SD33T Diesel Engine FOREWORD This supplement contains information con- ‘cerning necessary service procedures and relevant data for the SD33T diesel engine used in vehicles. All information, illustrations and specifica- tions contained in this supplement ae based fon the latest product information available at the time of publication. If your NISSAN ‘model differs from the specifications con- ‘tained in this supplement, consutt your NISSAN dealer for information. The right is reserved to make changes in specifications and methods at any time with- ‘out notice. NISSAN MOTOR CO.,LTD. © 1983 NISSAN MOTOR CO.,LTD. QUICK REFERENCE INDEX aay TEN tH UAL Tg HD a ee aT eMC CELTS SLES aaa tspeat HOW TO USE THIS MANUAL D> This manual is designed to give you the new service procedures, service data and specifications of the SD33T diesel engine used in vehicles. D> This manual, however, does net contain some items which are the same as those for the SD33 diesel engine. Please use this manual in conjunction with the Service Manual “Model SD Series Diesel Engine” (Pub. No.: SM3E-00SDG0} 2-7 MPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the mechanic and the efficient functioning of the engine. The service methods in this Service Manual are described in such a manner that the service may be per- formed safely and accurately. Special service tools have been designed to permit safe and proper performance of service. Be sure to use them. Service varies with the procedures used, the skills of the mechanic and the tools and parts available Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first completely satisfy himself that neither his safety nor the engine’s safety will be jeopardized by the service method selected.GENERAL INFORMATION CONTENTS SPECIFICATIONS ceveeeee GIZ ENGINE SERIAL NUMBER LOCATION . . GI-2 GI-1SPECIFICATIONS / ENGINE SERIAL NUMBER LOCATION SPECIFICATIONS Engine mode 03st ‘Number of lingers é ve erangemet on Bore x Stoke min) | 83x 1001927x398) innlacerent em tevin) | 32246 (198.07) Filing orcer ‘Number of piston rings ‘Compresion ou Number of main Eeoringe Compression aio Cetane numberof ea fue! ENGINE The engine number is stamped on the right side of the cylinder block. (SD33 30000 T } Eset No. Engine 26 Mere man 45 SERIAL NUMBER LOCATION GI-2MAINTENANCE INJECTION AND FUEL SYSTEM )LE SPEED ADJUSTMENT ‘Tum idle control knob fully coun- ‘clockwise ‘Start engine and warm it up until lant temperature indicator poimis ‘middle of gauge. ‘Attach tachometer’s pickup to el injection nozzle 4, Adjust engine to specified idle speed with idle speed adjusting serew. Idle speed: {600 - 650 rpm 700 -750 rpm (Equipped with power steering) MA-1 5. After adjusting idle speed prop- erly, tighten lock nut.ENGINE MECHANICAL CONTENTS €) ENGINE COMPONENTS (Outer parts}. EM-2 SERVICE DATA AND ENGINE COMPONENTS: SPECIFICATIONS cence EMG Internal parts). . migewes exemencce ENS Inspection end adjustment ems Tightening torque Emo. EM-1ENGINE COMPONENTS (Outer parts) ENGINE COMPONENTS (Outer parts) sans ag D 39-49 4-5, 29-36) Pe semar9s18 Oa coke © 10-13 (19-1.3,7-815 ont pipe ew (19°13,7-9 5 L@ 59-69 15-7,43- 51) \ ‘ “tier Nee Ot titer bracket \ tajestion pump \ bracket een \ ‘ Bs Kem tegen, fu) \~ Dieset pump contoler Thermozst housing > Always place Woe pump Se a. \ < Temeoupting> ~~, Aerator — é “Connector N ‘Turbocharger we es, : 2 20" ae.s0(a7-29,20.20 ' oa a Cw f towne \ awe D 26-36 127-32, 20-27|~ (15-18, am ©: No ho, fy wa \—ouweinie _suenonENGINE COMPONENTS (Internal parts) ENGINE COMPONENTS (internal parts) Rocker cover Push rod Varo aie Maia tott © 118-127 6 (92-13, 67-94) 20.25 20-25, 14-181 Glow ping Cinder head cere a6 -_ (os. 06.29-427 Di 4a-49 i iS"b0 28-287 ey Oe \ ann ce 2 Ds Nim Capen, ab) "1: Keep incomect onder XX *2: Always replace. Ol pan 3, 217-239) EM-3SERVICE DATA AND SPECIFICATIONS SERVICE DATA AND SPECIFICATIONS INSPECTION AND ADJUSTMENT Valve spring CYLINDER HEAD Painted red Units mm (in) Freelangin sen (in pee ‘Srandaed timc ma: 2081677 ae Tmm/N (mmfaa,infiol | (20.6/68, 1.205115) jrugina cretion ee ear 920100020) | conor) ‘Assembled height 3e776 ooseedicdbe Less than amiN mene, (397799, .569/7) 0.05 10.0020) Dut of quare se fl 22 10.087) VALVE Unit: men tint i Valve to head distance seme, Sandra ‘Serice Valve head diameter ‘Standard nie Se Intake 38.0 11.496) ‘make 0205-0675 (0.0088 - 0.0286) Exnour 32.0 11.260) 1.25 (0.0892) = ‘hue ‘0288-0745 vain (0.0100 -0.02s3) nae Exnaust emer “o Valve stem linder 7970-7985, 2370-8385 stem hole (Cylinder head) Intake (oa138- 03295 Unit nd oats) 033011 ‘Vave nem hole inner 8000-8015 7.965 -7.960 |8.145-8.160 | 8.345 8.350 ciamerer (0:3:60-0.31561 exnaust oaas- | wsz07- | jos2—s- esis! | 032i) | oszen Standara [ax clorance Ta ee