Problem:

Insufficient power
smoke generation

Possible cause:

Insufficient compression caused by:

1. Element of the contaminated air filter
2. Loose hose connection between the compressor and intercooler
3. Intake manifold leak
4. Exhaust manifold leak
5. Turbocharger mounting flange leak
6. Interference between the turbocharger compressor
turbine and box
7. Blocked duct between the air filter and the turbocharger
compressor
8. Blocked duct between the compressor and the intake manifold
9. Interference between the intake and exhaust collectors
10. Valve seat leakage
11. Stuck valve stem
12. Weak or broken valve spring
Failed cylinder head
14. Cracked or distorted receiver
15. Piston ring stuck, damaged or worn out
16. cracked or worn piston
Malfunction of the fuel system
slipping clutch
Incorrect tire size
Restricted escape system
system

Problem:

Excessive oil consumption

Possible Cause:

Abnormal viscosity of the engine oil

Compressor blow-off of the turbocharger
Adhesion of the oil to the casing or wheel
Turbocharger turbine leaks
Piston ring worn or stuck
Worn piston or cylinder
Defective valve seal
Worn valve stem or guide.

Problem:

The engine spins normally, but it doesn't start.

Possible Cause:

Malfunction of the fuel system

Malfunction of the electrical system
Restricted escape system
Timing belt and/or related parts Replace
Low compression
Worn camshaft

Problem:
Blue smoke comes out of the exhaust

Solution:

Usually caused by the burning of oil in the combustion chamber of:

worn rings, worn valve guides, worn or failed valve seals
Cylinder head
Contaminated air filter element
Loose connection of the hose between the compressor and the intercooler
Escape from the intake manifold
Blocked oil filter
Blocked duct between the air filter and the turbocharger compressor
Compressor escape of the turbocharger

Problem:

White smoke out of the exhaust

Possible Causes:

Usually caused by water vapor, which is a normal byproduct of combustion on cold days.
Excessive white smoke with the engine heated could be caused by a failed head gasket or an intake gasket.
it could also
to be a cracked block, exhaust manifold or intake manifold.

Problem:

Black smoke out of the exhaust

Possible Cause:

Malfunction of the fuel system

Malfunction of the emissions system

Problem:

Abnormal combustion:

Possible Cause:

Stuck or burnt valve Weak or broken spring valve carbon buildup in the combustion chamber

Problem:

Bad idle

Possible Cause:

Malfunction of the fuel system

Malfunction of the emissions system
Uneven compression of the cylinder Defective valve at valve seat contact Broken valve spring
Cylinder head with failure.

Problem:

Turbocharger noise

Possible Cause:

Element of the contaminated air filter

Strange material in the intake duct or in the compressor housing
Strange material between the intake manifold and the compressor
Strange material in the engine exhaust system
Carbon deposition in the turbine casing
Interference between the rotating parts of the turbocharger
Loose connection parts of the intake and exhaust system

Problem:

The engine knocks when it is hot and at idle.

Possible Cause:

Belt / loose or worn transmission accessory

Incorrect oil viscosity
Excessive clearance of the piston pin
Alignment of the connection bar
Insufficient distance between the piston and the hole
Defective belt tensioner or timing belt guide
Loose gate pulley

Problem:

A slight noise at idle becomes louder as the engine speed increases.

Possible Cause:

Valve spring clicking in the cap, out of frame or broken

Excessive shaft to release guides
Excessive seat drop of the valve
Exhaust pipe with holes

Problem:

The engine knocks when it is cold

Possible Cause:

Excessive clearance of the piston to the wall

Loose or broken shock absorber pulley (damper)

Problem:

Impact increases with torque

Possible Cause:

Excessive piston clearance in the bore

White folded

Problem:

The engine has heavy knocks when it is hot and torque is applied.

Possible Cause:

Broken shock pulley

belt accessories too tight or damaged
Damaged belt tensioner
Cracked flywheel or loose clutch plate
Excessive clearance of the main bearing
Excessive bearing play

Problem:

The engine has a slight knock when it is hot and under light load.

Possible Cause:

Incorrect time
Piston and/or connecting rod
Low-quality fuel
Escape leak in the collector
Excessive play of bearings

Problem:

The engine stalls at initial start-up and the jolt lasts only a few seconds.

