4G63 Turbo Engine Overhaul Manual GR00003400-11D

8/12/2019 4G63 Turbo Engine Overhaul Manual GR00003400-11D

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11D-1

GROUP 11D

ENGINE OVERHAUL

CONTENTS

HOW TO USE THIS MANUAL . . . . . . 11D-2

GENERAL INFORMATION . . . . . . . . 11D-4

GENERAL SPECIFICATIONS . . . . . . 11D-4

SERVICE SPECIFICATIONS . . . . . . . 11D-5

REWOK DIMENSIONS . . . . . . . . . . . 11D-6

TORQUE SPECIFICATIONS . . . . . . . 11D-7

SEALANTS . . . . . . . . . . . . . . . . . . . . 11D-10

SPECIAL TOOLS . . . . . . . . . . . . . . . . 11D-11

ALTERNATOR AND IGNITIONSYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11D-14

REMOVAL AND INSTALLATION . . . . . . . . 11D-14

SOLENOID AND VACUUM HOSE . . 11D-15REMOVAL AND INSTALLATION . . . . . . . . 11D-15

TIMING BELT . . . . . . . . . . . . . . . . . . . 11D-16REMOVAL AND INSTALLATION . . . . . . . . 11D-16INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 11D-26

FUEL AND EMISSION PARTS . . . . . 11D-28REMOVAL AND INSTALLATION . . . . . . . . 11D-28

INLET MANIFOLD . . . . . . . . . . . . . . . 11D-30REMOVAL AND INSTALLATION . . . . . . . . 11D-30

EXHAUST MANIFOLD . . . . . . . . . . . . 11D-31REMOVAL AND INSTALLATION . . . . . . . . 11D-31

WATER PUMP AND WATERHOSE . . . . . . . . . . . . . . . . . . . . . . . . . 11D-33

REMOVAL AND INSTALLATION . . . . . . . . 11D-33

ROCKER ARMS AND CAMSHAFT . . 11D-35

REMOVAL AND INSTALLATION . . . . . . . . 11D-35INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 11D-37

CYLINDER HEAD AND VALVES . . . . 11D-40REMOVAL AND INSTALLATION . . . . . . . . 11D-40INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 11D-43

OIL PAN AND OIL PUMP . . . . . . . . . . 11D-46REMOVAL AND INSTALLATION . . . . . . . . 11D-46INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 11D-53

PISTON AND CONNECTING ROD . . 11D-55REMOVAL AND INSTALLATION . . . . . . . . 11D-55INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 11D-60

CRANKSHAFT AND CYLINDERBLOCK . . . . . . . . . . . . . . . . . . . . . . . . 11D-62

REMOVAL AND INSTALLATION . . . . . . . . 11D-62INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 11D-66
http://gr00003200-11.pdf/http://gr00003200-11.pdf/http://gr00003200-11.pdf/


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HOW TO USE THIS MANUALENGINE OVERHAUL 11D-2

HOW TO USE THIS MANUALM1113025100296

This manual describes service procedures performed after removal of the engine from the vehicle.For removal of the engine from the vehicle, installation of the engine in the vehicle, and on-vehicle inspection and service ofthe engine, please use the separate Workshop Manuals prepared for the vehicle.

(1) A component part drawing is shown at the beginning of each section to enable the technician to ascertain the installed con- dition of the component parts.(2) Service steps are indicated by means of numbers in the component part drawing. Non-reusable parts are indicated as such,

and tightening torques are shown. Removal steps The numbers of the part names match the numbers in the component part drawing and indicate the removal sequence. Installation steps Installation steps are omitted wherever installation can be achieved simply by performing the removal steps in reverse. Disassembly steps The numbers of the part names match the numbers in the component part drawing and indicate the disassembly sequence. Reassembly steps Reassembly steps are omitted wherever reassembly can be achieved simply by performing the disassembly steps in reverse.

HOW TO USE THIS MANUAL

How to Read Explanations

Scope of Service Explanations

Service steps

Classification of Service PointsKey service points, service standards, and instructions forusing special tools are collated as service points and ex-plained in detail.

: Outward-pointing brackets denote removal service pointsor disassembly service points.

>>A


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HOW TO USE THIS MANUALENGINE OVERHAUL 11D-3

ENGINE OVERHAUL11-54

CRANKSHAFT AND CYLINDER BLOCKREMOVAL AND INSTALLATION

Section titlePage number

Procedures and cautions for removal, instal-lation, disassembly, and reassembly are ex-plained under this category of heading.

The alphabetical character in this category ofheading matches that of the relevant removalsteps, installation steps, disassembly steps, orreassembly steps.

Denotes non-reusable part.

Tightening torque

CRANKSHAFT AND CYLINDER BLOCK

Removal steps 1. Drive plate bolt 2. Adapter plate 3. Drive plate 4. Crankshaft bushing 5. Rear plate 6. Bellhousing cover >>E>D>C>B>A>A


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GENERAL INFORMATIONENGINE OVERHAUL 11D-4

GENERAL INFORMATIONM1113000100523

VEHICLE AND ENGINE MODELS

GENERAL SPECIFICATIONSM1113000200779

Vehicle name Vehiclemodel

Engine model DisplacementmL

Specification

OUTLANDER CU2W 4G63-7 1,997 Double overhead camshaft, 16-valve

Item Specification

Bore stroke mm 85 88

Displacement mL 1,997

Combustion chamber Pentroof type

Number of cylinders 4Valve mechanism Type Double overhead camshaft

Number of intake valves 2

Number of exhaustvalves

2

Lash adjusters Hydraulic

Rocker arms Roller cam followers

Compresssion ratio 9.0

Fuel injection system Electronically controlled multi-point injection (MPI)system

