D 427 Diezel Engine

EngineFor Skid Steer Loaders

D427 Diesel Engine

1550XL(DSL702)

SB4034E00Ju l . 2000

Engine 2.1. General Information

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safetyrules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before anaccident occurs. A person must be alert to potential hazards. This person should also have the necessarytraining, skills and tools to perform these functions properly.

Read and understand all safety precautions and warnings before operating or performing lubrication,maintenance and repair on this product.

Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safetyprecautions are listed in the “Safety” section of the owner/operation/maintenance publication.Specific safety warnings for all these publications are provided in the description of operations where hazardsexist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings inthis publication and on the product labels are identified by the following symbol.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could resultin injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you have read andunderstood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in thispublication.

DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings inthis publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operatingtechnique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you andothers. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at thetime it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and otheritems can change at any time. These changes can affect the service given to the product. Obtain the completeand most current information before starting any job. DAEWOO dealers have the most current informationavailable.

WARNING

1

Diesel Engine D427 Index

Index

Engine

Specifications ............................................................5Troubleshooting Guide ..............................................6Adjustment of Cylinder Head Valve Clearance/Idling....8Adjustment of Valve Clearance .................................8Idling

Inspection..............................................................9Adjustment ............................................................9

Injection TimingInspection..............................................................9Adjustment ..........................................................10

Checking of Compression Pressure........................10Disassembly and Assembly.....................................11Inspection and Adjustment

Cylinder Head .....................................................21Valve....................................................................24Valve Spring ........................................................24Push Rod ............................................................25Tappet .................................................................26Rocker Arm .........................................................26Piston and Piston Ring........................................27Connectng Rod ...................................................29Connectng Rod Bearing......................................30Crankshaft ...........................................................31Main Bearing .......................................................32Cylinder Block .....................................................33Cylinder liner .......................................................33Camshaft .............................................................34Gears ..................................................................35Oil Seal................................................................36

Lubrication System

OutlineStructural View ....................................................37Specifications ......................................................38

Troubleshooting Guide ............................................38Inspection

Checking Oil Pressure ........................................39Oil Pump

Removal and Installation.....................................39Disassembly........................................................39Inspection............................................................40Assembly.............................................................41

Oil PanRemoval ..............................................................41Installation ...........................................................41Inspection............................................................41

Cooling System

Specifications ..........................................................42Troubleshooting Guide ............................................42Thermostat

Removal ..............................................................43Inspection............................................................43Installation ...........................................................43

Water PumpOn-Vehicle Inspection .........................................44Removal and Inspection .....................................44Disassembly and Assembly ................................44Inspection............................................................45

V-BeltInspection............................................................45

Fuel System

Outline .....................................................................46Structural View ....................................................46Specifications ......................................................47

Troubleshooting Guide ............................................47Fuel Filter

Removal and Installation.....................................49Air Bleeding.........................................................49Water-Drain .........................................................50Replacement .......................................................50

Injection pumpStructural View ....................................................51On-Vehicle Inspection and Adjustment ...............52Removal ..............................................................53Installation ...........................................................54Air-Bleeding.........................................................54

Injection NozzleStructural View ....................................................55Removal ..............................................................55Inspection and Adjustment..................................55Assembly.............................................................57Installation ...........................................................57

3

Diesel Engine D427 Index

Engine Electrical System

Specifications ..........................................................58Troubleshooting Guide ............................................58Starter

On-Vehicle Inspection .........................................60Removal ..............................................................60Installation ...........................................................60Free Running Test...............................................60Disassembly........................................................61Inspection............................................................62

AlternatorCircuit Diagram ...................................................65Charging system cautions...................................65On-Vehicle Inspection .........................................65Checking No-Load Adjustment Voltage ..............66Checking Output .................................................66Removal ..............................................................66Installation ...........................................................67Disassembly and Assembly ................................67Inspection............................................................69

Glow PlugsChecking Open Circuit of Glow plugs .................70Removal and Installation.....................................70

Technical Data ..............................................72

4

Diesel Engine D427 Engine

Engine

Specifications

Specifications

5

Engine model D427

Type Diesel, four-cycle

Number and arrangement of cylinders Four cylinders, in-line

Displacement cc 2701

Type of combustion chamber Swirl floor type

Valve system Over head valve(O.H.V)

Bore and stroke mm X mm(in X in) 92.0 X 101.6(3.62 X 4.00)

Compression ratio 21.5 : 1

Intake valveOpen BTDC 14˚

Valve timingClosed ABDC 44˚

Exhaust valveOpen BBDC 48˚

Closed ATDC 10˚

Injection Timing ATDC 2˚

Valve clearance mm(in)Intake 0.30(0.012)

Exhaust 0.30(0.012)

Idling speed rpm 1100 L 25

Firing order 1-3-4-2


Troubleshooting Guide


6

Problem Possible Cause Remedy

Insufficient power Insufficient compressionimproper valve clearance AdjustCompression leakage from valve seat Repair

(grind the valve seat)Seized valve stem ReplaceWeak or broken valve spring ReplaceCracked or distorted cylinder head ReplaceSticking, damaged, or worn piston ring ReplaceCracked or worm piston Replace

Malfunction of fuel svstem Refer to Group 4

Excessive oil Oil working upconsumption Worn or sticking piston ring or piston ring groove Replace

Worn piston or cylinder Replace or repairOil working down

Bad valve seal ReplaceWorn valve stem or guide Replace

Oil leakage Refer to Group 2

Difficult starting Malfunction of engine-related componentsBurned valve ReplaceWorn piston, piston ring, or cylinder Replace or repairBurned cylinder head gasket Replace

Malfunction of fuel system Refer to Group 4Malfunction of electrical system Refer to Group 5

Abnormal Malfunction of engine related componentscombustion improper valve clearance Adjust

Sticking or burned valve ReplaceWeak or broken valve spring ReplaceCarbon accumulation in combustion chamber Eliminate the carbon

Malfunction of fuel system Refer to Group 4

Poor idling Malfunction of engine-related componentsImproper valve clearance AdjustPoor valve to valve seat contact Repair or replaceFailure of cylinder head gasket Replace

Malfunction of fuel system Refer to Group 4

Diesel Engine D427 Engine7

Problem Possible Cause Remedy

Engine noise Crankshaft or bearing-related partsExcessive main bearing oil clearance Replace or repairMain bearing seized or heat-damaged ReplaceExcessive crankshaft end play Replace or repairExcessive connecting rod bearing oil clearance Replace or repairConnecting rod bearing seized or heat-damaged Replace

Piston-related partsWorn cylinder Replace of repairWorn piston or piston pin ReplaceSeized piston ReplaceDamaged piston ring ReplaceBent connecting rod Replace

Valves or related partsExcessive valve clearance AdjustBroken valve spring ReplaceExcessive clearance between valve stem and guide Replace

OthersMalfunction of water pump bearing ReplaceImproper drive-belt tension AdjustMalfunction of alternator bearing ReplaceExhaust gas leakage RepairMalfunction of timing belt tensioner Replace


Adjustment of Cylinder HeadValve Clearance/Idling

Adjustment of Cylinder Head

1. Remove the cylinder head cover.

2. Remove the head bolts.

3. Tighten head bolts to the specified torque, in thenumbered order shown in the figure. Use thetorque wrench.

Tightening torque(under cold engine condition) :11.0 ~ 11.7 m•kg (78.6 ~ 84.6 ft•lb)

4. Adjust valve clearance when fixing bolts.

Adjustment of ValveClearance

1. Remove the cylinder head cover.

2. With the No. 1 cylinder piston at TDC, check andadjust piston clearance as follows :

Intake side : No.1, No.2Exhaust side : No.1, No.3Valve clearance(under cold engine condition)

Intake & Exhaust : 0.30 mm (0.012in)

3. Set the No.1 cylinder to compression TDC byturning crankshaft, and then check and adjustpiston clearance as follows :

Intake side : No.3, No.4Exhaust side : No.2, No.4

4. Assemble the cylinder head cover.

8

Fig 1-2

Fig 1-3


Idling

Inspection

1. Warm up the engine thoroughly.

2. Run the engine at idle.

Standard ldling speed : 1100 L 25

3. Adjust the idling speed if the speed is not withinthe specified range.

Adjustment

Adjust the idling speed by turning the idling adjustingbolt of the injection pump.

1. Remove the lock nut of the idling adjusting bolt.

2. Turn the idling adjusting bolt until the idling speedreaches standard valve.

3. Tighten the lock nut.

4. Run the engine for about 2-3 minutes and check ifthe idling speed is at standard value.

Injection Timing

Inspection

1. Remove all injection pipes.

2. Remove the head bolt and gasket from thedistributor on the injection pump.

3. Set measuring instrument to injection pump. Makesure that the filler end of measuring device is incontact with plunger head.

4. With the flywheel ring gear in proximity to BTDC30˚ find the point where needle of dial gaugestands still, even when the flywheel is being turned.

5. When it is confirmed that the needle of dial guageis not moving, then set the needle of the dialgauge to “O”

6. Turn the flywheel clockwise until it reaches TDC,lnjection timing is normal if dial gauge indicates1.00mm at this point.Adjust if more than 1.00mm.

Cam lift for optimal injection timing : 1.00 mm (0.039 in)

9

Fig 1-7

Fig 1-8

Fig 1-9

Fig 1-10


Adjustment

Injection timing is too early when cam lift value ismore that 1.00mm, and too late when it is less than1.00mm.

1. If injection timing is not right, then turn the injectionpump until the dial gauge indicates 1.00mm.(1) If cam lift value is less than 1.00mm, turn

injection pump in direction of engine rotation toits maximum, and then adjust the cam lift valueto 1.00mm, by turning it in counter direction.

