99709-68120

Service Manual

6D16 Diesel Engine

DP80
DP90
DP100
DP115
DP135
DP150

For use with Chassis & Mast

Service Manual
 11

GROUP 11 ENGINE

SPECIFICATIONS ....................................................................................... 2

STRUCTURE AND OPERATION ................................................................. 3

TROUBLESHOOTING ................................................................................. 6

ON-VEHICLE INSPECTION AND ADJUSTMENT ....................................... 8

• Measuring Compression Pressure ........................................................................... 8
• Inspecting and Adjusting Valve Clearances ............................................................. 10

CYLINDER HEAD AND VALVE MECHANISM ............................................. 12

PISTONS, CONNECTING RODS, AND CYLINDER LINERS ....................... 28

FLYWHEEL.................................................................................................. 42

TIMING GEARS........................................................................................... 48

CAMSHAFT................................................................................................. 54

CRANKSHAFT AND CRANKCASE ............................................................. 62

11-1
SPECIFICATIONS
Item Specifications
Engine model 6D16
Type 6-cylinder, in-line, water-cooled, 4-cycle diesel
Combustion chamber type Direct injection
Valve mechanism Overhead valve
Cylinder bore × stroke mm (in.) φ118 × 115 (φ4.65 × 4.53)
Total displacement cc (cu. in.) 7545 (460.4)
Compression ratio 17.5

11-2
STRUCTURE AND OPERATION 11

Cylinder Head and Crankcase

1 Connecting plate
2 Glow plug
3 Cylinder liner
4 Crankcase
5 Water jacket
6 Piston
7 Injection nozzle
8 Cylinder head

A: Cylinder liner size mark

Outer diameter mark: 1, 2, 3
Inner diameter mark: A, B

• The cylinder liners 3 are a dry type liners

that are easier to remove than wet liners.
Liners are press-fitted into the crankcase 4.
• The cylinder liners 3, crankcase 4, and
pistons 6 have size marks. They should be
combined as specified according to the size
marks. P.11-34
01925

11-3
STRUCTURE AND OPERATION
Valve Mechanism
1 Exhaust valve
2 Inlet valve
3 Camshaft
4 Tappet
5 Push rod
6 Rocker shaft
7 Rocker shaft spring
8 Rocker
9 Rocker shaft bracket
10 Valve cap
11 Valve cotter
12 Upper retainer
13 Outer valve spring
14 Inner valve spring
15 Valve stem seal
16 Valve guide

• The valve stem seals 15 are fitted onto the

01926 valves 1, 2 to control the amount of
lubricant flowing onto the sliding surfaces of
the valves 1, 2 and valve guides 16.
• The valve springs 13, 14 are unevenly
pitched to prevent abnormal vibration at
high speeds. To prevent the inner and outer
springs from meshing with each other, the
springs are wound in opposite directions.
• To facilitate removal and reinstallation of
the camshaft from the rear end of the
crankcase, the diameter of each bushing is
smaller toward the front of the engine.
Connecting Rods
1 Connecting rod bushing
2 Connecting rod
3 Connecting rod bearing
4 Connecting rod cap
5 Connecting rod bolt

A: Alignment mark
B: Weight mark stamp
(A, B, C, D, E, F, G, H, I, V, W, X, Y, Z)

13622

11-4
 11

Pistons
A: Part number
B: Size mark (A, B)
C: Weight mark
: Front mark

16936

Timing Gears
1 Camshaft gear
2 No. 2 idler gear
3 No. 1 idler gear
4 Oil pump gear
5 Crankshaft gear
6 Air compressor drive gear or injection
pump drive gear
7 No. 1 idler gear

Each gear is stamped with a timing gear

alignment mark (“1”, “2”, “3”, or “4”) to facilitate
reassembly.

16937

Flywheel
1 Flywheel
2 Pilot bearing
3 Ring gear

A: Angle scale, cylinder number

01934

11-5
TROUBLESHOOTING

Symptoms

Abnormal engine noise

Remarks

Low power output

Possible causes

Incorrect oil viscosity Gr 11

Incorrect/defective fuel Gr 13
Incorrect valve clearance
Defective cylinder head gasket
Worn valve/valve seat, and carbon deposits
Weakened valve spring
Worn/damaged piston ring(s)
Worn/damaged piston ring groove(s)
Incorrect injection timing Gr 13
Defective injection pump Gr 13
Defective cooling system Gr 14
Defective injection nozzle(s) Gr 13
Air trapped in fuel system Gr 13
Clogged air cleaner Gr 15
Clogged muffler Gr 15
Defective turbocharger Gr 15
Incorrectly fitted pipe(s)/hose(s) Gr 13
Injection pump, alternator, or other auxiliary device(s) defective/incorrectly fitted Gr 13, 54
Loose/damaged V-belt Gr 14
Incorrectly fitted crankshaft pulley
Defective air cleaner or muffler Gr 15
Defective valve spring(s)
Defective rocker shaft and bracket
Incorrect lubrication of rocker shaft bracket
Incorrect backlash in timing gears
Incorrect lubrication of timing gear peripheries and idler shafts
Worn connecting rod small end bushing and piston pin
Worn/damaged crankshaft pin and connecting rod big end bearing
Worn/damaged crankshaft journal and main bearing
Excessive end play in crankshaft and camshaft
Worn tappet(s) and camshaft

11-6
 11

MEMO

11-7
ON-VEHICLE INSPECTION AND ADJUSTMENT
Measuring Compression Pressure
Service standards
Location Maintenance item Standard value Limit Remedy
– Compression Each cylinder (at 200 rpm) 2550 kPa 1960 kPa Inspect
pressure (26 kgf/cm2) (20 kgf/cm2)
[370 psi] [284 psi]
Cylinder-to-cylinder – 390 kPa Inspect
pressure difference (4 kgf/cm2)
[56.6 psi]

Special tools Unit: mm (in.)

Location Tool name and shape Part No. Application

Compression Measuring compression

– MH061461
Gauge Adapter pressure

01942

Reductions in compression pressure should be used as a guide in determining the timing of engine overhauls. Take
measurements regularly and keep track of changes; an overview of pressure variations can be useful in fault
diagnosis.
During the engine's run-in period and after parts have been replaced, the compression pressure will increase slightly
as piston rings, valve seats, and other parts fit snugly in position. The pressure will then normalize as parts wear.
• Before inspections, check that the engine oil, starter, and battery are normal.
• Warm up the engine until the coolant temperature reaches 75 to 85°C (167 to 185°F).
• Turn off all lights and auxiliary devices.

• Remove the injection nozzle A.

Gr 13

CAUTION
Cover the mounting holes and injection pipes to prevent the
entry of dust and dirt.

01938

11-8
 11

• Cover the injection nozzle mounting hole B with a cloth C. Then,

turn the engine over with the starter and check that no foreign
matter adheres to the cloth.

WARNING
If any cylinder is cracked, coolant, engine oil, and fuel will
enter the cylinder through the crack. When the engine is
turned over, these substances will spray out of the nozzle
11735
mounting hole B at a high temperature. For safety, move away
from the nozzle mounting hole before turning over the engine.

• Fit the Compression Gauge Adapter onto an injection nozzle

mounting hole B together with a nozzle gasket. Then, connect the
compression gauge 1.
• Turn the engine over and measure the compression pressure.
• Measure the compression pressure in every cylinder and determine
the pressure differences between cylinders.
• If any compression pressure or cylinder-to-cylinder pressure
difference exceeds the specified limit, pour a little engine oil into the
01939 cylinder via the injection nozzle mounting hole B then take the
measurement again.
• If the compression pressure increases, there may be wear or
damage on piston rings and inner surfaces of cylinders.
• If the compression pressure does not increase, valves may be
seized or incorrectly seated, or the cylinder head gasket may be
defective.

11-9
ON-VEHICLE INSPECTION AND ADJUSTMENT
Inspecting and Adjusting Valve Clearances
Service standards Unit: mm (in.)
Location Maintenance item Standard value Limit Remedy
– Valve clearance (when cold) 0.4 (0.0158) – Adjust

Tightening torques Unit: N·m (kgf·m) [lbf·ft]

Location Parts to be tightened Tightening torque Remarks
2, 3 Rocker arm adjusting screw lock nut 34 (3.5) [25.1] –

Valve clearances should be checked and adjusted when the engine is cold.

[Inspection]
• Bring piston No. 1 or piston No. 6 to the top-dead-centre (TDC)
position of its compression stroke. To do this, crank the engine until
the “1.6” mark inscribed on the flywheel is aligned with the pointer A
in the flywheel housing inspection window.
NOTE
Pistons whose push rods are not pushing up their rockers are at
top-dead-centre (TDC) of their compression strokes.
01940

• When piston No. 1 or piston No. 6 is at the TDC position of its

compression stroke, measure the clearance B of every valve
marked “ ” in the following table.

Piston No. 1 2 3 4 5 6

Valve arrangement In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In. Ex.

