Unit Assembling Check Sheet

KOMATSU ENGINE

114-3

FORM：CSTS13-010 (COMPLETE SET)

Printed in Japan 2013.01
Engine Parts Unit Assembling Check Sheet

114-3 Engine Parts Unit Assembling Check Sheet

INDEX

1. Cylinder Block & Crankshaft ・・・・・・ 1

2. Piston , connecting rod , Front gear housing& Oil pump ・・・・・・ 2

3. Camshaft , Water pump & Front oil seal ・・・・・・ 3

4. Front cover assembly & Rear oil seal ・・・・・・ 4

5. Oil pan , Starting motor , Flywheel housing & Flywheel ・・・・・・ 5

6. Oil cooler , Cylinder head & Fuel injector ・・・・・・ 6

7. Rocker housing & Air intake manifold cover ・・・・・・ 7

8. Fuel supply pump ・・・・・・  8

9. Main controller , Common rail & piping ・・・・・・  9

10. Exhaust manifold , turbocharger , Alternator & Vibration damper ・・・・・・ 10

UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGINE 114-3 PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

1.Cylinder Block ・Clean the cylinder block thoroughly,especially cylinder

1 Cylinder Block
bores,oil drillings,and coolant passages.
2.Cylinder Liner
・When reusing a cylinder liner, insert it in the cylinder where it
was, turning it 45 from the original position. Fig①
45 kgm ・Tightening torque ：68 10 Nm｛ 6.9 1.0 kgm } Fig②

2 Cylinder Liner ・Cylinder liner protrusion： 0.026 ‒ 0.122 mm Fig③

No.1 No.2 No.3 No.4 No.5 No.6

Fig① Result

・Do not install a used tappet to a new camshaft.

・Apply engine oil (EO15W-40)
3 Tappet ・Do not turn the cylinder block more than 90 .
If it is turned more than 90 ,the tappets will be off the
mounting holes.
Piston cooling
Fig
Fig② Fig
Fig③ 4
nozzle
kgm
・Mounting bolt : 27 3 Nm｛ 2.75 0.3 kgm }

5.Crankshaft ・The size of a crankshaft checks STD or US before an assembly

kgm
Install speed sensor ring (1). - - Crankshaft: 80 kg - -
1 J Mounting bolt : 8 2 Nm｛ 0.8 0.2 kgm } Fig④

・Before installing the bearing,make sure that no foreign matter

is stuck on the back of thebearing. Don't coat oil on the
bearing backside then.
5 Crankshaft ・Before installing the bearings,make sure that size of bearings
is correct or not.
Fig
Fig④ Fig
Fig⑤
kgm
Main cap mounting bolt : End playof the crankshaft (A)
A 1] 167 8 Nm {17.0 0.8 kgm} End play : 0.084 - 0.385mm
120 5 2] Loosen by 360 Fig⑦
3] 30.4 3.0 Nm {3.1 0.3 kgm}
4] 50 4.9 Nm {5.1 0.5 kgm}
5] 120 5 (Use angle tightening tool J)
When not using tool J
Fig⑥
Fig Fig
Fig⑦ Make marks on the main cap and bolt with paint, then tighten
the bolt by 120 5. Fig⑤ Fig⑥

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

1/10
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGINE 114-3 PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

