGINE REMOVAL • Drain radiator and remove radiator hoses to engine


and to filler neck bracket.
The following procedures describe the steps necessary to
remove the engine. A hoist capable of lifting he overhead
guard, counterweight, and engine is required.
• Remove the overhead guard.
• Remove the driver’s seat and any electrical wires
mounted to the seat support.
• Remove the clamshell hood.

• Remove transmission oil cooling lines at radiator.

• Remove counterweight. See the procedures for


removing the counterweight in Group 38.
• Disconnect battery leads at battery and remove the
battery. Disconnect horn wires.
• Remove floor plates. Remove top and side body sheet
metal. • Remove the radiator.

SM 751 00(L)-1-1
Group 00(L), ENGINE

• Remove the air cleaner and air cleaner hoses and • Remove heat shield from the the muffler and mani-
clamps. fold.
• Remove the muffler and tail-pipe.
• Remove the exhaust pipe and heat shield wrap.

• Remove the engine oil cooler and hose.

• Remove accelerator control at carburetor throttle


lever.
• Remove the fuel line that goes from fuel pump to fuel
tank in frame.

• Remove the main pump inlet fitting assembly, inlet


hose, and stiffener.

• Remove the oil line from transmission.


• Remove and tag all wire harness leads to engine com-
ponents.
Coil the wire harness and tie it out of the way to pre-
vent damage when the engine is removed.

SM 751 00(L)-1-2
Group 00(L), ENGINE

• Connect OSHA-approved overhead chain to the ENGINE REPLACEMENT


engine lifting brackets.
The following procedures explain replacement of the
• Remove the engine mount bolts and dampeners. engine. A hoist capable of lifting the overhead guard,
• Remove the engine flywheel housing to transmission counterweight, and engine is required.
fasteners. NOTE
The following procedures assume the torque
convertor is in the transmission.

• Remove the cover plate of flywheel housing.


Unbolt the torque converter drive plate from the
engine flywheel through the top hole. • Begin lowering the engine into frame using the hoist
and chains hooked into enginelifting brackets. Put
• Carefully separate engine from transmission by mov-
engine mounting dampeners in place on frame-
ing the engine away from the transmission. Lift
mounting surfaces.
engine out of truck. Use prybars if necessary to assist
in separating engine from transmission; do not use • Remove top cover on flywheel housing. Check align-
unnecessary or excessive force. ment of torque converter and flywheel ensuring that
torque converter rotates freely.
• Insert engine-mounting bolts and tighten to a torque
of 23-27 lbf·ft (32–36 N·m).
• Insert transmission case-to-engine bolts.
Torque engine-to-transmission bolts to 24-27 lbf·ft
(33-37 N·m).

NOTE
Do not pry on the torque converter. Nicks
and scratches can cause fatigue and leaks.

SM 751 00(L)-1-3
Group 00(L), ENGINE

• Use hole on the flywheel housing to replace the • Install the exhaust pipe and heat shield wrap.
torque converter drive plate to engine flywheel bolts
• Install the muffler and tail pipe.
and tighten to a torque of 19 to 21 lbf·ft (25-28 N·m).
• Install the muffler and manifold heat shields.
• Tighten fasteners to a torque of 24-27 lbf·ft (33-37
N·m).

• Install the main pump inlet fitting assembly using a


• Replace all wires on correct components on engine new gasket; install the inlet hose and stiffener. Fill the
and remove all identification tags. oil sump to the correct level.
• Replace the oil line on the transmission.

• Install the air cleaner and air cleaner hoses and


clamps. Ensure that all connections are tight and do
• Replace the fuel line on the fuel pump. not leak.
• Connect the accelerator control at the carburetor
throttle lever.

SM 751 00(L)-1-4
Group 00(L), ENGINE

• Install the radiator. • Install the battery and connect the battery leads.

• Install the counterweight and tighten bolt to a torque


• Install the engine oil cooler and hoses.
of 350-400 lbf-ft (650-800N·m).

• Connect the transmission oil-cooling lines at the radi-


ator. ! WARNING
Use caution when replacing the counter-
weight.
Keep all body parts away; use prybars to
manuever the counterweight into exact
mounting position.

• Install sheet metal.


• Replace the overheadguard. Insert and tighten fasten-
ers to a torque of 50-55 lbf·ft (65-75 N·m).

• Connect engine cooling lines to the radiator; fill the


radiator to the correct level.
• Install front and rear floor plates.
• Install seat support and top hood.
• Attach electrical leads to the horn.

SM 751 00(L)-1-5
Group 00(L), ENGINE

Section 2

4.3 LITER V6 ENGINE REPAIR PROCEDURES

NOTICE
Always use the correct fastener in the correct
location. Use the correct fastener part num-
ber to replace a fastener. If the correct fas-
tener part number is not available, a fastener
of equal size and strength may be used. Do
not use a fastener that is stronger when the
correct fastener part number is not available
in the following applications:

• Some bolts are designed to permanently stretch, and if


a stronger fastener is used, the part will not be tight-
ened correctly. These permanently stretching bolts
will be called out. The correct part number fasteners
must be used to replace this type of fastener because
there is no available equivalent.
• Other bolts are designed to break if over tightened to
prevent part damage. Using a stronger fastener may
cause part damage to occur.
Fasteners that need to be replaced when removed will be
called out. Fasteners that require thread lockers or thread
sealant will be called out The correct tightening specifica-
tion and sequence must be used when installing fasteners.
Part or system damage may occur if the above instructions
are not followed.
Use only a razor blade type scraper on engine component
surfaces. Use extreme care so sealing surfaces are not
scratched. Do not use any other method or technique to
remove gasket material except where indicated. Do not
use abrasive pads, sand paper or power tools to remove
gasket material except where indicated. These techniques
will produce fine grit that the oil filter will not be able to
remove from the oil this grit is abrasive and has been
known to cause internal engine damage.

SM 751 00(L)-2-1
Group 00(L), ENGINE

GENERAL DESCRIPTION BALANCE SHAFT


A cast-ductile balance shaft is mounted in the crankcase
ENGINE CONSTRUCTION above and in-line with the camshaft for enhanced engine
smoothness under all operating conditions. A camshaft
The 4.3L (262 CID) engine is a liquid-cooled 90-degree gear drives the gear attached to the balance shaft. The
V6 type with overhead valves, cast-iron block, cylinder front end of the balance shaft is supported by a ball bear-
heads, and cast-iron balance shaft. ing and the opposite end uses a sleeve bearing.

CYLINDER BLOCK VALVE TRAIN


The cylinder block has 6 cylinders arranged in a “V” The valve train is a ball pivot type. Motion is transmitted
shape with 3 cylinders in each bank. from the camshaft through the hydraulic lifter and push-
Starting at the front of the engine, cylinders in the right rod to the rocker arm.The rocker arm pivots on its ball and
bank are numbered l-3-5 and cylinders in the left bank are transmits the camshaft motion to the valve. The hydraulic
numbered 2-4-6 (when viewed from the front of the valve lifters with roller followers keep all parts of the
engine). The firing order of the cylinders is 1-6-5-4-3-2. valve train in constant contact. Each lifter acts as an auto-
The cylinders are encircled by coolant jackets. matic adjuster and maintains zero lash in the valve train
and eliminates the need for periodic valve adjustment.
CYLINDER HEADS
The cylinder heads have one intake and one exhaust valve INTAKE MANIFOLD
for each cylinder. A spark plug is located between the A cast-aluminum intake manifold is used that has an
valves in the side of the cylinder head. The valve guides exhaust gas recirculation (EGR) port cast into it for the
are integral and the rocker arms are retained on individual mixture of exhaust gases with the fuel and air mixture.
threaded in Studs.

CRANKSHAFT
The crankshaft is supported by four main bearing inserts.
The number four bearing at the rear of the engine is the
end thrust bearing. The bearings are retained by bearing
caps that are machined with the block for proper align-
ment and clearances.

CAMSHAFT
The camshaft is supported by four full round, sleeve type
bearings. A sprocket on the crankshaft drives a timing
chain which in turn drives the camshaft through a
sprocket.

PISTONS AND CONNECTING RODS


The pistons are made of cast aluminum alloy using two
compression rings and one oil control ring. piston pins are
offset 1.58750 mm (0.0625 in.) toward the major thrust
side (right side) to reduce piston slap as the connecting
rod travels from one side of the piston to the other side
after a stroke. The pins are a press fit in the connecting rod
and a floating fit in the piston.

