EM·'
N' IN
MECH MECH NICA NICAIL IL Page
EN
ID IESEL
EM~2
LEGTRI>CAL. SY STEM
EM-l1
EN.'GINE
EM-14~ HE
TI
".
,.
,• "•
EM·19
. , . , . ,
IN
EM-20 EM-20
".
EM-20
.EM'-.24 [If
lnstellatlun
".
,.
,.
".
YlIN YlIN DE
EM-lIS
,.
,•
EM·31
EM~31 Remov-al of Cylinder
,.
,.
EM-32
,.
.EM-35 ce ticn ticn Head
iean ieanin in
and Repaiir
ylin ylinde de
"•
Re
ams
EM~36
EM~44
eaI
EM-45 (If
Installation
EM~-4Ei
N D A B ,. DiSassembl'y
".
".
. " . "
EM-50
". ,.
EM·50
,.
01 Cyminder Bllock
'EM-51
lnspectionot
EM-55 Pils Pilsto to
lDis.assembly
an
ctil ctilll ll
Iinspection
EM-·51 ctii ctii
Re'p~a Re'p~acem cemen enilt ilt of
Ro
IEM~61
Inspection ,•
R e p , W a l c e m e n t of Crankshaft A.ssembly
of Platen and Connecting
Rod nS1
,. III
ctin ctin
Ro
kshafi. P l
,..
a
•
•
•
•
-64
EM-·2
Dlagllosis
INE
IESE IESE
th
ENGI ENGINE NE DI·AG'NOS.1IS
ca se
'fue 'fue
system.
yste ystemp mprd rdb~ b~em em
Fuel syst system em tests, 'fir 'first st ch ek that the en in Befo Before re begi beginn nnin in Fuel majo majo svst svster erns ns re wi'l wi'lhi hi specttication:
compression,
applica icable ble to Toyota system dlaqnosls procedures are appl inje inje en ines ines equi equipp pped ed wIth wIth in
I M IN.A
ck
ai ther ther is
if th -f
ruel should
ck fo
tf}
(g
fuel 'sys'hml
compression,
swff swffic ic eh't eh't
l. is co
If
ti in
an
majo majo comp compon onen ents ts or systems.
th€! th€! terr terrk. k.
in
system by
(e
2C.
ECKS
necessary. Hn3·1
(d
1C~
other
it
·gosollns or th
Llrn Llrn in
the fuel Pliler if
th fu
primjng;
elements. nts. O·nIIY O·nIIYgood-qu~lity good-qu~lity fmeiign eleme
limes.
tank and drain as necessary.
it cranks slowly.
electrical
system.
diesel
Dis_grrosis.
N GI GI N
EM-3
PRECAUTION the
2.
dies diesel el engi engin0 n0 (val (valve ve clea cleara ra ce co pres pressi sion on
The
test test benc bench. h.
special
(IPo (IPoss ssib ible le C.au C.ause se
COR.ROOED
D lS lS -C -C .H .H A R G IE IE '
hear hearin ings gs
~Che ~Check ck Pr cedu cedure re and. and. Conec1i.on Method) t i
n e ce ce s
eo
rs
Check alternatcr
B A TT T T ER ER Y
ReU
starter and m a k e
the drive belt
OU
a s tlI(!!·cess~ry.
\r----------l
lt
starte te at star
term termin inal al
.s
16) for repair procedure.
NOT
inim inimum um urankinq speed:
Cold
IT
rp
Procedure dure ~.ndCor ~.ndCorre recti ction on M~thQ(U (Ched< Proce
lternsj CRANK_
IMPROPER
N G N I OIL
heck heck engi engine ne oil, oil, If impr improp oper er visc visccs csit itv, v, drain arid
vi ;'lC·031ity rec
nd
th oil of
e r t f~ctl.!i'rii: r~
EM-4
Pass Passib ible le
Corr Corr,e ,ect ctro ro,n ,n
au 1
its
r:
~ -
eng,ine for a b o u t firming
FU
UT
aL NOID NOID
I i
OPERATION
seco second nd
while con-
is'
fu
,.
M,et M,etho hodl dl
:r
i'tem 4.
trorn item
2,
tu¢1 cut ta tc turn turn ON ch ckfo ckfo nois (eli (eli,e ,eki king ng soun sound) d) while solenoid operation nois repeatedly Gonn@Ctur1g and discnnnectlnq fuel cut solenoid, IT no noise, check if 12 th 'ON, ~f 1 2 ts refer to replaced, no ElECTRICAL. D!AGNOSIS and mal~e necesserv
With
repairs,
~.
'FUE INTO INTO tNJE tNJE TlON TlON N O . c 'FUE
__ __
~nlet hoses hoses P~sGonneGt ~nlet
fro
th
1.
fu
fl te
rec fi Iter
the clogged
accordingN·
!'Fengine '"St:il~ llne between normal,
I
:<)mdfeed cleen f u e ~ pu p.
i n . b e w e s 11
be repaired
fuel
~riO
faultvano
ir
tl
into into PUffi PUffilp lp •.
r<,eep carrtalner
fu
IN,OP'E IN,OP'ERAT'IV RAT'IV
HIEATING
PRE
OPERATION
an
1
indicator
glow plug, refer 10 ELECnUCAL rv.
If
ne
O PE PE R
T lO lO N .
If
starter
plug volts
lig ht
IAGN IAGNOS OSIS IS an
plug. for continuity, t10
re ai
'EM-S
IN'J'ECTION
1.
P.P'E
PROPER ER INJ·EC INJ·ECTI TION ON 1M PROP TIMING
loose If lie' lie'ak akin ing, g, repl replac ac pipe pipe~s ~s~. ~.
NQ.
it necessary.
Or
is
piston
with S S T . 5tafldard~
io
2L
0.032. 0.032.
he
um
an ar
indi indi at
inje inject ctio io
ab
FAST FAST IDLE
OLDE OLDE
inje inje io
is off more ha
ti in
0°
slip slippe pe
piston
opernin~an,gl.e with with inje inject ctio io
FAULTY OZ L.
in.)
0,98 mm
.adj .adju~ u~te te properly.
is
Gould indicate
IMPROP PROP
0 :0 :0 4
rn
0.03 in.] 0.75- 0.87 mm 0.0343 in.)
2,L-T If
h'l.)
1.22
04
wI ACSD
mm 0.0417
Check, lnlectron Standard
te te
p,I' p,I'es essu sure re with with rl"OZZ~ 'tester,
plreSSLlirEi!;
t. 2L (ex.
rs
Hongl Kong '& SingaporeL
(1.,4~ (1.,4~ ._ 'I 778 psi,
2l-
'2
'S~ngaporel
16:8 kgjC:IT'!~ psi. 14,2 14,2.2 .2.0 .0
kf
(2,062 -2.389 with within in
16.-
pressure readjusted,
If pressure cannc] repl replac ac riOtzle hold hold
standard, ssse sssemb mbtv tv
Pa
EM-6
EN
(Possible
IN
ie el'l Engi Engine ne Di
Cause) -
OF
CCEL CCELER ER TO
and Correction
jChe· jChe·cI{ cI{ Proced Procedure ure
CABl CABl.E .E
Method)
accelera ra tor pedal rele releas ased ed chec chec 'that With accele adjr adjr'l'lls lsti ti,n ,n leve leve is in contact .adj .adjLJ LJst st tn crew crew Also Also ch ck i'f, co lera lerato to ca le sornettn ttnnq. nq. catching on sorne 'I'Fnecesaerv, is ill contact with ai
Check' if idII1l
lOW
NOTE:
UE
A KA G
rpm:
St.an St.andard dard idl
bn~:HGated below(ex,. LX (LX) 'A
ao MI
If less than standard,
r·ough.
I ol
delivery valve,
holder a.nd
o zz zz l
ny loose
Tlqhten
specified
CRANKS STA' STA'RT RT
T'MING OP :R -
VALVE
~d ij g. 'I
ln
Wi injection
he
ch
id
i'
ehange, Check
acco accord rdin in
Fau~tv Stand
cylinder is
fa lt
to
foLlowing
rd
pre 55
ress ressur ur
with nozzle
(ex,
~2., ~2.,06 0622If pressure
au tv De
..
tester.
Si_ngaporeL
(1,4931,778 Hong Kong
reedlusted.
procedure.
Holder'
Or
heck heck inje inject ctio io
If
abov above, e,
.3
2L·T kPa,)
Singaporel
psi. 1,4,220- 1£.475.I~Pa)
inJection
alvs standa dard rd within stan
de iv ry
Diesel Engine Diag rrosis
of EN IN ANKS ANKS 'STA 'START RT above.
fe
-
NO
oss
e)
EW
Check
Co
du
!!!n !!!ng, g,in in re-s re-sta tart rt
toSE!1
ENG NE ART
If
dl
-
no
to
necess ssar ary_ y_ repalr ·a nece
a b E f refer
repair
IDLE
OL NOI
accordinqlv. NOTE: so leno·id rna le prac eoedin
INJECnON
PUMP
tho
re
acco accord rdin in
pres prescr crib ibed ed proc proced edur ure. e.
