DE TS Diesel Engine: Disassembly & Assembly

SB2088E02
Sep. 2011
DE08TS Diesel Engine

Disassembly & Assembly
D100, D120, D150

D110S-5, D130S-5, D160S-5
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary training,
skills and tools to perform these functions properly.
Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any Iubrication, maintenance or repair on this product, until you have read and
understood the operation, Iubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not
heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING" as
shown below.
WARNING
The meaning of this safety alert symbol is as follows :
Attention! Become Alert! Your Safety is Involved.
The Message that appears under the warning, explaining the hazard, can be either written or pictorially presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this
publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, Iubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DOOSAN dealers have the most current
information available.
1 of 76
Index
Air Cleaner Assembly ...........................................24 Intake Manifold.......................................................31

Air Cleaner Elements .............................................25
Air Compressor (if equipped) .................................72 Muffler ....................................................................22
Alternator ...............................................................12
OIl Cooler ...............................................................39
Camshaft And Camshaft Bearing ..........................61 Oil Filter..................................................................38
Connecting Rod Bearings ......................................48 Oil Pan ...................................................................34
Cooling Water Pipe ................................................41 Oil Pump ................................................................42
Crankshaft..............................................................69
Crankshaft Pulley ...................................................63 Pistons ...................................................................53
Cylinder Head ........................................................49
Cylinder Head Cover..............................................34 Radiator .................................................................28
Cylinder Liners .......................................................57 Rocker Shaft ..........................................................46
Rocker Shaft And Push Rods ................................45
Electric Starting Motor............................................11
Engine And Transmission ........................................5 Timing Gear Case ..................................................60
Exhaust Manifold ...................................................33 Timing Gear Case Cover .......................................58
Timing Gears .........................................................58
Fan Assembly ........................................................26
Fan Belts ................................................................26 Water Pump ...........................................................35
Flywheel .................................................................64 Water Temperature Regulator ...............................27
Flywheel Housing...................................................68
Fuel Filter ...............................................................18
Fuel Injection Lines ................................................17
Fuel Injection Nozzle Assembly .............................20 WARNING
Fuel Injection Pump ...............................................13
Fuel Pump..............................................................19
Disconnect batteries before performance of any
Fuel Strainer ..........................................................18
service work
Engine 5
Remove Engine And

4
Transmission
A10999 & D40999 - 02
Tools Needed A
Link Bracket 1
IEED002P
Start By :
5. Remove bolts (4), washers and nuts that hold
a. Remove overhead guard.* coolant reservoir on the frame. Set coolant
reservoir (5) aside.
b. Remove floorplate.*
c. Remove hood.* 7
d. Remove air cleaner.
e. Remove universal joint.*

6
* This operation is in the Vehicle Systems,
Disassembly And Assembly Manual.
1. Drain the coolant from the radiator.
2 IEED003P
6. Disconnect two hoses (6) from the fuel tank.

3
7. Disconnect wiring harness (7) from fuel sender.
8
1
IEED001P
2. Remove engine harness assembly (1) from the

clips of bonnet assembly (3).
3. Remove screws, washers and circuit breaker (2)

from bonnet assembly (3).
IEED004P
4. Remove bolt and washer that hold bonnet
assembly. Remove bonnet assembly (3) from the
frame. 8. Remove tube (8) from the tube of air compressor
(if equipped).
DE08TS Diesel Engine 5 of 76 Disassembly and Assembly

13
10
IEED005P IEED008P
9. Remove two bolts washers (9) and hydraulic filter 12. Disconnect ground cable (13) from the alternator.
assembly (10). Set hydraulic filter assembly (10)
aside.
14
11
IEED009P
IEED006P 13. Disconnect three hoses (14) from the hydraulic

pump.
10. Disconnect battery cable (11) from the starting
motor. NOTE : Plug and cap all hydraulic connectors and hoses
to avoid debris and contamination from entering the
system.
15
12
IEED007P
IEED010P
11. Disconnect transmission neutral switch connector
(12).
14. Remove bolts (15) and washers that hold the
muffler expansion on exhanst manifold of the
engine.

17
21
16
IEED011P IEED014P
15. Disconnect two transmission cooling hoses (16) 19. Remove bolts (21), washers and nuts from the
from the transmission. two transmission support.
16. Disconnect transmission oil temperature switch NOTE : At this point, make a final check to be sure all
wiring (17). removals and disconnections have been made from
the engine and the transmission.
22
A
18
IEED012P
IEED015P
17. Disconnect two engine cooling hoses (18 ) from
the engine. 20. Install the tool (A) to the transmission. Fasten tool
(A) to the engine and transmission as shown.
20 21. Remove engine and transmission (22) from the

lift truck.
22. Put the engine and transmission on an

acceptable engine stand. Remove tool (A).
19
IEED013P
18. Remove bolts (19), washers, nuts from the two

engine support (20), one on both side of the
engine.

25 22 A
24
23
IEED016P IEED017P
23. Support transmission (24) with fasten a strap and 3. Install the tool (A) to the transmission.
remove twenty bolts(23) and washers. Remove
transmission (24) from engine (25). 4. Fasten tool (A) to engine and transmission (22) as
shown.
Install Engine And Transmission

A10999 & C40999 - 03 21
Tools Needed A B
Link Bracket 1
Eye Bolt 1
IEED014P
25
24
23 5. Put the engine and transmission in position on the
lift truck. Make an alignment of supports with the
frame.
6. Install bolts (21), washers and nuts that hold the

transmission support to the frame.
� 800 N�m
Tighten bolts (21) to a torque of 730�
(540 � 590 lb�ft).
IEED016P
1. Put transmission (24) in position in engine (25).
2. Install bolts (23) and washers that hold

transmission to the engine. Tighten bolts (23) to
torque of 55 ± 10 N�m (40 ± 7 lb�ft).

20 17
16
19
IEED013P IEED011P
7. Install bolts (19), washers and nuts that hold 9. Connect two transmission cooling hoses (16) to
engine support (20) to the frame. Tighten bolts (19) transmission.
to a torque of 280 N�m (205 lb�ft).
10. Connect transmission oil temperature switch
connector (17).
18
15
IEED012P
IEED010P
8. Connect two engine cooling hoses (18) and tighten
the hose clamps.
11. Install bolts (15) and washers that hold the muffler
expansion to exhaust manifold of the engine.
14
IEED009P
12. Connect three hydraulic hoses (14) to the

hydraulic pump.

13
10
IEED008P IEED005P
13. Connect ground cable (13) to the alternator. 16. Put hydraulic filter assembly (10) in position on
the frame. Install bolts (9) and washers.
12
IEED007P
IEED004P
14. Connect transmission neutral switch connector
(12). 17. Install tube (8) to the air compressor (if
equipped).
11
IEED006P IEED003P
15. Connect battery cable(11) to the starting motor.

18. Connect wiring harness (7) to the fuel sender.
19. Connect two fuel hoses (6) and tighten the hose
clamp.

5
Electric Starting Motor
Remove Electric Starting Motor

4 A61564 - 02
WARNING
Disconnect the battery before the starting motor

IEED002P
is removed
20. Put the coolant reservoir with bracket (5) in

position on the frame. Install bolts (4) and
washers that hold coolant reservoir (5).
2
1
IEED018P
1
1. Put identification on the starting motor and
IEED001P solenoid wires. Disconnect wirings (1) and battery
cable (2).
21. Put bonnet assembly (3) in position on the frame.
Install the bolts and washers. Tighten the bolts to
a torque of 200 N.m (150 lb.ft). 4
22. Install the screws and washers that hold circuit

breaker (2).
23. Clear engine harness assembly (1).
24. Fill the cooling system. See the Maintenance

Guide for the correct level.
End By :
3
a. Install universal joint. IEED019P
b. Install air cleaner. 2. Remove mounting nuts (3) and then remove
starting motor (4) from the lift truck.
c. Install hood.
d. Install floorplate.
e. Install overhead guard.

Install Electric Starting Motor Alternator
A61564 - 03
Remove Alternator B31018 - 02
4
3 6
IEED019P
IEED020P
1. Put starting motor (4) in position on the flywheel
housing and install nuts (3) that hold it.
1. Put identification on all wires (1) and the
disconnect them from alternator (6).
2. Disconnect ground cable (2) from alternator (6).
IEED018P 5
5
2. Connect wirings (2) to the starting motor and
solenoid. Connect battery positive cable (1). 4
6
IEED021P
3. Loosen nuts (4) and then remove belt (3) from the
alternator.
4. Remove bolts (5) from the alternator’s bracket to

remove alternator (6).

Install Alternator B31018 - 03 Fuel Injection Pump
3
Remove Fuel Injection Pump
A25663 - 02
Start By :
5
a. Remove air compressor (if equipped).
5
b. Remove intake manifold.
4
6
IEED021P
1. Put alternator (6) in position on its bracket and 3

2
install bolts (5) that hold it.
2. Install fan belt (3) on the alternator and tighten nuts

4
(4).
1
2
IEED022P
1. Remove two bolts (1) and washers.

