ENGINE MECHANICAL SECTION PRECAUTIONS. - Paris Requiring Angular Tightening. Liquid Gasket Application Procedure PREPARATION. Special Service Tools Commercial Service Tools... OUTER COMPONENT PARTS COMPRESSION PRESSURE... ‘Measurement of Compression Pressure. OIL PAN Removal, Installation. TIMING CHAIN Removal, Inspection, Installation. OWL SEAL REPLACEMENT CONTENTS CYLINDER HEAD.. Removal Disassembly... Inspection. Assembly Installation VALVE CLEARANCE. Checking Adjusting ENGINE REMOVAL. Removal... Installation rn CYLINDER BLOCK Disassembly, Inspection, ASSEMDIY sere SERVICE DATA AND SPECIFICATIONS (SDS) . General Specifications. Inspection and Adjustment BPRECAUTIONS | Py em | AVA { 1 neh Parts Requiring Angular Tightening * Use an angle wrench for the final tightening of the following engine parts: (1) Cylinder head bolts (2) Main bearing cap bolts (3) Connecting rod cap nuts (4) _ Crankshaft pulley bolt * Do not use a torque value for final tightening, The torque value for these parts are for a preliminary step. Ensure thread and seat surfaces are clean and coated with engine oi Liquid Gasket Application Procedure a. Use a scraper to remove alll traces of old liquid gasket from mating surfaces and grooves. Also, completely clean any oil from these areas. b. Apply a continuous bead of liquid gasket to mating sur- faces. (Use Genuine Liquid Gasket or equivalent.) * Be sure liquid gasket diameter is as specified. ¢. Apply liquid gasket around the inner side of bolt holes {unless otherwise specified). d. Assembly should be done within 5 minutes after coating. e. Wait af least 30 minutes before refilling engine oll and engine coolant. EM-2PREPARATION Special Service Tools “The actual shapes of Kent Moore tools may de tom those of spacial sence fools istatd here Too umber (Kent More No) Deserioton Too! name ai SFO501S000 D Diassarg and assonbing C3 aa Engh stand assembly @ Sras011000 (-) Engine stand ® sT05012000 SS (-) | Base kv10106500 | c=) Engine stand shat Kv10117000 st2s2) Engine subvattachment KV10117000 has been replaced with KV10117001 (KV10117000 is no longer in production, but its usable). N37 Kvi0117001 c=) Engine sub-attachment Instaling on the cylinder black nrsra ‘st 10120000 (24230-01) Gyiinder head bolt wrench Loosening and tightening eyindor Had bot ror Kv10716200 | (426836-A) \Vawe spring compressor @ Kvt0115900 (826836-20) ‘tachment Disassembling valve mechanism intaling vaive ol seal aL \VaWe oll sea! drt EN-3Too! numer (Ken itoare No.) Too! name KVI0715180 4198872) Litr stopper sot @ Kvtor15110 (9889721) Camshaft piers, ® Kvt0115120 (938972-2) Liter stopper PREPARATION Special Service Tools (contd) Description Changing shims toss EM03470000 (8037) Piston ring compressor ‘sT16610001 (23907) Pilot bushing puller Tntaling piston assembly into cylinder bore Now 7 Removing crankshalt pilot busting Noss KV 10111100 37208) Seal euler ‘wsse930000 c=) Tube presser Kvi0112100 (BT8653-A) Anglo wrench Fomoving steel ol pan and rear timing chain sr046 Prossing the tube of liquid gasket 1052 _ Tightening bats for bearing cap, cylinder oad, ee. prone EM-4PREPARATION Commercial Service Tools Tool name [_Deseaption ‘Spark pug wrench Flamaving and installing spark plug Noe Valve seat cuttor cot Finishing valve seat dimensions Piston ring expander — Removing and instaling piston ring Tare oa ot = Racing inchingvaregie a asi Intake & Exhaust = 98 mm (0374 oa o os B88 mm at? i ia eaming valve gude Dor hole for oversize valve guide @ Valve guide roamor Intake & Exhaust: F 4, = 6.0 mm (0.296 in) la, noe 4, = 10.2 mm (0.402) dia, EM-5OUTER COMPONENT PARTS SEC. 111+140°148+1639164+220+223 _-— PP 21 - 26 (2.1 - 2.7, 18 - 20) e aa FAW) oan t08 080 «14, 95.5) es. 08 fis 5 se’ 086, 451 572) (0.00 2109, 746 - 987) SE ae ns-24 13-10 als Fg) 20-28 (020-028, 174-208) fT Reter to “TIGHTENING ws 4) B@—~Pp rater to i TIGHTENING PROCEDURES” se a4- 108 J (006-113, 746 - 95.5) estat 10. 12(1.0 - 4.2, 67 - 104) 21-38 (0.21 - 0.39, 18.2 - 33.9) —@ \ 9-38 L- 30 - 0.30, ‘ weree UA CS ok - ‘D S “€ ee Nem (gem, iby KG WD stem kam, fe) SSNS) @ Intake manifold colector support ® Fuel prossure regulator ® Trottie body ® Intake manifold collector {® _lgniton col with power transistor @ IACV-AAC valve ® Subse tube ® Omament cover @ _EVAP canister purge contol valve @ injector ® Intake manifold ©@ _EVAP canister purge volume con- © Fol tube assembly trol valve EM-6OUTER COMPONENT PARTS SEC. 140-147-210-211-221 WH o-s003-08, 26-35 ADlat 28 2s -27,15-20) Ba 10 08 - 19,69 9) isn. a) ye 4 eee 26 a4 -27, 15-29) a Bia. (ans - aus a -2ar 1842-207) 1-27, 18- se e. NO Se asm Se / Fiz; n @0-30, 16-22) ' eet Bo “So, 20 - 36) Poss é team o ra a8 < pd Bisson con a “OD cate PGF — Gn! a . s-wes- Ke. eS Ses Soe. es . , cs ae / 5 aN d . \ eet east | A > ” SOO “"Be-arl-F 2? ONS 3 BB m/ \ S commer Z Pen te ae Sx / diene ut SP \, [ttl pA oI eg Sy < L S | “oe, 3 SS . Ore Fa Ore OS" Ré Le <' BR a PYS / Ay, on a Res n20m-ra.n0-me \ gaa eran ; Fis sussn aan BB FI tem tom 1 4 genre ne Bases BY @ FGRCAPT vaio © _Camshat postion sensor & Faas maniois @ EGR ave erase) % Water outet i EGR temperature sensor & Thermostat with water net EM-7 9OUTER COMPONENT PARTS. TIGHTENING PROCEDURES Intake manifold ‘Tighten in numerical order shown in the figure. 1. Tighten alf botts and nuts to § to 10 Nem (0.5 to 1.0 ka-m, 43 a ) 10 87 in-Ib). engine yop A A’| 2. Tighten all bolts and nuts to 26 to 31 Nem (2.7 to 3.2 kg-m, 20 trent to 23 felb). 3. Repeat step 2 at least five times to have all bolts and nuts tightened at a torque of 26 to 31 Nem (2.7 to 3.2 kg-m, 20 10 23 feb), Fuel tube + Tighten in numerical order shown in the figure. 