F70,F75,F77 7‘ Service manual ENGINE MECHANICAL DAIHATSU MOTOR CO., LTD. NO.9703-FEDAIHATSU F70,F75,F77 ENGINE MECHANICAL PRECAUTIONS - enseane EM 2 TROUBLE SHOOTING sessentnsese EM 3 ENGINE MAIN SPECIFICATIONS ew EM 5 ENGINE OUTLINE EM- 6 ENGINE TUNE-UP ..... EM- 8 CYLINDER HEAD {oR . EM-15 TIMING BELT COVER AND CASE EM-29 PISTON AND CONNECTING ROD .......... EM-38 REMOVAL OF ENGINE ASSY ...... EM-39 INSPECTION OF COMPONENTS . EM46 POSITIVE CRANKCASE VENTILATION (POV) senrsrrnrnnsntneenee . EM-62 TURBO CHARGER SYSTEM ...ccccrceenee EMHG4 POWER CONTROL SYSTEM EM-73 CS : EN-75 TIGHTENING TORQUE . EM77 ENGINE SERVICE SPECIFICATION ......... EM-79 THE ENGINE PROPER SPECIFICATIONS ...... one EM-81“ENGINE MECHANICAL PRECAUTIONS '. Make sure that only the specified bolts and nuts are used. Also, where specified, be sure to employ a [prque wrench to tighten bolts or nuts to specifications only genuine parts for every replacement operation, 3. For increased working efficiency and improved srewracy,utlized SSTs (Special Service Tools) efecvaly 4. When both front and rear parts of the vehicle or only the rear part thereof is jacked up, make certain piace chocks at the wheels correctly in order to assure este operations. 5. When t King poinge X20 UP: make sure to support the vehiole with safety s the specified jacking points, 6 Before any repair work is make on the electrical System or the engine is removed or installed, fist be DioeesenlSconnect the negative © terminal ofthe battery ‘ands positions at (1) When complicated parts are disassembled, put Stamped marks or marks on suitab siterg.! te Parts in order that the said parts may be easily assembled in the Positions. (2) Replacements of the cylinder block or crankshaft, ete Should be carried out after the engine assembly has been removed from the motor vehicle. 8 (Checks to the performed during disassembly. Each time a parts is removed, check conditions under which the part has been a: © See if the part exhibits any evidence of distortion breakage, wear or scores, etc rangement of disassembled parts, Put disassembled parts in a good order. Moreover, divide disassembled parts into two gr Ween e Pe feplaced and those parts which can be reused Washing disassembled parts. As for those parts which can be reused thoroughly clean or wash them. 11. Inspection and measurement Aceon Parts which are to be reused must be carefully inspected or measured, as required, 12. Assembly of parts. Those satisfactory parts only should be assembled in accordance with the prescribed standar herrnone watment values., tightening torque and so forth) sner™ore, seal packing or grease should be applied. se required. Ronfune a iy. sembled. Also, check s (e.g, Furthermore, in respect to packings, gaskets cotter pins and similar items, be certain to install new parts Adjustments and checking of service operations inaic® operations must be carried out correctly by méane of Gauges oF testers, if the use of these instruments is required, EM-2——————— ee 3 TROUBLE SHOOTING ENGINE MECHANICAL Engine overh ‘Coating system Fuel system faulty Lbrication system faulty Starting system Troubie Remedies Page 6% cooling system Trouble shoot fuel system, Trouble shoot ation system. gine will not crank or crank Trouble shoot starting system. ] may Charging system Trouble shoot charging system ngine wil not startHard to start | Preheating device problem x fer motor is normal inspect glow pi ; Inspect onnector Ingpect glow plug current sen | Check fuel tank and fuel line, + Fuel pipe on p pect injection pump. Reset injection timing, Check injectior Rough idie/Engine stall Adjust valve clearance ENW-10 7 Adjust idle speed. M13 ion timing Reset injection timing. EM-11 Low compression Check compressior EM-13 Fu! leakay (Check fuel line rus + Injection pipe * De ave Turbo charger problem spect tur EM-64 Injection pur lem spect Fu-4 3k of pow | Fultieai (Check fue! lve, Fu © Injection pipe © Injection nozzle Correct injection timing Reset injection timing MeN Turbo charger problem Check turbo charger | emea + Waste gate + Boost compensator +7 iarging pressure jection pump problem Inspect injection pum F L PP P EM-3ENGINE MECHANICAL ENGINE MECHANICALENGINE MECHANICAL oY ENGINE MAIN SPECIFICATIONSENGINE MECHANICAL ENGINE OUTLINE DL Engine Type DL engine is a w ' 55 ot he DL engine o ¥ a ine) type and the other DL-52 (turbo ne ro newly pro to incr preover y and reliability, the turbo ger employs a water-cooled type. ENGINE SECTIONAL VIEW r— [DL-42 Engine EM-6EE llttt—‘aN ENGINE MECHANICAL a tENGINE MECHANICAL | ENGINE TUNE-UP(4) Clean the element with compressed air. First, blow compressed air from inner