ENGINE MECHANICALS CYLINDER BLOCK COMPONENTS: Timing bet cover No. 1 Borankshattputey @Tining bel cover No. 2 BCrankshattdearng Water pum Ay GPision win pn @Waler pure gasket {BPision ting @Dustoeal BComnecting roa Oi pure Ay @BConnectng rod bearing Doi soa BOipan BCyindor hess gasket BOI punp siainer Cinder shook @Rear ena plate BCrenkshett BOI seal retainer BCrankshatt ming bet puley lange Boil seal BCrankshak tring bet puley BCrenkshat thrust boating EM-108ENGINE MECHANICALS INSTRUCTIONS PRIOR TO OPERATION e Install the fend covers tothe fenders so that rio seraich may ‘bermado tothe fenders, ENGINE REMOVAL 1. Femevalol batery (Q) Disconnect the battory ground cabie trom the negative (© terminal ofthe bakery. Then deoonnect te wires from the postive (+) terminal of he battery (2) Remove the battery hold-cown clamp andbattery lamp bots. ¢ Femove the battery from the engine compartrent. 2 Removal of engine hood (7) Disconnect the windshield washer hase form the three- way jon. Remove the hose remtheclampclthe engine oe. (2) Remove the rood, being care rotto soratch tne body and hood. SS 3, Drain the coolant. (See age 60-3) 4. Drain the engine ol (See page 1-4) EMLI045. Removal ot a cleaner assembly with nose [HD-C Engine] (1) Remove the alr leaner hose trom the ai leener case by removing the two bots (@ Disconnect the vacuum motor hoes an hot intake hoee. (Except for G0 and repeal specications) (3) Disconnect the folowing hoeee at hear cleaner side. + TC vacuumnoses + PoVhoses + Vacuum hoses to BYSY (4) Remove the air clesner assembly by removing th et- ‘aching bots of thea cleaner bracket ana wing ut THO-E Engine} (1) Remove the ai intake chamber by removing the two ‘lamps and tee bats, (2) Remave te two vaeuumhoseeor sr condtioneislewp {anc for power steering, (9 Disconnect the clamp for the cluicn cabie at the ar leaner. its provided at hele fender panel and raiator comer supper. (©) Rerreve tho ‘hvee a clearer attaching bots. Then. ‘erove the air loaner assem. eu-105, ENGINE MECHANICALS.ENGINE MECHANICALS 6. Removal of radiator reserve tank (4) Discomect the radiator reserve tank hose trom the radiate (@) Pullup the radiator reserve tank together with the hose. 7. Removalat power stosting pump an drive belt (power steering equipped vehicle) (41) Loosen the acjusing bot and two tightening bots, ‘Then push down tre sur. (2) Remove ine power steering drive bet (3) Remove tre power steering pump assembly trom the engine by removing te tes bok. Then, temporary Putthe pump assem onto the batiory mounting loca. 8. Removal of aciator (7) Disconnect he ar breather hose from the radiator upper tank. (@) Remove the raciator nist hose by aisconnecting the ‘eclator and water ovtet side camps. (®) Disconrecttne radiator outst hose atthe center connec ton, CAUTION: + Whon isconnecting the radiator cuet hose, take ‘measures to preventthe coolant trom entering the alter. ato. M108,(4) Dieconnoet te a cooler nage from te racitor. (6) Remove the two attaching bolts ofthe fan shroud. Then, isconnect Be eck section ofthe fan envoud rom te raxsator (8) Disconrect the fuid coupling with fan by removing the fourattzching bots. Then remove teFuis coupling with fan together win the fan shrews, (7) Remove the sacar gle (©) Remove tne radiator by reraving the four attaching vols 8, Removal ot a conditioner compressor (1) Remove the compressor cover by removing he attach ing baits, (2) Removes the compressor assemaly by emaving the at- taching bots. Then, temporary place he compressor assertby ontothe engine comparament iets, Bu107 ENGINE MECHANICALSENGINE MECHANICALS. 