No.

ME-S6SAE

MODEL: MITSUBISHI S6S-31TFL

S6S-31TFLW
S6S-Y231TFL
DIESEL ENGINE

TCM CORPORATION
 SAFETY PRECAUTIONS
MAINTENANCE & REPAIR
Take special attention when jacking up the truck. Fix it safely by using stands or wood blocks.

Confirm the safety of the surrounding. Use ropes having an extra load margin when lifting heavy
objects.

Make sure bolts, nuts, pipes and wires are completely removed when using power tools to dis-
mount parts.

To carry heavy articles, use tools or machines. Never attempt to do so with hand.

Your TCM machine requires TCM genuine parts. Designate TCM genuine parts when ordering
parts for your machine.

Use clean tools and select a clean, dustfree place when servicing hydraulic devices and other
precision parts.

Make sure battery terminals are disconnected when servicing electric system parts or welding.
(First remove the negative terminal, and then the positive one.)

Particular attention should be paid to keep oils, gases and flammables away from the workshop.
Tidy up and fix the disassembled parts and tools.

A sign post or caution board should be set up to arouse attention for prohibition of engine or lever
operation while servicing.
Do not attempt to remove any components while the engine is running.

Never stand beneath a upraised fork or carriage. Block machine and carriage when servicing.

Keep the servicing tools always in good order. Check them regularly, and handle properly.

In a poorly ventilated room (workshop), never operate the engine for a long while.
 FOREWORD

This Shop Manual was written to provide necessary information on the maintenance and repair instructions for the

Model S6S diesel engine designed for industrial equipment. To take full advantage of the features built in the engine

and industrial equipment on which the engine is installed, service the engine in an orderly manner and observe specified

requirements when performing overhaul or repair of any unit.

Keep this Shop Manual in the shop as a ready reference for service personnel who service the engine or equipment.

The specifications and standard values given in this Shop Manual are subject to change without notice.

This Shop Manual covers the following truck models:

 Howt
oUseT
hisManual

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rmat
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企 CAUTION
Wh enchangingpar
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mbly
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1
. NotesonD
esc
rip
tio
ns
(
1)P
art
sshowni
nfi
gur
esa
swe
lla
sint
het
exta
ren
umb
ere
dint
heo
rde
rofd
isa
sse
mbl
y.
(
2)I
nsp
ect
ingp
oin
tsd
uri
ngd
isa
sse
mbl
yar
eshowni
nth
edi
sas
sem
blyf
igu
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osi
ngi
nth
ebo
x.
(
3)Mai
ntenanc
es ta
ndard
sf o
rinsp
ect
ionandr ep
airar
el i
ste
dont heap
pro
priatepagesofth
ismanualwhereth
e
r
eleva
ntdes
cri
ptio
nsaremade
. A ls
o ，
ac om
prehe
nsivel
ist
ingo
fmain
tenanc
es ta
ndar
dsisp
rovi
dedinGroup1
.
(
4)P
artsrea
ssemb
lys e
quenc
eispro
videdbelowth
efi伊reoft
hatreas
sem
blyintheformof⑤→②→④→③→①.
(
5)In白i
smanu
al，
thef
oll
owi
ngmarksa
rep
rov
ide
dtod
rawt
her
ead
er'
sat
ten
tio
ntot
hes
afe
tyn
ote
sde
scr
ibe
dun
der
t
hema
rks
.

園-園調 百l
i
n
i
si
ju
r
n
di
yu
n
c
a
l
t
e
s
e
sad
sa
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a
o
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i
d
g
e
e
ro
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d.
ss
itu
ati
onw
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yli
kel
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sul
tind
eat
hors
eri
ous

図盟国璽E園 Thi
sind
ica
tesapot
ent
ial
lyd a
nge
rou
ssi
tua
tio
nwhichmayp
oss
ibl
yle
adt
ode
atho
r
se
rio
usin
jur
yunl
essavo
ided
.

留置E皿
ES
・
百lIsi
ndi
cat
esap
ote
nti
all
yda
nge
rou
ssi
tua
tio
nwhichmayc
aus
eminoro
rmo
der
ate
i
nju
ryu
nle
ssa
voi
ded
.

E盈I!II園E 百l
i
sin
dic
ate
sap
ote
nti
ald
ang
eri
nwh
ichp
rop
ert
ydamagemayr
esu
ltu
nle
ssa
voi
ded
.

N
ote
:・・・・・・・・・・・・・・・・ Thi
sst
res
ses耐l
pO此a
ntp
oin
tso
rpr
ovi
desu
sef
ult
ipsone
ngi
neo
per
ati
onsa
nds
erv
ice
.

(
6) Wh e
rev
erha
rdwa
ret
igh
te凶ngreq
uire
st h
eapp
lic
ati
onofengi
neoi
!
，“WE
T"i
sme
nti
one
d. I
fno
tme
nti
ond，
e
t
igh
tent
heh
ardw
are“
dry"(e
ngi
neoilsho
uldn
otbeapp
lie
d).
2
. Terms
Nominalv
alu
e..
...T
hisi
sth
eno
min
ald
ime
nsi
ono
fth
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口be
ingm
eas
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d.
S
tan
dar
d..
...
...
..ηlisisthedimens
ionoftheindi
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此 bein
gm ea
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anceb
etwee
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ep訂 tsi
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imi
t..
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pro
pri
ate.

3
. A
bbr
evi
ati
onsandS
tan
dar
ds
• BTDC=B
efo
reTopDeadC
ent
er
• ATDC=A
fte
rTopDeadC
ent
er
• BBDC=B
efo
reBottomDeadC
ent
er
• ABDC=A
食erBottomDeadC
ent
er
• TIR=T
ota
lIn
dic
ato
rRe
adi
ng
• API=AmericanP
etr
ole
umI
nst
itu
te
• ASTM=Am
eri
canS
oci
etyf
orT
est
inga
ndM
ate
ria
ls
•J
IS=J
apa
nIn
dus
tri
alS
tan
dar
ds
• LLC=LongL
ifeC
ool
ant
• MIL=M
ili
tar
ySp
eci
fic
ati
onsa
ndS
tan
dar
ds(U.
S.
)
• MSDS=M
ate
ria
lSa
feザD
ataS
hee
ts
• SAE=S
oci
etyofA
uto
mot
iveE
ngi
nee
rs(
U.S
.)

4
. U
nit
s
V
alu
esshowni
n出 i
smanualar
eb as
edonSIun
its(
Int
emat
ion
alSys
temofUn
its)
. Theco
rre
s p
ondin
gm et
ricv
alu
es
a
reshowni
n( )im
mediat
elyaf
terth
eSIv
alu
es. 百leSItom
etr
iccon
ver
sionsa
reb
ase
donthefol
lowin
g.
.P
res
sur
e:1MPa=1
0.1
97k
gfl
cm2

•T
orq
ue:1N'm=0
.10
197kgf'm
•F
orc
e:1N =0.
10197kgf
•H
ors
epo
we:1kW=1
r .34
1HP=1
.3596PS
• Metero
fme
rcu
ry:1kPa=0
.7cmHg
•M
ete
rofw
ate
r:1kPa=1
0.1
9 20(
7cmH cmA
q)
•R
ota
tio
nals
pee
d:1m
in.J=1rpm
 MAIN PARTS LIST

1. Engine model: S6S-31TFL, S6S-31TFLW, S6S-Y231TFL)

No Part name Part No. Q’ty

1 FILTER, OIL AG-32B40-00100 1

2 FILTER, FUEL AG-34462-21040 1

3 ELEMENT, AIR FILTER 230C1-02061 1
4 V-BELT AG-05910-20049 1

5 OVERHAUL GASKET KIT AG-32B94-01070 1

6 OIL SEAL, FRONT AG-F3015-07023 1
7 OIL SEAL, REAR AG-34407-11090 1

8 ALTERNATOR ASSY AG-32A68-06800 1

9 STARTER MOTOR AG-32B66-00400 1
10 GASKET, CYLINDER HEAD AG-32B01-12100 2

11 TIMER, GLOW 243C2-42421 1

12 RELAY, GLOW 243C2-42411 1
13 RELAY, SAFETY 243C2-42401 1

Note: The above list has been prepared using data obtained as of February 2005.
The specifications of the parts are subject to change without notice.
 GENERALCONTENTS

GroupNo GroupName Page

O S
afe
tyCautions 0-1
General 1-1
MaintenanceStandards 1・9
1 S
pec
ialT
ool
s 1-
21
O
ver
hau
lln
str
uct
ion
s 1・25
P
rep
ara
tio
nfo
rDisassembly 1-
29
Disassembly 2・1
2 EngineMainP
art
s I
nsp
ect
ionandR
epa
ir 2-
13
Reassembly 2-
37
Removal 3・1
3 F
uelSystem Disassembly
，In
spe
cti
onandReassembly 3-5
I
nst
all
ati
on 3-
11
Removal 4-1
4 L
ubr
ica
tio
nSystem Disassembly
，In
spe
cti
onandReassembly 4-5
I
nst
all
ati
on 4-
11
Removal 5-1
5 C
ool
ingSystem Disassembly
，In
spe
cti
onandReassembly 5-5
I
nst
all
ati
on 5・9
Removal 6-1
6 I
nle
tandExhaustSystems Disassembly
，In
spe
cti
onandReassembly 6・5
I
nst
all
ati
on 6-7
Removal 7-1
7 E
lec
tri
calSystem Disassembly
，In
spe
cti
onandReassembly 7-5
I
nst
all
ati
on 7・1
9
EngineAdjus加len
t 8-1
EngineAdjustment，Br
eak-In
8 Operati
on and Performance Break
-InO pe
ratio
n 8-7
Tests
PerformanceTe
sts 8・8
9 Others DisassemblyandReassemblyo
fGeneralP
art
s 9・1
 GENERAL

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 GENERAL

1
.2 O
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fFuelSystem

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uelinj
ect
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n
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e

F
uelr
etu
mpi
pe

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cti
onpump

t
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s
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bri
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1-3
 GENERAL

1.
4 Outlineo
fCoolingSystem

T
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tat

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y
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1
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utl
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1-4
 GENERAL

1
.6 EngineSe
ria
lNumberL o
cat
ion
τhee n
gin
es e
ria
lnumberiss t
amp
edont
her
igh
t-
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ank
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ngi
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1
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S
eri
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N
o.o
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lin
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s
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aga
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eryWorks

1-5
 GENERAL

2
. S
pec
ifi
cat
ion
s
Enginetype S6S
・3ITFL S6S-3ITFLW S6S-
Y231TFL

苛pe D
ies
ele
ngi
ne
C
ool
ings
yst
em W
ate
r-c
ool
ed
Cyc
1e 4・s
tro
kec
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No.o
fcy
lin
der
s・a
rra
nge
men
t 6-i
n-l
ine
Combustiont
ype S
wir
lchamber
V
alv
emechanism O
ver
hea
dva
lve
C
yli
nde
rbo
rex
str
oke m m[
in
.] 94x120[
3.70x4.72]

。
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時
位
T
ota
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spl
ace
men
t
Compressionr
ati
o
R
[U.
S.g
al.
] 4
.96[
9
2
2
1
.31
:1
99]

F
uel D
ies
elf
uel(
JISK2204Grade2o
req
uiv
ale
nt)
F
iri
ngo
rde
r 1-5-3-6-2-4
D
ire
cti
ono
fro
tat
ion C
oun
tec
r1o
ckw
isewhenv
iew
ed合omf
lyw
hee
len
d
O
ver
all
len
gth m m[
in
.] 1004[39.53]
Dimensions
O
ver
allw
idt
h m m[
in
.] 622[24.
49]
(inc
ludingfan
)
O
ver
allh
eig
ht m m[
in
.] 833 [32.80]
D
rymass kg[
lb
] 345[761]
C
yli
nde
rsl
eev
e 可r
pe I
nte
gra
lwi
thc
yli
nde
rbl
ock
C
omp
res
sio
nri
ng:2
P
ist
onr
ing No.ofrings
O
ilring(w/expander): 1
Open 。
BTDC30
g
回
国 I
nle
tva
lve
C
los
e 。
ABDC50
V
alv
etImi
ng
a
q
E
-
同
回
E
xha
ustv
alv
e
C
l
Open
os
e
。
BBDC74
。
ATDC30
S
tar
tin
gmethod S
旬rt
er
S
tar
tin
gai
d Growplugs
苛 pe BoschVE
Plun
gerdi
ame
ter
0.
φ11[ 43
]
F
ueli
nje
cti
onpump m m[
in
.]
Camli食 mm[泊.] .5
1 6
5[0
.06
16]
Govemor ，
Bosch a
ll-
spe
ed
‘
u
g
-
U
q
〉
b、
，
2 可pe ，
Densoth
rot
tle
No.ofs
prayhole
s
-
q
』s
b
Spra
yholedia
meter
F
ueli
nje
cti
onn
ozz
le φ1
.0[
0.0
394
]
mm[ 恒
.]
Spra
yangle 。
。

V
alv
eop
eM
nP
in
ag
t
Kp
6r
e
cs
ms
2
u)
r[
e
ps
i] 1
1.77(
120
)[1
707
]
F
uelf
il
te
r 乃pe P
ape
r-e
lem
entc
ar住i
dge

1-6
 GENERAL

Enginet
ype S6S-3ITFL S6S-3ITFLW

L
ubr
ica
tio
nmethod F
orc
edc
irc
ula
tin(
o p
res
sur
efe
edbyt
roc
hoi
dpump)
Grade CFc
Jas
s(APIc
Jas
sif
ica
tio
n)
E
ngi
neo
il
C
apa
cit
y .
f[U
.S.
gaJ
.
] E
nti
ree
ngi
ne:1
3[3.
4](
Oilp
an:1
2[3
.2])
‘
V
d
g
qh B
3 Type T
roc
hoi
d

Oilpump Speedrat
iotocran
kshaft 0
.74
z
s
E
2
ロ
・d Displa
cemen
.
f
t
[U
.S.g
alJ
. /mi
n.
3
8.7[
a
10
.
t0.
2]
/22
3
3MPa(
0mi
3k
g
n
f
'I(pumpr
/cm2
)[
4
u
n
3p
s
n
i
i
]
ng
)

Type P
ist
onv
alv
e
ie
ReJ fv
alv
e Valveopeni
ngpressu
re
35:
0. t0.05(
3.5:
t0.5)[49.8:
t7
.1]
MPa( kg
f/cm2) [
ps
i]
O
ilf
i
Jte
r Type P
ape
r-e
lem
entc
art
rid
ge
CooJ
ingmethod W
ate
r-c
ool
ed，f
orc
edc
irc
ula
tio
n
C
apa
cit
y(e
ngi
new
ate
rja
cke
t) .
f[U
.S.
gaJ
.
] 9[
2.4
]
Type 甘i
Cen fugalpump

Waterpump Speedra
tiotocra
nksha
ft .0
1
V
U
d
O
g
〉
U2
3、 Displ
acement 160[4
2.3
]/3
600mi-I(pumpr
n un
n i
ng)
2
.frU
.S.ga
J.l
fmi
n. a
t0.0
75MPa( 0
.75kgf
lcm )[
10.7psi
]
u
g
e
.
o
ロ Type s
Puhe
r(PPf
an)
CooJ
ingぬn
D
iam
ete
r m m[
in
.] φ480[
18.
90]
V
-be
lt 苛 pe m m[
in
.] Low-edgeBt
yp ， 1265[
eV-beltX1 49.
80]
Type Wax
T
her
mos
tat Valv
eop
eni
ngt
emp
era
tur
e
。
C[旬 7
6.5:
t2[169.7:
t3.
6] (FuJ
lop
en:90[
194
.0]
)

V
olt
age
-po
lar
ity 24V・N
ega
tiv
e(ー
)ground
Type M8T60372 M8T60374 M8T60372
P
ini
one
nga
gem
ent P
ini
ons
hif
t

S
tar
ter O
utp
ut V-kW 24-5
NO.ofunits
No.o fpinionte
e th l
1
0/1
22
flYWll~~1 r
inggeéiJ" t~~th
Type p
3・ha
sea
lte
mat
or，
wit
hre
cti
fie
r
O
utp
ut V-A 24・35
g
U
u
d
o
〉
令，
3、
Workingspe
ed m
in- I
upt
o8000
A
lte
mat
or Ratedout
put
E
言 generatin~peed
ロ
lIn
.I 5000
Maximum
m
in-I 1
000
0
per
miss
iblespe
ed
Speedra
tiot
ocran
ksh
a食 2
.0
乃pe E
lec
tri
c
Glowp
lug
Ratedv
olt
age
-cu
rre
ntV-A 22
・ 4(
4. 15
・se
con
dappJ
ica
tio
n)
Ratedvoltag
e V 24
Power w 14
M
agnet
icvalv
e
Workingv o
ltag
e V 1
3o rl
ess
(
Sto
ps o
len
oid
)
Retumingv o
ltag
e V 50rmore
Coi
lr esi
stan
ce Q 37

1-7
 GENERAL

3
. T
ipso
nDi
sas
sem
blya
ndR
eas
sem
bly
T
hisservi
cem anualdesc
ribesvariou
srecommended
p
roced町esf o
rs e
rvici
ngt h
ed ie
selengin
e sanda l
so
c
onta
insinforma
tionofspeci
altoolsandb a
sicsafe
ty
p
reca
utio
ns.Itshoul
dben otedth
atthemanualc ann
ot
c
overal
lp ot
ent
ialdangersinmaintai
ning，insp
ecti
ng
an
ds e
rvic
inganengine
.
Whenw o
rk i
ngont heengie，
n f
ollowthedire
ctio
nsin
t
hi
sm anualandpayc10seatt
entio
ntothefollowi
ngs:

3
.1 Disassembly
(
1) Usec or
recttoo
lsa n
di ns
trument
s.
(
2) Arrangeaw orkbencha ndboxesf o
rp l
acingremoved
par
ts，i fn eces
sary， and f ollow the s pec
ifie
d
disassem
blys e
quence.
(
3) Laydownd isassem
bledpartsneatiyandins equenc
e
topreven
tl os
ingthem.
(
4) Duringdisassembl
y，paya t
tentio
ntoa lig
nmentmarks
toen s
urep ro
perr eass
emblya ndi fneces
sary，plac
e
alignmen
tm arksonp釘 tsbeforedisas
sembly.
(
5) Careful
1yc hecke a
chp artf o
ra bnor
malitie
sb efor
e
disassem
blya ndalsoduringremovala ndc1ean
ingin
ordertodisco
veranys i
gnso fabnor
malit
iesordefect
s
tha
tmayn o
tb efoundafte
rc le
aning
.
(
6) Exerci
seu tmo
stc aut
iontoe nsuresafe
ty，par
ticu
larl
y
forbalancin
gremovedp ar
tsa ndt ra
nspor
tingheavy
p制 s
.(Us ejacksandchainbl o
ckswhenn eces
sary.
)

3
.2 Reassembly
(
1) Washa l
le n
ginep a
rts，excep
tf oroilseal，O
s -r
ings，
rubberseas，e
l t
c.，inc l
eanin
gs olven
tandd rythem
withcompressedair
.
(
2) Usec o
rrecttoo
lsa ndin柑 um
ents.
(
3) Useo nl
yh igh
-qualit
yl u
bric
atingoi
lsandg rea
ses.Be
sur
et oap p
lyac o
ato fol，g
i reaseors ea
lanttoparts
whens pe
c i
fiedso.
(
4) Wh eneve
rt ight
eningtorqu
eisi nd
icate，u
d seat orque
wrenchtot i
ghtentothespec
ifiedtigh
tenin
gt o
rque.
(
5) Ing e
neral，repl
a c
ea l
lg as
kets，packingandO -rings
withnewo nes
.

1-8
 MAINTENANCESTANDARDS

1
.MaintenanceStandardsT
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e..
...
...
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...
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・ 1-
19
 MAINTENANCESTANDARDS

1
. MaintenanceS
tan
dar
dsT
abl
e
Unit
: m m[
in
.
~
。
。
L叫 I
nsp
ect
ionp
oin
t
Nominal
value
S
tan
dar
d L
imi
t Remarks

Maximums
pee
d(n
o-l
oad
) 2
570:
t30min-1 A
djustgovemor
Minimums
pee
d(n
o-l
oad
) 8
20土 2
0mi
n- 1 s
ett
ing
.
3.
2MPa 2.8 MPa B othoila ndc oo
l-
(
33k g
ticm2) (29kgticm2) a
ntt e
mpera t
u resat
C
omp
res
sio
npr
ess
ure(
at3
00m泊
ー 1)
[4
69p s
i] [41
3p si
] 20t o30 0
C
orm or
e orl e
ss [68to8 60F]
0.
15MPa
0.
3t o0.5恥1 Pa
(
1.5k g
f/cm2)
。ど At 1
500m
in-1 (
3t o5k gtic m2
)
[21psi] Oi
lt emp
er atu r
ea t
-回

[
43to7 1p si]
za
d)

-
Ebg
;
;
!
orl e
ss 70to90 0
C
昌弘 0
.1 恥1Pa 0.
05 MPa [ 15 8to1 94 0
F]
一
慣
ら
咽 Ati
dles
pee
d (
1k g
t icm2
) (
0.5k g
ticm2)
ロ rmore I
U
b
qb
l
!!J
:>s
i
]o 1
..
..
2豆
]o rl es
s
l
nle
tva
lve
BTDC3
0.
。
U
g
ロ
・
回f 空陸型
Inl
e
tv al
ve
ABDC5
0。
弘J
V
alv
eti
min
g c
10sed
E対lau
st
BBDC7
4.
val
veo pen
E対lau
st
ATDC3
0.
val
vec10sed
l
nl
etv a
lve 0
.25[
0.0
098
]
V
alv
ecl
ear
anc
e Exhaust C
olde
ngi
ne
0
.25[
0.0
098
]
valve
Va
riesdependin
g
F
ueli
nje
cti
ont
imi
ng
・(31TFL，31TFLW)
BTDC5 ons p
eci
fic
ati
ons
.
・(Y23ITFL)
BTDC7 Seethespe
ci
fi
ca.
・
ti
onsofeachmode.
l
φ19 19
.010to1 9.03
0
R
ock
erb
ush
ingi
nsi
ded
iam
ete
r
[
0.7
48] [0.7484ω0.7492]
唱
.
。
ゐ
-d φ19 18
.980to1 9.00
0
8 R
ock
ers
haf
tdi
ame
ter
c
.
:
: [
0.7
48] [0.
7472to0 .74
80]
C
lear
anceb
etw
ece
le
n
ar
b
au
ns
c
he
i)
ng 0
.010to0 .05
0 0.070
andsha
食 (o
il [0.0
004to0 .00
20] 旦. 00
28]
φ8 7
.940to7 .95
5 7
.900
ー
-
ロ
同
[
l
nl
e
0.
t
315
] [0.
3126to0.3132] [0.
3110]
g V
alv
est
emd
iam
ete
r
φ8 7
.920to7 .94
0 7.850
ー
ロ E対l
aus
t
-
qB
旦.315
] [0.
3118to0 .3
126] [0.
3091]
g
f ab
〉
凶 0
.065to0 .09
5 0.150
〉 C
leara
ncebetween ln
le
t
国
[0.
0026to0 .00
37] [0.00
59]
v
alv
es temand
0
.080to0 .11
5 0.200
v
alv
eg ui
de E泣lau
st
[0.
0031to0 .00
45] 旦. 00
79]
1
4 1
3.9to1 4.
1
I
ns
ta
11e
dva
lveg
uid
epr
otr
usi
on
[
0.551
] [0.
547to0 .5
55]

1-10
 MAINTENANCESγANDARDS

U
nit
:mm[
in
.J
。a
2
0
旬:
i
' I
nsp
ect
ionp
oin
t
!
1、~ominal
V畠l
ue
S
tan
dar
d L
imi
t Remarks

V
alv
ese
at鉛 g
le 3
0.
0.4 0.
3to0.
5 1.0
U I
nle
t
〉
部
[
0.01
6] [0.
0 1
2to0.
020] [
0.03
9J

お￨
阿

V
alv
ehe
ads
ink
ag壱
，
0.5 0.
4to0.
6 1.0
勺
宮
司 E対l
aus
t
[
0.02
0] [0.
0 1
6to0.
024] [
0.03
9]
母
悶
由e
的 1.4 .2
1 6to1
.54 .8
1
V
alv
ese
atw
idt
h
国

[
0.05
5] 0
.0496to0
.060
6] [
0.07
1)
〉
名
〉
椙J
Upt o1.83
2.
13
V
alv
ehe
adm
arg
ine [
0.07
20]by
[
0.0
839
]
r
efa
cin
g

F
reel
en斜1 4
8.8
5[.9
1 2
32] 4
7.0[
6 1
.87
4司
。
=
も
町
0
.5
1
b 1出
2 ム口1. 5[0.
059)
0
U
b
Z S ムロL3
qua
ren
ess
同
・
ら4
acros
晶君沼健宮
[
0.051]
。
可
3
i開 g
th
〉 o
rl ess
国
〉 Lf=48.85 [.9
1 232]
43[1.6
93]1 43[ 16
衆 93]
1
176to1 96N 147N
I
nst
al
1edl
eng
th/l
oad
O (
[1
3
5
註 )
31
。
t
u
~ (14
la
0ωt
02
40
4k
lbg b
g
ff
]
時 行
弘
i
alindi
cat
or
P
ush
rod Bend 3[
0. 0
.01
2]o
r1俗$
.
!
:
5
5時
read
ing
2 Bottomf 通c
e 0
.05[0
.002
0J R
egrindif
J
q
Z 0
.20[
0.0
079
]
dis
tort
ion orl
ess d
ist
orti
onism i
nor
.
。。 C
・吋 ‘
ロ yli
nde
rhe
ad Compressed
UA 1.2 1
.15t
o12
.5
thi
cknessof
[
0.04
7] [
0.0
453t
o0.04
92]
gask
et
R
epair:
94.2
00 R
efm
ishc
yl
i設d悲r
〈9
争 4 94.
00 o94β35
0t [
3.7087
] ぬ 0.
25[
0.0
098
]
I
nsi
ded
iam
ete
r
[
3.7
00] [
3.7
008t
o3.
7022
] 記p
浪 laむemen:
t or0.50 [0
.019
7]
94.700 ove
rsiz
母 ofnorm 畠1

[
3.72
8 3
] val
uebyh on
ing
0.0
1[ 0
.000
4] and田 et hes拐犯
C
irc
ula
rit
y
orl
ess ove
rsiz
号 pis
tons
0.015[0.0
006] andpisto
nr i
ngs
.
T
ape
r
o
rless
93.955to93.985 93.
770

。
S
tan
dar
d
[3
.6990to3.700
2J [
3.6
917
]
D
iam
et. 0
.25[0.0
098
] 94 ヲ4.205to94.235 94.
020
。
佼

(
atsk
irt) ver
slz
e [
3.7
00 3.
] [ 7089to3.710
0] 3.
[ 7
016
]
0.
50 [0
.01
97] 94.455to94.485 94.
270
E
E
的
ov
ers
lze [
3.7187to3.719
9] [
3.7
114
]
」
心.25to0 .
15 Checkb ea
rin
g
P
rot
rus
ion
のβ098t
i o0 .
0059] cl
ear組 c
e.
Max.all
owa
blev語r
iat
ioni
n
5g[0
.01
1l b
]
weig
htamongpi
ston
sont he
o
rl e
ss
sameengme

1-11
 MAINTENANCESTANDARDS

U
ni: mml
t i
n.
]
。・。
‘1
5
‘
L In
spe
cti
onp o
int
Nominal
value
Sta
nda
rd L
imi
t Remarks
2.5 0.
07to0 .
11 0.200
Topring
[
0.098
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0043
] [
0 .
0 0
79]
C
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2.0 0 .0
45to0 .
085 0.150
p
ist
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[
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20to0 .
060 0.150
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ng
[
0.157
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0.0 0
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[
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P
ist
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仏 [1. 1~1] [1
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necti
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0. 0.0
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0.0
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F
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F
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0.0
197
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ula
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t 0.
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59] A食e
1 r8 000hours
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acer
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0.0
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s 1
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0.0
591
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nt
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orr
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0.0
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m
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6
. 6
84 6.384t
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784 6.
184
I
nl
et
[
0.263
1] [
0.251
3to 0.
267
1] [
0.24
35]
Camp
rof
ile
(Dj-D
2)
E対l
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t
6
. 7
20 420t
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820 6.
220 ，
主 [
0.264
6] [
0.2
528t
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268
5] [
0.244
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φ54 53
.94t
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.96 53
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N
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J
our
nald
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236t 12
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2.
1220]
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.94t
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2.90
No.
4
[2.~~7] [
2.0
842t
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085
0] [
2.082
7]
fc
I 1e
ar百nceexce
eds
Cl
earan
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ft 0.
040t
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ace
j
ourn
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hing [
0.0
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0.0
059
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ary
.
5 0
.10t
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5 0.
30 Repl
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st
Endp
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[
0.1
97] [
0.0
039t
o O.QQ~J [
0.0
118
] Pl
ate
s.

