Komatsu 102 Series Diesel Engine Shop Manual YEBM200101 – PDF DOWNLOAD

Komatsu 102 Series Diesel Engine Shop Manual YEBM200101 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 102 Series Diesel Engine Shop Manual YEBM200101 – PDF DOWNLOAD

Language : English
Pages : 806
Downloadable : Yes
File Type : PDF
Size: 40.2 MB

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu 102 Series Diesel Engine Shop Manual YEBM200101 – PDF DOWNLOAD

The Komatsu 102 Series Diesel Engine Shop Manual YEBM200101 is a digital PDF version of the comprehensive guide that provides detailed information on the maintenance, repair, and overhaul of Komatsu 102 series diesel engines. It is a convenient and portable option for individuals who prefer to have the manual available on their electronic devices.

• The PDF version of the manual is organized into the same sections as the print version, including an overview of the engine and its components, engine inspection and measurement procedures, engine disassembly and assembly procedures, engine testing and adjusting procedures, engine maintenance procedures, and engine troubleshooting and diagnosis procedures.
• One of the advantages of the PDF version of the manual is that it is searchable, making it easy to quickly find the information you need. Additionally, the PDF version includes hyperlinks to make navigation even easier, allowing the user to quickly jump to specific sections or subsections of the manual.
• Another advantage of the PDF version is that it is easily printable, allowing the user to create hard copies of specific sections or the entire manual for easy reference in the workshop or field.
• The digital PDF version of the Komatsu 102 Series Diesel Engine Shop Manual YEBM200101 can be downloaded from various websites, including the Komatsu website, for a fee. It is essential to ensure that the source of the PDF download is reputable to avoid any potential issues with the manual’s quality or accuracy.
• Overall, the Komatsu 102 Series Diesel Engine Shop Manual YEBM200101 in PDF format is an excellent resource for anyone working on or maintaining Komatsu 102 series diesel engines. It provides detailed information in a convenient and portable format, making it an essential tool for any mechanic or technician.

TABLE OF CONTENTS:

Komatsu 102 Series Diesel Engine Shop Manual YEBM200101 – PDF DOWNLOAD

COVER……………………………………………………………………………………… 1
SUB-COVER………………………………………………………………………………. 2
CONTENTS ………………………………………………………………………………. 3
SAFETY…………………………………………………………………………………. 4
SAFETY NOTICE……………………………………………………………………….. 4
FOREWORD ………………………………………………………………………………. 6
GENERAL ………………………………………………………………………….. 6
HOW TO READ THE SHOP MANUAL …………………………………………………………. 7
HOISTING INSTRUCTIONS………………………………………………………………… 8
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER ……………………………… 9
COATING MATERIALS……………………………………………………………………. 11
STANDARD TIGHTENING TORQUE ………………………………………………………….. 13
ELECTRIC WIRE CODE …………………………………………………………………. 16
UNITS………………………………………………………………………………. 17
CAPSCREW MARKINGS AND TORQUE VALUES …………………………………………………… 18
PIPE PLUG TORQUE VALUES………………………………………………………………. 21
SYMBOLS…………………………………………………………………………….. 22
ILLUSTRATIONS……………………………………………………………………….. 23
01 GENERAL ……………………………………………………………………………. 24
APPLICABLE MACHINE…………………………………………………………………… 25
GENERAL ASSEMBLY DRAWING……………………………………………………………… 29
S6D102E-1(PC200-6)FRONT VIEW………………………………………………………. 29
S6D102E-1(PC200-6)REAR VIEW……………………………………………………….. 30
S6D102E-1(PC200-6)LEFT-HAND VIEW…………………………………………………… 31
S6D102E-1(PC200-6)RIGHT-HAND VIEW………………………………………………….. 32
SAA6D102E-2(PC200/210-7)FRONT VIEW…………………………………………………. 33
SAA6D102E-2(PC200/210-7)REAR VIEW………………………………………………….. 34
SAA6D102E-2(PC200/210-7)LEFT-HAND VIEW……………………………………………… 35
SAA6D102E-2(PC200/210-7)RIGHT-HAND VIEW…………………………………………….. 36
SAA6D102E-2(PC220-7)FRONT VIEW…………………………………………………….. 37
SAA6D102E-2(PC220-7)REAR VIEW……………………………………………………… 38
SAA6D102E-2(PC220-7)LEFT-HAND VIEW…………………………………………………. 39
SAA6D102E-2(PC220-7)RIGHT-HAND VIEW………………………………………………… 40
ENGINE PERFORMANCE CURVE……………………………………………………………… 43
S6D102E-1(PC200,200LC-6,PC200,200LC-6 HYPER GX))…………………………………….. 44
S6D102E-1(PC200LC-6 EXCEL, PC200-6 CUSTOM)………………………………………….. 45
SA6D102E-1(PC220, 220LC-6)………………………………………………………… 46
SA6D102E-1(PC220,200LC-6 EXCEL)……………………………………………………. 47
SAA6D102E-2(PC200-7,PC200LC-7,PC210-7,PC210LC-7)…………………………………….. 48
WEIGHT TABLE………………………………………………………………………… 50
11 STRUCTURE AND FUNCTION ………………………………………………………………. 52
OUTLINE OF AIR INTAKE AND EXHAUST SYSTEMS………………………………………………. 53
INTAKE AND EXHAUST DEVICES……………………………………………………………. 54
(S)6D102E-1(INTAKE DEVICE)………………………………………………………… 54
(EXHAUST DEVICE)…………………………………………………………………. 55
SA6D102E-1(INTKAE DEVICE)…………………………………………………………. 56
(EXHAUST DEVICE)…………………………………………………………………. 57
AIR CLEANER…………………………………………………………………………. 58
FRG TYPE(RADIAL SEAL TYPE)………………………………………………………… 58
FTG TYPE(CYCLOPACK TYPE)………………………………………………………….. 58
TURBOCHARGER………………………………………………………………………… 59
S(A)6D102E-1…………………………………………………………………….. 59
SAA6D102E-2……………………………………………………………………… 60
OUTLINE OF WASTE GATE VALVE……………………………………………………….. 61
LUBRICATION OF TURBOCHARGER(ENGINE WITH TURBOCHARGER)………………………………… 62
CYLINDER HEAD……………………………………………………………………….. 63
(S)6D102E-1, SA6D102E-1…………………………………………………………… 63
SAA6D102E-2……………………………………………………………………… 65
CYLINDER BLOCK………………………………………………………………………. 68
(S)6D102E-1, SA6D102E-1 SAA6D102E-2………………………………………………… 68
