TECHNICAL INFORMATION

MODEL
2TE67L-BV on SV08-1
 CONTENTS

1. Technical Data ..........................................................................................................................................................................1-1

2. Servicing Standards ..................................................................................................................................................................2-1

3. Measurement, Inspection and Adjustment ................................................................................................................................3-1

3-1 Measuring the Compression Pressure ..............................................................................................................................3-1
3-2 Adjusting the Valve Clearance ..........................................................................................................................................3-2
3-3 Checking the V-belt Tension .............................................................................................................................................3-3
3-4 Checking the Fuel Injection Valve .....................................................................................................................................3-3
3-5 Checking and Adjusting the Fuel Injection Timing (FID) ...................................................................................................3-6
3-6 Adjusting the Maximum (or Minimum) Idling Speed ..........................................................................................................3-7
3-7 Checking the Cooling Water System and Radiator for Water Leakage.............................................................................3-7
3-8 Checking the Sensors .......................................................................................................................................................3-8

4. Measurement Procedure, Service Data and Corrective Action .................................................................................................4-1

4-1 Cylinder Head....................................................................................................................................................................4-1
4-2 Cylinder Block....................................................................................................................................................................4-6
4-3 Valve Rocker Arm..............................................................................................................................................................4-8
4-4 Piston and Piston Rings ..................................................................................................................................................4-10
4-5 Connecting Rod...............................................................................................................................................................4-13
4-6 Camshaft .........................................................................................................................................................................4-16
4-7 Crankshaft .......................................................................................................................................................................4-17
4-8 Gears...............................................................................................................................................................................4-20
4-9 Trochoid Pump ................................................................................................................................................................4-21

5. Precautions for Reassembly......................................................................................................................................................5-1

6. Fuel Injection System ................................................................................................................................................................6-1

6-1 Fuel Oil Injection Pump .....................................................................................................................................................6-1
6-2 Disassembling Procedures................................................................................................................................................6-2
6-3 Reassembling Procedures ................................................................................................................................................6-3

7. Electrical Equipment..................................................................................................................................................................7-1
7-1 Starter Motor......................................................................................................................................................................7-1
7-2 Alternator ...........................................................................................................................................................................7-6
7-3 Glow Plug ..........................................................................................................................................................................7-8
7-4 Stop Solenoid ....................................................................................................................................................................7-9
 1. TECHNICAL DATA

1. Technical Data
Item Unit SV08-1
Engine
Main specifications
Engine model 2TE67L-BV
Vertical type series water-cooled
Type 4 cycle diesel engine
Combustion system Swirl pre-combustion chamber
Number of cylinders - Bore¯Stroke pcs.-mm¯mm 2 - 67¯72
Total displacement cc 507
Rated output / engine speed kW (PS)/rpm 7.7 (10.5)/2400
N•m (kg•m)
Maximum torque / engine speed 31.5 (3.21)/2000
/rpm
Specific fuel consumption g/kW(PS)•h 280 (22.8 or less)
Maximum idling speed min-1 (rpm) 2575 to 2625
Minimum idling speed min-1 (rpm) 1175 to 1225
60
Engine dry mass (excluding air cleaner and silencer) kg (Exclude the air cleaner and the silencer)
Lubricating method Forced lubrication by trochoid pump
Specific lubricating oil consumption g/kW(PS)•h 0.1 to 0.8 (0.2 to 0.5)
Compression pressure MPa (kgf/cm²) 2.9 (30) at 300 min-1 (rpm)
Cylinder head
Open bTDC degrees 13
Intake valve
Close aBDC degrees 43
Open bBDC degrees 43
Exhaust valve
Close aTDC degrees 13
Intake valve clearance (Cold engine) mm 0.2
Exhaust valve clearance (Cold engine) mm 0.2
Intake valve seat angle degrees 90
Exhaust valve seat angle degrees 90
Piston
Ring shape Barrel face
First compression ring
Ring quantity pcs. 2
Ring shape Taper face
Second compression ring
Ring quantity pcs. 2
Ring shape I type (with coil expander)
Oil-ring
Ring quantity pcs. 2
Governor
Name Mechanical all speed type
Type Centrifugal type
Fuel feed system
Filter paper with automatic
Fuel filter air release device
Fuel filter filtration area cm² 432
Oil/water separator Mesh filter screen
Feed pump Mechanical, diaphragm

1-1
 1. TECHNICAL DATA

Item Unit SV08-1

Engine
Lubrication system
Lubrication pump Trochoid pump
LO pressure regulating valve opening pressure kPa (kgf/cm²) 353 to 451 (3.0 to 4.0)
LO filter Full flow filter
LO filter filtration area cm² 75
Filter valve opening pressure kPa (kgf/cm²) 80 to 120 (0.8 to 1.22)
Operating pressure of alarm switch kPa (kgf/cm²) 39.2 to 58.8 (0.4 to 0.6)
Cooling device
Forced circulation radiator cooling
Cooling system
system
Fan belt size HM28
Thermostat opening temperature ºC 73 to 77
Thermostat full-open temperature ºC 87 or more
Radiator cap pressure kPa (kgf/cm²) 88.2 (0.9)
Radiator fan pcs.¯Ømm 7¯Ø230
Operating temperature of water temperature alarm switch ºC 107 to 113
Air cleaner
Type Cyclone type
Filtration area m² 0.44
Fuel injection pump
Injection pump type ND-PFR 2NC50A 2ND 828
Injection pump plunger diameter mm Ø4.5
Injection pump cam lifting height mm 6.5
Fuel injection timing (FID) degrees 15 to 17
Firing order 1o2
Nozzle
Type ND10PD41
Nozzle hole diameter¯Number of holes Ømm¯pcs. Ø1.0¯1
Spray angle degrees 10
Fuel injection pressure MPa (kgf/cm²) 11.9 to 12.7 (125 to 135)
Turbocharger
Type -
-1
Revolution speed min (rpm) -
Turbocharging pressure mmHg -
Starting device
Cold starting aids Ceramic glow plug
Starting aids capacity V-W 11-93.5
Battery type 44B-19L
Battery voltage - 5 hrs rate capacity V-Ah 12-30
Electrical equipment
Type GP8146
Alternator Nominal output V-A 12-14
-1
Rated speed min (rpm) 5200

1-2
 1. TECHNICAL DATA

Item Unit SV08-1

Electrical equipment
Type RS5161
Current limiter
Regulation voltage V 14 to 15
Type Direct current type
Starter motor Nominal output V-kW 12-1.2
Engagement Magnet shift
Type - -
Stop motor
Nominal output V-A -
Regular V-A 12-0.566
Stop solenoid
Moment V-A 12-3.75
Hour meter V-W 12-0.18
Horn V-W 12-30
Fuse A¯pcs. 10¯2
Battery charge alarm lamp V-W 12-3
Monitor lamps Engine oil pressure alarm lamp V-W 12-3
Water temperature alarm lamp V-W 12-3
Headlight V-W -
Boom light V-W 12-27
Room lamp (for cabin) V-W -
Wiper motor (for cabin) V-W -
Cabin heater (for cabin) V-W -

1-3
 2. SERVICING STANDARDS

2. Servicing Standards

1) Nominal and Allowable Values

Applicable model 2TE67L-BV
Item Unit Standard Wear limit
Cylinder head
Cylinder head distortion mm 0.05 or less 0.12
Intake degrees 90 
Valve seat angle
Exhaust (°) 90 
Intake 1.59 to 1.8 2.5
Valve seat width mm
Exhaust 1.59 to 1.8 2.5
Stem outside dia. Ø5.960 to 5.975 Ø5.9
Intake valve Guide inside dia. mm Ø6.000 to 6.012 Ø6.08
Oil clearance Ø0.025 to 0.052 Ø0.2
Stem outside dia. Ø5.940 to 5.955 Ø5.9
Exhaust valve Guide inside dia. mm Ø6.000 to 6.012 Ø6.08
Oil clearance Ø0.045 to 0.072 Ø0.2
Intake 0.7 to 0.9
Valve sinkage mm 1.8
Exhaust 0.7 to 0.9
Valve head Intake 0.775 to 1.075
mm 0.5
thickness Exhaust 0.775 to 1.075
Intake valve Open b. TDC degrees 13 
operating timing Close a. BDC (°) 43 
Exhaust valve Open b. BDC degrees 43 
operating timing Close a. TDC (°) 13 
Free length mm 33 
Valve spring Inclination mm 1.0 1.2
Tension [28.3 mm compressed] kg 6.9 6.5
Intake / exhaust valve clearance mm 0.2 0.5
Cylinder block
Cylinder bore dia. 67.000 to 67.019 67.2
Cylinder bore dia. 67.250 to 67.265 Over size 0.25
Roundness of cylinder mm 0.00 to 0.01 0.03
Cylindricity of cylinder 0.00 to 0.01 0.03
Upper surface distortion 0.05 or less 0.12
Valve rocker arm
Shaft outside dia. 9.950 to 9.968 Ø11.57
Rocker arm for
Intake / exhaust Bush inside dia. 10.000 to 10.015 Ø10.09
valve
Oil clearance 0.032 to 0.065 0.2
Push rod bend mm 0.03 or less 
Stem outside dia. Ø17.965 to 17.980 Ø17.93
Tappet Guide hole inside dia. Ø18.000 to 18.018 Ø18.05
Oil clearance 0.02 to 0.053 0.12