41. Tighten all bolts to 9.3 to 10.8 Nem (0.95 to 1.1 kg-m, 82.5 to 95.5 in-tb) 2 Tiana al bois 0 21 to 26 Nem (2.1 10.27 kam, 15 0 20 Fuel pressure regulator Tighten fuel pressure regulator to 2.9 to 3.8 Nem (0.3 to 0.99 kg-m, 26.0 10 33.9 in-Ib). * Tighten screws evenly several times to have the fuel pres- sure regulator tightened at the specified torque. ‘Always replace O-ring with new ones. Lubricate O-ring with new engine oil. Sub-fuel tube 4. Temporarily tighten bolt @ 2 Tighten bolt @ to 20.6 to 26.5 Nem (2.10 to 2.70 kg-m, 15.19 to 19.55 fttb. 3, Tighten bolt @ to 8.5 to 10.8 Nem (0.87 to 1.10 kg-m, 75.5 to 95.5 in-tb).. Throttle body + Tighten in numerical order shown in the figure. 1. Tighten all bolts to 9 to 11 Nem (0.9 10 1.1 kgm, 78 10 96 in- tb). 2. Tighten all bolts 10 18 to 22 Num (1.8 to 2.2 kg-m, 13 to 16 ft- tb). senscnea| EM-8OUTER COMPONENT PARTS. EGR guide tube 1. Tighten all bolts to 9 to 10 Nem (0.9 to 1.0 kg-m, 78 to 87 in- Ib). 2, Tighten all bolts to 21 to 26 Nem (2.1 to 2.7 kgm, 15 to 20 ft- tb) * Before installing EGR guide tube, tighten intake manifold collector and collector bracket. Intake manifold collector Tighten bolts and nuts to 18 to 22 Nem (1.8 to 2.2 kgrm, 13 to 16 ‘t-lp) in numerical order shown in the figure —M-9 ie ee aLCOMPRESSION PRESSURE 20 ew (0.79 by) el. Use compressor tester whose en (usber portion) less than 20 mm (0.79 I) da. Dtnervisn, it may be cau By eyinder hese dunn emoval sexne7e Measurement of Compression Pressure 4. Warm up engine. 2. Tum ignition switch off 3. Release fuel pressure. Refer to “Releasing Fuel Pressure” in EC section. 4, Disconnect ignition coif with power transistor harness ‘connectors, then remove ignition coils. Remove all spark plugs. Disconnect all injector hamess connectors an Attach a compression tester to No. 1 cylinder Depress accelerator pedal fully to keep throttle valve wide open. Crank engine and record highest gauge indication. 10. Repeat the measurement on each cylinder as shown above, Always use a fully-charged battery to obtain specified engine speed. es Unit: kPa (hover, psivipm Difrence init bebveen Standard ioirum rim 1278 28 - (13.0, 785y300 (100, 1429300 98 (1.0, 14)300 11. If compression in one or more cylinders Is low: a. Pour a small amount of engine oil into cylinders through spark plug hotes. b. Retest compression. ‘+ Ifadding oil helps compression, piston rings may be worn ‘or damaged. If so, replace piston rings after checking pis- ton. ‘+ If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to SDS, EM-65 and EM-68,) If valve or valve seat is dam- aged excessively, replace them. * tf compression stays low in two cylinders that are next to each other: a. The cylinder head gasket may be leaking, or b. Both cylinders may have valve component damage. Inspect and repair as necessary. EM-10SEC. 110+150+221+251 _4@ _— Balle pate Front hated axygen sensor (ett ba) harness e'ame \-fhaa- 108 sensor (REF] . = Near cover plete (0.86 - 110, 748 - 95.5) flea -s08 Bi 6.4 - 75 (065 - 0.75, 95.4 - 56.0) (086 - 1.10, 748-955) to 19 (16-49, 12- Gee EA Ret se tm ty ve tearm, i Oa 22-20) em (age, fo) BA tg gasket 4 + 7.5 (005 - 0.76, 56.4 - 66.0) sever Removal CAUTION: When removing the aluminum oil pan from engine, first remove the crankshaft position sensors (POS and REF) from the assembly. Be careful not to damage sensor eciges and signal plate teeth. 1. Romove engine undercover, 2. Drain engine oil. 3. Remove steel oll pan bolts. 4. Remove steel oil pan. a. Insert Too! between aluminum oil pan and steel oil pan. * Be careful not to damage aluminum mating surface. * Do not insert screwdriver, or oil pan flange will be deformed. EM-11 iv a 3a Reg Ne A Ce “ semen! OIL PAN Removal (cont'd) b. Slide Too! by tapping on the side of the Too! with a hammer. c. Remove steel oll pan. 5. Remove oil strainer. 6. Remove front exhaust tube and its support 7. Set @ suitable transmission jack under transaxle and hoist engine with engine slinger. Remove crankshaft position sensors (POS and REF} from oil pan, 9, Remove front and rear engine mounting nuts and bolts. 10, Remove center member. EM-12OIL PAN Removal (Cont'd) = 11. Remove drive belts, 12. Remove air compressor and bracket, om SP Av compessor brisket // Seat SK o 3 Remove rear cover plate. 44. Remove aluminum oil pan bolts. iy a 18, Remove transaxle bolls. BR afr 16. Remove aluminum oil pan. Ra Insen an appropriate size tool into the notch of aluminum oil pan as shown in the figure. b * Be careful not to damage aluminum mating surtace. * Do not insert screwdriver, or oil pan flange will be deformed, b. Pry off aluminum oil pan by moving the tool up and down. 6. Remove aluminum oll pan, semisse EM-13veto ate est a rh. St 5 1s (020 020 16 em) KA po Se Tt nt @ : Seating point Trner see ‘sensa ia 4 For places E145 « 55 (0177 - 0217) Senvese OIL PAN Removal (Contd) 17. Remove O-rings from cylinder block and oil pump body. Installation 1. Install aluminum oil pan. a. Use a scraper to remove all traces of liquid gasket from mat ing surfaces, * Also remove traces of liquid gasket from mating surface of cylinder block, front cover and steel oil pan. + Remove old liquid gasket from the bolt hole and thread. b. Apply sealant to front cover gasket and rear oil seal retainer gasket. ©. Apply a continuous bead of liquid gasket to mating surface of aluminum oil pan. * Use Genuine Liquid Gasket or equivalent. d. Apply liquid gasket to inner sealing surface as shown in figure. Be sure liquid gasket is 4.0 to 5.0 mm (0.187 to 0.197 in) or 4.5 to 5.5 mm (0.177 to 0.217 in) wide. * Attaching should be done within 5 minutes after coating. EM-14OIL PAN Installation (Cont'd) e. Install O-rings, cylinder block and oil pump body. igine Yon’ RES S fas al 1, Install aluminum oil pan. * Tighten bolts in numerical order. * Wait at least 30 minutes before refilling engine oil. ee ST LAL | 2: Install the transaxle bolts GIL) YQ | 5) instal rear cover plate tt Ba Install air compressor and bracket. lee Install drive belts, Install center member. Install front and rear engine mounting insulator nuts and bolts. 