621202 13 DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY Air cleaner * muffler Starting motor Turbocharger drai Setting engine in engine overhaul stan: Corrosion resistor, air compressor suction tube .. nnn BB Bracket. CONNECT Tension pulley assembly. Fan pulley assembly Alternator assembly pulley . Tube, bracket, PTO 688@ wenn Fuel filter + fuel filter bracket Oil filter + off regulator nem 13-6 Oil pan... a 137 ‘Suction pipe, under frame 137 Flywheel fuera 137 Rear seal . - 137 Flywheel housing . Air vent tube, spill pipe, rocker arm housing cover ... ‘Nozzle holder, inlet conner Rocker arm Push rod Crosshead Rocker arm housing Cylinder head assembly... Vibration damper + cranks assembly Front support. Thermostat housing... Water pump assembly .. Oil cooler assembly ‘Cam follower .. Gear case cover Injection pump drive ge Camshaft... Oil pump assembly, oi! pump idler ge: Main idler gear, drive shaft.. ston cooling nozzle Piston and connecting rod assembly, Crankshaft Cylinder 1316ASSEMBLY AND DISASSEMBLY Special tools Part No. Part Name ay ‘A_| 790-901-1260 | Adapter 1 'B | 790-501-2001 | Engine overhaul stand [1 | 796-102-2102 | Spring pusher 7 D_| 796-100-1180 | Piston ring too! 1 E | 795-236-1000 | Liner puller 7 H | 795-502-1721 | Holder 1 | 795-937-1100 | Seal puller 7 Preparatory work © Clean off all mud and dirt. ¢ Drain cooling water and engine oil. ‘watey Engine oil: Approx. 37 © Prepare a stable engine stand which will prevent the engine from falling over, then put the engine securely in the stand. Engine assembly: Approx. 1550 kg (The weight of the engine differs accord- Ing to the model of machine on which it is mounted.) 1. Air cleaner - muffier 1) Disconnect hose (1) between air cleaner and ‘muffier and hose (2) between air cleaner and turbocharger, then remove band (3) then remove air cleaner (4). %* When removing turbocharger connection, cover the openings to prevent dirt or dust from entering the turbocharger. 2) Remove vaive (5), muffler mounting bolts (6) and band (7), then remove muffler (8). 3) Remove exhaust connector (9). ‘* When removing the turbocharger con- nection, cover the openings to prevent dirt or dust from entering the turbocharger. 2. Starting motor Remove mounting bolts (1), then remove starting motor (2). GENERAL DISASSEMBLY (ceE00135 621202621202 ASSEMBLY AND DISASSEMBLY 3. Turbocharger drain tube Remove turbocharger drain tube (1). ‘4 Setting engine in engine overhaul stand Install adapter A on eng 2 Sling engine assembly, engine overhaul stand assembly. ow Engine assembly: Approx. 1500 kg and install engine 5. Corrosion resistor, air compressor suction tube 1) Remove hoses (1) and (2). 2) Remove corrosion resistor (3). 3) Remove tubes (4) and (5). 4) Remove tubes from air compressor. (if equipped). 6. Bracket Remove mounting bolts, then remove brackets (1) and (2). 0600138ASSEMBLY AND DISASSEMBLY 7 Connector 1) Remove clamp (1), then remove turbocharger lubrication tube (2). 2) Remove mounting bolts (3), then remove ‘connector (4) and electrical intake air heaters ©). 8. Tension pulley assembly 1) Loosen tension pulley assembly mounting nuts (1). 2) Loosen adjustment bolt (2), move tension pulley toward inside, then remove V-belts @. 3) Remove mounting bolts (4), then remove tension pulley assembly (5). 9. Fan pulley assembly Remove mounting bolts (1), then remove fan pulley assembly (2). 10. Alternator assembly + pulley 1) Loosen mounting bolts (1), (2) and (3). 2) Loosen 2 adjustment nuts (4), then remove 2 alternator belts (5). 3) Rem inting bolts (1), (2) and (3), then fernator assembly (6) and adjustment rod (7). 4) Remove bracket (8). 8) Remove mounting bolts (9) and remove pulley (10). 13-4 GENERAL DISASSEMBLY ceeo0 N44 coecous 621202ASSEMBLY AND DISASSEMBLY GENERAL DISASSEMBLY 11. Dipstick guide, air cor sation tube (2), then remove air compressor (3). (If equipped.) 3) Remove air compressor mounting plate (4). (if equipped.) 12. Fuel hose Remove fuel hoses (5). 13. Turbocharger come 1) Disconnect turbochar tube. 2) Remove mounting bolts (1), then remove turbocharger (2). f lubrication intet 621202 14. Exhaust manifold Remove mounting bolts (1), then remove exhaust manifold (2). 15. After-cooler assembly (Intake manifold assembly) 1) Remove clamps (1). 2) Sling after-cooler assembly (2), remove ‘mounting bolts (3), then lift off after-cooler assembly. 16. Fuel injection tube Remove fuel injection tubes (4). 13-5 ®ASSEMBLY AND DISASSEMBLY GENERAL DISASSEMBLY 17. Fuel injection pump assembly 1) Remove lubrication tubes (1) and (2). 2) Remove lubrication tubes (3) and (4). 3) Remove 2 bolts (7) securing cross coupling (6) and front taminated coupling (5). 4) Remove 4 mounting bolts (8), then remove fuel injection pump assembly (9), * When doing this, leave flange coupling (10) and front laminated coupling (5) on the drive shaft. 5) Remove connecting bolts (11) of coupling and drive shaft, then remove flange coupling (10) and front laminated coupling (5). u ceeo0181 18, Tube, bracket, PTO case 1) Remove turbocharger lubrication tube (1). 2) Remove fuel injection pump bracket (2). 3) Remove PTO case (3). Fuel filter « fuel fitter bracket Remove fuel filter (1) and fuel filter bracket (2). 20. OU filter - oil regulator Remove oil filter (3) and oil regulator (4). 621202ASSEMBLY AND DISASSEMBLY 21. Oil pan 1) Remove wiring connector (1) from bracket. 2) Disconnect drain hose (2). 3) Remove oil pan (3). 22. Suction pipe, under frame 1) Remove bracket (1), then remove suction pipe (2). 621202 Flywheel Using eye bott @ (Dia. = 12 mm, Pitch = 1.75 mm), sting flywheel (1), then remove. CGE) Flywneet: 60 kg 24, Rear seal Remove rear seal (1) as follows. GENERAL DISASSEMBLY 2 ceEOoIs6ASSEMBLY AND DISASSEMBLY GENERAL DISASSEMBLY © Removal of standard seal Hook tip of tool L to metal ring of seal (1), then use impact force of slide hammer to remove seal. % Before removing the seal, knock it in slightly to release the contact between the seal and the housing. This will make it easier to remove the seal © Removal of seal with sieeve 1) Hook tip of tool L to metal ring of seal (1), then use impact force of slide hammer to remove seal. * Before removing the s¢ slightly to between the seal and the housing. This will make it easier to remove ‘the seal. 2) Use a hammer and chisel to cut sleeve (2) to remove: & Be extremely careful not to damage the crankshaft when cutting the seal. * If any metal particles are formed, be ‘sure to remove them all completely. 