CONTENTS
1. TROUBLESHOOTING.................................................................................................................1-S1
2. SERVICING SPECIFICATIONS ..................................................................................................1-S5
3. TIGHTENING TORQUES..........................................................................................................1-S11
4. CHECKING, DISASSEMBLING AND SERVICING ...................................................................1-S13
[1] CHECKING AND ADJUSTING............................................................................................1-S13
(1) Engine Body ..................................................................................................................1-S13
(2) Lubricating System ........................................................................................................1-S15
(3) Cooling System .............................................................................................................1-S16
(4) Fuel System...................................................................................................................1-S19
(5) Turbocharger .................................................................................................................1-S22
(6) EGR System..................................................................................................................1-S23
[2] PREPARATION...................................................................................................................1-S25
(1) Lubricant and Coolant ...................................................................................................1-S25
(2) 4WD Propeller Shaft and Power Steering Hose............................................................1-S25
[3] SEPARATING ENGINE (ROPS MODEL) ...........................................................................1-S26
(1) Separating Front Axle and Front Frame as a Unit.........................................................1-S26
(2) Separating Engine .........................................................................................................1-S28
[4] SEPARATING ENGINE (CABIN MODEL) ..........................................................................1-S30
(1) Separating Front Axle and Front Frame as a Unit.........................................................1-S30
(2) Separating Engine .........................................................................................................1-S33
[5] DISASSEMBLING AND ASSEMBLING ..............................................................................1-S34
(1) External Components ....................................................................................................1-S34
(2) Exhaust Gas Recirculation (EGR) .................................................................................1-S36
(3) Cylinder Head and Valves .............................................................................................1-S37
(4) Thermostat ....................................................................................................................1-S41
(5) Injection Pump Unit .......................................................................................................1-S42
(6) Water Pump and Oil Cooler...........................................................................................1-S52
(7) Front Cover....................................................................................................................1-S52
(8) Flywheel and Timing Gears...........................................................................................1-S53
(9) Piston and Connecting Rod...........................................................................................1-S56
(10)Crankshaft and Crankcase............................................................................................1-S59
[6] SERVICING.........................................................................................................................1-S61
(1) Cylinder Head and Valves .............................................................................................1-S61
(2) Timing Gears .................................................................................................................1-S67
(3) Piston and Connecting Rod...........................................................................................1-S72
(4) Crankshaft .....................................................................................................................1-S75
(5) Cylinder .........................................................................................................................1-S78
(6) Oil Pump........................................................................................................................1-S79
SERVICING
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