2-1
 2. SERVICING STANDARDS

Applicable model 2TE67L-BV

Item Unit Standard Wear limit
Piston
Piston outside dia. 66.938 to 66.953 67.90
Piston outside dia. 67.188 to 67.203 Over size 0.25
Minimum clearance between piston and cylinder 0.047 to 0.081 
0.5 to 0.6 Thickness of gasket 1.2
Projection of piston from the upper surface of cylinder block mm
0.6 to 0.7 Thickness of gasket 1.3
Outside dia. Ø18.996 to 19.002 Ø18.98
Piston pin Bush hole inside dia. Ø18.998 to 19.004 
Oil clearance 0.004 to 0.008 0.02
Piston ring
Ring groove width 1.550 to 1.570 
Ring width (B) 1.470 to 1.490 
Top ring
Clearance between groove and ring 0.060 to 0.100 0.25
End gap 0.130 to 0.280 1.0
Ring groove width 1.540 to 1.560 
Ring width (B) 1.470 to 1.490 
Second ring mm
Clearance between groove and ring 0.050 to 0.090 0.25
End gap 0.100 to 0.250 1.0
Ring groove width 3.010 to 3.030 
Ring width (B) 2.970 to 2.990 
Oil ring
Clearance between groove and ring 0.020 to 0.060 0.15
End gap 0.100 to 0.300 1.0
Connecting rod
Crank pin metal inside dia. Ø38.000 to 38.011 
Crank pin metal thickness 1.484 to 1.503 
Crank pin side
Crank pin outside dia. Ø34.964 to 34.975 Ø34.90
Oil clearance 0.031 to 0.079 0.15
Bush hole inside dia. mm Ø19.015 to 19.026 Ø20.10
Piston pin side Piston pin outside dia. Ø18.996 to 19.002 Ø18.98
Oil clearance 0.017 to 0.030 0.2
Twist and parallelism 0.08 or less for 100 mm 0.2
Oil clearance 0.040 to 0.085 
Cam
Cam shaft bend 0.02 or less 0.05
Intake / Exhaust 26.565 to 26.620 26.1
Cam height mm
Injection pump 34.480 to 34.520 34.3
Fuel pump 27.90 to 28.00 27.0
Crank shaft
#1, 2 Crank shaft 42.964 to 42.975 39.90
Journal Oil clearance 0.039 to 0.092 
#3 Crank shaft mm 45.948 to 45.959 
Journal Oil clearance 0.035 to 0.088 0.2
Bend 0.03 or less 0.06

2-2
 2. SERVICING STANDARDS

Applicable model 2TE67L-BV

Item Unit Standard Wear limit
Crank shaft 0.1 to 0.3 
Side gap Oil pump mm 0.1 to 0.15 
Connecting rod 0.1 to 0.3 
Crank gear
Backlash Cam gear mm 0.04 to 0.12 
Idle gear
Others

Lube oil pump High speed 13.7 at 3000 min-1 (rpm) 

L / min
discharge volume Low speed 4.6 at 1000 min-1 (rpm) 
kPa 382.4 to 422.2
Oil pressure regulating valve opening pressure 
(kgf/cm²) (3.9 to 4.1)
kPa 39.2 to 58.8
Oil pressure switch operating pressure 
(kgf/cm²) (0.4 to 0.6)
Cooling water pump discharge volume L / min 26.5 at 3000 min-1 (rpm) 
Temperature °C 73 to 77 
Thermostat valve opening
temperature 6.0 or more at
Lift at opening mm 
87°C or higher
Thermo-switch operating ON 107 to 113 
°C
temperature OFF 103 or more 

2-3
 2. SERVICING STANDARDS

2) Tightening torque for major bolts and nuts

No. Item Thread size × Pitch Tightening torque [Unit : N•m (kgf•m)] Lubricating oil
1 Cylinder head bolt M8 × 1.25 34.3 to 41.2 (3.5 to 4.0) Yes
2 Connecting rod nut M7 × 1.0 22.6 to 27.5 (2.1 to 2.6) Yes
3 Flywheel mounting bolt M10 × 1.25 80.4 to 86.3 (7.0 to 8.0) Yes
4 Bearing holder upper and lower tightening M9 × 1.25 52.0 to 55.9 (2.0 to 2.5) Yes
5 Crankshaft pulley tightening nut M12 × 1.5 84 to 93 (9.0 to 10.0) Yes
6 Fuel injection nozzle tightening M20 × 1.5 49.0 to 53.0 (6.0 to 7.0) No
7 Glow plug M10 × 1.25 14.7 to 19.6 (1.5 to 2.0) No

3) Tightening Torque for General Bolts and Nuts

Tightening torque
Item Thread size × Pitch Remarks
[Unit : N•m (kgf•m)]
M6 × 1 9.8 to 11.8 (1.0 to 1.2)
M8 × 1.25 22.6 to 28.4 (2.3 to 2.9)
M10 × 1.5 44.1 to 58.9 (4.5 to 6.0)
M12 × 1.75 78.5 to 98.1 (8.0 to 10.0) 1) Apply 80% of tightening torque
Coarse
when tightened to aluminum.
Hexagon head bolt (7T) thread M14 × 2 112.8 to 142.2 (12.0 to 15.0) 2) Apply 60% of tightening torque
Nut M16 × 2 166.8 to 206.0 (17.0 to 21.0) for 4T bolts and lock nuts.
3) Use fine screw threads for
M18 × 2.5 235.5 to 284.5 (24.0 to 29.0) engine only.
M20 × 2.5 323.8 to 402.2 (33.0 to 41.0)
Fine M14 × 1.5 127.5 to 147.1 (13.0 to 15.0)
thread M16 × 1.5 210.9 to 240.3 (21.5 to 24.5)
1/8 9.8 (1.0)
1/4 19.6 (2.0)
R (PT) plug
3/8 29.4 (3.0)
1/2 58.9 (6.0)
M8 12.7 to 16.7 (1.3 to 1.7)
M12 24.5 to 34.3 (2.5 to 3.5)
Pipe joint bolt
M14 39.2 to 49.0 (4.0 to 5.0)
M16 49.1 to 58.9 (5.0 to 6.0)

2-4
 3. MEASUREMENT, INSPECTION AND ADJUSTMENT

3. Measurement, Inspection and Adjustment

3-1 Measuring the Compression Pressure

1) Measurement Procedure
(1) Warm up the engine. Remove the fuel injection pipe
and the fuel injection valve from the cylinder to be
measured.
(2) Crank the engine before attaching the compression
gauge adapter.
Note :
Crank the engine when the regulator handle has been
turned to "STOP" position (no injection state).
(3) Attach the compression gauge adapter and the
compression gauge to the cylinder to be measured.
Note :
Never fail to attach the gasket to the tip of the adapter.
(4) Crank the engine with the starter motor until the Measuring the compression pressure
002184-00E
reading of the compression gauge is stabilized,
according to the above step (2) and Note.

[Engine compression pressure (Reference values)]

Compression pressure at 200 rpm MPa (kgf/cm2) Variations of compression
pressure among cylinders
Standard Allowable limit MPa (kgf/cm2)
2.94 (30) 2.45 (25) 0.2 to 0.3 (2 to 3)

2) Trouble Diagnosis Through Measurement of Compression Pressure

Reduction in the compression pressure of the cylinder is one of the major causes of the increase in blow-by gas
(which causes contamination and increased consumption of lubricating oil, and other trouble) and the engine start-
ing failure. The compression pressure is influenced by the following factors :
(1) Degree of the clearance between the piston and the cylinder ;
(2) Degree of the clearance around the intake / exhaust valve seats ; and
(3) Gas leak through the nozzle gasket or the cylinder head gasket.
This means that the compression pressure decreases as the engine parts are worn and lose durability through the
use of the engine over a long period of time.
In addition, the compression pressure is also decreased by scratches on the cylinder or the piston which are caused
by dust or other foreign matters drawn in through the soiled filter element of the air cleaner, and wear or breakage of
any piston rings. Therefore, the condition of the engine should be diagnosed by measuring the compression pres-
sure.