25. Flywheel housing Remove mounting bolts (1), sling flywheel housing (2), then remove. CED Flywheet housing: 55 kg 26. Air vent tube, spill pipe, rocker arm housing cover 1) Remove air vent tube (1). 2) Remove spill pipe (2). 3) Remove rocker arm housing covers (3). Too! tamer we00211 Standard seal Flames hove nat oveoo2!2 Seal with si Flywheel Chankshatt ove00213 cee00157 coe0otss 621202621202 ASSEMBLY AND DISASSEMBLY 27. Nozzle holder, inlet connector 1) Loosen locknut (1), then remove inlet connector (2). 2) Remove mounting bolts (3), then remove holder (4). 3) Fully screw bolt @ (Dia. = 10 mm, Pitch = 5 mm), then remove nozzle holder assembly (5) using bar ete. When removing nozzle holder assembly, clean around nozzle holder and be careful not to enter foreign material inside sleeve. t there is gasket (6) fitted to 28. Rocker arm Remove mounting bolts (1) and (2), then remove rocker arm (3). * Loosen lock nuts (4) of adjustment screws, then loosen each adjustment screw (5) 2-3 turns to avoid excessive pressure being brought to bear on the push rods when installing the rocker arm. GENERAL DISASSEMBLYASSEMBLY AND DISASSEMBLY 28. Push rod Remove push rod (1). 30, Crosshead Remove crosshead (2). 31. Rocker arm housing Remove mounting bolts, then remove rocker arm housing (3), 32, Cylinder head assembly 1) Remove mounting bolts (1), then remove cylinder head assembly (2). 2) Remove each cylinder head gasket. © Disassemble cylinder head assembly as lows. i) Using spring pusher C, compress valve spring and remove cotter (1). i) Remove upper vale seat (2), outer valve spring (3), and inner valve spring (4). ii) Remove tower valve seat (5). iv) Lift up cylinder head and remove valves (6). 13-10 ® GENERAL DISASSEMBLY cee001s4 ceE00167 621202621202 ASSEMBLY AND DISASSEMBLY ‘33. Vibration damper « crankshaft pulley assembly Remove mounting bolts (1), then remove vibration damper, crankshaft pulley assembly (2). 34, Front Remove front support (3). 35. Thermostat housing 1) Remove ring (1), then remove tube (2) up. 2) Remove mounting bolts (3), then remove thermostat housing (4). 36, Water pump assembly Remove tube (1), then remove water pump assembly (2), % The mounting bolts for the water pump are also used to tighten the gear case cover. 37. Oil cooler assembly Remove oil cooler assembly (1). GENERAL DISASSEMBLY see0o170 / 73 13-11 ®ASSEMBLY AND DISASSEMBLY 38. Cam follower Remove cover, then remove mounting bolts (1) and cam follower (2). * Each of twelve mounting bolts (1) has its ‘own oil holes s0 pass wire through the holes and keep the bolts in a safe place to prevent them from being lost. 39. Gear case cover Remove gear case cover (1). 40. Injection pump drive gear Remove mounting nut (1), then remove injection pump drive gear (2). 41. Camshaft Align mounting botts (3) with camshaft gear hole and remove mounting bolts then remove camshaft (4). % When removing the camshaft, rotate the camshaft to prevent damage to the cam bushing. 13-12 ® GENERAL DISASSEMBLY coeve17s ceteors ‘CEEQOITT 621202621202 ASSEMBLY AND DISASSEMBLY 42. Oil pump assembly, oil pump idler gear 1) Remove oil pump assembly (1). 2) Remove oi! pump idler gear (2). 43. Main idter gear, injection pump drive shaft 1) Remove mounting bolt (1), then remove main idler gear (2). 2) Remove mounting bolts (3), remove thrust plate (4) and injection pump drive shaft (8). 44, Piston cooling nozzle Remove mounting bolt (1), then remove piston cooling nozzle (2). 45. Piston and connecting rod assembly 1). Check number on connecting rod cap. * Check that the cap number and the cylinder number match, and that the ‘number is stamped at the cam end. %* if there is no number, stamp @ number before removing. 2) Rotete crankshaft so that piston to be femoved is at bottom dead center. Using fine sandpaper, remove carbon at top of finer. * If necessary, measure the end play of the connecting rod with dial gauge © before removing the connecting rod assembly. 3 GENERAL DISASSEMBLY ceeoo1at 13-13 ®ASSEMBLY AND DISASSEMBLY 4) Remove bolts (1) of connecting rod cap. 5) Tap cap with plastic hammer and remove connecting rod cap (2) together with ‘connecting rod bearing. %* Be careful not to damage the threads of the connecting rod bolts. 6) Using wooden ber, push piston and connecting rod from oil pan side. Support piston (6) at cylinder head side and remove. ‘* When removing, be careful not to damage the inside surface of the liner with the comers of the connecting rod. 7) Remove remaining pistons and connecting rods in the same way. Keep the pistons and connecting rods in a safe place and be careful not to damage the sliding surface of the piston or the bearing. * Keep the connecting rod and cap sssembled to prevent mistakes when assembling, and keep together with the bearing. © Disassemble piston and connecting rod assembly as follows. Remove snap ring (3). Hold connecting rod (4) by hand, and tap out piston pin (5). Disconnect piston assembly (6) and connecting rod. iv) Using piston ring tool D, remove piston rings (7). ‘Keep piston, connecting rod, bearing, piston rings and piston pin in sets according to cylinder number. 13-14 GENERAL DISASSEMBLY SeECO105 621202621202 ASSEMBLY AND DISASSEMBLY GENERAL DISASSEMBLY 46. Crankshaft * If necessary, meast crankshaft with di removing the crankshaft. the end play of the gauge @ before Remove mounting bolts (2) of main bearing cap (1). insert bolts (2) in holes in main bearing cap, then remove main bearing cap while shaking the cap with the inserted botts. The lower thrust bearings (3) are assembled ‘on both sides of the No. 7 main bearit 0 after removing, mark the p ‘assembly. Using @ wire, remove crankshaft (4). Crankshaft: 140 kg % When slinging the crankshaft, be careful not to let it hit or damage the cylinder block. + Keep the crankshaft in a safe place, and be careful not to damage the machined surfaces. cxeaoras 13-15 ®ASSEMBLY AND DISASSEMBLY 5) Remove upper thrust bearings (5). 6) Remove upper main bearing (6), Mark the positions for assembly of the main bearing caps, main bearings and ings with tags or felt pen. ts according to the cap number. Keep them in a safe place and be careful not to damage them. 47. Cylinder liner If necessary, measure the protrusion of the cylinder liner with dial gauge H before removing the liner. Using liner puller E, remove cylinder liner (1). 