1
2. Remove bolt (2), washers, spacer (3) and lifting
bracket (4).
6
IEED020P
3. Connect all wires (1) to their respective positions.
4. Connect ground cable (2) to alternator (6). 5
6
IEED166P
3. Remove bolts (5) and washers that hold the

tension adjusting bracket on the timing gear case.
4. Remove the idle pulley and V-belt tension

adjusting bracket assembly (6) and gasket.
Discard the gasket.

11
8
9
IEED023P IEED118P
5. Remove bolts (7), washers and cover (8). 8. Remove nut (11) and injection pump coupling and
gear (9) from the injection pump.
9
12
IEED024P
13
IEED025P
6. Make an alignment of the timing marks on fuel
injection pump gear (9) and the idle gear or put a 9. Disconnect accel rod (12) and engine stop cable
mark of identification on the gears for correct (13).
installation.
15
10
14
14
14
IEED026P
IEED117P
10. Disconnect five hoses (14) and tubes (15) from

7. Remove nut (10) from the injection pump coupling. the injection pump.

Install Fuel Injection Pump
A25663 - 03
16
IEED027P
11. Remove four nuts (16) and washers that hold the
injection pump in place. Remove the gasket and 17
IEED028P
discard it.
1. Install the new gasket in position on the timing

gear case. Put fuel injection pump (17) in position
on the timing gear case.
18 17
IEED028P
12. Support injection pump (17). Remove two bolts

(18) and washers that hold injection pump (17) on
IEED024P
the block. Remove injection pump (17).
2. Make sure the timing marks or the marks that were

put on the fuel injection pump gear (9) and the idle
gear are in alignment.
16
IEED027P
3. Install four nuts (16) and washers that hold the fuel
injection pump on the timing gear case.

11
9
18
IEED118P IEED028P
4. Put the fuel injection pump drive coupling and gear 8. Install bolts (18) and washers that hold the
(9) in position. Make an alignment of the key and injection pump on the block.
the groove (slot) in the coupling.
5. Install nut (11) that hold the injection pump drive 15

coupling and gear (9) in place. Tighten nut (11) to
a torque of 130 N� �m (96 lb� �ft).
10
14
14
14
IEED026P
9. Connect three hoses (14) and tube (15) to the

injection pump.
IEED117P
12
6. Install nut (10) into the injection pump coupling.
13
IEED025P
10. Connect accel cable (12) and engine stop cable

IEED023P (13) to the injection pump.
7. Install cover (8), bolts (7) and washers.

Fuel Injection Lines
Remove Fuel Injection Lines

5
A23525 - 02
6 1
IEED166P
11. Install the new gasket on the timing gear case.
12. Put the idle pulley and V-belt tension adjusting

bracket assembly (6) on the timing gear case and
install bolts (5) and washers.
IEED029P
1. Disconnect fuel injection lines (1) from the fuel

3 injection nozzle assemblies and the fuel injection
2
pump.
4
Install Fuel Injection Lines
A23525 - 03
1
IEED022P
1
13. Install lifting bracket (4), spacer (3), washers and
bolts (2) on the block.
14. Install two bolts (1) and washers.
End By :
a. Install air compressor (if equipped).
b. Install intake manifold. IEED029P
2. Connect fuel injection lines (1) to the fuel injection

pump and the fuel injection nozzle assemblies.
Tighten the fuel line nuts to a torque of
16 to 20 N�m (12 to 15 lb�ft).

Fuel Filter Fuel Strainer
Remove & Install Fuel Strainer
Remove Fuel Filter A21357SE - 02 A21357PR - 01
1
3
2 1
IEED030P
IEED031P
1. Loosen bolt (1). Remove bowl (2).

1. Remove bolt (1) and washers and disconnect fuel
2. Remove fuel filter. line (2) that connected the fuel tank.
2. Remove bolt (3), washers and fuel strainer (4) from

the injection pump.
Install Fuel Filter A21357SE - 03
3. Install fuel strainer (4) in reverse order of removal.
IEED030P
1. Install a new gasket in the filter bowl.
2. Put a new fuel filter element in position.
3. Put filter bowl (2) in position and tighten bolt (1)

that holds the bowl in position.

Fuel Pump Install Fuel Pump A21663 - 03
Remove Fuel Pump A21663 - 02

3
2
IEED033P
1
1. Put fuel pump (4) in position on the engine block
IEED032P with nuts (3) that hold it.
1. Disconnect fuel inlet line (1) and fuel outlet line (2)
from the fuel pump.
4
1
IEED032P
2. Connect fuel outlet line (2) and fuel inlet line (1) to
IEED033P the fuel pump.
2. Remove three nuts (3) that hold fuel pump (4) to

the injection pump. Remove fuel pump (4).

Fuel Injection Nozzle Install Fuel Injection Nozzle
Assembly Assembly A28999 - 03
Remove Fuel Injection Nozzle 2

Assembly A28999 - 02
3
IEED034P
1. Install the new seal rings in the nozzle hole of the

cylinder head.
IECD029P 2. Put fuel injection nozzles (2) in position. Install nuts
(3) and tighten them to a torque of 70 ± 10 N�m
1. Disconnect fuel lines (1) from the fuel injection (52 ± 7 lb�ft).
nozzles.
2 1
IEED029P
3
IEED034P
3. Connect fuel lines (1) to the injection nozzles and
2. Remove nuts (3) and then remove fuel injection then tighten the nuts to a torque of 30 N�m (22 lb�ft).
nozzles (2).
3. Remove the seals from the nozzle holders of the

cylinder head and discard it.

Disassemble & Assemble Fuel 6 4 2
Injection Nozzle Assembly
A28999 - 06
Start By :
a. Remove fuel injection nozzle assembly
1 7 5 3
IEED036P
4. Install shims (7), spring (6), guide (5) and

intermediate washer (4) to the nozzle holder.
5. Install needle valve (3) into fuel nozzle (2) and

install the fuel nozzle.
1
IEED035P
1. Remove union nut (1) from the nozzle assembly.
6 4 2
IEED035P
6. Install union nut (1) and tighten to a torque of

70 ± 10 N�m (52 ± 7 lb�ft).
End By :
7 5 3
IEED036P
a. Install fuel injection nozzle assembly.
2. Remove fuel nozzle (2), needle valve (3),

intermediate washer (4), guide (5), spring (6) and
shims (7) from the nozzle holder.
3. Check all parts for damage. If damaged, use new

parts for replacement.
NOTE : The following steps are for assembling the

fuel injection nozzle assembly.

Muffler 9
10
Remove Muffler A32570 - 02
2 5
3
IEED039P
1
4
4. Remove three bolts (8), washers and nuts.
5 5. Support tube assembly (5) and remove bolt (9),

washers, rubber mounts (10), shims and nuts that
IEED037P
hold tube assembly (5) on the frame. Remove tube
assembly (5).
1. Remove four bolts (1), washers and nuts (2) that
hold muffler tube assembly (3) on tube assembly
(5).
2. Remove two bolts (4) and washers that hold tube 11

assembly (5) on the frame.
15
12
13
14
IEED040P
6
7 6. Remove three bolts (11), washers and nuts (12).
7. Remove bolt (13), washers, rubber mounts (14),

shims and nuts that hold mount bracket of muffler
IEED038P
assembly (15) on the frame. Remove muffler
assembly (15).
3. Remove five bolts (6), washers and cover (7) from
the frame.

Install Muffler A32570 - 02
11
15 6
12 7
13
IEED038P
14
IEED040P 5. Install five bolts (6), washers and cover (7) to the
frame.
1. Put the muffler assembly (15) in position on the
frame. Install bolt (13), washers, rubber mounts
(14), shims and nuts that hold muffler assembly
(15) on the frame. Tighten bolt (13) to a torque of
75�� 90 N�m (55 � 65 lb�ft). 2
3
2. Install three bolts (11), washers and nuts (12).
1
4
9
5
10
IEED037P
6. Install two bolts (4) and washers that hold tube

8 assembly (5) on the frame.
7. Put muffler tube assembly (3) in position on tube

5
assembly (5). Install bolts (1), washers and nuts
IEED039P that hold muffler tube assembly (3).
3. Put the tube assembly (5) in position in place.

Install three bolts (8), washers and nuts.
4. Install bolt (9), washers, rubber mounts (10), shims

and nuts that hold tube assembly (5) to the frame.
Tighten bolt (9) to a torque of 75 � 90 N�m (55 �
65 lb�ft).

Air Cleaner Assembly Install Air Cleaner Assembly
A31999 - 03
Remove Air Cleaner Assembly
A31999 - 02
2 3
4
IEED042P
4
1. Put air cleaner assembly (4) in position and install

IEED041P bolts (3) and nuts that hold it. Tighten bolts (3) to a
torque of 55 � 65 N�m (40 � 45 lb�ft) with
1. Loosen hose clamps (1) and disconnect hoses (2) Loctite No. 242.
from air cleaner (4).
3
IEED041P
4
IEED042P
2. Install hoses (2) and tighten all hose clamps (1).
2. Remove bolts (3) and nuts, and then remove air
cleaner assembly (4).

