ENGINE

MECHANICAL
GENERAL ............................................................................... EM - 2
SERVICE PROCEDURES ....................................................... EM-21
CYLINDER HEAD AND VALVE MECHANISM ....................... EM-22
FLYWHEEL AND REAR PLATE ............................................. EM-35
TIMING GEAR AND CAMSHAFT ........................................... EM-38
CRANKCASE AND MAIN MOVING PARTS ........................... EM-47
EM-2 ENGINE

GENERAL
SPECIFICATIONS

Specifications
Engine Model
D4AF D4AE D4AL D4DA D4DB

Type 4 in-line 4-cycle Í Í Í Í

diesel engine

Combustion Direct injection Directinjection Directinjection Í Í

chamber type (With (With turbocharger &
turbocharger) intercooler)

Valve mechanism Overhead valve Í Í Í Í

Cylinder bore x
stroke mm 104 x 105 100 x 105 100 x 105 104 x 115 Í
Total displacement
cc 3,568 3,298 3,298 3,907 Í
Compression ratio 18 16.5 16.5(Euro-I) 18.5 18
17.5(Euro-II)
Firing order 1-3-4-2 Í Í Í Í
Cylinder liner type Dry Í Í Í Í
Piston type Slipper-skirt Í Í Í Í
No. of piston rings Compression Í Í Í Í
ring: 2; Oil ring:1
Performance
Maximum output
kW/rpm 73.6/3,400 88.3/3,600 84.6/3,400 : Euro-I 114/3,200 114/3,200 : Euro-I
84.6/3,400 : Euro-II 95.4/2,900 : Euro-II
(PS/rpm) (100/3,400) (120/3,400) (115/3,400) : Euro-I (155/3,200) (155/3,200) : Euro-I
(115/3,000) : Euro-II (131/2,900) : Euro-II
Maximum torque
Nm/rpm 235/2,200 284/2,000 284/2,000 : Euro-I 273/1,800 373/1,600
294/1,800 : Euro-II
(kgf·m/rpm) (24/2,000) (29/2,000) (29/2,000) : Euro-I (38/1,800) (37/1,600)
(30/1,800) : Euro-II
Minimum no-load
engine speed rpm 670 ± 25 750 ± 25 Í 650 ± 25 Í
700±25
(High land)
Maximum no-load
engine speed rpm 3,800 3,850 3,700 (Euro-I) 3,900 3,200
3,750(Euro-II)

NOTE:
The engine performace represents the standard specifications.
GENERAL EM-3

SERVICE STANDARDS

Nominal value Correction and

Description Limit
(Basic diameter in [ ]) remarks

Compression pressure 2.55 MPa 2.55 MPa Adjust

(26 kgf/cm²)/200 rpm (26 kgf/cm²)/ Difference between
200 rpm cylinders within 0.39
MPa (4kgf/cm²)/ 200 rpm
Rocker to rocker shaft clearance [19] 0.06-0.11 0.2 Replace bushing
Outer valve Free D4AE,D4AF, D4AL [57.8]60.84 57.8 Replace
spring length D4DA, D4DB [63]66.1 63
Installed D4AE,D4AF, D4AL 240 ±12N(24.5±1.2kgf) 204N(20.8kgf)
load D4DA, D4DB 273±14N(27.9±1.4kgf) 232N(23.7kgf)
Squareness 1.5° 2.5°
Inner valve Free D4AE,D4AF, D4AL 55.07 52.1 Replace
spring length D4DA, D4DB 60 57
Installed D4AE,D4AF, D4AL 93±4N(9.5±0.45kgf) 79N(8.1kgf)
load D4DA, D4DB 119±5.9N(12.1±0.6kgf) 100N(10.3kgf)
Squareness D4AE,D4AF, D4AL - 2°
D4DA, D4DB - 2.5°
Push rod runout - 0.4 Replace
Tappet to crankcase D4AE,D4AF, D4AL [28] 0.06 - 0.10 0.2 Replace
tappet hole clearance D4DA, D4DB [28] 0.045 - 0.096
Cylinder head bottom surface ditortion 0.05 or less 0.2 Correct or replace
Height of cylinder from top bottom surface 94.9 - 95.1 94.6 Replace
Valve seat width Intake D4AE,D4AF, D4AL 1.8 - 2.2 - Correct or replace
D4DA, D4DB 2.8±0.2 3.6
Exhaust D4AE,D4AF, D4AL 1.8 - 2.2 -
D4DA, D4DB 2±0.2 2.8
Valve to vlave Intake [9] 0.04 - 0.06 0.15 Replace
guide clearance Exhaust [9] 0.07 - 0.10 0.2
Valve stem O.D. Intake 8.96 - 8.97 8.85 Replace
Exhaust 8.93 - 8.94 8.85
Valve sinkage Intake 0.75 - 1.25 1.5 Replace valve seat
Exhaust D4AE,D4AF, D4AL 0.75 - 1.25 1.5
D4DA, D4DB 0.95 - 1.45 1.7
Valve margin(Intake/ Exhaust) 1.5 1.2 Correct or replace
Valve seat angle D4AE,D4AF, D4AL 45°
-
D4DA, D4DB 45°±15´
Flywheel Friction surface distortion 0.05 or less 0.2 Correct or replace
Height to friction surface 22.8 (D4AF, D4AE,D4AL) 21.8 Replace
24 (D4DA, D4DB) 23
Friction surface runout 0.1 or less 0.2 Correct or replace
(In installed state)
EM-4 ENGINE

Nominal value Correction and

Description Limit
(Basic diameter in [ ]) remarks
Timing gear Between crankshaft D4AE,D4AF 0.11-0.23 0.4 Replace
backlash gear and idler gear D4DA,D4DB 0.07-0.15 0.3
D4AL 0.062-0.159 0.3
Between idler gear D4AE,D4AF 0.12-0.25 0.4
and camshft gear D4DA,D4DB 0.07-0.17 0.3
D4AL 0.068-0.175 -
Between idler gear and D4AE,D4AF 0.18-0.31 0.4 Replace
injection pump gear D4DA,D4DB 0.07-0.17 0.3
D4AL 0.068-0.174
Between crankshaft gear 0.10 - 0.18 - Replace
and oil pump gear
Between crankshaft gear and 0.08 - 0.16 0.3
power steering oil pump gear
Camshaft end play 0.05 - 0.22 0.3 Replace thrust plate
Idler gear end play 0.05-0.15 0.3 Replace thrust plate
Camshaft journal No.1, No.2, No.3, No.4 [54.5] 0.04 - 0.09 0.15 Replace bushing
to bushing clearance No.5 [53] 0.04 - 0.09 0.15
Camshaft Difference Intake D4AE,D4AF,D4AL 6.86 6.36 Replace
between cam D4DA,D4DB 7.19±0.05 6.70
height and base Exhaust D4AE,D4AF,D4AL 6.86 6.36
circle diameter
D4DA,D4DB 7.32±0.05 6.82
Bend 0.02 or less 0.05 Correct or replace
Idler gear to idler shaft clearance [45] 0.03 - 0.06 0.1 Replace bushing
Connecting rod end play 0.15 - 0.45 0.6 Replace
Crankshaft end play 0.10 - 0.26 0.4 Replac thrust plate
Piston projection from Grade A 0.517-0.578 Check parts for
crankcase top surface D4AF Grade B 0.578-0.638 clearance
Grade C 0.638-0.699
Grade A 0.467-0.528
D4AE, D4AL Grade B 0.528-0.588
Grade C 0.588-0.649
Grade A 0.466-0.526
D4DA, D4DB Grade B 0.526-0.588
Grade C 0.588-0.648
Piston ring to 1st ring D4AF 0.078-0.146 0.2 Replace
piston ring D4AE, D4AL 0.060-0.125 0.2
groove D4DA 0.115-0.168 0.2
clearance
D4DB 0.117-0.170 0.2
2nd ring D4AF 0.045-0.85 0.15
D4AE, D4AL 0.065-0.105 0.15
D4DA, D4DB 0.045-0.085 0.15
Oil ring 0.025-0.065 0.15
GENERAL EM-5

Nominal value Correction and

Description Limit
(Basic diameter in [ ]) remarks
Piston ring end gap 1st ring D4AE,D4AL 0.25 - 0.40 1.5 Replace
D4DA,D4DB 0.30 - 0.45
D4AF 0.30-0.50
Piston pin to piston 2nd ring D4AE,D4AL 0.50 - 0.65 1.5 Replace
pin hole clearance D4DA,D4DB 0.40 - 0.55
D4AF 0.30-0.50
Piston pin to connecting Oil ring D4AE,D4AL 0.20 - 0.40 1.5 Replace bushing
rod small-end bushing D4DA,D4DB 0.25 - 0.45
clearance D4AF 0.40-0.55
Connecting rod bend and twist Correct and replace
Piston to cylinder D4AF [104] 0.045-0.095 - Correct to oversize
sleeve clearance D4AE, D4AL [100]0.107-0.153 or replace
D4DA [104]0.080-0.130
D4DB [104]0.065-0.115
Crankcase top surface distortion 0.07 or less 0.2 Regrind small amount
Crankcase to Standard D4AE, D4AF, D4AL 0.16 to 0.22 Less than 0.16 Replace with an
sleeve interference D4DA, D4DB 0.17 to 0.23 oversize
Over Size 0.18 to 0.20 Less than 0.18 Replace
Crankshaft Roundness of pins and journals 0.01 or less 0.03 Correct and replace
Cylindricity of pins and journals 0.006 or less 0.03
Bend 0.02 or less 0.05
Main bearing Oil clearance No.1,No.2,No.4,No.5 [78-0.036-0.098 0.15 Replace
No.3 [78]0.056 to 0.118
Tension when free - Less than 82.5
Connecting rod Oil clearance D4AE, D4AF, D4AL [60] 0.035 to 0.094 0.2 Replace
bearing D4DA, D4DB [65] 0.04 to 0.099
Tension when free - Less than 64.5
Valve clearance 0.4 - Adjust

