Hyundai D4DD Engine Workshop Manual

ENGINE MECHANI-

CAL SYSTEM

(D4DD)

GENERAL

DESCRIPTION ............................................. EM -2

SPECIFICATION ......................................... EM -6

SPECIAL TOOL ........................................... EM -12

DIAGNOSIS................................................. EM -15

ADJUSTMENT............................................. EM -16

TIMING SYSTEM

TIMING GEAR ASSEMBLY

COMPONENTS ..................................... EM -17

REMOVAL.............................................. EM -19

INSPECTION .......................................... EM -22

REPLACEMENT .................................... E M -25

INSTALLATION...................................... EM -26

CYLINDER HEAD ASSEMBLY

COMPONENTS........................................... EM -31

REMOVAL ................................................... EM -33

DISASSEMBLY........................................... EM -36

INSPECTION ............................................... EM -37

REPLACEMENT.......................................... EM -4 1

REASSEMBLY ............................................ EM -43

INSTALLATION ........................................... EM -44

CRANK CASE

FLYWHEEL

COMPONENTS ..................................... EM -46

REMOVAL.............................................. EM -47

INSPECTION .......................................... EM -47

INSTALLATION...................................... EM -48

CYLINDER BLOCK ASSEMBLY

COMPONENTS ..................................... EM -50

REMOVAL.............................................. EM -52

DISASSEMBLY ..................................... EM -5 5

INSPECTION .......................................... EM -55

REASSEMBLY...................................... EM -6 1

INSTALLATION...................................... EM -62

INTAKE AND EXHAUST SYSTEM

SPECIFICATIONS ....................................... EM -66

TROUBLESHOOTING ................................ EM -67

TURBO CHARGER

COMPONENTS ..................................... EM -69

REMOVAL.............................................. EM -71

INSPECTION.......................................... EM -72

INSTALLATION...................................... EM -73

INTAKE MAINIFOLD

COMPONENTS ..................................... EM -75

REMOVAL.............................................. EM -76

INSPECTION.......................................... EM -76

INSTALLATION...................................... EM -77

EXHAUST MANIFOLD

COMPONENTS ..................................... EM -78

REMOVAL.............................................. EM -79

INSTALLATION...................................... EM -80

AIR CLEANER

COMPONENTS ..................................... EM -81

INSPECTION.......................................... EM -85

LUBRICATION SYSTEM

DESCRIPTION............................................. EM -8 6

SPECIFICATION ......................................... EM -90

TROUBLESHOOTING ................................ EM -92

ADJUSTMENT............................................. EM -94

OIL PUMP

COMPONENTS ..................................... EM -96

DISASSEMBLY ..................................... EM -9 8

OIL COOLER

COMPONENTS ..................................... EM -99

DISASSEMBLY ..................................... EM -100

INSPECTION.......................................... EM -100

REASSEMBLY ...................................... EM -101

COOLING SYSTEM

DESCRIPTION............................................. EM -102

SPECIFICATION ......................................... EM -104

TROUBLESHOOTING ................................ EM - 106

WATER PUMP

COMPONENTS ..................................... EM -108

REMOVAL.............................................. EM -109

INSPECTION.......................................... EM -110

INSTALLATION...................................... EM -111

RADIATOR

COMPONENTS ..................................... EM -112

REMOVAL.............................................. EM -113

INSPECTION.......................................... EM -113

INSTALLATION...................................... EM -113

EM -2 ENGINE MECHANICAL SYSTEM

GENERA

L

DESCRIPTION EFA0EBB7

COMBUSTION

CHAMBER

1. Combustion chamber consists of cylinder head, pis­ton, injector installed to the cylinder head and valve.

Valve guide

Injector

Cylinder head

Valve

Piston

EM7001L

SUD

VALVE MECHANISM

1. Heat resistant steel with surface treatment is used for
intake and exhaust valve. The valve seat angle is 45

2. Valve stem seal, installed to the stem, adjusts the
lubricant amount on the sliding surface of valve and
valve guide.

NOTE

Valve guide with carbon cutter is used for exhaust
valve.

3. Valve spring consists of two valve springs having ir­regular pitches. The coil directions of inner and outer
springs are opposite each other.

4. Rocker shaft is hollow cylindrical rod, whose each end
are sealed with sealing cap. Inner space of the shaft
is an engine oil passage.

5. Steel ball is installed to the lower end of push rod and
rocker assembly is installed to upper end.

6. Tappet has a cylindrical shape. As enlarging the con­tacting surface contacted with camshaft, it helps to
prevent partial wear and to increase its durability.

.

2. Fuel is supplied to supply pump through the fuel filter
installed to the frame. Fuel is also supplied to injectors
through injection pipe No. 1, 2, 3 and 4 in common rail
assembly.

3. Combustion is accomplished when fuel is injected di­rectly into combustion chamber, at that time explosion
pressure applies to the piston directly.

4. Fo

r better efficient cooling of combustion chamber,

ter director is press-fit under cylinder head floor,

wa

ich induces the coolant flow.

wh

Rocker shaft

Push rod

Tappet

Outer spring

Inner spring

Rocker

Valve spring

Valve guide

Exhaust valve

Intake valve

Camshaft

SUDEM7003L

Water director

Engine coolant

SUDEM7002L

GENERAL EM -3

7. Camshaft assembly (1) consists of cam sensor plate,
thrust plate, cam and journal. Camshaft gear is cou­pled with the idler gear A (2).

2

1

SUDEM7004L

CRANKCASE AND CYLINDER SLEEVE

1. Crankcase is manufactured firmly with cast iron to
prevent stress concentration and deformation.

2. The 5 camshaft bushes are installed to the camshaft
bore of the crankcase.
To facilitate the removal and installation of camshaft,
inner diameter of bush is tapered to the rear side.

3. Cylinder sleeve made of special cast iron is pressed
fit into the crankcase.

Crank case

Cylinder sleeve

SUDEM7006L

PISTON

1. Piston pin type is full float type and piston pin is offset
from thrust.

2. Marks on the piston indicate weight, part number and
oversize. The front mark indicates the front direction
of the engine.

NOTE

Do not remove the cam sensor plate
unless it is damaged.

SUDEM7005L

When assembling a piston, let the arrow mark (→)
faced to the center of cylinder head bolt hole.

Weight mark

Part number

Front mark

SUDEM7007L

EM -4 ENGINE MECHANICAL SYSTEM

PISTON RING

Piston has two compression rings and one oil ring. All
sliding surfaces of rings are coated with hardened chrome.

Compression ring No. 1

Compression ring No. 2

Oil ring No. 3

SUDEM7008L

CRANKSHAFT

1. Crankshaft is forged with high-strength alloy built in
with balance weight.

2. Pin, journal and oil seal sliding-surface are hardened
with high frequency heat treatment to raise the resis­tance against frictional wear.

3. Through oil passage at the pin and journal, oil lubri­cates main bearing. Oil flows to the pin for the lubri­cation of connecting rod bearing.

6. Crankshaft gear (1) drives camshaft gear (2), idler
gear A (3), idler gear B (4), supply pump gear (5) and
oil pump gear (6).

3

5

2

4

6

1

SUDEM7010L

CRANKSHAFT MAIN BEARING

Upper main bearing has oil groove and oil hole which
matches with oil hole of the crankshaft.
Dividedtypethrustplateisinstalledtothebothendsofthe
last bearing (No.5).

Upper main bearing (No. 5)

Upper main bearing (No. 1)

4. Crankshaft pulley and crankshaft gear are installed
at the front end of crankshaft. The crankshaft pulley
drives alternator and water pump using V-belt.

5. Crankshaft damper pulley absorbs the distorting vi­bration of crankshaft.

Journal

Crankshaft gear

Oil passage

Pin

Crankshaft
damper pulley

SUDEM7009L

Thrust plate

Lower main bearing

SUDEM7011L

GENERAL EM -5

TIMING GEAR

1. Timing gear is installed in the timing gear case at the
frontofengine.

2. Each gear is helical gear manufactured with high pre­cision and its surface is treated by heat to enhance
the durability.

3. Timing marks are marked on the gear. When assem­bling, by aligning the timing marks, gears can be en­gaged correctly.

Camshaft gear

Idler gear A

Crankshaft gear

Idler gear B

Supply
pump gear

FLYWHEEL

1. Flywheel is made of forged iron. Pilot bearing of trans­mission drive pinion is disposed at the center portion.
Ring gear which can be geared with starter pinion is
pressed fit at the circumferential of the flywheel.

2. Processed is formed at the outer diameter of the fly­wheel to measure the engine rpm.

Ring gear

Processed

SUDEM7014L

SUDEM7012L

4. Bushes are press-fit into idler gear, which rotates idler
shaft A (1) and idler shaft B (2). Idler shaft and gear oil
hole provides oil passage to lubricate bush and gear.