side of the ele- ment thoroughly Then, blow off the outer side of the element. CAUTION: + The air pressure to be used this cleaning operation should not exceed 392. kPa (4.0 kgf/cm’). Replace the air filter element, if necessary (5) Place the element in the air cleaner case. Secure the element with the wing nut (6) Install the air cleaner cap to the air cleaner case. Secure the air cleaner cap by tightening the three clamps. Inspection of battery (Gee the charging system section.) Inspection of valve clearance (1) Warm up the engine completely. (2) Remove the cylinder head cover by loosen the four attaching nuts. EM-9ENGINE menu ENGINE MECHANICAL 3 a thickne fe nces (Hot condition) | [Ba tom | 026 005 | o252005 | Tightening Torque: 19.8 -24.5 ten | =] | | d, apply engine o} 9 boltENGINE MECHANICAL (7) Install the cylinder head cover on the cylinder he: (8) Tighten the cylinder head Nuts over two or three . 4ence, until they tightened to the specified torque Tightening Torque: 5.4 + 1.5 Nm (0.55 + 0.15 kgf-m) Check and adjustment of injection timing 1, Remove the distribut Then, install t T and set.a dial gauge SST: 09275-54010-000 head bolts on the injection pump. NOTE: * Since there is a hole-shaped notch at the end of the plunger, the measuring pin of the dial gauge must con tact the flat section of the plunger. Make sure that no dust gets into the pump. 2. Release automatic cold starting (ACSD equipped vehicle on! 1 the automat bout 20° de (2) Puta mete lat 4 cente 1e cranks f the No. 1 cylinder u s back off crankshaft approx align the pointer of the dial gauge w NOTE: * Atthis time, turn slightly the crankshaft pulley to the right and left sides and make sure that the pointer is stable at the zero position-_ ENGINE MECHANICAL 4 Tum the crankshaft in the normal direction and take the reading of the dial gauge when the top dead center mark on the pulley is aligned with the pointer Specified Value: 1.07 - 1.13 mm (Injection Timing ssenennneee BTDC 12) NOTE: * The gauge's reading of + 0.03 mm corresponds to the injection timing of + 0.5° on "0 1.07 = 113 mm 5. Slacken the attaching sections ofthe injection Pump proper & at the following points given below. Adjust tho injection ss a timing by moving the pump proper we ah. * Injection pump attaching nute Section A mB | t\E9 * Lower bracket attaching bolt Section B ove spectied v * Attaching nut of each high-pressure pipe YB) STS (union nut) Section C YAnder oe cea ¢ 8. Perform the injection timing check again and ensure that ‘Specified value the injection timing is proper. — ay ZEN V9 = 1.13 < ) 6 J Ra Pump at ""9=" Pull toward yor fr ‘ 4 Hee Pump ataching 4} = Al 7. ‘When the injection timing is adjusted, make sure that the fenton Pump is in a pulled state toward you, If the injec- tion timing is adjusted with the injection Pump in a pushed State toward the engine block side, the timing may be retarded. Tightening Torque: 18.1 +3.4 Num (1.85 + 0.35 kgf-m) NOTE: * Replace the copper washer the distributive head bolt Baaeaee with a new one. 7 EM-12» Measurement of compression pressure 1. Warm up the engine 2. Remove all the glow pl B. F plug, Set the compression gauge in place. the attachment into the installation hole of the glow ith the throttle valve opened fully, crar @ starter nking speed: 250 rom Compression Pressure: ak the engine, STD 3138 kPa (32 kgf/cm’) Limit 2158 kPa (22 kgt/cm*) Variation Between Cylinders: 196 kPa (2.0 kgt/cm*) Adjustment of idling speed 1. Warm up the engine. 2. Measure the idling speed. 3. Adjust the idling speed by turning the idling adjusting bolt Specified Idling Speed: 650 + 25 rpm EM. ENGINE MECHANICAL, ENGINE MECHANICAL |GINE MECHANICAL adjustment of maximum no-load revolution speed specified Mai DL-4 DL-52: 450OO ENGINE MECHANICAL CYLINDER HEAD 1 COMPONENTS * : Non-reusablerpart T _: Tightening torque Unit | Nim (kgm)ENGINE MECHANICAL \f REMOVAL OF CYLINDER HEAD Removal of batte 1) Disconnect the battery gro ) terminal of battery 1d cable fromthe negative ‘om the engine compertment by ‘ery holding clamp. ent ake duct by loosen thre hing bolt at air cleaner at air cleanerENGINE MECHANICA B-87310-000 * Arrange the injection nozzle in order |NICAL, c Remove the ft with valve rocker arm By sight figure NOTE: * Remove t Store the rem be mixed with each other wwence of cylinders. the parts in the Seq\ periy so that they may not ‘oved parts pro vlinder head bolts in Remove the cylinder head by 1oose pont figure NOTE: NOTjore the removed springs and valves in correct Se quence so that they may Be installed in their original positions on reassembly—<——— ENGINE MECHANICAL @ 16. Removal of combustion chamber Drive out the combustion chamber by instaring an about 4 nm dia rod through the glow plug installation hole. }j INSPECTION OF CYLINDER HEAD 1. Cleaning of cylinder head (1) Remove any remaining gasket cylinder head and manifold surf scraper. material from the es by using a gasket (2) Remove all carbon deposits from the combustion cham- bers by using a wire brush. CAUTION: + Be careful not to scratch the cylinder head gasket con- tact surtaces. (3) Clean all valve guide bushings by using a valve guide brush and solvent. 