CONTENTS
1. Safety Regulations & Specifications ............................................................................................1
1.1. Safety Regulations ................................................................................................................................. 1
1.2. Engine Specifications ............................................................................................................................. 8
1.3. Engine Power ......................................................................................................................................... 9
1.4. Engine Performance Curve .................................................................................................................. 10
1.5. Engine Assembly ................................................................................................................................. 12
2. Technical Information ..................................................................................................................16
2.1. Engine Model and Serial Number ........................................................................................................ 16
2.2. Diagnostic Tool (SCAN-200) ................................................................................................................ 17
2.3. Engine Character ................................................................................................................................. 17
2.4. Diagnosis and Remedy ........................................................................................................................ 36
2.5. Engine Inspection ................................................................................................................................ 45
3. Maintenance..................................................................................................................................46
3.1. Engine Disassembly ............................................................................................................................ 46
3.2. Inspection and Measurement on Major Parts ...................................................................................... 61
3.3. Engine Reassembly ............................................................................................................................. 79
3.4. Major Electric Parts Replacement ...................................................................................................... 104
3.5. Electrical System ............................................................................................................................... 116
4. Commissioning and Operation .................................................................................................148
4.1. Operation Preparation ........................................................................................................................ 148
4.2. Breaking-in ......................................................................................................................................... 148
4.3. Inspections after Starting ................................................................................................................... 150
4.4. Operation in Winter Time ................................................................................................................... 150
4.5. Tuning the Engine .............................................................................................................................. 151
4.6. Maintenance and Care ....................................................................................................................... 151
4.7. Cooling System .................................................................................................................................. 153
4.8. Adjustment of Valve Clearance .......................................................................................................... 155
4.9. Ignition Timing .................................................................................................................................... 156
4.10. Tightening the Cylinder Head Bolts ................................................................................................. 157
4.11. Cylinder Compression Pressure ...................................................................................................... 157
5. Maintenance of Major Components..........................................................................................159
5.1. Cooling System .................................................................................................................................. 159
5.2. Lubricating System ............................................................................................................................ 162
5.3. Air Intake System ............................................................................................................................... 165
5.4. Turbocharger ..................................................................................................................................... 170
Appendix
Special Tool List
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