6. Piston and connecting rod assembly ・Each ring and a bearing are installing, as shown in a figure. Fig① Fig②
・Set the FRONT mark at part (A) of piston (4) up and check
0
12 that the counter mark of the connecting rod cap is at part (B)
of connecting rod (2)at this time. Fig③
・Set projection (E) of the bearing to cuts (F) of the connecting
rod and cap. Fig④
180 12
0 ・Set the FRONT mark of piston (4) on the front side of the
cylinder block and insert the piston and connecting rod
Fig① Fig②
Fig assembly.
6 Piston and
E E connecting rod ・Mounting bolt ( Tighten both bolts alternately ) :
assembly 1] 60 4 Nm { 6.1 0.4 kgm }
2] Loosen both bolts by 360
B
2 kgm
3] 70 4.9 Nm { 7.1 0.5 kgm }
A F F 4] 60 5
4 ( Use angle tightening tool J )
Fig③
Fig Fig
Fig④ When not using tool J
・Make marks on the connecting rod cap and bolt with paint
7. Front gear housing and then tighten the bolt by 60 5
K
・Measure the side clearance between the connecting rod and
[5] crankshaft with tool K. Side clearance : 0.10 ‒ 0.30 mm Fig⑤
[1]
・Install gasket and gear housing .
7 Front gear kgm
Tighten the mounting bolts in the numerical order shown in
Fig⑤
Fig [6] housing the left figure : [ 1 ] → [ 6 ]
8. Oil pump [4] [3] [2] Mounting bolt : 39.2 2.0 Nm { 4.0 0.2 kgm }
・Fill the space in the pump rotor and idler shaft bore with
engine oil ( EO15W - 40 )and rotate the rotor by 2 turns.
・Install oil pump assembly . Fig⑥
[3] (C) [1] Set oil pump idler shaft (3) in the positioning hole of the
cylinder block securely. Fig⑦
Fig
Fig⑥ 8 Oil pump ・Tighten the mounting bolts in the numerical order shown in
3 kgm
the left figure : [ 1 ] → [ 4 ]
Mounting bolt : 1 st time : 5 1 Nm { 0.5 0.1 kgm }
2nd time : 24 4 Nm { 2.4 0.4 kgm } Fig⑧
・Rotate the crankshaft by 1 turn and measure backlash (C)
[4]
[2] between the pump and idler gear.
Fig
Fig⑦ Fig⑧
Fig Backlash (C) : 0.08 - 0.33 mm

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

2/10
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGINE 114-3 PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

9. Camshaft ・Rotate the crankshaft to set the No. 1 cylinder to the top
・dead center.
1 L kgm

Install thrust plate (4) with bolts (3).

3
Mounting bolt : 24 4 Nm { 2.4 0.4 kgm } Fig①
4
9 Camshaft
・Measure the end play of camshaft gear assembly (1) with tool L.
The end play depends on the thickness of the thrust plate and
the groove of the camshaft.
Fig① Fig
Fig② End play : 0.10 - 0.36 mm Fig②
L 10. Water pump ・Measure the backlash of camshaft gear assembly (1) with tool L.
1 Backlash : 0.08 - 0.33 mm Fig③

10 Water pump kgm ・Install water pump (1).

Mounting bolt : 24 4 Nm { 2.4 0.4 kgm }
1
11 Supply pump ・Set timing mark 00 of supply pump drive gear(2) to timing
Fig
Fig③
gear mark 0 of camshaft gear assembly (1).
11. Supply pump gear
1 12. Front oil seal ・Set front oil seal (8) to tool T with the oil seal lip side up.
2 Since pilot tool R on the inside of the front oil seal is used to
guide the front cover to the crankshaft, do not remove it
8 from the front oil seal.
Pilot tool R is contained in the spare front oil seal. Fig④
R ・Insert oil seal (8) from the front cover mounting side of
T carrier (7). Fig⑤
Set the seal flush with the face on the inserting side of the
12 Front oil seal carrier.
7 Fig
Fig④
Install carrier assembly to front cover .
8 ・Apply the gasket sealant not only to the flange surface but
also around each of the 5 bolts (a) and to the threaded parts
(b) of the nuts.
[4] ・Surface of flange : Gasket sealant ( LG - 7 ) Fig⑥
Fig
Fig⑤ [1]
・Tighten the mounting bolts in the numerical order shown in
[3] [2] kgm the left figure : [ 1 ] → [ 5 ]
Mounting nut : 9.8 2.0 Nm { 1.0 0.2 kgm } Fig⑦
[5]
a b
Fig⑥
Fig Fig
Fig⑦

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

3/10
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGINE 114-3 PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

13. Front cover assembly ・Do not apply oil, grease, etc. to the crankshaft and seal lip.
Wipe off oil and grease from the shaft.
[1] [4] [7]
[10] ・Install cover with mounting bolts . Cover mounting face:
[26]
[13] Gasket sealant (LG-7)
[24]
[21] [16]
[18] ・Tightening order of bolts
[19]
[12] [15] Tighten the bolts in the numerical order shown in the left
[22] 13 Front cover
[9]
assembly figure : [1] → [26]
[6] [2]
[5]
Mounting bolt : Fig①
[3] 9
[25]
[8] kgm
Position of bolt Size of bolt Tightening torque
[23]
[20] [17][14] [11] Fig① Fig
Fig② [1][2][4][5][7][8]
M8 30 2 Nm
14. Rear oil seal [10][11][13][16][17]
( Stem length 50 mm ) { 2.9 0.2 kgm }
[19][20][22][23]
1 [3)[6][9][12][14][15] M10 40 2 Nm
[18][21][24][25][26] ( Stem length 16 mm ) { 3.9 0.2 kgm }
A
・Install dust seal (9). Push in the dust seal until it touches the
oil seal. Fig②

