ENGINE MODE CODES

Engine Number Engine number is punch­marked on the position as illustrated. Name plate shows vehicle model, chassis number, and engine model. 1 Vehicle model 2 Chassis number 3 Engine model

Engine Name Plate The engine name plate is attached to the position shown in the illustration. The following items are indicated. 1 Engine model 2 Valve clearance 3 Firing order 4 Fuel injection timing

SPECIFICATIOS

1 Rocker 2 Valve cap 3 Valve cotter 4 Upper retainer 5 Outer valve spring 6 Inner valve spring 7 Lower retainer 8 Valve 9 Camshaft 10 Tappet 11 Push rod 12 Valve guide 13 Valve stem seal 14 Rocker shaft bracket 15 Lock nut 16 Adjusting screw 17 Rocker cover The valve stem seal 13 is fitted onto the valve 8 to control he amount of lubricant flowing onto the sliding surfaces of the valve and valve guide 12. The valve springs 5, 6 are unevenly pitched to prevent abnormal vibration at high speeds. To prevent the inner and outer springs from meshing with each other, the springs are wound in opposite directions. To facilitate removal and reinstallation of the camshaft 9 from the rear end of the crankcase, the diameter of each camshaft bearing is smaller toward the front of the engine.

CYLINDER LINER REMOVEL AND INTALLATION

CYLINDER LINER

PISTONS AND CYLINDER LINERS SIZES PİSTON SIZE MARK A B C CYLINDER LINER MARK A B C A, B, C arası fark 0,012mm dir. D Over Size: 0,5, 0,75, 1.00 mm

CONNECTING RODS 1 Connecting rod bushing 2 Connecting rod 3 Upper connecting rod bearing 4 Connecting rod bolt 5 Lower connecting rod bearing 6 Connecting rod cap a : Weight mark stamp “A” to “H”, “J” to “M” (where “A” indicates the greatest connecting rod weight) b : Alignment mark c : Lug

PISTONS a : Part number b : Weight mark c : Size mark Standard pistons are marked “A”, “B” or “C” (where “C” indicates the greatest outside diameter). d : Cooling cavity e : Front mark “F” and “¬” The pistons selected must bear the same size marks as the cylinder liners.

TIMING GEARS

Disassembly sequence 1 Bolt ROCKER COVER, CYLINDER HEAD AND VALVE MECHANISM Disassembly sequence 1 Bolt 2 Injection nozzle 3 O­ring 4 Nozzle tip gasket 5 Bolt 6 Bushing 7 Insulator 8 Rocker cover gasket 9 Rocker cover 10 Bolt 11 Rocker and bracket assembly 12 O­ring 13 Cylinder head bolt (short) 14 Cylinder head bolt (long) 15 Cylinder head and valve assembly 16 Cylinder head gasket 17 Push rod 18 Side cover 19 Tappet A: Locating pin X: Non­reusable part

CYLINDER HEAD AND VALVE ASSEMBLY [Removal] Before loosening the cylinder head bolts 13, 14, make sure all the valve springs are free by loosening the adjusting screw C on rocker A in case this is compressing its valve spring B due to the action of its push rod 17.

cylinder head bolt should be loosened a little at a time. LOOSEN AND REMOVE THE CYLINDER HEAD BOLTS Loosen and remove the cylinder head bolts 13, 14 in the sequence shown. Each cylinder head bolt should be loosened a little at a time.

