Canter Shop Manual

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GROUP 11 ENGINE

SPECIFICATIONS .............................................................................. 11-2

STRUCTURE AND OPERATION


1. Exploded View ............................................................................. 11-3
2. Valve Mechanism ......................................................................... 11-4
3. Cylinder Head Gasket .................................................................. 11-5
4. Water Director .............................................................................. 11-5
5. Connecting Rod ........................................................................... 11-5
6. Piston .......................................................................................... 11-6
7. Timing Gears ...................................................................................... 11-6

TROUBLESHOOTING ....................................................................... 11-7

ON-VEHICLE INSPECTION AND ADJUSTMENT


1. Measuring Compression Pressure ............................................... 11-8
2. Inspection and Adjustment of Valve Clearances ........................ 11-10

ENGINE REMOVAL AND INSTALLATION <TILT CAB> ................ 11-12

ENGINE REMOVAL AND INSTALLATION <FIXED CAB> ...............11-16

ROCKER COVER AND ROCKER CACE .........................................11-18

CYLINDER HEAD AND VALVE MECHANISM..................................11-20

PISTON AND CONNECTING ROD, CYLINDER SLEEVE ................11-34

FLYWHEEL ........................................................................................11-48

TIMING GEARS .................................................................................11-52

CAMSHAFT........................................................................................11-56

CRANKSHAFT AND CRANKCASE ..................................................11-60

CAMSHAFT BUSHINGS....................................................................11-70

11-1
SPECIFICATIONS
Item Specifications
Engine mode 4D33 4D34D 4D34
Type 4-cylinder, in-line, water-cooled, 4-cycle diesel engine
Combustion chamber Direct injection type
Valve mechanism Overhead valves
Maximum output kW {PS} /rpm 96 {130} /3200 81 {110} /3200 88 {120} /3200
Maximum torque N·m {kgf·m} /rpm 304 {31} /1800 225 {26} /1800 294 {30} /1800
Bore × stroke mm φ108 × 115 φ104 × 115
3
Total displacement cm {L} 4214 {4.214} 3907 {3.907}
Compression ratio 18

Remarks
Output and torque represent performance of run-in engine operating under the standard ambient conditions and
accessories specified below.
Barometric Temperature of
Standard Accessories
pressure inlet air
101.3 kPa Fan, Air cleaner
JIS JIS D1004, 1976 15.0°C
{760 mmHg}, dry

11-2
STRUCTURE AND OPERATION 11
1. Exploded View

11-3
STRUCTURE AND OPERATION
2. Valve Mechanism
• Each valve has a valve stem seal,
which regulates the flow of lubricating
oil to the contact surface between the
valve and the valve guide.
• The outer valve spring and the inner
valve spring are both variable-pitch
springs, with different coiling directions
to prevent meshing while the engine is
running.
• The valve clearance is adjusted using
an adjusting screw.

11-4
11
3. Cylinder Head Gasket
• Select and use a cylinder head gasket
of a thickness that can accommodate
the piston projection.
• The size (thickness) class of the gas-
ket can be identified by the shape of
the notches cut on the edge of each
gasket.

4. Water Director
• The water director is attached to the
bottom surface of the cylinder head,
and is used to direct the flow of the
coolant in the right direction.

5. Connecting Rod

11-5
STRUCTURE AND OPERATION
6. Piston

7. Timing Gears

• Each gear has one or two alignment marks (“1”, “2”, “3”) to facilitate reassembly.

11-6
TROUBLESHOOTING 11
Symptoms

Abnormal engine noise


Reference Gr

Low power output


Possible causes
Incorrect valve clearance O O
Defective cylinder head gasket O O
Worn valve and valve seat; carbon deposits O O
Cylinder head and valve
Weakened valve spring O O
mechanism
Defective rocker shaft and bracket O
Poor lubrication of rocker shaft bracket O
Worn tappet O
Incorrect backlash in timing gears O
Timing gears
Poor lubrication of timing gears and idler shaft O
Excessive end play in camshaft O
Camshaft
Worn camshaft O
Worn/damaged piston ring groove(s) O O
Pistons and connecting
Worn/damaged piston ring(s) O O
rods
Worn piston pin and connecting rod small end O
Excessive end play in crankshaft O
Incorrectly fitted crankshaft O
Crankshaft Worn/damaged crankshaft pins and connecting rod bear-
O
ings
Worn/damaged crankshaft journals and main bearings O
Injection timing faulty O O
Defective injection pump O O
Fuel system Gr13
Faulty fuel spray from injection nozzle O O
Air trapped in fuel system O
Malfunctioning cooling system components O
Cooling system Gr14
Loose/damaged V-belts O
Intake and exhaust Clogged air cleaner O O
Gr15
system Clogged muffler O O
Incorrect oil viscosity O Gr12
Improper fuel O
Incorrectly fitted piping and hoses O
Defective/incorrectly fitted alternator and other auxiliaries O

11-7
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Measuring Compression Pressure
Service standards
Location Maintenance item Standard value Limit Remedy
2550 kPa 1960 kPa
Each cylinder (at 200 rpm) Inspect
{26 kgf/cm2} {20 kgf/cm2}
– Compression pressure 390 kPa
Cylinder-to-cylinder pres-
– {4 kgf/cm2} Inspect
sure difference
or less

Special tools (Unit: mm)


Mark Tool name and shape Part No. Application

Compression gauge
adapter MH061460 Measuring compression pressure
A
M14 × 1.5

• A drop in compression pressure can be used as a guide to determine when the engine should be overhauled.
• Measure the compression pressure at regular intervals. Keeping track of its transitions can provide a useful tool
for troubleshooting. On new vehicles and vehicles with newly replaced parts, the compression pressure will be
somewhat higher depending on the break-in condition of piston rings, valve seats, etc., but this will return to nor-
mal as the parts wear down.
• Before the compression measurement, confirm that the engine oil, starter, and battery are in normal condition.
• Place the vehicle in the following conditions.
• Warm up the engine until the coolant temperature reaches approximately 75 to 85°C.
• Turn off the lights and auxiliaries.
• Place the transmission in neutral.
• Place the steering wheel in the straight-ahead position.

• Disconnect connector of the fuel-cut motor so that no injection of


fuel takes place when turning over the engine using the starter.

• Remove all injection nozzles.


• Cover the injection nozzle mounting holes with shop towels.
• After cranking the engine by the starter, check that no foreign
substances are deposited on the shop towels.
• If there are deposits (such as engine oil or coolant) on the shop
towels, the following may be the cause:
• Deposits of engine oil alone can mean a defective piston ring
seal; the piston rings must be inspected.
• Deposits of both engine oil and coolant can mean cracks in
the cylinders; the crankcase must be replaced.

11-8
11
WARNING
• When coolant and engine oil deposits are evident, cranking
the engine could be dangerous as these substances, heat-
ed to high temperatures, will blow out from the injection
nozzle mounting holes. Make sure to stay away from the in-
jection nozzle mounting holes when the engine is being
cranked.

• Attach the gasket and to one of the injection nozzle mount-


ing holes and fix it in place with the nozzle bridge. Then, connect
a compression gauge to .
• Crank the engine and measure the compression pressure for all
the cylinders one after another. Determine the compression
pressure difference between the cylinders.
• If the compression pressure is below the limit or the cylinder-to-
cylinder pressure differences is not within the limit, pour a small
amount of engine oil into the corresponding injection nozzle
mounting hole and remeasure the compression pressure.
• If the compression pressure increases, the piston rings and
cylinder surfaces may be badly worn or otherwise damaged.
• If the compression pressure remains unchanged, there may
be seizure in the valves, the valves may be incorrectly seated
or the cylinder head gasket may be defective.

11-9
ON-VEHICLE INSPECTION AND ADJUSTMENT
2. Inspection and Adjustment of Valve Clearances

Service standards (Unit: mm)


Location Maintenance item Standard value Limit Remedy
– Valve clearance (when cold) 0.4 – Adjust

Special tools (Unit: mm)


Mark Tool name and shape Part No. Application

Cranking handle
MH061289 For cranking the engine
A
36

For adjusting valve clearance (when


Slotted screwdriver MH060008
engine is mounted on vehicle)

• Valve clearances should be checked and adjusted as follows


while the engine is still cold.

[Inspection]
• Remove the rocker cover.
• Bring the No. 1 or No. 4 cylinder piston to the top dead center
(TDC) on the compression stroke by the following procedure:
• Rotate the crankshaft pulley in the illustrated direction so that
the pointer is aligned with the “0” mark next to the “1” to “4”
mark on the inscribed scale on the crankshaft pulley. Either
one of the two pointers can be used for this purpose.
• This will place either the No. 1 or No. 4 cylinder piston at TDC
on the compression stroke. The cylinder in which the rocker
arms for both the intake and exhaust valves can be pushed
down by hand by the valve clearance amounts has its piston
at TDC. Rotate the engine by one full turn to switch the TDCs
of the No. 1 and No. 4 cylinder pistons.