Fig
Fig③ Fig
Fig④ ・Using alignment tool A, insert the oil seal until it is flush with
15. Seal housing the mounting flange surface of seal housing (1). Fig③
・While lightly hitting the top, bottom, right, and left of
A
14 Rear oil seal alignment tool [1] with a hammer to check that the seal
1 carrier is not bent, push in the oil seal until the outside of
alignment tool [1] touches the housing. Fig④
1 ・Do not remove the seal mounting pilot tool.
・Insert seal housing (1), aligning it with crankshaft (4).
4 ・Do not apply oil, grease, etc. to the crankshaft and seal lip.
Wipe off oiland grease from the shaft.
Fig
Fig⑤ Fig⑥
Fig 15 Seal housing ・Housing mounting face : Gasket sealant (LG-7)
[6] [7] Evenly set the heights of seal housing (1) and both sides (A)
5 of the oil pan rail. Fig⑤ Fig⑥
[4] [1]
・Mounting bolts in the numerical order shown in the left
[2] [3] kgm
figure : [1] → [8]
[8] Mounting bolt : 12.7 2.0 Nm { 1.3 0.2 kgm } Fig⑦
[5]
・Cut off gasket (5). (Right and left)
Fig⑦
Fig Fig⑧
Fig Take care that the cut gasket will not fall in the engine. Fig⑧

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

4/10
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGINE 114-3 PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

16. Oil pan ・Bed plate (Mating surface with cylinderblock) :

FRONT
[17] [9] [1] [7] [15] [23] Gasket sealant (LG-7)
3 ・Application drawing of gasket sealant
[25] [21] [13] [5] [3] [11] [19] [29]
[27] [31]
・Diameter of gasket sealant string:
・Apply strings of gasket sealant 1 mm in diameter to the range
[28] [32]
[26] [22] [14] [6] [2] [12] [20] [30]
from the bolt hole center to the area of R7. Change the
16 Oil pan diameter of the gasket sealant smoothly from 1 mm to 3 mm
[18] [10] [4] [8] [16] [24]
Fig① Fig
Fig② for the other parts unless otherwise specified.
17. Flywheel housing Measuring radial runout Flange(3) : Gasket sealant (LG-7)
kgm

[11]
Flange mounting bolt : 7.8 2 Nm { 0.8 0.2 kgm } Fig①
[12]
[9] [10] ・Tighten the bolts in the numerical order shown in the left
kgm
[5] [8] figure : [1] → [32] Mounting bolt : 24 4 Nm { 2.4 0.4 kgm } Fig②
[3] [2]
[1] [4] ・Apply a string of gasket sealant (LG-7) 1 ‒ 3 mm in diameter
[7] [6] to the housing mounting flange face and around each
Fig
Fig④
Measuring facial runout mounting bolt hole.

Fig
Fig③
17 Flywheel ・Tighten the bolts in the numerical order shown in the left
housing kgm
figure: [1] → [12]
Mounting bolt : 77 12 Nm { 7.9 1.2 kgm } Fig③
18. Flywheel Fig④ Fig⑤
・Radial runout : Max. 0.20 mm Facial runout : Max. 0.20 mm
[1]
Fig⑤
Fig ・Flywheel mounting face : Gasket sealant (LG-7)
[5]
Facial runout
（ Flywheel assembly: 40 kg ）
[3] [7] Radial runout
[4] ・1] Install lock plate (1).
[8] kgm
2] Tighten the bolts in the numerical order shown in the left
[6] a figure : [1] → [8]
b
[2] 18 Flywheel Mounting bolt : 137 7 Nm { 14.0 0.7 kgm } Fig⑥
Fig
Fig⑥
19. Starting motor ・Set the probe of the dial gauge perpendicular to spigot joint
assembly portion (a) or periphery of the flywheel.
・Set the probe of the dial gauge perpendicular to end face (b)
Fig
Fig⑦
of the flywheel near the periphery. Fig⑦
A
Radial runout : Max. 0.13 mm Facial runout : Max. 0.20 mm
・Apply string (A) of gasket sealant 1 mm indiameter.
19 Starting motor
assembly Both sides of gasket : Gasket sealant (LG-7)
・Install starting motor assembly.