3? Noe 8. Install crankshaft position sensors (POS and REF) and front 28 heated oxygen sensor (left bank) hamess clamp. * Make sure that crankshaft position sensor (POS) and front heated oxygen sensor (left bank) harness clamp are installed correctly as shown in figure. 9. Install front exhaust tube and its support. 40. Install oil strainer. EB eek A \ ee inate, YP STN senazor EM-15 ©Installation (Cont'd) 1. a Install stee! oil pan. Use a scraper to remove all traces of liquid gasket from mat- ing surfaces. Also remove traces of liquid gasket from mating surface of aluminum oil pan. Apply a continuous bead of liquid gasket to mating surface of steal oil pan Use Genuine Liquid Gasket or equivalent. Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in) wide. Attaching should be done within 5 minutes after coating. Install steel oil pan. Tighten in numerical order shown in the figure. Wait at least 30 minutes before refilling engine oil. EM-16TIMING CHAIN fo - 108 098-14, 748-85) = 4 IP 7 a lee ZO ae ey Dis-19 018. 49,12-10 Plreter to inetatation” In : ran “TIMING CHAIM RR Wwo-s30.0-13,7-9 Tt 2s BSP reer torstaaton wma CHAN | Wes Eg Peter to “instalation” in “OIL PAN 8 \ . _ oT FE sop tat gue * Cg tort “station in “THAN ena IC). Cotrate with new enaine of etn nay \Laste: € os Shim tam nh fa \Leront of sew! 68 semsara or @ Rear ting chain case & Timing chain @ Water pump cover Lett camshaft onsoner & Cranechat sprocket Chan tonsoner cover a @ nena cain ice @ Lower cnn guce & Exhaust camshalt sprocket 2ND @ Camehat chain & Upper chain gude Ginko camstat eprocet 2D @ _ Right camshaft tensioner ® Front timing chain case @ Camshaft sprocket 1ST a © Taming chan tensioner & Ot pump assembly @ Olsiainer Slack side chain gue ® Grnksnet puley @ Water pump EM-17 °TIMING CHAIN POSITION FOR APPLYING LIQUID GASKET Refer to “installation” in “OIL PAN” for installing oil pan (EM-14). * Before installation, wipe off the protruding sealant. Front timing chain case = 36 (0.02 - 0.142) 8 Protuse 26-36 i (o.t02 - 0142)“ ‘cross noth ends as shown 5 (020) fans be sure to ranimize the Center ine ot ated gasket Protrusons at bepnning and end of taua gasket “15 Apply squid gasket 1 the chamfered surface between ‘amanat bracket mn eylnder head Camshaft bracket Rocker cover RA rocker e0¥0! ox TN tas Fm Foss 54020) 5 (0am) Sealing diameter = 80 (@08 - 032) Unt: mm Gn) 90 en sg v0 nae outer ade ssn SennagrTIMING CHAIN CAUTION: ‘After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. © When installing camshafts, chain tensioners, oll seals, or other sliding parts, lubricate contacting surfaces with new engine oil. * Apply new engine oil to bolt threads and seat surfaces when installing cylinder head, camshaft sprockets, crank- shaft pulley, and camshaft brackets. * Before disconnecting fuel hose, release fuel pressure. Refer to EC section (“Fuel Pressure Release”, “BASIC SERVICE PROCEDURE” * When removing the oil pans, oil pump assembly and ti ing chain from engine, first remove the camshaft position sensor (PHASE) and the crankshaft position sensors (REFY (POS) from the assembly. Be careful not to damage sensor edges. * Do not spill engine cootant on drive belts. Removal 1. Drain engine oi 2. Release fuel pressure. Refer to “Fuel Pressure Release” in EC section. 3. Drain coolant by removing cylinder block drain plugs {refer to “Water pump” in LC section) and radiator drain cock 4, Remove left side omament cover, 5. Remove air duct to intake manifold, collector, blow-by hose, vacuum hoses, fuel hoses, wires, hamess, connectors and so on, 6. Remove the following. © Vacuum hoses © Water hoses © EVAP canister purge hose © Blow-by hose 7. Remove RH and LH ignition coils, EM-19 cg a 1TIMING CHAIN Removal (Cont'd) 8. Remove EGR guide tube. 9. Remove intake manifold collector supports and intake manifold collector (RH cylinder head only) 10. Remove fuel tube assembly. Refer to “TIGHTENING PROCEDURES" in “OUTER COMPONENT PARTS", (EM-8). 11. Remove intake manifold in reverse order of installation. Refer to “TIGHTENING PROCEDURES” in “OUTER COMPONENT PARTS", (EM-8) EM-20TIMING CHAIN Removal (Contd) 12. Remove RH and LH rocker covers from cylinder head, 13, Remove engine undercover. 14. Remove front RH wheel and engine side cover. is 15. Remove drive belts and idler pulley bracket. 16. Remove power steering oil pump belt and power steering oll pump assembly. i ort scaing ot pum [fF F717. Remove camshatt position sensor (PHASE) and crankshaft = Position sensors (REF)/(POS). Canishat postion sensor (05) semoice EM-21 osSD a Front Low Ai compiessor bracket // SeNBt24; TIMING CHAIN Removal (Cont'd) 18. Set No. 1 piston at TDC on the compression stroke by rotat- jing crankshaft. 49. Loosen crankshaft pulley bolt. (At this time remove oil pan rear cover plate and set a suitable tool to ring gear so that crank- shaft cannot rotate.) * Be careful not to damage the signal plate teeth. 20. Remove crankshaft pulley with a suitable puller. 21, Remove air compressor and bracket. 22, Remove front exhaust tube and its support. 23. Hang engine at right and left side engine slingers with a suit: able hoist 24, Remove right side engine mounting, mounting bracket and nuts. 25. Remove center member assembly. 26. Remove upper and lower oil pans. cribed in steps 21 through 26, refer to IL PAN” (EW-11),.sever7e _Sutabe t0t TIMING CHAIN Removal (Cont'd) 27. Remove water pump cover. 