13-16 ® GENERAL DISASSEMBLY ceE00190 621202621202 GENERAL ASSEMBLY Tightening bolts by the plastic range turning angle method .. Drawing of special tool Preparatory work .. Cylinder finer Cam follower Oil cooler assembly Water pump assembly ... Thermostat housing... Front support... Vibration damper, crankshaft pulley assembly. Cylinder head sssembly. Crosshead Nozzler holder, inlet connector Rocker arm housing cover, spill pipe, Fuel fiter assembly = fuel PTO case tube, bracket... Fuel injection pump assembly, ‘Adjusting fuel injection pump Fuel injection tube ...... After-cooler assembly (Intake manifold Turbocharger werenmnnone Fue! HOSE een Dipstick guide, Alternator assembly, PUlleY semen Fan pulley assembly . Tension pulley assembly... intake connector... Muffler bracket, air cleaner bracket Corrosion resistor... Resetting engine in engine stand Starting motor .... nee 13-53 Air cleaner, muffler 13-54 Refilling with oil 13-54 13-17 ®@ASSEMBLY AND DISASSEMBLY TIGHTENING BOLTS BY THE PLASTIC RANGE TURNING ANGLE METHOD @ = Important bolts in the 140 Series engines are tightened by the plastic range turning angle method. In this method, special bolts are used. By being tightened to the load (plastic range) at which they begin to be permanently deformed, accurate and high tightening force can be obtained. ‘The most common method for tightening bolts is the torque control method. In this method, however, it is difficult to accurately control the tightening force because of the coefficient of friction. The piastic range turning angle method is based on the initial tightening torque and the tuming angle. % Elongation exceeding the elastic range results in permanent deformation. ‘© Bolts to be tightened by the plastic range turning angle method in the 140 Series engines. 1) Cylinder head mounting bolts 2) Main cap mounting bolts: 3) Connecting rod cap mounting bolts 4) Flywheel mounting bolts In the plestic range tuming angle method, the permanent strain remains in bolts after they are tightened. Therefore, the number of times that ‘each bolt can be reused is limited. Observe the following precautions, 1) Before tightening, measure the free length of bolt and check that bolt length exceeds: tolerance limit or not. Do not reuse any bolt which has exceeded the tolerance limit. Before tightening, measure the free length of bolt and check that bolt length exceeds tolerance limit or not. 2) ‘Ifa bolt has been tightened in excess of the specified turning angle, loosen the bolt and measure the free length of bolt again. 3) The tightening angle should be targeted at the standard value plus or minus tolerance. ‘Special tools Engine overhaul stand GENERAL ASSEMBLY [Part No_[ Part Name | Oty J _|__790381-1110 | Wrench 1 _|_7951-473-1710 | Push tool 1 796-521-1110 | Push tool [1 ola ry (01050-31640 | Bott ‘Spring pusher Piston ring toot ‘Liner driver 1D | 795-100-1791 F | 795-230-5472 G | 795-236-1500 | Piston holder | 796-502-1121 | Gauge 1 | 795-125-1210 | Fesler gauge 13-18 @ * Tr] 735-831-1210 | Sieeve fio 795-931-1220 Clean ail parts, and check for dents, scores or casting defects. Check that all the oll and water Passages are clear. 621202621202 ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY Drawing of special tool Push tool K Note) Komatsu has no responsibility for special tool made by this drawing. et 100 ‘cpeco26t TERT TREAT] are = sroni3k Far aE a V Push TOOL a 796T-473-1110 A 13-19ASSEMBLY AND DISASSEMBLY Preparatory work . Install adapter A on cylinder block, set cylinder block on engine overhaul stand B. Prepare the cylinder block before inserting the cylinder liner as follows. 1) Using sandpaper, remove rust and scale from faces @ and © until machined surface can be seen. 2) Using No. 60 sandpaper, polish portions ® and ® to give a smooth finish. If there is a sharp corner formed or any burrs on portion @, remove with a scraper or sandpaper. Be Particularly careful to finish this surface smoothly to prevent damage to the O-ring. '3) If there is pitting on face ® and it cannot be repaired, replace cylinder block. 4) If there is pitting on face @ or portion @, polish to give a smooth finish. 5) Inspect counterbore and remove all burrs. Remove all chips and dirt from face ©. Such dirt will cause defective sealing of the liner, leakage of water, or defective protrusion of the liner %* If there is any damage, corrosion or pitting in the counterbore, repair it. 13-20 @® GENERAL ASSEMBLY 621202621202 ASSEMBLY AND DISASSI BLY Cylinder finer Before assembling, carry out selection of clearance between liner and piston referring to MAINTENANCE STANDARD. Replace the liner O-ring and crevice seal with new parts just before assembling the liner. Method of installing liner O-rings and crevice seal 1) Check the cylinder liner O-ring groove and outside circumference of the liner to confirm that there is no rust or pitting. © the surface is rough end pitted, it may cause leakage of water, so replace the liner. 2) Coat the mating surface of the cylinder block ‘and cylinder liner counterbore with silicon- based gasket sealant (LG-6). © Use a cloth to wipe off all the dirt or oil from the cylinder block counterbore and liner flange contact surface. © Width of gasket sealant (LG-6): 62-3mm @ Make an overlap of 6 + 6 mm at the beginning and end when coating with gasket sealant LG-6. If the parts are left for a long time after coating them with gasket sealant, the surface will start to become hard, so complete assembly to the block within 50 minutes. GENERAL ASSEMBLY SS Clinger dioct owzoo216 ot liner aket sealant deen x00! Crevice seat ‘Block (Ethylene propylene rubber} O-ring ‘Black Ethylene propyiene rubber! O-ring ‘Orange (Scan rubber 13-21ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY 3) Coat the liner O-ring and cylinder block O- ring grooves with rubber lubricant RF-1. ‘* RF-1: Daido Kagaku Kogyo If RF-1 is not available, coat liner O-rings and crevice seals with clean SAE3O engine oil. + Oil causes the crevice seal and O-ring to swell and deteriorate, so do not leave them soaking in oil. Use @ brush and coat them with a smalt amount of oll immediately before assembly. 4) After installing the liner O-ring, check for twisting. If any twisting is found, use a smooth bar (approx. 10 mm) to remove the twisting. 5) To prevent the crevice seat from twisting when it is installed, press it around the whole 4 circumference so that it fits into the seal groove. * Assemble the crevice seal with the chamfered side facing down. cre00201 © Method of inserting cylinder liner Press to the grove: 1) Set the stamped mark “A” or “B” on the top, of the liner facing to the front, then insert the liner into the cylinder block taking care not to damage the O-ring. 2) Use your weight and push the liner in with ‘Chamtered side both hands. + ifthe liner does not go in smoothly when you apply your weight, there is danger that the O-ring may be damaged, so check the cylinder block for burrs or flashes. 