a5 520" Stem 10 sem hole clearance Tneake 20rs-0.045 Valve margin “T™ 1 0.0008 | 0.15 (0.0080) lima © ware 2.0018) Vai am and Ensue 008-007 surface ginaing 02 (0.08) ‘oov1s- | 02010.0079) Hee 0.0028) Valve clearance \Vawe defection limit (015 10.0088) (or! Intake 035 (0.014) Exnaust EM-4SERVICE DATA AND SPECIFICATIONS ‘Valve timing uni: aeorce 2 > @ = ' 2575 o 7 2 Valve seat nits mm Gn Ds e De By ewraa ‘Standard ‘Sener (user diameter "Ot" Inner elameser “D2 Diameter of at “03” 99.035 -36.045 (1 5068-15972) 32.9-33.1 1.295 -1.309) 36.95 37.05 (1.4547 - 1.48871 Valve seat fe angle "a eat 90 1 Outer giameter "OY 28.035 -36.085 (1.3799 - 1.3797) 36.295 96.286 (15972 3876) | 35,435-96.445 (1 3951 - 1.9955), Ine diarmeer "02" 284-286 11.118 +1126) 204-2860 1328) 7.4.28 (2.118 7.126) Diometer of wat “OS” 3098 - 31.05 12185 -1.2224) 30.96 -91.05 (12186-12224) | 3095.31.05 (12186-1.2226) (Gyinger esd vale zat diometer 34995 -35.01 1.5778 -1.37031 35.195. 35.21 (1.3688- 1.3962) | 35.395-35.41 (1.3635 - 1.2961), Vai sat fae angle" 29° 90° EM. 5SERVICE DATA AND SPECIFICATIONS CAMSHAFT AND CAMSHAFT BUSHING nits mm in) = ‘Sandor om ‘Camenatjournat 0 buting elorance [ot eterancel Front 0024-002 {0.0009 - 0.0020) enter 0937-0115 to.o015- 0.0085) | %*5(9.0059) Row ‘024-0102 0.0009 - 0.0080) ‘Camehat owns! siomerer Front 45494-45447 _ (17982 -1-76921 center 43.97 42.910 _ (17282-17287) Re 428-4201 7 4.6228 -1.62231 Commott bend (Tost | Lez man 0.03 incicator reac) tooora) | 908 10.0024) “Comatett ond say 0.08 -028 = (o.ooar -orr0) | 082100197) 5, ai 3728-3732, arahalare (14607-14893) (Cam neigh tit 368 0.409) CYLINDER BLOCK AND CYLINDER LINER Unit: en (in semes1 Stancard ies thon 0.10 10.0030 ‘Surtace Marne {shat dreeton) wut evden bes tman 03 (0012) fmihowrcvlinger liner) | 9.62 0.0008) ‘Right arate rection! Ctnger bore (rit eines ine) 22.995 -63.025 toner ci 32675-32607) | 92 0.912) Les then ourotround vy |g keetten, = Teper Ls han ae 0.02 (.00081 - Projection “S| ‘002-008 7 evens e.0006 0.0035), Dison of exch Les then eninge “5 0.05 1000201 = Piston #9 eylinge ine (0.05 .0.07 (0.0020 - 0.0928) EM. Inverterens ft einer lier te block 6 (0.01 0.05 0.0008 - 0.0012)SERVICE DATA AND SPECIFICATIONS Unt: mm in) o- semen ‘Senda ‘Service (vince tner inner 82995-83025 | §3.03-6305 diameter “D" | (3.2675-3.2687) | (3.2689-3.2697) PISTON, PISTON RING AND PISTON PIN Piston Units me int o zen i A, semr70a Piston ski diameter “A” | $2995-€2.965 (6.2652 - 3.2682) Paton pinhole diameter | 26.992- 26.00 (1.0233 - 1.0236) Piston ring vat mt fa oy saecmame 08-010 ot tn 23) | ostacan 008-008 nee os: 2%,., | esto 02-008 nee on 2, | onstoo% Foe 20-045 utes (0.0118 -0.0177) 020-036, a (0.0079 - 0.0138) Dee 036-030 Net (0.0059 - 0.0118) Piston pin Ui pct aad 28.993 - 26.000 (1.0233 - 1.0236) Inerernee 4 | 5.907 -.08(-0.90038-00080) ory career 0025-0045 92010-00018) coe CONNECTING ROD Unit: mm Gnd Center distance 1700 (6.69) ‘Gonnecting rod bend 0° torsion [er 100 mm (3.94 in) lenge) coma 0-005 0- 00020 a ee Pomel ae peo 2 0004 -c0m tnt | 02 oe) EM-7SERVICE DATA AND SPECIFICATIONS CRANKSHAFT BEARING Unie ee tn) Bearing clearance a Unit: mm in) 7 Standore ‘mie i (0.038 0.087 lain bearing clearance | 0088°2987 | 65 c.o0so ‘Connecting rod bearing | 00095-0081 : esnranee (o.00%6 -0.0032) |_°15 10.0059) semzss [——sosersmosze SCM earing undlersize nae 70.907 - 7020 Journal diamerer “A (27916-2.7921) nit: me ind vom ansieae — ‘rank journal ameter iamever (20832 -2.0837) Sener 70.907 -70:920 (2.7916 2.782%) 50.00 11.9685) =. | (0.25 (0.0038) 70857 - 70.670 (2.7818 -2.7823) Seaton ey eet 0.50 (0.0197) 70.407 - 70.820 (27719-27728) (0.75 (0.0208) 70.187 - 70,170 (2.7621 - 2.7626) 1.90 (0.0394) 69.907 69.920 (27522-27528) curs 0.01 0.00081 nit: me (in) Umi 0.02 0.0006) ‘crank pin diameter (Outofround of journal ana Standard 52.913 -$2.926 (20552-20897) pinay" ‘Standard 0.01 (0.0008) Unceriing 0.25 (0.0088), 52.663 - 52.676 (2.0793 - 20738) mi (0.02 0.0008) Sonn} 0.50 (00197) 52419 -$2.426 (20685 2.0640) Crankshaft beng =e sania 0-003 10 -0.00121 0.75 0.0295) 52,165 52,176 (20557 2.0542) ii 0.10 0.0028) 1.00 (0.0394) 51.913 51.926 (20838 - 2.0443) (rena ena play ‘Seana 0.06 -0.18 0.0026 -0.0055) Limit 0.40(0.01571 MISCELLANEOUS COMPONENTS Units mm tn) Gar vain Doro Backlaeh of each anor (0.0028 -0,0043) Fiyeneel Lar tan uncut (Total indieator eading) 0.15 (0.0059) EM-8TIGHTENING TORQUE SERVICE DATA AND SPECIFICATIONS Engine internal parts Engine outer parte Neen vm we Main raregcapbolt 67-172 170-178 129-127 ==nee a oa Crank paley out meee 30-29 27-9 Rearaamaier Fives! ol 4945-50 99-26 we ws wa 7-9 Froncov ble mio 20-28 20-25 4-18 we 456 aso) 2843 Masifoldbols and aut 15-18. wes ae (ats tata) Injection pump mut 20-2 20-25 14-18 