(2) If cam lift value is more than 1.00mm, adjust itby turning injection pump in counter direction toengine rotation, until value reaches 1.00mm.

2. Install the bolts and gasket after adjusting.

CAUTION : Use new head bolts and gasket.

3. Install the injection pipes.

Checking of CompressionPressure

1. Warm up the engine thoroughly.

2. Remove the nozzle holders from all cylinders.

3. Install the adapter set and use a pressure gaugeof capacity greater than 30 kg/cm2

4. Remove the fuel cut solenoid wiring.

5. Crank the engine and measure compressionpressure.

CAUTION : If the pressure does not come up to thespecified pressure, check the engine speed.

At normal engine speed, if compression pressure isless or more than the standard, and the pressuredifferences in each cylinder are more than 3 kg/cm2,it is necessary to disassemble and readjust theengine.

Compression pressure kg/cm2(lb•in2)-rpm

Standard 30(426)-200

Limit 27(384)-200

10

Fig 1-11

Fig 1-13


Disassembly and Assembly


Disassemble in the following sequence. Assembly isthe reverse order of disassembly.

1. Remove the Fuel pipes.

2. Remove the Starter motor.

3. Remove the Engine mounting bracket.

4. Remove coupler from the engine.

5. Set the engine on the engine hanger

6. Remove the following parts from the engine :(1) Alternator (7) Exhaust manifold(2) V-belt (8) Ventilation pipe(3) Crankshaft pulley (9) Injection pipe(4) Flywheel (10) Oil filter (5) End plate (11) Intake manifold(6) Water hose (12) Thermostat case

11


7. Remove the cylinder head parts in the numbered order shown in the figure.

(1) Cylinder head cover. (2) Gasket. (3) Rocker arm. (4) Cylinder head. (5) Gasket. (6) Push rod. (7) Intake valve. (8) Exhaust valve. (9) Valve guide.

Fig 1-24


8. Disassemble the piston and oil pan in the numbered order shown in the figure.

(1) Piston ring. (2) Piston. (3) Piston pin. (4) Connecting rod. (5) Connecting rod bearing set. (6) Oil pipe. (7) Set screw. (8) Oil pump. (9) Oil level gauge. (10) Gasket. (11) Oil pan.

Fig 1-25


9. Disassemble the timing gear and the related parts in the numbered order shown in the figure.

(1) Timing case cover. (2) Gasket. (3) Oil deflector. (4) Injection pump cover. (5) Gasket. (6) Locking bolt. (7) Thrust plate. (8) Idle gear. (9) Spindle. (10) Crankshaft gear. (11) Lock nut. (12) Lock plate. (13) Cam gear. (14) Lock nut. (15) Lock plate. (16) Injection pump gear. (17) Timing case. (18) Oil seal

Fig 1-26


10. Disassemble the crankshaft, cylinder block and the parts in the numbered order shown in the figure.

(1) Main bearing cap. (2) Bearing set. (3) Crankshaft. (4) Thrust plate. (5) Cam shaft. (6) Tappet. (7) Oil seal cap. (8) Gasket. (9) Oil seal. (10) Cylinder liner. (11) Cylinder block.

Fig 1-27


11. Disassemble the pulley lock bolts and crankshaftmounting bolts, preventing flywheel rotationprevent the flywheel from rotating and remove thepully lock bolts and crankshaft mounting bolts.

12. Remove crankshaft pulley by using the taper ringremover

13. Remove the taper sleeve after compressing thevalve spring by using valve spring lifter and pivot

14. Remove the valve guide, pushing it towardscombustion chamber by using the valve guideinstaller.

15. Assemble the valve guide in the following order.

(1) Set valve guide on the opposite side of thecombustion chamber and tap down by usingthe valve guide installer, until the height of thevalve guide comes near to the level of thevalve guide installer scale.

(2) Check the part of the valve guide protrudingafter assembling.

Standard Height of protruding part above thecylinder head : 16.5 mm (0.650 in)

16

Fig 1-28 Fig 1-31

Fig 1-32Fig 1-29

Fig 1-30


16. Remove the piston pin by using the piston pinremover & installer.

17. Assemble the piston and connecting rod, afterinserting connecting rod into piston as shown inthe figure.

18. Assemble the piston rings after checking that the“Y” marked surfaces of the rings appear on theupper side of the rings.

19. Assemble the piston rings and oil rings ontopiston as shown in the figure.

CAUTIONS :a) Gaps on the top ring and second ring must be

placed on the opposite side of combustionchamber.

b) Gap on the top ring should not face thrust side orcounter thrust side.

c) Gap on the top ring should be set on opposite side(180˚) of oil ring gap.

20. Install the piston into cylinder block by using thepiston ring compressor, and make sure that thepiston is placed as shown in the figure. (Installthe piston so that “F” mark on the piston facesthe front side of the engine).

17

Fig 1-33

Fig 1-34

Fig 1-35

Fig 1-36

Fig 1-37


21. Adjust valve clearance after assembling. Oil pangasket is composed of side, front and backgaskets as shown in the figure.

CAUTION : Use new oil pan gasket.

22. Remove the timing gear by using the bearingpuller set

23. Remove the cam gear by using the timing gearcase cover mounting bolts and bearing puller set.

24. Remove the injection pump gear by using theextractor.

25. Install the idling gear with its reference mark(punched mark) meeting those of other pears.

26. Insert the oil seal, by using the oil seal puller &installer timing cover.

18

Fig 1-39 Fig 1-42

Fig 1-43

Fig 1-44

Fig 1-40

Fig 1-41


CAUTIONSa) Position the bearing cap and bearing according to

their numbers.b) Line up thrust washers upright, and be careful not

to alter bearing combination.

27. Remove the cylinder liner, by using cylinder linerreplacer and press.

Cylinder liner assembling pressure :1 ~ 3 tons

NOTES :a) If cylinder liner is difficult to remove, then bore the

liner until it comes loose.b) Check for any damage or scratch on the cylinder

bore wall after removing the liner and, if there isany defect, repair by using fine sandpaper.

28. Install the cylinder liner, and measure cylinderinner diameter and height of liner protruding part.

Standard cylinder bore dia :92.025 ~ 92.050 mm (3.623 ~ 3.624 in )

Protrusion height above cylinder block :-0.101 ~ 0 mm (-0.004 ~ 0 in)

29. Assemble the main bearing in reverse order ofdisassembly carefully not to apply oil on the backof the bearing.

30. Apply the grease on crankshaft main journal andcrank pin.

19

Fig 1-45Fig 1-48

Fig 1-46

Fig 1-47

Fig 1-49


31. Assemble the main bearing cap, directing arrowmark on the top of the cap towards engine front.

32. Assemble the thrust washers on both sides ofcenter bearing, with their oil grooves facingoutwards.

33. Apply engine oil to connecting rod bearing, andmake sure that the weight marks on theconnecting rod and bearing cap meet each other.

34. Check to make sure that the end of push rod isset at the hollow point of the tappet.

35. Replacing valve seal(1) Remove the valve seal by using the suitable

tools.(2) Insert new seal into valve guide.(3) Assemble the valve seal by using the valve

seal pusher. Press valve seal pusher until thevalve seal reaches the bottom of valve springseat.

20

Fig 1-50 Fig 1-53

Fig 1-51

Fig 1-52


Inspection and Adjustment

Cylinder Head

Inspection of Cylinder Head

1. Inspect for distortion, damage and cracks. If aproblem is found, repair or replace the part.

2. Measure cylinder surface (combustion chamberside) for distortion with straight edge and fillergauge.

3. Measure cylinder head for distortion in the sixdirections shown in the figure. If cylinder headdistortion exceeds the limit, replace the cylinderhead.

Distortion limit :A, B : 0.1 mm (0.004 in)C, D, E, F : 0.25 mm (0.010 in)

Replacement of Insert

Inspect insert for damage and crack. If a problem isfound, replace the part.

1. Romove insert by hitting round steel rod with ahammer after inserting the round steel rod intoglow plug hole or nozzle holder hole.

2. Set the insert at the specified position on cylinderhead, adjust so that it connects with welsh washer.Set it facing towards cylinder head gasket and setthe welsh washer at its original positon.

3. Tap the center of the welsh washer slightly, to fix it.

21

Fig 1-55

Fig 1-57

Fig 1-58

Fig 1-59

Fig 1-56


Inspection of Valve and Valve Seat ContactSurface

Inspect contact surface of valve and valve seat asfollows :

1. Apply Prussian blue on contact area of valve seat.

2. Press down valve onto valve seat.

3. Check how Prussian blue adheres to the valve,and see if it is properly in contact with valve seat.

Inspection of Valve seat Contact Position

Check the surface which contacts the valve face. Thevalve contact position in relation to the valve seatmust be at the center of the circumference.

Standard valve seat contact width :2.0 mm (0.079 in)

Repair of Valve and Valve Seat Surface

1. If the problem is slight, grind the valve with a valvegrinder and compound.

2. If the problem is a little serious, repair the valveseat to the specifid angle with a valve cutter.

Valve seat angleIntake valve : 45˚Exhaust valve : 30˚

Valve seat contact with :Intake valve : 2.0 mm (0.079 in )Exhaust valve : 2.0 mm (0.079 in )

22

Fig 1-60

Fig 1-62

Fig 1-63

Fig 1-61


3. Grind the valve, with 3 valve grinder andcompound.

4. Check lenght “L” before adjusting.

Projection Length of Valve Stem Above CylinderHead(Length ÒLÓ)

Measure the projection length of the valve stem abovethe cylinder head (lenght “L” ) and, if more thanstandard, adjust according to the following instructions :

Standard lenght “L” 48.05 mm (1.89 in)

(1) 0 ~ 0.5mm longUse without adjusting.