2. Using a precision straight eage and thickness gauge heck the gasket surfaces contacting the cylinder block and manifolds for warpage. Maximum Surface Warpage: Cylinder Block Side: 0.10 mm Intake Exhaust Manifold Side: 0.20 mm Replace the cylinder head, if surface warpage of the : ter ~ cylinder block side exceeds the maximum limit. = | EM-19GINE ME 3ecord t Specified Vale 9.010 - 9.030 mm 2.010 - 9.030 mm IN: EX: oF Measured maximum value of guide bush b: Measured minimum value of vale ees A a-b = Oil clearance 2 dil Clearance Specified Value IN: 0.02¢ EX: 0.044 0.096 mm Allowable Lim N: 0.40 mm EX: 12mm ) ator tg (iS JPCeMent should be permed ony after the’ checke fo te cylinder head have been finishedENGINE MECHANICAL a * The valve guide bush hole must be used for refacing only valve Hence , if the valve guide bush hole exhibits any rough: ness due to seizure, etc., rectify the hole with an adjus. table reamer. a i the em end exhibits abno orrect the a However, this correction should be made within a limit from Standard Length: IN: 127.5 mm EX: 127.5mmENGINE MECHANICAL 5. Correction of seat position | (1) If the seat position is too high, reface the valve seat, NE using 45-degree and 75-degree cutters, aa These valve sea ould be employed in the re sequence as indicated by the illustration. at position is to low, reface the valve seat, using gree and 15-degree cutters. These valve seat cut- ters should be employed in the sequence as indicated by the illustratior re io R N After the valve seats have been refaced, carry out hand © gtinding of the valves, using valve grinding compound. 6. Inspection of vaive spring (1) Check the valve spring areness, using a steel Maximum Squareness: 1.6 mm Squareness' exceed the maximum limit, replace the valve spring. the valve spring for free length and spring nsion, using a spring tester, Minimum Free Length: 46 mm Minimum Tension Installation Height 264.8 N (27.0 kgf)/40.1mm If minimum free length and/or minimum tension is less than the minimum limit, replace the valve spring,———<———— re ENGINE MECHANICAL & _7 Inspection of valve rocker arm and valve rocker shaft (1) Visually inspect the valve rocker arm for cracks, seizure or wear. Replace the valve rocker arm, if necessary. for cracks, (2) Visually inspect the valve rocker sha seizure or wear. Replace the valve rock Shaft, if ne sary, heck valve rocker shaft-to valve rocker arm ] D Using a dial gauge, measure the inner diameter of the valve rocker arm in two directions, 90 degrees apart from each other Specified Value: 18.512 - 18.533 mm Using a micrometer, measure the outer dianieter of valve rocker a Specified Value: 18.472 - 18.493 mm Oil Clearance: 0.022 - 0.733 mm Limit: 0.1 mm. 8. Inspection of combustion chamber : (1) Visually inspect the combustion chamber for cracks or EM-23ENGINE MECHANICAL INSTALLATION OF CYLINDER HEAD NOTE * Prior to assembly, be certain to apply engine oil to the rotary sections or sliding sections of the parts. ected Projection Height: 0.8.10 mm | ing th T: 09201-87702-000 NOTE: * Once the valve has been removed, be sure to install new alve stem oil seal Sure to apply engine oil to the lip section of the oi z EM=To—CCrCt—CSS—sée™ ENGINE MECHANICAL @ + Assemble the parts given below, using the folowing SST: 09202-87001-000 Valve spring (3) Valve spring retainer (4) Valve spring retainer lock ark facin d gasket with its “Top’ up) NOTE + If the cylinder head gasket should be installed upside down, it would cause the oil passages to be clogged, thereby causing engine seizure. + Be sure to replace the gasket with a new one. 6. Install the cylinder head (1) Apply engine oil to the threaded portion and seating surface of each bolt (2) Tighten the cylinder head bolts progressively in the sequence as indicated by the illustra Tightening Torque: 117.7+9.8 Nm (12.0 + 1.0 kgf-m) 7. Install the push rods. 139 61 4 8 12 16 NOTE: ‘Those valve push rods which have been stored inorder Wares should be installed as a set to the original cylinder, respectively.ENGINE MECHANICAL i 1 ( | 1 l = = = 1 oe + After tt ine has bi mbled to t b . 