Komatsu 114 Series Diesel Engine Shop Manual SEBM024609 – PDF DOWNLOAD

Komatsu 114 Series Diesel Engine Shop Manual SEBM024609 – PDF DOWNLOAD

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Komatsu 114 Series Diesel Engine Shop Manual SEBM024609 – PDF DOWNLOAD

Language : English
Pages : 444
Downloadable : Yes
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Komatsu 114 Series Diesel Engine Shop Manual SEBM024609 – PDF DOWNLOAD

The Komatsu 114 Series Diesel Engine Shop Manual SEBM024609 is a comprehensive technical guide that provides information and instructions for the maintenance, repair, and overhaul of several Komatsu diesel engines. These engines are commonly used in a wide range of Komatsu equipment, including bulldozers, excavators, and wheel loaders.

• The manual is organized into several sections, each of which covers different aspects of engine maintenance and repair. These sections include general specifications, testing and adjusting procedures, disassembly and assembly instructions, and troubleshooting guidelines.
• The general specifications section provides an overview of the engine’s technical specifications, including its dimensions, weight, power output, and torque ratings. It also includes information on the engine’s various components, such as the cylinder block, cylinder head, crankshaft, and pistons.
• The testing and adjusting procedures section of the manual provides step-by-step instructions for performing various tests and adjustments on the engine. These procedures include compression tests, fuel injection timing adjustment, and valve clearance adjustment. The manual also provides information on the tools and equipment required for performing these procedures.
• The disassembly and assembly instructions section of the manual provides detailed guidance on how to disassemble and reassemble the engine, including the removal and installation of various components such as the cylinder head, pistons, and crankshaft. This section also includes detailed diagrams and illustrations that provide a clear understanding of the engine’s internal components and how they fit together.
• The troubleshooting guidelines section of the manual provides information on how to diagnose and repair common problems that may occur with the engine. This section provides a list of potential symptoms and causes, along with step-by-step instructions for identifying and fixing the problem.
• The manual also covers maintenance and safety guidelines, including routine inspections, cleaning, lubrication, and safety precautions that must be followed while working with the engine.
• Overall, the Komatsu 114 Series Diesel Engine Shop Manual SEBM024609 is an essential resource for technicians and mechanics working with the Komatsu 114 series engines. Its comprehensive coverage of maintenance, repair, and troubleshooting procedures makes it an indispensable tool for ensuring the reliable and efficient operation of Komatsu construction equipment.

TABLE OF CONTENTS:

Komatsu 114 Series Diesel Engine Shop Manual SEBM024609 – PDF DOWNLOAD