(2) 0.5mm ~ 1.5mm longPlace a washer (inner dia. 12.8mm, outer dia. 39mm) under the lower spring seat. Adjust length “L”as standard valve.

(3) 1.5mm aboveReplace new one, and then measure length “L”.

23

Fig 1-64 Fig 1-66

Fig 1-67

Fig 1-65


Valve

Checking Condition

Visually inspect the valve for even seating of valveseat with the center part of the valve, and check fordefect. If any defective part is wide, replace valveand grind it if defective area is minor.

Dimensions of Valve

Thickness of head (valve verge)Standard :

Intake : 1.7 mm (0.0669 in)Exhaust : 1.5 mm (0.0591 in)

DIA. of valve stem :Standard:

Intake : 8.955 ~ 8.980mm (0.3526 ~ 0.3535 in)Exhaust : 8.935 ~ 8.960mm (0.3518 ~ 0.3528 in)

Limit :Intake : 8.904mm (0.3506 in)Exhaust : 8.884mm (0.3498 in)

Clearance Between Valve Stem and Valve Guide

Measure the clearance of max-wear piston betweenvalve stem and valve guide with a dial gauge, byturning valve and moving valve stem horizontally.

Clearance limitIntake : 0.127mm (0.0050 in)Exhaust : 0.127mm (0.0050 in)

If the clearance exceeds the limit, replace valve andvalve guide.

Valve Spring

Checking Free Length

Measure uncompressed length with calipers.

Uncompressed length limitOuter spring : 52.9 mm (2.083 in)Inner spring : 42.0 mm (1.654 in)

Replace the spring if shorter than uncompressedlength limit.

24

Fig 1-68

Fig 1-70

Fig 1-71Fig 1-69


Checking Tension

Measure tension of assembled valve spring by usingvalve spring tester.

1. Place valve spring on a valve spring tester.

2. Compress the valve spring to assembled lenght.(Compress several times).

3. Measure the spring tension when the spring iscompressed longitudinally.

Checking Perpendicular

Place the spring on a surface, and measure thevariation form perpendicular at the top of the spring.

Angle limitOutter spring : 1.37mm (0.0539 in)Inner spring : 1.25 mm (0.0492 in)

Push Rod

Checking Condition

Inspect both ends of push rod for wear or damage,and replace if necessary.

Checking Deflection

Place the push rod on a plane surface, and measurethe clearance between the plane surface and rodwith feeler gauge.

Deflection limit : 0.19 mm (0.075 in)

If the deflection exceeds the limit straighten orreplace.

Spring Assembled length Standard, tension Allowable tensionof assembled spring

Outer spring 40.3 mm(1.587 in) 18.0 L 0.9kg(39.7 L 2.0 lb) 15.9kg(35.1 lb)

Inner spring 37.8 mm(1.488 in) 12.7 L 0.6kg(28.0 L 1.3lb) 11.3kg(24.9 lb)

25

Fig 1-74

Fig 1-75

Fig 1-73

Fig 1-72


Tappet

Checking Condition

Inspect tappet for crack or damage, and replace it ifnecessary. Inspect contact point with came, andreplace it if it is worn out.

Checking of Clearance Between Tappet andTappet Guide

Measure the clearance between tappet and tappetguide, and replace tapper or cylinder block if theclearance exceeds the limit.

Clearance limit : 0.10 mm (0.0039 in)

Rocker Arm

Checking Condition

1. Inspect every part of rocker arm assembly forcrack or damage, and replace it if necessary.

2. Inspect oil holes of rocker arm and shaft, andclean them if blocked.

Checking Clearance

Measure the clearance between rocker arm shaft androcker arm bushing with a dial gauge.


Replace the rocker arm shaft and bushing, if theclearance exceeds the limit.

26

Fig 1-78Fig 1-76

Fig 1-79

Fig 1-77


Replacement of Rocker Arm Bushing

1. Remove the bushing by using press and roundsteel rod of proper diameter.

2. Press into the bushing by aligning the oil hole ofrocker arm bushing.

3. Bore the bushing by using expansion reamer andpin hole grinder, in order to be within standardclearance between bushing and shaft afterinstalling.

Standard clearance :0.016 ~ 0.061 mm (0.0006 ~ 0.0024 in )

Piston and Piston Ring

Checking Condition

1. Inspect sliding surface, ring groove, and otherparts for crack or damage, and replace ifnecessary.

2. Inspect for breakage, burning, wear and otherdefects on the rings, and replace if necessary.

27

Fig 1-82

Fig 1-80

Fig 1-81


Checking Clearance

Measure the clearance between piston and cylinderliner, and replace piston or cylinder liner if theclearance exceeds the limit.

Piston and cylinder liner clearance limit :0.044 ~ 0.070 mm (0.0017 ~ 0.0028 in)

Measure the piston outer diameter in the thrustdirection, 18mm (0.71 in) above the bottom of piston.

Standard piston outer diameter :91.967 ~ 91.993mm (3.621 ~ 3.622 in)

Checking Piston Ring end Gap

Measure piston ring end gap after inserting pistonring into a cylinder liner.

(1) When reusing the piston ring :Measure the gap, placing the ring at the pointwhere the cylinder liner is most worn.

(2) When replacing the piston ring :Measure the gap, placing the ring at the pointwhere the cylinder liner is least worn.

End gap limit : 1.5 mm (0.059 in)

Checking clearance Between Piston Ring Grooveand Piston Ring

1. Install the piston ring into the piston.

2. Measure clearance between piston ring grooveand piston ring with a filler gauge. Replace pistonor piston ring if the clearance exceeds the limit.


28

Fig 1-83

Fig 1-85

Fig 1-86

Fig 1-84


Connecting Rod

Checking Condition

Inspect connecting rod at both ends for crack ofdamage on the surface, and replace it if necessary.

Checking for Bending & Torsion

Check for banding or torsion of connecting rod byusing connecting rod aligner, and modify theconnecting rod with a press, replace it.

Bending limit : 0.05 mm (per 100mm)

Checking end Play of Big end

Check end play of the big end of the connecting rod,and replace connecting rod or crankshaft if the playexceeds the limit.

1. Fit connecting rod to crankshsft.

2. Measure end play by using a dial gauge withmagnetic base.

End play limit : 0.40 mm (0.016 in)

Checking Clearance Between Piston Pin andBushing

Measure the clearance between piston pin andbushing as shown in the figure, and replace pistonpin or bushing if the clearance exceeds the limit.


29

Fig 1-89

Fig 1-87

Fig 1-90

Fig 1-88


Replacement of Small end Bushing

1. Replace the bushing by using a rod and press.

2. Push the bushing with a press, confirming that theoil holes of connecting rod and bushing are inalignment with each other.

3. Adjust bushing hole with a reamer so that theclearance between piston pin and bush is withinstandard.

Standard clearance :0.014 ~ 0.044 mm (0.0006 ~ 0.0017 in)

When grinding the bushing make sure that thereamer is precisely inserted to prevent a roughbushing surface always grind in the direction ofcutting. Always be sure not to stop the reamer atsame points. When repairing the small end bushingwith a pin hole horning machine, the bushing holetends to incline to one direction, so change theconnecting rod position many times during thehorning process until horning size reaches standard.

Connecting Rod Bearing

Checking Condition

Check connecting rod bearing for burning, meltingand other damage, and replace if necessary.

30

Fig 1-93

Fig 1-91

Fig 1-94

Fig 1-92


Checking Clearance

Measure the oil clearance between crankshaft journaland connecting rod bearing with a plasti-gauge, inthe follwing order.

1. Remove oil residue from joural and bearing.

2. Set plasti-gauge to axial direction on a journal.

3. Install bearing cap and tighen to the specified torque.

Cap bolt tightening torque : 7.6 ~ 8.3 m•kg (55.0 ~ 6.0 ft•lb)

4. Measure the clearance by using the plastigaugeafter removing the cap.

Oil clearanceStandard : 0.059-0.090 mm (0.0023 ~ 0.0035 in)Limit : 0.12 mm (0.0047 in)

If the oil clearance exceeds the standard value, grindthe crank pin use undersized bearing.

Crankshaft

Checking Condition

1. Inspect the crankshaft for crack, breakage, orother damage, and replace it if necessary.

2. Check if oil holes are clogged, and unblock themby using compressed air or a needle if clogged.

Checking Wear

1. Inspect the crankshaft for wear.

2. Inspect crankshaft pin and main journal in alldirections (front and rear, diagonal directions), andif wear and tear of the crankshaft is beyondallowance limits, grind it to undersize and useundersized main bearing.

31

Fig 1-96

Fig 1-95

Fig 1-97


Checking Deflection

1. Place and secure both ends of the crankshaft onV-blocks.

2. Measure the deflection by placing a dial gauge onthe center of main journal and crankshaft slowly.Replace crankshaft if the value exceeds the limit.Read the maximum value on the dial gauge.


Checking end Play

Measure crankshaft end play by placing a dial gaugeon crankshaft rear end and by moving crankshaftback and forth in the axial direction. If the valueexceeds the limit, replace the thrust washer, which isinserted to the center bearing with 0.718 mmoversized one.

End playStandard : 0.14 ~ 0.39 mm (0.0055 ~ 0.0154 in)Limit : 0.4 mm (0.016 in)

Main Bearing

Checking Condition

Check the main bearing for wear, melting and otherdamage and replace it if necessary.

