& NISSAN SERVICE MANUALQUICK REFERENCE INDEX aa aaa ae EG TT a Te a) Model LD20 & LD28 ne EM Diesel Engine A ae Ae Ug Lc FOREWORD CHOY Ea NS This service manual has been prepared pri- marily for the purpose of assisting service Anais ff personnel in providing effective service and maintenance of the model LO20 & L028 diesel engine for vehicles. This manual ineludes procedures for main- tenance, adjustments, removal and installa- tion, disassembly and assembly of com- ponents, and trouble-shooting. All information, illustrations and specifica- tions contained in this manual are based on the latest product information available at the time of publication. If your engine dif fers from the specifications contained in this manual, consult your NISSAN/ DATSUN dealer for information. The right is reserved to make changes in specifications and methods at any time with out notice NISSAN MOTOR CO, LTD. © 1981 NISSAN MOTOR CO, LTD,(@5__HOW_TO_USE THIS MANUAL >This Service Manual is designed as a guide for servicing diesel engines for vehicles. > A QUICK REFERENCE INDEX is provided on the first page. Refer to this index along with the index of the particular section you wish to consult, > The first page of each section lists the contents and gives the page numbers for the respective topics > SERVICE DATA AND SPECIFICATIONS are contained in each section. D> TROUBLE DIAGNOSES AND CORRECTIONS are included in ET section. This feature of the manual lists the likely causes of trouble and recommends the appropriate corrective actions to be taken. DP A list of SPECIAL SERVICE TOOLS is included in each section. The special service tools are designed to assist you in performing repair safely, accurately and quickly P The measurements given in this manual are primarily expressed with the SI unit (International System of Unit), and alternately expressed in the metric system and in the yard/pound system. D In the text, the following abbreviations are used S.0S.. Service Data and Specitications Ls Left Hand o Tiantaning Torque FLM.: Right Hand D The captions CAUTION and WARNING warn you of steps that must be followed to prevent personal injury and/or damage to some part of the engine. IMPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the mechanic and the efficient functioning of the engine. The service methods in this Service Manual are described in such a manner that the service may be per: formed safely and accurately Special service tools have been designed to permit safe and proper performance of service. Be sure to use them. Service varies with the procedures used, the skills of the mechanic and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first completely satisfy himself that neither his safety nor the engine's safety will be jeopardized by the service method selected.e903 4108 auvanvis 293 NOLLY907 M3EWNN TwINas 3NIONI 40 3NDYOL ONINALHOLL 293 SNOILWOISIOAdS: SLN3LNOO B 13 Fe eRe TS 1VYINIS INIDNISpecifications Engine Serial Number Location - ENGINE GENERAL SPECIFICATIONS Engine model L028 L020 Cylinder arrangement nine Number of eylinders 6 4 Valve arrangement OHS. Bore x stroke mm(in) | 84.5% 83.0 (3.327 x3.268) 85.0 x 86.0 (3.346 x 3.286) Displacement em? (eu in) 2,792 (170.37) 1,952 (119.11) Firing order 153624 1342 Compression 2 Number of piston rings oi 1 ‘Number of mein bearings 7 5 Compression ratio 20 22.2 Cetane numberof diesel fue! More than 45 ENGINE SERIAL NUMBER LOCATION The engine number is stamped on the right side of the cylinder block Lb28 XXXXXX Serial No, Engine model (LD20 or LD28) sciosENGINE GENERAL - Tightening Torque of Standard Bolt TIGHTENING TORQUE OF STANDARD BOLT Sake Tatearine orm cod Nominal size rch om — Nm kgm fb 6 so 70 34 | 03-04 | 22-20 135 ai | 08-14 | 58-80 we so 1 a | oats | seo _ —| } = 1s om |is22 | 26 « itt 100 125 we | 1622 | 126 78 we.26 | 27-37 | 20-27 wa v0 | 38 yo. | at-an ae ma 1s wr | 47-63 So to 37 | 06-07 | 125 wie [tate | wos 80 18 [ete [tate | wo I a [a3 [2636 | 26 n m0 100 | vas m3 | 27-37 | 20-27 75 won| sea ome v0 125 woe | s1-e9 | 37-50 ma vo 1s 76.105 | 77-105 | 56-76 6 60 10 o | oats | 58-80 138 wa [192s | wie we 80 10 7 | aeras | isc20 13 ae-s0 | ar-sa | a7-a7 or wo 100 vas wn | aoaa | mae 175 s.08 | 66-00 | «0-05 we 220 1 mar [vase | ae wa 140 is 109-147 [tna 150 | 00-108 1, Semi parse nchded. ¥ 2 Ritatce omen cototaneinge on Met totonin mats omboned on te bolt hd ae : ‘ 3 EG3sv-la- ea - za za za * aa” 13 tha Ce 6-13 613° 3 13 * $1001 3o1nuas Wioaas sa Yalta ONIOvT43u aNY ‘SNOLLENNOD USLWM Nivua ‘831113 ans ONDO3HD NV sasonovia 318N0uL 4-43 “'"" HOLVNOS3Y ONY U3LTId_YaNV3TO Serr" 3DHOL ONINALHOLL Biv ONIDVTE3H ONY SNINVST “" Nanusnray ONY NO!L93ESNI 93 $312Z0N NOILD3¢NI : ‘SNOLLVOISIDadS ONLSNraY ONY ONILSIL NY Viva 3O1AUaS 4a "aad WAWIXVIN ONY +21 gong MOTO ONIXDSHO 3101 ONLSNFaY ANY ONIND3HO ; AUBLLVE_ONINDSHD sua ONIWLL NOLLO3FNI WALSAS TV91NL9373 ONLISNraW ONY ONIYDIHS SAVI1 YOS WO 3NIONI ONIXDSHD saa W3LSAS Tan4 GNV NOLLO3INI M3114 GNV 110 3NIDN3 ONIONWHO 3 NOISS3¥4NOD 3NION3_ONIXOSHD ~** SWB HOd SNOLLD3NNOD ONY ea “"" 13@ 3Alua 38011 WILSAS ONITOOD ONINDSHD ONIuSAray ONY ONIXOSHO “7° INW1GO9 3NION3_ ONIONVHO zu 3ONVUWITD 3ATWA ISNYHXa W3LSAS ONY 3¥VANI ONLISNrov NOLLV9INEN GNY DNIT009 z-43 SLAN GTOSINYWY ‘SL108 © syW37 HOS (219 ‘s0199uU09 Qv3H Y3QNIIAD ONINSLHOILIY *6uid1d“sosoH) S3NIT-13N4 ONIND3HO 43 ~ WBULSAS TVOINVHOaW oISva SLN3LNOO dn-INNl INIDNI © ymgimatusus spomig pe sesge maneBasic Mechanical System — ENGINE TUNE-UP. BASIC MECHANICAL SYSTEM RETIGHTENING CYLINDER HEAD BOLTS, MANIFOLD NUTS CYLINDER HEAD BOLTS 1. Run engine until coolant temper- ture indicator points to the middle of gauge, then stop engine. 