COVER ……………………………………………………………………………. 1
CONTENTS………………………………………………………………………….. 2
LIST OF REVISED PAGES………………………………………………………………. 3
SAFETY……………………………………………………………………………. 5
SAFETY NOTICE………………………………………………………………….. 5
FOREWORD………………………………………………………………………….. 7
GENERAL……………………………………………………………………….. 7
HOW TO READ THE SHOP MANUAL……………………………………………………… 8
HOISTING INSTRUCTIONS…………………………………………………………… 9
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER………………………….. 10
COATING MATERIALS………………………………………………………………. 12
STANDARD TIGHTENING TORQUE………………………………………………………. 14
ELECTRIC WIRE CODE……………………………………………………………… 17
CONVERSION TABLE……………………………………………………………….. 18
UNITS…………………………………………………………………………. 24
CAPSCREW MARKINGS AND TORQUE VALUES………………………………………………. 25
CAPSCREW MARKINGS AND TORQUE VALUES – METRIC………………………………………. 26
CAPSCREW MARKINGS AND TORQUE VALUES – U.S. CUSTOMARY……………………………….. 27
PIPE PLUG TORQUE VALUES…………………………………………………………. 28
SYMBOLS……………………………………………………………………….. 29
ILLUSTRATIONS………………………………………………………………….. 30
01 GENERAL ……………………………………………………………………….. 31
APPLICABLE MACHINE……………………………………………………………… 32
SPECIFICATION………………………………………………………………….. 34
OVERALL DRAWING………………………………………………………………… 36
WEIGHT TABLE…………………………………………………………………… 41
ENGINE PERFORMANCE CURVE………………………………………………………… 42
11 STRACTURE AND FUNCTION ………………………………………………………….. 49
AIR INTAKE DEVICE………………………………………………………………. 50
EXHAUST MANIFOLD……………………………………………………………….. 53
AIR CLEANER……………………………………………………………………. 54
TURBOCHARGER…………………………………………………………………… 55
AFTERCOOLER……………………………………………………………………. 60
CYLINDER HEAD………………………………………………………………….. 62
CYLINDER BLOCK…………………………………………………………………. 66
CYLINDER LINER…………………………………………………………………. 70
MAIN CIRCULATION PART…………………………………………………………… 72
CRANK SHAFT……………………………………………………………………. 76
PISTON・PISTON RING・PISTON PIN……………………………………………………. 78
CONNECTING ROD…………………………………………………………………. 80
VIBRATION DAMPER……………………………………………………………….. 82
TIMING GEAR PORTION…………………………………………………………….. 84
FRONT GEAR COVER……………………………………………………………….. 85
CAMSHAFT TIMING PIN…………………………………………………………….. 86
TIMING GEAR……………………………………………………………………. 87
CAM SHAFT……………………………………………………………………… 88
VALVE MECHANISM………………………………………………………………… 90
VALVE, VALVE GUIDE……………………………………………………………… 94
ROCKER-ARM SHAFT・PUSH ROD・TAPPET…………………………………………………. 96
OIL PAN……………………………………………………………………….. 98
FLYWHEEL, FLYWHEEL HOUSING……………………………………………………….100
LUBRICATION SYSTEM DIAGRAM……………………………………………………….104
OIL PUMP……………………………………………………………………….105
OIL FILTER, OIL COOLER…………………………………………………………..108
REGULATOR VALVE, SAFETY VALVE…………………………………………………….109
FUEL SYSTEM DIAGRAM……………………………………………………………..110
FUEL INJECTION PUMP……………………………………………………………..112
TIMING LOCK PIN OF FUEL INJECTION PUMP…………………………………………….116
FUEL FILTER…………………………………………………………………….117
FUEL INJECTION NOZZLE……………………………………………………………118
FUEL CUT SOLENOID……………………………………………………………….120
COOLING SYSTEM DIAGRAM…………………………………………………………..121
WATER PUMP DRIVE………………………………………………………………..122
WATER PUMP (WITH ONE-PIECE BEARING, SHAFT, ONE-PIECE WATER SEAL)……………………..124
THERMOSTAT……………………………………………………………………..125
FAN DRIVE………………………………………………………………………128