SM 751 00(L)-2-2
Group 00(L), ENGINE

SM 751 00(L)-2-3
Group 00(L), ENGINE

1. Oil Pump Shaft Extension 120. Clutch Pressure Plate cover


2. Oil Pump Body 121. Dowel Pin
5. Pump Cover 122. Retainer
6. Pressure Regulator valve 123. Oil Pump Bolt
7. Pressure Regulator Valve Spring 124. Spring Stop Plug
8. Spring Stop Retaining Pin 125. Nut
10. Pickup Screen and Pipe 126. Gasket
70. Oil Pan Gasket 127. Oil Fan Drain Plug
71. Oil Pan Reinforcement 128. Oil Pan Stud
72. Oil pan 129. Bolt
80. seal Retainer Screw 130. Clip
81. Seal Retainer Nut 131. Bolt
82. Seal Retainer 132. Main Bearing Cap Bolt
83. Seal Retainer Stud 133. Groove Pin
84. Seal Retainer Gasket 134. Engine Flywheel
87. Camshaft Retainer 135. Flywheel Bolt
88. Camshaft Retainer Screw 136. Lower Main Bearing Insert
90. Seal 137. Crankshaft Front Oil seal
91. Gasket 138. Torsional Damper
92. Oil Fitter Adapter 139. Groove Pin
93. Bolt 140. Timing Pointer
100. Main Bearing Cap 141. Bolt
101. Crankshaft 142. Front Cover
102. Oil Filter 143. Front Cover Gasket
103. Piston Rings 144. Upper Main Bearing Insert
104. Piston 145. Woodruff key
105. Connecting Rod 146. Dowal Pin
106. Connecting Rod Bearing 148. Canshaft
107. Connecting Rod Cap 149. Coolant Pump Gasket
108. Connecting Rod Nut 150. Bolt
109. Plug 151. Coolant Pump
110. Knock Sensor 152. Crankshaft Sprocket
111. Plug 153. Bolt
112. Expansh Cup Plug 154. Camshaft sprocket
113. Plug 155. Timing Chain
114. Engine Block 156. Camshaft Bearing
115. Plug 157. Expansion Plug
116. Water Jacket Plug 158. Oil Level Indicator Tube
117. Clutch Driven Plate 159. Oil Level Indicator
118. Spring Lock washer 160. Bolt
119. Clutch Cover Bolt 161. Piston Pin

SM 751 00(L)-2-4
Group 00(L), ENGINE

SM 751 00(L)-2-5
Group 00(L), ENGINE

20. Valve Stem Key 165. Coolant Outlet Gasket


21. nlet Valve Spring Cap 166. Thermostat
22. Valve Stem Oil Shield 167. Vacuum Fitting
23. Valve Stem Oil Seal (O-Ring) 168. Engine Coolant
24. Inlet Valve Stem Seal Temperature, sensor
26. Valve Spring with Damper 169. Bolt
27. Inlet Valve 170. Intake Manifold
28. Exhaust Valve Rotator 171. Oil Pressure Sensor
29. Exhaust Valve 172. Oil Pressure Fitting
40. Lifter Restrictor Retainer Bolt 173. E.G.R. Valve Gasket
41. Lifter Restrictor Retainer 174. E.G.R. Valve
42. Rocker Arm Nut 175. Bolt
43. Rocker Arm Ball 176. Intake Manifold Gasket
44. Rocker Arm 177. Nut
45. Push Rod 178. Power Booster
Vacuum Pipe
46. VaIve Lifter Guide (Restrictor)
179. Exhaust Manifold
47. Lifter
180. Fower Booster Vacuum
48. Flat Washer
Pipe Fitting
50. Cylinder Head Bolt
181. Plug
51. Spark Plug
182. Coolant Temperature Sensor
52. Coolant Temperature Sensor
183. Crankcase Ventilation Valve
53. Drain Plug
184. Oil Filler Cap
54. Cylinder Head Gasket
185. Oil Filler Tube
60. Heat Shield
186. Bolt
61. Washer
700. Rocker Arm Cover Bolt
62. Exhaust ManifoId Lock
701. Rocker Arm Cover
63. Bolt/Stud
702. Rocker Arm Cover Gasket
162. Stud
704. Crankcase Vent Tube Grommet
163. Bolt
705. Crankcase Vent Valve Grommet
164. Coolant Outlet

SM 751 00(L)-2-6
Group 00(L), ENGINE

ENGINE LUBRICATION
Figures 8 and 9 page.
Lubrication schematics are shown in figures of 8 and 9 page. The gear type oil pump is driven from the distributor shaft,
which is gear driven from the camshaft. Oil is drawn into the oil pump through a pickup screen and pipe.
Pressurized oil is routed to the oil filter. In case of excessive oil pressure, a bypass valve is provided. Filtered oil flows
into the main gallery and then to the camshaft, balance shaft rear bearing, and crankshaft bearings.
The valve lifter oil gallery supplies oil to the valve lifters. Oil flows from the hydraulic lifters through the hollow push-
rods to the rocker arms. Oil frorn overhead drains back to the crankcase through oil drain holes.
The timing chain is drip fed from the front camshaft bearing. The pistons and piston pins are lubricated by oil splash.

SM 751 00(L)-2-7
Group 00(L), ENGINE

SM 751 00(L)-2-8
Group 00(L), ENGINE

GENERAL INFORMATION USING RTV SEALER


• Do not use RTV when extreme temperatures are
STATEMENT ON CLEANLINESS AND expected, such as exhaust manifold, head gasket or
CARE where gasket eliminator is specified.
• When separating components sealed with RTV, use a
• An engine is a combination of many machined,
rubber mallet and “bump” the part sideways to shear
honed, polished, and lapped surfaces with very fine
the RTV sealer. “Bumping” should be done at bends
tolerances.
or reinforced areas to prevent distortion of parts. RTV
• Whenever valve train components, cylinder head, cyl- is weaker in shear (lateral) strength than in tensile
inder, crankshaft, or connecting rod components are (vertical) strength.
removed for service, they should be retained in order.
NOTICE
At the time of installation, they should be installed in
the same locations and with the same mating surfaces Attempting to pry or pull components apart
as when removed. may result in damage to the part.

• Any time the air cleaner or TBI unit is removed, the • Surfaces to be resealed must be clean and dry.
intake opening must be covered.This will protect Remove all traces of oil and RTV with a chlorinated
against the entrance of foreign material which could solvent (GM P/N 1050454 or equivalent). Do not use
follow the intake passage into the cylinder and cause petroleum cleaners such as mineral spirits. They leave
extensive damage when the engine is started. a film onto which RTV will not stick.
• When any internal engine parts are serviced, care and • Apply RTV to one of the clean surfaces. Use abead
cleanliness are important. A liberal coating of engine size as specified in the procedure. Run the bead to the
oil should be applied to friction areas during assembly inside of any bolt holes. Do not allow the sealer in
to protect and lubricate the surfaces on initial opera- any blind threaded holes, as it may prevent the bolt
tion. Throughout this section, it should be understood from seating properly or cause damage when the bolt
that proper cleaning and protection of machined sur- is tightened.
faces and friction areas is part of the repair procedure.
This is considered standard shop practice even if not • Assemble while RTV is still wet (within 3 minutes).
specifically stated. Do not wait for RTV to skin over.

IMPORTANT • Torque bolts to specitications. Do not over-torque.


Use of RTV sealer and anaerobic gasket elim-
inator USING ANAEROBIC GASKET ELIMINA-
Two types of sealer are commonly used in the TOR
engines covered by this manual. These are
RTV sealer and anaerobic “gasket elimina- • Clean surfaces to be resealed with a chlorinated sol-
tor” sealer. vent (GM P/N 1050454 or equivalent) to remove all
oil, grease, and old material.
It is important that these sealers be applied properly and in
• Apply a continuous bead of gasket eliminator to one
their proper place to prevent oil leaks. The two types of
flange.
sealers are not interchangeable. Use the sealer recom-
mended in the procedure. • Spread the bead evenly with your finger to get a uni-
form coating on the complete flange.
• RTV (room temperature vulcanization) sealer is used
where a nonrigid part is assembled to a rigid part. • Assemble parts in the normal manner and torque
Common examples are oil pans and rocker covers. immediately to specifications.
• Anaerobic gasket ehminator hardens in the absence of IMPORTANT
air. This sealer is used where two rigid parts (such as Anaerobic sealed joints that are partially
castings) are assembled together. When two rigid torqued and allowed to cure more than five
parts are disassembled and sealer or gasket is readily minutes may result in incorrect shimming of
noticeable, the parts were probably assembled using the joint.
gasket eliminator.