Possible Cause:

Incorrect oil viscosity

Problem:

Turbocharger interference, poor rotation

Possible Cause:
The compressor blades were damaged due to an external cause.
Interference of the turbine and compressor blades with the casing
Excessive deposit in the compressor housing or wheel
Excessive coal deposit on the back of the turbine blade
Burns on the central casing

Problem:

Turbocharger turbine shaft escape

Possible Cause:

Excessive initial application of oil

Blocked crankcase breather
Obstacle in the oil drainage line of the turbocharger
Burns on the central casing
Wear of the turbocharger bearing, bearing hole or shaft axis
Excessive oil in the crankcase

Problem:

Turbocharger compressor leak

Possible Cause:

Element of the contaminated air filter

Blocked duct between the compressor and the air filter
Loose compressor and intake system that connects the duct
Leak from the intake manifold
Obstacle in the oil drainage line of the turbocharger
Blow-off passage blocked in the crankcase
Worn or damaged compressor blades
Wear of the turbocharger bearing, bearing or shaft of the shaft

Problem:

Wear on the bearing of the turbocharger, inner diameter or shaft

Possible Cause:

Contaminated oil
Insufficient supply of oil
Obstacle in the oil supply line of the turbocharger
Clogged oil filter
Poor oil pump operation
Serrated belt
Removal

Lift the vehicle and support it with safety stands.

2. Remove the upper radiator hose.
3. Remove the hoses from the fuel filter that are still connected.
4. Remove the mounting rubber from engine No.3.

Remove the engine mount bracket No. 3.

Remove the right side wheel.

7. Remove the A/C drive belt.
8. Remove the drive belt.
9. Remove the automatic tensioner.
10. Remove the pulley from the water pump.
11. Remove the crankshaft pulley.
12. Remove the top cover of the timing belt.
13. Remove the lower cover of the timing belt.
14. Rotate the crankshaft and align the timing mark on the timing belt pulley with the mark of
synchronization in the engine block.

15. Remove the automatic tensioner.

Remove the timing belt.

Replacement

1. Check that the timing mark on the timing belt pulley, the camshaft pulley, and the pulley
the high-pressure pump is aligned with the timing mark on the engine.

Install the timing belt.

1) Install the timing belt first on the crankshaft pulley, the idler pulley No. 2, the pump pulley.
high pressure, the guide pulley no. 1 and the camshaft pulleys.

News:
a) The automatic tensioner must be mounted on the engine after installing the timing belt.
b) Maintain the tension of the timing belt when installing the timing belt.

3. Install the automatic tensor.

1) Install the automatic tensioner as shown in the illustration.
The wedge pin must be located between the fork of the tensioner (rear plate).

2) Tighten the automatic tensioner.

Press pair:
2.9 pound-feet (3.9 N • m, 0.4 kg-m)

Announcement

a) The oil must not come into contact with the tensioner.
b) The tensor must be replaced with a new one if it is successful.
c) b) The positions of the pointer, the back plate, and the special washer must be in accordance with the illustration

4. Check again if the alignment marks on the camshafts, the crankshaft, and the high-pressure pump are
aligned with the marks in the distribution box.

5. Adjust the automatic tensor and then tighten it.

Align the pointer to the back plate by turning the special washer counterclockwise with the hex key.
is shown in the illustration.

2) Tighten the locking bolt of the self-tensioner while holding the special washer with the hex key when the pointer
be aligned with the back plate.

Pair of tightness:
17.4 lb-ft (23.5 N • m, 2.4 kg-m)

3) Remove the hex key.

Announcement
If the pointer cannot be aligned with the back plate, a new strap should be used.

6. Rotate the crankshaft two complete turns clockwise to align the TDC mark.
7. Check again if the alignment marks of the camshafts, crankshaft, and high-pressure pump are
aligned with the marks on the distribution box.
8. Check the alignment of the pointer and the rear plate.

Tolerance deviation: 5 °

9. If the misalignment between the pointer and the back plate is greater than 5°, repeat steps 4 to 8.
10. Install the upper and lower timing belt cover.

Couple of tightens:
5.1 ~ 7.2 lb-ft (6.9 ~ 9.8 N • m, 70 ~ 100 kg-cm)

11. Install the crankshaft pulley.

Tighten pair:
253 ~ 289 lb-ft (343 ~ 392 N • m, 35 ~ 40 kg-m)
12. Install the water pump pulley.
Tightening pair:
13.0 ~ 20.9 lb-ft (17.6 ~ 28.4 N • m, 1.8 ~ 2.9 kg-m)
13. Install the automatic tensor.
Pair of tightening:
13.0 ~ 20.9 lb-ft (17.6 ~ 28.4 N • m, 1.8 ~ 2.9 kg-m)
14. Install the drive belt and the A/C drive belt.
15. Install the right side wheel.

