621501 ENGINE 13 DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY s+ 18-002 WASHING ties : 13-023, MEASURING AND INSPECTING PARTS 13-027 GENERAL ASSEMBLY 13-039 This Chapter deals with procedures both for genoral disassembly and assembly putting emphasis on SA12V140-1 engine in case overhaul stand Is used. * When machine serial numbers and/or engine bases are different, or when en- gine without after cooler is handled, some of procedures mentioned here may \iffer in detailed part, but the essentials of the procedures are the same, 13-001 oODISASSEMBLY 1 Se2Nemeyn- 10. n 12, 13. 14, 15. 16. 7 18. 19. a. 2, 2. 24, Washing . Setting engine stand . Engine cooling water and engine oi Filter... 3. Mutter assembly Fan ese. 7 Fam belt .....csesseees . Fan pulley assembly Intake connector Exhaust broke assembly Turbocharger assembly Intake menifold, aftercooler assembly Exhaust manifold assembly Fuel injection pipe, spill tube Fuel injection pump assembly Water pump assembly ..... Breather Air compressor Oil cooler assembly it filler, oil level gauge Head cover Nozzle holder, connection . Rocker arm . Push rod . 13-002 ® 13-003 13-003 13-004 13-004 = 13-004 13-008 13-005 = 13-005 13-005 = 13-005, 13-006 13-006 13.007 13-007 - 13-007 13.009 13-009 13-009, = 13-010 13.010 213-011 = 13-011 = 13-012 + 13-012 . Crosshead . o 13-012 . Rocker arm housing . 13.012 Cylinder head assembly 13.012 Cam follower assembly . 13-013, ‘Thermostat housing 13-013 Accessory drive assembly 13.014 Damper crankshet pulley assembly 13-014 Cit pan... . 113.016 Main reliet valve, suction tube 213-015 Front support 13.015 Flywheel .. 13.015 Flywheel housing, rear seal 113-016 Gear case cover, front seal 13-016 . Idler gear (large) oe 13.016 Injection pump drive gear 13-016 . Injection pump drive case assembly ...... 19-017 il pump assembly . 213-097 Idler gear (smait) : 13-017 Camshaft assembly siessesseees 18018 ‘Timing gear case 13.018 Piston cooling nozzle =13-018 Piston and connecting rod assembly ....,. 13-018 Crankshaft : 13-020 1. Cylinder liner .. 218-021 621501621501 DISASSEMBLY al tools No] PartNo PartName [arty A | 795-102-2102 | Spring pusher i B | 79500-1197 _| Piston ring tool 1 ¢ | _795236-1000 _| Linor puller 1 p | 7966021121 _| Holder 7 E | _796607-1110 _| Remover 1 1. Washing © Before disassembling the engine, check all parts for any cracks or damage, then clean the whole engine carefully with steam so that the disassembly work can be carried out swiftly. 1), Before washing, remove starting motor assembly {), alternator assembly (2}, and electric wiring. 2} Cover all the openings of the engine with tape. 3} Using @ washing machine, clean engine. %* Wash with particular care all mating surfaces where mud tands to collect. 2. Setting engine stand © Prepare @ stable engine stand that will prevent the engine from falling over, then set the engine assem- bly on the stand and secure it in position. CEE ngine asemblys Approx. 320 ig (7,056 Ib}. (The welgt citer accocing tothe mechine mrt th engne 6216F00613. Engine cooling water and engine oi Drain engine cooling water and engine cil. ‘wate Engine cil: Approx. 90 £ [24 gat) (The amount of oil differs according to the ma- cine model.) 4. Filter © Engine equipped with fiters 1). Using filter wrench, remove corrosion resistor (1), oil filter (2), and fuel fier (3). 2) Remove bypess filter. 5. Muffler assembly © Engine equipped with mutter 1) Disconnect komaclone tube (4), then remove ‘muffler assembly (5) and mutfier bracket. 6 Fan 1) Using nylon sling, sling fan, then remove mounting bolts. 2) Remove fan (1). (CE) Fan: 759 (165 b) {The weight differs according to the machine model) 13-004 ® ST \ © re 62150055 621501621501 7. Fanbelt 4) Insert ber © (length: approx. 50 om [19.686 in}) in hole (g 18 mm [0.7087 in)) of tension pulley bracket, then pull it forward to loosen spring tension, and remove fan belt. A Insert the bar securely and make sure that it does not come out. 2) Remove tension pulley essembly (1) together with bracket. 8, Fan pulley assembly 1) Using nylon sling, sling fan pulley assembly, and remove mounting bolts. 2) Remove fan pulley assembly (2). [a] Fan pulley assembly: 85 ko 1187 ib) 9. Intake connector Remove intake connector (1). 10, Exhaust brake assembly 1). Disconnect clamp (2) of exhaust connector (1) 2) Remove exhaust brake assembly (4) together with bracket (3). e21sF00s6| 6215F0057| xisFo0es| 6215F00s9|11, Turbocharger assembly 1) Disconnect turbocharger oil supply tube (1) and drain tube (2) 2) Remove turbocharger assembly (3. * Remove the turbocharger oll supply tube ‘and the drain tube after removing the intake manifold 12, Intake manifold, aftercooler assembly © Left bank 1). Disconnect tubes (1) and (2} for air compressor. 2) Remove tubes (3) and (4) for aftercooler. 3) Remove heater relay wiring (5). 4) Remove boost compensator tube (6) 5) Remove clamp (7) of fuel injection tube. © Right bank 1) Remove tubes (8) and (9} for aftercooler. 2) Remove wiring (10) of electrical intake air hea- ter, 13-006 o 219F0061 62150068) 621501621501 3) Sling intake manifold and aftercooler assembly (11), and remove mounting bolts. * To prevent the electrical inteke air heater from falling off, install a guide bar in the mounting bolt hole of the intake manifold below. 4) Remove intake manifold end aftercooler assem- bly. [GE] Intake manifold, aftercooler assembly: 50 kg 1110 Ib), 6215F0064 © Romove the aftercooler core as follows. Remove connector (12). ii) Remove cover (13). iil) Remove aftercooler core (14). arsF000s| 13, Exhaust manifold assembly Remove exhaust manifold assembly (1). A [is] Exhaust manifold assembly: 30 kg [66 1b) 14, Fuel injection pipe, spill tube 1) Remove cover of injection pump drive shaft. 2) Remove fuel injection pipe (1). 3} Remove spill tube (2) Install @ protective cover to prevent any dirt ‘or dust from getting into the discharge port Of the injection pump or the inlet port of the nozzle connector. e21sF0067| 13-00718, Fuol injection pump assembly 1), Remove governor rod (1). 2), Disconnect fuel hoses {2) and (3). 3) Remove oll supply tubes (4) and (5) 4) 5) 6 Remove 4 bolts (6), then loosen coupling boit (7), and remove injection pump assembly (8). %* For the right bank injection pump assembly, disconnect the coupling, loosen 4 mounting bolts holding the injection pump bracket, pull out the injection pump and bracket at an angle as one unit, then remove the mounting botts. % Use tape to prevent the coupling key from being lost. CHE] Fuel injection pump assembly: 38 kg [84 ib} Disconnect fue! hoses (9} and (10). Remove bracket (11) Remove clamp, then remove tubes (12) and (13) 13-008 ® 6215F0060, eal sw 621601621501 16, Water pump assembly "7. 1) Disconnect 2 U-clamps and master joint (1), then remove bypass tube (2). 2) Remove bypass tube (3). 3) Remove tube (4) 4) Remove tubes (5}, (6), and (7) as a set. 5) Remove tube (8) 6) Remove bolts, then remove water pump assem- bly (9). % The water pump Is held by two mounting bolts at the front and two mounting bolts at the rear. Breather 1) Remove alternator bracket (1) The alternator bracket is on the right bank only. 2) Remove clamp, then remove tube (2). 3} Remove breather (3). . Air compressor Engine installed with air compressor. 1) Romove tubes (1}, (2), (3), (4), and (5). 2) Remove unioader valve (6) i 6215F0074| 621570078] 13-009 oO3) Remove front compressor (7). ‘+ With spline shaft 4) Remove rear compressor (8). * With gear 19. Oil cooler assembly 1) Remove front oll cooler assembly (1). 2) Remove manifolds (2) and (3). 3) Remove rear oil cooler assembly (4). 20. Oil filler, oil level gauge 1) Remove bracket, then cil filler (1). 2) Remove oil level gauge guide (2) Loosen the nut at the root of the level ‘guide, then remove the guide. 13-010 eS VV «215-0080 e2reF00n2| 621501621601 21. Head cover 1) Remove head cover (1). 2) Remove turbocharger oll supply tube (2) and drain tube (3) 38} Remove air vent tube (4), © There are two types of air vent tube: one type Is installed to the rocker housing and the other type is installed directly to the cy- linder head. 22. Nozzle holder, connection 1) Loosen locknut, and remove connection (1). 2) Remove holder (2). 3} Using tool E, remove nozzle holder (3}. * Mark each nozzle holder with the cylinder umber, keep it in a safe place,and be care- ful not to damage the tip. * Check that the gasket is fitted to the tip of the nozzle holder. Rocker arm by. housing FF? — Nontle holder assembiy ezisrote4 13-011 ®23. Rocker arm Remove rocker arm (1). * To prevent pressure on the push rod when in- stalling, loosen the locknut and turn the adjust ment screw back 2 to 3 turns before removing the rocker arm assembly. 24. Push rod Remove push rod (2). 28. Crosshead Remove crosshead (3). 26. Rocker arm housing Romove rocker arm housing (4). 27. Cylinder head assembly 1) Remove mounting bolts (1), then remove cylin= der head assembly (2). 