2. Remove valve rocker cover. 3. Using Tool, tighten cylinder head bolts according to the order shown in figure, starting with the center and moving toward the ends. 4. Install valve rocker cover. ® : Valve rocker cover bolt 6-9N-m (0.6 -0.9 kgm, 43-65 ft-lb) MANIFOLD AND EXHAUST TUBE NUTS WARNING: Do not check the exhaust sy until it has cooled off. Otherwise, you may burn yourself. seMas0 TIGHTENING TORQUE: Unit Nm kgm ftlb Bott (10) 32-36 33-37 24-27 Manifold (Ms) 17-21 17-21 12-15 Nut 17-21 17-21 12-15 Exhaust tube 26 - 36 27-37 20-27 eT-2 isassemble the intake ma ADJUSTING INTAKE AND EXHAUST VALVE CLEARANCE ‘a. Adjustment should be made while engine is hot. b. Adustment cannot be made while & When rocker cover is removed to adjust intake and exhaust valve clearance, check elongation of tim- ing chain. For details, INSTALLING TIMING CHAIN in EM section, To adjust, proceed as follows: 1, Remove valve rocker cover. 2. Set No. 1 cylinder at Top Dead Center on its compression stroke. 3. For LD20 engine, adjust clearance of half of the valves. Adjust ©, @, @ and © valves. For LD28 engine, adjust ©, @, ®, ©, ®and © valves. 4. Set No. 4 (for LD20) or No. 6 (for LD28) cylinder at Top Dead Center on its compression stroke. 5. For LD20 engine, adjust ®, © , @ and ® valves. LD20 From] op] ty | € IN 025mm (0010in) © EX 030mm (0.012 in} LD28 e_at rT Front| Tooln | a Ut ee @ © IN 0.25 mm (0.010 in) © EX 030mm (0.012 in} smazsse.ENGINE TUNE-UP — Basic Mechanical System For LD28 engine, adjust @ , @ , D+ @, Dand ® valves ‘Valve clearance (Hot): Intake 0.25 mm (0.010 in) Exhaust 0.30 mm (0.012 in) (1) If the clearance is not specified value, loosen pivot lock mut and turn valve rocker pivot to provide proper clearance. (2) Hold valve rocker tighten pivot lock nut using Tool. pivot and 49-59 Nm (5.0-60kgm, sMa6s1| 6. Install valve rocker cover. @ : Valve rocker cover bolt 6-9Nm (06 -0.9kg-m, 43-65 ttib) CHECKING AND ADJUSTING DRIVE BELT 1. Visually inspect for cracks or damage. The belts should not touch the bottom of the pulley groove. 2. Check belt tension by pushing it ‘The belts should deflect by the spe- cified amount. Drive belt deflection mm (in) Used belt deflection Si datnconet Limit ‘Adjust deflection new belt }+13* 8-12 (0.43 -0.51) (0.31-0.47) Alternator 15 (0.59) 12-14% 10-12 (0.47-0.55) | (039-047) - 12-13 9-11 AlCcompressor | 14 (0.55) (47-051) | (035-043) 8-85 7-8 P/S oil pump 90.35) (0315-0335) | (0.28-0.31) Pushing force: 98 N (10 kg, 22 Ib) * For 430 and C31 models equipped with LD28 ** For 910 and C120 models equipped with LD20 Power Idler pulley steering pump Water Alternator pump Crank compres pulley ‘SMA2608] 3. Adjust belt tension as follows: FAN BELT 1. Loosen alternator bracket bolts and adjusting bar bolt 2. Move alternator until fan belt tension is within the specified range Then tighten bracket bolts and adjust- ting bar bolt. sMA6s2 AIR CONDITIONER COMPRESSOR BELT 1, Loosen idler pulley lock nut. 2. Turn idler pulley adjusting bolt in either direction until air conditioner compressor belt's tension is within specified range. 3. Tighten idler pulley lock nut. POWER STEERING PUMP BELT 1, Loosen idler pully lock nut. 2. Tum idler pulley adjusting bolt in. either direction until power steering. pump belt’s tension is within specified range. 3, Tighten idler pulley lock nut. £13Basic Mechanical System — ENGINE TUNE-UP CHECKING ENGINE COMPRESSION 1, Run engine until water temper ture indicator points to the middle of gauge, then stop engine 2, Remove following parts: © Spill tube assembly Injection tubes on nozzle side Nozzle assemblies swagss CAUTION: Remove nozzle washer with 2 tweezers. Do not forget to remove this washer; otherwise, it may get lost whem the engine is cranked. 3. Fit compression gauge adapter to eylinder head. Make sure bleeder screw of gauge is closed 4. Crank engine and read gauge i cation ¢- Run engine at about 200 rpm. ‘¢ Engine compression measurement should be made as quickly as possi: ble. eT4 Compression pressure: Unit: kPa (bar, kg/om? , ps)/200 rpm Standan)_ | 3.138 014,32, 455 Minimum | 2452 (245,25,356)_ Differential | limb | a90¢ 49, 5, 7 cylinders 5. Cylinder compression in cylinders should not be less than 80% of the highest reading. If cylinder compression in one or more cylinders is low, pour @ small quantity of engine oil into cylinders through the nozzle holes and retest compression, f¢ If adding oil helps the compres: sion pressure, chances are that piston rings are worn or damaged. ‘© If presture stays low, valve may be sticking o seating improperly ‘© If eylinder compression in any two adjacent cylinders is low, and if ‘adding oil does not help the com- pression, there is leakage past the ‘gasketed surface il and water in combustion cham- bers can result from this problem. CHANGING TIMING BE 1. Remove fan shroud 2. Remove the following belts. ‘© Alternator