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ENGINE (Engine Mechanical) 6B1

6B. ENGINE MECHANICAL

GENERAL DESCRIPTION ...................................................................................................6B 2

ONCAR SERVICE ............................................................................................................. 6B 6

COMPRESSION PRESSURE CHECK ............................................................................6B 6ENGINE VACUUM CHECK ............................................................................................. 6B 6OIL PRESSURE CHECK ................................................................................................ 6B 7OIL FILTER CHANGE ..................................................................................................... 6B 8ENGINE OIL CHANGE ....................................................................................................6B 8ADJUSTMENT OF VALVE CLEARANCE ....................................................................... 6B 9AIR CLEANER ELEMENT .............................................................................................. 6B 10DISTRIBUTOR ................................................................................................................. 6B 10CARBURETOR AND INTAKE MANIFOLD ADJUSTMENT ........................................... 6B 11EXHAUST MANIFOLD .................................................................................................... 6B 12TIMING BELT AND BELT TENSIONER ......................................................................... 6B 13OIL PUMP ........................................................................................................................6B 16CYLINDER HEAD, CAMSHAFT, VALVE AND ROCKER ARM SHAFT ..........................6B 19PISTON, PISTON RING, CONNECTING ROD AND CYLINDER ................................. 6B 31

DISASSEMBLY ................................................................................................................ 6B 37

ENGINE ASSEMBLY ..................................................................................................... 6B 37MAIN BEARING, CRANKSHAFT AND CYLINDER BLOCK ......................................... 6B 39

6B2 ENGINE (Engine Mechanical)

GENERAL DESCRIPTION

Fig. 6B 1 Engine View

F8C TYPE ENGINEThe engine is mounted declied 50 with the exhaust manifold and oil filter equipped on the left side and the intakemanifold, carburetor and generator on the right sideThe engine is 4 cycle, watercooled, inline 3 cylinders with displacement of 796cc.

Bore x Stroke = 68.5 x 72.0(mm)

F8C Type SHOC 2 Valves Carburetor

DAMAS(7) DAMAS(2) LABOMAX. POWER(PS/rpm)

MAX. TORQUE(kgm/rpm)

COMPRESSION RATIO

38/5000

6.4/3000

9.3 : 1


ENGINE LUBRICATIONThe engine lubrication is of the wetsump method to draw up the oil forced by the oil pump.The oil pump is of a trochoid type, and mounted on crankshaft at crank shaft pulley side. Oil is drawn upthrough oil pump strainer and passed through pump to oil filter. The filtered oil flows into two paths in cylinderblock. In one path, oil reaches crankshaft journal bearings. Oil from carnkshaft journal bearings is suppliedto connecting rod bearings by means of intersecting passages drilled in crankshaft, and then injected from asmall hole provided on big end of connecting rod to lubricate piston, rings, and cylinder wall. In another path,oil goes up to cylinder head and lubricates rocker arm, valve, camshaft, etc. through the oil hole provided onthe rocker arm shaft.

Fig. 6B 2 Engine Lubrication

SMALL END OFCONNECTION ROD

CRANKSHAFTJOURNAL

BIG END OFCONNECTION ROD

CYLINDER OIL SEAL

OIL FILTER

OIL PUMP

OIL STRAINER

BY-PASS VALVE

RELIEF VALVE

CAMSHAFT FORNT#2 JOURNAL

ROCKER ARM SHAFT

ROCKER

CAMSHAFTJOURNAL #1 , #3

PISTON,CYLINDER WALL

CAMSHAFTJOURNAL #4

DISTRIBUTORGEAR CASE

CAMSHAFTCENTER HOLE


CYLINDER HEAD AND VALVETRAINThe cylinder head is made of cast aluminum alloy forbetter hardness with lightweight, and camshaft androcker arm shaft arranged in-line support.The combustion chambers are formed into the mani-fold combustion chambers with increased squish partsfor better combustion efficiency and its intake and ex-haust parts are installed in the cross flow arrange-ment.The rocekr arm operates in seesaw motion to close andopen the intake and exhaust valves with camshaft byturning the rocker arm shaft of each intake and exhaustpart.

CRANKSHAFTThis part is to convert the rectilinear motion into therotation motion through the connecting rod which trans-mits the power generated by combustion.On the one side of it, oil pump, crankshaft pulley andtiming belt pulley are attached, and oil seal housing andflywheel are on the other side. A special steel of highgrade cast iron is used for the material to stand thebending load and distortion.A metal bearing of aluminum alloy is used for the ma-terial of the bearings. The split thrust bearings are in-serted in the No. 3 journal bearing part.

CONNECTING RODSThe connecting rods are made of forged steel, and itssection is typed in "I" with its big end connected to crank-shaft and its small end to piston pin to transmit thepower.The big end is detachable, and its upper and lower partsare fastened by bolts after the metal bearings are in-serted.

Fig. 6B 3 Cylinder and Valve Train

CYLINDER BLOCKAs the largest part among the engine components, theblock has all the necessary parts attached to outersurface of it. On the inside surface of block, there arehorning-machined bore surfaces which are cylinders,and on the periphery of the cylinders, there are thepassages to prevent the over-heated and to lubricatethe cylinder block. A high grade cast iron is used forthe material of the cylinder block.

ROCKER ARM SHAFT

ROCKER ARM

CAMSHAFT

EXHAUST VALVEINTAKE VALVE

Fig. 6B 4 Cylinder Block, Crankshaft,Connecting Rod


TIMING BELT, PULLEYPISTON, PISTION RINGAND PISTON PINPistonThe piston is of the open skirt type and its crown partis exposed to the combustion chamber to generatepower. Its land and skirt parts are made of cast alumi-num alloy which is light and has excellent heat con-ductivity in order to meet its continuous and highspeed reciprocating movement.

Pistion PinThe pin is not fixed to the piston or connecting rod itsboth ends are assembled in the full floating type. Thepin is used to tranmsmit the power from the crown partof piston to connecting rod.

Pistion RingIt is composed of two compression rings and one oilring and installed between the grooves of the piston tomake the high speed reciprocating movement maintain-ing a remarkable air-tightness as well as cylinders. Itis a critical parts to affect the compression pressure,oil consumption, compression, blow-by pressure andengine performance.

1

2

3

54

1. PISTON2. COMPRESSION RING3. OIL RING4. PISTON PIN5. CIRCLIP

Fig. 6B 5 Piston, Ring, Pin, Circlip

CAMSHAFT PULLEY

WATER PUMP

TIMING BELT TENSIONER CRANK TIMING PULLEY

ALTERNATOR

Fig. 6B 6 Timing Belt


ON-CAR SERVICE

8. Upon checking, make the connection perfect airtightbetween the hole of spark plug and compressiongauge.

STANDARD VACUUM(mm Hg) 460 20

4. After checking, remove vacuum gauge and connectthe hose again as it was.

COMPRESSION PRESSURECHECKCheck the compression pressure to the following pro-cedures.1. Warm up the engine till the engine temperature be-

come 80C(normal engine operating temperature).2. Stop the enigne.3. Remove all spark plugs and lead wires of

distributor(pull out with 10kgfor less).4. Remove the air cleaner.5. Install the compression gauge in the hole of spark

plug.