No. 1 piston at TDC of compression

stroke
11620
No. 6 piston at TDC of compression
stroke

NOTE
To measure the clearance, insert a feeler gauge 1. The gauge
should be able to move in the gap, albeit not loosely. Accurate
measurements cannot be taken if the gauge moves loosely in the
gap.

11-10
 11

• If any measurement is out of specification, make adjustments as

follows:

[Adjustment]
• To adjust the valve clearance B, loosen the lock nut 2 and turn the
adjusting screw 3 until the feeler gauge 1 moves more stiffly in the
gap.
• After adjusting the clearance, tighten the lock nut 2. At this time, use
a screwdriver C to stop the adjusting screw 3 from turning. Next,
insert the feeler gauge 1 once more to confirm that the clearance B
is correct.
11621

11-11
CYLINDER HEAD AND VALVE MECHANISM

04134

● Disassembly sequence
1 Joint 8 Cylinder head bolt 12 Push rod
2 Oil filler cap 9 Rocker and bracket assembly 13 Tappet
3 Bolt P.11-16
4 Plate 10 Cylinder head and valve
*: Crankcase P.11-62
5 Rubber assembly P.11-20 A: Locating pin
6 Rocker cover gasket 11 Cylinder head gasket : Non-reusable part
7 Rocker cover

● Assembly sequence
Follow the disassembly sequence in reverse.

11-12
 11

Service standards Unit: mm (in.)

Location Maintenance item Standard value Limit Remedy
12 Push rod runout – 0.4 (0.0157) Replace
13, Tappet-to-crankcase clearance 0.06 to 0.10 0.2 Replace
* [Basic diameter: 31 mm (1.220 in.)] (0.00237 to 0.00394) (0.00787) tappet

Tightening torques Unit: N·m (kgf·m) [lbf·ft]

Location Parts to be tightened Tightening torque Remarks
1 Joint 29 (3.0) [21.4] –
3 Rocker cover bolt 3.9 (0.4) [2.88] –
8 Cylinder head bolt M14 bolt 78 (8) [57.5] + 180° • Wet
(installation of rocker and • Can be reused
bracket assembly and cylinder up to 3 times
head and valve assembly)
M10 bolt 17 (1.75) [12.5] + 34 (3.5) [25.1] –

Oils
Location Points of application Kinds Quantity
2 Rubber seal of oil filler cap Engine oil As required
8 Threads of cylinder head bolts Engine oil As required
12 Both ends of push rods Engine oil As required
13 Outer surfaces of tappets Engine oil As required

Special tools
Location Tool name and shape Part No. Application

Tightening cylinder head bolts

10 Socket Wrench MH061560
(M14 bolt only)

01984

◆ Service procedure
10 Cylinder head and valve assembly
[Removal]
• Before loosening the cylinder head bolts 8, loosen the adjusting
screw C on every rocker A that is compressing its valve spring B.

13021

11-13
CYLINDER HEAD AND VALVE MECHANISM
• Loosen and remove the cylinder head bolts 8 in the sequence
shown. Each cylinder head bolt should be loosened a little at a time.

01945

[Fitting]
• The M14 cylinder head bolts 8 can be reused only three times.
Before refitting the cylinder head bolts, make a punch mark on the
head of each one to indicate times of reuse.

CAUTION
If any bolt already has three punch marks, it must not be
reused any more; replace it with a new one.
01945

• Tighten the cylinder head bolts 8 to the specified torque {M14 bolts:
78 N·m (8 kgf·m) [57.5 lbf·ft]; M10 bolts: 17 N·m (1.75 kgf·m) [12.5
lbf·ft]} in the sequence shown. Then, turn the bolts further in
accordance with the following procedure.

*: Tighten together with rocker and bracket assembly

➀ to : M14 bolt (wet)
to : M10 bolt

<M14 Bolts>
• Before fitting the Socket Wrench over a cylinder head bolt, turn
the holder D counter-clockwise to tension the built-in spring.

E: Socket
F: Rod
G: Rod (extension)

01991

• Set the socket such that the built-in spring force forces the rod G
against the rocker shaft bracket, an injection pipe, or another nearby
part.
• On the holder D, select the inscribed line H that is easiest to see.
• Using the selected line as a reference, turn the socket E 180°
clockwise. (One gradation on the scale J represents 5°.)

CAUTION
12825
Since the M14 cylinder head bolts 8 utilize the plastic region
tightening method, they must not be tightened further after this
procedure.

11-14
 11

<M10 Bolts>
• After fitting the M14 cylinder head bolts 8, tighten the M10 bolts to
the specified torque {34 N·m (3.5 kgf·m) [25.1 lbf·ft]} in the
sequence shown.

01945

11 Cylinder head gasket

[Removal]

CAUTION
When removing the cylinder head gasket 11, be careful not to
scratch the cylinder head and valve assembly 10 and the
crankcase .
*

[Fitting]
• Fit the cylinder head gasket 11 onto the crankcase
* as shown.

13582

12 Push rod runout

If any measurement exceeds the specified limit, replace the defective
part(s).

01948

13
* Tappet-to-crankcase clearance
If any measurement exceeds the specified limit, replace the defective
part(s).

01949

11-15
CYLINDER HEAD AND VALVE MECHANISM
Rocker and Bracket Assembly
● Disassembly sequence
1 Rocker assembly
2 Rocker bushing
3 Lock nut
4 Adjusting screw
5 Rocker
6 No. 6 rocker shaft bracket
7 Set screw
8 No. 5 rocker shaft bracket
9 No. 4 rocker shaft bracket
10 No. 3 rocker shaft bracket
11 No. 2 rocker shaft bracket
12 No. 1 rocker shaft bracket
13 Rocker shaft spring
14 Rocker shaft

● Assembly sequence
Reverse the order of disassembly.
13022

Service standards Unit: mm (in.)

Location Maintenance item Standard value Limit Remedy
2, 14 Rocker bushing-to-rocker shaft clearance 0.01 to 0.08 0.12 Replace
[Basic diameter: 24 mm (0.945 in.)] (0.000394 to 0.00315) (0.00472)

Tightening torques Unit: N·m (kgf·m) [lbf·ft]

Location Parts to be tightened Tightening torque Remarks
3 Adjusting screw lock nut 34 (3.5) [25.1] –
7 Rocker shaft set screw 3.9 (0.4) [2.88] –

Oils
Location Points of application Kinds Quantity
2 Rocker bushing inner surface Engine oil As required

Special tools Unit: mm (in.)

Location Tool name and shape Part No. Application

Rocker Removing and installing rocker

2 MH061777
Bushing Puller bushings

01951

11-16
 11

◆ Service procedure
2 14 Rocker bushing and rocker shaft
[Inspection]
If any clearance exceeds the specified limit, replace the defective
part(s).

01952

Rocker bushing
[Removal]

12994

[Installation]
• Align the oil hole A in the rocker bushing 2 with the oil hole B in the
rocker 5.
• Position the notch C and seam D on the rocker bushing 2 as shown.
• Install the rocker bushing 2 into the rocker 5 from the chamfered
side F.

12995

6 8 to 12 14 Installing rocker shaft brackets and rocker shaft

Rocker shaft brackets
Be sure to fit the rocker shaft brackets 6, 8, 12 in their correct positions.

A: Oil hole
B: Threaded hole (for M8 rocker cover bolt)
C: Threaded hole (for M6 set screw)
D: No threaded hole

13023

11-17
CYLINDER HEAD AND VALVE MECHANISM
Rocker shaft
Align the oil hole G in the No. 6 rocker shaft bracket 6 with the oil hole
H in the rocker shaft 14.

13024

11-18
 11

MEMO

11-19
CYLINDER HEAD AND VALVE MECHANISM
Cylinder Head and Valve Mechanism

01955

● Disassembly sequence
1 Valve cap 9 Injection nozzle Gr 13 16 Inlet valve guide
2 Valve cotter 10 Dust seal 17 Exhaust valve seat
3 Upper retainer 11 Nozzle tip gasket 18 Inlet valve seat
4 Outer valve spring 12 Nut 19 Stud
5 Inner valve spring 13 Connecting plate 20 Cylinder head
6 Valve stem seal 14 Glow plug
7 Exhaust valve Gr 54 : Non-reusable part
8 Inlet valve 15 Exhaust valve guide

CAUTION
The injection nozzles 9 and glow plugs 14 project from the bottom surface of cylinder head 20. Take care
not to damage them.

● Assembly sequence
Follow the disassembly sequence in reverse.

NOTE
Any valve stem seal 6 removed from an exhaust valve 7 or inlet valve 8 must be replaced.

11-20
 11

Service standards Unit: mm (in.)