NOTE
If there is no unit indicated, its unit means “mm”
EM-6 ENGINE

TIGHTENING TORQUE

Thread size Tightening torque

Description Remarks
O.D. x pitch mm N·m (kgf·m)
Cylinder head bolt M14 x 2.0 175 (18) <D4AF, D4AL, D4AE> Wet
147 (15) +90° <D4DA, D4DB>
Flywheel bolt M12 x 1.25 123 (12.5)<D4AE, D4AL, D4AF> Wet
M14 x 1.5 39 (4.0) + 40° <D4DA, D4DB>
Rear plate bolt M10 x 1.5 59 (6)
64 (6.5)<D4DA, D4DB>
Crankshaft pulley nut M24 x 1.5 586 (60)
Main bearing cap bolt M14 x 2.0 175(18)<D4AF, D4AE, D4AL> Wet
49(5kgf·m)+90°(D4DA, D4DB)
Connecting rod nut M12x1.25 (D4AF,D4AE,D4AL) 100 (10.5) Wet
Connecting rod bolt M 12.5 X 1.25(D4DA,D4DB) 30(3) ±90° ± 5°
Front engine support bolt M12 x 1.25 98 to 115 (10 to 12)
Front mounting bracket bolt M10 x 1.5 89 to 115 (9 to 12)
Front cushion Mounting bracket side M12 x 1.25 89 to 115 (4 to 12)
rubber nut Engine support side M12 x 1.25 39 to 51 (4 to 5.5)
Crankcase drain plug M14 x 1.5 34 to 39(3.5 to 4)
Oil pan drain plug M14 x 1.5 34 to 44 (3.5 to 4.5)
GENERAL EM-7

SPECIAL TOOL

Tool
Illustration Use
(Number and name)
09212-41000 Removal of the bearing caps at front and
Bearing cap extractor rear. (Use with 09450-75100)

B1241000

09212-41100 Removal of the intermadiate bearing caps.

Intermadiate bearing cap (Use with 09450-75100)
extractor

B1241100

09212-41200 Removal and installation of camshaft

Camshaft bushing bushing.
remover and installer

B1241200

09235-41000 Removal and installation of the

Connecting rod bushing connecting rod bushing.
puller base (Use with 09235-41100)

B3541000

09246-41000 Removal and installation of the idler gear

Idler gear bushing puller bushing.

B4641000
EM-8 ENGINE

Tool
Illustration Use
(Number and name)
09251-41000 Removal of water pump flange and
Water pump inpeller puller impeller

B5141000

09450-75100 Removal of the bearing caps

Sliding hammer (Use with 09212-41000 and 09212-41100)

D5075100

09222-45100 Installation of valve stem seal

Valve stem seal installer

B2245100

09353-45100 Measurment of compression pressure

Air compression adapter

PT 1/4
C5345100

09222-83200 Removal and installation of piston ring

Piston ring tool(Universal tool)

B2283200
GENERAL EM-9

Tool
Illustration Use
(Number and name)
09222-83200 Installation of piston
Piston guide clamp
(Universal tool)

B2288200

09222-83300 Removal and installation of valve cotter

Valve spring compressor
(Universal tool)

B2283300

09431-83100 Removal of gear and bearing

Puller set (Universal tool)

D3183100

09221-41100 Removal of valve guide

Valve guide remove

B2141100

09221-41150 Installation of valve guide

Valve guide installer (Use with 09211-41100)

B2141150
EM-10 ENGINE

TROUBLESHOOTING

Engine will not start

Connect fuel in use? No

Replace fuel or oil
Adequate oil viscosity?
Yes

Connect valve clearance? No

Adjust
Connect injection timing?
Yes

No
Adequate compression pressure? Modify or replace after checking
Yes these things
• Defective head gasket
• Worn valve and valve seat
• Deteriorated valve spring
• Worn or damaged piston ring
• Worn or damaged piston ring
groove
• Wide clearence between
piston and cylinder sleeve

Starting system (including preheater) No Correct or replace of the

works properly? defective parts
Yes (refer to engine electrical system)

Check fuel system

(refer to fuel and engine control)
GENERAL EM-11

Rough Idle

Connect fuel in use? No

Replace fuel or oil
Adequate oil viscosity?
Yes

Connect valve clearance? No

Adjust
Connect injection timing?
Yes

No
Adequate compression pressure? Modify or replace after
Yes checking these things
• Defective head gasket
• Worn valve and valve seat
• Deterionated valve spring
• Worn or damaged piston ring
• Worn or damagd piston
ring groove
• Wide clearence between
piston and cylinder sleeve

No
Stuffed fuel-filter or feed-pump or air Correct or replace of the
trapped in fuel system? defective parts
Yes (refer to fuel and engine control)

Injection pump and injection nozzle work No

properly?
Yes

Check the governer for idle adjustment

(refer to fuel and engine control)
EM-12 ENGINE

Abnormal exhaust gas color

Connect fuel in use? No Replace fuel or adjust oil

Adequate oil viscosity? quantity.
Yes

Connect valve clearance? No

Adjust
Connect injection timing?
Yes

No
Adequate compression pressure? Modify or replace after
Yes checking these things
• Defective head gasket
• Worn valve and valve seat
• Deteriorated valve spring
• Worn or damaged piston ring
• Worn or damagd piston
ring groove
• Wide clearence between
piston and cylinder sleeve

No
Air cleaner and muffler in good Correct or replace
condition?
Yes

Check injection pump

injection timing
injection nozzle
Yes

Turbo-charger system functioning

properly?
GENERAL EM-13

Insufficiant Engine power

Connect fuel in use? No

Replace fuel or oil
Adequate oil viscosity?
Yes

Connect valve clearance? No

Adjust
Connect injection timing?
Yes

No
Adequate compression pressure? Modify or replace after
Yes checking these things
• Defective head gasket
• Worn valve and valve seat
• Deteriorated valve spring
• Worn or damaged piston ring
• Worn or damagd piston
ring groove
• Wide clearence between
piston and cylinder sleeve

No
Air cleaner and muffler in good Correct or replace
condition?
Yes

Stuffed fuel-filter or feed pump

or air trapped in fuel system?
Yes

Check injection pump

injection timing No
Correct or replace
injection nozzle
(refer to fuel and engine control)
EM-14 ENGINE

Excessive oil consumption

No
Connect injection timing? Adjust
Yes

No
Flawless in valve stem seal? Replace
Yes

Adequate clearance between No

Replace valves
valve and guide?
Yes

Flawless in piston ring and No

Replace pistons and piston rings.
piston ring groove?
Yes

Lubricating system functioning

properly ?
(refer to lubricating system)
Yes

Fuel system functioning properly?

(refer to fuel and engine control)
GENERAL EM-15

Abnormal engine noise

Noise produced around engine

Yes

No
Pipes and hoses assembled firmly? Adjust
Yes

Injection pump, water pump and No Inspect each part and

other attachments installed Adjust installing locations
normaly in proper places? (refer to fuel, engine control
Yes and cooling system)

Loosened or worn V-belt? No Replace V-belt or Adjust

Crankshaft pully installed properly? installing locations.
Yes

Air cleaner and muffler in good No

Correct or replace
condition?
Yes

Inspect the surface state of valves

and valve seats.

Noise produced around rocker cover

Yes

No
Proper valve clearance? Adjust
Yes

No
Valve springs in good condition? Adjust
Yes

Check the oil in rocker shaft.

EM-16 ENGINE

Noise produced around gear case

Yes

No
Proper back-lash in timing gear? Replace timing gear
Yes

Check timing gear and relevant parts

Noise produced from cylinder head No Check compression pressure

and crankcase Check the following and adjust
or replace
• Damaged cylinder head
gasket
• Worn valve and valve seat
• Worn or damaged piston ring
• Worn or damagd piston ring
groove
• Wide clearence between
piston and cylinder sleeve
• Deteriorated valve spring

Noise varies with cooling water tem-

perature and fuel injection timing?

Check injection timing

It varies amply injection pump
nozzle and timer
(refer to fuel and control)

Check the following

It varies slightly
• Worn piston or cylinder
• Damaged and adhering
piston and piston ring
• Worn connecting rod small end
bushing and piston pin
• Damaged crankshaft
• Seperated fly-wheel from
crankshaft
• Excessive crankshaft to
camshaft end play
• Worn tappet
GENERAL EM-17

DESCRIPTION
Combustion Chamber
The combustion chamber consists of the cylinder head and toroi-
dal pistons, hole type injection nozzles being installed in the cylin- Injection
der head. nozzle

Combustion occurs when the fuel is directly injected into the com-
Cylinder head
bustion chamber with the power operating the piston directly.