Ignition system Electronically controlled two-coil systemGenerator Alternator (with built-in IC regulator)

Starter motor Gear reduction drive type


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SERVICE SPECIFICATIONSENGINE OVERHAUL 11D-5

SERVICE SPECIFICATIONSM1113000300776

Item Standard value Limit

TIMING BELT

Auto-tensioner rod extension length(with timing belt installed) mm

3.8 4.5

Auto-tensioner rod extension length (when free) mm 12.0

Auto-tensioner rod retraction length(when pressed with force of 98 to 196 N) mm

Less than 1

ROCKER ARMS AND CAMSHAFTS

Cam height mm 34.91 34.41

CYLINDER HEAD AND VALVES

Cylinder head gasket surface warp mm Less than 0.05 0.2

Cylinder head gasket surface grinding limit(including cylinder block grinding amount) mm

0.2

Cylinder head overall height mm 131.9 132.1

Cylinder head bolt nominal length mm 99.4

Valve margin mm Intake valves 1.0 0.5

Exhaust valves 1.5 1.0

Valve stem diameter mm 6.6

Valve face angle 43.5 44

Valve stem-to-guide clearance mm Intake valves 0.02 0.05 0.10

Exhaust valves 0.05 0.09 0.15

Valve height mm Intake valves 109.5 109.0Exhaust valves 109.7 109.2

Valve stem projection mm Intake valves 49.2 49.7

Exhaust valves 48.4 48.9

Valve spring free height mm 47.0 46.0

Valve spring load/height N/mm 240/40

Valve spring squareness 1.5 or smaller 4

Valve face-to-seat contact width mm 0.9 1.3

Valve guide inside diameter mm 6.6

Valve guide press-in height mm 19.2 19.8

OIL PAN AND OIL PUMP

Oil pump gear side clearance mm Drive gear 0.08 0.14

Driven gear 0.06 0.12

Oil cooler by-pass valve mm Dimension (Normaltemperature)

34.5

By-pass hole closingtemperature 97 to103 C

40.0


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REWOK DIMENSIONSENGINE OVERHAUL 11D-6

REWOK DIMENSIONSM1113024300394

Oil pressure at curb idle speed kPa[oil temperature is 75 to 90 ]

78 or more

PISTONS AND CONNECTING RODS

Piston outside diameter mm 85.0

Piston ring side clearance in ringgroove mm No. 1 0.03

0.07 0.1No. 2 0.02 0.06 0.1

Piston ring end gap mm No. 1 0.20 0.30 0.8

No. 2 0.30 0.45 0.8

Oil ring 0.10 0.40 1.0

Piston pin outside diameter mm 22.0

Piston pin press-in load (at ambient temperature) N 7,350 17,100

Oil clearance at crankshaft pins mm 0.03 0.05 0.1

Connecting rod big end thrust clearance mm 0.10 0.25 0.4

CRANKSHAFT AND CYLINDER BLOCKCrankshaft end play mm 0.05 0.25 0.4

Crankshaft journal diameter mm 57.0

Crankshaft pin diameter mm 45.0

Oil clearance at crankshaft journals mm 0.03 0.04 0.1

Cylinder block gasket surface warp mm 0.05 0.1

Cylinder block gasket surface grinding limit(including cylinder head grinding amount) mm

0.2

Cylinder block overall height mm 284

Cylinder bore diameter mm 85

Taper of cylinder mm 0.01 or less

Cylinder-to-piston clearance mm 0.02 0.04

Crankshaft bearing cap bolt nominal length mm 71.1

Item Standard value Limit

Item Standard value


Diameter of oversize valve seat ring hole in cylinder headmm

Intake 0.3 oversize 35.30 35.33

0.6 oversize 35.60 35.63

Exhaust 0.3 oversize 33.30 33.33

0.6 oversize 33.60 33.63

Diameter of oversize valve guide hole in cylinder head mm 0.05 oversize 12.05 12.07

0.25 oversize 12.25 12.27

0.50 oversize 12.50 12.52


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TORQUE SPECIFICATIONSENGINE OVERHAUL 11D-7