Location Maintenance item Standard value Limit Remedy
Outer Free length 67.0 (2.64) 64.0 (2.52) Replace
valve Installed load 330 N 290 N Replace
4 spring [at 47.8 mm (1.88 in.) installed (33.5 kgf) (29.7 kgf)
length] [74.5 lbf] [65.2 lbf]
Squareness – 2.5 (0.0984) Replace
Inner Free length 55.1 (2.17) 52.1 (2.05) Replace
valve Installed load 92 N 78 N Replace
5 spring [at 40.5 mm (1.59 in.) installed (94 kgf) (8.0 kgf)
length] [20.7 lbf] [17.5 lbf]
Squareness – 2.0 (0.0787) Replace
Exhaust Stem outside diameter φ8.93 to 8.94 φ8.85 Replace
valve (φ0.3516 to 0.3520) (φ0.348)
Sinkage from cylinder head 1.3 to 1.7 2.0 Inspect
bottom surface (0.0512 to 0.0670) (0.0787) every
7 location
Valve margin 1.5 (0.0591) 1.2 (0.0472) Reface or
replace
Seat angle 45° – Correct
Inlet Stem outside diameter φ8.96 to 8.97 φ8.85 Replace
valve (φ0.3528 to 0.3531) (φ0.348)
Sinkage from cylinder head 1.1 to 1.5 1.8 Inspect
bottom surface (0.0433 to 0.0591) (0.0709) every
8 location
Valve margin 1.5 (0.0591) 1.2 (0.0472) Reface or
replace
Seat angle 45° ± 15’ – Correct
Exhaust valve stem-to valve guide 0.07 to 0.10 0.2 Replace
7, 15 clearance (0.00276 to 0.00394) (0.00787)
[Basic diameter: 9 mm (0.354 in.)]
Inlet valve stem-to-valve guide clearance 0.04 to 0.06 0.15 Replace
8, 16 [Basic diameter: 9 mm (0.354 in.)] (0.00157 to 0.00236) (0.00591)
Exhaust valve seat width 1.8 to 2.2 2.8 Correct or
17 (0.0709 to 0.0866) (0.110) replace
Inlet valve seat width 1.8 to 2.2 2.8 Correct or
18 (0.0709 to 0.0866) (0.110) replace
Cylinder Bottom surface distortion 0.08 (0.00315) 0.2 Correct or
head or less (0.00787) replace
20
Height from top to bottom 94.9 to 95.1 94.5 Replace
surface (3.736 to 3.744) (3.72)

Tightening torques Unit: N·m (kgf·m) [lbf·ft]

Location Parts to be tightened Tightening torque Remarks
14 Glow plug 15 to 20 (1.5 to 2.0) [11.1 to 14.8] –
19 Exhaust manifold mounting stud 29 (3) [21.4] –

11-21
CYLINDER HEAD AND VALVE MECHANISM

Oils
Location Points of application Kinds Quantity
1 Rocker contact surface on valve cap top Engine oil As required
6 Lip of valve stem seal Engine oil As required
7, 8 Valve stem Engine oil As required

Special tools Unit: mm (in.)

Location Tool name and shape Part No. Application

A: MH061668
A: Valve Lifter [with φ42
Removing and installing valve
2 B: Valve Lifter (φ1.65)
cotters
Hook valve lifter
seat]
B: MH061679
01956

Valve Stem
6 MH061293 Installing valve stem seals
Seal Installer

01957

30091-07500
7, 8 Valve Lapper Lapping valves and valve seats
(inlet, exhaust)

01958

Valve Guide MH061066

Removing valve guides
Remover (inlet, exhaust)

01959
15, 16

Valve Guide Installing inlet and exhaust

MH061998
Remover valve guides

01960

11-22
 11

Special tools Unit: mm (in.)

Location Tool name and shape Part No. Application
A: Caulking Tool Body
B: Installer Ring
A: MH061067
C dimen- B: MH061693
17, 18 sion (Inlet) Installing valve seats
MH061693 φ51 (φ2.01) MH061694
(Exhaust)
MH061694 φ44 (φ1.73)
01951

◆ Service procedure
2 Valve cotters
[Removal]
To remove the valve cotter 2, use the Valve Lifter to evenly
compress the valve springs 4, 5.

[Installation]
To install valve cotters, follow the removal instructions in reverse.

01962
CAUTION
Do not compress the valve springs 4, 5 more than is
necessary. If the valve springs are compressed excessively,
the upper retainer 3 can touch the valve stem seal 6 and be
damaged.

4 5 Installing outer and inner valve springs

Fit the outer and inner valve springs 4, 5 onto the cylinder head 20 with
their painted ends downward.

A: Painted end

11641

6 Installing valve stem seals

• Apply engine oil to the lip A of the valve stem seal 6.
• Install the valve stem seal 6 using the Valve Stem Seal Installer.
Strike the Valve Stem Seal Installer until it sits snugly on the
cylinder head 20.

01964

11-23
CYLINDER HEAD AND VALVE MECHANISM

7 8 Valves
[Inspection]
(1) Valve stem outside diameter
Replace the valves 7, 8 if its stem's outside diameter is below
specification or severely worn.
CAUTION
Whenever the valves 7, 8 are replaced, be sure to lap the
01965 valves and valve seats 17, 18. P.11-25.

(2) Valve seat angle and valve margin

Reface or replace the valves 7, 8 if the valve seat angle or valve margin
exceeds the specified limits.

A: Valve seat angle

B: Valve margin

02264

[Rectification]
NOTE
• Keep grinding to a minimum.
• If the valve margin is below specification after grinding, replace
the valves 7, 8.
• After grinding, be sure to lap the valves 7,8 and valve seats 17,
18. P.11-25

01966

7 8 15 16 Valves and valve guides

[Inspection]
If any clearance exceeds the specified limit, replace the defective
part(s).

01967

Valve guides
[Removal]

01972

11-24
 11

[Installation]
Install the valve guides 15, 16 using the Valve Guide Installer.
Strike the Valve Guide Installer until it sits snugly on the cylinder head
20.

CAUTION
• The valve guides 15, 16 must be pressed in to the specified
depth. Be sure to use the Valve Guide Installer for this
02220
operation.
• Exhaust valve guides 15 are longer than inlet valve guides 16.
Be sure to install the correct type of guide in each location.

7 8 17 18 Valves and valve seats

[Inspection]
• Apply an even coat of minimum to the valve seats 17, 18 surface A
that makes contact with the valves 7, 8.
• Using the Valve Lapper, strike the valves 7, 8 against the valve
seats 17, 18 once. Do not rotate the valve during this operation.
NOTE
Carry out these inspections after inspecting the valves and valve
01968
guides.

• If the minimum deposited on the valves 7, 8 indicate a poor contact

pattern, rectify the contact pattern as follows:

Contact Corrective action

Minor defect Lapping
Serious defect Reface or replace valve and valve seat

01969

[Refacing]
Lap the valve in accordance with the following procedure:
• Apply a thin, even coat of lapping compound to the surface A of the
valves 7, 8 that makes contact with the valve seats 17, 18.

CAUTION
Ensure that no compound adheres to the stem B of the valves
7, 8.
01970

NOTE
• Start with intermediate-mesh compound (120 to 150 mesh) and
finish with fine-mesh compound (200 mesh or more).
• The addition of a small amount of engine oil makes lapping
compound easier to apply.

11-25
CYLINDER HEAD AND VALVE MECHANISM
• Using the Valve Lapper, lightly strike the valves 7, 8 against the
valve seats 17, 18 while turning it little by little.
• Wash away the compound with gas oil or a similar fluid.
• Apply engine oil to the contact surfaces of the valve seats 17, 18
and rub it in so that the contact surfaces are lubricated and mate
together snugly.
• Inspect the contact pattern of the valves 7, 8 and valve seats 17, 18
once more.
01971
• If the contact pattern is still defective, replace the valve seats 17, 18.

17 18 Valve seats
[Inspection]
(1) Valve seat width
If the measurement exceeds the specified limit, rectify or replace the
valve seats 17, 18.

A: Valve seat width

01975
NOTE
Whenever the valve seats 17, 18 are rectified or replaced, be sure
to lap the valve seats 17, 18 and valves 7, 8. P.11-25

(2) Valve sinkage from cylinder head bottom surface

If any measurement exceeds the specified limit, rectify or replace the
defective part(s).

B: Valve sinkage

02265

[Rectification]
• Grind the valve seats 17, 18 using a valve seat cutter or valve seat
grinder.
• After grinding, put some sandpaper of around #400 grade between
the cutter and valve seat and grind the valve seat lightly.
• Use a 15° or 17° cutter to achieve the specified valve seat width A.

C: Valve seat angle

01977

CAUTION
Ensure that grinding does not cause the valve sinkage B to
exceed the specified limit.

• After rectification, lap the valves 7, 8 and valve seats 17, 18.
P.11-25

11-26
 11

[Removal]
Valve seats 17, 18 are installed by expansion fitting. To remove a valve
seat, grind the inside surface to reduce its thickness, then remove the
valve seat at room temperature.