2) Remove gasket (3) of each cylinder head. © Disassemble the cylinder head assembly as follows. i) Using spring pusher A, compress valve spring, then remove cotter (4). ii) Remove upper seat (5), outer spring (6), and in- ner spring {7}. 13-012 ® Engine No. 10001 10779 Engine No. 10780 and up == bzE00015) 21570087) sx16F088 | 621501621501 iil) Remove lower seat (8). Iv} Raise cylinder head, and remove valve (9). % Use tags to mark the assembly position of the valves of each cylinder. 28, Cam follower assembly 1) Remove cover (1) 2) Remove mounting bolts {2}, then remove cam follower assembly (3). %# The mounting bolt of the cam follower is 2 special bolt, so keep it in a safo place and bbe careful not to lose it. 29, Thermostat housing 1} Remove connector tube (1) 2) Screw eyebolts (Thread dia. ~ 10 mm, Pitch = 1.8. mm) [0.3937 in, P = 0.0591 in] into thermos- tat case (2), sling thermostat case assembly (2), {@), then remove it. 3} Disconnect thermostat case (2) and thermostat housing (3). 4) Remove thermostat (4) from thermostat case. 5) Remove seal (5). 2150080) 621570091 215F0002) 65218F0003| 218F00% 13-013 ©30. Accessory drive assembly 1) Remove pulley (1). 2) Remove drive assembly (2). © Disassemble the drive assembly. i) Pullout hub (3), and remove thrust plate (4), ii) Remove shaft (5), thrust plate (6), and gear {7) as one unit. ii) Remove gear (7) from shaft (6). iv} Pull out oi seal (9) and bushings (10) from housing @. 31. Damper, crankshaft pulley assembly 1) Sling damper and crankshaft pulley assembly (1), and remove mounting bolts. 2) Remove damper and crankshaft pulley assembly. (G2) Damper, crankshaft pulley assembly. 56 kg (123) + If an impact wrench is used to loosen the bolts, there is danger of demage to the thread, so loosen the botte with a hand tool Feves026 13.014 ® 6215F0086 62150097) 621501621501 32, Oilpan 1) Raise cylinder block assembly, and set stand un- der flywheel housing and front support. 2) Support oil pan with transmission jack, and re- move mounting bolts, then remove oil pan (1) (Ge) Otpan: 45 kg [99 1b) 33. Main relief valve, suction tube 1) Remove main relief valve (2). 2) Remove bracket (3), then remove suction tube (4). 34, Front support Raise cylinder block assembly, and remove front sup- port (1). 35. Flywheel Using eyebolts @ (Thread dia, ~ 12 mm, Pitch — 1.78 mm) (0.4724 in, P = 0.0689 in], sling flywheel (2), then remove mounting bolts (1), and screw in forcing screws @ (Thread dis. = 12 mm, Pitch = 1.75 mm) [0.4724 in, P = 0.0689 in} to remove fly- wheel (2). CED nes: 12040 [300 Ib] + an impact wrenth ed {0 ao8en the bots, tha ic anger St dutage ts the tad, Se loo te bala tnd ol rerea076 5215F0100) 521560101 13-015 ®36, Flywheel housing, rear seal 1) Remove 2 — 3 mounting bolts, then install guide bolts. 2). Sling flywheel housing (1), then remove remain- ing mounting bolts, and remove flywheel hous- ing (1). + Support the housing by hand when remov ing it to prevent it from faling over. [Ge] Flywheel housing: 102 kg (225 0) 3), Remove rear seal 37. Gear case cover, front seal 1) Using eyebolts © (Thread dia. — 10 mm, Pitch = 1.5 mm) [0.3937 in, P = 0.0891 in, sling gear case cover (1}, then remove mounting bolts, in- stall guide bolts, and remove gear case cover im. (Cie) Gear case cover: 72 kg 1159 Ib} 2), Remove front seo. 38, Idler gear large) Remove mounting bolts, then remove plate (1) and idier gear (large) (2). 39. Injection pump drive gear 1) Remove nut, then remove plate (1), 2). Using tool ®, remove drive gear (2) of injection pump on left and right banks, % Keop the key in a safe place and be careful not to lose it 13-016 ® 5218F0108) exisrotes _enisr0r0s| 621501621501 40, Injection pump drive case assembly ‘© Remove injection pump drive case assembly (1). @ Disassemble the drive case assembly. Remove thrust plate (2). ii) Pull out drive shatt (3) towards portion A. * Dimension B of drive shaft Loft bank: Short Right bank: Long i) Remove cil seal (4). iv} Pull bushings (6) out from drive case (6) 41. Oil pump assembly Remove cil pump assembly (1) 42, Idler gear (small) Remove mounting bolts, then remove plate (1) and idler goar (small) (2), s21gF0107| 6215F0103, 13-017, ®43. Camshaft assembly Remove bolt from hole in cam gear, then pull out camshaft assembly (1) * When removing the camshaft, rotate it while pulling it out to prevent damage to the cam bushing, . Timing gear case 1) Using eyebolts © (Thread dia. = 10 mm, Pitch = 1.5 mm) (0.3937 in, P = 0.0591 inl, sling gear case, then remove mounting bolts. 2} Install guide bolts, and remove gear case (1) (CS) Timing gear case: 65 kg (143 Ib) 48, Piston cooling nozzle Remove mounting bolts, then remove each piston cooling nozzle (1). % Before removing the piston and connecting rod assembly, remove the piston cooling nozzle. + Rotate 90° so that it does not contact the piston when itis removed. 46, Piston and connecting rod assembly 1) Using dial gauge ©, measure connecting rod side clearance to act as 2 guide when assembl- ing. % Check the stamped number on the connecting rod cap, [The cap number and cylinder number must match, The number is stamped on the cam side.] + If there is no stamped mark, mark the cylinder No. with an electric pen before removing. Do ‘not stamp a mark, 13-018 ® __saxseo1n enist0112 anisrortg 621560115, 621501621501 2 3) 4) 5) 8) a 8) Rotate the crankshaft so that the piston to be removed is at bottom dead center. Loosen connecting rod bolt {1) 5 — 6 turns. % If an impact wrench is used to loosen the bolts, there is danger of damage to the thread, s0 loosen the bolts with a hand tool. Foeao26 Tap head of connecting rod bolt with a plastic hammer, then disassemble connecting rod cap ‘and connecting rod. Remove carbon from top wall of liner with fine sandpaper. Rotate crankshaft, and align with top dead cen: ter, then remove connecting rod cap (2). Push in piston and connecting rod from oil pan ‘end with push bar ©, and support piston (3) at cylinder head end while removing I. + Be careful not to damage the inside surface of the liner with the corner of the connect- ing rod when removing it Remove other piston and connecting rods in the same way. %* Keep in a safe place and be careful not to demage the piston sliding surface and the bearing, * Assemble the connecting rod and cap tem- porarily and keep together with the bearing to prevent mistakes when reassembling. © Disassemble the piston and connecting rod assem- by. 7 m ity Remove snap ring (4). ‘Support connecting rod (6) with hand, then pull ‘out piston pin (6), and disassemble piston (7) and connecting rod. % If the piston pin is stiff and cannot be re- moved, heat it In hot water (100°C [212], 6 min.) before removing it Remove snap ring on the opposite side. exisror16 B20 1926794 enF735 13. 019 ®iv) Using piston ring tool B, remove piston ring (8) vy) Remove oil ring expander (9). % Keep the piston, connecting rod, connecting rod beering, piston ring, and piston pin in sets for each cylinder. 47. Crankshaft 1) Before removing the crankshaft, using die! gauge © to measure end play of crankshaft, and use it as a guide when assembling, 2) Remove mounting bolts (2) of mein cap (1), 3} Insert bolt in hole of main cap, and move the ‘main cap from side to side to remove it. + Lower thrust bearing (3) is installed to the No. 7 main cap, so after removing it, mark the assem- bly position. o1e2e7a7 2160122) 621501621801 4). Using wire, lift off crankshaft (4). * When ‘raising the crankshaft, be careful not to hit it against the cylinder block and da- mage It. After removal, keep it in a safe place. A Cia] Crankshaft: 210 kg (463 15] 5) Remove upper thrust bearing (5) 6) Remove upper bearing (6). % Use tags or a felt pen to mark the assembly position of the main cap, main beering, and thrust bearing, then keep them in sets for each cap in a safe place to prevent them from damage. 48, Cylinder liner 1) Before removing cylinder liner, use tool D and dial indicator © to measure protrusion of eylin- der liner. * When measuring the protrusion of finer, tighten the liner with @ plate to prevent the liner from floating up on the O-ring, G35 Plate mounting bolt: 7 — 10 kam (61-72 ftlb] 2). Using liner puller C, pull out cylinder liner (1). 652180123) 6215F0126)621501 WASHING Washing cylinder block Washing crankshaft Washing connecting rod 13.023 ®o‘WASHING ¢ When washing, divide the parts into small parts and large parts, and wash the small ports in a bath like the one shown on the right + Before washing disassembled parts, remove the gasket carbon with a wire brush + After washing, cry the wes! pletely with compressed air. (Be particularly careful that there is no washing fluid remaining in the bolt holes.) fluid off com WASHING CYLINDER BLOCK 1) Before washing the cylinder block, remove the plugs Of the oil ine in the cylinder block. © Timing case end: 7 places © Flywheel end: 6 places: 2) Clean with a stiff wire brush to prevent any metal particles from remaining in the oil line. 3} Use sandpaper to polish the O-ring contact surface smooth at the bottom of the liner bore and to re move the burrs and flashes from the liner bore. 4} Clean the oil line thoroughly with the jet cleaner nozzle of the cleaning machine. 