TORQUE SPECIFICATIONSM1113023400989

Item N m

ALTERNATOR AND IGNITION COIL

Oil level gauge guide bolt 13 1

Idler pulley bolt 79 5 Auto-tensioner assembly bolt (M8) 24 4

Auto-tensioner assembly bolt (M10) 44 10

Water pump pulley bolts 8.8 1.0

Alternator brace bolt (flange bolt) 23 3

Alternator brace bolts (washer assembled bolt) 22 4

Alternator nuts 44 10

Crankshaft pulley bolts 25 4

Center cover bolts 3.0 0.5

Ignition coil bolts 10 2Spark plugs 25 5

SOLENOID AND VACUUM HOSE

Vacuum pipe and hose assembly bolts 11 1

EGR valve bolts 20 2

Engine hanger bolt 19 3

Solenoid valve assembly nut 36 6

Solenoid valve assembly bolts(M6) 9.0 1.0

Solenoid valve assembly bolts(M8) 23 4

TIMING BELTTiming belt cover bolts (flange bolt) 11 1

Timing belt cover bolt (washer-assembled bolt) 9.0 1.0

Power steering pump bracket bolts 49 9

Tensioner pulley bolt 48 5

Tensioner arm bolt 21 4

Auto-tensioner bolts 23 3

Idler pulley bolt 35 6

Crankshaft angle sensor bolts 8.8 1.0

Oil pump sprocket nut 54 4Crankshaft bolt 167

Tensioner "B" bolt 19 3

Counterbalance shaft sprocket bolt 45 3

Rocker cover bolts 3.5 0.5

Engine support bracket bolts 49 5

Camshaft sprocket bolts 88 10


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FUEL SYSTEM

Throttle body bolts 19 3

Fuel pressure regulator bolts 9.0 2.0

Delivery pipe and injector assembly bolts 11 1

INLET MANIFOLDInlet manifold stay bolts 31 3

Inlet manifold bolts (M8) 20 2

Inlet manifold bolts and nuts (M10) 36 6

Detonation sensor 23 2

EXHAUST MANIFOLD

Engine hanger bolt 19 3

Turbocharger heat protector bolts 23 3

Oxygen sensor 44 5

Exhaust fitting bracket bolts 36 5Exhaust fitting bolts 59 5

Air outlet fitting bolts 19 1

Oil return pipe bolts 14 1

Exhaust manifold heat protector bolts 23 3

Turbocharger assembly and pipe assembly bolts, nuts 59 5

Oil pipe bolt (flange bolt) 11 1

Oil pipe bolt (eye bolt M10) 17 2

Water pipe bolt (eye bolt M12) 28 5

Water pipe bolt (flange bolt) 10 1Exhaust manifold nuts (M8) 33 6

Exhaust manifold nuts (M10) 55 10

WATER PUMP AND WATER HOSE

Engine coolant temperature sensor 29 10

Engine coolant temperature gauge unit 10.8 1.0

Water outlet fitting bolts 13 2

Water inlet fitting bolts 13 2

Thermostat housing bolts 23 4

Water inlet pipe bolt (M8) 13 2Water pump bolts 14 1

ROCKER ARMS AND CAMSHAFTS

Camshaft position sensor bolt 10 1

Cover bolts 10 2

Camshaft position sensing cylinder bolt 22 4

Camshaft position sensor support bolts 14 1

Bearing cap bolts 20 1

Oil delivery body bolts 11 1

Item N m


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Cylinder head bolts 78 2 0 20 2 + 90 + 90

OIL PUMP CASE AND OIL PAN

Drain plug 39 5

Oil filter 14 2Oil pan bolts 9.0 3.0

Oil screen bolts 19 3

Oil pressure switch 19 3

Oil cooler by-pass valve 54 5

Relief plug 44 5

Oil filter bracket bolts 19 3

Plug cap 23 3

Flange bolt 36 3

Oil pump case bolts 23 3Oil pump cover bolts 17 1

Oil pump cover screw 10 2

PISTONS AND CONNECTING RODS

Connecting rod cap nuts 20 2 90 to 94

CRANKSHAFT AND CYLINDER BLOCK

Flywheel bolts 132 5

Rear plate bolt 11 1

Bell housing cover bolts 9.0 1.0

Rear oil seal case bolts 11 1Beam bearing cap bolts 25 2 90 to 100

Item N m


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SEALANTSENGINE OVERHAUL 11D-10

SEALANTSM1113000500703

NOTE: *: Part to be sealed with a form-in-placegasket (FIPG)FORM-IN-PLACE GASKET (FIPG)This engine has several areas where theform-in-place gasket (FIPG) is used for sealing. Toensure that the FIPG fully serves its purpose, it is

necessary to observe some precautions whenapplying it.Bead size, continuity and location are of paramountimportance. Too thin a bead could cause leaks. Toothick a bead, on the other hand, could be squeezedout of location, causing blocking or narrowing of fluidpassages. To prevent leaks or blocking of passages,therefore, it is absolutely necessary to apply theFIPG evenly without a break, while observing thecorrect bead size.FIPG hardens as it reacts with the moisture in theatmospheric air, and it is usually used for sealingmetallic flange areas.

REMOVAL OF FIPG SEALED PARTSParts sealed with a FIPG can be easily removedwithout need for the use of a special method. Insome cases, however, the FIPG in joints may have tobe broken by tapping parts with a mallet or similartool. You can also tap a flat, thin gasket scraper intothe joint to break the FIPG, taking extreme care notto damage the mating surfaces.The oil pan cutter(MD998727) is available as a special tool forremoving the oil pan. The tool, however, must not be.

CLEANING FIPG APPLICATIONSURFACEThoroughly remove all substances deposited on theFIPG application surface, using a gasket scraper orwire brush. Make sure that the FIPG applicationsurface is flat and smooth. Also make sure that thesurface is free from oils, greases and foreignsubstances. Do not fail to remove old FIPG that mayremain in the fastener fitting holes.

APPLICATION OF FIPG Applied FIPG bead should be of the specified sizeand free of any break. FIPG can be wiped awayunless it has completely hardened. Install the mating

parts in position while the FIPG is still wet (in lessthan 15 minutes after application). Do not allow FIPGto spread beyond the sealing areas duringinstallation. Avoid operating the engine or letting oilsor water come in contact with the sealed area beforea time sufficient for FIPG to harden (approximatelyone hour) has passed. FIPG application method mayvary from location to location. Follow the instructionfor each particular case described later in thismanual.