G : Socket H : Rod J : Rod (extension) TIGHTEN THE CYLINDER HEAD BOLTS Before fitting any cylinder head bolt 13, 14, check the punch marks D on its head. Do not use the bolt if there are more than two punch marks. The punch marks indicate the number of times each bolt has been tightened using the plastic area tightening method. Any bolt that already has three punch marks must be replaced. Tighten the cylinder head bolts 13, 14 to the specified torque (180 N·m {18 kgf·m}) in the sequence shown and then confirm that the bolts 1, 2 and 3 are correctly tightened to 180 N·m {18 kgf·m}. (If the torque is insufficient, tighten them additionally.) After that, turn the bolts further in accordance with the following procedure. G : Socket H : Rod J : Rod (extension)

CYLINDER HEAD AND VALVE MECHANISM

VALVE COTTERS REMOVAL

VALVE SPRINGS

 Disassembly sequence ROCKER AND BRACKET ASSEMBLY  Disassembly sequence 1 Thrust plate 2 Rocker assembly <Inlet> 3 Rocker assembly <Exhaust> 4 Lock nut 5 Adjusting screw 6 Rocker bushing 7 Rocker 8 Rocker shaft bracket  Assembly sequence Follow the disassembly sequence in reverse.

SERVICE PROCEDURE Rocker bushing [Removal] J : Rocker Bushing Puller [Installation] Set the components as illustrated such that the oil hole A in the rocker bushing 6 is aligned with the oil hole B in the rocker 7. C : Seam of bushing D : Chamfered side of rocker Using the J Rocker Bushing Puller, install the rocker bushing 6 into the rocker 7 until the puller touches the chamfered side D of the rocker.

VALVE GUIDES REMOVAL AND INSTALLATION 30091-08100 Exhaust : 0.09 - 0.12 mm Limit: 0.2 mm Inlet : 0.05 - 0.09 mm Limit: 0.2 mm If any clearance exceeds the specified limit, replace the defective part(s).

THE VALVE STEM SEALS

INJECTION NOZZLE TUBE REMOVAL AND INSTALLATION

THE CONNECTING ROD BUSHING REMOVAL AND INSTALLATION

ADJUSTMENT VALVE CLEARANCES

When taking measurements using the J Feeler Gauge, the gauge should be ADJUSTMENT VALVE CLEARANCES NOTE When taking measurements using the J Feeler Gauge, the gauge should be able to move in the clearance with some resistance. Accurate measurements can not be taken if the gauge moves loosely in the clearance.

TIGHTENING TORQUE 1- TORK DEĞERLERİ 180 Nm veya 18Kgfm (Islak) 2- AÇI DEĞERİ 90 YENİDEN SIKMA 1000 Km-Yeni araç =>10º 4000 Km-Bakımdan Sonra =>10º

Removal sequence 1 Nut 2 Lower connecting rod bearing 3 Connecting rod cap 4 Upper connecting rod bearing 5 Piston and connecting rod assembly 6 O­ring 7 O­ring 8 Rubber packing 9 Cylinder liner *a: Oil pan L Gr12 *b: Crankcase L P11­56 X: Non­reusable part Installation sequence Follow the removal sequence in reverse.

PISTON PROJECTION Service procedure Pre­disassembly inspection (1)Piston projection from crankcase top surface NOTE The piston projections affect engine performance and must therefore be checked. Measure the projection of each piston at four points and calculate the average of the four values. A : Front of engine If the average value is out of specification, check the clearances between all relevant parts.

CYLINDER LINER FLANGE PROJECTION

CONNECTING ROD END PLAY

Pre­disassembly inspection Crankshaft end play Before removing the main bearing caps, measure the extent of crankshaft end play. If the measurement exceeds the specified limit, replace the thrust plates with oversize ones.

CRANKSHAFT THRUST PLATES AND MAIN BEARING CAPS

MAIN BEARING CAPS

CRANKSHAFT RECTIFICATION SIZES

MAIN BEARING CAPS 11-60

CRANKSHAFT MAIN BEARINGS [Installation] Install the main bearings 7, 16 such that their lugs A fit into the corresponding grooves. The upper main bearing 16 has an oil hole B. The lower main bearing 7 has no oil hole. Take care not to confuse the upper and lower parts.

CAMSHAFT BUSHINGS Disassembly sequence 6, 5, 4, 3, 2, 1, 7 Assembly sequence 5,4,3, 2,1 6 7

CAMSHAFT BUSHING REMOVAL

CAMSHAFT BUSHING INSTALLATION