Chapter 5 DISASSEMBLY OF BASIC ENGINE

1. Cylinder heads and valve mechanisms - Disassemble and inspect................... 5-3

1.1 Fuel inlet connector - Remove.................................................................................................. 5-4
1.2 Nozzle assembly - Remove ...................................................................................................... 5-4
1.3 Valve clearance - Inspect ......................................................................................................... 5-4
1.4 Fuel injection timing - Inspect ................................................................................................... 5-5
1.5 Rocker shaft assembly - Remove............................................................................................. 5-5
1.6 Clearance between the bottom face of valve bridge pusher and the top face of valve rotator -
Inspect ...................................................................................................................................... 5-5
1.7 Valve bridge - Remove ............................................................................................................. 5-6
1.8 Rocker case - Remove ............................................................................................................. 5-6
1.9 Cylinder head assembly - Remove........................................................................................... 5-6
1.10 Valve sinkage - Measure .......................................................................................................... 5-6
1.11 Valve and valve spring - Remove ............................................................................................. 5-7
1.12 Nozzle gland stud bolt and bridge guide - Remove .................................................................. 5-7
2. Rear mechanism - Disassemble and inspect........................................................ 5-8
2.1 Flywheel face and radial runouts - Measure............................................................................. 5-9
2.2 Governor drive - Remove ......................................................................................................... 5-9
2.3 Flywheel - Remove ................................................................................................................... 5-9
2.4 Rear idler shaft thrust collar - Remove ................................................................................... 5-10
2.5 Timing gear case - Remove.................................................................................................... 5-10
2.6 Timing gear backlash - Measure ............................................................................................ 5-10
2.7 Rear idler gear end play - Measure ........................................................................................ 5-10
2.8 Rear idler gear - Remove ....................................................................................................... 5-11
2.9 Accessory drive - Remove...................................................................................................... 5-11
2.10 Camshaft end play - Measure................................................................................................. 5-11
2.11 Camshaft gear - Remove........................................................................................................ 5-11
2.12 Camshaft - Remove................................................................................................................ 5-12
2.13 Rear idler shaft - Remove....................................................................................................... 5-12
2.14 Rear plate - Remove............................................................................................................... 5-12
3. Front mechanism - Disassemble and inspect..................................................... 5-13
3.1 Fan drive assembly - Remove ................................................................................................ 5-14
3.2 Damper face and radial runouts - Measure ............................................................................ 5-14
3.3 Damper and crankshaft pulley - Remove ............................................................................... 5-14
3.4 Fan drive idler gear backlash - Measure ................................................................................ 5-15
3.5 Fan drive idler gear end play - Measure ................................................................................. 5-15
3.6 Fan drive idler gear and fan drive idler shaft - Remove.......................................................... 5-15
3.7 Pump plate (for water pump and oil pump) - Remove ............................................................ 5-16
3.8 Oil pump gear - Remove......................................................................................................... 5-16
3.9 Breather Case, Thermostat Bracket - Remove....................................................................... 5-16
3.10 Front gear case - Remove ...................................................................................................... 5-16
3.11 Water pump bearing cover and oil pump bearing cover - Remove ........................................ 5-17
3.12 Front idler gear backlash - Measure ....................................................................................... 5-17
3.13 Front idler gear end play - Measure........................................................................................ 5-17
3.14 Front idler gear - Remove....................................................................................................... 5-17
3.15 Front idler shaft - Remove ...................................................................................................... 5-18
3.16 Coupling - Remove ................................................................................................................. 5-18

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

4. Cylinder liner, piston and connecting rod - Disassemble and inspect ............ 5-19
4.1 Piston protrusion - Measure.................................................................................................... 5-20
4.2 Connecting rod end play - Measure........................................................................................ 5-20
4.3 Hard carbon deposits on the upper part of cylinder liner - Remove ....................................... 5-20
4.4 Connecting rod cap - Remove ................................................................................................ 5-20
4.5 Piston - Remove ..................................................................................................................... 5-21
4.6 Piston ring - Remove .............................................................................................................. 5-22
4.7 Piston pin and piston - Remove.............................................................................................. 5-23
4.8 Cylinder liner inside diameter - Measure ................................................................................ 5-23
4.9 Cylinder liner flange protrusion - Measure.............................................................................. 5-23
4.10 Cylinder liner - Remove .......................................................................................................... 5-23
5. Crankcase, crankshaft and main bearing - Disassemble and inspect ............. 5-24
5.1 Crankcase - Invert .................................................................................................................. 5-25
5.2 Crankshaft end play - Measure............................................................................................... 5-25
5.3 Piston cooling nozzle - Remove ............................................................................................. 5-25
5.4 Main bearing cap - Remove.................................................................................................... 5-25
5.5 Crankshaft - Remove.............................................................................................................. 5-26