1

2

SUDEM7013L

EM -6 ENGINE MECHANICAL SYSTEM

SPECIFICATION ECC41378

Items

General Type

Cylinder inner diameter
Cylinder stroke
Displacement
Compression ratio
Firing order
Maximum output

Maximum torque

Compression pressure (at 200rpm)

Valve timing
Intake valve open (BTDC)
Intake valve close (ABDC)
Exhaust valve open(BBDC)
Exhaust valve close (ATDC)

Standard

([ ] indicates standard

diameter)

Serial 4-cylinder 4stroke

common rail system

104mm
115mm

3,907cc

17.5 : 1
1-3-4-2

140ps/2800rpm

(HD65, 72,78 Narrow)

140ps/2800rpm

(HD65, 72,78 Wide)

140ps/2800rpm (County)

38kgf.m/1600rpm

(HD65, 72,78 Narrow)

38kgf.m/1600rpm

(HD65, 72,78 Wide)

38kgf.m/1600rpm (County)

26kg/cm²

19
53
60
16

Limit

20kg/cm²

Corrective

action

Adjustment

(As the

difference

between

cylinders is

within 4kg/cm² )

Valve
Intake valve length
Exhaust valve length
Outer diameter of intake valve stem
Outer diameter of exhaust valve stem
Valve face angle
Thickness (margin) of intake/exhaust valve head
Valve clearance (when engine is cold)

Gap between valve stem and valve guide
Intake
Exhaust

Valve guide length
Intake
Exhaust

Valve sinkage
Intake
Exhaust

Push rod run out

Valve seat width
Intake
Exhaust

137mm
137mm

8.960~8.975mm

8.925~8.940mm
45

1.5mm

0.4mm

[9] 0.04~0.06mm
[9] 0.07~0.10mm

64mm

71.5mm

0.75~1.25mm

0.75~1.25mm

―

2.6~3.0mm

1.8~2.2mm

8.85mm

8.85mm

1.2mm

0.15mm

0.2mm

1.5mm

1.5mm

0.4mm

3.6mm

2.8mm

Replace

Valve s eat

Replace insert

Replace

Replace

GENERAL EM -7

Outer side valve Spring

Free height

Load installed
Winding direction
Out of squareness

Inner side valve spring

Free length
Load installed
Winding direction
Out of squareness

Cylinde
Cylinder
To rsion o
Flatness
Outofsqu
Clearanc

Clearanc

rblock

bore

f upper crankcase
of gasket surface

areness of gasket surface

e between tappet and crankcase tappet hole

e between piston ring and piston ring groove
No.1 ring
No.2 ring
Oil ring

Items

Standa

([]ind

icates standard

diamet

26.5~29
To t h e r i

11.5~12

Left sid

104.00~104.03mm
Below 0.07mm

[28] 0.045~0.096mm

0.106~0.170mm

0.07~0.11mm

0.03~0.07mm

rd

er)

66.1mm
.3kg

ght

1.5mm

60.0mm
.7kg

e

1.5mm

0.07mm

0.05mm

Limit

63mm

23.7kg

2.1mm

57mm

10.3kg

2.1mm

0.2mm

0.2mm

0.2mm

0.15mm

0.15mm

action

Replac

Replace

ive

e

Correct

Replace the

piston ring

Piston ri

Average protrusion of piston

Piston
Piston outer diameter
Clearance between piston and cylinder sleeve

Piston pin
Outer diameter of piston pin
Clearance between piston pin and piston pin hole
Clearance between piston pin and connect­ing rod end bush

Cylinder

ng end gap
No.1 ring
No.2 ring
Oil ring

Gasket grade A
Gasket grade B
Gasket grade C

sleeve

Inner dia

Outofrou

Out of cyl

meter

ndness

inderness

0.25~0.40mm

0.50~0.65mm

0.20~0.40mm

0.466~0.526mm

0.526~0.588mm

0.588~0.648mm

103.91~1

0.080~0.

37.994~3

0.007~0.

[38] 0.02

104.00~1

03.92mm
130mm

8.00mm
021mm

5~0.046mm

04.03mm

0.005mm

0.015mm

1.0mm

1.5mm

1.0mm

0.05mm

0.1mm

100.25mm
Below

0.01mm
Below

0.03mm

Replace

Measure
the average
protrusion and
replace the
gasket with the
corresponding
grade gasket

Repair wi
oversize
replace

Replace b

Repair wi
oversize
replace

th

or

Replace

ush

th

or

Cylinder head

Flatness of cylinder head bottom

Length from cylinder head top to bottom

Below 0.1

94.9~95.

mm

1mm

0.2mm

94.6mm

Repair or

replace

EM -8 ENGINE MECHANICAL SYSTEM

Items

Connecting rod

Connecting rod twist and distortion
Oil clearance

Connecting rod bearing

Free length of connecting rod bearing

Bearing crush (measured load 600kg)

Connecting rod endplay

Camshaf

t
Intake c
Intake c

Intake c
Exhaust c
Exhaust c

Exhaust c

Camshaft
Clearanc

am max. length
am min. length

am lift

am max. length
am min. length

am lift

endplay

e between camshaft journal and bushing

Standa

([ ] ind

icates standard

diamet

0.04~0.099mm

34.53~34.57mm

0.15~0.45mm

47.105mm

39.910mm

7.195mm

46.979mm

39.658mm

7.321mm

0.05~0.22mm

Stamp mark #1,2,3,4

([54.5] 0.04~0.09mm)

Stamp mark #5

([53] 0.04~0.09mm)

rd

er)

―

―

Limit

0.05mm

0.2mm

Min.

69.5mm

―

0.6mm

0.3mm

0.15mm

Correct

action

Repair or

replace

Replace b

ive

using

Crankshaft

Out of roundness of pin and journal
Out of cylindricity of pin and journal

Crankshaft distortion

(measured at journal No.1 and No.5)

Crankshaft endplay

Crankshaft main bearing

Oil clearance (#1, 2, 4, 5)

Oil clearance (#3)

Free length

Bearing crush( measured load 500kgf)

Timing gear

Crankshaft
Idler gear A
Idler gear A

Idler gear B a

Camshaft gea

Crankshaft g

Power steeri

Idler gear en

backlash

gear and idler gear A

and cam shaft gear

and idler gear B

nd supply pump gear

r and power steering pump gear

ear and oil pump gear

ng pump gear and vacuum pump gear

dplay

―

mm

6mm

mm

mm

8mm
8mm

101mm

0.03mm

0.03mm

0.05mm

0.4mm

0.15mm

0.15mm

Min 69.5mm

Below 0.01

Below 0.00

Below 0.02

0.10~0.26

0.036~0.09

0.056~0.11

41.061~41.

0.062~0.159mm

0.068~0.175mm

0.062~0.160mm

0.073~0.169mm

0.075~0.160mm

0.049~0.169mm

0.075~0.160mm

0.05~0.22mm 0.3mm

Replace thr

Replace

―

Repair or

replace

Replace thru

ust

plate

st

plate

Clearance between idler busing and idler shaft [45] 0.025~0.06mm

Flywheel

Distortion o

Height of fri

Run-out of fr

f frictional surface

ctional surface
ictional surface (while installed)

Below 0.05mm

24.5mm

Below 0.1mm

0.1mm

0.2mm

23.5mm

0.2mm

Replace busing

Repair or

replace

GENERAL EM -9

TIGHTENING TORQUE

Screw size

Items (diameter × length)

O.D×pitch

(mm)

Nm kgf.m Ib-ft

Cylinder
block

Lubrication
system

Main bearing cap bolt M14×2.0

Front plate flange bolt(8 ×16)

Rear oil seal slinger flange bolt(6×12)

Supply pump side timing gear case
mounting bolt

Supply pump flange bolt

Oil jet check valve M12×1.25

Rear plate flange bolt(10×22) M10×1.5

Rear stiffener bracket flange bolt(8 ×55)

Rear stiffener bracket flange bolt (10×90)

Engine mounting bracket mounting bolt

Crankcase oil line set screw M10×1.5

Oil strainer flange bolt(8 ×16)

Oil strainer flange bolt (8 ×40)

Oil p an mounting flange bolt (8×12) M8×1.2

Oil level gauge mounting flange bolt(8×16)

―

―

―

―

―

―

―

―

―

―

49+90 5.0+90 36.4+90

18.6~27.4 1.9~2.8 13.8~20.4

7.8~11.8 0.8~1.2 5.8~8.7

18.6~27.4 1.9~2.8 13.8~20.4

16.7~25.5 1.7~2.6 12.4~18.9

29.4 3.0 21.8

63.7 6.5 47.3

18.6~27.4 1.9~2.8 13.8~20.4

38.2~58.8 3.9~6.0 28.4~43.6

32.3~49 3.3~5.0 24~36.4

24.5 2.5 18.2

18.6~27.4 1.9~2.8 13.8~20.4

18.6~27.4 1.9~2.8 13.8~20.4

18.6~27.4 1.9~2.8 13.8~20.4

18.6~27.4 1.9~2.8 13.8~20.4

Oil pan drain plug M14×1.5

Oil filter element M26×1.5

Oil cooler by-pass M16×1.5

Oil cooler relief valve M16×1.5

Oil cooler drain plug M14×1.5

Oil cooler mounting flange bolt

Oil line flange bolt

Oil line eyebolt

Idler gear oil supply pipe

Turbo charger oil pipe eyebolt

Turbo charger oil pipe flange bolt(8×16)

Oil pump Oil pump mounting flange bolt(8 ×55)

Cylinder
head

Cylinder head mounting bolt M14×2.0

Cylinderheadstud(10×25)

Cylinderheadstud(10×48)

34.3~39.2 3.5~4.0 25.4~29.1

19.6 2.0 14.5

19.6 2.0 14.5

19.6 2.0 14.5

34.3 3.5 25.4

―

―

―

―

―

―

―

―

―

18.6~27.4 1.9~2.8 13.8~20.4

7.8~11.8 0.8~1.2 5.8~8.7

18.6~22.5 1.9~2.3 13.8~16.7

18.6~22.5 1.9~2.3 13.8~16.7

18.6~22.5 1.9~2.3 13.8~16.7

18.6~27.4 1.9~2.8 13.8~20.4

18.6~27.4 1.9~2.8 13.8~20.4

147+90 15.0+90 109+90

34.3 3.5 25.4

34.3 3.5 25.4

EM -10 ENGINE MECHANICAL SYSTEM

Fan and
pulley

Thermo

g

housin

Timing
system

Items (diameter × length)

Fan clu

Fan clutch spring washer bolt(8×25)

Fan fla

stat

Thermostat cover case flange bolt

Engine coolant temperature sensor
and gauge

Thermostat case flange bolt(10×25)

Timing gear case flange bolt M8×1.25

Rocke

Cam pl

Cam plate and oil drain plug

Camsh

Idler

Suppl

tch mounting flange bolt (8)

nge nut (6)

r cover mounting flange bolt

ate and thrust plate flange bolt

aft gear flange bolt

gear A, B mounting bolt

ypumpofflowervalve

Screw s

O.D×pi

(mm)

―

―

―

―

―

―

M8×1.