Frontendpiaebsit; 10-13; 10-118 7-8) Injection nozse to 58-69 © 60-70 43-51 ea ear Mai ABSD S83. cling bas 1 pum bate 119 12-19 9-16 i cater test wos 19s 7-8 ottpen woe 710 07-19 84-72, OMoooir pipe net HOSS 7-8 vader head bot ‘Timing gear cover bolt 10-13 113 7-8 = ie ee a Injection pump timer nut 59-9 6-7 43-5 ms Tee Sete: a7-04 Injection tube flare nut 29-34 30-35 22-28 ‘Rocker arm shat: bole 20-25 20-25 14-18 ‘Spill tube with cap aut 39-49 a5 79-36 cere ent mS, Saas: Ta: Oitieroncketbat 25-96 27-37 20-27 Camenstirtoim 4-6 04-08 28088 Awmstorbrecket belt 28-98 «27-37 20-27 Ccvecinttiy ates sae? saan AAkematorteadusting | 14-110 endmut ols Rocker cover bolt 10-13, 10-13 7-9 Deinerocosiey 10-1 183378 eel Se ee Thermonatnoving 10-18 10-13 7-8 Turbocharger tomar 78-29 3-428 mats Turbochrgertocometor 29-39 3-4 22028 —EM-9ENGINE LUBRICATION & COOLING SYSTEMS CONTENTS NGINE-LUBRICATION SYSTEM Loe Lubrication cireuit ica G Lc-1ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM LUBRICATION CIRCUIT \ onjet Por gear rain) ow jee Far piston & cylindes) Le-2INJECTION PUMP ASSEMBLY Disassembly Inspection Assembly : Governor (RLD-K typet Testing of injection pump Feed pump Timer Fuel filter Service data and specifications ... CONTENTS LER 2 Special service tools EF. 2 TURBOCHARGER 1 EFS Description EF- 6 Operation... eee EF- 8 Remeval anc installation EF-13 Disassembly and assembly EF-19 CRANKCASE EMISSION CONTROL £F20 SYSTEM ........... em - EF-23 Description ~ EF-23 ENGINE FUEL EF-1 F265 =. EF-25 . EF-26 EF-25 - EF-26 F.26 eR27 €F.27INJECTION PUMP ASSEMBLY INJECTION PUMP ASSEMBLY CAUTION: © Disassembly and assembly of the all injection pumps should be done only in service shops authorized by NISSAN/DATSUN or by the pump manufacturer. (© The pump tester is required for servicing the pump. ‘© Before removing fuel injection pump from vehicle, check closely to make sure that it is apparently malfune- tioning. Refer to Troubleshooting in MA section in SD series SERVICE MANUAL. DISASSEMBLY Dresses ~ ‘Tappet adjust bolt Nut Tappet Topple Saw pit eterna! | ae Tappet oe using EF-2INJECTION PUMP_ASSEMBLY PREPARATION fuel injection pump, clean all dust _sembling. 4 Before performing disassembly and _-an6 dirt from its exterior 4 Be careful not to bend or scratch adjustment, test fuel injection © Clean work bench completely, re- any pars pump and note test results except _-™oving all foreign mater. ‘© Be careful not to mix pasts of dif: ‘when testing is impossible © Collect only those service tools ne- ferent cylinders ‘© Prior to beginning to disasemble _cesaty for disssembling and reas- Special tools for disassembling and reassembling fuel injection pump Dk57915010. DKS7931210 | sr17080000 [ nuen es aoe a a a fn Hay a aa ps me to T.DC. for each cylinder and then install Tool between tappet adjusting. bolt and nut. If Tool cannot be installed, loosen tappet adjusting bolt. oe _ serssoa] 4 Check backlash between control rack and control pinion, Refer to Inspection. 3. Remove feed pump and cover 5. plate (1) Temporarily install timer to injec EF-36. Check camshaft end play. Refer to Inspection, 7. Remove boost compensator, gov emer cover, flyweight and govemor housing Refer to Governor for remov 8. Draw out camshaft. 9. Remove plug, 10, Remove tappet holder by pushing ‘appet with Tool, CAUTION: Be careful not to damage housing plug hole threads. INJECTION PUMP ASSEMBLY 11. Withdraw tappet assembly with Tool from camshaft chamber by DESTOSIGU, 14, Remove lock plate. 15, Remove delivery valve holder and then remove delivery holder spring, and delivery vale stopper. Toon Toa a i} il 12, Remove plungers together wath lower spring seat with Tool CAUTION: Lay out plunger and plunger barrel in ‘order in a pan of kerosene or solvent. Do not touch plunger with hand. 13, Remove plunger spring, upper spring seat ané control sleeve assem- bly, When disassembling control sleeve assembly, put matching mark. seros7s! 16, Remove delivery valve. 17, Remove plonger barrel by pushing it from below. 18, Remove cap and bolt and nut on control rack.INJECTION PUMP_ASSEMBLY 19. Remove control rack guide screw and then draw out control rack, aLees INSPECTION PUMP HOUSING 1, Inspect for damage, cracks, etc. If excessively damaged, replace it with a new housing, 2. Check plunger barrel drum surface for proper contact with plunger barrel seating hole, Also, check for damage or cracks. If faulty, replace with a new plunger and plunger barrel 3. Measure tappet to housing clear- ‘ance. If wom beyond wear limit, re- place tappet or housing ‘Tapper to housing clearance (A-B): Limit 0.2 mum (0,008 in) CAMSHAFT 1, Measure cam profile for uneven or excessive wear, If excessively or un- evenly worn, replace camshaft with a 2. Check for