Usage:
Start By:
a. remove rocker shaft and push rods
b. remove fan and fan drive
c. remove exhaust manifold
Typical Example
1. Remove breather tube (1) and disconnect wire (2) from sending unit.
Typical Example
2. Loosen four hose clamps and slide hose (4) on tube assembly and disconnect hose from elbow valve (3).
3. Disconnect wire (6) from sending unit and remove four bolts and elbow (5) from the water pump.
4. Remove tube assemblies (8) and (9) and disconnect wires from sending unit (7).
5. Disconnect hose (11) from precleaner. Remove precleaner (10) from air cleaner.
6. Disconnect hose assembly (12) from pipe assembly. Remove the bolts that fasten air cleaner (13) to bracket (15) and brace (14). Remove air cleaner (13).
7. Remove bolt (17) that holds clip on tube assembly. Remove tube assembly (16) between the aftercooler and the air fuel ratio control.
8. Remove hoses and wiring harnesses that are fastened to the aftercooler.
9. Install a hoist in position on the cylinder head lift brackets.
10. Remove head bolts (19), cylinder head (18) and head gasket from the engine block. The weight of the cylinder head assembly is 134 kg (295 lb.).
| NOTICE |
|---|
Do not set the cylinder head on a flat surface because of possible damage to the fuel injection nozzle tips. |
11. Remove water seals (21) and O-ring seal (20) from the spacer plate. Remove spacer plate (22).
| NOTICE |
|---|
Do not damage the dowels as the spacer plate is removed. |
12. Remove O-ring seal (23) and spacer plate gasket (24) from the cylinder block.
Install Cylinder Head And Spacer Plate
NOTE: When the cylinder head is removed, a new spacer plate gasket and cylinder head gasket must be installed.
1. Thoroughly clean the spacer plate and the cylinder block surface.
2. Install a new spacer plate gasket (3).
3. Install a new O-ring seal (2) on dowel (1).
NOTE: If dowel (1) has been removed for any reason, the overall installation height is 16.0 ± 0.5 mm (.630 ± .020 in.).
4. Install spacer plate (6).
NOTE: Both surfaces of spacer plate, top of cylinder block and both sides of spacer plate gasket must be clean and dry. Do not use any adhesive or other substances on these surfaces.
5. Install a new O-ring seal (4) on dowel (1).
6. Install new water seals (5) in the spacer plate.
7. Check the cylinder liner projection. See the topic, INSTALL CYLINDER LINERS.
8. Fasten a hoist to the cylinder head and put head gasket (8) and cylinder head (7) in position on the cylinder block.
9. Put 2P2506 Thread Lubricant on all the head bolts and rocker shaft bolts except bolt (25).
NOTE: Do not tighten bolts at this time.
10. Loosen the adjusting screws on the rocker arms for valve clearance. This will prevent a bent valve or push rod at installation.
11. Install push rods and rocker shaft assembly (9). Install the bolts and washers that hold the rocker shaft in place.
12. Tighten the bolts as follows:
a. Tighten bolts 1 through 26 in number sequence to a torque of 155 N·m (115 lb.ft.).
b. Tighten bolts 1 through 26 again in number sequence to a torque of 250 ± 17 N·m (185 ± 13 lb.ft.).
c. Tighten bolts 1 through 26 again in number sequence (hand tighten only) to a torque of 250 ± 17 N·m (185 ± 13 lb.ft.).
d. Tighten bolts A through G in letter sequence (hand tighten only) to a torque of 43 ± 7 N·m (32 ± 5 lb.ft.).
13. Make an adjustment until the intake valve clearance is 0.38 mm (.015 in.) and the exhaust valve clearance is 0.64 mm (.025 in.). Tighten the locknuts (5) for the adjusting screws to a torque of 29 ± 7 N·m (21 ± 5 lb.ft.).
14. Install a new gasket on the valve cover if needed. Put 5H2471 Cement on the contact surfaces of the gasket and valve cover when a new gasket is installed.
15. Put valve cover (10) in position on the cylinder head. Install the bolts that hold the valve cover in place. Tighten the bolts in the sequence shown to a torque of 11 ± 3 N·m (8 ± 2 lb.ft.).
16. Install tube assembly (12) from aftercooler to air fuel ratio control. Install hoses and wiring harness (11) on the aftercooler.
17. Install air cleaner (14) on bracket (16) and brace (15). Connect hose assembly (13) to pipe assembly.
18. Install precleaner (17) on air cleaner. Tighten bolt to a torque of 25 ± 7 N·m (20 ± 5 lb.ft.). Connect hose assembly (18).
19. Install tube assemblies (20) and (21). Connect wiring harness to sending unit (19).
Typical Example
20. Install a new gasket between elbow and water pump and a gasket between elbow (23) and head. Install three hoses (22) in position and tighten clamps. Connect wire (24) to sending unit.
Typical Example
21. Install oil breather cap (25). Tighten bolt to a torque of 14 ± 3 N·m (10 ± 2 lb.ft.). Install breather tube (26) on breather cap. Install wire (27) on sending unit.
End By:
a. install fan and fan drive
b. install exhaust manifold