4BD1-TRBG HEAVY REPAIR

TABLE OF CONTENTS
Page No Page No

Engine..................................................................................23
Cylinder Head .................................................................23
Engine .............................................................................28
Cylinder Liners ................................................................40
Camshaft Bearings..........................................................43
Cooling System....................................................................60
Water Pump ....................................................................60
Fuel ......................................................................................63
Fuel Injection Pump ........................................................63
Governor .........................................................................73 Electrical............................................................................ 206
Injection Pump Timing.....................................................87 Starter Motor................................................................. 206
Injection Pump Pressure Test .........................................89 Alternator and Vacuum Pump....................................... 211
Calibration .......................................................................89
Transfer Pump ................................................................95
Automatic Timer ..............................................................98
Fuel Injectors.................................................................101
Turbocharger.................................................................105

LIST OF FIGURES
Page No Page No
Figure 13 Removal of the Injection Pump Rear Mounting
Figure 2 Valve Removal ........................................................23 Bracket ........................................................................ 29
Figure 3 Checking the Cylinder Head Distortion ...................23 Figure 14 Removal of the Injection Pump............................. 29
Figure 4 Measuring the Valve Head Thickness ....................24 Figure 15 Checking the Idle Gear End-play.......................... 31
Figure 5 Measuring the Valve Depression ............................24 Figure 16 Checking the Timing Gear Backlash .................... 31
Figure 6 Removing the Valve Seat .......................................25 Figure 17 Checking the Crankshaft End-play ....................... 31
Figure 7 Valve Stem Measuring Points.................................25 Figure 18 Main Bearing Bolt Removal Sequence................. 32
Figure 8 Measuring the Valve Guide Wear ...........................26 Figure 19 Camshaft Follower Wear Patterns........................ 33
Figure 9 Installing the Valve Stem Oil Seal...........................26 Figure 20 Measuring Camshaft Follower and Bore Wear..... 33
Figure 10 Checking the Free Length, Inclination and Figure 21 Measuring the Cylinder Bore ................................ 34
Tension of the Valve Springs ......................................27 Figure 22 Measuring the Camshaft Bearing Journals .......... 34
Figure 11 Valve Spring..........................................................28 Figure 23 Measuring the Camshaft Bearings ....................... 35
Figure 12 Valve Installation...................................................28 Figure 24 Measuring the Crankshaft Bearing Journals ........ 35

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Figure 25 Measuring the Crankshaft Run-out....................... 36 Figure 79 Delivery Valve and Gasket - Sectional View ........ 71
Figure 26 Measuring the Bearing Spread ............................. 36 Figure 80 Control Sleeve Setting Position............................ 71
Figure 27 Measuring the Main Bearings ............................... 37 Figure 81 Installation of the Tappet Holders......................... 72
Figure 28 Measuring the Connecting Rod Bearing............... 37 Figure 82 Camshaft Identification Number Location ............ 72
Figure 29 Measuring the Gudgeon Pin ................................. 38 Figure 83 Connecting Link and Start Spring Location .......... 72
Figure 30 Checking the Connecting Rod Alignment ............. 38 Figure 84 Camshaft Coupling Tool....................................... 74
Figure 31 Measuring the Piston Diameter ............................ 39 Figure 85 Universal Vice and Bracket Assembly.................. 74
Figure 32 Measuring the Piston Ring Clearance .................. 39 Figure 86 Governor Shaft Cap-nut and Locknuts................. 75
Figure 33 Measuring the Idle Gear Shaft.............................. 40 Figure 87 Removal of the Torque Cam Rod Adjuster Plug .. 75
Figure 34 Measuring the Idle Gear ....................................... 40 Figure 88 Removal of the Idling Spring Capsule .................. 76
Figure 35 Removing the Cylinder Liners............................... 41 Figure 89 Removal of the Governor Cover........................... 76
Figure 36 Checking the Engine Block Distortion................... 41 Figure 90 Removing the Governor Shaft and Start Spring... 76
Figure 37 Installing the Cylinder Liners................................. 42 Figure 91 Removal of the Connecting Link .......................... 77
Figure 38 Checking the Cylinder Liner Protrusion ................ 42 Figure 92 Removal of the Sensor Lever............................... 77
Figure 39 Removal of the Camshaft Bearing........................ 43 Figure 93 Full-load Setting Lever Retaining Nut................... 77
Figure 40 Installing the Drive Gear ....................................... 43 Figure 94 Removal of the Full-load Setting Lever Shaft....... 78
Figure 41 Crankshaft Bearing Bolt Tightening Sequence..... 44 Figure 95 Removing the Stop Lever Assembly .................... 78
Figure 42 Installing the Camshaft ......................................... 44 Figure 96 Removal of the Flyweights ................................... 78
Figure 43 Connecting Rod Match Mark Location.................. 45 Figure 97 Removal of the Governor Housing ....................... 79
Figure 44 Piston Front Mark Location................................... 45 Figure 98 Removal of the Snap-ring..................................... 79
Figure 45 Installing the Snap-rings ....................................... 46 Figure 99 Removal of the Tension Lever Pivot Shaft ........... 79
Figure 46 Checking the Piston Ring Gap.............................. 46 Figure 100 Removal of the Torque Cam .............................. 80
Figure 47 Installing the Piston Rings .................................... 47 Figure 101 Removal of the Control Lever Shaft and
Figure 48 Crank Plate Secured to the Crankshaft ................ 48 Floating Lever Assembly ............................................ 80
Figure 49 Rear Crankshaft Oil Seal Located on the Crank Figure 102 Removal of the Snap-ring and Pivot Pin ............ 80
Plate Ready for Installation ......................................... 49 Figure 103 Removal of the Shifter and Bearing ................... 81
Figure 50 Push Cone Located on Crank Plate and Against Figure 104 Flyweight Inspection........................................... 81
Seal ............................................................................. 49 Figure 105 Removing the Bearing Race from the Shifter -
Figure 51 Flywheel Bolt - Tightening Sequence ................... 50 Sectional View ............................................................ 82
Figure 52 Aligning the Idle Gear Timing Marks..................... 51 Figure 106 Sensor Lever and Torque Cam Wear Points ..... 82
Figure 53 Oil Cooler – Bolt Tightening Sequence................. 51 Figure 107 Control Lever Shaft Assembly and Connecting
Figure 54 Installation of the Side Cover................................ 52 Link ............................................................................. 82
Figure 55 Installing the Injection Pump Rear Mounting Figure 108 Governor Springs ............................................... 83
Bracket ........................................................................ 52 Figure 109 Shifter and Sleeve Assembly Setting
Figure 56 Aligning the Gear Timing Marks ........................... 52 Dimension - Sectional View ........................................ 84
Figure 57 Installing the Timing Case Oil Seal....................... 53 Figure 110 Connecting Sleeve and Shifter Assembly .......... 84
Figure 58 Installing the Alternator and Mounting Bracket ..... 54 Figure 111 Installation of the Control Lever Shaft
Assembly .................................................................... 85
Figure 59 Installing the Vacuum Pump Oil Hoses ................ 54
Figure 112 Installation of the Torque Cam ........................... 85
Figure 60 Attaching the Lifting Equipment ............................ 55
Figure 113 Installing the Expansion Plugs ........................... 85
Figure 61 Removal of the Water Pump Impeller................... 60
Figure 114 Attaching the Cancel Spring to the Tension
Figure 62 Removal of the Drive Flange ................................ 60 Lever ........................................................................... 86
Figure 63 Removal of the Bearings and Spacers ................. 61 Figure 115 Installation of the Start Spring ............................ 86
Figure 64 Installation of the Water Pump Housing Seals ..... 61 Figure 116 Installation of the Governor Shaft....................... 87
Figure 65 Checking the Impeller Clearance.......................... 62 Figure 117 Installation of the Idling Spring Capsule ............. 87
Figure 66 Camshaft Coupling Tool ....................................... 63 Figure 118 Installation of the Pre-stroke Measuring
Figure 67 Universal Vice and Bracket Assembly .................. 64 Device ......................................................................... 88
Figure 68 Removing the Flyweight Locknut.......................... 64 Figure 119 Aligning the Adjusting Device Match Marks ....... 90
Figure 69 Removing the Flyweights...................................... 65 Figure 120 Positioning the Adjusting Device ........................ 90
Figure 70 Removal of the Connecting Link........................... 65 Figure 121 Adjustment of the Idle Setting Bolt ..................... 91
Figure 71 Removing the Tappet Holders .............................. 66 Figure 122 Adjustment of the Outer Idling Spring ................ 92
Figure 72 Removing the Tappet Assemblies ........................ 66 Figure 123 Adjustment of the Inner Idling Spring ................. 92
Figure 73 Removing the Spring Seat and Plunger ............... 67 Figure 124 Adjustment of the Governor Shaft Guide
Figure 74 Removing the Control Sleeves ............................. 67 Screw - Sectional View ............................................... 92
Figure 75 Removing the Delivery Valve Holders and Figure 125 Adjustment of the Governor Shaft Spring........... 93
Springs ........................................................................ 68 Figure 126 Adjustment of the Maximum Speed Setting
Figure 76 Removing the Delivery Valve Assemblies ............ 68 Bolt.............................................................................. 93
Figure 77 Checking the Plunger for Smooth Operation ........ 69 Figure 127 Adjustment of the Full-load Setting Bolt ............. 94
Figure 78 Checking the Control Rack and Pinion ................. 70 Figure 128 Adjustment of the Torque Cam Control Rod ...... 94

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Figure 129 Transfer Pump - Exploded View .........................95
Figure 130 Removal of the Priming Pump ............................96
Figure 131 Removal of the Check Valve...............................96
Figure 132 Removal of the Plug............................................96
Figure 133 Removal of the Piston.........................................97
Figure 134 Removal of the Tappet........................................97
Figure 135 Z Mark-to-Keyway Angle.....................................98
Figure 136 Removal of the Flyweight Spring Snap-ring........99
Figure 137 Installation of the Large and Small Cams .........100
Figure 138 Measuring the Flyweight Pin Distance..............100
Figure 139 Cam Pivot Pin Holes to Hub Dimensions..........100
Figure 140 Fuel Injector- Exploded View ............................101
Figure 141 Cleaning the Nozzle..........................................102
Figure 142 Cleaning the Nozzle Valve Seat .......................102
Figure 143 Cleaning the Nozzle Spray Holes .....................103
Figure 144 Inspection of the Injector Mating Faces ............103
Figure 145 Injector Spray Pattern Test ...............................104
Figure 146 Adjustment of the Starting Pressure .................105
Figure 147 Removal of the Turbine Housing ......................106
Figure 148 Checking the Journal Bearing Radial
Clearance ..................................................................107
Figure 149 Checking the Journal Bearing Axial Clearance.108
Figure 150 Installing the O ring ...........................................108

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 Figure 299 Removal of the Solenoid Switch....................... 206
Figure 300 Removal of the Solenoid .................................. 206
Figure 301 Removal of the Field Housing and Brush
Assembly .................................................................. 207
Figure 302 Removal of the Bearing Plate........................... 207
Figure 303 Removal of the Pinion Gear ............................. 207
Figure 304 Removal of the Pinion Cover and Plate ........... 208
Figure 305 Removal of the Clutch Lever and Pivot Bush... 208
Figure 306 Removal of the Pivot Bush and Pin.................. 208
Figure 307 Removal of the Pinion Bearing and Seal.......... 209
Figure 308 Installation of the Pivot Bush ............................ 210
Figure 309 Removal of the Vacuum Pump......................... 211
Figure 310 Disassembly of the Vacuum Pump .................. 211
Figure 311 Removal of the Alternator Rear Cover ............. 211
Figure 312 Removal of the Front Pulley and Cover ........... 212
Figure 313 Removal of the Front Cover Bearing................ 212
Figure 314 Removal of the Diode Assembly ...................... 212
Figure 315 Removal of the Diode Holder ........................... 213
Figure 316 Measuring the Slip Rings ................................. 213
Figure 317 Continuity Test of the Rotor and Slip Ring ....... 213
Figure 318 Earth Test of the Rotor and Slip Ring............... 214
Figure 319 Continuity Test of the Stator Coil...................... 214
Figure 320 Earth Test of the Stator Coil ............................. 214
Figure 321 Inspection of Brush Length............................... 214
Figure 322 Alternator Circuit Diagram ................................ 215
Figure 323 Measuring the Vacuum Pump Vanes............... 215
Figure 324 Measuring the Vacuum Pump Housing............ 215
Figure 325 Installation of the Vacuum Pump Oil Seal ........ 216
Figure 326 Reconnection of the Stator to the Diode
Holder ....................................................................... 216
Figure 327 Installation of the Rear Cover........................... 217
Figure 328 Installation of the Rear Cover Through Bolts ... 217

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Figure 329 Installation of the Vacuum Pump Rotor and
Vanes ........................................................................217
Figure 330 Installation of the Centre Plate..........................218
Figure 331 Installation of the Vacuum Pump ......................218

LIST OF TABLES
Page No Page No
Table 10 Fuel System Specifications.................................. 109

Table 5 Valve Spring Tolerances ..........................................27

Table 6 Piston Ring Clearance .............................................39
Table 7 Piston Ring Gap Clearance......................................46 Table 17 Electrical Specifications ....................................... 222
Table 8 Engine Group Specifications....................................57
Table 9 Water Pump Specifications ......................................62

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ENGINE

Cylinder Head
16. To overhaul the cylinder head proceed as follows:
a. Remove the cylinder head in accordance with Medium Repair – Group 1.
b. Install a valve spring compressor, special tool 9-8523-1426-0, over a valve, compress the valve springs
and remove the two collets (Figure 2).

Figure 2 Valve Removal

c. Remove the valve spring compressor; remove the spring retainer, the valve springs and the valve.
d. Mark the cylinder number on each part after removal. Repeat the procedure for each valve.
17. Check the cylinder head for distortion, using a straight edge and a feeler gauge (Figure 3). If the distortion
exceeds 0.2 mm (0.008 in) the cylinder head will require machining. Before machining the cylinder head, measure the
thickness with a micrometer. The standard thickness is 89.95 to 90.05 mm (3.541 to 3.545 in). The head may be
machined to 0.3 mm (0.012 in) under the standard minimum thickness. If the head is still not true after machining to
the limit of 89.65 mm (3.530 in), replace the head.

Figure 3 Checking the Cylinder Head Distortion

a. Check the condition of all studs, clean the threads with an appropriate die and replace any stud found
to be bent or damaged. Run an appropriate tap into all threaded holes to dress the threads.
b. To replace the expansion plugs, pierce the plug with a sharp instrument, then prise the plug out. Install
new plugs ensuring they are correctly seated.

NOTE
The small expansion plugs may be difficult to remove. If necessary, use a drill, but
do not exceed the outer diameter of the expansion plug.

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 c. If the cylinder head is serviceable, clean the cylinder head thoroughly, removing all trace of carbon and
metal cuttings.
d. Check the valve contact width of the valve seat. If the contact width exceeds the 2.0 mm (0.079 in)
limit, insert the valve which was originally positioned in the port, ensuring that the valve head
thickness (Figure 4) is not less than 1.0 mm (0.039 in), and measure the amount of depression between
the cylinder head surface and the head of the valve (Figure 5). The standard dimension is 1.0 to
2.5 mm (0.039 to 0.098 in). If the dimension is within these limits, carefully grind or cut the valve to
obtain the correct contact width and recheck the amount of depression. If the depression exceeds 2.5
mm (0.098 in) or if cracks or surface imperfections are evident, replace the valve seat. Repeat this
procedure for each valve seat.

Figure 4 Measuring the Valve Head Thickness

Figure 5 Measuring the Valve Depression

e. If the valve seats are to be removed, run a bead of weld on the angled face of the valve seat (Figure 6).
As the weld cools, this will cause the valve seat to shrink, enabling easy removal of the valve seat.

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 Figure 6 Removing the Valve Seat

NOTE
To assist with the installation of the valve seat insert, chill the insert in a freezer or
dry ice.
f. Ensure that the counterbore is clean, position the new valve seat insert over the counterbore and press
it into place using a bench press.
g. Carefully grind the valve seat to an angle of 45 degrees, ensuring that the contact width of the seating
face is 1.5 mm (0.059 in). Repeat this procedure for each valve seat.
h. Before lapping the valves to the valve seats, check the valve stems for wear. Using a micrometer,
measure the valve stems in three places (Figure 7). The standard diameters are:
(1) inlet valve - 8.88 to 8.961 mm (0.350 to 0.353 in); and
(2) exhaust valve - 8.88 to 8.936 mm (0.350 to 0.352 in).

Figure 7 Valve Stem Measuring Points

i. Replace any valve that is worn below 8.88 mm (0.350 in).
j. Check the valve guides for wear by installing the valves in their respective guides and, using a dial
indicator (Figure 8), push the valve stem back and forth against the micrometer plunger. The standard
clearances are:
(1) inlet valve guides - 0.039 to 0.200 mm (0.0015 to 0.008 in); and
(2) exhaust valve guides - 0.064 to 0.250 mm (0.0025 to 0.010 in).

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 Figure 8 Measuring the Valve Guide Wear
k. Replace any valve guide if the clearance exceeds the limit.
l. Using special tool 1-8522-0001-0 and a hammer, remove the worn guide(s) from the cylinder head.
Position the guide on the cylinder head and using the same tools knock the guide into the head, leaving
the guide protruding 13.9 to 14.3 mm (0.547 to 0.563 in) above the cylinder head.
m. Lap the valves to their respective seats ensuring that both the valve and seat are lapped in evenly.
Remove the valves and wipe all trace of lapping compound from the valves. Clean the cylinder head
thoroughly ensuring that all cuttings and filings are removed and that the water jacket and oil galleries
are clear.
n. Liberally coat the valve stems and guides with clean engine oil and install each valve into its respective
port.
o. Position new valve stem seals over the top of each valve guide. Using a hammer and special tool
1-8522-1005-0, install each seal (Figure 9).

Figure 9 Installing the Valve Stem Oil Seal

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p. Before installing the valve springs, check the condition of each spring. Check for cracks or damage and
also check the free length, tension and inclination of the spring (Figure 10).

Figure 10 Checking the Free Length, Inclination and Tension of the Valve Springs
q. Replace any spring that is cracked or damaged or is below the limits listed in Table 5.

Table 5 Valve Spring Tolerances

Free Length and Inclination
mm (in)
Free length Inner 50.0 to 52.4 (1.970 to 2.063)
Outer 50.65 to 53 65 (1.994 to 2.112)
Inclination Inner 1.0 (0.039)
Outer 1.0 (0.039)
Tension
Set length mm (in) kg (lb)
Inner 42.0 (1.65) 9.9 to 10.9 (21.83 to 24.03)
Outer 44.0 (1.73) 20.0 to 23.0 (44.10 to 50.71)

r. Position the inner and outer springs over their respective valve with the tighter wound coils of the
springs towards the cylinder head (Figure 11).

