SO5C Repair Manual

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1 MENU
FOREWORD
This workshop manual has been prepared to provide information covering general service repairs for the
S05CïB, S05CïTA and S05CïTB engines equipped on the Hino Motors,Ltd.
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Applicable models: XZU404, 412, 414, 422, 424, 434 series
Please note that the publications below have also been prepared as relevant service manuals for the compo-
nents and systems in this vehicles.
Manual Name Pub. No.

S DUTRO Workshop Manual S1ïYXZE05A
All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.
Hino Motors,Ltd.
2002 Hino Motors,Ltd.

All rights reserved. This book may not be repro-
duced or copied, in whole or in part, without the
written permission of Hino Motors,Ltd.
CAUTION
This manual does not include all the necessary items about repair and service. This manual is made
for the purpose of the use for the persons who have special techniques and certifications. In the
cases that nonïspecialized or uncertified technicians perform repair or service only using this manu-
al or without proper equipment or tool, that may cause severe injury to you or other people around
and also cause damage to your customer’s vehicle.
In order to prevent dangerous operation and damages to your customer’s vehicle, be sure to follow
the instruction shown below.
S Must read this manual thoroughly. It is especially important to have a good understanding of
all the contents written in the PRECAUTION of ”IN” section.
S The service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use tools spe-
cified and recommended. If using nonïspecified or recommended tools and service method,
be sure to confirm safety of the technicians and any possibility of causing personal injury or
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damage to the customer’s vehicle before starting the operation.
S If part replacement is necessary, must replace the part with the same part number or equivalent
part. Do not replace it with inferior quality.
S It is important to note that this manual contains various ”Cautions” and ”Notices” that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improper service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is
important to warn of all the possible hazardous consequences that might result from failure to
follow these instructions.
INTRODUCTION 1
PREPARATION 2
SERVICE SPECIFICATIONS 3
FUEL 11
INTAKE 13
ENGINE MECHANICAL 14
EXHAUST 15
COOLING 16
LUBRICATION 17
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STARTING & CHARGING 19
ALPHABETICAL INDEX
INTRODUCTION
HOW TO USE THIS ENGINE REPAIR

MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01ï1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 01ï1
REPAIR INSTRUCTION FOR ENGINE
REPAIR MANUAL . . . . . . . . . . . . . . . . . . . . . . 01ï4
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01ï4
TERMS FOR ENGINE REPAIR MANUAL . . . . 01ï7
ABBREVIATIONS USED IN THIS MANUAL . . . 01ï7
GLOSSARY OF SAE AND HINO TERMS . . . . . 01ï12
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01ï1
INTRODUCTION ï HOW TO USE THIS ENGINE REPAIR MANUAL
HOW TO USE THIS ENGINE REPAIR MANUAL

0108Jï02
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting
3. Final Inspection
(c) This manual explains ”Removing and Installing, Replacing, Disassembling, Installing and Checking,
Adjusting”, but ”Final Inspection” is omitted.
(d) The following essential operations are not written in this manual, however these operations must be
done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be
repaired.
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3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repairing condition. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed as the section or title when necessary.
(b) Illustrations of the parts catalog are placed as the ”disassembled parts drawing” so that it enables you
to understand the fitting condition of the components.
(c) Nonïreusable parts, grease applied parts, precoated parts and tightening torque are specified in the
components drawing.
Example:
OVERHAUL Camshaft,
No. 3 Camshaft Subïassy
Camshaft Drive Gear
Camshaft Timing Tube Assy
7.5 (80, 66 in.·lbf)

No. 2 Camshaft,
Seal Washer No. 4 Camshaft Subïassy
z Camshaft Setting Oil Seal Camshaft Driven Main Gear

Screw Plug
78 (790, 58)
15 (150, 11) Wave Washer Camshaft Timing Gear

Bolt Washer
Camshaft Sub Gear
N·m (kgf·cm, ft·lbf) : Specified torque Snap Ring
z Nonïreusable part A54988
01ï2
(d) Tightening torque, oil applying position, and nonïreusable parts are described as important points in
the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In that case, all the
information such as torque, oil, etc. are described in the illustration.
(e) Installing procedure of operation items is performed in the reverse order of the removing, and only the
important points are described.
(f) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notice are placed.
(g) There may be a case where the illustrations of similar models are used. In that case the details may
be different from the actual vehicle.
(h) The procedures are presented in a stepïbyïstep format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
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Illustration: Task heading: what to do
what to do and where
Detailed text:
Set part No. Component part No. how to do task
A59974
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for a quick reference.
6. TERMS DEFINITION
CAUTION Indicate the possibility of injury to you or other people.
NOTICE Indicate the possibility of damage to the components being repaired.
HINT Provide additional information to help you perform the repair efficiently.
01ï3
7. SI UNIT
(a) The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys-
tem of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 Nm (310 kgfcm, 22 ftlbf)
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01ï4 INTRODUCTION ï REPAIR INSTRUCTION FOR ENGINE REPAIR
MANUAL
REPAIR INSTRUCTION FOR ENGINE REPAIR MANUAL

0108Kï02
PRECAUTION
1. TO PREVENT FROM ENTERING FOREIGN SUBSTANCES
(a) When foreign substances such as dust, grain of sand or metallic dust enter inside of engine, it often
causes functional failure of the engine.
(1) Precaution before disassembly.
S Remove adequately all sand and mud adhere to the outside of engine .
(2) Precaution at reassembly.
S Protect disassembled parts from dust by using vinyl sheet to cover.
2. TO PREVENT SCRATCHES ON THE PARTS
(a) The existence of scratches on the contact and revolving surfaces often causes oil leak and seisure.
(1) Precautions at disassembly and reassembly.
S When disassemble the contact surface of the parts, use plastic hummer striking lightly. (Do
not pry out by screwdriver).
S When fix the parts to the vise, do not directly catch it in the vise. Fix the parts through alumi-
num bar.
3. TO CLEAN AND WASH THE PARTS
(a) Each parts needs to be well cleaned, washed, and dried by air, and apply specified oil before reas-
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sembly.
(1) Cleaning and washing by alkaline solvent is prohibited:
S Parts made of aluminum and rubber. (ex. cylinder head cover gasket etc.)
(2) Cleaning and washing by flushing oil (ex. kerosene, white gasoline etc.) is prohibited:
S Parts made of rubber. (ex. cylinder head cover gasket etc.)
4. POSITION AND DIRECTION OF EACH PARTS
(a) Each parts needs to be reassembled as the same position and direction as it disassembled.
(1) Precautions at disassembly and reassembly.
S Follow the directions when the manual designates to mark the matchmark and/or direction
mark.
S Disassembled parts needs to be put in order as disassembled, not to change position and/
or direction.
S Follow the directions when the manual instructs the position and direction.
5. INSTALL ENGINE ASSEMBLY TO OVERHAUL STAND WHEN OVERHAUL THE ENGINE
6. PUT THE DISASSEMBLED PARTS IN ORDER AS THEY DISASSEMBLED
7. APPLY ENGINE OIL TO THE SLIDING AND ROTATING SURFACES
8. NONïREUSABLE PARTS SUCH AS GASKET AND SEAL NEEDS TO BE CHANGED TO THE NEW
PARTS
9. BASIC REPAIR HINT
(a) Precoated Parts:

(1) Precoated parts are bolts, nuts, etc. that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(3) When reusing precoated parts, clean off the old
Seal Lock Adhesive
adhesive and dry with compressed air. Then apply
Z11554 the specified seal lock adhesive to the bolt, nut or
threads.
INTRODUCTION ï REPAIR INSTRUCTION FOR ENGINE REPAIR 01ï5
MANUAL
NOTICE:
Do the torque checking with the lower limit value of the torque tolerance.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) Gaskets:
When necessary, use a sealer on gaskets to prevent leaks.
(c) Bolts, Nuts and Screws:
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
(d) Torque When Using Extension Tool with Torque Wrench:

(1) In case of tightening by extending the entire length
L1 L2 of the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the read-
ing of the torque wrench by the formula.
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D02612
(3) Formula T’ = T x L2/(L1 + L2)

T’ Reading of torque wrench ^Nm kgfcm ftlbf`
L1 L2 T Torque ^Nm kgfcm ftlbf`
L1 Length of SST or tool (cm)
L2 Length of torque wrench (cm)
D01201
L1 L2
D01202
10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS

(a) Place for Removing and Installing Fuel System Parts:
(1) Place with good air ventilation and without anything flammable such as welder, grinder, drill, elec-
tric motor or stove in the surroundings.
(2) Never work in a place like a pit or nearby pit as there is a possibility that vaporized fuel fills those
places.
(b) Removing and Installing of Fuel System Parts:
(1) Prepare a fire extinguisher before starting the operation.
(2) For prevention of the static electricity, install a ground on the fuel changer, vehicle and fuel tank,
and do not spray much water so as to prevent slipping.
01ï6 INTRODUCTION ï REPAIR INSTRUCTION FOR ENGINE REPAIR
MANUAL
(3) Never use any electric equipment like an electric motor or a working light as they may cause
spark or high temperature.
(4) Never use an iron hammer as it may cause spark.
(5) Dispose the shop lag separately from any fuel deposit.
11. REMOVAL AND INSTALLATION OF ENGINE INTAKE

PARTS
(a) If any metal tip is mixed in the inlet pass, that may give a
bad effect to the engine and turbo charger.
(b) When removing and installing of the inlet system parts,
close the opening of the removed inlet system parts and
the engine with a clean shop lag or gum tape.
(c) When installing the inlet system parts, check that there is
D01563 no mixing of a metal tip.
12. HANDLING OF HOSE CLAMPS

Flat Spring Clamp
(a) Before removing the hose, check the depth of inserting
portion and the clamp position to restore it surely.
(b) Change a deformed or dented into a new one.
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(c) In case of reusing the hose, install the clamp on the hose
where it has a clamp track.
(d) For a flat spring type clamp, make it adjust by adding force
Clamp Track to the arrow mark direction after the installation.
D25081
01ï7
INTRODUCTION ï TERMS FOR ENGINE REPAIR MANUAL
TERMS FOR ENGINE REPAIR MANUAL

0108Hï02
ABBREVIATIONS USED IN THIS MANUAL

Abbreviations Meaning
ABS AntiïLock Brake System
A/C Air Conditioner
AC Alternating Current
ACC Accessory
ACIS Acoustic Control Induction System
ACSD Automatic Cold Start Device
A.D.D. Automatic Disconnecting Differential
A/F AirïFuel Ratio
AHC Active Height Control Suspension
ALR Automatic Locking Retractor
ALT Alternator
AMP Amplifier
ANT Antenna
APPROX. Approximately
ASSY Assembly
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A/T Automatic Transmission (Transaxle)
ATF Automatic Transmission Fluid
AUTO Automatic
AUX Auxiliary
AVG Average
AVS Adaptive Variable Suspension
B+ Battery Voltage
BACS Boost Altitude Compensation System
BAT Battery
BDC Bottom Dead Center
B/L BiïLevel
B/S BoreïStroke Ratio
BTDC Before Top Dead Center
BVSV Bimetallic Vacuum Switching Valve
CB Circuit Breaker
CCo Catalytic Converter For Oxidation
CD Compact Disc
CF Cornering Force
CG Center Of Gravity
CH Channel
CKD Complete Knock Down
COMB. Combination
CPE Coupe
CPS Combustion Pressure Sensor
CPU Central Processing Unit
CRS Child Restraint System
CTR Center
C/V Check Valve
CV Control Valve
CW Curb Weight
DC Direct Current
DEF Defogger
DFL Deflector
01ï8
DIFF. Differential
DIFF. LOCK Differential Lock
D/INJ Direct Injection
DLC Data Link Connector
DLI Distributorless Ignition
DOHC Double Overhead Cam
DP Dash Pot
DS Dead Soak
DSP Digital Signal Processor
DTC Diagnostic Trouble Code
ECAM Engine Control And Measurement System
ECD Electronic Controlled Diesel
ECDY Eddy Current Dynamometer
ECT Electronic Control Transmission
ECU Electronic Control Unit
ED ElectroïDeposited Coating
EDU Electronic Driving Unit
EDIC Electric Diesel Injection Control
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EFI Electronic Fuel Injection
E/G Engine
EGR Exhaust Gas Recirculation
EGRïVM EGRïVacuum Modulator
ELR Emergency Locking Retractor
ENG Engine
ESA Electronic Spark Advance
ETCS Electronic Throttle Control System
EVAP Evaporative Emission Control
EVP Evaporator
EïVRV Electric Vacuum Regulating Valve
EX Exhaust
FE Fuel Economy
FF FrontïEngine FrontïWheelïDrive
F/G Fuel Gauge
FIPG Formed In Place Gasket
FL Fusible Link
F/P Fuel Pump
FPU Fuel Pressure Up
FR Front
F/W Flywheel
FW/D Flywheel Damper
FWD FrontïWheelïDrive
GAS Gasoline
GND Ground
HAC High Altitude Compensator
H/B Hatchback
HïFUSE High Current Fuse
HI High
HID High Intensity Discharge (Head Lamp)
HSG Housing
HT Hard Top
HWS Heated Windshield System
01ï9
IC Integrated Circuit
IDI Indirect Diesel Injection
IFS Independent Front Suspension
IG Ignition
IIA Integrated Ignition Assembly
IN Intake (Manifold, Valve)
INT Intermittent
I/P Instrument Panel
IRS Independent Rear Suspension
ISC Idle Speed Control
J/B Junction Block
J/C Junction Connector
KD KickïDown
LAN Local Area Network
LB Liftback
LCD Liquid Crystal Display
LED Light Emitting Diode
LH LeftïHand
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LHD LeftïHand Drive
L/H/W Length, Height, Width
LLC LongïLife Coolant
LNG Liquified Natural Gas
LO Low
LPG Liquified Petroleum Gas
LSD Limited Slip Differential
LSP & PV Load Sensing Proportioning And Bypass Valve
LSPV Load Sensing Proportioning Valve
MAP Manifold Absolute Pressure
MAX. Maximum
MIC Microphone
MIL Malfunction Indicator Lamp
MIN. Minimum
MP Multipurpose
MPI Multipoint Electronic Injection
MPX Multiplex Communication System
M/T Manual Transmission
MT Mount
MTG Mounting
N Neutral
NA Natural Aspiration
NO. Number
O2S Oxygen Sensor
O/D Overdrive
OEM Original Equipment Manufacturing
OHC Overhead Camshaft
OHV Overhead Valve
OPT Option
O/S Oversize
P & BV Proportioning And Bypass Valve
PCS Power Control System
PCV Positive Crankcase Ventilation
01ï10
PKB Parking Brake
PPS Progressive Power Steering
PS Power Steering
PTO Power TakeïOff
P/W Power Window
R&P Rack And Pinion
R/B Relay Block
RBS Recirculating Ball Type Steering
R/F Reinforcement
RFS Rigid Front Suspension
RRS Rigid Rear Suspension
RH RightïHand
RHD RightïHand Drive
RLY Relay
ROM Read Only Memory
RR Rear
RRS RearïWheel Drive
RWD RearïWheel Drive
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SDN Sedan
SEN Sensor
SICS Starting Injection Control System
SOC State Of Charge
SOHC Single Overhead Camshaft
SPEC Specification
SPI Single Point Injection
SRS Supplemental Restraint System
SSM Special Service Materials
SST Special Service Tools
STD Standard
STJ ColdïStart Fuel Injection
SW Switch
SYS System
T/A Transaxle
TACH Tachometer
TBI Throttle Body Electronic Fuel Injection
TC Turbocharger
TCCS ComputerïControlled System
TCV Timing Control Valve
TDC Top Dead Center
TEMP. Temperature
TFT FreeïTronic
TIS Total Information System For Vehicle Development
T/M Transmission
TRC Traction Control System
TURBO Turbocharge
TWC ThreeïWay Catalyst
U/D Underdrive
U/S Undersize
VCV Vacuum Control Valve
VENT Ventilator
VIN Vehicle Identification Number
01ï11
VPS Variable Power Steering
VSC Vehicle Skid Control
VSV Vacuum Switching Valve
VTV Vacuum Transmitting Valve
VVTïi Variable Valve Timingïintelligent
W/ With
WGN Wagon
W/H Wire Harness
W/O Without
1ST First
2ND Second
2WD Two Wheel Drive Vehicle (4 x 2)
3RD Third
4TH Fourth
4WD Four Wheel Drive Vehicle (4 x 4)
4WS Four Wheel Steering System
5TH Fifth
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01ï12
0108Iï02
GLOSSARY OF SAE AND HINO TERMS

This glossary lists all SAEïJ1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their HINO equivalents.
SAE HINO TERMS
SAE TERMS
ABBREVIATIONS ( )ïïABBREVIATIONS
A/C Air Conditioning Air Conditioner

ACL Air Cleaner Air Cleaner, A/CL
AIR Secondary Air Injection Air Injection (AI)
AP Accelerator Pedal ï
B+ Battery Positive Voltage +B, Battery Voltage
BARO Barometric Pressure HAC
CAC Charge Air Cooler Intercooler
CARB Carburettor Carburettor
CFI Continuous Fuel Injection ï
CKP Crankshaft Position Crank Angle
CL Closed Loop Closed Loop
CMP Camshaft Position Cam Angle
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CPP Clutch Pedal Position ï
CTOX Continuous Trap Oxidizer ï
CTP Closed Throttle Position LL ON, Idle ON
DFI Direct Fuel Injection (Diesel) Direct Injection (DI)
DI Distributor Ignition ï
DLC1 Data Link Connector 1 1: Check Connector
DLC2 Data Link Connector 2 2: Total Diagnosis Comunication Link (TDCL)
DLC3 Data Link Connector 3 3: OBD II Diagnostic Connector
DTC Diagnostic Trouble Code Diagnostic Code
DTM Diagnostic Test Mode ï
ECL Engine Control Level ï
ECM Engine Control Module Engine ECU (Electronic Control Unit)
ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW)
Electrically Erasable Programmable Read Only Memory
EEPROM Electrically Erasable Programmable Read Only Memory (EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV)
EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR)
EI Electronic Ignition Distributorless Ignition (TDI)
EM Engine Modification Engine Modification (EM)
EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)
EVAP Evaporative Emission Evaporative Emission Control (EVAP)
FC Fan Control ï
Flash Electrically Erasable Programmable
FEEPROM ï
Read Only Memory
FEPROM Flash Erasable Programmable Read Only Memory ï

FF Flexible Fuel ï
FP Fuel Pump Fuel Pump
GEN Generator Alternator
GND Ground Ground (GND)
01ï13
HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S)

IAC Idle Air Control Idle Speed Control (ISC)
IAT Intake Air Temperature Intake or Inlet Air Temperature
ICM Ignition Control Module ï
IFI Indirect Fuel Injection Indirect Injection (IDL)
IFS Inertia FuelïShutoff ï
ISC Idle Speed Control ï
KS Knock Sensor Knock Sensor
MAF Mass Air Flow Air Flow Meter
Manifold Pressure
MAP Manifold Absolute Pressure
Intake Vacuum
Electric Bleed Air Control Valve (EBCV)

MC Mixture Control Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDP Manifold Differential Pressure ï
MFI Multiport Fuel Injection Electronic Fuel Injection (EFI)
MIL Malfunction Indicator Lamp Check Engine Lamp
MST Manifold Surface Temperature
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ï
MVZ Manifold Vacuum Zone ï
NVRAM NonïVolatile Random Access Memory ï
O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S)
OBD OnïBoard Diagnostic OnïBoard Diagnostic System (OBD)
OC Oxidation Catalytic Converter Oxidation Catalyst Convert (OC), CCo
OP Open Loop Open Loop
PAIR Pulsed Secondary Air Injection Air Suction (AS)
PCM Powertrain Control Module ï
PNP Park/Neutral Position ï
PROM Programmable Read Only Memory ï
PSP Power Steering Pressure ï
Diesel Particulate Filter (DPF)
PTOX Periodic Trap Oxidizer
Diesel Particulate Trap (DPT)
RAM Random Access Memory Random Access Memory (RAM)
RM Relay Module ï
ROM Read Only Memory Read Only Memory (ROM)
RPM Engine Speed Engine Speed
SC Supercharger Supercharger
SCB Supercharger Bypass EïABV
SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection
SPL Smoke Puff Limiter ï
SRI Service Reminder Indicator ï
SRT System Readiness Test ï
ST Scan Tool ï
TB Throttle Body Throttle Body
Single Point Injection
TBI Throttle Body Fuel Injection
Central Fuel Injection (Ci)
TC Turbocharger Turbocharger
TCC Torque Converter Clutch Torque Converter
01ï14
TCM Transmission Control Module Transmission ECU, ECT ECU

TP Throttle Position Throttle Position
TR Transmission Range ï
Bimetallic Vacuum Switching Valve (BVSV)
TVV Thermal Vacuum Valve
Thermostatic Vacuum Switching Valve (TVSV)
ThreeïWay Catalytic (TWC)

TWC ThreeïWay Catalytic Converter Manifold Converter
CCRO
TWC+OC ThreeïWay + Oxidation Catalytic Converter CCR + CCo
VAF Volume Air Flow Air Flow Meter
VR Voltage Regulator Voltage Regulator
VSS Vehicle Speed Sensor Vehicle Speed Sensor
WOT Wide Open Throttle Full Throttle
WUïOC Warm Up Oxidation Catalytic Converter ï
WUïTWC Warm Up ThreeïWay Catalytic Converter ï
3GR Third Gear ï
4GR Fourth Gear ï
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PREPARATION
INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï1
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï1
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . 02ï2
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï2
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï5
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï5
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï6
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï6
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï7
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï7
STARTING & CHARGING . . . . . . . . . . . . . . . . . 02ï8
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï8
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02ï1
PREPARATION ï INTAKE
INTAKE
022E2ï01
PREPARATION
Recomended Tools
09200ï00010 Engine Adjust Kit INTAKE MANIFOLD
Equipment
Precision straight edge
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02ï2
PREPARATION ï ENGINE MECHANICAL
ENGINE MECHANICAL
022E7ï01
PREPARATION
SST
09201ï41020 Valve Stem Oil Seal Replacer CAMSHAFT HOUSING AND
CYLINDER HEAD
09202ï70020 Valve Spring Compressor CAMSHAFT HOUSING AND