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

1. Cylinder heads and valve mechanisms - Disassemble and inspect

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the
efficient work.
Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with
any job.
ŒValve clearance - Inspect
ŒFuel injection timing - Inspect
ŒClearance between the bottom face of valve bridge pusher and the top face of valve rotator - Inspect
ŒValve sinkage - Measure

1
15
3
Replace
4
Replace
Replace 5
Crack, oil leak,
2
settling
Replace
16 6
17 Wear
Crack, oil leak,
scale deposit
Replace Crack, carbon deposit, Replace
flaw, scale deposit
8
18
Wear, oil hole clogging
Flaw
19
11
Wear 10 14
9 Contact, wear
Wear at both ends,
12 29 bend
7
20 13 Stem and seat face wear,
20 corrosion, flaw, 31
21
24 carbon deposit
22 Cam contact face
25 and outer peripheral
23 Settling, crack
contact face wear
26
27
28 Crack, flaw, settling, Replace
30
rubber crack
Exhaust
Double spring spec
Cylinder heads and valve mechanisms - Disassemble and inspect
Disassembling sequence
1 Rocker cover 12 Bridge cap 23 Stem seal
2 Fuel inlet connector 13 Valve bridge 24 Valve rotator
3 Washer, nut 14 Push rod (24 to 28 exhaust double spring spec)
4 Nozzle gland 15 Water outlet connector 25 Inner valve spring
5 Fuel injection nozzle 16 Rocker case 26 Outer valve spring
6 Gasket 17 Cylinder head bolt 27 Lower retainer
7 Adjusting screw 18 Cylinder head (approx. 35 kg [77.2 lb]) 28 Stem seal
8 Bolt 19 Inlet port packing 29 Valve
9 Rocker arm 20 Valve cotter 30 Cylinder head gasket
10 Spacer 21 Valve rotator 31 Tappet
11 Rocker shaft 22 Valve spring
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Chapter 5 DISASSEMBLY OF BASIC ENGINE

1.1 Fuel inlet connector - Remove

Remove the fuel inlet connector.

Fuel inlet connector

Fuel inlet connector - Remove

1.2 Nozzle assembly - Remove

Nozzle gland

When removing the nozzle assembly using a nozzle Gasket

remover, be careful not to get caught your fingers
between the nozzle remover weight and bar and
plate.
Nozzle remover
P/N:33591-10101

Before removing the nozzle assembly, clean the noz-

zle assembly to prevent foreign matter from getting
into the cylinder head. Keep the nozzle and the fuel Nozzle assembly - Remove
inlet connector as a set, and handle the nozzle with
care to avoid damage to the nozzle tip.
(1) Remove the nozzle gland.
(2) Remove the nozzle holder using the nozzle remover.
(3) Remove the gasket remained inside the cylinder head.

1.3 Valve clearance - Inspect

Inspect the valve clearance, and know the current condition.
For the inspection procedure, refer to "Valve clearance -
Valve clearance
Inspect and adjust" of "ASSEMBLY OF BASIC ENGINE. "

Valve clearance - Inspect

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

1.4 Fuel injection timing - Inspect

Inspect the fuel injection timing, and know the current con-
dition. Pointer
For the inspection procedures, refer to "Fuel injection tim-
ing - Check and adjust" of "ASSEMBLY OF BASIC
ENGINE. " Line mark on
the flywheel

Fuel injection timing - Inspect

1.5 Rocker shaft assembly - Remove
(1) Loosen the adjusting screw of rocker arm.
Lock nut
(2) Remove the rocker shaft assembly from rocker case.
Note: Keep the removed rocker shaft assembly and the bolts
as a set.
(3) Remove the push rod. Loosen

Adjusting screw

Rocker shaft assembly - Remove

(4) Disassemble the rocker shaft assembly.
Note: Do not remove the rocker bushing unless it is defective Rocker shaft
or its inside diameter exceeds the limit. Rocker arm

Spacer

Lock nut
Adjusting screw

Rocker shaft assembly - Disassemble

1.6 Clearance between the bottom face of valve bridge pusher and the top face of valve rotator - Inspect
Inspect the clearance between the bottom surface of valve
bridge and the top surface of valve rotator, and know the Hold down the top of bridge by hand.
current condition. Valve bridge Bridge cap
For the inspection procedure, refer to "Clearance between Clearance between
Valve rotator valve bridge bottom
the bottom surface of valve bridge and the top surface of face and valve
rotator top face
valve rotator - Measure" of "ASSEMBLY OF BASIC
ENGINE. "

Clearance between the bottom face of valve bridge

and the top face of valve rotator - Inspect

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

1.7 Valve bridge - Remove

Remove the valve bridge and bridge cap.
Bridge cap
Note: Be careful not to drop the bridge cap into the cylinder Screw
head.