3-1
 3. MEASUREMENT, INSPECTION AND ADJUSTMENT

Causes and countermeasures to be taken when the compression pressure is less than the limit value.
No. Item Causes Countermeasures
• Filter element of air cleaner • Clogged filter element • Clean the filter element.
1 • Broken filter element • Replace the filter element.
• Defective filter element seal portion
• Valve clearance • Excessive or no valve clearance • Adjust the valve clearance.
2
(Refer to Section 3-2.)
• Valve timing • Improper valve timing • Adjust the valve clearance.
• Improper valve clearance (Refer to Section 3-2.)
3
• Inspect and adjust the valve rocker arm.
(Refer to Sections 4-3, 4-6 and 4-8.)
• Cylinder head gasket • Gas leak through the gasket • Replace the gasket.
• Nozzle gasket • Re-tighten the cylinder head and the nozzle at the
4
specified torque.
(Refer to Section 2 2) of Chapter 2.)
• Intake/exhaust valve • Gas leak due to worn valve seats or • Lap the valve seats.
5 • Valve seat trapped foreign matters (Refer to Section 4-1 2).)
• Sticking of valves • Replace the intake/exhaust valves.
• Piston • Gas leak due to scratches or wear of • Do the honing and use oversize parts.
6 • Piston ring the piston, piston ring or cylinder (Refer to Sections 4-2 3) and 4-4 8).)
• Cylinder

3-2 Adjusting the Valve Clearance

(1) Inspect and adjust the intake / exhaust valve clear-

ance while the engine is in the cold state.
(2) Set the piston in the cylinder to be measured to the
top dead center (TDC) of compression.
(3) Loosen the lock nut and the adjust screw. Check
that the valve cap is free from inclination or foreign
matter.
(4) Insert a thickness gauge between the rocker arm
and the valve cap. Tighten the adjust screw until the
clearance listed below is attained.

Intake / exhaust valve Refer to Section "2 1) Nominal 002185-00X

clearance and Allowable Values".
Adjust screw
Notes : Lock nut
1. If the valve cap is worn or otherwise damaged in the
head, replace it with a new one.
2. Check that the valve cap is fitted on the head of
intake/exhaust valve.
Valve clearance
Valve cap

Good No good
003338-00E (Adjusting the valve clearance)
003337-00E

3-2
 3. MEASUREMENT, INSPECTION AND ADJUSTMENT

3-3 Checking the V-belt Tension

Press the center of the V-belt between the alternator and Fan pulley
the cooling water pump with a finger by 49 N (5 kgf). If Adjusting plate
the slack is about 4 mm, the V-belt tension is proper. If
not, adjust the V-belt tension using adjusting plate of the
alternator. Alternator
Loosen the alternator holding cap screw and the nut on
the adjusting plate in order to adjust the V-belt tension by
moving the cap screw to arrowed direction.

Alternator holding cap screw

Crank pulley
003340-00E

(Adjusting the V-belt tension)

003339-00E

3-4 Checking the Fuel Injection Valve

1) Measuring the Fuel Injection Pressure

Note :
Thoroughly remove carbon deposits from the injection
nozzle hole before the measurement.

(1) Connect the fuel injection valve to the high pressure

pipe of the nozzle tester.
Nozzle tester
(2) While pumping the lever of the nozzle tester slowly,
read the pressure gauge on the nozzle tester the
moment the nozzle starts fuel injection.
(For the fuel injection pressure, refer to Section "1.
Technical Data"). Injection nozzle
(3) If the measured fuel injection pressure is lower than
the specified value, replace the pressure adjusting ( Measuring the fuel injection pressure
with a nozzle tester )
shim with a thicker one. 003341-00E

Types of pressure adjusting shim thickness

Fuel injection pressure adjustment
mm
Thicker adjusting shim by 0.1 mm increases the fuel injection pressure for
0.9 to 1.45 (every 0.025 mm)
0.78 MPa (8 kgf/cm2).

3-3
 3. MEASUREMENT, INSPECTION AND ADJUSTMENT

[Reference : Structure of fuel injection valve]

Nut

Gasket

Nozzle holder

Pressure adjusting shim

Nozzle spring

Nozzle spring seat

Valve stop spacer

Nozzle valve

Nozzle body

Nozzle case nut

003342-00E

2) Checking the Spray Pattern

While pumping the lever of the nozzle tester once or twice per second at the specified fuel injection pressure (Refer
to Section "1. Technical Data"), check the spray pattern. If the spray pattern is not normal, clean or replace the noz-
zle.

(1) Check that the pattern is neither like a stream nor slivered.
(2) Check that fuel is sprayed conically around the nozzle center line and that the spray angle is 4 degrees.

[Normal spray pattern] [Abnormal spray pattern]

4 degrees

003343-00E

(3) Spray fuel on a sheet of white paper placed about 30 cm below the nozzle. The injection spray should form a
perfect circle.
(4) No fuel should drip from the nozzle after injection.
(5) Fuel should not ooze from the nozzle hole when the fuel injection pressure rises to a value that is a little lower
than the specified value : 2.0 MPa (20 kgf/cm2).
(6) Test the injection with a nozzle tester ; retighten the nozzle holder and test it again if there is excessive fuel leak
from the overflow coupling. Replace the nozzle as a set if the fuel leak is still excessive.
3-4
 3. MEASUREMENT, INSPECTION AND ADJUSTMENT

3) Nozzle Valve Sliding Test

Thoroughly wash the nozzle valve using clean fuel. Hold the nozzle
body vertical, and put the nozzle valve approx. 1 / 3 of its length into
the body.
Check if the nozzle valve falls smoothly by self-weight when
released. If so, the nozzle valve is good.

4) Nozzle Body Identification Number

NP DN - 4 P D 117
Design code
No code : Pintle type (Nozzle valve sliding test by self-weight)
Code D : Throttle type 003344-00E
Size : Size P (or S)

Spray angle
Type : Pintle type
Bosch automotive type

003345-00E

3-5
 3. MEASUREMENT, INSPECTION AND ADJUSTMENT

3-5 Checking and Adjusting the Fuel Injection Timing (FID)

(1) Using the crankshaft pulley, turn the engine in the specified
direction. Check the injection timing with the delivery valve
spring holder of the fuel injection pump for the cylinder
No.1. (Cylinder are numbered from No.1 sequentially from
the flywheel side).
(2) When the crankshaft is turned in the specified direction, the
fuel level rises at the tip of the delivery valve spring holder.
At that time, stop turning the crankshaft.

Cylinder No.1
003346-00E

(3) Check the timing marks imprinted on the timing gear case
and the crankshaft pulley.
(For the fuel injection timing, refer to Section "1. Technical Timing mark
Data".
(4) When the cylinder head is removed, set the dial gauge on
the top of piston to confirm fuel oil injection timing by the
piston movement.
Injection timing (BTDC) Piston movement (mm)

15.0 to 17.0 1.656 to 2.116

Crankshaft pulley

003347-00E

(5) If the present injection timing differs from the specified tim-
ing, remove the fuel injection pump, and adjust the timing by
increasing or decreasing the adjusting shim thickness
between the fuel injection pump and gear case.
• Increase the shim thickness by 0.3 mm to delay the injection
timing by approximate 2°.
• Decrease the shim thickness by 0.3 mm to advance the injec-
tion timing by approximate 2°.
Every 0.1 mm of thickness between 0.2 to 0.5 mm, adjusting
shims are established. Adjustment shim

003348-00E

3-6
 3. MEASUREMENT, INSPECTION AND ADJUSTMENT

3-6 Adjusting the Maximum (or Minimum) Idling Speed

(1) First warm up the engine. Then, gradually increase the

Timing gear case
engine speed up to the high idling speed. (Refer to Section
"1. Technical Data".)
(2) If the high idling speed differs from the specified one, Stop lever

adjust it by the cap screw on the timing gear case.

(3) Set the low idling speed to the specified value, (Refer to
Section "1. Technical Data") by turning the low idling
speed set bolt.

High idling
speed adjusting bolt Low idling speed
adjusting bolt 003349-00E

3-7 Checking the Cooling Water System and Radiator for Water Leakage

1) Checking the Cooling Water System for Water Leakage

Note :
The cooling water system can be checked effectively while the
engine is warm.