SM 751 00(L)-2-9
Group 00(L), ENGINE

REPLACING ENGINE GASKETS • Lubricate the insert with light engine oil (except when
installing in aluminum) and install.
! CAUTION
IMPORTANT
Composite type gaskets are used in some
When correctly installed, the insert should be
areas of the engine assembly. These gaskets
flush to one turn below the surface.
have a thin metal core. Use caution when
removing or handling composite gaskets to
• If the tang of the insert does not break off when back-
help avoid personal injury.
ing out the installer, break the tang off with a drift
THREAD REPAIR

Tools Required
General purpose thread repair kits are available com-
mercially.
Damaged threads may be reconditioned by drilling
out, rethreading, and installing a suitable thread insert.

! CAUTION
Wear safety glasses to avoid eye damage.

• Determine size, pitch, and depth of damaged thread.


If necessary, adjust stop collars on cutting tool and tap
to required depth.

IMPORTANT
Refer to the kit manufacturer’s instructions
regarding the size of drill and tap to be used.

• Drill out damaged thread.


• Tap hole. Lubricate tap with light engine oil. Clean
the thread.

IMPORTANT
Avoid buildup of chips. back out the tap
every few turns and remove chips.

• Thread the thread insert into the mandrel of the


installer.
Engage the tang of the insert on the end of the man-
drel.

SM 751 00(L)-2-10
Group 00(L), ENGINE

DISASSEMBLY OF ENGINE CLEANING


It is important that the engine be as clean as possible to
TOOLS AND SHOP EQUIPMENT prevent dirt from entering critical areas during disassem-
bly.
A clean well-lit work area should be available. other nec-
essary equipment includes: a suitable parts cleaning tank, Remove the engine accessories before cleaning, to pro-
compressed air supply, trays to keep parts and fasteners vide better access to the engines exterior surfaces. After
organized, and an adequate set of hand tools. removing the TBI unit, distributor, etc., cover the open-
ings with tape to prevent the entry of contaminants.
An approved engine repair stand will aid the work and
help prevent personal injury or component damage. Methods used to clean the engine will depend on the
means which are available. Steam cleaning, pressure
Special tools are listed and illustrated throughout this sec- washing, or solvent cleaning am some of the acceptable
tion with a complete listing at the end of the section. methods. AIlow the engine to dry thoroughly before
These tools (or their equivalents) are specially designed to beginning any work.
quickly and safely accomplish the operations for which
they are intended.
The use of these special tools will also minimize possible DRAINING THE ENGINE
damage to engine components.
Remove or Disconnect
Some precision measuring tools are required for inspec-
• Oil pan drain plug and washer.
tion of certain critical components. Torque wrenches are
necessary for the correct assembly of various parts. IMPORTANT
Allow the oil to drain into a proper container.
ACCESSORY REMOVAL
• Oil filter.
The various procedures in this manual assume that the
• Coolant drain plug and or knock sensor from the
engine accessories have been removed.
block
These accessories may include one or more of the follow-
ing: IMPORTANT
• Hydraulic Pump Allow the coolant to drain from the block
into a proper container.
• Generator
• Air Conditioning Compressor Install or Connect

• Cooling Fan NOTICE


Refer to “Notice” on page 00(L)-2-1.
• Distributor
• TBI unit • Oil pan drain bo1t.
It is beyond the scope of this section to cover in detail the Tighten
many different accessory installations.
Refer to the appropriate service manual section for this Drain plug to 25 N ·m (18 lbs. ft).
information. • Coolant drain plug and or knock sensor into the block.
Diagrams of emissions and vacuum hose routings, wiring
harness routing, accessory drive belt layout, etc. should be Tighten
found before removing accessories. • Coolant drain plug or knock sensor to 14 N ·m (124
lbs. in.).

SM 751 00(L)-2-11
Group 00(L), ENGINE

EGR VALVE REMOVAL


Remove or Disconnect
• Bolts.
• EGR valve.
• Gasket.

EXHAUST MANIFOLD REMOVAL


Remove or Disconnect
• Exhaust manifold bolts, washers, and tab washers.
• Heat shields.
• Exhaust manifold.

COOLANT PUMP REMOVAL


Remove or Disconnect
• coolant pump bolts.
• coolant pump.
VALVE TRAIN COMPONENT REMOVAL
• Gaskets. 19. Bolt
20. Retainer
ROCKER ARM COVER REMOVAL 21. Nuts
22. Balls
Remove or Disconnect
23. Rocker Arm
• Rocker arm cover bolts(1). 24. Pushrods
• Rocker arm covers (2). 25. Restrictor
• Gaskets. 26. Hydraulic Lifter

INTAKE MANIFOLD REMOVAL


Remove or Disconnect
• Intake manifold bolts.
• Intake manifold.
• Gaskets.

SM 751 00(L)-2-12
Group 00(L), ENGINE

Remove or Disconnect Remove or Disconnect

IMPORTANT NOTICE
Store all reusable components in an exact The inertial weight section of the torsional
order so they can be reassembled in the same damper is assembled to the hub with a rub-
position from which they were removed. ber sleeve. The removal procedures must be
followed (with the proper tools) or movement
• Rocker arm nuts (21), balls (22), and rocker arms of the inertia weight section of the hub will
(23). destroy the tuning of the torsional damper
and the engine timing reference.
• Push rods (24).
• Bolt (19). • Torsional damper bolt.

• Guide assembly (20). • Torsional damper using J 23523-E (figure 10).

• Hydraulic lifters (26). • Crankshaft key.

IMPORTANT
Remove the lifters one at a tune and place
them in an organizer rack

CYLINDER HEAD REMOVAL


Remove or Disconnect
• Engine lift bracket.
• Cylinder head bolts.
• Cylinder heads.
• Head gaskets.

TORSIONAL DAMPER REMOVAL


Tool Required
J 23523-E Torsional Damper Puller

SM 751 00(L)-2-13
Group 00(L), ENGINE

SM 751 00(L)-2-14
Group 00(L), ENGINE

OIL PAN REMOVAL • Camshaft sprocket (40) and timing chain (41)
together.
Remove or Disconnect
• Oil pan nuts (125).
• Oil pan bolts (129).
• Clips (130) and studs (128).
• Reinforcements.
• Oil pan (72).
• Gasket (70).

OIL PUMP REMOVAL


IMPORTANT
Remove or Disconnect
The sprocket has a light interference fit on
• Oil pump to main bearing cap bolt. the camshaft.
Tap the sprocket on its lower edge to loosen
• Complete oil pump assembly.
it.
• Shaft extension.
CAMSHAFT REMOVAL
FLYWHEEL REMOVAL
Tool Required:
Remove or Disconnect 5825-A Crankshaft Gear Remover
• Flywheel bolts. • Balance shaft drive gear stud (35).
• Flywheel. • Balance shaft drive gear (37).
• Crankshaft sprocket (38), if necessary. Use 5825 (fig-
FRONT COVER REMOVAL ure 13).

Remove or Disconnect • Camshaft retainer bolts and camshaft retainer.

• Front cover bolts. • Camshaft.

• Front cover.
• Front cover gasket.

TIMING CHAIN AND CAMSHAFT


SPROCKET REMOVAL
Remove or Disconnect
Check timing chain free play. If the timing chain can be
moved back and forth in excess of 1.58750 mm (0.625
in.), make a note that the timing chain should be replaced
during assembly. IMPORTANT
• Camshaft sprocket bolts (39) and nut (34). Install three 7.9375 mm (0.3125 in.- 18 pitch)
bolts 100 ~ 125 mm (3.937 in. - 4.921 in.)
long into the camshafts threaded holes. Use
these bolts to handle the camshaft. (figure
14).

SM 751 00(L)-2-15
Group 00(L), ENGINE

BALANCE SHAFT REMOVAL

Tools Required:
38834 Balance Shaft Bearing Service
Kit 26941 Bearing Remover
Remove or Disconnect
1. Bolt (49).
2. Driven gear (42).
3. Retainer bolts (48).
4. Retainer (43).
5. Balanceshaft(47)using a soft faced hammer(above figure).
6. Balance shaft rear bearing (45) using 38834 and 26941.

IMPORTANT
The balance shaft with front bearing are serviced as an assembly.
Use only the correct tools for bearing and shaft installation.
Inspect the balance shaft driven gear and the drive gear for nicks and burrs.