Valve bridge - Remove

1.8 Rocker case - Remove
(1) Remove the snap ring of water outlet connector.
Water outlet
(2) Slide the water outlet connector to the snap ring groove Rocker case connector Snap ring groove
side, and separate it from the next rocker case.
(3) Remove the rocker case from the cylinder head.

Rocker case - Remove

1.9 Cylinder head assembly - Remove

Eye nut
P/N:37591-02400
When removing the cylinder head gasket, be careful
not to damage the cylinder head or crankcase surface
with a screwdriver or the like.
(1) Remove the cylinder head bolts.
(2) Remove the cylinder head by lifting it up using the
sling.
Note: Dowel pins are used to retain the cylinder head in a
fixed position, and therefore, the cylinder head needs
to be removed perpendicular to the mounting surface. Cylinder head assembly - Remove
(3) Remove the cylinder head gasket.

1.10 Valve sinkage - Measure

Measure the valve sinkage, and know the current condition.
For the measurement procedure, refer to "Valve sinkage -
Measure" of "ASSEMBLY OF BASIC ENGINE."

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

1.11 Valve and valve spring - Remove

Using a valve spring pusher, compress the valve spring
evenly and remove the valve cotters.
Valve spring pusher
Note: If valves are reusable, mark each valve seat and the P/N:33591-04500
mating valve for identifying their original positions.
Do not change the combination of the valve seat and
the valve when reassembling.

Valve spring - Compress

Valve cotter
Valve rotator
Valve rotator
Inner valve spring
Valve spring
Outer valve spring

Stem seal
Lower retainer

Exhaust
double spring type

Exhaust side Inlet side

Valve and valve spring - Remove
1.12 Nozzle gland stud bolt and bridge guide - Remove
Do not remove the nozzle gland stud bolt and the bridge
guide from the cylinder head, unless they are defective.
Nozzle gland stud bolt
If they are removed, see "Nozzle gland stud bolt and bridge Bridge guide
guide - Inspect and replace" of "INSPECTION AND Bridge guide

REPAIR OF BASIC ENGINE."

Nozzle gland stud bolt and bridge guide -

Remove

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

2. Rear mechanism - Disassemble and inspect

Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the
efficient work. Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before
proceeding with any job.
ŒFlywheel face and radial runouts - Measure
ŒTiming gear backlash - Measure
ŒRear idler gear and camshaft end play - Measure

12
Replace: O-ring, gasket Flaw, wear

14

17
15
18 Clogging
13

Flaw, wear Peeling, wear

11
13
10
9 16
Crack, dowel
hole defect

16 10
12
11
7
Clogging, wear
6 Wear, flaw, aging
1 5
Crack, dowel hole defect,
6 8 flaw, abnormal wear
Electronic
governor spec

Flaw
2 5

3 3 Non-
Electronic Oil pressure attachment Hour meter
governor spec governor spec spec spec

Rear mechanism - Disassemble and inspect

Disassembling sequence
1 Pick up (Electronic governor spec) 10 Thrust plate
2 Hour meter (Hour meter spec) 11 Idler gear
3 Governor drive (Oil pressure governor spec) 12 Accessory drive (approx 21 kg [46 lb])
(Refer to the chapter "FUEL SYSTEM" for disassembly, in- (Refer to the chapter "FUEL SYSTEM" for disassembly, in-
spection and assembly.) spection and assembly.)
Cover (Electronic governor spec) 13 Camshaft gear
4 Flywheel (approx 140 kg [309 lb]) 14 Thrust plate
(Light weight spec: approx 104 kg [229 lb]) 15 Camshaft (approx 94 kg [207 lb])
5 Cover 16 Idler shaft
6 Thrust collar 17 Rear plate (approx 28.5 kg [62.8 lb])
7 Timing gear case (approx 150 kg [331 lb]) 18 Nozzle plate
8 Oil seal
9 Oil seal slinger

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

2.1 Flywheel face and radial runouts - Measure

Measure the face and radial runouts of the flywheel, and
know the current condition. Face runout
For the measurement procedure, refer to "Flywheel face and measuring
plane
radial runouts - Measure" of "ASSEMBLY OF BASIC
ENGINE."