Piston

D4AF0069

Valve Mechanism
The valve mechanism is an overhead valve type.
1. Both the inlet and exhaust valves are made of surface-treated Valve cap
Valve cotter
heat-resistant steel. The valve seat angle is 45° in both valves. Upper retainer
Valve stem seal is mounted to the valve stem, which controls Outer spring
Inner spring
the amount of lubricant on the sliding surfaces between the
Rocker
valve and valve guide. Rocker shaft
Valve stem seal

A valve guide with carbon cutter is used for the exhaust side. spring

2. Two unevenly pitched valve springs are used, the inner and Rocker Valve guide
shaft
outer with coil directions opposite to each other. Exhaust valve
Push
rod Inlet valve
3. The rocker has an induction-hardened surface in contact with
Tappet
the valve cap. A bushing is used in the hole, into which the
rocker shaft is fitted.
Camshaft
Because of them, wear resistance is improved.
4. The rocker shaft is a hollow round rod with sealing caps at both
ends to seal it off. Its inside is an engine oil passage.
D4AF0073
5. The push rod has a steel ball welded to its bottom end and a
spherical or depressed piece welded to its top end. Both ends
are carburized casehardened.
6. The tappet is of cylindrical shape . Its mating surface with the
tape camshaft is a largediameter sphere to prevent local wear.
EM-18 ENGINE

Crankcase and Cylinder Sleeve

1. The crankcase is made of cast iron and built rigid with mini-
mum stress concentration and deformation.
2. Three camshaft bushings are installed in the camshaft bear-
ings of the crankcase. To facilitate insertion and removal of the
camshaft form the front end of the crankcase, the bushing I.D
is made smaller toward the rear.
3. The special cast-iron cylinder sleeve, that is highly resistance
to wear, is press-fitted into the crankcase.

Crankcase

Cylinder sleeve

D4AF0075

Pistion and Pistion Ring D4AF, D4AL(Euro-II) D4AE, D4AL(Euro-I)

D4DA, D4DB
1. Pistion Part number
The piston, made of aluminum alloy casting, has a strut inside Over size mark

that ensures and adequate clearance between the piston and Weight mark

cylinder sleeve. Front mark

The piston pin arrangement is full-floating. the piston pin is off-

set toward the thrust side, which together with the effect of the Piston
strut, minimizes piston slap. EEEE06A/ EEEE07A

Weight grade table

Symbol mark
Weight range (gr.)
O P Q R S U
D4AF 1088-1093 1094-1098 1099-1103 1104-1108 1109-1113 1114-1118
D4AE, D4AL (Euro-I) 1005-1010 1011-1015 1016-1020 1021-1025 1026-1030 1031-1035
D4AL(Euro-II) 1012-1017 1018-1022 1023-1027 1028-1032 1033-1037 1038-1042
D4DA 1128-1130 1134-1138 1139-1143 1144-1148 1149-1153 1154-1158
D4DB 1088-1093 1094-1098 1099-1103 1104-1108 1109-1113 1114-1118

2. Piston Ring
There are three piston rings installed: two compression ring 1st compression ring
Barrel-faced
and one oil ring. The sliding surface of each ring, is hard chrome semi-keystone type
plated. 2nd compression ring
Taper-faced inner
Piston rings are shaped as illustrated. cut type
Oil ring
Dual type with
expander spring
D4AF0078
GENERAL EM-19

Connecting Rod and Connectiong rod Bearing Oil jet

<D4AE, D4AL, D4DA, D4DB>
The connecting rod is a die forging with an l cross section ensuring Connecting rod
high rigidity. A lead bronze bushing is press-fitted into its small
end, while a spilt-style plain bearing is used in its big end. Connecting rod
<D4AF>
bearing
On D4A, and oil passage is provided obliquely through the stem
and an oil jet at the small-end to lubricate the small-end bushing Connecting rod
and cool the piston. bushing
Connecting rod cap JCW20007

Crankshaft and Main Bearing Oil seal Crankshaft

1. Crankshaft

The crankshaft is a highly-rigid die forging integral with the bal-

ance weights. The pins and journals are induction-hardened
for improved wear resistance.
By means of oil passages drilled through the pins and journals,
Crankshaft pulley Crankshaft gear
part of the main bearing lubricating oil is fed to pins for lubrica-
JCW20008
tion of the connecting rod bearing.
At the fornt end of the crankshaft, there are a crankshaft pulley
and crankshaft gear attached with a nut. The crankshaft pulley
drives the alternator and water pump through V-belt.
A pulley with damper is installed that absorbs torsional vibra-
tion of the crankshaft.
Flywheel
The crankshaft gear drives the camshaft and injection pump.

The flywheel is mounted in the rear of the crankshaft.

An oil seal is installed at front and rear of the crankshaft. Oil seal

Flywheel bolt

Crakshaft

Rear plate
JCW20009

2. Main Bearing
The main bearing is a split-style plain bearing made of special Main bearing, upper
alloy plated kelmet metal with a steel back.
The upper main bearing has an internal oil groove and oil hole
which is aligned with the oil hole in the crankshaft.
Five pairs of mian bearings are used. Split-style thrust plates Thrust plate
are mounted with the rear pair of main bearings. Main bearing, lower
D4AF0083
EM-20 ENGINE

Timing Gear <D4AL, D4AF, D4AE>

The timing gears are housed in the timing gear case at the front of
the engine. Illustration shows the gear train.
Each gear is a helical gear machined by a shaving machine to high Camshaft gear

precision and surface-treated for enhanced durability.

A timing mark is stamped on each gear. At reassembly, correct
meshing can be achieved by aligning these marks.
Injection
A bushing is press-fitted into the idler gear which turns on the idler pump gear
shaft.
Idler gear

Crankshaft gear

EDAC004A

<D4DA, D4DB>

Camshaft gear

Idler gear

Injection
pump gear

Oil pump
gear
Crankshaft gear

D4DCEM017

Flywheel Ring gear

Flywheel
The flywheel is made of cast iron. The pilot bearing of the transmis-
sion drive pinion is installed at its center.
On its periphery, the ring gear is shrink-fitted that meshes with the
starter pinion.
Pilot
The ring gear tooth crests are induction-hardened for greater bearing
durability.
At the same time, one side of the crests is chamfered to ensure D4AF0086

that the starter pinion meshes easily when starter is operated.

SERVICE PROCEDURES EM-21

SERVICE PROCEDURES
Measurment of Compression Presure
Compression pressure must be measured prior to disassembly of
the engine.
Measure the compression pressure at regular intervals and keep
track of its changes. During the break-in period or after parts have
been replaced with new ones, there is a slight increase in the pres-
sure as the pistion rings and valve seats fit snugly in position. As
rough edges and friction betweeen parts are gradually reduced,
the pressure comes down.

Measurement Procedure
1. Retighten the cylinder head bolts to specified torque and let
the engine warm up until the coolant temperature reaches 75°C
to 85°C.

D4AF5554

2. Remove all injection nozzles from the cylinder head.

Injection nozzle
NOTE:
25 N·m
Cover the mounting holes and injection pipes to prevent (2.5 kgf·m)
entry of dust and dirt. Bridge

D4AF0112

3. Install Compression Gauge Adaptor (special tool) on the injec-

Compression ring (at 200 rpm)
tion nozzle together with a gasket and connect the compres- NV 2.55 MPa (26 kgf/cm²)
L 1.96 MPa (20 kgf/cm²)
sion gauge (measuring instrument). Difference between cylinders
4. Turn the engine with the starter and read the compression gauge 0.39 MPa (4 kgf/cm²) max.

pointer value with the specified engine speed.

NOTE Compression gauge
1. Keep no fuel injected. Compression
2. Make sure that the engine speed is also measured as Gauge Adap-
tor
compression pressure varies with the engine speed.
3. Make measurement for all cylinders, as wear and other
conditions vary from one cylinder to another.
5. If the measurement is below the limit, disassemble and check.
Unit : kgf/cm2(MPa)
Standard Limit Result NV ... Nominal Value
Compression Cylinder at 26(2.55) 20(1.96) Inspection L ... Limit
Pressure (2000 rpm)
* There is not unit indicated, its unit
Difference - 4(0.39) Inspection means “mm”
D4AF0114
Compression

If difference value between the cylinder and another’s.

EM-22 ENGINE

CYLINDER HEAD AND VALVE MECHANISM

1
2
3
4
6

Not re-useable 5 10 Disassembly sequence

1. Oil filler cap
7 9 Not re-useable 2. Spacer
8 3. Insulator
12 4. Breather cap
5. Rocker cover gasket
11 18 kg·m<D4AL>
6. Outer rocker cover
15 kg.m+90° <D4DA>
13 7. Washer
Apply engine oil 8. Insulator
Locating pin 9. Inner rocker cover gasket
10. Inner rocker cover
14
11. Cylinder head bolt
Crankcase 12. Rocker and bracket assembly
Not re-useable 15
13. Push rod
14. Cylinder head assembly
16 15. Cylinder head gasket
16. Tappet

Locating pin
CW20-063

CAUTION
Disassemble the cylinder head on a work bench with the in-
jection nozzle assembly removed.
If the cylinder head is placed on a work bench with the injec-
tion nozzle assembly mounted, the tips of the nozzles will be
damaged.

Removal
1. Where the push rod is forcing up the rocker, the rocker adjust- Adjusting screw
ing screw must be loosened before all cylinder head bolts are
Lock nut
removed.

D4AF2016
CYLINDER HEAD AND VALVE MECHANISM EM-23

2. Remove the cylinder head bolts in the sequence shown in

illustration.

3. Remove the rocker and bracket assembly and cylinder head

assembly, raising them straight upward.

4. When removing the cylinder head gasket, use care to prevent

scratches on the cylinder head and crankcase. CW20-065

5. Removal of the Tappet.

To remove the tappet, using Tappet Extractor (special tool)
For removal, press the special tool until its O-ring is pressed
tightly against each other, remove the tappet together with the
special tool.