START
CU
Proce
(Check I----~---l
EM-7
l.-__
be du
se
to
NOHMA1L
-----::-----1
above:
NOTE: 1.
that air eIea Ille logg ad all e e lc that Ille li Irro Irro logg desire re ut u1 appUcabh~~if customer desi chaasls dynamo.
lP'o lP'oss ssibl ibl
Gause Gause
'R O PE P E R _ A C CE C E L ER E R A TO TO R 1M P 'R ENT
eati ng.
ne
heck heck
Witi Witi:l :l.< .
roce rocedu dure re
full full
Correctkm
depr depres esse sed, d,
Method)
check that
01dj us'l: ill gl S~r~w.
no
INSU INSUFF FFIC ICIE IENT
adjust accordil1gry.
acceler:8Itar
NO-L NO-LOA OA
standard.
floor
no-load
I f n .o .o tttt , 6 d 1 j u ~ .t.t with t ith max,lmum w
sp~ed adjlustillg sc:rew.
Eng,il1e Diagnos.i:s
EM-8
,
IN
l1Iot be interchanged.
MARK)
fiTTING FUEL
RMer··to item ENGINE.
LEAKAGE
of
OL GI II LE
IT
AR
Disconnect inlet hose fro'rn fu~'l fine and feed c 1 1Y 1 Y lc lc m o h e pump. clean h . J e l c l e c1 engirnE! .cQnd·iti .cQnd·i tianimprQvi animprQvi3$, 3$, , i c l'l' og og g e d fU'E:!1 ~f and should b~ repla.;:ed.
d~
dilfefltl
rsto rsto PUll PUll'!P '!P 'fue!1
tank, increase se In If no increa
8r1ghlJt!l
fue~ fue~ft ftlt lter er chec chec
pfim~~'~l pump or perform other neeessa r:'f repa rs.
NORMALLY
TIMING
N O Z Z L E HOLDER
OR
Re:rer tb
sr Afrt
SM NOTiE: CIheC'k th 01 In99 ed ill ii- r: 2. Check w.ith uustum uustumer er whetber whetber consumption
KI
has beeneX beeneX essiv:e essiv:e
(PO 55.tO l{l C a u s e )
MP T~MIIM.G
'FlEifiefto item GI BUT WilL. No.T START
ECTION
CRANK s NORMALLY
NOTE: n d leates 1119 Black while while white white smio smioke kein indi dica cate te retarded tiMing. Adjus1ments should be ade .acco .accordi rding ngly. ly.
.T
~ i
i.lter' t8
;h
·t
m ak ak e
clo99led
;;1.1,1
white.
NG NI .M UL NOZZLE
CH NI
1--_----1'[
HOLDER
Engin,e Diagnosls
BUT WILL NO
ot
EM·9
GI
KS
STAR START. T.
ORMA ORMALL LL
NOTE NOTE xc,e xc,e sive sive xhau xhaust st smol"e ~s.often eaused by noul noul,e ,e ress ress :e ei low.
1VE FU rolu rolu oh
U Mi Mi P
sUpPling. brakes grab.bingl,
tires.
'w ron gl size
-or a , i i r filt filtef ef clog clogge ge
(Check Pmceduni!and
Correction
Method)
WrlH WARM ENGINE.
1
,Afte1r sufficiently idle idle rp
is as specified beJow.
Idh~ rpm:
00
IT
cheek
eillgine,
that
h~x. DO A/T
U' net,
II-----~--i
to floor
tart-engIne, tart-engIne, an Gh.~ Gh.~c. c. sttlnciard,
r;.TN_·_OO.-.·.O~L.·, .H .H-_AIG_
within
Ne-load m a m u {ex.. 2L
LV
LN56)
m:
I(ong
.&
j,ngapC j,ngapC iIfE!. iIfE!. Ausftalh!
rig i;llpore, Auslra ia
LY Ilf not, 3u1uS1 wi
4.
OP TIMING
GTO!
LT
NOZZLE
HOLDER
axim aximum um spe.ed. adjusting
screw,
Refer BUT WILL
G H A N K S NORMALLY
item BU WILL WILL N . O · T START.
CRANKS
NORMALLY
HE No
xcessiv'e Vi bratlon) '(Che '(Check ck Proeedu Proeedurean rean
c o a n e r p e 1 lu r e m pe p e ra ra tu tu r g a ug ug e If suff shou should ld O!:lre O!:lrep1 p1la lac, c,ed ed Il.~C
CorrtllcUon Metho~l wit
co
13
stat is
fa uHy
no
II
EM-1I0
Refer 10
ENGliNE
NOT START.
TIMING
J..
item
FAULTY
NOZZLE
HOLDER
ENGilNE WilL NOTE (ex. w/ACSO):
('Po ('Poss ssib ible le BI
ART
ID'lE
iChe iCheck ck Proc Proced edur ur
Caus Caus
nd chec check. k. jf engltle retL retLJr JrI1 I1 to ldle, If ccel cceler erat at ca le is bindIng repaired 't
GINE
HU
(Checl( I i
maladjusted ti
FF
C~us C~use) e)
OP RATI RATION ON
idle,
replaced,
faulty 'and
NO
and Correcti·o'!1 Method}
-
UNKAGE
SO
N OR O R MA MA L
idle
DING DING ACCE ACCE ER TO
(Pos (Pos,si ,sib1 b1
R AN AN K
Procedure
Dlsc Dlscor orin inec ec conn connec ecto to
check if engi engine ne st ps
starter
~f ellgil)9 R e p al al r
e e ssary.
and Correc Correc1io 1io
Me1hod~
011
i.f:'luhy CUlt solenoid by fOf'laign partlcles,
EM·"
SYSTE.M DIAGNOSIS as 12
er
Its ~·S"talrter swite hOFF.
eli
1. Sup.er Check if
INO 20°. 20°.
(68° (68°(= (=j: j:
,App ,Appro rox. x. 2s,.; 2s,.;;c ;cs. s.
Fuse Fuse Blow Blow (Se, (Se, pag€ pag€ ST-2 ST-2
YES Starter
sWi,tch O F F ,
'f necess·.1lry,
battery
vQ!tage toterminal
Check
switch
ulb. ulb. OK
NO"Voltage
Voltage
OV betw betwee ee terminals g, IIf't
R ep e p la la c
~b
eM, ness ness sjde sjde
okay, pre-heMing, shou should ld be .~~p .~~pal aln: n::d :d
Check tsrr lnat lnated ed pre-he·6ting ti er is tsrr No Voltage
e ·,·, h ea e a t i ng ng ·
Vo:ltagi3
faulty
and
miner
UI,j, LX,.U
vo ta g~ stterrn
timer,
nsl 4, of
.~
rfl!~ m a t l·l · o g .
I~fEl,Il'ty~ repair repair Ghar,g Ghar,ging ingsys syslem lem F1ec.essary, If ok",V, should
trill· ..
~TQo1>'l!~.
LH51,61,7l
12
~nsa\
STOO.~
EM-12
ENG
IN
ex. LX
]L:X
-3D
-ro
~o
-2.0
(~r.'
" "J "J I J ~ m r ..ff I r:r: u I~I~ r ~ ~ : = :':' ' :_:_ _ :I:I _ ~ f:f: _ 1
ta
tc
- ---- = .=.= r ~ n :l:l ~ : : : ; : : J O '
Timer is
p~L.Jg
a.
~------~--------~~
Disc nn ect pera pera tu re sensa of €!1J €!1J9I 9Iin ine) e)an chec chec if e e nds f, if -C rinector is duration ~s dire direct ctly ly grou groun( n(Je Je pre-haatinc ds 'f au ty per ture sen sor replaced. houl houl
Quite
D i"i" f:f: fe fe re re n t T h a
l~
ar
nd
heck heck fo voltage at terminal 1Olgairf'1
is
Timer is faul faulty ty
be. replaced.
Vo1tage
to terrninat check if fl in accordance with of coolant temperature
Isee
Volt Voltag ag,e ,e at
Check-for
If
ka If is
fa
(Fo compon component ent ST-5),
No /2 Voltage Them.after
Check fQF nlfold ld {Inlal\e rn nlfo IF no and should No Cont Contin inuit uit
Chec Chec glow glow plug for Contlnuitv
Glow
lu
ay
inspection,
id ;)
hwlty
.2
r------~----~--------------~___, p~ug'faultyaind
should
be replaced_
GINE GINE
.. Fuel
NI
Di
EI~ctriGa EI~ctriGa System System
DlJ3gnosi$
EM-13
ut Sole Sole 'oid 'oid
te r cS ·tci1 tu Ii; to Ii W~Ul s t r te operation tlIois.!3'(di.ck~f1g (di.ck~f1g fuel fuel cuts cutsol olsn snel el ;Si0 and GQ n n a id, disco fl ecti ng fu II
No se Check F u s: s: ~ S e e p s g e S T 2 J I
Apply baUBfY votts] dir~Gt,ly to ~;:ole,no~dII-----------------~
Tefr short cir.cuh
ano
rep:<:J.i
wire;;: h a n e fUSB
R ep e p l ac a c e u e Gut soller soller oj d.
ry
S e e p ag a g ! S 'T 'T - 2 }
CUlt
No NOise
~s ecasse
solenoid.