(1) Supply cooling water up to the normal water level in the

radiator. Attach the cap tester body to the radiator.
(2) Start operating the cooling water pump, and set the pres-
sure of the tester to 88.3 ± 14.7 kPa (0.9 ± 0.15 kgf/cm2).
Cap tester
Any lower reading of the pressure gauge on the cap tester
Checking the cooling water system
indicates water leakage from the cooling water system. ( for water leakage )
Then, find out the portion of the cooling water system from 003350-00E

which cooling water leaks.

2) Checking the Radiator Cap

Attach the radiator cap to a cap tester. Set the pressure of the
tester to 88.3 ± 14.7 kPa (0.9 ± 0.15 kgf/cm2). Check if the cap
is opened at the set pressure. If not, replace the cap, because
it is defective.

Radiator cap
(Checking the radiator cap)
003351-00E

3-7
 3. MEASUREMENT, INSPECTION AND ADJUSTMENT

3-8 Checking the Sensors

1) Checking the Thermostat and the Thermoswitch

(1) Thermostat
Put the thermostat into the water in a container. While
Thermometer
measuring the water temperature, heat the water. Check
that the thermostat begins to work at 73.0 to 77.0 °C and
fully opens at 90 °C.
Thermostat

003352-00E

(2) Thermoswitch
Put the thermoswitch into the antifreeze or oil in a con- Thermometer
tainer. While measuring the liquid temperature, heat the
liquid. If the tester shows continuity at a temperature of
107 to 113 °C, the thermoswitch is normal.

Tester probes
003353-00E

2) Oil Pressure Switch

Remove the connector from the switch. While running
the engine, bring the tester probes into contact with the
switch terminal and the cylinder block. If the tester
shows continuity, the hydraulic switch is defective.

Tester probes
(Continuity test)
003354-00E

3-8
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

4. Measurement Procedure, Service Data and Corrective Action

For the maintenance of all parts, make measurements according to the following measurement procedure. If any
part is found to be defective or if any part is not within the allowable value, replace it with a new one. However, if it is
expected that any part within the allowable value will exceed the value before the next maintenance based on the
record of its use, be sure to replace such a part beforehand.

4-1 Cylinder Head

1) Checking the Combustion Surface for Distortion Straight-edge

(1) Remove the intake / exhaust valves and the fuel
injection valve from the engine. Clean the surface of
the cylinder head.
(2) Place a straight-edge along each of the four sides
and each diagonal of the cylinder head. Measure
the clearance between the straight-edge and the
combustion surface with a thickness gauge.
Thickness gauge
Cylinder head
combustion Standard Wear limit
surface distortion
Refer to Section "2 1) Nominal and Allowable Values". ( Measuring the combustion
surface distortion ) 003355-00E

(3) Visually check if the combustion surface is free from

discoloration, cracks, and crazing. In addition, use the color check kit for cracks and crazing.

2) Intake / Exhaust Valve Seat

(1) Valve sinkage
Over long periods of use and repeated lappings, combustion efficiency may drop. Measure the sinking depth and
replace the valve and valve seat if the valve sinking depth exceeds the standard value.

Standard Wear limit

Intake
Valve valve Refer to Section "2 1) Nominal and
sinkage Exhaust Allowable Values".
valve

Depth micrometer Valve sinkage

003357-00E

(Measuring the valve sinkage)

003356-00E

4-1
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

(2) Width and angle of the valve seat

Remove carbon deposits from the seat surface. Mea-
sure the seat width and angle using vernier calipers and
an angle gauge respectively.

Standard Wear limit

Valve Intake
seat
Exhaust
width Refer to Section "2 1) Nominal and
Valve Intake Allowable Values".
seat
Exhaust
angle

(Measuring the valve seat width) 003358-00E

[Valve seat correction procedure] Seat grinder

(1) If the seat surface is worn or roughened slightly, lap
the seat surface to a smooth state with a valve com-
pound mixed with oil.
(2) If the seat surface is worn or roughened exces-
sively, correct the seat surface using a seat grinder
or a seat cutter, and finish it according to the above
step (1). Grindstone

003359-00E

[Procedure for using seat grinder and seat cutter]

(1) Correct the roughened seat surface with a seat
grinder or a seat cutter.
70

Seat grindstone Angle T (degrees)

Intake valve 45
15

Seat width
Exhaust valve 45

(2) When the seat width is enlarged from the initial

value, correct it by grinding the seat surface with a
Valve seat
70 degrees seat grinder or a seat cutter. Then, grind
the seat surface with a 15 degrees grinder so that
the seat width should be the standard value. (Valve seat correction angle)
Note :
003360-00E

When using a seat cutter, apply pressure evenly taking

care not to cut the seat surface unevenly.
(3) Knead a valve compound with oil and finish the valve seat by lapping with the compound.
Note :
If any valve requires correction, be sure to measure the oil clearance between the valve stem outside dia. and the
valve guide inside dia. If the oil clearance exceeds the wear limit, replace the valve or the valve guide before correct-
ing the valve seat surface. (For the oil clearance between the valve and the valve guide, refer to the subsection 3 in
this section.)

4-2
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

(4) Last, lap the valve using only oil.

Notes :
1. After correcting the valve seat, thoroughly clean the valve and the cylinder head using light oil or the like. Thor-
oughly remove the valve compound or the grindstone powder.
2. For slightly poor contact, take the steps (3) and (4) only.

3) Intake / Exhaust Valve

(1) Wear and bend of the valve stem
Replace the valve stem if bent or worn excessively. In this case, replace the valve guide together with the valve
stem.
(2) Valve stem and valve guide
Oil clearance is the difference between the valve guide inside diameter measured with a three-point micrometer or a
cylinder gauge and the stem outside diameter measured with a micrometer. If the oil clearance is near the wear limit,
replace both the intake / exhaust valve and the valve guide with new ones.
Note :
Three-point micrometer : Used for an inside diameter of 0.157 to 0.315 in. (4 to 8 mm).
Cylinder gauge : Used for an inside diameter of 0.236 in. (6 mm) or more.

Standard Wear limit

Stem
outside dia.
Intake
Guide
valve
inside dia.
Oil clearance Refer to Section "2 1) Nominal
Stem and Allowable Values". (Measuring the valve stem outside diameter)
outside dia.
003361-00E
Exhaust
Guide
valve
inside dia.
Oil clearance

(3) Thickness of valve head

Measure the thickness of the valve head with a micrometer.
If the measured value is near the wear limit, replace the
valve with a new one.

Standard Wear limit

Intake
Thickness valve Refer to Section "2 1) Nominal and
of valve
Exhaust Allowable Values".
head
valve
Seat width
Thickness
Valve diameter

Seat angle
003362-00E

4-3
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

4) Valve Stem Seal

[Time of replacement] Valve stem seal
(1) When oil loss is found excessive.
(2) When the valve stem seal is removed.
(3) When the intake / exhaust valve is removed. Valve guide
Cylinder head

003363-00E

[Precautions on installation]
Before reinstalling the intake / exhaust valve, thoroughly
remove the burrs on the valve stem surface and then apply
sufficient lubricating oil to the valve stem.

Hatched portion indicates

( where to apply lubricating oil. )
003364-00E

4-4
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

5) Checking the Valve Spring

(1) Visually check if the valve spring is free from flaws
and corrosion.
(2) Measure the free length (length of the spring) and
inclination (squareness of the side of the coil).

Standard Wear limit

Free length
Inclination
Valve Tension Refer to Section "2 1) Nominal
(Measuring the free length)
spring [lbs. (kg)] and Allowable Values".
[0.0394 in. 003365-00E

(1 mm)
compressed]

6) Checking Valve Spring Holder and Cotter Inclination

Check the contact of the inner surface of the valve spring
holder with the outer surface of the cotter as well as the Square
contact of the inner surface of the cotter with the notch in Free length
the head of the valve stem. If such contact is uneven or if
the cotter has sunk due to wear, replace the cotter with a
new one. Surface plate
(Measuring the inclination of valve spring)
003366-00E

4-5
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

4-2 Cylinder Block

Cylinder gauge
1) Checking the Cylinder Block
(1) Visually check if the cylinder block is free from water
leak, oil leak and cracks. If any portion of the cylinder
block might be cracked, check the portion by color
check.
(2) Replace the cylinder block if badly damaged and
unreparable.
(3) Thoroughly clean each oil hole. Make sure that it is
not clogged.