28. Remove front timing chain case bolts. Loosen bolts in numerical order as shown in the figure. 29, Remove ‘ront timing chain case. Do not scratch sealing surfaces. EM-23 95eer chan aus Internal chain guide ; | | | Lec sa cain ge Liam cin ener TIMING CHAIN Removal (Cont'd) 30. Remove internal timing chain guide. 31. Remove upper chain guide. 32. Remove timing chain tensioner and slack side chain guide. 83. Remove RH & LH camshall sprocket bolts 1ST. 84. Remove camshaft sprockets 1ST on both sides, crankshaft sprocket and timing chain. 35, Attach a suitable stopper pin to RH and LH camshaft tension- EM-24TIMING CHAIN Removal (Cont'd) fo 7) 36, Remove exhaust camshatt sprocket 2ND bolts on both sides. AEA Ab & Sc cana RR TOT ss gO Nw S intake carta sptcekst 2ND) Bae 37, Remove exhaust camshaft sprockets 2ND, intake camshaft sprockets 2ND and camshaft chains on both sides. sr ey, | 38. Remove lower chain guide. Ba, Coca seease) 39. Use a scraper to remove all traces of liquid gasket from front Fi timing chain case. EM-25 °So ls one f= seme Fagiee Font Canksnat sprockst semaoe No Tpstos at ToC SeMosoe| TIMING CHAIN Removal (Cont'd) ‘Remove old liquid gasket from the bolt hole and thread. 40. Use a scraper to remove all traces of liquid gasket from water pump cover. Inspection Check for cracks and excessive wear at roller links. Replace chain if necessary. Installation 1. Install crankshaft sprocket on crankshatt. ‘* Make sure that mating marks on crankshaft sprocket face front of engine. 2. Position crankshaft so that No. 1 piston is set at TOC on com- pression stroke. EM-26TIMING CHAIN Installation (Cont'd) 3. Install lower chain guide on dowel pin, with front mark on the | guide facing upside. Front mark eM 4. Align the marks on RH and LH intake camshaft sprockets (2ND), exhaust camshaft sprockets 2ND and camshaft chain, 1s as shown, 5. Put LH camshaft dowal pin into camshaft sprocket dowel groove and install these on camshaft. Tighten LH exhaust ‘camshatt sprocket 2ND bolt. 8. Put RH camshaft dowel pin in camshaft sprocket hole and install sprocket on camshaft FE stating mae 7. Tighten RH exhaust camshaft sprocket 2ND bolt. (cerent cote * Make sure that the timing marks on RH and LH intake ©: Carchat socket camshaft sprockets (2ND) are aligned with the camshaft ring mt chain mark. © Lubricate threads and seat surfaces of camshaft sprocket bolts with new engine oil. We aT j | stopper pn Fe Ene ewaustcansnat sprcist | | 1H exaust camenat speoesot pa L - ___ seer 8. Install intake and exhaust camshaft sprockets, being careful 2 ‘ylotake camshaft Exhaust camshat not to confuse the two (their thicknesses are different), \ sprocket \ sorocket 9. Remove RH and LH camshatt tensioner stopper pins. he Stopper bi EL Aye * ve EM-27 °9100 aur mark (iterent color) on ° Waar pie lead oh i t eer Loransra SE wang we / 1 sak sid cin aide Timing cha tensioner TIMING CHAIN Installation (Cont'd) 10. " 12. 13, 14, Align mating mark on crankshaft sprocket with matchmark on chain as shown. Attach lower timing chain on the water pump sprocket. Install RH and LH camshaft sprockets (1ST) onto timing chain by matching sprocket dowel grooves with camshatt Tighten RH and LH camshatt sprocket 1ST bots. Lubricate threads and seat surfaces of the bolts with new engine oil. Install timing chain. Make sure that mating marks on crank shaft sprocket and RH and LH camshaft sprockets are aligned with matchmarks on timing chain Install intemal chain guide. Install upper chain guide. Install timing chain tensioner and slack side chain guide. Apply liquid gasket to front timing chain case. Refer to “POSITION FOR APPLYING LIQUID GASKET" (EM- 48) Before installation, wipe off the protruding sealant. EM-28TIMING CHAIN Installation (Cont'd) 19. Install rear case pin into dowel pin hole on front timing chain case. 20. Tighten bolts to the specified torque in order shown in the fig- ure. * Leave the bolts unattended for 30 minutes or more after tightening. a, 28 rm da. bots es Sand tom (28-32 ngm 108-201 tH) D9 Sema vole _ fas 137 nom BE (12 1alagem 87 - 101 ea) Sens3se| “ 21. Apply liquid gasket to water pump cover. ag 22. Install water pump cover. aT © Apply a continuous bead of liquid gasket to mating surface of water pump cover. Refer to LC section ("Water Pump Installa- tion”) 28. Apply liquid gasket to RH and LH rocker covers. # Use genuine liquid gasket or equivalent. © Refer to “POSITION FOR APPLYING LIQUID GASKET” (EM- 18) BB 24. Install RH and LH rocker covers. IR ® @\ @ \ a er sen0sie r Rocker cover tightening procedure: te a mr or ‘* Tighten in numerical order as shown in the figure. a. Tighten bolts @ to @ in that order to 1 to 3. Nm (0.1 10 0.3 kg-m, 9 10 26 ine). b. Tighten bolts @ to @ as indicated in figure to 5.4 to 7.4 Nm (0.55 to 0.75 kg-m, 47.7 to 65.1 in-ib) stoe2eal EM-29 10102 Sen AO Tiahten in pumerica order. seuss % OQD0700? “erankahal play bot SeMR63E| sen220F) TIMING CHAIN Installation (Cont'd) 25. Install intake manifold. Tighton intake manifold nuts and bolts. Refer to “TIGHTENING PROCEDURES” in “OUTER COMPO- NENT PARTS”, (EM-8). 26. Install fuel tube assembly. 27. Install intake manifold collector gasket, with its front mark fac- ing forwards. Install intake manifold collector, supports and intake manifold collector bot 29. Install EGR guide tube. Refer to “TIGHTENING PROCEDURES” in “OUTER COMPO- NENT PARTS”, (EM-8). 30, install RH and LH ignition coils 31, Install rocker cover ornament on left side, 28. 