2.

2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERHEADSUBASSEMBLIES

! Disassembly:

! Remove glow plugs by using suitable socket spanner.

(Fig.1)

(Fig.1)

! Remove all the roller finger followers (RFF) along

with hydraulic lash adjusters (HLA) by lifting vertically
and place them in correct sequence and in vertical
direction only to avoid oil drain from HLA. (Fig.2)

(Fig.2)

! Fit the valve spring compressor, compress valve

springs and remove lock halves. (Fig.3)

! Remove the valve spring retainers, valve springs, and

spring seats.

! Remove all valves (Inlet and Exhaust) from the bottom

side of the cylinder head.

(Fig.3)

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2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERHEADSUBASSEMBLIES

! CYLINDERHEAD

! Using a straight edge and feeler gauge, check

evenness of cylinder head parting surface with crank
case.

Valves:

! Check valve leakages by pouring gasoline on valve

head. Gasoline must not seep past valve seat.

! Valves with burnt heads, excessive scoring and wear

on stem should be replaced.

! Check valve seat run out with respect to valve stem.

If it exceeds specified limit replace valve. No attempt
should be made to straighten bent valves. If valve is
free from any other defects except worn out seat,
then only it can be rematched on valve grinding
machine as follows:

! Clamp valve on grinding machine jaws as close as

possible to valve head

! Adjust grinding angle on graduated scale to achieve

correct valve seat angle

! Feed valve slowly towards grinding wheel until wheel

just touches valve head.

! Grind at low feed until valve seat is just clean all

around.

NOTE : After grinding, valve head thickness should not be

less than 0.85 mm.

! Remove glow plugs by using suitable socket spanner.

Valve Guide:

! In case of valve stem sticking in valve guide bore or

Excessive clearance between them, remove valve
guide From cylinder head using drift 2868 5890 06
05. (Fig. 4)

! Check the condition of valve guide seal. (Fig. 4)

50
2.2 L Dicor Engine

! Check valve guide bore diameter in cylinder head

and if necessary, ream valve guide bore in cylinder
head to next over size. (Fig. 5)

(Fig. 5)

! Install matching size valve guide in cylinder head

using drift 2868 5890 06 05 and spacer, 2653 5890
06 01 (Fig. 6)

Valve Seat:

! Check valve seat height with respect to cylinder

head mating surface. Replace valve seat inserts if
they are worn out beyond specified limit. (Fig. 6)

! Cut exhaust and inlet valve seats with a 45 deg.

cutter. (Fig. 7)

! VALVE SEAT MUST BE ABSOLUTELY FAULTLESS AND

WITHOUT ANY CHATTER MARKS

! If necessary lap the valve seats to a smooth and even

finish by using suitable hand pump grinder or a
lapping paste and valve itself.

! Smear valve seat with carbon blue. Install valve in

guide and turn it slowly under axial pressure.

(Fig.7)

51
2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERHEADSUBASSEMBLIES

! CONTACTLINEONVALVESEATMUSTBE AROUND ! Machine valve seat in cylinder head.

ENTIRECIRCUMFERENCEATEQUALWIDTH
! Check for leakages through valve seat by pouring
gasoline on valve head. Gasoline must not seep past
valve seat.
Valve Seat Insert:
! For removing valve seat inserts from cylinder head
use suitable boring machine. Bore old insert thin
(about 0.5 mm thickness) and then pry it out.
! Alternatively use a suitable turning tool to cut an
annular groove into valve seat insert and then pull it
out with a suitable puller. In order to avoid damaging
machined cylinder head mating surface with crank
case, place any soft protective sheet metal under
supports of puller.
CAM SHAFT INSPECTION
! Check cam shaft run out at 2nd journal by supporting
it on V-block at 1st and 3rd journal
! Check cam shaft journal dimensions. Record the
readings.
! Carry out visual inspection of cam shaft for:
Overheating of journals, which is indicated by bluish/
brown colour, Deep scoring marks on journals and
cam lobes, Cracks, which should be checked on a
magnetic crack detector. Check hardness of cam
shaft journals and cam lobes, it should be 47 HRC
Glow Plugs:
Check glow plugs for short circuits and/or for burning.
Replace them if necessary.