Air Cleaner Elements Install Air Cleaner Elements
A31330 - 03
Remove Air Cleaner Elements
A31330 - 02
2 6
1
IEED045P
1. Put inner element filter (7) in position inside the

3
IEED043P cleaner assembly and then install nut (6) that hold
it.
1. Loosen bolt (1) and remove clamp (2) and element
cover (3)
5 IEED044P
IEED044P 2. Install outer filter element (5) in position and install

nut (4) that hold it.
2. Remove nut (4) and outer filter element (5) from
the cleaner assembly.
6 1
7 3
IEED043P
IEED045P 3. Install element cover (3) with the clamp (2) that
hold it and tighten the bolt (1).
3. Remove nuts (6) and then remove inner filter
element (7) from the cleaner assembly.

Fan Assembly Remove Fan Belts A51087 - 02
Remove Fan Assembly

A51342 - 02
Start By :
a. Remove radiator
1
2
2 3
1
IEED047P
1. Loosen bolts (1) and nuts (2) on the alternator

bracket and idle pulley. Move the alternator in
1 toward the engine. Remove belt (3).
Install Fan Belts A51087 - 03

IEED046P
1. Remove six bolts (2) and then remove fan

assembly (1).
Install Fan Assembly A51342 - 03 1

2
2 3
1
IEED047P
1. Put belt (3) in position on the pulleys.

Move the alternator away from the engine to tighten
1
the belt. Tighten bolts (1) and nuts (2). See
Specifications for the correct belt tension.
IEED046P
1. Put the fan assembly (1) in position and install the

six bolts (2) that hold it.
End By :
a. Install radiator

Water Temperature Regulator Install Water Temperature
Regulator A56581 - 03
Remove Water Temperature
Regulator A56581 - 02
4
IEED049P
2
1. Put water temperature regulator (4) in position as
IEED048P shown.
1. Drain the coolant below the level of the water

temperature regulator.
2. Loosen clamps (1) to disconnect two hoses (2)

from the regulator.
2
IEED048P
2. Put water temperature regulator (4) in place and

connect hoses (2).
3
4
3. Tighten the hose clamps (1).
IEED049P
4. Fill the cooling system. See Maintenance Guide for
the correct level.
3. Loosen clamp (3) and remove water temperature
regulator (4).

Radiator
Remove Radiator A52670 - 02
Tools Needed A
Link Bracket 2
7
Start By : 6
8
a. Remove hood IEED053P
5. Disconnect over flow hose (6) from the radiator.
6. Loosen hose clamp (7) and disconnect top

radiator hose (8).
2
1
NOTICE
Plug and cap all cooling hoses to avoid debris from
entering the system.
IEED050P 10
1. Drain the coolant from the radiator.
2. Loosen clamps (1) and remove air cleaner hose

(2).
11
IEED054P
7. Loosen hose clamp (9) and disconnect hose (10).
8. Disconnect transmission cooling hose (11) from

3 the radiator.
5
4
IEED051P
3. Remove strap (3) from top cover (5).
4. Remove four bolts (4) and washers that hold top

cover (5) on the frame. Remove top cover (5) from
the frame.
12
IEED055P
9. Disconnect transmission cooling hose (12) from

the radiator.

Install Radiator A52670 - 03
Tools Needed A
Link Bracket 2
13
14
IEED056P
10. Install tool (A) and fasten a hoist. 17
11. Remove bolts (13), washers, rubbers (14), shims

and bolt that hold the radiator on the frame (both
side). IEED058P
1. Install tool (A) and fasten a hoist as shown. Put

radiator (17) in position on the lift truck.
15
17 16
IEED057P 15
17 16
12. Remove nuts (15), washers, rubbers (16), shims and
bolt that hold radiator (17) on the frame (both side). IEED057P
Remove radiator (17) from the lift truck.
2. Install bolt, shims, rubbers (16), washers and nuts

(15) that hold radiator (17) on the frame. Tighten
nuts (15) and bolt to a torque of 75 � 90 N�m (55
� 65 lb�ft).
13
14
IEED056P
3. Install bolt, shims, rubbers (14), washers and nuts

(13) that hold the radiator on the frame. Tighten
nuts (13) and bolt to a torque of 75 � 90 N�m (55
� 65 lb�ft).
3
5
12 4
IEED055P IEED051P
4. Connect transmission cooling hose (12) on the 9. Put top cover (5) in position on the frame. Install
radiator. bolts (4) and washers that hold top cover (5) on
the frame.
10 10. Install strap (3).
1
9
11
IEED054P
5. Connect hose (10) on the radiator and tighten hose IEED050P

clamp (9).
6. Connect transmission cooling hose (11) on the 11. Install air cleaner hose (2) and tighten hose
frame. clamps (1).
12. Fill the cooling system. See the Maintenance

Guide for the correct level.
End By :
a. Install hood.
7
6
8
IEED053P
7. Connect top radiator hose (8) and tight hose clamp

(7).
8. Connect radiator overflow hose (6).

Intake Manifold 5 6
Remove Intake Manifold

A325491N - 02
Start By :
a. Remove hood
IEED061P
2
3. Loosen clamp (5) and disconnect hose (6) from the
air compressor (if equipped).
7 10
12
1
IEED059P
1. Loosen hose clamps (1) and remove air cleaner 9

outlet hose (2). 8
IEED062P
4 4. Remove six nozzle pipes (7) and disconnect fuel

return hose (8).
5. Disconnect cooling temperature harness (9) from

the cooling water pipe.
6. Support intake manifold (12) with fasten a strap.

3 Remove ten bolts (10), washers and two nuts that
hold intake manifold (12) to the cylinder head.
IEED060P 7. Remove intake manifold (12).
8. Remove the intake manifold gasket and discard it.

2. Remove four bolts (3), washers and mount bracket
and fuel filter assembly (4) from the intake
manifold. Set the mount bracket and fuel filter
assembly aside to theframe.

Assemble Intake Manifold
A325491N - 03 4
7 10
12
3
IEED060P
9
8 6. Put the mount bracket and fuel filter assembly (4)
in position on the intake manifold. Install bolts (3)
IEED062P
and washers that hold the mount bracket and fuel
filter assembly (4).
1. Install new intake manifold gasket on the cylinder
head by aligning its openings with the intake port in
the cylinder head. 2
2. Put the intake manifold (12) in position on the

cylinder head. Install bolts (10), washers and nuts
that hold intake manifold (12).
3. Connect fuel return hose (8) and install six nozzle

pipes (7).
4. Connect cooling temperature harness (9).
1
IEED059P
5 6
7. Install air cleaner outlet hose (2) and tighten hose

clamps (1).
IEED061P
5. Connect hose (6) to the air compressor (if

equipped) and tighten clamp (5).

Exhaust Manifold Install Exhaust Manifold
A32549EX - 03
Remove Exhaust Manifold
A32549ES - 02 5
2 3
4
IEED063P
1
1. Check the seal ring on the jointing face of the
IEED010P exhaust manifold and replace it if needed.
2. Put the new gaskets, heat screens (4 and 5) and

1. Remove four bolts (1) and washers from the
exhaust manifold (3) in position on the cylinder
exhaust manifold.
head. Install nuts (2) and washers that hold the
exhaust manifold. Tighten nuts (2) to a torque of
5
45 N�m (33 lb�ft).
2 3
4
IEED063P
1
2. Remove twelve nuts (2) and washers that hold the IEED010P
exhaust manifold on the cylinder head. Remove
exhaust manifold (3), heat screens (4) and (5) and
3. Install eight bolts (1) and washers.
gaskets from the cylinder head.

Cylinder Head Cover Oil Pan
Remove Cylinder Head Cover Remove Oil Pan A43591-02
1 1. Put the lift truck in position up on the blocks.
2. Drain the oil from the oil pan (2).
2
IEED064P
1. Remove bolts (1) and washers that hold cylinder 1

head cover (2) onto the cylinder head.
2. Remove cylinder head cover (2) with gasket. IEED065P

Inspect the cylinder head cover gasket for wear or
3. Remove all bolts (1) and washers from around the
damage and replace if required.
oil pan and then remove oil pan (2) from the
engine block. Check gasket for damage.
Install Cylinder Head Cover

Install Oil Pan A43591-03
1
1
2
IEED064P
IEED065P
1. Fix the new gasket to the jointing face of cylinder
head cover (2). 1. Remove the gasket residue on the fixing surface of
the timing gear case, case cover and the cylinder
2. Position cylinder head cover (2) on the cylinder block using a scraper.
head, then install bolts (1) and tighten them torque
�m (15 lb�ft).
to 20 N� 2. Coat the new gasket fixing surface with silicon
grease.
3. Put a new gasket in position on oil pan if

necessary. Put oil pan (2) in position on the engine
with bolts (1) and washers that hold it. Tighten the
bolts (1) to a torque of 20 N�m (15 lb�ft).
4. Fill the engine with oil to the correct level. See the
operation And Maintenance Manual for further
information.
5. Remove the lift truck from the blocks.