Checking Clearance

Measure oil clearance between main journal andmain bearing by using plasti-gauge.

Oil clearanceStandard : 0.059 ~ 0.090 mm (0.0023 ~ 0.0035 in)Limit : 0.12 mm (0.0047 in)

If oil clearance exceeds the limit, grind the mainjounal and use the undersized bearing.

32

Fig 1-100

Fig 1-98

Fig 1-101

Fig 1-99


Cylinder Block

Checking Condition

1. Inspect the cylinder block for crack, breakage,damage or other defects, and repair or replace ifnecessary.

2. Check if oil holes and coolant passages areclogged, and pierce with compressed air orneedles as necessary.

Checking Distortion

Measure the distortion of top surface of the cylinderblock, and repair or replace if the distortion exceedsthe limit.

Distortion limitA B : 0.10 mm (0.004 in)C D : 0.25 mm (0.010 in)

Cylinder Liner

Checking Wear

Measure the inner diameter of cylinder liner, andcheck for wear, and its extent. Measure the innerdiameter at 3 positions, of top, middle and buttom atsections X-X, and Y-Y, as shown in the figure

Wear limitWear=Measured highest value-Standard highestvalue

Standard cylinder liner :92.025 ~ 92.050 mm (3.623 ~ 3.624 in)

If the wear exceeds 2.0 mm ( 0.079 in), replace thecylinder liner.

one-sided wear limitOne-sided wear=Measured highest value -

Measured lowest valve If the one-sided wear exceeds 2.0mm (0.079 in),replace the cylinder liner.

33

Fig 1-104

Fig 1-105

Fig 1-102

Fig 1-103


Camshaft

Checking Condition

Inspect camshaft for crack, breakage, damage ofother defects, and replace it necessary.

1. Repair for replace if necessary.

2. Be careful not to change the original shape of thecam when repairing.

Checking Height

Check the height of the cam, and replace if lowerthan minimum height.

Cam height limit : (42.478 mm) (1.672 in)

Minor cam surface defects can be repaired by usinga fine abrasive compound, but be careful not tochange the original of the cam when repairing.

Checking The Cam Journal Wear

Check the cam jounal for wear, and replace the camshaft if the wear exceeds the limit.

Checking Deflection

Support both ends of the camshaft with V-blocks.Measure in deflection with dial gauge on journal byturning the camshaft slowly. If the deflecetionexceeds the limit, replace the camshaft.


Journal DiameterWear limit

No.1 51.910-51.940mm2.044 - 2.045 in)

No.2 51.660-51.690mm(2.034-2.035 in) 0.008mm

No.3 51.410-51.440mm (0.0003 in)(2.24-2025 in)

No.4 51.160-51.190mm(2.014~ 2.015)

34

Fig 1-108

Fig 1-106

Fig 1-109

Fig 1-107


Checking end Play

Measure the end play, and replace thrust plate if thevalue exceeds the limit.

1. Mount thrust plate and camshaft gear oncamshaft.

2. Tighten the lock bolt to the specified torque.

Bolt tightening torque :6.2 ~ 7.0 m•kg (44.8 ~ 50.6 ft•lb)

End play limit : 0.3 mm (0.012 in)

Checking Journal Oil Clearance

Check the oil clearance by measuring inner diameterof camshaft bearing, and outer diameter of camjournal. If the oil clearance exceeds the limit, replacethe camshaft or cylinder block.

Oil clearance limit : 0.145 mm (0.006 in)

Gears(Cam Shaft Gear, Idling Gear,Cam Gear, Injection Pump Gear)

Checking Condition

Replace gear if the gear teeth have been cracked ordamaged.

Checking Backlash

Measure backlash between idling gear and othergears with a dial gauge.

BacklashStandard : 0.10 ~ 0.17 mm (0.004 ~ 0.007 in)Limit : 0.3 mm (0.012 in)

Checking Idle Gear end Play

Measure the end play by inserting a filler gaugebewteen idling gear and thrust.

Standard end play :0.15 ~ 0.28 mm (0.006 ~ 0.011 in)

35

Fig 1-113

Fig 1-110

Fig 1-114

Fig 1-111


Checking Oil Clearance Between Idling Gear andSpindle

Measure the oil clearance by checking inner diameterof idling gear and outer diameter of spindle. If the oilclearance exceeds limit, replace idling gear bushingand spindle.

Oil clearanceStandard : 0.034 ~ 0.048 mm(0.001 ~ 0.003 in)Limit : 0.15 mm (0.06 in)

Oil Seal (Timing Gear Cover OilSeal, Rear Oil Seal)

Checking

Inspect oil seals for wear, breakage and damage,and replace defective oil seals.

36

Fig 1-115

Fig 1-116

Fig 1-117

Diesel Engine D427 Lubrication Systems37

Lubrication System

Outline

Structural View

Fig 2-1

Diesel Engine D427 Lubrication Systems38

Specifications


Lubrication System Force-feed type

Type Trochoid typeOil pump

Oil pressure control valve opening pressure 3.8 kg/cm2(56.9 lb/in2)

Oil FilterType Full-flow type, paper filter

Oil filter relief valve opening pressure 0.8~1.2kg/cm2(11.4~17.1 lb/cn2)

Oil cooler Type water cooled type

Oil warning lamp activation pressure 0.2~0.4kg/cm2(2.8~5.7 lb/in2)

Preblem Possible Cause Remedy

OIl leakage Loose drain plug Tighten or replaceFaulty seal oil and cylinder block ReplaceDamaged cylinder head cover ReplaceLoose oil pump body bolt, cylinder head cover bolt, or oil pan bolt TightenDamaged front housing gasket, or cylinder head gasket ReplaceFaulty oil seal(s) ReplaceLoose oil filter TightenLoose or damaged oil pressure switch Tighten or replace

Oil pressure drop Oil leak As described aboveInsufficient oil Add oilWorn and/or damaged oil pump gear ReplaceWorn plunger(inside oil pump) or weak spring ReplaceClogged oil strainer Clean itExcessive lubrication clearance between main bearing and connecting rod bearing Refer to Group 1

Warning lamp Oil pressure drop As described aboveilluminates while Malfunction of oil pressure switch Repairengine running Problem in electrical system Repair

Diesel Engine D427 Lubrication Systems

Inspection

Checking Oil Pressure

1. Remove the oil pressure switch.

2. Mount the oil pressure gauge on the cylinder blockhole where oil pressure switch had been installed.

3. Start the engine and warm it up to an appropriatetemperature.

4. Read the gauge, holding the engine speedsteady(High idle).

Oil pressure limit : 3.8kg•cm2 (54.1 lb•in2)

IF the oil pressure exceeds the limit, each part andrepair if necessary.

Oil PumpRremoval and Installation

Remove each part in the following order, lnstallationis the reverse order of removal.

1. Drain engine oil.

2. Remove the oil pan.

3. Remove the oil pipe.

4. Remove the oil pump.

Disassembly

Disassemble in the following sequence :

(1) Oil pump body. (2) Set screw. (3) Nut. (4) Plunger. (5) Spring. (6) Plug. (7) Drive shaft. (8) Outer rotor(9) Inner rotor. (10) Cover. (11) Oil strainer. (12) Oil pipe

FIG 2-3

39

Fig 2-2


Inspection

Checking Condition

Check all parts visually, and replace if necessary.Carefully check the sliding surface of the pumpcover, and replace if significantly of the pump cover,and replace if significantly defective (Repair minordefects by grinding with grinding compound).

Clearance Between Pump Body And Shaft

Measure the clearance with a dial gauge andmagnetic base.


If the clearance exceeds the limit, replace the pumpdrive shaft, inner rotor, pump body and drive gear.

Clearance Between Inner and Outer Rotor

Measure the clearance with a leaf gauge. Replaceboth rotors if the clearance exceeds the limit.


Clearance Between Outer Rotor and Pump Doby

Measure clearance between outer rotor and pumpbody with a leaf gauge. If the clearance exceeds thelimit, replace the rotor or pump body.


Clearance Between Rotor and Pump Cover

Check the end float of the rotor. Place a flat ruleracross the pump body and measure the clearancebetween ruler and rotor. If the clearance exceeds thelimit, replace the drive gear, drive shaft, inner rotor,outer rotor and pump body.


Free Length of Plunger Spring

Check wear of relief valve plunger and spring defect.

Free length of spring : 40 mm (1.57 in)

40

Fig 2-5

Fig 2-7

Fig 2-8

Fig 2-6


Assembly

Assemble in reverse order of disassembly.

CAUTION : When assembling the rotor on the body,confirm that the matching marks are in the front ofthe cover.

Cover tightening torque : 0.8 ~ 1.2 m•kg (5.79 ~ 8.68 ft•lb)

Oil PanRemoval

1. Drain engine oil.

2. Remove the hose between the vacuum pump andthe oil pan upper block.

3. Remove the oil level gauge pipe from the rubberhose.

4. Remove the oil level switch coupler (if installed).

5. Remove the oil pan.

6. Remove the gasket.

7. Remove the gasket.

8. Remove the level switch from the oil pan (ifinstalled).

9. Remove oil level gauge pipe from the oil panupper bock.

Installation

Install in the reverse order of removal

CAUTION : Install oil pan upper block with itsassembly surface conforming to the cylinder blockunder part.

Replace the oil pan gasket with a new one. Apply athin coating of engine oil to gasket between thecylinder block and the oil pan. Tighten the oil panbolts and nuts on the cylinder block to the specifiedtorque.