CYLINDER HEAD
09960ï10010 Variable Pin Wrench Set CAMSHAFT HOUSING AND

CYLINDER HEAD
09402ï1480 Press subïAssy PISTON, CRANKSHAFT AND

CYLINDER BLOCK
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09407ï1030 Oil Seal Press CRANKSHAFT FRONT END, OIL
PAN, FLYWHEEL AND FLYWHEEL
HOUSING
09407ï1040 Oil Seal Press CRANKSHAFT FRONT END, OIL

HOUSING
09420ï1720 Sylinder liner puller PISTON, CRANKSHAFT AND

CYLINDER BLOCK
09420ï1731 Oil Seal Puller CRANKSHAFT FRONT END, OIL

HOUSING
09420ï1742 Oil Seal Puller CRANKSHAFT FRONT END, OIL

HOUSING
09444ï1630 Gauge PISTON, CRANKSHAFT AND

CYLINDER BLOCK
09472ï1210 Bar CAMSHAFT HOUSING AND

CYLINDER HEAD
09472ï1620 Tool PISTON, CRANKSHAFT AND

CYLINDER BLOCK
02ï3
09481ï1140 Guide PISTON, CRANKSHAFT AND

CYLINDER BLOCK
09481ï1340 Guide CRANKSHAFT FRONT END, OIL

HOUSING
9001ï24262 Check Bolt PISTON, CRANKSHAFT AND

CYLINDER BLOCK
9191ï08252 Bolt PISTON, CRANKSHAFT AND

CYLINDER BLOCK
9800ï06100 Steel Ball CAMSHAFT HOUSING AND

CYLINDER HEAD
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09200ï00010 Engine Adjust Kit CAMSHAF HOUSING AND CYL-
INDER HEAD
09905ï00013 Snap Ring Pliers TIMING GEAR
SSM
08826ï00080 Seal Packing Black or equivalent CAMSHAFT HOUSING AND CYL-
(FIPG) INDER HEAD
INTAKE MANIFOLD
CRANCKSHAFT FRONT END, OIL
HOUSING
08833ï00070 ”Adhesive 1324,” TIMING GEAR

THREE BOND 1324 or equivalent
Equipment
Abrasive compound
Connecting rod aligner
Cylinder gauge
Dial gauge
Dye penetrant
Heater
Micrometer
Piston ring compressor
Piston ring expander
Press
02ï4
Press Sliding hammer

Soft brush
Solvent
Spring tester
Steam cleaner
Steel square
Straight edge
Torch
Torque wrench
Valve guide bushing brush
Valve seat cutter
Vïblock
Vernier calipers
Wire brush
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02ï5
PREPARATION ï EXHAUST
EXHAUST
022E3ï01
PREPARATION
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09200ï00010 Engine Adjust Kit EXHAUST MANIFOLD
Equipment
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02ï6
PREPARATION ï COOLING
COOLING
022E4ï01
PREPARATION
SST
09236ï00101 Water Pump Overhaul Tool Set WATER PUMP ASSY
(09236ï15010) Bearing Stay WATER PUMP ASSY
09238ï47012 Water Pump Bearing Remover & WATER PUMP ASSY

Replacer
09950ï50013 Puller C Set WATER PUMP ASSY
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(09951ï05010) Hanger 150 WATER PUMP ASSY
(09952ï05010) Slide Arm WATER PUMP ASSY
(09953ï05010) Center Bolt 100 WATER PUMP ASSY
(09954ï05021) Claw No.2 WATER PUMP ASSY
09482ï2060A Press WATER PUMP ASSY
09420ï1820 Puller ASSY WATER PUMP ASSY
Recomended Tools
09905ï00013 Snap Ring Pliers WATER PUMP ASSY
Equipment
Vernier calipers
Torque wrench
02ï7
PREPARATION ï LUBRICATION
LUBRICATION
022E5ï01
PREPARATION
Equipment
Dial gauge
Micrometer
Torque wrench
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02ï8
PREPARATION ï STARTING & CHARGING
STARTING & CHARGING

022E6ï01
PREPARATION
SST
09285ï76010 Injection Pump Camshaft Bearing GENERATOR ASSY
Cone Replacer
09286ï46011 Injection Pump Spline Shaft GENERATOR ASSY

Puller
09820ï00021 Alternator Rear Bearing Puller GENERATOR ASSY
09820ï00030 Alternator Rear Bearing Replacer GENERATOR ASSY
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09820ï63010 Alternator Pulley Set Nut Wrench GENERATOR ASSY
Set
09950ï60010 Replacer Set STARTER ASSY

GENERATOR ASSY
(09951ï00260) Replacer 26 STARTER ASSY
(09951ï00390) Replacer 39 STARTER ASSY
(09952ï06010) Adapter STARTER ASSY
09950ï70010 Handle Set GENERATOR ASSY
09820ï00031 Alternator Rotor Rear Bearing Replacer STARTER ASSY(S05CïB)
Recomended Tools
09082ï00040 Electrical Tester STARTER ASSY
GENERATOR ASSY
02ï9
PREPARATION ï STARTING & CHARGING
Equipment
Ammeter (A)
Battery specific gravity gauge Except maintenanceï free battery
Belt tension gauge
Cylinder indicator Commutator
Micro meter Starter clutch
Plastic hammer
Pull scale Brush spring
Sandpaper Commutator
Torque wrench
Vernier calipers Commutator, Brush, Rotor (Slip ring)
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SERVICE SPECIFICATIONS
STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . . 03ï1

HOW TO DETERMINE BOLT STRENGTH . . . . 03ï1
SPECIFIED TORQUE FOR
STANDARD BOLTS . . . . . . . . . . . . . . . . . . . . . . 03ï2
HOW TO DETERMINE
NUT STRENGTH . . . . . . . . . . . . . . . . . . . . . . . . 03ï3
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï4
TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . 03ï4
INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï5
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï5
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . 03ï6
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï6
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï11
cardiagn.com
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï11
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï12
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï12
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï13
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï13
STARTING & CHARGING . . . . . . . . . . . . . . . . . 03ï14
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï14
03ï1
SERVICE SPECIFICATIONS ï STANDARD BOLT
STANDARD BOLT
03096ï06
HOW TO DETERMINE BOLT STRENGTH
Bolt Type
Hexagon Head Bolt Class
Stud Bolt Weld Bolt
Normal Recess Bolt Deep Recess Bolt
4 4T
No Mark No Mark No Mark
5 5T
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6 6T
w/ Washer w/ Washer
7 7T
8 8T
9 9T
10 10T
11 11T
B06431
03ï2
03097ï07
SPECIFIED TORQUE FOR STANDARD BOLTS

Specified torque
Diameter Pitch
Class Hexagon head bolt Hexagon flange bolt
mm mm
N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf
6 1 5 55 48 in.·lbf 6 60 52 in.·lbf
8 1.25 12.5 130 9 14 145 10
10 1.25 26 260 19 29 290 21
4T
12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 115 1,150 83 ï ï ï
6 1 6.5 65 56 in.·lbf 7.5 75 65 in.·lbf

8 1.25 15.5 160 12 17.5 175 13
10 1.25 32 330 24 36 360 26
5T
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1,050 76
16 1.5 140 1,400 101 ï ï ï
6 1 8 80 69 in.·lbf 9 90 78 in.·lbf
8 1.25 19 195 14 21 210 15
10 1.25 39 400 29 44 440 32
6T
12 1.25 71 730 53 80 810 59
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14 1.5 110 1,100 80 125 1,250 90
16 1.5 170 1,750 127 ï ï ï
6 1 10.5 110 8 12 120 9

8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
7T
12 1.25 95 970 70 105 1,050 76
14 1.5 145 1,500 108 165 1,700 123
16 1.5 230 2,300 166 ï ï ï
8 1.25 29 300 22 33 330 24

8T 10 1.25 61 620 45 68 690 50
12 1.25 110 1,100 80 120 1,250 90
8 1.25 34 340 25 37 380 27
9T 10 1.25 70 710 51 78 790 57
12 1.25 125 1,300 94 140 1,450 105
8 1.25 38 390 28 42 430 31
10T 10 1.25 78 800 58 88 890 64
12 1.25 140 1,450 105 155 1,600 116
8 1.25 42 430 31 47 480 35
11T 10 1.25 87 890 64 97 990 72
12 1.25 155 1,600 116 175 1,800 130
03ï3
03098ï06
HOW TO DETERMINE NUT STRENGTH

Nut Type
Present Standard Old Standard Hexagon Nut Class
Hexagon Nut Cold Forging Nut Cutting Processed Nut
4N
No Mark
5N (4T)
No Mark (w/ Washer) No Mark (w/ Washer) No Mark
6N
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6N
7N (5T)
8N
8N
10N (7T)
10N
No Mark
11N
11N
12N
12N
*: Nut with 1 or more marks on one side surface of the nut.

B06432
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more
03ï4
SERVICE SPECIFICATIONS ï FUEL
FUEL
030OAï02
TORQUE SPECIFICATION
Part tightened N·m kgf·cm ft·lbf
Nozzle retaining nut x Nozzle holder body 63.7 650 47
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03ï5
SERVICE SPECIFICATIONS ï INTAKE
INTAKE
030NNï02
SERVICE DATA
Intake manifold Warpage Maximum 0.20 mm (0.0079 in.)
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03ï6
SERVICE SPECIFICATIONS ï ENGINE MECHANICAL
ENGINE MECHANICAL
030NPï03
SERVICE DATA
Valve clearance at cold Intake 0.30 mm (0.012 in.)
Exhaust 0.45 mm (0.018 in.)
Timing gear Main idler gear

Outside diameter of main idler gear shaft STD 56.94 ï 56.97 mm (2.2417 ï 2.2429 in.)
Inside diameter of main idler gear bushing STD 57.00 ï 57.03 mm (2.2441 ï 2.2453 in.)
Oil clearance between bushing and shaft STD 0.030 ï 0.090 mm (0.0012 ï 0.0035 in.)
Maximum 0.20 mm (0.0079 in.)
Thrust clearance STD 0.114 ï 0.160 mm (0.0045 ï 0.0063 in.)
Maximum 0.20 mm (0.0078 in.)
Sub idler gear

Outside diameter of sub idler gear shaft STD 49.950 ï 49.975 mm (1.9665 ï 1.9675 in.)
Inside diameter of sub idler gear STD 50.000 ï 50.025 mm (1.9685 ï 1.9695 in.)
Maximum 0.20 mm (0.0079 in.)
Maximum 0.30 mm (0.0118 in.)
Camshaft idler gear

Outside diameter of camshaft idler gear shaft STD 33.950 ï 33.975 mm (1.3366 ï 1.3376 in.)
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Minimum 33.80 mm (1.3307 in.)
Inside diameter of camshaft idler gear STD 34.000 ï 34.015 mm (1.3386 ï 1.3392 in.)
Maximum 34.20 mm (1.3464 in.)
Maximum 0.20 mm (0.0079 in.)
Maximum 0.30 mm (0.0118 in.)
Backlash
Crankshaft gear x Main idler gear STD 0.028 ï 0.163 mm (0.0011 ï 0.0064 in.)
Maximum 0.30 mm (0.0118 in.)
Main idler gear x Injection pump drive gear STD 0.030 ï 0.218 mm (0.0012 ï 0.0086 in.)
Maximum 0.30 mm (0.0118 in.)
Injection pump drive gear x PS pump gear STD 0.030 ï 0.183 mm (0.0012 ï 0.0072 in.)
Maximum 0.30 mm (0.0118 in.)
Main idler gear x Sub idler gear STD 0.030 ï 0.162 mm (0.0012 ï 0.0064 in.)
Maximum 0.30 mm (0.0118 in.)
Sub idler gear x Oil pump gear STD 0.030 ï 0.131 mm (0.0012 ï 0.0052 in.)
Maximum 0.30 mm (0.0118 in.)
Sub idler gear x Camshaft idler gear STD 0.030 ï 0.299 mm (0.0012 ï 0.0118 in.)
Maximum 0.30 mm (0.0118 in.)
Camshaft timing gear x Camshaft idler gear STD 0.028 ï 0.163 mm (0.0011 ï 0.0064 in.)
Maximum 0.30 mm (0.0118 in.)
Sub idler gear x Vacuum pump gear STD 0.029 ï 0.187 mm (0.0011 ï 0.0074 in.)
Maximum 0.30 mm (0.0118 in.)
Cyliner head Warpage STD 0.04 mm (0.0016 in.) or less for longitudinal direction
0.03 mm (0.0012 in.) or less for lateral direction
Cylinder head bolt Length (Bolt number position: See page 14ï3)
Maximum No. 1, 2, 8, 9, 10, 15, 16, 17 126.5 mm (4.9803 in.)
No. 4, 5, 12, 13 156.5 mm (6.1614 in.)
No. 3, 6, 11, 14, 18 187.5 mm (7.3819 in.)
03ï7
Valve Valve seat angle Intake 30˚00’ ï 30˚30’

Exhaust 44˚15’ ï 45˚45’
Valve face angle Intake 29˚45’ ï 30˚00’
Exhaust 44˚45’ ï 45˚00’
Valve sink dimension STD Intake 0.55 ï 0.85 mm (0.0217 ï 0.0335 in.)
Exhaust 1.30 ï 1.60 mm (0.0512 ï 0.0630 in.)
Maximum Intake 1.20 mm (0.0472 in.)
Exhaust 1.80 mm (0.0708 in.)
Valve stem diameter STD Intake 6.957 ï 6.977 mm (0.2739 ï 0.2747 in.)
STD Exhaust 6.932 ï 6.950 mm (0.2730 ï 0.2736 in.)
Minimum Intake 6.92 mm (0.2724 in.)
Exhaust 6.85 mm (0.2700 in.)
Valve stem oil clearance STD Intake 0.023 ï 0.058 mm (0.0009 ï 0.0023 in.)
Exhaust 0.050 ï 0.083 mm (0.0020 ï 0.0033 in.)
Maximum Intake 0.12 mm (0.0047 in.)
Exhaust 0.15 mm (0.0059 in.)
Valve spring Deviation Maximum 2.0 mm (0.079 in.)

Free length STD Inner 64.6 mm (2.543 in.)
Outer 75.7 mm (2.980 in.)
Minimum Inner 61.6 mm (2.425 in.)
Outer 72.7 mm (2.862 in.)
Installed tension Inner at 44.8 mm (1.764 in.) 128.5 N (13.1 kgf, 28.9 lb)
Outer at 46.8 mm (1.843 in.) 313.8 N (32.0 kgf, 70.5 lb)
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Manifold Warpage Maximum 0.20 mm (0.0079 in.)
Camshaft Cam lobe height STD Intake 50.600 mm (1.9921 in.)
Exhaust 51.185 mm (2.0151 in.)
Minimum Intake 49.967 mm (1.9672 in.)
Exhaust 52.004 mm (2.0474 in.)
Journal diameter STD 39.959 ï 39.975 mm (1.5732 ï 1.5738 in.)
Minimum 39.85 mm (1.5689 in.)
Inside diameter of camshaft bearing STD 40.00 mm (1.5748 in.)
Maximum 40.15 mm (1.5807 in.)
Oil clearance STD 0.020 ï 0.063 mm (0.0008 ï 0.0025 in.)
Maximum 0.063 mm (0.0025 in.)
Circle runout Maximum 0.10 mm (0.0039 in.)
Maximum 0.296 mm (0.0116 in.)
Camshaft gear Length 30.0 mm (1.181 in.)
bolt
Valve rocker arm Valve rocker arm bushing inside diameter STD 22.00 ï 22.051 mm (0.8661 ï 0.8681 in.)
and shaft Maximum 22.08 mm (0.8693 in.)
Valve rocker arm shaft outside diameter STD 21.959 ï 21.980 mm (0.8645 ï 0.8654 in.)
Minimum 21.92 mm (0.8630 in.)
Oil clearance STD 0.020 ï 0.092 mm (0.0007 ï 0.0036 in.)
Maximum 0.16 mm (0.0063 in.)
Injection nozzle Protrusion STD 2.25 ï 2.75 mm (0.0886 ï 0.1083 in.)
Maximum 2.75 mm (0.1083 in.)
Connecting rod Rod bent Maximum per 100 mm (3.94 in.) 0.05 mm (0.0020 in.)
Rod twist Maximum per 100 mm (3.94 in.) 0.05 mm (0.0020 in.)
Bushing inside diameter STD 37.015 ï 37.025 mm (1.4573 ï 1.4577 in.)
Maximum 37.10 mm (1.4606 in.)
Bushing oil clearance STD 0.015 ï 0.036 mm (0.0006 ï 0.0014 in.)
Maximum 0.08 mm (0.0031 in.)
Rod big end inside diameter (w/o bearing) STD 68.985 ï 69.000 mm (2.7159 ï 2.7165 in.)
Maximum 69.00 mm (2.7165 in.)
Rod big end inside diameter (w/ bearing) STD 64.991 ï 65.022 mm (2.5587 ï 2.5599 in.)
Maximum 65.022 mm (2.5599 in.)
Rod big end oil clearance STD 0.031 ï 0.082 mm (0.0012 ï 0.0032 in.)
Maximum 0.20 mm (0.0079 in.)
Maximum 1.00 mm (0.0394 in.)
03ï8
Connecting rod Length 82.5 mm (3.280 in.)

bolt
Piston and piston Piston pin diameter STD 36.989 ï 37.000 mm (1.4563 ï 1.4567 in.)
ring Minimum 36.96 mm (1.4551 in.)
Piston diameter
S05CïB: STD 113.920 ï 113.944 mm (4.4850 ï 4.4860 in.)
Minimum 113.920 mm (4.4860 in.)
S05CïTA, S05CïTB: STD 113.869 ï 113.885 mm (4.4830 ï 4.4837 in.)
Minimum 113.869 mm (4.4830 in.)
Piston oil clearance STD 0.0515 ï 0.0715 mm (0.0020 ï 0.0028 in.)
Piston pin boss inside diameter STD 36.987 ï 37.003 mm (1.4562 ï 1.4568 in.)
Minimum 37.05 mm (1.4587 in.)
Clearance between piston pin boss and piston pin STD 0.013 (T) ï 0.014 (L) mm (0.0051 (T) ï 0.0055 (L) in.)
Maximum ï0.05 mm (ï0.0020 in.)
Piston ring groove width
S05CïB: STD 1st 2.55 ï 2.57 mm (0.1004 ï 0.1012 in.)
2nd 2.03 ï 2.05 mm (0.0799 ï 0.0807 in.)
Oil 4.01 ï 4.03 mm (0.1579 ï 0.1586 in.)
Maximum 1st 2.70 mm (0.1063 in.)
2nd 2.20 mm (0.0866 in.)
Oil 4.10 mm (0.1614 in.)
S05CïTA, S05CïTB: STD 1st 2.58 ï 2.60 mm (0.1015 ï 0.1023 in.)
2nd 2.06 ï 2.08 mm (0.0811 ï 0.0818 in.)
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Oil 4.01 ï 4.03 mm (0.1578 ï 0.1586 in.)
2nd 2.20 mm (0.0866 in.)
Oil 4.10 mm (0.1614 in.)
Piston ring thickness STD 1st 2.47 ï 2.49 mm (0.0972 ï 0.0980 in.)
2nd 1.97 ï 1.99 mm (0.0776 ï 0.0783 in.)
Oil 3.97 ï 3.99 mm (0.1563 ï 0.1571 in.)
2nd 1.90 mm (0.0748 in.)
Oil 3.90 mm (0.1535 in.)
Piston ring groove clearance
S05CïB: STD 1st 0.06 ï 0.10 mm (0.0024 ï 0.0039 in.)
2nd 0.04 ï 0.08 mm (0.0016 ï 0.0031 in.)
Oil 0.02 ï 0.06 mm (0.0008 ï 0.0023 in.)
2nd 0.30 mm (0.0118 in.)
Oil 0.20 mm (0.0079 in.)
S05CïTA,S05CïTB: STD 1st 0.09 ï 0.13 mm (0.0035 ï 0.0051 in.)
2nd 0.07 ï 0.11 mm (0.0016 ï 0.0031 in.)
Oil 0.02 ï 0.06 mm (0.0007 ï 0.0023 in.)
2nd 0.18 mm (0.0070 in.)
Oil 0.13 mm (0.0051 in.)
Piston ring end gap STD 1st 0.30 ï 0.40 mm (0.0118 ï 0.0157 in.)
2nd 0.50 ï 0.65 mm (0.0197 ï 0.0255 in.)
Oil 0.15 ï 0.30 mm (0.0059 ï 0.0118 in.)
2nd 1.20 mm (0.0472 in.)
Oil 1.20 mm (0.0472 in.)
Crankshaft Crank pin diameter STD 64.940 ï 64.960 mm (2.5567 ï 2.5575 in.)
Minimum 63.80 mm (2.5118 in.)
Circle runout Maximum 0.15 mm (0.0059 in.)
Main journal diameter STD 79.94 ï 79.96 mm (3.1472 ï 3.1480 in.)
Minimum for repair 79.80 mm (3.1417 in.)
for use 78.80 mm (3.1024 in.)
Main journal oil clearance STD 0.051 ï 0.102 mm (0.0020 ï 0.0040 in.)
Maximum 0.20 mm (0.0079 in.)
Maximum 0.50 mm (0.0197 in.)
03ï9
Cylinder block Warpage STD 0.05 mm (0.0020 in.) or less

Maximum 0.20 mm (0.0079 in.)
Main bearing bore diameter (w/o bearing) STD 84.985 ï 85.000 mm (3.3459 ï 3.3465 in.)
Maximum 85.20 mm (3.3543 in.)
Main bearing bore diameter (w/ bearing) STD 80.00 mm (3.1496 in.)
Maximum 80.30 mm (3.1614 in.)
Main bearing cap Length STD 106.80 mm (4.2047 in.)
bolt Maximum 108.00 mm (4.2520 in.)
Cylinder liner Protrusion

