T C M sHOPMANUAL

••
3
. ENGINEASSEMBLYI
(DISASSEMBLY)

TABLEOFCONTENTS

ITEM PAGE

Externalpar
tsdisassemblysteps….
..
・ ・ .
..
.
..
..
..
.・ ・.
..
.
.
・ ・ .
..
.
.
・ ・ .
..
.
.
・ ・ ..
….
..
・ ・ .
.
..
.
..
・ ・..
・ ・..
.
.
.・ ・.
..
.
.・ ・.
..
.
.・ ・.. 42
.

•
H H H H H H H H H H H

Majorcomponents・ ………..
..・ ・.
.
H.
.
・ ・.
H.
.
..
..
.
・ ・ ..
.
..
..
.
..
・ ・ ..
.
H.
…・…
..
...
..
...
..
..
..
H.
..
...
..
...
..
..
..
...
..
...
..
...
..
..
..
...
..
...
..
...
..
.. 45
Rockerarmandr ocke
rarms haftdisassemblysteps. ・ ・..
.
.
.・ ・..
….
..
・ ・ .
.
..
.
・ ・・・ ..
….
.
H.
・ ・ .
.
.
..
・ ・
H .
.……
...
・ ・ . 49
. H H H H H H H

Cylinderheaddisassemblysteps.・ ・・・H..
.
..
・ ・
H .
.…
H…
...
・ ・ ..
H…
……..
.・ ・ .
.
..
.
・ ・ .
.
..
.
・ ・
H..
.
.
.・ ・..
.
..
・ ・ .
.………
...・ ・.. 50
. H H H H H H

Pistonandconnectingroddisassemblysteps… ……..
...・ ・..
.
..
.
・ ・ .
.
..
.
・ ・ -・
…….
..・ ・・・ .
.
H.
.
.・ ・・・ ..
.
.
.・ ・
H ..
…….. 51 H H H H H H H H

•
•

•• -41 ・
T C M sHOPMANUAL
固 EXTERNALPARTSDISASSEMBLYSTEPS
(Right-hands
ide
)
••
MODEL6BG1TPL

3 8 7 4

13

•
•
1

•
14 9 1
2

DisassemblySteps 9
.O i
lp ip
e;i nje
cti
onpumpt ocyl
ind
er
body
1
. Coolingf a
n
1
0. Noti n
stalle
d
2
. Noti ns
talled
1
1.O i
lp ipe
;f i
lte
rtooi
lcool
er
3
.I ntakepipe
企 1
2.I nje
ctionpumpw ithi
njec
tio
npump
4
. Fuelr et
urnp ip
e
gear
5
. Fuelp i
pe;f u
elfil
te
rtoinj
ecti
onpump
1
3. Fuelfil
ter
6
. Fuelp i
pe;feedpumpt ofil
te
r
7
.I nje
ctionnozzleandl e
akoffpip
e 1
4.O i
lf i
lt
er
1
5. Glowp lug

••
8
.I nje
ctionpipe

-42・
 T C MsHOPMANUAL
•• v ImportantOperations
1
2.I
nje
cti
o
Uset
nPumpwithI

the i
h
n
es
j
ec
h
t
i
i
o
p
pin
nje
cti
onPumpGear
gplugs(orsomethings
npumpdeliveryvalvep o
r
i
t
m
i
s
la
r)t os
e
. Thisw
a
i
l
l
l
preventtheent
ryoffore
ignmateria.
l
FlangeMountedI
nje
cti
onPumpRemoval
1
) Removet
hei
nje
cti
onpumpf
lan
geb
olt
s.
2
) Pul
ltheinj
ect
ionpumpw
iththei
nje
cti
onpumpd
riv
e
gearf
ree
.
Refert
oth
eil
lus
tra
tio
n.
CouplingMountedI
nje
cti
onPumpRemoval
1
) Removethetwocoupling b
olt
stodisconnectthe
co
upl
ing
.

•
2
) Removet
hei
nje
cti
onpumpmountingb
olt
s.
3
) Removeei
the
rth
ei n
ject
ionpumpb
rac
ketb
olt
sorthe
in
jec
tio
npumpfi
xin
gb o
lts.

Removeo
ftheA
irCompressor(
i
fsoequipped)
Beforetheai
rcompressorisremovedtheinjec
tio
npump
mustbeunfastenedfromthemountingbrackettopermit
thepumpt obemovedf re
elyonthemountingbracket
.

