Page 361 of 513

ENGINE
MECHANICAL
Standard
Maximum
Crankshaft
bend
mm
in
0
05
0
0020
0
015
0
0006
Note
When
measuring
bend
use
a
dial
gauge
Bend
value
is
a
half
of
the
reading
obtained
when
the
crankshaft
is
turned
once
with
the
dial
gauge
applied
to
its
center
journal
3
After
regrinding
the
crankshaft
fmish
it
to
the
necessary
size
indicated
in
the
lists
on
pages
EM
25
by
using
an
adequate
undersize
bearing
according
to
the
extent
of
required
repair
4
Install
the
crankshaft
in
the
cylinder
block
and
measure
the
thrust
clearance
Fig
EM
60
Crankshaft
end
pldy
check
Standard
Limit
Crankshaft
free
end
play
rom
in
0
05
to
0
15
0
0020
to
0
0059
0
30
0
D118
5
Check
the
main
drive
shaft
pilot
bearing
at
the
rear
end
of
the
crankshaft
for
wear
and
damage
Replace
it
if
any
defects
are
detected
BUSHING
AND
BEARING
Measuring
main
bearing
clearance
Check
all
bearings
and
bushings
for
seizure
melt
scar
and
burr
Replace
bushings
if
any
defects
are
detected
2
Wipe
off
oil
and
dust
especially
the
rear
of
the
bushing
3
Set
the
main
bearing
on
the
cap
block
Scale
Plastigage
EM141
Fig
EM
61
Plastigage
4
Cut
a
plastigage
to
the
width
of
the
bearing
and
place
it
in
parallel
with
the
crank
pin
getting
clear
of
the
oil
hole
Install
the
cap
on
the
assembly
and
tighten
them
together
with
the
specified
torque
Tightening
torque
5
0
to
6
0
kg
m
36
to
43
ft
lb
Note
Be
sure
not
to
turn
the
crankshaft
when
the
plastigage
is
inserted
5
Remove
the
cap
and
measure
width
of
the
plastigage
at
its
widest
part
with
the
scale
printed
in
the
plastigage
envelope
EM
21
Page 362 of 513
ENGINE
Pig
EM
62
Bearing
clearance
check
Measuring
connecting
rod
bearing
clearance
Measure
connecting
rod
bearing
clearance
in
the
same
manner
Tightening
torque
3
2
to
3
8
kg
m
23
to
28
ft
Ib
Bearing
oil
clearance
Standard
Wear
limit
Main
bearing
clearance
rom
in
0
020
to
0
062
0
0008
to
0
0024
0
1
0
0039
Connecting
rod
bearing
clearance
mm
in
0
020
to
0
050
0
0008
to
0
0020
0
1
0
0039
2
If
clearance
exceeds
the
specified
value
replace
bearing
with
an
undersize
bearing
and
grind
out
the
crankshaft
journal
adequately
Fig
EM
63
Bearing
clearance
check
Fitting
crankshaft
bearings
I
Set
the
bushings
on
the
main
bearing
cap
and
the
cylinder
block
bearing
recess
and
tighten
the
cap
bolts
to
the
specified
torque
Tightening
torque
5
0
to
5
3
kg
m
36
to
38
ft
lb
2
Loosen
the
cap
bolt
on
one
side
and
measure
clearance
between
the
cap
and
cylinder
block
side
n
n
u
ii
Bearing
6
Weight
EM143
Fig
EM
64
Bearing
crush
check
EM
22
Page 363 of 513