• With the No. 1 or No. 4 cylinder piston at TDC, measure the


clearance of the valves marked with a circle in the table below.
• The feeler gauge must have a slight drag when taking measure-
ments. If the feeler gauge can be moved without any resistance,
the measurement will be incorrect.
Cylinder No. 1 2 3 4
Valve IN EX IN EX IN EX IN EX
No. 1 cylinder piston at
TDC on compression O O O – – O – –
stroke
No. 4 cylinder piston at
TDC on compression – – – O O – O O
stroke

• If the measurements are not within the standard value range,


adjust the value clearance by the following procedures.

11-10
11
[Adjustment]
• Adjust the valve clearance by loosening the lock nut and rotating
the adjusting screw so that the feeler gauge can only be moved
with a slight drag.
• After the adjustment, hold the adjusting screw in position with a
screwdriver and tighten the lock nut to the specified torque.
• Recheck the valve clearance with the feeler gauge, and readjust
if the measurements are not within the specified value range.

• When carrying out valve clearance adjustment with the engine


still mounted on the vehicle, use to facilitate rotation of the
adjusting screw.

11-11
ENGINE REMOVAL AND INSTALLATION <TILT CAB>
<FE>

WARNING
• Only use hoisting equipment appropriate for the engine weight (approximately 500 kg).

Tightening torque (Unit: N·m {kgf·m})


Mark Parts to be tightened Tightening torque Remarks
Nut (front mounting installation) 69 to 88 {6.9 to 9.0} –
Bolt (rear mounting installation) 130 to 170 {13 to 17} –

11-12
11
Removal procedure
Removal: Engine and transmission
• Hook the wire rope and lifting mechanism each onto the two
hangers on the engine and lift the engine with a crane until they
are tight.
• Support the transmission with the transmission jack.
• Check that all wiring and piping have been disconnected from
the engine.

• Taking care not to let the transmission back plate hit the engine
rear support, first push down the transmission part of the assem-
bly, and then move the engine and transmission assembly for-
ward.

• Once the transmission is out of the front end of the rear body,
turn the engine and transmission assembly 90° to the right so as
to prevent the assembly from hitting the frame and cab, and low-
er it to the right side of the vehicle. Make fine adjustments to the
hoisting equipment as necessary.

11-13
ENGINE REMOVAL AND INSTALLATION <TILT CAB>
<FG>

Removal sequence
1 Roll stopper
2 Transmission
3 Engine

Installation sequence
Follow the removal sequence in reverse.

CAUTION
• Be careful not to let the engine hit the cab or the rear body when hoisting the engine.
• Only use hoisting equipment appropriate for the engine weight (approximately 500 kg).

Tightening torque (Unit: N·m {kgf·m})


Mark Parts to be tightened Tightening torque Remarks
Nut (front mounting installation) 69 to 88 {6.9 to 9.0} –
Bolt (roll stopper bracket installation)
45 to 65 {4.5 to 6.5} –
Bolt (rear mounting installation)
Bolt (transmission instrallation) 47 {4.8} M10 × 1.25
Bolt (transmission instrallation) 82 {8.4} M12 × 1.75

11-14
11
Removal procedure
Removal: Engine
• Hook the wire rope and lifting mechanism each onto the two
hangers on the engine and lift the engine with a crane until they
are tight.
• Support the transmission with the transmission jack.
• Check that all wiring and piping have been disconnected from
the engine.

• Hoist the engine slowly, taking care not to let the engine hit the
frame and the cab.
• Once the bottom of the engine is out of the frame, turn the en-
gine by 90° and remove it out of the vehicle.

11-15
ENGINE REMOVAL AND INSTALLATION <FIXED CAB>

Removal sequence
1 Roll stopper
2 Engine and transmission

Installation sequence
Follow the removal sequence in reverse.

CAUTION
• Before removing each part, support the engine and transmission assembly in place using an engine lifter
and a transmission jack.

Tightening torque (Unit: N·m {kgf·m})


Mark Parts to be tightened Tightening torque Remarks
Nut (front mounting installation) 69 to 88 {6.9 to 9.0} –
Bolt (rear mounting installation) 130 to 170 {13 to 17} –
Bolt (roll stopper bracket mounting)
44 to 64 {4.5 to 6.5} –
Bolt (rear mounting installation)

11-16
11
Removal procedure
Removal: Engine and transmission
• Support the engine and transmission with an engine lift and a
transmission jack.
• Check that all wiring and piping have been disconnected from
the engine.

• Lower the engine and transmission to the greatest extent possi-


ble while keeping it horizontally balanced.
• Jack up the vehicle and slide the engine and transmission for-
ward.

11-17
ROCKER COVER AND ROCKER CASE

11-18
11
Disassembly sequence
1 Oil filler cap 8 Rear cylinder head cover 15 Rocker cover assembly
2 Front cylinder head cover assembly <4D33> 16 Rocker cover gasket
assembly <4D33> 9 Rear seal rubber <4D33> 17 Rocker cover
3 Spacer <4D33> 10 Rear cylinder head cover
4 Insulator <4D33>
5 Joint rubber <4D33>
<4D33>
11 Front spacer <4D33>
*a:: Rocker and bracket assembly
Non-reusable parts
6 Seal rubber <4D33> 12 Rear spacer <4D33>
7 Front cylinder head cover 13 Washer
<4D33> 14 Insulator

Assembly sequence
Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m})


Mark Parts to be tightened Tightening torque Remarks
Bolt (rocker cover assembly mounting) 3 to 4 {0.3 to 0.4} –

Lubricant and/or sealant


Mark Points of application Specified lubricant and/or sealant Quantity
Joint rubber on front cylinder head cover mounting sur-
face
Seal rubber on front cylinder head cover mounting sur-
Cemedine As required
face
Rear seal rubber on rear cylinder head cover mounting
surface

11-19
CYLINDER HEAD AND VALVE MECHANISM
Disassembly sequence
1 Cylinder head bolt
2 Rocker and bracket assembly
(See later sections.)
3 Push rod
4 Cylinder head
(See later sections.)
5 Cylinder head gasket
6 Tappet

*a: Crankcase
: Locating pin
: Non-reusable parts

Assembly sequence
Follow the disassembly sequence in reverse.

CAUTION
• Be careful not to damage the glow plugs and injection nozzles when placing the cylinder head on the
worktable, as they are protruding out of the bottom of the cylinder head.
• The cylinder head bolts are tightened using the torque-turn method. Any cylinder head bolt that has three
marks indicating that the bolt has been tightened three times already must be replaced with a new one.

Service standards (Unit: mm)


Location Maintenance item Standard value Limit Remedy
3 Push rod run-out – 0.4 Replace
6, *a Tappet-to-tappet hole clearance 0.05 to 0.09 0.2 Replace

Tightening torque (Unit: N·m {kgf·m})


Mark Parts to be tightened Tightening torque Remarks
Wet
Cylinder head bolt 150 {15} +90° Reusable up to
3 times

Lubricant and/or sealant


Mark Points of application Specified lubricant and/or sealant Quantity
Threads of cylinder head bolt
Upper and lower ends of push rod Engine oil As required
Outer surface of tappet

11-20
11
Special tools
Mark Tool name and shape Part No. Application

Socket wrench MH061560 Installation of cylinder head

Tappet extractor MH063329 Removal of tappet

Work before removal


Preparing for cylinder head removal: Releasing valve spring
tension
• If the rocker arms are pressing down on the valve springs, loos-
en the adjusting screws on the rocker arms before loosening the
cylinder head bolts to prevent any damage by the valve springs’
tension.

Removal procedure
Removal: Cylinder head
• To remove the cylinder head, first loosen the cylinder head bolts
in the order indicated in the illustration.

Removal: Cylinder head gasket


CAUTION
• Be careful not to scratch the cylinder head and crankcase
when removing the cylinder head gasket.

Removal: Tappets

11-21
CYLINDER HEAD AND VALVE MECHANISM
Inspection procedure
Inspection: Push rod run-out
• If the measured values exceed the limit, replace the push rod.

Inspection: Tappet-to-tappet hole clearance


• If the measured values exceed the limit, replace the defective
part(s).

Installation procedure
Installation: Cylinder head gasket
• The cylinder head gasket comes in three sizes. Choose the gas-
ket appropriate for the cylinder head by the following procedure.
• Measure the amount of piston projection for every cylinder.
(See the PISTON AND CONNECTING RODS section.)
CAUTION
• Replacement of the piston or connecting rod alters the pis-
ton projection. Always measure the amount of piston pro-
jection after either or both of them are replaced.

• Select a cylinder head gasket with the appropriate thickness


for the measured maximum piston projection value from the
following table.
If any of the piston projection measurements is more than
0.05 mm larger than the average value, then use the gasket
one rank higher than that rank (A→B, B→C).
Piston projection Cylinder head gasket
Average value of Thickness when
Size
piston projection tightened
0.466 to 0.526 A 1.35 ± 0.03
0.526 to 0.588 B 1.40 ± 0.03
0.588 to 0.648 C 1.45 ± 0.03

• The size class of the cylinder head gasket can be determined


from the shape of the notches cut on the gasket edge.
• Install the cylinder head gasket on the crankcase in the illustrat-
ed direction.