Pair of tightening:
65 ~ 79 lb-ft (88 ~ 108 N • m, 9.0 ~ 11.0 kg-m)
16. Install the engine mount bracket No.3.
Nose clamp:
26.7 ~ 39.8 lb-ft (36.2 ~ 53.9 N • m, 3.7 ~ 5.5 kg-m)
17. Install the engine mounting rubber No.3.
Pair of tightens:
Nut: 49.1 ~ 68.7 lb-ft (66.7 ~ 93.1 N • m, 6.8 ~ 9.5 kg-m)
Bolt: 62.9 ~ 86.0 lb-ft (85.3 ~ 116.7 N • m, 8.7 ~ 11.9 kg-m)

18. Install the fuel filter.

19. Install the radiator hose.
20. Fill the engine coolant with the specified type and amount.
21. Start the engine and then check for leaks.

Compression pressure
Inspection

1. Heat the engine to normal operating temperature, then stop the engine and disconnect the connector from the
fuel cut-off solenoid.
2. Remove all injection pipes, nozzles, and washers.
3. Connect the SST to the nozzle hole.
4. Measure the compression pressure during startup.

5. Repeat steps 3 ~ 4 again for each cylinder.

6. If the measurement value is below the limit, consider it as wear or abrasion of the piston and the ring of the
piston, valve misalignment, gasket damage, etc.

WITHDRAWAL AND REPLACEMENT PROCEDURES

Motor
Removal
1. Disconnect the negative and positive cable from the battery.
2. Properly lift and support the vehicle.
3. Drain the engine coolant.
4. Remove the battery and the battery tray.
5. Remove the air filter assembly from the air duct of the flash and the air filter bracket.
6. Disconnect the connector of the wiper motor on the right side.
7. Remove the hose from the coolant reservoir of the thermostat housing.
8. Disconnect the two ground connectors from the fuse box.
9. Remove the lands from the side of the body

10. Disconnect the five connectors.

11. Remove the U clip

12. Remove the nut and washer from the automatic transmission link.

13. Disconnect the heater hose from the thermostat housing.

14. Disconnect the two vacuum hoses and the connector of the water temperature sensor.

15. Remove the set of the automatic transmission filter tube.

16. Disconnect the vacuum hose from the alternator brake

17. Remove the fuel hose from the sedimenter.

18. Remove the two hoses from the power steering reservoir.

Caution
After removing the power steering line, connect the power steering line to prevent fluid leaks.

19. Remove the power steering fluid tube from the power steering pump.
Remove the hose from the heater.

21. Disconnect the two ATF hoses from the cooler

22. Remove both front wheels.

23. Remove the drive belt.
24. Disconnect the connector of the magnetic clutch.
25. Remove the A/C compressor with the hoses still connected.

26. Place the A/C compressor away from the engine and secure it with a cable.

27. Remove the exhaust collector.

28. eliminate both the right and left ends of the steering ball joint coupling bar by removal
of a cotter pin and a nut of each.
29. Remove the stabilizer support and then remove the stabilizer control link.
30. Remove the knuckle control link (Ball joints)

Caution

Be careful not to damage the boot of the ball joint.

31. Remove the bolt and nut from both the right and left joints. Separate the lower arm from the joint.

32. Remove the union shaft support bracket from the engine block (three bolts).

Caution
a) Gradually separate the drive shaft from the front wheel and the joint of the transaxle. If it is removed suddenly
From the axle, the oil seal of the differential may get damaged.
b) After removing the front wheel drive shaft, hold the front wheel drive shaft.
with a cable to prevent the transmission shaft from damaging the tripod joint bearing and starting.

33. Be careful when using the lever on both axes of the automatic transmission.

34. Install the appropriate tool to prevent the side gear from misaligning.

35. Remove the intermediate shaft bolt.

36. Remove the bolt from the A/C hose bracket on the auxiliary frame.

Remove the assembly of engine No.3 and No.4.

38. Automatic transaxle support, the engine and auxiliary frame with an appropriate floor jack.

39. Remove four auxiliary frame nuts and four tension rods, nut, and then remove the auxiliary frame.

Slowly lower the engine, the transmission, and the auxiliary frame.