32. Install crankshaft pulley to crankshaft * Lubricate thread and seat surface of the bolt with new engine a, Tighten to 39 to 49 N-m (4.0 to 5.0 kg-m, 29 to 36 ft-lb), b. Puta paint mark on the crankshaft pulley. ©. Again tighten by turing 60° to 66°, about the angle from one hexagon bolt head comer to another. 83. Install camshaft position sensor (PHASE), crankshaft position sensors (REF)/(POS) and Iront heated oxygen sensor (left bank) harness clamp. ‘+ Make sure that crankshaft position sensor (POS) and front heated oxygen sensor (left bank) harness clamp are installed correctly as shown in figure. Reinstall removed paris in reverse order of removal * When installing fuel tube assembly, refer to “Injector Removal and Installation’ in EC section. * Alter installing the tensioner, race the engine at about 3,000 tom under no load to purge air from the high-pressure cham- ber. The engine may produce a rattling noise. This indicates that air stil remains in the chamber and is not a matter of con- cern EM-30OIL SEAL REPLACEMENT wvierie200 evra sooo CAUTION: When removing the oil pans, oll pump assembly and timing chain from engine, first remove the camshaft position sensor (PHASE) and the crankshaft position sensors (REF)/(POS) from the assembly. Be careful not to damage sensor edges. VALVE OIL SEAL ina 4. Remove LH ornament cover. 2, Remove RH and LH ignition coils. 3, Remove EGR guide tube. 4, Remove intake manifold collector supports and intake manifold collector (RH cylinder head only). is Remove RH and LH rocker covers trom cylinder head. Remove camshatt position sensor (PHASE) and crankshaft position sensors (REF)/(POS). _ Remove oil pan. (Refer to “Removal” in “OIL PAN” EM-11.) Remove timing chain, (Refer to “Removal” in “TIMING CHAIN” EM-18.) 9, Remove camshaft brackets and camshalt. (Refer to “Disassembly” in “CYLINDER HEAD" EM-35.) 40. Remove valve lifters and shims. eh 14. Remove valve spring with Tool 12. Reinstall any parts removed in reverse order of removal. Before removing valve spring, fix valve as follows. Method A: Piston concerned should be set at TDC to prevent valve from falling. oN on Method B: wr Remove spark plug, then install air hose adapter into spark plug hole and apply air pressure to hold valves in place. Apply a pressure of 490 kPa (5 kglcm?, 71 psi). Method C: “ Install spark plug with suitable washer into spark plug hole from combustion chamber side. —M-31 tosOIL SEAL REPLACEMENT mae 108 OF seal tp seurisa| 13. Remove vaive oil seal. 14. Apply engine oil to new valve oil seal and install it with Tool. OIL SEAL INSTALLATION DIRECTION Install new oil seal in the direction shown in the figure. FRONT OIL SEAL 1. Remove the following parts: Engine undercover Front RH wheel and engine side cover Drive belts Crankshaft position sensor (REF) Crankshatt pulley Be careful not to damage sensor edge. 2. Remove front oll seal using a suitable tool, Be careful not to scratch front cover. 3. Apply engine oil to new oil seal and install it using a suitable tool. EM-32OIL SEAL REPLACEMENT ear ot sal raging REAR Olt. SEAL 1 eR Remove transaxle, (Refer to MT or AT section.) Remove tiywheel or drive plate. Remove oil pan. (Refer to OIL PAN.) Remove rear oil seal retainer. Remove traces of liquid gasket using soraper. Remove old liquid gasket from the bott hole and thread. Apply liquid gasket to rear oil seal retainer. EM-33 osCYLINDER HEAD SEC. 111-118-130-140-220 35) X, QD ‘installation’ a 4 | washer ge te ERS ont eS cute es 2 ef =) Ase og of \ Unit mm ‘SeueatAal EM-57 be[aeaeca je aeB ae NB epee bore Grade number No. 1 Syinser bore grade number SEHET# sensesaal Topor: A= 8 | Outotsaund X= ¥ senna) CYLINDER BLOCK Inspection (Cont'd) * If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block rear position. These numbers are punched either Arabic or Roman numerals. 3, Measure piston skirt diameter. Piston diameter “A”: Refer to SDS (EM-70). Measuring point “a” (Distance from the top): 45.4 mm (1.787 in) 4. Check that piston-to-bore clearance is within specification Piston-to-bore clearance “B” 0.010 - 0.030 mm (0.0004 - 0.0012 in) 5. Determine piston oversize according to amount of oylinder ‘wear. Oversize pistons are available for service. Refer to SDS (EM-70). 6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter Rebored size calculation: where, D: ‘Bored diameter Piston diameter as measured Piston-to-bore clearance Honing allowance 0.02 mm (0.0008 in) 7. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly. .. Cut cylinder bores. *© When any cylinder needs boring, all other cylinders must also be bored. * Do not cut too much out of cylinder bore at a time, Cut ‘only 0.05 mm (0.0020 in) or so in diameter at a time Hone cylinders to obtain specified piston-to-bore clearance. Measure finished cylinder bore for out-of-round and taper. Measurement should be done after cylinder bore cools “D-asB-c down. CRANKSHAFT 1. Check crankshaft main and pin journals for score, wear or cracks. 2. With a micrometer, measure journals for taper and out-of- round. Out-of-round (X - ¥): Standard 0.002 mm (0.0001 in) Taper (A — Standard 0.002 mm (0.0001 in) EM-58CYLINDER BLOCK Inspection (Cont'd) 3. Measure crankshaft runout Runout (Total indicator reading): Limit: 0.10 mm (0.0039 in) Unper main beara TF wor] BEARING CLEARANCE Wimct goers) Ne AAAS geove | «Use either of the following two methods, however, method "A" gives more reliable results and is preferable. x "S\ \ S LW Method A (Using bore gauge & micrometer) te S\ ws i ne, Main bearing = rc Xs 1. Set main bearings in their proper positions on cylinder block 2 Yams . Not ‘SEMI?5F, “ 2. Install main bearing cap and bearing beam to cylinder block. Tighten all bolts in correct order. 3. Measure inner diameters “A” of each main bearing. 