4. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES 4.1.3 Complete disassembly Peripheral parts such as air cleaner, muffler and radiator differ in installation and types for each application. Therefore, description in this Chapter is started with the steps to be taken just after the peripheral parts have been removed. 4-8 82E-5 – 98E-5 SERIES Step Removal Parts Remarks 1 1) Thoroughly remove sand, dust, dirt and soil from the surface of the engine. 2) Drain cooling water and lubricating oil from the engine. 2 1) Remove turbocharger and exhaust manifold. 2) Remove intake manifold and surge tank. 3 1) Close the fuel cock valve of the fuel tank. 2) Remove high-pressure fuel pipe.
3) Remove fuel return pipe. 4) Loosen the tightening nut on fuel injection noz- zle retainer and extract the retainer and fuel injection nozzle. * Fuel injection nozzle for Indirect injection sys- tem is screwed type. 1) If nozzle seat is left on the cylinder head, remove the cylinder head before extracting nozzle seat. 2) To prevent dust from entering fuel injection nozzle, fuel injection pump and high-pressure fuel pipe, seal their respective threads with a tape or the like. 3) Whenever extracting fuel injection nozzle, replace nozzle protector with a new one. 4 1) Remove rocker arm cover assembly. 5 1) Remove valve rocker arm shaft assembly. 2) Remove push rod.
1) Attach a tag to push rod for each cylinder No. to put the push rod in order. 2) Remove valve cap from the intake/exhaust valve head. 3) Note that tappet of the indirect injection sys- tem can be removed at the same time when push rod is extracted. 4) Attach a tag to tappet for each cylinder No. to put the tappet in order. 6 1) Remove fan mounting bolt, and then remove fan. 2) Loosen adjusting bolt for the V-belt adjuster, and then remove V-belt. 3) Remove alternator. 4) Remove the spacer for cooling fan and V-pul- ley. 1) Never turn down alternator vigorously toward the cylinder block. Otherwise, your finger may be nipped and alternator broken. 7 1) Remove lubricating oil filter assembly.
2) Extract oil level gauge from the oil level gauge hole. 8 1) Disconnect fuel return pipes. 2) Remove fuel filter. 9 1) Disconnect cooling water pipe from the cool- ing water pump. 2) Remove thermostat assembly. 3) Remove cooling water pump.