―

―

―

M8×1.

―

ize

tch

25

25

Nm kgf.m Ib-ft

21.6~32.3 2.2~3.3 16~24

16.7~25.5 1.7~2.6 12.4~18.9

3.9~5.9 0.4~0.6 2.9~3.6

21.6~32.3 2.2~3.3 16~24

29.4~39.2 3.0~4.0 21.8~29.1

35.3~52.9 3.6~5.4 26.2~39.3

18.6~27.4 1.9~2.8 13.8~20.4

12.7~15.7 1.3~1.6 9.5~11.6

18.6~27.4 1.9~2.8 13.8~20.4

58.8~78.4 6.0~8.0 43.6~58.2

18.6~27.4 1.9~2.8 13.8~20.4

18.6~27.4 1.9~2.8 13.8~20.4

7.8~12.7 0.8~1.3 5.8~9.5

er

Bleed

m

syste

nator

Alter
and

m

vacuu
pump

Piston and
connecting
rod

heel

Flyw
and

er

damp

ey

pull

Starter
motor

Blow-by return pipe and blow-by hose
Protect clip flange nut

parate mounting flange bolt

Oil se

PCV blow-by return coating clip flange bolt

by return pipe mounting flange bolt

Blow-

Alternator adjust plate mounting bolt(10×20)

nator adjust shaft mounting nut (10)

Alter

nator assembly mounting bolt

Alter

Vacuum pump pipe tightening bolt M6×14

m pump mounting flange bolt

Vacuu

Connecting rod and connecting rod
bearing cap mounting bolt

Flywheel mounting bolt M14×1.5

Crankshaft damper pulley mounting nut M24×1.5

ting flange bolt (12×25)

Moun

Mounting flange bolt (12×55)

―
―

―

―

―

―

―

M12×1

M12.5×1.25

34

M8×16

―

―

9.8~14.7

18.6~27.4 1.9~2.8 13.8~20.4

7.8~11.8 0.8~1.2 5.8~8.7

35.3~52.9 3.6~5.4 26.2~39.3

35.3~52.9 3.6~5.4 26.2~39.3

18.6~27.4 1.9~2.8 13.8~20.4

78.4~107.8 8.0~11 58.2~80

3.9~5.9 0.4~0.6 2.9~3.6

18.6~27.4 1.9~2.8 13.8~20.4

29.4+90 3.0+90 21.8+90

39.2+40 4.0+40 29.1+40

588 60 436

78.4~107.8 8.0~11.0 58.2~80

37.2~53.9 3.8~5.5 27.6~40

1.0~1.5

7.3~10.9

Glow

plug

ting flange bolt (12)

Moun

Glow plug harness flange nut

n washer nut

Plai

―

―

―

37.2~53.9 3.8~5.5 27.6~40

3.9~5.9 0.4~0.6 2.9~3.6

1~1.5 0.1~0.15 0.7~1.1

GENERAL EM -11

Intake
manifold

Exhaust
manifold

Engine
cover

o

Tu rb

ger

char

Fuel

em

syst

Screw s

Items (diameter × length)

or mounting flange bolt

Actuat

Butterfly valve shaft mounting nut (8)

Intake manifold front hanger mounting
flange bolt (10×20)

Intake manifold mounting flange bolt (8 ×20)

Exhaust manifold heater protector
cover mounting bolt

st manifold assembly self lock

Exhau

enut

Flang

Topshieldboltscrew

o charger and intake pipe clamp band

Tu r b

Turbo charger oil pipe eyebolt M8×1.25

Fuel suction hose

on rail fuel return B mounting screw

Comm

O.D×pi

M10×1

tch

(mm)

―

―

―

―

M8×1.25

.25

―

.5

M9×2

―

―

ize

Nm kgf.m Ib-ft

7.8~11.8 0.8~1.2 5.8~8.7

16.7~27.4 1.7~2.8 12.4~20.4

32.3~49 3.3~5.0 24~36.4

18.6~27.4 1.9~2.8 13.8~20.4

11.8 1.2 8.7

41.2 4.2 30.5

7.8~11.8 0.8~1.2 5.8~8.7

3.9 0.4 2.9

11.8 1.2 8.7

14.7~19.6 1.5~2.0 10.9~14.5

16.7~22.5 1.7~2.3 12.4~16.7

Sens

or

return A and fuel supply hose

Fuel

ect clip flange bolt

prot

return A and rear plate clamp plate bolt

Fuel

Injector pipe (No.1, 2, 3, 4)

ctor nozzle bridge bolt

Inje

Common rail bracket Flange bolt

(between supply pump and common rail)

Pipe

Engine speed sensor mounting bolt

peed sensor mounting bolt

Cam s

ter pressure sensor (M.A.P)

Boos

ting bolt

moun

―

―

―

―

―

―

―

―

―

9.8~19.6 1.0~2.0 7.3~14.5

3.9~5.9 0.4~0.6 2.9~3.6

39.2~49 4.0~5.0 29.1~36.4

30.4~34.3 3.1~3.5 22.5~25.4

21.6~32.3 2.2~3.3 16~24

39.2~49 4.0~5.0 29.1~36.4

7.8~11.8 0.8~1.2 5.8~8.7

7.8~11.8 0.8~1.2 5.8~8.7

7.8~11.8 0.8~1.2 5.8~8.7

EM -12 ENGINE MECHANICAL SYSTEM

SPECIAL TOOL E2E65F7D

Tool (part no. and par t name)

09212­Camsha
and ins

41200

ft bushing remover

taller

09246-41000
Idler gear bushing puller

09222-83200
Piston guide clamp

Shape

KDDEM5015A

M5016A

KDDE

Usage

Installation and removal of
camshaft bushing

Installation and removal of connecting
rod bushing

Installation of piston

09222-83300
Valve spring compressor

09221-41100
Valve guide remover

KDDEM5017A

Installation and removal of valve cotter

KDDEM5018A

Removal of valve guide

KDDEM5019A

GENERAL EM -13

Tool (part no. and par t name)

09221-41150
Valve guide installer

09222-45100
Valve stem seal installer

09353-45100
Air compressor adapter

Shape

KDDEM5020A

M5021A

KDDE

Usage

Installation of valve guide
(Use together with 09211-41100)

llation of valve stem seal

Insta

Measurement of compression
pressure

09222-83200
Piston ring tool

KDDEM5022A

DEM5023A

KD

tallation and removal of piston ring

Ins

EM -14 ENGINE MECHANICAL SYSTEM

Tool (part no. and par t name)

09222-45000
Rocker bush puller

09211-41000
Oil seal slinger installer

Shape

KDDEM5024A

KDDEM5025A

Usage

Installation and removal of rocker bush

llation and removal of crankshaft

Insta

il seal slinger

rear o

GENERAL EM -15

DIAGNOSIS E252285B

Symptom

Compression pressure
is excessively low

Oil pressure is
excessively low

Oil pressure is
excessively high

Connecting rod noise or
main bearing noise

Excessive engine
vibration

Possible cause Maintenance

Cylinder head Gasket is melt
Piston ring is worn or damaged
Piston or cylinder is damaged
Valve seat worn or damaged

Engine oil depleted
Oil pressure switch fail
Oil filter clogged
Oil pump gear or case is worn
Engine oil viscosity is low
Oil relief valve stuck (open)
Excessive bearing clearance

Oil relief valve stuck (close) Repair the relief valve

Improper oil supply
Low oil pressure
Low engine oil viscosity
Excessive bearing clearance

Engine mounting bolt is loose
Transmission mounting bolt is loose
Cross member bolt is loose
Engine mounting rubber is damaged
Transmission mounting rubber is damaged

Replace gasket (check the status of
head surface, block head)
Replace the ring
Repair or replace piston or cylinder block
Repair or replace valve or seat ring

Add engine oil
Replace oil pressure switch
Replace the filter with new one
Replace the gear or case
Replace engine oil
Repair valve
Replace the bearing

Check the engine oil level
Refer to ’oil pressure is excessively low’
Replace engine oil
Replace the bearing

Retighten
Retighten
Retighten
Replace
Replace

Engine coolant level
is low

Radiator is clogged

Engine coolant
temperature is
abnormally high

Engine coolant
temperature is
abnormally low

Oil cooling system leaks Hose or pipe connection is loose

Engine coolant leak
Radiator core joint is damaged
Radiator and heater hose corroded
and cracked
Radiator cap valve or spring setting
is defective
Thermostat defect
Water pump defect

Foreign substance intrusion into
engine coolant

Thermostat is defective
Radiator cap is defective
Cooling system flow is defective
Drive belt is loose
Water pump is defective
Temperature wiring is defective
Radiator fan is defective
Engine coolant is low

Thermostat is defective
Temperature wiring is defective

Hoseandpipeiscrackedordamaged

Replace

Replace

Replace
Replace
Replace
Adjust or Replace
Replace
Repair or replace
Repair or replace
Add coolant

Replace
Repair or replace

Retighten
Replace

Radiator fan is
inoperative

Damage Repair or replace

EM -16 ENGINE MECHANICAL SYSTEM

Sympto

m

Possible cause Maintenance

Exhaust gas leaks Connection is loose

Pipe or muffler is damaged

Unusua

l noise

plate inside the muffler fell off

Baffle
Rubber
Pipe or
Pipe or m

hanger is damaged

muffler interferes with the body

uffler is damaged

ADJUSTMENT E148032F

COMPRESSION PRESSURE

1. Before performing on-vehicle inspection, check to see
whether engine oil, starter motor and battery are in
normal condition.