SM 751 00(L)-2-16
Group 00(L), ENGINE

PISTON AND CONNECTING ROD • Check the connecting rod and cap for identification
marks.
REMOVAL
IMPORTANT
Mark the parts if required.
Marking them from the front to the rear,
with the engine in an upright position and
viewed from the front:
– The right bank is numbered l-3-5.
– The left bank is numbered 2-4-6.
Store the connecting rod, bearings and cap
together as mating parts, so they may be
reassembled in the same position from which
they were removed.
• Connecting rod cap.
• Connecting rod and piston.

IMPORTANT
Attach 5239 to the connecting rod bolts (fig-
ure 20 page below and right).
Use the long guide rod of 5239 to push the
connecting rod and piston out of the bore
through the top of the engine.

• Connecting rod beatings.

Tools Required :
5239 Guide Set
24270 Ridge Reamer
Remove or Disconnect
• Ridge or deposits from the upper end of the cylinder
bores as follows:
a. Rotate the crankshaft until the piston is at BDC.
b. Place a cloth on top of the piston.
c. Perform the cutting operation with 24270.
d. Rotate the crankshaft until the piston is at TDC.
e. Remove the cloth and cuttings.
f. Repeat this procedure for each piston.
• Mark the cylinder numbers on the tops of each piston.

IMPORTANT
Marking them from the front to the rear,
with the engine in an upright position and
viewed from the front :
– The right bank is numbered l-3-5.
– The left bank is numbered 2-4-6.

SM 751 00(L)-2-17
Group 00(L), ENGINE

CRANKSHAFT REAR OIL SEAL CRANKSHAFT REMOVAL


REMOVAL Remove or Disconnect
NOTICE Inspect
When removing the crankshaft rear oil seals,
• Check the main bearing caps for location markings.
be careful to not damage the crankshaft seal-
Mark the caps if necessary. The caps must be returned
ing surface. A minor scratch can cause a
to their original locations during assembly.
major oil leak.
1. Main bearing cap bolts.
Remove or Disconnect 2. Main bearing caps and lower main bearing
• Crankshaft rear oil seal. Insert a screwdriver into the inserts.
notches provided in the seal retainer and pry the seat 3. Crankshaft from the cylinder block with
out (figure right). extreme care, taking care to avoid damage to
crankshaft journals and thrust flange surfaces.
4. Upper main bearing inserts.

MAIN BEARING REMOVAL (WITHOUT


REMOVING CRANKSHAFT)
Tool required:
8080 Main Bearing Remover/Installer
Remove or Disconnect
Inspect
• Check the main bearing caps for location markings.
Mark the caps if necessary. The caps must be returned
CRANKSHAFT REAR OIL SEAL
to their original locations during assembly.
RETAINER REMOVAL
1. Main bearing cap bolts.
Remove or Disconnect 2. Main bearing caps
• Screws (50) and nuts (51). 3. Lower main bearing inserts from the main
bearing caps.
• Seal retainer (52).
4. Upper main bearing inserts.
• Gasket (54).
a. Insert 8080 into the crankshaft oil hole (figure
above).
b. Rotate the crankshaft to turn the upper main bear-
ing insert out of the block.

SM 751 00(L)-2-18
Group 00(L), ENGINE

CLEANING, INSPECTION, AND REPAIR


NOTICE
Carefully remove all gasket material from the part using a plastic or wood scraper.
Use Loctite brand “Chisel Gasket Remover” (P/N 79040), Permatex brand “Gasket Remover” (F/N
4MA) or equivalent. Follow all safety recommendations and directions that are on the can.

Do not use any other method or technique to remove gasket material. from a part Do not use abrasive pads, sand paper or
power tools to clean gasket surfaces. These methods of cleaning can damage the part Abrasive pads also produce a fine
grit that the oil filter cannot remove from the oil. This grit is abrasive and has been known to cause internal engine dam-
age.

NOTICE
If the engine is damaged internally and needs to be rebuilt, make sure all foreign material is completely
flushed out of the cooling system/oil cooler system (if equipped).
Failure to flush out the debris can result in damage to the rebuilt engine.

SM 751 00(L)-2-19
Group 00(L), ENGINE

A solvent tank large enough to hold the larger engine parts - Cylinder walls.
will be needed as well as various bristle brushes and gas- - Coolant jackets.
ket scrapers. A source of compressed air will also be help- - Engine mount bosses.
ful in the cleaning operations.
- Main bearing webs.
Special tools are listed and illustrated throughout this sec-
4. Main bearing bores and caps.
tion with a complete listing at the end of the section.
These tools (or their equivalents) are specially designed to - All main bearing bores should be rounded and uni-
quickly and safely accomplish the operations for which form in ID at all of the bearing supports.
they are intended. They should not be used in operations - The area were the main bearing inserts contact the
for which they are not designed. These special tools, when main bearing bore should be smooth.
they are properly used, will also minimize possible dam- - if a main bearing cap is found to be damaged,
age to engine. replace the cap and linebore the block.
Some precision measuring tools are required for inspec- 5. Cylinder head mounting surface for flatness,
tion of certain critical components. These include using a precision straight edge and feeler gage (fig-
micrometers, torque wrenches, feeler gages, dial indicator ure right).
set, etc. The inspection work, when performed with the
- Set the straight edge on the sealing surface to be
proper methods and tools, is most important.
inspected.
The rebuilt engine cannot be expected to perform properly - Take the feeler gage and at various locations, check
if the parts are worn beyond acceptable limits are reused. the gap between the straight edge and the sealing
surface.
CYLINDER BLOCK - If the gap is greater than 0.05 mm (0.002 in.) within
152 mm (6 in.) at any sealing location, the block
Remove or Disconnect must be replaced.
• Oil pressure fitting and sensor. - If the gap is found to be less than 0.05mm(0.002in.)
• Coolant drain plugs. at any sealing location and a cause for leakage is
suspected, then the minor irregularities may be care-
• Oil filter adapter bolts.
fully machined from the block.
• Oil filter adapter and gasket
• Camshaft and balance shaft cup plugs (89).
• Front oil gallery cup plugs (86).
• Rear oil gallery plugs (87,88, and 90).
Clean
• Sealing material from mating surfaces.
• Boil cylinder block in caustic solution.
- Flush with clean water or steam.
• Cylinder bores.
• Threaded holes.
• Oil galleries and passages. 6. Oil pan, timing cover, and intake manifold mounting
surfaces for nicks. Minor irregularities may be
• Scale deposits from coolant passages.
cleaned up with a flat file.
• Spray or wipe cylinder bores and machined surfaces
with engine oil.
Inspect
1. All expansion plugs for lack of fit or leakage.
2. Valve lifter bores for deep scratches and deposits.
3. Cracks in the block.

SM 751 00(L)-2-20
Group 00(L), ENGINE

CYLINDER BORE CYLINDER BORE RECONDITIONING


Inspect • Measure the cylinder bore for out of round and taper
as outlined previously.
• Cylinder bores for scoring or other damage.
• Measure for wear at the top of the bore (point “A”)
• Cylinder bore taper and out-of-round.
and at the bottom (point “B”).

MEASURING CYLINDER BORE TAPER


AND OUT-OF-ROUND
Tool required
58087 Cylinder Bore Gage (or equivalent)
IMPORTANT
If one or more cylinder bores are rough,
scored or worn beyond limits, it will be neces-
sary to smooth or true up such bores to fit
new pistons.
No attempt should be made to cut down over-
size pistons to fit cylinder bored as this will • Cylinder bores can be measured by setting the cylin-
destroy the surface treatment and affect the der gage dial at zero in the cylinder at the point of
weight. The smallest possible oversize pistons desired measurement. Lock the dial indicator at zero
should be used and the cylinder bores should before removing from the cylinder, and measure
be honed to size for proper clearances. across the gage contact points with an outside
micrometer, with the gage at the same zero setting
• Refer to “Specifications” for tolerances. when removed from the cylinder (figure right).

• Set the gage so the thrust pin must be forced in about


7 mm (l/4 in.) to enter the gage in the cylinder bore.
• Center the gage in the cylinder and turn the dial to
“0”.
• Carefully work the gage up and down to determine
taper and turn it to different points around the cylin-
der wall to determine the outof- round condition.
Measure the bore both parallel to and at right angles
to the engine centerline. Measure at the top, middle,
and bottom of the bore and note the readings.
• Recondition the cylinder bore as necessary, as out- • If the cylinders are found to exceed the specified out-
lined later. of-round or taper, honing or boring will be necessary.
Any cylinders that were found to have less than 0.13
mm (0.005 in.) wear or taper may not entirely clean
up when fitted to a high limit piston. If it is desired to
entirely clean up the bore in these cases, it will be
necessary to rebore for an oversize piston. If more
than 0.13 mm (0.005in.)taper or wear,they should be
bored and honed to the smallest oversize that will per-
mit complete resurfacing of all cylinders.
• Fine vertical scratches made by ring ends will not, by
themselves, cause excessive oil consumption; there-
fore, honing to remove them is unnecessary.