D: Material to remove

01973

[Installation]
• Check that the valve seat hole diameters E, F in the cylinder head
20 conform with the values shown below.
Unit: mm(in.)
Dimension
+0.03 +0.001
Inlet valve seat hole (E) φ51 0 (φ2.01 0 )
+0.025 +0.001
Exhaust valve seat hole (F) φ44 0 (φ1.73 0 )
01976

• Cool the valve seats 17, 18 by immersing it in liquid nitrogen.

• Install the valve seats 17, 18 in the cylinder head 20 using the
Caulking Tool Body and Installer Ring.
• After installing the valve seats 17, 18, lap the valve seats and valves
7, 8. P.11-25

01974

20 Inspecting cylinder head

• Measure the extent of distortion in the cylinder head's bottom
surface.
• If the degree of distortion exceeds the specified limit, rectify the
distortion with a surface grinder.

CAUTION
01978
Ensure that grinding does not cause the cylinder head's top
surface-to-bottom surface distance to fall below the specified
limit.

11-27
PISTONS, CONNECTING RODS, AND CYLINDER LINERS
● Pre-disassembly inspection
P.11-30

● Removal sequence
1 Bolt
2 Lower connecting rod bearing
3 Connecting rod cap
4 Upper connecting rod bearing
5 Piston and connecting rod assembly
P.11-36
6 Cylinder liner

*: Oil pan Gr 12

● Installation sequence
Reverse the order of removal.

16914

Service standards Unit: mm (in.)

Location Maintenance item Standard value Limit Remedy
– Piston projection 0.85 to 1.06 – Inspect
(0.0335 to 0.0417) each location
Connecting rod end play 0.15 to 0.45 0.6 Replace
(0.00591 to 0.0177) (0.236)
2, 4 Connecting Oil clearance 0.04 to 0.09 0.2 Replace
rod end play [Basic diameter: 65 mm (2.56 in.)] (0.00157 to 0.00354) (0.00787)
Span when free – Less than
69.5 (2.74)
5, 6 Piston and connecting rod assembly-to- 0.075 to 0.105 – Replace
cylinder liner clearance (0.00395 to 0.00413)
[Basic diameter: 118 mm (4.65 in.)]
6 Cylinder Flange projection 0.03 to 0.10 – Replace
liner (0.00118 to 0.00394)
Inside diameter φ118 to 118.03 φ118.25 Replace
(φ4.646 to 4.647) (φ4.656)
Cylindricity 0.03 (0.00118) or less – Replace or
grind to
oversize

11-28
 11

Tightening torques Unit: N·m (kgf·m) [lbf·ft]

Location Parts to be tightened Tightening torque Remarks
1 Bolt (connecting rod installation) 29 (3) [21.4] + 90° ± 5° Wet

Oils
Location Points of application Kinds Quantity
1 Both threads Engine oil As required
2, 4 Connecting rod bearing inside surface Engine oil As required
6 Cylinder liner outside surface Engine oil As required

Special tools Unit: mm (in.)

Location Tool name and shape Part No. Application

Installing piston and

5 Socket Wrench MH061560
connecting rod assembly

01984

A: Piston Guide Clamp A: MH061760 Installing piston and

5
B: Piston Guide Lever B: MH061658 connecting rod assembly

01981

Cylinder Liner Extractor MH061761 Removing cylinder liners

01982
6

Installing cylinder liners

Cylinder Liner Installer MH061771
(dry type)

01983

11-29
PISTONS, CONNECTING RODS, AND CYLINDER LINERS
◆ Service procedure
● Pre-disassembly inspection
(1) Piston projection from crankcase top surface
NOTE
The piston projections affect engine performance and must
therefore be checked.

WARNING
The cylinder liners may rise out of position when the crankcase
01985 is turned over or the crankshaft is turned. Hold their flanges
down using bolts and washers A.

• Measure the projection of each piston at two points and calculate

the average of the two values.

A: Front of engine

• If the average value is out of specification, check the clearances

between all relevant parts.

01986

(2) Connecting rod end play

• Measure the end play of every connecting rod.
• If any measurement exceeds the specified limit, replace the
defective part(s).

01987

(3) Cylinder liner flange projection

• If any measurement is out of specification, replace the defective
part(s).
B: Flange projection

CAUTION
If the cylinder liner 6 flange projection is insufficient, bearing
pressure on the cylinder head gasket will be too low in the
01988
region of the bore, possibly causing gas to leak.

11-30
 11

2 4 Connecting rod bearings

[Installation]
Install the connecting rod bearings 2, 4 by fitting the lugs A into their
respective grooves.

CAUTION
The upper connecting rod bearing has an oil hole B. The lower
01994 connecting rod bearing has no oil hole. Take care not to
confuse the upper and lower parts.

[Inspection]

CAUTION
• Do not attempt to manually expand a connecting rod bearings
2, 4 if its span is insufficient.
• Upper and lower connecting rod bearings 2, 4 must be
replaced as a set.

01995
(1) Span when free
If the span is less than the specified requirement, replace the upper
and lower connecting rod bearings 2, 4 as a set.
(2) Connecting rod bearing-to-crankshaft pin clearance
If the connecting rod bearing-to-crankshaft pin clearance exceeds the
specified limit, replace the defective part(s).

01995

01997

5 Installing piston and connecting rod assembly

CAUTION
• Ensure that the piston ring gaps A remain in their correct
positions. P.11-40
• Take care not to damage the piston crown B (the area that
forms part of the combustion chamber).
• Ensure that the connecting rod does not touch the oil jet C.
01985

11-31
PISTONS, CONNECTING RODS, AND CYLINDER LINERS
• With the piston’s “ ” front mark facing the front of the engine, install
the piston and connecting rod assembly in accordance with the
following procedure.

D: Front of engine

03384

• Fit the Piston Guide Clamp over the piston skirt. Using the bolt
E of the Piston Guide Lever, adjust the clamp's inside diameter
such that it matches the piston's outside diameter.
• Move the Piston Guide Clamp and Piston Guide Lever to
the top of the piston.

11651

02011

• With the piston installed, align the mating marks F on the connecting
rod and connecting rod cap 3 and tighten the bolts to the specified
torque. Then, tighten the bolts 1 further in accordance with the
following procedure.

01990

• Before fitting the Socket Wrench over a bolt, turn the holder G
counter-clockwise to tension the built-in spring.

H: Socket
J: Rod
K: Rod (extension)

01991

11-32
 11

• Set the socket wrench such that the built-in spring force forces the
rod K against the crankshaft.
• On the holder G, select the inscribed line L that is easiest to see.
• Using the selected line as a reference, turn the socket H 90° ± 5°
clockwise. (One gradation on the scale M represents 5°.)
NOTE
After fitting the connecting rod caps 3, inspect the following
items:
11652 • Connecting rod end play ( P.11-30)
• Piston projections ( P.11-30)

5 6 Piston-and-connecting rod assembly and cylinder liners

[Inspection]
If any clearance is out of specification, replace the defective part(s).

A: Outside diameter measurement position

B: Direction of crankshaft axis
C: Perpendicular to crankshaft axis

NOTE
The cylinder liners are of a thin design and cannot be bored to
oversize dimensions. To prevent deformation of the cylinder
liners, do not remove them except for replacement.
03375

02003

Cylinder liners
[Removal]
NOTE
If any cylinder liner 6 must be reused after removal, make an
alignment mark with paint and use this mark to reinstall the
cylinder liner in its original position.

02004

11-33
PISTONS, CONNECTING RODS, AND CYLINDER LINERS
[Installation]
M N P
• Apply engine oil to the outside surface of the cylinder liner 6.
1A
1 • Insert the cylinder liner into the crankcase and press it into position
1B using the Cylinder Liner Installer. Push down evenly on the
A
2A entire upper surface of the Cylinder Liner Installer.
2
2B
B
3A CAUTION
3
3B • Size marks L are provided on the cylinder liner 6, piston, and
02005 crankcase (6 places). When the cylinder liner is replaced,
select the proper one according to the size marks on the
crankcase and the piston, as shown in the illustration.
M: Crankcase size mark
N: Cylinder liner size mark
P: Piston size mark
02006 • The cylinder liners are of a thin design. Handle them with care,
and do not subject them to hammer blows or other severe
shocks.

02007

11-34
 11

MEMO

11-35
PISTONS, CONNECTING RODS, AND CYLINDER LINERS
Piston and Connecting Rod Assembly
● Disassembly sequence
1 Snap ring
2 Piston pin
3 Connecting rod bushing
4 Connecting rod
5 1st compression ring
6 2nd compression ring
7 Oil ring
8 Piston

● Assembly sequence
Reverse the order of disassembly.

02012

Service standards Unit: mm (in.)