EM··14
ENG'NE
TU_NE-UP 01
If low, low, ohecl< for le~l~og.e and add oil
a~
ua check that excessively dirty
marie
the
IS
not
oily,
6ff th
elem elemen ent. t.
CLEARANCES .a,djLJst clearence engine i18Sreached normal oper operat atif iflg lg temp temper erat atur ure. e.
~a}
Set
es
the pulley with
an
the rocker rocker arms
'I not. not. turn the ctanl ctanlrs rsh: h:aft aft
the
No
cvlinder me
ti,ght ht cylinder ar ti,g
ne
AOJ Front,.
Fir~t
(a) al
after
Measl~re nc
by arrows. a-lot):
in.l
ENGINE
Engi Engine ne Tune Tune-L -LIp Ip
MECHANICAL-
EM·15 rocker
arm, Loosen
the
the
prop proper er clee cleera rane nee, e, adju adju ti
cr
shou Id
drag.
an the ti rn iilg ,Adj nl
Second
4.
INST.A INST.A.L .L
IV8:S r'ld ic ated by
,ali ,align gn
arrows.
paiSe EM·49)
CYLI CYLI
EM01 EM01 05
IN
ENli OF
INJ.ECTI INJ.ECTI:ON :ON TtMIN 1.
INSTALL ~a)
PLUNGER STROK.E MEAS MEASUR URIN IN IN
TOOL TO OL (SST:I
'Remove the di5trib~tive. distributive
head plug hole.
SST 09-275 09-275-54 -54010 010
.2
S.ET N'O. 11OR NO.4 BT'DC/COMPRESSION'
3.
RE
SE
(a)
si FIg
OL
ST RING RING
SYSTEM u r n the
ar
ever
as show shown. n.
.m thic thic
betw betw
plunger,
pilate Gold tart tartin in the Gold
leve leve
ami
-0.394 in.! th rm
wa
EM-'6
AND ADJUST INJIECTION
TIMING
(0 ln.l.
(a mrn
zero lal in.], whl,le rotating, the cr,ankshaft pull,ey pull,ey slight slight I[,g hi.
il
crartkshatt ylin ylinde de iset TDC/comf:JnlSsion.
'i
{d)' {d)' Me,a Me,asu sur, r, tile tile plun plun'g 'ger er stro stroke ke rnrn
2l
wI
A.CSD
inJ
mm
00 0. 23
-T
0 . 0 38 38 6
0. 02
!111i11
in.)
0.03 0.03
in.)
injectlion nut
inle inle pipe pipe unio unio (f)
0..0.417 inJ
mm
w/o
l.oe 59
tJ III
two nuts.
by sl.ig'htlv tilting file injeG·If th stro stroks ksis is less less th
engine.
If mater en,gine.
I'
TO'r.QlIe:
"801'5.
.spe .spe ifig ifigat ati· i·on on tilt tiltth th fi atlo atlo
pump pump to ar away
'I
185 1<9-cm
stroke',
Tighten th on
inllElt
Torque:
-Ib" -Ib" 2, N·ml
m{
(17
ft-lb.
23
N'm~
STARTING IN,o!'CATOR
ta
indicator.
SST 09275 09275-54 -54010 010
ib ti Torq Torque ue
with
he bo
'ft-lb,,17 N'ml
II
new gasket
Tune-up
{a
.A
installed
n'g~ne dolant norma
ldls ldls Spee Speedt dtAd Adju just stin in
o p e r a ti 1 1 1 9 e r p e a t
SPEED
Scre Scre
at
nBC
ill
ust n 9 1 a ve ve r
·t he
th
acljlist
released.
idle speed
is
If not, adju adjust st th acce accele lera rato to linl linl~~ ~~~e ~e
is ta
!~~e ng ng
tac
II
ne,
{d Check
speed. MIT
Idie
,800 rpm M)T (D
Ali
.speed,
scon nect
h e a c cs c s l fi rater Iinkage. dj UI sting
screw. speed by
Iy ti
lit.
adjustment,
ADJUST
that 't
speed adIl.iIs.ting If not,
adjust th
MAXIMUM
accs accsle le
tor linkage_
S.PEED
ad usti usting ng leve leve touc touche he
he maximum
EM-1B nsta II (c.)
ta ho meter to the 'en
9,
ne.
Start the engine, the way_
~.ximum ~.ximum speed: speed: lex. LS lY lN56) ongi ongi Kong Kong
Singap(H€!;
Australia rpm
Singapore, Australia
rpm
SST 09275-54 09275-54020 020 ED NOTE:
speed
NG
Adh.
CR W_
by
h&n, rali
elile speed.
ne speed
SST 09275-5402 09275-5402 accelerator
iter
stop
pedal.
accelerator
IR VO .U
linkage.
MIT)
S,
INIT INITIA IAL. L. CONm CONmTI TIO' O'NS NS
Adju Adjust stin in
s<;n s<;n~w ~w
-r-l -r-l~. ~../ ./ ~""
{bl
Engine coolant
h.::}
Accessories
switched
temperature.
off
VOLUME
acuum
~'
normal operating
}I Gauge
.va
g8u'g,e
vacuum.
(c
i n. n. ,H ,H g • . (d).
Adjust th SCREW.
vacu vacuum um
:20. :20. kPa) kPa)
by kH;l~en~ngile CONST'RfCTOR
ADJUSTING
ENG IN,E
ECHl ECHli\ i\
ICAL-
surnptlen,
measure ENGINE
.2,
fUEL
DISC01NNECT CO'NNIE:CTOR
cur PLUGS
(S@ pa~ge pa~ge EM-21l EM-21l ake· ake· sure sure tth~ tth~ load
CAUTION: A.Ll
notgumnded.
PLU
SST 09992 09992-0002 -0002
.5
M.EASURE
CYUN.oIE
COMPRESSION
iPRESSU RE to SST.
SST 09.992 09.992-0002 -0002 !" lo g
the comp're's6idrJ A.lways.
NOlE:
Compressicm ==-"-r ,2l-T ,2l-T zt,
um
re
h( en9 ns with pressure.
hesta rtsr,
battery
ur
so that atleast
hed,
prassure: psl, 2,942 30.0 ikglcm2~427 kPa) ~2,O ~2,O kg!o kg!o.m .m'l 'l 55 psi, psi, ,1 s;sUl'e
pS'i, Differenc
€I D€ftwtl
·cy nder:
EtSS
IFt or lind lindar ar Iunall~ amount inlo UIe. is low, :cyi inder pi ug ola nd repea'tstep:;;' fl rou ( 0 ; 1 ) and~ and~b) b) or the ~:iylinder wIth ~ow compre compress ssion ion ~hat ttl€
:thE;! co.mp res qion, qion,
Ci1;;lf'lGOS
are
Or II!
gim
the gasket.
ieak:gl9€l'
past
'EM-20
BELT
TIMrNG
ropiacing imin imin warning light comes o!il,(I~ght
be
fo
0,
of
te
COMPONENTS
Gasket
raw
ro rnme
Connec,tor
!Fan
Id er Pu le
ll~~~-==~====~~~ r : :,
kc , : 9 _
(ft. lb.
l\
hp!,}Gified
Timing
el Guid Guid
Belt
~~'~~4
R'EMOV A I L .
(See
EW
PULLEY UL
SST, SS
0921 092133-54 54-0 -0
mount bolt, and 09330-00020
ENGINE MEOHAN
EM-21
SST 09213 09213-6 -60.017 0.017
nd
g.aske'ts,
bsh eave t" with
the two
IDE
:?
6;
R'I:
REMOVE PLUGS
the
GLOW u r crew gm mma
four gl the four ~G
R e m o \!!
.t
ix
rent sensor.
P~Mg connecting nuts.
LN)] pi
her, ! I n s u I
tl
r-
mov
~el
Hflmove
O.
to II
YU
U s n g . . crankshatt of th :cylii :cyliirld rldier ier head. head.
1<"'01-1'/
gl'ow plug ..
TO TDe/COM TDe/COMPRESSION PRESSION
pulleV mount ng pu'liey
bQlt,aHgfll 'Ule T D with the top
f f < 11 11 r
-nmin'g
E N G lN lN E
.REM .REMOV OV
Belt BELT
TIMI TIMING NG
timing
rnatchmarks 011 th
revolu luti tion on), ), 'and 'and plac plac e n g i n e revo puil puil.e .eys ys an timillg
tension S.pfH1g"
~I
idler pu~IBy
the
ount ount bolt bolts. s.
timing belt.
9,.
'Remave the two
and idler
pulley,
10.