10. Disconnection ot exnaust pipe (1) Remove te exhaust manifold cover. (2) Disconnect ine exnaus! pipe rom the exaust manifold by removing the thee ataohing nats. (@ Disconnectthe exraust pipe brackat rom the side ofthe vanes, 11, Removal of vacuum hoses st eurge tank ade (1 Dietrburchaptragm D @)BvEv@ (2) Pressure VSV @ (US. specifications ony) @ Arrcondtionerideup VSV@ (5) Power steering ACV @ (6) Brake booster ® () Crarcoal canister ® 12. Removal ctributor (Q) Disconnect te cstibutorwio connecter. (@) Remove he cistibuter rem the cyinder head by remow- ing te two staching bots, NOTE: ‘Since the remaining engine ol wil fow out, be cetan to Place a cloth or te ike 13. Removal of engle wie harness (1) Diseonneet he folowing connectors © Thott postion sensor D @ Intake ai temperature sensec® @ Idle speed control VSV @ (US. specications ony) © EGRVSV end namess clap DUS. specifications only) © Airconaitorer lew VEV® © Pressure sensor, pressure VSV and clamp © ® Aircondiioner water temperature switch ® © Water temperature sender gauge ® ® Wate: temperature sensor @ @ Oxygen sensor @ M108© e dscmestt our comecors &)pemove ne engi woo Saree and engi ground ‘aes assonger eat @ Disconnect the engine wire connector trom the en ‘ine control computer assemby (ECU). @ Puloutine engine wire toward the engine compart: ne © creSSinergrenre tom ne angina covert 44 Disconnection fuelling [HD-C Engine} Disconnect the fuel inet hose and retum hose fram fuel pum, NOTE: ‘Make sure to plug the dsconnacted hose so that fuel ay tow out [HO-E Engine} Disconnect the fuel hose et the upper part of fuel iter. @ tos: ‘+ Thepressure inthe fulline is kept 250kPa (2.85 kgtlem') higher than the atmospheric pressure. ‘+ Hence, when the fue tine is loosened, be sure to prevent ‘the fuel from splashing using an edequate cloth or the lie. ‘+ Furthermore, place & suitable container under the fuel ‘iter because the fuel ows out. 15. Deconnoctte uel rtum hose fram the pressure regulate. CAUTION: ‘+ When disconnecting the tut hose, take precautionary measures to prevent any dit from entering into the fue! Tne, exHt08 ENGINE MECHANICALSENGINE MECHANICALS 16 Disconnect the two water hoses from the at val, 17, Remove te eurge tank stay No. 2ftom the suge tank. 18. Disconnect the inlet and outlet hages rom theater pes. ‘CAUTION: + Care must be exorcsod not to damage the heater pipe ond. 18. Disconnect the following wires anc cords, [HD-C Engine) (1) Clamp of panery negative © teminal to engine bracket at battery carrer soe (2) Clamp of battery postive @ terminal state at patery care side, (8) Connector of cable leasing to battery at batory cartier side, [HD-E Engine} (1) Clamp of batery negative © terminal to engine bracket at battery carrie’ Se. (2) Clams of battery positive @ teminal to starter at battery carrer side (@) Clamp of batery cable ® leading to cow at battery carrer 6, (4) Taree connectors of eable leading to relay box at battary carrer side, EMeti0ENGINE MECHANICALS 20, Disconnect the connectors from ine transmission andrers- fer by jacking un the vehicle. Discomnact ine ar breather hase fom the tangmission 21. Remevalot starter (@) Disconnect the connector wity lock and remove the hamess caming bok. (2) Remove the eiare by removing the wo ateching bots. 22, Remove the etaching bots wich install the engine to the vvansmission 23, Remove the attaching bots ofthe engine mountings whe ‘suspending he engine, using a chan block 24, Take out the engine rom the engine compartment, using & chan Beck CAUTION: ‘+ Be careful not to alow the engine to ht the vice body ‘other ‘+ Make sure that all hoses and wires have been dscon- ‘ected rom the body. eenENGINE MECHANICALS: 25, Removal of engine harness trom engine (€) Disconnect he aienator connecter. (2) Remove the engine wire lame. (3) emote the engine wre from engine, 26, Remove