Kubota Z402-EB-ONAN-1 Instruction manual

WORKSHOP MANUAL
DIESEL ENG'INE
Z402-EB-ONAN-1

TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with
informationonthe service and maintenance
of KUBOTADieselEngine2402-8.
Disassembling and Servicing
Underthe heading”General” sectioncomes general precautions, troubleshooting, lists
of servicing specifications and periodic inspection items. For each engine section, there
are “Checking and Adjustment”, “Disassembling and Assembling”, and “Servicing” which
cover procedures, precautions, factory specificationand allowable limits.
AI1 information, illustrations and specifications contained in this manual are based on
The right is resewedto makechanges inall informationat any time without notice.
the latestproductioninformationavailableat the time of publication.
September
2000
@ KUBOTACorporation 2000
02090Z00010

SAFETY INSTRUCTIONS 2402-8 WSM, 02090
A DANGER :Indicates an imminentlyhazardoussituationwhich, if notavoided, will result in death
or serious injury.
i L
~/////////~////////////////////////~/////////////////~///////////////////////////////////~////~///////~/~/////////////////f///////~
g
f
f
A SAFETY FIRST
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and decals on 4
It is essentialthat you readthe instructions and safety regulationsbefore you attempt to repair or f
theengine itselftowarn of the possibility of personalinjury. Readthese instructions carefully.
usethis unit.
h
I
WARNING: Indicates a potentiallyhazardoussituationwhich, if notavoided, couldresult in death
orserious injury.
c
I
CAUTION :Indicates a potentlallyhazardoussituationwhich, if notavoided, may result in minor
la or moderateinjury.
IMPORTANT :Indicates that equipment or property damage could result if instructions are not
followed.
:Gives helpfulinformation.
I
OOOOOZOOOl 1
BEFORESERVICING AND REPAIRING
(1) Read all instructions and safety instructions in this
manualand on your enginesafety decals.
(2) Cleanthe work areaandengine.
(3) Placethe engineon a firm and levelground.
(4) allowthe enginetocool beforeproceeding.
(5) Stop the engine, and removethe key.
(6) Disconnectthe batterynegativecable.
OOOOOFOOOlO
ooooozooo21
.
1

2402-8 WSM, 02090 SAFETY JNSTRUCTIONS
00000F00021
00000F00030
00000F00040 A
)0000F00050
SAFETYSTARTING
(1) Do not start the engine by shorting across starter
terminals.
(2) Unauthorizedmodificationstothe enginemayimpair
thefunction and/or safetyandaffect engine life.
.
00000Z00031
SAFETYWORKING
(1) Do notwork on the enginewhile under the influence
of alcohol, medication, or other substances or while
fatigued.
(2) Wear close fitting clothing and safety equipment
appropriateto the job.
(3) Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
(4) Whenservicing isperformedtogether by two or more
persons, take careto performallwork safely.
(5) Do nottouchthe rotatingor hotpartswhilethe engine
is running.
(6) Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise,
hot water
will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressurebefore removingcompletely.
(7) Escapingfluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury.
Relieve pressure before disconnecting hydraulic or
fuel lines. Tighten all connections before applying
pressure.
(8) Wear a suitable hearing protective device such as
earmuffsor earplugsto protectagainstobjectionable
or uncomfortableloud noises.
I
0000020004 1
AVOID FIRES
(1) Fuel is extremely flammable and explosive under
certainconditions.
Do not smoke or allowflames or
sparks inyour working area.
(2) To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first
andconnect itlast.
(3) Battery gas can explode. Keep sparks and open ,
flame away from the top of battery, especiallywhen
chargingthe battery.
(4) Make sure that no fuel has been spilled on the
engine.
00000Z00050
2

SAFETY INSTRUCTIONS Z402-B WSM, 02090
VENTILATE WORK AREA
(1) If theengine mustberunningtodosomework, make
surethearea iswellventilated. Neverruntheengine
in a closed area. The exhaust gas contains
poisonous carbonmonoxide.
00000Z00060
PREVENTACID BURNS
(1) Sulfuricacid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness
if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing.