Tightening torque : 1.6 ~ 2.3 m•kg (11.6 ~ 16.6 ft•lb)

Inspection

1. Remove dust and chips from oil pan.

2. Inspect the oil pan for cracking, and check thedrain plug spiral part for damage. Check bolt holefor any damage due to excessive tightening.Repair such damaged part, and replace if difficultto repair.

41

Fig 2-10

Fig 2-9

Diesel Engine D427 Cooling System42


Cooling Method Water-cooled

Type Wax type(2 stage)

Opening temp 82 L 1.5˚C

Full-open temp 95˚C

Full-open lift 8.0mm (0.31 in) or more

Water pump type Type Centrifugal, timing belt driven

Radiator Type Corrugated

Cap valve opening pressure 1.0 L 0.15 kg/cm2(14.2 L 2.1 lb/in2)


Water leakage Damaged radiator core seam ReplaceLeakage from radiator hose or heater hose Repair or replaceLeakage from water temperature switch Repair or replaceLeakage from water seal (water pump) ReplaceDamaged or loose thermostat cover or gasket Repair or replaceLoose cylinder head bolt TightenDamaged cylinder block ReplaceCracked cylinder head Replace

Corrosion Impurities in coolant Clean

Overheating Water passage clogged CleanThermostat malfunction ReplaceRadiator fins clogged CleanWater pump malfunction Repair or replaceInsufficient coolant AddThermo - modulated cooling fan malfunction ReplaceRadiator cap malfunction Replace

Cooling System

Specifications

Diesel Engine D427 Cooling System

Thermostat

Removal

Remove the thermostat in the following sequence.

1. Remove the coolant. Drain the coolant until thecoolant level drops below the thermostat case.

2. Remove the radiator upper hose.

3. Remove the thermostat.

Inspection

Put the thermostat and a thermometer in water, heatthe water temperature gradually and raise thetemperature, both when the thermostat valve starts toopen and when it is fully open. If the temperaturevalues are lower than the specified values, replacethe thermostat.

Installation

Install the thermostat in the reverse order of removal.Notes

a) Replace the gasket whenever installing thethermostat cover.

b) Set the thermostat with its air hole on top.

c) After installing the thermostat, fill the coolant, startthe engine, and check for any leakage.

Opening temp Full-open temp Full-open lift

82˚C L 1.5˚C 95˚C 8mm(0.3in) or more

43

Fig 3-9

Fig 3-11

Fig 3-12

Fig 3-10


Water Pump

On-Vehicle Inspection

Check the water pump for leakage, noise andlooseness to the shaft or bearing. Clattering noise,when the fan blades are pushed up and down,indicates that the bearing is worn-out and defective,in the hole of pump body is leaking, disassemblehole of the pump and replace the seal.

Removal and Installation

Remove the water pump in the numbered order.Installation is the reverse order of removal.

1. Drain the coolant.

2. Remove the radiator cowling.

3. Remove the cooling fan.

4. Remove the V-belt.

5. Remove the cooling fan pulley.

6. Remove the water hose.

7. Remove the water pump.


Disassemble in the numbered sequence shown inthe figure, and assemble in reverse order ofdisassembly.

(1) Nut & washer. (2) Bearing housing. (3) Gasket. (4) Pulley boss. (5) Snap ring. (6) Shaft, spacer & bearing ass'y. (7) Impeller. (8) Seal ass'y. (9) Bearing. (10) Spacer. (11) Bearing. (12) Baffle plate. (13) Dust seal. (14) Snap ring.

1. Remove the pump pulley boss with the fan pulleyboss puller and press.

Fig 3-15

44

Fig 3-14

Fig 3-16

Fig 3-13


2. Remove the impeller and the shaft from bearinghousing by using the support block and press.

3. Remove the snap ring by using snap ring pliers,and push out the water pump shaft from thebearing.

4. Apply or inject grease to the following parts :

CAUTIONS : a) Fill 1/3 of the bearing space with lithium grease

(NLGI NO2).b) Apply grease on water seal surface contacting the

impeller.

Inspection

1. Disassemble scale from within the pump body.Clean removed parts.

2. Inspect all pump parts, and replace any part whichis cracked or damaged.

3. Check the water pump for noise and looseness,and replace if necessary.

4. Always use a new water seal after disassemblingthe water pump. Replace the impeller if there aredefects in water seal and impeller contact surface.

V-belt

Inspection

1. Check the V-belt for breakage or wear, andreplace if necessary.

2. If there is any noise, check tension of the belt andalignment of the pulleys.

3. V-belt should depress by a given amount when10kg power is applied to it.

Belt deflectionNew belt : 10 ~ 12 mm (0.39 ~ 0.47 in)Used belt : 13 ~ 16 mm (0.51 ~ 0.63 in)

45

Fig 3-17

Fig 3-18

Fig 3-19

Fig 3-20

Fig 3-21

Diesel Engine D427 Fuel Systems46

Fuel System

Outline

Structural View

Fig 4-1



Item Specification

Type VE type

Injection pumpInjection timing ATDC 2˚

Turning direction Clockwise

Idling speed 1100 L 25

Nozzle type Throttle type

Injection nozzleOrifice Dia. XNo. 8mm (0.032 in.)X1

Injection pressure 135~140 kg/cm2

Air cleaner Filter paper element type

Fuel Filter Cartridge type with water-detector

Injection order 1-3-4-2


Hard starting Clogged fuel filter ReplaceAir in fuel filter Air-bleedFaulty fuel cut valve ReplaceFaulty injection timing AdjustAir in injection pump Air-bleedTrouble inside of injection pump ReplaceSeized needle valve of injection nozzle Clean or replaceFuel dripping from injection nozzle AdjustFaulty cold start device Adjust or replace

Rough idling Clogged fuel filter ReplaceAir in fuel filter Air-bleedFaulty fuel cut valve ReplaceFaulty injection timing AdjustAir in injection pump Air-bleedTrouble inside of injection pump ReplaceSeized needle valve of injection nozzle Clean or replaceFaulty injection starting pressure AdjustImproper mounting to nozzle holder Disassemble and assemble or replaceLeakage at gasker ReplaceCrack in injection pipe ReplaceLeaking from injection pipe joint Retighten or replace improper idling speed Adjust

Engine knocking Faulty injection timing AdjustLow quality fuel ReplaceFaulty injection starting pressure AdjustSeized needle valve of injection nozzle Clean or replaceFuel dripping from injection nozzle Replace

Engine knockin Faulty injection timing AdjustLow quality fuel ReplaceFaulty injection starting pressure AdjustSeized needle valve of injection nozzle Clean or replaceFuel dripping from injection nozzle Replace

Specifications



High fuel consumption Faulty injection timing AdjustHigh idling speed AdjustFaulty injection starting pressure AdjustFuel dripping from injection nozzle ReplaceLeakage of gasket ReplaceLeaking from injection pipe joint Retighten or replaceClogged fuel filter ReplaceClogged air cleaner Clean or replace

Poor acceleration Clogged air cleaner Clean or replaceSeized needle valve of injection nozzle Clean or replaceFuel dripping form injection nozzle ReplaceFaulty fuel cut valve ReplaceFaulty injection timing AdjustAir in injection pump Air-bleedTrouble inside of pump ReplaceCrack of injection pipe ReplaceLeaking from injection pipe joint Retighten or replaceAir in fuel filter Air-bleedClogged fuel filter replace

Excessive Clogged air cleaner Clean of replaceexhaust smoke Improper injection timing Adjust

Faulty injection nozzle Adjust or replace

Diesel Engine D427 Fuel Systems

Fuel Filter

The fuel filter is installed between the fuel tank andthe injection pump, and it filters out all impurities fromthe fuel system.


Remove as the following sequence. Install the filter inthe reverse order of removal.

1. Drain fuel from the filter.

2. Remove the element, sealing, 0-ring and bowdownwards from the body.

NOTE: Apply fuel to the sealing (top & base) and0ring-before installing.

After installing the filter, remove the air breatherscrew in order to remove air with the priming thefilter, remove the air with priming pump, and afterstarting the engine, check for leakage

Air Bleeding

1. Loosen the air breather on the fuel filter.

2. Operate the priming pump in the fuel filter until thepure fuel comes out.

3. After bleeding all the between fuel tank and fuelfilter, fuel comes out.

4. Loosen the overflow pipe of injection pump.

5. Supply fuel to pump compartment in the injectionpump by operating the priming pump.

6. Start the engine, and bleed air in the injectionpump.

7. Tighten the overflow pipe connector.

8. Loosen the injection pipe on injection nozzle side.

9. Start the engine and check whether fuel us isbeing ejected from injection pipe

49

Fig 4-7

Fig 4-8

Fig 4-9

Fig 4-10


Water-Drain

Drain water when indicating lamp comes on or whenfloat level reaches standard level.

1. Loosen the drain plug.

2. Loosen the air breather if water does not come outeasily.

3. After draining water, supply fuel by operating thepriming pump on the filter.

4. DO air-bleeding.

Replacement

1. When removing the fuel filter, be careful not tospoil the fuel by holding the fuel filter upright.

(1) Adapter. (2) Cartridge. (3) Level sensor. (4) Drain plug(5) Air breather.

2. Apply a small amount of diesel on the packing.

3. Install the cartridge to adapter and tighten securelyby hand.

4. Install the sensor and drain plug to the cartridge.

5. Bleed air in the filter.

6. Start the engine and check whether there is anyleakage.

Fig 4-12

50

Fig 4-11


Fig 4-13

Injection Pump

If the inside of the injection pump is disassembled formaintenance, be sure to properly use the checking devicesuch as the injection tester, and carefully inspect eachcomponent.