2. Start the engine and warm up until the coolant tem­perature reaches 80~90

3. Stop the engine and remove the ECM fuse.

4. Remove all injectors from cylinder head.

CAUTION

Be careful that foreign materials do not intrude
through the injector installation hole.

5. Crank the engine to remove the foreign materials from
cylinders.

6. Install compression gauge adaptor (09353-45100) to­gether with gasket and then, connect the compression
gauge.

Compression pressure gauge

C.

Retighten
Repair or replace

Replac
Replac

e

e
Repair
Repair o

r replace

7. Crank the engine and measure the compression pres­sure.

CAUTION

a. Take care that fuel is not injected.
b. Since compression pressure varies depend-

ing on the engine speed, be careful in mea­suring.

c. Since worn amounts of each cylinder are dif-

ferent, measure the pressure at all cylinders.

8. Measure the compression pressure of all cylinders to
see if all compression pressures are within the limit.

Correc­tive ac-

tion

Items

Com­pression
pressure

(200rpm)

Each
cylinder

Differ­ence be­tween

Stan-

dard

Limit

26kg/cm² 20kg/cm² Check

―

4kg/cm² Check

cylinders

09353-45100

SUDEM7015L

9. If the compression pressure difference of any cylinder
exceeds the limit, fill some engine oil through injector
hole and measure the compression pressure of the
cylinder again.

1) If the compression pressure increases, it indi-

cates that the piston, piston ring or cylinder wall
is worn or damaged.

2) If the compression pressure does not increase, it

indicates that valve is stuck, valve contact is poor
or pressure is leaking through the cylinder head
gasket.

TIMING SYSTEM EM -17

TIMING

SYSTEM

TIMING GEAR ASSEMBLY

COMPONENTS E2F63E1E

18.6~27.4

(1.9~2.8, 13.8~20.4)

15

16

17

18

19

20

25

21

26

22

58.8~68.6

(6.0~7.0, 43.6~50.9)

23

11

10

9

24

3.9~5.9

(0.4~0.6,

2.9~4.4)

12

60.0

13

14

8

7

6

5

4

3

2

1

20.

Thrust plate

21.

Idler gear A

22.

Idler shaft

23.

Oil pump gear

24.

Crankshaft gear

Cam sensor plate

25. O-

ring

26.

Power steering oil pump

Tightening Torque : Nm (kgf.m, Ib-ft)

SUDEM7016L

EM -18 ENGINE MECHANICAL SYSTEM

If the cam sensor plate is not
damaged, do not remove.

18.6~27.4
(1.9~2.8,

13.8~20.4)

58.8~78.4

(6.0~8.0, 43.6~58.2)

2

1

8

7

6

5

4

3

Tightening Torque : Nm (kgf.m, Ib-ft)

1. Thrust plate

2. Semicircular key

3. No.1 camshaft bush

4. No.2 camshaft bush

5. No.3 camshaft bush

6. No.4 camshaft bush

7. No.5 camshaft bush

8. Sealing cap

SUDEM7017L

TIMING SYSTEM EM -19

REMOVAL E812C03D

1. Loosen the alternator (1) tensioner screw (2) and re­move the V-belt(3).

2

1

3

SUDEM7018L

2. Remove the cooling fan (1) and auto cooling fan cou­pling (2).

2

4. Remove the vacuum pump (1) and alternator assem­bly (2).

2

1

SUDEM7021L

5. Remove the power steering pump (1).

1

1

SUDEM7019L

3. Remove the water pump pulley (1) and water pump
assembly (2).

2

1

SUDEM7022L

6. Align the timing mark "0" of crankshaft damper pulley
(1) with the indicator (2) of the timing gear case. Then,
cylinder No. 1 is positioned at TDC of compression
stroke.

2

1

SUDEM7020L

SUDEM7023L

EM -20 ENGINE MECHANICAL SYSTEM

7. Remove the crankshaft damper pulley nut (2) and re­move the crankshaft damper pulley (1).

2

1

SUDEM7024L

8. Remove the engine coolant temperature sensor (1)
connector and remove the thermostat housing (2)
from the cylinder head.

NOTE

Checkthe front oil seal (1) state. If it is normal, do not
remove it.

1

SUDEM7027L

CAUTION

Before removing the timing gear case, remove
timing gear case mounting bolt (1) at the supply
pump first.
If the mounting bolt at the supply pump is not re­moved, timing gear case will not be removed.

2

1

SUDEM7025L

9. Remove the cam speed sensor (1) from the timing
gear case and then remove the timing gear case (2).

1

2

1

SUDEM7028L

SUDEM7026L

TIMING SYSTEM EM -21

10. Remove the front oil seal slinger (1).

11. Remove the oil pump gear (1).

1

SUDEM7029L

13. Remove the idler gear B (1).

1

SUDEM7032L

14. Remove the supply pump gear (1).

1

1

12. Remove the idler gear A (1).

SUDEM7030L

SUDEM7033L

15. Remove the camshaft assembly.

1. Remove the thrust plate-mounting bolt (4)

1

through cam sensor plate (2) hole (3) of camshaft
gear (1).

4

SUDEM7031L

1

3

2

SUDEM7034L

EM -22 ENGINE MECHANICAL SYSTEM

NOTE

Do not remove the cam sensor plate (2), if it is not
damaged.

1

2. When removing the camshaft assembly (1), han-

dle cam bush carefully not to be damaged.

1

2

SUDEM7037L

INSPECTION EB5EDDCB

1. Measure inner diameter of idler gear (1) and outer
diameter of idler shaft (2). If the gap exceeds the limit,
replace the idler gear bush.

SUDEM7035L

16. Remove the front plate (1).

Reference gap between idler bush and idler shaft ([
]indicates reference diameter): [45] 0.025~0.06mm
Limit: 0.1mm

1

SUDEM7036L

CAUTION

When removing the front plate (1), do not remove
the bolts (2) processed with spacers.
If they were removed, assemble them based on
the dowel pin and then sealant must be applied
between front plate and spacers.

1

2

SUDEM7038L

2. Measure cam max (1) and min diameter (2). Replace
the camshaft assembly, if it exceeds the limit.

OTE

N

The difference between the max and min diameter is
theliftofthecam

TIMING SYSTEM EM -23

Unit: mm

Items

ecam

Intak

Exhaust

cam

CAUTI

Min cam

diameter (2)

39.910 47.105 7.195

39.658 46.979 7.321

ON

Max cam

diameter (1)

Cam lift

Sincetapercamisused,measureitasshownin
the figure.

Measuring

position

A B

A B

6.5mm 6.5mm

1

2

SUDEM7040L

4. Measure the distortion of camshaft. If it exceeds the
limit, replace or repair it with press.

Distortion of camshaft: 0.02mm

NOTE

cethecamshaft on the precision blockand turn the

Pla

shaft in1 revolution. And read the dial indicator.

cam

distortion of the camshaft is a half of the mea-

The

ement.

sur

SUDEM7039L

3. Measure the outer diameter of camshaft journal and
the inner diameter of camshaft bush in the crankcase.
If the gap exceeds the limit, repair the camshaft bush­ing with oversize.

Outer diameter of camshaft journal

Journal No. # 1, 2, 3 and 4: 54.44~54.46 mm

Journal No. # 5: 52.94~52.96 mm

Inner diameter of camshaft bushing

Journal # 1, 2, 3 and 4: 54.5mm

Journal # 5: 53mm

Gap between camshaft journal and bushing

Reference: [54.5] 0.04~0.09mm

[53] 0.04~0.09mm

Limit: 0.15mm

UDEM7041L

S

EM -24 ENGINE MECHANICAL SYSTEM

5. Measure the camshaft (1) endplay. If it exceeds the
limit, repair or replace it.

Camshaft endplay
Reference: 0.05mm~0.22mm
Limit: 0.3mm

1

SUDEM7042L

6. Measure the backlash of each gear and replace it if
necessary.

2

1

SUDEM7044L

c. Idler gear A (1) and idler gear B (2)

Reference: 0.062~0.160mm

1

NOTE

When measuring the backlash,fixthe gear contacting
the corresponding gear and move the gear to the left
and right to measure the backlash.

a. Crankshaft gear (1) and idler gear A (2)

Reference: 0.062~0.159mm

2

1

SUDEM7043L

2

SUDEM7045L

d. Idler gear B (1) and supply pump gear (2)

Reference: 0.073~0.169mm

2

b. Idler gear A (1) and camshaft gear (2)

Reference: 0.068~0.175mm

1

SUDEM7046L

TIMING SYSTEM EM -25

e. Oil pump gear (1) and crankshaft gear (2)

Reference: 0.049~0.169mm

Camshaft bush

09212-41200

SUDEM7049L

1

2

REPLACEMENT EF56BCEF

1. Replacement of idler gear bush
Replace idler gear bush using the special tool (09246-

41000).