3) Using tool F, press fit cylirider liner (1) into the cylinder block. ‘ceeoo203 13-22 621202621202 ASSEMBLY AND DISASSEMBLY 4) After press fitting cylinder liner, use tool H to measure protrusion of cylinder liner. * When measuring the protrusion of the cylinder liner, clamp the liner with a plate to prevent it from being pushed up by the O-ring. * Protrusion of cylinder liner: 0.08 - 0.18 mm If any gasket sealant is squeezed out from the mating portion of the cylinder block ‘and cylinder liner on to the top of the cylinder block, wipe it off. 5) In addition, to prevent gasket sealant from being squeezed out from between the block and finer when the head is tightened, fit a used head gasket after inserting the liner and tighten the cylinder head temporarily. When tightening, use the tightening torque shown below and the order of tightening shown on the right. GE Temporary tightening torque for cylinder head: 187 = 157 Nm {14 ~ 16 kgm} 6) Remove the cylinder head, and wipe off the gasket sealant that has been squeezed out from the counterbore. + If gasket sealant sticks to the grommet in the head gasket, the grommet will be deformed, so always cary out Steps 5) and 6) to remove all the gasket sealant. (Crankshaft 1) Align protrusion of upper main bearing (6) with notch in cylinder block, and install in cylinder block + Check that there is no dirt or dust stuck to the rear face of the bearing. Coat the inside face of the bearing with engine oil (SAE#30) before assembling. Do not coat with oil to back face of metal. Se Upper metal: with oil hole. ceeeoise coeeozee 1 the sroamet i covers (heater hat 2 heart snase ane tar let Groafet ater holeASSEMBLY AND DISASSEMBLY 2) Knock in roll pin so that it protrudes 2.7 ~ ‘3.4: mm from block, then install upper thrust bearings (5). %* Install the thrust bearings with the groove on the crankshaft. 3) Using a wire, sling crankshaft (4) and set in position on cylinder block. When installing the be careful not to let it hit or damage the cylinder block. + Ifthe crankshaft gear has been replaced, heat the crankshaft gear In an electric furnace at 200°C for 30 minutes, then shrink fit. 4) Align protrusion of lower main bearing with notch in main bearing cap and instell bearing. + Check that there is no dirt or dust stuck to the rear face of the bearing when installing. 5) Knock in roll pin so that It protrudes 2.7 — 3.4 mm from cap, then assemble thrust bearings (3) on both sides of No. 7 main cap. + Install the thrust bearings with the groove ‘on the crankshaft side. 6) Coat journal surfaces of crankshaft with engine oil (SAE#30). Check that the number ‘on main bearing cap (2) matches the cyfinder block number, and install main besring cap. + Install the main bearing cep with the part number casting mark facing the front of ‘the engine. GENERAL ASSEMBLY 621202621202 ASSEMBLY AND DISASSEMBLY 7) Before tightening main cap mounting bolt (2), make sure as follows. i)" Measure the free length a of all bolts and check that boit length exceeds toler- ance limit or not. Do not reuse any bolt which has exceeded the tolerance limit. Before tightening, measure the free length of bolt and check that bolt length exceeds tolerance limit or not. ii) Tolerance limit of bolt free length: Max. 159.8 mm, * If the bolt length @ exceeds tolerance limit, do not reuse. 8) Coat washer and threads of mounting bolts ‘of main bearing cap with engine oil (SAE#30). Screw in bolts (1) to fit main bearing cap completely. 9) Tighten mounting botts (2) of main bearing cap as follows. + When tightening the mounting bolts of the main bearing cap, startin the middle and work to the outside. Then tighten all the mounting bolts again to the nex step. Mounting bolt of main bearing cap ‘st step: 108 - 128 Nm {11 - 13 kgm} 2nd step: 211 = 221 Nm (21.5 - 22.5 kgm) ‘3rd step: 1) When using tool J. Tur the bolt further 90-120, degrees with too! J. 2) When not using tool J. Mark the bolts and the cap with a felt-tip pen, and turn ‘the bolts further 90 - 120 degrees. 10) After tightening bolts, rotate crankshaft and check that it rotates smoothly. 11) Measure end play of crankshaft with dial gauge ©. ‘End play: 0.140 ~ 0.315 mm oweooars a" Se coetnto7ASSEMBLY AND DISASSEMBLY 3. Piston and connecting rod assembly * Before assembli Fry out selection of clearance between liner and piston referring to MAINTENANCE STANDARD. © Assemble piston and connecting rod assembly as follows. 1) Using piston ring tool D, install piston rings (7) on piston. ‘%* Assemble the rings as shown in the diagram. + Install the piston rings with the stamped mark facing up. + When fitting the oil ring, remove the ‘expander and fit the piston, then fit the oil ring. When doing this, check that the ‘expander is fitted completely inside the ing groove. 2) Set piston and connecting rod. * Match cylinder number on piston head with number stamped on connecting rod, and set numbers facing in the correct direction. Then insert piston pin (5) and assemble piston (6) to connecting rod . 3) Install snap rings (3) on both sides to secure piston pin. 4) Align protrusion of upper bearing of ‘connecting rod with notch in connecting rod and install bearing. + Check that there is no dirt or dust stuck to the rear face of the bearing when installing. 8) Set crankshaft to bottom dead center in cylinder to be sssembled, then cost inside ‘surfece of connecting rod bearing and inside surface of cylinder with engine oil (SAE#30). 13-26 @ GENERAL ASSEMBLY CEEOOIAS ¢ Grinder No. Gitta on eunsnart 4a) owe00226 621202621202 ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY n ‘Set cast number on connecting rod facing front of engine (number is on camshaft side), align end gaps of piston rings as shown in diagram, and insert piston and connecting rod assembly (8). Using piston holder G, compress piston rings. ‘and push in piston head with wooden bar. Before tightening connecting rod bolt, make sure 2s follows. i) Measure the free length @ of all bolts ‘and check that bolt length exceeds toler- ance limit or not. Do not reuse any bolt which has exceeded the tolerance limit. Before tightening, measure the free length of bolt and check that bolt length exceeds tolerance limit or not. i) Tolerance limit of bott free length: Max. 95.0 mm. + If the bolt length # exceeds tolerance limit, do not reuse. Align protrusion of lower bearing with notch in connecting rod cap and assemble. Align connecting rod cap (2) with mark on connecting rod and install. Check that there is not dirt or dust stuck to the rear face of the bearing when installing. + Coat the sliding surface of the connect- ing rod cap with engine oil (SAE#30). 