drive belt © Air conditioner compressor drive belt ‘© Power steering oil purnp drive belt 3. Set No. 1 cylinder at TDC. on its compression stroke. Make sure that grooves: in rear plate and drive plates are aligned with each other Make sure that No. 1 cam of camshaft isin the position as shown, 1 1 q 1 1 ] ] ] I 4. Remove front side engine parts. Fan, Tem-coupling and fan pulley ‘© Remove crank damper pulley by lightly tapping around it. it is difficult to remove, use a puller. Front dust cover 5. Remove tensioner shaft and spring set pin, hen remove tensioner pulley. My Tensioner pulley is fastened with a ; finersatenspengpn) semar7 6. Remove timing bet. 7. Visually check the condition of I the timing belt. If any abnormalities are noted, check and correct. [ J es: iENGINE TUNE-UP ~ Basic Mechanical System Trem 0 check Problem Coe Batis broken. improper handling Poor belt cover sealing Z Coolant takage at ter pum sewsoaa Tooth i broken/ «Injection pump tooth root in wacked + Domoged S QB crankshaft ol seal seuaoaa Back surface is = Tensioner amning uckedlnorn. = Overhead engine ‘Interference with & elt cover semaosa 8. Confirm that No. 1 cylinder is set at T.D.C. on its compression stroke that can be rotated smoothly. 9. Confirm 10. Install the position, 11. Install timing belt (1) Align both timing belt and crank pulley. tensioner pulley tensioner in “free” timing marks of (2) Properly align timing mark of pump pulley with that of timing belt. ‘Side surface is ‘Improper installation of belt ‘= Maifunctioning crank pulley piate/ timing belt plate Le ta # Sige surface of belt is worn to such an ex tent that there is no ace of cutoff per- formed during manu- facturing process Belt corners ave worn and round, (2 Wicks are frayed and coming out SeMa96 Teeth are worn ‘Poor belt cover seokna LO lp ‘* Coolant leakage at = EA water pump ‘riection pump not functioning properly «.canvas on tooth face is| © Excessive belt worn down, tension + Canvas on tooth Oit/Cootant o water is stuck tobelt ~S 20 protruding portions fluffy, rubber layer is worn down and faded white, or wett is worn down and invisible. ‘SEM397A '*Poor oil sealing of ch oil seal '* Coolant leakage a! water pump. '* Poor belt cover sealing Ensure timing belt is clean ‘and free from oil or water, Do not bend it. 12. Loosen spring set pin and ten- sioner so that belt is automatically set to “tension” position 13. Tighten spring set pin @: Tensioner shaft and spring set pin 30-40 Nm (3.1-4.1kg-m, 22-30 ft4b) eTSInjection and Fuel System — ENGINE TUNE-UP_ INJECTION AND FUEL SYSTEM CHECKING AND ADJUSTING INJECTION TIMING Refer to installation of injective pump in Section EF. CHECKING AND ADJUSTING IDLE AND MAXIMUM SPEED cauTio! Do not remove sealing wires unless absolutely necessary. S| Laaw Folin siting CW" Seesse b, Disturbing full-load adjusting screw adjustment will change fuel flow characteristics, resulting in an im- properly adjusted engine. Readjust- ment of fuel injection pump should be done using a pump tester. ¢. If maximum speed adjusting screw is turned in direction that increases control lever angle, engine damage may result, IDLE ADJUSTMENT 1. Start engine and warm it up until coolant temperature indicator points to middle of gauge. 2. Attach tachometer’s pickup to No. 1 fuel iniection tube In order to take accurate reading of engine rpm, remove clamp that secures No. 1 fuel injection tube. 3. Start engine and check engine idle speed. [At this time, make sure the accelerator wire and throttle control wire are removed. Idle speed (rpm) MIT 650 AIT 700 4, If engine idle speed is not within the specified value, proceed as follows. (1) Loosen idle adjust screw lock nut. (2) Turn idle adjust screw in either direction until the specified engine idle speed is obtained. (a smasce (3) Tighten idle adjust screw lock nut. 5. Fix the accelerator wire and throttle control wire. Do not stretch wires too tightly. THROTTLE CONTROL WIRE ADJUSTMENT 1. Turn throttle control knob fully counterclockwise 2. Make sure that clearance between idle control lever pin and fuel injection pump control lever is within specified range Clearance: 1.2mm (0.04 - 0.08 in) Throttle control wire adjusting nut ales. SeF663 (0.04 0.08 in) 3. If not within specified range, adjust with throttle control wire adjusting nut 4. After adjusting clearance proper- ly, tighten lock nut F.L.C.D. ADJUSTMENT 1. Make certain that the clearance between the idle control lever pin and the injection pump control lever is within the specified limits. 2. Adjust idle speed to specified rpm without the air conditioner operating. 3. Then check the idle speed when the air conditioner is operating and make sure it is correct. Unit: rpm 800 Idle speed (Air con- ditioner “ON”) If not, adjust it by turning F.1.C.D. actuator stroke adjusting screw.MAXIMUM SPEED ADJUSTMENT Maximum speed adjusting wire is retained by sealing wire and need not be adjusted under normal circum- stances. However, if it should become necessary to adjust it, the following procedure should be followed: 1. Start engine and warm it up until coolant temperature indicator points to middle of gauge. 