SEN00322-04 50 Disassembly and assembly

2) Install suction pipe (3) and stay (2). 33. Common rail
1) Install bracket (3).
2) Install common rail (2).
a Install the common rail at this point
since positioning of the high-pres-
sure pipe is needed when installing
the fuel injector.
3 Common rail mounting bolt:
59 – 74 Nm {4 – 5 kgm}

31. Oil pan

1) Install oil pan (1).
4 Oil pan: 75 kg

34. Cylinder head assembly

1) Assemble the cylinder head assembly
according to the following procedure.
1] Install valve (7).
2] Install lower seat (6).

2) Install the engine assembly to tool A

again.

32. Oil level gauge and oil filler tube

1) Install bracket (4).
2) Install oil level gauge (3) and then tighten
the sleeve nut at the base.
3) Install oil filler tube (2).
4) Install bracket (1).

3] Using tool L, install stem seal (8).

a Drive in tool L until its lower end
a is contacted against lower seat
(6).

24 12V140E-3 Series
50 Disassembly and assembly
4)
4] Install inner spring (5), outer spring
(4) and upper seat (3).
5] Using tool B, compress the valve
spring to install cotter (2).
a After the installation, hit the valve
stem lightly with the plastic ham-
mer to make sure the cotter is
installed stably.
2) Install the cylinder head gasket.
3) Lift and install cylinder head assembly (1).
4 Cylinder head assembly: 30 kg
12V140E-3 Series
SEN00322-04
Tighten the mounting bolts according to
the following procedure.
1] Tighten mounting bolts (No. 1 – 7)
temporarily.
2] Tighten the mounting bolts (No. 1 – 6)
in 3 steps according to the order indi-
cated in the figure.
a When a bolt with 5 punch marks,
which indicates the tightening
frequency up to today, in its head
is found, replace it with a new
one.
2 Cylinder head assembly mount-
ing bolt: Molybdenum disul-
fide lubricant (LM-P)
3 Cylinder head assembly mounting
bolt (No. 1 – 6)
1st time:
137 – 157 Nm {14 – 16 kgm}
2nd time:
284 – 294 Nm {29 – 30 kgm}
3rd time: 90 (+30/0)°
a When tool G is not used in tight-
ening of the 3rd time, check the
rotating angle after applying
marking b to the cylinder head
and bolt head using paint.
25
SEN00322-04 50 Disassembly and assembly

3] Tighten the mounting bolt (No. 7) with 2) Insert fuel injector (2) to the cylinder head
the following torque. along with holder (3).
2 Cylinder head assembly mount-
ing bolt:
Molybdenum disulfide lubri-
cant (LM-P)
3 Cylinder head assembly mount-
ing bolt (No. 7):
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
4] After the tightening, stamping punch
mark a to the head of mounting bolts
(No. 1 – 6).

3) Install spherical washer (7) and then

tighten holder mounting bolt (1) tempo-
rarily.
2 Special washer: Engine oil (EO30)
4) Tighten sleeve nut (5) of the high-pressure
pipe temporarily.
a Also tighten the sleeve nut on the
common rail side temporarily to pro-
ceed with the positioning.
a See "High-pressure pipe" for precau-
5) Install the water tube. tions on this operation.
3 Water tube joint bolt: 5) Tighten holder mounting bolt (1) with the
9.8 – 12.7 Nm {1.0 – 1.3 kgm} specified torque.
3 Holder mounting bolt:
35. Fuel injector 58.8 – 73.5 Nm {6 – 7.5 kgm}
a Check that the inside of the injector sleeve a Leave sleeve nut (5) being tightened
is free from dirt. temporarily in above operation as is.
1) Install O-rings (4) and (5) and gasket (6) to This nut is to be tightened with the
the fuel injector. specified torque in the next step.
2 O-ring: Engine oil (EO30)

26 12V140E-3 Series
50 Disassembly and assembly SEN00322-04

36. High-pressure pipe (between common rail - a After the tightening, make sure the O-
fuel injector) ring is not projecting from the sleeve
k Install the high-pressure pipe and nut.
clamp paying attention to the following
points.
q It is strictly prohibited to reuse a high-
pressure pipe by modifying its bend
or using the pipe in an unintended
location.
q The clamp used must be a legitimate
one. And it must be installed in the
specified position with the specified
torque.
q After installing the high-pressure pipe
and clamp, make sure that 10 mm
m i n im u m c l e a r a n c e i s p r o v i d e d
between the high-pressure pipe and
adjacent harness. If the clearance is
less than 10 mm, adjust the harness
position to secure the space.
k Before installing the high-pressure
pipe, check it for the following defects.
If there is any of these defects, it can
cause fuel leakage. Accordingly,
replace the high-pressure pipe.
q Check the taper seal of the connect-
ing part (Part a: Part of 2 mm from the
end) for visible lengthwise slit b and
dent c.
q Check part d (end of the taper seal:
Part at 2 mm from the end) for
stepped-type wear (fatigue) which
your nail can feel.