ALTERNATOR……………………………………………………………………..130
STARTING MOTOR………………………………………………………………….133
STARTING AID……………………………………………………………………135
12 TESTING AND ADJUSTING ……………………………………………………………137
SPECIAL TOOL LIST……………………………………………………………….140
SPECIAL TOOLS FOR INTAKE AND EXHAUST SYSTEM…………………………………….140
SPECIAL TOOLS FOR CYLINDER HEAD SYSTEM…………………………………………141
SPECIAL TOOLS FOR ENGINE……………………………………………………..145
SPECIAL TOOLS FOR FUEL SYSTEM…………………………………………………149
SPECIAL TOOLS FOR ACCESSORY COMPONENT SYSTEM……………………………………150
SPECIAL TOOLS FOR ELECTRICAL COMPONENT…………………………………………151
SPECIAL TOOLS FOR ENGINE PERFORMANCE TEST………………………………………152
TROUBLESHOOTING DEFECTIVE ACTUATION OF INTAKE AND EXHAUST SYSTEM……………………..154
MEASURING PLAY OF TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION……………………159
TESTING TURBOCHARGER WESTGATE VALVE……………………………………………….160
TESTING TURBOCHARGER WESTGATE CAPSULE……………………………………………..161
TESTING ACTUATION OF TURBOCHARGER WESTGATE…………………………………………161
REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE………………………………162
ADJUSTING TURBOCHARGER WESTGATE ACTUATOR…………………………………………..164
MEASURING EXHAUST RESISTANCE……………………………………………………..165
REPLACING TURBOCHARGER…………………………………………………………..165
TROUBLESHOOTING DEFECTIVE ACTUATION OF ENGINE………………………………………166
VALVE MECHANISM AND CYLINDER HEAD……………………………………………..166
TESTING AIR SYSTEM AND FUEL SYSTEM…………………………………………….166
TESTING VALVE CLEARANCE………………………………………………………167
TESTING COMPRESSION………………………………………………………….167
PISTON RING SEALING PERFORMANCE……………………………………………….167
VALVE SEALING PERFORMANCE…………………………………………………….168
HEAD GASKET SEALIN PERFORMANCE………………………………………………..168
VALVE SEAL WEAR……………………………………………………………..169
PROTRUDING PORTION OF FUEL INJECTION NOZZLE…………………………………….170
FRONT GEAR HOUSING AND GEAR TRAIN……………………………………………..171
ROCKER LEVER, VALVE STEM, PUSH ROD, TAPPET, AND CAMSHAFT…………………………172
PISTON AND CONNECTING ROD…………………………………………………….173
CRANKSHAFT AND MAIN BEARING…………………………………………………..175
CYLINDER BLOCK………………………………………………………………176
FLYWHEEL HOUSING AND FLYWHEEL…………………………………………………177
ADJUSTING VALVE CLEARANCE………………………………………………………..178
ADJUSTING 6-CYLINDER ENGINE…………………………………………………..179
TROUBLESHOOTING DEFECTIVE ACTUATION OF LUBRICATING SYSTEM……………………………181
HIGH PRESSURE……………………………………………………………….181
REGULATOR VALVE……………………………………………………………..181
LOW PRESSURE………………………………………………………………..182
OIL LEVEL…………………………………………………………………..182
OIL FILTER………………………………………………………………….182
OIL PRESSURE GAUGE…………………………………………………………..183
OIL PAN SUCTION TUBE…………………………………………………………183
BEARING AND OIL PUMP…………………………………………………………183
DILUTION OF OIL……………………………………………………………..183
COOLING WATER IN OIL…………………………………………………………184
FUEL IN OIL ………………………………………………………………..185
FUEL INJECTION PUMP CALIBRATION DATA………………………………………………188
RUNNING IN STANDARD……………………………………………………………..193
PERFORMANCE TEST CRITERIA………………………………………………………..196
TESTING FUEL FEED PUMP…………………………………………………………..198
DISASSEMBLY AND ASSEMBLY OF FUEL FEED PUMP……………………………………..199
ADJUSTING FUEL CUT-OFF SOLENOID…………………………………………………..201
DIRECTION OF FUEL CUT-OFF SOLENOID…………………………………………….201