ENGINE VACUUM CHECKThe vacuum that develops in the intake line is a goodindicator of the engine condition, and its checking pro-cedures are as follows :1. Warm up engine up to the normal operating tem-

perature.2. Stop the engine, and connect the vacuum gauge to

the vacuum hose on intake manifol.

3. Run the engine at specified idling speed, and un-der this running condition, read the vacuum gauge.

6. Depress the clutch pedal fully to decrese the sartingload when cranking. And then depress the accel-erator so that the throttle valve will be opened fully.

7. operate the starter motor by using key switch. Andthen read the highest value on the installed pres-sure gauge.

COMPRESSION PRESSURE(kg/cm2)

300 400rpm

12.5

12 13

1.0 or LESSTHAN

Fig, 6B 7 Installtion of CompressionPressure Gauge

1

1. COMPRESSION GAUGE(0991564510) 1. VACUUM GAUGE(0991567310)

Fig, 6B 8 Connecting Vacuum Gauge

STANDARD

LIMIT

DIFFERENCE BE-TWEEN CYLINDERS


OIL PRESSURE CHECK

CAUTIONPrior to check of oil pressure, check the followings. Check oil level and add if required. Replace the discolored, deteriorated or diluted

oil. Check any oil leakage and repair the defective

part.

1. Remove the oil pressure switch from the cylinderblock.

1. OIL PRESSURE SWITCH

1

Fig. 6B 9 Oil Pressure Switch

2.5 3.0OIL PRESSURE(kg/cm2)

2. Install the oil pressure gauge on the mounting placeof the pressur switch.

3. Start the engine and warm up to the normal operat-ing temperature.

4. Raise the enigne speed up to 2000rmp, and thenread oil pressure.

Fig. 6B 10 Installation of Oil PressureGauge

5. After checking, wrap the threads of oil pressureswitch with a seal tape and tighten it to the speci-fied torque.

6. Start the engine and check oil pressure switch foroil leakage.

OIL PRESSURE SWITCHTIGHTENING TORQUE(kgcm) 120 160

CAUTIONCut off the seal tape edge bulged out from thethreads of switch.


OIL FILTER CHANGE ENGINE OIL CHANGE

CAUTIONBe sure to use only the recommended oil.

Change the oil filter with oil filter wrench.

CAUTIONWhen installing oil filter, apply oil to its rubberseal.

TIGHTENING TORQUE FOR OILFILTER(kgcm)

PERIOD OF OIL FILTERREPLACEMENT

120 160

EVERY 10,000km

1. Drain engine oil by removing drain plug of oil pan.2. After draining oil, reinstall drain plug and tighten it

securely.3. Pour oil through the oil intake.(is on the cylinder

head)4. Refer to the following table for the recommended

oil and oil capacity :

2.5(2.7)

3.2

OIL CAPACITY( l )

PERIODICAL CHANGE(INC.OIL FILTER)

AFTER ENGINE OVERHAULING

AMBIENT AIR TEMPERATURE C

SAE 5W 30

30 20 10 0 10 20 30

SAE 10W 30

OIL GRADE : SF, SG GRADE

1

1. OIL FILTER WRENCH(0991547340)

Fig. 6B 11 Mounting Oil Filter


ADJUSTMENT OF VALVE CLEARANCE1. Remove the cylinder head cover.2. Turn the crankshaft so that No.1 cylinder position

will be the compression top dead centerposition.(Check the compression top dead centerafter confirming the direction of the rotor of distribu-tor is on the ignition sequence for No. 1 cylinder).

Fig. 6B 13 Valve Clevrance

Fig. 6B 14 Measuring Valve Clearance

0.15 0.02

0.20 0.02

0.25 0.02

0.30 0.02

IN

EX

IN

EX

VALVECLEARANCE

(mm)

COLD

HOT

Valve Clearance( A )

CAUTIONIn case of hot engine, warm up the engine untilthe electric cooling fan begins to work and stopthe engine, and then adjust the clearance after 2030 minutes therefrom. It is recommendable toadjust the valve clearnace while the eigine is cold.

4. Loosen the lock nut first and adjust the valve clear-ance by turning the adjusting screw to the right orleft. After setting the adjusting screw, tighten thelock nut to the specified torque.And then check again the valve clearance.

TIGHTENING TORQUE FOR LOCK(kgcm) 150 200

Fig. 6B 12 Location of CompressionTop Dead Center

3. Check and adjust the valve clearance using thick-ness gauge.

CYL. NO.

CONDITION

COMPRESSION TOP DEAD

CENTER OF NO.1 CYLINDER

EXHAUST TOP DEAD CENTER OFNO.1 CYLINDER(One turn from thecompression top dead center)

IN

EX

IN

EX

1 2 3

* marks indicates the place where the valve clear-ance can be checked and adjusted.

1. ADJUSTING SCREW LOCK NUT2. ADJUSTING SCREW3. VALVE STEM

3

A

2 1


AIR CLEANER ELEMENTRemoval

1. Air cleaner outlet hose.2. Blow-by hose.3. Air cleaner element.

Fig. 6B 15 Air Cleaner Assembly.

Inspection

check for dust

Cleaning

Blow off dust with compressed air from inside of ele-ment.

Fig. 6B 16 Element Cleaning

Fig. 6B 17 Distributor

Installation

It is the reverse of removal procedures. Take care ofthe followings. Use new gasket. Adjust the ignition timing with reference to the on-

car service.

DISTRIBUTORDisassembly

1. Disconnect ( ) terminal from the battery.2. Remove distributor from the distributor housing.3. When the distributor housing is being removed, en-

gine oil is dropping down, so place pieces of clothunder part.

PERIODICAL

SERVICE

CLEANING

REPLACE

EVERY 5,000 km

EVERY 20,000 km


CARBURETOR AND INTAKE MANIFOLD

1. CARBURETOR ASSEMBLY2. GASKET3. INSULATOR4. INTAKE MANIFOLD

FIG. 6B 18 Carburetor and Intake Manifold.

1

2 43

Removal

1. Front Seat2. Console Box3. Engine Room Center Member4. Air Cleaner Case5. Fuel Hose Accelerator6. Accelerator cable from Carburetor7. Choke Cable8. Vacuum Hoses9. Wiring Harness

10. Carburetor Assembly11. Intake Manifold.

180 280

180 280

TIGHTENING TORQUE FOR CARBURETOR(kgcm)

TIGHTENING TORQUE FOR INTAKE MANIFOLD(kgcm)

Tighten the mounting bolt and nuts of intake mani-fold to the specified torquue.