Water Pump 2
Remove & Install Water Pump 3
A53663-01
Start By :
a. Remove fan assembly
b. Remove radiator IEED067P
c. Remove alternator
5. Install the new gasket on the engine.
6. Put water pump (3) in position and install bolts (2)

and washers that hold it. Tighten bolts (2) to a
� m (15 lb�
torque of 20 N� � ft).
IEED066P
1. Remove hose (1) from the water pump.
IEED066P
2
7. Connect hose (1) to the water pump.
3 End By :
a. Install fan assembly.
b. Install alternator.
c. Install radiator.
IEED067P
2. Remove six bolts (2) and washers that hold water

pump (3) on the engine.
3. Remove water pump (3) from the engine.
4. Remove the gasket and discard it.
NOTE : Use the following steps to install the water

pump.

Disassemble Water Pump
A53663-07
Tools Needed A B C
5
Gear Puller 1
Pliers 1
Drive Group 1
Start By :
IEED070P
a. Remove water pump
4. Remove snap ring (5) with tool (B).
IEED068P
1. Remove flange (1) using tool (A). IEED071P
5. Put the water pump in position on a press. Install

3 tool (C) and remove shaft assembly (6) from the
impeller and the water pump housing.
4 7
IEED069P
2. Remove three screws (2) that hold pump cover (3)

on the pump housing.
IEED072P
NOTE : Before unscrewing the screws (2) slight
impacts on them are necessary to loosen the loctite 6. Remove seals (7) from the water pump housing if
connection. they are damaged.
3. Remove pump cover (3) and gasket (4) and
discard it.

8
9
IEED073P IEED072P
7. Put shaft assembly (8) in position in a press. Install 2. Install seal (7) in the housing.
Tool (A) to remove bearing (9) from the shaft.
Assemble Water Pump A53663
Tools Needed A B
6
Pliers 1
Drive Group 1
IEED071P
3. Put the water pump housing in position on a press

8 and install shaft assembly (6) in the housing.
5
9
IEED073P
1. Put shaft bearing (9) in position in a press. Make

sure there is support for the inner race of the
bearing. Push shaft into bearing (9).
IEED070P
4. Install snap ring (5) over the bearings with tool (A).

Oil Filter
Remove & Install Oil Filter

A42357-01
6
IEED071P
2
5. Install impeller (10) on the shaft with tool (B) and a

press. The clearance between the impeller blade
and pump body have not to exceed 0.35 mm
(.0138 in).
IEED074P
3
1. Remove four bolts (1) and washers that hold oil
filter assembly (2) on the block.
2. Remove oil filter assembly (2) from the block.

2
3. Remove the gasket from the block and discard it.
4. Install the oil filter assembly (2) in reverse order of

4 removal.
IEED069P
6. Install cover (3) and gasket (4) on the pump housing.
7. Install three screws (2) that hold cover (3).

Tighten the screws (2) to a torque of 22 N m (16
lb ft).
IEED068P
8. Install flange (1) on the shaft with tool (B) and a

press.
End By :
a. Install water pump.

Disassemble & Assemble Oil 4. Assemble the oil filter assembly in reverse order of
disassembly.
Filter A42357
End By :
Tools Needed A
a. Install oil filter.
Filter Wrench 1
Start By :
a. Remove oil filter Oil Cooler
Remove & Install Oil Cooler
1
IEED075P
1. Remove filter (1) on the filter head using tool (A). 2

IEED077P
6 5 3 1. Loosen clamps (1) and disconnect hoses (2) from

the oil cooler.
4 2
IEED076P
2. Remove plug (2), seal ring (3), shim (4), spring (5)
and valve plunger (6) from the filter head. IEED078P
7
2. Remove PCV valve (3) and O-ring from the cooler
housing.
IEED167P
3. Remove relief valve assembly (7) with seal ring

from the filter head.

5
5
3
6
7
IEED079P IEED081P
3. Remove two bolts (5), nuts (6) and washers that 3. Inspect the condition of gasket (3). Replace gasket
hold oil cooler (7) on the block. (3) with new if needed.
4. Remove oil cooler assembly (7).

4
5. Remove the gasket from the block and discard it.
6. Install the oil cooler in reverse order of removal.
Disassemble & Assemble Oil

Cooler
Start By : IEED082P
a. Remove oil cooler 4. Remove four bolts (4) and washers that hold
element in oil cooler housing.
2 5. Remove element (5) from oil cooler housing.
6 6
1
IEED080P
1. Remove eight bolts (1) and washers that hold

cover (2) on the oil cooler housing. IEED083P
2. Remove cover (2) from the oil cooler housing. 6. Remove two gaskets (6) from the oil cooler
housing and discard it.

7 9 11
8 10
IEED084P IEED086P
7. Remove plug (7), seal-ring (8), pin (9), spring (10) 2. Loosen clamp (2) and disconnect hose (3) from the
and ball (11) from the oil cooler housing. cooling pipe.
8. Assemble the oil cooler in reverse order of

disassembly. 4 5 4
End By :
a. Install oil cooler.
Cooling Water Pipe
Remove & Install Cooling Water IEED087P

Pipe
3. Remove six bolts (4) and washers that hold cooling
pipe (5) on the cylinder head.
NOTE : For purpose of reassembly, the torque for

�m (15 lb�
bolts (4) is 20 N� �ft).
4. Remove cooling water pipe (5).

1 5. Remove gasket and discard it.
6. Install the cooling water pipe (5) in reverse order of

1 removal.
IEED085P
1. Disconnect two wirings (1) from the cooling water

pipe.

Oil Pump
5
Remove Oil Pump A41663-02
Start By :
a. Remove oil pan
6
IEED090P
1
5. Remove bolts (5), washers and suction tube
2 assembly (6).
6. Remove the gasket and discard it
IEED088P 8
1. Remove bolts (1), washers and tube assembly (2).
2. Remove the gaskets and discard it.
3
IEED091P
4 7. Remove two bolts (7) and washers that hold oil

pump (8) in place.
8. Remove oil pump assembly (8) from the engine.
IEED089P
3. Remove bolts (3), washers and tube assembly (4).
4. Remove the gasket and discard it.

Install Oil Pump A41663-03 3
8
4
IEED089P
IEED091P 5. Install new gasket on tube assembly (4).
6. Put tube assembly (4) in place and install bolts (3)

1. Put oil pump assembly (8) in position on No.7 and washers that hold tube assembly (4). Tighten
bearing cap, by tapping slightly with a plastic bolts (3).
hammer.
2. Install bolts (7) and washers that hold the oil pump
in place and tighten bolts (7) to a torque of 44 N�m
1
�ft).
(32 lb�
3. Bend the lock washer towards bolt (7) to prevent 2

from loosening.
IEED088P
7. Install new gasket on tube assembly (2).
8. Put tube assembly (2) in place and install bolts (1)

and washers that hold tube assembly (2). Tighten
bolts (1).
6
IEED090P
End By :
4. Put suction tube assembly (6) in place and install a. Install oil pan.
new gasket, bolts (5) and washers that hold
suction tube assembly (6).

Disassemble & Assemble Oil 6
Pump A41663-06
Start By :
a. Remove oil pump
1
3
IEED094P
6. Check the conditions of bushing (6) in the rear

cover. Replace with a new one if worn or
2 damaged.
8 9 7
IEED092P
1. Bend washer (1) that lock nut (2) on the shaft of

drive gear.
2. Remove washer (1), nut (2) and oil pump drive

gear (3).
NOTE : For the purpose of reassembly, tighten nut

(2) to a torque of 127 N m (94 lb ft).
IEED095P
3. Remove wooden roof key from the shaft.
7. Remove plug (7), valve plunger (8) and spring (9)
from the rear cover.
5
10
IEED093P
4. Remove four bolts (4) and nuts that hold rear cover IEED096P
(5) on the pump housing.
NOTE : For the purpose of reassembly, tighten bolts 8. Remove two pump gears (10) from the pump
(4) and nuts to a torque of 22 N m (16 lb ft). housing.
5. Remove rear cover (5).

