PERKINS DIESEL ENGINES, SERIES 1000
1.1 GENERAL
This section has the description and repair instructions
for four models of the Series 1000 Perkins diesel engine,
The four diesel engines described in this section:
1004±4 (AA) 4±cylinder normally aspirated
1004±4T (AB) 4±cylinder turbocharged
1006±6 (YA) 6±cylinder normally aspirated
1006±6T (YB) 6±cylinder turbocharged
GENERAL SAFETY RULES
WARNING
Viton Seals
Some seals used in this engine are made of a synthetic
material called Viton. Viton is a safe material when
used under normal conditions of operation.
If Viton is burned, a dangerous acid is produced as
a by±product. Never permit burned material to
come into contact with the skin or the eyes.
If it is necessary to handle components that have
been burned, Use the following procedures:
Make sure the components are cool.
Use Neoprene gloves and discard the gloves
af-ter use.
Wash the area with calcium hydroxide solu-
tion and then clean with water.
Discard the components and gloves in accor-
dance with environmental regulations.
Burned Viton by±product that touches the skin or
eyes must be immediately flushed with water or a
calcium hydroxide solution. Get medical help
imme-diately.
WARNING
Disconnect the battery cables before doing any
disassembly and repair of the engine or parts of the
electrical system. Put a ªDO NOT OPERATEº tag in
the operator's area and on the battery connectors.
Long term exposure to used engine oil can cause skin
irritation or cancer. Wash with detergent and water
CAUTION
Disposal of lubricants and fluids must meet local
en-vironmental regulations.
Exhaust from internal combustion engines
contains carbon monoxide and other harmful
chemicals. Carbon monoxide is a colorless,
odorless poison and can cause unconsciousness or
death without warn-ing. Long term exposure to
exhaust or chemicals in the exhaust can cause
cancer, birth defects and other reproductive harm.
Avoid exposure to engine ex-haust
Do not use diesel engines indoors where soot can
ac-cumulate.
If engines are operated in confined spaces maintain
adequate ventilation or vent exhaust to the outside.
Do not exceed applicable air contaminant limits.
Follow the inspection and maintenance schedule
and procedures in this manual. Do not alter
exhaust, ignition or fuel systems.
Disposal of batteries must meet local
environmental regulations.
The diodes and resistors in the electrical system
can be damaged if the following cautions are not
followed:
 Do not disconnect the battery when the
engine is running. The voltage surge can
damage the diodes and resistors.

 Do not disconnect an electric wire before the
engine is stopped and the switches are ªOFFº.

 Do not cause a short circuit by connection of
the electric wires to the wrong terminals.
Make sure a correct identification is made of
the wire before it is connected.

 Make sure a battery is the correct voltage
and polarity before it is connected.

 Do not check for current flow by making a
spark because the electronic components can
be damaged.
1
 1004±4T DIESEL ENGINE SHOWN

1. FILLER CAP FOR ENGINE OIL 7. DRAIN PLUG, ENGINE OIL

2. FUEL FILTER 8. CRANKSHAFT PULLEY
3. OIL COOLER 9. DRIVE BELT
4. FUEL INJECTION PUMP 10. FAN
5. DIPSTICK 11. WATER PUMP
12. FUEL INJECTOR
6. OIL FILTER 13. COOLANT OUTLET

14. INLET MANIFOLD 20. DRAIN PLUG ENGINE OIL

15. EXHAUST MANIFOLD 21. FLYWHEEL HOUSING
16. ALTERNATOR 22. FLYWHEEL
17. TURBOCHARGER 23. FUEL PUMP
18. STARTER MOTOR 24. REAR LIFT BRACKET
19. OIL SUMP

FIGURE 1. 4±CYLINDER DIESEL ENGINES, PERKINS 1000 SERIES

2
 1006±6 DIESEL ENGINE SHOWN

1. FILLER CAP FOR ENGINE OIL 7. CRANKSHAFT PULLEY

2. FUEL FILTER
3. OIL COOLER
4. FUEL INJECTION PUMP
5. DIPSTICK, ENGINE OIL
6. DRAIN PLUG, ENGINE OIL
8. FAN
9. WATER PUMP
10. FRONT LIFTING BRACKET
11. COOLANT OUTLET
12. FUEL INJECTOR

14. ALTERNATOR 19. FLYWHEEL HOUSING

15. OIL FILTER 20. FLYWHEEL
16. STARTER MOTOR 21. FUEL PUMP
17. OIL SUMP 22. EXHAUST MANIFOLD
18. DRAIN PLUG, ENGINE OIL 23. INLET MANIFOLD
FIGURE 2. 6±CYLINDER DIESEL ENGINES, PERKINS 1000 SERIES

3
1.2 DESCRIPTION
The cylinder head is cast iron and has one inlet valve
and one exhaust valve for each cylinder. The valve seats
and the valve guides are replaceable on the turbocharged
models. Valve seats can be installed during overhaul on
the normally aspirated engines. The fuel injectors are in
the cylinder head. The overhead valve assembly is actu-
ated by a camshaft inside of the engine block. A gear
train, turned by the crankshaft, turns the camshaft, cool-
ant pump, injection pump, and a power±takeoff (PTO) is
available for additional equipment. The hydraulic pump
for the steering function or a compressor is nor-mally
turned by the PTO. The fuel pump is actuated by the
camshaft.
The crankshaft in the 6±cylinder models have seven
main bearings. The crankshaft in the 4±cylinder
models have five main bearings. The main bearing in
the center of the crankshaft is the thrust bearing and
has thrust washers on both sides of the bearing.
The pistons are aluminum alloy with a steel insert in the
piston skirt to control expansion. Each piston has three
piston rings (two compression rings, and an oil control
ring). The top compression ring has a special insert for
the groove. A special jet for cooling oil to the bottom of
the piston is installed on the engines with turbochargers.
A special combustion chamber is cast in the top of the
piston to increase the efficiency of the combustion proc-
ess and reduce combustion noise.
The CAV DPS fuel injection pumps for the tur-
bocharged engines have a boost control. The boost
pres-sure from the turbocharger increases the fuel
supply at higher engine speeds. At low engine speeds,
the fuel supply is reduced to match the reduction in
air supply to the cylinders.
1.3 Engine Serial Number Codes
The engine number is on a label on the side or the rear
of the engine block.
A typical serial number has the following code:
AB 80350 U 510327 S
1 2 3 4 5
where:
1 = Type of engine;
(AA = 1004±4, AB = 1004±4T,
YA = 1006±6, YB = 1006±6T)
2 = Parts list number
3 = Country of manufacture (U = manufactured in the
United Kingdom)
4 = Serial number
5 = Year of manufacturer. The letter indicates the year
of manufacture starting with ªAº in 1974 (S=1988).
The letters I, O, Q, R, and Z are not used.
If parts or service are required for your engine, the com-
plete engine number must be given to your dealer.

The cooling fan and the alternator are turned by a

drive belt. The cooling fan is not connected to the
coolant pump.

The timing and quantity of fuel sent to the fuel injectors

is controlled by a throttle and governor in the fuel injec-
tion pump. The static timing is set by the position of the
fuel injection pump when it is installed. The throttle
linkage must be correctly adjusted to control the quan-
tity of fuel sent to the injectors. A mechanical governor
is used to control the engine speed.
FIGURE 3. SERIAL NUMBER LOCATIONS
A CAV DPA fuel injection pump is used on the nor-
mally aspirated engines AA and YA. A CAV DPS
fuel injection pump is used on turbocharged engines 1.4 Engine Data
AB an YB. Special tools are needed to repair a CAV
injection pump and they are normally sent to an The specifications and tolerance details for engine re-
authorized CAV repair station if repairs are necessary. pair are in a chart at the end of this chapter.

4
1.5 1004±4 ENGINE
Power Rating at 2600 rpm . . . . . . . 63 kW (84.5 bhp)
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . 4
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . 1±3±4±2
Bore and stroke . . . 100 x 127 mm (3.937 x 5.000 in)
2 (at 2600 rpm and normal operating temperature)
Displacement . . . . . . . . . . . . . . . . . . 4 litres (243 in )
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . 16.5:1
Minimum oil pressure . . . . . . . . . . . 207 kPa (30 psi)
(at 2600 rpm and normal operating temperature)
Governor speed (no load)
H3.50±5.00XL(H70±110XL) . . . . 2300 to 2400 rpm
S3.50±5.50XL(S70±120XL) . . . . . 2400 to 2500 rpm
S6.00±7.00XL (S135±155XL) . . . . 2400 to 2500 rpm
H6.00±7.00XL(H135±155XL) . . . 2400 to 2500 rpm
Idle speed
H3.50±5.00XL(H70±110XL) . . . . . . 725 to 775 rpm
S3.50±5.50XL(S70±120XL) . . . . . . . 625 to 800 rpm
S6.00±7.00XL (S135±155XL) . . . . . . 725 to 775 rpm
H6.00±7.00XL(H135±155XL) . . . . . 725 to 775 rpm
Thermostat
Begin to open . . . . . . . . . 77 to 85C (170 to 185F)
Fully open . . . . . . . . . . . 92 to 98C (198 to 208F)
Valve clearance (cold)
Inlet . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in)
Exhaust . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in)
1.6 1004±4T ENGINE
Power Rating at 2600 rpm . . . . . . . . 84 kW(113 bhp)
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . 4
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . 1±3±4±2
Bore and stroke . . . 100 x 127 mm (3.937 x 5.000 in)
2 Governor speed (no load) . . . . . . . 2700 to 2800 rpm
Displacement . . . . . . . . . . . . . . . . . . 4 litres (243 in )
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . 16.0:1
Minimum oil pressure . . . . . . . . . . . 280 kPa (40 psi)
(at 2600 rpm and normal operating temperature)
Governor speed (no load) . . . . . . . 2700 to 2800 rpm
Idle speed . . . . . . . . . . . . . . . . . . . . . . 800 to 850 rpm
Thermostat
Begin to open . . . . . . . . 77 to 85C (170 to 185F)
Fully open . . . . . . . . . . 92 to 98C (198 to 208F)
Valve clearance (cold)
Inlet . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in)
Exhaust . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in)
1.7 1006±6 ENGINE
Power Rating at 2600 rpm . . . . . . . . 95 kW(127 bhp)
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . 6
Firing order . . . . . . . . . . . . . . . . . . . . . 1±5±3±6±2±4
Bore and stroke . . . 100 x 127 mm (3.937 x 5.000 in)
2
Displacement . . . . . . . . . . . . . . . . . . 6 litres (365 in )
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . 16.5:1
Minimum oil pressure . . . . . . . . . . . 207 kPa (30 psi)
Governor speed (no load with sound reduction)
H8.00±12.00XL(H165±280XL) . . 2460 to 2610 rpm
H13.00±16.00XL (H300±360XL) . 2400 to 2550 rpm
Governor speed (no load without sound reduction)
H8.00±12.00XL(H165±280XL) . . 2660 to 2810 rpm
H13.00±16.00XL (H300±360XL) . 2660 to 2810 rpm
Idle speed
H8.00±12.00XL(H165±280XL) . . . . 725 to 775 rpm
H13.00±16.00XL (H300±360XL) . . . 725 to 775 rpm
Thermostat
Begin to open . . . . . . . . . 77 to 85C (170 to 185F)
Fully open . . . . . . . . . . . 92 to 98C (198 to 208F)
Valve clearance (cold)
Inlet . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in)
Exhaust . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in)
1.8 1006±6T ENGINE
Power Rating at 2600 rpm . . . . . . 127 kW (170 bhp)
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . 6
Firing order . . . . . . . . . . . . . . . . . . . . . 1±5±3±6±2±4
Bore and stroke . . . 100 x 127 mm (3.937 x 5.000 in)
2
Displacement . . . . . . . . . . . . . . . . . . 6 litres (365 in )
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . 16.0:1
Minimum oil pressure . . . . . . . . . . . 280 kPa (40 psi)
(at 2600 rpm and normal operating temperature)
Idle speed . . . . . . . . . . . . . . . . . . . . . . 800 to 850 rpm
Thermostat
Begin to open . . . . . . . . . 77 to 85C (170 to 185F)
Fully open . . . . . . . . . . . 92 to 98C (198 to 208F)
Valve clearance (cold)
Inlet . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in)
Exhaust . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in)
1.9 REMOVAL AND INSTALLATION
See the THE FRAME section for the procedure for
re-moving the engine and transmission. See the
TRANS-MISSION section for the procedure to
separate the transmission from the engine.
5
 CYLINDER HEAD ASSEMBLY
1.10 VALVE COVER
1.11 Removal
1. Disconnect the breather pipe.
2. Remove the cap nuts and the sealing washers from
the top of the valve cover. See FIGURE 4.
3. Lift the valve cover, gasket, and seal from the
cylinder head. The valve cover seal fits between the
valve cover and the inlet manifold.
4. When the valve cover is installed, the cap nuts are
tightened onto the nuts of the rocker brackets. When
the cap nuts are removed, the nuts for the rocker
brackets can be loosened. Check that the nuts for the
rocker brackets are tight each time that the valve
cover is re-moved.
1. VALVE COVER SEAL
2. CAP NUT AND SEAL WASHER
FIGURE 4. VALVE COVER
1.12 Installation
1. Check the condition of the valve cover gasket and
the seal washers used under the cap nuts. Make sure
that the surfaces are clean.
2. Install the valve cover, gasket, and seal on the
cylinder head. Install the seal washers under the cap
nuts. Tighten the cap nuts to 20 Nm (15 lbf ft). Do not
tighten the cap nuts so that they are fastened to the
nuts for the rocker brackets.
6
1.13 ROCKER ARM ASSEMBLY
1.14 Removal
1. Remove the valve cover.
2. Loosen the nuts evenly that fasten the brackets for
the rocker arm shafts to the cylinder head. Loosen the
brackets at each end of the cylinder head first and
loosen the brackets in sequence towards the center.
Remove the nuts and washers when the pressure is
removed from the rocker arms. Lift the rocker arm
assembly from the cyl-inder head.
3. See FIGURE 5. Remove the rubber seal from the
oil supply connection or the hole for the oil supply in
the cylinder head.
1.15 Installation
1. Install a new rubber seal in the hole for the oil
supply in the cylinder head.
2. Check that the push rods fit correctly in the sockets
for the tappets. Install the rocker arm assembly. Make
sure that the oil supply connection fits correctly into
the rub-ber seal.
3. Make sure that the alignment of the rocker arms
and the push rods are correct. Install the nuts and
washers on the studs that hold the brackets for the
rocker arm shafts to the cylinder head. Tighten the
nuts evenly. Begin tightening the nuts at the center of
the rocker arm shaft and tighten in sequence towards
the ends of the shaft. The final torque on the nuts:
aluminum brackets = 40 Nm (30 lbf ft)
iron brackets = 75 Nm (55 lbf ft).
FIGURE 5. LOCATION OF RUBBER SEAL
1.16 Disassembly 3. Use a press to install a new bushing in the rocker
arm. Make sure that the lubrication hole in the
1. Remove the clips from both ends of the rocker arm
bushing is aligned with the hole in the rocker arm.
shaft. Make sure that the ends of the rocker arm shaft
are not damaged. Loosen the location screw for the oil
4. Use a reamer in the bushing as necessary to give a
sup-ply connection.
clearance on the rocker arm shaft of 0.03 to 0.09 mm
2. Make a note of the position of each component on the (0.001 to 0.004 in).
rocker arm shaft so that they can be assembled correctly.
Remove the components from the rocker arm shaft. 1.18 Assembly

1.17 Inspection
1. Clean and inspect all the components for wear and
damage. Check the clearance of the rocker arms on the
rocker arm shaft. If the clearance is greater than 0.13
mm (0.005 in), install a new bushing in the rocker arm
or install a new rocker arm shaft if it is worn.
2. If the bushing in the rocker arm is worn, use a press
to remove the bushing.
1. Make sure that the lubrication holes in the rocker
arms and the rocker arm shaft are open and clean.
2. Lubricate the components with clean engine oil as
they are assembled on the rocker arm shaft. Make sure
the components are assembled in the correct order. See
FIGURE 6. Make sure that the location screw for the oil
supply connection is fitted correctly in the rocker arm
shaft. Install the clips at the ends of the rocker arm shaft.

FIGURE 6. ROCKER ARM ASSEMBLY

1.19 VALVE CLEARANCE ADJUSTMENTS

The valve clearance is measured between the top of

the valve stem and the rocker arm as shown in
FIGURE 7. Valve clearance (cold)
Inlet 0.20 mm (0.008 in)
Exhaust 0.45 mm (0.018 in)

FIGURE 7. VALVE CLEARANCE ADJUSTMENT

7
Number 1 cylinder is at the end of the engine with the
fan. The inlet valve is the first valve in the sequence.
See FIGURE 8.
FIGURE 8. VALVE POSITIONS
1.20 Four Cylinder Engines
1. Turn the crankshaft in the normal direction of rotation
until the inlet valve of number 4 cylinder has just opened
and the exhaust valve of the same cylinder has not fully
closed. Check the clearance of the valves of number 1
cylinder and adjust them as necessary.
2. Turn the crankshaft in the normal direction of rotation
until the inlet valve of number 2 cylinder has just opened
and the exhaust valve of the same cylinder has not fully
closed. Check the valve clearances on number 3 cylin-
der and adjust them as necessary.
3. Turn the crankshaft in the normal direction of rotation
until the inlet valve of number 1 cylinder has just opened
and the exhaust valve of the same cylinder has not fully
closed. Check the valve clearances on number 4 cylin-
der and adjust them as necessary.
4. Turn the crankshaft in the normal direction of rotation
until the inlet valve of number 3 cylinder has just opened
and the exhaust valve of the same cylinder has not fully
closed. Check the valve clearances on number 2 cylin-
der and adjust them as necessary.
1.21 Six Cylinder Engines
1. Turn the crankshaft in the normal direction of rotation
until the inlet valve of number 6 cylinder has just opened
and the exhaust valve of the same cylinder has not fully
closed. Check the clearance of the valves of number 1
cylinder and adjust them as necessary.
2. Turn the crankshaft in the normal direction of rotation
until the inlet valve of number 2 cylinder has just opened
and the exhaust valve of the same cylinder has not fully
8
closed. Check the valve clearances on number 5 cylin-
der and adjust them as necessary.
3. Turn the crankshaft in the normal direction of rotation
until the inlet valve of number 4 cylinder has just opened
and the exhaust valve of the same cylinder has not fully
closed. Check the valve clearances on number 3 cylin-
der and adjust them as necessary.
4. Turn the crankshaft in the normal direction of rotation
until the inlet valve of number 1 cylinder has just opened
and the exhaust valve of the same cylinder has not fully
closed. Check the valve clearances on number 6 cylin-
der and adjust them as necessary.
5. Turn the crankshaft in the normal direction of rotation
until the inlet valve of number 5 cylinder has just opened
and the exhaust valve of the same cylinder has not fully
closed. Check the valve clearances on number 2 cylin-
der and adjust them as necessary.
6. Turn the crankshaft in the normal direction of rotation
until the inlet valve of number 3 cylinder has just opened
and the exhaust valve of the same cylinder has not fully
closed. Check the valve clearances on number 4 cylin-
der and adjust them as necessary.
1.22 VALVE SPRINGS
NOTE: This procedure is normally for changing the
valve springs of a single cylinder while the cylinder
head is still installed on the engine. If the valves and
springs must be removed from the cylinder head for
re-pairs, see the procedures under 1.26 Valves And
Valve Springs later in this section.
Special Tools: Valve spring compressor
Stud adaptor
Setscrew adaptor
1. Remove the valve cover.
2. Turn the crankshaft in the normal direction of
rotation until the piston for the cylinder is at top dead
center (TDC). The inlet valve will just open and the
exhaust valve will not be fully closed when the
cylinder is at TDC.
3. Remove the rocker arm assembly.
4. Install the spring compressor and the adaptor. See
FIGURE 9.
 piston in cylinder 2 is at TDC, the piston in cylinder 3
is also at TDC.

ENGINES YA and YB. When the piston in cylinder 1

is at TDC, the piston in cylinder 6 is also at TDC.
When the piston in cylinder 2 is at TDC, the piston in
cylinder 5 is also at TDC. When the piston in cylinder
3 is at TDC, the piston in cylinder 4 is also at TDC.

If the rocker arm assembly was removed before TDC was

found, install the valve spring compressor and com-press
the valve springs to open the valve. Turn the crank-shaft by
hand in the normal direction until the piston touches the
1. VALVE SPRING COMPRESSOR valve. Continue to turn the crankshaft, and at the same
2. STUD ADAPTOR
time, release the pressure on the valve spring compressor
3. SETSCREW ADAPTOR
until the piston is at TDC. See FIGURE 10.
FIGURE 9. VALVE SPRING COMPRESSOR

5. Compress the valve springs and remove the retainers.

Make sure the valve springs are compressed parallel to
the valve stems or the valve stems can be damaged.

6. Release the valve spring compressor and remove

the retainer cap and valve springs.
NOTE: Do not turn the crankshaft while the valve
springs are removed.
7. Install the new valve springs. Make sure the closed
damper coils of the valve springs are towards the
cylin-der head.
8. Install the retainer cap.
9. Use the valve spring compressor to compress the
valve springs and install the retainers. Remove the
valve spring compressor.
10. Install the rocker arm assembly.
11. Check the valve clearances. See 1.19 Valve Clear-
ance Adjustments.
12. Install the valve cover.
NOTE: Valve springs can be changed in two
cylinders at a time.
ENGINES AA and AB. When the piston in cylinder 1 is at FIGURE 10. FIND TDC WITH THE VALVE
SPRING COMPRESSOR
TDC, the piston in cylinder 4 is also at TDC. When the

9
1.23 CYLINDER HEAD ASSEMBLY
1.24 Removal
1. If the engine is still in the lift truck, do the
following procedures:
a. Drain the cooling system.
b. Disconnect the battery terminals.
c. Disconnect the sender unit for the coolant
temperature gauge.
2. ENGINES AA and YA. Remove the hose from the
air filter at the inlet manifold.
ENGINES AB and YB. Remove air filter connection
at the compressor inlet of the turbocharger.
3. Remove the fuel line between the cold start aid in
the inlet manifold and the fuel filter. Disconnect the
electri-cal connection.
4. ENGINES AB and YB. Remove the boost control
line between the front of the inlet manifold and the
fuel injection pump.
5. Remove the inlet manifold.
6. ENGINES AB and YB. Disconnect all connections
to the turbocharger and remove the turbocharger. See
1.108 Turbocharger, Removal.
7. Remove the exhaust manifold.
FIGURE 11. CYLINDER HEAD TIGHTENING SEQUENCE, 6±CYLINDER ENGINES
10
8. Remove the low pressure fuel lines between the
fuel injection pump and the fuel filter. Remove the
fuel filter bracket and the fuel filter.
9. Remove the high pressure fuel lines. Put plugs in
the open ports of the fuel injection pump.
10. Remove the return fuel line from the fuel injectors.
11. Remove the fuel injectors from the cylinder head.
Keep the fuel injectors clean and prevent damage to
the nozzles.
12. ENGINES YA and YB. If a compressor is installed,
remove the coolant pipe between the cylinder head and
the compressor. Remove the coolant pipe between the
by±pass connection and the compressor.
13. Loosen the hose clamp and remove the coolant
by± pass hose from the cylinder head. Remove the
capscrews and remove the coolant by±pass
connection and the hose.
14. ENGINES AA and AB. Remove the oil cooler.
See 1.164 Oil Cooler, Removal.
15. Remove the valve cover. See 1.11 Valve Cover,
Re-moval.
16. Remove the Rocker arm assembly. See 1.14
Rocker Arm Assembly, Removal.
17. Remove the push rods.
18. Loosen the capscrews for the cylinder head evenly
in a reverse sequence from the sequence shown in
FIGURE 11. or FIGURE 12.
 FIGURE 12. CYLINDER HEAD TIGHTENING
SEQUENCE, 4±CYLINDER ENGINES

1. STRAIGHT EDGE
2. CAPSCREW MUST BE STRAIGHT
AND WITHOUT DISTORTION
3. THREADS MUST BE IN GOOD CONDITION
19. Lift the cylinder head from the engine block. Do AND NOT HAVE REDUCED DIAMETER
not use a prybar between the cylinder head and the FIGURE 14. INSPECT THE CAPSCREWS
engine block that can cause damage to the gasket
surfaces. See FIGURE 13. 1.25 Installation
Special Tools: Angle gauge to tighten the capscrews
for the cylinder head.

1. Make sure the surfaces of the cylinder head and the

top of the engine block are clean. Make sure that there
is no dirt or objects in the cylinders.
2. Install the gasket for the cylinder head as shown in
FIGURE 15. Make sure the ªTOP FRONTº is in the
correct position. Do not use any gasket sealant on any
of the surfaces.