TION

CAU

a. When assembling the bush, align the bush oil

hole with gear oil hole.

b. Check to see whether the clearance between

bush and idler gear shaft satisfies the refer­ence.

Removal

09246-41000

Assembly

SUDEM7047L

c. Install the camshaft bush (1).

NOTE

When assembling camshaft bush, distinguish the
bush by the number marked outside, which tells
the installing position. If the marked numbers are
illegible, measure the inner diameter and width of the
bush.

Unit: mm

Bush No.

(From the

front of

engine)

No.1

No.2

No.3

No.4

No.5

Carved

mark

1 58.519 54.5 33

2 58.269 54.5 22

3 58.019 54.5 22

4 57.769 54.5 22

5 57.019 53.0 22

Outer

diame-

ter

Inner di-

ameter

Width

Idler gear

Idler gear bush

09246-41000

Idler gear oil hole

Idler gear

2. Replacement of camshaft bush
a. Remove the sealing cap from the crankcase

camshaft hole.

b. Remove the camshaft bush using the special tool

(09212-41200).

SUDEM7048L

1

SUDEM7050L

EM -26 ENGINE MECHANICAL SYSTEM

d. Press fit the bush using the special tool (09212

- 41200) so that the camshaft bush end aligns
crankcase end.

NOTE

When installing the camshaft bushing, align the oil
hole of bush with crankcase oil hole (2).

1

Camshaft bush

09212-41200

2

Crankcase

INSTALLATION EEFAD1F1

SUDEM7051L

2. Install the crankshaft gear (1).

1

SUDEM7053L

3. Install the idler shaft A (1) and idler shaft B (2).

CAUTION

a. When installing the idler shaft A and B, do not

tighten the mounting bolts at once.

b. After installing the idler shaft A and B, check

to see w hether the shaft rotates smoothly.

1. Install the front plate (1).

1

2

SUDEM7054L

1

SUDEM7052L

TIMING SYSTEM EM -27

4. Install idler gear A and B.

CAUTION

a. When installing, align the timing mark "1" of

idler gear A (1) with the timing mark "1" of
crankshaft gear (2).

1

2

b. When installing, align the tim ing mark “ 4”

ofidlergearB(1)withthetimingmark“ 4”
of idler gear A (2).

1

2

SUDEM7057L

b. Press fit the camshaft gear assembly (1) of the

cam plate (2) so that it faces outward.

SUDEM7055L

2

1

2

5. Install the camshaft gear assembly.
a. Install the thrust plate (1) so that the "F" mark of

its oil hole faces to the camshaft gear (2).

SUDEM7056L

1

SUDEM7058L

c. Measure the endplay between camshaft gear (1)

and thrust plate (2) and install them as the clear­ancetobewithinthereference.

Reference: 0.05~0.22mm

1

2

SUDEM7059L

EM -28 ENGINE MECHANICAL SYSTEM

d. Install the camshaft assembly (1) to the

crankcase.

1

SUDEM7060L

CAUTION

When installing, align the timing mark "2" of
camshaft gear A (1) with the timing mark "2" of
idler gear A (2).

1

2

6. Install the supply pump gear.

CAUTION

When installing, align the timing mark "5" of sup­ply pump (1) with the timing mark "5" of idler gear
B(2).

1

2

SUDEM7063L

7. Install the oil pump gear (1).

SUDEM7061L

e. Install the thrust plate (2) mounting bolt (3)

through the hole of camshaft cam plate hole (1).

2

1

3

SUDEM7062L

1

SUDEM7064L

8. Install the front oil seal slinger (1).

1

SUDEM7065L

TIMING SYSTEM EM -29

9. Install the front timing gear case (1).

Tightening torque: 21.6~32.3 Nm

(2.2~3.3 kgf.m, 16~24 Ib-ft)

CAUTION

a. Apply t

assemb
then a

b. Do not s

stall

he Loctite #5699 or equivalent on the

ly surface of timing gear case (1), and

ssemble it within 3 minutes.

tart the engine within 1 hour after in-

ing the timing gear case.

1

11. Install the water pump pulley (1) and water pump as­sembly (2).

2

1

SUDEM7068L

12. Install the crankshaft damper pulley (1) and damper
pulley mounting nut (2).

Tightening torque: 588 Nm

(60 kgf.m, 436 Ib-ft)

10. Install the power steering pump (1).

SUDEM7066L

1

SUDEM7067L

1

2

UDEM7069L

S

EM -30 ENGINE MECHANICAL SYSTEM

13. Install the vacuum pump (1) and alternator assembly
(2).

2

1

SUDEM7070L

14. Install the cooling fan (1) and automatic cooling fan
coupling (2).

2

1

SUDEM7071L

15. Install the V-belt (1). Adjust the belt tension using the
tension adjusting screw (2) of alternator.

2

1

SUDEM7072L

CYLINDER HEAD ASSEMBLY EM -31

CYLIND
ASSEM

ER HEAD

BLY

COMPONENTS E2 48774A

7.8~11.8

(0.8~1.2, 5.8~8.7)

12.7~15.7

(1.3~1.6, 9.5~11.6)

(Not reusable)

11

1

2

3

4

Not reusable

5

147+90

(15+90 , 109+90 )

10

Tightening Torque : Nm (kgf.m, Ib-ft)

6

7

8

9

1. Engine cover bolt

2. Engine cover

3. Cylinder head cover

4. Cylinder head cover gasket

5. Rocker and bracket assembly

6. Cylinder head bolt

7. Cylinder head assembly

8. Cylinder head gasket

9. Crank case

10. Push rod

11. Oil filler cap

SUDEM7073L

EM -32 ENGINE MECHANICAL SYSTEM

2

1

3

4

7

5

8

6

9

10

11

12

1. Valve cap

2. Valve cotter

3. Valve retainer

4. Outer side spring

5. Inner side spring

6. Valve stem seal

7. Push rod

14

13

8. Cylinder head

9. Water director

10. Intake valve

11. Exhaust valve

12. Cylinder head gasket

13. Tappet

14. Crankcase

SUDEM7074L

CYLINDER HEAD ASSEMBLY EM -33

REMOVAL EDE5E369

1. Remove the engine cover(1) from the cylinder head
cover.

1

SUDEM7280L

2. Remove the glow plug and glow plug plate (1).

1

4. Loosen the hexa-bolt (2) of injector nozzle bridge (1)
and remove the injector (3).

2

3

1

SUDEM7078L

5. Remove the oil separator (1) and blow-by hose (2)

2

SUDEM7076L

3. Remove the injection pipe(1) No 1, 2, 3 and 4 running
from the common rail assembly to the injector.

1

SUDEM7079L

6. Remove the oil level gauge (1).

1

1

SUDEM7077L

SUDEM7080L

EM -34 ENGINE MECHANICAL SYSTEM

7. Remove the intake manifold assembly (1).

1

2

NOTE

Do not remove the actuator (2) of the intake manifold
if its operation is normal.

8. Remove the thermostat housing (1).

10. Remove the turbocharger assembly (1) from the cylin­der head.

1

SUDEM7081L

SUDEM7084L

11. Loosen the exhaust manifold mounting nut (1) and
then remove exhaust manifold (2).

2

1

SUDEM7082L

9. Remove the turbocharger heater protector cover (1)
and exhaust manifold heater protector cover (2).

1

2

1

SUDEM7085L

12. Remove the cylinder head cover (1).

1

SUDEM7083L

SUDEM7086L

CYLINDER HEAD ASSEMBLY EM -35

13. Remove the cylinder head bolts.

NOTE

a. Since push rod is pressing the rocker, loosen the

rockeradjustingscrews (1) toremovethecylinder
head bolts (2).

2

1

b. When removing the cylinder head bolts, remove

them according to the sequence as shown in the
following figure.

14. Remove the rocker arm and rocker bracket assembly
(1).

1

SUDEM7089L

15. Remove the cylinder head assembly (1).

1

SUDEM7087L

1

3

7

5

11

9

15

13

14 10

17

16

12

6

2

4

8

SUDEM7090L

SUDEM7088L

EM -36 ENGINE MECHANICAL SYSTEM

16. Remove the cylinder head gasket (1).

CAUTION

When removing the cylinder head gasket, be
careful not to damage the cylinder head and
crankcase.

1

17. Remove the valve tappet (1).

SUDEM7091L

DISASSEMBLY ECC7ED4F

ROCKER AND ROCKER SHAFT BRACKET
ASSEMBLY

1. Remove the set bolt from the front rocker shaft
bracket.

2. Remove the front and rear rocker shaft bracket.

3. Remove the rocker assembly.

4. Remove the rocker shaft spring from the rocker shaft.

5. Remove the rocker shaft bracket No.2, 3 and 4 and
then, remove the rocker shaft.

Rocker
bush

Set bolt

Rocker

Rocker shaft

Rear rocker
shaft bracket

Rocker shaft spring

Rocker assembly

1

Front rocker shaft bracket

SUDEM7093L

VALVE AND CYLINDER HEAD ASSEMBLY

1. Remove the valve cotter (2) with pushing the
valve spring (1) evenly using the special tool
(09222-83300).

09222-83300

SUDEM7092L

2

1

SUDEM7094L

CYLINDER HEAD ASSEMBLY EM -37

2. Remove the retainer (1), valve spring (2), valve stem
seal (3) and intake and exhaust valve from the cylinder
head.

CAUTION

Valve stem seal should be replaced with new one.