(Measuring the cylinder bore diameter)

003367-00E

2) Measuring the Cylinder Bore and the Distortion of the Cylinder

Measure each cylinder bore with a cylinder gauge. Mea-
sure the cylinder bore diameters at the point a, approx. 20
a
0.79 in. (20 mm) below the crest of the liner, and at the
points b and c at equal intervals.
b
Obtain the distortion of the cylinder (the roundness and
cylindricity of each cylinder) from the following measured
values : c

• Roundness :
Difference between the max. and min. bore values on
the same cross section of each liner. A
• Cylindricity :
Difference between the max. and min. bore values in
the same direction of each liner.
Apply honing (honing and boring) if any measured value
B
exceeds the allowable limit.
Note : Measurement should be made at the points
Note : a, b and c in the directions of A and B
For oversized pistons and piston rings, refer to Section "4-
Cylinder bore measuring
4 Piston and Piston Rings". ( points )
003368-00E
Standard Wear limit

Cylinder bore dia.

Refer to Section "2 1) Nominal and
Roundness of cylinder
Allowable Values".
Cylindricity of cylinder

4-6
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

3) Honing
(1) Application of honing
Apply honing or boring to the cylinder if it is partially
worn, flawed, or otherwise damaged. If the partial wear,
flaw or other damage is minor, it can be repaired only by
honing with a Flex-Hone. However, if it is not minor,
apply honing after boring. In this case, taking the maxi-
mum wear into consideration, it is important to examine
whether the cylinder can attain perfect roundness after
honing and / or boring, and whether prepared oversized
pistons and piston rings can be used. (For the oversized (Flex-Hone)
003369-00E
pistons and piston rings, refer to Section "4-4 Piston and
Piston Rings".)
(2) Procedure for using the Flex-Hone
Flex-Hone
It is common practice to use the Flex-Hone for honing.
The procedure for using it is described below. Any mate-
rial needs a honing allowance of approx. 0.00004 in. (1 /
1000 mm) for honing with the Flex-Hone.
[1] Items to be prepared Power drill
Flex-Hone, power drill, and honing liquid
Flex-Hone Applicable bore dia. Engine oil Light oil
Yanmar code No. (mm) 50% 50%

129400-92400 63 to 70

Honing liquid 003370-00E

[2] Handling procedure

Soak the Flex-Hone in the honing liquid. Insert the Flex-
Hone into the cylinder and move it up and down for about
30 seconds while turning it at a cross hatch angle of about
30 to 40 degrees. Then, extract the Flex-Hone while turn- 30 to 40 degrees
ing it.
Notes :
1. Use the Flex-Hone at a speed of 300 to 1200 rpm. Use
of the Flex-Hone at a higher speed may be hazardous.
2. Never insert into or extract from the cylinder the Flex- 003371-00E

Hone, with the power drill stopped.

4-7
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

4) Overhaul of Cylinder (Reference)

Service life of cylinder block (H3)
(H3 = 3H1)

Time for boring and honing (H2)

(H2 = 1.5H1)

Time for honing (H1)

Increase in L.O.C* Increase in L.O.C Increase in L.O.C Increase in L.O.C

and blow-by and blow-by and blow-by and blow-by

Honing Boring
Examine the applicability
( of oversized
pistons and piston rings.
)
*L.O.C = lubricating oil consumption 003372-00E

4-3 Valve Rocker Arm

1) Measuring the Rocker Arm Shaft Outside Diameter and the Rocker Arm Bush Inside Diameter
Oil clearance is the difference between the rocker arm bush inside diameter measured with a cylinder gauge and the
rocker arm shaft outside diameter measured with a micrometer. If the oil clearance is near the wear limit, replace the
rocker arm shaft and the rocker arm with new ones.

Standard Wear limit

Intake /
Shaft
outside dia.
( Measuring the rocker arm shaft
outside diameter )
003373-00E
exhaust Refer to Section "2 1) Nomi-
Bush inside
valve rocker nal and Allowable Values".
dia.
arm
Oil clearance

( Measuring the rocker arm

busu inside diameter ) 003374-00E

4-8
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

2) Checking the Push Rod Bend, Measuring the Tappet

Stem Outside Diameter and Checking the Tappet
Contact Surface
Put the push rod on the surface plate to check that there is no
clearance between the push rod and the surface plate. Mea-
sure the tappet stem outside diameter with a micrometer.

Standard Wear limit

Push rod bend

Thickness gauge
Stem outside
diameter
Refer to Section "2 1) Nomi-
Guide hole nal and Allowable Values".
Tappet
inside
diameter
Oil clearance (Measuring the push rod bend)
003375-00E

3) Other Inspections
(1) Valve rocker arm shaft spring
Check if the rocker arm shaft spring is free from corro-
sion and wear. If not, replace it with a new one.
(2) Wear of intake/exhaust valve rocker arm and valve cap
Check the intake / exhaust valve rocker arm for the con-
tact surface with the valve cap. If any of them is exces-
sively worn or partially flaked, replace it.
(3) Check the portion where the valve clearance adjust
screw is in contact with the push rod. If the portion is
worn or flaked, replace the push rod or the adjust screw.
(Measuring the tappet stem outside diameter)
003376-00E
Adjust screw

Check of contact surface

Check of contact
surface of rocker arm
Push rod

003377-00E

4-9
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

4-4 Piston and Piston Rings

1) Checking the Piston

(1) Remove carbon deposits from the head and com-
bustion surface of the piston while taking care not to
damage the piston. Check if there are any cracks or
damage.
(2) Check the outer surface and ring grooves of the pis- Measuring
ton, and replace it if worn or damaged. position

15 to 17 mm

003378-00E

2) Measuring the Piston Outside Diameter

To measure the piston outside diameter, measure the
long diameter of the oval hole in the vertical direction to
the piston pin bush hole at a position which is 15 to 17
mm above from the lower end of the piston.

Standard Wear limit

Piston outside dia.

Minimum clearance Refer to Section "2 1) Nominal and
between piston Allowable Values".
and cylinder
( Measuring the rocker arm
busu inside diameter ) 003374-00E

3) Shapes of Piston Rings

Top ring

Second ring

Oil ring

003380-00E

4-10
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

4) Measuring the Ring Groove Width, the Ring Width (B), and the End Gap
To measure the piston ring groove width, first measure
the width (B) of the piston ring. Then, fit the piston ring
into the ring groove after cleaning the groove carefully.
Insert a thickness gauge between the piston ring and the
groove to measure the clearance between them. Obtain
the ring groove width by adding the ring width to the mea-
sured clearance.

Width
(B)
(Measuring the ring groove width)
003382-00E

Thickness 003381-00E

To measure the end gap, push the piston ring into the End gap
sleeve using the piston head, insert a thickness gauge
Approx. 30 mm
between both ends of the piston ring. If the sleeve is worn,
measure the end gap after pushing the piston ring into the
Piston ring
sleeve to the portion which is less worn (approx. 30 mm
from the lower end of the sleeve).

Standard Wear limit Cylinder block

Ring groove
width
Ring width (B)
Top
ring Clearance
between
groove and ring
End gap
Ring groove
( Measuring the end gap
of piston ring )
003383-00E
width
Ring width (B)
Second Refer to Section "2 1) Nominal
ring Clearance and Allowable Values".
between
groove and ring
End gap
Ring groove
width
Ring width (B)
Oil ring Clearance
between
groove and ring
End gap

4-11
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

5) Installation of Piston Rings

(1) Using a piston ring replacer, fit the piston ring into
the ring groove, with the manufacturer's mark near
the end of the piston ring facing upward (to the com-
bustion chamber side). After fitting the piston ring,
check that the piston ring moves smoothly.
(2) After fitting all the piston rings, shift the end gaps of
them at 120 degrees intervals, so that they are not
aligned along the piston. Apply lubricating oil to the
piston pin before inserting it into the piston.

6) Measuring the Outside Diameter and Bush Hole

Inside Diameter of the Piston Pin
Measure the outside diameter and bush hole inside
diameter of the piston pin. Replace the piston pin if one
or both of the measured values exceed the wear limit.
Apply lubricating oil to the piston pin before inserting it
003385-00X

into the piston.

(Measuring points of the piston pin

outside diameter )
003384-00E

Standard Wear limit

Outside dia.
Piston Bush hole Refer to Section "2 1) Nominal
pin inside dia. and Allowable Values".
Oil clearance

(Measuring the piston pin outside diameter) (Inserting piston pin)

003386-00E 003387-00E

4-12
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

7) Top Clearance (Reference)

Top clearance

Refer to Section "2 1) Nominal and Allowable Values".

8) Oversized Piston and Piston Ring

[0.250S : Oversized by 0.25 mm]

Piston assembly code

Size classification Piston ring assembly code
(including piston ring assembly)

0.250S 165000-47550 165000-47560

4-5 Connecting Rod

1) Visual Inspection
Inspect the following portions for cracks, distortion and discoloration :
(1) Portions close to the boundaries between the chamfered parts of the large and small ends, and the I-beam sec-
tion of the connecting rod.
(2) Portion around the oil hole in the bush at the small end.