If you spill
electrolyte on yourself, flush with water, and get
medicalattentionimmediately.
00000Z00070
DISPOSE OF FLUIDSPROPERLY
(1) Do not pourfluids intothe ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmentalprotectionregulationswhendisposing
of
oil, fuel, coolant, electrolyte and other harmful
waste.
00000Z00080
PREPARE FOR EMERGENCIES
[I (1) Keep a first aid kit and fireextinguisher handyat all
._ -
times.
(2) Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
OOOOOFOOO9O
00000200090
3

ZW-B LVS?J, 02090 SPEClFlCATl ONS
~~~ ~
Number of cylinders
Tw
Bore xstroke
SPECIFICATIONS
~ ~~~
2
Vertical, Water-cooled,4-cycle dieselengine
64 x 62.2 mm (252 x 245 in.)
I Model I 2402 I
Totaldisplacement
SAEnetcont. H.P.
SAE netintermittentH.P.
n
2 SAEgross intermitlent H.P.
2 DIN6270-NA
DIN6270-NB
' DIN70020
Maximumbarespeed
CombustionChamber
Fuelinjectionpump
Governor
Directionof rotation
Injectionnozzle
Injectiontiming
Injectionpressure
Compressionratio
Lubricatingsystem
Oilpressureindicating
Lubricatingfilter
Coolingsystem
Startingsystem
Startingsupportdevice
Bettely
Fuel
Lubricatingoil
Lubricatingoilcapacity
Weight
(Dry)
Dimension(L x W x H)
~~ ~
Injectionorder
400CC(24.41 cu.in.)
5.5 kW/3000
rpm (7.4 HPl3000 rpm)
6.3 kW/3000 rpm (8.4 HP/3000 rpm)
6.5 kW/3000 rpm (8.7 HP/3000 rpm)
5.5 kW13000 rpm (7.5 PS/3000 rpm)
6.1 kW/3000 rpm (8.3 PS/3000 rpm)
6.6 kW/3000 rpm (9.0 PS/3000 rpm)
3200to3300 rpm
Sphericaltype
BoschMD
type minipump
Centrifugalball mechanicalgovernor
Counter-clockwise (viewedfromflywheel)
Boschthrottletype
0.31 to 0.35 rad. (18to20') beforeT.D.C.
1 -2
13.73 MPa(140 kgf/crn2, 1991psi)
23:
1
Forcedlubricationbypump
Electricaltypeswitch
Fullflow paperfilter (cartridge
type)
Pressurizedradiator, forcedcirculationwith water pump
Electricstartingwithstarter
12
V, 1.2 kW
By glowplug
in combustionchamber
12
V, CCA 600, equivalent
Dieselfuel No. 2-D (ASTM D975)
API serviceCD orCE
1.9
L (2.0 U.S.qts., 1.7 Imp.qts.)
56kg (123.5 Ibs)
314.5
x 380.4 x 449.1 mm (12.38 x 14.98 x 17.68 in.)
