Inspection: Connecting rod bearing span when free •If the span is less than the specified limit, replace both the upper and lower bearings as a matched set. •Inspection: Connecting rod bearing-to-crankshaft oil clearance – Fit the lower bearing to the connecting rod cap and the upper bearing to the connecting rod, then tighten the nut… Read More »
Inspection: Piston projection from upper crankcase top surface • Set the piston at the top dead center. • Mark reference points A (five points in total) on the top surface of the upper crankcase as shown in the illustration. Using each of the marks as a zero point, measure the amount of piston projection relative… Read More »
•Installation: Sealing cap – Apply sealant to the press fitting hole in the cylinder head. – Install sealing caps and press them in to the depths respectively specified. Installation: Valve stem seal – Apply engine oil to the valve stem seal lip. – Install the valve stem seal until it contacts the lower retainer closely… Read More »
Removal: Valve cotter <Method 1> • Using and, remove and install the valve cotters according to the following procedure. • Install on the cylinder head using any bolts (M8 × 1.25 mm). • Install on using any washers and nuts (M6 × 1.0 mm). • Set the stay to a level position. • Adjust the… Read More »
Assembly sequence Follow the disassembly sequence in reverse. Removal: Cylinder head • Loosen the cylinder head bolts (M10: 1, 2), (M12: 3 to 20) by turns in the order indicated in the illustration before they are removed in the same order. • With the timing chain kept attached to the cam sprocket, remove the cylinder… Read More »
Assembly sequence Follow the disassembly sequence in reverse. Removal: Cam sprocket • Bring the No. 1 cylinder piston to the top dead center (TDC) on the compression stroke. Make sure that the camshaft cam faces up in this position. • After holding on the hexagonal portion of the camshaft to prevent it from turning, loosen… Read More »
Disassembly sequence 1. Oil filler cap 2. Grommet 3. Cover 4. Spacer 5. Insulator 6. Rocker cover rubber 7. Snap ring 8. Fuel return hose 9. Injection pipe (See Gr13.) 10. Bolt (with hexagonal hole) 11. Injector (See Gr13.) 12. O-ring 13. Tip gasket 14. Rocker cover 15. O-ring 16. Rocker cover gasket A 17.… Read More »
Disassembly sequence 1. Transmission mounting support 2. Engine and transmission Assembly sequence Follow the disassembly sequence in reverse. Removal procedure Removal: Engine and transmission • Hook the wire rope and lifting mechanism each onto the three hangers on the engine and lift the engine with a crane until they are tight. • Support the transmission… Read More »
• Remove the starter from the engine. (See Gr54.) • Visually examine the starter pinion contact surface of the ring gear for crack and other damage from the starter mounting hole. • If there is any cracks or damages, replace the ring gear. (See “FLYWHEEL”.)
• Measure the protrusion of the chain tensioner’s plunger to determine the elongation of the timing chain. • Remove the chain tensioner from the cylinder head. The plunger is bounced a little out of the chain tensioner by the spring inside. Prevent the plunger from falling. • Measure the distance from the forward end of… Read More »