Installation

It is the reverse of removal procedures. Take care ofthe followings. Tighten the mounting bolt of carburetor to the speci

fied torque.


EXHAUST MANIFOLD

1. EXH. MANIFOLD2. GASKET3. UPPER COVER4. LOWER COVER

FIG. 6B 19 Exhaust Manifold

3

4

1

2

Removal

1. Front passenger's seat2. Air cleaner outlet hose3. Muffler4. Exh. manifold upper cover5. Exh. manifold lower cover6. Exh. manifold.

Installation

It is the reverse of removal procedures. Take care ofthe followings. Check the gasket and replace the aging or damaged

gasket with a new one. Install the exhaust manifold with the specified torque.

180 280TIGHTENING TORQUE FOR EXHAUSTMANIFOLD(kgcm)


TIMING BELT AND BELT TENSIONER ADJUSTMENT

Fig. 6B 21 Removal of Crank Pulley Fig. 6B 22 Removal of Timing Belt

1. TIMING BELT INSIDE COVER2. CAMSHAFT TIMING PULLEY3. TIMING BELT COVER OUTSIDE4. TIMING BELT OUTSIDE COVER5. TIMING BELT TENSIONER6. TIMING BELT

Removal

1. Set the No. 1 cylinder to exhaust top dead center byturning crank pulley.

2. Crank pulley3. Outside cover4. Timing belt tensioner5. Timing belt

ALTERNATOR

CRANK TIMING PULLEYTIMING BELT TENSIONER

WATER PUMP

CAMSHAFT PULLEY

Fig. 6B 20 Timing Belt, Tensioner, Timing Belt Cover

1. CRANKSHAFT PULLEY HOLDER(09927 56020)

1

3

2

1

56

4


CAUTIONNever turn the crankshaft or camshaft with timingbelt removed.!!The piston and valve are to be collaspsed togetherwhen crankshaft turns 30 and more against thetiming mark.

Inspection

Replace the damaged or worn timing belt. Check the smooth operation of tensioner.

Installation

It is the reverse of the removal procedures.Take care of the followings. Tighten bolt roughly by hand before installation of

tensioner.

CAUTIONBefore installation of timing belt, check the arrowdirection on the belt and install it on the same di-rection of turning.

2

1

3

1. CAMSHAFT TIMING PULLEY2. TIMING MARK3. TIMING BELT INSIDE COVER

Fig. 6B 24 Timing Mark(CAMSHAFT)

1. TENSIONER2. TENSIONER BOLT

FIG. 6B 23 Installation of Tensioner

1

2

CAUTIONReplace the old tensioner spring with a newone.

Match the timing mark of camshaft pulley with thetiming mark of inside cover.

1 2

1. PUNCH MARK OF THE OIL PUMP SURFACE2. PUNCH MARK OF PULLEY GEAR

Fig. 6B 25 Timingmark(CRANKSHAFT PULLEY)

Turn the crankshaft and adjust the punch mark ofpulley gear to be matched with the mark on the oilpump surface.

Make the timing marks of pulley on the cam sidematched with crank side, and then install timing beltand mount the tensioner spring with mountingscrews.


Fig. 6B 27 Tightening of Tensioner Bolt

Tighten crank pulley to the speciffied torque.

650 750 TIGHTENING TORQUE FOR CRANK PULLEY(kgcm)

Adjust the clearance of intake and exhaust valvesreferring to page the preceding page.

150 230

Install the belt and turn the crankshaft twice to itsturning direction, then tighten the tensioner bolt tothe specified torque.Check again the corresponding line with the timingmark.

CAMSHAFT PYLLEY

WATER PUMP

ALTERNATOR

CRANK TIMING PULLEYTIMING BELT TENSIONER

FIG. 6B 26 Installation of Timing Belt

1. TENSIONER2. TENSIONER BOLT

1

2

Fig. 6B 28 Mounting Crank Pulley

TIGHTENING TORQUE FOR TENSIONER BOLT(kgcm)


OIL PUMPPRINCIPLES OF OPERATIONRotary pump

OUTER ROTORNO.1 INTAKE

INLET

NO.2 INTAKE NO.3 INTAKE EXHAUST

Fig. 6B 29 Rotary Pump

The rotary pump is also called as trochoid pump and its structure is formed with the inner and outer rotors in ac-cordance with trochoid curve.The teeth of inner rotor are one less than those of outer rotor. Both of the inner and outer rotors are joining thepump case to rotate the outer rotor in the same direction when the inner rotor is to rotate to the arrow direction bythe crankshaft.When the rotor turns, the lug of inner rotor is engaged into the dented parts of outer rotor one by one, and it makesdifferent volumatric clearance between the inner and outer ortors. The oil is to be taken in the increased part of theclearance, and transported to the opposite side in the jammed space to be pressed out to the outlet due to de-creased clearance.

Specifications

LUBRICATION

OIL CAPACITY

OIL REPLACEMENT

OIL FILTER REPLACEMENT

USABLE OIL

OIL PUMP TYPE

OIL FILTER TYPE

OPERATIONAL PRESSUREOF OIL PRESSURE SWICH

OIL PRESSURE(2000 rpm)

FORCED FEED TYPE

REPLACED WITH FILTER : 2.7lWHEN DISASSEMBLING ENGINE : 3.2l

EVERY 10,000 km

EVERY 10,000km

ABOVE SE GRAND(SAE 10W-30)

ROTARY(TROCHOID)TYPE

FILTER ELEMENT

0.3 0.1kg / cm2

2.5 3.0kg / cm2


Inspection

Check the rib for damage and replace the damagedoil seal.

Check the excessive wear or damage in the outerand inner rotors, rotor plate and oil pump case.

Measurement

Measure the clearance between outer rotor and its caseusing thickness gauge, and replace the outer or casewhen its measurement is over the specified valve.

5

12

3

4

1. OIL PUMP ASSEMBLY2. INNER ROTOR3. OUTER ROTOR4. ROTOR PLATE5. RELIEF VALVE

Fig. 6B 30 Oil Pump

1. OUTER ROTOR2. INNER ROTOR

Fig. 6B 32 Clearance Measuring

1

2

Side Clearance

Measure the side clearance using a straight ruler andthickness gauge.

REMOVAL

1. Crank pulley, outside cover, timing belt tensioner2. Timing belt pulley.3. Engine front mounting4. Oil pan5. Oil strainer6. Oil pump

Fig. 6B 31 Remove Bolts for Oil Pump

CLEARANCE BETWEEN OUTERROTOR AND CASE(mm) 0.31 AND LESS

SIDE CLEARANCE(mm) 0.15 AND LESS


Install the oil pump to the specified torque.

