JCB JS160W WHEELED EXCAVATOR Service Repair Manual SN:2584081fujdfjjskekmwem
This is the Highly Detailed factory service repair manual for theJCB JS160W WHEELED EXCAVATOR, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.JCB JS160W WHEELED EXCAVATOR Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
01 - Machine
03 - Attachments, Couplings and Load Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air-Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveJCB JS160W WHEELED EXCAVATOR Service Repair Workshop Manual.
Thanks for visiting!
JCB JS160W WHEELED EXCAVATOR Service Repair Manual SN:2584081fujdfjjskekmwem
This is the Highly Detailed factory service repair manual for theJCB JS160W WHEELED EXCAVATOR, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.JCB JS160W WHEELED EXCAVATOR Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
01 - Machine
03 - Attachments, Couplings and Load Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air-Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveJCB JS160W WHEELED EXCAVATOR Service Repair Workshop Manual.
Thanks for visiting!
1997 YAMAHA VENTURE VT480 SNOWMOBILE Service Repair Manualjkksemd yeuyhd
This is the Highly Detailed factory service repair manual for the1997 YAMAHA VENTURE VT480 SNOWMOBILE, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.1997 YAMAHA VENTURE VT480 SNOWMOBILE Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
General Information
Periodic Inspection and Adjustment
Chassis
Power Train
Engine Overhaul
Carburetion
Electrical
Appendices
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to have1997 YAMAHA VENTURE VT480 SNOWMOBILE Service Repair Workshop Manual.
Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/
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8
1994 Yamaha Viking VK 540 Series Snowmobile Service Repair Manualjkksemd yeuyhd
This is the Highly Detailed factory service repair manual for the1994 YAMAHA VIKING VK 540 SERIES SNOWMOBILE, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.1994 YAMAHA VIKING VK 540 SERIES SNOWMOBILE Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
General Information
Periodic Inspection and Adjustments
Engine Overhaul
Carburetion
Power Train
Chassis
Electrical
Appendices
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to have1994 YAMAHA VIKING VK 540 SERIES SNOWMOBILE Service Repair Workshop Manual.
Looking for some other Service Repair Manual,please check:
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Thanks for visiting!
8
1997 YAMAHA VENTURE VT480 SNOWMOBILE Service Repair Manualjkksemd yeuyhd
This is the Highly Detailed factory service repair manual for the1997 YAMAHA VENTURE VT480 SNOWMOBILE, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.1997 YAMAHA VENTURE VT480 SNOWMOBILE Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
General Information
Periodic Inspection and Adjustment
Chassis
Power Train
Engine Overhaul
Carburetion
Electrical
Appendices
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to have1997 YAMAHA VENTURE VT480 SNOWMOBILE Service Repair Workshop Manual.
Looking for some other Service Repair Manual,please check:
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Thanks for visiting!
8
1994 Yamaha Viking VK 540 Series Snowmobile Service Repair Manualjkksemd yeuyhd
This is the Highly Detailed factory service repair manual for the1994 YAMAHA VIKING VK 540 SERIES SNOWMOBILE, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.1994 YAMAHA VIKING VK 540 SERIES SNOWMOBILE Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
General Information
Periodic Inspection and Adjustments
Engine Overhaul
Carburetion
Power Train
Chassis
Electrical
Appendices
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to have1994 YAMAHA VIKING VK 540 SERIES SNOWMOBILE Service Repair Workshop Manual.
Looking for some other Service Repair Manual,please check:
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Thanks for visiting!
8
What Does the PARKTRONIC Inoperative, See Owner's Manual Message Mean for You...Autohaus Service and Sales
Learn what "PARKTRONIC Inoperative, See Owner's Manual" means for your Mercedes-Benz. This message indicates a malfunction in the parking assistance system, potentially due to sensor issues or electrical faults. Prompt attention is crucial to ensure safety and functionality. Follow steps outlined for diagnosis and repair in the owner's manual.
In this presentation, we have discussed a very important feature of BMW X5 cars… the Comfort Access. Things that can significantly limit its functionality. And things that you can try to restore the functionality of such a convenient feature of your vehicle.
"Trans Failsafe Prog" on your BMW X5 indicates potential transmission issues requiring immediate action. This safety feature activates in response to abnormalities like low fluid levels, leaks, faulty sensors, electrical or mechanical failures, and overheating.
