S-1 Disassembly and Installation of Starter Motor Assembly

1. Disassembly
Disconnect the cable from negative terminal
(-) of battery.
(1) Open the engine hood.
(2) Disconnect 4 wires from the engine
starter motor, of which the locations are
as below:
Disconnect wires 1 and 2 from terminal B
Disconnect wire 3 from terminal C
Disconnect grounding wire 4 of starter motor.
(3) Disassemble 2 mounting bolts 5 to ease
the disassembly of engine starter motor
assembly 6.

2. Installation
The installation procedure is in reverse order of disassembly procedure.
Fastening nut for terminal B of engine starter motor: 17.7-24.5Nm (1.8-2.5kgm)
Two surfaces for gasket of engine starter motor: Gasket sealant (LG-1)
Fastening nut for terminal B of engine starter motor: 43±6Nm (4.38±0.61kgm)

40-S-1
S-2 Disassembly and Installation of Fuel Injection Pump Assembly
1. Tools
Code Part Name Quantity
A Puller 1

2. Disassembly
Disconnect the negative (-) terminal of the
battery.
(1) Open the engine hood.
(2) Disassemble the crossbeam 1.

(3) Take out the radiator fan guard 3.

(4) Disconnect the air intake pipe 4.

(5) Disconnect the fuel inlet hose 5 and fuel

outlet hose 6.
Insert the wood plugs into hoses to stop the
fuel outflow.

40-S-2
(6) Disconnect the pipes 7 and 8 between the
fuel filter element and fuel injection
pump and disassemble the fuel filter
element bracket 9.

(7) Disconnect the lubricating pipe 10.

(8) Disconnect 6 delivery pipes 11.
(9) Disconnect the regulator motor connector
and disassemble the regulator spring 12
on the fuel injection pump side.

(10) Use the timing pin 13 on the timing gear

side to adjust the injection timing of the
timing gear, with reference to the
“Checking and Adjustment” in section
“Fuel Injection Timing”.

(11) Loosen the cap 14 to ease the

disassembly.
Use the filter element wrench to remove the
cap.

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(12) Disassemble the nut 15 and washer 16
from the fuel injection pump and take
cautions to prevent the nut or washer
from falling into the housing.

(13) Use tool A to separate the fuel injection

pump shaft and drive gear.

(14) Disassemble two bracket mounting bolts

17 beneath the fuel injection pump.

(15) Disassemble the sound absorption

material 18.
(16) Disassemble 4 nuts 19 to ease the
disassembly of fuel injection pump
assembly 20.

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3. Installation
Install as per reverse order of disassembly procedure.
Air hose clamp: 5.4-6.4Nm (0.55-0.65kgm)
Hose clamp: 2.84-3.82Nm (0.29-0.39kgm)
Connecting bolt: 19.6-29.4Nm (2.0-3.0kgm)
Socket nut: 24±4Nm (2.45±0.41kgm)
Adjust the travel of regulator joystick, with reference to the section “Special Functions of Monitor
Panel” in chapter “Checking and Adjustment" of this manual.
Nut: 95±10Nm (9.7±1.0kgm)

Install the fuel injection pump assembly as per

the method below:
(1) Check whether the timing pin is correctly
adjusted to fuel injection timing.
Refer to the step 10 in above-mentioned
“Disassembly” procedure.
(2) Disassemble the plug 21, overturn the
fuel injection pump timing pin 22,
assemble the plug onto the pump again,
and check whether the slot on the timing
pin is engaged with the protrusion a
within the pump, with reference to the
checking and adjustment contents in
section “Fuel Injection Timing” of
chapter “Testing and Adjustment” in this
manual.