4, Measure outer diameters “Dm” of each crankshaft main jour- gj nal. 5. Calculate main bearing clearance. Main bearing clearance = A—_Dm a ‘Standard: 0.035 - 0.053 mm (0.0014 - 0.0021 in) Limit: 0.065 mm (0.0026 in) * fit exceeds the limit, replace bearing me © If clearance cannot be adjusted using any standard bearing grade, grind crankshaft journal and use undersized bearing, a. When grinding crankshaft journal, confirm that “L" dimension in fillet roll is more than the specified limit. “L”: 0.1 mm (0.004 in) 7 b. Refer to SDS for grinding crankshaft and available service © parts. OX EM-59 big 6a Life finan jours rade narber ANG mein four grace maze (& os) \ Engine front Tio. eramaham ‘main Journal No, & crankshaft main journal grace number _/ grade rember Cee ‘main joural grace Engine tont site scuss7e| CYLINDER BLOCK Inspection (Cont'd) 6. If crankshaft is reused, measure main bearing clearances and select thickness of main bearings. If crankshaft is replaced with a new one, select thickness of main bearings as follows: a. Grade number of each cylinder block main journal is punched ‘on the respective cylinder block. These numbers are punched in either Arabic or Roman numerals. b. Grade number of each crankshaft main journal is punched on the respective crankshaft. These numbers are punched in either Arabic or Roman numerals. ©. Select main bearing with suitable thickness according to the following calculation or table. Example of calculation: Cylinder block main journal grade number: 4 Crankshaft main journal grade number: 2 Main bearing grade number = 1 + 2 = 3 (Yellow) Main bearing grade number (Identification color): These numbers are punched in either Arabic or Roman numerals. Cylinder bloak main journal grade number 5 = $ Crankshatt [0 (Black) [1 (Brown) [2 (Green) [3 (Velow) main jour T__[1Growr) [2 (Groan) [3 (Yellow) | 4 Blue) nal grade "2 __[2iGreen) |S (velow [4 (Bive) [5 (pind umber “3 [3(vellow) [4 (Busy [5 (Pink) [6 (Purple) Connecting rod bearing (Big end) 1. Install connecting rod bearing to connecting rod and cap. 2. Install connecting rod cap to connecting rod. Tighten bolts to the specified torque. 3. Measure inner diameter “C" of connecting rod. 4, Measure outer diameter “Dp” of each crankshaft pin journal. 5. Caloulate connecting rod bearing clearance. Connecting rod bearing clearance = C ~ Dp Standard: 0.034 - 0.059 mm (0.0013 - 0.0023 in) Limit: 0.070 mm (0.0028 in) 6. fit exceeds the limit, replace bearing. 7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing. Refer to "BEARING CLEARANCE — Main bearing” (EM-59) EM-60CYLINDER BLOCK Inspection (Cont'd) 8. If crankshaft is replaced with a new one, select connecting rod bearing according to the following table. = Syraahat pn urn } Connecting rod bearing grade number (Identification color): HE grade rarer These numbers are punched in either Arabic or Roman numerals. Lo. 1 exinder eraneshat gin jour grade ruribor CGrankcshat pin journal grade | pin ‘Connecting rod bearing grade number 2 (Black) ZL} ) a TiBrown) ~ SPL tive to eo ewe) L - S=Ne'S5] Wethod B (Using plastigage) CAUTION: * Do not turn crankshaft or connecting rod while plastigage is being inserted. * When bearing clearance exceeds the specified timit, ensure that the proper bearing has been installed. If incor- "~ rect bearing clearance exists, use a thicker or undersized main bearing to ensure specified clearance. CONNECTING ROD BUSHING CLEARANCE (Small end) 1, Measure inner diameter “C” of bushing, 2. Measure outer diameter “Dp” of piston pin, 3. Calculate connacting rod bushing clearance, Connecting rod bushing clearance = C - Dp ‘Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in) Limit: 0.030 mm (0.0012 in) Fa It it exceeds the limit, replace connecting rod assembly or connecting rod bushing and/or piston set with pin. REPLACEMENT OF CONNECTING ROD BUSHING B (Small end) 1. Drive in small end bushing uni itis fish with end surface of Q 5 Be sure to align the oil holes. 2. After driving in small end bushing, ream the bushing. This is 25 to ensure the clearance between connecting rod bushing and piston pin is the specified value Clearance between connecting rod bushing and pis- 9 ton pin: 0.005 - 0.017 mm (0.0002 - 0.0007 in) FLYWHEEL/DRIVE PLATE RUNOUT Runout (Total indicator reading): Flywheel (M/T model) Less than 0.15 mm (0.0059 in) Drive plate (A/T model) Less than 0.15 mm (0.0059 in) OK Measurement position: “ Approximately 145 mm (5.71 in) from the crankshaft center CAUTION: * The signal plate is built into the flywheel assembly. Be sessseal EM-61 bs* al ee sevasoe | engine Tone 3 Front ire Punehmark sie up| (itmark te present) ea eg ‘9 Top tng 3 of rng Stee Sa \\ Sy peer gy ome iron SY olring | SS PW omer | Upper main baanng oi A fone - \ No.2 yninout ei groove) sears CYLINDER BLOCK Inspection (Cont'd) careful not to damage the signal plate, especially the teeth. Check the drive plate for deformation or cracks. Never place the flywheel assembly with the signal plate facing down. ‘+ Keep any magnetized objects away from the signal plate. + Do not allow any magnetic materials to contact the signal plate teeth. * Do not surface flywheel. Replace as necessary. Assembly PISTON 4. Install new snap ring on one side of piston pin hole. 2. Heat piston to 60 to 70°C (140 to 188°F) and assemble piston, piston pin, connecting rod and new snap ring © Align the direction of piston and connecting rod. * Numbers stamped on connecting rod and cap correspond to each cylinder. * After assembly, make sure connecting rod swings smoothly. 