! Measure valve seat insert bore diameter in cylinder
head.
! If boring and prying is done carefully without
damaging valve seat insert bore in cylinder head,
fitment of an over size valve seat insert will not be
necessary.
! Re-machined valve seat insert bore in cylinder head
must be exactly at right angle to cylinder head mating
surface with crank case.
Assembly of Cylinder Head:
! Install valves (Inlet & Exhaust) in their respective
positions.
! Install spring seats, valve springs and valve retainers.
! Fit valve spring compressor on cylinder head.
! Using valve spring compressor, compress the valve
springs and install valve lock halves.

! All specified dimensions should be strictly ! Assemble the glow plugs.

maintained to ensure proper interference of valve
seat insert in its bore. (Fig. 8)

! Clean valve seat insert and its bore in cylinder head

thoroughly.

JUSTBEFOREINSTALLATION:

! Place valve seat insert in mixture of Methanol and

dry ice for about 20-30 minutes to bring temperature
down to —150 deg. C.

! Heat cylinder head to approximately 80 deg. in hot

water bath.

! Install valve seat insert in cylinder head bore quickly

by light hammering

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2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERHEADSUBASSEMBLIES

Hydraulic Lash Adjuster (Fig. 9)

Hydraulic lash adjuster uses Engine oil pressure for its

operation. In case of a freshly assembled Engine, do not
run for a long time; there are chances of valve train noise
/ tappet noise appearing when engine is started / fixed.

There is no danger of damage to other components if

engine is run for few minutes on no load condition. HLA
noise can be heard as repeated tappet like noise when
engine is running at low idle speed.

Following procedure is recommended to eliminate the

noise :

! Raise the Engine RPM to 2500 without load (Vehicle

stationary) to bleed the hydraulic chamber of HLA.
The noise should disappear in 15-30 seconds.

! If the noise still persists, run the engine further under (Fig. 9)
same condition (no load @ 2500 RPM) for several
minutes.The noise should disappear in 3 to 30 mins,
in few case.

! In a very rare case if still noise is heard, the HLA stuck

in compressed condition needs to be replaced.

53
2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERHEADSUBASSEMBLIES

CYLIINDER HEAD CROSS - SECTIONAL VIEW

54
2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERBLOCK

Disassembly of Cylinder Block

! Remove the cylinder head gasket. (Fig. 1)

(Fig.1)
! Remove the thermostat housing assembly. (Fig. 2)
! Remove the oil filters &oil cooler assembly.

(Fig.2)

! Remove the dipstick assembly. (Fig. 3)

(Fig.3)

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2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERBLOCK

! Remove the HP pump (Fig. 4 & Fig. 5)

(Fig.4)

(Fig.5)

! Remove the HP pump mounting bracket

(Fig. 6)

(Fig.6)

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2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERBLOCK

! Remove the Idler pulley. (Fig. 7)

(Fig. 7)
! Remove the water pump. (Fig. 8)

(Fig. 8)
! Lock the flywheel with the help of locking pin
(Part No. 265358900604) (Fig. 9)

(Fig.9)

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2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERBLOCK

! Remove the crankshaft pulley. (Fig. 10)

(Fig. 10)
! Remove the clutch plate & pressure plate assembly.
(Fig. 11 & Fig. 12)

(Fig. 11)

(Fig. 12)

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2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERBLOCK

! Unstake lock plates, loosen flywheel mounting bolts

& remove the same (Fig. 13)

(Fig. 13)

! Remove crankshaft rear cover (Fig. 14)

(Fig. 14)

! Remove the oil sump by removing it’s mounting

bolts (Fig. 15)

(Fig. 15)

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2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERBLOCK

! Remove the ladder frame. ( Fig. 16)

( Fig. 16)

! Remove the Oil pump strainer. (Fig. 17)

( Fig. 17)

! Remove the Crankshaft gear. (Fig. 18)

( Fig. 18)

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2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERBLOCK

! Remove the Crankshaft gear key & friction plate.

(Fig. 19)

(Fig. 19)

! Remove the Oil pump. (Fig. 20)

(Fig. 20)
! Turn the Crankshaft & bring a pair of pistons to BDC.
Unscrew connecting rod bearing cap mounting nuts.
(Fig. 21)

(Fig. 21)

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2.2 L Dicor Engine

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! Push the piston assemblies out of cylinders using

wooden handle of mallet. (Fig. 22)
! Remove connecting rod bearing shells & duly mark
them with paint on their back in case these are to be
reused.
! Verify serial numbers on connecting rod bearing caps
& connecting rods.
! Remove remaining pistons in the same-manner

Note : It is essential to assemble conrod bearing caps to

their respective conrods only.