41. Remove the three bolts from the engine frame No.1 to the auxiliary frame.

42. Remove the four mounting bolts of engine No.2 and then remove the engine No.2 mount from the cross shaft and the frame.
auxiliary.
Remove the starter motor.
Remove the bottom cover.

Remove the six mounting nuts from the converter of the transmission plate. Rotate the engine at the crankshaft pulley.
to access the six nuts.

Remove the bolts from the converter housing.

Gently separate the axle from the engine.

Ladder frame and extraction of the balance shaft

Remove the oil pan.

2. Adjust the TDC mark of the V-groove on the outside of the pulley to the 'T' TDC mark on the timing cover by turning
the crankshaft pulley.

3. To check the time, loosen the 3 bolts of the balance gear cover at the back of the
ladder frame and check the mark of the balance gear assembly.

notice
To prevent the rocker arm shaft from being extracted, hand-tighten the bolts of the balance gear cover 1.
of 3 in the center of the thrust plate.

4. Upon reassembling after checking the mark of the balancing gear set, mark the link of the
chain with a marker that matches a round TDC mark of Ø0.12 in (3 mm) for timing adjustment.

notice
Ignore the 2 yellow dots on the chain link because they are only available for engine assembly.

5. Loosen the equilibrium pinion bolt.

notice

Insert the 0.2-inch (5 mm) urethane foam between the balance gear to prevent the balance shaft.
the gear and the equilibrium gear are damaged.

6. When disassembling the gear of the scale, hold the gear of the scale with one hand while pushing.
The push plate slightly, then the scale separates from the neck of the scale.

7. When disassembling the ladder frame, separate the oil supply pipe from the oil pump by loosening the
oil feed pipe pin.

8. Loosen the closure bolt of the ladder frame. Remove the ladder frame.

Replacement

What does the axial game of the balance shaft mean.

Final game: 0.0039 ~ 0.0098 in (0.1 ~ 0.25 mm)

2. Install the balance axle set and the thrust plate on the ladder frame.

notice
To prevent the rocker shaft from being extracted, hand-tighten the bolts of the balance gear cover 1.
of 3 in the center of the thrust plate.

3. Install the ladder frame in the block. Check that the ladder frame pin aligns with the surface.
lower part of the block and insert the oil level indicator into the hole in the ladder frame

Tightening torque (ladder frame bolt): 32.5 lb-ft (44 N • m, 4.5 kg-m)

4. Install the crankshaft pinion, the oil pump pinion, the guide, and the chain tensioner.

5. Align the position mark of the balance shaft sprocket with the chain link mark, and then insert the sprocket.
in the neck of the balance shaft.
notice
For smooth operation, pull the push plate outward and hold it, then press the gear wheel in.
the axis of balance.

6. Push the chain tensioner plunger to the maximum and then install the chain tensioner lever between the
chain and the chain tensor.

7. Tighten the pinion bolt of the scale

notice
Insert the 0.2-inch (5 mm) urethane rubber between the balance gear to prevent the balance shaft
the gire and the equilibrium gear get damaged.

Tighten pair:
Mark 10T: 50.6 lb-ft (68.6 N • m, 7 kg-m)
Mark 8T: 43.4 lb-ft (58.8 N • m, 6 kg-m)

8. Rotate the crankshaft pulley 2 times and make chain 1 complete a full turn, check the alignment with the TDC mark.
from the crankshaft pulley and the TDC mark on the timing cover after verifying the mark of the assembly
balance gear. If not, readjustment is needed.

notice
The position of the chain link brand is only efficient for assembly, but it does not match after 2.
rotations of the crankshaft pulley. Timing verification is only possible through the balance shaft gear.

9. Loosen the thrust plate bolt and install the gear cover and tighten the 3 bolts.

Pair of squeeze:
16.6 lb-ft (23 N • m, 2.3 kg-m)

10. Install the oil feed pipe on the ladder frame, the oil pump on the block, and then
tighten the bolts.

11. Install the oil pan.

12. Fill the engine oil with the specified type and amount.
13. Start the engine and then check for leaks.

DISASSEMBLY, INSPECTION, AND REASSEMBLY

PROCEDURE

notice
a) Code all identical parts (such as pistons, piston rings, connecting rods, and valve springs) so that they can
to reinstall in the cylinder from which they were extracted.
b) Clean the parts with steam, remove the remaining water with compressed air.
c) Care must be taken during the disassembly of any part or system to study its assembly order.
Any deformation, wear, or damage should also be noted.

