F198 20 05L

CONTENTS
Section
Title Previous New
GENERAL INFORMATION GI 00
RANGER ENGINE B 01
Overhaul DRIVE LINE/AXLE J 03
TRANSMISSION/
Manual TRANSAXLE
J 05
© 2005 Ford Sales & Sarvice (Thailand) Co., Ltd.
• ENGINE PRINTED IN THAILAND, DECEMBER 2005
• MANUAL TRANSMISSION F198–20–05L
FOREWORD
This Manual explains the disassembly,

inspection, repair, and reassembly
procedures for the above-indicated engines
and manual transmissions. In order to do
these procedures safely, quickly, and
correctly, you must first read this manual and
any other relevant service materials carefully.
The information in this manual is current
up to DECEMBER 2005. Any changes that
occur after that time will not be reflected in
this particular manual. Therefore, the
contents of this manual may not exactly
match the mechanism that you are currently
servicing.
Ford Motor Company

GENERAL INFORMATION 00
SECTION
00
Toc of SCT INFORMATION . . . 00-00
GENERAL
Toc of SCT
00–00 GENERAL INFORMATION
HOW TO USE THIS MANUAL. . . . . . . . . 00–00–2 ELECTRICAL SYSTEM . . . . . . . . . . . . . . 00–00–9
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–5 NEW STANDARDS. . . . . . . . . . . . . . . . . . 00–00–10
FUNDAMENTAL PROCEDURES . . . . . . 00–00–5 ABBREVIATIONS. . . . . . . . . . . . . . . . . . . 00–00–12
End of Toc
00–00–1
GENERAL INFORMATION
HOW TO USE THIS MANUAL
DCF000000000W01
Range of Topics
• This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
— Removal/Installation
— Disassembly/Assembly
— Replacement
— Inspection
— Adjustment
• Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
Service Procedure
Inspection, adjustment
• Inspection and adjustment procedures are
divided into steps. Important points regarding the SHOWS PROCEDURE ORDER
location and contents of the procedures are FOR SERVICE
explained in detail and shown in the illustrations.
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
Tightening torque
39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}
49 1232 670A
49 H002 671 SHOWS TIGHTENING

TORQUE
49 H032 322 SPECIFICATIONS
Caution
Connect the gauge set from under
the vehicle to prevent contact with
the drive belt and the cooling fan.
WGIWXX0009E
00–00–2
GENERAL INFORMATION
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be 00
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
SHOWS SERVICE
Procedure ITEM (S)
INDICATES ANY RELEVANT
1
LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION REFERENCES WHICH NEED
1. Jack up the rear of the vehicle and support it with safety stands. TO BE FOLLOWED DURING
"Removal/Installation" 2. Remove the undercover. (See 01-10-4 Undercover Removal)
Portion 3. Remove in the order indicated in the table. INSTALLATION
4. Install in the reverse order of removal.
2 5. Inspect the rear wheel alignment and adjust it if necessary.
"Inspection After SHOWS SPECIAL
Installation" Portion 11 SERVICE TOOL (SST)
9 SST
SHOWS PROCEDURE ORDER FOR SERVICE OPERATION
GREASE
FOR SERVICE 12 SST R
INSTALL THE PARTS BY SHOWS APPLICATION

PERFORMING STEPS 8 43—56 {4.3—5.8, 32—41}
POINTS OF GREASE, ETC.
10
— IN REVERSE ORDER
1—3 44—60 {4.4—6.2, 32—44} 7 R
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS SHOWS NON-REUSEABLE PARTS
SST
3
5
6 SHOWS DETAILS
SST
GREASE
4 R
94—116 {9.5—11.9, 69—86}
2 118—156 {12.0—16.0, 87—115} SHOWS TIGHTENING
SHOWS THERE 1 R TORQUE UNITS
ARE REFERRAL
N·m {kgf·m, ft·lbf}
NOTES FOR SERVICE
1 Split pin 7 Split pin
2 Nut 8 Nut
3 Lower trailing link ball joint 9 Upper trailing link ball joint
(See 02-14-5 Lower Trailing Link Ball Joint Removal Note) (See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
4 Bolt 10 Nut
5 Lower trailing link 11 Upper trailing link
6 Dust boot (lower trailing link) 12 Dust boot (upper trailing link)
Lower Trailing Link Ball Joint, Upper Trailing Link 49 T028 304 UPPER TRAILING LINK
Ball Joint Removal Note 49 T028 305 LOWER TRAILING LINK
Remove the ball joint using the SSTs.
SHOWS SPECIAL
SERVICE TOOL (SST)
NO. KNUCKLE
49 T028 303
SHOWS REFERRAL
NOTES FOR
SERVICE
BHE0000W104
00–00–3
GENERAL INFORMATION
Symbols
• There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
Symbol Meaning Kind
New appropriate
OIL Apply oil engine oil or gear
oil
New appropriate
BRAKE Apply brake fluid
FLUID brake fluid
New appropriate
Apply automatic
automatic
transaxle/
ATF
transaxle/
transmission fluid
transmission fluid
Appropriate
Apply grease
GREASE
grease
Appropriate
SEALANT Apply sealant
sealant
Apply petroleum Appropriate

P jelly petroleum jelly
O-ring, gasket,
R Replace part
etc.
Use SST or
SST equivalent
Appropriate tools
Advisory Messages
• You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this
manual.
Warning
• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Caution
• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.
Note
• A Note provides added information that will help you to complete a particular procedure.
Specification
• The values indicate the allowable range when performing inspections or adjustments.
Upper and lower limits

• The values indicate the upper and lower limits that must not be exceeded when performing inspections or
adjustments.
End Of Sie
00–00–4
GENERAL INFORMATION
UNITS
DCF000000000W02
Electric current A (ampere) N·m (Newton meter)

kgf·m (kilogram force meter)
00
Electric power W (watt)
Electric resistance ohm Torque kgf·cm (kilogram force centimeter)
Electric voltage V (volt) ft·lbf (foot pound force)
mm (millimeter) in·lbf (inch pound force)
Length L (liter)
in (inch)
kPa (kilo pascal) US qt (U.S. quart)
Negative pressure mmHg (millimeters of mercury) Imp qt (Imperial quart)
inHg (inches of mercury) Volume ml (milliliter)
kPa (kilo pascal) cc (cubic centimeter)
kgf/cm2 (kilogram force per square cu in (cubic inch)
Positive pressure
centimeter) fl oz (fluid ounce)
psi (pounds per square inch) g (gram)
Weight
Number of oz (ounce)
rpm (revolutions per minute)
revolutions
Conversion to SI Units (Système International d'Unités)

• All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted
from these values.
Rounding Off
• Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit
value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.
Upper and Lower Limits

• When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is
an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI
unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications:
210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}

270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}
• The actual converted values for 2.7 kgf/cm2 are 264 kPa and 38.4 psi. In the first specification, 2.7 is used as
an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
End Of Sie
FUNDAMENTAL PROCEDURES
DCF000000000W03
Preparation of Tools and Measuring Equipment
• Be sure that all necessary tools and measuring
equipment are available before starting any work.
CHU0014W003
00–00–5
GENERAL INFORMATION
Special Service Tools
• Use special service tools or equivalent when they
are required.
49 SE01 310
WGIWXX0024E
Disassembly
• If the disassembly procedure is complex,
requiring many parts to be disassembled, all parts
should be marked in a place that will not affect
their performance or external appearance and
identified so that reassembly can be performed
easily and efficiently.
WGIWXX0027E
Inspection During Removal, Disassembly

• When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.
WGIWXX0028E
Arrangement of Parts
• All disassembled parts should be carefully
arranged for reassembly.
• Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
WGIWXX0029E
00–00–6
GENERAL INFORMATION
Cleaning of Parts
• All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method. 00
Warning
• Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.
C5U0000W001
Reassembly
• Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
• If removed, the following parts should be replaced
with new ones:
— Oil seals
— Gaskets
— O-rings
— Lockwashers
— Cotter pins
— Nylon nuts
WGIWXX0031E
• Depending on location:
— Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
— Oil should be applied to the moving
components of parts.
— Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
CHU0014W006
Adjustment
• Use suitable gauges and testers when making
adjustments.
CHU0014W005
00–00–7
GENERAL INFORMATION
Rubber Parts and Tubing
• Prevent gasoline or oil from getting on rubber
parts or tubing.
WGIWXX0034E
Hose Clamps
• When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.
WGIWXX0035E
Torque Formulas
• When using a torque wrench-SST or equivalent
combination, the written torque must be SST 3
recalculated due to the extra length that the SST

2
or equivalent adds to the torque wrench.

1 0
Recalculate the torque by using the following

1
formulas. Choose the formula that applies to you.

2
3
Torque Unit Formula

N·m N·m × [L/ (L+A)]
kgf·m kgf·m × [L/ (L+A)]
A L
kgf·cm kgf·cm × [L/ (L+A)]
ft·lbf ft·lbf × [L/ (L+A)] WGIWXX0036E
in·lbf in·lbf × [L/ (L+A)]
A : The length of the SST past the torque wrench drive.

L : The length of the torque wrench.
Vise
• When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
End Of Sie
PROTECTIVE PLATES
CHU0014W010
00–00–8
GENERAL INFORMATION
ELECTRICAL SYSTEM
DCF000000000W04
Connectors
Disconnecting connectors 00
• When disconnecting connector, grasp the
connectors, not the wires. GOOD NO GOOD
CHU0000W014
• Connectors can be disconnected by pressing or

pulling the lock lever as shown.
WGIWXX0042E
Locking connector
• When locking connectors, listen for a click
indicating they are securely locked.
WGIWXX0043E
Inspection
• When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from GOOD NO GOOD
the wiring harness side.
CHU0000W011
00–00–9
GENERAL INFORMATION
• Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the
wiring harness side.
Caution
• To prevent damage to the terminal, wrap
a thin wire around the tester probe before GOOD NO GOOD
inserting into terminal.
End Of Sie
CHU0000W012
NEW STANDARDS
DCF000000000W05
• Following is a comparison of the previous standard and the new standard.
New Standard Previous Standard
Abbrevi- Abbrevi- Remark
Name Name
ation ation
AP Accelerator Pedal — Accelerator Pedal
ACL Air Cleaner — Air Cleaner
A/C Air Conditioning — Air Conditioning
BARO Barometric Pressure — Atmospheric Pressure
B+ Battery Positive Voltage Vb Battery Voltage
— Brake Switch — Stoplight Switch
— Calibration Resistor — Corrected Resistance #6
CMP sensor Camshaft Position Sensor — Crank Angle Sensor
CAC Charge Air Cooler — Intercooler
CLS Closed Loop System — Feedback System
CTP Closed Throttle Position — Fully Closed
CPP Clutch Pedal Position — Idle Switch
CIS Continuous Fuel Injection System — Clutch Position
CS sensor Control Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6
CKP sensor Crankshaft Position Sensor — Crank Angle Sensor 2
DLC Data Link Connector — Diagnosis Connector
DTM Diagnostic Test Mode — Test Mode #1
DTC Diagnostic Trouble Code(s) — Service Code(s)
DI Distributor Ignition — Spark Ignition
DLI Distributorless Ignition — Direct Ignition
EI Electronic Ignition — Electronic Spark Ignition #2
ECT Engine Coolant Temperature — Water Thermo
EM Engine Modification — Engine Modification
— Engine Speed Input Signal — Engine RPM Signal
EVAP Evaporative Emission — Evaporative Emission
EGR Exhaust Gas Recirculation — Exhaust Gas Recirculation
FC Fan Control — Fan Control
FF Flexible Fuel — Flexible Fuel
4GR Fourth Gear — Overdrive
— Fuel Pump Relay — Circuit Opening Relay #3
FSO
Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
solenoid
GEN Generator — Alternator
GND Ground — Ground/Earth
HO2S Heated Oxygen Sensor — Oxygen Sensor With heater
IAC Idle Air control — Idle Speed Control
— IDM Relay — Spill Valve Relay #6
00–00–10
GENERAL INFORMATION
New Standard Previous Standard
Abbrevi- Abbrevi- Remark
ation
Name
ation
Name 00
— Incorrect Gear Ratio — —
— Injection Pump FIP Fuel Injection Pump #6
— Input/Turbine Speed Sensor — Pulse Generator
IAT Intake Air Temperature — Intake Air Thermo
KS Knock Sensor — Knock Sensor
MIL Malfunction Indicator Lamp — Malfunction Indicator Light
MAP Manifold Absolute Pressure — Intake Air Pressure
MAF sensor Mass Air Flow Sensor — Airflow Sensor
MFL Multiport Fuel Injection — Multiport Fuel Injection
OBD On-Board Diagnostic — Diagnosis/SelfDiagnosis
OL Open Loop — Open Loop
— Output Speed Sensor — Vehicle Speed Sensor 1
OC Oxidation Catalytic Converter — Catalytic Converter
O2S Oxygen Sensor — Oxygen Sensor
PNP Park/Neutral Position — Park/Neutral Range
— PCM Control Relay — Main Relay #6
PSP Power Steering Pressure — Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
— Pressure Control Solenoid — Line Pressure Solenoid Valve
Pulsed
PAIR Pulsed Secondary Air Injection — Secondary Air Injection System
injection
— Pump Speed Sensor — NE Sensor #6
Injection
AIR Secondary Air Injection — Secondary Air Injection System with air
pump
SAPV Secondary Air Pulse Valve — Reed Valve
SFI Sequential Multipoint Fuel Injection — Sequential Fuel Injection
— 12 Shift Solenoid Valve
— Shift Solenoid A
— Shift A Solenoid Valve
— 23 Shift Solenoid Valve
— Shift Solenoid B
— Shift B Solenoid Valve
— Shift Solenoid C — 34 Shift Solenoid Valve
3GR Third Gear — 3rd Gear
TWC Three Way Catalytic Converter — Catalytic Converter
TB Throttle Body — Throttle Body
TP sensor Throttle Position Sensor — Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch — Lockup Position
Transmission (Transaxle) Control
TCM — EC-AT Control Unit
Module
Transmission (Transaxle) Fluid
— — ATF Thermosensor
Temperature Sensor
TR Transmission (Transaxle) Range — Inhibitor Position
TC Turbocharger — Turbocharger
VSS Vehicle Speed Sensor — Vehicle Speed Sensor
VR Voltage Regulator — IC Regulator
VAF sensor Volume Air Flow Sensor — Air flow Sensor
Warm Up Three Way Catalytic
WUTWC — Catalytic Converter #5
Converter
WOT Wide Open Throttle — Fully Open
#1 : Diagnostic trouble codes depend on the diagnostic test mode

#2 : Controlled by the PCM
#3 : In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#4 : Device that controls engine and powertrain
#5 : Directly connected to exhaust manifold
#6 : Part name of diesel engine
00–00–11
GENERAL INFORMATION
End Of Sie
ABBREVIATIONS
DCF000000000W06
ATDC After Top Dead Center

BTDC Before Top Dead Center
EX Exhaust
IN Intake
SST Special Service Tool
TDC Top Dead Center
4×2 4-wheel 2-drive
4×4 4-wheel 4-drive
End Of Sie
00–00–12
ENGINE 01SECTION
Toc of SCT
MECHANICAL [WL-3] . . . . . . . 01-10A TECHNICAL DATA 01
MECHANICAL [WL-C, WE-C] . . . . . . . . . . . . . 01-50B
[WL-C, WE-C] . . . . . . . . . . . . 01-10B SERVICE TOOLS [WL-3] . . . . . 01-60A
TECHNICAL DATA [WL-3] . . . 01-50A SERVICE TOOLS
[WL-C, WE-C] . . . . . . . . . . . . . 01-60B
Toc of SCT
01–10A MECHANICAL [WL-3]
ENGINE MOUNTING [WL-3]. . . . . . . . . . 01–10A–2 CRANKSHAFT INSPECTION [WL-3] . . . 01–10A–25
ENGINE DISMOUNTING [WL-3]. . . . . . . 01–10A–3 CRANKSHAFT OIL CLEARANCE
TIMING BELT DISASSEMBLY [WL-3] . . 01–10A–4 INSPECTION/REPAIR [WL-3] . . . . . . . . 01–10A–26
CYLINDER HEAD CRANKSHAFT END PLAY
DISASSEMBLY(I) [WL-3] . . . . . . . . . . . 01–10A–6 INSPECTION/REPAIR [WL-3] . . . . . . . . 01–10A–26
CYLINDER HEAD DISASSEMBLY (II) CONNECTING ROD INSPECTION
[WL-3] . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10A–8 [WL-3] . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10A–26
CYLINDER BLOCK DISASSEMBLY (I) CONNECTING ROD OIL CLEARANCE
[WL-3] . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10A–9 INSPECTION/REPAIR [WL-3] . . . . . . . . 01–10A–27
CYLINDER BLOCK DISASSEMBLY (II) CONNECTING ROD SIDE CLEARANCE
[WL-3] . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10A–10 INSPECTION [WL-3] . . . . . . . . . . . . . . . 01–10A–27
CYLINDER BLOCK DISASSEMBLY (III) PISTON AND CONNECTING ROD
[WL-3] . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10A–15 INSPECTION [WL-3] . . . . . . . . . . . . . . . 01–10A–28
CYLINDER HEAD INSPECTION/REPAIR BOLT INSPECTION [WL-3] . . . . . . . . . . . 01–10A–28
[WL-3] . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10A–16 TENSIONER SPRING INSPECTION
VALVE INSPECTION [WL-3]. . . . . . . . . . 01–10A–17 [WL-3] . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10A–28
VALVE GUIDE INSPECTION [WL-3] . . . 01–10A–18 VALVE CLEARANCE INSPECTION
VALVE GUIDE REPLACEMENT [WL-3] . 01–10A–19 [WL-3] . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10A–29
VALVE SEAT VALVE CLEARANCE ADJUSTMENT
INSPECTION/REPAIR [WL-3]. . . . . . . . 01–10A–19 [WL-3] . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10A–29
VALVE SPRING INSPECTION [WL-3] . . 01–10A–20 INJECTION TIMING ADJUSTMENT
CAMSHAFT INSPECTION [WL-3] . . . . . 01–10A–21 [WL-3] . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10A–30
CAMSHAFT OIL CLEARANCE GEAR CLEARANCE INSPECTION
INSPECTION [WL-3] . . . . . . . . . . . . . . . 01–10A–21 [WL-3] . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10A–32
CAMSHAFT END PLAY PLUNGER SPRING INSPECTION
CYLINDER BLOCK CYLINDER BLOCK ASSEMBLY (I)
INSPECTION/REPAIR [WL-3]. . . . . . . . 01–10A–22 [WL-3] . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10A–33
OIL JET VALVE, NOZZLE CYLINDER BLOCK ASSEMBLY (II)
PISTON INSPECTION [WL-3]. . . . . . . . . 01–10A–23 CYLINDER BLOCK ASSEMBLY (III)
PISTON CLEARANCE [WL-3] . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10A–42
INSPECTION/REPAIR [WL-3]. . . . . . . . 01–10A–23 CYLINDER HEAD ASSEMBLY (I)
PISTON RING CLEARANCE [WL-3] . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10A–44
INSPECTION [WL-3] . . . . . . . . . . . . . . . 01–10A–23 CYLINDER HEAD ASSEMBLY (II)
PISTON PIN CLEARANCE [WL-3] . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10A–46
INSPECTION [WL-3] . . . . . . . . . . . . . . . 01–10A–24 TIMING BELT ASSEMBLY [WL-3] . . . . . . 01–10A–51
End of Toc
01–10A–1
MECHANICAL [WL-3]
ENGINE MOUNTING [WL-3]
DCF011002000W01
1. Install the engine hanger (JE48 10 561C) or SST
JE48 10 561C or SST (303-050 (49 UN30 3050))
(303-050 (49 UN30 3050)) to the cylinder head
using the bolt (99794 0820 or M8X1.25, 6T,
length 20mm {0.79 in}) as shown in the figure.
Tightening torque
18.6—25.5 N·m {1.90—2.60 kgf·m, 13.8—18.8 ENGINE
ft·lbf} FRONT
BOLT
DBG110AEBR01
2. If the SST (303-050 (49 UN30 3050)) is used, use

the SST (49 L017 5A0) when suspending the 49 L017 5A0
303-050
engine.
(49 UN30 3050)
M8 x 1.25
BOLT
DBG110AEBR84
3. Install the SST (arms) to the holes as shown in

49 L010 102
the figure, and hand tighten the SST (bolts).
49 L010 107
49 L010 106
DBG110AEB002
4. Assemble the SSTs (bolts, nuts and plate) to the

specified positions. 49 L010 101
49 L010 105 49 L010 104

DBG110AEB003
01–10A–2
MECHANICAL [WL-3]
5. Adjust the SST (bolts) so that 20 mm {0.79 in} or
more of thread is exposed. PARALLEL
6. Align the SSTs (plate and arms) so that they are 49 L010 101
parallel by adjusting the SSTs (bolts and nuts). 49 L010 102
7. Tighten the SSTs (bolts and nuts) to affix the SST
firmly. 49 L010 105 01
8. Mount the engine on the SST (engine stand). ENGINE
Warning
• The self-locking brake system for the
49 L010 104 49 L010 103 APPROX. 20 mm {0.79 in}
engine stand may not operate if the
engine is held in an unbalanced position.
DBG110AEB105
This could lead to sudden, rapid
movement of the engine and mounting
stand handle and cause serious injury. Never hold the engine in an unbalanced position, and
always grasp the rotating handle firmly when turning the engine.
9. Remove the engine hanger (JE48 10 561C) or

SST (303-050 (49 UN30 3050)). 49 0107 680A
10. Drain the engine oil into a container.
11. Install the drain plug using new washer.
Tightening torque
29.4—41.2 N·m {3.00—4.20 kgf·m, 21.7—30.3
ft·lbf}
End Of Sie
DBG110AEB004
ENGINE DISMOUNTING [WL-3]

DCF011002000W02
1. Dismount in the reverse order of mounting.
End Of Sie
01–10A–3
MECHANICAL [WL-3]
TIMING BELT DISASSEMBLY [WL-3]
DCF011002000W03
1. Disassemble in the order shown in the figure. .
2
7
R
4
DBG110AEBR05
1 Water pump 6 Tensioner, tensioner spring

2 Vacuum pump (See 01–10A–5 Tensioner, Tensioner Spring
Disassembly Note.)
3 Cylinder head cover
7 Timing belt
4 Timing belt cover (See 01–10A–5 Timing Belt Disassembly Note.)
5 Pulley plate
01–10A–4
MECHANICAL [WL-3]
Tensioner, Tensioner Spring Disassembly Note
1. Turn the crankshaft clockwise and align the timing TENSIONER TIMING MARK
marks as shown in the figure. LOCK BOLT CAMSHAFT
PULLEY
01
TENSIONER
SPRING
TIMING TENSIONER
MARK
FUEL INJECTION PUMP
PULLEY
DBG110AEBR11
Timing Belt Disassembly Note

1. Mark the timing belt rotation on the belt for proper
reinstallation.
Caution NG NG
• The following will damage the timing belt
and shorten its life; forcefully twisting it,
turning it inside out, or getting oil or
grease on it.
• After removing the timing belt, do not ROTATION
ARROW
move the crankshaft and/or camshaft NG
pulley from this position because it can 30 mm {1.2 in } MIN.
cause the valve and piston to contact and
DBG110AEBR10
damage them.
End Of Sie
01–10A–5
MECHANICAL [WL-3]
CYLINDER HEAD DISASSEMBLY(I) [WL-3]
DCF011002000W04
1. Disassemble in the order shown in the figure.
.
LOWER CAP IS MACHINED TOGETHER WITH

CYLINDER HEAD AND CANNOT BE REMOVED
3
7
4
R
5
6
R
8
R 10 11 R
DBG110AEBR08
1 Camshaft pulley 5 Rocker arm

(See 01–10A–7 Camshaft Pulley Disassembly 6 Water temperature sender unit
Note.)
7 ECT sensor
2 Seal plate
8 Water outlet pipe
3 Camshaft cap
(See 01–10A–7 Camshaft Cap Disassembly Note.) 9 Blind cover
4 Camshaft 10 Cylinder head
(See 01–10A–7 Camshaft Disassembly Note.) (See 01–10A–7 Cylinder Head Disassembly Note.)
11 Cylinder head gasket
01–10A–6
MECHANICAL [WL-3]
Camshaft Pulley Disassembly Note
Caution
• Do not move the camshaft from this position because it can cause the valve and piston to contact
each other and damage them.
01
1. Hold the camshaft by using a wrench on the cast
hexagon.
DBG110AEB015
Camshaft Cap Disassembly Note
Caution
• Removing the camshaft cap under load can break the camshaft. When removing the camshaft cap,
loosen the locknut and the adjust screw to prevent the camshaft from pressing down the rocker
arm.
Note
• Mark the camshaft cap so that they can be reinstalled in the position from which they were removed.
1. Loosen the camshaft cap bolts in three or four

steps in the order shown in the figure. 3 7 10 6 2
ENGINE
FRONT
4 8 9 5 1
DBG110AEB025
Camshaft Disassembly Note

1. Before removing the camshaft, inspect the camshaft oil clearance. (See 01–10A–21 CAMSHAFT OIL
CLEARANCE INSPECTION [WL-3].)
Cylinder Head Disassembly Note

1. Remove bolts A.
2. Loosen the cylinder head bolts in two or three
steps in the order shown in the figure. 3 7 11 15 18 14 10 6 2 A
End Of Sie
4 8 12 16 17 13 9 5 1 A
DBG110AEB016
01–10A–7
MECHANICAL [WL-3]
CYLINDER HEAD DISASSEMBLY (II) [WL-3]
DCF011002000W05
SST 2
3
4
R SST 5
7 1
DBG110AEBR24
1 Pivot 5 Lower valve spring seat

2 Valve keeper 6 Valve
(See 01–10A–8 Valve Keeper Disassembly Note.) 7 Valve seal
3 Upper valve spring seat (See 01–10A–9 Valve Seal Disassembly Note.)
4 Valve spring
Valve Keeper Disassembly Note

1. Remove the valve keeper using the SST.
49 0636 100B
49 B012 0A2
DBG110AEB026
01–10A–8
MECHANICAL [WL-3]
Valve Seal Disassembly Note
1. Remove the valve seal using the SST.
End Of Sie
49 S120 170 01
VALVE SEAL
VALVE GUIDE
DBG110AEB104
CYLINDER BLOCK DISASSEMBLY (I) [WL-3]

DCF011002000W06
R
3
1
R
DBG110AEB033
1 Oil drain plug 3 Oil strainer

2 Oil pan 4 Oil pipe
(See 01–10A–10 Oil Pan Disassembly Note.)
01–10A–9
MECHANICAL [WL-3]
Oil Pan Disassembly Note
1. Remove the oil pan using a separator tool.
End Of Sie
SEPARATOR TOOL
DBG110AEB035
CYLINDER BLOCK DISASSEMBLY (II) [WL-3]

DCF011002000W07
17
14
13 16
12 15
R
R SST
8
5 4
R
SST
2
6 SST
3 R
9
1 SST SST
11 10
DBG110AEBR40
1 Crankshaft pulley 4 Oil pump

(See 01–10A–11 Crankshaft Pulley Disassembly 5 Fuel injection pump gear
Note.) (See 01–10A–12 Fuel Injection Pump Gear
2 Fuel injection pump pulley Disassembly Note.)
(See 01–10A–11 Fuel Injection Pump Pulley 6 Timing gear
Disassembly Note.) 7 Fuel injection pump
3 Timing gear cover
(See 01–10A–12 Timing Gear Cover Disassembly
Note.)
01–10A–10
MECHANICAL [WL-3]
8 Timing gear case 12 Oil pump cover
(See 01–10A–14 Timing Gear Case Disassembly 13 Driven gear
Note.)
14 Plug
9 Flywheel
15 Plunger spring
10
(See 01–10A–14 Flywheel Disassembly Note.)
End plate 16 Control plunger 01
11 Rear cover 17 Oil pump body
(See 01–10A–14 Rear Cover Disassembly Note.)
Crankshaft Pulley Disassembly Note

1. Remove the crankshaft pulley using the SST.
Caution
• The CKP sensor plate is a very important
part for engine operation control; any
deformation of the plate may disable the
operation control.
When disassembling/assembling the
crankshaft pulley, be very careful not to
deform the plate by interference with
other parts or improper handling. 49 E011 1A0
DBG110AEB042
PLATE
CRANKSHAFT
PULLEY
DBG110AWB021
Fuel Injection Pump Pulley Disassembly Note

1. Remove the fuel injection pump pulley using the
SST.
49 E011 1A0
DBG110AEB043
01–10A–11
MECHANICAL [WL-3]
Timing Gear Cover Disassembly Note
1. Remove the timing gear cover using a separator
tool.
SEPARATOR TOOL
DBG110AEB044
2. Remove the oil seal using a screwdriver protected
with a rag.
RAG
DBG110AEB045
Fuel Injection Pump Gear Disassembly Note

1. Set the No.1 cylinder to TDC of compression.
2. Rotate the flywheel ring gear from TDC to BTDC30°
approximately 30° BTDC (about 13 teeth on the TDC
gear).
DBG110AEB046
3. Verify that the end-gap (V groove) of the timing

gear case and the chip cut gear of the fuel GEAR CASE (V GROOVE)
VIEW A
injection pump gear are aligned.
Note FUEL INJECTION

• If the chip cut gear is hard to find, move the PUMP GEAR
fuel injection pump gear on notch back and
forth, then check the chip cut gear.
VIEW A
No.2 IDLER
FUEL INJECTION CHIP CUT GEAR
PUMP GEAR
(HELICAL GEAR)
ABOUT 0.5 mm
{0.02 in}
ABOUT 3.0 mm
{0.12 in}
SCISSORS GEAR
DBG110AEBRR8
01–10A–12
MECHANICAL [WL-3]
4. Fix the scissors gear to the fuel injection pump gear using a lock bolt (M8×1.25; length under the bolt head is
approximately 14 mm {0.55 in}).
Warning
• When removing the fuel injection pump gear, be sure to secure the scissors gear to the fuel
injection pump gear using a lock bolt (M8×1.25; length under the bolt head is approximately 14 mm
01
{0.55 in}). Otherwise, the scissors gear will rotate with the spring force, causing personal injury.
Caution
• When removing the fuel injection pump gear, be sure to secure the scissors gear to the fuel
injection pump gear using a look bolt (M8×1.25; length under the bolt head is approximately 14
mm {0.55 in}) to prevent the scissors gear form rotating with the spring force. Otherwise, the
scissors gear will not align with the fuel injection pump gear, and the fuel injection pump gear with
the scissors gear will not engage with the idler gear.
Note
LOCK BOLT
• The fuel injection pump gear with a scissors
gear has a lock bolt hole.
DBG110AEBR97
5. Hold the crankshaft using the SST and loosen the

gear nut.
GEAR NUT
49 E011 1A0
DBG110AEB047
01–10A–13
MECHANICAL [WL-3]
6. Remove the fuel injection pump gear using the
SST.
49 S120 215B
DBG110AEBR48
Timing Gear Case Disassembly Note

1. Remove the timing gear case using the separator
tool.
SEPARATOR TOOL
DBG110AEB050
Flywheel Disassembly Note

1. Remove the flywheel using the SST.
KNOCK PIN
3 1
5 8
7 6
2 4
49 E011 1A0
DBG110AEBR56
Rear Cover Disassembly Note

with a rag.
End Of Sie
RAG
DBG110AEB052
01–10A–14
MECHANICAL [WL-3]
CYLINDER BLOCK DISASSEMBLY (III) [WL-3]
DCF011002000W08
15
5
01
3
13
SST 6
7
8
9
12
2
14
11
1
10
DBG110AEBR67
1 Connecting rod cap 8 Piston

(See 01–10A–15 Connecting Rod Cap Disassembly 9 Connecting rod
Note.)
10 Main bearing cap
2 Lower connecting rod bearing (See 01–10A–16 Main Bearing Cap Disassembly
3 Piston, connecting rod Note.)
(See 01–10A–15 Piston, Connecting Rod 11 Lower main bearing, lower thrust bearing
Disassembly Note.)
12 Crankshaft
4 Upper connecting rod bearing (See 01–10A–16 Crankshaft Disassembly Note.)
5 Piston ring 13 Upper main bearing, upper thrust bearing
6 Piston pin clip 14 Oil jet valve, nozzle
7 Piston pin 15 cylinder block
(See 01–10A–16 Piston Pin Disassembly Note.)
Connecting Rod Cap Disassembly Note

1. Before removing the connecting rod cap, inspect the connecting rod side clearance. (See 01–10A–27
CONNECTING ROD SIDE CLEARANCE INSPECTION [WL-3].)
Piston, Connecting Rod Disassembly Note

1. Before removing the piston and connecting rod, inspect the connecting rod oil clearance. (See 01–10A–27
CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR [WL-3].)
2. Inspect the oscillation torque. (See 01–10A–28 PISTON AND CONNECTING ROD INSPECTION [WL-3].)
01–10A–15
MECHANICAL [WL-3]
Piston Pin Disassembly Note
1. Remove the piston pin using the SST.
49 G011 001
DBG110AEB069
Main Bearing Cap Disassembly Note

1. Before removing the main bearing cap, inspect the crankshaft end play. (See 01–10A–26 CRANKSHAFT END
PLAY INSPECTION/REPAIR [WL-3].)
2. Loosen the main bearing cap bolts in two or three
3 7 10 6 2
steps in the order shown in the figure.
4 8 9 5 1
DBG110AEB070
Crankshaft Disassembly Note

1. Before removing the crankshaft, inspect the main journal oil clearance. (See 01–10A–26 CRANKSHAFT OIL
CLEARANCE INSPECTION/REPAIR [WL-3].)
End Of Sie
CYLINDER HEAD INSPECTION/REPAIR [WL-3]
DCF011010100W01
1. Inspect the cylinder head surface for cracks. Replace the cylinder head if necessary.
2. Inspect for the following and repair or replace.
(1) Sunken valve seats
(2) Excessive camshaft oil clearance and end play
3. Measure the cylinder head for distortion in the
seven directions as shown in the figure. Y
Maximum cylinder head distortion

X distortion: 0.02 mm {0.0008 in}
Y distortion: 0.05 mm {0.0020 in}
DBG110AEB115
01–10A–16
MECHANICAL [WL-3]
4. Measure the receded or projected amount of
combustion chamber insert from the cylinder
head surface.
• If it exceeds the maximum specification,
replace the cylinder head.
01
Maximum combustion chamber recession
0.02 mm {0.0008 in}
Maximum combustion chamber projection COMBUSTION CHAMBER

0.005 mm {0.0002 in} INSERT
DBG110AEB074
5. Inspect the combustion chamber insert crack.

• If it exceeds the limit specification, replace the
cylinder head.
Combustion chamber crack CRACK

Limit: 10mm {0.39 in}
DBG110AEB075
6. Measure the manifold contact surface distortion

as shown in the figure.
• If the distortion exceeds the maximum
specification, grind the surface or replace the
cylinder head.
Maximum manifold contact surface distortion

0.05 mm {0.0020 in}
Maximum manifold contact surface grinding

0.15 mm {0.0059 in}
DBG110AEB076
End Of Sie
VALVE INSPECTION [WL-3]
DCF011012111W01
1. Measure the valve head margin thickness of each
valve.
• If it exceeds the standard specification, THICKNESS
replace the valve.
Standard valve margin thickness

IN: 1.5 mm {0.059 in}
EX: 0.75 mm {0.030 in}
2. Measure the length of each valve. Replace the LENGTH

valve if necessary.
• If it is less than the minimum specification,
B3E0110ER68
replace the valve.
Standard valve length

IN: 111.6—112.1 mm {4.394—4.413 in}
EX: 111.5—112.0 mm {4.390—4.409 in}
Minimum valve length

IN: 111.35 mm {4.384 in}
EX: 111.25 mm {4.380 in}
01–10A–17
MECHANICAL [WL-3]
3. Measure the stem diameter of each valve in the X
and Y directions at the three points (A, B, and C) X
shown in the figure.
• If it is less than the minimum specification, Y
replace the valve.
A
Standard valve stem diameter
IN: 6.970—6.985 mm {0.2745—0.2749 in} B
EX: 6.965—6.980 mm {0.2743—0.2748 in}
C
Minimum valve stem diameter
IN: 6.920 mm {0.2724 in}
DBG110AEB106
EX: 6.915 mm {0.2722 in}
End Of Sie
VALVE GUIDE INSPECTION [WL-3]
DCF011010280W01
1. Measure the inner diameter of each valve guide in
X
the X and Y directions at the three points (A, B,
and C) shown in the figure. Y
• If it is not within the specification, replace the
valve guide. A
Standard valve guide inner diameter

7.025—7.045 mm {0.2766—0.2773 in} B
DBG110AEB108
2. Measure the protrusion height (dimension A) of

each valve guide without lower valve spring seat.
valve guide.
A
Standard valve guide height
14.0—14.5 mm {0.552—0.570 in}
End Of Sie
DBG110AEB077
01–10A–18
MECHANICAL [WL-3]
VALVE GUIDE REPLACEMENT [WL-3]
DCF011010280W02
Valve Guide Removal
1. Remove the valve guide from the combustion
chamber side using the SST. 49 B012 015
01
VALVE GUIDE
DBG110AEB107
Valve Guide Installation

1. Assemble the SSTs so that depth L is as
specified.
Depth L 49 L012 004A

L
14.0—14.5 mm {0.552—0.570 in}
49 L012 003A
49 L012 002A
DBG110AEB110
2. Tap the valve guide in from the side opposite the

combustion chamber until the SST contacts the 49 L012 003A
49 L012 004A
cylinder head.
3. Verify that the valve guide projection height is
within the specification.