damage, cracks, ete. If excessively damaged, replace it with a new one. 3. Measure camshaft end play by pushing camshaft from timer end s0 25 to move camshaft in shaft direction, (Camshaft end play ‘Seanda (0- 0,03 mm (0 - 0.0012 in) Limit: ‘0.40 mm (0.0039 in) If camshaft end play is over limit, adjust as follows: (1) Remove bearing inner race from camshaft. (2) Based upon end play measure- ment, increase or decrease adjusting shims. Use the same shim thickness on each end, (3) Reinstall bearing inner sace on camshaft. BEARINGS Check for wear or discoloration. If faulty, replace with a new one. PLUNGER AND PLUNGER BARREL “The operation of the plunger should bbe checked based on the results of fuel injection volume measurement. it-tightness check 1, Thoroughly clean plunger barrel an clear Kerosene or solvent, 2. Tilt it to approximately 60° Then, let plunger side down through barrel, making suze that plunger slides smoothly. Repeat this procedure by tuming plunger to various postions, EF-5 rmaking sure that plunger sides smoothly in any ofthe positions. \ 3 av PMA A ere When replacement is requited, re- place both the plunger and plunger barrel as aset DELIVERY VALVE Airsightnes chece 1, Thoroughly clean delivery valve ane delivery valve satin eat Kero sone or solvent. 2 Place finger over lower part of wave seat, Tightly depress delivery valve with your finger tp, and make sore that valve springs back when relesed. If valve falls to valve sat, it if not operating property due to excesve pton wear I fatty, replace with 3 new wae and valve sat sembly. 4 ‘TAPPET Inspect tappet, roller, roller bushing, and pin for wear or damage. If faulty, replace with new components, as re: quired‘Adjusting bolt head recess oar limit: (0.20 mm {0.0079 in) Roller end play leit: (0.20 ren {0.0079 in) 7 Recess Pa SE g End play CONTROL RACK AND CONTROL SLEEVE ASSEMBLY 1. Inspect control rack for bending and damage. If faulty, repair or replace with a ‘new control rack, 3s required 2. Measure control sleeve to plunger lug clearance. If worn excessively, re place control sleeve or plunger, 28 re quired. Control sleeve to plunger lug ‘learance (AB): Limit (0.12 mm (0.0047 in) 4 3. Measure backlash between control rack and contro} pinion Backlash berween control rack and ‘control pinion: Limit 0.30 mm (0.0118 in} INJECTION PUMP_ASSEMBLY. SPRING Ingpect plunger and delivery valve springs for damage and squateness. ASSEMBLY Clean parts thoroughly and apply 2 thin coat of engine oil to rotating and sliding parts. ‘Assemble injection pump in the e= verse order of disassembly. Note the following items. L. Set plunger barrel in position, ‘with hole in bareel aligned with dowel pin of housing : Delivery valve holder 39-44Nm 14.0-4.5k9m, 29-33 ftlb) 4, Install lock plates. s (1) Set the control rack so that marks fon both sides are same distance “A” from each end of pump housing. (2) Adjust bolt length and tighten Jock nut (3) Then install control rack guide 6. Install contro! sleeve assembly with gap of control sleeve facing straight up. Then install upper spring seats and plunger springs. a 2. Install delivery valve 3. Install delivery valve spring de Livery vavle stopper and delivery valee holder. QB @ 7. Install plunger together with lower spring seat by using Tool with plunger alignment mark facing up- ‘ward (cover side of pump housing).Do not use plunger with a barrel from a different cylinder. 8. After adjusting tappet height to 345 to 35.0 mm (1.358 to 1.378 in), install tappet assembly by reversing. the removal procedure. @: Lock nut 25-29 Nem (25-30 kgm, 18-22 fei) JECTION PUMP ASSEMBLY 9. Install camshaft so that its align ment mark is toward governor. Alignment mak Governor — 58° \ SEFGOEA EF-7 10, Install governor housing and then adjust camshaft end play. Refer to Inspection, 11, Install screw plug on bottom of pump housing ‘Seal the plug with sealant. @ : Screw plug ‘54-74.Nem (55.7.5 kom, 40-54 fetb) 12, Temporarily install taner and re- move Tool (Plunger spring holder) ‘while turing timer, 13. Testa Ayweight, govemor cover snd boost compensator in that order. Refer to Governor for installation. 14, Install control rack ap, cover plate and feed pump. 15. Install pump bracket 16. Install timer. ® : Round nut 59-69.N-m (6-7 kom, 43-51 fb)INJECTION PUMP ASSEMBLY GOVERNOR {RLD-K type) DISASSEMBLY Aquisce gus Suds Bumpy Sa EF-8Preparation Work with the disaserbling table and keep the work room clean. Prior to Gisassembling, if you record the gover- nor performance and the degree of serewing the screws at the adjusting points, and if you arrange the parts on the work table during the disassembl- ing work, assembling and adjustment ccan be made quickly with case If there is extreme error in the adjust- iment or there are parts of poor func- tion, the cause of poor functioning can bbe known by comparing the adjust- ment values before and after dsassem- bly. Prior to disassembling, the governor, remove dust adhered to the external surface and extract the lubricating oil (engine oil) stored in eam chamber of the injection pump and the governor chamber. 