ADJUSTING FUEL CUT-OFF SOLENOID……………………………………………….202
INSTALLATION OF MECHANICALLY OPERATED SOLENOID, CYLINDER BLOCK……………………203
TESTING FOR AIR INSIDE THE FUEL SYSTEM…………………………………………….204
TESTING WATER SEPARATOR, FUEL FILTER………………………………………………206
TESTING HIGH-PRESSURE FUEL PIPING…………………………………………………207
TESTING FUEL INJECTION NOZZLE…………………………………………………….208
TESTING FUEL DRAIN PIPING………………………………………………………..210
BLEEDING AIR FROM FUEL SYSTEM…………………………………………………….210
BLEEDING AIR FROM LOW-PRESSURE CIRCUIT AND FUEL FILTER…………………………..211
BLEEDING AIR FROM FUEL INJECTION PUMP………………………………………….211
BLEEDING AIR FROM HIGH-PRESSURE CIRCUIT………………………………………..212
ADJUSTING TIMING OF FUEL INJECTION PUMP……………………………………………213
TROUBLESHOOTING DEFECTIVE OPERATION OF COOLING SYSTEM……………………………….216
TROUBLESHOOTING……………………………………………………………..216
RADIATOR CAP………………………………………………………………..218
WATER PUMP………………………………………………………………….219
RADIATOR, FAN, AND RADIATOR SHUTTER……………………………………………220
THERMOSTAT………………………………………………………………….221
WATER TEMPERATURE GAUGE, EXCESSIVE FUEL, OVERLOAD……………………………….223
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING……………………..224
TROUBLESHOOTING OF ENGINE (S MODE)………………………………………………..227
METHOD OF USING TROUBLESHOOTING CHARTS…………………………………………228
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…………………….232
S-2 ENGINE DOES NOT START…………………………………………………….233
(1) ENGINE DOES NOT TURN………………………………………………….233
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)……234
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)….235
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…………………………236
S-4 ENGINE STOPS DURING OPERATIONS…………………………………………….237
S-5 ENGING DOES NOT ROTATE SMOOTHLY (HUNTING)…………………………………..238
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)……………………………………….239
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)………………………………240
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)………………………241
S-9 OIL BECOMES CONTAMINATED QUICKLY…………………………………………..242
S-10 FUEL CONSUMPTION IS EXCESSIVE…………………………………………….243
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN……….244
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…………………..245
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)………………………………………246
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)……………………………247
S-15 ABNORMAL NOISE IS MADE…………………………………………………..248
S-16 VIBRATION IS EXCESSIVE…………………………………………………..249
13 DISASSEMBLY AND ASSEMBLY …………………………………………………………251
SPECIAL TOOL LIST……………………………………………………………….254
SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY……………………………………..254
OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE………………………………………258
OUTLINE…………………………………………………………………….258
OVERALL DISASSEMBLY OF ENGINE…………………………………………………….259
ENGINE LIFTING TOOL AND BRACKET……………………………………………….259
PREPARATION FOR STEAM CLEANING OF ENGINE……………………………………….259
STEAM CLEANING OF ENGINE……………………………………………………..259
DRAINING OIL………………………………………………………………..260
DRAINING COOLANT…………………………………………………………….260
REMOVAL OF OIL FILTER………………………………………………………..260
REMOVAL OF FUEL FILTER……………………………………………………….261