• 1
. Removet
2

3
th
h
. Removet
h
epumpt
ei
n
ei
ot
h
j
n
e
c
j
e
er
. Removethea
i
t
c
i
o
t
i
e
a
npumpcouplingb
o
rabout50m m(
o

2i
l
npumpmountingb
o
n
)
s②.
t
l
.
t

rcompressormountingb
o
sands

ls①.
t
hif
t

4
. P
ulloutt h
ecompressort otherearabout50m m( 2
i
n)topul
louttheaircompressorcrankshaftf
ron
tend
s
plinefromthein
ject
ionpumpd rivegear.

• Mark
5
. A

d
f

r
t

i
rremoval，v
e
ends
v
plin
eandt
egears
importantf
h
o
af
is
h
ua
ll

thavef
ymakesuret
efemales
itt
i
rreassembly.
n
pli
neo
hatthecrankshaft
ftheinj
ect
ionpump
gmarks. Thosemarksare

•• -43・
T C M sHOPMANUAL
図 EXTE聞聞凹
刊R~
R 剛附れ陥~\\、
l、h
(
Lef
thands
圃 ide
)
••
MODEL6BG1TPL

10 1 3 6 7 12

1
1
•
9 4 5 8 •
DisassemblySteps
1
.D ipst
ickandguidetube 7
. Gasket

•
2
.A irbreather 8
.S tarter
3
. Turboadaptor 9
. Fanb elt
4
.O i
lfeedp ip
e 1
0. Generator
5
.O i
ld rainpipe 1
1. Fanp ulley
..6
. Turbocharger 1
2. Cylinderheadcover

v ImportantOperations
6
. Turbocharger
Plugoilp
ort
sinturbochargerbodyimmediatelya
fte
r
removaloft
heturb
ocharger.

-44 ・
••
. 7 C M SHOPMANUAL
MAJORCOMPONENTS-1

•
3

•
7

•
14
12¥

• 11 て¥、
10¥)...¥
..
'h

13 合

合: R
epa
irk
it

DisassemblySteps
1
. Rubberhose;waterby-pass 9
.O i
lpumpd ri
vingpin
ion
企 2
. Rockerarms ha
ftassembly 企 1
0.S tart
inghandlenut
3
. Pushrod 企 1
1.Taperbushing
企 4
. Cylinderheadbol
t 1
2. Crankshaftpu
lleyanddustthrower
5
. Cylinderheadassembly 1
3. Timinggearcover
1
4.O i
lthrower

••
6
. Cylinderheadgasket
7
. Waterpumpassembly 企 1
5. Flywheel
8
. Tappetchambercover

-45・
T C M sHOPMANUAL
v ImportantOperations
2
. RockerArmShaft
Loosentherockerarms
timei
ha
ftfi
x
nnumericalsequenceass
i
p
n
e
c
gb
if
i
o
e
l
t
d
sal
.
it
tl
eata
••
4
. CylinderHead80lts
Loosent hecylin
derheadbol
tsal i
tt
leatatimei
nthe
numericalordershownintheiIu
strat
ion
.
C
yli
nde
rheadb
oltwrench:1・85111・003・0
4・ 圏
•
Front

園
1
0. CrankshaftPulleyNut
Wrench:54m m(
2.1
3in
)
Useana
ppr
opr
iat
ewrencht
oremovethecrankshaft
山 ynu.
t .

1
1. Taper8ushing
圏 Remover:9・8521・0122・0
Use the taper bushing remover t
cr
ank
s ha
ftendtaperb ushi
n g
.
o remove the

•
T
e
b
ro

n
u
叩m

S
hH

内初、
'
v
同

1
5. Flywheel
Loosentheflywheel bol
ta li
tt
lea
ta time i
n the
numericalorderass
pec
ifie
d.