STD 0.01 ï 0.08 mm (0.0004 ï 0.0031 in.)
Maximum 0.08 mm (0.0031 in.)
Inside diameter
STD 113.988 ï 114.012 mm (4.4877 ï 4.4887 in.)
Maximum 114.15 mm (4.4941 in.)
Flywheel Grind limit 1.00 mm (0.0394 in.)
Maximum deflection 0.04 mm (0.0016 in.)
Warpage STD 0.05 mm (0.0020 in.) or less
Maximum 1.00 mm (0.0394 in.)
Sliding surface play Maximum 0.15 mm (0.0059 in.)
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03ï10
030O8ï03
Rear end plate bolt 55 560 41
Oil pump x Cylinder block 28.5 290 21
Sub idler gear shaft x Cylinder block 108 1,100 80
Main idler gear shaft x Cylinder block 172 1,750 127
Camshaft gear x Camshaft 59 + 90˚ 600 + 90˚ 44 + 90˚
Camshaft idler gear shaft x Cylinder head 108 1,100 80
Cylinder head x Cylinder block (Bolt number position: See page 14ï3)
M12 bolt No. 1, 2, 8, 9, 10, 15, 16, 17 59 + 90˚ + 90˚ 600 + 90˚ + 90˚ 44 + 90˚ + 90˚
No. 4, 5, 12, 13 59 + 90˚ + 135˚ 600 + 90˚ + 135˚ 44 + 90˚ + 135˚
No. 3, 6, 11, 14, 18 59 + 90˚ + 180˚ 600 + 90˚ + 180˚ 44 + 90˚ + 180˚
M10 bolt No. 19, 20, 21 59 600 44
Camshaft bearing cap x Cylinder head 31 320 23
Valve rocker support x Cylinder head 28.5 290 21
Injection nozzle clamp bolt 25 250 18
Injection pipe nut (both end nipples) 39 400 29
Heater plug 25 250 18
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Cylinder head cover x Cylinder head 28.5 290 21
Water pump x Cylinder block 28.5 290 21
Thermostat case x Cylinder head 28.5 290 21
Thermostat case x Water pump 55 560 41
Fan clutch (w/ cooling fan) x Water pump 11 110 8
Exhaust manifold x Cylinder head Inner 59 600 44
Outer 61 620 45
Intake manifold x Cylinder head 28.5 290 21

Power steering oil pump bolt 47 480 35
Engine mounting nut Front Engine side 118 1,200 87

Chassis side 74 750 55
Rear 74 750 55
Main bearing cap x Cylinder block 1st 69 700 51

2nd Loosen Loosen Loosen
3rd 69 + 90˚ + 45˚ 700 + 90˚ + 45˚ 51 + 90˚ + 45˚
Connecting rod cap x Connecting rod 69 + 90˚ + 45˚ 700 + 90˚ + 45˚ 43 + 90˚ + 45˚
Flywheel x Crankshaft 1st 186 1,900 137

2nd Loosen Loosen Loosen
3rd 186 1,900 137
Oil pan bolt 28.5 290 21
Crankshaft pulley x Crankshaft 108 1,100 80
Drain plug 41 420 30
03ï11
SERVICE SPECIFICATIONS ï EXHAUST
EXHAUST
030O3ï02
SERVICE DATA
Exhaust manifold Warpage Maximum 0.20 mm (0.0079 in.)
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03ï12
SERVICE SPECIFICATIONS ï COOLING
COOLING
030O4ï04
SERVICE DATA
Water Pump Water Pump bearing Refarence value 5 mm (0.020 in.)
Water Pump pulley Refarence value 6.3 mm (0.25 in.)
Thermostat Valve opening temperature 80 ï 84˚C (176 ï 183˚F)

Valve lift at 95˚C (203˚F) 10 mm (0.39 in.) or more
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03ï13
SERVICE SPECIFICATIONS ï LUBRICATION
LUBRICATION
030O5ï04
SERVICE DATA
Oil pump Backlach STD 0.073 ï 0.203 mm (0.0029 ï 0.0081 in.)
Maximum 0.3 mm (0.0118 in.)
Shaft diameter Driven gear shaft 18.064 ï 18.082 mm (0.7112 ï 0.7119 in.)
Inside diameter Driven gear bush 18.122 ï 18.147 mm (0.7135 ï 0.7144 in.)
Driven gear clearance STD 0.040 ï 0.083 mm (0.0016 ï 0.0032 in.)
Minimum 0.15 mm (0.0059 in.)
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03ï14
SERVICE SPECIFICATIONS ï STARTING & CHARGING
STARTING & CHARGING

030O6ï02
SERVICE DATA
Starter Commutator
Diameter STD 32.0 mm (1.260 in.)
Minimum 30.0 mm (1.181 in.)
Undercut depth STD 0.7 mm (0.028 in.)
Brash length STD 18.0 mm (0.709 in.)
Spring installed load STD 42.2 ï 51.0 N (4.3 ï 5.2 kgf, 9.3 ï 11.2 lbf)
Minimum 22.5 N (2.3 kgf, 4.9 lbf)
Magnetic switch
Resistance (M ï C) STD 0.16 ï 0.19 :
Resistance (M ï body) STD 0.84 ï 0.94 :
Starter clutch
Outside diameter STD: A 26.0 mm (1.024 in.)
STD: B 12.1 mm (0.476 in.)
Minimum: A 25.88 mm (1.019 in.)
minimum: B 12 mm (0.472 in.)
Starter drive housing
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Inside diameter STD 26 mm (1.024 in.)
Minimum 26.2 mm (1.031 in.) or more
Starter motor housing
Inside diameter STD 12.1 mm (0.476 in.)
Minimum 12.3 mm (0.484 in.) or more
Commutator end frame
Inside diameter STD 12 mm (0.472 in.)
Alternator Rotor coil resistance at 20˚C (68˚F) Open circuit 11.6 ï 12.4 :
Ground 10 M: at more
Slip ring diameter STD 14.2 ï 14.4 mm (0.559 ï 0.567 in.)
Brush exposed length STD 9.5 ï 11.5 mm (0.374 ï 0.453 in.)
IC regulator Regulating voltage at 115˚C (239˚F) 27.7 ï 28.7 V
03ï15
SERVICE SPECIFICATIONS ï STARTING & CHARGING
030O7ï02
Motor housing x Starter drive housing 15 153 11
Magnetic switch x Starter drive housing 14.7 150 11
Commutator end frame x Starter drive housing 14.7 150 11
Commutator end frame x Brush holder 4.3 44 38 in.·lbf
Bearing retainer x Drive end frame 2.0 30 26 in.·lbf
Rectifier end frame with cord clip x Drive end frame Nut A 4.5 46 40 in.·lbf
Nut B 5.4 55 48 in.·lbf
Alternator pulley x Rotor 39 400 29
Rectifier holder x Lead wire on rectifier end frame 70 A Screw 1.96 20 17 in.·lbf
Bolt 3.9 40 35 in.·lbf
IC regulator x Rectifier holder 2.0 20 18 in.·lbf

Brush holder x Rectifier holder 2.0 20 18 in.·lbf
Brush holder x IC regulator 2.0 20 18 in.·lbf
Rear end cover x Rectifier holder 5.4 55 48 in.·lbf
Terminal insulator x Rectifier holder 4.1 42 36 in.·lbf
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FUEL
NOZZLE HOLDER AND NOZZLE SET . . . . . . 11ï1

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 11ï1
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11ï2
cardiagn.com
11ï1
FUEL ï NOZZLE HOLDER AND NOZZLE SET
NOZZLE HOLDER AND NOZZLE SET

110R0ï01
COMPONENTS
Nozzle Clamp
Nozzle Holder and

Nozzle Set
63.7 (650, 47)
z OïRing
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Sleeve
z OïRing
Nozzle Holder Body
Joint Bolt
z Gasket
Nozzle Holder
Cap Nut
Nozzle
Assy Adjusting Screw
Pressure Spring
Nozzle Retaining Nut
Nm (kgfcm, ftlbf) : Specified Torque

z NonïReusable Part A74294
11ï2
110R1ï01
OVERHAUL
1. REMOVE NOZZLE ASSY

(a) Remove the nozzle holder retaining nut.
NOTICE:
When disassembling the nozzle, be careful not to drop the
inner parts.
(b) Disassemble the nozzle holder and nozzle set, and re-
move the nozzle assy.
A71018
2. CLEAN NOZZLE ASSY

(a) Using a wooden stick and brass brush, clean the nozzle.
Wash them in clean diesel fuel.
HINT:
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Do not touch the nozzle mating surfaces with your fingers.
A71019
(b) Using a wooden stick, remove the carbons adhering to

the nozzle needle tip.
A71020
(c) Using a brass brush, remove the carbons from the exteri-
or of the nozzle body (except lapped surface).
A71021
11ï3
(d) Check the seat of the nozzle body for burns or corrosion.
(e) Check the nozzle needle tip for damage or corrosion.
If any of these conditions are present, replace the nozzle assy.
A71022
3. INSPECT NOZZLE ASSY

(a) Wash the nozzle in clean diesel fuel.
HINT:
Oneïthird Of
Its Length Do not touch the nozzle mating surfaces with your fingers.
(b) Tilt the nozzle body about 60 degrees and pull the needle
60_
out about oneïthird of its length.
(c) When released, the needle should fall into the body vent
smoothly by its own weight.
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A74295
(d) Repeat this inspection, rotating the needle slightly each

time. If the needle does not fall freely, replace the nozzle
assy.
A71024
4. INSTALL NOZZLE ASSY

(a) Assemble the nozzle holder body, adjusting shim, capsule subïassembly, adjusting shim, No. 1 pres-
sure spring, distance piece, 2 straight pins and nozzle subïassembly, and fingerïtighten the retaining
nut.
HINT:
S Align the holes of the nozzle body, distance piece and nozzle holder body.
S When the thickness of the adjusting shim originally used is unclear, use a shim with 1.5 mm (0.56 in.)
thickness instead.
(b) Using a deep socket wrench, tighten the retaining nut.

Torque: 63.7 Nm (650 kgfcm, 47 ftlbf)
Deep NOTICE:
Socket Overïtorquing could make the nozzle deformed, the
needle stuck or other areas defective.
A71025
11ï4
5. INSPECT NOZZLE HOLDER AND NOZZLE SET

(a) Check for leaks.
(1) While maintaining pressure at about 981 ï 1,961
kPa (10 ï 20 kgf/cm2 142 ï 284 psi) below No.1
opening pressure (adjust it by tester handle), check
that there is no dripping from the injection hole or
around the retaining nut for 10 seconds.
Good Faulty If there is dripping within 10 seconds, replace or clean and over-
A74296 haul the nozzle assy.
(b) Check the spray pattern.

(1) The injection nozzle should shudder at a certain
pumping speed between 15 ï 60 times (old nozzle)
or 30 ï 60 times (new nozzle) per minute.
(2) Check the spray pattern during shuddering.
If the spray pattern is not correct during shuddering, replace or
clean the nozzle.
Good Faulty Faulty Faulty
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A74297
INTAKE
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 13ï1

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13ï1
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13ï1
INTAKE ï INTAKE MANIFOLD
INTAKE MANIFOLD
1305Zï01
INSPECTION
1. INSPECT INTAKE MANIFOLD

HINT:
Clean the intake manifold with a commercial cleaning agent be-
fore the inspection.
(a) Using a dye penetrate, check the intake manifold for
cracks, using a dye penetrate.
If cracks are found, replace the manifold.
A71649
(b) Using a precision straight edge and feeler gauge, mea-

sure the surface contacting the cylinder head for war-
page.
Maximum warpage: 0.20 mm (0.0079 in.)
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If warpage is greater than the maximum, replace the intake
manifold.
(c) Visually check the seal surface of the intake manifold for
deformation or wear.
A64523 If damage such as deformation and wear is excessive, replace
the manifold.
ENGINE MECHANICAL
CAMSHAFT HOUSING AND

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . 14ï1
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï1
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï3
CRANKSHAFT FRONT END, OIL PAN,
FLYWHEEL AND FLYWHEEL
HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï27
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï27
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï30
TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï39
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï39
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï40
PISTON, CRANKSHAFT AND
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CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . 14ï46
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï46
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï47
14ï1
ENGINE MECHANICAL ï CAMSHAFT HOUSING AND CYLINDER HEAD
CAMSHAFT HOUSING AND CYLINDER HEAD

1417Jï01
COMPONENTS
S05CïTB
Oil Filler Cap
28.5 (290, 21)
Cylinder Head Cover
Spacer
z Gasket
Camshaft
Camshaft Bearing 59 (600, 44) + 90˚
Camshaft
Timing Gear
Valve Rocker Shaft
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Knock Pin
Camshaft 28.5 (290, 21)
Valve Rocker
Support 25 (250, 18)
Valve Rocker Arm Valve Rocker Support
59 (600, 44) + 90˚+ 90˚ or 135˚ or 180˚

Cross Head Adjusting Screw
Lock Nut 25 (250, 18) 25 (250, 18)
Adjusting Screw Valve Bridge
Valve Spring Retainer Plug
Valve Spring Seat Upper

Valve Spring Outer Plug
Valve Spring Inner

Valve Spring Seat Lower
z Valve Stem Seal Cylinder Heater Plug

Valve Head Head Valve Seat
z Gasket
N·m (kgf·cm, ft·lbf) : Specified torque

z Nonïreusable part
A78676
A65468
14ï2
S05CïB, S05CïTA
Oil Filler Cap
S05CïTA Model:
Oil Filler Cap
Cylinder Head Cover
28.5 (290, 21)
28.5 (290, 21)
Spacer Spacer
z Gasket z Gasket
Cylinder Head Cover
Camshaft
Camshaft Bearing 28.5 (290, 21)
59 (600, 44) + 90˚
Camshaft
Timing Gear Valve Rocker Shaft
Camshaft 25 (250, 18)

Knock Pin
Valve Rocker Support
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Valve Rocker Arm
Cross Head Adjusting Screw

Nozzle Clamp
Lock Nut 25 (250, 18)
Adjusting Screw Valve Bridge 59 (600, 44) + 90˚+ 90˚ or 135˚ or 180˚
Valve Spring Retainer

Valve Spring Seat Upper
Valve Spring Outer
Valve Spring Inner
Valve Spring Seat Lower Plug
z Valve Stem Seal
Valve
Plug
Cylinder
Head Head Valve Seat 25 (250, 18)
z Gasket
Heater Plug

14ï3
1417Kï01
OVERHAUL
S05CïTA 1. REMOVE CYLINDER HEAD COVER SUBïASSY

S05CïTB NOTICE:
Clean all dust around the cylinder head cover before re-
moving it to prevent foreign particles from getting in.
S05CïB
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A64145
A70957 A80466
2. REMOVE INTAKE AIR CONNECTOR

(a) S05CïTA, S05CïTB:
Remove the 4 bolts and intake air connector.
S05CïTB 3. REMOVE INJECTION PIPE SET

(a) Loosen the 4 union nuts from the 4 injectors.
NOTICE:
S After removing the fuel pipe, affix the gummed tape to
the common rail for preventing dust.
S After removing the fuel pipe, put a vinyl bag and rub-
ber band over the injectors inlet to prevent foreign
particles from getting in.
A77166
S05CïB (b) Loosen the 4 union nuts from the 4 injection nozzles.
S05CïTA NOTICE:
After removing the fuel pipe, put it in a vinyl bag and bind
the vinyl bag with a rubber band to prevent mixing foreign
objects from getting into the injection nozzle inlet.
A70958
14ï4
4. REMOVE NOZZLE HOLDER SEAL
S05CïTB 5. REMOVE NOZZLE LEAKAGE PIPE NO.1
A64549
S05CïB 6. REMOVE NOZZLE LEAKAGE PIPE

S05CïTA (a) Remove the 5 joint bolts, fuel return pipe and 5 gaskets.
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A70959
S05CïTB
7. REMOVE INJECTOR HARNESS BRACKET
(a) Disconnect the injector connectors.
(b) Remove the 5 nuts and injector harness bracket.
A64122
8. REMOVE INJECTOR ASSY

S05CïTB
A64547
14ï5
S05CïB 9. REMOVE INJECTION NOZZLE SUBïASSY

S05CïTA (a) Loosen the injection pipe nut.
(b) Remove the injection pipe seal mounting bolts. Then, re-
move the injection pipe seal together with the injection
pipe out of the cam housing.
(c) Remove the nozzle clamp bolt.
(d) Pull out the nozzle holder assembly, avoiding any interfer-
ence.
A70961
S05CïB (e) Remove the Oïring.

S05CïTA NOTICE:
Oïring Replace the 2 Oïrings with a new ones.
Nozzle Holder
Asemmbly
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A70960
10. LOOSEN VALVE CLEARANCE ADJUSTING SCREW

S05CïTB (a) Loosen the lock nut on the top of the rocker arm, then
Adjusting Screw wind up the adjusting screw completely.
HINT:
Lock Nut If the adjusting screw is left unwound, the rocker shaft may be
bent when the rocker arm support is loosened.
S05CïB
S05CïTA
Adjusting Screw
Lock Nut
A64726
A70962 A77167
14ï6
S05CïB 11. REMOVE VALVE ROCKER ARM ASSY

S05CïTA Rocker Arm Support (a) Remove the rocker arm support bolt in the order as shown
in the illustration.
(b) Remove the valve bridge.
NOTICE:
When the rocker arm assembly is removed, the rocker arm
and support tend to come off the rocker shaft. Be careful
in handling.
S05CïTB Rocker Arm Support
A70963
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A60049 A77204
12. REMOVE CAMSHAFT

(a) Remove the cam bearing cap bolt.
(b) Remove the camshaft together with the gear.
NOTICE:
Be extremely careful not to drop any part into the interior of the engine.
13. REMOVE CYLINDER HEAD SUBïASSY
(a) Remove the cylinder head bolts in the order as shown in
the illustration.
(b) Lift and remove the cylinder head from the cylinder block.
A60050
NOTICE:
S Place a piece of wood under the cylinder head and
table.
S When placing the cylinder head together with the in-
jection nozzle, avoid contact between the injection
nozzle and piece of wood.
S Check that there is no oil, water or gas leakage in the
cylinder head gasket if overheated or not.
A70964
14ï7
14. REMOVE CAMSHAFT TIMING GEAR

(a) Using SST, remove the timing gear.
SST 09960ï10010 (09962ï01000, 09963ï01000)
SST
A63492
15. REMOVE VALVE

SST
(a) Using SST, pressïfit the valve spring seat upper, then re-
move the valve spring retainer.
SST 09202ï70020
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A64525
(b) Remove the valve spring seat upper, valve springs outer
and inner.
(c) Remove the intake and exhaust valves from the cylinder
head.
NOTICE:
S Do not remove the valve guide and valve spring seat
lower unless they need to be replaced.
S Align the removed parts in the order of the cylinder
A63493 number.
16. CLEAN CYLINDER HEAD SUBïASSY

(a) Remove the gasket material.
(1) Using a gasket scraper, remove all the gasket mate-
rials from the cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(b) Clean the intake and exhaust ports.
A63449 Using a wire brush, clean all the intake and exhaust ports.
NOTICE:
Be careful not to scratch the valve contact surface.
(c) Clean the valve guide.
Using a valve guide brush and solvent, clean all the valve
guide.
(d) Clean the cylinder head.
Using a soft brush and solvent, thoroughly clean the cylin-
der head.
14ï8
17. INSPECT CYLINDER HEAD SUBïASSY

(a) Inspect for cracks.
(1) Using a dye penetrate, check the intake ports, ex-
haust ports and the surface contacting the cylinder
block.
If cracks are found, replace the cylinder head.
A63451
(b) Inspect for flatness.

(1) Using a precision straight edge and a feeler gauge,
measure warpage of the surfaces that contact the
cylinder block and the manifolds.
Standard warpage:
0.04 mm (0.0016 in.) or less for longitudinal direction
0.03 mm (0.0012 in.) or less for lateral direction
If the warpage is greater than the maximum, replace the cylin-
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der head.
A63450
18. CLEAN VALVE

(a) Using a gasket scraper, chip off any carbons from the
valve head.
(b) Using a wire brush, thoroughly clean the valve.
A63452
19. INSPECT VALVE

(a) Visually check the valves for damage, burns, carbons or
warpage, and check the valve heads, valve stems and
valve stem grooves for cracks.
If wear, burns, warpage or cracks are excessive, replace the
valves.
(b) Check the valve seating condition.
(1) Lightly apply red lead marking compound to the
A63494 valve face.
14ï9
(2) Tapping and rotating the valve against the seat,

check the seating condition.
If the red lead mark is not concentric or the compound is scat-
tered all around the valve face or seat, correct the valve face or
the valve seat.
20. REPAIR VALVE SEAT
(a) Grind the valve and seat.
HINT:
S Grinding of valves should only be performed when handï
lapping, does not result in proper seating.
S When handïlapping, always recheck the seating condi-
tion.
CAUTION:
When grinding, a metal tip may fly off on impact. Wear safe-
ty glasses to protect your eyes.
Valve seat angle:
Intake 30˚00’ ï 30˚30’
Exhaust 44˚15’ ï 45˚45’
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Valve face angle:
Intake 29˚45’ ï 30˚00’
30˚ 45˚
Exhaust 44˚45’ ï 45˚00’
Intake Exhaust
A16293
A16206 A63496
(b) Handïlap the valve and valve seat.