3. Set piston rings as shown CAUTION: © When piston rings are not replaced, make sure that piston rings are mounted in their original positions. * When replacing piston rings, these without punchmarks, present, piston rings can be mounted with «Align piston rings so that end gaps are positioned as shown in the figure. CRANKSHAFT 4. Set main bearings in their proper positions on cylinder biock and main bearing beam. * Confirm that correct main bearings are used. Refer to “inspection” of this section. EM-62UA mth. af on a: 6 rar G9) gasuing Measuring wes point o de pom 20 | core | (uss) lengine Sota i ie we sue CYLINDER BLOCK ‘Assembly (Cont'd) 2. Instructions for re-use of main bearing cap bots. * A plastic zone tightening method is used for tightening main bearing cap bolts. Measure d1 and d2 as shown in elect minimum diameter in the measuring area. Wf the difference between di and d2 exceeds the limit, replace the bolts with new ones. Limit (41 ~ d2): 0.11 mm (0.0043 in) 3. After installing crankshaft, main bearing cap, main bearing beam and bearing cap bolts, tighten bearing cap bolts in numerical order. ‘© Tightening procedure (1) Tighten all bolts to 32 to 38. Nan {8.3 to 3.9 kg-m, 24 to 28 ft-lb). (2) Turn all bolts 90 to 95 degrees clockwise with angle wrench. * Prior to tightening bearing cap bolts, place bearing beam in its proper position by shifting crankshaft in the axial direction. + After securing bearing cap bolts, make sure crankshaft turns smoothly by hand. * Lubricate threads and seat surfaces of the bolts with new engine oil. 4, Measure crankshaft end play. Crankshaft end play: ‘Standard: 0.10 - 0.25 mm (0.0039 - 0.0098 in) Limit: 0.30 mm (0.0118 in) If beyond the limit, replace bearing with a new one. 5. Install connecting rod bearings in connecting rods and con- necting tod caps. ‘© Contirm that correct bearings are used. 6. Install pistons with connecting rods. a. Install them into corresponding cylinders with Tool. * Be careful not to scratch cylinder wall with the connecting rod. * Arrange so that front mark on engine front. ston head faces toward b. A plastic zone tightening method is used for tightening con- necting rod bolts and nuts, Check the old bolts for deformation before re-using them. * Ensure that the connecting rod nut can be screwed ‘smoothly as far as the bolt thread end. * If this is not possible, use slide calipers to measure the ‘outside diameter of the narrowest thread part of the bolt at 16 mm (0.63 in) from the thread end. Replace the con- necting rod bolt and nut, if under the limit. Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 in) Limit: 7.75 mm (0.3081 in) EM-63 135CYLINDER BLOCK Assembly (Cont'd) . Install connecting rod caps. + Lubricate threads and seat surfaces with new engine oil. Tighten connecting rod bearing cap nuts to the specitiod torque. Connecting rod bearing nut: (1) Tighten nuts to 19 to 21. Nm (1.9 to 2.1 kg-m, 14 to 15 ft-lb). (2) Turn nuts 90 to 95 degrees clockwise with angle wrench 7. Measure connecting rod side clearance. Connecting rod side clearance: Standard 0.20 - 0.35 mm (0.0079 - 0.0138 In) Limit’ 0.40 mm (0.0157 in) If beyond the limit, replace connecting rod and/or crankshatt EM-64SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications COMPRESSION PRESSURE der arangarent ve Cyne sangeet Unt Pa len? 300 ron Disoloamont cmt (evie) 2.988 18239) oej{j™m{’{[Mmhaskt— Compresaan presure Boxe and take min) 92x79 (66.2 885 ‘Sanson 1275 180, 185) @ Vote aongernent one imum 981 (100, 142) Fring ore 123456 Diteret! nt netcon as oie 80 (19, 4 A Number of piston rings Sine ae compression 2 on ' Number fran beatings 4 compression alo 00 FRONT SEW pg Inspection and Adjustment CYLINDER HEAD VALVE - ea mr) uae en) Standard Lit 7 (Marin tikes) oT Teeth see 0 089 “tt X . 7a FR u Hosa eurace dltorton . sein Nominal eyinder head height Take hand ner "aed" tans mon (4972 take aeo-26a(n4t7-142) Exhaust aiz-ms(s2a0-s20 St Sees Tare eran ake 97.22 - 97.82 (98018-38512) xa 96.5 -95.05 (3.7042 3.7530) Tae ser damier" ake 5966 - 5.900 (02048-02058) BY Exhaust 845 5.960 (0.204 0 2048) Vaio sea anger os tae eis asag RA ee 919 - Aas Tae marge F _ Inoke oss-125 00074-00182) EL — 45 (00453-0057) Tae mae a Than 05 (200) Yate stem ent ace M9 pan 0:2 2.008) lim Vane dearance (G38) mae 026-034 (0010-0013) Exhaust 029-037 (011-0035) EM-65, 137138 SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (contd) Valve clearance Unt: i) Thickness mm (i) Identileabion mark 265 (0104 288 cas roranoe dale) ea = pom 029-097 ‘ane 04 2.68 0.1055 8 wor-oor | @or-o01n 2.69 (0.1059) 208 Reponinatay 80° (OF) 270 (0.1088) aro 271 (01067) 2 Available shims or Or) ze 275 (01075) ae Theknwse rom Or) Idoneaion mark 274 (01079 ze 232 (0091) me 275 (03085 28 2.39 (0.0817) - 233 2.76 (0.1087) 276 2234 (00823) Be 277 03081) a 2:35 (000025) 235, 2:78 (0.1034) En 2:96 (1.0829) 236 279 (61008) a 2.87 (0.0853) - 237 2.80 (0.1102) 280 2.38 (00887) 28 265 (01908) zt _ 2.30 (0.0041), 230, 2.82 (0.4140) 282 "240 (0.046) 240 289 (01104) 280 Za 0.09) zai Zen iia) ae a (0.0959) 2a 286 (0.122) 25 23 (00957) 28 2.06 (0.128) 20 244 (00961) ou 257 1139) mer 2.48 (0.0965) 285 7 2.88 (0.1134) Ea 26 (00069) 208 2.0 (0.928) 280 2.47 (0.0972) Eu - 2.90 (0.1142) 200 218 0.0976) 2a 291 (01168) Ey 2.40 (0.0980) 249 — 2.92 (0.1150) pee 20 (0.084) 280 293 0 158) 239 2351 (00086) 25 294 (0.1157) 2 252 (0982) 252 295 (07161) 288 2.53 (0.0996) 253 7 254 0.1000) 254 255 07008 258 256 10 257 ©7012) i 258 (07016) 2:59 07020) 2 024) 260 2 10 oo oe 2.52 (1059) 2 2.65 0.7085) 268 seuoese 254 01009) EM-66SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont'd) Valve spring Valve guide — on ey Fras ner mea] Sanne Pressure (kat ih er) santas 454 963,102) Limit 27.58 (1.0846) mcrae ven] __ tes hon 2079) Valve lifter on: mm to) eo ‘Vat ter ote dam Gasca stars — Suandard sono ‘Vale guide Se ‘35000-95001 te uid ner ameter eT er deme roca9- 000 | r9220- 10234 SEE wine Sartor | fossse-o.30s0) | (24025-04000) pg ' 0025-0061 Le Clearnes bemoan ter and iter guce ——«giG28 0081, ‘ive wide tne dameter 6000 - Frosted se) zee i Cynder ead vane pide] 9078 0.908 tele dameter co2n2o.amis) | (008 04010 i Tieden Halvane ‘0027-0059 ice {e001 -o0ez0, Sania [Max wierance aa 0088 swmrogude | 08 covery | 008 00050 ttearnce 000 cam Y mas] 00-9073, | 01 (oaow “nn cenechon nae = came) feat Exhaust 0.28 (04 126-128 0495. 