Disassembly of auxiliary parts

Remove the cover of the refrigerator.

2. Remove the air intake hose from the intercooler and the intercooler.

3. Remove the engine harness.

4. Remove the hose from the fan.
5. Remove the fuel injection tube.

6. Remove the air separator and the hose/pipeline from the air separator.

7. Remove the hose and the ventilation pipe.

8. Remove the lower water hose from the cylinder block.
Remove the EGR tube.
10. Remove the alternator, the hose, the alternator bracket, and the automatic tensioner.

11. Remove the thermostat housing assembly.

12. Remove the turbocharger isolator.

13. Remove the turbocharger assembly.

14. Remove the water bypass hose and the water bypass pipe.

15. Remove the power steering pump support.

16. Remove the exhaust manifold insulator, the exhaust manifold, and the gasket.
17. Remove the EGR valve and the gasket.
18. Remove the intake manifold and the gasket.

19. Remove the common rail.

20. Install SST (0K410 101 004) on the engine.

21. Mount the motor on the SST (0K130 990 007).

Reassembly

The assembly will be carried out in reverse order.

DISASSEMBLY, INSPECTION AND RESETTING PROCEDURE

Cylindrical block

Oil collector
oil supply pipe
(3) Tooth strap case
Chain
Ladder frame
Oil filter
(7) Lever
oil pump
tensor
Guide
Clutch cover and clutch disc (only MTX)
(12) Steering wheel (MTX only)
Rear cover
(14) rod cover
white
main bearing
Piston and piston pin
Piston rings
Main bearing cover
main bearing
crankshaft
(22) Balance shaft gear
Push plate
balance axis
stream of oil
Balance shaft pinion

Disassembly

1. Remove the clutch cover, the clutch disc, and the flywheel.
Remove the mounting bolts from the oil tray.
3. Remove the oil tray with a screwdriver or appropriate tool.

Caution
a) Do not force the tools between the cylinder block and the oil pan as this can damage the surface of
sealed.
b) Do not damage the sealing surface when removing the old sealant

4. Remove the oil supply pipe.

5. Remove the timing belt cover.
6. Loosen the pinion gear bolt.
Announcement
Insert the 0.2-inch (5 mm) polyurethane foam between the balance gear to prevent the balance shaft.
the gear and the balance gear get damaged.

7. When removing the gear of the balance, hold the balance gear with one hand while pushing it.

slightly push the plate, then the balance separates from the neck of the balance.
Remove the chain.
9. Remove the ladder frame.
10. Remove the oil filter and the oil pump.
11. Remove the lever, the tensioner, and the guide.
12. Remove the back cover.

13. Before removing the connecting rod, measure the lateral play of the connecting rod.

0.0055 ~ 0.0153 in (0.14 ~ 0.39 mm)

14. Remove the cover from the connecting rod.

15. Measure the oil clearance of the connecting rod bearing.

Remove all foreign material and oil from the crankshaft pin and the bearing surface.
2) Place the Plastigage on top of the crankshaft pin in the axial direction.
3) Install the connecting rod cover and tighten.

Pair of tightening:
Tighten to 50.6 lb-ft (68.6 N • m, 7.0 kg-m),
tighten to 21.7 lb-ft (29.4 N • m, 3.0 kg-m) and then tighten 90°.

4) Loosen the blind nuts of the connecting rod.

5) Measure the oil clearance at each crankshaft journal.

oil clearance:
0.00169 ~ 0.00303 in (0.043 ~ 0.077 mm)

16. Remove the connecting rod and the piston.

17. Before removing the cap from the main bearing, measure the clearance at the end of the crankshaft.

Final game: 0.0055 ~ 0.0153 in (0.14 ~ 0.39 mm)

18. Remove the cover from the main bearing.

19. What is the oil clearance of the main bearing
Remove all the foreign material and oil from the magazines and the support surface.
2) Place Plastigage on top of the journal bearings in the axial direction.
3) Install the main bearing cap and tighten as shown in the figure.

Pair of tightens:
First tighten to 54.97 lb-ft (74.5 Mm, 7.6 kg-m), and then tighten 60 °.

4) Loosen the bolts of the main bearing cap and remove the main bearing cap.