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

5/10
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGINE 114-3 PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

20. Oil cooler and Filter 21. Cylinder head assembly ・Tighten the bolts in the numerical order shown in the left
20 Oil cooler and kgm
figure : [1] → [11]
[11] [10] c
Filter Oil cooler mounting bolt : 24 4 Nm { 2.4 0.4 kgm }
[9] [8] Oil filter : 13 2 Nm { 1.3 0.2 kgm }
[7] [6] ・Apply engine oil (EO15W-40) to the valve stem and inside of
valve guide and install valve. Fig①
[1] [2]
・Using tool C, compress valve spring (3) and install valve collet (4).
[3] [4] 4
[5] 21 Cylinder head ・Using limit length of bolt : less than 162.6 mm
3 ・Tighten the bolts in the numericalorder shown below.
Fig① assembly
[26] [22] [18] [14] [10] [6] [2] [3] [7] [11] [15] [19][23] 1] 150 9.8 Nm { 15.3 1.0 kgm }
kgm
2] Return all bolts 360
3] 115 4.9 Nm { 11.7 0.5 kgm }
4] Check tightening torque of 115 4.9 Nm { 11.7 0.5 kgm}
5] 120 5 ( Tighten with angle tightening tool ) Fig②
・Insert injector in the cylinder head.
・Install holder and tighten bolts by 3 ∼ 4 turns by hand.
[25][21] [17][13] [9] [5] [1] [4] [8] [12] [16][20] [24]
Fig
Fig② ・Install inlet connector (11) temporarily with retainer (10). Fig③
22.Fuel injector assembly Retainer : 15 5.0 Nm { 1.5 0.5 kgm }
5 6 11 10
・Tighten bolts (5) of holder (6) alternately.
11 Bolt : 10 2 Nm { 1.0 0.2 kgm }
22 Fuel injector kgm
The top of the holder must be in parallel with the top of the
assembly cylinder head.
Allowable angle: 2.4
Tighten inlet connector (11) to the specified torque.
10 Retainer (10) : 41 4 Nm { 4.1 0.4 kgm } Fig④
・Apply the caulking compound (e) (hatched section) to
Fig
Fig③
retainer (10) and the cylinder head.
23. Rocker arm assembly Caulking compound : GE TOSHIBA SILICON TOSSEAL 381 Fig④
e
Fig
Fig④ ・Before tightening the bolts, check that the ball of the
a b
kgm
adjustment screw is set in the push rod socket securely.
Bolt : 64.7 4.9 Nm { 6.6 0.5 kgm } Fig⑤
23 Rocker arm
assembly ・The shapes of holes (a) and (b) of each crosshead are
different. Accordingly,when reusing the crossheads,install
each of them to the same intake and exhaust valve in the
same direction as it has been installed.
Fig
Fig⑤ Fig
Fig⑥ ・A new crosshead may be installed in either direction. Fig⑥

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

6/10
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGINE 114-3 PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

24. Adjusting valve clearance ・Valve clearance (when cold)

Unit : mm
Intake valve Exhaust valve
4 2 0.30 0.05 0.56 0.05
K 24 Adjusting valve
clearance ・Insert clearance gauge K between rocker arm (2) and
kgm
crosshead (3) and set adjustment screw (4) to a degree that
you can move the clearance gauge lightly.
3 ・Tighten locknut (5)  24 4 Nm { 2.4 0.4 kgm }
5 After tightening the locknut, check the valve clearance again.