2) Measuring the Twist and Parallelism

Measure the twist and parallelism of the connecting rod with a connecting rod aligner.

Twist and parallelism

Refer to Section "2 1) Nominal and Allowable Values".

m
0m
10

m
0m Parallelism
10

Twist

Reference axis

(Measuring the twist and parallelism)

003388-00E

4-13
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

3) Measuring the Clearance Between the Crank Pin and Bush

To measure the oil clearance between the crank pin and
the crank pin metal, measure the inside diameter of the
crank pin metal and the outside diameter of the crank
pin, and calculate the difference between them.
If the measured oil clearance exceeds or near the wear
limit, replace the crank pin metal. If the crank pin is
excessively or partially worn, grind the crank pin, and
use an oversized crank pin metal.
Note :
To measure the inside diameter of the crank pin metal,
install the metal into the large end of the connecting rod
and tighten the rod bolts at a specified tightening torque,
Cylinder gauge
making sure that each half of the metal is set in the cor-
rect way.
Rod bolt tightening torque Refer to Section "2 2) Engine
(Apply lubricating oil to Tightening torque for major
the rod bolt) bolts and nuts" ( Measuring the inside diameter of
the crank pin metal )
003389-00E
Standard Wear limit

Crank
pin metal
inside dia.
Crank
Crank Refer to Section "2 1) Nominal
pin metal
pin side and Allowable Values".
thickness
Crank
pin outside
dia.

4) Measuring the Oil Clearance Between the Piston

Pin Bush and the Piston Pin
To measure the oil clearance between the piston pin
bush and the piston pin, measure the inside diameter of
the piston pin bush and the outside diameter of the pis-
ton pin, and calculate the difference between them.

Standard Wear limit

Bush
inside dia. Cylinder gauge
Piston Refer to Section "2 1) Nominal
Piston pin
pin side. and Allowable Values".
outside dia
Oil clearance

( Measuring the inside diameter of

the piston pin bush
)
003390-00E

4-14
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

5) Checking the Contact of the Crank Pin Metal

Apply a blue ink or a minium to the inside surface of the
crank pin metal. Instal the crank pin metal to the crank-
shaft, and tighten the rod bolts at a specified tightening
torque (refer to the above 3 of this section) to check the
contact of the metal. If the contacted surface of the metal
occupies 75 % or more of the total surface, the crank pin
metal is good in terms of contact.

6) Installing the Piston and the Connecting Rod

Install the piston with the connecting rod, with the marks
at the large end of the connecting rod facing the fuel
injection pump. Also, install the piston so that the recess
of the combustion chamber is on the fuel injection pump
side as seen from the top.

7) Side Gap of the Connecting Rod

After installing the connecting rod to the crankshaft,
tighten the rod bolts at a specified tightening torque
(refer to the above 3 of this section). Measure the side
gap by inserting a thickness gauge between the con-
necting rod and the crank arm. If the measured value
exceeds the wear limit, replace the crank pin metal or
the connecting rod.
Refer to Section "2 1) Nomi-
Side gap
nal and Allowable Values".

8) Undersized Crank Pin Metal 003391-00X

Undersized by 0.25 mm
Crank pin metal
Metal thickness [in. (mm)]
Part code No.
Standard
165000-15870 1.625

4-15
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

4-6 Camshaft

1) Removing the Camshaft

Remove the tappets and fuel oil injection pump, and
loosen two cap screws (M6) inside of the camshaft gear
to remove the camshaft.

2) Checking the Camshaft Appearance

Check the camshaft for the contact surface of the cam
with the tappet, seizure and wear of the bearing, and
damage of the cam gear.

003393-00X

3) Measuring the Bend of the Camshaft

Support the camshaft with V-blocks. Using a dial gauge,
measure the runout of the journal at the center of the
camshaft while rotating the camshaft.
Take 50 % of the measured runout as bend.

Standard Wear limit

Dial gauge

Refer to Section "2 1) Nominal and

Camshaft bend
Allowable Values".

V-block

(Measuring the camshaft bend)

003394-00E

4) Measuring the Intake / Exhaust Cam Height

Standard Wear limit

Intake
Cam cam Refer to Section "2 1) Nominal and
height Exhaust Allowable Values".
cam Micrometer

(Measuring the cam height)

Cam height
003395-00E

003392-00E

4-16
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

4-7 Crankshaft

1) Side Gap Around the Crankshaft

Before extracting the crankshaft and when installing it, Relief valve
contact a dial gauge with the end of the crankshaft.
Press the crankshaft to each of the right and left sides in
the axial direction to measure the side gap. Alternatively,
insert a thickness gauge directly into the clearance
between the thrust metal in the reference part and the
thrust face of crankshaft to measure the side gap. If the
measured value exceeds the wear limit, replace the rear
end bearing holder (flywheel side) with a new one.
Refer to Section "2 1) Nomi-
Side gap
nal and Allowable Values".
Dial gauge

2) Removing the Crankshaft

Crankshaft
Remove the three cap screws shown below to pull out 003396-00E

the crankshaft to flywheel end. Remove the relief valve

beforehand.

Allen head cap screws

Cap screw

003888-00E

3) Removing the Main Bearing

Remove two bearing holding cap screws to remove the
main bearing.

Bearing holder

003889-00E

4-17
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

4) Color Check of Crankshaft

Clean the crankshaft and check it using a color check kit
or a magnetic inspector. Replace the crankshaft if it is
cracked or badly damaged. If the damage is minor, cor-
rect it by re-grinding.

5) Checking the Metals

Check the metals for flaking, melting, seizure, and the
state of the contact spur face. Replace any of the metals
if it is damaged.

6) Bend of the Crankshaft

Support the journals of the crankshaft with V-blocks at
both ends. Measure the runout at the center journal with Bend

a dial gauge while rotating the crankshaft to check the

bend of the crankshaft.
Refer to Section "2 1) Nomi-
Bend Runout
nal and Allowable Values".
Dial gauge

7) Measuring the of Crank Pin and Journal

Measure the outside diameters, roundness, taper angles
of the crank pin and journal. If the partial wear or the
roundness exceeds the wear limit but the measured out-
side diameter is within the limit, correct it by regrinding.
Replace the crankshaft with a new one, if it is unrepara-
V-block V-block
ble. An under sized crank pin metal by 0.0098 in. (0.25
(Measuring the crankshaft bend)
mm) is available. (Refer to Section 4-5, 4-8 in this chap- 003397-00E

ter.)
R

Crank journal
Crank pin
003399-00X

( Measuring
and journal
points of the crank pin
)
003398-00E

4-18
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

Standard Wear limit

Crank Crank pin

pin outside dia.
Outside
dia. Refer to Section "2 1) Nominal and
Crank Main metal Allowable Values".
journal thickness
Oil
clearance

8) Precautions for Installation of the Metal Caps

(1) The lower half of the metal on the holder side has no oil groove.
(2) The upper half of the metal on the cylinder block side has an oil groove.
(3) The aluminum bearing holders are on the flywheel side.
(4) Place the embossed mark "F" of the bearing holder to front (crankshaft pulley side).
Install the bearing holder without the embossed mark "F" facing its chamfered side to front (crankshaft pulley
side).

Main metal (reference)

Thrust metal (flywheel side)

Main metal
Metal cap (reference)

Metal cap
Metal cap

003400-00E

9) Undersized Main Metal by 0.25 mm and Bushings by 0.25 mm

No. Part code No. Metal thickness
#1 Bushing 165000-15850 2.125
#2 Metal 165000-15920 2.125
#3 Metal 165000-15900 2.125

4-19
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

4-8 Gears

1) Checking the Gears

Check the teeth surfaces of each gear and replace the gear if the teeth are damaged, worn, or flaked.

2) Measuring the Backlashes

Apply a dial gauge onto the pitch circle of the gear, and measure the backlash.

Standard Wear limit

Crank gear,
cam gear, idle
Refer to Section "2 1) Nomi-
Backlash gear and fuel
nal and Allowable Values".
injection pump
drive gear

3) Gear Train
After installing all the gears, check that the matchmarkes of idle gear and camshaft gear, idle gear and crankshaft
gear are aligned as below.

Cam gear

Idle gear

Crank gear
*P.T.O. (Option) 003401-00E

4-20
 4. MEASUREMENT PROCEDURE, SERVICE DATA
AND CORRECTIVE ACTION

4-9 Trochoid Pump

Lube oil pump is installed in the idle gear. Remove the E-ring to disassemble the trochoid pump.

Adjusting shim

Collar

E-ring

003402-00E

1) Clearance Between Outer Rotor and Inner Rotor Inner rotor

Insert a thickness gauge between the top of the inner
rotor tooth and the top of the outer rotor tooth to mea-
sure the clearance.