(3) Assemble the fuel injection pump

assembly 20 and tighten with 4 nuts 19.
Nut: 44±2Nm (4.5±0.2kgm)

40-S-5
(4) Install the washer 16 and temporarily
tighten the nut 15. While installing the
nut and washer, take caution to prevent
them from falling into the housing.
Temporarily tighten the nut to the torque
specified below and take cautions not to
damage the timing pin.
Temporary tightening torque of nut:
12±2.5Nm(1.2±0.25kgm)

(5) Disassemble the timing pin from the

protrusion a on the timing gear side and
place the timing pin of fuel injection
pump to original place.

(6) Tighten the nut 15 of fuel injection pump

to the specified torque.
Nut: 92Nm±10Nm (9.4±1.02kgm)
(7) Install the service cap of gear cover and
tighten with hand.
(8) Bleed the air from the fuel injection
system.

40-S-6
S-3 Disassembly and Installation of Engine Front Seal
1. Tools
Code Part Name Quantity
A Puller 1

2. Disassembly
(1) Disassemble the radiator assembly, with
reference to the disassembly and
installation contents in section “Radiator
Assembly” in this manual.
(2) Use the rod ➀ to disassemble the engine
fan belt 1 and pulley 2.

(3) Disassemble the mounting bolt 3 and

take out the crankshaft pulley and pulse
shock absorber 4.
(4) Disassemble the mounting bolts 5 of gear
chamber cover 6 and remove the cover 6.

(5) Reliably fix the gear chamber cover 6

and use a screwdriver to push the oil seal
7 from the back of the cover to the front.

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3. Installation
Install as per reverse order of disassembly
procedure.
Mounting bolt for crankshaft pulley and pulse
shock absorber:
125±5Nm(12.75±0.51kgm)
Temporarily tighten the mounting bolts of
crankshaft pulley and pulse shock absorber,
install the engine fan belt, and tighten the
bolts to specified torque. While installing the
pulse shock absorber, check the rubber
material D on the shock absorber hub B. If the
rubber material D is damaged, replace with
new one.

The protrusion amount of the gearbox gasket from the mounting surface of the oil sump shall be
maintained at below 0.25mm. Apply Three BondTM or equivalent onto the gasket mounting
surface of the cover (particle diameter: 1~2mm), install the gasket onto the cover, and install the
cover onto the engine.
Mounting bolt of cover: 24±4Nm (2.45±0.41kgm)
Tighten 20 cover mounting bolts from 1 to 20 as per the sequence shown in the figure. The
installation method of oil seal is as below:

(1) Install the guide ring ② onto the oil seal

8.
(2) Place the oil seal onto the tool B, with the
dust-proof face and lips facing upward.

40-S-8
(3) Push the oil seal into the cover 6 from
inside to outside. While pushing in the oil
seal, use the tool B, till the bottom of
cover 6 is contacted. Clean the sealing
face of crankshaft to prevent oil leakage
and thoroughly remove all oil and dry.

(4) While the guide ring ② is still fixed on

the crankshaft, apply the cover sealant,
tighten the mounting bolts of cover to
specified torque, and take out the guide
ring ②.
Mounting surface of cover: Gasket sealant
(LG-6).

40-S-9
S-4 Disassembly and Installation of Engine Rear Seal

1. Disassembly
(1) Disassemble the hydraulic pump
assembly, with reference to the section
“Disassembly of Hydraulic Pump
Assembly” in this manual.
(2) Disassemble the shock absorber
assembly 1.
(3) Disassemble the mounting bolts from the
flywheel assembly 2, install the guide
bolts ➀, and hoist it for disassembly.

(4) Disassemble the seal 3.

The recommended method to disassemble the

seal is to drill a hole of approximate 3mm in
diameter on the seal mounting seat, insert the
sliding hammer with puller into the hole, pull
out the seal, and user a hammer to destruct the
seal base to disassemble the seal.
While using above method, pay attention not
to damage the flywheel seal and crankshaft
support ring.

40-S-10
Fix a toothed puller on the sliding hammer,
insert the hammer into the drilled hole, and
take out the seal 3 by means of the sliding of
the hammer.

