Mitsubishi S16R-Y1PTA-2 Diesel Index:

• BINDING
• INTRODUCTION
  • How to Use This Manual
    • Methods of Indication
    • Terms Used in This Manual
    • Abbreviations, Standards, Etc.
    • Units of Measurement
  • Safety Cautions
    • Warning Fire and Explosion
      • Keep flames away
      • Keep engine and surrounding area clean
      • Never open crankcase until engine cools
      • Check for fuel, oil and exhaust gas leaks
      • Use flameproof light
      • Do not short electrical wires
      • Keep fire extinguishers and first-aid kit nearby
    • Warning Stay Clear of All Rotating and Moving Parts
      • Install protective covers on rotating parts
      • Check surrounding area for safety
      • Stay clear of all rotating and moving parts while engine is operating
      • Lockout and Tagout
      • Always stop engine before inspection and maintenance
      • Always return turning tools to original position
    • Warning Be Careful of Burns
      • Do not touch engine during operation or immediately after operation
      • Open radiator filler cap carefully
      • Add coolant only after coolant temperature drops
      • Do not dismount heat protection covers
    • Warning Be Careful of Exhaust Fume Poisoning
      • Perform engine operation in a well-ventilated site
    • Warning Protect Ears from Noises
      • Wear earplugs
    • Warning Be Careful of Falling Down
      • Lifting engine carefully
      • Do not climb onto engine
      • Always prepare steady platform
    • Caution Be Careful of Handling Fuel, Engine Oil and LLC
      • Use only specified fuel, engine oil and coolant (LLC)
      • Handle LLC carefully
      • Properly dispose of drained oil and LLC
    • Caution Service Battery
      • Handle battery carefully
    • Caution When Abnormality Occurs
      • If engine overheats, conduct cooling operation before stopping engine
      • If engine stops due to abnormality, exercise caution when restarting
      • If engine oil pressure drops, stop engine immediately
      • If fan belt is broken off, stop engine immediately
    • Caution Other Cautions
      • Never modify engine
      • Never break seals
      • Everyday checkup and periodic inspection and maintenance
      • Perform engine break-in
      • Warm up engine before use
      • Never operate engine under overload condition
      • Conduct cooling operation before stopping engine
      • Do not splash water on engine
      • Conduct proper maintenance of air cleaner/ pre-cleaner
      • Observe safety rules at workplace
      • Wear proper work clothes and protective gear
      • Use appropriate tools for maintenance work
      • Do not use starter continuously
      • Keep battery switch ON when engine is in operation
      • Cautions concerning transportation
      • Do not operate engine continuously under low load
      • Ventilate the engine room sufficiently
      • Do not touch high-pressure injection fuel
    • Caution About Warning Labels
      • Always keep warning labels clean and legible
• GENERAL CONTENTS
• GENERAL
  • 1. Outline
    • 1.1 External view
    • 1.2 Outline of fuel system
    • 1.3 Outline of lubrication system
    • 1.4 Outline of cooling system
    • 1.5 Outline of inlet and exhaust system
    • 1.6 Outline of electrical system
    • 1.7 Engine serial number location
    • 1.8 Engine model code identification
  • 2. Main specification
  • 3. Tips on disassembling and reassembling
    • 3.1 Disassembling
    • 3.2 Reassembling
• MAINTENANCE STANDARDS
  • 1. Maintenance standard table
    • 1.1 General
    • 1.2 Engine main part
    • 1.3 Inlet and exhaust system