(Fig. 22)
! Unscrew & remove main bearing-cap mounting
bolts. (Fig. 23)

(Fig. 23)

! Take out the Crankshaft from the cylinder block.

(Fig. 24)

(Fig. 24)

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2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERBLOCK

! Remove Allen screws & take out all piston cooling

nozzles. (Fig. 25)

(Fig. 25)

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2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERBLOCK

CYLINDERBLOCK

Check cylinder block for cracks by pressure testing method.

Clean cylinder bores, bearing surfaces, oil passages in
crank case thoroughly. Check water jackets for leakages
by blowing air at a pressure of 5 bar & then dipping the
cylinder block in the hot water (temp of water 70° to
80°C)

THEBLOCKWITHANYLEAKAGES/CRACKSSHOULDBE
DISCARDED.

Check crank case mating surface with cylinder head for

unevenness with the help of straight edge and feeler
gauge (Fig.26 & 27). If necessary grind this surface just to
clear unevenness.
Ensure that the minimum height of crank case is not less (Fig 26)
than the specified minimum height

(Fig 27)

Cylinder bores

! Clean cylinder bores thoroughly

! Check cylinder bore dimension, taper and ovality.

(Fig 28)

! If taper and ovality is found to exceed specified limit

or bore is excessively worn out then replace liners.

! Record the readings in Engine inspection sheet no.

1 given in this manual.

(Fig 28)

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2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERBLOCK

CONNECTINGRODS
Inspect connecting rod small end bush and if necessary,
replace it.
Check connecting rod small end parent bore dimension
(Fig. 29)
If necessary machine connecting rod small end parent
bore to next over size.

ENSURETHATCONNECTINGRODBIGENDANDSMALL
END AXESARE PARALLEL TO EACH OTHERANDARE
WITHIN SPECIFIED LIMITS. ENSURE THAT CENTRE
DISTANCE BETWEEN SMALL END TO BIG END IS
MAINTAINED WITHIN SPECIFIED LIMIT.

Smear oil on parent bore of connecting rod. (Fig.29)

Install new bush in such a way that slits are

symmetrically positioned at approximately in vertical
axis.

Machine the side faces of bush to match the taper

faces of connecting rod.

Drill oil hole in new bush.

Finish connecting rod small end bush bore on a

connecting rod boring machine.

Alternately connecting rod small end bush may be

reamed. The end edges to be chamfered/deburred
manually.

Install connecting rod bearing caps without bearing (Fig.30)

shells on connecting rod.

Tighten connecting rod bearing cap mounting nuts to

specified torque (Fig 30)

ENSURE THAT IDENTIFICATION NUMBERS FOR

CONNECTING ROD AND CONNECTING ROD BEARING
CAP ARE MATCHED AND NOTCHES FOR BEARING
SHELLS ARE ON THE SAME SIDE.

Check twist and bend of connecting rod by using new

piston pin in connecting rod small end bush.
Measure twist and bend of connecting rod with feeler
gauge with respect to vertical face of connecting rod
alignment gauge in vertical and horizontal plane at a
distance of 50 mm from line joining centers of connecting
rod small end and big end bosses.(Fig 31 & 32)
(Fig.31)

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If necessary, straighten connecting rod in cold

condition. Since a slight clearance exists between
connecting rod bolts and corresponding connecting
rod bearing cap holes, it is possible that connecting
rod bearing cap once removed may be installed off
center, by which dimension of connecting rod big end
parent bore will be different in different directions. If
there is a difference noticed in connecting rod big
end parent bore dimension, connecting rod bearing
cap can be centralized by lightly tapping it with mallet
in required direction after slightly loosening
connecting rod bearing cap mounting nuts.

(Fig.32)

! Check connecting rod big end parent bore

dimension (Fig.33)
! If connecting rod big end parent bore is slightly
more than maximum permissible limits, it is
possible to reclaim connecting rod provided the
wear is confined only to connecting rod bearing
cap. Connecting rod bearing cap mating surface
may be slightly faced. Parent bore should then
be finished on a connecting rod boring machine.

