Kubota Engine V3800-TIEF4 V3800-TIEF4C V3800-TIEF4H workshop service manual

Description Kubota Engine V3800-TIEF4 V3800-TIEF4C V3800-TIEF4H workshop service manual

Kubota Diesel Engine V3800-TIEF4, V3800-TIEF4C, V3800-TIEF4H pdf workshop service & repair manual

MANUAL CONTENT:
1. INFORMATION
SAFETY
1. Before you start service
2. Start safely
3. Operate safely
4. Avoiding high pressure fluid
5. Avoiding hot exhaust
6. Cleaning exhaust filter
7. Prevent a fire
8. Keep a good airflow in the work area
9. Discard fluids correctly
10. Prevent acid burns
11. Preparing for emergencies
SPECIFICATIONS
1. Specification for V3800-TIEF4, TIEF4C, TIEF4H
PERFORMANCE CURVES
1. Performance curve for V3800-TIEF4, TIEF4C
2. Performance curve for V3800-TIEF4H
DIMENSIONS
1. Dimension for V3800-TIEF4, TIEF4C, TIEF4H
WIRING DIAGRAM
1. Engine intermediate harness (Engine side harness)
2. Injector intermediate harness (Engine side harness)
3. ECU intermediate harness (OEM side harness)
4. ACU intermediate harness (OEM side harness)
5. System wiring diagram

2. GENERAL
ENGINE IDENTIFICATION
1. Model name and engine serial number
2. EF4B engine
3. Cylinder number
MUFFLER FULL ASSEMBLY IDENTIFICATION
1. Part number and serial number (DPF)
2. Parts number and serial number (SCR)
GENERAL PRECAUTIONS
MAINTENANCE CHECK LIST
CHECK AND MAINTENANCE
1. Daily check points
1.1 Checking engine oil level
1.2 Checking fuel level
1.3 Checking coolant level
1.4 Checking fan belt
1.5 Checking DEF/AdBlue® level
2. Every fuel refilling
2.1 Refilling diesel exhaust fluid (DEF/AdBlue®)
3. Check points of initial 50 hours
3.1 Changing engine oil
3.2 Replacing oil filter cartridge
4. Check point of every 50 hours
4.1 Checking fuel hoses and clamp bands
5. Check points of every 250 hours
5.1 Checking radiator hose and clamp bands
5.2 Cleaning air cleaner primary element
5.3 Adjusting fan belt tension
5.4 Checking intake air line
6. Check points of every 500 hours
6.1 Changing engine oil
6.2 Replacing oil filter cartridge
6.3 Replacing fuel filter cartridge
6.4 Replacing water separator filter (Type 2)
6.5 Cleaning water jacket and radiator interior
6.6 Replacing fan belt
7. Check point of every 1000 hours
7.1 Checking valve clearance
8. Check points of every 1500 hours
8.1 Checking injector (with Diagmaster)
8.2 Checking EGR cooler
8.3 Replacing oil separator element
8.4 Checking PCV (positive crankcase ventilation) valve
8.5 Checking DEF/AdBlue® injector tip
8.6 Checking DEF/AdBlue® hoses
9. Check points of every 3000 hours
9.1 Checking turbocharger
9.2 Cleaning DPF
9.3 Judging reuse of DPF filter comp before cleaning (Service dealer)
9.4 Judging reuse of DPF filter comp after cleaning (Cleaning contractor)
9.5 Checking EGR system (with Diagmaster)
9.6 Replacing DEF/AdBlue® pump filter
9.7 Checking DEF/AdBlue® injector
10. Check point of every 8000 hours
10.1 Replacing DEF/AdBlue® tank filter
11. Check points of every 1 year
11.1 Replacing air cleaner element
11.2 Checking DPF differential pressure pipes and hoses
11.3 Checking EGR piping
11.4 Checking intake air line
11.5 Checking exhaust manifold
11.6 Replacing water separator filter (Type 2)
12. Check points of every 2 years
12.1 Replacing fan belt
12.2 Replacing oil separator rubber hose
12.3 Replacing rubber hose of differential pressure sensor
12.4 Replacing intake hose (after air flow sensor) and intercooler hose
12.5 Replacing pressure detection hose of boost sensor
12.6 Replacing EGR cooler hose
12.7 Replacing water hose
12.8 Replacing lubricant hose
12.9 Changing radiator coolant
12.10 Replacing radiator hose and clamp bands
12.11 Replacing fuel hose and clamps
12.12 Replacing intake air line
SPECIAL TOOLS
1. Diesel engine compression tester
2. Oil pressure tester
3. Small end bushing replacing tool
4. Idle gear bushing replacing tool
5. Gear case oil seal press fit tool
6. Valve guide replacing tool
7. Crankshaft sleeve press fit tool
8. Supply pump gear puller
9. Supply pump gear reinstall jig
10. Flywheel stopper
11. Crankcase 1 and 2 aligning tool
12. Compression tester adaptor
13. Air gap of the crankshaft position sensor measuring jig 1
14. Air gap of the crankshaft position sensor measuring jig 2
15. Rotation sensor signal interface unit