REMOVAL OF FUEL SUPPLY PIPE (LOW-PRESSURE SIDE)…………………………………261
REMOVAL OF FUEL FEED PUMP…………………………………………………….261
REMOVAL OF FUEL SUPPLY PIPE (HIGH-PRESSURE SIDE)………………………………..262
REMOVAL OF FUEL INJECTION PUMP FUEL SUPPLY PIPES………………………………..262
REMOVAL OF BOOST COMPENSATOR TUBE……………………………………………..262
REMOVAL OF TACHOMETER DRIVE…………………………………………………..263
REMOVAL OF FUEL INJECTION PUMP………………………………………………..263
REMOVAL OF AIR CONDITIONER COMPRESSOR………………………………………….264
INSTALLATION OF ENGINE TO ENGINE STAND…………………………………………265
REMOVAL OF TURBOCHARGER EXHAUST OUTLET CONNECTOR………………………………..266
REMOVAL OF WESTGATE ACTUATOR HOSE……………………………………………..266
REMOVAL OF CYLINDER BLOCK BREATHER TUBE………………………………………..266
REMOVAL OF CROSSOVER TUBE…………………………………………………….267
REMOVAL OF INTAKE MANIFOLD COVER………………………………………………267
REMOVAL OF AFTERCOOLER……………………………………………………….267
REMOVAL OF FUEL DRAIN MANIFOLD………………………………………………..268
REMOVAL OF INJECTOR………………………………………………………….268
REMOVAL OF CYLINDER HEAD COVER………………………………………………..269
REMOVAL OF ROCKER LEVER………………………………………………………269
REMOVAL OF PUSH ROD………………………………………………………….270
REMOVAL OF TURBOCHARGER OIL SUPPLY HOSE………………………………………..270
REMOVAL OF TURBOCHARGER OIL DRAIN TUBE…………………………………………270
REMOVAL OF TURBOCHARGER………………………………………………………270
REMOVAL OF EXHAUST MANIFOLD…………………………………………………..271
REMOVAL OF DRIVE BELT………………………………………………………..271
REMOVAL OF BELT TENSIONER…………………………………………………….271
REMOVAL OF BELT TENSIONER BRACKET……………………………………………..271
REMOVAL OF ALTERNATOR BRACKET…………………………………………………272
REMOVAL OF ALTERNATOR………………………………………………………..272
REMOVAL OF ALTERNATOR BRACKET…………………………………………………272
REMOVAL OF COOLANT OUTLET CONNECTOR……………………………………………272
REMOVAL OF COOLANT AIR BLEED TUBE……………………………………………..273
REMOVAL OF COOLANT AIR BLEED VALVE…………………………………………….273
REMOVAL OF THERMOSTAT AND HOUSING……………………………………………..273
REMOVAL OF THERMOSTAT AND HOUSING……………………………………………..273
REMOVAL OF CYLINDER HEAD……………………………………………………..274
DRAINING OIL FROM OIL COOLER………………………………………………….274
REMOVAL OF COOLANT INLET CONNECTOR…………………………………………….274
REMOVAL OF FAN HUB ASSEMBLY…………………………………………………..275
REMOVAL OF WATER PUMP………………………………………………………..275
REMOVAL OF VIBRATION DAMPER…………………………………………………..276
REMOVAL OF GEAR COVER………………………………………………………..276
REMOVAL OF FRONT CRANKSHAFT SEAL………………………………………………276
REMOVAL OF STARTING MOTOR…………………………………………………….276
REMOVAL OF COOLANT HEATER…………………………………………………….277
REMOVAL OF FLYWHEEL………………………………………………………….277
REMOVAL OF FLYWHEEL HOUSING…………………………………………………..277
REMOVAL OF OIL PAN…………………………………………………………..277
REMOVAL OF SUCTION TUBE………………………………………………………278
REMOVAL OF REAR CRANKSHAFT SEAL……………………………………………….278
REMOVAL OF CAMSHAFT………………………………………………………….278
REMOVAL OF VALVE TAPPET………………………………………………………280
MEASUREMENT OF OIL PUMP GEAR BACKLASH………………………………………….280
REMOVAL OF OIL PUMP………………………………………………………….281
REMOVAL OF ENGINE FRONT SUPPORT……………………………………………….281
REMOVAL OF GEAR HOUSING………………………………………………………281
REMOVAL OF CARBON ACCUMULATED ON CYLINDER LINER…………………………………282
REMOVAL OF PISTON ASSEMBLY……………………………………………………283
REMOVAL OF PISTON PIN………………………………………………………..284