11-22
11
Installation: Cylinder head
CAUTION
• Before fitting the cylinder head bolts, check the punch
marks on each bolt’s head. Do not use the bolt if there are
three punch marks.
• The punch marks indicate the number of times each bolt
has been tightened using the torque-turn tightening meth-
od. Any bolt that already has three punch marks must be re-
placed.

• Tighten the bolts to half the specified torque (75 N·m {7.5 kgf·m})
in the order indicated in the illustration.
• Tighten these bolts further to the specified torque (150 N·m {15
kgf·m}) in the same order, then completely tighten them by the
following procedure.
: Bolts also fastening rocker arm and bracket assembly

• Turn the holder of counterclockwise to pretension the inter-


nal spring.

• Fit on the bolt and set it so that the rod (extension) is held
pressed by the spring force against a surrounding part such as
the rocker shaft bracket or the injection pipe.
• Select a clearly visible mark on the scale on the holder.
• Use this mark as a point of reference and turn the socket clock-
wise by 90° (One graduation on the socket scale represents 5°).
• After tightening each bolt, make a punch mark on the head of
the bolt to indicate the number of times that it has been used
(bolts may not be used more than three times).
CAUTION
• Cylinder head bolts that have been tightened using the
torque-turn method must never be additionally tightened af-
ter the final angular tightening.

11-23
CYLINDER HEAD AND VALVE MECHANISM
Rocker and Bracket
Disassembly sequence
1 Set bolt
2 Rocker shaft bracket
3 Adjusting screw
4 Rocker bushing
5 Intake valve rocker
6 Rocker shaft spring
7 Exhaust valve rocker
8 Rocker shaft

: Non-reusable parts

Assembly sequence
Follow the disassembly sequence in re-
verse.

Service standards (Unit: mm)


Location Maintenance item Standard value Limit Remedy
4, 8 Rocker bushing-to-rocker shaft clearance 0.06 to 0.11 0.2 Replace

Lubricant and/or sealant


Mark Points of application Specified lubricant and/or sealant Quantity
Rocker bushing inside surface Engine oil As required

Special tools (Unit: mm)


Mark Tool name and shape Part No. Application

Rocker bushing puller Removal and installation of rocker


MH061378
A B bushing
φ19 φ21

Inspection procedure
Inspection: Rocker bushing-to-rocker shaft clearance
• If the difference between the measurements exceeds the limit,
replace the bushing.

11-24
11
Replacement of rocker bushing
[Removal]

[Installation]
• Assemble the tool and parts as illustrated while aligning the oil
hole in the bushing and the oil hole in the rocker.
• Force the bushing into the rocker until touches the rocker’s
chamfered end.
• After the installation is completed, measure the clearance be-
tween the rocker shaft and the bushing.
• If the measurement is less than the minimum value in the stan-
dard value range, ream the rocker bushing.

Installation procedure
Installation: Rocker shaft
• Install the rocker shaft with its ends facing in the illustrated direc-
tions.

11-25
CYLINDER HEAD AND VALVE MECHANISM
Cylinder Head

Disassembly sequence
1 Valve cap 9 Nozzle bridge 17 Exhaust valve seat
2 Valve cotter 10 Injection nozzle (See Gr13) 18 Water director
3 Upper retainer 11 O-ring 19 Stud
4 Outer valve spring 12 Nozzle tip gasket 20 Cylinder head
5 Inner valve spring 13 Dummy plug
6 Valve stem seal 14 Intake valve guide : Non-reusable parts
7 Intake valve 15 Exhaust valve guide
8 Exhaust valve 16 Intake valve seat

Assembly sequence
Follow the disassembly sequence in reverse.

CAUTION
• When an intake valve or exhaust valve have been removed, make sure to replace the valve stem seal.

Service standards (Unit: mm)


Location Maintenance item Standard value Limit Remedy
Free length 66.1 63.0
Installed load 275 ± 14 N 230 N
4 Outer valve spring Replace
(47.25 in installed length) {27.9 ± 1.4 kgf} {23.7 kgf}
Squareness – 2.5
Free length 60.0 57.0
Installed load 120 ± 5.9 N 100 N
5 Inner valve spring Replace
(40.3 in installed length) {12.1 ± 0.6 kgf} {10.3 kgf}
Squareness – 2.5
Stem outside diameter 8.96 to 8.97 8.85 Replace
Sinkage from cylinder head
1.0 ± 0.25 1.5 Inspect
7 Intake valve bottom surface
Valve margin 1.5 1.2
Reface or replace
Seat angle 45° ± 15’ –
11-26
11
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
7, 14 Intake valve stem-to-valve guide clearance 0.04 to 0.06 0.15 Replace
Stem outside diameter 8.93 to 8.94 8.85 Replace
Sinkage from cylinder 4D33 1.25 ± 0.25
1.7 Inspect
8 Exhaust valve head bottom surface 4D34 1.2 ± 0.25
Valve margin 1.5 1.2
Reface or replace
Seat angle 45° ± 15’ –
8, 15 Exhaust valve stem-to-valve guide clearance 0.07 to 0.1 0.2 Replace
4D33 2.0 ± 0.2 2.8 Correct or
16 Intake valve seat width
4D34 2.8 ± 0.2 3.6 replace
Correct or
17 Exhaust valve seat width 2.0 ± 0.2 2.8
replace
Correct or
Bottom surface distortion 0.05 or less 0.2
replace
20 Cylinder head
Height from top surface to
95 ± 0.1 94.6 Replace
bottom surface

Tightening torque (Unit: N·m {kgf·m})


Mark Parts to be tightened Tightening torque Remarks
Bolt (nozzle bridge installation) 25 {2.5} –
Dummy plug 15 to 20 {1.5 to 2.0} –

Lubricant and/or sealant


Mark Points of application Specified lubricant and/or sealant Quantity
Contact surfaces between valve cap and rocker
Lip of valve stem seal
Engine oil As required
Valve stem
O-ring

Special tools (Unit: mm)


Mark Tool name and shape Part No. Application

Valve lifter
MH061668
A
φ 42
Removal and installation of
valve cotters

Valve lifter hook MH061679

Valve stme seal installer


MH061293 Installation of valve stem seals
A B
φ 28 φ9

11-27
CYLINDER HEAD AND VALVE MECHANISM
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application

Lapping valves and valve


Valve lapper 30091-07500
guides

Valve guide remover


MH061066 Removal of valve guides
A B
φ9 φ 13

Valve guide installer


MH061998 Installation of valve guides
A B C
φ 28.5 φ 15 φ 18

Caulking A
tool body MH061067
φ9

Caulking ring
Model B MH061695 <4D33> Installation of valve seat
MH061275 <4D34>
4D33 φ 49
Intake <intake>
4D34 φ 47.6 MH061696 <4D33>
MH061069 <4D34>
4D33 φ 42
Exhaust <exhaust>
4D34 φ 40.6

Removal procedure
Removal: Valve cotters
• Remove the valve cotters by evenly compressing the valve
springs.
CAUTION
• Do not compress the valve springs more than necessary, as
this may cause the upper retainer to touch the valve stem
seal and damage it.

Inspection procedure
Inspection: Valve stem outside diameter
• Replace the valve if the stem’s outside diameter is below the lim-
it or is severely worn.
• When the valve has been replaced with a new one, make sure to
lap the valve and valve seat.

11-28
11
Inspection: Valve seat angle and valve margin
• Reface or replace the valve if the valve seat angle or valve mar-
gin exceeds the specified limits.

Refacing
• Limit grinding to a necessary minimum.
• If the valve margin is below the limit after grinding, replace the
valve.
• After grinding, make sure to lap the valve and valve seat.

Inspection: Valve-to-valve guide clearance


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

Replacement of valve guides


[Removal]

[Installation]
• Install the valve guide until sits snugly on the cylinder head.
CAUTION
• The valve guides must be pressed to a depth of 10 mm. Be
sure to use for this operation.
• Exhaust valve guides are longer than intake valve guides.
Make sure to install the correct type of guide in each loca-
tion.

11-29
CYLINDER HEAD AND VALVE MECHANISM
Inspection: Contact between valve and valve seat
• Before starting inspection, check that the valve and valve guide
are intact.
• Apply an even coat of red lead to the valve contact surface of
the valve seat.
• Strike the valve once against the valve seat. Do not rotate the
valve during this operation.

• If the red lead deposited on the valve indicates a poor contact


pattern, take either of the following corrective actions.
Corrective action
Minor defect Lapping
Serious defect Reface or replace valve and valve seat

Lapping
• Apply a thin coat of lapping compound to the seat contact sur-
face of the valve.
CAUTION
• Do not put any compound on the stem.
• Start with an intermediate-grit compound (120 to 150 grit)
and finish with a fine-grit compound (200 grit or more).
• Adding a small amount of engine oil to the lapping com-
pound can facilitate even application.