4 ® E fear C ~ we00275ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY 10) Coat bolt threads and bolt seat with engine oil (SAE#30). Tighten mounting bolt (1) of connecting rod as follows. G25=) Mounting bolt of connecting rod ist step: 123 ~ 132 Nm {125 - 13.5 kgm} 2nd step: 1) When using tool J. ‘Tum the bott further 90 - 120 degrees with tool J. 2) When not using tool J. Mark the bolts and the cap with a felt-tip pen and turn the bolts further 90 - 120 degrees. ceecanta ‘* Make a punch mark on the bolt head each time the bolts are used. if there are already five marks on the bott head, re- place with new bolts. 11) After installing piston and connecting rod assembly, rotate crankshaft and check that it rotates smoothly. There must be no catch- ing or other abnormality. 621202 12) Measure side clearance of connecting rod with dial gauge ©. %* Side clearance: 0.100 - 0.274 mm 4. Piston cooling nozzle Fit piston cooling nozzle (2) and install mounting bolts (1). %® Check that the tip of each nazzle is directed at the center of each piston shaker hole.621202 5. Main idler gear, fuel injection pump drive shaft 1) Coat fue! injection pump drive shatt (5) with engine oil (SAE#30) and install. 2) Install thrust plate (4), then install mounting bolts (3). 3) Install shaft (6) to main idler gear (2), then fit washer (7) on inside. 4) Align “A” mark on crankshaft gear with “A” mark on main idler gear (2), then tighten mounting bolts (1). -a=5 Idler mounting bott: ‘Ist step: 265 ~ 343 Nm {27 - 35 kgm) 2nd step: Mark the bolts and the side seat of idler gear shaft with a felt-tip pen and tum the bolts further 90 = 120 degrees. ‘% Make a punch mark on the bolt head ‘each time the bolts are used. © If there are already five marks on the bolt head, replace with new bolts. 2 ee00218 00217 Put one punch mark 13-29 ®ASSEMBLY AND DISASSEMBLY 6. Oil pump idler gear, oil pump assembly 1) Install oil pump idler gear (2). 2). Fit O-ring and install oil pump assembly (1). 35 Oil pump idler mounting bott: 377.6 - 426.6 Nm (38.5 - 43.5 kgm} S35 Oil pump mounting bolt: ‘98 - 123 Nm {10 - 12.5 kgm) Camshaft Coat camshaft journal surfaces with engine oil (SAE#30). Align “B” mark of camshaft gear with “BT mark of mi ar, then tighten mounting bolts (3) of camshaft (4). ==] Mounting bott of plate: ‘98 ~ 123 Nm {10 - 12.5 komt % When installing the cemshaft, rotate the camshaft to prevent damage to the cam bushing. % Ifthe camshaft gear has been replaced, heat the camshaft gear in an electric furnace at 220 - 240°C for 30 minutes, then shrink fit ‘the gear. Fuel pump drive gear Fit key to shaft, align “C” mark of main idler gear with °C" mark of drive gear, then fit drive gear (2) and tighten nut (1). GasD Nut: 226 - 255 Nm {23 - 26 kgm} ‘& Check that the match marks of each drive gear and idler gear are aligned. 621202 coe00217621202 ASSEMBLY AND DISASSEMBLY. ‘Measure backlash and end play of each gear using dial gauge @. %* Standard backlash for each gear GENERAL ASSEMBLY Position] Range (mm) A 0,141 ~ 0.425 B 0.129 - 0.391 c 0.129 - 0.397 0 | _onat-0.426 E 0.095 - 0.346 ceeoorta F 0.080 - 0.417 G 0.118 - 0.369 H (OP) 0.118 - 0.369 1 40P) 0.025 - 0.486 ‘%* Standard end play for each gear Range (mm) 1 0.140 - 0.315 0.100 - 0.250 coevorts 2 3 0.050 - 0.170 4 0.050 - 0.170 5 0,070 - 0.200 6 0.030 - 0.088 9. Fuel injection pump drive shaft oil seal * Before assembling the seal, check that there is no damage, burrs, flashes, or rust on the housing and sliding surface of the lip. + When assembling the seal, do not coat the shaft, and the space between the sleeve and seal lip with oil or grease. If there is any oil or grease on the shatt, wipe it off completely. Handle the seal and sleeve as an assembly. Never separate them. Hy suide He aneASSEMBLY AND DISASSEMBLY 1) Put large inside diameter end of plastic inner tube (1) in contact with end of shaft (2). * Be particularly careful not to mistake the direction when assembling. 2) Hold metal ring of seal (3) with both hands, Push evenly, and use sudden pushing force to push in, 3) After pushing in seal, remove plastic inner tube (1). Be particularly careful not to damage the seal lip when removing the inner tube. 4) Using tool K, press fit oil seal (3) until seal contacts to housing (4). 10. Gear case cover Fit gasket, install gear case cover (1). * When installing the gear case cover, remove the service meter gear box. After installing gear case cover, install service meter gear box. 11. Breather 1) Fit O-ring, install breather (3). S32 Mounting bolt: 24.5 - 28.4 Nm {2.5 - 3.0 kgm) 2) Install hose (4) and tube (5), then secure with clamps. 13-32 ® GENERAL ASSEMBLY eveoor21 coevo2es 3 ie enz00z23 coe0017§ 621202621202 ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY 12. Front seat Assemble front seal (1) as follows. ‘* Before assembling the seal, check that there is no damage, burrs, flashes, or rust on the housing, sliding surface of the lip and the corner of the end face of the crankshaft. ‘* When assembling the seal, do not coat the shaft or seal lip with oil or grease. If there is, any oil or grease on the shaft, wipe it off completely. * Do not remove the plastic tube inside the standard seal provided as a spare part until oweoo2s immediately before assembling the se: 1) Put large inside diameter end of plastic inner tube (2) in contact with end of crankshaft ly careful not to mistake the direction when assembling. LS 2) Hold metal ring of seal (1) with both hands, push evenly, and use sudden pushing force to push in. 3) After pushing in seal, remove plastic inner tube (2). * Be particularly careful not to damage the seal lip when removing the inner tube. 00231 4) Tighten bolts of tool M uniformly until end face of tool M contacts ends face of crankshaft (3) to press fit seal (1). * When press fitting the seal, be extremely careful not to damage the lip at the PTO ‘end when setting the tool. ‘* After press fitting the seal, remove the red sealant layer from the outside circumference. — coeeona? 13-33 ®ASSEMBLY AND DISASSEMBLY 13. Cam follower v 2 14. Oi! Fit gasket and * 13-34 @ Align cam follower (2) with dowel pin, then tighten mounting bolts (1). 