2. Connect tachometer’s pickup to No. 1 fuel injection tube. To obtain accurate reading of ‘engine rpm, remove clamp that secures No. 1 fuel injection tube. 3. Turn maximum speed adjusting screw fully clockwise. ‘Maximum speed adjusting screw 4. Depress the accelerator pedal fully under no load and, at this point, read engine speed indication. ‘Specified maximum engine speed (Under notoad): 5,300 rpm 5. If indication is lower than speci- fied maximum engine speed, turn maximum speed adjusting serew counterclockwise 1 or 2 rotations. Then depress accelerator pedal to floor ENGINE TUNE-UP — /njection and Fuel System under no load and, at this point, read indication. 6. If indication is still lower than specified speed, repeat step 5 above until specified engine speed is reached 7. After adjustment, tighten lock nut securely. 8. Slide a sealing sleeve over max. speed adjusting screw, and wind up with a wire F596 TESTING AND ADJUSTING INJECTION NOZZLES WARNING: When using nozzle tester, be careful not to allow diesel fuel sprayed from nozzle to come into contact with your hand or body, and make sure that your eyes are properly protected. 1, Clean and check nozzles. SMA747 2. Install nozzle to injection nozzle tester and bleed air from flare nut. 3. Check initial injection pressure by pumping tester handle one time per second. Initial injection pressure: 12,259 - 13,239 kPa (122.6 - 132.4 bar, 125 - 135 kg/cm’, 1,778 - 1,920 psi) New nozzle initial injection pressure: 13,239 - 14,024 kPa (132.4 - 140.2 bar, 135 - 143 kg/em?, 1,920 - 2,033 psi) The new nozzle is not required to adjust initial injection pressure. 4. To adjust change adjusting shims, injection pressure, a. Increasing the thickness of adjust: ing shims increases initial injection pressure. Decreasing shim thickness reduces initial injection pressure. b. A. shim thickness of 0.04 mm (0.0016 in) corresponds approxi- mately to a difference of 471 kPa (4.71 bar, 4.8 kg/em*, 68 psi) in initial injection pressure. 17Injection and Fuel System -ENGINE TUNE-UP ‘Adjusting shim sMa6so 5. Check spray pattern by pumping tester handle one time per second. 3. Install filter element and air clean- er cover. RESONATOR (For LD28) If resonator makes noise, drain water by loosening resonator bottom screw smas7a| Remove fuel filter, using Tool. ee ESE) 6. Inadequate fuel spray pattern or Wrong, drips from nozzle and is often due to improper contact of needle with seat. If such a failure is experienced, service injection nozzle. When servicing noz- zle, refer to Injection Nozzle Assembly in section EF. EF7948 CLEANING AND REPLACING AIR CLEANER FILTER AND RESONATOR AIR CLEANER 1. Remove air cleaner cover and filter element. 2. Wipe inside of air cleaner housing and cover with a damp cloth ETS CHECKING FUEL FILTER, DRAIN WATER AND REPLACING FILTER This filter includes priming pump and fuel filter sensor. Type A Priming pump. Fuel filter sensor sMas72 Type pas “Priming pump Bieter Lh oe (TTD Fuet iter Fuel filter sensor ‘Drain cock ‘smaosos, Reuse the fuel filter sensor. Replacing fuel filter 1. Remove fuel filter sensor and drain fuel. 3. Install fuel filter sensor to new fuel filter. 4, Install fuel filter to priming pump. 5. Bleed Refer to Section EF for fuel system bleeding instructions. Start engine and check for leaks. Drain water 1, Set a container under fuel filter. 2. For type A, loosen bleeder screw and remove fuel detector senosor and drain water. 3. For type B, loosen drain cock and drain water. 4. Bleed air. Refer to section EF for bleeding fuel system. For type B, bleeder screw or cock does not need to be loosened because ‘automatically enters from the dr: passage. Loosening drain cock 4 to 5 turns causes water to start drainin Do not remove drain cock by loosen ing it excessively. CHECKING FUEL LINES (Hoses, piping, connectors, etc.) FOR LEAKS Check fuel lines for loose connec- tions, cracks and deterioration. Re- tighten loose connections; if necessary, replace any damaged or faulty parts.ENGINE TUNE-UP — Cooling and Lubrication System COOLING AND LUBRICATION SYSTEM CHANGING ENGINE COOLANT WARNING: To avoid being scalded, never at: tempt to change the coolant when engine is hot. When changing engine coolant, on heater-equipped models, set heater “TEMP” control lever at fully “HOT” position. 1. Open drain cock at bottom of radiator, and remove radiator cap 2. Remove cylinder block drain plug located at left rear of cylinder block. 3 | = SMAG75 3. Drain coolant completely. Then flush cooling system. 4. Close drain cock and plug. 5. Fill radiator and reservoir tank with coolant to the specified level. When using anti-freeze coolant, mix the antifreeze coolant with water, observing instructions attached to anti: freeze container, sMa676 6. Run engine for a few minutes. Then stop engine, and check coolant level. If necessary, add coolant. Check for coolant leaks. CHECKING COOLING SYSTEM HOSES AND CONNECTIONS FOR LEAKS Check hoses and fittings for loose connections or deterioration. Retighten or replace if necessary CHECKING RADIATOR CAP Using cap tester, check the radiator cap relief pressure. If the pressure gauge drops rapidly and excessively, replace the radiator cap. su.cost CHECKING COOLING SYSTEM FOR LEAKS Attach pressure tester and pump tester, and apply specified pressure Check for drop in pressure If pressure drops, check for leaks from hoses, radiator, or water pump. If no external leaks are found, check heater core, block and head. CHANGING ENGINE OIL AND FILTER 1. Run engine until water tempera- ture indicator points to the middle of gauge, then stop engine 2. Remove oil filler cap and oil pan drain plug, and allow oil to drain. WARNING: Be careful not to burn yourself, as the engine oil may still be hot. ‘© A milky oil indicates the presence of cooling water. Isolate the cause and take corrective measures. An oil with extremely low viscosity indicates the presence of gasoline. eT9Cooling and Lubrication System —- ENGINE TUNE-UP 3 plug with washer. D : Oil pan drain plug 20-29 Nm (2.0 -3.0kg-m, 14-22 ft-lb) 4. Using Tool, remove oil filter. 