~~
~ ~~
02090Z00020
4

CONTENTS
GENERAL .......................................................................................................... S-I
[I] ENGINE IDENTIFICATION ........................................................................ 5-1
(1) ModelNameand EngineSerial Number ............................................... 5-1
(2) Cylinder Number .................................................................................... 5-1
(1) TighteningTorquesfor Special UseScrews. Boltsand Nuts ................ 5-3
[2] GENERAL PRECAUTION
.......................................................................... 5-2
[3] TIGHTENING TORQUES .......................................................................... 5-3
(2) TighteningTorquesfor General Use Screws. Boltsand Nuts
............... 5-3
[4] TROUBLESHOOTING
................................................................................ 5-4
[5] SERVICING SPECIFICATIONS ................................................................ 5-7
(1) EngineBody .......................................................................................... 5-7
(3) CoolingSystem ................................................................................... 5-11
(4) FuelSystem ......................................................................................... 5-12
(1) DailyCheck Points .............................................................................. 5-14
(2) Check Pointof Every 50 Hours ........................................................... 5-15
(2) LubricatingSystem .............................................................................. 5-11
[6] MAINTENANCE CHECK LIST ................................................................ 5-13
[71 CHECK AND MAINTENANCE ................................................................ 5-14
(3) Check Points of Every 100 Hours ........................................................ 5-16
(4) Check Pointsof Every200 Hours ........................................................ 5-18
(5) CheckPoints of Every800 Hours ........................................................ 5-19
(6) CheckPointsof Every 1000 Hours
...................................................... 5-20
[8] SPECIAL TOOLS ..................................................................................... 5-20
0 ENGINE BODY ............................................................................................... 5-26
CHECKING AND ADJUSTING
..................................................................... 5-26
DISASSEMBLING AND ASSEMBLING ........................................................ 5-27
[I] DRAINING WATER AND OIL ................................................................ 5-27
[23 EXTERNAL COMPONENTS ................................................................... 5-27
[3] CYLINDER HEAD AND VALVES
.......................................................... 5-28
[4] TIMING GEAR AND CAMSHAFT .......................................................... 5-30
[5] PISTON AND CONNECTING ROD
....................................................... 5-32
[6] FLYWHEEL AND CRANKSHAFT ........................................................... 5-35
SERVICING .................................................................................................... 5-36
[I] CYLINDER HEAD .................................................................................... 5-36
[2] TIMING GEAR AND CAMSHAFT .......................................................... 5-40
[3] PISTON AND CONNECTING ROD
....................................................... 5-42
[4] CRANKSHAFT .......................................................................................... 5-45
[5] CYLINDER ................................................................................................ 5-49
IEl LUBRICATING SYSTEM ................................................................................ 5-50
CHECKING ..................................................................................................... 5-50
SERVICING .................................................................................................... 5-50
[I] OIL PUMP ................................................................................................ 5-50
IF1 COOLING SYSTEM ........................................................................................ 5-52
CHECKING ..................................................................................................... 5-52
[I] FAN BELT ................................................................................................ 5-52
[2] RADIATOR ............................................................................................... 5-52
DISASSEMBLING AND ASSEMBLING
........................................................ S-53
A
*

FUEL SYSTEM ................................................................................................ 5-54
CHECKING AND ADJUSTING ...................................................................... 5-54
[i] INJECTION PUMP ................................................................................... 5-54
[2] INJECTION NOZZLE ................................................................................ 5-55
DISASSEMBLING AND ASSEMBLING ........................................................ 5-56
[I] INJECTION NOZZLE ................................................................................ 5-56

DIESELENGINE 2402-B WSM, 02090
GENERAL
[I] ENGINE IDENTIFICATION
(1) Model Nameand EngineSerial Number
When contacting the manufacturer, always specify your engine
modelnameand serial number.
02090510010
(2) Cylinder Number
The cylinder numbers of 2402 diesel engine are designated as
The sequence of cylinder numbers
is given as No. 1 and No. 2
shown in thefigure.
startingfromthe gear caseside.
c
t
(1) No. 1 Cylinder
(2) No. 2 Cylinder
(A) GearCaseSide
01650510010
.
s-1

Z4M-B VJSM. 02090 DIESEL ENGINE
[Z] GENERAL PRECAUTION
11790F00051
0 Duringdisassembly, carefullyarrange removedparts in a clean
areato preventconfusion later. Screws, bolts and nuts should
be replaced in their original position to prevent reassembly
errors.
When specialtools are required, use KUBOTA genuine special
tools. Special tools which are not frequently used should be
make accordingtothedrawingsprovided.
Before disassembling or servicing live wires, make sure to
alwaysdisconnectthegroundingcablefromthe batteryfirst.
Remove oil anddirtfrom partsbeforemeasuring.
Use only KUBOTA genuine parts for parts replacement to
maintainengine performanceandto ensuresafety.
Gaskets and O-rings must be replaced during reassembly.
Apply greaseto newO-ringsor
oil seals beforeassembling.
When reassembling external or internal snap rings, position
them
so that the sharp edge faces against the direction from
which force isapplied.