MAIN MOVING PARTS……………………………………………………………………. 71
(S)6D102E-1, SA6D102E-1 SAA6D102E-2………………………………………………… 71
CRANKSHAFT AND MAIN BEARING……………………………………………………….. 73
PISTON CONNECTING ROD…………………………………………………………….. 73
TIMING GEAR PORTION………………………………………………………………….. 76
FRONT GEAR COVER…………………………………………………………………….. 77
CAMSHAFT TIMING PIN………………………………………………………………….. 78
VALVE MECHANISM……………………………………………………………………… 79
(S)6D102E-1, SA6D102E-1 SAA6D102E-2……………………………………………….. 79
(S)6D102E-1, SA6D102E-1 SAA6D102E-2……………………………………………….. 82
FLYWHEEL, FLYWHEEL HOUSING……………………………………………………………. 83
LUBRICATION SYSTEM DIAGRAM……………………………………………………………. 85
FLOW OF LUBRICAING OIL …………………………………………………………… 86
LUBRICATION OF OUTPUT POWER RELATED EQUIPMENT……………………………………….. 88
OIL PUMP …………………………………………………………………………. 90
OIL FILTER, OIL COOLER……………………………………………………………….. 91
REGULATOR VALVE, SAFETY VALVE…………………………………………………………. 92
FUEL SYSTEM DIAGRAM………………………………………………………………….. 95
(S)6D102E-1, SA6D102E-1…………………………………………………………… 95
SAA6D102E-2……………………………………………………………………… 98
FUEL INJECTION PUMP………………………………………………………………….. 99
TIMING LOCK PIN FOR FUEL INJECTION PUMP…………………………………………………101
FUEL FILTER………………………………………………………………………….102
FUEL INJECTION NOZZLE…………………………………………………………………103
FUEL CUT SOLENOID…………………………………………………………………….104
COOLING SYSTEM DIAGRAM………………………………………………………………..105
(S)6D102E-1 SAA6D102E-2…………………………………………………………..105
SA6D102E-1……………………………………………………………………….106
WATER PUMP…………………………………………………………………………..108
THERMOSTAT…………………………………………………………………………..109
FAN DRIVE……………………………………………………………………………110
OUTSIDE DIAMETER OF PULLEY…………………………………………………………111
AIR COMPRESSOR……………………………………………………………………….113
FLOW DIAGRAMS-COMPRESSED AIR SYSTEM…………………………………………………….115
ALTERNATOR…………………………………………………………………………..117
ALTERNATOR(OPTIONAL)………………………………………………………………….118
STARTING MOTOR……………………………………………………………………….119
STARTING MOTOR……………………………………………………………………….120
STARTING MOTOR(OPTIONAL)………………………………………………………………121
STARTING AID…………………………………………………………………………122
12 TEATING AND ADJUSTING ………………………………………………………………..124
SPECIAL TOOL LIST…………………………………………………………………….126
SPECIAL TOOLS FOR INTAKE AND EXHAUST SYSTEM………………………………………….126
SPECIAL TOOLS FOR ENGINE…………………………………………………………..127
SPECIAL TOOLS FOR FUEL SYSTEM………………………………………………………129
SPECIAL TOOLS FOR COMPONENTS……………………………………………………….130
SPECIAL TOOLS FOR ELECTRICAL COMPONENTS……………………………………………..131
SPECIAL TOOLS FOR ENGINE PERFORMANCE TEST……………………………………………132
TROUBLESHOOTIN DEFECTIVE ACTUATION OF INTAKE AND EXHAUST SYSTEM……………………………134
CLEAN AIR………………………………………………………………………..134
TESTING INTAKE RESISTANCE………………………………………………………….134
DAMAGE CAUSED BY UNFILTERED AIR…………………………………………………….135
LEAKAGE OF INTAKE AIR(ENGINE WITH TURBOCHARGER)………………………………………135
LEAKAGE OF EXHAUST AIR (EINGINE WITH TURBOCHARGER)……………………………………136
MEASURING PRESSURE OF TURBOCHARGED AIR(EINGINE WITH TURBOCHARGER)………………………136
DEFECTIVE ACTUATION OF TURBOCHARGER (ENGINE WITH TURBOCHARGER)…………………………137
OIL CONSUMPTION AND OIL LEAKAGE…………………………………………………….137
NOISE FROM TURBOCHARGER (ENGINE WITH TURBOCHARGER)……………………………………138
MEASURING PLAY OF TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION(ENGINE WITH TURBOCHARGER)….139
TESTING TURBOCHARGER WESTGATE VALVE(ENGINE WITH TURBOCHARGER)……………………………..140
TESTING TURBOCHARGER WESTGATE CAPSULE (ENGINE WITH TURBOCHARGER)…………………………..141
TESTING ACTUATION OF TURBOCHARGER WESTGATE (ENGINE WITH TURBOCHARGER )……………………..141
REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE(ENGINE WITH TURBOCHARGER)…………….142
ADJUSTING TURBOCHARGER WESTGATE ACTUATOR(ENGINE WITH TURBOCHARGER)…………………………144
MEASURING EXHAUST RESISTANCE…………………………………………………………..145
REPLACING TURBOCHARGER(ENGINE WITH TURBOCHARGER)…………………………………………145
TROUBLESHOOTING DEFECTIVE ACTUATION OF ENGINE……………………………………………146
VALVE MECHANISM AND CYLINDER HEAD…………………………………………………..146
TEATING AIR SYSTEM AND FUEL SYSTEM………………………………………………….146
TESTING VALVE CLEARANCE……………………………………………………………147
TEATING COMPRESSION……………………………………………………………….147
PISTON RING SEALING PERFORMANCE…………………………………………………….147
VALVE SEALING PERFORMANCE………………………………………………………….148
HEAD GASKET SEALING PERFORMANCE…………………………………………………….148
VALVE SEAL WEAR…………………………………………………………………..149
PROTRUDING PORTION OF FUEL INJECTION NOZZLE………………………………………….150
FRONT GEAR HOUSING AND GEAR TRAIN…………………………………………………..151
VIBRATION DAMPER………………………………………………………………….151
ROCKER LEVER, VALVE STEM, PUSH ROD, TAPPET, AND CAMSHAFT………………………………152
PISTON AND CONNECTING ROD………………………………………………………….153
CRANDSHAFT AND MAIN BEARING………………………………………………………..155
CYLINDER BLOCK……………………………………………………………………156
FLYWHEEL HOUSING AND FLYWHEEL………………………………………………………157
ADJUSTING VALVE CLEARANCE……………………………………………………………..158
ADJUSTING 4-CYLINDER ENGINE………………………………………………………..159
ADJUSTIN 6-CYLINDER ENGINE…………………………………………………………160
TROUBLESHOOTING DEFECTIVE ACTUATION OF LUBRICATING SYSTEM…………………………………161
OUTLINE………………………………………………………………………….161
HIGH PRESSURE…………………………………………………………………….161
REGULATOR VALVE…………………………………………………………………..161
LOW PRESSURE……………………………………………………………………..161
OIL LEVEL………………………………………………………………………..162
OIL FILTER……………………………………………………………………….162
OIL PRESSURE GAUGE………………………………………………………………..162
OIL PAN SUCTION TUBE ……………………………………………………………..163
BEARING AND OIL PUMP ……………………………………………………………..163
UNSUITABLE OIL PUMP……………………………………………………………….163
DILUTION OF OIL ………………………………………………………………….163
COOLING WATER IN OIL ……………………………………………………………..164
FUEL IN OIL ……………………………………………………………………..165