Standard Wear limit

Outer rotor
Clearance between
Refer to Section "2 1) Nominal and
outer rotor and
Allowable Values".
inner rotor Thickness gauge

(Measuring the clearance between

outer rotor and inner rotor )
003403-00E

4-21
 5. PRECAUTIONS FOR REASSEMBLY

5. Precautions for Reassembly

Reassemble the engine components in the reverse order of the disassembly procedure. Follow the precautions
below particularly before and during the reassembly.

1) Cleaning the Components

Clean the cylinder block, the cylinder head, the crankshaft, and the camshaft carefully so that they are free from
chips, dust, sand, and other foreign matter.

2) Parts to be Replaced in Reassembly

Be sure to replace the following parts with new ones in reassembly.
(1) Valve guide seal
(2) Head gasket packing
(3) All of the copper packings, O-rings and gasket packings

3) Measuring the Side Gap Around the Crankshaft

Apply a dial gauge to the end of the crankshaft. Press the
crankshaft to each of the right and left sides in the axial
direction to measure the side gap. Alternatively, insert a
thickness gauge directly into the clearance between the ref-
erence thrust metal and the thrust surface of the crankshaft
to measure the side gap. If the measured value exceeds the
Dial gauge
wear limit, replace the thrust metal with a new one.
Refer to Section "2 1) Nomi-
Side gap Crankshaft
nal and Allowable Values". 003404-00E

4) Gear Train
After installing all the gears, check that the match marks (From the gear case side)
idle gear - crankshaft gear and idle gear - camshaft gear.
Cam gear

Idle gear

Crank gear
*P.T.O. (Option)
003405-00E

5-1
 5. PRECAUTIONS FOR REASSEMBLY

5) Applying Lubricating Oil to the Intake / Exhaust

Valve Stem Valve guide

Apply lubricating oil to the valve guide so that the oil

spreads over the lower surface (hatched portion in the fig-
ure) of the valve guide, before reinstalling the valve guide.
003406-00E

6) Reinstalling the Piston Rings

(1) Fit the piston ring into the ring groove, with the manu-
facturer's mark near the end of the piston ring facing
upward (to the combustion chamber side), using a
piston ring replacer. After fitting the piston ring, check
that it moves smoothly.
(2) Install the piston their end gaps rings into their
respective ring grooves so that their end gaps are
shifted at 120 degrees intervals, making sure that
they are not aligned along the piston. Apply lubricat-
ing oil to the outside surface of the piston.

7) Applying Lubricating Oil to the Push Rod Adjust Screw Contact Portion
Apply lubricating oil to the hatched portion of the push rod as shown in the figure, before reassembly.

Apply lubricating oil

003407-00E

8) Installation Direction of the Piston and the Connecting Rod

Front end of the engine

Matchmarks 003408-00E

Install the piston so as for the apex of the triangle on the top of piston to face the front end of the engine. Assemble
the connecting rod so that the matchmarks of large end of the connecting rod face the fuel oil injection pump.

5-2
 5. PRECAUTIONS FOR REASSEMBLY

9) Installation of the Cylinder Head Gasket

Install the gasket with the part number stamp on it facing No. stamp
up. The thickness of it is determined by piston projection
from the top of cylinder block.

Piston projection and gasket thickness

Sink of piston (mm) Stamp No. Thickness (mm)
0.5 to 0.6 7600 1.2
0.6 to 0.7 7610 1.3

008548-00E

008549-00X

10) Tightening Order and Tightening Torque of the Cylinder Head Bolts
Tighten the cylinder head bolts at a specified tightening torque in the numerical order as shown below.
㧟 㧡

㧝 㧥
㧣

Flywheel side Front end of the engine

㧞
㧤 

㧠 㧢
008550-00E

Refer to Section "2 2) Engine

Tightening torque Tightening torque for major
bolts and nuts".

11) After Completing the Reassembly, Carry Out a Verification Run of the Engine to Check That There is No
Water or Oil Leakage.

5-3
 6. FUEL INJECTION SYSTEM

6. Fuel Injection System

6-1 Fuel Oil Injection Pump

The injection pump is a PFR model of Bosch type. The

pump camshaft has pump drive cams and injection oil
flow is controlled by a control lever in the gear case.

1) Injection Pump
Disassemble the pump at a specified service shop only.
Part Code No. 165000-15210

2) Governor
The governor is a mechanical all speed type and
installed in the gear case. The fly weight assembly is
installed on the camshaft and its movement is conveyed
through slider-control lever-link to the control rack of the
pump. The fly weight control spring is installed on the
arm complete and tension bar so that the governor lever
angle changes spring tension to control the engine
speed.

003412-00X

3) High Idling Speed Set Screw

The arm complete movement is restricted by the high
idling speed set screw and idling speed is limited. (As 3
shown to the right, caps 3 are installed by the factory not
to be readjusted the preset.

008552-00J

6-1
 6. FUEL INJECTION SYSTEM

4) Smoke Set and Start Spring

Smoke set 1 is installed on the cylinder block. It restricts
fuel oil injection in high speed range and the angleich
spring is installed in it so as to increase fuel oil injection
1
to gain a big torque in mid speed range.
The start spring is installed on gear case and governor
2
link to increase fuel oil injection when the engine is
started.
The smoke set is preset by the factory and sealed by a
cap 3 not to be readjusted locally.
008551-00X

5) Adjusting the High Idling Speed (Refer to 3-7) Start spring

The set screw 2 is preset by the factory and sealed,
however, the idling speed can be readjusted.
(1) Screw in the left hand side screw of the governor
lever to decrease high idling speed.
(2) Screw in and out the right hand side screw of the
governor lever to increase and decrease low idling
speed respectively.

008553-00E

6-2 Disassembling Procedures

(1) Remove the engine stop solenoid.

(2) Remove the fuel oil injection pump holding screws
and 4 nuts.
(3) Pull up the injection pump a little and remove R-pin
that connects the control rack and governor link to
remove the timing gear case. R-pin
Note :
Remove the gear case after covering the key groove for
crankshaft pulley with a friction tape or something so as 008554-00E

not to damage the oil seal of the timing gear case.

6-2
 6. FUEL INJECTION SYSTEM

6-3 Reassembling Procedures Cam gear pin

(1) Install the slider after aligning it and the cam gear
pin.
(2) Fix the control lever with the stopper lever and then
Slider
assemble the gear case.
Note :
Make sure if the start spring is securely installed.

003416-00E

Start spring

Control lever
003417-00E

(3) Align the gear case pin and oil pump cover hole
Oil pump cover hole
when the gear case is reinstalled.
Note :
Rotate the oil pump cover clockwise and counterclock-
wise, fix the spring pin hole in the center of its movement
and install the timing gear case.

(4) After reinstalling of the timing gear case, make sure

if the link simultaneously moves when the stop lever Gear case pin

is operated.
Note :
Cover the key groove for crankshaft pulley with a friction
tape or something so as not to damage the oil seal of the 003418-00E

timing gear case.

6-3
 7. ELECTRICAL EQUIPMENT

7. Electrical Equipment

7-1 Starter Motor

To start the engine, the starter motor rotates the ring gear installed on the engine flywheel with the pinion gear
engaged with the ring gear so that the force generated by the rotation exceeds the resistance including the engine
compression pressure and all frictional force. The starter motor consists of the following major parts : a motor which
generates torque ; a pinion which transmits the torque to the engine ring gear ; a clutch ; and a magnetic switch
which pushes out the pinion and turns on and off the principal current.