D4AF0118

Installation <D4AE, D4AF, D4AL>

1. Install the cylinder head assembly and rocker and bracket as-
sembly to align the locating pins.
2. Tighten the cylinder head bolts as the sequence shown in
illustratrion. Tighten step by step, and as a final step, tighten to
specified torque.
NOTE: 175 N·m (18 kgf·m)(Wet)
D4AF0119
Longer bolts are used at locations No.1, 6, 7, 14 and 15
shown above as these bolts are used to tighten the cylin-
<D4DA, D4DB>
der head together with the rocker shaft bracket.

147N·m(15kgf·m)
+ 90°(wet)

CW20-067-1

3. After the installation, adjust the valve clearance.

EM-24 ENGINE

Disassembly
1. Rocker and Bracket Assembly

Oil hole clogging

Wear, oil hole clogging 5
3
1

2
4 Thread damage Disassembly sequence
Deterioration
Oil hole clogging 1. Set bolt
2. Rocker shaft bracket
3. Rocker
4. Rocker shaft spring
Wear 5. Rocker shaft
Wear
D4AF0120

2. Cylinder Head Assembly

2 Wear
3
4 Ridged wear

5
Wear, damage Deterioration
6
Wear and damage 7
on both end faces
1

11
Carbon and scale deposits, Disassembly sequence
cracks, damage, water leak 1. Push rod
Corrosion 10 2. Valve cap
9 3. Valve cotter
Carbon deposits,
ridged wear, 4. Upper retainer
8
seizure,cracks, 5. Outer valve spring
damage 6. Inner valve spring
7. Valve stem seal
8. Intake valve
9. Exhaust valve
Wear, damage 12
10. Water director
11. Cylinder head
12. Tappet

D4AF0121
CYLINDER HEAD AND VALVE MECHANISM EM-25

1. To remove the valve cotter, use the special too(09222-83300)

and compress evenly the valve spring.
09222-83300

ECHA910B

2. Whenever the valve stem seal or valve is removed, the valve

Upper retainer
stem seal must be replaced with a new one.
NOTE Valve spring

The lower retainers are integral with the cylinder head. Valve stem seal

Valve

D4AF0124

3. Water director
Remove the water director if corroded. Water director

D4AF0125
EM-26 ENGINE

4. Cylinder head gasket Cylinder head gasket

"Up" mark
Caution
Check the cylinder head and crankcase damased or not

1) Place the gasket's "UP" mark on upper side.

Identification
of gasket
2) Choose the proper head gasket, considering the piston's
projecting dimension and assemble it.
JCW20129

<D4AL, D4AF, D4AE> Unit : mm <D4AL, D4AF, D4AE>

Average piston
Gasket size Gasket thickness Identification mark
dimension projected
A B C
0.467-0.528 A 1.35 ± 0.03
Not I·D mark
0.528-0.588 B 1.40 ± 0.03
0.588-0.649 C 1.45 ± 0.03

CUBEM005

<D4DA, D4DB> Unit : mm <D4DA, D4DB>

Average piston Identification mark

Gasket size Gasket thickness
dimension projected
0.466-0.526 A 1.35 ± 0.03
0.526-0.588 B 1.40 ± 0.03
0.588-0.648 C 1.45 ± 0.03

JCW20121
CYLINDER HEAD AND VALVE MECHANISM EM-27

Inspection
1. Rocker and Bracket Assembly

Set bolt

Clearance Rocker shaft

BD 19mm
Rear rocker shaft bracket
NV 0.06 to 0.11mm
L 0.2mm or less
No.4 Rocker shaft bracket

No.3 Rocker shaft bracket

Set bolt

No.2 Rocker shaft bracket

Rocker shaft spring

Rocker assembly BD ... Basic Diameter

NV ... Nominal Value
L ... Limit
Front rocker shaft bracket

D4AF0127

Using the rocker Inner Diameter(I·D) and rocker shaft Outer

Diameter(O.D) calculate the clearance. If the limit is exceeded,
replace the bushing in the rocker. For replacement, use Rocker
Bushing Puller (special tool).

D4AF2734

NOTE: Installation
Removal
1. Align the oil hole in the bushing with that in the rocker.
2. Ensure that the bushing clinch is on the adjusting
screw end.
Rocker Bushing Puller
3. When press-fitting the bushing into rocker, start with Bushing
Notch in bushing
the chamfered side on the rocker. Chamfered
Clinch
Bushing rocker face Buhing oil hole

Rocker oil hole D4AF0128

EM-28 ENGINE

2. Cylinder Head Assembly

Nominal value
(Basic diameter in[ ]) Limit
Description
D4AL D4DA D4AL D4DA
Outer valve Free length 60.84 66.1 57.8 63
spring Installed load 25.4kgf 27.9±1.4kgf 20.8kgf 23.7kgf
Outer valve spring Squareness 1.5° 2.5°
Inner valve Free length 55.07 60 52.1 57
spring Installed load 9.5kgf 12.1±0.6kgf 8.1kgf 10.3kgf
Squareness - - 2 2.5
*D4AL : D4AF, D4AE, D4AL *D4DA : D4DA, D4DB
Inner valve spring

Distortion of bottom surface

NV 0.05 or less
L 0.2
Valve seat width
NV 1.8 to 2.2
L 2.8
Height from top to bottom surface
NV 94.9 to 95.1
L 94.6

Valve sinkage from cylinder head bottem surface

Section D4AL, D4AF, D4AE D4DA, D4DB

BD ... Basic Diameter
BD Intake 0.75~1.25 0.75~1.45 NV ... Nominal Value
Exhaust 0.75~1.25 0.95~1.45 L ... Limit
Limit 1.5 1.5

NOTE :
If there is no unit indicated, its unit mean “mm”
D4AF0129
CYLINDER HEAD AND VALVE MECHANISM EM-29

1. Check the valve spring for squareness, free length, and proper
tension, and replace if the limit is exceeded. Squareness

Free length
D4AF2701

2. Tappet to Crankcase Clearnace

Measurng position
If the tappet to crankcase clearance exceeds the limit, replace
the tappet.

D4AF2745

Measuring position

D4AF0131

3. Measure the push rod runout. If the limit is exceeded, replace.

NOTE
When a dial gauge is used in the measurement, the runout
is a half of the gauge reading.

D4AF2747

4. If the distortion of cylinder head bottom surface exceeds the Measuring position
limit, correct with a surface grinder. If the cylinder head height
from top to bottom surface is below the limit, replace.

D4AF0132
EM-30 ENGINE

5. Measure the valve stem Outer Diameter(O.D) and, if the mea- Measuring position
surement value is below the limit, replace.

D4AF3102

6. Calculate the clearance with the valve guide Inner Diameter(I. Measuring position
D) and valve stem Outer Diameter(O.D). If the limit is exceeded,
replace the valve guide.

D4AF0133

7. For removal of the valve guide, use the special tool (09221- Removal
41100). 09221-41150

To install, use the special tools(09221-41100,09221-41150) and 09221-41100

ensure that the special tool is positively seated on the cylinder 09221-41100

head. The pressing depth is specified for the valve guide, which
must be reached by using the special tool.

D4AF0134

8. Check the contacting condition of the valve seat and valve,

after inspection and replacment of the valve guide.
When the valve is pressed aginst the valve seat coated with
red lead, make sure that the valve is not turned.

Good Defective Defective

D4AF2707

9. To correct the valve face, grind the valve face with a valve
refacer. The grinding dimension should be limited to a minimum.
NOTE
1. The valve seat angle is 45°.
2. Correct to ensure that the valve margin is up to the
limit.

D4AF2708
CYLINDER HEAD AND VALVE MECHANISM EM-31

10. To correct a valve seat, grind with a valve seat cutter or valve
seat grinder.
After grinding, hold a #400 or similar sand paper between the
cutter and valve seat and regrind lightly.
NOTE
1. The valve seat angle is 45°
2. Correction must be made to ensure the valve seat width
and valve sinkage are within the limit. D4AF3106

11. Using a 15°or 75° cutter, correct the seat width to the nominal Valve
Sinkage Valve seat angle
value. margin

Seat the valve and valve seat.

Seat width

Valve seat
Valve D4AF2710

12. The valve seat is cold fitted. Replacement procedure is given

below.
Grind the valve seat from inside to reduce the wall thickness.
Then, remove it at normal temperature.

Cut here 0.5 to 1.0mm

D4AF2711

13. Check if there is sufficient interference between the cylinder

head and valve seat.
Dip the valve seat into liquid nitrogen and let it cool down. But
heat the cylinder head sufficiently.
Intake Exhaust
side side
Head I.D. Head I.D.
+0.025mm +0.025mm
46 0mm 46 0mm

I·D : Inner Diameter D4AF2737

14. Using Caulking Tool Body and Caulking Ring (special tools),
Installation Caulking
install the valve seat.
Caulking Tool
Body
NOTE Caulking Ring
After pressing in position the valve seat with the cham-
Chamfered
fered side of the Caulking Ring, face the Ring in the oppo- side
site direction to caulk the cylinder head.
Reface the valve seat to obtain the nominal values for the D4AF0135

seat width and valve sinkage.

EM-32 ENGINE

15. Reface the valve seat to obtain the nominal values for the seat
width and valve sinkage.
The valve and valve seat must be in even contact throughout
the surfaces. Seat width
Whenever the valve or valve seat is corrected or replaced, they
must be seated.

Valve sinkage
D4AF2714

16. Apply a thin coat of compound evenly to the seating surface of

the valve.

CAUTION
1. Make sure that there is no compound on the stem of
the valve. Compound
2. Use intermediate mesh compound (120 to 150 meshes)
first and then use fine mesh compound (200 meshes
or more) for the finish. D4AF2715

3. Mix the compound with a small amount of engine oil

and the compound can be applied evenly.