14.0—14.5 mm {0.552—0.570 in} 49 L012 002A
End Of Sie VALVE GUIDE
B3E0110E072
VALVE SEAT INSPECTION/REPAIR [WL-3]

DCF011010102W01
1. Measure the seat contact width.
• If it is not within the specification, resurface
the valve seat using the 45° valve seat cutter.
Standard valve seat contact width

IN: 1.6—2.2 mm {0.063—0.086 in} SEAT CONTACT
WIDTH
EX: 1.7—2.3 mm {0.067—0.090 in}
DBG110AEB109
01–10A–19
MECHANICAL [WL-3]
2. Verify that the valve seating position is at the
center of the valve face.
• If the seating position is too high, correct the IN EX
valve seat using a 60° cutter, and then a 45°
cutter.
• If the seating position is too low, correct the 60°
60°
valve seat using a 37° (IN) or 30° (EX) cutter, 45°
and a 45° cutter. 45°
37°
Valve seat angle 30°
IN: 45°
EX: 45°
DBG110AEBR75
3. Measure the receded amount from the cylinder

head surface.
replace the cylinder head.
Standard valve recession

IN: 0.61—1.09 mm {0.025—0.042 in}
EX: 0.71—1.19 mm {0.028—0.046 in}
Maximum valve recession

IN: 1.50 mm {0.059 in}
EX: 1.60 mm {0.063 in}
DBG110AEB112
End Of Sie
VALVE SPRING INSPECTION [WL-3]
DCF011012125W01
1. Apply a pressing force to the pressure spring and
check the spring height.
valve spring.
Valve spring installation pressing force

238—269 N {25—27 kgf, 54—60 lbf}
Valve spring installation height

35.5 mm {1.40 in}
DBG0110AEB11
2. Measure the amount the valve spring is out-of-

square.
replace the valve spring.
Maximum valve spring out-of-square

2.0° (1.70mm {0.067 in})
End Of Sie
DBG110AEB079
01–10A–20
MECHANICAL [WL-3]
CAMSHAFT INSPECTION [WL-3]
DCF011012420W01
1. Set the No.1 and No.5 journals on V-blocks.
Measure the camshaft runout.
replace the camshaft. 01
Maximum camshaft runout
0.03 mm {0.0012 in}
DBG110AEB114
2. Measure the cam lobe height at the two points as

• If it is less than the minimum specification,
replace the camshaft.
Standard cam lobe height

IN: 42.400—42.500 mm {1.6692—1.6732 in}
EX: 42.395—42.495 mm {1.6691—1.6730 in}
Minimum cam lobe height

IN: 42.050 mm {1.6555 in}
EX: 42.045 mm {1.6711 in}
DBG110AEB080
3. Measure the journal diameters in the X and Y

directions at the two points (A and B) as shown in
the figure.
• If it is less than the minimum specification, B
replace the camshaft.
A
Standard cam journal diameter
No.1, No.5: 25.940—25.965 mm {1.0213— X
Y
1.0222 in}
No.2—No.4: 25.910—25.935 mm {1.0201— Y
1.0210 in} X
DBG110AEB081
Minimum cam journal diameter
No.1, No.5: 25.890 mm {1.0193 in}
No.2—No.4: 25.860 mm {1.0181 in}
End Of Sie
CAMSHAFT OIL CLEARANCE INSPECTION [WL-3]
DCF011012420W02
1. Position a plastigage on top of the journals in the axial direction.
2. Install the camshaft cap. (See 01–10A–49 Camshaft Cap Assembly Note.)
3. Remove the camshaft cap. (See 01–10A–7 Camshaft Cap Disassembly Note.)
4. Measure the oil clearance.
• If it exceeds the maximum specification, replace the camshaft.
Standard camshaft clearance

No.1, 5: 0.035—0.081 mm {0.0014—0.0031
in}
No.2—4: 0.065—0.111 mm {0.0026—0.0043
in}
Maximum camshaft clearance

No.1, 5: 0.12 mm {0.0047 in}
No.2—4: 0.15 mm {0.0059 in}
End Of Sie DBG110AEB082
01–10A–21
MECHANICAL [WL-3]
CAMSHAFT END PLAY INSPECTION [WL-3]
DCF011012420W03
1. Install the camshaft cap. (See 01–10A–49 Camshaft Cap Assembly Note.)
2. Measure the camshaft end play.
• If it exceeds the maximum specification, replace the cylinder head or camshaft.
Standard camshaft end play

0.030—0.160 mm {0.0012—0.0062 in}
Maximum camshaft end play

0.20 mm {0.0079 in}
3. Remove the camshaft cap. (See 01–10A–7

Camshaft Cap Disassembly Note.)
End Of Sie
DBG110AEB083
CYLINDER BLOCK INSPECTION/REPAIR [WL-3]

DCF011010300W01
1. Measure the distortion of the cylinder block top
surface in the seven directions as shown in the Y
figure.
• If the distortion exceeds the maximum
specification, replace the cylinder head.
Maximum cylinder block distortion

X direction: 0.02 mm {0.0008 in}
Y direction: 0.05 mm {0.0020 in}
DBG110AEB115
2. Measure the cylinder bore using the cylinder

X
gauge. Measurement positions are in the X and Y
directions at 83 mm {3.27 in} below the top
surface of the cylinder. Y
• If the cylinder bore exceeds the wear limit,
replace the cylinder block or rebore the
cylinder and install the oversized pistons so
that the specified piston-to-cylinder clearance 83.0 mm {3.27 in}
is obtained.
Note
• Base the boring diameter on the diameter of
ADA2224ER91
an oversized piston. All cylinders must be
the same diameter.
Cylinder bore size

Standard: 93.000—93.022 mm {3.6615—3.6622 in}
0.25 {0.01} oversize: 93.250—93.272 mm {3.6713—3.6721 in}
0.50 {0.02} oversize: 93.500—93.522 mm {3.6811—3.6819 in}
Cylinder bore wear limit

0.15 mm {0.0059 in}
End Of Sie
01–10A–22
MECHANICAL [WL-3]
OIL JET VALVE, NOZZLE INSPECTION [WL-3]
DCF011010730W01
1. Apply compressed air to oil jet valve A and verify
that air passes through oil jet valve B. A
oil jet. 01
Oil jet air pressure
137.6—196.4 kPa {1.5—2.0 kgf/cm2, 20—28
psi}
2. Check the oil jet nozzle for clogs. Replace the B

nozzle if necessary.
PISTON INSPECTION [WL-3]

DCF011011010W01
1. Measure the outer diameter of each piston at right
angle (90°) to the piston pin, 17 mm {0.67 in}
from the lower end of the piston.
piston.
Piston diameter
Standard: 92.951—92.977 mm {3.6595—
3.6605 in}
17 mm
0.25 {0.0098} oversize: 93.186—93.212 mm {0.67 in}
{3.6688—3.6697 in}
0.50 {0.02} oversize: 93.436—93.462 mm
DBG110AEBR74
{3.6786—3.6795 in}
End Of Sie
PISTON CLEARANCE INSPECTION/REPAIR [WL-3]
DCF011011010W02
1. Measure the piston-to-cylinder clearance.
• If it exceeds the maximum specification, replace the piston or rebore the cylinders to fit the oversized
piston.
Standard piston clearance

0.055—0.073 mm {0.0022—0.0028 in}
Maximum piston clearance

0.15 mm {0.0059 in}
2. If the piston is replaced, the piston rings must also be replaced.

End Of Sie
PISTON RING CLEARANCE INSPECTION [WL-3]
DCF011011010W03
1. Measure the piston ring-to-ring land clearance
around the entire circumference.
replace the piston and piston ring.
Standard piston ring clearance

Top: 0.06—0.10 mm {0.0024—0.0039 in}
Second: 0.04—0.08 mm {0.0016—0.0031 in}
Oil: 0.03—0.07 mm {0.0012—0.0027 in}
Maximum piston ring clearance

0.15 mm {0.0059 in}
DBG110AEB116
2. Insert the piston ring into the cylinder by hand and

use the piston to push it to the bottom of the ring travel.
01–10A–23
MECHANICAL [WL-3]
3. Measure each piston ring end gap with a feeler
gauge.
replace the piston ring.
Standard piston ring end gap

Top: 0.22—0.32 mm {0.0087—0.0125 in}
Second: 0.32—0.47 mm {0.0126—0.0185 in} PISTON
Oil: 0.22—0.37 mm {0.0087—0.0145 in} RING
Maximum piston ring end gap

1.0 mm {0.039 in}
DBG110AEB087
End Of Sie
PISTON PIN CLEARANCE INSPECTION [WL-3]
DCF011011010W04
1. Measure each piston pin bore diameter in the X
and Y directions at the four points (A, B, C, and D)
Standard piston pin bore diameter

31.997—32.007 mm {1.2598—1.2601 in}
X
A
B
C
D
Y
DBG110AEB088
2. Measure each connecting rod small end inner

X
diameter in the X and Y directions as shown in the
figure.
Standard connecting rod small end inner Y

diameter
32.012—32.033 mm {1.2604—1.2611 in}
DBG110AEB117
3. Measure each piston pin diameter in the X and Y X

directions at the four points (A, B, C and D) as
Y
Standard piston pin diameter
31.994—32.000 mm {1.25961—1.25984 in}
A
4. Calculate the piston pin-to-piston pin bore B
clearance.
• If it is not within the specification, replace the C
piston or the piston pin.
D
DBG110AEB118
Standard piston pin-to-piston pin bore
clearance
–0.003—0.013 mm {–0.00011—0.00051 in}
5. Calculate the connecting rod small end-to-piston pin clearance.

• If it is not within the specification, replace the connecting rod or the piston pin.
Standard connecting rod small end-to-piston pin clearance

0.012—0.039 mm {0.00048—0.00153 in}
End Of Sie
01–10A–24
MECHANICAL [WL-3]
CRANKSHAFT INSPECTION [WL-3]
DCF011011301W01
1. Measure the crankshaft runout.
replace the crankshaft.
01
Maximum crankshaft runout
0.05 mm {0.0020 in}
DBG110AEB089
2. Measure the main journal or crank pin diameter in

the X and Y directions at the two points (A and B) A B
• If it is not within the specification or if it X
exceeds the maximum off-round, grind the
main journal or crank pin with an undersized
bearing. Y
Main journal diameter

Standard
No.1, 2, 4, 5: 66.937—66.955 mm {2.6354—
2.6360 in}
DBG110AEB090
No.3: 66.920—66.938 mm {2.6347—2.6353
in}
0.25 {0.01} undersize
No.1, 2, 4, 5: 66.687—66.705 mm {2.6255—2.6261 in}
No.3: 66.670—66.688 mm {2.6248—2.6255 in}
No.1, 2, 4, 5: 66.437—66.455 mm {2.6157—2.6163 in}
No.3: 66.420—66.438 mm {2.6150—2.6156 in}
No.1, 2, 4, 5: 66.187—66.205 mm {2.6058—2.6064 in}
No.3: 66.170—66.188 mm {2.6052—2.6058 in}
Main journal wear limit

0.05 mm {0.0020 in}
Main journal out-of-round

0.03 mm {0.0012 in}
Crank pin diameter

Standard: 54.940—54.955 mm {2.1630—2.1635 in}
0.25 {0.01} undersize: 54.690—54.705 mm {2.1532—2.1537 in}
0.50 {0.02} undersize: 54.440—54.455 mm {2.1434—2.1438 in}
0.75 {0.03} undersize: 54.190—54.205 mm {2.1335—2.134 in}
Crank pin wear limit

0.05 mm {0.0020 in}
Crank pin out-of-round

0.03 mm {0.0012 in}
End Of Sie
01–10A–25
MECHANICAL [WL-3]
CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR [WL-3]
DCF011011301W02
2. Install the main bearing cap. (See 01–10A–34 Main Bearing Cap Assembly Note.)
3. Remove the main bearing cap. (See 01–10A–16 Main Bearing Cap Disassembly Note.)
4. Measure the main journal oil clearance.
• If the clearance exceeds the maximum specification, replace the main bearing or grind the main journal and
install the undersize bearings so that the specified oil clearance is obtained.
Standard main journal clearance

No.1, 2, 4, 5: 0.027—0.046 mm {0.0011—0.0018 in}
No.3: 0.044—0.063 mm {0.0018—0.0025 in}
Maximum main journal clearance

0.08 mm {0.0031 in}
Main bearing thickness

Standard: 2.006—2.021 mm {0.0790—0.0795 in}
0.25 {0.01} undersize: 2.124—2.134 mm {0.0837—0.0840 in}
0.50 {0.02} undersize: 2.249—2.259 mm {0.0886—0.0889 in}
0.75 {0.03} undersize: 2.374—2.384 mm {0.0935—0.0938 in}
End Of Sie
CRANKSHAFT END PLAY INSPECTION/REPAIR [WL-3]
DCF011011301W03
1. Install the main bearing cap. (See 01–10A–34 Main Bearing Cap Assembly Note.)
2. Measure the crankshaft end play.
• If the end play exceeds the maximum
specification, replace the thrust bearing or
grind the crankshaft and install an oversized
bearing so that the specified end play is
obtained.
Standard crankshaft end play

0.040—0.282 mm {0.0016—0.0111 in}
Maximum crankshaft end play

0.3 mm {0.012 in}
DBG110AEB120
Thrust bearing thickness

Standard: 2.454—2.506 mm {0.0967—0.0986 in}
0.35 {0.014} oversize: 2.629—2.681 mm {0.1036—0.1055 in}
3. Remove the main bearing cap. (See 01–10A–16 Main Bearing Cap Disassembly Note.)
End Of Sie
CONNECTING ROD INSPECTION [WL-3]
DCF011011211W01
1. Measure each connecting rod for bending and
distortion.
replace the connecting rod.
Maximum connecting rod bending

0.075 mm {0.0030 in} /50 mm {2.0 in}
Maximum connecting rod distortion

0.18 mm {0.0071 in} /50 mm {2.0 in}
Connecting rod center-to-center distance

DBG110AEB119
151.96—152.04 mm {5.9827—5.9858 in}
01–10A–26
MECHANICAL [WL-3]
2. Measure the length of the connecting rod bolt.
replace the connecting rod and connecting
rod cap.
Standard connecting rod bolt length

01
67.5—68.5 mm {2.66—2.69 in}
Maximum connecting rod bolt length

69 mm {2.7 in}
LENGTH
CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR [WL-3]

DCF011011211W02
2. Install the connecting rod cap. (See 01–10A–35 Piston, Connecting Rod Assembly Note.)
3. Remove the connecting rod cap.
4. Measure the crankpin oil clearance.
• If the clearance exceeds the maximum,
replace the connecting rod bearing or grind
the crankpin and use undersized bearings so
that the specified clearance is obtained.
Standard connecting rod oil clearance

0.025—0.052 mm {0.0010—0.0020 in}
Maximum connecting rod oil clearance

0.08 mm {0.0031 in}
DBG110AEB121
Connecting rod bearing thickness
Standard: 1.507—1.516 mm {0.0594—0.0596
in}
0.25 {0.01} undersize: 1.624—1.634 mm {0.0640—0.0643 in}
0.50 {0.02} undersize: 1.749—1.759 mm {0.0689—0.0692 in}
0.75 {0.03} undersize: 1.874—1.884 mm {0.0738—0.0741 in}
End Of Sie
CONNECTING ROD SIDE CLEARANCE INSPECTION [WL-3]
DCF011011211W03
1. Install the connecting rod cap. (See 01–10A–35 Piston, Connecting Rod Assembly Note.)
2. Measure the connecting rod large end side
clearance.
replace the connecting rod and connecting
rod cap.
Standard connecting rod side clearance

0.110—0.262 mm {0.0044—0.0103 in}
Maximum connecting rod side clearance

0.35 mm {0.014 in}
DBG110AEB122
End Of Sie
01–10A–27
MECHANICAL [WL-3]
PISTON AND CONNECTING ROD INSPECTION [WL-3]
DCF011011010W05
1. Check the oscillation torque as shown in the
figure. If the large end does not drop by its own
weight, replace the piston or the piston pin.
End Of Sie
DBG110AEB093
BOLT INSPECTION [WL-3]

DCF011010135W01
1. Measure the length of each bolt.
replace the bolt.
Cylinder head bolt length

Bolt head mark W
Standard length: 101.2—101.8 mm {3.985—
4.007 in}
Maximum length: 102.5 mm {4.035 in} LENGTH
Bolt head mark N
4.480 in}
DBG110AEB097
Maximum length: 114.5 mm {4.508 in}
Main bearing cap bolt length

Standard length: 84.7—85.3 mm {3.34—3.35 in}
End Of Sie
TENSIONER SPRING INSPECTION [WL-3]
DCF011012711W01
1. Measure the free length of the tensioner spring.
• If it exceeds the standard specification,
replace the tensioner spring.
Standard tensioner spring length

63.0 mm {2.48 in}
End Of Sie
FREE LENGTH
DBG110AEB098
01–10A–28
MECHANICAL [WL-3]
VALVE CLEARANCE INSPECTION [WL-3]
DCF011012111W02
1. Turn the crankshaft and align the timing mark so that the piston of the No.1 or No.4 cylinder is at TDC of
compression.
2. Measure valve clearances A with the No.1
cylinder at TDC of compression, and those of B A A A
01
with the No.4 cylinder at TDC of compression.
• If it is not within the specification, adjust and
recheck the valve clearance. ENGINE
FRONT
B B B
DBG110AEB099
Valve clearance (engine cold) ADJUST

IN: 0.05—0.15 mm {0.0020—0.0059 in} FEELER GAUGE SCREW
EX: 0.15—0.25 mm {0.0060—0.0098 in}
LOCKNUT
3. Turn the crankshaft one full turn and measure the
remaining valve clearances. Adjust if necessary.
End Of Sie
DBG110AEB100
VALVE CLEARANCE ADJUSTMENT [WL-3]

DCF011012111W03
Caution
• Loosening the locknut and the adjust screw while the cam lobe is not pressing down the rocker
arm will damage the claw of the rocker arm. When loosening the locknut and the adjust screw,
rotate the crankshaft clockwise and be sure that the cam lobe presses down the rocker arm firmly
1. Remove the cylinder head cover.

2. Turn the crankshaft and align the timing mark so CAM LOBE ADJUST SCREW
that the piston of the No. 1 or No. 4 cylinders is at
TDC of the compression.
ROCKER ARM
LOCKNUT
CLAW
DBG110AWB002
01–10A–29
MECHANICAL [WL-3]
3. Adjust the valve clearances A with the No.1
cylinder at TDC of compression, and those of B A A A
ENGINE
FRONT
B B B
DBG110AWB001
Valve clearance ADJUST SCREW

IN: 0.05 — 0.15 mm {0.0020 — 0.0059 in} FEELER
[Engine cold] GAUGE
0.15 mm {0.0059 in} LOCKNUT
[Engine hot (reference)]
EX: 0.15 —0.25 mm {0.0060 — 0.0098 in}
[Engine cold]
0.25 mm {0.0098 in}
[Engine hot (reference)]
Tightening torque (locknut)

DBG110AWB003
16—20 N·m {1.7—2.0 kgf·m, 12—14 ft·lbf}
4. Turn the crankshaft one full turn and adjust the remaining valve clearances.
End Of Sie
INJECTION TIMING ADJUSTMENT [WL-3]
DCF011002000W09
Caution
• Excessive tension on the timing belt may cause damage to the timing belt and camshaft. If the bolt
and nuts of the fuel injection pump are temporarily loosened, re-tension the timing belt.
1. Loosen the bolts and nuts of the fuel injection

pump and bracket.
DBG110AEBR76
2. Rotate the crankshaft clockwise and align the INDICATOR PIN

crankshaft pulley TDC mark (yellow mark) with
the indicator pin. TDC (YELLOW MARK)
3. Remove the hydraulic head plug of the fuel
injection pump.
ATDC 10° (WHITE MARK)

DBG110AEBR81
01–10A–30
MECHANICAL [WL-3]
4. Insert the SST into the hydraulic head plug hole
and install it so that the dial gauge indicates 49 9140 074
approx. 2 mm {0.08 in}.
01
DBG110AEBR80
5. Rotate the crankshaft counterclockwise and find BTDC 30°

the place where the dial gauge needle does not TDC M12 x 1.75
ATDC 10° BOLT HOLE
move near approx. 30° BTDC. (SST installation
bolt hole of crankshaft pulley and indicator pin
align at approx. 30° BTDC)
6. Set the dial gauge to 0 mm {0 in}.
DBG110AEBR78
7. Rotate the crankshaft clockwise and read the dial INDICATOR PIN
gauge when the 10° ATDC mark (white mark) of
the crankshaft pulley and the indicator pin align. TDC (YELLOW MARK)
8. Adjust the dial gauge within the specification.
Fuel injection pump plunger adjustment value

0.95—1.05 mm {0.038—0.041 in}
ATDC 10° (WHITE MARK)

DBG110AEBR79
9. Tighten the fuel injection pump in the order shown

in the figure. 2
10. Remove the SST and install the hydraulic head 4
plug through a new gasket.
11. Re-tension the timing belt.
End Of Sie
1 4
5 3 1
5 3
DBG110AEBR77
01–10A–31
MECHANICAL [WL-3]
GEAR CLEARANCE INSPECTION [WL-3]
DCF011019220W01
1. Measure the following clearance.
• If it exceeds the maximum specification, replace the gear and/or pump body.
Standard oil pump tip clearance

0.10—0.19 mm {0.0040—0.0074 in}
Maximum oil pump tip clearance

0.20 mm {0.0079 in}
DBG110AEB101
Standard oil pump side clearance

0.04—0.09 mm {0.0016—0.0035 in}
Maximum oil pump side clearance

0.15 mm {0.0059 in}
End Of Sie
DBG110AEB102
PLUNGER SPRING INSPECTION [WL-3]

DCF011014116W01
1. Measure the free length of plunger spring.
• If it exceeds the standard specification,
replace the plunger spring.
Standard plunger spring length

43.8 mm {1.72 in}
End Of Sie
DBG110AEB103
01–10A–32
MECHANICAL [WL-3]
CYLINDER BLOCK ASSEMBLY (I) [WL-3]
DCF011002000W10
1. Assemble in the order indicated in the table.
1
01
OIL
OIL
11 13 OIL
3
OIL
10
9
OIL
8
7
OIL
12
OIL
4
2
14 OIL
OIL
5
15
12—18 N·m {123—183 kgf·cm, 107—159 in·lbf}
26.5—31.5
{2.8—3.2, 20—23} + 82.5°—97.5° 6
14.5—34.5 {1.5—3.5, 11—25}

+74.0—82.0 {7.6—8.3, 55—60}
Loosen all the bolts (until bolts are torque-free)
+14.5—34.5 {1.5—3.5, 11—25}
+42.5—45.5 {4.4—4.6, 32—33}
+ 90°—105°
DBG110AEBR68
1 Cylinder block 9 Piston pin

2 Oil jet valve, nozzle (See 01–10A–34 Piston, Connecting Rod, Piston
Pin Assembly Note.)
3 Upper main bearing, upper thrust bearing
10 Piston pin clip
4 Crankshaft
11 Piston ring
5 Lower main bearing, lower thrust bearing (See 01–10A–35 Piston Ring Assembly Note.)
6 Main bearing cap 12 Upper connecting rod bearing
(See 01–10A–34 Main Bearing Cap Assembly
Note.) 13 Piston, connecting rod
(See 01–10A–35 Piston, Connecting Rod Assembly
7 Connecting rod Note.)
(See 01–10A–34 Piston, Connecting Rod, Piston
Pin Assembly Note.) 14 Lower connecting rod bearing
8 Piston 15 Connecting rod cap
(See 01–10A–34 Piston, Connecting Rod, Piston
Pin Assembly Note.)
01–10A–33
MECHANICAL [WL-3]
Main Bearing Cap Assembly Note
1. Apply clean engine oil to the bolt threads and seat faces of the lower cylinder block bolts.
2. Tighten the bolts in two or three steps in the order
8 4 1 5 9
Tightening procedure
(1) 14.5—34.5 N·m {1.5—3.5 kgf·m, 11—25
ft·lbf}
(2) 74.0—82.0 N·m {7.6—8.3 kgf·m, 55—60
ft·lbf}
(3) Loosen all the bolts (until bolts are
torque-free).
(4) 14.5—34.5 N·m {1.5—3.5 kgf·m, 11—25 7 3 2 6 10
ft·lbf}
DBG110AEB071
(5) 42.5—45.5 N·m {4.4—4.6 kgf·m, 32—33
ft·lbf}
3. Put a paint mark on each bolt head.

4. Using the marks as a reference, tighten the bolts
by turning each 90°—105° as in Step 2.
90°—105°
PAINT MARK
DBG110AEBR72
Piston, Connecting Rod, Piston Pin Assembly Note

1. Install one piston pin clip.
2. Assemble the piston and connecting rod in the direction indicated in the figure.
3. Apply clean engine oil to the piston pin.
4. Install the piston pin until the pin contacts the clip
F MARK
as shown. If the pin cannot be installed easily,
heat the piston.
PROJECTION FOR ALIGNING

CONNECTIOG ROD BEARING
DPE110ZE1R18
01–10A–34
MECHANICAL [WL-3]
Piston Ring Assembly Note
1. Install the oil ring.
2. Install the second ring with tapered face side upward.
3. Install the top ring with tapered face side upward.
SECTION OF TOP RING
01
SECTION OF SECOND RING
DBG110AEBR96
Piston, Connecting Rod Assembly Note

1. Insert the piston and connecting rod assembly
into the cylinder with the F mark facing the front of
the engine.
2. Tighten the connecting rod cap nuts in two or
three steps. F MARK
Tightening torque
26.5—31.5 N·m {2.8—3.2 kgf·m, 20—23 ft·lbf}
3. Put a paint mark on each nut.
DBG110AEBR95
4. Using the marks as a reference, tighten the nuts

by turning each 82.5°—97.5°
End Of Sie
82.5°—97.5°
PAINT MARK
DBG110AEBR73
01–10A–35
MECHANICAL [WL-3]
CYLINDER BLOCK ASSEMBLY (II) [WL-3]
DCF011002000W11
8.8—12.7 N·m
{90—129 kgf·cm, 18.6—25.5 {1.9—2.6, 14—18}
78—112 in·lbf} 1
OIL
24.5—33.3 11
{2.5—3.3,
19—24}
4
OIL
5 2
6 3 OIL
R
SEALANT
R SST
10
OIL OIL 13 14
R 59—69
SST {6.1—7.0,
SST 44—50}
7.8—10.8 N·m 96.1—102.9 {9.8—10, 71—75}

{81—110 kgf·cm,
70—95 in·lbf}
18.6—25.5 {1.9—2.6, 14—18} R
16 7.8—9.8 N·m {80—99 kgf·cm,

70—86 in·lbf}
12 SST
OIL
18.6—25.5 {1.9—2.6, 14—18}
OIL
15 SEALANT R
SST
18.6—25.5 {1.9—2.6, 14—18}
9
17 SST SST
392—441 {40—44, 290—325}
SEALANT
7 8
7.8—10.8 N·m {80—110 kgf·cm,
70—95 in·lbf}
DBG110AEBR41
1 Oil pump body 11 Fuel injection pump

2 Control plunger 12 Timing gear
3 Plunger spring (See 01–10A–38 Timing Gear, Fuel Injection Pump
Gear Assembly Note.)
4 Plug
13 Fuel injection pump gear
5 Driven gear (See 01–10A–38 Timing Gear, Fuel Injection Pump
6 Oil pump cover Gear Assembly Note.)
(See 01–10A–37 Oil Pump Cover Assembly Note.) 14 Oil pump
7 Rear cover, end plate 15 Timing gear cover
(See 01–10A–37 Rear Cover, End Plate Assembly (See 01–10A–40 Timing Gear Cover Assembly
Note.) Note.)
8 End plate 16 Fuel injection pump pulley
(See 01–10A–37 Rear Cover, End Plate Assembly (See 01–10A–41 Fuel Injection Pump Pulley
Note.) Assembly Note.)
9 Flywheel 17 Crankshaft pulley
(See 01–10A–38 Flywheel Assembly Note.) (See 01–10A–41 Crankshaft Pulley Assembly
10 Timing gear case Note.)
(See 01–10A–38 Timing Gear Case Assembly
Note.)
01–10A–36
MECHANICAL [WL-3]
Oil Pump Cover Assembly Note
8 3
4
01
7
5
1 6
DBG110AEB053
Rear Cover, End Plate Assembly Note

1. Apply soapy water along the perimeter of the new oil seal.
2. Push the oil seal slightly in by hand.
3. Tap the oil seal in evenly by using the SST and a
hammer.
4. To ensure that the oil seal is installed correctly,
measure the distance between the end of the rear
cover and the face of the oil seal. 49 S011 103
Rear oil seal press-in amount

0—0.5 mm {0—0.01 in}
0—0.5 mm {0—0.01 in}
REAR OIL SEAL
DBG110BEB059
5. Apply silicone sealant to the rear cover as shown

in the figure. SEALANT
Thickness
φ2.0—3.0 mm {0.079—0.118 in}
DBG110AEBR55

in the figure.
Thickness
φ2.0—3.0 mm {0.079—0.118 in}
7. Install the end plate.

SEALANT
DBG110AEBR94
01–10A–37
MECHANICAL [WL-3]
Flywheel Assembly Note
1. Hold the crankshaft using the SST.
2. Tighten the bolts in the order shown in the figure.
KNOCK PIN
3 1
5 8
7 6
2 4
49 E011 1A0
DBG110AEB056
Timing Gear Case Assembly Note

1. Install the new O-ring.
2. Apply silicone sealant to the timing gear case as
shown in the figure. Do not apply sealant to the O- R
ring.
Thickness
φ2.0—3.0 mm {0.079—0.118 in}
SEALANT
DBG110AEBR57

1
6 5
2
4
DBG110AEBR58
Timing Gear, Fuel Injection Pump Gear Assembly Note

1. Put a paint mark on the chip cut gear of the fuel FUEL INJECTION
injection pump gear. PAINT MARK
PUMP GEAR
(HELICAL GEAR)
CHIP CUT
GEAR
SCISSORS GEAR
DBG110AEB9R3
01–10A–38
MECHANICAL [WL-3]
2. Put a paint mark on the 11th and 12th teeth of the CHIP CUT GEAR
helical gear counting clockwise from the chip cut
gear. FUEL
VIEW A
INJECTION
PUMP GEAR
2
1
1
01
.3 2
.. .
. .
..
.. 11
1211 12
VIEW A
PAINT MARK
DBG110AEBR83
3. Verify that the 11th and 12th teeth of fuel injection
pump gear (helical gear) and the teeth of the SCISSORS GEAR HELICAL GEAR
scissors gear are aligned, then put a paint mark
on the scissors gear.
11 TEETH
12 TEETH
PAINT MARK
DBG110AEBR82
approximately 30° BTDC (13 teeth on the gear). TDC
DBG110AEBR59
6. Align the timing marks. For the fuel injection pump gear, align the timing mark as shown in the figure (View A).
Note
• The helical gears except for the fuel injection pump gear have a punch mark as the timing mark. The
timing mark of each gear can be aligned easily if the paint mark is made on the punch mark.
VIEW A
TIMING MARK (WHITE PAINT)
FUEL INJECTION
PUMP GEAR VIEW A
No.2 IDLER
No.1 IDLER
CRANKSHAFT TIMING GEAR

DBG110AEBR60
01–10A–39
MECHANICAL [WL-3]
7. Remove the lock bolt.
LOCK BOLT
DBG110AEBR97
8. Tighten the bolts using the SST.
49 E011 1A0
DBG110AEB061
Timing Gear Cover Assembly Note

3. Tap the oil seal in evenly using the SST and a
hammer. 49 S010 301
measure the distance between the end of the
timing gear cover and the face of the oil seal.
Front oil seal press-in amount

0—0.4 mm {0—0.01 in}
Fuel injection pump oil seal press-in amount

49 F027 009
0—0.4 mm {0—0.01 in}
DBG110BEBR12
5. Apply silicone sealant to the timing gear cover as

SEALANT
Thickness
φ2.0—3.0 mm {0.079—0.118 in}
DBG110AEBR63
01–10A–40
MECHANICAL [WL-3]
11 1
10 4
5
6
7
01
9
8
3 2
DBG110AEBR64
Fuel Injection Pump Pulley Assembly Note

1. Install the fuel injection pump pulley using the
SST.
49 E011 1A0
DBG110AEB065
Crankshaft Pulley Assembly Note
Caution
• The CKP sensor plate is a very important
part for engine operation control; any
deformation of the plate may disable the PLATE
CRANKSHAFT
operation control. PULLEY
When disassembling/assembling the
crankshaft pulley, be very careful not to
deform the plate by interference with
other parts or improper handling.
DBG110AWB021
1. Install the crankshaft pulley using the SST.

End Of Sie
49 E011 1A0
DBG110AEB066
01–10A–41
MECHANICAL [WL-3]
CYLINDER BLOCK ASSEMBLY (III) [WL-3]
DCF011002000W12
R OIL
1
R 18.6—25.5 {1.9—2.6, 14—18}
R OIL
18.6—25.5 {1.9—2.6,
14—18}
2
7.9—10.8 N·m
{81—110 kgf·cm, 3 SEALANT
70—95 in·lbf}
4 29.4—41.2 {3.0—4.2, 22—30}

R
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf} N·m {kgf·m, ft·lbf}
DBG110AEBR90
1 Oil pipe 3 Oil pan

(See 01–10A–43 Oil Pipe Assembly Note.) (See 01–10A–43 Oil Pan Assembly Note.)
2 Oil strainer 4 Oil drain plug
01–10A–42
MECHANICAL [WL-3]
Oil Pipe Assembly Note
shown in the figure. 2
ENGINE
FRONT 01
1
3
DBG110AEBR89
Oil Pan Assembly Note

1. Apply silicone sealant to the oil pan as shown in
the figure. SEALANT
Thickness
φ2.0—3.0 mm {0.08—0.118 in}
DBG110AEBR87
2. Tighten the oil pan bolts A as shown in the figure.
Caution
• If the bolts are reused, remove the old DAMAGE
sealant from the bolt threads. Tightening
a bolt that has old sealant on it can cause
bolt hole damage.
3. Tighten the remaining oil pan bolts in several

OLD SEALANT
passes.
End Of Sie
CHU0111W004
01–10A–43
MECHANICAL [WL-3]
CYLINDER HEAD ASSEMBLY (I) [WL-3]
DCF011002000W13
SST 6
5
4
30—41 {3.1—4.1, 23—30}
R SST 3
1 7
OIL
2
DBG110AEBR27
1 Valve seal 5 Upper valve spring seat

(See 01–10A–44 Valve Seal Assembly Note.) 6 Valve keeper
2 Valve (See 01–10A–45 Valve Keeper Assembly Note.)
3 Lower valve spring seat 7 Pivot
4 Valve spring
Valve Seal Assembly Note

1. Assemble the SSTs so that depth L is as
specified. 49 L012 005
Depth L L
15.6 mm {0.614 in} 49 L012 001
2. Press the valve seal onto the valve guide by hand.