! ENSURE THAT CONNECTING ROD BIG END AND

SMALLENDAXESAREPARALLELTOEACHOTHER
WITHIN SPECIFIED LIMITS. CENTRE TO CENTRE
DISTANCE BETWEEN CONNECTING ROD SMALL
END AND BIG END IS MAINTAINED WITHIN
SPECIFIEDLIMITS.

(Fig.33)

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! If one or more connecting rods are to be replaced,

ensure that difference in weight of connecting rod
in one engine is within permissible limits.

! Install new pair of connecting rod bearing shell

according to size of crank pin journal diameter,
making sure that securing lugs of bearing shells are
properly seated in grooves of connecting rod and
its bearing cap.

NOTE: Lower and upper bearings are different and to be

fitted properly.

! Install connecting rod bearing cap with bearing shell

on connecting rod.Tighten connecting rod bearing
cap mtg. nuts to specified torque (Fig. 34)

(Fig. 34)

! Measure connecting rod bearing bore (Fig. 35)

Record the readings in the standard format

(Fig. 35)
! IF CONNECTING ROD BIG END PARENT BORE
DIMENSION IS MAINTAINED WITHIN SPECIFIED
LIMITS, PROPER BEARING BORE DIMENSION IS
AUTOMATICALLY ACHIEVED.

! However, it must be physically measured and

confirmed. Measure pre-tension of connecting rod
bearing shell with a feeler gauge after loosening
connecting rod bearing cap mounting nut on
opposite side of bearing shell lug (Fig. 36)

CONNECTING ROD BEARING SHELLS ARE PRECISION

FINISHED AND SHOULD NOT BE BORED OR
SCRAPED.

(Fig. 36)

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2.2 L Dicor Engine

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PISTON AND PISTON RINGS

! Remove piston pin circlip with suitable plier (fig37).

(Fig.37)
! Remove piston pin from the piston by pushing it out
using a soft drift (Fig.38)

! Remove the connecting rod.

(Fig.38)

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2.2 L Dicor Engine

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! Remove piston rings from piston using ring expander

(Fig. 39)

! Remove carbon deposits from piston.

! Clean piston and piston rings thoroughly.

! In case cylinder bore taper and ovality is within

specified limit, then same piston and piston rings
may be reused. Examine pistons for cracks, scoring,
other damages, like Ring groove wear, piston pin
bore wear, spring clip groove wear/ damage etc.

! In case of any one piston with any one of this defect,

complete piston set should be replaced.

(Fig.39)

! Examine piston rings for scoring, lateral clearance

(Fig.40) in piston ring groove and butt clearance in
cylinder bore (Fig. 41).

(Fig.40)

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2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERBLOCK

BUTT CLEARANCE OF PISTON RING SHOULD BE MEASURED

IN UNWORN PORTION OF CYLINDER BORE.
! In case of any piston ring with any one of this defect,
complete ring set should be replaced.
! When cylinder bores are re-bored or honed, pistons
and rings of appropriate size should be used. Piston
size grade is stamped on piston crown.

(Fig.41)

! Install piston rings in their respective position on

piston using ring expander (Fig. 42).

! Stagger piston rings gaps such that they are 120°

apart (with butt gap not in line with piston pin)

(Fig.42)

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2.2 L Dicor Engine

DISASSEMBLYANDASSEMBLYOFCYLINDERBLOCK

CRANKSHAFT
Clean and carry out visual inspection of crank shaft for
Following:
! Overheating of journals, which is indicated by bluish
brown colour
! Scoring marks on journals
! Cracks, which should be checked on magnetic crack
detector
! Check crank shaft run out by supporting it on V-block
at 1st and 5th main bearing journals (Fig. 43)
! If run out exceeds permissible limits, straighten crank
shaft in cold condition on press carefully.
! Similarly check lateral and radial run outs of flywheel
mounting flange.
! Check crank shaft main bearing and crank pin journal
dimension.
! Record the readings in the Engine Inspection Sheet
(Fig. 43)
No. 3 given in this manual.
If necessary, grind crank shaft main bearing and crank
pin journals to next under-size.