0 Be sure to perform run-in the serviced or reassembledengine.
Do not attempt to give heavy load at once, or serious damage
may resulttotheengine.
A CAUTION
Certain components used in this engine (cylinder head-
gasket, exhaust gasket,etc.) containasbestos. Handlewith
careaccordingto safety regulation.
(1) Grease
(2) Force-
(3) Placethe Sharp Edge againstthe
Direction
of Force
(A) External SnapRing
(B) internalSnap Ring
01 64051 0030
s-2

DIESELENGINE 2402-6 WSM, 02090
[3] TIGHTENING TORQUES
Screws, bolts and nuts must be tightenedto the specifiedtorque using a torque wrench, several screws, bolts
and nutssuch as thoseusedon the cylinder head must be tightened in propersequence andat the propertorque.
01640S10760
(1) TighteningTorquesfor Special Use Screws,Boltsand Nuts
NOTE
For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before
tightening.
t
The letter “M” inSize x Pitchmeansthat the screw, bolt or nutdimensionstands for metric. The size is
the nominaloutsidediameterinmm of thethreads. The pitchisthe nominaldistanceinmm betweentwo
threads.
StandardScrew and Bolt
@
Item
SpecialScrew andBolt
Q
* Cylinderheadcovercapnuts
* Cylinder headscrews
* Mainbearingcasescrews 1
* Mainbearingcase screws 1
(Flywheelside)
* Mainbearingcase screws 2
* Flywheelscrews
* Connectingrodscrews
* Rockerarm bracketnuts
* Idlegear shaft screws
* Crankshaftend bolt
* Bearingcase cover screws
Glowplugs
Nozzleholderassembly
Oilswitchtaper screw
Injectionpiperetainingnuts
Overflowpipeassemblyretainingnuts
Starter’sterminal
B mountingnut
N-m kgf.m ft-lbs
Diameter
M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.9
Size x Pitch
Nmm kgf.m ft-lbs
9.8 to 11.3 1-00 to 1.15 7.23 to 8.32
M6
x 1.0
M8 x 1.25
M6
x 1.0
M8 x 1.25
M7
x 1.0
MI0 x 1.25
M7
x 0.75
M6
x 1.0
M6 x 1.0
MI2 x 1.5
M6x 1.0
M8 x 1.0
M20 x 1.5
PT 118
MI2 x 1.5
MI2 x 1.5
M8
MI0
MI2
N.m
39.2 to 45.1 4.0 to 4.6 28.9
to 33.3 48.1 to 55.9 4.9 to 5.7 35.4
to 41.2
62.8
to 72.6 6.4 to 7.4 46.3
to 53.5 77.5 to 90.2 7.9 to 9.2 57.1
to 66.5
3.9 to 5.9
37.2
to 42.1
12.7
to 15.7
23.5
to 27.4
None or 4
7
26.5
to 30.4
53.9
to 58.8
26.5
to 30.4
9.8
to 11.3
9.8
to 11.3
117.6 to 127.4
9.8
to 11.3
7.8
to 14.7
49.0 to 68.6
14.7
to 19.6
24.5
to 34.3
19.6
to 24.5
8.8
to1 1.8
Standard screw and bolt SS41 , S20C
Specialscrewandbolt S43C, S48C (Refined)
kgfam
0.4 to 0.6
3.8
to 4.3
1.3
to 1.6
2.4 to 2.8
2.7
to 3.1
5.5
to 6.0
2.7
to 3.1
1.00 to 1.15
1.00 to 1.15
12.0 to 13.0
1.00 to 1.15
0.8 to 1.5
5.0 to 7.0
1.5 to 2.0
2.5
to 3.5
2.0
to 2.5
0.9 to 1.2
ft-lbs
2.9 to 4.3
27.5 to 31 .I
9.4 to 11.6
17.4
to 20.3
19.5
to 22.4
39.8 to 43.4
19.5
to 22.4
7.2
to 8.3
7.2
to 8.3
86.4
to 93.6
7.2
to 8.3
5.8 to 10.8
36.2 to 50.6
10.8
to 14.5
18.1 to25.3
14.5
to 18.1
6.5
to 8.7
01650510020
(2) TighteningTorquesfor GeneralUse Screws, Boltsand Nuts
I I I I I
I
M8
I 17.7 to 20.6 I 1.8 to 2.1 I 13.0 to 15.2 I 23.5 to27.5 I 2.4 to 2.8 I 17.4 to 20.3 I
Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to
tightening,besure to check out the numbersas shown below.