    • 1.4 Fuel system
    • 1.5 Lubrication system
    • 1.6 Cooling system
    • 1.7 Electrical system
  • 2. Tightening torque table
    • 2.1 Major bolt and nut
      • 2.1.1 Engine
      • 2.1.2 Inlet and exhaust system
      • 2.1.3 Fuel system
      • 2.1.4 Lubrication system
      • 2.1.5 Cooling system
      • 2.1.6 Electrical system
    • 2.2 Standard bolt and nut tightening torque
    • 2.3 Standard eyebolt tightening torque
    • 2.4 Standard union nut tightening torque
    • 2.5 High-pressure fuel injection pipe tightening torque
  • 3. Sealant and lubricant table
    • 3.1 Engine main part
    • 3.2 Lubrication system
    • 3.3 Cooling system
    • 3.4 Inlet system
    • 3.5 Others
• BASIC AND SPECIAL TOOLS
  • 1. Commercially-available tool
  • 2. Special tool
• OVERHAUL INSTRUCTIONS
  • 1. Determing overhaul timing
  • 2. Testing compression pressure
• DISASSEMBLY OF ENGINE MAIN PARTS
  • 1. Disassembling cylinder head and valve mechanism
    • 1.1 Removing nozzle assembly
    • 1.2 Removing rocker arm assembly and push rod
    • 1.3 Removing rocker assembly
    • 1.4 Removing valve bridge
    • 1.5 Removing rocker case
    • 1.6 Removing cylinder head assembly
    • 1.7 Removing valve and valve spring
  • 2. Disassembling flywheel, timing gear, camshaft
    • 2.1 Removing flywheel
    • 2.2 Removing idler shaft thrust collar
    • 2.3 Removing timing gear case
    • 2.4 Measuring timing gear backlash and end play
    • 2.5 Removing accessory drive (right and left)
    • 2.6 Removing idler gear
    • 2.7 Removing idler shaft
    • 2.8 Removing camshaft gear
    • 2.9 Removing camshaft
  • 3. Disassembling damper and front gear
    • 3.1 Removing damper
    • 3.2 Removing mounting plate for oil pump and water pump
    • 3.3 Removing oil pump gear
    • 3.4 Removing fan drive case
    • 3.5 Removing front gear case
    • 3.6 Removing bearing cover for oil pump and water pump
    • 3.7 Measuring idler gear backlash and end play
    • 3.8 Removing idler gear on the front side
    • 3.9 Removing idler shaft on the front side
  • 4. Disassembling cylinder liner, piston and connecting rod
    • 4.1 Removing connecting rod cap
    • 4.2 Removing carbon deposits at the upper section of cylinder liner
    • 4.3 Removing piston
    • 4.4 Removing piston ring
    • 4.5 Removing piston pin and piston
  • 5. Disassembling crankcase, crankshaft and main bearing
    • 5.1 Reversing crankcase
    • 5.2 Removing main bearing cap
    • 5.3 Removing crankshaft
    • 5.4 Removing piston cooling nozzle
• INSPECTION AND REPAIR OF ENGINE MAIN PARTS
  • 1. Cylinder head and valve mechanism
    • 1.1 Measuring rocker arm inside diameter and rocker shaft outside diameter
    • 1.2 Replacing rocker bushing
    • 1.3 Measuring rocker inside diameter and rocker shaft diameter
    • 1.4 Replacing valve guide and stem seal
    • 1.5 Inspecting valve face
    • 1.6 Correcting valve face
    • 1.7 Correcting valve seat
    • 1.8 Replacing valve seat
    • 1.9 Lapping valve against valve seat
    • 1.10 Measuring valve spring perpendicularity and free length
    • 1.11 Inspecting clearance between valve bridge with valve cotter and valve rotator
    • 1.12 Inspecting tappet
    • 1.13 Measuring push rod bend
    • 1.14 Measuring cylinder head bottom face for distortion
  • 2. Cylinder liner, piston and connecting rod
    • 2.1 Measuring cylinder liner bore diameter
    • 2.2 Measuring cylinder liner collar protrusion
      • 2.2.1 When cylinder liner is not to be replaced
      • 2.2.2 When cylinder liner is to be replaced
      • 2.2.3 Measuring step height of cylinder liner
      • 2.2.4 Inserting cylinder liner shim