17. Using a valve lapper seat the valve on valve seat.

While turning the valve slightly at a time, strike it against the
valve seat.
Valve Lapper
Wash off the compound with gas oil or similar object.
Valve
Seat the contact surfaces with engine oil.
Check if they are properly seated.

D4AF3310
CYLINDER HEAD AND VALVE MECHANISM EM-33

Reassembly
Rocker and Bracket Assembly

2 1 3 5 4

Apply engine oil to bushing

Locating pin

Assembly sequence

5→2→3→4→1
D4AF0136

Cylinder Head Assembly

4 2 3 Crowded coil down

Blue paint
1 5
6
7

Apply engine
oil
Assembly sequence NV ... Nominal Value

9→8→7→6→5→4→3→2→1

For assembly of parts with an encircled number, see following

pages. D4AF0137
EM-34 ENGINE

1. Install the water director with its cut facing toward the specified
direction.
Water director

Water director
groove direction

D4AF0140

2. To install the valve stem seal, apply engine oil to seal lip, then
strike the seal with the special tool (09222-45100) until the In- 09222-45100
staller touches to the cylinder head. Valve
Apply engine oil
Valve stem seal

D4AF6621

3. To install the valve cotter, use the special tool (09222-83300)

to compress the valve spring.
09222-83300
CAUTION
When compressing the valve spring, do not allow the up-
per retainer to be in contact with the valve stem seal.

ECHA910B
FLYWHEEL AND REAR PLATE EM-35

FLYWHEEL AND REAR PLATE

Disassembly and Inspection

4 Streaks on friction surface,

ridged wear, cracks, damaged gear,
excessive wear
1
Rotating condition
<D4DA, D4DB> 2

Wear, dmage, deterioration

Oil leaks 3
4

Friction surface distortion

NV 0.05 mm or less
L 0.1 mm
Height to friction surface
NV 22.8 mm
L 21.8 mm

<D4AL, D4AF, D4AE>

Disassembly sequence
1 Flywheel
2. Pilot bearing
3. Oil seal
4. Rear plate
For disassembly of parts with an encircled number, see follwoing pages.
CW20-099

Inspection
1. Replacement of Flywheel Ring Gear
To remove, use an acetyline torch or similar device and evenly
heat the ring gear.
By applying a protective rod, hammer the entire periphery of
the ring gear, forcing it off. Chamfered
To install, heat the ring gear with piston heater (approx. 100°C)
for three minutes. D4AF3501

Fit the ring gear onto the flywheel with the nonchamfered side
of tooth crests toward the flywheel.
EM-36 ENGINE

2. Friction Surface Distortion

Place the flywheel on a surface plate and move a dial indicator
Dial indicator
over the flywheel friction surface to measure the distortion.
Surface plate
For more accurate measurement, use a portable jack. Flywheel

If the distortion is beyond the limit, regrind the friction surface.

NOTE
If the ring gear develops any unusual condition, replace it
with a new one before taking a measurement. D4AF3502

3. Correction of Friction Surface

Correct the friction surface with a surface grinder.
Parallelism
Make sure that the friction surface is parallel to surface A within 0.1 or less
0.1mm.
NOTE
After correction, make sure that the height of the friction Surface A
B
surface (dimension B) is within the limit.

D4AF2355

Reassembly

4
5 Oil seal side

2
Install with "UP" mark
Apply engine oil to lip

59 N·m (6 kgf·m)<D4AF, D4AE, D4AL>

64N·m(6.5kgf·m)<D4DA, D4DB>
1

3
NV ... Nominal Value
123N·m(12.5 kgf·m)<D4AF, D4AE, D4AL> L ... Limit
39N·m(4 kgf.m) + 40° <D4DA, D4DB>
4

Reassembly sequence
5→4→3→2→1
Friction surface runout (as installed)
NV 0.1 mm or less
L 0.2 mm

D4AF0146
FLYWHEEL AND REAR PLATE EM-37

1. Installation of the rear oil seal slinger using the special tool
19.7 Rear oil seal slinger
(09211-41000)
09211-41000

Crank shaft CW20-104

2. Apply liqued gasket to the side of the oil seal and install the oil <D4AF, D4AE, D4AL>
seal.

CAUTION
After installing the rear plate and install the rear oil seal.

123N·m(12.5kg·m) CW20-106

3. Installation of flywheel <D4DA, D4DB>

Install the flywheel onto the crankshaft and tighten bolts to speci-
fied torque.
Measure runout (installed position) of the flywheel.
If the dial indicator deflects cover the limit, check bolts for loose-
ness or mounting surface. 39N·m(40kg·m)±40°

CW20-105
EM-38 ENGINE

TIMING GEAR AND CAMSHAFT

Disassembly

<D4AE, D4AF, D4AL>

5
9
4

Damper pulley (for bus)

60kg·m

Disassembly sequence
1. Crankshaft pulley
2. Timing gear case
3. Oil seal
4. Ider gear
5. Idler shaft
6. Camshaft gear
7. Thrust plate NV ... Nominal Valve
8. Camshaft L ... Limit
9. Front plate
CUBEM019
TIMING GEAR AND CAMSHAFT EM-39

<D4DA, D4DB>

T= 30 N·m Injection
(3 kgf·m) pump gear
4 Camshaft
10 18

9
18
5 13
17
7

Oil pump gear Crankshaft gear

13 Injection pump gear

12

16

Crankshaft gear
2 15
11
24 N·m
(2.4 kgf·m) 14
Front oil seal slinger
3 Key

600 N·m 1
(60 kgf·m)

Disassembly sequence
1. Dumper pulley(for bus) 7. Vacuum pump assembly 13. Idler gear assembly
2. Crankshaft pulley 8. Front oil seal 14. Idler gear push
3. Bolt 9. Bearing 15. Idler gear
4. Engine revolution sensor 10. Timing gear case 16. Idler shaft
5. O-ring 11. Bolt 17. O-ring
6. O-ring 12. Thrust plate 18. Power steering oil pump

NOTE
Remove front oil seal and bearing only when it is damaged.

JCW20108
EM-40 ENGINE

Disassembly of Camshaft

<D4DA, D4DB>

12

11
13
10

8 9
2

6
1 7

5
4
3

Disassembly sequence
1. Bolt 8. No.1 Camshaft bush
2. Camshaft assembly 9. No.2 Camshaft bush
3. Bolt 10. No.3 Camshaft bush
4. Camshaft gear 11. No.4 Camshaft bush
5. Thrust plate 12. Seal cap
6. Key 13. No.5 Camshaft bush
7. Camshaft

NOTE
Do not remove camshaft gear when it is not bad. JCW20109
TIMING GEAR AND CAMSHAFT EM-41

1. If the crankshaft pulley flange or crankshaft pulley are hard to

remove, use the special tool(09431-83100)

09431-83100

Crankshaft pulley
D4AF0152

2. Do not remove oil seal unless abnormal condition is evident.

Timing gear case

Oil seal D4AF0153

3. Measurement of backlash
Measure the backlash between gears and replace if the limit is
exceeded.
NOTE
1. For a pair of gears, the backlash must be measured at
more than three points to determine the condition.
2. When measuring the backlash in injection pump gears,
D4AF0153
keep the pump fixed onto the front plate.

4. Measurement of end play

Measure the end play of the idler gear and camshaft with a
thickness gauge or dial indicator. If the measurements exceed
the limit, replace the parts.

D4AF0155
EM-42 ENGINE

5. Removal of camshaft gear <D4AE, D4AF, D4AL>

Thrust plate
attaching bolt
1) Accessing through the holes in camshaft gear, loosen the
thrust plate attaching bolts. Then, remove the gear together
with the camshaft.

Camshaft gear
D4AF0157

<D4DA, D4DB>

Bolt
Camshaft gear

Camshaft

JCW20115

2) To remove, use the special tool(09431-83100).

CAUTION
1. Do not remove the gear unless defect is evident.
2. For removal, never attempt to tap the gear with a
hammer. Plug

09431-83100
D4AF0158

Inspection
1. With the idler gear Inner Diameter(I.D) and idler shaft Outer
Diameter(O.D),calculate the clearance. If the limit is exceeded,
replace the bushing in the idle gear.

D4AF0161

D4AF0162
TIMING GEAR AND CAMSHAFT EM-43

2. Replacement of Idler Gear Bushing Removal Installation

Using the special tool(09246-41000), replace the idler gear

bushing. See illustration for procedure.
09246-41000
NOTE Bushing
1. When installing the bushing, align the oil hole in bush- oil hole
ing with that in idler gear. Idler gear

2. After installation, make sure that the bushing to idler

shaft clearance is within nominal value. If the clear- Idler gear bushing Idler gear oil hole
D4AF0163
ance is below specification, ream the bushing.
3. Measure the base circle diameter and lobe height of each cam.
If the difference between them is below the limit, replace. Measurement point
NOTE
Since the taper cam is used, ensure that the measurement Cam lobe
Front height
is taken at the location indicated in illustration.
A B A B Basic diameter
D4AF, D4AE, D4AL 5.5mm 5.5mm
D4DA, D4DB 6.5mm 6.5mm D4AF4101

4. Measure the camshaft journal Outer Diameter(O.D) and crank-

case Inner Diameter(I.D) If the limit is exceded, replace the
bushing in the crankcase.

