Beruflich Dokumente
Kultur Dokumente
Main
Index
SPECIFICATIONS
GENERAL SPECIFICATIONS
Descriptions
Specifications
Type
Number of cylinders
Combustion chamber
Pentroof type
Total displacement cc
Cylinder bore mm
Piston stroke mm
Valve timing
Intake valve
Exhaust valve
Opens (BTDC)
9_
Closes (ABDC)
59_
Opens (BBDC)
47_
Closes (ATDC)
21_
Lubrication system
Trochoid type
Cooling system
EGR type
Single type
Electromagnetic, 6
CDH210
Throttle bore mm
65
11B
Index
SERVICE SPECIFICATIONS
Items
Standard value
Limit
11B
Index
Alternator
Drive belt
Tension N
New belt
784980
Used belt
539637
New belt
6.07.2
Used belt
8.29.3
1316 at 20_C
Intake
37.58
37.08
Exhaust
36.95
36.45
44.93 44.94
0.03
0.2
*0.2
Overall height mm
120
Intake
1.0
0.5
Exhaust
1.2
0.7
Intake
6.0
Exhaust
6.0
Intake
0.020.05
0.10
Exhaust
0.040.07
0.15
45_45.5_
Free height mm
51.0
50.0
267/44.2
Out of squareness
2_ or less
Max. 4_
Valve seat
0.91.3
Valve guide
Inner diameter mm
6.0
Outer diameter mm
11.0
Deflection mm
(Reference value)
Fuel and emission parts
Injector coil resistance
Rocker arms and camshaft
Camshaft
Camshaft
Cam height mm
Journal diameter mm
Valve
Limit
Main
Index
Tip clearance mm
0.060.18
Side clearance mm
0.040.10
11B
Index
Body clearance mm
0.100.18
0.35
Outer diameter mm
0.020.04
0.030.07
0.1
0.020.06
0.1
0.300.45
0.8
0.450.60
0.8
6G72 0.200.60
6G74 0.100.35
1.0
Outer diameter mm
22.0
Press-in load
Press-in temperature
Crankshaft
0.020.05
0.1
Connecting rod
0.100.25
0.4
End play mm
0.050.25
0.3
60
50
0.020.04
0.1
Runout mm
0.13
0.05
0.1
*0.2
Overall height mm
210.4210.6
Items
Front case, oil pump and oil pan
Oil pump
Piston ring
Piston pin
REWORK DIMENSIONS
Items
Standard value
Limit
0.05
11.0511.07
0.25
11.2513.32
0.50
11.5011.52
0.3
34.3034.33
0.6
34.6034.63
0.3
31.8032.83
0.6
32.1032.13
0.005
Crankshaft
Crankshaft
11B
Index
TORQUE SPECIFICATIONS
Items
Nm
21
50
M8
48
M10
23
44
Crankshaft bolt
180-190
4.9
18
9.8
19
18
59
M8
18
M10
36
22
Bracket bolt
24
12
Ignition system
Spark plug
25
Distributor nut
23
Timing belt
Crank angle sensor bolt
24
49
44
44
88
12
18
11
30
19
19
19
14
21
11B
Index
Nm
Exhaust manifold
Oil level gauge guide bolt
14
14
29
M8
24
M10
41
3.5
23
13
31
108
10
M8
24
M10
40
Drain plug
40
11
Cover bolt
11
M6
11
M8
19
Plug
45
14
10
52
75
Flywheel bolt
98
11
93
Bracket
Bracket bolt
M8
22
M10
41
M12
75
Main
Index
11B
Index
SEALANTS
Items
Specified sealant
Quantity
Loctite 577
As required
Loctite 577
As required
Loctite 577
As required
As required
Oil pan
As required
As required
Loctite 262
As required
Loctite 577
As required
11B
Index
SPECIAL TOOLS
Tool
Supersession
Application
MB990767
End yoke holder
EMB990767
MD991559
Camshaft oil seal
installer adaptor
EMD991559
MD998051
Cylinder head bolt
wrench
E1139
MD998440
Leak-down tester