5) Measure the oil clearance at each bearing

oil clearance
No.1,2,4,5: 0.00177 ~ 0.00311 in (0.045 ~ 0.079 mm)
No.3: 0.00267 ~ 0.00397 in (0.068 ~ 0.101 mm)

20. Loosen the main bearing cap bolts in two or three steps in the order shown in the figure.
21. Remove the main bearing cap, the main bearing, and the crankshaft.

22. Remove the balance shaft and the thrust plate.

23. Remove the balance gear.
Remove the oil stream.
25. Remove the snap ring with snap ring pliers and then remove the piston pin.
26. Using a piston ring expander, remove the piston rings.

Inspection
Ladder frame and balance axis
1. Measure the outer diameter of the balance shaft and the inner diameter of the ladder frame. Replace if necessary.
necessary.

Piston

Announcement
Replacing a piston also requires replacing the piston rings.

1. Check the piston circumference for damage, unusual marks or wear patterns. Replace the
piston as necessary.

2. Check the outer diameter of each piston at a right angle of 90° to the piston pin, at 0.16 in (15 mm)
above the lower end of the piston.

Piston diameter

A grade: 3.8195 ~ 3.8201 in (97.015 ~ 97.030 mm)

B grade: 3.8201 ~ 3.8207 in (97.030 ~ 97.045 mm)

Announcement:

If the piston is collapsed or looks like a bell, replace the piston.

3. Check the free space between the piston wall and the cylinder by subtracting the piston diameter from the largest diameter.
from the lining wall of the cylinder, in each cylinder.

Free space: 0.0028 ~ 0.0039 in (0.070 ~ 0.098 mm)

4. If the clearance exceeds the maximum, replace the piston or the cylinder liner.

Piston rings

Insert a new piston ring into the piston ring groove and check the clearance between the piston and the side.
Clearance of the piston ring groove.

Clearance of the groove of the piston ring:

Upper ring: 0.0029 ~ 0.0040 in (0.076 ~ 0.102 mm)

Second ring: 0.0016 ~ 0.0031 in (0.040 ~ 0.080 mm)

Oil ring: 0.0012 ~ 0.0028 in (0.030 ~ 0.070 mm)

Limit: 0.0118 in (0.30 mm)

2. If the clearance exceeds the limit, replace the piston.

3. Inspect the piston rings for damage, abnormal wear or breakage.
4. Replace the piston rings if necessary.
5. Insert the piston ring into the cylinder by hand.
6. Adjust the ring in the cylinder by inverting a piston in the cylinder and pushing the ring to the end of its travel.
the cylinder lining.

7. Place a distance caliper between ends and check the distance between tips.

Final free space:

Upper ring: 0.0118 ~ 0.0177 in (0.30 ~ 0.45 mm)
Second ring: 0.0157 ~ 0.0217 in (0.40 ~ 0.55 mm)
Oil groove: 0.0079 ~ 0.0157 in (0.20 ~ 0.40 mm)
Limit: 0.0591 in (1.50 mm)

8. Replace the piston ring if necessary.

Piston slider

Measure each diameter of the piston pin in the X and Y directions at the four locations shown.

Diameter: 1.2596 ~ 1.2598 in (31.994 ~ 32.000 mm)

White

1. Check the inner diameter of the connecting rod bushing.

Internal diameter:
1.2603 ~ 1.2611 in (32.012 ~ 32.033 mm)

2. Subtract the diameter of the piston pin from the inner diameter of the connecting rod bushing to determine the fit of the pin.
of the piston.

Free space: 0.0005 ~ 0.0015 in (0.012 ~ 0.039 mm)

3. If the clearance is not within specifications, replace the connecting rod bushing.

4. Check each connecting rod for bending

5. Replace the cranks if necessary.

Announcement

The connecting rods should always be replaced as a set. The connecting rod cap, the connecting rod, the bolts, and the nuts are
a combined set.

Crankshaft

Check the crankshaft bearings and crankshaft journals for damage and scratches.

2. Check that the oil holes are not obstructed.

3. Place the crankshaft in the V blocks.

4. What is the misalignment of the crankshaft in the central bearings.

Replace the crankshaft if it is not within specifications.

0.0055 ~ 0.0154 in (0.14 ~ 0.39 mm)

Connecting rod bearing selection

1 Check the code at the large end of the connecting rod

notice
The code is engraved on the side of the hole of the cap bolt of the connecting rod.