Rocker Shaft & Push Rods
11 Remove Rocker Shaft & Push

Rods A17744 & A17702-02
Start By :
a. Remove head cover

12
IEED097P
NOTE : Mark front cover (11) for the purpose of 2

reassembly.
9. Remove front cover (11) from the pump housing.
10. Check the conditions of bushings (12) in the front

cover. Replace with new ones if worn or
damaged.
3
NOTE : Assemble the oil pump in reverse order of
removal. 1
IEED098P
End By :
1. Remove bolts (2) and washers from the rocker
a. Install oil pump. shaft assembly. Remove rocker shaft assembly (1)
from the cylinder head.
2. Remove twelve push rods (3).
Install Rocker Shaft & Push

Rods A17744 & 17702-03
1
IEED098P
1. Install push-rods (3) coated with engine oil in the

cylinder head.
2. Install rocker arm shaft assembly (1) and align the

end of the rocker arm adjust screw with the push
rod, then tighten bracket bolts (2).
3. Adjust valve clearance as following procedure ;

a. Bring the TDC mark on the crankshaft pulley Rocker Shaft
into alignment with the gear case by turning the
crankshaft, then check the state of the rocker
arms on No. 1 cylinder to see in which cylinder
the poston is at the top dead center (TDC) on
Disassemble Rocker Shaft
compression stroke. A17744-07
NOTE : When both the intake and exhaust valve
Tools Needed A
rocker arms are in free state, it indicates that the
piston in that cylinder is at the top dead center on Drive Group 1
compression stroke.
Start By :
b. Perform valve clearance adjustment operation
commencing with the valves on the cylinder in a. Remove rocker shaft and push rods
which the poston is at the top dead center on
compression stroke. Insert a feeler gauge of
specified thickness into the clearance between
the valve stem end and rocker arm and adjust
the clearance with the adjust screw. Fully
tighten the rock nut when a correct adjustment
is obtained.
Valve clearance (Cold) Intake 0.3

(mm) Exhaust 0.3
c. When adjustment of the valve on the No.1 IEED099P

cylinder is completed, turn the crankshaft one
full turn and adjust the clearances of the valve
1. Remove circlip (1) and washer from both end of
on remaining cylinders.
the rocker shaft.
1 2 3 4 5 6
I E I E I E I E I E I E
2 4
#1 ��
#6 ◎ ◎ ◎ ◎ ◎ ◎
I:Intake valve E : Exhaust valve.
NOTE : Adjust the clearance of the valves marked

with '�' in the table when the piston in No. 1 cylinder 3
is held at the top dead center on compression stroke. IEED100P
Conversely, adjust the clearance of the valves
marked with '◎' in the table when the piston in No. 6 2. Remove rocker arms (2), brackets (3) and springs
cylinder is held at the top dead center on (4) from both side of the rocker shaft.
compression stroke.
End By :
a. Install head cover.

Assemble Rocker Shaft A17744-08
5
Tools Needed A
Driver Group 1
6
7 5
IEED001S
3. Remove nut (5) and adjusting screw (6) from the 6

rocker arm.
7
4. If a replacement is needed, remove bushing (7)
with tool (A) and a press.
IEED001S
1. If replacement was needed, make an alignment of

oil hole in the bushing with the oil hole in the rocker
arm. Install new bushing (7) in the rocker arm with
tool (A) and a press.
NOTE : Check the bore dimension of the bushing in

the rocker arm after installation. It must be within the
tolerance given in the specifications.
NOTICE
IEED002S Do not turn the adjusting screw too far into the rocker
arms. Damage to the valve can be the result after the
5. Support the rocker arm shaft on V-blocks at its rocker shaft and push rods have been installed in the
ends and check the amount of run-out at the engine.
center part using a dial indicator. If a slight amount
of run-out is noticeable, correct with a bench press
without applying heat. Replace the rocker arm 2. Install adjusting screw (6) and nut (5) in the rocker
shaft if the amount of run-out is 0.3 mm (.012 in). arm.
6. Measure the diameter of the rocker shaft at both of

the rocker arm locations. The diameter must be
23.959 to 23.978 mm (.9432 to .9440 in).
NOTE : The maximum permissible clearance

between the rocker arm bearings and shaft is 0.25
mm (.0099 in.).

2 4 Connecting Rod Bearings
Remove Connecting Rod

Bearings A14078-02
Start By :
a. Remove oil pump

3
IEED100P
3. Install springs (4), brackets (3) and rocker arms (2)

in their original positions.
IEED101P
1. Remove two bolts (1). Remove connecting rod cap

1 (2).
IEED099P NOTE : Put identification on the bearings for correct

installation.
4. Install washer and circlip (1) on both end of the
2. Remove the lower bearing half from the cap.
rocker shaft.
3. Push the connecting rod away from the crankshaft
End By :
and remove the upper bearing half.
a. Install rocker shaft and push rods.
4. Do Steps 1 through 4 for the other connecting rod
bearings.

Install Connecting Rod Bearings 9. Put the connecting rod cap in position and install
the bolts. Tighten the nuts to a torque of 180 N�m
A14078-03 (133 lb�ft).
NOTE : When installing undersize bearings, have the

crankshaft journals and crankpins ground to size
indicated in the below table :
Outside diameter of Outside diameter of

Bearing Size crank journals after crankpins after
grinding (mm) grinding (mm)
1 Standard 83.966�83.988 70.971�70.990

Undersize 0.25 83.716�83.738 70.721�70.740
Undersize 0.50 83.466�83.488 70.471�70.490
IEED101P
Undersize 0.75 83.216�83.238 70.221�70.240
Undersize 1.00 82.966�82.988 69.971�69.990
1. Make sure all parts are clean and free of all dirt
and foreign material.
10. Tighten main bearing cap bolts to a torque of 300
2. Put clean engine oil on the bearings and the N�m (220 lb�ft).
crankshaft journals.
11. Do steps 6 through 9 for the other connecting rod
NOTE : If the same bearings are used, install as per caps.
identification.
End By :
3. Put the upper bearing halves in position on the
a. Install oil pump.
connecting rods. Make an alignment of the tabs on
the bearings and the grooves (slots) in the
connecting rods.
4. Put the connecting rods in position on the Cylinder Head

crankshaft.
5. Install the lower bearing halves on the caps. Make Remove Cylinder Head A17429-02
an alignment of the tabs on the bearings and the
grooves (slots) in the caps.
Tools Needed A
NOTE : Make an alignment of the number on the cap Link Bracket 1
with the correct number on the connecting rod.
6. Put clean engine oil on the connecting rod bolt Start By :

threads. Install all bolt one of the connecting rod a. Remove air cleaner
caps.
b. Remove intake manifold
7. Use Plastigage to check the bearing clearance of
the connecting rods. Install connecting rod cap (1) c. Remove exhaust manifold
and tighten the bolts to a torque of 180 N�m (133
lb�ft). d. Remove cylinder head cover
8. Remove the connecting rod cap and measure the e. Remove rocker shaft and push rods
Plastigage. The bearing clearance for new rod
bearings must be 0.035 to 0.075 mm (.0010 to
.0029 in.).

1 Install Cylinder Head A17429-03
Tools Needed A
Link Bracket 1
NOTE : Clean the bolt holes on the cylinder block

with compressed air and throughly clean the upper
face of the cylinder block.
2
IEED102P
1. Remove bolts (1) that hold the cylinder head on

the block.
A 2
3
IEED104P
1. Install new cylinder head gasket (3) on the cylinder

block by aligning the holes with the dowels.
IEED103P
Typical Example 2
A
2. Install tool (A) in the cylinder head, and then fasten

a hoist. Remove cylinder head assemblies (2).
IEED103P
Typical Example
2. Install tool (A) on the cylinder head. Fasten a hoist

3 and put cylinder head (2) in position on the cylinder
IEED104P block.
3. Remove cylinder head gasket (3) and discard it.

1 Disassemble Cylinder Head
A17429-07
Tools Needed A B C
Valve Spring Compressor 1
Valve Spring Tester 1
Valve Guide Installer 1
Start By :
2
IEED102P
a. Remove cylinder head
3. Remove tool (A) and the hoist. Put engine oil on

the bolt threads and then install bolts (1) that hold 1 2
the cylinder head in place.
4. Tighten bolts (1) as follows :
a. Tighten all bolts in number sequence to a torque of

100 N�m (74 lb�ft).
b. Tighten all bolts in number sequence to a torque of

180 N�m (133 lb�ft). 3
c. Again tighten all bolts in number sequence to a IEED105P

torque of 220 N�� m (163 lb� � ft).
NOTE : After engine has run at normal temperature 1. Apply cylinder number mark to the head of each
of operation for a very short time, tighten all bolts valve.
again to the final torque. Rocker shaft assembly has
to be removed and valves have to be adjusted again. 2 . Install tool (A) on the cylinder head.
End By : 3. Compress the valve springs and remove valve

cotters (1), spring retainer (2) and springs (3).
a. Install rocker shaft and push rods.
b. Install cylinder head cover. 4
c. Install exhaust manifold.
d. Install intake manifold.
e. Install air cleaner.
IEED106P
4. Remove valve (4), stem seal and spring seat.

5
IEED003S IEED107P
4. Remove valve guide (5) using tool (C). 8. Check the spring force with tool (B) and replace
springs (3) if measured valve is beyond the below
5. Do steps 1 through 4 again for the remainer of the limit.
valves.
6. Carefully remove carbon from lower face of Spring Set Limit for
Description Nominal(kg)
cylinder head to prevent scratching of valve seat Length(mm) Use(kg)
faces. Intake Valve 41 65.5�73.5 65.5
Exhaust Outer 41 62.7�63.9 62.7
Valve Inner 38 27.2�30.0 27.2
Assemble Cylinder Head

A17429-08
Tools Needed A B C D
Valve Compressor 1
Valve Keeper Inserter 1
IEED004S
Valve Guide Installer 1
Stem Seal Installer 1
7. Replace valve (4) with valve guide if reduction in
diameter of the valve stem due to wear, is beyond
the below specified limit.
Description Nominal Limit for use 5

Intake Valve 8.95�8.97 8.93
Exhaust Valve 8.935�8.955 8.91
IEED003S
1. Install valve guide (5) with tool (C) in the cylinder

head.