Location Maintenance item Standard value Limit Remedy
2, 3 Piston pin-to-connecting rod small end 0.02 to 0.05 0.1 Replace
bushing clearance (0.000787 to 0.00197) (0.00394)
[Basic diameter: 38 mm (1.50 in.)]
2, 8 Piston pin-to-piston clearance 0.004 to 0.02 0.05 Replace
[Basic diameter: 38 mm (1.50 in.)] (0.000157 to 0.000787) (0.00197)
4 Connecting rod bend and torsion – 0.05 Replace
(0.00197)
5 to 7 Piston ring 1st compression ring 0.35 to 0.55 1.5 Replace
end gap (0.0138 to 0.0217) (0.0591)
2nd compression ring 0.35 to 0.55 1.5 Replace
(0.0138 to 0.0217) (0.0591)
Oil ring 0.35 to 0.55 1.5 Replace
(0.0138 to 0.0217) (0.0591)
5 to 8 Piston ring-to- 1st compression ring 0.11 to 0.15 0.2 Replace
piston ring (0.00433 to 0.00591) (0.00787)
groove
clearance 2nd compression ring 0.05 to 0.08 0.15 Replace
(0.00197 to 0.00315) (0.0591)
Oil ring 0.03 to 0.06 0.15 Replace
(0.00118 to 0.00236) (0.0591)

11-36
 11

Oils
Location Points of application Kinds Quantity
2 Piston pin outer surface Engine oil As required
3 Connecting rod bushing outer surface Engine oil As required
4 Bushing installation surface of connecting rod Engine oil As required

Special tools Unit: mm (in.)

Location Tool name and shape Part No. Application

Connecting
Removing and installing
3 Rod Bushing MH061778
connecting rod bushings
Puller

02014

Piston Ring Removing and installing

5 to 7 30091-07100
Tool piston rings

02013

◆ Service procedure
2 3 Rocker bushing and rocker shaft
If the clearance exceeds the specified limit, replace the defective
part(s).

02017

Connecting rod bushing

[Removal]
Apply the Connecting Rod Bushing Puller to the connecting rod
bushing 3. Using a press, apply pressure of approximately 49 kN (5,000
kgf) [11,015 lbf] such that the bushing is pressed out of the connecting
rod 4.

13616

11-37
PISTONS, CONNECTING RODS, AND CYLINDER LINERS
[Installation]
• Align oil hole A in the connecting rod bushing 3 with oil hole B in the
connecting rod 4.
• Apply the Connecting Rod Bushing Puller to the connecting rod
bushing 3. Using a press, apply pressure of approximately 49 kN
(5,000 kgf) [11,015 lbf] such that the bushing is pressed into the
connecting rod 4 from the chamfered side C.
NOTE
13617 After installing the connecting rod bushing 3, insert the piston pin
2 and check that it turns smoothly and without play.

2 4 8 Piston pin, connecting rod, and piston

[Removal]
• Tap out the piston pin 2 using a rod and hammer.
• If the piston pin 2 is difficult to remove, heat the piston 8 in hot water
or using a piston heater.

02022

[Installation]
• Apply engine oil to the piston pin 2. With the connecting rod 4 and
piston 8 aligned as illustrated, insert the piston pin to hold these
components together.

A: Weight mark
B: Weight mark (A, B, C, D, E, F, G, H, I, V, W, X, Y, Z)
C: Alignment mark for connecting rod cap
02023 : Front mark

• If the piston pin 2 is difficult to insert, heat the piston 4 in hot water
or using a piston heater.

CAUTION
• No piston should differ from any other piston by a weight of
more than log.
• The connecting rods must all have the same weight mark.
• After inserting the piston pin 2, check that it turns smoothly
and without play.

11-38
 11

2 8 Piston pin-to-piston clearance

If the clearance exceeds the specified limit, replace the defective
part(s).

02016

4 Connecting rod bend and twist

• Fit the connecting rod bushing 3 and piston 2 in their respective
positions of the connecting rod 4.
• Measure the extent of bending A and twisting B in the connecting
rod 4.
• If either measurement exceeds the specified limit, replace the
connecting rod 4 or rectify it.

C: Connecting rod 4 aligner (measurement device)

02039

NOTE
• Before mounting the connecting rod 4 on the connecting rod
aligner C, install the upper and lower connecting rod bearings in
their respective positions.
• Measurements must be made with the connecting rod cap
mounting nuts tightened to their specified torque. P.11-29

02040

11-39
PISTONS, CONNECTING RODS, AND CYLINDER LINERS

5 to 8 Piston rings and piston

Piston rings
[Removal]

02024

[Installation]
• Fit the oil ring 7 onto the piston 8 with its side rail gaps A and the
expander spring gap B in the positions illustrated.
• Fit the compression rings 5, 6 onto the piston such that the
manufacturer's marks C near the gaps face upward.
• Align the compression ring gaps D, E as illustrated.

D: 1st compression ring gap

02028 E: 2nd compression ring gap
: Front mark

[Inspection]
(1) Piston ring end gap
• Using the crown of a piston 8, push the piston ring 5, 6 or 7
horizontally into a cylinder liner F for measurement.
• Taking care not to move the piston ring 5, 6 or 7, measure the end
gap. Replace all the rings of a piston if any gap exceeds the
specified limit.
NOTE
02027 • To keep the piston ring 5, 6 or 7 horizontal, be sure to insert them
into the cylinder liner F using a piston 8.
• Push the piston ring 5, 6 or 7 down to the bottom of cylinder liner
F; the bottom should be less worn than the top.
• Piston ring 5, 6 or 7 must be replaced as a set. Never replace
piston rings individually.

11-40
 11

(2) Piston ring-to-piston ring groove clearance

• If any measurement exceeds the specified limit, replace the
defective part(s).
• Measure the 1st compression ring 5 clearance with a thickness
gauge H while pressing the ring against the piston 8 with a straight
edge G.
NOTE
• Remove any carbon deposits from the ring groove of the piston 8
and measure the clearance around the piston's entire periphery.
02025 • Piston rings 5, 6, 7 must be replaced as a set. Never replace
piston rings individually.

02026

11-41
FLYWHEEL

16923

● Disassembly sequence
1 Spacer 8 Rear oil seal
2 Bolt 9 Plug
3 Washer plate 10 Flywheel housing
4 Flywheel assembly
5 Pilot bearing
*: Crankcase P.11-62
6 Ring gear A: Locating pin
7 Flywheel : Non-reusable part

● Assembly sequence
Reverse the order of disassembly.

11-42
 11

Service standards Unit: mm (in.)

Location Maintenance item Standard value Limit Remedy
4 Flywheel Friction surface distortion 0.05 (0.00197) 0.2 (0.00787) Correct or
assembly or less replace
Height of friction surface 20 (0.787) 19 (0.748) Replace
Friction surface runout – 0.2 (0.00787) Correct or
(when fitted) replace
3 Eccentricity of joint – 0.2 (0.00787) Inspect or
replace

Tightening torques Unit: N·m (kgf·m) [lbf·ft]

Location Parts to be tightened Tightening torque Remarks
8 Flywheel mounting bolt 98 (10) [72.3] + 150° • Wet
• Can be reused
up to 3 times
9 Plug 88 (9) [64.9] –

Oils and sealants

Location Points of application Kinds Quantity
2 Bolt threads Engine oil As required
8 Rear oil seal lip Engine oil As required
Flywheel mounting surface of rear oil seal Threebond 1207C As required
10 Engine mounting surface of flywheel housing Threebond 1207C As required

Special tools Unit: mm (in.)

Location Tool name and shape Part No. Application

Socket Wrench MH062354

01984
4 Fitting flywheel

Magnetic Base MH062356

00471

11-43
FLYWHEEL
◆ Service procedure
4 Flywheel assembly
[Removal]
To remove the flywheel assembly 4, screw the mounting bolts 2 into the
removal holes A.

02052

[Installation]
• The bolts 2 can be used only three times. Before refitting the bolts,
make a punch mark on the head of each one to indicate times of
reuse.

CAUTION
If any bolt already has three punch marks, it must not be
reused any more; replace it with a new one.
01991

• Tighten the bolts 2 to their specified torque, then tighten them

further in accordance with the following procedure:
• Turn the holder B of the Socket Wrench counter-clockwise to
tension the built-in spring.

C: Socket
D: Rod
E: Rod (extension)

• Set the Socket Wrench such that the built-in spring forces the
rod E against the Magnetic Base.
• On the holder B, select the inscribed line F that is easiest to see.
• Using the selected line as a reference, turn the socket 150°
clockwise. (One gradation on the scale G represents 5°.)

CAUTION
Since the bolts 2 utilize the plastic region tightening method,
14312
they must not be tightened further after this procedure.

[Inspection]
(1) Runout
• Tighten the bolts 2 to their specified torque.
• If runout exceeds the specified limit, check that the bolts 2 are
tightened correctly and inspect the crankshaft * mounting surface.
Then, rectify or replace the flywheel assembly 4 as required.

02055

11-44
 11

(2) Height of friction surface

If the measurement is below the specified value, rectify or replace the
flywheel assembly 4.

H: Height of friction surface

03349

(3) Distortion of friction surface

If distortion exceeds the specified limit, rectify or replace the flywheel
assembly 4.
NOTE
If any abnormality is evident on the ring gear 6, replace the ring
gear before making inspections.