1

2

3

4

SUDEM7095L

3. Remove the water director (1) from the cylinder head.

4. Remove the cylinder gasket (1).

CAUTION

When removing the cylinder head gasket, check
the cylinder head and crankcase for any damage.

1

SUDEM7097L

INSPECTION E5264C2D

NOTE

If water director is corroded, removeit. If not, leave it.

1

SUDEM7096L

1. Check to see whether valve cap (1) and retainer (2)
have any irregular wear.

2. Check the intake and exhaust valve (3) for any stuck,
crack or damage.

1
2

3

SUDEM7098L

EM -38 ENGINE MECHANICAL SYSTEM

3. Check the valve tappet (1) for any damage or wear.

1

SUDEM7099L

4. Measure the rocker inner diameter and rocker shaft
outer diameter. Replace the bush of rocker, if the gap
exceeds the limit.

Items

Inner diameter of
rocker bush

Standard

18.980~18.993mm

Limit

―

5. Inspect the out of squareness (A), free length (B), load
installed (C) of valve spring, replace it if any of them
exceeds the limit.

Outer side
Valve
spring

Inner side
Valve
spring

Items

Free length

Load
installed

Out of
squareness

Free length

Load
installed

Out of
squareness

Standard

66.1mm 63mm

27.9±1.4kg 23.7kg

1.5mm 2.1mm

60mm 57mm

12.1±0.6kg 10.3kg

1.5mm 2.1mm

A

Limit

C

Outerdiameterof
rocker shaft

Gap

19.05~19.09mm

―

0.06~0.11mm 0.2mm

SUDEM7100L

B

DEM7101L

SU

6. Measure the outer diameter of tappet (1) and inner
diameter of crankcase tappet hole (2). Replace the
tappet if the gap exceeds the limit.

Reference: 0.045~0.096mm
Limit: 0.2mm

1

SUDEM7102L

CYLINDER HEAD ASSEMBLY EM -39

8. Measure the deformation of cylinder head bottom

2

SUDEM7103L

7. Measure the run-out of push rod (1). Replace it if it
exceeds the limit.

Limit of pushrod run-out: 0.4mm

face. If the measurement exceeds the limit, repair it
with surface grinder or replace it.

Flatness of cylinder head
Reference: 0.05mm
Limit: 0.2mm

NOTE

Deform
the po

ation of cylinder head bottom is measured at

sition as shown in the following figure.

SUDEM7105L

9. Mea

Out

1

SUDEM7104L

― In

― Ex

sure the outer diameter of valve stem. If the mea-

ement is below the limit, replace the valve stem.

sur

er diameter of valve stem

take valve

erence : 8.96~8.97mm

Ref

it : 8.85mm

Lim

haust valve

erence : 8.93~8.94mm

Ref

t : 8.85mm

Limi

SUDEM7106L

EM -40 ENGINE MECHANICAL SYSTEM

10. Measure the inner diameter of valve guide and outer
diameter of valve stem. If the clearance exceeds the
limit, replace the valve guide.

Clearance between valve stem and valve guide
― Intake

Reference: 0.04~0.06mm

Limit: 0.15mm

― Exhaust

Reference: 0.07~0.10mm

Limit: 0.2mm

c. Measure the seat contact area (A).

Area of the valve seat contact
― Intake

Reference: 2.8± 0.2mm

Limit: 3.6mm

― Exhaust

Reference: 2.0± 0.2mm

Limit: 2.8mm

A

M7107L

SUDE

11. Check the contacting state of valve seat and valve.
a. Apply light blue coating on the valve surface.
b. Check the valve contacting state by pressing the

valvetothevalveseat.

CAUTION

reful that valve does not turn, when valve

Be ca

is pressed by valve.

seat

Normal Abnormal Abnormal

SUDEM7109L

SUDEM7108L

CYLINDER HEAD ASSEMBLY EM -41

REPLACEMENT E03FAF94

REPLACEMENT OF ROCKER BUSH

1. Remove the bush from rocker using the special tool
(09222-45000).

2. Press fit the bush into rocker using the special tool
(09222-45000).

NOTE

When pressing fit bush into rocker, let the chamber
side of the rocker be inserted first.

CAUTION

When pressing fit, align the bush oil hole with
rocker oil hole.

At removing At installing

09222-45000

Rocker chamber

Rocker bush

Rocker

SUDEM7110L

VALVE SEAT REPAIR

1. Repair the valve face using valve refacer (1).

CAUTION

Valve seat angle is 45

1

.

SUDEM7112L

2. To repair the valve seat, use the valve seat cutter or
valve seat grinder (1). After grinding, insert the #400
or equivalent sand paper between cutter and valve
seat and grind lightly.

CAUTION

Repair the valve seat width and valve sinkage to
satisfy the specified limit.

REPALCEMENT OF VALVE GUIDE

Remove the valve guide using the special tool
(09221-41100). Install the valve guide using the special
tool (09221-41150, 09221-41100).

At removing At installing

09221-41100

09221-41150

18mm

Valve guide

Valve
guide

SUDEM7111L

1

SUDEM7113L

EM -42 ENGINE MECHANICAL SYSTEM

3. Install the valve seat using the caulking tool body (1)
and locking ring (2).

CAUTION

Press the valve seat (3) with the chamferred side
of the locking ring. A nd then, caulk it to the cylin­der head as the ring faces the other side.

Installing Caulking

1

2

3

SUDEM7114L

5. Apply the compound evenly over the valve seat sur­face (1).

CAUTION

a. Valve stem (2) should be free from any

compound. Use the medium mesh (mesh
between 120 and 150) compound at first
and finish the grinding with the fine mesh
compound (above 200 mesh)

b. Mix the compound with some engine oil to

apply evenly.

2

1

4. Grind the seat width (A) and valve sinkage (B) to be
within the standard.
Valve and valve seat should touch evenly all over the
surface.

Valveseatwidth(A)

Reference: 2.6~3.0mm (Intake)

1.8~2.2mm (Exhaust)

Limit: 3.6mm (Intake)

2.8mm (Exhaust)

Valve sinkage (B)

Reference: 1.5mm

Limit: 1.2mm

A

SUDEM7116L

6. Place the valve on the valve seat using the valve lap­per (1). Tap the valve with turning the valve slightly.
Clean the compound with diesel or equivalent. Apply
the engine oil and check whether the contact surface
is securely positioned.

1

SUDEM7117L

B

SUDEM7115L

CYLINDER HEAD ASSEMBLY EM -43

REASSEMBLY EBF48CA7

ROCKER AND ROCKER SHAFT ASSEMBLY

1. Install rocker shaft bracket No. 1, 2, 3 and 4 to the
rocker shaft.

2. Install the rocker shaft spring.

3. Apply engine oil on the rocker bush, and then install
thebushtotherocker.

4. Install the rocker assembly.

5. Install the front and rear rocker shaft bracket.

6. Install the front and rear rocker shaft bracket set bo

Tightening torque: 7.8~11.8 Nm

(0.8~1.2 kgf.m, 5.8~8.7 Ib-ft)

Rocker
bush

Rocker

Rocker shaft

lts.

2. Install the intake and exhaust valve.

SUDEM7118L

3. Apply the engine oil on the valve stem seal lip and in­stall the valve stem seal using the special tool (09222-

45100).

NOTE

Tap the seal until the special tool (09222-45100) con­tacts the cylinder head.

Set bolt

Rocker shaft spring

Rocker assembly

Front rocker shaft bracket

Rear rocker
shaft bracket

VALVE AND CYLINDER HEAD ASSEMBLY

1. Install the water director to the cylinder head.

SUDEM7093L

09222-45100

Valve

Cylinder head

Valve stem seal

SUDEM7119L

CAUTION

When installing the vavle stem seal (1), use the
new one.

1

SUDEM7096L

EM -44 ENGINE MECHANICAL SYSTEM

1

1

SUDEM7120L

4. Install the retainer, valve spring and valve cotter using
the special tool (09222-83300).

09222-83300

SUDEM7121L

INSTALLATION EDA3BF2F

1. Assembly is performed in the reverse order of disas­sembly.

SUDEM7097L

b. Selectionand assembly of cylinder head gas-

ket.
Select the cylinder head gasket according to
the piston protrusion amount.

Average piston

protrusion

0.466~0.526

0.526~0.588

0.588~0.648

Gasket

size

A

B

C

Gasket

thickness

1.35±0.03

1.40±0.03

1.45±0.03

Unit : mm

Measuring gauge of piston

protrusion

2. Installation of cylinder head gasket.

CAUTION

hen installing the cylinder head gasket (1),

W

ylinder head installing surface should be free

c

rom any impurities or foreign materials such as

f
oil.

ssemble the cylinder head so that "UP"

a.A

mark of the cylinder head gasket faces to the
cylinder head.

SUDEM7122L

NOTE

If the max protrusion of the piston is 0.05mm more
than average protrusion, then use the grade up
(A→B) gasket.

CYLINDER HEAD ASSEMBLY EM -45

Cylin-

1 2 3 4

In-

take

Ex-

haust

In-

take

Ex-

haust

In-

take

Ex-

haust

○ ○ ○ ○

× × × ×

ure the clearance between rocker and valve

sing the thickness gauge.

cap u
a. If th

b. Afte

NOT

e valve clearance exceeds the reference

e, loosen the lock nut (2) and adjust the

valu

rance with thickness gauge by turning

clea

djusting screws.

the a

r the valve clearance adjustment, fix the

sting screw using the screw drive (3) and

adju

en the lock nut securely.

fast

E

In-

take

Ex-

haust

AB C

3. Checking and adjusting of valve clearance

NOTE

Checkand adjust the valveclearance while the engine
is cold.