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 Figure 11 Valve Spring
s. Install a valve spring retainer over the valve springs, install a valve spring compressor (special tool
9-8523-1426-0) and compress the valve springs. Install the two collets ensuring that they are properly
positioned and correctly seated on the valve stem (Figure 12) then release the spring compressor.
Repeat this procedure for each valve and spring assembly.

Figure 12 Valve Installation

t. Install the cylinder head in accordance with Medium Repair – Group 1.

Engine
18. Disassembly. Disassemble the engine as follows:

a. Refer to Medium Repair – Group 1 for the removal of the following:(1)

the engine, and
(2) the cylinder head.
b. Remove the bolts and nuts securing the engine mounting brackets to the engine and remove the
mounting brackets.
c. Replace the engine mountings if they are cracked or damaged.
d. Position the engine in a universal engine overhaul stand and secure the engine to the stand.

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e. Position a suitable container beneath the engine, remove the drain plug from the oil pan and drain the
oil from the engine. Reinstall the drain plug.

NOTE
The oil filter will contain some residual oil; care should be taken to avoid spillage.
f. Remove the oil filter, and the two bolts securing the oil feed pipe to the oil cooler.
g. Remove the four bolts securing the oil filter adapter to the engine and remove the adapter.
h. Disconnect the oil feed pipe from the injection pump and from the engine block. Plug the oil feed port
in the injection pump to prevent the ingress of dust or dirt.
i. Remove the nut and washer securing the injection pump adapter to the rear mounting bracket
(Figure 13).

Figure 13 Removal of the Injection Pump Rear Mounting Bracket

j. Remove the two bolts securing the mounting bracket to the engine and remove the mounting bracket
and the oil feed pipe from the engine.
k. Remove the plug from the timing cover (Figure 14) and remove the seven bolts (one is accessed from
the rear of the timing case below the injection pump) securing the injection pump to the timing case.

Figure 14 Removal of the Injection Pump

l. Remove the injection pump from the engine, place a protective cover over the injection pump and
place the pump aside.
m. Disconnect the vacuum pump oil feed and return hoses from the engine block.
n. Disconnect the vacuum hose from the vacuum pump.

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 o. Remove the alternator adjusting bolt and mounting bolts and remove the alternator and fanbelt.
p. Remove the four bolts securing the cooling fan to the water pump drive flange; remove the fan, spacer
and drive pulley.
q. Disconnect the heater hose from the water pump.
r. Remove the bolts securing the water pump to the engine block and remove the water pump.
s. Remove the two nuts and one bolt securing the starter motor to the flywheel housing and remove the
starter motor.

Under no circumstances is compressed air to be used to remove dust from the

clutch assembly and flywheel housing. Dust from the clutch assembly and
flywheel housing can be a health risk if inhaled.
t. Remove the clutch pressure plate and clutch plate by alternately slackening each of the twelve bolts to
prevent distortion of the pressure plate housing.
u. Lock the flywheel to prevent it from turning and slacken the crankshaft pulley retaining nut.
v. Remove the six bolts securing the flywheel to the crankshaft and remove the flywheel.
w. Remove the side cover plates from the left-hand side of the engine and discard the gaskets and bolt
seals.
x. Remove the bolts securing the oil cooler to the engine block and remove the oil cooler.
y. Remove the nut and washer securing the crankshaft pulley to the crankshaft, install special tool
9-8521 -0063-0 and remove the pulley.
z. Remove the bolts securing the timing cover to the timing case and remove the cover. Remove and
discard the oil seal.
aa. Invert the engine and remove the nuts and bolts securing the oil pan to the engine block.
bb. Remove the oil pan, supporting plates and the gaskets. Discard the gaskets.
cc. Remove the two bolts securing the oil feed pipe to the engine block.
dd. Remove the two bolts securing the oil pump to the engine block and remove the oil pump.
ee. Remove the thirteen bolts and washers securing the flywheel housing to the engine block and remove
the housing. Pry out and discard the oil seal.
ff. Prior to removing the pistons and connecting rods, turn the engine over (right way up) and remove all
carbon deposits and/or ridging from the top of each cylinder. Invert the engine and remove the bearing
caps from the connecting rods ensuring that each bearing cap, connecting rod and piston are match
marked with the relevant cylinder number.
gg. Remove each piston and connecting rod assembly by pushing the assembly out through the cylinders.
hh. Before further removal of components from the engine, check the idle gear end-play with a feeler
gauge (Figure 15). The standard end-play is 0.058 to 0.20 mm (0.002 to 0.008 in).

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 Figure 15 Checking the Idle Gear End-play
ii. Using a dial indicator check the backlash between the crankshaft, idle and camshaft gears (Figure 16).
The standard backlash is 0.10 to 0.30 mm (0.004 to 0.012 in).

Figure 16 Checking the Timing Gear Backlash

jj. Using a feeler gauge, check the crankshaft end-play (Figure 17). The standard dimension is 0.15 to
0.45 mm (0.006 to 0.018 in).

Figure 17 Checking the Crankshaft End-play

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 kk. Using the sequence shown in Figure 18, remove the crankshaft main bearing bolts and bearing caps,
ensuring that each bearing cap is numbered. With the aid of a suitable piece of wire, push the thrust
bearings out.

Figure 18 Main Bearing Bolt Removal Sequence

ll. Lift the camshaft followers from the camshaft lobes and support the followers in the raised position
with suitable clips or tape, ensuring that there is sufficient clearance to remove the camshaft.
mm. Remove the oil pump cover from the left hand side of the engine block. Using an Allen key, remove
the grub screw locating the thrust bearing.
nn. Remove the thrust bearing and the oil pump drive pinion.
oo. Rotate the camshaft drive gear to align the holes in the gear with the thrust plate retaining bolts.
pp. Remove the retaining bolts and carefully withdraw the camshaft from the engine block, ensuring that
the camshaft lobes do not scratch or damage the camshaft bearings.

NOTE
The camshaft followers will drop from the engine when the support is removed.
qq. Match mark or number the camshaft followers to ensure correct location at installation. Remove the
device supporting the followers and remove the followers.
rr. Remove the two bolts securing the idle gear thrust collar and shaft to the engine block and remove the
idle gear assembly.
ss. Remove the bolts securing the timing case to the engine block and remove the timing case. Lift the
crankshaft from the engine.
tt. Remove all the expansion plugs and threaded plugs from the engine block.
19. Cleaning and Inspection. Clean and inspect the engine as follows:

a. Thoroughly clean the engine block and engine components with a recommended cleaning agent and
blow them dry with compressed air.
b. Ensure all carbon deposits and gasket residues are removed and inspect the engine block for cracks,
damage or wear. Repair or replace the engine block as necessary.
c. Inspect the camshaft followers for pitting, cracking or wear (Figure 19). If no fault is evident, measure
the diameter of the follower with a micrometer. The standard dimension is 27.92 to 27.98 mm

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 (1.100 to 1.102 in). Replace any follower which is pitted, cracked or has irregular wear, or if the
diameter is worn below the limit.

Figure 19 Camshaft Follower Wear Patterns

d. Check a camshaft follower bore in the engine block with an internal micrometer (Figure 20) and
subtract the diameter of the follower, removed from that bore, from the dimension found. The standard
clearance is 0.02 to 0.10 mm (0.0008 to 0.0039 in). Repeat this procedure for each bore and camshaft
follower. Replace the engine block if any bore exceeds the limit.

Figure 20 Measuring Camshaft Follower and Bore Wear

NOTE
Each cylinder liner and piston form a matched set and should not be interchanged. If
a cylinder liner replacement is required the respective piston must also be replaced.

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 e. Measure the bore of each cylinder liner by inserting an inside diameter micrometer 20 mm down into
the cylinder bore. Take a reading from two points approximately 90 degrees apart (Figure 21). The
standard dimension of the bore is 102.021 to 102.20 mm (4.0166 to 4.0236 in). Replace the cylinder
liners if they are worn beyond this limit in accordance with Para 20.

Figure 21 Measuring the Cylinder Bore

f. Position the camshaft in V-blocks and with a micrometer measure the diameter of the camshaft bearing
journals (Figure 22). The standard dimension is 55.60 to 55.97 mm (2.1889 to 2.2035 in). Position a
dial indicator on the centre bearing and check the camshaft run-out. If the run-out exceeds 0.1 mm
(0.0039 in) or the journal wear is below the limit, replace the camshaft.

Figure 22 Measuring the Camshaft Bearing Journals

g. Using an internal micrometer, measure the internal diameter of the camshaft bearings (Figure 23). The
standard diameter is 56.00 to 56.03 mm (2.2047 to 2.2059 in). If the camshaft is serviceable, subtract
the camshaft bearing journal dimensions from the internal dimensions of the camshaft bearings. The
standard clearance dimension is 0.03 to 0.l5 mm (0.0012 to 0.0059 in). If the clearance exceeds the
limit, replace the camshaft bearings. Refer to Para 22. for the camshaft bearing removal procedure.

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 Figure 23 Measuring the Camshaft Bearings
h. Measure the height of the camshaft lobes with the micrometer. The standard height of the lobes is
47.7 mm (1.878 in) and the limit is 46.5 mm (1.830 in), also inspect the oil pump drive gear. Replace
the camshaft if the lobes are worn below the limit or if the oil pump drive gear is cracked, damaged or
excessively worn.
i. With a feeler gauge, measure the clearance between the camshaft Number one bearing journal and the
thrust plate. The standard clearance is 0.050 to 0.200 mm (0.0020 to 0.0079 in).
j. If the thrust plate wear exceeds the limit or the timing gear backlash is excessive, clamp the camshaft
securely in a soft-jawed vice and remove the timing gear retaining bolt. Using a puller (special tool
5-8840-0086-0), remove the timing gear and the thrust plate from the camshaft. Install a new thrust
plate and, using a bench press, install the timing gear.
k. If the crankshaft gear backlash was excessive, remove the gear using special tool 9-8521-0141-0 and
with an external micrometer measure the bearing journals on the crankshaft (Figure 24). For the main
bearing journals, the standard dimension is 79.000 to 79.925 mm (3.1102 to 3.1467 in). The
connecting rod bearing journal standard dimension is 63.000 to 63.944 mm (2.4803 to 2.5174 in).
Check each journal for taper and ovality. Discard the crankshaft if the wear exceeds the limits.

Figure 24 Measuring the Crankshaft Bearing Journals

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 l. With the crankshaft cradled on V-blocks, check for bend or run-out with a dial indicator positioned on
the centre main bearing journal (Figure 25). The crankshaft should be supported on the main bearing
journals at each end. Ensure that bearing journal wear is taken into consideration when measuring the
run-out. Standard run-out is 0.05 mm (0.002 in) or less, and the limit is 0.30 mm (0.012 in). If the
run-out exceeds the limit, replace the crankshaft.

Figure 25 Measuring the Crankshaft Run-out

m. Inspect the crankshaft oil seal journals for any abrasion or scoring which may have been caused by
previous oil seals. Carefully remove any burrs or rough areas with emery paper or a fine file.
n. Before installing new bearings, check the bearing spread (Figure 26). The spread limit for main
bearings is 85.0 mm (3.35 in) and for the connecting rod big-end 68.0 mm (2.68 in). Install each half of
each bearing into its respective position and check that a slight pressure is required to seat the bearing.
Replace the set if the bearings are not to specification.

Figure 26 Measuring the Bearing Spread

o. Install the main bearing caps, together with the bearings, onto the engine block, ensuring that they are
seated squarely and in their correct location. Torque the retaining bolts to 225 to 245 N.m
(166 to 181 lbf.ft). Lubricate the bearing shells with clean engine oil and with an internal micrometer,
measure the diameter of the bearings (Figure 27). The nominal diameter is 80.0 mm (3.15 in). Subtract
the bearing journal diameter from the diameter of the bearing and check that the clearance falls within
the standard dimension of 0.039 to 0.110 mm (0.0015 to 0.0043 in). If the clearance exceeds the limit,
replace the crankshaft.

36
 Figure 27 Measuring the Main Bearings
p. Install the new bearings into the connecting rod big-end cap. Install the cap and torque the retaining
bolts to 39 N.m (29 lbf.ft), tighten each bolt a further 60 to 90 degrees. With an internal micrometer,
measure the inside diameter of the bearing (Figure 28). The nominal diameter is 64 mm. Subtract the
crankshaft bearing journal diameter from the diameter of the bearing to obtain the clearance. The
standard clearance is 0.10 to 0.073 mm (0.004 to 0.0029 in). If the clearance exceeds the limit, replace
the crankshaft.

Figure 28 Measuring the Connecting Rod Bearing

q. Remove the piston rings from the pistons, then remove the gudgeon (piston) pin retaining snap-rings
from each piston and push the gudgeon pin out.
r. Measure the diameter of the gudgeon pin with a micrometer (Figure 29). The nominal dimension is
35.00 mm (1.377 in) and the limit is 34.95 mm (1.375 in). Replace the gudgeon pin if the wear exceeds
the limit.

37
 Figure 29 Measuring the Gudgeon Pin

NOTE
Each piston and cylinder liner form a matched set and should not be interchanged. If
a piston replacement is required, the respective cylinder liner must also be replaced.
s. Using an internal micrometer, measure the diameter of the gudgeon pin bore in the piston. The
diameter should be no more than 0.005 mm (0.0002 in) smaller than the diameter of the gudgeon pin,
creating an interference fit between the pin and the piston. If the bore of the piston is worn so that an
interference fit is no longer possible, replace the piston.
t. Before checking the small-end bush on the connecting rod for wear, ensure that the connecting rod is
serviceable. Install the connecting rod on an alignment jig and check it for twisting or bending
(Figure 30). The standard twist or bend is less than 0.05 mm (0.002 in) per 100 mm of the connecting
rod length. Replace the connecting rod if twist or bend exceeds 0.200 mm (0.0079 in) per 100 mm.

Figure 30 Checking the Connecting Rod Alignment

u. Using an inside micrometer, check the inside diameter of the connecting rod small-end bush. The
standard dimension is 35.017 to 35.025 mm (1.3786 to 1.3789 in). Subtract the diameter of the
gudgeon pin (Para 16. q.) from the diameter of the bush to obtain the amount of clearance. The
standard clearance is 0.012 to 0.05 mm (0.0005 to 0.002 in). If the clearance limit is exceeded and the
gudgeon pin is within the standard dimension, replace the connecting rod small-end bush.
v. Remove the small-end bush. With the aid of a press and a suitable adapter, install a new bush. Machine
the bush out to obtain a clearance of 0.012 to 0.025 mm (0.0005 to 0.0010 in) between the gudgeon pin
and the bush.
w. Using a micrometer, measure the diameter of the pistons. Place the pistons upside down on the work
bench, position the micrometer 82 mm up from the crown of the piston and at 90 degrees to the

38
 centreline of the gudgeon pin bore and measure the diameter (Figure 31). Subtract the diameter of the
piston from the inside diameter of the cylinder liner (Para 16. e.) to obtain the piston-to-cylinder liner
clearance. The standard clearance is 0.057 to 0.075 mm (0.0022 to 0.0030 in). If the dimension
obtained exceeds the standard clearance, replace the piston and the cylinder liner.

Figure 31 Measuring the Piston Diameter

NOTE
Each piston and cylinder liner forms a matched set and should not be interchanged.
If a piston replacement is required, the corresponding cylinder liner must also be
replaced.
x. Ensure that all trace of carbon is removed from the piston ring grooves. With the aid of a set of
standard piston rings and feeler gauges, measure the clearance between the piston ring and the ring
land (Figure 32). Refer to Table 6 for the standard clearances and limits. Replace any piston where the
clearance exceeds the limits.

Figure 32 Measuring the Piston Ring Clearance

Table 6 Piston Ring Clearance

Standard Limit
Piston Ring
mm (in) mm (in)
0.085 to 0.11 0.2
First compression
(0.0033 to 0.0043) (0.008)
0.030 to 0.055 0.15
Second compression
(0.0012 to 0.0022) (0.006)
0.030 to 0.07 0.15
Oil
(0.0012 to 0.003) (0.006)

39
 y. Measure the diameter of the idle gear shaft with a micrometer (Figure 33). The standard dimension is
44.84 to 44.97 mm (1.765 to 1.770 in). Replace the idle gear shaft if the wear exceeds the limit.

Figure 33 Measuring the Idle Gear Shaft

z. If the idle gear shaft is within specification, measure the internal diameter of the idle gear (Figure 34).
Subtract the shaft diameter from the gear diameter to obtain the running clearance. The standard
clearance is 0.009 to 0.060 mm (0.00035 to 0.0024 in). If the running clearance exceeds the limit, or if
the gear backlash (measured at disassembly) exceeds the limit, replace the idle gear.

Figure 34 Measuring the Idle Gear

Cylinder Liners
20. Cylinder Liner Removal. Remove the cylinder liners as follows:
a. Position the cylinder liner remover, special tool 9-8523-1169-0, over the defective cylinder liner,
ensuring that the tool is squarely seated and firmly supported on the engine block. Install the foot
(ankle) of special tool 9-8523-2557-0 onto the leg of the remover, ensuring that the foot is correctly
positioned on the liner. Operate the cylinder liner remover and withdraw the liner from the engine
block (Figure 35). Remove other cylinder liners as necessary, in the same manner.

40
 Figure 35 Removing the Cylinder Liners
b. After removing the cylinder liners, check the engine block deck for distortion using a straight edge and
a feeler gauge (Figure 36). If the distortion exceeds 0.20 mm (0.008 in) the engine block deck will
require machining. The maximum allowable amount of metal that can be removed is 0.3 mm
(0.012 in). If distortion still exists after the maximum amount of metal has been removed, replace the
engine block.

Figure 36 Checking the Engine Block Distortion

NOTE
The difference in the amount of protrusion from liner-to-liner should be less than
0.03 mm (0.0012 in).
c. If the engine block is serviceable after machining, it will be necessary to cut the cylinder liner lip
counterbore the same amount to ensure that the protrusion of the cylinder liners (when installed) is
between 0.03 to 0.10 mm (0.0012 to 0.0039 in) above the engine block deck.
d. Check the bores in the engine block for scoring, damage or wear, also measure the bore diameter. If
the bore diameter exceeds the standard dimension of 105.001 to 105.010 mm (4.1339 to 4.1342 in) or
if excessive scoring, damage or wear is evident, replace the engine block. Ensure that the bore is
machined to allow for an interference fit of between 0.001 to 0.019 mm (0.00004 to 0.00075 in) when
the cylinder liner is installed.
e. Overhaul the oil pump in accordance with Medium Repair – Group 1.
f. Overhaul the water pump (Group 2).