49U012005
MD998441
Lash adjuster retainer
EMD998441
MD998442
Air bleed wire
E9M401
MD998443
Lash adjuster holder
(8)
E9M402
MD998713
Camshaft oil seal
installer
EMD998713
MD998717
Crankshaft front oil
seal installer
EMD998717
11B
Index
Main
Index
Supersession
Application
MD998718
Crankshaft rear oil seal
installer
EMD998718
MD998715
Pulley holding pins (2)
EMD998715
MD998715
Valve spring compressor
J8062
MD998767
Tension pulley wrench
EMD998767
MD998769
Crankshaft spacer
MD998772
Valve spring compressor
MD998774
Valve stem seal installer
EMD998774
MD998780
Piston pin setting tool
Removal and
piston pin
MD998781
Flywheel stopper
installation
of
11B
Index
11B
Index
13
14
15
13 Nm
16
7
21 Nm
48 Nm
23 Nm
49 Nm
180-190
Nm
12
44 Nm
6
11
9
10
1
Removal steps
"BA 1. Drive belt
2. Tensioner pulley
AA" "AA 3. Crankshaft bolt
4. Washer
5. Crankshaft pulley
6. Alternator
7. Alternator bracket
8. Harness connector
9.
10.
11.
12.
13.
14.
15.
16.
MB998781
MB998781
Tension N
New
784 980
Used
539 637
Tension
pulley
Fixing
nut
Adjusting bolt
Standard value:
Alternator pulley
Tension pulley
A/C
pulley
Crankshaft
pulley
100 N
New
6.0 7.2
Used
8.2 9.3
Main
Index
11B
Index
11B
Index
10 Nm
2
1
3 Nm
11 Nm
11
12
13
17 Nm
9 Nm
17 Nm
17 Nm
4
10 Nm
6
7
14
35 Nm
17 Nm
15
9
10
11 Nm
Removal steps
1. Engine cover
2. Clamp
3. Accelerator cable bracket
4. Intake plenum stay, front
5. Intake plenum stay, rear
6. EGR valve
7. EGR valve gasket
8. EGR pipe
9.
10.
11.
12.
13.
14.
15.
IGNITION SYSTEM
REMOVAL AND INSTALLATION
11B
Index
1
3
23 Nm
4
1
25 Nm
Removal steps
1. Spark plug cables
2. Spark plugs
"AA 3. Distributor
4. O-ring
Aligning
marks
Main
Index
TIMING BELT
REMOVAL AND INSTALLATION
11B
Index
21
23 Nm
22
20
13 Nm
19
88 Nm
23 Nm
7
9
10
14
44 Nm
12
11
17
48 Nm
18 16
8
15
13
44 Nm
8 Nm
13 Nm
9 Nm
8 Nm
3
44 Nm
Removal steps
1. Timing belt front upper cover, rear
2. Timing belt front upper cover, front
3. Timing belt front lower cover
"DA 4. Engine support bracket
5. Crank angle sensor
AA" "CA 6. Timing belt
"BA 7. Automatic tensioner
8. Tensioner pulley
9. Tensioner arm
10. Shaft
11. Idler pulley
12.
13.
14.
15.
16.
17.
18.
AB" "AA 19.
20.
21.
22.
Main
Index
11B
Index
Index
Timing marks
Caution
If the camshaft sprocket is rotated with the piston
at the top dead centre on the compression stroke
of the No. 1 cylinder, the valve and piston might
interfere.
Crankshaft sprocket
Right bank
Timing marks
Left bank
Camshaft sprocket
Timing marks
Camshaft
sprocket
Tensioner pulley
11B
Index
MD998769
Right bank
Left bank
Timing mark
Camshaft sprocket
Camshaft sprocket
Tensioner pulley
Idler pulley
Auto-tensioner
Crankshaft sprocket
Timing mark
EMD998767
Index
INSPECTION
Main
Index
TIMING BELT
Replace belt if any of the following conditions exist.