MAINTAINCORRECTFILLETRADIUSFORJOURNALS
! Care must be taken during grinding to ensure that
width of journals is not increased.
! Should it be necessary to grind sides of 4th main
bearing journal, grind it to next under size.
! Re-chamfer oil holes on journals to avoid scoring of
new bearing shells.
! Finish journals by lapping them with 320 grit lapping
cloth of suitable width.
! After grinding recheck main bearing and crank pin
journal dimensions.
! Also recheck run out of crank shaft.
! Thoroughly clean crank shaft with kerosene. Use wire
brush for cleaning oil holes.

IT IS ESSENTIAL TO RECHECK CRANK SHAFT FOR

CRACKSANDBALANCEAFTERGRINDING

! Apply grease to all machined surfaces, if crank shaft

is to be stored. Crank shaft must always be stored in
vertical position.

! Thoroughly clean main bearing caps and

corresponding machined surfaces of crank case.
Install main bearing caps without bearing shells in
their respective positions on crank case.

! ENSURE THAT SERIAL NUMBERS ON CRANK CASE

AND MAIN BEARING CAPS ARE MATCHING. ALSO
CAPS ARE IN SERIAL ORDER AND NOTES FOR
BEARING SHELLS ARE ON SAME SIDE.

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2.2 L Dicor Engine

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! Tighten main bearing cap mounting bolts to specified

torque (Fig. 45)

(Fig. 45)

! Check crank case main bearing parent bore

dimensions (Fig 46)

(Fig. 46)

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2.2 L Dicor Engine

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! Install new pairs of main bearing shells according to

size of crank shaft main bearing journal diameter,
making sure that securing lugs of bearing shells are
properly seated in grooves of crank case and main
bearing caps.

! Install main bearing caps with bearing shells in their

respective position on crank case. Tighten main
bearing cap mounting bolts in specified sequence
to specified torque (Fig. 47). Measure main bearing
bore

! IF MAIN BEARING PARENT BORE DIMENSION IS

MAINTAINED WITHIN SPECIFIED LIMITS, PROPER
MAIN BEARING BORE DIMENSION IS AUTOMATICALLY
ACHIEVED.
(Fig. 47)
! However, it must be physically measured and
confirmed. Record the readings in Engine inspection
sheet no. 2 given in this manual.Measure pre tension
of main bearing shell with a feeler gauge after
loosening main bearing cap mounting bolt on
opposite side of bearing shell lug (This is to be done
on a flat surface plate as it can not be measured on
engine cylinder block because the main bearing
caps are guided). Clamp main bearing cap over the
bearing shell half on a flat surface plate, tighten the
bolts to specified torque. Measure pretension with a
feeler gauge after loosening main bearing cap
mounting bolt on opposite side of bearing shell lug
(Fig. 48).

! MAIN BEARING SHELLS ARE PRECISION FINISHED

AND SHOULD NOT BE BORED OR SCRAPPED.
(Fig. 48)
! Select new pair of thrust washer according to crank
shaft 4th main journal width.

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2.2 L Dicor Engine

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ASSEMBLYOFCYLINDERBLOCK
! Assemble all piston cooling nozzles (Fig. 49)

(Fig. 49)

! Install main bearing shell. (Fig. 50)

(Fig. 50)

! Install thrust washers in crankcase at their respective

location on 4th main bearing. (Fig. 51)

! Apply light coat of engine oil to all main bearing

shells & crankshaft journals.

(Fig. 51)

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2.2 L Dicor Engine

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! Install the Crankshaft. (Fig. 52)

(Fig. 52)

! Apply a light coat of grease to the fourth crankshaft

bearing cap & Fix the thrust washers.
(Fig. 53)

! Install the main bearing shells to the main bearing

caps.

(Fig. 53)

! Install 4th main bearing cap with thrust washer on

sides.

! Install 3rd, 5th, 2nd & 1st Main bearing caps with
shell in their respective position on crankcase.

! Tighten main bearing cap mounting bolts evenly &

uniformly to the specified torque (1st,3rd cap, next
4th & 2nd , lastly 5th & 1st) (Fig. 54)

(Fig. 54)

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! Fix. the dial gauge & check crankshaft axial play. It

should be within the range. (Fig. 55)

(Fig. 55)
! Check crankshaft for free rotation. The effort should
be in the range. (Fig. 56)

(Fig. 56)
! Turn the crankshaft & bring 1-4 & 2-3 crankpin journals
to top most position (TDC) on to which connecting
rod with piston are to be fitted.