Things to remember while upgrading the brakes of your carjennifermiller8137
Upgrading the brakes of your car? Keep these things in mind before doing so. Additionally, start using an OBD 2 GPS tracker so that you never miss a vehicle maintenance appointment. On top of this, a car GPS tracker will also let you master good driving habits that will let you increase the operational life of your car’s brakes.
Core technology of Hyundai Motor Group's EV platform 'E-GMP'Hyundai Motor Group
What’s the force behind Hyundai Motor Group's EV performance and quality?
Maximized driving performance and quick charging time through high-density battery pack and fast charging technology and applicable to various vehicle types!
Discover more about Hyundai Motor Group’s EV platform ‘E-GMP’!
Symptoms like intermittent starting and key recognition errors signal potential problems with your Mercedes’ EIS. Use diagnostic steps like error code checks and spare key tests. Professional diagnosis and solutions like EIS replacement ensure safe driving. Consult a qualified technician for accurate diagnosis and repair.
What Exactly Is The Common Rail Direct Injection System & How Does It WorkMotor Cars International
Learn about Common Rail Direct Injection (CRDi) - the revolutionary technology that has made diesel engines more efficient. Explore its workings, advantages like enhanced fuel efficiency and increased power output, along with drawbacks such as complexity and higher initial cost. Compare CRDi with traditional diesel engines and discover why it's the preferred choice for modern engines.
Why Is Your BMW X3 Hood Not Responding To Release CommandsDart Auto
Experiencing difficulty opening your BMW X3's hood? This guide explores potential issues like mechanical obstruction, hood release mechanism failure, electrical problems, and emergency release malfunctions. Troubleshooting tips include basic checks, clearing obstructions, applying pressure, and using the emergency release.
What Does the Active Steering Malfunction Warning Mean for Your BMWTanner Motors
Discover the reasons why your BMW’s Active Steering malfunction warning might come on. From electrical glitches to mechanical failures and software anomalies, addressing these promptly with professional inspection and maintenance ensures continued safety and performance on the road, maintaining the integrity of your driving experience.
𝘼𝙣𝙩𝙞𝙦𝙪𝙚 𝙋𝙡𝙖𝙨𝙩𝙞𝙘 𝙏𝙧𝙖𝙙𝙚𝙧𝙨 𝙞𝙨 𝙫𝙚𝙧𝙮 𝙛𝙖𝙢𝙤𝙪𝙨 𝙛𝙤𝙧 𝙢𝙖𝙣𝙪𝙛𝙖𝙘𝙩𝙪𝙧𝙞𝙣𝙜 𝙩𝙝𝙚𝙞𝙧 𝙥𝙧𝙤𝙙𝙪𝙘𝙩𝙨. 𝙒𝙚 𝙝𝙖𝙫𝙚 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙥𝙡𝙖𝙨𝙩𝙞𝙘 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙪𝙨𝙚𝙙 𝙞𝙣 𝙖𝙪𝙩𝙤𝙢𝙤𝙩𝙞𝙫𝙚 𝙖𝙣𝙙 𝙖𝙪𝙩𝙤 𝙥𝙖𝙧𝙩𝙨 𝙖𝙣𝙙 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙛𝙖𝙢𝙤𝙪𝙨 𝙘𝙤𝙢𝙥𝙖𝙣𝙞𝙚𝙨 𝙗𝙪𝙮 𝙩𝙝𝙚 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙛𝙧𝙤𝙢 𝙪𝙨.
Over the 10 years, we have gained a strong foothold in the market due to our range's high quality, competitive prices, and time-lined delivery schedules.
Comprehensive program for Agricultural Finance, the Automotive Sector, and Empowerment . We will define the full scope and provide a detailed two-week plan for identifying strategic partners in each area within Limpopo, including target areas.:
1. Agricultural : Supporting Primary and Secondary Agriculture
• Scope: Provide support solutions to enhance agricultural productivity and sustainability.
• Target Areas: Polokwane, Tzaneen, Thohoyandou, Makhado, and Giyani.
2. Automotive Sector: Partnerships with Mechanics and Panel Beater Shops
• Scope: Develop collaborations with automotive service providers to improve service quality and business operations.
• Target Areas: Polokwane, Lephalale, Mokopane, Phalaborwa, and Bela-Bela.
3. Empowerment : Focusing on Women Empowerment
• Scope: Provide business support support and training to women-owned businesses, promoting economic inclusion.
• Target Areas: Polokwane, Thohoyandou, Musina, Burgersfort, and Louis Trichardt.