Structural View


On-Vehicle Inspection andAdjustment

Checking Idling Speed

1. Warm up the engine.

2. Put the tachometer

3. Idle the engine.

4. Check the engine speed.

5. Adjust the idling-speed if the idling speed a withthe specified range.

Standard idling speed : 1100 L 25

Adjusting Idling Speed

1. Confirm the accelerator cable deflection. If thedeflection is not suitable, adjust it by turningaccelerator cable lock nuts.

2. Loosen the lock nut of the idle adjusting bolt andadjust the idling speed by turning the idle adjustingbolt.

NOTE : Idle speed will increase when the adjustingbolt is turned clockwise and decrease when turnedcounter-clockwise.

3. After adjusting, press the accelerator pedal 2 ~3times, and check the return of the acceleratorcable

Checking Injection Timing

1. Disconnect the fuel injection pipes from theinjection pump.

2. Remove the bolt and gasket from distributor headof the injection pump.

3. Mount the measuring device on the injectionpump. Make sure that the tip of the tester feelerneedle touches the plunger end of pump.

4. Set the flywheel ring gear BTDC 30˚ and find aposition where the pointer of dial gauge fixed.

5. After confirming the stability of the dial gaugepointer, set the dial gauge pointer to “O” point.

52

Fig 4-16

Fig 4-17

Fig 4-18

Fig 4-19


6. Turn the flywheel clockwise until indicator pointercomes to TDC. The injection timing is right if thepointer is increased 1mm.

Cam lift at optimal injection timing :1.00 mm (0.039 in)

7. Adjust injection timing if the cam lift exceeds 1mm.

Adjusting Injection Pump

1. If the injection timing is not correct, turn theinjection pump, and set at a position where the dialgauge pointer indicates 1.00 mm (0.039 in).

• If the cam lift value is more than 1mm, adjust sothat the cam lift becomes 1.00mm, by turning theinjection pump one full turn clockwise(in directionof engine rotation) and counter-clockwise it asnecessary again.

• If the cam lift is less than 1mm, adjust the camlift by turning the injection pump counter-clockwise.

2. After adjustment, install the gasket and tighten thehead bolt.

NOTE : When adjusting, use a new head bolt andgasket.

Removal

1. Remove the (+) (-) terminals from the battery.

2. Remove the upper cover and the cooling fan.

3. Disconnect the air hose.

4. Disconnect the fuel pipe and the injection pipe.

5. Remove the accelerator cable from the injectionpump.

6. Remove the fuel-cut solenoid wire.l

7. Remove the injection pump cover.

8. Loosen the lock nut.

9. Remove the plane washer. Be sure not to drop thewasher into the gear case by using a wire.

10. When checking the shaft key of the injectionpump, turn the flywheel through the timing holeon the clutch cover until the key arrives at theposition.

53

Fig 4-20

Fig 4-21

Fig 4-22

Fig 4-23


11. Remove the bolt on the auxiliary bracket, whichfixes the lower part of the injection pump.

12. Remove the injection pump mounting nut. Alsoremove the spring washer and flat washer.

13. Remove the pump shaft and the gear.

• Set the extractor and use M marked side of it.• Disconnect the shaft and the gear by tightening

extractor bolt.

14. Remove the injection pump. Remove the injectionpump in turn by pushing other pump gear near toit, being careful not to drop the key into gearcase.

15. Remove the extractor.

Installation

Install the injection pump in the reverse order ofremoval, paying attention to the following points :

1. Before installing the key on the drive shaft ofinjection pump, tap the key hole slightly until thekey is inserted into the key hole completely.

2. Remove air after installing the injection pump.

Drive gear tightening torque : 4.0 ~ 7.0 m•kg (28.9 ~ 50.6 ft•lb)

Air-Bleeding

Make sure to bleed the air replacing the fuel filter orcleaning the sedimenter.

1. Loosen the air bolt on fuel filter.

2. Pump with feed pump until fuel comes out.

3. Tighten the air bolt with pressing the feed pump.

54

Fig 4-24

Fig 4-25

Fig 4-26


Injection Nozzle(KCA Type)

Structural View

(1) Nozzle holder body. (2) Pressure Pin. (3) Pressure Spring.(4) Retaining Nut. (5) Distance Piece. (6) Shim. (7) Washer.(8) Nut. (9) Nozzle.

Removal

Remove the injection nozzle in the following order :

1. Fuel injection pipe

2. Fuel leak pipe lock nut

3. Fuel leak pipe

4. Injection nozzle

5. Washer

Inspection and Adjustment

Checking Injection starting pressure

1. Set the nozzle on the nozzle tester.

2. Bleed the air by pumping the nozzle tester handleseveral times.

3. Slowly lower the nozzle tester handle, and checkthe value shown on the pressure gauge wheninjection is started.

Injection starting pressure :135 ~ 140 kg•cm2 (1920 ~ 1991 lb•in2)

Fig 4-27

55

Fig 4-28

Fig 4-29


4. If the injection starting pressure is not within thespecified range, adjust the starting pressure withthe shim. The shim has 20 different thicknessesfor every 0.05mm (0.0020in.) to 1.95mm(0.0768in.). As 0.05mm (0.0020in.) is added,approx. 5kg•cm2 (71.12 lb•in2) of injection pressureincreases.

Checking Tightness of Valve Seat

Apply a pressure of 115kg•cm2 (1635.3 lb•in2), andcheck for fuel leaks from the nozzle injection hole. Iffuel leaks, it is necessary to disassemble, clean andrecheck the injection nozzle or replace it.

Checking Atomizing Condition

1. Set the injection nozzle on a nozzle tester.

2. Bleed the air by operating the nozzle tester handleseveral times.

3. Keeping the pressure gauge of the nozzle tester inthe non-functioning condition, quickly lower thehandle several times (lower the handle as quicklyas possible so that a pulsation whistling sound canbe heard) and check the atomizing condition.

(1) Fuel is atomized uniformly and properly.

(2) The injection angle and direction are normal. Ifthe atomizing condition is incorrect, it isnecessary to disassemble, wash and recheckthe injection nozzle, or to replace it.

Checking Nozzle Valve and Needle Valve

1. Check and ensure that the valve seat of theneedle valve and other parts are not damaged.

2. Make sure that the nozzle body is not damaged.Hold the nozzle body upright and insertapproximately two thirds of the needle valve andsee if the needle valve drops to the valve seat byits own weight.

56

Fig 4-30

Fig 4-31

Fig 4-32

Fig 4-33


Assembly

Pay attention to the following matters whenassembling injection nozzle.

CAUTIONS :a) After assembling the injection nozzle, check the

injection starting pressure and atomizing condition.b) Tighten the nozzle body on the nozzle holder to

the specified torque.

Nozzle tightening torque:8 ~ 10 m•kg (58 ~ 72 ft•lb)

Installation

Install in reverse order of removal.

CAUTIONS :a) The gasket and corrugated gasket and not be

reused.b) Tighten the injection nozzle on the cylinder head

to the specified torque.

Nozzle tightening torque :6 ~ 7 m•kg (43 ~ 52 ft•lb)

57

Fig 4-34

Fig 4-35

Diesel Engine D427 Engine Electrical System58

Engine Electrical System

Specifications


Item Specification

Voltage 12V, Negative Ground

Type Alternating

Alternator Output 12V-60A

Regulator Type Transistorized(built-in IC regulator)

Starter Type Electromagnetic push-in-type

Output 12V-2.5kW

Type Sheathed type

Glow plug Voltage 11V

Amperage 52A


Battery and related partsPoor contact of battery terminals Clean and tightenPoor grounding of negative cable Clean and repairVoltage drop caused by discharged battery RechargeInsufficient voltage caused by battery malfunction Replace

Magnetic switch and related partsLoose wiring and / or connectors RepairBurnt magnetic switch contact plate or improper contact ReplaceBroken wire in magnetic switch contact plate or improper contact Replace

plate or improper contactBroken wire magnetic switch holding coil Replace

Starter and related partsPoor contact of brushes Adjust contact or replaceFatigued brush spring ReplacePoor grounding of field coil ReplacePoor soldering of field coil RepairCommutator malfunction RepairGrounded armature ReplaceWorn parts Replace

Starting problem Insufficient battery capacity Recharge

Tip of overrunning pinion is worn ReplaceFatigued overrunning clutch drive spring ReplaceOverrunning clutch races ReplaceImproper sliding of spline Adjust contact and repairWorn bushing ReplaceWorn ring gear Replace

Starter turns Sticking contact place of magnetic switch Replacecontinuously Layer shorting of coil magnetic switch Replace(does not stop)

Starter does notturn at all, or itsturning speed istoo slow to startthe engine.

Starter turns butpinion gear doesnot mesh withring gear



Misfiring of motor Malfunction of wiring, or poor wiring contact Replace

Discharging of Loose drive belt Adjustbattery Grounded or broken stator coil Replace

Broken rotor coil ReplacePoor contact of brush and slip ring Clean or replaceMalfunction or rectifier ReplaceMalfunction of IC regulator ReplaceInsufficient or unsuitable battery electrolyte AdjustMalfunction of battery electrode(internal short-circuit) ReplacePoor contact of battery terminals Clean and tightenExcessive electric load Check power consumption

Overcharging IC regulator malfunction Replaceof battery Operating in extremely high temperature Repair

Diesel Engine D427 Engine Electrical System

Starter


1. Turn off the ignition switch and place the gear shiftlever to neutral position before inspection.

2. Directly connect the battery terminal B and starterterminal M.

3. The starter is functioning properly if it turnssmoothly, without abnormal noise.

Be specially careful, when the starter is operated,the engine may start.