inecrenkahattpuley by removing he four attaching bots NOTE: ‘+ Prevent the crankshatt rom turing, using the folowing Sst SST: 09210-87701-000 27 Rernoval of timing beh (See page EM-24.) (2) Remove te eight timing ct cover attaching bots. (2) Renove ihe tiring belt covers No. 1 ana ND. 2 (@) Loosen the attaching bolt ofthe timing bet tensioner. Movethetersioner othele as forasi will goanct ghien the batt temcorarly, (4 Remove he tring bet, emeni2ENGINE MECHANICAL. @ x remove of eve gauge gid atcrrg bot 25, Remove the al evel gage Guide rm tne eyncer Dock 90. Removal of eyinder head cover (1) Remove the ground cabie rom the cylinder head cover. (2) Remove the spark pugs, using the SST. SST: 0928887703000 (@) Loosen tne cylinder head! cover attaching Boks eveniy e ‘overtwo three stages inthe sequence incicated inthe foure, Rlarove the cyinder head cover ataching bots 31. Removal of cylinder neas ) Loosenthe cyinerheac bots, usingabexagon wrench. ‘CAUTION: + Loosen the eyinder head bets evenly over two or trae stages in the sequence indcatedin tho figure (2 Remove the cyindar head with te intake and exaust antovs, e NOTE: ‘+ Hits etfcut to remove the cyinder head, pry up the cine heed, using an ton bar CAUTION: + Place the removed oyiinder heacton sultable wo wooden Docks in order thatthe cylinder head eurtace and valve ‘may not be damaged, DISASSEMBLY OF CYLINDER BLOCK 1. Remove thecil pressure swith, NOTE: + Use ahexagon box wrench forthe removal operation, EMettsENGINE MECHANICALS 2 Remove the cilfiter, using the following SST. SST; 09228-8720'-000 3, Removalotoilcooter (1) Rerove the al cooler pipe from the cinder bick (2) Release the hose band and remove the of cooker pipe. (©) Remove te ollcoster tom the evinder block, ing the following SST. SST: 09268-87708-000 (4) Remove the water hose rom teal cooker, 4. Remove the compressor bracket by removing the four t= tacrang bots 5, Remove the crartsnalt pile bot NOTE: + Prevent the rg gear tom ting, sg the owing SST! 09210.87701-000 eensENGINE MECHANICAL 6. Remove te erankshatt pullay NOTE + the crankshaft puley can not be removed by hand, instal the folowing SST with the crankenat puley Dok Imterposed, SST: 09609-2001 1-000 7. Remove te crankshaft pulley flange. 8, emove te tensioner end tensicn spring 8. Remove the water pump by roreving the thes ataching bolts anc two nuts, 10, Remove te water purnp gasket 11, Remove the atemator assembly wih bracket by removing the two ataching batts and one adusing bol emis.ENGINE MECHANICALS. wz ove he waterinetand themosiatby ceoving the three atacting bots. 18, Romove he pressure plate anc clutch die by removing the ‘sxattachng bots, NOTE: Prevent prossue pst rom tuning, using the flow. ing 8ST. SST: 08210-87701-000 14. Loosen the ateching bolts ofthe flywheel inthe sequence as indicatadin te right figure. Remove ie fywne. NOTE: + Prevent the flywheel from tuming, using the following ssr. SST! 08210-87701-000, 18. Remove the rear ond plate by removing the two ataching bots. 16. Removal fc pat (7) Leosen te ten ateching bolts andfour nuts ol hecilpan ‘ver too three etages. Pulletthe bolts anc nut, aniseENGINE MECHANICAL: (2) Separate the ol pan from tne cylinder block by diving the folowing SST niobetween he oyincer block end fie ‘llpan 8ST: 09032-00100-000 17-Rerrove he oll pen gasket 18. Remove the ol pump strainer by removing the two attaching ots and wo nits 18, Remove he rear i seal etainer, 20, Remove the il pump. EmrENGINE MECHANICALS. 