7. Install new oil filter. Screw in oil filter until a slight resistance is felt, then tighten additional 2/3 of a turn. 8. Refill engine with new engine oil, referring to Recommended Lubricants. Approximate oil refill capacity Unit: liter (Imp 0) b. Run engine until water tempera- ture indicator points to the middle of gauge. Then stop engine and check oil level with dipstick. If necessary, add engine oil, ¢, When checking oil level, park the car ona level surface. Refil oto “Heel, Donot overfl aes ee L Without ot | With oi! filter chage [Fiter change 290 [ascse| as S {ci [36 G1 [4303 g[s0 [4363 |soasm cr [43.63 | 506-3) 719320000 suctsa 5. Wipe oil filter mounting surface with a clean rag. 6. Smear a little engine oil on rubber lip of new oil filter. ‘SMA010 ET-10 isMa679 a. Start engine. Check area around drain plug and oil filter for any sign of oil leakage. If any leakage is evident, these parts have not been properly installed. CHECKING ENGINE OIL FOR LEAKS Check cylinder head, front engine cover, oil pan, oil pump, oil filter gasket, etc. or other parts for sign of leaks past their gasketed surfaces. If necessary, replace gaskets or faulty parts. After maintenance has been done, check replaced parts to see if any leaks occur.ENGINE TUNE-UP — Electrical System CHECKING BATTERY WARNING : Do not expose the battery to flames or electrical sparks. Hydrogen gas generated by battery action is ex- plosive, Do not allow battety fluid to come in contact with skin, eyes, fabrics, or painted surfaces. If the acid contacts the eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention, In freezing weather, run the engine for while after adding distilled water, to make ‘sure that the water mixes properly with the fluid. Otherwise the water may freeze and damage the battery. VISUAL CHECK 1. Rusted battery support. 2. Loose terminal connections. 3. Rusted or deteriorated terminals. 4. Damaged or leaking battery. ELECTRICAL SYSTEM ‘Translucent battery Fluid level should be between ‘Read top level with scale, CHECK ELECTROLYTE GRAVITY 1. Place the hydrometer in the cell Be sure the float is not in contact with the cylinder wall 2. Take enough electrolyte into the hydrometer to allow the float to suspend freely between the top and bottom of the cylinder. 3. Read indication. Fully charged Permissible |vaiue (at 20°C sMazi8 value (68°F)] 7a Fred | ovwri22| 128 Tropical | 4 CHECK ELECTROLYTE climate | Over 1-18] 12 LEVEL Other Check the fluid level in each cell. gjimates | Over 1.20 | 1.26 If necessary , add only distilled water. upper and lower levels gMa2to swaza1 Black battery NG. OK. NG. St irir Indicator sma220 CHECKING GLOW PLUGS 1. Remove glow plugs from cylinder head. 2. Apply battery voltage (over 10V) to glow plug and see if it will tum red within 15 seconds. If it takes too much time to tum red, replace it sMacst eTService Data and Specifications - ENGINE TUNE-UP. SERVICE DATA AND SPECIFICATIONS INSPECTION AND ADJUSTMENT BASIC MECHANICAL SYSTEM COOLING SYSTEM AND LUBRICATION SYSTEM Radiator cap relief pressure Vawsediies intake 0.25 (0010) Pe tbr, keglon?.pal) 82 (0.88, 09, 13) Hot me Gnd Test 0:30 (0012) Cooling system leakage testing pressure 152 (1.57, 16,23) a 3.38 Pa bar, ko/em?, pi " Seenceed (31.4,32, 458) coterie CComprestion presure 2482 Approximate oil refill eapacity i mbar, egem?, pai) | Minimuen Jats titer (mp at Pa bar, kalem?, pid | a oe! ie a Winoutentiter [yg Ditterentat mit | 490(49,5,71) aaa With ot filter change [a0 38 0.3/8) 450) rive ion 8 Drive lett deflection a tie 3 [er20 360178) 430.94) attr omc g [= 430%) 50 4318) Set detection § ae | ee cat 42034) 50 (4378) i re = ELECTRICAL SYSTEM 0.43-051 | 31-047) onen 15 (059) Frit | Tropical | other tae | 10.12 or climate | climate | climate (047-058) | 0.29-047) & [ermasibie oie | Over't.22 | Overtae | Owr120 12-13 on & Alccomressor | 1410 & = 85) | (o.47-051 | (0.35-043) F | cal ahwresd wien & | Fully craroe ze | 12 | 126 a ae ae § [tor 20°C e071) PIS oil pum 90361 eee ©35) lio.315 0.335) | (0.28-0.31) Pushing force: 98 N (10 kg, 22 Ib) TIGHTENING TORQUE + For 490and C31 models equipped with L028 + For 910 and C120 models equipped with LO20 Unie Nims fc tom tet Cylinder head bole ve-127 | 12-19 | 97-94 INJECTION AND FUEL SYSTEM Rocker cover 6-9 06-09 | 43-65 mio | 32-36 | 33-37 | 24-27 eT-412 tte reset L028 L020 Manifold mission ma | 7-21 | 72a | 12-15 Injection timing | MT | 8.7.0.¢. 