MITSUBISH FORKLIFT TRUCKS SERVICE MANUAL Diesel Engine S6éS FD35 thru FD50 FD60 and FD70 99709-56110 Quality Makes the DifferenceINTRODUCTION ‘This publication covers the Mitsubishi S6S diesel engine. The information, specifications, and illustrations in this publication are on the basis of information that was current at the time this issue was written, The fuel injection pump and governor are described in the separate volumes of this publication. ‘The sections and their contents will be found in TABLE OF CONTENTS and the contents of each section in the first page of the section. 1. How To Use This Manual (1) The parts read in the texts or shown in the illustrations are numbered in the disassembly sequence prescribed for each system or assembly. (2) What to be inspected for during disassembly are indicated in [—_] in the disassembled view. (3) The maintenance standards to be referred to for inspection and repairs are indicated in easy-to-refer passages of the texts and also in Section 2 in a tabulated form. (4) Some marks are used in this manual to emphasize important and critical instructions as shown below: (5) Tightening torque in “wet” condition is indicated as [wet]. Unless indicated as such, the torque is to be considered in “dry” condition, Procedures, conditions, etc. which it is essential to highlight. Procedures, practices, etc. which will result in damage 10 or destruction of engine if not strictly observed. Procedures, practices, etc. which will result in personal injury or loss of life if not correctly followed.2. Glossary NOMINAL SIZE is the named size which has no specified limits of accuracy. ASSEMBLY STANDARD is the dimension of a part to be attained at the time of assembly or the standard performance. Its value is rounded to the nearest whole number needed for inspection and is different from the design value. STANDARD CLEARANCE is the clearance to be obtained between mating parts at the time of reassembly. REPAIR LIMIT is the maximum or minimum dimension specified for a part. A part which has reached this limit must be repaired. SERVICE LIMIT is the maximum or minimum dimension specified for a part. A part which has reached this limit must be replaced.TABLE OF CONTENTS Section Contents No. Typical engine arrangements; location of engine serial Genera information number; specifications suggestions for disassembly and 1 assembly es Maintenance standards; tightening torques; 2 sealanis Special tots Special tol list, 3 Overhaul instrctons | Determining wen wo overhaul the engines 4 measuring the compression pressure | | - |— Testing and adjusting; dynamometer test; “Testing and adjusting ng and adnsng performance test ; Engine accessory removal and | Removal and installation ‘ installation Fuel injection pump, alternator, water pump, starter, ee Disassembly, inspection and assembly | gine proper Cylindes head andvalve mechanism ywhee: damper, ining Engine prope ‘Bears and camshal pistons, connecting rods, erankshaf, 7 __ Ertene nd pyc “ Airinlet and exhaust systems | Exhaust manifold inspection 8 tvication stem Disassembly, inspection and assembly Lubrication syste Oil pump; oi fier oil pressure relief valve a Disassembly, inspection and assembly ing system Cooling syste ‘Water pump thermostat “0 sytem Disassembly, inspection and assembly Fuel syste Fuel filter, injecion nozzles uw lecwical sysem Disassembly, inspection and assembly Pb Starter; alterates; glow plugs Basic recommended asembly procedures Workshop theory Oil seals; O-rings bearings split pins and | os spring pinsGENERAL INFORMATION 1.GENERAL 1.1 Typical engine arrangement (FD35 thru FDSO). . . 1.2. Typical engine arrangement (FD60 and FD70) . ... 1.3. Location of engine serial number ............++ 2. SPECIFICATIONS 3. SUGGESTIONS FOR DISASSEMBLY AND ASSEMBLY 3.1. Disassembly 3.2. Assembly wo me RUNGENERAL INFORMATION 1, GENERAL 1.1 Typical engine arrangement (FD35 thru FDS0) Fuel injection pump Airinletmanifold—_ipstick | uel fier | Put injection nozzle = Governor ‘Water pump Coolant drain plug iu oe a A ' Xu Oil pressure relief valve ml eZ a eat Leni — at ar a baw : rere x a] | t L ‘V-belt a _ 407462 Right side NOTE: The rotation of crankshaft is counterclockwise when seen from the flywheel end.GENERAL INFORMATION 1.2 Typical engine arrangement (FD60 and FD70) Fuel injection pump Ai inlet manifold Dipstick Fuel filter se |_— Fil injection nozzle ‘Water pump ae Coolant drain plug. (er Rear si — _ Fuel feed pump Oil fier L Fi ay | Oil pressure relief valve il drain plug 407482 Left side Exhaust manifold it filter fi il filter Alternator Flywheel Veet Starter 407465 Right side NOTE: The rotation of crankshaft is counterclockwise when seen from the flywheel end.GENERAL INFORMATION ‘The engine serial number is located on the side of the crankcase.2, SPECIFICATIONS GENERAL INFORMATION Model 36S (FD35 thru FSO) ‘S65 (FD6O and FD70) Type No. of eylinders~ arrangement ‘Combustion chamber, ype ‘Valve mechanism Bore x stroke, mm (in.) 94 x 120 (3.70 x 4.72) Piston displacement, Titer (cu in.) 4.996 (305) Compression ratio General 21 Firing ord 1=5-3-6-2-4 Roution of enka Countrlockvise when sen fom Fywhed end ‘Oren ng, mi Ga) 9075 (5.7) 86 (38.1) Dimensions [Over widh mm in) 2.053) 5673.1) Over eight Ga) wT) Weight (dry), kg (lb) +350 (772) 345 (761) Cylinder sleeves, type Dy No. of piston | Compression rings 2 5 ings Oil ring 1 Gwispring expander) 2 Init valves 2% Senne 8 | vate dining oa WeEDe. 2 Exhaust valves OPS fr [Tess BP ATD. Staring em Blac saree Siang ad iow puss Type Face Feed by oi pap API service classification cc - Engine ol [Refieaci, | Wise engines 126.2) | g Titer (U.S. gal.) Oil pan (high level): 11 (2.9), Filter: 1 (0.3) 3 “Type _ Trochoid 2 | ot pump | Speed tio w crankshaft 074 3 ‘Capacity, 38.7 (10.2) at 0.3 MPa discharge pressure of 4 SEE cary Ming ops at ; 3 | oi pressure wee saints Piston valve reli valve | ee Pal 35.405 (6047) [343+ 49} Oil filter Type Paper-element cartridge |GENERAL INFORMATION [ Moder 'S6S (FD35 thre FDS0) | _S6S (FD60 and FD70) Refill capacity (engine water jacket), Beil apace Jacket), san Type Cenwifugall Lcryuny eine — 3 Capacity, 160 (42.3) at 0.75 MPa discharge pressure of 2 Titer (U.S. ga.)iminfepm ‘pump running at 3600 spm & | Bee Type Low-edge B type V-belt | | ‘Wax pellet ‘Thermostat ‘st 765 +15 (1702.7) Injection Bosch A pump Diameter of plunger, mm (in) 65 (0256) Type Bosch, piston Feedpump [camshaft lobe lift mam Ga) 60.236), [Governor | Type Bosch RSV, centifgal Ee Type Bosch throttle zg Diameter of discharge S| a orifice, mm (in.) foc nozzle Discharge angle 15° o Valve opening pressure, | Katie Ge) Wes) 40 (1 991) 137291 120 (1706) (11.768) Fuel filter, ype Paper-clement cartridge Voltage — polarity 2AV — negative ground Model MOO3TS8771 | Type Pinion shift ed ‘Oupat, V— EW 24-5 _ é 'No. of pinion weeth/lywheel 5 ring gear teeth 1122 & ‘Type S-phase, with rectifier £ Output, V~ A, 24-35 24-30 3 Rated voliage generating Tran "ASSES [Reet oepaamonn : (standar ated Output generating Rated out - 5000 ‘Maximum permissible Maman 8000 . Speed ratio to erankshatt 20GENERAL INFORMATION Model 365 (FDIS thru FDS) | _ S68 (FSO and FD70) ype Fephase, with rectifier Ouiput, V-A 24-35, 24-50 Rated volage generaing 11000, 1100 {| acme atone sae & | (option B | Rated ou 5.000, 5 000 g Maximum permissible E Maximum 8000, 8 000 = Speed ratio 10 crankshaft ee Type Sheathed pl | Glow plugs | Rated voluge ~ curren 22-44 (15 second rating)GENERAL INFORMATION 3. SUGGESTIONS FOR DISASSEMBLY AND ASSEMBLY This manual outlines basic recommended procedures, some of which require special tools, devices or work methods, and contains basic safety precautions. The safety precautions contained herein, however, are not for the whole of service work. It is the responsibility of the service personnel to know that specific requirements, precautions and work hazards exist and to discuss these with his foreman or supervisor. Following is a list of basic precautions that should always be observed: 3.1 Disassembly (1) Always use tools that are in good condi- tion and be sure you understand how to use them before performing any service work. (2) Use an overhaul stand or a work bench, if necessary. Also, use bins to keep engine parts in order of removal. (3) Lay down the disassembled and cleaned parts in the order in which they were removed to save time for assembly. (4) Pay attention to marks on assemblies, ‘components and parts for their positions or directions. Put on marks, if necessary, to aid assembly. (5) Carefully check each part for any sign of faulty condition during removal or cleaning. The part will tell you how it acted or what was abnormal about it more accurately during removal or cleaning. (© When lifting or carrying a part too heavy or too awkward for one person to handle, {get another person’s help and, if neces- sary, use a jack or a hoist 3.2 a) @ GB) (4) () Assembly Wash all parts, except for oil seals, ‘O-rings, rubber sheets, etc., with cleaning solvent and dry them with pressure air. Always use tools that are in good condi- tion and be sure you understand how to use them before performing any service work. Use only good-quality lubricants. Be sure to apply a coat of oil, grease or sealant to arts as specified. Be sure to use a torque wrench to tighten parts for which torques are specified. Replace gaskets and packings with new ones. Apply a proper amount of sealant to gaskets or packings, if necessary.~ MAINTENANCE STANDARDS 1. MAINTENANCE STANDARDS 2. TIGHTENING TORQUES 2.1, Major bolts and nuts . 2.2. Standard bolts 2.3. Standard studs 2.4. Standard plugs 3,SEALANTS .. 10 16 7 7 7 18MAINTENANCE STANDARDS: 1, MAINTENANCE STANDARDS Unit: mm (in) Repair | Sevice Timit | limit Remarks (clearance) | (clearance) ] Nominal] Assembly standard |Group} Item size | (standard clearance) FD35 thru FDSO: 2650 .$ Maximum pm (nou) | eet Aa sve ‘Minimum rpm, (no-load) 650°" | ‘Compression pressure, 33,(469) (3.236) | 29 (412) Sewre eaten (ps) kPa) 21300 pm ins) | (81086) 3105 43071) [29410490] | 15213) en Engine oil pressure, 21300 rm (iat) it temperature Kgf/em? (psi) {kPa} 1.(14.2) (98), 05) (14010 158°F) wee BT [BP ; & Tnle valves open 30° BTD.G Inavivercae 30° ABDC. Valve timing Exhast valves open 4° BRD. Exhust valves cove 30° ATD.C 33+ Grank angle) Valve clearance (cold) 0.25 0.009 8) naan ees Fuel injection timing | IS BTID i ‘Posh bel inward with V-belt deflection 125), rpprox. thumb pressure and ‘measure deflection, g . Re-grind crankcase & | warpage of gaskot 0.05 (0.002 0), 0.20 within the range of 3 contact surface ‘maximum (0.0079) retaining specified Piston proystion. . 94,000:094035 | 94200 | 98.700 | Refinish eylinder to Leeda 1007 216) | 6.70865) | 6.72834) | 0.95 (0.008 8) or 0:50 2 | owotsoune 201 0004, toma ave by & _neinam honing and use the fans anos same oversize pistons i ie | pein and piston rings. 