3. ENGINE
MECHANISM
1. General (Introduction)
1.1 Feature of combustion (E-CDIS)
1.2 Structure of combustion (Center direct injection system (E-CDIS))
1.3 Flow of combustion (E-CDIS)
1.4 Control of combustion (E-CDIS)

2. Engine body
2.1 Structure of engine body
2.2 Feature of engine body
2.3 Crankcase
2.3.1 Outline of crankcase
2.3.2 Structure of crankcase
2.3.3 Function of crankcase
2.3.4 Specification of crankcase
2.4 Cylinder head
2.4.1 Outline of cylinder head
2.4.2 Function of cylinder head
2.5 Cylinder head cover
2.5.1 Outline of cylinder head cover
2.5.2 Structure of cylinder head cover
2.5.3 Function of cylinder head cover
2.6 Breather
2.6.1 Outline of breather
2.6.2 Structure of breather
2.6.3 Function of breather
2.6.4 Specification of breather
2.7 Oil separator
2.7.1 Outline of oil separator
2.7.2 Structure of oil separator
2.7.3 Function of oil separator
2.8 Piston
2.8.1 Outline of piston
2.8.2 Structure of piston
2.8.3 Function of piston
2.8.4 Specification of piston
2.9 Piston ring
2.9.1 Outline of piston ring
2.9.2 Structure of piston ring
2.9.3 Function of piston ring
2.9.4 Specification of piston ring
2.10 Connecting rod
2.10.1 Outline of connecting rod
2.10.2 Structure of connecting rod
2.10.3 Function of connecting rod
2.11 Crankshaft
2.11.1 Outline of crankshaft
2.11.2 Structure of crankshaft
2.11.3 Function of crankshaft
2.11.4 Specification of crankshaft
2.12 Main bearing case
2.12.1 Outline of main bearing case
2.12.2 Structure of main bearing case
2.12.3 Function of main bearing case
2.13 Flywheel
2.13.1 Outline of flywheel
2.13.2 Structure of flywheel
2.13.3 Function of flywheel
2.13.4 Specification of flywheel
2.14 Rocker arm
2.14.1 Outline of rocker arm
2.14.2 Structure of rocker arm
2.14.3 Function of rocker arm
2.15 Camshaft
2.15.1 Outline of camshaft
2.15.2 Structure of camshaft
2.15.3 Function of camshaft
2.15.4 Specification of camshaft
2.16 Valve
2.16.1 Outline of valve
2.16.2 Structure of valve
2.16.3 Function of valve
2.16.4 Specification of valve
2.17 Tappet
2.17.1 Outline of tappet
2.17.2 Structure of tappet
2.17.3 Function of tappet
2.18 Push rod
2.18.1 Outline of push rod
2.18.2 Structure of push rod
2.18.3 Function of push rod
2.19 Timing gears
2.19.1 Outline of timing gears
2.19.2 Structure of timing gears
2.19.3 Function of timing gears

