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Install the wave washer between the rocker arm. Install the rocker arm bracket. Install the camshaft bracket. Rocker Arm Shaft. Bridge Cap 2. Camshaft Bracket Fixing Nut 2. Camshaft Bracket Fixing Bolt 3. Rocker Arm Bracket Fixing Bolt 4. Rocker Arm Shaft Set Bolt. Remove the camshaft bearing cap. Remove the bearing upper. Remove the bearing lower. Disassembly 1. Remove the scissors gear ASM. Use snap ring pliers to remove the sub gear. Caution: Take care not to damage to the cam portion and the journal portion of the camshaft.
Snap Ring 2. Dish Spring 3. Sub Gear 4. Spring 5. Camshaft Gear 2. Remove the camshaft gear. WSHK Name 1. Wood 3. Remove the knock pin. Inspect the camshaft visually. Height of the cam lobe. Check the axial play of the camshaft. End clearance of the camshaft Standard Limit. Check if the camshaft journal is worn. External diameter of the camshaft journal part Standard Limit. Check for bent of the camshaft. If it exceeds the limit, replace the camshaft. Install the knock pin.
Install the camshaft gear. Measure a camshaft journal oil clearance. Measure an inside diameter of the camshaft bearing with a dial gauge. Read the difference between the inside diameter of the camshaft bearing and the diameter of the camshaft journal.
If the measured oil clearance exceeds the limit, replace the camshaft bearing. Assemble the spring with its left end contacting the pin of camshaft main gear to make a gap on the right.
Align the hole of the sub gear with the camshaft main gear and install the phase alignment pin from the sub gear side to match the teeth. Special tool Scissors gear spring wrench: WSHK 2. Install the camshaft bearing lower. Install the baring upper to the bearing cap. Install the bearing cap. Camshaft Bearing Cap 2. Camshaft Bearing 3. Camshaft 4. Valve Stem Oil Seal.
Remove the bridge cap 1. Caution: Keep the removed bridge and bridge cap properly so that they may be put back to the original place. Remove the valve spring. Put the removed valve springs in order by cylinder number. Remove the valve stem oil seal. Remove the valve spring seat. Bridge Caution: Pay full attention so as not to drop the bridge cap in the gear case of the rear part of the cylinder head or the hole into which oil pours back in the front.
Remove the split collar. Inspection Check the valve spring. Caution: Check the valve spring visually and if there is clear damage or wear-out, replace it. If the measured value exceeds the specified limit, the valve spring must be replaced. Install the valve stem oil seal. Caution: After installing the valve stem oil seal, check if it is inserted nice and deep and the oil seal is not tilted or the garter spring has not come off.
Measure tension of the compressed spring. If the measurement is lower than the limit, replace the spring. Install the spring upper seat. Install the split collar. Install the valve spring. Paint mark Intake air. Apply engine oil over the bridge and install it. Caution: Move it up and down to check if it moves smoothly. Apply engine oil over the bridge cap and install it. Bridge 7. Bridge 3. Bridge Guide 4. Split Collar 5. Spring Upper Seat 6. Valve Spring 7. Valve Stem Oil Seal 8.
Drain the coolant. Remove the engine harness. Remove the turbocharger. Remove the EGR water feed pipe. Remove the EGR water return pipe. Remove the EGR cooler. Remove the water feed pipe for coolant water for the EGR cooler and the water return pipe.
Harness Bracket 2. Harness Connector 3. Fuel Injector Terminal Nut 4. Nozzle Leak-Off Pipe Remove the fuel leak-off hose.
Remove the fuel leak-off pipe 2. EGR Adapter 2. Water Return Pipe 3. EGR Cooler 4. EGR Pipe 5. Water Feed Pipe Remove the fan guide bracket. Remove the left-hand intake pipe between the inter-cooler and the inlet duct. Remove radiator upper hose. Loosen the fuel injector terminal nuts alternately to the same level, and remove the terminal. Loosen the fuel injector harness bracket bolt, remove the inside connector, and remove the harness bracket.
Remove the nozzle leak-off pipe 4. High Pressure Pipe 2. Leak-Off Pipe Remove the water bypass hose from the cylinder head side. Water Bypass Remove the cam angle sensor connector. Remove the bridge cap carefully so that it does not fall into inside the engine. Remove the bridge.
Caution: Store the removed bridge and bridge cap so that they can be placed in their original locations. Remove the glow plug connector.
Remove the glow plug. Remove the injection pipe clip, and remove the injection pipe. If you have difficulty in removing the fuel injector, set the fuel injector remover in the fuel injector, tighten the attachment part on the joint of the leakoff pipe and pull out the fuel injector upward. Special tool Fuel injector remover: EN Sliding hammer: J Caution: When removing an fuel injector ID code, be sure to attach the cylinder number.
When pulling out the fuel injector using a special tool, check that the fuel injector sleeve does not come off. Fuel Injection Pipe 2. Fuel Injection Pipe Clip Sliding Hammer 2.
Fuel Injector Remover 3. Be sure not to make the nozzle touch something. Remove the lower head cover. Caution: Be sure not to overlook 1 and 2 because they are attached with the flywheel housing with M10 bolts. Remove the exhaust gasket. Disconnect the water outlet pipe. Remove the thermostat. Remove the idle gear C cover. Remove the spring upper seat. Use a replacer to compress the valve spring to remove the split collar. Sort the removed valve springs by cylinder number.