41
21. Cylinder Liner Installation. Install the cylinder liners as follows:

NOTE
To assist with the installation of the cylinder liners, chill the liners in a freezer or
with dry ice.
a. Ensure that the engine block is thoroughly clean and all trace of machine cuttings is removed from
each of the cylinder liner bores. Position the engine block on a hydraulic press, then start a new
cylinder liner into a bore. Position special tool 9-8523-2554-0 over the cylinder liner and press the
liner into the block by initially applying a load of 500 kg (1100 lbs), apply a final load of 2500 kg
(5500 lbs) to ensure that the cylinder liner is properly seated (Figure 37). Repeat this procedure for
each cylinder liner being replaced.

Figure 37 Installing the Cylinder Liners

b. After installing the cylinder liners, verify that each liner is protruding 0.03 to 0.10 mm
(0.0012 to 0.0039 in) above the engine block deck and that the variation of the amount of protrusion
between the cylinder liners is less than 0.03 mm (0.0012 in). Use a straight edge and a feeler gauge to
check the amount of protrusion (Figure 38).

Figure 38 Checking the Cylinder Liner Protrusion

c. If one or more of the cylinder liners exceed the protrusion limit, carefully machine the liners down to
the desired dimension. Clean the engine thoroughly to ensure that all metal filings or cuttings are
removed.

42
Camshaft Bearings
22. Camshaft Bearing Removal. Remove the camshaft bearings as follows:
a. Position special tool 9-8523-1818-0 over the camshaft bearing and drive the bearing from the engine
block by hitting the end of the special tool with a hammer (Figure 39). Repeat this procedure for each
bearing.

Figure 39 Removal of the Camshaft Bearing

b. Check the bearing bores in the engine block for burrs. Remove any burrs with a scraper or fine file and
clean the bores ensuring that all metal filings are removed.
c. Check the camshaft bearing oil galleries for blockage and clear as necessary.
23. Camshaft Bearing Installation. Install the camshaft bearings as follows:

NOTE
The Number one camshaft bearing (timing case end) has two oil holes, while the
other bearings have only one.
a. Position the new bearing over the bearing bore and align the oil hole with the port in the bearing bore.
Using special tool 9-8523-1818-0 and the hammer, install the bearing. Ensure that the oil hole and the
port are aligned. Repeat this procedure with the other bearings.
24. Engine Reassembly. Reassemble the engine as follows:
a. Position the engine block on a universal engine overhaul stand and secure the engine block to the
stand.
b. Using special tool 9-8522-0033-0 and a hammer, install the drive gear onto the crankshaft (Figure 40).
Install the main bearing shells and the main bearing caps into the engine block.

Figure 40 Installing the Drive Gear

43
 c. Liberally coat the bearings with clean engine oil and position the crankshaft over the bearings in the
engine block.
d. Install a new thrust bearing on the timing case side of the centre main bearing, with the oil grooves
against the rotating face of the crankshaft.
e. Install the main bearing caps ensuring that each cap is correctly located in relation to the number
placed on the cap during disassembly.
f. Smear the threads, shaft and head of the bearing cap retaining bolts with clean engine oil.
g. Install and torque the bolts to 225 to 245 N.m (166 to 181 lbf.ft) in the sequence shown (Figure 41),
while tapping the bearing cap from side to side to centralize and seat the bearing correctly.

Figure 41 Crankshaft Bearing Bolt Tightening Sequence

h. Ensure that the crankshaft revolves freely without binding.
i. Position the timing case to engine block gasket on the back of the timing case and insert two retaining
bolts through the timing case to hold the gasket in position.
j. Locate the timing case on the front of the engine block and screw in two retaining bolts. Install the four
remaining bolts and torque all six bolts to 21 to 30 N.m (15 to 22 lbf.ft).
k. Lubricate the camshaft followers and each of the bores with clean engine oil. Position the camshaft
followers in their corresponding bores and ensure that each follower moves freely within the bore.
Secure each of the followers in the fully raised position using a suitable clip or tape.
l. Ensure that the camshaft bearings in the engine block are clean and lubricate each bearing with a
liberal amount of clean engine oil.
m. Carefully install the camshaft ensuring that the lobes are not dragged across the bearings. Install and
torque the thrust plate retaining bolts (Figure 42) to 21 to 30 N.m (15 to 22 lbf.ft).

Figure 42 Installing the Camshaft

n. Invert the engine so that the engine block deck is uppermost.

44
 Use suitable personal protection equipment and mechanical aids to prevent
personal injury when handling pistons heated to 60 degrees C. Burns will result
in handling heated pistons without wearing personal protection equipment.

NOTE
Heating the pistons will facilitate installation of the gudgeon pin.
o. Place the pistons in a suitable heating device and heat them to approximately 60 degrees C to facilitate
fitting the gudgeon pins.
p. Using suitable personal protection equipment and mechanical aids, position a piston over the small end
of a connecting rod ensuring that both the piston and connecting rod are matched with their respective
cylinder. Ensure the match marks on the connecting rod (Figure 43) are positioned towards the
camshaft and the Front Mark on the piston is positioned toward the front of the engine block
(Figure 44).

Figure 43 Connecting Rod Match Mark Location

Figure 44 Piston Front Mark Location

q. Align the gudgeon pin holes in the piston and connecting rod. Coat the outer surface of the gudgeon
pin with clean engine oil and push the gudgeon pin into position in the piston and connecting rod.
Install the gudgeon pin retaining snap-rings into the grooves in the piston (Figure 45) ensuring that the
snap-rings are correctly seated. Repeat the procedure for each piston and connecting rod set.

45
 Figure 45 Installing the Snap-rings
r. Repeat the procedure detailed in sub-paragraphs p to q for each piston and connecting rod set.
s. Check the piston ring gap by installing the piston rings in the cylinders and measuring the gap with
feeler gauges (Figure 46). Refer to Table 7 for the correct ring gap limits.

Figure 46 Checking the Piston Ring Gap

Table 7 Piston Ring Gap Clearance

Standard Limit
Piston Ring
mm (in) mm (in)
0.25 to 0.45 1.5
First compression
(0.010 to 0.018) (0.059)
0.2 to 0.4 1.5
Second compression
(0.008 to 0.016) (0.059)
0.2 to 0.4 1.5
Oil
(0.008 to 0.016) (0.059)

t. If the piston ring gap is insufficient, clamp the piston ring securely in a soft-jawed vice and carefully
file the end of the ring with a suitable fine file. Ensure that only a small portion of the ring end is
protruding above the vice jaws to prevent ring distortion and/or breakage. Check the ring gap regularly
to ensure that the tolerance is not exceeded.
u. Once the piston rings are correctly sized, install the rings onto each piston with the aid of a piston ring
installer. Ensure that the first and second compression rings are installed with the face marked NPR or
TOP uppermost, and the ring gaps positioned as shown (Figure 47).

46
 Figure 47 Installing the Piston Rings
v. Lubricate the piston rings, piston skirt and the connecting rod big-end bearing with a liberal amount of
clean engine oil.

NOTE
Ensure that the piston and connecting rod assembly is correctly orientated.
w. Install a ring compressor, special tool 9-8522-1251-0, over the piston and compress the piston rings.
Remove the connecting rod bearing cap (if not previously removed), lubricate both halves of the
connecting rod bearing with clean engine oil and install the piston and connecting rod assembly into its
respective cylinder. Ensure that the Front Mark on the piston is positioned toward the front of the
engine block.
x. Guide the connecting rod big-end bearing over the connecting rod journal on the crankshaft while
pushing the piston into the cylinder. Install the remaining pistons in the same manner.
y. Install the remaining pistons by repeating the procedure detailed in sub-para v to x.
z. Position the engine on its side.
aa. Lubricate a big-end cap bearing with a liberal amount of clean engine oil. Locating the connecting rod
on the crank pin journal, install the big-end bearing cap to the appropriate connecting rod and install
the retaining bolts.
bb. Tighten the retaining bolts to 39 N.m (29 lbf.ft), while tapping the bearing cap from side to side to
centralise and seat the bearings correctly. Tighten the bolts a further 60 to 90 degrees.
cc. Install the remaining big end bearing caps by repeating the procedure detailed in sub-para z and bb.
dd. Position the engine with the sump face uppermost.
ee. Install the flywheel housing as follows:
(1) Apply a narrow bead of a suitable sealant to the mounting surface of the flywheel housing and
install the housing ensuring that it is properly located over the dowel pins. Install the smaller
retaining bolts, together with new lock-washers and tighten them to 21 to 30 N.m (15 to
22 lbf.ft).
(2) Install the large retaining bolts, together with new lock-washers and tighten them to 123 to
152 N.m (90 to 112 lbf.ft).

47
 ff. Install the rear crankshaft oil seal (using special tool EYA 3737) as follows:
(1) Clean and inspect the crankshaft oil seal journal for any abrasion or scoring which may have
been caused by previous oil seals.
(2) Carefully remove any burrs or rough areas with emery paper or a fine file. Thoroughly clean
away any resulting filings or emery paper dust. If wear is greater than 0.1 mm deep or wide, fill
the damaged area with Loctite 3805 to prevent oil seeping under the seal.

Emery dust or metal filings must not be allowed to enter the engine and must
be completely removed before continuing.
(3) Inspect the seal installation, crank plate and push cone and carefully remove any burrs or sharp
edges, particularly those on the outer diameter of the crank plate.

Handle the crank plate and push cone carefully during use to avoid causing
burrs or sharp edges that may damage the seal during installation and cause
early failure.
(4) Fit the crank plate to the crankshaft, with one hole positioned at the dowel pin and the other
three holes aligned with the flywheel bolt holes (Figure 48). Secure the crank plate with the
short screws ensuring the screws are evenly tightened.

Figure 48 Crank Plate Secured to the Crankshaft

NOTE
Before installation, apply only clean engine oil to the outside surface of the new type
of seal. Do not apply any type of sealant in an attempt to improve the sealing
between the housing and the outer surface of the new seal.
(5) Lubricate the outside surface of the seal with clean engine oil and do not apply any type of
sealant in an attempt to improve the sealing between the housing and the outer surface of the
seal.
(6) Position the seal over the crank plate so that the part number stamped on the flange of the green
inner sleeve is visible. Push the seal, by hand, along the crank guide until it contacts the
crankshaft (Figure 49).

48
Figure 49 Rear Crankshaft Oil Seal Located on the Crank Plate Ready for Installation
(7) Position the push cone over the crank plate, locate it onto the seal and then engage the long
screw into the crank plate (Figure 50).

Figure 50 Push Cone Located on Crank Plate and Against Seal

To prevent the rubber seal from creeping back and to ensure the seal remains
in the correct position during service, the push cone must be left tight against
the seal for at least two minutes.
(8) Rotate the screw to push the seal into its housing, until hard resistance is felt. Leave the push
cone in place for at least two minutes before loosening the screw.
NOTE
The presence of green bore sealant after the seal has been installed does not indicate
there is a fault with the newly installed seal.
(9) Remove the push cone and crank guide and clean away any green bore sealant that may have
been forced from inside the seal.

NOTE
The inner green flange on the seal will stand proud of the housing after installation.
(10) The inner green flange on the seal will stand proud of the housing after installation. This is
intentional and no attempt should be made to alter the position of the seal as it is preset by the
step on the push cone tool.

49
 (11) Clean away any excess engine oil from the general area.
gg. Install the oil pump drive pinion, together with a new thrust bearing, into the engine block. Install and
securely tighten the thrust bearing locating grub screw. Position a new gasket on the cover and install
the cover. Install the two retaining bolts and tighten them securely.
hh. Pour clean engine oil into the oil pump intake to prime the oil pump, position the oil pump on the
engine block ensuring that the drive shaft is properly engaged with the drive pinion. Install the two
retaining bolts and torque them to 42 to 62 N.m (31 to 46 lbf.ft).
ii. Install the two bolts that secure the oil feed pipe to the engine block and tighten them securely.
jj. Fit new sealing sleeves to the oil pan retaining bolts and studs.
kk. Position a new gasket on the bottom of the engine block, place the oil pan over the gasket
ll. Position a new gasket and the supporting plates over the rim of the oil pan. Install the retaining bolts
and nuts and torque them to 10 to 20 N.m (8 to 15 lbf.ft).
mm. Install a new sealing washer onto the drain plug and install and securely tighten the drain plug.
nn. Invert the engine.
oo. Install new expansion plugs into their appropriate positions on the engine block, (e.g. water jacket and
camshaft rear bearing bore).
pp. Install the threaded plugs into the oil galleries ensuring that the plugs are tightened securely.
qq. Install the crankshaft extension, complete with a new spigot bush, into the crankshaft.
rr. Install the flywheel locating dowel pin if it was previously removed.
ss. Position the flywheel on the crankshaft, lock the flywheel to prevent it from turning, smear the threads
of the retaining bolts with engine oil and install the bolts. Torque the bolts, in the sequence shown
(Figure 51), to 142 to 172 N.m (105 to 127 lbf.ft).

Figure 51 Flywheel Bolt - Tightening Sequence

tt. Position the clutch plate on the flywheel and install special tool 18G79 to hold the clutch plate in
position. Install the pressure plate ensuring the dowel pins in the flywheel align with the respective
holes in the pressure plate. Install the twelve retaining bolts and alternately tighten each of the bolts to
prevent distortion of the pressure plate. Torque the bolts to 16 N.m (12 lbf.ft), remove the clutch
aligning tool and the flywheel locking device.
uu. Install the idle gear shaft using the thrust collar retaining bolts as a guide and ensure that the oil port is
facing toward the camshaft.
vv. Rotate the crankshaft to bring Number one cylinder onto Top Dead Centre (TDC), which also brings
the timing mark on the gear toward the idle gear shaft. Rotate the camshaft to bring the timing mark on
the gear toward the idle gear shaft (Figure 52).

50
ww. Lubricate the idle gear and the idle gear shaft with clean engine oil. Install the gear onto the idle shaft
aligning the timing marks on the idle gear with the timing marks on both the crankshaft and camshaft
gears (Figure 52). If necessary, remove the idle gear and rotate the camshaft to align the timing marks.

Figure 52 Aligning the Idle Gear Timing Marks

xx. Remove the thrust collar bolts and install the thrust collar with the chamfer away from the gear. Install
and torque the bolts to 42 to 62 N.m (31 to 45 lbf.ft).
yy. Position a new gasket on the oil cooler cover and position the oil cooler on the engine block. Install
and torque the retaining bolts to 21 to 30 N.m (15 to 22 lbf.ft) in the sequence shown (Figure 53).

Figure 53 Oil Cooler – Bolt Tightening Sequence

zz. Place new gaskets on the side cover plates (if necessary use a suitable sealant to hold the gaskets in
position). Position the cover plates on the engine block ensuring that the plate with the engine breather
outlet is positioned to the rear of the engine (Figure 54). Install the retaining bolts and torque them to
16 to 25 N.m (12 to 19 lbf.ft).

51
 Figure 54 Installation of the Side Cover
aaa. Position the injection pump on the engine and align the timing mark on the pump drive gear with the
mark on the idle gear. Install the seven injection pump-to-timing case retaining bolts, together with
new lock-washers, but do not tighten them at this stage.
bbb. Install the injection pump rear mounting bracket over the injection pump mounting adapter and onto
the engine block. Install the nut and the two retaining bolts together with new lock-washers
(Figure 55). Torque the injection pump-to-timing case retaining bolts to 21 to 30 N.m (15 to 22 lbf.ft).
Torque the adapter-to-mounting bracket retaining nut and the two bracket retaining bolts to 21 to 30
N.m (15 to 22 lbf.ft).

Figure 55 Installing the Injection Pump Rear Mounting Bracket

ccc. Install the injection pump oil feed pipe adapter onto the engine and tighten it securely. Connect the oil
feed pipe to the adapter and tighten the pipe connector securely.
ddd. Ensure that the timing marks are aligned (Figure 56), lock the flywheel to prevent it from turning and
torque the camshaft drive gear retaining bolt to 123 to 152 N.m (90 to 112 lbf.ft).

Figure 56 Aligning the Gear Timing Marks

52
eee. Using special tool 18GA092 and a hammer, install a new oil seal into the timing cover (Figure 57).
Smear the sealing lip with rubber grease and position a new gasket on the timing cover using the
timing cover retaining bolts to hold the gasket in place. Install the timing cover ensuring that the gasket
is correctly aligned and the sealing lip on the seal is not distorted.

Figure 57 Installing the Timing Case Oil Seal

fff. Install the retaining bolts and torque them to 21 to 30 N.m (15 to 22 lbf.ft).
ggg. Install the two Woodruff keys onto the crankshaft and the dust thrower onto the back of the crankshaft
pulley. Smear the seal rubbing surface on the crankshaft pulley with rubber grease.
hhh. Position the pulley over the end of the crankshaft, align the keyway with the keys and push the pulley
onto the crankshaft. Install the retaining nut and washer and torque the nut to 382 to 480 N.m
(282 to 354 1bf.ft). Remove the flywheel locking device.

NOTE

iii. Apply a suitable sealant to the gasket prior to installing the water pump.Position the water pump,
together with a new gasket, onto the engine block. Install the retaining bolts and torque them to 42 to
62 N.m (31 to 45 1bf.ft).
jjj. Position the oil filter adapter, together with a gasket, on the engine block. Install and torque the four
retaining bolts to 42 to 62 N.m (31 to 45 lbf.ft). Apply a film of clean engine oil on the rubber seal and
install the filter until the seal contacts the adapter face, tighten the filter a further half a turn by hand
only.
kkk. Position the alternator adjusting bracket on the thermostat housing, install the bolt but do not tighten it
at this stage.
lll. Position the alternator mounting bracket on the engine, install the two retaining bolts together with new
lock-washers, and torque them to 42 to 62 N.m (31 to 45 lbf.ft).
mmm.Position the alternator on the mounting bracket and install the two mounting bolts. Align the alternator
adjusting bracket with the adjusting bolt hole on the alternator and install the adjusting bolt
(Figure 58). Do not tighten the alternator adjusting and mounting bolts at this stage.

53
 Figure 58 Installing the Alternator and Mounting Bracket
nnn. Install the vacuum pump oil feed and oil return hose adapters onto the engine block. Connect the oil
feed and return hoses (Figure 59), ensuring that the hose connections are secure.

Figure 59 Installing the Vacuum Pump Oil Hoses

ooo. Position the starter motor on the flywheel housing. Install the retaining nuts and bolt and tighten them
securely.

NOTE
A screwdriver slot in the top of the locating bolts will facilitate their removal once
the cylinder head is in position.

