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//-->ENGINE MECHANICALSECTIONEMRDCONTENTSPRECAUTIONS...............................................................2Parts Requiring Angular Tightening.............................2Liquid Gasket Application Procedure ..........................2PREPARATION................................................................3TBNOISE, VIBRATION AND HARSHNESS (NVH)TROUBLESHOOTING...................................................10NVH Troubleshooting Chart - Engine Noise .............11OUTER COMPONENT PARTS (TB42S)......................12OUTER COMPONENT PARTS (TB45E)......................13COMPRESSION PRESSURE (TB42S).........................16Measurement of Compression Pressure...................16COMPRESSION PRESSURE (TB45E).........................17Measurement of Compression Pressure...................17OIL PAN (TB42S)..........................................................18Removal.....................................................................18Installation..................................................................19OIL PAN (TB45E)..........................................................21Removal.....................................................................21Installation..................................................................23TIMING CHAIN (TB42S)................................................25Removal.....................................................................26Inspection...................................................................28Installation..................................................................28TIMING CHAIN (TB45E)................................................31Removal.....................................................................32Inspection...................................................................34Installation..................................................................34OIL SEAL REPLACEMENT..........................................36CYLINDER HEAD..........................................................38Removal.....................................................................39Disassembly...............................................................40Inspection...................................................................41Assembly ...................................................................46Installation..................................................................46ENGINE REMOVAL.......................................................49CYLINDER BLOCK (TB42S)........................................51CYLINDER BLOCK (TB45E)........................................52CYLINDER BLOCK.......................................................53Disassembly...............................................................53Inspection...................................................................54Assembly ...................................................................66NOISE, VIBRATION AND HARSHNESS (NVH)TROUBLESHOOTING...................................................69NVH Troubleshooting Chart - Engine Noise .............70OUTER COMPONENT PARTS.....................................71COMPRESSION PRESSURE........................................73Measurement of Compression Pressure...................73OIL PAN.........................................................................76Removal.....................................................................76Installation..................................................................77TIMING BELT.................................................................78Removal.....................................................................78Inspection...................................................................80Installation..................................................................81OIL SEAL REPLACEMENT..........................................83TURBOCHARGER.........................................................86Removal and Installation ...........................................86Inspection...................................................................87CHARGE AIR COOLERS..............................................90CYLINDER HEAD..........................................................91Removal.....................................................................92Disassembly...............................................................93Inspection...................................................................94Assembly .................................................................100Installation................................................................100VALVE CLEARANCE..................................................103Checking ..................................................................103Adjusting ..................................................................104ENGINE REMOVAL.....................................................106Removal...................................................................107Installation................................................................107CYLINDER BLOCK.....................................................108Disassembly.............................................................109Inspection.................................................................109Assembly .................................................................116CONTENTSTDNOISE, VIBRATION AND HARSHNESS (NVH)TROUBLESHOOTING.................................................119NVH Troubleshooting Chart - Engine Noise ...........120OUTER COMPONENT PARTS...................................121COMPRESSION PRESSURE......................................122Measurement of Compression Pressure.................122OIL PAN.......................................................................123Removal...................................................................123Installation................................................................123CYLINDER HEAD........................................................124Removal...................................................................125Disassembly.............................................................126Inspection.................................................................127Assembly .................................................................133Installation................................................................134OIL SEAL REPLACEMENT........................................137ENGINE REMOVAL.....................................................139Removal...................................................................140Installation................................................................140(Cont’d)GIMAENGINE OVERHAUL..................................................141Disassembly.............................................................142Inspection and Replacement ...................................144Assembly .................................................................156TBSERVICE DATA AND SPECIFICATIONS (SDS)........161General Specifications.............................................161Inspection and Adjustment ......................................161RDSERVICE DATA AND SPECIFICATIONS (SDS)........168General Specifications.............................................168Inspection and Adjustment ......................................168TDSERVICE DATA AND SPECIFICATIONS (SDS)........176General Specifications.............................................176Inspection and Adjustment ......................................176LCECFECLMTATTFPDFARABRSTRSBTHAELSEIDXPRECAUTIONSParts Requiring Angular Tightening¼¼Some important engine parts are tightened using an angular-tightening method rather than a torque setting method.If these parts are tightened using a torque setting method, dis-persal of the tightening force (axial bolt force) will be two orthree times that of the dispersal produced by using the correctangular-tightening method.Although the torque setting values (described in this manual)are equivalent to those used when bolts and nuts are tightenedwith an angular-tightening method, they should be used forreference only.To assure the satisfactory maintenance of the engine, bolts andnuts must be tightened using an angular-tightening method.Before tightening the bolts and nuts, ensure that the thread andseating surfaces are clean and then coated with engine oil.The bolts and nuts which require the angular-tightening methodare cylinder head bolts.¼¼¼¼Liquid Gasket Application Procedurea. Before applying liquid gasket, use a scraper to remove alltraces of old liquid gasket from mating surface.b. Apply a continuous bead of liquid gasket to mating sur-faces. (Use Genuine Liquid Gasket or equivalent.)¼Be sure liquid gasket is specified width (for oil pan) 3.5to 4.5 mm (0.138 to 0.177 in) for gasoline engine.¼Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in)wide in areas except oil pan for TB and RD seriesengines and 2.5 to 3.5 mm (0.098 to 0.138 in) for TDseries engine.c. Apply liquid gasket to inner surface around hole perimeterarea.(Assembly should be done within 5 minutes after coating.)d. Wait at least 30 minutes before refilling engine oil andengine coolant.SEM371CEM-2PREPARATIONSPECIAL SERVICE TOOLS* Special tool or commercial equivalentTool numberTool nameST0501S000*Engine stand assemblykST050110001Engine standkST050120002BaseEngine applicationDescriptionTBDisassembling andassemblingRDTDGIMALCXXXECNT042FECLXXXKV10106500*Engine stand shaftMTNT028KV11104800*Engine sub-attachmentX—XATTFPDFA—X—NT577KV1011070Engine sub-attachmentRABRNT582KV10111200*AdapterDisassembling andassembling valve com-ponentsX—XSTRSNT687KV101092S0Valve spring compressorkKV101092101CompressorkKV101092202AdapterDisassembling andassembling valve com-ponentsBTHAXXXELSENT718IDXEM-3PREPARATIONTool numberTool nameKV10107902Valve oil seal pullerkKV101161001Valve oil seal pulleradapterEngine applicationDescriptionTBRDTD—XXNT605KV101151S0Lifter stopper setkKV101151101Camshaft plierskKV101151202Lifter stopperNT041Changing shims—X—EM03470000*Piston ring compressorInstalling piston assem-bly into cylinder boreXXXNT044ST16610001*Pilot bushing pullerRemoving crankshaftpilot bushingXXXNT045KV10109300Puller holder—a = 68 mm (2.68 in)b = 8 mm (0.31 in) dia.XXNT628kED196010001Compression gaugekED196006002Compression gaugeadapter (for glow plughole)kED196007003Compression gaugeadapter (for injectorhole)Checking compressionpressure—XXNT742KV11100300Nozzle holder socket—X—NT563EM-4
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