Item Specified sealant

Engine support bracket bolts Mitsubishi Genuine Part No.MD970389or equivalent

Semicircular packing 3M ATD No.8660 or equivalent

Rocker cover Mitsubishi Genuine Part No. MD970389or equivalent

Engine coolant temperature e gauge unit 3M Nut Locking Part No.4171 orequivalent

Engine coolant temperature sensor 3M ATD No.8660 or equivalent

Water outlet fitting* Mitsubishi Genuine Part No. MD970389or equivalentThermostat housing*

Cylinder head (camshaft bearing cap fitting section) 3M ATD No.8660 or equivalent

Camshaft position sensor support* Mitsubishi Genuine Part No. MD970389

or equivalentOil pressure switch 3M ATD No.8660 or equivalent

Oil pan* Mitsubishi Genuine Part No. MD970389or equivalentRear oil seal case*


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SPECIAL TOOLSENGINE OVERHAUL 11D-11

SPECIAL TOOLSM1113000600788

Tool Number Name Use

MD998781 Flywheel stopper Retention of flywheel

MD998778 Crankshaft sprocketpuller

Removal of crankshaft sprocketand crankshaft sprocket B

MD998785 Sprocket stopper Retention of counterbalancershaft sprocket

MD998767 Tension pulley socketwrench

Manipulation of tensioner pulleyduring adjustment of timing belttension

MD998738 Set screw Retention of tensioner arm andauto-tensioner during timing beltinstallation

MD998713 Camshaft oil sealinstaller

Installation of camshaft oil seal

MD998442 Air bleed wire Air bleeding of lash adjuster

D998781

D998767

D998738

D998713


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MB991654 Cylinder head boltwrench

Removal and installation ofcylinder head bolts

MD998772 Valve springcompressor

Compression of valve spring

MD998735 Valve springcompressor

Compression of valve spring

MD998737 Valve stem sealinstaller

Installation of valve stem seal

MD998162 Plug wrench Removal and installation of frontcase plug cap(Use with MD998783.)

MD998783 Plug wrench retainer Removal and installation of frontcase plug cap(Use with MD998162.)

MD998371 Silent shaft bearingpuller

Removal of counterbalancer shaftfront bearing

MD998372 Silent shaft bearingpuller

Removal of counterbalancer shaftfront and rear bearings


B991654


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MB991603 Silent shaft bearinginstaller stopper

Guide and stopper for removaland press-fitting ofcounterbalancer shaft rearbearing

MD998705 Silent shaft bearinginstaller

Press-fitting of counterbalancershaft front and rear bearings

MD998375 Crankshaft front oilseal installer

Installation of crankshaft front oilseal

MD998285 Crankshaft front oilseal guide

Guide for installation ofcrankshaft front oil seal

MD998780 Piston pin setting tool Removal and press-fitting ofpiston pin

MD998776 Crankshaft rear oilseal installer

Installation of crankshaft rear oilseal

MB990938 Handle Installation of crankshaft rear oilseal(Use with MD998776.)


D998285

D998776


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ALTERNATOR AND IGNITION SYSTEMENGINE OVERHAUL 11D-14

ALTERNATOR AND IGNITION SYSTEMREMOVAL AND INSTALLATION

M1113001000701

AK305988

12

3

4

56

7

8

9

10

12

11

1310 2 N m

25 5 N m

44 10 N m

13 1 N m

23 3 N m

25 4 N m

22 4 N m

8.8 1.0 N m

3.0 0.5 N m

AC

79 5 N m

44 10 N m

24 4 N m

14

15

Removal steps1. Oil level gauge2. O-ring3. Oil level gauge guide4. O-ring5. Idler pulley6. Cap7. Auto-tensioner assembly8. Water pump pulley

9. Alternator brace10. Alternator 11. Crankshaft pulley12. Center cover 13. Spark plug cable14. Ignition coil15. Spark plug

Removal steps (Continued)


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SOLENOID AND VACUUM HOSEENGINE OVERHAUL 11D-15

SOLENOID AND VACUUM HOSEREMOVAL AND INSTALLATION

M1113025300074

AK400296

11 1 N m

AB

19 3 N m

1

8

6 11 1 N m

36 6 N m

23 4 N m

2

7

9.0 1.0 N m

5

3

4

20 2 N m

11 1 N m

Removal steps1. Vacuum pipe and hose assembly2. Vacuum pipe and hose assembly3. Vacuum pipe and hose assembly4. EGR valve

5. EGR valve gasket6. Solenoid valve7. Solenoid valve8. Engine hanger

Removal steps (Continued)


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TIMING BELTENGINE OVERHAUL 11D-16

TIMING BELTREMOVAL AND INSTALLATION

M1113001900867

AK305989

712

5 6

121

22

24

23

2528

20

26

27

11

2

32

33

29

16

14

431

93419

1815

13

10

17

3

8.8 1.0 N m

49 9 N m

48 5 N m

21 4 N m

23 3 N m

167 N m

49 5 N m

9.0 1.0 N m

11 1 N m

35 6 N m

88 10 N m

54 5 N m

19 3 N m

45 3 N m

11 1 N m11 1 N m

3.5 0.5 N m

AB

11 1 N m

8

30

Removal steps1. Timing belt front upper cover 2. Timing belt front lower cover 3. Power steering pump bracket

>>M>L>K>J>I>I>I>H>G>F>E


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CRANKSHAFT SPROCKETREMOVAL

Use the special tool Crankshaft sprocket puller(MD998778) if the sprocket is stuck and hard toremove.

TIMING BELT "B" REMOVAL

CAUTION

Water or oil on the belt shortens its life drasti-cally, so the removed timing belt, sprocket, andtensioner must be free from oil and water. Theseparts should not be washed or immersed in sol-vent. Replace parts if contaminated. If there is oilor water on each part, check the front case oilseals, camshaft oil seal and water pump forleaks.

1. Mark the belt running direction for reinstallation.2. Loosen the tensioner "B" bolt, and then remove

the timing belt "B."

