20.Cylinder Head Assembly

Transcription

1 MEHNIL 20.ylinder Head ssembly : REMOVL 1) Remove the V-belt. <Ref. to ME(SOH)-41, RE- MOVL, V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME(SO- H)-43, REMOVL, rankshaft Pulley.> 3) Remove the belt cover. <Ref. to ME(SOH)-45, REMOVL, elt over.> 4) Remove the timing belt assembly. <Ref. to ME(SOH)-46, REMOVL, Timing elt ssembly.> 5) Remove the camshaft sprocket. <Ref. to ME(SOH)-51, REMOVL, amshaft Sprocket.> 6) Remove the intake manifold. <Ref. to FU(SO- H)-14, REMOVL, Intake Manifold.> 7) Remove the bolt which installs / compressor bracket on cylinder head. 8) Remove the valve rocker assembly. <Ref. to ME(SOH)-54, REMOVL, Valve Rocker ssembly.> 9) Remove the camshaft. <Ref. to ME(SOH)-56, REMOVL, amshaft.> 10) Remove the cylinder head bolts in alphabetical sequence shown in the figure. Leave the bolts (a) and (c) engaged by three or four threads to prevent cylinder head from falling. YLINDER HED SSEMLY UTION: Do not scratch the mating surface of cylinder head and cylinder block. 14) Similarly, remove the right side cylinder head. : INSTLLTION 1) Install the cylinder head and gaskets on cylinder block. UTION: Use new cylinder head gaskets. e careful not to scratch the mating surface of cylinder block and cylinder head. 2) Tighten the cylinder head bolts. (1) pply a coat of engine oil to the washers and bolt threads. (2) Tighten all bolts to 29 N m (3.0 kgf-m, 22 ftlb) in alphabetical sequence. Then tighten all bolts to 69 N m (7.0 kgf-m, 51 ftlb) in alphabetical sequence. (3) ack off all bolts by 180 first; back them off by 180 again in reverse order of installation. (4) Tighten the bolts (a) and (b) to 34 N m (3.5 kgf-m, 25 ft-lb) in reverse order of installation. (5) Tighten the bolts (c), (d), (e) and (f) to 15 N m (1.5 kgf-m, 11 ft-lb). (6) Tighten all bolts by 80 to 90 in alphabetical sequence. UTION: Do not tighten bolts more than 90. ME ) While tapping the cylinder head with a plastic hammer, separate it from cylinder block. 12) Remove the bolts (a) and (c) to remove cylinder head. 13) Remove the cylinder head gasket. ME ME(SOH)-60

2 YLINDER HED SSEMLY MEHNIL (7) Further tighten all bolts by 80 to 90 in alphabetical sequence shown in figure below. UTION: Ensure that the total re-tightening angle [in the former two steps], do not exceed 180. : DISSSEMLY 1) Place the cylinder head on ST. ST YLINDER HED TLE 2) Set the ST on valve spring. ompress the valve spring, and then remove the valve spring retainer key. Remove each valve and valve spring. ST VLVE SPRING REMOVER UTION: Mark each valve to prevent confusion. Use extreme care not to damage the lips of intake valve oil seals and exhaust valve oil seals. ME ) Install the camshaft. <Ref. to ME(SOH)-57, IN- STLLTION, amshaft.> 4) Install the valve rocker assembly. <Ref. to ME(SOH)-54, INSTLLTION, Valve Rocker ssembly.> 5) Install the / compressor bracket on cylinder head. 6) Install the intake manifold. <Ref. to FU(SOH)- 16, INSTLLTION, Intake Manifold.> 7) Install the camshaft sprocket. <Ref. to ME(SO- H)-51, INSTLLTION, amshaft Sprocket.> 8) Install the timing belt assembly. <Ref. to ME(SO- H)-47, INSTLLTION, Timing elt ssembly.> 9) Install the belt cover. <Ref. to ME(SOH)-45, INSTLLTION, elt over.> 10) Install the crankshaft pulley. <Ref. to ME(SO- H)-43, INSTLLTION, rankshaft Pulley.> 11) Install the V-belt. <Ref. to ME(SOH)-41, IN- STLLTION, V-belt.> ME ME(SOH)-61

3 MEHNIL YLINDER HED SSEMLY D: SSEMLY ME (1) Valve (6) Retainer (11) Plug (2) Valve guide (7) Retainer key (12) amshaft cap (3) Valve spring seat (8) Spark plug gasket (13) Valve rocker SSY (4) Oil seal (9) amshaft (5) Valve spring (10) Oil seal 1) Installation of valve spring and valve (1) Place the cylinder head on ST. ST YLINDER HED TLE (2) oat the stem of each valve with engine oil and insert valve into valve guide. When inserting the valve into valve guide, use special care not to damage the oil seal lip. (3) Install the valve spring and retainer. e sure to install the valve springs with their closecoiled end facing the seat on the cylinder head. (4) Set the ST on valve spring. ST VLVE SPRING REMOVER ME ME(SOH)-62