REMOVAL OF PISTON RING……………………………………………………….284
REMOVAL OF MAIN BEARING CAP…………………………………………………..285
REMOVAL OF MAIN BEARING (LOWER)……………………………………………….285
REMOVAL OF CRANKSHAFT………………………………………………………..286
REMOVAL OF MAIN BEARING (UPPER)……………………………………………….286
REMOVAL OF PISTON COOLING NOZZLE………………………………………………286
TESTING PROTRUSION OF CYLINDER LINER…………………………………………..286
REMOVAL OF CYLINDER LINER…………………………………………………….287
REPLACEMENT OF EXPANSION PLUG…………………………………………………288
REMOVAL OF EXPANSION PLUG…………………………………………………….288
REMOVAL OF CYLINDER BLOCK FROM ENGINE STAND…………………………………….289
ASSEMBLY OF ENGINE………………………………………………………………290
INSTALL THE CYLINDER BLOCK TO THE ROLL-OVER STAND……………………………….290
INSTALLATION OF CYLINDER LINER………………………………………………..290
INSTALLATION OF TAPPET……………………………………………………….295
INSTALLATION OF PISTON COOLING NOZZLE………………………………………….295
INSTALLATION OF MAIN BEARING (UPPER)…………………………………………..296
INSTALLATION OF CRANKSHAFT……………………………………………………298
INSTALLATION OF MAIN BEARING (LOWER)…………………………………………..299
INSTALLATION OF MAIN BEARING CAP………………………………………………299
INSTALLATION OF CONNECTING ROD BOLT……………………………………………302
INSTALLATION OF PISTON PIN……………………………………………………303
MEASURING PISTON RING END GAP…………………………………………………303
INSTALLATION OF PISTON RING…………………………………………………..304
INSTALLATION OF PISTON ASSEMBLY……………………………………………….306
INSTALLATION OH GEAR HOUSING………………………………………………….311
INSTALLATION OF OIL PUMP……………………………………………………..312
INSTALLATION OF CAMSHAFT……………………………………………………..314
INSTALLATION OF WATER PUMP……………………………………………………316
INSTALLATION OF OIL SUCTION TUBE………………………………………………316
INSTALLATION OF REAR CRANKSHAFT SEAL…………………………………………..316
INSTALLATION OF WEAR SLEEVE, REAR CRANKSHAFT SEAL……………………………….317
INSTALLATION OF OIL PAN………………………………………………………320
INSTALLATION OF TIMING PIN ASSEMBLY……………………………………………321
INSTALLATION OF FLYWHEEL HOUSING………………………………………………324
TESTING COAXIALITY OF FLYWHEEL HOUSING BORE…………………………………….325
INSTALLATION OF FLYWHEEL……………………………………………………..329
MEASURING RUNOUT OF FLYWHEEL BORE……………………………………………..331
MEASURING FACE RUNOUT OF FLYWHEEL……………………………………………..333
INSTALLATION OF STARTING MOTOR………………………………………………..334
INSTALLATION OF OIL COOLER……………………………………………………334
INSTALLATION OF OIL FILTER……………………………………………………335
INSTALLATION OF CYLINDER HEAD…………………………………………………335
INSTALLATION OF PUSH ROD……………………………………………………..339
ASSEMBLY OF ROCKER LEVER AND SHAFT…………………………………………….339
INSTALLATION OF ROCKER LEVER ASSEMBLY………………………………………….341
ADJUSTING VALVE CLEARANCE…………………………………………………….342
INSTALLATION OF HEAD COVER……………………………………………………344
INSTALLATION OF CYLINDER BLOCK BREATHER TUBE……………………………………345
INSTALLATION OF INJECTOR……………………………………………………..345
INSTALLATION OF FUEL DRAIN MANIFOLD……………………………………………346
INSTALLATION OF ENGINE LIFTING BRACKET…………………………………………346
INSTALLATION OF INTAKE MANIFOLD COVER………………………………………….346
INSTALLATION OF AFTERCOOLER…………………………………………………..347
INSTALLATION OF EXHAUST MANIFOLD………………………………………………347
INSTALLATION OF TURBOCHARGER………………………………………………….348
INSTALLATION OF TURBOCHARGER OIL DRAIN TUBE…………………………………….349