ENGINE
MECHANICAL
3
Ascertain
that
the
clearance
is
within
double
the
figure
listed
below
If
it
is
not
replace
the
bearing
4
Handle
the
connecting
rod
bearing
in
the
same
manner
Connecting
rod
cap
tightening
torque
3
2
to
3
8
kg
m
23
to
28
ft
lb
Bearing
crush
All
main
bearing
mm
in
o
to
0
03
0
to
0
0012
All
connecting
rod
bearing
mm
in
0
Ql5
to
0
040
0
0006
to
0
0016
Main
bearing
undersize
Bearing
size
Bearing
top
Crank
journal
1
100
thickness
mm
in
diameter
mm
in
STD
1
835
to
1
822
49
951
to
49
964
0
0722
to
0
0717
1
9666
to
1
9671
25
1
960
to
1
947
49701
to
49
714
undersize
0
0772
to
0
0767
1
9567
to
1
9572
50
2
085
to
2
072
49451
to
49
464
undersize
0
0821
to
0
0816
1
9469
to
1
9474
75
2
210
to
2
197
49
201
to
49
214
undersize
0
0870
to
0
0865
1
9370
to
1
9376
100
2
335
to
2
322
48
951
to
48
964
undersize
0
0919
to
0
0914
1
9272
to
1
9277
Connecting
rod
bearing
undersize
Bearing
top
Crank
pin
Bearing
size
thickness
mm
in
diameter
mm
in
1
500
to
1
508
44
961
to
44
974
0
0591
to
0
0594
1
8489
to
I
7706
8
1
540
to
1
548
44
881
to
44
894
undersize
0
0606
to
0
0609
1
7670
to
I
7675
STD
12
1
560
to
1
568
44
841
to
44
854
undersize
0
0614
to
0
0617
I
7654
to
I
7659
25
1
625
to
1
633
44
711
to
44
724
undersize
0
0640
to
0
0643
1
7603
to
I
7608
50
I
750
to
1
758
44
461
to
44
474
undersize
0
0689
to
0
0692
1
7504
to
I
7509
75
1
875
to
1
883
44
211
to
44
224
undersize
0
0738
to
0
0741
1
7406
to
I
7411
100
2
000
to
2
008
43
961
to
43
974
undersize
0
0787
to
0
0791
1
7307
to
I
7313
Fitting
camshaft
bushings
When
clearance
exceeds
the
specified
value
remove
all
camshaft
bushings
by
using
the
special
tool
and
replace
with
service
parts
Notes
3
Coincide
the
bearing
oil
hole
with
the
oil
hole
of
the
cylinder
block
side
b
After
replacing
all
bushings
correct
the
bear
ings
by
line
boring
c
I
nstall
the
taper
plug
into
the
cylinder
block
applying
the
sealing
agent
Fig
EM
65
Replacing
camshaft
bushings
EM
23
Page 364 of 513

Bearing
thickness
mm
in
STD
I
No
1
I
No
2
I
I
I
1
585
to
1
565
No
3
0
0624
to
0
0616
I
No
4
I
No
5
I
NO
11
0
25
I
1
710
to
1
690
undersize
No
3
0
0673
to
0
0665
I
No
4
I
No
5
I
No
1
I
I
No
2
I
0
50
I
1
835
to
1
815
undersize
No
3
0
0722
to
0
0715
No
4
No
5
I
I
No
1
I
No
2
I
0
75
I
11
960
to
1
940
undersize
No
3
0
0772
to
0
0764
I
No
4
I
I
No
5
I
ENGINE
Camshaft
journal
diameter
mm
in
D
783
to
43
796
1
7237
to
1
7242
43
283
to
43
296
1
7041
to
1
7046
42
783
to
42
796
1
6844
to
1
6849
42
283
to
42
296
1
6647
to
1
6652
41
208
to
41
221
1
6224
to
1
6229
43
533
to
43
546
11
7139
to
1
7144
43
023
to
43
036
1
6983
to
1
6943
42
523
to
42
536
1
6741
to
1
6746
42
023
to
42
036
1
6544
to
1
6550
40
958
to
40
971
1
6t25
to
1
6
30
43
283
to
43
296
1
7041
to
1
7046
42
773
to
42
786
1
6840
to
1
6845
42
273
to
42
286
11
6643
to
1
6648
41
773
to
41
786
1
6446
to
1
6451
40
708
to
40
721
1
6027
to
1
6023
43
033
to
43
046
1
6942
to
1
6947
42
523
to
42
536
1
674t
to
1
6746
42
023
to
42
036
1
6554
to
1
6550
41
523
to
41
536
1
6348
to
1
6353
40
458
to
40
471
1
5928
to
1
5933
EM
24
MISCELLANEOUS
COMPONENTS
Crankshaft
sprocket
and
camshaft
sprocket
I
Check
tooth
surfaces
for
flaws
and
wears
Replace
defective
sprocket
2
Install
the
camshaft
sprocket
in
position
and
check
for
run
out
If
it
exceeds
0
1
mm
0
0039
in
replace
the
camshaft
sprocket
Check
the
camshaft
thrust
deviation
If
it
is
deviated
replace
the
camshaft
locating
plate
f
EMl48
Fig
EM
66
Camshaft
sprocket
run
out
check
Clearance
limit
0
Imm
0
0039
in
SJ
l
ldar
Q
0
02
to
0
08mm
0
0008
to
0
0031
in
Fig
EM
67
Check
locating
plate
thrust
clearance
Page 365 of 513