5} Dry off the cleaning fluid completely with com- pressed ai + Bo particularity careful not to leave any cleaning fluid in the bolt holes. 13-024 @ ero2eres Plug Plug OO BAe Pug 6216F0128 extsrot29 LL] e1e2F744 621501621501 6) Press fit plug with push tool. AOX= Outer circumference of plug: ‘Throad tightener (LT-2) Ifthe plug is bent when it is pushed in, it will cause leakage of water, so be careful to insert it straight. Push tool jes Wi 61250130) nit_ mm Insite diameter $20 0 ‘of ak 1811 in) (1.8748 in) Soo or ‘ 2950, may Joan 1.1614 fi 19.18512 fu In) ae in} 840 me > $ 8748 in} 265. 364 4a 01 03 1.0483. $,09 ial 1.4331 Saf ho) 84 kod 901 (0.252 + 0.0030 in) | (0.604 = 0.0099 in} 61250131 ‘ 10 10 (0.0334 i [0.0334 in) Push tool oR cE fe = 135 mm e315im) Tmm* 10.316 ia) e2sr0192 13-025 ©WASHING CRANKSHAFT disassembled, wash the crankshaft Clean the crankshaft with @ steam cleaner, then use a wire brush like the one shown in the di gram on the right to clean all the oil holes. After washing, dry the cleaning fluid off thor- oughly with compressed air. Use @ small magnet ot completely remove all the metal particies from the oll holes. WASHING CONNECTING ROD ” 2) 3) Clean the connecting rod with a steam cleaner, then use a wire brush to clean the oil holes. If the inside surtace of the hole at the big end of the connecting rod is black, but the problem is small and the dimensions are still within the speci fied value, the connecting rod can be used as it is, If the black portion is to be removed, use sandpa- per (#800 ~ #1000) and polish lightly. Polish lightly so that the original honing grain is not removed. If the polishing removes the honing grain, and. the wave on the inside surface exceeds the limit, ‘the connecting rod must not be used again. Blow with air and use a cloth to remove all the fe the big end of the connecting rod. 13-026 @ 6162605, a c {O10 1o2F746 621501621501 MEASURING AND INSPECTING PARTS MEASURING PARTS Measuring curvature of crankshaft ..... 13-028 Measuring outside diameter of journal ..13-028 Measuring out-of roundness of journal... 13-028 Measuring surface roughness of outside diameter Of JOUrMAL .newenennne-nsee 1-029 Measuring depth of cyli counterbore sen Measuring main bearing bore... ‘Measuring curvature of camshaft .. Measuring outside diameter of journal Measuring height of cam Measuring piston ring gr00¥8 wn Measuring piston ring end gap... Measuring length of connecting rod Measuring inside diameter at smail end of connecting rod .. Measuring inside diameter at big end of ‘connecting rod Measuring curvature, t ‘connecting rod Standard pressure for parts pressure $WSHING enn 13-030 13-030 13-031 13-031 13-031 13-032 13-032 13-033 13-033 13-027 ®MEASURING PARTS '® Before reassembling disassembled parts, check visu- ally that there are no cracks, damage, or abnormal wear. © Determine the standard for whether the parts are good or not according to the Parts Judgement Guide. © If mo abnormalities are found during the visual in- spection, use an accurate measuring device to moa- sure the specified position precisely. © Action and judgement on whether the parts cen be reused shall be in accordance with the maintenance standard, MEASURING CURVATURE OF CRANKSHAFT 1) Support the center of both ends of the crankshaft {tthe indicator of the dial gouge per- in contact with the journal at the cen- tor, and sot it to 0. 4 If no lathe is available, support the No. 1 and No. 7 Journals in a V block. 2) Rotate the crankshaft one turn, and measure the dif ference between the maximum reading and mi mum reading of the dial gauge. * Do not measure with both ends of the crank- shatt supported on V blocks. This method pro- duces an error because of the eccentric wear of the journal. MEASURING OUTSIDE DIAMETER OF JOURNAL 1) Using a micrometer, measure the outside diameter of the main journal and pin journal in the X and Y directions. MEASURING OUT-OF-ROUNDNESS OF JOURNAL 1) Measure the outside diameter of the journal in the X and Y directions and calculate the difference. 13-028 ® HzE00021 Pin journal (measure at 5 paces) — 12348 123 Moin journal imeasure ot 3 places) ret6a143 621501621501 MEASURING SURFACE ROUGHNESS OF OUTSIDE DIAMETER OF JOURNAL 1 ‘Check the surface roughness using the surface rough- ness standard piece shown in the diagram on the right. oe —— Part No. 790-107-2110 Standard piece + When measuring the surface roughness, compare the surface roughness of the journal with the stan- dard piece. + Ifthere are any scratches or dents in the surface of the crankshaft journal, correct the surface rough- ness. However, if the outside diameter of the journal is close to the standard value and there is no margin ‘for correction (the scratches and dents cannot be removed by correcting the surface roughness), correct by grinding, Flat surface Rrms roughness standard piece FLAT SURFACE ROUGHNESS STANDARD e12sro1a8 13-029 ®MEASURING DEPTH OF CYLINDER LINER COUNTERBORE 1) Set depth gauge @ on gauge block @, then set the gauge indicator to 0. 2) Set the gauge block parallel with the top surface of the cylinder block, and measure the depth of the counterbore. When doing this, slide the measurement portion and measure at several places. * Clean tho counterbore and top surface of the cylinder block before measuring MEASURING MAIN BEARING BORE 1) Install the main bearing cap to the cylinder block, and tighten to the specified torque. 2) Using @ dial bore gauge or inside micrometer, mea- sure the main bering bore. When measuring the main bearing bore, measure in two directions (X and Y}. 13-030 ® 2200007 621601621501 MEASURING CURVATURE OF CAMSHAFT 1) Support the center of both ends of the camshaft with lathes, put the indicator of the dial gauge per- pendicularly in contact with the journal at the cen- ter, and set it to 0. 2) Rotete the camshaft one turn, and measure the dif- ference between the maximum reading and mini- mum reading of the dial gauge. % Do not measure with both ends of the camshaft supported on V blocks. This method produces fan error because of the eccentric wear of the journal MEASURING OUTSIDE DIAMETER OF JOURNAL 1) Using a micrometer, measure the outside diameter of the journal. MEASURING HEIGHT OF CAM 1) Using @ micrometer, measure cam height H for the intake ond exhaust. 61626759 | 162754 1626755, 13-031 ®621501 ASSEMBLY 10, 12. 18, 14, 16. 16, 17. 18, 19, 20. a. 22, 23. 24, 25. 26. 21. 3. Injection pump drive case Cylinder liner ..... . 19-042 Crankshaft... sestensncee 19045 Piston, connecting rod assembly 13-048 1. Piston cooling nozzle 13-053, 5 Gear C882 eee ves 13-054 ‘Camshaft assembly 13-054 . kdler gear (small) . 13-054 ll pump assembiy 13-085 19-055 Injection pump drive gear 13-086 Idler gear (large) (right bank) 13-086, Idler gear (large) (left bank) s...csessssesess 18087 Measuring backlash of gear 13-057 Gear case cover... sever 13-059 Front oil seal, sleeve esse 13-089 Flywheel housing 13-060-2 Rear oil seal, sleeve... -19-060-2 Flywheel 13-061 Front support . 13-062 Main relief valve, suction pipe 13.063 Oil pan . . 13-063 Damper, crankshaft pulley assembly ....... 19-063 Accessory drive assembly ....sssssesesseee- 12064 13-065 13-065 13-065 13-068 ‘Thermostat housing Cam follower assembly «..... Cylinder head assembly Rocker arm housing 28, 29. 30. 31 32 33, 34. 35. 36. 37. 38, 39, 40. a 42, 43, 45. 48, 47. 48, 49, 50. 51 52 53. Crosshead Push rod .. Rocker afin sosssceseense Nozzle holder, connection . Adjusting vaive clearance Head cover, turbocharger Iu tube cee Oil level gauge, oil filer il cooler assembly .. Air compressor Breather ... sesenseesenen Water pump assembly ss... suse Fue! injection pump assembly Fuel injection pipe, spill tube Exhaust manifold assembly Intake manifold, aftercooler assembly ‘Turbocharger assembly Exhaust brake assembly Intake connector Fan pulley assembly Fan belt Fan ‘Mutfier assembly Filters. Sotting engine stand Alternator assembly Starting motor assembly - 13-068, 13-068, 13-068 13-070 13.070 13.071 213-071 13-071 13.071 = 13-072 = 13-073 13-073 18-075 13.075 13.076 -13-077 13.077 13-078 13-078 13.078 13-078 13.079 13-079 =13-079 13.079 13-080, 13-039 ®TIGHTENING BOLTS BY PLASTIC RANGE TURNING ANGLE METHOD pst 099) © The important bolts on the 12V140 Series engine Use the plastic range turning angle method for tigh- tening. This method uses specis! bolts, and by tightening the bolts to the load where the bolt starts to de- form permanently (plastic range, it is possible to get an accurate, high tightening forc {Of the methods used for tightening bolts, the meth- fod using checking of the torque is the most com- mon, but because of the influence of friction factors, it is difficult to contro! the tightening force accurate- Nya © The tightening method using the plastic range turn- ing angle method uses the initial tightening torque and the turning angie to tighten the bolts. © Bolts tightened with the plastic range turning angle method on the 12V140 Series engine 1) Cylinder head mounting bolts 2) Main cap mounting bolts 3) Connecting rod cap mounting bolts * With the plastic range turning angle method, there is a permanent deformation remaining after tighten- ing. ‘Therefore, there Is a limit 10 the number of times that the bolt can be used, so please observe the following. 