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DIESEL ENGINE MECHANICAL
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
otherwise noted.
Description and Operation ...............................1B3-2
Valve Device .................................................... 1B3-2
Component Locator .......................................... 1B3-4
Cylinder Head ................................................... 1B3-4
Cylinder Block .................................................. 1B3-6
Engine Component ........................................... 1B3-8
Repair Instructions .......................................... 1B3-10
On-Vehicle Service ........................................... 1B3-10
Engine Assembly ..............................................1B3-10
Poly V-Belt and Tensioning Device .................... 1B3-19
Poly V-Belt ...................................................... 1B3-19
Tensioning Device .......................................... 1B3-23
Crankcase and Cylinder Head ........................... 1B3-26
Cylinder Head ................................................. 1B3-26
Prechamber .................................................... 1B3-46
Oil Pan ............................................................ 1B3-48
Timing Case Cover ......................................... 1B3-49
Crankshaft Assembly ........................................ 1B3-56
Vibration Damper and Hub ............................. 1B3-56
Flywheel and Crankshaft End Cover ............... 1B3-62
Crankshaft Ball Bearing .................................. 1B3-66
Crankshaft ...................................................... 1B3-67
Crankshaft Sprocket ....................................... 1B3-76
Piston .............................................................1B3-81
Flywheel Ring Gear ......................................... 1B3-87
Timing Device and Valve ................................... 1B3-90
Valve Tappets ................................................ 1B3-90
Valve Spring (Cylinder Head Removed) ......... 1B3-92
Valve Spring (Cylinder Head Installed) ...........1B3-95
SECTION 1B3
TABLE OF CONTENTS
Valve Stem Seals ............................................ 1B3-98
Valve Guides ................................................ 1B3-102
Valve Seat Rings .......................................... 1B3-105
Camshaft ...................................................... 1B3-112
Timing Chain ................................................ 1B3-118
Chain Tensioner ............................................ 1B3-122
Lubrication System .......................................... 1B3-124
Oil Filter ........................................................ 1B3-124
Oil Spray Nozzle........................................... 1B3-126
Oil Pump ....................................................... 1B3-127
Unit Repair ..................................................... 1B3-129
Milling of Prechamber Sealing Surface ......... 1B3-129
TDC(TDC Sensor Bracket) Setting ................ 1B3-133
Machining of Flywheel .................................. 1B3-135
Valve Springs Check .................................... 1B3-138
Check and Machining of Valves ................... 1B3-139
Machining of Valve Seat ............................... 1B3-144
Camshaft Timing Test ................................... 1B3-149
Cylinder Head Pressure Leakage Test ......... 1B3-151
Facing Cylinder Head Mating Surface .......... 1B3-152
Replacement of Crankcase Core Plug .......... 1B3-154
Facing Crankcase Contacting Surface .......... 1B3-156
Cylinder Bore Measurement ......................... 1B3-157
Specifications ................................................ 1B3-158
Fastener Tightening Specifications ............... 1B3-158
Special Tools and Equipment ...................... 1B3-160
Special Tools Table ...................................... 1B3-160
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