VANGUARD 3CYL. Diesel & TURBO-Diesel Engine Repair Manual

FORM MS-1055-5/02  2002 BRIGGS & STRATTON DAIHATSU LLC PRINTED IN U.S.A. REPAIR MANUAL For 3 Cylinder LiquidĆCooled Diesel Engines

FOREWORD The information, procedures and specifications provided in this repair manual are current as of the date of publication and subject to change without notice. Appropriate changes will be included in the next revision of this manual. Note: Manufacturing standards may vary from service specifications. Always refer to the service procedures and specifications in this manual when engine service is required. GENERAL REPAIR INSTRUCTIONS Before attempting a B&SD engine overhaul or a tune-up, it is necessary that your shop be equipped with proper tools, equipment and mechanics who are thoroughly familiar with Briggs & Stratton engine design and construction. With your shop thus equipped, this book will serve as a guide in performing the various steps necessary to do a complete and satisfactory job. Use only genuine replacement parts. Always use recommended service tools. This engine is designed and manufactured using metric dimensions. The English equivalents provided may have been rounded up or down to the closest numerical interpretation of the metric dimension. The terms Inspect, Check, Test and Replace are used as follows: INSPECT  Visual inspection  look for signs of wear, scoring, cracks, stripped threads, etc. CHECK  Measure by means of plug gauges, micrometer, feeler gauges, scale, etc. TEST  Analyze with proper test equipment. REPLACE  This usually means to take off the old part and reassemble it or replace it with a new one. Disassembly As engine is being disassembled, mark parts which are part of an assembly, to prevent interchanging. Arrange parts in an orderly manner, keeping parts which are an assembly together. Visually inspect each part as it is removed  look for signs of wear, scoring, cracks, stripped threads, etc. Inspection and Measurement Carefully check parts that can be reconditioned and/or reused. Replace any parts that are not within specification. Clean parts to be reused Clean or wash disassembled parts. Assemble Use a torque wrench to torque bolts and nuts to required specifications. Replace all gaskets, cotter pins, oil seals and O-rings. ABBREVIATIONS Abbreviation Meaning ASSY Assembly BDC Bottom Dead Center DT Diesel Turbocharger EX Exhaust ID Inside Diameter IN Intake LH Left Hand MP Multi-purpose Abbreviation Meaning OD Outside Diameter OPT Optional O/S Oversize RH Right Hand SAE Society of Automotive Engineers T/C Turbocharger TDC Top Dead Center U/S Undersize Copyright " 2002 by Briggs & Stratton Corporation All rights reserved. No part of this material may be reproduced or transmitted, in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage and retrieval system, without permission in writing from Briggs & Stratton Corporation.

TABLE OF CONTENTS See Pages II and III for Section Contents GENERAL INFORMATION Section 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD AND VALVES Section 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIMING GEARS AND GEAR CASE Section 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLYWHEEL AND REAR SEAL RETAINER Section 4 . . . . . . . . . . . . . . . . . . . . . . . CYLINDER BLOCK DISASSEMBLY Section 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER BLOCK INSPECTION AND REPAIR Section 6 . . . . . . . . . . . . . . . . . . CRANKSHAFT, CAMSHAFT AND BEARINGS Section 7 . . . . . . . . . . . . . . . . . . . . PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY Section 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER BLOCK ASSEMBLY Section 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM AND RELATED COMPONENTS Section 10 . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS Section 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION SYSTEM Section 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM Section 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOOLS Section 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I