7 ion undk 4.75 if NOTE + Be sure to rep with new one + Onthe tu arge x to install the turbo 4 the exhaust >efore installing the ylinENGINE MECHANICAL NC Be TE Be Tight ipe ning Torque n ing the nozzle e Ry “i | z =f ipa 2ts.. - | | = ) | | | = |ENGINE MECHANICAL ( terminal 3ENGINE MECHANICAL TIMING BELT COVER AND CASE a COMPONENTS 4 Genera! speciation co — > a 4: Non-rousable part J Tightening torque Unit: Nim (kom) ai ENGINE MECHANICAL ENGINE MECHANICAL REMOVAL OF TIMING BELT AND PULLEY [ENGINE MECHANICAL a SST: 09213-31021-000 (M6 bolt 2017-000i ICAL 16. Remove the valve lifters Gib NOTE — * Store the vaive lifters in order. Fer" 17. Remove the camshat timing belt pulley with camshatt. INSPECTION OF COMPONENTS 1. Timing belt inspection CAUTION A {De not bend, twist or turn the belt inside out 4 * Dornot allow the belt to come into contact with ol, water q or steam, { * Keep the belt clean © are defect 19 points . Check the timing gear c k for correct ?) If the belt teeth are cracked or dar if the camshaft is seize EM-32ENGINE MECHANICAL 4 | Timing Belt Specifications Le — | 3 i ) 4 ‘ é : = CAUTION: 4 | * Never wash the timing belt tensioner. ec : | | Specified Value :ENGINE MECHANICAL alt ter INSTALLATION OF TIMING BELT 1. Installation of camsh amshaft timing belt pulley, (1) Install the camst I not to damage the cam. shaft bearings. FE i | the valve lifter * Those valve lifters which have been stord in oder should be installed as a set to original cylinders, respectively. . 3) Install the push rod cover Tightening Torque: 9.3 + 2.5 Nm (0.95 + 0.25 kgt-m) 2. Install the injection pump timing belt pulley Tightening Torque: 83.4 + 4.9 Nim (8.50 + 0.52 kgf-m)————————————— ENGINE MECHANICAL 3. 4 6 Install the timing belt idler No. 2 Temporarily install the timing belt tensioner. Install the crankshaft timing belt pulley NOTE: + The flange should be installed only in the correct install ing direction + Be sure to install the crankshaft timing belt pulley in such direction that the recessed mark stamped on the pulley comes at the front side. Adjustment of timing belt te’ (1) Align each of the three pulleys for the crankshaft, car with each corresponding mark of the marks on the timing belt case. Under this condition, the piston No. 1 is set to about 30 .grees before the top dead center, of the timing bel nshaft and injection pump three mating (2) Asser lines) at the back at the same position o NOTE: ‘* Be sure to displace the front end surface of the timing belt about 2: mm toward the timing belt case from the front end surface of each pulley the front. (3) Adjust timing belt tension. @ Insert @ hexagonal w into the hexagonal hole of the timing tensioner. Tigt bolt @ of the ming tensioner by applying tension to the wrench Tension: 9.8 N.m (1 kgf-m) EM-35ENGINE MECHANICAL the timing Id the crankshaft back raft two turn i in Specified Deflection: 1.8 mr Specified Pushing Force: 18.6 19 ntening Torque 123.4 Ne as 0.35 kgf-m} ightening Torque Nm kgf-m) | g xENGINE MECHANICAL om | force of 98 N (10 kgf) applied) - Tightening TorqueENGINE MECHANICAL G PISTON AND CONNECTING ROD COMPONENTS 4 | T= Tightening torque Unit : Nem (kgf-m)Ss ne » REMOVAL OF ENGINE ASSY 1. Drain the coolant 2. Remove the be id engine oil ry. Remove the engine hood. Remove the air cleaner sub-assy Remove the water ho: Disconnect the fuel radiator and cooling fan. pipes and choses. 1@ assy by us EM-39 ENGINE MECHANICALENGINE MECHANICAL F DISASSEMBLY OF CYLINDER BLOCK l is 1 ! ‘ M. (—— lr e—CC ENGINE MECHANICAL 4 4. Remove the inje (See page FU-6.) 5. Removal of the camshaft. (1) Remove the push rod cover. (2) Remove the push rod and the valve lifter. NOTE: + Remove the parts in the sequence of cylinders. | + Store the removed parts properly so that they may not to be mixed with each other. (3) Remove the thrust plate attaching bolts. (4) Remove the camshaft with the camshaft timing bett pul- ° ley 6. Remove the water pump by loosen four bolts. EM-41ENGINE MECHANICAL DISASSEMRI v or ~ ENGINE MECHANICAL ST 5011-000 7 << ~yENGINE MECHANICAL * When pulling ratch ttENGINE MECHANICAL ENGINE MECHANICAL ination of and connecting rod 49. Store the pist quence without ¢ jing the correct c 20. Remove the timins 21. Remove the crank: PI remove’ that they may 22. Clean cylinder bloc (1) Remove all the aterial from the top of the (2) Blow carbon and oil from WARNING: » Protect your eyes when using compressed alt- 23 cting rod from pistor ap ring, using needienose pliersSST: 09221-87601-000 NOTE: + The piston and pin are a matched set. + Keep the piston, pin, rings and connecting rod together EM-45ENGINE MECHANICAL ' ENGINE MECHANICAL NGINE MECHANICAL COMPONENTS LINDER BLOCK NSPECTION OF NSPECTION OF cy Remove a Piigwable Wapage: 0-0" INSPECTION OF CAMSHAFT i \ENGINE MECHANICAL diameter, using a Specified Value: 1st journal: 46.559 - 46.575 2nd journal: 46.259 - 46.275 K 3rd journal: 45.959 - 45.975 TN 4th journal: 45.659 - 46.675 sth journal: 45.359 - 45.375 Measure the camshaft thr Specified Value: 0.10 - 0.19 mm NOTE: * Prior to the measurement of the camshaft ti clearance, tighten the camshaft timing belt pulley to the camshatt to the specified torque.ENGINE sen ENGINE MECHANICAL ENC —— (2) Inspect the valve push rod for bend. INS Bend Limit of Push Rod: 0.4 mm INS! 7. Inspection of value lifter (1) Visually inspect the value lifter for wear or damage. 