1. Install injection pump to universal 2. Install tappet holder after remove ing feed pump and cover plate. 3. Remove control lever spring and spring bracket 4. Remove hoost compensator as sembly and draw push rod. INJECTION PUMP ASSEMBLY. 6. Remove govemor shaft lock nut Strasse 8. Remove cap nut fastening idling spring assembly. 5, Remove guide screw cap svt on governor shafi. 9. Loosen Jock nut fastening idling spring assembly and remove idling spring assembly with screwdriver. 10, Loosen control lever nut slightly 11, Loosen plug for hole for adjusting torque cam 12, Remave seven bolts fastening 20v- femor cover and remove governor cover. 13, Extract governor spring and gov- ermor shaft together with spring sheet from governor housing 14, Remove start spring from rack ‘connecting fink. 15, Remove rack connecting link bolt from control rack. iepsrs 16, Remove snap ring fastening sensor lever.INJECTION PUMP_ASSEMBLY. 17, Take out sensor lever 19, Remove guide plug on opposite side of full-toad set lever. 20, Remove U-type lever and fullead control shaft together with spring 21, Remove bolt fastening stop lever and remove stop lever. 22, Remove round mut fastening fly- weight with Tools. At this time, stop ‘turing of camshaft with Tool. e000 24. Remove bolt and screw fastening governor housing to pump housing. Remove spring eye at the same time. 25. Remove govemor housing from Pump housing by lightly tapping gov- emor housing with mallet or plastic hammer, 26. Remove plug, which has been loosened before, from governor cover. 27. Remove guide screw together with Jock nut from governor cover. 28, Remove snap rings connecting tor- ‘que cam and remove torque cam. EF-10 29. Remove plug which holds in place the shaft supporting the tension lever assembly, 30, Extract shaft 31. Extract tension lever asembly. 32. Extract guide lever together with collar. Extract cancel spring at the 33. Remove nut fastening control lever and remove control lever.34. The lever assembly consists of parts as shown below, and is connes~ ted by a snap ring. @ oie Ditassembly of boost compensator 1. Fix boost compensator in vite 2. Remove spring washer and disc by removing push rod mut Stop rotating push rod with screw driver to prevent it from being dam- aged by diaphragm. 3. Remove boost compensator cover. 4. Excract diaphragm and spring. less 1} er | 5. Measure and record distance between upper surface of guide screw and surface of housing. INJECTION PUMP_ASSEMBLY INSPECTION 1. Flyweight © Check pin and holder bushing for wear. IF worn excessively, replace with a new one © Check slider for uneven wear or charring, IF necessary, replace with © Remove burrs from contact surface of flyweight at spring washer loca- ion © Check screw threads for damage. IF necessary, repair or replace dam- ped parts Tension lever astembly: © Check tension lever shaft for ab- ‘normal wear or charting. © Check governor spring seat pin for © Check torque cam rod for bending ‘nd serew threads for damage © Check shifter pin for abnormal Wwear and bearing for charring or Replace damaged parts as needed. To disassemble tension lever assembly fer parts replacement, proceed as follows: a. Remove left and right snap rings from shifter pin and withdraw shifter pin b. Remove snap ring which holds sleeve to hearing. . Press shifter bearing guide out. Oh = | EF-11 3. Guide lever, rack connecting link and floating lever Check guide lever, rack connecting Jink and groove width of floating lever for excessive play of wear. Replace ‘worn or damaged parts. 4. Governor housing and cover ‘@ "Pressed-in™ locks Cheek pins for bending or damage. Repair or replace damaged parts or entire assembly. © Check tension lever shaft bushing for wear © Check serew threads for abnor. repair or malities. If neces replace with new ones. 5. Sensor lever and torque cam ‘© Check for abnormal year on pawl at tip end of sensor lever and sur face of torque cam. Replace sensor andjor torque cam as required. '© Check sensor lever fork for uneven © Check torque cam rod pin and pin hhole for wear. Replace worn parts 6. Governor shaft Cheek for proper operation of gover- nor shaft, governor housing, spring seat, guide screw, etc. 7. Control lever assembly (Check control lever shaft, Bushing and supporting lever for abnormalities. 