1-12
 MAINTENANCESTANDARDS

U
nit
: mm [
in
.]
。
。
c
コ
L
』
I
nsp
ect
ionp
oin
t
Nominal
value
S
tan
dar
d L
imi
t Remarks

C
lea
ran
ceb
etw
eens
haf
tand 0.
009t
o0.
050 0.
100
b
ush
ing [
0.0
004t
o0.
002
0] [
0 .
003
9]
~
弘
帽b
司

30 0
.05t
o0.
20 0.
35 Rep
lacet
hru
st
Endp
lay
~コ
司同
- B
噌
[
1.
181
] [
0.0
020t
o0.
007
9] [
0.0
138
] p
lat
es.
F
it(in
ter
fer
enc
e)o
fsh
afti
n φ35 -0
.035t
o・0.0
76 M加国(・)v a
luein-
c
ran
kcasebore [
1.
378
] [
-0.00
14t
o・0
.0030
] d
ica
tesi
nte
rfe
ren
ce.
0
.0 o0.
5t 15 0.
25
Timingg
earb
ack
las
h R
epl
aceg
ear
s.
[
0.0
020t
o0.
005
9] [0.00
98]
R
epair:
φ78 77.955 t
o77.
970 77.8
50[ 3.06
50]
J
oum
ald
iam
ete
r
[
3.0
71] [
3.0691to3.
0697
] R
eplacement:
77.
100f 3.03
541
φ58 57.
955to57.
970 57.80
0
C
ran
kpi
ndi
ame
ter
f
2.283
1 [
2.281
7to2.
2823
] [2.27
56]
C
ente
rt ocente
rdist
anc
e 60 59.
96to60
.04
be
tweenioumalandcrank
pin 2.
f 362
1 [2 .3 60JUQ~_.3 638]
P
aral
1el
ismbetwee
njoumal 0
.01[
c0m
.00
出0p
41
morle
ss
andcra
nkpi
n I
(o
vercrru
lkp
inle
n帥)
c
C
rI
ar
n
ck
ul
p
ai
rn
it
yofj
our
naland 0.
03
0
.01[
0.0
004
]orl
ess
f
O.0
012
1
0.
03
T
ape
rofjoumal andc
ran
kpi
n 0
.01[
0.0
004
]orl
ess
[
0.0
012
]

ロ
g
司
Ecrankpin
Z Fi
1
1e
tra
diu
sofjoumaland
[
0.
3
1
18] [
0.
2
1
1
.
0
8t
o3
2t
o0
.
2
.
126
0]
Bend(Def
lec
tio
natωnterjouma
l
dwi
~。
ロ。
凶B
whenm
supp
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eas
， 1
d
ur
e
1
2ofd
由 bo
ia
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血e
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ca
n
d
t
o
s
r
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0.0
008
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ess
[
0
0
.
.
0
0
0
5
20
]
C
o
c
r
r
a
r
e
n
k
c
s
to
h
af
rr
t
.
e
pla
ce

re
adi
ng.
)
Ift h
rustp late
c1eara
n cee xceeds
せleIim it，repla
ce
出r u
stp l
ate.
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lay 3
1 0.
100t
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264 0.
300
furthe rmore，use
[
1.220
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0.00
39t
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010
4] [0.
0118]
oversi
z et hru
st
pla
tes.
Th r
ustp la
teo ver-
sins:0.1 5
[[00.
.0
0
015
1
98
]
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0.30
IfcIearancee xce
eds
thel i
mi，t re
place
0.200
b伺 巾1 9
S.I fitise x・
[0.
0079]
回e ded白rthermore，
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nkshaf
t
2C
l
c
r
e
a
a
n
k
r
s
a
n
h
c
a
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f
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[
0
0
.
.
0
0
0
5
2
0t
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0t
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.
1
.
0
1
0
0
4
3] ー0
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g
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z eb eぽ加gs.
惜
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l
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:
dia
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0.25[ 0.009]，
8
isφ78[ 3.0
71]
0.5010
[
仰.
.00
21
99
71，
5
]
0.75

1-13
 MAINTENANCESTANDARDS

0
ロ
。
.
.. Nominal
司
I
nsp
ect
ionp
oin
t S
tan
dar
d L
imi
t R
ema
rks
val
ue
0.
05[0
.019
7] 0.
20 R
egrindifdis
tor
-
Topf
aced
ist
ort
ion
orles
s [
9.007
9] t
ion1S m
ino
r.
14.
000to1 4.0
18 14.
100

;
i言 Clearancebetweentappetand
E
T
app
etb
orei
nsi
ded
iam
ete
r
[
0.
0
5
5
.
0
1
1
2t
6t
o0
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05
.
2
5
519] [0.
0
55
.
08
51]
fc
I
exc
I
e
e
e
a
d
ra
st
nce
eI
h imit，
t
app
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ore [
0.0
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002
0] [
0.0
031
]
re
placetapp
ets
.
Adjus
tw ithshims
.
日官ssurev釘iesb y
V
alv
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re 11
.77 11
.77t
o12
.75
1MPa( 10k g
f7cm2
)
2 (12
0) (
120t
o13
0)
MPa( k
gfl
cm) [
ps
i] [ [142p s
i]p e
r
1707] 17
[ 07t
o18
49]
0.
1 mm[ 0.004in.
]
百 thi
cknes
so fs h
i m
.
T箆 twithhand
z
t
U
o
g、 te
s回;u sin
gd i
esel
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S fu
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8甲町.
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n
i
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na f
te
r
~ n
c
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e
a
lei
nd
sw
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ese
a
lf
sh
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e
di
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n

rep
lacenozz
letip
.
Sa
etshal
lh ol
dat es
tp r
ess町 e2MPa
O
il-
tig
htn
esso
fne
edl
eva
lves
eat ο
okgflαn 2
)[ 28
5p s
i]l ow
er血a nva
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ing
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nozz
let
rr
i
p.
e
place
p
ress
urefor1 0se∞nds.
C
lea
ranceb
etw
eeno
ute
rro
tor 0
.20t o0.30 0.50 R e
placepump
組dc a
se [0.0
079t o0.0118] [ 0.019
7] a s
sembl
y.
φ16 15
.985t o1 6.0
00
Mains
haf
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ame
ter(
cas
esi
de)
10.
630] [ 0.
6293t o0.6299]
Mains h食d
a ia
meter φ14 13
.957t o1 3.9
75
(o
ilpumpb ushin
gs id
e) [0.5
51] [ 0.
5495t o0.5502]
o
g
U
d
〉
吻2、 Clea
rancebetw
eenmains h
aft 0
.032t o0.074 0.150 Repl
acepump伺 s e
andpumpc ase [0.
0013t o0.0029] [ 0.005
9] o rJumpぉ s
l e
mbly
.
d Clea
rancebetwe
enmains h
aft 0
.025t o0.111 0.200 Repl
aceb u
shingor

E
z
s
E
a
C
n
l
do
ea
r
i
a
lpumpb
ncebetw
e
u
e
sh
ni
i
ng
nn
erro
tor
[0.
001
.l
0
0t
3t
o0.
o0.
00
15
44] [ 0
.
0
0
.
0
2
7
9
0
] pumpa
Repl
ac
s
eo
s
u
e
t
J
:
m
e
>
I
rr
y
.
oωr
組 do u
terro
tor [0.
0051t o0.0059] [ 0.007
9] a nds h
aftωse
mbly.
0
.04t o0.09 0.15 Repl
acepump
R
oto
rendp
lay
[0.
0016t o0.0035] [ 0
. 005
9] a ss
embl
y.
0.35 0.30t
o0 .4
0
古・~同叫~~里 Valveopeningpr
〉
国
F
ess
ur
Mpa(
e
kg2
f
/c
)m [
ps
i]
(3
. 6
) (3.1ω4.1)
[
51.2] [
44.1t
o5 8.
3]

~、 76
.5土2 C
0

V
alv
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eni
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era
tur
e
〉
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[
169.7
I3.
6 0
F]

g
u
ロ
bb 9m m[0.
354i
n.
]va
lveI
i
食 900
C
te
mpe
ratu
re [
1940
F]

1-14
 MAINTENANC豆 STANDARDS

t
: mm[
Uni i
Il
.}
0 Nominal
ぬ
0
2
恥.
鋼
I
nsp
ect
ionp
oin
t S
tan
d墨付 L
imi
t Remarks
V器lue

D
ist
orti
onofexh
aus
t
0
.2[
0.0
079
]orl
es
s G
rin
dorr
epl
ace
.
m
anifo
ldt1
ang
e
。
s
:
:
吋
阿
判

φ32.0 31.
4
I
Commutatord
iam
ete
r
[
1.260
] [
1.236]
18 11
Le
n俳
[
0 .
709
] [
0.433]
B
rus
h 343 2
9.4to3 9.
2 13.
7
S
pri
ngl o
ad
需

N( kf
g)[lf
b] 〈
[
37
5
.7
}1 [06
.0 t
O4.0
8)1 (
{
31
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)
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6t o8
0.5to2 .0
P
ini
ongap
[0.020ω0.079]
∞
志
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No・ l
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[
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[0.
846
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[ 315
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(Whenr
ate
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。
-
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h 設車総d v
s olt
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lta
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f
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S
O
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C
urr
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8
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1-15
 MAINTENANCESTANDARDS

2
. T
igh
ten
ingTorqueT
abl
e
2
.1 I
mpo
rta
ntB
olt
sandN
uts
1) E
( ngi
nem
ainp
art
s
Thre
ads T
igh
ten
ingt
orq
ue
D
esc
rip
tio
n D
iam
eterXpi
tch R
ema
rks
(mm) N'm kgf'm l
bf
'食
C
yli
nde
rhe
adb
olt .7
M12X1 5 1
13t
o12
3 1
1.5t
o12.
5 8
3.2t
o90.
4
C
yli
nde
rhe
adp
lug MI6X1
.5 3
9.2t
o49
.0 4
.0t
o5.
0 2
8.9t
o36
.2
R
ock
erc
ove
rbo
lt M8X1
.25 1
0.0t
o13
.0 .0t
1 o1.
3 7
.2t
o9.
4
R
ock
ers
ha食 b
rac
ketb
olt M8X1
.25 1
0.0t
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.0 1
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0 7.
2to1
4.5
Mainb
ear
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apb
olt M14X2.0 9
8to1
08 1
0.0t
o1.0 7
1 2.3t
o79
.6
C
onn
ect
ingr
odc
apn
ut MIOX1
.25 4
9.0t
o59
.0 5
.0t
o6.
0 3
6.1t
o43
.4
F
lyw
hee
lbo
lt M12X1
.25 7
8.5t
o88.
3 8
.0t
o9.
0 5
7.9t
o65
.1
C
ams
ha1
王th
rus
tpl
ateb
olt M8X1
.25 1
0.0t
o13
.0 .0t
1 o1.
3 7
.2t
o9.
4
F
ron
tpl
ateb
olt M8X1
.25 1
0.0t
o13
.0 .0t
1 o1.
3 7
.2t
o9.
4
T
irn
ingg
earc
asec
ove
rbo
lt M8X1
.25 1
7.0t
o20
.0 .7t
1 o2.
0 1
2.3t
o14.
5
C
r加 k
sha
食 p
ull
eyn
ut M30X1
.5 4
80t
o50
0 49t
o51 3
544t
. o3
68.
9
I
dle
rge
art
hru
stp
lat
ebo
lt MIOX1
.25 2
9.0t
o39
.0 3
.0t
o4.
0 21
.7t
o28
.9
R
earp
lat
ebo
lt MIOX1
.25 5
4.0t
o65
.7 5
.5t
o6.
7 3
9.8t
o48
.5

(
2) F
uels
yst
em
Thre
ads T
igh
ten
ingt
orq
ue
D
esc
rip
tio
n D
iam
eterXpi
tch R
ema
rks
(mm) N"m kgf"m l
bf
"ft
F
ueli
nje
cti
onn
ozz
le(
eng
ine
) M20X1
.5 4
9.0t
o68
.6 5
.0t
o7.
0 3
6.2t
o50
.6
F
ueli
nje
cti
onn
ozz
ler
eta
ini
ngn
ut M16XO.75 3
4.3t
o39
.2 3
.5t
o4.
0 2
5.3t
o28
.9
F
ueli
nje
cti
onpumpg
earn
ut M12XI
.75 5
9.0t
o69
.0 6
.0t
o7.
0 4
3.4t
o50
.6
F
uelin
jec
tio
npump
.0
M12X1 2
0.0t
o29
.0 2
.0t
o3.
0 1
4.5t
o21
.7
o
ver
flo
wv al
ve
F
ueli
nje
cti
onp
ipen
ut M12X1
.5 2
6.5t
o32.
4 2
.7t
o3.
3 1
9.5t
o23
.9
F
uelr
etu
rnp
ipef
la
ren
ut MIOX1
.25 1
7.7t
o21
.6 1
.8t
o2.
2 1
3.0t
o15
.9

1-16
 MAINTENANCESTANDARDS

(
3) L
ubr
ica
tio
nsy
ste
m
T
hre
ads T
igh
ten
ingt
orq
ue
D
esc
rip
tio
n
D
iam
ete
rXp
itc
h Remarks
(mm) N"m kgf"m l
bf"
ft
O
ilp
anb
olt M8X1
.25 1
0.0t
o13
.0 o1
.0t
1 .
3 7
.2t
o9.
4
O
ilp
and
rai
npl
ug M20X1
.5 7
3.0t
o83
.0 7
.5t
o8.
5 5
4.2t
o61
.5
O
ilpumpg
earn
ut MIOX1
.25 2
8.0t
o38
.0 2
.9t
o3.
9 21
.0t
o28
.2
O
ilp
res
sur
ere
lie
fva
lve M22X1
.5 4
4.1t
o53
.9 4
.5t
o5.
5 3
2.5t
o39
.8

(
4) C
ool
ings
yst
em
Thr
e a
ds T
igh
ten
ingt
orq
ue
D
esc
rip
tio
n D
iam
eterX p
itc
h Remarks
(
mm) N"m kgf"m l
bf・
食

T
her
mos
tatc
aseb
olt M8X1
.25 1
6.0t
o20
.0 .6t
1 o2.
0 1
1.6t
o14
.5
C
ool
antd
rai
npl
ug 1
I 5.
4-18NPSF 3 3t
o43.
1 3
.6t
o4.
4 2
6.0t
o31
.8
L一一一一

一
(
5) I
nl
eta
nde
xha
usts
yst
ems
T
hre
ads T
igh
ten
ingt
orq
ue
D
esc
rip
tio
n D
iam
ete
rX p
itc
h Remarks
(mm) N"m kgf"m l
bf"
ft
E
xha
ustm
ani
fol
dbo
lt M8X1
.25 I1
5.0t
o22
.0I1
.5t
o22 I1
. 0.8t
o15
.9

(
6) 日e
c甘i
ca
lsy
ste
m
Thr
ead
s T
igh
ten
ingt
orq
ue
D
esc
rip
tio
n D
iam
ete
rX pi
tch Remarks
(mm) N"m kgf"m l
bf"
ft
S
tar
tert
erm
ina
lB M8X1
.25 9
.8t
o1.8
1 .0t
1 o1.2 7
.2t
o8.
7
A
lte
mat
orp
ull
eyn
ut M20X1
.5 1
32t
o16
2 1
3.5t
o16
.59
7.6t
o19.
1 3
Glowp
lug MI0X1
.25 1
4.7t
o19
.6 .
15t
o2.
0 1
0.8t
o14.
5

1-17
 MAINTENANCESTANDARDS

2
.2 StandardB
olt
sandNuts
Threa
ds S
treng
thc1a
ssi
fic
atio
n
D
i a
meterX p
itc
h 4T 7T
(mm) N'm kgf'm l
bf.
ft N'm kgf'm l
bf・
食
恥16X1.0 2.9
4t04.9
0 0
.3to0.5 2
.2t o3.6 7
.85to9.80 0
.8to1.0 5
.8to7.2
M8X1 .25 9.8
0to12.
7 .0t
1 o1.3 7
.2t o9.4 1
4.7to21.6 1
.5to2.2 10
.8to1 5.
9
Ml OX1.25 17.
7to24.
5 1
.8to2.5 13
.0t o18.1 29. 4to41.2 3
.0to4.2 .7t
21 o3 0.
4
M12X1 .25 29.
4to41
.2 3
.0to4.2 企1.7t o30.4 5 3.9to73.5 5
.5to7.5 39
.8to5 4.
2

N
ote
:(a)Theabovet
ableshowsthet
ighte
ningtorq
ueforstand
ardbol
tsa ndnu
ts.
(
b)Thevalu
esinthetab
leappl
ywhent ighte
nedtog
etherwithspr
ingwashe
rs.
(
c)Theaboveta
bleshowsstan
dardval
u e
s，forwhic
hat oler
anceof10% isa1o
l we
d.
(
d)Unle
ssothe
rwisespec
ifi
ed，st
andar
db o
ltsandnutsshoul
dbet ig
htene
dtothet
orq
uei
nth
eta
ble
.
(
e)Don o
tappl
yoiltothrea
dedport
ions(Tig
htenunderdrycon
diti
ons)
.

2
.3 StandardE
yeb
olt
s
Thre
ads Widthacr
oss S
tre
ngthc1as
sifi
cat
ion
D
iam
eterX p
itc
h f
1a
ts 4T
(mm) Mm[凪] N'm kgf'm lbf
.ft
M8X1 25
. 12[
0.47
] 8士 l 0.8土0 .
1 5.
8士0 .7
MI0X1.25 14[
0.55
] 15士2 1.5士0 .
2 1
O.8: .4
t1
M12X1.25 17[
0.67
] 25土3 2.5土 0.
3 1
8.1土 2.
2
M14X1.5 22[
0.87
] 34:t4 3.5:t0.4 2
5.3土2 .
9
恥1l6X1
.5 24[
0.95
] 44土5 4.5:t0.
5 3
2.5土3 .
6
恥118X1
.5 27[
1.06
] 74:t5 7.5:t0.
5 5
4.2土 3.
6
M20X1 .
5 30[
1.18
] 9
8土 10 10.
0:t1.0 7
2.3:t7.
2
恥124X1
.5 36[
1.42
] 147土 15 15.
0土1.5 10
8.5土1 0
.8
M27X1.5 i
llt
&!] 226士20 2
3 .
0:t2.0 16
6.4:t14
.5
(
Dryc
ond
iti
ons
)
2.
4 StandardUnionNuts

Nominal Capn
uts
ize Widtha
cro
ssf
1a
ts
N'm kgf'm l
bf・
食
diam
eter M(mm) m m[
in
.]
6
3 .5
14X1 19[0.75
] 39 4 28.9
80 16X1
.5 22[0.87
] 49 5 36.2
100 20X1
.5 27[1.06
] 78 8 57.9
120 22X1
.5 30[1.18
] 98 10 72.
3
150 27X1
.5 32[1.26
] 1 5
7 16 11
5.7
180 30X1
.5 36[.4
1 2
] 1 9
6 20 14
4.7
200 .5
30X1 36[.4
1 2
] 1 9
6 20 14
4.7
220 33X1
.5 41[1.61
] 245 25 18
0.8
254 36X1
.5 4.
1.
.[1.
61
] 294 30 2
17.0
(
Tol
era
ncei
s:t1
0%. 企y c
ond
iti
ons)

2
.5 TaperB
olt
s
T
igh
ten
ingi
ntoaluminum T
igh
ten
ingi
ntoi
ron
S
ize
N'm kgf'm l
bf
'ft N'm kgf'm l
bf
'ft
NPTF1116 4
.90t
o7.
85 0
.5to0.8 3
.6t
o5.
8 7
.85t
o1.8
1 0
.8to1.2 5.8t
o8.
7
PTl/8 7
.85t
o1.8
1 0
.8to1.2 5
.8t
o8.
7 1
4.7t .6
o21 1
.5to2.2 1
0.8t
o15
.9
PTl/4
.
1
9.6t
o29
.4 2
.0t
o3.
0 1
4.5t
o21
.7 3
4.3t
o44
.1 3
.5t
o4.
5 2
5.3t
o32
.5
NPTF1I4
PT3/8 5
3.9t
o73
.5 5
.5t
o7.
5 3
9.8t
o54.
2

1-18
 MAINTENANCESTANDARDS

3
. S
eal
ant
sTa
ble

A
ppl
ied
p訂t M
ati
ngcomponent S
eal
ant Remarks

Applytocir
cumfe
ren
ceofoi
l
C
rankc
as，
eti
min
gge
ar panf
1ange
.Applytogroo
ves
O
ilpan T
hre
eBond1207C
c
ase andbol
tholesofo
ilpanf
1an
ge
alon
ginnercir
cum
fer
ence
.

R
earbe
ari
ngc
aps
eaton Applytoco
rner
sbe
for
e
No.7b
ear
ingc
ap T
hre
eBond1
212
c
ran
kca
se in
stal
lin
gcap
.

C
ran
kca
se，
No.7b
ear
ing
S
ides
eal
s T
hre
eBond1
211 Applyt
osi
des
eal
s.
c
ap

C
ylin
derhe
adc
ool
ant
C
yli
nde
rhe
ad T
hre
eBond1
386D Applyt
opl
ugh
ole
.
h
oleplu
g

C
rankc
asec
ool
anth
ole
C
ran
kca
se e
ThreBond1386D Applyt
opl
ugh
ole
.
p
lug

C
ran
kca
seo
ilh
olep
lug C
ran
kca
se η
rre
eBond1386D Applyt
opl
ugh
ole
.

R
etur
no i
lh ol
ep l
ugo
r
C
ran
kca
se T
hre
eBond1386D Applyt
opl
ugo
rpi
pe.
p
ipeofc
rank
case

Apply t
oc ra
nksha
ftth
rea
ds
C
ran
ksh
aftt
hre
ads C
ran
ksh
aftp
ull
eyn
ut e
ThreBond1
212
bef
oretig
hte
ningnut
.

4
. R
ega
rdi
ngP
art
sfo
rExhaustGasR
egu
lat
ion
C
aref
ullyha
ndlethef
ollow
ingpa
rtsfo
rExha
ustGasReg
ula
tio
n.
(
1) F
uelinj
ect
ionpumpassembly
(
2) F
uelinj
ect
ionnoz
zle
(
3) O
therrela
tedp訂 t
s( i
nc1
udingdesi
gnat
edfue
l and
l
ubr
ica
nt)

企 CAUTION
Wh enchangingpar
ts，bes ur
etou seourd e
signate
dp ar
ts.Unles
so urdesi
gnate
dpart
sa r
eu se
d，thee x
hau
st
emi
ssionregu
lati
onscannotbemet
.
Takecar
ethat出ep a
rtsmayb epar
tlymodif
iedduet oimprovemen，
t f
orexa
mple.
Workrelat
edtotheexhau
ste m
issio
nregul
ation
sc anbec o
nductedonlya
t0町 des
i伊a t
edser
vicefa
cto
rie
s.
However，don o
tc han
get headj
ustmen
tbyc utti
nga ndremovingthetamp
er-pr
oofsonthefuelin
ject
ionpump
ass
embly
.Thef uelin
ject
ionpumpmustb erepla
cedasa nasse
mbly.

1-19
 MAINTENANCESTANDARDS

1-20
 SPECIALγ00しS

S
pec
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s..
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22
 SPECIALTOOLS

SpecialTools

A
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Compressionpr
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AG
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1-22
 SPECIALTOOLS
"

A
ppl
ica
tio
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Camshaftbushin
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⑧@~
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1-23
 SPECIALTOOLS

1-24
 OVERHAUしI
NST
RUC
TIO
NS

1
.De
ter
min
ati
ono
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.

2
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・・・・・
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2 r
epar
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ons
....
....
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....
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a ・
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2 eas
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. . 1-
.. 27
 OVERHAULINSτRUCγIONS

1
. D
ete
rmi
nat
iono
fOv
erh
aulT
iming
I
nrnos
tc as
es，t
heengin
es ho
uldbeove
rhau
ledwhenth
ecorn
pres
sio
np r
essur
eofth
eengi
neislowanddec
reas
ed
c
orn
press
ionpre
ssur
eres
ult
sinanoti
cea
bleinc
rea
s n宰n
ei gi
neoi
lconsu
rnpti
onandb
low-
bygasandth
eses
yrnp
tor
ns
c
anbeusedtoeva
luat
etheeng
inec
ond
iti
on.

Reducedpoweroutp
u，
ti n
cr号asedfu
elconsu
rnp
tion，lowoilp
ress
ur，
容d i部cu
ltyi
ns t
ar
ti汲 私 書ndin
creas
edo
per
ati
ng
noi
sea r
ealsosi
gnstha
ts uggestthenee
df o
r翻 o ver
hau，how告ver，s
l i
nceth
esepr
oble
rnsc a nbecau
sedbyva
rio
us
fa
ctor
s，the
ydonotserv君議事 re
lia
bleso
urce
sforass
essi
ngthene
悲dforano v
erha
ul
.

Reducedcornpr
essio
npr
ess
urema
nifes
tsavar
iet
yo fs
ymp
tor
ns削 de n
gin
econ
dit
ion，t
s husrn
紘i n
gitdi
ffi
cul
t10
acc
urate
lyd e
termi
newhenthe獄事 i
n母nee
ds釦 over
ha.
lThef
u o
llo
win
gshowst
ypi
calpro
bl俄 sca
usedbyreduce
d
cor
npr田s np
lO re
ssu
re.

(a
)Decreasedout
putpower
(b
)lncre
asedぬ.e
lc on
surnp
tion
()I
c ncr
eased紛 が 加 o
ilconsumpt
ion
()I
d ncr
easedblowゐ.ygasthrou
ghthebre
athe
rduetowornc
yli
nde
rline
rs鍬 dp
ist
onr
ing
s
付対ぉc r
easedgasleaka
伊 duetop oo
rseat
ingofin
le
tande沿線us
tvaIv
es
(
f)Di絞icu
Ityinsta
rti
ng
()l
g ncr
easednois
e会' o
rnengi
nepart
s
制 Abnormal容がl a
ustcol
ora恥r w:叡m-upoper
ati
on

Thee n
ginecane xhi
bitthe
s告c on
d itio
nsinvari
ouscomb
ina
t ions
.
Sorneofthe
sepr obl
ernsaredire
ct l
yc a
usedbyworne n
ginep 叙ts，whi
1eothersar
eno t
.
Phenom側 ad es
c ribe
di ni附 ns( b)組 d伶 c anres
ult企omi mproperf u
eli n
jec
tionvolu
rneandtir
ningofthefue
l
in
jecti
onpurnp，womp lun
ge ，
rfaultynozz
les組 dals
ofaul
tyc ond
itio
nso fele
ctr
ica
lお vice
ss u
chasba
tter
yandst制:e
r.
Themostv ali
dr 意義sontoo verh
a ul鵠 e ngi
neisad ec
rea
s 母 i
nc omp
re ss
ionp r
essur
ed uetowomc yl
inderlin
ersa
nd
pi
stonr i
ngs，
畠sd escri
bedi nit，m ゆ，間do
老 ncethおお d e
termined，i
ti sreaso
nable10takeot
herp rob
lems泳to
con
sidera
tionforrnakingthefin
aljudgmen .
t

ど CAUTION
Wh enchangingpart
s，bes 被告 t
ou se0町 desig
nate
dp ar
ts.Unles
so urdesig
natedp
art
s絞 eu s
ed，t
hee 幼aus
t
er
niss
ionregu
latio
nscannotbeme .
t
Takecぽe t
hatthepar
tsrnaybepart
lymodif
iedduetoimprovem慌たお，r ex
ample.
Workrelat
edtothee泌 総ste r
nis
sionr
e群l a
tio
nscanbec o
nductedonl
yatourdesi
郡畠tedser
vic
e僻 tor
ies
.
However，don o
tc hangetheadj
us臨e ntbycut
ting組 drerno
vingthetampe
r-pro
of注onthefu
el同部録。np u
rnp
ass
embl.百 減 免e
y linj
ecti
onpω郎 総u stberep
laceda
sa nasse
mbly.

1-26
 OVERHAULINSTRUCTIONS

2
. Measurement ofCompressionPressure
2
.1 Prepa
ratio
n s
Ch容 は 枕1母 f
ollo
wing befo
re measu
ring t
he
com
preSS
lonpress
ure
.
(
1) Ensu
rethatthee ng
ineoi
l，器ircl
ean
er，s
t制 .
e
rand
ba
tter
yar詰inprop
ercon
dit
ion
.

2
.2 Measureme ぽ C
ompr
ess
ion
(
1) Movet h
ec o
ntrollevertoSTOPpos
iti
on(t
治 会lel g
age
sup
plyshu
t0的.
(
2) Removetheg lowplugsfroma
llcy
lin
der
s. In
sta
ll
th
eg agea 語:
d pt
era n
dc omp
res
sio
ng ageontothe
cy
lind
erbein
gm eas
ured. 詣s
Me u
rem
ento
fco
mpr
ess
ionp
res
sur
e
Partnumber
AG-30691-21100
AG-33391-02100
(
3) 双なli
lecrank
ingth母engin
ewitht
hest
art
er，re剖 偽e
compr
essiongage
. No ぬ th
ere誠in
ga tw h
icht h
e
gageneed
lesta
bil
ize
s盆

(
4) Ifめem鵠 皐 ぽ 吋 v alu
eis 震torbelo
wt h
el imゑ
ove
rhaul也君 en
gin
e.

Ar
Ht
llτ
I
(
a) M鵠 s
urea Ic
l yl
inおおお，rc omp
ressi
onp r
翠ss
ure
.
00 n otm e
asureo nlyo necylin
dera nd make
a s
sump
tiona b
outt heoth
ercyli
nde
rsa st h
iswil
l
l
eadt
oawrongc onclu
sio
n.
(
b)C o
mpress
ionp ressur
ev 語r
ie
sd epend
ing on t h
e
engin
es pee
d. Ke 叩 thespe
cif
iedengi附 spee
d
whenm 鵠 su
ringthecomp
ress
ionpre
ssu
re.

S純白dard
3.2MPa
Com
press
ion
(
33主gf/
i孤立}
p
ressu
re
ヰ6 9
psiJ [
413p
si
N
ote
:M ea
sureth
ecompr
essionpre
ssu悲w
r ithめee
ngin
e
ru
rmin
ga t3 m∞in-I a
0
nd泌をho i
la n
dcoo
lan
t
総mper墨知r
esat20ω30C( 68t
o860F
).

l~，.m.j凶 I
I
tisi m
porta
ntt or egul
紋lyc hec主役l ec om
pre s
sion
p
ress
ur牢sothatyouc a
ntel食器 d
l i己r
自 e
nce.
.New o ro verh
a u
lede ngin
esh aves lig
htl
yh ig
her
compre
SSlonpress
ure
.
・百lecom 予re
ssionpres
surese泌総 tothestan
d器rdv a
lue
asthepis
tonrin
gsa ndv語lv
eseat
sfi
tin.
.Aswearp rogr
ess宰sft羽her，t
hecompr昏ssio
np r母ss
ure
dro
ps.

1-27
 OVERHAULINSτRUCTIONS

1-28
 PREPARAγ
IONFORD
ISA
SSE
MBL
Y

1
.Preparation.........・
・
・ B ・
・・・
・・・
・..
...
...
...
...
...
...
...
事...
..............事事・・・・・・・・・・・・・ー・・・・・・・・ 1-30
1
.1C
utt
ing0仔 F
uelS
upp
ly.
...
...
...
...
...
.網~ .
. .
. ，
...
..
.，.
..
..
..
..
..
...
. .
需.
..
..
....・・・・・・・・・・・・・・ ・
・・・
・ 6 1-30
1
.2RemovingE
lec
tri
calW
iri
ng ...........・・・・・・・・・・・・・凶・掴・・・・・・・・・・ ・・・・・・・・・ w・・・・・・・・・
a 1-30
1.3Dr
，i
滋 n
ingC
ool
ant・
・・.
...
...
...
...
...
...
...
...
‘盆・
・・・
雀..
...
...
...
...
...
...
...
....
...
...
...
...
...
...
健・・
‘・・
・・・
‘・ 130
欄

1
.4D
rai
nin
gEn
gin
eOi
l・・
・・ ・・・・・・・・守.....
e ...
...
...
.・“
...
...
...
...
.
‘
・ ・
・‘
・ ・
・・・
...
....
...
...
..・
・
a・ e 1・30

2
.TheEngineRemovalProcedure................・・・・・・・・・・・・・・・・附 w ・・・・・・・・・・・・・・・・・・・・ 1-
31
 PREPAR
AγIONドORDISASS医MBLY
'

1. Preparation
1
.1 C
utt
ingo
ffF
uelSupply

!&CAUTION
B
efo
red i
sasse
mblingtheeng
in久 clo
sethemaiおおel
s
upp
lyv皐lv
e，註nddrainf
uelf
romthepip
ecomp
let
el)
に

I
ffu
eli
sremainin
gi nth
epip
e，se
riou
sacci
den
tssuc
has
a
nexpl
osio
na ndf
iremayr母s
ul.
t

1
.2 RemovingE l
ect
rica
lWiring
Dis
connectthewir
ingharn
esse
sf romthefo
llow知事
equ
ipme
n t.
Bef
oredi s
con
nec
ting，a
tta
chtagsoroth
母rin
dic
ation
s
onthet
e rm
ina
lstofa
ci1
it
at
er e
conn
ect
ion.
.S
tar
ter
.Swi
tch部

1
.3 Drain
ingCoola
nt
Removethecool
antdra
inplu
go nt
heleft
.ha
nds
ide
fお eofth悲 cr
ankca
set odrai
ncool
antf r
omthe
engme
.
(Coo
lantc
apa
cit
y:appro
x.9f[
. 2.
4U.
S伊1.])

D
rai
nin
gco
ola
nt
1
.4 Drai
ningEngineOil
Remo開 設leengi
neoildr
aiぉpl
ugfr
omtheoi
lpa
nto
d創設 t
r h
eengineoi
.l
(O
ilpancap
aci
ty:appr
ox.12.
f[3
.2U
.S.
gal.
]
)

r&CAUTION
Becar
efu
lnottoto
uchh
otd
rai
nede
ngi
neo
ils
inc
eit
co
uldca
useb
urn
s
・.

a
Drin
inge
ngi
neo
il

1-30
2. The engine Removal Procedure
2.1 It makes key position “OFF” and it removes the earth
cable (–) of the battery.

2.2 It drains the engine oil, cooling water.

(It refers to the clause preparation 1.3, 1.4.)

2.3 It removes an air intake hose from the engine.

(After loosening the hose band, it remove.)

2.4 It removes two radiator cover.

(The front cover and the rear cover.)

2.5 It removes a headguard as occasion demands.

1-31
 2.6 It removes a bonnet. (It remove two gas spring and
it removes the mounting bolt of bonnet hinge.)

! CAUTION: When removing two gas spring, the

support of the bonnet passes away and
there is possibility to close suddenly at
the weight of bonnet. Support a bonnet
with sim tree and so on and work.

2.7 It removes two nuts in the connection between the

exhaust manifold and front pipe.)
(When it is difficult to remove, it removes muffler
mounting bolt.)

2.8 It removes radiator hose (upper and lower) and

removes fan shroud or radiator.

! CAUTION: When it moves a radiator hose, there is

possibility that hot cooling water rush cut.
Even if it drain out, be careful sufficiently.

2.9 It removes the electric wiring and the tube of fuel which
connects to the engine.

2.10 It makes for a placing transmission to be supported in the wooden block by the bottom of the
transmission.

2.11 It hangs with crane and it maintains an engine.

1-32
2.12 It removes bolt and nut of the engine mount part.

2.13 It removes a pin cotter in the drive shaft in the clutch

housing and it removes the drive shaft from the clutch
disk. (The clutch type)

2.14 It removes the bolt between input plate and flywheel.

The bolt is ten pieces.
(The torque converter type.)

2.15 It removes the bolt of clutch (torque) housingcase.

2.16 It removes an engine.

! CAUTION: When removing an engine, it careful of whether or not the interference in the
neighborhood. Specifically, it is careful of interference of the radiator, when it is
difficult to remove, it removes a radiator fan.

* It does engine installation by the procedure which the removal is opposite to.

1-33
 PR芝P
ARA
TIO
NFORD
ISA
SS在MBLY

1-34
 DISASSEMBLYOFENGINEMAINPARTS

1
.CylinderHeadandValveMechanism......• .....................
...
... . 2・2
............
1.1Removalo
fRockerS
haf
tAssembly.
....
...
...
....
....
....
........
.......
....
...... .2・ 3
...
1.2 Disassemblyo
fRockerS
haf
tAssembly .
...
...
...
...
...
...
.....
...
...
...
...
...
...
...
...2・ 3
1
.3 Removalo
fCy
lin
derHeadAssembly..
....
....
....
....
.• .
......
....
...
.....
........
... 2-3
1.
4 Removalo
fVa
lve
sandV
alv
eSp
rin
gs・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ ・・
・・・
・・・
・ ・・
・
・ 2・ 3

2
.Flywheel............................................................................. 2・4
2
.1Removalo
fFl
ywh
eel.
....
...
...
....
....
....
.....
....
..........
...
......
.....
.....
... 2・5
2
.2 Removalo
fRearP
lat
e• . ..
...
...
• ..
...
...
.....
.....
....
• ......
...
...
....
..........
.. 2-5

.T
3 imingGearsandCamshaft・・・・・・・・・・・・・・・ ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2・ 6
3.1RemovalofCra
nksh
aftPu
lleyandDamper ....................... ..................... 2-7
3.2 Removalo
fTim
ingGearCaseAssembly........................... .................. 2・7
.
3.3Measuremento
fBackl
ashandEndp la
y......
.... ........................... ......... 2・ 7
.
3.4 Removalo
fOlPumpGear. . ...... . .................................•............... 2・ 8
i
3.5 Removalo
fId
lerGear.
....
...
...
...
....
...
...
...
....
..........
...
...
........
...
...
.. 2-8
3
.6 Removalo
fOi
lPan.
...
...
...
...
...
...
....
....
......
...........
...
.................
. 2-8
3
.7Removalo
fOi
lSt
rai
ner
"...
...
....
.....
...
....
....
....
........
....
....
......
.....
... 2-8
3
.8 Removalo
fCamshaft・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ ・・・・・・・・・・・・・・・・・・・・・・・・ 2-9
3.9 Removalo
fCamshaftGear.
....
......
...
....
...
....
...
...........
......
............
. 2-9
3.
10Removalo
fFr
ontP
lat
e..
...
....
...
....
.....
....
.....
...........
...
..........
.....
... 2・ 9
3
.11Removalo
fOi
lPump..................... . .........•............................... 2・ 9

4
.Pistons，ConnectingRods，Crankshaft，CrankcaseandTappets.................. 2・10
4
.1Removalo
fCo
nne
cti
ngRodCaps・・・・・・・・・・・・・・・・ ・・
・・・
・・・ ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2・1
1
4.2 P
rep
ara
tio
nbe
for
eRemovingP
ist
ons.
....
....
...
...
............
...
...
..............
.. 2・1
1
4.3 Removalo
fPi
sto
ns.
...
...
...
.....
....
.....
....
...
...........
....
............
.....
.. 2-
11
4.4 Removalo
fPi
sto
nRi
ngs..•........... •. ..... . ......................... . ............ 2・1
1
4.5 Removalo
fPi
sto
nPi
ns'・
・・・
・・・
・・ ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
a 2-1
2
4
.6 Removalo
fMainB
ear
ingCaps・
・・・
・・・
・・・
・・・ ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ ・・
・
・ ・・
・・・
・・・
・ 2・1
2
4
.7 Removalo
fCranksha
代・・
・・・
・・・
・・・・
・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ ・・
・・・
・・・
・・・
・・・ 2-1
2
4.8 Removalo
fTa
ppe
ts・
・・・
・・・ ・・
・・・
・・・
・ ・・
・・・
・・・
・・・・
・・・・・・・・・・・・・・・・・・・・・・・・・・ ・・
・・・
・・・
・・ 2・1
2
 DISASSEMBLYOFENGINEMAINPA~TS 、

1
.Cy
lin
derHeadandValveMechanism

R
epl
aceg
ask
et
.