1) After tightening, make one punch mark. If any bolt hes more than § punch marks, do not use ‘again; replace it with a new bolt. 2) When tightening to an angle greater than the specified angle, loosen completely before tigh- ‘ening again. (In this case, make two punch marks.) 3) The target for the tightening angle should be the standard value + tolerance. eye en, 9) “Toxaue matnoe {soneona method) Eongston of bl 150°302-1 13-040 ® 621501621501 ASSEMBLY Special toots No. | Parti Part Name ‘A_[ 7961022102 _| Spring pushor 7 B_|_795100-1191 | Piston ring tool 1 >| vessoaray [Gurecammen” [1 | 796-290-6472 | Liner diver 1 F | 705-286-1600 | Praton ring holdor | 1 © | vosaranno | Wen Age fa [2 [ 2358022200 [instar For fron 1 [2 | 795-602-2900 | installer (Forreo) | 1 © Wash all parts clean, and check that there are no dents, scratches, or casting defects. Check also that all oll or water passages are clear before assembl- ing, Preparatory work Before inserting the cylinder liner, teke the following action with the eylinder block. 1} Remove the rust and scale from surfaces ® and @ with sandpaper until the machining surface appears. 2) Polish portions @ and © 0 that the R surface is smooth. 3) Polish portions @, ® and ® with +¥200 sandpaper so that they become smooth. If the corner of the R portion is sharp or there are burrs, polish with a screper or sandpaper. Be sure to finish this surface particulerly ‘smoothly s0 that it does not scratch the O-ring, 4) If surface @ is pitted and rough, and cannot be corrected, replace the cylinder block. 5) If surface ® and portions @ and © are ‘and rough, finish them smoothly. 6} Inspect the counterbore, and remove eny burrs ‘or flashes. if there are any metal particles or dirt on surface ©, the liner will not fit property in close contact, and this may cause problems such as leakage of water or protrusion of liner. + If there is any drooping, corrosion, or pitting left in the counterbore, carry out additional machining #200 sandpaper oI e215f049 13-041 ®Cylinder liner Roplace the liner O-ring and clevis seal with new parts immediately before assembling the liner. Method of installing liner O-ring and clevis seal 1) Check the cylinder liner O-ring groove and out- side circumference of the liner to confirm that there is no rust or pitting © If the surface is rough and pitted, it may cause leakage of water, so replace the line! 2) Coat the liner*O-ring and clevis seal with soapy water. ‘Oil causes the clevis seal and O-ring to swell and deteriorate, so do not leave them soaking in oil If oll is used, coat with a small amount of clean engine oil (SAE30) with a brush immediately be fore assembly. 3) Assemble the liner O-ring and clevis seal to the liner @s shown in the diggram on the right. 4) Attor installing the liner O-ring, check for twist- ing. if any twisting ts found, use @ smooth bar {approx. § 10) {g 0.3937 in] to remove the twist- ing. % To prevent the clevis seal from twisting when it is installed, press it around the whole circumfer- tence so that it fits into the seal groove. + Assemble tho clevis seal with the chamfered side facing down. 13-042 ® i Covinder finer levis soal A Blok (ethylene propylene rubber) O+ing ‘Black (ethylene propylene rubber} \ ong ‘Orange alleen rubber) e180r9094 — 6136F203, Push into groove oS 61250138 621501621501 5} Method of inserting cylinder liner i) Using a cloth, wipe off all the dirt and oil from the contact surface of the liner lip and the cylinder block counterbore. Coat the mating surface @ of the cylinder block and eyiinder liner counterbore with si con-based gasket sealant (LG-6) + Width of gasket sealant: {$1.5 — 2.0 mm [0.0590 ~ 0.0787 i * Make an overlap of 6 & 6 mm [0 — 0.4724 in] at the beginning and end when coating with gasket sealant LG-6. e1e2F 789 6164029) Top surace of block So Meting portion of rer Postion to coat with gasker sealant [coat the corner of the deck) O210F 304 Overlap: 6 4 6 mm [o~ 04728 in} +44 Block ———_ 13-043 ®6) n 8) 9) © When machining the bottom contact surface ‘of the counterbore liner lip and using © shim, Goat the bottom of the shim thinly with gasket sealant LG6, then assemble the shim. fi) Next, coat with gasket sealant LG-6 in the ‘same way as when not using a Coat the liner O-ring, clevis seal, and cylinder block contact surface with a small amount of engine oll (SAE #30) immediately before press fitting the liner. Coat the contact surface of the cylinder block uniformly around the whole circumference by hand. Set the "TY mark on the top surface of the liner facing the front, then insert cylinder liner (1) into the cylinder block, taking care not to demege the O-ring Use your weight and push the liner in with both hands. + If the liner does not go in smoothly when you apply your weight, there is danger that the O-ring may be damaged, so check the cylinder block for burrs or flashes. Using @ liner driver E, press fit cylinder liner (1) into the cyinder biock. Using the following procedure, squeeze out the gasket sealant coated on the counterbore. |) Tighten the cylinder head temporarily with a used head gasket. ‘+ Bolt © may be tightened partially 13-044 @ Lg-6 (92-3 mm) [0.787 ~ 0.1184 i) {Coat shim with 166) 1626760 6125F0139| | _@ _Iirtate side_s210F301 621601621501 iil Remove the cylinder head, and wipe off gas- TTorornmet le pushed by geaket ket sealant that comes out from between the ‘sealant, there is danger that it wil be cylinder liner and cylinder block. pushed inwards past the edge of the If the gasket sealant sticks to the head ‘water hole, causing water leakage. gasket grommet, the grommet will be deformed, This will cause water leak- age, so be sure to wipe off all excess ‘gasket sealant. hole 6164127 10) After press fiting the cylinder liner, use too! D to measure the protrusion of the cylinder liner. ‘When measuring the protrusion of the eylin- der liner, hold the cylinder liner down with plate © to prevent the cylindor liner from being forced up by the elasticity of the O- ring during measurement, Moasuroment positions: @, ©, ©, @ (4 places) T=] Plate mounting bolt: 7 - 10 kgm ‘% Protrusion of cylinder liner: 0.07 ~ 0.15 mm = ‘fit is not within the standard value, take the bzeo0011 action given in the MAINTENANCE STAN- DARD. r 2. Crankshaft 1) Align the protrusion of upper main bearing (6) with the noteh in the cylinder block, then assemble in the oylinder block. Upper bearing: With oil hole %& The bearing for No. 4 is wider than the other bearings, so be careful not to misteke it when assembling. Width a of bearing iS — ly jo ‘ No. 4 bearing: 52 mm 6 Other besrings: 48 mm Keon) > —~> “stor % Check that there is no dirt at the rear face of the bearing before tightening, % Do not coat the rear face of the bearing with oi. 2) Knock in roll pin so that protrusion from end face of block is 2.7 ~ 3.4 min, then install upper thrust bearing (5). | % Install the thrust bearing with the side with the groove on the crankshaft side. ZE00012| 0zE00013] 13-045, ®3) Coat inside surface of upper main bearing with engine oll (SAE#30). 4 Check for the following before assembling the crankshaft, ji) Abnormality in the front, roar side threaded portion {The bolt must go in smoothly when turned by hand.) ii) Scratches or dents on the pin or main jour- nal portion iii) Dirt stuck to the inside of the oil hole 4) Raise crankshaft (4), and assemble to the mount- ing position, taking care not to hit the oylinder block. 