3. Fuel system
3.1 Structure of common rail system (CRS) engine
3.2 Feature of common rail system (CRS) engine
3.3 Flow of common rail system (CRS) engine
3.4 Control of common rail system (CRS) engine
3.5 Fuel tank
3.5.1 Outline of fuel tank
3.5.2 Structure of fuel tank
3.5.3 Function of fuel tank
3.5.4 Specification of fuel tank
3.6 Water separator
3.6.1 Outline of water separator
3.6.2 Structure of water separator
3.6.3 Function of water separator
3.6.4 Specification of water separator
3.7 Electromagnetic fuel feed pump
3.7.1 Outline of electromagnetic fuel feed pump
3.7.2 Structure of electromagnetic fuel feed pump
3.7.3 Function of electromagnetic fuel feed pump
3.7.4 Specification of electromagnetic fuel feed pump
3.8 Fuel filter
3.8.1 Outline of fuel filter
3.8.2 Structure of fuel filter
3.8.3 Function of fuel filter
3.8.4 Specification of fuel filter
3.9 Supply pump
3.9.1 Outline of supply pump
3.9.2 Structure of supply pump
3.9.3 Function of supply pump
3.9.4 Specification of supply pump
3.10 Injection pipe
3.10.1 Outline of injection pipe
3.10.2 Structure of injection pipe
3.10.3 Function of injection pipe
3.10.4 Specification of injection pipe
3.11 Rail assembly
3.11.1 Outline of rail assembly
3.11.2 Structure of rail assembly
3.11.3 Function of rail assembly
3.11.4 Specification of rail assembly
3.12 Injector
3.12.1 Outline of injector
3.12.2 Structure of injector
3.12.3 Function of injector
3.12.4 Specification of injector
3.13 Overflow pipe
3.13.1 Outline of overflow pipe
3.13.2 Structure of overflow pipe
3.13.3 Function of overflow pipe
3.14 Check valve
3.14.1 Outline of check valve
3.14.2 Structure of check valve
3.14.3 Function of check valve
3.14.4 Specification of check valve
3.15 Fuel cooler
3.15.1 Outline of fuel cooler
3.15.2 Structure of fuel cooler
3.15.3 Function of fuel cooler
3.16 Engine ECU
3.16.1 Outline of engine ECU
3.16.2 Structure of engine ECU
3.16.3 Function of engine ECU
3.16.4 Specification of engine ECU
3.17 Crankshaft position sensor
3.17.1 Outline of crankshaft position sensor
3.17.2 Structure of crankshaft position sensor
3.17.3 Function of crankshaft position sensor
3.17.4 Specification of crankshaft position sensor
3.18 Camshaft position sensor
3.18.1 Outline of camshaft position sensor
3.18.2 Structure of camshaft position sensor
3.18.3 Function of camshaft position sensor
3.18.4 Specification of camshaft position sensor
3.19 Intake air temperature sensor
3.19.1 Outline of intake air temperature sensor
3.19.2 Structure of intake air temperature sensor
3.19.3 Function of intake air temperature sensor
3.19.4 Specification of intake air temperature sensor
3.20 Coolant temperature sensor
3.20.1 Outline of coolant temperature sensor
3.20.2 Structure of coolant temperature sensor
3.20.3 Function of coolant temperature sensor
3.20.4 Specification of coolant temperature sensor
3.21 Boost sensor
3.21.1 Outline of boost sensor
3.21.2 Structure of boost sensor
3.21.3 Function of boost sensor
3.21.4 Specification of boost sensor
3.22 Atmosphere pressure sensor
3.22.1 Outline of atmosphere pressure sensor
3.22.2 Structure of atmosphere pressure sensor
3.22.3 Function of atmosphere pressure sensor

4. Intake and exhaust system
4.1 Structure of intake and exhaust system
4.2 Feature of intake and exhaust system
4.3 Flow of intake and exhaust system
4.4 Control of intake and exhaust system
4.5 Pre-cleaner
4.5.1 Outline of pre-cleaner
4.5.2 Structure of pre-cleaner
4.5.3 Function of pre-cleaner
4.5.4 Specification of pre-cleaner
4.6 Air cleaner
4.6.1 Outline of air cleaner
4.6.2 Structure of air cleaner
4.6.3 Function of air cleaner
4.6.4 Specification of air cleaner
4.7 Turbocharger
4.7.1 Outline of turbocharger
4.7.2 Structure of turbocharger
4.7.3 Function of turbocharger
4.7.4 Specification of turbocharger
4.8 Intercooler4.8.1 Outline of intercooler
4.8.2 Structure of intercooler
4.8.3 Function of intercooler
4.8.4 Specification of intercooler
4.9 Intake air heater
4.9.1 Outline of intake air heater
4.9.2 Structure of intake air heater
4.9.3 Function of intake air heater
4.9.4 Specification of intake air heater
4.10 Intake manifold
4.10.1 Outline of intake manifold
4.10.2 Structure of intake manifold
4.10.3 Function of intake manifold
4.11 Exhaust manifold
4.11.1 Outline of exhaust manifold
4.11.2 Structure of exhaust manifold
4.11.3 Function of exhaust manifold