INSTALLATION OF TURBOCHARGER OIL SUPPLY HOSE……………………………………351
INSTALLATION OF TURBOCHARGER EXHAUST OUTLET PORT CONNECTOR……………………….351
INSTALLATION OF CROSSOVER…………………………………………………….351
INSTALLATION OF THERMOSTAT AND HOUSING…………………………………………351
INSTALLATION OF COOLANT OUTLET CONNECTOR……………………………………….352
INSTALLATION OF COOLANT AIR BLEED JOINT………………………………………..352
INSTALLATION OF COOLANT AIR BLEED VALVE………………………………………..352
INSTALLATION OF COOLANT AIR BLEED TUBE…………………………………………353
INSTALLATION OF COOLANT INLET CONNECTOR………………………………………..353
INSTALLATION OF ALTERNATOR BRACKET…………………………………………….353
INSTALLATION OF ALTERNATOR……………………………………………………353
INSTALLATION OF ALTERNATOR BRACE………………………………………………354
INSTALLATION OF BELT TENSIONER BRACKET…………………………………………355
INSTALLATION OF BELT TENSIONER………………………………………………..355
REMOVAL FROM ENGINE ASSEMBLY STAND…………………………………………….355
INSTALLATION OF FAN HUB ASSEMBLY………………………………………………356
INSTALLATION OF FUEL INJECTION PUMP……………………………………………356
INSTALLATION OF FUEL INJECTION PUMP, FUEL SUPPLY LINE……………………………361
INSTALLATION OF FUEL FILTER HEAD………………………………………………361
INSTALLATION OF FUEL FILTER…………………………………………………..362
INSTALLATION OF FUEL INJECTION PIPE (HIGH-PRESSURE SIDE)…………………………362
INSTALLATION OF BOOST COMPENSATOR TUBE…………………………………………363
INSTALLATION OF FRONT CRANKSHAFT SEAL………………………………………….363
INSTALLATION OF FRONT CRANKSHAFT WEAR SLEEVE……………………………………363
INSTALLATION OF GEAR COVER……………………………………………………366
INSTALLATION OF TACHOMETER DRIVE………………………………………………367
INSTALLATION OF CRANKSHAFT PULLEY, VIBRATION DAMPER……………………………..367
INSTALLATION OF BELT…………………………………………………………368
INSTALLATION OF ENGINE FRONT SUPPORT…………………………………………..368
INSTALLATION OF FUEL FEED PUMP………………………………………………..368
INSTALLATION OF FUEL PIPING TUBE (LOW-PRESSURE SIDE)…………………………….369
INSTALLATION OF FUEL PUMP SOLENOID…………………………………………….369
INSTALLATION OF AIR COMPRESSOR………………………………………………..369
INSTALLATION OF ENGINE ACCESSORY………………………………………………371
15 REPAIR AND REPLACEMENT OF PARTS …………………………………………………..373
OUTLINE………………………………………………………………………..374
REPAIR GUIDE LINE……………………………………………………………374
WHEN SHOULD SUBSTITUTE REPAIRS BE CARRIED OUT…………………………………..374
INSPECTION………………………………………………………………….374
TO ENSURE SAFETY, FOLLOW ALL INSTRUCTIONS IN MANUAL……………………………..374
FOLLOW WASHING METHODS GIVEN IN MANUAL…………………………………………374
FOLLOW INSPECTION METHODS GIVEN IN MANUAL………………………………………374
REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT………………………………….375
METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS………..376
REPAIR PROCEDURE…………………………………………………………….376
METHOD FOR REPAIRING TAPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS…….379
METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS…………………………………..380
INSPECTION FOR REUSE OF CYLINDER BLOCK…………………………………………….381
INSTALLATION OF EXPANSION PLUGS…………………………………………………..385
INSTALLATION OF PIPE PLUGS……………………………………………………385
INSTALLATION OF EXPANSION PLUG TO CAMSHAFT HOLE…………………………………….388
REMOVAL OF CAMSHAFT BUSHING………………………………………………………389
CLEANING OF CAMSHAFT BUSHING HOLE……………………………………………..389
INSTALLATION OF CAMSHAFT BUSHING………………………………………………….390