8. Springs Check springs for bending, rust forma tion or damage. If necessary, replace with new ones. ASSEMBLY Assembly is in the reverse order of dis- assembly, Observe the following: Do not reuse old gaskets, cil seals, O- rings and snap E-tings, Always install 1. Governor housing and flyweight (1) Place gasket. between governor and pump housings and then instal spring eye. Tighten all seven bolts equally in a crisscross fashion. (2) Install fulldoad set lever, Usype lever, sensor lever and connecting link in that order.INJECTION PUMP ASSEMBLY (3) Imert hook of start spring into b. Too small a value of Ly prevents 4, Governor shaft hole on upper side of connecting rod. the flyweight from moving and (1) Screw guide screw into governor If spring is installed backwards, its making maximum lift ‘cover until its end is aligned with inner ‘hook will enter fork groove on floating wall of cover, Tighten lock nut. Ensure lever and not operate properly. Part No, an Ga that Jength "L.” measures 1420.5 mim (055#0.020 in), 16826-99008. | 0.1 (0.004) 1682699009 | 0.5 (0.020) 1 Asiaing its 7 wml | ROE (8) Insert key into groove on camn- shaft, install flyweight and tighten Foon? ts, (2) Assemble shifter assembly to ten- sion lever. 3. Governor cover internal parts () Installation of control lever and floating lever a. Insert control lever assembly into place on inside of governor cover. (2) Install spring seat and governor spring onto governor shaft. Then insert {governor shaft into spring seat on up- per end of tension lever Spring seat on each side of governor To facitate insertion, apply acoat 496. should be installed with its pad portion fartig he srag- of grease to upper oil seal and sur- z af sea te ue G) ‘Temporarily tighten the out on SEESSIAS b.Insall ating lever on supporting SE tes pert Hat lee © xtiwishd teeth amie we omit rpg of tenner 29-59 im un eine Cowm. .resed in goretnoreoter, coat sre ©-ckom, a si lock in peiphery of pg. Unless screw 36-43 ft) ae er upper cod of tension lever O08 Coated, brian oll may leak to torque cam. Tighten lock serew. UE © Soerccnnnslls b. Plce left and right collars between 5. Fiting governor to pump When aifer i ememibledlto:dleove s- tension lever and guide lever, and (1) Have control rod side of support wien ieapaiiel ns ieeert tem ever caf Snl~ ing lever polled ext topasd goremor , is prened agiint ae housing, and then mount deve. Next, the flyweight holder so that the lift of the flyweight becomes the state of O and itis so adjusted that size Ly from the governor cover adhered surface to the center of the pin hole of the shifter may be 2940.2 mm (1.14 0,008 in) by using an adjusting shim. S A functional difficulty will occur if Cancel spring the dimension 1, isnot within specifi- ) cations a. Too large a value of Ly causes the KC flyweights to open too wide, allow: eal ing the slide to come off the sleeve and wear on the contacting surface of the sleeve. This wear is evidenced by a surface offset (3) When cancel spring for mtegrating insert ball joint (on control cod side) the guide lever with the tension lever is inte slot of floating lever. This se- built in, itis convenient to use screw- quence makes it easier t0 attach gov. driver with a grooved blade. ernor cover assembly to pump.(2) When governor cover isto be built {nto governor housing upon comple- tion of the shim adjustment of shifter, fasten guide screw after confirming that governor shaft is inserted in the faucet portion of housing s0 a8 to slide and rotate smoothly. If governor shaft does not rotate smoothly, loosen governor cover fastening bolt and re TESTING OF INJECTION PUMP PREPARATION Injection pump test conditions INJECTION PUMP ASSEMBLY build governor. (3) Confirm that the following con ‘tol rod position ean be obtained after ‘governor cover is attached and idling and set of governor spring are loosen: ed. Manipulated control lever to full, speed side in such state that control lever and full load stop lever are not limited by stopper bolt. Insert control tod in nominjection direction irom pump driving side. Then, confrim that control 10d reaches the following maximum position smoothly when control 10d is released, Shift volume of control rod: 9.5 to 21 mm (0.374 10 0.83 in). Nozzle KV11257800 Nozzle holder ky11257802 Nozzle starting pressure kPa (bar, kg/em?, psi) 17,162 (171.6, 175, 2,489) Nozzle tube Inner dia. x outer dia. x length Kv11257805 2.0 x 6.0 x 600 (0.079 x 0.236 x 23.62) ‘mum (in) Fuel feed pressure kPa (bar, kg/om?, psi) 147-157 (0.47 -1$7, 15 -1.6, 21-23) Fuel (test oll) 180 4113 or SAE Standard Test Oil (SAE 19674) Fuel temperature °CCF) 40-45 (104-113) Rotating direction Right (observed from the drive shaft) Injection sequence 1426. EF-13INJECTION PUMP ASSEMBLY 1, Prepare necessary service tools. (ckvin257800 y-Kvinas7a02 f Lpxosia2618 enn ™~® KV1i208781 kv11282617 DxS7911010 2. Remove fuel feed pump and cover plate 3. Remove timer drive gear and at- tach coupling. (1) Set a Tool to No. 1 cylinder tappet. KVLI208784 | — eynizoster ed ‘SEFDezA & 7. Remove cap and apply tester dial erzeaa| wae Tas 98-177 Wm (10-18 km, 72-1301) 1, Place timer astembly on Tools with fyweight hol 0 base pin. 2, Remove inject Ider hole positioned tion pump drive gear, EF-21INJECTION PUMP_ASSEMBLY. 