TIGHTENING TORQUE FOR OIL PUMP(kgcm) 90 120

Fig. 6B 33 Measuring Side Clearance

Installation

It is the reverse of removal procedures. Take care ofthe followings. When installing of oil pump case, protect the oil seal

rib by using seal guide.

1

2

1. CRANKSHAFT2. OIL SEAL GUIDE

FIG. 6B 34 Installation of Oil Seal Guide

Fig. 6B 35 Attachment of Oil Pump

Cut off the projected edge of the oil pump gasketusing a scraper, and make it to the same height asthe section of cylinder bolck.

Fig. 6B 36 Cutting off the Edge of Gasket

Refer to the preceding pages for installing timing belt.


CYLINDER HEAD, CAMSHAFT, VALVE, ROCKER ARM SHAFT

1. CYLINDER HEAD2. VALVE GUIDE3. CAMSHAFT4. VALVE ROCKER ARM SHAFT5. VALVE ROCKER ARM6. VALVE SPRING7. INTAKE VALVE8. EXHAUST VALVE

8

Fig. 6B 37 Cylinder Head, Camshaft, Rocker Arm Shaft

7

6

2

1

4

3

4

5

Removal

1. Front seat2. Battery "" terminal3. Engine service cover4. Drain coolant5. Air cleaner case6. Coolant hoses7. Vacuum hoses8. Fuel hoses9. Accelerator cable

10. Wiring harness11. Timing belt outside cover and Timing belt

tensioner12. Camshaft pulley13. Timing belt inside cover14. Exhaust center pipe15. Exhaust manifold16. Distributor Case17. Cylinder head cover.18. Cylinder head bolt(8EA) and Cylinder head as-

sembly.

2 8 6 4

1753

Fig. 6B 38 Romoval of Cylinder Head Bolts


5. Install valve lifter, compress the valve spring andremove the valve cotter pin.

Disassembly

1. Remove the distributor case and exhaust manifoldfor easy disassembling.

2. Rocker arm shaft bolt.

3. Remove the intake and exhaust rocker arm shaft,rocker arm and spring.

4. Remove the camshaft from cylinder head.

2

1

1. FORCEPS(0991684510)2. VALVE COTTER PIN

FIG. 6B 43 Removal of Valve Cotter

1. VALVE LIFTER(09916 14510)2. VALVE LIFTER ATTACHMENT(09916 48210)

2

1

Fig. 6B 42 Installation of Valve Lifter

Fig. 6B 39 Removal of Rocker Arm Shaft Bolt

Fig. 6B 40 Remove of Rocker Arm Shaft

Fig. 6B 41 Removal of Cam Shaft

1

1. CAMSHAFT


Fig. 6B 45 Removal of Valve Guide

CAUTIONThe removed valve guide should be replaced bynew one of oversized.Do not reuse valve guide.

6. Remove the valve lifter and then spring retainer andvalve spring.

7. Pull out the valves.8. Remove the valve stem oil seal and valve spring

seat.

9. Remove the valve guide from the combustion cham-ber to the direction of the installed valve spring byhitting valve guide remover.

Inspection

Abrasion of cam

Measure the height of cam using a micrometer, andreplace the camshaft when measured valve is less thanthe specified limit.

Measuring the bending of camshaft

Measure the bending of camshaft using a dial gauge,and replace it when the measured value is over thespecified limit.

BENDING LIMIT(mm) 0.03 AND LESS

CAUTIONThe removed oil seal should be replaced.Do not reuse oil disassembled. ITEM LIMIT

36.10

36.11

IN

EXHEIGHT OF CAM(mm)

STANDARD

36.132

36.135

Fig. 6B 44 Removal of Valve Stem Oil Seal

Fig. 6B 46 Measuring the Cam Height

1. VALVE GUIDE REMOVER(09916 44910)

1. VALVE STEM OIL SEAL2. DRIVER3. VALVE SPRING SEAT

1

3

2 H

1


CAMSHAFTPULLEY SIDE

Fig. 6B 47 Measuring the Bendingof Camshaft

FUEL PUMP SIDE

Fig. 6B 48 Measuring Diameter ofCamshaft Journal

Abrasion of camshaft journalMeasure the outer diameter of each journal at the 4different places, and then measure the inner diameterof cylinder head journal at the 4 places by using cylin-drical gauge. The claearance of journal is measuredby the difference between the journal diameter and borediameter of the journal part. Replace the camshaft(orcylinder head, if necessary) of which limit is over thespecified limit.

LIMIT

0.15

STANDARD

0.0500.091

ITEM

JOURNAL CLEARANCE(mm)

INNER DIAMETER(CYLINDER HEADJOURNAL PART)

43.50043.516

43.525

43.70043.716

43.725

43.90043.916

43.925

44.10044.116

44.125

OUTER DIAMETER(CAMSHAFTJOURNAL)

43.45043.425

43.375

43.62543.650

43.575

43.82543.850

43.775

44.02544.050

43.975

STANDARD

LIMIT

STANDARD

LIMIT

STANDARD

LIMIT

STANDARD

LIMIT

A

B

C

D

ITEM(UNIT : mm)

FIG. 6B 49 Measuring Bore Diameter ofJournal Part


Bending of rocker arm shaftMeasure the bending by using V block and dial gauge.Replace the rocker arm shaft if bending is over thelimit.

BENDING LIMIT(mm) 0.10

Fig. 6B 51 Measuring Diameter of RockerArm Shaft and Inner Diameterof Rocker Arm

Fig. 6B 50 Measuring the RockerArmshft Bending

Clearance between rocker arm and rocker armshaft

Measure the outer diameter of rocker arm shaft andinner diameter of rocker arm using a micrometer andcylindrical gauge. Replace the shaft or rocker arm, orboth of them, if the difference between the outer diam-eter and inner diameter is over the limit.

LIMIT

0.06

CLEARANCE BETWEENROCKER ARM ANDROCKER ARM SHAFT(mm)

STANDARD

0.0050.040


Valve guideMeasure the diameter of valve stem and bore diameteror guide(at least 1 place in the direction to length), andcalculate the clearance between stem and guide.

LIMIT

5.53

5.53

0.07

0.09

ITEM

VALVE STEM DIAMETER

(mm)

VALVE GUIDE INNER

DIAMETER(mm)

CLEARANCE BETWEEN

STEM AND GUIDE(mm)

IN

EX

IN

EX

IN

EX

STANDARD

5.4655.480

5.4405.455

5.5005.512

5.5005.512

0.0200.047

0.0450.072

Fig. 6B 52 Measuring Valve Stem Diameter and Valve Guide Inner Diameter

If a cylindrical gauge is not available, measure the clear-ance using a dial gauge by moving the edge of stem tothe directions of , .Replace the valve stem or valve guide, if the measuredvalue is over the limit.