4. If starting is slow, if the starter doesn’t turn, or ifabnormal noise is heard, remove the starter andcheck it, but be sure to check the following mattersbefore removing it.A. Charging condition of batteryB. Looseness or corrosion of battery terminalC. Condition of ignition switchE. Locked engine.

Removal

1. Disconnect the battery (-) and (+) terminals.

2. Disconnect the wiring from the starter.

3. Remove the fixing bolts and remove the starter.

Installation

Install the start in the reverse order of removal, takingcare of the following.

1. Tighten terminals B and M to the specified torque.

Tightening torque :8.0 ~ 10.0 m•kg (57.9 ~ 72.3 ft•lb)

Free Running Test

Measure the current when the start begins to runconstantly connecting the battery, starter andammeter as shown in the figure.

Current : 200 A or lessVoltage : 11 V

WARNING

60

Fig 5-5

Fig 5-6

Fig 5-7


Disassembly

Fig 5-8


Inspection

Checking the Armature

1. Check insulation between all segments and coreof the armature coil.

2. It is normal if there is no continuity.

3. Check for continuity between all segments. It isnormal if there is continuity.

4. Check for short circuit with a glower tester. Thearmature is shorted if an iron piece, when placedon the core while the armature is rotated, isattracted or vibrates. In that case, replace thecore.

5. Measure the shrinkage of the mold betweensegments. If the value is 0.2mm (0.008 in) or less,undercut by 0.5 to 0.8mm (0.02 ~ 0.03 in).

Field Coil

1. Check for continuity between the yoke and thefield terminal by using a circuit tester. It is normal ifthere is continuity.

2. Check for continuity between leads by using acircuit tester. It is normal if there is continuity.

62

Fig 5-9

Fig 5-11

Fig 5-12

Fig 5-10


Checking the Brush Holder

Check for continuity between brush holder (+) lineand brush holder frame with a circuit tester. It isnormal if there is no continuity.

Checking for Brush Wear

Check the brush for any damage or wear.Wear limit : 14 mm (5.51 in)

Replacement the Brush

1. Pull out the brush and brush lead wire from thebrush holder.

2. Remove the brush from the brush lead wire bycrushing the brush.

3. Replace a new brush in the brush lead wire. Cleanthe brush lead wire. Fix the brush lead by insertingthe lead through the small tapered hole on thebrush.

4. Solder the brush brush lead wire together. Use asoldering iron of more than 200W.

63

Fig 5-13 Fig 5-15

Fig 5-16

Fig 5-14


Checking the Magnetic Switch

Attraction Test

1. Disconnect the lead wire between terminal M andstarter terminal.

2. It is normal if the plunger is pulled in and thepinion jumps out when power is supplied to themagnetic switch S and the terminal M.

CAUTION : Do not supply power for more than 10seconds.

Attraction-holding Test

1. Disconnect the lead wire between the terminal Mand starter.

2. Supply battery power to S terminal of magneticswitch and switch body, and then pull the pinion byhand.

3. It is normal if the pinion does not return to itsoriginal position when the pulled-out pinion isreleased.

Return Test

1. Disconnect the lead wire between the terminal andthe starter.

2. Connect battery power to terminal M of magneticswitch and its body.

3. Pull and release the pinion. It is normal if thepinion returns quickly to its original position ; but, ifit does not return, replace the magnetic switch.

Pinion Jumping-out Condition

1. Disconnect the wire from the terminal M.

2. The pinion jumps out when battery power issupplied to terminal S and to starer body. Measurethe clearance between the pinion and stopper.

Standard Pinion clearance :0 ~ 2.0mm (0 ~ 0.078 in)

CAUTION : Do not supply power to starter formore than 20 seconds.

64

Fig 5-19

Fig 5-17

Fig 5-20

Fig 5-18


AlternatorCircuit Diagram

Charging System Cautions

1. Be sure battery connections are not reversed,because this will damage the rectifier.

2. Do not use high-voltage testers, such as aMegger, because they will damage the rectifier.

3. Remember that battery voltage is always appliedto the alternator’s B terminal.

4. Do not ground the L terminal while the engine isrunning.

5. Do not start the engine while the coupler isdisconnected from the L and R terminals.


Inspection of Charging System

1. Make current and voltage connections as shown inthe figure.

2. Turn the ignition switch OFF.

3. Read the voltage between the L terminal andground. The alternator is bad if the reading is not 0V.

4. Turn the ignition switch ON and read the voltmeter.If the reading is 0 V, there is a malfunction of thealternator or wiring.

65

Fig 5-23Fig 5-21


Checking No-Load AdjustmentVoltage

1. Check to be sure that the battery is fully charged.

2. Connect an ammeter and a voltmeter as shown inthe figure. Be sure that the voltmeter reading is 0 V.

3. Turn the ignition key to ON, and then check to besure that the voltmeter reading is significantlylower than the battery voltage(1 ~ 3V). If thevoltmeter reading is the same as the batteryvoltage, there may be a malfunction in thealternator.

4. Short circuit the terminals of the ammeter, andthen start the engine. After starting, discontinuethe short circuiting.

NOTE : Be careful, when starting the motor, that thecurrent of the starter doesn’t flow to the ammeter.

5. Under no-load conditions, increase the alternatorspeed to 5,000 rpm (engine speed of 2,000 ~2,500 rpm).

6. Read the indication shown by the voltmeter andthe ammeter.

Ammeter : 5A or lessVlotemter (adjustment voltage) :

14.7 L 0.3 V (at 20˚C (68˚F))

Checking Output

1. Disconnect the negative battery cable.

2. Connect an ammeter and a voltmeter as shown inthe figure.

3. Connect the negative battery cable.

4. Start the engine.

5. Apply a increase the engine speed. and read theoutput current. If the voltage is higher than thebattery voltage and there is an output current,there is no problem.

Removal

1. Lift the seat cushion and fasten is with the strap.

2. Remove the driver’s seat cushion.

3. Disconnect the negative battery cable.

4. Remove the drive belt.

5. Disconnect the wire from the B terminal of thealternator and coupler from the L and R terminals,and disconnect the wire harness from the clip.

6. Disconnect the vacuum hose and oil hose.

66

Fig 5-24

Fig 5-25

Fig 5-26


Installation

Installation is the reverse order of removal. Note thefollowing points.

1. Install the drive belt so that the V fits into thegrooves of each pulley.

2. Adjust the drive belt tension.


Disassemble in numbered order shown in the figure.Assembly is the reverse order of disassembly.

(1) Front bracket. (2) Fan and pulley. (3) Rotor. (4) Rear bracket. (5) Stator coil. (6) Brush holder. (7) Rectifier.

Fornt Bracket and Rotor

Fit a flat-tipped - screwdriver between the frontbracket and the stator core, and than separate thestator and rotor by tapping the screwdriver with anylon hammer.

CAUTION : Be careful not to force the screwdrivertoo far in, because the coil may become scratched.

LOCK NUT

Secure the rotor in a vise, and loosen the pulley nut.Fig 5-28

67

Fig 5-27

Fig 5-30

Fig 5-31

Fig 5-32


Stator

Use a soldering iron to disconnect the stator leadwiring.

CAUTION : Do the disconnecting quickly, using thesoldering iron no more than about 5 seconds,because the rectifier may become damaged if theinside is overheated.

Brush Holder and ic Regulator Assembly

Use a soldering iron to disconnect the brush holderand IC regulator assembly from the rectifier.

Brushes

When the rotor is to be attached to the rear bracket,insert a wire through the hole in the rear bracket sothat the brushes are at the specified position

Seal Washers

Insert a seal washer at each end of the front bracket.

68

Fig 5-35

Fig 5-36

Fig 5-37

Fig 5-33

Fig 5-34


Inspection

Inspect the following parts, and repair or replace if aproblem is found.

Stator

1. Use a circuit tester to check for continuity betweenthe core and each lead wire. No continuity is thenormal condition.

2. Use a circuit tester to check for continuity betweenlead wires. Continuity is normal condition.

Rotor

1. Use a circuit tester to check for continuity betweenthe core and each slip ring. No-continuity is the normal condition.

2. Use an ohmmeter to check the resistance betweeneach slip ring. Resistnace : 3 ~ 4 Ω

69

Fig 5-38 Fig 5-40

Fig 5-41

Fig 5-39


Rectifiers

Use a continuity tester to check the continuity of eachrectifier. There should be high resistance in onedirection and low resistance in the other direction.There is a short-circuit if the resistance is low in bothdirections, and there is a broken wire if the resistanceis high in both directions. In either instance, replacethe rectifier.

Brushes and Spring

1. Check the force of the brush spring. Measure theforce of the brush spring by using a springpressure gauge, and push the brush into the brushholder until the tip projects 2mm (0.079 in).

Limit : Less than 210 g (7.4 oz)

2. Check for burnt or worn brushes.

Limit : 6.5 mm (0.256 in)

Bearings

Check the front and rear bearings for improperrotation and/or abnormal noise. Replace if anabnormal condition is discovered.

Glow PlugsChecking Open Circuit of GlowPlugs

Check the continuity between the positive terminal ofthe glow plug and cylinder head block with a circuittester. If there is no continuity, replace the glow plug.

70

Fig 5-42 Fig 5-44

Fig 5-45Fig 5-43



Remove in the following order :

1. Glow plug connector attaching nut. Use a suitablewrench.

2. Glow plug connector

3. Glow plug

NOTE : Turn the glow plug counterclockwise andremove it.

To install the glow plug, reverse order of removing.