4 ~ "Vieira as 5 og | Beem reached replace | (Sooss) | Rely i heen 23s journal | °XCeeded. reer x | creaance between 0.050 10.110) | (0200) | $8590 | Soma and se | bearing and journal (0.001 97 te 0.004 33)) (0.007 87] BREET | undersize metals. i Woo | Meal andeizes 3 1.25 (0.009 8) 2 050 (0.0197) 075 (0.0295) (300) Wid of tse 0.100 0026 | ace thrust plates journal (2003 941001039) (CON 8D) aaa 10MAINTENANCE STANDARDS Unit: mm (in) Repair] Service ] Nominal) Assembly standard Grou tem Timit | Timi Remarks , Sze | Gtandardstearancs) | (iearanc) | (clearance) | 14.0006 14.018 14.100 g eee | (0.551 18 100.551 89) (0.555 12) 4 ~ T ~ - g | & | Clearance berwoon | (0.016 160052) | (0.08) pac packer i & | tappet and bore } (0.000 63 to 0.002 05))| ((0.003 10) | ne oT, repair imit has = eee ees Earley ans joural (0.001 57 0.004 69))| (0.005 9) | replace bashing or 8 | camshaft. vy | Warpage of gasket 0.05 (0002.05, 020 | ‘Regrind if warpage E_| contct surface maximum (0.0079) is minor. SF) Compressed thickness | 1.2 4005 [52 ) organket 0.05) 40.002) | | Inlet 7.980 17.955 7.900 |g [Piamecr | vate |g | @3126000313 19) 031102) 3 | oem Exhaust | (0.3) | 7.92010 7.940 7.850 Whey vane (0311 8110031260) (0.3095) | Chcarance | Inlet (2055 10 0.085) (0.150) |g | between | ave (0.002.176 0.003 35)) (0.005 91) |g | euideand [Exhaust (0.070 00.105) (0.300) & | stem ((0.002 76 1 0.004 13)) («200787») > | Height to op of 14 valve guide” ess | __ #34001) | [Angie w al ae | 04 s Bll vane [vane | 016) 10 2 5 | f|intire fen] os | “02600 oom | ~ ole valve | (0.020) = \z 1a 18 Valve | wiatn (outs) | #014 0.005 5) 007) 2a — Tew Lee Math Valve margin 2.13 (0083 9) Gotz) es fein. —_ 4385 | | 47.60 Free lengit (1.92) 0.87) | Squareness of ends Squareness | 1s with spect o center Tine {Length under test 436.69) 3.6) - 2 | 5 Test fore, 4010 48) os ae 1177 196) isn "MAINTENANCE STANDARDS: Units mm Gin.) Repair | Service Nominal) Assembly standard | Repair | Servic — |Group| Item See | Guandarddearace) |i tit Inside diameter of| 19010 w 19.050 g | rster busing rg | (0748 42100.749 21) _ g | § | Diameter of (0.25) | “18.980 19.000 BY | rocvershan | (0.747 24100748 03) § | © | Cheam bewesn (0.010 10.050) C07 z bushing and shaft (0.000 39 t0 0.001 97) («0.002 76)| o 7 Dial indicator readin ©) runout 03 (0.012), with both ends 34] raxiam Supported in V-blocks Run ‘0.02 (00008), 005 maximum | (0.0020) Diameter of 7a | 7955.77.97 | 7850 | 77.100 journal 8.07) | 6.069 09 103.069 68) | (4.06495) | 6.035 43) Diameter of 38 | 57.95St0s7970 | 57.100 rani 2.28) | (228169 10238228) | 224803) Distance fromeenter | gg | fjoumal cance of | gy) | 40.08 40.001 6) srankpin ‘Runout: 0.01 0.008), Parallelism between maximum (over zz | Jourmal and crankpin crankpin length) a Out-of-round of H | Joumal and crankpin |__| 0.01 (0.0004), 0.03, = | S| Taper of journal and maximum (0.001 2) | z crankpin | = Fillet radius of journal [3 2) [SYS N| ely | 2020008 _ i iFrepair iit as boc 5 reached, replace 3 thrust plates. It has been exceeded, use 33. | 1000264 | (0.300) H End play ' oversize thrust plates. | 1.30) | (0.003 94 1 0.01039) |(@.011 81), Fanaa plus overtone: | 0.15 0.005 8) 030(0.011 8) 045 (0.0177) & 93.955 993.985 93.770 g | Standard 6.699 01 1 3.700 19) eon) = [oss@oms | 9 | sa20swoans | 94.020 Bg oes | 6.70) | 6.70885 10371008) 6.7015, B 2% [050 00197) 94.455 1 94.485 94.270 E [8S ovens QT oA798 ers | 02310015 Check metal Projection (0.009 8:0 0.005 9) clearance. | Clearance between (0.000 1 0.016), (0.050) Piston pin and bore 0.000 00 19 0.000 63) \¢o.001 979) 12MAINTENANCE STANDARDS Unit: mm (in) ] Nominal | Assembi oy | min sembly standard | RePal = Grove) a size | Glandard clearance) | fit) aoe ¥ oT wo. ari (0.07 100.11) (0.200) ‘| 2B p| No tring (0.0028 100.004 3)) «0.007 87| Seino | oS (eq QO W008 7 50 al | (0.079) | (0001 77 160.003 35)) |(@.005 919) | 38] onan 40 (02025 100.065), (0.150) 8 [SE OM is | odode 00.002 56 (600591) EY glNou2 a 030 00.50 150 SET cums (0.0118 100.0197) (0.0591) GE 29.994 10 30.000 & | Diameter (2.18086 101.181 10) 7 B | & | Clowmecteweon (0,020 100.051) coos, | B | & | pgmdcomecting {050079 fo0.002 01) («003 19) z Inside diameter of | 30 30.020 10 30.045 a bushing 1.18) _| 2.181 8910118287) | 2 0.10100 \neee| Twistbend 6.003939, | (0059) | repair iit has Clearance between ‘been reached, replace crankpin and (0.030 16 0.090) (0.200), | metals. fit has boon eonnecting rod (0.001 18 160.003 54) ((0.00787)] exceeded, rerind metal ‘rankpins and use underize metals 35 (0.15 035) (0150) | Replace connecting Py 38) | (0.005916 0013 8) | (020) | rod 1B] Baoess (0.15 (0.005 9), 0.50 | | Facerbore ranoar maximum, 0.20) ' 0.02 (0.000 8), 0.05 Straghion by cold aa ‘maximum (0.0020) working or replace. Re - Inlet 8 6.536, 6.184 © e 46o16% Zalvare lasers) 025815 2846) | Ble lge ae & | 2 [SS Exhaust | “sesso 6.700 cae ?|2 valve |ageseraam] 26457) (0.244 88) 5, E/°!S (nouas 54 53.94 10 53.96 53.90 BelNeb23 | Gin | @ii6w2imy | | e120 EE | Nos 3 52.94 1052.96 52,90 Bs 20 | e042 20850) | 2.0827), 7 3 (0.10 0.25) (0.30) ae [Batley on _| (oses30%0 | (Guiry | Recent 13MAINTENANCE STANDARDS. ‘Unit: mm (in). Ropar Nominal] Assembly standard ; ona i i Site | Gundarddeanncs) | gore) Renee Clearances between (0.008 0.050) , [sites |__| cooossionoor on» oa Dy] Replace bushing z 30 | 05 0020 (035) | peace wan pute a | & | Enaphay 2m) | (080201000079) (ors bp | Replace trust pl 2 | 2 [Riguaisemet | 30 | ostmomen E] | BaNRSRRE” | Gy | oS lerone dm | O03 woiw O25) a (0.001 210.007 ») (.009 5) | Reviee sears Crean bowen (02016030) (050) sucrrowransene | (oso? te0at! 8) «oi» _ Diameter ofmain | 16] 15,9851 16000 shaft (case side) (0.63) | (0.629 33 10 0.629 92) Dine ofmin | 14] 13957 « 97S a. | tal basing side) | 38) | (038949 10059020) | _ § | El ccens toes omaeone iso Rarer 3 | © |muinstan andes (0001 2610000290) 6.005 90) oc pup assenby. 5 | © [Chearance berween (0.025 10.111) (0.200) | Replace bushing or S| | sinshaeand bushing! | (0.00098 0.004 37) 6007 87y| puny assembly E ‘Clearance between inner (0.13 00.15) (0.20) 3 rotor and oster oor 0.08 1 160.005 99 (0.0079) _ Clearance beweon (0.04 6009) “O13)_ | pai cae or cover rotors and cover ((0.001 6 to 0,003 5)) ((0.005 9)) “ Opie 3540s Reletvaive | PRSSUS Go: Felon ies BBE | | Tene at which valve Testi se | sant opening __am#275) 8] E [tem aon | B) 2 | titismore than 8 90°C (194°F) 3 Foes | a0 1250151 Mate aim adh Vatve opening] th | (1991) | 206202147) mene Pressure Nate opening] so {113 729)| (1220 w 14808) vars by 10 (182) Entenstes) [p60] 120 | 1200130 [880] yor 0.1 mem (hPa) tnd | 1700, | 1706 1849) (0004) iickness | Fbvo [Aires] cit 08 w 1241 oti . {8 aoe sis ‘hand tester, using Ble diel a 27 | & | piensa Y (68"P, I alscharge EZ | § | Discharee anale ® patter is bad eves 2 Ther nownle i wasbed inelean desl fc myce nove ‘Seat shall bold a test pressure oitsghmess ot | 20kgten* (84 psp tt 91 Wash o replace feedevatveseat | APal lower tha Vale opening monet pressure for 10 seconds 14MAINTENANCE STANDARDS. Unit: mm (in) Nominal | Assembly standard Repair Service Group Tem cminal) Assembly wanda) | um | limit Remarks Ce ) (clearance) | (clearance) Diameter of 387 a7 commutator 4.52) (1.43) 7 11 Leng (0.67) (0.43) Brush fe 3.0 cat 66) ‘kgf (Ibf) IN}. G4) Thus clearance of | 05 ° [asin at (0.020) minima 5 O1to25| | Pinion clearance | (0.00410 0.088), Nolosd chareccrsics [Locked cheractevistion | Magnetic ewitch Voltage | Current | Speed Current |, Foran Switch-in wie Care| Spee em ache) ae 9.065) | ws | 8 | 5300 9 | 1400 | fin 16m € J 5 Brash spring 32010440 200 < force, (67110097) ou 2 | seman, #0201 Bl o43} ta) | 2ve30a B | Z2¥-304)) Brash iengtn Bes con Resistance in ees - 20°C (68 Brush spring 330 force, 03016) 7) Aterator| ef (60 (N) {581070} Bal 2av-35A Fj (Gtandard) | Brosh length 215 (085) cn Revue a swan aoc @er Hipage 910 1040 _ rR) Brush spring 32010 440, 200 force, (0.71 100.97) (0.44) Altemator,|_8f (1b) [NI 3.11043] 2.0) 24V-35A, B ~ (prion) | Brush lenges 19075) on Resistance in | Nipsige 402 38 20°C (68°F) ‘Alternator, bavesoa’| Resistance in Swen 120°C (66°F) Gepuion” | sienes | 15MAINTENANCE STANDARDS. 2. TIGHTENING TORQUES 2.1 Major bolts and nuts Thread) Width Tightening torque Secured part or component | dia. xpitch, | across fla, = - Remarks mm mm | gem Nm Cylinder head Maxis | 19 | 12205 118s 5 Rocker shaft brackets MB x 125 2 | 15205 15z5 Main metal caps Midx2 2 | 10s05 10325 ‘Connecting rod caps M10 x 1.25 | 55205 S445 Flywheel Mizxi2s | _17 | asz05 825 Camshaft thrust pate M8 x 125 2 | 10013 00 Front plate MB x 1.25 2 | 10wi3 1013 Timing gear case MB x 1.25 2 | 10013 0B Crankshaft pulley M30x15 | 46 SO#1 | 36247 | 490210 Tiler gear thrust plate Mioxi2s | 14 | 35205 | 2524 | sas il pan MB x 1.25 2 | 10013 | 709 | Wwi3 Oil pan drain plug M20 x15 4 esos | S8t4 WES uel injection nozzles 20x15 2 S07 | 36051 | we - Fuel leak-off pipe nuts MI2x 15 17 | 20025 | 141018 | 201025 - Geliven valve bolders 20x15 ua |3.754025) 2742 | 37425 Fuel injection pump gear | Mi4x 1.5 2 | &5wl0 | wn | 1098 B teminal of starter MB x 1.25 a | tasi | sei | ner ‘Alternator pulley M20x15 a | asais | toasen| w7eis Oil pump gear ‘Mi0x 1.25 4 | 34e05 | 2524 as | Glow plug. (body) MIO x 1.25 12 | 15020 | twid | 15020 ~~ (Germinal) M4 x07 8 [010w01S| O71 | Tos Exhaust manifold MB x 1.25 2 | 3480s | mea | 3025 Oil pressure relief valve | _M22x1.5 27 | 5205 | saa | 4925 Biingpiugoniowersieot | yugx2 | 24 | 7205 | sisa | wes ‘Coolant drain plug waxienrtF [14 | 45205 | 3324 | 4425 _| Fuel injection pipe nuts | MI2x 15 19 | 25035 | 18025 | 250% 7 Fuel reuir pipe nuts mioxi2s | 14 | 16024 | 12017 | 161024 162.2 Standard bolts MAINTENANCE STANDARDS ‘Torque ‘Thread dia. x pitch, — a aT ‘TT and large kgm WoFt kgtem ett Nm M6 x 1.0 04 3 4 07 5 7 MB x 1.25 12 9 pn | ow 2 7 MIOx 1.25 paar | 22 16 2 34 25 33 MI2x 1.25 | Raa 36 6 35 61 “4 oo Mi4x15 60 3 59 99 2 7 2.3 Standard studs ‘Thread dia. x pitch, “Torque (tap end) Thread dia. x pitch, For driving in aluminum materials For driving in ferrous materials ketm | tbe | Nm | kgm | tbe | Nm MB x 125 075 34 74 13 9 B MiOx 15 1a “10 “4 2a 7 24 2.4 Standard plugs ] Torque For ferrous materials = Toft Nm ketm | Tort Nw ~ RUB PTI) 10 7 10 3 18 RUA PTV) 25 | 18 25 ! 40 29 39 R3/8 PTH/8) =a ie — | 65 a7 o Remarks; 1. The torque values shown above are for the bolts with spring washers, 2. Tolerance on the torque values shown above is +10%. 3. Unless otherwise specified, use the torque values shown above. 4, Do not apply any oil to the bolt threads. 7MAINTENANCE STANDARDS 3. SEALANTS ‘Apply 0 Mating part Sealant Remarks Oil pan Crankease Thee Bond 12076 Apply to sealing surfaces of oilpan Rear metal cap seaton | Rear meta cap Three Bond 1212 Apply corners of cap crankcase ‘ator installing cap Side seals CCrankcase rear metal cap | Three Bond 1212 Apply to side seals before installing them. Pug for coolant hole in| Cylinder head ‘Three Bond 1386D Apply o hole before cylinder head ‘installing plug Pug for coolant olen | Crankease ‘Three Bond 1386D Apply tool before crankease, ting pg Piug fr oil gallery in| Crankcase Three Bond 1386D ‘Apply to hole before crankease installing pug. it return hole blind plug. | Crankease Three Bond 1344 Apply to plug or pipe ox pipe of crankease ‘efor tightening Starter mounting suds | Rear plate Three Bond 1344 Apply to studs before tighining them. Crankshaft threads Crankshaft palley nut | Three Bond 1212 Apply 1o threads before tighening nut Rear pate Crankease | ‘Three Bond 1104 ‘Apply to rear plate and crankcase, 18SPECIAL TOOLS Special tool listSPECIAL TOOLS. SPECIAL TOOL LIST Tool ame Pan No Shape “Arplicaton Valve spring pusher | 30601-04500 ‘Vave spring removal and ao inslavon worn Valve guide remover | 3291-00300 Valve guide removal | ZA 70230 Valve guide installer | 32491-00100 Valve guide installation 70228 Stem sealinsaler | 32491-10200 3 Valve stem sal installation sosr36 Valve seat insert Tne valve: ‘Valve set installation caulking tool 43701-00300 Exhaist aber 34251-03000 Piston ing pers 31391-12900 Piston rng removal and instalation Piston installer 34491-00200 Piston installation Tater bushing installer | 30091-07300 <= Tater gear bushing emoval 2nd usaltion sroat2 20‘SPECIAL TOOLS. Too! name Par No. ‘Shape ‘Application Iter shaft puller MH061077 Idler gear shaft removal _ _ _ 70231 7 il seal sleeve installer | 30691-13010 — eH AN f — a\ 408793 Adaptor 30691-21100 | Compression pressure ; smieasurement | 70203 Compression gauge 33391-02100 a Compression pressure antes ‘Tuming socket 58309-73100 , | Engine tuming 400908, Socket 34491.00300 (Camshaft thrust plate and 2 rocker bracket installation - 70235 a ‘Connecting rod bushing | MH061236 Connecting rod bushing puller | removal and installation 70242 | Camshaft bushing 30691-00010 (Camshaft bushing removal installer set and installation 21‘SPECIAL TOOLS. ‘Too! name PartNo, Shape ‘Application it pump bushing installer 3291-00400 407215 (il pump bushing installation1, DETERMINING WHEN TO OVERHAUL THE ENGINE 2. MEASURING THE COMPRESSION PRESSURE ...... OVERHAUL INSTRUCTIONS‘OVERHAUL INSTRUCTIONS. 