Page 116 of 364
94G6 – ALTERNATOR, IGNITION SYSTEM
Removal Service Point
Removal of ignition coil boot
Note :
• If the ignition coil boot is not installed according to the
specifications, then this can lead to various problems, such
as malfunction of the ignition coil, damage to the ignition coil,
leaking of high voltage to external parts, infiltration of water
into the hole, etc.
• The spark plug coupling section of the ignition coil boot is
coated with a white powder. This coating helps to prevent the
boot from welding to the spark plug, and must not be touched
or wiped away.
1. Please check that a spring is fitted inside the new ignition coil
boot.
2. Press the new ignition coil boot firmly onto the ignition coil,
and turn the coupling section 2 or 3 times to seat it correctly
in position, ensuring that there are no gaps.
3. After installation, turn the boot until the air blow hole is
positioned as shown in the diagram.
Coupling
section
Air blow hole
White powder coating on
interior part. Do not touchAir blow hole
Upper faceA *
Page 125 of 364
184G6 – ROCKER ARM / CAMSHAFT
Rocker Arm / Camshaft
Removal and Installation
Removal Sequence
1. Cam position sensor
2. O ring
3. Cover
4. Gasket
5. Cam position sensing cylinder
6. Cam position sensor support
7. Cam position sensor
8. O ring
9. Cover
10. Gasket
11.Cam position sensing cylinder
12. Cam position sensor support
13. Camshaft oil seal
14. Bearing cap : rear right
15. Bearing cap : rear left
16. Bearing cap : front17. Bearing cap No. 5
18. Bearing cap No. 2
19. Bearing cap No. 3
20. Bearing cap No. 4
21. Camshaft
22. Rocker arm
23. Lash adjuster
24. Oil delivery body
25. Oil control valve (OCV)
26. O ring
27. Check valve
28. Eye bolt
29. Oil pump
30. OCV filter
31. Oil pump joint
32. Gasket
Apply engine oil to all
sliding parts before
installing.
E *
E
*
D
*
D
*
C
*
C
*
E
*
E
*
* 1*
*1*
* 1*
* 1*
*1*
* 1*
* 1*
* 1*
* 1*
* 1* * * 1
B*
A *
Page 126 of 364
194G6 – ROCKER ARM / CAMSHAFT
Installation Service Point
Installation of OCV filter
Note :
Before fitting the filter, check that it is clean and is not damaged
or deformed in any way.
Installation of eye bolt
Note :
The oil pump may be damaged if the oil pipe joint turns with the
eye bolt when it is fitted.
Hold the oil pipe joint in place with a spanner, etc., and then tighten
the eye bolt to the specified torque 42 ±2 N-m.
Installation of cam position sensor
support
1. Wipe away all traces of the old liquid gasket left on the cam
position sensor support and the cylinder head.
2. Apply a 3 mm-thick coat of the liquid gasket to the parts of the
cam position sensor support indicated on the diagram.
Liquid Gasket
Product name : MZ100191 or equivalent
Installation of cam position sensing
cylinder
1. Set the camshaft to the top dead centre for No.1.
2. Install the various vanes of the cam position sensing cylinder at
the positions indicated on the diagram.
Installation of cover / gasket
1. Before installing the cover and gasket, put the camshaft to the
No.1 top dead centre position, and check that the vanes of the
respective sensing cylinders are located in the positions shown in
the diagram.
Eye bolt
Hold with
spanner, etc.
Oil pipe joint
Exhaust sideIntake side
Exhaust side
Exhaust sideIntake side
Intake sideVane
Vane
Vane
Vane VaneVane
Vane Vane
Vane
(large) Vane
(large) Vane
(small)
Vane
(small)
A*
B *
C
*
D
*
E
*
Page 131 of 364
244G6 – PISTONS CONNECTING RODS
Inspection
Piston rings
1. Check the clearance between the piston rings and the piston grooves.
If it exceeds the clearance limit value, replace the piston ring, or both
the piston ring and the piston.
Standard values :
No. 1 0.03 – 0.07 mm
No. 2 0.02 – 0.06 mm
Limit value : 0.1 mm
2. Insert the piston ring and the side rail of the oil ring into the cylinder
bore, and press in using the top surface of the piston. After reaching
a right-angle position, measure the opening gaps in the rings using a
thickness gauge.
Remark :
Press the openings of the piston ring and the oil ring side rail with the
piston in the position shown in the diagram, and measure the opening
gaps in this position.
Standard value
No. 1 0.20 – 0.30 mm
No. 2 0.35 – 0.45 mm
Oil ring 0.10 – 0.40 mm
Standard value
No. 1 0.8 mm
No. 2 0.8 mm
Oil ring 1.0 mm
Press with piston
Opening gap
Piston ring
Page 132 of 364
254G6 – CRANKSHAFT / CYLINDER BLOCK
Crankshaft / Cylinder Block
Removal and Installation
Removal Procedure
1. Flywheel bolt
2. Flywheel
3. Rear plate
4. Bell housing cover
5. Rear oil seal case
6. Rear oil seal
7. Bearing cap bolt
8. Beam being cap9. Crankshaft bearing lower
10. Crankshaft
11.Crankshaft bearing upper
12. Thrust bearing
13. Check valve
14. Oil jet
15. Cylinder block
Apply engine oil to all
sliding parts before
installing. Bolt with washer : 9.0 ± 1.0 N-m
Flange bolt : 10 ± 2 N-m (supplementary part)
A*
A*
* 1*
* 1*
* 1*
* 1*
*1*