5) Align the protrusion of lower bearing (6) with the noteh in the main cap, and install, + Check that there is no dirt at the rear face of the bearing before tightening. Coat the in- side surface of the bearing with engine oil (SAE#30}. ‘Do not coat the rear face of the bearing with oil. 13-046 © 125F0149 ezer0tat ex1sr0123 126760 61626770 621501621501 6 7 8) 9) Lower bearing : No oil hole ‘The bearing for No. 4 is wider than the other bearings, so be careful not to mistake it when assembling. Width a of bearing No. 4 bearing : 52 mm Other bearings : 48 mm For No. 7 cap, knock in the roll pin so that the protrusion from the end face of the cap is 2.7~ 3.4mm, then install lower thrust bearing (3} on both sides % Install the thrust bearing with the side with ‘the groove on the crankshaft side. Coat the journal surface of the crankshaft with engine oll (SAE#30), check that the stamped num- ber on each main cap (2} matches the number on ‘the eylinder block, then install the main cape. 4 Assemble the main cap with the cast part number facing the front of the engine, Coat the washer and the mounting bolt thread of tho main cap with engine oil (SAEH20), then screw in the bolts in turn to insert the main cap com- pletely. % Do not use an impact wrench to tighten the bolts. This may damage the threads. Al- ways tighten with a hand tool. When tightening, start from the canter main cap and work in order to the outside. Tighten the bolts to the specified tightening torque using the following steps. ===] Main cap mounting bolt Precodire Tighian both bots in turn 1029218 kgm (Target: 210, Range: 109 ~220 Ib) 4g _| Tishten bot bots in tun 10 $8 10 kgm 2d | srarget 420 elo, Range: £13 ~ 426" 1) cea | Pate markon the bott and cap with a pen, then turn the bolt a further 90s" 2€00012 No oil hole pg zE00017 eaisr0129) 164030 2sFo142| 13-047 ®+ Alter tightening, make one punch merk on awe the bolt head If the bot heed has to /AMGROn ponent punch mare, donot rouve te eplace the Fer bolt wth anew bo ter aig, ole 10) After tightening bolts, rotate crankshaft, and Burch mark oh bot he ‘check that it rotates smoothly. times of tightening % Starting torque of shaft: Max. 18 kgm [Max. 108.5 ft.lb] s12srovaa| 11) Measure end play of crankshaft with dial gauge © End play: 0.140 — 0.32 mm [0.0086 — 0.0126 in} * Lever the center portion of the counter ‘weight and measure the end play. % If it is within the standard value, take the action given in the maintenance standard. 4 KZ zisratz9 3. Piston, connecting rod assembly © Assemble piston and connecting rod, i) Fitoil ring expander (9) in oil ring groove. 7) Using piston ring tool B, assemble oll ring, second ring, and top ring in order. _—_8162°737| er25Fot4 % Assemble each piston ring as shown in the dia | jon Top ig % Set each ring with the stamped mark facing up, eS then ascombla tothe piston. rer % When assembling the oll ring, tt take out the one ‘expander and fit it to the piston, then assemble 6c the oil ring. When doing this, check that the ex: & pander is ted completely into the ring groove. % The ond gap of the expander ceil must be ot 180" tothe end gap of the ol rng exiseores 13-048 ® 621501621501 ) Install snap ring (10) on one side. iv) Set piston (7) and connecting rod (8) in posi- tion. Align the casting mark [EX — F] on the piston with the chamfered side of the hole at the big ‘end of the connecting rod when assembling, v) Coat the piston pin boss and the inside of the connecting rod bushing with engine cit (SAE#30), face the connecting rod in the posi- tion described above, then insert piston pin ch vi) Install snap ring (4) on the opposite side. 4 Rotate the left and right snap rings to check that the snap rings are completely fitted into the ring groove. 4 Check that the connecting rod moves smoothly. vii) Align the protrusion of connecting rod upper bearing (11) with the notch in the connecting rod, then install. 4 Check that there is no dirt at the rear face of the bearing before assembling. ‘Do not coat the rear face of the bearing with oil 4 Check that the hole in the bearing at the big end and the bushing at the small end ofthe connecting rod are aligned with the cil hole in the connecting rod %* Before assembling the connecting rod, check that there Is no dirt stuck inside the connecting rod oil hole. vii) Align the protrusion of connecting rod lower bearing (12) with the notch in the connect- ing rod cap, then install. 4 Check that there is no dirt at the rear face of the bearing before assembling. When assembling, do not coat the rear face with engine oil. 61626775 51628735 s102F778 8162770 13-049 ®v 2 3) 13-049-1 @ Coat cylinder liner with engine oil (SAE #30), : + Coat the whole circumference uniformly with engine oil by hand. Rotate crankshaft and set pin journal of cy- linder for insertion at top dead center. Check number of piston and connecting rod assembly, and insert in cylinder at position ‘shown in the diagram on the right. Set the cylinder block so that the cylin- der faces the side in order to prevent the piston and connecting rod assembly from entering the cylinder suddenly ‘when It is inserted. o co. _ 6125F0145) Fight Denk Rear of ‘ongine —— Paton ring Piston sing rotor note Chartered, Chamfered_| 0 sie exisF0s2 5215F083) 621501Piston assembly position Fight bank OOCS EZ REY OT OY SY fear ol engine & OO RY NY NGF SZ 8 Lebar 4) Align ene gap of each piston ring in the po Sivon shown in the diagram below Sttotlchgreercfawne, — meoese can Dkecton ofa isto of acon rng end 99 Revttenta™ messae oie \ Set cating mark EX on piston facing ron of engine, then assembla Center of evlinder Conte of evinder Direction of second’ Ting end gap | Direction of olring end gap Direction of top ring end ep Fight bank Left bank (Front of engine) : _ e26F081 13-050 © 621501621601 5) Coat piston ring uniformly with engine oil {SAE #30) 66) Tighten piston ring with piston ring holder F, then push in piston head with wooden bar. 7) Using connecting rod pulling tool shown in the diagram on the right, pull connecting rod, and fit It in close contact with pin jour- ral % Check that the connecting rod bearing Is correctly in position, + To make @ connecting rod pulling tool, weld a bar to an old connecting rod bolt. 8) Coat crankshaft pin journal with engine oil (SAE #30). 9) Rotate crankshaft 180° while pulling conneot- ing rod. 10) Coat connecting rod lower bearing (12) with engine oil (SAE #30), check cap number, then align with dowel pin, and install con- necting rod cap (2). * When coating with engine cil, spread the oil with a finger over the whole part, % When assembling 2 naw connecting rod, mark the cylinder number with an electric pen, (Do not make a stamped mark) Do not change combination of connecting rod and ‘cap under any circumstances. ‘Approx 690 rum [19.7 ia =] 7 \ Canecting od bot ber Cylinder No rores03011) Coat thread and washer of connecting rod bolt with engine oil (SAE #30). 12) Tighton connecting rod boits (1) in tur until ‘connecting rod cap isin tight contact. + If an impact wrench is used to loosen the bolts, there is danger of damage to the thread, .so loosen the bolts with a hand tool Fe62028 13) Rotate crankshaft 180", and insort piston and connecting rod assembly of other benk us- ing procedure in Steps 1] ~ 12) GHB) Tighten the connecting rod bolts as follows impact wrench is used to tighten bolts quickly, there is danger of damage to thread, s0 tighten the bolts with hand tool. ‘ot stop: Tighten to 7 ~ 8 kgm [51 ~ 67 ftlb) in order shown in diagram. 2nd step: Tighten again to 7 - 8 kgm (61 - 57 ftlbl in order shown in diagram. 3rd step: Using wrench G, turn 80°3* to tighten 13-052 ® ozsF0t62 Corder for tightening of connecting roa bok © O @ 621501621501 © When not using wrench G, tighten as fok tows. ZED Connecting rod bolt Step Procedure Tighten to 78 kgm 161-57 Rib] in order shown in degrom Tighton again to7 = 8 kgm I 67 Rb] in order chown in iogram. Puta mark on the bolt and cap with a felt pen, then turn the bolt a further 90°" ast and a6 + Attar tightening, make one punch mark fon the bolt head. If the bolt head has five punch marks, do not reuse it, Re place the bolt with a new bolt % After assembling the connecting rod, check thet the crankshaft rotates smoothiy. 14) Using dial gauge ©, moasure side clearance ‘of connecting rod. © Standard for side clearance: (03 — 0.484 mm [0.0119 — 0.0178 in} + Ifthe connecting rod does not move, r move the connecting rod cap and check that there is no misteke in assembly, and thet there are no burrs, or dirt caught anywhere 4, Piston cooling nozzle 1) Install cooling nozzle (1). BE) Mounting bolt: 5.5 + 2.0 kgm Target: 40 ftlb, Range: 26 ~ 54 ftb] ‘Before installing, check for cracks in the nozzle, land check that there is no clogging inside the nozzle. % Face the tip of the nozzle to the side with the mounting hole at the top, insert into the piston, taking care thet it does not hit the piston, then turn $60" to install. Before installing, check for cracks in the nozzle, and check that there is no clogging inside the nozzle. 2) Rotate crankshaft slowly and check that there is no interference between piston cooling nozzle and piston, crankshaft. Make mark on| Tighten 127 — 8 kam 308 bolt and cap (1 ~ §7 fu) ‘tor tightening, make bunch mark on bolt bead {o indicate number of mes of tighten 6125F0143) exisr0r15| e2sF0114) Cconneeting 100 Piston cooling nozzle. 521560106 13-053 ®5. Gear casi Fit gasket and install gear caso (1). % Coat the gasket thinly in several places with gasket sealant and stick it in position to prevent it from coming off. 6. Camshaft assembly 1) Coat cam bushing with engine oil (SAE #30). 