49 L012 002A 11.5 mm
{0.453 in}
49 L012 005
DPE110ZE1R26
01–10A–44
MECHANICAL [WL-3]
3. Tap the SST using a plastic hammer until its lower
end touches the cylinder head.
49 L012 001
49 L012 002A
VALVE SEAL
01
49 L012 005
VALVE GUIDE CYLINDER HEAD
DGB110AEB111
Valve Keeper Assembly Note

1. Install the valve keeper using the SST. 49 0636 100B
End Of Sie
49 B012 0A2
DBG110AEB029
01–10A–45
MECHANICAL [WL-3]
CYLINDER HEAD ASSEMBLY (II) [WL-3]
DCF011002000W14
11.27—14.21 N·m {115—144 kgf·cm,
100—125 in·lbf}
15.7—23.5 {1.7—2.3, 12—17}
5
9
6.5—9.0 N·m {67—91 kgf·cm,
58—79in·lbf} R
6 SEALANT
OIL 8
OIL
17.6—19.6 {1.8—1.9, 13—14}

SST
7 OIL
16—20
R {1.7—2.0, 12—14}
20—30 {2.1—3.0, 15—22}
OIL
29 {3.0, 21}
+ 90°—105°
+ 90°—105°
4
R 2 1 R
7.8—10.8 N·m {80—110 kgf·cm, 18.6—25.5 {1.9—2.6, 14—18}

70—95 in·lbf}
3
SEALANT
10
11
123—140 {13—14, 91—103} N·m {kgf·m, ft·lbf}
DBG110AEBR09
1 Cylinder head gasket 7 Rocker arm

(See 01–10A–47 Cylinder Head Gasket Assembly (See 01–10A–49 Rocker Arm Assembly Note.)
Note.) 8 Camshaft
2 Cylinder head 9 Camshaft cap
(See 01–10A–48 Cylinder Head Assembly Note.) (See 01–10A–49 Camshaft Cap Assembly Note.)
3 Blind cover 10 Seal plate
(See 01–10A–48 Blind Cover Assembly Note.) (See 01–10A–50 Seal Plate Assembly Note.)
4 Water outlet pipe 11 Camshaft pulley
5 ECT sensor (See 01–10A–50 Camshaft Pulley Assembly Note.)
6 Water temperature sender unit
(See 01–10A–48 Water Temperature Sender Unit
Assembly Note.)
01–10A–46
MECHANICAL [WL-3]
Cylinder Head Gasket Assembly Note
1. Measure the piston topping of all the cylinders.
TOPPING 01
CYLINDER PISTON
BLOCK
DPE110ZE1R02
2. Choose the gasket according to each measured

piston topping.
Cylinder head gasket select table
Cylinder head gasket
Piston topping (mm {in})
identification mark
0.205—0.325 {0.081—0.127}
IDENTIFICATION MARK
POSITION
0.265—0.385 {0.105—0.151}
DPE110ZE1R01
0.325—0.445 {0.128—0.175}
3. Apply silicone sealant to the cylinder block as

16.0 mm
Thickness {0.63 in}
φ2.0—3.0 mm {0.079—0.118 in} SEALANT 40.5 mm
{1.59 in} ENGINE
FRONT
48.5 mm
{1.91 in}
9.0 mm
{0.35 in}
DBG110AEBR17
01–10A–47
MECHANICAL [WL-3]
Cylinder Head Assembly Note
1. Before installing the cylinder head bolts, inspect their length. (See 01–10A–28 BOLT INSPECTION [WL-3].)
2. Apply clean engine oil to the threads and the seat face of each bolt and install them.
3. Tighten the cylinder head bolts in the order
indicated in the figure in several passes. 16 12 8 4 1 5 9 13 17 A
Tightening torque
29 N·m {3.0 kgf·m, 2.1 ft·lbf}
4. Retighten the bolts in the order shown in the

figure until all the bolts are tightened to 29 N·m
{3.0 kgf·m, 2.1 ft·lbf}.
15 11 7 3 2 6 10 14 18 A
DBG110AEB018

6. Using the marks as a reference, tighten the PAINT MARK
cylinder head bolts by turning each 90°—105° in 90°—105° 90°—105°
the order indicated in Step 3.
7. Further tighten each bolt by turning another 90°—
105° in the order indicated in Step 3.
8. Tighten the bolts A.
Tightening torque
17.6—19.6 N·m {1.8—1.9 kgf·m, 13—14 ft·lbf}
PAINT MARK
DBG110AEB019
Blind Cover Assembly Note

1. Apply silicone sealant to the blind cover as shown
in the figure. SEALANT
Thickness
φ1.5—2.5 mm {0.059—0.098 in}
DBG110AEBR23
Water Temperature Sender Unit Assembly Note

1. Apply silicone sealant to the thread of the water
temperature sender unit as shown in the figure.
3 PITCHES
SEALANT
DBG110AEB022
01–10A–48
MECHANICAL [WL-3]
Rocker Arm Assembly Note
1. If new rocker arm is used, set dimension A as
follows.
Dimension A
0.0—4.0 mm {0.0—0.15 in}
01
DBG110AEB030
Camshaft Cap Assembly Note

1. Apply silicone sealant to the front camshaft cap
SEALANT
mounting surfaces as indicated in the figure.
Avoid getting sealant onto the camshaft journal,
camshaft oil seal surface, and camshaft thrust
surface. ENGINE
FRONT
DBG110AEB031
2. Tighten the camshaft cap bolts gradually in three

or four steps in the order shown in the figure. 8 4 1 5 9
Caution
• Because there is little camshaft thrust
clearance, the camshaft must be held ENGINE
horizontally while it is installed. FRONT
Otherwise, excessive force will be
applied to the thrust area, causing burrs
on the thrust receiving area of the
cylinder head journal. To avoid this, the 7 3 2 6 10
following procedure must be observed.
DBG110AEB032
3. Apply soapy water along the perimeter of the new

oil seal.
5. Tap the oil seal lightly into the cylinder head
using the SST and a hammer.
6. To ensure that the oil seal is installed correctly, 49 S010 001
cylinder head and the face of the oil seal.
CYLINDER
HEAD 0.5—1.0 mm {0.02—0.03 in}
Camshaft oil seal press-in amount
0.5—1.0 mm {0.02—0.03 in}
HAMMER
OIL SEAL
DPE110ZE1R41
01–10A–49
MECHANICAL [WL-3]
Seal Plate Assembly Note
1. Tighten the seal plate bolts in the order indicated
in the figure.
3
DBG110AEB020
Camshaft Pulley Assembly Note

1. Install the camshaft pulley on the camshaft with
the knock pin fitted into the hole at the timing TIMING MARK
mark.
KNOCK PIN
Timing mark
WL
DBG110AEBR85
2. Hold the camshaft using a wrench on the cast hexagon and tighten the pully lock bolt.
Caution
• Do not move the camshaft from this
position because it can cause the valve
and piston to contact each other and
damage them.
End Of Sie
DBG110AEB021
01–10A–50
MECHANICAL [WL-3]
TIMING BELT ASSEMBLY [WL-3]
DCF011002000W15
4.9—8.8 N·m {50—90 kgf·cm, 44—78 in·lbf}
5 01
R
18.6—25.5 {1.9—2.6, 14—18}
SEALANT
7
OIL
6
1
7.8—10.8 N·m {80—110 kgf·cm,

70—95 in·lbf} 3
2
37—52 {3.8—5.3, 28—38}
18.6—25.5 {1.9—2.6, 14—18}
R
4 N·m {kgf·m, ft·lbf}
DBG110AEBR07
1 Timing belt 4 Timing belt cover

(See 01–10A–52 Timing Belt, Tensioner, Tensioner (See 01–10A–52 Timing Belt Cover Assembly
Spring Assembly Note.) Note.)
2 Tensioner, tensioner spring 5 Cylinder head cover
(See 01–10A–52 Timing Belt, Tensioner, Tensioner (See 01–10A–52 Cylinder Head Cover Assembly
Spring Assembly Note.) Note.)
3 Pulley plate 6 Vacuum pump
7 Water pump
01–10A–51
MECHANICAL [WL-3]
Timing Belt, Tensioner, Tensioner Spring Assembly Note
Caution
• Overtensioning of the timing belt can cause breakage of the belt and the camshaft.
1. Align the timing marks as shown in the figure. TENSIONER TIMING MARK
2. Verify that the fuel injection pump attaching bolts LOCK BOLT CAMSHAFT
and nuts are tightened to the specified torque. PULLEY
This must be done to prevent overtensioning of
the timing belt after it has been installed.
3. Install the timing belt.
4. Install the tensioner, tensioner spring, and the TENSIONER
lock bolt. SPRING
5. Tighten the tensioner lock bolt. TIMING TENSIONER
6. Turn the crankshaft clockwise twice, and align the MARK
timing marks. If they are not aligned, remove the FUEL INJECTION PUMP
PULLEY
timing belt and repeat from Step 1.
DBG110AEBR11
7. Loosen the tensioner lock bolt to apply tension to
the belt. Do not apply tension other than that of
the tensioner spring.
8. Tighten the tensioner lock bolt. Be sure the tensioner does not move together with the bolt rotation.
Timing Belt Cover Assembly Note
1. Tighten the timing belt cover bolts in the order
3
4
5
6
DBG110AEB012
Cylinder Head Cover Assembly Note

1. Before installing the cylinder head cover, inspect the valve clearance. (See 01–10A–29 VALVE CLEARANCE
INSPECTION [WL-3].)
2. Apply silicone sealant to the cylinder head as
shown. SEALANT
SEALANT
DBG110AEB013
3. Tighten cylinder head cover bolts A and B.
Tightening torque 13
1.5—2.9 N·m {16—29 kgf·cm, 14—25 in·lbf} 8 9 10 11 12 1 A
4. Tighten the cylinder head cover bolts in the order

shown in the figure. ENGINE
FRONT
Tightening torque
7 6 5 4 3 2 B
4.9—8.8 N·m {50—89 kgf·cm, 44—77 in·lbf}
End Of Sie DBG110AEBR14
01–10A–52
MECHANICAL [WL-C, WE-C]
01–10B MECHANICAL [WL-C, WE-C]

ENGINE MOUNTING [WL-C, WE-C] . . . 01–10B–2 PISTON RING CLEARANCE
ENGINE DISMOUNTING INSPECTION [WL-C, WE-C] . . . . . . . . . 01–10B–26
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–3 PISTON PIN CLEARANCE
TIMING BELT DISASSEMBLY INSPECTION [WL-C, WE-C] . . . . . . . . . 01–10B–26
01
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–4 CRANKSHAFT INSPECTION
CYLINDER HEAD DISASSEMBLY(I) [WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . . 01–10B–27
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–6 CRANKSHAFT OIL CLEARANCE
CYLINDER HEAD DISASSEMBLY (II) INSPECTION/REPAIR
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–8 [WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . . 01–10B–28
CYLINDER BLOCK DISASSEMBLY (I) CRANKSHAFT END PLAY
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–9 INSPECTION/REPAIR
CYLINDER BLOCK DISASSEMBLY (II) [WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . . 01–10B–28
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–10 CONNECTING ROD
CYLINDER BLOCK DISASSEMBLY (III) INSPECTION [WL-C, WE-C] . . . . . . . . . 01–10B–29
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–15 CONNECTING ROD OIL CLEARANCE
CYLINDER HEAD INSPECTION/REPAIR INSPECTION/REPAIR
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–16 [WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . . 01–10B–29
VALVE INSPECTION [WL-C, WE-C] . . . 01–10B–17 CONNECTING ROD SIDE CLEARANCE
VALVE GUIDE INSPECTION INSPECTION [WL-C, WE-C] . . . . . . . . . 01–10B–29
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–18 PISTON AND CONNECTING
VALVE GUIDE REPLACEMENT ROD INSPECTION [WL-C, WE-C] . . . . . 01–10B–30
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–18 BALANCE SHAFT INSPECTION
VALVE SEAT INSPECTION/REPAIR [WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . . 01–10B–30
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–19 BOLT INSPECTION [WL-C, WE-C] . . . . . 01–10B–31
VALVE SPRING INSPECTION VALVE CLEARANCE INSPECTION
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–20 [WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . . 01–10B–31
CAMSHAFT INSPECTION VALVE CLEARANCE ADJUSTMENT
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–20 [WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . . 01–10B–32
CAMSHAFT OIL CLEARANCE GEAR CLEARANCE INSPECTION
INSPECTION [WL-C, WE-C]. . . . . . . . . 01–10B–21 [WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . . 01–10B–33
CAMSHAFT END PLAY INSPECTION PLUNGER SPRING INSPECTION
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–21 [WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . . 01–10B–33
CYLINDER BLOCK CYLINDER BLOCK ASSEMBLY (I)
INSPECTION/REPAIR [WL-C, WE-C] . 01–10B–22 [WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . . 01–10B–34
DUAL-MASS FLYWHEEL CYLINDER BLOCK ASSEMBLY (II)
OIL JET VALVE, NOZZLE CYLINDER BLOCK ASSEMBLY (III)
PISTON INSPECTION CYLINDER HEAD ASSEMBLY (I)
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–25 [WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . . 01–10B–45
PISTON CLEARANCE CYLINDER HEAD ASSEMBLY (II)
INSPECTION/REPAIR [WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . . 01–10B–47
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–10B–25 TIMING BELT ASSEMBLY
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . . 01–10B–51
End of Toc
01–10B–1
ENGINE MOUNTING [WL-C, WE-C]
DCF011002000W16
1. Install the SST to the cylinder head using the bolt
(99784 1020 or M10X1.25, 8T, length 20mm 303-050
{0.79 in}) as shown in the figure. (49 UN30 3050)
Tightening torque
43.1—60.8 N·m {4.40—6.10 kgf·m, 31.8—44.8 BOLT
ft·lbf}
DBG110BWB90
2. Suspend the engine using the SST.

49 L017 5A0
303-050
(49 UN30 3050)
DBG110BWB89
3. Install the SST (arms) to the holes as shown in

49 L010 102
the figure, and hand tighten the SST (bolts).
49 L010 107
49 L010 106
DBG110AEB002
4. Assemble the SSTs (bolts, nuts and plate) to the

specified positions. 49 L010 101
49 L010 105 49 L010 104

DBG110AEB003
01–10B–2
5. Adjust the SST (bolts) so that 20 mm {0.79 in} or
more of thread is exposed. PARALLEL
6. Align the SSTs (plate and arms) so that they are 49 L010 101
parallel by adjusting the SSTs (bolts and nuts). 49 L010 102
7. Tighten the SSTs (bolts and nuts) to affix the SST
firmly. 49 L010 105 01
ENGINE
49 L010 104 49 L010 103 APPROX. 20 mm {0.79 in}
DBG110AEB105
8. Mount the engine on the SST (engine stand).

49 0107 680A
Warning
• The self-locking brake system for the
engine stand may not operate if the
engine is held in an unbalanced position.
This could lead to sudden, rapid
movement of the engine and mounting
stand handle and cause serious injury.
Never hold the engine in an unbalanced
position, and always grasp the rotating
handle firmly when turning the engine.
DBG110AEB004
9. Remove the SST (303-050 (49 UN30 3050)).

10. Drain the engine oil into a container.
11. Install the drain plug using new washer.
Tightening torque
29.4—41.2 N·m {3.0—4.2 kgf·m, 22—30 ft·lbf}
End Of Sie
ENGINE DISMOUNTING [WL-C, WE-C]
DCF011002000W17
1. Dismount in the reverse order of mounting.
End Of Sie
01–10B–3
TIMING BELT DISASSEMBLY [WL-C, WE-C]
DCF011002000W18
2
5
6
3
DBG110BEB014
1 Water pump 5 Idler

2 Vacuum pump 6 Timing belt
3 Timing belt cover (See 01–10B–5 Timing Belt Disassembly Note.)
4 Tensioner 7 Injector
(See 01–10B–5 Tensioner Disassembly Note.) 8 Cylinder head cover
01–10B–4
Tensioner Disassembly Note
1. Turn the crankshaft clockwise and align the timing INTAKE
marks as shown in the figure. EXHAUST
CAMSHAFT CAMSHAFT
PULLEY PULLEY
01
TIMING TIMING MARK

MARK
SUPPLY PUMP PULLEY

DBG110BWB98
2. Turn the auto tensioner counterclockwise using

an Allen wrench. (Rotate the auto tensioner with a C
force of 39 N·m {4.0 kgf·m, 28.8 ft·lbf} or less.) B
3. Insert a fixing pin of approx. 6 mm {0.24 in}
diameter into hole A to secure the auto tensioner.
4. Remove the bolts in the order of B and C, then
remove the auto tensioner.
Note 39 N·m {4.0 kgf·m, 28.8 ft·lbf}

• If the rod projects suddenly while removing MAX.
the auto tensioner, the air flows into the A
pressure chamber and the rod could move
DBG110BEB033
slightly. If this occurs, bleed the air from the
pressure chamber using the following
procedure.
5. Assemble the auto tensioner to the engine.

6. Turn the auto tensioner with a force of 39 N·m
{4.0 kgf·m, 28.8 ft·lbf} or less using an Allen ALLEN
wrench, then turn it back slowly. Repeat this WRENCH RETURN IT
SLOWLY
procedure several times.
7. Verify that the rod has resistance when it is in the
most projected position. If there is no resistance,
repeat the above procedure.
REPEAT
39 N·m SEVERAL
{4.0 kgf·m, TIMES ALLEN
28.8 ft·lbf} MAX. WRENCH
DBG110BWB999
Timing Belt Disassembly Note
Caution
• The following will damage the timing belt and shorten its life; forcefully twisting it, turning it inside
out, or getting oil or grease on it.
• After removing the timing belt, do not move the crankshaft and/or camshaft pulley from this
position because it can cause the valve and piston to contact and damage them.
1. Mark the timing belt rotation on the belt for proper

reinstallation.
End Of Sie
NG NG
ROTATION
ARROW
NG
30 mm {1.2 in } MIN.
DBG110BWB003
01–10B–5
CYLINDER HEAD DISASSEMBLY(I) [WL-C, WE-C]
DCF011002000W19
.
R
5
6
R
1
R
8
R
DBG110BEB062
1 Camshaft pulley 5 Camshaft cap Lower

(See 01–10B–7 Camshaft Pulley Disassembly 6 ECT sensor
Note.)
7 Cylinder head
2 Seal plate (See 01–10B–7 Cylinder Head Disassembly Note.)
3 Camshaft cap upper 8 Cylinder head gasket
(See 01–10B–7 Camshaft Cap Upper Disassembly
Note.)
4 Camshaft
01–10B–6
Camshaft Pulley Disassembly Note
1. Hold the camshaft using a wrench on the cast hexagon.
Caution
01
CAMSHAFT PULLEY
damage them.
DBG110BEB082
Camshaft Cap Upper Disassembly Note

1. Loosen the camshaft cap bolts in three or four
6 5 14 13 19 20 11 12
steps in the order shown in the figure. 4
1
7 8 15 16 18 17 10 9
DBG110BEB083
Camshaft Disassembly Note

1. Before removing the camshaft, inspect the camshaft oil clearance. (See 01–10B–21 CAMSHAFT OIL
CLEARANCE INSPECTION [WL-C, WE-C].)
Cylinder Head Disassembly Note

1. Remove bolts A.
2. Loosen the cylinder head bolts in two or three
steps in the order shown in the figure. 3 7 11 15 18 14 10 6 2 A
End Of Sie
4 8 12 16 17 13 9 5 1 A
DBG110BEB084
01–10B–7
CYLINDER HEAD DISASSEMBLY (II) [WL-C, WE-C]
DCF011002000W20
SST 4
1
5
2
6
10
R
SST 8
9
R
7
DBG110BEB016
1 Rocker arm 6 Valve spring

2 Pivot 7 Valve
3 Valve cap 8 Valve seal
4 Valve keeper (See 01–10B–9 Valve Seal Disassembly Note.)
(See 01–10B–8 Valve Keeper Disassembly Note.) 9 Lower valve spring seat
5 Upper valve spring seat 10 Water outlet pipe
Valve Keeper Disassembly Note

1. Remove the valve keeper using the SST.
49 0636 100B
49 B012 0A2
DBG110BEB011
01–10B–8
Valve Seal Disassembly Note
1. Remove the valve seal using the SST.
End Of Sie
49 S120 170 01
VALVE SEAL
VALVE GUIDE
DBG110BEB085
CYLINDER BLOCK DISASSEMBLY (I) [WL-C, WE-C]

DCF011002000W21
R 3
R
1
DBG110BEB075
1 Oil drain plug 3 Oil strainer

2 Oil pan 4 Oil pipe
(See 01–10B–10 Oil Pan Disassembly Note.)
01–10B–9
Oil Pan Disassembly Note
1. Remove the oil pan using a separator tool.
End Of Sie
SEPARATOR TOOL
DBG110BEB086
CYLINDER BLOCK DISASSEMBLY (II) [WL-C, WE-C]

DCF011002000W22
19
13
16
15 18
14 8
17
9
SST
6 R
5
SST
3 R
7 SST
R
4
1 2 10
SST SST
12
11
DBG110BEB019
01–10B–10
1 Crankshaft pulley 9 Timing gear case
(See 01–10B–11 Crankshaft Pulley Disassembly (See 01–10B–14 Timing Gear Case Disassembly
Note.) Note.)
2 Seal plate 10 Dual-mass flywheel
3 Supply pump pulley
(See 01–10B–11 Supply Pump Pulley Disassembly
(See 01–10B–14 Dual-mass flywheel Disassembly
Note.)
01
Note.) 11 End plate
4 Timing gear cover 12 Rear cover
(See 01–10B–11 Timing Gear Cover Disassembly (See 01–10B–14 Rear Cover Disassembly Note.)
Note.) 13 Seal plate
5 Oil pump 14 Oil pump cover
6 Supply pump gear 15 Driven gear
(See 01–10B–12 Supply Pump Gear Disassembly
Note.) 16 Plug
7 Timing gear 17 Plunger spring
8 Supply pump 18 Control plunger
19 Oil pump body
Crankshaft Pulley Disassembly Note

1. Remove the crankshaft pulley using the SST.
49 E011 1A0
DBG110BEB064
Supply Pump Pulley Disassembly Note

1. Remove the supply pump pulley using the SST.
49 E011 1A0
DBG110BEB055
Timing Gear Cover Disassembly Note

1. Remove the timing gear cover using a separator
tool.
SEPARATOR TOOL
DBG110BEB087
01–10B–11
with a rag,
RAG
DBG110BEB088
Supply Pump Gear Disassembly Note

approximately 30° BTDC (about 13 teeth on the TDC
gear).
DBG110BEB089
3. Verify that the end-gap (V groove) of the timing

gear case and the chip cut gear of the fuel GEAR CASE (V GROOVE)
VIEW A
injection pump gear are aligned.
Note SUPPLY
• If the chip cut gear is hard to find, move the PUMP GEAR
supply pump gear on notch back and forth,
then check the chip cut gear.
VIEW A
No.2 IDLER
SUPPLY CHIP CUT GEAR
PUMP GEAR
(HELICAL GEAR)
ABOUT 0.5 mm
{0.02 in}
ABOUT 3.0 mm
{0.12 in}
SCISSORS GEAR
DBG110BEB90
01–10B–12
4. Fix the scissors gear to the supply pump gear using a lock bolt (M6×1.0; length under the bolt head is
approximately 16 mm {0.63 in}).
Warning
• When removing the supply pump gear, be sure to secure the scissors gear to the supply pump
gear using a lock bolt (M6×1.0; length under the bolt head is approximately 16 mm {0.63 in}).
01
Otherwise, the scissors gear will rotate with the spring force, causing personal injury.
Caution
• When removing the supply pump gear, be sure to secure the scissors gear to the supply pump
gear using a look bolt (M6×1.0; length under the bolt head is approximately 16 mm {0.63 in}) to
prevent the scissors gear form rotating with the spring force. Otherwise, the scissors gear will not
align with the supply pump gear, and the supply pump gear with the scissors gear will not engage
with the idler gear.
Note
LOCK BOLT
• The supply pump gear with a scissors
gear has a lock bolt hole.
DBG110BEB091
5. Hold the crankshaft using the SST and loosen the

gear nut.
GEAR NUT
49 E011 1A0
DBG110BEB092
6. Remove the supply pump gear using the SST and

bolt (M6X1.0, Length 30mm {1.18 in}).
BOLT
49 S019 005
DBG110BEB093
01–10B–13
Timing Gear Case Disassembly Note
1. Remove the timing gear case using the separator
tool.
SEPARATOR TOOL
DBG110BEB094
Dual-mass flywheel Disassembly Note

1. Remove the Dual-mass flywheel using the SST.
KNOCK PIN
3 1
5 8
49 E011 1A0
7
6
2 4
DBG110BEB034
Rear Cover Disassembly Note

with a rag.
End Of Sie
RAG
DBG110BEB095
01–10B–14
CYLINDER BLOCK DISASSEMBLY (III) [WL-C, WE-C]
DCF011002000W23
6 4
01
SST 7
8
9
10 16
5
14
1
13
15
12
11
DBG110BEB021
1 Balance shaft 9 Piston

2 Connecting rod cap 10 Connecting rod
(See 01–10B–16 Connecting Rod Cap Disassembly 11 Main bearing cap
Note) (See 01–10B–16 Main Bearing Cap Disassembly
3 Lower connecting rod bearing Note)
4 Piston, connecting rod 12 Lower main bearing, lower thrust bearing
(See 01–10B–16 Piston, Connecting Rod 13 Crankshaft
Disassembly Note) (See 01–10A–16 Crankshaft Disassembly Note)
5 Upper connecting rod bearing 14 Upper main bearing, upper thrust bearing
6 Piston ring 15 Oil jet valve, nozzle
7 Piston pin clip 16 Cylinder block
8 Piston pin
(See 01–10B–16 Piston Pin Disassembly Note)
01–10B–15
Connecting Rod Cap Disassembly Note
1. Before removing the connecting rod cap, inspect the connecting rod side clearance. (See 01–10B–29
CONNECTING ROD SIDE CLEARANCE INSPECTION [WL-C, WE-C].)
Piston, Connecting Rod Disassembly Note

1. Before removing the piston and connecting rod, inspect the connecting rod oil clearance. (See 01–10B–29
CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR [WL-C, WE-C].)
2. Inspect the oscillation torque. (See 01–10B–30 PISTON AND CONNECTING ROD INSPECTION [WL-C, WE-
C].)
Piston Pin Disassembly Note

1. Remove the piston pin using the SST.
49 G011 001
DBG110BEB096
Main Bearing Cap Disassembly Note

1. Before removing the main bearing cap, inspect the crankshaft end play. (See 01–10B–28 CRANKSHAFT END
PLAY INSPECTION/REPAIR [WL-C, WE-C].)
2. Loosen the main bearing cap bolts in two or three 3 7 10 6 2
steps in the order shown in the figure.
4 8 9 5 1
DBG110BEB079
Crankshaft Disassembly Note

1. Before removing the crankshaft, inspect the main journal oil clearance. (See 01–10B–28 CRANKSHAFT OIL
CLEARANCE INSPECTION/REPAIR [WL-C, WE-C].)
End Of Sie
CYLINDER HEAD INSPECTION/REPAIR [WL-C, WE-C]
DCF011010100W02
1. Inspect the cylinder head surface for cracks. Replace the cylinder head if necessary.
2. Inspect for the following and repair or replace.
(1) Sunken valve seats
(2) Excessive camshaft oil clearance and end play
3. Measure the cylinder head for distortion in the
seven directions as shown in the figure. Y

X distortion: 0.02 mm {0.0008 in} max.
Y distortion: 0.05 mm {0.0020 in} max.
4. If the cylinder head distortion exceeds the

maximum, replace the cylinder head. Do not
attempt to repair a cylinder head by milling or
grinding. X
DBG110BEB080
01–10B–16
5. Measure the manifold contact surface distortion as shown in the figure.
Maximum manifold contact surface distortion

0.05 mm {0.002 in} max.
6. If the distortion exceeds the maximum, grind the

01
surface or replace the cylinder head.
Maximum manifold contact surface grinding

0.15 mm {0.0059 in} max.
End Of Sie
DBG110BEB140
VALVE INSPECTION [WL-C, WE-C]

DCF011012111W04
1. Measure the valve head margin thickness of each
valve. Replace the valve if necessary.
THICKNESS
IN: 1.55—1.85 mm {0.061—0.072 in}
EX: 1.80—2.10 mm {0.070—0.082 in}
2. Measure the length of each valve. Replace the

valve if necessary.
LENGTH
IN: 111.65—112.25 mm {4.394—4.413 in}
DBG110BEB098
EX: 111.6—112.2 mm {4.390—4.409 in}

IN: 111.50 mm {4.390 in}
EX: 111.45 mm {4.388 in}
3. Measure the stem diameter of each valve in the X

and Y directions at the three points (A, B, and C) X
shown in the figure. Replace the valve if
necessary. Y
Standard valve stem diameter A

IN: 5.970—5.985 mm {0.2350—0.2356 in}
EX: 5.965—5.980 mm {0.2348—0.2354 in} B
Minimum valve stem diameter C

IN: 5.920 mm {0.2330 in}
EX: 5.915 mm {0.2328 in}
DBG110BEB099
End Of Sie
01–10B–17
VALVE GUIDE INSPECTION [WL-C, WE-C]
DCF011010280W03
1. Measure the inner diameter of each valve guide in
X
the X and Y directions at the three points (A, B,
and C) shown in the figure. Replace the valve Y
guide if necessary.
A
Standard valve guide inner diameter
6.025—6.045 mm {0.2372—0.2379 in}
B
DBG110BEB100
2. Measure the protrusion height (dimension A) of

each valve guide without lower valve spring seat.
Replace the valve guide if necessary.

A
IN: 15.0—15.5 mm {0.59—0.61 in}
EX: 17.0—17.5 mm {0.67—0.69 in}
End Of Sie
DBG110BEB101
VALVE GUIDE REPLACEMENT [WL-C, WE-C]

DCF011010280W04
Valve Guide Removal
• Remove the valve guide from the combustion
chamber side using the SST. 49 B012 015
VALVE GUIDE
DBG110BEB102
Valve Guide Installation

1. Mark the dimension L position on the valve guide.
VALVE GUIDE
Depth L
IN: 15.0—15.5 mm {0.59—0.61 in} L
EX: 17.0—17.5 mm {0.67—0.68 in}
THE CYLINDER HEAD SIDE
DBG110BEB110
01–10B–18
2. When the valve guide nears the dimension L
position while it is being tapped in, verify the 49 B012 015
dimension L position again with vernier calipers to
prevent deviation in insertion.
3. Verify that the valve guide projection height is
within the specification.
01
VALVE GUIDE
IN: 15.0—15.5 mm {0.59—0.61 in}
EX: 17.0—17.5 mm {0.67—0.68 in}
L
End Of Sie DBG110BEB045
VALVE SEAT INSPECTION/REPAIR [WL-C, WE-C]

DCF011010102W02
1. Measure the seat contact width. If necessary,
resurface the valve seat using a 45° valve seat
cutter and/or resurface the valve face.

1.3—1.9 mm {0.052—0.074 in} SEAT CONTACT
WIDTH
DBG110AEB109
2. Verify that the valve seating position is at the center of the valve face.
1. If the seating position is too high, correct the valve seat using a 60° cutter, and then a 45° cutter.
2. If the seating position is too low, correct the
valve seat using a 30° cutter, and a 45° cutter.
IN EX
Valve seat angle
IN: 45°
EX: 45° 60°
60°
45°
45°
30°
30°
DBG110AEB078
3. Measure the receded amount from the cylinder

head surface. If it exceeds the maximum, replace
the cylinder head.

IN: 0.79—1.27 mm {0.039—0.050 in}
EX: 0.84—1.32 mm {0.033—0.051 in}

IN: 1.68 mm {0.066 in}
EX: 1.73 mm {0.062 in}
DBG110AEB112
End Of Sie
01–10B–19
VALVE SPRING INSPECTION [WL-C, WE-C]
DCF011012125W02
1. Apply a pressing force to the pressure spring and
check the spring height. Replace the valve spring
if necessary.
Valve spring installation pressing force

172.9—195.6 N {15.67—17.74 kgf, 34.48—
39.02 lbf}
Valve spring installation height

39.0 mm {1.53 in}
DBG0110AEB11
2. Measure the amount the valve spring is out-of-

square. Replace the valve spring if necessary.
Maximum valve spring out-of-square

2.0° (1.60mm {0.062 in})
End Of Sie
DBG110AEB079
CAMSHAFT INSPECTION [WL-C, WE-C]

DCF011012420W04
1. Set the No.1 and No.5 journals on V-blocks.
Measure the camshaft runout. Replace the
camshaft if necessary.
Maximum camshaft runout

0.03 mm {0.001 in} max.
DBG110AEB114
2. Measure the cam lobe height at the two points as

shown in the figure. Replace the camshaft if
necessary.

IN: 42.067—42.167 mm {1.6561—1.6601 in}
EX: 41.949—42.049 mm {1.6515—1.6554 in}

IN: 41.717 mm {1.6424 in}
EX: 41.599 mm {1.6377 in}
DBG110AEB080
01–10B–20
directions at the two points (A and B) as shown in
the figure. Replace the camshaft if necessary.
B
No.1: 31.940—31.965 mm {1.2575—1.2582 A 01
in}
No.2—No.4: 25.910—25.935 mm {1.0201— X
Y
1.0210 in}
No.5: 25.940—25.965 mm {1.0212—1.0222 Y
in} X
DBG110AEB081
No.1: 31.890 mm {1.2555 in}
No.2—No.4: 25.860 mm {1.0181 in}
No.5: 25.890 mm {1.0193 in}
End Of Sie
CAMSHAFT OIL CLEARANCE INSPECTION [WL-C, WE-C]
DCF011012420W05
2. Install the camshaft cap. (See 01–10B–49 Camshaft Cap Upper Assembly Note.)
3. Remove the camshaft cap. (See 01–10B–7 Camshaft Cap Upper Disassembly Note.)
4. Measure the oil clearance. Replace the cylinder
head if necessary.

No.1: 0.035—0.081 mm {0.0014—0.0031 in}
No.2—4: 0.065—0.111 mm {0.0026—0.0043
in}
No.5: 0.056—0.081 mm {0.0014—0.0031 in} PLASTIGAUGE

No.1: 0.12 mm {0.0047 in}
No.2—4: 0.15 mm {0.0059 in}
DBG110BEB053
No.5: 0.16 mm {0.0063 in}
End Of Sie
CAMSHAFT END PLAY INSPECTION [WL-C, WE-C]
DCF011012420W06
1. Install the camshaft cap. (See 01–10B–49 Camshaft Cap Upper Assembly Note.)
2. Measure the camshaft end play. Replace the
cylinder head or camshaft if necessary.
Standard camshaft end play

0.030—0.160 mm {0.0012—0.0062 in}
Maximum camshaft end play

0.20 mm {0.0078 in}
3. Remove the camshaft cap. (See 01–10B–7

Camshaft Cap Upper Disassembly Note.)
End Of Sie DBG110BEB109
01–10B–21
CYLINDER BLOCK INSPECTION/REPAIR [WL-C, WE-C]
DCF011010300W02
1. Measure the distortion of the cylinder block top
surface in the seven directions as shown in the Y
figure. Replace if necessary.

DBG110AEB115
2. Measure the cylinder bore using the cylinder gauge. Measurement positions are in the X and Y directions at 83
mm {3.27 in} (WL-C) or 88 mm {3.46 in} (WE-C) below the top surface of the cylinder.
• If the cylinder bore exceeds the wear limit,
X
replace the cylinder block or rebore the
cylinder and install the oversized pistons so
that the specified piston-to-cylinder clearance WL-C 83.0 mm {3.27 in} Y
is obtained. WE-C 88.0 mm {3.46 in}
Note
• Base the boring diameter on the diameter of
an oversized piston. All cylinders must be
the same diameter.
Cylinder bore size [WL-C]

DBG110BEB047
Standard: 93.000—93.022 mm {3.6615—
3.6622 in}
0.25 {0.01} oversize: 93.250—93.272 mm {3.6713—3.6721 in}
0.50 {0.02} oversize: 93.500—93.522 mm {3.6811—3.6819 in}
Cylinder bore size [WE-C]

Standard: 96.000—96.022 mm {3.6615—3.6622 in}
0.25 {0.01} oversize: 96.250—96.272 mm {3.7893—3.7902 in}
0.50 {0.02} oversize: 96.500—96.522 mm {3.7992—3.8000 in}
Cylinder bore wear limit

0.15 mm {0.0059 in}
End Of Sie
DUAL-MASS FLYWHEEL INSPECTION [WL-C, WE-C]
DCF011011500W01
Caution
• Do not rework the flywheel if it is distorted.
• Do not clean the dual mass flywheel with any kind of fluid. Clean the flywheel with a dry cloth only.
• Do not clean the gap between the primary and secondary mass. Only clean the bolt connection
surface and the clutch surface.
Note
• Correct slight scratches and discoloration
using sandpaper.
• Inspect the runout of the surface that
contacts the clutch disc with the flywheel
installed to the crankshaft.
1. Inspect the flywheel.
— Cracks
— Worn ring gear teeth
— Chipped or cracked ring gear teeth
— Surface that contacts the clutch disc for
scratches, nicks, and discoloration.
• If there is any malfunction, replace the C3U0510W004
flywheel.
01–10B–22
2. Verify that the center of the flywheel does not move.
(1) Rotate the flywheel or attempt to move it up
and down, and left and right to verify that the
center of the flywheel does not move.
• If there is any movement as indicated by
the arrows in the figure, replace the
01
flywheel with a new one.
B3E0510W055
3. Verify that the secondary mass rotates by 15

teeth or more.
• If it rotates by 15 teeth or more, replace the
dual-mass flywheel.
D3E510ZW8001
4. Inspect for locating dowels touching the primary

mass of the flywheel.
Caution
• Make sure that the three locating dowels
are installed.
• If the locating dowels are touching the primary

mass of the flywheel, replace the flywheel
with a new one.
5. Visually inspect the secondary mass.
• If there is any damage, replace the dual-mass
B3E0510W056
flywheel.
6. Visually inspect the ring gear on the dual-mass
flywheel. RING GEAR
• If there is any damage, replace the dual-mass
flywheel.
D3E510ZW8002
01–10B–23
7. Inspect the welded area of the dual-mass
flywheel for grease leakage.
• If there is grease leakage, replace the dual-
mass flywheel.
B3E0510W057
8. Inspect the dual-mass flywheel runout.
Flywheel maximum runout

1.5 mm {0.059 in}
• If it is more than the maximum specification,

replace the dual-mass flywheel.
D3E510ZW8007
9. Inspect the dual-mass flywheel for the amount of

guide pin projection.
• If not within the specification, replace the
dual-mass flywheel.
11mm {0.4330}
D3E510ZW8005
10. Rotate the secondary mass left and right and

verify that it rotates within a range of five teeth
without resistance.
• If there is any malfunction, replace the dual-
mass flywheel.
11. Inspect the dual-mass flywheel for cracks.
• If there are cracks, replace the dual-mass
flywheel.
End Of Sie
D3E510ZW8006
01–10B–24
OIL JET VALVE, NOZZLE INSPECTION [WL-C, WE-C]
DCF011010730W02
1. Apply compressed air to oil jet valve A and verify that air passes through oil jet valve B. If not, replace the oil jet
valve.
Oil jet air pressure 01

137.6—196.4 kPa {1.4—2.0 kgf/cm2, 20—28 psi}
2. Check the oil jet nozzle for clogs. Replace the

nozzle if necessary. A
End Of Sie
DBG110AEB085
PISTON INSPECTION [WL-C, WE-C]

DCF011011010W06
1. Measure the outer diameter of each piston at right angle (90°) to the piston pin, 20 mm {0.79 in} below the oil
ring land lower edge.
Piston diameter [WL-C]

Standard: 92.918—92.944 mm {3.6582—
3.6592 in}
0.25 {0.010} oversize: 93.153—93.179 mm
{3.6675—3.6684 in}
0.50 {0.020} oversize: 93.403—93.429 mm
{3.6773—3.6782 in}
20 mm
Piston diameter [WE-C] {0.79 in}
Standard: 95.918—95.944 mm {3.7763—
3.7773 in}
DBG110AEBR86
0.25 {0.010} oversize: 96.153—96.179 mm
{3.7856—3.7865 in}
0.50 {0.020} oversize: 96.403—96.429 mm {3.7954—3.7964 in}
End Of Sie
PISTON CLEARANCE INSPECTION/REPAIR [WL-C, WE-C]
DCF011011010W07
1. Measure the piston-to-cylinder clearance. Replace the piston or rebore the cylinders to fit the oversized piston
if necessary.
Standard piston clearance

0.071—0.089 mm {0.0015—0.0022 in}
Maximum piston clearance

0.15 mm {0.0059 in}
2. If the piston is replaced, the piston rings must also be replaced.