FIGURE 13. CYLINDER HEAD REMOVAL

20. Inspect the capscrews for the cylinder head with a

straight edge. See FIGURE 14. Check that the capscrews
are straight and do not have distortion. If there is a
reduction in the diameter of the thread that has
not been in engagement with the cylinder block, the
capscrew must be discarded. FIGURE 15. POSITION OF THE HEAD GASKET

11
3. Use two 1/2 UNF studs in positions 15 and 20 (see
FIGURE 16. and FIGURE 17. to hold the gasket in
po-sition. Lower the cylinder head into position on the
en-gine block.
FIGURE 16. CYLINDER HEAD INSTALLATION
CAUTION
There are three lengths of capscrews. S = short,
M = medium, L = long. FIGURE 17. and FIGURE
18. show their positions in the engine. Make sure
that the capscrews are installed in the correct
positions.
4. Lubricate the capscrews with a thin coat of oil and in-
stall them into their holes in the cylinder head. When the
cylinder head and gasket are held in position, remove
FIGURE 18. CYLINDER HEAD TIGHTENING SEQUENCE, 6±CYLINDER ENGINES
12
the two studs and install the two capscrews in those
posi-tions.
5. Evenly tighten the capscrews in the sequence
shown in FIGURE 17. or FIGURE 18. The final
torque on the capscrews is 110 Nm (80 lbf ft).
6. Make sure all of the capscrews are tightened to the
correct torque described in step 5. The capscrews
must be further tightened in the sequence shown in
FIGURE 17. or FIGURE 18. according to the
following procedure:
a. The short capscrews (S) must be tightened an
additional 150 (2.5 flats).
b. The medium capscrews (M) must be tightened
an additional 180 (3.0 flats).
c. The long capscrews (L) must be tightened an
additional 210 (3.5 flats).
FIGURE 17. CYLINDER HEAD TIGHTENING
SEQUENCE, 4±CYLINDER ENGINES
NOTE: A special tool shown in FIGURE 19. can be
used for this procedure to measure the tightening angles.
If an angle gauge is not available, make a mark in a line
with one of the corners of the capscrew. See FIGURE
20. Make another mark at the correct angle
(counter±clockwise) on the edge of the flange of the cyl-
inder head for each capscrew and according to the length
of each capscrew. Tighten each capscrew in the correct
sequence until the two marks are aligned.
FIGURE 19. ANGLE GAUGE
FIGURE 20. TIGHTEN CYLINDER HEAD
CAPSCREWS WITHOUT AN ANGLE GAUGE
7. Install the push rods in the engine. Make sure that the
end of each push rod fits correctly in the tappet socket.
8. Install the rocker arm assembly. See 1.18 Rocker
Arm Assembly, Installation.
9. Adjust the valve clearances. See 1.19 Valve Clear-
ance Adjustments.
10. Install the fuel injectors. See 1.143 Fuel Injectors,
Installation.
11. Install the high pressure fuel lines between the
fuel injection pump and the fuel injectors.
12. Install the fuel filter and bracket. Install the low±
pressure fuel lines between the fuel filter and the fuel
in-jection pump.
13. Install the coolant by±pass connection. Tighten
the capscrews and the hose clamp.
14. ENGINES YA and YB. If a compressor is installed
on the engine, install the coolant pipe between the cylin-
der head and the compressor. Install the pipe between
the coolant by±pass and the compressor.
15. Install the oil cooler. See 1.167 Oil Cooler,
Installa-tion.
16. Install the exhaust manifold. Do not use sealant on
the joints of the exhaust manifold.
17. ENGINES AB and YB. Install the turbocharger.
See 1.109 Turbocharger, Installation.
18. ENGINES AA and AB. Install the inlet manifold.
The front and rear gaskets for the inlet manifold have
notches. Make sure that the gaskets are installed with
the notches installed in the top left position. See
FIGURE 21. Do not use sealant on the joints of the
inlet manifold.
FIGURE 21. INLET MANIFOLD
INSTALLATION, ENGINES AA AND AB
ENGINES YA and YB. Install the inlet manifold.
Make sure that the gaskets are installed with the notch
at the top and the straight edge towards the center of
the en-gine. See FIGURE 22. Do not use sealant on
the joints of the inlet manifold.
13

FIGURE 22. INLET MANIFOLD
INSTALLATION, ENGINES YA AND YB
19. Install the fuel line between the fuel pump and the
fuel filter.
20. Install the fuel line between the fuel filter and the
cold start aid. If the engine is in the lift truck, install
the electrical connection to the cold start aid.
21. ENGINES AB and YB. Install the boost control
line between the front of the inlet manifold and the
fuel in-jection pump.
22. If the engine is still in the lift truck, do the
following procedures:
a. Connect the sender unit for the coolant
temperature gauge.
b. ENGINES AB and YB. Install air filter
connection at the compressor inlet of the
turbocharger.
ENGINES AA and YA. Install the hose from
the air filter at the inlet manifold.
c. Fill the cooling system.
d. Connect the battery terminals.
e. If the engine is ready to operate, remove the air
from the fuel system. See the procedure
described in 1.136 Remove Air From The Fuel
System.
14
23. When the engine can be started, run it at low
speed. Check that oil flows from the holes in the
rocker arms. If the oil flow is correct, install the valve
cover. See 1.12 Valve Cover, Installation.
1.26 VALVES AND VALVE SPRINGS
Special Tools: Valve spring compressor
Stud adapter
Setscrew adaptor
1.27 Removal
1. Remove the cylinder head. See 1.24 Cylinder Head
Assembly, Removal.
2. Clean the bottom face of the cylinder head and
check the depth of the heads of the valves below the
face of the cylinder head. See FIGURE 23.
FIGURE 23. CHECK THE DEPTH OF THE
VALVES
Check the depth of the valves below the face of the cyl-
inder head before the valve springs are removed. Put the
dial indicator and fixture or other measuring tool on the
face of the cylinder head and set the gauge to zero. Care-
fully put the dial indicator over the head of each valve
and make a note of the measurement. The maximum
service depth for the inlet valves is 1.85 mm (0.073 in)
and for the exhaust valves is 2.08 mm (0.082 in). If a
valve is below the depth limit, remove the valve and in-
stall a new valve in that position. If the valve depth is
still below the limit, the valve seat must be replaced. See
1.37 Installation Of New Valve Seats.
3. If the valves will be used again, make a mark on Make sure the valve springs are compressed parallel
each valve head so that they can be installed again in to the valve stems or the valve stems can be damaged.
the same positions.
5. Repeat the installation procedure for each valve.
4. Use the valve spring compressor and the correct adap-
tor to compress the valve springs and remove the retain- 1.30 VALVE GUIDES
ers. Make sure the valve springs are compressed parallel
to the valve stems or the valve stems can be damaged.
1.31 Inspection
Check the valve guides for wear. The maximum clear-
5. Release the valve stem compressor. Remove the
ance between the valve stem and the bore of the guide
valve spring cap, valve springs, seal, and seat washer.
is 0.13 mm (0.005 in) for inlet valves and 0.15 mm
6. Repeat steps 4 and 5 to remove the other valves. (0.006 in) for exhaust valves. If the clearance is
greater than the limit when a new valve is installed,
1.28 Inspection the valve guide must be replaced.
Check the valves for cracks. Check the stems of the
valves for wear and the correct clearance in their
valve guides. See 1.30 Valve Guides.
Check that the seat faces of the valves are not badly
burned. A correction for minimum wear and damage to
the valve and valve seat can be done by a process called
ªlappingº. Seat faces of valves that are damaged, but can
be repaired, must be checked for valve depth when they
are installed. See FIGURE 23. When new valves are
installed, the valve depth must be checked.

Check that the load on the valve springs is correct at

their installed length. See the ENGINE SPECIFI-
CATIONS.

Install new valve springs during a complete overhaul

of the engine.
1.29 Installation
1. Lubricate the valve stems with engine oil when
they are installed in their valve guides.

2. Install the seat washer. Install new seals on the

valve guides.

3. Install the inner and outer valve springs on the seat

washer. Make sure that the damper coils of the valve 1. RETAINERS 5. SEAL
springs are towards the cylinder head. 2. VALVE SPRING CAP 6. SEAT WASHER
3. VALVE SPRING, INNER 7. INLET VALVE
4. VALVE SPRING, OUTER 8. EXHAUST VALVE
4. Use the valve spring compressor and the correct adap-
tor to compress the valve springs. Install the retainers. FIGURE 24. VALVE COMPONENTS

15
1.32 Removal
Install the tool for removal and replacement and the
adaptor on the valve guide. Pull the valve guide from
the cylinder head. See FIGURE 25.
FIGURE 25. REMOVAL OF A VALVE GUIDE
1.33 Installation
1. Make sure the bore in the cylinder head is clean.
2. Lubricate the outer surface of the new valve guide
with engine oil.
3. Install the valve guide on the special tool. See
FIGURE 26. Use the special tool to pull the valve
guide into the cylinder head. When the valve guide is
correctly installed, the valve guide will extend 15.10
mm (0.594 in) above the seat of the valve spring.
16
FIGURE 26. INSTALLATION OF A VALVE
GUIDE
1.34 CYLINDER HEAD AND VALVE SEATS
1.35 Inspection
The valves must be removed from the cylinder head
be-fore the valve seats can be inspected and repaired.
Care-fully clean the cylinder head.
1. Check the cylinder head for cracks. Carefully check
the areas around the valve seats and around the holes
for the fuel injectors.
2. Use a straight edge and spacer gauges to check the
cylinder head for distortion across and along its face
that joins the engine block. See the ENGINE
SPECIFI-CATIONS. If the distortion is more than the
specifica-tions, the face can be machined. Remove
only the mini-mum metal so that the thickness of the
cylinder head will not be less than 120.48 mm (4.035
in) after the cylinder head has been machined.
NOTE: After the cylinder head has been machined,
the valve seats must be checked for the correct depth.
See 1.28 Valves And Valve Springs, Inspection. If the
depth of the valve seats must be increased, use the
minimum limit to allow for later wear.
3. Check the valve seats for wear and damage. Before
any work is done on the valve seats, make sure the
valve guides are good. See 1.31 Valve Guides,
Inspection for inspection and replacement.
4. A correction for minimum wear and damage to the
valve and valve seat can be done by a process called
ªlappingº. When the valve seats are ªlappedº, keep the
valve seat as narrow as possible. Make sure all of the
lapping compound is removed from the valve and
valve seat when the process is completed.
5. Damaged valve seats can be repaired with a cutter
tool. See FIGURE 27. If the valve seat can not be re-
paired so that the valve depth is within the specifica-
tions, the valve seat must be replaced.
1.36 Repair
Special Tools: Cutter for inlet valve seats
Cutter for exhaust valve seats
Pilot for use with valve seat cutters
Handle for valve seat cutters
1. Install the correct cutter into the valve seat that is to
be repaired. Carefully turn the cutter in a clockwise
direc-tion. Remove only the minimum metal to repair
the valve seat. Keep the valve seat as narrow as possible.
FIGURE 27. CUTTER FOR VALVE SEATS
2. When the valve seat has been cut, remove the cutter
and pilot. Clean the port area and remove any particles.
3. Use the ªlappingº process to make sure the valve
and valve seat fit tightly together.
4. Check the valve depth. See 1.28 Valves And Valve
Springs, Inspection. If the valve seat is badly
damaged or worn, replace the valve seat as described
in the fol-lowing paragraphs.
NOTE: AA and YA engines do not have valve seat
in-serts installed when they are manufactured. A
valve seat insert can be installed in these engines
when the cylinder head is overhauled. Installation of
new valves seats is described in 1.37 Installation Of
New Valve Seats. AB and YB engines have valve seat
inserts installed by the manufacturer.
1.37 Installation Of New Valve Seats
1. Remove the valve guide. Clean the bore and install
a new valve guide. See 1.31 Valve Guides for
inspection and replacement.
2. Use the bore of the new valve guide as a pilot and
use a milling machine to remove the old valve seat.
See the ENGINE SPECIFICATIONS. Clean the
particles from the port and the area where the new
valve seat will be in-stalled.
3. If the bottom face of the cylinder head has been ma-
chined, the back face of the new valve seat must be
ma-chined so that it will not extend above the surface
of the cylinder head. If the back face of the valve seat
is ma-chined, make sure that the outer edge of the
back face has a 0.9 to 1.3 mm (0.0035 to 0.0510 in)
chamfer at 30 to the vertical.
4. Use the bore of the valve guide as a pilot. Use a press
to install the valve seat into the cylinder head. Make sure
the valve seat is fully inserted into the cylinder head.
5. Use a cutter to cut the valve seat at an angle of 88.
Use the ªlappingº process to make sure the valve and
valve seat fit tightly together. Check the valve depth as
shown in FIGURE 23. Make sure that the dimensions
are within the ENGINE SPECIFICATIONS.
17
 PISTON AND CONNECTING ROD ASSEMBLIES
1.38 ROD BEARINGS
The connecting rods are forged from steel.
ENGINES AA and YA. Grooves are machined in the
joint faces of the connecting rod and bearing cap to
keep the alignment between the two parts. The
bearing cap is fastened to the connecting rod with two
nuts and special bolts. See FIGURE 28.
FIGURE 28. CONNECTING ROD ASSEMBLY,
ENGINES AA AND YA
ENGINES AB and YB. The pistons have an
ªanodizedº surface on the top face of the piston. The
pistons have a reduced diameter above the groove for
the top piston ring. Two steel dowels are installed into
the bearing cap to keep the alignment with the
connecting rod. Two capscrews fasten the bearing cap
to the connecting rod. See FIGURE 29.
FIGURE 29. CONNECTING ROD ASSEMBLY,
ENGINES AB AND YB
18
1.39 Removal
1. Drain the engine oil from the sump. Remove the oil
sump. See 1.114 Oil Sump, Removal.
2. Remove the suction pipe and oil strainer. See
FIGURE 30. Remove the capscrew that holds the
bracket to the main bearing cap. Remove the two
capscrews from the flange of the suction pipe and re-
move the suction pipe and screen. Clean the faces of
both flanges.
1. SUPPORT BRACKET, MAIN BEARING CAP
2. CAPSCREWS, FLANGE, SUCTION PIPE
FIGURE 30. REMOVE THE SUMP SCREEN
3. Turn the crankshaft until the connecting rod to be
re-moved is at the lowest position on the crankshaft.
4. ENGINES AA and YA. Remove the nuts and
remove the bearing cap.
ENGINES AB and YB. Loosen the capscrews for the
bearing cap approximately four turns. Lightly hit the
heads of the capscrews with a soft hammer to separate
the connecting rod from the bearing cap. Remove the
capscrews and the bearing cap.
CAUTION
Do not permit the connecting rods to hit the
cooling jets for the pistons. If a cooling jet is hit,
the alignment must be checked and the cooling jet
replaced if necessary.
5. Remove the lower bearing half from the bearing
cap. Keep the bearing half with its cap.
6. Carefully push the connecting rod up the cylinder
bore just enough to permit access to the upper bearing
half. Remove the upper bearing half from the connect-
ing rod. Keep the bearing halves together.
1.40 Installation
1. Clean the bearing surfaces of the connecting rod
and the crankshaft. Clean the bearing halves and
lubricate them with clean engine oil.
2. Install the upper bearing half into the connecting rod.
Make sure that the location tab is installed correctly into
its position in the connecting rod. See FIGURE 31.
1. POSITION OF LOCATION TAB IN
BEARING HALF AND CONNECTING ROD
(BEARING CAP FOR AA AND YA ENGINES SHOWN)
FIGURE 31. POSITION OF ROD BEARINGS
3. Install the bearing cap on the connecting rod. Make
sure that the assembly number on the bearing cap is
the same as the number on the connecting rod. Make
sure that the two assembly numbers are on the same
side of the connecting rod as shown in FIGURE 32.
4. ENGINES AA and YA. Install and tighten the nuts
evenly to a torque of 125 Nm (92 lbf ft). Make sure
that the crankshaft turns freely.
ENGINES AB and YB. Install and tighten the
capscrews evenly to a torque of 155 Nm (114 lbf ft).
Make sure that the crankshaft turns freely.
FIGURE 32. BEARING CAP POSITION,
CONNECTING ROD
5. Loosely assemble the bracket of the suction pipe to
the main bearing cap. Install a new gasket and fasten the
flanges of the suction line to the oil pump. Make sure
that the suction pipe is aligned correctly and tighten the
capscrew that holds the bracket to the main bearing cap.
6. Install the oil sump. See 1.115 Oil Sump, Installation.
1.41 PISTON AND CONNECTING ROD
ASSEMBLY
1.42 Service Note
CAUTION
The design of the pistons and rings were changed
in 1995 beginning with the following engine serial
numbers:
A±±±±±±U664793Y (4±cylinder)
A±±±±±±U654110Y (4±cylinder turbocharged)
Y±±±±±±U576870Y (6±cylinder turbocharged)
The pistons and piston rings are not
interchangeable with earlier production parts and
must be changed in complete engine sets.
1.43 Removal
1. If the engine is still in the lift truck, drain the engine
oil and the coolant.
2. Remove the cylinder head assembly as described un-
der 1.24 Cylinder Head, Removal. Remove the carbon
from the tops of the bores of the cylinder liners.
3. Remove the oil sump. See 1.114 Oil Sump, Removal.
4. Remove the suction line and oil strainer. See
FIGURE 30. Remove the capscrew that holds the
19
bracket to the main bearing cap. Remove the two
capscrews from the flange of the suction line and re-
move the suction line and screen. Clean the faces of
both flanges.

5. Remove the bearing cap and rod bearings as

described under 1.39 Rod Bearings, Removal. Mark
the bearing caps and rod bearings so that they can be
installed again in their original positions.

6. Push the piston and connecting rod out of the top of

the cylinder liner.
CAUTION
Do not permit the connecting rods to hit the
cooling jets for the pistons. If a cooling jet is hit,
the alignment must be checked and the cooling jet
replaced if necessary.
FIGURE 33. PISTON INSTALLATION TOOL
5. Put the spaces in the three piston rings so that they are
120 apart. Put the connecting rod through the piston in-
stallation tool and permit the piston to enter the tool. The
piston and connecting rod must be turned so that the
connecting rod does not hit the cooling jet for the piston.

6. When the connecting rod has passed the cooling jet

7. Inspect the bearing surfaces on the crankshaft for during installation, the arrow or ªFRONTº mark on
damage. the piston must be turned towards the end of the
engine with the cooling fan. When the piston is in this
1.44 Installation position, the combustion bowl in the top of the piston
will be towards the side of the engine with the fuel
Special Tools: Piston installation tool
injection pump. See FIGURE 34.
(piston ring compressor)
Piston height tool
Dial indicator gauge

1. Make sure all of the parts are clean. Lubricate the

parts with engine oil as they are installed.

2. Turn the crankshaft until the position for the

connect-ing rod to be installed is at the lowest
position on the crankshaft.

3. Install the upper bearing half into the connecting rod.

Make sure that the location tab is installed correctly into FIGURE 34. POSITION OF THE PISTON IN
its position in the connecting rod. See FIGURE 31. BORE

7. Lubricate the lower half of the rod bearing and

4. Put the piston installation tool at the top of the
cylin-der. See FIGURE 33. The tool has a bore with a
taper to compress the piston rings when the piston and
connect-ing rod assembly is installed. Make sure the
smaller end of the taper is toward the engine block.
install in into the bearing cap.
8. Install the bearing cap on the connecting rod. Make
sure that the assembly number on the bearing cap is the
same as the number on the connecting rod. Make sure

20
that the two assembly numbers are on the same side
of the connecting rod as shown in FIGURE 32.
9. ENGINES AB and YB. Install and tighten the nuts
evenly to a torque of 125 Nm (92 lbf ft). Make sure
that the crankshaft turns freely.
ENGINES AB and YB. Install and tighten the
capscrews evenly to a torque of 155 Nm (114 lbf ft).
Make sure that the crankshaft turns freely.
10. Measure the height of the piston above the top of the
engine block with a dial indicator gauge. The crankshaft
must be turned so that the piston is at TDC in the engine
block. Put the dial indicator on the top of the engine
block and measure the height of the piston above the
face of the engine block. See FIGURE 35.
The correct height of the piston above the engine block
is 0.14 to 0.36 mm (0.005 to 0.014 in). Two piston
heights are used by the manufacturer when a new engine
is assembled. The pistons are marked ªHº for high, and
ªLº for low. When replacement pistons are ordered from
the manufacturer, only the ªLº pistons are supplied. If an
ªLº piston is used to replace a ªHº piston, the height of
the piston can be a maximum of 0.19 mm (0.0075 in)
below the bottom limit. The tops of the pistons must
not be changed or machined.
FIGURE 35. MEASURE THE HEIGHT OF THE
PISTON ABOVE THE ENGINE BLOCK
11. Loosely assemble the bracket of the suction pipe to
the main bearing cap. Install a new gasket and fasten the
flanges of the suction pipe to the oil pump. Make sure
that the suction pipe is aligned correctly and tighten the
capscrew that holds the bracket to the main bearing cap.
12. Install the oil sump. See 1.115 Oil Sump, Installa-
tion.
13. Install the cylinder head. See 1.25 Cylinder Head,
Installation.
1.45 PISTON RINGS
1.46 Removal
Check that the piston rings can move freely in their
grooves and are not broken.
Remove the piston rings with a ring expander.
Increase the diameter of the piston rings only enough
to remove them without damaging the piston.
1.47 Inspection
1. Check the piston for wear and damage.
2. Clean the carbon from the top of the cylinder liners.
Fit the piston rings in the top part of the cylinder liner
and measure the clearance at the ends of the ring. See
FIGURE 36. The spring must be installed in the oil
con-trol ring when its end clearance is measured. The
clear-ance measurements for the piston rings are
shown in the specifications. See 1.42 Service Note.
FIGURE 36. CHECK THE END CLEARANCE OF
THE PISTON RING
3. Install new piston rings on the piston and check the
clearance in the grooves with a spacer gauge. See
FIGURE 37. If the clearance between the piston rings
and the piston are greater than the specifications, the
pis-ton must be replaced. See the ENGINE SPECIFI-
CATIONS.
ENGINES AB and YB. The clearance in the top
groove of the pistons for these engines can not be
checked be-cause it has a taper.
21
 ENGINES AA AND YA

FIGURE 37. CHECK THE PISTON RING FIGURE 39. INSTALLATION OF THE PISTON
CLEARANCE RINGS

2. Install the cast iron ring with the taper into the
second groove of the piston. Make sure that the word
ªTOPº or the manufacturer's symbol is towards the top
1.48 Installation of the pis-ton. New piston rings have a green
identification mark which must be on the left of the
Install the piston rings with a ring expander. Increase clearance at the ends of the ring when the ring is
the diameter of the piston rings only enough to installed on the piston and the piston is upright.
remove them without damaging the piston.
ENGINES AB AND YB
1. See FIGURE 39. and FIGURE 40. Install the spring
for the oil control ring in the bottom groove of the pis-
ton. Install the latch pin inside both ends of the spring.
See FIGURE 38. Install the oil control ring over the
spring so that the end space in the oil control ring is
180 to the latch pin.

FIGURE 40. INSTALLATION OF THE PISTON

RINGS

3. Install the barrel face ring with the molybdenum in-

sert into the top groove of the piston.
ENGINES AA and YA. The top ring has a chamfer
on the inner top face.
ENGINES AB and YB. The top ring has a shape like
wedge.
FIGURE 38. INSTALL THE SPRING FOR THE Make sure that the word ªTOPº or the manufacturer's
OIL CONTROL RING symbol is towards the top of the piston. New piston rings
have a red identification mark which must be on the left

22
of the clearance at the ends of the ring when the ring
is installed on the piston and the piston is upright.
4. Make sure that the clearances at the ends of the
piston rings are installed in an orientation 120 apart
before the piston is installed.
1.49 PISTON AND CONNECTING ROD
1.50 Disassembly
1. Remove the piston rings as described in 1.46 Piston
Rings, Removal.
2. Make a mark on the piston to indicated the cylinder
number as shown on the connecting rod. Make the
mark on the same side of the piston as the number on
the con-necting rod. See FIGURE 41.
FIGURE 41. MARK THE PISTON
3. Remove the snap rings that hold the piston pin in
the piston. Push the piston pin from the piston with
your thumb. If the piston pin is tight, heat the piston
and con-necting rod to 40 to 50C (100 to 120F) to
make re-moval of the piston pin easier.
1.51 Inspection
1. Clean and inspect all the components for wear and
damage. Check the alignment of the connecting rod
with a test mandrel. See FIGURE 42.
The large and small bores in the connecting rod
must be square and parallel with each other
within the limits of + 0.25 mm (0.010 in). The
measurement is made at 127 mm (5.0 in) on
each side of the axis of the connecting rod. If the
bush-ing is installed in the small end of the
connecting rod, the limits are reduced to
+ 0.06 mm (0.0025 in).
FIGURE 42. CHECK THE ALIGNMENT OF THE
CONNECTING ROD
2. Check the clearance of the bushing in the
connecting rod with the piston pin. If the clearance is
greater than than 0.043 mm (0.0017 in) or is
damaged, install a new bushing.
3. If the bushing in the connecting rod is worn, use a
press to remove the bushing.
4. Use a press to install a new bushing in the connecting
rod. Make sure that the lubrication hole in the bushing is
aligned with the lubrication hole in the connecting rod.
5. Use a reamer in the bushing as necessary to give a
clearance on the piston pin of 0.020 to 0.043 mm
(0.0008 to 0.0017 in).
6. Machine the ends of the bushing to fit the shape of
the connecting rod.
1.52 Installation
1. Make sure that the parts are clean. Lubricate the
parts with engine oil as they are assembled.
2. Install a new snap ring into one of the grooves to
hold the piston pin.
3. Turn the piston for access to install the connecting
rod. Install the connecting rod in position in the piston.
If the original piston is to installed again, make sure that
the mark on the piston is aligned with the mark on the
connecting rod as shown in FIGURE 41. Make sure that
23
the piston and connecting rod are installed in the same
cylinder again.

If a new piston or connecting rod is being installed,

make sure that index slot in the connecting rod for the
rod bearing is on the same side of the piston as the
boss for the piston pin. See FIGURE 43.

1. ALIGNMENT DOWEL

FIGURE 44. PISTON COOLING JET

FIGURE 43. ORIENTATION OF PISTON AND
CONNECTING ROD
4. Install the piston pin to fasten the connecting rod to
the piston. If the piston pin is tight, heat the piston to
40 to 50C (100 to 120F) to make installation of the
piston pin easier.
5. Install the other snap ring to hold the piston pin in
the piston.
1.55 Installation
1. Check that the ball assembly moves freely against
the spring pressure in the valve assembly and that the
jet tube is not damaged. Replace any damaged or
worn parts.
2. Install the cooling jet. Make sure that the assembly
is installed correctly on the alignment dowel in the
cylin-der block. Tighten the valve assembly to 27 Nm
(20 lbf ft).
3. Check the alignment of the cooling jet. Insert a 1.70
mm (0.067 in) rod into the nozzle of the cooling jet. The
length of the rod must extend out of the top of the cylin-
der. If a rod of the correct diameter is not available,
grind one end of a thicker rod to the 1.70 mm (0.067 in)
diame-ter for a length of 16.00 mm (0.630 in) so that it
will fit into the nozzle of the cooling jet. See FIGURE
45. for checking the alignment of the cooling jet.

6. Install the piston rings as described under 1.48

Piston Rings, Installation.