54
 ppp. Position a new cylinder head gasket on the engine block ensuring that the gasket is correctly orientated
with the TOP mark facing up and the FRONT mark toward the front of the engine. Use two
M 12 x 1.25 bolts, approximately 130 mm long with the bolt head removed to hold the gasket in
position and to guide the cylinder head into place.
qqq. Install the dipstick tube into position on the engine block and install the cylinder head in accordance
with Medium Repair – Group 1.
rrr. Position the drive pulley, spacer and cooling fan on the water pump drive flange. Align the bolt holes,
install and securely tighten the four retaining bolts.
sss. Position the fanbelt over the pulleys and adjust the tension of the fanbelt by moving the alternator
outward. Remove the adjusting bolt if additional clearance is required. Check for a belt deflection of
10 to 15 mm between the water pump and the alternator pulleys. When the correct tension is obtained,
securely tighten the alternator adjusting bolt and the alternator mounting bolts.
25. Engine Installation. Install the engine as follows:

The overhead lifting equipment must have a minimum Safe Working Load
(SWL) of 500 kg. Lifting equipment with a lower SWL may fail unexpectedly
causing injury to personnel and damage to the equipment.
a. Secure special tool EYA3745 to the overhead lifting equipment.
b. Position the overhead lifting equipment above the engine (Figure 60) and secure the chains to the
engine lifting brackets. Take up the weight of the engine with the overhead lifting equipment and
remove the engine from the overhaul stand.

Figure 60 Attaching the Lifting Equipment

c. Position the engine mounting brackets on the engine, install the retaining nuts and bolts and tighten
them securely.

During installation of the engine or transmission, DO NOT use the bell housing
bolts to pull the assemblies together, if there is a gap evident. This will cause the
transmission input bearing retaining plates to bend and allow excess end-float
of the main shaft. If the plates are bent the transmission must be removed and
returned for overhaul.
d. Install the engine in accordance with Medium Repair – Group 1.

55
 e. Fill the engine with 8.5 litres of clean engine oil. Disconnect the in-line fuse (blue wire) at the stop
motor, rendering the stop motor inoperable. Using the starter motor, crank the engine over to circulate
oil throughout the engine. Reconnect the fuse, then start and run the engine for several minutes, while
checking for oil or coolant leaks.
f. Stop the engine, rectify any leaks and check the oil level. Top-up the engine with clean engine oil as
necessary.
g. Road test the vehicle.

56
26. The engine specifications are detailed in Table 8.
Table 8 Engine Group Specifications
Serial Item Specification
Cylinder head
1 Distortion Less than 0.2 mm (0.008 in)
2 Thickness 89.95 to 90.05 mm (3.541 to 3.545 in)
3 Machining limit 89.65 mm (3.530 in)
4 Head to valve depression 1.0 to 2.5 mm (0.039 to 0.098 in)
Valves
5 Seat contact width 1.5 to 2.0 mm (0.059 to 0.079 in)
6 Head thickness Not less than 1.0 mm min. (0.039 in)
7 Seat angle 45°
8 Inlet valve stem diameter 8.88 to 8.961 mm (0.350 to 0.353 in)
9 Exhaust valve stem diameter 8.88 to 8.936 mm (0.350 to 0.352 in)
10 Valve stem wear limit 8.88 mm (0.350 in)
Valve guides
11 Inlet valve - clearance 0.039 to 0.2 mm (0.0015 to 0.0079 in)
12 Exhaust valve - clearance 0.064 to 0.25 mm (0.0025 to 0.010 in)
13 Protrusion above cylinder head 13.9 to 14.3 mm (0.547 to 0.563 in)
Valve springs
14 Free length - Inner 52.4 mm (2.063 in)
15 Limit 50.0 mm (1.970 in)
16 Free length - Outer 53.65mm (2.112in)
17 Limit 50.65 mm (1.994 in)
18 Inclination limit – Inner and Outer 1.0 mm (0.039 in)
19 Tension - Inner 9.9 kg at 42 mm (21.83 lb at 1.65 in)
20 Tension - Outer 20.0 kg at 44 mm (44.10 lb at 1.73 in)
Idle gear
21 End-play - clearance 0.058 to 0.2 mm (0.002 to 0.008 in)
22 Shaft diameter - standard 44.84 to 44.97 mm (1.765 to 1.770 in)
23 Limit 44.84 mm (1.765 in)
24 Shaft to gear clearance - standard 0.009 to 0.060 mm (0.00035 to 0.0024 in)
25 Limit 0.2 mm (0.0079 in)
26 Idle gear tightening torque 42 to 62 N.m (31 to 46 lbf.ft)
Crankshaft, idle and camshaft gears
27 Backlash - standard 0.10 to 0.3 mm (0.004 to 0.012 in)

57
 Table 8 Engine Group Specifications (Continued)
Serial Item Specification
Camshaft followers
28 Diameter - standard 27.92 to 27.98mm (1.100 to 1.1016in)
29 Bore clearance 0.02 to 0.1 mm (0.0008 to 0.0039 in)
Cylinder liners
30 Bore l.D. - clearance 102.021 to 102.2 mm (4.0165 to 4.0236 in)
31 Interference fit 0.001 to 0.019 mm (0.00004 to 0.00075 in)
32 Protrusion – above engine block 0.03 to 0.10 mm (0.0012 to 0.0039 in)
33 Maximum variation 0.03 mm (0.0012 in)
Camshaft
34 Bearing journal O.D. - standard 55.60 to 55.97 mm (2.189 to 2.2035 in)
35 Run-out (ovality) 0.1 mm (0.0039 in)
36 Bearing journal l.D. 56.0 to 56.03 mm (2.2047 to 2.2059 in)
37 Bearing - clearance 0.03 to 0.15 mm (0.0012 to 0.0059 in)
38 Lobe height - standard 47.7 mm (1.878 in)
39 Wear limit 46.5 mm (1.830 in)
40 Journal to thrust plate - clearance 0.050 to 0.2 mm (0.002 to 0.0079 in)
41 Thrust plate tightening torque 21 to 30 N.m (15 to 22 lbf.ft)
42 Drive Gear tightening torque 123 to 152 N.m (90 to 112 lbf.ft)
Crankshaft
43 End-play - clearance 0.15 to 0.45 mm (0.006 to 0.018 in)
44 Main bearing journal O.D. - standard 79.0 to 79.925 mm (3.1102 to 3.1467 in)
45 Main bearing nominal I.D 80.00mm (3.15in)
46 Main bearing to journal - clearance 0.039 to 0.11 mm (0.0015 to 0.0043 in)
47 Con rod bearing journal O.D. - standard 63.0 to 63.944 mm (2.4803 to 2.5174 in)
48 Crankshaft run-out - standard 0.05 mm (0.002 in)
49 Limit 0.30 mm (0.012 in)
50 Flywheel tightening torque 142 to 172 N.m (105 to 127 lbf.ft)
51 Pulley tightening torque 382 to 480 N.m (282 to 354 lbf.ft)
Main bearings
52 Tightening torque 225 to 245 N.m (166 to 181 lbf.ft)
53 Bearing spread 85.0 mm (3.35 in)
Connecting rods
54 Big-end spread 68.0 mm (2.68 in)
Less than 0.05 mm (0.002 in) per 100 mm of
55 Distortion – standard
connecting rod length
56 Limit 0.2 mm (0.0079 in) per 100 mm of connecting
rod length
57 Small-end bush – standard 35.017 to 35.025 mm (1.3786 to 1.3789 in)
58 Gudgeon pin - clearance 0.012 to 0.05 mm (0.00047 to 0.002 in)
59 Big-end tightening torque 39 N.m (29 lbf.ft), then turn a further 60 to 90
degrees

58
 Table 8 Engine Group Specifications (Continued)
Serial Item Specification
Gudgeon pins
60 Diameter - nominal 35.0 mm (1.377 in)
61 Limit 34.95 mm (1.375 in)
Pistons
0.005 mm (0.0002 in) smaller than the diameter of the
62 Gudgeon pin bore
gudgeon pin
63 Piston to cylinder liner - clearance 0.057 to 0.075 mm (0.0022 to 0.0030 in)
Piston ring clearance
64 First compression – standard 0.085 to 0.11 mm (0.0033 to 0.0043 in)
65 Limit 0.2 mm (0.008 in)
66 Second compression – standard 0.030 to 0.055 mm (0.0012 to 0.0022 in)
67 Limit 0.15 mm (0.006 in)
68 Oil – standard 0.030 to 0.07 mm (0.0012 to 0.003 in)
69 Limit 0.15 mm (0.006 in)
Piston ring gap tolerance
70 First compression – standard 0.25 to 0.45 mm (0.010 to 0.018 in)
71 Limit 1.5 mm (0.059 in)
72 Second compression – standard 0.2 to 0.4mm (0.008 to 0.016in)
73 Limit 1.5 mm (0.059 in)
74 Oil - standard 0.2 to 0.4 mm (0.008 to 0.016 in)
75 Limit 1.5 mm (0.059 in)
Engine block
76 Distortion Less than 0.2 mm (0.008 in)
77 Machining limit 0.3 mm (0.012 in)
78 Cylinder liner bore 105.001 to 105.010 mm (4.1339 to 4.1342 in)
79 Rear oil seal housing tightening torque 21 to 30 N.m (15 to 22 lbf.ft)
80 Oil pump tightening torque 42 to 62 N.m (31 to 46 lbf.ft)
81 Oil pan (sump) tightening torque 11 to 21 N.m (8 to 15 lbf.ft)
82 Flywheel housing tightening torque 123 to 152 N.m (90 to 112 lbf.ft)
83 Oil cooler tightening torque 21 to 30 N.m (15 to 22 lbf.ft)
84 Side cover plates tightening torque 16 to 25 N.m (12 to 19 lbf.ft)
85 Water pump tightening torque 42 to 62 N.m (31 to 45 lbf.ft)
86 Oil filter adapter tightening torque 42 to 62 N.m (31 to 45 lbf.ft)
87 Alternator mounting bracket tightening torque 42 to 62 N.m (31 to 45 lbf.ft)
88 Timing case tightening torque 21 to 30 N.m (15 to 22 lbf.ft)
89 Timing cover tightening torque 21 to 30 N.m (15 to 22 lbf.ft)
90 Injection pump to timing case tightening torque 21 to 30 N.m (15 to 22 lbf.ft)
91 Injection pump rear mounting tightening torque 21 to 30 N.m (15 to 22 lbf.ft)
Clutch
92 Pressure plate tightening torque 16 N.m (12 lbf.ft)

59
COOLING SYSTEM

Water Pump
27. Disassembly. Disassemble the water pump as follows:
a. Remove the water pump in accordance with Light Repair – Group 2.
b. Remove the three screws securing the rear cover to the water pump. Remove the cover and discard the
gasket.
c. Using special tool 9-8521-0097-0, remove the impeller from the pump shaft (Figure 61).

Figure 61 Removal of the Water Pump Impeller

d. Position the pump in a suitable press, press the drive flange from the shaft and remove the dust cover.
e. Remove the circlip from the front of the water pump housing (Figure 62).

Figure 62 Removal of the Drive Flange

To avoid damaging the water pump housing the shaft must be pressed out from
the impeller end of the housing.
f. Using the press, remove the shaft and bearing assembly from the housing.

60
 g. Press out the two seals from the front of the housing and discard the seals.
h. Press the bearings and spacers from the shaft; do not remove the circlip (Figure 63) unless it is
damaged.

Figure 63 Removal of the Bearings and Spacers

28. Cleaning and Inspection. Clean and inspect the water pump as follows:

DO NOT spin the bearings with compressed air as personal injury or damage
to the bearings may result.
a. Clean all parts with a recommended cleaning agent and blow them dry with compressed air. Do not
blow dry the bearings.
b. Remove all trace of gasket material from the water pump housing, rear cover and the engine block.
c. Check the water pump housing and impeller for cracks, excessive corrosion or damage and replace as
necessary.
d. Check the bearings for smooth, noiseless operation. Replace them as necessary.
e. Check the shaft for straightness, excessive wear or damage and replace as necessary.
29. Reassembly. Reassemble the water pump as follows:
a. If the circlip was removed from the shaft during disassembly, fit a new circlip to the shaft.

NOTE
When installing the bearings, ensure that the bearing sealed surfaces face outward.
b. Pack the bearings with grease, in the sequence shown (Figure 63) fit the spacers and bearings to the
shaft, use a suitable press for the bearings.
c. Apply liquid gasket to the contact surfaces of the new seals (Figure 64) and press the seals into the
housing.

Figure 64 Installation of the Water Pump Housing Seals

d. Install the shaft and bearing assembly from the front of the water pump using the press and special tool
9-8522-1140-0.

61
 e. Install the circlip in the front of the housing to retain the shaft and bearing assembly in position.
f. Position the dust cover on the shaft and press the drive flange onto the shaft.
g. Turn the water pump over and position the impeller on the shaft. Press the impeller onto the shaft until
the clearance between the impeller and the pump housing (Figure 65) is 0.3 to 0.8 mm
(0.012 to 0.031 in).

Figure 65 Checking the Impeller Clearance

h. Using a new gasket and a liquid sealer, secure the rear cover to the water pump. Tighten the screws
securely.
i. Install the water pump in accordance with Light Repair – Group 2.
30. The water pump specification is detailed in Table 9.
Table 9 Water Pump Specifications
Serial Item Specification
1 Impeller clearance 0.3 to 0.8 mm (0.012 to 0.031 in)

62
FUEL

Fuel Injection Pump

31. Disassembly. Disassemble the fuel injection pump as follows:

All work on fuel injection equipment must be carried out in a clean, dust free
environment. Dust or dirt could damage the internal components.
a. Remove the fuel injection pump in accordance with Light Repair – Group 4.
b. Lock the injection pump drive gear with a suitable locking device. Remove the nut and washer
securing the drive gear and timing device to the injection pump camshaft and remove the drive gear
and timing device.
c. Remove the four nuts and washers securing the injection pump-to-timing case mounting adapter to the
injection pump. Remove the adapter by tapping it lightly with a soft faced hammer.

NOTE
The drive gear and timing device securing nut can be used in place of special tool
157842-4420 to facilitate the rotation of the camshaft.
d. Install the camshaft coupling tool, special tool 157842-4420, (Figure 66) on the camshaft and remove
the control lever return spring.

Figure 66 Camshaft Coupling Tool

NOTE
A suitable soft-jawed vice can be utilized in place of the universal vice and bracket
assembly.
e. Install the mounting bracket base, special tool 157944-8720, onto the universal vice special tool
157944-8520. Attach the injection pump mounting bracket, special tool 157944-7820, onto the
mounting bracket base and secure it with two bolts (Figure 67).

63
 Figure 67 Universal Vice and Bracket Assembly
f. Position the injection pump on the vice and bracket assembly and secure the pump to the bracket using
four bolts, tighten the bolts securely. Position the coupling spanner, special tool 157916-5420, onto the
camshaft coupling, hold the coupling while tightening the coupling retaining nut with special tool
157914-0100.
g. With the injection pump secured to the vice, remove the three nuts securing the fuel transfer pump to
the injection pump and remove the transfer pump.

Ensure that the tappet holders (service pins) are properly installed, otherwise
personal injury could result.
h. Remove the bolts securing the side cover plate to the injection pump and remove the cover plate. Using
special tool 157916-5420, rotate the camshaft until a plunger return spring is compressed (the plunger
is at TDC) and install the tappet holder, (special tool 157931-2500), into the hole. Secure the
remaining tappets in the same manner.
i. Remove the seven bolts securing the cover to the governor housing and remove the cover by tapping
the cover lightly with a soft faced hammer. Discard the gasket.
j. Position special tool 157916-5420 on the camshaft coupling to prevent the camshaft from turning.
With special tool 157915-0100 and a lever, (special tool 157910-1120), remove the flyweight locknut
(Figure 68).

Figure 68 Removing the Flyweight Locknut

64
k. Position special tool 157926-5110 in the flyweights and remove the flyweights from the camshaft
(Figure 69).

Figure 69 Removing the Flyweights

l. Using long nose pliers remove the start spring from the rack connecting link. Using two spanners
(8 and 10 mm), remove the nut from the bolt securing the connecting link to the control rack and
remove the connecting link complete with the bolt and plate (Figure 70).

Figure 70 Removal of the Connecting Link

m. Remove the nut and spring washer securing the full-load set lever to the U-shaped lever and carefully
remove the full-load set lever and spring. Remove the U-shaped lever pivot plug from the side of the
governor housing, remove the U-shaped lever complete with the full-load set lever shaft and the sensor
lever.
n. Using a Phillips screwdriver and a 12 mm socket (special tool 157914-2400 and a suitable lever),
remove the six bolts, together with the start spring eye, securing the governor housing to the injection
pump. With a soft faced hammer, lightly tap the governor housing to separate it from the injection
pump.
o. Turn the injection pump on its side, using special tool 157910-1120, remove the four plugs from the
base of the pump.
p. Position the pump upright, using special tools 157916-5420, 157914-0100 and 157910-1120, remove
the coupling from the camshaft.
q. Rotate the injection pump camshaft until the key at the drive-end of the camshaft faces upward.
Remove the key from the camshaft and the four bolts and spring washers securing the front bearing
cover to the pump.
r. Tap the governor end of the camshaft with a soft faced hammer to unseat the bearing cover. Using two
screwdrivers in the cut-aways provided in the bearing cover, pry the cover off.
s. Remove the camshaft from the drive end of the injection pump.

65
 Never place hands (fingers) inside the injection pump camshaft bore while the
plunger return springs are held compressed as personal injury could result.
t. Position the injection pump with the plunger return springs uppermost. Install the plunger return spring
compression tool 157921-0120. Compress each spring in turn, remove the tappet holders and slowly
release the pressure on the springs (Figure 71).

Figure 71 Removing the Tappet Holders

u. Using special tool 157931-6120, remove the tappet assemblies from the injection pump through the
camshaft bore (Figure 72).

Figure 72 Removing the Tappet Assemblies

v. Using special tool 157921-5620, remove the lower spring seats and plungers through the holes in the
base of the pump (Figure 73).

66
 Figure 73 Removing the Spring Seat and Plunger
w. Remove the plunger return springs and the upper spring seats from the injection pump and remove the
control sleeves from the barrel assemblies (Figure 74).

Figure 74 Removing the Control Sleeves

x. Remove the delivery valve holder locking plates and slacken the delivery valve holders using a
suitable socket (special tool 157914-0500). Remove the delivery valve holders and the delivery valve
springs (Figure 75).

67
 Figure 75 Removing the Delivery Valve Holders and Springs
y. Using a suitable pair of tweezers or tool, remove the delivery valve assemblies and gaskets from the
top of the injection pump (Figure 76). Place each delivery valve assembly into clean diesel fuel in their
order of removal.