• Strike the valve several times against the valve seat while rotat-
ing the valve a little at a time.
• Wash away the compound with diesel fuel.
• Apply engine oil to the valve contact surface of the valve seat
and rub in the valve and seat well.
• Inspect the contact pattern of the valve and valve seat again.
• If the contact pattern is still defective, replace the valve seat.

Inspection: Valve seats


(1) Valve seat width
• If the measurement exceeds the limit, reface or replace the
valve seat.
• After refacing or replacing the valve seat, make sure to lap the
valve seat and valve.

11-30
11
(2) Valve sinkage from cylinder head bottom surface
• Perform measurement keeping the valve in close contact with
the valve seat.
• If the measurement exceeds the limit, adjust or replace the de-
fective part(s).

Refacing the valve seat


• Grind the valve seat using a valve seat cutter or valve seat
grinder.
• Place a sandpaper of around #400 between the cutter and valve
seat and grind the valve seat lightly.
• Use a 15° or 75° cutter to cut the valve seat to a width within the
standard range.
CAUTION
• Make sure that the valve seat refacing does not cause the
valve sinkage to exceed the specified limit.

• Lap the valve and valve seat.

Replacement of valve seat


[Removal]
• The valve seats are installed by expansion fitting. To remove a
valve seat, grind inside the metal stock to reduce the wall thick-
ness, then remove the valve seat at room temperature.

[Installation]
• Check that the diameters of the intake and exhaust valve seat
holes A and B in the cylinder head conform with the values
shown below.

4D33 4D34
Intake valve seat hole: A φ50 +0.025
0 mm φ46 +0.025
0 mm
+0.025
Exhaust valve seat hole: B φ43 0 mm φ39 +0.025
0 mm
• Replace the cylinder head if necessary.

• Chill the valve seat thoroughly by immersing in it in liquid nitro-


gen.
CAUTION
• Handle the chilled valve seats extremely carefully to avoid
getting frostbites.

• Install the valve seat in the cylinder head using and .


• Lap the valve seat and valve.

11-31
CYLINDER HEAD AND VALVE MECHANISM
Inspection: Cylinder head bottom surface distortion
• If the distortion exceeds the specified limit, rectify it using a sur-
face grinder.
CAUTION
• Make sure that the height of the cylinder head from the top
surface to the bottom surface is not reduced to a value be-
low the specified limit.

Inspection procedure
Installation: Water director
• Install the water director to the specified depth (4 mm) with the
notch facing in the illustrated direction.

Installation: Valve stem seal


• Apply engine oil to the lip of the valve stem seal.
• Install the valve stem seal until sits snugly on the cylinder
head.
CAUTION
• After installing the valve stem seal, check that its spring is
not deformed or damaged. Replace the valve stem seal if
the spring is defective.

Installation: Valve cotter


• To install the valve cotter, follow the removal procedure. (See
“ Removal: Valve cotter”.)

11-32
11
M E M O

11-33
PISTON AND CONNECTING ROD, CYLINDER SLEEVE
Disassembly sequence
1 Lower connecting rod bearing
2 Connecting rod cap
3 Upper connecting rod bearing
4 Piston and connecting rod
(See later sections.)
5 Cylinder sleeve

: Non-reusable parts
* a: Crankcase

CAUTION
• The connecting rod bolts are fas-
tened using the torque-turn meth-
od. Any connecting rod bolt that
has three marks indicating that it
has been tightened three times al-
ready must be replaced with a new
bolt together with its nut.

Assembly sequence
Follow the disassembly sequence in re-
verse.

Service standards (Unit: mm)


Location Maintenance item Standard value Limit Remedy
Piston projection from crankcase top surface (average
– 0.48 to 0.74 – Inspect
value)
– Connecting rod end play 0.15 to 0.45 0.6 Inspect
Less than
Span when free –
1, 3 Connecting rod bearing 64.5 Replace
Oil clearance 0.04 to 0.09 0.2
Correct or re-
4, 5 Piston and connecting rod-to-cylinder sleeve clearance 0.05 to 0.08 0.04 to 0.10 place with over-
size ones
Correct, replace
with oversize
Clearance between piston and connecting rod assem- Basic diameter : 108
4, a
* bly and crankcace cylinder <4D33> 0.07 to 0.12
– ones or install
cylinder sleeve
for correction
Bore diameter φ104 to 104.03 φ104.25
Correct or re-
5 Cylinder sleeve <4D34> Out-of-roundness 0.01 or Less – place with over-
size ones
Taper 0.03 or Less –
Bore diameter φ108 to 108.03 φ108.25
Crankcace cylinder or cyl-
inder sleeve for correction Out-of-roundness 0.01 or Less – Correct
<4D33>
Taper 0.03 or Less –
Interference between cylinder sleeve for correction and
5,
*a crankcace <4D33>
0.21 to 0.27 – Replace

Interference between cyl- Replace with


Standard 0.17 to 0.23 –
inder sleeve and crank- oversize ones
case <4D34> Oversize 0.19 to 0.21 – Replace
Crankcace sleeve hole Bore diameter φ111.18 to 111.21 –
(when cylinder sleeve for
*a correction is installed)
Out-of-roundness 0.01 or Less – Replace
<4D33> Taper 0.03 or Less –

11-34
11
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Nut (connecting rod cap installation) 100 {10.5} Wet

Lubricant and/or sealant


Mark Points of application Specified lubricant and/or sealant Quantity
Nut threads
Connecting rod bearing inside surface
Engine oil As required
Piston outside surface
Cylinder bore surface
Sleeve hole of crankcase Spindle oil (ISO VG 32) As required

Special tools
Mark Tool name and shape Part No. Application
<4D33>
MH062041
Piston guide clamp
<4D34>
MH061890 Installation of piston and connecting
rod
Piston guide lever MH061658

Cylinder sleeve installer <4D33>


A MH062728
Installation of cylinder sleeve
<4D34>
4D33 φ107 MH062228
4D34 φ103

Inspection before removal


Inspection: Piston projection from crankcase top surface
CAUTION
• The amount of piston projection affects engine perfor-
mance and must therefore be inspected without fail.

• Set the piston at the top dead center.


• Mark reference points A (five points in total) on the top surface of
the crankcase as shown in the illustration. Using each of the
marks as a zero point, measure the amount of piston projection
relative to the zero point (height of measurement point B –
height of reference point A).
• Make the measurements at the two measurement points B for
each cylinder (eight points in total) using the reference point A
nearest to each measurement point, and calculate the average
value of all the measurements.
• If the average value is out of the standard value range, check
the clearances between all relevant parts.
• Select and use a cylinder head gasket that can accommodate
the average piston projection (average value of the eight mea-
surements). (See the CYLINDER HEAD section.)

11-35
PISTON AND CONNECTING ROD, CYLINDER SLEEVE
Inspection: Connecting rod end play
• Measure the end play for every connecting rod.
• If any measurement exceeds the specified limit, replace the de-
fective part(s).

Inspection: Connecting rod bearing span when free


CAUTION
• Do not attempt to manually expand the bearings.
• The upper and lower connecting rod bearings must be re-
placed as a set.

• If the span is less than the specified limit, replace both the upper
and lower bearings.

Inspection: Connecting rod bearing-to-crankshaft clearance


(oil clearance)
• Fit the lower bearing to the connecting rod cap and the upper
bearing to the connecting rod, then tighten the nut to a torque of
69 N·m {7 kgf·m}.
• Measure the inside diameter of the bearing and the diameter of
the crankshaft pin.
• If the clearance exceeds the limit, replace the defective part(s).
• If a bearing has to be replaced with an undersized one, machine
the crankshaft pin to the specified undersize diameter. (See the
CRANKSHAFT section.)

11-36
11
Inspection: Clearance between piston and cylinder sleeve
[Inspection]
<4D33 (With cylinder sleeve for correction), 4D34>
• Measure the clearance between the inner diameter of cylinder
sleeve and outer diameter of the piston part of piston and con-
nection rod.
A: Measuring point on the crankcase (in direction of the crank-
case axis).
B: Measuring point on the crankcase (vertical to the crankcase
axis).
C: Measuring point on the piston outer diameter (vertical to the
piston pin hole).
• If the measured value is higher than the standard value, correct
according to one of the following methods, depending on the
condition of the parts.
CAUTION
• Even if only one cylinder is faulty, correct all the cylinders
to oversize ones of the same size.

• Replacing the piston with an oversize one.


• Replacing cylinder sleeve.
• After determining the proper method of correction, correct by fol-
lowing one of the procedures described below.

Inspection: Piston and connecting rod assembly, crankcase


[Inspection]
<4D33>
• Measure the clearance between the inner diameter of the cylin-
der part of crankcase and the outer diameter of the piston part of
piston and connecting rod assembly.
A: Measuring point on the crankcase (in direction of the crank-
case axis).
B: Measuring point on the crankcase (vertical to the crankcase
axis).
C: Measuring point on the piston outer diameter (vertical to the
piston pin hole).
• If the measured value deviates from the standard value, correct
according to one of the following methods, depending on the
condition of the parts.
CAUTION
• Even if only one cylinder is faulty, correct all the cylinders
to oversized ones of the same size.