We will also prioritize Industrial Economic Zone areas and their priorities.
Sign up on https://profilesmes.online/welcome/
To be eligible:
1. You must have a registered business and operate in Limpopo
2. Generate revenue
3. Sectors : Agriculture ( primary and secondary) and Automative
Women and Youth are encouraged to apply even if you don't fall in those sectors.
5 Warning Signs Your BMW's Intelligent Battery Sensor Needs AttentionBertini's German Motors
IBS monitors and manages your BMW’s battery performance. If it malfunctions, you will have to deal with an array of electrical issues in your vehicle. Recognize warning signs like dimming headlights, frequent battery replacements, and electrical malfunctions to address potential IBS issues promptly.
3. DISASSEMBLY AND ASSEMBLY GOVERNOR MOTOR ASSEMBLY
PW160-7K 30-9
12
REMOVAL
1. Open engine hood and disconnect governor
motor electrical connectors E10 and E11.
2. Disconnect rod (1) from governor motor (2) by
removing rod locking nut (3).
3. Remove governor motor assembly (2) by remov-
ing the three securing bolts (4).
INSTALLATION OF GOVERNOR MOTOR ASSEM-
BLY
q Carry out installation in the reverse order to
removal.
a When installing the governor motor,
rotate the shaft by hand to the correct
orientation -
Do not stop the the rod rotation sud-
denly.
a Adjust the rod. For details, see TESTING
AND ADJUSTING, Testing and adjust-
ing of governor motor lever stroke.
REMOVAL AND INSTALLATION OF
ASSEMBLY
GOVERNOR MOTOR
ASSEMBLY
Disconnect the cable from the negative (-)
terminal of the battery.
1 2 4
4
3
E11 E10
4. DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF Assembly
30-10 PW160-7K
12
REMOVAL
1. Open up the engine hood.
2. Disconnect the two wires from the engine start-
ing motor at:
q Wire (1) and (2) from terminal B.
q Wire (3) from terminal C.
3. Remove two mounting bolts (4) to detach engine
starting motor assembly (5).
INSTALLATION
q Install in reverse order of removal.
REMOVAL AND INSTALLATION OF
ASSEMBLY
STARTING MOTOR
ASSEMBLY
Disconnect the cable from the negative (-)
terminal of the battery.
2
3 1
4 5
Engine starting motor Terminal B
Securing nut:
17.7 to 24.5 Nm (1.8 to 2.5 kgm)
Engine starting motor Terminal C
Securing nut:
2.6 to 4.6 Nm (0.26 to 0.46 kgm)
Both faces of engine starting motor gas-
ket: Gasket sealant (LG-1)
Engine starting motor to Engine Secur-
ing Bolt:
43 ± 6 Nm (4.38 ± 0.61 kgm)
5. DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF Assembly
PW160-7K 30-11
12
SPECIAL TOOLS
a Disconnect the fuel drain manifold. (A)
a Remove the injection pump supply. (B)
a Remove the high-pressure lines. (C)
a Disconnect the electrical wire to the fuel
shutoff valve. (D)
REMOVAL
WARNING! Do not remove the control lever. The
fuel control lever on the fuel injection pump is
indexed to the shaft during pump calibration. If the
lever has been removed and reinstalled incorrectly,
engine speed and power will be affected.
1. Disconnect all control linkage. Refer to OEM ser-
vice manual.
2. Remove the pump support bracket (1).
3. Remove the access cap (2), gear retaining nut
(3) and washer (4).
4. Locate top dead centre (TDC) for cylinder No.1
by barring engine slowly while pushing in on
TDC pin.
See “INSPECTION AND ADJUSTMENT OF
FUEL INJECTION TIMING<$paranumonly>-20 -
110
Note:Be sure to disengage the pin after locating
TDC.
REMOVAL AND INSTALLATION OF
ASSEMBLY
FUEL INJECTION PUMP
ASSEMBLY
Mark Part No.
Part
Name
Neces-
sity Qty
Distinc-
tion* Sketch
A 795-799-1390 Puller n 1
*Distinction between new and existing part.
A
C
D
B
1
2
3
4
6. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
30-12 PW160-7K
5. The special washer (5) on the fuel injection pump
must be removed so the lock screw (6) can be
tightened against the driveshaft.
6. Pull the fuel injection pump drive gear loose from
the pump driveshaft.