2) Measure the oil clearance of value lifter Specified Oil Clearance: 0.015 - 0.049 mm Limit: 0.1 mm 8. Inspection of crankshaft Al (1) Measure the crankshaft for runout. oa) Take a reading on dial gauge during the turning Ay Runout Limit: 0.05 mm LO A (2) Visually inspect the crankshaft main journals and 7 1 crankpin journals for wear or damage. “ EM-48Spe Main Journal: 67.955 - 67.970 Grankpin Journal: 55.075 - 55.990 Specified Value: 0.050 - 0.159 mm Limit: 0.25 mm. TE * Tighten the crankshaft bearing torque in advance. Tightening Torque: 103.0+ 6.9 Nm (10.50 + 0.70 kgt-m| cap to the specified Specified Value No.1 and No.5 journals: 0.025 - 0.060 mm No.2, No.3 and No.4 journals: 0.030 - 0.065 mm Limit: 0.12 mm NOTE + Wipe off the oil or the like getting to the main journal .ection in advance. «Tighten the crankshaft bearing cap to the specified torque. Tightening Torque: 103.0 + 6.9 Nm (10.50 + 0.70 kgt-m) Then, calculate the piste ance Specified Value: Piston Outer Diameter DL-42; 91.93- 91.96 mm DL-52: 91.92 - 91.95 mm Piston Clearance: DL-42: 0,06 - 0.08 mm DL-52:_ 0.07 - 0.09 mm ENGINE MECHANICAL Ie yi” | —— —— ¥ | , | | 6 | . |ENGINE MECHANICAL \ 1 (3) Measure the groove width of piston rings No. 1, No. 2, : No. 3 with a thickness gauge. z ———— DL-42 DLs2 NS ——— {|__| __ No. 1 piston ring groove wiath | 266-257 | 7° kay stone 2 No. 2 piston ring groove wiath | 203-205 | 208-208 No. 3 piston ring groove wiath | 401-403 | 401-403 10. Inspection of piston ring (1) Inspect the piston ring width 3 Specified Value: Engine] ee DL-42 oLs2 Component ‘Compression ring No. 1 25 38 | 7 key stone 1 ‘Compression ring No. 2 20 3% 20 % Oil ting 40 38 40 38 : (2) Inspect the piston ring thickness. 4 oes DL-42 DLs2 ‘Compression ring No. 1 3601 | 384012 Compression ring No. 2 a8to1 | 384010 (3) Calculate the piston ring side clearance. Specified Value: — DL-42 DL-s2 Compression ring No. 1 (006-010 Compression ring No.2 | 004-008 | 007-011 Oil ring No. 3 sd 002-006 | 002-006 (4) Measure the piston ring end gap. Place the piston ring in the cylinder bore at lower part where very little wear exists. Measure the end gap of the piston ring, Specified Value: DL-#2 DL-S2 Compression ring No. 1 030-045 | 035-050 mpression ring No. 2 030-045 | 090-045 Oilring No. 3 (030-050 | 030-050<< ee ENGINE MECHANICAL 4% 1% Inspection of piston pin (1) Measure the length of piston pin. A (2) Measure the diameter of piston pin Specified Value: D = 27.993 - 28.000 (3) Visually inspect the piston pin for wear or damage. 12. Inspection of connecting rod (1) Visually inspect the connecting rod for damage. (2) Check the connecting rods alignment using a rod alig- ner If the rod is bend or twisted, replace the connecting rod. Specified Value: Bend Limit: 0.05 mm Twist Limit: 0.05 mm, ENGINE MECHANICAL ! EN IN‘ INS | AY | ee Co | f >pecified Clearance: 0.005 - 0. 027 mm Limit: 0.05 mm NOTE / bal * Be sure not to turn during this crankpin journal—— = ENGINE MECHANICAL REPLACEMENT OF CYLINDER LINER SST: 09221-87301-000 lationship Between Stamped Numbers and inder Liner & Cylinder Block NOTE * Alter new cylinder liners been press-fitted, boring machining and honing operation should be carried out for each bore in accordance with the STD piston outerENGINE MECHANICAL E ENGINE MECHANICAL on height of Speci 3 Projection Height: “0.01 - REPLACEMENT OF CAMSHAFT BEARING Removal of camshaft he expe SST: 09215-87601-000 ») Remove the camshaft t SST: 09215-87601-000 (4) Install ne ylinder block.a 3 the camshaft bearings by using SS SST: 09215-87601-000 ASSEMBLY OF CYLINDER BLOCK ENGINE MECHANICALi. FNGING Meru asunas EN ENGINE MECHANICAL EN — = [ IN IN' Cap Bolt Tightenin, 1 6.9Nm | 0 + 0.7 kgf-m) L I J RE NOTE I * Prior to the assembly, apply engine oil to the threaded portion and bearing section of each cap bolt Tightening Torque: 18.1 + 3.4 Nem% — 7. Install the ol seal retainer 8. Install the rear end plate. 