5. Exhaust gas recirculation (EGR) system
5.1 Structure of EGR system
5.2 Feature of EGR system
5.3 Flow of EGR system
5.4 Control of EGR system
5.5 EGR cooler
5.5.1 Outline of EGR cooler
5.5.2 Structure of EGR cooler
5.5.3 Function of EGR cooler
5.5.4 Specification of EGR cooler
5.6 EGR valve
5.6.1 Outline of EGR valve
5.6.2 Structure of EGR valve
5.6.3 Function of EGR valve
5.6.4 Specification of EGR valve
5.7 Reed valve
5.7.1 Outline of reed valve
5.7.2 Structure of reed valve
5.7.3 Function of reed valve

6. Lubricating system
6.1 Structure of lubricating system
6.2 Feature of lubricating system
6.3 Flow of lubricating system
6.4 Oil pan
6.4.1 Outline of oil pan
6.4.2 Structure of oil pan
6.4.3 Function of oil pan
6.4.4 Specification of oil pan
6.5 Oil strainer
6.5.1 Outline of oil strainer
6.5.2 Structure of oil strainer
6.5.3 Function of oil strainer
6.5.4 Specification of oil strainer
6.6 Oil pump
6.6.1 Outline of oil pump
6.6.2 Structure of oil pump
6.6.3 Function of oil pump
6.6.4 Specification of oil pump
6.7 Relief valve
6.7.1 Outline of relief valve
6.7.2 Structure of relief valve
6.7.3 Function of relief valve
6.7.4 Specification of relief valve
6.8 Oil filter
6.8.1 Outline of oil filter
6.8.2 Structure of oil filter
6.8.3 Function of oil filter
6.8.4 Specification of oil filter
6.9 Oil cooler
6.9.1 Outline of oil cooler
6.9.2 Structure of oil cooler
6.9.3 Function of oil cooler
6.9.4 Specification of oil cooler
6.10 Oil switch
6.10.1 Outline of oil switch
6.10.2 Structure of oil switch
6.10.3 Function of oil switch
6.10.4 Specification of oil switch

7. Cooling system
7.1 Structure of cooling system
7.2 Feature of cooling system
7.3 Flow of cooling system (Bottom by-pass system)
7.4 Control of cooling system (Bottom by-pass system)
7.5 Water pump
7.5.1 Outline of water pump
7.5.2 Structure of water pump
7.5.3 Function of water pump
7.6 Thermostat
7.6.1 Outline of thermostat
7.6.2 Structure of thermostat
7.6.3 Function of thermostat
7.6.4 Specification of thermostat
7.7 Radiator
7.7.1 Outline of radiator
7.7.2 Structure of radiator
7.7.3 Function of radiator
7.7.4 Specification of radiator
7.8 Radiator cap
7.8.1 Outline of radiator cap
7.8.2 Structure of radiator cap
7.8.3 Function of radiator cap
7.8.4 Specification of radiator cap
7.9 Cooling fan
7.9.1 Outline of cooling fan
7.9.2 Structure of cooling fan
7.9.3 Function of cooling fan
7.9.4 Specification of cooling fan
7.10 Reserve tank
7.10.1 Outline of reserve tank
7.10.2 Structure of reserve tank
7.10.3 Function of reserve tank
7.11 Fan belt
7.11.1 Outline of fan belt
7.11.2 Structure of fan belt
7.11.3 Function of fan belt