    • 2.3 Replacing cylinder liner
    • 2.4 Inspecting piston exterior
    • 2.5 Measuring piston outside diameter
    • 2.6 Inspecting piston ring groove
    • 2.7 Measuring piston pin bore diameter
    • 2.8 Measuring piston protrusion
    • 2.9 Measuring piston ring end gap
    • 2.10 Measuring piston pin diameter
    • 2.11 Measuring connecting rod bushing inside diameter
    • 2.12 Replacing connecting rod bushing
    • 2.13 Inspecting connecting rod bend and twist
    • 2.14 Inspecting connecting rod bearing
    • 2.15 Measuring connecting rod end play
    • 2.16 Weight difference of connecting rods in one engine
    • 2.17 Measuring connecting rod big-end bore diameter and circularity
    • 2.18 Inspecting connecting rod big-end bore serration
    • 2.19 Measuring connecting rod bearing thickness
  • 3. Damper and front gear
    • 3.1 Inspecting damper
    • 3.2 Measuring front gear backlash
    • 3.3 Inside and outside fitting surface conditioning oil pump gear bearing
    • 3.4 Measuring idler bushing inside diameter and idler shaft diameter
    • 3.5 Measuring idler gear end play
    • 3.6 Replacing idler bushing
  • 4. Flywheel, timing gear and camshaft
    • 4.1 Measuring face and radial runout of flywheel
    • 4.2 Measuring timing gear backlash
    • 4.3 Measuring idler bushing inside diameter and idler shaft diameter
    • 4.4 Measuring idler gear end play
    • 4.5 Replacing idler bushing
    • 4.6 Measuring camshaft cam height
    • 4.7 Measuring camshaft deflection
    • 4.8 Measuring camshaft journal diameter
    • 4.9 Measuring camshaft bushing inside diameter
    • 4.10 Measuring camshaft end play
    • 4.11 Replacing camshaft bushing
      • 4.11.1 Removing camshaft bushing
      • 4.11.2 Installing camshaft bushing
  • 5. Crankcase, crankshaft and main bearing
    • 5.1 Measuring crankshaft crankpin and journal diameter
    • 5.2 Grinding crankshaft
    • 5.3 Crankshaft end play
    • 5.4 Measuring crankshaft deflection
    • 5.5 Replacing oil seal slinger
      • 5.5.1 Removing oil seal slinger
      • 5.5.2 Installing oil seal slinger
    • 5.6 Replacing crankshaft gear
      • 5.6.1 Removing crankshaft gear
      • 5.6.2 Installing crankshaft gear
    • 5.7 Inspecting main bearing surface
    • 5.8 Measuring main bearing thickness
    • 5.9 Replacing main bearing
    • 5.10 Measuring crankcase gasket surface distortion
    • 5.11 Measuring main bearing bore diameter
• REASSEMBLY OF ENGINE MAIN PARTS
  • 1. Reassembling crankcase,crankshaft and main bearing
    • 1.1 Installing main bearing
    • 1.2 Installing thrust plate
    • 1.3 Installing crankshaft
    • 1.4 Installing main bearing cap
    • 1.5 Installing main bearing cap bolt
    • 1.6 Measuring crankshaft end play
  • 2. Reassembling cylinder liner, piston and connecting rod
    • 2.1 Reassembling piston and connecting rod
    • 2.2 Installing piston ring
    • 2.3 Preparation for installing piston
    • 2.4 Installing connecting rod bearing upper half
    • 2.5 Installing piston
    • 2.6 Installing connecting rod cap
  • 3. Reassembling damper and front gear
    • 3.1 Installing front plate
    • 3.2 Installing idler shaft
    • 3.3 Installing idler gear
    • 3.4 Installing oil pump and water pump drive bearing cover
    • 3.5 Installing front gear case and pointer
    • 3.6 Installing oil pump gear and oil pump/water pump mounting plate
    • 3.7 Installing damper
  • 4. Reassembling flywheel, timing gear, camshaft, oil pan
    • 4.1 Installing rear plate
    • 4.2 Turning engine
    • 4.3 Installing idler shaft
    • 4.4 Installing camshaft
    • 4.5 Installing camshaft gear