1.53 PISTON COOLING

JETS (Engines AB and YB)

1.54 Removal

Release the valve assembly and remove the piston

cool-ing jet. The crankshaft has been removed in
FIGURE 44. to more clearly show the piston cooling FIGURE 45. ALIGNMENT OF THE PISTON
jet. COOLING JET

24
 CRANKSHAFT ASSEMBLY

1.56 GENERAL capscrews evenly to 115 Nm (85 lbf ft). Check each
capscrew again for the correct torque.
The crankshaft is forged from chrome±molybdenum
2. Install the drive belts. See 1.178 Drive Belts.
steel. The 4±cylinder engines have five main journals
and the 6±cylinder engines have seven main journals. 1.60 Removal, Engines YA and YB
The center main bearing is the thrust bearing that con-
1. Remove the drive belts.
trols the axial movement of the crankshaft. The thrust
bearing has thrust washers on both sides of the bearing. 2. See FIGURE 47. Remove the three capscrews which
The main bearings are an alloy of tin and aluminum. The hold the pulley to the crankshaft. Remove the thrust
center main bearing in the 6±cylinder engines is a lead block. If the crankshaft pulley will not slide from the
and bronze alloy. The front and rear oils seals are lip crankshaft, DO NOT use a puller to remove the pulley.
seals with an additional dust seal outside of the main lip Hold a wood block against the inner hub of the pulley
and oil return grooves on the face of the main lip. and lightly hit the wood block with a hammer. See
FIGURE 46. This action will loosen the inner ring (2)
ENGINES AA and AB. The crankshaft has splines for and outer ring (3) so that the pulley can be removed
the position of the front pulley. The crankshaft pulley is from the crankshaft as shown in FIGURE 47.
fastened to the crankshaft with a thrust block and three
capscrews. A damper is part of the crankshaft pulley. 3. If a separate damper is connected to the crankshaft
pulley, remove the capscrews and remove the damper.
ENGINES YA and YB. The crankshaft pulley is fas-
tened to the crankshaft with a plain thrust block and
three capscrews. A special arrangement holds the
crank-shaft pulley in position. See FIGURE 47. A
separate damper is sometimes fastened to the rear face
of the crankshaft pulley. Some engines have the
damper as part of the crankshaft pulley.

1.57 CRANKSHAFT PULLEY

1.58 Removal, Engines AA and AB

1. Remove the drive belts.

2. Remove the three capscrews which hold the pulley

to the crankshaft. Remove the thrust block and pulley. FIGURE 46. CRANKSHAFT PULLEY
INSTALLATION, ENGINES YA AND YB
3. Clean the parts and check for damage. Replace any
damaged parts. 1.61 Installation, Engines YA and YB

1.59 Installation, Engines AA and AB
1. Put the pulley into position on the crankshaft. Lubri-
cate lightly the threads of the three capscrews. Install the
thrust block and the three capscrews. Tighten the three
1. If your engine has a separate damper that is
connected to the crankshaft pulley and it was
removed, install it on the crankshaft pulley. Install the
clamp ring or the wash-ers and tighten the capscrews
gradually and evenly to 35 Nm ( 26 lbf ft).

25

1. SPACER RING 4. THRUST BLOCK
2. INNER RING 5. O±RING
3. OUTER RING
FIGURE 47. CRANKSHAFT PULLEY
ARRANGEMENT, ENGINES YA AND YB
2. Clean the end of the crankshaft and the parts of the
crankshaft pulley. Do not use a degreasing solution. See
FIGURE 47. Do not make any changes to the inner ring
(2) or the outer ring (3).
3. Put the crankshaft pulley on the crankshaft so that the
key is engaged. Push the pulley onto the crankshaft.
NOTE: If the rings (2) and (3) are not installed cor-
rectly, the crankshaft pulley will be very difficult to
re-move again.
4. Install the spacer ring (1), inner ring (2), and the
outer ring (3) in the correct order.
5. Lightly lubricate the O±ring (5) and the thrust faces
of the capscrews with engine oil. Put the thrust block
(4) and the capscrews in position.
6. Gradually and evenly tighten the capscrews to push
the crankshaft pulley on the crankshaft. Tighten the
capscrews to 115 Nm (85 lbf ft).
7. Install the drive belts. See 1.178 Drive Belts.
1.62 REAR OIL SEAL
1.63 Replacement
Special Tools: Replacement tool for oil seal
1. Remove the drive components from the rear of the
en-gine.
26
2. Remove the flywheel and housing. See 1.172 Fly-
wheel and 1.176 Flywheel Housing, Removal.
3. Remove the capscrews and remove the seal housing
and seal assembly. Clean the parts.
4. Inspect the oil seal for wear and damage. If there is
any question about the condition of the oil seal,
replace the oil seal.
5. Check that the oil seal area and outer circumference
of the crankshaft flange are not worn or damaged.
6. Press the oil seal out of the housing
7. Lubricate the oil seal with engine oil and carefully
press the oil seal into one of the positions in the housing.
The spring in the seal goes toward the housing.
8. There are four positions in which the oil seal can be
installed in the seal housing. See FIGURE 48.
FIGURE 48. OIL SEAL POSITIONS
Position 1 is used by the manufacturer or if a new oil
seal is installed on a crankshaft that has a new surface
ground on the crankshaft flange.
Position 2 is used when a new oil seal is installed and
the crankshaft flange is worn at Position 1.
Position 3 is used when a new oil seal is installed and the
crankshaft flange is worn at Position 1 and Position 2.
Position 4 can be used when a new oil seal is installed
if a wet clutch is not installed.
If all positions have been used, the crankshaft must have
a new surface ground on the crankshaft flange. See the
ENGINE SPECIFICATIONS for the size limits.
9. Make sure that the two position dowels are installed
in the engine block. Use a new gasket. Do not use
gasket compound on any of the surfaces.
10. Make sure the lip of the seal is lubricated with
engine oil where it touches the crankshaft flange. This
lubrica-tion of the oil seal is necessary to prevent
damage to the oil seal when the engine is first started.
11. Put the oil seal and housing on the seal guide. Care-
fully push the oil seal assembly into position on the
crankshaft flange and onto the dowels. See FIGURE 49.
1. SEAL GUIDE
2. OIL SEAL AND HOUSING
3. DOWEL (2)
FIGURE 49. INSTALLATION OF THE OIL SEAL
12. Remove the seal guide. Install the capscrews.
Tighten the smaller capscrews to 18 Nm (13 lbf ft).
Tighten the larger capscrews to 22 Nm (16 lbf ft).
1.64 MAIN BEARINGS
NOTES: The following procedure is for replacement
of the main bearings without removing the crankshaft
from the engine.
If the rear main bearing must be replaced, the
flywheel, flywheel housing, rear oil seal housing, and
bridge piece must be removed.
The front main bearing can be difficult to replace when
the timing case is on the engine. The oil pump is in-
stalled on the front bearing cap. A special wrench can be
required to apply the correct torque to the capscrews for
removal and installation. If a wrench is not available to
install the capscrews on the main bearing cap, the
timing case must be removed. The oil pump will be
removed with the cap for the front main bearing. The
suction pipe, oil strainer, delivery pipe, and relief
valve must be re-moved.
1.65 Removal
1. Drain the engine oil and remove the oil sump.
2. Remove the necessary components for access to the
bearing cap for the bearing that must be replaced.
3. Remove the capscrews and remove the bearing cap.
Remove the lower half of the bearing from the
bearing cap.
4. Use a thin flexible tool to push on the side of the
upper bearing half that is opposite from the location
tab. Push on the bearing half so that it begins to rotate
out of the engine block. Carefully rotate crankshaft so
that bearing will rotate out of the engine block.
5. Check that the bearing journal on the crankshaft is
clean and in good condition.
1.66 Installation
NOTE: Only the upper half of the bearing has lubrica-
tion holes and it must be installed into the engine block.
1. Lubricate the upper bearing half with engine oil. In-
stall the plain end of the bearing between the
crankshaft journal and the side of the bearing housing
that has the location slot. Carefully slide the bearing
half into the bearing housing until the location tab fits
into the loca-tion slot.
2. Lubricate the lower bearing half with engine oil
and install it into the bearing cap. Make sure the
location tab is installed correctly into the location slot.
3. Make sure that the location thimbles are installed in
either the bearing cap or the bearing housing of the
en-gine block. Make sure that the orientation of the
location slots for the bearing halves are correct as
shown in FIGURE 50. Install the bearing cap.
27
 1. LOCATION SLOTS FOR MAIN
BEARING HALVES FIGURE 51. THRUST WASHERS
FIGURE 50. ORIENTATION OF THE MAIN
BEARING CAP

4. Make sure the capscrews are in good condition. In-

stall the capscrews into the bearing cap. Tighten the
capscrews gradually and evenly. Tighten the
capscrews to a final torque of 265 Nm (196 lbf ft).

5. Make sure that the crankshaft rotates freely. If the

thrust washers have been removed and installed again,
the axial movement of the crankshaft must be checked.
See 1.67 Thrust Washers in the following paragraphs.
FIGURE 52. MEASURE THE AXIAL
6. Install the components that were removed for CLEARANCE WITH A SPACER GAUGE
access to the main bearing.

7. Install the oil sump.

1.67 THRUST WASHERS

1.68 Check The Axial Movement Of The

Crankshaft

The axial movement of the crankshaft is controlled by

two half thrust washers installed on each side of the
cen-ter main bearing. See FIGURE 51. The axial
clearance can be checked with a spacer gauge inserted
between the crankshaft and the thrust washer. See FIGURE 53. MEASURE THE AXIAL
FIGURE 52. A dial indicator can be used to check the MOVEMENT WITH A DIAL INDICATOR
axial movement from the end of the crankshaft as
shown in FIGURE 53. The normal axial movement is If the axial movement is greater than the specifications,
0.05 to 0.38 mm (0.002 to 0.015 in). The maximum oversize thrust washers can be installed on one side or
axial movement permitted is 0.51 mm (0.020 in). both sides of the main bearing. The oversize thrust

28
washers are 0.019 mm (0.0075 in) larger than the
stan-dard thrust washers.
1.69 Removal
1. Drain the engine oil from the sump. Remove the oil
sump. See 1.114 Oil Sump, Removal.
2. Remove the suction pipe and oil strainer. See
FIGURE 30. Remove the capscrew that holds the
bracket to the main bearing cap. Remove the two
capscrews from the flange of the suction pipe and re-
move the suction pipe and screen. Clean the faces of
both flanges.
3. Remove the capscrews for the center main bearing
cap. Remove the bearing cap, lower bearing half, and
the lower halves of the thrust washers.
4. Use a thin flexible tool to push the upper halves of
the thrust washers from their positions next to the
main bearing housing. See FIGURE 54. Use a small
prybar as necessary to move the crankshaft to loosen a
tight thrust washer.
FIGURE 54. REMOVE THE UPPER HALF OF THE
THRUST WASHER
1.70 Installation
1. Lubricate the thrust washers with engine oil. Slide the
upper halves of the thrust washers into their positions in
the engine block. Make sure that the sides of the thrust
washers with the grooves are against the crankshaft.
2. Install the lower halves of the thrust washers into
the main bearing cap. Make sure that the location tabs
are in their correct positions.
3. Make sure that the location thimbles are installed in
either the bearing cap or the bearing housing of the
en-gine block. Make sure that the orientation of the
location slots for the bearing halves are correct as
shown in FIGURE 50. Lubricate the bearing and
thrust washers with engine oil. Install the bearing cap.
4. Make sure the capscrews are in good condition. In-
stall the capscrews into the bearing cap. Tighten the
capscrews gradually and evenly. Tighten the
capscrews to a final torque of 265 Nm (196 lbf ft).
5. Make sure that the crankshaft rotates freely. Check
the axial movement of the crankshaft to make sure
that it is within the specifications.
6. Loosely assemble the bracket of the suction line to the
main bearing cap. Install a new gasket and fasten the
flanges of the suction line to the oil pump. Make sure
that the suction line is aligned correctly and tighten the
capscrew that holds the bracket to the main bearing cap.
7. Install the oil sump. See 1.115 Oil Sump, Installation.
1.71 CRANKSHAFT
1.72 Removal
1. Remove the engine from the lift truck. See THE
FRAME section. See the TRANSMISSION section
for separating the engine from the transmission.
2. Remove the oil sump. See 1.114 Oil Sump, Removal.
3. Remove the fan, drive belts, fan drive pulley and
housing, and the coolant pump.
4. Remove the crankshaft pulley. See 1.57 Crankshaft
Pulley.
5. Remove the alternator and its mount bracket.
6. Remove the timing case cover. See 1.77 Timing
Case Cover, Removal.
7. Remove the fuel injection pump. See 1.127 Fuel In-
jection Pump, Removal.
29
8. Remove the timing gears and the timing case. See
the sections 1.75 through 1.92 Timing Case And
Timing Gears.
9. Remove the flywheel and the flywheel housing.
See 1.172 Flywheel and 1.176 Flywheel Housing, Re-
moval.
10. Remove the rear oil seal housing. See 1.63 Oil
Seal, Replacement.
11. If the engine is not already in a position with the
crankshaft facing up, turn the engine to that position.
Remove the suction pipe and oil strainer. See
FIGURE 30. Remove the capscrew that holds the
bracket to the main bearing cap. Remove the two
capscrews from the flange of the suction pipe and re-
move the suction pipe and screen. Clean the faces of
both flanges. Remove the oil pump, delivery tube and
relief valve. See 1.117 through 1.121 on the oil pump
and relief valve.
12. Remove the bridge piece over the rear main bearing.
Make a note if there is a round rubber seal at each end of
the bridge piece where it joins the crankcase. Some en-
gines have rubber seals and other engines have sealant.
13. Remove the bearing caps and lower bearing halves
from the connecting rods. Make an arrangement so that
the parts for each connecting rod will be assembled
again in their original positions. Carefully push the pis-
tons into their bores a small amount so that the connect-
ing rods are separated from the crankshaft.
CAUTION
Make sure the cooling jets for the pistons are not
damaged or moved out of alignment. If a cooling
jet is hit, the alignment must be checked and the
cooling jet replaced if necessary.
14. Make sure that the main bearing caps are marked
with their position number. Remove the main bearing
caps, lower bearing halves, and the upper and lower
thrust washers. Keep all the parts in an arrangement so
that the parts can be installed in their original positions.
15. Lift the crankshaft from the engine block. Remove
the upper bearing halves and put each of them with
their lower bearing half.
30
1.73 Inspection
Check the crankshaft for wear and other damage. The
maximum wear and out±of±round on the bearing
jour-nals is 0.04 mm (0.0016 in).
The bearing journals on standard crankshafts can be
ground to the following diameters smaller than the
original size:
0.25 mm (0.010 in)
0.50 mm (0.020 in)
0.75 mm (0.030 in)
Special bearings are available for these sizes.
The crankshaft must be replaced if the surface must
be ground more than 0.75 mm (0.030 in).
The area on the crankshaft flange for the rear oil seal
can be machined to remove wear marks if the oil seal
has been used in all four positions. See the ENGINE
SPEC-IFICATIONS. The minimum diameter of this
area is 133.17 mm (5.243 in).
1.74 Installation
1. Make sure that all of the oil passages are clean.
2. Make sure all of the bearings and bearing caps are
clean. Install the upper bearing halves into their posi-
tions in the connecting rods and the housings for the
main bearings. Make sure that the position tags of the
bearings fit into their position slots. Lubricate the
bear-ings with engine oil.
3. Install the crankshaft in position on the main bearings.
4. Lubricate the thrust washers with engine oil. Slide the
upper halves of the thrust washers into their positions in
the engine block. Make sure that the sides of the thrust
washers with the grooves are against the crankshaft.
5. Install the lower halves of the thrust washers into
the main bearing cap. Make sure that the location tags
are in their correct positions.
6. Make sure that the location thimbles are installed in
either the bearing cap or the bearing housing of the
en-gine block. Make sure that the orientation of the
location slots for the bearing halves are correct as
shown in FIGURE 50. Lubricate the bearing and
thrust washers with engine oil. Install the bearing cap.
7. Make sure the main bearing caps are installed accord-ing
to their position numbers shown on the cap. The se-rial
numbers on the main bearing caps will also be in
alignment. The serial number on the main bearing caps
must be the same as the number on the bottom face of the
engine block. (The third and fifth bearing caps on 6±cyl-
inder engines are not marked with with a serial number.)
8. Make sure the capscrews are in good condition. In-
stall the capscrews into the main bearing cap. Tighten
the capscrews gradually and evenly. Tighten the
capscrews to a final torque of 265 Nm (196 lbf ft).
Re-peat this step for all five main bearings.
9. Apply a thin coat of sealant in the corners and
around the thread holes of the bridge piece where it
joins the en-gine block. Install the bridge piece and
the two rubber seals. See FIGURE 55.
NOTE: Some engines do not have the two rubber
seals installed and the grooves in the bridge piece are
filled with sealant.
FIGURE 55. BRIDGE PIECE AND RUBBER
SEALS
10. Use a straight edge to make sure the the bridge
piece is aligned with the rear face of the engine block.
See FIGURE 56. Tighten the capscrews.
FIGURE 56. ALIGN THE BRIDGE PIECE
11. Install the upper bearing half into the connecting rod.
Make sure that the location tab is installed correctly into
its position in the connecting rod. See FIGURE 31.
12. Install the bearing cap on the connecting rod. Make
sure that the assembly number on the bearing cap is the
same as the number on the connecting rod. Make sure
that the two assembly numbers are on the same side of
the connecting rod as shown in FIGURE 32.
13. Install and tighten the capscrews evenly to a
torque of 155 Nm (114 lbf ft). Make sure that the
crankshaft turns freely.
14. Install the oil pump, delivery pipe, and relief
valve. See 1.119 through 1.124 for installation.
Loosely assemble the bracket of the suction pipe to the
main bearing cap. Install a new gasket and fasten the
flanges of the suction line to the oil pump. Make sure
that the suction pipe is aligned correctly and tighten the
capscrew that holds the bracket to the main bearing cap.
15. Install the rear oil seal housing. See 1.62 Oil Seal.
16. Install the flywheel and the flywheel housing. See
1.174 Flywheel and 1.177 Flywheel Housing, Installa-
tion.
17. Install the timing gears and the timing case. See
the sections after 1.75 for the Timing Gears And
Timing Case, Installation.
31
18. Install the fuel injection pump. See 1.128 Fuel
Injec-tion Pump, Installation.
19. Install the timing case cover. See 1.78 Timing
Case Cover, Installation.
20. Install the alternator and its mount bracket.
21. Install the crankshaft pulley. See 1.57 Crankshaft
Pulley.
22. Install the coolant pump, fan drive pulley and fan
housing, drive belts, and the fan.
23. Install the oil sump. See 1.115 Oil Sump, Installa-
tion.
24. Install the engine into the lift truck. See THE
FRAME section and the TRANSMISSION section
for the lift truck.

TIMING CASE AND TIMING GEARS

1.75 GENERAL
The timing case can be either cast aluminum or cast
iron. The timing gears are steel. A PTO turns the
hydraulic pump for the steering, brakes, and frame
leveling func-tions.
The gear train includes the crankshaft gear, idler gear,
gear for the fuel injection pump, camshaft gear, and
PTO gear. The timing case cover is aluminum and has
the front oil seal for the crankshaft. The timing case
cover has a noise shield on its front surface.
1. Use a new gasket and install the timing case cover on
the timing case. Use two capscrews to hold the timing
case cover in position. Install the special tool on the
crankshaft. Use the special washer and the capscrews for
the crankshaft pulley to hold the alignment tool in
position. The purpose of the special tool is to make sure
that the front oil seal evenly fits the circumference of the
seal surface of the crankshaft pulley. See FIGURE 57.

The camshaft is made from cast iron. The lobes for

the fuel pump are hardened.

1.76 TIMING CASE COVER

1.77 Removal
1. Drain the coolant. Remove the fan.

2. Remove the drive belts.

3. Remove the three capscrews which hold the crank-
shaft pulley to the crankshaft. Remove the thrust
block and pulley.
4. Remove the fan drive pulley if additional clearance
is needed.
5. Remove the coolant pump. See 1.154 Coolant
Pump, Removal.
5. Remove the capscrews and nuts that hold the
timing case cover to the timing case. Remove the
timing case cover and the sound shield.
1.78 Installation
Special Tools: Alignment tool, front oil seal
FIGURE 57. ALIGNMENT TOOL, FRONT OIL
SEAL
When the timing case cover is aligned with the crank-
shaft, install the capscrews and nuts in the timing case
cover. Tighten the capscrews and nuts to 22 Nm (16
lbf ft). Remove the alignment tool.
2. Install the coolant pump. See 1.157 Coolant Pump,
Installation.
3. Install the crankshaft pulley and thrust block.
Install the three capscrews and tighten the three
capscrews evenly to 115 Nm (85 lbf ft). Check each
capscrew again for the correct torque.
4. Install the fan drive pulley if it was removed.

32
5. Install the drive belts and adjust the tension. See
1.178 Drive Belts.
6. Install the fan. Fill the cooling system.
1.79 FRONT OIL SEAL
1.80 Removal
1. Remove the fan and drive belts.
2. Remove the crankshaft pulley.
3. Use a prybar to remove the front oil seal from the tim-
ing gear cover. Put the prybar behind the main lip of the
front oil seal. Make sure that the edge of the housing for
the oil seal is not damaged during removal.
1.81 Installation
Special Tools: Replacement tool for front oil seal
Pressure plate
Fastener plate
Sleeve
Seal adaptor
seal. If the crankshaft pulley is worn at that place, the
front oil seal can be installed at a maximum depth of
9.3 mm (0.366 in).
1. Clean the oil seal housing. Inspect the oil seal for
damage. Do not install a front oil seal that has a
scratch or any damage on the lip of the seal.
2. Lubricate the outer circumference of the oil seal with
engine oil and install the front oil seal into the oil seal
housing. Make sure that the lip of the seal is towards the
inside of the cover for the timing gear case and the front
oil seal is parallel to the bore of the oil seal housing.
3. Put the replacement tool for the front oil seal on the
crankshaft as shown in FIGURE 58. Use the fastener
plate (3) to fasten the installation tool to the crankshaft.
Install the seal adaptor (5) so that the 9.3 mm mark is to-
wards the front oil seal. Put the sleeve (4) and the pres-
sure plate (2) into position and fasten it to the stud of the
fastener plate as shown in FIGURE 58.
4. Install a rod through the hole in the end of the tool
so that the tool will not turn. Turn the nut on the
pressure plate (2) with a wrench and the front oil seal
will be pushed into the housing. Push the seal into the
correct depth. If the seal is to be pushed into the 9.3
mm posi-tion, turn the nut on the pressure plate (2)
until the face of the seal adaptor (5) is against the oil
seal housing. Re-move the installation tool.
5. Lubricate the seal area of the crankshaft pulley with
engine oil. Install the crankshaft pulley. See 1.57
Crank-shaft Pulley.
6. Install the drive belts and adjust the belt tension.
7. Install the fan.

1. REPLACEMENT TOOL 1.82 IDLER GEAR AND HUB

FOR FRONT OIL SEAL
2. PRESSURE PLATE 1.83 Removal
3. FASTENER PLATE
4. SLEEVE 1. Remove the timing case cover. See 1.77 Timing
5. SEAL ADAPTOR Case Cover, Removal.
FIGURE 58. INSTALLATION, FRONT OIL SEAL 2. Turn the crankshaft until the marked teeth of the
crankshaft gear, the camshaft gear, and the gear for
NOTE: The front oil seal is normally installed to a depth of the fuel injection pump are aligned as shown in
6.75 to 7.25 mm (0.266 to 0.285 in) from the front face of FIGURE 59. The marked teeth on the idler gear will
the oil seal housing to the flat front face of the oil not necessarily be aligned with the marked teeth of

33
the other three gears because of the different speed of TIMING MARKS ON GEARS:
ro-tation of the idler gear. 4 = 4 Cylinder Engine
6 = 6 Cylinder Engine

3. Remove the three capscrews, remove the plate of

the idler gear, and remove the idler gear. The gear for
the fuel injection pump will turn a small amount in
the counter±clockwise direction as the teeth become 4
disen-gaged from the idler gear.
3

5
CAUTION 1

Make sure that the crankshaft is not turned while

the idler gear is removed. A piston can hit and 2
damage a valve.

. 1. CAMSHAFT GEAR
. 2. CRANKSHAFT GEAR
4. Inspect the idler gear and bushings for wear and . 3. IDLER GEAR
dam-age. The idler gear and bushings are available as . 4. GEAR FOR FUEL INJECTION PUMP
an as-sembly or as separate parts. . 5. PTO GEAR

FIGURE 59. ALIGNMENT OF THE TIMING

5. If the bushings must be replaced, use a puller to re-
move them from the idler gear. If a puller is not avail-
able, grind one of the faces from the bushings and use
a press to remove them from the idler gear. Use a
press to install new bushings. The bores and faces of
the bush-ings will need machining to correctly fit the
hub. See the ENGINE SPECIFICATIONS, Idler Gear
And Hub for the measurements.
MARKS
3. Install the plate for the idler gear and the three
capscrews. Tighten the capscrews to 44 Nm (33 lbf ft).
4. Check the clearance between the bushings of the idler
gear and the plate of the idler gear. The correct clearance
is 0.10 to 0.20 mm (0.004 to 0.008 in). A maximum
service limit is 0.38 mm (0.015 in). See FIGURE 60.

1.84 Installation

1. Use the three capscrews for the idler gear to make

sure that the hub for the idler gear is in the correct
position with the lubrication hole at the top.