9. Install the flywheel Tightening Torque: 125.0 + 12.3 Nm (12.75 + 1.25 kgf-m) 10. Drive the bearing into position, using the SST. SST: 09304-12012-000 11. Install the clutch disc and clutch cover, using the SST. SST: 09301-22020-000 12. Install the clutch cover. Tightening Torque: 19.6 + 4.9 Nm (2.00 + 0.50 kgf-m) EM-57ENGINE Menu aninas — EN ENGINE MECHANICAL ’stall piston rings in such ¢ amped mark at the end rn17. Set the piston rings in si way that their end gaps assume the respective positions as shown in the illu the pistons in the cylinder block, using the SST: 09217-87001-000 NOTE: + When installing the pistons, make sure that the front mark of each piston faces toward the front of the engine. the connecting rod Tightening Torque: 68.6 + 4.9 Nm (7.00 + 0.50 kgf-m) NOTE * Tighten the connecting rod bearing cap with the front mark facing forward. . * Prior to the assembly, coat the inside of each bearing with a film of engine oil * Also, apply engine oil to the threaded portion of each bolt and the bearing section of each nut. 20. Installl the oil pa ) ealer to the gaske slock sic Tightening Torque ENGINE MECHANICAL ENGINE MECHANICAL *= 22. 24. ENGINE MECHANICAL Install the valve lifter NOTE: * Those valve lifters which have been stored in order should be installed as a set to the original cylinders, respectively. Install the push rod cover. Install the alternator TTReee ENGINE MECHANICAL INSTALLATION OF ENGINE ASSY {, Place the engine assy into engine compartment by using chain block ngine mounting. \smission into the engine ins llation part and e fuel pipes and hoses. 7. Connect the 8. Install the radiator and cooling fan. 9. Install th the battery. ler sub-assy. 41. Fill the coolant and engine o 12. Install the engine hood 43. Start the engine 14, Check and tune up th =ENGINE MECHANICAL E POSITIVE CRANKCASE VENTILATION (PCV) DL-42 Engine | 1-42 Engine | Positive crankcase ventilation systemENGINE MECHANICAL : 4 DL-52 Engine Js Positive crankcase ventilation system » | \ | i Inspection of PCV Hose & Connection : Visual inspection of hose and connection : EM-63ENGINE MECHANICAL ENGINE MECHANICAL TURBO CHARGER SYSTEM +. intake pipes have been provided newly an iency has been of the newly employment of the intercooler ‘d cool air intake duct have been changed. uently, volumettic effic wutput power has been in from 67 KW to 75 KW. ty an cooling water is circulated in the turbo charger Furthermore, fo ed durabii housing so a: the floating s —— 4 in DL ool air intake duc Aad je | |Ee ENGINE MECHANICAL & COMPONENTS Do | | ood ° e | at oe ‘6 | a QoQ i . Bi > * \ * iF | * ( | | Z Jeashd, . | ‘ vans . * » ee A . , Be 4: Noneoveabe pat |a) r Tl ENGINE Meruasun.. ENGINE MECHANICAL SERVICING INSTRUCTIONS FOR TURBOCHARGER er disassemble the turbocharger, because it is a Dn component whose assembly requires utmost 2. After the turbocharger has been removed, affix gum tape’ etc. to the inletfoutlet ports of the oil and those of the lust gases so that no dirt or foreign matter may intake/ex When disassembling the intake, exhaust and lubricating SEE ating pects ‘are must be taken so that no dirt or foreign matter systems, may enter 4. Never rotate the engine when the intake manifold No. 2 intake air connector and turbine outlet elbow, etc. are dis- connected (so as to prevent foreign matters from entering) Use the specified attaching set bolts and nuts of the tur- bocharger since they have under-gone the heat-resistant treatment, 6. After the turbocharger has been replaced, keep the engine idling for more than ten seconds after it starts. If the revolu- tional speed is increased sharply, the bearings of the tur- bocharger may be damaged. In addition, make sure that no oil leaks from the oil pipe. Replace the removed gasket and seal, etc. with new ones. Moreover, tighten the section to the specified torques so that no leakage takes place fating More thar ten seconds 8. Do not hold the waste gate valve rod section 9. Since the turbocharger is a precision part, do not drop it. 10. Do not remove the residual oil completely from the bearing ection. (The residual oil refers to such an amount of oil that after the oil has flown naturally.) remains on the surfact 11. Do not place the turbocharger vertically. J Under such condition, the oil in the shaft section flows to the impeller room and this may be mistakenly regarded as an oil leakage. bochargerENGINE MECHANICAL @*- Checking operation of turbocharger waste gate valve (1) Remove the waste gate actuator hose at the actuator side (2) Connect the turbocharger pressure gauge. Ensure that the rod and link operate when a pressure of 92.2 kPa (0.94 kgf/cm’) is applied and that the valve returns to the