D4AF4102

D4AF2398
EM-44 ENGINE

5. Replacement of Camshaft Bushing

Camshaft
To remove the bushing, first remove the sealing cap through bushing
09212-41200
the camshaft hole in the rear-end face of the crankcase. Then,
using the special tool(09212-41200), remove camshaft bushing
1) D4AF, D4AE, D4AL

Bushing No.
(From the Stamped number Outer diameter D4AF0165
front of engine)
No.1 1 ø58.5 Number is stamped here
No.2 3 ø58
No.3 5 ø57

2) D4DA, D4DB

Bushing No.
(From the Stamped number Outer diameter
front of engine)
D4AF0166
No. 1 1 58.5mm
No. 2 2 58.25mm Make camshaft
bushing end face
No. 3 3 58.0mm Camshaft bushing flush with
crankcase
No. 4 4 57.75mm 09212-41200 end face.

No. 5 5 57.0mm

6. When installing the bushing, identify bushings with a unique

Oil hole (ø8)
number stamped on the external surface, indicating the instal- Align with oil
hole in crankcase D4AF0167
lation position.
If the number is illegible, determine by mesuring the Inner Diameter
(I.D) and width.

1) D4AF, D4AE, D4AL

Bushing No.
(From the No.1 No.2 No.3
front of engine)
Inner diameter 54.5mm 54.5mm 53mm
Width 41mm 21mm 21mm
Stamped number 1 3 5

2) D4DA, D4DB Unit : mm

Bushing No.
(From the No.1 No.2 No.3 No.4 No.5
front of engine)
Inner diameter 54.5 54.5 54.5 54.5 53
Width 33 21 21 21 21
Stamped number 1 2 3 4 5

Then, using the special tool(09212-41200), press-fit the

bushings.
TIMING GEAR AND CAMSHAFT EM-45

7. Measure the bend of camshaft. If the limit is exceeded, replace.

NOTE
Rotate the camshaft a turn and read the deflection of the
D4DA, D4DB
dial indicator pointer.
One half of the reading is bent.
Standard valve : 0.02 mm(0.0008 in.) or less
Camshaft bend measurement
D4AF0168

Reassembly <D4DA, D4DB>

“F” mark
1. Install the thrust plate with the oil hole for the gear. Washer
Camshaft gear

Thrust plate

Camshaft

CW20-126

2. Installation of Camshaft Gear <D4DA, D4DB> Push

“2”
After mounting the thrust plate, install the camshaft gear with
its number marking side facing outward. Camshaft gear

NOTE
Install camshaft gear after checking the key (D4DA , D4DB Camshaft
Key
engine)

JCW20127

3. Check the camshaft end play. Then, install the camshaft into
the crankcase.

D4AF0172

4. Installation of the idler gear <D4AE, D4AF, D4AL>

Idler gear
When installing the idler gear, keep the surface which is printed Injection pump
Camshaft
gear
numbers on outward and assemble the crankshaft “1”, the cam- gear

shaft “2” and the injection pump “3”.

Camshaft
gear
CUBEM101
EM-46 ENGINE

<D4DA, D4DB>
Idler gear
Camshaft Injection pump
gear gear

Camshaft
gear
CUBEM102

5. Check gears for backlash. <D4AE, D4AF, D4AL>

Oil seal
CUBEM103

6. Apply lithium-base grease to the oil seal lips. <D4DA, D4DB>

Oil seal
CUBEM104

7. Assembly of the timing gear case <D4AL, D4AF, D4AE>

Fix up the case within three minutes after putting a seal on the
ø1mm
assembly-surface as illustrated. Sealant

CAUTION
Do not switch on the ignition within one hour after the
assembly.

CUBEM105

<D4DA, D4DB>
ø1~1.5mm

Sealant

CUBEM106
CRANKCASE AND MAIN MOVING PARTS EM-47

CRANKCASE AND MAIN MOVING PARTS

Disassembly

<D4AF, D4AE, D4AL>

4
5 Breakage, damage
Damage, 6
discoloration
8
3
7 Carbon deposits,
cracks, scratches
Cracks,oil hole on outer surfaces,
clogging discoloration
End play 9
NV 0.15 to 0.45
L 0.6 Do not remove from connecting
rod except for replacement
Scratches on inner 2
and outer surfaces,
flaking, corrosion
Corrosion, scale deposits,
cracks, damaged threads,
oil hole clogging 17
End play
NV 0.10 to 0.26
L 0.4
14 Scratches, cracks,
Scratches on inner and 16 dents, seizure,
outer surfaces, oil hole clogging
corrosion, flaking

Tooth
surface wear
15
11 Wear
Disassembly sequence
1. Connecting rod cap
2. Connecting rod bearing 13 12
Scratches on inner
3. Piston and outer surfaces,
4. 1st compression ring corrosion, flaking 103N·m(10.5kgf·m)
5. 2nd compression ring
Scratches on inner 2 10
6. Oil ring
and outer surfaces,
7. Snap ring corrosion, flaking 1
8. Piston pin
9. Connecting rod
10. Main bearing cap
11. Thrust plate
12. Side seal NV...Normal Value
13. Lower main bearing L ... Limit
14. Crankshaft
15. Crankshaft gear
NOTE:
16. Upper main bearing
If there is no unit indicated, its unit means “mm”.
17. Crankcase
D4AF0176
EM-48 ENGINE

<D4DA, D4DB>

3 1

4
24 2

22

21

20

12

23

14

6 13

7 11
18 10 5
19 49N·m(5kgf·m)+90°
17 9 Non-reusable
8
16
15

Disassembly sequence
1. Bolt 9. No. 3 main bearing cap 17. Key
2. Rear oil seal 10. No.4 main bearing cap 18. Rear oil seal slinger
3. Bolt 11. Rear main bearing cap 19. Crankshaft
4. Rear plate 12. Thrust plate 20. Upper main bearing
5. Main bearing cap bolt 13. Side seal 21. Front plate
6. Lower main bearing 14. Crankshaft assembly 22. Gasket
7. No.1 main bearing cap 15. Front oil seal slinger 23. Check valve
8. No. 2 main bearing cap 16. Crankshaft key 24. Crankcase

Caution
Do not remove the crankshaft gear when it is not bad.
JCW20137
CRANKCASE AND MAIN MOVING PARTS EM-49

Piston and connecting rod assembly

<D4DA, D4DB>

11
12
13

8
7 14 Piston's projected dimension
Projection Projection Projection
0.466~0.526 A 1.35±0.03
10
0.526~0.588 B 1.40±0.03
9
0.588~0.648 C 1.45±0.03

End play
5 NV 0.15 to 0.45
L 0.6
15

Crank case

Crankshaft
End play
NV 0.10 to 0.26
L 0.4 3
4
29N·m(3kgf·m) 2

NV...Normal Value
1
L ... Limit

Disassembly sequence
1. Oil pan 9. Connecting rod push
2. Bolt 10. Connecting rod
3. Lower connecting rod bearing 11. No.1 compression ring
4. Connecting rod cap 12. No.2 compression ring
5. Upper connecting rod bearing 13. Oil ring
6. Piston and connecting rod assembly 14. Piston
7. Snap ring 15. Cylinder sleeve
8. Piston pin

NOTE:
If there is no unit indicated, its unit means “mm”.
JCW20137
EM-50 ENGINE

Disassembly
1. Piston Projection
Incorrect piston projection adversely affects the engine performance. Measurement points
If measurements are out of specification, check parts for clearance.
1) Hold the dial indicator on the crankcase top surface to make
zero adjustment.
2) Locate the piston TDC with the dial indicator.
3) Measure projections at three points on the piston top sur-
face to obtain the average value. D4AF0177

2. Measure the end play of each connecting rod. If the limit is

exceeded, replace the connecting rod.

D4AF0178

3. Removal of Piston
Withdraw the piston from the crankcase, pushing it up together Piston pin
with the connecting rod. Snap ring

NOTE
1. If the piston pin is hard to remove, heat piston with a
piston heater or hot water.
2. Do not remove the connecting rod bolts from the con- Connecting rod
necting rod unless defective. Connecting
If the bolt is damaged, install a new connecting rod rod bolt D4AF0179
bolt.
4. Removal of Piston Ring
To remove the piston rings, use the special tool(09222-83200)

09222-83200

D4AF0180

5. Crankshaft end play

If the end play exceeds the limit, replace the thrust plate with
an oversize.
Three oversize thrust plates are available:
+0.15, +0.30 and +0.45
NOTE
The thrust plates on both ends of the bearing cap need
not be of the same size; however, use the one of the same D4AF0181

size for those at the rear end of the crankcase and in rear
of the bearing cap.
CRANKCASE AND MAIN MOVING PARTS EM-51

6. To remove the front and rear end bearing caps, use the special
tools(09212-41000, 09450-75100).

7. Intermediate position 09450-75100

To remove the main bearing cap, use the special tools(09212-
09212-41100
41100, 09450-75100)

D4AF0184

8. Removal of crankshaft gear

09431-83100
To remove the crankshaft gear, use the special tool(09431-
83100).
NOTE
It is not necessary to remove the crankshaft gear unless
defect is evident.