REMOVE
CA
HA
SST 09278-54011 09278-54011
Tt
LLEV
GI
!:.M-23 ULL
Us i( 'I
<:
SS
t'", ~" ..'
0.
tH
nut.
-5 01
{b
IDLE IDLE R€irnci.v:€!.thG
rnourtt
boltarrd N o . .
RA KS AF ftlrIlOV€
SST 09213-6 09213-6 017
,.
./'---.
~---
'.
. . . .
",,:
/~--
....
IPUL IPULLE LE
IMIN IMIN
·the. tr~I tr~I~: ~:st st\a \aft ft
PULL.IEY ti h~ puHey_
GI
HA
Be
NS EC IO
OF
PO
NT
1.
CAUTION:
oil,
twist
not all
01'
ur
he be
om
belt steam.
utUi2e the
p'ulley. 'If
defe defect ct
followif-lg
s. show show
replace the
de ut
into
GO
or installing camsbart timing
ln the: figures,
if necessarv.
lnstallat latlon lon proper lnstal damage,
GOVer
heck heck Fe corr corr ct
st il tl n.
teetha hare re tile el teet crackeo see if the camshaft, lcclesd.
~'Cl G.h~ck pu'l pu'lle le lock lock
{eI)
puHey,
nicks
end
d~ma.ged, 011"
'one side side Oil 'one
il
the idler
or
each
th €rcl €rclll llis is no tice tice bl weaf 0 n .gas .gaske ke!t !t fo
teeth,
On the: the: pull pulley ey
.2
NSPE NSPE
c he he c check for corforeign rnatertals
P'UILlEYS
IO
Check "the tllrlnung smoothness;
'liming
lPu~leys_
Ilf
3.
ep
lor puHI!i'y,
NSIO NSP'ECT TENSIO
SPRI SPRI.N .N
length
(<;))
Free
leng th:
'the 'the spri spring ng
'1
in.}
te installed lenglh_
ns
ns
1~39,7-4D,7
spring
n: (2.05 in.)
.0 1( (8.,B lb.
If
ot
.5
fi d ,
the s' ri ng,_
BE
IN ISee ISee p,ag p,ag 1.
,a'~
,M~20) ~20)
IINSTA,iLL CRANKSHAFT' 111M (a)
I tg tg r ! th tim he m:in m:in pull pullay ay
PULIlI:Y
wirth ti am
er
ri;v ri;v
ro
ti
SST 09214~.6 09214~.60010 EM
33
Torq Torque ue.: .:
000' 000'I. I. g~ lm (29
rnl
ey
'O
ENGJNE
EM·26
Timil1Q Belt 3"
l'NISTAlL
(GI)
IO
Align the drive pulley the drive pulley. T, In tall tall
50 l
Torque:
-l
SST 0 9 2 7 8 ~ 5 4 < O T
n01
im,pact wrench,
UL
th
timing pul'ley ti illg illg pulley,
bolt. kg-em
N·m)
SST 09278 09278-54 -54011 011 -5.
PULLEY
ID ~a}
Tarnporarilv gt
install
th
pull pulley ey towa toward rd
the lett,
[M0131
F,M01t9
Aligllthe CAUnON:
I;MClr3B
t~mbng
driv driv
puiI puiIBY BYiJ iJ at each each posi positi tion on
Gold.
IN
If usin usin
be'li:
in
tothe
ri
p'l,Jiney.
CAllIT'ION:
iss~curely
the pu
drivl~ pullav.
belt
C_At:lTION:
meshed
Be
sure
the
driv driv Plllieyand
timing
belt
to Ul~ No .2 idle idle ing. ing. p'.u p'.uHe Hey. y.
in
cran ks a'ftti
is,
wi
is
securelv
pu.l pu.lle leya yarr rr air tOO
tight.
reu' reu'si sing ng ti h~. 'beR 'beR
AJ~gn 'Ul€ poin poin revolution,
EM 11
1 3M 3M B1 B1 ' 1
rner rner ed d;ui d;ui ln remo remo al an insta installt llthe he tim~nthe directicn o·fengin.e
po.jnt ntin in the' arrow po.j
EM-28
ENG INEMECHAN INEM ECHAN TENSION
SIPR1NG
CAU'TION; LOo~a\!!1I idme idme pull pullie ie llig llight htly ly fon~e.
tim"
moves wi1h
rene 1 " 1 , utio utio
!'1r91
bo
hac
prin prin
bolt on th
shaft.
(c)
te si
TDe to TDe.
fr
1 . 1 9ns wi
th
marKS reinstall
UL f1-lb, b, (1,4 f1-l _1
N'm)
not
ENGINE
IMECHANIICAl.-
T!rn~r'Ilg Belt
EM-29 CU RIFIEN RIFIEN
SENSOR
it-Ib, g.
piugcQllnectot
In-stall h e c u washer.
nsta II the' the'
fO;Uf
13, N·m) on
sensor with the lnsulatores, g! ow
nne ct ng
tile fourscrew
plate
fHJtS.
grommets,
LT
AI grl the et eyon eyon th u~dean Irid
TIMING
{a
ra nks haft wilt
it
the keygrDovs
itl,
BELT COVER
st
(lOVB.L
bol,s,
{b)
..
~a
Al
{bl'
LJ;Ei1ig
pullev,
he
SST 0922 ,-6 010
w itit h 11[:1
t he he l~ l~ ~ Yg Yg i o bv bv e pl..Ill,ey,
of the-
it
the -/
~----
To
ue
00
01f
SS
09 l3~5"4 ~5"4 12 an 093-30-00'Cl20.
4D!1
6. ~NST ~NST
Ale Compress Compressor or Ptlll~y
P',
Driv Driv-e -e belt belt defl defloG oGti tiol ol
...~ater ...~ater Pump Pulley
"'-t..\.
Po
tilt 10 kg
---------12:~ cenditlcn
New
cn
£"'-..-1~6s~"mpp",!" - 1~6s~"mpp",!"
3 -
i C co
Alternator 81;.1":)I,i;
(C,·anks.l.1aft-
8-10
"1
NOTE.;
bel l.
®w bett"
to
Qelt
Used
+ 0.91)
---I-----------~
10-14
se
ich has
II
used
ENGtNE
MECHANICAL-
Cyli Cylind nder er Head Head
EM-31
COMPONEiNTS
r-
·S al
sh
Heat Heat Insu Insul;: l;:'! '!to to
Exhaus Exhaus Manifo Manifold ld
~~~~;;~~;;~iitY----GaSke'l
I. Gasket
lnta lntaka ka Mani Manifo fold ld rnshaft
il Se
Ca ms.h~ft Se<:l R~tainer
U-i Engiii Engiii .H~riger ,-2-.5-0-(-11-1,5~~ 5~~
N-mn:
T~ghteningtorque
EM·32
·ENG IN
:M
HEAD i'
lSee step
INJECTION N O . Z Z L E S (See steps
tSee step 10 on page page
4.
U-14 U-14
REMOVE
~al'
0!
belt belt cove cover. r.
eI
{b·~ {b·~ Remo Remove ve th three and.qasket, to
C,OVE!r"
to th
wasne~ wasne~s, s, hea cover
on p.i: p.i:I.y I.yes esEM-2.0 to 22)
.A.M .A.MSH SHAATIM.NG Oil 'P·age EM-221'
EM VE .::::..():..=''19-
7.
DISC DISCON ONNE NECT CT ACCE ACCELE LERA RATO TO OM AC A TO TO R NK
8.
HE.MOVE HA'NGER
PULL'EY
CO NE.C NE.CTI TING NG RO
~NTAKE M A N U ; : O < L O AND IL th
REMOVE
head
BELT
(See steps
9.
tne
ix
tw
arrd
rH;i 'g B,s'ket
W A T 'E 'E R O U T
E.NGI:NE
ASSE.M'BLY
EM·33 HANGER
th
fQyr 00 tis
e ul ul a t or or s
move the and exhaust man~fald,
plate
lWG
VIi;;:l
sJwrs
AIINlI:A
:bo
~6}
b)
seal an
g~sk g~sket et.. ..
Loos Loosen en th valve clearance adjustLng screws, Usinge
d~a~'mdlcator, measure w'l"~i.lemmt~f1g the camshaft ba ~O.O:0 ~O.O:022 22 G~e~ G~e~r6 r6nc ncei eiis isgr grea eate tert rt'h 'har ar be,l;Iri
thl:)
he an
forth"
o.omn
c l a ra ra nc nc e
in,)
replace
ax mu
A~SEM.BL v, CHECK
1L CLEARANCE II
ssesan 'w th th
osen th
11 u m e
mo
rder sh own.
e r shaft assemblyandoamshaft three upper bj1Nlrin~s." u;
be
~G
ca
in tt fe
:nsi@ftad wlththe
caps.
an d b e a r t l'l' Q Clean each camshaft journal ' an camshaft
·;!!r.lld
.seratches,
Ihhe. carn carneh ehaf af't 't jo.u jo.uma mala land nd r®P ~ G leel th ca rn
ourn ournal al an b,etJr:ing fo pitt pittin in b:ear!F1lg
ep
gri
EM-34 {e
P!lacethe qarn.s'haf't
Pli'iistigage across each each jour journa nal. l.
t'F}~ay
(g)
cyiinde~ head.