ENGINE
MECHANICAL
Standard
mm
in
Camshaft
sprocket
run
out
Thrust
deviation
O
OIS
0
0006
Locating
plate
thrust
clearance
0
02
to
0
08
0
0008
to
0
003
Wear
limit
mm
in
less
than
0
0
0039
O
OS
0
0020
0
1
0
0039
3
Check
the
chain
for
damage
excessive
wear
and
stretch
at
its
roller
links
Replace
chain
if
defective
Flyw
heel
I
Check
the
clutch
disc
contact
surface
of
the
flywheel
for
damage
and
wear
Repair
or
replace
if
necessary
2
Measure
deviation
of
the
clutch
disc
contact
surface
with
a
dial
gauge
If
it
exceeds
0
2
mm
0
0079
in
replace
it
3
Check
tooth
surfaces
of
the
ring
gear
for
flaw
and
wear
Replace
if
necessary
Note
Replace
the
ring
gear
at
about
180
to
2000C
356
to
3920
Fl
ENGINE
ASSEMBLY
PRECAUTION
CYLINDER
HEAD
PRECAUTION
CONTENTS
EM
25
EM
25
Use
thoroughly
cleaned
parts
Particularly
make
sure
that
oil
holes
are
clear
of
foreign
matter
2
When
installing
sliding
parts
such
as
bearings
be
sure
to
apply
engine
oil
to
them
3
Use
new
packings
and
oil
seals
4
Keep
tools
and
work
benches
clean
S
Keep
the
necessary
parts
and
tools
near
at
hand
6
Be
sure
to
follow
specified
tightening
torque
and
orders
CYLINDER
HEAD
Assembly
of
valve
and
valve
spring
Set
the
valve
spring
seat
in
position
and
fit
the
valve
guide
with
the
oil
lip
seal
Assemble
the
parts
in
order
valve
spring
spring
retainer
valve
collet
and
valve
rocker
guide
PISTON
AND
CONNECTING
ROO
ASSEMBLING
ENGINE
EM
25
EM
26
I
I
11
00
I
I
I
t
I
J
ftr
J
J
1
l
J
r
N
1
n
r
VI
I
I
C
I
L
I
Fig
EM
68
Valve
installation
Note
Make
sure
that
the
valve
face
is
clear
from
foreign
matters
PISTON
AND
CONNECTING
ROD
Assemble
piston
piston
pin
and
connecting
rod
assorted
according
to
cylinder
number
for
every
cylinder
EM
25
Page 366 of 513