1, DETERMINING WHEN TO OVERHAUL THE ENGINE Generally, when to overhaul the engine is to be determined by taking into consideration a drop in compression pressure as well as an increase in lube oil consumption and excessive blowby. Lack of power, increase in fuel consumption, drop in lube oil pressure, hard starting and abnormal sound are also engine problems. These problems, however, are not always the result of low compression pressure and give no valid reason for overhauling the engine. The engine develops problems of widely dif- ferent varieties when the compression pressure drops in it. Following are the list of typical problems caused by this compression pressure drop: (a) Lack of power (b) Increase in fuel consumption (©) Increase in lube oil consumption (@) Excessive blowby through breather due to worn cylinders, piston rings, etc. (©) Excessive blowby due to poor seating of worn inlet and exhaust valves. (f) Hard starting (g) Abnormal sound 24 In most cases, these problems occur concur- rently, Some of them are directly caused by low compression pressure, but others are not. Among the problems listed above, (b) and (f) are caused by a fuel injection pump improperly adjusted with respect to injection quantity or injection timing, worn injection pump plung- ers, faulty injection nozzles, or poor care of the battery, starter and alternator. The problem to be considered as the most valid reason for overhauling the engine is (4); in actually determining when to overhaul the engine, it is reasonable to take this problem into consideration in conjunction with the other problems.2, MEASURING THE COMPRESSION PRESSURE (1) Remove the glow plug from a cylinder on which the compression pressure is to be measured. (2) Attach Adaptor (special tool) (30691- 21100) to the cylinder, and connect Compression Gauge (special tool) (33391- 02100) to the Adaptor. (3) Crank the engine by means of the starter, with the governor stop lever pulled (the fuel supply shut off), and read the com- pression gauge indication when the engine begins to run at the specified rpm. ex Securely hold the governor stop lever in STOP position. Should hand slip off the lever, the engine might start inadvert- ently, resulting in personal injury, When measuring the compression pressure, keep hands and clothing away from moving parts. (4) If the compression pressure is lower than the repair limit, overhaul the engine. C a) Be sure to measure the compression pressure on all cylinders. It is not a good practice to measure the compres sion pressure on two or three cylinders and judge the compression pressure of the remaining cylinders therefrom. b) The compression pressure varies with changes of engine rpm. This makes it necessary to check the engine rpm at the time of measuring the compression pressure. \ (OVERHAUL INSTRUCTIONS: Measuring compression pressure Te * Governor stop lever 407481) 25OVERHAUL INSTRUCTIONS. Unit: kgtfem (psi) [Pal = Assembly] Z standard 33 Compression pressure | (469) a2 13.236) (2844) NOTE ~ Measure the compression pressure with the {engine running at 300 zpm | a) It is important to measure the compres- sion pressure at regular intervals to obtain the data on the gradual change of the pressure. b) The compression pressure would be slightly higher than the assembly standard in a new or overhauled engine owing to break-in of the piston rings, | valve seats, etc. It drops as the engine parts wear down, 26TESTING AND ADJUSTING J 1. TESTING AND ADJUSTING 1.1 Valve clearance . . 1.2 Priming the fuel system 1.3. Injection timing 1.4 No-load minimum (low idle) rpm and maximum rpm setting. 1.5. V-belt inspection and adjustment 2. DYNAMOMETER TEST (BREAK-IN OPERATION) 2.1 Starting the engine . 2.2. Inspection after starting the engine 36 2.3. Dynamometer test conditions. 36 2.4 Inspection after break-in .. 36 3, PERFORMANCE TEST 3.1. Standard test conditions 36 3.2. Tests to be conducted .. 36 3.3. Items to be tested .TESTING AND ADJUSTING 1, TESTING AND ADJUSTING 1.1 Valve clearance Check and adjust the valve clearance when the engine is cold, Unit: mm Gin) Them Assembly standard ‘Valve clearance | Inlet 0.25 (0.009 8) (old setting) | Exhaust (1) Inspection (a) Check the valve clearance in the injec- tion sequence. To check, turn the crank- shaft by the specified crank angle in the normal direction to bring the piston to the top dead center on compression stroke. [Injection sequence | Turing angle 1-5-3-6-2-4 120" (b) To tum the crankshaft, put Turing Socket (special tool) (58309-73100) and ratchet handle on the nut holding the crankshaft pulley. Unit: mm (in) Width across flats of| 46 crankshaft pulley nut | (1.81) (©) The top dead center on compression stroke of the No. 1 cylinder piston is identified by the timing mark “O” (on the crankshaft pulley) being aligned with the pointer on the gear case. With the piston so positioned, both the inlet and exhaust valve rocker arms are not being pushed up by their push rods. (@) Insert a feeler gauge into between the rocker arm and valve cap, and check the clearance. 28 407425 | ‘Checking valve clearance (turning) conta ay |TESTING AND ADJUSTING (2) Adjusting (a) Loosen the lock nut of the adjusting screw. Adjust the clearance by turning the screw in either direction to the extent that the gauge is slightly gripped between the rocker arm and valve cap. (b) Afier adjusting the clearance, tighten the lock nut, and again check the clearance, making sure it is correct. 1.2 Priming the fuel system Fuel filter (@) Loosen air vent plug @ on the fuel filter (by turning it 1.5 turns). (b) Unlock priming pump plunger @ by turning it to the left, and operate the pump. (©) Tighten the air vent plug when the fuel flows free of bubbles. Before tighten- jing the vent plug, lock the priming pump Priming fuel system plunger by turn it to the right while pushing down on it. Fuel injection pump (a) Loosen air vent plug ® on the injection pump (by turning it 1.5 turns). () Operate priming pump plunger ®. (©) When the fuel flows free of bubbles from the vent, tighten the plug. Before tightening the last plug, lock the prim- ing pump plunger by turning it to the right while pushing down on it. a) If the vent plug is closed before the priming pump plunger is locked, fuel pressure acts on the feed pump, making it difficult to restore the plunger. b) Clean up fuel spillage. i 29TESTING AND ADJUSTING 1.3 Injection timing The injection timing varies according to the output, rpm and specifications of the engine Be sure to verify the timing by referring to the specifications. a) Bring the No. 1 cylinder piston to the top dead center on compression stroke. (a) Put Turning Socket (special tool) (58309-73100) on the crankshaft pulley nut and turn the crankshaft in the normal direction (clockwise as seen from the front end) (b) Stop turning the crankshaft when the timing mark “0” on the crankshaft pulley is aligned with the pointer. (©) Push down on the inlet and exhaust @) valve rocker arms for the No. 1 cylinder to make sure they are not being pushed up by the push rods (the inlet and exhaust valves have some clearance). Check the injection timing. (a) Remove delivery valve holder © from the No. 1 plunger of the injection pump. Remove delivery valve ®, spring ® and stopper from the holder. Restore the holder to the pump, (b) Connect a spare injection pipe to the No. 1 plunger, with its free end held downward so that you can observe the fuel flow from that end. (©) Tum the crankshaft to bring the No. 1 piston to approximately 60° position before top dead center on compression stroke. (4) While operating the priming pump to allow the fuel to flow from the injection pipe, slowly turn the crankshaft in the normal direction. Stop turning the crankshaft when the fuel flow stops. (©) Make sure the timing mark on the 30 crankshaft pulley is aligned with the pointer. Pointer Bringing No. 1 piston to T.D.C. on compression stroke 400016 ‘Checking injection timing — (Removing delivery valve) Checking injection timing —(3) Adjust the injection timing. (@) If the injection timing is retarded, move the injection pump toward the crank- case. If the timing is advanced, move the pump away from the crankcase. (b) One graduation of the scale on the injection pump coupling changes the timing by 6° in terms of crank angle. ad minimum (low idle) rpm and maximum rpm setting a) The no-load minimum (idle) rpm and maximum rpm have been set for each engine on the test bench at the factory. The set bolts are sealed. These settings are to be inspected and adjusted at the Mitsubishi -authorized service shop only. b) After adjusting the governor by breaking the seals, be sure to re-seal all visible stoppers. | ©) Whether the seals are intact or not has important bearing on the validity of claims under warranty. d) When inspecting and adjusting these settings, be on standby to operate the engine stop lever manually in the event of engine overrun. —___/ For inspection and adjustment, warm up the engine thoroughly until the coolant and oil temperatures are above 70°C (158°F). TESTING AND ADJUSTING To advance injection timing aoraia Adjusting injection timing — 31TESTING AND ADJUSTING (1) Start the engine. *On overhauled engine (D Before starting the engine, check the coolant level, oil level and the amount of fuel in the tank, and bleed air out of the fuel system and cooling system. (11) Crank the engine with the starter for about 15 seconds to permit lube oil to circulate through the engine. For this cranking, do not supply fuel to the en- gine, During cranking, remove the oil filler cap and make sure that the oil ‘comes out of the rockers. (a) Pull speed control lever @ to the high rpm side. Operate the starter switch to crank the engine. (b) The engine will fire up at approximately 150 rpm of cranking speed. When the engine fires, hold the engine speed between 800 and 1000 rpm. (©) When the engine runs with a steady speed, move the speed control lever back to the low idle position. (2) Set the no-load minimum (low idle) rpm. (a) Hold the speed control lever at the posi- tion for no-load minimum (low idle) rpm and set low idle set screw @. 5 : If a critical speed (the speed at which th engine excessively vibrates due to torsional resonance) might exist, shift the setting to a lower or higher idle rpm level. | —— J 32(b) The engine rpm will increase when the low idle set screw is turned clockwise. (©) If the engine rpm tends to fluctuate, turn idle sub-spring adjusting screw @ clockwise to bring this spring into slight contact with the tension lever for elimi- nating fluctuation. —(Renurion) Tightening the idle sub-spring adjusting screw is likely to cause the engine to overspeed when the load is removed during operation. Carefully tighten this adjusting screw just enough to eliminate the unstable condition, (3) Set the rack (maximum output). (a) Hold the speed control lever at the posi- tion for the indicated output and rpm. (b) Under this condition, check to be sure that the engine is running in a steady state. (©) With the engine running in a steady state, tighten or loosen the full-load stopper bolt to find out the position where the engine delivers the rated out- put (@) After adjusting the stopper bolt, back it off slowly while observing the engine 1pm. Stop backing off the stopper bolt just when the engine rpm begins to decrease from the rated level and secure it in that position with its lock nut. (©) At this time, the speed control lever should be in the maximum speed posi- tion. (©) Turning the full-load stopper bolt clock- wise will increase the injection quantity (engine output), and vice versa. TESTING AND ADJUSTING -406022| Setting idle sub-spring adjusting screw Setting rack (maximum output) 406023 33TESTING AND ADJUSTING 4 Set the governor (maximum rpm). (a) Apply full load to the engine and hold the speed control lever at the position for the indicated maximum rpm. (b) Set governor set bolt © (maximum G) speed set bolt) at the position for the indicated