3. Remove nut, lock washer, lock plate, adjusting shia and thrust washer after unbending lock washer, 4. Remove timer flange by prying with lever while pressing spring with Tool DKS7916432, DKS7916832| 5. Remove timer spring, adjusting shim and Dyweight INSPECTION (Check all parts for wear or damage ASSEMBLY 1. Set flyweight holder on Tools with flyweight holder pin hole posi tioned on base pin, a A 2. Apply grease to flyweight holder pin and flyweight holder hole 3. Install lyweight and insert Tool under timer spring, positioning spring ‘on flyweight, Nea hl 4, Insert suitable adjusting shim into hhole at pin part of timer flange. 5. Cover timer flange to flyweight holder by matching notch of flange and key groove of flyweight holder. 6. (Q) Tum Tool DKS7916432 in direc ton to compress timer spring, thread in Tool DK57924190, and then se ‘move Too] DK57932020. (2) Using a lever, insert timer spring into flange hole, ead in Tool DKS7924190 all the way and install flange in ss proper position ‘Make sure that spring is fully seated in holes in flange and Flyweight holder 7, Adjust flyweight older and flange clearance. (2) Install theust washer, lock plate ang adjusting shims, and completely, tighten them with mut Di Nut ‘98-177 Nm (10-18 kgm, 72-130 felb) Lock plate and thrust washer Clearance: 0.02-0.10 mm, {0.0008 - 0.0039 int (2) Measure lock plate and thmst washer clearance. If the clearance is not within specifications, adjust with adjusting shim, EF-22INJECTION PUMP_ASSEMBLY 8 Alien “O" mark on drive gear ‘with notch in timer flange, and install drive gear, SERVICE DATA AND SPECIFICATIONS FUEL FILTER ump. If pressure is not within range of 147 to 157 kPa (1.47 to 1.57 bar, Bleed air from fuel system after im 1.5 10 1.6 ke/om®, 21 to 23 psi, re stalling fuel iter, place overflow valve, 347-157 ere (147-157 bar, 15-18 kyon’, 21-23pal Test Overflow valee __ Attach a pressure gauge to fuel filter discharge port, and check valve opening pressuce by operating priming |For fuel tank INSPECTION AND ADJUSTMENT TABLE OF MODELS AND CORRESPONDING Injection purnp PUMP NUMBERS ait mm in ‘ecet | treme | recount | Aumenunber smnawe nt eRDeen Pumproningtotpenr | 092-095 | 95 agra ro | sosar | teroocsrer cove (e008 -00028) ier dad Tappet adjusting bolt Tepeated z 020 00078) Convol sew purge | 002-008 | 9, trunnion shatt clearance | (0.0008 -0,0031) | °'2 (0.0087) 0-008 5 Camenet ond ay ane, | 0101000 Conwoteaccropinien | 9450059) | 0:0 0011 ‘ejection eral ; _ (Comsat se30 ear Inaction sag rina 225-235 (crestor long = ese (ooses 0.0028) Tappet dear atcan | _ More tan - reer oxo oor) Thine | Pers mabor @10,0.0008) | 16761-37500 oz rooomn | teri a7s01 074 0.0055) | 16761 7500 Camabatt aa pay mn See ore ooo | vereraran exe acer | 167a797608 omar | tert a7e06 oso iooien | rererars0e EF-23INJECTION PUMP_ASSEMBLY nena Fuel fitter Soncoo | Weartini Tree [__ Fathom, paper sv iter ‘omit [mid anton | Setar ork een 347-157 (147-187, liter to in clearance 0300.07 reer, a 15-16,2) fe Jtooors 0931] 992000718) ee iba, kslem?, wi) Satraa Rolerouwdeoee | 10 @581 | 149005m7 300m (106 inp fv como 0 feed ane itn Beco pum ‘Benda 1.00 TIGHTENING TORQUE _ Dacharee ould oe wihin one fe hoanely minute (60 seconde) with 2 Dump ee thom | __y " speed of 100 rom and intake ead 7 = Seo meter Gf ion ae ineevensumot | 39.05 | 20.25 | 14-18 ‘The me required to develoo an ewe Senne pie fend presureot 157A (57 conyers - : : Oil feed pressure bar, 1.6 kg/em?, 23 pil with @ oa we mest || Oras) | meee {Suns of 600m Sew pion wm | sss | aos Shout be wih 30 scone “ooo ating bo ‘Operate pring pve wo — wm | 25-20 | 10-22 Pumping cps ‘ta ot 80 o Wo rrakee pe ‘orimina poms) ‘rion erty a urna Somer eared wisn sven Firigt round | 40-50 | so-0 | 6-40 Tier ‘Round mit 9-09 | 60-70 | «-s1 Timer eck at wea? | vor | 72-130 Fini arto fares 7 Gene (eocksiewto | gp .40too00e -0.0080) soamty Sates 08 «9.08 Tctemsteie | ap. 52 | ao-t00 | 0-72 Tasers | par number mnytoongne | $2782 | 60-70 | 9-51 0.1 (0.004) ‘16822 37500 Mgnt se A ie zx | 30.35 | 22-2 Pine sing acing 3 0.012) | s6802 37501 sim Overtow nt ee ee os teano) | 16822 37502 Bite nt was | «aso | mice i a9 0) | 16806 95007 | 272 (000e7| | 168m 99000 4 0008s) | +86 S001 es 016 0.0088) | 16826 99002 wietingtien: 0.18 (0.0071) | 16826 99003 o70,0.0078) | sa80m 2088 caa;oorvei | sean6 