2. Installation
Install as per reverse order of disassembly
procedure.
Mounting bolt of flywheel: 137±7Nm
(13.97±0.71kgm)
(1) Tighten the mounting bolts as per the
sequence shown in the figure.

(2) The installation method of the oil seal is

as below:
1) Fix the guide ring ② on new oil seal 1.
Before installing the oil seal, clean the
sealing surfaces and lip surfaces of the
crankshaft, thoroughly clean all oils, and
dry, in order to prevent oil leakage.

2) Push the oil seal into the flywheel in such

manner that the guide ring ② and oil seal
4 are installed in the crankshaft together.
3) Pull out the guide ring ② and push the
oil seal into the front cover from inside to
outside.

40-S-11
4) Install the oil seal onto the flywheel
housing at an appropriate depth and use
an alignment tool and knock the head,
bottom, right, and left of the tool to
prevent the seal seat from distortion
while being pushed inward.

40-S-12
S-5 Disassembly and Installation of Cylinder Head Assembly
1. Tools
Code Part Name Quantity
1 Installer 1
C
2 Wrench 1

2. Disassembly
Disconnect the cable from negative terminal
(-) of battery.
(1) Drain the engine coolant.
Coolant: 22.8L
(2) Close the fuel cutoff valve.
(3) Open the engine hood.
(4) Disassemble the clamp 1 from the engine
fuel level gauge guide plate and place
near the counterweight.
(5) Disassemble the air intake pipe 2.
(6) Disconnect the pipes 3 and 4 between
fuel filter element and fuel injection
pump.
(7) Disassemble the entire bracket 5 along
with the fuel filter element assembly.
(8) Disassemble the band heater harness 6.
(9) Disconnect 6 delivery pipes 7.

(10) Disassemble the heat insulation cover 8

from the turbocharger assembly.
(11) Disassemble the exhaust muffler
connector clamp 9.
(12) Disconnect the air cleaner intake hose 10.
(13) Disconnect the air intake hose 11
between turbocharger and inter-cooler.
(14) Disconnect the lubricating oil inlet pipe
12 and lubricating oil outlet pipe 13.
(15) Disassemble the turbocharger assembly
14.
(16) Disassemble the exhaust manifold 15.

40-S-13
(17) Disassemble the radiator fan guard 16.

(18) Disassemble the A/C compressor wire

connector 17.
(19) Disassemble the A/C compressor
pipelines 18 and 19.

(20) Use wrench ① to loosen the fan belt 23

and disassemble it.
Attention: Do not clamp your finger in the belt
during disassembly.
(21) Disassemble the tensioner 24.
(22) Disassemble 4 mounting bolts to ease the
disassembly of fan and fan pulley 25 and
place the fan belt near the radiator.
(23) Disassemble the radiator inlet hose 26
and heater hose 27.

(24) Disconnect the connector 29 from the

terminal B (28) of AC alternator.
(25) Disassemble 3 mounting bolts 30 of AC
alternator bracket and 2 mounting bolts
of AC alternator plate and disassemble
the AC alternator assembly 31 along with
the bracket.

40-S-14
(26) Disassemble the connector from the
engine coolant temperature sensor and
disassemble the wire clamp 32.

(27) Disassemble the clamps (2 places) and

disassemble the overflow pipe 33.
(28) Disassemble 6 nozzle seats 34. If it’s
difficult to disassemble the nozzle seat
assembly, the tool C1 may be used. Pay
attention to prevent the dust or foreign
material from adhering to the installation
location of nozzle seat assembly.

(29) Disassemble the band heater wire and air

intake connector 35.

(30) Disassemble the cylinder head cover 37.

40-S-15
(31) Disassemble the rocker arm assembly 38,
loosen the lock nut, and loosen the
adjustment screw for 2~3 turns.

(32) Disassemble the push rods 39.

(33) Disassemble 26 mounting bolts from the

cylinder head assembly 40 and hoist to
ease the disassembly.
Cylinder head assembly: Approximate 52kg.
(34) Disassemble the cylinder head gasket 41.