• Replace the piston with an oversized one.


• Install cylinder sleeve for correction
(When a cylinder sleeve for correction is not already installed)
• After determining the proper method of correction, correct by fol-
lowing one of the procedures described below.

11-37
PISTON AND CONNECTING ROD, CYLINDER SLEEVE
[Correction]
Piston
<When replacing the pistons with oversize ones>
Amount of oversize: 0.5, 1.0 (4D34) mm
• Measure the outer diameter C of the oversize piston to be used.
• Bore each cylinders so that the clearance between the piston
and the cylinder sleeves conform to the standard value.
CAUTION
• To prevent deformation as a result of the rise in temperature
during boring, bore the cylinders in the following order.
No. 2 → No. 4 → No. 1 → No. 3

Dimension after boring finish (tolerance ± 0.005) = oversize pis-


ton outer dimension C (measured value) + clearance between
piston and cylinder (service standards mean value) - 0.02 mm
(honing extent).
• Boring is followed by honing to obtain the proper dimensions
(tolerance +0.005 to -0.00).
Dimension after final finish (tolerance ± 0.005) = oversize piston
outer dimension C (measured value) + clearance between pis-
ton and cylinder (service standards mean value).
NOTE
• Honing finished surface coarseness: 3.2 µm or less.
• Honing cross-hatching angle: 15 to 25° (half angle).
• Cylinder bore secureness: 0.05 mm.

• Check the clearance between the piston and the cylinder.

NOTE
• Piston rings must be replaced with the corresponding over-
size ones.

Cylinder sleeve
<When replacing the cylinder sleeve>
. [Removal]
• Mount a boring machine on crankcase and centralize. Central-
ization should be done at the lower part of cylinder sleeve which
is less unevenly worn.
• Bore until the wall thickness of cylinder sleeve is approximately
0.5 mm.
• Insert tool (Screwdriver, etc. part of which has been altered) into
the gap between crankcase and cylinder sleeve, and, tapping
the tool lightly, break up and remove the sleeve.
CAUTION
• Make sure rounded side of the tip of tool faces crankcase.

11-38
11
[Inspection]
• Before installing cylinder sleeve, inspect the sleeve hole of
crankcase. Bore and correct, if there is a flaw or if there is not
enough interference.
NOTE
• When a sleeve hole of crankcase needs boring, remove cyl-
inder sleeves from all of the cylinders and bore the sleeve
holes uniformly.
• After applying spindle oil (ISO VG 32) to the sleeve hole of
crankcase press fit cylinder sleeve into the hole.
Inspect interference as follows:
• Measure the inner diameter of the sleeve hole of crankcase and
the outer diameter of cylinder sleeve at each of the locations for
measurement as illustrated.
• Find the mean value for the vertical directions (D1, D2, D3) and
diametrical directions (A, B). Measure the interference.

<When there is sufficient interference>


• Install STD cylinder sleeve.

<When there is not sufficient interference>


• Install cylinder sleeve which is 0.5 mm oversize in diameter.

[Installation]
<When there is sufficient interference>
• Press-fit cylinder sleeve into crankcase from the chamfered end.
E: Pressure (press-fitting load: 46.1 to 88.2 kN {4700 to 9000
kgf})
NOTE
• After applying spindle oil (ISO VG 32) to the sleeve hole of
crankcase press fit cylinder sleeve into the hole.
• Align the upper face of cylinder sleeve with the upper face
of crankcase when press-fitting.
• Measure the outer diameter of the standard size piston to
be used.
• Bore and hone to make the clearance between the piston
and the cylinder sleeve conform to the standard value.
(See “ Inspection: Piston to cylinder sleeve clearance”.)

11-39
PISTON AND CONNECTING ROD, CYLINDER SLEEVE
<When there is not sufficient interference>
• Measure the interference between the outer diameter of cylinder
sleeve and the inner diameter of the cylinder of crankcase.
Make sure the interference in vertical directions (D1, D2, D3)
and diametrical directions (A, B) conform to the mean value.
• Bore and hone the cylinder area until measured value conforms
to the standard value. (See “ Inspection: Piston to cylinder
sleeve clearance”.)
NOTE
• Honing finished surface coarseness: 8 µm or less.
• Honing cross-hatching angle: 15 to 25° (half angle).
• Cylinder bore secureness: 0.05 mm.

• Press-fit oversize cylinder sleeve.


See “When there is sufficient interference”.

Installation procedure
Installation: Connecting rod bearings
CAUTION
• Do not reverse the positions of the lower bearing and the
upper bearing (with oil hole) when installing, as this may
cause seizure in the engine.

Installation: Piston and connecting rod


• Check that the piston ring end gaps are in their correct positions.
A: 1st compression ring gap
B: 2nd compression ring gap
C: Oil ring gap
D: Oil ring expander spring gap

“ ”: Front mark on piston

• Cover the connecting rod bolts with vinyl hoses to prevent them
from scratching the crankshaft pins and the cylinders in the
crankcase.

11-40
11
• Face the front mark “ ” of the piston toward the front of the en-
gine.
• Using the adjusting bolt of , adjust the inside diameter of
such that it matches the piston’s skirt diameter.
• Remove the tools from the piston and apply engine oil to the fol-
lowing parts:
• Outside surface of piston
• Inside surface of
• Cylinder wall surface

CAUTION
• Be careful not to scratch or damage head of the piston (a
part of the combustion chamber).
• Make sure that the connecting rod does not hit oil jet.

• After installing the piston and connecting rod assembly, align the
mating marks on the connecting rod and connecting rod cap and
tighten the nuts alternately.

11-41
PISTON AND CONNECTING ROD, CYLINDER SLEEVE
Piston and Connecting Rod
Disassembly sequence
1 1st compression ring
2 2nd compression ring
3 Oil ring
4 Snap ring
5 Piston pin
6 Connecting rod bushing
7 Connecting bolt
8 Connecting rod
9 Piston

: Non-reusable parts

CAUTION
• Do not remove the connecting rod
bolt unless defects are evident.

Assembly sequence
Follow the disassembly sequence in re-
verse.

Service standards (Unit: mm)


Location Maintenance item Standard value Limit Remedy
1st compression ring 0.3 to 0.45
4D33 0.3 to 0.45
2nd compression ring
1 to 3 Piston ring end gap 4D34 0.3 to 0.5 1.5 Replace
4D33 0.3 to 0.5
Oil ring
4D34 0.25 to 0.45
4D33 0.09 to 0.13
1st compression ring 0.2
4D34 0.13 to 0.18
Piston ring side clearance 4D33 0.04 to 0.06
1 to 3, 9 2nd compression ring Replace
in piston groove 4D34 0.025 to 0.065
0.15
4D33 0.04 to 0.06
Oil ring
4D34 0.025 to 0.065
4D33 0.03 to 0.05
5, 6 Piston pin-to-connecting rod bushing clearance 0.1 Replace
4D34 0.023 to 0.054
5, 9 Piston pin-to-piston clearance 0.007 to 0.021 0.05 Replace
Bend – 0.05
8 Connecting rod Replace
Twist – 0.1

Lubricant and/or sealant


Mark Points of application Specified lubricant and/or sealant Quantity
Piston pin outside surface
Connecting rod bushing outside surface
Engine oil As required
Connecting rod bolt knurled surface
Connecting rod bushing fitting surface of connecting rod

11-42
11
Special tools
Mark Tool name and shape Part No. Application

Removal and installation of piston


Piston ring tool MH060014
rings

Connecting rod bushing Removal and installation of connect-


MH061891
puller kit ing rod bushings

Removal procedure
Removal: Piston ring

Removal: Piston pin


• Remove the piston pin by striking it with a rod and hammer.
• If the piston pin is difficult to remove, first heat the piston in hot
water or with a piston heater.

Inspection procedure
Inspection: Piston ring end gap
• Using the crown of a piston, push the piston ring horizontally into
a cylinder in the crankcase until it reaches the lower part of the
cylinder sleeve, where there is relatively small wear.
• Taking care not to move the piston ring, measure the end gap.
• If any of the rings has a gap exceeding the specified limit, re-
place all the piston rings as a set.

11-43
PISTON AND CONNECTING ROD, CYLINDER SLEEVE
Inspection: Piston ring side clearance in piston groove
• Remove any carbon deposits from the ring groove in the piston.
• Measure the side clearance of each ring around the piston’s en-
tire periphery.
• If any of the measurements exceeds the specified limit, replace
the defective part(s). If any of the piston rings is defective, re-
place all the rings on the piston as a set.

Inspection: Piston pin-to-piston clearance


• If any of the measurements exceeds the specified limit, replace
the bushing.

Inspection: Piston pin-to-connecting rod bushing clearance


• If the measurement exceeds the specified limit, replace the de-
fective part(s).