5°/650 | 8,7.0.c. 7°/650 Alternator 43-58 | 44-9 | 32-43 ‘and idle speed degree/cpm | A/T | 6.7.0.c.5°/700 | 8.7.0.c. 7°/700 Iniection pumo ting | agg | xe-21 | 12-45 Idle speed of air conditioner | MT Injection tube 22-25 | 22-25 | 16-18 Sone an 800 fo) Spill tube 15-18 | ts-18 | 11-13 TShia Elestion brome Nozzle fixing nut we-21 | 16-21 | 12-15 kPa (bar, kg/em?, psil Oil pan drain plug 20-29 | 20-30 | 14-22 Nast 13,239 - 14,024 (192.4 - 140.2, 135 - 143, 1,920 - 2,033) Glow plug 20-25 | 20-25 | 14-18 12,259 - 13,239 (1226 - 132.4, Glow plug connecting Used : : 125 - 135, 1.78 - 1,920) plate LORS | OtTOnE | OF Tensioner shaft 31-41 | 22-30 Spring set pin 30-40 | 31-41 | 22-30ENGINE TUNE-UP — Trouble Diagnoses and Corrections TROUBLE DIAGNOSES AND CORRECTIONS Condition Check points Cc <> Action Cc Probable cause system with scale, ct Read optever y F Ox. 1 ‘Check timing mark of injection pump ‘and front cover, \, Crank engine and check compression pressure. | ‘Ignition switch, ‘Starting circuit. ‘Starter motor. Cheek points. manana ‘Valve lip seal worn. ‘Piston or piston ring worn. ‘© Valve stem or valve seat worn. © Cylinder gasket damaged. OK. NOTO. Repair or repla ‘*Glow timer. *Glow plug. @ sMare S32 'sMa720 NOT O.K. ox. NOTOK. J ox ET-13Trouble Diagnoses and Corrections - ENGINE TUNE-UP. ¢ 1s fuel delivered to injection pump? Ox. elongated? [Oe rors (Location notch senoar xo. YES. Check valve clearance OK, notox. | Gheek points Circuit. ‘© Function, jo @ Cheek injection SMA731 ‘* Fuel injection pattern. OK. NOT OK. Clogging. Sticking Replace. # Injection pressure. y___ NOT OK. Hoes detirony. oes st ‘Adjust, repair or replace ox. NOTOK. Inspection points. ‘© Rusted or tardy movement of feed pump vane. ‘© Weak, broken, worn or rusted plunger spring. ‘© Abnormal wear on cam disc, eT14 ‘Overhaul injection pump. Inspection points. ‘© Rusted or tardy movement of feed pump vane ‘© Weak, broken, or rusted regulating valve spring. «Low setting pressure of regulating valve, ‘* Weak or broken delivery valve spring. ‘© Poor seating at delivery valve seat ‘* Weak, broken, worn, or rusted plunger spring. ‘* Malfunction of governor lever. ‘© Broken or weak timer spring. ‘© Rusted or tardy movement of timer piston. ‘¢ Weak or broken governor spring. ‘¢ Maladjusted injection quantity. ‘© Abnormal wear on camENGINE TUNE-UP ~ Trouble Diagnoses and Corrections FUEL SYSTEM on rer ena es a3 CIR >| ok No ves. | ) Check idle | ‘Check valve clearance. speed. t cz) ‘Check engine mounting. a i i fe ox worox| ‘OK. ox. norox ¥ Purge air and drain water ox. ET-15Trouble Diagnoses and Corrections - ENGINE TUNE-UP ‘Check injection nozzle. Check points. ‘© Fuel injection pattern. Clogging « Sticking. see =) Ox. NOT OK. ¥ Does delivery valve stick? No. ‘Overhaul injection pump. Inspection points. ‘* Rusted or tardy movement of feed pump vane, ‘* Weak, broken, or rusted regulating valve spring. '* Low setting pressure of regulating valve © Weak or broken delivery valve spring, ‘© Poor seating at delivery valve seat. ‘© Weak, broken, worn, or rusted plunger spring. ‘# Malfunction of governor lever. ‘* Broken or weak timer spring. ‘© Rusted or tardy movement of timer piston. ‘* Weak or broken governor spring. ‘© Maladjusted injection quantity. © Abnormal wear on cam disc ET-16ENGINE TUNE-UP ~ Trouble Diagnoses and Corrections EXCESSIVE WHITE or BLACK SMOKE FUEL SYSTEM MECHANICAL SYSTEM ‘Check timing ma front cover. f injection pump and Black smoke or white smoke? (Biace smote) | White smokey No. le "J teair cleaner element clogged? -—— Ox. No. Check for oil or similar material in or on tail pipe. Cove vey |__| OK. | chit smoke) (Black smoks) : ‘Crank engine and check compression pressure. ‘Check points. ‘© Cylinder head gasket damaged. « Piston or piston ring worn, «Valve stem or valve seat worn. ‘© Valve lip seal worn, Ox. ox. | NOTOK. (Black smoke) (White smoke) 1s valve timing chain elongated? ‘Cheek points © Nozzle worn. * Spring worn. # Injection pressure. No. (White smoke) Does delivery valve stick? @« eTA7abla 297 WI ma PRT ° Uo4019 “POA & anyyap 18 BUNIEOS 1004] @ ‘duund wonsafur neys240 | ; ‘XO LON | Oo ‘e019 10 BOM 10} Buds anea ABATED 7208 ¥0 ‘ dN-ANNL ANIDNA ~ 8429281709 pue sesouberg ayqno4,ENGINE TUNE-UP — Trouble Diagnoses and Corrections NOISY ENGINE. c r AT INJECTION ENGINE ( FROM CYLINDER ) AUDEN AT FAN Check fan for exacks. 1 FROM ENGINE IT- SELF (CYLINDER : ‘Check engine Check cylinder head maaan bolt. is Check injection OK. | NOT O.K. OK. |NOTOK, OK] NOTOK | Te is BE seca, } Cai sheet som. t 4 rs 4 Ganka bento ‘Check injection ‘Check for gas leakage. ‘Ox. ] NOT OX. Siti, timing. A ‘Adjust Ox. | NOTOR] ox] SOTO. | 1. ee Replace —— head eo x , gasket Ta Check compression + NO . pressure. Check valve ‘© Check piston and clearance, + (Hest) Beton tog for OK] NOTOK Check alter for bearing play. # Check vave seat armatere shat + + ‘Check injection ‘Check water pump. nozzle. oe ¢ Check body assem- ‘Fuel injection pat- biy and vane for tern rust formation or + Clogging nozzle. corrosion. * Damage ste. + Check end play or # Injection pressure. roughness of bear- in operation. Ox.