25. Rocker housing ・Tighten the bolts in the numerical order shown in the left
No.①cylinder No.②cylinder figure: [1] → [7]
[6] b a 4 d c 1 kgm Mounting bolt : 24 4 Nm { 2.4 0.4 kgm }
[4]
[2] ・Install wiring harness (4).
[1] Mounting nut : 1.25 0.25 Nm { 0.10 0.03 kgm } Fig①
[3]
[5]
[7] Locations of wiring harnesses
Color of cable Cylinder No.
25 Rocker housing a Yellow Right side
①,③,⑤
b Orange Left side
Fig① Fig
Fig②
5 c Red Right side
②,④,⑥
6 ok d Brown Left side
ok
・Install the injector wiring harness terminal (5) in a direction
where it will not interfere with the rocker arm (6) which moves
up and down.
・Take care that wiring harness (4) will not be pressed strongly
5 6 against the inside wall of housing (1), will not come off guide,
Fig③
Fig Fig④
Fig
or will not be bent sharply. Fig② Fig③ Fig④
26. Air intake manifold cover
・Fit the gasket and install manifold cover (1).
26 Air intake kgm
Both sides of gasket : Gasket sealant (LG-7)
1
manifold cover Tube mounting bolt : 24 4 Nm { 2.4 0.4 kgm }

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

7/10
UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGINE 114-3 PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

27. Fuel supply pump ・Rotate the crankshaft forward to bring stamped line (a) of the
supply pump gear to the top and set the No. 1 cylinder to the
1 compression top dead center (T.D.C). Fig①
・Before installing, check that dowel pin (1) of the supply pump
a drive shaft is not damaged. Fig②
・If the dowel pin is damaged, replace the supply pump
assembly and drive gear.
・Install new O-ring to the supply pump flange. O-ring :
Fig① Fig
Fig②
Engine oil (EO-30)
・Install new O-ring (3) to the supply pump lubrication port.
3
・Clean the periphery of the supply pump drive shaft and the
b
contact surface on the inside of the supply pump gear with
2 contact cleaner. Fig③
5 6,7
・Push in supply pump drive shaft (5) in supply pump drive gear
(4), setting the pin of the former to the key way (b) of the
latter, and fit washer (6), then tighten nut (3) temporarily. Fig④
27 Fuel supply
4 pump
Fig
Fig③ Fig
Fig④ ・Fix supply pump (8) according to the following procedure.
11 10 1] Tighten supply pump mounting nuts (9) to the degree that
8 12
they are not loose.
2Mounting nut (9) : Adhesive (LT-2)
2] Tighten mounting bolts (10) and (11) to the degree that
they are not loose.
3] Tighten supply pump mounting nuts (9) to the following
kgm torque.
Mounting nut (9) : 43 6 Nm { 4.4 0.6 kgm }
9 4] Tighten mounting bolt (10) on the cylinder head side to the
following torque.
13 Mounting bolt (10) : 65 6 Nm { 6.6 0.6 kgm }
5] Tighten mounting bolt (11) on the pump flange side to the
following torque.
Mounting bolt (11) : 77 12 Nm { 7.9 1.2 kgm }
・Tighten nut (12).
Mounting nut : 180 12.7 Nm { 18.4 1.3 kgm } Install cap (13).

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

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UNIT ASSEMBLING CHECK SHEET
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KOMATSU ENGINE 114-3 PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

28. Fuel lift pump and main controller cooling plate kgm
・Install fuel lift pump (3) to main controller cooling plate (2).
28 Fuel lift pump Mounting bolt : 10 2 Nm { 1.0 0.2 kgm } Fig①
2 and main
controller ・Lightly press the valve of the check valve (4) of main
cooling plate controller cooling plate (2) from the arrow side and check that
it moves smoothly and the sealing face is closed perfectly. Fig②

・IInstall main controller assembly (1) to the cylinder block with

29 Main controller kgm mounting bolts (2).
assembly,Fuel
4 Fuel drain tube Joint bolt : 24 4 Nm { 2.4 0.4 kgm }
3 drain tube,Fuel
Fig① Fig
Fig② filter bracket, ・Fuel low-pressure hose
Fuel The internal parts of the adapter maybe damaged when the
29. Main controller assembly,Fuel drain tube, low-pressure hose is removed. Accordingly, do not reuse theadapter but
Fuel filter bracket,Fuel low-pressure hose hose use new one when installing the hose again, as a rule.

