5-1
Chapter 5 DISASSEMBLY OF BASIC ENGINE
1. Cylinder Heads and Valve Mechanisms - Disassemble and Inspect..................5-3
1.1 Fuel Pipe - Remove.................................................................................................................. 5-4
1.2 Nozzle Assembly - Remove......................................................................................................5-4
1.3 Valve Clearance - Inspect......................................................................................................... 5-4
1.4 Fuel Injection Timing - Inspect.................................................................................................. 5-5
1.5 Rocker Shaft Assembly - Remove............................................................................................ 5-5
1.6 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect... 5-5
1.7 Valve Bridge - Remove............................................................................................................. 5-6
1.8 Cylinder Head Assembly - Remove.......................................................................................... 5-6
1.9 Valve Sinkage - Measure.......................................................................................................... 5-6
1.10 Valve and Valve Spring - Remove............................................................................................ 5-7
1.11 Nozzle Gland Stud Bolt and Bridge Guide - Remove............................................................... 5-7
1.12 Fuel Connector - Remove......................................................................................................... 5-7
2. Rear Mechanism - Disassemble and Inspect........................................................5-8
2.1 Flywheel Face and Radial Runout - Measure........................................................................... 5-9
2.2 Flywheel - Remove................................................................................................................... 5-9
2.3 Timing Gear Case - Remove....................................................................................................5-9
2.4 Timing Gear Backlash - Measure ........................................................................................... 5-10
2.5 Idler Gear End Play - Measure ............................................................................................... 5-10
2.6 Camshaft End Play - Measure................................................................................................ 5-10
2.7 Idler Gear - Remove ............................................................................................................... 5-11
2.8 Fuel Injection Pump Gear - Remove ...................................................................................... 5-11
2.9 Governor Drive and Fuel Injection Pump Accessory Drive - Remove.................................... 5-11
2.10 Camshaft Gear - Remove.......................................................................................................5-12
2.11 Camshaft - Remove................................................................................................................ 5-12
2.12 Idler Shaft - Remove............................................................................................................... 5-12
2.13 Rear Plate - Remove .............................................................................................................. 5-13
3. Front Mechanism - Disassemble and Inspect.....................................................5-14
3.1 Fan, Fan Bracket Assembly and Belt - Remove..................................................................... 5-15
3.2 Damper Face and Radial Runout - Measure.......................................................................... 5-15
3.3 Front Pulley, Damper and Crankshaft Pulley - Remove......................................................... 5-15
3.4 Front Cover - Remove ............................................................................................................ 5-16
4. Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect .........5-17
4.1 Piston Protrusion - Measure ...................................................................................................5-18
4.2 Connecting Rod End Play - Measure ..................................................................................... 5-18
4.3 Hard Carbon Deposits on the Upper Part of Cylinder Liner - Remove................................... 5-18
4.4 Connecting Rod Cap - Remove.............................................................................................. 5-18
4.5 Piston - Remove ..................................................................................................................... 5-19
4.6 Piston Ring - Remove............................................................................................................. 5-20
4.7 Piston Pin and Piston - Remove............................................................................................. 5-21
4.8 Cylinder Liner Inside Diameter - Measure .............................................................................. 5-21
4.9 Cylinder Liner Flange Protrusion - Measure........................................................................... 5-21
4.10 Cylinder Liner - Remove.........................................................................................................5-21
5. Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect.............5-22
5.1 Crankcase - Turn Over (Upend) ............................................................................................. 5-23
5.2 Crankshaft End Play - Measure.............................................................................................. 5-23
5.3 Piston Cooling Nozzle - Remove............................................................................................ 5-23
5.4 Main Bearing Cap - Remove .................................................................................................. 5-23
5.5 Crankshaft - Remove.............................................................................................................. 5-24
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