7. Remove the 3 mounting nuts, and take off the
fuel injection pump.
8. Remove the gasket, and clean the surface.
Installation
1. Verify cylinder No.1 is at TDC by barring engine
slowly while pushing in on TDC pin.
See “INSPECTION AND ADJUSTMENT OF
FUEL INJECTION TIMING<$paranumonly>-20 -
110
2. Install a new gasket (1).
WARNING! The driveshaft must be clean and free
of all oil before installation. Failure to make certain
the driveshaft is free of oil can result in the drive gear
slipping on the shaft.
3. Install the pump (2).
Torque value: 30Nm
5
6
1
2
7. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
PW160-7K 30-13
4. Use your hands to tighten the 3 mounting nuts.
Note:Fuel pumps on engines designed to meet
Tier 2 industrial emmissions levels have
straight holes (not kidney slots) and do not
use a timing key.
WARNING! Be sure the timing pin is disengaged
before the final torque step to avoid damage to the
timing pin.
5. Install the pump driveshaft nut (3) and rotate
washer (4). The pump will rotate slightly because
of gear helix and clearance. This is acceptable
provided the pump is free to move on the flange
slots and the crankshaft does not move.
6. If installing the orignal pump, rotate the pump to
align the scribe marks.
7. If installing a new or rebuilt pump without scribe
marks, take up gear lash by rotating the pump
against the direction of drive rotation. Tighten the
flange mounting nuts.
8. Permanently mark the injection pump flange to
match the mark on the gear housing.
Torque value: 15 - 20Nm
34
Torque value: 24Nm
Torque value: 24Nm
8. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
30-14 PW160-7K
9. The special washer is wired to the pump and
must be installed under the lockscrew.
10. Disengage the timing pin before rotating the
crankshaft.
11. Install the injection pump support bracket. Fin-
ger-tighten all capscrews before final tightening.
Note:Tighten the bracket to block mounting cap-
screw before tightening the bracket to injec-
tion pump capscrews.
12. Tighten the bracket capscrews to the cylinder
block (5).
Tighten the tail support bracket capsrew to the
fuel pump (6).
13. Tighten the pump retaining nut.
14. Install all high-pressure fuel lines and the electri-
cal wire to the fuel shutoff valve.
Install drain manifold fitting and reconnect drain
tube.
Torque value: 13Nm
Tightening torque:
M14x1.5 nut: 98Nm
M12 nut: 93Nm
5
6
9. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
PW160-7K 30-15
15. When connecting the rod to the control lever,
adjust the length so the lever has stop-to-stop
movement.
See “Function for Governor Motor Adjustment”
on page 20-175.
16. Bleed air from the fuel system and reinstall fan
guard as intial machine condition.
10. DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
30-16 PW160-7K
Removal
a Disconnect the cable from the negative
(–) terminal of the battery.
1. Drain the coolant.
a Drain the coolant to a degree that it will
not leak when hose (1) is disconnected.
2. Remove hoses (1) and (2).
3. Remove fan guards (3) and (4).
4. Remove air conditioner compressor belt.[*1]
5. Disconnect connector E06 (16) and remove air
conditioner compressor (5) and bracket and
move them toward the counterweight.
a Do not separate the air conditioner pip-
ing.
6. Remove fan shroud (6).
a Take care that the fan shroud will not
interfere with the other parts.
7. Remove the cooling fan.
8. Install lever [1] to tensioner (7) and move the
lever in the direction of the arrow to remove fan
belt (8).
a Take care not to catch your hands
between the tensioner and pulley.
9. Remove fan pulley (9).
10. Remove 4 mounting bolts (10) and crank pulley
(11). [*2]
a Remove the crank pulley with its timing mark
(a) matched to pointer (12) or make match
marks on the crank pulley and front cover so
that you can position the crank pulley cor-
rectly when installing it.
11. Remove 20 mounting bolts (13) and front cover
(14). [*3]
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
1
2 4
36 16 5
11. DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
PW160-7K 30-17
12
12. Remove engine front seal (15) from front cover
(14). [*4]
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Install the air conditioner compressor belt.
For details, see TESTING AND ADJUSTING,
Inspection and adjustment of air compressor
belt tension.
[*2]
a Install the belt to the position from which it
was removed.
a Install the crank pulley temporarily and fan
belt, and then tighten the mounting bolts to
the specified torque.