OIL LEAKAGE………………………………………………………………………168
FUEL INJECTION PUMP CALIBRATION DATA……………………………………………………171
RUNNING IN STANDARD…………………………………………………………………..180
PERFORMANCE TEST CRITERIA……………………………………………………………..181
TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP(DIAPHRAGM TYPE)…………………………..183
TEST1: TESTING OUTPUT PRESSURE……………………………………………………..183
TEST2: TESTING FLOW……………………………………………………………….184
TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP(PISTON TYPE)……………………………..185
TEST1: TESTING OUTPUT PRESSURE……………………………………………………..186
TEST2: TESTING FLOW……………………………………………………………….187
TESING AIR INSIDE FUEL SYSTEM………………………………………………………….190
TESING WATER SEPARATOR FUEL FILTER……………………………………………………..191
TROUBLESHOOTING FAILURE OF FUEL INJECTION PUMP(BOSCH VE, LUCAS CAV)………………………..193
DEFECTIVE ACTUATION OF GOVERNOR…………………………………………………….194
STROKE OF FUEL CONTROL LEVER AND ADJUSTMENT………………………………………….194
LUCAS CAV ADJUSTIMENT SCREW………………………………………………………..194
BOSCH VE ADJUSTMENT SCREW………………………………………………………….195
MANUAL SHUT-OFF LEVER……………………………………………………………..195
TIMING PROPULSION ANGLE MECHANISM…………………………………………………..196
ELECTRICAL SHUT-OFF VALVE………………………………………………………….196
DELIVERY VALVE(LUCAS CAV)………………………………………………………….198
TESTING HIGH-PRESSURE FUEL PIPING………………………………………………………199
TESING FUEL INJECTION NOZZLE…………………………………………………………..200
TESING FUEL DRAIN PIPING ……………………………………………………………..202
BLEEDING AIR FROM FUEL SYSTEM………………………………………………………….202
BLEEDING AIR FROM LOW PRESSURE CIRCUIT AND FUEL FILTER………………………………..203
BLEEDING AIR FROM FUEL INJECTION PUMP……………………………………………….203
BLEEDING AIR FROM HIGH-PRESSURE CIRCUIT……………………………………………..204
ADJUSTING FUEL INJECTION TIMING………………………………………………………..204
ADJUSTING FUEL INJECTION TIMING FOR BOSCH VE…………………………………………207
ADJUSTING FUEL INJECTION TIMING FOR LUCAS CAV………………………………………..208
ADJUSTING LOW IDLING SPEED (BOSCH VE, LUCAS CAV)…………………………………………209
REPLACING FUEL INJECTION NOZZLE………………………………………………………..209
TROUBLESHOOTING DEFECTIVE ACTUATION OF COOLING SYSTEM…………………………………….213
TROUBLESHOOTING…………………………………………………………………..213
RADIATOR CAP……………………………………………………………………..215
WATER PUMP……………………………………………………………………….216
RADIATOR, FAN AND RADIATOR SHUTTER………………………………………………….217
THERMOSTAT……………………………………………………………………….219
WATER TEMPERATURE GAUGE, FUEL GAUGE, OOVERLOAD……………………………………….220
TESTING CARBON DEPOSIT IN AIR COMPRESSOR………………………………………………..221
TESING AIR LEAKAGE FROM AIR COMPRESSOR………………………………………………….222
TESING AIR GOVERNOR, UNLOADER VALVE…………………………………………………….223
TESING AIR GOVERNOR…………………………………………………………………..224
TESING BATTERY……………………………………………………………………….226
TESING BATTERY TERMINAL CONNCTIONS …………………………………………………….227
TESTING STARTING CIRCUIT ……………………………………………………………..227
TESTING BATTERY RELAY……………………………………………………………..227
TESING STARTING SWITCH…………………………………………………………….229
TESING STARTING MOTOR AND MAGNETIC SWITCH……………………………………………230
STARTING MOTOR……………………………………………………………………231
TESTING DROP IN CRANKING SPEED……………………………………………………..232
TESING ALTERNATOR…………………………………………………………………….233
ABNORMAL DISPLAY OF CHARGE LAMP…………………………………………………….234
ABNORMAL ACTUATION OF CHARGING SYSTEM……………………………………………….235
TESING OIL PRESSURE SWITCH AND WATER TEMPERATURE SENSOR…………………………………..236
TESTING OIL PRESSURE SWITCH………………………………………………………..236
TESTING WATER TEMPERATURE SENSOR……………………………………………………237
TESING WHITE SMOKE……………………………………………………………………238
NORMAL ACTUATION OF INTAKE HEATER SYSTEM…………………………………………….238
TESING INTAKE HEATER………………………………………………………………….239
TESTING PREHEATING CYCLE…………………………………………………………..240
SIDE VIEW OF ENGINE…………………………………………………………………..241
OUTLINE OF ENGINE PERFORMANCE TEST……………………………………………………..243
BLOW-BY MEASUREMENT AND REPLACEMENT TABLE……………………………………………….244
ENGINE DYNAMOMETER …………………………………………………………………..245
INSTALLING ENGINE…………………………………………………………………245
PROCEDURE FOR RUNNING IN ENGINE…………………………………………………….252
ENGINE PERFORMANCE TEST……………………………………………………………255
ENGINE PAINWORK………………………………………………………………………257
TROUBLESHOOTING………………………………………………………………………260
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING……………………….261
TROUBLESHOOTING OF ENGINE (S MODE)………………………………………………….264
METHOD OF USING TROUBLESHOOTING CHARTS…………………………………………..265
S-1 STRATING PERFORMANCE IS POOR (STARING ALWAYS TAKES TIME)……………………….269
S-2 ENGINE DOES NOE START………………………………………………………271
(1)ENGINE DOES NOT TURN…………………………………………………….271
(2)ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)………272
(3)EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED)……..273
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)……………………….274
S-4 ENGINE STOPS DURING OPERTIONS……………………………………………275
S-5 ENGINE DOES NOT ROTATE SMOOOTHLY (HUNTING)………………………………..276
S-6 ENGINE LACKS OUTPUT(OR LACKS POWER……………………………………….277
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)……………………………..278
S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)……………………..279
S-9 OIL BECOMES CONTAMINATED QUICKLY…………………………………………280
S-10 FUEL CONSUMPTION IS EXCESSIVE…………………………………………..281
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN……..282
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)………………….283
S-13 OIL LEVEL RISES(WATER, FUEL IN OIL) …………………………………….284
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)…………………………..285
S-15 ABNORMAL NOISE IS MADE…………………………………………………286
S-16 VIBRATION IS EXCESSIVE…………………………………………………287
13 DISASSEMBLY AND ASSEMBLY……………………………………………………………….288
SPECIAL TOOL LIST…………………………………………………………………….293
SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY…………………………………………..293