EDGE OF VALVE

CLEARANCE LIMIT(mm)

IN

EX

0.14

0.18

1 2

1

2

Fig. 6B 53 Measuring the Clearance of ValveStem

MACHINING LIMIT OF VALVE STE(mm) 0.5 AND LESS

Valve Remove all carbon from valve. Check the valve or stem for the abrasion, burn, bend-

ing, and then replace if necessary. Check the edge of each valve for abrasion.

Some uneven abraison would be made on the edgebecause the rocker arm gets contacted at this sur-face when operating. Repair the section within0.5mm if requried, or repace it if required modifica-tion is more than that.

1 2

< >


Measure the deviation to the rotating direction us-ing a dial gauge and V block by turning the valveslowly. Replace valve, if the measured value ex-ceeds the limit.

Fig. 6B 56 Machining of the Valve Seat

DEVIATION LIMIT OF VALVE HEAD TO THE ROTATING DIRECTION(mm) 0.08

Fig. 6B 54 Measuring the Deviation to theRotating Direction

Checking the contact width

Clean valve and valve seat and apply red stamping inkthinly to the contacting surface of the valve seat. Checkthe fitness after installing the valve on it. A good con-tact shows the equal contact width within the specified.

CONTACT WIDTH O THE

SURFACE OF VALVE SEAT(mm)

IN

EX1.46 1.66

1

1. CONTACT WIDTH OF VALVE SEAT

Fig. 6B 55 Contact Width of Valve Seat

Valve seat repair

If its contact width is not even or beyond the specifiedvalue, grind or machine the valve seat. And then lap it. When applying a seat cutter, use the one of smaller

angle first and increase the angle of the using cut-ter up to the light and final modification of the con-tact. And finish contact surface and its location withthe cutter of 45

CAUTION When machining, take care of the contact width. Finish the cutting with gradually reduced power

for no cutting mark on the surface.

1. VALVE SEAT CUTTER

1


CAUTIONMeasure the flatness of cylinder head surface inthe location of each 4 side and diagonal.

(EXHAUST SIDE)(INTAKE SIDE)

1545

1545

Fig. 6B 57 Valve Seat Angle

Valve lapping

Make lapping in two stages, first with normal lap andsecond with fine one for the both sides.

Cylinder head

Remove carbon from the combustion chamber. Be sure not to make scratch on the intake and ex-

haust ports of cylinder head, combustion chamber,and head surface together with and valve seats.

CAUTIONAll carbon should be wiped up on the head andmake no scratch on the metallic surface togetherwith valve and valve seat.

Flatness of cylinder head

Measure the flatness of the 6 different places using astraight ruler and thickness gauge. If the measurementis read over the limit of use, confirm the deformed areaby placing it on the flat plate and repair it with fine abra-sives. Replace the cylinder head of which repair isimpossible.The deformation of the cylinder head surface may causethe loss of power due to the leakage of the compres-sion.

DEFORMATION LIMIT OF FLATNESS ON THE CYLINDER HEAD SURFACE(mm) 0.05

Fig. 6B 58 Measuring of Cylinder Head

Deformation of the surface for manifold installation

Inspect the surface for installing manifold of cylinderhead using a straight ruler and thickness gauge andrepair the installing surface or replace the cylinder headif necessary.

LIMIT OF MANIFOLD DEFORMATION(mm) 0.10

Fig. 6B 59 Measuring the Deformation ofInstalling Surface for IntakeManifold


Valve springs

Weakened valve springs can be the cause of chatter,not to mention the possibility of reducing the poweroutput due to gas leakage caused by decreased seat-ing pressure.Replace the springs of which valve spring free lengthand valve spring preload are less than the limits.

I T E M STANDARD

54.45

23.4 27

LIMIT

53.4

22

Fig. 6B 60 Measuring Free Length ofSpring

Fig. 6B 61 Measuring Spring Preload

Spring squareness

Measure squarenss of each spring using a flat plate andsquare.Replace the valve spring if squarness is over the limit.

VALVE SPRING FREE LENGTH(mm)

VALVE SPRING PRELOAD(kg/44.2mm)

VALVE SPRING SQUARENESS LIMIT(mm) 2.4

Fig. 6B 62 Measuring the SpringSquareness


Assembly

1. Before installing new valve guide into cylinder head,ream guide hole with 11 mm reamer to removeburrs. Make sure that the guide hole comes to acomplete roundness.

1

Fig. 6B 63 Reamer Tool

1. 11MM REAMER(09916 38210)

2. Install valve guide. Heat cylinder head uniformly at a temperature 80

100C not to make the head deformed, and drivenew valve guide completely into hole with specialtools(guide installer).

After installation, check the protruded part of theguide from cylinder head.

3

2

1

1. VALVE GUIDE INSTALLER ATTACHMENT(09917 98220)2. VALVE GUIDE INSTALLER(09916 58210)3. VALVE GUIDE PROTRUSION(14MM)

Fig. 6B 64 Installation of Valve Guide

3. Repair the valve guide bore with 5.5mm reamer, andmake the hole free from foreign material.

4. Install new valve stem seal to valve guide. After applying engine oil to seal and installing seal

to valve guide and make sure that seal is properlyfixed to valve guide.

Fig. 6B 65 Modification of Valve Guide

1. VALVE GUIDE 2. 5.5MM REAMER

2 1

CAUTIONDo not reuse valve guide once disassembled, re-place it with new oversized valve guide.

VALVE GUIDE OVERSIZE(mm)

VALVE GUIDE PROTRUSION(mm)

0.03

14


Fig. 6B 67 Valve Spring

7. Using valve lifter, compress valve spring and insertvalve cotters with pincettes into the valve stemgroove.

Fig. 6B 68 Insertion of Valve Cotters

1. LARGE-PITCH2. SMALL-PITCH3. VALVE SPRING

RETAINER SIDE4. VALVE SPRING

SEAT SIDE 4

3

CAUTION Do not reuse disassembled oil seal and replace

it with new one. When installing, never tap or hit special tool with

a hammer or else. Install seal to guide only bypushing special tool with hand. Tapping or hit-ting special tool may cause damage on seal.

5. Install valve to valve guide. Before installing it, ap-ply engine oil to stem seal, valve guide bore andvalve stem.

Fig. 6B 66 Installation of Valve

6. Install valve spring and spring retainer. Each valve spring has top end(large-pitch end) and

bottom end(small-pitch end). Be sure to positionspring in place with its bottom end (small-pitch end)down to valve spring seat side.