D4AF0185

Inspection Crankcase A: Crankshaft direction

Cylinder sleeve B: Direction perpendicular
1. Measurement of cylinder sleeve inner diameter. to crankshaft
Measure the cylinder sleeve inner diameter at the six points D1 20mm or more
shown in illustration.
If the inner diameter exceeds the limit, replace or bore to D2
A B
oversize.
If the cylinder sleeve is to be used without being bored, grind the D3
ring ridge at its top with a ridge reamer.
60mm or more
D4AF0188

2. Replacement of cylinder sleeve

With a boring machine fixed in the crankcase, center the
machine. Make sure that the machine is centered at the bottom
of the the cylinder sleeve which develops uneven wear least. X
Bore until the wall thickness is reduced down to approximately
0.5mm. Make round.
Insert a screwdriver (machined as illustrated) between the
crankcase and cylinder sleeve. Tap the screwdriver to break View X
and remove the sleeve.
Make sure that the rounded part of the screw driver faces to the D4AF4406

case.
EM-52 ENGINE

After the cylinder sleeve has been removed, check the crank- A: Crankshaft direction
case sleeve hole for damage and proper interference. If denfects B: Direction perpendicular
are evident, bore the crankcase sleeve hole. D1 15 to crankshaft

For measurement of interference, measure the cylinder sleeve

outer diameter and crankcase sleeve hole inner diameter at the D2 Cylinder A B
sleeve
positions indicated in illustration. Calulate the average value of
the measurements in the vertical (D1, D2, F3) and diametrical Crankcase
(A, B) directions. If the interference exceeds the limit, bore the D3
15mm
crankcase sleeve hole to oversize.
D4AF0189

1) When crankcase sleeve hole interference is sufficient, using

the special tool(09211-42100) and hydraulic press (sleeve
09211-42100
installation load : 4.7 to 9 ton), install the standard cylinder
sleeve into the crankcase. During installation, ensure that
the chamfered side of the sleeve faces down and the sleeve
top surface is flush with the crankcase top surface.
2) After installing the cylinder sleeve, obtain the nominal dimen-
sion for inner diameter and finish 3.2-S by honing operation. D4AF0190

3) When crankcase sleeve hole inteference is insufficient,

ready an oversize cylinder sleeve with a 0.5mm larger outer
diameter Hone the crankcase sleeve hole to 8S to obtain
the nominal value for the interference between the cylinder
sleeve outer diameter and crankcase sleeve hole.
4) Using the special tool(09211-42100), install the cylinder sleeve
into the crankcase. After installation, obtain the nominal value
for the cylinder sleeve inner diameter and hone the surface to
3.2-S.
NOTE
1. When boring the crankcase sleeve hole, remove
sleeves from all cyliders and bore to roundness
2. Before installing the sleeve, apply spindle oil
(MECHANIC #32 or equivalent) to the crankcase
sleeve hole.
An oversize must be determined in consideration
of the part developing the most serious wear from
all cyliner inner diameter measurements.
3. Available oversizes (4 types) :
+0.25, +0.5, +0.75, +1.00 mm Crankcase A: Crankshaft direction
Cylinder sleeve B: Direction perpendicular
5) Using a micrometer, measure the outer diameter of indi- to crankshaft
vidual oversize pistons to be used. D1 20 mm or more

Bore and hone the cylinder sleeve to obtain the nominal D2 A B

value for the cylinder sleeve to piston clearance.
D3
CAUTION
1. Even if only one cylinder requires boring, make sure 60 mm or more
D4AF0188
that all cylinders are bored to the same oversize.
2. Replace the piston and the piston rings with the
corresponding oversizes.
CRANKCASE AND MAIN MOVING PARTS EM-53

3. Crankcase top surface distortion

If distortion of crankcase top surface exceeds the limit, correct
with a surface grinder.
Measurement points
NOTE
Crankcase must be ground only to the extent that the
piston projection does not exceed the nominal value.

D4AF4417

4. Piston outer diameter

Outer diameter measurement position
1) Measure the piston skirt outer diameter and calculate the
70.65 mm
clearance with the smallest cylinder sleeve inner diameter (D4AL, D4DE)
measurement [See1]. If the limit is exceeded, replace the 72.15 mm
(D4DA, D4DB)
crankcase, cylinder sleeve, or piston. 86.7mm (D4AF)

NOTE
1. If a piston is replaced, replace also the piston ring.
D4AF0191

2. If piston to piston ring clearance exceeds the limit,

replace the piston ring or piston.
3. Remove carbon and measure the clearance
thoughout the entire periphery of the piston.
4. Replace piston rings as a set.

D4AF0192

2) For the 1st compression ring, press the ring against the
piston with a straight edge.
Piston

Thickness gauge
Ring
Straight edge
D4AF4810

3) To measure the piston ring gap, place piston rings into a

standard or new cylinder sleeve by using a piston.
If the limit is exceeded, replace.
Standard inner diameter :
104~104.03mm(D4DA, D4DB, D4AF)
100~100.03mm(D4AE, D4AL)

Level piston ring D4AF0193

EM-54 ENGINE

4) If piston to piston pin clearance exceeds the limit, replace Piston

the piston pin or piston.

Piston pin

D4AF4811

5. Piston pin to connecting rod clearance Connecting rod

If the limit is exceeded, replace the connecting rod bushing.

Piston pin

D4AF0194

6. Replacement of connecting rod bushing

1) To remove bushing, use the special tool(09235-41100).

09235-41100

Bushing
D4AF0195

2) With the connecting rod bearing removed from the con- Approx. 49 kN (5tons)
necting rod big end, secure the connecting rod to the spe- 09235-41100
cial tool(09235-41000).
Set the special tool(09235-41100) onto the connecting rod Bushing
small ends as illustrated above and gradually apply force Fixing bracket

with a press.

09235-41000 D4AF5218

3) To press-fit the bushing, insert the bushing into the special Approx. 49 kN (5tons)
tool(09235-41100).
Apply engine oil to the bushing and connecting rod. 09235-41100
Oil hole
Press-fit the bushing into the connecting rod.
NOTE Bushing
1. When press-fitting the bushing into connecting rod, Chamber
start with the chamfered side on the connecting
rod. D4AF0196
CRANKCASE AND MAIN MOVING PARTS EM-55

2. When installing the bushing, make sure that the oil

hole in bushing is aligned with that in the connect-
ing rod.
3. After the piston pin has been inserted, make sure
that there is no excessive play and it turns
smoothly.

7. Bend and twist of connecting rod

C
1) Measurement of bend Connecting rod
aligner
100

Piston pin

D4AF5206

2) Measurement of twist
C
Measure with connectin rod aligner (special tool). If the limit
is exceeded, replace or correct with a press.
NOTE 100
1. Measure with the bushing and connecting rod bear-
Piston pin
ing installed in the connecting rod.
Connecting
2. The connecting rod and connecting rod cap must rod aligner
also be tightened to specified torque in measuring. D4AF5208

8. Connecting rod bearing tension

Measure the tension of the connecting rod bearing when free
and, if the measurement falls short of the limit, replace the up-
per and lower bearings as a set.
CAUTION
Never attempt to expand the bearing for reuse.

D4AF5209
EM-56 ENGINE

9. Connecting rod bearing to crankshaft clearance Measurement Measurement

directions positions
If the limit is exceeded, replace the upper and lower connect-
ing rod bearing as a set.

D4AF5214

Measurement Measurement
directions positions
D4AF5514

10. Main bearing to crankshaft clearance

If the limit is exceeded, replace the upper and lower main bear-
ings as a set.

D4AF0198

Measurement Measurement
directions positions D4AF5215

11. Main bearing tension

Measure the tension of the main bearings when free.
If the measurements are below the limit, replace the upper and
lower main bearings as a set.
CAUTION
Never attempt to expand the bearings for reuse.

D4AF5504
CRANKCASE AND MAIN MOVING PARTS EM-57

12. Roundness and cylindricity of crankshaft

Determine roundness and cylindricity of the crankshaft based
on measurements of journal and pin outer diameters If the limit
is exceeded, grind to undersize.
Roundness of pins and journals :
Standard value : 0.01 mm or less, Limit : 0.03 mm
Cylindricity of pins and journals :
Standard value : 0.006 mm or less, Limit : 0.03 mm D4AF5515

13. Crankshaft bend

If the limit is exceeded, replace.
NOTE
Read the crankshaft center journal runout with a dial indi-
cator. One half of the reading is the bend.
Crankshaft bend :
Standard value : 0.02 mm or less, Limit : 0.05 mm
D4AF5515

14. Correction of crankshaft to undersize

Pin Journal Unit : mm
±0.2
A 0 B
Item Normal Value
C±0.2

A 41mm C±0.2

B 35mm D±0.05

C R4
D4AF, D4AE, D4AF 52.5
D
D4DA, D4DB 57.5 Shore hardness Hs 75 or more D4AF0200

If a journal or pin is damaged or seized, grind the crankshaft by Grinding Finishing

using the following procedures.
Replace the bearing with an undersize.
1) During grinding, use care not to change the center distance
of journal and pin.
Grindstone or sandpaper
2) Use care also not to change the width of journal and pin.
Grinder
3) Finish the fillet smooth to the specified radius. Crankshaft
4) Check for grinding cracks by the magnetic particle inspec- D4AF5509
tion method. Make also sure that the surface hardness
(Shore hardness Hs 75 or more) has not decreased.
5) When grinding the crankshaft with a grinder, the grinder
and crankshaft must be turned counterclockwise as viewed
from the crankshaft front end.
6) To finish the crankshaft with a grindstone or sandpaper,
turn the crankshaft clockwise.
EM-58 ENGINE

Crankshaft undersize dimensions Unit : mm

Journal outer diameter finish dimension Pin outer diameter finish dimension
Undersize Out-of-rundness Cylindricity
#1, #2, #4, #5 #3 <D4AE,D4AF,D4AL> <D4DA, D4DB>
0.25 77.68 ~ 77.70 77.66 ~ 77.68 59.695 ~ 59.715 64.69 ~ 64.71 0.01 or less 0.006 or less
0.50 77.43 ~ 77.45 77.41 ~ 77.43 59.445 ~ 59.465 64.44 ~ 64.46
0.75 77.18 ~ 77.20 77.16 ~ 77.18 59.195 ~ 59.215 64.19 ~ 61.21
1.00 76.93 ~ 76.95 76.91 ~ 76.93 58.945 ~ 58.965 63.94 ~ 63.96

Reassembly Lug
Oil hole
1. Install the thrust plate and upper main bearing to the crankcase. Upper main bearing
CAUTION Crankcase
1. Install the thrust plate with its side having no oil groove
toward the crankcase. Lug groove
2. Line up the lug of main bearing with the lug groove in
Pin hole
crankcase. Note that the upper main bearing has an oil Oil groove
hole, which must not be confused with the lower. Thrust plate Thrust plate
attaching pin D4AF0212
3. Apply engine oil to all sliding surfaces.
2. Installation of crankshaft gear
Crankshaft gear
When the crankshaft gear was removed, it must be heated with
a piston heater or similar device before being reinstalled onto
the crankshaft.