4 YLINDER HED SSEMLY MEHNIL (5) ompress the valve spring, and then fit the valve spring retainer key. () Retainer Painted face ME (6) fter installing, tap the valve spring retainers lightly with plastic hammer for better seating. E: INSPETION 1. VLVE SPRING 1) heck the valve springs for damage, free length, and tension. Replace the valve spring if it is not to the specifications presented below. 2) To measure the squareness of valve spring, stand the spring on a surface plate and measure its deflection at the top using a try square. 2. INTKE ND EXHUST VLVE OIL SEL Replace the oil seal with new one, if lip is damaged or spring out of place, or when the surfaces of intake valve and valve seat are reconditioned or intake valve guide is replaced. Use pliers to pinch and remove oil seal from valve. 1) Place the cylinder head on ST1. 2) Press-fit oil seal to the specified dimension indicated in the figure using ST2. UTION: pply engine oil to oil seal before press-fitting. When press-fitting oil seal, do not use hammer or strike in. Differentiate between intake valve oil seal and exhaust valve oil seal by noting their difference in color. ST YLINDER HED TLE ST VLVE OIL SEL GUIDE olor of rubber part: Intake [lack] Exhaust [rown] olor of spring part: Intake [Silver] Exhaust [Silver] Free length Squareness Tension/spring height mm ( in) 2.5, 2.4 mm (0.094 in) N ( kgf, lb)/ 45.0 mm (1.772 in) N ( kgf, lb)/ 34.7 mm (1.366 in) ME F: DJUSTMENT ME YLINDER HED 1) Make sure that no crack or other damage exists. In addition to visual inspection, inspect important areas by means of red lead check. lso make sure that gasket installing surface shows no trace of gas and water leaks. 2) Place the cylinder head on ST. ST YLINDER HED TLE 3) Measure the warping of the cylinder head surface that mates with crankcase using a straight edge and thickness gauge. If the warping exceeds 0.05 mm ( in), regrind the surface with a surface grinder. ME(SOH)-63

5 MEHNIL YLINDER HED SSEMLY Warping limit: 0.05 mm ( in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder head: 97.5 mm (3.839 in) Uneven torque for the cylinder head bolts can cause warping. When reassembling, pay special attention to the torque so as to tighten evenly. 2. VLVE SET Inspect the intake and exhaust valve seats, and then correct the contact surfaces with valve seat cutter if they are defective or when valve guides are replaced. Valve seat width: W Intake Standard 1.1 mm (0.043 in) Limit 1.8 mm (0.071 in) Exhaust () Standard 1.5 mm (0.059 in) Limit 2.2 mm (0.087 in) () W W ME () Straight edge Thickness gauge ME ME ME(SOH)-64

6 YLINDER HED SSEMLY MEHNIL 3. VLVE GUIDE 1) heck the clearance between valve guide and stem. The clearance can be checked by measuring the outside diameter of valve stem and the inside diameter of valve guide with outside and inside micrometers respectively. learance between the valve guide and valve stem: Standard Intake mm ( in) Exhaust mm ( in) Limit 0.15 mm ( in) (2) Insert the ST2 into valve guide and press it down to remove valve guide. ST YLINDER HED TLE ST VLVE GUIDE REMOVER ME (3) Turn the cylinder head upside down and place ST as shown in the figure. Intake side: ST VLVE GUIDE DJUSTER Exhaust side: ST VLVE GUIDE DJUSTER ME ME Valve guide ME ) If the clearance between valve guide and stem exceeds the limit, replace the valve guide or valve itself whichever shows greater amount of wear. See the following procedure for valve guide replacement. Valve guide inner diameter: mm ( in) Valve stem outer diameters: Intake mm ( in) Exhaust mm ( in) (1) Place the cylinder head on ST1 with the combustion chamber upward so that valve guides enter the holes in ST1. (4) efore installing new oversize valve guide, make sure that neither scratches nor damages exist on the inside surface of valve guide holes in cylinder head. ME(SOH)-65

7 MEHNIL YLINDER HED SSEMLY (5) Put new valve guide, coated with sufficient oil, in the cylinder, and then insert the ST1 into valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST VLVE GUIDE REMOVER Intake side: ST VLVE GUIDE DJUSTER Exhaust side: ST VLVE GUIDE DJUSTER (7) Ream the inside of valve guide with ST. Gently rotate the reamer clockwise while pressing it lightly into valve guide, and return it also rotating clockwise. fter reaming, clean the valve guide to remove chips. UTION: pply engine oil to the reamer when reaming. If the inner surface of the valve guide is torn, the edge of the reamer should be slightly ground with an oil stone. If the inner surface of the valve guide becomes lustrous and the reamer does not chips, use a new reamer or remedy the reamer. ST VLVE GUIDE REMER ME (6) heck the valve guide protrusion. Valve guide protrusion: L Intake mm ( in) Exhaust mm ( in) ME (8) Recheck the contact condition between valve and valve seat after replacing valve guide. ME Valve guide ME(SOH)-66