35) Mounting bolt: 44.1 ~ 58.8 Nm (65 - 6.0 kgm) Fit O-ring and install cover. >= Mounting bolt: 9.8 - 12.7 Nm {1.0 - 1.3 kgm} ‘* The mounting botts for the cam follower are fitted with lubrication holes, so check that the holes are clear. cooler assembly all oil cooler assembly (1). ‘When installing thermo vaive, confirm the protrusion amount of spring. Fit spring again when exceeding standard value. Protrusion amount of spring GENERAL ASSEMBLY icm cee00174 cen ceto0233 621202ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY 15. Water pump assembly 1) Fit O-ring and install water pump assembly Q). The mounting botts of the water pump are used to tighten the gear case. 2) Fit gasket and install tube (1). 16. Thermostat housing 7~ 1) Fit O-ring to tube (2), then install to ‘thermostat housing (4). 2) Fit gasket and install thermostat housing (4) with mounting bolts (3). 3) Move tube (2) down and install ring (1). ceE00170 621202 17. Front Install front support (3). %& For trunnion type, fill 20 cc of grease (G2-LI) to groove on mounting face of support (3), ‘then install. 18. Vibration damper, Crankshaft pulley assembly Install vibration damper, crankshaft pulley assembly (2), then tighten with mounting bolt bolt: 245 - 308.7 Nm (25 - 31.5 kgm)ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY 18, Cylinder head assembly 1) Assemble cylinder head assembly as follows. i) Coat valve stem and inside surface of valve guide with engine oil (SAE#30) then assemble vaive (6). fi) Raise cylinder head and assemble lower valve seat (5). t cee001 67 cetonise ii) Install inner valve spring (4) and outer valve spring (3), then assemble upper valve seat (2). iv) Using spring pusher C, compress valve spring and install valve cotter (1). * Tap the valve stem with a plastic hammer to check that the cotter is, completely fitted in the groove of the valve stem. 2) Check that the mounting surfaces of the cylinder head and cylinder block are clean and that there is no dirt or foreign matter inside the cylinder. Set cylinder head gasket (9) in position. %* When installing the gesket, check that the grommets are correctly in place. ceeooase 3) Before tightening cylinder head bolt, make sure as follows. i) Measure the free length a of all bolts ‘and check that bolt length exceeds toler- ‘ance limit or not. Do not reuse any bolt Which has exceeded the tolerance limit. fe Before tightening, measure the free length of bott and check that bolt length exceeds tolerance fimit or not. Ti) Tolerance limit of boit free length: Max. 166.3 mm. * if the bolt length a exceeds tolerance limit, do not reuse. veoe278 621202621202 ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY 4) Install cylinder head assembly (2), then tighten mounting bolts (1). AXXs Mounting bolt: ‘Antifriction compound (LM-P} S3=) Mounting bot: ‘ist step: 137 - 157 Nm {14 - 16 kgm ‘2nd step: 211 — 221 Nm {21.5 - 22.5 kgm} ‘3rd step: 1) When using tool J Tighten bolts further 90 - 120 degrees in tightening order © to © with tool J. (2) ‘When not using tool J Mark the bolt and head with a felttip pen, tum bolt further torque 58.8 - 74.5 Nm {6.0 - 7.8 kgm} after tightening bolts Owe. Pat mark on ertinger war bveoo226 13-37 ®(ASSEMBLY AND DISASSEMBLY 20. Crosshead Install crosshead (1). %& Adjust crosshead as follows. i) Loosen focknut, and loosen adjustment screw. ii) Hold top of crosshead lightly and tighten adjustment screw. ii) Tighten adjustment screw untit it contacts ve stem, then tighten a further 20°. iv) Tighten locknut to hold in position. Ss Lockni ut 53 - 64.7 Nm {5.4 - 6.6 kgm} 21. Rocker arm housing Fit gasket and install rocker arm housing (1). (35) Mounting bolt: ‘58.8 ~ 73.5 Nm {6.0 ~ 7.5 kgm) 22. Push rod Install push rods (1). ‘Check that the push rod is properly fitted in the cam follower. 13-38 ®@ GENERAL ASSEMBLY 621202621202 ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY 23. Rocker arm Install rocker arm (3) and tighten with mounting bolts (2) and (1). % Check that the ball of the adjustment screw is properly fitted into the socket of the push rod. Then tighten bolts. S353 Mounting bolt: 93 - 103 Nm (9.5 - 10.5 kgm} 24. Adjusting vaive clearance Adjust valve clearance as follows. + Adjust the clearance between the crosshead and rocker arm to the following values. Valve clearance (When engine is hot or cold.) Unit: mm Intake valve Exhaust valve 45 0.78 - 0.82 cneeon40 Crank the engine and follow the firing order oR to adjust the valve clearance of each cylinder. Firing order: 1-5-3-6-2-4 1) Rotate the crankshaft in the normal direction to align pointer (2) with the 1.6 ‘TOP mark on vibration damper (1). When rotating, check the movement of the valves. 2) To adjust, insert feeler gauge | between rocker arm (3) and crosshead (4) and turn | adjustment screw (5) until clearance is a sliding fit. ‘ceeDO2« 3) Tighten locknut (6) to hold adjustment screw in position. =D Lock nut: 53 - 64.7 Nm (5.4 ~ 6.6 kgm} After tighteni the clearance a the lock nut, checkASSEMBLY AND DISASSEMBLY 25. Nozzle holder, inlet connector * v 2 3 4) 5) n 13-40 Check that there is no dirt or dust inside the nozzle holder sleeve. Fit O-ring (7), and coat with engine oi (SAEA30). ‘* Check that there is no damage to the O- ting. Install gasket (6) to nozzle holder. Align nozzle holder (5) with mounting hole of inlet connector and insert nozzle holder. Insert inlet connector (2) in rocker arm housing and tighten partially. Fit holder (4), then fit ball washer to ‘mounting bolt (3) and tighten mounting bolt. 52 Holder mounting bolt: 58.8 - 73.5 Nm (6.0 ~ 7.5 kgm} ‘Install one end of the holder to the rocker arm housing, lay on the bolt head and tighten with the bolt. Tighten inlet connector (2), then tighten locknut (1). S3=) Inlet connector: 34.3 - 39.2 Nm {3.5 - 4.0 komt Sas Locknut: 29.4- 34.3 Nm (3.0- 3.5 kgm} Install air compressor pipe bracket. GENERAL ASSEMi CEEDONS 621202621202 ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY 26, Rocker arm housing cover, spill pipe, sit vent tube 1) Fit O-ring and install rocker arm housing cover (3). =] Mounting botts: 147 ~ 34.3 Nem (1.5 - 3.5 kgm} 2) Fit gasket on both sides and install spill pipe (2. wD Joint bolt: 7.8 - 9.8 Nm {0.8 ~ 1.0 kgm) coe09158 3) Fit gasket on both sides and install tube (1). FED Joint bolt: 9.8 - 12.7 Nm {1.0 - 1.3 kgm} vent 27. Flywheel housing 1) Sling fiywheel housing (2), coat mounting surface with gasket sealant, then install on cylinder block and tighten bolts (1), ‘When installing the housing, be careful not to damage the oil seal. Xs Contact surface: Gasket sealant (LG-7) Dds Coat the bolt t with engine oil (SAE#30) before tightening. %* Tighten the mounting bolts of the flywheel housing in the order shawn in the diagram and to the following torques. .