3. Installation
Install as per reverse order of disassembly procedure:
(1) Apply gasket sealant onto the thread of clamping bolt (for fixing the engine fuel level gauge
guide plate).
(2) Clamping bolt of air intake hose: 5.4-6.4Nm (0.55-0.65kgm).
(3) Connecting bolt: 19.6-29.4Nm (2.0-3.0kgm).
(4) Apply gasket sealant onto the thread of a bolt on the cylinder head cover side of the fuel filter
element bracket.
(5) Socket nut: 24±4Nm (2.45±0.41kgm).
(6) Clamping bolt of air cleaner intake hose: 5.4-6.4Nm (0.55-0.65kgm).
(7) Clamping bolt of air intake hose: 5.4-6.4Nm (0.55-0.65kgm).
(8) Tighten the mounting bolts of exhaust manifold as per the sequence shown below.

40-S-16
Mounting bolts of exhaust manifold:
1) Tighten as per the sequence of ① to (12)
to: 24±4Nm (2.45±0.41kgm)
2) Tighten as per the sequence of ① to (12)
to:43±6Nm (4.38±0.61kgm)
3) Tighten as per the sequence of ① to ④
to:43±6Nm (4.38±0.61kgm)

(9) Refer to contents “Checking and Adjustment” in "Air Compressor Belt Tension” of chapter
“Testing and Adjustment” in this manual.
(10) Mounting bolts for radiator fan and fan pulley: 33±5Nm (3.37±0.51kgm);
(11) Clamping bolt for radiator inlet hose: 8.3-9.3Nm (0.85-0.95kgm);
(12) Clamping bolt for radiator hose: 8.83-14.7Nm (0.9-1.5kgm);
(13) Bolt for overflow pipe: 30±5Nm (3.06±0.51kgm); nozzle seat assembly: 60±9Nm
(6.12±0.92kgm);
(14) Mounting bolt of cylinder head cover: 24±4Nm (2.45±0.41kgm);
(15) Install the rocker arm assembly and cylinder head assembly as per the method below:

Check for contamination of dust or foreign

material on the mounting surface of cylinder
head or the inside of cylinder.
1) Place the cylinder head gasket 41 onto
the cylinder block and check for correct
fit between gasket and cylinder block
bore.
2) Hoist the cylinder head assembly 40 and
install onto the cylinder block.

3) Assemble the push rods 39 and apply

engine oil (15W-40) onto the surfaces of
push rods.

40-S-17
4) Install the rocker arm assembly 38 and
tighten the bolts with hand. Check and
adjust whether the screw ball is correctly
seated in the ball socket of the push rod
and apply engine oil (15W-40) to the
threads of mounting bolts and seat
surface (8mm and 12mm).

5) Tighten the mounting bolts of cylinder

head as per the sequence shown and
apply engine oil (15W-40) onto the
threads of mounting bolts and seat
surface.
Mounting bolts of cylinder head:
Tighten as per sequence of 1~26 to:
90±5Nm (9.18±0.51kgm)；
Tighten as per sequence of 3, 6, 11, 14, 19,
and 22 to: 120±5Nm (12.24±0.51kgm);

a. If the tool C2 is used:

Use an angular tightening wrench (tool C2) to
tighten the bolts for 90°±5° as per the
sequence of 1~26.

b. If the tool C2 is not used:

Use a felt tip pen to add fit marks on the bolt
and cylinder head and tighten the bolts for
90°±5°.

40-S-18
6) Tighten the mounting bolts of rocker arm
assembly (8mm).
Mounting bolts of rocker arm assembly:
24±3Nm(2.45±0.31kgm)

7) Adjust the valve clearance.

With reference to the section “Adjustment of Valve Clearance" of chapter “Testing and
Adjustment” in this manual, refill coolant through filler port to specified level, start the engine to
circulate the coolant and bleed all air bubbles, and re-check the coolant level.

40-S-19