Replacement of connecting rod bushing


• Replace the connecting rod bushing using .
[Removal]
• Remove the upper bearing (if fitted) from the big end of the con-
necting rod.
• Mount the connecting rod on the base and lock it in position with
the bracket and plate.
• Fit collar A over the puller with its ends facing in the illustrated di-
rections. Then, slowly apply a pressure of approximately 49 kN
{5000 kgf} to the puller with a press to force out the connecting
rod bushing.

11-44
11
[Installation]
• Apply engine oil to the outside surface of the connecting rod
bushing and the bushing fitting surface of the connecting rod.
• Fit collar B, the bushing, and collar A over the puller in the illus-
trated directions and lock this arrangement together with the nut.
• Align the oil holes in the connecting rod bushing and the con-
necting rod. Then, use a press to slowly apply a pressure of ap-
proximately 49 kN {5000 kgf} to the puller until the bushing is
forced into place.
• After press-fitting the connecting rod bushing, measure the
clearance between the piston pin and connecting rod bushing.
• If the measurement is less than the standard clearance range,
ream the bushing.

Inspection: Connecting rod bend and twist


• Mount the connecting rod on the connecting rod aligner. Also
mount the connecting rod bearings, piston pin, and connecting
rod cap to create the same conditions as are expected when the
connecting rod is mounted on a crankshaft. Tighten the nuts of
the connecting rod bearing cap to a torque of 69 N·m {7 kgf·m}.
• Measure the extent of bend and twist in the connecting rod.
• If either measurement exceeds the specified limit, replace the
connecting rod.

Inspection procedure
Installation: Connecting rod bolts
• Check that there are no burrs or other defects on the surfaces of
the connecting rod bolt holes. Replace the connecting rod if de-
fects are evident.
• Apply engine oil to the knurled surface of the connecting rod
bolt. Then, install the bolt by using a press to slowly apply a
pressure of approximately 4.9 kN {500 kgf} to it with the cuts of
the bolt head facing in the illustrated directions.

11-45
PISTON AND CONNECTING ROD, CYLINDER SLEEVE
Installation: Piston to connecting rod
• If the piston and connecting rod have been replaced, make sure
that the weight marks are the same for every cylinder.
• Apply engine oil to the piston pin, and assemble the piston and
connecting rod with their marks facing in the illustrated direc-
tions.
“ ”: Front mark
• If the piston pin is difficult to insert, heat the piston in hot water or
with a piston heater.

Installation: Piston rings


• With the manufacturer’s marks (found near the piston ring end
gaps) facing up, install the piston rings so that the end gap of
each ring is positioned as illustrated.
A: 1st compression ring end gap
B: 2nd compression ring end gap
C: Oil ring end gap
D: Oil ring’s expander spring end gap
“ ”: Front mark on piston
The manufacturer’s marks are present only on the 1st and 2nd
compression rings.

11-46
11
M E M O

11-47
FLYWHEEL

Disassembly sequence
1
2
Plate
Bearing
*a:: Crankshaft
Locating pin
3 Ring gear
4 Flywheel

Assembly sequence
Follow the disassembly sequence in reverse.

Service standards (Unit: mm)


Location Maintenance item Standard value Limit Remedy
Friction surface runout (when fitted) – 0.2
Friction surface C3 16.5 15.5
4 Flywheel Rectify or replace
height C4 24.5 23.5
Friction surface distortion 0.05 or less 0.2

Tightening torque (Unit: N·m {kgf·m})


Mark Parts to be tightened Tightening torque Remarks
Bolt (flywheel installation) 39 {4.0} + 40° Wet

Lubricant and/or sealant


Mark Points of application Specified lubricant and/or sealant Quantity
Bolt threads Engine oil As required

11-48
11
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application

Socket wrench MH062183

Installation of flywheel

Magnet base MH062356

Inspection before removal


Inspection: Flywheel runout
• If the runout exceeds the specified limit, check that the bolts are
tightened correctly and that there are no abnormalities on the
crankshaft mounting surface. If the runout is still excessive even
after necessary steps have been taken according to the check
results, rectify or replace the flywheel.

Removal procedure
Removal: Ring gear
• Heat the ring gear evenly with a gas burner or the like until it
reaches approximately 200°C, then remove it from the flywheel.
WARNING
• You could get burnt if you touch the heated ring gear.

Inspection procedure
Inspection: Flywheel
(1) Friction surface height
• If the height is below the specified limit, replace the flywheel.

11-49
FLYWHEEL
(2) Friction surface distortion
• If the measured amount of distortion is above the specified limit,
rectify or replace the flywheel.

Rectification of friction surface


• Rectify the friction surface so that its height is not below the
specified limit, and it is parallel with surface A with an error not
exceeding 0.1 mm.

Inspection procedure
Installation: Ring gear
• Heat the ring gear evenly with a gas burner or the like until it
reaches approximately 200°C.
WARNING
• You could get burnt if you touch the heated ring gear.

• Fit the ring gear with the side having non-chamfered tooth edges
toward the flywheel.

Installation: Flywheel
• Tighten all the bolts to 39 N·m {4.0 kgf·m} and then additionally
tighten them by the following procedure.
• Rotate the holder of counterclockwise to pretension the in-
ternal spring.

• Fit on the bolt and set so that the rod (extension) is


held pressed against it by the spring force.
• Align a scale mark on the socket with a scale mark on the hold-
er. (This point will be the point of reference, or the 0° point.)
• Starting with this point of reference, turn the socket clockwise
with a wrench by 40° ± 5° (one graduation on the socket scale
represents 10°).

11-50
11
M E M O

11-51
TIMING GEARS

Disassembly sequence
1 Vacuum pipe 9 Bearing
*b:
a: Crankshaft gear
2 Vacuum pump (See Gr35) 10 Timing gear case
* c: Oil pump gear
3 O-ring 11 Thrust plate
* Camshaft gear
4
5
Power steering pipe
Power steering oil pump
12
13
Idler gear bushing
Idler gear
*d: Injection pump gear

(See Gr37A) 14 Idler shaft : Non-reusable parts


6 O-ring 15 Front oil seal slinger
7 Crankshaft pulley 16 Key
8 Front oil seal

CAUTION
• Do not remove the front oil seal or bearing unless defects are evident.

Assembly sequence
Follow the disassembly sequence in reverse.

11-52
11
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
Crankshaft gear and oil
0.10 to 0.18 0.3
pump gear
Camshaft gear and power
steering oil pump gear
0.08 to 0.16 0.3
<with power steering sys-
tem>
– Backlash between gears Replace
Idler gear and crankshaft
0.07 to 0.15 0.3
gear
Idler gear and camshaft
0.07 to 0.17 0.3
gear
Idler gear and injection
0.07 to 0.17 0.3
pump gear
– Idler gear end play 0.05 to 0.15 0.3 Replace
12, 14 Idler gear bushing-to-idler shaft clearance 0.03 to 0.06 0.1 Replace

Tightening torque (Unit: N·m {kgf·m})


Mark Parts to be tightened Tightening torque Remarks
Vacuum pipe 29.4 {3.0} –
Nut (power steering pipe installation) 29.4 to 39.2 {3 to 4} –
Nut (crankshaft pulley installation) 590 {60} –
Bolt (thrust plate installation) 24 {2.4} –

Lubricant and/or sealant


Mark Points of application Specified lubricant and/or sealant Quantity
O-ring
Front oil seal lip Engine oil As required
Idler gear bushing inside surface
Timing gear case mounting surface THREEBOND 1207C As required

Special tools (Unit: mm)


Mark Tool name and shape Part No. Application

Idler gear bushing Removal and installation of idler gear


puller MH062224
bushing
A B C
φ 44.5 φ 49 φ 45

11-53
TIMING GEARS
Inspection before removal
Inspection: Backlash between gears
• For each pair of gears, measure the backlash at more than three
teeth.
• If any of the measurements exceeds the specified limit, replace
the defective part(s).

Inspection: Idler gear end play


• If the measurement exceeds the specified limit, replace the de-
fective part(s).

Inspection procedure
Inspection: Idler gear bushing-to-idler shaft clearance
• If the measurement exceeds the specified limit, replace the
bushing.

Replacement of idler gear bushing


[Removal]

[Installation]
• Place the idler gear with its ends facing as illustrated.
• Press-fit the idler gear bushing until sits snugly on the
chamfered end of the idler gear.
• After press-fitting the bushing, measure the clearance.
• If the measurement is less than the minimum of the standard
value range, ream the idler gear bushing until the clearance falls
within the standard value range.

11-54
11
Inspection procedure
Installation: Idler gear
• Place the No. 1 cylinder piston and the No. 4 cylinder piston at
their top dead centers.
• Install the idler gear while aligning the marks “1”, “2”, and “3”
on its teeth with the corresponding marks on the teeth of the oth-
er gears.