(1) Lightly apply lapping compound to the valve face.
Then, tap and rotate the valve against the seat.
HINT:
S After handïlapping, clean off any lapping compound on
the valves and valve seats.
S When handïlapping, always recheck the seating condi-
tion.
A63495
21. REMOVE VALVE SEAT

Block Brass
Hammer (a) Cut the 3 places on the circumference of an unwanted
Valve Seat
valve and weld it to the valve seat.
NOTICE:
To protect the lower surface of the cylinder head from weld-
Electric welding
Valve ing spatters, be sure to apply grease before welding.
applied
Grind this point (b) Place a block brass on the top of the valve stem and strike
with a grinder it with a hammer to remove the valve seat.
A63497 CAUTION:
When striking, a metal tip may fly off on impact. Wear safety
glasses to protect your eyes.
14ï10
22. INSTALL VALVE SEAT

(a) Machine the valve seat according to the specified valve
seat dimensions.
Cylinder head dimension:
Intake (A) 41.000 ï 41.016 mm (1.6142 ï 1.6148 in.)
Intake (B) 9.400 ï 9.600 mm (0.3701 ï 0.3780 in.)
C C
Exhaust (A) 39.000 ï 39.016 mm (1.5354 ï 1.5361 in.)
Intake Exhaust Exhaust (B) 8.600 ï 8.800 mm (0.3386 ï 0.3465 in.)
A63498
Valve seat dimension:
Intake (C) 41.085 ï 41.100 mm (1.6175 ï 1.6181 in.)
Intake (D) 7.000 ï 7.200 mm (0.2756 ï 0.2835 in.)
Exhaust (C) 39.120 ï 39.135 mm (1.5402 ï 1.5407 in.)
Exhaust (D) 6.000 ï 6.200 mm (0.2362 ï 0.2441 in.)
(b) Heat the cylinder head to 80 ï 100 ˚C (176 ï 212 ˚F) with
hot water. Cool the valve seat with dry ice for approxi-
mately 30 minutes.
(c) Hold the valve seat with pincers and place it into the
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heated cylinder head. Lightly hitting the valve seat can
easily fit them it.
HINT:
When valve grinding the valve, always recheck the seating
A63499 condition.
CAUTION:
S Never touch the cooled valve seat with your bare
hands.
S When hitting, a metal tip may fly off on impact. Wear
safety glasses to protect your eyes.
23. INSPECT VALVE SINK

Standard dimension:
Intake 0.55 ï 0.85 mm (0.0217 ï 0.0335 in.)
Exhaust 1.30 ï 1.60 mm (0.0512 ï 0.0630 in.)
Valve Seat Maximum dimension:
Intake 1.2 mm (0.0472 in.)
Valve Sink
Dimension Cylinder Valve
Head A63500 HINT:

S If the valve heads are protruding from the cylinder head
surface, the valve heads may hit against the pistons while
the engine is running.
S When replacing the valve and valve seat, always recheck
the seating condition.
14ï11
24. INSPECT VALVE STEM AND VALVE GUIDE

(a) Using a micrometer, measure the diameter of the stem.
Standard valve stem diameter:
Intake 6.957 ï 6.977 mm (0.2739 ï 0.2747 in.)
Exhaust 6.932 ï 6.950 mm (0.2730 ï 0.2736 in.)
Minimum valve stem diameter:
Intake 6.92 mm (0.2724 in.)
Exhaust 6.85 mm (0.2700 in.)
A63453
If the stem diameter is less than the minimum, replace the valve.
(b) Using a cylinder gauge, measure the inside diameter of
the valve guide.
90˚ (c) Calculate the oil clearance between the valve stem and
valve guide.
Standard oil clearance:
Intake 0.023 ï 0.058 mm (0.0010 ï 0.0022 in.)
Exhaust 0.050 ï 0.083 mm (0.0020 ï 0.0033 in.)
Maximum oil clearance:
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A63456
Intake 0.12 mm (0.0047 in.)
Exhaust 0.15 mm (0.0059 in.)
If the oil clearance is greater than the maximum, replace the
valve or valve guide.
25. REMOVE VALVE GUIDE

(a) Remove the valve stem seal.
(b) Using a brass bar and a hammer, Strike out the valve
guide.
CAUTION:
A63501
26. INSTALL VALVE GUIDE

Intake Exhaust (a) Pressïfit a new valve guide straight allowing it to pro-
trude, as shown in the illustration.
Protrusion:
H Intake Exhaust
H 20.9 mm (0.823 in.) 21.3 mm (0.839 in.)
HINT:
Apply engine oil lightly to the valve guide outer circumference
A63502 before the installation.
27. REMOVE VALVE STEM SEAL

(a) Remove the valve stem seal when the valve guide is replaced or when seal clearance is excessive
or the stem seal has been worn or damaged.
14ï12
28. INSTALL VALVE STEM SEAL

Valve Stem Seal
(a) Install the lower spring seat and valve to the cylinder head
Valve Spring Seat SST (for guide of SST), then apply engine oil to the lip of the
Lower
stem seal and drive the guide with SST.
SST 09201ï41020
CAUTION:
Valve A63488
HINT:
Coat Oil S After installing the valve stem seal, make sure the there
are gaps (A) and (B) as shown in the illustration.
S Do not use SST if its surface contacting the valve spring
lower seat is deformed.
S Check that the seal has not been deformed or cracked af-
ter the installation.
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A63489
29. INSPECT VALVE SPRING

Deviation (a) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.079 in.)
If the deviation is greater than the maximum, replace the valve
spring.
EM0988
(b) Using vernier calipers, measure the free length of the

valve spring.
Standard free length:
Inner spring 64.6 mm (2.543 in.)
Outer spring 75.7 mm (2.980 in.)
Minimum free length:
EM0801
If the free length is less than the minimum, replace the spring.
(c) Using a spring tester, measure the tension of the valve

spring at the specified setting height.
Install tension:
Item Setting Height Tension
128.5 N
(13.1 kgf, 28.9 lbf)
313.8 N
(32.0 kgf, 70.5 lbf)
EM0281
If the installed tension is not as specified, replace the spring.
14ï13
30. INSPECT VALVE SPRING SEAT

(a) Visually check the contact surface of the upper and lower
valve spring seats.
If damage such, as wear and scratches, is excessive, replace
the valve spring seat.
A63503
31. INSPECT CYLINDER HEAD COOLANT GALLERY FOR LEAKS

(a) Close all coolant holes and apply air pressure of about 2.5 kgf/cm2 (36 psi.) from one of the coolant
holes.
(b) Immerse the cylinder head into the water, then check for air leakage.
If any leakage is found, replace the cylinder head.
32. REMOVE NOZZLE SLEEVE

(a) Engage a tap to the nozzle sleeve from the bottom of the
cylinder head. Screw in an appropriate bolt, then strike
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the bolt head with a hammer and tap out the nozzle
sleeve.
CAUTION:
When tapping, a metal tip may fly off on impact. Wear safety
A63447
33. INSTALL NOZZLE SLEEVE

Cylinder Head (a) Install a new Oïring to the nozzle sleeve insert hole of the
cylinder head. Then apply seal packing to the bottom of
Oïring a new nozzle sleeve, and insert it to the nozzle sleeve in-
sert hole of the cylinder head.
Nozzle Sleeve Seal packing: Part No. 08826ï00080 or equivalent
NOTICE:
Be sure to install a new Oïring. Reused Oïrings may cause
A63486 water or gas leakage and lead to overheating or cracked
heads.
(b) Using SST, caulk the nozzle sleeve.
Nozzle SST 09472ï1210, 09800ï6100
SST
Sleeve
Cylinder
Head
SST
A63487
14ï14
(c) Install the injector or injection nozzle to the cylinder head.

Using vernier calipers, measure the protrusion of the in-
jector from the lower surface of the cylinder head.
Protrusion:
S05CïTB
Cylinder Head
Standard 2.35 ï 2.85 mm (0.0930 ï 0.1122 in.)
Maximum 2.85 mm (0.1122 in.)
Protrusion:
Protrusion
A63504 S05CïB, S05CïTA
Standard 2.25 ï 2.75 mm (0.0886 ï 0.1083 in.)
Maximum 2.75 mm (0.1083 in.)
If the protrusion is greater than the maximum, replace the injec-
tor.
34. INSPECT OIL CLEARANCE BETWEEN CAMSHAFT

IDLER GEAR SHAFT AND IDLER GEAR BUSH
(a) Using a micrometer, measure the shaft diameter of the
idler gear shaft.
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Shaft diameter:
Standard 33.950 ï 33.975 mm (1.3366 ï 1.3376 in.)
Minimum 33.80 mm (1.3307 in.)
If the outside diameter is less than the minimum, replace the
A64449 idler gear shaft.

the idler gear bush.
Inside diameter:
Standard 34.000 ï 34.015 mm (1.3386 ï 1.3392 in.)
Maximum 34.20 mm (1.3464 in.)
If the inside diameter is greater than the maximum, replace the
idler gear.
(c) Calculate the oil clearance between the idler gear shaft
A64526 and idler gear bush.
Oil clearance:
Standard 0.025 ï 0.065 mm (0.0010 ï 0.0026 in.)
Maximum 0.20 mm (0.0079 in.)
If the clearance is greater than the maximum, replace the idler
gear shaft and/or idler gear bush.
35. INSPECT CAMSHAFT

(a) Visually check the camshaft surface for wear and
scratches.
A64098
14ï15
(b) Using a micrometer, measure the cam lobe height.

Standard cam lobe height:
Intake 50.067 mm (1.9711 in.)
Exhaust 52.104 mm (2.0153 in.)
Minimum cam lobe height:
Intake 49.967 mm (1.9672 in.)
Exhaust 52.004 mm (2.0474 in.)
If the lobe height is less than the minimum, replace the cam-
EM2011
shaft.
(c) Measure the oil clearance of the camshaft journal.

(1) Using a micrometer, measure the journal diameter
of the camshaft.
Journal diameter:
Standard 39.959 ï 39.975 mm (1.5732 ï 1.5738 in.)
Minimum 39.85 mm (1.5689 in.)
If the jounal diameter camshaft is less than the minimum, re-
place the camshaft.
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EM2538
(2) Using a cylinder gauge, measure the inside diame-

ter of the camshaft bearing.
Inside diameter:
Standard 40.00 mm (1.5748 in.)
Maximum 40.15 mm (1.5807 in.)
If the inside diameter is less than the minimum, replace the
camshaft.
(3) Calculate the oil clearance from the above mea-
A63491 surement.
Oil clearance:
Maximum 0.10 mm (0.0039 in.)
camshaft or camshaft bearing.
(d) Inspect the camshaft for circle runout.

(1) Place the camshaft on Vïblocks.
(2) Using a dial gauge, measure the circle runout at the
center journal.
Maximum circle runout: 0.10 mm (0.0039 in.)
If the circle runout is greater than the maximum, replace the
camshaft.
A63490
14ï16
36. INSTALL CAMSHAFT TIMING GEAR

(a) Measure the length of the camshaft gear bolts.
Maximum length (A): 30.0 mm (1.181 in.)
If the length is greator than A, replace them with new bolts.
(b) Make sure that there is no dirt or scratch on the camshaft
gear and tightening surface of the camshaft.
A
A64099
(c) Apply clean engine oil to the bolt seating and bolt thread,
then tighten the bolt to the specified torque below.
90˚ (d) Retighten them by 90_ (1/4 turn).
HINT:
When adding torque, never untighten the nuts even if they have
been over tightened.
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A64100
37. INSPECT OIL CLEARANCE BETWEEN VALVE

ROCKER ARM AND SHAFT
(a) Using a cylinder gauge, measure the inside diameter of
the rocker arm bushing.
Inside diameter:
Standard 22.000 ï 22.051 mm (0.8661 ï 0.8681 in.)
Maximum 22.080 mm (0.8693 in.)
If the diameter is greater than the maximum, replace the bush.
A63457 If the diameter is greater than the maximum, replace the bush.
HINT:
When installing a bush into the rocker arm, align the bush with
the oil hole of the rocker arm.
(b) Using a micrometer, measure the outside diameter of the

rocker arm shaft.
Shaft diameter:
Standard 21.959 ï 21.980 mm (0.8645 ï 0.8654 in.)
Minimum 21.920 mm (0.8630 in.)
If the outside diameter is less than the minimum, replace the
rocker arm.
(c) Calculate the oil clearance between the rocker arm bush
A64101 and rocker arm shaft.
Oil clearance:
Standard 0.020 ï 0.092 mm (0.0007 ï 0.0036 in.)
Maximum 0.16 mm (0.0063 in.)
rocker arm bush.
14ï17
38. INSPECT VALVE ROCKER ARM AND VALVE BRIDGE

(a) Visually check the contact between the rocker arm and
valve bridge.
Replace the rocker arm and the valve bridge if damage such as
wear and scratches is excessive. If there is only a minimal
amount of wear, correct the surface using a resurfacer.
(b) Visually check the adjusting screw thread.
HINT:
A64102 Replace the adjusting screw if damage such as wear and
scratches is excessive.
39. INSTALL VALVE
SST
(a) Apply engine oil to the intake and exhaust valve stems.
Then insert them into the valve guide installed in the cylin-
der head.
(b) Install the valve inner and outer springs and valve spring
seat upper.
(c) Using SST, pressïfit the valve spring seat upper, then se-
curely fit the valve spring retainer.
SST 09202ï70020
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A64525
HINT:
If parts are reused, be sure to install them to their original posi-
tion.
NOTICE:
S Be sure to apply engine oil to the contact surface of
the parts before the assembly.
S Be sure to place each valve in its original position.
S When the valve spring is compressed, be careful that
the upper seat will not damage to the stem seal.
S Since this valve spring is evenly pitched, it can be
installed with either end up.
40. INSTALL CAMSHAFT IDLER GEAR
(a) Install the idler gear shaft through a thrust plate, with the
oil filler facing downward (See step 27).
(b) Tighten the idler gear shaft bolt to the specified torque be-
low.
Torque: 108 Nm (1,100 kgfcm, 80 ftlbf)
A64104
41. INSPECT CAMSHAFT IDLER GEAR THRUST CLEARANCE

HINT:
After installing the idler gear, measure the clearance between the idler gear and thrust bearing by using a
dial gauge.
Standard thrust clearance: 0.040 ï 0.0095 mm (0.0016 ï 0.0037 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum, replace the thrust bearing.
14ï18
42. INSTALL CYLINDER HEAD GASKET

HINT:
Seal Packing S Do not reuse the head gasket for any reason, because it
Application Point will cause the engine damage.
S Before installing the cylinder head gasket, remove dirt,
moisture and oil on the cylinder head and cylinder block
surface.
Seal Packing S The 8 water hole seal rings between the bores can be
Application Point easily damaged. Do not touch them with your hands or
Cylinder Head Seal Packing
other objects. Make sure that the seal rings are not loose
Cylinder Flywheel CORRECT
Block Housing
or damaged.
Rear End Clearance S Since silicon material is used for the gear case print seal,
Plate make sure that there is no peeling before the assembly.
POOR
(a) Install the cylinder head gasket on the cylinder block and
Clearance Clearance flywheel housing.
PROTRUDING (b) Fill the hole on the back side of the cylinder head gasket
with seal packing.
AïA SECTION Seal packing: Part No. 08826ï00080 or equivalent
HINT:
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A64734
Make sure that the seal packing surface is flush with the cylin-
der head gasket upper surface.
43. INSTALL CYLINDER HEAD BOLT

(a) Preparation
(1) Measure the length of the M12 head bolts.
Maximum length (A):
A Bolt Number
A
126.5 mm (4.9803 in.) 1, 2, 7, 8, 9, 10, 15, 16, 17
156.5 mm (6.1614 in.) 4, 5, 12, 13
187.5 mm (7.3819 in.) 3, 6, 11, 14, 18
A64106 If the length is greater than the maximum, replace them with
new bolts.
(2) Make sure that no dirt or scratch is on the tightening
surface of the cylinder head bolt.
(3) Apply clean engine oil to the bolt surface and bolt
threads.
HINT:
Since the cylinder head bolts are unique to this engine, do not
substitute ordinary bolts for them.
14ï19
(b) Tighten the cylinder head bolts.

(1) Tighten bolts No. 1 ï No. 18 (M12) in the order
shown in the illustration.
(2) After tightening bolt No. 18, check the torque again
all through the bolts from No. 1 to No. 18.
(3) Mark the bolts with paint to indicate the same direc-
tions as shown in the illustration.
A64730 (4) Turn the bolts No. 1 ï No. 18 by 90_ (1/4 turn).
(5) Make sure that all paint marks face the same direc-
tion.
HINT:
been overtightened.
(6) Tighten the head bolts again (M12 bolts only) in the
same sequence to their respective tightening
90˚ 90˚ angles.
or Tightening angle:
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135˚ Tightening Angle Head Bolt No.
or
90_ 1, 2, 7, 8, 9, 10, 15, 16, 17
180˚
135_ 4, 5, 12, 13
180_ 3, 6, 11, 14, 18
HINT:
(7) Tighten bolts No. 19 ï No. 21 (M10) in the order
A16198 A64108
44. INSTALL CAMSHAFT

Drill Hole
(a) Install the camshaft into the cam housing so that two drill
holes on the camshaft gear is located at left side and low-
er drill hole match with the camshaft housing upper face.
HINT:
Incorrect installation may damage the engine.
Ruller
SM3ïJ1009
14ï20
45. INSTALL CAMSHAFT BEARING CAP

(a) Adjust the orientation and position of the camshaft bear-
ing and cam cap, and install them Do not tighten the bolt
at this time.
Front Side HINT:
The stamp marks (triangle) of the camshaft bearing cap are di-
rected to the front side of the engine, and they are arranged in
order of 1 through 5 from the front side.
A64732
(b) Install the rocker arm assembly.

(1) Check that the valve bridge is properly installed on
Click each valve.
NOTICE:
Good S To check the proper installation of the valve bridge,
move it right and left by hand. If you hear click sound
at this time, it means the valve bridge is properly
installed.
No Good S If the valve bridge is off the valve, it will push the up-
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A64437
per seat. This will cause the valve to slip off.

(2) Completely screw up the adjusting screw placed in
the tip of the rocker arm.
NOTICE:
Apply engine oil to the cam part after the installation.
(c) Install the rocker arm assembly on the cylinder head.

(d) Check that the rocker arm is properly install on the valve
bridge.
(e) Gradually tighten the rocker arm support bolts, dividing
them into small groups, in accordance with the illustrated
order.
NOTICE:
Check that the rocker arm moves smoothly after tightening
A64110 the bolts.
46. INSPECT BACKLASH OF CAMSHAFT GEAR AND

CAMSHAFT IDLER GEAR
HINT:
Using a dial gauge, measure the backlash between the cam-
shaft gear and camshaft idler gear.
Backlash:
Maximum 0.30 mm (0.0118 in.)
If the backlash is greater than the maximum, replace the cam-
A64111 shaft gear.
14ï21
47. INSPECT CAMSHAFT THRUST CLEARANCE

HINT:
Using a feeler gauge, measure the thrust clearance between
the camshaft and camshaft bearing.
Thrust clearance:
Maximum 0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum, replace the
camshaft.
A64112
48. INSTALL VALVE ROCKER ARM ASSY

(a) Make sure of the correct direction of the rocker arm sup-
port and assemble the rocker arm assembly.
HINT:
Wrong mounting of the rocker arm support results in seizure of
the valve mechanism due to incorrect lubrication.
(b) Wind up the adjusting screw of the rocker arm completely.
HINT:
If the adjusting screw is left unwound, the rocker shaft may be
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A64103
bent when the rocker arm support is tightened.

S05CïTB 49. INSTALL INJECTOR ASSY
(a) Install a new Oïring into the groove of the cylinder head,
Bolt Injector and then insert the injector.
Injection Pipe NOTICE:
Apply engine oil to the Oïring so that the Oïring will not be
caught.
(b) Install the injector clamp and temporarily install the injec-
tor.
NOTICE:
Clamp
Do not fix the injector clamp before the injection pipe is
temporarily installed.
Oil Seal (c) Cover the injector with a new injection pipe oil seal, and
Oïring then install the plate and nut.
NOTICE:
Be careful not to put excessive force to the injector when
applying the injection pipe oil seal to it. If the injection pipe
oil seal and injector are moved even slightly, it may cause
oil leakage or faulty assembling of the injection pipe.
A64731 (d) Assemble the injection pipe temporarily, and completely
tighten the installation bolt of the injector clamp.
14ï22
S05CïB
50. INSTALL INJECTION NOZZLE SUBïASSY
Injection (a) Install a new Oïring into the groove of the cylinder head.
S05CïTA Valve Spring
Pipe Unit (b) Make sure that there is no dirt or foreign particles at the
sealing part between the nozzle holder and related parts
(Oïring, nozzle sleeve and injection pipe seal), and con-
necting part between the nozzle holder and nut of the in-
Rocker
jection pipe.
Arm
(c) Insert the nozzle holder, taking care not to make it in con-
tact with the valve spring as shown in the illustration.
Injection
NOTICE:
Pipe Seal
Apply clean engine oil to the Oïring and be careful that the
Oïring is not caught.
Leakage (d) Cover the end of the injection pipe seal with the nozzle
Pipe holder as shown in the illustration, and tighten the bolts
to fasten the injection pipe seal to the cam housing.
Nozzle Clamp
Bolt
(e) Tighten the nut of the injection pipe provisionally.
Tighten the nozzle clamp bolt to the specified torque.
NOTICE:
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After tightening the bolt, make sure that the rocker arm
moves smoothly.
(f) Tighten the nut of the injection pipe to the specified
OïRing torque.
Nozzle Holder Assy
(g) Install the leakage pipe.
Cylinder Head
A70965
51. INSPECT VALVE CLEARANCE

(a) Turn the crankshaft to align mark 14 on the outer periph-
ery of the flywheel with the pointer of the flywheel hous-
ing.
A64169
HINT:
Camsaft Gear
Among three drill holes on the camshaft gear, when two drill
holes are on horizontal position, and the rest of the drill hole is
visible , the No.1 piston is at the Top Dead Center of the com-
pression stroke.
NOTICE:
Drill If the rest of the drill hole is invisible by camshaft housing, the
Hole No.4 piston is at the Top Dead Center of the compression
SM3ïJ843AA stroke.
14ï23
S05CïTB
(b) Check only those valves indicated in the illustration with
the No.1 piston in the top dead center.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
Standard clearance:
Intake 0.30 mm (0.012 in.)
(2) Record the measurement of the valve clearance
that is out of the specification.
No. 1 No. 1 No. 2 No. 3
IN EX IN EX
S05CïB
S05CïTA
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No. 1 No. 1 No. 2 No. 3
IN EX IN EX
A64337
A70966
A77203
S05CïTB
(c) Turn the crankshaft 1 revolution (360_) and align the
marks as shown in the illustration.
(d) Check only the valves indicated in the illustration.
Measure the valve clearance with the No. 4 piston in the
top dead center.
No. 2 No. 3 No. 4 No. 4

EX IN IN EX
S05CïB
S05CïTA
No. 2 No. 3 No. 4 No. 4

EX IN IN EX
A64337
A70966
A77203
14ï24
52. ADJUST VALVE CLEARANCE

(a) Loosen the adjusting screw nut of the valve bridge com-
Adhesion
pletely.
10 mm
or more
HINT:
S The adjusting screw must protrude by 10 mm (0.3931 in.)
or more from the valve bridge upper surface.
S Unless the adjusting screw is completely loose to the
valve stem, the following adjustments may be adversely
A64439 affected.
(b) Insert a feeler gauge between the rocker arm and valve
bridge. Adjust the clearance with the adjusting screw of
the rocker arm. Tighten the lock nut with the following
torque.
HINT:
The feeling of the feeler gauge during the clearance adjustment
is the same as before.
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A64440
(c) With the feeler gauge inserted, loosen the adjusting

screw of the valve bridge. Make sure that the feeler gauge
is not felt loose.
HINT:
If it is loose, repeat the following steps.
(d) Tighten the adjusting screw of the valve bridge until the
feeler gauge dose not move.
(e) While loosening the adjusting screw of the valve bridge
A64441 gradually, adjust the valve clearance. Tighten the lock nut
of the valve bridge when the feeler gauge is felt correct.
Feeler Gauge Adhesion HINT:

Start S The feeling of the feeler gauge during the clearance ad-
No Nut Fixing Position
justment is the same as before.
Movement
S Do not over loosen the adjusting screw will cause the
Proper valve bridge to come off from the valve stem. The feeler
Contact gauge may be excessive clearance between the adjust-
ing screw of the valve bridge and the valve. This dose not
Loosening Amount Feeling is Same
of Adjusting Screw allow for correct adjustment.
=> Large
A64442
14ï25
S The adjustable valve clearance, when either the No. 1 or

No. 4 piston is at the TDC of the compression stroke, is
shown in the following chart. After completing the valve
clearance adjustment when the No.1 piston is at the TDC
of the compression stroke, turn the crankshaft one com-
plete revolution and make the No.4 piston be at the TDC
of the compression stroke (The arrow printed on the cam-
shaft points down and the underline is horizontal) and ad-
A64443 just the rest of the valve clearances.
(f) Finally, tighten all the lock nuts of the rocker arm and the
Rocker Arm Valve Bridge cross head by the following torques and make sure that
they are all tight (the nuts do not turn).
HINT:
Neverover tighten them.
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A64444
S05CïTB 53. INSTALL INJECTOR HARNESS BRACKET

(a) Install the injector harness bracket with the 5 nuts.
(b) Connect the injector connector.
(c) Connect the wire harness connector.
A64122
54. INSTALL CYLINDER HEAD COVER SUBïASSY

Head Cover (a) Install the cylinder plugs at the front and rear ends of the
cam housing. Clean the cylinder plugs and the mounting
surface of the cam housing.
Cylinder Head Cylinder Plug

A64116
(b) Apply seal packing to the front and rear half circles of the
cam housing, then install the cylinder plug within 20 min-
utes.
Seal packing: Part No. 08826ï00080 or equivalent
Coating width: 1.5 ï 2.5 mm (0.059 ï 0.098 in.)
HINT:
S If more than 20 minutes have elapsed, clean off the seal
packing completely and reapply the seal packing.
A64117 S Make sure to wipe off excessive liquid gasket.
14ï26
(c) Apply seal packing to plug corner A at the front and rear
ends of the cam housing.
(d) Install the cylinder head cover gasket into the gasket
groove at the head cover lower surface.
(e) Insert the spacer from the head cover to the cam housing.
(f) Install the cylinder head cover to the cam housing im-
mediately before mounting the head cover.
HINT:
If left more than 20 minutes have elapsed, clean off the liquid
gasket completely and reapply the seal packing.
(g) Tighten the mounting bolt of the head cover through the
silent block and fix the head cover on the cylinder head.
Silent Block Torque: 28.5 Nm (290 kgfcm, 21 ftlbf)
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A64162
ENGINE MECHANICAL ï CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL 14ï27
AND FLYWHEEL HOUSING
CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND

FLYWHEEL HOUSING
1417Lï01
COMPONENTS
Oil Seal Retainer
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Crankshaft Front
Oil Seal
Flywheel Housing
Rear End Plate Dust Cover
z Gasket
Crankshaft Position
Sensor
Dust Cover
z Gasket L 55 (560, 40)
Flywheel
Knock Pin
Crankshaft 186 (1,900, 137)
Crankshaft
Gear
Crankshaft Pulley
Crankshaft Rear
Oil Seal Ring Gear
108 (1,100, 80)

14ï28 ENGINE MECHANICAL ï CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL
S05CïTA
S05CïTB
See page 14ï47

69 (700, 43) + 90˚+ 45˚
Liner
Oil Jet
Valve 22 (220, 16)
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S05CïTB Only
z Gasket
Upper Oil Pan

Oil Level Gauge
28.5 (290, 21)
171.5 (1,750, 127)
S05CïTB Only
25 (255, 18)
97 (990, 70.7)
z Gasket
Lower Oil Pan
Gasket z
28.5 (290, 21)
Drain Plug
41 (418, 30)

A64140
S05CïB
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z Gasket
Oil Pan
Soft Washer
Drain Plug
28.5 (290, 21) 41 (420, 30)
Nm (kgfcm, ftlbf) : Specified torque

A70968
1417Mï01
OVERHAUL
1. REMOVE CRANKSHAFT PULLEY
A64128
2. REMOVE OIL PAN

S05CïTA
(a) Remove the oil pan cover.
S05CïTB
(b) Remove the lower oil pan.
(c) Remove the upper oil pan.
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A64524
3. REMOVE OIL PAN AND OIL STRAINER

S05CïB
A70969
4. REMOVE FLYWHEEL SUBïASSY

(a) Remove the pilot bearing.
(b) S05CïTB:
Remove the crankshaft position sensor from the flywheel
housing.
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A64129
(c) Remove the flywheel mounting bolts.

(d) Hold a copper rod through the starter hole against the fly-
wheel, and drive the rod lightly with a hammer to remove
the flywheel from the crankshaft while rotating the crank-
shaft.
NOTICE:
The flywheel is heavy. When removing, be careful not to
drop it on your feet.
A60052
5. REMOVE CRANKSHAFT OIL SEAL

(a) Using SST, remove the crankshaft oil seals.
SST SST 09420ï1731 (Front), 09420ï1742 (Rear)
(1) Place SST (plate) at the crankshaft end with the
crank pulley mounting bolts (front) or the flywheel
mounting bolts (rear).
A64518
(2) Install SST (hook) to the crankshaft end with the

supplied bolt.
HINT:
Engage the hook with the oil seal notch.
(3) Remove the bolt installed in step (1).
SST A64519
(4) Install SST (center bolt) and tighten it to remove the

oil seal.
SST
A64520
6. REMOVE FLYWHEEL HOUSING

(a) Remove the 2 front mounting bolts of the flywheel hous-
ing.
(b) Remove the rear mounting bolts of the flywheel housing.
Vacuum HINT:
Pump Before removing the flywheel housing, remember to loosen the
bolt A.
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Bolt A
A60053
(c) Using a plasticïfaced hammer, remove the flywheel

housing by it lightly striking.
A60054
CAUTION:
The flywheel housing is heavy. When removing, be careful
not to drop it on your feet.
A60055
7. REMOVE OIL SEAL RETAINER
A63426
8. INSPECT CRANKSHAFT PULLEY

HINT:
Clean the torsional damper with a commercial cleaning agent
before the inspection.
Use a cleaning agent that does not damage gum.
(a) Check if there are any cracks in the damper rubber sec-
tion.
If the cracks are excessive, replace the pulley.
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A64130
9. INSPECT FLYWHEEL SUBïASSY

(a) Check the friction surface for damage.
(b) Check the friction surface for distortion.
(c) Grinding and replacement should be performed as nec-
essary.
Maximum deflection: 0.04 mm (0.0016 in.)
Grind limit: 1.00 mm (0.0394 in.)
If the flywheel is ground over the limit, replace it with a new one.
A64131
10. INSPECT PILOT BEARING

(a) Rotate the bearing lightly by hand, and check whether
there is any abnormal noise or clatter and whether the
balls run smoothly.
If there is any fault, replace the pilot bearing.
A64132
11. INSPECT FLYWHEEL RING GEAR

(a) Visually check the flywheel ring gear.
If damage such as wear and scratches is excessive, replace the part.
12. REMOVE FLYWHEEL RING GEAR

(a) Using a torch, heat the ring gear evenly to about 200_C
(392_F) with a torch. Insert the ring gear periphery lightly,
using a cushion bar to remove the gear.
CAUTION:
Never touch the ring gear or flywheel with your bare hands
when they are hot.
A64133
13. INSTALL FLYWHEEL RING GEAR

(a) Using a torch, heat the ring gear evenly to about 200_C (392_F) with a touch. Insert the ring gear into
the flywheel so that the chamfered side is facing upward.
NOTICE:
Do not overheat the ring gear.
14. INSTALL OIL SEAL RETAINER
(a) Clean the cylinder block mounting surface of the oil seal
retainer.
Seal Packing
(b) Apply seal packing to the oil seal retainer, then install it to
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the cylinder block within 20 minutes.
If more than 20 minutes have elapsed, clean off the seal pack-
A64134 ing completely and reapply the seal packing.
15. INSTALL FLYWHEEL HOUSING

(a) Clean the rear end plate mounting surface of the flywheel
housing.
Matching Face with Rear End Plate (b) Apply seal packing to the flywheel housing, then install it
to the rear end plate within 20 minutes.
Seal Packing Coating width: 1.5 ï 2.5 mm (0.059 ï 0.098 in.)
Bolt A
If more than 20 minutes have elapsed, clean off the seal pack-
ing completely and reapply the seal packing.
NOTICE:
Before installing the flywheel, remember to tighten the bolt
B
A. Be sure to apply seal packing to the flywheel housing.
Be sure to assemble the stud bolt on the block side. The fly-
wheel is heavy. When installing, be careful not to drop it on
your feet.
A63432
16. INSTALL CRANKSHAFT OIL SEAL

SST (a) Clean the edges and surface of the crankshaft and SST.
Guide
(b) Insert a new crankshaft oil seal into SST (guide of oil seal
press).
SST 09407ï1030 (Front), 09407ï1040 (Rear)
New
Oil Seal A64135
Edge of Crankshaft HINT:

Felt Side of Pay attention to the orientation of the oil seal (The felt side
Oil Seal
should face the outside of the cylinder block).
Guide Bolt
Guide
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A64136
(c) Apply a little amount of engine oil to the seal portion of the
shaft oil seal.
SST (d) Attach SST (oil seal press guide) with the oil seal onto the
crankshaft with SST (attached guide bolt).
A64527
(e) Insert the oil seal press by adjusting the oil seal press hole
to the guide bolt.
(f) Press the crankshaft oil seal inside by attaching the ac-
companying center bolt onto the oil seal press and tighten
it until it stops.
A64528
17. INSTALL FLYWHEEL SUBïASSY

(a) Make sure that there are no burns or dirt on the contact
surface or in the threaded hole of the crankshaft or fly-
wheel.
SST (b) Insert SST into the crankshaft.
SST 09481ï1340
HINT:
Place one guide bar on one side of the collar knock and another
on the opposite side of the collar knock.
(c) Insert the flywheel slowly until it contacts the collar knock
in order to prevent impact on the guide bar. Adjust the
position, then insert it completely.
CAUTION:
The flywheel is heavy. When installing, be careful not to
drop it on your feet.
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A64137
(d) Apply clean engine oil to the threads of the flywheel bolt
Tightening Order
Crankshaft Collar and the flywheel bolt seat. Be sure to tighten 2 or 3
threads provisionally by hand. Then, tighten the flywheel
bolts (6) with a lowïtorque impact wrench.
(e) Pull out the guide bar and tighten the remaining 2 flywheel
bolts provisionally as in step (d).
(f) Tighten the flywheel bolts in the order shown in the il-
lustration.
A64733 Torque: 186 Nm (1,900 kgfcm, 137 ftlbf)
(g) Loosen all the bolts and tighten them again.
(h) Measure the sliding surface play of the flywheel.

(1) Using a dial gauge, measure the runout of the fly-
wheel.
Maximum runout: 0.15 mm (0.0059 in.)
If the runout is greater than the maximum, resurface the sliding
surface.
A63435
(i) Install the pilot bearing.

(j) S05CïTB:
Install the crankshaft position sensor.
A63436
18. INSTALL OIL PAN

Seal Packing (a) Make sure that there is no deformation, impact marks or
(2 Parts Each) foreign particles on the mounting surface and stiffener
surface of the upper oil pan.
(b) Place a guide pin of 70 mm (2.76 in.) or longer in the cylin-
der block.
(c) Apply seal packing to the front and back ends of the cylin-
der block lower surface.
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A63437

S05CïTA (d) Install the upper oil pan gasket so that the protrusion will
S05CïTB be on the flywheel housing side and the print seal surface
will be on the cylinder block side.
Oil Pan Lower (e) Install the upper oil pan.
HINT:
Oil Pan Gasket Lower
S Install the upper oil pan along the guide pin.
B Oil Pan Upper
Bolt Tightening S If more than 20 minutes have elapsed, clean off the seal
Direction packing.
(f) Tighten the upper oil pan installation bolts in the order 1
ï 2 ï 3 ï 4 as shown in the illustration.
Rear Side Torque: 28.5 Nm (290 kgfcm, 21 ftlbf)
(g) Make sure that there is no deformation, impact marks or
Front Side
foreign particles on the mounting surface and stiffener
Lobe surface of the lower oil pan.
Oil Pan Gasket Upper
Oil Strainer
(h) Finish tightening the bolts in the order shown in the il-
lustration.
HINT:
Intake Port Side A63438 Make sure that the washer is not on the flange.
S05CïB Bolt Tightening Direction (i) Install the upper oil pan gasket so that the protrusion will
3 be on the flywheel housing side and the print seal surface
4 will be on the cylinder block side.
(j) Install the upper oil pan.
2
1 HINT:
S Install the upper oil pan along the guide pin.
S If more than 20 minutes have elapsed, clean off the seal
Back packing.
(k) Tighten the upper oil pan installation bolts in the order 1
Front
ï 2 ï 3 ï 4 as shown in the illustration.
Protrusion Torque: 28.5 Nm (290 kgfcm, 21 ftlbf)
Oil Strainer (l) Finish tightening the bolts in the order shown in the il-
lustration.
HINT:
Make sure that the washer is not on the flange.
Intake Side
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A70970
19. INSTALL CRANKSHAFT PULLEY

(a) Apply clean engine oil to the threads of the crankshaft
pulley bolt. Be sure to tighten 2 or 3 threads provisionally
by hand. Then, tighten the crankshaft pulley 6 bolts with
a lowïtorque impact wrench.
(b) Tighten the crankshaft pulley bolts.
(c) Loosen all the bolts and tighten them again.
A64128
14ï39
ENGINE MECHANICAL ï TIMING GEAR
TIMING GEAR
1417Nï01
COMPONENTS
Camshaft Timing Gear
Main Idler Gear Camshaft Idler Gear
Sub Idler Gear
Vacuum Pump Gear
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Power Steering
Pump Gear Oil Pump Drive Gear
Supply Pump
Drive Gear
Crankshaft Timing Gear
Rear End Plate Camshaft

Camshaft Idler Gear
108 (1,100, 80)
Idler Gear Thrust Plate
Sub Idler Gear 108 (1,100, 80)
172 (1,750 127)

Supply
Pump Gear
z Gasket
Idler Gear Shaft
55 (560, 41)
Main Idler Gear
z Gasket

A64141
14ï40
1417Oï01
OVERHAUL
1. REMOVE MAIN IDLER GEAR

(a) Remove the mounting bolts of the main idler gear shaft.
(b) Remove the main idler gear.
A60057
(c) Using a sliding hammer, drive out the main idler gear
shaft.
(1) Check the teeth of each gear for wear and pitching.
If there is damage, replace the gear.
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A64446
2. REMOVE SUB IDLER GEAR

(a) Remove the mounting bolts of the sub idler gear shaft.
(b) Remove the sub idler gear.
A63419
(c) Using a sliding hammer, drive out the sub idler gear shaft.
(1) Check the teeth of each gear for wear and pitching.
If there is damage, replace the gear.
A64447
14ï41
3. REMOVE OIL PUMP ASSY
A63420
4. REMOVE REAR END PLATE

(a) Using a socket wrench, remove the 2 torx bolts adjacent
to the supply pump drive shaft mounting section.
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Rear End Plate
A16232
A16124 A63421
5. INSPECT OIL CLEARANCE BETWEEN MAIN IDLER

GEAR BUSH AND SHAFT
(a) Using a micrometer, measure the diameter of the main
idler gear shaft.
Standard shaft diameter:
56.94 ï 56.97 mm (2.2422 ï 2.2430 in.)
A63423

the main idler gear bush.
Standard inside diameter:
57.00 ï 57.03 mm (2.2441 ï 2.2453 in.)
(c) Calculate the clearance from the above measurements.
Oil clearance:
Standard 0.030 ï 0.090 mm (0.0012 ï 0.0035 in.)
Maximum 0.20 mm (0.0079 in.)
A63422
14ï42

main idler gear shaft and/or main idler gear bush.
6. INSPECT OIL CLEARANCE BETWEEN SUB IDLER

GEAR BUSH AND SHAFT
(a) Using a micrometer, measure the outside diameter of the
sub idler gear shaft.
Standard shaft diameter:
49.950 ï 49.975 mm (1.9665 ï 1.9675 in.)
A63425

the sub idler gear bush.
50.000 ï 50.025 mm (1.9685 ï 1.9695 in.)
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(c) Calculate the oil clearance from the above measure-
ments.
Oil clearance:
Standard 0.025 ï 0.075 mm (0.0010 ï 0.0030 in.)
A63424 Maximum 0.20 mm (0.0079 in.)
If the oil clearance is greater than the maximum, replace the sub
idler gear shaft and/or sub idler gear bush.
7. INSTALL REAR END PLATE

Rear End Plate (a) Insert a new gasket between the block and plate.
(b) Apply adhesive to threads of the 2 torx bolts.
Adhesive:
Part No. 08833ï00070, THREE BOND 1324 or equiva-
lent.
(c) Using a wrench, tighten the 2 torx bolts adjacent to the
supply pump drive shaft mounting section to the specified
torque below.
(d) Tighten the 3 bolts as shown in the illustration to the speci-
fied torque below.
HINT:
S Be careful that the gasket should not be moved off the
proper place.
S Always use a new gasket.
A16124
A16232 A63427
14ï43
8. INSTALL OIL PUMP ASSY

(a) Apply oil to the pump case and bearings of the block
(hatched area) before installing the oil pump.
HINT:
Not applying oil may cause oil suction failure at start up, result-
ing in seizure and abnormality.
(b) To prevent misalignment of the gasket, apply engine oil
to the gasket matching face of the block. Then, place and
fix the gasket.
(c) Tighten the oil pump mounting bolts provisionally in the
Apply Oil (Hatched Area)
order as shown in the illustration. Then, retighten them.
(d) Check that the gear rotates smoothly by hand after the
installation.
A63428 HINT:
Be sure to observe the tightening order of the bolts, otherwise
the oil pump will be damaged.
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Thrust Plate
Camshaft Timing Gear
Cylinder
Main Idler Gear Camshaft Idler Gear Block Oil Hole
CïC Section
A B
Sub Idler Gear
Vacuum Pump Gear
B Oil Pump Drive Gear

Supply Pump
Drive Gear A
Cylinder
Crankshaft Timing Gear Block
BïB Section
Match- Thrust Plate

Match-
Marks
Marks
(2)
(1)
Oil Hole
Cylinder
A16237
Block AïA Section
A16238
A16125 A16235 A63429
14ï44
9. INSTALL SUB IDLER GEAR

(a) Install the sub idler gear shaft through the thrust plate so
that the lubrication hole faces downward.
(b) Install the sub idler gear.
(1) Apply engine oil to the seat and thread of the bolt.
(c) Tighten the mounting bolts of the sub idler gear shaft.
A63430
10. INSPECT SUB IDLE GEAR THRUST CLEARANCE

Thrust Clearance (a) Using a dial gauge, measure the clearance between the
sub idler gear and thrust bearing.
Thrust clearance:
Thrust
Standard 0.040 ï 0.095 mm (0.0016 ï 0.0037 in.)
Bearing
Maximum 0.30 mm (0.0118 in.)
Move
Cylinder
Block thrust bearing.
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A64735
11. INSTALL MAIN IDLER GEAR

(a) Install the main idler gear shaft through the thrust plate so
that the lubrication hole faces downward.
(b) Install the main idler gear.
HINT:
S Apply engine oil to the contact surface of the idler gear
and idler gear shaft before the installation.
S Adjust the timing of the main idle gear to align it with the
A63431 supply pump gear.
(c) Tighten the mounting bolts of the main idler gear shaft to
the specified torque below.
Thrust 12. INSPECT MAIN IDLER GEAR THRUST CLEARANCE

Clearance (a) Using a dial gauge, measure the clearance between the
main idler gear and thrust bearing.
Standard thrust clearance:
Thrust Standard 0.114 ï 0.160 mm (0.0045 ï 0.0063 in.)
Bearing Maximum 0.20 mm (0.0078 in.)
Move If the thrust clearance is greater than the maximum, replace the
Cylinder
Block thrust bearing.
A60056
14ï45
13. INSPECT TIMING GEAR BACKLASH

(a) Using a dial gauge, measure the backlash between the gears.
Backlash:
Item Standard backlash Maximum backlash
Crankshaft x Main idler 0.030 ï 0.167 mm (0.0012 ï 0.0065 in.)
Main idler x Injection pump or Supply
0.030 ï 0.218 mm (0.0012 ï 0.0085 in.)
pump
Injection pump or Supply pump x PS
0.030 ï 0.183 mm (0.0012 ï 0.0072 in.)
pump
0 30 mm (0.0118
0.30 (0 0118 in.)
i )
Main idler x Sub idler 0.030 ï 0.162 mm (0.0012 ï 0.0063 in.)
Sub idler x Oil pump 0.030 ï 0.131 mm (0.0012 ï 0.0051 in.)
Sub idler x Camshaft idler 0.030 ï 0.299 mm (0.0012 ï 0.1693 in.)
Camshaft idler x Camshaft timing 0.028 ï 0.163 mm (0.0011 ï 0.0064 in.)
Sub idler x Vacuum pump 0.029 ï 0.187 mm (0.0011 ï 0.0073 in.)
If the backlash is greater than the maximum, replace the gear.
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14ï46
ENGINE MECHANICAL ï PISTON, CRANKSHAFT AND CYLINDER BLOCK
PISTON, CRANKSHAFT AND CYLINDER BLOCK

1417Pï01
COMPONENTS
Piston Pin
Piston
Retainer Ring Piston Ring
Camshaft
z Connecting Rod Bush
108 (1,100, 80)

Connecting Rod
z Connecting Rod Cap 172 (1,750, 127)
69 (700, 51) + 90_ + 45_
Main Idler Gear
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Cylinder Liner
Connecting Rod Bearing
Cylinder Block
Crankshaft Bearing Cap Oil jet

22 (220, 16)
69 (700, 51) + 90_ + 45_
Knock Pin
Crankshaft Crankshaft Gear
Crankshaft Pulley
Oil Seal
108 (1,100, 80)

Flywheel
186 (1,900, 137)
Crankshaft Bearing
Ring Gear

14ï47
1417Qï01
OVERHAUL
1. REMOVE PISTON AND CONNECTING ROD

(a) Remove the connecting rod bearing cap mounting bolts
and pull out the pistons along with the connecting rods
from the cylinder block upper side.
A64171
HINT:
S Before pulling out the pistons, remove carbon deposits
from the upper end inside the cylinder liner with a scraper
or an emery paper (recommended: No.150), working in a
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circular direction.
S When pulling out the pistons, be careful that the insides
of the cylinder liners are not damaged by the connecting
rod big ends.
A64172 S When pulling out the pistons, be careful that the nozzle of
the cooling jet should not be deformed. If it is deformed,
replace or correct it.
S When pulling out the pistons, be careful not to drop the
connecting rod bearings from the connecting rod big
ends, which may cause deformation or damage.
S Arrange the removed parts in the order of the cylinder
numbers. Be careful not to change the combination of the
connecting rod and cap.
S 2 pistons can be removed at a time (Nos. 1 and 4, Nos.
2 and 3).
2. REMOVE CRANKSHAFT
(a) Remove the bearing cap mounting bolts.
A64173
14ï48
(b) Remove the crankshaft.
A64176
3. REMOVE CYLINDER LINER

HINT:
Before removing the piston, put alignment marks on the cylin-
der liner and cylinder is bent by ”runïin”. When reusing the cyl-
inder liner, misalignment with the cylinder block may concen-
trate stress on the thin part of the cylinder liner and it may be
broken.
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A70971
(a) Remove the cylinder liner.