Radial runout
measuring
plane

Flywheel face and radial runouts - Measure

2.2 Governor drive - Remove
(Oil pressure governor spec)
O-ring
Remove the governor drive from the rear plate.
(Refer to the chapter "FUEL SYSTEM" for disassembly,
inspection and assembly.)

Governor drive

Governor drive - Remove

2.3 Flywheel - Remove

(a) Be careful not to drop or bump the flywheel. It can,

not only cause damage to the part, but also lead
to personnel injuries.
(b) Be careful not to cut your hands with the ring gear
when pulling-out the flywheel.
Flywheel
Jack bolt
Be sure to remove the pickups before removing the P/N:64362-68500
(M12×1.25 mm)
flywheel. Flywheel - Remove
(1) Hitch a sling to the flywheel to prevent it from falling.
(2) Screw two jack bolts evenly into the jack bolt holes,
and remove the flywheel.

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

2.4 Rear idler shaft thrust collar - Remove

(1) Remove the cover from the timing gear case.
(2) Install the bolts (M6 × 1.0 mm) into the dedicated bolt
holes for removal of rear idler shaft thrust collar, and
remove the rear idler shaft thrust collar.
Note: Mark the collar right or left to ensure the correct back- Rear idler shaft
lash and end play on reassembling. thrust collar
Cover

Put a right and left

identification mark.
Rear idler shaft thrust collar - Remove
2.5 Timing gear case - Remove

Eyebolt
Be careful not to drop or bump the timing gear case. It P/N:05930-00200
(M12 × 1.25 mm)
can, not only cause damage to the part, but also lead
to personnel injuries.
(1) Hitch a sling to the timing gear case to prevent it from
falling.
(2) Lift the timing gear case to disengage the dowel pins
and remove the timing gear case. Timing gear case
(3) Remove the oil seal from the timing gear case.
Note: Replace the oil seal with a new one whenever it is re- Timing gear case - Remove
moved. The oil seal can not be re-used.

2.6 Timing gear backlash - Measure

Measure the timing gear backlash, and know the current
condition. Camshaft gear
For the measurement procedure, refer to "Timing gear back- Injection pump gear

lash - Measure" of "ASSEMBLY OF BASIC ENGINE."

Rear idler gear

Timing gear backlash - Measure
2.7 Rear idler gear end play - Measure
Measure the rear idler gear end play, and know the current
condition.
For the measurement procedure, refer to "Rear idler gear
end play - Measure" of "ASSEMBLY OF BASIC
ENGINE."

Rear idler gear

Rear idler gear end play - Measure

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

2.8 Rear idler gear - Remove

(1) Remove the oil seal slinger from the crankshaft.
(2) Remove the thrust plate.
(3) Remove the rear idler gears (right and left).
Thrust plate

Rear idler gear

Slinger
Rear idler gear - Remove
2.9 Accessory drive - Remove
Remove the accessory drive from the rear plate.
(Refer to the chapter "FUEL SYSTEM" for disassembly,
inspection and assembly.)
Note: Remove the rearmost cylinder cam cover on the left
side before removing the left side fuel injection pump
accessory drive case so that bolts do not interfere with
the cover.

Fuel injection pump accessory drive

Accessory drive - Remove

2.10 Camshaft end play - Measure
Measure the camshaft end play, and know the current condi-
tion. Camshaft gear
For the measurement procedure, refer to "Camshaft end
play - Measure" of "ASSEMBLY OF BASIC ENGINE."

Camshaft end play - Measure

2.11 Camshaft gear - Remove
Remove the camshaft gear from the camshaft.

Camshaft gear

Camshaft gear - Remove

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

2.12 Camshaft - Remove

Support the camshaft with a wood stick or the like

through the side cover. Remove the camshaft paying
attention not to damage the crank case and camshaft
bushing.
(1) Remove the thrust plate.
(2) Support the camshaft from the side cover mounting sec- Camshaft
Thrust plate
tion, remove the camshaft from the crankcase.
Note: Before removing camshaft, remove the oil seal case,
oil seal and coupling from the cam shaft front end. Camshaft - Remove

2.13 Rear idler shaft - Remove

Install the sliding hammer to the top face thread (M22 × 1.5
mm) for removal , and remove the rear idler shaft. Rear idler shaft

Sliding hammer

Rear idler shaft

Rear idler shaft - Remove

2.14 Rear plate - Remove
(1) Remove the rear plate from the crankcase.
(2) Remove the nozzle plate from the crankcase. Nozzle plate
Rear plate

Rear plate - Remove

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

3. Front mechanism - Disassemble and inspect

Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the
efficient work. Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before
proceeding with any job.
ŒDamper face and radial runouts - Measure ŒFront idler gear backlash and end play - Measure
ŒFan drive idler gear backlash and end play - Measure