31

2

1. VALVE LIFTER2. FORCEPS3. VALVE COTTER

8. Apply engine oil to the parts for lubrication as camand journals of camshaft.

9. Install camshaft from transmission case side.

2

1


Cylinder headApply engine oil to cylinder head bolts, and tighten thebolts in the sequence as shown in the figure to thespecified torque.

650 700 TIGHTENING TORQUE FOR CYLINDER HEAD BOLTS(kgcm)

Fig. 6B 69 Installation of Camshaft

10. Apply engine oil to rocker arms and rocker armshafts, and install rocker arms, springs and rockerarm shafts. Rocker arm shafts for intake valvesand exhaust are identical but their directions of in-stallation are different.

Fig. 6B 70 Installation Sides of Rocker Armshafts

Installation

It is the reverse of removal procedures. Take care ofthe followings.

Cylinder head and gasketReplace the old with new gasket after confiming the oilholes. The oil hole on the gasket should be located onthe crankshaft pulley side.

Fig. 6B 71 Installation of Cylinder HeadGasket

5317

8 4 2 6

Fig. 6B 72 Tightening Sequence forCylinder Head Bolts

Refer to the preceding pages for adjusting the intake,exhaust valve clearence.

Using the special tool(camshaft holder), tighten thecamshaft pulley to the specified torque.

TIGHTENING TORQUE FOR CAMSHAFT PULLEY(kgcm) 550 600

OIL HOLE


Fig. 6B 74 Insertion of Guid Hose

6. Remove piston and connecting rod from cylinderhead by pressing connecting rod toward cylinderhead.

7. Mark the cylinder number on the piston and con-necting rod with marking pen.

8. Arrange the piston and connecting rod of No. 2 andNo. 3 cylinders according to the sequence as aboveparagraphs 3 to 7.

Disassembly

Remove the compressing rings and oil rings usingthe piston ring expander, and arrange it carefully notto be mixed together.

Remove the circlip and pull out the piston pin toseparate piston and connecting rod.

Cleaning

Wipe out carbon on the piston and ring with softcloth. In the cleaning process, no metal tool norexcess force be used.

Inspection

Cylinder

Wipe out the wall side of cylinder and check anyscratch or excess abrasion on it. Apply boring withoversize when such damage is over the limits.

Measure the bore diameter of cylinder with cylinderguage in longitudinal and transverse directions.There are 3 measuring locations(see figure). Reboreto next oversize in following cases.

1. Abrasion over the limit is found in the gore diam-eter of cylinder.

2. The maximum taper deviation of the measured val-ues obtained from the 3 checking locations are overthe limit(perpendicularity).

3. The measured valves are over the limit roundnessat the 3 checking locations.

LIMIT

68.570

0.10 AND LESS

0.05 AND LESS

ITEM

BORE DIAMETER OF CYLINDER(mm)

TAPER(mm)

ROUNDNESS, CYLINDRICITY(mm)

PISTON, PISTON RING,CONNECTING ROD AND CYLINDER

1. NO. 1 RING2. NO. 2 RING3. OIL RING4. PISTON5. CONNECTING ROD6. BEARING CAP7. BEARING8. PISTON PIN9. CIRCLIP

Fig. 6B 73 Disassembly of Piston andConnecting Rod

1

2

3

4

9

98

5

67

Removal

1. Remove te parts attached around cylinder block.2. Turn over the cylinder block to remove oil pan and

oil strainer.3. Turn crankshaft slowly to make the big end of con-

necting rod come to the top side, and then loosenconnecting rod bolts.

4. Separate the connecting rod cap.5. Insert guide hose in the screw side of connecting

bolt to prevent any damage on the crankshaft pinand cylinder wall side.

1

1. GUIDE HOSE


CAUTION When rebore to oversize, the oversizes on the 3

cylinders should be maintained. Specification of oversizes shall be varied as 0.25,

0.50, 0.75 and 1.00, and the oversizes should bethe same for cylinder, piston and rings when bor-ing and installing.

Piston Clean piston with soft cloth and check any damage

to determine whether to replace it. Use micrometer to measure the outer diameter of

piston. Check the outer diameter of the piston in theperpendicular direction of the piston pin at 15mmheight from the skirt.

1. 5.8mm2. 50mm3. 92mm

1

2

3

Fig. 6B 75 Measurement and MeasuringLocation of Cylinder BoreDiameter

1

Fig. 6B 76 Measuring the Outer Diameterof Piston

1. 15MM

OUTER DIAMETER

OF PISTON(mm)

68.465 68.485

68.715 68.735

68.965 68.985

STANDARD

OVERSIZE 0.25

OVERSIZE 0.50

Piston clearance

Calculate the different value of the measurement be-tween cylinder inner diameter(50mm below the headsurface) and piston outer diameter(15mm above thepiston skirt).

PISTON CLEARANCE(mm) 0.025 0.045

CAUTIONWhen measuring cylinder bore diameter and pis-ton outer diameter, calculate the measured valuesboth in the same directions of crankshaft and pis-ton pin.


CLEARANCE OF

RING GROOVE

(mm)

STANDARD

0.02 0.06

0.02 0.06

0.06 0.10

PISTON RING

NO.1 RING

NO.2 RING

OIL RING

LIMIT

0.10

0.10

Piston ring clearance in the groove

De-carbon and make the groove clean before insertingthe ring, and measure the clearance between ring andring land with thickness gauge.If the measured exceeds the limit, replace the piston.

1. PISTON RING2. THICKNESS GAUGE

Fig. 6B 77 Measuring the Ring Groove

Piston ring gap

To measure the end gap, insert the piston ring into thecylinder bore with the piston, locating it at the lowestpart of the bore, then use a filler gauge to measure thegap. If the gap measured exceeds the limit, replacethe ring.

2

1

Fig. 6B 78 Measuring the Piston Ring Gap

1. CYLINDER BLOCK2. FILLER GAUGE3. PISTON RING

3

4

2

1

LIMIT

0.35

STANDARD

0.10 0.20

CONNECTING ROD BIG END

THRUST CLEARANCE(mm)

Connecting rods Big-end thrust clearance

Check the big end of each connecting rod for thrustclearance, with the rod fitted and connected to itscrank pin in the normal manner. If the measuredclearance is found to exceed the limit or any dam-age is found on the thrust surface of both ends, theresponsible connecting rod or the crankshaft mustbe replaced.

Fig. 6B 79 Measuring the Piston Pin

ITEM

OUTER DIA. OF PISTON(mm)INNER DIA. OF PISTON PIN BOSS(mm)

PISTON PIN CLEARANCE(mm)

STANDARD

15.995 16.000

16.006 16.014

0.006 0.019

Piston pinMeasure the clearance between piston pin and pistonboss part, and if the measured exceeds the standard,replace the piston pin.