02054

[Rectification]
Grind the friction surface such that its height H remains greater than the
specified minimum. The friction surface must remain parallel with
surface J with a tolerance of 0.1 mm (0.00394 in.).

03351

6 Ring gear
[Inspection]
Inspect the ring gear 6 for damage and abnormal wear. If any defect is
evident, the ring gear must be replaced.

[Removal]
• Heat the ring gear 6 evenly with an acetylene torch or the like.

CAUTION
Be careful not to get burned.

• Remove the ring gear 6 from the flywheel 7 by tapping around its
entire periphery.
02057

11-45
FLYWHEEL
[Installation]
• Using a piston heater or the like, heat the ring gear 6 to
approximately 100°C (212°F) for 3 minutes.

CAUTION
Be careful not to get burned.

03353
• Fit the ring gear 6 with the non-chamfered side of its teeth toward
the flywheel 7.

A: Chamfered side of ring gear

8 Fitting rear oil seal

• Apply an even, unbroken bead of sealant A to the rear oil seal 8 in
the position illustrated B.
• Fit the rear oil seal 9 onto the flywheel housing 10 within 3 minutes
of applying the sealant A.

CAUTION
11702 • Ensure that the sealant application position B on the oil seal 8
is clean before applying sealant.
• When fitting the rear oil seal 8, hold it firmly in position to
prevent spreading the sealant.
• After fitting the rear oil seal 8, wait at least 30 minutes before
starting the engine.
• Apply a new bead of sealant A whenever the mounting bolts of
the rear oil seal 8 have been loosened.

• Apply engine oil to the lip of the rear oil seal 8.

• Fit the rear oil seal 8 onto the flywheel housing 10 in the direction
illustrated.

02059

11-46
 11

10 Flywheel housing
[Installation]
• Apply an even, unbroken bead of sealant A to the crankcase
mounting surface of the flywheel housing 10.
• Fit the flywheel housing 10 onto the crankcase within 3 minutes of
applying the sealant A.

CAUTION
• Ensure that the sealant application position on the flywheel
11704
housing 10 is clean before applying sealant.
• When fitting the flywheel housing 10, hold it firmly in position to
prevent spreading the sealant.
• After fitting the flywheel housing 10, wait at least an hour before
starting the engine.
• Apply a new bead of sealant A whenever the mounting bolts of
the flywheel housing 10 have been loosened.

[Inspection]
• Rotate the crankshaft and check the extent of eccentricity at the
joint A of the flywheel housing 10.
• If eccentricity exceeds the specified limit, carry out reassembly.
• If eccentricity still exceeds the specified limit after reassembly,
replace the defective part(s).

02062

11-47
TIMING GEARS

16939

● Pre-disassembly inspection
P.11-50

● Disassembly sequence
1 Bolt 10 Thrust washer : Non-reusable part
2 No. 1 idler shaft 11 No. 2 idler gear bushing
3 No. 1 idler gear bushing 12 No. 2 idler gear CAUTION
4 No. 1 idler gear 13 No. 2 idler shaft Since the No. 1 idler gear 4
5 Nut is supported by the No. 1
6 O-ring *1: Drive gear idler shaft 2, these parts
7 Collar *2: Camshaft gear P.11-54 must be removed as a
8 O-ring *3: Crankshaft gear P.11-62 single unit.
9 Bolt

● Assembly sequence
Reverse the order of disassembly.

11-48
 11

Service standards Unit: mm (in.)

Location Maintenance item Standard value Limit Remedy
– Gear Between No. 1 idler gear and 0.08 to 0.15 0.35 Replace
backlash crankshaft gear (0.00315 to 0.00591) (0.0138)
Between No. 1 idler gear and 0.07 to 0.15 0.35 Replace
No. 2 idler gear (0.00276 to 0.00591) (0.0138)
Between No. 1 idler gear and 0.07 to 0.15 0.35 Replace
drive gear (0.00276 to 0.00591) (0.0138)
Between No. 2 idler gear and 0.08 to 0.16 0.35 Replace
camshaft gear (0.00315 to 0.00630) (0.0138)
2. 3 No. 1 idler shaft-to-gear bushing clearance 0.01 to 0.05 0.2 Replace
[Basic diameter: 37 mm (1.46 in.)] (0.000394 to 0.00197) (0.00787)
4, 12 Idler gear end play 0.05 to 0.15 0.3 Replace
(0.00197 to 0.00591) (0.0118)
11, 13 No. 2 idler gear bushing-to-shaft clearance 0.01 to 0.05 0.2 Replace
[Basic diameter: 32 mm (1.26 in.)] (0.000394 to 0.00197) (0.00787)

Tightening torques Unit: N·m (kgf·m) [lbf·ft]

Location Parts to be tightened Tightening torque Remarks
1 No. 1 idler gear mounting bolt 88 (9) [64.9] –
5 Collar mounting nut 82 (8.4) [60.5] –
9 No. 2 idler gear mounting bolt 95 (9.7) [70.1] –

Oils
Location Points of application Kinds Quantity
6, 8 O-ring Engine oil As required

11-49
TIMING GEARS

Special tools Unit: mm (in.)

Location Tool name and shape Part No. Application

Removing No. 1 idler

2, 4 Gear Puller MH061326
shaft and gear

02065

Idler Gear Bushing Puller

A B <No. 1>
MH062601 Removing and fitting
3, 11 No. 1 idler φ37 φ40
<No. 2> idler gear bushings
gear bushing (φ1.46) (φ1.57)
MH061779
No. 2 idler φ32 φ35
gear bushing (φ1.26) (φ1.38)
02066

Removing No. 2 idler

13 Idler Shaft Puller MH062405
gear shaft

02067

◆ Service procedure
● Pre-disassembly inspection
(1) Gear backlash
For each gear pair, measure backlash at three or more points. If any
measurement exceeds the specified limit, replace the defective part(s).

02284

(2) Idler gear end play

If the measurement exceeds the specified value, replace the defective
part(s).

02069

11-50
 11

2 3 No. 1 idler shaft and No. 1 idler gear bushing

[Inspection]
If the clearance exceeds the specified limit, replace the defective
part(s).

02576

No. 1 idler gear bushing

[Removal]

A: Press

02577

[Installation]
• Using the Idler Gear Bushing Puller, press the No. 1 idler gear
bushing 3 into the No. 1 idler gear 4 from the side of the gear whose
internal diameter is chamfered B.

A: Press

• After installation, measure the clearance again. If the measurement

02578 is below the nominal value range, ream the bushing 3.

2 4 Removing No. 1 idler shaft and No. 1 idler gear

Loosen the bolt 1 by approximately 15 mm (0.591 in.), then remove the
No. 1 idler shaft 2 and No. 1 idler gear 4 as a single unit.

02070

4 12 Installing No. 1 and No. 2 idler gears

Fit the No. 1 and No. 2 idler gears 4, 12 such that their alignment marks
(“1”, “2”, “3”, “4”) are aligned with those on the gears with which they
mate.

*1: Drive gear

*2: Camshaft gear
*3: Crankshaft gear
02074
11-51
TIMING GEARS

11 13 No. 2 idler gear bushing and No. 2 idler shaft

[Inspection]
If the clearance exceeds the specified limit, replace the defective
part(s).

02579

No. 2 idler gear bushing

[Removal]

A: Press

02580

[Installation]
• Using the Idler Gear Bushing Puller, press the No. 2 idler gear
bushing 11 into the No. 2 idler gear 12 from the side of the gear
whose internal diameter is chamfered B.

A: Press

• After installation, measure the clearance again. If the measurement

02581 is below the nominal value range, ream the bushing 11.

13 Removing No. 2 idler shaft

02075

11-52
 11

MEMO

11-53
CAMSHAFT

18061

● Pre-disassembly inspection
P.11-56

● Disassembly sequence
1 Engine speed sensor 8 Camshaft gear
<models with electric speed sensor> 9 Thrust plate
2 Adapter <models with electric speed sensor> 10 Key
Tachometer drive case 11 Camshaft
<models with mechanical tachometer> 12 No. 4 camshaft bushing
3 O-ring 13 No. 3 camshaft bushing
4 Pulse rotor <models with electric speed sensor> 14 No. 2 camshaft bushing
Tachometer drive coupling 15 No. 1 camshaft bushing
<models with mechanical tachometer>
5 Side cover
6 Camshaft assembly *: Crankcase P.11-62
: Non-reusable part
7 Bolt

NOTE
• Do not remove the engine speed sensor 1 unless defects are evident.
• Do not remove the camshaft gear 8 unless defects are evident.

● Assembly sequence
Reverse the order of disassembly.

11-54
 11

Service standards Unit: mm (in.)