ENGINE
ST130300
1
EM156
Fig
EM
69
Piston
pin
installation
Fig
EM
70
Piston
and
connecting
rod
assembly
Notes
8
Piston
pin
is
press
fitted
to
the
connecting
rod
tightly
and
fitting
force
is
from
1
to
3
tons
When
fitting
piston
pin
special
tool
must
be
used
When
pressing
the
piston
pin
into
the
connecting
rod
apply
engine
oil
to
the
pin
and
the
small
end
of
the
connecting
rod
b
Arrange
the
connecting
rod
so
that
the
oil
jet
of
the
connecting
rod
large
end
is
directed
toward
the
right
side
of
the
cylinder
block
2
Installing
piston
rings
Install
the
top
and
second
fings
in
right
positions
so
that
the
marks
are
faced
upward
3
Fix
bearings
on
the
connecting
rod
and
the
con
necting
rod
cap
Note
Clean
the
back
side
of
the
bearing
carefully
ASSEMBLING
ENGINE
Set
the
cylinder
block
on
the
working
stand
with
the
engine
bottom
faced
upside
2
Install
the
valve
lifters
Install
the
camshaft
and
retain
by
the
camshaft
locate
plate
Locate
plate
tighten
ing
torque
is
0
4
to
0
5
kg
m
2
9
to
3
6
ft
lb
Note
Set
the
locate
plate
so
as
the
LOWER
mark
comes
to
the
engine
bottom
side
Set
the
main
bearings
on
their
positions
on
the
cylinder
block
Fig
EM
71
Installing
camshaft
ocate
plate
Fig
E1U
7
2
lvlajn
betlrj
lg
cap
Notes
a
The
center
bearing
No
3
bearing
is
a
flanged
type
for
thrust
force
b
Two
inner
bearings
No
2
and
No
4
are
of
the
same
type
c
The
front
bearing
No
1
is
the
same
type
a
the
rear
bearing
No
5
d
All
bearings
except
for
No
1
bearing
are
interchangeable
between
upper
and
lower
bear
ings
EM
26
Page 367 of 513

ENGINE
MECHANICAL
3
Apply
engine
oil
to
the
main
bearing
surfaces
on
both
sides
of
the
cylinder
block
and
cap
Install
the
crankshaft
4
Install
the
main
bearing
cap
and
tighten
the
bolts
with
specified
torque
Tightening
torque
5
0
to
6
0
kg
m
36
to
43
ft
lb
Notes
a
Arrange
the
parts
so
that
the
arrow
mark
on
the
bearing
cap
is
faced
toward
the
front
of
the
engine
b
Prior
to
tightening
the
bearing
cap
bolts
place
the
bearing
cap
at
a
proper
position
by
shifting
the
crankshaft
in
the
axial
direction
c
Tighten
the
bearing
cap
bolts
gradually
in
separating
two
to
three
stages
and
outwardly
from
the
center
beari
ng
d
After
securing
the
bearing
cap
bolts
ascertain
that
the
crankshaft
can
be
easily
rotated
5
Make
sure
that
the
crankshaft
end
play
is
correct
Crankshaft
end
play
0
05
to
0
15
rom
0
0020
to
0
0059
in
Fig
EM
73
Crankshaft
end
play
check
EM
27
Fig
EM
73
t
Applying
adhesive
6
Install
the
rear
oil
seal
7
Install
the
flywheel
securely
using
the
lock
washers
and
tighten
the
bolts
with
specified
torque
Tightening
torque
6
5
to
7
5
kg
m
47
to
54
ft
lb
Iii
Fig
EM
74
Flywheel
installation
8
Rotate
the
engine
a
quarter
turn
and
install
the
piston
rod
assembly
Page 368 of 513

ENGINE
Fig
EM
75
Piston
and
connecting
rod
assembly
installation
Notes
8
I
nsert
the
pistons
in
the
corresponding
cyl
inders
b
Apply
engine
oil
to
parts
as
requried
c
Arrange
pistons
so
that
the
F
mark
on
the
piston
is
faced
to
the
front
of
the
engine
d
Install
piston
rings
at
180
to
each
other
avoiding
to
fit
them
in
the
thrust
and
piston
pin
axial
directions
Fig
EM
76
Connecting
rod
cap
installation
Note
Arrange
connecting
rods
and
connecting
rod
caps
so
that
the
cylinder
numbers
are
faced
toward
the
same
direction
EM
28
q
Install
the
connecting
rod
cap
Tightening
torque
32
to
3
8
kg
m
23
I
to
7
S
ft
lb
10
Make
sure
that
end
play
of
the
connecting
rod
large
end
is
correct
Big
end
play
j
I
Fig
EM
77
Big
end
play
check
Big
end
end
play
0
2
to
0
3
0
0079
to
0
0118
11
Install
the
camshaft
and
crankshaft
sprockets
temporarily
for
adjustment
of
the
tooth
height
by
using
adjusting
washers
Height
difference
mm
in
less
than
O
S
0
0197
Adjusting
washer
thickness
mm
in
O
IS
0
006
Fig
EM
78
Adjusting
sprocket
tooth
height