1) Crank the engine with the cranking handle and
align the needle to "0" position of crankshaft
damper pulley (side marked with No. 1 through

4). Or align it to the "0" position of crankshaft
damper pulley (side marked No. 2 to 3). (This is
at the TDC of comopression stroke of cylinder
No. 1).

SUDEM7123L

der
No.

Valve

TDC

of

No.1

TDC

of

No.4

3) Meas

Make sure to check whether the valve clearance sat­isfies the reference after valve clearanc e adjustment.

1

SUDEM7124L

2) AttheTDCofcompressionstrokeofcylinderNo.
1, check and adjust the clearance of the valve
with "O" mark at the following table. And then,
turn the crankshaft in one turn to check and ad­just the valve clearance of remaining valves with
"X"mark.

3

2

1

UDEM7125L

S

EM -46 ENGINE MECHANICAL SYSTEM

CRANKC

ASE

FLYWHEEL

COMPONENTS E60B5C72

1

2

39.2+40

(4+40 , 29.1+40 )

7

4

3

5

1. Front plate

2. Gasket

3. Crankcase

4. Rear plate

5. Rear oil seal

6. Pilot bearing

7. Flywheel

8. Flywheel mounting bolt

8

6

7

Tightening Torque : Nm (kgf.m, Ib-ft)

SUDEM7126L

CRANKCASE EM -47

REMOVAL EECFB3A9

1. Remove the flywheel mounting bolt (1), and then re­move the flywheel (2).

2

1

SUDEM7127L

2. Remove the rear plate mounting bolt (1), and then
remove the rear plate (2).

2

4. Remove the rear oil seal slinger (1).

1

SUDEM7130L

INSPECTION EE08EBFD

1. Distorsion check of frictional surface
a. Put the flywheel (2) on the precision table (1) and

set up the dial indicator (3).

b. Move the dial indicator on the flywheel frictional

surface to measure the distortion.

c. If the distortion of the frictional surface exceeds

the limit, regrind the frictional surface.

1

SUDEM7128L

3. Remove the rear oil seal mounting bolt (1), and then
remove the rear oil seal (2).

Distortion of the frictional surface

Reference: Below 0.05mm

Limit: 0.2mm

3

2

1

SUDEM7131L

2

1

SUDEM7129L

EM -48 ENGINE MECHANICAL SYSTEM

2. Repair of the frictional surface
Repair the frictional surface with the surface grinder.

CAUTION

a. After repairing the frictional surface, check

whether the frictional surface is parallel with
surface A within 0.1mm.

b. Check the frictional surface (size B) whether

its height is within the limit.

Height to the frictional surface (B)

Reference: 24.5mm

Limit: 23.5mm

B

INSTALLATION E561 D9B1

1. Install the rear oil seal slinger using the special tool
(09211-41000).

09211-41000

SUDEM7133L

19.7mm

Dowel pin

09211-41000

3. Rep
a. When

b. Whe

A

SUDEM7132L

lacement of flywheel ring gear

removing the ring gear (1), heat the ring

r evenly using acetylene torch or equivalent

gea

ls and then remove the ring gear by tapping

too

circumference with rod or hammer.

the

n installing, heat the ring gear with piston

ter for 3 minutes (about 100

hea

ert the ring gear so that the un-chamfered gear

ins

es to flywheel.

fac

1

The chamfer was machined.

C). And then,

Crankshaft

Rear oil seal slinger

SUDEM7134L

UDEM7279L

S

CRANKCASE EM -49

2. Apply the sealant (Loctite #5699) to the rear oil seal
(1), and then install the rear oil seal.

Tightening torque: 7.8~11.8 Nm

(0.8~1.2 kgf.m, 5.8~8.7 Ib-ft)

Sealant

1

SUDEM7135L

4. Install the flywheel (1).

Tightening torque: 39.2Nm+40

(4.0kgf.m+40 ,29.1Ib-ft+40)

1

SUDEM7138L

3. Install the rear plate (1).

Tightening torque: 63.7 Nm

(6.5 kgf.m, 47.3 Ib-ft)

1

SUDEM7136L

1

SUDEM7137L

EM -50 ENGINE MECHANICAL SYSTEM

CYLINDER BLOCK ASSEMBLY

COMPONENTS EBC859AD

1

2

6

3

4

5

7

8

9

10

11

29.4+90

(3.0+90 , 21.8+90 )

Tightening Torque : Nm (kgf.m, Ib-ft)

18.6~27.4

(1.9~2.8, 13.8~20.4)

12

1. Compression ring No.1

2. Compression ring No.2

3. Oil ring No. 3

4. Snap ring

5. Piston

6. Piston pin

7. Connecting rod

8. Connecting rod upper bearing

9. Crankcase

10. Connecting rod lower bearing

11. Connecting rod cap

12. Oil pan

SUDEM7139L

CRANKCASE EM -51

588 (60.0, 436)

12

11

1

10

29.4 (3.0, 21.8)

2

9

8

3

4

5

6

7

49+90

(5.0+90 , 36.4+90 )

1. Oil jet

2. Oil jet mounting bolt

3. Upper main bearing

4. Thrust plate

5. Rear oil seal slinger

6. Lower main bearing

7. Main bearing cap

8. Crankshaft assembly

9. Semicircular key

10. Crankshaft gear

11. Front oil seal slinger

12. Crankshaft pulley

Tightening Torque : Nm (kgf.m, Ib-ft)

SUDEM7140L

EM -52 ENGINE MECHANICAL SYSTEM

REMOVAL EE4DAE0F

1. Remove the engine and transaxle.

2. Remove the flywheel and rear plate.

3. Remove the intake and exhaust manifold.

4. Remove e the cylinder head assembly.

5. Remove the supply pump (1) and common rail assem­bly (2).

2

SUDEM7143L

8. Remove oil cooler assembly.

1

1

SUDEM7281L

6. Remove the V-belt (1) and remove the alternator as­sembly (2).

2

1

SUDEM7142L

7. Align the timing mark (2~3 side) of crankshaft damper
pulley to the compression TDC of cylinder No. 1.

NOTE

As for the removal of cooling fan pulley, crankshaft
damper pulley and timing gear case, refer to the re­moval procedure of timing system.

SUDEM7144L

9. Remove timing gear train [(oil pump gear (6),
camshaft assembly (2), idler gear A (3), idler supply
pump gear (5)), and then remove front plate.

3

5

2

4

6

1

SUDEM7145L

CRANKCASE EM -53

10. Remove the power steering pump (1).

11. Remove the starter motor assembly (1).

1

SUDEM7146L

13. Remove the oil strainer (1).

1

SUDEM7149L

14. Remove rear oil seal (1) and oil seal slinger (2).

1

12. Remove the oil pan (1).

1

SUDEM7147L

1

2

SUDEM7148L

SUDEM7150L

SUDEM7151L

EM -54 ENGINE MECHANICAL SYSTEM

15. Remove the connecting rod bearing cap (1).

NOTE

Make marks at the connecting rod and cap to be re­assembled correctly.

1

SUDEM7152L

16. Remove the piston and connecting rod assembly (1)
from cylinder block.

1

2

3

SUDEM7154L

18. Remove the crankshaft (1) from the cylinder block.

CAUTION

Handle the crankshaft carefully so that the journal
is not damaged.

1

SUDEM7153L

17. Remove the front, rear and main bearing caps.
a. Remove the front bearing cap and rear end bear-

ing cap. Remove the thrust plate (2) from the
rear-bearing cap (1).

b. Remove the main bearing cap (1) and bearing

(3).

1

SUDEM7155L

19. Remove the oil jet (1) from the cylinder block.

1

SUDEM7156L

CRANKCASE EM -55

DISASSEMBLY E190BEAB

PISTON AND CONNECTING ROD ASSEMBLY

1. Remove the piston ring using the special tool (09222-

83200).

09222-83200

SUDEM7157L

2. Remove the piston pin snap ring (2) using the snap
ring pliers (1).

1

4. Remove the connecting rod (1) from the piston.

1

SUDEM7160L

INSPECTION EBE61DCA

CYLINDER BLOCK

NOTE

a. Before repairing, clean each part to remove dus t,

oil, carbon and fur.

b. Before cleaning the cylinder block, check water

leakage or damages.

c. Remove the adhesives at each oil hole using air

brush and check whether any hole is clogged.

2

3. Remove the piston pin (1) from the piston.

1

SUDEM7158L

1. In addition to the visual check about scratch, rust and
corrosion, inspect the slight scratches with precipi­tant. Repair or replace it if needed.

2. Measure the twist of cylinder block using straight edge
(1) and thickness gauge (2). Measure them by placing
the straight edge as shown in the following figure.

NOTE

When measuring, cylinder upper block should be free
from foreign materials such as gasket piece.

CAUTION

When grinding the cylinder block, grind it as the
piston protrusion does not exceed the reference.

SUDEM7159L

EM -56 ENGINE MECHANICAL SYSTEM

Flatness figure of cylinder block

Reference : Below 0.07mm

Limit : 0.2mm

1

2

M7161L

SUDE

3. Check the cylinder wall to see if it is cracked or dam­aged. If it is abnormal, repair (oversize) or replace the
cylinder sleeve.