CAUTIONDe-carbon the cylinder bore and insert the ring.

PISTON RING

GAP(mm)

PISTON RING

NO.1 RING

NO.2 RING

OIL RING

LIMIT

0.7

0.7

1.8

STANDARD

0.15 0.30

0.1 0.3

0.2 0.7


Measure the oil clearance by using the plastigauge. Prepare, by cutting a length of plastigauge equal to

bearing width and place it axially on crankpin, avoid-ing oil hole.

Install connecting rod bearing and bearing cap andtighten to the specified torque. At this time, neverturn or rotate the crankshaft.

CAUTIONNever use scraper or sandpaper to repair thebearing

Bearing clearance

Inspect the bearing for damage, burn, etc., and observethe contact pattern. Bearings found in defective condi-tion through this inspection must be replaced.

Fig. 6B 80 Measuring Big-End ThrustClearance

LIMIT

0.05 (IN CASE OF 100mm)

0.10 (IN CASE OF 100mm)

LTEM

BENDING

TWIST

100mm

100mm

CONNECTING ROD ALIGNER

Fig. 6B 81 Measuring the Bending andTwist

1. PLASTIGAUGE2. SCALE

Fig. 6B 82 Measuring the ConnectingRod Bearing Oil Clearance

21

TIGHTENING TORQUE FOR BEARING CAP(kgcm) 310 350

Remove the cap, and measure the width ofplastigauge with the scale marked on theplastigauge case. This measurement must be takenat the widest part of the compression and attentionshould be also paid to the different values measuredat the both ends of the plastiguge.

OUTER DIAMETER OF CRANK PIN(mm)

37.982 38.000

SIZE

STANDARD

BEARING SIZE

If the oil clearance exceeds the limit, replace the bear-ings.

STANDARD

0.020 0.040

LIMIT

0.065

Bending, Twist

Check the bending and twist of connecting rod usingthe connecting rod aligner, and if the limit is exceeded,replace it.

BEARING OIL CLEARANCE(mm)


Assembly

It is the reverse of disassembly procedures. Take careof the followings.1. Assenbly of connecting rod and piston,

Connect small ends of piston and connecting rodwith piston pin, and fix them with circlip. Thereare assembling directions on the piston and con-necting rod. Determine the directon by front markon the piston head and oil hole on the connect-ing rod.

1. NO.1 RING2. NO.2 RING3. OIL RING

Fig. 6B 84 Postion and Mark of Piston Ring

3. Install three rings and position their openings asshown in Fig. 6B 85.

1

2

3

MARK

R

5

24

1

7

7 7

7

3

6 8

9

1. MARK2. OPENING OF NO.1 RING3. OPENING OF NO.2 RING4. OPENING OF OIL RING RAIL (UPPER RAIL)5. INTAKE SIDE6. EXHAUST SIDE7. 458. PENING OF OIL RING SPACER9. OPENING OF OIL RAIL(LOWER RAIL)

Fig. 6B 85 Postions of Opening of Piston Ring

1. PISTON2. ARROW MARK3. CONNECTING ROD4. OIL HOLE(TO INTAKE SIDE)

CRANKSHAFT PULLY SIDE

1 2

Fig. 6B 83 Assembly of Piston andConnecting Rod

3

4

2. Install piston ring to piston. It is marked "R" on the upside of No. 2 ring as

shown in Fig. 6B 84.When installing to piston place the marked sideupward.

Rings No. 1 and No. 2 are different in thickness,shape and color of contact part to cylinder wall.For identification, refer to Fig. 6B 84.

When installing oil ring, insert spacer first andtwo rails later.


Installation

1. Apply enigne oil to piston, ring, cylinder wall andbearing crank pin of connecting rod.

2. When install connecting rod and piston, install theguide hose to connecting rod bolt as shown in Fig.6B 74 to prevent damage to crank pin.

3. Insert piston into cylinder with the arrow pointingtowards crank pulley.

5. Install cap with the arrow on the cap towards crankshaft pulley and tighten the cap nut with specifiedtorque.

6. Assembly other parts with reverse procedures ofdisassembly. Refer to the para. "Timing Belt andbelt tensioner" in section 6B.

7. Add the oil to engine.8. Refill the coolant.9. Check and adjust ignition timing.

10. After completing installation, check the leakage ofcoolant, fuel and oil from each connection.

Fig. 6B 86 Mark on Piston Heads

1. CRANKSHAFT PULLEY SIDE2. FLYWHEEL SIDE

12

4. Pucker piston ring with piston ring compressor, andinsert connecting rod and piston to cylinder prop-erly. At this time, push the ring compressor againstthe cylinder block, and insert the piston head intocylinder by hitting the head of piston lightly.

1. PISTON RING COMPRESSER(09916 77310)

Fig. 6B 87 Insertion of Piston Into Cylinder

1

310 350

2 1

3

4

1. BEARING GAP 3. CRANKSHAFT PULLEY SIDE2. ARROW MARK. 4. CAP NUT

Fig. 6B 88 Installation of Bearing Cap

TIGHTENING TORQUE FOR CONNECTING ROD BEARING CAP NUT(kgcm)


DISASSEMBLY

ENGINE ASSEMBLY

9. Oil pressure gauge harness10. Propeller shaft11. Clutch wiring harness from mounting member12. Rear mounting13. Mounting member14. Engine and transmission assembly.

Fig. 6B 90

Lower parts of engine

1. Drain coolant2. Radiator outlet hose3. Heater hose4. Booster hose5. Clutch cable6. Gear shift cable, Gear select cable7. Speedometer cable8. Exhaust center pipe

Removal

Upper parts of engine

1. Front seat2. Engine service cover3. Battery "" terminal4. Radiator inlet hose on engine side5. Air cleaner case on carfuretor side6. Accelerator cable7. High tension cable8. Generator and wiring harness on start motor9. Fuel feeding and return hose on carburetor.

Fig. 6B 89


Installation

It is the reverse of removal procedures and its tightening is to be mad to the specified torque.

350 450

350 450

2

450 600

350 450

180 280

4

1

450 6003

5

: TIGHTENING TORQUE(kgcm)1. FRONT MOUNTING MEMBER2. FRONT MOUNTING LEFT BRACKET3. FRONT MOUNTING RIGHT BRACKET(LABO)4. FRONT MOUNTING RIGHT BRACKET(DAMAS)5. CLUTCH CABLE BRACKET.