Da
magedth
rea
ds，
wom
p
ushr
odco
nta
ctfa
ce

Womval
vec
apcon
tac
tfa
ce，
W
ear
，c¥o
gge
doi
lho
le ¥o
c g
gedo
ilh
ole

Womste
morfa
ce，
da
mag
e，fa
ti
gu
e

D
isa
sse
mbl
yan
din
spe
cti
ono
fcy
lin
derh
eada
ndv
alv
emechanism
D
i
くsa
sse
mbl
yse
que
nce
>
① R ocke
rc o
ver ⑧ E x
haustva
lveroc
kerarm ⑮ Valvecot
ter
② A d
justin
gs cr
ew ⑨ R o
ckersha
ftspr
ing ⑮ Valveret
ain
er
③ B o
lt(sho
rt) ⑩ R o
ckersha
ft ⑪ Valvespri
ng
④ B o
lt(lon
g) ⑪ Valvecap ⑩ ln
letvalve
Remove⑤仕l fOU
gh⑩ a s組 a
sse
mbl
y. ⑫ Pushrod ⑩ Exhaustval
ve
⑤ R ocke
rs h
aftbr
acke
t ⑬ Cylind
erheadbo
lt ⑩ Stemseal
⑥ S naprin
g Remove⑩ t 加ough⑩ a sa
nas
sem
bly
. ⑪ Cylind
erheadga
ske
t
⑦ lnle
tv a
lverocke
rarm ⑩ Cylind
erhead

2-2
 DISASSEMBLYOFENGINEMAINPARTS

1
.1 Removalo fRockerShaftAssembly
(
1) Loosenth
ea dj
usti
ngscrewofeachroc
kerabou
to n
e
ro
tat
ion
.
(
2) Loosenth
eb o
lts，s
hor
ta ndlon
g，tha
tholdth
er o
cker
sh
aftbrac
kettothecyli
nderhea
d.Bes ur
etol o
ose
n
th
es h
ortbo
ltfrr
s.Removet
t h
er o
ckers
hafta
ssembl
y
企omt hecy
lind
erhead
.

|企 ~q.[.]~1
I
fth
elongbo
lti
sloos
ene
dfr
rs
t，t
her
ock
ers
haf
tbr
ack
et
m
ights
uff
erdam
age
.
Removalo
fro
cke
rsh
afta
sse
mbl
y

1
.2 Disassemblyo
fRockerS
haf
tAssembly
A
rra
nget
hed
isa
sse
mbl
edr
ock
ersi
nth
eor
dero
f
remov
alsot ha
tt he
yc a
nb eins
tal
ledea
silyinth
at
or
deratrea
ssembly.
Thi
si stoensur
et heclea
ran
ceb e
twee
nt heroc
ker
sh
aftandroc
kerthesameasbe
for
et h
edisa
ssem
bly
.

D
isa
sse
mbl
yofr
ock
ers
ha食a
sse
mbl
y
1
.3 Removalo fC yl
inderHeadAssembly
Removethecylin
derheadbolt
s.Liftupt hecylin
der
hea
dtoremove企omt h
ec r
ankc
ase.
Not
e:( a)Wh enr e
movingt h
eg ask
et，bec ar
efuln o
tt o
damage theg ask
etc onta
cts urf
aces of the
cran
kcaseandthecylin
derhead
.
(
b)Ifanycylind
erheadparts訂 efau
lty，checkthe
cyl
inderheadb o
ltsfort or
quew it
h at o
rque
wrenchbefor
eremovingthem.

Removalo
fcy
lin
derh
ead

1.
4 Removalo fValvesandValveSprin
gs
Usethevalves pri
ngpus
hertoc o
mpres
st h
evalv
e
spr
ingsqu
arel
y.Thenr emov
et h
evalveco
tte
r，v
alv
e
andval
vespring.
Partnumber
AG-30691-04500
Note:I
ftheori
gin
alva
lve
saretobereu
sed，markthemfo
r
t
hei
rl oc
atio
nstoens
uret h
eori
gin
all oc
ati
onand
co
mbinati
onsofthev a
lve，va
lveseata ndval
ve
g
uide.

Removalo
fva
lvea
ndv
alv
esp
rin
g

2-3
 DISASSEMBLYOFENGINEMAINPARTS

2
.Fl
ywh
eel

Damagedt
hre
ads

R
epl
aceg
ask
et
.

C
rac
ks，
def
ect
ivedowelh
ole

Wom，
damagedo
rde
ter
ior
ate
dli
p

C
rac
ks，
def
ect
ived
owe
lho
le，
damagedg
ear

D
isa
sse
mbl
yan
din
spe
cti
onoff
lyw
hee
l

く Disassemblys
equ
enc
e>
① Flywheel ③ Oilse
al ④ Gasket
② Rearplate Remove② a
nd③ a
sana
sse
mbl
y.

2-4
 DISASSEMBLYOFENGINEMAINPARTS

2
.1 Removalo fFlywhee
l
(
1) Removeoneo ft
hef l
ywheelret
aini
ngbol
ts.
(
2) In
st
allasafet
ys tu
d(M12x 1 .2
5mm)i nt
ot h
eh o
le
合omw hichtheret
ainin
gb o
lthasjustbeenremov
ed.
Witht h
es t
udi nsta
lle，remove t
d h
er e
maini
ng
fly
whee
lretai
ningbo
lts
.
(
3) Wh i
leho
ldingtheflywh
eelw i
thb o
thh a
nds，roc
kt h
e
fly
whee
lt owar
dyoua ndawayt opul
litouts回 igh
t
towa
rdyou.

l ~ CAUTION
R
emo
val
off
lyw
hee
l
(
a)Whenp u
llin
go f
fthefly
whee
l，becar
efu
lnottocu
t
yourhandswit
htheri
nggea
r.
(
b)Becar
efulnott
odamagetheflyw
hee
lbyd r
opp
ingi
t
orbumpingitag
ain
sthar
dobje
cts
.

2
.2 RemovalofRearP
late
Removetherea
rpl
ateret
ain
ingb
ols，t
t henremove
th
erearp
lat
e.

l&CAUTION
Whe
nremovi
ngt
her
earp
lat
e，b
eca
ref
uln
ott
odamage
t
heo
ils
ea.
l

Removalo
fre
arp
lat
e

2-5
 DISASSEMBLYOFENGINEMAINPARTS

3
.Ti
min
gGearsandCamshaft

C
log
gedo
i
lho
le，
w
ear
sdnn

dq
m
M

m
mKM
凶的叩
-EC1

ob
3
治yg
O

v且 目 別

ρ
a
L
.

内
ub

v
en
伊山内山

Wom，damag
edor
d
ete
rio
rat
edl
ip

Womb
el
tgr
oov
e

D
isa
sse
mbl
yan
din
spe
cti
ono
fti
min
gge
ar
<
Dis
ass
emb
lys
equ
enc
e>
① Damper ⑥ T
hrustpl
ate ⑪ Camsha
ft
② Cra
nksha
ftpul
ley ⑦ I
dle
rg e
ar ⑫ Camsl凶 gear
③ Cover ⑧Fuelinje
cti
onpump ⑬Thrustpla
te
④ Timin
gg e
arcas
e ⑨Oilpan Remove⑪由r ou
gh⑬ お 組 制e
mbl
y.
⑤ Oi
lpumpg ea
r ⑩ O
il抑 制e r ⑬ Fron
tplat
e
⑮ Oilpump

2-6
 DISASSEMBLYOFENGINEMAINPARTS

3.1 Removalo fCran

k shaf
tP ul
leyandDamper
(1
) Lockt hecrank
sha食s otha
titwillno
tr ot
ate
.Tol ock
th
ecranksh
aft，in
sta
lltwos afe
tystud
s(M12x 1 .2
5
mm)i n
tot hethr
e a
dedh o
lesa tth
er e釘 endo fth
e
cr
anks
haftandthenplac
eab arbetwee
nt hest
uds
.
(2
) Removet henutandr emovethecra
nksh
aftpulle
ya n
d
th
edamper.

!企1m切
While甘y i
ngtoremovethecrank
sha
ftp
ull
e yandth
e
damper，thebar may d
islo
dge 合omthe sωds.P
ay
Removalo
fcr
ank
sha
食pu
lle
yan
ddamper
su釘ic
ien
tatte
nti
ontoe
nsur
esafe
ty
.

3
.2 RemovalofTimin
gGearCaseAssembly
Removethetim
inggearcas
er e
tai
nin
gbo
lt ，
s.Then
removet
heti
minggea
rcas
ea s
sembl
y.

A CAUTION
Whenremo
vingthetim
inggea
rca
sea
sse
mbl
y，be
c
are
fuln
ott
odamaget
heoi
lse
a.
l

Removalo
fti
min
gg訂 c
e asea
sse
mbl
y

3
.3 Measuremento fBackl as handEndP la
y
Meas
u r
et hebackl
asha nde ndpla
yo feachgearto
ob
tainthedat
aforp紅tsr epla
ceme.
t
n
Unit
:mm[ i
n.]
Stand
ard L
imit
0.05to0.15 0.
25
Timi
ngg earbackl
ash
rO . 0020t ∞
oO. 5 1 [
9 0.
0098]
0.05to0.20 I 0. 35
Id
lergeare ndplay
[O . OO_~ !o0.0
07]L[
9 0.01
38]
0.10to0.25 I 0. 30
Cams
hafte ndp la
y
[0 . 0039t o0.
009]I
8 [0.0
118]
M
eas
ure
men
tof
bac
kla
sha
ndendp
lay

2-7
 DISASSEMBLYOFENGINEMAINPARTS

3.
4 RemovalofO
ilPumpGear
Removeth
ereta
ini
ngn
ut，t
henremovet
heo
ilpump
ge
ar.

Removalo
foi
lpumpg
ear

3.
5 RemovalofI
dle
rGear
Removeth
ethru
stp
lat
ere
tai
nin
gbo
lt，t
henremove
th
eidl
erge
釘.

Removalo
fid
lerg
ear

3.
6 Removalo
fOi
lPan
Removet
her
eta
ini
ngb
ols，
t t
henremovet
heo
ilp
an.

Removalo
foi
lpan

3.
7 RemovalofOilStra
ine
r
Remove th
er et
ain
ingbol
ts，t
hen remove t
heo
il
st
rai
nera
ndthest
ay.

Removalofo
i 汀a
ls i
ner

2-8
 DISASSEMBLYOFENGINEMAINPARTS

3
.8 RemovalofCamshaft
(
1) Tumthecrankcas
eu p
sidedown
(
2) Po
sit
ionthec a
mshaf
tg e
arsotha
tit
slig
hten
ingh
oles
cometot o
pandb ot
tom. Removethethr
ustpl
ate
re
tai
nin
gbolts，th
engent
lypul
loutth
ecamsha食合om
th
ecrank
case.

A CAUTION
Whenpu
lli
ngoutt
hecam
shaft，becar
efu
lnott
odamage
t
hecamsur
fac
esofth
ecams
ha f
ta n
dthebus
hin
gs.
Removalo
fcamsha
食

3
.9 Removalo fCamshaftGear
Removethecamsha
ftger合omt
a h
ec am
shaf
tw it
hth
e
ge
arpull
er.Thet h
rus
tpla
tecanals
ob eremovedi
n
血isremova.
l
N
ote
: Don otremovethecamsh
aftgearan
dth
et h
rus
t
p
lat
eu nle
sst h
eya r
e damaged t
oth
eext
entof
r
equi
ringrep
lacem
ent
.

Removalo
fca
msh
aftg
ear

3.
10RemovalofFro
ntPl
ate
Removete合'
h on
tpl
atere
tain
ingbo
lts
.The
nremove
社l
e合ontpl
ate企omth
ecran
kcase
.

Removalof企o
ntp
lat
e

3
.11 RemovalofOi
lPump
Removet heoi
lpumpret
aini
ngbo
lts.The
nremove
theoilpump企omth
ecr
ankca
se.

Removalo
foi
lpump

2-9
 DISASSEMBLYOFENGINEMAINPARTS

4
.Pi
sto
ns，ConnectingRods，C
ran
ksh
aft，CrankcaseandTappets

S
cal
ede
pos
it，
sco
rro
sio
n，f
lak
ing

S
cra
tche
s，cr
acs，
k n
ick
in，
g
c
logg
edoi
lhole
s，w
ear

F
laki
ng，
abn
orr
nal
t
oot
hcon
tac
t

N
ote
: Whenrepl
aci
ngthecran
kcase，
ca
ref
ull
yremovethecompo
ne n
ts
(s
uchasth
ereli
efval
ve，e
tc
.)to
reus
ethem
.

Di
sas
sem
blyandi
nsp
ect
iono
fpi
sto
ns，
con
nec
tin
gro
ds，c
ran
ksh
a，
食cr
ank
cas
eandt
app
出

D
i
くsa
sse
mbl
yse
que
nce
>
① Nut ⑧ Pist
onp in ⑭Thru s
tplat
e
② Connec
tingr odcap ⑨ Pist
on ⑮ Mainb e
arig(
n I
ower)
③ Connec
tingr odbear
ing ⑩ Connect
ingrod ⑩ Cra
r帥 d
④ Topc ompre
ssionring Remove④伽'Ou h⑩ a
g sa
nas
sem
bly
. ⑪ Mainb e
arin
g(upp
er)
⑤ Secondc omp
ressi
onr in
g ⑪ Bearin
gc apbolt ⑩ Tapp
et
⑥ Oi1ring ⑫ Mainb ear
ingc叩 ⑩ Cran
kcase
⑦ Snapr in
g ⑮ Sideseal

2-10
 DISASSEMBLYOFENGINEMAINPARTS

4
.1 Removalo fConnectingRodCaps
(
1) Removet hec onnec
tingrodc a
pr et
ain
ingnut
s.T a
p
th
er et
ainingb o
ltss qua
relya n
de v
enlyw itha
hammer.
(
2) Af
tert hec on
nectingrodc a
pc omesoffthereame
r
bo
lts，removetheconnecti
ngrodcap.
(
3) Mark t h
e removed c onnec
tingr o
db e
arin
gsf o
r
id
entif
icat
iono fcyl
indernumbe
rsa ndforuppe
ra n
d
low
e rshe
IIs.

Removalo
fco
nne
cti
ngr
odc
ap
4.
2 Prepar
ationbeforeRemovingP iston
s
(1
) Pla
cethecrankc
a s
eoni t
ssid
e.
(2
) Useac l
othoroilpapertoremo
veaIIcarb
ondep
osi
ts
合omt heu p
pera reasofthecyl
ind
er.Ifanycarb
on
dep
osit
sa r
ep r
esent，th
iswi
llmakeitdif
fi
cul
ttopuI
I
apist
onupward.

P
rep
ara
tio
nfo
rpi
sto
nre
mov
al
4
.3 RemovalofPistons
(
1) Tum thecrank
sha食 tob ringth
ep i
sto
na ss
emb
ly
(fr
omw hicht h
ec o
n ne
ctingrodc aphasb e
en
removed)ωωpd e
adc 相 te
r.
(
2) Pu
tt hehan
dleofah arnmeronthebig
-endofth
e
con
necti
ngrodandpusht hepis
tonas
sembl
yoffth
e
cy
lind
er.

Removalo
fpi
sto
n
4.
4 RemovalofP
isto
nRings
R.
emoveth
epi
sto
nrin
gswi
tht
hep
ist
onr
ingp
lie
rs.
.
Pis
tonr
ingp
lie
rs
Par
tnumbe
r
3
1391・1
2900

Removalo
fpi
sto
nri
ngs

2-11
 DISASSEMBLYOFENGINEMAINPARTS

4.5 Removalo fP i
stonPins
(1
) U singthes napringplie
rs，removet h
es napr i
ngs
fromthepist
on.
(2
) Removet hepis
tonpintosepa
ratethep
istonfromthe
con
nectingrod
.
(3
) I f
itisdif
licu
lttopu
lloutthepin，he
atth
ep is
tonwith
apist
onheaterori
nh o
tw a
tertoe x
pandthepinbo
re.

Removalo
fpi
sto
npi
n

4
.6 RemovalofMainB e a
ringCaps
(
l) Removethemainbearingca
pb o
lts
.Thenremovet
he
mainbe
aringcapwiththel
owerbeari
ng.
(
2) Useapul
lertoremovetherea
rmostbear
ingc
ap.
N
ote
: Whenremovingthemainbear
ingcaps，becare
ful
n
ott o damage thel o
werb e
arin
gs.P l
acet he
rem
oved main be
arin
gc ap
sa ndl owerbear
ings
n
eatl
ysot ha
tt h
eycanb ereass
emble
db ackonto
t
hei
rori
gina
lloc
ati
ons
.

Removalo
fmainb
ear
ingc
aps

4
.7 RemovalofCrank
shaft
Ca
refu
llyli
食 thec ra
nksh
a食 企om t
hec
ran
kca
se，
ke
epingi
thor
izo
nta.
l
N
ote
: Whe nremovingthec r
anksh
aft，be c
are
fuln o
tto
damagetheupperb
eari
ngs.Plac
etheremovedupper
bea
ring
sneatlysoth
attheycanbereas
sembledbac
k
ont
othei
ro r
igin
all
ocat
ions
.

4
.8 RemovalofT
appet
s Removalofc
ran
ksh
a食
Removeth
eta
ppe
tsfro
mth
ecr
ank
cas
e.
N
ote
:Plac
etheremovedt
appe
tsnea
tlysoth
atthe
ycanb
e
r
easse
mbl
edb ac
kontot
hei
rorig
ina
llo
cat
ion
s.

2-12
 INSPECTIONANDREPAIROFENGINEMAINPARTS

1
.CylinderHeadand 4.Pistons，
ConnectingRods， Crankshaft，
ValveMechanism .
...
....
...
...
... 2-14 Crankcaseand Tappets.......... 2 ・25
1.1 MeasurementofRα氷e rB ushingInside 4.1MeasurementofCrankcaseTop
DiameterandR∞k e
rS ha
ftDiameter' 2 -14 FaceDisto
rti
on. ..
........
...
...
..2-25
1.2 MeasurementofValveStemD i
amete r'.2 -14 4.2 MeasurementofCyli
nde
r
1
.3 Measuremento fClearancebetween Insi
deDiameter'...
......
...
....
. 2-25
ValveStemandValveGuide. ..• ...'2 -15 4.3 MeasurementofPistonDiameter... 2-26
1.4 ReplacementofValveGuides. ......2・15 4
.4 MeasurementofPisto
nR ingEndGap' 2・ 26
1.5 Insp
ectionofValveFace . ....... .
. 2 -16 4.5MeasurementofPisto
nR ingGrooves. 2・26
1
.6 C orr
ectionofValveFace . ....... .
. 2 -16 4.6 Measuremento
fPisto
nP i
nB ore
1.7C orr
ectionofValveSeats. ......... 2 -17 andP is
tonPinDiameter. ....
..... 2-27
1.8 ReplacementofValveSeats.. ..... 2 -17 4.7 Measuremento
fPistonP r
o加s i
on.... 2-27
1.9L appin
go fV
alveagainstValveSeat.・・ 2 ・18 4
.8 MeasurementofC l
earancebetween
1.10Measuremento fValveSp r
ing Connect
ingRodB ear
ingandC悶 n k
pin 2・28
SquarenessandFreeLength・ ・・
・・・ 2 ・18 4.9 Measuremento
fC l
earancebetween
1.11Measuremento fCylinderHead Cαm 配 tin
gRodB ushingandPis
tonPin2-28
BottomFaceD ist
ortio
n.• .......... 2 -19 4.1
0Replacemento fConnecting
1.
12Measuremento
fPushrodDef
lec
tion.
. 2 -19 RodBushings. ..........
........ 2・29
1.
13Replacemento
fCombustionJets..
. 2 ・19 4.
11Ins
pectio
nofConnectingRod
BendandT w
ist・ ・・
・ ・・
・・・・・
・・・・
・ ・ 2-29
・
2
. Flywheel......................2 ・20 4.
12l
nspecti
onofConnectingRod
2
.1Measuremento fFlywheelFlat
ness・・ 2 ・20 Beari
ngs................
....... 2-30
2
.2 Measuremento fFlywhee . 2・20
lRunout . 4.
13Measuremento fConnectingRod
2.3 Replacemento
fRingGear.・ ・・・
・・・ 2 ・20
・ EndPlay........••....... .
...
... 2・30
4.
14ReplacementofConnectingRod..
. 2-30
.T
3 iming Gears and Camshaft・ ・
・・ 2 ・21 4.
15MeasurementofCrankshaft
3.1 MeasurementofCamshaftEndP l
ay . 2・21 JoumalDiameter ........
....
...
. 2-31
3.2 MeasurementofCamshaftCamL if
t.. 2 -21 4.
16Measuremento fCra
nksha
ft
3.3 MeasurementofCamsha 伐D e
flect
ion'.2 -21 CrankpinDiameter...
......
...
... 2・31
3.4 MeasurementofCamshaftJoumal 4.17G rind
in gofCrankshaft・ ・
・・・・・・・
・・ ・・ 2-31
Diame
terandB ushingInsideDi、
aneter.2・22 4.18M e;
笛 u rementofC問n ksha代EndP la y .2・ 32
3
.5 Replacemento fCamsha 代B ushings 2・22 4.
1 9Measuremento fCranksh
aftDe fl
ect
i o
n.2-33
3
.6 Measuremento fTimingGearB a
cklash 2 -22 4.20Replacemento fCran
kshaftGear. .. 2・33
3
.7 Measuremento fIdlerGearEndPlay' 2・23 4.
2 1I n
spectionofOilSealCo蜘 c tSu巾 ce. 2-33
3.8 Measuremento fIdlerBushingI n
side 4.
2 2
ln s
tallationofOilSealSleeve. .
.• . • 2-34
DiameterandS haftDiameter.. .... 2 -23 4.
23Removalo fO i
lSealSleeve... .
... . 2-34
3.9Replacemento fI d
lerShaft.・・・・・
・・・ 2 ・23 4.
2 4lnspectiono fMainB earingSurface ' 2・ 35
3.10Ins
pectio
no fCrankshaftPu l
ley..... 2・24 4.25Measuremento fClearancebetween
3.
11I ns
pectio
no fDamper. ............ 2・24 MainB earin
gandC rankshaftJoumal' 2・ 35
4.
26Replacemento fMainB earings'. •.. 2・35
4.27lnspectiono fCamContact
FaceofTappet . ...
............. . 2・36
4
.28MeasurementofClearancebetween
TappetandTappetGuideBore'. ..
. 2-36
 INSPECTIONANDREPAIROFENGINEMAINPARTS

1
. C
yli
nde
rHeadandV
alv
eMechanism
1
.1 Measuremenlo fRockerBushingI nsideD iameter
andRockerS haftDiameler
Measurether oc
kerb ushi
nginsi
ded iameterandt h
e
rock
ershaftdiamete
rt oobt
aintec
h 1earanc
eb etwe
en
th
eb ush
inga ndshaf
t.
I
ft ec
h 1earanc
ed oesnote x
ceedthelimit，re
plac
et h
e
ro
c k
era rm
.I fite x
ceedsthelimi
t，r epl
aceb o
tht h
e
sh
aftandr o
ckerarm.
Unitmm[ i
n.
]
Nominal
¥ ¥ ¥ ¥ Sta
nd ar
d L
imit
Value
19
.010t o
Rockerbushing φ19 19
.0 30 M
eas
ure
men
to f
rocke
rbush
ingins
ided
iam
ete
r
泊sid
ed iame
ter [0
.74] [
8 0.7484to androc
kersh
a食diam
eter
0.7492]
18
.980t o
Rocke
rs ha
ft φ19 19
.0 0
0
di
ameter [
0.74] [
8 0.7472to
0.7480]
0.010to
Cl
earancebetween
0.050 0
.070
r
ockerbushingand
[0.0004to [ 0
.ω1
28]
sh
a食
0.0020]

1
.2 Measuremento fValveSlemDiameler
Mea
suret h
ev alves te
md iame
ter.Ifthemeasured
v
aluee xceed st helimi
t，repla
cew ithanewp a
rt
.
R
eplacea lsowhent h
ev alv
es temh asexc
ess
ively

-
-
u
nevenw ear.
Uni
t:m m[i
n.
]
Nominalvalu
e S tandad L
r imi
t
7.
940to
Inle
t φ8 7.
955
[0.
315] [0.3126to [0.
3110
]
Va
lvestem 0.
3132]
d
iamete
r 7.9
20to
E対l au
st φ8 7.
940 7.85
0 M
eas
ure
men
tofv
alv
est
emd
iam
ete
r
[0.
315] [0.3118to 伊.3091
]
ーーーーー」ー
0.
312重LL 」

2-14
 INSPECTIONANDREPAIROFENGINEMAINPARTS

1
.3 Measuremento fClearancebetweenV alveStem
andV alveGuide
M
easurin
g
ηlev a
lveguidewearsmorer apid
lyati t
sbothends d
ire
cti
ons
-
thanata nyo t
her p釘 t
s. Measure th
ev a
lveguide
ins
idediamet
eratitse n
dsi ntwoc ros
singdire
cti
ons
toobta
int h
ec l
earanc
eb etweent hevalveguid
ea nd
valv
es t
em.
Ifth
ec l
earan
cee x
ceedst h
el im
it，rep
lacewithanew
par
t.
Unit
:mm[ in
.]
M
easurin
g
N
o m
inal l
oca
tio
ns
Standard Limit
val
ue
M
eas
ure
men
tofv
alv
egu
ide凶 s
ided
iam
ete
r
0.065to
0.095 0.150
I
nle
t
C
lea
ran印 [
0.0026to [
0.
0059]
b
etwee
n 0
.00371
v
alve
ste m 0.080to
a
ndgui
de 0.115 0.200
E対laus
t
[
0.0031to [
0.00
79]
0.00451
14 :
t0.1
V
alv
e伊 i d
epr
otr
usio
n
[0.
551] [
:t0.004]

1.4 ReplacementofValveGuides V
alv
egui
de
(1
) U sin
gt hevalv
eg uideremove
r，removet
hev
alv
e r
emov
er
gu
ide合omt hecyl
inde
rhead.
P一

e
帥
rZ
川
utd
ω
一
HU--q4
一K

x
山
υ
A

A3
n
内
u
u

Removalo
fva
lveg
uid
e
(
2) To i
nst
al
lth
eva
lveg
uie，u
d set
hev
alv
egu
ide
泊st
all
er.
V
alveg
uid
e
Pa
rtnumbe
r i
ns
ta
lle
r
AG-
32A91・0
0100

￨CAUTION I
Bec
auset h
ev al
veguide must b
ei ns
ert
edtot he
s
pecif
iedde
pt，bes
h ur
et ouseth
evalv
eguidei
nst
all
er
t
oe n
suret
heco
rre
ctd
epth.

I
nst
all
ati
onofv
alv
egu
ide

2-15
 INSPECTIONANDREPAIROFENGINEMAINPARTS

1
.5 I
nsp
ect
iono
fValveFace
Applyat hi
nc oa
tingofredlea
do nt
ot hevalv
ef a
ce.
Then，usin
gt h
ev al
velap
per，chec
kt h
ev al
vef a
ce-
to・
sea
tc o
ntact
.
Ifthec o
ntactisn o
tu n
iforma ndt h
ed efe
ctiveis
found，o
rifthei
I m
itisexc
e e
ded，re
pairorrepl
acethe
valv
eandv alv
es e
at
.
N
ote
:(a)Inspe
ctt hev al
vef a
cea 食eri n
spe
ctio
no r
replace
mentof由evalveguide
.
(
b)Don otro
tatet
heval
vewhenp ressi
ngtheval
ve，
whichc o
atedwithredlead，aga
instthevalv
e
seat
.
(
c)Afterrefac
ingorreplac
ingt hevalv
eo rt h
e I
nsp
ect
iono
fva
lvef
ace
valvese
at，besur
etolapthevalv
ei nt
heseat
.
U
nit
:m m[
in
.]
N
o m
inal
￨ ¥ ¥ ¥ ¥ S
tan
dar
d L
imit
val
ue
Angle 30。
0.
3to0.5
0.4 1.0
I
nle
t [0.
012to
Valve [
0.01
6] [
0.03
9]
ー
叫
帽 sink
age
0.0
2旦
0.
4to0.6
同
0.5 1.0 Good Bad
み
‘ E対l
aus
t [0.
016to
ー
〉 [
0.02
0] [
0.03
9]
〉
国 0.
024]
.26t
1 o
1.4 1
.54 1.8
Width V
alv
eco
nta
ctw
ithi
t
sse
at
[
0.05
5] 0.
0496to [
0.07
1]
0.0~06]
Upto
2
.13
V
alv
ema
rgi
n 1.
83[0.0
720
]
1
[0.
083
9]
' - -
L
!
立 reぬcing
、
、
晴
曹
ゐen
L
ad 引
.eoea

1
.6 C
orr
ect
iono
fValveFace
I
fth
eva
lvef
acei
sex
ces
siv
el ，
yworn r
efa
cei
twi
tha
v
alv
ere
fac
er.
Reassemblyofv
alv
ese
atandv
alv
e
N
ote
:(a)Ref
acethev a
lvef a
cewithth
ev al
v eref
acera
t
o
an
gleof30 •
(
b)百levalvemarginesho
uldbemaintain
edabove
t
heiI t
mi.Ifi
ta p
pearsth
atth
eminimummargin
ca
nnotbem ai
ntaineda
fte
rrefac
ing，re
placeth
e
v
alve.

R
efa
cin
gof
val
vef
ace

2-16
 INSPECTIONANDREPAIROFENGINEMAINPARTS

1
.7 CorrectionofValveSeats
(
1) Uset hev al
ves ea
tc ut
terorv a
lvesea
tg rin
derto
re
facet h
ev a
lvesea.
t
(
2) Aft
err e
facin，g
g ri
ndt hevalv
es ea
tl i
ght
lyu si
ng
#400・grad
es andp
aperinse
rte
dbetweent
hecutt
erand
val
ves eat
.
N
ote
:( a
)V alv
es e
atc orr
ecti
ons ho
uldb el i
mite
da s
minimuma spos
sib
le.
(b
)I ft
hes e
atwidthexceedst
helim
itasaresu
ltof
gri
ndingorwear，re
plac
etheva
lvesea
t
.

C
orr
ect
iono
fva
lves
eat

1
.8 ReplacementofV a
lveSeats
(
l) Weldastudtoth
ev al
veseat
. 十=
(
2) In
ser
tas h
aftinぬthevalv
eg u
ideho
le企omth
eto
po f
t
hec yl
ind
erh ead，the
nd r
ivethesea
tof
f企omt h
e
cy
lind
erhead.
N
ot: Whe
e nwe
ldi
ngthes
tu，don
d otal
lowsp
att
erto
a
dher
eonthem
achi
nedsu
rfa
ceso
fthecyl
ind
er
h
ead
.

S
tud

Removalo
fva
lves
eat

(
3) B
efor
ei ns
ert
ing a new v
alv
es e
at，measure t
he
c
yli
nderh
eadbore
stoe n
sur
etha
tthe
yarewithi
nthe
s
tan
dardv
alu
es.

I
nl
et E
xha
ust U
nit
:mr
n[i
n
.]