rpm. Adjust the speed regulation (make gover- nor notch adjustment), (a) This adjustment is to be made by turn- (o) © @) © 34 ing adjusting screw © for swivel lever @ to increase or decrease the preload of the governor spring, To gain access to the adjusting screw, remove the plug at the top of the gover- nor housing. Tum the speed control lever all the way to the low idle posi- tion: this will turn up the swivel lever, pointing the head of the adjusting screw toward the plug hole. Insert a flat-tip screwdriver through the hole to catch the screw head. Tightening the adjusting screw will narrow the speed regulation; loosening it will widen the regulation. One notch corresponds to 1/4 tum of the adjusting screw and to 3 to 5 rpm change of the engine speed. Changing the setting of this adjusting screw changes the governor setting (for limiting the maximum rpm). After making a governor notch adjustment, be sure to readjust the governor setting, as explained in (4), above. Tightening the adjusting screw, men- tioned above, will increase the maxi- mum rpm, and vice versa. Adjusting speed regulation 408925| Never loosen the adjusting screw by more than 20 notches (5 turns) from the fully tightened position, or the control action of the governor will become hazardous. eee (7) Seal the set bolts, 1,5 V-belt inspection and adjustment Push the belt inward with thumb pressure exerted midway between the pulleys, as shown, to check the belt tension (deflection). If the tension is incorrect, loosen the adjusting bracket bolt and mounting bolt, and move the alternator in or out. TESTING AND ADJUSTING Unit: mm (in) Tem ‘Assembly standard 901348 Fan belt deflection 1205), approx. Checking fan belt 35TESTING AND ADJUSTING 2. DYNAMOMETER TEST (BREAK-IN OPERATION) An overhauled engine should be tested on a dynamometer. This test is also for “break-in” of the major running parts of the engine. 2.1 Starting the engine See (1) Start the engine, 1.4 No-load minimum (low idle) rpm and maximum rpm setting. 2.2. Inspection after starting the engine After starting the engine, check the following items. Upon discovery of any faulty condition, immediately stop the engine and investigate for the cause. (1) Engine oil pressure — Should be 3 to 5 kgf/em? (43 to 71 psi) (294 to 490 kPa] when the engine is running at rated speed. It should be 1 to 2 kgf/cm? (14 to 28 psi) 198 to 196 kPa] when the engine is run- ning at low idle rpm, 2) Coolant temperature — Should be 75°C to 85°C (167°F to 185 °F) (3) Engine oil temperature — Should be 60°C 10 95°C (140°F to 203°F), (4) Check to make sure no oil, coolant or fuel leaks are present. (5) Knocking — Should die away as the coolant temperature increases. No other defects should be noted. (6) Check for abnormal exhaust smoke and smell. 2.3 Dynamometer test conditions [Sar —Sear aa [ H 1 1000 No-load 30 Ht asp _ a a a 36 2.4 Inspection after break-in operation (a) Check on and around the engine for loose bolts or nuts. (b) Check and adjust the valve clearance. (©) Check the adjust the V-belt tension. 3. PERFORMANCE TEST 3.1 Standard test conditions ‘The engine should be equipped with fan, air cleaner and alternator. 3.2 Tests to be conducted (1) Fuel consumption test (2) No-load maximum rpm test (3) No-load minimum rpm test 3.3 Items to be tested (1) Fuel consumption test (@) Rpm (b) Injection quantity (©) Output power (2) No-load maximum rpm test For this test, the governor should be set for no-load maximum rpm. (3) No-load minimum rpm test (@) The speed control lever should be held in the position for stable minimum rpm. By “stable minimum rpm” is meant a minimum level to which the engine rpm can be quickly dropped from the maxi- ‘mum rpm without stalling. (b) Specified no-load minimum rpm (4) Others During the performance test, check for gas, coolant or oil leaks, abnormal sound and hunting.ENGINE ACCESSORY REMOVAL AND INSTALLATION ] L.REMOVAL «2.20.0. 0eeeeeeeeeee see ee eee eee 5 7 38 2AINSTALLATION «2.2.0... ee 0 Beeee Ee Ee eRe see eralENGINE ACCESSORY REMOVAL AND INSTALLATION This section explains the procedures for removal and installation of the engine acces- sories — the preparatory steps to go through for overhauling the engine. 1. REMOVAL Start by: (@) shut off the fuel supply and disconnect the starter system from the engine (b) remove the drain plug on the left rear side of the crankcase and drain the coolant (©) remove the drain plug of the oil pan and drain engine oil (cies the oil sampled from the engine for metallic particles and other contaminants. rts Hot oil can cause personal injury. | (1) Exhaust manifold removal Remove the bolts that hold exhaust manifold © to the cylinder head. Remove the manifold and gasket ® from the head. (2) Fuel filter removal (@) Disconnect fuel pipes © and @ from the fuel filter. (b) Remove fuel filter assembly © com- plete with bracket @ from the engine, 38 Removing fuel filter(3) Fuel injection pipe removal (a) Remove pipe clamps ® and disconnect injection pipes @ from the injection pump and nozzle holders. (b) Disconnect leak-off pipe @. (©) Disconnect return pipe ® Be sure to install rubber caps to the openings of the injection pump and nozzle holders to keep dust out. P J (4) Inlet manifold removal (a) Remove the bolts that hold inlet pipe © and remove the pipe. (b) Remove the bolts that hold inlet mani- fold ® to the cylinder head. Remove the manifold and gasket @ from the cylinder head. (9) Fuel injection nozzle removal Remove injection nozzle @ and gasket @ from the cylinder head. (6) Glow plug removal Remove connection plate @ and glow plugs ® by removing nuts O. ENGINE ACCESSORY REMOVAL AND INSTALLATION, 407187 407198 Removing glow plugENGINE ACCESSORY REMOVAL AND INSTALLATION (7) Fuel injection pump removal (a) Disconnect oil pipe @ from the injec- tion pump. (b) Remove bracket ® from the engine. (©) Remove bolts ® that hold the gear case cover. (d) Remove bolts @ that hold injection pump ®, and remove the pump com- plete with gear @ and mounting flange from the front plate. (8) Oil filter removal Remove oil filter © with a filter wrench. (9) Alternator removal (a) Disconnect hamess from alternator ©. Disconnect oil pipes and ®. Remove bolt @ that holds the V-belt adjusting plate. (b) Remove bolts @ that hold the alternator and remove the alternator from the en- gine. (©) Remove V-belt ®. (10) Water pump removal (a) Remove the bolts that hold pulley ® and remove the pulley. (b) Remove the bolts that hold water pump @ , and remove the pump and gasket @. 40 406833 497190 | Removing water pump 407192](11) Starter removal Disconnect harness from starter @ Remove mounting nuts @ and remove the starter, 2, INSTALLATION Follow the reverse of removal procedure and do the following steps: (a) Fill the engine with recommended engine oil up to the specified level. (b) Fill the engine with coolant. (©) Check each line for oil or coolant leaks. ENGINE ACCESSORY REMOVAL AND INSTALLATION Removing starter at42ENGINE PROPER 4d 1.CYLINDER HEAD AND VALVE MECHANISM 1.1 Disassembly 44 1.2 Inspection wee 46 1.3 Assembly ........6 53, 2. FLYWHEEL 2.1 Disassembly ... 55 2.2. Inspection 37 2.3. Assembly we 5D 3. DAMPER, TIMING GEARS AND CAMSHAFT 3.1 Disassembly . see eee cette eee eee ve eeeeeees OL 3.2. Inspection 65 3.3, Assembly, 69 4, PISTONS, CONNECTING RODS, CRANKSHAFT, CRANKCASE AND TAPPETS 4.1 Disassembly . oe 4.2 Inspection ........ cence 1 4.3 Assembly - 90ENGINE PROPER, 1. CYLINDER HEAD AND VALVE MECHANISM Ld | [oefrctrd ct. 44 Disassembly ‘Check treads for sping ‘Check push od contact face for wear ck or wear or ‘logged of ole Replace Cheek for wees Lf LU Check for uneven wear. ‘heck face for png oF Hin (exhaust valve) Check stem for Scratching or sculfing. © Rocker cover @® Adjusting screw @® Bolt (shon) @® Bolt (long) Remove © through @ as an assembly, @® Rocker shaft bracket © Snap ring © Inket valve rocker arm @ Exhaust valve rocker arm © Rocker shaft spring @ Rocker shaft ® Valve cap ® Valve push rod @ Cylinder head bolt Remove @ through @® as an assembly. ® Cylinder head Check valve cap contact face | for wear” Check ol hole for log "| tb ‘Chock end faces for wear. | | Check for tend ® Valve cotters @® Valve retainer ® Valve spring & Valve @ Valve stem seal @ Cylinder head gasket(1) Rocker shaft assembly removal (a) Loosen the adjusting screw one turn. (b) Loosen the bolts, long and short, that hold the rocker shaft bracket to the cylinder head. Be sure to loosen the short bolt first. Remove the rocker shaft assembly from the cylinder head. | If the long bolt is loosened first, the rocker shaft bracket might suffer damage (2) Rocker shaft assembly disassembling After the rocker shaft assembly has been disassembled, all parts should be marked or set aside separately in groups, each marked for its location, so that the same clearance as before can be obtained between the rocker shaft and each bushing at the time of assembly. (3) Cylinder head removal Remove the bolts that hold the cylinder head. Lift off the cylinder head from the crankease. NOTE = | a) When removing the gasket from the crankcase, be careful not to damage the | | gasket contact surface of the crankcase. b) If any cylinder head parts are faulty, | check the cylinder head bolts for torque | with a torque wrench before removing them. Le" ENGINE PROPER Removing cylinder head 45ENGINE PROPER, (4) Valve and valve spring removal (a) Using Valve Spring Pusher (A) (special tool) (30691-04500), compress the valve spring and remove the valve cotters. (b) Remove the valves and valve springs. ——— (rore If the existing valves are to be reused, mark them for their locations to insure the ori | nal combination of the valve, valve seat and | valve guide at the time of assembly. 1.2 Inspection Rocker arms, rocker bushings and rocker shaft (1) Clearance between rocker bushings and shaft Measure the inside diameter of each rocker bushing and the diameter of the rocker shaft as shown in the illustration to find the clearance. If the clearance has reached the service limit, replace the rocker arm. If it has exceeded the limit, replace both arm and shaft. Unit: mm (n.) Tem [Nominal] Assembly ] Service Size | —sandard_| “limit Inside diameter | | 19.010 wrest jee bushing. (0.748 42 10 | ag | 034921) (0.75) 118,980 10 Diameter of 19.000, | rocker shaft | (0.787 26 0 0.74863) Clearance 001000 between rocker 0050, 0.070 bushing and (0,000 39 0 (0.002 76 shat ! 