8 YLINDER HED SSEMLY MEHNIL 4. INTKE ND EXHUST VLVE 1) Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if H is less than the specified limit. H: Intake Standard 1.0 mm (0.039 in) Limit 0.6 mm (0.024 in) Exhaust Standard 1.2 mm (0.047 in) Limit 0.6 mm (0.024 in) Valve overall length: Intake mm (4.75 in) Exhaust mm (4.79 in) ME ) Put a small amount of grinding compound on the seat surface and lap the valve and seat surface. <Ref. to ME(SOH)-64, VLVE SET, DJUST- MENT, ylinder Head ssembly.> Install a new intake valve oil seal after lapping. ME(SOH)-67

9 MEHNIL 21.ylinder lock : REMOVL efore conducting this procedure, drain the engine oil completely if applicable. 1) Remove the intake manifold. <Ref. to FU(SO- H)-14, REMOVL, Intake Manifold.> 2) Remove the V-belt. <Ref. to ME(SOH)-41, RE- MOVL, V-belt.> 3) Remove the crankshaft pulley. <Ref. to ME(SO- H)-43, REMOVL, rankshaft Pulley.> 4) Remove the belt cover. <Ref. to ME(SOH)-45, REMOVL, elt over.> 5) Remove the timing belt assembly. <Ref. to ME(SOH)-46, REMOVL, Timing elt ssembly.> 6) Remove the camshaft sprocket. <Ref. to ME(SOH)-51, REMOVL, amshaft Sprocket.> 7) Remove the crankshaft sprocket. <Ref. to ME(SOH)-43, REMOVL, rankshaft Pulley.> 8) Remove the generator and / compressor with their brackets. 9) Remove the rocker cover. 10) Remove the cylinder head bolts in alphabetical sequence shown in the figure. Leave bolts (a) and (c) engaged by three or four threads to prevent cylinder head from falling. YLINDER LOK 12) Remove the bolts (a) and (c) to remove cylinder head. Front ME ) Remove the cylinder head gasket. Do not scratch the mating surface of cylinder head and cylinder block. 14) Similarly, remove the right side cylinder head. 15) Remove the clutch housing cover. (MT vehicles) 16) Remove the flywheel (MT vehicles) or drive plate (T vehicles). Using the ST, lock the crankshaft. ST RNKSHFT STOPPER MT VEHILES ME ME T VEHILES Front 11) While tapping the cylinder head with a plastic hammer, separate it from cylinder block. ME ME(SOH)-68

10 YLINDER LOK MEHNIL Using STs, remove the flywheel. (2500 cc MT model) ST RNKSHFT STOPPER ST TORX PLUS (2) Remove the bolts which secure oil pan to cylinder block. (3) Insert a oil pan cutter blade between cylinder block-to-oil pan clearance, and then remove the oil pan. Do not use a screwdriver or similar tool in place of oil pan cutter. ME Flywheel 17) Remove the oil separator cover. 18) Remove the water by-pass pipe for heater. 19) Loosen the bolts in alphabetical sequence as shown in the figure, and then remove water pump. (E) (F) ME ) Remove the oil strainer stay. 23) Remove the oil strainer. 24) Remove the baffle plate. 25) Remove the oil filter using ST. ST OIL FILTER WRENH (D) () () ME ) Remove the oil pump from cylinder block. Use a flat-bladed screwdriver as shown in the figure when removing oil pump. e careful not to scratch the mating surface of cylinder block and oil pump. 26) Remove the water pipe. ME ME ME ) Removal of oil pan (1) Turn the cylinder block to face the #2 and #4 piston sides upward. ME(SOH)-69

11 MEHNIL YLINDER LOK ME (1) Service hole plug (3) irclip (5) Service hole cover (2) Gasket (4) Piston pin (6) O-ring 27) Remove the service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 in)]. 28) Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, and then remove the piston circlip through service hole of #1 and #2 cylinders. ST PISTON SNP RING PLIER ME ME ME(SOH)-70

12 YLINDER LOK MEHNIL 29) Draw out the piston pin from #1 and #2 pistons using ST. ST PISTON PIN REMOVER e careful not to confuse the original combination of piston, piston pin and cylinder. 30) Similarly remove the piston pins from #3 and #4 pistons. 31) Remove the bolts which connect cylinder block on the side of #2 and #4 cylinders. 32) ack off the bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns. 33) Set up the cylinder block so that #1 and #3 cylinders are on the upper side, and then remove the cylinder block connecting bolts. 34) Separate the cylinder blocks (RH) and (LH). When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block. ME ME (1) ylinder block (3) rankshaft (5) Piston (2) Rear oil seal (4) rankshaft bearing 35) Remove the rear oil seal. 36) Remove the crankshaft together with connecting rod. 37) Remove the crankshaft bearings from cylinder block using hammer handle. Do not confuse the combination of crankshaft bearings. Press bearing at the end opposite to locking lip. ME(SOH)-71 38) Draw out each piston from cylinder block using wooden bar or hammer handle. Do not confuse the combination of piston and cylinder.