Figure 76 Removing the Delivery Valve Assemblies

The plungers and barrels form a matched pair and should not be intermixed.
z. Remove the plunger barrels from the injection pump and attach them to the corresponding plungers.
Place the assemblies in the clean diesel fuel and align them with the corresponding delivery valve
assemblies.
aa. Remove the control rack guide screw from the back of the injection pump and carefully withdraw the
control rack from the injection pump.
bb. With the aid of a suitable puller, remove the bearing cones from the camshaft and retain the shims and
spacers. With the aid of a suitable soft drift and a hammer, remove the bearing cups from the governor
housing and the front bearing cover.

68
32. Cleaning and Inspection. Clean and inspect the fuel injection pump as follows:
a. Wash all parts except the barrel and plunger assemblies and the delivery valve assemblies, with a
suitable cleaning agent and blow them dry with clean, moisture free compressed air.
b. Wash the delivery valve assemblies and the barrel and plunger assemblies in clean diesel fuel. Ensure
that the matched barrels and plungers are kept together and are aligned with their corresponding
delivery valve assemblies.
c. Remove all trace of gasket material from the mating surfaces of covers and housings. Ensure that the
camshaft compartment is thoroughly clean and that the oil feed pipe and connections are clean and free
from restrictions.
NOTE
Avoid excessive individual handling of the plungers or the barrel as body heat,
through convection, can affect the fine tolerances between each barrel and plunger
assembly.
d. Inspect each plunger and barrel assembly. Ensure that the helix and the inlet/spill port are not
damaged, that neither the plunger nor the barrel are discoloured or scored and that the plunger moves
smoothly in the barrel.
e. Lubricate each barrel and plunger assembly in clean diesel fuel. Check that when the assembly is
inclined at 60 degrees each plunger slides smoothly into the barrel under its own weight (Figure 77).
Rotate the plunger slightly several times and check that each time the plunger slides smoothly into the
barrel. Replace the barrel and plunger assembly if the plunger fails to slide smoothly, or if it slides too
quickly into the barrel.

Figure 77 Checking the Plunger for Smooth Operation

f. Inspect the delivery valve and valve seat for nicks, dents or excessive wear. Hold the valve assembly
and block off the fuel inlet port with a finger while pushing the valve into the valve body, then release
the valve. Pressure of the air compressed in the bore of the valve body should cause the valve to rise
when the valve is released. Replace the delivery valve assembly if the valve fails to rise when released
or if damage or wear is evident.
g. Check the delivery valve return spring for damaged, broken or weakened coils (loss of tension) and
replace it as necessary. Inspect the delivery valve holder for cracks or damage and for a scratched or
scored sealing face. Replace the delivery valve holder as necessary.
h. Inspect the control rack bushes in the injection pump body for wear and replace the bushes as
necessary. Inspect the control rack for bend, excessive wear on the bush sliding area of the rack and for
excessive wear in the gear teeth (when checked with each control pinion). Also check the control
pinion locking screw for damage (Figure 78) which may prevent the control pinion from being locked
in position. Replace worn or damaged parts as necessary.

69
 Figure 78 Checking the Control Rack and Pinion
i. Check the camshaft for damaged or worn lobes, damaged threads and key slots. Replace the camshaft
if damage or wear is evident.
j. Inspect the camshaft roller bearings for scoring, wear or damage. Ensure that the bearings turn
smoothly and freely and are a firm (press) fit onto the camshaft. Replace the bearings as necessary.
Check the governor housing and the front bearing cover for evidence of bearing cup rotation. Replace
the governor housing and/or the front bearing cover as necessary.
k. Inspect the injection pump housing for signs of cracks or damage, and check the tappet bores for wear,
scoring or damage. Replace the injection pump housing if any of these faults are evident.
l. Check the injection pump housing for damaged gasket (mating) surfaces. If necessary, refinish the
surfaces and ensure that they are smooth and flat. Check for damaged threads and loose or damaged
studs. If necessary, clean the threads with an appropriate tap and replace any damaged stud.
m. Check the tappet rollers, bushes, guides and pins for excessive wear or damage. If wear or damage is
apparent, replace the tappet assembly.
n. Inspect the plunger return springs and the upper and lower spring seats for wear or damage. Also check
the control sleeves for damage and worn plunger slots. Replace any damaged or worn parts as
necessary.
o. Overhaul the transfer pump (Para 42. to 45.).
33. Reassembly. Reassemble the fuel injection pump as follows:
a. Apply clean engine oil to the control rack and the bushes in the injection pump housing and install the
control rack into the bushes. Centralize the control rack by aligning the setting marks, on the outer
circumference of each end of the control rack, an equal distance from the injection pump housing.
Install the control rack guide screw in the back of the injection pump housing and torque it to
4.9 to 6.9 N.m (43 to 61 lbf.in).
b. Install the plunger barrels into their respective bores. Ensure that each barrel is properly seated and try
to rotate the barrel by hand. If the barrel can be rotated, the barrel locating pin is not entered far enough
into the injection pump housing barrel bore. Remove the affected barrel and with the aid of a suitable
drift (pin punch) and hammer, carefully drive the pin into the bore until there is a sufficient amount of
the pin to effectively locate the barrel. Install the barrel.
c. Lubricate the delivery valves with clean diesel fuel and install the delivery valves into their respective
bores together with new copper gaskets. Ensure that the gasket is installed as shown (Figure 79).

70
 Figure 79 Delivery Valve and Gasket - Sectional View
d. Position the delivery valve springs over the delivery valves and install the delivery valve holders over
their respective delivery valve. Tighten the delivery valve holders to a torque of 39 N.m (29 lbf.ft),
slacken each holder off, again torque the holders to 39 N.m (29 lbf.ft) and slacken each holder off once
more. Finally torque each holder to 44 N.m (32 lbf.ft). Install the delivery valve holder locking plates
and torque the retaining bolts to 4.4 to 6.8 N.m (39 to 60 lbf.in).
e. If removed, position the control pinions onto the control sleeves with the slit in the control pinion
aligned with one of the plunger slots in the control sleeve. Tighten the locking screws to secure the
control pinion in position. Position the injection pump on its side and install the control sleeve
assemblies with the slit in the control pinion uppermost.
f. When all control sleeve assemblies are installed, move the control rack back and forth and ensure that
the control sleeves rotate equal amounts from the centre position as the control rack is moved in both
directions (Figure 80).

Figure 80 Control Sleeve Setting Position

g. Using a depth gauge or vernier caliper, check that the full stroke of the control rack is 21 mm from the
position where the control rack is pushed fully toward the governor to the position where it is pulled
fully toward the drive-end of the injection pump. If the stroke of the control rack is not within 21 mm,
reposition the control pinions to obtain the correct stroke.
h. Position the upper spring seats over the control sleeves and install the plunger return springs. Assemble
the lower spring seats onto their respective plungers and insert special tool 157921-5620 into the base
of the spring seat. Dip each plunger into clean diesel fuel, and then carefully install each plunger into
its respective barrel ensuring that the plunger helix is facing upward and the identification number is
towards the slot in the control sleeve.
i. Lubricate each tappet assembly with clean engine oil and position a new shim, of equivalent thickness
to the one removed, on each tappet assembly. Using special tool 157931-6120, position the tappet
assemblies in their respective bores, align the tappet guide with the pump housing guide groove and
insert the tappet.

Never place hands (fingers) inside the injection pump camshaft bore while the
plunger return springs are held compressed as personal injury could result.

71
 j. Using special tool 157921-0120, slowly compress each plunger return spring while aligning the
plunger control arms with the slots in the control sleeve. When each spring is fully compressed, install
the tappet holders. Ensure that each tappet holder is positively installed into the hole in the tappet and
slowly release the spring compressor (Figure 81).

Figure 81 Installation of the Tappet Holders

k. Install the spacers and shims onto the camshaft. Using a suitable arbor and a press, press the bearings
on with the tapers facing toward the ends of the camshaft. Ensure that the bearings butt firmly against
the shims. Lubricate the bearings and camshaft lobes with clean engine oil. Insert the camshaft into the
bore in the injection pump housing with the identification code (Figure 82) on the camshaft toward the
front of the injection pump.

Figure 82 Camshaft Identification Number Location

l. Press the bearing cups into the governor housing and the front bearing cover, then position the
governor housing together with a new gasket onto the injection pump. Install the six retaining bolts
with new spring washers ensuring that the start spring eye is correctly positioned (Figure 83). Torque
the bolts to 6.9 to 8.8 N.m (61 to 78 lbf.in).

Figure 83 Connecting Link and Start Spring Location

72
 m. Position the front bearing cover onto the front of the injection pump. Install the four retaining bolts
together with new spring washers and torque the bolts to 6.9 to 8.8 N.m (61 to 78 lbf.in). Attach a dial
indicator to the measuring device (special tool 105782-4200) and install the measuring device onto the
drive-end of the camshaft. Pull the camshaft toward the drive-end of the injection pump and zero the
dial indicator. Push the camshaft toward the governor housing and check for a reading of 0.03 mm
(0.001 in). If the reading is not to specification, remove the camshaft and remove one of the camshaft
bearings and the shims. Increase the thickness of the shims to reduce the camshaft end-play, or reduce
the thickness of the shims to increase the end-play.
n. Press the bearing onto the camshaft, lubricate the bearing and camshaft lobes and install the camshaft
and the bearing cover. Torque the retaining bolts and check the amount of end-play. Repeat this
procedure as necessary to obtain the correct end-play, and then remove the measuring device.
o. Install the Woodruff keys onto both ends of the camshaft and install special tool 157842-4420 onto the
drive-end of the camshaft. Using special tool 157916-5420, rotate the camshaft and remove the tappet
holders as the camshaft lobes make contact with the tappets compressing the plunger return springs.
Rotate the camshaft several times to ensure that there is no jamming and that the components operate
smoothly.
p. Turn the pump on its side, apply a thin coating of Loctite 271 to the plug threads and install the four
plugs into the injection pump base. Tighten the plugs to a torque of 54 to 74 N.m (40 to 55 lbf.ft).
q. Position the U-shaped lever in the governor housing. Apply a suitable liquid adhesive to the U-shaped
lever pivot plug and install the pivot plug into the governor housing. Ensure that it is properly engaged
with the U-shaped lever and tighten the plug securely. Carefully install the full-load set lever and
spring onto the full-load set lever shaft and secure the set lever with the nut and spring washer. Torque
the nut to 10 to 14 N.m (88 to 124 lbf.in).
r. Position the control rack connecting link, complete with bolt and plate, onto the control rack. Install
the retaining nut and using two spanners (8 and 10 mm) tighten it securely. Install the start spring into
the spring eye on the governor housing. With a pair of long-nose pliers, connect the spring to the
control rack connecting link.
s. Position the flyweights onto the camshaft in the governor housing. Position the flyweight locknut and
new spring washer on the camshaft. Install special tool 157916-5420 onto the camshaft coupling to
prevent the camshaft from turning, then with special tool 157915-0100 and lever (special tool
157910-1120), torque the flyweight locknut to 49 to 59 N.m (36 to 43 lbf.ft).
t. Position a new gasket on the governor cover and hold the gasket in position with two of the cover's
retaining bolts. Turn the free-end of the floating lever outward and position the governor cover on the
governor housing, engaging the free-end of the floating lever with the ball joint on the connecting link.
Install the remaining governor cover-to-housing retaining bolts and torque them to 6.9 to 8.8 N.m
(61 to 78 lbf.in).
u. Install a new O ring onto the transfer pump flange and install the transfer pump onto the injection
pump. Install the three retaining nuts, together with new spring washers, and torque the nuts to 4.9 to
6.9 N.m (43 to 61 lbf.in).
v. Connect special tool 157916-5420 onto the camshaft coupling and rotate the camshaft until the lobe on
Number one cylinder raises the tappet. Remove the tappet holder and repeat the procedure for the
remaining cylinders.
w. The injection pump is now ready to be timed, pressure tested and calibrated (Para 37., 38. and 39.).

Governor
34. Disassembly. Disassemble the governor as follows:

All work on fuel injection equipment must be carried out in a clean, dust free
location. Dust or dirt could damage the internal components.
a. Remove the injection pump in accordance with Light Repair – Group 4.

73
 b. Lock the injection pump drive gear with a suitable locking device. Remove the nut and washer
securing the drive gear and timing device to the injection pump camshaft and remove the drive gear
and timing device.
c. Remove the four nuts and washers securing the injection pump-to-timing case mounting adapter to the
injection pump and remove the adapter by tapping it lightly with a soft faced hammer.

NOTE
The drive gear and timing device securing nut can be used in place of special tool
157842-4420 to facilitate the rotation of the camshaft.
d. Install the camshaft coupling tool 157842-4420 (Figure 84) on the camshaft and remove the control
lever return spring.

Figure 84 Camshaft Coupling Tool

NOTE
A suitable soft-jawed vice can be utilized in place of the universal vice and bracket
assembly.
e. Install mounting bracket base, special tool 157944-8720, onto the universal vice, special tool
157944-8520. Attach the injection pump mounting bracket, special tool 157944-7820, onto the
mounting bracket base and secure it with two bolts (Figure 85).

Figure 85 Universal Vice and Bracket Assembly

f. Position the injection pump on the vice and bracket assembly and secure the pump to the bracket using
four bolts, tighten the bolts securely. Position the coupling spanner, special tool 157916-5420, onto the
camshaft coupling and hold the coupling while tightening the coupling retaining nut with special tool
157914-0100.

74
g. With the injection pump secure to the vice, remove the three nuts securing the fuel transfer pump to the
injection pump and remove the transfer pump.

Ensure that the tappet holders (service pins) are properly installed otherwise
personal injury could result.
h. Remove the bolts securing the side cover plate to the injection pump and remove the cover plate. Using
special tool 157916-5420, rotate the camshaft until a plunger return spring is compressed (the plunger
is at TDC), then install the tappet holder (service pin) special tool 157931-2500 into the hole. Secure
the remaining tappets in the same manner (Figure 81).
i. Remove the cap-nut and gasket from the governor shaft (Figure 86), with two spanners (13 and
19 mm) remove the two locknuts from the governor shaft and slacken the guide screw locknut
(27 mm) with a suitable spanner.

Figure 86 Governor Shaft Cap-nut and Locknuts

j. Remove the plug (19 mm) covering the torque cam rod adjuster (Figure 87).

Figure 87 Removal of the Torque Cam Rod Adjuster Plug

k. Remove the cap-nut from the idling spring capsule, then slacken the locknut and remove the idling
spring capsule (Figure 88).

75
 Figure 88 Removal of the Idling Spring Capsule
l. Remove the seven bolts securing the cover to the governor housing and remove the cover by tapping
the cover lightly with a soft faced hammer (Figure 89). Discard the gasket.

Figure 89 Removal of the Governor Cover

m. Remove the governor shaft, complete with springs and spring seat, from the housing (Figure 90). With
a pair of long-nose pliers, disconnect the start spring from the rack connecting link.

Figure 90 Removing the Governor Shaft and Start Spring

n. Using two spanners (8 and 10 mm), remove the nut securing the connecting link to the control rack,
then remove the connecting link, complete with the bolt and plate (Figure 91).

76
 Figure 91 Removal of the Connecting Link
o. Remove the snap-ring securing the sensor lever to the U-shaped lever and remove the sensor lever
(Figure 92).

Figure 92 Removal of the Sensor Lever

p. Remove the nut securing the full-load setting lever to the U-shaped lever (Figure 93) and remove the
full-load setting lever together with the return spring.

Figure 93 Full-load Setting Lever Retaining Nut

q. Remove the U-shaped lever guide plug from the side of the governor housing. Remove the U-shaped
lever and the full-load setting lever shaft and cancel spring (Figure 94).

77
 Figure 94 Removal of the Full-load Setting Lever Shaft
r. Remove the bolt securing the stop lever to the stop lever shaft and remove the stop lever, cap, return
spring, O ring, shim and shaft from the governor housing (Figure 95).

Figure 95 Removing the Stop Lever Assembly

s. Position special tool 157916-5420 on the camshaft coupling to prevent the camshaft from turning.
Remove the flyweight retaining nut using special tool 157915-0100 and lever (special tool
157910-1120). Install special tool 157926-5110 into the flyweights and remove the flyweights
(Figure 96).

Figure 96 Removal of the Flyweights

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t. Using a Phillips screwdriver and a 12 mm socket (special tool 157914-2400), remove the seven bolts
and spring eye from the governor housing. Lightly tap the housing with a soft faced hammer to
separate the housing from the injection pump (Figure 97).

Figure 97 Removal of the Governor Housing

u. Remove the governor shaft guide screw and locknut from the governor housing. Remove the snap-ring
securing the torque cam adjusting rod to the torque cam (Figure 98).

Figure 98 Removal of the Snap-ring

v. Using a suitable punch, remove the two plugs pressed into the sides of the governor cover. Unhook the
cancel spring from the tension lever and push the tension lever pivot shaft out through the hole in the
side of the governor housing (Figure 99).

Figure 99 Removal of the Tension Lever Pivot Shaft

79
 w. Remove the guide lever and cancel spring and the tension lever assembly from the governor cover.
Remove the snap-ring securing the torque cam to the pivot pin and remove the torque cam
(Figure 100).

Figure 100 Removal of the Torque Cam

x. Remove the nut and spring washer securing the control lever to the control lever shaft and remove the
control lever. Remove the control lever shaft and floating lever assembly from the governor cover
(Figure 101).

Figure 101 Removal of the Control Lever Shaft and Floating Lever Assembly
y. Remove the snap-ring from the pivot pin and separate the sleeve and shifter assembly from the tension
lever (Figure 102).

Figure 102 Removal of the Snap-ring and Pivot Pin

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 z. Remove the circlip securing the shifter to the sleeve, then remove the shifter and bearing assembly
from the sleeve (Figure 103).

Figure 103 Removal of the Shifter and Bearing

35. Cleaning and Inspection. Clean and inspect the governor as follows:

DO NOT spin the bearings with compressed air as personal injury or damage
to the bearings may result.
a. Clean all components with a suitable cleaning agent and blow them dry with compressed air.

NOTE
If the governor housing is to be replaced, remove the camshaft bearing outer race
from the housing.
b. Inspect the governor cover and housing for wear, damage, bent or damaged pivot pins or worn bushes.
Replace the governor cover or housing if any of these faults are evident.
c. Inspect the flyweight assembly. Check for perceivable radial clearance between the flyweight and the
pivot pin, and the slider and pivot pin on the contact surface of the slider (Figure 104). If any of these
faults are evident, replace the flyweight assembly.

Figure 104 Flyweight Inspection

d. Inspect the pivot pin bores in the tension lever for wear and check for wear on the spring seat and the
governor shaft bore in the spring seat. If excessive wear is evident in any of these locations, replace the
tension lever.
e. Inspect the shifter for wear in the pivot pin bore and check the sleeve for excessive wear on the slider
contact surface. Replace the shifter and/or the sleeve if excessive wear is evident.
f. Inspect the shifter/sleeve bearing for wear, pitting, cracks or damage. If replacement is required, press
the bearing outer race from the shifter (Figure 105).