SECTION CONTENTS IV 1 Section 1 GENERAL INFORMATION Engine Identification In The Interest Of Safety Engine Views Engine Specifications And Data Fastener Specifications Briggs & Stratton Numerical Number System Maintenance Schedule 2 Section 2 CYLINDER HEAD AND VALVES Remove Cylinder Head Disassemble Cylinder Head Inspect And Repair Cylinder Head Valve Guides Valves Disassemble Rocker Arm Shaft Assemble Rocker Arm Shaft Assemble Cylinder Head Install Cylinder Head Adjust Valves 3 Section 3 TIMING GEARS AND GEAR CASE Remove Timing Gear Cover And Gears Checking Gears Remove Gear Case Replace Timing Gear Cover Oil Seal Assemble Timing Gear Case And Gears 4 Section 4 FLYWHEEL AND REAR SEAL RETAINER Removing Flywheel And Rear Seal Retainer Replacing Oil Seal Installing Rear Seal Retainer And Flywheel Install Oil Pan 5 Section 5 CYLINDER BLOCK DISASSEMBLY Engine Stand Fixture Cylinder Block Disassembly 6 Section 6 CYLINDER BLOCK INSPECTION AND REPAIR Checking Cylinder Block Replacing Camshaft Bearing Replacing Camshaft Plug 7 Section 7 CRANKSHAFT, CAMSHAFT AND BEARINGS Checking Crankshaft Checking Main Bearing Clearances Checking Connecting Rod Bearing Clearances Checking Crankshaft End Play Checking Camshaft 8 Section 8 PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY Disassemble Piston And Connecting Rod Checking Piston And Rings Checking Piston Pin And Connecting Rod Assemble Piston And Connecting Rod Assemble Piston Rings To Piston 9 Section 9 CYLINDER BLOCK ASSEMBLY Install Crankshaft Install Pistons And Connecting Rods General Assembly Oil Pickup Tube Rear Seal Retainer And Starter Motor Flywheel Install Timing Gear Case, Camshaft And Gears Install Oil Pan Install Alternator 10 Section 10 FUEL SYSTEM AND RELATED COMPONENTS General Information Injector Pump Timing Specifications Checking Injector Pump Timing

SECTION CONTENTS (contd) III Adjusting Injector Pump Timing Injectors Remove Injectors Checking Injectors Install Injectors Fuel Filter  General Draining Water Collector Change Fuel Filter Fuel Shut-Off Solenoid Checking Fuel Shut-Off Solenoid Wiring Injector Pump Identification Engine Speed Identification Chart Adjust Idle Speed Adjust Top No Load Speed 11 Section 11 ELECTRICAL SYSTEMS Electrical System Components Glow Plug System Glow Plug Specifications Remove Glow Plugs Test Equipment Testing Glow Plug Preheat Timer And Glow Relay Testing Preheat Timer Testing Glow Relay Keyswitches Charging Systems 14 Amp Charging System Test Equipment Testing Alternator  AC Output Testing Regulator-Rectifier  DC Output Testing Charge Indicator Bulb And Wiring 40 Amp Charging System Test Equipment Testing Alternator  DC Output Disassemble Alternator Checking Bearings Install Ball Bearing Check Brushes Check Regulator Check Rectifier Assemble Alternator Starter System Starter Current Draw Test  Installed Test Equipment Testing Starter Starter Current Draw Test  No Load Testing Starter (No Load) Starter Solenoid Equipment To Test Solenoid Testing Solenoid Remove Solenoid Check Pinion And Clutch Assembly Assemble Pinion And Clutch Assembly Install Solenoid Install Solenoid Contacts And Plunger Disassemble Starter Motor Inspect Armature Commutator Inspect Brushes Replace Brushes Assemble Starter Motor Wiring Diagrams 40 Amp Wiring Diagram 14 Amp Wiring Diagrams 12 Section 12 LUBRICATION SYSTEM Description Change Oil Change Oil Filter Check Oil Pressure Disassemble Gear Case Remove Oil Pump Assemble Gear Case Install Oil Pump 13 Section 13 COOLING SYSTEM General Information Checking Cooling System Pressure Testing Cooling System Testing Radiator Cap Changing Coolant Thermostat Removing Thermostat Checking Thermostat Installing Thermostat Water Pump Inspecting Water Pump Removing Water Pump Installing Water Pump