End Of Sie
01–10B–25
PISTON RING CLEARANCE INSPECTION [WL-C, WE-C]
DCF011011010W08
1. Measure the piston ring-to-ring land clearance
around the entire circumference. Replace the
piston and piston ring if necessary.
Standard piston ring clearance [WL-C]

Top: 0.06—0.10 mm {0.0024—0.0039 in}
Second: 0.04—0.08 mm {0.0016—0.0031 in}
Oil: 0.02—0.06 mm {0.0012—0.0023 in}
Standard piston ring clearance [WE-C]

Top: 0.06—0.10 mm {0.0024—0.0039 in}
Second: 0.04—0.08 mm {0.0016—0.0031 in}
DBG110AEB116
Oil: 0.02—0.06 mm {0.0008—0.0023 in}
Maximum piston ring clearance

0.15 mm {0.0059 in}
2. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel.
3. Measure each piston ring end gap with a feeler
gauge. Replace the piston ring, if necessary.
Standard piston ring end gap [WL-C]

Top: 0.22—0.32 mm {0.0087—0.0125 in}
Second: 0.49—0.64 mm {0.0193—0.0251 in}
Oil: 0.22—0.52 mm {0.0087—0.0204 in}
PISTON
Standard piston ring end gap [WE-C] RING
Top: 0.23—0.33 mm {0.0091—0.0129 in}
Second: 0.50—0.65 mm {0.0197—0.0255 in}
Oil: 0.22—0.52 mm {0.0087—0.0204 in}
DBG110AEB087
Maximum piston ring end gap

1.0 mm {0.039 in}
End Of Sie
PISTON PIN CLEARANCE INSPECTION [WL-C, WE-C]
DCF011011010W09
1. Measure each piston pin bore diameter in the X
and Y directions at the four points (A, B, C, and D)
Standard piston pin bore diameter

33.997—34.007 mm {1.3384—1.3388 in}
X
A
B
C
D
Y
DBG110AEB088
2. Measure each connecting rod small end inner

X
diameter in the X and Y directions as shown in the
figure.
Standard connecting rod small end inner Y

diameter
34.012—34.033 mm {1.3391—1.3398 in}
DBG110AEB117
01–10B–26
3. Measure each piston pin diameter in the X and Y X
directions at the four points (A, B, C and D) as
Y
Standard piston pin diameter
33.994—34.000 mm {1.3384—1.3385 in}
01
A
4. Calculate the piston pin-to-piston pin bore B
clearance. Replace the piston and/or piston pin if
necessary. C
D
Standard piston pin-to-piston pin bore
DBG110AEB118
clearance
–0.003—0.013 mm {–0.0001—0.0005 in}
5. Calculate the connecting rod small end-to-piston pin clearance. Replace the connecting rod or piston pin.
Standard connecting rod small end-to-piston pin clearance

0.012—0.039 mm {0.00048—0.0015 in}
End Of Sie
CRANKSHAFT INSPECTION [WL-C, WE-C]
DCF011011301W04
1. Measure the crankshaft runout. Replace the
crankshaft if necessary.
Maximum crankshaft runout

0.05 mm {0.002 in}
DBG110AEB089
2. Measure the journal diameter in the X and Y

directions at the two points (A and B) as shown in A B
the figure. Replace the crankshaft or grind the
journal and install the undersize bearing if X
necessary.
Main journal diameter [No.1,2,4,5] Y

Standard: 66.937—66.955 mm {2.6354—
2.6360 in}
0.25 {0.010} undersize: 66.687—66.705 mm
{2.6255—2.6261 in}
0.50 {0.020} undersize: 66.437—66.455 mm
DBG110AEB090
{2.6157—2.6163 in}
0.75 {0.030} undersize: 66.187—66.205 mm
{2.6058—2.6064 in}
Main journal diameter [No.3]

Standard: 66.920—66.938 mm {2.6347—2.6353 in}
0.25 {0.010} undersize: 66.670—66.688 mm {2.6367—2.6373 in}
0.50 {0.020} undersize: 66.420—66.438 mm {2.6150—2.6156 in}
0.75 {0.030} undersize: 66.170—66.188 mm {2.6052—2.6058 in}
Main journal wear limit

0.05 mm {0.002 in}
Main journal out-of-round

0.03 mm {0.001 in}
01–10B–27
Crank pin diameter [WL-C]
Standard: 54.940—54.955 mm {2.1630—2.1635 in}
0.25 {0.010} undersize: 54.690—54.705 mm {2.1532—2.1537 in}
0.50 {0.020} undersize: 54.440—54.455 mm {2.1434—2.1438 in}
0.75 {0.030} undersize: 54.190—54.205 mm {2.1335—2.1340 in}
Crank pin diameter [WE-C]

Standard: 56.940—56.955 mm {2.2417—2.2423 in}
0.25 {0.010} undersize: 56.690—56.705 mm {2.2318—2.2324 in}
0.50 {0.020} undersize: 56.440—56.455 mm {2.2220—2.2226 in}
0.75 {0.030} undersize: 56.190—56.205 mm {2.2122—2.2128 in}
Crank pin wear limit

0.05 mm {0.0020 in}
Crank pin out-of-round

0.03 mm {0.0012 in}
End Of Sie
CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR [WL-C, WE-C]
DCF011011301W05
2. Install the main bearing cap. (See 01–10B–35 Main Bearing Cap Assembly Note.)
3. Remove the main bearing cap. (See 01–10B–16 Main Bearing Cap Disassembly Note.)
4. Measure the main journal oil clearance. If the clearance exceeds the maximum, replace the main bearing or
grind the main journal and install the undersize bearings so that the specified oil clearance is obtained.

No.1, 2, 4, 5: 0.027—0.045 mm {0.0010—0.0017 in}
No.3: 0.044—0.062 mm {0.0017—0.0024 in}
Maximum main journal clearance

0.08 mm {0.003 in}

Standard: 2.006—2.021 mm {0.0789—0.0794 in}
0.25 {0.010} undersize: 2.124—2.134 mm {0.0836—0.0838 in}
0.50 {0.020} undersize: 2.249—2.259 mm {0.0885—0.0888 in}
0.75 {0.030} undersize: 2.374—2.384 mm {0.0934—0.0937 in}
End Of Sie
CRANKSHAFT END PLAY INSPECTION/REPAIR [WL-C, WE-C]
DCF011011301W06
1. Install the main bearing cap. (See 01–10B–35 Main Bearing Cap Assembly Note.)
2. Measure the crankshaft end play. If the end play
exceeds the maximum, replace the thrust bearing
or grind the crankshaft and install an oversized
bearing so that the specified end play is obtained.

0.040—0.282 mm {0.0016—0.0111 in}
Maximum crankshaft end play

0.3 mm {0.01 in}

DBG110AEB120
Standard: 2.455—2.505 mm {0.0967—0.986
in}
0.35 {0.010} oversize: 2.630—2.680 mm {0.1036—0.1055 in}
3. Remove the main bearing cap. (See 01–10B–16 Main Bearing Cap Disassembly Note.)
End Of Sie
01–10B–28
CONNECTING ROD INSPECTION [WL-C, WE-C]
DCF011011211W04
1. Measure each connecting rod for bending and
distortion. Replace the connecting rod if
necessary.
01
Connecting rod bending
0.075 mm {0.0030 in} max./50 mm {1.968 in}
Connecting rod distortion

0.18 mm {0.0070 in} max./50 mm {1.968 in}
Connecting rod center-to-center distance

[WL-C]
DBG110AEB119
162.96—163.04 mm {6.416—6.418 in}
Connecting rod center-to-center distance [WE-C]

157.96—158.04 mm {6.219—6.222 in}
End Of Sie
CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR [WL-C, WE-C]
DCF011011211W05
2. Install the connecting rod cap. (See 01–10B–36 Piston, Connecting Rod Assembly Note.)
4. Measure the crankpin oil clearance. If the
clearance exceeds the maximum, replace the
connecting rod bearing or grind the crankpin and
use undersized bearings so that the specified
clearance is obtained.
Standard connecting rod oil clearance

0.025—0.052 mm {0.0009—0.0020 in}
Maximum connecting rod oil clearance

0.08 mm {0.003 in}
DBG110AEB121
Standard: 1.507—1.516 mm {0.0592—0.0595
in}
0.25 {0.010} undersize: 1.624—1.634 mm {0.0638—0.0642 in}
0.50 {0.020} undersize: 1.749—1.759 mm {0.0687—0.0691 in}
0.75 {0.030} undersize: 1.874—1.884 mm {0.0737—0.0740 in}
End Of Sie
CONNECTING ROD SIDE CLEARANCE INSPECTION [WL-C, WE-C]
DCF011011211W06
1. Install the connecting rod cap. (See 01–10B–36 Piston, Connecting Rod Assembly Note.)
2. Measure the connecting rod large end side
clearance. Replace the connecting rod and cap if
necessary.

0.110—0.262 mm {0.0043—0.0103 in}
Maximum connecting rod side clearance

0.35 mm {0.014 in}

01–10B–29
PISTON AND CONNECTING ROD INSPECTION [WL-C, WE-C]
DCF011011010W10
• Check the oscillation torque as shown. If the large
end does not drop by its own weight, replace the
piston or the piston pin.
End Of Sie
DBG110AEB093
BALANCE SHAFT INSPECTION [WL-C, WE-C]

DCF011010300W03
1. Install the balance shaft and tighten the thrust plate fitting bolt.
Tightening torque
7.85—10.8 N·m {80—110 kgf·m, 70—95 in·lbf}
2. Measure the balance shaft end play. Replace the

balance shaft and/or cylinder block if necessary.
Balance shaft Standard end play

0.04—0.16 mm {0.002—0.006 in}
DBG110AEB094

directions at the two points (A and B) as shown in A B
the figure. Replace the balance shaft if necessary. X
Standard diameter
Front: 41.945—41.960 mm {1.6514—1.6519
in} Y
Center: 39.945—39.960 mm {1.5727—1.5732
in}
Rear: 37.975—37.990 mm {1.4951—1.4956
in}
DBG110AEB095
4. Measure the balance shaft bore in the cylinder

block. Calculate the balance shaft-to-balance
shaft bore clearance. Replace the balance shaft
and/or cylinder block if necessary.
Standard clearance
Front, rear: 0.050—0.115 mm {0.0020—
0.0045 in}
Center: 0.080—0.145 mm {0.0032—0.0057 in}
End Of Sie
DBG110AEB096
01–10B–30
BOLT INSPECTION [WL-C, WE-C]
DCF011010135W02
• Measure the length of each bolt. Replace the bolt
if necessary.
Cylinder head bolt length 01

Bolt head mark W
4.007 in}
Bolt head mark N LENGTH
4.480 in}
DBG110AEB097
Bolt head mark I
5.905 in}

Connecting rod cap bolt length

End Of Sie
VALVE CLEARANCE INSPECTION [WL-C, WE-C]
DCF011012111W05
2. Turn the crankshaft and align the timing mark so that the piston of the No. 1 or No. 4 cylinders is at TDC of
compression.
3. Measure valve clearances A with the No.1 B A B A
cylinder at TDC of compression, and those of B
• If it is not within the specification, adjust and EX
recheck the valve clearance. (See 01–10B–32
VALVE CLEARANCE ADJUSTMENT [WL-C, ENGINE
WE-C].) FRONT
IN
B B A A
DBG110BEB023
CAMSHAFT
Valve clearance [Engine cold] FEELER
IN: 0.10—0.16 mm {0.0040—0.0062 in} GAUGE ADJUST SCREW
EX: 0.17—0.23 mm {0.0067—0.0090 in}
LOCKNUT
5. Install the cylinder head cover.
End Of Sie
ROCKER ARM
DBG110BTBRR5
01–10B–31
VALVE CLEARANCE ADJUSTMENT [WL-C, WE-C]
DCF011012111W06
Caution
• Loosening the locknut and the adjust
screw while the cam lobe is not pressing
down the rocker arm will damage the
ADJUST SCREW
claw of the rocker arm. When loosening
the locknut and the adjust screw, rotate CAM LOBE LOCKNUT
the crankshaft clockwise and be sure that
the cam lobe presses down the rocker
arm firmly as shown in the figure.
CLAW
2. Turn the crankshaft and align the timing mark so ROCKER ARM
that the piston of the No. 1 or No. 4 cylinders is at
DBG110BTBRR6
TDC of compression.
3. Adjust the valve clearances A with the No.1 B A B A
cylinder at TDC of compression, and those of B
EX
ENGINE
FRONT
IN
B B A A
DBG110BEB023
CAMSHAFT
Valve clearance [Engine cold] FEELER
IN: 0.10—0.16 mm {0.0040—0.0062 in} GAUGE ADJUST SCREW
EX: 0.17—0.23 mm {0.0067—0.0090 in}
LOCKNUT
Tightening torque (lock nut)
20—24 N·m {2.1—2.4 kgf·m, 15—17 ft·lbf}

5. Install the cylinder head cover. ROCKER ARM
End Of Sie DBG110BTBRR5
01–10B–32
GEAR CLEARANCE INSPECTION [WL-C, WE-C]
DCF011019220W02
1. Measure the following clearance.
• If it exceeds the maximum specification, replace the gear and/or pump body.
Standard oil pump tip clearance 01

0.10—0.19 mm {0.0040—0.0074 in}
Maximum oil pump tip clearance

0.20 mm {0.008 in}
DBG110AEB101
Standard oil pump side clearance

0.04—0.09 mm {0.0016—0.0035 in}
Maximum oil pump side clearance

0.15 mm {0.0059 in}
End Of Sie
DBG110AEB102
PLUNGER SPRING INSPECTION [WL-C, WE-C]

DCF011014116W02
1. Apply pressing force to the pressure spring and
check the spring height. Replace the plunger
spring if necessary.
Standard plunger spring length

43.8 mm {1.72 in}
End Of Sie
DBG110AEB103
01–10B–33
CYLINDER BLOCK ASSEMBLY (I) [WL-C, WE-C]
DCF011002000W24
11
OIL
13
OIL
10
9
OIL
8
OIL
7 1
OIL
12 3 OIL
OIL
14
15
46.5—51.5
{4.8—5.2, 34.1—37.9}
+82.5° —97.5°
16 OIL
OIL
4
5
OIL
12—18 N·m {123—183 kgf·cm,

7.8—10.8 N·m 107—159 in·lbf}
6
{80—110 kgf·cm,
70—95 in·lbf}
14.5—34.5 {1.5—3.5, 11—25}

+74.0—82.0 {7.6—8.3, 55—60}
Loosen all the bolts (until bolts are torque-free)
+14.5—34.5 {1.5—3.5, 11—25}
+42.5—45.5 {4.4—4.6, 32—33}
+90°—105°
DBG110BEB052
1 Cylinder block 8 Piston

(See01–10B–35 Piston, Connecting Rod, Piston Pin
2 Oil jet valve, nozzle
Assembly Note.)
3 Upper main bearing, upper thrust bearing
9 Piston pin
4 Crankshaft (See01–10B–35 Piston, Connecting Rod, Piston Pin
5 Lower main bearing, lower thrust bearing Assembly Note.)
6 Main bearing cap 10 Piston pin clip
(See01–10B–35 Main Bearing Cap Assembly 11 Piston ring
Note.) (See01–10B–36 Piston Ring Assembly Note.)
7 Connecting rod 12 Upper connecting rod bearing
(See01–10B–35 Piston, Connecting Rod, Piston Pin
Assembly Note.)
01–10B–34
13 Piston, connecting rod 15 Connecting rod cap
(See01–10B–36 Piston, Connecting Rod Assembly 16 Balance shaft
Note.)
14 Lower connecting rod bearing
01
Main Bearing Cap Assembly Note
1. Apply clean engine oil to the bolt threads and seat faces of the lower cylinder block bolts.
8 4 1 5 9
Tightening procedure
(1) 14.5—34.5 N·m {1.5—3.5 kgf·m, 11—25
ft·lbf}
(2) 74.0—82.0 N·m {7.6—8.3 kgf·m, 55—60
ft·lbf}
(3) Loosen all the bolts (until bolts are
torque-free).
(4) 14.5—34.5 N·m {1.5—3.5 kgf·m, 11—25 7 3 2 6 10
ft·lbf}
DBG110AEB271
(5) 42.5—45.5 N·m {4.4—4.6 kgf·m, 32—33
ft·lbf}

by turning each 90°—105° as in Step 2.
90°—105°
PAINT MARK
DBG110AEB072
Piston, Connecting Rod, Piston Pin Assembly Note

1. Install one piston pin clip.
2. Assemble the piston and connecting rod in the direction indicated in the figure.
3. Apply clean engine oil to the piston pin.
4. Install the piston pin until the pin contacts the clip
F MARK
as shown. If the pin cannot be installed easily,
heat the piston.
PROJECTION FOR ALIGNING

CONNECTIOG ROD BEARING
DPE110ZE1R18
01–10B–35
Piston Ring Assembly Note
1. Install the oil ring.
2. Install the second ring with R mark side upward.
3. Install the top ring with tapered face side upward.
SECTION OF TOP RING
SECTION OF SECOND RING
DBG110AEBR96
Piston, Connecting Rod Assembly Note

1. Insert the piston and connecting rod assembly
into the cylinder with the F mark facing the front of
the engine.
2. Tighten the connecting rod cap bolts in two or
three steps.
F MARK
Tightening torque
46.5—51.5 N·m {4.8—5.2 kgf·m, 34.3—37.9
ft·lbf}
3. Put a paint mark on each bolt.

DBG110AEBRR5

by turning each 82.5°—97.5°
End Of Sie
82.5°—97.5°
PAINT MARK
DBG110AEBRR3
01–10B–36
CYLINDER BLOCK ASSEMBLY (II) [WL-C, WE-C]
DCF011002000W25
8.8—12.7 N·m
{90—129 kgf·cm, 1
01
78—112 in·lbf}
10
OIL 24.5—33.3 18.6—25.5
{2.5—3.3, 19—24} {1.9—2.6, 14—18}
4
OIL
5 2 12
6 3
OIL
11 SEALANT
59—69 N·m SST

OIL
{6.1—7.0, 44—50} 14 R
OIL 15
SST R
96.1—102.9
17 SST {9.8—10, 71—75}
R
7.8—10.8 N·m
18.6—25.5 {80—110 kgf·cm,
{1.9—2.6, 14—18} 70—95 in·lbf}
13 SST
OIL
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
18.6—25.5
{1.9—2.6, 14—18} R OIL
SST
16 SEALANT
18.6—25.5
{1.9—2.6, 14—18}
9
19 18 SST
392—441
{40—44, 290—325} SEALANT 7
7.8—10.8 N·m 8
SST {80—110 kgf·cm,
70—95 in·lbf}
DBG110BEB001
1 Oil pump body 8 End plate

2 Control plunger (See01–10B–38 Rear Cover, End Plate Assembly
Note.)
3 Plunger spring
9 Dual-mass flywheel
4 Plug (See01–10B–39 Dual-mass Flywheel Assembly
5 Driven gear Note.)
6 Oil pump cover 10 Seal plate
(See01–10B–38 Oil Pump Cover Assembly Note.) 11 Timing gear case
7 Rear cover (See01–10B–39 Timing Gear Case Assembly
(See01–10B–38 Rear Cover, End Plate Assembly Note.)
Note.) 12 Supply pump
01–10B–37
13 Timing gear 17 Supply pump pulley
(See01–10B–40 Timing Gear, Supply Pump Gear (See01–10B–42 Supply Pump Pulley Assembly
Assembly Note.) Note.)
14 Supply pump gear 18 Seal plate
(See01–10B–40 Timing Gear, Supply Pump Gear 19 Crankshaft pulley
Assembly Note.) (See01–10B–43 Crankshaft Pulley Assembly Note.)
15 Oil pump
16 Timing gear cover
(See01–10B–42 Timing Gear Cover Assembly
Note.)
Oil Pump Cover Assembly Note

8 3
7
5
1 6
DBG110AEB053
Rear Cover, End Plate Assembly Note

hammer
measure the distance between the end of the rear
cover and the face of the oil seal. 49 S011 103
Rear oil seal press-in amount

0—0.5 mm {0—0.01 in}
0—0.5 mm {0—0.01 in}
REAR OIL SEAL
DBG110BEB059
5. Apply silicone sealant to the rear cover as shown.

SEALANT
Thickness
φ2.0—3.0 mm {0.07—0.12 in}
DBG110BEB003
01–10B–38
in the figure.
Thickness
φ2.0—3.0 mm {0.07—0.12 in}
01
7. Install the end plate.
SEALANT
DBG110AEBR94
Dual-mass Flywheel Assembly Note

1. Hold the crankshaft using the SST.
2. Tighten the bolts in the order shown in the figure.
KNOCK PIN
3 1
49 E011 1A0
5 8
7
6
2 4
DBG110BEB051
Timing Gear Case Assembly Note

1. Install the new O-ring.
2. Apply silicone sealant to the timing gear case as
shown in the figure. Do not apply sealant to the O- SEALANT
ring.
R
Thickness
φ2.0—3.0 mm {0.07—0.12 in}
DBG110BEB104

1
5
2
4
DBG110BEB072
01–10B–39
Timing Gear, Supply Pump Gear Assembly Note
1. Put a paint mark on the chip cut gear of the SUPPLY PUMP
supply pump gear. PAINT MARK
GEAR (HELICAL
GEAR)
CHIP CUT
GEAR
SCISSORS GEAR
DBG110AEBR93
2. Put a paint mark on the 10th and 11th teeth of the CHIP CUT GEAR
helical gear counting clockwise from the chip cut
gear. SUPPLY
VIEW A
PUMP GEAR
1
2 1
.3 2
.. .
. .
..
10 10
11 11
VIEW A
PAINT MARK
DBG110BEB141
3. Verify that the 10th and 11th teeth of supply pump

gear (helical gear) and the teeth of the scissors SCISSORS GEAR HELICAL GEAR
gear are aligned, then put a paint mark on the
scissors gear.
10 TEETH
11 TEETH
PAINT MARK
DBG110BEB103

approximately 30° BTDC (13 teeth on the gear). TDC
DBG110AEBR59
01–10B–40
6. Align the timing marks. For the supply pump gear, align the timing mark as shown in the figure (View A).
Note
• The helical gears except for the supply pump gear have a punch mark as the timing mark. The timing
mark of each gear can be aligned easily if the paint mark is made on the punch mark.
01
VIEW A
TIMING MARK (WHITE PAINT)
SUPPLY PUMP GEAR

VIEW A
IDLE GEAR
IDLE GEAR
IDLE GEAR
BALANCE SHAFT
GEAR
BALANCE SHAFT
GEAR
DBG110BEB078
7. Remove the lock bolt.

LOCK BOLT
DBG110AEBR97
8. Tighten the bolts using the SST.
49 E011 1A0
DBG110AEB061
01–10B–41
Timing Gear Cover Assembly Note
hammer. 49 F027 009
timing gear cover and the face of the oil seal.
Front oil seal press-in amount

0.0—0.40 mm {0.0—0.015 in}
Fuel injection pump oil seal press-in amount

0.0—0.40 mm {0.0—0.015 in} 49 S010 301
DBG110BEB012
5. Apply silicone sealant to the timing gear cover as

shown.
SEALANT
Thickness
φ2.0—3.0 mm {0.079—0.118 in}
DBG110BEB071

1
8 4
5
6
7
3 2
DBG110BEB073
Supply Pump Pulley Assembly Note

1. Install the supply pump pulley using the SST.
49 E011 1A0
DBG110BEB054
01–10B–42
Crankshaft Pulley Assembly Note
1. Install the crankshaft pulley using the SST.
End Of Sie
01
49 E011 1A0
DBG110BEB055
CYLINDER BLOCK ASSEMBLY (III) [WL-C, WE-C]

DCF011002000W26
R OIL
18.6—25.5 {1.9—2.6,
14—18}
1
OIL
R
2
7.85—10.8 N·m
{80—110 kgf·cm, SEALANT
70—95 in·lbf}
3
29.4—41.2 {3.0—4.2,
22—30}
R
DBG110BEB074
1 Oil pipe 3 Oil pan

(See01–10B–44 Oil Pipe Assembly Note.) (See01–10B–44 Oil Pan Assembly Note.)
2 Oil strainer 4 Oil drain plug
01–10B–43
Oil Pipe Assembly Note
ENGINE
FRONT
1
3
DBG110BEB076
Oil Pan Assembly Note

1. Apply silicone sealant to the oil pan as shown in
the figure. SEALANT
Thickness
φ2.0—3.0 mm {0.07—0.12 in}
2. Tighten the oil pan bolts A as shown in the figure.

A
Caution
• If the bolts are reused, remove the old
sealant from the bolt threads. Tightening
a bolt that has old sealant on it can cause
DBG110BEB056
bolt hole damage.
3. Tighten the remaining oil pan bolts in several

passes.
End Of Sie
DAMAGE
OLD SEALANT
CHU0111W004
01–10B–44
CYLINDER HEAD ASSEMBLY (I) [WL-C, WE-C]
DCF011002000W27
8 20—24 {2.1—2.4 , 15—17}

01
SST 7
10
6 15—19 {1.6—1.9 , 11—14}
5 9
1
R
SST 3
2
R
18.6—25.5 {1.9—2.6 , 14—18}
OIL
4
N·m { kgf·m, ft·lbf}
DBG110BEB065
1 Water outlet pipe 7 Valve keeper

2 Lower valve spring seat (See01–10B–46 Valve Keeper Assembly Note.)
3 Valve seal 8 Valve cap
(See01–10B–46 Valve Seal Assembly Note.) 9 Pivot
4 Valve (See01–10B–46 Pivot Assembly Note.)
5 Valve spring 10 Rocker arm
(See 01–10B–46 Rocker Arm Assembly Note.)
6 Upper valve spring seat
01–10B–45
Valve Seal Assembly Note
1. Tap the SST using a plastic hammer.
49 B012 015
49 B012 016
VALVE SEAL
DBG110BEB008
Valve Keeper Assembly Note

1. Install the valve keeper using the SST.
49 0636 100B
49 B012 0A2
DBG110BEB011
Pivot Assembly Note

1. Apply adhesive to the thread of the pivot.
Rocker Arm Assembly Note

1. If a new rocker arm is used, set dimension A as
follows.
Dimension A
0.0—4.0 mm {0.0—0.115 in}
End Of Sie A
DBG110BWB92
01–10B–46
CYLINDER HEAD ASSEMBLY (II) [WL-C, WE-C]
DCF011002000W28
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf} 01
6
R
OIL
SST
4
29 {3.0, 21}
R + 90°—105°
123—140 {12.6—14.2, 90.8—103.2} 3
+ 90°—105°
+ 90°—105°
8
R OIL
17.6—19.6
{1.8—1.9, 13—14}
1
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}

DBG110BEB026
1 Cylinder head gasket 5 Camshaft

(See 01–10B–48 Cylinder Head Gasket Assembly 6 Camshaft cap upper
Note.) (See 01–10B–49 Camshaft Cap Upper Assembly
2 Cylinder head Note.)
(See 01–10B–48 Cylinder Head Assembly Note.) 7 Seal plate
3 ECT sensor (See 01–10B–50 Seal Plate Assembly Note.)
4 Camshaft cap lower 8 Camshaft pulley
(See 01–10B–49 Camshaft Cap Lower Assembly (See 01–10B–50 Camshaft Pulley Assembly Note.)
Note.)
01–10B–47
Cylinder Head Gasket Assembly Note
1. Measure the piston topping of all the cylinders.
TOPPING
CYLINDER PISTON
BLOCK
DPE110ZE1R02
2. Choose the gasket according to each measured

piston topping.
Cylinder head gasket select table
Cylinder head gasket
Piston topping (mm {in})
identification mark
0.080—0.190 {0.004—0.007}
0.135—0.255 {0.006—0.010} IDENTIFICATION MARK

POSITION
0.200—0.310 {0.008—0.012} DPE110BEBR94
3. Apply silicone sealant to the cylinder block as

shown in the figure. 16.0 mm
{0.63 in}
Thickness
ø2.0—3.0 mm {0.08—0.11 in} 44.0 mm
{1.73 in} ENGINE
SEALANT 39.5 mm FRONT
{1.56 in}
23.5 mm
{0.93 in}
DBG110BWBR9
Cylinder Head Assembly Note

1. Before installing the cylinder head bolts, inspect their length. (See01–10B–31 BOLT INSPECTION [WL-C, WE-
C].)
2. Apply clean engine oil to the threads and the seat face of each bolt and install them.
3. Tighten the bolts in two or three steps in the order shown in the figure.
Tighten torque
29 N·m {3.0 kgf·m, 21 ft·lbf}
4. Retighten the bolts in the order shown in the

16 12 8 4 1 5 9 13 17 A
figure until all the bolts are tightened to 29 N·m
{3.0 kgf·m, 2.1 ft·lbf}.
15 11 7 3 2 6 10 14 18 A
DBG110BEB027
01–10B–48
6. Using the marks as a reference, tighten the bolts PAINT MARK
by turning each 90°—105° in the sequence 90°—105° 90°—105°
shown.
105°.
01
105°.
9. Apply adhesive to the thread of bolt A. 90°—105°
10. Tighten bolts A.
PAINT MARK
Tighten torque
DBG110AWB311
17.6—19.6 N·m {1.8—1.9 kgf·m, 13—14 ft·lbf}
Camshaft Cap Lower Assembly Note

SEALANT
DBG110BEB105
Camshaft Cap Upper Assembly Note

1. Apply adhesive to the front camshaft cap
mounting surfaces as shown in the figure.
2. Tighten the camshaft cap bolts gradually in three
or four steps in the order shown in the figure.
Caution ADHESIVE
• Because there is little camshaft thrust
clearance, the camshaft must be held
horizontally while it is installed.
Otherwise, excessive force will be
applied to the thrust area, causing burrs
on the thrust receiving area of the
DBG110BWB86
cylinder head journal. To avoid this, the
following procedure must be observed.
3. Apply soapy water along the perimeter of the new

16 15 8 7 2 1 10 9
oil seal. 17
18
19
20
14 13 6 5 4 3 12 11
DBG110BEBR25
01–10B–49
5. Tap the oil seal lightly into the cylinder head using
the SST and a hammer.
6. To ensure that the oil seal is installed correctly, 49 S010 001
cylinder head and the face of the oil seal.
CYLINDER
HEAD 0.5—1.0 mm {0.02—0.03 in}
Camshaft oil seal press-in amount
0.5—1.0 mm {0.020—0.039 in}
HAMMER
OIL SEAL
DPE110ZE1R41
Seal Plate Assembly Note

1. Tighten the seal plate bolts in the order indicated
in the figure. 2
SEAL PLATE
DBG110BEB041
Camshaft Pulley Assembly Note

1. Install the camshaft pulleys, positioning the knock
pins as shown in the figure. INTAKE EXHAUST
CAMSHAFT KNOCK PIN CAMSHAFT
PULLEY PULLEY
DBG110BWB85
2. Hold the camshaft using a wrench on the cast hexagon.
Caution
CAMSHAFT PULLEY
damage them.
End Of Sie
DBG110BEBR17
01–10B–50
TIMING BELT ASSEMBLY [WL-C, WE-C]
DCF011002000W29
21—26 {2.2—2.6, 16—19}

01
7.8—10.8 N·m {80—110 kgf·cm,
2 70—95 in·lbf}
R
18.6—25.5 {1.9—2.6, 14—18}
7
SEALANT
35—52 {3.5—5.3,
25—38}
6 4
7.9—10.8 N·m
37—52 {3.7—5.3, {81—110 kgf·cm,
27—38} 70—95 in·lbf}
7.8—10.8 N·m {80—110 kgf·cm,

70—95 in·lbf} N·m {kgf·m, ft·lbf}
DBG110BEB046
1 Cylinder head cover 3 Auto tensioner

(See01–10B–52 Timing Belt Assembly Note.)
2 Injector
01–10B–51
4 Timing belt 6 Timing belt cover
(See01–10B–52 Timing Belt Assembly Note.) (See 01–10B–53 Timing Belt Cover Assembly
5 Idler Note.)
(See01–10B–52 Timing Belt Assembly Note.) 7 Water pump
8 Vacuum pump
Cylinder Head Cover Assembly Note

shown in the figure. SEALANT SEALANT
Thickness
ø2.0—3.0 mm {0.08—0.11 in}
SEALANT SEALANT
DBG110BWB84
2. Tighten the cylinder head cover bolts in the order

14 3 15 4 5
2 16
6
12
1 17
11 10 9 8 7
DBG110BEB005
Timing Belt Assembly Note

1. Align the timing marks as shown in the figure. INTAKE
2. Verify that the supply pump attaching bolts and EXHAUST
CAMSHAFT CAMSHAFT
nuts are tightened to the specified torque. This PULLEY PULLEY
must be done to prevent over-tensioning of the
timing belt after it has been installed.
TIMING MARK
TIMING SUPPLY PUMP

MARK PULLEY
DBG110BWB97
3. Install the tensioner and hand-tighten lock bolts A

and B.
4. Install the timing belt.
5. Install the idler.
6. Tighten the lock bolt A.
TENSIONER
7. Tighten the lock bolt B.
8. Remove the set pin from the tensioner.
9. Turn the crankshaft clockwise twice, and align the BOLT B
camshaft pully timing marks. If they are not BOLT A
aligned, remove the timing belt and repeat from
Step 1.
DBG110BWB96
01–10B–52
Timing Belt Cover Assembly Note
1. Tighten the timing belt cover bolts in the order
shown in the figure. 3 4
End Of Sie
01
1
2
6 5
DBG110BEB043
01–10B–53
TECHNICAL DATA [WL-3]
01–50A TECHNICAL DATA [WL-3]