2. Lubricate the bushings in the idler gear with engine

oil. Align the timing marks on the idler gear with the
marks on the crankshaft gear and the cam shaft gear.
Turn the gear for the fuel injection pump clockwise as
necessary to align the timing marks when the teeth of the
idler gear engage the other gears. Make sure all of the FIGURE 60. CHECK THE HUB CLEARANCE
alignment marks are aligned as shown in FIGURE 59. ON THE IDLER GEAR

34
5. Check the timing gear clearances as shown in
FIGURE 61. The minimum clearances for all gears is
0.08 mm (0.003 in).
FIGURE 61. CHECK THE TIMING GEAR
CLEARANCES
6. Install the timing case cover, coolant pump, crank-
shaft pulley, fan drive pulley, drive belts, and fan. See
1.78 Timing Case Cover, Installation.
1.85 GEAR FOR THE FUEL INJECTION
PUMP OR THE CAMSHAFT GEAR
1.86 Removal
Special Tools: Gear puller with adaptors
1. Remove the timing case cover. See 1.77 Timing
Case Cover, Removal.
2. Turn the crankshaft until the marked teeth of the
crankshaft gear, the camshaft gear, and the gear for
the fuel injection pump are aligned as shown in
FIGURE 59. The marked teeth on the idler gear will
not necessarily be aligned with the marked teeth of
the other three gears because of the different speed of
rotation of the idler gear.
CAUTION
Make sure that the crankshaft is not turned while
the camshaft gear is removed. A piston can hit and
damage a valve.
3. Camshaft gear. Remove the capscrew and washer.
Use a puller and adaptor to pull the gear from the
cam-shaft. Make sure that the woodruff key in the
camshaft is not lost. Inspect the camshaft gear for
wear and dam-age. See FIGURE 62.
FIGURE 62. REMOVE THE CAMSHAFT GEAR
4. Gear for the fuel injection pump. Remove the nut and
spring washer from the gear for the fuel injection pump.
Use a puller and adaptor to remove the gear for the fuel
injection pump. The gear has the letter M on the gear to
indicate that the threads for the screws of the gear puller
are metric. Make sure that the woodruff key in the shaft
for the fuel injection pump is not lost. Inspect the gear
for wear and damage. See FIGURE 63.
FIGURE 63. REMOVE THE GEAR FOR THE
FUEL INJECTION PUMP
1.87 Installation
CAUTION
If the crankshaft or the camshaft must be turned
to permit the alignment of the marks on the timing
gears, a piston can hit and damage a valve. The
rocker arm assembly must be loosened so that the
valves are closed when the crankshaft or the
camshaft are turned.
1. Make sure that the woodruff key is installed
correctly in the end of the camshaft.
35
2. Install the gear on the shaft with the marked teeth
to-wards the idler gear. Use a soft hammer to push the
gear onto the camshaft. Make sure that the timing
marks are aligned correctly as the gear teeth are
engaged. See FIGURE 59.
3. Camshaft gear. Install the capscrew and washer and
tighten the capscrew to press the gear into position.
Tighten the capscrew to 78 Nm (58 lbf ft).
4. Gear for the fuel injection pump. Install the nut and
spring washer. Tighten the nut to 80 Nm (59 lbf ft).
5. If new gears have been installed, check the timing
gear clearances as shown in FIGURE 61. The minimum
clearances for all gears is 0.08 mm (0.003 in).
6. Install the timing case cover, coolant pump, crank-
shaft pulley, fan drive pulley, drive belts, and fan. See
1.78 Timing Case Cover, Installation.
1.88 CRANKSHAFT GEAR
1.89 Removal
1. Remove the timing case cover. See 1.77 Timing
Case Cover, Removal.
2. Turn the crankshaft until the marked teeth of the
crankshaft gear, the camshaft gear, and the gear for
the fuel injection pump are aligned as shown in
FIGURE 59. The marked teeth on the idler gear will
not necessarily be aligned with the marked teeth of
the other three gears because of the different speed of
rotation of the idler gear.
CAUTION
Make sure that the crankshaft is not turned while
the idler gear or the crankshaft gear is removed. A
piston can hit and damage a valve.
3. Remove the three capscrews, remove the plate of
the idler gear, and remove the idler gear. The gear for
the fuel injection pump can turn a small amount in the
counter±clockwise direction as the teeth become
disen-gaged from the idler gear.
4. The crankcase gear is pressed onto the crankshaft.
Sometimes a puller will remove the crankcase gear.
Sometimes the gear fits so tightly on the crankshaft
that the crankshaft must be removed from the engine
and the gear must be removed by destroying it.
36
1.90 Installation
1. Put the crankshaft gear in a pan of hot oil. Make
sure that the temperature can be controlled. DO NOT
heat the crankshaft gear more than 108C (226F).
Use boil-ing water if a container of hot oil and a
temperature con-trol is not available. DO NOT use an
open flame to heat the gear.
2. Align the gear with the key on the crankshaft and
with the timing marks on the gear away from the
engine. Push the gear onto the crankshaft.
3. Install the idler gear. See 1.84 Idler Gear, Installation.
4. Check the timing gear clearances as shown in
FIGURE 61. The minimum clearances for all gears is
0.08 mm (0.003 in).
5. Install the timing case cover, coolant pump, crank-
shaft pulley, fan drive pulley, drive belts, and fan. See
1.78 Timing Case Cover, Installation.
1.91 TIMING CASE
1.92 Removal
1. Remove the timing case cover. See 1.77 Timing
Case Cover, Removal.
2. Remove the alternator and its mount bracket, and
the front support plate.
3. Remove the timing gears. See 1.82 through 1.90 for
removal of the timing gears.
4. Remove the capscrews that hold the timing case to
the engine block. Remove the capscrews that hold the
oil sump to the timing gear case.
5. Remove the timing gear case, gasket, and hub for
the idler gear. Do not permit the hub to fall and
become damaged.
1.93 Installation
1. Make sure that the gasket for the oil sump is not
dam-aged. If the gasket is damaged, remove the oil
sump and install after the timing case has been
installed. A dam-aged section of the gasket can be cut
and a new section can be installed in its place, but the
work must be care-fully done to prevent oil leaks.
2. If the oil sump has been removed, install the hub for the
idler gear on the front of the engine block. Use the three
capscrews for the idler gear to hold the hub in posi-
tion. Make sure that the oil hole in the hub is towards
the top of the engine.
3. Make sure that the thrust washer for the camshaft is
in the correct position.
4. Install a new gasket for the timing case to the
engine block. Cut the bottom ends of the gasket to
correctly fit the space. Use gasket compound at the
bottom ends of the gasket.
5. Put the timing case into position on the engine
block. If the oil sump was not removed, install the
hub for the idler gear. Use the three capscrews for the
idler gear to hold the hub in position. Make sure that
the oil hole in the hub is towards the top of the engine.
Install the four capscrews that hold the hub of the
idler gear to the en-gine block. See FIGURE 64.
1. CAPSCREWS FOR HUB
2. HUB FOR IDLER GEAR
FIGURE 64. INSTALL THE HUB FOR THE
IDLER GEAR.
6. Install the alternator and its front support plate in
posi-tion and install the remainder of the capscrews
into the timing case. If the front support plate has
been separated from the alternator bracket, make sure
that the support plate is even with the machined face
of the engine block where the alternator bracket is
installed. Tighten the M8 capscrews to 22 Nm (16 lbf
ft). Tighten the M10 capscrews to 44 Nm (33 lbf ft).
NOTE: If a new timing case is being installed,
remove the two studs from the timing case and clean
the threads that fit into the timing case. Apply liquid
sealant to the threads of the studs and install them into
the new timing case.
7. Install the camshaft gear. Install the capscrew and
washer and tighten the capscrew to press the gear into
position. Tighten the capscrew to 78 Nm (58 lbf ft).
8. Lubricate the bushings in the idler gear with engine
oil. Align the timing marks on the idler gear with the
marks on the crankshaft gear and the cam shaft gear.
Re-move the three capscrews from the hub for the
idler gear and install the idler gear. Make sure that the
timing marks are aligned as shown in FIGURE 59.
9. If a new timing case was installed, put a new timing
mark for the fuel injection pump on the rear face of
the timing case. See 1.129 CAV Fuel Injection Pump,
Checks And Adjustments.
10. Install the fuel injection pump. See 1.128 Fuel
Injec-tion Pump, Installation. Install the nut and
spring washer. Tighten the nut to 80 Nm (59 lbf ft).
11. If new gears have been installed, check the timing
gear clearances as shown in FIGURE 61. The minimum
clearances for all gears is 0.08 mm (0.003 in).
12. If the oil sump was removed, install it. Make sure
that any joints in the gaskets are fitted to prevent oil
leaks.
13. Install the timing case cover, coolant pump, crank-
shaft pulley, fan drive pulley, drive belts, and fan. See
w 1.78 Timing Case Cover, Installation.
1.94 CAMSHAFT AND TAPPETS
NOTE: The removal and installation of the camshaft
and tappets require disassembly of many components
of the engine. The engine is normally removed from
the lift truck for this operation. See THE FRAME
section for procedures to remove the engine. See the
TRANSMIS-SION section for procedures to separate
the engine from the transmission.
37
1.95 Removal
1. Remove the timing case cover. See 1.77 Timing
Case Cover, Removal.
2. Remove the timing gears. See 1.82 through 1.89 for
removal of the timing gears.
3. Remove the timing case. See 1.92 Timing Case,
Re-moval.
4. Remove the valve cover, rocker arm assembly, and
push rods.
5. Remove the fuel pump.
6. Turn the engine so that the oil sump is up and
remove the oil sump.
7. Remove the thrust washer for the camshaft. See
FIGURE 65.
1. THRUST WASHER, CAMSHAFT
2. POSITION DOWEL
FIGURE 65. THRUST WASHER, CAMSHAFT
8. Carefully remove the camshaft. See FIGURE 66.
9. Remove the tappets.
10. Inspect the camshaft and the tappets for wear and
damage. See the ENGINE SPECIFICATIONS for the
measurements. Replace any bad parts.
38
FIGURE 66. CAMSHAFT,REMOVAL AND
INSTALLATION
1.96 Installation
1. Make sure all of the parts are clean. Lubricate the
parts with engine oil as they are assembled.
2. Install the tappets in their positions.
3. Carefully install the camshaft. See FIGURE 66.
4. Install the thrust washer for the camshaft. Make
sure the thrust washer fits correctly on the dowel. See
FIGURE 65.
5. Use a new gasket and install the timing case. See
1.93 Timing Case, Installation.
6. Check the clearance of the camshaft. A dial indicator
can be used to check the axial movement from the end of
the camshaft. The normal axial movement is 0.10 to 0.41
mm (0.004 to 0.016 in). The maximum axial move-ment
permitted is 0.53 mm (0.021 in).
7. Turn the camshaft until the cam for the fuel pump is
at the minimum lift position. Install the fuel pump.
8. Turn the engine to the upright position. Turn the
crankshaft until the key slot in the crankshaft is
towards the top. Install the timing gears. See 1.84
through 1.90 for installation of the timing gears.
9. Install the fuel injection pump.
10. Install the push rods and the rocker arm assembly.
See 1.15 Rocker Arm Assembly, Installation.
11. Adjust the valve clearances. See 1.19 Valve Clear-
ance Adjustments.
12. Install the oil pump.
13. Install the timing case cover. See 1.78 Timing
Case Cover, Installation.
14. Install the engine. When the engine can be operated,
ENGINE BLOCK ASSEMBLY
1.97 DESCRIPTION
The engine block is made of cast iron. The removable
cylinder liners are pressed into the engine block. A
bushing is installed in the front of the engine block for
the front journal of the camshaft. The other camshaft
journals do not have bushings and run directly in the
en-gine block.
1.98 ENGINE BLOCK
1.99 Disassembly
1. Remove the engine from the lift truck. See THE
FRAME section for procedures to remove the engine.
See the TRANSMISSION section for procedures to
separate the engine from the transmission.
2. Remove the fan, drive belts, fan drive pulley and
housing, and the coolant pump.
3. ENGINES YA and YB. If the engine has a
compres-sor, remove it.
4. Remove the crankshaft pulley. See 1.57 Crankshaft
Pulley, Removal.
5. Remove the alternator and its mount bracket.
6. Remove the timing case cover. See 1.77 Timing
Case Cover, Removal.
7. Remove the fuel injection pump. See 1.127 Fuel In-
jection Pump, Removal.
8. Remove the fuel injectors, fuel lines, fuel filter, and
fuel pump. See the Fuel System sections beginning
with 1.140 .
9. Remove the oil cooler. See 1.164 Oil Cooler, Re-
moval.
10. ENGINES AB and YB. Remove the turbocharger.
See 1.108 Turbocharger, Removal.
11. Remove the starter motor. See 1.181 Starter
Motor, Removal.
remove the air from the fuel system before operation.
12. Remove the timing gears and the timing case. See
the sections 1.75 through 1.92 Timing Case and
Timing Gears.
13. Remove the oil sump. See 1.114 Oil Sump, Re-
moval. Remove the oil filter.
14. Remove the cylinder head assembly. See 1.24
Cyl-inder Head Assembly, Removal.
15. Remove the flywheel and the flywheel housing.
See 1.172 Flywheel And Flywheel Housing.
16. Remove the rear oil seal housing. See 1.63 Oil
Seal, Replacement.
17. If the engine is not already in a position with the
crankshaft facing up, turn the engine to that position.
Remove the suction line and oil strainer. See FIGURE
75. Remove the capscrew that holds the bracket to the
main bearing cap. Remove the two capscrews from
the flange of the suction line and re-move the suction
line and screen. Clean the faces of both flanges.
Remove the oil pump, delivery pipe and relief valve.
See the sections 1.117 through 1.121 to remove the oil
pump and relief valve.
18. Remove the bridge piece over the rear main bearing.
Make a note if there is a round rubber seal at each end of
the bridge piece where it joins the crankcase. Some en-
gines have rubber seals and other engines have sealant.
19. Remove the bearing caps and lower bearing halves
from the connecting rods. Make an arrangement so that
the parts for each connecting rod will be assembled
again in their original positions. Carefully push the pis-
tons into their bores a small amount so that the connect-
ing rods are separated from the crankshaft.
CAUTION
Make sure the cooling jets for the pistons are not
damaged or moved out of alignment. If a cooling jet
39
is hit, the alignment must be checked and the
cooling jet replaced if necessary.
20. Make sure that the main bearing caps are marked
with their position number. Remove the main bearing
caps, lower bearing halves, and the upper and lower
thrust washers. Keep all the parts in an arrangement so
that the parts can be installed in their original positions.
21. Lift the crankshaft from the engine block. Remove
the upper bearing halves and put each of them with
their lower bearing half.
22. Carefully remove the pistons and connecting rod
as-semblies from the engine.
23. Remove the camshaft and tappets. See 1.95 Cam-
shaft And Tappets, Removal.
24. ENGINES AB and YB. Remove the cooling jets
for the pistons.
1.100 Inspection
1. Make sure all of the oil and coolant passages in the
en-gine block are clean.
2. Check the engine block for cracks and damage.
NOTE: The top face of the engine block can not be
ma-chined because the cylinder liners and pistons will
not fit.
3. Check the front bushing for the camshaft for wear. If a
new bushing must be installed, use a puller to remove
the old bushing. Make sure the oil hole for the new
bush-ing is away from the engine when it is installed.
Make sure the oil hole is aligned with the passage in the
engine block when it is installed. Use a press to install a
new bushing and align it in position in the engine block.
1.101 Assembly
1. Make sure all the parts are clean.
2. Remove the screw plugs from the engine block and
clean the threads. Apply a sealant to the threads of the
plugs and install them in the engine block.
3. ENGINES AB and YB. Install the cooling jets for
the pistons. See 1.55 Cooling Jets, Installation.
4. Install the crankshaft and the rear oil assembly. See
1.63 through 1.74 Crankshaft Assembly sections.
40
5. Install the flywheel housing and flywheel. See
1.174 Flywheel and 1.177 Flywheel Housing section.
6. Install the tappets and the camshaft. See 1.96 Cam-
shaft And Tappets, Installation.
7. Install the relief valve, oil pump, suction line and
oil strainer. See the sections 1.119 through 1.124 .
8. Install the timing case and the timing gears. See
The sections 1.78 through 1.93 Timing Case And
Timing Gears
9. Install the cylinder head assembly. See 1.25
Cylinder Head Assembly, Installation.
10. Install the starter motor.
11. Install the fuel pump.
12. ENGINES AB and YB. Install the turbocharger.
See 1.109 Turbocharger, Installation.
13. Install the oil filter assembly and the oil sump. See
1.115 Oil Sump, Installation.
14. Install the oil cooler. See 1.167 Oil Cooler,
Installa-tion.
15. Install the fuel injectors, fuel lines, fuel filter, and
fuel injection pump. See 1.128 through 1.148 Fuel
Sys-tem sections.
16. Install the coolant pump, fan drive pulley, and fan.
See 1.157 through 1.162 Cooling System sections.
17. Install the alternator and mount brackets.
R. Install the drive belts and adjust the tension. See
1.178 Drive Belts.
18. Install the engine into the lift truck.
19. Remove the air from the fuel system before
operat-ing the engine. See 1.136 Remove Air From
The Fuel System.
1.102 CYLINDER LINER
1.103 Inspection
Check the cylinder liners for wear and damage. Check
for wear in the liner as shown in FIGURE 67. and
FIGURE 68. The wear limit is 0.25 mm (0.010 in).
If the cylinder liner has a very smooth finish (glaze),
the engine will use oil at a rapid rate even though the
cylin-der liners are within specifications.
FIGURE 67. CHECK THE WEAR IN THE
CYLINDER LINER
FIGURE 68. WHERE TO MEASURE TO CHECK
THE WEAR IN THE CYLINDER LINER
1.104 Hone
Use a tool called a hone to correct the surface of the cyl-
inder liner. The pistons, connecting rods, and piston
cooling jets must be removed from the engine before the
hone operation. Use a grade 80SC hone that can expand
to 102 to 105 mm (4 to 4.2 in). Make sure the other parts
of the engine are covered so that particles do not enter
and damage the engine during operation.
NOTE: If the glaze in a cylinder liner has been re-
moved, the following recommendations are for the
next five hours of engine operation:
Do not operate the engine at full load.
Do not operate the engine at high speed.
Do not permit the engine to operate at idle
speed for long periods.
1.105 Removal
Special Tools: Removal and installation tool and
adaptors for cylinder liners.
Piston height tool
Dial indicator gauge
NOTE: If several cylinder liners must be removed, or
a cylinder liner is very tight, a recommendation is to
re-move the crankshaft and use a press to remove the
cylin-der liners. The removal and installation tool can
also be used to remove and install a cylinder liner if a
press is not available or the crankshaft must stay in
the engine. This procedure can be difficult.
1. Disassemble the engine as necessary. The piston,
con-necting rod, and piston cooling jet must be
removed from the engine for each cylinder liner that
must be re-moved.
2. Turn the crankshaft to give access to the cylinder
liner and protect the bearing journal.
3. Install the removal and installation tool over the
cen-ter of the cylinder liner as shown in FIGURE 69.
Make sure that the base of the tool is not on top of the
flange of the next cylinder liner.
4. Make sure that the lugs on the top of the removal
adaptor (6) engage flats on the threaded rod (1). Install
the nut and washer on the threaded rod and tighten the
nut against the removal adaptor (6). Turn the handle to
remove the cylinder liner from the engine block. Use lu-
bricating oil on the moving parts to reduce the friction.
41
 1. THREADED ROD
1. THREADED ROD
2. HANDLE
2. HANDLE
3. BEARING
3. BEARING
4. SHELL REMOVAL ADAPTOR
4. INSTALLATION ADAPTOR
5. CYLINDER LINER
5. CYLINDER LINER
6. REMOVAL ADAPTOR
6. BASE, INSTALLATION ADAPTOR
FIGURE 69. CYLINDER LINER REMOVAL FIGURE 70. CYLINDER LINER INSTALLATION

1.106 Installation
NOTE: Some replacement cylinder liners are easier to
install than others because of the manufacturing toler-
ances. A cylinder liner installation tool can be used to in-
stall a tight cylinder liner. See FIGURE 70. A press can
also be used to install a tight cylinder liner. DO NOT
use a hammer to install a cylinder liner.
2. Install the cylinder liner in the bore in the engine
block. Make sure the cylinder liner is vertical and
aligned with the bore in the engine block. Use the
cylin-der installation tool as shown in FIGURE 70. to
press the cylinder liner into the engine block to within
50 mm (2 in) of the final position.

1. Make sure the parts are clean. Lubricate the bore in 3. Apply Loctite 602 to the upper 25 mm (1 in) of the
the engine block with engine oil. DO NOT lubricate outer surface of the cylinder liner. Apply Loctite 602
the upper 50 mm (2 in) of the bore in the engine to the flange and the engine block where the flange of
block. Sealant will be applied to this area. the cylinder liner will fit into the engine block.

42
4. Press the cylinder liner into its final position in the
en-gine block. Remove the tool and clean the Loctite
from the engine block.
5. Wait 15 minutes before the dimensions in the bore
of the cylinder liner are checked. The Loctite will
reach full strength after three hours.
6. Use the piston height tool and dial indicator gauge to
check that the cylinder liner is in the correct position.
See FIGURE 71. The flange of the cylinder liner must
be between 0.10 mm (0.004 in) above to 0.10 mm (0.004
in) below the top surface of the engine block.
FIGURE 71. CHECK THE CYLINDER LINER
TURBOCHARGER, ENGINES AB AND YB
1.107 GENERAL
The turbocharger is installed between the inlet and ex-
haust manifolds. Exhaust gases turn the turbocharger
and causes it to supply air to the inlet manifold at
greater than atmospheric pressure. The bearings in the
turbo-charger are lubricated with engine oil from the
main oil passage in the engine block. The oil passes
through the bearing housing of the turbocharger and
returns to the oil sump.
1.108 Removal
1. Clean the turbocharger. Remove the duct from the air
filter where it connects to the inlet of the turbocharger.
2. Remove or disconnect the support bracket for the
tur-bocharger. Remove the heat shield for the fuel
pump if additional clearance is necessary.
7. Install new piston rings on the piston. See 1.48
Piston Rings, Installation.
8. Install the piston and connecting rod assembly. See
1.52 Piston And Connecting Rod Assembly, Installa-
tion.
9. ENGINES AB and YB. Install the cooling jets for
the pistons. See 1.55 Cooling Jets, Installation.
10. Install the cylinder head assembly. See 1.25
Cylin-der Head Assembly, Installation.
11. Install the oil sump. See 1.115 Oil Sump, Installa-
tion.
NOTE: If a new cylinder liner has been installed, the
following recommendations are for the next five
hours of engine operation:
Do not operate the engine at full load.
Do not operate the engine at high speed.
Do not permit the engine to operate at idle
speed for long periods.
3. Remove the nuts and remove the exhaust elbow
and its gasket from the turbocharger.
4. Release the hose clamps and push the hose from the
compressor outlet up the elbow of the inlet manifold.
5. Disconnect the oil supply line at the flange at the
top of the bearing housing of the turbocharger.
Remove the oil supply line and gasket.
6. Disconnect the oil drain line at the flange at the
bot-tom of the bearing housing of the turbocharger.
Remove the oil drain line and gasket. If necessary,
release the hose clamps from the oil drain line and
push the hose down.
7. Remove the nuts at the flange that holds the turbo-
charger to the exhaust manifold. Disconnect the turbo-
charger from the exhaust manifold. Remove the gasket.
43
8. Check the hoses, lines, and duct for cracks, wear, or
damage.
1.109 Installation
1. Check that the openings of the turbocharger and the
manifolds are clean. Make sure that the compressor
shaft in the turbocharger rotates freely.
2. Install a new gasket where the turbocharger
connects to the exhaust manifold. See FIGURE 72. If
the original nuts are to be used, make sure they are in
good condi-tion. Use a compound on the threads to
prevent seizure of the nuts to the studs.
3. Install the turbocharger. Tighten the nuts to 44 Nm
(33 lbf ft).
1. GASKET
FIGURE 72. INSTALL THE TURBOCHARGER
4. Lubricate the bearing housing of the turbocharger
with clean engine oil. Use a new gasket and install the
oil supply line.
5. Use a new gasket and install the oil drain line.
Tighten the capscrews, but do not connect the hose.
6. Install the exhaust elbow on the turbocharger. If
the original nuts are to be used, make sure they are in
good condition. Use a compound on the threads to
prevent seizure of the nuts to the studs. New nuts have
a coating on them to prevent seizure. Install a new
gasket on the studs.
7. Install the support bracket for the turbocharger. Install
the heat shield for the fuel pump if it was removed.
44
8. Slide the hose on the elbow for the inlet manifold onto
the outlet of the turbocharger. Install the hose clamps.
9. Make sure that there is no restriction in the duct
from the air filter to the turbocharger. Install the duct
on the turbocharger and tighten the fastener.
10. Check that the bearings in the turbocharger have
an oil flow. Disconnect the electric stop control so
that the engine can not start. Use the starter motor to
operate the engine until engine oil flows from the oil
drain line from the turbocharger. Connect the hose to
the oil drain line. Connect the electric stop control.
1.110 Clean The Impeller And
Compressor Housing
NOTE: The compressor housing can sometimes be
re-moved for cleaning without removing the
turbocharger first. The compressor housing is held by
a circlip and ac-cess to the circlip (large snap ring) is
not always possi-ble.
1. Clean the turbocharger. Remove the duct from the air
filter where it connects to the inlet of the turbocharger.
2. Release the hose clamps and push the hose from the
compressor outlet up the elbow of the inlet manifold.
1. REFERENCE MARK
FIGURE 73. REMOVE THE COMPRESSOR
HOUSING
3. Make a reference mark on the compressor housing
and the bearing housing as shown in FIGURE 73.
4. Remove the circlip that holds the compressor hous-
ing. Carefully remove the compressor housing from
the turbocharger as shown in FIGURE 73. If the
compres-sor housing is a tight fit, use a soft hammer.