8. Electrical system
8.1 Structure of electrical system
8.2 Feature of electrical system
8.3 Flow of electrical system
8.4 Control of electrical system
8.5 Battery
8.5.1 Outline of battery
8.5.2 Structure of battery
8.5.3 Function of battery
8.5.4 Specification of battery
8.6 Key switch
8.6.1 Outline of key switch
8.6.2 Structure of key switch
8.6.3 Function of key switch
8.6.4 Specification of key switch
8.7 Starter (Planetary gear reduction type)
8.7.1 Outline of starter (planetary gear reduction type)
8.7.2 Structure of starter (planetary gear reduction type)
8.7.3 Function of starter (planetary gear reduction type)
8.7.4 Specification of starter (planetary gear reduction type)
8.8 Alternator
8.8.1 Outline of alternator
8.8.2 Structure of alternator
8.8.3 Function of alternator
8.8.4 Specification of alternator

9. After treatment system
9.1 Structure of diesel particulate filter (DPF) system
9.2 Feature of diesel particulate filter (DPF) system
9.3 Flow of diesel particulate filter (DPF) system
9.4 Control of diesel particulate filter (DPF) system
9.5 Diesel oxidation catalyst (DOC)
9.5.1 Outline of diesel oxidation catalyst (DOC)
9.5.2 Structure of diesel oxidation catalyst (DOC)
9.5.3 Function of diesel oxidation catalyst (DOC)
9.6 Diesel particulate filter (DPF)
9.6.1 Outline of diesel particulate filter (DPF)
9.6.2 Structure of diesel particulate filter (DPF)
9.6.3 Function of diesel particulate filter (DPF)
9.7 Air flow sensor
9.7.1 Outline of air flow sensor
9.7.2 Structure of air flow sensor
9.7.3 Function of air flow sensor
9.7.4 Specification of air flow sensor
9.8 Exhaust temperature sensor
9.8.1 Outline of exhaust gas temperature sensor
9.8.2 Structure of exhaust gas temperature sensor
9.8.3 Function of exhaust gas temperature sensor
9.8.4 Specification of exhaust gas temperature sensor
9.9 Differential pressure sensor
9.9.1 Outline of differential pressure sensor
9.9.2 Structure of differential pressure sensor
9.9.3 Function of differential pressure sensor
9.9.4 Specification of differential pressure sensor
9.10 Intake throttle valve
9.10.1 Outline of intake throttle valve
9.10.2 Structure of intake throttle valve
9.10.3 Function of intake throttle valve
9.10.4 Specification of intake throttle valve
9.11 Structure of selective catalyst reduction (SCR) system
9.12 Feature of selective catalyst reduction (SCR) system
9.13 Flow of selective catalyst reduction (SCR) system
9.14 Control of selective catalyst reduction (SCR) system
9.15 Selective catalytic reduction (SCR)
9.15.1 Outline of selective catalytic reduction (SCR)
9.15.2 Structure of selective catalytic reduction (SCR)
9.15.3 Function of selective catalytic reduction (SCR)
9.16 After treatment control unit (ACU)
9.16.1 Outline of after treatment control unit (ACU)
9.16.2 Structure of after treatment control unit (ACU)
9.16.3 Function of after treatment control unit (ACU)
9.16.4 Specification of after treatment control unit (ACU)
9.17 SCR inlet temperature sensor
9.17.1 Outline of SCR inlet temperature sensor
9.17.2 Structure of SCR inlet temperature sensor
9.17.3 Function of SCR inlet temperature sensor
9.17.4 Specification of SCR inlet temperature sensor
9.18 NOx sensor
9.18.1 Outline of NOx sensor
9.18.2 Structure of NOx Sensor
9.18.3 Function of NOx sensor
9.18.4 Specification of NOx sensor
9.19 Diesel exhaust fluid (DEF) tank
9.19.1 Outline of diesel exhaust fluid (DEF) tank
9.19.2 Structure of diesel exhaust fluid (DEF) tank
9.19.3 Function of diesel exhaust fluid (DEF) tank
9.19.4 Specification of diesel exhaust fluid (DEF) tank
9.20 DEF injector
9.20.1 Outline of DEF injector
9.20.2 Structure of DEF injector
9.20.3 Function of DEF injector
9.20.4 Specification of DEF injector
9.21 DEF pump
9.21.1 Outline of DEF pump
9.21.2 Structure of DEF pump
9.21.3 Function of DEF pump
9.21.4 Specification of DEF pump
9.22 Coolant valve
9.22.1 Outline of coolant valve
9.22.2 Structure of coolant valve
9.22.3 Function of coolant valve
9.22.4 Specification of coolant valve

