Workshop Manual

CONTENTS
SERVICING
1. TROUBLESHOOTING ......................................................................................S-1
2. SERVICING SPECIFICATIONS ......................................................................S-5
3. TIGHTENING TORQUES ..............................................................................S-13
[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS
AND NUTS...............................................................................................S-13
[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS
AND NUTS...............................................................................................S-14
4. CHECKING, DISASSEMBLING AND SERVICING......................................S-15
[1] CHECKING AND ADJUSTING ...............................................................S-15
(1) Engine Body........................................................................................S-15
(2) Lubricating System .............................................................................S-17
(3) Cooling System...................................................................................S-17
(4) Fuel System ........................................................................................S-19
(5) Electrical System ................................................................................S-22
(6) Turbocharger ......................................................................................S-26
[2] DISASSEMBLING AND ASSEMBLING..................................................S-27
(1) Draining Oil and Coolant.....................................................................S-27
(2) External Components .........................................................................S-27
(3) Cylinder Head and Valve ....................................................................S-28
(4) Gear Case and Timing Gears .............................................................S-32
(5) Piston and Connecting Rod ................................................................S-37
(6) Flywheel and Crankshaft ....................................................................S-40
(7) Starter .................................................................................................S-42
(8) Alternator ............................................................................................S-44
[3] SERVICING ..............................................................................................S-45
(1) Cylinder Head and Valves ..................................................................S-45
(2) Timing Gears, Camshaft and Governor Gear .....................................S-51
(3) Piston and Connecting Rod ................................................................S-54
(4) Crankshaft...........................................................................................S-58
(5) Cylinder...............................................................................................S-63
(6) Oil Pump .............................................................................................S-64
(7) Starter .................................................................................................S-65
(8) Alternator ............................................................................................S-68
KiSC issued 06, 2011 A