! Apply oil on piston rings, cylinder bore & bearing

shells.

! Insert connecting rod with piston up to piston rings

into cylinder bore with arrow on piston crown
pointing towards front (Timing Side).

! Clamp piston ring compressor over piston rings such

that piston rings can slide inside it. (Fig. 57).

(Fig. 57)

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! Push piston gradually inside cylinder bore using

wooden handle of mallet till connecting rod locates
on crank pin journal. Slowly rotate crankshaft
simultaneously pushing piston till crank pin journal
reaches BDC position.

! Install connecting rod bearing caps with bearing shell

on connecting rod ensuring that bearing shell lugs
are on same side.

! Tighten conrod bearing cap mounting nuts to

specified torque. (Fig.58)

(Fig.58)

! Install the remaining piston in the similar manner

(Fig.59)

(Fig.59)
! Check the axial play of conrod on crankshaft journal.
(Fig. 60)

(Fig.60)

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! Measure piston projection above crankcase with the

help of piston topping dial gauge as shown in the
(Fig. 61)

(Fig. 61)

! Assemble the oil pump with new gasket. (Fig. 62)

(Fig. 62)
! Fit the crankshaft friction plate (Fig. 63)

(Fig. 63)

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! Assemble the water pump with new gasket.

(Fig. 64)

(Fig. 64)
! Clean the mating surface of crankcase & rear cover.

! Fit the oil seal to the crankcase rear cover using the
special tool.

! Assemble the crankcase rear cover & tighten the

mounting bolts to the specified torque. (Fig. 65)

(Fig. 65)

! Apply liquid (silicon) gasket on crankcase-oil sump

face evenly in appropriate quantity before the
fitment of ladder frame. (Fig. 66)

(Fig. 66)

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! Assemble the ladder frame & tighten the mounting

bolts to the specified torque. (Fig. 67)

(Fig. 67)

! Assemble the oil pump strainer (Fig. 68)

(Fig. 68)

! Assemble the oil sump with new gasket. (Fig. 69)

(Fig. 69)

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! Assemble the flywheel & tighten the mounting bolts

to the specified torque. (Fig. 70)

(Fig. 70)

! Lock the flywheel mounting bolt washers properly.

(Fig. 71)

(Fig. 71)

! Assemble clutch plate pressure plate assembly &

align the clutch plate using mandrel.

! Tighten the clutch pressure plate assembly mounting

bolts to specified torque. (Fig. 72)

(Fig. 72)

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! Fit the HP pump mounting bracket & assemble fitted) (Fig.73 & Fig. 74)
the HP pump (With the rear mounting bracket
! Tighten the HP Pump mounting bolts to the specified
torque.

(Fig. 73)
(Fig. 74)
! Assemble the oil filter-oil cooler assembly.
(Fig. 75)

(Fig. 75)

! Fit the thermostat housing (Fig. 76)

(Fig. 76)

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! Lock the flywheel using locking pin.

! Install the cylinder head gasket of proper thickness.
(Fig.1)

Piston Gasket Indentification

projection Thickness
0.56-0.64 1.3 1 Notch
0.65-0.73 1.4 2 Notches
0.74-0.82 1.5 3 Notches

(Fig.1)

! Install cylinder head on cylinder block (Fig. 2)

(Fig.2)

! Tighten the cylinder head mounting screw’s to

0
6kgm +180 torque in the proper sequence as
shown (Fig. 3)

Cylinder head mounting bolt tightening sequence:

(Fig.3)

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! Install the roller finger follower & hydraulic lash

adjuster assemblies. (Fig. 4 & Fig. 5)

(Fig. 4)

(Fig. 5)

! Fit the new gasket Intake manifold (Fig. 6)

(Fig. 6)

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! Assemble the Intake manifold/swirl actuators

assembly & tighten the mounting bolts to specified
troque. (Fig. 7)

(Fig. 7)

! Fit the new gasket-Exhaust manifold (Fig. 8)

(Fig. 8)

! Assemble the exhaust manifold & tighten the

mounting bolts to specified torque. (Fig. 9)

(Fig. 9)

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! Fit the water outlet elbow with the new gasket

(Fig. 10)

(Fig. 10)

! Assemble both intake & exhaust camshaft to their

respective places. (Fig. 11)
! Align the timing marks provided on both camshaft.