21, Removal of piston () Remove al carbon deposit from the piston rng ridges (2) Tur the crankshat, unt the connecting rod bearing a to be removed corres atthe of pan sce. (3) Look he fyeee! io prevent ne crankshaft om tuning, sing the folowing SST. SST: 08210-87701-000 (4) Laveen tne connecting rod bearing cap russ evenly over {M0 oF three stages. Then, remove the connecting rod Dearing cap nuts (5) Rerrove the beating cao, NOTE: + Replace the crankshat i the erankpin journals exhibit ‘damages, such as seizure, (See page EM-121.) (©) Cover each connecting cod balt wih a short piece of hese to protect tne crankpin journal from damage. (7) Push out the piston and conneating rod assembly end tho upper bearing through the top ofthe cylinger Block. eweENGINE MECHANICALS Note: + Arrange the disassembled pistons and comecting rin ‘order thatthe instalation postions may be known read ly + Care shouls be exercised s0 at not 10 damage the earings. 22, Loosen the attaching bets of the fywheo! inthe sequence as incicated inne right igure. Remove the yahoo: NOTE: + Brevent the lyateal for tuming, using the following ser. SST! 09210-87701.000 23, Removalet ctankshet (2) Grasuaty loosen ine main bearing cap bolts over thee ‘ages inthe ruraical sequence shown in fe figure Remove ine bearing cap bot. (@) Win the main bearing cap bots inserted into the bot holes of te main bearing cap, wiggle the Bearing cap back and forth. Remove the beanng cap together wih {ne owar bearing. NOTE: + Keep the lower boarng fit to the main bearing cap. * Arrange the removed main bearing caps nerde. (2) Lito he erankshatt NOTE: ‘+ Bevery careful nott allow the main beanngstobe mixed with the bearings of the other cyinders. + Remove the ttust washer, BanENGINE MECHANICALS. 24, Disassombiy of piston and connecting rod (G) Install he connecting roan he folowing SST ae ehown, ln ne night figure SST: 06221-€7706-000 (2) inser he longer SST into te piston pin hoe, Press of the piston, usng a nycraule press ‘SST: 09221-87705-000 25. Removal et piston tinge NOTE: + Arrange the removed piston rings in order £0 that their Installaion posiions may be known realy. ‘+ Donotexpand the piston ring umecessaty boyond the requiredextont. (1) Remove the piston ings No. + and No.2, using a piston ring expancer. (2) Remove tne org sie rate by hand (@) Remove ine ax rg expancir by hand, 28. Cleaning ofpistone (@) Remove the carbon deposts rom the piston top, using ‘a gasket scraper ore Ike, NoTE: ‘Be very careful otto serach the piton (2) Clean he piston grooves wih a roken piston ring or & groeve clearing ool NOTE: + Be very caret notto scratch the piston. 27. Wash the cisassembied pars wit clearing agent. Store the ars ater crying tem by blowing wit compressed ai. eMe120ENGINE MECHANICALS INSPECTION OF EACH PART INSPECTION OF CYLINDER BLOCK. 1. Removal of gasket material Remove al gasket materi rom the cylinder block. 2 Cleaning ofeyiraer Bock Giean the eyinder block, using a got bruh and cleaning ‘oven '. Inspection of tp surface of cylinder block Using @ precision siraght edge and a thickness gauge, Check the surface contacting the cylinder head gasket for \warpage inte four rections as shown the fare, ‘Alowable Warpage: 0.1 mm It the warpage exceeds tho allowable mt, replace the cyvinder bloc, 4. Mossuremert of cyincer bore (1) Measure the bore clameter of each oylnler atthe sx Bins shown in the right figure. Enaure thet the c= ference between the maximum anc) minirum bore lamers ef each eyinder ie within G1 mm, If te ciference between the maximum and minimum Valves exceeds 0.1 me, perform borg fr the cylinor bore in accordance withthe oversized piston, (2) Messure the bore diameter of each cyinder at point shown in the right figure. The maasures value is fegarced as te cyinder bore darter ‘Speciied Bore Diameter 76.000 7.090 mm 5. Removal of eyinder ridges ridges are formed ar the upper pais ofthe cylinder bores, se ridge reame: to remove merges, eureENGINE MECHANICALS INSPECTION OF CRANKSHAFT 1. Visual inspect the main journals and crankpin journals for piting or seratones, Ite man jounals and crankpin journals are camaged, replace the crankshaft. 