0.001 97) 46 Removing valve and valve spring Measuring rocker shaft and bushingValves, valve guides and valve seats (1) Diameter of valve stem Measure the diameter of the valve stem as shown in the illustration. If the stem is worn in excess of the service limit or unevenly worn excessively, replace the ENGINE PROPER valve. Unit: mm (in.) Mae Par we | eal oli of valve |g [0313 19) stem | 0.31) |7.920 to valve | (0.311 81 to) (0.309 05) | less (2) Clearance between valve stem and valve guide The valve guide wears more rapidly at its both ends than at any other parts. Meas- ure the inside diameter of the guide at its ends as shown in the illustration t0 find the clearance. If clearance has exceeded the service limit, replace the valve or guide whichever is excessively worn. Unit: mm (in.) [Nominal] Assembly | Service T 1 0.055 10 | 0.085, 0.150 | (0.002 17 to| (0.005 91) | _|o.003'35)” 0.07010 | 0,105 0.200 (0.002 76 to | (0.07 87) 0.00413) | Height to top of | 14 +03, valve guide (0.55) | (0.012) | (3) Valve guide replacement (a) To replace the valve guide, remove it with Valve Guide Remover (special tool) (32491-00300). Measuring valve stem Measuring. Measuring valve guide SS cess) Removing valve guide 47ENGINE PROPER, (b) To install a new guide, use Valve Guide Installer (special tool)(32A91-00100). ———rexurion}-— The height to the top of the valve guide is | specified; be sure to use the valve guide in- staller to insure the correct height. (4) Valve face Pot a small amount of Prussian blue or red lead on the valve face and, using a valve lapping tool, check the valve contact with its seat. If the contact is not uniform, repair or replace the valve. Measure the valve face (seat) angle, valve sinkage and valve seat width. If any of these items exceeds the service limit, reface or replace the valve and valve seat. I | a) Check the valve face after checking and | replacing the valve guide. b) Do not rotate the valve coated with Prussian blue when pressing it against the seat. | ©) After refacing or replacing the valve or the valve seat, be sure to lap the valve in Loth ‘See (8) Valve lappit the seat. (See (8) Valve lapping.) ) Unit: mm (in.) i Assembly | Service standard imi | ‘Angle ow TU - 04202 | g (0.016 * 0.008) | 2 | Valve Gini) | 10 2 | sinkage 05203 | (0.039) 3 | (0.020 = 0.008) - (exhaust) 142014 18 |___ Wish | @085 0.0055) | _ amy 213 Up 101.83 Valve margin (ovass) | (0072) by refacing 48 14mm 5S), Valve lapping - _ 400088 Valve contact pattern Valve seat wieth | | Valve seat angle | Valve margin Valve sinkage 403636 |(5) Valve refacing If the valve face is badly worn, reface it with a valve refacer. a) Seta valve refacer to an angle of 30°. b) The valve margin should not exceed the service limit after the valve has been refaced. If the margin seems to exceed the limit when refaced, replace the valve. (6) Valve seat refacing Using a valve seat cutter or a valve seat grinder, cut the valve seat. After cutting, gzind the seat lightly with a sandpaper of #400 grade or so inserted between the cutter and valve seat. ——_——__ a) Cut or grind the valve seat only as nec- | | essary for refacing. | b) If the seat width seems to exceed the | service limit when refaced, replace the valve seat. a (7) Valve seat replacement (a) Weld a stud to the existing valve seat. Insert a bar into the valve guide from the upper side of the cylinder head to put its tip on the stud, and remove the seat from the head. fon {Note} | When welding the stud to the valve seat, be | careful not to permit spatters to come in contact with the machined surfaces of the cylinder head. ENGINE PROPER PF SF oka Refacing valve seat | O=v | Removing valve seat 49ENGINE PROPER, (b) Before installing new valve seats in the cylinder head, measure the bores in the cylinder head for the valve seats to make sure their dimensions are correct. (©) Chill the valve seat in liquid nitrogen to approximately —170°C (-274°F) for more than 4 minutes with the cylinder head kept at normal temperature, or heat the cylinder head up to 80°C to 100°C (176%F to 212°F) with the valve seat chilled in ether or alcohol containing dry ice. (@) Using Insert Caulking Tool (special tool), drive the seat into position. Insert caulking tools For inlet valve seat 36791-00200 For exhaust valve seat 34491-03020 (8) Valve lapping ‘After refacing or replacing the valve seat, be sure to lap the valve in the valve seat. (a) Put a small amount of lapping com- pound on the valve face. ) Do not put the lapping compound on the valve stem. b) Use a compound of 1200 150 mesh for initial lapping and a compound of finer than 200 mesh for finish lapping. ©) Mix the compound with a small amount of engine oil to facilitate putting the compound on the valve face. J 50 Inlet valve Exhaust valve seat bore Valve seat dimensions Installing valve seat Putting lapping compound ‘bore 01333 Lapping compound | 400065(b) Using a lapping tool, hold the valve against the seat and rotate it only a part of a tum, then raise the valve off the seat, rotating it to a new position. Then press the valve against the seat for another part of a tum. Repeat this operation until the compound wears and loses it cutting property. (©) Wash the valve and valve seat with kerosene. (4) Put engine oil on the valve seat and again lap the valve in the seat. (e) Check the valve face and valve seat for contact. Valve springs Check the free length, squareness and force of each spring as shown in the illustration. If any of the specification items has exceeded the service limit, replace the spring. Unit: mm (in.) — ‘Assembly Service standard | Timit__| Free length 48.85 (1.92) _| 47.60 (1.87) Squareness _|_1.5°, maximum =| Length under | be oe 43.01.69) 43.(2.69) j 181020 15 Test force, Aeoan ea) xetaoihy | dttioise | det ENGINE PROPER Valve lapping wool ° 2 SAAS Sas Lapping valve “ Checking valve spring 2 51ENGINE PROPER, Cylinder head Using a heavy accurate straight edge and a feeler gauge, check the gasket contact surface for warpage in two positions lengthwise, two crosswise and two widthwise as shown in the illustration. If the warpage exceeds the repair limit, reface the head with a surface grinder. Unit: mm (in) | Assembly] a | 'sandard | ‘Warpage of gasket 0.05 (0.0020),) 0.20 contact surface maximam "| (0.0079) Valve push rods ‘Measure the push rod runout with a V-block and a dial indicator as shown in the illustration, If the dial indicator reading exceeds the assembly standard, replace the nush rod. p Unit: mm Gin.) Trem “Assembly standard Runout (ial indicator reading) of valve push | 03 (0.012), maximum 52 Checking cylinder head warpage Checking valve push rod bending1.3. Assembly (1) Valve stem seal installation After installing the valve in position, install the stem seal to the valve guide with Stem Seal Installer (special tool) (32A91-10200). a) Do not apply any oil or retaining com- pound to the face of the stem seal that comes in contact with the valve guide. When installing the seal, apply engine oil to the seal contact surface of the stem to insure initial lubrication of the lip of the seal. b) Do not remove the valve after the seal has been installed in position to prevent damage to the seal lip (2) Valve and valve spring installation (a) Put the valve spring and retainer on the valve guide. Using Valve Spring Pusher (special tool) (30691-04500), compress the valve spring and install the valve otters, (b) Hit the valve stem top with a plastic hammer several times to make sure the valve spring and cotters are properly installed. (3) Cylinder head installation (@) Put the gasket on the crankcase, making sure two dowel pins enter their hole in the gasket () Put the cylinder head on the crankcase, making sure two dowel pins enter their hole in the head. -———(enttion} —— Do not use any gasket adhesive. Make sure the gasket contact surface of the crankcase is free from any defects. ENGINE PROPER Valve ave sem aia Valve guide | Installing valve stem seal Valve spring pusher Installing cylinder headENGINE PROPER (©) Tighten the cylinder head bolts to the specified torque in number sequence. Tango” | a7 22 Re = (4) Rocker shaft and arm assembling After assembling the rocker shaft and arms, make sure the arms move freely. (5) Rocker shaft assembly installation (@) Install the valve caps in position. (b) Put the rocker shaft assembly on the cylinder head and tighten the bolts that hold the rocker shaft brackets to the specified torque. roeker shaft bo 4 tbe) i T 1520.5 kfm Tightening torque for | TO A 's [is £5 Nm) > ‘When securing each rocker shaft bracket, be sure to tighten long bolt 1 and short bolt 2 in that order. (6) Valve clearance adjustment Refer to page 28. 54 302078 40so4s 1g rocker shaft and arms wore) Installing rocker shaft assembly Adjusting valve clearanceENGINE PROPER 2. FLYWHEEL 2.1 Disassembly (FD35 thru FDS) ous | © Flywheel @ Rear plate @ Oil seal 55ENGINE PROPER (FD60 and FD70) 9 @ ug (Check for rotation. forwor or arecave a | ® ~ ~~ 407477 @® Flywheel ® Rear plate ® Oil seal 56(1) Flywheel removal (a) To remove the flywheel, use two men — one holding the crankshaft at the pulley with a wrench or the like to pre- vent the flywheel from turning, the other removing the flywheel bolts. (b) Remove the bolts that hold the flywheel to the crankshaft, and remove the fly- wheel. (2) Rear plate removal Remove the bolts that hold the rear plate to the crankcase, and remove the rear plate. ———{@caution}— (0. rot cause damage tothe oil sel 2.2 Inspection Flywheel and ring gear (1) Flatness (difference between lower and higher measurements) of flywheel Put the flywheel on the surface plate. Set a dial indicator at one side of the friction surface and move it over to the opposite side of that surface as shown in the illus- tration. If the flatness has exceeded the repair limit, regrind it. Unit: mm (in.) m™ ‘Assembly Repair ie standard Timit Flatness of flywheel] 0.15 (0.0059), | 0.50 friction surface maximum (0.020) ENGINE PROPER, 407195 Removing flywheel 407196 Removing rear plate 401758 Measuring flywheel flatness 57ENGINE PROPER (2) Face runout (axial eccentricity) and bore runout (radial eccentricity) of flywheel Set a dial indicator at the friction (vertical) surface and tum the flywheel one full revolution to check the face runout. Set a dial indicator at the horizontal surface of the pilot bearing bore and turn the fly- wheel one full revolution to check the bore runout. Excessive runout of the flywheel in either position will probably be caused by dirt in the mounting face or improper tightening of the bolts. Check for pres- ence of dirt and improper bolt tightening. Unit: mm Gin.) Assembly Repair ea ‘standard Timit Facefbore runout of | 0.150.005 9), | 0.50 fywhee! maximum (0.020) (3) Ring gear replacement Check the ring gear teeth and, if they are defective, replace the gear as outlined below. (Removal) (a) Heat the ring gear evenly with an acety- lene torch. (b) Hit the ring gear all the way around with a bar and a hammer to remove it from the flywheel. (installation) Heat a new ring gear up to 100°C (212°F) with a piston heater, and install the gear to the flywheel with the unchamfered side of the teeth. toward the flywheel. Do not heat the ring gear more than 100° (212°F). 58 aozr79 Measuring flywheel runouts Removing ring gear Two types of the oil seal are available for the present engine, one being of single-lip type (for the engine with the dry clutch and. torque converter) and the other being of double-lip type (for the engine with the wet clutch).2.3 Assembly (1) Oil seal installation Apply a thin coat of grease to the oil seal and, using an installer, install the oil seal to the rear plate with the lip of the seal toward the engine, = ‘Two types of the oil seal are available for | the present engine, one being of single-lip | type (for the engine with the dry clutch and | torque converter) and the other being of double-tip type (for the engine with the wet clutch) — woe) ——— If the oil seal contact surface of the crank- shaft is excessively worn, replace the oil seal with an oil seal with sleeve, Sleeve installation To install the sleeve, apply oil to the in- side surface of the sleeve and, using Oil Seal Sleeve Installer (special tool) (30691- 13010), drive the sleeve into position. Do not cause damage to the outside surface of the sleeve. ENGINE PROPER For the engine — Rear plate with wet clutch Apply a thin coat of grease. Engine side Fiywheel side Oil seal | _ 407197 Installing oil seal (double-lip type) For the engine — Rear plate feth dry ebtch andionpe Aly anc convent Tee Engin side Pywbed side | il seal LI aor Installing oil seal (single-lip type) =, Sleeve installer A {9 407458 Installing oil seal sleeve 59ENGINE PROPER, (2) Rear plate installation (a) Apply engine oil to the lip of the oil seal. (b) Put the rear plate and gasket in position on the crankcase, making sure the dowels are in alignment, (b) Tighten the bolts that hold the rear plate to the specified torque. 35205 kghm Tightening orque for | 332.05 kee rear plate bolts Brine 407 Installing rear plate If the oil seal contact surface of the crankshaft is excessively worn, use the il seal sleeve for installing the rear plate. (3) Flywheel installation (a) Put the flywheel in position on the crankshaft, making sure the dowels enter their holes in the flywheel. () Hold the crankshaft as in case of re- moving the flywheel, tighten the fly- wheel bolts and washers to the specified — Tightening worqe for | 85205 ayeact ois | GEER Z\caution a ‘One man holding the crankshaft should give the other man a sign to install the flywheel to avoid personal injury. 