ENGINE TECHNICAL DATA [WL-3] . . . . 01–50A–1
End of Toc
01
ENGINE TECHNICAL DATA [WL-3]
DCF015000000W01
Item Specification
X distortion: 0.02 mm {0.0008 in}
Y distortion: 0.05 mm {0.0020 in}
Maximum combustion chamber recession 0.02 mm {0.0008 in}
Maximum combustion chamber projection 0.005 mm {0.0002 in}
Combustion chamber crack Limit: 10mm {0.39 in}
Maximum manifold contact surface distortion 0.05 mm {0.0020 in}
Maximum manifold contact surface grinding 0.15 mm {0.0059 in}
IN: 1.5 mm {0.059 in}
EX: 0.75 mm {0.030 in}
IN: 111.6—112.1 mm {4.394—4.413 in}
EX: 111.5—112.0 mm {4.390—4.409 in}
IN: 111.35 mm {4.384 in}
EX: 111.25 mm {4.380 in}
IN: 6.970—6.985 mm {0.2745—0.2749 in}
EX: 6.965—6.980 mm {0.2743—0.2748 in}
IN: 6.920 mm {0.2724 in}
EX: 6.915 mm {0.2722 in}
Standard valve guide inner diameter 7.025—7.045 mm {0.2766—0.2773 in}
Standard valve guide height 14.0—14.5 mm {0.552—0.570 in}
IN: 1.6—2.2 mm {0.063—0.086 in}
EX: 1.7—2.3 mm {0.067—0.090 in}
IN: 45°
Valve seat angle
EX: 45°
IN: 0.61—1.09 mm {0.025—0.042 in}
EX: 0.71—1.19 mm {0.028—0.046 in}
IN: 1.50 mm {0.059 in}
EX: 1.60 mm {0.063 in}
Valve spring installation pressing force 238—269 N {25—27 kgf, 54—60 lbf}
Valve spring installation height 35.5 mm {1.40 in}
Maximum valve spring out-of-square 2.0° (1.70mm {0.067 in})
Maximum camshaft runout 0.03 mm {0.0012 in}
IN: 42.400—42.500 mm {1.6692—1.6732 in}
EX: 42.395—42.495 mm {1.6691—1.6730 in}
IN: 42.050 mm {1.6555 in}
EX: 42.045 mm {1.6711 in}
No.1, No.5: 25.940—25.965 mm {1.0213—1.0222 in}
No.2—No.4: 25.910—25.935 mm {1.0201—1.0210 in}
No.1, No.5: 25.890 mm {1.0193 in}
No.2—No.4: 25.860 mm {1.0181 in}
No.1, 5: 0.035—0.081 mm {0.0014—0.0031 in}
No.2—4: 0.065—0.111 mm {0.0026—0.0043 in}
No.1, 5: 0.12 mm {0.0047 in}
No.2—4: 0.15 mm {0.0059 in}
Standard camshaft end play 0.030—0.160 mm {0.0012—0.0062 in}
Maximum camshaft end play 0.20 mm {0.0079 in}
Standard: 93.000—93.022 mm {3.6615—3.6622 in}
Cylinder bore size 0.25 {0.01} oversize: 93.250—93.272 mm {3.6713—3.6721 in}
0.50 {0.02} oversize: 93.500—93.522 mm {3.6811—3.6819 in}
Cylinder bore wear limit 0.15 mm {0.0059 in}
Oil jet air pressure 137.6—196.4 kPa {1.5—2.0 kgf/cm2, 20—28 psi}
01–50A–1
Item Specification
Standard: 92.951—92.977 mm {3.6595—3.6605 in}
Piston diameter 0.25 {0.0098} oversize: 93.186—93.212 mm {3.6688—3.6697 in}
0.50 {0.02} oversize: 93.436—93.462 mm {3.6786—3.6795 in}
Standard piston clearance 0.055—0.073 mm {0.0022—0.0028 in}
Maximum piston clearance 0.15 mm {0.0059 in}
Top: 0.06—0.10 mm {0.0024—0.0039 in}
Standard piston ring clearance Second: 0.04—0.08 mm {0.0016—0.0031 in}
Oil: 0.03—0.07 mm {0.0012—0.0027 in}
Maximum piston ring clearance 0.15 mm {0.0059 in}
Top: 0.22—0.32 mm {0.0087—0.0125 in}
Standard piston ring end gap Second: 0.32—0.47 mm {0.0126—0.0185 in}
Oil: 0.22—0.37 mm {0.0087—0.0145 in}
Maximum piston ring end gap 1.0 mm {0.039 in}
Standard piston pin bore diameter 31.997—32.007 mm {1.2598—1.2601 in}
Standard connecting rod small end inner diameter 32.012—32.033 mm {1.2604—1.2611 in}
Standard piston pin diameter 31.994—32.000 mm {1.25961—1.25984 in}
Standard piston pin-to-piston pin bore clearance –0.003—0.013 mm {–0.00011—0.00051 in}
Standard connecting rod small end-to-piston pin
0.012—0.039 mm {0.00048—0.00153 in}
clearance
Maximum crankshaft runout 0.05 mm {0.0020 in}
Standard
No.1, 2, 4, 5: 66.937—66.955 mm {2.6354—2.6360 in}
No.3: 66.920—66.938 mm {2.6347—2.6353 in}
No.1, 2, 4, 5: 66.687—66.705 mm {2.6255—2.6261 in}
No.3: 66.670—66.688 mm {2.6248—2.6255 in}
Main journal diameter
No.1, 2, 4, 5: 66.437—66.455 mm {2.6157—2.6163 in}
No.3: 66.420—66.438 mm {2.6150—2.6156 in}
No.1, 2, 4, 5: 66.187—66.205 mm {2.6058—2.6064 in}
No.3: 66.170—66.188 mm {2.6052—2.6058 in}
Main journal wear limit 0.05 mm {0.0020 in}
Main journal out-of-round 0.03 mm {0.0012 in}
Standard: 54.940—54.955 mm {2.1630—2.1635 in}
0.25 {0.01} undersize: 54.690—54.705 mm {2.1532—2.1537 in}
Crank pin diameter
0.50 {0.02} undersize: 54.440—54.455 mm {2.1434—2.1438 in}
0.75 {0.03} undersize: 54.190—54.205 mm {2.1335—2.134 in}
Crank pin wear limit 0.05 mm {0.0020 in}
Crank pin out-of-round 0.03 mm {0.0012 in}
No.1, 2, 4, 5: 0.027—0.046 mm {0.0011—0.0018 in}
No.3: 0.044—0.063 mm {0.0018—0.0025 in}
Maximum main journal clearance 0.08 mm {0.0031 in}
Standard: 2.006—2.021 mm {0.0790—0.0795 in}
0.25 {0.01} undersize: 2.124—2.134 mm {0.0837—0.0840 in}
0.50 {0.02} undersize: 2.249—2.259 mm {0.0886—0.0889 in}
0.75 {0.03} undersize: 2.374—2.384 mm {0.0935—0.0938 in}
Standard crankshaft end play 0.040—0.282 mm {0.0016—0.0111 in}
Maximum crankshaft end play 0.3 mm {0.012 in}
Standard: 2.454—2.506 mm {0.0967—0.0986 in}
0.35 {0.014} oversize: 2.629—2.681 mm {0.1036—0.1055 in}
Maximum connecting rod bending 0.075 mm {0.0030 in} /50 mm {2.0 in}
Maximum connecting rod distortion 0.18 mm {0.0071 in} /50 mm {2.0 in}
Connecting rod center-to-center distance 151.96—152.04 mm {5.9827—5.9858 in}
Standard connecting rod bolt length 67.5—68.5 mm {2.66—2.69 in}
Maximum connecting rod bolt length 69 mm {2.7 in}
Standard connecting rod oil clearance 0.025—0.052 mm {0.0010—0.0020 in}
Maximum connecting rod oil clearance 0.08 mm {0.0031 in}
01–50A–2
Item Specification
Standard: 1.507—1.516 mm {0.0594—0.0596 in}
0.25 {0.01} undersize: 1.624—1.634 mm {0.0640—0.0643 in}
0.50 {0.02} undersize: 1.749—1.759 mm {0.0689—0.0692 in}

0.75 {0.03} undersize: 1.874—1.884 mm {0.0738—0.0741 in}
0.110—0.262 mm {0.0044—0.0103 in}
01
Maximum connecting rod side clearance 0.35 mm {0.014 in}
Bolt head mark W
Cylinder head bolt length
Bolt head mark N
Standard tensioner spring length 63.0 mm {2.48 in}
IN: 0.05—0.15 mm {0.0020—0.0059 in}
Valve clearance (engine cold)
EX: 0.15—0.25 mm {0.0060—0.0098 in}
Fuel injection pump plunger adjustment value 0.95—1.05 mm {0.038—0.041 in}
Standard oil pump tip clearance 0.10—0.19 mm {0.0040—0.0074 in}
Maximum oil pump tip clearance 0.20 mm {0.0079 in}
Standard oil pump side clearance 0.04—0.09 mm {0.0016—0.0035 in}
Maximum oil pump side clearance 0.15 mm {0.0059 in}
Standard plunger spring length 43.8 mm {1.72 in}
Front oil seal press-in amount 0—0.4 mm {0—0.01 in}
Fuel injection pump oil seal press-in amount 0—0.4 mm {0—0.01 in}
Camshaft oil seal press-in amount 0.5—1.0 mm {0.02—0.03 in}
End Of Sie
01–50A–3
TECHNICAL DATA [WL-C, WE-C]
01–50B TECHNICAL DATA [WL-C, WE-C]

ENGINE TECHNICAL DATA
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–50B–1
End of Toc 01
ENGINE TECHNICAL DATA [WL-C, WE-C]
DCF015000000W02
Item Specification
X distortion: 0.02 mm {0.0008 in} max.
Y distortion: 0.05 mm {0.0020 in} max.
Maximum manifold contact surface distortion 0.05 mm {0.002 in} max.
Maximum manifold contact surface grinding 0.15 mm {0.0059 in} max.
IN: 1.55—1.85 mm {0.061—0.072 in}
EX: 1.80—2.10 mm {0.070—0.082 in}
IN: 111.65—112.25 mm {4.394—4.413 in}
EX: 111.6—112.2 mm {4.390—4.409 in}
IN: 111.50 mm {4.390 in}
EX: 111.45 mm {4.388 in}
IN: 5.970—5.985 mm {0.2350—0.2356 in}
EX: 5.965—5.980 mm {0.2348—0.2354 in}
IN: 5.920 mm {0.2330 in}
EX: 5.915 mm {0.2328 in}
Standard valve guide inner diameter 6.025—6.045 mm {0.2372—0.2379 in}
IN: 15.0—15.5 mm {0.59—0.61 in}
EX: 17.0—17.5 mm {0.67—0.69 in}
IN: 15.0—15.5 mm {0.59—0.61 in}
EX: 17.0—17.5 mm {0.67—0.68 in}
Standard valve seat contact width 1.3—1.9 mm {0.052—0.074 in}
IN: 45°
Valve seat angle
EX: 45°
IN: 0.79—1.27 mm {0.039—0.050 in}
EX: 0.84—1.32 mm {0.033—0.051 in}
IN: 1.68 mm {0.066 in}
EX: 1.73 mm {0.062 in}
Valve spring installation pressing force 172.9—195.6 N {15.67—17.74 kgf, 34.48—39.02 lbf}
Valve spring installation height 39.0 mm {1.53 in}
Maximum valve spring out-of-square 2.0° (1.60mm {0.062 in})
Maximum camshaft runout 0.03 mm {0.001 in} max.
IN: 42.067—42.167 mm {1.6561—1.6601 in}
EX: 41.949—42.049 mm {1.6515—1.6554 in}
IN: 41.717 mm {1.6424 in}
EX: 41.599 mm {1.6377 in}
No.1: 31.940—31.965 mm {1.2575—1.2582 in}
Standard cam journal diameter No.2—No.4: 25.910—25.935 mm {1.0201—1.0210 in}
No.5: 25.940—25.965 mm {1.0212—1.0222 in}
No.1: 31.890 mm {1.2555 in}
Minimum cam journal diameter No.2—No.4: 25.860 mm {1.0181 in}
No.5: 25.890 mm {1.0193 in}
No.1: 0.035—0.081 mm {0.0014—0.0031 in}
Standard camshaft clearance No.2—4: 0.065—0.111 mm {0.0026—0.0043 in}
No.5: 0.056—0.081 mm {0.0014—0.0031 in}
No.1: 0.12 mm {0.0047 in}
Maximum camshaft clearance No.2—4: 0.15 mm {0.0059 in}
No.5: 0.16 mm {0.0063 in}
Standard camshaft end play 0.030—0.160 mm {0.0012—0.0062 in}
Maximum camshaft end play 0.20 mm {0.0078 in}
Standard: 93.000—93.022 mm {3.6615—3.6622 in}
Cylinder bore size [WL-C] 0.25 {0.01} oversize: 93.250—93.272 mm {3.6713—3.6721 in}
0.50 {0.02} oversize: 93.500—93.522 mm {3.6811—3.6819 in}
01–50B–1
Item Specification
Standard: 96.000—96.022 mm {3.6615—3.6622 in}
Cylinder bore size [WE-C] 0.25 {0.01} oversize: 96.250—96.272 mm {3.7893—3.7902 in}
0.50 {0.02} oversize: 96.500—96.522 mm {3.7992—3.8000 in}
Cylinder bore wear limit 0.15 mm {0.0059 in}
Flywheel maximum runout 1.5 mm {0.059 in}
Oil jet air pressure 137.6—196.4 kPa {1.4—2.0 kgf/cm2, 20—28 psi}
Standard: 92.918—92.944 mm {3.6582—3.6592 in}
Piston diameter [WL-C] 0.25 {0.010} oversize: 93.153—93.179 mm {3.6675—3.6684 in}
0.50 {0.020} oversize: 93.403—93.429 mm {3.6773—3.6782 in}
Standard: 95.918—95.944 mm {3.7763—3.7773 in}
Piston diameter [WE-C] 0.25 {0.010} oversize: 96.153—96.179 mm {3.7856—3.7865 in}
0.50 {0.020} oversize: 96.403—96.429 mm {3.7954—3.7964 in}
Standard piston clearance 0.071—0.089 mm {0.0015—0.0022 in}
Maximum piston clearance 0.15 mm {0.0059 in}
Top: 0.06—0.10 mm {0.0024—0.0039 in}
Standard piston ring clearance [WL-C] Second: 0.06—0.08 mm {0.0024—0.0031 in}
Oil: 0.02—0.06 mm {0.0012—0.0023 in}
Top: 0.06—0.10 mm {0.0024—0.0039 in}
Standard piston ring clearance [WE-C] Second: 0.04—0.08 mm {0.0016—0.0031 in}
Oil: 0.02—0.06 mm {0.0008—0.0023 in}
Maximum piston ring clearance 0.15 mm {0.0059 in}
Top: 0.22—0.32 mm {0.0087—0.0125 in}
Standard piston ring end gap [WL-C] Second: 0.49—0.64 mm {0.0193—0.0251 in}
Oil: 0.22—0.52 mm {0.0087—0.0204 in}
Top: 0.23—0.33 mm {0.0091—0.0129 in}
Standard piston ring end gap [WE-C] Second: 0.50—0.65 mm {0.0197—0.0255 in}
Oil: 0.22—0.52 mm {0.0087—0.0204 in}
Maximum piston ring end gap 1.0 mm {0.039 in}
Standard piston pin bore diameter 33.997—34.007 mm {1.3384—1.3388 in}
Standard connecting rod small end inner diameter 34.012—34.033 mm {1.3391—1.3398 in}
Standard piston pin diameter 33.994—34.000 mm {1.3384—1.3385 in}
Standard piston pin-to-piston pin bore clearance –0.003—0.013 mm {–0.0001—0.0005 in}
Standard connecting rod small end-to-piston pin
0.012—0.039 mm {0.00048—0.0015 in}
clearance
Maximum crankshaft runout 0.05 mm {0.002 in}
Standard: 66.937—66.955 mm {2.6354—2.6360 in}
0.25 {0.010} undersize: 66.687—66.705 mm {2.6255—2.6261 in}
Main journal diameter [No.1,2,4,5]
0.50 {0.020} undersize: 66.437—66.455 mm {2.6157—2.6163 in}
0.75 {0.030} undersize: 66.187—66.205 mm {2.6058—2.6064 in}
Standard: 66.920—66.938 mm {2.6347—2.6353 in}
0.25 {0.010} undersize: 66.670—66.688 mm {2.6367—2.6373 in}
Main journal diameter [No.3]
0.50 {0.020} undersize: 66.420—66.438 mm {2.6150—2.6156 in}
0.75 {0.030} undersize: 66.170—66.188 mm {2.6052—2.6058 in}
Main journal wear limit 0.05 mm {0.002 in}
Main journal out-of-round 0.03 mm {0.001 in}
Standard: 54.940—54.955 mm {2.1630—2.1635 in}
0.25 {0.010} undersize: 54.690—54.705 mm {2.1532—2.1537 in}
Crank pin diameter [WL-C]
0.50 {0.020} undersize: 54.440—54.455 mm {2.1434—2.1438 in}
0.75 {0.030} undersize: 54.190—54.205 mm {2.1335—2.1340 in}
Standard: 56.940—56.955 mm {2.2417—2.2423 in}
0.25 {0.010} undersize: 56.690—56.705 mm {2.2318—2.2324 in}
Crank pin diameter [WE-C]
0.50 {0.020} undersize: 56.440—56.455 mm {2.2220—2.2226 in}
0.75 {0.030} undersize: 56.190—56.205 mm {2.2122—2.2128 in}
Crank pin wear limit 0.05 mm {0.0020 in}
Crank pin out-of-round 0.03 mm {0.0012 in}
No.1, 2, 4, 5: 0.027—0.045 mm {0.0010—0.0017 in}
No.3: 0.044—0.062 mm {0.0017—0.0024 in}
Maximum main journal clearance 0.08 mm {0.003 in}
01–50B–2
Item Specification
Standard: 2.006—2.021 mm {0.0789—0.0794 in}
0.25 {0.010} undersize: 2.124—2.134 mm {0.0836—0.0838 in}
0.50 {0.020} undersize: 2.249—2.259 mm {0.0885—0.0888 in}

0.75 {0.030} undersize: 2.374—2.384 mm {0.0934—0.0937 in}
0.040—0.282 mm {0.0016—0.0111 in}
01
Maximum crankshaft end play 0.3 mm {0.01 in}
Standard: 2.455—2.505 mm {0.0967—0.986 in}
0.35 {0.010} oversize: 2.630—2.680 mm {0.1036—0.1055 in}
Connecting rod bending 0.075 mm {0.0030 in} max./50 mm {2.0 in}
Connecting rod distortion 0.18 mm {0.0070 in} max./50 mm {1.968 in}
Connecting rod center-to-center distance [WL-C] 162.96—163.04 mm {5.983—5.986 in}
Connecting rod center-to-center distance [WE-C] 157.96—158.04 mm {5.983—5.986 in}
Standard connecting rod oil clearance 0.025—0.052 mm {0.0009—0.0020 in}
Maximum connecting rod oil clearance 0.08 mm {0.003 in}
Standard: 1.507—1.516 mm {0.0592—0.0595 in}
0.25 {0.010} undersize: 1.624—1.634 mm {0.0638—0.0642 in}
0.50 {0.020} undersize: 1.749—1.759 mm {0.0687—0.0691 in}
0.75 {0.030} undersize: 1.874—1.884 mm {0.0737—0.0740 in}
Standard connecting rod side clearance 0.110—0.262 mm {0.0043—0.0103 in}
Maximum connecting rod side clearance 0.35 mm {0.014 in}
Balance shaft Standard end play 0.04—0.16 mm {0.002—0.006 in}
Front: 41.945—41.960 mm {1.6514—1.6519 in}
Standard diameter Center: 39.945—39.960 mm {1.5727—1.5732 in}
Rear: 37.975—37.990 mm {1.4951—1.4956 in}
Front, rear: 0.050—0.115 mm {0.0020—0.0045 in}
Standard clearance
Center: 0.080—0.145 mm {0.0032—0.0057 in}
Bolt head mark W
Bolt head mark N
Cylinder head bolt length Standard length: 113.2—113.8 mm {4.457—4.480 in}
Bolt head mark I
Connecting rod cap bolt length
IN: 0.10—0.16 mm {0.0040—0.0062 in}
Valve clearance [Engine cold]
EX: 0.17—0.23 mm {0.0067—0.0090 in}
IN: 0.10—0.16 mm {0.0040—0.0062 in}
Valve clearance [Engine cold]
EX: 0.17—0.23 mm {0.0067—0.0090 in}
Standard oil pump tip clearance 0.10—0.19 mm {0.0040—0.0074 in}
Maximum oil pump tip clearance 0.20 mm {0.008 in}
Standard oil pump side clearance 0.04—0.09 mm {0.0016—0.0035 in}
Maximum oil pump side clearance 0.15 mm {0.0059 in}
Standard plunger spring length 43.8 mm {1.72 in}
Front oil seal press-in amount 0.0—0.40 mm {0.0—0.015 in}
Fuel injection pump oil seal press-in amount 0.0—0.40 mm {0.0—0.015 in}
Camshaft oil seal press-in amount 0.5—1.0 mm {0.020—0.039 in}
End Of Sie
01–50B–3
SERVICE TOOLS [WL-3]
01–60A SERVICE TOOLS [WL-3]

ENGINE [WL-3] . . . . . . . . . . . . . . . . . . . . 01–60A–1
End of Toc
01
ENGINE [WL-3]
DCF016000000W01
1: Mazda SST number
2: Global SST number
Example
1:49 UN30 3050
2:303-050
Engine lifting
brackets
1:49 0107 680A 1:49 L010 1A0 1:49 0636 100B

2:– 2:– 2:–
Engine stand Engine hanger Valve spring

set lifter arm
1:49 B012 0A2 1:49 S120 170 1:49 B012 015

2:– 2:– 2:–
Pivot Valve seal Installer

remover (Part of 49 B012
0A3)
1:49 S010 001 1:49 E011 1A0 1:49 S120 215B

2:– 2:– 2:–
Oil seal installer Ring gear brake Pulley puller

set
1:49 S011 103 1:49 S010 301 1:49 F027 009

2:– 2:– 2:–
Oil seal installer Oil seal installer Oil seal installer
1:49 G011 001 1:49 L012 001 1:49 L012 002A

2:– 2:– 2:–
Piston pin Installer Body

replacer (Part of 49 L012 (Part of 49 L012
0A0B) 0A0B)
1:49 L012 005 1:49 L012 003A 1:49 L012 004A

2:– 2:– 2:–
Spacer Installer Nut

(Part of 49 L012 (Part of 49 L012 (Part of 49 L012
0A0B) 0A0B) 0A0B)
01–60A–1
SERVICE TOOLS [WL-3]
1:49 UN30 3050 1:49 L017 5A0 1:49 9140 074
2:303-050 2:– 2:–
Engine lifting Support hanger Cam lift

brackets measuring
device
End Of Sie
01–60A–2
SERVICE TOOLS [WL-C, WE-C]
01–60B SERVICE TOOLS [WL-C, WE-C]

ENGINE SERVICE TOOLS
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01–60B–1
End of Toc 01
ENGINE SERVICE TOOLS [WL-C, WE-C]
DCF016000000W02
1: Mazda SST number
Example
1:49 UN30 3050
2:303-050
Engine lifting
brackets
1:49 0107 680A 1:49 L010 1A0 1:49 0636 100B

2:– 2:– 2:–
Engine stand Engine stand Valve spring

hanger set lifter arm
1:49 B012 0A2 1:49 S120 170 1:49 F027 009

2:– 2:– 2:–
Pivot Valve seal Oil seal installdr

remover
1:49 S010 001 1:49 E011 1A0 1:49 S120 215B

2:– 2:– 2:–
Oil seal installer Ring gear brake Pulley puller

set
1:49 S011 103 1:49 S010 301 1:49 UN30 3050

2:– 2:– 2:–
Oil seal installer Oil seal installer Engine lifting

brackets
1:49 G011 001 1:49 B012 015 1:49 L017 5A0

2:– 2:– 2:–
Piston pin Valve guide Support hanger

replacer remover and
installer
01–60B–1
SERVICE TOOLS [WL-C, WE-C]
1:49 B012 016
2:–
Valve seal
installer
End Of Sie
01–60B–2
DRIVELINE/AXLE 03
SECTION
Toc of SCT
TRANSFER . . . . . . . . . . . . . . . 03-16 SERVICE TOOLS . . . . . . . . . . . 03-60
TECHNICAL DATA . . . . . . . . . 03-50
03
Toc of SCT
03–16 TRANSFER
TRANSFER CLEANING . . . . . . . . . . . . . 03–16–1 TRANSFER ASSEMBLY . . . . . . . . . . . . . 03–16–8
TRANSFER DISASSEMBLY . . . . . . . . . . 03–16–2
End of Toc
TRANSFER CLEANING
DCF031600000W01
Cleaning Precautions
1. Clean the surface of the transfer using steam and cleaning fluids when disassembly.
Warning
• Always wear safety glasses when using compressed air since the foreign material could be blown
by the compression air and damage your eyes.
2. Clean removed components with cleaning fluids and use compressed air to blow off the oil. Clean the oil holes
and passages with compressed air.
End Of Sie
03–16–1
TRANSFER
TRANSFER DISASSEMBLY
DCF031600000W02
Before Service Precautions
• To prevent foreign material from entering the transfer, perform disassembly and servicing in a clean, dust-free
environment.
• Inspect the each part while disassembling.
Transfer Disassembly
9 SST
10 R
13
18
19 17
21
24 22
23
27 SST
25 R 46
26 SST 47
14 R
B
D
B 15 R SST
16 SST
20
32 29
28
12 R 31 R
11 SST
30 49
38 R 50
52
39 R
54
40 SST 51
53 R
33 A
C
55
41
A 62 37
1
2 R 36
64 SST 35
3
4 56 34 R
42
E C
5 D 66
6 7
8
65
E
63 R 68 R
67 R
61 57
48 60 SST
45 44
58
69 43
59 SST
DBG316BMB026
03–16–2
TRANSFER
1 Control case 34 Retaining ring
2 E-ring 35 H/L clutch hub
3 Spacer 36 Low gear
4 Reverse gate spring 37 Needle bearing
5 Reverse gate lever 38 Retaining ring
6 Guide plate 39 Retaining ring
7 Control rod end Mainshaft center bearing 03
8 Control rod 40 (See 03–16–7 Mainshaft Center Bearing
Disassembly Note.)
Companion flange (rear case side)
9 (See 03–16–4 Companion Flange Disassembly 41 Mainshaft
Note.) 42 Needle bearing
10 Oil seal (rear case) 43 Retaining bolt
Companion flange (center case side) 44 Spring
11 (See 03–16–4 Companion Flange Disassembly 45 Steel ball
Note.)
46 2W/4W shift rod
12 Oil seal (center case)
47 2W/4W shift end
13 Rear case
48 Interlock pin
14 Speed drive gear
49 Snap ring
Mainshaft rear bearing
15 (See 03–16–5 Mainshaft Rear Bearing Disassembly 50 H/L shift rod
Note.) 51 Snap ring
2W/4W clutch hub 52 Plain washer
16 (See 03–16–5 2W/4W Clutch Hub Disassembly 53 Spring
Note.) 54 Plunger
17 Snap ring 55 H/L shift fork
18 Spacer 56 H/L hub sleeve
19 2W/4W shift fork 57 Adjustment shim
20 2W/4W hub sleeve 58 Countershaft
21 Spring Countershaft front bearing (front case side)
22 Collar 59 (See 03–16–7 Countershaft Bearing Disassembly
23 Snap ring Note.)
Chain Countershaft rear bearing (center case side)
24 (See 03–16–6 Chain, Front Drive Shaft and 60 (See 03–16–7 Countershaft Bearing Disassembly
Sprocket Disassembly Note.) Note.)
Front drive shaft 61 Baffle plate
25 (See 03–16–6 Chain, Front Drive Shaft and 62 Retaining bolt
Sprocket Disassembly Note.) 63 Retaining ring
Front drive shaft bearing (center case side) Maindrive gear bearing
26 (See 03–16–6 Front Drive Shaft Bearing 64 (See 03–16–7 Maindrive Gear Bearing Disassembly
Disassembly Note.) Note.)
Front drive shaft bearing (rear case side) 65 Retainer
27 (See 03–16–6 Front Drive Shaft Bearing
Disassembly Note.) 66 Maindrive gear
Sprocket 67 Oil seal (control rod)
28 (See 03–16–6 Chain, Front Drive Shaft and 68 Oil seal (front case)
Sprocket Disassembly Note.) 69 Front case
29 Needle bearing
30 Center bearing retainer
31 Oil catcher
32 Oil passage
33 Center case
03–16–3
TRANSFER
Companion Flange Disassembly Note
1. Hold the companion flange using the SST.
Center case side
49 S120 710
DBG316BMB003
Rear case side
49 S120 710
DBG316BMB001
2. Remove the locknut.

3. Remove the companion flange using the SST.
Center case side
49 0839 425C
DBG316BMB004
Rear case side
49 0839 425C
DBG316BMB002
03–16–4
TRANSFER
Oil Seal (Rear Case) Disassembly Note
1. Remove the oil seal (rear case) using a flathead
screwdriver as shown in the figure.
03
DBG316BMB039
Oil Seal (Center Case) Disassembly Note

1. Remove the oil seal (center case) using a
flathead screwdriver as shown in the figure.
DBG316BMB040
Mainshaft Rear Bearing Disassembly Note

1. Remove the mainshaft rear bearing using the
SSTs. 49 0839 425C
49 H017 101
DBG316BMB005
2W/4W Clutch Hub Disassembly Note

1. Remove the 2W/4W clutch hub using the SSTs.
49 0839 425C
49 H017 101
DBG316BMB006
03–16–5
TRANSFER
Chain, Front Drive Shaft and Sprocket Disassembly Note
1. Remove the front drive shaft using the plastic
hammer.
DBG316BMB042
2. Remove the chain, front drive shaft and sprocket

as a single unit.
DBG316BMB036
Front Drive Shaft Bearing Disassembly Note

1. Remove the front drive shaft bearing using the SSTs and press.
Center case side
49 H027 002
DBG316BMB007
Rear case side
49 E032 303
49 H027 002
DBG316BMB008
03–16–6
TRANSFER
Mainshaft Center Bearing Disassembly Note
1. Remove the mainshaft front bearing using the
press.
03
DBG316BMB012
Countershaft Bearing Disassembly Note

1. Remove the countershaft bearing using the SSTs and press.
Front case side
49 E032 303
49 F026 103
DBG316BMB010
Center case side
49 E032 303
49 H027 002
DBG316BMB011
Maindrive Gear Bearing Disassembly Note

1. Remove the maindrive gear bearing using the
SST, press and steel plate.
Note STEEL PLATE

• Steel plate height: 10 mm {0.39 in} or more.
49 F026 103
DBG316BMB009
03–16–7
TRANSFER
Oil Seal (Control Rod) Disassembly Note
1. Remove the oil seal (control rod) using a flathead
DBG316BMB043
Oil Seal (Front Case) Disassembly Note

1. Remove the oil seal (front case) using a flathead
End Of Sie
DBG316BMB041
TRANSFER ASSEMBLY
DCF031600000W03
Before Service Precautions
• Assemble with bare hands or using vinyl gloves. To prevent foreign material from entering the transfer, do not
use cotton work gloves or a rag.
• Apply sufficient gear oil to the sliding surfaces and O-rings, and be careful not to damage when assembling.
• Replace the transfer with a new one if the case alignment surface is damaged. Be careful not to damage it
since it may cause oil leakage.
• When installing silicone sealant, clean off the old sealant adhering to the sealing area and clean the sealing
area with cleaning fluids.
• After installing a seal, leave the parts alone for 2 h or more. Do not add oil or operate the vehicle during this
time.
03–16–8
TRANSFER
Transfer Assembly
61 SST 294.2—451.1
{30.01—45.99,
217.0—332.7}
60 R
57
SEALANT
52 03
41.2—48.1 51 53
{4.21—4.90, 49
45 30.4—35.4} 48
47
42 SST 24
R
44
R
23
43 SST
56 15.7—20.6 B
D {1.61—2.11,
55 R SST 3.73—5.00 N·m
11.6—15.1}
B {38.1—50.9 kgf·cm,
54 SST 33.1—44.1 in·lbf}
38 50
41 46 OIL
SEALANT
58 R 39 R
40 21
59 SST
32 R SELECTIVE 20
18 15
31 R 16
30 SST 19
225.6—323.6
17
37 R
{23.01—32.99,
166.4—238.6} 41.2—48.1 A
{4.21—4.90, C
30.4—35.4}
29
A 8 19.6—23.5
69 {2.00—2.39,
33
15.7—22.5 11.6—17.3}
{1.61—2.29, 68 R 34
11.6—16.5}
6 SST 35
67 36 R 15—19
7.8—11 N·m 66 R 14 {1.6—1.9,
{80—112 kgf·cm, 12—14}
70—99 in·lbf} E 28 OIL
65 C D 4
64 63
SEALANT
5 62
7 R SELECTIVE 3.73—5.00 N·m E
{38.1—50.9 kgf·cm, 2
33.1—44.1 in·lbf}
3 R
9 13 SELECTIVE
22 10 SST
25 26
15.7—21.6 12
1 SEALANT 27 {1.61—2.20,
11.6—15.9} 11 SST N·m {kgf·m, ft·lbf}
DBG316BMB027
1 Front case Oil seal (control rod)

2 (See 03–16–11 Oil Seal (control rod) Assembly
Note.)
03–16–9
TRANSFER
Oil seal (front case) Sprocket
3 (See 03–16–11 Oil Seal (front case) Assembly 41 (See 03–16–14 Chain, Front Drive Shaft and
Note.) Sprocket Assembly Note.)
4 Maindrive gear Front drive shaft bearing (rear case side)
5 Retainer 42 (See 03–16–15 Front Drive Shaft Bearing Assembly
Note.)
Maindrive gear bearing
6 (See 03–16–11 Maindrive Gear Bearing Assembly Front drive shaft bearing (center case side)
Note.) 43 (See 03–16–15 Front Drive Shaft Bearing Assembly
Note.)
Retaining ring
7 (See 03–16–11 Maindrive Gear Bearing Assembly Front drive shaft
Note.) 44 (See 03–16–14 Chain, Front Drive Shaft and
Sprocket Assembly Note.)
8 Retaining bolt
Chain
9 Baffle plate 45 (See 03–16–14 Chain, Front Drive Shaft and
Countershaft rear bearing (center case side) Sprocket Assembly Note.)
10 (See 03–16–12 Countershaft Bearing Assembly Needle bearing
Note.) 46 (See 03–16–14 Chain, Front Drive Shaft and
Countershaft front bearing (front case side) Sprocket Assembly Note.)
11 (See 03–16–12 Countershaft Bearing Assembly 47 Snap ring
Note.)
48 Collar
Countershaft
12 49 Spring
(See 03–16–12 Countershaft Assembly Note.)
Adjustment shim 50 2W/4W hub sleeve
13
(See 03–16–12 Countershaft Assembly Note.) 51 2W/4W shift fork
14 H/L hub sleeve 52 Spacer
15 H/L shift fork 53 Snap ring
16 Plunger 2W/4W clutch hub
17 Spring 54 (See 03–16–15 2W/4W Clutch Hub Assembly
Note.)
18 Plain washer
19 Snap ring 55 (See 03–16–16 Mainshaft Rear Bearing Assembly
20 H/L shift rod Note.)
21 Snap ring 56 Speed drive gear
22 Interlock pin Rear case
57
23 2W/4W shift end (See 03–16–16 Rear Case Assembly Note.)
24 2W/4W shift rod Oil seal (center case)
25 Steel ball 58 (See 03–16–16 Oil Seal (center case) Assembly
Note.)
26 Spring
59 Companion flange (center case side)
27 Retaining bolt
Oil seal (rear case)
28 Needle bearing 60 (See 03–16–17 Oil Seal (rear case) Assembly
Mainshaft Note.)
29 (See 03–16–13 Mainshaft and Mainshaft Center 61 Companion flange (rear case side)
Bearing Assembly Note.)
62 Control rod
Mainshaft center bearing
30 (See 03–16–13 Mainshaft and Mainshaft Center 63 Control rod end
Bearing Assembly Note.) 64 Guide plate
31 Retaining ring 65 Reverse gate lever
Retaining ring 66 Reverse gate spring
32 (See 03–16–13 Mainshaft and Mainshaft Center 67 Spacer
Bearing Assembly Note.) 68 E-ring
33 Needle bearing Control case
34 Low gear 69
(See 03–16–17 Control Case Assembly Note.)
35 H/L clutch hub
36 Retaining ring
Center case
37
(See 03–16–13 Center Case Assembly Note.)
Oil passage
38
(See 03–16–14 Oil Passage Assembly Note.)
Oil catcher
39
(See 03–16–14 Oil Catcher Assembly Note.)
40 Center bearing retainer
03–16–10
TRANSFER
Oil Seal (control rod) Assembly Note
Caution
• Assemble the oil seal being careful not to assemble it in the incorrect direction.
1. Apply specified grease to the lip of a new oil seal.