Inst Instal al th valv valv rock rocker er shaft assembly on th cyli cylind nder er head, gradually .t'ighten
pass passes es in th sequ sequ nc
in three-
shown.
Torque the
915kg~cm 915kg~cm 14
racket rn ve th upper bearing.
th
shaft
as embl embl
with with 'the three
IPas IP asti ti gag'9
Standard
mm
'10. '10.00 00 ln.l ln.l lfcl lfclea eare renc nc
is tira8ter th
maxi maximu mum, m, re lace lace .rhe bearinq,
~Grlnd the camsha-ft 61'replace the 'camshaft
requir required ed
remove the P~astlgagl5, Remove
bearings
,-Vi, 1'""CTi
~~.,
I.
order.
,t:;il ':.....~.::':--._,
IN (.a)
Gradually IOOSEiI1 nd remove th e-i.ght@sn head bolts ill tu'6 tu'6fl fl pass passes es anti anti ill th um rica rica rd hown hown
cr ck
from from re ovin ovin
in Ineo Ineorr rrec ecto tord rd r.
EM·35
d ' on wo de
place
bench,
bl ck
01113
with
is saliences, .cylil1der head gasket CAUTIO,N:
the
Bec,areful
cvrrndet
gask gasket et si es., es.,
H.EAD ('See ('See pag,e' ,t:M-31)
1.
AE OV
AL
the keBp keBpet ets. s. is.p is.pri ring ng r¢ta r¢tail ille le
spring. SST 09;20 09;202~ 2~43 43013 013
(b)
R e m Q v e the
~an
order.
REMO REMOVE VE
eOM' eOM'B. B.US US:T :TfO fO
Driv Driv ou th co bust bustio io
CHAM.BERS oharnbers
the disassembled
·4
arrd arrd/o /o shim shim
parts in order.
.and .and
EM~36
ENG'IN
CHANICAL CHANICAL
er He
INSPECTION, ND
,CLE ,CLEAN ANIN IN
AND, AND, REPAiR
COMPONENTS
.S
eaoh
th
mat~.r .rij ija: a:1f 1fro ro g.asket mat~
from
th
to
ist
bloc of th bloc
usiJ19 EM0161.
re
top.
com-
air. air.
bu tion tion
carbon
cham chambe bers rs
CAUnON:
Be carefiUllno1 contact surface.
Using
KE
A. surface.
UT
N:
ca
gasket ra ch he
from from
ENG IN
Cyli Cylind nd:e :e
ME
Head Head
straight
~,xi ~,xi .umw .umwar ar aUf; aUf;!. !. 0.
te
J'
rn 0.008, ln.!
9re
head.
I~~I
EM·37
[M01?'1 ~1O'72
"..,l.l1'1'3
LJsi LJsing ng ye inu
s,urhlce_·
foun found. d. repl replac ac the, cylinder
8,
~~--
'~,."
LEAN VA VE
~E1)
Using ,i;! gasketti,crap\5I" .. valve:
~b)
USi'r1g
the head,
the
the Guid Guid
alve alve
in id
uide uide di,ameter:
,5
8.53 mm
0.
valve
stem.
icro icrome mete ter, r,
0.
in.)
easu easure re
Stem. diameler.~
in.) 111m
0.
28
0.
in,,)
.the .the valv valv stem measurement from th valv valv 9uid~ measu measurem rement ent stem stem oHcle oHclear aran ance ce 1 - 0.051 mm .0 in
Standard
0.00 0.0016 16 ,a;d ,a;d um
te
0.00 0.00
in.!
0 ' 1 1 clearance,: 1ll!11
0.00 0.00
9i i,n.) i,n.) values, re-place
10. the vallve-guide.
SS
09
th
-6001
in¢litator, ty n d e r M a c L
asur asur
th
V I';! guide bote of 'ValVI';!
EM~39 {c)
0.
-f the .v:alve Hk(J"i Hk(J"i mm ('b, in dime dimens nsio ions ns
1~ O1 .619
(0,S519)
cylinder
~nJ; machtne the
Aebored cylinder
head head bush bushin in
af
14.068 rnm
4.
than follow-
more
bore
dtme dtmens ns ons: ons:
0.·55,39 in.)
.
ne ~t
in SS
from
protl'uding
the: o y n d : e
vall vallve ve;g ;gui uid. d.e. e. (1657
h € ia ia d ,
20 1- 00
1 ' ' 0 obtein th spedfied. c l s a gll~ide.and new valv'L!l,
ar
ream n c e b€tween' the
It
iv
e: 0.
in.) .0
1"1".
IN (a
Ma:J,;. Ma:J,;.sure sure the' valves face i:lng,le, fli1'Iule:
Ch
ttl';::
re :g rouno to
he co ec
vable.
44.So
[email protected]
head m.arg~n,·
lnlmurn m3rgih 1:hic!lit!rH;!SS: 0.9 Intake O,03 O,03
.] ~.O.039 in.)
e a d m i:i : l g ~ F i lliCknezs-s, is less v a l v e h ea r.~pIQt.,e
a n m in in im im u m ,
E.M-40
ENGINE
o k th III v iJ iJ . v e a ve v e ra ra '
1and 1andar ar
ng
ov rall rall le gt
.'
n.
Mini Minimu mu
Length
over overal al
'J
lenglth:
12.2.25
~xhaust
Ef.,22EO
(d)
th
valv valvas aste tern rn
tip
grin grinde de or re ~a eth
worn worn
vaiv vaiv
rel~ rel~~d ~d.a .ac: c: th 'tip
CAUTION:. ,amO'IJllilt.
DO' not grind Qf1 more
(a)
45
US!Iig'
utte utter, r, re urfa urface ce th
m,inimufT'l
al
only eMiJgh metal to clean the seats-
valv the valv
eats eats
emQv emQv
se.a se.ati ting ng positlo.1],
Apply prussian blue {o whit whit lead lead to the valve 'face. ln ta ly
rotate th
seat. the
foUo the foUo
fs
lul! lul!
pear pear
36
uqde uqde and seat seat
irIE irIE or 'l:~ 'l:~ lr c,
seat
valv~ f..ace with the foHowing width: in.)
If
5:
ti '19 '1$<:>
the
no t, re~urf ace 'the
seat
mm
th
iing iing
is concentric. If not, replace the valve..
al If
lv
viii viii~v ~veag eag in
aI
corr correc ec th 'ssat,
ENGINE
Gyander H e a : d
NO
IfseatiAg
(2)
EM-411
low on th va ve
and va ve ssat ssat
pound.
th ab as ve om
va ~v sprl sprl n g ' 5 . ,
xi um
qu rs
07
in
If
the, valve
spring,
b}
Using Galil~l'en", spring,
thie' thie' valve valve (1.8890 ln.l
specified, replace .the .the va ve spring, 1\1]
'--1,\
\'
(c}
e as as u la e r at 'the 'the peci peci ed in ta le
va ve sp in
Installed tension: '29.2
.4 Ib
specified,
en
:Ien :Iengt gth. h.
of th
INI at 39.3 mm (1.5.47 lin.)
repl replac ac th valv valv spring',
VALVE
SHAFT
rocker arrn-to-shatt each rocker arm. 1'[ movement
clearance
and check, roller turn turn
{el
by moving
Disassemble the fi~ure,
srno srnoot othl hly, y,
tha parts, irr order.
Valve Valve Rocke Rocke Shaft
Bearin in Ca Camshaft Bear
Ij.·' Front
~_o _"."
Valv\';!Roo Valv\';!Rooker ker Support Support Inta Intake ke V~lv V~lv Booker Arm diameter
-8
Shaft -tUameter: 18.4 18.4 18.483
~e} U~;in9dial dial indi indica cate ter, r, th rock rocker erar arm, m,
of the-
0.7217
(O,.72S·9-
easu easure re the
diameter;
1M
(f)'
ocke ocke
Maximum
i'fthe (g)
rm
ea urem uremen ent, t,
0:00 0:0007 07
on
olea a n c
shaft meas measur urem emen en from from th
greater
than
0.,.0.57 mm 0..0'0. 0 '0.22I 22In. n. in.)
~ S 1 x i u r n , reple oe the
~ , j ~ ~ - - - - - - - - - - - - - - -ENIGTNE. -------------------~~~~----------~----~~~~~~·,~II ~I
{a
indi indica cato tor, r, meas measur ur
V-'b.locks the cilrc.le
and, uSing
dial
journal,
;l the C'8I1il!3
mci cl ii
ru
rn
ill.)
x~m u m
rchi rchi ru
1 1 , ; l ft.
a p a C ~ the
he~ght in im
lobe he~gt1t: rnm .8 09 ln.l ln.l mr:n (1.8224 ln.]