2 Measurement of crankshatt runout (1) Suppor the both ends te crankshaft witha V-shaped look Measure the crankshaft runout with aca gauge. ‘Allowable Funout Umi: 0.8 mm if the runout exceeds the allowable limt, replace the crankarate 3, Measurement of crankshatt journals (1) Measure the clametor ct each orankshattrrain journal at {our points, 20 degrees spaced as shown inthe right figure, ‘The maximum val le regarded as the crankshatt main fournal diameter. 19 variation in the measured dhameters exceeds 0.026 mm replace the crarkshat, (@) Measure the diameter of each orankpin journal at four ins, 80 degrees spaced as shown inte ight figure. ‘The maximum vale ie regarded aa the crankpin jocenal clamote, if the variation in the measured diameters exceeds 0.086 men, replace the crankshaft, ‘Specified Diameter: Main Journal: 49.976 - 50.000 man ‘Grankpin Journal: 44.978 - 45,000 mm INSPECTION OF CONNECTING ROD 1) Visualy inspect the connecting reds for damage or cracks. 2 Check the comecting od for bend and twit using a con necting rod align. ‘Alowabie Bend: 0.05 mm ‘Aiowable Twist: 0.05 mm Ifthe bendortwistis greater than the alowabloliit replace {he connecting red assembly, euteeENGINE MECHANICALS 3. Measuretheinner diameter of he connecting od smllend, Using a bore cla gauge, Speciied Valve: 18.983. 18.979 mm {ttneinverctameterctthe comectrg red emallendexceeds ‘he specie valu. repiace the connecting ro, ee 4% Measure the with of the connecting fod big end, using @ riccoratee, ‘Specifed Value: 21.80-21.85mm ‘Alowable Limit: 21.70 mm the width wear of the connecting rodbig eng exoee0s the ‘lowabe it, replace the vonnecting roe. NOTE: + Beforemeasuringthewidth othe connecting rodbig end, tighten the connecting roc bearing cap nus eveniy over {wo ort stages tthe epectod Torque ‘Specited Torque: 34.3. 44.1 Nm (25-45 kglem) INSPECTION OF PISTONS 1. Vieualyinsoect the piston for cracks, damage or seizure, place he piston, serequired, 2, Measurement ct piston diameter (7) Measure te piston over alameter horizontally ta point 15mm fomthe lower end oft piston at igh angies (0 the piston pi Spocited Value: 75.965 - 75.995 mm fsa ew-tasENGINE MECHAMIGALS evoweecnamonts © intpnncpnaraonceeecn e See i Cam ane sceecsaoemees sen sae cmeane Se Ti cnn Roi 2 It the plstonto-oyinder Bore clearance exceeds the lowabie it, perform baring and honing the Cyingt bores sotnatthe cylinder bore ameter may maton i theoverszedpiston, 8. Meesuiersent cf piston rng groove wicth Measure me groove wictn ofthe piston tings No. 1. No. 2 ‘anc No. wih a thionnaes gauge, ‘Species Value Ne pon ona reo wah ‘o Spineorng groove wan] 4. Measuremert of piston pin bore diameter of piston Moasure the piston pin bore diameter atthe two points as shounintheright figure, usngadialgaugefor bore siameter moasurement, Record ine miamum measured valve a3 the Piston pin bore claret. ‘Specified Value: 18.990.-79,008 mm INSPECTION OF PISTON PIN 1. Vaualy inspect the piston pin for damage or scratches, Replace the piston pin, as required EMei24ENGINE MECHANICALS a _____ENGINE MECHANICAL 2 Measure the outer ciameter ofthe piston pinatte wopoints 28 shown inthe right figure, using a merormeer Specied Value: 18.991 = 18997 mm INSPECTION OF PISTON RINGS 1. Visual inspect tne piston ring for excestive uneven wear or Scratches. f any aonermalty exsta, replace the ator tg ‘witha new pat 2. Check of pleton rng dimensions (4) Measure the wth ofthe piston rng et 280-300 2a 3.00-329 ed Sidera 2.25 2.45 Spacer 2 (2) Measure th length of the pston rng. 1st 