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 Figure 105 Removing the Bearing Race from the Shifter - Sectional View
g. Check the sensor lever and the torque cam for wear at the points shown (Figure 106). Replace either or
both if excessive wear is evident.

Figure 106 Sensor Lever and Torque Cam Wear Points

h. Inspect the control lever shaft assembly and the control rack connecting link for damage or wear
(Figure 107). Replace any part showing excessive wear.

Figure 107 Control Lever Shaft Assembly and Connecting Link

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 i. Inspect all springs (Figure 108) for distortion, excessive wear, cracks or damage and replace as
necessary.

Figure 108 Governor Springs

j. Inspect the governor shaft and replace the shaft if wear or damage is evident.
36. Reassembly. Reassemble the governor as follows:
a. Install a new oil seal into the control lever shaft bore at the top of the governor housing. Install the
camshaft bearing outer race into the governor housing. Position a new gasket and the governor housing
on the injection pump and install the seven retaining bolts with new spring washers and the start spring
eye. Ensure that the start spring eye is correctly positioned and torque the bolts to 6.9 to 8.8 N.m
(61 to 78 lbf.in).
b. Align the keyway in the flyweight assembly with the key on the camshaft and install the flyweight
assembly. Install the flyweight assembly retaining nut and toque the nut to 49 to 59 N.m
(36 to 43 lbf.ft).
c. If the shifter/sleeve was replaced, press the new bearing outer race onto the shifter bush ensuring that
the bearing running surface is facing away from the bush shoulder and that the bearing butts against
the bush shoulder.
d. Smear the bearing cage, balls and both races with grease. Position the inner race, the cage and ball
assembly and the outer race and shifter assembly into the sleeve. Install a new circlip ensuring that it is
properly seated in the groove in the sleeve. Ensure that the sleeve rotates smoothly on the shifter.
e. Position the shifter and sleeve assembly in the flyweight assembly ensuring that the shifter and sleeve
assembly contacts the flyweight holder. Hold the shifter and sleeve assembly against the flyweight
holder to ensure that the flyweights are in the zero lift position. Measure the distance between the
governor housing face and the centre of the pivot pin hole in the shifter (Figure 109). The dimension
should be between 28.8 to 29.2 mm (1.134 to 1.149 in).

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 Figure 109 Shifter and Sleeve Assembly Setting Dimension - Sectional View
f. If the dimension is not to specification, disassemble the shifter and sleeve assembly, then press the
bush and bearing outer race from the shifter to gain access to the adjusting shims. Either increase or
decrease the thickness of the shims to obtain the correct dimension. Reassemble the shifter and sleeve
assembly and verify that the dimension is correct. If necessary repeat this procedure until the correct
dimension is obtained.
g. Position the tension lever over the shifter, align the pivot pin holes and install the pivot pin. Secure the
pivot pin in place with new snap-rings (Figure 110). Install the torque cam control rod into the
governor seat locating pin on the tension lever and adjust the nut until 3 to 6 mm of thread protrudes
from the nut.

Figure 110 Connecting Sleeve and Shifter Assembly

h. Lubricate the sealing lip on the oil seal with grease and carefully install the control lever shaft
assembly into the bore at the top of the governor cover (Figure 111). Position the control lever over the
control lever shaft, install the retaining nut together with a new spring washer and tighten the nut
securely.

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 Figure 111 Installation of the Control Lever Shaft Assembly
i. Position the torque cam on the pivot pin in the governor cover (Figure 112) and secure the torque cam
in place with a new snap-ring.

Figure 112 Installation of the Torque Cam

j. Install new bushes in the guide lever and position the guide lever in the governor cover ensuring that
the ball joint is correctly engaged in the floating arm. Install the tension lever into the governor cover,
positioning the lever between the bushes on the guide lever. Align the tension lever shaft holes in the
guide lever and tension lever with those in the governor cover and start the tension lever shaft into the
governor cover, guide lever and tension lever.
k. Install the cancel spring between the tension lever fork, align the bore of the spring with the tension
lever shaft and push the shaft in until both ends of the shaft are supported by the governor cover. Using
a suitable tool, e.g. a socket, install a new expansion plug into the governor cover at both ends of the
tension lever shaft (Figure 113). Apply a liquid adhesive to the outside of each plug to prevent oil
leakage.

Figure 113 Installing the Expansion Plugs

85
 l. Using a suitable tool, e.g. a Vee-notch screwdriver, attach the cancel spring to the tension lever
(Figure 114).

Figure 114 Attaching the Cancel Spring to the Tension Lever

m. Connect the torque cam control rod to the torque cam and secure it in place with a new snap-ring.
n. Install the stop control lever shaft through the aperture in the top of the governor housing and position
a new O ring, the shims, return spring, cap and stop lever onto the shaft. Install the retaining bolt
together with a new spring washer and torque the bolt to 10 to 14 N.m (7 to 10 lbf.ft).
o. Install the full-load setting lever shaft and cancel spring into the governor housing and position the
full-load setting lever over the end of the shaft. Install the retaining nut together with a new spring
washer and torque the nut to 10 to 14 N.m (7 to 10 lbf.ft).
p. Position the U-shaped lever onto the full-load setting lever shaft and link the end of the cancel spring
over the U-shaped lever. Apply a suitable liquid adhesive to the threads of the U-shaped lever guide
plug and install the guide plug into the governor housing, ensuring that the U-shaped lever is properly
engaged with the guide plug. Torque the guide plug to 20 to 29 N.m (15 to 21 lbf.ft).
q. Position the sensor lever on the U-shaped lever and secure it in place with a new snap-ring.
r. Position the control rack connecting link, complete with bolt and plate, on the control rack with the end
of the bolt positioned in the fork of the sensor lever. Install and securely tighten the retaining nut using
two spanners (8 and 10 mm).
s. With the aid of long-nose pliers, install the start spring into the spring eye secured to the governor
housing and to the control rack connecting link, (Figure 115).

Figure 115 Installation of the Start Spring

86
 t. If removed, install the spring seat and springs onto the governor shaft and insert the governor shaft into
the bore in the governor housing (Figure 116).

Figure 116 Installation of the Governor Shaft

u. Position a new gasket on the governor housing and install the governor cover. Align the ball joint on
the connecting link with the fork in the floating lever and align the shifter and sleeve assembly with the
flange on the flyweights. Install and torque the seven retaining bolts to 7 to 9 N.m (62 to 80 1bf.in).
v. Install the governor shaft guide screw complete with locknut. Install the idling spring capsule, together
with the idling spring (Figure 117).

Figure 117 Installation of the Idling Spring Capsule

w. Connect special tool 157916-5420 onto the camshaft coupling and rotate the camshaft until the lobe on
Number one cylinder raises the tappet. Remove the tappet holder and repeat the procedure for the
remaining cylinders.

Injection Pump Timing

37. Adjustment. Adjust the injection pump timing as follows:
a. Remove the injection pump from the overhaul vice and install the pump on the calibration stand. Add
approximately 180 ml of clean engine oil and install a suitable plug into the oil feed hole.
b. Connect the fuel feed hose directly to the injection pump fuel gallery and connect the high pressure
fuel lines to the delivery valve holders. Install a dial indicator (special tool 105782-6280), over the end
of the control rack.

87
 c. Fully slacken off the governor shaft locknuts and set the pump rotating in a clockwise direction (as
viewed from the drive-end of the injection pump) at a speed of 1000 to 1200 rpm. Push the governor
shaft in until it contacts the wall of the injection pump housing, then set the control rack at the position
where the dial indicator reads zero. Stop the injection pump.
d. Set the injection pump control lever to the full-load position and remove the high pressure fuel line
from the injection pump Number one cylinder. Remove the delivery valve holder locking plate, the
delivery valve holder, delivery valve return spring and the delivery valve assembly. Install the plunger
pre-stroke measuring device (special tool 105782-4330), together with a dial indicator (special tool
157954-3600), into the bore of Number one cylinder (Figure 118).

Figure 118 Installation of the Pre-stroke Measuring Device

e. Rotate the injection pump camshaft by hand to bring the camshaft lobe on Number one cylinder to
BDC. Zero the dial indicator; continue rotating the camshaft and check that the reading of the dial
indicator varies with the lift of the camshaft lobe.

Do not place fingers near the plunger return spring while the spring is being
held in compression otherwise personal injury could result.
f. Using a suitable calibration oil, set the test stand supply pump to 20 kPa (3 psi) and start the pump.
Open the bleed screw on the injection pump to bleed off all the air from the injection pump fuel
gallery. After bleeding close the bleed screw. With calibration oil flowing from the measuring device
on Number one cylinder, rotate the camshaft in the clockwise direction until the calibration oil stops
flowing. Check for a pre-stroke reading of 3.6  0.05 mm on the dial indicator. If the reading is not to
specification, stop the supply pump and rotate the camshaft until Number one camshaft lobe is at TDC.
Install a plunger return spring holding tool and rotate the camshaft until the tappet is sufficiently clear
of the spring seat to enable the shim to be replaced.
g. Using a suitable tool, e.g. magnetic pencil or similar, remove the shim from the top of the tappet and
install a thicker shim to decrease the plunger lift-to-port closing or a thinner shim to increase the
plunger lift-to-port closing. Rotate the camshaft until the Number one lobe is at TDC and remove the
plunger return spring holding tool.
h. Start the supply pump and measure the pre-stroke again, replace the shim as necessary to obtain the
correct pre-stroke specification. Once the correct setting has been obtained, stop the supply pump and
set the test stand flywheel pointer to an arbitrary angle graduation and record the exact degree setting.
Remove the plunger pre-stroke measuring device from Number one cylinder and install the delivery
valve assembly, the delivery valve return spring and the delivery valve holder together with a new
copper gasket. Torque the delivery valve holder to 39 N.m (29 lbf.ft), then slacken the holder, re-
torque the delivery valve holder and slacken once more. Finally torque the holder to 44 N.m (32 lbf.ft).

88
 i. Ensure that the port closing of each successive cylinder is 90 degrees  30 minutes from the previous
cylinder. As the injection order is 1-3-4-2, the next cylinder to be checked is Number three. Open the
bleed-off valve at the Number three fuel outlet on the test stand and start the supply pump. Adjust the
pressure until a steady stream of calibration oil flows from the bleed-off valve. Rotate the camshaft
(clockwise) by hand until the oil stops flowing and note the number of degrees on the test stand
flywheel. If the degree of rotation is not to specification (90 degrees  30 minutes), stop the supply
pump and replace the tappet shim as detailed in Paras 34. f. and g. Install a thicker shim to decrease the
number of degrees of rotation or a thinner shim to increase the degrees of rotation. Repeat the test
procedure until the correct reading is obtained, and then test the remaining cylinders in a like manner.
Injection Pump Pressure Test
38. Test Procedure. Test the injection pump pressure as follows:

NOTE
With the injection pump installed on the test stand and air bled from the fuel system,
perform the following test to ensure that there is no fuel leakage from the injection
pump.
a. Connect the test stand fuel supply hose to the injection pump fuel gallery and tighten the connection
securely.
b. Start the test stand fuel supply pump and slowly supply fuel to the injection pump until a pressure of
1725 kPa (250 psi) is obtained. Stop the supply pump and check for signs of fuel leakage.

NOTE
A rapid drop in pressure indicates fuel leakage. A very gradual leak between the
barrel and plunger is permissible.
c. Repair or replace parts as necessary to rectify any leakage.

Calibration
39. Preliminary Checks. Carry out the following preliminary checks:
a. Ensure that the pump is aligned, properly connected and secured to the test stand.
b. Check that the fuel supply hoses are correctly connected and secured to the transfer pump, and that an
overflow valve is installed in place of the blanking plug in the injection pump fuel gallery.
c. Ensure that the fuel supply hoses to the transfer and injection pumps, and the fuel return hose from the
overflow valve are correctly installed and free from restriction.
d. Check that each test nozzle is functioning correctly. Repair or replace any faulty nozzle as necessary.
e. Ensure that the high pressure fuel lines are in good condition and correctly installed, and that each of
the injection pump cylinders is connected to its corresponding test nozzle on the calibration stand.
f. Check the temperature of the calibration oil (or test fuel) at the injection pump fuel inlet. The
temperature should be 38 to 41 degrees C.
40. Preparation and Run-in. Prepare the injection pump as follows:

NOTE
As injection from each of the injection pump cylinders takes place in one revolution
of the injection pump camshaft, set the test stand counter to the number of strokes in
the pump calibration procedures.
a. Ensure that the fuel system is primed. Slacken the overflow valve connection on the injection pump
and operate the hand primer plunger on the transfer pump. The system is primed when the calibration
oil (or test fuel) flows from the overflow valve in a steady stream, free from air bubbles.
b. Remove the idling spring capsule assembly from the governor cover and slacken the maximum speed
setting bolt and the full-load setting bolt.

89
 c. Position special tool 105782-6170 (adjusting device) over the control lever, attach the adjusting device
support bracket to the test stand and align the mark on the supporting bracket with one of the match
marks on the scale plate (Figure 119).

Figure 119 Aligning the Adjusting Device Match Marks

d. Move the support bracket of the adjusting device until pin A is over the centre hole of the control lever
shaft (Figure 120). Secure the support bracket in place and insert pin B into the hole in the control
lever.

Figure 120 Positioning the Adjusting Device

e. Slacken the adjusting device locking handle and check that the injection pump control lever and pin B
move smoothly.
f. Verify that there is sufficient lubricating oil in the injection pump and governor assembly
(approximately 180 ml of clean engine oil).
g. Install the control rack travel measuring device, special tool 105782-6280, onto the end of the control
rack. Lock the control lever in the idle position and push the governor shaft into the governor housing
until it contacts the injection pump housing.
h. Start the test stand motor and run it at 1000 to 2000 rpm. Check the zero position as indicated on the
dial indicator.
41. Calibration Procedure. Calibrate the injection pump using the following procedure:
a. Remove the control rack guide screw from the back of the injection pump and replace it with a locking
screw (special tool 157976-3100). Using the dial indicator, set the control rack at 11.3 mm and lock the
rack in position with the locking screw.

90
b. Set the calibration stand to 1000 strokes. Start and run the motor at 950 rpm. Fuel delivery should be
67.3 to 70.3 ml per cylinder, with a maximum variation of  2.5% between cylinders.
c. If the fuel injection quantity on any cylinder is not to specification, adjust the cylinder(s) by slackening
the clamping screw on the control pinion. With the aid of a suitable tool inserted into one of the holes
in the side of the control sleeve, rotate the sleeve to adjust the quantity of the fuel delivered by that
cylinder. Rotating the control sleeve towards the governor increases the fuel quantity. Once the correct
adjustment has been made, tighten the clamping screw and remove the adjusting tool. Repeat the
procedure for the other cylinders as necessary.

NOTE
Fuel delivery figures are per 1000 rpm. Drain the calibrated containers after each
fuel delivery reading.
d. Set the control rack to 9.6 mm and lock it in position. Start and run the motor at 290 rpm. Fuel delivery
should be 6.7 to 9.3 ml per cylinder with a maximum variation of  14% between cylinders. Adjust the
position of the control sleeves as necessary to achieve the correct fuel delivery at the cylinders.
e. Slacken the control rack locking screw and adjust the position of the control rack to 11.3 mm using the
control lever. Lock the control lever in position. Start and run the motor at 950 rpm. Fuel delivery
should be 67.8 to 69.8 ml without variation between cylinders. Adjust the cylinders as necessary to
achieve the correct fuel delivery.
f. Using the control lever, adjust the control rack position to 10.95 mm and lock the control lever. Run
the motor at 1600 rpm and check that the fuel delivery is 67.0 to 70.2 ml without variation between
cylinders. Adjust the cylinders as necessary to achieve the correct fuel delivery.
g. Move the control lever to bring the control rack to 11.5 mm, lock the control lever, run the motor at
1300 rpm and check that the fuel delivery is 70.9 to 74.1 ml without variation between cylinders.
Adjust the cylinders as necessary to achieve the correct fuel delivery.
h. Run the motor at 650 rpm and adjust the control lever to obtain a reading of 11.05 mm at the control
rack. Check that the fuel delivery is 48.7 to 51.9 ml without variation between cylinders.
i. Move the control lever to bring the control rack to 11.4 mm, run the motor at 500 rpm and check that
the fuel delivery is 49.9 to 53.9 ml without variation between cylinders.
j. After setting the fuel injection quantities, adjust the governor. Hold the control lever in the idling
position and increase the pump speed to 500 to 600 rpm. Move the control lever to the maximum speed
position and adjust the full-load setting bolt to set the control rack 3 mm beyond the maximum speed
position.
k. Set the pump speed at 80 to 100 rpm and adjust the idle setting bolt (Figure 121) so that the control
rack will be at 11.5 mm.

Figure 121 Adjustment of the Idle Setting Bolt

91
 l. Increase the pump speed to 220 rpm and install the idling spring capsule together with a new gasket.
Screw the capsule in until the control rack is at about 9.5 mm (Figure 122). The outer idling spring is
now set. Torque the idling capsule locknut to 18 to 22 N.m (13 to 16 lbf.ft).

Figure 122 Adjustment of the Outer Idling Spring

m. Adjust the pump speed to 240 rpm and adjust the screw on the idling capsule until the control rack is at
9.5 mm (Figure 123). Tighten the locknut securely. The inner idling spring is now set. Install the
cap-nut, together with a new gasket, and torque the cap-nut to 16 to 20 N.m (12 to 15 lbf.ft).

Figure 123 Adjustment of the Inner Idling Spring

n. Adjust the governor shaft guide screw so that it protrudes 13.5 to 14.5 mm from the governor cover
(Figure 124). Torque the locknut to 39 to 49 N.m (29 to 36 lbf.ft).

Figure 124 Adjustment of the Governor Shaft Guide Screw - Sectional View

92
o. Position and lock the control lever in the idling position and set the pump speed to 630 rpm. Turn the
adjusting nut on the governor shaft to bring the control rack to 6.6 mm (Figure 125). Torque the
locknut to 10 to 14 N.m (7 to 10 lbf.ft), increase the pump speed to bring the control rack to 3.5 mm
and check that the pump speed is 1100  50 rpm.

Figure 125 Adjustment of the Governor Shaft Spring

p. Increase the pump speed until the control rack reaches the zero position on the dial indicator and check
that the pump speed is 1340 rpm. After the correct adjustment is made, install the cap-nut together with
a new gasket and torque the cap-nut to 29 to 39 N.m (21 to 29 lbf.ft).
q. Decrease the pump speed to 240 rpm and adjust the idling setting bolt to bring the control rack to
9.5 mm. Tighten the locknut securely. Decrease the pump speed to 80 to 100 rpm and check that the
control rack is at 11.5 mm.
r. Set the pump speed to 1120 rpm and set the control lever in the position where is makes contact with
the maximum speed setting bolt. Adjust the maximum speed setting bolt (Figure 126) so that the
control rack begins to move in the fuel decrease direction while the pump speed is 1575 to 1635 rpm.
Tighten the locknut on the maximum speed setting bolt.