SECTION CONTENTS IV 14 Section 14 TURBOCHARGER General Information Turbocharger Lubrication System Turbocharger Cooling System Turbocharger Waste Gate Turbocharger Pressure Control System Crankcase Bloeby Recirculating System Checking Waste Gate Actuator Servicing And Operating Information Remove Turbocharger Checking Turbocharger Install Turbocharger Installation Of Coolant Inlet Tube

1 MAY 2002 Section 1 General Information BRIGGS & STRATTON DAIHATSU 3 CYLINDER LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055) Section Contents Page ENGINE IDENTIFICATION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN THE INTEREST OF SAFETY 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE VIEWS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SPECIFICATIONS AND DATA 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FASTENER SPECIFICATIONS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRIGGS & STRATTON NUMERICAL NUMBER SYSTEM 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SCHEDULE 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE IDENTIFICATION NUMBERS The engine model and type number are located on the vale cover, Fig. 1. The serial number is stamped into the right side of the cylinder block, behind the intake manifold, Fig. 2. Fig. 1  Engine Model And Type Number MODEL AND TYPE NO. Fig. 2  Engine Serial Number SERIAL NO.

2 GENERAL INFORMATION IN THE INTEREST OF SAFETY This safety alert symbol indicates that this message involves personal safety. Signal words danger, warning and caution indicate hazard degree. Death, personal injury and/OR property damage may occur unless instructions are followed carefully. WARNING: DO NOT 1. DO NOT run engine in an enclosed area. Exhaust gases contain carbon monoxide, an odorless and deadly poison. 2. DO NOT place hands or feet near moving or rotating parts. Keep all guards in place. 3. DO NOT place hands or feet near electric cooling fan (if equipped). Fan may start suddenly, de- pending on coolant temperature. 4. DO NOT store, spill, or use diesel fuel near an open flame, or devices such as a stove, furnace, or water heater which use a pilot light or devices which can create a spark. 5. DO NOT refuel indoors where area is not well ventilated. Outdoor refueling is preferred. 6. DO NOT fill fuel tank while engine is running. Allow engine to cool for 2 minutes before refueling. Store fuel in approved, correct color safety containers. 7. DO NOT remove fuel tank cap while engine is running. 8. DO NOT operate engine when smell of fuel is present or other explosive conditions exist. 9. DO NOT operate engine if diesel fuel is spilled. Move machine away from the spill and avoid creating any ignition until the spill has been wiped up. 10. DO NOT smoke when filling fuel tank. 11. DO NOT tamper with maximum speed set screw or full load set screw of the injector pump which may increase the governed engine speed. 12. DO NOT tamper with the engine speed selected by the original equipment manufacturer. 13. DO NOT operate engine with a damaged muffler or without muffler. Inspect periodically and replace, if necessary. If engine is equipped with muffler deflector(s), inspect periodically and replace, if necessary, with correct deflector(s). 14. DO NOT operate engine with an accumulation of grass, leaves, dirt or other combustible material in the muffler area. 15. DO NOT use this engine on any forest covered, brush covered, or grass covered unimproved land unless a spark arrester is installed on the muffler. The arrester must be maintained in effective working order by the operator. In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. 16. DO NOT touch hot muffler(s) or cylinder(s) because contact may cause burns. 17. DO NOT remove the radiator cap while the engine is hot. To avoid scalding from hot coolant or steam blowing out of the radiator, use extreme care when removing the radiator cap. If possible, wait for engine to cool. If not possible, wrap a thick rag around cap while removing. To release pressure, slowly turn cap counter clockwise to the first stop. When all pressure has been released, press down on cap and continue turning. 18. DO NOT start or run engine with air cleaner or air cleaner cover removed. WARNING: DO 1. ALWAYS DO disconnect the negative wire from the battery terminal when servicing the engine or equipment, TO PREVENT ACCIDENTAL STARTING. 2. ALWAYS DO disconnect fuel shut off solenoid wire from injection pump before checking compression, TO PREVENT ACCIDENTAL STARTING. 3. DO wear eye protection when operating or repairing equipment. 4. DO keep governor parts free of grass and other debris which can affect engine speed. 5. DO examine muffler(s) periodically to be sure it is functioning effectively. A worn or leaking muffler(s) should be repaired or replaced as necessary. 6. DO check fuel lines and fittings frequently for cracks or leaks. Replace if necessary. CAUTION: DO use clean fresh diesel fuel with a minimum of 40 cetane. DO NOT use kerosene. The injection pump requires diesel fuel for lubrication. Damage to the injection pump and/or engine may result if kerosene is used. NOTE: Use Original Briggs & Stratton-Daihatsu Service Replacement Parts when servicing your engine. Authorized Briggs & Stratton-Daihatsu Service Centers carry a stock of such parts. The use of Briggs & Stratton-Daihatsu parts preserves the original design of your engine. Imitation replacement parts may not fit or function as original Briggs & Stratton-Daihatsu parts and can expose the operator to potential personal injury. Contact any Authorized Briggs & Stratton-Daihatsu Service Center for Original Briggs & Stratton-Daihatsu Replacement Parts.