-o!|e@ @o|@ * When ‘st step tightening, tighten elo ole iting bolts (1), (4), (2) and (9) by two steps a | eo | @ a= Flywheel housing mounting bolt Jst step: 147 - 235 Nm {15 ~ 24 kgm> @ eB ® @ 2nd step: 245 - 309 Nm (25 - 31.5 kgm) ® @ o © ee step 2nd step 13-47ASSEMBLY AND DISASSEMBLY 2) After installing the flywheel housing, ‘measure the radial runout and face runout gauge @. runout: Max. 0.30 mm. %* Face runout: Max. 0.30 mm 28, Rear seal * Check condition of wear of shaft, then select standard seal or seal with sleeve for Teflon seal (lay-down lip seal) and assemble seal. The condition of wear of the shaft can bt judged from the degree of luster (touch with the flat of your finger to check that the depth of wear is less than 10 ym). If there are no scratches, assemble a standard seal. In all other cases, assemble a seal with sleeve. Procedure for assembling standard seal * Before assembling the seal, check that there no damage, burrs, flashes, or rust on th housing, sliding surface of the lip and the corner of the end face of the crankshaft. ‘* When assembling the seal, do not coat the shaft oF seal fip with oil or grease. if there is any oil or grease on the shaft, wipe it off completely. * Do not remove the plastic tube inside the standard seal provided as @ spare part until immediately before assembling the seal. 1) Put large inside diameter end of plastic inner tube (3) in contact with end of crankshaft (4). % Be particularly careful not to mistake the direction when assembling. 13-42 @® GENERAL ASSEMBLY oOo Ly eeE00045 -: ‘Assombly guide ‘plastic tube) Standerd seo! Seal with steove este petro Lip at engine ond Lip at PTO ena Assembly guide lastic tube) ‘Large inside Smal inside slametor end iometer ond eres 3 P0085 621202621202 ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY 2) Hold metal ring of seal (1) with both hands, push evenly, and use sudden pushing force to push in. 3) After pushing in seal, remove plastic inner tube (3). ‘* Be particularly careful not to damage the } seal lip when removing the inner tube. ceeoo43e 4) Tighten bolts uniformly until end face of tool NI contacts ends face of crankshaft (4) to press fit seal (1). f * Firstly tighten tool N1 bolt NB NE {45 mm) until tool contacts end face of N3 (4500) crankshaft, then tighten with bolt N& NA (25na) (25 mm). * When press fitting the seal, be extremely careful not to damage the lip at the PTO end when setting the tool. : + After press fitting the seal, remove the red sealant layer from the outside corven? circumference. © Procedure for assembling seal with sleeve Before assembling the seal, check that there is no damage, burrs, flashes, or rust on the housing, sliding surface of the lip and the corner of the end face of the crankshaft. %* When assembling the seal, do not coat the shaft, and the space between the sleeve and with oil or grease. If there is any oil or grease on the shaft, wipe it off completely. %* Handle the seal and sleeve as an assembly. Steeve Never separate them. oveooz21 1) Set sieeve/seal (2) to tool NZ. DXe Surface of sleeve inner tul Gasket sealant (LG-7) ‘ND sieeve oweco222 13-43 ®ASSEMBLY AND DISASSEMBLY. 2 3 4 Put sleeve of seal in contact with end face of crankshaft, tighten 3 bolts uniformly until end face of tool NZ contacts ends face of crankshaft (4) to press fit sleeve/seal (2). Remove too! N2 and replace with tool N1. Tighten 3 bolts uniformly until end face of tool NT contacts ends face of crankshaft (4) to press fit steeve/seal (2). % Firstly tighten tool N1 with bolt N3 (45 mm) until too! contacts end face of crankshaft, then tighten with bolt N4& (25 mm). * After press fitting the st red sealant tayer fro circumference. |, remove the the outside 13-44 GENERAL ASSEMBLY 1 ND NB 45ne) NA (2520) 4 ceeooeso 2 NI NB (45mm) f NA (2500) 1 4 EEO0251 621202621202 ASSEMBLY AND DISASSEMBLY 1) Using eye bolt @ (Di . mm), sling flywheel (1), install the flywhee! to the crankshaft, and tighten the mounting bolt. Xe Coat the threads of the bolts and the seat face, with engine oil SAE No. 30 before tightening the bolts. (CE) Flywheel: 60 ko ‘Tighten mounting bolts as follows. S-H=1 Flywheel mounting bolt ist step: 112.7 ~ 122.5 Nm {11.5 ~ 12.5 kgm) 2nd step: 1) When using tool J Tighten bolts further 90 ~ 120 degrees in tightening order © to © with toot J. 2). When not using toot J Mark the bolt and head with a felttip pen, turn bolt further 90 - 120 degree in tightening order @ to ©. ‘Make a punch mark on the bolt head each time the bolts are used. % i there are already five marks on the bolt head, replace with new bolts. GENERAL ASSEMBLY ceeo0nss @ ae oO pots ‘alo a, oO o For construction ‘machine and generator For marine engine oxee Pot mark on tlyeheet it © veoo223 0% Put one punch mark 13-45ASSEMBLY AND DISASSEMBLY * After installing the flywheel, measure the face runout and radial runout using dial gauge @. * Face runout: Max. 0.30 mm % Radial runout: Max. 0.30 mm 30. Suction pipe Fit O-ring, then fit suction pipe (2) and install bracket (1) to the under frame. 31. Oil pan 1) Fit gasket and install oil pan (3). 2) Install drain hose (2). QD Hose clamp: 3.9 - 4.9 Nm {0.4 - 0.5 kgm} 3) Install wiring connector (1) to bracket. 32, Oil filter assembly, oil regulator 1) Fit O-ring and install oil regulator (4). it and install oil filter assembly (3). 33. Fuel fitter assembly « fuel filter bracket 1). Fit O-ring and install fuel filter bracket (2). 2) Install fuel fitter assembly (1). 13-46 GENERAL ASSEMBLY ceP00261 ° 1 Y 0E00155 ceECoIS4 621202621202 ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY 34, PTO case tube, bracket 1) Install fuel injection pump bracket (2). 2) Install turbocharger lubrication inlet tube (1). >= Turbocharger lubrication inlet tube (Bracket side of tube): 24.5 ~ 58.8 Nm (2.5 - 6 kgm) 3) Fit O-ring and install PTO case (3). = Mounting bolt: 107.8 = 122.5 Nm (11.0 - 12.5 kgm} 35. Fuel injection pump assembly 1) Knock key (13) into drive shaft (12) of fuel injection pump. 2) Remove 2 coupling bolts (7) of fuel injection pump, then remove flange coupling (10) and front laminated coupling (6). 3) Install flange coupling (10) and front Jaminated coupling {5) to fuel injection pump drive shaft (12). Do not tighten mounting bolt (11). " cxtoonss a=] Mounting bolt (14) {D1S5AX-3 + LW500-1): 58.8 - 63.7 Nm {6.0 - 6.5 kgm} {HD325 with electronic governor P20: ‘447 ~ 168.6 Nem {15 - 17 kam} {Except above): 63.3 - 93.1 Nm {8.5 - 9.5 kgm) 13-47ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY 4) Align coupling key groove with drive shaft key, push in fuel injection pump assembly (9), align with pin portion of bracket, and set in position. 