4 WARNING
Valve cotters (1) can be thrown from valve (4)

when tool (A) is released if they are not in their
correct position on the valve stem.
7. Remove tool (A) and hit the top of the valve with a
plastic hammer to be sure the locks are in their
correct position on the valve.
IEED106P
8. Do steps 1 through 7 again for the remainder of
the valves.
2. Press in new valve stem seal in valve guide using
tool (D) if they were removed. End By :
a. Install cylinder head.
3. Put clean engine oil on the valve stems.
4. Install spring seat and valve (4) into the cylinder

head.
Pistons
Remove Pistons A14615-02

4
Start By :
a. Remove cylinder head
b. Remove oil pan plate
1 c. remove oil pump
IEED005S 2 3 2
1 2
3
IEED101P
IEED105P
1. Remove the ring of carbon from the top inner
surface of the cylinder liner.
5. Install springs (3) and spring retainer (2).
2. Turn the crankshaft until the connecting rod
bearing cap to be removed is at bottom center.
NOTICE Remove connecting rod bearing cap (1) from the
The close coil of spring (3) must be mext to the head. connecting rod.
6. Use tool (A) and put springs (3) under

compression. Use tool (B) and install valve cotters
(1) that hold the springs (3) in place.

4. Use tool (A) and put piston (3) and the connecting
3
rod in the same cylinder from which it was
removed. Make sure the identification “FRONT” on
the piston is toward the front of the engine.
IEED108P
1
3. Push the piston and connecting rod away from the
crankshaft until the piston rings are above the
cylinder liner. Remove piston (3) and the
connecting rod from the engine. IEED101P
4. Do Steps 2 and 3 for the remainder of the pistons.

NOTICE
When connecting rod caps are installed, make sure the
Install Pistons A14615-03 number on the side of the cap is next to and respective
with the number on the side of the connecting rod. The
Tools Needed A identification numbers must be opposite to the camshaft
Ring Compressor 1 when the piston and connecting rod are installed.
3 5. Put connecting rod bearing cap (1) in position and

install the nuts that hold it in place. Tighten the
nuts to a torque of 180 N�m (133 lb�ft).
6. Follow the same above procedure for installation of

A the remainder of the pistons.
End By :
a. Install oil pan plate.
IEED109P b. Install cylinder head.
c. Install oil pump.

1. Turn the crankshaft until the bearing journal for the
piston to be installed is at bottom center.
2. Put clean engine oil on the crankshaft journal and
on the inside of the cylinder liner. Put clean engine
oil on the piston rings and connecting rod bearings.
3. Move the rings on the piston until the ring openings
are approximately 90�apart.
NOTICE
Never install the ring compressor on the piston
unless the cylinder liner is used as a guide. Damage
to the piston rings can be the result.

Disassemble Pistons A14615-07 6 5
Tools Needed A B C
Pliers 1
Pliers 1
Drive Group 1
Start By :
a. Remove piston
IEED112P
1 2
4. Remove bushing (6) with tool group (C) from
connecting rod (5).
5. See Specifications for use of the parts again.
Assemble Pistons A14615-08

Tools Needed A B C D
IEED110P Driver Group 1
Piston Ring Groore Cleaner 1
NOTE : Put identification on all parts for correct Pliers 1
assembly.
Pliers 1
1. Remove rings (1) from piston (2) with tool (A).
6 5
4
5
IEED112P
2
IEED111P
1. Install the bushing in connecting rod (5) with tool
2. Remove retaining ring (3) from both side of the group (A) and a press. Make the new bushing to
piston with tool (B). the correct size with one.
See SPECIFICATIONS.
3. Remove pin (4) and connecting rod (5) from piston
(2).

1 2
IEED113P IEED110P
Typical Example
4. Install a retaining ring (3) on both side of the piston
2. When the oil pistons are used, clean the piston (2) with tool (C).
grooves with tool (B) before the rings are installed.
5. Install rings (1) on the piston with tool (D).
NOTE : The concave area (the part that makes the
curve to the inside) in the piston is toward one side of NOTE : See Specifications for piston ring location.
the piston. Install the piston on the connecting rod
End By :
with the concave area toward the side which has the
connecting rod and cap identification on it. a. Install pistons.
4
5
2
IEED111P
3. Slide connecting rod (5) inside the piston. Install

pin (4) in the piston and the connecting rod.

Cylinder Liners Timing Gear Case Cover
Remove And Install Cylinder Remove Timing Gear Case Cover

Liners A11552-01 A17198-02
Start By :
Start By :
a. Remove pistons
a. Remove oil pan
b. Remove crankshaft
b. Remove crankshaft pulley
2
1
IEED006S
IEED114P
1. Pull out cyliner liner (1) using the cylinder liner
extractor or by hand carefully so as not to damage 1. Remove bolts (1) and washers that hold timing
the cylinder bore. gear case cover (2) to the timing gear case.
Remove timing gear case cover (2) from the timing
2. Do step 1 for the other cylinder liners.
gear case.
3. Number cylinder liners (1) according to installed
position.
4. Install the cylinder liners (1) in reverse order of

removal.
End By :
a. Install pistons.
b. Install crankshaft.
IEED115P
2. Remove lip type seal (3) from timing gear case

cover (2).

Install Timing Gear Case Cover Timing Gears
A17198-03
Remove Timing Gears A16387-02
Tools Needed A
Drive Group 1
Tools Needed A
Puller Group 1
Start By :
a. Remove timing gear case cover
NOTE : Make an alignment of the timing marks on

the fuel injection pump gear and idle gear, crankshaft
gear and idle gear and camshaft gear and idle gear
or put a mark of identification on the gears for correct
3
installation.
IEED115P
1
1. Install lip type seal (3) with tool group (A) with the
lip of the seal toward the inside of the timing gear 2
case cover.
2 IEED116P
1
1. Remove bolts (1) and thrust washer (2). Remove
idler gear (3). Remove the bushings from the
inside gear if damaged.
IEED114P
4
2. Make sure the gasket is in position between the
timing gear case and cover.
3. Put the timing gear case cover (2) in position on

the timing gear case and install bolts (1) that hold it
to the case.
End By :
a. Install crankshaft pulley.

IEED117P
b. Install oil pan.
2. Remove nut (4) from injection pump coupling.

Install Timing Gears A16387-03
5
Tools Needed A
Dial Indicator 1
9
6
IEED118P
10
3. Remove nut (5) and injection pump coupling and
gear (6) from injection pump.
IEED120P
7 1. Put camshaft gear (10) in position on the camshaft

and install washers and bolts (9). Tighten bolts (9)
to a torque of 22 N�m (16 lb�ft).
8
7
IEED119P
4. Remove six bolts (7) and washers that hold

injection pump gear (8) in place and remove
injection pump gear (8). 8
IEED121P
9 2. Put injection pump gear (8) in position on coupling

and install washers and bolts (7).
10 3. Spread the end of bolts (7).
IEED120P
5. Remove four bolts (9), washers that hold camshaft

gear in place.
6. Remove camshaft gear (10) from camshaft.

8. Install thrust washer (2) and bolts (1) that hold the
5 idler gear. Tighten the bolts to a torque of 40 N�m
(30 lb�ft).
9. When installing the timing gears in position, check

the amount of backlash between gears using tool
(A). If the amount of backlash is beyond the
specified value(below table) correct it.
Backlash
6 Camshaft gear and idler gear 0.16�0.28
IEED118P
Crankshaft gear and idler gear 0.16�0.28
Injection pump drive gear and idler gear 0.16�0.28
4. Put fuel injection pump drive coupling and gear (6)
in position. Make an alignment of the key and the
groove (slot) in the coupling.
End By :
5. Install nut (5) that hold the injection pump drive
a. Install timing gear case cover.
coupling and gear (6) in place. Tighten nut (5) to a
torque of 130 N�m (96 lb�ft).
Timing Gear Case

4
Remove Timing Gear Case

A17198-02
Start By :
a. Remove timing gears
IEED117P b. Remove fuel injection pump
c. Remove oil pan

6. Install nut (4) into the injection pump coupling.
1
1
IEED122P
IEED116P
1. Remove bolts (1) and then remove timing gear

7. Put idler gear (3) in position on the idler gear pin,
case (2) from the cylinder block.
so that the marks on the idler gear are aligned with
marks on the camshaft gear, crankshaft gear and 2. Remove gasket from the timing gear case.
the injection pump gear respectively.

Install Timing Gear Case Camshaft & Camshaft
A17198-03 Bearing
Remove Camshaft & Camshaft

1
Bearing A17174 & 17078 - 02
2 Start By :
a. Remove rocker shaft and push rods
b. Remove timing gear cover
IEED122P
1. Install a new gasket on the timing gear case.

1
2. Put timing gear case (2) in position on the cylinder
block and install bolts (1) that hold it.
2
End By :
a. Install oil pan.
b. Install fuel injection pump.

IEED123P
c. Install timing gears.
1. Remove four bolts (1), washers that hold camshaft

gear (2) in place.
2. Remove camshaft gear (2) from the camshaft.
IEED124P
3. Remove bolts (3), washers and flange (4) from the

camshaft.