COUNTERBALANCER SHAFTSPROCKET REMOVAL

1. Use the special tool Sprocket stopper(MD998785) to prevent the counterbalancer shaftsprocket from rotating.

2. Remove the counterbalancer shaft mounting bolt.

CRANKSHAFT SPROCKET "B"REMOVAL

Use the special tool Crankshaft sprocket puller(MD998778) if the sprocket is stuck and hard toremove.

CAMSHAFT SPROCKET BOLTREMOVAL

Remove the camshaft sprocket bolt while preventingthe camshaft from rotation using a wrench fitted onthe hexagonal portion of the camshaft.

AK304176

MD998778

AB

AK300137

AK300138

MD998785

AD

AK300139ADMD998778

AK305990AC


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INSTALLATION SERVICE POINTS>>A>B>C


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>>D>E>F


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>>G>H


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>>I>J>K


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2. Install the auto-tensioner in position. Leave thewire installed until the auto-tensioner iscompletely installed.

>>L>M


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(2) Insert a crosspoint screwdriver with a shankdiameter of 8 mm through the plug hole. If itcan be inserted 60 mm or more, the sprocketis in the correct phase. If the insertion depth isup to 20 25 mm, the screwdriver is blockedby the counterbalancer shaft. Then turn the oilpump sprocket one turn and realign the timing

marks. Then check that the screwdriver canbe inserted 60 mm or more. Keep thescrewdriver inserted until installation of timingbelt is finished.

(3) Turn the oil pump sprocket counterclockwiseby one sprocket tooth.

5. Install the timing belt on the exhaust camshaftsprocket, and hold it in place with a paper clip atthe point indicated in the drawing.

6. Turn the intake camshaft sprocketcounterclockwise to bring the timing mark on itone sprocket tooth away from the mating timingmark in the counterclockwise direction. Theninstall the timing belt on the sprocket and hold it inplace with a paper clip.NOTE: The timing marks will be aligned when thebelt is installed since the intake camshaft is turnedslightly clockwise by the force of the valvesprings.

7. Turn the exhaust camshaft sprocket clockwise toalign the timing marks, and make sure that theintake camshaft sprocket timing marks are alsoaligned.

8. Install the timing belt on the idler pulley, oil pumpsprocket, and crankshaft sprocket, in this order.NOTE: There should be no slack in the installed

portion of the belt.

9. Install the timing belt on the tensioner pulley.

AK202761

Timing marks

AD

AK202771

AK202772

AK305994

Timing marks

AC

AK202762AE

Crankshaftsprocket

Oil pumpsprocket

AK202773

Camshaftsprocket

Tensionerpulley

AD


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NOTE: Turning slightly the intake camshaftsprocket counterclockwise will facilitate installa-tion of the belt on the tensioner pulley.

10.Turn slightly the crankshaft sprocket clockwise totake up the slack in the idler pulley portion of thetiming belt.

11.Check that each of the timing marks on thecrankshaft, oil pump, and exhaust camshaftsprockets is one sprocket tooth away from itsmating timing mark in the counterclockwisedirection.

12.Turn the tensioner pulley counterclockwise usingthe special tool Tension pulley socket wrench(MD998767) to give tension to the belt and holdthe tensioner in position by temporarily tighteningthe tensioner lock bolt.NOTE: Take up the slack in the belt portionbetween the intake and exhaust camshaft sprock-ets.

13.Turn the crankshaft clockwise to make the timingmark align with the No.1 cylinder top dead centermark.

14.Install the special tool Set screw (MD998738) andturn down the tool until the wire (inserted in theauto-tensioner when it was installed) can bemoved freely.

15.Loosen the tensioner pulley lock bolt.

CAUTION

Prevent the timing belt from slipping as itbecomes loose following rotation of the intake

and exhaust camshafts.16.Turn the torque wrench attached to the special

tool Tension pulley socket wrench (MD998767)counterclockwise until the slack in the timing beltis taken up.

17.Turn the torque wrench clockwise from theposition of step 16 until the torque wrench readingbecomes 3.5 N m, then tighten the tensionerpulley lock bolt.

18.Remove the special tool Set screw (MD998738)that was installed in step 14.

19.Turn the crankshaft clockwise two turns, then let italone for approx. 15 minutes.

AK202763AB

Crankshaftsprocket

AK202764

MD998767

AD

AK202774

MD998738

AD

AK202775MD998767 AD


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20.Check that the wire (inserted in the auto-tensionerwhen it was installed) can be moved freely. If thewire can be pulled freely, the belt tensioner isadjusted properly. Remove the wire. At that time,check that the auto-tensioner rod extends by thespecified amount.

Standard value: 3.8 4.5 mm

CAUTIONBe sure to check the tightening torque of thecrankshaft bolt anytime the crankshaft has beenturned counterclockwise. If the torque lower thanspecification, tighten the bolt to the specifiedtorque.21.If the wire cannot be pulled out freely, perform the

steps 14 through 18 again to make the belttension proper.

INSPECTIONM1113002000685

TIMING BELTCheck closely the entire timing belt.Replace it if any of the following conditions is found.

1. Hardened back side rubber.

Back side surface is glossy, lacking in elasticity,and so hard that no impression is left whenpressed with fingernail.

2. Cracks in back rubber surface.3. Cracks in canvas.4. Cracks in tooth roots.5. Cracks in belt sides.

6. Abnormally worn belt sides;NOTE: belt sides are normal if they haveknife-cut surfaces.

7. Badly worn teeth.

Initial stage: Canvas is worn (canvas fiber is fluffy;teeth look whitish due to worn-out rubber; canvastexture is unclear)Second stage: Canvas is lost and rubber is exposed(tooth width narrows down)8. Missing tooth.