2. Install the oil seal (control rod) using the SST.
03
Installation depth A: 0 mm {0 in}
49 M005 797
DBG316BMB030
Oil Seal (front case) Assembly Note

2. Install the oil seal (front case) using the SST.
A
Installation depth A: 2.4—3.0 mm {0.095—
0.118 in} 49 F027 009
DBG316BMB013
Maindrive Gear Bearing Assembly Note

1. Assemble the maindrive gear bearing using the
SST and press.
2. Install the retaining ring. 49 G028 203
DBG316BMB021
03–16–11
TRANSFER
3. Measure the clearance between the retaining ring
and groove of the maindrive gear. RETAINING RING
• If not within the specification, adjust by
choosing the proper retaining ring.
Maindrive gear bearing end play

0—0.15 mm {0.0—0.0059 in} MAINDRIVE GEAR END PLAY
Maindrive gear bearing retaining ring

Thickness (mm {in})
2.60 {0.102}
2.67 {0.105} DBG316BMB033
2.74 {0.108}
Countershaft Bearing Assembly Note

1. Assemble the countershaft bearing using the SSTs and press.
Front case side
49 F401 331
49 H001 628
DBG316BMB019
Center case side
49 F401 331
49 H001 628
DBG316BMB020
Countershaft Assembly Note

1. Assemble the countershaft to the front case.
2. Measure the depth A as shown in the figure.
3. Select the correct countershaft adjustment shim A
thickness.
Countershaft adjustment shim selective chart

Dimension A (mm {in}) Shim thickness (mm {in})
25.0—25.1
0.5 {0.020}
{0.985—0.988}
25.1—25.2
0.4 {0.016}
{0.989—0.992}
25.2—25.3
0.3 {0.012}
{0.993—0.996} DBG316BMB032
25.3—25.4
0.2 {0.008}
{0.997—1.000}
25.4—25.5
0.1 {0.004}
{1.000—1.003}
25.5—25.6
-
{1.004—1.007}
4. Install the adjustment shim.

03–16–12
TRANSFER
Mainshaft and Mainshaft Center Bearing Assembly Note
1. Assemble the mainshaft center bearing using the
SST and press.
49 U025 001 03
DBG316BMB018
2. Measure the clearance between the retaining ring MAINSHAFT CENTER BEARING
and groove of the mainshaft.
• If not within the specification, adjust by RETAINING RING
MAINSHAFT
Mainshaft center bearing end play

0—0.15 mm {0.0—0.0059 in}
Mainshaft center bearing retaining ring

Thickness (mm {in}) MAINSHAFT CENTER BEARING
END PLAY
3.1 {0.122}
3.2 {0.126} DBG316BMB031
3.3 {0.130}
3. Assemble the mainshaft to the center case using the plastic hammer.
Center Case Assembly Note

1. Apply sealant to the contact surfaces of the front
case and center case as shown in the figure.
SEALANT
DBG316BMB028
2. Assemble the center case.
Bolt length (measured from below the head)

43 mm {1.69 in}
DBG316BMB038
03–16–13
TRANSFER
Oil Passage Assembly Note
1. Assemble the oil passage to the center case.
Note
• Align the oil passage of the center case
groove as shown in the figure.
OIL PASSAGE
CENTER CASE
DBG316BMB035
Oil Catcher Assembly Note

1. Align the oil catcher groove as shown in the
figure.
DBG316BMB016
3. Install the oil catcher using the SST.
49 G033 107A
DBG316BMB017
Chain, Front Drive Shaft and Sprocket Assembly Note

1. Assemble the chain, front drive shaft and sprocket
as a single unit.
Note
• Assemble the front drive shaft using the
plastic hammer.
DBG316BMB036
03–16–14
TRANSFER
2. Install the needle bearings while turning the
mainshaft.
03
DBG316BMB037
Front Drive Shaft Bearing Assembly Note

1. Assemble the front drive shaft bearing using the SSTs and press.
Center case side
49 F401 331
49 F401 336B
DBG316BMB023
Rear case side
49 F401 331
49 F401 336B
DBG316BMB022
2W/4W Clutch Hub Assembly Note

1. Assemble the 2W/4W clutch hub using the SST.
49 0727 415
DBG316BMB024
03–16–15
TRANSFER
Mainshaft Rear Bearing Assembly Note
1. Assemble the mainshaft rear bearing using the
SST.
49 F401 331
DBG316BMB025
Rear Case Assembly Note

1. Apply sealant to the contact surfaces of the center
case and rear case as shown in the figure. SEALANT
DBG316BMB029
2. Assemble the rear case.
Bolt length (measured from below the head) B

A: 58 mm {2.28 in} A
B: 113 mm {4.45 in}
A
A
DBG316BMB034
Oil Seal (center case) Assembly Note

2. Install the oil seal (center case) using the SST.
49 T019 005
DBG316BMB014
03–16–16
TRANSFER
Oil Seal (rear case) Assembly Note
2. Install the oil seal (rear case) using the SST.
Installation depth A: 6.7—7.3 mm {0.27— A

0.28 in}
03
49 T019 005
DBG316BMB015
Control Case Assembly Note

1. Apply sealant to the contact surfaces of the
control case and transfer case as shown in the
figure.
2. Install the control case to the transfer case. SEALANT
End Of Sie
DBG511BMB021
03–16–17
TECHNICAL DATA
03–50 TECHNICAL DATA

TECHNICAL DATA . . . . . . . . . . . . . . . . . 03–50–1
End of Toc
TECHNICAL DATA
DCF035000000W01
Item Specification 03
Maindrive gear bearing end play 0—0.15 mm {0.0—0.0059 in}
Mainshaft center bearing end play 0—0.15 mm {0.0—0.0059 in}
Maindrive gear bearing retaining ring

Thickness (mm {in})
2.60 {0.102}
2.67 {0.105}
2.74 {0.108}
Countershaft adjustment shim selective chart

Dimension A (mm {in}) Shim thickness (mm {in})
25.0—25.1
0.5 {0.020}
{0.985—0.988}
25.1—25.2
0.4 {0.016}
{0.989—0.992}
25.2—25.3
0.3 {0.012}
{0.993—0.996}
25.3—25.4
0.2 {0.008}
{0.997—1.000}
25.4—25.5
0.1 {0.004}
{1.000—1.003}
25.5—25.6
-
{1.004—1.007}
Mainshaft center bearing retaining ring

Thickness (mm {in})
3.1 {0.122}
3.2 {0.126}
3.3 {0.130}
End Of Sie
03–50–1
SERVICE TOOLS
03–60 SERVICE TOOLS

SERVICE TOOLS . . . . . . . . . . . . . . . . . . 03–60–1
End of Toc
SERVICE TOOLS
DCF036000000W01
49 H017 101 49 0727 415 49 0839 425C 03

Hook Bearing Installer Bearing puller
set
49 E032 303 49 S120 710 49 F401 336B
Bearing Coupling flange Attachment

Remover holder
49 H027 002 49 F026 103 49 G028 203
Bearing Wheel Hub Support

remover Puller
49 H001 628 49 F401 331 49 U025 001
Guide Pin Body Installer

Protector
49 F027 009 49 T019 005 49 G033 107A
Attachment 68 Support Block Installer Dust

And 77 Cover
49 M005 797
Installer oil seal

– –
End Of Sie
03–60–1
TRANSMISSION/TRANSAXLE 05
SECTION
Toc of SCT TRANSMISSION

MANUAL TECHNICAL DATA
[R15M-D] . . . . . . . . . . . . . . . . 05-11A [S15M-D, S15MX-D] . . . . . . . . 05-50B
MANUAL TRANSMISSION SERVICE TOOLS
[S15M-D, S15MX-D] . . . . . . . 05-11B [R15M-D] . . . . . . . . . . . . . . . . 05-60A
TECHNICAL DATA SERVICE TOOLS
05
[R15M-D] . . . . . . . . . . . . . . . . 05-50A [S15M-D, S15MX-D] . . . . . . . . 05-60B
Toc of SCT
05–11A MANUAL TRANSMISSION [R15M-D]
PRECAUTION [R15M-D]. . . . . . . . . . . . . 05–11A–1 MAINSHAFT AND COUNTER SHAFT
CLUTCH HOUSING AND EXTENSION COMPONENTS DISASSEMBLY
HOUSING DISASSEMBLY [R15M-D] . . . . . . . . . . . . . . . . . . . . . . . . 05–11A–23
[R15M-D] . . . . . . . . . . . . . . . . . . . . . . . . 05–11A–2 MAINSHAFT AND COUNTER SHAFT
5TH/REVERSE GEAR AND HOUSING COMPONENTS INSPECTION
PARTS DISASSEMBLY [R15M-D] . . . . 05–11A–4 [R15M-D] . . . . . . . . . . . . . . . . . . . . . . . . 05–11A–25
5TH/REVERSE GEAR AND HOUSING MAINSHAFT AND COUNTER SHAFT
PARTS INSPECTION [R15M-D] . . . . . . 05–11A–7 COMPONENTS ASSEMBLY
5TH/REVERSE GEAR AND HOUSING [R15M-D] . . . . . . . . . . . . . . . . . . . . . . . . 05–11A–26
PARTS ASSEMBLY [R15M-D] . . . . . . . 05–11A–8 CLUTCH HOUSING AND EXTENSION
TRANSMISSION CASE COMPONENTS HOUSING INSPECTION [R15M-D] . . . . 05–11A–29
DISASSEMBLY [R15M-D]. . . . . . . . . . . 05–11A–16 CLUTCH HOUSING AND EXTENSION
TRANSMISSION CASE COMPONENTS HOUSING ASSEMBLY [R15M-D] . . . . . 05–11A–30
ASSEMBLY [R15M-D]. . . . . . . . . . . . . . 05–11A–19
End of Toc
PRECAUTION [R15M-D]
DCF051100000W03
1. Clean the transmission exterior thoroughly using a steam cleaner or cleaning solvents before disassembly.
Warning
• Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eye wear whenever using compressed air.
Caution
• Cleaning sealed bearings using cleaning fluids or a steam cleaner can wash the grease out of the
bearing.
2. Clean the removed parts using cleaning solvent, and dry them using compressed air.
3. Clean out all holes and passages using compressed air, and check that there are no obstructions.
4. Use a plastic hammer when disassembling the transmission case and other light alloy metal parts.
5. Make sure each part is cleaned before assembling.
6. Coat all movable parts with the specified oil.
7. Replace parts whenever required.
8. Remove old sealant from contact surfaces before applying new sealant.
9. Assemble the parts within 10 min after applying sealant. Allow all sealant to cure at least 30 min after
assembling before filling the transmission with transmission oil.
Warning
• Although the stand has a self-locking brake system, there is a possibility that the brake may not
hold when the transmission is held in a lopsided position on the stand. This would cause the
transmission to turn suddenly, causing serious injury. Never keep the transmission tilted to one
side. Always hold the rotating handle firmly when turning the transmission.
End Of Sie
05–11A–1
MANUAL TRANSMISSION [R15M-D]
CLUTCH HOUSING AND EXTENSION HOUSING DISASSEMBLY [R15M-D]
DCF051117011W03
Caution
• Remove the oil seal (clutch housing, extension housing) only if there is a malfunction.
1. Disassemble in the order indicated in the table.

4
5
6 R
16
17
18
1
3
19
10
20
13 R
11
21 R
R
7
R R
15 R
8
R
12
9
14
DCF511AMB006
05–11A–2
1 Release fork Extension housing
2 Release collar 12 (See 05–11A–3 Extension Housing Disassembly
Note.)
3 Boot
13 Control rod end
4 Clutch housing
14 Control rod
5 Adjustment shim
15 Oil passage
6 Oil seal (clutch housing)
16 Snap ring
7 Neutral switch
17 Speed drive gear
Vehicle speed sensor
8 18 Snap ring
9
(speed driven gear)
Back-up light switch 19 Steel ball
05
10 Control case 20 Under cover
11 Stopper pin 21 Oil seal (extension housing)
Extension Housing Disassembly Note

1. Remove the control rod from the shift rod end by
moving the control rod end.
2. Remove the extension housing.
End Of Sie
BHJ0511M009
05–11A–3
5TH/REVERSE GEAR AND HOUSING PARTS DISASSEMBLY [R15M-D]
DCF051117030W06
R
R C
A 28
30
34 B
32
40 SST R
33 31
19
29 41 SST
R 20 42
27 R 43
R 44
20 47 45 4
46
36 5
35 R
37 6
D 7
39 R
3
38 R
48 A
1
20 B 2
C 3
21 9
11
22 8
24
23 10 SST
18
SST
13
14 25 R
15 26
12
SST
R
D 17 16
DCF511AMB001
1 5th/reverse shift rod end Locknut

2 3rd/4th shift rod end 12 (See 05–11A–5 Locknut, Countershaft Rear
Bearing Disassembly Note.)
3 1st/2nd shift rod end
Countershaft rear bearing
4 Retaining ring 13 (See 05–11A–5 Locknut, Countershaft Rear
5 Spring retainer Bearing Disassembly Note.)
6 Spring 14 Counter 5th gear
7 Pin and retaining ring 15 Spacer
8 Bearing housing 16 Set bolt, packing
9 C-clip 17 Center housing
Mainshaft rear bearing 18 Oil passage
10 (See 05–11A–5 Mainshaft Rear Bearing 19 Blind cover
Disassembly Note.)
20 Spring cap, spring, detent ball
11 C-clip
21 Thrust lock washer
22 Steel ball
05–11A–4
23 Bearing 35 Thrust washer
24 5th gear 36 Reverse idler gear shaft
25 Retaining ring 37 Reverse idler gear
26 Synchronizer ring (5th) 38 Thrust washer
27 Retaining ring 39 Counter reverse gear
5th/reverse shift rod Locknut
28 (See 05–11A–6 5th/Reverse Shift Rod Disassembly 40 (See 05–11A–6 Locknut, 5th/Reverse Clutch Hub
Note.) Component Disassembly Note.)
29 Spring 5th/reverse clutch hub component
30 5th/reverse shift fork 41 (See 05–11A–6 Locknut, 5th/Reverse Clutch Hub 05
Component Disassembly Note.)
31 Interlock pin
42 Reverse synchronizer ring
3rd/4th shift rod
32 (See 05–11A–6 1st/2nd Shift Rod, 3rd/4th Shift Rod 43 Reverse gear
Disassembly Note.) 44 Bearing
33 Interlock pin 45 Bearing race
1st/2nd shift rod 46 Thrust washer
34 (See 05–11A–6 1st/2nd Shift Rod, 3rd/4th Shift Rod 47 Bearing cover
Disassembly Note.)
48 Oil passage

1. Remove the C-clip (rear).
Caution
• Be sure to identify the front and rear C-
clips to reinstall them correctly.
2. Remove the mainshaft bearing using the SSTs.

3. Remove the C-clip (front).
49 H017 101
49 0839 425C
BHJ0511M006
Locknut, Countershaft Rear Bearing Disassembly Note

1. Shift the 1st/2nd shift rod and 5th/reverse shift rod
to engage the 1st gear and reverse gear.
2. Uncrimp the tab of the locknut.
3. Install the SST to the mainshaft and secure it in a
vise.
4. Remove the locknut.
Caution
• Do not reuse the locknut.
49 S120 440
BHJ0511M007
5. Remove the countershaft rear bearing using the

SST.
Caution
• Do not damage the countershaft.
49 0839 425C
BHJ0511M008
05–11A–5
5th/Reverse Shift Rod Disassembly Note
1. Remove the spring caps, springs, detent balls and
packing. PACKING
2. Remove the roll pins.
3. Remove the retaining ring.
4. Remove the 5th/reverse shift rod and retaining
spring.
DCF511AMB007
1st/2nd Shift Rod, 3rd/4th Shift Rod Disassembly Note

1. Shift the transmission into 4th gear.
2. Remove the roll pin from the 3rd/4th shift rod.
3. Remove the 3rd/4th shift rod and interlock pin (small) from the rear of the transmission case as a single unit.
4. Remove the roll pin from the 1st/2nd shift rod.
5. Remove the 1st/2nd shift rod from the rear of the transmission case.
6. Remove the interlock pin (large).
Locknut, 5th/Reverse Clutch Hub Component Disassembly Note

1. Uncrimp the tab of the locknut.
2. Shift the clutch hub sleeves to engage the 1st and
4th gears.
BHJ0511M014
3. Remove the locknut using the SST.

49 1243 465A
Caution
• Do not reuse the locknut.
4. Remove the bearing cover installation bolts.
BHJ0511M015
5. Install the SSTs to the bearing cover and remove

the following parts as a single unit: 49 H017 101
• 5th/reverse clutch hub component
• Synchronizer ring 49 0839 425C
• Needle bearing
• Bearing race
• Reverse gear
• Thrust washer
6. Remove the thrust washer, reverse idler gear
shaft and reverse idler gear.
End Of Sie
BHJ0511M016
05–11A–6
5TH/REVERSE GEAR AND HOUSING PARTS INSPECTION [R15M-D]
DCF051117030W07
Clutch Hub Component
1. Measure the clearance between each shift fork
and clutch hub sleeve groove using a feeler
gauge.
• If not within the specification, replace the shift
fork and clutch hub sleeve as a set.
Standard
0.2—0.3 mm {0.008—0.012 in}
Maximum
05
0.5 mm {0.020 in}
BHJ0511M018
Synchronizer Ring (5th, Reverse)

1. Measure the clearance between the synchronizer
ring and flank surface of the gear using a feeler
gauge around the entire circumference.
synchronizer ring.
Standard
1.5 mm {0.059 in}
Maximum
0.8 mm {0.031 in}
Note
• Set the synchronizer ring squarely in the
BHJ0511M020
gear.
Reverse Idler Gear, Shaft

1. Measure the clearance between the reverse idler
gear bushing and shaft using a micrometer and
caliper gauge.
reverse idler gear.
Standard
0.02—0.05 mm {0.0008—0.0020 in}
Maximum
0.15 mm {0.006 in}
BHJ0511M022
Spring
1. Measure the free length of each spring.
spring.
FREE LENGTH
Standard
mm {in}
Detent ball spring 22.5 {0.886}
5th/reverse rataining spring 73.0 {2.874}
End Of Sie
BHE0511M023
05–11A–7
5TH/REVERSE GEAR AND HOUSING PARTS ASSEMBLY [R15M-D]
DCF051117030W08
OIL
APPLY SPECIFIED OIL TO INDIVIDUAL PARTS
SST
FRONT
5TH/REVERSE
CLUTCH HUB
R
R C
FRONT
A 27
25
SST 21 B
7.8—12 N·m
{80—120 kgf·cm, 23
70—104 in·lbf}
13 SST R
SST 157—235
22 24
{16—24,
116—173}
30 39—59 SST
{4.0—6.0,
29—43}
26 12
R
11 44
29 28 R 10
9 43
R 8 18—26
42
29 6 7 {1.8—2.7,
14—19} 41
4 R
R
5 45
3
D
1
R
2
47
48 A
29 B 46
SELECTIVE C
USE 19 SST 45
39
19—25 38 40
{1.9—2.6, 18
14—18} 16
17
SELECTIVE
33
USE
20 SEALANT
SST
36
35 15 R
34 14
RETAINING
37 RING
SST FRONT
R
127—196
{13—20,
95—144}
D 31
32
8.8—14 N·m
{90—140 kgf·cm,
79—121 in·lbf}
SEALANT
DCF511AMB002
05–11A–8
.
1 Counter reverse gear 26 Spring

2 Thrust washer 5th/reverse shift rod
3 Reverse idler gear 27 (See 05–11A–12 Shift Fork, Shift Rod Assembly
Note.)
4 Reverse idler gear shaft
28 Retaining ring
5 Thrust washer
29 Spring cap, spring, detent ball
6 Bearing cover
30 Blind cover
7 Thrust washer
Center housing
8 Bearing race 31
(See 05–11A–13 Center Housing Assembly Note.)
9 Bearing 32 Set bolt, packing
05
10 Reverse gear 33 Oil passage
Reverse synchronizer ring 34 Spacer
11
(See 05–11A–9 Synchronizer Ring Assembly Note.)
35 Counter 5th gear
5th/reverse clutch hub component
12 (See 05–11A–10 5th/Reverse Clutch Hub Countershaft rear bearing
Component Assembly Note.) 36 (See 05–11A–14 Countershaft Rear Bearing
Assembly Note.)
13 Locknut
37 Locknut
Synchronizer ring (5th)
14 Mainshaft rear bearing
(See 05–11A–9 Synchronizer Ring Assembly Note.)
38 (See 05–11A–14 Mainshaft Rear Bearing Assembly
15 Retaining ring Note.)
5th gear 39 C-clip
16
(See 05–11A–11 5th Gear Assembly Note.)
Bearing housing
17 Bearing 40
(See 05–11A–15 Bearing Housing Assembly Note.)
18 Steel ball 41 Pin and retaining ring
19 Thrust lock washer 42 Spring
20 C-clip 43 Spring retainer
1st/2nd shift rod 44 Retaining ring
21 (See 05–11A–12 Shift Fork, Shift Rod Assembly
Note.) 1st/2nd shift rod end
45
(See 05–11A–15 Shift Rod End Assembly Note.)
22 Interlock pin
3rd/4th shift rod end
3rd/4th shift rod 46
Note.) 5th/reverse shift rod end
47
24 Interlock pin
48 Oil passage
5th/reverse shift fork
Note.)
Synchronizer Ring Assembly Note

1. Identify the 5th and reverse synchronizer rings
according to the identification marks and
assemble.
Identification mark
One tooth missing in three places
5th
around its circumference
Reverse None
5TH REVERSE
BHE0511M025
05–11A–9
5th/Reverse Clutch Hub Component Assembly Note
Caution
• Be sure to assemble the 5th/reverse
clutch hub component and 5th/reverse
synchronizer ring while aligning the
synchronizer ring grooves with the
synchronizer keys.
BHJ0511M026
• The standard synchronizer key

dimensions are as follows:
mm {in}
1 2 3 1 3
5th/reverse 17.0 {0.67} 4.25 {0.17} 5.0 {0.20}
2
BHJ0511M027
Caution
• Be sure to assemble the 5th/reverse
clutch hub component to the mainshaft
so that the chamfered side faces the
vehicle front as shown in the figure.
FRONT
CHAMFER
BHE0511M028
1. Shift the clutch hub sleeves to engage the 1st and

4th gears.
2. Install a new locknut using the SST.
Tightening torque
157—235 N·m {16—24 kgf·m, 116—173 ft·lbf} 49 1243 465A
BHJ0511M029
05–11A–10
3. Measure clearance A between the synchronizer
key and synchronizer ring.
choosing the proper thrust washer on the
front of the mainshaft front bearing. A
Standard
0.66—2.0 mm {0.026—0.079 in}
Thickness (mm {in})

4TH GEAR 3RD GEAR 05
2.5 {0.098}
Thrust washer 3.0 {0.118} BHE0511M030
3.5 {0.138}
Caution
• The total combined thickness of the front and rear thrust washers must equal 6.0 mm {0.236 in}.
4. Stake the locknut into the mainshaft groove.
BHJ0511M031
5th Gear Assembly Note

1. Assemble a new retaining ring.
2. Install the synchronizer ring, 5th gear and RETAINING RING
bearing.
3. Install the steel ball and thrust lock washer.
4. Install the 3.0 mm {0.118 in} C-clip.
5TH GEAR
BEARING
BHE0511M032
5. Measure the clearance (5th gear end play)

between the thrust lock washer and C-clip.
choosing the proper thrust lock washer.
0.1−0.2 mm
Standard
{0.004−0.008 in}
0.1—0.2 mm {0.004—0.008 in}
Thickness (mm {in})

6.2 {0.244}
6.3 {0.248}
BHE0511M034
6.4 {0.252}
Thrust lock washer
6.5 {0.256}
6.6 {0.260}
6.7 {0.264}
Caution
• Be sure to measure the 5th gear end play with the C-clip pushed toward the 5th gear.
05–11A–11
Shift Fork, Shift Rod Assembly Note
Note
• The 3rd/4th shift rod is the longest.
• The 5th/reverse shift rod has an extra hole
for the roll pin at the rear of the rod. 1ST/2ND SHIFT ROD
• When assembling the shift rods, set the DETENTS
3RD/4TH SHIFT ROD
detents toward the ball side.
5TH/REVERSE SHIFT ROD
DCF511AMB009
1. Slide the 1st/2nd shift rod.
BHJ0511M036
2. Assemble a new roll pin in the direction shown in the figure.
Note
• The interlock pins must be assembled as
DCF511AMB011
3. Slide the SSTs into the transmission case to

guide the interlock pins, and insert the first pin.
4. Remove the SST (for 3rd/4th shift fork guide) from
the transmission case.
5. Slide the 3rd/4th shift rod containing the interlock
pin (small) into the transmission case.
6. Secure the 3rd/4th shift rod onto the fork with the
new roll pin.
7. Insert the remaining interlock pin and remove the
SSTs.
8. Assemble the 5th/reverse fork to the clutch hub. 49 0862 350
9. Assemble the 5th/reverse shift rod in the
BHJ0511M038
transmission case through the spring.
05–11A–12
10. Install a new retaining ring using the SST.
49 S017 401
05
BHJ0511M039
11. Assemble a new roll pin in the direction as shown

in the figure and secure the 5th/reverse shift fork
to the shift rod.
12. Assemble the blind covers, wiring harness clip
and new gaskets.
Tightening torque
7.8—12 N·m
{80—120 kgf·cm, 70—104 in·lbf}
BHJ0511M040
13. Install new packing, detent balls, springs and

spring caps. A PACKING
Tightening torque
A: 39—59 N·m
{4.0—6.0 kgf·m, 29—43 ft·lbf}
B: 19—25 N·m
{1.9—2.6 kgf·m, 14—18 ft·lbf}
B
DCF511AMB008
Center Housing Assembly Note

transmission case and center housing as shown
in the figure.
2. Install the oil passage to the center housing.
3. Install the center housing.
4. Align the reverse idler gear shaft with the set bolt
hole, and install the packing and set bolt.
Tightening torque
8.8—14 N·m
{90—140 kgf·cm, 79—121 in·lbf}
BHJ0511M042
5. Assemble the spacer and counter 5th gear.
05–11A–13
Countershaft Rear Bearing Assembly Note
1. Assemble the countershaft rear bearing using the
SSTs. 49 F401 335A
49 F401 331
BHJ0511M044
2. Install the SST to the mainshaft and secure it in a

vise.
3. Shift the 1st/2nd shift rod and 5th/reverse shift rod
to engage the 1st gear and reverse gear.
4. Tighten a new locknut.
Tightening torque
127—196 N·m
{13—20 kgf·m, 95—144 ft·lbf}
5. Stake the locknut into the countershaft groove. 49 S120 440

BHJ0511M045
Mainshaft Rear Bearing Assembly Note

1. Assemble the mainshaft rear bearing using the
SST.
49 N017 103
BHJ0511M047
2. Install the C-clip.

3. Measure the clearance between C-clip and
groove.
choosing the proper C-clip. 0−0.1 mm
{0−0.004 in}
Standard
0—0.1 mm {0—0.004 in}
Thickness (mm {in})

2.9 {0.114}
C-clip 3.0 {0.118} BHE0511M048
3.1 {0.122}
05–11A–14
Bearing Housing Assembly Note
1. Apply sealant to the contact surfaces of the center
housing and bearing housing as shown in the
figure.
2. Assemble the bearing housing.
05
BHJ0511M049
Shift Rod End Assembly Note

1. Assemble the shift rod ends onto the proper shift
rods, and secure them with new roll pins pointing
in the direction shown in the figure.
End Of Sie
BHJ0511M050
05–11A–15
TRANSMISSION CASE COMPONENTS DISASSEMBLY [R15M-D]
DCF051117030W09
6 SST
7
15
D
5 SST
SST
2
A 14
13 B
C
1 8
4
R
3 SST
11
10 12
D
A
9
C
BHJ0511M051
1 Snap ring Mainshaft front bearing

Main drive gear bearing 6 (See 05–11A–18 Mainshaft Front Bearing
2 (See 05–11A–17 Main Drive Gear Bearing Disassembly Note.)
Disassembly Note.) 7 Adjustment shim
Countershaft front bearing 8 Thrust washer
3 (See 05–11A–17 Countershaft Front Bearing 9 Countershaft component
Disassembly Note.)
10 Main drive gear
4 Adjustment shim
11 Bearing
Countershaft center bearing
5 (See 05–11A–18 Countershaft Center Bearing 12 Mainshaft gear component
Disassembly Note.) 13 3rd/4th shift fork
14 1st/2nd shift fork
15 Transmission case
05–11A–16
Main Drive Gear Bearing Disassembly Note
1. Install the SST between the 4th gear synchronizer
ring and main drive synchromesh gear. 49 F017 101
05
BHJ0511M072
2. Turn the bearing snap ring so that the ends are at

a 90° angle to the transmission case groove.
90°
BHJ0511M053
3. Remove the main drive gear bearing using the

SST.
Caution
49 0839 425C
• When using the SST (bearing puller set),
tighten the screws securely and be
extremely careful not to damage the
bearing snap ring.
BHJ0511M054
Countershaft Front Bearing Disassembly Note

1. Turn the bearing snap ring so that the ends are at
a 90° angle to the transmission case groove.
90°
BHJ0511M055
05–11A–17
2. Remove the countershaft front bearing using the
SST. 49 0839 425C
Note
• When replacing the countershaft front
bearing, replace the spacer.
BHJ0511M056
Countershaft Center Bearing Disassembly Note

1. Remove the countershaft center bearing using
the SST.
49 0839 425C
BHJ0511M057
Mainshaft Front Bearing Disassembly Note

1. Remove the mainshaft front bearing using the
SSTs.
End Of Sie
49 0839 425C
49 H017 101
BHJ0511M058
05–11A–18
TRANSMISSION CASE COMPONENTS ASSEMBLY [R15M-D]
DCF051117030W10
10 SST
SELECTIVE USE 9
1
B 05
D
11 SST
SST
12
A 3
C 4 B
15 8 SELECTIVE USE
13 SELECTIVE USE
R
14 SST
5
6 2
D
A
7
C
GREASE
MOLYBDENUM GREASE
BHE0511M062
Transmission case Mainshaft front bearing

1 (See 05–11A–20 Transmission Case Assembly 10 (See 05–11A–21 Mainshaft Front Bearing Assembly
Note.) Note.)
2 Mainshaft gear component Countershaft center bearing
3 1st/2nd shift fork 11 (See 05–11A–21 Countershaft Center Bearing
Assembly Note.)
4 3rd/4th shift fork
Main drive gear bearing
5 Bearing 12 (See 05–11A–21 Main Drive Gear Bearing
6 Main drive gear Assembly Note.)
7 Countershaft component 13 Adjustment shim
8 Thrust washer Countershaft front bearing
9 Adjustment shim 14 (See 05–11A–22 Countershaft Front Bearing
Assembly Note.)
15 Snap ring
05–11A–19
Transmission Case Assembly Note
1. Adjust the mainshaft front bearing end play.
(1) Measure dimension D using a vernier caliper.
BHJ0511M063
(2) Measure dimension E using a vernier caliper.
Formula: T = D - E
T: Mainshaft front bearing end play

D: Depth of mainshaft front bearing bore in
the transmission case
E: Mainshaft front bearing snap ring height
E
Standard: 0—0.05 mm {0—0.002 in}
(3) If not within the specification, adjust by

BHJ0511M064
choosing the proper adjustment shim.
Thickness (mm {in})
0.1 {0.004}
Adjustment shim
0.3 {0.012}
2. Adjust the countershaft front bearing end play.

(1) Measure dimension B using a vernier caliper.
B
BHJ0511M065
(2) Measure dimension A using a vernier caliper.
Formula: T = A - B + adjustment shim

B A T 0—0.1 mm
thickness
{0—0.004 in}
T: Countershaft front bearing end play

A: Countershaft front bearing snap ring
height
B: Depth of countershaft front bearing bore ADJUSTMENT SHIM
in the transmission case
Standard: 0—0.1 mm {0—0.004 in}

BHE0511M066
(3) If not within the specification, adjust by

choosing the proper adjustment shim.
Thickness (mm {in})
0.1 {0.004}
Adjustment shim
0.3 {0.012}
05–11A–20
3. Assemble the 1st/2nd shift fork and 3rd/4th shift fork to the clutch hub component.
4. Apply specified grease to the needle bearing and assemble it to the main drive gear.
5. Assemble the main drive gear onto the front of the mainshaft.
6. Assemble the countershaft component to the transmission case.
7. Verify that the countershaft gears engage each gear of the mainshaft.
Mainshaft Front Bearing Assembly Note

1. Install the adjustment shim onto the rear of the mainshaft.
Caution
• Be sure to install the adjustment shim selected during the mainshaft front bearing end play 05
adjustment.
2. Assemble the mainshaft front bearing using the

SSTs.
49 N017 104
49 N017 103
BHJ0511M069
Countershaft Center Bearing Assembly Note

1. Assemble the countershaft center bearing onto
the rear of the countershaft using the SSTs. 49 F401 335A
49 F401 331
BHJ0511M070
Main Drive Gear Bearing Assembly Note

1. Install the SST between the 4th gear synchronizer
ring and main drive synchromesh gear. 49 F017 101
BHJ0511M072
05–11A–21
2. Assemble the main drive gear bearing using the
SSTs. 49 F017 101
49 0500 330
BHJ0511M073
Countershaft Front Bearing Assembly Note
Note
• When replacing the countershaft front bearing, replace the spacer.
1. Install the adjustment shim onto the countershaft front bearing.
Caution
• Be sure to install the adjustment shim selected during the countershaft front bearing end play
adjustment.
2. Assemble the countershaft front bearing using the

SSTs. 49 F401 335A
3. Assemble new snap rings to the main drive gear
and countershaft gear.
Note
• The counter drive gear side snap ring is
smaller than the main drive gear side snap
ring.
End Of Sie 49 F401 331
BHJ0511M074
05–11A–22
MAINSHAFT AND COUNTER SHAFT COMPONENTS DISASSEMBLY [R15M-D]
DCF051117040W04
Caution
• Remove the countershaft center bearing race only if there is a malfunction.
1. Disassemble in the order indicated in the table. .
SST 14
7 13
12 05
11
R 6 10
8
11
9
5
26
4
19
18
16 1
15 19 2
3
17
30
23
22 31
21
24 29
25 20 27 28
DCF511AMB003
1 1st gear 13 Bearing

2 Bearing 14 3rd gear
3 Bearing race 1st/2nd clutch hub component
4 Synchronizer ring (1st) 15 (See 05–11A–24 1st/2nd Clutch Hub Component
Disassembly Note.)
5 Synchronizer ring (4th)
16 1st/2nd clutch hub
6 Snap ring
17 Synchronizer key
3rd/4th clutch hub component
7 (See 05–11A–24 3rd/4th Clutch Hub Component 18 Clutch hub sleeve
Disassembly Note.) 19 Synchronizer key spring
8 3rd/4th clutch hub 20 Synchronizer ring component (2nd)
9 Synchronizer key 21 Inner cone
10 Clutch hub sleeve 22 Double cone
11 Synchronizer key spring 23 Synchronizer ring (2nd)
12 Synchronizer ring (3rd) 24 2nd gear
05–11A–23
25 Bearing 29 Friction gear
26 Mainshaft Countershaft center bearing race
27 Countershaft front bearing spacer 30 (See 05–11A–24 Countershaft Center Bearing Race
Disassembly Note.)
28 Diaphragm spring
31 Countershaft
3rd/4th Clutch Hub Component Disassembly Note

1. Remove the snap ring.
Caution
• Do not reuse the snap ring.
BHJ0511M077
2. Install the SST between the 2nd gear and 3rd

gear. 49 0636 145
3. Using a press, remove the 3rd/4th clutch hub
component, 3rd synchronizer ring and 3rd gear.
Caution
• Be sure to support the mainshaft
component so that it does not fall.
BHJ0511M078
1st/2nd Clutch Hub Component Disassembly Note

1. Using a press, remove the 1st/2nd clutch hub
component, 2nd synchronizer ring component
and 2nd gear.
Caution
BHJ0511M079
Countershaft Center Bearing Race Disassembly Note

1. Remove the countershaft center bearing race
using the SST.
Caution
• Be sure to support the countershaft so
that it does not fall. 49 0710 520
Note
• When replacing the countershaft center
bearing, replace the bearing race.
End Of Sie BHJ0511M080
05–11A–24
MAINSHAFT AND COUNTER SHAFT COMPONENTS INSPECTION [R15M-D]
DCF051117040W05
Mainshaft
1. Measure the mainshaft runout using a dial gauge.
replace the mainshaft.
Maximum: 0.03 mm {0.0012 in}
05
BHJ0511M084
2. Measure the clearance between the mainshaft

and gear (or bushing) using a micrometer and
caliper gauge.
replace the gear.
Maximum: 0.15 mm {0.006 in}
BHJ0511M085
Synchronizer ring (1st, 2nd, 3rd, 4th)

gauge.
synchronizer ring.
Standard: 1.5 mm {0.059 in}

Note
• Set the synchronizer ring squarely in the
gear.
BHJ0511M088

gauge.
Standard: 0.2—0.3 mm {0.008—0.012 in}

End Of Sie
BHJ0511M018
05–11A–25
MAINSHAFT AND COUNTER SHAFT COMPONENTS ASSEMBLY [R15M-D]
DCF051117040W06
OIL
CLUTCH HUBS FRONT
FRONT
13
3RD/4TH 1ST/2ND 14
R
21 15
22 19
18
16 17
19
20
1 FRONT
26
25
7 24
23
6 11
5 27 SST
4 10
8 9
11
12 31
2 3 28
30 29
DCF511AMB004
1 Mainshaft 10 Clutch hub sleeve