050% ) we B EM-67 139SERVICE DATA AND SPECIFICATIONS (SDS, Inspection and Adjustment (Contd) VALVE SEAT os MEL, ‘yin hoa ines Contacting width (W); 4.09 191 (00820 - 09516) te —-ss8 58 as 4 (ae 400) [287 (1190) “208 - 208 ao (12051213) Contacting width (W129 - 1.51 (0.0508 - a.0800) ‘senate Unit: a) Standart Senioe Cytnder hess een racass dameter (©) 37.000 a7 016 (ABST ~ 14879) 37.800 a7 616 (IATEA 14770) ee 52.200 92296 (92677 - +2685) "32700 92.796 (2874 1.2860) ir (0.087 - 0.173 (0.082 - 0.0088) Valve seat inlertrence ee 0.064 - 0.006 (0.0085 0.0038) in {7.087 - 97.119 (14608-1481), {37.507 - 67.619 (14808-14608) Vavve seat outer slamater Ee 32.280 - 52.296 (12700-12718) ‘32,780 - 62796 (1.2006 - 1.2612) in 59-60 (0252-0238) ‘505 5.15 (01986 - 0.2028) Height gn Be 50-60 (0282-0236) “4.95 505 (0.1940 - 0.1988) eth () 50-61 (0202-0240) 140 EM-68SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont'd) CAMSHAFT AND CAMSHAFT BEARING CYLINDER BLOCK nim Lit: mn (nd Standard Lint Carshat journal io ‘0.048 - 0.086 owing Cearance [ote (00080) al 25.000 - 26.001 inner tamater of cam- | (1.0298 1.0248), _ shat beeing No. 284 125500 25.521 (0.9282 - 0.8260) Noi 25.005 - 25.955 ‘Outar kamera of cam- | (10214 - 1.0218) - SEMOZIEA | att journal No. 23.6 SSG 23.435 - 25.458 ‘Surface fatness (o.gz2s - 0.9254) Standard {Loss than 0.09 (0.0012) : yshat unout [TIF tess tan 0.08 (0.0020 Lint 0.10 (0.0099) & rou TF’) | 9.02 (0.0008) {0.0020} ee CGamsnan sprockei [Leas than render Dore ranout 1] 0.15 0.0059), = ber lametar ONS 0.188 Standen Camshatt ond play “Boars | 924 (0098) . soon 00078) GradeNo.1 98.600 -98.010 9.6614-9.6618) il Grade No.2 s9.011 - 29.020 (36618 - 3.6622) Grade No.2 98.02" -na.000 (3.6622- 9.6628) pp 0.20 (0.0079) than 0.015 (0.0006), Loss than €.010 (0.0008) ‘Main Journal inner ar ert “ Grade No. 0 68,999 - 63.909 (2 5194-25196) ‘Cam height" Grado No. t 64.000 - 64.005 (25187-25198) oe Irvako & Exeaust 48,990 - 44.100 (17200 1.7878) ® ve ee Grado No. 2 64.006 - 64011 (2.8199 - 2.5201) Wosr tof cam Regt 02 (0.008) Grade No.3 sare - 64017 (2.5000 - 25209) Tia demoreaaeg p= ee ameter between cit ors Stand Loss nan 0.69 (0.0012) Vale ting ar ee) ry a 2 EM-69 uuSERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Contd) PISTON, PISTON RING AND PISTON PIN Piston ring tm Available piston a oa: on Standard Tint ‘Sie cesranes| 010-0080 7 m cons -o.00a | 9% (00049) oc 0070 1 one ont (0.0012 - 0.0028) 0.1 (0.004) ers op 022-041 ™ (oer aoe | 05° 00817 om0-074 ana oe) 020-060 seve 1 (a ng) ne 88 | 09s 0087 Pion sa etn ‘Standard ‘rade No.4 52.900 - 62.990 (3.6508 2.5610) Piston pin race No.2 12.990 - 9.000 (9.6610 - 2.0614) oi en) race No.2 3000 - 20010 (26814-2668) Piston pin over ametor | 21.980 22001 (08657 68082) Torerenoe Hf plo pn 0.20 (0.0079) 193,180 - 98210 (3.6085 - 3.6607) t Piston pin o,002 - 0.008 (0.000 - 0.0002) verze (Sore) iroston ‘a elmension 45.4 (1.787) Fiston pin to cannecting rod (0.005 - 0.017 (0.0002 - 0.0007) —Bomenon __* (787) _ Siang cearanee ‘son pn at dmetr 1.90922 008 08850-01680 f ‘ ‘ “Yelues measured af ambsent temperature of 20°C (60°F) Psion doarance ar oy9. a0 (20004-00012) CONNECTING ROD Lt Center enance 147.60 19770 (58110-58149) Bend per 100 (3.84) nit 2.15 (0.0080) Tren par 100 G94 Lie a0 (oor) Grevecing ed smaller | 73959. 24.00 (094s - 05846) Pen pl busing ar Psion pn 22000 22.012 (0.8661 - 0.3666) Connecting aby ena ener | amos) Gon (2.000 - 48.019 (1.8598 - 1.8905) See asaranca Stair 020-098 (90078 - 00x98) ini 040 (0157) Shar naaiing H Somreang OS we EM-70SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont'd) CRANKSHAFT Unit: mtn Mai Gade No. 0 52.978 (2610-29612) Grade No 59.060 (2.9607 - 2.9610) Grade No 2 + 59:965 (2.605 - 2.9607) Gade No.3 59.957 (23608 - 2.3605) Pin urna dla “Dp AVAILABLE MAIN BEARING Upper main bearing Not yan 0 (al roove) yoo ne 3 ER 2g NONE % a ow waa Yee Gace Wo. 6 458 4497417708170) C Grado No. 2 44.956 « 44.902 (1.7699 - 1.7702) No lu Cranes 7 Eee eT) ‘ Se deere FE ae | Takes | wane Qut-of-round (x — ¥) wmbor | nm fin) mun fi) Sener © 2.000 - 2.008, 1 Black ‘Taper (A- 6) (@.0787 - 0.0789) | | ‘Standerd Less than 0.002 (0.0001) 1 2.003 - 2.006 1 Brown FE oars oar | 2008-2008 bog Lint Lass han 0900.09) a | eam 28, | emmy tnt ess than 97000009) | To ond oy a | 20-20% | 10-201 | eae Standard 8.10 - 0.25 (0.0086 - 0.0096) | eorer-coray | ces ora | ii ova. 2018 i war ON) 4 (0.0792 - 0.0783) t * ' © | cans Sore ) oe a (0.0724 0.0796) | Fune FA Ts Undersize : ——______ Somn Ta ua sev = a3 926 22-240 (terre pa cette | conse. ota% fence et EN-71 143144 SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont'd) AVAILABLE CONNECTING ROD BEARING Connecting rod bearing Fiyuhoe! wnout TAI MISCELLANEOUS COMPONENTS ‘nit: mm in Loss than 0.18 (0.0080) om, | mee, een re lt rout tess an 0.8 (9053) - — Rampant 70-1505, ° (0.0591 - 0.0882) Blew : ‘ta 108 rom | (otea 000s) Bearing clearance 108-1600 Une mm 2 (0.6598 - 0.0554) ‘Green Tar beng cours Sian 2035-0088 0014-06021 , tii 0.008 00026 Undersize “Comoang caveaing Unit: n(n) Seeranee ° Crank pa oma senor 1006-0058 0.003 - 0.0029) Teens ‘heme e Limit 0.070 (9.0028) Gy [eit wo ba bese ar caso | il 58H, sauce EM-72