1470-4480 2nd 470 7.490 3G Sera ‘0.48-0.82 Spacer a 275-280 5187-192 (8) Inspection of piston cing end gap ‘Apply engine ol tothe oyinder wal ® inser the pisten ings ino the cyincer bore. @ Using 2 picton, pusn cewn = ston ring fo @ point HE mm messed em th cyngor Book ype EM128 Tae on Cy co 2ENGINE MECHANICALS ® Measure the piston rng end gap, using @ thickness gauge or a feter gauge, Piston ring end gap asta Tiowabie eter Capressan ren OF 0a ca Canpreen 736 No 2 38-086. oe Ot 020-075 7a, the piston rng end gap exceeds the alowable it, a tf piston ringe for one cyindler shouldbe replaced, INSPECTION OF FLYWHEEL +. Visually inspect the fywhee for damage or cracks, Repiace he fywhsel a required. 2. Wile hoicng he flywheel by your hand, ensure thet here ‘sno excessive clay or isplacemert i any anomaly es, replace the fywheol INSPECTION OF CRANKSHAFT PULLEY 1. Vaual inspection of cranksha't pulley (71) Croce he cranksnat pul etching seat ox deforma: tion, wear or cracks (2) Check tne Vsiebed ett ataching surtaceforscratchoe, elermaton or weer Replace the crankshaft puley, as required. BMS Kaen ornateINSPECTION OF OIL PUMP 1. Visually inspect the otor sutace and ol seal section of the ‘i pump fer scratches, wat and 20 forth, Wany abnoraliy exists. replace the ol Soa or rotor 2 Using soremeiver, ensure tat he oll pump cover attach: ing bok isnot ease tthe bas loose, retigtton the bol to he epacitad torque. ‘Tiehioning Torque: 78-127 Nem (08 1.3 Kaen) 8, Tum the rotor by han. Ensure thatthe rotor turne smoothly. $he rotor wil not ti smoothiy. cieassembie te of pump land check each pan carey (Gee page EM-00) Replace te pars, as required, NOTE: *+ The oll pump pertormance is descibed in the LU see- ‘en. (See page LU-6) ‘+ Tho danssombiing and assembling procedures for the Cl pump is deseribed i the folowing paragraph (See page EM=i44) INSPECTION OF WATER PUMP 1. Visual inspect ho water pump. (1) Mechanical seal seston for evidence of water leakage (2) Rotary tn of water pump for soratches, delormation ot cracks {) Water puro etaching surtace for scratches (4) Water pam pulley attaching seat fr sratenes or fet tenes condon Replace te water pump, as requred. ewig ENGINE MECHANICALSENGINE MECHANICALS 2 Check me water pump bearing and water pumg pulley sttaching section fr excessive pay. Replace tre water pump, as required 3, Tum the water pump by hand Ensure tat the water pump tums smooth Feelace the water pump, as required. WATER PUMP PULLEY 1. Visual inspection of wator purnp pulley (0) loapect the water pump pulley attaching saction for etormaton or weer (@) inspect the Vode bet amaching surface for deforma: tion or wear. place the wate: pump pulley, as required. INSPECTION OF THERMOSTAT 1. Ensure that the thermostat valve is closed complotely at room temperature 20°C anc the spring has n0 Day. FRepiace the tnermostat if the vale 's open or the spring has a play. 2. Chackne mober grommet ofthe tarnoett for damage or crack Faplece the thermostat f the rubber grommet exhibits damage of rack eM2683. lmnerse the thermostat in water, ane check the vale oper- ing temperature by healing the water racualy. sonctcanons | gag geeng, vane Se. | ne [Re Se | ee eee Replace the thermoctat if the valve operation fae to oon- form tote specitcators. INSPECTION OF OIL PAN 1. Visualy inspect the oil pan for damage or cracks Repiace te oll pan. as required INSPECTION OF OIL CLEARANCE AND SELECTION OF BEARING 1, Measurement of main journal ef clearance (7) esa the main bearings 1o tw cyinder block and crankehat main bearng cap, NoTe: + Do not touch the metal suraoe of the bearing. (2) Place the crankshat inthe eyinder block Bui8 ENGINE MECHANICALS: TaeENGINE MECHANICALS: (8) Lay a stip of piastigage