Diameter of the hole at the large end of the connecting rod

Diameter of the crankshaft journal:

2.24827 ~ 2.24898 in (57.106 ~ 57.124 mm)

2 Choose the appropriate bearing for the stub as shown in the table below.
Bearing clearance at the journal

0.00138 ~ 0.00272 in (0.035 ~ 0.069 mm)

Bearing selection table for connecting rod journal

Degree of the connecting rod

Bearing grade of the journal

oil clearance

Announcement
The paint brand is located on the side face of the bearing.

Thickness of the bearing of the stub

Correctly position the upper bearing and the lower bearing in the connecting rod and the connecting rod cap, and then install the connecting rod and
the connecting rod cover on the crankshaft journal

Couple of tightening:
Tighten 50.6 lb-ft (68.6 N • m, 7.0 kg-m), tighten 21.7 lb-ft (29.4 N • m, 3.0 kg-m) and
then squeeze 90 °

Selection of main journal bearing

Check the main bearing size code on the cylinder block

Announcement
The code is located on the side of the bolt hole of the ladder frame.

Diameter of the main bearing hole in the cylinder block

Check the main journal size code of the crankshaft

Announcement

The code is located between the main stub and the connecting rod stub.

Diameter of the main bearing of the crankshaft

Choose the correct main bearing in the following table

Main bearing block size code

Code for the size of the main crankshaft bearing

Play of the main bearing

No.1,2,4,5: 0.00146 ~ 0.00280 in (0.037 ~ 0.071 mm)
No.3: 0.00232 ~ 0.00366 in (0.059 ~ 0.093 mm)

Thickness of the main bearing

Black
brown
Green
Yellow

Correctly place the upper bearing and the lower bearing in the cylinder block and the main bearing cap.
Place the crankshaft in the cylinder block and then install the main bearing cap in the cylinder block.

Couple of tightening:
Before tightening 54.97 lb-ft (74.5 Nm, 7.6 kg-m),
and then tighten 60 °.
Cylinder and piston shirt selection

Check the code for the inner diameter size of the cylinder in the cylinder block.

Announcement
The code is carved on the top of each cylinder.

Interior diameter of the cylinder

Y 3.9966 ~ 3.9971 in (101.513 ~ 101.526 mm)

X 3.9960 ~ 3.9966 in (101.500 ~ 101.513 mm)

Choose the appropriate cylindrical shirt as shown in the table below.

The free space between the cylinder sleeve and the cylinder hole of the cylinder block:
0.0003 ~ 0.0013 in (0.007 ~ 0.033 mm)

Cylinder Shirt Selection Table

Cylinder diameter size code

cylinder shirt brand
oil clearance

Piston selection table

cylinder shirt brand

Piston brand

oil clearance

Announcement

The mark for the outer diameter is engraved on the outer surface of the sleeve and for the inner diameter it is
painted on the top of the shirt.

Outer diameter and inner diameter of the cylinder sleeve

Outside diameter of the piston

Announcement
a) Clean all the parts before reassembling them.
b) Apply new motor oil to all sliding and rotating parts.

Install the three-piece oil rings on the pistons.

1) Apply motor oil to the oil ring spacer and the rails.
2) Install the oil ring spacer so that the opening is facing upwards.
3) Install the upper rail and the lower rail.

Announcement
a) The upper rail and the lower rail are the same.
b) Each rail can be installed with any side facing up.

2. Check that both rails are expanded by the spacer tabs, as shown in the figure.
checking that both rails turn smoothly in both directions.

3. Install the second ring on the piston first, then install the upper ring. Use a piston ring expander.

Announcement
The rings must be installed with the 'Y' marks facing up.

4. Apply a generous amount of clean motor oil to the second and top piston rings.
5. Place the opening of each ring as shown in the figure.

6. Install an elastic ring of the piston pin in the grooves of the piston.

7. Insert the connecting rod into the piston and slide the piston pin through the piston and through the connecting rod until it fits.
contact with the retaining ring of the installed piston pin.

Announcement

Check that the piston and the connecting rod are assembled in the same direction as before disassembly.

8. Install the second ring grooves of the piston pin on the opposite side of the piston

9. Keep the piston in a vertical position and move the connecting rod back and forth. Check that the connecting rod moves.
freely.

Install the oil jet.

11. Before installing the crankshaft, inspect the oil clearance of the main bearing as follows.