If this is difficult, use SST.
SST 09420ï1720
HINT:
SST Arrange the removed parts in the order of the cylinder numbers.
A64175
4. CLEAN CYLINDER BLOCK SUBïASSY

(a) Rinse the cylinder block in a hot commercial alkaline solution, and remove oil from the cylinder block.
(b) Remove the alkaline solution from the cylinder block using a steam cleaner.
(c) If the water jacket is dirty, clean it as follows.
(1) Rinse the cylinder block in a commercial acid solution.
(2) After rinsing the cylinder block for a while, immerse it in the solution for approximately 30 minutes.
(3) Pull out the cylinder block. After the solution has drained off, reïimmerse the cylinder block in
the solution and leave it for approximately 10 minutes.
(4) Repeat step 3 until deposits are removed.
(5) Remove the acid solution with hot water.
(6) Immerse the cylinder block in the alkaline solution to neutralize the acid.
(7) Finish by cleaning with a steam cleaner.
(d) When the cooling water passage and oil passage are cleaned completely, dry the cylinder block,
pressïfit a new blank cap and apply seal packing.
14ï49
5. REMOVE CONNECTING ROD SUBïASSY

(a) Using snap ring pliers, remove the retainer rings from the
both ends of the piston pin.
CAUTION:
Removing the retainer rings may cause the retainer rings
to fly up. Be sure to wear protective goggles.
(b) Using a hammer, apply the reinforcing plate to the piston
pin and punch out the piston pin.
A64177 HINT:
If it is difficult to punch out the piston pin, first immerse the piston
and piston pin in hot water 80 ï 90_C (176 ï 194_F) for approxi-
mately 5 minutes to facilitate removal.
CAUTION:
Never touch the piston with your bare hands when it is hot.
6. REMOVE PISTON RING

(a) Using a piston ring expander, remove the piston ring.
HINT:
S Handle the piston rings carefully because they are made
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of a special casting which is easily broken.
S Arrange the piston rings in the order of the cylinder num-
bers.
A64163
7. INSPECT CONNECTING ROD SUBïASSY

(a) Using dye penetrant examination or magnetic examina-
tion, check the connecting rod for cracks or damage.
If there are any cracks or damage, replace the connecting rod
with a new one.
A64178
(b) Check that there is no clogging in the lubrication passage

to the connecting rod small end.
If there is any clogging, blow air through the lubrication passage
using an air gun, or clean by inserting a wire.
A64179
14ï50
(c) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If the bend is greater than the maximum, replace the connecting
rod with a new one.
A64180
(2) Check for twist.

Maximum twist:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum, replace the connecting
rod with a new one.
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A64181
8. INSPECT PISTON PIN

(a) Using a micrometer, measure the piston pin diameter.
Standard pin diameter:
36.989 ï 37.000 mm (1.453 ï 1.4567 in.)
Minimum pin diameter: 36.96 mm (1.4551 in.)
If the diameter is less than the minimum, replace the piston pin
with a new one.
HINT:
A64182 Never grind the piston pin, because the surface is coated with
a special material.
9. INSPECT CONNECTING ROD SMALL END BUSH
(a) Using a cylinder gauge, measure the connecting rod bush
inside diameter.
37.015 ï 37.025 mm (1.4573 ï 1.4577 in.)
Maximum inside diameter: 37.10 mm (1.4606 in.)
connecting rod bush with a new one.
A64183 (b) Calculate the oil clearance between the piston pin and
piston pin bush.
Standard oil clearance:
0.015 ï 0.036 mm (0.0006 ï 0.0014 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the oil clearance is greater than the maximum, replace the pis-
ton with a new one.
14ï51
10. INSPECT CONNECTING ROD BIG END

(a) After tightening the connecting rod cap without bearing,
using a cylinder gauge, measure the inside diameter of
the connecting rod big end to calculate the roundness.
68.985 ï 69.000 mm (2.7159 ï 2.7165 in.)
HINT:
For tightening of the connecting rod cap, see step 34.
If the diameter is greater than the maximum, replace the con-
necting rod big end a new one.
A16307
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A16309 A64184
11. INSPECT CRANKSHAFT PIN AND BEARING

(a) Using a micrometer, measure the crankshaft pin diame-
ter.
Standard crankshaft pin diameter:
64.940 ï 64.960 mm (2.5566 ï 2.5575 in.)
Minimum crankshaft pin diameter:
63.80 mm (2.5118 in.)
If the diameter is less than the minimum, replace the crankshaft
pin a new one.
X
Y Y’
X’
A16433
A16310 A64185
14ï52
(b) Using a cylinder gauge, measure the connecting rod

bearing inside diameter.
64.991 ï 65.022 mm (2.5587 ï 2.5599 in.)
(c) Calculate the clearance between the crankshaft pin and
connecting rod bearing.
Standard clearance:
0.031 ï 0.082 mm (0.0012 ï 0.0032 in.)
Maximum clearance: 0.20 mm (0.0079 in.)
If the clearance is greater than the maximum, replace the con-
necting rod bearing with the correct one.
Undersize machining dimension: 2 sizes below
Undersize machining dimension:
0.25 mm (0.0098 in.) 0.50 mm (0.0197 in.)
A16307
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A16308 A64186
HINT:
Machined dimension of filet R
Crankshaft pin: 5.0 ï 5.5 mm (0.20 ï 0.21 in.)
CORRECT WRONG
A64217
12. INSPECT PISTON AND CYLINDER LINER

HINT:
Before the measurement, remove carbon deposits from the up-
per end inside the cylinder liner with a scraper or an emery pa-
per (recommended: No.150), working in a circular direction.
Make sure that there is no scratches inside the cylinder liner.
A64171
14ï53
(a) Using a micrometer, measure the piston diameter at the

in the illustration points.
Standard piston diameter:
S05CïB:
113.920 ï 113.944 mm (4.4850 ï 4.4859 in.)
S05CïTA, TB:
113.869 ï 113.885 mm (4.4830 ï 4.4837 in.)
Minimum piston diameter: 113.869 mm (4.4850 in.)
If the piston diameter is less than the minimum, replace the pis-
ton with a new one.
Outside
Diameter
(0.83 in.)
21 mm
A16311
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A16312 A64187
(b) Using a cylinder gauge, measure the cylinder liner inside

diameter at the 4 points in the piston boss and thrust
direction, as shown in the illustration.
113.988 ï 114.012 mm (4.4877 ï 4.4886 in.)
cylinder liner with a new one.
A64188 HINT:
S Apply the value measured at the most worn point to the
cylinder liner inside diameter.
S If the cylinder liner is heavily wornor if only the piston ring
must be replaced, correct the corrugation at the top of the
cylinder liner.
(c) Measure the clearance between the piston and cylinder

160 (6.30)
20 (0.79)
40 (1.57)
80 (3.15)
liner.
Standard clearance:
S05CïB:
0.056 ï 0.080 mm (0.0022 ï 0.0031 in.)
S05CïTA, TB:
0.0515 ï 0.0715 mm (0.0020 ï 0.0028 in.)
mm (in.) Maximum clearance: 0.15 mm (0.0059 in.)
A64189 If the clearance is greater than the maximum, replace the cylin-
der liner and/or piston with a new one.
HINT:
Apply the value measured at the most worn point to the cylinder
liner inside diameter.
14ï54
13. INSPECT PISTON PIN BOSS

(a) Using a cylinder gauge, measure the piston pin boss in-
side diameter.
Standard piston pin boss inside diameter:
36.987 ï 37.003 mm (1.4561 ï 1.4568 in.)
Maximum piston pin boss inside diameter:
37.05 mm (1.4587 in.)
A64190 piston with a new one.
(b) Calculate the clearance between the piston pin and the
piston pin boss.
Standard clearance:
(ï0.00051 (T) ï 0.00055 (L) in.) ï0.013 (T) ï 0.014 (L)
mm
Maximum oil clearance: 0.05 mm (0.0020 in.)
HINT:
T = tightening allowance, L = clearance
If the clearance is greater than the maximum, replace the piston
or piston pin.
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14. INSPECT PISTON RING AND PISTON RING GROOVE
(a) Insert the piston ring into the piston ring groove.
(b) Using a feeler gauge, measure the clearance between
the piston ring and piston ring groove.
Clearance:
S05CïB
Item Standard Maximum
0.06 ï 0.10 mm
1st ring 0.30 mm (0.0118 in.)
A64191 (0.0024 ï 0.0039 in.)
0.04 ï 0.08 mm
2nd ring 0.30 mm (0.0118 in.)
(0.0016 ï 0.0031 in.)
0.02 ï 0.06 mm
Oil ring 0.20 mm (0.0079 in.)
(0.0008 ï 0.0023 in.)
Clearance:
S05CïTA, TB
0.09 ï 0.13 mm
1st ring 0.20 mm (0.0078 in.)
(0.0035 ï 0.0051 in.)
0.07 ï 0.11 mm
2nd ring 0.18 mm (0.0070 in.)
(0.0016 ï 0.0031 in.)
0.02 ï 0.06 mm
Oil ring 0.13 mm (0.0051 in.)
(0.0007 ï 0.0023 in.)
If the clearance is greater than the maximum, measure the

width of the piston ring and piston ring groove individually and
replace any parts that do not meet the limit with new ones.
14ï55
Groove width:
S05CïB
2.55 ï 2.57 mm
1st ring 2.70 mm (0.1062 in.)
(0.1003 ï 0.1011 in.)
2.03 ï 2.05 mm
2nd ring 2.20 mm (0.0866 in.)
(0.0799 ï 0.0807 in.)
4.01 ï 4.03 mm
Oil ring 4.10 mm (0.1614 in.)
(0.1578 ï 1586 in.)
Groove width:
S05CïTA, TB
2.58 ï 2.60 mm
1st ring 2.70 mm (0.1062 in.)
(0.1015 ï 0.1023 in.)
2.06 ï 2.08 mm
2nd ring 2.20 mm (0.0866 in.)
(0.0811 ï 0.0818 in.)
4.01 ï 4.03 mm
Oil ring 4.10 mm (0.1614 in.)
(0.1578 ï 1586 in.)
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Ring thickness:
Item Standard Minimum
2.47 ï 2.49 mm
1st ring 2.40 mm (0.0944 in.)
(0.0972 ï 0.0980 in.)
1.97 ï 1.99 mm
2nd ring 1.90 mm (0.0748 in.)
(0.0775 ï 0.0783 in.)
3.97 ï 3.99 mm
Oil ring 3.90 mm (0.1535 in.)
(0.1562 ï 0.1570 in.)
A70972
15. INSPECT PISTON RING GAP

(a) Fit the piston ring into the cylinder liner.
(b) Using a feeler gauge, measure the end gap of the piston
ring matching point.
Clearance:
0.30 ï 0.40 mm
1st ring 1.50 mm (0.0590 in.)
(0.0119 ï 0.0157 in.)
A64192 0.50 ï 0.65 mm
2nd ring 1.20 mm (0.0472 in.)
(0.0197 ï 0.0255 in.)
0.15 ï 0.30 mm
Oil ring 1.20 mm (0.0472 in.)
(0.0059 ï 0.0118 in.)
If the end gap is greater than the maximum, replace the piston
ring with a new one.
14ï56
16. INSPECT CRANKSHAFT

HINT:
Before the inspection, clean the crankshaft with a commercial
cleaning agent and clean the lubrication passage using an air
gun.
A64193
(a) Performing the dye penetrant test, and check the crank-
shaft for cracks.
HINT:
Pay special attention to the finished R section and oil hole of the
crankshaft journal and crankpin.
(b) Visually check the condition of the crankshaft journal and
pin for damage or wear.
If any damage are found, replace the crankshaft with a new
one.
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A64194
(c) Inspect for circle runout.

(1) Place the crankshaft on Vïblocks.
(2) Using a dial gauge, measure the circle runout of the
crankshaft at the center journal.
Maximum circle runout: 0.15 mm (0.0059 in.)
If the circle runout is greater than the maximum, replace the
crankshaft with a new one.
A64214
17. INSPECT CRANKSHAFT BEARING CAP

(a) After tightening the main bearing caps without bearing,
using a cylinder gauge, measure the inside diameter of
the main bearing caps to calculate the roundness.
Inside diameter:
Standard 84.985 ï 85.000 mm (3.3459 ï 3.3465 in.)
Maximum 85.20 mm (3.3543 in.)
If the inside diameter is greater than the maximum, carry out
boring after overlay welding or replace the cylinder block with
a new one.
HINT:
S When installing the main bearing caps, make sure to re-
turn them to the original position according to the number
stamped on the caps. The main bearing caps together
with the cylinder block are round.
S For tightening of the main bearing caps, see step 28.
A16435
A16317
A64216
14ï57
18. INSPECT CRANKSHAFT JOURNAL AND BEARING

(a) Using a micrometer, measure the main journal outside di-
ameter.
Standard journal diameter:
79.940 ï 79.960 mm (3.1472 ï 3.1480 in.)
Minimum journal diameter:
Repair 79.80 mm (3.1417 in.)
Use 78.80 mm (3.1024 in.)
If the diameter is less than the minimum for use, replace the
X
crankshaft with a new one.
Y Y’
X’
A16436
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A16310 A64197
(b) After installing and tightening the bearing caps, using a

cylinder gauge, measure the bearing inside diameter.
Inside diameter:
Maximum 80.30 mm (3.1614 in.)
bearing with a new one.
HINT:
S When installing the bearing caps, make sure to return
them to the original position according to the number
stamped on the caps. The bearing caps together with the
cylinder block are round.
S For tightening of the bearing cap, see step 28.
(c) Calculate the oil clearance between the crankshaft jour-
nal and bearing.
Oil clearance:
Standard 0.051 ï 0.102 mm (0.0020 ï 0.0040 in.)
A16435
A16317
Maximum 0.20 mm (0.0079 in.)
A64216
Undersize machining dimension:

0.25 mm (0.0098 in.) 0.50 mm (0.0197 in.)
bearing with a correct one.
14ï58
HINT:
Make sure to replace the top and bottom main bearings as one
set. The top and bottom main bearings must be round.
HINT:
Machined dimension of filet R
Main crankshaft journal:
CORRECT WRONG 5.0 ï 5.5 mm (0.1969 ï 0.2165 in.)
A64217
19. INSPECT CYLINDER BLOCK SUBïASSY

(a) Remove the water gallery plug, and visually check the
condition of the worn hole.
If the wear is excessive, replace the part with a new one. Also
inspect the inside of the cylinder block, and clean the cylinder
block main body with a commercial cleaning agent as required.
(b) Check the cylinder for cracks.
Check the cylinder block for cracks and perform the dye
penetrant test.
cardiagn.com
If any cracks are found, replace the cylinder block with a new
one.
(c) Check the flatness of the cylinder block upper surface.
Using a straight edge and feeler gauge, measure the war-
page of the surfaces contacting the cylinder head.
Standard warpage: 0.05 mm (0.0020 in.) or less
If the warpage is greater than the maximum, replace the cylin-
der block with a new one.
A16318
A16291 A64308
20. REMOVE CHECK VALVE AND OIL JET

(a) Remove the 4 check valves and 4 oil jets.
A64513
21. INSPECT CHECK VALVE

(a) Using a wooden stick, push the valve and check if it is
stuck.
Push If stuck, replace the check valve.
A64514
14ï59
22. INSPECT OIL JET

(a) Check the oil jet for damage or clogging.
If necessary, replace the oil jet.
A64515
23. ADJUST OIL JET

(a) Align the pin of the jet with the pin hole of the cylinder
Oil Jet
block.
(b) Using SST, install the jet with SST.
SST 9001ï24262
SST
(c) Connect a commercial oil pump (hydraulic pressure: 2
kgf/cm2 (28 lb/psi.)) to the SST using a hose.
Oil Hose
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A64198
(d) Set the SST on the cylinder block upper surface against
SST the dowel pin.
SST 09444ï1630
Cylinder Block
A64309
(e) Start the oil pump, let the engine oil spray out the oil jet
to check that the center of the jet flow is within the ø 7 mm
(ø 0.27 in.) reference line of the gauge as well as to judge
Spray Target whether the jet flow is normal as shown in the illustration.
NOTICE:
S Use new engine oil.
S Engine oil is flammable.
Abnormal Abnormal Normal Normal
S This spray test should be performed in a well venti-
lated room and away from any open flames or electric
Spray Pattern sparks.
Spray
Oil Jet
Abnormal
A16248
A16319 A64310
14ï60
If the center of the jet flow is out of the ø 7 mm (ø 0.27 in.) refer-
ence line of the gauge, adjust the jet sight using the SST.
(f) Remove the checking bolt after the inspection.
SST 09472ï1620
SST
A64311
24. INSTALL CHECK VALVE AND OIL JET

(a) Align the pin of the jet with the pin hole of the cylinder block.
(b) Install the jet with the check valve.
Torque: 22 N·m (220 kgf·cm, 16 ft·lbf)
NOTICE:
S Always install the soft washer.
S When installing the piston, make sure that the oil jet is not struck by the piston when at bottom
dead center.
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25. INSTALL CONNECTING ROD SMALL END BUSH
Wing Nut (a) Prepare the SST.
SST 09402ï1480, 09481ï1140, 9233ï10360
Guide (1) Assemble the guide and press subïassy inserting
its pin into the guide, then secure them with the wing
nuts.
Press Subïassy A64165
HINT:
Connecting Rod S Bring lever ”H” punched on the guide above the pin.
S Make sure to align both supporting surfaces of the guide
and press subïassy flush on a flat plane.
(b) Using SST, remove the bush.

(1) Set the connecting rod assembled without crank-
Guide shaft pin bore bearing on the guide and press subï
Press Subïassy
A64166 assy.
(2) Using a SST, install the spindle into the bush.

Groove SST 09402ï1540
Spindle
HINT:
Bushing Align the grooving of the spindle with the oil hole of the bush.
Connecting Rod
Oil Hole
Press Subïassy
A64167
14ï61
(3) Using a press, remove the bush.

Press
HINT:
Spindle
Always operate the press slowly and smoothly.
Connecting Rod
A64168
(c) Assemble the bush.

C 0.5 ï 1.0 mm (1) Chamfer one edge of the bush hole at the small end
of the connecting rod uniformly by C 0.5 ï 1.0 mm
(0.0196 ï 0.0393 in.)
HINT:
Irregular chamfering can cause outïofïroundness of the
pressed bushing, which may result in jamming during insertion.
Remove dust from the inner surface of the smaller hole.
Connecting Rod
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A64199
(d) Mount the bushing on the spindle.

Spindle
SST 09402ï1540, 09481ï1540, 9191ï08252
Groove (1) Set the bushing and guide on the spindle, then se-
cure them with the bolt.
Oil Hole Oil Hole Torque: 4.9 ï 6.9 Nm (50 ï 70 kgfcm, 43 ï 61 in.lbf)
(B) (A) HINT:
Align oil hole (A) in the bushing with both groove or the spindle
Guide Bushing Groove and guide, making sure that the oil hole (B) will meet with oil
Bolt Guide A64200 path in the connecting rod led from the big end bore in the rod.
(2) Apply fresh engine oil around the bush and guide.
Press
(e) Install the bush in the connecting rod. Position the bush
Spindle tool assembly so that the oil hole (B) aligns with the oil
Oil Hole (B)
Bush path through the connecting rod.
Guide HINT:
Oil Path Before installing, fully coat the bore in the connecting rod with
Connecting Rod
fresh engine oil.
A64201
(f) Inspect the bush positioning after the installation.