original position smoothly when the pressure released Specified Value: Shaft Stroke: About 2 mm With a pressure of 92.2 kPa (0.94 kgf/cm’) NOTE: ‘© Ifthe pressure exceeding 117.7 kPa (1.2 kgf/cm’) should be applied to the waste gate actuator, the diaphragm may be damaged. (3) Check the hose for crack and damage we Checking air-tightness of boost compensator (1) Connect the turbocharger to the boost compensator (2) ‘Apply a positive pressure of 133.4 kPa (1.36 kgf/om’) and measure the time required for the pressure to drop to 190.4 kPa (1.33 kgf/cm’) Specified Value: Not less than 10 seconds Check of supercharging pressure (running test) ‘0 obtain total evaluation, perform a running test and » measure the supercharging pressure. The running test must be carried out at a place where the vehicle can be accelerated safely with full throttle accelerator pedal in the second gear. One person drives fa vehicle and the other person performs measurement. (Two persons aboard) (1) Connect a turbo charger pressure gauge to the va hose of the intake manifold with a three-way join posed, Place the gauge in the vehicle interior. (2) After the engine has warmed up, accelerate the vehicle at full throttle up to 3,500 rpm with the second gear EM-67 eee eeP pNeme ENGINE MECHANICAL Specified Valu REMOVAL OF TURBO CHARGERENGINE MECHANICAL | : | | ; : | | : a yi Famed Wien, | i = 4 » . ‘ to preve NOTE . reuse the removed gasket.: EE ENGINE MECHANICAL ass hose No.1 44. Disconnect the water by NOTE: * Never reuse the removed gasket. c [ 12. Disconnect the oil inlet pipe of the turbo charger: | 13: Remove the two attaching bolts of the oil outlet pipe at the turbo charger side. NOTE ‘Never reuse the removed gasket. | 14. Move the front exhaust pipe downward by removing the ree attaching nuts of the front exhaust pipe, ove the exhaust manifold together with the turbo arger by loosening the six attaching nuts of the exhaust 15. Ri ct manifold, NOTE: Never reuse the removed gasket. | 16. Removal of turbo charger turbine outlet elbow from the turbo charger | 1) Remove the by loosening the two bolts and two nuts. 2) Remove the turbo charger from the exhaust manifold by loosening the four attaching nuts. NOTE Never reuse the removed gasket. Never hold the actuator rod section during the removal of the turbo charger. + Affix a tape or the like so as to prevent any foreign matters from entering each of water port and oil port of the turbo charger. EM-70ee ENGINE MECHANICAL a INSTALLATION OF TURBO CHARGER 1. Clean each gasket installing s of the turbo charger. 2. Install the exhaust manifold to the turbo charger. Tightening Torque: 24.5 + 4.9N-m (2.5 + 0.5 kgf-m) Install the turbine outlet elbow to the tur Tightening Torque: 24.5 + 4.9N.m (2.5 + 0.5 kgf-m) NOTE: * Be very careful not to deform the turbo charger actuator rod. Never disassemble the turbo charger or tighten the bolts 4 further. + Use a new gasket. ‘emporarily install the exhaust manifold tog} urlbo charger to the engine. i NOTE: * Use a new gasket. pipe to the turbo charger 7441.5 Nm 2 (0.78 + 0.15 kgtm) 6. Connect the oil inlet pipe of the turbo charger. Tightening Torque: 17.2 + 2.5 Nm (1.75 + 0.25 kgf-m) NOTE: * Use a new gasket. ully tighten the exhaust mani Tightening Torque: 46.6 + 4.9 Nm (4.75 + 0.75 kgf-m) 8. Install the front exhaust pipe Tightening Torque: 49.0 + 4.9 Nm (6.00 + 0.50 kgf-m) EM-71ENGINE MECHANICAL ENGINE MECHANICAL Tightening Torque: 29.4 4.9Nm 0 kgt-m Tightening Torque: 29.4 3.00 Tightening TorqueENGINE MECHANICAL ‘onnect the ground cable to the negative (-) terminal of theENGINE MECHANICAL POWER CONTROL SYSTEMENGINE MECHANICAL nA and B: Air continuity exists ween A and C: No air continuity e) Between A and B: No air continuity exists. Between A and C: Air continuity exists M Specified Value =rs ENG) ENGINE MECHANICAL = pow SSTENGINE MECHANICAL > Pe & K : 301-2002 7 a | i : | case C Used for press fywheel bearing | > Jniversal Used for remove injection pump timing f ba] a sed for guide piston inset & ( - Used for pressfit cranksh eal oo) ; } 000 E sy eENGINE MECHANICAL TIGHTENING TORQUE Ve oe—E—x—— ENGINE MECHANICAL: ENGINE MECHANICAL -, ENGINE MECHANICAL + ENGINE SERVICE SPECIFICATION c = 9EN Th Fo ¢ ENGINE MECHANICAL | THE ENGINE PROPER NOTE: SPECIFICATIONS The entry figures are those values at a temperature of 20°C. Cylinder liner outer diameter x Cylinder block bore diameter Cylinder block x Crankshaft x Crankshaft bearing _ 0-80 001-008 2 G6016- 96080 | act-00« 5 [e885 a70 seae0-ee0is | 001-000 Cylinder liner inner diameter x Piston outer diameter (DL-42) mm Ter c — | 91.93 - 91.94 at Cylinder liner inner diameter x Piston outer