Remove the intake and exhaust valves. Put the nozzle sleeve remover on the nozzle sleeve from the bottom side of the cylinder head, then pull out the nozzle sleeve.
Remove the valve guide. Nozzle Sleeve Remove the bridge guide. Improper installation Defective tightening of the cylinder head. Winding seal surface of the cylinder block. Damage on the screw surface or extracted cylinder head bolt due to extra tightening torque. Caution: Replace suspicious bolt. Inside the combustion chamber, glow plug hole.
Check the collar if necessary. Nut Remove the oil seal. Strike the tool to remove the seal from the inside of the cylinder head. Distortion of the under surface of the cylinder head. Inspection 1. Check the cylinder head ASM. Use metal brush and others so that the seal surface of the surface where the gasket is installed is not hurt.
Distortion of the surface where the manifold and cover are installed Standard Limit. Abrasion of the bridge cap Limit. If it exceeds the limit, replace the exhaust manifold. Bridge 2. Bridge Guide. Check the valve guide. Caution: If there is a scratch or abnormal abrasion in the valve stem and the inner diameter part of the valve guide, replace it with new one along with valve guide.
Measure the valve guide clearance. If the diameter of the valve stem is smaller than the limit, replace the valve and valve stem altogether. Inspect abrasion of the bridge gap. Install the valve in the cylinder head. Measure the depth of the valve from the under surface of the cylinder head, using a depth gauge or straight edge ruler. If the value exceeds the limit, replace the valve insert or the cylinder head ASM. Check the valve.
If the seat contact surface has a scratch or is rough, or if the abrasion of the contact surface exceeds the limit, modify or replace it. Contact width of the valve seat. Caution: Remove only scratches and roughness, and do not cut the surface too much. Use the free adjustment valve cutter pilot. Do not let the valve cutter pilot waver inside the valve guide. Contraction fur to cooling makes it easier to remove the valve seat insert. Be sure not to hurt the cylinder head.
Caution: Remove compound completely after grinding. Arc-Weld 2. Valve Seat Insert 3. Caution: Do not apply too much pressure with the press. Attach compound on the valve seat surface, rotate the valve and hit it lightly to grind them, and confirm that it has even contact all round.
Install the oil seal. Caution: Be sure not to hurt the rip. Special tool Oil seal installer: J Cylinder Head 2. Oil Seal Installer 2. Install the bridge guide. Note: the height of the bridge guide is about Loctite No. Apply Seal Material 2. Punch Bar 2.
Ball 3. Guide Sleeve 4. Nozzle Sleeve 5. Bracket 6. Bolt 4. Install the valve guide. Height from the upper surface of the cylinder head to the edge surface of the valve guide: Install the intake and exhaust valves. Caution: After installation of the valve stem seal, confirm that the oil seal is not inclining and the garter spring is in place.
Spring Pitch 2. Paint Mark 8. Install the idle gear C. Shaft Install the idle gear C cover. Special tool Sealing cup installer: EN Thermostat Connect the water outlet pipe. Install the exhaust gasket. Install the exhaust manifold. Distance Tube 2.
Conical Spring 3. Caution: Do not tighten it too much so that it hinders extraction and contraction of the manifold due to heat. Install the cylinder head gasket. Measure at two points of each cylinder. Caution: Be sure not to hurt the head gasket when installing it. Install the fuel injector on the cylinder head.
Apply molybdenum disulfide on the screw part and setting face of the fuel injector tighten bolt and tighten it tentatively. Fuel Injector ASM 2. Fuel Injector Tighten Bolt 5. Install the injection pipe.
Fuel Injection Pipe Clip 7. Final tighten the injection clamp bolts to the specified torque. Tighten the injection pipes to the specified torque. Injection Clamp Bolt 2. Injection Pipe Sleeve Nut 9. Install the glow plug. Install and tighten the glow connector with the designated torque. Tightening torque: 1.
Bridge Install and tighten the camshaft speed sensor with the designated torque. Apply a thin coat of engine oil inside the bridge cap, install it. Connect the water bypass hose. Install the leak off pipe. Install the fuel leak-off hose. Clip a new gasket to the fuel nozzle leak-off pipe and install the fuel leak-off pipe.
Install the fuel injector harness connector from inside, tighten the harness bracket with the designated torque. Connect the exhaust pipe. Install the engine harness. Fuel Injector 2. Fuel Injector Harness 3. Fuel Injector Terminal Nut Connect the radiator upper hose. Install the oil level gauge and guide tube. Remove the oil pan. Remove the cylinder head. Remove the connecting rod cap. Caution: Sort the removed bearings according to cylinders by using tags.
Remove the piston and connecting rod. Caution: Be sure not to damage the oil jet and cylinder liner when pushing out the connecting rod. Remove the snap ring. Remove the piston pin. Caution: Sort the disassembled piston pins, pistons and connecting rods together in the order of cylinders.
Remove the connecting rod bearing. Caution: Sort the bearings in the order of cylinders when reusing them so that they will not be confused with the bearing of other cylinders. Remove the piston ring. You have 0 items in your shopping cart. View Cart. All of our products are backed up by a money back guarantee if you are received wrong product from us! Click Here to Read Our Guarantee.
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