SM 751 00(L)-2-21
Group 00(L), ENGINE

• Make sure the honing stones are clean, sharp, and HONING
straight Move the hone slowly up and down to pro-
duce a 46 to 66 degree crosshatch pattern. Clean the • When honing the cylinders, follow the hone manufac-
bore thoroughly with soap and water. Dry and rub in turer’s recommendations for use, cleaning, and lubri-
clean engine oil, then re-measure. cation during honing. Use only clean, sharp stones of
the proper grade for the amount of material to be
• If honing is not required, the cylinder bores should be removed. Dull, dirty stones cut unevenly and generate
cleaned with a hot water and detergent wash. Apply excessive heat. When using coarse or medium grade
clean engine oil to the bore after cleaning. stones, use care to leave sufficient metal so that all
stone marks may be removed with the fine stones
BORING used for finishing to provide proper clearance.

• Before the honing or re-boring operation is started, • Occasionally, during the honing operation, the cylin-
measure all new pistons with the micrometer contact- der bore should be thoroughly cleaned and the piston
ing at points exactly 90 degree from the piston pin selected for the individual cylinder checked for cor-
centerline. rect fit.
Some pistons must be measured at a specified dis- • When honing to eliminate taper in the cylinder, full
tance from the piston crown. Refer to the proper sec- strokes of the hone in the cylinder should be made in
tion for additional instructions. Then select the addition to checking measurement at the top, middle
smallest piston for the first fitting. The slight variation and bottom of the bore repeatedly.
usually found between pistons in a set may provide
for correction in case the first piston is fitted too NOTICE
loose. Handle the pistons with care and do not
attempt to force them through the cylinder
• Before using any type of boring bar, the top of the until the cylinder has been honed to the cor-
cylinder block should be filed to remove any dirt or rect size as the piston can be distorted
burrs. This is very important. If not checked, the bor- through careless handling.
ing bar may be tilted which would result in the
rebored cylinder wall not being at right angles of the • When finish honing a cylinder bore to fit a piston, the
crankshaft. hone should be moved up and down at a sufficient
• The instructions furnished by the manufacturer of the speed to obtain very fine uniform surface finish marks
equipment being used should be carefully followed. in a crosshatch pattern at the specified angle of 45” to
65’.
• When reboring cylinders, all crankshaft bearing caps
must be in place and tightened to the proper torque to • The finish marks should be clean but not sharp,free
avoid distortion of the bores in the final assembly. from imbedded particles and torn or folded metal.
Always make sure the crankshaft is out of the way of • By measuring the piston to be installed at the sizing
the boring cutter when boring each cylinder. point specified in the propersection, and adding the
Crankshaft bearings and other internal parts must be average of the clearance specification, the finish hone
covered or taped to protect them during the boring or cylinder measurement can be determined. It is impor-
honing operation. tant that the block and the piston be measured at room
• When taking the final cut with a boring bar, leave tempemture.
0.025 mm (0.001 in.) on the diameter for finish hon- • It is of the greatest importance that refinished cylinder
ing to give the required position to the cylinder clear- bores are trued up to have the less than specified out-
ance specifications. (The honing or boring operation of-roundtaper. Each bore must be final honed to
must be done carefully so the specified clearance remove all stone or cutter marks and provide a
between pistons, rings, and cylinder bores is main- smooth surface.
tained).
• Refer to “Specifications” in the proper section piston
to bore clearance tolerances.
• After final honing and before the piston is check for
fit, clean the bores with hot water and detergent.

SM 751 00(L)-2-22
Group 00(L), ENGINE

Scrub with a stiff bristle brush and rinse thoroughly PISTON DISASSEMBLY
with hot water. It is essential that a good cleaning
operation be performed. If any of abrasive material is NOTICE
allowed to remain in the cylinder bores, it will wear The connecting rod, bearing and cap need to
the new rings and cylinder bores in addition to the be stored together as mating parts, so they
bearings lubricated by contaminated oil. After wash- may be reassembled in the same position
ing, the dry bore should then be brushed clean with a from which they were removed.
power-driven fiber brush.
• Permanently mark the piston for the cylinder which it
has been fitted.
• Apply clean engine oil to each bore to prevent rusting.
NOTICE
For steps 2,4,5, and 6, refer to “Notice” on
page 1.

Install or Connect
1. Front oil gallery plugs (86).
IMPORTANT
Coat plug outside diameter with sealant (GM
P/N 1052080) or equivalent.

2. Rear oil gallery plugs (87,88, and 90).

Tighten
• Plug (87) to 30 N·m (22 lbs. ft.).
• Plug (88) to 40 N·m (30 lbs. ft).
• Plug (90) to 40 N·m (30 lbs. ft.).
3. Camshaft and balance shaft cup plugs (89) to proper
depth.
IMPORTANT
Coat plug outside diameter with sealant (GM
P/N 1052080) or equivalent.

4. Oil filter adapter, gasket, and bolts.

Tighten
• Bolts to 22 N·m (16 lbs. ft.).
5. Coolant drain plugs.

Tighten
• Plugs to 20 N·m (15 lbs. ft.)
6. Oil pressure fitting and sensor.

Tighten
• Fitting tighten with 11 N·m (97 lbs. in.) and if neces-
sary tighten for alignment more.

SM 751 00(L)-2-23
Group 00(L), ENGINE

Tool Required: 3. Connecting rod for cracks, nicks, etc. If a suitable jig
J 24086-B Piston Pin Remover and Jnstaller is available, check the connecting rod for a bent or
twisted condition.
Remove or Disconnect
4. Piston.
1. Piston rings. In most cases,the rings should be dis-
carded and replaced with new ones at assembly. • Ring land for cracking, wear, etc.
2. Connecting rod bearing inserts. If the inserts are to be • Ring grooves for burrs, nicks, etc.
reused, place them in a rack so they may be rein- • Skirts and pin bosses for cracking.
stalled in their original connecting rod and cap. • Skirts for scuffing.
3. Piston pin. 5. Connecting rod bearing inserts for scratches or deep
• Place the piston/connecting rod on support fixture pitting.
J2408620. Make sure the connecting rod is fully
supported. MEASURING PISTON PIN TO PISTON
• Press out the piston pin. CLEARANCE
Measure
1. Piston pin diameter. Check against “Specifications.”

2. Piston pin to piston clearance.


• Measure the piston pin hole diameter.
• Subtract the piston pin diameter from the piston pin
hole diameter to obtain the clearance.
• Replace the piston and piston pin if the clearance
exceeds specifications. The piston and piston pin are
a matched set and not available separately.
Clean
1. Piston.
• Remove all varnish and carbon deposits. Do not use
a wire brush
• Remove the carbon from the ring grooves.
• Oil control ring groove holes.
Inspect
1. Piston pin bore in the piston and connecting rod.
Check for scuffing, burrs, etc.
2. Piston for scratches wear, etc.

SM 751 00(L)-2-24
Group 00(L), ENGINE

PISTON SELECTION PISTON ASSEMBLY


1. Check the used piston to cylinder bore clearance. ASSEMBLING THE PISTON AND CONNECTING
ROD
Measure
Tool Required
• Cylinder bore diameter Use a telescoping bore gage,
J 24086-B Piston Pin Remover and Installer Set
located 65 mm (2.5 in.) below the top of the cylinder
bore. Install or Connect
• Piston diameter. Measure the piston skirt at a right 1. Piston and connecting rod.
angle to the piston pin, at the centerline of the piston
pin. • The valve cutouts in the piston crown must be oppo-
site the connecting rod bearing tangs.
• Subtract the piston diameter from the cylinder bore
diameter to determine piston to bore clearance. • Lubricate the piston pin holes in the piston and con-
necting rod with engine oil.
• Refer to “Specifications” in the proper section.
Determine if the piston clearance is in the acceptable • Install the pin guide to hold the piston and connect-
range. ing rod together. Be sure to use the proper pin guide.
Refer to the instructions supplied with the tool.
2. Piston pin.
• Insert the piston pin into the piston pinhole.
• Place the assembly on the support fixture.
• Adjust the piston pin installer (J24086-9) to the cor-
rect length, using the letter number scale on the
installer adjuster. This is necessary to ensure that the
piston pin is pressed into the piston to the correct
depth. Refer to the instructions supplied with the
tool for the proper setting.
• Lock the adjuster in place with the lock ring.
2. If the used piston is not acceptable, determine it a
new piston will fit the cylinder bore.
3. If a new piston does not bring the clearance within
tolerances, the cylinder bore must be reconditioned.
4. Mark the piston to identify the cylinder for which it
was fitted.