(0
es than than rninlrnurn, I'Gpla I'GplaGe Ge the
lobe
camshaft.
Us~n Us~n
JOl,.llrna
micr microm omet eter er
meas measur ur the journal di·amete·r. 985 rnm
lame lame ter: ter:
in.~
(1.3 (1.3 67 .~. 1.3
lcl ha
grei grei!t !ter er
an tiG'<:;i gs u s ,IS r!;u.)laie the eamstratt, pE lcif lcif~e ~ed, d, regrind or r!;u.)laie
AND HON
CA SHAFT SHAFT
JOURNAL
Grind
undersi siae ae the under
<31l!d
diameter, ta
fini finish shed ed
]0 rrl il bea n g
Bea. Bea.r~ r~ng ngsi size ze OJ/S OJ/S 0.12 0.125, 5, 0.250 0.250
Journa Journa
finish finishe.d e.d diamet diameter: er:
U/S 00.12 U/SO U/SO
17.INSp
50
·34.8 4.8·4 ·44· 4· .34.8 .34.8
mm
~1. 18 1.3 24 inJ -3.4.735 mm .7 1, 1.: '675ln '675ln.l .l
ANID
.'HAUST .'HAUST
ANIFOL ANIFOLDS DS
Usfng.~l pn·.eci;s~onstrai:glit ~dg'eandf'€teler g·aug:e,measure 'thl~ ,smrac(;j-.scMtacting ,smrac(;j-.scMtacting the cylinder head fo -w.i -w.i;l ;lrp rp~g ~ge_ e_
~~~-
> :•-:;• -:;-• •< •- .- . ~ 3 . , ' ' " ' ' (;l\Wl91
0.4 mm W . 0 1 G i in.)
Maxi Maximu mu
rTIJ rTIJan anif ifol oldswa dswarp rpag age: e:
If warp warpag ag
is grea greate te than than maxi maximu mum, m, repl repl.~ .~cet cethe he mani manifo fold ld ..
EM-44
NG NE
Nt
Head
Cylinder
REPLACEMENT OIFCAMSHAFT
OIL a,EAL seal replacement.
RE'P RE'PLA LACE CE CAMS CAMSHA HAFT FT
ou,
SEAL
head: seal
/"
./'~-... J_
--
and until its surface i.s flush flush with the 0 1 ' 1 seal reta retain iner er edge edge
'4~60010
~~~
-c::_:s.:.!S'
(el'
seal
eas
retal
head:
lnsta Ue d.
nder
oil seal lip,
the Tape, the scr,ewdrivel".
cams haft.
to,
C u t P o s t iQ iQ ! ,,,, !
tt"tu
5 ,u ,u r ia ia c :
fIIush
SST 09214~6 09214~60010 0010
in ta
its
Head
lB
VLlND
HEAD
(-SeE!page EM·3'f~ NOTE: 'R Thowughly
dean al part part
10'
im.talling
t~ all
di
ga$k~ts,
parts,
l.illder haadn etch,
piastk: ha (lh~mber
k:
charn charnbe be
ombu ombust stio io
er
driv driv
sh~m}-
alial prot protru rusl slcn cn
cham chambe be
inths swir swir comb combus usti tion on
the' swirll cornousncn
prct prctnr nrel elen en 0'.0028
ir
pfo,tmsIOT1 Is-not
in.l
it witna
m b e r shl
Comblllst:io!1 cham chambe be shim shim 'thk 'thkkn knes ess: s: (1.005mmiO;002cO ln.] 0.10 (0.003,9 il'l.J 0.15 W·.0059 lin,'1 0:-20
{i;I~~
(b) (a
ru
(O.0079in.1
ln er the: the: V.,I V.,I\I \I in Check n e v a e$ ar
linstrrfll the valvE: spring ri
lnst
.0 rder,
S®1H rl
and newouseal. etaln
r!
th
va lie' lie's. s.
EM-46
IENG.NE
Head
Cylinder
SST.
SST 092.02
(6
~.see
around
013
Using as ur
NS
valve. sprin"9filTld
ro
LL
fit. fit.
DE
IF
HEAD,
1)
'Il'S.g
HEA'D '(ifl)
sw cyli cylind nder er head head g a s < ; e t a n d the Gy~irider block.
he
Fronl
coat
!d
Inst,all
Te
tighten
the 'eHghte'EHl head
boas
·nUJ
the bolts
pass.. H"lb. 1,1 N'm
I,
U pp pp e
e; ,N,o
Cllm Cllmsr srna naft ft
Be:a Be:ari ring ng
and L O W ' € r r Be-ari.ng
AN'D
Uppm Uppm Bear Bearin in
No.1 No.1 Ca Beari!1gl
haft haft
caps. (c
PI,ace
EM-47
cranksh shaf af to lowe lowert rths hs the crank
pistons.
th
head, {f
nd 'llg hten HH;!:ten
Gn'~du;;iHy fnst!;ldl
shown, the final pass.
Torque
k91~orn
3·.
IN TALL TALL
ft-I ft-Ib, b,
AM H: FT
cyli cylir] r]de de
in three
bolts
N.nil) N.nil)
ETAI ETAI
EF
the. the. reta retair irne ne
bolts
001:t8.
Ie.g-em
4. fl,ew
(,id
is
ke:t and th
ust
anift;d!CI
with
,h
53
~q
th
I~g~C'.m
t2.9fH~b~3 t2.9fH~b~3 N'rrd N'rrd (38 H·llb, :5.2 N'm)
bolts,
Torque :120
ft-
kg~G'm
-rn]
EM(!'!.~~
~27'ft ft~l ~lb, b, !
6.
N'
INSTALL th
ot
tw
To
he
with
lts,
kg-em ~'14U-lb,'.9
MANIFOLD
N'mt
A.ND
LH
iENGINE
HANGER
nsta II 'r:!
ga.sket, ta ke 01 ani to~ . a n ,1 ,x ,x b o t s : a n d w o nuts, wit hth e 5 ,1
g i n ha
IlfllW
h::U-GITI
CON' CON'NI NIEC EC (See steps
17 U-Il U-Ilb, b, 24 N'~n N'~n
ACCE ACCELE LERA RATO TO
CONINfCTl'NG
ROD
page .FU-12J FU~47)
E,~NG~NE I:I: IN JECTI JECTI
2~
~PES ~PES LL~Y
See' See' ag
EM-l EM-l
~NSl ~NSl lL TI INGB INGB (Se(Se- s,te s,te'p 'p,s ,s ,6 to16 to16 011 .pages' 'EM-261:J] 3Q)
CLEARA.I\UJ·.ES
Afig th groove r! h e p u e y wh'h the- t~i n te te r min by 'ill! n i n era haft Iockw i,se w~t it! wrench.
ha
leo
arms emt the No..4 cyli cylim: m:le le
'If not, tu rt"I th
(c
•.
dj
[0
o s e v · a Jv e . s: s: i lid icated
First
'(3'60
are are tLg.ht, ,8
by II rro WS,
);
th TE AUer AUerin in ;tal ;talli ling ng eng ill and aqJu stthe v a v e
aa
e.
U ~~ ~ ~ r1 r1 l
feeh~T g a u g : e , fTI'9cE1SUl"e' t~W!valv€: clesranca ke arm, to osen betwe,en 'the th ~o kt1l kt1lut ut nd ur the .adj .adjuM uMin inig ig SQr~ SQr~Wt Wt et th Hoidthe
t h € .1 .1 o c
adju adjust stin in
'scr 'screw ew In
id t~ghten
nut.
ec the vo:j~\fe c~ The shou shou1d 1d sl da with a\/ery s!i.ght drag.
Tu
th t~m~ t~m~ng ngma mark rk as!; as!;Ib Ibav ave, e, A d j u ~ t "bn~v t h · v t:t: l.l. lv lv e s 1rldiG,~t~d by arrows.
Second
[M0105
aI
Nl
NE
C H N UO UO A
Cy
EM·49
LU ~.a} Ap ply se
rt
(3
~OdO80) or
rc
th
~1 al
fC
III
earL
COVEIR ta)
(b,) '{9}
Apply
·b
II
(p rt
08B.216~iOOO.80} or saal reta retain iner er cyli cyli10 100e 0e
the Iiiead
~n;l61 washers and
inst'll~1he cHi nuts. nuts. bollts.
two timj timjrl rl
gear gear cover mount
\'.
ENIGIINE
IEM·50
MECHANICAL
Cyli Cyliin ind. d.;l ;l Bloc Bloc
COMIPONENTS
Compressioni---'
Piston
(No,
PistonRing PistonRing (Oil) Piston
Comp Co mpress ression ion
.-------------=--r
Snap Rin ----------------
Rod Bushin Bushin II---II-----~ -~
Crankshaft
nned nneding Rod
~OilJel
9•.2
Ikij~c.m ('fl-llb, N : m ) -r
Specifled
torque
Block
DI
CVLI N D E R BLOCK
(Se€! page
50 DRIVE PLATE
ND
U\ end pl-at"e iElno dust cover,
,3
INSTAll ENGI.NE DISA DISABS BSEI EI\I \I SL JS,eesteps 1,
IN
STAN
1.2,
to
ag
.E.M
10
D.IL P U M P Se
st ps
b o ltlt s
r et et a :i:i ne ne l and gasket,
_----indina nato tor. r. meas measur ur dial indi c:le.ara nee::
the.
