SEN01452-00 50 Disassembly and assembly

Removal and installation of fuel 4. Remove muffler mounting bracket (4). injector assembly 1 5. Disconnect wiring (5) from air intake connector Special tools (6).

6. Remove tube (7) and air intake connector (6). Part number Part name [*1] N/R Q’ty Sketch Symbol Necessity 7. Remove 2 bolts (8) so that the head cover will 1 795-799-1131 Gear t 1 A not interfere with them when the head cover is t 2 795-799-6700 Puller 1 removed. Removal k Disconnect the cable from the negative (–) terminal of the battery.

1. Remove the engine hood assembly. For details, see “Removal and installation of engine hood assembly”.

2. Remove right and left covers (1).

8. Disconnect the connector of wiring harness (9) from cylinder head (10) and common rail (11) and move it to the left. [*2] a While pressing the lock of the connector with a flat-head screwdriver, insert another screwdriver in the clearance of the con- nector and pry off the connector gradually.

3. Remove the muffler heat insulation cover and lift off muffler (2). a Remove tube (3) in advance.

4 Muffler: 33 kg

4 WA380-6 50 Disassembly and assembly SEN01452-00

9. Using hexagonal wrench (3 mm), remove blow-by duct (12) from head cover (13). [*3]

10. Remove head cover (13). [*4] a Clean around the head cover in advance so that sticking mud etc. will not enter the engine.

14. Remove the mounting bolts and rocker arms (16). a Loosen locknut (17) and then loosen adjustment screw (18) by 2 – 3 turns so that an excessive force will not be applied to the push rod when the rocker arm is installed. 11. Remove bellows (14) of the high-pressure pipes. [*5]

12. Disconnect 6 high-pressure pipes (15) from the cylinder head. [*6] a Remove the bellows on the common rail side, too, and loosen the sleeve nut.

15. Remove crossheads (19). a Record the position and direction (shapes of holes (a) and (b)) of each crosshead. (Reinstall each crosshead in the same direction.)

13. While watching the movement of the damper, rotate the engine and set the stamp (TDC) of the damper to the top and set the No. 1 cylin- der to the compression top dead center. a If the No. 1 cylinder is not at the compres- sion top dead center, rotate the engine one more turn. a See Testing and adjusting, “Adjusting valve clearance”. a Use gear A1 to rotate the engine.

WA380-6 5 SEN01452-00 50 Disassembly and assembly

19. Using puller A2, remove fuel injector assembly (23). a Take care that dirt will not enter the mount- ing section of the fuel injector assembly.

16. Remove retainer (20) and inlet connector (21). a Clean the inlet connector carefully so that mud, etc. sticking around it will not enter its hole. Installation 1. Fuel injector assembly a Check that the fuel injector sleeve is free from flaw and dirt. 1) Fit O-ring (25) and gasket (26) to fuel injector (23). 2) Apply engine oil (EO15W-40) to the O-ring of fuel injector (23) and the mounting hole on the head side. 3) Matching convex and concave parts (A), install holder (27) to fuel injector (23).

17. Remove nuts (22) of the wiring harness from fuel injector (23).

18. Remove mounting bolts (24) of fuel injector (23).

4) Insert fuel injector (23) in the cylinder head, directing its fuel inlet hole toward the air intake manifold. 5) Tighten mounting bolts (24) of fuel injector (23) by 3 – 4 turns. 6) Install the wiring harnesses to fuel injector (23) and tighten nuts (22). 3 Wiring harness mounting nut: 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}

6 WA380-6 50 Disassembly and assembly SEN01452-00

a Installed positions of wiring harnesses

Wiring harness color Cylinder No. White 1, 3, 5 Black 2, 4, 6

2. Crosshead and rocker arm 1) Install the crosshead and rocker arm. a The shapes of holes (a) and (b) of each crosshead are different. Accordingly, when reusing the cross- heads, install each of them to the 7) Apply engine oil (EO15W-40) to the same intake/exhaust valve in the mounting hole of inlet connector (21) on same direction as it has been the head side. installed. 8) Apply engine oil (EO15W-40) to O-ring a Before tightening the mounting bolts, (28) of inlet connector (21) and insert inlet check that the ball of adjustment connector (21) perfectly, matching part (B) screw (18) is set in the push rod to the groove on the head side. socket securely. 3 Rocker arm mounting bolt: 36 ± 5 Nm {3.7 ± 0.5 kgm} 2) Adjust the valve clearance. For details, see Testing and adjusting, “Adjusting valve clearance”. 3 Locknut (17): 24 ± 4 Nm {2.4 ± 0.4 kgm}

9) Secure inlet connector (21) by tightening retainer (20) with the fingers. (Push the inlet connector into the hole of the injec- tor.) 10) Tighten mounting bolts (24) of fuel injector (23) alternately. 3 Fuel injector mounting bolt 1st time: 3.5 ± 0.35 Nm {0.35 ± 0.035 kgm} 2nd time: 75 ± 5° (Tighten with angle tightening tool) 11) Tighten retainer (20). 3 Retainer: 50 ± 5 Nm {5.1 ± 0.5 kgm}

WA380-6 7 SEN01452-00 50 Disassembly and assembly

q Carry out the following installation in the 1. Temporarily install high-pressure pipes (27) – reverse order to removal. (32) between common rail (10) and cylinder head. [*1] 3 Sleeve nut: 3 Tube mounting band: 0.2 – 0.8 Nm {0.02 – 0.08 kgm} 7 ± 1 Nm {0.7 ± 0.1 kgm} 3 Air intake connector mounting bolt: 2. Tighten high-pressure pipes (27) – (32) in the 24 ± 4 Nm {2.4 ± 0.4 kgm} following order. 3 Sleeve nut: [*2] 35 ± 3.5 Nm {3.6 ± 0.4 kgm} k Install each high-pressure pipe and wiring 1) Tighten head side of high-pressure pipes harness at least 10 mm apart from each (27) and (32). other. 2) Tighten common rail side of high-pressure pipes (32) and (27). [*3] 3) Tighten head side of high-pressure pipes 3 Blow-by duct mounting bolt: (28), (29), (30), and (31) in this order. 7 ± 2 Nm {0.7 ± 0.2 kgm} 4) Tighten common rail side of high-pressure pipes (28), (29), (30), and (31) in this [*4] order. 3 Head cover mounting nut: 24 ± 4 Nm {2.4 ± 0.4 kgm}

[*5] [*6] q High-pressure pipe k Do not bend the high-pressure pipe to cor- rect before installing. k Be sure to use the genuine high-pressure pipe clamps and observe the tightening torque. a When installing each high-pressure pipe, check the taper seal of its joint (Part (a): Part of 2 mm from the end) for visible lengthwise slit (b) and spot (c) and check part (d) (End of taper seal: Part at 2 mm from the end) for 3. Install bellows (9) to each high-pressure pipe. stepped-type wear caused by fatigue which a Install each bellows with the slits out and your nail can feel. If there is any of those down. defects, it can cause fuel leakage. In this case, a The bellows are installed so that fuel will not replace the high-pressure pipe. spout over the hot parts of the engine and catch fire when it leaks for some reason.

8 WA380-6