SERVICING
1. Troubleshooting
1.1 Troubleshooting for V3800-TIEF4, TIEF4C

2. Servicing specifications
2.1 Servicing specification for engine

3. Tightening torques
3.1 Tightening torques of screws, bolts and nuts for general use
3.2 Tightening torques of screws, bolts and nuts for special use

4. Checking and adjusting
4.1 Checking compression pressure of cylinder
4.2 Adjusting valve clearance
4.3 Checking engine oil pressure
4.4 Checking fan belt tension
4.5 Checking fan belt damage and wear
4.6 Checking radiator cap air leakage
4.7 Checking radiator water leakage
4.8 Checking opening temperature of thermostat valve
4.9 Checking battery voltage
4.10 Checking battery specific gravity
4.11 Checking starter motor
4.12 Checking magnetic switch of starter
4.13 Checking intake air heater
4.14 Checking exhaust gas leakage of turbocharger turbine side
4.15 Checking air leakage of turbocharger compressor side
4.16 Checking radial clearance of turbocharger
4.17 Checking injector
4.18 Checking pre-stroke control valve (PCV)
4.19 Checking pressure relief valve (PRV)
4.20 Checking boost sensor
4.21 Checking intake air temperature sensor
4.22 Checking crankshaft position sensor
4.23 Checking camshaft position sensor
4.24 Checking coolant temperature sensor
4.25 Checking EGR system
4.26 Checking air flow sensor
4.27 Checking exhaust gas temperature sensor
4.28 Checking SCR inlet temperature sensor
4.29 Checking DEF pump
4.30 Checking DEF tube
4.31 Checking DEF injector
4.32 Checking DEF tank unit
4.33 Checking coolant valve
4.34 Adjusting crankshaft position sensor air gap
4.35 Checking fuel leakage of the overflow pipe
4.36 Selecting cylinder head gasket
4.37 Measuring angular deviation between crankshaft T.D.C. and crank position sensor detected T.D.C.
4.38 Replacing the SCR mixing pipe and slip ban

5. Disassembling
5.1 Draining engine oil
5.2 Draining coolant
5.3 Removing selective catalytic reduction (SCR) muffler
5.4 Removing CRS intermediate harness
5.5 Removing external components
5.6 Removing DPF muffler full assembly
5.7 Disassembling DPF assembly
5.8 Removing EGR cooler
5.9 Removing turbocharger
5.10 Removing intake throttle valve and intake air heater
5.11 Removing EGR valve
5.12 Removing common rail
5.13 Removing injector harness connector
5.14 Removing cylinder head cover
5.15 Removing sensors
5.16 Removing injector
5.17 Removing rocker arm
5.18 Removing injector oil seal
5.19 Removing cylinder head
5.20 Removing tappet
5.21 Removing valve
5.22 Removing thermostat assembly
5.23 Removing water pump
5.24 Removing supply pump
5.25 Removing oil cooler
5.26 Removing fan drive pulley
5.27 Removing gear case cover
5.28 Removing relief valve
5.29 Removing idle gear
5.30 Removing oil pump drive gear
5.31 Removing crank gear with crank pulsar gear
5.32 Removing camshaft with cam gear
5.33 Removing plate
5.34 Removing oil pan and oil strainer
5.35 Removing piston
5.36 Removing piston ring
5.37 Disassembling piston assembly
5.38 Removing flywheel
5.39 Removing flywheel housing
5.40 Removing bearing case cover
5.41 Removing crankcase 2
5.42 Removing main bearing case
5.43 Removing crankshaft
5.44 Disassembling starter
5.45 Disassembling alternator