Bored
ime
nsi
onsf
orv
alv
ese
ati
nst
all
ati
on
(
4) Withthecy
lind
erh ea
dk e
p ta
troomt emp
erature，co
ol
thevalvesea
ti nl iq
uidn it
rogen(appr
o x
.- 1
70oC
[2
・ 740F]
)f o
r more t ha
n4 m in
utes
. Or h eatthe
cyl
inde
rh eadto8 0to1 00
0C[ 176to2 120F]，and
keeptheval
ves ea
tc h
ill
edine it
hereth
ero ralcoh
ol
cont
ain
ing命γice.
(
5) Usingthevalv
es ea
ti n
sertcaulk
ingtool，in
st
allthe
val
veseati
ntothecyli
nderhead
.
Par
tnumber
In
let AG-36791・00200
E沿lau
st AG・ 34
491・03020

I
nst
all
ati
ono
fva
lves
eat

2-17
 INSPECTIONANDREPAIROFENGINEMAINPARTS

1.9 Lap
pingofValvea ga
instValveSeat
I
fthevalv
eo rvalv
es e
ati
sc o
rrec
tedorre
place
d，be
s
uretola
pt h
ev a
lvefaceag
ain
sttheva
lvesea
tint h
e
f
ollow
ingmanne
r.
() A
1 pplyal igh
tc oa
tingoflappi
ngcompounde ven
ly
o
vertheval
veface
.
N
ote
:(a)Takecarenottoa llo
wl appi
ngcompoundt o
adhe
reont h
evalvestem. L
app
ingcompound
(
b)Useacompoundofmediumc oar
sene
ss(120to
150m esh)f o
ri ni
ti
all appi
nga ndaf m
er
compound(200meshorfine
r)forfi
nish
ing
.
(
c)Lapp
ingcompounds pr
eadsmoree v
enlyifi
tis L
app
ingcompounda
ppl
ica
tio
n
mixedwit
has mal
lamou n
to feng
ineoi.
l

(
2) Usingavalvelap
per，lapth
ev al
vef a
cea g
ains
tthe
val
vesea
trepea
ted
lyw h
ilerot
ati
ngitgr
adua
lly.
(
3) Washawaythelapp
ingcompoundinligh
toiloroth
er
si
mila
rliq
ui
d.
(
4) Applyengi
neoilontot helapp
edf a
cea ndlapthe
val
veaga
in.
(
5) Checkth
elappedfa
ceforcor
rec
tconta
ct.

1
.10Measuremento fValveS pr
ingSquarenessand
FreeL eng
th
Measuretheva l
ves pri
ngf orsq
uar
enes
s 組 d 企'
ee
le
ngth.If卸 y ofthem easuredv
alu
ese xce
edst h
e
li
mi，
tr e
plac
eth
es pr
ing.

ー
-一
一 Standard
Unit:
L
mm[
im
it
i
n.
]
7
日
48.
85 47
.60
Fr
eel e
ngth
[
1.9232
] [
1.874
0]

ム=1.5
Squar
eness
~J;i-で~ド
-
ア4 τ
f8
L =
ム1(
g
デaa同
p
) [0.
059
]
=1.
3[0
.05
1]acro
ssenti
re
o
rle
ssl M
eas
ure
men
to f
valv
espri
ngs
q回 r
ene
ss
eng
th
←
L 4
8.8
5[1
.92
32] 組 dfr
eele
ngt
h
43
[1.6
93]/
In
sta
lle
d 4
3[1
.69
3]/
176to196
147
le
ngt
hllo
ad (18to20
)
(
15)
mm[弘]/N
(kgf)[
lf
b] [40to4
4]
[
33]

2-18
 INSPECTIONANDREPAIROFENGINEMAINPARTS

1.
11Measurement o fC y
linde
r Head Bottom Face
Di
stort
ion
Pl
aceas trai
ghte
dgeo nt h
eb ottomfac
eo fthe
cy
linde
rheada ndmeasur
ethedis
tor
tio
nwithaf
eel
er
ga
ge.
I
ft h
em easu
r eddis
tor
tio
ne xc
eedstheI
im
it，co
rre
ct
wi
thas ur
facegrin
der.
Uni:mm[
t in
.
Stan
dard
C
ylind
erh e
adb
ott
omf
aceI
0.0
5[ 0.0
020]
d
ist
ort
ion orle
ss
M
eas
ure
men
tofc
yli
nde
rhe
adb
ott
omf
aced
ist
ort
ion

1.
12MeasurementofPushrodDefl
ectio
n
Meas
uret hepush
rodd ef
lec
tio
n.I ft h
em eas
ured
va
lueexce
edsth
estanda
rdval
ue，re
placethep
ushr
od.

Pushr
oddefl
ect
ion
(d
ialin
dic
atorr
ead
ing
)

M
eas
ure
men
tofp
ush
rodd
efl
ect
ion

1.1
3Replacemento fCombustionJets Roundrod
Rep
lacet hecombustionj
etso n
ly when t
heyare
cr
ackedorfau
lty
.
(
I) Toremovet hecombus
t i
onj
et，in
ser
tar o
undrodw
ith
adiamet
erofappro
x.6mm[ 23
0. 6i n
.]in
tot
heglow
pl
ugm ount
ingh o
lea ndge
ntlytapthepe討p
heryof
t
hec o
mbustio
njetbore. C
omb
ust
ionj
et

Removalo
fco
mbu
sti
onj
et

(
2) Toins
ta
lltheco
mbustio
njet，
tapi
tintot
hemounti
ng
ho
leu si
ngap la
sti
chammero ro t
hersim
ila
rt o
o.
l
Ens
uret h
atth
en ozz
leh o
leface
sthecent
ero fth
e
C
omb
ust
ionj
et
cy
lind
er.

N
ozz
leh
ole

I
nst
all
ati
o
~@@延
no
fco
mbu
sti
onj
et

2-19
 INSPECTIONANDREPAIROFENGINEMAINPARTS

2
. F
lyw
hee
l
2
.1 Measuremento fFlywhee
lF lat
ness
Pla
cethef ly
wheelonasurfa
cepla
te
.Runad i
ag a
ge
overt
he企i cti
ona
lsurf
aceoftheflyw
heeltomeas
ure
th
ef l
atn
ess.
Ifthemea s
uredv a
lueexceedsthelimi，g
t ri
ndt h
e
企ict
ion
als u
rfac
e.
Unit
:mm[ i
n.
]
S
tandar
d
0.
15[ 0
.005
9]
F
lyw
hee
lfl
atn
ess
orle
ss

Measuremento
ffl
ywh
eelf
lat
nes
s

2
.2 Measuremento fFlywhe
elRunout
Measureth
er un
outsofthef ly
whe
elintheins
tal
led
co
nditi
on.Iftheruno
utse x
c e
edthestan
dar
dv al
ue，
chec
kforloos
eb o
ltsandadhes
ionoff
orei
gnp釘 t
icl
es
on白ef ly
whee
lm ount
ingface.
Unit
:mm[ in
.]
Stand
ard
0.
15[0.
005
9]
F
lyw
hee
lru
nou
t
orle
ss

Measuremento
ffl
ywh
eelr
uno
ut

2.
3 Replacemento fRingGear

明浦
Checkt heringgearfor企a c
turedorexcess
ivelywom
ge釘 teet
h.
Iffau
lty，repl
aceitinthefollo
wingmanner.
(
1) Removalo fringgear
(
a)Usinga na c
etylenetorc
ho rothersimi
lareq u
ipment，
heattheringgeareven
ly.
(
b)Usingahammerandar od，tapt h
er i
ngg e釘 eve
nly
ont h
ee nt
ireperiphe
ryunti
ltheg e
arcomesot T.
(
2) Inst
all
ationof巾19ge 釘

(
a)Usingap isto
nh ea
teroro t
hersir
nil
arequipment，he
at
theringgeartoapproxima
tely1 000C[2120F
]. Removalofr
ingg
e釘
(
b)Witht her in
gg earwarmedup ，ins
ta
llito ntothe
flywhe
e lwiththeun-chamfer
eds id
efir
st
.

2-20
 INSPECTIONANDREPAIROFENGINEMAINPARTS

. T
3 imingGearsandCamshaft
3.
1 Measuremento fCamshaftEndP l
ay
Measu
ret he camsha食 end p
la.I
y ft heendp
lay
exc
eedsth
elimit，r
epl
acetheth
rus
tpl
ate
.
Uni
t:mm[
in
.]

食e
Camsha n
dpl
ay

M
eas
ure
men 食e
tofcamsha n
dpl
ay
3.
2 MeasurementofCamshaftCaml if
t
Usingam ic
romet
er，measureth
ediam
eter
so f“D
."
組 d“D2" oneachcam.I fthecaml
if
te xc
eedsth
e

-
Q
-
口
li
mi，
t r
epl
aceth
ec a
msh
aft.
Un :mm[
it i
n.
] D2
¥ ¥ ¥ ¥ N om ina
l
Standa
rd L imi
t M
easurin
g
val
ue d
ire
cti
ons
6.384to
6
. 6
84 6.
784 6.
184
Inl
et
[
0.263
1] [
0 .
2563to [
0 .
2435
]
Campro f
i
1e 0.
2671]
(.・D2)
D 6.420to
6. 7
20 6
.820 6 .22
0 Measuremento
fcaml
i
ft
E泣la
ust
[
0.264
6] [
0.2528to [
0 .
2449
]
0 .
2685]

3.3 Measuremento fCamshaftD e

flec
tion
Measuret hecamshaftdefle
ctio
n.Ift h
ed e
flec
tio
n
exceedsthelim
it，cor
rec
tw ithapressorr e
placeth
e
C創 nsh
a食.
Note:W ithad ia
lg agesetont hec amsha， r
食 otat
et h
e
c am
shaftoneturnandreadthegageindic
atin.On
o e
h a
lfo ft heg agei n
dic
ationist he amount o f
d e
fle
cti
on.
Uni:mm[
t i
n.
]
Stand
ard
0
.02[0.
000
8]
Camsha
食de
fle
cti
on
orle
ss M
eas
ure
men
to 食d
fcamsha e
fle
cti
on

2-21
 INSPECTIONANDREPAIROFENGINEMAINPARTS

MW
口
3.
4 Measuremento fCamshaftJ ourn
alDiameterand

irum
BushingI n
sideDiameter

司陶伽
Measurethediam
eterofthecams
ha抗j o
urn
alsandthe
in
sidediamete
ro fthebushin
gsint hecran
kcas
et o

E
checktheclea
ranc
eb et
wee nt
hejour
nalandbushi
ng.
Ifthec l
eara
ncee xceed
st hel im
it，repla
cet he
bus
hings
.
Unit
:mm[ in
.]
Nomina
I
¥ ¥ ¥ ¥ Standar
d L imit
val
ue
53 .
94to
No，
1
. φ54 5 3.
96 5
3.90
Measurementofc
ams
haf
tjo
urn
ald
iam
ete
r
2，3 [
2.12
6] [
2. 1
236to [
2.12
20]
Cams
haft
2.12441
j
ourn
al
52 .
94to
di
amete
rs
φ53 5 2.
96 5
2.90
No.4
[
2.08
7] [
2.0842to [
2.08
27]
2. 0
850]
0.040to
Cl
earancebet
we en
0 .
090 15
0.
ca
mshaftjo
urnaland
[
0.0016to [
0.00
59]
bu
shing
0.0035]

Measuremento
fca
msh
aftb
ush
ingi
nsi
ded
iam
ete
r

3
.5 Replacemento
fCamshaftBushings
(
1) Tor emoveo
rins
ta
llthecams
haf
tbu
shi
ngs，u
set
he
camsha食bus
hin
gins
tal
lers
et
.
Partnumber
A0-30691・00010
(
2) I
nsaI
tlthecams
haftb
ush
ingswi
ththe
iroilho
les
a
lign
edw
itht
hehol
esl
ead
ingt
oth
eoi
lgal
ler
y.

R
epl
ace
men
tofc
ams
haf
tbu
shi
ngs
3
.6 MeasurementofTimingGearBacklash
Se
tadialgagesq
uarel
ytothe凱 ia
ldirec
tions
othati
t
i
sincont
actwit
ht h
epitchci
rcl
eo ft
heg e釘.M
easure
th
ebackl
ashbetweenth
eg e
ars.
I
ftheback
lashexc
eedstheli
n】i
t，r
eplac
e白 egear
.
Unit
:mm[
in.
]
S
tan
dar
d
B
ack
las
h

N
ote
:I n
sta
llth
efue
li吋e
cti
onpumpgeart
oth
e企on
tplat
e
inthest
at
eofbei
ngins
tal
ledo
nt h
efue
lin
jec
tio
n
pump. Measuremento
fti
min
gge
arb
ack
las
h

2-22
 INSPECTIONANDREPAIROFENGINEMAINPARTS

3
.7 Measuremento
fId
lerGearEndP
lay
Measureth
ei d
lerg
earendp
laywithf
eel
ergage
so ra
di
alg a
ge.Iftheendplayexc
eed
st h
el i
mi，r
t epl
ace
th
et h
rustp
lat
e.
:m m[
t
Uni in
.]
St
anda
rd
0
.05to0.2
0
I
dle
rge
arendp
lay
0
.0020to0.00
79

Measurementofi
dle
rge
arendp
lay
3
.8 Measuremento
fId
ler Bushing I
nsi
de Diameter
andS haftDiameter
斗;ふ ~easl:lring

宮川
Measuret h
ei d
lerbushingins
idediamet
erand the ¥
+-' d
lre
ctl ons
id
lersha食d iam
etertoc he
ckthec i
eara
ncebetween n
g
th
eb ushingands h
af.I
t fthecle
aran
cee xc
eed
s泊l e l
oca
t¥On
s
li
mit，re
plac
etheidle
rg e
釘 orid
lersha
食.
Unit
:m m[in
.]
Ma
-
-Eh
bd

-
n
4-
制時
CLU

AU
-
訂

渇釦

ρwρuv
ρLWCd

伊且
・
n
L

f-
M

・
s
し
・1

免 um

Measurementofid
lerbus
hingins
ided
iam
ete
r
組 dshaf
tdiam
e t
er

3
.9 Replacemento
fId
lerS
haf
t
I
dl
ers
ha
ft
Toremovetheidl
ers
ha合 f
orr
epl
ace
men
t，uset
he
id
lers
haf
tpu
lle
r.
Par
tnumber
AG-MH061077

Replacementofi
dle
rsh
a食

2-23
 INSPECTIONANDREPAIROFENGINEMAINPARTS

3.
10Inspec
tionofC rankshaftP u
lley
ChecktheV- b
eltgrooveforwear.
Wrapanewb e
lta ro
undthewornp ulley，pre
ssin
gitin
thegrooveasfarasitgoes，ands e
ei fthetopsurf
ace
ofthebe
ltisabovet h
et o
po fthepul
ley.
Ifthetopsurf
aceo fthenewb eltisu n
iformlyabove
thetopo fthep ul
leyallt hewaya round，iti
sn ot
nece
ssarytorepla
cethepulley
.
Ifth
etops u
rfac
eo fthenewb eltsin
ksi n
tothegroove
morethan1.6mm[ 0.0
63in.]，rep
lacethepull
ey.

I
nsp
ect
iono
fV-
bel
tgr
oov
ewear

3
.11I nspe
ctionofDamper
Checkthedamperf orcracs，d
k efo
rmationso rcra
ck s
加 thee ndpla
te，discolo
redorpeelin
gp a i
ntd uet o
exc
essiveheat
.
Repla
ceitw it
hanewo nea食er8000s ervicehours，
evenwhennod efe
ctiso b
serv
ed.
Measurethecirc
ularandf a
cerunou
tso ft hedamper
wit
h ad ialgage.Ift herunou
te xceedst heIimit，
re
placei
tw i
thanewo ne.
Uni :mm[
t in.
]
C
irc
ula
rru
nou
t
Standa
rd Remarks
Cir
cularr u
nout
0
.5[ 0.
020] A f
te ∞
r8 o M
eas
ure
men
tofd
amp
erf
acea
ndc
irc
ula
rru
nou
ts
orless servi回 ho町s，
0.5[0.02
0] repl四ceit
Fa
cer uno
ut w i
thnewo ne.
orles
s

2-24
 INSPECTIONANDREPAIROFENGINEMAINPARTS

4
. Pistons，ConnectingRods，Crankshaft，CrankcaseandTappets
4
.1 MeasurementofCrankcaseTopFaceD is
tor
tio
n
Usin
gas trai
ghte
dgea n
df ee
lergages，measureth
e
to
pfacedi
stor
tio
no f
thecrank
case
.
If
themeasure
dv a
lueexcee
dsthelimi
t， r
efac
etheto
p
fa
cewithasurf
acegri
nde
r.Bec ar
efu
ln ottogri
ndth
e
to
pfaceexc
ess
ivel
y.
Uni:mm[
t i
n.
]
Stan
dard
0
.05[0.0
020
]
C
ran
kca
set
opf
aced
ist
ort
ion
orle
ss

4
.2 Measuremento fCylinde
rI n
sid
eDiameter M
eas
ure
men
tofc
ran
kca
set
opf
aced
ist
ort
ion
(
l) Measurethecyli
nde
ri n
sid
ed i
amet
eratt h
etop(mo
st
wom s ect
io)，m
n iddl
ea ndbottom，eachi ntwo
dir
ecti
o
showni
nsp
nth
ar
a
ei
l
l
l
e
l
u

S
t
la
s

a
n
甘a

n
t

d
d仕 a
i

a
o
n

r
.

d
n
sver
setot

L
h

im
i
ec

t
ra

Uni
nk
sha
f

:mm[
t
t，

i
n
a
s

.
] ⑦ザ
「
プt!
J(z
E
ー町-司岡崎司ー司周司回・・ー句陣司帽』司旬同同ー

94.000to Repa
ir:94.2
00
C
ylind
erinsi
de 94.035 [3.
708
7]
d
iamet
er [3.7
008to Replacemen:9
t 4.7
00
3.7
0221 [3.
728
3] M
easurin
g
0.
01[0.000
4] l
oc
at n
!Os
C
irc
ular
ity
orless L
Jn
it:
mm[
i
n.
]
0
.015[0.
0006]
C
yli
ndric
ity M
eas
ure
men
tofc
yli
nde
rin
sid
edi
ame
ter
o
rles
s

(
2) I fthecylin
derh asr e
achedt herepa
irl i
mit，withthe
wearf a
rl e
sst hant h
er eplacementlimi
t，b or
eitt o
0.25m m[ 0
.0098in.]or0.5mm[ 0.0197in
.]overs
ize.
(
3) Honet hecylinderwithina naccuracyof0t o0.035
mm[ 0.
0014in.]，andu sethep i
stonandp ist
onr i
ngs
ofthesameo v
ersize
.
(
4) I fany c y
linderi su nevenly wom ，determine the
over
sizeont h
eb asisoft hemaximumwearn otedto
ensur
ep e
rfec
tr oundnessintheoversiz
edb o
re.
Not
e:( a
)R e
fmisha l
lc yl
inder
st othesameo ve
rsize
.
(b
)Ifthec y
li n
derisf oundingoodc onditi
on，with
t
hew earf a
rl es
st hant h
er ep
airl i
mit，rep
lace ¥¥¥』
t
hepistonringsandream0貸 出er idgeatthetop
oft
hecylinder
.Honet heboreifnec
essar
y.
R
idg
e-r
eam
ingo
fcy
lin
der

2-25
 INSPECTIONANDREPAIROFENGINEMAINPARTS

4.3 Measuremento
fPi
sto
nDiameter M
eas
uri
ngl
oca
tio
n
Using a mi
cromete，measure t
r hepist
ond i
amete
r
acro
ssthep i
stonski
rtandsqua
relywit
hthep i
sto
n
pin，a
sill
ust
rat
ed.
Ifthemeas
uredv a
lueexce
edstheI
imt，r
i ep
lacewit
h
anewp a
rt.
:m m[
t
Uni in
.]
S
t a
ndard Lim it
93.
955to9 3.
985 93.770
Standard
[3.
6990to3 .
7002
] [
3.6917]
P
isto
n 0.
25[ ∞
0. 9 8] 94.
205to94.235 94.020
d
iamet
ers ove
rsl z
e [ 3.
7089to3.710
0] [
3.7
0 16
] Measurementofp
ist
ond
iam
ete
r
0.
50[0.0197] 94.
455to94.485 94.270
ov
erslZe [ 3.
7187to3.7199
] [
3.7114
]
P
isto
nw ei
ght 5g[O.Ol1lb]
d
iff
erenc
einonee ngine orl e
ss

4.4 Measuremento
fPi
sto
nRingEndGap
P
lacethepist
onr in
gi ntheg
ag eoranewc y
linde
r，
t
henmeasurethepisto
nr i
nggapwithfee
ler伊 ges.If
t
hemeasure
dv alueexcee
d eI
s出i imi
t， r
eplac
ea l
lr i
ngs
a
sas t
.
e
I
nsi
ded i
ame町 o fgag:94+~ぺnm [
e 3.701+~ 00
14i
n.]
Note:To p
la峨 thepis
tonri
ngint
hegageor a new P
ist
onw
eig
htstampl
oca
tio
n
cy
lin
der，
useth
epist
ont
opu
sht
her
inge
ven
ly.
t
:m m[
Uni in
.]
Stan
dard
0.
30to0.50
P
ist
onr
ing I
O iIr ing I[
0.
0118ω0. 0197
伊p I
C1A~nnA ~;nn I 0.
50ω0.70
0.0197ω0.0276

4
.5 Measuremento
fPi
sto
nRingGrooves
Put anew p i
stonringinthep i
stonringgr
oove. R
ingendgap
Measuretec
h 1earan
cebetwe
entheg ro
oveandpis
ton
rin
gw it
has t
raig
hted
geandfe
ele
rg a
ges. Measuremento
fpi
sto
nri
nge
ndgap
Iftec
h 1ear
anceexcee
dsthel
imi
t，repl
aceth
epis
ton.
U
nit
:m m[
in
.}
Sta
ndard L
imi
t
0.
07to0.11
0.200
Topring [
0.002
8to
[
0.0
079}
g. ~Q4]J
Clearan
ce
0.
045to0.
085
between p
isto
n 0.150
Secondri
ng [0.0
018to
ringandgroo
ve [
0.00
59}
0.
0033]
0.
020to0.0
60
0.150
Oilrin
g [0.
0008to
[
0.0
059}
0.
0024]

Measuremento
fpi
sto
nri
ngg
roo
ves

2-26
 INSPECTIONANDREPAIROFENGINEMAINPARTS

4
.6 Measuremento fPis
tonPinBoreandP isto
nP in
Diamete
r
Meas
uret h
ei ns
idediam
eterof出ep is
tonpinbore
andthed ia
meteroft hepis
tonpintoc hec
kt he
c
1eara
ncebetweenth
ep i
sto
npinbor
ea ndpi
n.Ifthe
c
1eara
nceexcee
dsthelim
it，
rep
lac
ewithnewpar
ts.
Uni:mm[ in
.]

+
t M
eas
uri
ngl
oca
tio
ns M
eas
uri
ngd
ire
cti
ons

-
-
-
--
-
-
-- j i
N
ominal
Stand
ard Limit
va
lue
2
9. 9
94to ￨ 1
P
ist
onp
ind
iam
ete
r
φ30 3
0 .0
00 t
[1
.18] [
1 1
.1809t o
1.1811] Measuremento
fpi
sto
npi
nbo
reandp
ind
iam
ete
r
0.
000t o
C
leara
nceb
etw
een 0.016 0.
050
p
ist
onpina
ndbor
e 一 [O.O
to [ 0
.002
0]
0.0006]

4
.7 Measuremento fPistonP rotr
usion
Measuret hep rot
rusio
no fe ac
hp i
stoni nt h
e
fol
l o
wingmethod.Ifthem easuredvalu
eisn οtwithi
n
t
hes ta
ndardvalue，checkthec1eara
nceofthep紅 ts
.
(
1) Usingad ia
lg age，b r
ingt hepistontothet opd e
ad
ce
nter
.
(
2) Se
tt hedia
lg agβatt h
et opo fthecrankc
ase，ands e
t
t
heg ageindica
torto0( z
ero)
.
(
3) Measurethep isto
np ro加 sionat出r eel oca
tionson
t
het opo ft h
ep istona nda ver
aget het hre
e
measurem
en tstoc heckthep r
otrus
ion
.Tod et窓口ni
ne
t
hec 1
earancebet w
eent hepisωnt o
pa ndthec yl
inde
r
head， sub仕actt he p ist
onp r
otrus
ion 企. om ぬe
compress
edt hi
cknessof吐lecylinde
rh ea
dg asket
.
Measuremento
fpi
sto
npr
otr
usi
on
Unit:m m[ i
n.]
St
anda
rd
0
・.2
5t 15r
o0. ・0.
0098ω
0.0
059

「 &CAUTION
Keepthep
ist
onpro仕us
ionwith泊th
esta
nda
rdrang
eto
mai
ntai
nhighengi
n eperf
orman
ceandtopre
ven
tt h
e
val
ves企omcont
act
ingthep
ist
on.

2-27
 INSPECTIONANDREPAIROFENGINEMAINPARTS

4.8 MeasurementofClearancebetweenConnecting
4
9.0105
9.0N.m
RodB eari
ngandCrankpin (
50t
. o6.0kg
f.m)
() M
l easureth
ediam
eterofthecrank
pinandtheinsi
de M
eas
urin
gMeas
uri
nl! [
36.
2104 4l
3. bf
.ft
]
d
lr
ec
tto
ns l
oc
at
ion
s
diame
terofth
econnec
tingrodbeari
ngtocheckthe
cl

¥ ¥ ¥
e
aranc
ebetw
eenth
et wo
.

Nominal
Sta
ndar
U
ni:
tmm[

d L imi
i

t
n
.] @国
v
alue
5
7.955to
φ58 57.970 57.800
<
:ra
nkp
ind
iam
ete
r
[
2.28
3] [
2.2817to [
2.2756
]
2.2
823]
0 .
030to M
eas
ure
men
to fco
nnect
ingro
dbe
ari
ng
<:lea
ranc
ebetwe
en in
sid
ed i
amete
r
0.0
90 0
. 2
00
connect
ingrodbe
ari
ng
[
0.0012to [
0.0079
]
andc ra
nkpi
n
0.
0035]
ι -
一一一
No
te:M e
a s
uret heinsid
ed iame
tero ftheconnectingrod
be釘泊gi nthefollow
ingmanner.
(a)Inst
al
lt heconnect
ingr odbear
ings( u
p perand
lower)int
ot h
ec o
nnectingro
d.
(b)T i
ghtenthec apn u
tst othes p
ecif
iedt orqu，
e
thenm e
asuret h
ei n
sided iame
tero fthe
connecti
ngr o
db e
arin
g.
(
2) Ift hec le
arancee xcee
dst h
el imi
t，p erfo r
mt he
fol
1owing.
(
a)Ifanyf a
ultyi
sn otobserve
dont hecrankpin，repl
ace
thebea
ring.
(
b)Ifthecrankpinisbadlyoru neve
nlywom ，gr i
ndthe
crankp
ina n dusea nu nders
izeb ear
ing.0. 25 mm
[ 0098 i
0. n]，0
. .50 mm [ 0.
0197i n
.]a nd0 .75 mm
[ 0295 也]u
0. nder
sizec onn
ectingrodb ear
i ngsare
avai
labl
ef o
rs e
rvic
e.

4
.9 Measuremento
fClearancebetweenConnecting
RodBushingandP istonPin
Measuret h
ei n
sid
ed iameteroft h
ec onne
ctingrod
bushingandthediameterofthep i
stonpintoc he
ck
theclea
ranc
ebetweenthetwo.
Iftheclear
anc
ee xce
e dsthelim
it，repla
cew it
hnew
p釘 t
s
.
Unit
:mm[ i
n.
] Eヨ
M
eas
uri
ng
¥ ¥ ¥ ¥N ominal
Standa
rd L im
it
value
30
. 00t
2 o
<
:onn
ectingrodbus
hing φ30 30.0
45
i
nsi
ded i
ameter [1.18] [
1 1.
1819t o M
eas
ure
men
to fc
onn
ectin
grodb
ush
ing
1.1829] in
sid
ediam
eter
0.020to
<
:
learanc
eb etw
een 0.051 0.
080
b
ushingandpin [ 0008t
0. o [∞
0. 31]
0
.00
20]

2-28
 INSPECTIONANDREPAIROFENGINEMAINPARTS

4.10ReplacementofConnectingRodBushings
(1
) Uset heconne
ctin
gr odbushi
ngpu
lle
rtor e
pla
cet
he
con
necti
ngrodbush
ing.
Partnumber
AG-32A91・00500 O
ilh
ole

(
2) Wh enins
tal
lin
ganewb ushi
ng，alig
nt h
eoilhol
esof
th
eb us
hingandconn
ecti
ngrod. Posit
ionthee
ndsof
th
eb us
hingasshowninth
eillu
str
ati
on.
(
3) A食eri n
sta
lli
ngthebush
ing，ins
ertthepist
onpinin B
ush
inge
nds
po
sitio
nandmakes ureth
epinr o
tat
es企e e
lywitho
ut
p
lay.
R
epl
ace
men
tofc
onn
ect
ingr
odb
ush
ing

4
.11Inspect
ionofConnectingRodBendandT wist ~/生虫色盟主
(
1) MeasureC andfa si1
Ius回 t
ed.I
fthemeasuredC i
s E 、 1
00[
3.9
4]
C
moreth佃 0 .
05m m[0.002in
.]pe
r100m m[ 3.94i
n.]
ofm easur
edf，c o
rrec
tt heconn
ect
ingr odu s
inga 2 ‘ A

」- 盟主些些11よム」
t!
pr
ess.
u

2 1
ω[3.
94
]C子fi:E:ß~
m
m?

n-
n

‘
-

一
S一
EZQl
均一小円以

C
onn
ecting
目
一
JU
hM OJM山ω

一
O伽

r
odtw
ist
C
onnecti
ng
Conn
ectingr
odbend
MHS

rodbend Uni
t:mm[
in
.]
andtwi
st
m
w

I
nsp
ect
iono
fco
nne
cti
ngr
odb
endandt
wis
t

(
2) Normal
l ，
yac o
nnectin
grodal
igne
risuse
dtomeas町e
th
econnectin
gr odfo
rbendandtwi
s.
t
N
ote
:B eforem easu
ringt hecon
nectin
gr o
df o
r bend，
tig
htentheconnec
tingrodcapnut
stothes
pec
ifie
d
tor
que.

4
9.0t
o59.
0N'm( 5
.0t
o6.0kgf'm)
[
36.2t
o43.
4lb
f・食
]

M
eas
ure
mentofcon
nec
tingrod
(出i
ngco
nne
ctin
gr，吋ali
gne
r)
(
3) To inspe
ctt hec onn
ectin
gr odc o
mple
tew it
ht he
pi
ston，placethep i
stononas urf
acepla
te，in
ser
ta
roun
db arh avingthesamediam
eterasthecrank
pin
in
totheb ig-en
db oe，
r thenme
asuretheheig
htofthe
C
ba
rw ithad i
algage.

Measuremento
fco
nne
cti
ngr
odb
end(
usi
ngd
ialg
age
)

2-29
 INSPECTIONANDREPAIROFENGINEMAINPARTS

4.12I
nsp
ect
iono
fConnectingRodB
ear
ing
s
I
nsp
ectea
chcon
necti
ngrodb
ear
ing.Ifd
efe
ctssuch
a
sdent
sands
cra
tch
esaref
oud，
n rep
¥ac
ethebe
ari
ng.

~H a
kin
g

I
nsp
ect
ionofc
onn
ect
ingr
odb
ear
ing
s

4.13Measuremento fConnectingRodEndP lay

(1
) I n
sta
llthec o
nnectingrodtothemat
ingcrankpinby
ti
ghten
ingthecapnutstothesp
eci
fie
dtorq
ue.
(2
) Measuret heendp ¥
ay( c
¥ear
anc
ebetwee
nt herodand
cran
karm)w ithfee
lergag
es.
I
ft he end p ¥a
ye xc
eedst h
el im
it，repla
cet he
conn
ectin
gr o
d.
t
:m m[
Uni in
.]
Sta
nda
rd
0.
15to0.3
5
C
onn
ect
ingr
odendp
lay
0
.0 0
59to0.013
8
Measurementofc
onn
ect
ingr
odendp
lay

4.14Replacemento
fConnectingRod
Whenreplac
ingthec
onnec
tingrod，makes u
retouse
t
he one which h
ast h
e same weigh. (Check t
t he
w
eightmarkonit.
)

Alignment
mark
Weightrank
mark

Weightr
ankmarkonc
onn
ect
ingr
od

2-30
 INSPECTIONANDREPAIROFENGINEMAINPARTS

4.
(

(
1

2
15Measuremento
) U
d

b
s
i
a

e
i
m

t
n
gam
e

w
e
t
e

e
r
) Check t
.
h
n t
i

ec
c
r

h
om

i
r
e

c
e b
fC
t

u
l
e
e

a
a
r

r
i
r
a
，m
r

t
i
n

y
n
k
e
s
a

，c
g a
h
s
u

y
a
r

l
n
f

i
tJ
et

nd
r
d j
o
h

i
u

c
i
o
r
ec

t
u
n
a
r
lDiameter
a

ya
r
na
n
k

.
l
s

n
ha

dc
食j

1e
I
o

a
u
r

r
a
f a
n

n
a

c
n
l

e
y
φ日
~eas\1ring !vfe~uring
d
ire
cti
ons
-lo
cat
ion
s
measur
emente xcee
dst her e
parI
i imit，gri
ndt he
cr
anksh
aftt o釦 u nd
ersize. I
fi te xc
eedst he
re
placeme
ntIim
it，re
placethecran
ksh
aft
.
Unit
:mm[ in.
]

¥ ¥ ¥Nominal
S
tan
dar
d L
imi
t
value
Repair: Measurementofc
ran
ksh
aftj
our
nald
iam
ete
r
77.9
55t o 77.85
0
Jo
urna
l φ78 77.
97 0 [3.
0650]
di
ameter [ 3.0
71] [
3.0691to R叩 lac
ement:
Crank 3.0697] 77.1
00
jo
urna
l f
3.03541
0.
01[0
.飢渇4 ] 0
.03
Ci
rcu
lari
ty
orles
s rO .
00121
0.
01伊.飢渇4 ] 0.03
Cyl
in企ic
ity
orles
s [
0.0012]

4.
(
(
1
2
16Measuremento
) U

m
s

e
i
n

a
佃 u
gam
) Check t
bet
we
s
n
e
u
r
d
e
e
r
h

m
s
i
i
c

e
z
r
ec
n th
n
e
om
i
r

te
，o
e
c
e b
x
rr
fC
t
e
u
e
c
e
e
r
l
a
a
e
p
r
，
r
r
d
l
a
m
i
t
i
n
n
e
y

st
a
c
k
a
s

h
et
s

，c
g a
h
u
r
y

eI
h
i
a

l
n
m
ec
f
tC
et
i
n
h
dr
i
d c
i
r
t
a
，
出s
r
a
ec
c
r
g
r
n
r
i
t
a
n
i
h
a
k
a

k
n
f
p
n

p
i
k
p

i
nDiameter
i
y an
n
.
nd

d出ec
t
.
i
dc

r
a
l

a
m
e
e
I
n
k
t
a
e
r
r
a
fa
pi
.
nc
n
nt
e
y
o
φ口
M
d
i
e
a
r
s
e
c
u
t
r
i
o
i
n
n
s
g M
- l
e
o
a
c
s
a
t
u
i
r
o
n
i
n
s
g

Unit
:m m[in
.]
Nominal
¥ ¥ ¥ ¥ Standa
rd Li
m it
value
57.95
5to
φ58 57.97
0 57.800
Diame
ter
[
2.28] [
3 2
.2817to [
2.2756] Measurementofc
ran
kpi
ndi
ame
ter
2.
28231
C
ran
kpi
n
0.
01[0似ゆ4
. ] 0.03
Ci
rcu
lar
ity
orles
s [
0.0012]
0.
01[0
.似ゆ4] 0.03
C
yli
ndr
ici
ty
orl郎S [0
.0012]

4.
17G
rin
din
gofC
ran
ksh
aft
R
e f
mishthecra
nks
haf
tac
cord
ingtot
hedim
ensi
ons
of批 u nd
ers
izemainbe
ari
nga n
dconn
ect
ingrod
b
eari
ng.
Note:(
a)Wheng ri
ndin
gt h
ec r
ar邸h af
t，don otc hange
th
efill
etra
diu
sorwidt
h .
(
b)If the surf
ace hardnes
s i s s i
gnif
ican
tly
dec
rease，r
d e-h
arden t h
e c ran
kshat， 組d
f
cond
uctaM agnafl
ux( magne
ticp a
rti
cle)test
.
The cran
kpin
sa ndj ourn
alss houl
dh av
ea
har
dnesso f550o r more (Vi
ckersh a
rdness
num
ber).