I Punchednumber I Screw and boltmaterialgrade
0164OS10040
5-3

zm-B WSM. 02090 DIESEL ENGINE
[4] TROUBLESHOOTING
Symptom
Engine
Does Not
Start
(Starter
Does Not
Run)
~
Engine Revolution Is
Not Smooth
Either White
or Blue
Exhaust
Gas Is
0 bserved
ProbableCause
Nofuel
Air inthefuel system
Water inthe fuelsystem
Fuelpipeclogged
Fuelfilter clogged
Excessively highviscosity of fuel or engineoil
at lowtemperature
Fuelwith lowcetane number
Fuel leakdueto looseinjectionpipe retaining
Incorrect injectiontiming
Fuelcamshaftworn
Injectionnozzle clogged
Injectionpump malfunctioning
nut
Seizure of crankshaft,camshaft, piston,
Compression leakfromcylinder
cylinder or bearing
Impropervalvetiming
Pistonringand cylinderworn
0 Excessivevalve clearance
Battery discharged
Starter malfunctioning
Key switchmalfunctioning
Wiring disconnected
Fuelfilter cloggedor dirty
Air cleaner clogged
Fuel leakdueto looseinjectionpipe retaining
Injectionpumpmalfunctioning
nut
Incorrectnozzleopeningpressure
Injectionnozzlestuckor clogged
Governor malfunctioning
Excessive engine oil
0 Pistonringandlinerworn or stuck
0 Incorrectinjectiontiming
0 Deficientcompression
Solution
Replenishfuel
Vent air
Changefueland
repairor replacefuel
system
Clean
Cleanor change
Use specifiedfuel or
engine
oil
Usespecifiedfuel
Tighten retainingnut
Adjust
Replace
Clean
Repairor replace
Repairor replace
Replacehead
gasket, tighten
cylinderheadscrew,
glowplugandnozzle
holder
Corrector replace
timinggear
Replace
Adjust
Charge
Repairor replace
Repairor replace
Connect
Cleanor change
Cleanor change
Tightenretainingnut
Repairor replace
Adjust
Repairor replace
Repair
Reduce
to specified
level
Repairor replace
Adjust
Adjusttop clearance
Reference
Page
-
S-15
-
-
S-17
S-16
-
-
s-54
S-31
s-55
S-30,
54,
55
-
S-26,28
S-31
s-34,35
s-19
-
-
-
-
S-17
S-17
-
S-30,54,
55
s-55
S-56
S-31
S-16
s-34,35
s-54
S-26
02090S70020
5-4

DIESELENGINE 2402-8 WSM, 02090
Either Blackor Dark
Gray Exhaust Gas Is
Observed
DeficientOutput
ExcessiveLubricant
Oil Consumption
FuelMixed into
Lubricant
Oil
Water Mixed into
LubricantOil
Low
Oil Pressure
~~
HighOil Pressure
ProbableCause
Overload
0 Lowgradefuel used
Fuelfilter clogged
Air cleaner clogged
0 Deficientnozzle injection
0 Incorrect injectiontiming
0 Engine’s movingparts seemto beseizing
0 Unevenfuelinjection
Deficientnozzleinjection
Compressionleak
0 Pistonring’s gapfacingthe same direction
Oil ringworn or stuck
Pistonringgroove worn
0 Valve stem andvalve guideworn
Carnkshaftbearing, andcrank pinbearing
0 Oil leakingdueto defectiveseals or packing
worn
Injectionpump’s plungerworn
0 Deficient nozzle injection
0 Injectionpumpbroken
Headgasket defective
0 Cylinderblockorcylinder headflawed
__ ~-~
0 Engineoil insufficient
0 Oilstrainerclogged
0 Relief valve stuck with dirt