CAUTION
Be careful that the blades of the impeller is not
damaged. If the impeller is damaged, the
turbocharger must be replaced or repaired by a
special repair service.
5. Put the compressor housing in a container with a
sol-vent that is not caustic. When the dirt has
loosened, use a hard brush or a soft scraper to clean
the compressor housing. Use compressed air at low
pressure to dry the compressor housing.
6. Clean the impeller with a soft brush.
LUBRICATION SYSTEM
1.111 GENERAL
The oil pump is turned by a gear on the crankshaft
through an idler gear. A relief valve on the outlet of
the oil pump controls the maximum oil pressure in the
lubri-cation system. The engine oil flows from the oil
pump through an oil cooler fastened on the side of the
engine block. The oil flows from the oil cooler
through the oil filter. The oil cooler has a by±pass
valve that controls the oil pressure in the oil cooler
and permits some cold oil to flow directly to the oil
filter. The oil filter has a by±pass that permits oil flow
directly to the main oil passage if the oil filter
becomes too dirty. The normal oil flow is through the
oil filter to the main oil passage in the engine block.
Engine oil from the main oil passage flows to the main
bearings of the crankshaft and through the passages in
the crankshaft to the rod bearings. The pistons and cylin-
der bores are lubricated by splash and oil mist.
Engine oil also flows from the main bearings to the jour-
nals of the camshaft. Some engine oil goes through the
center camshaft bearing to the rocker arm assembly.
The hub of the idler gear has an oil passage to the
main oil passage. The oil flow through the hub
lubricates the timing gears.
An outlet from the main oil passage supplies oil to the
bearings of the turbocharger. The engine flows through
the bearings of the turbocharger and returns to the oil
sump. All turbocharged engines have a cooling jet con-
7. Carefully push the impeller towards the bearing hous-
ing and turn the impeller with your hand. Check that the
impeller turns freely and there is no noise that can indi-
cate wear or damage. If there is a fault, the turbocharger
must be replaced or repaired by a special repair service.
8. Install the compressor housing on the turbocharger.
Make sure the reference marks are aligned. Install the
circlip loosely on the bearing housing. Make sure that
the face of the circlip with the bevel is towards the ex-
haust end of the turbocharger. Install the circlip in the
groove.
9. Install the ducts on the inlet and outlet of the
compres-sor housing and tighten the clamps.
nected to the main oil passage for each cylinder. The
cooling jets spray engine oil on the bottoms of the pis-
tons for additional cooling.
1.112 OIL FILTER, REPLACEMENT
1. Change the oil filter when the engine oil is changed.
Put a drain pan under the filter. Remove the filter car-
tridge. Make sure the adaptor stays in the filter head as
shown in FIGURE 74. Discard the filter cartridge.
1. ADAPTOR
FIGURE 74. OIL FILTER
2. Clean the filter head.
3. Add some clean engine oil to the new filter
cartridge. Apply clean engine oil to the gasket. Turn
the filter until the gasket touches the filter head.
Tighten the filter car-tridge 1/2 to 3/4 turn.
45
4. When new oil has been added and the engine can
be operated, start the engine. Check the area around
the fil-ter for leaks.
1.113 OIL SUMP
1.114 Removal
1. Drain the engine oil. Remove the capscrews and the
two nuts that fasten the oil sump to the engine block.
Lower the oil sump. Remove the gasket.
2. Clean the oil sump with mineral oil solvent.
3. If the suction line and oil strainer must be removed.
See FIGURE 75. Remove the capscrew that holds the
bracket to the main bearing cap. Remove the two
capscrews from the flange of the suction line and re-
move the suction line and screen. Clean the faces of
both flanges.
1. SUPPORT BRACKET, MAIN BEARING CAP
2. CAPSCREWS, FLANGE, SUCTION PIPE
FIGURE 75. REMOVE THE OIL SUMP
SCREEN
1.115 Installation
1. If the oil strainer and suction line was removed,
loosely assemble the bracket of the suction line to the
main bearing cap. Install a new gasket and fasten the
flanges of the suction line to the oil pump. Make sure
that the suction line is aligned correctly and tighten the
capscrew that holds the bracket to the main bearing cap.
2. Use a new gasket and install the oil sump. Use
capscrews on each side of the oil sump to align and hold
the gasket in position during assembly. Install the re-
46
mainder of the capscrews and the two nuts. Tighten
all of the fasteners to 22 Nm (16 lbf ft).
3. Install the drain plug in the oil sump. Use a new O±
ring.
1.116 OIL PUMP
1.117 Removal
1. Drain the engine oil and remove the oil sump. Re-
move the oil strainer and suction line. See 1.114 Oil
Sump, Removal.
2. Remove the relief valve and connection line.
3. The oil pump is fastened to the number 1 main bearing
cap. Access to the capscrews on the main bearing can be
difficult when the timing case is on the engine. A special
wrench can be required to apply the correct torque to the
capscrews for removal and installation. If a wrench is not
available to install the capscrews on the main bear-ing cap,
the timing case must be removed. See 1.77 through 1.92
for removal of the timing case.
4. Remove the snap ring that holds the idler gear to
the oil pump. Remove the washer and the idler gear.
See FIGURE 76.
1. WASHER 3. BUSHING
2. IDLER GEAR
FIGURE 76. REMOVE THE IDLER GEAR, OIL
PUMP
5. Remove the capscrews and remove the oil pump.
See FIGURE 77.
 FIGURE 77. REMOVE THE OIL PUMP
1.118 Inspection
If the oil pump is worn so that the performance is de-
creased, the oil pump must be replaced.
1. Remove the capscrews and remove the cover of the
oil pump.
2. Remove the outer rotor and clean all of the parts.
Check for damage and wear.
3. Install the outer rotor and check the clearances. See
FIGURE 78. See the ENGINE SPECIFICATIONS
for the wear tolerances.
FIGURE 78. CHECK THE CLEARANCE OF THE
OUTER ROTOR
4. Check the clearances of the inner rotor. See
FIGURE 79. See the ENGINE SPECIFICATIONS
for the wear tolerances.
FIGURE 79. CHECK THE CLEARANCES OF
THE INNER ROTOR
5. Check end clearance and axial movement of the
rotor. Use a spacer gauge and a straight edge. See
FIGURE 80. See the ENGINE SPECIFICATIONS
for the wear toler-ances.
FIGURE 80. CHECK THE END CLEARANCES
OF THE ROTOR
6. When the parts are clean and inspected, install the
cover to the oil pump. Tighten the capscrews to 28
Nm (21 lbf ft).
1.119 Installation
1. Lubricate the internal parts of the oil pump with en-
gine oil before installation. Install the oil pump on the
main bearing cap and tighten the capscrews to 22 Nm
(16 lbf ft).
2. Make sure the idler gear and bushing are in good con-
dition. The bushing is available as a separate part. Install
the idler gear, washer, and snap ring. Check the gear
clearance. See FIGURE 81. The minimum clearance is
47
0.0076 mm (0.003 in) between the oil pump gear and
the idler gear.

3. If the main bearing cap was removed, lubricate the

bearing with engine oil and install the bearing cap.
Tighten the capscrews to 265 Nm (196 lbf ft). Check
the gear clearance. See FIGURE 81. The minimum
clear-ance is 0.0076 mm (0.003 in) between the
crankshaft gear and the idler gear.

1. THIMBLE, RELIEF VALVE

2. CONNECTION PIPE WITH O±RINGS
FIGURE 82. REMOVE THE RELIEF VALVE,
ENGINES AA AND AB

ENGINES YA and YB. See FIGURE 83. Remove the

capscrews (1) that fasten the cross flow pipe to the
relief valve. Remove the flange. Remove the two
capscrews that fasten the relief valve to the cylinder
block and re-move the relief valve.

FIGURE 81. CHECK THE CLEARANCES

BETWEEN THE OIL PUMP GEAR AND IDLER
GEAR

4. If the timing case was removed, install the timing

case. See 1.78 through 1.93 Timing Gears And
Timing Case sections.

5. Install the relief valve and the connection line. See

1.124 Relief Valve, Installation.

6. Install the oil sump. See 1.115 Oil Sump, Installation. 1. CAPSCREW (2)
2. CAPSCREW (2)
1.120 RELIEF VALVE FIGURE 83. REMOVE THE RELIEF VALVE,
ENGINES YA AND YB
1.121 Removal 1.122 Disassembly

1. Drain the engine oil. Remove the oil sump. See NOTE: The relief valve can be disassembled without
1.114 Oil Sump, Removal. removing it from the engine.

2. ENGINES AA and AB. Remove the capscrew and CAUTION

carefully pull the relief valve from the engine block. See The relief valve has a compressed spring. Do not
FIGURE 82. Pull the relief valve from the connection permit the spring to be released so that it causes an
line. Pull the connection line from the oil pump. injury.

48
1. See FIGURE 84. Apply pressure against the end plate
(4) of the spring assembly. Remove the snap ring (5).
Carefully release the end plate (4) and release the pres-
sure on the compressed spring. Remove the end plate
(4), spring (3), and the plunger (2).
1.123 Inspection
1. Clean the parts. Check the parts for wear and damage.
Check the spring compression as necessary. The correct
spring compression is 34 to 39 N (7.6 to 7.8 lbf) when
the spring is compressed to 42.7 mm (1.7 in).

2. Check that the seat of the plunger is not damaged

and that the plunger moves easily in its bore.
3. Lubricate the parts with engine oil during
assembly. Install the plunger in the bore as shown in
FIGURE 84. Install the spring and end cap. Compress
the spring and end cap into the bore so that the snap
ring can be in-stalled. Install the snap ring.
1. BODY, RELIEF VALVE 4. END PLATE
2. PLUNGER 5. SNAP RING
3. SPRING
FIGURE 84. RELIEF VALVE ASSEMBLY
1.124 Installation
1. Install new O±rings on the connection line.
Lubricate the O±rings with engine oil and push the
connection line into position in the oil pump.
2. Push the relief valve onto the connection line and
in-stall the relief valve into position on the engine
block. Install and tighten the capscrew.
3. Install the oil sump. See 1.115 Oil Sump, Installation.

FUEL SYSTEM
1.125 DESCRIPTION

NOTE: Special tools and training are needed to repair

the CAV injection pumps and they are normally sent
to an authorized CAV repair station if repairs are
neces-sary. Fuel injectors also require special
equipment and training for repair. Most users have a
special repair serv-ice do this work.
A CAV DPA fuel injection pump is used on the normally
aspirated engines AA and YA. See FIGURE 85.

FIGURE 85. FUEL INJECTION PUMP,

ENGINES AA AND YA
A CAV DPS fuel injection pump is used on tur-
bocharged engines AB and YB. A boost control is added
to the engine because of the turbocharger. See
FIGURE 86. The boost control is a device that is af-
fected by the pressure from the turbocharger and re-
duces the the maximum fuel flow at lower engine

49
speeds. When the engine speed is lower, there is a re-
duced air supply the the cylinders. A mechanical
gover-nor controls the maximum engine speed.
The fuel injectors receive fuel under high pressure from
the fuel injection pump. The fuel injectors are set by the
manufacturer, but must be checked according to the
maintenance schedules. See PERIODIC MAINTE-
NANCE. The operation pressure of a fuel injector can
be changed by adding or removing shims above the
spring in the fuel injector.
1. BOOST CONTROL
FIGURE 86. FUEL INJECTION PUMP WITH
BOOST CONTROL, ENGINES AB AND YB
The fuel pump has a diaphragm that is actuated by a
lever. The lever is actuated by a lobe on the camshaft.
The fuel pump has a small lever that can be operated
with your hand to ªprimeº the fuel pump.
NOTE: Good operation of the fuel injection system
re-quires clean fuel and no dirt can be permitted in the
sys-tem. Always clean carefully around a connection
before it is disconnected. Install covers on open ports
during maintenance. When the fuel system is opened
for main-tenance, the air must be removed from the
fuel system before the engine is operated.
1.126 CAV FUEL INJECTION PUMP
1.127 Removal
Special Tools: Gear Puller
Adaptors for gear puller
Wrench (spanner) for flange nuts
50
1. Disconnect all of the fuel lines from the fuel
injection pump. Disconnect the engine stop control.
Disconnect the control rod to the fuel injection pump.
2. Remove the gear cover from the cover of the timing
case. Remove the nut and lock washer for the gear.
3. Turn the crankshaft so that the woodruff key in the
gear for the fuel injection pump is towards the top of
the engine. See 1.86 Gear For The Fuel Injection
Pump, Re-moval.
4. Remove the capscrew and the nut for the support
bracket that is under the fuel injection pump.
5. Remove the flange nuts that hold the fuel injection
pump to the timing case. A special wrench can be re-
quired if there is a limit to the access to the nuts.
6. Use a puller to remove the gear for the fuel
injection pump. Make sure that the woodruff key does
not fall into the timing case.
7. Remove the fuel injection pump from the engine.
1.128 Installation
1. Align the timing marks on the timing gears as
shown in FIGURE 88. See 1.87 Gear For The Fuel
Injection Pump, Installation.
2. Turn the drive shaft of the fuel injection pump so that the
key slot aligns with the key slot in the gear. Install the
woodruff key and install the gear onto the drive shaft.
3. Align the mark on the flange of the fuel injection
pump with the mark on the timing case. See FIGURE
87. Install the flange nuts for the fuel injection pump.

1. ALIGNMENT MARKS
2. ADJUSTMENT SCREW, IDLE
3. ADJUSTMENT SCREW, GOVERNOR SPEED
FIGURE 87. FUEL INJECTION PUMP
4. Install the support bracket, capscrew, and nut.
Make sure that a force to the side is not applied to the
fuel in-jection pump by the support bracket.
5. Install the nut and spring washer to the drive shaft of
the fuel injection pump. Tighten the nut to 80 Nm (59
lbf ft). Install the gear cover on the timing case cover.
6. Connect the fuel lines. Connect the engine stop con-
trol and the control rod for the fuel injection pump.
7. Remove the air from the fuel system. See 1.136 Re-
move Air From The Fuel System.
7. When the engine can be operated, do 1.129 Checks
And Adjustments.
1.129 CAV FUEL INJECTION PUMP,
CHECKS AND ADJUSTMENTS
1. Operate the engine until it reaches normal operating
temperature and check the idle speed. The idle speed
can be adjusted with the idle adjustment screw (2)
shown in FIGURE 87. The correct idle speed is in
sections 1.5 through 1.8 .
NOTE: The idle speed and the the governed speed
can be different than the Engine Data when these
engines are installed some models of lift trucks. See
the section, PE-RIODIC MAINTENANCE for the
specifications that apply to a lift truck model.
2. Check the governed speed. The maximum engine
speed can be adjusted with (3) shown in FIGURE 87.
See the Engine Data at the beginning of this section for
the correct governed speed. The setting code for the fuel
injection pump is also found on a data plate fastened to
the side of the pump. A typical setting code can be
2643M000AK/1/2750 where 2750 is the correct gov-
erned speed. The governed speed on an original fuel in-
jection pump is set and sealed by the manufacturer. A re-
placement fuel injection pump must have the governed
speed correctly set and the adjustment screw sealed. A
setting that has been changed from the correct setting
can affect the engine warranty.
1.130 Timing Gear Marks
The timing gears have timing marks to make sure that
they are installed on the engine correctly. When the
number 1 piston is at TDC the marks on gears for the
crankshaft, camshaft, fuel injection pump will be
aligned as shown in FIGURE 88. The marks on the
idler gear can be different than the illustration because
of the different speeds at which the gears rotate.
The gear for the fuel injection pump has timing marks
for the 4±cylinder and 6±cylinder engines.
The gear also has the letter C when a CAV fuel
injection pump is installed. A letter M is on the gear
to indicate that the threads for the screws of the gear
puller are met-ric.
TIMING MARKS ON GEARS:
4 = 4 Cylinder Engine
6 = 6 Cylinder Engine
FIGURE 88. ALIGNMENT OF THE TIMING
MARKS
51
1.131 How To Set Number 1 Piston To TDC
On The Compression Stroke
Special Tools: Valve spring compressor
Stud adaptor for valve spring com-
pressor
Capscrew adaptor for valve spring
compressor
1. Fasten a temporary pointer to the timing case cover
so that its tip is near the outer edge of the crankshaft
pulley as shown in FIGURE 89.
2. Remove the valve cover.
3. Turn the crankshaft in a clockwise direction until the
push rod for the rear cylinder just begins to push on the
rocker arm for the inlet valve for the rear cylinder.
4. Remove the spring clip and the spacer from the
front of the rocker arm shaft. Loosen the nuts from the
first two brackets of the rocker arm shaft. Remove the
rocker arm for the first inlet valve from the rocker
arm shaft. Tighten the nuts on the first two brackets of
the rocker arm shaft.
5. Use the valve spring compressor and adaptor to re-
move the valve springs from the first inlet valve.
1. POINTER, TEMPORARY
2. DIAL INDICATOR
FIGURE 89. PROCEDURE TO FIND TDC
6. Make sure that the valve will be held in its valve guide
by the top of the piston. If the piston is not at approxi-
mately TDC to hold the valve, hold the valve so that it does
not drop into the cylinder. Rotate the crankshaft so that the
piston will hold the valve in position.
52
7. Install a dial indicator so that its plunger touches the
top of the valve stem as shown in FIGURE 89. Slowly
turn the crankshaft in a clockwise direction until the dial
indicator just shows that the piston is not raising in its
cylinder. Make a mark on the crankshaft pulley that
aligns with the temporary pointer. Slowly turn the
crankshaft in a clockwise direction until the dial indica-
tor just begins to show that the piston is lowering in its
cylinder. Make another mark on the crankshaft pulley
that aligns with the temporary pointer. Mark the center
point between the two marks on the crankshaft pulley
and remove the other two marks.
8. Turn the crankshaft approximately 45 counter±
clockwise and then clockwise until the mark on the
crankshaft pulley is aligned with the temporary
pointer. Number 1 piston is now at TDC.
1.132 Check The Valve Timing
1. Use the procedure 1.131 , How To Set Number 1
Pis-ton To TDC On The Compression Stroke.
2. Remove the dial indicator and install the valve
springs and rocker arm. Tighten the nuts on the
brackets for the rocker arm shaft to the correct torque.
3. Turn the crankshaft clockwise until the inlet valve
for the rear cylinder is fully open.
4. Adjust the valve clearance on the inlet valve of
num-ber 1 cylinder to 1.5 mm (0.059 in).
5. Turn the crankshaft clockwise until the clearance
be-tween the push rod and the rocker arm begins to be
re-moved. Check if the the marks on the crankshaft
±1
pulley is within 2 /2 of the temporary pointer.
6. If the mark on the crankshaft pulley is more than
±1
2 /2 away from the temporary pointer, either the tim-
ing gears are not aligned correctly or the procedure to
find TDC of number 1 piston was not correct.
NOTE: One tooth on the camshaft gear is equal to 23.0
mm (0.90 in) of the circumference of the crankshaft pul-
ley.
7. Turn the crankshaft clockwise until the inlet valve
of the rear cylinder is fully open. Adjust the valve
clear-ance on the inlet valve of number 1 cylinder to
0.20 mm (0.008 in).
8. Install the valve cover. See 1.12 Valve Cover,
Instal-lation.
9. Remove the temporary pointer.
1.133 Check The Timing Of The Fuel
Injection Pump
If the mark on the flange of the fuel injection pump is
aligned with the mark on the timing case the timing of
the fuel injection pump is normally correct. See
FIGURE 90. If the alignment marks are correctly
aligned and the operation of the engine indicates that
the timing is wrong, use the following procedures,
1.134 Check The Timing Mark Of The Fuel Injection
Pump and 1.135 Check The Engine Timing Mark, to
check their positions.
FIGURE 90. ALIGNMENT MARKS
1.134 Check The Timing Mark Of The Fuel
Injection Pump
Special Tools: Universal timing tool
Gear adaptor for the universal timing
tool
1. Remove the fuel injection pump. See 1.127 CAV
Fuel Injection Pump, Removal.
2. Install the gear adaptor on the shaft of the fuel
injec-tion pump. Fasten it with the nut from the gear
for the fuel injection pump. See FIGURE 91.
3. Remove the special bolt (banjo bolt) from the high
pressure outlet to cylinder number 1. (This outlet is
marked W for 4±cylinder engines and Y for
6±cylinder engines.) Install a ªbanjo boltº that does
not have a pres-sure valve.
4. Connect the number 1 outlet to a tester for a fuel
injec-tor. See FIGURE 99. Operate the hand pump
until there is a pressure of 30 atm (3000 kPa) (440
psi) indicated on the gauge.
FIGURE 91. INSTALL THE ADAPTOR GEAR
ON THE FUEL INJECTION PUMP
5. Loosen the screw (1) on the universal timing tool
and set the tool to the correct angle shown in the
ENGINE SPECIFICATIONS. Tighten the screw (1).
See FIGURE 92.
6. Install the universal timing tool on the drive shaft
of the fuel injection pump as shown in FIGURE 92.
Turn the drive shaft of the fuel injection pump with
your hand in the normal direction of rotation until the
fuel pressure prevents movement. (See the arrow on
the data plate for the direction of rotation.) When the
rotation of the fuel pump is stopped, the fuel pump is
set at the start of injec-tion from number 1 outlet.
7. Loosen the screw (2) and slide the pointer (3) until
it is over the center of the pump flange as shown in
FIGURE 92. Check that the mark on the pump flange
is in the center of the slot in the pointer.
53

1. SCREW FOR POINTER ADJUSTMENT
2. SCREW FOR HORIZONTAL ADJUSTMENT
3. POINTER
FIGURE 92. UNIVERSAL TIMING TOOL
8. If the timing mark on the flange is not correct, remove
the universal timing tool and remove the mark. Install
the universal timing tool again and make sure that the
fuel injection pump is at the start of injection for number
1 cylinder. Slide the pointer (3) so that it covers the
width of the flange and tighten the screw (2). Make a
new mark on the flange through the slot in the pointer.
9. Remove the universal timing tool and adaptor gear.
10. Disconnect the tester for a fuel injector and install
the original special bolt (banjo bolt) in the number 1
port (high pressure outlet).
11. Install the fuel injection pump. See 1.128 Fuel
Injec-tion Pump, Installation.
12. Remove the air from the fuel system See 1.136
Re-move Air From The Fuel System
1.135 Check The Engine Timing Mark
Special Tools: Universal timing tool
Adaptor for the timing gear for the
fuel injection pump.
54
Pointer
Adaptor shaft with splines
1. Use the procedure described in the paragraphs with
FIGURE 89. See 1.131 How To Set Number 1 Piston
To TDC On The Compression Stroke.
2. Remove the fuel injection pump. See 1.127 CAV
Fuel Injection Pump, Removal.
3. Align the key in the adaptor with the key slot in the
gear for the fuel injection pump. See FIGURE 93.
Make sure that the adaptor is against the face of the
timing case. Fasten the adaptor to the gear with the
nut that is with the adaptor.
FIGURE 93. INSTALL THE ADAPTOR IN THE
GEAR FOR THE FUEL INJECTION PUMP
4. See FIGURE 94. Loosen the screw (1) on the univer-
sal timing tool. Set the universal timing tool to the cor-
rect engine check angle shown in the ENGINE SPEC-
IFICATIONS and tighten the screw. Loosen the screw
(2) and install the shaft with splines (5) into the universal
timing tool. Loosen the screw (4) and install the 90
pointer (3) against the timing case. Tighten the screw
(4).

1. SCREW FOR POINTER ADJUSTMENT
2. SCREW FOR HORIZONTAL
ADJUSTMENT OF SHAFT WITH SPLINES
3. POINTER
4. SCREW FOR HORIZONTAL
POINTER ADJUSTMENT
5. SHAFT WITH SPLINES
FIGURE 94. INSTALLATION OF THE
UNIVERSAL TIMING TOOL
5. Check that the mark on the timing case aligns with the
pointer (3). If the timing mark is not correct, remove the
universal timing tool. Remove the mark on the timing
case. Install the universal timing tool again. Make sure
that the pointer (3) is against the timing case and make a
new timing mark on the timing case.
6. Remove the timing tool and the adaptor.
7. Install the fuel injection pump. See 1.128 CAV
Injec-tion Pump, Installation.
8. Return the engine to operating condition as
described in the following steps:
a. Turn the crankshaft clockwise until the inlet
valve of the rear cylinder is fully open. Adjust
the valve clearance on the inlet valve of
number 1 cylinder to 0.20 mm (0.008 in).
b. Install the valve cover. See 1.12 Valve Cover,
Installation.
c. Remove the temporary pointer.
9. Remove the air from the fuel system See 1.136 Re-
move Air From The Fuel System
1.136 REMOVE AIR FROM THE FUEL
SYSTEM
The engine can not be started if there is air in the fuel
system. The air must be removed from the fuel system if
any part of the fuel system has been disconnected or
there is a leak in the low pressure part of the fuel system
during operation of the engine. The following proce-
dures are for removal of air from the fuel system.
1.137 Fuel Injection Pump With Vent Tube
Some engines have a fuel injection pump with a tube in-
stalled in place of the vent screw. See FIGURE 95. Air
can move through the tube from the pump to the fuel re-
turn line. It is not necessary to loosen plugs or connec-
tions to remove air from this type of injection pump. Use
the procedure in Step 1 or Step 2 to remove air from a
fuel system with an injection pump that has a vent tube.
1
1. VENT TUBE 12592
FIGURE 95. FUEL INJECTION PUMP WITH
VENT TUBE
1. If the fuel system or a component in the fuel system
has been drained:
a. Turn the key switch to the ON position.
b. Slowly operate the priming lever of the fuel
pump for approximately two minutes.
c. Operate the engine with the starter motor until
the engine starts.
55
2. If air in the fuel system causes the engine to stop:
a. Make sure that there is enough fuel in the tank.
Check the system for leaks and make the
necessary repairs.

b. Operate the engine with the starter motor until

the engine starts.

1.138 Fuel Injection Pump With Vent Screw

Use the following procedure to remove air from the
fuel system if the fuel injection pump has a vent
screw as shown in FIGURE 96.
STEP 2. Operate the priming lever on the fuel
pump until fuel, without air bubbles,
comes from the loosened connection
bolt. If the lobe on the camshaft has
moved the internal lever of the fuel pump
to the highest point of its lift, the priming
lever will not operate. The crankshaft
must be rotated one revolution to move
the lobe on the camshaft.
FIGURE 96. REMOVE AIR FROM THE
FUEL SYSTEM (2 of 5)

STEP 1. Loosen the connection bolt (1) on top of

the filter.
FIGURE 96. REMOVE AIR FROM THE FUEL
SYSTEM (1 of 5)

STEP 3. Turn the key switch to the ªRº position.

Loosen the vent screw (1) on the top of
the governor housing. Operate the
priming lever on the fuel pump until fuel,
without air bubbles, comes from the
loosened vent screw.
FIGURE 96. REMOVE AIR FROM THE FUEL
SYSTEM (3 of 5)

56

STEP 4. Loosen the connection (1) on the inlet to
the cold start aid. Operate the priming
lever on the fuel pump until fuel, without
air bubbles, comes from the loosened
connection. Then tighten the connection.
FIGURE 96. REMOVE AIR FROM THE FUEL
SYSTEM (4 of 5)
STEP 5. Loosen the connections (1) at two of
the inlets to the fuel injectors. Operate
the engine with the starter motor until
fuel, without air bubbles, comes from
the loosened connections. Then
tighten the connections.
FIGURE 96. REMOVE AIR FROM THE FUEL
SYSTEM (5 of 5)
The engine is now ready to start. if the engine runs
cor-rectly for a short time and then stops, or runs
roughly, check for air in the fuel system. Make sure
you check for leaks in the low pressure (suction) part
of the fuel sys-tem.
1.139 FUEL FILTER (REPLACEMENT)
1. Clean the outside of the fuel filter assembly. If there
is a drain on the filter bowl, drain the fuel from the
fuel filter. See FIGURE 97.
2. Hold the bowl and connector and loosen the
through bolt from the top of the filter head.
3. Lower the bowl and filter element and discard the
fil-ter element.
4. Clean inside of the bowl and the filter head.
5. Install new seal rings. Put the bowl on the new
filter element and hold the bowl and filter element in
position against the filter head. Install and tighten the
through bolt.
6. Remove the air from the fuel system. See 1.136 Re-
move Air From The Fuel System.
FIGURE 97. FUEL FILTER ASSEMBLY
1.140 FUEL INJECTORS
The engine will run roughly if a fuel injector has a de-
fect. To find which fuel injector has a defect, operate
the engine at approximately 1000 rpm. Loosen and
tighten the connection to the inlet of each fuel injector
in a se-quence. When the connection to the defective
fuel injec-tor is loosened, there will not be a change in
the engine speed.
WARNING
Do not put your hands on fuel lines under
pressure. Diesel fuel can be injected into your body
by the hydraulic pressure.
1.141 Removal
1. Disconnect the fuel return line from the fuel injector.
57
2. Disconnect the high pressure line at the inlet to the
fuel injector. Disconnect the other end of the high
pres-sure line from the fuel injection pump. Hold the
outlet fitting from the fuel injection pump with a
wrench so that it does not turn while the connection is
loosened for the fuel line. Do not bend the fuel line.
Remove the line clamps as necessary.
3. See FIGURE 98. Remove the capscrews from the
flange (1) and remove the flange. Remove the fuel
injec-tor (2) and its washer (3). Remove the dust seal
(4) and the spacer (5).
5. Check the spray pattern of the nozzle. See
FIGURE 99. If the spray pattern is not correct, the
nee-dle valve is not against the valve seat. Remove
carbon deposits or replace parts as required.
WARNING
Make sure that the nozzle of the injector is away
from the operator during a test. Test oil can be
injected into your body by the hydraulic pressure.