Fan spec Crack, dowel hole defect

10
2 B A
7 PTAW
7
Without fan spec

5
1
B 6
A
Fan spec
12

8
Lip wear, flaw, aging

Crack, dowel hole defect 18

12
Crack, oil leak
11

17
4 16
19
15
Front power take-off
spec (pulley type)
13
Wear Lip wear

14 Lip wear Tachometer spec

4 9
Front power take-off Rotation
spec (shaft type) S16R2 Non-
Peeling, flaw, attachment
Replace: O-ring, gasket spline defect Oil hole clogging, wear spec

Front mechanism - Disassemble and inspect

Disassembling sequence
1 Fan (with fan spec: approx 60 kg [132 lb]) 9 Oil pump gear
(Big fan spec: approx 80 kg [176 lb]) 10 Front gear case (approx 70 kg [154 lb])
2 Fan drive assembly (approx 55 kg [121 lb]) (with fan spec) 11 Oil seal
(Refer to the section "COOLING SYSTEM" for disassembly, 12 Water coupling
inspection and assembly.) 13 Water pump bearing cover
3 Crankshaft pulley 14 Oil pump bearing cover
4 Damper (approx 50 kg [110 lb]), spacer 15 Thrust plate
5 fan drive idler shaft (with fan spec) 16 Idler gear
6 Fan drive idler shaft (with fan spec) 17 Idler shaft
7 Breather case (without fan spec) 18 Front plate (approx 25 kg [55 lb])
8 Pump plate 19 Oil seal case, coupling (with tachometer spec)
Note:(a) Fan, breather case and crankshaft pully differ according to the customization and specifications.
(b) The consisting parts of the damper differ according to the customization and specification.

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

3.1 Fan drive assembly - Remove

(With fan spec)
Remove the fan and fan drive from the front gear case.
3.2 Damper face and radial runouts - Measure
Measure the face and radial runouts of the damper, and
know the current condition.
For the measurement procedure, refer to "Damper face and
radial runouts - Measure" of "ASSEMBLY OF BASIC
ENGINE."

Face runout

Radial runout

Damper face and radial runouts - Measure

3.3 Damper and crankshaft pulley - Remove

Raise using a rope, etc.

Jack bolt Crankshaft pulley
Be careful not to drop or bump the damper. It can, (S16R: M14 × 1.5 mm)
not only cause damage to the part, but also lead to (S16R2: M12 × 1.25 mm)
personnel injuries.
(1) Install the guide bolt to the damper mounting thread on
the crankshaft.
(2) Hitch a rope to the groove of crankshaft pulley and sup-
port the crankshaft pulley. Screw two jack bolts evenly
into the jack bolt holes, and remove the crankshaft pul-
ley. Crankshaft pulley - Remove
(3) While supporting the damper with a sling, screw two
Jack bolt
jack bolts evenly into the jack bolt holes, and remove P/N:64362-68500
Guide bolt
the damper. (M12 × 1.25 mm)

Damper

Damper - Remove

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

3.4 Fan drive idler gear backlash - Measure

(With fan spec)
Measure the fan drive idler gear backlash, and know the
current condition.
For the measurement procedure, refer to "Fan drive idler
gear backlash - Measure" of "ASSEMBLY OF BASIC
ENGINE. "

Fan drive idler gear backlash - Measure

3.5 Fan drive idler gear end play - Measure
(With fan spec)
Measure the fan drive idler gear end play, and know the cur-
rent condition.
For the measurement procedure, refer to "Fan drive idler
gear end play - Measure" of "ASSEMBLY OF BASIC
ENGINE. "

Fan drive idler gear end play - Measure

3.6 Fan drive idler gear and fan drive idler shaft - Remove
(With fan spec)
(1) Remove the mounting bolts of gear case flange. Fan drive idler
shaft mounting
bolt

Gear case flange

mounting bolt
Gear case flange - Remove
(2) Insert your hand through the fan drive assembly mount-
ing hole, and support the fan drive idler gear. Fan drive idler gear
(3) Remove the gear case flange and the fan drive idler
shaft as a set.
(4) Remove the fan drive idler gear through the fan drive
assembly mounting hole.