    • 4.6 Installing idler gear
    • 4.7 Installing fuel injection pump accessory drive (right-and- left side)
    • 4.8 Inspecting and adjusting timing gear after installation
      • 4.8.1 Inspecting backlash and end play
      • 4.8.2 Inspecting valve timing
    • 4.9 Installing timing gear case
    • 4.10 Installing rear oil seal
    • 4.11 Installing idler shaft thrust collar
    • 4.12 Installing flywheel
    • 4.13 Installing pickup
    • 4.14 Installing oil pan
  • 5. Reassembling cylinder head and valve mechanism
    • 5.1 Installing inlet and exhaust valve
    • 5.2 Installing tappet
    • 5.3 Applicating liquid gasket
    • 5.4 Installing cylinder head gasket
    • 5.5 Installing cylinder head assembly
    • 5.6 Tightening cylinder head bolt
      • 5.6.1 2-step tightening method
      • 5.6.2 Angle tightening method
    • 5.7 Installing rocker case
    • 5.8 Installing bridge and bridge cap
    • 5.9 Installing rocker shaft assembly
    • 5.10 Installing fuel injection nozzle assembly
    • 5.11 Adjusting valve clearance
• FUEL SYSTEM
  • 1. Removing fuel system
    • 1.1 Removing and inspecting fuel injection pipe and fuel leak-off pipe
    • 1.2 Removing and inspecting fuel filter and fuel pipe
    • 1.3 Removing and inspecting fuel control link
    • 1.4 Removing and inspecting actuator
    • 1.5 Removing and inspecting stop solenoid
    • 1.6 Removing fuel injection pump
  • 2. Removing, inspecting and assembling fuel system
    • 2.1 Removing and inspecting fuel filter
    • 2.2 Fuel filter assembly
    • 2.3 Disassembling and inspecting fuel injection nozzle
    • 2.4 Inspecting and adjusting fuel injection start pressure
    • 2.5 Inspecting fuel injection nozzle spray condition
    • 2.6 Cleaning and exchange at defective injection
      • 2.6.1 Removing nozzle tip
      • 2.6.2 Cleaning and mounting nozzle tip
    • 2.7 Reassembling fuel injection nozzle
    • 2.8 Disassembling and inspecting fuel injection pump
      • 2.8.1 Preparing fuel injection pump disassembly
      • 2.8.2 Disassembling rack set cap
      • 2.8.3 Disassembling spring case
      • 2.8.4 Disassembling return spring
      • 2.8.5 Disassembling coupling assembly and fuel feed pump
      • 2.8.6 Disassembling delivery valve
      • 2.8.7 Disassembling plunger assembly
      • 2.8.8 Disassembling controller rack
      • 2.8.9 Disassembling tappet
      • 2.8.10 Disassembling camshaft
      • 2.8.11 Disassembling rear cover
      • 2.8.12 Disassembling plunger assembly
    • 2.9 Inspecting fuel injection pump
      • 2.9.1 Inspecting plunger barrel
      • 2.9.2 Inspecting delivery valve
      • 2.9.3 Inspecting tappet
      • 2.9.4 Inspecting bearing
      • 2.9.5 Inspecting valve holder
      • 2.9.6 Inspecting pump case
      • 2.9.7 O-ring and bellow on each unit
      • 2.9.8 Inspecting camshaft
      • 2.9.9 Inserting oversize sleeve to camshaft
      • 2.9.10 Inspecting plunger spring and delivery valve spring
    • 2.10 Reassembling fuel injection pump
      • 2.10.1 Installing bearing and front cover
      • 2.10.2 Installing camshaft and center bearing
      • 2.10.3 Installing rear cover
      • 2.10.4 Measuring thrust clearance of camshaft
      • 2.10.5 Installing tappet roller assembly
      • 2.10.6 Installing tappet
      • 2.10.7 Reassembling plunger assembly
      • 2.10.8 Installing controller rack
      • 2.10.9 Positional relationship between plunger and barrel
      • 2.10.10 Reassembling plunger assembly
      • 2.10.11 Measuring control rack sliding resistance
      • 2.10.12 Reassembling delivery valve
      • 2.10.13 Reassembling bellow
      • 2.10.14 Reassembling fuel feed pump