seen ono raaion | 16806 a0bo4 EF-24SPECIAL SERVICE TOOLS TURBOCHARGER Tool number Tool name DK0S782618 Measuring device 1DKS7913362 ‘Special wrench KV11282617 ‘Adjusting device — DESCRIPTION ‘The turbocharger is installed on the exhaust manifold. This system utilizes exhaust gus energy 10 rotate the tur bine wheel which drives the compres: sor turbine installed on the other end ‘of the turbine wheel shaft. The com- prestor supplies compressed air to the fengine to increase the charging ef- ficiency so as to improve engine ‘output and torque. To prevent an excessive cise in the supercharging pressure, a system is adopted which maintains the turbine speed within a certain range by con- trolling the quantity ef exhaust gas that passes through the turbine, This system consists of a by-pass valve controller which detects the super charged. pressure and activates a by pass valve that allows a part of exhaust gas to be discharged without passing through the turbine, To provent an abnormal rise in super ‘charging pressure and possible engine damage in case of a malfunction, an emergency relief valve is provided 252 safety device in the intake manifold, TURBOCHARGER OPERATION ‘The by-pass valve controller nocmally detects the supercharging pressure at the outlet of the compressor housing. All exhaust gas flows through the turbine when the supercharging pres- sure is below the specified pressure Po. From aac manifold a sm. To intake manifold fi charzine| sit — wim From se dows Shaw @_ @ _serseo 1 By-pase vale 2. By-past valve controller 3. Compressor 4 Tubine [As the engine speed increases and the superchacging pressure approaches the specified pressure value Po, it exerts a force on the diaphragm of the by-pass valve controller, thereby opening the by-pass valve EF-25 As the valve opens, part of the exhaust gas by-passes the turbine and goes directly to the exhaust tube. As a result, the turbine speed is kept con stant and the supercharging pressure ‘maintained at the specified pressuce levelTURBOCHARGER ‘The emergency relief valve operatesas 3. Remove ool inlet pipe for turbo- DISASSEMBLY AND follows charger. ASSEMBLY When the pressure in the intake manie 4, Remove turbocharger oll dria Turbocharger should not be diy fold exceeds Pas, exerts fore on tube bolls n turbocharge se = diaphragm. Then the upper cover, 5. Remove exhaust manfold conte: connected to the dipnagm by ator —_— shat, pushed ope, andthe excess 6.” Remove rurbocharger bracket. ‘eC pressure in the intake manifold is re 7. Remove turbocharger. 1. Inspect turbine and compressor eased into the atmosphere. 8. Install in the reverse order of Wheels for cracks, clogging, deformity mir rotier damage, When the presuce in the intake Use double rats when tightening © ey arena mae Se at rmanifold is below Pon forthe bois at lower rearsge, | Y tppe coves SAE 3 heck operation of by-pass ae ; S3\C. | consater A Do not apply more than 66.7 KPa (667 Ty ber, 500 mila, 19.69 inl) pres sure to controler diaphragm, By-pass valve controller aa sonore r "mm (5 Be ea he orecinpene Se 205 mats the pes in th intake - Tubochrw exhort man wears rnlold abo Poa Bs Tebochare od | Atmosphere (3-4 kg-m, 22 - 29 fib) Terecharge to commoner 391m les || (3. dkge 22-294) ae 4 serra | REMOVAL AND INSTALLATION 1. Remove air cleaner. 2. Remove air intake duct. seramie 4 Move by-pass valve to make sure 5, Always replace tucbocharger as an that itis not sticked or scratched assembly if any of the above items shows abnormalities. EF-26CRANKCASE EMISSION CONTROL SYSTEM CRANKCASE EMISSION CONTROL SYSTEM DESCRIPTION ‘The closed-type crankcase ventilation system is utilized as a crankease emis. sion control system. ‘The closedtype crankcase emission control system prevents blow-by gas from entering the atmosphere and keeps the intemal crankcase pres sure constant. During the valve operation, the blow bby gas is fed into the intake manifold by the air control valve. ‘This is activated by the internal rocker cover pressure. When the intake air flow is restricted by the throttle cham: ber, the internal rocker cover pressure decreases. At this point, the crankcase emission control valve Keeps the inter- nal rocker cover pressure constant so that ait or dust isnot sucked in around the crankshaft oil seal 3. After plugging the center hole ‘with adhesive tape, check that air flows from inlet by orally sending air from outlet and that air does not flow sucking in ar ty Frethaie aoe Blowsby ss —e INSPECTION Air control valve 1, Remove rocker cover. 2. Remove control valve from rocker VENTILATION HOSE 1. Check hoses and hose connections for leaks. 2, Disconnect all hoses and clean with compressed ait. If any hose cannot be free of obstruc- tions, replace. secrsoa! seceo2 EF-27