ENGINE MECHANICAL (J08E)
3-1
ENGINE MECHANICAL (J08E)
3-001
CYLINDER HEAD......................3-2
COMPONENT LOCATOR................3-2
SPECIAL TOOL.....................3-5
OVERHAUL.........................3-6
INSPECTION AND REPAIR...........3-16
CRANKSHAFT FRONT END..............3-20
COMPONENT LOCATOR...............3-20
SPECIAL TOOL....................3-21
OVERHAUL........................3-22
FLYWHEEL AND FLYWHEEL HOUSING.....3-24
COMPONENT LOCATOR...............3-24
SPECIAL TOOL....................3-25
OVERHAUL........................3-26
INSPECTION AND REPAIR...........3-30
TIMING GEAR.......................3-31
COMPONENT LOCATOR...............3-31
SPECIAL TOOL....................3-32
OVERHAUL........................3-33
INSPECTION AND REPAIR...........3-35
MAIN MOVING PARTS AND CYLINDER BLOCK ....3-37
COMPONENT LOCATOR...............3-37
SPECIAL TOOL....................3-39
OVERHAUL........................3-41
INSPECTION AND REPAIR...........3-51
3—2
ENGINE MECHANICAL (J08E)
COMPONENT LOCATOR
CYLINDER HEAD
EN01F01103020C01001001
SHTS011030200001
ENGINE MECHANICAL (J08E)
3-3
1	Oil filler cap	17	Collar
2	Cylinder head cover	18	Valve rocker shaft
3	Silent block	19	Camshaft bearing cap
4	Head cover gasket	20	Camshaft gear
5	Harness assembly	21	Camshaft
6	Union bolt	22	Nut
7	Gasket	23	Plate
8	Leakage pipe	24	Injection pipe oil seal
9	Injector clamp bolt	25	Injector
10	Rocker arm support bolt	26	O-ring*
11	Rocker arm assembly	27	Camshaft housing
12	Lock nut	28	Camshaft housing gasket
13	Adjust screw	29	Camshaft bearing
14	Rocker arm support	30	Plug
15	Rocker arm	31	Cylinder head assembly
16	Injector clamp	32	Cylinder head gasket *
*: Nonreusable part
Tightening torque	Unit: N m {kgfcm, Ibfft}
A	28.5 {290, 20}	G	23 {230, 16}
В	31 {320, 23}	H	59 {600, 43}+90°+90°#
c	59 {600, 43}+90°#	I	25 {250, 18}
D	25 {250, 18}	J	6 {61, 4.4}
E	59 {600, 43}	К	28 {286, 21}
F	12.3 {125,9}		
#=Apply oil to the threads and seat surfaces before tightening.
3-4
ENGINE MECHANICAL (J08E)
SHTS011030200002
1	Flange	10	Valve stem seal
2	Idle gear shaft	11	Valve spring seat lower
3	Camshaft idle gear	12	Valve stem guide
4	Idle gear thrust plate	13	Valve seat
5	Cross head	14	Valve
6	Valve spring retainer	15	Nozzle seat
7	Valve spring seat upper	16	O-ring *
8	Valve spring outer	17	Cylinder head block
9	Valve spring inner		
*: Nonreusable part Tightening torque	Unit: N m {kgfcm, Ibf ft}
A 108 {1,100, 79}#	
#=Apply oil to the threads and seat surfaces before tightening.
ENGINE MECHANICAL (J08E)
3-5
SPECIAL TOOL
EN01F01103020K01001001
Illustration		Part No.	Name	Remarks
		S0943-31070	EYE BOLT	
		S0949-11010	WIRE	
		S0947-01170	VALVE SPRING PRESS	
		S0943-11020	VALVE LAPPING TOOL	
		09201-E4010	VALVE STEM SEAL PRESS	
		S0947-21210	BAR	For Nozzle sleeve
	.	^7	SN441-00610	STEEL BALL	Used with S0947-21210
		S0947-11520	GUIDE	
3-6
ENGINE MECHANICAL (J08E)
OVERHAUL
EN01F01103020H02001001
IMPORTANT POINTS - DISASSEMBLY
SHTS011030200011
SHTS011030200014
1.	DISASSEMBLE THE CYLINDER HEAD.
(1)	Clean parts around the injector and fuel system connections.
NOTICE
Entry of foreign particles into the combustion chamber may result
in engine trouble.
(2)	Remove the injector harness assembly.
a.	Disconnect the connector of injector.
b.	Remove the 7 nuts, disconnect the injector harness
assembly with plate.
(3)	Remove the injector assembly.
Reference: FUEL SYSTEM (J08E), INJECTOR, OVER-
HAUL, REMOVING THE INJECTOR (Page 8-16)
(4)	Remove the rocker arm assembly.
a.	Loosen the lock nut at the end of the rocker arm and turn
the adjusting screw counterclockwise completely.
NOTICE
Not loosening the adjusting screw may result in a bent rocker
shaft.
b.	Loosen the injector clamp bolt.
c.	Loosen the rocker arm support bolt as shown in the figure.
NOTICE
If the cross head is removed from the valve during disassembly of
the rocker arm assembly, reassemble the cross head as it was.
(5)	Remove the cylinder head bolts.
a. Gradually loosen bolts three times in the order shown in
the figure.
ENGINE MECHANICAL (J08E)
3—7
SHTS011030200016
SHTS011030200017
(6)	Lift and remove the cylinder head using the special tool and
hoist.
SST: S0943-31070
Eye bolt
S0949-11010
Wire
NOTICE
•	Do not damage the cylinder head lower surface or cylinder
block upper surface during removal of the cylinder head.
•	If it is difficult to lift off the cylinder head, pry with a chisel
between the cylinder head and cylinder block.
2.	DISASSEMBLE THE VALVE SYSTEM.
(1)	Remove the valve spring retainer using the special tool.
SST: S0947-01170
Valve spring press
(2)	Remove the intake and exhaust valve.
NOTICE
Attaching tags to the valves (giving corresponding cylinder Nos.)
will eliminate time required for lapping the valve seats on reas-
sembly.
3.	CLEAN THE CYLINDER HEAD.
(1)	Clean the cylinder head and remove carbon deposits or for-
eign particles.
NOTICE
Be careful not to damage the cylinder head lower surface when
removing carbon deposits or foreign particles.
SHTS011030200018