      • 2.10.15 Reassembling flywheel
      • 2.10.16 Reassembling coupling assembly
      • 2.10.17 Reassembling controller rack return spring
    • 2.11 Adjusting fuel injection pump
      • 2.11.1 Adjusting pre-stroke (injection timing)
      • 2.11.2 Adjusting injection interval
      • 2.11.3 Adjusting injection volume
    • 2.12 Disassembling and inspecting fuel feed pump
    • 2.13 Reassembling fuel feed pump
      • 2.13.1 Tightening priming cap
    • 2.14 Fuel feed pump test
      • 2.14.1 Fuel feed pump air-tightness test
      • 2.14.2 Fuel feed pump fuel feeding pressure test
      • 2.14.3 Priming pump suction capacity test
      • 2.14.4 Fuel feed pump fuel feed rate test
    • 2.15 Disassembling and inspecting fuel injection pump accessory drive
    • 2.16 Inspecting outer and inner diameters of fuel injection pump accessory drive bearing engagement section
    • 2.17 Reassembling fuel injection pump accessory drive
  • 3. Installing fuel system
    • 3.1 Installing fuel injection pump
      • 3.1.1 Fuel injection timing check
      • 3.1.2 Reassembling coupling on driving side
      • 3.1.3 Checking before assembly fuel injection pump
      • 3.1.4 Reassembling fuel injection pump
      • 3.1.5 Adjusting clearance of flywheel and coupling
      • 3.1.6 Assembling fuel injection pump (left)
    • 3.2 Installing stop solenoid
    • 3.3 Installing actuator
      • 3.3.1 Installing and adjusting actuator link
    • 3.4 Adjusting and confirming working of stop solenoid
      • 3.4.1 Adjusting stop solenoid
      • 3.4.2 Stop solenoid working inspection
    • 3.5 Re-adjusting adjusting bolt
    • 3.6 Installing fuel control link
    • 3.7 Installing fuel filter and fuel pipe
    • 3.8 Installing fuel injection pipe and fuel leak pipe
    • 3.9 Installing pickup
• LUBRICATION SYSTEM
  • 1. Removing lubrication system
    • 1.1 Removing oil cooler and oil pipes for fuel injection pump
    • 1.2 Removing oil pump, oil filter and oil pan
  • 2. Disassembling, inspecting and reassembling lubrication system
    • 2.1 Disassembling and inspecting oil pump and safety valve
    • 2.2 Inspecting oil pump and safety valve
      • 2.2.1 Measuring of backlash between drive and driven gears
      • 2.2.2 Measuring radical clearance between gear and case
      • 2.2.3 Measuring side clearance between gear and case
      • 2.2.4 Measuring drive and driven gear shaft diameters and bushing inside diameter
      • 2.2.5 Checking oil pump safety valve spring
    • 2.3 Reassembling oil pump and safety valve
    • 2.4 Disassembling and inspecting oil filter, oil filter alarm, relief valve, left-side oil cooler and oil thermostat
    • 2.5 Inspecting oil filter, oil filter alarm, relief valve, left-side oil cooler and oil thermostat
      • 2.5.1 Inspecting oil filter
      • 2.5.2 Inspecting oil filter alarm
      • 2.5.3 Measuring relief valve pressure
      • 2.5.4 Checking oil cooler
      • 2.5.5 Inspecting oil thermostat
      • 2.5.6 Reassembling oil filter, oil filter alarm, relief valve, left-hand oil cooler and oil thermostat
    • 2.6 Disassembling and inspecting right-side oil cooler and oil thermostat
    • 2.7 Inspecting right-side oil cooler and oil thermostat
    • 2.8 Reassembling oil cooler and oil thermostat
  • 3. Installing lubrication system
    • 3.1 Installing oil pump, oil filter and oil pan
    • 3.2 Installing fuel injection pump oil pipes and oil cooler
• COOLING SYSTEM
  • 1. Removing cooling system
    • 1.1 Removing thermostat case and water pipe
    • 1.2 Removing water pump
  • 2. Disassembling, inspecting, and reassembling cooling system