Figure 126 Adjustment of the Maximum Speed Setting Bolt

s. Decrease the pump speed to 1120 rpm and adjust the full-load setting bolt to bring the control rack to
11.3 mm, tighten the locknut securely (Figure 127).

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 Figure 127 Adjustment of the Full-load Setting Bolt
t. Set the pump speed to 225 rpm and with special tool 157913-3620, adjust the nut on the torque cam
control rod (Figure 128) to bring the control rack to 11.15 mm. Once the correct adjustment has been
made, lock the adjusting nut with the lock screw.

Figure 128 Adjustment of the Torque Cam Control Rod

u. Decrease the pump speed to 190 rpm and then increase the pump speed to 1575 to 1635 rpm. Ensure
that the control rack position is to specification for the corresponding pump speeds. If not, adjust the
torque cam control rod to obtain the correct settings. If adjustment cannot be made, replace the torque
cam.
v. Check the fuel injection quantities as specified in Paras 38. e., f., g., h. and i. If necessary, adjust the
full-load setting bolt and the torque cam adjusting nut to bring the quantities to specification.
w. Increase the pump speed to 1600 + 35 – 25 rpm, then move the control lever to maximum speed and
lock the control lever when it makes contact with the maximum speed setting bolt. Adjust the
maximum speed setting bolt until the control rack begins to move from 11.3 mm toward fuel decrease
and tighten the setting bolt locknut.
x. Check the speed drop by gradually increasing the pump speed to 1780  50 rpm and checking that the
control rack reaches 9.5 mm. Increase the pump speed further to ensure that the control rack reaches
zero mm.

94
 y. After the governor adjustments have been made, stop the pump and install the plug and new gasket
into the governor cover of the torque cam adjusting nut. Torque the plug to 20 to 29 N.m
(15 to 21 lbf.ft).
z. Install lockwire and seals between the idle and maximum speed setting bolts, between the governor
shaft and idling spring cap-nuts and into the full-load setting bolt.
aa. Disconnect the fuel lines from the fuel injection pump and the transfer pump and remove the injection
pump from the calibration stand. Remove the coupling device from the injection pump camshaft and
install the automatic timing device. Torque the timing retaining nut to 49 to 59 N.m (36 to 43 lbf.ft).
bb. Install the fuel injection pump in accordance with Light Repair – Group 4.

Transfer Pump
42. Disassembly. Disassemble the transfer pump as follows:

All work on the fuel transfer pump must be performed in a clean, dust free
location. Dust or dirt could damage the internal components.
a. An exploded view of the transfer pump is shown in Figure 129.

Figure 129 Transfer Pump - Exploded View

All work on the fuel transfer pump must be performed in a clean dust free
environment. Dust or dirt could damage the internal components.
b. Clamp the pump in a suitable vice ensuring soft jaw covers are used. Remove the priming pump and
discard the O ring (Figure 130).

95
 Figure 130 Removal of the Priming Pump
c. Remove the adapter and, using long-nose pliers, lift out both check valves and springs (Figure 131).
Discard the O ring.

Figure 131 Removal of the Check Valve

d. Clamp the pump in the vice so that the plug faces upward and remove the plug (Figure 132). Discard
the gasket.

Figure 132 Removal of the Plug

e. Lift out the piston spring and, using long-nose pliers, remove the piston (Figure 133).

96
 Figure 133 Removal of the Piston
f. Clamp the pump in the vice so that the tappet assembly faces upward. Using a screwdriver or a similar
device, pry off the snap-ring that retains the tappet and remove the tappet assembly (Figure 134).
Remove the push rod.

Figure 134 Removal of the Tappet

43. Cleaning and Inspection. Thoroughly clean all parts in clean diesel fuel and inspect the valve seats, piston
and related parts for wear, cracks and scoring. Replace parts if necessary.

NOTE
Should the push rod or the pump body show any signs of wear, they must be
replaced together as they are a matched pair.
44. Reassembly. Reassemble the transfer pump as follows:
a. Clamp the pump in a vice so that the mounting flange faces upwards and insert the tappet into the
body.
b. Install the snap-ring to prevent the tappet dislodging.
c. Clamp the pump in a vice so that the tappet assembly faces downwards and insert the push rod, piston
and piston spring.
d. Using a new gasket, install the plug and torque it to 78 to 88 N.m (57 to 64 lbf.ft).

97
 e. Clamp the pump in a vice and install the two check valves and springs.
f. Using new O rings, install the transfer pump and adapter and torque them to 40 N.m (29 1bf.ft) and
12 N.m (8 lbf.ft) respectively.
45. Testing. Test the transfer pump by plugging the outlet (delivery) port. Use a plug with a thread of
M17 x 1.5 mm, tighten the plug securely. Connect an air supply to the pump inlet port and tighten the connection
securely. Immerse the transfer pump assembly in a container of clean diesel fuel and apply clean moisture free air at a
pressure of approximately 200 kPa (29 psi) to the pump. Replace the transfer pump if air leakage is evident.

Automatic Timer
46. Removal. Remove the automatic timer as follows:
a. Remove the fuel injection pump in accordance with Light Repair – Group 4.
b. Position the injection pump in a soft-jawed vice and lock the injection pump drive gear with a suitable
locking device. Remove the nut and washer securing the automatic timer assembly to the injection
pump camshaft.
c. Install the outer piece of special tool 157926-5820 in the centre of the automatic timer. Insert the centre
bolt and tighten it until the timer is withdrawn from the camshaft.
47. Disassembly. Disassemble the automatic timer as follows:
a. Secure the automatic timer in a soft-jawed vice and match mark the drive gear to the timing flange
hub, or gauge and record the angle between the Z mark on the drive gear and the keyway in the timing
flange hub (Figure 135).

Figure 135 Z Mark-to-Keyway Angle

b. Remove the six bolts and lock-washers securing the drive gear to the drive flange and remove the drive
gear.
c. Invert the assembly and using a suitable pair of circlip pliers, remove the circlip securing the cover to
the timing flange hub and remove the cover.
d. Lift the flyweight and spring assembly from the timing flange, check and record the positions of the
pivot pin holes in the cams in relation to the timing flange. Remove the cams from the timing flange.
e. Invert the assembly and using a suitable pair of circlip pliers, remove the circlip securing the timing
flange to the drive flange. Remove the spacer and shim then separate the two flanges.
f. Position special tool 157921-9820 over the flyweight springs, compress the springs and remove the
snap-rings securing the springs to the pilot pins (Figure 136). Remove the spring seats, shims and
springs from the pilot pins.

98
 Figure 136 Removal of the Flyweight Spring Snap-ring
48. Cleaning and Inspection. Clean and inspect the automatic timer as follows:
a. Clean all parts with a suitable cleaning agent and then blow them dry with compressed air.
b. Inspect the drive gear for worn or damaged teeth and replace the gear if necessary.

NOTE
The springs and adjusting shims must always be replaced as a set.
c. Inspect the timing flange for signs of uneven wear, ridging or scoring in the cam bores and on the drive
flange mounting surface of the hub. Replace the timing flange if damage is excessive.
d. Check the cams for uneven wear in the pivot pin bores and on the outer surfaces. Replace parts as
necessary.
e. Check the pivot pins on both the drive flange and the flyweights for uneven wear and replace as
necessary.
f. Check the flyweight springs and replace them if they are worn or bent.
g. Replace all circlips and snap-rings.
49. Reassembly. Reassemble the automatic timer as follows:

Exercise care when installing the timer flange as the springs are compressed
and could cause personal injury if they should dislodge.

The shims must be installed in their original positions.

a. Lubricate the drive and the timing flanges with clean engine oil. Position the drive flange over the
timing flange hub, ensuring that the punch mark or the alignment mark on the drive flange is aligned
with the keyway in the timing flange hub. Position the shim and spacer over the hub and secure the two
flanges together with a new circlip. Check for a clearance of 0.02 to 0.1 mm (0.0008 to 0.004 in)
between the shim and the drive flange. If necessary, replace the shim to achieve the specification.
b. Apply clean engine oil to the cams and assemble them into position, as previously noted, in the timing
flange (Figure 137).

99
 Figure 137 Installation of the Large and Small Cams
c. Using special tool 157921-9820, assemble the pilot pins, spring seats and springs on the flyweights and
secure the springs with new snap-rings. Measure the distance between the outer edges of the pivot pins
(Figure 138) and adjust the large cams to bring the pivot pin holes to the same dimension, while
maintaining the pivot pin holes equidistant from the centre line of the timing flange hub (Figure 139).

Figure 138 Measuring the Flyweight Pin Distance

Figure 139 Cam Pivot Pin Holes to Hub Dimensions

d. Position the flyweight assembly above the timing flange, align the flyweight pivot pins with the pivot
pin holes in the large cams and insert the flyweight assembly into the timing flange.
e. Install the cover over the flyweights and install a new circlip to secure the cover to the timing flange.
Using a set of feeler gauges, check the clearance between the circlip and the cover. If necessary,

100
 replace the cover with either a thicker or thinner cover to obtain a clearance of 0.05 to 0.2 mm
(0.002 to 0.008 in).
f. Place the gear on the drive flange and set the Z mark on the gear at the correct angle (recorded
previously) with the keyway in the timing flange hub, or align the match marks. Install and torque the
six retaining bolts to 7.8 to 11.8 N.m (69 to 104 lbf.in).
50. Installation. Fit the automatic timer to the injection pump camshaft ensuring that the key aligns. Install the
lock-washer and round nut and torque the nut to 59 to 69 N.m (43 to 51 lbf.ft).
51. Adjustment. Adjust the automatic timer as follows:
a. Install the fuel injection pump on a calibration test stand (Para 37.).
b. Operate the test stand and check, using a stroboscope, that at 1200 to 1300 rpm there is no advance and
at 1500 rpm the advance finishes at 3 to 4 degrees.
c. If the advance is not within specification, adjustment can be made by replacing the timer springs
and/or the shims.

Fuel Injectors
52. Disassembly. Disassemble the fuel injectors as follows:

All work on the fuel injectors must be performed in a clean, dust free
environment. Dust or dirt could damage the internal components.
a. Secure the injector body in a soft-jawed vice and remove the end cap and gasket (Figure 140).

Figure 140 Fuel Injector- Exploded View

b. Remove the adjuster, washer, pressure spring and lift out the push rod. Unscrew the connector and
remove and discard the gasket.
c. Invert the injector body in the vice and remove the cap-nut and nozzle assembly. Remove the injector
body from the vice.

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53. Cleaning and Inspection. Clean and inspect the fuel injectors as follows:
a. Soak all components in a suitable carbon removing and cleaning agent. Wash all external dirt, grease
and carbon deposits from the body and cap-nut. Use a brass wire brush to assist in the removal of
carbon deposits.

NOTE
When cleaning the needle valve and nozzle, take care not to scratch or score the
valve seat.
b. Using a suitable diameter wire or drill, clean the fuel feed passages in the nozzle (Figure 141). Using
an injector cleaning kit, remove the carbon from the recess in the nozzle.

Figure 141 Cleaning the Nozzle

c. Using the tools provided in the cleaning kit, remove the carbon from the valve seat and the main fuel
outlet (Figure 142).

Figure 142 Cleaning the Nozzle Valve Seat

d. To prevent the wire bending or breaking in the nozzle ensure that no more than 1.5 mm (0.062 in)
extends from the holder. Use the probe wire to clean out the carbon from the nozzle spray holes
(Figure 143).

102
 Figure 143 Cleaning the Nozzle Spray Holes

NOTE
If the needle valve is blued or has a dull appearance, this indicates wear. The valve
and the nozzle must be replaced as a matched pair. Do not attempt to lap the valve in
the nozzle.
e. Clean the needle valve and inspect it for wear or damage.
f. Inspect the mating faces of the nozzle and the body, these should be smooth and free of scratches or
scores (Figure 144). Replace the injector assembly if these components are faulty.

Figure 144 Inspection of the Injector Mating Faces

54. Reassembly. Reassemble the fuel injectors as follows:

NOTE
Do not hold the needle valve for too long as expansion due to body heat transfer will
prevent valve installation.
a. Immerse the nozzle and needle valve in clean fuel and insert the valve in the nozzle. Ensure that the
valve moves freely.
b. Ensure that the injector body is clean, fit the nozzle to the body and align the locating pegs. Install the
cap-nut and tighten it securely. Secure the injector body in the vice and torque the cap-nut to 58 to 78
N.m (43 to 58 lbf.ft).
c. Insert the push rod in the body and fit the pressure spring, washer and adjuster. Install a new gasket
and the end cap. Fit the connector together with a new gasket. Remove the injector from the vice.

103
55. Spray Pattern Test. Test the spray pattern of the fuel injectors using the following procedure:

Due to the high pressures involved in the spray pattern test and the possibility
of a defective injector spraying in any direction, keep hands away from the
injector outlet to prevent personal injury.

Injector spray patterns should be checked by operating the pump lever at a

rate of four to six strokes per second. Operating the lever too slowly will not
generate sufficient test pressure and will cause the fuel to spray in coarse
particles which will not give a true indication of the injector’s condition.
a. Ensure that there is sufficient clean fuel in the reservoir. Install the injector on the test rig and close off
the fuel supply to the gauge. Operate the handle two to three times while observing the fuel spray
pattern (Figure 145).

Figure 145 Injector Spray Pattern Test

b. Replace any injector that fails to spray correctly.
c. Open the fuel supply to the gauge and operate the handle to build up pressure, do not allow the injector
to spray. Observe the starting pressure reading on the test rig gauge while holding the pressure with the
handle as the injector sprays. The injection starting pressure must be 18 134 kPa (2630 psi). If it is not
within specification, turn the adjuster with a screwdriver to increase or decrease the starting pressure as
required (Figure 146).

104
 Figure 146 Adjustment of the Starting Pressure
d. Install the end-cap and gasket and torque the end-cap to 58 to 78 N.m (43 to 58 lbf.ft). Check that the
starting pressure is correct and the leak down rate is not less than six seconds from 18134 kPa
(2630 psi) to 10 132 kPa (1469 psi) when the handle is released and the pressure is allowed to fall
naturally.
e. Check the end-cap and the cap-nut for any leaks and rectify them as necessary. If the leak down rate is
less than six seconds, replace the nozzle assembly.
f. Replace the injector if it does not conform to specification.
Turbocharger
56. Disassembly. Disassemble the turbocharger as follows:
a. Remove the turbocharger in accordance with Light Repair – Group 4.
b. Remove the exhaust adaptor from the exhaust outlet on the turbine housing.
c. Clean the exterior of the turbocharger with a suitable non-caustic solvent and blow it dry with
compressed air.
d. Using a scribe, match mark the relative positions of the turbine housing, the bearing housing and the
compressor housing.
e. Remove the coolant inlet and outlet fittings from the bearing housing.

Use care when removing the turbine housing and the compressor housing. Do
not tilt the housings during removal or damage to the turbine and/or
compressor wheel blades could result.
f. Remove the bolts securing the turbine housing to the bearing housing (Figure 147). Remove the
clamp-plates and carefully remove the turbine housing. If necessary, tap the turbine housing with a
soft-headed hammer to free it from the bearing housing flange.

105
 Figure 147 Removal of the Turbine Housing
g. Using a suitable pair of circlip pliers, remove the circlip securing the compressor housing to the
bearing housing and carefully remove the compressor housing.
57. Cleaning and Inspection. Clean and inspect the turbocharger as follows:

Damage to the turbocharger will result if:

It is cleaned with abrasives.
The bearing housing is immersed in the cleaning solvent.
Compressed air is blown under the compressor wheel.
The wheel and shaft assembly are spun when using compressed air to remove
residue and solvent.

NOTE
Before cleaning the turbocharger inspect all components for burning, rubbing or
impact damage which might not be evident after cleaning.
a. With the aid of a soft-bristle brush and a plastic blade scraper, clean all components with a suitable
non-caustic solvent, then blow them dry with clean, dry, compressed air.
b. Inspect the compressor housing for the following:
(1) nicks, dents or warpage that could prevent sealing between the compressor housing and the
bearing housing;
(2) a worn, broken or corroded circlip groove; and
(3) wheel-rub damage in the contour area.
c. If the wheel-rub damage cannot be polished out using an 80 grit silicone carbide abrasive cloth, or if
any of the other faults are evident, replace the compressor housing.
d. Inspect the turbine housing for the following:
(1) nicks, dents or warpage that could prevent sealing between the turbine housing and the bearing
housing;
(2) corroded or stripped threads in the mounting bolt holes;
(3) cracks or blow-by burns in the mounting flange; and
(4) wheel-rub damage in the contour area.

106
e. If the wheel-rub damage cannot be polished out using a 60 grit silicone carbide abrasive cloth or if any
of the other faults are evident, replace the turbine housing.
f. Check the condition of the compressor and turbine wheels. If wear or damage is evident, replace the
bearing housing assembly.

Use care when installing the dial indicator assembly to avoid damaging the
machined surface of the bearing housing.
Before installing a new bearing housing, ascertain and rectify the cause of the
bearing failure.
g. Suitably support the bearing housing in a soft-jawed vice. Install a dial indicator into the oil inlet port
in the bearing housing with the cranked plunger resting on the shaft (Figure 148). Push the turbine
wheel shaft away from the plunger by applying equal pressure simultaneously to both the turbine and
compressor wheels. Zero the dial indicator and apply equal pressure simultaneously to both the wheels
to move the shaft toward the plunger. Roll the shaft slightly in both directions while applying pressure
to the wheels to ensure that the reading indicated is the maximum possible. Move the shaft away from
the plunger using equal and simultaneous pressure to ensure that the indicator returns exactly to zero.
Repeat the test procedure several times to ensure that the maximum radial clearance of the bearings has
been obtained. If the clearance is not within 0.056 to 0.127 mm (0.0022 to 0.005 in), replace the
bearing housing assembly.

Figure 148 Checking the Journal Bearing Radial Clearance

h. Position the dial indicator assembly on the turbocharger so that the indicator plunger rests squarely on
the end of the turbine wheel shaft at the compressor wheel end (Figure 149). Manually press on the
compressor wheel to push the turbine shaft as far as it will go away from the indicator plunger. Zero
the dial indicator, then push the shaft, at the turbine wheel end, as far as it will go toward the plunger
and note the reading on the dial indicator. Push the shaft away from the plunger as far as it will go and
check that the reading on the dial indicator returns exactly to zero. Repeat the clearance check several
times to ensure that the maximum reading is obtained. If the axial clearance of the bearings is not
within 0.025 to 0.084 mm (0.001 to 0.0033 in), replace the bearing housing assembly.

