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Engine - Cylinder heads - Cylinder head - Install

1. Make sure that the faces of the cylinder head and cylin-
der block are perfectly clean.
2. Place the cylinder head gasket (1) on top face of the
cylinder block with mark “front top” facing upwards.
NOTE: Non re-torque type gasket is being used. It should
be fitted dry. This gasket does not require re-torquing in
Post-Delivery inspection.

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3. Install the cylinder head on the cylinder block using

suitable hoist.
4. Tighten the cylinder head bolts from centre of the cylin-
der head and move outwards while tightening, as se-
quence shown in image 3 .

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5. Use a suitable torque wrench to torque the bolts num-

bered from (1) to (8) to 40.0  N·m ( 29.5  lb ft ) in
the sequence as shown in image 3 .
6. Use a suitable angular gauge to apply an angular
torque of 225 ° to the bolts numbered (1) to (8) in the
sequence as shown in image 3 .
7. Then tighten the remaining bolts numbered (9) to (12)
to the torque 65.0  N·m ( 47.9  lb ft ) in the sequence
as shown in the image 3 .
NOTE: Make sure to replace the cylinder head bolts (1)
to (8) every time that you removed from the cylinder head.
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8. Install the rocker shaft assembly on the cylinder head.

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9. Tighten the rocker shaft assembly mounting bolts (1) .

10. Set the valve tappet clearance. See the Valves - Ad-
just .

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11. Connect the pipe (1) on rocker shaft lubricating oil

circulation by tightening the nut (2) .

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12. Install the injectors (1) on the cylinder head.

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13. Tighten the injector (1) to the torque 60  N·m ( 44

 lb ft ) .

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14. Install the three fuel injection pipes (1) connecting to

the fuel pump to injector.
15. Tighten the injection pipe nuts to the torque 20.0
 N·m ( 14.8  lb ft ) .

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16. Install the cylinder head cover (2) along with breather
pipe, gasket and tighten the nuts (1) .

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17. Connect the breather pipe (2) on the cylinder block

side and secure it with clamp.

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18. Connect the oil flow pipe on the camshaft to rocker

assembly shaft and secure it with banjo (1) .

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19. Tighten the drain plug (1) on the cylinder block.

20. Fill 9.8  L coolant to the radiator.

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Next operation:
Connect the exhaust pipe on the engine exhaust manifold.
Next operation:
Connect cold starting equipment connections (if equipped).
Next operation:
Install air cleaner and hose connections.
Next operation:
Connect the battery negative terminal. See the Battery - Install .

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Engine - Cylinder heads - Valves - Adjust

The three throw 120 ° crankshaft makes it necessary

to adopt a slightly different sequence for tappet adjust-
ment to the normally accepted procedure for four and
six cylinder engines.

Valve tip clearances for both inlet and exhaust should

be set to 0.30  mm ( 0.01  in ) in cold or hot.

1. Rotate the crankshaft in clockwise direction and bring

No. 3 Cylinder exhaust valve to full open position and
set the valve tip clearance for No. 1 Cylinder inlet and
exhaust valves. (At this position No. 1 piston is at the
end of compression stroke).

2. Then rotate the crankshaft in the same direction and

bring No. 1 Cylinder exhaust valve to full open position
and set the valve tip clearance for No. 2 Cylinder inlet
and exhaust valves. (At this position No. 2 piston is at
the end of compression stroke).

3. Again rotate the crankshaft in the clockwise direction

and bring No. 2 Cylinder exhaust valve to full open po-
sition and set the valve tip clearance for No. 3 Cylinder
inlet and exhaust valves. (At this position No. 3 piston
is at the end of compression stroke).

Valve layout

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Electrical systems - Battery - Install

Installation of battery is reversal of removal procedure

(refer to Battery - Remove ), but observe the following:
• Clean the battery case and battery terminals and
clamps before installation, by using a solution of
sodium bicarbonate (baking soda) and water.
NOTE: Cover vents while cleaning.

• Connect positive terminal last.

• Do not over tighten the battery securing clamp as
this may damage the battery case.

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