2) Manually tighten and install temporarily

the stay and top and bottom clamps of
high-pressure pipe clamp (7).
3) Tighten the top and bottom clamps perma-
nently.
a Before tightening the stay perma-
nently, deflect the rubber fist.
3 Top and bottom clamp bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
4) Tighten the stay permanently.
5) Manually tighten and install temporarily
the stay and top and bottom clamps of the
high-pressure pipe.
1) After installing fuel injector (5) and com- 6) Install the high-pressure pipe clamp and
mon rail (6) temporarily to high-pressure gate type frame temporarily.
pipe (4), tighten the sleeve nut with the a First tighten the high-pressure pipe
specified torque. clamp permanently, and then tighten
a Control the torque by using a spanner the gate type frame permanently to
type torque wrench (commercially the common rail mounting bolt.
3 Gate type frame mounting bolt:
available) for the tightening.
3 High-pressure pipe sleeve nut 9.8 ± 1 Nm {1 ± 0.1 kgm}
(injector side): 7) Tighten the high-pressure pipe clamp per-
39.2 – 49 Nm {4 -– 5 kgm} manently.
3 High-pressure pipe sleeve nut 3 High pressure pipe clamp bolt:

(common rail side): 9.8 ± 1 Nm {1 ± 0.1 kgm}

39.2 -– 49 Nm {4 – 5 kgm}

12V140E-3 Series 27
SEN00322-04 50 Disassembly and assembly

8) Tighten the clamp stay permanently.

a Tighten the clamp of the air intake
manifold after installing the manifold.

37. Crosshead
1) Install crosshead (1).
2 Crosshead sliding portion:
9) Install the rubber cover to the sleeve nut
on the high-pressure pipe. Engine oil (EO30)
a Direct the slit downward when install-
ing the rubber cover.
q Injector side (8): Bottom
q Common rail side (9): Cylinder
block side

2) Adjust the crosshead according to the fol-

a When installing the high-pressure pipe without
removing the fuel injector (for example, when
replacing only the high-pressure pipe with new
one), follow the procedure below.
q Tighten sleeve nut (10) by 2 turns with the
hand into the threads of the fuel injector
and then tighten it with the spanner.
a If sleeve nut (10) does not catch the
threads, it will help to turn the spanner
while pressing sleeve nut (8) end with a
small rod, etc. toward the injector.
lowing procedure.
1] Loosen locknut (2) and then loosen
adjustment screw (3) to a position
where it does not valve stem (4).
2] Maintain the contact with valve stem
(5) on the push rod side by pressing
the contact face against the rocker
arm using a finger.
3] Tighten adjustment screw (3) to con-
firm the position where adjustment
screw (3) is contacted against valve
stem (4).
4] Drive in adjustment screw (3) further
by 20° from the contacting position
against valve stem (4).
5] Tighten locknut (2) while suppressing
move of adjustment screw (3).
3 Locknut:
58.8 ± 5.9 Nm {6.0 ± 0.6 kgm}

28 12V140E-3 Series
50 Disassembly and assembly SEN00322-04

38. Injector harness

40. Rocker arm assembly
1) Push connector (3) out of the cylinder
1) Assemble the rocker arm assembly
head and then install injector harness (4)
according to the following procedure.
in the cylinder head.
1] Install adjustment screw (2) on rocker
2) Tighten injector terminal mounting nut (1)
arms (4) and (6), and then install lock
and clamp mounting bolt (2).
nut (1).
a Alternately tighten injector terminal
a Screw in adjustment screw (2)
mounting nuts (1).
3 Injector terminal mounting nut:
until its spherical part touches
rocker arms (4) and (6).
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
a After tighten the injector terminal
mounting nut, push the harness
against the injector body to eliminate
sagging.

2) Install exhaust rocker arm (4), spacer (5)

and air intake rocker arm (6) to rocker arm
shaft (7).
2 Rocker arm shaft:
Engine oil (EO30)
39. Push rod
Install push rod (1).
a Make sure that the push rod end is
securely fitted to the cam follower socket.
2 Both ends of push rod:
Engine oil (EO30)

12V140E-3 Series 29
SEN00322-04 50 Disassembly and assembly

3) Install rocker arm assembly (3).

a Make sure that the ball of adjustment
screw (2) is securely fitted to the push
rod socket.
a When tightening the mounting bolt,
make sure adjustment screw (2) is
not pushing the push rod.
2 Rocker arm: Engine oil (EO30)
3 Rocker arm assembly mounting
bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
a Tighten locknut (1) after adjustment of
the valve clearance is completed.