(Fig. 11)

! Apply ANABOND 610 ANAEROBK liquid gasket on

bearing frame.

! Assemble the bearing frame on cylinder head (Fig. 12)

(Fig. 12)

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! Slightly tighten all the mounting bolts of bearing

frame & assemble the camshaft oil seal using the
drift (Part No.265358900603) (Fig. 13).

(Fig. 13)

! Tighten all the mounting bolts of bearing frame to a

specified torque & sequence as shown. (Fig. 14)

(Fig. 14)

Bearing Frame Tightening Sequence: (fig. 15)

(Fig. 15)

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! Assemble the touch Idler. (Fig. 16)

(Fig. 16)
! Fix the timing cover rear & tighten the mounting
screws to a specified torque. (Fig. 17 & Fig. 18)

(Fig. 17)

(Fig. 18)

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! Assemble the HP pump gear using lock pin (Part

No. 265358900607). (Fig. 19)

(Fig. 19)

! Fit the Auto tensioner (Fig. 20)

(Fig. 20)

! Fit the Idler pulley. (Fig. 21)

(Fig. 21)

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ASSEMBLYOFCYLINDERHEADONCYLINDERBLOCK

! Lock the exhaust camshaft with the locking tool.

(Part No. 265358900605) (Fig. 22)

(Fig. 22)

! Slightly tighten the camshaft gear. (Fig. 23)

(Fig. 23)

! Assemble the crankshaft gear (Fig. 24)

(Fig. 24)

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ASSEMBLYOFCYLINDERHEADONCYLINDERBLOCK

! Lock the flywheel .

! Assemble the crankshaft pulley & tighten it to a

specified torque. (Fig. 25)

(Fig. 25)

! Assemble the timing belt.

! Using Allen key & spanners adjust the Autotensioner
to set the belt tension. (Please refer timing belt
setting procedure section for details)
(Fig. 26).

! Tighten the camshaft gear.

! Remove the camshaft locking tool.

(Fig. 26)

(Fig. 27)

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ASSEMBLYOFCYLINDERHEADONCYLINDERBLOCK

! Assemble the timing cover front (Fig. 28)

(Fig. 28)
! Assemble the common rail & tighten the mounting
bolts to a specified torque. (Fig. 29)

(Fig. 29)

! Assemble the EGR-cooler assembly. (Fig.30).

(Fig. 30)

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! Fit the EGR tube between EGR cooler & Intake elbow-
Intake manifold (Fig. 31)

(Fig. 31)

! Fit the EGR pipe between EGR valve & exhaust

manifold (Fig. 32).

(Fig. 32)

! Fit the HP pipe between common rail & HP pump

(by removing the caps) (Fig.33 & Fig.34)

(Fig. 33)

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ASSEMBLYOFCYLINDERHEADONCYLINDERBLOCK

(Fig. 34)

! Assemble the cylinder head cover & tighten the

mounting bolts to the specified torque & sequence.
(Fig. 35)

(Fig. 35)

! Tightening sequence of cylinder head cover

(fig. 36)

(Fig. 36)

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ASSEMBLYOFCYLINDERHEADONCYLINDERBLOCK

! Assemble the vacuum pump (Fig. 37)

(Fig. 37)

! Assemble the VGT assembly. (Fig.38)

(Fig.38)

! Fit the oil supply & return lines of VGT. (Fig. 39)

(Fig.39)

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ASSEMBLYOFCYLINDERHEADONCYLINDERBLOCK

! Install all injector & mounting claw assemblies.

(Fig.40)

! Note down the cylinder numbers & respective

injectors C2I values.

(Fig.40)

! Tighten the injector mounting claws to a specified

torque. (Fig. 41)

(Fig.41)

! Remove the caps.

! Assemble all the HP lines between common rail &

injectors respectively (Fig. 42 & Fig. 43)

(Fig.42)

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(Fig. 43)

! Fit the injector’s leak of lines (Fig. 44)

(Fig. 44)

! Assemble the EGR cooler cooling hoses.

(Fig. 45)

(Fig. 45)

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! Assemble the upper cooling pipe lines, oil separator

assembly etc. (Fig. 46)

(Fig. 46)

98