1 2 ・Do not remove fuel pressure sensor (2) from common rail (1)
for a purpose other than replacement.
・Once the fuel pressure sensor is removed from the common
30 Fuel pressure rail, be sure to replace it.
30. Fuel pressure sensor sensor and
・Fuel pressure sensor : Gear oil (#90) 70 5 Nm { 7.1 0.5 kgm }
and relief valve relief valve
Relief valve : Gear oil (#90) 100 4 Nm { 10.2 0.4 kgm }
1
kgm
Excessive tightening can cause leakage. Take care not to
・tighten too strongly.
Adapter : Gear oil (#90) 37 4 Nm { 3.8 0.4 kgm }

・Install each high-pressure pipe and wiring harness at least 10 mm

31. Common rail and piping
7 3
b 2
2 apart from each other.
・When installing each high-pressure pipe, check the taper seal
of its joint (Part(a): Part of 2 mm from the end) for visible
lengthwise slit (b) and spot (c) and check part (d) (End of
4 5 taper seal: Part at 2 mm from the end) for stepped-type wear
6 31 Common rail
and piping caused by fatigue which your nail can feel.
If there is any of those defects, it can cause fuel leakage. In
this case, replace the high-pressure pipe. Fig③

Tubes (1) ‒ (7) Nut : 37.3 4 Nm { 3.8 0.4 kgm }

a c Tube (18) Joint bolt : 24 4 Nm { 2.4 0.4 kgm }
d 1 18 16 kgm
Common rail (16) Joint bolt : 43.1 4.0 Nm { 4.4 0.4 kgm }
Fig
Fig③ Fig④
Fig Head cover assembly mounting bolt :11.8 1.96 Nm { 1.2 0.2 kgm }
Fig④

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

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UNIT ASSEMBLING CHECK SHEET
ASSEMBLING CONFIRMATION
KOMATSU ENGINE 114-3 PROCEDURE CHECK POINT : Visual : Measure kgm : Tightening Torque : Caution

32. Exhaust manifold and turbocharger ・Tighten the mounting bolts in the numerical order shown in
the left figure : [1] → [12]
Tightening order of Exhaust manifold bolts :
[12] [8] [4] [1] [5] [9] 1 3 2 1] Tighten all the bolts to
24 4 Nm { 2.4 0.4 kgm }
[11] [7] [3] [2] [6] [10]
kgm
2] Retighten only bolts [1] ‒ [4] in the figure to
24 4 Nm { 2.4 0.4 kgm } in the order of their numbers.
3] Tighten all the bolts to
32 Exhaust 43 6 Nm {4.4 0.6 kgm}.
manifold and
4] Retighten only bolts [1] ‒ [4] in the figure to
Fig① Fig
Fig② turbocharger
43 6 Nm { 4.4 0.6 kgm } in the numerical order. Fig①
33. Coolant connector,Alternator,Vibration damper, ・Turbocharger assembly (3)mounting nut :
Fan belt,Wiring harness,Muffler
45 7 Nm { 4.6 0.7 kgm }
3 kgm
Lubrication hose (1)nut :
35.3 4.9 Nm { 3.6 0.5 kgm }
1 Drain hose clamping bolt :
24 4 Nm { 2.4 0.4 kgm } Fig②

・Coolant connector (1),(2) mounting bolts :

24 4 Nm { 2.4 0.4 kgm } Fig③
2 ・Alternator mounting bolt (3) :
4 33 Coolant 43 6 Nm { 4.4 0.6 kgm } Fig④
Fig
Fig③ Fig
Fig④ connector, ・Alternator mounting bolt (4) :
Alternator, 24 4 Nm { 2.4 0.4 kgm }
Vibration damper, ・Vibration damper mounting bolt :
5 Fan belt, 200 10 Nm { 20 1.0 kgm }
Wiring harness,
・Check that the clearance between wiring harness (5) and fan
Muffler
belt (6) is 15 mm or wider. Fig⑤
・Install tube (7). Clamp :
6.9 ∼ 8.8 Nm { 0.7 ‒ 0.9 kgm } Fig⑥

6 7 Engine oil pan : Approx. 24 ℓ

Fig⑤
Fig Fig
Fig⑥ Engine assembly : Approx. 800 kg

Date Work Order No. Customer Machine Model & Type Machine Serial SMR Engine Serial Inspected By

10/10