60 | \e | | sos060| Installing oil seal sleeve on worn crankshaft roy it seal Installing flywheelENGINE PROPER, 3. DAMPER, TIMING GEARS AND CAMSHAFT 3.1. Disassembly ‘Check for cracks or Jefective dowel holes, Seek =m] soreee ® Damper © Timing gear case Remove @ through @ as an ©® Crankshaft pulley © Oil pump gear assembly. ® Cover © Thnist plate @ Camshaft @ Fuel injection pump @ Idler gear @ Camshaft gear © Oil pan © Thrust plate © Front plate © Oil seal 61ENGINE PROPER, (1) Damper removal (a) Screw two safety bars (M12 x 1.25) in the rear end of the crankshaft. Put a bar between the safety bars to hold the | crankshaft. (b) Remove the damper by removing the bolts. EMD o There is the possibility of the safety bars 407455} slipping off the crankshaft. Be on stand- Removing damper by to act when the bars slip off. (2) Crankshaft pulley removal (a) Screw two safety bars (M12 x 1.25) in the rear end of the crankshaft. Put a bar between the safety bars to hold the crankshaft. (b) Remove the pulley from the crankshaft by removing the nut. rc ro There is the possibility of the safety bars ——_______--_. lenses off the crankshaft. Be on stand- Removing crankshaft pulley 407466 by to act when the bars slip off. (3) Oil pan removal Remove the bolts that hold the oil pan, and remove the oil pan. (4) Timing gear case assembly removal Remove the timing gear case assembly as shown, (pe not cause damage to the oil seal. Removing timing gear case 62ENGINE PROPER (5) Gear backlash and end play measurement Measure the back lash and end play of the gears to aid in replacing the parts. (6) Oil pump gear removal Remove the nut with washer that holds the oil pump gear, and remove the gear. 407467 (7) Idler gear removal Remove the bolt with washer that holds the thrust plate, and remove the idler gear. Removing idler gear (8) Camshaft removal (a) Turn the crankcase upside down. (b) Position the camshaft gear so that its lightening holes are at top and bottom. Remove the bolts that hold the thrust plate. Remove the camshaft from the ‘orankcase. | Do not cause damage to the lobe faces of the \ camshaft and the bushings. Removing camshaftENGINE PROPER (9) Camshaft gear removal Remove the gear from the camshaft with a puller. Now the thrust plate can be removed. (wore Do not remove the camshaft gear and thrust plate unless they are damaged to the extent of requiring replacement. (10)Front plate removal Remove the bolts that hold the front plate to the crankcase and remove the front plate. 64 Removing camshaft gear Removing front plate 6700 4071694]3.2. Inspection ‘Camshaft and camshaft bushings (1) End play of camshaft ‘Measure the camshaft end play as shown in the illustration. If the end play has exceeded the service limit, replace the thrust plate. Unit: mm (in.) ENGINE PROPER “Assembh Service io standard iimit, End play of 0,10 10 0.25 030 camshaft” | (0.0039 10 0.0098) | (0.011 8) (2) Lobe lift of camshaft To find the lobe lift, use the procedure that follows: (@) Measure lobe height (A). (b) Measure base circle (B). (©) Subtract base circle (B) from lobe height (A). The difference is lobe lift (C). If the lobe lift has exceeded the service limit, replace the camshaft. Unit: mm (in.) Nominal [Assembly] Service Kem Size | standard | limit Inlet vy |, 6584, | 6184 9168 | valve : 2483 4 Sa cep (0263 15) [0.243 46 3S} sxtaun [42 6.720 | 6.220 aust ay | 83 ¥ A | valve | £68005, lc0264 57| 0.244 88) { (1.845 6798805 l — Measuring di 670338 65ENGINE PROPER, (3) Runout of camshaft Support the camshaft on its front and rear journals in V-blocks. With the dial indi- ator set at 0.00 mm (0,000 0 in.) at the center journal, turn the camshaft full one revolution and read the indicator, as shown in the illustration, 1/2 of the reading on the indicator is runout of the camshaft. If runout has exceeded the repair limit, straighten the camshaft by cold working, or replace it. Unit: mim Gin.) tem ‘Assembly Repair standard limit Runout of | 0.02 (0.0008), 005 camshaft | _ maximum (0.002 0) (4) Clearance between camshaft journals and bushings Measure the diameter of the camshaft journals and the inside diameter of the bushings in the crankcase to find the clearance. If the clearance has exceeded the service limit, replace the bushings. Unit: mm Cin.) ‘Assembly | Service a standard | limit No 3] 5394105396 | 53.90 Diameters | No. 3 | (2.123 6 wo 2.124 4) | 2.1220) journals | g| , 52.98 52.96 | 52.90 » 4 | (2.0842 to 2.685 0) | 2.082 7) O15 Clearance between 0,040 100.119 | (0.005 9) SRAM ooh 1 loon) em ion 66 — ___ e274 Measuring camshaft bending ‘Measuring diagram On Rs | & XO ens] Measuring camshaft journals Measuring camshaft bushings(5) Camshaft bushing replacement (a) To replace the camshaft bushings, use Camshaft Bushing Installer Set (special tool) (30691-00010). (b) Install a new bushing with its oil hole aligned with the hole leading to the oil gallery. Timing gears Backlash measurement Put a dial indicator on each gear (camshaft gear, idler gear, crankshaft gear and injection pump gear) along its pitch circle as shown. Hold it tightly in place. Move one of the mating gears back and forth to check the backlash. If the backlash exceeds the service limit, replace the gears. Unit: mm (in) ]__ Assembh Service cd Standard | limit 0.03 100.17 025 oe (0.001 2 to 0.006 7), (0.009 8) Idler gear, bushing and shaft (1) Idler gear end play measurement Measure the idler gear end play with a feeler gauge or a dial indicator as shown in the illustration. If the end play has ENGINE PROPER Ny, ic im =|. Tite sete Tie | ONS Replacing camshaft bushing __ nn exceeded the service limit, replace the thrust plate. Unit: mm (in.) = ‘Assembly | Service he standard Timit _ End play of idler | ~0.0510020 | 0.35 Measuring idler gear end play gear (0.00200 to 0.007 9)| (0.013 8) 67ENGINE PROPER, (2) Clearance between idler gear bushing and shaft Measure the inside diameter of the bushing and the diameter of the shaft to find the clearance. If the clearance has exceeded the service limit, replace the bushing. Unit: mm (in.) tem Assembly | Service standard Timi Clearance between 0.009 10 0.050. | 0.100 idler gear bushing A breed {0.000 35 to 0.001 97)| (0.003 94) (3) Idler gear bushing replacement (a) To replace the bushing, use Idler Gear Bushing Puller (special tool) (30091- 07300). (b) Force a new bushing into the idler gear until its end is even with the end face of the gear boss. (4) Idler gear shaft replacement To remove the idler gear shaft for replacement, use Idler Gear Shaft Puller (special tool) (MH061077). Crankshaft pulley Check the groove for the V-belt for wear. To check, wrap a new belt around the pulley. Press it in the groove as far as it goes and see if the top surface of the belt is above the top of the pulley. If the top surface of the new belt is uniformly above the top of the pulley all the way around, it is not necessary to replace the pulley. If the top surface of the new belt sinks into the groove more than 1.6 mm (0.06 in.), replace the pulley. 68 _ some Measuring clearance between idler gear bushing and shaft later gear _me me watts | = Replacing idler gear bushing | _ rons Removing idler gear shaft Lomm | (oem) soors0 Checking V-belt groove3.3 Assembly (1) Front plate installation (a) Put the gasket on the crankcase, making sure the dowels enter the holes in the gasket. (b) Tighten the bolts that hold the front plate to the crankcase to the specified torque. ] 10013 kgtm Tightening org for from plate bo oan, (© Cut the gasket even with the bottom face of the crankcase, (2) Camshaft gear and thst plate installation Heat the camshaft gear for installation, Have the thrust plate installed in advance. (3) Camshaft installation (@) Apply engine oil to the lobes and jour- nals of the camshaft. (>) Carefully put the camshaft in the bore in the crankcase. (©) Tighten the bolts that hold the thrust plate to the specified torque. Twa kgf Tigheningionue or | TOOTS Betpae bas | sesMe Do not cause damage to the lobes and bush- ings. Installing camshaft gear and thrust plate ENGINE PROPER 406977 ‘Camshaft gear WOE 4076s! Installing camshaft 69ENGINE PROPER (4) Idler gear installation (@) Put the idler gear in position with its marks in alignment with those on the injection pump drive gear, crankshaft ‘gear and camshaft gear. (b) Put the thrust plate in position and tighten the bolt to the specified torque. - T3205 erm Tignening ore or | 35 Basrpaeeans | @emiay (© With the marks on the timing gears in alignment as shown, the No. 1 piston is at top dead center on compression stroke. (5) Oil pump gear installation (a) Put the gear in position on the oil pump shaft. (©) Tighten the jam nut to the specified torque. Tightening orque for | 34495 ket Smoot G345N-m) (6) Inspection and adjusting after timing gear installation Timing gear backlash and end play After installing the timing gears, check the backlash and end play and, if necessary, adjust them. (Refer to page 67.) 70 Installing idler gear (Zz aN A~ . \\ Cy) > Y/ EZ | = “eatin pomp Co ‘rive gear —O) ee, 40570 Inspecting backlash and end play(7) Valve timing It is not necessary to check the valve timing if the timing gears are installed with the marks in alignment. Check the timing for verification as outlined below. (@) Using a 3 mm (0.12 in.) thick smooth steel plate, add 3 mm (0.12 in.) clear- ance to the inlet and exhaust valves of the No. 1 cylinder. (b) Put a 0.05 mm (0.0020 in.) feeler gauge between the top of the valve cap and the rocker, (© Slowly turn the crankshaft to find a position where the feeler gauge is firmly gripped (the valve starts opening) and a position where the gauge is just ungripped (the valve starts closing). (@) Check to make sure these positions coincide with the angular positions shown in the valve timing diagram with 3 mm (0.12 in.) clearance added to the valves. (8) Oil seal installation Apply a small amount of grease to the oil seal and install it to the timing gear case with an installer. ENGINE PROPER ‘Top dead center — a Direction of. mu 4 Inlet valve Exhaust valve 7 sc | Bottom dead center 401762) Valve timing diagram Valve timing diagram with 3 mm (0.12 in.) “Top dead center Direction of " Inlet valve | \ Exhaust valve Bottoms dead center 401763 | clearance added to valves Installing oil seal mnENGINE PROPER (9) Timing gear case installation (a) Put the gasket on the front plate, mak- ing sure the dowels are in alignment. (b) Apply oil to the lip of the oil seal. (© Tighten the bolts that hold the timing ‘gear case to the specified torque. 1.0 10 13 ktm ‘Tightening torque for timing gear case bots | {410 43ND) (10) Oil pan installation (a) Clean the mounting faces of the crank- case, timing gear case and oil pan. (b) Squeeze out Three Bond 1207C (32A91- 05100) in a thickness of 4 mm (0.2 in.) from the tube and put it on the oil pan flange. (©) Put the oil pan in position on the crankcase within 5 minutes after putting the Three Bond. (@) Tighten the oil pan bolts to the specified torque. 1.01013 ketm Tightening torque for 2 oil pan bolts| Beene 72 Installing timing gear case Oil pan flange surface Installing oil pan Cuthere, 408772 Gasket adhesive (Three Bond) tube(11) Crankshaft pulley installation Turn two safety bars (M12 x 1.25) in the rear end of the crankshaft. Put a bar between the safety bars to hold the crankshaft. Install the crankshaft pulley and tighten the nut to the specified torque. Dike Tihening wrqe or | Gog ARE Seely | Gee Tbe ENGINE PROPER rN There is the possibility of the safety bars ipping off the crankshaft. Be on stand- by to act when the bars slip of eee ee (12)Damper installation With the crankshaft held as for crankshaft pulley installation, install the damper in position. Installing crankshaft pulley Installing damper 73ENGINE PROPER 4, PISTONS, CONNECTING RODS, CRANKSHAFT, CRANKCASE AND TAPPETS. 