Engine components removable with the engine in place Engine components which can be removed while the engine is installed on the chassis are listed below. For the installing and removing procedures, refer to respective paragraphs describing each component. Engine left side PARTS REMOVAL INSTALLATION...
Engine removal Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. Drain the engine oil. ( 2-13 ) Drain the...
Engine installation Remount the engine in the reverse order of engine removal. Pay attention to the following points: Note: The engine mounting nuts are self-locking. Once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten...
Engine top side disassembly Caution! Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their original positions. Remove the spark plugs. ( 2-6 ) Disconnect the crankcase breather...
Engine bottom side disassembly Oil filter Remove the oil filter (1) with the special tool. 09915-40610: Oil filter wrench Generator cover Remove the generator cover (1). Remove the gasket (2) and dowel pins (3). Remove the starter idle gear (4) and its shaft (5). Clutch cover...
Cylinder head cover — disassembly and assembly Disassembly Caution! Be sure to identify each removed part as to its location, and lay the parts out in groups designated as "No.1", "No.2" "Exhaust", "Intake", so that each will be restored to the original location during assembly. Remove the PAIR...
Camshaft/camshaft journal — disassembly and assembly Caution! Be sure to identify each removed part as to its location, and lay the parts out in groups designated as "No.1", "No.2", "Exhaust", "Intake", so that each will be restored to the original location during assembly. Camshaft All camshafts...
Cylinder head — disassembly and assembly Valve and valve spring disassembly Remove the tappets (1) and shims (2) by fingers or magnetic hand. Caution! Identify the position of each removed part. Using special tools, compress the valve springs and remove the two cotter halves (3) from valve...
Cylinder — disassembly and assembly Cylinder distortion Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. If the largest reading at any position of the straightedge exceeds the...
Piston and piston ring — disassembly and assembly Piston diameter Using a micrometer, measure the piston outside diameter at 20 mm (0.79 in) (A) from the piston skirt end. If the measurement is less than the limit, replace the piston. Piston diameter: Service Limit: 80.88 mm (3.184 in) at 20 mm...
Conrod and crankshaft — disassembly and assembly Conrod small end I.D. Using a small bore gauge, measure the inside diameter of the conrod small end. Conrod small end I.D. Service Limit: 20.040 mm (0.7890 in) 09900-20602: Dial gauge (1/1 000 mm, 1 mm) 09900-22403: Small bore gauge (18-35 mm) If...
Crankcase — disassembly and assembly Oil pressure regulator Remove the oil pressure regulator (1). Check the operation of the oil pressure regulator by pushing on the piston with a proper bar. If the piston does not operate, replace the oil pressure regulator with a new one. Tighten...
Crankshaft journal bearing — inspection Inspection Inspect the crankshaft journal bearings for any damage. If any, replace them with a specified set of bearings. Selection Inspect the crankshaft journal for any damage. Measure the crankshaft journal O.D. with the special tool. Crankshaft...
Crankcase bearing and oil seal — removal, installation and inspection Inspection Rotate the bearing inner race by finger to inspect for abnormal play (A), noise and smooth rotation while the bearings are in the crankcase. Replace the bearing with new ones, if there is anything unusual. Inspect the oil seals for any...
Starter clutch — disassembly and assembly Inspection Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand to inspect the starter clutch for a smooth movement. The gear turns in one direction only. If a large resistance is felt for rotation,...
Generator and signal generator — inspection Inspection Refer to pages 8-10 , 8-27 for generator and CKP sensor inspection. Reassembly When installing the generator starter set bolts (1) and the CKP sensor set bolts (2) tighten them to the specified torque. Generator stator set bolt: 11 N·m...
Oil pump inspection Rotate the oil pump by hand and check that it moves smoothly. If it does not move smoothly, replace the oil pump assembly. Caution! Do not attempt to disassemble the oil pump assembly. The oil pump is available only as an assembly.
Engine bottom side reassembly Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken. Note: Apply engine oil to each running and sliding part before reassembling. Transmission Install the...
Engine top side reassembly Piston Install the piston rings in the order of oil ring, 2nd ring and 1st ring. The first member to go into the oil ring groove is a spacer (1). After placing the spacer, fit the two side rails (2). Note: Side designations, top and bottom, are not...