D4AF0213

3. Installation of main bearing cap Embossed number

Main bearing cap
1) Fit the lower main bearing into the main bearing cap. Oil groove side Thrust plate
At the time, make sure that the main bearing lug is aligned attaching pin
Lower main bearing Thrust plate
with the main bearing cap lug groove. Lug Oil groove
Install also the thrust plate onto the main bearing cap in
Apply sealant
the rear-end position. (THREEBOND 1105D
or equivalent)
Make sure that the main bearing cap lug groove and crank-
case lug groove are on the same side. Ensure also that the D4AF0214
embossed numbers on main bearing caps are in ascend-
ing order from the front of engine.
NOTE
1. Face the side of thrust plate having no oil groove
toward the main bearing cap.
2. Use thrust plates of the same size for the crank-
case and main bearing cap rear end.
3. Apply sealant to the crankcase front and rear sur-
faces onto which bearing caps are mounted.
CRANKCASE AND MAIN MOVING PARTS EM-59

2) Tighten the main bearing cap bolt to specified torque. <D4AF, D4AE, D4AL>
Then, make sure that the crankshaft turns smoothly by hand.
175 N·m (18 kgf·m) (Wet)
Measure the crankshaft end play to determine if it is within
the nominal value.

D4AF0215

NOTE <D4DA, D4DB> 5N·m (6 kg·m)+90°

Before tightening bearing cap bolt, mark the tighten- Crankshaft
ing number of bolt so as not to use more than 2 times.

JCW20176

4. Installation of side seal Side seal

Install the side seal with sealant applied to its end. Cap
end
Then, apply sealant to the bearing cap.
Apply sealant
(THREEBOND 1105D or
NOTE equivalent) to ends
When installing the side seal, ensure the correct installa- Apply sealant
(THREEBOND 1105D
or equivalent) after
tion direction. installing side seals

D4AF0216

5. Reassembly of piston and connecting rod

Weight mark
1) Assemble the piston and the connecting rod, ensuring cor-
rect direction as illustrated. Front mark

Insert the piston pin to couple the piston and connecting

rod. Mount the snap ring to hold the piston pin in position.
Apply engine oil
The piston pin is a clearance fit in the position. If the piston pin
is hard to fit, heat the piston with a piston heater or hot water.
CAUTION
1. The parts for an engine must be of the same weight
mark.
2. Apply engine oil to all sliding surfaces. Alignment mark side
Weight
Weight marks identification(I·D) mark
Weight(gr.)
M L K J H N O Lug side
D4AF 1745-1764 1725-1744 1705-1724 1685-1704 1665-1684 - - indicating
protrushion Lug
D4AE, D4AL 1700-1719 1680-1699 1660-1679 1640-1659 1620-1639 - -

D4DA, D4DB 1961-1980 1941-1960 1921-1940 1901-1920 1881-1900 1981-2000 2001-2020 D4AF0217
EM-60 ENGINE

2) The connecting rod bolts do not normally need removal; <D4AF,D4AE,D4AL> Press-fit with apress.
Max. 4.9kn (500 kgf)
however, where replacement is necessary for damaged bolt, Face top groove
install new bolts by using the following procedures. inside
Apply
Make sure that the connecting rod bolt hole is free from engine oil
damage and burrs. Then, with engine oil applied to the con-
necting rod bolt, press it into position with a press. [Pressing
load: Max. 4.9 kN (500 kgf)]
Check for scratches
and burrs
NOTE D4AF0220

Install the connecting rod in D4DA, D4DB engine, the

way of assembling bolts is the same as others but the <D4DA, D4DB>

direction is opposite.
Connecting rod

Connecting rod cap

3kgf·m + 90°
EEEE008A

6. Installation of piston rings

1) To install piston rings, use the special tool(09222-83200).
NOTE
A manufacturer's mark is stamped near the piston ring
ends. Install with the mark up.

09222-83200

D4AF0180

2) Direct the open ends of piston ring as shown.

Oil ring expander 1st compression
spring butt joint ring ends

Front of engine

2nd compression Oil ring ends

ring ends
D4AF0221

7. Installation of piston and connecting rod assembly.

Fit the upper connecting rod bearing into the connecting rod
and install the piston into the crankcase with the special tool 09222-83200

(09222-83200).
NOTE
1. Face the position mark on the lug end toward front of
engine.
2. Make sure that the piston ring ends position does not D4AF1323
change during installation.
3. Cover the connecting rod bolt with a vinyl hose so as
not to damage to crankshaft pins.
CRANKCASE AND MAIN MOVING PARTS EM-61

8. Using the piston guide(09222-83200).

1) Align the piston guide to piston skirt, insert lever in that
position and adjust the bolt of piston guide to align the in-
ner diameter of clamp with piston's outer diameter.
2) After adjusting, remove piton guide from piston and apply
engine oil to piston, piston guide and piston sleeve.

Adjudtment bolt
JCW20183

3) After applying engine oil, set the top surfaces of piston guide
and piston at the same level and then hit hte top of piston
with rubber hammer.

JCW20184

9. Fit the lower connecting rod bearing to the connecting rod cap 100Nm(10.5kgf·m) : D4AF, D4AE, D4AL
30Nm(3kgf·m)+90 : D4DA, D4DB
and tighten the connecting rod to specified torque.
CAUTION
The lug sides of the connecting rod and connecting rod
cap must be in the same direction.
10. Check the connecting rod end play.

D4AF0224

11. Check the projected dimension of piston.

The improper projected dimension of piston cause the engine
performance bad.
Measurement
1) If the dimension is out of specified standard value, check points
Crankcase
the parts gap
2) To adjust the zero point, install the dial indicator on the up-
per crank case.
3) Using the dial indicator, set the piston in the top dead center. JCW20139

4) To get the average value, check the projected dimension of

two points on piston's upper side.
EM-62 ENGINE

5) Considering the projected dimension, take proper head "UP"

gasket and install its mark "UP" to be upper side. Gasket

The gasket sige is shown on the corner of gasket.

NOTE
When replacing the piston or connecting rod, the pro- Alignment
jected dimension may be changed and should be mark

checked.
JCW20129

<D4AL, D4AF, D4AE> Unit : mm <D4AL, D4AF, D4AE>

Average piston's Identification mark

Gasket size Thickuess
projected dimension
A B C
0.467-0.528 A 1.35±0.03
Not mark
0.528-0.588 B 1.40±0.03
0.588-0.649 C 1.45±0.03

CUBEM005

<D4DA, D4DB> Unit : mm <D4DA, D4DB>

Average piston's Identification mark

Gasket size Thickuess
projected dimension
0.466-0.526 A 1.35±0.03
0.526-0.588 B 1.40±0.03
0.588-0.648 C 1.45±0.03

JCW20121
CRANKCASE AND MAIN MOVING PARTS EM-63

Inspection and Adjustment of Valve Clearance

Inspect and adjust the valve clearance when the engine is cold by
using the following procedures.
Pointer
1. Crank the engine with Cranking Handle (special tool) to align
the inscribed line "0" position of the crankshaft pulley flange or
crankshaft pulley with the pointer.
Another pointer is provided on the top of the crankshaft pulley
flange or crankshaft pulley. If this pointer is used, align this
with the inscribed line "0" position on the "2, 3" marking side of
the crankshaft pulley or pulley flange.
2. When the piston in No.1 cylinder is at TDC on the compression
stroke (the push rods of No.1 cylinder not pushing up the in-
Cranking Handle
take and exhaust valves), check and adjust clearances of valves
marked with "o" in the following Table. Then, with the crank-
shaft rotated a turn, check and adjust clearance of the remain-
ing valves marked with "x".
Pointer
If the No.4 cylinder piston is at TDC on the compression stroke
(push rods in the No.4 cylinder not pushing up the intake and
exhaust valve), similarly check and adjust the clearance of valve D4AF0225

marked with "x" first; then, turn the crankshaft a turn, check
and adjust valves marked with "o".

Cylinder No. 1 2 3 4
Valve arrangement In. Ex. In. Ex. In. Ex. In. Ex.
No.1 at TDC on
compression stroke O O O O

No.4 at TDC on
X X X X
compression stroke
In : Intake valve Ex : Exhaust valve

3. Insert the specified thickness gauge between the rocker and

Valve clearance
valve cap to check for clearance. (both intake and
exhaust when cold)
1) If the valve clearance is out of the nominal value, loosen NV 0.4 mm

the lock nut and turn the adjusting screw to the extent that
the thickness gauge moves slightly tight.
2) After adjustment, hold the adjusting screw in position with
a screwdriver, and tighten to secure the lock nut. NV ... Nominal
D4AF0228

3) For on-vehicle adjustment of the valve clearance, use a

slotted screwdriver to turn the adjusting screw, which makes
Slotted Screwdriver
the job easier.

D4AF0229