2-31
 INSPECTIONANDREPAIROFENGINEMAINPARTS

G
rin
din
gdi
men
sio
nsf
oru
nde
rsi
zec
ran
ksh
aft
Unit
:m m[in
.] R3mm R3mm
Undersize F
i n
isheddim
ension [
0.1
2in
.] [0.
12i
n.
]
77.7
05to77.720
0.
25[
0.0
098
]
[3.059
2to3.059包
77.
455to77.470
J
our
nald
iam
etr 0
e .50[
0.0
197
]
[
3.0494to3.050
0]
7.2
7 05to77.220
0.
75[
0.0
295
]
[
3.0396to3.040
2]
57.7
05to57.720
25[
0. 0.0
098
]
[2.
2718to2.27当l
C
rankp
in 57.4
55to57.470
0.
50[
0.0
197
]
d
iam
eter [
2.2620to2.262
6]
57.2
05to57.220 F
ini
she
dra
diu
sdi
men
sio
noff
il
le
t
0
.75[
0.0
295
[
]
__[ii~i2~~~お2包

1&CAUTION I
I
fanyoft
hec
ran
kpi
nso
rjo
urn
alsn
eed
sgr
ind
in，
g g
rin
d
a
llcra
nkpi
nsorjou
rna
lsonth
esamecra
nksha
ftt
oth
e
d
imens
ion.
F
ini
shthefi
ll
et
stoara
diu
sof3mm[0.
12in.
]

4
.18Measuremento fCra
n kshaf
tEndP lay
(
1) I
ft h
ec r
ank
shaftendp lay(cle
aran
cebetweent h
rust 31+&
.03
9
be
aringjou
rnalw i
dtho fcrank
shaft and w
idth of [
1 1
.22 ∞ 1
5]
be釘加g capw iththrus
tp la
tes)e x
cee d
st helim
i，t
re
placet
hethr
ustpl
ateswithnewp a
rts
.
U n
it:m m[i
n.]
S
tan
dar
d
0
.100t
o0.264
C
ran
ksh
afte
ndp
lay
0
.0039t
o0.0104

t
Uni:rnm[
in
.]
C
ran
ksh
aftj
our
nalw
idt
h
(
2) Iftheendp layst
illexceedsthel i
miteve nafte
rt h
e
new thrus
tp la
tesh aveb eeni n
stall
ed，r ep
lacet h
e
thr
ustplat
eswiththeoversi
zeones.
N
ote
:( a)0 .
15rnm[ 0.0059in.
]a nd0.30rnm[ 0.0
118in.
]
ov
ersiz
et h
rustp
l a
tesareava
ilableforserv
ice
.
(
b)Ing ene
ral，therearjourn
alw earsq uick
ert h
an
t
he企o ntjour
nals，the
refo
re，replacementoft h
e
r
earthr
ustpla
teswillbesuff
icien
tinmostc ase
s.
Unit:m m[ i
n.
]
O
versi
zefor Ove
rsizefor
¥ ¥ ¥ Tol
eran
ce
f
ron
torrear f
ron
tan dre
ar
+0.
15 31.
15 31.30
伊
.∞5 9
] [1
.2264
] [.2
1 323] + 0
.0
30
9[
100
].
001
5] Measuremento
fcr
ank
sh食e
a n
dpl
ay
I
0
+.
00
.
13
10
81 [
132
13
32
03
1 I1
32
13
.4
852
1

2-32
 INSPECTIONANDREPAIROFENGINEMA/NPARTS

4.19Measuremento fCrank
s haf
tD ef
lect
ion
1) S
( upportthecranks
haftatthe仕o n
ta ndrea
rj o
urna
l s
withV -b
locks，thenmeasurethedefl
ecti
on(tob o
t h
di
r ec
tio
ns)atthecent
erjoumalwithadia
lgage.
(2
) Ift hem easured valu
em oder
atelye xcee
dst he
st
a nda
rdv a
lue，corr
ectthedefl
ecti
onb ygri
ndin
g.I f
th
em eas
uredv aleぬre
u xcee
dst hestan
dardvalue，
co
r re
ctthed e
flect
ionusingap re
ssoro th
ers i
milar
eqUlpment
.
I
ft hem eas
uredv al
ueexceedstheiIm
it，repla
cet h
e
cr
a nk
shaf
t.
Uni:mm[
t i
n.]
M
eas
ure
men
tofc
ran
ksh
aftd
efl
ect
ion
Stan
dard
0.
02[0.0
008
]
C
ran
ksh
aftd
efl
ect
ion
orle
ss

4.
20Replacemento fCranksha
ftGear
() U
1 sin
gag e釘 pul
le，
rremovethecra
nks
haftg
ear企om
th
ecranks
ha食.
Note:Don o
tremovethegea
rbyh i
tti
ngi
twithahammer.

Removalo
fcr
ank
sha
ftg
ear

(
2) H
eatt h
ec ra
nksh
aftgeartoatempe
ratur
eo fapp
rox.
100
0C[ 2120
F]withagearhe
ate
r.Putthegearonthe
c
ranksha
食w ithi
tskeywayalig
nedwiththekey，t
hen
t
apthegearendfac
ewithacopperhammer.

I
nst
all
ati
ono
fcr
ank
sha
ftg
ear
4
.21Inspe
ctionofOilSealContactSur
face
(
1) Checkt h
eo i
lsealcon
tactsurf
aceofth
ec ra
nksh
a食
rea
re n
df o
rwear.
(
2) Ifthecrank
shaf
tisb a
dlywom，r ep
lac
et h
eo i
lseal
compl
etew i
thoilse
alsle
eve
.

O
ilse
aIc
ont
act
s
urf
ac
e

I
nsp
ect
iono
foi
lse
alc
ont
acts
urf
ace

2-33
 INSPECTIONANDREPAIROFENGINEMAINPARTS

4.22I
nsta
"ati
ono fOilSealSleeve
(1
) Applyengin
eo iltot
heinsi
deoftheo
ils
ealsle
eve
.
(2
) Usingtheoils ea
lsleev
ei n
sta
lle
rse
t，in
sta
lltheoi
l
s
ealsl
eev
eo n
t othecr
anksha
貧.

P
artnumber
AG-30691・130
10

￨&CAUTION
Be car
efu
ln o
tto damage t
heo
ils
eals
lee
ve when
in
sta
lli
ngit
.
I
nst
all
ati
onofo
ils
eals
lee
ve

4.23RemovalofOilSealSleeve
Removethewomo i
ls ea
ls l
eeveint
hefol
low
ing
man
ner.Repl
aceitwit
hanewo ilse
alc
omp
let
ewith
o
ilsea
lsle
eve
.

O1
ise
als
lee
ve

I
nsp
ect
ionofo
ils
ealc
ont
acts
urf
ace

Removingtheoilsealsle
eve
Holdaf l
atchis
elatr i
ghtang
letotheslee
vea n
dc u
t
thesle
eveatthr
eep l
acestoloo
seni
t，asil
lu
s仕ate
d.
Ifi
tisimpos
sibletoremovetheslee
veinth
ismethod，
holdthechis
eli nthe飢 ia
ld i
rec
tionandlig
htl
yt a
p
thesl
eevetoloosenit
.

恒 Pト
[&CA l
Beca
ref
ulno
ttodamaget
hec
ran
ksh
a食whenr
emo
vin
g
th
eoi
lsea
lsl
eev
e.

Removalofo
ils
eals
lee
ve

2-34
 INSPECTIONANDREPAIROFENGINEMAINPARTS

4.
24In
spectio
nofMainBearin
gS urfa
ce
() I
1 nspec
tthemainbe
ari
ngsur
facefo
ra b
norma
lcont
act，
s
cratc
hesbyf
orei
gnpa
rti
cls，
e cor
rosi
on，t
1ak
ing，e
tc
.
() A
2 lsoc heckf
ors i
gnsofp oo
rs e
atin
go fthemain
b
earingcaporbea
ringbackmet
ali nthecra
nkca
se
b
ore.

I
nsp
ect
ionofmainb
ear
ings
urf
ace
4
.25Measurement o
f C
lea
ran
ce between Main
BearingandC rankshaftJournal
(
1) Ins
tal
lt hemainb ea
rings( up
pe ran dlower
)t othe
crank
caseandthem ainb e
aringc a
p.T ig
htenthecap
bol
tstothespe
cifi
edtorque
.
(
2) Measuretheinsi
ded i
ametero fthem ainbeari
ngsin
two posi
tion
sl engthw
isea nd 白re ec r
osswi
sea s
i
1lus
trat
edtotak
ea naver
a g
e.
(
3) Checkt h
ec le
aran
ceb etweent hem ainbearingand
cranks
ha食joumalont h
eb as
iso fth
ism easur
emen.
t
Uni:mm[
t in
.]
Stand閣rd IL im
it
0.
050t o0.1l0 I 0 .2
00 M
eas
ure
men
tofmainb
ear
ingb
ored
iam
ete
r
0
. 00
20t o0.0043]I [0
.007
9]

4
.26Repla目 mento
fMainB
ear
ing
s
Ift h
ec lea
ranc
eb et
weent hem ai
nb e
aringand
crank
shaftjoumalisl e
ssth組 thelim
it，re
placet
he
main bearin
g.I fite xcee
dst helimi
t，g ri
ndthe
加 k
CI shaf
ta nduseunders
izebea
rin
gs.
Wh enthec rank
sha食isg rou
ndtothespeci
fiedbo
re
dimensio
n ，themainb eari
ngd oe
sn otneedt obe
refi
nish
eda f
terin
sta
lla
tio
n.

2-35
 INSPECTIONANDREPAIROFENGINEMAINPARTS

4.
27I
nspec
tionofCamContactFaceofTappet
I
nsp
ectthecamcon
tac
tfaceofeac
ht a
ppetfo
rwear
.
I
fth
es u
rfac
eisu
neven
1ywom， r
ep1
acetheta
ppet
.

Good
O⑩Bad Bad

Camc
ont
actf
aceo
fta
ppe
t
4.
28Measuremento fClearancebetweenTappetand
TappetGuideBore

+
M
eas
uri
ngd
ire
cti
ons
(
1) Measureth
etapp
etdiame
ter.
(
2) Measurethet app
etg uideb or
ed i
amet
eri nt h
e
cran
kcaseintwop os
itio
nsasi Ju
l s
trat
edtotakean
aver
age.
(
3) Checkthecle
ara
ncebetweenthetwo.
Ift
heclear
anceexc
eedsthelim
it，re
pla
cethet
appet
.
Uni
t:m m[i
n.
]
St
anda
rd
1
4. 0
00to14.0
18 M
eas
uri
ngl
oca
tio
ns
0.5512to0.
5519
0.016to0.
052 Measurementofc
lear
anc
eb et
wee
n
0.0006tひ0.
0020
1 tap
petandta
ppe
tb or
e

2-36
 REASSEMBLYOFENGINEMAINPARTS

1
.Pistons，ConnectingRods，Crankshaft，CrankcaseandTappets・・・・・・・・・・・・・・・・・・・ 2・38
1.1Inst
all
ati
onofMain8 eari
ngsandTappets'. ................................ ...
...... .. 2・38
1.2Inst
all
ati
onofCranks
ha t・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2-
f 38
1.3Inst
all
ati
onofMain8 e
a r
ingCaps・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2・3 8
1.4Inst
all
ati
onofMain8 e
a r
ingCap8 0lt
s. ................................... ....
...... .. 2・39
1.5MeasurementofCrankshaftEndP lay. ..................................... ..
...... .. 2・39
1.6ReassemblyofPistonsandC onnectingRods......................................... 2・3 9
1.7Inst
all
ati
onofPis
tonR ings................................................. ......... 2-40
1.8Prepar
ationfo
rPisto
nI nst
alla
tion.................................. .
.. ..
. ..........
. . 2・40
1.9Inst
all
ati
onofConnectingRod8 0ltsand8 earings ..................................... 2・4 0
1.10I
nst
all
ati
onofPist
ons. ......................................• ...................... 2-41
1.1
1Inst
all
ati
onofConnectingRodCaps ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2- 41

.TimingGearsandCamshaft・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2-
2 42
2.1I
nst
all
ati
ono
fOi
lPump'. .................... ....................................... 2・42
2.2Inst
all
ati
ono
fFron
tP l
ate...
........ ........................ .
............ ........... 2-42
2.3Inst
all
ati
ono
fCamshaftGearandT hrustP lat
e. . ...
. .
. ..
. .
................ .........." 2- 42
2.4Inst
all
ati
o fCamshaft・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2-
no 42
2
.5I
nst
all
ati
ono
fOi
lSt
rai
ner.
....
......
.......
....
....
....
......
.....
....
....
...
.....
.. 2-43
2
.6 I
nst
all
ati
ono
fFu
ell吋e
cti
onPump・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2-
43
2.7I
nst
all
ati
ono
fId
lerGear.
...
...
................
...
................
.......
....
.....
.. 2-
44
2
.8I ns
tall
ati
onofOi
lPumpGear... ............................. ................ ....... 2-
. 44
2
.9I nspe
ctionandAdjustmentofTimi
n gGearsa f
terInsta
llat
ion ............................ 2-44
2.
10Inspe
ctionofVa
lveT iming....
................................... ................ . 2-
.. 45
2
.11Ins
tall
ati
onofOi
lS eal.......
.............................. ...• ............. . 2-
....... 45
2
.12Ins
tall
ati
onofTimingGearCase. ................................... ........ . 2-
........ 45
2
.13l
nst
allati
onofOlPan ............................................................... 2-
i 46
2
.14l
nst
allati
onofCranksh胡 P u
lle
yandDamper'..... ..........• ........• ......... . 2-
...... 46

3
.Flywheel............................................................................. 2-47
3.1Insta
llat
ionofOilS ea
l.. ...
.. ........................................................ 2-
47
3.2Insta
llat
ionofRearP late ......................................................•..... 2-
47
3.3Insta
llat
ionofFlywheel.............................................................. 2-47

4
.CylinderHeadandValveMechanism.• ......................• ...
......
..... . 2-
...... 48
4
.1I
nst
all
ati
ono
fStemS
eal
s..
• ..
...
...............
...
.........
......
........
... . 2-
...... 48
4
.2 I
nst
all
ati
ono
fVa
lveS
pri
ngsandV
alv
eCo
胎 r
s •....................................... 2-
48
4
.3I
nst
all
ati
ono
fCy
lin
derHead........................................................ 2-49
4
.4 Reassemblyo
fRockerArmandRockerSha
代Assembly.............
.........
...
.....
.. 2-49
4
.5I
nst
all
ati
ono
fRockerS
haf
tAssembly.
...
...
...
...
...
...
...
......
....
....
....
....
...
. 2・49
4
.6Adjustmento
fVa
lveC
lea
ran
ce.
.......
• ....• .....
...
............
...
...
....
...
......
. 2・50
 REASSEMBLYOFENGINEMAINPARTS

1
. Pistons，ConnectingRods，Crankshaft，CrankcaseandTappets
Toreasse
mbl
e，fol
lowth
edis
ass
embl
ys eq
uenc
ein
re
ver
se.
1
.1 Ins
talla
tionofMainB earin
g sandTapp ets
(
1) In
sta
lle achuppershe
llo fthemainb eari
ngstot h
e
crank
cases otha
tt hebearingl u
gf i
tsintothel u
g
grooveinthecrankc
ase.Theo i
lholesinthebeari
ng
andcrankcas
ew i
llbea l
ignedwhent hebeari
ngisso
ins
tal
led.
(
2) Applyas ma
ll amounto fe ngi
neo i
lt ot h
ei nne
r
sur
faceofeachbear
ing.
(
3) In
sta
llthethr
ustpla
tetotherearfac
eo ft
hec r
ankca
se
withoilgroove
sf acedtheoutsideasshowni nthe
il
lus
tra
tio
n.
(
4) Applye n
gineoi
lt othetap
petsandi n
ser
tt h
et a
ppe
ts
加tothecrank
case.

1.
2 Ins
tall
atio
no fCranksha代
(
1) Washthecranks
haftthoro
ughlywit
hclea
nin
gsolve
nt
.
Drythecrank
shaf
tw it
hc ompr
essedai
r
.
(
2) Holdt h
eCI加 ksha食 hori
zon
tall
yw ithahoi
st，th
en
car
eful
lyplacei
tintoth
ec ra
nkca
se.
(
3) Applyas mal
lamouto fengi
neoiltoth
ecrank
shaf
t
jo
urna
ls.

I
nst
all
ati
ono
fcr
ank
sha
ft

1.
3 Insta
llatio
no fMainB earingCaps
A
ppl
yThr
eeBond1
212.
(
1) Applye ngi
neo i
lt ot h
el owermainb e
arins，t
g he
n
inst
al
lt hebearin
gstothem ainbearin
gcaps.
(
2) ApplyThr eeBond1 212o n
tot h
em atin
gf a
ceso f
t h
e
NO.7mainb ear
ingcapa ndthecrank
case
.
No
te: Don otapplyThreeBond1 212o nt
oo t
herpo此ion
. 亡
〉
(
3) Inst
allthemainb earingcapt othecrankc
ases otha
t
therearf a
ceo fthecapisf lu
shw it
ht h
er e
arfaceo f
thecrankcas
e.
(
4) Apply官官e eBond1 211t othesideseal
s.Inse
rtt h
e A
ppl
yTh
reeBond1
211
.
sidesealswi白y o町 handi n
totheg r
oovesinthemain
bearingcapw it
hr ound
eds i
def a
cedouts
ide. I
nst
all
ati
ono
fma
inb
ear
ingc
ap
Pushthemi nt
op o
sitio
nw ithaflatpiec
e，taki
ngc ar
e
nottobendo rtwistthem
.
(
5) ApplyT hreeBond1 2
11toa ndaroundthesid
es e
als.
N
ote:Inst
allt h
emainb e
aringcapsinnumbero rder企om
th
e企o ntsideofthecrankca
se.

I
nst
all
ati
ono
fsi
des
eal
s

2-38
 REASSEMBLYOFENGINEMAINPARTS

1.4 In
sta
lla
tiono
fMainBearingCapB o
lts
(1
) Applye ng
ineoi
ltothemainb e
ari
ngcapb
olt
sand
t
ight
enthemωthesp
eci
fiedto
rqu
e.

ゆteningω珂~e 198t
o10
8N.m(
10.
0t 1
o1.0kgf.m)
f
ormainb
ear
ing I
附]
capboh￨[723MMlb

(
2) Ensu
ret h
atth
ecr
ank
sha
食ro
tat
ess
moo
thl
ywi
tho
ut
加 ybin
ding
.

I
nst
all
ati
onofmainb
ear
ingc
apb
olt
s

1
.5 MeasurementofCrankshaftEndP lay
Aft
erins
tall
ingthemainb ea
ringcas，m
p easur
et he
endpl
ayofthecrank
shaf
tt oen
suret
hatthemeasured
val
ueiswi
thinth
es ta
ndardva
lue.
Unit
:m m[ in.
]
d一
So
凶

AU-A14
υ

μ
釘
oo
一
一・
nU
h

一
ω
0
聞 9

m
o o・

m
・n

Et

・ h v
-

C
ran
ksh
afte
ndp
lay
u
AU

8斗
-Ea

M
eas
ure
men
tofc
ran
ksh
afte
ndp
lay

耐
と
う
1.
6 Reassemblyo fPis
tonsandConnectingRods
(
1) Reasse
mblet h
epistonandt heconn
ectingrodwith
th
ew ei
ghtmarkofthepistonandth
ea li
gnmentmark
ofthecon
necti
ngrodont h
esames i
de
. E
(
2) Applyengineo
iltothepist
onp i
n，the
ninser
tthepin
in
tothepist
onandthrou
ght h
ec o
nnec
tingrod
.

Weightmark

← A
lignme
nt
mark

R
eas
sem
blyo
fpi
sto
nan
dco
nne
cti
ngr
od

(
3) In
stal
lt h
es napringsi
ntot
hegro
ove
soft h
ep is
ton
withtherin
gplie
rs.
Checkt h
es na
pr i
ngsfo
rten
sio
nandpro
perfi
tti
ngin
血eg roo
ves.
Note:P
ositi
onth
ee ndgapofe
achs
napr
ingt
owa
rdt
he
bot
tomofth
epist
on.

I
nst
all
ati
ono
fsn
apr
ing
s

2-39
 REASSEMBLYOFENGINEMAINPARTS

1
.7 I
nst
all
ati
ono
fPi
sto
nRings

f叫￨ム口、
(
1) U
singt h
epi
sto
nri
ngpl
ies，i
r nst
allth
ec om
pre
ssi
on
r
ing
sandt h
eoilr
ingi
ntoth
er inggro
ovesofth
e
p
ist
on.
P
artnumber
AG-31391・129
00
Note:I
ns
r“
o
t
allth
ec o
mp
2T"markf
r
e
a
c
s
e
si
o
dt
nr
h
et
i
n
o
g
po
sont
f
th
h
ep
ep
is
i
t
o
s
n
t
.
o
nwi
th“
T"
¥-dgo 同

P
ist
onr
inga
rra
nge
men
t

(
2) I
nst
allt
heo
ilri
ngwithit
sendga
pposi
tion
edat1
800
t
otheco
ils
pri
ngjo
in，
t a
sshownint
hefi
gur
e. C
oils
pri
ngj
oin
t

I
nst
all
ati
ono
foi
lri
ngandc
oils
pri
ng

1
.8 P
rep
ara
tio
nfo
rPi
sto
nIn
sta
lla
tio
n
(
1) P
lac
et h
ecran
kcaseoni
tssi
de.
(
2) C
leanthecylin
derbore
sw ith ac
1oh，t
t hena
ppl
y
e
ngin
eoilt
otheboresu
rfac
es.

P
rep
ara
tio
nfo
rpi
sto
nin
sta
lla
tio
n

1.
9 I
nst
all
ati
ono
fConnectingRodB
olt
sandB
ear
ing
s
(
1) I
nst
alltheconne
ctingr odbol
tsint
othebige n
do fth
e
c
onnectingrodsothatthefla
tsofth
eirhea
dsfitt
ot h
e
c
onnectingrodpro
perly
.
(
2) I
nst
alltheu p
perhalfoft h
ec on
nec
tingrodbeari
ngto
t
heb igendoft hec on
nectingrod，ens
uringtha
t廿le
l
uge nga
ge swit
ht helugg roov
e.Applyengineoi
lto
t
hebeari
ng.

2-40
 REASSEMBLYOFENGINEMAINPARTS

1.
(1
10I
nst
all
) Applye
at
i
n
o
g
no
in
fP
eo
i
i
s
lt
to
ot
ns
h
epist
onrins，t
g h
enmovet h
e
， T
hru
std
ire
cti
on
camhaaside
Top
p
isto
nr i
ngssotha
ttheendgapsdonota
lig
nwithth
e 18
0. ，. cpmpress¥On
p
in direct
ion，thru
std i
rec
tiono rcoun
ter
-th
rus
t 不rmgg勾
d
ire
ctio
n.

Secon
d 叫
c.o
mpres
sio
n/<
:
"
nnggap 6
0.
.S~~~.~~r~thrust
.
.
d
irection
A
rra
nge
men
tofp
ist
onr
inge
nds

(
2) Turnthecra
nks
haftun
tilthecran
kpinontowhicht he
pist
onandconne
ctin
gr odassemb
lyisbeinginst
alled
comestot h
et opdeadc e
nte
r.F ac
et hepisto
na n
d
conne
ctin
grodassemblysotha
tthefron
tmark( 0)on
thetopof
thepis
tonpoi
ntstothe合ontoftheengine.
(
3) Using th
ep is
toni n
sta
lle
r，i n
ser
tt hep is
tona n
d
conne
ctin
grodassembl
yi n
tothecyl
ind
er.
Pa
rtnumber
AG-3449
1-0020
0
(
4) A
fte
rr es
tin
gt h
eb i
g-en
do f
theconnect
ingrodonth
e P
ist
oni
nst
all
er
c
rankp
in，tur
nt hecra
nksha
食1 800 w
hilepush
ingth
e
p
ist
onh eadtobringth
eb i
g-e
ndt oap o
sit
ionwhe
re I
nst
all
ati
onofp
ist
onandc
onn
ect
ingr
oda
sse
mbl
y
t
heconne
ctingrodcapcanbein
stall
edea
sil
y.

1.11I
nsta
llati
onofConnectingRodCaps
(1
) Inst
allthelowe
rh a
lfofthecon
nectin
grodbeari
ngto
t
hec on
necti
ngrodc a
p，ensu
ringth
atthelugengag
es
w
iththeluggroov
e.Applyengineo
iltothebe
ari
ng.
(2
) Inst
allthecaptotheconn
ectin
gr d，
o thentig
hte
nt h
e
c
apn ut
stothespec
ifi
edtorq
ue.

T
ighte
ning
ω珂 ue1
49.
0to5
9.0N'm( 5
.0t
o6.0kg・
fm)
f
orcapnut
s 41
[36.2ω43. b
f・食
]

[二位岨!己
E
nsuretha
tt h
ea l
ign
rne
ntmark
sont
hec
apand I
nst
all
ati
onofc
onn
ect
ingr
odc
ap
c
onn
ecti
ngrodar
eonth
esames
id
e.

2-41
 REASSEMBLYOFENGINEMAINPARTS

2
. TimingGearsandCamshaft
Toreasse
mbl
e，followt
hed
isa
sse
mbl
yse
que
ncei
n
re
ver
se.
2
.1 In
sta
lla
tio
nofOilPump
Fi
ttheO-r
ingi
ntoth
eoiIpumpc
ase，白e
nin
st
al
lth
e
Jpumpo
oi ntot
hecra
nkc
ase
.

I
nst
all
ati
ono
foi
lpump

2
.2 I
nstall
ati
onofFrontP late
(
1) P
lacet heg a
sket on t hec ra
nkca e，e
s nsu
ringt he
d
owelse n
terth
ehole si
nt heg asket
.
ο
) Tightenthe企ontplateretainingboltstothespecified
t
orq田 to泊Sぬ 1th
e企o n
tp lateontot hecr
a n
kcase.

Ti酔teningω~que 1
10.
0to1
3.0N・m(1.0t
o1.3匂f
.m)
f
or合o
ntp
lat
e
b~It~- --' r---'- [7.2ω9. ・
4Ibf町

(
3) C
hecktoe ns
ure白紙 theIoweren
doft hegas
keti
s
f
lus
hw i
tht h
eb o
ttomsur
fac
eo fth
ec ra
nkc
ase
.C ut
o
ffanyexc
essgask
etne
atl
ywithacu
tte
r. I
nst
all
ati
onoff
ron
tpl
ate

2
.3 I
nsta
lla
tio
nofCamshaftGearandT hrus
tP la
te
H
eatt h
e camsha食 ge
arforin
sta
lla
tio
n. Have t
he
t
hru
stpl
atein
stal
ledi
nadv
anc
e.

2.4I
nsta
lla
tionofCamshaft I
nst
all
ati
onofc
ams
haf
tge
訂 a
ndt
hru
stp
lat
e
(1
) Ap
plye ngin
eo iltotheIobe
sa ndjou
rnaIsofthe
c
amsh
aft.
(2
) C
aref
ullyins
ertth
ecamsha食int
othecr
ankc
ase.
(3
) T
ighte
nt h
ethrus
tpla
teret
ain
ingbo
ltst
othespec
ifi
ed
t
orqu
e.
T
ighte
nin
gtorq
ueI
f
or伽 出tpla
te
I1
0.0t
o13
.0N.m(1.0t
o1.3k
gf.
m)
b
olt
s ￨ [72t09.
4lbf
・向

￨ 盃じM
.m.
jli
Be ca
ref
uInotto damage t
hecams
haftIub
es佃 d
cr
ankc
asebu
shi
ngswhenins
ert
ingt
hecam
sha
ftint
oth
e I
nst
all
ati
ono
fca
msh
aft
cr
ank
case
.

2-42
 REASSEMBLYOFENGINEMAINPARTS

2.
5 I
nst
all
ati
ono
fOi
lSt
rai
ner
I
ns
ta
llt
heo
ils
tra
ine
r.

I
nst
aII
ati
ono
foi
Ist
rai
ner

2
.6 In
sta
lla
tio
no fF
uelln
jectionPump
Fu
el
Byusingthefla
ngepla
ter e
tai
nin
gbolt，in
st
aI
Ithe IO
Je
c¥o
t n
pump
fu
eIinj
ect
ionpumpc om
pletewithth
eg ea
ra ndt
he
fl
ang
eplat
etoth
e企o n
tplat
e.

l~ CAUTION I
Whe nreass
embI
ingt h
es epa
ratedfla
ngepla
teandfu
eI
in
ject
ionpump a ssem
bly，b es u
retoa I
i伊 themark
pla
cedont heflan
gep l
atebeforedisa
sse
mblywit
hthe B
olt
mark on thefueIi n
ject
ion pump toe n
sureprop
er
rea
ssemb
ly.
Thesamep r
oceduremustbef oIIo
wedwhenins
taI
l
inga I
nst
aII
ati
ono
ffu
e 吋e
Ii c
tio
npumpa
sse
mbl
y
newfueIin
ject
ionpumpa ssemb
ly.

2-43
 REASSEMBLYOFENGINEMAINPARTS

2.7 I
nsta
llati
onofIdle
rGear
(1
) Inst
alltheid
lergearbyalign
ingit
sa l
ignme
ntm a
rks
w
itht h
oseonthecrank
sha食gear，i
nje
cti
onpumpg ea
r
andcamsha食gear
，thenin
sta
llthet
hru
stpla
te.
(2
) Tightentheth
rus
tp l
atere
taini
ngbol
ttothespec
ifie
d
t
orqu
e.
Ti ghte ni
ngtorq
ueI
129.
0to39.
0Nom( 3
.0t
o4.0k
gfo
m)
fort hr u
stpl
ate
-
-
b~lt--- r-
--- [
21.7t
o28
.9lb
f・食
]

I
nst
all
ati
ono
fid
lerg
ear

(
3) Themarksont h
eg ear
swil
lbeal
ign
eda
s shown C創 出h
a食g
ear I
dle
rge
ar
when t
heN O
.lp i
sto
ni satt
opdeadc
ent
ero f
com
pre
ssionst
rok
e.