1. Hardening of backing rubber, backing rubber is glossy, 11B
without resilience and leaves no indent when pressed Index
with fingernail.
Cracks
2.
3.
4.
5.
Cracks
Cracks
Cracks
Cracks
on backing rubber
or peeling of canvas
on tooth bottom
on side of belt
Peeling
Cracks
Cracks
Abnormal wear
(Fluffy strand)
AUTO-TENSIONER
1. Check for oil leaks. If oil leaks are evident, replace the
auto-tensioner.
2. Check the rod end for wear or damage and replace the
auto-tensioner if necessary.
3. Measure the rod projection length. If the reading is outside
the standard value, replace the auto-tensioner.
Standard value: 11.712.3 mm
11.712.3 mm
98196 N
Movement
1 mm or less.
17
11 Nm
11B
Index
18 Nm
19
20
18 Nm
9 Nm
18
23
12
18 Nm
21
11
24 18 Nm
26
8
9
7
9 Nm
10
25
22
15
27
11 Nm
16
13
21 Nm
29 Nm
14
18 Nm
30
14
"HA
"GA
"FA
"EA
"DA
31
Removal steps
1. Engine harness
2. Injector and fuel rail
3. Insulator
4. Fuel pressure regulator
5. O-ring
6. Insulator
7. Injector
8. O-ring
9. Grommet
10. Fuel pipe
11. O-ring
12. Delivery pipe
13. Intake manifold
14. Intake manifold gasket
15. Engine coolant temperature gauge
unit
16. Engine coolant temperature sensor
13 Nm
29
28
"CA
"AA
"CA
"AA
"BA
"AA
"AA
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Water hose
Water hose
Heater inlet pipe
O-ring
Heater inlet pipe
O-ring
Water outlet fitting
Water outlet fitting gasket
Water inlet fitting
Thermostat
Thermostat housing
Thermostat housing gasket
O-ring
Water pipe
O-ring
Jiggle valve
Outlet pipe
Inlet pipe
Surge tank stay
Main
Index
11B
Index
Front
11B
Index
13 Nm
4
5
6
8
13 Nm
49 Nm
11
10
12
41 Nm
1
2
9
49 Nm
13 Nm
23 Nm
Removal steps
1. Oil level gauge
2. Oil level gauge guide
3. O-ring
4. Heat protector, rear
5. Exhaust manifold, rear
"BA 6. Exhaust manifold gasket, rear
7. Heat protector, front
8. Engine lift bracket
9. Exhaust manifold, front
"BA 10. Exhaust manifold gasket, front
"AA 11. Water pump
12. Water pump gasket
Water pump
Cylinder No.
For right bank
Front
Front
Main
Index
11B
Index
11B
Index
3.5 Nm
31 Nm
2
10
6
3
8
7 9
8
5
11
7
13
12
12 Nm
12
14
12
16
15
17
4
Lubricate all internal
parts with engine oil
during reassembly.
Removal steps
1. Rocker cover
2. Rocker cover gasket
3. Oil seal
"EA 4. Camshaft oil seal
AA"
5. Rocker arm, rocker arm shaft
AA"
6. Rocker arm, rocker arm shaft
"DA 7. Rocker shaft spring
8. Rocker arm A
9. Rocker arm B
Main
Index
NOTE
If the lash adjuster is to be re-used, it must be cleaned and
checked before installation, refer to Lash Adjuster Cleaning
and Checking.
Slit
Right bank
Approx.
60
Left bank
Approx.
71
E9M402
Lash
adjuster
NOTE
The right bank camshaft is identified by a slit 4 mm wide
at the rear end of the camshaft.
11B
NOTE
Before installing the exhaust rocker arms and rocker arm Index
shaft, mount the rocker shaft spring.
Chamfered
Oil hole
2. The side with the oil holes is on the lower side (cylinder
head side).
Rocker shaft
spring
EMB991559
INSPECTION
ROCKER ARM SHAFT
1. Check the rocker arm mounting portions of the rocker
arm shafts for wear or damage. Replace as necessary.