Gear case flange

Fan drive idler gear and fan drive idler shaft - Remove

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

3.7 Pump plate (for water pump and oil pump) - Remove
Install two jack bolts evenly into the jack bolt holes, and
remove the pump plate.
Note: Remove the oil pump and water pump, then remove
the pump plate.
Refer to the chapter "OIL SYSTEM" for the removal
of oil pump.
Refer to the chapter "COOLING SYSTEM" for the re- Jack bolt
P/N:64362-68500
moval of water pump. (M12 × 1.25 mm)

Pump plate (for water pump and oil pump) - Remove

3.8 Oil pump gear - Remove
Remove the oil pump gear together with the bearing.
Oil pump gear

Oil pump gear - Remove

3.9 Breather Case, Thermostat Bracket - Remove
(Without fan spec)
PTAW
Remove the breather case or the thermostat bracket from the
front gear case. Thermostat
bracket

Breather case
Breather Case, Thermostat Bracket -
Remove
3.10 Front gear case - Remove

Eyebolt
05930-00200
When removing the front gear case, be careful not to (M12 × 1.25 mm)
damage the oil seal or not to distort the pointer by
hitting.
(1) Hitch slings to the front gear case.
(2) Pull the front gear case to disengage the dowel pins,
and remove the front gear case.
(3) Remove the oil seal from the front gear case. Front gear case

Front gear case - Remove

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

3.11 Water pump bearing cover and oil pump bearing cover - Remove
Remove the water pump bearing cover and oil pump bear-
ing cover from the front plate.
Water pump bearing cover

Oil pump bearing cover

Water pump bearing cover

oil pump bearing cover - Remove
3.12 Front idler gear backlash - Measure
Measure the front idler gear backlash, and know the current
condition.
For the measurement procedure, refer to "Front idler gear
backlash - Measure" of "ASSEMBLY OF BASIC
ENGINE."

Front idler gear

Front idler gear backlash - Measure

3.13 Front idler gear end play - Measure
Measure the end play of front idler gear, and know the cur-
rent condition.
For the measurement procedure, refer to "End play of front Front idler gear

idler gear - Measure" of "ASSEMBLY OF BASIC

ENGINE."

Front idler gear end play - Measure

3.14 Front idler gear - Remove
Remove the thrust plate and front idler gear from the front
idler shaft.

Front idler gear

Front idler gear - Remove

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

3.15 Front idler shaft - Remove

Do not remove the front idler shaft unless it is necessary. If
necessary, screw two jack bolts evenly into bolt holes, and
remove the front idler shaft.

Jack bolt
(M10×1.25 mm)

Front idler shaft - Remove

3.16 Coupling - Remove
(With tachometer spec)
(1) Remove the oil seal case and oil seal from the crank-
Oil seal case
case.
Note: Replace the oil seal with a new one whenever it is re-
moved. The oil seal can not be re-used.

O-ring
Oil seal

Oil seal case - Remove

(2) Screw two jack bolts evenly into the jack bolt holes,
and remove the coupling from the camshaft.

Jack bolt
(M12×1.25 mm)

Coupling - Remove

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

4. Cylinder liner, piston and connecting rod - Disassemble and inspect

Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the
efficient work.
Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with
any job.
ŒPiston protrusion - Measure
ŒConnecting rod end play - Measure
ŒCylinder liner inside diameter - Measure
ŒCylinder liner flange protrusion - Measure

Wear, flaw

5
9
6
7

Outer peripheral surface scratch,

crack, flaw, carbon deposit
10

8
11 Crack, oil hole clogging
Inner surface scratch, wear,
outer surface/O-ring groove
rust, cavitation

Inner face wear, 12

flaw, discoloration
Replace.
deformation, wear

Inner and outer surface flaw,

seizure, peeling
4
Serrated portion wear,
crack 3

1
Flaw

Cylinder liner, piston and connecting rod - Disassemble and inspect

Disassembling sequence
1 Connecting rod cap bolt 7 Oil ring
2 Connecting rod cap 8 Snap ring
3 Lower connecting rod bearing 9 Piston pin
4 Upper connecting rod bearing 10 Piston
5 No. 1 compression ring 11 Connecting rod
6 No. 2 compression ring 12 Cylinder liner (S16R: approx 16 kg [35 lb])
(S16R2: approx 19 kg [42 lb])

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

4.1 Piston protrusion - Measure

Measure the piston protrusion, and know the current condi-
tion. Piston protrusion

For the measurement procedure, refer to "Piston protrusion -

Measure" of "ASSEMBLY OF BASIC ENGINE."

Piston protrusion - Measure

4.2 Connecting rod end play - Measure
Measure the connecting rod end play, and know the current
condition.
Connecting rod
For the measurement procedure, refer to "Connecting rod
end play - Measure" of "ASSEMBLY OF BASIC
ENGINE."