CLEANING AND INSPECTION OF CYLINDER LINERS BEFORE REUSING THEM……………………….393
CREANING OF CYLINDER LINERS…………………………………………………..393
INSPECTION OF CYLINDER LINERS…………………………………………………394
CLEANING AND INSPECTION OF PISTON BEFORE REUSING IT…………………………………396
REMOVE THE PISTON RINGS………………………………………………………396
CLEANING OF PISTONS………………………………………………………….396
INSPECTION OF PISTONS………………………………………………………..397
CLEANING AND INSPECTION OF CRANKSHAFT BEFORE REUSING IT……………………………..399
CLEANING OF CRANKSHAFT……………………………………………………….399
INSPECTION OF CRANKSHAFT……………………………………………………..399
REPLACEMENT OF CRANKSHAFT GEAR……………………………………………………403
REMOVAL OF CRANKSHAFT GEAR……………………………………………………403
INSPECTION OF CRANKSHAFT……………………………………………………..403
INSTALLATION OF CRANKSHAFT GEAR……………………………………………….404
CLEANING AND INSPECTION OF MAIN BEARINGS BEFORE REUSING THEM…………………………406
GENERAL INFORMATION………………………………………………………….406
CLEANING OF MAIN BEARINGS…………………………………………………….406
INSPECTION OF MAIN BEARINGS…………………………………………………..406
INSPECTION OF THRUST BEARING………………………………………………….407
CLEANING AND INSPECTION OF MAIN BEARING CAPS AND MOUNTING BOLTS BEFORE REUSING THEM…….408
CLEANING……………………………………………………………………408
INSPECTION………………………………………………………………….408
CLEANING AND INSPECTION OF CONNECTING ROD BEARINGS BEFORE REUSING THEM………………..409
CLEANING OF CONNECTING ROD BEARINGS……………………………………………409
INSPECTION OF CONNECTING ROD BEARINGS………………………………………….409
CLEANING AND INSPECTION OF CONNECTING RODS BEFORE REUSING THEM……………………….411
CLEANING OF CONNECTING RODS…………………………………………………..411
INSPECTION OF CONNECTIONG RODS………………………………………………..411
INSPECTION OF CONNECTING RODS FOR BEND AND TORSION………………………………….414
CALIBRATION OF FIXING TOOL……………………………………………………414
INSPECTION OF ALIGNMENT OF CONNECTING RODS……………………………………..415
REPAIR PROCEDURE FOR CONNECTING RODS…………………………………………..415
REPLACEMENT OF CONNECTING ROD BUSHINGS…………………………………………….416
REMOVAL…………………………………………………………………….416
INSTALLATION………………………………………………………………..418
INSPECTION………………………………………………………………….420
REPLACEMENT OF VALVE INSERTS OF CYLINDER HEAD………………………………………421
REMOVAL…………………………………………………………………….421
INSPECTION………………………………………………………………….423
ASSEMBLY……………………………………………………………………423
INSPECTION OF VALVE GUIDES……………………………………………………424
INSPECTION OF VALVE SEAT INSERTS………………………………………………425
INSPECTION OF VALVE SPRINGS…………………………………………………..426
INSPECTION OF VALVE STEM SEAL…………………………………………………427
INSPECTION OF VALVES…………………………………………………………427
GRINDING OF VALVES…………………………………………………………..428
GRINDING OF VALVE SEAT INSERTS………………………………………………..429
ASSEMBLY……………………………………………………………………433
INSTALLATION OF PIPE PLUGS……………………………………………………433
REPLACEMENT OF VALVE GUIDES OF CYLINDER HEAD……………………………………….436
DISASSEMBLY…………………………………………………………………436
INSPECTION………………………………………………………………….436
ASSEMBLY……………………………………………………………………436
CYLINDER HEAD-PRESSURE TEST………………………………………………………439
VACUUM TEST ON VALVE SEATS OF CYLINDER HEAD………………………………………..441
CLEANING AND INSPECTION OF CYLINDER HEAD BOLTS……………………………………..443
CLEANING……………………………………………………………………443
INSPECTION………………………………………………………………….443
FREE LENGTH-MEASUREMENT………………………………………………………444