ROCKER ARM
1. Check the roller surface and replace the rocker arm if
recesses, damage or heat seizure is observed.
2. Check roller rotation and replace the rocker arm if uneven
rotation or roller backlash is observed.
3. Check the inside diameter and replace the rocker arm
if damage or seizure is observed.
CAMSHAFT
1. Inspect the camshaft bearing journals for damage and
binding. If the journals are binding, also check the cylinder
head for damage. Also check the cylinder head oil holes
for clogging.
2. Check the cam surface for abnormal wear and damage
and replace if defective. Also measure the cam height
and replace if out of limit.
Standard value
Limit
Intake mm
37.58
37.08
Exhaust mm
36.95
36.45
Main
Index
11B
Index
Inside
cleaning
Filling
diesel fuel
Caution
D The lash adjusters are precision-engineered
mechanisms. Do not allow them to become 11B
contaminated by dirt or other foreign substances. Index
D Do not attempt to disassemble the lash adjusters.
D Use only fresh diesel fuel to clean the lash
adjusters.
1. Prepare three containers and approximately five litres
of diesel fuel. Into each container, pour enough diesel
fuel to completely cover a lash adjuster when it is standing
upright. Then, perform the following steps with each lash
adjuster.
2. Place the lash adjuster in container A and clean its outside
surface.
NOTE
Use a nylon brush if deposits are hard to remove.
EMD998441
Diesel
fuel
E9M40 1
Caution
The steel ball spring is extremely weak, so the lash
adjusters functionality may be lost if the air bleed
wire is pushed in hard.
4. While gently pushing down the internal steel ball using
special tool E9M40 1, move the plunger through five
to ten strokes until it slides smoothly. In addition to
eliminating stiffness in the plunger, this operation will
remove dirty oil.
NOTE
If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.
EMD998441
E9M40 1
Diesel fuel
Main
Index
EMD998441
Diesel
fuel
E9M40 1
Caution
The steel ball spring is extremely weak, so the lash
adjusters functionality may be lost if the air bleed 11B
wire is pushed in hard.
Index
7. Place the lash adjuster in container B. Then, gently push
down the internal steel ball using special tool
E9M40 1 and move the plunger through five to ten
strokes until it slides smoothly. This operation will clean
the lash adjusters pressure chamber.
8. Remove the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
EMD998441
E9M40 1
Diesel fuel
E9M40 1
Diesel fuel
EMD998441
EMD998441
Caution
Do not use container C for cleaning. If cleaning is
performed in container C, foreign matter could enter
the pressure chamber when the chamber is filled with
diesel fuel.
9. Place the lash adjuster in container C. Then, gently push
down the internal steel ball using special tool
E9M40 1.
10. Stand the lash adjuster with its plunger at the top, then
push the plunger downward firmly until it moves through
its greatest possible stroke. Return the plunger slowly,
then release the steel ball and allow the pressure chamber
to fill with diesel fuel.
11. Remove special tool EMD998441.
E9M40 1
Main
Index
Diesel fuel
12. Remove the lash adjuster from the container, then stand
the lash adjuster with its plunger at the top. Push the
plunger firmly and check that it does not move. Also,
check that the lash adjusters height matches that of a
new lash adjuster.
NOTE
If lash adjuster contracts, perform the operations (9)
through (12) again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts after performing
these steps.
Lash Adjuster
13. Set the lash adjuster on the special tool 49U012005 (leak Main
Index
down tester).
14. After the plunger has moved downward slightly [ 0.2 to
0.5mm ], measure the time taken for it to move downward
11B
by a further 1 mm.
Standard value: 5 20 seconds/1mm [with diesel fuel
at 15 to 20_C]
NOTE
Replace the lash adjuster if the time measurement is
out of specification.
E9M40 1
EMD998441
Diesel fuel
Index
2
5
6
7
13
14
17
19 16
11
22
18 15
21
10
12
20
8
3
Removal steps
AA" "DA 1. Cylinder head bolt
2. Washer
3. Cylinder head assembly
4. Cylinder head gasket
AB" "CA 5. Retainer lock
6. Valve spring retainer
"BA 7. Valve spring
8. Intake valve
AB" "CA 9. Retainer lock
10. Valve spring retainer
"BA 11. Valve spring
12.