3 GENERAL INFORMATION ENGINE VIEWS 1. Thermostat 2. Oil filler cap 3. Electric starter 4. Oil pan 5. Alternator 2 3 5 4 Diesel 1 11 6. Injector nozzle 7. Glow plug 8. Oil drains 9. Oil filter 10. Dipstick 11. Injector pump 12. Engine Date code xxxxxxxx 13. Engine Model & Type number xxxxxx xxxx-xx 7 10 13 9 6 8 12 1. Thermostat 2. Oil filler cap 3. Turbocharger 4. Electric starter 5. Alternator 6. Oil pan Turbo-charged Diesel 7. Injector nozzle 8. Glow plug 9. Oil drains 10. Oil cooler (if equipped) 11. Oil filter 12. Dipstick 13. Injector pump 14. Engine Date code xxxxxxxx 15. Engine Model & Type number xxxxxx xxxx-xx

4 GENERAL INFORMATION ENGINE SPECIFICATIONS Model 432447 522447 582447 @58A447 @588447 Type Diesel, 4-cycle, 3 cylinder, in-line, liquid cooled Valve mechanism OHV, gear driven Bore x stroke mm (in) 68 x 64 (2.680 x 2.520) 68 x 78 (2.680 x 3.070) 72 x 78 (2.834 x 3.070) Piston displacement cc (cu in) 697 (42.5) 850 (52.0) 952 (58.1) Firing order 1-2-3 (front, center, back) Compression ratio 25.0:1 24.4:1 24.0:1 @ 24.8:1 Compression pressure (normal) @ 300 RPM Bar Engine at operating temperature  (psi) glow plugs removed 33.0 (469) 32.0 (455) 34.0 (498) @ 37 (526) Compression pressure (minimum) @ 300 RPM Bar Engine at operating temperature  (psi) glow plugs removed 30.0 (425) 29.0 (412) 30.5 (433) @ 27 (384) Gross HP @ 3600 RPM 19.5 23.6 26.5 @ 28.0 Gross Torque @ 2400 RPM 32.5 40.0 44.1 @ 49.2 Dimensions (L x W x H) mm (in) 441.8 x 440.4 x 523.9 (17.4 x 17.34 x 20.6) 434.4 x 442.9 x 548.4 (17.1 x 17.44 x 21.59) 434.4 x 442.9 x 548.4 (17.1 x 17.44 x 21.59) @ 434.4 x 447.5 x 559.0 (17.1 x 17.62 x 22.01) Dry weight kg (lbs) 76 (168) 78 (172) 89 (196)

VANGUARD 3CYL. Diesel & TURBO-Diesel Engine Repair Manual

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