|NOTOK, ee : Check injection pump, Refer to EF section, —T-19Trouble Diagnoses and Corrections - ENGINE TUNE-UP €T-20 OIL LEAKAGE ‘OIL PUMP ENGINE COMPONENT Check mating areas of oil pump and front cover. Check rocker cover Ox. NOTOK Retighten or replace. OK NOT OK t ‘ Check regulator valve. ] ‘Check mating areas of eylinder block and soraE cylinder head OK. : Retighten or replace = NoTOX. t Replace gaiket ‘Check oil pump body for cracks or damage. Ox, NOTO. ir + ‘Check oll pump cover mounting ar noroK ox + ‘Check areas around blind plug at cylinder block’s oil gallery, Retighten or replace.» OK. NOT OK. | OK, NOT OK. 4 Sot aiyacteayamighie tal OK. NOT OK. t Gack cond OK. NOT OK. Retighten or replace gasket. | Check areas around rear plate OX. NOT OK. ¥ 7 Tr | ox vorox ]ENGINE TUNE-UP — Trouble Diagnoses and Corrections WATER LEAKAGE [ ¢ RADIATOR > -f OIL COOLER ) -¢ ENGINE COMPONENT) week drain coe! Oil cooler for cracks. ‘Check mating areas of eylinder block [cveck drain cock Cesk me Ox. NOT OK. o | SG I ay setighten. ¥ Cheek oil cooler hoses for cracks and + ‘Check radiator for cracks. loose joints. ‘Check areas around blind plug at cylinder aE woTOK J NOTOK. J block's water gallery. maaan om | s0Tox ! Radiator hoses for cracks. 4 ox Check water pumps. NOT OK + END [Cneron omnenon _] ‘Crank engine and check compression pressure tC . um ‘Check points # Cylinder gasket damaged. ‘Piston or piston ring worn. ‘© Valve stem or valve seat worn, ‘Valve lip seal worn. NOT Ox. END €T-21Trouble Diagnoses and Corrections - ENGINE TUNE-UP_ ET-22 OVERHEATING Check amount of coolant. OK NOTOK. Check cooling system for leakage. ‘© Check hose connection. © Check radiator cap. © Check radiator fins for breakage. ‘© Check cylinder head gasket for leakage. ‘Check water pumps for leakage. © Check cylinder block for eracks. OK. NOT OK | Check fan belt tension. Ox NOTOK. 's cooling system clogging? 80, ves. Is thermostat sticking? NO. VES ‘ (Check water pump. ‘© Check body assembly and vane for rust formation ‘© Check end play or roughness of bearing in ‘operation. OK. NOT OK. Replace water pump assembly. ENDENGINE TUNE-UP — Trouble Diagnoses and Corrections FUEL SYSTEM MECHANICAL SYSTEM Foe qualy normal pp) ac a ee ent eg ox. | norox Ox norox] t cs Does cont iv contr manimom apd Crank engine and cock compremion posure ‘© Accelerator pedal stroke. ‘* Accelerator wire elongated. ‘* Accelerator linkage stuck = ‘Check timing mi front cover. Check points. ‘© Valve lip seal worn. ‘Piston or piston ring worn. ‘© Valve stem or valve seal worn, '* Cylinder gasket damaged. OK. NOT OX. I OK. ‘Check points. ‘* Fuel ine twisted or clogged. ‘© Fuel filter clogged. '* Leaks or loose. OK. NOT O.K, Repair, retighten or repla Purge air and drain water. Ox. €T-23Trouble Diagnoses and Corrections - ENGINE TUNE-UP- Sox Is valve timing chain Oblong groove elongated? 7 Location notch ‘Check injection nozzle. Check points. ie ‘Fue! injection pattern. + Closeing ‘Adjust or replace chain, « Sticking, « Injection pressure. ‘Check valve clearance. NOTOK. Ox. — sar oe Cae) : ‘Overhaul injection pump. [ bos dtvery valve stick? Inspection points. ww. YES. J ‘© Rusted of tardy movement of feed pump vane. ‘© Weak, broken, or rusted regulating valve spring. ‘© Low setting pressure of regulating valve. ‘ Weak or broken delivery valve spring. ‘© Poor seating at delivery valve seat ‘* Weak, broken, worn, or rusted plunger spring. |¢—___—_ ‘* Malfunction of governor lever. ‘© Broken or weak timer spring. ‘© Rusted of tardy movement of timer piston. ‘* Weak or broken governor spring. ‘¢ Maladjusted injection quantity. ‘© Abnormal wear on cam disc. eT-2492-13 sadepe a8ne8 uorssardwoy eb 00£009610a =u) 398 afined uorssardwio,) 0000096143 a youaim 42111) LO 00076118 Zo ‘youam yJoq peay x9pur|d3) 0000210118 aureu joo, Jaquinu Joo, STOOL SDIAHAS TWIDAdS $100L soynsas je!oeds — A-ANN.L INIDNAez-w3 “$1004 391ANaS TWidads era a ONIY NOJSId ena “"7* BOHOL ONINSLHOIL ONY Nid NOJSId ‘NOLSId zen3 LNANUSNrGY ONY NOILD3dSNI -N3 oe 49018 Y3GNIIAD zen3 °° SNOLLWOISID3ES TWWH3NID zew3 me ONE wena "" SNOLLYOIIDadS JAVHSWW9 ONY LJVHSWW9 GNV Viva 39IAUSS ——(OL-W3 29°" Qua w3QNITAD cena TIVE3AO 3NIDN3 ONITBN3SSY ovwa «°° “* WIWd3a GNY NOLLOZdSNI cena * + “GOW ONILD3NNOD 6-w3 7 vos 4IN3W30¥1438 ONY NOUSid ONITEW3SSY ¥38NVHO NOLLSNEWOD oLn3 “ QW3H W3QNITAD ONITAWASSY 6 -N3 QV3H WAGNITAD ONITENASSYSIO una : SNOLLNWO3ud 6-N3 “*" GOW ONILI3NNOD ONY ota . “> ATSINSSSV 3NIONS NOISid ONMIEWasswSIO Sta SAN3NOdMOD SNOANVT739SIN 9-w3 . “9-5 .ygNassySiO sina > ONIW3a GOH ONILDBNNOD Sena ern SNOLLNVI34d GNY ONINV38 NIV! 9-3 “°"" ATSWASSYSIG 3NIDNS Peg, ton -L3VHSHNVED. vy Wa ** (s34ed {pog) LNANOdINOD 3NIDN3 SLvg crete * Gow ONILD3NNOD Z-W3 ** (348d 4990) LNZNOdWOD 3NIDNI SLN3ALNOO TVSINVHIIW INIDONIEngine Component (Outer parts) ~ ENGINE MECHANICAL ENGINE COMPONENT (Outer parts) LD20 engine DMG: 4-5.