O.
0..:2
0.0079 ln.l
~O.003
r&8ter
ks a1 t"
ax rnum rnum repl replac ac
he
CliEARANCE
rod (I;l.)
Rernove the rod nuts-
[e)
UghUy t;lH~ring.
ri
cap, the caps l/IJittl the th€·C.,p,
~rt
teet teet th
.r
bo
it
crank cranksh shaft aft frorn frorndam damaqe aqe
"ea
crank pi
Check scratches,
(g}
an beai beairi ring ng pin and
Plro;l ;lls lsti tig, g,a. a.ge geacro across ss th la.y·a strip of Plro
ro
he
Meas Measun un'l'l th
pin. pin.
pagr€! EM-67) ft~lb.
He
cran cran
59 N·
p, PI~i PI~i"s "st: t:i9 i9ag ag at lt
wide wide
point
4i b~ar b~ar n9 Gr nd the crank pins requ requir ired ed ..
crenksheft
different ',
nq ol
as
distin-
b~ue), For ~T e.ng e.ng.i .i s, re ~ace be ri09 with ne 0 1 \ 1 ing enu ar bearin inqo qoap ap Fa Land Land 2L 'the bear with corresol engines replace. wilh ne
Dr
.~.
brown.
'\ \,
Brown., Bla·ck
tid
Blue EMJ~t"\.
the
tbe
PI;;H~tigag.@.
with
ENG IN
EM-53 ROD
COINNECTING
BEARING
ring ridg ridge, e, piston ring
1 3 1 1 the
(See,
J1)
bear-
piston and rod assembly
ilng through the
NOTE: with
Ar
the
:di~a~lnoir :di~a~lnoir.rator, .rator, measur ry~ng, th rrks 'l't be ck
while scre screwd wd rivs rivsr, r,
nh wi th
Standard thrust
~O.0016- 0.0098
in..,)
10.012 in.)
set,
CLEARANCE
eElA eElA.R .RI: I:NG NG AJ'l AJ'lJO JO C'HE C'HECK CK Oi {a}
{b
loosen
the threads
ra ping' th
bot
g .e . e th th e
pul]
longer mesh. ff b e
n g c s p, caps,
(c
Lift ut the crankshaft.
~d}
Cl an
[o rnal rnal .and .and bt'!!Minid.
eaph cr tc
pining
:.
beari.ng th
TA,FJ:'
ri
replace
EM·54
NGINE
Cyli1nder Block
CHANICALCHANICAL-
P~ac thecranks thecrankshaft haft I(g'}
011
Lay
·176n·llb, 103 N'm' NOTE:
Do
~a ur
0)
I'O(
turn the crankshaft.
Plas Plast, t,ig igag age' e'at at
oil
Standard
Ma ximU'rn
it
to
po t.
(0.004 inJ
clearance:
is grea,tel'
id
than
rsqulred.
NOTE;
~.2.
.
l
\:&:. Br,QWfI.
~f
standard bear bearin ing. g.
i- e.
y.
repl replac ac havcylinder block Or
uc
Black.! :3 lo Slue)
~Of
·0
MO BEARINGS
(a
lin outthe-crankshaft. gf 'thrus )Nesh{ )Nesh{:m~ :m~,n ,n a n d , 'thrus
ordeL
LowerO '1
EM-55 .J
'11":3..
EMH23
IN 1,
Al" n9
me
SClCl
th cy inde inde bloe bloe
su face face
2. si[l'g
,s
nd
yent, cl aan th
od
cvu fe~l~r ~r gaug LJSirl'g~1 reci recisl slon on .str .strai aigh gh edge edge and fe~l gauge, e, rnea rneasu sure re he urla urlaca ca co ac in he cylinder head head ga ke.tfo ke.tfo warwarax
~fw; ~fw;i'i'lr lrp, p,ag ag
o'iock,
Vi ual
(0.008 in.]
wa Ra
I. ,~rea'ter than maximum,
c he he c
th
ind
c1
rep.~ rep.~ac ace~ e~
~vli ~vlind nder er
rat hes,
present, rebo rebore re allf allfou ou
G y l l id id fW fW S
ylin ylinde de
Bl ck
Thrust
tiorrs
' D
axia', direct direction ions. s. nd axia',
Band
Sta.ndard diameter
~. Ax al
Direction
-
1 10 10 _
mm.
l st st o
15 rnm
~~'-----+T (0_5.9
;3.. 5445)
.5 {3.5 {3.5 30'30'-
iS 0.50 0.50
.;
3,13
~-------F---so.zs
STI)
If th di:~ di:~ et r e 'p' p l a .G .G o e t h e
3.6429)
~J,&524)
92.23 (3.63111
f3$720)
9 <2 < 2 .7 3 ~ 3 -6 -6 50 50 S .
~--~-----r-----
fo
.5
ylinde·r- bore
-
rebo rebore re
in.) in.)
90,030
S'fD
ird
rnrn rnrn
·T
MiddJe j,
re
Cy
si
ST'D size size the ST'D
.gr cyli cylind nd rs
is g:reat€ll" g:reat€ll" than
rrm.c'hin€l '~hE!piston ri,ng
of the
cylinder;
O NN E
NG
OD AS
MB
WE ry to
on 'the
movement
expand nder er remo remove veth th piSt_O.il ring expa piston .separats for .Iillii'l.ch cylinder.
rings,
NEC (6
Usin Usin
RO
FROM FROMIP IPIS ISTO TO
needl needlee-no nose se pli:€Js. remo remove ve he snap rinqs,
\1 E1V<716B
platen
158,on
in
a stic-
ta
he
ha
tly
!1
is
ma
{J
nnectlnq
rod,
NOTE:
piston
Me
in , .rin.gs th p i n , p in Ilif! der. ech
t.
S.cr~ S.cr~pll pllicarbo icarbo ve
'0
move
(c) EM2'1 '!O
CO
e d o ge ge t e r
NEC
C L E A N I PISTON {Eli)
\\
conneetlnq
PISTONI
ROD ASSE BLY
set.
fromth fromth
piston top,
r1lng too
roken ring ring clea clea
the
s;
.USh19 solvent
nd brus brush, h, 1i.h 1i.hor orou ough gh~y ~y clea clea the ptstorr. aw
(.a}
hole center
23 mrn {O.· {O.·9. 9.,i ,inJ nJ belo belo
{1:34
~inGl
the skirt bottom
edge. i:o;l
2L 2l·
.si.zf.l
34 rnrn 23.· rnrn
metar
1 -
91
3.542 ~V
(];Ped
nb
-
Thrust [:lJir.e [:lJir.e tnQn
Starul3fd· clearance:
{O .59.... .59....ll..). Mijddh,
92,410
05
cylinder bore diam diam in page EM-,56)ano subtract the· piston nder diam diamet eter er the yl nder
{iJ)
5mrn
1.
.4 63
Oi
["2; A~ial. ,- Dire Dire tion tion
0-
rom O. 01
5 -
rnrn
.0
0.0028
in.) in.)
mm lO,OQSS in.)
,d'*t..
the clearance "'·'piston,: reb-ore pistons.
E111
four four
ey.l ey.lii iild lder er
and replace
N.o. ring to th pi s.nd, lIsing . a e e e r .gaug .gauge, e, meas measure ure the No..1 ring clea cleara ranc nc betw betwee ee the f~ts.h· nd nd new pi sto ti the ring l9
0.055
lear learan ance ce
betw betwee ee
ring c:'eatance: .040 .' Oil rJng 0.070
0.0022 in.)
mm
the
rnen O "; "; ( O ·
an
No.2 a,nd oil r~t1g ew ,n
0.0028
inJ
EM·59
PISTON R l N G I cylind nd the cyli
piston
~b) Usiing
il
piston,
'(d
Iii
r~
g'
litt little le beyo beyoll ll
.1
:,,surface
~5.51
bl
bore bore
"\i: "\i:
ng
,'
feel'Elf
au
a' u r
he $' fd gap mrr; mrr; (in, (in,
€Ina gap IPiston
tem
2L.2L-T
rm.g
', _0._'
'-+-1_(0_'0_'
'_'_8_" _-_0_._.0_2._2_4_)1 O,
.2
0_0.205)
0 ,0 0 7 9 '
0.47 0_01
5]
0,5.2 I------~~---~--------c
o,1
1.3. 1.3.
(O.0 (O.05· 5·''-
1. 1,12 \0,0441,
Oil
piston ring. new
the spec speclf lfia ia
exceeds
axlr axlr urn, urn, re:plac€! the
the
piston
Ir.ilflg,.
rebore rebore theevl theevllnd lnder er
70< !!C C
nd use an
pis ton
58 F) YDU with your your thum thumb, b,
push
ns merit.