across each crankshaft main Journal (4) instal the crankshaft bearing cape. Tighten the ‘rankshaft bearing eap bots evenly in he Sequence indicated in th right gure, Tightening Torque: 44.1 53.8 Nm (45 -5.5 kgtmm) (©) Remove the main bearing cape win the lower bearings fied on ther (6) Measure the pastigage width att widest pot. (Of Ciesrance: 0.024 = 0.042 mm IW the oll clearance falls to conlorm to the spectiog value, measure the crarkshalt mein Jounal demeter and select sutabo crankshaft main onal earings of Teplace the crankshaft, (See page M31) (7) Remove the plastgage tom the erankshalt main jou pas. 2. Selection of orankahatt bearings NOTE: ‘+The replacement ofthe cankshatt bearings should be Performed ate al inspections have been ished. (1) Rec! the cylinder block main joumal clameter code umber NOTE: +The main journal diameter code comes in four kinds of 5,6,7 and 8. 4-120ENGINE MECHANICALE © ieee cance ana seaat rap ame eeianacamte ceca ior, Senge peas eens eras ar rt ‘the poms shoun inthe ight Ture, The maxim valve 'S regarded as the craneshaf main aural Gameter However, she vatiaton inthe measured diemeters ‘exceods 0.026 mm, replace the crash, (3) Select the crankshatt bearings or reolace the orarkshat, based on the resus of (1) nd (2) Minanelconeroce | OMS [Seara sear] pone 8505 S005 “ivetow) = see ENGINE MECHANICALS: Gaeeve arecng estan amie con ecto a ee @ ‘Comncing eeig and bae] Cranchjeuna/aanam | Gouna castes] fone cent sn oe a ison) ——] = : mas aaa] iGeeany = [Tesi [Sst oe] oi Teen = : esse eo) = a4976 44966 a ieacK) = I 44.575 or ines = ‘Crankahat replacement oer Sie = : esa va = ae ae Soa ——e@ aoe 5 Crest of rankana trust clewance Nore: + Measure te teat erence, sng a loa Thus Cavance ‘Spectied Value: 0,02 -0.22 mm Allowable Limit: 0.30 mm ithe trust clearance axcseds the towable lint, measure the width of the ecankshalt thrust bearing cortact surface Hf the measured vaive is loss tren 29.83 mim replace the thrust waster. the measured value axcoace $9.92 mm, replace the crankshaft and trust washer 8. Measurement of connecting fed nrst clearance Measure the trust clearance between the connecting rod andithe crerkshat. using @ thickness gauge. learance: ‘Standard: 0.15 -0.40 mm Maximum: 0.45 mm NOTE: + The thrust clearance should be measured while the con- necting rod is being pushed against either side of the ‘rankshat inthe axl drooton. ‘+ Measure tho trrust cearance atthe cpposie sido Ifthe clearance exceeds the spacifed value, replace the enneeting rod or ine crancshafe or bot of thot. refering ‘the wicth ofthe big end ot the connecting od inthe trust A oi ee eee Cmmnioy | RS Wenoatiae seems aa MNGOF A as oo a ow ee Lose than 0.01 V ‘gritce swiich ON, [= = fear | psoaeameyvtage | ontan enen on od | Stange oat pete ec as sngre seas spss asso) | EAS jvosge ‘ oN | bits mma penn e-@ |rsa0v ee Sman @-8 [essere eer engers eav = = |usemmary — | ipso eicn on mr a ‘ema 20¥ [leven swion on | When Swoosh red OW inane wunae | vor eh Gh _| Taste ve My oan asrnans0¥ [owen cn cn | Trae wave iy oted os Teenanzsa | Troe vve Ay need Teta Tentovanon On [Won bra pelalona ems Poa Reoatbaneny wage | alee [Wien ate poate copreae —| e197ENGINE MECHANICALS —eeS re cai faves a ee a ae Taare Yin iO rancor nagetenra | Ses oes 9 |Lssmeory | igmenavanon | foe Resse vue | oman aS ON Web pee Bea e-8 Sime Lassen 20¥_[foenaetcon | ent rrecpeniogy | aS, Reto age [loinc OW Wen penae Vora aes e-8 near hock taster 30¥ inion On [Fras man esa atr / S—Eare | Lose mana.ry ‘gniion switch ON Ey eons wong. [Teen 36 wr ton [re © 9 [Reo sce tae [eter ch on | War at rans OE oe eaten rane Taahan 100 | Rig Socotra sore ar amag OF aah ole a= Saeco a Se tea ©- 9 ecstonary | guonewnou on I [oe ut98