AK202829

Extensionamount

AB

AK202794

AK202793

Cracks

Peeling of canvas

Cracks in tooth roots

Cracks

AB

Cracks in sides

AK202795

Rounded edge

Abnormal wear(Fluffy strand) AB

AK202796

MissingTooth

Canvas lost andrubber exposed

AB


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AUTO-TENSIONER

1. Check the auto-tensioner for leaks from thesealed sections.

Replace it if leaky.2. Check the rod end for wear and other damage.

Replace the auto-tensioner if the rod is badlyworn or damaged.

3. Measure the extension length of the rod.

If it is not within the standard value range, replacethe auto-tensioner.

Standard value: 12 mm

4. Press the rod with a force of 98 to 196 N andmeasure the amount of retraction. If themeasurement exceeds the standard value,replace the auto-tensioner.

Standard value: 1 mm maximum

AK301307AD

12 mm

AK301308AE

98 to 196 N

Movement


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FUEL AND EMISSION PARTSENGINE OVERHAUL 11D-28

FUEL AND EMISSION PARTSREMOVAL AND INSTALLATION

M1113002200708

AK400297 AB

1

4

2

3

910

5

1119 3 N m

9.0 2.0 N m

11 1 N m

8 7

6

Removal steps1. Throttle body

>>C>B>A


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FUEL AND EMISSION PARTSENGINE OVERHAUL 11D-29



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INLET MANIFOLDENGINE OVERHAUL 11D-30

INLET MANIFOLDREMOVAL AND INSTALLATION

M1113026100062

INSTALLATION SERVICE POINTS>>A>A


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EXHAUST MANIFOLDENGINE OVERHAUL 11D-31

EXHAUST MANIFOLDREMOVAL AND INSTALLATION

M1113004900725

AK400396

3

14

15

1

12

8

20

6

94

5

23 3 N m

14 1 N m

19 3 N m

36 5 N m

59 5 N m

11

10

23 3 N m

7

55 10 N m

17 2 N m59 5 N m

11 1 N m

33 6 N m

23 3 N m

19 1 N m

17 2 N m

16

10 1 N m

28 5 N m 10 1 N m

28 5 N m

1718

19

13

21

AC

244 5 N m

Removal steps1. Engine hanger 2. Oxygen sensor 3. Turbocharge heat protector 4. Exhaust fitting bracket5. Exhaust fitting6. Exhaust fitting gasket7. Air outlet fitting

>>C>B>A


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EXHAUST MANIFOLDENGINE OVERHAUL 11D-32

INSTALLATION SERVICE POINT>>A>B>C


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WATER PUMP AND WATER HOSEENGINE OVERHAUL 11D-33

WATER PUMP AND WATER HOSEREMOVAL AND INSTALLATION

M1113017900372

INSTALLATION SERVICE POINTS>>A>E>D>C>B>A>A>A


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WATER PUMP AND WATER HOSEENGINE OVERHAUL 11D-34

>>B>C>D>E


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ROCKER ARMS AND CAMSHAFTENGINE OVERHAUL 11D-35

ROCKER ARMS AND CAMSHAFTREMOVAL AND INSTALLATION

M1113005400853

SERVICE POINTS FOR REMOVAL LASH ADJUSTER REMOVAL

CAUTION

When reusing a lash adjuster, it must be washedand inspected before installation. (Refer toP.11D-37 , the instruction under LASH ADJUSTERin the INSPECTION section.)

AK306000 AC

7

16

17

15

10

1213

14

11 8

5

18

1

2

34

620 1 N m

11 1 N m

22 4 N m

10.8 1.0 N m

14 1 N m

10 2 N m

9

Apply engine oil toall moving partsbefore installation.

Removal steps1. Camshaft position sensor 2. O-ring3. Cover 4. Gasket

>>F>E>D>C>C>C>C>C>C>C>B>A


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>>E>F


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2. Place the lash adjuster in container A and washits outside surface.NOTE: Use a nylon brush if there arehard-to-remove deposits.

CAUTION

The steel ball spring of the lash adjuster isextremely weak. The lash adjuster's functionalitymay be badly affected if the special tool is

inserted too strongly.3. While gently pushing the internal steel ball using

the special tool Air bleed wire (MD998442), movethe plunger in and out 5 10 times to eliminatestiffness in the plunger and expel contaminatedoil.NOTE: The plunger must be free from jammingand any other abnormalities. If a defect is found in

plunger operation, replace the lash adjuster.

CAUTION

The hole in the side of the lash adjuster must bedirected toward the inside of container A. Neverdirect it against any person.

4. Take the lash adjuster out of the container, thenmove the plunger by pushing the steel ball gently

to discharge the diesel fuel from the pressurechamber.

CAUTION

The steel ball spring of the lash adjuster isextremely weak. The lash adjuster's functionalitymay be badly affected if the special tool isinserted too strongly.

5. Soak the lash adjuster in the diesel fuel incontainer B. Move the plunger in and out 5 10times by gently pushing the internal steel ballusing the special tool Air bleed wire (MD998442)until the plunger moves smoothly to wash the lash

adjusters pressure chamber.

CAUTIONThe hole in the side of the lash adjuster must bedirected toward the inside of container B. Neverdirect it against any person.

6. Take the lash adjuster out of the container, thenmove the plunger by pushing the steel ball gentlyto discharge the diesel fuel from the pressurechamber.