Location Maintenance item Standard value Limit Remedy
1 Resistance of engine speed sensor 2.3 ± 0.2 kΩ – Replace
[at 25°C (77°F)]
6 Camshaft assembly end play 0.05 to 0.22 0.4 Inspect
(0.00197 to 0.00866) (0.0157) each part
11 Camshaft Cam lift Inlet 6.901 6.40 Lobe height:
(0.272) (0.252) 49.011 (1.930)
Base circle
diameter:
41.627 (1.659)
Exhaust 7.680 7.18 Lobe height:
(0.302) (0.283) 49.307 (1.941)
Base circle
diameter:
41.627 (1.659)
Bend 0.02 (0.000787) 0.04 Replace
or less (0.00157)
11, Camshaft No. 1 journal 0.05 to 0.10 0.25 Replace
12 to 15 journal-to- [Basic diameter: (0.00197 to 0.00394) (0.00984)
camshaft 57.75 mm (2.27 in.)]
bushing
No. 2 journal 0.05 to 0.10
clearance
[Basic diameter: (0.00197 to 0.00394)
58.00 mm (2.28 in.)]
No. 3 journal 0.13 to 0.18
[Basic diameter: (0.00512 to 0.00709)
58.25 mm (2.29 in.)]
No. 4 journal 0.05 to 0.10
[Basic diameter: (0.00197 to 0.00394)
58.50 mm (2.28 in.)]

Tightening torques Unit: N·m (kgf·m) [lbf·ft]

Location Parts to be tightened Tightening torque Remarks
1 Engine speed sensor 29 ± 5.9 (3.0 ± 0.6) –
<models with electric speed sensor> [21.4 ± 4.4]
4 Pulse rotor 98 (10) [72.3] –
<models with electric speed sensor>
7 Camshaft gear mounting bolt 175 (18) [129] –

Oils and sealants

Location Points of application Kinds Quantity
1 Engine speed sensor threads Threebond 1104J As required
<models with electric speed sensor>
5 Crankcase mounting surface of side cover Threebond 1207C As required
11 Camshaft journals Engine oil As required
12 to 15 Inside surfaces of camshaft bushings Engine oil As required
11-55
CAMSHAFT

Special tools Unit: mm (in.)

Location Tool name and shape Part No. Application

Blanking plug for

Plug MF665007 use when removing
camshaft gear

02082
8

Removing camshaft
Gear Puller MH061326
gear

02065

Camshaft Bushing Installer

and Extractor

A, C dimension B dimension Removing and

12 to 15 MH062025 installing camshaft
No. 1 φ62.00 (φ2.44) φ57.75 (φ2.27)
bushings
No. 2 φ62.25 (φ2.45) φ58.00 (φ2.28)
No. 3 φ62.50 (φ2.46) φ58.25 (φ2.29)
No. 4 φ62.75 (φ2.47) φ58.50 (φ2.30)
02083

◆ Service procedure
● Pre-disassembly inspection
Camshaft end play
If the end play measurement exceeds the specified limit, replace the
defective part(s).

02084

1 Inspecting engine speed sensor

<Models with electric speed sensor>
• Measure the electrical resistance between terminals ➀ and ➁.
• If the measurement is out of specification, replace the speed sensor
1. P.11-55

CAUTION
Check the tightening torque of the engine speed sensor 1. If
03674
the sensor is insufficiently tightened, it may not produce
signals.

11-56
 11

5 Fitting side cover

• Apply an even, unbroken bead of sealant A to the side cover 5.
• Fit the side cover 5 onto the crankcase within 3 minutes of applying
the sealant A.

CAUTION
• Ensure that the sealant application surface of the side cover 5
18062 is clean before applying sealant.
• When fitting the side cover 5, hold it firmly in position to
prevent spreading the sealant.
• After fitting the side cover 5, wait at least an hour before
starting the engine.
• Apply a new bead of sealant A whenever the mounting bolts of
the side cover 5 have been loosened.

6 Camshaft assembly
[Removal]
• When removing the camshaft assembly 6, take off the side cover 5
and support the camshaft by hand.
• Remove the bolts A from the camshaft gear holes, then slowly
remove the camshaft assembly 6.

CAUTION
02086
Take care not to damage the camshaft bushings 12 to 15 when
removing the camshaft assembly 6.

[Installation]
• Before installing the camshaft assembly 6, measure the end play
between the thrust plate 9 and camshaft 11.
• If the measurement exceeds the specified limit, replace the
defective part(s).
• With the alignment marks lined up on the camshaft gear 8 and No. 2
idler gear, fit the camshaft assembly.

02092

8 Camshaft gear
[Removal]

CAUTION
The camshaft gear 8 must be removed with the appropriate
special tools. Do not tap off the camshaft gear since this
would damage it.

02088
: Gear Puller
: Plug

11-57
CAMSHAFT
[Installation]
• Fit the camshaft gear 8 onto the camshaft 11 in the direction
illustrated.
• Do not forget to fit the key 10.

11714

11 Inspecting camshaft
(1) Cam lift
If any base circle-to-lobe height difference is less than the required
value, replace the camshaft 11.
NOTE
Since the cams are tapered, they must be measured at the
position A shown in the diagram.

02090
B: Lobe height
C: Base circle diameter
D: Front of engine

(2) Camshaft bend

Support the camshaft 11 at its No. 1 journal E and No. 4 journal F, then
take measurements at the No. 2 journal G and No. 3 journal H. If either
measurement exceeds the specified limit, replace the camshaft.
NOTE
Turn the camshaft 11 through one revolution. One-half of the dial
indicator reading represents the camshaft's bend.

04108

11 to 15 Camshaft and camshaft bushings

[Inspection]
If any clearance exceeds the specified limit, replace the defective
part(s).
NOTE
Measure the camshaft bushings 12 to 15 with the camshaft
installed in the crankcase *.

02093

11-58
 11

Camshaft bushings
Removal and installation of camshaft bushings should be carried out
using the Camshaft Bushing Installer and Extractor. Each guide of
the tool is stamped with an identification mark (“1”, “2”, “3”, “4”) in the
position shown. Use correct adapter and/or guide piece to remove and
install a bushing according to the table below.

Bushing No. (from front of engine) Identification mark

13020 No. 1 1
No. 2 2
No. 3 3
No. 4 4

<Components of Camshaft Bushing Installer and Extractor>

A: Rod
B: Camshaft bushing adapter
C: Guide piece
D: Nut

[Removal]
Remove the No. 4 and No. 3 camshaft bushings 12, 13 from the rear of
the engine. Remove the No. 2 and No. 1 camshaft bushings 14, 15
from the front of the engine.

: Camshaft Bushing Installer and Extractor

02094

[Installation]
• Identify the No. 1 to No. 4 camshaft bushings 12 to 15 from their
identification marks (“1”, “2”, “3”, “4”) in accordance with the table
below. If any bushing's identification mark is unclear, identify the
bushing from its internal diameter E.

Bushing No. Identification mark Internal diameter

(from front of engine) [mm (in.)]
11741 No. 1 1 φ57.75 (φ2.27)
No. 2 2 φ58.00 (φ2.28)
No. 3 3 φ58.25 (φ2.29)
No. 4 4 φ58.50 (φ2.30)

11-59
CAMSHAFT
• Install the bushings 12 to 15 by using all components of the
Camshaft Bushing Installer and Extractor (rod A, camshaft bushing
adapter B, guide piece C and nut D).
• Install the camshaft bushings 12 to 15 in the following order: No. 3,
No. 4, No. 2 and No. 1.
NOTE
Install the No. 3 and No. 4 camshaft bushings 12, 13 from the rear
of the engine. Install the No. 1 and No. 2 camshaft bushings 14,
06225
15 from the front of the engine.

• Ensure that the oil holes F in the No. 1 and No. 4 camshaft bushings
15, 12 are aligned with the oil holes G in the crankcase. With the
No. 4 camshaft bushing, ensure also that the longer oil hole H is
toward the rear of the engine.

J: Bushing clinch joint

: Camshaft Bushing Installer and Extractor

04109

11-60
 11

MEMO

11-61
CRANKSHAFT AND CRANKCASE

18070

● Pre-disassembly inspection
P.11-65

● Disassembly sequence
1 Bolt 8 Bolt 15 Crankshaft gear
2 Crankshaft pulley 9 Lower main bearing 16 Crankshaft
3 Bolt 10 Main bearing cap 17 Upper main bearing
4 Torsional damper 11 Thrust plate 18 Crankcase
5 Front cover assembly 12 Crankshaft assembly
6 Front oil seal 13 Front oil seal slinger : Non-reusable part
7 Front cover 14 Rear oil seal slinger

● Assembly sequence
Reverse the order of disassembly.

11-62
 11

Service standards Unit: mm (in.)