1. FLANGE
2. FUEL INJECTOR 4. DUST SEAL
3. WASHER 5. SPACER
FIGURE 98. FUEL INJECTOR

1.142 Inspection
NOTE: The inspection and repair of fuel injectors re-
quire special tools and training. Many users have a
spe-cial repair service make repairs on injectors. Fuel
injec-tor nozzles that have a defect will cause black
smoke in the exhaust, a decrease in engine power, and
an increase in engine noise.
1. Start the engine and run it at approximately 1200 rpm.
2. Loosen the fitting for the high pressure fuel line at
the injector. If the engine speed does not change, the
injec-tor has a defect.
3. Use an injector tester to check the pressure at which
the nozzle operates. The correct pressure is 23.3 MPa
(3381 psi) (230 atmospheres).
4. To change the pressure at which the nozzle
operates, add or remove shims in the fuel injector.
FIGURE 99. CHECK THE FUEL INJECTORS
6. The operation of the fuel injector must be checked
with an injection tester. The injection tester uses a
spe-cial oil for calibration tests.
Special oils for calibration tests:
SHELL (UK) Calibration fluid C
SHELL (worldwide) Calibration fluid B
ESSO Calibration fluid IL 1838
CASTROL Calibration oil 8327
7. When the injector operates at the correct pressure, re-
move any oil from the tip of the nozzle. Apply a pressure of
22.0 MPa (3190 psi) (217 atmospheres) and hold the
pressure for more than 10 seconds. Test oil must not leak

58
from the injector tip at this pressure. Do not try to internal lever of the fuel pump to the highest point of
stop leakage from the tip by tightening the nozzle cap its lift, the fuel pump can be difficult to remove. The
nut. If the nozzle tip leaks test oil, the valve and crank-shaft must be rotated one revolution to move
nozzle must be replaced. the lobe on the camshaft.

8. Increase the pressure slowly to 22.9 MPa (3322 psi)

(226 atmospheres) for a leak back test. Release the lever
on the tester and make a note of the time required for the
pressure to decrease to 15.2 MPa (2205 psi) (150 atmos-
pheres). If the time to decrease is less than six seconds,
the fuel injector has a problem and can not be used.
(Make sure the test equipment operates correctly.)

9. Continue to check the decrease in pressure for the

leak back test. The pressure must not decrease to less
than 10 MPa (1450 psi) (99 atmospheres) in less than
45 sec-onds.

1.143 Installation
1. Use a new dust seal and spacer with the
replacement fuel injector. Put the fuel injector and
washer into posi-tion in the cylinder head. Install the
flange and the capscrews. Make sure that the fuel
injector fits correctly and is not tilted. Tighten the
capscrews to 12 Nm (9 lbf ft).
2. Install the high pressure line and tighten the connec-
tions to 18 Nm (13 lbf ft). Hold the outlet fitting from
the fuel injection pump with a wrench so that it does not
turn while the connection is tightened for the fuel line.
Install the line clamps if they were removed.
3. Install new seal washers and connect the fuel return
line to the fuel injector.
4. Remove the air from the fuel system. See 1.136 Re-
move Air From The Fuel System.
5. When the engine can be operated, check for fuel
leaks.
1.144 FUEL PUMP
1.145 Removal
1. Remove the heat shield for the fuel pump.
Disconnect the fuel lines to the fuel pump.
2. Remove the capscrews and the lock plates. Remove
the fuel pump. If the lobe on the camshaft has moved the
FIGURE 100. FUEL PUMP, REMOVAL AND
INSTALLATION
1.146 Disassembly
1. Clean the outside surfaces of the fuel pump. Make
a mark across the flanges of the two halves of the fuel
pump to make sure that it is assembled again in the
same positions.
2. See FIGURE 101. Remove the cover (1) and the
screen (2). Remove the screws and separate the two
halves of the fuel pump.
3. Turn the diaphragm assembly (5) 90 to release the
pull rod from the link arm (8) and remove the
diaphragm assembly.
4. Remove the stem seal (6), the spring seat washer (7),
and the spring (12) from the pull rod. The diaphragm
and pull rod assembly must be replaced as a unit.
5. The valves (4) are held in their seats by punch
marks in the metal. The metal must be made smooth
so that valves can be removed.
6. Remove the link arm (8). Hold the rocker lever (11)
in a vise and hit the body of the fuel pump with a soft
ham-mer to release the two retainers (10). Be careful
that the joint face of the fuel pump body is not
damaged. Re-move the rocker lever (11), pin (9), link
arm (8), and the return spring.

59
 2. Install the rocker lever (11), pin (9), and the link
arm assembly (8) into position in the body of the fuel
pump. Install the return spring. Make sure that the
ends of the return spring are in their correct positions.
3. Use a small hammer and a drift or a punch to install the
retainers (10) in their grooves in the body of the fuel pump
until they fasten the pin (9). Use a punch to close the ends
of the grooves to fasten the retainers in position.

4. Install the diaphragm spring (12) into its position

un-der the diaphragm (5). Put the spring seat washer
(7) and the new stem seal (6) into position on the pull
rod. Make sure that the small diameter at the top of
the stem seal is on the round part of the pull rod.
5. Put the diaphragm assembly into position over the
lower half of the body of the fuel pump. Align the blade
of the pull rod with the slot in the link arm. Press down
lightly on the diaphragm until the notch in the pull rod is
in the slot in the link arm. Then turn the diaphragm 90
in either direction. This action will engage and retain the
pull rod in the slot of the link arm.
6. Push the rocker arm towards the body of the fuel
pump until the diaphragm is level the the flange half. In-
1. COVER stall the top half of the body in position. Align the refer-
2. SCREEN ence marks. Keep the pressure on the rocker arm and in-
3. SEAT WASHER (2) stall the lock washers and screws. Tighten the screws
4. VALVE (2)
evenly around the circumference of the fuel pump.
5. DIAPHRAGM ASSEMBLY
6. STEM SEAL 7. Install the screen (2) and the cover (1). Make sure
7. SPRING SEAT WASHER
8. LINK ARM that the rubber seal is fitted correctly and tighten the
9. PIN screw that hold the cover.
10. RETAINER (2)
11. ROCKER LEVER 1.148 Installation
12. DIAPHRAGM SPRING
1. See FIGURE 100. The lobe on the camshaft must be
FIGURE 101. FUEL PUMP, DISASSEMBLY in the minimum lift position before the fuel pump is in-
stalled. Use a new gasket and install the fuel pump on
the engine block. Install the lock plates and capscrews.
Tighten the capscrews to 22 Nm (16 lbf ft).

2. Connect the fuel lines to the fuel pump. Install the

1.147 Assembly
1. Install new seat washers (2). Push new valves (4) into
position. The valves are the same, but they are installed
in the opposite directions from each other. See FIGURE
101. to make sure that the valves are installed in the
correct position. When the valves are correctly in-
stalled, use a punch on the edge of the valve housings to
hold the valves in position. Use the punch in six places
around each valve to hold the valve in position.
heat shield.
3. Loosen the connection bolt on top of the filter as
shown in FIGURE 96.
4. Operate the priming lever on the fuel pump until
fuel, without air bubbles, comes from the loosened
connec-tion bolt. See (2 of 5) of FIGURE 96.
5. When the engine can be operated again, check for
leaks.

60
1.149 Test
1. Disconnect the fuel line from the outlet of the fuel
pump. Install a 0 to 70 kPa (0 to 10 psi) pressure gauge to
the outlet of the fuel pump. Loosen the connection at the
gauge and operate the priming lever on the fuel pump to
remove air from the fuel pump and the connection to the
pressure gauge. Then tighten the connection.
2. Use the starter motor to operate the engine for 10 sec-
onds. See the maximum pressure indicated on the pres-
sure gauge. If the pressure is less than 42 to 70 kPa (6 to
10 psi), repair or replace the fuel pump. Also check the
rate at which the pressure reduces to half of the maxi-
COOLING SYSTEM
1.150 GENERAL
Coolant from the bottom of the radiator flows through
the centrifugal coolant pump which is installed on the
front of the timing case. The coolant pump is gear driven
from the gear for the fuel injection pump. The coolant
goes from the coolant pump through a passage in the
timing case to the front of the engine block.
ENGINES AA and AB. The coolant flows through a
passage in the left side of the engine block to the rear
of the engine block. Some coolant flows around the
oil cooler and then to the rear of the engine block. The
cool-ant then flows around the cylinders and then into
the cyl-inder head. The coolant leaves the cylinder
head and flows through the thermostat housing. If the
thermostat is closed, the coolant flows through a
by±pass to the in-let of the coolant pump. If the
thermostat is open, the thermostat closes the by±pass
and the coolant flows to the top of the radiator.
The coolant flows through a passage in the left side of
the engine block to the rear of the engine block. If an oil
cooler is installed, some coolant flows through the oil
cooler. The coolant flows around the cylinders and then
into the cylinder head. The coolant leaves the cylinder
head and flows through the thermostat housing. If the
thermostat is closed, the coolant flows through a by±
pass to the inlet of the coolant pump. If the thermostat is
open, the thermostat closes the by±pass and the coolant
flows to the top of the radiator.
ENGINES YA and YB. The coolant divides as it flows
through a passage in the engine block. Most of the cool-
mum pressure. If the rate is less than 30 seconds to re-
duce to half of the maximum pressure, repair or
replace the fuel pump.
3. Remove the pressure gauge from the fuel pump. Con-
nect the fuel line to the outlet of the fuel pump again.
4. Loosen the connection bolt on top of the filter as
shown in FIGURE 96. Operate the priming lever on
the fuel pump until fuel, without air bubbles, comes
from the loosened connection bolt.
5. When the engine can be operated again, check for
leaks.
ant flows along the right side of the engine block and
around the cylinders to the rear of the engine block.
Some coolant flows through a passage on the left side
of the engine block to the oil cooler. The coolant
flows around the element of the oil cooler and then to
the rear of the engine block.
The coolant flows forward through the cylinder head
and into the thermostat housing. These engines have
two thermostats. If the thermostats are closed, the
coolant flows through a by±pass to the inlet of the
coolant pump. If the thermostats are open, the coolant
flows to the top of the radiator.
1.151 THERMOSTAT
1.152 Replacement
1. Drain the cooling system so that the coolant level is
below the thermostat position and disconnect the top
hose from the outlet connection.
2. Remove the capscrews and remove the outlet
connec-tion.
3. Remove the thermostat.
NOTE: Engines YA and YB have two parallel
thermo-stats. See FIGURE 102.
4. Make sure that the surfaces for the joint in the outlet
are clean. Install a new thermostat in the housing.
5. Use a new gasket and install the outlet connection.
Tighten the capscrews.
6. Connect the top hose and fill the cooling system.
61
 1.155 Disassembly
Special tool: Gear puller

1. See FIGURE 104. Remove the three long studs and

the O±ring (1) from the body (4) of the coolant pump.
2. Remove the front cover (8) and the gasket (9).
3. Use a puller to remove the gear (2).
4. Use a puller or prybar to remove the oil seal (3).
Dis-card the oil seal.
5. If necessary, remove the studs from the pump body.
Put a support under the impeller end of the pump body
1. THERMOSTAT so that it is not damaged. Use a press and adaptor to
FIGURE 102. THERMOSTATS, push the shaft and bearing assembly (7), impeller (6),
ENGINES YA AND YB and the water seal (5) from the pump body.
6. Put a support under the impeller so that it is not dam-
aged. Use a press to push the shaft and bearing assembly
1.153 COOLANT PUMP from the impeller. Be careful that the impeller is not
damaged. Remove the water seal (5) and discard it.
1.154 Removal

1. Drain the cooling system and disconnect the hose at

the inlet to the coolant pump.

2. Remove the capscrews from the flange for the

coolant by±pass. Remove the three capscrews that
hold the flange of the coolant pump to the timing gear
cover. Re-move the three nuts that hold the coolant
pump to the timing gear case.

3. Remove the coolant pump. Make sure that the O±ring

on the timing case cover is not lost. See FIGURE 103.

1. O±RING 6. IMPELLER
2. GEAR 7. SHAFT AND
3. OIL SEAL BEARING ASSEMBLY
1. O±RING 2. O±RING 4. PUMP BODY 8. FRONT COVER
5. WATER SEAL 9. GASKET
FIGURE 103. COOLANT PUMP CONNECTIONS FIGURE 104. COOLANT PUMP ASSEMBLY

62
1.156 Assembly
1. Clean the pump body. Give special attention to the
bore for the bearing and the bore for the water seal.
Both of these bores and their chamfers must be clean
and free of corrosion.
2. Apply a thin layer of Loctite 35 to the outer surface
of the bearing. Make sure the Loctite is not applied to
the ends of the bearing. Use a support under the side
of the pump body for the gear and use a press to push
the shaft and bearing assembly (7) into the pump
body. See FIGURE 104. Put the shaft and bearing
assembly in po-sition in the bore of the pump body
(4). The shortest end of the shaft goes into the pump
body. Make sure the alignment is correct and the shaft
is parallel with the bore. Apply the force from the
press to the bearing and not to the shaft. Push the
shaft and bearing assembly into the bore until the
bearing is even with the bottom of the counterbore for
the water seal. Remove any Loctite that is on the end
of the bearing.
3. Do not lubricate the water seal (5). It is important that
there is no oil or grease on the water seal. Hold the water
seal by the edges so that oil from your skin does not
touch the seal material. The widest side of the water seal
goes against the bearing (7). Push the water seal onto the
shaft until it is against the chamfer of the counterbore.
Make sure the water seal is correctly aligned with the
counterbore and press the seal into the counterbore until
the outer flange is against the pump body. Apply force
only to the outer flange of the water seal when it is
pushed into position. Hold the force on the water seal for
approximately 10 seconds to make sure that it stays in
position.
4. Use a support under the shaft (7) and use a press to
push the impeller (6) onto the shaft. If the original im-
peller is used again, use Loctite 35 in the bore of the
im-peller. Use an adaptor as necessary so that the
impeller is not damaged. Check that the impeller and
shaft will rotate smoothly.
5. Lightly lubricate the oil seal (3) with engine oil. Put
the oil seal into position on the shaft with the flat face
of the oil seal towards the bearing. Use a press to push
the oil seal into the counterbore until the oil seal is
even with the edge of the counterbore.
6. Put a support under the impeller end of the shaft. Use a
press to push the gear (2) onto the shaft to the dimension
shown in FIGURE 104. If the original gear is used,
use Locktite 35 in the bore of the gear.
7. Use a new gasket (9) and install the front cover (8).
Tighten the capscrews.
1.157 Installation
1. Make sure that the joint surfaces are clean. Use
new O±rings.
2. Check that drive gear for the coolant pump is in
good condition. Replace a worn or damaged gear.
3. Lightly lubricate the O±ring (2) on the coolant pump
with engine oil. Install the coolant pump on the timing
case cover with the drive gear engaged with the gear for
the fuel injection pump. The coolant pump will fit
tightly in the timing case cover. The coolant pump can
be pulled into position if the nuts that hold the coolant
pump are gradually and evenly tightened. Make sure that
the O±ring in the timing case cover stays in position
while the coolant pump is being installed.
4. Install and tighten the three capscrews that hold the
coolant pump to the timing case cover (two capscrews
from the front and one capscrew from the rear).
5. Install a new gasket in the flange of the coolant by±
pass. Install the bypass and tighten the capscrews.
6. Connect the hose to the inlet of the coolant pump
and fill the cooling system. Check for leaks.
1.158 FAN AND FAN DRIVE
1.159 Removal
1. Remove the capscrews and remove the fan.
2. Loosen the pivot fasteners for the alternator and the
fastener for the adjustment bracket. Remove the drive
belts.
3. Check the axial movement of the fan shaft. If the
axial movement is greater than 0.25 mm (0.010 in),
the fan bearing assembly must be repaired.
4. Remove capscrews and remove the fan drive from
the timing case cover.
1.160 Disassembly
1. See FIGURE 105. Use a puller to pull the hub (1)
from the fan shaft and bearing assembly (2).
2. Remove the snap ring (3) that holds the bearing in
the housing (4).
63
3. Use a press and adaptor to push the bearing and
shaft assembly from the front of the housing. Do not
push on the fan shaft. Press on the bearing shell to
remove the bearing and shaft assembly.

1.161 Assembly

1. See FIGURE 105. Use a press to push the bearing

and shaft assembly into the housing. Do not use force
on the shaft to push the bearing into the housing.

1. HOSE CLAMP
2. CAPSCREW AND NUT
3. SUPPORT BRACKET
4. CAPSCREWS (6)
FIGURE 106. OIL COOLER, ENGINE AB

3. Remove the capscrew and nut (2) which fastens the

low±pressure fuel lines to the top of the oil cooler.
4. Loosen the hose clamp (1) at the top of the oil cooler.

5. Remove the six capscrews (4) that fasten the oil

1. HUB cooler to the engine. Remove the oil cooler.
2. FAN SHAFT AND 3. SNAP RING
BEARING ASSEMBLY 4. HOUSING 1.165 Removal, Engines YA and YB
FIGURE 105. FAN DRIVE 1. Drain the cooling system.
2. Install the snap ring (3) in the housing (4). 2. Disconnect the oil lines at the flange on the cover
of the oil cooler.
3. Use a support under the fan shaft so that force is
not applied to the bearing. Use a press to push the hub 3. Remove the capscrews and nuts from the cover of
onto the fan shaft to the dimensions shown in the oil cooler and remove the cover and element. See
FIGURE 105. Make sure the edge of the hub with the FIGURE 107.
chamfer is away from the engine.

1.162 Installation

1. Install the fan drive on the timing case cover and

tighten the capscrews to 44 Nm (33 lbf ft).

2. Install the fan. Tighten the capscrews.

3. Install the drive belts and adjust the tension.

1.163 OIL COOLER

1.164 Removal, Engine AB

1. Drain the cooling system. 1. STUDS

2. See FIGURE 106. Release the support bracket (3) FIGURE 107. OIL COOLER AND ELEMENT,
at the oil cooler. ENGINES YA AND YB

64
1.166 Disassembly And Assembly

1. Remove the capscrews and remove the cover.

2. Engine AB. Remove the lock nuts at the back of the

oil cooler and remove the cooler element.

Engines YA and YB. Remove the nuts on the front of the

cover and remove the cooler element from the cover.

3. Clean the cooler element and check for cracks. If a

cleaning solution is used to clean the outside of the ele-
ment, make sure that the cleaning solution does not enter 1. O±RINGS
the element. Check that there are no restrictions for the
oil flow through the element. If the internal part of the
FIGURE 109. JOINTS FOR THE COOLER
ELEMENT, ENGINES YA AND YB
element must be cleaned, use a cleaning solution that
will not damage copper. Flush the element to remove the 1.167 Installation, Engine AB
cleaning solution and dry the element with compressed 1. See FIGURE 110. Use new O±rings on the inlet
air at low pressure. Then flush the internal part of the con-nection (3) for the coolant and the outlet flange
element with clean engine oil. (5) for the coolant. Make sure that the joint surfaces
are clean. Use a new gasket (4) for the oil line flange.
4. Use new O±rings on the flanges and studs as shown
in FIGURE 108. or FIGURE 109.

5. Engine AB. Install the cooler on the back plate and

tighten the lock nuts to 22 Nm (16 lbf ft).

Engines YA and YB. Install the cooler element on the cover

and tighten the nuts to 22 Nm (16 lbf ft).

1. VENT 4. GASKET, OIL

2. VENT CONNECTION PIPE FLANGE
3. O±RING, INLET 5. O±RING, OUTLET
FIGURE 110. OIL COOLER JOINTS,
ENGINE AB

2. Lightly lubricate the bore of the vent connection (2)

1. O±RINGS
FIGURE 108. JOINTS FOR THE COOLER
ELEMENT, ENGINE AB
and the O±ring (2) on the inlet coolant connection
with engine oil.
3. Loosely install the hose clamp on the vent connection.
2. O±RINGS
4. Install the oil cooler on the engine. Make sure that
the vent (1) fits correctly in its connection. Install the
six capscrews. Tighten the hose clamp on the vent
connec-tion.

65
5. Install and tighten the capscrew for the support
bracket.
6. Install the capscrew and nut that fasten the low
pres-sure fuel lines to the top of the oil cooler.
7. Fill the coolant system.
1.169 By±Pass Valve, Oil Cooler
1. See FIGURE 111. Remove the cap and remove the
by±pass valve.
2. Check the spring and the valve seat for damage.
Re-place the parts if they are damaged.

8. When the engine can be operated again, check for 3. Use a new aluminum washer (1). Install the
leaks. by±pass valve into the oil cooler and tighten the cap
to 50 Nm (37 lbf ft).
1.168 Installation, Engines YA and YB

1. If the studs have been removed and will be used

again, clean the threads on the studs and on the engine
block, Use liquid sealant on the threads before they
are in-stalled in the engine block.

2. Use a new gasket and install the oil cooler assembly

to the engine block. Tighten the capscrews and nuts to
22 Nm (16 lbf ft).

3. Use a new gasket and connect the oil lines to the

flange on the cover and tighten the screws.

4. Fill the coolant system.

1. O±RING
5. When the engine can be operated again, check for
leaks. FIGURE 111. BY±PASS VALVE, OIL COOLER

FLYWHEEL AND FLYWHEEL HOUSING

1.170 GENERAL 1.173 Ring Gear (Replacement)

The steel flywheel has a hardened steel starter ring.
The starter ring has 126 teeth. The flywheel housing
is made of cast iron.
1.171 FLYWHEEL
1.172 Removal
1. Remove two opposite capscrews from the flywheel
and temporarily install two studs to help control the
fly-wheel when the other capscrews are removed.
2. Remove the other capscrews that fasten the
flywheel to the crankshaft. Remove the flywheel.
3. Check the flywheel and ring gear for damage.
WARNING
Wear eye protection for this operation to prevent
eye injury from metal chips. You will be using a
hammer and chisel to break the ring gear.
Before the ring gear is removed, check the position of
the chamfer on the teeth.
Use a hammer and chisel to break the ring gear. Make
sure that you do not damage the flywheel.
The ring gear must be heated before it can be installed
on the flywheel. Use an oven that has a temperature
con-trol. Make sure that the ring gear is not heated to
more than 250C (480F).
Install the ring gear on the flywheel. Make sure that
the chamfer on the teeth is in the correct direction.
1.174 Installation
1. Make sure the surfaces of the crankshaft and flywheel
are clean so that the two parts will fit together correctly.

66
2. Install the flywheel over the guide studs. Install
four capscrews. Remove the two studs and install the
remain-der of the capscrews. Tighten the capscrews in
a cross pattern to 120 Nm (88 lbf ft).
3. Check the concentric variation (often called the ªrun±
outº) when the flywheel is turned. Use a dial indicator.
See FIGURE 112. This measurement must be less than
0.30 mm (0.012 in) total indicator reading.
FIGURE 112. CHECK THE ªRUN±OUTº OF THE
FLYWHEEL
4. Check the alignment of the face of the flywheel with a
dial indicator. See FIGURE 113. This measurement
must not be greater than 0.03 mm (0.001 in) total indica-
tor reading for every 25 mm (1.0 in) of the flywheel ra-
dius from the axis of the crankshaft to the indicator
plunger. When this measurement is made, force must be
applied against the flywheel to remove the axial move-
ment of the crankshaft from the measurement.
FIGURE 113. CHECK THE ALIGNMENT OF THE
FLYWHEEL FACE
1.175 FLYWHEEL HOUSING
1.176 Removal
1. Remove the starter motor and the flywheel. See
1.181 Starter, Removal and 1.172 Flywheel, Removal.
2. Remove the capscrews that hold the flywheel housing
to the engine block. Use a soft hammer to carefully hit
the flywheel housing and remove it from the dowels.
1.177 Installation
1. Make sure the surfaces of the engine block and the
fly-wheel housing are clean so that the two parts will
fit to-gether correctly. Make sure that the location
dowels are installed correctly.
2. Install the flywheel housing onto the dowels. Install
the capscrews, but do not tighten them to their final
torque.
3. Check the flywheel housing for concentric measure-
ments as shown in FIGURE 114. If any adjustments are
made, check the measurements again. See the ENGINE
SPECIFICATIONS for the measurements.
FIGURE 114. CHECK THE CONCENTRIC
MEASUREMENTS OF THE FLYWHEEL
HOUSING
4. When the concentric measurements are correct,
tighten the capscrews to the following torques:
M10 capscrews = 44 Nm (33 lbf ft)
M12 capscrews = 75 Nm (55 lbf ft)
5. Check the alignment of the flywheel housing with
the crankshaft as shown in FIGURE 115. See the
ENGINE SPECIFICATIONS for the measurements.
Any neces-sary adjustments must be made to the
flywheel housing and not to the engine block.
67
 6. Install the flywheel. See 1.174 Flywheel, Installation.

7. Install the starter motor. See 1.182 Starter, Installa-

tion.

FIGURE 115. CHECK THE ALIGNMENT OF THE

FLYWHEEL HOUSING

ELECTRICAL EQUIPMENT
1.178 DRIVE BELTS thumb pressure is 100 N (20 lbf), the correct
deflection is approximately 13 mm (0.5 in).
Check the drive belts for wear and damage. When a
pair of drive belts are used, they must be replaced as a
pair. When a pair of drive belts are used, adjust the
tension for the tightest belt.
2
A gauge is available that will indicate the tension in
the drive belt. Fit the gauge at the center of the
longest length of the drive belt and measure the
tension. See FIGURE 116. The correct tension is
approximately 355 N (80 lbf)

1. PIVOT FASTENER
FIGURE 116. GAUGE TO CHECK DRIVE BELT
12593 2. ADJUSTMENT LINK
TENSION
FIGURE 117. CHECK AND ADJUST DRIVE
BELT TENSION
Many service people press on the drive belt with their
thumb at the center of the longest length of the drive belt Loosen the bolt on the adjustment link (2) and the pivot
and check the deflection. See FIGURE 117. When the fasteners (1) to adjust the tension of the drive belts.