SM 751 00(L)-2-25
Group 00(L), ENGINE

NOTICE • Slip the outer surface of the top and second com-
After the installer hub bottoms on the sup- pres-sion ring into the respective piston ring groove,
port assembly, do not exceed, 35,000 kPa to make sure that the ring is free.
(5,000 psi) pressure, as this could cause dam- If binding occurs at any point, the cause should be
age to the tool. determined. If binding is caused by the ring groove,
correct by depressing the groove with a fine cut file.
• Place the adjuster in the support future. Press the If the binding is caused by a distorted ring, try a new
piston pin into place (until the adjustable installer ring.
bottoms in the support fixture).
• Remove the piston and connecting rod assembly
from the tool and check the piston for freedom of
movement on the piston pin.

INSTALLING THE PISTON RINGS


Figures 34 Through 36
Measure
1. Ring end gap as follows:
• Select rings comparable in size to the piston being Assemble
Used.
NOTICE
• Slip the compression ring into the cylinder bore and All compression rings are marked on the
press it down about 7mm (0.250 in.) above ring upper side of the ring. When installing the
travel. compression rings, make sure the Marked
Make sure the ring is square with the cylinder wall. side is toward the top of the piston
• Measure the space or gap between the ends of the
ring with a feeler gage. NOTICE
• Refer to “Specifications” in the proper section for The oil control rings are three piece
correct gap. types,consisting of two rails and an expander.
• If the gap between the ends of the ring is not as spec-
ified, remove the ring and try another for fit. 1. Expander.
2. Lower rail.
3. Upper rail.
4. Upper compression ring.
5. Lower compression ring.
• Flex all rings to make sure they are free. If binding
occurs at any point the cause should beGdetermined.
If binding is caused by the ring groove, correct by
dressing the groove with a fineGcut file. If binding is
caused by a distorted ring, try a new ring.

Inspect - Ring gaps must be 180° apart.


- Rail gaps must be 180° apart.
1. Ring fit as follows:
• Fit each compression ring to the piston on which it is
going to be used.

SM 751 00(L)-2-26
Group 00(L), ENGINE

Measure CAMSHAFT
• Ring clearance. Use a feeler gage. CompareG with IMPORTANT
“Specifications” in the proper section. Do not attempt to repair the camshaft,
replace it if damaged.
Whenever the camshaft is replaced, a new set
of lifters must also he installed.

Inspect
• Bearing surfaces and lobes for wear
• Sprocket.
• Keyway and threads.
- Galling
- Gouges
- Overheating
INTAKE AND EXHAUST MANIFOLDS • Camshaft journal diameters (figure 37), ReferG to
Clean “Engine Specifications” in the back of thisGsection for
proper diameters.
• Mating surfaces on intake manifold and cylinder
head.
• Excessive carbon buildup in the exhaustG passages of
the intake manifold.
• Scale and deposits from the coolant passagesG of the
intake manifold.
• EGR passage of excessive carbon deposits.
Inspect
• Manifolds for cracks, broken flanges, andGgasket sur-
face damage.
• Alignment of manifold flanges. Use a straightG edge
and feeler gage. If the flanges do notGalign, the mani-
fold is warped and should beGreplaced.

SM 751 00(L)-2-27
Group 00(L), ENGINE

CAMSHAFT BEARINGS Clean

CAMSHAFT BEARING REPLACEMENT • Camshaft bearing bores in the blockG Install or Con-
nect
Inspect
Tool Required
• Camshaft bearings for scratches, pits, or loose fitG in J 6098-01 Camshaft Bearing Remover and Installer
their bores. Replace the camshaft bearingsG if neces-
saty.
Remove or Disconnect
Tool Required
J 6098-01 Camshaft Bearing Remover and Installer
1. Rear camshaft plug.
2. Inner camshaft bearings. Use J 6098-01.
• Insert the pilot into the front camshaft bearing bore.
• Slide the puller screw, with the nut and washer,
through the pilot.
• Insert the bearing tool into the inner camshaft bear-
ing bore with the shoulder of the tool againstG the
NOTICE
bearing.
The outer camshaft bearings must be
• Hold the puller screw with a wrench.Turn the nut
installed first. These bearings serve as guides
with a second wrench to pull the camshaftG bearing
for the pilot, and help center the inner bear-
from its bore.
ings during the installation process.
• Repeat this procedure to remove the remaining inner
camshaft bearings. Note that the rearG inner bearing NOTICE
must be removed with the pilot fitted into the rear Besure to fit the correct cam bearing into the
camshaft bearing. bore. The cam bearing bores vary inGsize.
3. Outer camshaft bearing. Use J 6098-01.
1. Outer camshaft bearings. Drive the bearingsG into
• Assemble the bearing tool and driver handle.
place using J 6098–01.
• Drive the outer camshaft bearings out of theGblock.
IMPORTANT
Make sure the camshaft bearing hole (or
holes) align with the oil hole (or holes)Gin the
block. On some engines, the oilGholes may be
difficult to see. If so, useGa piece of 2 mm rod
to check alignment.

SM 751 00(L)-2-28
Group 00(L), ENGINE

2. Inner camshaft bearing. Use tool J 6098-01. TIMING CHAIN AND SPROCKETS
• Assemble the tool with the pilot engaged in the front Inspect
bearing and the pilot flange againstGthe front face of
the block. • Sprockets for chipped teeth and wear.
- Excessively worn sprockets will rapidly wear a new
• Slide the puller screw, with nut and washer, through
chain.
the pilot.
• Timing chain for damage.
• Place the new bearing on the bearing tool. Hold the
bearing tool and bearing against theGbearing bore. - An excessively worn chain will rapidly wear a new
Align the bearing oil hole with the oil hole in the set of sprockets.
block.
• Thread the puller screw into the bearing tool enough CRANKSHAFT SPROCKET
to hold the tool and bearing in place. REPLACEMENT
Holding the puller screw with a wrench, turn the nut
Tool Required~
with a second wrench to pull theG camshaft bearing
5825-A Crankshaft Sprocket Puller
into place.
5590 Crankshaft Sprocket installer
• Holding the puller screw with a wrench, turn the nut
Remove or Disconnect
with a second wrench to pull theG camshaft into
place. 1. Crankshaft sprocket using 5825–A.
• Remove the puller screw, pilot, and bearing tool. 2. Key (if necessary).

IMPORTANT Install or connect


Make sure the camshaft bearing hole (or 1. Key (if removed).
holes) align with the oil hole (or holes) inGthe 2. Crankshaft sprocket using 5590.
block. If it is difficult to see the alignment,
use a piece of brass rod as describedGin step 1.

3. Camshaft rear plug.


• Coat a new camshaft plug with sealer (Loctite #592
or equivalent).
• Install the plug flush to 0.80 mm (0.03125 in) deep.

SM 751 00(L)-2-29
Group 00(L), ENGINE

FRONT COVER Inspect

Clean • Coolant pump shaft for rotation and end play. The
shaft and fan hub should turn straight andG smoothly.
• Old gasket from the gasket surfaces. If the hub wobbles or the shaft is noisy or feels
Inspect “lumpy” when turned, replace theG coolant pump. If
the shaft end play exceeds 0.381 mm (0.015 in),
• Front cover for damage, dents, or cracks. replace the coolant pump.
Remove or Disconnect • Coolant pump body at the drain (weep) hole. Slight
1. Oil seal from the front cover. staining around the weep hole is normal.
Replace the coolant pump only if coolant is dripping
• Pry the seal out with a large screwdriver.
from the weep hole while the engine isG running or
• Be careful not to distort the front cover. while the system is pressurized.
Install or Connect
Tool Required: OIL PAN AND ROCKER ARM COVERS
J 35468 Front Cover Aligner aud Oil Seal
Clean
Installer
• Parts in solvent. remove all sludge and varnish.
1. New seal so that the open end of the sealG is toward • Old gaskets from the gasket surfaces.
the inside of the cover.
Inspect
• Support the cover at the seal area.
• Rubber grommets and parts on the rocker arm cover
• Drive the seal into position with 35468. for deterioration.
Lubricate the seal with engine oil before
• Oil pan for rock damage or cracks.
installing the torsional damper.
• Oil pan baffle for lack of fit.
• Drain plug threads for stripping.

