ASSIGNMENT NO:

DISMANTLING & ASSEMBLING OF A/E CYL.HEAD

MODEL : DAIHATSHU DK-20
NATURE OF JOB : ROUTINE MAINTENANCE
NAME OF JOB : CLEANING OF CYL.HEAD AFTER
DISASSEMBLING & CHECK FOR HEAD
TIGHTENING TORQUE.
TOOLS : Spanner, allen key, rod, hydraulic jack,
chain block, cyl. head hanger, cyl. head fixing nut, copa
slip .
PROCEDURE :
CHECKS BEFORE DISMANTLING;
Confirm that generator is completely stopped.
Make sure that power supply is cut off & a tap is
put on panel.
Close v/v of air tank.

OVERHAULING ;
Open v/v at end of cooling water inlet main
pipe to drain cooling water remaining in the
jacket.
Remove the exhaust pipe cover in cyl head
side.
Remove the heat box cover.
Remove the cyl. Head top cover.
Disconnect all piping around the head.
Take off the rocker arm holder.
Remove the push rod.
Disconnect the high pressure fuel hose.
Remove the nozzle holder.
Unscrew the exhaust pipe mounting bolt.
Mount a cylinder head hanger in the head
top face.
Mount a hydraulic jack on the cyl. Head bolt.
Disconnect the cyl.head fixing nut.
CLEANING ;
Replace the rubber ring located at intake
pipe bottom end with new one.
When lowering the head take care not to
damage fit up surface of oring.
Scrape carbon deposit from combustion
chamber wall completely and check for
crack and corrosion.
Replace cyl.head packing with new one.
Check for corrosion on fit up surface of
oring for cooling water guide & gas
leakage from packing.
Replace the push rod rubber seal with
new one.
Clean upper surface of cyl. head.
ASSEMBLING ;
When lifting the cyl. Head lift it
horizontally. Take care not to allow
water inside jacket to enter cylinder.
When mounting cyl. Head take special
care so as not to dent packing.
Tight exhaust pipe bolts prior to
tightening cyl.head bolts.