SPECIAL TOOLS FOR ENGINE…………………………………………………………..295
SPECIAL TOOLS FOR FUEL SYSTEM………………………………………………………297
OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE……………………………………………299
OUTLINE………………………………………………………………………….299
DISASSEMBLY…………………………………………………………………..299
ASSEMBLY ……………………………………………………………………299
DISASSEMBLY OF ENGINE…………………………………………………………………300
STEAM CLEANING OF ENGINE…………………………………………………………..300
REMOVAL OF STARTING MOTOR………………………………………………………….300
WEIGHT OF ENGINE(REFERENCE VALUE NOT INCLUDING AUXILIARIES SUCH AS MUFFLER)……………..300
INSTALLATION TO ENGINE STAND……………………………………………………….300
DRAINING OIL……………………………………………………………………..301
REMOVAL OF REAR LIFTING BRACKET…………………………………………………….301
REMOVAL OF BELT…………………………………………………………………..301
REMOVAL OF FAN PULLEY……………………………………………………………..302
REMOVAL OF VIBRATION DAMPER, CRANKSHAFT PULLEY……………………………………….302
REMOVAL OF BELT TENSIONER………………………………………………………….302
REMOVAL OF FAN HUB………………………………………………………………..303
REMOVAL OF ALTERNATOR……………………………………………………………..303
REMOVAL OF THERMOSTAT……………………………………………………………..304
REMOVAL OF TURBOCHARGER(ENGINE WITH TURBOCHARGER)…………………………………….304
REMOVAL OF EXHAUST MANIFOLD………………………………………………………..306
REMOVAL OF FUEL FILTER…………………………………………………………….306
REMOVAL OF FUEL FILTER HEAD ……………………………………………………….307
REMOVAL OF FUEL PIPING…………………………………………………………….307
REMOVAL OF DIPSTICK……………………………………………………………….309
REMOVAL OF INTAKE MANIFOLD COVER……………………………………………………309
REMOVAL OF AFTERCOOLER(ENGINE WITH AFTERCOOLER)………………………………………310
REMOVAL OF CYLINDER HEAD COVER……………………………………………………..310
REMOVAL OF FUEL INJECTION NOZZLE……………………………………………………310
REMOVAL OF ROCKER LEVER……………………………………………………………311
REMOVAL OF PUSH ROD……………………………………………………………….312
REMOVAL OF CYLINDER HEAD…………………………………………………………..312
REMOVAL OF FRONT COVER…………………………………………………………….312
REMOVAL OF WATER PUMP……………………………………………………………..313
REMOVAL OF FLYWHEEL……………………………………………………………….313
REMOVAL OF FLYWHEEL HOUSING………………………………………………………..314
REMOVAL OF COMPONENTS(COMPRESSOR, HYDRAULIC PUMP, ETC.)……………………………….314
REMOVAL OF FUEL INJECTION PUMP(BOSCH A, ZEXEL A)……………………………………..314
REMOVAL OF FEED PUMP(ENGINE MOUNT TYPE)……………………………………………..317
REMOVAL OF TAPPET COVER……………………………………………………………317
REMOVAL OF OIL FILLER……………………………………………………………..317
REMOVAL OF OIL COOLER……………………………………………………………..317
REMOVAL OF WATER INLET…………………………………………………………….318
REMOVAL OF OIL PAN………………………………………………………………..318
REMOVAL OF OIL PAN SUCTION TUBE…………………………………………………….318
REMOVAL OF REAR SEAL COVER…………………………………………………………319
REMOVAL OF CAMSHAFT……………………………………………………………….319
REMOVAL OF TAPPET…………………………………………………………………321
REMOVAL OF OIL PUMP……………………………………………………………….321
REMOVAL OF TIMING PIN HOUSING………………………………………………………322
REMOVAL OF GEAR HOUSING……………………………………………………………322
REMOVAL OF BALANCER(WHEN BALANCER IS INSTALLED)………………………………………323
REMOVAL OF PISTON CONNECTING ROD……………………………………………………325
REMOVAL OF CRANKSHAFT……………………………………………………………..327
REMOVAL OF TURBOCHARGER LUBRICATION DRAIN TUBE……………………………………….329
REMOVAL OF CYLINDER BLOCK FROM ENGINE STAND………………………………………….329
ASSEMBLY OF ENGINE……………………………………………………………………330
PREPARATION FOR ASSEMBLY OF CYLINDER BLOCK…………………………………………..330
INSTALLATION OF TAPPET…………………………………………………………….330
INSTALLATION OF CRANKSHAFT…………………………………………………………331
INSTALLATION OF PISTION AND CONNECTING ROD ASSEMBLIES…………………………………335
INSTALLATION OF PISTION AND CONNECTING ROD ASSEMBLY…………………………………..335
INSTALLATION OF GEAR HOUSING……………………………………………………….339
INSTALLATION OF OIL PUMP…………………………………………………………..340
INSTALLATION OF CAMSHAFT…………………………………………………………..341
INSTALLATION OF TIMING PIN…………………………………………………………344
INSTALLATION OF BALANCER…………………………………………………………..347
INSTALLATION OF REAR OIL SEAL………………………………………………………351
INSTALLATION OF OIL PAN SUCTION TUBE………………………………………………..352
INSTALLATION OF OIL PAN……………………………………………………………353
INSTALLATION OF OIL COOLER…………………………………………………………354
INSTALLATION OF OIL FILLER PORT…………………………………………………….354
INSTALLATION OF FEED PUMP………………………………………………………….355
INSTALLATION OF TAPPET COVER……………………………………………………….355
INSTALLATION OF FUEL INJECTION PUMP (BOSCH A, ZEXEL A)………………………………..357
INSTALLATION OF COMPONENTS(COMPRESSOR, HYDRAULIC PUMP, ETC.)…………………………..362
INSTALLATION OF FLYWHEEL HOUSING……………………………………………………362
INSTALLATION OF FLYWHEEL…………………………………………………………..363
INSTALLATION OF WATER PUMP…………………………………………………………364
INSTALLATION OF FRONT COVER………………………………………………………..364
INSTALLATION OF CYLINDER HEAD………………………………………………………366
INSTALLATION OF PUSH ROD…………………………………………………………..367
INSTALLATION OF ROCKER LEVER……………………………………………………….367
TIGHTENING OF CYLINDER HEAD………………………………………………………..369
ADJUSTING VALVE CLEARANCE………………………………………………………….371
INSTALLATION OF FUEL INJECTION NOZZLE……………………………………………….373
INSTALLATION OF CYLINDER HEAD COVER…………………………………………………374
INSTALLATION OF INTAKE MAINIFOLD COVER………………………………………………374
INSTALLATION OF FUEL FILTER HEAD……………………………………………………376
INSTALLATION OF EXHAUST MANIFOLD……………………………………………………377
INSTALLATION OF TURBOCHARGER(ENGINE WITH TURBOCHARGER)………………………………..378
INSTALLATION OF THERMOSTAT…………………………………………………………381
INSTALLATION OF CRANKSHAFT PULLEY, VIBRATION DAMPER…………………………………..382
INSTALLATION OF FAN HUB……………………………………………………………382
INSTALLATION OF BELT TENSIONER……………………………………………………..382
INSTALLATION OF WATER INLET………………………………………………………..383
INSTALLATION OF ALTERNATOR…………………………………………………………383
INSTALLATION OF BELT………………………………………………………………384
INSTALLATION OF OIL FILTER…………………………………………………………385
