面向飞轮左手边的凸轮轴: 面向飞轮右手边的凸轮轴

1.校正凸轮轴孔
6.校正凸轮轴定位销
2. 校正凸轮轴定位销

面向飞轮左手边的凸轮轴壳下端:
1. 飞轮壳
2. 速度/正时传感器连接头
3. 速度/正时传感器

安装时注意密封圈有无损坏

1. -0465 Push-Puller Plate.

2. 1P-2403 Dial Indicator.
3. 1P-2402 Gauge Body. Measuring The Cylinder Liner
4. 0S-1575 Bolt and 3B-1925 Washer.(Copper) Projection
5. Space plate.
3H
6. 1U-9895 Crossblock.
Note: Cylinder surface must be clean.
Step 1: Install gasket and spacer plate
using 4X 0S-1575 Bolt /3B-1925 Washer(4).
Evenly torque 95N Nm(70lb ft.)
2: Install cyl liner w/o seal or band
3: Install 1U-9895 Crossblock.(6) at the center
4: Install 3H-0465 Push-Puller Plate(1)
and 2X8F-6123 bolts.
evenly torque 95N Nm(70lb ft.)
5: Use 8T-0455 Liner Projection Tool Group
to measure the cylinder liner projection
6: Mount 1P-2403 Dial Indicator(2) and 1P-2402 Gauge Body
use the back of the 1P-5507 Gauge Block to set zero dial indicator.
7: The cylinder liner projection must be 0.059 to 0.199mm(0.0023 to 0.0078 inch)
Note: Max. allowable difference between the four positions around each cylinder liner is
0.05mm(0.0002 inch) must not exceed on the same liner.
 Unit Injector Timing Adjustment

9U-5132 ENGINE TIMING TOOL GROUP:

included below:
1. 9U-5137 Magnetic Fixture.
2. 122-0451 Timing Fixture Rod.
3. 122-0449 Rod Sleeve Extension.
4. 9U-5138 Setting Gauge 7. Injector follow
5. 6V-3075 Dial Indicator 8. Shoulder
6. 8S-3675 Indicator Contact Point.

Valve Bridge Adjustment: 6-7 procedure

 Valve Bridge Adjustment:
147-5482 VALVE LASH GAUGE GROUP:
If use the Valve Lash Gauge Group no need to
remove the Rocker Arm Shaft Assembly

Valve and Valve Bridge Adjustment:

1. 147-2060 Wrench. 3
2. 147-2059 Torque Wrench.
3. 148-7211 Bridge Nut Socket.
4. 145-5191 Gauge Support.
5. 147-5537 Dial Indicator. ( Metric)
or 147-2056 Dial Indicator. ( English)
Top Edge of the Valve Bridge:
3. 147-5536 Indicator Contact Point.
6. 147-5536 Indicator Contact Point.
7. 147-2057 Indicator Contact Point.
8. 147-2058 Indicator Extention.

1
a) Loosen locknut for the adjustment screw and
Adjustment Screw( 5 ) by several turns.
b) Apply force of 5 to 45 Nm (1-10lb) push down
the top contract surface of the Valve Bridge.
145-5191 Gauge Support. c) Turn adjustment screw( 5 ) CW direction until the
1. Knurled Knob. Dial Indicator reads 0.038mm.

2 5

2. Valve Cover Base Rear Bolt Hole Hold Adjustment Screw(5) with 148-7211 Bridge Nut
Socket.(6) and tighten the locknut to30  4Nm(22  3lb ft.)

Valve Lash Adjustment 6-7 procedure

6
7

Install the 145-5191 Gauge Support.(1) Use

the 147-5537 Dial Indicator and 147-2057 Move the Rocker Arm Assembly upward and
Indicator Contact Point(2) and install the tool downward several times to get the zero reading on
in the rear bolt located on the Valve Cover the dial indicator.
Base Use 147-2060 Wrench(3) and 147-2059 Torque
Wrench(4). Apply upward pressure to the front of
the rocker arm and set the dial indicator to zero.
Loosen the locknut on the adjusting screw of the
push rod and turn the adjustment screw until the
valve lash is set to the specification.
Tighten the locknut for the adjustment screw to
70  15Nm(50  11 lb ft.)

Cylinder Head Tighten Procedure

Step 1: Tighten bolts 1 to 8 in the number sequence: Torque 30  5Nm(22  4 lb ft.)
Step 2: Tighten bolts 1 to 8 in the number sequence: Torque 200  15Nm(148  11 lb ft.)
Step 3: Tighten bolts 1 to 8 in the number sequence: Torque again 200  15Nm(148  11 lb ft.)
Step 4: Tighten bolts 9 and 19: Torque 55  0Nm(40  7 lb ft.)

1. Angle of the Valve face:

Inlet: 19.400.25 degree
Exhaust: 44.400.25 degree
2. Angle of face of Valve seat
insert:
Inlet: 200.25 degree
Exhaust: 450.25 degree

Remove/Install Piston Ring Tools

1. Top Ring
2. IntermediateRing
3. Olil Control Ring.
4. Piston Pin Bore.
5. Pin.
6. Retainer.
 Service Tools
Items Part No: Description
1 6V-4040 Piston Ring Expender Group
2 6V-4023 Handle Assemly
3 6V-4024 Guide Ring
4 1P-1861 Retaining Ring Pliers
5 1U-7616 Piston Ring Compressor Group
6 246-1176 Piston Ring Groove Gauge Gp-1
7 1U-6431 Piston Ring Groove Gauge Gp-2
Note: 197-0560 Piston Pin is not interchangeable with other pistons and connecting
rods.

Remove and Install Crankshaft Seal Procedure

1. Flywheel Housing.
2. Front Housing.
3. 113-8433 Crankshaft Seal Group
–Flywheel Housing .
4. 113-8432 Crankshaft Seal Group
–Front Housing
5. Crankshaft Seal deph.
6. Wear sleeve.
7. Wear seal depth.

Step 1: Use 5P-7409 Sleeve Distorter and 6V3143 Distorter Adapter to remove the wear sleeve (6).
Note: Do not separate the new wear sleeve(6) from crankshaft seal(3) or (4).
Step 2: Use 169-5464 Quick Cure Primer (Aerosol Spray) to clean crankshaft outer surface and wear
sleeve surface.
Step 3: Put a thin coat of 4C-9507 Retaining Compound on the crankshaft outer surface and wear
sleeve surface.
Step 4: Install the new wear sleeve(6) of crankshaft seal(3) or (4) as a unit with correct crankshaft seal
Front or Rear installation tool.

Install Front Housing

Torque for ½ -13NC bolts - 70  5Nm(50  4 lb ft.)
Torque for 5/8 -13NC bolts - 215  40Nm(160  30 lb ft.)
Front Housing Bolt Lenght
Bolt Dia inch Qty Part No: mm inch
1/2 1 4 9H-8260 158.75 6.25
1/2 2 4 0S-1587 44.50 1.75
5/8 3 8 1D-4593 139.70 5.50
 Install Flywheel Housing
Torque for ½ -13NC bolts - 135  20Nm(100  15 lb ft.)
Torque for 5/8 -13NC bolts - 270  40Nm(200  30 lb ft.)
Flywheel Housing Bolt Lenght
Bolt Dia inch Oty Part No: mm inch
A 6 9X-8873 57.20 2.25
B 4 9X-8875 88.90 3.25
9M-7269 171.50 6.75
C 1/2
2 6M-9613 228.60 9.00
D 9S-1374 203.20 8.00
E 4 8S-9089 114.30 4.25
F 5/8 16 1D-4590 120.70 4.75