(1) Make sure that the oil hole of the bush and the oil
path of the connecting rod are suitably aligned al-
lowing a 6 mm (0.23 in.) diameter rod to penetrate.
HINT:
Misalignment can lead to insufficient lubrication, which may re-
sult in seizure.
(2) Make sure that the bushing can be rotated by hand
A64202 withïout rattling while a new piston pin is inserted
in the piston pin.
14ï62
26. INSTALL CYLINDER LINER

Marks of Liner HINT:
S When assembling the cylinder liner with the cylinder
block, clearance can be set to three levels.
S When using a new cylinder liner, the upper surface and
side surface of the cylinder block are stamped A, B or C.
Insert a matching cylinder liner having the same symbol.
A64203
S When reusing a cylinder liner, install it according to the

alignment marks made during removal. The cylinder liner
is bent by ”runïin”. When reusing the cylinder liner, mis-
alignment with the cylinder block may concentrate stress
on the thin part of the cylinder liner and it may be broken.
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A70971
27. INSPECT PROTRUSION OF CYLINDER LINER

SST (a) Install SST onto the cylinder block.
SST 09420ï1720
(b) Tighten the center bolt to the specified torque below to set
the cylinder liner in the normal installation condition.
Torque: 9.8 N·m (100 kgf·cm, 87 in.·lbf)
A64204
(c) Using a dial gauge, measure the protrusion of the cylinder

Pressure: 4,903 N (500 kgf, 1,100 lbf) liner.
Standard protrusion:
0.01 ï 0.08 mm (0.0004 ï 0.0031 in.)
Maximum protrusion: 0.08 mm (0.0031 in.)
Protrusion
If the protrusion is greater than the maximum, replace the cylin-

der liner.
A64205A
28. INSTALL CRANKSHAFT

(a) Install the main bearings onto the cylinder block and main
bearing caps.
HINT:
S When reusing a bearing, make sure to reassemble the re-
moved bearing as it was originally installed.
S Install the bearing with the oil hole on the block side and
the bearing without the oil hole on the cap side.
A64206 S Match the bearing protrusion with the notch of the block
or cap.
14ï63
S After the installation, apply engine oil to the journal sur-

faces of the bearings.
(b) Install the thrust washers onto the 4 points of the No. 2
journal of the cylinder block and either side of the bearing
caps.
(c) Install the crankshaft onto the cylinder block.
A64176
HINT:
S When reusing a bearing, make sure to reassemble the re-
moved bearing as it was originally installed.
S Install the thrust washers with the groove side (front) to-
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ward the crankshaft arm and with the part number stamp
(back) toward the main bearing cap or cylinder block.
S Apply engine oil or grease to the back of the bearing to
prevent looseness during installation.
S Fit the bearing to the mounting groove of the block and
cap side.
(d) Install the bearing cap.
HINT:
Facing the arrow stamped on the cap forward, install it in the or-
der of the stamped numbers.
A64312
(1) Measure the length of the bearing cap bolts.

Length (A):
Standard 106.80 mm (4.2047 in.)
Maximum 108.00 mm (4.2520 in.)
If the length is greater than the maximum, replace them with
new bolts.
(2) Apply clean engine oil to the bolt seat and bolt
threads.
A64313
14ï64
(3) Tighten the bolts in the order shown in the illustra-

tion.
(4) Loosen all the bolts.
Front
(5) Tighten the bolts as in step (3).
A64314
(6) Mark the bolts with paint to indicate the same direc-
Paint Mark tion.
(7) Tighten the bolts by 90˚ (1/4 turn) in the same order
as in step (5).
(8) Finally, retighten the bolts by 45˚ (1/8 turn) as in
step (7).
(9) Make sure that all the paint marks face the same
direction.
HINT:
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A64315
(10) After tightening, using a plasticïfaced hammer, tap
the front and back ends of the crankshaft to make
a complete fit.
29. INSPECT CRANKSHAFT THRUST CLEARANCE

(a) Using a dial gauge, measure the crankshaft thrust clear-
ance.
Thrust clearance:
Standard 0.050 ï 0.239 mm (0.0020 ï 0.0094 in.)
Maximum 0.50 mm (0.0197 in.)
thrust bearing with the oversized one of 0.25 mm (0.0098 in.).
A64207
30. INSTALL CONNECTING ROD SUBïASSY

Piston Identification Symbol HINT:
S Before assembling the piston with the connecting rod,
check whether the piston is specified for this engine
S Check should be performed using the engine compatible
identification code on the top of the piston.
S05CïB:
Engine compatible identification code: 80
80 or 89 A64208 S05CïTA, TB:
Engine compatible identification code: 89
(a) Install a new retainer ring onto one end of the piston boss.
HINT:
Installing the retainer ring may cause it to fly up. Be sure to wear
protective goggles.
14ï65
(b) Immerse the piston in hot water, 80 ï 90˚C (176 ï 194˚F)

for approximately 5 minutes.
(c) Assemble the piston with the O mark being opposite to

O Mark Piston
the connecting rod matchmark.
CAUTION:
Never touch the piston with your bare hands while it is hot.
Oil Hole
Match Marks
A64317
(d) Insert the piston pin into the piston.

HINT:
S Insert the piston pin from the piston boss attached to the
retainer ring so that the ring groove is not damaged.
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(e) Install a new retainer ring to the other end of the piston
boss.
CAUTION:
Installing the retainer ring may cause it to fly up. Be sure
A64316 to wear protective goggles.
HINT:
S When using an oversized piston, hone the liner so that the
clearance between the cylinder liner and the piston.
S Prevent parts from damage by wrapping them in a cloth
while they are being installed onto the cylinder block.
S Measure the entire length of the connecting rod bolt (see
step 34).
14ï66
31. INSTALL PISTON RING

Ring Upper Face (a) Facing the identification marks on the piston ring upper
surface, install them in the order of oil ring, 2nd ring and
1st ring using a piston ring expander.
HINT:
S Never change the combination of the coil and oil ring.
Identification S Connect the joint of the coil expander for the oil ring and
Mark install it inside the piston ring. Assemble the ring with the
joint 180˚opposite to the matching point of the ring.
1st Ring 2nd Ring Oil Ring
Joint
Gap
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A64209A
HINT:
Top Ring Position the matching points of the piston ring at an even dis-
O Mark
tance. Be careful not to position at the piston boss.
Oil Ring 2nd Ring

A64318
32. INSTALL CONNECTING ROD BEARING

NOTICE:
S When reusing the bearing, make sure to reassemble
the removed bearing as it was originally installed.
S Install the bearing with the oil hole on the connecting
rod side and the bearing without the oil hole on the
cap side.
S Match the bearing protrusion with the notch of the
A64210 connecting rod or cap.
33. INSTALL PISTON AND CONNECTING ROD

(a) Using a piston ring compressor and a hammer handle, in-
sert the piston through the connecting rod assembly into
the cylinder block.
A64211
14ï67
HINT:
S Before the installation, apply engine oil to the piston pin,
piston ring, cylinder liner and connecting rod bearing.
S Recheck the matching point of each piston ring.
Oil Jet
A64319
S Make sure that the O mark on the piston is at the exhaust

Exhaust Port Side O Mark
side.
S When inserting the piston, be careful that the oil jet is not
struck by the connecting rod. If struck, make sure to re-
check the sight of the oil jet.
S Also, do not damage the inside of the liner.
Intake Port Side
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A64320
34. INSTALL CONNECTING ROD CAP
A64212
(a) Measure the length of the bolts.

Length (A):
Maximum 82.5 mm (3.2480 in.)
A If the length is greater than the maximum, replace them with

new ones.
(b) Apply clean engine oil to the nut seat surface and bolt
thread of the connecting rod cap.
A64321
(c) Tighten the connecting rod nut in the order shown in the
Paint Mark illustration to the specified torque below.
(1) Tighten the connecting rod nuts 1 and 2 temporarily,
dividing into small amount.
(d) Mark the cap nut with paint to indicate the same direction.
(e) Tighten the cap nut by 90˚ (1/4 turn) in the same order as
in step (c).
A64322 (f) Tighten the cap nut by 45˚ (1/8) turn as in step (e).
(g) Make sure that all paint marks face the same direction.
14ï68
(h) Turn the crank to make the piston in the bottom dead cen-
ter, and then check that the piston and oil jet nozzle of the
block do not interfere each other.
HINT:
been overtightened.
35. INSPECT CONNECTING ROD THRUST CLEARANCE

(a) Using a dial gauge, measure the clearance between the
connecting rod and crank pin end surface.
Standard thrust clearance:
0.20 ï 0.52 mm (0.0079 ï 0.0204 in.)
Maximum thrust clearance: 1.00 mm (0.0393 in.)
connecting rod.
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A64213
EXHAUST
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 15ï1

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15ï1
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15ï1
EXHAUST ï EXHAUST MANIFOLD
EXHAUST MANIFOLD
1508Lï01
INSPECTION
S05CïTA 1. INSPECT EXHAUST MANIFOLD

S05CïTB HINT:
Clean the exhaust manifold with a commercial cleaning agent
before the inspection.
(a) Using a dye penetrate, check the exhaust manifold for
cracks.
If cracks are found, replace the manifold.
S05CïB
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A64170
A71648 A77930
(b) Using a precision straight edge and feeler gauge, mea-

sure the surface contacting the cylinder head for war-
page.
If the warpage is greater than the maximum, correct the exhaust
manifold by grinding it so that the warpage is within 0.1 mm
(0.004 in.) per 2 flanges or 0.1 mm (0.004 in.) per flange.
If damage such as deformation and wear is excessive, replace
A64097 the manifold.
COOLING
WATER PUMP ASSY . . . . . . . . . . . . . . . . . . . . . 16ï1

OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16ï1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 16ï3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16ï3
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16ï1
COOLING ï WATER PUMP ASSY
WATER PUMP ASSY

160KSï01
OVERHAUL
1. REMOVE WATER PUMP ROTOR

(a) Using SST, remove the rotor.
SST SST 09420ï1820
B58339
2. REMOVE WATER PUMP PULLEY SEAT

(a) Remove the 4 stud bolts.
(b) Using SST, remove the pulley seat.
SST 09950ï50013 (09951ï05010, 09952ï05010,
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SST
09953ï05010, 09954ï05021)
B58340
3. REMOVE WATER PUMP BEARING & SHAFT

SUBïASSY
(a) Using snap ring pliers, remove the snap ring.
B58341
(b) Using SST and a press, press out the bearing and shaft.
SST 09236ï00101 (09237ï00050)
SST
B58342
16ï2
COOLING ï WATER PUMP ASSY
4. REMOVE WATER PUMP SEAL SET

(a) Using SST and a press, press out the seal.
SST 09236ï00101 (09236ï15010)
SST
B58343
5. INSTALL WATER PUMP BEARING & SHAFT

SUBïASSY
(a) Using a press, press in the bearing and shaft into the
place, as shown in the illustration.
SST 09482ï2060A
Reference value: 5 mm (0.20 in.)
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B58344
6. INSTALL WATER PUMP SEAL SET

(a) Using SST, install the seal set.
SST SST 09236ï00101 (09237ï00020)
B58345
7. INSTALL WATER PUMP ROTOR

(a) Using a press, press in the water pump rotor flush against
the end of the bearing and shaft.
B58346
8. INSTALL WATER PUMP PULLEY SEAT

(a) Using SST and a press, press in the pump pulley set into
the place, as shown in the illustration.
SST 09238ï47012
Reference value: 6.3 mm (0.25 in.)
SST
B58347
16ï3
COOLING ï THERMOSTAT
THERMOSTAT
160KTï01
INSPECTION
1. INSPECT THERMOSTAT CASE ASSY

HINT:
The thermostat is numbered with the valve opening tempera-
ture.
76.5 _C
A64555
(a) Immerse the thermostat in water and gradually heat the

water.
(b) Check the valve opening temperature.
Valve opening temperature:
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74.5 ï 78.5˚C (166 ï 173˚F)
If the valve opening temperature is not as specified, replace the
thermostat.
A57677
(c) Check the valve lift.

Valve lift: 10 mm (0.39 in.) or more at 90˚C (194˚F)
If the valve lift is not as specified, replace the thermostat.
(d) Check that the valve is fully closed when the thermostat
is at low temperatures (below 40˚C (104˚F)).
If not closed, replace the thermostat.
Valve Lift
A57678
LUBRICATION
OIL PUMP ASSY . . . . . . . . . . . . . . . . . . . . . . . . . 17ï1

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 17ï1
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17ï2
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17ï5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17ï5
cardiagn.com
17ï1
LUBRICATION ï OIL PUMP ASSY
OIL PUMP ASSY

170EIï01
COMPONENTS
Oil Cooler with Oil Filter
24.5 (250, 18)
z OïRing
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z Gasket Oil Pump 28 (290, 20.7)
Driven Gear
Relief Valve
Relief Valve Spring
Seat
Seat
z Cotter Pin
z OïRing
28 (290, 20.7)
Oil Strainer
B58380
17ï2
170EJï01
OVERHAUL
1. REMOVE OIL PUMP DRIVEN GEAR

(a) Remove the driven gear from the oil pump.
NOTICE:
Since the drive gear is a pressïfit type, it can not be disas-
sembled.
B58348
2. REMOVE OIL PUMP RELIEF VALVE

(a) Pull out the cotter pin, and remove the 2 seats, relief valve
spring and safety valve.
NOTICE:
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Removing the cotter pin may cause the 2 seats and the re-
lief valve spring to spring out. Be sure to wear protective
goggles.
B58375
3. INSPECT OIL PUMP ASSY

(a) Visually check each part of the oil pump for damage or wear.
If damage or wear is excessive, replace the oil pump assembly with a new one.
(b) Inspect the backlash between the drive gear and driven
gear.
(1) Using a vise, fix the oil pump assembly.
(2) Using a dial gauge, measure the backlash between
the drive gear and driven gear.
Backlash:
Standard 0.073 ï 0.207 mm (0.0029 ï 0.0081 in.)
Maximum 0.3 mm (0.0118 in.)
B58376 If the backlash is greater than the maximum, replace the oil
pump assy with a new one.
17ï3
(c) Inspect the clearance between the diameter of the driven

gear shaft and the inside diameter of the driven gear
bush.
(1) Using a micrometer, measure the diameter of the
driven gear shaft.
Shaft diameter:
18.064 ï 18.082 mm (0.7112 ï 0.7119 in.)
B58377
(2) Using a dial gauge, measure the inside diameter of

the driven gear bush.
Inside diameter:
18.122 ï 18.147 mm (0.7135 ï 0.7144 in.)
(3) Calculate the difference between the diameter of
the driven gear shaft and the inside diameter of the
driven gear bush.
Clearance:
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B58378 Standard 0.040 ï 0.083 mm (0.0016 ï 0.0032 in.)
Maximum 0.15 mm (0.0059 in.)
If the oil clearance is greater than the maximum, replace the oil
pump assy or the driven gear bush.
4. INSTALL OIL PUMP RELIEF VALVE

(a) Attach the relief valve, relief valve spring and 2 seats onto
Safety Valve
the oil pump assembly.
Relief Valve
Spring
Seat 1
Seat 2
B58379
(b) Using a plasticïfaced hammer, lightly tap the cotter pin.
B58375
17ï4
5. INSTALL OIL PUMP DRIVEN GEAR

(a) Install the driven gear to the oil pump.
B58348
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17ï5
LUBRICATION ï OIL COOLER
OIL COOLER
170EKï01
INSPECTION
1. INSPECT OIL COOLER
NOTICE:
Before the inspection, please refer to the following items.
S Be sure to clean the oil cooler element and oil passage, using a commercial cleaning agent.
S Clean the metal parts using treated oil.
(a) Carry out a pneumatic test for the oil cooler element.
Test pressure:6 kg/cm2 (85.3 lb/sq.in.)
Test time: 1 minute
If defective, replace the oil cooler element with a new one.
(b) Visually check each part for damage or wear.
If the damage or wear is excessive, replace the safety valve
with a new one.
If the spring is flattened, replace the safety valve with a new
one.
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B58455
STARTING & CHARGING
STARTER ASSY . . . . . . . . . . . . . . . . . . . . . . . . . 19ï1

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 19ï1
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19ï2
GENERATOR ASSY . . . . . . . . . . . . . . . . . . . . . . 19ï10
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 19ï10
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19ï11
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19ï1
STARTING & CHARGING ï STARTER ASSY
STARTER ASSY
190LZï01
COMPONENTS
Lead Wire
Magnet Starter
Switch
4.3 (44, 38 in.·lbf)
z OïRing
14.7 (150, 11)
Brush Holder
Starter Yoke Assy
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14.7 (150, 11)
Commutator End Frame
Felt
Brush
Washer
Armature
Felt (Commutator)
Washer
Spring
Holder
z Dust Protector Cap

Drive Lever
Pin Motor Housing
Armature
Starter Drive Housing Bearing
z Starter Dust Protector
Pinion Gear 15 (153, 11)

Snap Ring
Rubber Seal
Plate
Starter Clutch
Bush

z Nonïreusable part B58440
19ï2
190M0ï01
OVERHAUL
1. REMOVE STARTER YOKE ASSY

Lead Wire M
Terminal M (a) Move the cap of terminal M, then remove the nut and lead
(Cap) wire M.
Terminal C
(Cap) (b) Move the cap of terminal C, then remove the bolt.
Lead Wire C
B58381
(c) Remove the 2 through bolts, and pull out the starter yoke
together with the armature.
HINT:
Hold the starter by hand so that it will not fall or drop.
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B58382
2. REMOVE STARTER COMMUTATOR END FRAME

ASSY
(a) Remove the 2 screws, commutator end frame and Oï
ring.
HINT:
Holding lead wire M, remove the bracket rear by taking it up-
ward.
B58383
3. REMOVE STARTER BRUSH HOLDER ASSY

(a) Using a screwdriver, hold the spring tank back and dis-
connect the brush from the brush holder.
(b) Disconnect the 4 brushes, and remove the brush holder.
B58384
4. REMOVE STARTER ARMATURE ASSY

(a) Remove the armature from the starter yoke assy.
(b) Remove the felt and washer from the armature.
19ï3
5. REMOVE MAGNET STARTER SWITCH ASSY

A
(a) Loosen the 2 bolts holding the magnet switch to the drive
housing.
(b) Pull out the magnet switch in direction B by tilting the up-
per part of the main switch in the direction A, as shown in
B
the illustration.
B58385
6. REMOVE MOTOR HOUSING

(a) Remove the bolt and motor housing.
(b) Remove the plate, spring and rubber seal from the drive housing.
7. REMOVE ARMATURE BEARING

SST
(a) Using SST, remove the bearing from the motor housing.
SST 09820ï63010
cardiagn.com
B58386
8. REMOVE PINION GEAR

(a) Fix the pinion softly, place 2 screwdrivers against the both
sides of the retainers opening port and then take the re-
tainer off by tapping those handles ends lightly with a
plastic hammer.
(b) Remove the pinion gear.
B58387
9. REMOVE STARTER CLUTCH SUBïASSY

(a) Remove the starter clutch together with the drive lever
Holder from the starter drive housing.
Lever
Rod
Shaft Assembly
B58388
10. REMOVE STARTER PINION DRIVE LEVER

(a) Remove the lever and shaft assembly out simultaneously from the pinion case.
(b) Pull out the rod and remove the holder from the lever.
11. REMOVE STARTER DUST PROTECTOR
(a) Remove the protector by prying it with a screwdriver.
19ï4
Ohmmeter
12. INSPECT STARTER ARMATURE ASSY
Continuity
(a) If the surface of the commutator is dirty or burned, polish
the part with sandpaper (#400) or replace the armature.
(b) Check the commutator open circuit.
(1) Using an ohmmeter, check that there is continuity
between the segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature assy.
B58389
Ohmmeter No Continuity (c) Check the commutator ground.

(1) Using an ohmmeter, check that there is no continu-
ity between the commutator and armature coil core.
If there is continuity, replace the armature assy.
cardiagn.com
B58390
(d) Check the commutator diameter.

(1) Using vernier calipers, measure the commutator di-
ameter.
Diameter:
Standard Minimum
32.0 mm (1.260 in.) 30.0 mm (1.181 in.)
If the diameter is less than the minimum, replace the armature
assy.
B58391
(e) Measure the undercut depth of the commutator.

(1) Check that the undercut depth is clean and free of
foreign materials. Smooth out the edge.
Undercut depth:
Standard Minimum
0.7 mm (0.028 in.) 0.2 mm (0.008 in.)
If the undercut depth is less than the minimum, correct it with
a hacksaw blade.
B58392
13. INSPECT STARTER YOKE ASSY

Continuity
(a) Using an ohmmeter, check that there is continuity be-
tween the lead wire and field coil brush lead.
Ohmmeter If there is no continuity, replace the starter yoke assy.
B58393
19ï5
(b) Inspect for ground.

