S4Q2 Diesel Engine

Service Manual # 99719-77100

The following modules do not cover all of the material in the manual. We have identified and chosen some of the more important key points. To fully understand the engine in more depth you will need to read the manual. More hands on work with the lift truck, and real life work will improve your overall knowledge of this equipment.

External View (Left Side)

External View (Right Side)

Serial Number Location

S
Series code

Number of cylinders Sagamihara Plant

Engine Main Parts

Cylinder Heads & Valve Mechanism

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Rocker cover Adjusting screw Bolt (short) Bolt (long) Valve cap Snap ring Rocker arm Rocker shaft bracket Rocker shaft spring Rocket shaft Valve pushrod Cylinder head bolt Cylinder head Valve cotters Upper valve retainer Valve spring Valve (inlet) Valve (exhaust) Valve stern seal Cylinder head gasket

Cylinder Heads & Valve Mechanism

Cylinder Head
Remove the rocker cover Removing rocker shaft assembly. 1. Loosen the adjusting screw one turn. 2. Loosen the bolts, long and short, that hold the rocker shaft bracket to the cylinder head. Be sure to loosen the short bolt first.Remove the rocket shaft assembly from the cylinder head.

Cylinder Head
Remove the cylinder head bolts. Lift the head off the crankcase.

Cylinder Head
Tighten the cylinder head bolts to the specific torque in the sequence shown. Tightening torque:118 5N-m (12.00 0.5kgfm) [87 4 lbfft]

Pistons, Crankshaft & Crankcase

1. Connecting rod cap 2. Connecting rod bearing (lower half) 3. Main bearing cap 4. Main bearing (lower half) 5. Crankshaft 6. Main bearing (upper half) 7. Connecting rod 8. Connecting rod bearing (upper half) 9. Snap ring 10. Piston pin 11. Piston 12. No.1 ring 13. No. 2 ring 14. Oil ring 15. Tappet 16. Crankcase

Pistons, Crankshaft & Crankcase

Piston Head
Note the shape of the injection swirl chamber on the top of the piston.

Installing Piston Assembly

Make sure the piston ring end gaps are arranged on the piston, as shown in the illustration.

Timing Gears, Camshaft & Oil Pan

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Crankshaft pulley Cover Timing gear case Pump drive gear PTO idler gear Baffle plate Idler gear Oil pan Oil pump Camshaft Front end plate

Timing Gears, Camshaft & Oil Pan

Timing Gear Train

The timing marks of the gears should be aligned as shown when the no. 1 piston is at top dead center on compression stroke.

Inlet and Exhaust System

Inlet and Exhaust

Inlet and Exhaust

Gasket Exhaust manifold

Gasket

Gasket

Inlet manifold

Air inlet pipe

Cooling System

Coolant Block Diagram

Water Pump & Fan

Gasket Cover Water pump Assy Fan Pulley Gasket

Gasket Spacer

Fan belt

Fan Belt Tension

Unit: mm (in.) Item

Belt Tension (crankshaft pulley alternator pulley)

Standard Value
Approx. 13 (0.5118) (when pressed with force of 98 N (10 kgf) [22 lbf])

Fuel System
ZEXEL VE Type Injection Pump

Fuel System Diagram

Fuel Injection pump

1. Distribution VE-type fuel injection pump. 2. Uses a single high pressure pumping plunger to accurately meter and distribute fuel to each of the engine cylinders. 3. Smaller and lighter than its In-line counterpart.

Comparison of Dimension Size

Cross-section of VE Pump

Sectional View of VE Pump

Fuel Injection Pump

VE Feed Pump
1. The rotary-vane type feed pump draws fuel from the fuel tank. 2. Feed pump rotor is driven by the pump drive shaft which is connected to the injection pump gear. 3. As the rotor spins, centrifugal force holds the van against the pressure chamber wall. 4. Due to the off-center, fuel becomes trapped between the vane and is pressurized and force out through the delivery port.

VE Pressure Regulating Valve

1. The pressure regulating valve is located in the upper portion of the injection pump housing. 2. Fuel pressure is proportional to pump speed. 3. As fuel pressure increases with pump speed, the piston within the pressure regulator is forced against the tension of the regulator spring. 4. At a predetermined value, the valve will begin to open a port in the regulator to allow excess fuel to bypass back to the intake port.

Feed Pump Pressure Vs Speed

Plunger and Camplate

1. The face cam is driven by drive shaft and its rides on the rollers. 2. The distributor plunger and face cam are held against the roller by the plunger spring. 3. As the face cam & plunger rotate, they reciprocate back and forth, delivers high pressure fuel to each cylinder.

