Repair Procedures

Disassembly

CAUTION:
- Use fender covers to avoid damaging painted surfaces.
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE:
- Mark all wiring and hoses to avoid misconnection.
- Turn the crankshaft pulley so that the No.1 piston is at top dead center.
- Engine removal is required for this procedure.

WARNING:
In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don't do any repair work right after engine stops.

1. Remove the balance shaft module.

2. Remove the ladder frame.

3. Remove the piston & connecting rod assembly.

4. Remove the crankshaft.

5. Remove the oil jet (A).






Inspection

1. Remove gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the contacting surface of the cylinder block and the manifolds for warpage.

Flatness of cylinder block gasket surface
Standard : Less than 0.05 mm (0.0019 in.) for all
Less than 0.02 mm (0.0007 in.) for 100 mm (3.9370 in.) x 100 mm (3.9370 in.)




4. Inspect cylinder bore diameter.
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
5. Inspect cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions.

Standard diameter :
88.00 - 88.03 mm (3.4645 - 3.4657 in.)





NOTE:
Measure position points (from the bottom of the cylinder block)
: 110.7 mm (4.3582 in.) / 160 mm (6.2992 in.) / 210 mm (8.2677 in.)

6. Check the cylinder bore size code on the cylinder block.




Cylinder Bore Inner Diameter





7. Check the piston size code on the piston top face.





NOTE:
Stamp the grade mark of basic diameter with rubber stamp.

Piston Outer Diameter





8. Select the piston related to cylinder bore class.

Clearance :0.020 - 0.040 mm (0.00079 - 0.00157 in.)

Reassembly

1. Install the oil jet (A).

Tightening torque :
24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)




2. Install the crankshaft.

3. Install the piston & connecting rod assembly.

4. Install the ladder frame.