Content

Safety cautions

General

• Outline
• Specifications
• Tips on disassembly and reassembly

Maintenance standards

• Maintenance standards table
• Tightening torque table
• Sealants and lubricants table

Special tools

Overhaul instructions

• Determination of overhaul timing
• Testing compression pressure

Preparation for disassembly

Disassembly of main engine parts

• Cylinder head and valve mechanism
• Flywheel
• Damper, timing gears and camshaft
• Pistons, connecting rods, crankshaft and crankcase

Inspection and repair of main engine parts

• Cylinder head and valve
• Flywheel, camshaft and timing
• Crankcase, pistons, connecting rods, crankshaft and tappets

Reassembly of main engine parts

• Crankcase, tappets, crankshaft, pistons and connecting rods
• Timing gears
• Flywheel
• Cylinder head and valve mechanisms

Removal of fuel system

• Fuel filter and fuel pipes
• Fuel injection pipes, fuel leak-off pipes and fuel injection nozzles
• Fuel injection pump

Disassembly, inspection and reassembly of fuel system

• Fuel filter
• Fuel injection nozzles

Removal of lubrication system

• Oil filter and relief valve
• Oil cooler
• Oil pump, oil pan and oil strainer

Disassembly, inspection and reassembly of lubrication system

• Oil pump
• Oil cooler
• Oil filter
• Relief valve
• Safety valve

Installation of lubrication system

• Oil pump, oil pan and oil strainer
• Oil cooler
• Oil filter and relief valve

Removal of cooling system

• Cooling fan, fan pulley and v-belt
• Thermostat
• Water pump

Disassembly, inspection and reassembly of cooling system

• Thermostat
• Water pump

Installation of cooling system

• Water pump
• Thermostat
• Cooling fan. Fan pulley and v-belt

Removal of inlet and exhaust systems

• Turbocharger
• Inlet manifold
• Exhaust manifold

Disassembly, inspection and reassembly of inlet and exhaust systems

• Inlet and exhaust manifolds

Installation of inlet and exhaust systems

• Exhaust manifold
• Inlet manifold
• Turbocharger

Removal of electrical system

• Starter
• Alternator
• Glow plug

Disassembly, inspection and reassembly of electrical system

• Starter
• Alternator
• Magnetic valve (stop solenoid)
• Glow plug

Installation of electrical system

• Glow plug
• Alternator
• Starter

Inspection, adjustment, break-in operation and performance tests

• Adjustment of engine
• Break-in operation
• Performance tests

Others

• Disassembly and reassembly of general parts