Page 137 of 2103
ENGINE OVERHAUL R o c k e r
OIL
INSTALLATION
SEAL PACKING
TSB Revision
Page 138 of 2103

11 ENGINE OVERHAUL Rocker
.
INSPECTION
CAMSHAFT
(1) Measure the cam height.
Roller
Standard value mm (in.)Limit mm (in.)
Intake 34.91 (1.37) 34.41 (1.36)
Exhaust
34.91 (1.37)34.41
ROCKER ARM
(1) Check the roller surface. If any dents, damage or seizure
is evident, replace the rocker arm.
(2) Check rotation of the roller. If it does not ro tate smoothly
or if looseness is evident, replace the rocker arm.
(3) Check the inside diameter. If damage or seizure is evident,
replace the rocker arm.
LASH ADJUSTER LEAK DOWN TEST
Caution
1. The lash adjuster is a precision part. Keep it f ree
from dust and other foreign matter.
2. Do not disassemble lash adjuster.
3. When
lash adjuster, use diesel fuel
(1) Immerse the lash adjuster in clean diesel fuel.
(2)While lightly pushing down inner steel ball using t he special
tool, move the plunger up and down four or five tim es
to bleed air. Use of the special tool helps facilitate the air bl eeding
of the rocker arm mounted type lash adjuster.
(3) Remove the special tool and press the plunger. If the
plunger is hard to be pushed in, the lash adjuster is normal.
If the plunger can be pushed in all the way readily, bleed
the lash adjuster again and test again. If the plun ger
is still loose, replace the lash adjuster.
Caution
Upon completion of air bleeding, hold lash adjuster
upright to prevent inside diesel fuel from
TSB Revision
Page 139 of 2103
ENGINE OVERHAUL Rocker Arms and
(4) After air bleeding, place lash adjuster on the
(Leak down tester).
(5) After plunger has down
measure time taken for it to go down 1mm. Replace
if measured time is out of specification.
Standard
seconds mm in.)
[Diesel fuel at
TSB Revision
Page 140 of 2103
11E N G I N E O V E R H A U L
CYLINDER HEAD AND VALVES11300690201
REMOVAL AND INSTALLATION
Removal steps1. Cylinder head bolt
head assembly
Retainer lock
5. Valve spring retainer
6. Valve spring
7. Intake valve 8. Retainer lock
9. Valve spring retainer
10. Valve spring
TSB Revision
11.Exhaust valve
12. Valve stem seal 13. Valve spring seat
14. Valve stem seal
15. Valve spring seat
16. Intake valve guide
17. Exhaust valve guide
18. Intake valve seat
19. Exhaust valve seat
20.Cylinderhead
Page 141 of 2103
ENGINE OVERHAUL Cylinder Head and Valves
colorSpring
retainer
Stem seal
, Spring seat
REMOVAL
PRECAUTION FOR PARTS
(1) Keep removed parts in order according to the cy linder,
number and intake/exhaust.
H E A D B O L T S R E M O V A L
(1) Using the special tool, the cylinder bolts.
Loosen evenly, little by little.
,
L O C K R E M O V A L
(1) Store removed valves, springs and other parts,‘ tagged
to indicate their cylinder No. and location for reassembly.
STEM SEAL REMOVAL
(1) Do not reuse valve stem seal.
INSTALLATION SERVICE POINTS
VALVE STEM SEAL INSTALLATION
(1) Install the valve spring seat.
(2) The special tool must be used to install the
stem
seal. Improper installation result in oil leaking ‘past
the valve guide.
Caution
Do not reuse the valve ,
VALVE SPRINGS INSTALLATION
(1) Direct the valve spring end with identification color end
toward the spring retainer.
TSB RevisionI
Page 142 of 2103

11 E N G I N E O V E R H A U L Cylinder Head
Identification mark
RETAINER LOCK . .
The ‘valve spring,if excessively, compressed, causes the
bottom end of retainer to be in contact with, and d amage,:
the stem seal.
H E A D G A S K E T
I d e n t i f i c a t i o n m a r k :
HEAD BOLT INSTALLATION
(1) When installing the cylinder bolts, that
shank length of each bolt meets the limit. If the
exceeded, replace the’ bolt.’
Limit: Max. 99.4 mm (3.91 in.)
(2) Apply engine oil to the threaded portions of bo lts
to the washers.
(3) According to the tightening sequence, tighten’ the bolts
to the specified torque 78 Nm
t o o l
(4) Loosen bolts completely.
(5) Retighten the loosened bolts to
Nm in
the specified tightening sequence.
(6) Make a paint mark across each-‘bolt cylinder
head.
(7) Give a turn to the bolts in the specified’ tightening
sequence.
(8) Give another turn to the bolts and sure that
the paint mark on the head of each, bolt ‘and that
the cylinder head are on the same straight line.
Caution
1.If the bolt is turned less than
may e x p e c t e d .
tightening the bolt, therefore, be
a sufficient turn to
2. If the bolt is t h e b o l t
completely and then retighten It
the
tightening procedure from step
,
T S B R e v i s i o n
Page 143 of 2103
ENGINE OVERHAUL Cylinder Head and
Valve seat
contact
Margin
I
I
Free
height
INSPECTION
CYLINDER HEAD (1) Check the cylinder head gasket surface for flat ness by
using a straightedge and feeler gauge.
Standard value: 0.05 mm
in.)
Limit: 0.2 mm
in.)
(2) If the service limit is exceeded, correct to me et specifica-
tion.
Grinding limit: mm in.)
Includes combined with cylinder grinding.
Cylinder head height (Specification when
1 3 1 . 9 - 1 3 2 . 1 m m in.)
VALVE
(1)Check the valve face for correct contact. I/incorre ct, reface
using valve Valve seat contact should be main-
tained uniform at the center
valve face.
(2) the margin exceeds the service limit, replace the valve.
(3) Measure the valve’s total length. If the measurement is
less than specified, replace the valve.
VALVE
(1) Measure the free height of spring and, if it is smaller
than the limit, replace.
Standard value: 47.0 mm
in.)
Limit: 46.0 mm (1.811 in.)
TSB Revision
Page 144 of 2103

ENGINE OVERHAUL Head and
(2) Measure the squareness of the spring and,
is exceeded, replace.
Standard value: or less
Limit: Max.
Stem O.D.
Valve stem end
Valve stem
projection
Spring seating
surface
GUIDE
(1)Measure the clearance between the valve guide and v alve
stem. If the limit is exceeded, replace the valve guide
or valve, or both.
Item
Intake
Exhaust Standard value mm (in.) Limit mm (in.)0.10
0.15
VALVE
(1) Assemble the valve, then measure the valve stem
projection between the end of the valve stem and th e
spring seating surface. If the measurement
the
specified limit, replace the valve seat.
VALVE SEAT RECONDITIONING PROCEDURE
(1) Before correcting the valve seat, check for cle arance
between the valve guide and valve and, if necessary ,
replace the valve guide.
(2) Using the seat grinder, correct to obtain the s pecified
seat width and angle.
(3) After correcting the valve seat, lap the valve and valve
seat using lapping compound. Then, check the valve
stem projection (refer to VALVE SEAT in INSPECTION) .
VALVE SEAT REPLACEMENT
(1) Cut the valve seat to be replaced inside to thin
the wall thickness. Then, remove the
seat..
I
mm in.)
mm in.)