DISASSEMBLY AND ASSEMBLY 6) Coat the crankshaft journal with SAE No. 30 engine oil, confirm that the stamp No. on main cap (1) coincides with the number on the cylinder block, and install the main cap. %* Install_the main cap with the cast number facing the engine front, 7) Cost the threads of the mounting bolts and the ‘washers for the main cap with SAE No, 30 engine land secure the main cap by tightening the bolts. 8) Tighten’ main bearing cap mounting bolts (2) as follows. + Starting from the center to the outside, tighten the bolts to the specified tightening torque as follows. REI Main bearing cap mounting bolts Unit: kam ‘Order Target Range iststep | 10 an 2nd step 20 19.5205 Wark the bolts and the cap with 2 felttip pen, and turn the bolts 3rd step | with following degrees. 90° 90° — 120° Mark the bolt and the cap oo 30° ‘After tightening the bolts, put one punch mark on the head of each bolt. Do not reuse a bolt which has 5 punch marks. Replace it with a new one. 9) After tightening the bolts, confirm that the erenk- shaft rotates smoothly. 10) Measure the end play of the crankshaft using dial gauge 8) # End play: 0.140.315 mm 4. Piston and connecting rod assembly 1). Assemble the piston and connecting rod assembly as follows. i) Install piston rings (7) to the piston using piston ring tool D. 60125 SERIES GENERAL ASSEMBLY 1 3-025DISASSEMBLY AND ASSEMBLY 4) 5) 6) Contract the piston rings using piston holder G, and push the piston head into the cylinder with » wooden stick, For S6D125-1 Take care not to damage the piston cooling nozzle when inserting the piston. Make sure also that the nozzle is located in the center of the notched part on the piston, Install the lower bearing to the connecting rod ap with the projected part on the bearing aligned with the notch on the cap, and install connecting rod cap (2) in alignment with the stamped mark on the connecting rod, + Make sure the back of the bearing is free from any foreign matter before installing it. * Coat the sliding surface of the connecting rod with SAE No, 30 engine oil Coat the threads and seating surface of connecting rod bolts (1) with SAE No, 30 engine oil and tighten them as follows. S3EI_ Connecting rod cap mounting bolts Unit: kom ‘Order Targot Range 1st step 10 95 — 108 | Mark the bolts and the eap with | 8 felttip pen and turn the bolts 2nd step | with following degrees. 90° — 120° 7 8) After tightening the bolts, put one punch mark on, the head of each bolt. Do not reuse @ bolt which has 5 punch marks. Replace it with a new one. ‘After the piston and connecting rod assembly is installed, make sure the crankshaft rotates smooth. v, Measure the side clearance of the connecting rod with dial gauge ‘# Standard side clearance: 0.20 — 0.375 mm 60125 SERIES. GENERAL ASSEMBLYDISASSEMBLY AND ASSEMBLY iii) Sot the eylinder head upright, and install valve spring (3) and upper seat (5). iv} Contract the valve spring using spring pusher C, and install valve cotters (4). Tap the valve stem lightly with a plastic hammer to make sure the cotters fe securely installed in the valve stem groove. 2) Make sure the mounting surface of cylinder head and the inside of eylinders ae fre from dust and for position. matter, and place eylinder head gasket (9) in + When installing the gasket, make sure the grommet is not loose. 3) Install each cylinder head assembly (2) and tighten mounting bolts (1). Coat the threads and lower side of the bolt head before tightening the mounting bolts, with lubricant (LMP) ‘+ First sorew in the mounting bolts two or three revolutions by hand, then tighten the bolts as follows S321 Cylinder head mounting bolts Unit: kgm FT Order Target Range [is sep 10 ot p [aise | 14 135-145 | [TM te bois and the ovinder © | seastep | heod mth ele tp pony and turn | Sr¢step | the bolts with following degrees. cae _[ p75 = 108" oT - 675 60-75 Put amark on the elt and eylinder hea e1sorais. ‘4 After tightening the bolts, put one punch mark on the head of each bolt, Do not reuse a bolt which has 5 punch marks. Replace it with a new one. 13.034 GENERAL ASSEMBLY e1s0e331 6180°330 Co 6125 SERIESDISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY 22. Adjustment of valve clearance ‘Adjust the valve clearance in the following procedure. % Adjust the valve clearance to obtain the following clearances between the crosshead and the rocker 4% Valve clearances (when engine is cold) Unit:_mm Intake valve Exhaust valve 0.33 0.7 4 With the engine cranking in firing order 1-5~-3-6~ 2-4, adjust the valve clearance for each cylinder. 1) Rotate the crankshaft in the normal direction. While watching the movement of the valve, align stamped line “1,6 TOP" on vibration damper (1) with pointer (2) 2). Insert a Feeler gauge I between rocker arm (3) ‘and crosshead (4), and adjust the clearance with adjustment screw (5) until the gauge can slide lightly. 3). Tighten lock nut (8) to secure the adjustment screw. GE) Lock nut: 6.75 + 0.75 kam % Recheck the valve clearance after tighten ing the lock nut. Refer 12 ADJUSTING VALVE CLEARANCE. 23. Nozzle holder % Make sure the inside of nozzle holder sleeve is free from dust and foreign matter. Fit Osrings and install nozzle holders (2) to the cylinder head, then tighten mounting bolts (1) % Tighten the nozzle holder mounting bolts equally to ‘achieve even tightening, G1 Mounting bolt: 2.2 + 0.3 kgm 13-036 6D125 SERIES