Ch Malx.imum bend:
0".05 mm (O.OOZO
100 mm (3.94 in.]
tw t-
aximum aximum twist twist 0.15
If the
rnm (0.0059 01
ln.l per
100
mrn (3,.'94 in.l
twisted, replac€! the conn connec ecti tinq nq rod. rod.
{b}
b~1we,Bn the
Meas_wl!1'e
bushing
diam diamet eter er of the
m e a s u r e th
micrometer, isto isto
,f the
diar diarrr rret eter er
in
Subt Subtra ract ct the, isto isto in diameter hom the rod bu hi nsid nsid diameter.
il1.~
(0.0020 in.)
ro
than rnax rnaxir irrr rrum um
bush bushin ing. g.
the
repl replac ac
BUSH.ING press. SS
0092 009222 22-4 -400 00
bu.shing,
'I
TA ta}
A.ll A.llg, g,11 11he he oi
ing and connecting
IriOIBS
red,
the bushing,
and
SST 09222 09222-40011 -40011
t;M2'174"
HONE HONE RO USHI USHING NG ,AND, CON,NECTING ROD 11
bushif,g and check wiJhrn standard speclfication,
pin
is!)
that the: III
cl
the roo
ce
0.00 0.0002 02
0.0'1,2 mm
pill witl1 engijne
0.00 0.0005 05 w n . 1 it into
EM-61
(8
Us
I11S.1lSLlre-
axim aximum um
lr la ru
ut
the circle er k s aft
-$
0.1'1
gre-ater than maximum,
th
main main Jour Journa na an crank pin, Stan Standa dard rd ,~ia ,~iame me1i 1i:e :e '(Standard Ma,in j:ournal 1. 2.
size size
0·
diameter
,o
the
bear bear ng
,2.4 ,2.4 09in 09in
.2
2.086:6 ln.) 2.1654 inJ
.1
the main main jour journa na and crank pin
and
ax.i urn taper taper and out-e out-ef-re f-reund und 0.02
'I till till
0.00 0.00
oi ci 'i;l 'i;lra rapc pc
ln
even even
J O ' U ! R N A L AN D-/OR CRAiN,K
PIN Grin,cIand unde undelr lrsi siz! z!il il ai
he cr~nk5haft.
and/or c.l'ank p u n s to the
journals fini finish shed ed 'dla 'dlarn rnet eter er
hOIl€:
diiametet:
jcur jcur al fi ish~ ish~
I!
mm
0. ran! ran! pi
frni frni he
2.
05
2,,4 2,,4
2.4213
diam diamet eter er
mm
.2L,
54.750
in.)
mm
52.5 52.500 00 ~2.06 ~2.06'6 '655.06 in,) 8rom
Inst Instal al'l'l ne
lnqs,
Jm a , a n d/ d/ O r rnal rnal j O L Jm
crank pi
unde unde size size bear bear
ENGI
EM-t:i2
Bl
Pisto Pisto dia eter eter Standardsi.ze
(:3. (:3.54 541· 1·
.~ 3.5421 in,) rnm
0~ 55-
92..
2L.2L-T
Aepl.a G~ '@II '@IIth th R· pi ce th
2.
pisto pistons ns ri ng
ones
CALCULATE
0.
in.l 92.470 mrn illl.)
rna teh n 9
BOHE BOHE CYLI CYLIIN INDE DE:R :R
Us.i Us.ing ng;; ;;;l ;lirn irnic icto torn rnat ater er meas measur ur th piston (II "igdltangl€ PhFl 34 rnrn 23. mm W.91 in.) b.el b.elow ow he skir skir bo to
edg ..
2L
t.
13
rnrn rn
cylinder I,sto
(bl
rebcrsd
astcltows:
'""" Pis.to Pis.to diameter diameter P~ston clearance
0,03 0,03
0.05 0.05 mrn
in.)
.2L, .2L, 2L
0.050
Allowance
fo
>=
0.070 mrn
ln.l
CALCliLATED IlIMENSJONiS
02 CAUTlONI: roundness.
EXC;E!.ss honing
( O . O O C H 3 . in.}
will destroy
th
fi ishe ishe
Block
EP
EM·53
1L
RA
0" oil seat replacement. NK from cylinder block:
a r r i V e out
seal,
'S
.d from
body edge, Ie
gr4;:N;lse
Apply
,nstalledto Usingl
kn fe
block:
cylinder
sea! lip.
ut
seal.
~:)lFy
.a
Tap th
ha
sere serewdr wdrlv lver er
Cl:.I'tPosition Position
~~
(c~
Apply
new the oi,l
um
body body
edge.
SST 0'9 1.4-6 1.4-60010 0010
2.
seal {a
rarnoved
frorn cylinde'r
narnrner, seaL
bku::k.:
bl
Usilng
SST 09223 09223
Ap
seal uilt~1
ha r, driv driv Husb Husb with with the rear
e ta ta in in e
e dg dg e
010
MP
If rear
ii1e ii1e
is nsta nstaUe Ue
to cyHn cyHnde de bl
I(
Hp.
knife, plFY
to damaqe th
cran cranks ksha haft ft ..
Tap ttle ttle scre screwd wdri rive ver. r. C \ : d P o s i ~ ip ip n ~:~
~C;)
Ap Y' MP
as ,8
is
surface SS
newoMse~L
hammer,
!;loBEI'I
0922 09223' 3'-6 -630 3010 10
NN
ROiDASSEMBLY SS
until its
BL
PIST PISTON ON
ND
ON
T'NG T'NG
01
:1
hole.
\. E M 1" 1" 16 16 B _
heat th 16S:<>F),
isto iston, n, 'to about
pis.toll
p~n
IN
the
Frofit
Mar~
rod, rod,
Front M a r k
sn.ap r.~ng
pi hole hole
F ro ro n
he
tlhe piston and COM9cting W_ith y"Our thumb tl e r
de
the: phrton
Ma
2.,
INS,TAlL
PISTON
RINGiS
thG: pist piston on ring l;!)I;p·~nder, install thG: the. ·j;:Ode marks tacing u.pwEI'r{L ,<'1
ell
rr th
of
ring ringl€ l€ln lntl tl!i !il, l,
·r
Ringr:nds
o s l t lo lo n the
dn9
tha
the
en
aps~ aps~.r .re, e,
as show shown. n.
,e'nd gaps.
rl!lsta II the beat beat
caps,
gi nserts
th ~; CIOn CIOnna na ting ting
rods rods .a nd rod
ENGiNE
M EC EC .H .H AN A N IC IC A
Cylind,er Block
.0
BE;A,RINGS
3,
Install the bearinq in the, the, cyli cylind nde' e' bloc bloc
an bearing, caps.
UTION: UTIO N: bloc.k.
he
al .th
wlit bearing wlit
hole in he
IN,·STAll UPPER THRUST WASHERS
lnst lnstal al th thru thrust st wash washes es under the main main b-Ba b-Bari ringc ngcap ap position eilg,roQve:s facing outward, O G with 'th,e eilg,roQve:s SH
ON
THRU THRUST ST WASH WASHEI EIRS RS
IN
BLOCK
CAPS
hbe {al
with the o'il o'il ~roov ~roov-es -es facin facin
the outward.
GI Ex. No.3 No.3 Beari!llg
IA ICAL-
Cylind.rilr Block
EM~67
the tH~arir)9
Bel;lrin.gCap
(c)
Apply
ligh ligh
heads
coat coatin in
th ir
cap
ro er location.
threads
shown. To qu {ej (f
05
q-
b,
cran cran
three
tn
03 N'
Check that the heck heck th
and
holts,
smoothly. haft haft
(Sa,a p a g B EM~53)
thrust clearanee.
W!0:150
6.
INSTALL ASSEMBLY
h e o d bo ts
(b}
F ro ro n M a
Us·ing
ithQ ithQ shor shor pi~:cEl damage',
r~ng
~j
'11~.
1\ ~I ~I
CONNECTING
ward.
to
pro-
nurn-
~I
Fron Fron f\ila f\ilark rk
ho
RO
CAPS CAPS
EM~68
Apply ~~!;Int nd th rod
k:.}
the engiifllei
rod nuts altematatv
dti
three pa·5se~.
in
I(g~(lm
Check th
(8
hec
turns smoothly.
th
(See (See ag
ea an e,
M~5~) M~5~)
BLOCK Se
ag
~50) ~50)
OIL SEAL SEAL RETA RETAIN INER ER
Install new ga.sket and the retainer holts, To ue 9f
INS,TALL
N·m)
P'
(Se'l!
ISee ISee ,step ,step
with· the four bolts,
,7
HEAD
to
!;lInd 16 on 'age 'age EM
1(49)
E.NGIINf STAND
TA and the end plate with
l'nst!!}'11
fl
WH EE
INSTALL
Torq To rq
,2
-e
OR f1~I f1~I.b .b
N·
the