0 Relief valve spring weaken orbroken
0 Excessiveoilclearance of crankshaft bearing
0 Excessiveoilclearance of crankpin bearing
0 Excessiveoilclearance of rockerarmbearing
Oil passageclogged
Different type of oil
0 Oil pumpdefective
0 Differenttype of oil
0 Relief valve defective
Solution
Lessenload
Use specifiedfuel
Cleanor change
Cleanor change
Repair
or replace
nozzle
Adjust
Repair or replace
Repairor replace
injectionpump
Repairor replace
nozzle
Replacehead
gasket, tighten
cylinderheadscrew,
glowplugandnozzle
holder
Shift ringgap
direction
Replace
Replacepiston
Replace
Replace
Replace
Replacepump
elementor injection
Pump
Repair
or replace
nozzle
Replace
Replace
Replace
Replenish
Clean
Clean
Replace
Replace
Replace
Replace
Clean
Usespecifiedtype of
oil
Repair or replace
Usespecifiedtype of
oil
Replace
Reference
Page
8.-
-
S-17
S-17
5-55
5-54
5-30,54,
55
5-56
S-26,28
-
5-33
s-33, 34
s-44
s-37
S-46
-
5-54,55
S-56
5-30
5-28
S-36’37
-
S-32
-
c
S-47,40
S-46
5-40
-
-
5-50
.
02090510030
5-5

DIESEL ENGINE
2402-6 WSM. 02090
Symptom
Engine Overheated
Battery Quickly
Discharge
Probable Cause
0 Engine oil insufficient
0 Fan belt broken or elongated
0 Cooling water insufficient
0 Radiator net and radiatorfin clogged with dust
0 Inside of radiatorcorroded
0 Cooling waterflow route corroded
0 Radiator capdefective
Overload running
0 Head gasket defective
0 Incorrect injectiontiming
0 Unsuitable fuel used
Battery electrolyteinsufficient
0 Fan belt slips
Wiring disconnected
Rectifierdefective
0 Alternator defective
0 Battery defective
Solution
Replenish
Replace oradjust
Replenish
Clean
Clean or replace
Clean
or replace
Replace
Loosen load
Replace
Adjust
Use specified fuel
Replenish distilled
water and charge
Adjust belttension or
change
Correct
Replace
Replace
Change
Reference
Page
-
S-16
-
-
-
-
s-53
S-28
s-54
-
-
02090510040
S-6

DIESEL ENGINE 2402-8 WSM, 02090
VarianceAmong Cylinders -
I
[5] SERVICING SPECIFICATIONS
10 %orless
(1) EngineBody
Cvlinder Head
0.145 to 0.1 85 mm
0.0057
to 0.0072 in.
0.785 rad.
45"
0.785 rad.
45'
Cylinder HeadSurface Flatness
Top Clearance
-
-
FactorySpecification
-
Open
Close
0.50 to 0.70 mm
0.0197 to 0.0276 in.
0.35 rad.
(20") -
beforeT.D.C.
0.79 rad. (45')
after B.D.C.
-
AllowableLimit
0.05 mm
0.0019 in.
Close
CompressionPressure
0.26 rad.
(15') -
afterT.D.C.
2.84 to 3.23 MPa
29.0
to 33.0 kgf/cm2
412 to469 psi
2.25 MPa
23 kgflcm2
327 psi
Valves
I Valve Clearance (Cold)
Valve Seat Angle
Valve FaceAngle
I Valve Recessing
ClearancebetweenValve Stem and Valve Guide
Valve StemO.D.
Valve GuideI.D.
Valve Timing
-
IntakeValve
ExhaustValve
- 0.10 to 0.10 mm
- 0.0039 to0.0039 in.
0.030 to0.057 mm
0.3 mm
0.01 18 in.
0.1 mm
+ 0.001 18to 0.00224 in. 0.0039 in.
5.968 to
5.980 mm
0.23496 to 0.23543 in.