(04-0.5,29-3.6) Bottom by-pass inlet Injetion pump auive gar © orta.7s + 1.2,7-9) rem 3 96: 148-90 (7 D20- 29 2.0 -3., 14-22) Tenions om ” Intake manifold G-44, 22 Dust cover 4-5 Teaslonss “tale (04-05, 29-36) per / ones 12-15) Crank damper "4 pulley Exhaust pulley . < manifold so o Pinas “yey Cosme |i 22-28, OL 116), 8-4, 22-39) Ol feed Pipe 16- 20) (20°30, 14-22) Cpe D 43-58 4 -5.9,32-43) O15-18 Spill tube (5-18, 11-13) Norse @16-21 ~~? ar thong ee? ue Nozzle Engine singer 22-25 J 02°25,16-18) “Sepa \, @w-12 > Ol pump (1.0-1.2,7-9) 7 drive spindle Glow plug a Oil pump Pump cover Cores <7 e > connecting plate 8 ‘se / q / Qos D22-25~/ (1 -15,8-11) 2-25, » \@ 16-2106 -24, 12-15) 16-18) semaaa @ + Nm (kgm, feb) EM-2ENGINE MECHANICAL -— Engine Component (Outer parts) LD28 engine Water pump: F 16-21 1.6 - 2.4, 12- 15) @ ms: 4-5004-053,29-36 [ 9-25 (19-2: MB: 9-12(0.9-1.2,65-8.7) | D19-25 19-25, ’ | Water outlet 9 H— Memon Power steering pump pulley ecw mo Seen Tensioner shaft 2" 7-9 sae joan oso EN BS se = 2-2 a ¢ / 16-20) Tensioner! / / (44-5.9,32 -43) 3 “pire pulley Compressor (7-21, @ 7-1574-16, 101-116 / \ Pe @ 32-36 ® 20-29 Injection pump jk pulley ‘® 20-29 G.3-3.7, 24-27) (2.0 -3.0, 14-22) (20-30, 14-22) Spill tube Nozzle @is-18 ‘isc Cs-t8 1-1 [ "rover setig ump oackt © 16-2 | GS pre | [ot panne aeeK197 SO wetter Powe! sisaeg phere 2 2 Oit evel stick A , g vs cari Giow pug \ Za connecting ae) \ Ay e \ Newsnet: i z t Yoon : \e pump drive spindle a Z Pr Injection tube ‘® 22-25 (22-2.5, 16-18) is @ 10-15 — Injeetion pump | Lo oa-o.1s, e ® Le piy 2TED O16 10 BM? Oils o> Glow plug (16-21, (1-15, 8-10, 12-15) D: Nem kg-m, feb) SEM267 —M3Engine Component (Body parts)~ ENGINE MECHANICAL ENGINE COMPONENT (Body parts) LD20 engine Rocker cover @ us-127 (12-13, 87-94),) ‘Swirl chamber (comboustion chamber) Valve seat -Vatve rocker am a «Valve cotter 3 ~ Spring retainer @ 118-157 (12-16, 87 -116) H6-10 (0.6 - 1.0, 4.3 = 7.2) q Vales doving “ate eat ! a 6 - Valve ccna ee ‘noone - ve pie @6-10(06-1.0,4.3-7.2) Flywheel (for M/T) 137-157 G4 16,101 - 116) Rear plate @ 13 7-187 yo 101 - 116) Main bearing OR Main bearing ‘cap Canlshatt sprocket — ay : @ MB: 9-12(09- 1.2,68-8.7) Bi deo il pump drive » (for A/T) @9-12 09° 1.2,6.5-8.7) Oil strainer D 20-29 (2.0-3.0, 14-22)—_ Cian & 0 6-9106-0.9,4.3-6.5) seals EM-4ENGINE MECHANICAL — Engine Component (Body parts) LD28 engine Rocker cover h6-9 (06 -0.9,4.3-6.5) @ 118-127 (12-13, 87-94) ‘Switl chamber Camshaft (combustion chamber) Camshaft thrust plate cree Timing chain * Camshaft sprocket — Senin Leu Mees (12-16, 87-116) f / 8 al ioe e Cylinder head > g a © Bg orien 6-10 , BS es. Valve spring ee 8 ‘Valve aa d tock 5 Fiywheel (for M/T) a NF D 137-157 f We Gate, 101-116) Sot ~ Xv fe © Rea pate Connecting ston ’ oe un Ceankshaft @ 44-5 i 137-187 © Se Main bearin Front oil wat] 4) (4.5-5.5,33- 40) OP a bens (14-16, 191 - 116) . Crankshaft sprocket a5 Mal @us; 9-12009 c 9 ee Oit tower 2 4-$(0.4-0. Mer 450 it pump drive gear 69-83 —h “Drive plate (for A/T) (70-8. @9:3 i 51-61) 09-1265 -8.) 2 it strainer — D 6-9 (0.6 -0.9,4.3-6.5) @: Nem (kgm, feb) seM268 EMSEngine Disassembly - ENGINE MECHANICAL PRECAUTIONS Arrange the disassembled parts on the parts stand in accordance with their assembled locations, sequence, etc., so that the parts will be re- assembled in their original locations. Place mating marks on the parts if necessary. DISASSEMBLY MOUNTING ENGINE ON WORK STAND 1. Remove rear and left side parts. © Starter motor (on right side of engine) © Transmission assembly ‘© Clutch cover assembly (M/T) ‘¢ Engine mounting bracket Alternator assembly and fan belt Alternator bracket (on air con- ditioner equipped models, one bracket holds both alternator and tompressor) 2. Install engine attachment to cylin- der block. Then, mount the engine on the work stand, ENGINE DISASSEMBLY 3. Install Tool, to prevent crankshaft rotation, seMa70 4. Drain engine oil and coolant. REMOVING OUTER PARTS 1. Remove front side engine parts: © Fan, tem-coupling and fan pulley © Alternator adjusting bar © Remove crank damper pulley by lightly tapping around it. If it is difficult to remove, use a puller. sema271 2. Remove left side engine parts. © Thermostat housing and bottom bypass inlet with hose SEM273, manifold © Intake, engine slinger exhaust and Do not separate the intake mani- fold. seMa74 © Pulley bracket with idler pulley (If so equipped) © Front dust cover KV11101400 sT0s01S000 SEM269 SeM272 eM6 = sema75, © Oil return hose from oil pan3. Remove right side engine parts, © Spill tube © Fuel return hose ‘© Injection tubes at nozzle side ‘@ Injection nozzles © Nozzle washers Sem330 Plug nozzle holes to prevent entry of dust and dirt. © Oil cooler and coolant hoses with oil filter Above parts can be removed only after injection pump has been detach- ed (LD20 engine). SEM276 Water inlet Oil level stick Engine mounting bracket Engine singer (If power steering is equipped, remove power steering ump bracket.) © Oil pump REMOVING BODY PARTS. 1, Remove oil pan and oil strainer. 2. Injection pump (1) Remove tensioner shaft and spring set pin, then remove tensioner pulley. (Tensioner pulley is fastened with a tensioner shaft and spring pin.) ENGINE MECHANICAL - Engine Disassembly seMa77 (2) Remove injection pump drive belt. (3) Remove injection pump drive gear. Do not remove drive shaft nut as this will cause drive gear to pop out. SEM278 (4) Remove injection pump assembly with injection tubes. SEM290 3. Remove valve rocker cover. 4. Cylinder head assembly (1) Remove camshaft bolt (2) Remove camshaft sprocket and slowly lower timing chain, emer (3) Remove bolts securing cylinder head to front cover. (4) Loosen cylinder head bolts in the sequence as shown. LD20 engine ®©BO® oe LD28 engine ®@OO2BBO® em708 | Gradually loosen cylinder head bolts in two or three stages. (5) Remove cylinder head. When removing cylinder head from engine installed on car, follow the instructions below. M7