2) Loosen locknut (6) of adjustment screw

(5) of the right No. 1 cylinder and then
i n s e rt c l ea r a n c e g a ug e M , whic h is
adjusted to the specified thickness,
between crosshead (4) and rocker arm
(3). Then using the adjustment screw,
adjust the clearance to a degree that
allows only slight move of the gauge.
a Standard valve clearance:
q Intake valve: 0.35 ± 0.02 mm
q Exhaust valve: 0.57 ± 0.02 mm
3) Tighten locknut (6) to secure adjustment
screw (5).
3 Locknut tightening torque:
52.9 – 64.7 Nm {5.4 – 6.6 kgm}
41. Adjusting valve clearance
a After tightening the locknut, check the
1) Rotate the crankshaft forward and drive
valve clearance again.
right No.1 cylinder to the compression top
4) Repeat the same procedure for other
dead center, while watching move of the
engines, too, in the order of firing. Namely,
intake valve on right No. 6 cylinder. Then
crank the engine and then locate the
locate the stamped line of R1.6 TOP of
stamped of the damper to the pointer to
vibration damper (1) to pointer (2).
adjust the valve clearance of respective
a Crank the engine using the burring
cylinders.
tool (B) being provided in the front
a Firing order
right side of the flywheel housing.
R1 - L1 - R5 - L5 - R3 - L3 - R6 - L6 -
a The intake valve of right No. 6 cylin-
R2 - L2 - R4 - L4
der will start moving as right No. 1 cyl-
inder is driven to vicinity of the
compression top dead center. (Open)
a Figure shows the cylinder No. and
their firing order (circled numbers
indicate the firing order).

30 12V140E-3 Series
50 Disassembly and assembly SEN00322-04

42. Head cover

Install head cover (1).
3 Head cover mounting bolt:
14.7 – 34.3 Nm {1.5 – 3.5 kgm}

43. Fuel tube

Install fuel tube (1).
3 Fuel tube joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}

44. Plate and block

Install block (3) and plates (2) and (1).

12V140E-3 Series 31
SEN00322-04 50 Disassembly and assembly

45. Oil cooler (rear side) 4) Install block (1).

1) Install oil cooler (2).
2) Install oil manifold (1).

47. Corrosion resister and filter head assembly

Install corrosion resister and filter head assem-
46. Water pump assembly bly (1).
1) Install housing (5) to water pump (4).

48. Exhaust manifold assembly

2) Install water pump assembly (3). 1) Install the gasket.
a Install the gasket directing its "OUT"
marking to the exhaust manifold side.
2) Lift and install exhaust manifold assembly
(5).
4 Exhaust manifold assembly: 25 kg

3) Install water connector (2).

32 12V140E-3 Series
50 Disassembly and assembly SEN00322-04

a Tighten the mounting bolts in the fol-

lowing order.
a Tighten it once and then tighten again
with the same torque.
2 Exhaust manifold assembly mount-
ing bolt:
Molybdenum disulfide lubricant
(LM-P)
3 Exhaust manifold assembly mount-
ing bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}

4 Turbocharger assembly: 35 kg
2 Turbocharger assembly mounting
bolt and nut:
Molybdenum disulfide lubricant
(LM-P)
3 Turbocharger assembly mounting
bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}

3) Install bracket (4), water pipe (3), muffler

bracket (2) and insulating plate (1).

2) Install water pipes (2) and (3) and oil pipes

(4) and (5).
a As for the air-cooled turbocharger,
install the oil pipes alone.
3 Water connector (Block side):
78.5 – 103 Nm {8 – 10.5 kgm}
3 Water pipe flare nut (Water connec-
49. Turbocharger assembly tor side):
1) Lift and install turbocharger assembly (1). 24.5 – 59 Nm {2.5 – 6 kgm}
a Tighten turbocharger assembly 3 Water pipe joint bolt (Turbocharger
mounting bolt according to the proce- side):
dure below. 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
1] Tighten mounting bolts at each con- 3 Water connector (Turbocharger
necting portion temporarily for posi- side): 29.4 – 39.2 Nm {3 – 4 kgm}
tioning. 3 Water pipe flare nut (Water connec-

2] Tighten turbocharger assembly tor side):

mounting bolts in the following order. 29.4 – 39.2 Nm {3 – 4 kgm}
1st time: [1],[2],[3] and [4]
2nd time: [1],[3],[2]and [4]

12V140E-3 Series 33