6.010 to 6.025 mm
0.23661 to 0.23720 in.
Open 0.87 rad.
(50')
1 beforeB.D.C.
-
I
.
s-7

ZM2-B LVSM, 02090 DIESEL ENGINE
Factory Specification
31.6 mm
1.244 in.
64.7 N / 27 mm
6.6 kgf / 27 mm
14.6
Ibs / 1.063 in.
-
i.
Aliowable Limit
28.4mm
1.118
in.
54.9 N / 27mm
5.6
kgf / 27mm
12.3
Ibs / 1.063 in.
1.2 mm
0.047
in.
Valve Spring
Clearancebetween Rocker Arm Shaft and Rocker Arm
0.016 to 0.045 mm
0.0006 to 0.0018 in.
Item
0.15 mm
0.0059
in.
FreeLength
Set€ingLoad
/ SettingLength
RockerArm
I.D. 10.500 to 10.518 mm
0.41339 to 0.4141 0 in.
Tilt
Clearancebetween Tappet and Guide
0.016 to 0.052 mm
0.00063 to 0.00205 in.
0.10 mm
0.0039 in.
Tappet GuideI.D.
RockerArm Shaft O.D.
18.000 to 18.018 mm
0.70866
to 0.70939 in.
-
10.473 to 10.484 mm
0.41232 to 0.41276 in.
CamshaftSide Clearance 0.15 to 0.31 mm
0.0059 to 0.01220 in.
Cam Height 27.00 mm
1.0630 in.
Oil Clearance of Camshaft
0.050 to 0.091 mm
0.0020 to 0.0036 in.
32.934 to 32.950 mm
1.2966 to 1.2972 mm
33.000 to 33.025 mm
1.2992 to 1.3002 in.
CamshaftJournal
O.D.
Camshaft Bearing I.D.
0.5 mm
0.020 in.
26.97mm
1.0618 in.
0.15 mm
0.0059
in.
-
-
Tappet O.D. 17.966 to 17.984 mm
0.70732 to 0.70803 in.
.

DIESEL ENGINE 2402-B WSM, 02090
PistonPinBore
ClearancebetweenCompression Ring
2 and RingGroove
Timing Gear
20.000 to 20.013 mm
0.78740
to 0.78791 in.
0.085 to 0.1 12mm
0.0033
to 0.0044 in.
20.05 mm
0.7894
in.
0.15 mm
0.0059 in.
item
ClearancebetweenOilRingand RingGroove
RingGap
CompressionRing
1, CompressionRing 2
Timing Gear Backlash
Crank Gear-Idle Gear
IdleGear-CamGear
IdleGear-Injection Pump Gear
CrankGear-Oil PumpDrive Gear
0.04 to0.08 mm
0.0016
to 0.0031 in.
0.25 to 0.40 mm
0.0098 to
0.01 57 in.
ClearancebetweenIdleGear Shaft and IdleGear Bushing
IdleGear BushingI.D.
IdleGear Shaft
O.D.
IdleGear Side Clearance
Piston Piston Ring
FactorySpecification
0.043 to 0.124 mm
0.001 69to 0.00488 in.
0.047 to 0.123 mm
0.001 85to0.00484 in.
0.046 to 0.124 mm
0.00181
to 0.00488 in.
0.041 to 0.123
mm
0.001 61 to 0.00484 in.
0.020 to 0.084 mm
0.0008 to0.00331 in.
20.000 to20.051 mm
0.78740 to 0.78941 in.
19.967
to 19.980 mm
0.7861
0 to 0.78661 in.
0.20 to 0.51 mm
0.0079
to 0.0200 in.
Allowable Limit
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.10 mm
0.0039
in.
-
-
0.60 mm
0.0236
in.
Oil Ring
0.15 to0.30 mm
0.0059 to
0.01 77 in.
I
0.15 mm
0.0059 in.
1.25mm
0.0492 in.
1.25 mm
0.0492 in.