    • 2.1 Disassembling and inspecting water pump
      • 2.1.1 Inspecting pump mounted on engine
      • 2.1.2 Removing impeller
      • 2.1.3 Removing water pump gear
    • 2.2 Inspecting water pump
    • 2.3 Reassembling water pump
      • 2.3.1 Installing water pump oil seal
      • 2.3.2 Installing unit seal
      • 2.3.3 Striking in impeller side ball bearing
      • 2.3.4 Reassembling unit seal ring
      • 2.3.5 Striking in nut side ball bearing
      • 2.3.6 Press-fitting water pump impeller
      • 2.3.7 Installing water pump pulley
    • 2.4 Disassembling thermostat
    • 2.5 Inspecting water thermostat
    • 2.6 Disassembling and inspecting fan drive
    • 2.7 Inspecting fan drive
  • 3. Installing cooling system
    • 3.1 Installing water pump
    • 3.2 Installing thermostat case and water pipe
    • 3.3 Installing fan drive
      • 3.3.1 Installing bearing
      • 3.3.2 Installing drive shaft
      • 3.3.3 Installing fan drive gear
      • 3.3.4 Installing fan
• INLET AND EXHAUST SYSTEMS
  • 1. Air duct (Air cooler-to-turbocharger)
    • 1.1 Disassembling and inspecting air duct
    • 1.2 Reassembling air duct
  • 2. Insulator
    • 2.1 Disassembling and inspecting insulator
    • 2.2 Reassembling insulator
  • 3. Exhaust manifold
    • 3.1 Disassembling and inspecting exhaust manifold
    • 3.2 Reassembing exhaust manifold
  • 4. Turbocharger oil pipe
    • 4.1 Disassembling and inspecting turbocharger oil pipe
    • 4.2 Reassembing turbocharger oil pipe
  • 5. Exhaust pipe
    • 5.1 Disassembling and inspecting exhaust pipe
    • 5.2 Reassembling exhaust pipe
  • 6. Air duct (Air cooler-to-crankcase)
    • 6.1 Disassembling and inspecting air duct
    • 6.2 Reassembling air duct
  • 7. Turbocharger
    • 7.1 Disassembling and inspecting turbocharger
      • 7.1.1 Removing turbine housing
      • 7.1.2 Removing compressor cover
      • 7.1.3 Removing compressor wheel
      • 7.1.4 Removing snap ring
      • 7.1.5 Removing insert and oil deflector
      • 7.1.6 Removing V-clamp
      • 7.1.7 Removing shaft & turbine wheel
      • 7.1.8 Removing snap ring and bearing
    • 7.2 Cleaning
    • 7.3 Inspecting turbocharger
      • 7.3.1 Bearing housing
      • 7.3.2 Bearing
      • 7.3.3 Shaft & turbine wheel
      • 7.3.4 Insert Measuring piston ring end gap
    • 7.4 Reassembling turbocharger
      • 7.4.1 Installing shaft & turbine wheel and bearing
      • 7.4.2 Installing thrust bearing
      • 7.4.3 Installing O-ring
      • 7.4.4 Installing oil deflector
      • 7.4.5 Reassembling insert sub-assembly
      • 7.4.6 Installing snap ring
      • 7.4.7 Measuring clearance between turbine wheel and turbine housing
      • 7.4.8 Installing compressor wheel
      • 7.4.9 Measuring play of shaft & turbine wheel in axial direction
      • 7.4.10 Measuring clearance between turbine backplate and back side of turbine wheel
      • 7.4.11 Installing compressor cover
      • 7.4.12 Installing lock plate
      • 7.4.13 Installing turbine housing
      • 7.4.14 Tightening turbine housing V-clamp
• ELECTRICAL SYSTEM
  • 1. Removing electrical system
    • 1.1 Removing starter
    • 1.2 Inspecting before removing alternator
      • 1.2.1 Checking alternator operation
      • 1.2.2 Handling precaution
    • 1.3 Removing alternator
  • 2. Inspecting and reassembling electrical system
    • 2.1 Disassembling and inspecting starter
      • 2.1.1 Removing magnetic switch
      • 2.1.2 Removing rear bracket
      • 2.1.3 Removing armature and yoke assembly
      • 2.1.4 Removing center bracket
      • 2.1.5 Removing pinion set
    • 2.2 Inspecting and correcting starter