Plunger Delivery to Each Nozzle

Intake Stroke
1. Fuel from feed pump fills the pressure chamber of the head as the plunger moves toward the drive end of the pump and rotates to align the plunger intake port with the fill port in the distributor head.

Injection Stroke
2. As the plunger rotates, the intake port is closed and fuel becomes trapped within the pressure chamber. 3. With the continued rotation and now forward motion of the plunger, fuel pressurization and delivery begins. 4. At this point, the outlet port aligns with a distributor passage in the distributor head and injection begins.

End of Injection
5. As a point of forward motion, the spill port of the distributor plunger moves out of the spill ring. 6. Pressure is released and injection is stopped.

Pressure Equalization
1. An additional 180o degrees of rotation of the distributor plunger aligns the pressure equalization groove with the distributor passage of the head. 2. This allows the pressure in the distributor passage to equalize to that of the pressure in the pump housing. 3. This pressure equalization minimizes fuel delivery spread between cylinders and allows for a smoother running engine.

Non-Reversing
1. As illustrated in the figure, if the pump is rotated in the wrong direction, fuel pressurization cannot take place because the fuel intake port is open during cam lift. 2. This non-reversing feature in the pump prevents the engine from running backwards.

Fuel Shut-Off Solenoid

1. Turning the ignition switch to OFF position shuts off the current to the solenoid. 2. With no current to hold the valve, the spring forces the valve to close the fill port. 3. This shut off the fuel supply and the engine stop.

Fuel Filter
Priming pump

Bracket

Element assembly

Level sensor assembly

Drain plug

Draining Water and Sediment

Loosen the drain plug at the bottom of the fuel filter. Operate (push down on) the priming pump of the filter seven times to facilitate draining. After draining, tighten the drain plug. After draining, prime the fuel system.

Priming Filter Side

Pump the priming button on the fuel feed pump.

Bleeding Air from Fuel Filter

Loosen the air vent plug of the fuel filter (by turning it 1.5 turns)

Remove Injection Pump

Remove the pipe clamps from the injection pipe. Disconnect the injection pipes at the injection pump and at the injection nozzles. Disconnect the leak-off pipes from the nozzles by loosening the lock nuts.

Remove Injection Pump

Using a box wrench, remove the fuel injection nozzles with gaskets from the engine. Note: remove the nozzle gaskets from the cylinder head, if any, with a wire or a screwdriver and discard them.

Remove Injection Pump

Check the alignment of the mark on the fuel injection pump with mark on the flange plate

Remove Injection Pump

Remove the front end cover from the engine. Put marks on the fuel injection pump drive gear and idler. Unscrew the bolts that hold the fuel injection pump flange to the front end plate and remove the pump and flange from the end plate..
Note: (1)Do not attemp to run engine after removing the injection pump from the engine. (2)To remove the fuel injection pump drive gear, loosen its nut with the pump on the engine

Lubrication System

Engine oil Lubricating system

Oil Filter

Oil filter

500

Pressure Relief Valve

Unit: MPa (kgf/cm2) [psi] Item Valve opening pressure Assembly Standard 0.29 to 0.39 (3.0 to 4.0) [43 to 57]

Check the valve opening pressure (the oil pressure when engine is running at the rated rpm). If the pressure is not correct, remove the cap bolt and make adjustment by adding or removing shims. The pressure tap (RP 1/8 thread [PS 1/8]) is located near the oil filter.

Adjusting Ignition Timing

WARNING
Always adjust valves with engine stopped to avoid personal injury. Turn the engine by hand and not by use of the starter. Disconnect the battery.

Adjusting Ignition Timing

Bring no. 1 cylinder piston to top dead center on compression stroke

Adjusting Ignition Timing

Confirm TDC1 by attempting to move the inlet and exhaust rocker arms for no. 1 cylinder

Adjusting Ignition Timing

Set the timing to 6 before top dead center

Adjusting Ignition Timing

If the injection timing is retarded, move the injection pump toward the crankcase. If the timing is advanced, move the pump away from the crankcase.

Adjusting Valve Clearance

Governor Adjustment
Warm up engine until coolant and oil temperature rise to 70 oC (158oF) or higher. Low idling setting (no-load minimum rotation speed setting). 700 rpm. Adjust by idling adjust screw. Governor setting (maximum rotation speed setting) 2700 rpm. Adjust by maximum speed adjusting screw.

Caution: The idling and maximum speed are preset at factory. Do not adjust unless necessary.

Testing Compression Pressure

Measure the compression pressure on all cylinders Measure the compression pressure with the engine running at 150 to 200 rpm.

Unit: MPa (kgf/cm2) [psi] Item Compressure pressure Assembly Standard 2.94 (30) [427] Repair Limit 2.55 (26) [370]

Maintenance Schedule