O
ilP
叩npg
ear
Marksont
imi
ngg
ear
s
2.8 I
nst
alla
tio
nofOi
lPumpGear
(
l) Ins
tal
ltheoi
lpumpg
earon
totheoi
lpumpsh
aft
.
(
2) Tighte
nthejamn
utt
othesp
eci
fie
dtor
que
.
T
igh
teni
ngωrque128.0ω38.0Nom(2.9ω3.9k
gfo
m)
f
orjamnu
t [21
.0t
o28
.2lbf吐]

2
.9 Inspe
ctionandAdjustmentofTimingGearsa
fte
r
Ins
tall
atio
n I
nst
all
ati
ono
foi
lpumpg
e訂

Checkt h
eb ac
klashandtheendpla
yb etwe
eneac
h
gea
ra 食erin
sta
lli
ngth
etimingg
ear
s.
Uni
t:mm[i
n.
]
Standar
d L
im it

Timingge
arb a
cklas I 0 .05t o0.
h [0.0~Ó2Õ ;~ U :
15
OO59I 0.25
] [0~ÒÕ98]
0.0 5t o0.20 I 0. 35
I
dlerge訂 endp l
ay I
[0.0~Ò2Õ ;~ U
:OU7
9 I
] [0~Ò13~1
0. 10t o0.25 I 0. 30
Camshaftgea
rendp la
y1 0.0039t oO.00
98]I[0.0118]

M
eas
ure
men
tof
tim
ingg
e釘 b
ack
las
han
den
dpl
ay

2-44
 REASSEMBLYOFENGINEMAINPARTS

2.10Ins
pectionofV alveT iming T
opd
eadc
ent
er
I
ti sn otn ec
essaryt oi n
spectt h
ev a l
vet i
ming， 3
0. ， 30
。
pr
ovidedtha
ta l
la li
gn m
e ntmarksont h
et iminggear
s
a
rea li
gnedproper
ly.However ，itisrecommendedt o
che
ckt h
ev al
vet i
ming.
() U
1 sin
ga3mm[ 0.
12i n.
]t hi
ckfeele
rg age，add3mm
[0
.12in.
]c le
arancetoth einl
etande xh
au s
tv a
lveso f
t
heNo.1c yl
inde
r.
(
2) Inser
ta0. 05mm[ 0.0020in.
]f e
ele
rg ageb e
tweent h
e
t
opo ft
hev al
vec apandt heroc
ker.
(
3) S lo
wlytumt h
ec ranksha食 t
of in
dt h
ep osi
tionwhere B
ott
omd
eadc
ent
er
t
hef ee
lerg a
gei sf mnl yc lam
ped( th
ev a
lves t
art
s
o
pening)andthep o
sitionw h
eret h
efeele
rg ageisjus
t V
alv
eti
min
gdi
agr
am
r
eleas
ed(thevalvesta
rtsc l
osi
ng).
(
4) Checkt omakes urethattheseposi
tion
sc oinc
idew i
th
t
hea ngularpositio
ns shown i nt hev alvet imi
ng
d
iagramw it
h3mm[ 0.
1 2in
.]cleara
ncea ddedtothe D
ire
cti
on
v
alve
s. o
fro
tat
ion I
nl
et

B
ott
omd
eadc
ent
er

2
.11Ins
tall
ati
onofOi
lSeal V
alv
eti
min
gdiagra
mw i
th3m m[
0.1
2in
.]
Applyas ma
llamountofg
rea
setot
heo
ilse
al，t
hen c
lea
ranc
ea dd
ed
in
sta
lli
ttothet
imingge
arc
asewi
tha
nin
st
al
le
r.

I
nst
all
ati
ono
foi
lse
al
2
.12Ins
tall
ationofTimingGearCase
(
1) Plac
et hegaske
tont he企ontplae，m
t akingsurethe
dowelpinsent
erthe
irhol
esinthegas
ket
(
2) Applyengineoi
ltotheli
poftheoi
lsea.
l
(
3) In
sta
llthet i
minggearca
setothecrank
case
.T ig
hten
th
et iminggearcasere
tain
ingbol
tstot h
es p
ecif
ied
to
rque.
Tight eningtorq
ueI
forti minggear
I
1.0t
1 o13.
0N.m(1. o1
1t .3k
gf.
m)
case-b~it; "
'-
-- [
8.0t
o9.
41bf
.f
t]

I
nst
all
ati
ono
fti
min
gge釘 c
ase

2-45
 REASSEMBLYOFENGINEMAINPARTS

2.
13Ins
talla
tionofO lPan
i
(
1) Cleanthemoun tingsurf
aceso ft
hecrankc
ase，timi
ng
gea
rc as
ea ndoilpan.
(
2) Squeezeouta4mm [ 0.16in.]thic
kne
ssofT h
ree
Bond1207C( liqu
idg βs
ket，AG-32A91-05100)仕om
thet ubea nda pplyitont hec ir
cumfe
renceofo i
l
pan fla
nge
.

6
(
3) In
st
alltheo i
lp ant othec r
ankca
sew i
thin5m in
utes
af
terputt
ingtheIiquidgasket
.
(
4) Tig
h t
ent h
eo ilp anr e
tainin
gb o
ltstot h
es pe
cifi
ed
to
rque.
T
igh
ten
ingω珂u e110.0ω13.0N'm(1.0ω 13k
. gf'm) A
ppl
ica
tio
nofl
iqu
idg
ask
et
f
oro
ilpanb
olt
s [
7.2ω 9.
4lbf
.ft
]

N
ote
: Tosq
uee
zeou
ta4mm[ 0
.16in
.]thi
ckne
ssofl
iqu
id
ga
ske
t，c
utt
hefr
rs
tnodeoft
he知 b
en o
zzle
.

N
ozz
leofThreeBond1
207t
ube

2.14Ins
tall
atio
no fCrankshaf
tP ul
leyandDamper
(1
) Lockt hecranks
haftsothati
twilln o
trotate.Tol o
ck
th
ec ranksh
a， i
合 n
sta
lltwo safetystuds (M12x1.25
mm)i ntothethreade
dh ole
sa tther e
are ndo fthe
cra
nksha
fta n
dt h
enplaceabarbe t
weenthes tu
ds.
(2
) I n
sta
llt hec rank
sha食 p u
lleyc ompletew itht he
dampertothecran
kshaf
t.Tightentheret
ainingnutto
th
es p
ecif
iedtorq
ue.

480t
o500N'm(4
9to51kgf'm)
[
354t
o36
91bf
.ft
]
I
nst
all
ati
onofc
ran
ksh
aftp
ull
eya
nddamper
l&CAUTION
Whil
e町 ingt oin
sta
llthecrank
sha
ftp
ull
eya n
dt he
da
mper，thebar may dis
lod
ge 企om t
hestu
ds. Pay
s
uff
ici
enta
tte
nti
ontoens
uresa
fet
y.

2-46
 REASSEMBLYOFENGINEMAINPARTS

3
. F
lyw
hee
l
Toreas
sem
ble，f
oll
owt
hed
isa
sse
mbl
yse
que
ncei
n
re
ver
se.
3.1 Ins
tall
ati
onofO i
lSeal
(1
) ApplyasmaJ lamountofg r
easetoanewoi
lseaJ
.
(2
) I n
stal
Jtheoi
lsealintotherea
rp l
atewi
thanin
sta
lle
r. R
ear
pla
te
Ensur
et h
attheoi
ls e
alisinst
alJedint
hed
ire
ctionas
shownintheill
ust
rat
ion
. F
lyw
hee
lsi
de
N
ote
:Iftheo
ilsea
lcont
actsu
rfac
eo fthecr
anksh
a食 i
s 〈コ 亡〉
e
xce
ssi
vel ，
yworn u
seanoi
lsealwi
thsl
eeve
.

O
ils
ea
l

I
nst
aJ
lat
iono
foi
lse
al

3
.2 Ins
tall
ati
ono fRearP late
(
l) Plac
eanewg as
ketont h
ecran.
kcas
e.
(
2) Applyengin
eo i
Itot heen
tireper
ipher
yoft heoi
lseal
li
ps
.
(
3) In
sta
lltherearpla
teo nt
ot h
ec ra
n.k
case，makingsure
th
edowelp i
n senterthei
rh ole
s oft herearpla
te.
Tigh
tentherearpl幻 eret
ainin
gb o
ltstothes p
ecif
ied
，r
ぬ que
.

T
igh
teni
ngtor
que15
4.0t
o65.
7Nom( 5
.5t
o6. ・
7kgfm)
f
orr
earpl
ateb
olsI
t [3
9. o48.
8t 5Ib
fof
t]

I
nst
all
ati
ono
fre
arp
lat
e
3
.3 Ins
talla
tionofFlywheel
(
1) In
sta
llas afe
tys tud(M12x1 .25r nm)intotherea
rend
ofthecranksha食.
(
2) In
sta
llthef ly
wh eeltot hecran
kshaft，makingsurethe
saf
etystudente
r stheb ol
th ol
eo ftheflywheeJ
.
(
3) Tempora
rilytightent hef l
ywheelretain
ingbol
ts( f
ive
bo
lts
).
(
4) Removet hes a
f et
ys t d，t
u heninst
allandt empor
arily
ti
ghtenthela
sto neb olt
.
(
5) Usingat orqu
ewrencho rothersimil
art o
ol，lockthe
cra
n.
kshaftpuJ
le ynut
.
(
6) Tigh
tent heflyw h
e e
lr e
taini
ngb o
ltst othespeci
fied
to
rque. I
nst
all
ati
onoff
lyw
hee
l
T
igh
tenin
gt o
rque1
78.
5to88.
3Nom( 8
.0t
o9.0kgfom)
f
orfly
whee
lb o
lts1 [5
7.9t
o65.
1lbfo
ft
]

￨ 企 CAUTION
Theper
sonwhol oc
kst h
ec ra
n.
ksh
aftp
ull
eyn
uts h
ould
dosowithex仕emecar
e.Communicatewi
theac
ho th
er
cl
ose
lytopr
even
taccid
ents.

2-47
 REASSEMBLYOFENGINEMAINPARTS

4
. C
yli
nde
rHeadandV
alv
eMechanism
Toreasse
mbe，f
l oll
owt
hed
isa
sse
mbl
yse
que
ncei
n
re
ver
se.
4
.1 I
nst
al
A
f
s
e
l
a
t
a
t
e
i
o

lt
no
ri
fStemS
n
s
ot
h
ta
l
ev
l
a
i
n
l
e

v
a
gt
eg
l
s
h
ev
ui
a
d
l
ew
v
ei
it
np
ht
o
h
s
es
i
t
t
i
e
n，i
o
mse
a
p
a
n
st
a
li
rt
n
l
lt
n
s
u
t
a
m
b
h
l
l
e
es
e
r
r
.
te
m

AG-32A91・10200
S
t
i
n
e
s
t
ms
a
ll
e
e
a
r
l
• V
alv
e

!~ CAUTION I
(
a)Don otapplyanyo i
lors ea
lantont hefac
eo fthe
stemsea
lthatcomesincont
actwiththevalv
eg u
ide
.
(
b)Wh eninst
all
ingthestemseal，appl
ye ngin
eo i
lo n
th
es temsealconta
cts u
rfac
eo fthev al
ves temto I
nst
all
ati
ono
fst
ems
eal
en
sureiniti
allu
bri
cat
ionofthestemseal
lip
.
(
c)Donotr e
mov eth
ev a
lveaft
erthestemsealhasbeen
in
stal
ledinposit
iontopreventdamaget othestem
se
alli
p.

4.2 I
nsta
lla
tio
nofVal
veS pr
ingsandV al
veCo
tte
rs
() I
1 nst
alltheva
lvespri
nga n
dr et
ain
er ont
heval
ve
g
uide
.
(2
) Usingt heval
ves p
ringpush
er，inst
allt
heval
ve

P
'ar
tnu
mbe
r
AG-30691・04500

I
nst
all
ati
ono
fva
lves
pri
ngsa
ndv
alv
eco
即時

(
3) Lig
htl
yt apthev a
lves te
mt opw i
th asof
t-f
ace
d
hammerseve
raltime
stomakes u
rethev
alv
es p
rin
g
andco悦e
r訂 epro
perlyi
nst
all
ed.

ns
I p
ect
iono
fva
lvec
ott
eri
nst
all
ati
on

2-48
 REASSEMBLYOFENGINEMAINPARTS

4
.3 I
nst
all
atio
no fCylinde
rHead
1) I
( ns
ta
llthegasketonthetopofth
ec r
ankca
se，maki
ng C
yli
nde
rhe
ad
s
urethe two dowel pin
sente
rt he
irh o
leso fth
e
g
aske.
t
(
2) I
ns
ta
llt h
ec yli
nderheadont h
ec rank
case，maki
ng
s
urethe two dowel pi
nsente
rt he
irh o
leso fth
e
c
yli
nderhea
d. T igh
tenthec
yli
nderheadbol
ts
.

|~tiMlJl厄
(
a)Donotuseli
qui
dpa
ckingoroth
ersim
ila
rsea
lat
.
n
(
b)En
sure 白 紙 白e gas
ketc ont
acts u
rfa
ceo fth
e I
nst
all
ati
ono
fcy
lin
derh
ead
cran
kca
seis企ee企oma nyde
fec
ts.

(
3) T
igh
tenthec
yli
nde
rheadb
Olt
sωthes p
eci
fie
dto
rqu
e
加th
es e
quen
ceshowni
ntheil
lu
st
ra
ti
閣1.

首 位 蜘i
ngt
o叫田 1113ω123N'm( 11.5t
o山 kg
f'm
)
f
orcyl
ind
erh
eadI
b
olt
s ￨ [83.2ω90.41
bf・
町

告側

o
o
o

02
0H
07
03
w
m
EI

n Numbero
fbo
lts
:25

T
igh
ten
ings
equ
enc
efo
rcy
lin
derh
eadb
olt
s

4.
4 Reassemblyo f RockerArm and RockerS haft
Assembly
Reass
embletherocke
ra r
msa ndroc
kershaf
t，making
su
rethea ss
emblymarkoft herock
ers h
a食i sfac
ing
企ontsid
eoftheengi
ne.
A食erreassem
bli
ngt herock
era r
msa ndrock
ershaf
t，
ens
uretha
ttherocke
rarmsmoves moot
hly.

R
eas
sem
blyo
fro
cke
rsh
afta
sse
mbl
y
4
.5 In
sta
lla
tio
nofRockerS haf
tAssembly
(
1) I
nst
al
ltheval
vecapsinpo
sit
ion.
(
2) I
nst
al
ltheroc
kersha食assemb
lyo nth
ecyli
nde
rheadヲ

t
hentig
hte
nthere
tain
ingbo
ltstothes
pec
ifi
edtor
que
.

T
i
f
o
脚 n
rr
oc
i
k
e
昭 t
rs
町田 1
h
aft
0
.0tI
o20
.0N'm(
1.0ω2.0同f
'm)
bmktbolt3￨[72ω14.5めf 吐]

N
ote
: Besur
etoti
ght
ent
hel
ongb
oltf
ir
st，
the
nti
ght
ent
he
sh
ortbo
lt
.

2-49
 REASSEMBLYOFENGINEMAINPARTS

4.
6 AdjustmentofValveClearance
Refertothe"En
gineInsp
ectio
na ndA
djust
ment(1.
1
Ins
pectio
na n
dA dj
ustm
ento fVal
veClea
ran
ces
)."

A
dju
stm
ento
fva
lvec
Iea
ran
ce

2-50
 REMOVALOFFUELSYSTEM

1
.Fu
elHosesandF
uelF
ilt
er.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 3-2

2
.Fu
ell
nje
cti
onP
ipe
sandF
uel
lnj
ect
ionN
ozz
les
...
...
...
...
...
...
...
...
...
...
...
...
. 3・2

3
.Fu
ell吋e
cti
onPump.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 3・ 3
 REMOVALOFFUELSYSTEM

F
uelHosesandF
uelF
ilt
er

J
r
-/
‘

Remova!o
ffu
e!h
ose
sandf
ue!f
il
te
r
く Remova!sequence>
① F
ue!h
ose ③ F
ue!f
il
te
rbr
ack
et附 a
ini
ngb
o!t ⑤ B
rac
ketre
tai
nin
gbo
!t
② F
ue!h
ose ④ F
ue!f
il
te
r ⑥ B
rac
ket

2
. F
uel
lnj
ect
ionPipesandF
uel
lnj
ect
ionNozzles

¥
弘
、
Remova!off
ue!i
nje
cti
onp
ipe
san
dfu
e!i
nje
cti
onn
ozz
!es
<Remova!s
equ
enc
e>
① Pi
pec!amp ⑤ No.4fue
!inj
ect
ionp
ipe ⑨ F
ue!pipe
② No.1f
ue!i
nje
cti
onp
ipe ⑥ No.5fue
!inj
ect
ionp
ipe ⑩ F
ue!!
eak-offp
ipe
③ No.2f
ue!i
nje
cti
onp
ipe ⑦ No.6fue
!inj
ect
ionp
ipe ⑪Fue!in
ject
ionnoz
z!e
④ No.3f
ue 吋e
!i cti
onp
ipe ⑧ Fue!retump
ipe

￨CAUTION
Topreventdi
rt企ome n
ter
ing加toth
ef u
e!sys
tem，p!ug
th 吋e
ei c
tionpumpopen
ings，
then
ozzl
ein!e
tcon
nect
ors，
andtheinj
ect
ionp
ipe
s.

3-2
 REMOVALOFFUELSYSTEM

3
. F
uelI
nje
cti
onPump

l
)

Removaloff
ueli
nje
cti
onpump
Removals
く equ
enc
e>
① Fuelinj
ect
ionpumpre
tain
ingb
olt ④ Gearcasecover
② Brack
et ⑤ Flang
er e
tain
ingbo
lt
③ Gearcasecove
rret
ain
ingbo
lt ⑥ Fuelinj
ect
ionpump

E
nsure白紙 themarkont heflang
ep l
ateisalig
ned
w
i白 themark ofthef u
eli nj
ect
ion pump bef
ore
r
emovingth
ef u
elin
jec
tio
npump.I fm ar
kesarenot
a
lig
ned，pu
tanewmarkont heflang
ep la
tewhere
a
lig
nedwit
ht h
emarkofth
ef u
elinje
ctio
npump.

|~ CAUTIO
E
nsure白atm a
rkesa
rea
lig
ne，
dbe
for
ere
mov
ingt
hef
uel
I
Dje
cti
onp山 np.

Removalo
ffu
eli
nje
cti
onpump

3-3
 REMOVALOFFUELSYSTEM

A CAUTION
Whe nchan gin
gp制 s ，bes ur
et ouseourdesig
nate
dp釘 t
s.U n
lessourdesi
gnate
dpart
s訂 eu s
ed，thee x
hau
st
emiss
ionregulatio
nscannotbemet.
Takecarethatthepar
tsmayb epart
lymodi
fiedduetoimpr
ovement，f
orexa
mple.
Workr e
lat
e dtotheexhaus
te mi
ssionr
egul
ati
onscanbecondu
ctedonlya
tourdesig
nat
edser
vic
efacto
rie
s.
However，don otc hang
et headjus
tmen
tbyc ut
tingandremovi
ngthetamp
er-pr
oofsonthefu
eli n
ject
ionpump
asse
mbly. Thefuelinje
ctionpumpmustberepl
acedasanasse
mbly
.

3-4
 D
ISA
SSE
MBL
Y，I
NSP
ECT
IONANDR
EAS
SEM
BLYOFF
UELS
YST
EM

1
.FuelF
ilt
er..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.. 3-6
D
isa
sse
mbl
yandI
nsp
ect
iono
fFu
elF
ilt
er'.
...
...
...
...
...
....
....
...
...
...
...
....
...
.. 3・ 6

2
.FuelInjectionNozzles..............................................................
. 3・ 7
2.1Disassemblyo
fF u
ell吋ect
ionN ozzl
es'. .............................................. 3・ 7
.
2.2In
spectionofFu
ellnj
ect
ionNozz les...........................................
........ 3・ 8
2
.3Reassemblyo
fFu
ell
nje
cti
onN
ozz
les.
...
....
....
...
....
...
...
...
...
...
...
...
...
...
... 3-10
 ，INSPECTIONANDREASSEMBし
DISASSEMBLY YOFFUELSYSTEM

1. Fu
elF
il
te
r
D
isa
sse
mbl
yandI
nsp
ect
iono
fFu
elF
ilt
er

官
C
rac
ks，
dam
age
dth
rea
ds

A
irb
lee
derp
lug

C
logg
edel
emen
t，cr
ack
s
R
epl
acee
ver
y3m o
nths
o
r600hou
rs.

D
isa
sse
mbl
yan
din
spe
cti
ono
ffu
elf
il
te
r
く D
isa
sse
mbl
yse
que
nce
>
① L
eve
lse
nso
ras
sem
bly ② F
ilt
ere
lem
ent ③ B
rac
ket

3-6
 ，
Y INSPECTIONANDREASSEMBLYOFFUELSYSTEM
DISASSEMBL

2
. FuelInjectionNozzles
2.
1 Disassemblyo
fFu
ell
nje
cti
onNozzles

@トーや

Ca
rbond
epos
its，
c
logg
ednoz
zleho
les

D
isa
sse
mbyof白 e
l lin
jec
tio
nno
zzl
e
D
i
くsa
sse
mbl
yse
que
nce
>
① Retai
nin
gnut ④ Pres
sur
epi
n ⑦ Body
② Nozzlet
ip ⑤ Pre
ssur
esp
rin
g
③ Piece ⑥ Washer

3-7
 ，
Y INSPECTIONANDREASSEMBLYOFFUELSYSTEM
DISASSEMBL

2.
2 I nspect
iono fF uell吋ec tionNozzles
Conductt hef ollowingi n
spect
ionsa nd，iff aul
ty，
re
pairorreplaceasr e
quired.
() I
1 n
jectio
nv al
veo peningp ress
ure
(a
) I ns
tallthef uel 吋e cti o
nn ozzl
eo ntot hen ozz
le
t
este
r. Pump t het es
t erh a
ndle up and down to
bleedai
r.
(b
) Pumpt heteste
rh andlea tarat
eofa pprox.onecyc
1e
persecondwhileo bservingtheneedl
eoft hetes
te
r.
Note:The n ee
dles ho
ul dris es l
owlya nd，d ur
ingf ue
l
inje
ction，shouldv ib
rate. Thep res
surea twhich
then ee
dles tar
tst ov ibra
teist hei nj
ecti
onv al
ve
opemngp ressu
re.
(c
) I fthem easuredp res
s 附 doe
sn otconforrntot h
e
stan
dardv a
lue，d i
s a
sse mbleandadjustbyc hangi
ng
t
het hic
knessofthew asher. I
nsp
ect
iono
fin
jec
tio
nva
lveo
peni
ngp
res
sur
e

St
anda
rd
1V 5
ω唱
t
e

e
-e
Cn

1.77t
1 o12.
75MPa
町m

V 戸
TAr-

免U F O しV
・
A

2
(
120to130kgfl
cm
I

)
ρ
、

し'

1707t
o1 849p
si

lCAUTION I
Nevertou
cht
hes
pra
yoff
uel合omt
hef
ueli
nje
cti
on
nozz
le.

(
d) Changeinw a
she rthic
knes
sby0. 1m m( 0.
004in.
)
2
r
esul
tsinapress町 echang
eo f1
.0MPa( l0k gf
lcm )

[14
2psi]
.
Washe
rsa r
ea v
ailabl
ein1 0diffe
ren
tt h
i c
k n
esse
sat
in
ter
valsof0 .05 mm ( 0.002
0泊 .)i nt her ang
e
betw
een1.25and1 .70mm( 0.
0492a nd0.0669inふ

3-8
 ，INSPECTIONANDREASSEMBLYOFFUELSYSTEM
DISASSEMBLY

(
2) In
spectin
gt hef uels p
rayp a 抗em 合om t hef u
el
吋e
i c
tionnozzl
e
(
a) Whe n i n
spec
tingt he inje
c tion valveo pen
ing
pr
essureusin
gt h
en oz
zletest
er ，alsocheckfo
rsuch ー

a
sc Ioggednozzl
eh ol
e，f u
els pr a
yp att
ema ndfu
el Il).一人J l
)-
-.
.ム
) ~人よJ ムム)
l ~人--l)
le
ak a
gef r
omthen o
zzlehole. L
".-
J L，..Jし~ L
"..
J L".
.J
(
b) Whe よthetesterhandle is pumped a t a附 o f IiTh 4~ 1 ~II~
ap
prox.o nec ycIe pers econ d，f u
els ho
uldb e IGood Bad Bad Bad Bad
spr
a y
edinaf a
irl
ystra
ightpa町m . (
Diff
use
d)(
Drib
bli
ng)(
Defl
ect
ed)(
Fea
the
rin
g)

F
uels
pra
ypa
tte
ms
(
3) Cl
eaningorrepl
aci
ngwhenspray
ingb
adly
(
a) Loos
ent h
en ozz
ler e
tai
ningnuttor em
oveth
e
no
zzleti
pa s
sembly
.C leanthene
edl
ev al
vea
nd
t
henozzl
et i
pbody
.
N
ozz
let
i
pen
d

￨&CAUTION
Whe
nr emo
vin
gtheno
zzl
eti
pas
sem
bl，nevert
y apo
n
t
heendo
fthen
ozz
let
ip
.

(
b) Washthenee
dlevalveandt henoz
zlet
ipbodyin Removalo
fno
zzl
ere
tai
nin
gnu
t
Ie
c an
ingso
lven.
t Reassembletheminc
Iea
ndie
sel
f
ue.
l
Note:Then eedl
ev alv
ea ndt h
en ozzleti
pb odyar
e
pr
ecisi
onm ach
inedpart
s. H a
ndlewithcarea
nd
nev
erc ha
ngethe
ircom
binat
ion.
(c
) A ssemb
let heful 同e
e c
tio
nn ozz
le，ti
ght
eni
ngth
e
n
ozzlere
tai
nin
gnuttot
hespec
ifi
edto珂u
e.
T
igh
teni
ngt o
rqueI
34.
3ω39.
2N.m(3.
5ω4.0kg
f.m
)
f
orr
eta
inin
gn u
t [
25.
3ω2
8.9I
bf.
ft] Needle~ !ZF骨~
v
al
ve
(
d) If
thefu
els
praypat
temi
ssti
l
Ino ，
tgood r
epl
acet
he N
ozz
let
i
p
n
ozzl
eti
passe
mbl
y. b
ody
N
ote
:(a)Nevertoucht h
es li
din
gs urf
aceo fth
en eed
le C
lea
nin
gofn
ozz
let
ipc
omp
one
nts
valvewi
thyo ぽ han
ds.
(
b)lfthenozzlet i
pa sse
mblyist ob erepl
aced，
removethesealpee
l( s
ynth
eticre
sinfi
lm)企om
the new nozzletipa sse
mblya nds l
idethe
nozzleandneedlevalveincIea
ningsolv
entto
remove thea nt
i-co
rros
ivea ge
ntc omp
letel
y.
AssemblethemincIeandie
selfu
e.l

3-9
 ，INSPECTIONANDREASSEMBLYOFFUELSYSTEM
DISASSEMBLY

fFuell吋e
2.3 Reassemblyo cti
onNozzles

、
己

R
etaini
ngnut
T
ighteni
ngtor
quet
obo
dy:
3
4.3to39.2N'm
(
3.5to4.0kgf
'm)
[
25.3to289l
. bf
'ft
]

T
ighteni
ngtor
quetoe
ngi
ne:
4
9.0to68.6N'm
(
5.0to7.0kgf
'm)
[
36.2to506l
. bf
'ft
]

Reassemblyoff
ueli
nje
cti
onn
ozz
le

く Reassemblysequence>
⑦→⑥→⑤→④→③→②→①

3-10
 INSTALLATIONOFFUELSYSTEM

1
.Fu
ell
nje
cti
onPump.
...
...
...
....
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.. 3-
12

2
.Fu
ell
nje
cti
onPipesandF
uel吋e
l cti
onNozzles.
...
...
...
...
...
...
...
...
...
...
...
.. 3・13

3
.Fu
elHosesandFu
elF
ilt
er.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...3-
13
 INSTALLATIONOFFUELSYSTEM

1
. F
uel
lnj
ect
ionPump

I
nst
all
ati
onof白 e
lin
jec
tio
npump

く I
nst
all
ati
ons
equ
enc
e>
⑥→⑤→④→③→②→①

I
nst
allthefuelinj
ecti
onpumpw iththemarkont
he
f
uelinje
ctio
npumpg e
訂 ali
gnedwithth
emarkont
he C
ams
haf
tge
ar I
dle
rge
ar
i
dle
rg e
ar.Alsoensur
et h
atmar
kso neachti
min
gge
ar
a
realignedasshownintheil
lus
tra
tio
n.
Note:Witht h
ese marks a
llali
gne
d，theNO.Icyl
inde
r
pis
tonisatt het o
pd e
adc en
teron c
omp
ressi
on
st
roke
.

O
ilpumpg
ear

A
lig
nme
nto
fti
min
gge
arm
ark
s

3-12
 INSTALLATIONOFFUELSYSTEM

2
. FuelI
nje
cti
onPipesandF
ue 吋ectionNozzles
lI
T
ighte
ningtorq uef o
r
ue
f 1in
jec
tionp ip enut:
2
6.5to32.4N.m
)(
1 2.
7103 3k.g~. I?~
.
[
19.5t
o2 3.
9IbHt]

\~i~
I
nst
all
ati
onoff
ueli
nje
cti
onp
ipe
sandf
ueli
nje
cti
onn
ozz
les
く I
nst
all
ati
ons
equ
enc
e>
⑪→⑩→⑨→⑧→⑦→⑥→⑤→④→③→②→①

3
. FuelHosesandFuelF
ilt
er

j
ハ/‘

I
nst
all
ati
ono
ffu
elh
ose
sandf
uelf
il
te
r
く I
nst
all
ati
ons
equ
ence>
⑥→⑤→④→③→②→①

3-13
 INSTALLATIONOFFUELSYSTEM

3-14
 REMOVALOFLUBRICATIONSYSTEM

1
.Oi
lFi
lte
r，R
eli
efValveandSideCover..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 4-2

2
.OlPan，O
i ilS
tra
ine
randO
ilPump.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
. 4・3
 REMOVALOFLUBRICATIONSYSTEM

1
. O
ilF
ilt
er，R
eli
efV
alv
eandSideCover

/ 瓦

/ eそ 〆/愈

¥
QI
グ匂紗メ号

Removalofo
ilf
il
te
r，r
eli
efv
alv
eands
idec
ove
r

く Removals
equ
enc
e>
① O
ilfi
lt
er ③ S
idec
ove
rre
tai
nin
gbo
lt ⑤ Gasket
② R
eli
efval
ve ④ S
idec
ove
r

4-2
 REMOVALOFLUBRICATIONSYSTEM

2
. O
ilPan，O
ilS
tra
ine
randO
ilPump

R
epl
ace0・nng.

Removalofo
ilpan，
oils
tra
ine
r釦 do
ilpump

く Removals
equ
enc
e>
① O
ilpanre
tai
nin
gbo
lt ③ O
il抑 制erre
tai
nin
gbo
lt ⑤ O
ilpumpre
tai
nin
gbo
lt
② O
ilpan ④ O
ils
tra
ine
r ⑥ O
ilpump

4-3
 REMOVALOFLUBRICATIONSYSTEM

4-4
 D
ISA
SSE
MBL
Y，I
NSP
ECT
IONA
NDR
EAS
SEM
BLYO
FLU
BRI
CAT
IONS
YST
EM

1
.Oi
lPump.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 4・ 6
1
.1Disassemblyo
fOi
lPump...........
...
...
....
...
...
...
...
....
....
....
....
....
.....
..4-6
1
.2 I
nsp
ect
iono
fOi
lPump.
........
.....
...
...
...
.....
...
...
....
....
....
...........
.. . 4・ 7
..
1
.3 Reassemblyo
fOlPump............................................................ 4・ 8
i

2
.Oi
lFi
lte
r..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 4-9
DisassemblyandI
nsp
ect
iono
fOi
lFi
lte
r....
...
...
...
....
....
...
....
....
.....
........
.. 49回

3
.Re
lie
fVa
lve
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
"..
...
...
...
..
. 4-9
I
nsp
ect
iono
fRe
lie
fVa
lve..
.........
...
....
...
...
...
...
....
...
....
...
.....
.... . 4-9
......
 ，INSPECTIONANDREASSEMBLYOFLUBRICATIONSYSTEM
DISASSEMBLY

1
. O
ilPump
1.
1 Disassemblyo
fOi
lPump

D
isa
sse
mbl
yofo
iIpump
<
Dis
ass
emb
lys
equ
ence>
① O-r
ing ③ I
nne
rroto
r ⑤ Pumpc
ase
② Mainsh
aft ④ O
uterr
otor
Remove② a
nd③ a
sana
sse
mbl
y.