-46・
••
. 7 C M S H O PMANUAL
MAJORCOMPONENTS-1

•
3

•
4

•
• 6 合

合 :R
epa
irk
it

DisassemblySteps
1
.O i
lcooler 9
. Timinggearcase
2
.O i
lpan 1
0.I dl
ergears haf
t
3
.O i
lpumpandcoupling 企 1
1.Crankshaftbearingcap
4
. Flywheelhousing 1
2. Crankshaftbearing(Iowerh
alf)
5
.P istonandconnectingrod 1
3. Thrustbearing
• 6
.I dl
ergear 1
4. Crankshaft
企 7
. Camshaft 1
5. Crankshaftbearing(upperhal
f)

•• 8
. Tappet

-47・
1
6.O ilin
gj e
t
T C M sHOPMANUAL

V圏
ImportantOperations
6
. I
dle
rGear
Measuret
hef
oll
owi
ngp
oin
tsbeforedisassembly.
m m(i
n)
••
---ー『
Standard L
imit
I
dle
rGearEnd 0.128・ 0.185 0.2
P
lay (0.005 0.0070)
・ (
0.00
8)

n
m
m
一
一
-
園

t- 勾
m一日m
t﹂一 ・
Standard

t
・ nU
TimingGears 0.10・ 0.17
Backlash (0.004 0.007)
・

Inc
ludesth ，thecamshaftgear，and
ecrankshaftgear
t
hei d
lerg
ear. _

C
，!m
sha
ftg
ear
園 7
. Camshaft
Measuret
hef
oll
owi
ngp
oin
tsbeforedisassembly.
m m(
in)

CamGearEnd
Pl
ay
Standard
0.050 0.114
・

(0.002 0.005)
・ (
0
L
imit
0
.
.
2
00
8) •
圏 1
1. CrankshaftBearingCap

•
Measurethec
ranks
haftendp layatt hethr
ustbearing
(ce
ntermainbea
ring)beforedisassembly.
m m(
in)
-
-・・
-
E-
-，
Standard L
imit
CrankshaftEnd 0.15-0.33 0.4
Play (0.006・ 0.014) (
0.0
16)

-48 ・
••
. T C M釧OPMA肌
.回
L
ヲJ ROCKERARM，
I ANDROCKERARMSHAFT
DISASSEMBLYSTEPS

•
•
• DisassemblySteps
1
. Bracket 3
. Spring
2
. Rockerarm 4
. Rockerarms
haf
t

•• -49
・
T C M 5HOPMANUAL
図 CY山 DERHEADDISASSEMBLYSTEPS
••
2 r/

•
5
10 *
:Repairkit
•
DisassemblySteps
1
. Exhaustmanifoldandgasket
2
.I
3
4

企 6
.S
n

p
t

l
i
ak
emanifoldandgasket
. Watero

tco
u

l
t

l
a
l

r
e
tpipe
. Thermostat
5
. Thermostathousingandgasket
7
8
9
1
0
1
1
. Springseat(
. Valvesprin
g
. Springseat(
. Valve
. Valvestemoi
u

I
p

o
w

ls
p

e
e
r

a
)o

l
r*Valver
(
i
ota
tor
fsoequipped)
•
V圏

ImportantOperation
6
. S
pli
tco
lla
r
Usethevalves
pri
ngcompressort
oremovethes
pli
t
co
lla
r.
ValveSpringCompressor:1・85235-006・0

Val
帽 s ∞mpr
pring 借関『

-50 ・
••
 T C M SHOPMANUAL
•• ττ1PISTONANDCONNECTINGROD
L
.:
.
.JDISASSEMBLYSTEPS
!

'
。~
3

•
• 5

• 企 1
.P
DisassemblySteps
is
tonri
ngs 4
.P isto
n
企 2
. Snapri
ng 5
. Connectingrodbearing
.
..3
.P is
tonpi
nandconnectingrod

•• -5
1・
T C M sHOPMANUAL
v ImportantOperation
Note:
Removeanycarbondepositsfromtheupperp
cy
lin
derb
ore
.
arto
fthe
••
Thisw
il
lpreve
ntdamagetothepis
tonandthepi
sto
nri
ngs
whentheyareremovedfromthecyl
ind
erbor
e.

1
. PistonRings
図 Useap
ist
onr
ingremovert
oremovet
hep
ist
onr
ing
s.
Donotattemptt lP
ousesomeothertoo. istonrin
g
st
ret
chi
ngwil
lr e
sul
tinreducedp
ist
onringtensio
n.
P
ist
onr
ingremover:

2，
•
図
3.SnapRingandPistonPin
(
1) Useap
airo
fsnapr
ingp
lie
rst
oremovethesnapr
ing
.

•
(
2) Tapt
hep
ist
onp
ino
utw
ithahammerandbrassb
ar.
P
ist
onpin

¥¥
•

ー52・
••