Fig. 6B 91 Engine Mounting Illustration


MAIN BEARING, CRANK SHAFT, CYLINDER BLOCK

Fig. 6B 92 Main Bearing, Crankshaft, Cylinder Block

1

2

3 4

9

87

5

10

1. CYLINDER BLOCK 6. REAR OIL SEAL2. FORNT OIL SEAL 7. OIL SEAL HOUSING GASKET3. MAIN BEARING 8. OIL SEAL HOUSING4. CRANKSHAFT 9. INPUT SHAFT BEARING5. THRUST BEARING 10. FLYWHEEL


Removal

1. Remove engine from body.2. Disconnect transmission assembly.3. Alternator bracket, timing belt, crankshaft pulley.4. Cylinder head.5. Oil pan and oil strainer.6. Piston and connecting rod.7. Main bearing cap and crankshaft.

Inspection

Cankshaft Bending

Measure runout at center journal with V block and dialgauge by turning crankshaft slowly. If runout exceedsthe limit, replace the crankshaft.

Crankshaft thrust play

Install crankshaft thrust bearings and journal bearingson the cylinder block, and tighten bearing cap bolt tothe specified torque, then measure the axial play ofcrankshaft. If the measured exceeds the limit, replacethe thrust bearing with the new standard one or the oneof the next oversize.

CAUTIONTo measure bending, turn crankshaft once to bematched with dial gage on the journal part, andread run out, and then take 1/2 value of the maxi-mum gauge as bending.

Fig. 6B 95 Measuring the Thrust End Playof Crankshaft

Fig. 6B 93 Measuring the Bending ofCrankshaft

LIMIT OF BENDING(mm) 0.03

TIGHTENING TORQUE FOR MAIN BEARING CAP BOLT(kgcm) 550 600

Fig. 6B 94 Thrust Bearing

1

1. THRUST BEARING

LIMIT

0.4

STANDARD

0.11 0.31CRANKSHAFT THRUSTPLAY(mm)


Roundness and Taper.(uneven wear)

Measure the fluctuations of journal diameter in theaxial and right angle direction of crankshaft and con-firm the condition of uneven wear. If some seriousdamage is found, or the deviation and partial devia-tion exceeds the limit, replace the crankshaft or re-pair it by polishing.

LIMIT OF ROUNDNESS AND TAPER(mm) 0.01

TIGHTENING TORQUE(kgcm) 550 600

FIG. 6B 98 Measuring the Oil ClearanceBetween the Main Bearing

Fig. 6B 96 Checking Partial Abrasion

Crankshaft Bearing

Check the surface in contact for wear, burn, scratch,etc. and if necessary, replace it.

CAUTIONNever use scraper to repair bearings.

Measure the oil clearance with plastigauge Cut the plastigauge to the length equal to the width of

the bearing and place it axially on the journal, aboidingthe oil hole.

Install crankshaft bearing and bearing cap, and tightenit to the specified torque. Do not rotate the crank-shaft at this moment.

Fig. 6B 97 Tightening to the Specified Torque

Remove the caps and measure the width ofplastigauge with the scale marked on the plastigaugecase. This measurement must be taken at the wid-est part of the compression and attention should bealso paid to the different values measured at the bothends of the plastigauge. If the oil clearance exceedsthe limit, replace the bearing.

LIMIT

0.065

STANDARD

0.020 0.040

OIL CLEARANCE FOR CRANK-SHAFT BEARINGS(mm)

ITEM

OUTER DIAMETER OF CRANK JOURNAL(mm)

STANDARD

43.982 44.000

CAUTIONBe sure to use the specified bearing when install-ing new crankshaft.

21 1. PLASTIGAUGE2. SCALE


Rear Oil Seal

Inspect the oil seal lips for wear, damage, and mixtureof foreign material. Replace it if necessary.

Cylinder block

Measuring the Distortion of the Gasket Surface (flat-ness)

Measure 6 different places using thickness gauge andstraight scale in the same method as for the cylinderhead. Polish and repair it, if the distortion, bent or twistexceeds the limit. If polishing needs more than 0.15mm,replace it with new one.Pay attention to the flatness on the surface betweencombustion chambers.

Fig. 6B 101 Measuring Flatness

Flywheel Inspect it for damage, crack and abnormal wear at

the ring gear part, or the contaction surface to theclutch plate. Replace the flywheel if necessary.

Measure runout of the flywheel using block and dialgauge, and replace it if runout exceeds the limit.

LIMIT OF RUNOUT(mm) 0.2

LIMIT OF CYLINDER DISTORTION(mm)

STANDARD FLATNESS(mm)

0.05

0.03

1

Fig. 6B 99 Rear Oil Seal

1. REAR OIL SEAL

Fig. 6B 100 Measuring the Flatness of Flywheel


Installation

It is the reverse of removal procedures. Take care ofthe followings. Apply engine oil in the oil groove to install the crank

thrust bearing, and place the oil groove in the outerpart of the joumal portion.

Apply engine oil to the inner surface of bearing, orjournal surface of crank(crank pin side) when install-ing bearing.

On the bearing cap of the crank journal part, Num-bers 1 to 3 are marked in sequence. Tighten it insequence to the specified torque with the arrow di-rection towards crank pulley side.

THGHTENING TORQUE(kgcm) 550 600

Fig. 6B 102 Installation of Thrust Bearing

1

2

1. THRUST BEARING2. OIL GROOVE

Attach the main bearing with the oil port part to thecylinder block, and the part without oil port to thebearing cap.

1

2

3

1. CYLINDER BLOCK2. MAIN BEARING3. OIL POT

Fig. 6B 103 Installation of Bearing

Fig. 6B 104 Location of Main Bearing Cap

Oil seal housing and gasket.Do not reuse gasket disassembled once.Replace it with new one. Apply engine oil to the con-tact surface to install the oil seal, and tighten thehousing bolts to the specified torque.

TIGHTENING TORQUE FOR HOUSING BOLT(kgcm) 90120


After installing oil seal housing, if the gasket edgesare bulged, cut it with scraper to be the same heightwith cylinder block and oil seal housing.

Install piston(refer to preceding page). Install oil pump strainer and oil pan. Install cylinder head assembly on cylinder block

CAUTION When installing cylinder head on a new cylinder

block, tighten the cylinder bolts in sequence fromcenter to outer part, with tightening torque 50%to the specified first, then tighten it with 80% andloosen it. And tighten it again in the above se-quence with 50% and finally 100% of the speci-fied torque.

Intall crankshaft timing belt pulley, camshaft timingbelt pulley, water pump pulley.

Refer section 8B to install clutch on flywheel. Mount the engine on the body.(Refer to preceding

page).

Refer to the oil pump section to install oil pump Tighten the flywheel to the specified torque with the

special tool.

400450 TIGHTENING TORQUE FOR FLYWHEEL BOLT(kgcm)

THGHTENING TORQUE(kgcm) 650 700

Fig. 6B 105 Cutting the Gasket Edge

2

1

1. SPECIAL TOOL(09924 17810)2. FLYWHEEL BOLT

Fig. 6B 106 Flywheel

ficha tecnioca de chevolet cmv y cmp

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