4-6
 ，
Y INSPECTIONANDREASSEMBLYOFLUBRICATIONSYSTEM
DISASSEMBL

1
.2 I
nsp
ect
iono
fOi
lPump
(
l) Measurementofc lea
ran
ceb etwe
eno ut
err o
torand
inn
errotor
Measuretheclea
rancewithfe
ele
rg a
ges，asshowni n
th
ei llu
str
ati
on. Iftheclea
ranc
ee xce
edst h
el i
mit，
rep
lacethepumpa ss
embl
y.
Unit
:m m[in.]
S
tan
dar
d
Cl
eara
nceb e
t w
eenout
erI 0.13t
o0.15
r
otorandi
nnerrot
or I
rO.
0051t
o0.0059

Measurementofc
lea
rancebetweeno
ute
r
(
2) Measurementofrot
orendplay r
oto
randinn
errotor
Measure t he en
d p l
ayw ithf eel
er gages and
str
a i
ght
edge，asshownintheil
lus
tra
tio
n. Iftheend
playexce
ed sth
elimi
t，re
pla
cethepumpa sse
mbly.
Uni
t:m m[in
.]
St
anda
rd
0
.04to0.0
9
R
oto
ren
dpl
ay
0
.0016to0.00
35

Measurementofr
oto
rendp
lay

(
3) Measurementofc le
aran
ceb etw
eenout
erroto
rand
case
Measuretheclea
rancewithfe
ele
rgag
es，asshownin
白ei ll
us甘at
io. I
n ftheclea
ranc
eexcee
dsthel i
mi，
t
rep
lacethepumpa ss
embl
y.
U
nit
:m m[
in
.]
St
anda
rd
C
leara
ncebetween 0
.20to0.
30
o
ute
rroto
ra ndcas
e 0
.0079to0.0118

(
4) Measurementofc lear
ancebetw
eenmain sha食 a nd Measurementofc
1ea
ran
cebetweeno u terrot
orand c
ase
pumpc ase
Measure th
ed i
amete
r oftheshaf
t and th
ei n
side
diame
teroft heboreintheca
seforthesha
ftt ofind ~eas1:lring →ζ瓜←
th
ec le
aranc
e between thetwo.Ift h
ec l
earance 間取@ dir
ecti ons →ぐ下7←
exceed
st h
el i
mit，r
eplac
ethepumpc a
seorthepump
Mb(

g二 一
.nnut--4l﹃
uSJo
nuri--4
闘訓﹁︺

asse
mbly.
M b nド
u
n
n
ω
σ
闘訓

，n
HU

t
Uni:m m[
in.
]
-﹁

S
tan
dar
d
-
﹂

15
.985t
o16.000
﹄
d

0
.6293t
o0.6299
0
.032t
o0.074
0
.0013t
o0.0029
Measurementofc
1ea
ran
cebetweenmains
ha食
a
ndpumpcase

4-7
 ，INSPECTIONANDREASSEMBLYOFLUBRICATIONSYSTEM
DISASSEMBLY

(
5) Measuremento fc Iear
anceb etw
eenm ai
ns ha食 and
b
M
d
u
e
i
s
a
a
h
s
m
e
i
n
u
t
g
r
e
et
ro
hed
fth
i
am
eoi
e
t e
ro ft
lpumpb
hemains
ush
ingi
h
af
nt
ta
h
n
ec
dt
ra
h
n
ei
k
ca
n
s
s
id
et
e
o
ど窓際→合← @mrr
Eヨ
fi
ndt h
ec lea
r a
nceb etweent etwo.I
h ftheclear
ance
e
a
x
s
c
s
e
e
m
e
d
b
st
ly.
heIimit，replac
et hebush
ingo rthepump
r
:z
gn
g
Un tmm[
i: in
.]

d一
S一

m
Ju--5
M
ah-nyA崎一Aunu-
一
一
u 内
15-aρ一
-
・
79
5

9571
10

万
O1・
'inu-nu-

ω一
Measuring

ム
EEE
5

一
一
一
loc
ation
o
一

iρ-
G
21-
50-
---t-t-
o
10
o-
-
判一
田
fc
Measuremento Iea
ranceb
etw
eenm
ains
haf
t
an
db u
shin
g

(
6) I
nst
all
ati
ono fo
ilpumpbu
shin
g
I
nst
aI
lt h
eo ilpumpbus
hingbyu
sin
gth
eoi
lpump
b
ushin
gi n
staI
le
r.
n
帥一川
M三4
PL

一A
e-AU
V且-凋品寸
.
A
G

AU
hU

￨&CAUTIO
I
nst
aI
ltheo
ilpumpb
ush
ingint
hec
rankc
ases
oth
ati
tis
e
venwit
hthe企on
tfa
ceoft
hecr
a凶c
cas
e.

1
.3 Reassemblyo
fOi
lPump

R
eas
sem
blyo
foi
lpump
く R
eas
sem
blys
equ
enc
e>
⑤→④→③→②→①

4-8
 ，
Y INSPECTIONANDREASSEMBLYOFLUBRICATIONSYSTEM
DISASSEMBL

2
. O
ilF
ilt
er
DisassemblyandI
nsp
ect
iono
fOi
lFi
lte
r

C
logge
delemen
t，cr
ack
s
R
epl
aceever
y3m o
nths
o
r600hou
rs.

D
isa
sse
mbl
yan
din
spe
cti
ono
foi
lfi
lt
er

く D
isa
sse
mbl
yse
que
nce
>
① O
ilf
il
te
rel
eme
nt

3
. R
eli
efV
alv
e
In
spectio
no fReliefValve
(
1) I
nspe
ctf o
rp ro
perv al
ve-to
-se
atc on
tact，s
pring
向
-
1
NUH5

，breakage o ，
mh o h
n
--
f
atig
ue ra nyo th
erd a
mage.I ff
ault
y
円M 4 3

・
o--ny

肱
0blha 4

uuεJZJE

首Y
p
4([

m叫州
353
w，

r
epl
ace.
Y L区

J
山

・
s
ii

(
2) Me
asuret her e
liefvalveo pen
ingpressu
re.I
ft he
民‘
l
四勾

ー
hu
A ，

m
easuredp r
essur
e e xceedst hes t
andar
d va
lue，
r
emovet h
ec apbo
ltanda dju
stbyshimming.

R
elie
fvalv
eop
eni
ng
p
res
sure

I
nsp
ect
iono
fre
lie
fva
lve

4-9
 ，INSPECTIONANDREASSEMBLYOFLUBRICATIONSYSTEM
DISASSEMBLY

4-10
 INSTALLATIONOFLUBRICATIONSYSTEM

1
.Oi
lPan，O
ilS
tra
ine
randO
ilPump.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
. 4-
12

2
.Oi
lFi
lt
er，R
eli
efV
alv
eandS
ideC
ove
r..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.. 4-
13
 INSTALLATIONOFLUBRICATIONSYSTEM

1
. O
ilPan，O
ilS
tra
ine
randO
ilPump

-
非β 0 2

tvOKH
t引b
叩

・
川O L -

加叩 明 向
U1J'iny

uvu
DRAgdH
郎
、
334
-([
-o

‘PE 九

、
to
t

i
瓦

I
nst
all
ati
onofo
ilp
an，o
ils
tra
ine
ran
doi
lpump

く I
nst
all
ati
ons
equ
enc
e>
⑥→⑤→④→③→②→①

4-12
 INSTALLATIONOFLUBRICATIONSYSTEM

2
. O
ilF
ilt
er，R
eli
efValveandS
ideCover

/ 瓦

/ @~③

¥q
。
"
"-
可 伊γ-T
ig
(
3
h
t
)
en
ingt
orq
ue:
刊ノ 44.1t
o53.9N'm
( 5t
4. o5.
5k g
f'm)
[32
.5to39
.8lb'f
f t
J

I
nst
all
ati
onofo
ilf
il
te
r，r
eli
efv
alv
ean
dsi
dec
ove
r

く I
nst
all
ati
ons
equ
enc
e>
⑤→④→③→②→①

4-13
 INSTALLATIONOFLUBRICATIONSYSTEM

4-14
 REMOVALOFCOOLINGSYSTEM

1
.Co
oli
ngFanandP
ull
ey.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 5-2

2
.WaterPump.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.. 5・2

3
.Thermostat.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 5-3
 REMOVALOFCOOL
lNGSYSTEM

1
. C
ool
ingFanandP
ull
ey

Removalofc
ool
ingf
anandp
ull
ey
くRemovals
equ
enc
e>
① C
oolin
gfa
n附 a
ini
ngb
olt ③ Coolingf
an
② P
lat
e ④ Pulley

2
. WaterPump

Removalofwaterpump
<Removals
equ
enc
e>
① Thermostatb
ypa
sshos
e ④ Gasket ⑦ Gasket
② Waterpump附 aini
ngbol
t ⑤ Waterpumps
pac
erre
tai
nin
gbo
lt
③ Waterpump ⑥ Waterpumps
pac
er

5-2
 REMOVALOFCOOL
lNGSYSTEM

3
. Thermostat

C
rac
ks，w
ate
rle
ak
s，
d
amage

~\ 〆

ゲ
〆
も
Removalofthennostat

Removalsequence>
く

① Thennostatc
aser
eta
ini
ngb
olt ② Thennostatc
ase ③ Gasket

5-3
 REMOVALOFCOOL
lNGSYSTEM

5-4
 D
ISA
SSE
MBL
Y，I
NSP
ECT
IONA
NDR
EAS
SEM
BL FCOOl
YO LNGS
YST
EM

1
.WaterPumpandC
ool
ingFan.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 5・6
I
nsp
ect
iono
fWaterPumpandC
ool
ingFan..
.....
......
......
.....
....
....
..........
.. 5-6

2
.Thermostat.
...
....
...
....
...
...
...
...
....
...
...
...
...
...
...
...
...
...
...
...
...
...
...
. 5-7
I
nsp
ect
iono
fThermostat.
..........................................................
. 5・ 7
 ，
Y INSPECTIONANDREASSEMBLYOFCOOL
DISASSEMBL lNGSYSTEM

1
. WaterPumpandC
ool
ingFan
I
nsp
ect
iono
fWaterPumpandCoolingFan

C
rac
ks，e
lon
gat
ion，
wea
r
a
nddam
ageofV-
bel
t

I
nsp
ect
iono
fwa
terpumpandc
ool
ingf
an
<D
isa
sse
mbl
yse
que
nce>
① CooI
ing:
f
i
加 ③ Pul
Iey ⑤ Spacer
② V-
bel
t ④ Waterpumpassembly

Vis
uall
yc heckt hew a
terpump f orcool
antl e
aks，
roughrot
ati
on，c r
acksorotherdef
ect
sandr e
placeit
asanassemblyifanyofthes
ed e
fec
tsisfo
und.
Checkthecooli
ngf a
nbladeforcra
cksorde
form
ation.
Iff
ault
y，rep
lacethecooli
ngfan.

5-6
 ，
Y INSPECTIONANDREASSEMBLYOFCOOL
DISASSEMBL lNGSYSTEM

2
. Thermostat
Inspec
tiono fThermostat (
mm)
[in.
]
Plac
et hethennos
tatinac ont
aine
rf i
ll
edwithwate
r. [
0.3
5]1 ー
(
9)，ーア:7(
While h ea
ting t h
e w ate， measure t
r he w a
te r
~ I1/h I
temp
e
anda
r
l
a
s
tu
ot
r
h
ea
ew
twhicht
a
tertempe
h
et
ra
tu
h
r
e
nn
ea
os
tw
t
a
h
ts
ic
t
a
ht
r
t
h
st
ev
oo
al
v
p
el
e
i
n，
ft
2 1 //1
~ 0(
76.
5土2
)
LTemp.
仰) CC)
rea
ches 9 mm (0.
354 in.
).I fthem e
asure d [
169
.7:
t3句 [
19](F1
4

temperaωr
esdon otconfonntothes t
anda
rdvalues，
rep
lacethethennost
at
.
Stan
dard
0
76.5士 2C
V
alv
eop
eni
ngt
emp
era
tur
e
[
169.7:
t3.60F]
0
0.
9m m[354
in]v
. a
lve
-li
食te
mpe
rat
ure 90C [ 1940F
] I
nsp
ect
iono
fth
enn
ost
at

N
ote
:(a)S
tirthew aterinthecontai
nerwithas t
ickto
mai
ntain i t
s t em
peratur
e u nif
onn d ur
ing
mspectlOn
.
(
b)Wheni nst
all
ingth
et h
ennos
tat，b
es ur
etocheck
t
hev alveopeningtempe
raturestampedonthe
t
opo fthefla
nge.

l&CAUTION 1

η1Isisa"
hot"o
per
ati
on.Paye
ver
yat
ten
tio
ntop
rev
ent
bu
r n
sandfi
re
.

5-7
 ，INSPECTIONANDREASSEMBLYOFCOOL
DISASSEMBLY lNGSYSTEM

5-8
 INSTALLATIONOFCOOLINGSYSTEM

1
.Thermostat.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.5-
10

2
.WaterPump.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..5・10
.

3
.Co
oli
ngFanandP
ull
ey.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 5・1
1
 INSTALLATIONOFCOOL
lNGSYSTEM

1. Thermostat

T
ighten
ingtor
que
: μ
1
6.0to20.0N'm ③ ， - /
(
1.6to2.0kg
f'm) r 斤y
11
[ .6to14.
51b
f.ft
] ~、 _.-/'

~も/ \

ゲ
〆
。/
-

。
n∞ ①

I
nst
all
ati
ono
fth
erm
ost
at
州②
q③

副↓
閣↓

n
，

Hu

2
. WaterPump

I
nst
all
ati
ono
fwa
terpump

<
Ins
tal
lat
ions
equ
enc
e>
⑦→⑥→⑤→④→③→②→①

5-10
 INSTALLATIONOFCOOL
lNGSYSTEM

3
. C
ool
ingFanandP
ull
ey

X I
nst
all
ati
ono
fco
oli
ngf
ana
ndp
ull
ey
く I
nst
all
ati
onsequence>
④→③→②→①

5-11
 INSTALLATIONOFCOOL
lNGSYSTEM

5-12
 REMOVALOFINLETANDEXHAUSTSYSTEMS

1
.ExhaustM
ani
fol
d..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
. 6-2

2
.In
letM
ani
fod・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 6-2
l
 REMOVALOFINLETANDEXHAUSTSYSTEMS

1
. ExhaustM
ani
fol
d

Removalo
fex
hau
stm
ani
fol
d
く Removals
equ
ence>
① Exhaustmanifoldr
eta
ini
ngb
olt ② Exhaustm
ani
fol
d ③ Gasket

2
. I
nle
tMa
nif
old

/
づ

Removalofi
nl
etm
ani
fol
d

くRemovals
equ
enc
e>
① Breatherhose ④ Gasket ⑦ Gasket
② Inl
etp ip
er et
ain
ingb
olt ⑤ In刷
letma
如n凶i
出E
b
お
制ωl
d問
ret
a
創i
旬
凶加n
山i
③ Inl
etp ip
e ⑥ In
叫
叫
1l
etm
加 a
泌 n
叫l
i
f
i
白bld

6-2
 REMOVALOFINLETANDEXHAUSTSYSTEMS

&CAUTION
Wh enchangin s，bes
gp訂 t ur
etou seo u
rd es取l a
tedpa
rt
S.U nl
esso u
rd es
ignat
edpart
sa r
eu se
d，theexh
aus
t
emiss
ionregu
latio
nscannotbeme t
.
Takecareth
atthepar
tsmaybep ar
tlymodifie
dd uetoimpro
vement，fo
re x
ample.
Workr e
lat
edtotheexhaus
te m
issionreg
ulat
ionscanbeconduc
tedonlyatourdesi
gnat
edser
vicefa
cto
rie
s.
However，don o
tc hang
et headj
ustmentbyc ut
tingandremovingth
et am
per-p
roofsonthefue
li n
jec
tio
npump
asse
mbly.Th efu
elinje
ctio
npumpm u
stb erepla
cedasanasse
mbly.

6-3
 REMOVALOFINLETANDEXHAUSTSYSTEMS

6-4
 D
ISA
SSE
MBL
Y.I
NSP
ECT
IONA
NDR
EAS
SEM
BLYO
FIN
LE
TAN
DEX
HAU
STS
YST
EMS

1
.In
letM
ani
fol
dandExhaustM
ani
fol
d..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
. 6-6
1
.1I
nsp
ect
iono
fIn
letM
ani
fol
dandExhaustM
ani
fol
d........
....
...
............• ...
....
...
. 6・6
1.2 Measuremento
fExhaustM
ani
fol
dMountingFaceD
ist
ort
ion.....•....................... 6・6
 ，
Y INSPECTIONANDREASSEMBLYOFINLETANDEXHAUSTSYSTEMS
DISASSEMBL

1. I
nle
tMa
nif
oldandE
xha
ustM
ani
fol
d
1.
1 I
nsp
ect
iono
fIn
letM
ani
fol
dandExhaustM
ani
fol
d

I
nsp
ect
ionofi
nle
tma
nif
olda
nde
xha
ustm
ani
fol
d

1
.2 Measurement o f Exhaust M anifold Mounting
FaceDistor
tion
Usin
gas trai
ghted
gea cr
osst hee xh
a u
stm ani
fold
moun
tingf ace and a feele
rg a
ge，measure any
di
sto
rti
on.
I
fthemeasureddist
ort
ionexceedsthestand
ardvalu，
e
co
rre
ctbyg ri
ndingorrep
lacethemanif
old.
Uni:m m[
t in.
]
St
andar
d
E油 a
ustman
ifo
ldm
oun
tin
gfa
ce
0
.2[
0.007
9]orl
es
s
di
sto
rti
on

M
eas
ureme
nto fex
hau
stmanif
old
mo
untin
gf a
cedi
sto
rti
on

6-6
￨INSl

1
.In
le
tMa
nif
old・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ ・・・・・・・・・・・・・・・・・ 6-8

2
.Ex
hau
stM
ani
fol
d..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.. 6-8
 INSTALLATIONOFINLETANDEXHAUSTSYSTEMS

1
. I
nle
tMa
nif
old

/三

I
nst
all
ati
ono
fin
letm
ani
fol
d

くI
nst
all
ati
ons
equ
enc
e>
⑦→⑥→⑤→④→③→②→①

2
. ExhaustM
ani
fol
d
一
ω
T10nh

-
m ぬ O L﹀ u t ℃
m22
m.22K
-J

肱m同
1JOK(υ
mp札
叶 比 しu

wt
，
A u

m
‘。
仏民、

巾
。
私押
hv
UB

¥
¥
¥

I
nst
all
ati
ono
fex
hau
stm
ani
fol
d

くI
nst
all
ati
ons
equ
enc
e>
③→②→①

6-8
 REMOVALOFELECTRICALSYSTEM

1
.St
art
er.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 7-2

2
.Al
ter
nat
or..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.. 7-2

3
.GlowP
lug.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.. 7-3
 REMOVALOFELECTRICALSYSTEM

1
. S
tar
ter

Removalofs
tar
ter
く Removals
equ
enc
e>
① S
tar
terr
eta
ini
ngn
ut ② S
t制 e
r

2
. A
lte
rna
tor
3

Removalofa
lte
mat
or
く Removals
equ
enc
e>
① Adjustingb
olt ③ Altemator ⑤ A
dju
sti
ngp
lat
e
② Altematorre
tain
ingb
olt ④ V-belt ⑥ B
rac
ket

7-2
 REMOVALOFELECTRICALSYSTEM

3
. GlowP
lug

¥J
Removalofglowp
lug

<Removals
equ
enc
e>
① C
onn
ect
ionp
lat
ere
tai
nin
gnu
t ② Connectionp
l蹴 ③Glowplug

7-3
 REMOVALOFELECTRICALSYSTEM

7-4
 D
ISA
SSE
MBL
Y，I
NSP
ECT
IONA
NDR
EAS
SEM
BLYO
FEL
ECT
RIC
ALS
YST
EM

1
.Start
er......
....
.....
....
...
.....
....
....
....
....
....
....
....
...
....
....
.....
....
... 7・ 6
1.1Disass
emblyo
fSta
rte
r. .
....
....
....
....
....
....
....
....
....
...
....
....
.....
....
... 7-6
1.2Insp
ect
ionofSt
ar
ter....
...
....
....
....
....
....
....
....
....
....
...
....
....
....
....
..7・ 7
1.3Reassemb
lyofSta
rt
er. .
...
....
....
....
....
....
....
....
....
....
...
....
....
....
...
.. 7・1 1
1.4 I
nsp
ect
ionandAdj
ustm
entaf
te
rReasse
mbly...
....
...
.....
...
....
....
....
.....
....
.. 7・1 3

2
.Alt
ern
ator
....
...
....
.....
...
....
....
....
...
...
...
....
....
....
....
....
....
....
...
....
.7- 14
2.1Di
sasse
mblyo
fAlt
ern
ato
r.....
....
....
...
...
...
...
....
....
...
....
....
....
...
....
... 7・14
2.2In
spe
cti
onofA
lte
rna
tor
'....
....
...
....
...
...
...
...
....
....
....
....
....
....
....
.... 7・15
2.3Rea
ssembl
yofAl
ter
nat
or...
...
.....
...
...
...
...
...
....
....
....
....
....
....
....
.... 7-17

3.GlowPlug...
...
...
...
...
...
....
....
....
....
....
....
....
....
....
....
....
...
.....
...
.. 7-18
.1I
3 n
spe
cti
onofG
lowPl
ug....
....
....
...
.....
...
....
....
....
....
....
....
....
....
...
...7・18
.2I
3 n
st
al
lat
io
nofGlo
wPlu
g....
....
....
.....
...
....
....
....
....
....
....
....
.....
....
... 7-
18
 ，
Y INSPECTIONANDREASSEMBLYOFELECTRICALSYSTEM
DISASSEMBL

1
. S
tar
ter
1
.1 D
isa
sse
mbl
yofS
tar
ter

Bu1d
i upo
fbru
shd
ust，
P
oleandf
iel
dco
il un
evenwea
r，o
rst
icki
ng
i
ns
tal
la
tio
ncond
iti
on i
nhold
er

D
isa
sse
mbl
yan
din
spe
cti
ono
fst
ar
te
r
D
i
くsa
sse
mbl
yse
que
nce>
① Switchasse
mbly ⑦ B
allbea
ring ⑬ L
everasse
mbl
y
② Magr附 cs w
itchas
semb
ly ⑧ B
all ⑩ P
ini
onset
③ Rearbrac
ket ⑨ P
ackin
gs e
t ⑮ O
verrun
ningc
lut
ch
④ Brushhold
erassem
bly ⑩ Wa
sherset ⑩ B
earin
gset
⑤ Yokea s
sembly ⑪ I
ntem
alg e
ar ⑪ F
ron
tb r
ack
etass
embl
y
⑥ Armatur
e ⑫ G
earshaf
t，ge
ar

7-6
 ，
Y INSPECTIONANDREASSEMBLYOFELECTRICALSYSTEM
DISASSEMBL

1.
2 In
spec
tionofStar
ter
(
1) A
nnaturec
oi
ls h
ort
-ci
rcu
itte
st
U
sing agrowl
er，tes
tt h
ea nn
atur
ec o
ilf o
rsh
ort
-
c
irc
ui.
t Repla
ceifsh
ort-
cir
cu
itisin
dic
ate
d.
In
spect
ionmethod
(
a) Withat hi
ni r
onp l
ateposi
tione
dp釘 all
elwitht
he
ann
atureco
il，slow
lyrot
atetheanna
turecoi.
l
(
b) Wh i
lethecoi
lisr u
nnig，t
n hei r
onpla
tes ho
uldn
ot
bepull
edontotheco
ilorvib
rate
.

Ann
atu
rec
oils
hor
t-c
irc
uitt
es
t
(
2) Annatu
recoi
lcont
inui
tytes
t
Meas
ureb etwe
ent h
ec ommut
atorsegmentandt
he
an
naturec
oil T
. he
res h
ouldbenoco
nti
nuit
y.
I
fconti
nui
tyisind
icat
ed，re
pla
cethea
nnatu
re.

A
nna
tur
eco
ilc
ont
inu
ityt
est
(
3) In
spec
tio
no fcommutat
or
(
a) Usi
ng ad ia
lg age，measuret h
e commutator fo
r
r
adi
alrunou.
t
(
b) I
fthemeas
u redval
ueisequa
ltoo rexce
edstheli
mit，
c
orre
ct(wi
thinthediame
terlim
it)orrep
lac
e.
(c) I
fthecommutatorsur
facei
sr ough，c
orre
ctitwit
ha
sa
ndpap
ero f再300to#500.
Un
it:m m[in.
]
S
tan
dar
d
Commutatorr
adi
alr
uno
ut 0
.I
05[
0.0
020
]

Measuremento
fco
mmu
tat
orr
adi
alr
uno
ut

7-7
 DISASSEMBlY
，INSPECTIONANDREASSEMBlYOFELECTRICAlSYSTEM

(
d) M
easur
ethecommutatordia
meter.Ift
hem e
asure
d
v
alu
eisle
sstha
nt h
el i
mi，
trepl
aceth
earma
ture.

U
nitmm[
: in
.]

Commutatord
iam
ete
r

M
eas
ure
men
tofc
omm
uta
tord
iam
ete
r

(
e) M
ea sur
et h
ed epth ofun
der
cutt
ingbetw
eent he
c
om m
uta t
ors egmen
ts. Ifth
em eas
ure
dv alu
ei s
l
essthantheli
mi，
tcorre
cto
rrep
lacet
hea
rmat
ure.
Und~rçutting
Uni
t:m m[
in
.]
M
ica

M
eas
ure
men
tofm
icau
nde
rcu
tti
ngd
ept
h

(
4) Yokecoi
lopen
-ci
rcu
itte
st
Meas
ureb etwee
nt heterm
inalleadwire and t
he
po
sit
ive(+)br
ush
. T her
eshouldbeco
nti
nui
ty.Ifno
co
ntin
uity，
rep
lac
etheyokeass
embl
y.

Yokec
oilo
pen
-ci
rcu
itt
es
t
(
5) Yokecoilc
onti
nuitytes
t
Measurebetw
eent heyokeandthep
osi
tive(
+)brus
h.
Thereshou
ldb enoc onti
nui
ty.Ift
her
eiscont
inuit
y，
checkthei
nsul
atio
nbetweent he
m.Corr
ectorre
place
th
eyokea s
sembly
.

Yokec
oi
lco
nti
nui
tyt
es
t

7-8
 DISASSEMBL
Y，INSPECTIONANDREASSEMBLYOFELECTRICALSYSTEM

(
6) Measurementofbrushlen
gth
Measurethelengthofthebrus
hes
. Ifthem ea
sured
valu
eisl es
st ha
nt heli
mit，re
pla
cethebru
sh.Ifthe
brus
hesareu n
evenlywomo rrou
gh，c
orr
ectitwit
ha
sandpa
perof#300t o#5
00.
t
:m m[
Uni in
.]

M
eas
ure
men
tof
bru
shl
eng
th
(
7) Measurementofbrushspri
ngload
Measuret h
es pr
ingl o
ado ftheb r
ushspringinthe
follo
wingmanner.
(
a) Useanewb ru
shf o
rmeasurement
.
(
b) Usingas p
rin
gb alan
cea sillu
str
ate
d，measurethe
spri
ngl o
adatwhichthesprin
glif
ts企omt hebru
sh.
Ifthemeasuredvalueisles
st h
ant h
elim
it，repla
ce
thespr
ing.
U
ni:N (
t kgf
)[bf
l ]
S t
andar
d
29.4to39.2
B
rus
hsp
rin
glo
ad (
3.0to4.
0)
21
[ .7to28.9
M
eas
ure
men
tof
bru
shs
pri
ngl
oad

(
8) Brushhold
erinsul
atio
ntes
t
Measurebetweenthebrushhold
er(+
)andthebru
sh
hold
erp la
te( )f
・ orc o
ntin
uit
y. Ifcont
inui
tyis
ind
icate
d，rep
lacethebru
shhold
er.

B
rus
hho
lde
rin
sul
ati
ont
est

7-9
 ，INSPECTIONANDREASSEMBLYOFELECTRICALSYSTEM
DISASSEMBLY

(
9) Inspecti
ono fover
runn
ingclut
ch
(
a) R ota
tet hep ini
ons h
aftb yhanda ndc he
ckt he
fol
lowin
g.I ff
ault
y，r
epla
cetheove
rrunn
ingclu
tch.
• The shaf
ts houldrota
tes mo
othlyinc lock
wise
di
rec
tion
.
• The sh
afts hou
ldb el o
ckedinc o
unter
clock
wise
di
rec
tion
.
(
b) Checkt h
ep i
nionforw e
aro rdamage.Iff a
ult
y，
r e
plac
e.

[&CAUTION
Don
otwasht
heo
ver
run
nin
gcl
utc
hinc
lea
nin
gso
lve
nt
. I
nsp
ect
iono
fov
err
unn
ingc
lut
ch

10
( )Ins
pectio
no fm a
gneticswitch
Checkthef ol
1owingandr epla
cethem a
gneticswitc
h
if
faul
ty.
(
a) Coil
open-circuit
Measureb etweent e
rmina
l sSa ndM a ndb et
w e
en T
err
nin
alS
thetermin
a lS a ndtheb odyf o
rc on
tin
uity
.I fno
con
tinui
tyi sindi
cate
d，replac
ethemagneticswi
tch.
(
b) Conta
ctp o
i nt白 si
on
Measurebe tweenter
minal
sBa ndM forcont
inu
ity.
Ifc o
ntinu
i tyisi ndic
ated，r e
plac
et hem agnet
ic
swi
tch.

T
err
nin
alM
I
nsp
ect
iono
fma
gne
tics
wit
ch
(
11)Insp
ectio
nofs t
art
errel
ay
(
a) Coilo
pen-ci
rcuit
Measure b etwe
en t er
mina
ls SW a n
d L f o
r
contm
ulty.
Ifnoconti
nuit
yisindic
ated，
rep
lac
eth
es t
art
erre
lay
.
(
b) Contac
tp o
intfusi
on
Measurebetweenterm
inal
sSa ndBfo
rc o
ntin
uit
y.
Ifcon
tinu
ityisindi
cat
ed，rep
lac
ethes
tar
terr
elay
.

I
nsp
ect
ionofs
tar
terr
ela
y

7-10
 Y
DISASSEMBL.INSPECTIONANDREASSEMBLYOFELECTRICALSYS丁EM

1
.3 Reassemblyo
fSt
art
er

R
eas
sem
blyo
fst
ar
te
r
く R
eas
sem
blys
equ
enc
e>
⑪→⑮→⑮→⑭→⑬→⑫→⑪→⑩→⑨→⑧→⑦→⑥→⑤→④→③→②→①

N
ote:O
bse
rvet
her
eas
sem
blys
equ
enc
ean
dbes
uret
ost
訂tr
eas
sem
bli
ng企omp
ini
on.

7-11
 ，
Y INSPECTIONANDREASSEMBLYOFELECTRICALSYSTEM
DISASSEMBL

(
1) A dj ust me nto fp i
n i'ns
O haft白r u
stc leara
n ce C
ent
erb
rac
ket
Thep ini'Ons ha食 t hrustc learanceist hep laye xh
ibite
d
byt
d
M
i
e
r
a
e
ct
s
h

u
ep
i'On
r
.
et
in

h
i o

et
ns

h r
h

u
s
aftwheni

tc learanc
ti

ei
sm'Ov

nt h
ef'
e

Ol
di

Ow
'
nt h

ingm
et

an
h
r

n
u

e
s
t

r
.
M 〉
Ift hem ea sur edv alued evi ates 合'Om t hes tandar
d
value ，sel 配 t ap r'Opera d
justin gw ashera n dadjus
tt h
e
clearan心ew itht hew asher.
(
a) W ithp i ni'Ono ffsta巾 r:
Installt heg ea r'Ont hep ini'Ons ha
ft，insertt hesha貧
血t 'Ot hec enterb r acket，andl OC
' kth es haftw i
tht h
e A
dju
sti
ngw
ash
er
wa she ra n dr ing. Undert hisc οndii'On，m'Ov
t et h
e
sha 食 i nt h ea xiald i
rection，andmeasuret hethrus
t A
dju
stm
ent'Of
pin
ions
haf
tth
rus
tcl
ear
anc
e
cle訂a nce.
(
b) W ithp i nio n'On5 t加 稔r:
Installt hep ini'Ons h
afta ndg earb etwe ent he企o n
t
an dc en terb racke ts，andtemp'Or a
ril
yt ightent h .
t
eb'Ol
Undert hisc 'Ondition，m'Ovet hesh a
fti nt heaxia
l
directi'On， andm eas uret h
et h r
ustc l
e a
rance.
Uni t:mm[ i
n.
]
N'Om i
n alv alueI S tan da
rd
0.4t O1.
1
i
ni' O 川a 食 I 0.5[0.01 97] 1 [0.01- 5
'
8ω0倒 33]

7-12
 ，
Y INSPECTIONANDREASSEMBLYOFELECTRICALSYSTEM
DISASSEMBL

1.
4 Inspect
ionandAdjustmenta代. erReassembly
Ins
pecta n
da dju
s tthesta
rteraft
erreass
e m
blyint h
e
foll
owingmanner.
(
1) Insp
ectio
no fpiniongap
(
a) Ifthereassembledsta
rte
risw ire
da sil
lust
rat
ed，th
e
pini
onw ills hi食 a n
d turn slow
ly. Remove t h
e
connec
tor企omt heM termina
ltos t
opthepinio
n.
(
b) Undert hi
sc ondition
，l ig
htl
yp ushi nt h
ep ini
on
towardthea rmature，andm easurethe movement
(gap
)o fth
ep inion.
(
c) Toa dj
ustt h
ep iniong p，i
a nαea
seo rdecrea
set h
e
packin
gsf it
tedt othem ag
netics w
itc
h.I ncr
easi
ng
thep即 ki
ngsd e
c rea
sesthepinio
ng a
p.
Un
it:m m[ i
n.]
Sta
nda
rd A
dju
stm
ento
fpi
nio
nga
p
0
.5to2.
0
P
ini
ong
ap
[
0.0
197to0.07
87

￨ 企 m
Donott
es
tthesta
rte
rcont
inu
ousl
yfo
rmorethan1
0
se
con
dst
opre
ven
ttheswi
tchco
il企omo
ver
hea
tin
g.

(
2) N
o-loadte
st
A
fter adjus
tin
g t h
e p i
nion g ap， c
onn
ect the
i
ns汀umentsbetwe
ent h
es ta
rte
ra ndthebatt
eryas
i
llu
str
ate
d a nd test the s t
art
er for no-l
oad
c
hara
cte
ris
tic
s.

￨&CAUTION
Usewire
sast
hic
kasp
oss
ibl
ean
dti
ght
ene
acht
erm
ina
l
se
cur
ely
.

N
o-l
oadc
har
act
eri
sti
cte
st
N
o-load
c
har
act
eri
sti
cs

7-13
 DISASSEMBLY
，INSPECTIONANDREASSEMBLYOFELECTRICALSYSTEM

2
. A
lte
rna
tor
2.
1 Disassemblyo
fAl
ter
nat
or

D
irt
y，dam
agedo
rse
ize
dsl
ipr
ing
s，
c
oi
lres
ist
anc
e

.
，
.