Installation: Timing gear case


• Clean off oil and all other foreign substances from the sealant
application surface of the timing gear case.
• Apply a bead of sealant to the timing gear case evenly and with-
out any breaks, then mount the case onto the front plate within
three minute. When doing so, make sure that the sealant is not
forced out of position.
CAUTION
• Do not start the engine less than an hour after installation of
the timing gear case.
• If the timing gear case mounting bolts are loosened or re-
moved, be sure to reapply sealant.

11-55
CAMSHAFT
Disassembly sequence
1 Camshaft gear
2 Thrust plate
3 Key
4 Camshaft

: Non-reusable parts

CAUTION
• Do not remove the camshaft gear
unless defects are evident.

Assembly sequence
Follow the disassembly sequence in re-
verse.

Service standards (Unit: mm)


Location Maintenance item Standard value Limit Remedy
– Camshaft end play 0.05 to 0.22 0.3 Replace
Reassemble
1, 4 Camshaft gear and camshaft interference 0.03 to 0.07 – Permitted up to
three times
Lobe
height:
47.105
Intake 7.195 ± 0.05 6.70 Base
circle
diameter:
Re- 39.910
Cam lift
4 Camshaft place Lobe
height:
46.979
Exhaust 7.321 ± 0.05 6.82 Base
circle
diameter:
39.658
Bend 0.02 or less 0.05 Replace

Lubricant and/or sealant


Mark Points of application Specified lubricant and/or sealant Quantity
Thrust plate thrust receiving surface
Engine oil As required
Camshaft cams and journals

11-56
11
Inspection before removal
Inspection: Camshaft end play
• If the measurement is above the specified limit, replace the de-
fective part(s).

Removal procedure
Removal: Camshaft
• Loosen the thrust plate bolts through the holes in the camshaft
gear.
CAUTION
• Be careful not to damage the camshaft bushings when re-
moving each camshaft.

Removal: Camshaft gear


• The camshaft gear is press-fitted onto the camshaft. Remove
the camshaft gear by pushing on the camshaft using a press.
CAUTION
• Do not use a hammer, but use only a press to remove the
camshaft gear.

Inspection procedure
Inspection: Camshaft gear and camshaft interference
• If the measurement is not within the standard value range, re-
place the defective part(s).

11-57
CAMSHAFT
Inspection: Camshaft
(1) Cam lift
• If the measurement is not up to the specified limit, replace the
camshaft.
NOTE
• Each cam is tapered, so the cam lobe height and base circle
diameter should be measured at the measurement points
indicated in the illustration.

(2) Bend
• Place supports under the journals at the ends of the camshaft
and measure the bend of the camshaft at the central journal.
• If the measurement exceeds the specified limit, replace the cam-
shaft.
CAUTION
• Turn the camshaft by one turn and read the dial gauge. Di-
vide the reading by two to obtain the camshaft bend.

Installation procedure
Installation: Camshaft gear
• Before installing the camshaft gear, check the number of punch
marks at its center. The camshaft can only be reassembled
three times. If there are already three punch marks, replace the
camshaft gear and camshaft with new ones.

• Install the camshaft gear on the camshaft with the illustrated side
facing outward while preventing its rotation on the camshaft by
installing the key.
CAUTION
• Always use the press with the jig applied on the central part
of the camshaft gear. Applying it on any other part will dam-
age the camshaft gear.

• After installing the camshaft gear, make a punch mark on its


center to indicate that it has been reassembled.

11-58
11
Installation: Camshaft
• Place the No. 1 cylinder piston and No. 4 cylinder piston at their
top dead centers, and install the camshaft by aligning the mating
marks “2” on the camshaft gear and idler gear as shown in the
illustration.

11-59
CRANKSHAFT AND CRANKCASE

11-60
11
Disassembly sequence
1 Rear oil seal 8 Crankshaft gear 15 Check valve
2 Rear plate 9 Key 16 Oil jet
3 Main bearing cap bolt 10 Rear oil seal slinger 17 Crankcase
4 Lower main bearing 11 Crankshaft
5 Main bearing cap 12 Front plate : Non-reusable parts
6 Side seal 13 Gasket
7 Thrust plate 14 Upper main bearing

NOTE
• Do not remove the parts marked unless defects are evident.

Assembly sequence
Follow the disassembly sequence in reverse.

CAUTION
• The main bearing cap bolts are tightened using the torque-turn tightening method. Any bolt that has three
punch marks must be replaced.
• Do not overtighten the check valve. If it is tightened to a torque exceeding the specification, the check
valve may malfunction, resulting in seizures in the engine.

Service standards (Unit: mm)


Location Maintenance item Standard value Limit Remedy
Replace thrust
– Cranckshaft end play 0.10 to 0.26 0.4
plate
All except No. 3 0.04 to 0.09
Oil clearance 0.15
4, 14 Main bearing No. 3 0.06 to 0.12 Replace
Span when free – 82.5
Bend 0.02 or less 0.05 Replace
Out-of-round-
11 Crankshaft 0.01 or less 0.03
Pins and journals ness Rectify or replace
Taper 0.006 or less –
17 Distortion of crankcase top surface 0.07 or less 0.2 Rectify or replace

Tightening torque (Unit: N·m {kgf·m})


Mark Parts to be tightened Tightening torque Remarks
Bolt (rear plate installation) 64 {6.5} –
Wet
Main bearing cap bolt 59 {6} + 90° Reusable up to 3
times
Check valve 29 {3.0} Wet

Lubricant and/or sealant


Mark Points of application Specified lubricant and/or sealant Quantity
Rear oil seal lip
Main bearing cap bolt threads
Engine oil As required
Main bearing inside surface
Check valve threads
Crankcase mating surface of rear oil seal
THREEBOND 1207C As required
Side seal tips and grooves

11-61
CRANKSHAFT AND CRANKCASE
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application

Socket wrench MH061560 Installation of main bearing cap

Bearing cap extractor Removal of main bearing cap (rear-


MH061083
A B most cap)
60 M8 × 1.25

Gear puller MH061326 Removal of crankshaft gear

Rear oil seal slinger


installer
MH062677 Installation of rear oil seal slinger
A B C
φ 103 φ 100 φ 15

Inspection before removal


Inspection: Crankshaft end play
• If the measurement exceeds the specified limit, replace the
thrust plates with oversize ones.
• Available oversizes:
+ 0.15 mm, + 0.30 mm, + 0.45 mm
• Replace the crankshaft if the end play is too large to adjust using
oversize thrust plates.

Removal procedure
Removal: Main bearing caps
• Side seals are press-fitted between the rearmost main bearing
cap and the crankcase. Use to remove the rearmost main
bearing cap.

11-62
11
Removal: Crankshaft gear
CAUTION
• Do not tap off the crankshaft gear as this can damage it.

Removal: Rear oil seal slinger


• Taking care not to damage the crankshaft, split the rear oil seal
slinger using a chisel or a similar tool.

Removal procedure
Inspection: Main bearing span when free
CAUTION
• Do not attempt to manually expand the bearings.
• Always replace the upper and lower bearings as a set.

• If the measurement exceeds the specified limit, replace the


bearing.

Inspection: Main bearing-to-crankshaft clearance


• Fit the upper bearing into the crankcase and the lower bearing
into the main bearing cap.
• Tighten the main bearing cap bolts to a torque of 59 N·m {6
kgf·m}.
• Measure the inside diameter of the main bearing and the diame-
ter of the corresponding crankshaft journal. If the difference be-
tween the measurements exceeds the specified limit, machine
the crankshaft journal to one of the specified undersize dimen-
sions indicated on the next page.

11-63
CRANKSHAFT AND CRANKCASE
Inspection: Crankshaft
(1) Bend
• Support the crankshaft at its No. 1 journal and No. 5 journal.
Measure the extent of bending in the crankshaft at the center of
the No. 3 journal.
• If the measurement exceeds the specified limit, replace the
crankshaft.
NOTE
• Turn the crankshaft through one revolution. One-half of the
dial indicator reading represents the extent of bending.

(2) Out-of-roundness and taper of crankshaft journals and


pins
• If any of the measurements exceeds the specified limits, grind
the crankshaft journal(s) and/or pin(s) to undersize(s) or replace
the crankshaft.

Grinding of crankshaft
CAUTION
• If the crankshaft is ground to an undersize, the main bear-
ings must be replaced with the undersize ones of the corre-
sponding undersize.

• Do not change the center-to-center distance A between the jour-


nal and pin.
A: 57.5 ± 0.05 mm
• Do not change the journal width B and the pin width C.
B: 35 mm (32 mm for No. 1 journal)
C: 41 +0.2
0 mm
• Finish the fillets D smoothly.
D: R4 ± 0.2 mm
• Carry out a magnetic inspection to check for cracks possibly
caused by grinding. Also, check that the hardness of the surface
has not dropped below Shore hardness number (Hs) 75.
• Replace the crankshaft if defects are evident.