AC" "AA 13.
14.
AC" "AA 15.
16.
17.
18.
19.
20.
21.
22.
Exhaust valve
Valve stem seal
Valve spring seat
Valve stem seal
Valve spring seat
Intake valve guide
Snap ring
Exhaust valve guide
Intake valve seat
Exhaust valve seat
Cylinder head
11B
Index
E1139
J8062
MD998772
Main
Index
11B
Index
Intake
Identification
our: Black
col-
Exhaust
EMD998774
Identification
colour
Spring
retainer
Stem seal
Spring seat
Main
Index
11B
Index
J8062
11B
Index
MD998772
Exhaust side
<Left bank>
Rounded side
6
5
2
1
3
4
Intake side
Cylinder head
bolt washer
<Right bank>
8
7
4
3
1
2
Exhaust side
7
8
Engine
front
5
6
INSPECTION
Main
Index
CYLINDER HEAD
1. Check the cylinder head gasket surface for flatness by
using a straightedge in the directions of A through G 11B
shown in the illustration.
Index
Standard value
0.03 mm
Limit: 0.2 mm
2. If the service limit is exceeded, correct to meet the
specification.
Grinding limit: *0.2 mm
* Total resurfacing depth of both cylinder head and cylinder
block.
Overall height
120 mm
VALVE
1. If the valve stem is worn (ridge wear) or otherwise
damaged, replace. Also replace the valve if the stem
end (that contacts the rocker arm lash adjuster) has an
indentation.
Ridge
wear
Margin
<Intake>
1.0 mm
<Exhaust>
1.2 mm
Limit
<Intake>
0.5 mm
<Exhaust>
1.2 mm
Standard value
51.0 mm
Free
height
Limit
50.0 mm
2. Measure the squareness of the spring and, if the limit
is exceeded, replace.
Standard value: 2
Limit: Max. 4
VALVE GUIDES
1. Measure the clearance between the valve guide and valve
stem. If the limit is exceeded, replace the valve guide
or valve, or both.
Standard value
Valve
guide
<Intake>
0.020.05 mm
<Exhaust>
0.040.07 mm
Guide I.D.
Limit
<Intake>
0.10 mm
<Exhaust>
0.15 mm
0.91.3 mm
0.91.3 mm
65
65
15
15
44
44
11B
Index
0.51 mm
11B
Index
Cut
away
0.51 mm
Oversize I.D.
3. Before fitting the valve seat, either heat the cylinder head
up to approximately 250C or cool the valve seat in liquid
nitrogen, to prevent the cylinder head bore from galling.
4. Using a valve seat cutter, correct the valve seat to the
specified width and angle.
See VALVE SEAT RECONDITIONING PROCEDURE.
14 mm
Main
Index
NOTE
1. When press-fitting the valve guide, work from the
cylinder head top surface.
2. Pay attention to the difference in length of the valve
guides. [intake side: 45.5 mm; exhaust side: 50.5
mm]
3. After installing the valve guides, insert new valves
in them to check for sliding condition.
11B
Index
20
21
18
22
13
9.8 Nm
13 Nm
12
19
3
41 Nm
16
15
14
17
44 Nm
9.8 Nm
11
10
18 Nm
11 Nm
9.8 Nm
9.8 Nm
23 Nm
23 Nm
11 Nm
5
39 Nm
Removal steps
"HA 1. Oil pressure gauge unit
"GA 2. Oil filter
3. Oil filter bracket
4. Oil filter bracket gasket
5. Drain plug
"FA 6. Drain plug gasket
AA" "EA 7. Oil pan, lower
8. Cover
AB" "DA 9. Oil pan, upper
10. Baffle plate
11. Oil screen
5.9 Nm
6
11 Nm
"CA
"BA
AC" "AA
AC" "AA
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
3. Thread the bolt into the illustrated bolt hole A (at each
end) to float and remove the oil pan.