4.1 Disassembly ‘carbon depos. ‘Check for a thread | Cheek for wear for racking, ‘Check fr pining, fisking, cupping. tracing, loss of overlay or signs of ovetheating [ Chaak forsale depot, cerrosion or ober Secs, | (Check for eating, scoring, wear or clogged ol ole Sa @ ts 2a RS 4 ee a MS re Check for sipped] Sead Pees NOTE: When placing the crankcase, carculy 2 Check fr ering remove the components (such as an oil pressure relief valve, et.) to reuse them, ONnut © Oil ring ® Side seal @® Connecting rod cap @® Snap ring @® Thrust plate © Connecting rod metal © Piston pin ® Main metal (lower half) Remove @ through @® as © Piston ® Crankshaft an assembly. ® Connecting rod ® Main metal (upper half) @ Top compression ring @® Metal cap bolt @ Tapper © Second compression ring Main metal cap ® Crankcase 74 [ Check fr wea, seoring, caching. damaged or] ‘idened rng grooves, elogged al dain holes or i = 407209(1) Connecting rod cap removal (@) Remove the nuts that hold the cap to the connecting rod. ‘Tap the ends of the bolts squarely and evenly with a hammer and, after the cap has come off the reamed portions of the bolts, remove the cap. (b) Mark the connecting rod bearings for cylinder number and location. (2) Piston removal Start by: a) lay the crankcase on its side b) remove carbon from the upper areas of the cylinders with a rag or sand paper. Carbon, if any, will make it difficult to pull the piston upward (@) Turn the crankshaft to bring a piston (from which the connecting rod cap has been removed) to top position. (b) Push the big end of the connecting rod with the handle of a hammer to remove the piston, (3) Remove piston rings To remove the piston rings, use Piston Ring Pliers (special tool) (31391-12900). ENGINE PROPER 405768 Removing carbon from cylinders an 405709 Removing piston Piston ring pliers Removing piston rings 75ENGINE PROPER (4) Piston pin removal (@) Using a snap ring pliers, remove the | snap rings from the piston. (b) Remove the piston pin to disconnect the piston from the connecting rod. (©) If it is difficult to remove the pin, heat the piston with a piston heater or in hot water to expand the bore for the pin. 401770 (5) Main metal cap removal Remove the bolts that hold the cap to the crankcase. Remove the cap with the lower half of the main metal. To remove the tearmost metal cap, use a puller. ~ (iste) — When removing the caps, do not cause damage to the lower halves of the main metals. The removed metals and caps should be set aside in groups, each marked for location, so that they can be installed in the same position. eee (6) Crankshaft removal Fasten a hoist to the crankshaft and lift the crankshaft in horizontal position. (7) Tappet removal Remove the tappets. Ccumtcsterme a mark on each tappet so that it can be installed in the same position, Removing crankshaft 764.2. Inspection Crankcase (1) Gasket contact surface Check the gasket contact (top) surface for warpage, using a heavy accurate straight edge and a feeler gauge, in three positions lengthwise, two crosswise and two widthwise as shown in the illustration. If warpage has exceeded the repair limit, grind the crankcase within the range of retaining the specified piston projection. Unit: mm (in.) “Assembh na standard Warpage of gasket | 0.05 (0.0020) contact sartve "| maximum (2) Inside diameter of cylinder (a) Measure the inside diameter of the cylinder at the top (ridged portion), middle and bottom, each in two diree- tions parallel and transverse to the ‘crankshaft, as shown in the illustration. Unit: mm in.) ‘Assembly | Repair | Service Le standard | Timit | limit Tnside 94.000 10 diameter of | 94.035 94.200 | 94.700 cylinder | (3.700 78 to | (3.708 65)| (3.728 34) sleeve 3.702 16) 0.01 Out-of-round} (0.000 4), ois Taper (0.000 59), maximum’ (b) If the cylinder has reached the repair limit, with the wear far less than the service limit, bore it o 0.25 mm (0.0098 in.) or 0.5 mm (0.0197 in.) oversize. (6) Hone the cylinder within an accuracy of 0.035 mm (0.00138 in.), and use the piston and piston rings of the same oversize. ENGINE PROPER, J i g 20 BAe Checking crankcase warpage ‘Measuring diagram De & Unit: mm Gn) Measuring cylinder 7ENGINE PROPER, (@) If any cylinder is unevenly worn, deter- mine the oversize on the basis of the maximum wear noted to insure perfect roundness in the oversized bore. Refinish all cylinders to the same over- size. If the cylinder is found in good condition, with the wear far less than the repair limit, replace the piston rings and ream off “ridge” at the top of the cylinder. Hone the bore if necessary. Pistons and piston rings (1) Diameter of pistons (a) Measure the diameter of the piston at skirt in the direction transverse to the piston pin with a micrometer as shown in the illustration, If the diameter has exceeded the service limit, replace the piston. Unie mm Gin) 7 Aseaby | Sevice say | Sine S 93.955 093.985 | 93.770 Boo | Standart [4.69901 103.100 198.691 72) 23 Wow | seco woes | vam E2 coms Tees eo thivos|onr sy 32/0) | sasswosas | s4270 2) 60109 lattes wai eniorit sn} 78 Measuring piston diameter Engine front FRONT mark on position aovr74(2) Clearance between ends of piston rings Put the piston ring in the gauge and measure the clearance between the ends of the ring with a feeler gauge as shown in the illustration. If the clearance has exceeded the service limit, replace all piston rings. Inside diameter of gauge: 94°}. 3.70°39138 y (6998) Use the piston to put the ring in the gauge squarely. J) Unit: mm Gin.) = “esembly | Service te standard | limit, No.1 Glearance | and No. | 03010050 | 4.59 Ceaser | 28n8s || Ont | 0891) Piston rings | Oi ping | ©9197) (3) Clearance between groove and piston ring Put a new piston ring in the groove. Measure the clearance between the groove and piston ring with a straight edge and a feeler gauge as shown in the illustration. If the clearance has exceeded the service limit, replace the piston. Unit: mm (in.) ‘Assembl Service a Standard | im Not] 0071011 | 0.200 Clearance |Fing_| (0.0028 t0 0.0043) |(0.007 87) between | No.2 | 0.045 100085 | 0.150 groove and| ring [0.001 77 to 0.003 35)|(0.005 91) Piston ing Toit | 0.02510 0065 | 0.150 Fing {0.00098 to 0.002 56)|0.005 91) ENGINE PROPER > CLE Measuring clearance between ends { 400050} Measuring clearance between groove and piston ring 79ENGINE PROPER, (4) Clearance between piston pin and bore for pin Measure the inside diameter of the bore for the piston pin and the diameter of the pin as shown in the illustration to find the clearance. If the clearance has exceeded the service limit, replace the pin or piston whichever is excessively worn. Unit: mm Gn.) Tem | Nominal | Asembly ] Servies Size | ‘standard | “limit 79.994 10 Diameter of | 30 | 30.000 piston pin. | (1-18) | (1.18086 to 1181 10) _ Clearance 0.000 to between S16 0.050, piston pin {0.000 00 | (0.001 97) and bore 0.000 63) _| (5) Projection of pistons Measure the piston projection as outlined below. If the piston projection is not correct, check the various paris for clear- ance. (a) Determine the top dead center of the piston with a dial indicator. (b) Install the dial indicator on the top of the crankcase. Set the indicator to read 0.00 mm (0.000 0 in.). (©) Measure the piston projection in at least three locations on the top of the piston and average the three measurements to find the projection. Subtract the projec- tion from the compressed thickness of the cylinder head gasket to find the clearance between the piston top and the cylinder head. ‘Unit: mm (in.) Tem Assembly standard — 02510 0.15 Piston projection (0.008 8 to 0.005 9) ‘Compressed thickness of cylinder head gasket 1.2 £0.05 404159 Measuring clearance between piston pin and bore for pin Measuring piston projection ——— @eauon)——_ Incorrect piston projection affects engine performance and causes valve interference with the piston,Connecting rods, connecting rod metals and piston pin bushings (1) Clearance between connecting rod metal and crankpin Measure the diameter of the crankpin and the inside diameter of the connecting rod metal as shown in the illustration to find the clearance. If the clearance has exceeded the service limit, replace the metal. If the crankpin is badly or un- evenly worn, grind the crankpin and use an undersize metal, 0.25 mm (0.009 8 in.), 0.50 mm (0.019 7 in.) and 0.75 mm (0.029 5 in.) underside connecting rod metals are available for service. NOTE! | To measure the inside diameter of the con- necting rod metal, install the upper and lower halves in the connecting rod and tighten the cap bolts to the specified torque. Usait: mm (in) aay Tapa | Sores ten | moe | eae | Si | Tiressw | Diameter of | 58 | 57.970 | 57.100 Samet | aby | Fer abdaiy| ot ° ‘| Gamer 00% Sct, | — |B" 9300 somite | — [foie obattn en) (Ss 2) Clearance between connecting rod bushing and piston pin Measure the inside diameter of the con- necting rod bushing and the diameter of the piston pin as shown in the illustration to find the clearance. If the clearance has exceeded the service limit, replace the pin or bushing whichever is badly worn. ~~ Measuring diagram _ ENGINE PROPER, SEz0S igi (oeanen) {St35Nel iN Measuring connecting rod metal Measuring diagram| sour ‘Measuring connecting rod bushing 81ENGINE PROPER, Unit: mm ¢in.) Nominal] Assembly | Service a Size | standard | limit Tasac dancer] ay [BOB | of connecting | 1g) | (1.181 89 10 eI 1.i8287) _| Clearance 002010 | eiweenpin, | _ |0081" | .080 and connecting (0,000 79 to |(0.003 15) rod bushing {0.002 01), (3) Connecting rod bushing replacement (a) Use Connecting Rod Bushing Puller (special tool) (MHO61236) to replace the connecting rod bushing. (b) When installing a new bushing. align the oil holes in the bushing and connect- ing rod. Position the ends of the bushing as shown in the illustration, (©) After installing the bushing in position, put the piston pin in position and make sure the pin stides freely. (4) Bending or twisting of connecting rod (@) Measure “C” and“ £.” If the measure- ment at “C” is more than 0.10 mm (0.0039 in.) per 100 mm (3.94 in.) of “2,” straighten the rod with a press. Unit: mm (in.) ee 0.10/100 5. often ed | ORSB99. | soy (b) A connecting rod aligner is generally used for checking the connecting rod for bending or twisting. (nore) To check for bending, install the metal =| to the connecting rod and tighten the cap nuts to the 5.5 0.5 kgfim (404 4 Ibf- ft) 4 (S425Nem), 82 Matching m: Oit hole Ends of bushing _ _ 408708 Installing connecting rod bushing Unit mm Gn) cL @ c 010 00s, nh 400110 Measuring connecting rod bending and twisting Checking connecting rod on a connecting rod aligner(© To check the rod complete with the pis- ton, put the piston on the surface plate, put a round bar identical with the crank- pin in diameter in the big end bore and ‘measure the heights “A” and “B” of the bar with a dial indicator. (5) Connecting rod metal inspection Check each metal for loss of overlay, scratching, burning, pitting or other de- fects. Replace defective metals if any. (© End play of connecting rods Install the connecting rod to the mating crankpin by tightening the cap nuts to the specified torque. Measure the end play (Clearance between the rod and crank arm) with a feeler gauge as shown in the illus- tration. If the end play has exceeded the service limit, replace the connecting rod. Unit: mm (in.) ‘Assembly Service ee End play of 0.15 100.35 0.50 Connecting rod |(0.005 9 v0 0.0138) | (0.020) ENGINE PROPER 401781 Scratching \) i sii) \ \ a | Failure due to ‘poor seating 40112 Measuring connecting rod end play 83ENGINE PROPER, Crankshaft (1) Diameter of journals Measure the journal with a micrometer as shown in the illustration to find wear, out- of-round, taper and clearance between the bearing and journal. If any measurement has exceeded the repair limit, grind the crankshaft to an undersize. If it has exceeded the service limit, replace the crankshaft. Unit: mm (in,) tem Nominal] Assembly] Repair | Service size | ‘standard | limit | limit 177.9550 Diam | 78. [77970 | 77.850 | 77.100 eter of || (3.07) |(3:069 09 tol(3.064 95)| (3.035 43) i 3.069 68) Out-of- oni round 0.03 aa 0.000 4). | (0.001 2) (2) Diameter of crankpins Measure the crankpin with a micrometer as shown in the illustration to find wear, out-of-round, taper and clearance between the metal and crankpin. If any measure- ‘ment has exceeded the repair limit, grind the crankshaft to an undersize. If it has exceeded the service limit, replace the crankshaft. 