Install Camshaft And Camshaft
Bearing A17174 & A17078-03
5
6
IEED125P
4. Remove camshaft assembly (5) by carefully sliding

it out from the block. Do not force shaft as damage
IEED126P
can occur to the camshaft bearings.
5. Check the conditions of thrust washer (6) and NOTE : Make an alignment of the oil holes in the
replace thrust washer (6) if needed. bearing with the oil holes in the engine block.
1. Install a new bushes (7) in place in block if

7 removed.
IEED126P
6. Remove camshaft bushes (7) from the block if

IEED165P
necessary.
2. Install thrust washer (6). Make an alignment of the

hole in the washer and the dowel in the camshaft.

Crankshaft Pulley
5
Remove Crankshaft Pulley
A12660-02
Start By :
a. Remove fan belts

6
IEED125P
1
3. Clean engine oil to the cams and journals of the
camshaft and the camshaft bushes, then install
camshaft (5) in position in the cylinder block. 3
NOTE : When installing camshaft, exercise care not

to scratch camshaft bearings. 2
IEED127P
4
1. Remove eight bolts (1) and thrust washer (2) that

hold crankshaft in place. Remove crankshaft pulley
(3).
IEED124P
5
4
4. Put flange (4) in place and install washers and
bolts (3) that hold the flange.
1
IEED128P
2
2. Remove eight bolts (4) and washers and separate
the crankshaft pulley and vibration damper (5).
IEED123P
5. Put camshaft gear (2) in position on the camshaft

and install washers and bolt (1) that hold camshaft
gear (2) in the camshaft.
End By :
a. Install timing gears.
b. Install rocker shaft and push rods.

Install Crankshaft Pulley Flywheel
A12660-03
Remove Flywheel
5 Start By :
4
a. Separation of engine and transmission
1
2
IEED128P
1. Put vibration damper (5) in position on the

crankshaft pulley. Install washers and bolts (4) that
hold them.
IEED129P
1
1. Remove bolts (1) that hold adapter (2) in place.

3 2. Remove adapter (2) from the flywheel housing.
2 3
IEED127P
2. Put crankshaft pulley (3) in position on the

crankshaft. Install thrust washer (2) and bolts (1)
that hold crankshaft pulley. Tighten bolts (1) to a
torque of 130 N�m (96 lb�ft).
IEED130P
3. Remove eight bolts (3) and washers that hold

adapter and ring gear assembly (4) on the
flywheel.
4. Remove adapter and ring gear assembly (4) from

the flywheel.

5
11
IEED131P IEED007S
5. Remove bolts (5) and washers that hold adapter 11. Remove flywheel ring gear (11) with a brass
(6) on the flywheel. punch. If necessary, put a little heat on the
flywheel ring gear.
6. Remove adapter (6) from the flywheel.
8
Install Flywheel A13366-03
7
Tools Needed A
6 Dial Indicator Group 1
IEED132P
7. Remove two bolts (7) and washers that hold

bushing on adapter (6).
11
8. Replace bushing (8) with new one if they was
worn or damaged. IEED007S
1. Heat ring gear (11) to a maximum temperature of

9
10 246℃(475℉). Install the ring gear so the chamfer
on the gear teeth is next to the starter pinion when
the flywheel is installed.
IEED133P
9. Remove two bolts opposite each other and install

two M14x1.5 guide bolts in the flywheel.
10. Remove the remainder of bolts (9) and then

remove flywheel (10).

9
10 A
IEED133P IEED135P
Typical Example
2. Install two M14x1.5 guide bolts in opposite holes of
the crankshaft flange. 6. Check the pilot bore runout of the flywheel as follows:
3. Install enough bolts (9) with Loctite No.271 to hold a. Install tool group (A) as shown.
flywheel (10) in position. Remove guide bolts.
b. Set the dial indicator to read 0.0 mm (.000 in.).
4. Install remainder of bolts (9). Tighten bolts (9) to a c. Turn the flywheel and read the indicator at 90�
torque of 180 N�m (133 lb�ft). intervals.
d. The difference between the lower and higher

measurements taken at all four points must not be
more than 0.30 mm (.0.12 in.) which is the maximum
pilot bore runout (eccentricity) of the flywheel.
A
IEED134P
Typical Example
5. Check the flywheel face runout as follows:
a. Install tool group (A) as shown. Move the IEED136P

crankshaft the same way before the indicator is Typical Example
read so the crankshaft end clearance
(movement) is always removed. 7. Check the outside diameter runout of the flywheel
as follows:
b. Set the dial indicator to read 0.0 mm (.000 in.).
a. Install tool group (A) at top dead center of the
c. Turn the flywheel and read the indicator every 90�
flywheel as shown. Mount the dial indicator to
d. The difference between the lower and higher the flywheel housing or the engine block.
measurements taken at all four points must not b. Set the dial indicator to read 0.0 mm (.000 in.).
be more than 0.20mm (.008in.) which is the
maximum permissible face runout (axial .
c. Turn the flywheel and read the indicator every 90�
eccentricity) of the flywheel.
d. The difference between the lower and higher
measurements taken at all four points must not
be more than 0.30 mm (.012 in.) which is the
maximum permissible outside diameter runout
(eccentricity) of the flywheel.

7 8 3
4
6
IEED132P IEED130P
8. Install bushing (8) in position on adapter (6) and 11. Put the adapter and ring gear assembly (4) in
tighten bolts (7) to a torque of 12 ± 4 N�
�m (106 position and install bolts (3) and washers that
± 35 lb� � in). hold adapter and ring gear assembly (4) on the
flywheel. Tighten bolts (3) to a torque of
9. Put the anti-seize compound (FEL-PRO C5-A) 55 ± 10 N� � m (40 ± 7 lb�ft).
inside of bushing (8).
5 1
2
IEED129P
IEED131P
12. Put adapter (2) in position and install bolts (1) that
10. Put adapter (6) in position and install bolts (5) and hold adapter (2) on the flywheel housing. Tighten
washers that hold adapter (6) on the flywheel. bolts (1) to a torque of 55 ± 10 N�m (40 ± 7 lb�ft).
± 10 N�
Tighten bolts (5) to a torque of 55± �m (40
± 7 lb�ft). End By :
a. Connection engine and transmission.

Flywheel Housing Install Flywheel Housing
A11453-03
Remove Flywheel Housing
Tools Needed A B
A11453-02 Link Bracket 1
Seal Installer 1
Tools Needed A
Link Bracket 1
Start By :
1
a. Remove flywheel
b. Remove electric starting motor 3
IEED008S
1. Install lip type seal (3) in flywheel housing (1) using

tool (B).
1
IEED137P
1. Fasten tool (A) and a hoist to the flywheel housing.

Remove bolts (2) to remove housing (1)
NOTE : Flywheel housing is put in a location with

dowels.
IEED137P
1 2. Fasten tool (A) and a hoist to the flywheel housing.
3. Put flywheel housing (1) in position on the dowels.

3 Install bolts (2) that hold it in position. Tighten bolts
(2) to a torque of 80 N�m (60 lb�ft).
IEED008S
2. Remove lip type seal (3) from flywheel housing (1)

and discard it.

Crankshaft 5
Remove Crankshaft A12264-02

Tools Needed A
Spuller Assembly
Ratchet Box Wrench
Bearing Puller Attachment
Step Plate
IEED139P
Start By :
3. Fasten straps and a hoist to the crankshaft
a. Remove oil pump
4. Remove crankshaft (5).
b. Remove timing gear case
c. Remove flywheel housing
6
1 7
4 3
IEED140P
Typical Example
IEED138P
5. Remove upper main bearing halves (6).
NOTE : Put identification on the main bearings and 6. Remove thrust washers (7) from the center main.
the thrust washers for correct installation if used
again.
8
1. Remove bolts (1). Remove crankshaft main
bearing caps (2). Remove the lower main bearing
halves from the caps and the thrust washers from
the outer main cap.
2. Remove bolts (3). Remove connecting rod caps

(4).
IEED141P
7. Remove gear (8) from the crankshaft with tool (A).

Remove the dowel.

Install Crankshaft A12264-03 5
IEED139P
IEED141P 5. Fasten two straps and a hoist to crankshaft(5). Put

the crankshaft in position. Remove the hoist and
the straps.
1. Check all parts for damage. If damaged, use new
parts for replacement.
2. Make sure all parts are clean and free of dirt and
foreign material.
3. Install dowel and gear (8) on the crankshaft.
IEED143P
Typical Exqmple
6. Install lower main bearing halves (2) in the caps.

The tabs on the bearings must be in alignment with
the notches in the caps. Install the thrust washers
IEED142P
in the center main cap.
Typical Example
NOTE : The tabs of the lower main bearing halves
NOTE : Put clean engine oil on the crankshaft main must be on the same side as the tabs on the upper
jounals, the main bearings and thrust washers. The main bearing halves.
upper main bearing halves have a long oil groove
7. Install all bolt one of the main bearing caps as per
(slot). If the same bearings and thrust washers are
identification.
used again, install as per identification.
NOTE : Do not turn the crankshaft as it will damage
4. Put upper main bearing halves (4) in position. The
the plastigage.
tabs on the bearings must be in alignment with the
notches in the housing. Install the thrust washers 8. Put the plastigage in position on the lower main
in the center main housing. The steel side of the bearing half.
thrust washers must be next to or toward the
engine block and the cap.