1) Specifications and Service Data

Yanmar code 165000-47590
Applicable model 2TE67L-BV
MITSUBISHI
Starter motor model M000T84281
Nominal output / Weight kW / kg 1.2 / 2.65
Rotation direction Clockwise
(viewed from pinion side)
Engagement method Magnetic shift
Terminal voltage / Current V/A Less than 11/90
No load
Speed rpm More than 2800
Load Terminal voltage / Current V/A Less than 4.0/650
characteris- N•m / (kgf•m)
tics Torque / speed / rpm 15.7 (1.60)
Pinion DP or module
DP10 / 12
/ Number of pinion teeth
Standard spring force N (kg) 20.5 to 22.6
(2.09 to 2.31)
Brush
Standard height
/ Wear limit mm 12.3 / 7.0
Outside Standard
Commutator mm Ø29.4 / Ø28.8
diameter / Wear limit
Gap between pinion and pinion stopper mm 0.5 to 2.0

7-1
 7. ELECTRICAL EQUIPMENT

1. Structure
The starter is 4-P direct drive type motor and the overrunning clutch is activated by the solenoid.

Switch

Brush

Lever

Internal gear

Gear shaft

Overrunning clutch
Ball

Armature Yoke Planetary gear

Armature shaft

Fig.1

7-2
 7. ELECTRICAL EQUIPMENT

2. Disassembly
Note :
Put two matching marks on the switch and yoke before disassembling.
(1) Remove the terminal nuts of the magnet switch to remove connector.
Remove switch holding screws to remove the switch and plunger.
(2) Remove the brush holding screws and through screws.
Remove the rear bracket but do not remove the brush holders.
(3) Slip in a socket (OD Ø29.4 mm) or something between the commutator and brush holder for inspection and
reassembly.
(4) Remove the armature and the yoke.
(5) Remove the planetary gear and packing.
Remove the gear shaft assembly and lever at the same time.
Note :
For easy reassembling, line up the lever, plate and packing according to disassembling order.
(6) Remove the overrunning clutch
[1] Drive a pipe that matches the snap ring with a hammer to remove the stop ring and snap ring.
[2] Remove the overrunning clutch from the armature shaft. If the snap ring is damaged, replace it with a new one.

3. Inspection
(1) Armature
[1] Check the coil for short circuit. If any, replace the armature.
[2] Check the coil for ground. If it grounds, replace the armature.
[3] Check the commutator for wear. If it is too much, replace the armature.
[4] Check the commutator for insulation depth. Repair if it is inadequate.
(2) Gears
Check for excessive wear or damage.
(3) Brush
[1] Check brushes for wear. If it is too much, replace them with new ones.
[2] Check if the brushes smoothly move in the holder to verify the springs work well.
[3] Check the brush holder plate and brush holder insulated for connection. If any, replace the brush holder assem-
bly with a new one.
(4) Overrunning Clutch and Pinion Gear
Rotate the pinion gear with holding the clutch housing.
It should rotate one way only. If something is wrong, replace the overrunning clutch.
If any wear and burrs in the pinion gear, replace the overrunning clutch.
Note :
Never wash the overrunning clutch not to remove lubrication grease in it.
(5) Front Bracket / Rear Bracket
Check metals of them for wear. If it is too much, replace metals with new ones.
(6) Switch
Check the terminal M and body of the switch for connection. Unless they are connected, replace the switch with
a new one.

7-3
 7. ELECTRICAL EQUIPMENT

4. Reassembly and Adjustment

Reassemble in the reverse order of the disassembly procedures with observing the following instructions.
(1) Fill or coat grease on the following parts.
Greasing points Grease
a Front sleeve bearing MULTEMP #6129
b Rear sleeve bearing MULTEMP #6129
c Reduction device (Armature shaft gear, Internal gear, Planetary gear) MULYKOTE RAG-650
d Overrunning clutch and lever friction part MULTEMP #6129
e Gear shaft spline and pinion friction part MULYKOTE RAG-650
f Ball MULYKOTE RAG-650

b c f d
Fig.2

7-4
 7. ELECTRICAL EQUIPMENT

5. Non Load Testing

Ammeter
A

Switch
B
+ S
Voltmeter V

Battery
12V
Starter motor
-

Fig.5 003422-00E

(1) Arrange the test circuit with the voltmeter and ammeter as shown in Fig.5.
Note :
Use as bold wire as possible and securely connect all terminals.
(2) Close the switch and compare RPM, ammeter and voltmeter readings with the service data.
(3) If anything is not within the standard, repeat the inspection mentioned above.

7-5
 7. ELECTRICAL EQUIPMENT

6. Service Data
Standards or limit
V 11.0
Non load performance A Less than 90
RPM 2800
O.D. 29.4 mm
Commutator
Limit 28.8 mm
Length 12.3 mm
Brush
Limit 7.0 mm
Pressure 21.57±15% N
Brush spring
Limit 5.88 N
Pinion gap 0.5 - 2.0 mm

7-2 Alternator

The alternator is a revolving-field type three-phase AC generator. The AC electricity generated by the alternator is
converted to DC through the full-wave rectification by the diode and is stored in the battery.

Specification
Nominal output voltage
V/A 14 / 8.5
(Full-wave rectification)
Alternator model GP8146
Yanmar code 165000-15580
Working speed rpm 1600 to 5200
Maximum speed rpm 5600 Connection diagram
Less than 15 / 14
Nominal output current A/V Starter switch
(5200 rpm) Alternator
Working ambient temperature °C -40 to 80
Battery charge

Current
alarm lamp

Pulley diameter / V-belt size mm Ø65, FM28

Battery

Load
limiter
Ground polarity Negative
Applicable models 2TN67-BV
003423-00E

(Disassembly procedures)
(1) Remove the alternator from the engine. 1
2
(2) Remove the cap and cap screw (M10).
Fix the shaft tip. Do not fix the flywheel 4. 4
(3) Remove the flywheel 4. Drive lightly the tip of M10
screw of the shaft.

1 Stater coil
2 Roter
3 Ball bearing
4 Flywheel 003424-00E

7-6
 7. ELECTRICAL EQUIPMENT

(4) Lead wire clamp of the coil plate.

Remove a M4 cap screw to remove the coupler.
(5) Loosen two screws to remove stater coil 1 from coil plate.

(Reassembly procedures)
(1) Reassemble in the reverse order of disassembling.
Tightening Torque 29.4 to 34.3 N•m (3.0 to 3.5 kgf•m)

(Inspection)
1. Combination of the alternator and regulator
Normal Not normal Cause
Charge current and battery voltage 1. More than 14 A at 14 V or More than 14 A at 15 V or Mulfunction of regulator
(5200 rpm at alternator) less more
2. 14 A to 0.5 A at 14 to 15 V Charge current : 0 A Alternator, regulator or wir-
ing.
Charge current flows but Battery (over discharging)
battery voltage is low.

2. Alternator
(1) Performance
Normal Not normal Cause
Non load voltage (between two sky blue wires) Less than AC 28 V Poor magnetic force at flywheel.
More than AC 28 V
when running (about 5200 rpm) or nothing Cutting in coil or wires.
Connection Between two sky blue
Connected Not connected Coil cutting
wires
Insulation resistance
More than 3 M: Less than 3 M: Poor Insulation of coil.
(between a lead wire and coil plate)

(2) Rotation of flywheel

Normal Not normal Cause
Rotate flywheel by hand 12 times of resistance Noise while rotating Bearing
develop at 1 turn but it Foreign material
smoothly rotates No rotation resistance Poor magnetic force

7-7
 7. ELECTRICAL EQUIPMENT

7-3 Glow Plug

The glow plug installed on the cylinder head is a starting aid in cold weather, which serves to warm the air in the
combustion chamber to start the engine easily at low ambient temperature.
The glow plug is operated to warm the air in the combustion chamber by setting the starter switch key to "GLOW"
and supplying electricity for about 6 seconds.

(1) Specifications
Yanmar code 165000-15620
Rating DC11 V / 0.5 :
Rated operating time 6 sec.
Applicable models 2TE67L-BV

Tightening torque
8.0 to 15 N•m
Glow plug body
(0.8 to 1.5 kgf•m)
1.0 to 1.5 N•m
Terminal mounting nut
(0.1 to 0.15 kgf•m)

The glow plug is ceramic glow. Be careful of its handling.

(1) When removing
Loosen by a specified tool and remove by hand.
No air tool is allowed.
(2) When installing
[1] Screw in the plug for 2 - 3 threads by hand.
[2] No air tool is allowed.
[3] Tighten it to 8 to 15 N•m (0.8 to 1.5 kgf•m) by a torque wrench.
(3) If a glow plug is dropped, never use it again.

7-8
 7. ELECTRICAL EQUIPMENT

7-4 Stop Solenoid

B (for holding) B

A (for pulling) A

Terminals of solenoid
003425-00E

Inspection
(1) The solenoid is normal as long as the plunger is pulled into the body when the terminal A is connected to (+) of
the battery and body to (-).
(2) The solenoid is normal as long as the plunger is kept holding in the body when the plunger is pushed in and
battery’s (+) and (-) terminals are connected to the terminal B and body respectively.
Note :
Complete the pulling test in a short time, or wiring may be cut.

7-9
 2TE67L-BV on SV08-1

Technical Information

First Edition : Jan. 2006

Published by : Engineering & Development Dept.

Edited by : Quality Assurance Dept.
Finished by : Yanmar Technical Service Co., Ltd.

Copyright c 2006 YANMAR CONSTRUCTION EQUIPMENT CO., LTD. All Rights Reserved.
This manual may not be reproduced or copied in whole or in part, without the written consent of
YANMAR CONSTRUCTION EQUIPMENT CO., LTD.