Connecting rod end play

Connecting rod end play - Measure

4.3 Hard carbon deposits on the upper part of cylinder liner - Remove

Hard carbon
Be sure to remove hard carbon deposits from the
upper part of the cylinder liner before pulling-out the
piston. Hard carbon deposits, if not removed, cause
damage to the piston and piston rings. Cylinder liner

Remove hard carbon deposits from the upper part of cylin-

der liner using a carbon remover (e.g. scraper, sandpaper,
etc.)
Note: Be careful not to damage the inner surface of the cyl-
inder liner. Hard carbon deposits on the upper part of cylinder
liner - Remove
4.4 Connecting rod cap - Remove
Using a socket wrench, remove the connecting rod bolts
through the inspection window on the side of the crankcase,
and remove the connecting rod cap and connecting rod bear-
ings. Connecting rod cap
Note:(a) Be careful not to damage the connecting rod bear-
ings by dropping them into the oil pan.
(b) Make marks, such as cylinder number and upper or
lower, on the removed connecting rod bearings to
ensure the correct reassembly.

Connecting rod cap - Remove

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

4.5 Piston - Remove

When holding the connecting rod with your hand to prevent it from swinging, be very careful, as you may suffer
hand injuries from accidental movement of the connecting rod.

(a) When pulling-out the piston, be careful not to drop the upper connecting rod bearing.
(b) Use care not to damage the cylinder liner by the swing of the connecting rod when pulling-out the piston and
connecting rod from the cylinder liner.
(c) When only a few pistons remain in the cylinders, the crankshaft tends to turn by weight imbalance. Be sure to
hold the crankshaft to prevent it from rotating while removing pistons.
(d) When removing the piston, be careful not to allow connecting rod to hit the piston cooling nozzle.
(e) When pulling-out piston from cylinder liner, support the piston so that it does not swing. If piston swings, it can
result in piston inner surface hitting the connecting rod, causing damage to the piston.

4.5.1 Removing the piston with chain block lifting

Eyebolt
(1) Remove the connecting rod cap and rotate the crank- P/N: 37591-02500
shaft to bring the piston to the top dead center position. (M10 × 1.25 mm)
(2) Install the eye bolt to the threaded hole on the piston
top, and support the piston to prevent from falling
down.
(3) Rotate the crankshaft to place the crank pin slightly
near to the inspection window so that the connecting
Weight of piston and
rod big end does not contact the cylinder liner. connecting rod assembly:
Crankpin approx 24 kg [53 lb]
(4) Gently pull-out the piston by making sure that the con-
Removing the piston with chain block lifting
necting rod big end slides into the cylinder liner.

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

4.5.2 Removing the piston with pushing-up the con- Eyebolt

necting rod big end P/N: 37591-02500
(M10 × 1.25 mm)
(1) Remove the connecting rod cap and rotate the crank-
shaft to bring the piston to the top dead center position.
(2) Install the eye bolt to the threaded hole on the piston
top, and support the piston to prevent from falling
down.
(3) Rotate the crankshaft gently until the crankpin is dis- Weight of piston and
placed from the connecting rod and the lower bolt hole connecting rod
assembly:
Crankpin approx 24 kg [53 lb]
can be seen trough the inspection window.
Crankshaft - Rotate
(4) Insert a bar wrapped with cloth, and push up the bottom
of connecting rod gently, using the crankpin as a ful-
crum.
Note: Protect the crankpin and connecting rod big end with
cloth or rubber to prevent the damage with the bar.
(5) Push-up the connecting rod and piston while adjusting
Wrap in cloth
the supporting position.
When the oil ring is slide out of the cylinder liner, gen- Turning bar
tly sit the oil ring on the top face of cylinder liner.
(6) Lift the piston using the eye bolt on the piston top, and
pull-out the piston from the cylinder liner. Connecting rod big end - Push-up
4.6 Piston ring - Remove

Ring expander
When removing the piston ring, be careful not to get P/N:37191-03200

caught your fingers between the piston and connect-

ing rod by rocking movement of the piston.

If the piston is forcibly moved and interfered with the

connecting rod, the piston can be damaged.
Hold the piston and connecting rod in a vise, and remove
the piston rings using a ring expander. Piston ring - Remove

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

4.7 Piston pin and piston - Remove

(1) Remove the snap ring using ring pliers.
(2) Place a piece of wood against the end face of piston pin
and lightly tap with a hammer to remove the piston pin,
and separate the piston from the connecting rod.
Note:(a) Do not tap the piston pin directly with a hammer.
(b) If the piston is stubborn, heat the piston with a heat-
er or in hot water.