REMOVAL OF ENGINE FROM ENGINE STAND…………………………………………………385
INSTALLATION OF STARTING MOTOR……………………………………………………..385
INTAKE GROUP…………………………………………………………………………386
DISASSEMBLY AND ASSEMBLY DRAWING……………………………………………………386
OUTLINE………………………………………………………………………….388
REPLACEMENT OF TURBOCHARGER(ENGINE WITH TURBOCHARGER)…………………………………….389
REMOVAL………………………………………………………………………….389
INSTALLATION……………………………………………………………………..390
CLEANING AND INSPECTION……………………………………………………………392
REPLACEMENT OF AFTERCOOLER, GASKET(ENGINE WITH AFTERCOOLER)……………………………….394
REMOVAL………………………………………………………………………….394
CLEANING ……………………………………………………………………….394
INSTALLATION……………………………………………………………………..395
CLEANING AND INSPECTION……………………………………………………………396
ASSEMBLY ……………………………………………………………………….396
REPLACEMENT OF INTAKE CONNECTOR………………………………………………………..397
REMOVAL AND INSTALLATION…………………………………………………………..397
AIR CONNECTOR………………………………………………………………………..397
CLEANING ……………………………………………………………………….397
INSPECTION ……………………………………………………………………..397
REPLACEMENT OF INTAKE MANIFOLD COVER, GASKET…………………………………………….397
REMOVAL………………………………………………………………………….398
CLEANING ……………………………………………………………………….398
INSTALLATION……………………………………………………………………..398
AIR CROSSOVER TUBE……………………………………………………………………399
CLEANING ……………………………………………………………………….399
INSPECTION ………………………………………………………………………399
EXHAUST GROUP………………………………………………………………………..400
DISASSEMBLY AND ASSEMBLY DRAWING……………………………………………………400
OUTLINE OF EXHAUST MANIFOLD………………………………………………………..401
REPLACEMENT OF EXHAUST MANIFOLD, GASKET ………………………………………………..402
REPLACEMENT OF EXHAUST MANIFOLD, GASKET …………………………………………….402
REMOVAL………………………………………………………………………402
CLEANING AND INSPECTION………………………………………………………..402
INSTALLATION………………………………………………………………….402
REPLACEMENT OF EXHAUST MANIFOLD…………………………………………………….403
REMOVAL………………………………………………………………………403
CLEANING ……………………………………………………………………403
INSTALLATION………………………………………………………………….404
INSPECTION……………………………………………………………………404
REPLACEMENT OF TURBOCHARGER……………………………………………………………405
REMOVAL………………………………………………………………………….405
INSTALLATION……………………………………………………………………..406
TURBOCHARGER MOUNTING STUD(ENGINE WITH TURBOCHARGER)……………………………………..409
REPLACEMENT………………………………………………………………………409
CYLINDER BLOCK GROUP………………………………………………………………….410
DISASSEMBLY AND ASSEMBLY DRAWING……………………………………………………410
OUTLINE OF CYLINDER BLOCK GROUP…………………………………………………….413
OUTLINE OF CAMSHAFT……………………………………………………………413
OUTLINE OF CRANKSHAFT………………………………………………………….413
OUTLINE OF CYLINDER BLOCK………………………………………………………413
OUTLINE OF OIL SEAL……………………………………………………………413
REPLACEMENT OF FRONT OIL SEAL………………………………………………………414
REMOVAL………………………………………………………………………414
CLEANING AND INSPECTION………………………………………………………..415
INSTALLATION………………………………………………………………….415
REPLACEMENT OF REAR OIL SEAL……………………………………………………417
OUTLINE OF PISTION…………………………………………………………….419
OUTLINE OF VIBRATION DAMPER…………………………………………………….419
CHECK LIST FOR CYLINDER BLOCK GROUP……………………………………………..420
CYLINDER BLOCK……………………………………………………………………….421
CYLINDER BLOCK……………………………………………………………………421
INSPECTION BEFORE DISASSEMBLY…………………………………………………..421
DISASSEMBLY OF CYLINDER BLOCK…………………………………………………..421
CLEANING OF CYLINDER BLOCK……………………………………………………..423
INSPECTION OF CYLINDER BLOCK……………………………………………………….426
REMOVAL OF GLAZE FROM CYLINDER BORE…………………………………………………428
DISASSEMBLY…………………………………………………………………..428
INSPECTION……………………………………………………………………429
REMOVAL OF GLAZE………………………………………………………………429
CLEANING ……………………………………………………………………432
ASSEMBLY …………………………………………………………………….433
REMOVAL OF GLAZE FROM CYLINDER BLOCK…………………………………………….434
REPLACEMENT OF PLUG……………………………………………………………….437
REMOVAL………………………………………………………………………437
CLEANING AND INSPECTION………………………………………………………..437
INSTALLATION………………………………………………………………….438
REPLACEMENT OF CAP………………………………………………………………..438
REMOVAL …………………………………………………………………….438
CLEANING ……………………………………………………………………439
INSTALLATION ………………………………………………………………..439
INSTALLATION OF CUP PLUG……………………………………………………….440
INSTALLATION OF CAP AND PLUG……………………………………………………….442
INSTALLATION OF CAMSHAFT CUP……………………………………………………444
INSTALLATION OF CAMSHAFT BUSHING………………………………………………..445
REPLACEMENT OF DIPSTICK TUBE……………………………………………………446
STORING CYLINDER BLOCK…………………………………………………………447
CRANKSHAFT…………………………………………………………………………..447
REPLACEMENT OF MAIN BEARING………………………………………………………..448
CLEANING OF CRANKSHAFT…………………………………………………………….455
INSTALLATION OF CRANKSHAFT…………………………………………………………455
REPLACEMENT OF CRANKSHAFT GEAR……………………………………………………..456
REPLACEMENT OF CAMSHAFT AND TAPPET………………………………………………….458
REMOVAL OF CAMSHAFT……………………………………………………………458
REMOVAL OF TAPPET……………………………………………………………..459
INSPECTION OF TAPPET…………………………………………………………..461
STANDARDS FOR PITTING WHEN REUSING………………………………………………463
STANDARD FOR DETERIORATION……………………………………………………..464
INSPECTION OF CAMSHAFT BORE…………………………………………………….467
REPLACEMENT OF CAMSHAFT BUSHING…………………………………………………….467
INSTALLATION OF TAPPET…………………………………………………………468
INSTALLATION OF CAMSHAFT……………………………………………………….471
CLEANING OF CAMSHAFT………………………………………………………………473
INSPECTION OF CAMSHAFT, GEAR……………………………………………………474
REPLACEMENT OF CAMSHAFT,GEAR……………………………………………………….476
REMOVAL………………………………………………………………………476
CLEANING AND INSPECTION………………………………………………………..477
INSTALLATION………………………………………………………………….478
REPLACEMENT OF TIMEING PIN…………………………………………………………….480
REPLACEMENT OF GEAR HOUSING, GASKET…………………………………………………….481
REMOVAL………………………………………………………………………….481
CLEANING AND INSPECTION……………………………………………………………482
INSTALLATION……………………………………………………………………..483