OIL PUMP
Remove or Disconnect
1. Shaft Extension (1).
IMPORTANT
• Do not remove pickup pipe and screen
unless replacement is required.
• The pickup pipe has a press fit in to the
pump cover.
• Do not remove the screen from the pipe.
COOLANT PUMP The pickup screen and pipe are servicedGas a
complete assembly only.
Clean
• All gasket mating surfaces. Be sure old gasket mate- 2. Pickup pipe and screen (10).
rial is removed and free of oil or otherGforeign materi- 3. Screws (9).
als.
4. Pump cover (5).
NOTICE
IMPORTANT
Do not immerse the pump in solvent. The sol-
Mark where the idler gear (4) and drive gear
vent may enter the pump’s permanently
lubricated bearings and cause premature (3) mesh together, so they can beG reinstalled
bearing failure. with the same gear teeth indexed.

SM 751 00(L)-2-30
Group 00(L), ENGINE

5. Idler gear (4) and drive gear (3). • Pressure regulator valve (6) for fit. The regulator
6. Retaining pin (8). valve should slide freely in its bore withoutG sticking
or binding.
7. Pressure regulator spring (7).
Install or Connect
8. Pressure regulator valve (6).
Tool Required
21882 Rickup Tube and Screen Installer.
1. Pressure regulator valve (6) into the pumpGcover.
2. Pressure regulator spring (7) into the pumpGcover.
3. Retaining pin (8) into the pump cover.
4. Drive gear and shaft (3) into the pump body.
5. Idler gear (4) into the pump body.

IMPORTANT
Match together the index marks on theG two
gears made during disassembly.

Clean 6. Pump cover (5).


• All parts in clean solvent and dry them with com- NOTICE
pressed air. Refer to “Notice” on page 00(L)-2-1.
Inspect
7. Screws (9).
• Pump body (2) for cracks, wear, or other damage.
• Inside of the cover (5) for cracks and wear that would Tighten
permit oil to leak past the ends of theGgears. • Screws to 9 N·m (80 lbs·in)
• Gears (3 and 4) for wear. Inspect
• Drive gear and shaft (3) for lack of fit in the pump
• With the shaft extension (1) installed on the pump,
body (2).
turn the drive shaft by hand to check for smooth oper-
• The pump gears, cover, and body are not serviced ation.
separately.
NOTICE
If any of the parts are damaged or worn, the entire oil
Be careful of twisting, shearing, or collapsing
pump assembly must be replaced.
the pipe when installing it to the pump.
• Pickup screen and pipe (10) for damage to the screen A damaged pipe can cause lack of lubrication
or loose fit of the pipe. and engine failure.

SM 751 00(L)-2-31
Group 00(L), ENGINE

8. Pickup screen and pipe. HYDRAULIC LIFTERS


• If the pickup screen and pipe assembly was The type of hydraulic lifters used in this engine are the
removed, it should be replaced with a new part. Loss roller type. Hydraulic litters are serviced only as an
of press fit condition could result in an air leak and assembly. No internal parts are available.
loss of oil pressure.
• Mount the oil pump in a soft-jawed vise. IMPORTANT
• Service is limited to a disassembly and
• Apply sealer to the end of the pipe.
cleaning. Discard any valve lifter(s) that are
• Tap the pickup screen and pipe into place, using worn.
21882 and a hammer. • Whenever the camshaft needs to be
• The pump screen must be parallel with the bottom of replaced, a new set of hydraulic lifters must
the oil pan when installed. also be installed.
9. Oil pump drive shaft and connector (1).

VALVE TRAIN COMPONENTS


• Store all reusable components in an exact order, so
they may be reassembled in the same position from
which they were removed.

PUSHRODS, ROCKER ARMS, BALLS,


AND NUTS
Clean
• All parts in clean solvent and dry them with com-
pressed air.
• Make sure the oil passages through the pushrods are
clear.
Inspect
• Rocker arms and balls at their mating surfaces. These
surfaces should be free from wear or damage.
• Rocker arm areas that contact the valve stems and the
socket areas that contact the ends of the pushrods.
These areas should be free of wear or damage.
• Rocker arm nuts.
• Pushrod ends for scoring, roughness, or bends.
- Roll the pushrod on a flat surface to determine its
straightness. If the rod is bent, the rod will not roll
freely. Replace if necessary.

SM 751 00(L)-2-32
Group 00(L), ENGINE

CYLINDER HEAD

DISASSEMBLY
Tool required
J 8062 Valve Spring Compressor

Remove or disconnect
1. Valve keepers (67).
• Compress the springs with 8062 (figure
• Remove the keepers (67).
• Remove J 8062.
2. Intake valve components.
• Cap (68).
• Shield (69).
• Seal (71).
• Damper (72).
• Spring (73).
3. Exhaust valve components.
• Rotator (75) IMPORTANT
• Shield (69). • Place the valves (74 and 76) in an organizer
• Seal (71). rack so they can be replaced in their original
• Damper (72). position at reassembly.
• Spring (73).

SM 751 00(L)-2-33
Group 00(L), ENGINE

CLEANING AND INSPECTION NOTICE


Excessive valve stem to guidebore clearance
Clean will cause excessive oil consumption and may
Tools Required cause valve breakage. Insufficient clearance
J 8089 Wire brush will result in noisy and sticky functioning of
J 8101 Valve Guide Cleaning Tool the valve and disturb the engine’s smooth-
ness.
• Carbon from the combustion chambers. Use J 8089.
• Valve guides. Use J 8101.
• Valve stems and heads on a wire wheel.
• Carbon and old gasket from the cylinder head gasket
surface.

• Clamp a dial indicator (J 8001 or equivalent) on one


side of the cylinder head rocker arm cover gasket rail.

Inspect • Locate the indicator so movement of the valve stem


from side to side (crosswise to the head) will cause
• Cylinder head for cracks in the exhaust ports, com- direct movement of the indicator stem. The indicator
bustion chambers, or external cracks to the coolant stem must contact the side of the valve stem just
chamber. above the valve guide bore.
Gasket surfaces should be free of damage.
• Drop the valve head about 1.6 mm (0.0625 in) off the
• Valves for burning, pitting, or warpage. Refer to valve seat.
“Valve Grinding.”
• Move the stem of the valve from side to side using
• Check the valve stems for scoring or excessive wear. light pressure to obtain a clearance reading. If clear-
Stems must not be bent. ance exceeds specifications, it will be necessary to
• Rocker arm studs for wear, damage, or improper fit. ream the valve guide bores for oversize valves as out-
lined later in this manual.
• Valve seats for pitting or other damage. Grind or
reface as needed.
• Rotators. The rotators should rotate smoothly without
binding

Measure
Tools required
J8001 Dial Indicator (or equivalent)
J9666 Valve spring tester
1. Valve stem to guide bore clearance.

SM 751 00(L)-2-34
Group 00(L), ENGINE

2. Valve spring length. Replace the spring if the length Valve Seat Grinding
is not as specified.
Reconditioning the valve seats is very important because
the seating of the valves must be perfect for the engine to
deliver the power and performance built into it.
Another important factor is the cooling of the valve head.
Good contact between each valve and its will ensure that
heat will be properly carried away.
Several different types of equipment are available for
reseating valve seats. The recommendations of the manu-
facturer of the equipment being used should be carefully
followed to attain proper results.
Regardless of what type of equipment is used, it is essen-
tial that valve guide bores be free from carbon or dirt to
ensure proper centering of the pilot in the guide. Refer to
REPAIR “Specifications” for valve seat angle specifications.
Valve Grinding
Reaming Valve Guides
Pitted valves must be refaced to the proper angle. Valve
stems that show excessive wear, or valves that are warped The valve guides used in this engine are simply holes
excessively must be replaced. When an excessively bored in the cylinder head Therefore, the valve guides are
warped valve head is refaced, a knife edge will be ground not replaceable.
on part or all of the valve head due the amount of metal If the valve stem-to-bore clearance (as measured previ-
that must be removed to completely reface. Knife edges ously in this manual) is excessive, the valve guides should
lead to breakage, burning, preignition due to heat localiz- be reamed and a valve with an oversize stem installed.
ing on this knife edge.
If the edge of the valve head is less than 0.80 mm (1 in)
after grinding, replace the valve.
Several different types of equipment are available for
refacing valves. The recommendation of the manufacturer
of the equipment being used should be carefully followed
to attain the proper results.
Refer to “Specifications” for valve face angle specifica-
tions.