Location Maintenance item Standard value Limit Remedy
9, 17 Main Oil clearance 0.05 to 0.10 0.15 Replace
bearing [Basic diameter: 80 mm (0.00197 to 0.00394) (0.00591)
(3.15 in.)]
Span when free – Less than Replace
85.5 (3.37)
16 Crankshaft End play 0.10 to 0.25 0.4 Replace
bearing (0.00394 to 0.00984) (0.0157)
Bend 0.05 (0.00197) or less 0.1 Contact or
(0.00394) replace
Pin and Roundness 0.01 (0.000394) or less 0.03 Contact or
journal (0.00118) replace
Cylindricity 0.006 (0.000236) or less – Contact or
replace
18 Distortion of crankcase top surface 0.07 (0.000276) or less 0.2 Replace
(0.00787)

Tightening torques Unit: N·m (kgf·m) [lbf·ft]

Location Parts to be tightened Tightening torque Remarks
1 Crankshaft pulley mounting bolt 185 (19) [136] –
3 Torsional damper mounting bolt 67 (8) [49.4] –
8 Main bearing cap mounting bolt 67 (8) [49.4] + 90° • Wet
• Can be reused
up to 3 times

Oils and sealants

Location Points of application Kinds Quantity
5 Crankcase mounting surface of front cover Threebond 1207C As required
assembly
6 Front oil seal lip Engine oil As required
8 Bolt threads Engine oil As required
9, 17 Main bearing inside surfaces Engine oil As required

11-63
CRANKSHAFT AND CRANKCASE

Special tools Unit: mm (in.)

Location Tool name and shape Part No. Application

Main Bearing
MH061189 Removing main bearing caps
Cap Extractor

02097
10

Socket Wrench MH061560 Fitting main bearing caps

01984

Front Oil Seal

13 MH062710 Installing front oil seal
Slinger Installer

13625

Rear Oil Seal

14 MH061470 Installing rear oil seal slinger
Slinger Installer

02051

15 Gear Puller MH061326 Removing crankshaft gear

02065

11-64
 11

◆ Service procedure
● Pre-disassembly inspection
Crankshaft assembly end play
If the measurement exceeds the specified limit, replace the defective
part(s).

02098

4 Torsional damper <Viscous type>

CAUTION
Leakage of silicon oil from the caulked seam A can cause the
viscous-type torsional damper to stop functioning. Note the
following points:
• Check that the caulked seam is free of gouges and other
damage.
14933
• Do not submit the torsional damper to shock by striking it
with a hammer or dropping it.
• Do not roll the torsional damper or stack it with other units.

5 Installing front cover assembly

• Apply an even, unbroken bead of sealant A to the mating surface of
the front cover assembly 5 to be mounted to the crankcase 18.
• Fit the front cover assembly 5 onto the crankcase 18 within 3
minutes of applying the sealant A.

CAUTION
• Ensure that the sealant application surface of the front cover
11729
assembly 5 is clean before applying sealant.
• When fitting the front cover assembly 5, hold it firmly in
position to prevent spreading the sealant.
• After fitting the front cover assembly 5, wait at least an hour
before starting the engine.
• Apply a new bead of sealant A whenever the mounting bolt of
the front cover assembly 5 have been loosened.

9 17 Main bearings
[Installation]
Install the main bearings 9, 17 such that their lugs A fit into the
corresponding grooves.

CAUTION
The upper main bearing 17 has an oil hole B. The lower main
bearing 9 has no oil hole. Take care not to confuse the upper
11730
and lower parts.

11-65
CRANKSHAFT AND CRANKCASE
[Inspection]

CAUTION
• Do not attempt to manually expand either bearing 9, 17 if its
span is insufficient.
• Upper and lower bearings 9, 17 must be replaced as a set.

(1) Span when free

01995 If either bearing's span when free exceeds the specified limit, the
bearings 9, 17 must be replaced.
(2) Main bearing-to-crankshaft clearance
• Fit the upper main bearing 17 into the crankcase 18 and the lower
main bearing 9 into the main bearing cap 10. Then, tighten the bolts
8 to their specified torque.
• Measure the internal diameters of the main bearings 9, 17 and the
outside diameter A of the crankshaft journal. If the clearance
exceeds the specified limit, replace the defective part(s).

02104

10 Main bearing caps

[Removal]

02100
[Installation]
• Starting at the front of the engine B, fit the main bearing caps 10 in
the order of the numbers A embossed on them and such that the
numbers are in the positions illustrated.
• The bolts 8 can be reused only three times. Before fitting the bolts,
make a punch mark on the head of each bolt to indicate times of
reuse.

CAUTION
If any bolt already has three punch marks, it must not be
02103 reused any more; replace it with a new one.

11-66
 11

• Tighten the bolts 8 to the specified torque. Then, turn the bolts
further in accordance with the following procedure:
• Turn the holder C of the Socket Wrench counter-clockwise to
tension the built-in spring.

D: Socket
E: Rod
F: Rod (extension)
01991

• Set the socket wrench such that the built-in spring force forces the
rod F against the crankshaft assembly 12.
• On the holder C, select the inscribed line G that is easiest to see.
• Using the selected line as a reference, turn the socket D 90°
clockwise. (One gradation on the scale H represents 5°.)

CAUTION
Since the bolts utilize the plastic region tightening method,
12829 they must not be tightened further after this procedure.

11 Installing thrust plates

Fit a thrust plate 11 on each side of the main bearing caps 10 and at
the rear end of the crankcase 18 such that the oil grooves A are on the
outside.

B: Locating pin

NOTE
11731
If oversize thrust plates 11 are used, they must be fitted on both
sides of the bearing caps 10. Ensure that the bearing cap rear
thrust plates and the rearmost thrust plate in the crankcase 18
are the same size. Note, however, that the front and rear thrust
plates on each bearing cap may be of different sizes.

13 Installing front oil seal slinger

Using the Front Oil Seal Slinger Installer, drive the front oil seal
slinger 13 onto the crankshaft 16 until the tool's end face A is pressed
firmly against the guide B.

11969

11-67
CRANKSHAFT AND CRANKCASE

14 Installing rear oil seal slinger

Using the Rear Oil Seal Slinger Installer, drive the rear oil seal
slinger 14 onto the crankshaft 16 until it is pressed firmly against the
end face A of the crankshaft gear 15.

02063

15 Removing and fitting crankshaft gear

[Removal]

CAUTION
Do not tap off the crankshaft gear 15 since this could damage
it.

02110 : Gear Puller

[Installation]
• Using a piston heater or the like, heat the crankshaft gear 15 to a
temperature of approximately 100°C (212°F).
• Align the locating pin A on the crankshaft 16 with the notch B in the
crankshaft gear 15. Then, drive the gear into position by striking its
end face with a plastic mallet.

02111

16 Crankshaft
[Inspection]
(1) Roundness and cylindricity of crankshaft journal and pin
If either measurement exceeds the specified limit, replace the
crankshaft 16 or grind it to undersize.

02105

(2) Bend
• Support the crankshaft 16 at its No. 1 journal A and No. 7 journal B.
Measure the extent of bending in the crankshaft at the centre of the
No. 4 journal C.
• If the measurement exceeds the specified limit, replace the
crankshaft.
NOTE
With the dial indicator applied to the centre journal, turn the
04110 crankshaft 16 through one revolution. One-half of the dial
indicator reading represents the extent of bending.
11-68
 11

[Rectification]
NOTE
If the crankshaft 16 is rectified by grinding, the main bearings 9,
17 must be replaced with undersized ones.

• Grind such that the centre-to-centre distance F between the journal

D and pin E does not change.
F: 57.5 +0.025 +0.001
−0.075 mm (2.26 −0.003 in.)
02107 • Grind such that the journal width G and pin width H do not change.
G: 37 mm (1.46 in.)
H: 42 +0.2
0 mm (1.65 +0.008
0 in.)
• Finish the corner fillet smoothly and to the specified radius J.
J: Radius 4 ± 0.2 mm (Radius 0.157 ± 0.008 in.)
• Carry out a magnetic inspection to check for cracks caused by
grinding. Also, check that the Shore hardness of the surface has not
dropped below Hs 75.

Crankshaft undersize dimensions Unit: mm (in.)

Degree of undersize
0.25 (0.00984) 0.50 (0.0197) 0.75 (0.0295) 1.00 (0.0394)
Finished journal diameter 79.685 to 79.705 79.435 to 79.455 79.185 to 79.205 78.935 to 78.955
(3.137 to 3.138) (3.127 to 2.537) (3.117 to 3.118) (3.107 to 3.108)
Finished pin diameter 64.67 to 64.69 64.42 to 64.44 64.17 to 64.19 63.92 to 63.94
(2.546 to 2.547) (2.536 to 2.537) (2.526 to 2.527) (2.516 to 2.517)
Roundness 0.01 (0.000394) or less
Cylindricity 0.006 (0.000236) or less

• When grinding K, turn the crankshaft 16 counter-clockwise as

viewed from its front end. The grinder L should rotate in the same
direction.
• When finishing N the crankshaft 16 with sandpaper or a whetstone
M, rotate the crankshaft clockwise.

02108

18 Distortion of crankcase top surface

If distortion exceeds the specified limit, correct it with a surface grinder.

A: Measurement positions

CAUTION
When grinding the crankcase 18, take care that the piston
projections stay within specification.
02114

11-69