107
 Figure 149 Checking the Journal Bearing Axial Clearance
58. Reassembly. Reassemble the turbocharger as follows:

If any housing has been replaced, ensure that the scribed match marks have
been transferred form the old to the new housing.
a. Position the turbine housing, on a flat level surface, with the discharge side down. Carefully insert the
turbine wheel end of the bearing housing into the turbine housing. Ensure that the match marks are
aligned and that the bearing housing enters the turbine housing squarely to avoid damaging the turbine
wheel blades.
b. Install new clamp-plates over the flange on the bearing housing and align the bolt holes in the plates
with the bolt holes in the turbine housing. Install new bolts and torque the bolts to 52 N.m (38 lbf.ft.).
c. Smear a new compressor housing retaining circlip with engine oil and install the circlip onto the
bearing housing, ensuring that the bevelled side is toward the turbine housing. Position the
bearing/turbine housing assembly and install a new O ring on the flange at the compressor end of the
bearing housing (Figure 150). Carefully install the compressor housing onto the bearing housing and
align the match marks. Without disturbing the turbocharger assembly, invert and position the
assembly, compressor housing inlet down, on the base plate of the press. Position a suitable piece of
flat steel plate on the turbine housing outlet and apply a uniform load of 159 to 182 kg (350 to 400 1bs)
to the steel plate at a point directly above the wheel shaft centre-line. Install the oiled circlip, lug end
first, into the groove in the compressor housing. Align the match marks and ensure that the circlip is
correctly seated by tapping around the inner circumference of the circlip with a suitably sized drift and
a hammer. Release the pressure from the turbocharger and remove it from the press.

Figure 150 Installing the O ring

d. Install the coolant inlet and outlet fittings into position on the bearing housing and tighten the fittings
securely.
e. Apply clean engine oil through the bearing housing oil inlet port and rotate the turbine wheel shaft
several times to pre-oil the journal bearings, then refill the oil inlet hole with clean engine oil.
f. Install the turbocharger in accordance with Light Repair – Group 4.

108
59. The fuel system specifications are detailed in Table 10.

Table 10 Fuel System Specifications

Serial Item Specification
1 Control rack guide screw tightening torque 4.9 to 6.9 N.m (43 to 61 lbf.in)
Delivery valve holders tightening torque
2 Initial 39 N.m (29 lbf.ft)
3 Final 44 N.m (32 lbf.ft)
4 Delivery valve holder locking plates tightening torque 4.4 to 6.8 N.m (39 to 60 Ibf.in)
5 Governor housing tightening torque 6.9 to 8.8 N.m (61 to 78 Ibf.in)
Front bearing cover
6 Tightening torque 6.9 to 8.8 N.m (61 to 78 Ibf.in)
7 Camshaft end-play 0.03 mm (0.001 in)
8 Injection pump base plugs tightening torque 54 to 74 N.m (40 to 55 lbf.ft)
9 Full-load set lever retaining nut tightening torque 10 to 14 N.m (88 to 124 Ibf.in)
10 Transfer pump tightening torque 4.9 to 6.9 N.m (43 to 61 Ibf.in)
11 Flyweight assembly retaining nut tightening torque 49 to 59 N.m (36 to 43 lbf.ft)
12 Governor housing face-to-pivot pin hole 28.8 to 29.2 mm (1.134 to 1.149 in)
13 Stop control lever tightening torque 10 to 14 N.m (7 to 10 lbf.ft)
14 U-shaped lever guide plug tightening torque 20 to 29 N.m (15 to 21 lbf.ft)
Injection pump timing

15 Plunger pre-stroke 3.6  0.05 mm

Pump cylinder port closure
16 Cylinder 1 0°

17 Cylinder 3 90°  30'

18 Cylinder 4 180°  30'

19 Cylinder 2 270°  30'

20 Idling capsule locknut tightening torque 18 to 22 N.m (13 to 16 lbf.ft)
21 Inner idling spring cap-nut tightening torque 16 to 20 N.m (12 to 15 lbf.ft)
Governor shaft guide screw protrusion
22 Protrusion above governor cover 13.5 to 14.5 mm
23 Locknut tightening torque 39 to 49 N.m (29 to 36 lbf.ft)
Governor shaft
24 Locknut tightening torque 10 to 14 N.m (7 to 10 lbf.ft)
25 Cap-nut tightening torque 29 to 39 N.m (21 to 29 lbf.ft)
26 Governor cover tightening torque 20 to 29 N.m (15 to 21 lbf.ft)
27 Automatic timer tightening torque 49 to 59 N.m (36 to 43 lbf.ft)
28 Transfer pump piston plug tightening torque 78 to 88 N.m (57 to 64 lbf.ft)
29 Transfer pump tightening torque 40 N.m (29 lbf.ft)

109
 Table 10 Fuel System Specifications (Continued)
Serial Item Specification
30 Transfer pump adapter tightening torque 12 N.m (8 lbf.ft)
Automatic timer advance
31 Pump speed and degrees advance - 1200 to 1300 rpm No advance
32 1500 rpm 3 to 4 degrees
Automatic timer
33 Flange end-float 0.02 to 0.1 mm (0.0008 to 0.0039 in)
34 Locknut tightening torque 98 N.m (72 lbf.ft)
35 Timer flange tightening torque 43 N.m (32 lbf.ft)
36 Round nut tightening torque 59 to 69 N.m (43 to 51 lbf.ft)
Fuel injectors
37 Starting pressure 18 134 kPa (2630 psi)
Not less than six seconds from 18 134
38 Leak-down rate
kPa (2630 psi) to 10 132 kPa (1469 psi)
39 End-cap tightening torque 58 to 78 N.m (43 to 58 lbf.ft)
Turbocharger bearing clearance
40 Radial 0.056 to 0.127 mm (0.0022 to 0.005 in)
41 Axial 0.025 to 0.084 mm (0.001 to 0.0033 in)
42 Turbine housing retaining bolts tightening torque 52 N.m (38 lbf.ft)
43 Compressor housing
44 Circlip installation pressure (Hydraulic press) 159 to 182 kg (350 to 400 lbs)

110
ELECTRICAL
Starter Motor
113. Disassembly. Disassemble the starter motor as follows:
a. Remove the two nuts securing the two wires to the solenoid switch terminals and remove the two
wires.
b. Remove the two screws and washers securing the switch to the housing and remove the switch
(Figure 299).

Figure 299 Removal of the Solenoid Switch

c. Remove the small hexagonal headed screw securing the field wire to the solenoid and match mark the
solenoid to the housing.
d. Remove the two screws securing the solenoid to the starter motor housing and remove the solenoid by
disengaging the plunger from the clutch lever (Figure 300). Remove the shim.

Figure 300 Removal of the Solenoid

e. Match mark the brush cover and field housing in relation to the starter motor housing. Remove the two
screws securing the brush cover and the two long screws securing the field housing to the starter motor
housing.
f. Remove the field housing and brush assembly from the starter motor housing (Figure 301) and discard
the O ring. Disengage the brushes from the brush holder.

206
 Figure 301 Removal of the Field Housing and Brush Assembly
g. Remove the armature and bearings from the housing.
h. Remove the single bolt securing the bearing plate to the housing and remove the two screws securing
the cover to the plate (Figure 302). Remove the cover and C-clip from the end of the clutch then
remove the washer and plate. Withdraw the bearing plate from the housing and remove the washers
from the shaft.

Figure 302 Removal of the Bearing Plate

NOTE
Prior to removing the pinion drive gear, note the position of the drive gear in relation
to the clutch shaft.
i. Apply pressure on the pinion retaining collar and remove the circlip (Figure 303). Remove the collar,
pinion and spring.

Figure 303 Removal of the Pinion Gear

207
 j. Remove the two screws securing the pinion cover and plate to the housing (Figure 304). Remove the
cover and plate.

Figure 304 Removal of the Pinion Cover and Plate

k. Remove the rubber seal from the clutch pivot bore and remove the shims and plastic spacer
(Figure 305). Remove the clutch assembly, lever and pivot bush.

Figure 305 Removal of the Clutch Lever and Pivot Bush

l. Remove the lever pivot pin and pivot bush, taking note of the position of the bush halves (Figure 306).

Figure 306 Removal of the Pivot Bush and Pin

m. Remove the bearing and the oil seal from the pinion housing (Figure 307).

208
 Figure 307 Removal of the Pinion Bearing and Seal
114. Cleaning and Inspection. Clean and inspect the starter motor as follows:
a. Clean all components in a suitable cleaning agent and blow them dry with compressed air.
b. Check that the bearings rotate smoothly without any noise.
c. Check the length of the brushes and replace them if they are below or approaching 9 mm (0.35 in).
Replace the brush springs if the pressure is weak.
d. Inspect the commutator for excessive wear or scoring, and replace it if it is worn more than 1.0 mm
(0.039 in) below the manufactured diameter.
e. The commutator under cut must not exceed 0.2 mm (0.007 in). Replace the commutator if the
specification is exceeded.

NOTE
As the starter motor is a waterproof component, all gaskets and rubber seals must be
replaced on reassembly.
115. Reassembly. Reassemble the starter motor as follows:

NOTE
The oil seal lips must face the pinion bearing.
a. Install the oil seal, plain face first. Using a suitable press, install the pinion bearing.
b. Install the pinion bearing retaining plate and cover and secure them in place with two screws and
washers.
c. Position the clutch lever bush halves on the lever (Figure 308), smear the lever and bush halves with
suitable grease and insert them in the pivot bore.

209
 Figure 308 Installation of the Pivot Bush
d. Smear grease on the clutch shaft and clutch groove. Install the clutch assembly in the housing ensuring
that the fork engages with the clutch groove.
e. Install the plastic bush, the shims and the rubber seal into the housing ensuring that the locating tab on
the seal is positioned on the screw hole.

NOTE
Ensure that the pinion gear is fitted in the correct position as noted in the
disassembly procedure.
f. Install the pinion spring, the pinion and retaining collar, apply pressure on the collar and install the
circlip.
g. Install the clutch gear on the clutch shaft and fit the shim washers. Fit the bearing plate on the housing
and secure it with the single bolt, tighten the bolt securely.
h. Fit the plate and washer on the bearing plate (Figure 302) and secure them with the C-clip. Install the
cover and secure it with the two screws.
i. Apply grease to the armature shaft teeth. Install the armature and bearings in the bearing plate ensuring
the shaft teeth engage with the clutch gear teeth. Press the bearing fully into the bearing plate.
j. Fit the O ring onto the bearing plate and install the field housing ensuring the match marks align.
Install the O ring onto the field housing and engage the two tabs in the slots provided.
k. Position the brush holder on the field housing and install the two field brushes. Push back the four
brushes into the holders and place the brush holder over the commutator. Fit the brush cover on the
brush holder and secure it with the two screws. Align the match marks on the brush holder and field
housing and secure it with the two long screws.
l. Install the solenoid and shim on the housing ensuring the plunger engages the clutch fork and the
match marks align. Secure the solenoid and shim to the housing with the two screws. Connect the field
wire to the solenoid lower terminal and tighten the nut securely.
m. Fit the solenoid switch to the housing and secure it with the two screws and washers. Connect the wire
from the switch lower terminal to the solenoid side terminal and tighten the small hexagonal headed
screw securely (Figure 299). Connect the wire from the switch upper terminal (with the protective
boot), to the solenoid upper terminal and tighten the nut securely.

210
Alternator and Vacuum Pump
116. Disassembly. Disassemble the alternator and vacuum pump as follows:
a. Remove the alternator in accordance with Light Repair – Group 15.
b. Remove the three bolts securing the vacuum pump to the alternator. Securing the centre plate, remove
the vacuum pump from the rotor shaft (Figure 309).

Figure 309 Removal of the Vacuum Pump

c. Turn the vacuum pump centre plate to release it from the three lugs. Remove the plate, rotor and vanes
(Figure 310).

Figure 310 Disassembly of the Vacuum Pump

d. Apply a suitable tape to the rotor shaft splines. Taking care not to dislodge the stator coils and damage
the rear seal, remove the four through bolts that secure the rear cover to the front cover (Figure 311).

Figure 311 Removal of the Alternator Rear Cover

211
 e. Carefully clamp the rotor in a vice fitted with soft-jaw protectors, remove the nut retaining the pulley
(Figure 312), and remove the washer, pulley and cover from the rotor.

Figure 312 Removal of the Front Pulley and Cover

f. Remove the three screws and washers securing the bearing retaining plate to the front cover
(Figure 313). Remove the plate, then using a suitable press and arbor, remove the bearing.

Figure 313 Removal of the Front Cover Bearing

g. Remove the nut retaining the B-terminal to the rear cover (Figure 314). Remove the five nuts retaining
the diode holder taking note of the insulating washer positions.

Figure 314 Removal of the Diode Assembly

NOTE
When using the soldering iron to separate the diodes from the stator coils, hold the
lead wire with long-nose pliers to prevent heat being transferred to the diodes
causing them to malfunction.
h. Hold the lead wire connecting the stator coil to the diode with long-nose pliers and melt the solder
connection with a soldering iron (Figure 315). Repeat the procedure for the remaining connections and
separate the coil from the diode holder.

212
 Figure 315 Removal of the Diode Holder
117. Cleaning and Inspection. Clean and inspect the alternator and vacuum pump as follows:
a. Clean all components in a suitable cleaning agent and blow them dry with compressed air.
b. Check the bearings and seals for damage or excessive wear and replace parts if necessary.
c. Using a vernier caliper, measure the outside diameter of the slip rings (Figure 316), the figure must be
between 33.6 to 34.6 mm (1.31 to 1.36 in). If the dimension is not within specification, replace the
rotor assembly.

Figure 316 Measuring the Slip Rings

d. Using an ohmmeter, check the resistance across the slip rings. If continuity does not exist, replace the
rotor assembly (Figure 317).

Figure 317 Continuity Test of the Rotor and Slip Ring

e. Check for continuity between the slip ring and rotor core (or shaft). If continuity exists, replace the
rotor assembly (Figure 318).

213
 Figure 318 Earth Test of the Rotor and Slip Ring
f. Check for continuity across the stator coils (Figure 319). If continuity does not exist, replace the coil
assembly.

Figure 319 Continuity Test of the Stator Coil

g. Check for continuity across one of the stator coils and the stator core (Figure 320). If continuity exists,
replace the coil assembly.

Figure 320 Earth Test of the Stator Coil

h. Ensure the brushes are between 5.5 to 12.5 mm (0.22 to 0.49 in). Replace the brushes if they are worn
to (or near) the line scribed on the brush (Figure 321).

Figure 321 Inspection of Brush Length

214
i. Check each diode for continuity across the diode terminals and ensure that continuity exists in one
direction and infinity in the opposite direction. Replace the diode assembly if any diode is suspected of
being faulty.
j. Replace the regulator if it is suspected of being faulty.
k. Figure 322 is included as an aid to circuit tracing.

Figure 322 Alternator Circuit Diagram

l. Inspect the vacuum pump for damage or excessive wear and replace the vanes if the overall length is
not between 12.5 to 13.5 mm (0.492 to 0.531 in) (Figure 323).

Figure 323 Measuring the Vacuum Pump Vanes

m. Measure the inside diameter of the pump housing and check that the dimension is between 57.0 to
57.1 mm (2.244 to 2.248 in). Replace the pump assembly if it is not within tolerance (Figure 324).

Figure 324 Measuring the Vacuum Pump Housing

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 n. Check the vacuum pump oil seal for signs of damage or excessive wear. If necessary, pry out the seal
with a screwdriver, then using a suitable arbor, press in the new seal (Figure 325).

Figure 325 Installation of the Vacuum Pump Oil Seal

o. Check that the pump check valve operates smoothly.
118. Reassembly. Reassemble the alternator and vacuum pump as follows:
a. Position the diode holder on the stator coil assembly and solder each connection, ensuring the lead
wires are held by long-nose pliers to prevent the heat damaging the diodes (Figure 326).

Figure 326 Reconnection of the Stator to the Diode Holder

b. Press the new bearing into the front cover. Install the retaining plate and secure it with the three screws
and lock-washers.
c. Clamp the rotor in a vice fitted with soft-jaw protectors and install the front cover. Fit the pulley, a new
lock-washer and the nut. Torque the nut to 45 to 58 N.m (33 to 43 lbf.ft).
d. Insert the diode holder and stator into the rear cover ensuring that the insulating washers are in the
correct locations. Install the lock-washers and nuts and tighten the nuts securely.
e. Insert a piece of wire through the rear cover to hold the brushes back in the holder and install the rotor
and front cover (Figure 327). Remove the wire when the rotor is fully installed. Check that the rear
bearing and locking ring engage fully.

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 Figure 327 Installation of the Rear Cover
f. Insert a suitable bar or rod through the front and rear pivot holes and install the four through bolts
(Figure 328). Tighten the bolts securely.

Figure 328 Installation of the Rear Cover Through Bolts

g. Remove the protective tape from the rotor shaft splines.
h. Insert the vacuum pump rotor in the housing with the serrated boss uppermost. Fit the vanes in the
rotor with the round end towards the housing (Figure 329).

Figure 329 Installation of the Vacuum Pump Rotor and Vanes

i. Fit a new O ring on the pump housing and install the centre plate. Turn the plate to engage the three
lugs in the housing (Figure 330). Position a new O ring on the alternator pump mounting face.

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 Figure 330 Installation of the Centre Plate
j. Align the rotor bore and the centre plate hole and install the pump on the alternator. If necessary turn
the housing to align with the holes in the alternator rear cover (Figure 331). Insert and tighten the three
bolts securely.

Figure 331 Installation of the Vacuum Pump

k. Apply a few drops of clean engine oil through the filler port and rotate the alternator pulley to ensure
that the pump is adequately lubricated on initial start up. Check that the pulley rotates smoothly.
l. Install the alternator in accordance with Light Repair – Group 15.

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121. The electrical specifications are detailed in Table 17.

Table 17 Electrical Specifications

Serial Item Specification
1 Starter motor brush length 9 mm (0.35 in)
2 Commutator maximum wear 1.0 mm (0.039 in)
3 Commutator maximum under-cut 0.2 mm (0.007 in)
4 Alternator slipring outer diameter 33.4 to 34.6 mm (1.31 to 1.36 in)
5 Alternator brush length (minimum) To the scribed line on the brush
6 Vacuum pump vane length 12.50 to 13.50 mm (0.492 to 0.531 in)
7 Vacuum pump housing inner diameter 57.0 to 57.10 mm (2.244 to 2.248 in)
8 Fanbelt pulley tightening torque 45 to 58 N.m (33 to 43 lbf.ft)

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