13 MEHNIL : INSTLLTION YLINDER LOK (4) (1) (3) (2) (3) ME (1) rankshaft bearing (3) ylinder block (4) Rear oil seal (2) rankshaft Remove oil in the mating surface of bearing and cylinder block before installation. lso apply a coat of engine oil to crankshaft pins. 1) Position the crankshaft on #2 and #4 cylinder block. 2) pply fluid packing to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block. Fluid packing: Part No THREE OND 1215 or equivalent Do not allow fluid packing to jut into O-ring grooves, oil passages, bearing grooves, etc. ME ME(SOH)-72

14 YLINDER LOK MEHNIL 3) Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (LH side) 6) Further tighten the RH side bolts (E J) to 90 in alphabetical sequence. Tightening torque: 15 N m (1.5 kgf-m, 10.8 ft-lb) (G) (E) (J) (D) (I) (F) (H) () ME ) Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (RH side) Tightening torque: 15 N m (1.5 kgf-m, 10.8 ft-lb) () ME ) Tighten the 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. Tightening torque: (G): 25 N m (2.5 kgf-m, 18.1 ft-lb) (H): 6.4 N m (0.65 kgf-m, 4.7 ft-lb) (G) (E) (J) (I) (F) ME ) Further tighten the LH side bolts ( D) to 90 in alphabetical sequence. (H) ME ) Install the rear oil seal using ST1 and ST2. ST OIL SEL GUIDE ST OIL SEL INSTLLER (D) () () ME ME () Rear oil seal Fly wheel attaching bolt 9) Position the top ring gap at or () in the figure. ME(SOH)-73

15 MEHNIL YLINDER LOK 10) Position the second ring gap at 180 on the reverse side for top ring gap cc MODEL 12) Position the lower rail gap at (D) in the figure cc MODEL SH 0SH 2500 cc MODEL ME cc MODEL ME (D) () 5SH 5SH ME ) Position the expander gap at () in the figure cc MODEL ME lign the lower rail stopper (F) to the lateral hole (E) on the piston. 0SH 2500 cc MODEL ME ME ) Position the upper rail gap at (G) in the figure cc MODEL (G) 5SH 0SH () ME ME ME(SOH)-74

16 YLINDER LOK MEHNIL 2500 cc MODEL 2500 cc MODEL (G) 5SH 5SH ME ME UTION: Ensure ring gaps do not face the same direction. Ensure ring gaps are not within the piston skirt area. 14) Install circlip. Install circlips in the piston holes located opposite service holes in cylinder block, when positioning all pistons in the corresponding cylinders. Use new circlips. Front mark ME Front side UTION: Piston front mark faces towards the front of the engine cc MODEL 0SH ME ME(SOH)-75

17 MEHNIL YLINDER LOK ME (1) Piston (4) Gasket Tightening torque: N m (kgf-m, ft-lb) (2) Piston pin (5) Service hole plug T: 70 (7.0, 50.6) (3) irclip 15) Installing piston (1) Turn the cylinder block to face the #1 and #2 piston side upward. (2) Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center. ST RNKSHFT SOKET (3) pply a coat of engine oil to pistons and cylinders, and then insert the pistons in their cylinders using ST2. ST PISTON GUIDE (2000 cc model) ST PISTON GUIDE (2500 cc model) ST PISTON PIN GUIDE ME (3) pply a coat of engine oil to the piston pin, and then insert the piston pin into piston and connecting rod through service hole. (4) Install the circlip. Use new circlips. ST PISTON SNPRING PLIER ME ) Installing piston pin (1) pply a coat of engine oil to the ST3 before insertion. (2) Insert the ST3 into service hole to align piston pin hole with connecting rod small end. ME ME(SOH)-76

18 YLINDER LOK MEHNIL (5) pply fluid packing around the service hole plug. Fluid packing: Part No THREE OND 1215 or equivalent (6) Install the service hole plug and gasket. Use a new gasket. ME ME ME (1) Piston (5) Service hole plug Tightening torque: N m (kgf-m, ft-lb) (2) Piston pin (6) Service hole cover T1: 6.4 (0.65, 4.7) (3) irclip (7) O-ring T2: 70 (7.1, 51.4) (4) Gasket (7) Turn the cylinder block to face the #3 and #4 piston side upward. Using the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins. ME(SOH)-77

19 MEHNIL 17) Install the water pipe. YLINDER LOK 23) Install the flywheel or drive plate. To lock the crankshaft, use ST. ST RNKSHFT STOPPER Tightening torque: 72 N m (7.3 kgf-m, 52.8 ft-lb) MT VEHILES ME ) Install the baffle plate. Tightening torque: 6.4 N m (0.65 kgf-m, 4.7 ft-lb) 19) Install the oil strainer and O-ring. Tightening torque: 10 N m (1.0 kgf-m, 7 ft-lb) 20) Install the oil strainer stay. 21) pply fluid packing to the matching surfaces, and then install the oil pan. Fluid packing: Part No THREE OND 1215 or equivalent T VEHILES ME ME Using STs, remove the flywheel. (2500 cc MT model) ST RNKSHFT STOPPER ST TORX PLUS ME ) pply fluid packing to the matching surfaces, and then install the oil separator cover. Fluid packing: Part No THREE OND 1215 or equivalent ME Flywheel 24) Install the housing cover. ME ME(SOH)-78