Caution
Do not use a scraper or special tool to remove the
oil pan.
Alignment dots
Main
Index
11B
Index
EMD998717
EMD998717 Crankshaft
Guide
Oil seal
Main
Index
Main
"DA OIL PAN, UPPER INSTALLATION
Index
1. Clean the gasket surfaces of the cylinder block and upper
oil pan.
2. Apply a 4 mm diameter bead of sealant to the oil pump 11B
case. Be sure to install the oil pan quickly while the
Index
sealant is wet (within 15 minutes).
3. After installation, keep the sealed area away from the
oil and coolant for approx. 1 hour.
Caution
When installing the upper oil pan, be sure not to expel
the sealant from the oil pan flange at portion A in
the illustration.
Specified sealant:
MITSUBISHI GENUINE Part No. MD970389 / Loctite
587 Ultra blue or equivalent
10
9
8
7
5
Specified sealant:
MITSUBISHI GENUINE Part No. MD970389 / Loctite
587 Ultra blue or equivalent
Gasket
Main
Index
11B
Index
Oil pan
Oil pan
side
Bracket
side
Apply
engine oil
INSPECTION
OIL PUMP
1. Check the tip clearance.
Standard value: 0.060.18 mm
Main
Index
11B
Index
11B
Index
6
Lubricate all internal
parts with engine oil
during reassembly.
7
10
12
11
3
2
1
52 Nm
Removal steps
1. Nut
AA" "EA 2. Connecting rod cap
3. Connecting rod bearing, lower
"DA 4. Piston and connecting rod
assembly
5. Connecting rod bearing, upper
"CA 6. Piston ring No.1
11B
Index
7
8
12
10
11
4
14
13
3
2
1
52 Nm
AA" "EA
"DA
"CA
"CA
Removal steps
1. Nut
2. Connecting rod cap
3. Connecting rod bearing, lower
4. Piston and connecting rod
assembly
5. Connecting rod bearing, upper
6. Piston ring No.1
7. Piston ring No.2
"BA 8.
9.
AB" "AA 10.
11.
12.
13.
14.
Oil ring
Snap ring
Piston pin
Snap ring
Piston
Connecting rod
Bolt
Cylinder number
Push rod
Guide A:
17.9mm
Guide B
Guide A:
18.9mm
Guide C
Guide A:
20.9mm
Base
Guide A:
21.9mm
Push rod
Front
mark
Front mark
Guide C
Base
Main
Index
1. Insert the special push rod tool from the front marked
(arrow) side of the piston and attach guide C.
2. Set the piston and connecting rod assembly to the special
tool piston pin setting base such that the front mark on
the piston faces upward.
3. Remove the piston pin with a press.
NOTE:
After removing the piston pin, place the piston, the piston
pin, and the connecting rod in order for each cylinder
number.
70_C
Main
AB" REMOVAL OF PISTON PIN<6G74>
Index
1. Remove the snap rings.
2. Heat the piston to approximately 70_C and pull out the
piston pin.
11B
Index
Caution
Connecting rod
Piston pin
Piston
3mm + L
3. Insert the special push rod tool into the piston pin and
attach guide A to it.
4. Combine the piston and connecting rod, matching their
front marks.
5. Apply engine oil to the outer periphery of the piston pin.
6. Insert the side of the piston pin guide A attached per
step (3) into the pin hole from the side of the piston
containing the front mark.
7. Screw guide B into guide A until they are distance L
(obtained per step (2) above) plus 3 mm apart as shown.
8. Use special tools to set the piston pin to a special tool
piston base with the front mark of the piston facing up.
9. Press fit the piston pin with a press. When the load required
for press fitting the piston pin is below the standard value,
change the piston pin (piston assembly) or connecting
rod or both.
Standard value: 7,350 17,200 N
Guide A
Guide B
Push rod
11B
Index
Piston pin
Front
mark
Front mark
Guide A
Base
Guide B
Front mark
74
Front mark
Main
Index
NOTE
The side rails and spacer may be installed in either 11B
direction.