REPOSITIONING OF TIMING PIN………………………………………………………..486
REPLACEMENT OF CAMSHAFT GEAR……………………………………………………….491
REMOVAL………………………………………………………………………491
INSTALLATION (SHRINK-FITTING METHOD)…………………………………………….492
INSTALLATION (METHOD USING SPECIAL TOOL)…………………………………………493
INSTALLATION OF CAMSHAFT MOUNTING BOLTS………………………………………….495
REPLACEMENT OF VIBRATION DAMPER, CRANKSHAFT PULLEY……………………………………….496
REMOVAL ………………………………………………………………………..496
INSPECTION OF RUBBER DAMPER………………………………………………………..496
INSTALLATION …………………………………………………………………….497
INSPECTION OF VISCOUS DAMPER……………………………………………………….497
VIBRATION DAMPER (RUBBER TYPE)……………………………………………………..499
CLEANING AND INSPECTION………………………………………………………..499
CLEANING AND INSPECTION OF VIBRATION DAMPER………………………………………499
PISTON, PIN, CONNECTING ROD……………………………………………………………501
REPLACEMENT OF PISTON AND RING……………………………………………………..501
REMOVAL OF PISTON CONNECTING ROD……………………………………………………502
DISASSEMBLY OF PISTON CONNECTING ROD………………………………………………..504
CLEANING OF PISTON, PIN, CONNECTING ROD……………………………………………..504
INSPECTION OF PISTON………………………………………………………………505
INSPECTION OF PISTON PIN…………………………………………………………..506
ASSEMBLY OF PISTON CONNECTING ROD…………………………………………………..507
INSPECTION OF PISTON RING GAP………………………………………………………508
INSTALLATION OF PISTON RING………………………………………………………..509
INSTALLATION OF PISTON CONNECTING ROD……………………………………………….510
REPLACEMENT OF CONNECTING ROD………………………………………………………514
REMOVAL………………………………………………………………………514
CLEANING AND INSPECTION………………………………………………………..515
INSTALLATION………………………………………………………………….517
REPLACEMENT OF CONNECTING ROD BEARING……………………………………………….518
REMOVAL………………………………………………………………………518
CLEANING AND INSPECTION………………………………………………………..520
INSTALLATION………………………………………………………………….521
DISASSEMBLY OF PISTON CONNECTING ROD…………………………………………….524
CLEANING OF PISTON,PIN,CONNECTING ROD……………………………………………525
INSPECTION OF PISTON…………………………………………………………..526
INSPECTION OF PISTON PIN……………………………………………………….527
INSPECTION OF CONNECTING ROD……………………………………………………527
INSPECTION OF CONNECTING ROD BEARING CLEARANCE……………………………………527
ASSEMBLY OF PISTON CONNECTING ROD……………………………………………….528
INSPECTION OF PISTON RING END GAP……………………………………………….529
INSTALLATION OF PISTON RING…………………………………………………….530
BALANCER …………………………………………………………………………..531
DISASSEMBLY………………………………………………………………………531
ASSEMBLY ……………………………………………………………………….534
GEAR COVER ………………………………………………………………………….541
REPLACEMENT OF GEAR COVER …………………………………………………………541
REMOVAL………………………………………………………………………541
CLEANING AND INSPECTION………………………………………………………..542
INSTALLATION………………………………………………………………….542
INSTALLATION OF GEAR COVER……………………………………………………..544
INSPECTION OF GEAR HOUSING AND TIMING PIN………………………………………..546
DISASSEMBLY OF GEAR HOUSING…………………………………………………….546
REPLACEMENT OF FUEL INJECTION PUMP MOUNTING STUD………………………………….547
REPLACEMENT OF ENGINE NAME PLATE………………………………………………..547
CYLINDER HEAD ……………………………………………………………………….550
DISASSEMBLY AND ASSEMBLY DRAWING……………………………………………………550
OUTLINE………………………………………………………………………….552
REPLACEMENT OF CYLINDER HEAD……………………………………………………….553
REMOVAL………………………………………………………………………553
INSPECTION BEFORE DISASSEMBLY OF CYLINDER HEAD……………………………………556
DISASSEMBLY OF CYLINDER HEAD……………………………………………………557
CLEANING OF CYLINDER HEAD………………………………………………………558
INSPECTION OF VALVE……………………………………………………………560
INSPECTION OF VALVE GUIDE………………………………………………………561
INSPECTION OF CYLINDER DECK…………………………………………………….561
INSPECTION OF VALVE SEAT……………………………………………………….562
STANDARDS FOR CRACKS IN CYLINDER HEAD WHEN REUSING………………………………..562
REPLACEMENT OF VALVE SPRING…………………………………………………….563
ASSEMBLY OF CYLINDER HEAD………………………………………………………563
INSTALLATION OF CYLINDER HEAD…………………………………………………..564
INSTALLATION OF PUSH ROD……………………………………………………….565
INSTALLATION OF ROCKER LEVER……………………………………………………565
ADJUSTING VALVE CLEARANCE………………………………………………………568
INSTALLATION OF THERMOSTAT……………………………………………………..569
INSTALLATION OF FAN HUB………………………………………………………..569
INSTALLATION OF BELT TENSIONER………………………………………………….570
INSTALLATION OF ALTERNATOR……………………………………………………..570
INSTALLATION OF DRIVE BELT……………………………………………………..571
INSPECTION BEFORE DISASSEMBLY…………………………………………………..571
DISASSEMBLY OF CYLINDER HEAD……………………………………………………572
CLEANING OF CYLINDER HEAD………………………………………………………573
INSPECTION OF VALVE……………………………………………………………575
INSPECTION OF VALVE GUIDE………………………………………………………576
INSPECTION OF CYLINDER HEAD COMBUSTION DECK………………………………………576
INSPECTION OF VALVE SEAT……………………………………………………….577
STANDARDS FOR CRACKS IN CYLINDER HEAD WHEN REUSING………………………………..577
REPLACEMENT OF VALVE SPRING…………………………………………………….578
REPLACEMENT OF CAP…………………………………………………………….578
POLISHING VALVE……………………………………………………………….580
POLISHING VALVE SEAT ………………………………………………………….581
CALCULATING GRINDING DEPTH AND MEASURING DEPTH OF VALVE……………………………582
ASSEMBLY OF CYLINDER HEAD………………………………………………………586
ROCKER LEVER…………………………………………………………………………588
DISASSEMBLY AND ASSEMBLY DRAWING……………………………………………………588
OUTLINE………………………………………………………………………….590
REPLACEMENT OF ROCKER LEVER AND PUSH ROD…………………………………………….591
REMOVAL………………………………………………………………………….591
DISASSEMBLY OF ROCKER LEVER………………………………………………………..592
CLEANING OF ROCKER LEVER…………………………………………………………..593
INSPECTION OF ROCKER LEVER…………………………………………………………593
ASSEMBLY OF ROCKER LEVER…………………………………………………………..594
INSTALLATION OF ROCKER LEVER……………………………………………………….595
DISASSEMBLY OF ROCKER LEVER………………………………………………………..597
CLEANING OF ROCKER LEVER, ROCKER LEVER SHAFT…………………………………………598