20 YLINDER LOK MEHNIL 25) Installation of oil pump (1) Discard the front oil seal after removal. Replace with a new one using the ST. ST OIL SEL INSTLLER ME (2) pply fluid packing to the matching surface of oil pump. Fluid packing: Part No THREE OND 1215 or equivalent UTION: Do not forget to the install the O-ring and seal when installing oil pump. lign flat surface of oil pump's inner rotor with crankshaft before installation. 26) Install the water pump and gasket. Tightening torque: First; 12 N m (1.2 kgf-m, 8.7 ft-lb) Second; 12 N m (1.2 kgf-m, 8.7 ft-lb) UTION: e sure to use a new gasket. When installing the water pump, tighten the bolts in two stages in alphabetical sequence as shown in the figure. (D) (E) () (F) () ME O-ring ME (3) pply a coat of engine oil to the inside of oil seal. ME (4) Install the oil pump on cylinder block. e careful not to damage the oil seal during installation. Tightening torque: 6.4 N m (0.65 kgf-m, 4.7 ft-lb) 27) Install the water by-pass pipe for heater. 28) Install the oil filter using ST. ST OIL FILTER WRENH 29) Tighten the cylinder head bolts. (1) pply a coat of engine oil to the washers and bolt threads. (2) Tighten all bolts to 29 N m (3.0 kgf-m, 22 ftlb) in alphabetical sequence. Then tighten all bolts to 69 N m (7.0 kgf-m, 51 ftlb) in alphabetical sequence. (3) ack off all bolts by 180 first; back them off by 180 again. (4) Tighten the bolts (a) and (b) to 34 N m (3.5 kgf-m, 25 ft-lb). (5) Tighten the bolts (c), (d), (e) and (f) to 15 N m (1.5 kgf-m, 11 ft-lb). (6) Tighten all bolts by 80 to 90 in alphabetical sequence. UTION: Do not tighten bolts more than 90. ME(SOH)-79

21 MEHNIL YLINDER LOK (7) Further tighten all bolts by 80 to 90 in alphabetical sequence. UTION: Ensure that the total re-tightening angle [in the former two steps], do not exceed 180. Front 30) Install the oil level gauge guide, and then tighten the attaching bolt (left side only). : DISSSEMLY ME ) Install the rocker cover. 32) Install the crankshaft sprocket. <Ref. to ME(SOH)-53, INSTLLTION, rankshaft Sprocket.> 33) Install the camshaft sprocket. <Ref. to ME(SO- H)-51, INSTLLTION, amshaft Sprocket.> 34) Install the timing belt assembly. <Ref. to ME(SOH)-47, INSTLLTION, Timing elt ssembly.> 35) Install the belt cover. <Ref. to ME(SOH)-45, INSTLLTION, elt over.> 36) Install the crankshaft pulley. <Ref. to ME(SO- H)-43, INSTLLTION, rankshaft Pulley.> 37) Install the generator and / compressor brackets on cylinder head. 38) Install the V-belt. <Ref. to ME(SOH)-41, IN- STLLTION, V-belt.> 39) Install the intake manifold. <Ref. to FU(SOH)- 16, INSTLLTION, Intake Manifold.> ME (1) onnecting rod cap (3) Top ring (5) Oil ring (2) onnecting rod bearing (4) Second ring (6) irclip 1) Remove the connecting rod cap. 5) Remove the circlip. 2) Remove the connecting rod bearing. rrange the removed connecting rod, connecting rod cap and bearing in order to prevent confusion. 3) Remove the piston rings using the piston ring expander. 4) Remove the oil ring by hand. rrange the removed piston rings in good order to prevent confusion. ME(SOH)-80

22 D: SSEMLY YLINDER LOK MEHNIL ME (1) onnecting rod bearing (5) Second ring Tightening torque: N m (kgf-m, ft-lb) (2) onnecting rod (6) Top ring T: 45 (4.6, 33) (3) onnecting rod cap (7) irclip (4) Oil ring (8) side mark 1) pply oil to the surfaces of the connecting rod bearings. 2) Install the connecting rod bearings on connecting rods and connecting rod caps. 3) Position each connecting rod with the marked side facing forward, and then install them. 4) Install the connecting rod cap with connecting rod nut. Ensure the arrow on connecting rod cap faces the front during installation. UTION: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number. When tightening the connecting rod nuts, apply oil on the threads. 5) Install the expander, lower rail and upper rail in this order by hand. Then install the second ring and top ring with a piston ring expander. E: INSPETION 1. YLINDER LOK 1) Visually check for cracks and damage. Especially, inspect the important parts by means of red lead check. 2) heck the oil passages for clogging. 3) Inspect the crankcase surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary. Warping limit: 0.05 mm ( in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder block: mm (7.91 in) ME(SOH)-81