Piston pin and piston - Remove

4.8 Cylinder liner inside diameter - Measure
Measure the cylinder liner inside diameter, and know the
current condition. Cylinder liner
For the measurement procedure, refer to "Cylinder liner
inside diameter - Measure" of "ASSEMBLY OF BASIC
ENGINE."

Cylinder liner inside diameter - Measure

4.9 Cylinder liner flange protrusion - Measure
Measure the cylinder liner flange protrusion, and know the
Bolt, P/N:37591-06300 Cylinder liner
current condition. Tightening torque flange protrusion
For the measurement procedure, refer to "Cylinder liner 98 N·m {10 kgf·m}
[72 lbf·ft]
flange protrusion - Measure" of "ASSEMBLY OF BASIC
ENGINE."

Liner pusher
P/N:37591-06200
Cylinder liner flange protrusion - Measure
4.10 Cylinder liner - Remove
(1) Set the cylinder liner remover to the cylinder liner.
Note: Use care not to hit the piston cooling nozzle when set- Cylinder liner remover
Removing stroke
80 mm [3.15 in.]

ting the remover plate to the bottom of cylinder liner. P/N:37591-04100

(2) Rotate the handle, and remove the cylinder liner.

Cylinder liner

Cylinder liner - Remove

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

5. Crankcase, crankshaft and main bearing - Disassemble and inspect

Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the
efficient work.
Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with
any job.
ŒCrankshaft end play - Measure

11
Local contact/crack on
counterbore,
fretting/corrosion on
Scale deposit, flaw, fitting bore of cylinder liner
crack, oil hole clogging
Replace

Valve operation,
oil hole clogging, 2
Replace Flaw
bend of oil discharge
pipe, deformation 8

Wear
10

9
Inner and outer
peripheral face flaw, Peeling, wear, contact
corrosion, peeling 6
7
Wear, flaw, crack 4
Wear

5
Crack

Flaw

3
1

Crankcase, crankshaft and main bearing - Disassemble and inspect

Disassembling sequence
1 Main bearing cap bolt 5 Lower thrust plate 9 Eye bolt
2 Side bolt 6 Crankshaft (approx 620 kg [1367 lb]) 10 Piston cooling nozzle
3 Main bearing cap (approx 16 kg [35 lb]) 7 Upper main bearing 11 Water drain cock
4 Lower main bearing 8 Upper thrust plate 12 Crankcase (approx 1850 kg
[4079 lb])

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

5.1 Crankcase - Invert

Using a turn table, invert the crankcase. When the turn table
Weight of crankcase and
is not available, hitch slings to the crankcase using wood crankshaft assembly: approx 2615 kg
[5765 lb]
pieces and cloth pads, and raise the crankcase with a hoist or
crane and lay it on the wooden block with its side facing
downward. Then, change the positions of the slings, and
turn over to invert the crankcase.

Crankcase - Invert
5.2 Crankshaft end play - Measure
Measure the crankshaft end play, and know the current con-
dition.
For the measurement procedure, refer to "Crankshaft end
play - Measure" of "ASSEMBLY OF BASIC ENGINE."

Crankshaft end play - Measure

5.3 Piston cooling nozzle - Remove
Remove the piston cooling nozzle from the crankcase.

5.4 Main bearing cap - Remove

Main bearing cap

When removing the main bearing cap from the crank-
case, be careful not to damage the lower main bearing
Eyebolt
or the lower thrust plate attached to the cap. Also be P/N:37791-02100
careful not to drop those parts from the cap, which (M27 × 1.5 mm)
may damage the crankshaft.
(1) Remove the main bearing cap bolts and side bolts. Side bolt
(2) Install the eye bolts to the outer bolt holes on the main
Main bearing cap bolt
bearing cap.
(3) Give a light shake, and remove the main bearing cap by Main bearing cap - Remove
raising gradually.
(4) Remove the lower thrust plate from the rearmost main
bearing cap.

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

5.5 Crankshaft - Remove

(a) Before removing the crankshaft, remove the front Crankshaft assembly
side upper thrust plate first, and be careful not to
let it fall into the crankcase.
(b) When placing the crankshaft onto a pallet or other
stands, be careful not to damage the crankshaft.
Once placed on a pallet, place some support to
prevent the crankshaft from moving.
(1) Push the mating face of the front upper thrust plate,
rotate the thrust plate and remove. Crankshaft - Remove
(2) Suspend the crankshaft in a horizontal position, and
slowly lift the crankshaft upward.
Note: Do not hitch a chain directly onto the crankshaft, as it
could damage the crankshaft. Place cloth belts or pads
in the positions before lifting the crankshaft.
(3) Remove the upper main bearing from the crankcase,
paying attention to the lug position, and remove the
upper thrust plate on the rear side.

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