Index
No. 2 ring
T2
No.1
Piston pin
Main
"DA PISTON AND CONNECTING ROD INSTALLATION
Index
1. Liberally coat the circumference of the piston, piston ring,
and oil ring with engine oil.
2. Arrange the piston ring and oil ring gaps (side rail and 11B
spacer) as shown in the illustration.
3. Rotate the crankshaft so that the crank pin is on the Index
centre of the cylinder bore.
Lower
side rail
Cylinder No.
Notches
INSPECTION
Main
Index
CYLINDER BLOCK
1. Visually check for scratches, rust, and corrosion. Also
use a flaw detecting agent for the check. If defects are 11B
evident, correct, or replace.
Index
2. Using a straightedge and feeler gauge, check the flatness
of the block top surface. Make sure that the surface is
free from gasket pieces and other foreign matter.
Standard value: 0.05 mm
Limit: 0.1 mm
3. If distortion is excessive, correct within the allowable limit
or replace.
Grinding limit: 0.2 mm
*Includes/combined with cylinder head grinding.
Cylinder block height (when new):
210.4210.6 mm
12 mm
Centre
Bottom
Size
Identification mark
0.50 mm O.S.
0.50
1.00 mm O.S.
1.00
NOTE
Size mark is stamped on the piston top.
2. Measure the outside diameter of the piston to be used.
Measure it in the thrust direction as shown.
3. Based on the measured piston O.D., calculate the boring
finish dimension.
Boring finish dimension =
Piston O.D. + (clearance between piston O.D. and
cylinder) 0.02 mm (honing margin)
4. Bore all cylinders to the calculated boring finish dimension.
Caution
To prevent distortion that may result from temperature
rise during honing, bore cylinders in the order of No.2,
No.4, No.6, No.1, No.3 and No.5.
5. Hone to the final finish dimension (piston O.D. + clearance
between piston O.D. and cylinder).
6. Check the clearance between the piston and cylinder.
Clearance between piston and cylinder:
0.020.04 mm
NOTE
When boring cylinders, finish all of six cylinders to the
same oversize. Do not bore only one cylinder to an
oversize.
PISTON
1. Replace the piston if scratches or seizure are evident
on its surfaces (especially the thrust surface). Replace
the piston if it is cracked.
PISTON PIN
1. Insert the piston pin into the piston pin hole with a thumb.
You should feel a slight resistance. Replace the piston
pin if it can be easily inserted or there is an excessive
play.
2. The piston and piston pin must be replaced as an
assembly.
PISTON RING
1. Check the piston ring for damage, excessive wear, and
breakage and replace if defects are evident. If the piston
has been replaced with a new one, the piston rings must
also be replaced with new ones.
11B
Index
Push in by piston
Piston ring
Piston
ring gap
3. Insert the piston ring into the cylinder bore. Force the
ring down with a piston, the piston crown being in contact
with the ring, to correctly position it at right angles to
the cylinder wall. Then, measure the end gap with a feeler
gauge.
If the ring gap is excessive, replace the piston ring.
Standard value:
No. 1: 0.300.45 mm
No. 2: 0.450.60 mm
Oil: 0.200.60 mm
Limit:
No. 1, No. 2: 0.8 mm
Oil: 1.0 mm
Plastigauge
11B
Index
11B
Index
75 Nm
11 Nm
11 Nm
7
5
98 Nm
18
16
15
17
14
12 <6G72>
11 <6G72>
13
10
<6G72>
9
10
<6G74>
93 Nm
9
7080 Nm
Removal steps
1. Adaptor plate
2. Drive plate
3. Plate
4. Adaptor plate
5. Flywheel
6. Rear plate
"DA 7. Oil seal case
"CA 8. Crankshaft rear oil seal
"BA 9. Bearing cap bolt
"BA
"AA
"AA
"AA
10.
11.
12.
13.
14.
"AA 15.
"AA 16.
"AA 17.
18.