Of650S10070
s-9

Z402-B WSM, 02080 DIESELENGINE
8
Connecting Rod
I item 1 Factory Specification I Allowable Limit
-
I
I ConnectingRodAlignment 0.05 mm
0.0020 in.
Clearance betweenPiston PinandSmallEndBushing
PistonPin
O.D.
Small EndBushing I.D.
0.014 to0.038 mm
0.0006 to0.0015
in.
20.002 to 20.01 1 mm
0.78748 to0.78783
in.
20.025 to 20.040 mm
0.78839 to0.78897
in.
0.10 mm
0.0039 in.
Crankshaft
CrankshaftAlignment
OilClearancebetweenCrankshaftand Crankshaft Bearing
1
Crankshaft O.D.
Crankshaft Bearing1 I.D.
OilClearancebetween Crankshaftand Crankshaft Bearing2
Crankshaft
O.D.
CrankshaftBearing2 I.D.
OilClearancebetweenCrankshaftand Crankshaft Bearing3
Crankshaft
O.D.
Crank bearing3 I.D.
OilClearancebetween Crank Pinand CrankPinBearing
Crank Pin
O.D.
Crank PinBearing I.D.
CrankshaftSideClearance
0.034 to 0.1 06 mm
0.0013to0.0042
in.
39.934 to 39.950 mm
1.57221to1.57281
in.
39.984 to 40.040 mm
1.57428 to 1.57648
in.
0.034 to0.092 mm
0.001 3 to 0.0036 in.
43.934 to43.950 mm
1.7297 to 1.7303 in.
43.984 to44.026 mm
1.731 7to 1.7333 in.
0.028 to 0.059 mm
0.001 1 to0.0023 in.
39.934 to39.950 mm
1.5722 to 1.5728 in.
39.978 to39.993 mm
1.5739 to 1.5745 in.
0.02 to0.051 mm
0.0008 to
0.0020 in.
33.959 to33.975 mm
1.3370 to 1.3376 in.
33.995 to34.010 mm
1.3384to 1.3390
in.
0.15 to0.25 mm
0.0059 to0.0098
in.
0.02 mm
0.0008 in.
0.20 mm
0.0079 in.
0.20 mm
0.0079 in.
0.20 mm
0.0079 in.
-
-
0.15 mm
0.0059 in.
0.50 mm
0.01 97 in.
01 650s 10080
s-10

DIESEL ENGINE 2402-9 WSM, 02090
Item Factory Specification
64.000 to 64.019 mm
2.51 99 to 2.5204 in.
+ 0.5 mm
+ 0.01 97 in.
CylinderLiner I.D.
OversizedCylinder Liner
1.D.
Allowable Limit
64,169 mm
2.52634 in.
+ 0.15 mm
0.0059 in.
(2) LubricatingSystem
Oil Pump
At IdleSpeed
At RatedSpeed
98 kPa
1 .O kgf/cm2, 14 psi
196.0 to 441 .O kPa
2.0 to 4.5 kgf/cm2
28.0 to 64.0 psi
ClearancebetweenInnerRotor and Outer Rotor
-
98 kPa
1 .O kgf/cm2
14 psi
ClearancebetweenOuter Rotorand Pump Body
EndClearancebetweenInner Rotorand Cover
0.03 to 0.14 mm
0.0012 to 0.0055 in.
0.07 to 0,15 mm
0.0028 to 0.0059 in.
0.075 to 0.135 mm
0.0029 to 0.0053 in.
01650S10090
-
-
Thermostat's Valve OpeningTemperature
Temperatureat WhichThermostatCompletely Opens
69.5 to 72.5 'C -
85 'C -
157.1 to 162.5 'F
01640S10511
RadiatorWater Tightness
RadiatorCap Air Leakage
FanBeltTension
Watertightnessat
-
specifiedpressure
I57 kPa
1.6 kgf/cm2, 23 psi
10 secondsor more -
80 3 59 kPa
0.9 + 0.6 kgf/cm2
13 + 9 psi
10 to 12 mm / 10 kgf
0.394 to 0.472 in. /
10 kgf (22.1 Ibs.)
I
I 185 'F I
4-
s-11