INSPECTION OF ROCKER LEVER…………………………………………………………598
INSPECTION OF ROCKER LEVER SHAFT……………………………………………………599
ASSEMBLY OF ROCKER LEVER…………………………………………………………..599
TAPPETS AND PUSH RODS…………………………………………………………………601
DISASSEMBLY AND ASSEMBLY DRAWING……………………………………………………601
OUTLINE………………………………………………………………………….602
CLEANING OF PUSH ROD………………………………………………………………603
INSPECTION OF PUSH ROD…………………………………………………………603
INSTALLATION OF PUSH ROD……………………………………………………….603
INSPECTION OF TAPPET…………………………………………………………..604
INSPECTION OF PUSH ROD…………………………………………………………605
ENGINE MOUNT GROUP……………………………………………………………………606
OUTLINE OF FLYWHEEL HOUSING………………………………………………………..606
OUTLINE OF FLYWHEEL, RING GEAR……………………………………………………..606
OUTLINE OF FRONT SUPPORT…………………………………………………………..606
FLYWHEEL, RING GEAR…………………………………………………………………..607
INSPECTION OF FLYWHEEL, RING GEAR…………………………………………………..607
REPLACEMENT OF FLYWHEEL, RING GEAR………………………………………………….607
REPLACEMENT OF RING GEAR……………………………………………………….607
INSTALLTION OF FLYWHEEL………………………………………………………..608
REPLACEMENT OF RING GEAR……………………………………………………….608
FLYWHEEL HOUSING……………………………………………………………………..609
REPLACEMENT OF REAR OIL SEAL ………………………………………………………609
REMOVAL………………………………………………………………………609
CLEANING AND INSPECTION………………………………………………………..611
INSTALLATION………………………………………………………………….611
REPLACEMENT OF FLYWHEEL HOUSING…………………………………………………….614
REMOVAL………………………………………………………………………614
CLEANING AND INSPECTION………………………………………………………..615
INSTALLATION(DRY CLUTCH SPECIFICATION)…………………………………………..616
INSPECTION OF RADIAL RUNOUT OF FLYWHEEL HOUSING…………………………………..617
INSPECTION OF FACE RUNOUT OF FLYWHEEL HOUSING…………………………………….619
INSTALLATION (WET CLUTCH SPECIFICATION)………………………………………….620
INSPECTION……………………………………………………………………622
INSTALLATION………………………………………………………………….623
FRONT SUPPORT………………………………………………………………………..624
CLEANING AND INSPECTION……………………………………………………………624
REMOVAL OF ENGINE…………………………………………………………………….625
INSPECTION OF ENGINE MOUNT…………………………………………………………….627
INSTALLATION OF ENGINE………………………………………………………………..628
CONNECTION OF FUEL CONTROL LEVER……………………………………………………629
OIL PAN AND SUCTION TUBE………………………………………………………………632
DISASSEMBLY AND ASSEMBLY DRAWING……………………………………………………632
REPLACEMENT OF OIL PAN, SUCTION TUBE, GASKET…………………………………………633
CLEANING AND INSPECTION……………………………………………………………635
REGULATOR VALVE………………………………………………………………………636
REPLACEMENT OF REGULATOR VALVE, SPRING………………………………………………636
DISASSEMBLY…………………………………………………………………..636
CLEANING AND INSPECTION……………………………………………………………636
ASSEMBLY ……………………………………………………………………637
DISASSEMBLY ………………………………………………………………….637
INSPECTION……………………………………………………………………638
ASSEMBLY …………………………………………………………………….638
OIL FILTER BYPASS VALVE……………………………………………………………….639
REPLACEMENT………………………………………………………………………639
OIL COOLER…………………………………………………………………………..640
DISASSEMBLY AND ASSEMBLY DRAWING……………………………………………………640
REPLACEMENT OF OIL COOLER CORE, GASKET………………………………………………641
CLEANING ……………………………………………………………………….643
INSPECTION ……………………………………………………………………..644
OIL PUMP …………………………………………………………………………..645
DISASSEMBLY AND ASSEMBLY DRAWING……………………………………………………645
REPLACEMENT OF OIL PUMP……………………………………………………………646
REMOVAL OF OIL PUMP……………………………………………………………646
CLEANING AND INSPECTION………………………………………………………..647
INSTALLATION OF OIL PUMP…………………………………………………………..650
INSPECTION……………………………………………………………………….651
FUEL INJECTION PUMP GROUP……………………………………………………………..655
DISASSEMBLY AND ASSEMBLY DRAWING……………………………………………………655
FUEL INJECTION NOZZLE GROUP……………………………………………………………656
FUEL INJECTION NOZZLE……………………………………………………………..657
DISASSEMBLY…………………………………………………………………..657
CLEANING AND INSPECTION……………………………………………………………658
ASSEMBLY …………………………………………………………………….660
TEST…………………………………………………………………………662
FEED PUMP(CYLINDER BLOCK MOUNT TYPE)……………………………………………………663
REPLACEMENT OF FEED PUMP(DIAPHRAGM TYPE)…………………………………………….663
REPLACEMENT, ASSEMBLY OF FEED PUMP(PISTON TYPE)………………………………………665
REMOVAL………………………………………………………………………665
CLEANING ……………………………………………………………………666
ASSEMBLY …………………………………………………………………….666
INSTALLATION………………………………………………………………….667
CLEANING AND INSPECTION………………………………………………………..667
ASSEMBLY(PISTON TYPE)………………………………………………………….669
CLEANING ……………………………………………………………………669
ASSEMBLY ……………………………………………………………………670
REPLACEMENT OF FUEL FILTER …………………………………………………………..670
FUEL PIPING………………………………………………………………………….672
REPLACEMENT OF HIGH-PRESSURE FUEL PIPING(BOSCH VE, LUCAS CAV) …………………………672
REPLACEMENT OF FUEL SUPPLY PIPING(BOSCH VE, LUCAS CAV) ……………………………….673
CLEANING AND INSPECTION OF HIGH-PRESSURE FUEL PIPING………………………………….675
REPLACEMENT OF FUEL RETURN PIPING(BOSCH VE, LUCAS CAV) ……………………………676
CLEANING AND INSPECTION OF FUEL DRAIN PIPING……………………………………..678
REPLACEMENT OF LOW-PRESSURE FUEL PIPING (BOSCH VE, LUCAS CAV)………………………….678
CLEANING AND INSPECTION OF LOW-PRESSURE FUEL PIPING…………………………………..679
REPLACEMENT OF AIR-FUEL RATIO CONTROL TUBE(BOSCH VE) …………………………………680
WATER PUMP…………………………………………………………………………..681
DISASSEMBLY AND ASSEMBLY DRAWING……………………………………………………681
REPLACEMENT OF WATER PUMP………………………………………………………….682
INSPECTION……………………………………………………………………….683
FAN HUB……………………………………………………………………………..683
REPLACEMENT OF FAN PULLEY………………………………………………………….683
REPLACEMENT OF FAN HUB…………………………………………………………….684
INSPECTION……………………………………………………………………….684
DISASSEMBLY………………………………………………………………………685
ASSEMBLY ……………………………………………………………………….686
BELT TENSIONER……………………………………………………………………….688
DISASSEMBLY AND ASSEMBLY DRAWING……………………………………………………688
REPLACEMENT OF BELT……………………………………………………………….689