71

Fig 5-46

Diesel Engine D427 Technical Data72

Technical Data

Engine

Item

Type Diesel, four-cycle

Number and arrangement of cylinders Four cylinders, in-line

Type of combustion chamber Swirl floor type

Bore and Stroke mm B mm(in*in) 92.0 B 101.6 (3.62 B 4.00)

Total piston displacement cc 2701

Compression ratio 21.5 : 1

Valve system Over head valve(0•H•V)

Intake valve Open(BTDC) 14˚

Closes(ABDC) 44˚

Exhaust valve Open(BBDC) 48˚

Closes(ATDC) 10˚

Firing order 1-3-4-2

Idling speed 1075 ~ 1125

Valve timing

Valve clearance(cold) mm(in) Intake 0.30(0.012)

Exhaust 0.30(0.012)

Cylinder head distortion limit mm(in) 0.10(0.0040)

Cylinder head

Seat sinking mm(in) Intake standard 48.05(1.892)

(Length “L”) Limit 49.05(1.931)

Exhaust Standard 48.05(1.892)

Limit 49.05(1.931)

Seat angle Intake 45˚

Exhaust 30˚

Seat contact width mm(in) Intake 2.0(0.079)

Exhaust 20(0.079)

Valve stem mm(in) Intake Standard 8.995 ~ 8.989(0.3526 ~ 0.3535)

Limit 8.904(0.3506)

Exhaust Standard 0.038 ~ 0.085(0.0015 ~ 0.0033)

Limit 0.127(0.0050)

Valve stem to guide Intake Standard 0.038 ~ 0.085(0.0015 ~ 0.0033)

clearance mm(in) Limit 0.127(0.0050)

Exhaust Standard 0.058 ~ 0.105(0.0023 ~ 0.0041)

Limit 0.127(0.0050)

Valve seat


Standard outer diameter mm(in) 14.218 ~ 14.223(0.5598 ~ 0.5600)

Standard tappet hole diameter mm(in) 14.288 ~ 14.319(0.5625 ~ 0.5637)

Clearance between tappet mm(in)

Standard 0.055 ~ 0.101(0.0022 ~0.0040)

hole and outer Limit 0.10(0.0040)

Tappet

Piston pin to small and bushing Standard 0.014 ~ 0.44(0.0006 ~ 0.0017)


Connecting rod side Standard 0.239 ~ 0.330(0.0094 ~ 0.00130)


Undersize connecting rod bearing mm(in) 0.254(0.010), 0.508(0.020), 0.762(0.030)

Connecting rod and connecting rod bearing

Crankshaft deflection limit mm(in) 0.05(0.002)

Crank pin diameter mm(in) Standard 57.112 ~ 57.125(2.2485 ~ 2.2490)

Limit 0.05(0.0020)

Grinding limit 56.35 (2.2185)

Standard 65.812~69.825(2.7485~2.7490)

Main journal diameter mm (in) Limit 0.008(0.0003)

Grinding limit 69.14(2.7220)

Main journal bearing mm(in) Standard 0.059 ~ 0.090(0.0023 ~ 0.00035)

oil clearance Limit 0.12(0.0047)

Undersize bearings mm(in) 0.254(0.010), 0.508(0.020), 0.762(0.030)

Crankshaft end play mm(in) Standard 0.14 ~ 0.39(0.0055 ~ 0.0154)

Limit 0.4(0.0157)

Crankshaft and main bearing

Cam height mm(in) Intake Standard 42.580(1.6764)

Wear limit 42.478(1.6724)

Exhaust Standard 42.580(1.6764)

Wear limit 42.478(1.6724)

Journal mm(in) Elliptical limit 0.008(0.0003)

Diameter 1 51.910 ~ 51.940(2.044 ~ 2.045)

2 51.660 ~ 51.690(2.034 ~ 2.035)

3 51.410 ~ 51.440(2.024 ~ 2.025)

4 51.160 ~ 51.190(2.014 ~ 2.015)

Camshaft deflection limit mm(in) 0.8(0.00079 ~ 0.000709)

Camshaft end play mm(in) Standard 0.02 ~ 0.18(0.00079 ~ 0.000709)

Limit 0.3(0.0118)

Camshaft


Distortion limit 0.10(0.0040)

Cylinder liner inner diameter mm(in) A : 92.025 ~ 92.037(3.6230 ~ 3.6235) B : 92.037 ~ 92.050(3.6235 ~ 3.6240)

Cylinder to cylinder liner clearance limit mm(in) 0.021 ~ 0.078(0.0008 ~ 0.0031)

Cylinder liner wear limit mm(in) 0.20(0.0079)

Piston standard outer diameter (Diameter measured at 90˚ to pin bore mm(in) A : 91.967 ~ 91.980(3.6207 ~ 3.6213)axis and 19 mm(0.75 in) below the oil B: 91.980 ~ 91.993(3.6213 ~ 3.6218)ring groove)

Ring groove width mm(in) Top 2.433 ~ 2.453(0.0958 ~ 0.0966)

Second 2.423 ~ 2.443(0.0954 ~ 0.0962)

Oil 4.793 ~ 4.813(0.1887 ~ 0.1895)

Piston ring thickness mm(in) Top 2.363 ~ 2.383(0.0930 ~ 0.0938)

Second 2.363 ~ 2.383(0.0930 ~ 0.0938)

Oil 3.97 ~ 3.99(0.1563 ~ 0.1571)

Clearance between piston mm(in) Top 0.05 ~ 0.09(0.0020 ~ 0.0035)

ring and ring groove Second 0.04 ~ 0.08(0.0016 ~ 0.0032)

Oil 0.830 ~ 1.043(0.0316 ~ 0.0411)

Wear limit 0.3(0.0118)

Piston ring end gap Top 0.35 ~ 0.55(0.0138 ~ 0.0217)

mm(in) Second 0.35~ 0.55(0.0138 ~ 0.0217)

Oil O.35 ~ 0.55(0.0138 ~ 0.0217)

Wear limit 0.3(0.0118)

Piston pin diameter mm(in) 31.744 ~ 31.749(1.2498 ~ 1.2500)

Cylinder block, piston and piston ring

Tightening torque m ¥ kg(ft-lb)

Cylinder head(cold engine) 11.0 ~ 11.7(80 ~ 85)

Manifold Intake 1.6 ~ 2.4(12 ~ 17)

Exhaust 2.7 ~ 3.3(20 ~ 24)

Crankshaft pulley 3.5 ~ 4.0(25 ~ 29)

Camshaft thrust plate 1.6 ~ 2.4(12 ~ 17)

Connecting rod bearing caps 7.6 ~ 8.3(55 ~22)

Cooling fan 1.6 ~ 2.4(12 ~ 17)

Injection pipe 2.5 ~ 3.0(18 ~ 22)

Oil pan 1.6 ~ 2.3(12 ~ 17)

Main bearing cap 11.0 ~ 11.7(80 ~ 85)

Idle gear 2.3 ~ 3.2(17 ~ 23)

Rear oil seal 1.5 ~ 2.0(11 ~ 14)

Water pump 1.6 ~ 2.3(12 ~ 17)

Camshaft gear 6.2 ~ 7.0 (45 ~ 51)

lnjection pump gear 4.0 ~ 7.0(29 ~ 51)


Item Specification

Lubricating method Force-fed type

Tightening torque m•kg (ft-lb)

Oil filter By hand + 1/2 turn

Oil pan 1.6 ~ 2.3(12 ~ 17)

Oil pipe 0.8 ~ 1.2(6 ~ 9)

Oil pressure switch 1.2 ~ 1.8 (9 ~ 13)

Lubrication System

Type Trochoid type

Oil pressure kg/cm2(lb/in2) 3.8(54) or more

Outer rotor and body mm(in) Standard 0.14 ~ 0.25(0.0055 ~ 0.0098)

clearance Limit 0.3(0.0118)

Pump shaft and body mm(in) Standard 0.06 ~ 0.15(0.0024 ~ 0.0059)

clearance Limit 0.1(0.0039)

Oil Pump

Item Specification

Fan belt tension New belt 10 ~ 12(0.39 ~ 0.47)

(10kg force mm(in) Used belt 13 ~ 16(0.51 ~ 0.63)

Fan Type Blower

Number of blades 6

Outer diameter mm(in) 430(16.93)

Cooling System

Item Specification

Thermostat Opening temp ˚C(˚F) 82 L 1.5(179.6 L 34.7)

Full-open temp ˚C(˚F) 95(203)

Full-open lift mm(in) 8.0(0.31)

Water pump Type Centrifugal, timing belt driven

Radiator Type Corrugated

Cap valve opening 1.0 L 0.15(14.2 L 2.1)Pressure kg/cm2(lb/in2)


Item Specification

Engine electrical system

Alternator Type Alternating

Voltage capacity V-A 12 - 60

Regulated voltage V 14.4 L 0.3

Charging system

Starting motor Type Electromagnetic push-in type

Voltage V 12

Output kW 2.5

Free running test Voltage V 11

Current A 200 or less

Speed rpm 3000 or more

Tightening torque m¥kg (ft-lb)

Starting motor 8.9 ~ 12.0(64 ~ 87)

Alternator 1.8 ~ 2.7(13 ~ 20)


Flywheel Housing 3.3 ~ 4.8(23 ~ 34)

Flywheel 13.1 ~ 13.8(94 ~ 99)

Starting system


Injection pump gear 4.0 ~ 7.0(29 ~ 51)

Injection nozzle holder 6.0 ~ 8.0(43 ~ 58)

Injection pipe 2.5 ~ 3.0(18 ~ 22)

Item Specification

Idle speed rpm 1100 L 25

Injection timing ATDC 2˚

Injection pressure kg/cm2(lb/in2) 135 ~ 140(1920 ~ 1991)

Fuel System

D 427 Diezel Engine

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