No Continuity (1) Using an ohmmeter, check that there is no continu-
ity between the field coil end and starter yoke.
Ohmmeter If there is continuity, repair or replace the starter yoke assy.
B58394
14. INSPECT BRUSH

(a) Using vernier calipers, measure the brush length.
Length:
Standard Minimum
18 mm (0.709 in.) 12 mm (0.472 in.)
If the length is less than the minimum, replace the brush holder
and starter yoke assy.
cardiagn.com
B58419
15. INSPECT STARTER BRUSH HOLDER ASSY

Ohmmeter
No Continuity (a) Using an ohmmeter, check that there is no continuity be-
tween the positive (+) and negative (ï) brush holders.
If there is continuity, repair or replace the brush holder.
B58420
(b) Take the pull scale reading instant the brush spring sepa-
rates from the brush.
Installed load:
Standard Minimum
42.2 ï 51.0 N (4.3ï5.2 kgf, 9.3ï11.2 lbf) 22.5 N (2.3 kgf, 4.9 lbf)
If the installed load is less than the minimum, replace the brush
springs.
B58421
16. INSPECT MAGNET STARTER SWITCH ASSY

(a) Perform the pullïin coil open circuit test.
Using an ohmmeter, check that there is resistance be-
tween terminals M and C.
Standard resistance: 0.16 ï 0.19 :
(b) Perform the holdïin coil open circuit test.
Using an ohmmeter, check that there is resistance be-
tween terminal M and the switch body.
B58422 Standard resistance: 0.84 ï 0.94 :
19ï6
(c) Using an ohmmeter, check that there is continuity be-

Main Switch Assembly
M tween terminals B and M.
If there is continuity, replace the magnet switch assy.
(d) Push the main switch assembly, using an ohmmeter,
check that there is continuity between terminals B and M.
If there is no continuity, replace the magnet switch assy.
B
B58423
17. INSPECT STARTER CLUTCH SUBïASSY

(a) With the clutch fixed, turn only the inner sleeve right and
Clutch
left.
(b) Check that the inner sleeve turns lightly in the arrow mark
direction but does not turn in the opposite direction.
Inner
Sleeve
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B58424
(c) Using a micrometer, check each diameter of the starter

B A
clutch.
Diameter:
Standard Minimum
A: 26 mm (1.024 in.) A: 25.88 mm (1.019 in.)
B: 12.1 mm (0.476 in.) B: 12 mm (0.472 in.)
If the diameter is less than the minimum, replace the starter
clutch.
B58425
18. INSPECT DRIVE HOUSING

(a) Using a cylinder gauge, check the inside diameter of the
starter drive housing bush.
Inside diameter:
Standard Maximum
26 mm (1.024 in.) 26.2 mm (1.031 in.)
If the diameter is greater than the maximum, replace the drive
housing.
B58426
19. INSPECT MOTOR HOUSING

motor housing bush.
Inside diameter:
Standard Maximum
12.1 mm (0.476 in.) 12.3 mm (0.484 in.)
If the diameter is greater than the maximum, replace the motor
housing.
B58427
19ï7
20. INSPECT STARTER COMMUTATOR END FRAME

ASSY
end frame bush.
Inside diameter:
Standard Minimum
12.0 mm (0.472 in.) 12.2 mm (0.480 in.)
If the diameter is greater than the minimum, replace the frame.
B58428
21. INSTALL STARTER DUST PROTECTOR

(a) Using SST and a plasticïfaced hammer, tap in the protec-
SST
tor.
SST 09950ï60010 (09951ï00260, 09951ï00390,
09952ï06010)
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B58429
22. INSTALL STARTER PINION DRIVE LEVER

(a) Install the holder to the drive lever with a pin.
(b) Apply grease to the portions of the drive lever.
Apply Grease
B58430
23. INSTALL STARTER CLUTCH SUBïASSY

(a) Apply grease to the portions of the starter clutch, and
install the drive lever together with it to the starter drive
housing.
HINT:
Check that the starter clutch is in the depth, then lightly slides
there.
Apply Grease
B58431
(b) Apply much grease to the extent that it would overflow

from the reservoir of the start drive housing.
: Apply Grease B58432

19ï8
24. INSTALL PINION GEAR

(a) Install the pinion gear to the shaft by tapping it uniformly.
(b) Using pliers, pinch a new retainer and the shaft, then
press them in.
B58433
25. INSTALL ARMATURE BEARING

SST (a) Using SST and a press, install the bearing.
SST 09820ï36010
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B58434
26. INSTALL MOTOR HOUSING

Rubber Seal
Spring (a) Apply grease to the parts as shown in illustration.
Plate (b) Install a new rubber seal, spring and plate.
(c) Install the bolt and motor housing.
Apply Grease
B58435
27. INSTALL MAGNET STARTER SWITCH ASSY

A
(a) Attach the drive lever to the upper port of the main switch
in direction A, then install it with the 2 bolts by inserting it
in direction B.
Torque: 14.7 N·m (150 kgf·cm, 11 ft·lbf)
B
B58385
28. INSTALL STARTER ARMATURE ASSY

(a) Apply grease to the portions of the armature as shown in
illustration.
(b) Install the armature to the motor housing.
Apply Grease
B58436
19ï9
29. INSTALL STARTER YOKE ASSY

(a) Align the cutout of the starter yoke with the cutout of the
motor housing.
(b) Install the starter yoke.
Cutout
B58437
30. INSTALL STARTER BRUSH HOLDER ASSY

(a) Place the brush holder in position on the armature.
(b) Using a screwdriver, hold the brush spring back, and con-
nect the brush into the brush holder. Connect the 4
brushes.
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B58439
31. INSTALL STARTER COMMUTATOR END FRAME ASSY

(a) Install the end frame 2 with the through bolts.
Torque: 14.7 N·m (150 kgf·cm, 11 ft·lbf)
(b) Install a new Oïring to the screws.
(c) Install the 2 new screws with Oïrings.
Torque: 4.3 N·m (44 kgf·cm, 38 in.·lbf )
19ï10
STARTING & CHARGING ï GENERATOR ASSY
GENERATOR ASSY
190M1ï01
COMPONENTS
Generator Washer
Bearing Cover
Rotor
2.9 (30, 26 in.·lbf)
z Generator Drive End

Frame Bearing (Front)
Drive End Frame zGenerator Rotor

Bearing (Rear)
Bearing Cover
Generator Pulley
Bearing Retainer
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Rear End Cover No.2
110 (1,125, 81) 4.1 (42, 36 in.·lbf)
Rear End Cover
Terminal Insulator 2.0 (20, 18 in.·lbf)
Generator Brush
Holder Assy
5.4 (55, 48 in.·lbf)

3.85 (39, 34 in.·lbf)
Cord Clip Plate Seal
Brush Holder Cover

2.0 (20, 18 in.·lbf)
Plate Terminal
Voltage Regulator
x4 2.94 (30, 26 in.·lbf) 4.4 (45, 39 in.·lbf)

Generator Holder w/ Rectifi-
er
Rubber Insulator
4.5 (46, 40 in.·lbf)
Rectifier End Frame

19ï11
190M2ï01
OVERHAUL
1. REMOVE REAR END COVER NO. 2

2. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.
B58309
(b) Remove the 3 nuts, bolt, plate terminal and rear end cover
and brush holder cover.
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B58310
3. REMOVE GENERATOR BRUSH HOLDER ASSY

(a) Remove the 2 screws and brush holder.
4. REMOVE VOLTAGE REGULATOR
(a) Remove the 3 screws and voltage regulator.
B58312
(b) Remove the plate seal from the rectifier end frame.
B58313
19ï12
5. REMOVE GENERATOR HOLDER W/ RECTIFIER

(a) Remove the 4 screws and generator holder.
B58314
(b) Remove the 4 rubber insulators.
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B58315
SST (A)
6. REMOVE GENERATOR PULLEY
SST (B)
(a) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
(b) Check that SST (A) is secured to the rotor shaft.
Turn SST 09820ï63010
B58316
(c) As shown in the illustration, mount SST (C) in a vise, and

attach the pulley nut to SST (C).
(d) To loosen the pulley nut, turn SST (A) in the direction
NOTICE:
SST (C) To prevent damage to the rotor shaft, do not loosen the
pulley nut more than oneïhalf of a turn.
Turn (e) Remove the generator from SST (C).
B58317 (f) Turn SST (B), and remove SST (A and B).
(g) Remove the pulley nut and pulley.
7. REMOVE RECTIFIER END FRAME
(a) Remove the 4 nuts and cord clip.
B58318
19ï13
(b) Using SST, remove the rectifier end frame.

SST 09286ï46011
SST
B58319
(c) Remove the generator washer.
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B58320
8. REMOVE GENERATOR ROTOR ASSY
B58338
9. INSPECT VOLTAGE REGULATOR

(a) Using an ohmmeter, check the continuity between termi-
nals F and B.
Ohmmeter
Standard:
When the positive and negative poles between termi-
F nals F and B are exchanged, there is continuity in one
way but no continuity in another way.
B If the continuity is not as specified, replace the regulator.
A64727
(b) Using an ohmmeter, check the continuity between termi-

nals F and E.
E Standard:
Ohmmeter
When the positive and negative poles between termi-
nals F and E are exchanged, there is continuity in one
way but no continuity in another way.
F
A64728
19ï14
10. INSPECT GENERATOR ROTOR ASSY

(a) Check the rotor for open circuit.
between the slip rings.
Ohmmeter Standard resistance:
11.6 ï 12.4 : at 20˚C (68˚F)
If there is no continuity, replace the rotor assy.
Continuity
B58321
(b) Check the rotor for ground.

ity between the slip ring and rotor.
Standard resistance:
Ohmmeter 10 M: or more at 20˚C (68˚F)
If there is continuity, replace the rotor assy.
No Continuity
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B58322
(c) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
(d) Using vernier calipers, measure the slip ring diameter.
Diameter:
Standard 14.2 ï 14.4 mm (0.559 ï 0.567 in.)
If the diameter is less than the minimum, replace the rotor assy.
B58323
11. INSPECT DRIVE END FRAME

(a) Check the starter for open circuit.
Continuity between the coil leads.
Ohmmeter
If there is no continuity, replace the drive end frame.
B58324
(b) Check the starter for ground.

ity between the coil lead and drive end frame.
No Continuity If there is continuity, replace the drive end frame.
Ohmmeter
B58325
19ï15
12. INSPECT GENERATOR BRUSH HOLDER ASSY

(a) Using vernier calipers, measure the exposed brush
length.
Standard exposed length:
9.5 ï 11.5 mm (0.374 ï 0.453 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the exposed length is less than the minimum, replace the
brush holder assy.
B58326
13. INSPECT GENERATOR BRUSH HOLDER ASSY

(a) Check the positive (+) rectifier.
(1) Using an ohmmeter, connect one tester probe to the
positive (+) terminal and the other to each rectifier
terminal.
Positive (+) (2) Reverse the polarity of the tester probes and repeat
Ohmmeter Terminal
step (1).
Rectifier
(3) Check that one shows continuity and the other
Terminal
shows no continuity.
cardiagn.com
B58327
If the continuity is not as specified, replace the rectifier holder.

(b) Check the negative (ï) rectifier.
(1) Using an ohmmeter, connect one tester probe to
Negative (ï) each negative (ï) terminal and the other to each
Terminal rectifier terminal.
(2) Reverse the polarity of the tester probes and repeat
step (1).
Ohmmeter
(3) Check that one shows continuity and the other
shows no continuity.
B58328 If the continuity is not as specified, replace the rectifier holder.
14. INSPECT BEARING

(a) Check that the bearing is not rough or worn.
If necessary, replace the bearing.
15. REMOVE BEARING (FRONT)

(a) Remove the 4 screws and bearing retainer.
B58329
19ï16
(b) Using SST and a press, press out the bearing.

SST SST 09950ï60010, 09950ï70010
B58330
16. INSTALL BEARING (FRONT)

(a) Using SST and a press, press in a new bearing.
SST
(b) Install the bearing retainer with the 4 screws.
Torque 2.9 N·m (30 kgf·cm, 26 in.·lbf)
SST 09950ï60010, 09950ï70010
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B58331
17. REMOVE BEARING (REAR)

SST (a) Using SST, remove the bearing cover (outside) and bear-
ing.
SST 09820ï00021, 09820ï00030, 09825ï76010
NOTICE:
Be careful not to damage the fan.
(b) Remove the bearing cover (inside).
B58332
18. INSTALL BEARING (REAR)

(a) Place the bearing cover (inside) on the rotor.
B58333
(b) Using SST and a press, press in a new bearing.

SST 09820ï00031
SST
B58334
19ï17
(c) Using SST, push in the bearing cover (outside).

SST 09285ï76010
SST
B58335
19. INSTALL GENERATOR ROTOR ASSY

(a) Place drive end frame on pulley.
(b) Install the rotor to the drive end frame.
Pulley
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B66458
20. INSTALL RECTIFIER END FRAME

(a) Place the generator washer on the rotor.
B58320
(b) Using a 30 mm socket wrench and press, slowly press in

30 mm the rectifier end frame.
Socket
Wrench
B58336
B (c) Install the cord clip and 4 nuts.

Torque:
4.5 N·m (46 kgf·cm, 40 in.·lbf) for A
A 5.4 N·m (55 kgf·cm, 48 in.·lbf) for B
A
A B58318
19ï18
21. INSTALL GENERATOR PULLEY

SST (A)
SST (B)
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820ï63010
Torque 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Check that SST (A) is secured to the pulley shaft.
B58316
(d) As shown in the illustration, mount SST (C) in a vise and

attach the pulley nut to SST (C).
(e) To torque the pulley nut, turn SST (A) in the direction
Torque 110.5 N·m (1,125 kgf·cm, 81 ft·lbf)
SST (f) Remove the generator from SST (C).
(g) Turn SST (B) and remove SST (A and B).
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B58317
22. INSTALL GENERATOR HOLDER W/ RECTIFIER

(a) Install the 4 rubber insulators on the lead wires.
B58315
(b) Install the rectifier holder while pushing it with the 4

screws.
Torque 2.94 N·m (30 kgf·cm, 26 in.·lbf)
B58314
23. INSTALL VOLTAGE REGULATOR

(a) Install the voltage regulator with the 3 screws.
Upward Torque 2.0 N·m (20 kgf·cm, 18 in.·lbf)
24. INSTALL GENERATOR BRUSH HOLDER ASSY
(a) Place the plate seal on the rectifier end frame.
(b) Install the brush holder with the 2 screws.
NOTICE:
B58337 Be careful of the holder installation direction.
19ï19
25. INSTALL REAR END COVER

(a) Place the brush holder cover on the brush holder.
B58311
(b) Install the rear end cover and plate terminal with the 2 nuts
and bolt.
Torque:
3.85 N·m (39 kgf·cm, 34 in.·lbf) for bolt
4.4 N·m (45 kgf·cm, 39 in.·lbf) for nut
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B58310
(c) Install the terminal insulator with the nut.

B58309
26. INSTALL REAR END COVER NO. 2

(a) Install the generator rear end cover with the 2 nuts.
27. INSPECT GENERATOR ASSY
(a) Check that the pulley rotates smoothly.
00ï1
ALPHABETICAL INDEX
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00ï2
ALPHABETICAL INDEX (A ï T)
A L
Page Page
ABBREVIATIONS USED IN THIS MANUAL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï7
(TERMS FOR ENGINE REPAIR MANUAL) . . . . . . 01ï7 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï13
C N
CAMSHAFT HOUSING AND CYLINDER HEAD . . . . . 14ï1 NOZZLE HOLDER AND NOZZLE SET . . . . . . . . . . . . . 11ï1
COMPONENTS (CAMSHAFT HOUSING AND
CYLINDER HEAD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï1
COMPONENTS (CRANKSHAFT FRONT END,
O
OIL PAN, FLYWHEEL AND
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17ï5
FLYWHEEL HOUSING) . . . . . . . . . . . . . . . . . . . . . . . 14ï27
OIL PUMP ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17ï1
COMPONENTS (GENERATOR ASSY) . . . . . . . . . . . . . 19ï10
OVERHAUL (CAMSHAFT HOUSING
COMPONENTS
AND CYLINDER HEAD) . . . . . . . . . . . . . . . . . . . . . . . 14ï3
(NOZZLE HOLDER AND NOZZLE SET) . . . . . . . . . 11ï1
OVERHAUL (CRANKSHAFT FRONT END,
COMPONENTS (OIL PUMP ASSY) . . . . . . . . . . . . . . . . 17ï1
OIL PAN, FLYWHEEL AND
COMPONENTS (PISTON, CRANKSHAFT AND
FLYWHEEL HOUSING) . . . . . . . . . . . . . . . . . . . . . . . 14ï30
CYLINDER BLOCK) . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï46
OVERHAUL (GENERATOR ASSY) . . . . . . . . . . . . . . . . 19ï11
COMPONENTS (STARTER ASSY) . . . . . . . . . . . . . . . . 19ï1
OVERHAUL
COMPONENTS (TIMING GEAR) . . . . . . . . . . . . . . . . . . 14ï39 (NOZZLE HOLDER AND NOZZLE SET) . . . . . . . . . 11ï2
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï6 OVERHAUL (OIL PUMP ASSY) . . . . . . . . . . . . . . . . . . . 17ï2
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï12 OVERHAUL
CRANKSHAFT FRONT END,
cardiagn.com
(PISTON, CRANKSHAFT AND
OIL PAN, FLYWHEEL AND CYLINDER BLOCK) . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï47
FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . 14ï27 OVERHAUL (STARTER ASSY) . . . . . . . . . . . . . . . . . . . 19ï2
OVERHAUL (TIMING GEAR) . . . . . . . . . . . . . . . . . . . . . 14ï40
E OVERHAUL (WATER PUMP ASSY) . . . . . . . . . . . . . . . 16ï1
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï2

ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï6
P
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï5 PISTON, CRANKSHAFT AND CYLINDER BLOCK . . . 14ï46
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï11 PRECAUTION (REPAIR INSTRUCTION FOR
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . 15ï1 ENGINE REPAIR MANUAL) . . . . . . . . . . . . . . . . . . . 01ï4
PREPARATION (COOLING) . . . . . . . . . . . . . . . . . . . . . . 02ï6
F PREPARATION (ENGINE MECHANICAL) . . . . . . . . . . 02ï2
PREPARATION (EXHAUST) . . . . . . . . . . . . . . . . . . . . . . 02ï5
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï4 PREPARATION (INTAKE) . . . . . . . . . . . . . . . . . . . . . . . . 02ï1
PREPARATION (LUBRICATION) . . . . . . . . . . . . . . . . . . 02ï7
PREPARATION (STARTING & CHARGING) . . . . . . . . 02ï8
G
GENERAL INFORMATION (HOW TO USE R
THIS ENGINE REPAIR MANUAL) . . . . . . . . . . . . . . 01ï1
GENERATOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19ï10 REPAIR INSTRUCTION FOR
GLOSSARY OF SAE AND TOYOTA TERMS ENGINE REPAIR MANUAL . . . . . . . . . . . . . . . . . . . . 01ï4
(TERMS FOR ENGINE REPAIR MANUAL) . . . . . . 01ï12
S
H
SERVICE DATA (COOLING) . . . . . . . . . . . . . . . . . . . . . . 03ï12
HOW TO DETERMINE BOLT STRENGTH SERVICE DATA (ENGINE MECHANICAL) . . . . . . . . . . 03ï6
(STANDARD BOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï1 SERVICE DATA (EXHAUST) . . . . . . . . . . . . . . . . . . . . . . 03ï11
HOW TO DETERMINE NUT STRENGTH SERVICE DATA (INTAKE) . . . . . . . . . . . . . . . . . . . . . . . . 03ï5
(STANDARD BOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï3 SERVICE DATA (LUBRICATION) . . . . . . . . . . . . . . . . . . 03ï13
HOW TO USE THIS ENGINE REPAIR MANUAL . . . . . 01ï1 SERVICE DATA (STARTING & CHARGING) . . . . . . . . 03ï14
SPECIFIED TORQUE FOR STANDARD BOLTS
(STANDARD BOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï2
I STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï1
INSPECTION (EXHAUST MANIFOLD) . . . . . . . . . . . . . 15ï1 STARTER ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19ï1
INSPECTION (INTAKE MANIFOLD) . . . . . . . . . . . . . . . 13ï1 STARTING & CHARGING . . . . . . . . . . . . . . . . . . . . . . . . 02ï8
INSPECTION (OIL COOLER) . . . . . . . . . . . . . . . . . . . . . 17ï5 STARTING & CHARGING . . . . . . . . . . . . . . . . . . . . . . . . 03ï14
INSPECTION (THERMOSTAT) . . . . . . . . . . . . . . . . . . . . 16ï3
INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02ï1 T
INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03ï5
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13ï1 TERMS FOR ENGINE REPAIR MANUAL . . . . . . . . . . . 01ï7
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16ï3
TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ï39
00ï3
ALPHABETICAL INDEX (T ï W)
Page
(ENGINE MECHANICAL) . . . . . . . . . . . . . . . . . . . . . . 03ï10
TORQUE SPECIFICATION (FUEL) . . . . . . . . . . . . . . . . 03ï4
(STARTING & CHARGING) . . . . . . . . . . . . . . . . . . . . 03ï15
W
WATER PUMP ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16ï1
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■■■■■■■■

Manual Name Pub. No.

2002 Hino Motors,Ltd.

HOW TO USE THIS ENGINE REPAIR

HOW TO USE THIS ENGINE REPAIR MANUAL

Camshaft Drive Gear

Camshaft Timing Tube Assy

7.5 (80, 66 in.·lbf)

z Camshaft Setting Oil Seal Camshaft Driven Main Gear

15 (150, 11) Wave Washer Camshaft Timing Gear

REPAIR INSTRUCTION FOR ENGINE REPAIR MANUAL

(a) Precoated Parts:

(d) Torque When Using Extension Tool with Torque Wrench:

(3) Formula T’ = T x L2/(L1 + L2)

10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS

11. REMOVAL AND INSTALLATION OF ENGINE INTAKE

12. HANDLING OF HOSE CLAMPS

TERMS FOR ENGINE REPAIR MANUAL

ABBREVIATIONS USED IN THIS MANUAL

GLOSSARY OF SAE AND HINO TERMS

A/C Air Conditioning Air Conditioner

FEPROM Flash Erasable Programmable Read Only Memory ï

HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S)

Electric Bleed Air Control Valve (EBCV)

TCM Transmission Control Module Transmission ECU, ECT ECU

ThreeïWay Catalytic (TWC)

09202ï70020 Valve Spring Compressor CAMSHAFT HOUSING AND

09960ï10010 Variable Pin Wrench Set CAMSHAFT HOUSING AND

09402ï1480 Press subïAssy PISTON, CRANKSHAFT AND

09407ï1040 Oil Seal Press CRANKSHAFT FRONT END, OIL

09420ï1720 Sylinder liner puller PISTON, CRANKSHAFT AND

09420ï1731 Oil Seal Puller CRANKSHAFT FRONT END, OIL

09420ï1742 Oil Seal Puller CRANKSHAFT FRONT END, OIL

09444ï1630 Gauge PISTON, CRANKSHAFT AND

09472ï1210 Bar CAMSHAFT HOUSING AND

09472ï1620 Tool PISTON, CRANKSHAFT AND

09481ï1140 Guide PISTON, CRANKSHAFT AND

09481ï1340 Guide CRANKSHAFT FRONT END, OIL

9001ï24262 Check Bolt PISTON, CRANKSHAFT AND

9191ï08252 Bolt PISTON, CRANKSHAFT AND

9800ï06100 Steel Ball CAMSHAFT HOUSING AND

09905ï00013 Snap Ring Pliers TIMING GEAR

08833ï00070 ”Adhesive 1324,” TIMING GEAR

Press Sliding hammer

(09236ï15010) Bearing Stay WATER PUMP ASSY

09238ï47012 Water Pump Bearing Remover & WATER PUMP ASSY

09950ï50013 Puller C Set WATER PUMP ASSY

(09952ï05010) Slide Arm WATER PUMP ASSY

(09953ï05010) Center Bolt 100 WATER PUMP ASSY

(09954ï05021) Claw No.2 WATER PUMP ASSY

09482ï2060A Press WATER PUMP ASSY

09420ï1820 Puller ASSY WATER PUMP ASSY

STARTING & CHARGING

09286ï46011 Injection Pump Spline Shaft GENERATOR ASSY

09820ï00021 Alternator Rear Bearing Puller GENERATOR ASSY

09820ï00030 Alternator Rear Bearing Replacer GENERATOR ASSY

09950ï60010 Replacer Set STARTER ASSY

(09951ï00260) Replacer 26 STARTER ASSY

(09951ï00390) Replacer 39 STARTER ASSY

(09952ï06010) Adapter STARTER ASSY

09950ï70010 Handle Set GENERATOR ASSY

09820ï00031 Alternator Rotor Rear Bearing Replacer STARTER ASSY(S05CïB)

STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . . 03ï1

Nm (kgfcm, ftlbf) : Specified Torque