REPLACEMENT OF BELT TENSIONER………………………………………………………689
INSPECTION……………………………………………………………………….689
THERMOSTAT…………………………………………………………………………..690
DISASSEMBLY AND ASSEMBLY DRAWING……………………………………………………690
REPLACEMENT OF THERMOSTAT………………………………………………………….691
INSPECTION……………………………………………………………………….692
FAN…………………………………………………………………………………694
COOLANT……………………………………………………………………………..694
FILLING WITH WATER………………………………………………………………..695
ACCESSORY DRIVE ADAPTER……………………………………………………………….696
DISASSEMBLY AND ASSEMBLY DRAWING……………………………………………………696
CLEANING ……………………………………………………………………….697
INSPECTION ………………………………………………………………………697
DISASSEMBLY ……………………………………………………………………..697
ASSEMBLY ………………………………………………………………………..698
DISASSEMBLY OF UNLOADER VALVE, CYLINDER HEAD…………………………………………700
CLEANING …………………………………………………………………….701
INSPECTION …………………………………………………………………..702
ASSEMBLY ……………………………………………………………………706
REPLACEMENT OF AIR COMPRESSOR………………………………………………………709
REMOVAL………………………………………………………………………709
POWER STEERING COUPLING(WHEN USED) ……………………………………………..711
INSTALLATION………………………………………………………………….712
CLEANING AND INSPECTION……………………………………………………………714
INSPECTION……………………………………………………………………714
ALTERNATOR…………………………………………………………………………..715
REPLACEMENT OF ALTERNATOR………………………………………………………….715
INSPECTION……………………………………………………………………….716
STARTING MOTOR……………………………………………………………………….716
REPLACEMENT OF STARTING MOTOR………………………………………………………716
INSPECTION……………………………………………………………………….717
REPLACE HYDRAULIC SWITCH……………………………………………………….717
REPLACEMENT OF WATER TEMPERATURE SENSOR………………………………………….717
14 MAINTENANCE STANDARD…………………………………………………………………..719
TURBOCHARGER…………………………………………………………………………720
EXHAUST MANIFOLD……………………………………………………………………..722
CYLINDER HEAD………………………………………………………………………..724
VALVE, VALVE GUIDE……………………………………………………………………726
LOCKER ARM SHAFT, PUSH ROD AND TAPPET…………………………………………………..728
CYLINDER BLOCK……………………………………………………………………….730
CYLINDER ………………………………………………………………………….734
CRANKSHAFT …………………………………………………………………………736
CAMSHAFT …………………………………………………………………………..738
TIMING GEAR………………………………………………………………………….742
PISTON, PISTON RING AND PISTON PIN……………………………………………………..744
CONNECTING ROD……………………………………………………………………….746
VIBRATION DAMPER……………………………………………………………………..748
FLYWHEEL, FLYWHEEL HOUSING…………………………………………………………….750
FAN HUB……………………………………………………………………………..752
OIL PUMP …………………………………………………………………………..753
WATER PUMP, THERMOSTAT………………………………………………………………..754
FUEL INJECTION PUMP ………………………………………………………………….755
FUEL INJECTION NOZZLE…………………………………………………………………756
15 REPAIR AND REPLACEMENT OF PARTS…………………………………………………………759
OUTLINE……………………………………………………………………………..760
REPAIR GUIDELINE………………………………………………………………….760
WHEN SHOULD SUBSTITUTE REPAIRS BE CARRIED OUT………………………………………..760
INSPECTION……………………………………………………………………….760
TO ENSURE SAFETY, FOLLOW ALL INSTRUCTIONS IN MANUAL…………………………………..760
FOLLOW WASHING METHODS GIVEN IN MANUAL………………………………………………760
FOLLOW INSPECTION METHODS GIVEN IN MANUAL……………………………………………760
REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT……………………………………….761
METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS……………..762
METHOD FOR REPAIRING TRPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS………….765
METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS………………………………………..766
PROCEDURE AND TOOLS FOR REPAIRING CYLINDER BLOCK…………………………………………767
INSPECTION AND GRINDING TO REPAIR COMBUSTION DECK………………………………………..767
INSPECTION AND INSTALLATION OF VALVE GUIDE………………………………………………768
PROCEDURE 1 FOR BUILDING UP USING SERVICE VALVE GUIDE…………………………………….769
PROCEDURE 2 FOR BUILDING UP USING SERVICE VALVE GUIDE…………………………………….770
OUTLINE OF VALVE SEAT REPAIR…………………………………………………………..770
CALCULATING GRINDING DEPTH OF VALVE SEAT………………………………………………..771
METHOD OF GRINDING VALVE SEAT………………………………………………………….771
METHOD OF INSTALLING VALVE SEAT………………………………………………………..775
MACHINING EXHAUST VALVE INSERT POCKET…………………………………………………..775
REPLACING VALVE SEAT………………………………………………………………778
METHOD OF GRINDING VALVE………………………………………………………………779
CHECKING TENSION OF VALVE SPRING……………………………………………………780
ASSEMBLY OF CYLINDER HEAD……………………………………………………………..781
PROCEDURE FOR REPAIRING CYLINDER BLOCK………………………………………………….782
COMBUSTION DECK…………………………………………………………………..782
CAM BORE ……………………………………………………………………….783
OUTLINE OF REPAIR OF CYLINDER BORE ………………………………………………..784
CYLINDER BORE …………………………………………………………………..784
INSTALLATION OF REPAIR SLEEVE………………………………………………………786
PROCEDURE FOR REPAIRING CRANKSHAFT……………………………………………………..790
REPAIR TOOLS……………………………………………………………………..790
OUTLINE OF GRINDING GRANKSHAFT……………………………………………………..790
REGRINDING SPECIFICATIONS FOR CRANKSHAFT JOURNAL……………………………………..791
REGRINDING CRANKSHAFT JOURNAL RADIUS………………………………………………..792
SPECIFICATION FOR REGRINDING CRANKSHAFT ROD JOURNAL…………………………………..793
REGRINDING CRANKSHAFT ROD JOURNAL RADIUS…………………………………………….793
OPTIONAL PROCEDURE………………………………………………………………..794
PROCEDURE FOR REPAIRING CONNECTING ROD………………………………………………….795
REMOVAL OF PIN BORE BUSHING………………………………………………………..795
INSTALLATION OF PIN BORE BUSHING……………………………………………………797
MACHINING OF CONNECTING ROD BUSHING…………………………………………………799
INSPECTION OF CURVATURE AND TWISTING OF CONNECTING ROD………………………………..800
TESTING ALIGNMENT OF CONNECTING ROD…………………………………………………801
INSPECTION OF TWISTING OF CONNECTING ROD…………………………………………….801
REPLACING VALVE SEAT INSERT………………………………………………………..802
PACKING STYLE OF CYLINDER HEAD AND HOW TO INSTALL PLUGS…………………………………..805
UNDER COVER…………………………………………………………………………………806