84 Measuring diagram 4 I t Measuring journals Measuring diagram Kf | | I | ce Measuring crankpinsENGINE PROPER, Unit: mm (in) cm Repair a iimit 31955 Dapewrot | se 57870" || sco, one ) | dsr 09 0 |e | Sm) | oor | | 093 (0.0004). | @.001 2) maximan (3) Grinding Crankshaft grinding dimensions Tor undersize bearings When grinding the journals and crankpins, Unit: mm Gin) be sure to insure the same radius of fillet Undersize | Grinding dimension and width as the original ones. They nz FTa0s TT should have a hardness of 620 or more in (0.009 8) (3.059 25 to 3.059 84) terms of Vickers Hardness Number. 1f | Journals | 0.80 77455 wo 77.470 necessary, re-harden the journal and 0.0197) _| 6.049 40 10 3.049 99) crankpins. Test the crankshaft for crack- 0.75 77.205 to 77.220, ing by a magnaflux (magnetic particle) (0.029 5)_| (3.039 56 to 3.640 15) method. 025 51.105 to 57.720 (0909.8) | @.271'85 10237244) upins | 050, 57.455 10 57.470, Ceamkpins | (0.0197) | 2.26200 wo 2.262 59) 075 57,205 to 57.220 (0.0295) _| 2.252 16 0 2.35275) (4) End play (a) Install the crankshaft in position with the thrust plates put in the rear journal and all metal caps installed (the cap bolts tightened to the specified torque). Measure the end play of the crankshaft | (the difference in width between the rear journal and the metal cap and thrust plates) with a dial indicator as shown. | If the end play has exceeded the repair, | (_—"__ 80707} limit, replace the thrust plate(s). Crankshaft end play (b) If the end play is still in excess of the repair limit even after new thrust plates have been installed, replace the thrust plates with the oversize ones, 0.15 mm (0.005 9 in.), 0.30 mm (0.011 8 in.) and 0.45 mm (0.0177 in.) oversize thrust plates are available for service. 85ENGINE PROPER, Unit: mm Gin.) tem “Assembly ‘Service K standard limit End play of 0.100 100.264 | 0.300 crankshaft |(0.003 94 to 0.010 39)| (0.011 81) Crankshaft grinding dimensions for oversize thrust plates Unit: mm (in) ‘Oversize for [Oversize for Ovesize | single thrust | double thrut| Tolerance plate plates ois 3115 | 31.30 (00059) | 1.2264) | 1.2323) | 939 030 31.30, 3145 | 0 | .on18)| ¢.2323) | «2382 | soonss, 0.45 3145 31.60 | ° or | 2382) | (2441) (5) Runout ‘Support the crankshaft on its front and rear journals in the V-blocks or in a lathe and measure the runout at the center journal with a dial indicator as shown in the illustration, Depending on the amount of the runout, repair the crankshaft by grinding or straightening with a press. If the runout has exceeded the repair limit, replace the crankshaft. Unit: mm ¢in.) Item’ ‘Assembly standard | Repair limit ‘Runout of (0.02 (0.0008), 0.05 crankshaft ‘maximum (0.002 0) (6) Crankshaft gear replacement (@) Use a gear puller to remove the gear from the crankshaft. cr CAUTION }--—— | Do not remove the gear by hitting with a hammer. 86 ‘Measuring crankshaft end play aoea42 Measuring crankshaft runout 401784 Removing crankshaft gear(b) Heat a new gear up to 100°C (212°F) with a gear heater. Put the gear on the crankshaft with its keyway aligned with the key and tap the end face of the gear with a copper hammer. q) Oil seal contact surface inspection Check the oil seal contact surface for wear. If the crankshaft is badly worn, re- place it with a replacement oil seal with sleeve. ‘Two types of the oil seal are available for the present engine, one being of single-lip type (for the engine with the dry clutch and torque converter) and the other being of double-lip type (for the engine with the wet clutch). —e (2) Oil seal sleeve installation Apply oil to the inside of an oil seal sleeve and, using Oil Seal Sleeve Installer Set (special tool) (30691- 13010), install the sleeve in position, as shown in the illustration, QXCAUTION Be extra careful not to cause damage to the sleeve when stalling it. The oil seal sleeve will be worn in the course of time. In such a case, replace both the oil seal and sleeve by new ones. ENGINE PROPER 401765 Installing crankshaft gear \: + Oil seal it seal surface 405989 Checking oil seal running surface Sleeve installer 4 / ao7ase! Installing oil seal sleeve \ a , U Gide (0681-13100) il seat il seat sleeve | 406990 Checking oil seal running surface 387ENGINE PROPER, (b) Oil seal sleeve removal Hold a flat chisel at right angles to the sleeve and hit the sleeve at three places to loosen it as shown in the illustration, If it is impossible to remove the sleeve in this method, hold the chisel in the axial direction and lightly hit the sleeve to loosen it. | Be extra careful not to cause damage to the crankshaft when removing the sleeve. Main metals (2) Inspection Check each metal for abnormal contact, scratching, pitting, flaking, chipping or loss of overlay. Also, check it for a sign of poor seating in the bore of the cap. (2) Clearance between metals and crank- shaft journals Install the metals to the crankcase and metal caps. Tighten the cap bolts to the specified torque. Measure the inside diameter of the metal in two positions lengthwise and three crosswise as shown in the illustration to take an average. Check the clearance between the metal ‘and journal on the basis of this measure- ment. Unit: mm Gin.) ‘Assembly | Repair | Se Kem standard | “limit | limit Clearance [0050.0 between main | 0.110, 020 | -09 metaland | (6,001.97 w |(0.007 87)| (-0.035) journal 0.00433) 88 Removing oil seal sleeve Checking main metal ‘Measuring main metal Scratching, corrosion or 42012 400028 406091) If the clearance has reached the repair limit, replace the metals. If it has exceeded the repair limit, grind the crankshaft journals to an undersize and use undersize metals. 0.25 mm (0,009 8 in,), 0.50 mm (0.019 7 in.) and 0.75 mm (0.0295 in.) undersize metals are available for service. | b) If the crankshaft is ground in compli- ance with any of the specified under- sizes, it is not necessary to check the ‘metal contact after installation. Tappets (1) Cam contact face Check the cam contact face of each tappet. Replace the tappet if the face is abnor- mally worn. (2) Clearance between tappets and tappet bores Measure the diameter of the tappet and the inside diameter of the bore for the tappet as shown in the illustration to find the clearance. If the clearance has exceeded the repair limit, replace the tappet. Unit: mm (in) | Assembly 7 Repair | Service j Me™ | standard | imi’ | “imi, 74.000 0 Inside diame | 120% 14.100 SeEOF PPE | (0.551 18 10 (0.555 12) 0.551 89) a Ciearance ~ FO0.016 0 between appet| 0052” | aos and tappet (0.000 63 to | (0.003 1) tow 00205) ENGINE PROPER, Bad Bad | ‘Cam contact face of tappet Newnes ge > 407009 ‘Measuring clearance between tappet and tappet boreENGINE PROPER, 4.3. Assembly (1) Main bearing installation (a) Install the upper halves of the main metals in the crankcase, being sure the tabs in the back of the metals are in the tab grooves of the crankcase. The oil holes in the metals and crankcase will be aligned when the metals are so prop- erly installed. (b) Apply a small amount of engine oil to the metals. (©) Install the thrust plate to the rear face of the crankcase with oil grooves toward the outside as shown in the illustration, (2) Crankshaft installation (a) Wash the crankshaft with cleaning sol- vent and blow dry with compressed air. (b) Fasten a hoist to the crankshaft. Hold the crankshaft in horizontal position and carefully put it in the crankcase. (© Apply a small amount of engine oil to the journals of the crankshaft. @) Main metal cap installation (@) Apply engine oil to the metals and install the metals to the caps. (b) Apply Three Bond No. 1212 to the rear metal cap. 90 No. 1212 407205 Installing main metal caps(©) Put the rear metal cap in position. Make sure it is even with the crankcase wall on the rear sides. (@ Apply potash soapy water to the side seals and put the seals in the groove in the metal cap with rounded side toward outside. Push them into position with the blade of a screwdriver or the like, taking care not to bend or twist them. (©) Apply Three Bond No. 1212 to and around the side seals. Install the main bearing caps in number | sequence from the front side. ) (4) Main metal cap bolt installation Apply engine oil to the bolts and tighten them to the specified torque. 10.5 £05 ktm (76+ 4 IDF) (103 + 5 Nem} Tightening torque for main metal cap bolls (5) Crankshaft end play measurement After installing the metal caps, measure the end play of the crankshaft to make sure itis correct. (Refer to page 85.) ENGINE PROPER Crankease Metal cap Side seal J. Rounded side 670198 Installing side seals, 405810 Tightening main metal cap bolts 405807 | ‘Measuring crankshaft end play 1ENGINE PROPER (©) Piston and connecting rod assembling (a) Assemble the piston and the connecting rod with the weight mark of the piston and the matching mark of the rod on the same side. (b) Apply engine oil to the piston pin and insert the pin into position to connect the piston to the rod, (©) Install the snap rings in the snap ring grooves of the piston with a snap ring pliers. Make sure the snap rings fit in the groove properly. Install each snap ring with the ends toward | the bottom of the piston. (7) Piston ring installation Install the compression rings and oil ring on the piston with Piston Ring Pliers (special tool) (31391-12900). NOTE, ) Install the top and second rings with “R” | or “T” mark toward the top of the piston. b) Install the oil ring with the ends of the coil spring 180° apart from those of the ring as shown in the illustration. 92 Piston rings FRONT mark View A ‘Matching mark 407205 ‘Assembling piston and connecting rod 401770 No. 2 compres- sion ring. | Ends of coil spring Ends of oil ring 404005, Location of oil ring and coil spring ends(8) Piston installation Start by: 8) lay the crankcase on its side b) clean the cylinder bores with a clean rag and apply engine oil to the bore surfaces, ©) put the connecting rod cap bolts in the big end of the connecting rod so that the flats of their heads fit to the rod properly 4) install the upper half of the connecting rod metal to the big end of the connect- ing rod, making sure the metal tab is in the tab groove of the rod. Apply engine oil to the metal (a) Apply engine oil to the piston rings. Install the rings on the piston with the ring ends positioned as shown in the illustration. ENGINE PROPER, Preparing for piston installation 401796 Camshaft side End gap of No. 1 ea \ g compression ring | y w « ‘End gap of End gap of No. 2 oil ring ee Combustion chamber side 405804 Configuration of piston ring ends 93ENGINE PROPER (b) Turn the crankshaft to bring a crankpin to which the piston and connecting rod assembly is to be installed to the top dead center. Using Piston Installer (Special tool) (34491-00200), put the assembly in the cylinder, with FRONT ‘mark (A) on the piston toward the front of the engine. (©) After resting the big end of the connect- ing rod on the crankpin, turn the crank- 7 shaft 180° while pushing the piston head Installing piston and connecting rod to bring the big end to a position where assembly the cap can be installed easily. (9) Connecting rod cap installation (a) Install the lower half of the connecting rod metal to the cap, making sure the bearing tab is in the tab groove of the cap. Apply engine oil to the metal. (b) Install the cap to the rod and tighten the cap nuts to the specified torque. ‘ightening torque for | 5520.5 kef-m Tyger ones | SOR i | tsee sn} Installing connecting rod cap & ann) Make sure the matching mark on the cap is on the same side as the mark on the con- necting rod 94