23 MEHNIL YLINDER LOK 2. YLINDER ND PISTON 1) The cylinder bore size is stamped on cylinder block's front upper surface. Measurement should be performed at a temperature 20 (68 F). Standard sized pistons are classified into two grades, and. These grades should be used as a guide line in selecting a standard piston. Standard diameter: 2000 cc model : mm ( in) : mm ( in) 2500 cc model : mm ( in) : mm ( in) 2) How to measure the inner diameter of each cylinder Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights shown in the figure, using a cylinder bore gauge. Measurement should be performed at a temperature 20 (68 F). Taper: Standard mm ( in) Limit mm ( in) Out-of-roundness: Standard mm ( in) Limit mm ( in) ME Main journal size mark ME () () (D) (E) (F) ylinder block RH-LH combination mark #1 cylinder bore size mark #2 cylinder bore size mark #3 cylinder bore size mark #4 cylinder bore size mark () Piston pin direction Thrust direction H1 10 mm (0.39 in) H2 45 mm (1.77 in) H3 80 mm (3.15 in) H4 115 mm (4.35 in) 3) When the piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance. ME(SOH)-82

24 YLINDER LOK MEHNIL 4) How to measure the outer diameter of each piston Measure the outer diameter of each piston at the height shown in the figure. (Thrust direction) Measurement should be performed at a temperature of 20 (68 F). Piston grade point H: 2000 cc model 40.0 mm (1.575 in) 2500 cc model 37.0 mm (1.457 in) Piston outer diameter: Standard: 2000 cc model : mm ( in) : mm ( in) 0.25 mm ( in) oversize mm ( in) 0.50 mm ( in) oversize mm ( in) 2500 cc model : mm ( in) : mm ( in) 0.25 mm ( in) oversize mm ( in) 0.50 mm ( in) oversize mm ( in) 5) alculate the clearance between cylinder and piston. Measurement should be performed at a temperature of 20 (68 F). ylinder to piston clearance at 20 (68 F): Standard mm ( in) Limit mm ( in) 6) oring and honing (1) If the value of taper, out-of-roundness, or cylinder-to-piston clearance measured exceeds the specified limit or if there is any damage on the cylinder wall, rebore it to use an oversize piston. UTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use oversize pistons. Do not perform boring on one cylinder only, nor use an oversize piston for one cylinder only. (2) If the cylinder inner diameter exceeds the limit after boring and honing, replace the crankcase. Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention to this when measuring the cylinder diameter. Limit of cylinder enlarging (boring): 0.5 mm (0.020 in) ME ME(SOH)-83

25 MEHNIL YLINDER LOK 3. PISTON ND PISTON PIN 1) heck the pistons and piston pins for damage, cracks, and wear and the piston ring grooves for wear and damage. Replace if defective. 2) Measure the piston-to-cylinder clearance at each cylinder. <Ref. to ME(SOH)-82, YLINDER ND PISTON, INSPETION, ylinder lock.> If any of the clearances is not to specification, replace the piston or bore the cylinder to use an oversize piston. 3) Make the sure that piston pin can be inserted into piston pin hole with a thumb at 20 (68 F). Replace if defective. Standard clearance between piston pin and hole in piston: Standard mm ( in) Limit mm ( in) 5) heck the piston pin circlip for distortion, cracks and wear. ME ME ) heck the circlip installation groove on piston for burr. If necessary, remove the burr from groove so that piston pin can lightly move. ME ME(SOH)-84

26 YLINDER LOK MEHNIL 4. PISTON RING 1) If the piston ring is broken, damaged, or worn, or if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new one of the same size as the piston. UTION: Marks are shown on the end of top and second rings. When installing the rings to piston, face these marks upward. Oil ring is composed of upper rail, expander and lower rail. e careful of the rail direction when installing oil ring to the pisiton. 3) Squarely place the piston ring and oil ring in cylinder, and then measure the piston ring gap with a thickness gauge. Unit: mm (in) Standard Limit Piston ring gap Top ring Second ring Oil ring rail 2000 cc 2500 cc ( ) 1.0 (0.039) ( ) (0.039) ( ) ( ) 1.5 (0.059) () () () ME ) Measure the clearance between piston ring and piston ring groove with a thickness gauge. () () Upper rail Expander Lower rail () ME learance between piston ring and piston ring groove Top ring Second ring Standard ( ) ( ) Unit: mm (in) Limit 0.15 (0.0059) 0.15 (0.0059) 2) lean the piston ring groove and piston ring. ME ME(SOH)-85

27 MEHNIL YLINDER LOK 5. ONNETING ROD 1) Replace the connecting rod, if the large or small end thrust surface is damaged. 2) heck for bend or twist using a connecting rod aligner. Replace the connecting rod if the bend or twist exceeds the limit. Limit of bend or twist per 100 mm (3.94 in) in length: 0.10 mm ( in) 4) Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc. 5) Measure the oil clearance on individual connecting rod bearings by means of plastigauge. If any oil clearance is not within specification, replace the defective bearing with a new one of standard size or undersize as necessary. (See the table below.) onnecting rod oil clearance: 2000 cc MODEL Standard mm ( in) Limit 0.05 mm ( in) earing Standard 0.03 (0.0012) undersize 0.05 (0.0020) undersize 0.25 (0.0098) undersize earing size (Thickness at center) ( ) ( ) ( ) ( ) Unit: mm (in) Outer diameter of crank pin ( ) ( ) ( ) ( ) onnecting rod oil clearance: () Thickness gauge onnecting rod ME ) Install the connecting rod fitted with bearing to crankshaft, and then measure the side clearance (thrust clearance). Replace the connecting rod if the side clearance exceeds the specified limit. onnecting rod side clearance: Standard mm ( in) Limit 0.4 mm (0.016 in) 2500 cc MODEL Standard mm ( in) Limit 0.05 mm ( in) earing Standard 0.03 (0.0012) undersize 0.05 (0.0020) undersize 0.25 (0.0098) undersize earing size (Thickness at center) ( ) ( ) ( ) ( ) Unit: mm (in) Outer diameter of crank pin ( ) ( ) ( ) ( ) ME ME(SOH)-86