2) Install camshaft assembly (1), then align with mounting hole of thrust plate, and tighten nylock bolts. + Replace the nylock bolts with new parts. ZED Nylock bolt: 9.0 + 3.5 kgm (Target: 65 ftlb, Range: 40 ~ 90 tt1b] When inserting the cam shaft, rotate it while inserting it in order to prevent damage to the ‘cam bushing. AX When inserting the camshaft, be careful not to get your fingers caught. 7. Idler gear small) 1) Align match mark “D" of cam gear and idler ‘gear (2}, and install idler gear. 2} Fit plate (1) and tighten mounting bolts. 13-054 oO exisro110 earsFote9 621501621501 8. Ollpump assembly : — Fit O-ring, set cil pump assembly (1) in mounting position, then tighten mounting bolts. =) Mounting bolt: 5.5 + 2.0 kgm [Targat: 40 til, Renge: 26 — $4 f.1b] .218F0108| 9. Injection pump drive case © Assemble drive case. £ ’ i) Put face A of drive case (6) facing up, and Bh O 4 set on press stand. A ji) Assemblo bushings (5) in drive case, and press fit with press. « <4 5 * | * 218F0107) % Align the bushing slot with the position Not neoea Tor Tet Rani ave cas} (because compressor olf supply pipe Is shown In the diagram on the right, then v ‘ied i tht contac press fit. + The bushing must be press fitted blow St the pressefiing end face. + Check thet a ¢ 4 mm [g 0.1875 in} pin z can pass through the drive case oil hole roy nd bushing oil hole. push tool, press ft ol seal (4) in drive lpgaiigh of View Z bushing sot | 5 4 Face B_er2srotss eo Fill approx. 50% with grease (G20. |v) Coat inside surface of bushing with engine oil (SAE #30), and assemble shaft (3) in drive case from face A side. 3 Dimansion B of drive shaft. Left bank: Short Dive cate Fight bank: Long ¥) Set notch of thrust plate (2) fecing up, as- . ‘semble in drive case, and tighten bolts. - y Check tht the shatt rotates smooth vi} Knock key (7) into key groove. vi) Install O-ring (8) to drive case. sxzstons 13-055viii) Install injection purnp drive case (1). + Check that the O-ting has not come off, then install, 10, Injection pump drive gear 1) Fix key to shaft, and install injection pump drive ‘gears {1} and (2). 2) Install plates (3) and (4), and tighten nut. GwD) Nut: 255 + 25 kgm (Target: 184 ftlb, Range: 167 — 202 fell] 11. Idlor gear (large) (right bank) 1) Align match mark of gear and install idler gear (large. ) Align mark "D" of cam gear (1) and idler ‘gear (small (2) Align mark “A* of idler goar (small) (2) and sub-idler goar (3) Align mark “B1" of sub-idler gear (3) and in: jection pump drive gear (4), vi) Align mark “R" of idler gear (larger) (3) and crankshaft gear (6). 2) Fit plate (6) and tighten mounting bolts, + ‘Sot plate (6) with the OUT mark facing the outside, then assemble. % Check that match marks °D", “A", “B1", and “RY at four places are aligned. 13-056 ® 1250157 Fight bank Talibank Condition whan No. 1 evinder of right bank ie at compression top dead center 62185055 621501621501 12. Idler gear (large) (left bank) 1) Align match mark of gear and install idler gear {largo). 1) Align mark “C* of cam gear (1) and sub-idier gear (2). li) Align mare "B2" of sub-idler gear (2) and in jection pump drive gear (3). iil) Align mark “L" of idler gear (large) (2) and ‘crankshaft gear (4). 2). Fit plate (6) and tighten mounting bolts. % Set plate (6) with the QUT mark facing the outside, then assemble. %* Check that match marks °C’ at three places are aligned. % After assembling each gear, check the timing mark of the gear again. 82", and *L" 13, Measuring backlash of gear 1) Fit gear (1) to rear compressor and install tem- porary. 2) Install water pump assembly (2) temporarily. Condition witen No.1 cylinder of eight banks at compression top deed center 5215055, 12560189) 125F0160) 13-057 ©@ Measure the backlash and end play of each gear with a dial gauge, 1) Standard value for backlash of each gear ‘izerot61 Fes | rdgoment pion roa aca | Bight ier gear fsmall’ 9.190 0380 | 0.0062 acres 8,-2, | Blam subldlr goa and | posi —a69 | o.02t - aore4 8-8) ee irisector pump gear | 2051~0409 | 0.0021 — acres cnc | bet abide or 0129-0391} 0.0051 — tsa op | Ramer gear eral | 129—aa6r | 0051 ~ acts Ee | eet domperbe gear | 2082—0481 | 0.0021 — ore Foe | Sapeicter goer terse) ona7—eazt | coos ores 105-381 | 00a ~ ans en | Right cam gear and eecess0r] 995 gusz | 0.0034 — 0.0199 wou | Genre gear and lett ont —oa5 | 0.0058 ~ 0.0167 FoR | Sota geet a 0.141 ~ 0.425 | 0.0086 — 9.0167 2} Standard value for end play of each gear Post Part Nome L. a 1 | ser gear forge 007-08 | 0.0027 0.0070 2 | tale gear (smal | oc7-o16 | 00% oom 3 | injection pump deve gear | ag7—a20 | oo026— 0.0078 4 | ot pump deve gear 009-0088 | 00012-00008 5 | Accessory drive gear c1-o4 | o004~oors7 © | crankshat gear 014-032 | 0.0056~ 9.0125 7 | camenat goor 010-025 | 0.004 ~ 009 13-058 ® 621501621501 14, Gear case cover Using eyebolts @ (Thread dia. = 10 mm, Pitch = 1.5 mm) [0.3937 in, P — 0.0591 in], sling, then fit ‘gasket and install gear case cover (1). 15, Front oil seal, sleeve Take the following action according to the wear of the crankshaft seal contact surface. 1) If crankshaft is new, or if there is no wear of surface in contact with seal oll. © Measure dimension of portion @® of front cover and check for @ bolt hole in the end face of the cover. Then use the table below and press fit the oil seal to press-fiting depth a Prese-fting Dimension of | Bolt hole : portion b 8 taxt7s | dept 9 foro 309 mm No 13-14mm tamm Yea 18—13mm 2) If there is wear of oil seat contact surfece of cranksheft, and it is possible to correct by mov- ing mounting position of cil sea. © Push in a new oil seal and install it at 2 point where the lip of the oil seal does not reach the wear groove on the crankshaft, 62150103) 2150187, Bott hole 8124175 ezisF0rse! Cronkshatt ex16F0189| 13-059 ®3} If crankshaft has already been corrected in Step 2) # Install sleeve to crankshaft, then install over~ size oll seal 4} Install sloove as follows. i) Remove all rust from sleeve presscfiting portion of crankshaft (range of 60 mm from tip) il) Coat whole of inside surface of sleeve with gasket sealant (LG-7). lil) Using plastic hammer, tep end face of sleeve around circumference and install sleeve (1) parallel to crankshaft. ‘* The slesve is symmetrical, so it can be Installed in either Iv} Using tool H1, press fit sleeve (1) to speci- fied position. Tighten the bolts uniformly. * After press fitting the sleeve, wipe off the gasket sealant that has been squeezed out. (If the gasket sealant thet hhas been squeezed out gets on the seal lip, it will eause oil leakage.) 13-060 stseve Crankshat _ - 621se0180| eons e21srorst \ oka exisrors2 Z Ht ic eniseorsa 621501621501 5). Front oil seal Using too! H1, install front oll seal (2) % Tighten the mounting bolts uniformly. % The press-ftting depth for the oil seal differs according to the condition of the crankshaft Select one of the following three types. i) When crankshaft is new, or there is no wear (on seal contact surface. © Insert spacer @ of 1.8 — 2.8 mm be- tween installer and oil seal, then install When changing mounting position of oil seal to install. © Install oil seal with installer H1. ) When using sleeve on crankshaft. © Fit one washer between the installer and crankshaft, and instal. % Before assembling the cil seal, clean the outside circumference of the crankshaft, then coat the whole circumference with engine oil (SAE#3O}, + Coat the whole circumference of the oil seal lip with engine oil (SAE#30). X= Surface of metal ring on outside circumference of oil seal: Gasket sealant (LG-4) 4 Bo caroful not to let the gasket seal- ant get on the seal lip. + If the oil seal is 2 rubber type, coat the outside circumference with rub- ber lubricant (RF-1) or with soapy water. Stendara Ht g é 3 SB, é / | 2 6215F0194, When pushing in ol Dusting in ol 323 yy E /, E i 2 s ecnstoiss When using sleev fen Ht /o HAs or] Bi l (Blom e2sF0196| 13-060-1 @16. Flywheel housing Fit gasket, raise flywheel housing (2), then install and tighten bolts (1). © Tighten the flywheel housing mounting bolts in the order shown in the diagram using the fol lowing procedure. = Flywheel housing mounting bolt Step Procedure tst__ | Tightan to 35 + 5 kgm 2nd__| Loosen completely 3rd__| Tighten to 42+ 2 kgm 17. Roar oil seal, sloove Take the following action according to the wear of the crankshaft seal contact surface. 1) If crankshaft is new, or if there is no wear of surface in contact with seal oi. © Install at the standerd dimension from the end face of the crankshaft. 2) If there is wear of oil seal contact surface of crankshaft, and It is possible to correct by mov- ing mounting position of oil seal © Push in @ new oil seal and install it at 2 point where the lip of the oll seal does not reach the wear groove on the crankshaft. 