C
oilo
pen
-ci
rcu
it，
con
討nu
ity

D
isa
sse
mbl
yan
din
spe
cti
ono
fal
ter
nat
or

s
くDias
sem
blys
equ
enc
e>
① Nut ④ F
rontb
rac
keta
sse
mbl
y ⑦ R
egula
torass
emb
ly
② Pul
le，
ysp
ace
r ⑤ R
otora
sse
r巾ly ⑧ R
ect
ifi
erasse
mbl
y
③ Screw ⑥ S
tat
or ⑨ R
earbrac
ket

7-14
 ，
DISASSEMBLYINSPECTIONANDREASSEMBLYOFELECTRICALSYSTEM

2
.2 In
spectionofAlterna
tor
(
1) I
nspec
tionofrec
tifi
er
T
esttheresi
stan
c ebetwee
ne achdi
odeleadwirea n
d
h
eatsink.Totest，con
nectthepos
itiv
e( )l
+ ea
dw ir
e
o
fthetest
ertothediodeandthenth
enegati
ve(・)lead
w
ireo fthetest
e rtothed i
ode.Iftheresis
tanc
eis
i
nfi
nit
einb o
thc ass，
e thedio
deisopen
-cir
cuit
ed.Ifit
i
sn ea
rlyz er
oi nbothc as
es，thed io
dei ss h
ort
-
c
ircu
ite
d.I fthed iodeiso pe
n-o rshor-
tcir
cuit
ed，
r
epla
cet h
erect
ifie
r.

I
nsp
ect
ionofr
ect
ifi
er

(
2) Ins
pectio
no f
fiel
dcoi
l
(
a) Measuretheresi
sta
ncebet
wee
nth
esl
ipri
ngs
.If出e
measuredvaluedevi
ate
s企omt h
estan
dardva
lu，
e
rep
lacetherot
or.
S
tan
dar
d
R
esi
sta
nceb
etw
eens
l
i 0t
9. o1
0.4n

Measuremento
fre
sis
tan
ceb
etw
eens
li
pri
ngs

(
b) Checkforco
nti
nuit
ybetw
eenth
esl
iprin
gandthe
sh
aft(o
rthecor
e).I
fco
nti
nui
tyi
sin
dic
atd，
e r
epl
ace
th
eroto
r.

I
ns戸c
tio
noff
iel
dco
ilc
ont
inu
ity

7-15
 DISASSEMBLY
.INSPECTIONANDREASSEMBLYOFELECTRICALSYSTEM

(
3) ]ns
pect
i o
no fs
tat
orcore
(
a) Check forconti
nui
tyb etwe
enle
adw i
res ofth
e
st
ato
rc ore
.] fno c o
ntin
uit
yisind
icat
ed( o
pen
-
ci
rcu
it)，re
pla
cethest
ato
r.

I
nsp
ect
ionofs
tat
orc
ore(
foro
pen
-ci
rcu
it)

(
b) Checkforco
nti
nui
tybetwe
ent
heleadwi
reandt
he
st
ato
rc o
re.Ifcon
tin
uit
yisind
ica
ted，r
epl
acet
he
st
at
or.

I
nsp
ect
ionofs
tat
orc
ore(
forc
ont
inu
ity
)

(
4) In
spec
tio
nofbr
ushleng
th
(
a) Meas
ureth
eb ru
shlengt
h.Re
pla
ceb r
ush
esi
fth
ey
ar
eworndowntoth
ewearli
rn
itl
in
e.

2
].
S
ta
5[
n
d
0
a
.
r
8
4
d
65

…J
[ U
nit:
mm[
in
.J

I
nsp
ect
iono
fbr
ushl
eng
th

7-16
 ，
Y INSPECTIONANDREASSEMBLYOFELECTRICALSYSTEM
DISASSEMBL

2
.3 Reassemblyo
fAl
ter
nat
or

R
eas
sem
blyo
fal
tem
ato
r
く R
eas
sem
blys
equ
enc
e>
⑨→⑧→⑦→⑥→⑤→④→③→②→①

Brushh
old
ingfori
nst
all
ingrot
or
Pushth
ebrushe
sintotheholde
ra ss
embly，andh
old
thembyinse
rti
nga2mm[ 0
.08in.
]d iam
eterw
ire
加totheho
lesinthebru
shes.Then，ins
tal
lt h
ero
to
r.
Removeth
ewireaf
terin
stal
lin
gthero
tor
.

B
rus
hho
ldi
ngf
ori
nst
all
ingr
oto
r

7-17
 ，INSPECTIONANDREASSEMBLYOFELECTRICALSYSTEM
DISASSEMBLY

3
. GlowP
lug
3.
1 Inspe
ctionofGlowP lug
Checkf o
rconti
nuitybetwe
enthete
rmi
nalandth
e
bod
y.R epla
cet he glow p
lugifno c
ont
inu
ityi
s
ind
icat
edorthe問 s
ista
ncemea
sur
edi
stoogr
eat
.
l 一
一一← S
tanda
吋
!
Res
ist
anc
e A
pprox
.1 0n
.

I
nsp
ect
ionofglowp
lug
3
.2 I
nst
all
ati
onofGlowPl
ug
(
l) I
ns
ta
]]theglowplugt
othec
yli
nde
rhe
adw
itht
he
s
pec
ifi
edtor
que
.
T
ight
enin
gt or
queI1
4.7t
o19.
6N'm(1.5t
o2.0k
gf'
m)
f
orglowplu
g [
10.
8to1
4.5lb
f.
ft
]

(
2) I
nst
al
lt h
econn
ect
ionpl絢 to伽 g l
owp
luga
nd
t
igh
t怠nth
enu
ttoth
espe
cifie
dtor
que
.
T
ight
enin
gω珂ue10.
98ω l
.47Nom(0.
10ω0.
15k
gfo
m)
f
orglowplu
gntI
u [
0.
7to11l
. b・
f貧]

7-18
 INSTALLATIONOFELECTRICALSYSTEM

1
.GlowP
lug.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
....
..
...
....
...
..
...
...
...
. 7・20

2
.Al
ter
nat
or.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.. 7-
20

3
.St
art
er.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.. 7-
21
 INSTALLATIONOFELECTRICALSYSTEM

1
. GlowP
lug

く I
nst
all
ati
ons
equ
enc
e>
③→②→①

2
. A
lte
rna
tor
玄

I
nst
all
ati
ono
fal
tem
ato
r
くI
nst
all
ati
ons
equ
enc
e>
⑥→⑤→④→③→②→①

7-20
 INSTALLATIONOFELECTRICALSYSTEM

3
. S
tar
ter

I
nst
all
ati
onofs
tar
ter
く I
nst
all
ati
ons
equ
enc
e>
②→①

7-21
 INSTALLATIONOFELECTRICALSYSTEM

7-22
 I
NSP
ECT
ION，
ADJ
UST
MEN
T，即日比I
NOP
ERA
TIO
NAN
DPE
RFO
RMA
NCET
EST
S

1
.EngineI
nsp
ect
ionandAdjustment・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 8・ 2
1
.1I
nsp
ect
ionandAdjustmento
fVa
lveClearances .
...
...
...
...
...
...
...
...
...
...
...
...
... 8・ 2
1
.2 B
lee
din
gFu
elSystemo
fWater.....
.....
.......
.........
....
...
...
...
....
.....
....
... 8・3
1.3B
lee
din
gFu
elSystemo
fAi
r'.....
....
....• ..
......• ..• ...
...
....
...
...
...
...
...
....
.. 8・ 3
1 fFuell吋e
.4Adjustmento cti
onT
iming.
....
.....
.........• ...
...
....
...
...
....
...
...
...
.. 8・4
1
.5 I
nsp
ect
ionandAdjustmento
fV-
Bel
tTe
nsi
on............
• ...
...
...
...
....
•...
...
...
...
. 8・ 6

2
.EngineB
rea
k-I
nOperation.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
. 8・ 7
2
.1S
tar
tin 8・ 7
gUp.......•................................................•...............
2.2 I
nsp
ect
iona
fte
rSt
art
ingUp...
..........
.......
...........
...
..•. ..
...
...
.....
....
... 8・ 7
2
.3 B
rea
k-I
nPe
rid .................................................................... 8-7
o
2.4I
nsp
ect
ionandAdjustmenta
fte
rBr
eak
-InO
per
ati
on..........
...
....
...
....
.....
...
....
. 8・ 7

3
.PerformanceT
est
s..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
. 8-8
3
.1EngineEquipmentC
ond
iti
on.....
• ....
....
.......
• ........
...
...
....
....
....
....
...
.. 8・ 8
3
.2T
estI
tem
sandPurposes.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.. 8・ 8
3
.3OtherI
nsp
ect
ion
s'..
...........
.....
• ...............
• ...
...
...
....
...
...
...
....
....
. 8・ 8
3
.4 EngineOutputAdjustment・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 8・ 8
 INSPECTION， ，BREAK-INOPERATIONANDPERFORMANCETESTS
ADJUSTMENT

1
. EngineI
nsp
ect
ionandA
dju
stm
ent
1
.1 Insp
ect
ionandAdjustmento
fValveClearances
Val
vec le
aranc
es h
ouldbeinsp
ect
eda nda dj
ust
ed
whenth
ee ng
ineisco
ld.
Unitmm[ i
n.]
S
tan
dar
d
V
alvec
lea
rance
0
.25[
0.0
098
]
(
col
dse
tti
ng)

(
1) In
spec
tingth
evalvecle
aran
ce
(
a) In
spec
tt h
ev alv
ec le
ara
nceint h
efirin
go rd
erb y
t
urnin
gt h
ec ranks
ha食(1200) i
nt h
ed ire
cti
ono f
nor
malrota
tio
ntobringth
epist
ontotopdeadcen
ter
of
the∞m pres
sionstr
oke
.
一 ー 一 C
ran
ksh
aftro
tat
iona
ngl
e
12
0。
Note:To tu
rnt h
ec ranksh
a食 i
nt henorm
ald ir
ect
ion
(c
lock
wiseasviewed合omthe企onte
nd)，a
tta
chthe
tu
rni
ngs ock
et and theratc
hethand
le on the
cr
ank
shaf
tpulle
ynu t
.
Pa
rtnumber
AG-
5830
9・73100

Unitmm[
in.
]
Widtha
cro
ssf
la
tso
fcr
ank
sha
ft
46[
1.8
11]
ull
evn
ut
(
b) Thetopdeadc en
teronc om
p r
essionst
rokeofNo.l
pi
stonisiden
tifi
edbyt het im
ingmark" 0"ofthe
po
inte
ront het im
inggearc a
seb e
ingalign
edwith
th
e mark on t hed ampe
r.W iththe pist
ons o
pos
itio
ne，b
d oththeinl
etan dexha
ustvalveroc
ker
armsar
enotb e
ingp u
shedu pbythe
irpus
hrods
.
(
c) In
ser
taf eel
erg ageinbetweentheroc
kerarma nd
val
vecap，andcheckthecle
aranc
e.
I
nsp
ect
iono
fva
lvec
lea
ran
ce(
tur
nin
g)

(
2) Ad
just泊gt h
ev al
vec l
earanc
e
(
a) Loosenthelocknutofthea dj
usti
ngscrew.A d
just
t
heclearan
cebyt urn
ingthes cre
wineith
erdi
rect
ion
t
ot hee xten
tt hatt heg ageiss lig
htl
yg ri
pped
betw
eent h
er o
ckerarrnandv a
lvecap
.
(
b) Af
tera d
justi
ngt h
ec lear
ance，tig
hte
nt helo
cknu .
t
In
spec
tt heclear
ancea g
aina ndmakes u
retha
titis
co
rrect
.

A
dju
stm
ento
fva
lvec
lea
ran
ce

8-2
 INSPECTION，ADJUSTMENT
，BREAK-INOPERATIONANDPERFORMANCETESTS

1.
2 BleedingF u
elSystemo fWater
Whe nw a
ters taye
di nthebottomofthef
uelfi
lt
er
exceed
st hespeci
fiedle
vel，th
ew a
termaye
nterin
to
teぬe
h lsystem.
Bleedt hef ue
lf il
terofw ateri nth
ef o
llow
ing
proced
町e s
.
(
1) Loosenthedrainplugonthebott
omofth
efu
elfi
lt
er
.

B
lee
din
gfu
elf
il
te
rof
wat
er(
dra
inp
lug
)

(
2) Wateriseas
ilydrai
nedbypres
singt
hemanualf ee
d
pumpr e
peate
dly(ap
prox
.7time
s)tofe
edthe白e.l
(
3) Tig
htent h
ed rainplu
gs e
cur
elyaft
erdrain
ingt h
e
wa
ter.
(
4) Bleedthefuelsyst
emo fa
ira食erble
edi
ngt h
ef ue
l
syst
emofw a
ter.

Manu
alf
eed
l&CAUTIO pump
F
uelisdrain
edt og
eth
erw i
thwate
rwhenb l
eedi
ngth
e
f
uelf
il
te
rofw a
ter.Compl
etelyw
ipeoffan
yspi
ltfu
ela
s
t
heya
ref1ammableandcanbeafi
reha
zar
d.
B
lee
din
gfu
elf
il
te
rofw
ate
r(m
anu
alf
eedpump)

1
.3 BleedingFuelSystemo
fAi
r
(
1) Loosenth
eai
rbl
eed
erp
lugo
fth
efu
elf
il
te
rwi
tha
w
r ench
.

irb
A lee
derp
lug

B
lee
din
gfu
elf
il
te
rofa
ir(
airb
lee
derp
lug
)

(
2) Re
peated
lypres
sthemanualfee
dpumpw i
ththec
10t
h
a
pplie
dtotheai
rbleed
erplu
g.
(
3) Whenf u
elw i
tha i
rb ub
blesno lon
gercomesout，
t
ight
enthea
irblee
derplugse
cur
ely
.

Manu
alf
eed
pump

B
lee
din
gfu
elf
il
te
rofa
ir(
man
ualf
eedpump)

8-3
 INSPECTION，ADJUSTMENT
，BREAK-INOPERAγIONANDPERFORMANCETESTS

1.
4 AdjustmentofF u
ellnject
ionTiming
Wh enthefuelinje
ctio
npumpi sr e
placed，adj
ustthe
fu
eli n
ject
iontimingaft
erthereplacem
ent.Toa dj
ust
t，
i bringNo.1c ylin
derpisto
ntot h
et opd e
adc e
nter
onc o
mpressionstro
ke.Makes uretha
tt hemarkson
th
ef la
ngeplat
eandt hefuelinj
ect
ionpumpbodya re
ali
gne
d.
(
1) Removet h
eg ea
rc a
sec o
ver
.

Gearc
asecover--- ;
;
〆'
Removalofg
earc
asec
ove
r

(
2) A
tta
cht h
etumingsoc
kettot
hepull
eyn
utandtu
rn
t
hecran
ksha
ftinth
en orm
aldi
rec
tio
n(c
loc
kwi
seas
v
iewed企omt h
e合onten
d).
Partnumber
AG-58309・73100

E
ngi
net
urn
ing
(
3) S
toptumingth
ec r
ank
sha
ftwhenthemarksofthe
f
ueli
nje
cti
onpumpgea
randi
dle
rge
arareali
gne
d. C
ams
haf
tge
ar I
dle
rge
ar

O
ilpumpg
ear

A
lig
nme
nto
fti
min
gge
arm
ark
s

8-4
 INSPECTION，
ADJUSTMENT
，BREAK-INOPERATIONANDPERFORMANCETESTS

(
4) P
utamark(B
)onth
ef l
ang
epla
tewher
eal
ign
edw
ith
t
hemark(
A)oft
hef
ueli吋ec
tio
npump.

P
utt
ingamark
(
5) Unscrewtheflang
ep la
teret
ain
ingbo
ltandremove
th
ef u
elin
ject
ionpumpf romt
he合ontpl
ate
. Fu
e!in
je
ct
io
n
(
6) Removet am
per-proo
fn us，t
t h
enremovet h
efla
nge pump
pl
ate合omt h
ef u
elinje
ctio
npump.

A CAUTION
Whenremo
vingthefla
ngepla
te合omt h
ef u
elinj
ect
ion
pumpas
sembl，
ybesu
retoputamarkonthefla
ngepl
ate
be
for
eremov
altoens
urepro
perrea
sse
mbly.

(
7) R
epl
acet
hef
ueli
nje
cti
onpumpw
ithanewo
ne.
Removalo
ffu
eli
nje
cti
onpump

A CAUTION
Wh enchang
ingp a
rts，besuretouseourd e
signat
edpar
ts.
Unle
sso urd esignate
d pa ロs areu sed，t h
ee x
hau
st
emis
sionregu
lation
sc a
nnotb emet
.
Takecaretha
tt hep訂 t
smayb ep a
rtl
ym o
difieddueto
improvem
ent，forexample
.
Workrelat
edtot h
ee xhau
ste miss
ionregulat
ionscanbe
cond
uctedonlyat0町 designatedse
rvi
cef ac
tor
ies
.
However，don o
tc hangethea djus
tmentbyc utti
ngand
removi
ngt h
et amper
-proofso nthefu
eli nje
ctio
npump
ass
embly
.Thef u
eli n
ject
ionpumpmustb ereplac
edas
anassemb
ly.

8-5
 INSPECTION，
ADJUSTMENT
，BREAK-INOPERATIONANDPERFORMANCETESTS

(
8) In
sta
lltheflang
ep l
ateandt h
efue
li nj
ect
ionpump
ge
artothefue
linje
ctio
npump.
(
9) AI
ignt h
emark( A)oft h
ef u
e!in
ject
ionpumpw it
h
t
hemark( B)whichwasmarkedaboveproced
ure(4
)
(
B
andtig
htenth
enu .
tTheni n
st
allt
hetamper-p
rooft
o
t
henu .
t

A
lig
nme
nto
ffu
e!i
nje
cti
onpumpmark

(
10) Bya!i
gnin
gt hetimin
gmarksofth
efue
!inje
cti
on
C
ams
haf
tge
ar I
d!e
rge
ar
pumpge
ara n
dt h
eid!
erge
ar，i
ns
ta
llt
hef
ue!i
nje
cti
on
pumpt
othe合o n
tp!a
te.

O
i1pumpg
ear

A
!ig
nme
nto
fti
min
gge
arm
ark
s

11
( )I
nst
allt
heg
earc
asec
ove
r.

G
earc
asec
ove
r""
"--
- ;
;
〆.
I
nst
all
ati
ono
fge
arc
asec
ove
r

1
.5 InspectionandAdjustmento
fV-
Bel
tTe
nsi
on
Pr
essth
eV- be
ltatthemidpoi
ntbetwee
nt h
ep ul
leys W
ate
r
andmea
surethet e
nsio
noft h
ebel.I
t fthemeasured PU!
!
1P
tul
1ey
te
nsi
ond oe
sn otc onfonntot hestan
dardv al
ue，
lo
osentheadjus
tingboltandreta
ini
ngb o
lts，then A
dju
sti
ng
moveth
ealtemat
orforadju
stme.
t
n Ip1ate
Uni:mm[
t in
.] A
lte
mato
r
S
tan
dar
d 凶1
p ey

I
nsp
ect
iona
nda
dju
stm
ento
fV-
bel
tte
nsi
on

8-6
 INSPECTION，
ADJUSTMENT
，BREAK-INOPERATIONANDPERFORMANCETESTS

2
. E
ngi
neB
rea
k-I
nOp
era
tio
n
Whent h
ee ngi
nei so verha
uld，i
e ts ho
uldbe 2.
2 Inspectiona f
terS t
artingUp
mo
unted on a dynamometer a
ndope
ratedf
or Duringtheb reak
-ino per
ation，checkthefollowin
g.
b
reak
-inandi
nspec
tion. Ifana bnormalityisf ound，stopt hee ng
in ，t
e h
en
inve
stiga
te t h
e c a
u s
e a nd take a p
propria
te
2
.1 S
tar
tin
gUp measu
re s
.
(1
) Lubr
icatin
go Jp
i ressu
res houl
db e0.29t o0.49恥1Pa
2
(3.
0to5.0k g f
7cm )[42.
7to71 .
1psi](atrate
de ngi
ne
ト CAUTION spee)，a
d nd more t han 0.10 MPa ( 1.0 kgf7cm2)
Do notr unt h
ee ngineatl owi dl
es peedfora n [14.
2psi](atidli
ng).
ext
endedp er
iodo ftimeino rd
ertop rev
entc a
rbon (2
) Coolantt emperatures houldbe7 5t o8 50C [ 1
67
de
posi
ts on f ue
li nje
ctio
nn o
zzle
s，w hite smoke to185F
0
].
em
lsslon，e
tc. (3
) Lubri
catingo i
lt emperatu
res houl
db e60t o9 50C
Li
mitthelow-id
leopera
tionto10minute
s. [140to2 03F
0
]
.
A
fterthee ng
inewarmsupi nthelow-
idleope
ratio，
n (
4) Checkf o
rle 北a geofo ic
，
J ool
antandf ue.
l
gr
adua
llyi n
creas
etheloa
d. (
5) Kn o
cking s hould d isa
ppear a s t he c oola
nt
A
fterthee ngin
es t
ar
ts，don otacce
ler
atethee ng
ine tempera旬rer ises.ηlee ngines h
ouldn otp rese
nt
sp
eedsu dd
enlyorincr
easetheloa
da b
rupt
ly. anyothera bnormalnoise.
(
6) Checkf o
re 油a ustcoloranda bn
orma lodors
.

1) B
( efo
res t制 ingt h
ee ngin
e，c heckt h
el ev
elso f
coo
lant，engin
eo i
landf u
el，andbleedthefu
eland 2.
3 Break
-InPeriod
coo
lingsystems. Thefoll
owingshowsther
ela
tio
nsh
ipbetwe
enthe
(
2) Withthefuelsupplycutof
f，oper
atethesta
rte
r叩 d loa
dinbrea
k-inop
erat
iona
ndtheop
era
tio
ntime
.
cra
nkt heengineforabout15s econ
dstoc i
rcu
lat
e Bre
ak-i
nper
iod
eng
ineoi.
l
E
ng(
imn
e
泊s・p
l
)ee
d Load Time

ヘ
(
3) Movet hecon甘01l ev
erslig
htl
yi nthedire
cti
ono f
(kWf PS
1) (
min.
)
fu
eli n
c r
ease( d
on otmovei tt o"ぬ1 i n
jec
tion
"
1000 Nol o
ad 30
po
siti
on)，thentumt hesta
rte
rs witc
hk eytot h
e
2 1500 25% 30
[START]p o
sitio
ntostar
ttheengine.
3 (
var
iesd e
pendi
ngo n 25% 10
(
4) A貧.e
rt heengines t
art
s，letitoperat
ea tno-Ioa
d
4 e
ngines
pec
ifi
cat
ion
s) 50% 10
minimums peed(id
lin
g).
5 75% 30
6 100% 20

2.
4 Ins
pectio
n and Adjustment a
fte
r B
rea
k-I
n
Oper
ation
(
a)A
djustm
entof
val
vec
1earanc
es
(
b 司
)Aju
stm
ento
ffu
eli
nje
cti
ont
imi
ng
(
c)R
e-t
igh
ten
inge
xte
malb
olt
sandn
uts

8-7
 INSPECTION，
ADJUSTMENT
，BREAK-INOPERATIONANDPERFORMANCETESTS

3. PerformanceTests
Therearevariou
sp e
rfonnancete
stp r
ocedur
es.The (2
) Ca I
cula
tio
no fcorre
ctedpower
fol
lowingd escr
ibest h
ep roced
ur e
ss p
ecif
iedi n Mu
ltipl
yt h
em ea
suredb r a
kepowerortorq
uebγ
"Ea
rthmovingm achi
nery-E ngines-P art1:Test t
hec a
lcul
atedd ie
sele ngineco
rrec
tio
nf a
cto
rt o
codeo fn et power (J
IS D0006 ・1
)" and " E
arth o
btai
nac or
rectedval
ue.
movingm achinery-E ngines-P art2 :St佃 dard ￨臼Ir
re
ct
ed叩刷t=COIT<制io
nfac
ωr，(α:
JxMe制 限:
dbr
恥 po州￨
fonn
a tofs pecif
ica
tion
sa ndt es
t i
ng methods of ，At
mosphericcon
ditio
nsdu r
ingte
st
di
eselengine
s( JI
SDO006・2)." T
empe団ure(
T)
:283K(loC)[
50"F
]孟T孟3 1
3K(40"C
)[I
040
F]
Othert es
ti tems may b er e
q ui
red i n some D
rya
tmo
sph
er
icpr
es
su
re
(P
):80蜘 (6
00mmHg)訂孟 11
0kP
a(8
25mmH
g)
app
licat
ions.Allt e
str e
sul
tss ho
u ld be eva
luat
ed
compre
hensivelyino rde
rt odetenninet h
ee ngi
ne
per
fonnance. (
3 I
) Cacu
lat
ionofc
orr
ect
ionf
act
orα
(c)
広三盃ヨ β:Atm叫 h
er
icf
act
or 角:E
ngi
nef
ac
to
r

3
.1 EngineEquipmentCon
dit
ion (
a)C
alcul
atio
nofa t
mosph
ericfact
or仰
The engi
nem ust be eq
uippe
dwiths t
and
ard ① Na
tural aspi
rati
on e n
gine and e
ngi
ne w
ith
au
xili
arydev
icessuc
ha scoo
lin
gfn，a
a i
rclea
ner mech
anical
Iydriv
enaircha
rger
andalt
ema
tor
.
舟 =
(3
3)・
(
会 )0.
7
3.
2 TestItemsandPurposes
② Tur
bochar
gedeng
inew
ith
outa
irc
ool
ero
rwi
th
(
1) Ope
rationloadte
st
a
ir-
to-
airc
ool
er
Conductthistes
tt oe va
luateth ee n
gineo utp
ut，
t
p
o
r
e
q
r
u
f
e
o
n
，f
nan
u
c
e
l c
eund
o
e
ns
rv
u
a
m
r
p
i
o
ti
u
o
sl
n r
o
a
a
dc
t
e a
o nd
it
n
i
d govemor
o
ns.
舟= わ
( ，
(
会 0
.7 y.
2

(
2) Conti
nuousloadte
st ③ T
urb
och
arg
ede
ngi
new
itha
ir-
tol
・iq
uidc
ool
er
Ope
r
90%l
a
tet
oa
h
d(
ee
co
n
n
g
t
i
i
n
n
u
ec
ou
o
sl
nt
o
i
a
nu
da
o
p
u
s
p
l
l
i
yf
cat
o
i
r1
o
n
0h
)ofn
o
o
u
r
m
sa
ina
t
l 戸 =(
号)0.7 ， 会
( )0.
7
ne
tb rak
e power w hilet hee ngin
es peedi s
mai
ntainedatr evolu
tionsc orrespon
dingt ot he (
b)C
alc
ula
tio
nofeng
inef
act
or併時
nom
i n
alb ra
kep ow
er.I nthi
stest，eval
uatethefuel
戸 =0.
036
qc
-・1
.14
consum
ptionr at
ea ndo pe
ratingc ondi
tion，and
con
frrmt h
att h
ee ngin
ei sc a
pableofc on
tinuous q
c:C
orr
ect
edf
uels
upp
lyvolume

(
3
o
p
) N
e
o
r
-
l
at
o
a
i
on.
dminimume ng
ines pe
edtest
①qc= チ
Conductthi
st e
sttoc onfirmthatt heenginec an (
:
z)Xσuelf
lowr
ateg
/s)
op
eratestabl
ya tthes pe
cifie
dn o
-loadminimum q= (
Str
okevolumef)X(Engines
pee サ
dmin
s
peed.
z=120000(
4-c
ycl
een
gin
e)
r:R
ati
obe
twe
enp
res
s町 ea
ttu
rbo
cha
rge
rora
irc
ool
er
3
.3 OtherInsp
ecti
ons o
utl
etandatmosp
h釘icpres
sure
Checkforlea
kageofgas
es，coolantandoi
l，and r=1f
( orn
atu
ralasp
ira
tio
ne n
gine
)
abnon
nalodor
s佃 dh u
nti
ng.Makea dju
stm
entas
②A
ppl
ica
bler
ang
eofe
ngi
nef
acω
r併n
)
nee
ded.
g!
〔
3
7.2孟q
c孟65m fc
( y
cle
)

3.
4 EngineOutputAdjustment 肝
qc
必
必凶
孟刈
3
記 ω
Die
sele ng
ineo utp
uti sa tf
ecte
dbya tm
ospher
i c .
φ65
mg
ダ凶
/υ
(f句cycle
べ 吟
)
::
:玉q
孟 伊c 向
か戸
:β1=1.2や
(∞
co
ns
tω nt
為加 ) ノ
p
c
r
o
e
s
r
r
s
e
u
c
r
t
i
，temperature 組 d humidity. 百l
e
oncalc
ulat
ionsmustb eperfon n
edt
e
r
oo
e
b
f
o
t
r
a
e，
in の
(
ωc
)R加 g浄o
伊 ぱfcωor
n
沼
汀冗
官
汀e
'
官 “
c
叫t
io
卯nequatio
nu s
e
th
ev alueo fe n
gineo utputu ndert hes t
andard Ther angeo fc orrec
tionfac
tor(a)i
c sasfol
Io
ws:
atmo
spheri
cc o
ndit
ions. 0.9孟α c孟1.1.
(
1) Stan
dardatmosp
hericcondit
ions
: Ifthisr angei se xceed
ed，i n
dicat
et h
ec o
rrec
ted
Basetempe
ratur
e:298K( 250C)[770F] valuesa ndr ecordt h
et e
stc o
nditio
nsont h
et e
st
Atmos
phericpres
s町e :100k Pa[750mmHg] r
官c o
rd.
Dryatmosph
ericpress町e:99k Pa[74 3mmHg]

8-8
 OTHERS

1
.Di
sas
sem
blya
ndR
eas
sem
blyo
fGe
ner
alP
art
s..
...
...
...
...
...
...
...
...
...
...
..
. 9・2
1
.1O
ilS
eal 9-2
s..... . .......................... . ....................... • .................
1.2O
-ri
ngs
...
...
...
...
.......
.......................
....
.....................
....
.. . 9・2
..
1.3B
ear
ing
s..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...9-
. 3
1
.4 LockP
lat
es...............
...
...........
• ......
......
.....
.................
...
...
.. 9-3
1
.5S
pli
tPi
nsandS
pri
ngP
ins・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 9・ 3
 OTHERS

1
.Di
sas
sem
blya
ndR
eas
sem
blyo
fGe
ner
alP
art
s
1
.1O
ilSeals
Whe ni n
sta
lli
ngoiIse
aIs，p
ayp
art
icu
lara
tte
nti
ont
o
thefol
Iowingpoi
nts
.
In
sta
IIat
ionofoiIseaIstohousings
(
a) Checkthes e
aIIipf orscr
atche
sa nddamage，andbe
su
retoorien
tt heI
i pcorre
ctly
.
(
b) Applyas m
aIIamounto fgreasetothep er
iphe
ry
(ho
usingc ont
acts urf
ace)o fthe oi
Is ea
Ib efo
re
in
sta
IIa
tio
n.
(
c) Str
iketheoIiseaIinas tra
ightlin
eusinganoiIse
aI
i
p
s
n
s
e
r
u
t
i
c
a
I
p
ha
I
h
e
rt
er
ya
h
atg
si
u
I
i
Iu
sahammer
d
s
e
t
st
ra
t
.I
e
h
d
tc
eseaII
. Don
ouldr
i

e
pa
o
s
th
u
l
n
i
dp
tt
ti
h
re
ss
eoi
est
Ise
ndamagea
h
a
es
Iw
n
e
a
i
t
do
I
h
i
I
O
Ie
aks
.

OI
ise
aIi
nst
aII
er
In
staI
Iat
ionofoi
IseaI
stosha
fts
(
a) Applygreas
etotheoi
Isea
IIip.
(
b) Usea noiIsea
Ig u
idesimI
iartoth
eo neiII
ust
rat
ed
wheni n
staI
I
inganoiIse
aIo v
erth
es t
eppe
dp o
rtin，
o
spl
ine，
sthre
adsorkeygro
oves.

OI
ise
alg
uid
e
1
.2O
-ring
s
Use anO -
ringg u
ides imi
Iartoth
eo neil
Ius
tra
ted
wheni n
staI
I
inga nO-ringoverth
es te
ppedpo
rti
on，
spI
ine
s，thre
adsorkeygroove
s.
Bes u
retoa pp
lyas maI
Iamountofg r
easetot
he0・
rin
gbefor
ei n
sta
IIa
tio
n.

O
-ri
ngg
uid
e

9-2
 OTHERS

1
.3Bearings
(
a) Wh eninst
all
ingabear
ing，besuretopushtheinn
er
oroute
rrac巴tha
tfi
tsint
otheist
n a
1 1
ati
onpos
itio
n.
Bes u
retou s
eab ear
ingins
tal
lersir
ni
lartoth巴one
il
lus
tra
ted
.

〈コ

B
ear
ingi
nst
all
er

(
b) Useofapre
ssmini
mizestheimp
acto
nth
ebe
ari
ng
ande
nsu
respro
perist
n a
11a
tio
n.

B
ear
ingi
nst
al
1a
tio
nbyu
sin
gpr
ess

4L∞kP
1. lat
es

ロロロ
Besur
etobendloc
kplat
esse
cur
ely
.
τbefi
gur
eontherigh
tshowsth
em e
tho
dso
fbe
ndi
ng
typ
ica
lloc
kpl
ate
s.
聖母

Fζu~王ヨ F23
働舟勺

Good Good Bad

1
.5Spl
i
tP i
nsandS pr
ingPins
Gener
ally，news p
li
tpinss h
ouldb
eu se
dw henev
er
spl
itpinsarer em
oved
. Bes uret
ob e
nds p
li
tp in
s
secぽ'e
ly
.E nsu
re 白ata l
ls pr
ingpi
nsa r
es ec
urel
y
ins
tal
led
.
ω

Lockp
lat
ebe
ndi
ng

9-3
9-4
No. ME-S6SAE
Issued: May, 2005

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