4. Measure the cylinder sleeve ID using the cylinder
gauge. If it is excessively worn, repair it with oversize
and replace the piston and piston ring.

a. Measure the inner diameter of cylinder sleeve us-

ing the cylinder gauge (1).

Inner diameter of cylinder sleeve: 104.00~104.03mm

1

SUDEM7162L

b. Measure the outer diameter of piston skirt at the

position, which is 85mm down from the upper pis­ton.

Outer diameter of piston: 103.91~103.92mm

Clearance between piston and cylinder sleeve :

0.080~0.130mm

CAUTION

1. When replacing piston, piston ring should be

replaced together.

2. Even if only one cylinder needs boring, all

cylinder walls should be grinded with over­size at the same time.

3. Measure the most seriously worn cylinder

wall and select the oversize based on the
measurement.

4. Available oversizes are +0.25, +0.50, +0.75

and +1.00.

5. Piston and connection rod should be re-

placed with the new one which has identical
weight and grade with the old one.

SUDEM7163L

CRANKCASE EM -57

PISTON

1. Check each piston to see whether it is damaged.

2. Check whether the piston pin (1) is installed correctly
in the piston hole.
If any defect is found, replace the piston and piston
pin as an assembly.
Piston pin should slide into the piston hole smoothly
when it is pushed by hand.

1

4. Measure the clearance between piston pin and con­necting rod end.

Outer diameter of piston pin: 38mm
Inner diameter of connecting rod end: 38mm
Clearance Reference: 0.025~0.046mm
Clearance Limit: 0.1mm

SUDEM7166L

SUDEM7164L

3. Measure the clearance between piston pin and piston
hole by measuring the inner diameter of piston pin (1)
and piston boss.

Inner diameter of piston boss: 38mm
Outer diameter of piston pin: 38mm
Clearance Reference: 0.007~0.021mm
Clearance Limit: 0.05mm

1

PISTON RING

1. Check the piston ring for any damage, unusual wear
or breakage. If damaged, replace the ring.

2. When replacing the piston, replace the piston pin to­gether.

3. Measure the clearance between piston ring and the
wall of the ring groove, using a feeler gauge.

Piston ring

Ring No.1

Ring No.2

Oil ring

Standard

0.106~0.170mm 0.2mm

0.07~0.11mm 0.15mm

0.03~0.07mm 0.15mm

Limit

SUDEM7165L

1

SUDEM7167L

EM -58 ENGINE MECHANICAL SYSTEM

4. After installing the piston ring to the cylinder bore,
push the piston ring to the vertical direction with the
piston.

Piston ring end gap

Ring No.1: 0.25~0.40mm
Ring No.2: 0.50~0.65mm

Oil ring: 0.20~0.40mm

CRANKSHAFT

1. Measure the endplay of crankshaft.

Crankshaft endplay

Reference :0.10~0.26mm

Limit: 0.4mm

a. If the endplay exceeds the limit, replace the thrust

plate with the oversize.

b. Oversizes of the thrust plate are +0.15, +0.30,

and +0.45.

SUDEM7168L

SUDEM7169L

2. Measure the oil gap of crankshaft main bearing.
a. Remove the main bearing cap.
b. Measure the oil gap of main bearing.

1) Remove the oil or other foreign materials from

main journal and main bearing surface.

2) Plac

e the plastic gauge along with the shaft di-

tion of the journal.

rec

CRANKCASE EM -59

3) Install the main bearing cap and fasten the bolt.

Tightening torque: 49.0 Nm+90

(5.0kgf.m+90 ,36.4Ib-ft+90)

SUDEM7170L

4) Remove the main bearing cap and measure oil
gap at each journal.

Oil gap of journal #1, 2, 4 and 5

Reference: 0.036~0.098mm, Limit: 0.15mm

Oil gap of journal #3

Reference: 0.056~0.118mm, Limit: 0.15mm

3. Measure roundness and cylindricity of crankshaft
journal and pin. If the measurement exceeds the
limit, repair it with under size.

Roundness of crankshaft

Reference : less than 0.01mm , Limit : 0.03mm

Cylindricity of crankshaft

Reference : less than 0.006mm , Limit : 0.03mm

SUDEM7172L

4. Check to see if the crankshaft is bent.
Install the dial gauge of crankshaft center journal, and
check the bending of the crankshaft.

SUDEM7171L

5) If the oil gap of the main bearing is excessively
large, replace the main bearing.

Bending of the crankshaft

Standard : Below 0.02mm

Limit : 0.05mm

NOTE

Actual bending is a half of the measurement.

SUDEM7173L

EM -60 ENGINE MECHANICAL SYSTEM

CONNECTING ROD BEARING

1. Before removing the connecting rod cap, measure the
connecting rod endplay. If the gap exceeds the refer­ence, replace the connecting rod.

Connecting rod endplay
Reference: 0.15~0.45mm
Limit: 0.6mm

SUDEM7174L

d. Remove the connecting rod bearing cap and

measure the oil gap at each pin journal.

Connecting rod oil gap
Reference: 0.040~0.099mm
Limit: 0.2mm

SUDEM7176L

e. If the oil gap is excessively large, replace the

connecting rod bearing.

2. Measure the oil gap of the connecting rod bearing.

1) Remove the connecting rod cap.

2) Measure the oil gap of the connecting rod bear-

ing.
a. Remove the oil or foreign materials from pin

journal and connecting rod bearing surface.

b. Place the plastic gauge on the shaft of pin

journal along with its direction.

c. Install the connecting rod bearing cap and

fasten the bolt.

Tightening torque: 29.4 Nm+90

(3.0kgf.m+90 ,21.8Ib-ft+90)

3. Length of the connecting rod bearing.
Length of the Connecting rod bearing (1) is measured
at the free state. If the measurement is below the limit,
replace the upper and lower bearing.

Length of the connecting rod bearing
Limit: above 69.5mm

CAUTION

Bearing should not be artificially expanded to
reuse.

1

SUDEM7175L

SUDEM7177L

CRANKCASE EM -61

REASSEMBLY E49D5D90

PISTON AND CONNECTING ROD ASSEMBLY

1. Install the piston ring using the special tool (09222-

83200).

09222-83200

SUDEM7178L

NOTE

2. Apply engine oil at the piston rod end and piston pin
hole, and then install the piston pin (1).

1

SUDEM7180L

3. Install the piston pin snap ring (2) using snap ring
pliers (1).

a. Install the piston r ing so that open end of the pis-

ton ringfaces to the direction shown in the figure.

b. Install the oil ring expander spring to be posi-

tioned at 180

direction with the oil ring end. Oth-

erwise, expander spring may be loosened.

Oil ring ex pander spri ng Compression r ing N o. 1

Engine f ront

Compression r ing N o. 2

Oil r ing

SUDEM7179L

1

2

SUDEM7181L

EM -62 ENGINE MECHANICAL SYSTEM

INSTALLATION EE5ABFA8

1. Install oil jet (1) to the cylinder block.

1

SUDEM7182L

2. Install thrust plate (1) and upper main bearing (2) to
the crankcase.

CAUTION

a. Install the thrust plate with the oil grooveless

side toward the crankcase.

b. Alignthe lug groove of crankcase with the lug

of main bearing.

c. Since there is oil hole at upper bearing, take

care not to be interchanged with lower bear­ing.

d. Apply engine oil on the all over the sliding

surface.

3. Install the crankshaft (1) to the cylinder block.

CAUTION

Handle crankshaft carefully not to be damaged.

1

SUDEM7184L

4. Install the front, rear and main bearing caps.
a. Insert the lower main bearing (1) into bearing cap

(2).

NOTE

Check to see whether the main bearing lug matches
main bearing cap lug groove.

b. Install thrust plate (3) to the rear-bearing cap.

3

2

2

1

SUDEM7185L

1

SUDEM7183L

CRANKCASE EM -63

c. Install the main bearing cap with the specified

torque.

Tightening torque: 49.0 Nm+90

(5.0kgf.m + 90 , 36.4 Ib-ft+90 )

5. Install piston and connecting rod assembly.

CAUTION

a. Install piston and connecting rod to the

crankshaft pin journal using the special tool
(09222-83200).

SUDEM7186L

b. When installing connecting rod cap, align

mark (1) on connecting rod big end cap with
mark (2) on connecting rod cap.

1

21

SUDEM7188L

c. When installing piston, assemble it so that

front mark (1) of the piston faces to the front
side.

d. Assemble so that the arrow mark (→)ofpis-

ton head faces to the center of cylinder head
bolt hole.

09222-83200

1

SUDEM7189L

SUDEM7187L

EM -64 ENGINE MECHANICAL SYSTEM

e. Tighten the connecting rod cap with specified

torque.

Tightening torque: 29.4 Nm+90

(3.0kgf.m + 90 , 21.8 Ib-ft+90 )

SUDEM7190L

6. Install rear oil seal slinger using the special tool
(09211-41000).

7. Apply the sealant (Loctite #5699) to the rear oil seal,
and then install the rear oil seal (1).

1

SUDEM7192L

8. Install the oil strainer (1).

1

09211-41000

SUDEM7193L

SUDEM7191L

CRANKCASE EM -65

9. Install the oil pan (1).

1

SUDEM7194L

10. After installing the cylinder block assembly, measure
the piston protrusion. Install the right cylinder head
gasket.

NOTE

As for the cylinder head gasket selection and assem­bly, refer to the cylinder head assembly procedure.

11. Install the timing system.

12. Install the flywheel and rear plate.

13. Install the cylinder head assembly.

14. Install intake and exhaust manifold.

15. Install engine accessories.