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SEN01452-00

50 Disassembly and assembly

Removal and installation of fuel


1
injector assembly

4.

Remove muffler mounting bracket (4).

5.

Disconnect wiring (5) from air intake connector


(6).

6.

Remove tube (7) and air intake connector (6).


[*1]

7.

Remove 2 bolts (8) so that the head cover will


not interfere with them when the head cover is
removed.

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 connector and pry off the connector gradually.

1 795-799-1131

Gear

t 1

2 795-799-6700

Puller

t 1

N/R

Sketch

Part name

Qty

Part number

Necessity

Symbol

Special tools

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).

3.

Remove the muffler heat insulation cover and


lift off muffler (2).
a Remove tube (3) in advance.
4

Muffler: 33 kg

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50 Disassembly and assembly

9.

SEN01452-00

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 cylinder to the compression top dead center.
a If the No. 1 cylinder is not at the compression 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

SEN01452-00

50 Disassembly and assembly

19. Using puller A2, remove fuel injector assembly


(23).
a Take care that dirt will not enter the mounting 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)

5)
6)

Insert fuel injector (23) in the cylinder


head, directing its fuel inlet hole toward
the air intake manifold.
Tighten mounting bolts (24) of fuel injector
(23) by 3 4 turns.
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}

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50 Disassembly and assembly

SEN01452-00

Installed positions of wiring harnesses

Wiring harness color

Cylinder No.

White

1, 3, 5

Black

2, 4, 6

2.

7)

8)

Apply engine oil (EO15W-40) to the


mounting hole of inlet connector (21) on
the head side.
Apply engine oil (EO15W-40) to O-ring
(28) of inlet connector (21) and insert inlet
connector (21) perfectly, matching part (B)
to the groove on the head side.

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 crossheads, install each of them to the
same intake/exhaust valve in the
same direction as it has been
installed.
a Before tightening the mounting bolts,
check that the ball of adjustment
screw (18) is set in the push rod
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 injector.)
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

SEN01452-00

Carry out the following installation in the


reverse order to removal.

50 Disassembly and assembly

1.

Temporarily install high-pressure pipes (27)


(32) between common rail (10) and cylinder
head.
3 Sleeve nut:
0.2 0.8 Nm {0.02 0.08 kgm}

2.

Tighten high-pressure pipes (27) (32) in the


following order.
3 Sleeve nut:
35 3.5 Nm {3.6 0.4 kgm}
1) Tighten head side of high-pressure pipes
(27) and (32).
2) Tighten common rail side of high-pressure
pipes (32) and (27).
3) Tighten head side of high-pressure pipes
(28), (29), (30), and (31) in this order.
4) Tighten common rail side of high-pressure
pipes (28), (29), (30), and (31) in this
order.

3.

Install bellows (9) to each high-pressure pipe.


a Install each bellows with the slits out and
down.
a The bellows are installed so that fuel will not
spout over the hot parts of the engine and
catch fire when it leaks for some reason.

[*1]

Tube mounting band:


7 1 Nm {0.7 0.1 kgm}
Air intake connector mounting bolt:
24 4 Nm {2.4 0.4 kgm}

[*2]

Install each high-pressure pipe and wiring


harness at least 10 mm apart from each
other.

[*3]

Blow-by duct mounting bolt:


7 2 Nm {0.7 0.2 kgm}

[*4]

Head cover mounting nut:


24 4 Nm {2.4 0.4 kgm}

[*5] [*6]
High-pressure pipe
q
k Do not bend the high-pressure pipe to correct 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
stepped-type wear caused by fatigue which
your nail can feel. If there is any of those
defects, it can cause fuel leakage. In this case,
replace the high-pressure pipe.

WA380-6

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