[*3]
a Apply ThreeBond 1207D or equivalent in the
form of a continuous string 1 – 2 mm thick to
the fitting face of the front cover.
a Install the gasket to the front cover, and then
install them to the engine.
a Tighten the mounting bolts in the following
order.
[*4]
Mounting bolt:
125 ± 5 Nm {12.75 ± 0.51 kgm}
Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
12. DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
30-18 PW160-7K
a Using the push tool, install so that dimension
b will be as follows.
q Dimension b: 21 ± 0.38 mm
13. DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
PW160-7K 30-19
12
Removal
1. Remove the hydraulic pump assembly. For
details, see Removal and installation of hydraulic
pump assembly.
2. Remove damper assembly (1).
3. Set guide bolts [1] and lift off flywheel assembly
(2). [*1]
a Flywheel assembly: 25 kg
4. Remove engine rear seal (3). [*2]
a Break the seal carrier with a screwdriver, etc.
to remove the seal.
a Take care not to damage the other parts.
a The engine rear seal may be removed
according to the following procedure.
1) Make a hole about 3 mm in diameter on the
seal with a drill.
2) Attach a dent puller to a slide hammer and
insert the hammer into the drilled hole. Then
pull out seal (3) by sliding the hammer.
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
14. DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
30-20 PW160-7K
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Tighten the mounting bolts in the following
numerical order.
[*2]
a Install the engine rear seal according to the
following procedure.
1. Install pilot [2] to new engine rear seal (3).
a Before installing the engine rear seal,
degrease and dry the seal contact surface of
the crankshaft and the lip surface of the seal
to prevent oil leakage.
2. Install pilot [2] fitted with engine rear seal (3) in
the crankshaft.
3. Pull out pilot [2].
4. Using the push tool, set the engine rear seal so
that dimension "a" will be the following value.
q Dimension a: 25.8 mm
a Lightly hit the top, bottom, right, and left of
the push tool with a hammer to push in the
seal, taking care that the seal carrier will not
be bent.
Mounting bolt:
137 ± 7 Nm {13.97 ± 0.71 kgm}
15. DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
PW160-7K 30-21
SPECIAL TOOLS
REMOVAL
a Disconnect the cable from the negative (–)
terminal of the battery.
1. Drain the coolant.
2. Close the fuel stop valve.
3. Open the engine hood.
4. Disconnect hose (1) from the engine. [*1]
5. Remove fan guard (2).
6. Remove the air conditioner compressor belt.[*2]
7. Disconnect connector E06 (35), and then
remove air conditioner compressor (3) and
bracket and move them toward the counter-
weight.
a Do not separate the air conditioner piping.
8. Disconnect terminal E01 (4) - Grid heater.
9. Remove the bracket mounting bolts of engine oil
level gauge guide (5) and move the level gauge
guide.
10. Remove 4 delivery tubes (6).
11. Remove tubes (7) and (8) between fuel filter and
fuel injection pump.
12. Remove bracket (9) and fuel filter as a unit. [*3]
13. Remove air intake connector (10) and ribbon
heater (11). [*4]
a Cover the openings with adhesive tapes, etc.
to prevent foreign matter from entering the
engine.
14. Remove heat insulation covers (12) and (13).
15. Remove muffler (14). [*5]
REMOVAL AND INSTALLATION OF
ASSEMBLY
CYLINDER HEAD ASSEM-
BLY
Symbol
Part No. Part name
Necessity
Q'ty
New/Remodel
Sketch
A
2 795-799-1171 Puller t 1
3 790-331-1110 Wrench t 1
Engine cooling water: Approx. 16.2 l
2
1
3
35
14
13
12
16. DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
30-22 PW160-7K
16. Disconnect hoses (15) and (16). [*6]
17. Disconnect tubes (17) and (18). [*7]
18. Remove turbocharger assembly (19). [*8]
19. Remove exhaust manifold (20). [*9]
20. Referring to REMOVAL AND INSTALLATION OF
ENGINE FRONT SEAL, Removal procedure
steps 2 – 9, remove the cooling fan pulley.
21. Remove the tensioner.
22. Disconnect hoses (21) and (22). [*10]
23. Disconnect terminal B (23) and connector E12
(24).
24. Remove alternator (25) and bracket.
25. Disconnect connector E05 (26) in the rear of the
left of the engine.
26. Disconnect spill tube (28).
27. Remove 4 nozzle holder assemblies (27).
a If it is difficult to pull the nozzle holder
assemblies out of the cylinder head, use tool
A2.
17. DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
PW160-7K 30-23
a Cover the nozzle holder assembly mounting
parts to prevent foreign matter from entering
the engine.
28. Remove head cover (29). [*11]
29. Remove rocker arm assemblies (30). [*12]
a Loosen the locknut and loosen the adjust-
ment screw of each rocker arm 2 – 3 turns.
30. Remove push rods (31). [*13]
31. Lift off cylinder head assembly (32). [*14]
Cylinder head assembly: 40 kg
32. Remove cylinder head gasket (33).
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19. DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
30-24 PW160-7K
INSTALLATION
q Carry out installation in the reverse order to
removal.
[*1]
[*2]
a Install the air conditioner compressor belt.
For details, see TESTING AND ADJUSTING,
Inspection and adjustment of air compressor
belt tension.
[*3]
a Apply gasket sealant to the threads of the
bolt (only 1 piece) on the head cover side
among the 3 fuel filter bracket mounting
bolts.
[*4]
a Apply gasket sealant to the threads of only
the 2 of the air intake connector mounting
bolts indicated by the arrows in the following
figure
[*5]
a When connecting the exhaust pipe to under
the muffler, apply thermosetting sealant
(Firegum manufactured by Nihon Holts Co.,
Ltd. or equivalent) all round the pipe end.
[*6]
[*8]
[*9]
a Tighten the mounting bolts in the following
numerical order.
[*10]
[*11]
Hose clamp:
1st time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
Clamp nut of muffler U-bolt:
9.8 – 14.7 Nm {1.0 – 1.5 kgm}
Clamp of hose (15):
10.0 – 11.0 Nm {1.02 – 1.12 kgm}
Clamp of hose (16):
1st time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
Tube (17):
Turbocharger side:
10.3 ± 1.2 Nm {1.1 ± 0.1 kgm}
Cylinder block side:
35 ± 5 Nm {3.6 ± 0.5 kgm}
Tube (18):10 ± 2 Nm {1.0 ± 0.2 kgm}
Mounting nut: 24 ± 4 Nm {2.4 ± 0.4 kgm}
Mounting nut: 24 ± 4 Nm {2.4 ± 0.4 kgm}
Mounting bolt:
1st time: Tighten all the bolts to:
43 ± 6 Nm {4.38 ± 0.61 kgm}.
2nd time: Tighten only bolts 1 – 4 to:
43 ± 6 Nm {4.38 ± 0.61 kgm}
Clamp of hose (22):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
20. DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
PW160-7K 30-25
12[*12] [*13] [*14]
a Install the rocker arm assembly and cylinder
head assembly according to the following
procedure.
a Check that there is not foreign matter on the
cylinder head mounting face and in the cylin-
der.
1) Set cylinder head gasket (33) to the cylinder
block.
qCheck that the gasket is matched to
the holes of the block.
2) Sling cylinder head assembly (32) and set it
to the cylinder block.
3) Install push rods (31).
4) Install rocker arm assemblies (30) and
tighten mounting bolts (34) with the fingers.
a Check that the balls of adjustment
screws (35) are fitted to the sockets of
push rods (31).
5) Tighten the cylinder head bolts in the follow-
ing numerical order in 3 times.
Threads and seat of mounting bolt:
Engine oil (SAE15W-40)
a When not using tool A3, make marks on
the bolts and cylinder head, and then
tighten each bolt by the above angle.
6) Tighten rocker arm assembly mounting bolts
(34) permanently.
Cylinder head bolt:
1st time: Tighten all the bolts to:
90 ± 5 Nm {9.18 ± 0.51 kgm} in the
numerical order shown in the figure.
2nd time: Tighten bolts 3, 6, 11, and 14
to:
120 ± 5 Nm {12.24 ± 0.51 kgm} in order.
3rd time: Using tool A3, tighten all the
bolts by 90° ± 5° in the numerical order
shown in the figure. (Angle tightening)
Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
21. DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
30-26 PW160-7K
7) Adjust the valve clearance. For details, see
TESTING AND ADJUSTING, Adjustment of
valve clearance.
q Refilling with water
Add water to the specified level. Run the engine
to circulate the water through the system. Then,
check the water level again.
q Bleeding air
Bleed air from the fuel piping. For details, see
REMOVAL AND INSTALLATION OF FUEL INJEC-
TION PUMP ASSEMBLY.
Cooling water: Approx. 16.2 l