diameter (DL-52) mm A - 92 22.03 91.94 - 91.95 B - 12.02 91.93 - 91,94 4 50-8201 32-9199 Ttem ournal a7, ] 205 (Brown) ‘eat 2 2.000 (Black) Ni 1.995 - 2 00 [Brown 2.000 - 2.005 [Biack}errETETETETETETETETETETETETE ll, ” ENGINE MECHANICAL Connecting rod large end x Crankshaft x Connecting rod bearing mm 19 fod large end ‘Connecting rod bearing nbination No nctng cos lero Crankshaft Grankpin diameter ae 58.000 - 58.010 = 1.485 - 1.490 [Blown] | 54.990 58.010 - 58.0% 1.400 — 1.495 [Black] Piston pin x Connecting rod smalll end x Piston pin hole mm ; a inner diameter Peter pine 93 - 28,00¢ 28.005 - 28.020 | Valve lifter x Cylinder block me . Valve lifter outer diameter Oylinder block valve lifter inner diameter —e 3972-2 24,000- 24.024 Valve stem Valve guide bush : Valve stem outer diameter Valve guide bush inner diameter ako valve 901-908 hau 901-908 Valve rocker shaft x Valve rocker arm mm Valve rocker shaft outr diameter Valve cocker arm inner lame 18472 18.499 Z 18512-10595 @ Connecting rod x Crankshaft mn Connecting rod large end thickness Cra ournal thickness 33.00 33.95 34.16 Pre combustion chamber x Cylinder head nm Pre combustion chamber Cynder head pre see y Interference 20-3 0-0.085 Valve guide bush « Cylinder head m Valve guide bush outer diameter inter — 4.085 - 14058 4000-14018 | 5018 - 0.058 EM-831 ENGINE MECHANICAL = Camshaft bearing x Cylinder bloc Valve guide bush x Valve stem oil seal Valve rocker shaft x Valve rocker support Camshaft x Camshaft bearing | Piston ring x Piston (DL-52) |ENGINE MECHANICAL } Connecting rod x Connecting rod small end bush Cylinder liner x Cylinder block upper gasket surface Valve x Cylinder head lower gasket surface 4 a Camshaft x Camshaft timing belt pulley Precombusion chamber x Cylinder head lower gasket surface 2 a Cylinder HeadENGINE MECHANICAL Valve Spring vi Alowable 5d Beh oa Valve Rocker Arm & Shaft Ten val Aliowabie tn aranc m | 0.061 01 Valve Guid Bush Protrus rom cylinder head (IN & EX) 160 Valve intake 010 Camshatt & Bearing : Specited va iowa intakeENGINE MECHANICAL 4 Valve Rocker Arm & Shaft AL] Specified value ‘Allowable limi et surface distor im = 04 Wea! mm 15 Pressing force N kat | Connecting Rod | Allowable limit g end t 2 mm 30 | Bearing oil clearan 7m 0.15 Crankshaft hs tem | Allowable limit even wear or tape 0015 a< = Ve les Va r | [ Can FE ENGINE MECHANICAL ENGINE MECHANICAL Flywheel Intake, Exhaust Manifold Piston,PistonRing Camshaft timing pulley, Crankshaft timing pulley, Injection timing pulley r OipumpRadiator Lo ENGINE MECHANICAL item valve opening prest Radiator cap re KPa (katie) jen) | 736 ‘Allowable Specified value iit 8 (0.60) Radiator ak test pressure Waterpump: Tem Specified vale Towable ik Bearing ietaling temperature 20-90 Clearance between body andor | 35 = ‘Thermostat item ] ied value ‘Allowable limit Valve opening temperature (Start to open at) @ Valve fll opening temperature opening travel [ 60 Waste gate valve, Turbo indicator lamp item | Specified value _ = When pressure exceeds 23.5 KPa (0:34 katlom?) ae Turbo indicator lamp goes on. icing ts When pressure is below 19.6 kPa (0.20 katicm’) Turbo indicator lamp goes of c of wat al ait stroke: About 2 mr Checking operation of waste gate valve Shans treaeure of 88.2 kPa (0.91 kolon*) applied ‘Checking supercharging pressure (Running test) 158.9 - 83.4 kPa (0.55 - 0.85 kglicrV/At 3400 rpm Starter Tem Woior ype Nominal opt [ votage Novload ¢ istics Saient | Revolution speed 120 'Not less than 4000 EM-89A ENGINE MECHANICA! ENGINE MECHANICAL Alternator Specified value 12V type Alternator Regulator i tem ] Specitod value aulating voltage — _ 7 138-148 ge relay actual ae v ‘Alowabie limit | 002 inch) inerement ‘or adjusting————————™ INJECTION PUMP ENGINE MECHANICAL i= OPT General ‘Switerland om 2 3. x Pump speciicati | t —- t smote “0 40 | 378 —— —$— 7 Injection order aBOD | ABCD [ Goverrspcieiow | Tispoods | Alepeecs | Overtiow amount UNrpm | _ 21 47/1900 [ir-srnreo_| 17-7700 increase ammount duringstaring | 68-85/100 | 66-ssji00 | 66-85/100 period msrp End of inerease 5. co arann't| Aaa sj | Engotinerease, | a1s-sosv4oo | 418-505400 | 50-58 2 i ara | Full load 45,71500 | | el 54/680 | 65 - 70/1700 | 27.75/2250 stom 56.5 - 64.5/1800 | Low-speed side Chara 6.16 -6.95/2250 | cde compensator 85 ASK 1) a (N= 1100 7pm with lever postioned at fll stoke positon) rosea (ra = = = e770 | mnoensator 7 512-862/240 (180) | 512-8 se ey — 55.6 - $9.6/333 (250) | 55.6 - 59.6/33.3 (250) - = fs.75- 67 2576.7 (0065.75 - 67 25/667 (00) aay ; 153-25 nad sersion timer _mn 3.98 -4.98/Fu T eh | 205% Automatic cold stan devies - Pb = 66.7 kPa (600 mmHg) ; Pb = 0 KPa (0 mmHg) r) 7 EM-91