28 YLINDER LOK MEHNIL 6) Inspect the bushing at connecting rod small end, and replace if worn or damaged. lso measure the piston pin clearance at connecting rod small end. learance between piston pin and bushing: Standard mm ( in) Limit mm ( in) 6. RNKSHFT ND RNKSHFT ERING 1) lean the crankshaft completely and check for cracks by means of red lead check etc., and replace if defective. 2) Measure the crankshaft bend, and correct or replace if it exceeds the limit. If a suitable V-block is not available, install the #1 and #5 crankshaft bearing on cylinder block, position the crankshaft on these bearings and measure the crankshaft bend using a dial gauge. rankshaft bend limit: mm ( in) ME ME ME ) Replacement procedure is as follows. (1) Remove the bushing from connecting rod with ST and press. (2) Press the bushing with ST after applying oil on the periphery of bushing. ST ONNETING ROD USH- ING REMOVER ND IN- STLLER 3) Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace the bearing with a suitable (undersize) one, and then replace or recondition the crankshaft as necessary. When grinding the crank journal or crank pin, finish them to specified dimensions according to the undersize bearing to be used. rank pin and crank journal: Out-of-roundness mm ( in) or less Taper limit 0.07 mm ( in) Grinding limit mm ( in) ME (3) Make two 3 mm (0.12 in) holes in bushing. Ream the inside of bushing. (4) fter the completion of reaming, clean the bushing to remove chips. ME ME(SOH)-87

29 MEHNIL YLINDER LOK Standard 0.03 (0.0012) undersize 0.05 (0.0020) undersize 0.25 (0.0098) undersize Journal O.D. earing size (Thickness at center) Journal O.D. earing size (Thickness at center) Journal O.D. earing size (Thickness at center) Journal O.D. earing size (Thickness at center) O.D.: Outer Diameter 4) Measure the thrust clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace bearing. rankshaft thrust clearance: Standard mm ( in) Limit 0.25 mm ( in) Unit: mm (in) rank journal diameter rank pin diameter #1, #3 #2, #4, # cc 2500 cc ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) Unit: mm (in) rankshaft oil clearance #1 Standard ( ) Limit (0.0016) #2 Standard ( ) Limit (0.0018) #3 Standard ( ) Limit (0.0016) #4 Standard ( ) Limit (0.0018) #5 Standard ( ) Limit (0.0016) ME ) Inspect the individual crankshaft bearings for signs of flaking, seizure, melting, and wear. 6) Measure the oil clearance on each crankshaft bearing by means of plastigauge. If the measurement is not within the specification, replace the defective bearing with an undersize one, and then replace or recondition the crankshaft as necessary. ME(SOH)-88

30 ENGINE TROULE IN GENERL MEHNIL 22.Engine Trouble in General : INSPETION RNK shown in the chart refer to the possibility of reason for the trouble in order ( Very often to Rarely ) Very often Sometimes Rarely TROULE PROLEM PRTS, ET. POSSILE USE RNK 1. Engine will not start. 1) Starter does not turn. Starter Defective battery-to-starter harness Defective starter switch Defective inhibitor switch or neutral switch Defective starter attery Poor terminal connection Run-down battery Defective charging system Friction Seizure of crankshaft and connecting rod bearing Seized camshaft Seized or stuck piston and cylinder 2) Initial combustion does Starter Defective starter not occur. Engine control system <Ref. to EN(SOH)-2, asic Diagnostic Procedure.> Fuel line Defective fuel pump and relay Lack of or insufficient fuel elt Defective Defective timing ompression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) 3) Initial combustion occurs. Engine control system <Ref. to EN(SOH)-2, asic Diagnostic Procedure.> Intake system Defective intake manifold gasket Defective throttle body gasket Fuel line Defective fuel pump and relay logged fuel line Lack of or insufficient fuel elt Defective Defective timing ompression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) ME(SOH)-89

31 MEHNIL ENGINE TROULE IN GENERL TROULE PROLEM PRTS, ET. POSSILE USE RNK Engine control system <Ref. to EN(SOH)-2, asic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Dirty air cleaner element Fuel line logged fuel line Lack of or insufficient fuel elt Defective Defective timing ompression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Engine control system <Ref. to EN(SOH)-2, asic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay logged fuel line Lack of or insufficient fuel elt Defective timing ompression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure Defective rocker cover gasket ooling system Overheating Others Malfunction of evaporative emission control system Stuck or damaged throttle valve ccelerator cable out of adjustment 4) Engine stalls after initial combustion. 2. Rough idle and engine stall ME(SOH)-90