9. Put the bearing cap in position and tighten the
1
bolts to a torque of 300 N�m (220 lb�ft).
2
10. Remove the main bearing cap and measure the
Plastigage. The bearing clearance for new
bearings must be 0.025 to 0.075 mm (.001 to
.003 in.).
11. Put clean engine oil on the bearing and the 4 3
crankshaft journal.
12. Install main bearing cap (2). Tighten the bolts to a

torque of 300 N�m (220 lb� �ft). IEED138P
13. Do Steps 8 through 12 for the other main

17. Remove the connecting rod cap and measure the
bearings.
Plastigage. The bearing clearance for new rod
bearing must be 0.025 to 0.075 mm (.001 to .003
in.).
18. Put the connecting rod cap in position and install

the nuts. Tighten the nuts to a torque of 180 N�m
7 (133 lb�ft).
19. Do steps 16 through 18 for the other connecting

rod caps.
End By :
a. Install flywheel housing.

IEED144P
b. Install timing gear case.
Typical Example
c. Install oil pump.
14. Measure the crankshaft end play. The end play
must be 0.15 to 0.325 mm (.006 to .013 in.).
15. Put clean engine oil on the connecting rod bolt

threads. Install all bolt one of the connecting rod
caps.
16. Use Plastigage to check the bearing clearance of

the connecting rods. Install connecting rod cap
(7) and tighten the to a torque of 180 N�m (133
lb�ft).
71 of 73
Air Compressor (if equipped) 8
Remove Air Compressor
2 7
IEED009S
6. Remove nut (7), washer and pulley (8) from air

compressor.
1
IEED145P
1. Loosen the tension adjusting bolts and nut (1) and Install Air Compressor
nut attached on the idle pulley.
2. Take off V-belts (2). 6
IEED147P
4
1. Put air compressor assembly (6) in position on the
IEED146P idle gear bracket.
3. Disconnect tube (3) from the air compressor. 2. Install bolts (5) and washers that hold it.
Tighten bolts (5) to a torque of 22 N�m (16 lb�ft).
4. Loosen clamp and disconnect hose (4).
6
3
5
4
IEED146P
IEED147P
3. Connect oil supply tube (3) and air supply hose (4)
5. Remove four bolts (5) and washers that hold the on the air compressor.Tighten the hose clamp.
air compressor assembly in place. Remove air
compressor assembly (6).

2 2
1
3
IEED145P IEED149P
4. Assemble V-bolts (2) and adjust the tension of V- 2. Remove four bolts (2) and washers that hold the
belt using tension adjusting bolt (1). Tighten cylinder head on the cylinder.
tension adjusting bolts (1).
NOTE : For the purpose of reassembly, tighten bolts
(2) to a torque of 25 � 31 N�m (19 � 23 lb�ft).
Disassemble Air Compressor 3. Remove cylinder head (3).
Tools Needed A
Bearing Puller 1 4
Start By :
a. Remove air compressor

5
IEED150P
4. Remove gasket (4) and discard it.
5. Remove seat plate assembly (5) from the cylinder.
1
7 6
IEED148P
1. Remove plug (1) and drain oil from the crankcase.
NOTE : For the purpose of reassembly, put Loctite

No.572 on plug (1).
IEED151P
6. Remove two bolts (6), washers, pressure catcher

(7) and disc if needed.

8 9
14
15
IEED152P IEED155P
NOTE : Put identification on all parts for correct

7. Remove suction disc (8). assembly.
8. Remove gasket (9) and discard it. 13. Remove three oil rings (14) and wiping ring (15)
using a piston ring expander.
11
16 17
10
IEED153P 18
9. Remove four nuts (10) and washers that hold IEED156P

cylinder (11) on the crankcase. 14. Remove piston pin (16) and snap rings from both
NOTE : For the purpose of reassembly, tighten nuts side of the piston using snap ring plier.
� 21 N�m (150�
(10) to a torque of 17� � 186 lb�ft).
15. Remove piston pin (16) and connecting rod (17)
10. Remove cylinder (11) from the crankcase. from piston (18).
11. Remove gasket and discard it.
19 20
13
12 17
IEED154P IEED157P
16. Inspect bushings (19) and (20) in connecting rod
(17). If the bushings has a large amount of wear,
12. Remove two bolts (12) and separate piston and
make a replacement of the bushing.
connecting rod assembly (13) from the
crankshaft.
NOTE : For the purpose of reassembly, tighten bolts
(12) to a torque of 27 � 32 N�m (20 � 24 lb�ft)

23 28
24
22
21 27
IEED158P IEED161P
17. Remove four bolts (21) and washers that hold 23. Remove woodroof key (27) from the crankshaft.
bearing cover (22) on the crankcase.
24. Remove bearing cover (28) using tool (A).
NOTE : For the purpose of reassembly, put Loctite
No.572 on bolt thread and tighten bolts (21) to a
torque of 17 � 21 N�m (150 � 186 lb�ft).
18. Remove four bolts (23), washers and end cover

28 29
(24) from the crankcase.
19. Remove gasket and discard it.
IEED162P
33
25. Remove oil seal (29) from bearing cover (28).
25
IEED159P
20. From rear of crankcase tap crankshaft from

crankcase (33).
21. Remove the crankshaft assembly and bearing

cover (25) as a unit.
30 31
IEED163P
26. Remove bearing (30) from crankshaft (31).
26
IEED160P
22. Remove O-ring (26) from the bearing cover.

32
33
IEED164P
27. Inspect bushing (32) in the crankcase (33). If the

bushing has a large amount wear, replace with
new one.
28. Assemble the air compressor assembly in

reverse order of disassembly.
End By :
a. Install air compressor.

DE TS Diesel Engine: Disassembly & Assembly

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DE TS Diesel Engine: Disassembly & Assembly

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SB2088E02

DE08TS Diesel Engine

D100, D120, D150

The meaning of this safety alert symbol is as follows :

Attention! Become Alert! Your Safety is Involved.

Air Cleaner Assembly ...........................................24 Intake Manifold.......................................................31

Remove Engine And

d. Remove air cleaner.

e. Remove universal joint.*

1. Drain the coolant from the radiator.

6. Disconnect two hoses (6) from the fuel tank.

2. Remove engine harness assembly (1) from the

3. Remove screws, washers and circuit breaker (2)

DE08TS Diesel Engine 5 of 76 Disassembly and Assembly

IEED006P 13. Disconnect three hoses (14) from the hydraulic

DE08TS Diesel Engine 6 of 76 Disassembly and Assembly

20 21. Remove engine and transmission (22) from the

22. Put the engine and transmission on an

18. Remove bolts (19), washers, nuts from the two

DE08TS Diesel Engine 7 of 76 Disassembly and Assembly

Install Engine And Transmission

6. Install bolts (21), washers and nuts that hold the

1. Put transmission (24) in position in engine (25).

2. Install bolts (23) and washers that hold

DE08TS Diesel Engine 8 of 76 Disassembly and Assembly

12. Connect three hydraulic hoses (14) to the

DE08TS Diesel Engine 9 of 76 Disassembly and Assembly

15. Connect battery cable(11) to the starting motor.

DE08TS Diesel Engine 10 of 76 Disassembly and Assembly

Remove Electric Starting Motor

Disconnect the battery before the starting motor

20. Put the coolant reservoir with bracket (5) in

22. Install the screws and washers that hold circuit

23. Clear engine harness assembly (1).

24. Fill the cooling system. See the Maintenance

e. Install overhead guard.

DE08TS Diesel Engine 11 of 76 Disassembly and Assembly

2. Disconnect ground cable (2) from alternator (6).

4. Remove bolts (5) from the alternator’s bracket to

DE08TS Diesel Engine 12 of 76 Disassembly and Assembly

1. Put alternator (6) in position on its bracket and 3

2. Install fan belt (3) on the alternator and tighten nuts

1. Remove two bolts (1) and washers.

3. Connect all wires (1) to their respective positions.

4. Connect ground cable (2) to alternator (6). 5

3. Remove bolts (5) and washers that hold the

4. Remove the idle pulley and V-belt tension

DE08TS Diesel Engine 13 of 76 Disassembly and Assembly

10. Disconnect five hoses (14) and tubes (15) from

DE08TS Diesel Engine 14 of 76 Disassembly and Assembly

1. Install the new gasket in position on the timing

12. Support injection pump (17). Remove two bolts

2. Make sure the timing marks or the marks that were

DE08TS Diesel Engine 15 of 76 Disassembly and Assembly

5. Install nut (11) that hold the injection pump drive 15

9. Connect three hoses (14) and tube (15) to the

10. Connect accel cable (12) and engine stop cable

7. Install cover (8), bolts (7) and washers.