AK300587AB

Diesel fuel

AK202839

MD998442

AB

Diesel fuel

AK202840Diesel fuel

MD998442

AC

AK202839

MD998442

AB

Diesel fuel

AK202840Diesel fuel

MD998442

AC


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CAUTION

Do not use container C for cleaning. If cleaning isperformed in container C, foreign matter couldenter the pressure chamber when the chamber isfilled with diesel fuel.

7. Soak the lash adjuster in the diesel fuel incontainer C. Gently push the internal steel ball

using the special tool Air bleed wire (MD998442).

8. Place the lash adjuster upright with the plunger atthe top. Push the plunger firmly until it makes afull stroke, then return the plunger slowly andrelease the hold of the steel ball to allow thepressure chamber to be filled with diesel fuel.

9. Take the lash adjuster out of the container, place itupright with the plunger at the top, and push theplunger firmly. The plunger must not move at all.NOTE: If the lash adjuster contracts, perform theoperations 7 through 9 again. Replace the lashadjuster if it still contracts even after the pressurechamber has completely been filled with dieselfuel (air has been bled).

10.Keep the serviced lash adjusters in their uprightpositions to prevent diesel fuel from spilling out.Protect them from dust or other foreign matter.Install the lash adjusters onto the engine as soonas possible.

AK202841

Diesel fuelMD998442

AB

AK202842

Diesel fuelMD998442

AB

AK202843


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CYLINDER HEAD AND VALVESENGINE OVERHAUL 11D-40

CYLINDER HEAD AND VALVESREMOVAL AND INSTALLATION

M1113006900787

AK306002 AC


3

15

16

14

9

11

19

1213

1020

18

7

17

1

2

8

45

6

78 2 N m 0 N m 20 2 N m +90 +90

Removal steps >>D>C>B>C>B>A


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REMOVAL SERVICE POINTS CYLINDER HEAD BOLT REMOVAL

Use the special tool Cylinder head bolt wrench(MB991654) to loosen the cylinder head bolts.

RETAINER LOCK REMOVAL

Compress the valve spring using the special toolValve spring compressor (MD998735 or MD998772),then remove the retainer lock.

NOTE: Store removed valves, springs and other parts, after putting to each of them a tag thatidentifies its cylinder No. or installation location.

VALVE STEM SEAL REMOVAL

Do not reuse removed valve stem seal.

INSTALLATION SERVICE POINTS>>A>A


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NOTE: Do not confuse the stem seals for intakevalves with those for exhaust valves.

>>B>C>D


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CAUTION If the tightening angle is smaller than 90 ,

proper fastening performance could not beassured. Be sure to respect that angle.

If the bolt is tightened to an angle greater thanthe specified angle, loosen the bolt com-pletely and then retighten it beginning withthe first step.

6. Make paint marks on each bolts head and on thecylinder head.

7. Turn the bolts 90 in the tightening direction and inthe indicated sequence.

8. Give another 90 turn in the tightening direction toeach bolt, making sure that the paint mark on thebolt head and that on the cylinder head are on thesame line.


CYLINDER HEAD1. Before cleaning the cylinder head, check it for

traces of water and gas leakage and for cracksand any other damage.

2. Thoroughly remove oils, scale, sealants, carbonand other contamination. Clean the oil passages,then check using compressed air that they are notblocked.

CAUTION

The thickness of the metal that can be removedby grinding from both the cylinder head and themating cylinder block is limited to 0.2 mm intotal.

3. Check the cylinder head gasket surface for warp

using a straightedge and thickness gauge.If the surface is warped beyond the limit, grind thesurface for rectification.

Gasket surface warpStandard value: Less than 0.05 mmLimit: 0.2 mmGrinding limit: 0.2 mm

Cylinder head height (standard value for newpart): 131.9 132.1 mm

VALVES1. Check the valve face for correct contact with the

seat. Reface the valve if the contact is partial orone sided.

2. Measure the margin.

Replace the valve if its margin is smaller than thelimit.

Standard values:Intake 1.0 mmExhaust 1.5 mm

Limits:Intake 0.5 mm

Exhaust 1.0 mm

AK202720

Paint marks

90

90

AB

AK202724

AK300593AB

Margin

Contact(Should be atcentre of face)


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3. Measure the total length of the valve.

Replace the valve if the length is less than thelimit.


Limits:Intake 109.0 mmExhaust 109.2 mm

VALVE SPRINGS

1. Measure the free height of the spring.

Replace the spring if its height is smaller than thelimit.

Standard value: 47.0 mmLimit: 46.0 mm

2. Measure the squareness of the spring.

Replace the spring if it is out of square beyond thelimit.Standard value: 1.5 or smaller Limit: 4

VALVE GUIDE

Measure the valve guide inside diameter and valvestem diameter to calculate the clearance betweenthe valve guide and valve stem.If the limit is exceeded, replace the valve guide orvalve, or both.

Standard values:Intake 0.02 0.05 mmExhaust 0.05 0.09 mm


VALVE SEATS

With the valve installed in position and its facepressed against the valve seat, measure the valvestem projection (distance between the valve stemend and spring seating surface). If the measurementexceeds the limit, replace the valve seat.



AK202876

Total length

AB

AK300594

Out of square

Free height

AB

AK300168Guide inside diameterStem diameter

Valve

guide

AE

AK202814

Valve stemprojection

Valve stemend

Springseatingsurface

AB


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VALVE SEAT RECONDITIONING1. Before reconditioning the valve seat, check the

clearance between the valve guide and valvestem and, if necessary, replace the valve guide.

2. Resurface the valve seat to the indicated widthand angles.

3. After resurfacing, lap the valve and valve seat

using lapping compound.