5) Tighten 4 mounting bolts (8) of fuel injection pump. 6) Tighten connecting bolts (11) of coupling (10) and drive shaft (12). eneeoise ‘=I Mounting bolt (11) {HD325 with electronic governor {KP-21)): 206 ~ 255 Nm (21-23 kgm} {Except above) 83.3 - 93.1 Nm {85-95 kgm} 7) Install lubrication tubes (3) and (4). 8) Install fuel hoses (1) and (2). 36. Adjusting fuel injection pump 2 Under the following conditions, it is possible to increase the setting precision of the crankshaft a angle. % If pin (19) is still in the condition set when 0 shipped from the factory {if front cover (22) and flange (23) have not been removed): 1) Pull out pin (24), then remove nut (15). 621202 2) Rotate the crankshaft in the normal direction, and afign pointer (17) with the fuel injection line (16° position) on damper (16). ‘%* When doing this, check that line (18) on the coupling block is near the line on the pump housing. it cannot be seen, rotate the crankshaft one more turn. e00286 13-48621202 3) Rotate crankshaft and push lock towards engine so that pin (19) enters hole in fuel injection pump drive gear (20). %* When tock pin (19) is fully inserted in the hole in gear (20), the dimension from the tip of lock pin (19) to housing (23) is approx. 6 mm. 4) In this position, check position of line (18) ‘on coupling block and line (21) on pump housing. A Never try to crank the engine by force when the pin is inserted. 5) If the lines in Step 4) are not correct, adjust as follows, i) Loosen bolt (11) and flange coupling bolts and nuts (14) at two places. Rotate coupling block (22) and (21) on fuel injection pump housing with line (18) on coupling block completely. Tighten bolt (11) and flange coupling bolts and nuts (14) again. ==] Mounting bolt, nut (14): (D155AX-3, LW500-1) 58.8 - 63.7 Nm (6.0 - 6.5 kgm) {HD325 Electronic governor specification (KP-21)) 147 ~ 166.6 Nm (15 - 17 kgm) {Other models) 83.3 - 93.1 Nm {8.5 - 9.5 kgm} Mounting bolt (11); (HD325 Electronic governor specification (KP-21)) 206 ~ 226 Nem (21 - 23 kgm} (Other models) 83.3 - 93.1 Nm 18.5 - 9.5 kom) 6) Pull lock pin (19) out from hole in gear (20). If pin (19) is stiff, tighten nut (15) before pulling the pin out. * Pull the pin out completely to 2 point where it does not move. 7) Tighten nut (15). 8) Install pin (24). GENERAL ASSEMBLY ceeoors7 a ceeeonseASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY 37. Fuel injection tube Install fuel injection tube (4). >=] Sleeve nut (Fuel injection pump end) 22.5 - 24,5 Nm (2.3 - 2.5 kgm} 38. After-cooler assembly (Intake manifold assembly) 1) Fit gasket, sling after-cooler assembly (2) and tighten mounting bolts (3). Tighten bolts in order shown in diagram at right. =] Mounting bolt: 58.8 ~ 73.5 Nm {6 - 7.5 kgm) 2) Install clamp (1) of fuel injection tube. h = . i '@OO9 OO OO OOOO: cewooss? 39. Exhaust manifold 1 7 Fit gasket and install exhaust manifold (2), then tighten with mounting bolts (1). — ceeoor6e ‘Firstly tighten mounting bolts in order @ to @ shown in diagram, then tighten other bolts. =) Mounting bolt: 58.8 - 73.5 Nm (6~7.5 kgm) ceeoo2se 621202621202 ASSEMBLY AND DISASSEMBLY 40. Turbocharger a. Fit gasket and install turbocharger (2) with mounting bolts (1). =] Mounting bolt and nut: 44.1 - 49.0 Nm (45 ~ 5.0 kgm} Fuel hose Fit gasket on both sides and install fue! hose (5). 9 and install air compressor mounting plate (4). {If equipped.) 2) Fit O-ring and install air compressor (3), then install lubrication tube (2). (If equipped.) 3) Install dipstick guide (1). . AKternator assembly, pulley 1). Install pulley (10) and tighten with mounting bott (9). 2) Install alternator assembly (6) with bott (1). Temporarily tighten bott (1). 3) Install bracket (8). 4) Install adjustment rod (7) with bolts (2) and 3. + Temporarily tighten bolts (2) and (3) + Loosen 2 adjustment nuts (4), 5) install alternator belts (5). 6) Adjust belt tension with adjustment nuts (4) ‘that deflection is 13 - 16 mm when pushed with a force 98 N (10 kg). 7) Tighten bolts (1), (2) and (2). GENERAL ASSEMBLY coeoor4sASSEMBLY AND DISASSEMBLY. 44. Fan pulley assembly Install fan pulley assembly then secure with bolts m, 45. Tension pulley assembly 1) Install tension pulley assembly (5) with mounting bots (4). 2) Set fan belt (3) on groove of pulley. 3) Adjust fan belt tension with tightening adjustment bott (2) and move tension pulley toward outside that deflection is 13 - 15 mm (new belt) or 17 - 19 mm (when tension adjustment) when push a force 98 N {10 kg) at middle of fan belt (3), then tighten locknut (1), (Machine without auto-tension) 48. intake connector 1) Fit gasket to electrical intake air heater (5) and intake connector (4), then install with ‘mounting bolts (3). 2) Install turbocharger lubrication inlet tube (2), ‘and secure with clamp (1). 47. Mutter bracket, air cleaner bracket Install muffler bracket (2) and air cleaner bracket a. 13-52 ® GENERAL ASSEMBLY cecooius ceeno4s coeo0138 621202621202 ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY 48. Corrosion resistor 1) Install air compressor tubes. (if equipped) a a 3 2) Install tubes (4) and (5). 3) Install corrosion resistor assembly (3). 4) Install hoses (2) and (1). 4 coeeorse 49. Reseting engine in engine stand ) Sling engine assembly, remove bolts connecting too! A and tool B to disconnect engine assembly. 2) Set engine assembly on engine stand or block. 3) Remove tool A. 50. Turbocharger drain tube Fit gasket and install turbocharger drain tube a. 51. Starting motor Fit gasket and install starting motor (2) with mounting bolts (1). eE00135 13-53 ®ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY 82. Air cleaner, muffier 1) Install exhaust connector (9). 2) Fit gasket and install muffler (8) with ‘mounting bolts (6), then secure with band a. 3) Fit gasket and install valves (5). 4) Install air cleaner (4) and install hose (2) between air cleaner and turbocharger and hose (1) between air cleaner and muffier, then tighten mounting bolt of band (3), >= Band mounting bolt: 9.8 - 11.76 Nm {1.0 - 1.2 kgm} coeaons3 5) precleaner (11) to air cleaner body (10). ‘* Tighten until clearance a is 0. n ” ee00260 53, Refilling with oi! 1) Check that engine drain plug is tightened. 2) Add engine oil through oil filler to the specified level. 4B Engine oil pan: Approx. 37 £ 621202