2 Bearing 11 Synchronizer key spring
3 2nd gear 1st/2nd clutch hub component
4 Inner cone 12 (See 05–11A–27 Clutch Hub Component (1st/2nd,
3rd/4th) Assembly Note.)
5 Double cone
13 3rd gear
6 Synchronizer ring (2nd)
14 Bearing
Synchronizer ring component (2nd)
7 (See 05–11A–27 Synchronizer Ring Component 15 Synchronizer ring (3rd)
Assembly Note.) 16 3rd/4th clutch hub
8 1st/2nd clutch hub 17 Synchronizer key
9 Synchronizer key 18 Clutch hub sleeve
05–11A–26
19 Synchronizer key spring Countershaft center bearing race
3rd/4th clutch hub component 27 (See 05–11A–29 Countershaft Center Bearing Race
20 (See 05–11A–27 Clutch Hub Component (1st/2nd, Assembly Note.)
3rd/4th) Assembly Note.) 28 Friction gear
21 Snap ring 29 Diaphram spring
22 Synchronizer ring (4th) Countershaft front bearing spacer
23 Synchronizer ring (1st) 30 (See 05–11A–29 Countershaft Front Bearing
Spacer Assembly Note.)
24 Bearing race
31 Countershaft
25 Bearing
26 1st gear
05
Synchronizer Ring Component Assembly Note

1. Assemble the inner cone, double cone and
SYNCHRONIZER RING
synchronizer ring as shown in the figure.
DOUBLE CONE
INNER CONE
BHE0511M090
Clutch Hub Component (1st/2nd, 3rd/4th) Assembly Note
Caution
• Be sure to assemble the clutch hub
components and synchronizer ring
components while aligning the
synchronizer ring grooves with the
synchronizer keys.
BHJ0511M093

mm {in}
1 2 3 1 3
1st/2nd,
17.0 {0.670} 4.25 {0.167} 5.0 {0.197}
3rd/4th 2
BHJ0511M095
05–11A–27
Caution
• Be sure to install each clutch hub
component onto the mainshaft in the
proper direction.
FRONT
MAINSHAFT
BHE0511M096
Caution
• Be sure to align the synchronizer ring projections with the inner cone notches.
• Be sure to assemble the gears and the
synchronizer ring components while
aligning the double cone projections with
the gear holes as shown in the figure.
BHE0511M097
1. Using a press, assemble the needle bearing, 2nd

gear, synchronizer ring component (2nd), 1st/2nd
clutch hub component to the mainshaft.
Caution
• When using a press, be careful not to
damage the parts.
BHJ0511M098
2. Set the needle bearing, 3rd gear, synchronizer

ring (3rd) and 3rd/4th clutch hub component on
the mainshaft, then press them onto the
mainshaft using the SST.
3. Install a new snap ring on the front of the 49 F401 331
mainshaft.
BHJ0511M099
05–11A–28
Countershaft Center Bearing Race Assembly Note
1. Assemble the countershaft center bearing race
using the SSTs.
49 F401 331
49 F401 335A
05
BHJ0511M201
Countershaft Front Bearing Spacer Assembly Note
Note
• When replacing the countershaft front bearing, replace the spacer.
End Of Sie
CLUTCH HOUSING AND EXTENSION HOUSING INSPECTION [R15M-D]
DCF051117011W04
Shift Rod End, Control Rod
1. Measure the clearance between the shift rod end
and control rod using a feeler gauge.
rod end and control rod as a set.
Standard
0.8 mm {0.031 in} or less
End Of Sie
YYJ5110M105
05–11A–29
CLUTCH HOUSING AND EXTENSION HOUSING ASSEMBLY [R15M-D]
DCF051117011W05
21 16 SELECTIVE USE
42—55
{4.2—5.6, 30—40}
17 R SST
OIL
GREASE
18
31—46
{3.1—4.5, R
23—32} 5
R 4
3
GREASE
19
20
2
SEALANT
19—25
19—25 {1.9—2.6,
SEALANT
{1.9—2.6, 14—18}
14—18}
9
SEALANT
1
41—55 SEALANT
{4.1—5.6, 8 R 15 R OIL SST
31—40} 14
R 25—34
13 {2.5—3.5,
19—25 18—25}
{1.9—2.6,
14—18}
R
R
OIL
6 R
7.8—10.8 N·m 12
{80—110 kgf·cm, R 7.8—10.8 N·m
SEALANT 10 {80—110 kgf·cm,
70—95 in·lbf}
70—95 in·lbf}
11
25—34
{2.5—3.5, 18—25}
7
DCF511AMB010
05–11A–30
Under cover 14 Stopper pin

1
(See 05–11A–31 Under Cover Assembly Note.) Oil seal (extension housing)
2 Steel ball 15 (See 05–11A–31 Oil Seal (Extension Housing)
Assembly Note.)
3 Snap ring
16 Adjustment shim
4 Speed drive gear
Oil seal (clutch housing)
5 Snap ring
17 (See 05–11A–32 Oil Seal (Clutch Housing)
6 Oil passage Assembly Note.)
7 Control rod Release collar
8 Control rod end 18 (See 05–11A–33 Release Collar, Release Fork
Assembly Note.)
05
9 Control case
Extension housing component Release fork
10 (See 05–11A–32 Extension Housing Component 19 (See 05–11A–33 Release Collar, Release Fork
Assembly Note.) Assembly Note.)
11 Back-up light switch 20 Boot
Vehicle speed sensor Clutch housing
12 21
(speed driven gear) (See 05–11A–32 Clutch Housing Assembly Note.)
13 Neutral switch
Oil Seal (Extension Housing) Assembly Note

1. Apply specified oil to the lip of a new oil seal.
2. Install the oil seal evenly and gradually using a
plastic hammer. 49 G030 795
BHJ0511M003
Under Cover Assembly Note

transmission case and under cover as shown in
the figure.
2. Assemble the under cover.
Tightening torque:
19—25 N·m {1.9—2.6 kgf·m, 14—18 ft·lbf}
BHJ0511M210
05–11A–31
Extension Housing Component Assembly Note
1. Apply sealant to the contact surfaces of the extension housing and bearing housing as shown in the figure.
2. Install the extension housing and bearing A
housing.
Bolt length
A: 165 mm {6.50 in} C
B: 48 mm {1.89 in}
C: 135 mm {5.31 in} C
Tightening torque:
41—55 N·m {4.1—5.6 kgf·m, 31—40 ft·lbf}
B
BHJ0511M212
Oil Seal (Clutch Housing) Assembly Note

1. Apply specified oil to the lip of a new oil seal.
2. Install the oil seal evenly and gradually using the
SST.
49 0813 235
OIL SEAL
DCF511AMB012
Clutch Housing Assembly Note

1. Adjust the clutch housing end play.
(1) Measure dimension K using a vernier caliper.
BHJ0511M214
(2) Measure dimension M using a vernier caliper.
Formula: T = K - M
T: Clutch housing end play

K: Depth of main drive gear bearing bore in
the clutch housing
M: Difference between the main drive gear
bearing surface and transmission case
surface (main drive gear bearing height)
Standard: 0—0.1 mm {0—0.004 in}

BHJ0511M215
05–11A–32
(3) If not within the specification, adjust by choosing the proper adjustment shim.
Thickness (mm {in})
0.3 {0.012}
0.4 {0.016}
Adjustment shim 0.5 {0.020}
0.6 {0.024}
0.7 {0.028}
2. Apply sealant to the contact surfaces of the clutch housing and transmission case as shown in the figure.
3. Assemble the adjustment shim.
05
Caution
• Be sure to install the adjustment shim selected during the clutch housing end play adjustment.
4. Assemble the clutch housing.
Tightening torque:
42—55 N·m {4.2—5.6 kgf·m, 31—40 ft·lbf}
Release Collar, Release Fork Assembly Note

1. Apply specified grease to the areas shown in the
figure.
GREASE
2. Install the release collar and release fork.
End Of Sie
GREASE
GREASE
BHJ0511M219
05–11A–33
MANUAL TRANSMISSION [S15M-D, S15MX-D]
05–11B MANUAL TRANSMISSION [S15M-D, S15MX-D]

PRECAUTION [S15M-D, S15MX-D] . . . . 05–11B–1 MANUAL TRANSMISSION PARTS
TOP COVER COMPONENT AND INSPECTION [S15M-D, S15MX-D] . . . . 05–11B–21
EXTENSION HOUSING DISASSEMBLY SHIFT COMPONENT ASSEMBLY
[S15M-D, S15MX-D] . . . . . . . . . . . . . . . 05–11B–2 [S15M-D, S15MX-D] . . . . . . . . . . . . . . . . 05–11B–23
REVERSE GEAR COMPONENT AND 1ST/2ND GEAR COMPONENT, 3RD/4TH
3RD/4TH GEAR COMPONENT GEAR COMPONENT AND
DISASSEMBLY COUNTERSHAFT ASSEMBLY
[S15M-D, S15MX-D] . . . . . . . . . . . . . . . 05–11B–9
MAINSHAFT COMPONENT,
[S15M-D, S15MX-D] . . . . . . . . . . . . . . . . 05–11B–26
MAINSHAFT COMPONENT,
05
COUNTERSHAFT COMPONENT AND COUNTERSHAFT COMPONENT AND
TRANSMISSION CASE DISASSEMBLY TRANSMISSION CASE ASSEMBLY
1ST/2ND GEAR COMPONENT, 3RD/4TH REVERSE GEAR COMPONENT AND
GEAR COMPONENT AND 3RD/4TH GEAR COMPONENT
COUNTERSHAFT DISASSEMBLY ASSEMBLY [S15M-D, S15MX-D]. . . . . . 05–11B–37
[S15M-D, S15MX-D] . . . . . . . . . . . . . . . 05–11B–16 TOP COVER COMPONENT AND
SHIFT COMPONENT DISASSEMBLY EXTENSION HOUSING ASSEMBLY
End of Toc
PRECAUTION [S15M-D, S15MX-D]
DCF051100000W04
1. Clean the transmission exterior thoroughly using a steam cleaner or cleaning solvents before disassembly.
Warning
• Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eye wear whenever using compressed air.
Caution
• Cleaning sealed bearings using cleaning fluids or a steam cleaner can wash the grease out of the
bearing.
2. Clean the removed parts using cleaning solvent, and dry them using compressed air.
3. Clean out all holes and passages using compressed air, and check that there are no obstructions.
4. Make sure each part is cleaned before assembling.
5. Coat all movable parts with the specified oil.
6. Replace parts whenever required.
7. Remove old sealant from contact surfaces before applying new sealant.
8. Assemble the parts within 10 min after applying sealant. Allow all sealant to cure at least 30 min after
assembling before filling the transmission with transmission oil.
Warning
• Although the stand has a self-locking brake system, there is a possibility that the brake may not
hold when the transmission is held in a lopsided position on the stand. This would cause the
transmission to turn suddenly, causing serious injury. Never keep the transmission tilted to one
side. Always hold the rotating handle firmly when turning the transmission.
End Of Sie
05–11B–1
TOP COVER COMPONENT AND EXTENSION HOUSING DISASSEMBLY [S15M-D, S15MX-D]
DCF051117011W06
Caution
• Remove the oil seal (extension housing and control rod) only if there is a malfunction.

4x2
33
4
31
6 32
3 A
18 R
B
1
7
8 R
B
11 9
2
10
12
15
13
R 21 22 29 R SST
20
14 28 R
30 R SST
17 R
23 R
26
SST R 29 R
19
A
27 R
25
24 R 16
DBG511BMB001
05–11B–2
1 Release fork 20 Spring cap
2 Release collar 21 Select lock spindle spring
3 Dust boot 22 Select lock spindle
Top cover, shift component Oil seal (extension housing)
4
(See 05–11B–5 Top Cover Disassembly Note.) 23 (See 05–11B–5 Oil Seal (extension housing)
5 Oil passage Removal Note.)
6 Control lever Extension housing
24 (See 05–11B–6 Extension Housing Disassembly
7 Dust boot Note.)
8
9
Gasket
Wave washer
25 Funnel 05
26 Control rod
10 Change bush 27 Oil passage
11 Shift lever Oil seal (control rod)
12 Change seat 28 (See 05–11B–6 Oil Seal (control rod) Disassembly
13 Control case Note.)
14 Control rod end Bush
29
15 Blind cover (See 05–11B–7 Bush Disassembly Note.)
16 Neutral switch Sealing cap
30
(See 05–11B–7 Sealing Cap Disassembly Note.)
17 Vehicle speed sensor
31 Retaining ring
18 Back-up light switch
32 Speed drive gear
19 Select spindle component
33 Steel ball
05–11B–3
4x4
4
6
3 A
21 R
2
7
11 8 R
9
R 14 12
R 10
15
16 13
17
19
R
29 R R
SST R 30 18 R
25
SST R 30
22
24
23 R
R 20 R
A
SST R 28
26
27
DBG511BMB063
1 Release fork 5 Oil passage

2 Release collar 6 Control rod end
3 Dust boot 7 Dust boot
Top cover, shift component 8 Gasket
4
(See 05–11B–5 Top Cover Disassembly Note.) 9 Wave washer
05–11B–4
10 Change bush 23 Breather
11 Shift lever 24 Transfer
12 Transfer shift lever 25 Blind cover
13 Change seat Extension housing
14 Transfer neutral switch 26 (See 05–11B–6 Extension Housing Disassembly
Note.)
15 Switch pin
27 Funnel
16 Spring
Oil seal (extension housing)
17 Steel ball 28 (See 05–11B–5 Oil Seal (extension housing)
18 4x4 indicator switch Removal Note.) 05
19 Vehicle speed sensor Oil seal (control rod)
20 Neutral switch 29 (See 05–11B–6 Oil Seal (control rod) Disassembly
21 Back-up light switch Note.)
22 Breather dust boot Bush
30
(See 05–11B–7 Bush Disassembly Note.)
Oil Seal (extension housing) Removal Note

1. Remove the oil seal using a flathead screwdriver as shown in the figure.
4x2
DBG511BMB003
4x4
DBG511BMB077
Top Cover Disassembly Note

1. Pry the seal open at the projection on the case
using a flathead screwdriver or similar tool as
shown in the figure, and then remove the top
cover.
DBG511BMB004
05–11B–5
Extension Housing Disassembly Note
1. Remove the extension housing component.
Note
• Pry open the seal at the projection on the
case using a flathead screwdriver or similar
tool as shown in the figure, and then remove
the extension housing.
DBG511BMB005
Oil Seal (control rod) Disassembly Note

1. Using a flathead screwdriver, remove the oil seal as shown in the figure.
4x2
DBG511BMB006
4x4
DBG511BMB068
05–11B–6
Sealing Cap Disassembly Note
1. Remove the sealing cap using the SST.
Caution
• Remove the sealing cap only if there is
malfunction.
49 G033 102
05
49 B032 308
DBG511BMB007
Bush Disassembly Note

4x2
1. Remove the bush using the SST.
49 0636 040
DBG511BMB075
2. Remove the bush using the suitable steel bar

through the sealing cap hole as shown in the B
figure.
Distance A: Approx. 200 mm {7.87 in}
Distance B: Approx. 17.0—17.5 mm {0.670— A

0.688 in}
DBG511BMB074
05–11B–7
4x4
1. Remove the bush using the SST.
Front side
49 0636 040
DBG511BMB073
Rear side
End Of Sie
49 0636 040
DBG511BMB076
05–11B–8
REVERSE GEAR COMPONENT AND 3RD/4TH GEAR COMPONENT DISASSEMBLY [S15M-D, S15MX-D]
DCF051117030W11
24
22 R
23
25
26 05
27 41
28 A
A
B
30
31 40
29 32
42 39
7
38
6 37
34
5 SST
4 R 36 33
SST
21 35
B
15
35 14
13
12
R 16
8
11
R 10
20
19
18
3 17 9
2
1 R
DBG511BMB019
Locknut 2 Countershaft rear bearing

(See 05–11B–10 Mainshaft Rear Bearing locknut 3 Thrust washer
1
and Countershaft Rear Bearing locknut
Disassembly Note.)
05–11B–9
Locknut 22 Retaining ring
(See 05–11B–10 Mainshaft Rear Bearing locknut 23 Washer
4
and Countershaft Rear Bearing locknut
Disassembly Note.) Counter lever
24
(See 05–11B–12 Counter Lever Disassembly Note.)
5 (See 05–11B–11 Mainshaft Rear Bearing 25 Retaining bolt
Disassembly Note.) Counter lever shaft component
26
6 Reverse counter gear (See 05–11B–12 Counter Lever Disassembly Note.)
7 Spacer 27 Retaining bolt
8 Retaining bolt 5th/reverse clutch hub and shift fork component
28 (See 05–11B–12 5th/reverse Shift Fork
Reverse idler gear shaft component Disassembly Note.)
9 (See 05–11B–11 Reverse Idler Gear Shaft
Component Disassembly Note.) 29 5th/reverse shift fork
10 Retaining ring 30 5th/reverse shift rod
11 Thrust washer 31 Detent ball
12 Reverse idler gear 32 Detent spring
13 Needle bearing 33 Clutch hub sleeve
14 Thrust washer 34 Synchronizer key
15 Reverse idler gear shaft 35 Synchronizer key spring
Friction damper 36 5th/reverse clutch hub
16 (See 05–11B–11 Reverse Idler Gear Friction 37 Synchronizer ring
Damper Disassembly Note.) 38 5th gear
17 Reverse gear 39 Needle bearing
18 Needle bearing 40 5rd gear bearing inner race
19 Thrust washer 41 Steel ball
20 Thrust washer 42 5th counter gear
21 Synchronizer ring
Mainshaft Rear Bearing locknut and Countershaft Rear Bearing locknut Disassembly Note
1. Slide the 3rd/4th and 1st/2nd clutch hub sleeves
to lock the transmission into 4th and 2nd gears.
E5U511BM5011
2. Remove the countershaft rear bearing locknut by

rotating it clockwise.
DBG511BMB027
05–11B–10
3. Remove the mainshaft rear bearing locknut by
rotating it counterclockwise using the SST.
49 UN01 011
(308-168)
49 F017 1A0
05
DBG511BMB028

1. Using the SSTs remove the mainshaft rear
bearing.
49 H017 101
49 0839 425C
E5U511BM5014
Reverse Idler Gear Shaft Component Disassembly Note

1. Remove the reverse idler gear shaft retaining bolt
and then remove the reverse idler gear shaft
component from the transmission case.
E5U511BM5015
Reverse Idler Gear Friction Damper Disassembly Note

1. Remove the friction damper using a flathead
screwdriver.
E5U511BM5019
05–11B–11
Counter Lever Disassembly Note
Caution
• To prevent the shaft position from
deviating when removing the counter
lever, remove the countershaft lever
component without loosening the
locknut unless it is necessary.
COUNTER LEVER
SHAFT
LOCK NUT
PLATE
DBG511BMB016
5th/reverse Shift Fork Disassembly Note

1. Remove the 5th/reverse shift rod retaining bolt.
DBG511BMB017
2. Remove the 5th/reverse shift fork component and

5th/reverse clutch hub component at the same
time.
End Of Sie
DBG511BMB018
05–11B–12
MAINSHAFT COMPONENT, COUNTERSHAFT COMPONENT AND TRANSMISSION CASE DISASSEMBLY
[S15M-D, S15MX-D]
DCF051117030W12
12
05
11
14 R
A 6
13 5
B 7
A C 4
B
9
15
10
1
DBG511BMB024
1 Bearing cover 6 Bearing shim

Front cover Maindrive gear bearing race
2 7
(See 05–11B–14 Front Cover Disassembly Note.) (See 05–11B–14 Bearing Race Disassembly Note.)
3 Pivot pin Mainshaft bearing race
8
4 Bearing shim (See 05–11B–14 Bearing Race Disassembly Note.)
5 Oil baffle 9 Countershaft front bearing
05–11B–13
10 Countershaft rear bearing Countershaft component
Mainshaft component 13 (See 05–11B–14 Mainshaft Component and
11 (See 05–11B–14 Mainshaft Component and Countershaft Component Disassembly Note.)
Countershaft Component Disassembly Note.) 14 Front oil seal
Maindrive gear 15 Transmission case
12 (See 05–11B–14 Mainshaft Component and
Countershaft Component Disassembly Note.)
Front Cover Disassembly Note

1. Remove the front cover.
Caution
• Insert the front cover tightening bolts
into the bolt holes for the front cover
disassembly, tighten the two bolts
uniformly and, then remove the front
cover.
BOLTS
DBG511BMB025
Bearing Race Disassembly Note

1. Grasping the mainshaft and countershaft, move
them forward and back to remove the bearing
races.
E5U511BM5074
Mainshaft Component and Countershaft Component Disassembly Note

1. Tilt the mainshaft component as shown in the
figure and remove it from the transmission case.
2. Remove the maindrive gear.
DBG511BMB049
05–11B–14
3. Tilt the countershaft component as shown in the
figure and remove it from the transmission case.
End Of Sie
05
E5U511BM5073
05–11B–15
1ST/2ND GEAR COMPONENT, 3RD/4TH GEAR COMPONENT AND COUNTERSHAFT DISASSEMBLY [S15M-
D, S15MX-D]
DCF051117030W13
Caution
• Remove the countershaft center bearing race only if there is a malfunction.
1. Disassemble in the order indicated in the table. .
2 R
3 SST
5
6 R
4
7
8
1 9
11
12
10
11
13
14
15
16
17
37
33
32
31
30
29
25
27
28
26
27 35 SST
24
23
22
36
21
20
19
18 SST 34 SST
DBG511BMB026
1 Needle bearing Retaining ring

2 Scoop ring 6 (See 05–11B–17 3rd/4th Clutch Hub Component
Disassembly Note.)
Maindrive gear shaft bearing
3 (See 05–11B–18 Maindrive Gear Shaft Bearing 7 Spacer
Disassembly Note.) 8 Synchronizer ring
4 Maindrive gear shaft 9 Clutch hub sleeve
5 Needle bearing
05–11B–16
3rd/4th clutch hub 25 Clutch hub sleeve
10 (See 05–11B–17 3rd/4th Clutch Hub Component 1st/2nd clutch hub
Disassembly Note.) 26 (See 05–11B–17 1st/2nd Clutch Hub Component
11 Synchronizer key spring Disassembly Note.)
12 Synchronizer key 27 Synchronizer key spring
13 Synchronizer ring 28 Synchronizer key
14 Double cone 29 Synchronizer ring
15 Inner cone 30 Double cone
16 3rd gear 31 Inner cone
17 Needle bearing 32 2nd gear
05
Mainshaft center bearing 33 Needle bearing
18 (See 05–11B–17 1st/2nd Clutch Hub Component Countershaft center bearing race
Disassembly Note.) 34 (See 05–11B–18 Countershaft Center Bearing Race
19 1st gear bearing inner race Disassembly Note.)
20 Needle bearing Countershaft front bearing race
21 1st gear 35 (See 05–11B–18 Countershaft Front Bearing Race
Disassembly Note.)
22 Inner cone
36 Countershaft
23 Double cone
37 Mainshaft
3rd/4th Clutch Hub Component Disassembly Note

1. Remove the retaining ring using the two flathead
screwdrivers.
Caution
• Do not reuse the retaining ring.
FLATHEAD SCREW
DRIVERS
RETAINING RING
E5U511BM5010
2. Supporting the 3rd/4th clutch hub with your hand

as shown in the figure, tap the mainshaft with a
plastic hammer to remove the 3rd/4th clutch hub.
E5U511BM5022
1st/2nd Clutch Hub Component Disassembly Note

1. Using a press, remove the mainshaft center
bearing, 1st gear, 1st synchronizer ring
component, 1st/2nd clutch hub component, 2nd
synchronizer ring component and 2nd gear at the
same time.
Caution
E5U511BM5023
05–11B–17
Maindrive Gear Shaft Bearing Disassembly Note
1. Remove the maindrive gear shaft bearing using
the SST and press.
49 H027 002
DBG511BMB029
Countershaft Center Bearing Race Disassembly Note

1. Remove the countershaft center bearing race
using the SST and press.
Caution
• Be sure to support the countershaft so 49 H027 002
that it does not fall.
DBG511BMB030
Countershaft Front Bearing Race Disassembly Note

1. Remove the countershaft front bearing race using
the SST.
End Of Sie 49 0710 520
E5U511BM5026
05–11B–18
SHIFT COMPONENT DISASSEMBLY [S15M-D, S15MX-D]
DCF051117030W14
4x2
19 18
17 13
05
A
B R
C
15 11 1
7
14 6
12
10 R
R
5
9 R
16
B
4 R
3 8
A
DBG511BMB031
1 Retaining bolt 11 Interlock pin

2 Detent ball, spring 12 3rd/4th shift fork
3 Rubber plug 13 Detent ball, spring seat, spring
4 5th/reverse shift rod end 14 1st/2nd shift rod end
5th/reverse shift rod 1st/2nd shift rod
5 15
(See 05–11B–21 Shift Rod Disassembly Note.) (See 05–11B–21 Shift Rod Disassembly Note.)
6 Interlock pin 16 1st/2nd shift fork
7 Interlock pin 17 Detent ball, spring seat, spring
8 Stopper block 18 Baffle plate
9 3rd/4th shift rod end 19 Breather
3rd/4th shift rod
10
(See 05–11B–21 Shift Rod Disassembly Note.)
05–11B–19
4x4
29 28
27 19
A
B R
C
R
25 2
22 17 1
21
23 13
24 12 18
20 16 R
R
10
11
15 R B
26 R
14
3 A
8 6
4 9 7 C
5
DBG511BMB036
1 Retaining bolt 3rd/4th shift rod

16
2 Detent ball, spring (See 05–11B–21 Shift Rod Disassembly Note.)
3 Rubber plug 17 Interlock pin
4 5th/reverse shift rod end 18 3rd/4th shift fork
5 Retaining ring 19 Detent ball, spring seat, spring
6 Plain washer 20 1st/2nd shift rod end
7 Spring 21 Retaining ring
8 Push pin 22 Plain washer
9 Retaining ring 23 Spring
10 Detent ball, spring 24 Push pin
5th/reverse shift rod 1st/2nd shift rod
11 25
(See 05–11B–21 Shift Rod Disassembly Note.) (See 05–11B–21 Shift Rod Disassembly Note.)
12 Interlock pin 26 1st/2nd shift fork
13 Interlock pin 27 Detent ball, spring seat, spring
14 Stopper block 28 Baffle plate
15 3rd/4th shift rod end 29 Breather
05–11B–20
Shift Rod Disassembly Note
1. Remove the spring pins from each of the shift
rods using a pin punch.
2. Place the shift mechanism in the neutral position.
Caution
• When pulling out the shift rods, press the
top of each detent ball so that it doesn’t
spring out.
05
DBG511BMB033
3. Pull out the shift rods from the top cover.

End Of Sie
DBG511BMB034
MANUAL TRANSMISSION PARTS INSPECTION [S15M-D, S15MX-D]

DCF051100000W05
gauge.
Standard clearance between shift fork and

clutch hub sleeve groove
0.05—0.40 mm {0.002—0.015 in}
Maximum clearance between shift fork and

clutch hub sleeve groove
BHJ0511M018
0.5 mm {0.020 in}
Synchronizer Ring
gauge around the entire circumference.
synchronizer ring.
Standard clearance between synchronizer

ring and flank surface of gear
1.5 mm {0.059 in}
Maximum clearance between synchronizer

ring and flank surface of gear
BHJ0511M020
0.8 mm {0.031 in}
Note
• Set the synchronizer ring squarely in the gear.
05–11B–21
Spring
1. Measure the free length of each spring.
spring.
FREE LENGTH
Detent ball springs for 1st/2nd and 3rd/4th
shift rods
Standard length: 22.5 mm {0.886 in}
Detent ball spring for 5th/reverse shift rod

1st/2nd select lock spindle spring [4x2]

BHE0511M023
Push pin spring for 1st/2nd shift rod end [4x4]

Push pin spring for 5th/reverse shift rod end [4x4]

Detent ball spring for 5th/reverse shift rod end [4x4]

Mainshaft
1. Measure the mainshaft runout using a dial gauge.
replace the mainshaft.
Mainshaft maximum runout

0.03 mm {0.0012 in}
DBG511BMB035
Shift Rod End, Control Lever

1. Measure the clearance between the shift rod end
and control lever using a feeler gauge.
rod end or control lever as a set.
Standard clearance between shift rod end and

control lever
End Of Sie
DBG511BMB022
05–11B–22
SHIFT COMPONENT ASSEMBLY [S15M-D, S15MX-D]
DCF051117030W15
4x2
6.9—9.8 N·m
{71—99 kgf·cm, 62—86 in·lbf}
1 7.8—11.8 N·m {80—120 kgf·cm, 70—104 in·lbf}
2
3 8 05
A
B R
C
18
7
4 19 25—34
11 {2.6—3.4, 19—25}
6 12
9 R
R 10
14
13 R
5
B
16 R
17 15
A
C N·m {kgf·m, ft·lbf}
DBG511BMB037
1 Breather 10 3rd/4th shift fork

2 Baffle plate 11 Interlock pin
3 Detent ball, spring seat, spring 12 Interlock pin
1st/2nd shift rod 13 3rd/4th shift rod end
4
(See 05–11B–25 Shift Rod Assembly Note.) 5th/reverse shift rod
14
5 1st/2nd shift fork (See 05–11B–25 Shift Rod Assembly Note.)
6 1st/2nd shift rod end 15 Stopper block
7 Interlock pin 16 5th/reverse shift rod end
8 Detent ball, spring seat, spring 17 Rubber plug
3rd/4th shift rod 18 Detent ball, spring
9
(See 05–11B–25 Shift Rod Assembly Note.) 19 Retaining bolt
05–11B–23
4x4
6.9—9.8 N·m
1 7.8—11.8 N·m {80—120 kgf·cm, 70—104 in·lbf} {71—99 kgf·cm, 62—86 in·lbf}
2
3 12
A
B R
C
4 28
R
11 29 25—34
9 8
{2.6—3.4, 19—25}
7 16
6 17 14
10 13 R
R
20
18
15 R B
R
5
27 19
A
22 24
26 21 23 C
DBG511BMB038
1 Breather 16 Interlock pin

2 Baffle plate 17 Interlock pin
3 Detent ball, spring seat, spring 5th/reverse shift rod
18
1st/2nd shift rod (See 05–11B–25 Shift Rod Assembly Note.)
4
(See 05–11B–25 Shift Rod Assembly Note.) 19 Stopper block
5 1st/2nd shift fork 20 Detent ball, spring
6 Push pin 21 Retaining ring
7 Spring Push pin
22
8 Plain washer (See 05–11B–25 Push Pin Assembly Note.)
9 Retaining ring 23 Spring
10 1st/2nd shift rod end 24 Plain washer
11 Interlock pin 25 Retaining ring
12 Detent ball, spring seat, spring 26 5th/reverse shift rod end
3rd/4th shift rod 27 Rubber plug
13
(See 05–11B–25 Shift Rod Assembly Note.) 28 Detent ball, spring
14 3rd/4th shift fork 29 Retaining bolt
15 3rd/4th shift rod end
05–11B–24
Shift Rod Assembly Note
1. Install each shift rod.
Caution
• Do not forget to insert the interlock pins.
Note
• Insert the shift rod while pressing the detent
ball with a flathead screwdriver as shown in
the figure.
05
DBG511BMB039
Push Pin Assembly Note

1. Install the push pin.
Note
• Insert the push pin while pressing the detent
ball with a flathead screwdriver as shown in
the figure.
End Of Sie
DBG511BMB040
05–11B–25
1ST/2ND GEAR COMPONENT, 3RD/4TH GEAR COMPONENT AND COUNTERSHAFT ASSEMBLY [S15M-D,
S15MX-D]
DCF051117040W07
MOLYBDENUM 33 R
32 SST
GREASE
DISULFIDE
GREASE 30
29 R
31
28
27
34 26
SELECTIVE
25
24
23
25
22
21
20
19
18
1
3
4
5
6
10
9
8
7
9 37 SST
11
12
13
35
14
15
16
17 SST 36 SST
OIL
DBG511BMB041
1 Mainshaft 1st/2nd clutch hub

2 Needle bearing 7 (See 05–11B–27 1st/2nd Clutch Hub Component
Assembly Note.)
3 2nd gear
8 Synchronizer key
4 Inner cone
9 Synchronizer key spring
5 Double cone
10 Clutch hub sleeve
6 Synchronizer ring
05–11B–26
11 Synchronizer ring Clutch hub sleeve
12 Double cone 26 (See 05–11B–28 3rd/4th Clutch Hub Component
Assembly Note.)
13 Inner cone
14 1st gear
28 Spacer
15 Needle bearing
Retaining ring
16 1st gear bearing inner race 29 (See 05–11B–28 3rd/4th Clutch Hub Component
Mainshaft center bearing Assembly Note.)
17 (See 05–11B–27 1st/2nd Clutch Hub Component 30 Needle bearing
Assembly Note.)
18 Needle bearing
31 Maindrive gear 05
Maindrive gear shaft bearing
19 3rd gear 32 (See 05–11B–29 Maindrive Gear Shaft Bearing
20 Inner cone Assembly Note.)
21 Double cone 33 Scoop ring
22 Synchronizer ring 34 Needle bearing
Clutch hub 35 Countershaft
23 (See 05–11B–28 3rd/4th Clutch Hub Component Countershaft center bearing race
Assembly Note.) 36 (See 05–11B–29 Countershaft Center Bearing Race
Synchronizer key Assembly Note.)
24 (See 05–11B–28 3rd/4th Clutch Hub Component Countershaft front bearing race
Assembly Note.) 37 (See 05–11B–30 Countershaft Front Bearing Race
Synchronizer key spring Assembly Note.)
25 (See 05–11B–28 3rd/4th Clutch Hub Component
Assembly Note.)
1st/2nd Clutch Hub Component Assembly Note

Caution
• Be sure to assemble the clutch hub
components and synchronizer ring
components while aligning the
synchronizer ring grooves with the A C
synchronizer keys.
dimensions are as follows: B
mm {in}
A B C
1st/2nd 17.0 {0.669} 5.9 {0.23} 5.0 {0.20}
A6E5110M131
• Be sure to align the synchronizer ring

projections with the inner cone notches.
aligning the double cone projections with A
A
B
B
DBG511BMB042
05–11B–27
• Align the clutch hub sleeve alignment
mark with the clutch hub synchronizer ALIGNMENT MARK
SYNCHRONIZER KEY
key installation position and assemble.
Caution
• When using a press, be careful not to
damage the parts.
E5U511BM5058
1. Using a SSTs and press, assemble the needle

bearing, 2nd gear, synchronizer ring component
(2nd), 1st/2nd clutch hub component,
synchronizer ring component (1st), 1st gear,
needle bearing, needle bearing race and
mainshaft center bearing to the mainshaft at the
49 B034 201
same time.
49 H027 002
DBG511BMB043
3rd/4th Clutch Hub Component Assembly Note

1. Assemble the 3rd/4th clutch hub component.
Caution
mm {in} A C
A B C
3rd/4th 17.0 {0.669} 5.9 {0.23} 5.0 {0.20}
B
A6E5110M131
• Be sure to align the synchronizer ring

projections with the inner cone notches.
aligning the double cone projections with A
A
B
B
DBG511BMB042
05–11B–28
SYNCHRONIZER KEY
2. Install the 3rd/4th clutch hub component to the

mainshaft.
3. Install the spacer.
4. Install the retaining ring.
05
E5U511BM5058
5. Measure the clearance between retaining ring

and spacer.
3rd/4th clutch hub end play

0—0.05 mm {0.0—0.0019 in}
3rd/4th clutch hub retaining ring

Thickness (mm {in})
1.50 {0.0591}
1.55 {0.0610} DBG511BMB044
1.60 {0.0630}
1.65 {0.0650}
1.70 {0.0669}
1.75 {0.0689}
1.80 {0.0709}
1.85 {0.0728}
1.90 {0.0748}
1.95 {0.0768}
Maindrive Gear Shaft Bearing Assembly Note

1. Assemble the maindrive gear shaft bearing using
the SSTs.
49 F401 331
49 G030 338
49 G033 106
DBG511BMB062
Countershaft Center Bearing Race Assembly Note

