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Engine Manual

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272 views5 pages

Engine Manual

Uploaded by

kefiyalew agegn
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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GENERAL REPAIR INSTRUCTIONS

1. 2. 3. 4. 5. 6.
2. Use fender, seat and floor covers to keep the vehicle clean and prevent damage.
3.
During disassembly, keep parts in order to facilitate reas sembly. Observe the following: (a) Before
performing electrical work, disconnect the negative ( —) cable from the battery terminal. (
b) If it is necessary to disconnect the battery for inspec tion or repair, always disconnect the cable
from the negative ( —) terminal which is grounded to the vehi cle body.
(c) To prevent damage to the battery terminal post, loosen the terminal nut and raise the cable
straight up with out twisting or prying it.

(d) Clean the battery terminal posts and cable terminals with a shop rag. Do not scrape them with a file
or other abrasive object.

(e) Install the cable terminal to the battery post with the nut loose, and tighten the nut after
installation. Do not use a hammer to tap the terminal onto the post.
(f) Be sure the cover for the positive ( + ) terminal is properly in place. Check hose and wiring connectors
to make sure that they are secure and correct.

Non-reusable parts
(a) Always replace cotter pins gaskets, O-rings, oil seals, etc. with new ones.
(b) Non-reusable parts are indicated in the component illustrations by the

TROUBLESHOOTING
Diesel Engine Diagnosis
GENERAL 1. 2.
Diesel engine problems are usually caused by the engine or fuel system.
The injection pump is very rarely the cause of fuel system problems.
Before beginning fuel system tests, first check that the engine compression, valve timing and other
major systems are within specifications.

PRELIMINARY CHECKS
1. Before performing fuel system checks, ensure that the engine is in good running condition.
2. If necessary, first check the compression, timing and major components or systems.
3. Check the air filter, and clean or replace it if necessary.
4. Check that there is sufficient fuel in the tank.
5. Check if the fuel is contaminated with gasoline or other foreign elements.
6. Only good-quality diesel fuel should be used.
7. Bleed air from the system by pumping the priming.
8. Check for water in the fuel filter and fuel tank, and drain as necessary.
9. If the engine will not crank or if it cranks slowly, first troubleshoot the electrical system

REMOVAL OF CYLINDER HEAD

. DRAIN ENGINE COOLANT


. REMOVE INTAKE PIPE
. REMOVE INJECTION PIPES
. REMOVE OIL DIPSTICK AND OIL DIPSTICK GUIDE
. REMOVE INTAKE MANIFOLD
. REMOVE WATER OUTLET
. REMOVE NOZZLE LEAKAGE PIPE
. REMOVE INJECTION NOZZLES
. REMOVE GLOW PLUGS
. REMOVE EXHAUST MANIFOLD
. REMOVE TURBOCHARGER AND EXHAUST MANIFOLD ASSEMBLY
. SEPARATE EXHAUST MANIFOLD
. REMOVE CAMSHAFT OIL SEAL RETAINER
. REMOVE CAMSHAFT
. REMOVE CYLINDER HEAD
DISASSEMBLY OF CYLINDER HEAD
. REMOVE VALVE LIFTERS
. REMOVE VALVES
. REMOVE COMBUSTION CHAMBERS
. REMOVE HALF CIRCULAR PLUG

INSPECTION, CLEANING AND REPAIR OF CYLINDER HEAD COMPONENTS


.CLEAN TOP OF PISTONS AND TOP OF BLOCK
. REMOVE GASKET MATERIAL
. CLEAN COMBUSTION CHAMBERS
. CLEAN VALVE GUIDE BUSHINGS
. CLEAN CYLINDER HEAD
. INSPECT CYLINDER HEAD FOR FLATNESS
. INSPECT CYLINDER HEAD FOR CRACKS
. CLEAN VALVES
. INSPECT VALVE STEMS AND GUIDE BUSHINGS
. IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS
. INSPECT AND GRIND VALVES
. INSPECT AND CLEAN VALVE SEATS
. INSPECT VALVE SPRINGS
. INSPECT CAMSHAFTS AND BEARING
. INSPECT INTAKE AND EXHAUST MANIFOLDS

INSTALLATION OF CYLINDER HEAD

. Select new cylinder head gasket


. INSTALL CYLINDER HEAD
.INSTALL CAMSHAFT
. ADJUST VALVE CLEARANCE (Valve clearance (Cold):
Intake 0.15-0.25 mm (0.006-0.010 in.)
Exhaust 0.35-0.45 mm (0.014-0.018 in.)
. INSTALL PULLEYS AND TIMING BELT
ASSEMBLY EXHAUST MANIFOLDS
. INSTALL EXHAUST MANIFOLD
. INSTALL TURBOCHARGER AND EXHAUST MANIFOLD
. INSTALL GLOW PLUG
. INSTALL INJECTION NOZZLES
. INSTALL NOZZLE LEAKAGE PIPE
. INSTALL WATER OUTLET
. INSTALL INTAKE MANIFOLD
. INSTALL OIL DIPSTICK GUIDE AND OIL DIPSTICK
. INSTALL INJECTION PIPES
. INSTALL INTAKE PIPE
. FILL WIT ENGINE COOLANT
. START ENGINE AND CHECK FOR LEAKS
. RECHECK ENGINE COOLANT LEVEL AND OIL LEVEL

CYLINDER BLOCK

. PREPARATION FOR DISASSEMBLY


. REMOVE FLYWHEEL
. REMOVE DRIVE PLATE AND FLYWHEEL
. REMOVE REAR END PLATE
. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
. REMOVE TIMING BELT AND PULLEYS
. REMOVE CYLINDER HEAD
. REMOVE WATER PUMP
. REMOVE ALTERNATOR
. REMOVE TIMING GEARS
. REMOVE INJECTION PUMP
. REMOVE OIL PAN AND TIMING GEAR CASE (OIL PUMP)
. REMOVE OIL COOLER
. REMOVE WATER INLET AND THERMOSTAT
. REMOVE WATER INLET AND THERMOSTAT
. REMOVE ENGINE MOUNTING

DISASSEMBLY OF CYLINDER BLOCK

REMOVE CONNECTING ROD CAPS


. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES
. REMOVE MAIN BEARING CAP
. REMOVE CRANKSHAFT
. REMOVE CHECK VALVES AND OIL NOZZLES
. REMOVE CYLINDER BLOCK OIL HOLE GASKET

INSPECTION OF CYLINDER BLOCK

REMOVE GASKET MATERIAL


. CLEAN CYLINDER BLOCK
. INSPECT TOP OF CYLINDER BLOCK FOR FLATNESS

DISASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLIES


.
. CHECK FIT BETWEEN PISTON AND PISTON PIN
. REMOVE PISTON RINGS
. DISCONNECT CONNECTING ROD FROM PISTON

POST ASSEMBLY
1. 2. 3. 4.
2. INSTALL ENGINE MOUNTING
3. INSTALL THERMOSTAT AND WATER INLET (See page CO-11)
4. INSTALL OIL COOLER (See page LU-18) EM-113
5. INSTALLTIMING GEAR CASE (OIL PUMP) AND OIL PAN (See page LU-12) 5. 6. 7. 8. 9.
6. INSTALL INJECTION PUMP (See page FU-93)
7. INSTALL TIMING GEARS (See page EM-50)
8. INSTALL ALTERNATOR INSTALL WATER PUMP (See page CO-8)
9. INSTALL CYLINDER HEAD (See page EM-75) 10.
10. INSTALL PULLEYS AND TIMING BELT (See page EM-38) 11.
11. REMOVE ENGINE STAND
12. INSTALL FLYWHEE

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