Crankshaft undersize dimensions (Unit: mm)


Undersizes
0.25 0.50 0.75 1.00
Finished journal No. 1, 2, 4, 5 77.68 to 77.70 77.43 to 77.45 77.18 to 77.20 76.93 to 76.95
diameter No. 3 77.66 to 77.68 77.41 to 77.43 77.16 to 77.18 76.91 to 76.93
Finished pin diameter 59.695 to 57.715 59.445 to 59.465 59.195 to 59.215 58.945 to 58.965
Out-of-roundness 0.01 or less
Taper 0.006 or less

11-64
11
• When grinding, turn both the crankshaft and the grinder counter-
clockwise as viewed from the crankshaft front end.
• When finishing the crankshaft with westone or sandpaper, rotate
the crankshaft clockwise.

Inspection: Distortion of crankcase top surface


• If the measurement exceeds the specified limit, grind the crank-
case top surface with a surface grinder.
• Limit the amount of removed metal to make sure that the amount
of piston projection above the crankcase top surface stays within
the standard value range.

Installation procedure
Installation: Rear oil seal slinger
• Drive the rear oil seal slinger onto the crankshaft until it touches
the guide.

Installation: Crankshaft gear


• Heat the crankshaft gear to approximately 100°C with a burner
or the like.
CAUTION
• Be careful not to get burned.

• Align the key fitted in the crankshaft with the slot in the crank-
shaft gear. Drive the gear into position by lightly striking its end
face with a plastic hammer.

11-65
CRANKSHAFT AND CRANKCASE
Installation: Thrust plate
• Install the thrust plates on the rearmost main bearing cap and
crankcase with the oil grooves on the inner plates facing inward
and those on the outer plates outward as shown in the illustra-
tion.
: Locating pin
CAUTION
• Be sure to position the oil grooves as indicated above, oth-
erwise seizures may occur in the engine.

• Use oversize thrust plates when adjusting the crankshaft end


play. The upper and lower thrust plates on the same side must
be of the same size. The thrust plates on one side may differ in
size from those on the other side.

Installation: Side seal


• Put sealant into each side seal groove in the main bearing cap.

• Apply sealant to the tip of each side seal, and fit the side seal in
the hole formed by the groove between the main bearing cap
and the crankcase with its sides facing in the illustrated direc-
tions.
A: Crankshaft side
B: Crankcase side
• After installing each side seal, apply sealant as indicated in the
illustration to prevent the engine oil from leaking out.

Installation: Main bearing


• Install the main bearings with their lugs aligned as shown in the
illustration. When the crankshaft journals have been ground to
an undersize, use undersize main bearings.
Available main bearing undersizes: 0.25 mm, 0.50 mm, 0.75
mm, 1.00 mm
CAUTION
• The upper main bearing has an oil hole. The lower main
bearing has no oil hole. Do not confuse the upper and lower
bearings, as this can cause seizure in the engine.

11-66
11
Installation: Main bearing cap
CAUTION
• Before installing the main bearing cap bolts, check the
number of punch marks on the head of each bolt. (A bolt
with two or less marks is reusable.)
• The number of punch marks corresponds with the number
of times the main cap bolt has been tightened using the
torque-turn tightening method. Any bolt that has three
marks (i.e. that has been used three times) must be re-
placed.

• Starting at the front of the engine, fit the main bearing caps in the
order of the embossed numbers “1” to “4” with the numbers,
letter “R”, and front mark “ ” facing the illustrated direction.

• Apply engine oil on the threads and seat of the main cap bolts.
Tighten all the bolts to 59 N·m {6 kgf·m}, then additionally tighten
them according to the following procedure.
• Turn the holder of counterclockwise to pretension the inter-
nal spring.

• Fit on the bolt and set it so that its rod (extension) is held
pressed against the crankshaft by the spring force.
• Align a scale mark on the socket with a scale mark on the hold-
er. (This point will be the point of reference, or the 0° point.)
• Starting with this point of reference, turn the socket with a
wrench in the illustrated direction until the scale on the socket in-
dicates 90°.
One graduation on the socket-side scale represents 5°.
• After tightening the bolts using the above torque-turn tightening
method, make a punch mark on the head of each bolt to indicate
the number of times that it has been used.
CAUTION
• The bolts that have been tightened using the torque-turn
method must never be additionally tightened after the final
angular tightening.

• After installing the main bearing cap, rotate the crankshaft by


hand. If it cannot be rotated smoothly, inspect the main bearing
caps for correct installation.

11-67
CRANKSHAFT AND CRANKCASE
Installation: Rear oil seal
• Apply engine oil to the lip of the rear oil seal.
• Clean the seal surface of the crankshaft.
• Apply a bead of sealant along the line on the rear oil seal evenly
without any breaks.
• Install the rear oil seal within three minutes after applying the
sealant. Be careful not to let the applied sealant slip out of place
during installation.
CAUTION
• After fitting the rear oil seal, wait at least an hour before
starting the engine.
• Apply a new bead of sealant whenever the mounting bolts
of the rear oil seal have been loosened.

11-68
11
M E M O

11-69
CAMSHAFT BUSHINGS
Disassembly sequence
1 No. 1 camshaft bushing
2 No. 2 camshaft bushing
3 No. 3 camshaft bushing
4 No. 4 camshaft bushing
5 Sealing cap
6 No. 5 camshaft bushing

*a:: Camshaft
Non-reusable parts

NOTE
• Do not remove the camshaft bush-
ings unless defects are evident.

Assembly sequence
Follow the disassembly sequence in re-
verse.

Service standards (Unit: mm)


Location Maintenance item Standard value Limit Remedy
1 to 4,
Camshaft bushing-to-camshaft clearance 0.04 to 0.09 0.15 Rectify or replace
*
6, a

Lubricant and/or sealant


Mark Points of application Specified lubricant and/or sealant Quantity
Camshaft bushing inside surface Engine oil As required

Special tools (Unit: mm)


Mark Tool name and shape Part No. Application

Camshaft Bushing Install- Removal and installation of camshaft


MH061276
er and Extractor bushings

11-70
11
Inspection procedure
Inspection: Camshaft bushing-to-camshaft clearance
• If the measurements exceed the specified limit, replace the
bushings.

Replacement of camshaft bushing


• To remove the No. 4 bushing, have an extension like the one in-
dicated in the illustration ready for use with the rod.

[Removal]
• Attach to the rod the adapter appropriate to each camshaft
bushing and use them to remove the camshaft bushing.
(Unit: mm)
Adapter
Bushing Identifica-
A B C
tion mark
No. 1 “1” φ 54.5 41.5 φ 58.5
No. 2
“2” φ 54.5 26.5 φ 58
No. 3
No. 4 “3” φ 54 26.5 φ 57.5
No. 5 “4” φ 53 30.5 φ 57

11-71
CAMSHAFT BUSHINGS
(1) No. 1 to No. 3 camshaft bushings
• Remove the No. 1 to No. 3 camshaft bushings by tapping on
them lightly from the front of the engine.

(2) No. 4 camshaft bushing


• Attach an extension jig on the rod. Then, remove the No. 4 bush-
ing by tapping on it lightly from the front of the engine.

11-72
11
(3) No. 5 camshaft bushing
• Remove the sealing cap. Then, remove the No. 5 bushing by
tapping on it lightly from the rear of the engine.

[Installation]
• Attach to the rod an adapter and a guide appropriate to each
camshaft bushing and use them together to install the camshaft
bushing. Each bushing has a stamped identification mark. Use
these marks to identify bushings No.1 to No. 5. If the identifica-
tion mark is unclear, identify the bushings based on their outside
diameters.
(Unit: mm)
Bushing Adapter Guide
Ident Identi- Identi-
Out-
ifica- fica- fica-
side di- A B C D
tion tion tion
ameter
mark mark mark
No. 1 “1” φ 58.5 “1” φ 54.5 41.5 φ 58.5 “1” φ 58.5
No. 2 “A” φ 58.25
“2” φ 54.5 26.5 φ 58 “2” φ 58
No. 3 “2” φ 58.06
No. 4 “C” φ 57.75 “3” φ 54 26.5 φ 57.5 “3” φ 57.5
No. 5 “4” φ 57.06 “4” φ 53 30.5 φ 57 “4” φ 57

11-73
CAMSHAFT BUSHINGS
(1) No. 5 camshaft bushing
• Align the oil hole in the No. 5 bushing with the oil hole in the
crankcase.
• Install the No. 5 bushing by tapping lightly on it from the rear of
the engine until it reaches the illustrated position.

(2) No. 4 camshaft bushing


• Align the oil hole in the No. 4 bushing with the oil hole in the
crankcase.
• Install the No. 4 bushing by tapping lightly on it from the rear of
the engine until it reaches the illustrated position.

11-74
11
(3) No. 3 to No. 1 camshaft bushings
• Align the oil hole in the No. 3 bushing with the oil hole in the
crankcase.
• Install the No. 3 bushing by tapping lightly on it from the front of
the engine until it reaches the illustrated position.
• Install the No. 1 and No. 2 bushings in the same way.

Installation procedure
Installation: Sealing cap
• Force the sealing cap into the crankcase to the specified depth.

11-75

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