1. Assemble the countershaft center bearing race
using the SSTs.
49 F401 331
49 F401 337A
DBG511BMB046
05–11B–29
Countershaft Front Bearing Race Assembly Note
1. Assemble the countershaft front bearing race
using the SSTs.
End Of Sie 49 F401 331
49 H025 003A
DBG511BMB047
05–11B–30
MAINSHAFT COMPONENT, COUNTERSHAFT COMPONENT AND TRANSMISSION CASE ASSEMBLY
[S15M-D, S15MX-D]
DCF051117040W08
C
3
05
4
31—46
{3.2—4.6, 23—33}
14
19—25 {2.0—2.5, 15—18}
15
12 SELECTIVE
A 10 R
2
B 13
7
C SEALANT
A
B 11 SELECTIVE
5
1
17.7—26.4
{1.81—2.69, 13.1—19.4}
6
9
DBG511BMB048
1 Transmission case Mainshaft component

Countershaft component (See 05–11B–32 Maindrive Gear Component,
3
(See 05–11B–32 Maindrive Gear Component, Mainshaft Component and Countershaft
2 Component Assembly Note.)
Mainshaft Component and Countershaft
Component Assembly Note.)
05–11B–31
Maindrive gear Front oil seal
10
(See 05–11B–32 Maindrive Gear Component, (See 05–11B–32 Front Oil Seal Assembly Note.)
4
Mainshaft Component and Countershaft 11 Bearing shim
12 Bearing shim
5 Countershaft front bearing
13 Oil baffle
6 Countershaft rear bearing
14 Pivot pin
7 Maindrive gear bearing race
Front cover
8 Mainshaft bearing race (See 05–11B–32 Maindrive Gear Component,
15
9 Bearing cover Mainshaft Component and Countershaft
Front Oil Seal Assembly Note

2. Install the oil seal to the front cover using the
SST.
49 0813 235
DBG511BMB051
Maindrive Gear Component, Mainshaft Component and Countershaft Component Assembly Note
1. Install the countershaft component.
2. Install the maindrive gear.
E5U511BM5073
3. Install the mainshaft component.
DBG511BMB049
05–11B–32
4. Assemble the Mainshaft component and
Maindrive gear.
MAINDRIVE GEAR
05
DBG511BMB050
5. Install the countershaft front and rear bearing.
E5U511BM5046
6. Install the maindrive gear bearing race and

mainshaft center bearing race.
E5U511BM5047
7. Install the bearing cover with the arrow pointing to

the top of the case.
Tightening torque:
17.7—26.4 N·m {1.81—2.69 kgf·m, 13.1—19.4
ft·lbf}
E5U511BM5048
05–11B–33
8. Select the mainshaft component and countershaft component bearing shims according to the following
procedure.
(1) Set the clutch housing side upward and level the transmission case.
Caution
• Securely assemble the mainshaft, maindrive gear component, and countershaft component so
that there is no looseness or play.
(2) Using a depth gauge, measure the maindrive

gear bearing outer race height A.
DEPTH GAUGE
DBG511BMB054
(3) Using a depth gage, measure the maindrive

DEPTH GAUGE
gear bearing retainer depth B.
(4) Calculate and select the correct maindrive
gear bearing shim thickness.
Formula: C = B - A
C: Dimension between the maindrive gear

bearing and bore in the front cover
B: Depth of the maindrive gear bearing bore BEARING SHIM
in the front cover INSTALLATION SURFACE
A: Maindrive gear bearing height
DBG511BMB055
• Refer to the maindrive gear bearing shim

selective chart.
Maindrive gear bearing shim selective chart

Dimension C (mm {in}) Shim thickness (mm {in})
1.45—1.55
1.4 {0.055}
{0.0571—0.0610}
1.55—1.65
1.5 {0.059}
{0.0611—0.0649}
1.65—1.75
1.6 {0.063}
{0.0650—0.0688}
1.75—1.85
1.7 {0.067}
{0.0689—0.0728}
1.85—1.95
1.8 {0.071}
{0.0729—0.0767}
1.95—2.05
1.9 {0.075}
{0.0768—0.0807}
2.05—2.15
2.0 {0.079}
{0.0808—0.0846}
2.15—2.25
2.1 {0.083}
{0.0847—0.0885}
2.25—2.35
2.2 {0.087}
{0.0886—0.0925}
2.35—2.45
2.3 {0.090}
{0.0926—0.0964}
2.45—2.55
2.4 {0.094}
{0.0965—0.1003}
2.55—2.65
2.5 {0.098}
{0.1004—0.1043}
05–11B–34
2.65—2.75
2.6 {0.102}
{0.1044—0.1082}
2.75—2.85
2.7 {0.106}
{0.1083—0.1122}
2.85—2.95
2.8 {0.110}
{0.1123—0.1161}
2.95—3.05
2.9 {0.114}
{0.1162—0.1200}
3.05—3.15
3.0 {0.118}
05
{0.1201—0.1240}
Maindrive gear shaft total end play

0.05—0.15 mm {0.002—0.0059 in}
(5) Using a depth gauge, measure the

DEPTH GAUGE
countershaft front bearing depth D.
Note
• The countershaft bearing is located below
the contact surface of the case and front
cover.
DBG511BMB056
(6) Using a depth gauge, measure the

countershaft front bearing retainer depth E. DEPTH GAUGE
(7) Calculate and select the correct countershaft
front bearing shim thickness.
Formula: F = E + D
F: Dimension between the countershaft
front bearing and bore in the front cover
E: Depth of the countershaft front bearing BEARING SHIM
bore in the front cover INSTALLATION SURFACE
D: Countershaft front bearing depth
• Refer to the countershaft front bearing DBG511BMB057
shim selective chart.
Countershaft front bearing shim selective chart

Dimension F (mm {in}) Shim thickness (mm {in})
3.15—3.25
3.0 {0.118}
{0.1240—0.1279}
3.25—3.35
3.1 {0.122}
{0.1280—0.1318}
3.35—3.45
3.2 {0.126}
{0.1319—0.1358}
3.45—3.55
3.3 {0.130}
{0.1359—0.1397}
3.55—3.65
3.4 {0.134}
{0.1398—0.1437}
3.65—3.75
3.5 {0.138}
{0.1438—0.1476}
3.75—3.85
3.6 {0.142}
{0.1477—0.1515}
3.85—3.95
3.7 {0.147}
{0.1516—0.1555}
Countershaft total end play

0.15—0.25 mm {0.006—0.0098 in}
05–11B–35
9. Position the maindrive gear bearing shim, oil baffle, and the countershaft bearing shim onto the front cover.
Note
• If necessary, apply a light coat of petroleum jelly to the shims and oil baffle.

transmission case and front cover as shown in the
figure. SEALANT
11. Install the pivot pin.
Tightening torque:
31—46 N·m {3.2—4.6 kgf·m, 23—33 ft·lbf}
DBG511BMB053
12. Install the front cover to the transmission case.
Tightening torque:
19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}
Note
• To prevent damage to the oil seal lip during
assembly, tape maindrive gear shaft splines.
End Of Sie
DBG511BMB052
05–11B–36
REVERSE GEAR COMPONENT AND 3RD/4TH GEAR COMPONENT ASSEMBLY [S15M-D, S15MX-D]
DCF051117040W09
19
21 R
7.8—11 N·m
20
{80—112 kgf·cm, 70—97 in·lbf}
18
17
05
21.6—30.4
16 {2.21—3.09, 16.0—22.4}
2
A
A 15
B
13
12 3
14 11
1 4
36
5
37 6
9
38 SST 10
7
39 R SST 22 8
211—269
{21.6—27.4, 156—198}
B
28
8 29
30
31
R 27
35 SEALANT
R 33 32 78.5—117
{8.01—11.9,
57.9—86.2}
23 SELECTIVE
25 24 SELECTIVE
26 34
40
41
OIL
42 R APPLY SPECIFIED OIL TO INDIVIDUAL PARTS
127—196
{13.0—19.9, 94—144} N·m {kgf·m, ft·lbf}
DBG511BMB058
1 5th counter gear 5rd gear bearing inner race

2 Steel ball 3 (See 05–11B–38 5th Gear Bearing Inner Race
Assembly Note.)
05–11B–37
4 Needle bearing 27 Friction damper
5 5th gear 28 Reverse idler gear shaft
6 Synchronizer ring 29 Thrust washer
7 5th/reverse clutch hub 30 Needle bearing
8 Synchronizer key spring 31 Reverse idler gear
9 Synchronizer key 32 Thrust washer
10 Clutch hub sleeve 33 Retaining ring
11 Detent spring Reverse idler gear shaft component
12 Detent ball 34 (See 05–11B–41 Reverse Idler Gear Component
Assembly Note.)
13 5th/reverse shift rod
35 Retaining bolt
14 5th/reverse shift fork
36 Spacer
5th/reverse clutch hub and shift fork component
(See 05–11B–39 5th Counter Gear, 5th/Reverse 37 Reverse counter gear
15
Clutch Hub Component and 5th/Reverse Shift Fork Mainshaft rear bearing
Assembly Note.) (See 05–11B–42 Mainshaft Rear Bearing and
38
16 Retaining bolt Countershaft Rear Bearing Locknut Assembly
Note.)
Counter lever shaft component
17 (See 05–11B–41 Counter Lever Shaft Assembly Locknut
Note.) (See 05–11B–42 Mainshaft Rear Bearing and
39
Countershaft Rear Bearing Locknut Assembly
18 Retaining bolt Note.)
19 Counter lever 40 Thrust washer
20 Washer Countershaft rear bearing
21 Retaining ring (See 05–11B–42 Mainshaft Rear Bearing and
41
22 Thrust washer Countershaft Rear Bearing Locknut Assembly
23 Thrust washer Note.)
24 Spacer Locknut
(See 05–11B–42 Mainshaft Rear Bearing and
25 Needle bearing 42
Countershaft Rear Bearing Locknut Assembly
Reverse gear Note.)
26
(See 05–11B–40 Reverse Gear Assembly Note.)
5th Gear Bearing Inner Race Assembly Note

1. Install the steel ball to the countershaft.
2. Align the ball groove position of the 5rd gear STEEL BALL
bearing inner race and assemble it to the
countershaft.
E5U511BM5032
05–11B–38
5th Counter Gear, 5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note
1. Assemble the 5th drive gear and 5th/reverse clutch hub component.
Caution
• Be sure to assemble the clutch hub components and synchronizer ring components while aligning
the synchronizer ring grooves with the synchronizer keys.
mm {in}
A B C
A C
05
5th/6th 18.0 {0.709} 5.45 {0.215} 6.0 {0.236}
B
A6E5110M131

SYNCHRONIZER KEY
E5U511BM5058
2. Assemble the 5th counter gear component, 5th/

reverse clutch hub component, and 5th/reverse
shift fork component as a single unit.
DBG511BMB018
3. Install the 5th/reverse shift rod retaining bolt.
Tightening torque:
21.6—30.4 N·m {2.21—3.09 kgf·m, 16.0—22.4
ft·lbf}
4. Install the thrust washer.
E5U511BM5017
05–11B–39
5. Measure the clearance between thrust washer
and groove of the countershaft.
choosing the proper thrust washer.
THRUST
WASHER
5th/Reverse clutch hub end play 5TH/REVERSE
0—0.05 mm {0.0—0.0019 in} CLUTCH HUB
END PLAY
5th/Reverse clutch hub thrust washer
Thickness (mm {in})
3.00 {0.118}
3.05 {0.120} DBG511BMB060
3.10 {0.122}
3.15 {0.124}
3.20 {0.126}
3.25 {0.128}
3.30 {0.130}
3.35 {0.132}
3.40 {0.134}
Reverse Gear Assembly Note

1. Measure the clearance A and B.
(1) Calculate and select the thrust washer
thickness.
Formula: C = A - B
A
B
C: Dimension between the 5th/Reverse
clutch hub and reverse gear
B: Reverse gear height
A: Dimension between the 5th/Reverse
REVERSE GEAR
clutch hub and thrust washer
• Refer to the reverse gear thrust washer

DBG511BMB061
selective chart.
Reverse gear thrust washer

Dimension C (mm {in}) Thickness (mm {in})
7.60—7.70
7.35 {0.289}
{0.300—0.303}
7.70—7.80
7.45 {0.293}
{0.304—0.307}
7.80—7.90
7.55 {0.297}
{0.308—0.311}
7.90—8.00
7.65 {0.301}
{0.312—0.314}
8.00—8.10
7.75 {0.305}
{0.315—0.318}
Reverse gear end play

0.25—0.35 mm {0.002—0.0059 in}
2. Install the thrust washer.

3. Install the reverse gear.
05–11B–40
Counter Lever Shaft Assembly Note
1. Install the counter lever shaft component.
Caution CHAMFER
• If the counter lever shaft has been
replaced or the locknut is loose,
assemble the counter lever shaft with the
chamfer side of the shaft pointed straight
upward.
• Apply sealant to the threads of the LOCK NUT
locknut. 05
• If there is an abnormality in the 3rd/4th 7.8— 11 N·m {80—112 kgf·cm, 70—97 in·lbf}
shift stroke after assembling, loosen the

E5U511BM5072
locknut and readjust.
Locknut tightening torque:

37.3—51.9 N·m {3.81—5.29 kgf·m, 27.6—38.2 ft·lbf}
Reverse Idler Gear Component Assembly Note

1. Using the SSTs, install the friction damper to the
reverse idler gear. 49 G030 797
49 H025 001
FRICTION DAMPER
DBG511BMB078
• Verify the depth of the friction damper

installation position. 1.0—1.6 mm {0.040—0.062 in}
FRICTION DAMPER
DBG511BMB059
2. Assemble the reverse idler gear component.

3. Measure the clearance between the retaining ring
and thrust washer.
Reverse idler gear end play

0.1—0.2 mm {0.0040—0.0078 in}
Reverse idler gear retaining ring

Thickness (mm {in})
1.5 {0.059}
1.6 {0.063} E5U511BM5039
1.7 {0.067}
1.8 {0.071}
1.9{0.075}
05–11B–41
4. Install the reverse idler gear component to the
transmission case.
E5U511BM5070
5. Install the reverse idler gear shaft retaining bolt.
Tightening torque
78.5—117 N·m {8.01—11.9 kgf·m, 57.9—86.2
ft·lbf}
E5U511BM5015
Mainshaft Rear Bearing and Countershaft Rear Bearing Locknut Assembly Note
1. Slide the 3rd/4th and 1st/2nd clutch hub sleeves
to lock the transmission into 4th and 2nd gears.
2. Insert the mainshaft rear bearing into the
mainshaft and install the locknut.
E5U511BM5011
3. Attach the SST to the locknut and tighten the nut to the specified torque.
Caution
• Attach the SST with the locknut seated in
the bearing.
Tightening torque:
211—269 N·m {21.6—27.4 kgf·m, 156—198 49 UN01 011
ft·lbf} (308-168)
49 F017 1A0
DBG511BMB028
05–11B–42
4. Tighten the countershaft locknut in the
counterclockwise direction.
Tightening torque:
127—196 N·m {13.0—19.9 kgf·m, 94—144
ft·lbf}
05
DBG511BMB027
5. Using the pin punch, stake the mainshaft rear

bearing locknut.
E5U511BM5042
6. Using the pin punch, stake the countershaft rear

bearing locknut.
End Of Sie
E5U511BM5089
05–11B–43
TOP COVER COMPONENT AND EXTENSION HOUSING ASSEMBLY [S15M-D, S15MX-D]
DCF051117011W07
4x2
SEALANT 7.8—11.0 N·m
15.7—22.5 {80—112 kgf·cm, 70—97 in·lbf}
{1.60—2.29, 11.6—16.5}
18
19 15—19
{1.53—1.93, 3
11.1—14.0}
17 2
31 A
30 R
25—34
{2.55—3.46,
SEALANT 18.5—25.0}
GREASE
32 7.8—11.0 N·m
{80—112 kgf·cm,
GREASE
R 70—97 in·lbf}
27
26 R
25
23
33 24
OIL
GREASE
15.7—22.5
{1.60—2.29,
11.6—16.5}
7.9—9.8 N·m 22
GREASE
{81—99 kgf·cm,
70—86 in·lbf}
21
20 15—19
15 R 14 13 {1.53—1.93, 11.1—14.0}
11 4 R SST
5 R SST
6 R SST
29 SEALANT
R
7.8—11.0 N·m 16 R SST
{80—112 kgf·cm,
70—97 in·lbf} SEALANT
7
R
SST R 4
12
7.8—11.0 N·m
{80—112 kgf·cm,
A 70—97 in·lbf}
8
SEALANT 31.4—46.0 28 R
{3.21—4.69, 25—34
23.2—33.9} {2.55—3.46,
9 R 18.5—25.0}
6.9—9.8 N·m 10
{71—99 kgf·cm, 61—86 in·lbf}
DBG511BMB002
1 Steel ball 3 Retaining ring

2 Speed drive gear
05–11B–44
Bush Top cover, shift component
4 19
(see 05–11B–47 Bush Assembly Note.) (see 05–11B–50 Top Cover Assembly Note.)
Oil seal (control rod) Blind cover
20
5 (see 05–11B–48 Oil Seal (control rod) Assembly (see 05–11B–51 Blind Cover Assembly Note.)
Note.) 21 Control case
Sealing cap 22 Change seat
6
(see 05–11B–49 Sealing Cap Assembly Note.)
23 Shift lever
7 Control rod
24 Change bush
8 Oil passage
25 Wave washer
9 Funnel
26 Gasket
05
Extension housing
10 (see 05–11B–50 Extension Housing Assembly 27 Dust boot
Note.) 28 Neutral switch
11 Control rod end 29 Vehicle speed sensor
12 Select spindle component 30 Back-up light switch
13 Select lock spindle 31 Dust boot
14 Select lock spindle spring Release fork
15 Spring cap 32 (see 05–11B–51 Release Collar, Release Fork
Assembly Note.)
Oil seal (extension housing)
16 (see 05–11B–49 Oil Seal (Extension Housing) Release collar
Assembly Note.) 33 (see 05–11B–51 Release Collar, Release Fork
Assembly Note.)
17 Control lever
18 Oil passage
05–11B–45
4x4
SEALANT 7.8—11 N·m
15.7—22.5 {80—112 kgf·cm, 70—97 in·lbf}
{1.60—2.29, 11.6—16.5}
26
27 15—19
{1.53—1.93,
11.1—14.0}
28 A
25
SEALANT
10 R
25—34
GREASE
{2.6—3.4,
19—25}
30
GREASE
GREASE
24
29 7.8—11.0 N·m 23 R
{80—112 kgf·cm,
70—99 in·lbf} 22
21
20
25—34
{2.6—3.4, 19—25}
R 17 OIL
19
GREASE
7.8—11.0 N·m
{80—112 kgf·cm, R
OIL
70—97 in·lbf} 16
15
18
14
12
7.9—9.8 N·m
{81—99 kgf·cm,
70—86 in·lbf} R
2 R SST R
13 R
SST R 1 25—34
{2.6—3.4, 19—25}
6
5
9
7
SST R 1 SEALANT 8 R SST
R 11 R
25—34
A {2.6—3.4, 19—25}
SST R 3 SEALANT
31.4—46.0 N·m {kgf·m, ft·lbf}
4 {3.21—4.69, 23.2—33.9}
DBG511BMB064
Bush Oil seal (extension housing)

1
(see 05–11B–47 Bush Assembly Note.) 3 (see 05–11B–49 Oil Seal (Extension Housing)
Oil seal (control rod) Assembly Note.)
2 (see 05–11B–48 Oil Seal (control rod) Assembly 4 Funnel
Note.)
05–11B–46
Extension housing 19 Transfer shift lever
5 (see 05–11B–50 Extension Housing Assembly 20 Shift lever
Note.)
21 Change bush
Blind cover
6 22 Wave washer
(see 05–11B–51 Blind Cover Assembly Note.)
7 Transfer 23 Gasket
Breather 24 Dust boot
8 25 Control rod end
(see 05–11B–51 Breather Assembly Note.)
9 Breather dust boot 26 Oil passage
10 Back-up light switch 27
Top cover, shift component
(see 05–11B–50 Top Cover Assembly Note.)
05
11 Neutral switch
12 Vehicle speed sensor 28 Dust boot
13 4X4 indicator switch Release collar
29 (see 05–11B–51 Release Collar, Release Fork
14 Steel ball Assembly Note.)
15 Spring Release fork
16 Switch pin 30 (see 05–11B–51 Release Collar, Release Fork
17 Transfer neutral switch Assembly Note.)
18 Change seat
Bush Assembly Note

4x2
1. Install the bush using the SST.
Installation depth A: 1—2 mm {0.040—0.078

in}
A
BUSH
49 0636 040
DBG511BMB069
2. Install the bush using the suitable steel bar

through the sealing cap hole as shown in the
figure.
Distance A: Approx. 200 mm {7.87 in}

B
A
Distance B: Approx. 17.0—17.5 mm {0.670—
0.688 in}
Installation depth C: 1—2 mm {0.040—0.078

in}
BUSH
DBG511BMB070
05–11B–47
4x4
1. Install the bush using the SST.
Front side
Installation depth A: 0—1 mm {0.0—0.039 in}
BUSH
49 0636 040
DBG511BMB071
Rear side
Installation depth A: 1—2 mm {0.040—0.078

in}
BUSH
49 0636 040
DBG511BMB072
Oil Seal (control rod) Assembly Note

4x2
2. Install the oil seal using the SSTs through the
sealing cap hole as shown in the figure.
Installation depth A: 109.5—110.5 mm

{4.312—4.350 in}
49 0221 251A OIL SEAL
49 D032 326A
A
DBG511BMB013
05–11B–48
4x4
2. Install the oil seal using the SST.
Installation depth A: 2.0—3.0 mm {0.079— OIL SEAL

A
0.118 in}
05
49 G033 102
DBG511BMB066
Sealing Cap Assembly Note

1. Install the sealing cap using the SSTs.
Caution
• Apply silicone sealant to the sealing cap.

0.078 in}
SEALING CAP
49 G033 102
49 B032 308
DBG511BMB015
Oil Seal (Extension Housing) Assembly Note

2. Install the oil seal evenly and gradually using the SST and a hammer.
4x2
49 G028 203
DBG511BMB020
05–11B–49
4x4

OIL SEAL
1.94 in}
A
49 G033 102
49 G030 728
DBG511BMB067
Extension Housing Assembly Note

extension housing and transmission case as SEALANT

2. Install the extension housing to the transmission
case.
Tightening torque:
31.4—46.0 N·m {3.21—4.69 kgf·m, 23.2—33.9
ft·lbf}
DBG511BMB008
Top Cover Assembly Note

SEALANT
transmission case and top cover as shown in the
figure.
2. Install the top cover component to the
transmission case.
Tightening torque:
15.7—22.5 N·m {1.60—2.29 kgf·m, 11.6—16.5
ft·lbf}
DBG511BMB009
Control Case Assembly Note

control case and extension housing as shown in
the figure. SEALANT
2. Install the control case to the extension housing.
Tightening torque:
15.7—22.5 N·m {1.60—2.29 kgf·m, 11.6—16.5
ft·lbf}
DBG511BMB010
05–11B–50
Blind Cover Assembly Note
1. Apply sealant to the contact surfaces of the blind
cover and extension housing as shown in the SEALANT
figure.
2. Install the blind cover to the extension housing.
Tightening torque:
7.9—9.8 N·m {81—99 kgf·cm, 70—86 in·lbf}
05
DBG511BMB011
Breather Assembly Note

1. Install the new breather using the SST.
49 B012 004
BREATHER
DBG316BMB044
Release Collar, Release Fork Assembly Note

1. Apply specified grease to the areas shown in the
figure.
2. Install the release collar and release fork.
GREASE
End Of Sie
GREASE
GREASE
DBG511BMB023
05–11B–51
TECHNICAL DATA [R15M-D]
05–50A TECHNICAL DATA [R15M-D]

TECHNICAL DATA [R15M-D] . . . . . . . . . 05–50A–1
End of Toc
TECHNICAL DATA [R15M-D]
DCF055000000W03
Item Specification
Transmission type R15M-D
Type API Service GL-4 or GL-5 05
All-season SAE 75W-90
Transmission oil Viscosity
Above 10°C {50°F} SAE 80W-90
Capacity (L {US qt, lmp qt}) 2.8 {3.0, 2.5}
Mainshaft runout (mm {in}) Maximum 0.03 {0.0012}
Clearance between mainshaft and each gear (mm {in}) Maximum 0.15 {0.006}
Clearance between reverse idler gear bushing Standard 0.02—0.05 {0.0008—0.0020}
and shaft (mm {in})
Maximum 0.15 {0.006}
Clearance between shift fork and Standard 0.2—0.3 {0.008—0.012}
clutch hub sleeve groove (mm {in})
Maximum 0.5 {0.020}
Clearance between shift rod end and
(mm {in}) Standard 0.8 {0.031} or less
control rod
Synchronizer
Clearance between synchronizer ring and Standard 1.5 {0.059}
flank surface of gear (mm {in})
Maximum 0.8 {0.031}
Length 17.0 {0.670}
1st/
Height 4.25 {0.167}
2nd
Width 5.0 {0.197}
Length 17.0 {0.670}
3rd/
Synchronizer key (mm {in}) Standard Height 4.25 {0.167}
4th
Width 5.0 {0.197}
Length 17.0 {0.670}
5th/
Height 4.25 {0.167}
reverse
Width 5.0 {0.197}
Clearance between C-clip and mainshaft groove (mm {in}) Standard 0—0.1 {0—0.004}
C-clip (mm {in}) Thickness 2.9, 3.0, 3.1 {0.114, 0.118, 0.122}
Clearance between the thrust lock washer and
(mm {in}) Standard 0.1—0.2 {0.004—0.008}
C-clip (5th gear end play)
Thrust lock washer 6.2, 6.3, 6.4, 6.5, 6.6, 6.7
(mm {in}) Thickness
{0.244, 0.248, 0.252, 0.256, 0.260, 0.264}
End play
Standard 0—0.1 {0—0.004}
Clutch housing (mm {in}) Adjustment 0.3, 0.4, 0.5, 0.6, 0.7
shim {0.012, 0.016, 0.020, 0.024, 0.028}
Standard 0—0.05 {0—0.002}
Mainshaft front bearing (mm {in}) Adjustment
0.1, 0.3 {0.004, 0.012}
shim
Standard 0—0.1 {0—0.004}
Countershaft front bearing (mm {in}) Adjustment
0.1, 0.3 {0.004, 0.012}
shim
Clearance between synchronizer key
(mm {in}) Standard 0.66—2.0 {0.026—0.079}
(clutch hub) and synchronizer ring
Thrust washer (1st) (mm {in}) Thickness 2.5, 3.0, 3.5 {0.098, 0.118, 0.138}
Detent ball spring free length (mm {in}) Standard 22.5 {0.886}
5th/reverse rataining spring free length (mm {in}) Standard 73.0 {2.874}
End Of Sie
05–50A–1
TECHNICAL DATA [S15M-D, S15MX-D]
05–50B TECHNICAL DATA [S15M-D, S15MX-D]

TECHNICAL DATA
[S15M-D, S15MX-D] . . . . . . . . . . . . . . . 05–50B–1
End of Toc
DCF055000000W05
Item Specification
Standard clearance between shift fork and clutch hub
sleeve groove
0.05—0.40 mm {0.002—0.015 in} 05
Maximum clearance between shift fork and clutch hub
0.5 mm {0.020 in}
sleeve groove
Standard clearance between synchronizer ring and
1.5 mm {0.059 in}
flank surface of gear
Maximum clearance between synchronizer ring and
0.8 mm {0.031 in}
flank surface of gear
Detent ball springs for 1st/2nd and 3rd/4th shift rods Standard length: 22.5 mm {0.886 in}
Detent ball spring for 5th/reverse shift rod Standard length: 24.97 mm {0.9831 in}
1st/2nd select lock spindle spring [4x2] Standard length: 57.5 mm {2.26 in}
Push pin spring for 1st/2nd shift rod end [4x4] Standard length: 32.8 mm {1.29 in}
Push pin spring for 5th/reverse shift rod end [4x4] Standard length: 41.0 mm {1.61 in}
Detent ball spring for 5th/reverse shift rod end [4x4] Standard length: 24.97 mm {0.9831 in}
Mainshaft maximum runout 0.03 mm {0.0012 in}
Standard clearance between shift rod end and control
lever
3rd/4th clutch hub end play 0—0.05 mm {0.0—0.0019 in}
Maindrive gear shaft total end play 0.05—0.15 mm {0.002—0.0059 in}
Countershaft total end play 0.15—0.25 mm {0.006—0.0098 in}
5th/Reverse clutch hub end play 0—0.05 mm {0.0—0.0019 in}
Reverse gear end play 0.25—0.35 mm {0.002—0.0059 in}
Reverse idler gear end play 0.1—0.2 mm {0.0040—0.0078 in}
3rd/4th clutch hub retaining ring

Thickness (mm {in})
1.50 {0.0591}
1.55 {0.0610}
1.60 {0.0630}
1.65 {0.0650}
1.70 {0.0669}
1.75 {0.0689}
1.80 {0.0709}
1.85 {0.0728}
1.90 {0.0748}
1.95 {0.0768}
05–50B–1
Maindrive gear bearing shim selective chart
1.45—1.55
1.4 {0.055}
{0.0571—0.0610}
1.55—1.65
1.5 {0.059}
{0.0611—0.0649}
1.65—1.75
1.6 {0.063}
{0.0650—0.0688}
1.75—1.85
1.7 {0.067}
{0.0689—0.0728}
1.85—1.95
1.8 {0.071}
{0.0729—0.0767}
1.95—2.05
1.9 {0.075}
{0.0768—0.0807}
2.05—2.15
2.0 {0.079}
{0.0808—0.0846}
2.15—2.25
2.1 {0.083}
{0.0847—0.0885}
2.25—2.35
2.2 {0.087}
{0.0886—0.0925}
2.35—2.45
2.3 {0.090}
{0.0926—0.0964}
2.45—2.55
2.4 {0.094}
{0.0965—0.1003}
2.55—2.65
2.5 {0.098}
{0.1004—0.1043}
2.65—2.75
2.6 {0.102}
{0.1044—0.1082}
2.75—2.85
2.7 {0.106}
{0.1083—0.1122}
2.85—2.95
2.8 {0.110}
{0.1123—0.1161}
2.95—3.05
2.9 {0.114}
{0.1162—0.1200}
3.05—3.15
3.0 {0.118}
{0.1201—0.1240}
Countershaft front bearing shim selective chart

Dimension F (mm {in}) Shim thickness (mm {in})
3.15—3.25
3.0 {0.118}
{0.1240—0.1279}
3.25—3.35
3.1 {0.122}
{0.1280—0.1318}
3.35—3.45
3.2 {0.126}
{0.1319—0.1358}
3.45—3.55
3.3 {0.130}
{0.1359—0.1397}
3.55—3.65
3.4 {0.134}
{0.1398—0.1437}
3.65—3.75
3.5 {0.138}
{0.1438—0.1476}
3.75—3.85
3.6 {0.142}
{0.1477—0.1515}
3.85—3.95
3.7 {0.147}
{0.1516—0.1555}
05–50B–2
5th/Reverse clutch hub thrust washer
Thickness (mm {in})
3.00 {0.118}
3.05 {0.120}
3.10 {0.122}
3.15 {0.124}
3.20 {0.126}
3.25 {0.128}
3.30 {0.130}
3.35 {0.132}
05
3.40 {0.134}
Reverse gear thrust washer

Dimension C (mm {in}) Thickness (mm {in})
7.60—7.70
7.35 {0.289}
{0.300—0.303}
7.70—7.80
7.45 {0.293}
{0.304—0.307}
7.80—7.90
7.55 {0.297}
{0.308—0.311}
7.90—8.00
7.65 {0.301}
{0.312—0.314}
8.00—8.10
7.75 {0.305}
{0.315—0.318}
Reverse idler gear retaining ring

Thickness (mm {in})
1.5 {0.059}
1.6 {0.063}
1.7 {0.067}
1.8 {0.071}
1.9{0.075}
End Of Sie
05–50B–3
SERVICE TOOLS [R15M-D]
05–60A SERVICE TOOLS [R15M-D]

SERVICE TOOLS [R15M-D] . . . . . . . . . . 05–60A–1
End of Toc
SERVICE TOOLS [R15M-D]
DCF056000000W02
49 0839 425C 49 H017 101 49 S120 440
Bearing puller Hook Mainshaft

set holder 05
49 1243 465A 49 0862 350 49 S017 401
Mainshaft Shift fork Retaining ring

locknut wrench assembly guide replacer
49 F401 331 49 F401 335A 49 F017 101
Bearing installer Attachment A Synchronizer

body ring holder
49 0500 330 49 0636 145 49 0710 520
Transmission Fan pulley boss Bearing puller

bearing installer puller
49 N017 103 49 N017 104 49 0813 235
Gear installer Joint Main bearing

pipe puller & installer
49 G030 795
Oil seal installer

- -
End Of Sie
05–60A–1
SERVICE TOOLS [S15M-D, S15MX-D]
05–60B SERVICE TOOLS [S15M-D, S15MX-D]

SERVICE TOOLS [S15M-D, S15MX-D] . 05–60B–1
End of Toc
DCF056000000W04
1: Mazda SST number
Example
1:49 UN01 011 05
2:308-168
Socket
1:49 0839 425C 1:49 H027 002 1:49 G033 106

2: – 2: – 2: –
Bearing Puller Remover, Attachment

Set Bearing
1:49 G033 102 1:49 H017 101 1:49 0813 235

2: – 2: – 2: –
Handle Hook Main Bearing

Puller & Installer
1:49 0710 520 1:49 H025 003A 1:49 G028 203

2: – 2: – 2: –
Bearing Puller Bearing Installer Support
1:49 F401 331 1:49 B034 201 1:49 G030 338

2: – 2: – 2: –
Body Support Block Attachment E
1:49 B032 308 1:49 0221 251A 1:49 D032 326A

2: – 2: – 2: –
Attachment A Valve Guide Attachment A

Installer
05–60B–1
1:49 F401 337A 1:49 UN01 011 1:49 0636 040
2: – 2:308-168 2:–
Attachment C Socket Piston Pin

Installer
1:49 G030 797 1:49 F017 1A0 1:49 G030 728

2: – 2: – 2: –
Handle Wrench Attachment B
1:49 H025 001 49 B012 004

2: –
Valve seal
Installer pusher
–
End Of Sie
05–60B–2

F198 20 05L

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F198 20 05L

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CONTENTS

This Manual explains the disassembly,

Ford Motor Company

49 H002 671 SHOWS TIGHTENING

INSTALL THE PARTS BY SHOWS APPLICATION

Apply petroleum Appropriate

Upper and lower limits

Electric current A (ampere) N·m (Newton meter)

Conversion to SI Units (Système International d'Unités)

Upper and Lower Limits

210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}

Inspection During Removal, Disassembly

recalculated due to the extra length that the SST

or equivalent adds to the torque wrench.

Recalculate the torque by using the following

formulas. Choose the formula that applies to you.

Torque Unit Formula

in·lbf in·lbf × [L/ (L+A)]

A : The length of the SST past the torque wrench drive.

• Connectors can be disconnected by pressing or

#1 : Diagnostic trouble codes depend on the diagnostic test mode

ATDC After Top Dead Center

2. If the SST (303-050 (49 UN30 3050)) is used, use

3. Install the SST (arms) to the holes as shown in

4. Assemble the SSTs (bolts, nuts and plate) to the

49 L010 105 49 L010 104

9. Remove the engine hanger (JE48 10 561C) or

ENGINE DISMOUNTING [WL-3]

1 Water pump 6 Tensioner, tensioner spring

Timing Belt Disassembly Note

LOWER CAP IS MACHINED TOGETHER WITH

1 Camshaft pulley 5 Rocker arm

Camshaft Cap Disassembly Note

1. Loosen the camshaft cap bolts in three or four

Camshaft Disassembly Note

Cylinder Head Disassembly Note

1 Pivot 5 Lower valve spring seat

Valve Keeper Disassembly Note

CYLINDER BLOCK DISASSEMBLY (I) [WL-3]

1 Oil drain plug 3 Oil strainer

CYLINDER BLOCK DISASSEMBLY (II) [WL-3]

1 Crankshaft pulley 4 Oil pump

Crankshaft Pulley Disassembly Note

Fuel Injection Pump Pulley Disassembly Note

Fuel Injection Pump Gear Disassembly Note

3. Verify that the end-gap (V groove) of the timing

Note FUEL INJECTION

5. Hold the crankshaft using the SST and loosen the

Timing Gear Case Disassembly Note

Flywheel Disassembly Note

Rear Cover Disassembly Note

1 Connecting rod cap 8 Piston

Connecting Rod Cap Disassembly Note

Piston, Connecting Rod Disassembly Note

Main Bearing Cap Disassembly Note

Crankshaft Disassembly Note

Maximum cylinder head distortion

Maximum combustion chamber projection COMBUSTION CHAMBER

5. Inspect the combustion chamber insert crack.

Combustion chamber crack CRACK

6. Measure the manifold contact surface distortion

Maximum manifold contact surface distortion

Maximum manifold contact surface grinding