32 ENGINE TROULE IN GENERL MEHNIL TROULE PROLEM PRTS, ET. POSSILE USE RNK 3. Low output, hesitation and Engine control system <Ref. to EN(SOH)-2, asic Diagnostic Procedure.> poor acceleration Intake system Loosened or cracked intake duct Loosened or cracked PV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay logged fuel line Lack of or insufficient fuel elt Defective timing ompression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure ooling system Overheating Over cooling Others Malfunction of evaporative emission control system 4. Surging Engine control system <Ref. to EN(SOH)-2, asic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay logged fuel line Lack of or insufficient fuel elt Defective timing ompression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) ooling system Overheating Others Malfunction of evaporative emission control system ME(SOH)-91

33 MEHNIL ENGINE TROULE IN GENERL TROULE PROLEM PRTS, ET. POSSILE USE RNK 5. Engine does not return to Engine control system <Ref. to EN(SOH)-2, asic Diagnostic Procedure.> idle. Intake system Loosened or cracked vacuum hose Others Stuck or damaged throttle valve ccelerator cable out of adjustment 6. Dieseling (Run-on) Engine control system <Ref. to EN(SOH)-2, asic Diagnostic Procedure.> ooling system Overheating Others Malfunction of evaporative emission control system 7. fter burning in exhaust Engine control system <Ref. to EN(SOH)-2, asic Diagnostic Procedure.> system Intake system Loosened or cracked intake duct Loosened or cracked PV hose Loosened or cracked vacuum hose Defective PV valve Loosened oil filler cap elt Defective timing ompression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Lubrication system Incorrect oil pressure ooling system Over cooling Others Malfunction of evaporative emission control system 8. Knocking Engine control system <Ref. to EN(SOH)-2, asic Diagnostic Procedure.> Intake system Loosened oil filler cap elt Defective timing ompression Incorrect valve clearance Incorrect valve timing ooling system Overheating 9. Excessive engine oil consumption Intake system Loosened or cracked PV hose Defective PV valve Loosened oil filler cap ompression Defective valve stem Worn or stuck piston rings, cylinder and piston Lubrication system Loosened oil pump attaching bolts and defective gasket Defective oil filter seal Defective crankshaft oil seal Defective rocker cover gasket Loosened oil drain plug or defective gasket Loosened oil pan fitting bolts or defective oil pan ME(SOH)-92

34 ENGINE TROULE IN GENERL MEHNIL TROULE PROLEM PRTS, ET. POSSILE USE RNK 10. Excessive fuel consumption Intake system Dirty air cleaner element Engine control system <Ref. to EN(SOH)-2, asic Diagnostic Procedure.> elt Defective timing ompression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Lubrication system Incorrect oil pressure ooling system Over cooling Others ccelerator cable out of adjustment ME(SOH)-93

35 MEHNIL ENGINE NOISE 23.Engine Noise : INSPETION Type of sound ondition Possible cause Regular clicking sound Heavy and dull clank High-pitched clank (Spark knock) lank when engine speed is medium (1,000 to 2,000 rpm). Knocking sound when engine is operating under idling speed and engine is warm Sound increases as engine speed increases. Oil pressure is low. Oil pressure is normal. Sound is noticeable when accelerating with an overload. Sound is reduced when fuel injector connector of noisy cylinder is disconnected. (NOTE*) Sound is reduced when fuel injector connector of noisy cylinder is disconnected. (NOTE*) Sound is not reduced if each fuel injector connector is disconnected in turn. (NOTE*) Valve mechanism is defective. Incorrect valve clearance Worn valve rocker Worn camshaft roken valve spring Worn crankshaft main bearing Worn connecting rod bearing (big end) Loose flywheel mounting bolts Damaged engine mounting Ignition timing advanced ccumulation of carbon inside combustion chamber Wrong spark plug Improper gasoline Worn crankshaft main bearing Worn bearing at crankshaft end of connecting rod Worn cylinder liner and piston ring roken or stuck piston ring Worn piston pin and hole at piston end of connecting rod Unusually worn valve lifter Worn cam gear Worn camshaft journal bore in crankcase Squeaky sound Insufficient generator lubrication Rubbing sound Defective generator brush and rotor contact Gear scream when starting engine Sound like polishing glass with a dry cloth Hissing sound Timing belt noise Valve tappet noise Incorrect valve clearance Defective ignition starter switch Worn gear and starter pinion Loose drive belt Defective water pump shaft Loss of compression ir leakage in air intake system, hoses, connections or manifolds Loose timing belt elt contacting case/adjacent part NOTE*: When disconnecting fuel injector connector, Malfunction Indicator Light (HEK ENGINE light) illuminates and trouble code is stored in EM memory. Therefore, carry out the LER MEMORY MODE <Ref. to EN(SOH)-47, OPERTION, lear Memory Mode.> and INSPE- TION MODE <Ref. to EN(SOH)-40, OPERTION, Inspection Mode.> after connecting fuel injector connector. ME(SOH)-94