68
Move the alternator pulley against the drive belts to
ad-just the tension. Tighten the adjustment link and
pivot fasteners.
The drive belts are removed from the engine by
loosen-ing the tension and then removing them from
the pul-leys.
1.179 ALTERNATOR
NOTE: The alternator normally used with this engine is
made by Delco Remy or Motorola. See THE ALTER-
NATOR, 2200 SRM 2 for troubleshooting and repairs.
1.180 STARTER MOTOR
See THE STARTER, 2200 SRM 106 for
troubleshoot-ing and repairs for the starter motor.
1.181 Removal
1. Disconnect the battery.
2. Disconnect the cables to the starter motor.
3. Remove the capscrews and remove the starter motor.
AIR COMPRESSOR, ENGINES YA AND YB
1.184 GENERAL
The air compressor is installed in the PTO position on
the rear face of the timing case. There are two sizes of
compressors available for these engines. The drive as-
sembly has two gears of equal size on a common
shaft. The forward gear is engaged with the idler gear
in the timing gear train. The rear gear turns the
compressor gear.
The cylinder head of the single cylinder compressor is
cooled by coolant from the engine. The compressor is
lubricated from the engine oil system of the engine. En-
gine oil flows through a pipe from the main oil passage in
the engine to the crankcase of the compressor. The en-gine
oil then flows through the bearings of the compres-sor and
the bushing for the drive shaft. The engine oil re-turns to
the oil sump through the timing case.
During 1994 the WABCO (Clayton Dewandre) (Model
159 and Model 229) air compressor was replaced by the
Bendix 1W150R or 1W250R air compressor beginning
1.182 Installation
1. Install the starter motor in position on the flywheel
housing. Install and tighten the capscrews.
2. Connect the cables to the starter motor.
3. Connect the battery.
1.183 COLD START AID
The cold start aid is an electrical device. A controlled
amount of diesel fuel is inserted into the inlet manifold
where it is ignited by the cold start aid to heat the induc-
tion air. A heater coil in the body of the cold start aid ex-
pands a valve holder so that fuel can flow into the device
where it is ignited by an ignition coil. The cold start aid
is operated by a switch button on the instrument panel.
If the cold start aid is removed for cleaning or
replace-ment, make sure that the surfaces between the
inlet manifold and the cold start aid are clean. Tighten
the cold start aid to 31 Nm (23 lbf ft). If air is in the
fuel sys-tem because the fuel line was disconnected,
remove the air as described in 1.136 Remove Air
From The Fuel System.
with engine serial number Y±±±±±±U661001Y. The
op-eration of the air compressors is similar.
1.185 Air Compressor, Removal, WABCO
NOTE: The compressor and its drive housing can be
re-moved from the engine as an assembly or only the
com-pressor can be removed.
1. Drain the cooling system.
2. Release the air pressure in the air system and
discon-nect all the pipe connections to and from the
cylinder head of the compressor.
3. Remove the pipe for the engine oil between the
com-pressor and the engine block.
4. If an oil pump for the steering system is fastened to
the back of the compressor housing, remove it.
5. Remove the support bracket which is installed be-
tween the bottom of the compressor and the engine
block.
6. If the drive housing must be removed, remove the
capscrew (1) that goes through the timing case. See
69
FIGURE 118. If only the compressor is to be removed,
remove the five capscrews that hold the compressor
flange to the drive housing. Remove the other three
capscrews that hold the compressor to the drive housing.
7. Remove the compressor from the drive housing or
re-move the compressor and its drive housing from
the en-gine. Make sure that the alignment dowels are
still in po-sition.
1. CAPSCREW THROUGH TIMING CASE
2. O±RING
3. ALIGNMENT DOWEL
FIGURE 118. AIR COMPRESSOR REMOVAL
AND INSTALLATION, WABCO
1.186 Compressor Drive, Inspection
Check the drive gears for wear and damage.
Check the bushing (1) for wear. See FIGURE 119.
NOTE: For The Disassembly And Assembly Of The
Air Compressor, see the SERVICE MANUAL
section for your air compressor.
1.187 Air Compressor, Installation, WABCO
1. If the drive housing has been removed, install a
new O±ring (2) and lubricate it with clean engine oil.
See FIGURE 118.
2. See FIGURE 118. or FIGURE 119. Make sure the
alignment dowels are installed correctly. Install the
compressor or the compressor and drive housing.
Install and tighten the capscrews.
3. Install the support bracket for the compressor.
Make sure that a side force is not applied to the
compressor when the support bracket is installed.
70
1. BUSHING
2. ALIGNMENT DOWELS
FIGURE 119. AIR COMPRESSOR, REMOVAL
FROM THE DRIVE ASSEMBLY, WABCO
4. If an oil pump for the steering system is fastened to
the back of the compressor housing, install it.
5. Install the oil pipe between the compressor and the
en-gine block.
6. Install the pipe connections to the cylinder head of
the compressor.
7. Fill the cooling system with correct coolant.
8. When the engine can be operated, check for leaks.
1.188 Compressor Drive,
Disassembly, WABCO
1. See FIGURE 120. Raise the tabs on the lock washer
(2). Hold the shaft so that it does not turn and remove
the nut (1). Discard the lock washer (2).
NOTE: Some compressor drives do not have a lock
washer (2). Loctite thread adhesive is used to lock the
nut (1) to the shaft (5).
2. Use a puller to remove the gear (3).
3. Remove the snap ring (4).
4. Raise the tabs on the lock washer (12). Hold the
shaft so that it does not turn and remove the nut (13).
Discard the lock washer (12).
NOTE: Some compressor drives do not have a lock
washer (12). Loctite thread adhesive is used to lock
the nut (13) to the shaft (5).
5. Press the shaft (5) and bearing (7) from the side of
the housing that fastens to the timing case.
6. Remove the gear (11) from the housing (8). 2. Use a press to push the shaft (5) into the bearing
(7). Use an adaptor so that force is not applied to the
outer parts of the bearing. Apply force only to the
inner ball guide of the bearing.
3. If necessary, remove the alignment dowels (9) from
the housing (8) of the compressor drive. Put the housing
(8) on a support so that the shaft and bearing can be
pushed into the housing.
4. Lubricate the bearing receptacle in the housing (8)
with engine oil. Push the bearing and shaft into the
hous-ing. Use an adaptor so that force is not applied
to the shaft or the inner parts of the bearing. Apply
force only to the outer ball guide of the bearing.
5. Install the snap ring (4) in its groove.
6. If your compressor (Model 159) has a spacer (10),
in-stall it on the shaft. Install the woodruff keys (6) in
the slots in the shaft.
7. Align the woodruff keys with the gears (3, 11) and
in-stall the gears on the shaft. The gear (11) has a boss
on Model 229 compressor drives that must be toward
the bearing when the gear is installed. Use a press to
com-pletely install the gears on the shaft.
NOTE: Some compressor drives do not have a lock
washer (2, 12). Loctite thread adhesive is used to lock
the nuts (1, 13) to the shaft (5).
1. NUT 9. ALIGNMENT 8. Install new lock washers with tabs (2, 12) on the shaft.
2. LOCK WASHER* DOWEL (2)
3. GEAR 10. SPACER* Install the nuts (1, 13). If the nut has a thickness of 6.4
4. SNAP RING 11. GEAR mm (0.25 in), tighten the nut to 80 Nm (59 lbf ft). If the
5. SHAFT 12. LOCK WASHER* nut has a thickness of 10 mm (0.4 in), tighten the nut to
6. WOODRUFF KEY (2) 13. NUT
130 Nm (95 lbf ft). Bend the tabs on the lock washers
7. BEARING * NOT ON ALL
8. HOUSING COMPRESSOR
to lock the nuts in position.
DRIVES
9. If the alignment dowels (9) were removed, install
FIGURE 120. COMPRESSOR DRIVE, WABCO them in the housing. Install the compressor drive as
de-scribed in 1.187 Compressor Drive, Installation.

7. Remove the woodruff keys (6) and the spacer (10)
from the shaft (5). [NOTE: Only the Model 159 com-
pressor drive has a spacer (10).] Press the shaft from
the bearing (7). Do not apply force to the outer parts
of the bearing. Apply force only to the inner ball
guide of the bearing.
1.189 Compressor Drive, Assembly, WABCO
1. Clean the parts and check them for wear and
damage. Replace any worn or damaged parts.
1.190 Air Compressor, Removal,
BENDIX (See FIGURE 121.)
NOTE: The compressor and its drive housing can be
re-moved from the engine as an assembly or only the
com-pressor can be removed.
1. Drain the cooling system.
2. Release the air pressure in the air system and
discon-nect all the pipe connections to and from the
cylinder head of the compressor.

71
3. Remove the oil tube (6) for the engine oil between ing case. Slide the compressor onto the stud (3) for
the compressor and the engine block. the bottom of the flange.

5. Slide the compressor into the timing case until the

teeth of the drive gear are against the teeth of the idler
gear (2). Slowly turn the rear of the crankshaft of the air
compressor clockwise until the teeth of the drive gear
and the idler gear are fully engaged. Check that the tim-
ing mark on the crankshaft of the air compressor is
aligned with the 6A area on the timing label.

1. COOLANT HOSES
2. SPACERS (1W150R ONLY)
3. CAPSCREWS
4. SUPPORT BRACKET
5. CAPSCREWS
6. OIL TUBE, LUBRICATION
7. NUT
FIGURE 121. COMPRESSOR REMOVAL AND
INSTALLATION, BENDIX
1. THROUGH HOLE IN TIMING CASE
2. IDLER GEAR
4. If an oil pump for the steering system is fastened to 3. STUD
the back of the compressor housing, remove it. 4. STUD
5. O±RING
5. Loosen the two capscrews (3). Remove the two
FIGURE 122. COMPRESSOR, INSTALLATION
caps-crews (5). Remove the support bracket (4).
INTO THE DRIVE ASSEMBLY, BENDIX
6. Remove the nut from the stud at the bottom of the
compressor flange. Remove the nut (7) from the stud
at the front of the timing case and remove the air
compres-sor from the engine.

1.191 Air Compressor, Installation, BENDIX

1. Set the piston of number 1 cylinder to TDC.

2. See FIGURE 122. Install a new O±ring (5) in its re-

cess in the drive housing.

3. See FIGURE 123. Turn the crankshaft of the air

com-pressor until the timing mark (1) on the rear face
of the crankshaft is aligned with the 6A line on the
label at the rear face of the air compressor.
1. TIMING MARK (SHOWN ALIGNED FOR
4. See FIGURE 122. Install the end of the stud (4) with the 4±CYLINDER ENGINES. ALIGN WITH 6A
FOR 6±CYLINDER ENGINES)
shortest thread into the flange of the air compressor. Install
the nut fully on the stud. Move the air compressor into its FIGURE 123. COMPRESSOR, INSTALLATION
INTO THE DRIVE ASSEMBLY, BENDIX
position and engage the stud in its hole in the tim-

72
6. Install the nut (item 7, FIGURE 121.) on the stud.
Install the nut on the stud (item 3, FIGURE 122.).
Tight-en both nuts to 75 Nm (55 lbf ft).

7. Install the support bracket. See FIGURE 121. Install

the capscrews (5) loosely. Install the spacers (2) if used
and the capscrews (3). Adjust the support bracket so that
it only holds the air compressor and does not put tension
on it. Tighten the two capscrews (3) to 22 Nm (16 lbf ft).
Tighten the two capscrews (5) to 44 Nm (33 lbf ft).

8. Check that the O±ring in the cover at the rear of the

air compressor is not damaged. Install the cover and
tighten the two capscrews.
1. O±RING
9. Make sure the oil tube (item 6, FIGURE 121.) is in 2. CAPSCREW
good condition and does not have a restriction. Make 3. BRACKET
4. DRIVE GEAR, AIR COMPRESSOR
sure the engine stop solenoid is disconnected or the en- 5. TIMING CASE
gine stop control is in the STOP position. Operate the 6. COVER,TIMING CASE
started motor until engine oil flows from the oil tube. 7. NEEDLE BEARING
Connect the oil tube. Connect the engine stop solenoid. 8. CAPSCREW (3)
9. IDLER HUB
10. Connect the coolant hoses and air pipes to the air 10. COVER PLATE
11. IDLER GEAR
compressor. 12. ENGINE IDLER GEAR
11. Install the engine coolant. When the engine can be FIGURE 124. COMPRESSOR DRIVE, BENDIX
operated, check for oil, air, and coolant leaks.

1.192 Compressor Drive, 7.

Disassembly, BENDIX

CAUTION
Do not turn the engine crankshaft nor the
crankshaft for the air compressor. If either
crankshafts are moved, the air compressor must
be timed to the engine.

1. Remove the timing case cover as described in 1.77

Timing Case Cover, Removal.

2. Remove the three capscrews shown in (item 8,

FIGURE 124.). Remove the cover plate (10). Remove
the idler gear (11) and the needle bearings (7).
1. TIMING CASE
3. Remove the three capscrews (item 3, FIGURE 2. BRACKET, IDLER HUB
125.) which fasten the idler hub to the bracket (2). 3. CAPSCREWS (3)
Remove the idler gear hub. 4. CAPSCREWS (4)
5. IDLER GEAR
4. Remove and discard the O±ring (item 1, FIGURE
FIGURE 125. COMPRESSOR DRIVE, BENDIX
124.).

1.193 Compressor Drive, Assembly, BENDIX

5. Inspect the parts for wear or damage. 1. Install the O±ring (item 1, FIGURE 124.).

73
2. Check that the four capscrews which fasten the
idler hub bracket (item 4, FIGURE 125.) to the timing
case are tightened to 35 Nm (26 lbf ft).
3. Install the hub (item 9, FIGURE 124.) into the
timing case. Install the three capscrews (item 3,
FIGURE 125.) and tighten them to 60 Nm (44 lbf ft).
Install the needle bearing assembly on the hub.
4. Lubricate the bore of the idler gear with clean engine
oil and install the idler gear on the needle bearings.
Install the cover plate (item 9, FIGURE 124.) and tight-
en three capscrews (8) to 22 Nm (16 lbf ft).
5. Check the clearance between the bushings of the idler
gear and the plate of the idler gear. The correct clearance
is 0.12 to 0.16 mm (0.005 to 0.006 in). A maximum
service limit is 0.38 mm (0.015 in). See FIGURE 60.
74
6. Check the timing gear clearances as shown in
FIGURE 61. The minimum clearance is 0.08 mm
(0.003 in).
7. Install the timing case cover as described in 1.78
Tim-ing Case Cover, Installation.
8. Install the air compressor as described in 1.191 Air
Compressor, Installation, BENDIX.
9. Install the coolant pump. See 1.157 Coolant Pump,
Installation.
10. Install the crankshaft pulley and thrust block.
Install the three capscrews and tighten the three
capscrews evenly to 115 Nm (85 lbf ft). Check each
capscrew again for the correct torque.
11. Install the drive belts and adjust the tension. See
1.178 Drive Belts.
12. Install the fan. Fill the cooling system.
 ENGINE SPECIFICATIONS

1.194 CYLINDER HEAD ASSEMBLY Interference fit of valve guide in cylinder head
0.03 to 0.07 mm
1.195 Cylinder Head (0.0012 to 0.0027 in)

Angle of valve seat 46 (88 included angle)

Total length
to Inlet 57.94 mm (2.281 in)
Diameter of parent bore for valve guide to Exhaust 61.10 mm (2.406 in)
15.87 to 15.89 mm
Extension from bottom of recess for valve spring
(0.6247 to 0.6257 in)
15.10 mm (0.594 in)
Leak test pressure 200 kPa (29 psi)
Head thickness 102.70 to 103.50 mm
(4.047 to 4.078 in)
Minimum thickness of head in service
102.48 mm (4.035 in)
Maximum distortion of cylinder head. See FIGURE 126.

INLET VALVE:
1 = 1.59 mm (0.063 in)
2 = 19.05mm (0.750 in)
3 = 6.35 mm (0.250 in)
4 = 76.20 mm (3.00 in)
5 = 37.26 to 37.28 mm (1.467 to 1.468 in)
6 = 51.00 to 51.23 mm (2.008 to 2.017 in)
ENGINES AA, AB: 7 = 0.79 mm (0.031 in)
1 = 0.08 mm (0.003 in) 8 = 1.59 mm (0.063 in)
2 = 0.15 mm (0.006 in) 9 = 1.59 mm (0.063 in)
3 = 0.15 mm (0.006 in) 10 = 9.45 to 9.47 mm (0.372 to 0.373 in)
ENGINES YA, YB: EXHAUST VALVE:
1 = 0.13 mm (0.005 in) 1 = 1.59 mm (0.063 in)
2 = 0.25 mm (0.010 in) 2 = 19.05mm (0.750 in)
3 = 0.25 mm (0.010 in) 3 = 7.92 mm (0.312 in)
4 = 76.20 mm (3.00 in)
FIGURE 126. CHECK THE CYLINDER HEAD 5 = 32.58 to 32.84 mm (1.283 to 1.293in)
FOR DISTORTION 6 = 42.39 to 42.62 mm (1.669 to 1.678 in)
7 = 0.79 mm (0.031 in)
1.196 Valve Guides 8 = 1.59 mm (0.063 in)
9 = 1.59 mm (0.063 in)
Inside diameter 9.51 to 9.56 mm 10 = 9.45 to 9.47 mm (0.372 to 0.373 in)
(0.3744 to 0.3764 in)
Outside diameter 15.90 to 15.91 mm FIGURE 127. PILOT TOOL TO INSERT VALVE
(0.6260 to 0.6265 in) SEATS

75
 Maximum clearance in valve guide
0.15 mm (0.005 in)
Diameter, valve head 37.26 to 37.52 mm
(1.467 to 1.477 in)
Angle of valve face 45
Depth of valve head below face of cylinder head:
to Production limit 1.28 to 1.83 mm
(0.050 to 0.072 in)
to Service limit 2.08 mm (0.082 in)
Total length 123.07 to 123.57 mm
(4.845 to 4.865 in)
Seal arrangement Rubber seal installed on
valve guide
INLET VALVE:
1 = 7.19 to 7.32 mm (0.283 to 0.288 in) 1.199 Double Valve Springs To Outer
2 = 51.22 to 51.24 mm (2.0165 to 2.0175 in)
Installed length 35.8 mm (1.41 in)
3 = Maximum Radius 0.38 mm (0.015 in)
EXHAUST VALVE: Load, installed length 176 to 195 N
1 = 9.52 to 9.65 mm (0.375 to 0.380 in) (39.5 to 43.7 lbf)
2 = 46.62 to 42.65 mm (1.6780 to 1.6790 in) Active coils, number 3.6
3 = Maximum Radius 0.38 mm (0.015 in)
Damper coils, number 1
FIGURE 128. DIMENSIONS FOR VALVE Direction of coils Left hand to damper coil
SEAT INSERTS to cylinder head
1.200 Double Valve Springs To Inner
1.197 Inlet Valves Installed length 35.8 mm (1.41 in)
Diameter, valve stem 9.46 to 9.49 mm Load, installed length 89 to 104 N (20 to 23 lbf)
(0.3725 to 0.3735 in) Active coils, number 4.9
Clearance in valve guide Damper coils, number 1
0.02 to 0.10 mm Direction of coils Right hand to damper coil
(0.0008 to 0.0039 in) to cylinder head
Maximum clearance in valve guide 1.201 Single Valve Springs
0.13 mm (0.005in)
Installed length 40.0 mm (1.57 in)
Diameter, valve head 44.86 to 45.11 mm
Load, installed length 312 to 344 N
(1.766 to 1.776 in)
(70.1 to 77.3 lbf)
Angle of valve face 45
Active coils, number 4.5
Depth of valve head below face of cylinder head: Damper coils, number 0
to Production limit 1.27 to 1.60 mm
Direction of coils Left hand
(0.050 to 0.063 in)
to Service limit 1.85 mm (0.073 in) 1.202 Tappets
Total length 122.66 to 123.07 mm Diameter, tappet stem 18.99 to 19.01 mm
(4.829 to 4.845 in) (0.7475 to 0.7485 in)
Diameter, tappet bore in cylinder block
Seal arrangement Rubber seal installed on
19.05 to 10.08 mm
valve guide
(0.7500 to 0.7512 in)
1.198 Exhaust Valves Clearance of tappet in engine block
Diameter, valve stem 9.43 to 9.46 mm 0.04 to 0.09 mm
(0.0015 to 0.0037 in)
(0.371 to 0.372 in)
Clearance in valve guide 1.203 Rocker Arm Shaft
0.05 to 0.13 mm Outside diameter 19.01 to 19.04 mm
(0.002 to 0.005 in) (0.7485 to 0.7495 in)

76
1.204 Rocker Arms And Bushings Width of groove for top ring
Diameter, bore in rocker arm for bushing tapered
22.23 to 22.26 mm Width of groove for second ring
(0.8750 to 0.8762 in) 2.56 to 2.58 mm
(0.1008 to 0.1016 in)
Diameter, outside of bushing
22.28 to 22.31 mm Width of groove for third ring
(0.8770 to 0.8785 in) 4.04 to 4.06 mm
(0.1591 to 0.1598 in)
Interference fit of bushing in rocker arm
0.020 to 0.089 mm 1.208 Piston Rings, Engines AA And YA
(0.0008 to 0.0035 in) Top compression ring Barrel face, molybdenum
Internal diameter, bushing (finished size) insert, chamfer at the top
19.06 to 19.10 mm of the inner face
(0.7505 to 0.7520 in) Second compression ring
Clearance between rocker arm and rocker arm shaft Taper face, cast iron
0.03 to 0.09 mm Oil ring Coil spring back to up,
(0.001 to 0.0035 in) chromium face
Maximum clearance (service) between rocker arm and Width of top ring 2.48 to 2.49 mm
rocker arm shaft 0.13 mm (0.005in) (0.097 to 0.098 in)
Width of second ring 2.48 to 2.49 mm
1.205 PISTON AND CONNECTING RODS (0.097 to 0.098 in
Width of third ring 3.98 to 3.99 mm
1.206 Pistons, Engines AA And YA (0.156 to 0.157 in)
Type: ªQuadramº combustion bowl, controlled expan- Clearance of top ring in groove:
sion, top ring groove has insert. 0.08 to 0.11 mm
(0.003 to 0.004 in)
Diameter, bore for piston pin
34.928 to 34.934 mm Clearance of second ring in groove
(1.3751 to 1.3754 in) 0.06 to 0.09 mm
(0.002 to 0.003 in)
Height of piston above top face of engine block
Clearance of third ring in groove
0.14 to 0.36 mm
0.04 to 0.08 mm
(0.005 to 0.014 in)
(0.002 to 0.003 in)
Width of groove for top ring
Gap of top ring 0.30 to 0.76 mm
2.57 to 2.59 mm
(0.012 to 0.030 in)
(0.101 to 0.102 in)
Gap of second ring 0.30 to 0.76 mm
Width of groove for second ring
0.012 to 0.030 in)
2.55 to 2.57 mm
(0.100 to 0.101 in) See 1.42 Service Note. The gap for the second ring for later
production engines 0.040 to 0.85 mm
Width of groove for third ring (0.016 to 0.033 in)
4.03 to 4.06 mm
(0.1587 to 0.1598 in) Gap of third ring 0.38 to 0.84 mm
(0.015 to 0.033 in)
1.207 Pistons, Engines AB And YB
1.209 Piston Rings, Engines AB And YB
Type: ªQuadramº combustion bowl, controlled expan- Top compression ring Barrel face, molybdenum
sion, top ring groove has insert, diameter of top land insert, wedge
is reduced, anodized top face. Second compression ring
Taper face, cast iron
Diameter, bore for piston pin
38.103 to 38.109 mm Oil ring Coil spring back to up,
(1.500 to 1.5004 in) chromium face
Height of piston above top face of engine block Width of top ring Wedge
0.14 to 0.36 mm Width of second ring 2.48 to 2.49 mm
(0.005 to 0.014 in) (0.097 to 0.098 in

77
Width of third ring 3.98 to 3.99 mm
(0.156 to 0.157 in)
Clearance of top ring in groove: Wedge
Clearance of second ring in groove
0.07 to 0.11 mm
(0.003 to 0.004 in)
Clearance of third ring in groove
0.05 to 0.08 mm
(0.002 to 0.003 in)
Gap of top ring 0.35 to 0.75 mm
(0.014 to 0.030 in)
The large and small bores in the connecting rod
Gap of second ring 0.30 to 0.76 mm must be square and parallel with each other
0.012 to 0.030 in) within the limits of + 0.25 mm (0.010 in). The
measurement is made at 127 mm (5.0 in) on
Gap of third ring 0.38 to 0.84 mm
each side of the axis of the connecting rod. If the
(0.015 to 0.033 in) bush-ing is installed in the small end of the
connecting rod, the limits are reduced to
1.210 Connecting Rods, + 0.06 mm (0.0025 in).
Engines AA And YA
FIGURE 129. CHECK THE ALIGNMENT OF
Type ªHº section, square shape THE CONNECTING ROD
at small end
Location of cap to connecting rod 1.212 Piston Pins, Engines AA And YA
Serrations Type Full floating
Diameter, parent bore at big end Outside diameter 34.929 to 34.925 mm
67.21 to 67.22 mm (1.3748 to 1.3750 in)
(2.6460 to 2.6465 in) Clearance fit in piston 0.003 to 0.014 mm
(0.0001 to 0.0006 in)
Diameter, parent bore at small end
38.89 to 38.92 mm 1.213 Piston Pins, Engines AB and YB
(1.531 to 1.532 in) Type Full floating
Length between centers Outside diameter 38.095 to 38.100 mm
219.05 to 219.10 mm (1.4998 to 1.5000 in)
(8.624 to 8.626 in) Clearance fit in piston 0.003 to 0.014 mm
(0.0001 to 0.0006 in)
1.211 Connecting Rods,
Engines AB And YB 1.214 Small End Bushings,
Engines AA And YA
Type ªHº section, wedge shape
Type Steel back, lead bronze
at small end
bearing material
Location of cap to connecting rod Outside diameter 38.94 to 39.03 mm
Flat joint face with dowels (1.535 to 1.536 in)
Diameter, parent bore at big end Inside diameter 34.94 to 34.96 mm
67.21 to 67.22 mm (1.3758 to 1.3765 in)
(2.6460 to 2.6465 in) Clearance between bushing and piston pin
Diameter, parent bore at small end 0.020 to 0.043 mm
42.07 to 42.09 mm (0.0008 to 0.0017 in)
(1.656 to 1.657 in) 1.215 Small End Bushings,
Length between centers Engines AB And YB
219.05 to 219.10 mm Type Steel back, lead bronze
(8.624 to 8.626 in) bearing material