6. Assembling
6.1 Assembling alternator
6.2 Assembling starter
6.3 Installing crankshaft
6.4 Installing main bearing case
6.5 Installing crankcase 2
6.6 Installing flywheel housing
6.7 Aligning surface of crankcase 1 and crankcase 2
6.8 Installing bearing case cover
6.9 Installing flywheel
6.10 Assembling piston assembly
6.11 Installing piston ring
6.12 Installing piston
6.13 Installing oil strainer and oil pan
6.14 Installing plate
6.15 Installing camshaft with cam gear
6.16 Installing crank gear with crank pulsar gear
6.17 Installing oil pump drive gear
6.18 Installing idle gear
6.19 Installing relief valve
6.20 Installing gear case cover
6.21 Installing fan drive pulley
6.22 Installing oil cooler
6.23 Installing water pump
6.24 Installing supply pump
6.25 Installing thermostat assembly
6.26 Installing valve
6.27 Installing tappet
6.28 Installing cylinder head
6.29 Installing injector oil seal
6.30 Installing rocker arm assembly
6.31 Installing injector
6.32 Installing cylinder head cover
6.33 Installing sensors
6.34 Installing injector harness connector
6.35 Installing common rail
6.36 Installing EGR valve
6.37 Installing intake throttle valve and intake air heater
6.38 Installing turbocharger assembly
6.39 Installing EGR cooler
6.40 Assembling DPF assembly
6.41 Installing DPF muffler full assembly
6.42 Installing CRS intermediate harness
6.43 Installing external components
6.44 Installing SCR muffler assembly
6.45 Filling coolant
6.46 Filling engine oil

7. Servicing
7.1 Checking cylinder head top clearance
7.2 Checking cylinder head surface flatness
7.3 Checking cylinder head flaw
7.4 Checking valve recessing
7.5 Adjusting valve lapping
7.6 Checking clearance between valve stem and valve guide
7.7 Replacing valve guide
7.8 Adjusting valve angle
7.9 Adjusting valve seat
7.10 Checking free length of valve spring
7.11 Checking tilt of valve spring
7.12 Checking set load of valve spring
7.13 Checking oil clearance between rocker arm and rocker arm shaft
7.14 Checking oil clearance between valve bridge shaft and valve bridge arm
7.15 Checking push rod alignment
7.16 Checking oil clearance between tappet and tappet guide bore
7.17 Checking timing gear backlash
7.18 Checking side clearance of idle gear 1, 2
7.19 Checking side clearance of idle gear 3
7.20 Checking side clearance of camshaft
7.21 Checking camshaft alignment
7.22 Replacing idle gear bushing
7.23 Checking cam height
7.24 Checking oil clearance between camshaft journal and cylinder block bore
7.25 Checking oil clearance between idle gear shaft 1, 2 and idle gear 1, 2 bushing
7.26 Checking oil clearance between idle gear 3 shaft and idle gear 3 holder
7.27 Checking piston pin bore I.D.
7.28 Checking oil clearance between piston pin and small end bushing
7.29 Replacing small end bushing
7.30 Checking connecting rod alignment
7.31 Checking piston ring gap
7.32 Checking clearance between piston ring and ring groove
7.33 Checking side clearance of crankshaft
7.34 Checking crankshaft alignment
7.35 Checking oil clearance between crankpin and crankpin bearing
7.36 Checking oil clearance between crankshaft journal and crankshaft bearing
7.37 Replacing crankshaft sleeve
7.38 Checking cylinder wear
7.39 Adjusting cylinder correction (over size)
7.40 Checking clearance between inner rotor and outer rotor
7.41 Checking clearance between outer rotor and pump body
7.42 Checking clearance between rotor and cover
7.43 Checking overrunning clutch of starter
7.44 Checking commutator and mica of starter
7.45 Checking brush wear of starter
7.46 Checking brush holder of starter
7.47 Checking armature coil of starter
7.48 Checking field coil of starter
7.49 Checking bearing of alternator
7.50 Checking stator of alternator
7.51 Checking rotor of alternator
7.52 Checking slip ring of alternator
7.53 Checking brush wear of alternator
7.54 Replacing supply pump
7.55 Replacing injector
7.56 Replacing ECU
7.57 Replacing DPF
7.58 Replacing SCR
7.59 Replacing ACU
7.60 Replacing DEF injector