      • 2.2.1 Testing magnetic switch coil
      • 2.2.2 Testing magnetic switch contact point
      • 2.2.3 Measuring armature shaft runout
      • 2.2.4 Inspecting commutator radial runout
      • 2.2.5 Measuring commutator undercut
      • 2.2.6 Measuring commutator outside diameter
      • 2.2.7 Checking armature coil
      • 2.2.8 Checking field coil for open circuit
      • 2.2.9 Inspecting overrunning clutch
      • 2.2.10 Inspecting brushes for wear
      • 2.2.11 Measuring brush spring load
      • 2.2.12 Inspecting safety switch
    • 2.3 Reassembling starter
      • 2.3.1 Installing pinion shaft
      • 2.3.2 Installing shift lever and pinion shaft
      • 2.3.3 Installing armature, yoke, brushes and holder
      • 2.3.4 Installing rear bracket
      • 2.3.5 Measuring armature end play
      • 2.3.6 Measuring pinion shaft end play
      • 2.3.7 Measuring pinion gear retraction length
      • 2.3.8 Installing magnetic switch
    • 2.4 Disassembling and inspecting alternator
      • 2.4.1 Separating front bracket from stator
      • 2.4.2 Removing pulley
      • 2.4.3 Removing rear bearing
      • 2.4.4 Removing front bearing
      • 2.4.5 Removing stator
      • 2.4.6 Removing regulator assembly
      • 2.4.7 Removing rectifier assembly
    • 2.5 Inspecting and repairing alternator
      • 2.5.1 Checking rectifier
      • 2.5.2 Checking field coil
      • 2.5.3 Checking stator
      • 2.5.4 Inspecting brushes for wear
      • 2.5.5 Replacing brushes
    • 2.6 Reassembling alternator
      • 2.6.1 Installing rectifier assembly and regulator assembly
      • 2.6.2 Installing stator
      • 2.6.3 Installing front bearing
      • 2.6.4 Installing rear bearing
      • 2.6.5 Installing pulley
      • 2.6.6 Assembling stator and front bracket
  • 3. Reinstalling electrical system
    • 3.1 Installing starter
    • 3.2 Installing alternator
• ADJUSTMENT, BREAK-IN OPERATION AND PERFORMANCE TESTS
  • 1. Adjusting engine
    • 1.1 Inspecting and adjusting valve clearance
      • 1.1.1 Checking clearance between bridge and valve rotator
      • 1.1.2 Using turning gear
      • 1.1.3 Inspecting valve clearance
      • 1.1.4 Adjusting front and rear valve heights by valve bridge
      • 1.1.5 Adjusting valve clearance
    • 1.2 Bleeding fuel system
      • 1.2.1 Bleeding fuel filter
      • 1.2.2 Bleeding fuel injection pump
      • 1.2.3 Tightening priming pump cap
    • 1.3 Inspecting and adjusting fuel injection timing (right side)
      • 1.3.1 Injection timing and its indication location
      • 1.3.2 Checking No. 1 cylinder top dead center in compression stroke
      • 1.3.3 Inspecting fuel injection timing
      • 1.3.4 Adjusting fuel injection timing
    • 1.4 Adjusting no-load minimum engine speed (idling) and no-load maximum engine speed
    • 1.5 Inspecting and adjusting tension of alternator drive belt
  • 2. Break-in operation
    • 2.1 Starting up
    • 2.2 Inspecting during break-in operation
    • 2.3 Break-in duration
    • 2.4 Inspecting and adjusting after break-in operation
  • 3. Performance test (JIS standard)
    • 3.1 Engine equipment condition
    • 3.2 Test items and purposes
      • 3.2.1 Operation load test
      • 3.2.2 Continuous load test
      • 3.2.3 Low idel test
    • 3.3 Other inspections
    • 3.4 Engine output adjustment
      • 3.4.1 Standard atmospheric conditions:
      • 3.4.2 Calculation of corrected power
• OTHERS
  • 1. Dissassembling and reassembling general part
    • 1.1 Oil seal
      • 1.1.1 Installing oil seal to housing
      • 1.1.2 Installing oil seal to shaft
    • 1.2 O-ring
    • 1.3 Bearing
    • 1.4 Lock plate
    • 1.5 Split pins and spring pin