13-060-2 @ (Order for tghtening Boke alee Coane ao \ e2isros8 20mm ‘Standace ler. om TT \ WL env6F0197 oxisFo198 621501621501 3) If crankshaft has already been corrected in Step 2 g © Install sleeve to crankshaft, then install over- gl size oil s 5 aver 0199 4) Install sleeve as follows. i) Remove all rust from sleeve press-ftting portion of crankshaft (range of 60 mm from tip). Coat whole of inside surface of sleeve with any gasket sealant (LG-7), 162180200 )) Using a plastic hammer, tap end face of sleeve around circumference end install sleeve (1) parallel to crankshaft. % The sleeve is symmetrical, so it can be Installed in either direction. | 52150201 iv} Using tool H2, press fit sleeve (1) to speci- 1 fied position. 1 % Tighten the bolts uniformly. % After press fitting the sloave, wipe off | the gasket sealant that has been He squoozed out. (If the gasket sealant that has been squeezed out gets on the seal | lip, it will cause cil leakage.) 62180202 13-060-3 ®3) Secure flywheel with housing @. 4 Tighten the mounting bolts as follows. S51 Flywheel mounting bolt Torget Renge step tom [ee | tom | i | 10 | 7 | a1 | eo ana | 90 | 27 | 20-92 [203-200 za | ss | so | s9—67 [se —a12 4) Using dial gauge (, measure face runout and radial runout, © Face runout: Max. 0.30 mm [0.0118 in} © Radial runout: Max. 0.30 mm [0.0118 in} 19. Front support Fill oil groove of front support (1) with grease and instal ‘+ Amount of grease: Approx. 20 cc [1.2 cu.in] ADs Groove of front mount: Coat with G2-LI © Lower the cylinder block assembly on the stable stand, 13-062 @ 125F0187 ozisrose 6215F0100) 621501621501 20. Main relief valve, suction pipe 1) Fit gasket and install main relief valve (2) 2) After firing O-ring, fit suction pipe (4), install bracket (3), end secure in position. 21. Oil pan 1 gasket to oil pan. (1) with transmission jack, set in ‘mounting position, then tighten mounting bolts. 22. Damper, crankshaft pulley assembly 1) Raise crankshaft pulley and camper assembly {1}, then align dowel pin of crankshaft and in- stall. ‘AD Coat the throad and washer of the bolts with engine oil (SAE #30). 2} Tighten bolts in turn until damper and crank- shatt pulley assembly are in tight contact. If an impact wrench is used to loosen the bolts, there is danger of damage to the ‘thread, so loosen the bolts with a hand tool Fe161028 164030 13-063 @% Tighten the mounting bolts as follows, ‘SEH Crankshaft pulley mounting bolt T Target Range Step kom] | kom | te 1 75 4 | 86-95 | 40-68 2nd 25 vor | 2927 [167-198 3a 7% 550 | 74—7e | 696— 554 =) Damper mounting bolt: 11 + 1.0 kgm. Target: 79 ftlb Range: 73 — 86 ftib 23. Accessory drive assembly © Assemble accessory drive. i) Press fit bushings (10) and oil seal (9) to housing (@). 4% Press fit the bushing 2 mm {0.0787 in} below the end face. Xs Inside surface of bushing: Engine oll (SAE #30) + Press fit the oil seal 1.5 mm [0.0581 in} below the end face. ADS Lip of seal: Grease (62-LI) 4% Fill the 50 — 80% of the space at the lip. Press fit gear (7) to shaft (6). Assemble thrust plate (6) to shaft and gear as ‘sembly, then insert from rear of housing, iv) Assemble thrust plate (4) to shaft, and press fit hub ‘Be careful not to damage the seal I 1) Fit O-ring and install drive assembly (2). 2) Install pulley (1) Cranky toh GE (Order for ghtering Bohs Oamertot Gy | ® ' Kee ® g 5 oe , i Q 3 a \ \ 3 \ 4 4 .6218F0097| 621601621501 24, Thermostat housing 1) Pross fit seal (6) to thermostat case (2). Make sure that the seal is not at an angle when press fiting. 2} Assemble thermostat (4) in thermostat case. 3} Fit gasket, then install thermostat case (2) to thermostat housing (8), and tighten mounting bolts. 4) Screw eyebolts (Thread dia, = 10 mm, Pitch = 4.8 mm} [0.3937 in, P — 0.0591 in] into thermos- tat case, and sling 5) Fit gasket and install thermostat case assembly (2), (8) to cylinder block. 6). Fit gasket and install connector tube (1). 25. Cam follower assembly 1) Install cam follower assembly (3), then tighten ‘mounting bolts (2) and secure in pot GSE Mounting bolt: 6.25 + 0.75 kgm (ee 38 ftlb } Range: 33 — 43 fulb 2). Fit gasket and install cover (1). HD) Mounting bolt: 4.0 + 0.5 kom Target: 29 ftlb (range: 263210) + Fitthe seal washers to 4 bolts under the cover, and tighten. 26. Cylinder head assembly © Assemble cylinder head assembly as follows. 1) Coat valve ster and inside surface of valve guide with engine oil (SAE #30), and assemble valve (9). ji! Raise cylinder head, and assemble lower seat @. .6218F0083 6218F0001 6215F0080 13-065 ®iil) Install a stem seal to the exhaust valve, Knock in until bottom surface @ of the jig contacts lower seat (796-130-1720). Iv) Fit inner spring (7) and outer spring (6), end assemble upper seat (5) v) Using spring pusher A, compress velve spring, then assemble valve cotter (4) Tap the valve stem with a plastic ham- mer, and check that the cotter is fitted securely in the vaive stem groove. 1) Check that there is dirt or dust inside cylinder and mounting surface of cylinder head, and set cylinder head gasket (3) in position. * When installing the gasket, check that the grommet has been fitted and has not come ‘out of position, * The grommets in the head gasket may be- come deformed by swelling, so do not coat them with gasket sealant. 13-066 ® Portion zE00014 Stem seal Lower seat 6215F0087| 621601621501 2 Install cylinder head assembly (2), and tighten mounting bolts (1). ‘D+ Coat under the bolt thread and the bolt heed with antifricion compund (LM?) and tighten. EI Screw in the mounting bolts at least the first 2 — 3 tums by hand, then tighten 2s follows. i) Ast step: Tighten to 14— 16 korn (102 — 115 ftlb) 1). and tap: Tighten wo 21.5 ~ 225 kom (156 — 162 ft.lb) i) or step: Using wrench G, tun 0 *3° to tahten ‘© When not using wrench G, tighten as follows, Step Procedure Tighten to 18.4 1 kgm (102 — 118 fb) Tighten t0 22 + 05 kgm [155 ~ 162 fu) Put ¢ merk on the bolt and head witha felt sea pen, then un he Sot ate or *2° LMP 61250170) Line + Tighten bolt D to 6.78 + 0.75 kgm [44 — 54 ful) After tightening, make one punch mark on the bolt head. % If the bolt head has five punch marks, do not reuse it. Replace it with a new bolt. a 6215F0143) ress] [xr tortaeiva So ) \ O, a, savor Take maton BES PN gy ‘Alter tightening, make punch mark on bolt head to Indieste number of times of tightening 13-067 ®27, Rocker arm housing Fit gasket and O-ring (1), and install rocker arm housing (2). + When installing, be careful not to let the O-ring ‘come off or get caught. Engine No. 10780 and up 4 Following the change of rocker arm, there is no O-ring (1). 1250171 28. Crosshead Install crosshead (3). + Adjust the crosshead as follows, i) Loosen locknut, and turn beck adjustment screw. ii) Hold top surface of crosshead lightly, and screw in adjustment screw. |i) After adjustment screw contacts valve stem, screw in a further 20. iv) Tighten focknut to hold in positon. FEI Locknut: 6.0 0.8 kgm (eraet 43 fulb, J 6125F0172| Range: 32 — 47 lb - —_—— — 29. Push rod Install push rod (2). % Check thet the push rod is fitted in the cam fol lower. 612560173, 30. Rocker arm © Assemble rocker arm. i) Using push tool, align oll hole of bushing, and knock in rocker arm (2) ii) Assemble adjustment screw (3) and locknut (4) to rocker arm, s12se0174 6126F0175 13-068 ® 621601621501 lil) Coat rocker shaft with engine oil (SAE #30), set side with plug facing exhaust rocker ‘arm, then insert rocker shatt. % Exhaust end rocker arm: Long + Intake end rocker arm: Short iv} install rocker arm (1) % Install with the wide end face of the rocker arm shaft facing down. + Check that the ball of the adjustment screw is fitted securely into the socket of the push rod, then tighen the mounting bolts. = Mounting bolt: 10 + 0.5 kam ffersee 72 ftlb (Range: 68 ~ 75 ft Engine No. 10001 - 10779 8 8 “ 2 Rocker shaft 51250176) 1e No. 10780 and up ke Rocker shaft | 0zE00015; Engine No. 10001 ~ 10778 DzE00016 13-069 @31. Nozzle holder, connection % Chock that there is no dirt or dust inside the nozzle holder sleeve, 1) Fit Oring (7) and coat with engine oll (SAE #30). % Check that there are no serathees on the O-ring, 2} Install gasket (6) to nozzle holder. 3) Align with mounting hole of connection of nozile holder (8), and Insert nozzle holder. % Align the match mark, and make sure that the inlet connector tap hole (nozzle holder end) and iniet connector insertion hole {rocker housing end) do not move ‘ut of position, 4) Insert connection (2) in rocker arm housing, and tighten temporarily, 5) Fit holder (4), then fit spherical washer to mounting bott (3), and tighten. + Set one holder on top of the head of the rocker housing mounting boitand tighten it, 6} Tighten connection (2, then tighten focknut (, FE Holder mounting bolt: 6.75 4 0.75 kgm (Target: 48 flo Range: 44— 64 ftlb Connection: 3.8 4 0:3 kam Tarone a7) Range: 26 ~ 29 ftlb Locknut: 4.0 + 0 kgm Target: 29 fulb Range: 26 ~ 32 ful 32. Adjusting valve clearance Adjust valve clearance. For details, see TESTING AND ADJUSTING, Adjust- ing valve clearance. 