SM 751 00(L)-2-35
Group 00(L), ENGINE

Available oversize valves are as follows (nominal dimen- Tighten


sions are given):
• Rocker arm stud to 47 N·m (35 lbs·ft).
• INTAKE : 0.08 mm (0.003 in) A
0.38 mm (0.015 in)
0.76 mm (0.030 in) B
• EXHAUST : 0.08 mm (0.003 in)
0.38 mm (0.015 in)

Select a reamer that will provide a straight, clean bore


through the guide’s entire length. Reamer availability is as
follows (sizes given are nominal):
• J 5830–l 0.08 mm (0.003 in) oversize
• J 6621 0.13 mm (0.005 in) oversize
• J 5830–2 0.38 mm (0.015 in) oversize
• J 5830–3 0.76 mm (0.030 in) oversize
These reamers (except J 6621) also available in Reamer
Set J 5830-02.

ROCKER ARM STUD REPLACEMENT


The 4.3L engine has screw-in rocker arm studs with posi-
tive stop shoulders. You must follow the replacement pro-
cedures outlined below under “Screw-In Studs.” No valve
adjustment is necessary. When the valve train requires
service, you simply tighten the rocker arm nuts to 27 N·m
(20 lbs·ft).
Tools Required
J 5802–01 Rocker Arm Stud Remover
J 6880 Rocker Arm Stud Installer

Remove or Disconnect
1. Rocker arm stud by unscrewing using J 5802-01.
ASSEMBLY
NOTICE
Install or connect
Refer to ‘Notice” on page 00(L)-2-1.
1. Insert the valves(74 and 76) into the proper valve
Install or connect guides until the face of the valve contacts the valve
seat.
1. Rocker arm stud using J 6880.
2. Seal (71) (intake valves only).
• Install the seal (71) over the valve stem.
• Hold the valve (74) against the valve seat.
• Push the seal (71) down the valve stem until it bot-
toms out against the head.
3. Springs (73) and dampers (72).
4. Shields (69).
5. Cap (68) or rotator (75).

SM 751 00(L)-2-36
Group 00(L), ENGINE

IMPORTANT 3. If this measurement exceeds the amount given in


Compress the valve spring using 8062, “Engine Specifications,” install valve spring seat
enough so the lower valve stem groove can be shims, approximately 1.58750 mm (0.0625 in) thick,
seen clearly. between the spring and cylinder head.
NEVER shim the spring so as to give an installed
6. O–ring seal (70) onto the valve stem’s lower groove, height under the specified amount.
making sure the seal (70) is flat and not twisted.
• Apply a small amount of grease to the area of the THERMOSTAT AND COOLANT OUTLET
upper valve stem groove.
Remove or Disconnect
• Assemble the two valve keepers into the upper
groove using the grease to hold them in place. 1. Bolts.
• Release the compressor tool 8062, making sure the 2. Stud.
valve keepers stay in place. 3. Coolant outlet.
• Repeat the preceding steps on the remaining valves. 4. Gasket.
5. Thermostat (with gasket).

Inspect
• Coolant outlet for cracks.

Install or Connect
1. Thermostat
2. New gasket.
3. Coolant outlet.
NOTICE
Refer to “Notice” on page 00(L)-2-1.

4. Bolt.
Inspect
5. Stud
• O–ring seals for leakage (figs 57).
Tighten
- Place the suction cup supplied with 23738-A over
the shield. • Bolts to 28 N·m (21 lbs·ft).
- Connect 23738–A to the suction cup and apply a • Stud to 28 N·m (21 lbs·ft).
vacuum.
- Watch the vacuum pump gage, no air should be able TORSIONAL DAMPER
to leak past the seal.
- If the seal will not hold a vacuum, it may have been Inspect
damaged or improperly installed. • Torsional damper weight for signs of shifting on the
- Repeat the preceding steps on the remaining valves. hub. Replace as needed. Area of the torsional damper
hub shaft that contacts the front crankshaft seal for
Measure roughness or nicks. Replace the damper if this condi-
• Valve spring installed height of each spring as fol- tion exists. If damper is replaced, new balance
lows: weights of the same size must be installed on the new
damper in the same location as the old damper.
1. Use a narrow thin scale. A cut away scale may be
helpful.
2. From the top of the shim or the spring to the top of
the shield.

SM 751 00(L)-2-37
Group 00(L), ENGINE

CRANKSHAFT AND BEARINGS


Some engines may have rear main bearings that are
0.2032mm (0.008 in) wider than standard across the thrust
faces.
The crankshaft on these engines can be identified by
0.2032mm (0.008 in) stamped on the rear counterweight.

Clean
• Crankshaft with solvent.
- Do not scratch the bearing journals.
- Remove all sludge from the oil passages with com-
pressed air.
• Main bearing inserts.
- Wipe free of oil with a soft cloth.
ASSEMBLY OF THE ENGINE
Prior to assembly
Inspect
The importance of cleanliness during the assembly proce-
• Crankshaft for cracks. dure cannot be overstressed. Dirt will cause premature
- Use the magnaflux method, if available. wear of the rebuilt engine. Lubricate all moving parts
- Crankpins, main bearing journals and thrust surfaces lightly with engine oil or engine assembly lubricant
scoring, nicks or damage caused by lack of lubrica- (unless otherwise specified) during assembly. This will
tion. provide initial lubrication when the engine is started.
- Main bearing inserts for scoring or other damage.
CRANKSHAFT AND MAIN BEARING
Measure INSTALLATION
• Main bearing and connecting rod journal diameters.
Main bearings are of the precision insert type and do not
Compare with “‘Engine Specifications”
use shims for adjustment. If clearances are excessive, both
• Main bearing and connecting rod journals for taper upper and lower bearing inserts will be required. Service
and out-of-round. bearings are available in standardize and 0.0254 mm
(0.001 in), 0.0508 mm (0.002 in), 0.2286 mm (0.009 in),
• Maximum journal taper is 0.025 mm (0.001 in)
0.254 mm (0.010 in) and 0.508 mm (0.020 in) undersize.
• Maximum out-of-round is 0.05 mm (0.002 in)
Selective fitting of both rod and main bearing inserts is
• Crankshaft run-out. necessary in production to obtain close tolerances. For
this reason you may find one half of a standard insert with
- Mount the crankshaft in V-blocks or between cen-
one half of a 0.0127 mm (0.0005 in) undersize insert
ters.
which will decrease the clearance 0.0127 mm (0.0005 in)
- Use a dial indicator. from using a full standard bearing.
- If the main journals are misaligned, the crankshaft is
bent and must be replaced. The main bearings must Some engines may have rear main bearings that are
also be replaced at the same time. 0.2032mm (0.008 in) wider than standard across the thrust
faces. If there rear main bearings are replaced, they must
• Grind or replace the crankshaft if necessary. In gen- have the proper distance between thrust faces to obtain
eral, the lower inserts (except the #1 bearing) show proper distance between thrust faces to obtain proper
the greatest wear and distress from fatigue. Upon crankshaft end play.
inspection, if a lower insert is suitable for reuse, it can
be assumed that the upper insert is also satisfactory. If
a lower insert shows evidence of wear or damage,
both the upper and lower inserts must be replaced.

SM 751 00(L)-2-38
Group 00(L), ENGINE

INSPECTING CRANKSHAFT END PLAY the journal. Do not rotate the crankshaft while the
gaging plastic is between the bearing and journal.
Install or Connect
NOTICE
For steps 4 and 6, refer to “Notice” on page
00(L)-2-1.

1. Upper main bearing inserts to the block.


IMPORTANT
If any undersized bearings are used, they
must be fitted to the proper journals.

2. Crankshaft
3. Lower main bearing inserts to the main bearing caps.
3. Main bearing cap and bolts.
NOTICE
Refer to “Notice” on page 00(L)-2-1.

Tighten
• Bolts to Specification.

Remove or Disconnect
• Main bearing cap. DO NOT REMOVE THE GAG-
ING PLASTIC FROM THE JOURNAL OR LOWER
MAIN BEARING INSERT.

Measure
MEASURING MAIN BEARING CLEAR- • Gaging plastic as follows:
ANCE - The flattened gaging plastic will be found adhering
The simplest, most accurate way to measure main bearing to either