78
Outside diameter 42.16 to 42.19 mm
(1.6600 to 1.6613 in)
Inside diameter 38.12 to 38.14 mm
(1.5008 to 1.5015 in)
Clearance between bushing and piston pin
0.020 to 0.043 mm
(0.0008 to 0.0017 in)
1.216 Connecting Rod Bearings,
Engines AA And YA
Type Steel back, aluminum to tin
bearing material
Width 31.62 to 31.88 mm
(1.245 to 1.255 in)
Thickness 1.835 to 1.842 mm
(0.0723 to 0.0725 in)
Inside diameter 63.525 to 63.548 mm
(2.5010 to 2.5019 in)
Bearing clearance 0.025 to 0.076 mm
(0.001 to 0.003 in)
Available undersize bearings:
±0.25 mm ( ±0.010 in)
±0.51 mm ( ±0.020 in)
±0.76 mm ( ±0.030 in)
1.217 Connecting Rod Bearings,
Engines AB And YB
Type Steel back, lead bronze
bearing material with lead
finish
Width 31.55 to 31.88 mm
(1.240 to 1.255 in)
Thickness 1.835 to 1.842 mm
(0.0723 to 0.0725 in)
Inside diameter 63.525 to 63.548 mm
(2.5010 to 2.5019 in)
Bearing clearance 0.025 to 0.076 mm
(0.001 to 0.003 in)
Available undersize bearings:
±0.25 mm ( ±0.010 in)
±0.51 mm ( ±0.020 in)
±0.76 mm ( ±0.030 in)
1.218 Piston Cooling
Jets, Engines AB And YB
Valve open pressure 178 to 250 kPa
(26 to 36 psi)
1.219 CRANKSHAFT ASSEMBLY
1.220 Crankshaft
Diameter, main journal 76.16 to 76.18 mm
(2.998 to 2.999 in)
Maximum wear and oval wear on main and crank
journals 0.04 mm (0.0016 in)
Width of front journal 36.93 to 37.69 mm
(1.454 to 1.484 in)
Width of center journal 44.15 to 44.22 mm
(1.738 to 1.741 in)
Width of all other main journals
39.24 to 39.35 mm
(1.545 to 1.549 in)
Diameter of crank journal
63.47 to 63.49 mm
(2.499 to 2.500 in)
Width of crank journals 40.35 to 40.42 mm
(1.589 to 1.591 in)
Diameter of flange 133.27 to 133.37 mm
(5.247 to 5.251 in)
Axial movement 0.05 to 0.38 mm
(0.002 to 0.015 in)
Maximum axial movement (service)
0.51 mm (0.020 in)
Fillet radii, all journals 3.68 to 3.96 mm
(0.145 to 0.156 in)
Undersize journals, all ±0.25 mm ( ±0.010 in)
±0.51 mm ( ±0.020 in)
±0.76 mm ( ±0.030 in)
1.221 Crankshaft Heat Treatment
The following part numbers are induction
hardened: 31315662
31315992
3131H024
The following part numbers are nitrocarburised:
31315661
31315991
3131H022
1.222 Crankshaft Overhaul
Induction hardened crankshafts do not need to be
hard-ened after they have been machined undersize.
Nitrocarburised crankshafts must be hardened again
each time after they have been machined. If nitrocar-
burised or nitrided hardening methods are not
available, the crank shaft must be replaced or
exchanged with a crankshaft from the manufacturer.
Check the crankshaft for cracks before and after it is
ma-chined (ground). Remove any magnetism after the
crankshaft has been checked for cracks.
79
After the crankshaft has been machined, remove any specifications. The finished sizes for machined crank-
sharp edges from the oil holes for lubrication. shafts are shown in FIGURE 130.
Surface finish and fillet radii must be according to the

Undersize
Item 0.25 mm (0.010 in) 0.51 mm (0.020 in) 0.76 mm (0.030 in)
1 75.905 to 75.926 mm 75.651 to 75.672 mm 75.397 to 75.418 mm
(2.9884 to 2.9892 in) (2.9784 to 2.9792 in) (2.9684 to 2.9692 in)
2 63.216 to 63.236 mm 62.962 to 62.982 mm 62.708 to 62.728 mm
(2.4888 to 2.4896 in) (2.4788 to 2.4796 in) (2.4688 to 2.4696 in)
3 39.47 mm (1.554 in) maximum
4 37.82 mm (1.489 in) maximum
5 44.68 mm (1.759 in) maximum
6 40.55 mm (1.759 in) maximum
7 133.17 mm (5.243 in) maximum
8 Do not machine this diameter
9 3.68 to 3.96 mm (0.145 to 0.156 in)
Surface finish for all bearing journals must be 0.4 microns (16 micro inches).
Surface finish for all radii must be 1.3 microns (51 micro inches).

FIGURE 130. SPECIFICATIONS, CRANKSHAFT OVERHAUL

80
 When the crankshaft is on mounts at the front and rear main journals, the maximum variation
(run±out) (total indicator reading) at the other main journals can not be greater than the following table.
The ªrun±outº must not be opposite. The difference in ªrun±outº between one journal and the next
one must not be more than 0.10 mm (0.004 in). The ªrun±outº on the crankshaft pulley diameter,
rear oil seal diameter, and the rear flange diameter must not be more than 0.05 mm (0.002 in) total
indiactor reading.
Journal 4±cylinder crankshafts 6±cylinder crankshafts
1 Mount Mount
2 0.08 mm (0.003 in) 0.10 mm (0.004 in)
3 0.15 mm (0.006 in) 0.20 mm (0.008 in)
4 0.08 mm (0.003 in) 0.25 mm (0.010 in)
5 Mount 0.20 mm (0.008 in)
6 0.10 mm (0.004 in)
7 Mount

1.223 Main Bearings to Oversize 2.45 to 2.50 mm

Type Steel back, 20% tin to
aluminum bearing material
Type, center bearing Steel back, lead bronze
(Engines YA and YB) bearing material with lead
finish
Width, center bearing 36.32 to 36.70 mm
(All engines) (1.430 to 1.445 in)
Width, other bearings 31.62 to 31.88 mm
(Engines AA and AB) (1.245 to 1.255 in)
Width, other bearings 30.86 to 31.12 mm
(Engines YA and YB) (1.215 to 1.225 in)
Bearing thickness 2.083 to 2.89 mm
(All engines) (0.0820 to 0.0823 in)
Bearing thickness, center bearing
(Engines YA and YB only)
2.087 to 2.096 mm
(0.0822 to 0.0825 in)
Inside diameter 76.23 to 76.27 mm
(3.0010 to 3.0025 in)
Bearing clearance 0.046 to 0.107 mm
(0.0018 to 0.0042 in)
Available undersize bearings:
±0.25 mm ( ±0.010 in)
±0.51 mm ( ±0.020 in)
±0.76 mm ( ±0.030 in)
1.224 Crankshaft Thrust Washers
Type Steel back, lead bronze
bearing material
Position each side of the center
main bearing
Thickness:
to Standard 2.26 to 2.31 mm
(0.089 to 0.091 in)
(0.096 to 0.098 in)
1.225 TIMING CASE AND DRIVE
ASSEMBLY
1.226 Camshaft
Diameter, journal No.1 50.71 to 50.74 mm
(1.9965 to 1.9975 in)
Diameter, journal No.2 50.46 to 50.48 mm
(1.9865 to 1.9875 in)
Diameter, journal No.3
Engines AA and AB 49.95 to 49.98 mm
(1.9665 to 1.9775 in)
Engines YA and YB 50.20 to 50.23 mm
(1.9765 to 1.9775 in)
Diameter, journal No.4
Engines YA and YB 49.95 to 49.98 mm
(1.9665 to 1.9775 in)
Clearances, all journals 0.06 to 0.14 mm
(0.0025 to 0.0055 in)
Cam lift:
Inlet 7.62 to 7.69 mm
(0.2999 to 0.3029 in)
Exhaust 7.71 to 7.79 mm
(0.3036 to 0.3066 in)
Maximum out of round and wear on journals
0.05 mm (0.021 in)
Axial movement:
Production limit 0.10 to 0.41 mm
(0.004 to 0.016 in)
Service limit 0.53 mm (0.0020 in)
Width, thrust washer space
5.64 to 5.89 mm
(0.222 to 0.232 in)
1.227 Camshaft Thrust Washer
Type 360

81
Clearance fit, thrust washer in engine block
5.41 to 5.49 mm
(0.213 to 0.216 in)
Thickness, thrust washer
5.49 to 5.54 mm
(0.216 to 0.218 in)
Extension of thrust washer beyond front face of engine
block 0.00 to 0.13 mm
(0.000 to 0.005 in)
1.228 Camshaft Gear
No. of teeth 65
Diameter, bore 34.93 to 34.95 mm
(1.3741 to 1.3747 in)
Outside diameter, hub of camshaft
34.90 to 34.92 mm
(1.3741 to 1.3747 in)
Clearance fit, gear on hub
0.008 to 0.048 mm
(0.0003 to 0.0019 in)
1.229 Gear For Fuel Injection Pump
No. of teeth 56
Bore Tapered
1.230 Crankshaft Gear
No. of teeth 28
Diameter, bore 47.625 to 47.650 mm
(1.8750 to 1.8760 in)
Diameter, hub for gear on crankshaft
47.625 to 47.645 mm
(1.8750 to 1.8758 in)
Press fit of gear on crankshaft
±0.020 to +0.048 mm
(±0.0008 to +0.0010 in)
1.231 Idler Gear And Hub
No. of teeth 63
Diameter, gear bore 57.14 to 57.18 mm
(2.2495 to 2.2512 in)
Width, gear with split bushing assembly
30.14 to 30.16 mm
(1.186 to 1.187 in)
Width, gear with flange bushing assembly
50.80 to 50.82 mm
(1.9998 to 2.0007 in)
Outside diameter, hub 50.70 to 50.74 mm
(1.9960 to 1.9975 in)
Clearance, bushings on hub
0.058 to 0.119 mm
(0.0023 to 0.0047 in)
82
Axial movement:
to Production limit 0.10 to 0.20 mm
(0.004 to 0.008 in)
to Service limit 0.38 mm (0.015 in)
Gear clearance (all) 0.08 mm (0.003 in)
1.232 ENGINE BLOCK ASSEMBLY
1.233 Engine Block
Height between top and bottom faces
441.12 to 441.33 mm
(17.367 to 17.375 in)
Diameter, bore for cylinder liner
104.20 to 104.23 mm
(4.103 to 4.104 in)
Depth of space for flange of cylinder liner
3.81 to 3.91 mm
(0.150 to 0.154 in)
Diameter of space for flange of cylinder liner
107.82 to 107.95 mm
(4.245 to 4.250 in)
Diameter of bore for main bearing
80.416 to 80.442 mm
(3.1660 to 3.1670 in)
Diameter, camshaft bore (Engines AA and AB):
to No. 1 55.56 to 55.59 mm
(2.188 to 2.189 in)
to No. 2 50.55 to 50.60 mm
(1.990 to 1.992 in)
to No. 3 50.04 to 50.09 mm
(1.970 to 1.972 in)
Diameter, camshaft bore (Engines YA and YB):
to No. 1 55.56 to 55.59 mm
(2.188 to 2.189 in)
to No. 2 50.55 to 50.60 mm
(1.990 to 1.992 in)
to No. 3 50.29 to 50.34 mm
(1.980 to 1.982 in)
to No. 4 50.04 to 50.09 mm
(1.970 to 1.972 in)
Bore in bushing for No. 1 camshaft journal
50.79 to 50.85
(2.000 to 2.002 in)
1.234 Cylinder Liners
Outside diameter, production cylinder liner
104.25 to 104.28 mm
(4.105 to 4.106 in)
Fit of production cylinder liner
0.03 to 0.08 mm
(0.001 to 0.003 in)
Inside diameter of production cylinder liner
100.00 to 100.03 mm
(3.937 to 3.9395 in)
Fit of service cylinder liner
+0.03 mm (+0.001 in)
Inside diameter of service cylinder liner (installed)
100.04 to 100.06 mm
(3.9385 to 3.9395 in)
Maximum wear of liner bore
0.25 mm (0.010 in)
Thickness of flange 3.81 to 3.86 mm
(0.150 to 0.152 in)
Top of flange even with face of engine block
+0.10 mm (+0.004 in)
1.235 TURBOCHARGER
Engine AB Airesearch T31 or
Schwitzer S2A
Engine YB Airesearch T04B
1.236 LUBRICATION SYSTEM
1.237 Oil Pump, Engines AA And AB
Type Differential rotor,
gear driven
Number of lobes Inner rotor 6, outer rotor 7
Clearance of outer rotor to pump body
0.15 to 0.34 mm
(0.006 to 0.013 in)
Clearance of inner rotor to outer rotor
0.04 to 0.13 mm
(0.0015 to 0.0050 in)
Axial movement, rotor 0.03 to 0.10 mm
(0.001 to 0.004 in)
1.238 Oil Pump, Engines YA And YB
Type Differential rotor,
gear driven
Number of lobes Inner rotor 4, outer rotor 5
Clearance of outer rotor to pump body
0.15 to 0.34 mm
(0.006 to 0.013 in)
Clearance of inner rotor to outer rotor
0.04 to 0.13 mm
(0.0015 to 0.0050 in)
End clearance, Engine YA
to Inner rotor 0.05 to 0.12 mm
(0.002 to 0.005 in)
to Outer rotor 0.04 to 0.11 mm
(0.0015 to 0.0044 in)
End clearance, Engine YB
to Inner rotor 0.043 to 0.118 mm
(0.0017 to 0.0046 in)
to Outer rotor 0.031 to 0.106 mm
(0.0012 to 0.0042 in)
Clearance, bushing of idler gear on shaft
0.020 to 0.066 mm
(0.0008 to 0.0026 in)
1.239 Relief Valve
Diameter, bore for plunger
18.24 to 18.27 mm
(0.718 to 0.719 in)
Outside diameter, plunger
18.16 to 18.18 mm
0.715 to 0.716 in)
Clearance of plunger in bore
0.06 to 0.11 mm
(0.002 to 0.004 in)
Length of spring, installed (Engines AA and AB)
59.8 mm (2.4 in)
Length of spring, installed (Engines YA and YB)
55.6 mm (2.2 in)
Load on spring, installed (Engines AA and AB)
18.9 to 20.1 N
(4.3 to 4.5 lbf)
Load on spring, installed (Engines YA and YB)
15.2 to 16.2 N
(3.4 to 3.6 lbf)
Pressure to open valve, (Engine AA)
360 to 415 kPa
(52 to 50 psi)
Pressure to open valve, (Engine AB)
435 to 490 kPa
(63 to 71 psi)
Pressure to open valve, (Engines YA and YB)
345 to 414 kPa
(50 to 60 psi)
1.240 Oil Filter
Type Full flow, canister
Pressure to open by to pass valve in oil filter
55 to 83 kPa (8 to 12 psi)
Pressure to open by to pass valve in oil cooler
172 kPa (25 psi)
1.241 FUEL SYSTEM
1.242 Cav Fuel Injection Pump
Type DPA (Engines AA and YA)
Type DPS (Engines AB and YB)
Direction of rotation, (from drive end)
Clockwise
Outlet for No. 1 cylinder:
to Engines AA and AB Letter ªWº
to Engines YA and YB Letter ªYº
83
Static timing: The engine check angle must be used Fuel pump Engine check Pump mark angle
with special tool MS67B and with the engine set with code letters angle (degrees) (degrees)
No. 1 piston at TDC on the compression stroke. The 1
AK 325 /2 336
pump is checked with the pump set at the start of AM 282 290 1/2
BM 281 1 291
injec-tion for cylinder No. 1. /2 1
CM 282 291 /2
1 1
DM 282 /4 290 /2
The code letters are included in the setting code on FK 325 1/2 336
the data plate on the fuel injection pump. A typical GK 324 336
1
GM 282 290 /2
setting code is 2643C601BM/4/2700. In this example HK 327 336
the code letters are ªBMº. HM 282 291
1
JK 325 / 334
KK 325 2 334
1 1
LK 326 /2 337 /2
MK 325 336
PK 326 334
1
RK 327 /2 336
1 1
RM 282 /2 290 /2
TK 327 334
UK 325 1/ 334
XM 282 2 291
FIGURE 131. STATIC TIMING CODES
1.243 FUEL INJECTORS
The code letters are on the side of the fuel injector body and just below the connection for the nut of the high
pressure line.

FIGURE 132. FUEL INJECTOR CODES

Code Holder Nozzle Set and Reset Pressure
atm psi MPa
HU LRB67014 JB6801022 220 3234 22.3
HV LRB67014 JB6801052 250 3675 25.3
HZ LRB67014 JB6801029 220 3234 22.3
JA LRB67014 JB6801057 250 3675 25.3
JB LRB67014 JB6801058 250 3675 25.3
JE LRB67014 JB6801058 220 3234 22.3
JF LRB67032 JB6801052 250 3675 25.3
JG LRB67032 JB6801057 230 3381 23.3
JH LRB67014 JB6801084 250 3675 25.3
JJ LRB67014 JB6801082 250 3675 25.3
JK LRB67014 JB6801088 220 3234 22.3
JL LRB67032 JB6801093 250 3675 25.3
JR LRB67032 JB6801100 250 3675 25.3
JS LRB67032 JB6801084 250 3675 25.3
JT LRB67032 JB6801104 250 3675 25.3
JU LRB67014 JB6801106 220 3234 22.3
JY LRB67014 JB6801157 250 3675 25.3
NJ 2645L304 2645L607 220 3234 22.3
NK 2645L305 2645L609 225 3308 22.8
NL 2645L305 2645L608 225 3308 22.8

84
 NM 2645L304 2645L611 230 3381 23.3
NN 2645L303 2645L612 230 3381 23.3
NP 2645L304 2645L613 220 3234 22.3
NR 2645L303 2645L614 230 3381 23.3
NS 2645L303 2645L612 250 3675 25.3
NT 2645L304 2645L615 230 3381 23.3
NU 2645L303 2645L605 220 3234 22.3
NV 2645L304 2645L616 220 3234 22.3
NW 2645L303 2645L613 220 3234 22.3
RD KBEL66S45 DLLA140S1039 250 3675 25.3
RE KBEL66S47 DLLA150S1055 250 3675 25.3
RF KBEL66S47 DLLA150S1072 250 3675 25.3
RH KBEL66S47 DLLA150S1087 250 3675 25.3
RK KBEL66S47 DLLA145S1172 270 3970 27.4
RM KBEL66P69 0433±175±044 250 3675 25.3
RN KBEL66P69 0433±175±067 250 3675 25.3
RP KBEL66P99 0433±175±044 250 3675 25.3
RR 0433±176±079 DSLA140P292 250 3675 25.3
RS 0433±175±079 3374287 250 3675 25.3
RT KPEL66P111 0433±175±044 250 3675 25.3
RU KPEL65P113 DSLA140P472 250 3675 25.3
RV 2645F311 2645F610 250 3675 25.3

1.244 Fuel Pump, Engines AA And AB Outside diameter of shaft

Type A.C. Delco, types XD 15.91 to 15.92 mm
(0.6264 to 0.6267 in)
Method of drive Eccentric on camshaft
Diameter, bore of drive gear
Static pressure (no delivery) 15.88 to 15.89 mm
42 to 70 kPa (6 to 10 psi) (0.6252 to 0.6256 in)
1.245 Fuel Pump, Engines YA And YB Press fit of drive gear on shaft
Type A.C. Delco, types LU 0.01 to 0.04 mm
(0.0005 to 0.0016 in)
Method of drive Eccentric on camshaft
Diameter, bore of impeller
Static pressure (no delivery)
15.87 to 15.89 mm
34.5 to 55.2 kPa (5 to 8 psi)
(0.6249 to 0.6257 in)
Test pressure (75% of minimum static pressure)
Diameter, bearing 29.99 to 30.00 mm
26 kPa (3.75 psi)
(1.1807 to 1.1811 in)
1.246 Fuel Filter Diameter, bore for bearing
Type single element 29.96 to 29.98 mm
(some YA and YB engines are equipped with twin (1.1795 to 1.1803 in)
parallel flow filters) Press fit, bearing in pump body
0.01 to 0.04 mm
1.247 COOLING SYSTEM (0.0004 to 0.0016 in)
Installed dimension, impeller boss to front face of pump
1.248 Coolant Pump body 8.1 to 8.5 mm
Type centrifugal, gear drive (0.319 to 0.335 in)

85
Installed dimension, gear from rear face of pump 1.251 FLYWHEEL AND HOUSING
body 0.6 to 2.6 mm
(0.024 to 0.102 in) 1.252 Limits for flywheel ªrun outº and
1.249 Thermostat alignment (total indicator reading). See
FIGURE 133.
Type, Engines AA and AB
Single, wax pellet,
by to pass blanking Diameter of housing Maximum limit (total
flange bore indicator limit)
Type, Engines YA and YB
mm in mm in
Twin, wax pellet,
by to pass blanking less than 362 less than 14.25 0.15 0.006
362 to 511 14.25 to 20.125 0.20 0.008
ªStart to openº 77 to 85C (170 to 185F) 511 to 648 20.125 to 25.50 0.25 0.010
ªFully openº 92 to 98C (198 to 208F) over 648 over 25.50 0.30 0.012
Valve lift, fully open 9.1 mm (0.358 in) FIGURE 133. FLYWHEEL AND HOUSING
LIMITS
1.250 Fan Drive Housing
Bore of housing for bearing
41.98 to 41.99 mm 1.253 ELECTRICAL EQUIPMENT
(1.6527 to 1.6531 in)
1.254 Alternator
Outside diameter, bearing
41.99 to 42.00 mm Type Delco Remy or
(1.6531 to 1.6535 in) Motorola
Press fit, bearing in housing 1.255 Starter Motor
0.00 to 0.02 mm
Type Delco Remy
(0.0000 to 0.0008 in)
Bore of hub 21.946 to 21.958 mm 1.256 Cold Start Aid
(0.8656 to 0.8661 in) Type Diesel fuel, electrically
Press fit, shaft in hub 0.029 to 0.054 mm operated heater
(0.0011 to 0.0021 in) Voltage 12 volts
Maximum axial movement: 0.25 mm (0.010 in) Fuel flow 3.5 to 5.9 millilitres/minute

86
 TORQUE SPECIFICATIONS
DESCRIPTION Thread TORQUE
Size N.m lbf ft
Cylinder Head Assembly
Capscrews, Cylinder head (See 1.25 Installation) 1/2 UNF
Fasteners, rocker arm brackets:
to Aluminum M12 40 30
to Cast iron M12 75 55
Cap nuts, valve cover M12 20 15

Piston And Connecting Rod Assemblies

Nuts, connecting rods 1/2 UNF 125 92
Capscrews, connecting rods 1/2 UNF 155 114
Banjo bolts, piston cooling jets 3/8 UNF 27 20

Crankshaft Assembly
Capscrews, main bearings 5/8 UNF 265 196
Capscrews, crankshaft pulley 7/16 UNF 115 85
Capscrews, damper to crankshaft pulley
Capscrews, rear oil seal housing to engine block M8 35 26
Capscrews, rear oil seal housing to bridge piece M8 18 13

Timing Case And Drive Assembly

Capscrews, timing case to engine block M8 22 16
M10 44 33
Capscrews, hub of idler gear M10 44 33
Capscrew, camshaft gear M12 78 58
Capscrews, timing case cover to timing case M8 22 16
Nuts, timing case cover to timing case M8 22 16

Turbocharger
Nuts, turbocharger to manifold M10 44 33

Lubrication System
Plug, oil sump 3/4 UNF 34 25
Capscrews, oil pump to front bearing cap M8 22 16
Capcrews, cover for oil pump M8 28 21
Fasteners, oil sump M8 22 16
Fuel System
Nuts, high to pressure fuel lines M12 18 14
Capscrews, fuel injectors M8 12 9
Capscrews, fuel pump M8 22 16
Nut for gear for fuel injection pump M14 80 59
Nuts for flange of fuel injection pump M8 22 16

Cooling System
Capscrews for fan drive housing to timing case M10 44 33
Capscrews, fan drive pulley to hub M8 22 16
Capscrews, fan M10 44 33

Flywheel And Flywheel Housing

Capscrews, flywheel to crankshaft 1/2 UNF 120 88
Capscrews, flywheel housing to engine block M10 44 33
M12 75 55
Auxiliary Equipment
Nuts for gears of auxiliary drive (hydraulic pump or compressor)
6.4 mm (0.25 in) thick nut 3/4 UNF 80 59
10 mm (0.4 in) thick nut 3/4 UNF 130 95
M20 130 95

87
 SPECIAL TOOLS
PD.1D
Remove and replace tool for valve guides.

PD.1D±1A
Adaptor tool for use with PD.1D.

PD.1C±6
Adaptor tool for use with PD.1D and PD.1D±1A.

PD.41D
Gauge for piston height, valve depth and cylinder liner flange; for use
with PD.208.

PD.67±2
Drive adaptor for use with MS.67B.

PD.67±3
Gear adaptor for use with MS.67B.

PD.67±4
Pointer for use with MS.67B.

PD.145D
Replacement tool for rear seal of crankshaft.

88
PD.150B
Remove and replace tool for cylinder liner.

PD.150B±17
Adaptors for use with PD.150B.

PD.155B
Puller for camshaft and fuel pump gears

PD.155B±5
Adaptors for use with PD.155B.

PD.163A
Alignment tool for timing case cover.

PD.170
Replacement tool for seal of timing case cover.

PD.170±1
Pressure plate for use with PD.170.

PD.170±2
Fastener plate for use with PD.170.

89
 PD.170±3
Sleeve for use with PD.170.

PD.170±4
Seal adaptor for use with PD.170.

PD.199
Spanner (wrench) for flange nuts of fuel injection pump.

PD.206
Replacement tool for pistons.

PD.208
Dial gauge for use with PD.41D.

PD.6118B
Valve spring compressor.

PD.6118±7
Stud adaptor for use with PD.6118B.

PD.6118±8
Capscrew adaptor for use with PD.6118B.

MS67B
Timing gauge.

90
MS.73A
Set of adjustable cutters for valve seats.

MS.76B
Handle set for valve seat cutters (also included in MS.73A).

MS.99
Gear puller for coolant pump.

MS.107
Gear adaptor for use with MS.67B.

MS.150±9.5
Adjustable pilot for valve seat cutters (also included in MS.73A).
MS.275
Cutter for exhaust valve seats (also included in MS.73A).

MS.281
Cutter for exhaust valve seats (also included in MS.73A).

MS.1531
Angle gauge to tighten cylinder head capsrews.

91