13-070 ® 621201069 61250178) 621601621501 33, Head cover, turbocharger lubrication tube 1). Fit gasket and install ir vent tube (4. 2} Fit gasket and install turbocharger dein tube (3, then install ol supply tube (2) 3) Fitgasket and intall head cover (1). GE Mounting bolt: 0.5 + 0.1 kgm Target: 3.6 ftlb ange: 23 "#3 4) 34. Oil level gauge, oil filler 1) Install oil level gauge guide (2) + Fit the O-ring and tighten the nut at the root of the level gauge guide to secure it in posi- tion. SD Nut: 6.25 + 0.75 kgm (leer Range: 33 ~ 43 ftlb] 2) Fit O-ring and install cit filer (1), thon secure with bracket. 35. Oil cooler assembly 1) Fit gasket and install rear oil cooler assembly (a). 2). Fit O-ring and install manifolds (2) and (2), 3) Fit gasket and install front oil cooler assembly (. 36. Air compressor 1) Fit key to air compressor front (7) and install spline shaft (9). SE) Nut: 17.5 + 2.5 kgm [feroee 128 ey } Range: 109 ~ 144 fulb 2) Fit key to air compressor rear (8) and install gear (10), GEL Nut: 178 2 25 kgm U /\wo sane vont J Mtoe oe “O 10 _ 13-071 ®3) Fit O-ring and install air compressor assembly (8) rear. 4) Fit O-ring and cost spline shaft with grease, and install air compressor assembly (7) front. Ds Spline: Coat with grease (G2-LN) 5} Install unloader valve (6) 6} Fit gasket and install lubrication tube at side of ‘compressor. FD Joint bolt: 1.15 + 0.16 kgm (Fargct 8 Renge: 7.3—9.4 ftlb 7). Fit gasket and install cooling water tubes (5) and a. FD Joint bolt: 3 kgm [21.7 feb] 8) Fit gasket and install alr tubes (3), (2, and (1). S21 Joint bolt (3), (2); 8 kgm [56 fll] EME Joint bolt (1): 8 kgm [21.7 feb] 37, Breather © Breather with O-ring groove i) Fit O-ring and install breather (3). ii) Fittube (2), then tighten with clamp. Ii) Install aiternator bracket (1). % The alternator bracket i right bank only. © Breather with no O-ring groove. |) Install breather (3). ATX= Breather mounting surtace: Gaskot sealant (LG-7) R21 Mounting bolt: 2.75 + 0.25 kgm Target: 19.9 ftlb Range: 18.0 — 21.5 ftib, i) Install tube (2), and secure with clamp. Install alternator bracket (1). % The alternator bracket is on the right bank only. installed to the xisroe7s Right bank 2180077 621501621501 38, Water pump assembly 39, 1) Fit Orring and install water pump assembly (9), then tighten bolts. % Tighten two mounting bolts for the water pump assembly from the front, and two from the rear. 2) Fit O-ring and install tube (8) 3) Fit gasket and install tubes (6), (6), and (7) as 2 set 4) Fit gasket and install tube (4) 5}. Fit O-ring and install bypass tube (3). 6) Fit O-ring and install bypass tube (2), then con- rect master joint (1), and secure with U-clamp, Fuel injection pump assembly Machines with electronic governor pump 1) Insert Key jn injection pump drive shaft, align 9 Key groove, then set fuel injec: position. ten 4 injection pump mounting bolts (7), then tighten coupling bolt (8). ==] Mounting bolt :6.7 + 0.8 kgm [Taroer 48 tb Range: 43 ~ 54 fb GE Coupling bolt : 18+ 2.0 kom Target 130 ib] Range: 116~ 148 ftlb 3) Install priming pump (6) + For left bank pump only 4) Fit gasket, then install fuel hose (5) GEE] Joint bolt: 2.75 + 0.28 kgm [forest 188th Range: 18 ~ 21.5 fib e21sF0075 6218F0073 13-073 ®5). Fit gasket, then install spill tube (4) 6} Fit gaskets, then install outlet tube (3) and inlet tube (2) 7). Install fue! injection pipes (D. GEE) Sleeve nut: 2.4 + 0.1 kgm [laree 77.5 ie Range: 16.7 ~ 18.0 ftib. 8) Install cover of injection pump drive shaft. Machines with mechanieal governor pump 41) Inetall bracket (11 2) Fit gaskets, then install tubes (13) and (12), and secure in position with clamp. 3) Connect fuel hoses (10) and (9). Gra Joint bolt: 2.75 + 0.25 kgm [Teroee 189 tty Range: 18 ~ 21.5 ftlb 4) Insert key in injection pump drive shaft, align pump coupling key groove, then set fuel injec- tion pump (8) in position. % For the right bank injection pump assembly, tem- porarly install the bracket, then set at an angle and install 5) Tighten 4 injection pump mounting bolts (7), then tighten coupling bolt (8). G1 Mounting bolt: 6.7 + 0.8 kgm [Taree 48 te Range: 43 ~ 54 fulb FEI Coupling bolt: 9.0 + 0.5 kgm [ Target: 65 ft.lb Range: 62 - 68 fulb 6) Fit gaskets, then install oil supply tubes (5) and oo 7). Fit geskets, then connect fuel hoses (3) and (2). 8) Install governor rod (1). + Check the injection timing. For details, see TESTING AND ADJUSTING, Test- ing and adjusting fuel injection timing. 13-074 @ 6215F0050| 6216F0058, 621501621501 40. Fuel injection pipes, spill tube + Mechanical governor pump. 1) Fit gasket and install spill tube (2). 2) Install fuel injection pipes (1). GE Injection pipe: 2.4: 0.1 kam [Taiset 75K | Range: 16.7 - 18.0 ftlb 3} Install cover of injection pump drive shaft. 41, Exhaust manifold assembly Fit gasket and install exhaust manifold assembly (1) ==] Mounting bolt: 5.0 + 0.5 kgm [ Target: 36 eb ] Range: $2.6 ~ 39.7 fib Fit a spacer to the bolt before tightening. ‘Tighten the mounting bolts in the order shown in the diagram, X= Coat the thread of the bolt and the bottom of, the bolt head with antifriction compound {LIV-P) before tightening. we ant 6215F0066| 188 ve 18 we 3a Bt 6128F0179)42. Intake manifold, after-cooler assembly + Install after-cooler care as follows. 1) Fit gasket and install after-cooler core (14). * Install with the welded after-cooler core ii) iii) Fit gaskets and install connectors (12). | 1) gots to bth onde of let nak a hesr sn ial aero aed ete as \ fold assembly (11}. W ‘To prevent the electrical intake air heater from falling out, fit a guide bar into the bottom ‘mounting bolt hole of the intake manifold when installing. GE] Mounting bolt : 6.75 + 0.78 kam [ Tarost: 49 fp Range: 4¢ ~ 54 ftlb, e215F0088, ‘* Tighten the mounting bolts in the order shown in the diagram. Nisa av we si '8 pis wm eisro0es + Right bank 1) Install electricat intake air heater wiring (10). 2), Fit O-ring and install tube (8). 8). Fit gasket and install tube (9). 216F0082, 13-076 ® 621501Losize + Left bank 41). Install clamp (7) of fuel injection tubes and se- 2} Install boost compensator tube (6). 3) Install heater relay wiring (6). 4) Install tubes (4) and (3) for after-cooler. . 5) Install tubes (1} and (2) for air compressor. 43, Turbocharger assembly 1} Install turbocharger assembly (3). GEE Tightening torque: 6.0 + 0.5 kom [Terget 36 ] Range: 22.6 ~ 39.7 fib % When installing the turbocharger mounting bolts, install each connection, then align the center and tighten fully 2). Fit gasket and connect turbocharger drain tubs . 3} Connect turbocharger oil supply tubes (1) 44, Exhaust brake assembly 1) Install exhaust brake assembly (4) together with bracket (3). 2). Fit gasket and install connector (1), then tighten clamp (2). 6218F0061 621570060]45, Intake connector Fit gaskets and O-rings at each end, then install in- take connector (1). 48. Fan pulley assembly Using a nylon sling, sling fan pulley assembly (2), set in mounting position, then tighten mounting bolts. 4 Check that the fan pulley rotates smoothly. «7. Fan bett 1) Instat tension pulley assembly (1) as one unit wath bracket 2) Insert bar © (length: approx. 50 cm) in hole (918 mmm) of tension pulley bracket, celleve tension of Spring, and instal fen bet. Ai insert the bar securely and be careul that doos not come out 48. Fan Using a nylon sling, sling fen (1), set in mounting position, then tighten mounting bolts. 13-078 ® 52150057) 621501621501 49, 50. 51 52, Muffler assembly 1). Install muffler bracket. 2) Put muffler assembly (5) on bracket and secure with band. 3). Fit gaskot and install Komaclone tube (4). Fitter 1) Install bypass filter. (D475A specification only) 2) Install fuel filter (3), oil filter (2), and corrosion resistor (1). ‘Install each filter as follows. i) Coat seal portion and thread portion of filter cartridge thinly with engine oil (SAE#30) i) Tighten until packing surface contacts seal surface of filter holder, then tighten further by hand as follows Bypass filter: 3/4 ~ 1 turn Oil filter: 9/4 — 1 turn Fuel filter: 1/2 - 3/4 turn Corrosion resistor: 2/3 turn Setting on engine stand + Prepare a stable engine stand, then set the en- gine assembly on the stand and secure it in post tion s0 that it does not fall over. Alternator assembly 1) Install alternator assembly (4), tighten lock bolt (2) and adjustment bolt (1) temporarily, then in- stall belt (3). 2) Set so that locknut of adjustment bolt (1) faces in direction of extension of belt (3), then adjust so that deflection is approx. 15 mm when belt (3) is pressed at mid-point with a force of approx. 6 kg. After adjusting, tighten lock bolt (2} and locknut of adjustment bolt. 6218F0054 250142] 13-079 ®53. Starting motor assembly 1). Fit gesket and install upper starting motor (4) 2). Fit gasket and install lower starting motor (2). 3) Fit bracket (2) and instal 2 wiring connectors (1). 13-080 ® 621501