Bearing cap
Thrust bearing A <6G72>
Thrust bearing B <6G72>
Crankshaft bearing, lower
Crankshaft
Thrust bearing B
Thrust bearing A
Crankshaft bearing, upper
Cylinder block
No. 1 journal
Main
"AA CRANKSHAFT BEARING INSTALLATION
Index
MAIN BEARINGS
When bearing replacement is required, select and install the
correct bearing by the following procedure.
11B
1. Measure the crankshaft journal diameter and confirm its
Index
classification from the following table. In the case of a
crankshaft supplied as a service part, identification colours
of its journals are painted at the positions shown in the
illustration.
2. The cylinder block bearing bore diameter identification
marks are stamped at the position shown in the illustration
from left to right, beginning at No. 1.
<6G72>
Combination of crankshaft journal diameter
and cylinder block bearing bore diameter
Crankshaft journal
Cylinder block
bearing bore
diameter
identification mark
Classification
Identification
colour
Produc- Service
tion part
part
Identification mark
None
None
Yellow
None
Identification colour
3
Oil groove
Groove
None
White
O.D.
mm
59.994
60.000
59.988
59.994
59.982
59.988
Bearing
identification
Cylincolour or
der
identiblock
fication
bearing
mark (for
bore diservice
ameter
part)
identification
mark
l
Pink(1)
ll
Red(2)
lll
Green(3)
Red(2)
lll
Green(3)
lll
Black(4)
Green(3)
ll
Black(4)
lll
Brown(5)
<6G74>
Bearing
identification
Cylincolour or
der
identiblock
fication
bearing
mark (for
bore diservice
ameter
part)
identification
mark
l
Pink(1)
Classification
Identification
colour
Produc- Service
tion part
part
None
None
None
Yellow
None
White
O.D.
mm
63.994
64.000
63.988
63.994
63.982
63.988
ll
Red(2)
lll
Green(3)
Red(2)
lll
Green(3)
lll
Black(4)
Green(3)
ll
Black(4)
lll
Brown(5)
11B
Index
No. 3 journal
No. 5 journal
No. 6 journal
Main
Index
Identification mark
Identification colour
Items
Standard value
Crankshaft
Identification mark
(colour)
Production part
None
None
None
Spare
part
Yellow
None
White
Limit
Connecting rod
Big end
Journal O.D.
mm
54.99455.000
54.99854.994
54.98254.988
Identification mark
Bearing
I.D. mm
Identification colour
Thickness mm
58.00058.006
Pink
1.4831.486
58.00658.012
Red
1.4861.489
58.01258.018
Green
1.4891.492
58.00058.006
Red
1.4861.489
58.00658.012
Green
1.4891.492
58.01258.018
Black
1.4921.495
58.00058.006
Green
1.4891.492
58.00658.012
Black
1.4921.495
58.01258.018
Brown
1.4951.498
Crankshaft
Front mark
15 7
8 16
Bearing cap
Bearing cap bolt
3
11 3
14 12
10 2
14 6
5 13
Cylinder block
<6G74>
<6G72>
EMD998718
Oil seal
case
EMD998718
INSPECTION
CRANKSHAFT
If the oil clearance exceeds the limit, replace the bearing,
and crankshaft if necessary.
1. Measure the outside diameter of the journals and the
inside diameter of the crankshaft bearings.
If the
difference between them (oil clearance) exceeds the limit,
replace the crankshaft bearing and, if necessary,
crankshaft.
Standard value: 0.020.04 mm
Limit: 0.1 mm
Caution
Do not attempt an undersize machining of the
crankshaft with special surface treatment. This
crankshaft can be identified by its dull gray
appearance.
Plastigauge
FLYWHEEL
1. Check the clutch disc friction surface for ridge wear, cracks
and seizure.
2. If the runout of the flywheel exceeds the limit, replace
the flywheel assembly.
Limit: 0.13 mm
Bolts
Caution
The flywheel mounting bolts shown must not be
removed. If the bolts are removed, the flywheel will
lose its original balance and could break during
operation.