VALVE SEAT REPLACEMENT

1. Cut inside of the valve seat to be replaced until itswall becomes thin enough for removal, thenremove the valve seat.

2. Rebore the valve seat hole in the cylinder head toa diameter matched to the diameter of theselected oversize valve seat.

Intake valve seat hole diameters:0.3 oversize: 35.30 35.33 mm0.6 oversize: 35.60 35.63 mm

Exhaust valve seat hole diameters:0.3 oversize: 33.30 33.33 mm0.6 oversize: 33.60 33.63 mm

3. Before fitting the valve seat, cool it in liquidnitrogen to prevent damage to its hole in thecylinder head due to interference.

4. Resurface the valve seat. See the VALVE SEATRECONDITIONING section.

VALVE GUIDE REPLACEMENT1. Force out the valve guide toward the cylinder

block using a press.CAUTION

Do not use a replacement valve guide of the

same size as the removed one.2. Machine the valve guide hole in the cylinder head

to the size matched to the selected oversize valveguide.

Valve guide hole diameters0.05 oversize: 12.05 12.07 mm0.25 oversize: 12.25 12.27 mm0.50 oversize: 12.50 12.52 mm

3. Press-fit the valve guide until it remains protrudedabove the cylinder head by the amount indicatedin the drawing.

Standard value: 19.2 19.8 mmNOTE: Press the valve guide from above thecylinder head.NOTE: The valve guides for the intake valves aredifferent in length from those for the exhaustvalves (45.5 mm for intake valves; 50.5 mm forexhaust valves)

4. After installing the valve guide, insert a new valvein it to check for smooth movement.

AK304983 AC

0.9 1.3 mm0.9

1.3 mm

65 65

10 10

44 44

AK300719AB

0.5 - 1 mm

0.5 - 1 mm

Cut

AK300720AB

Oversize hole diameter

Valve seatheight

AK400848

19.2 19.8 mm

AB


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OIL PAN AND OIL PUMPENGINE OVERHAUL 11D-46

OIL PAN AND OIL PUMPREMOVAL AND INSTALLATION

M1113008100657

AK400304

3

1

4

6

5

78

17 18

19

10

11

12

1314

15

16

21

22

2324

25

27

26

2029

28

31

9.0 3.0 N m

9.0 3.0 N m9.0 3.0 N m

39 5 N m

23 3 N m

23 3 N m

19 3 N m

23 3 N m

19 3 N m

23 3 N m

44 5 N m

36 3 N m

10 2 N m

17 1 N m

22 4 N m

19 3 N m

30

32

2

AB


9

54 5 N m

Removal steps1. Drain plug

>>N>M>L>L>K>J>I>H>G>G>F>E>D>C>B>A


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REMOVAL SERVICE POINTS

OIL PAN LOWER REMOVALRemove the oil pan by tapping it through a piece ofwood applied to a side with a plastic hammer.

CAUTION

Do not use a scraper or the special tool toremove the oil pan.

OIL PAN UPPER REMOVAL

Screw bolts into the bolt holes A shown in thedrawing (holes at both ends) to remove the oil pan.

CAUTION

Do not use a scraper or the special tool toremove the oil pan.

PLUG REMOVAL

Fit the teeth of the special tools in notches of the plugas shown in the drawing and support the tool with thespecial tool to loosen the plug.

Plug wrench (MD998162) Plug wrench retainer (MD998783)

FLANGE BOLT REMOVAL

1. Remove the plug on the left side of the cylinderblock. Insert a cross point screwdriver (shankdiameter 8 mm) into the plug hole more than 60mm to prevent the left counterbalancer shaft fromrotating.

2. Loosen and remove the flange bolt.

COUNTERBALANCER SHAFTFRONT BEARING REMOVAL

CAUTION

Remove the front bearing first. Otherwise, thespecial tool cannot be used.Use the special tool Silent shaft bearing puller(MD998371) to remove the counterbalancer shaftfront bearing from the cylinder block.

AK304400

A

AAB

AK300171

MD998162

MD998783 AD

AK202752

Crosspointscrewdriver

AD

Plug

AK300173

AK300174MD998371

AD


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COUNTERBALANCER SHAFTREAR BEARING REMOVAL

1. Use the special tool Silent shaft bearing puller(MD998372) to remove the counterbalancer shaftrear bearings from the cylinder block.

2. When removing the rear bearing of the leftcounterbalancer shaft, install the special toolSilent shaft bearing installer stopper (MB991603)on the front of the cylinder block and use a specialtool Silent shaft bearing puller (MD998372) to pullout the bearing.

INSTALLATION SERVICE POINTS>>A>B


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4. Using special tool Silent shaft bearing installer(MD998705), install the rear bearing. Make surethat the oil hole of the bearing is aligned with theoil hole of the cylinder block.

>>C


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5. Using special tool Silent shaft bearing installer(MD998705), install the rear bearing. Make surethat the oil hole of the bearing is aligned with theoil hole of the cylinder block.

>>D>E>F>G>H


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>>L


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>>M>N


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OIL COOLER BY-PASS VALVE

1. Make sure that valve moves smoothly.

2. Ensure that the dimension L measures thestandard value under normal temperature andhumidity.

Standard value: 34.5 mm

3. The dimension must be the standard value whenmeasured after the valve has been dipped in 97 to

103C oil.Standard value: 40.0 mm

AK000032

L

Valve AC


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PISTON AND CONNECTING RODENGINE OVERHAUL 11D-55

PISTON AND CONNECTING RODREMOVAL AND INSTALLATION

M1113008400863

AK306012 AC

5

11

9

6

78

10

12

4

3

2

1


20 2 N m + 90 to 94

Removal steps>>G>F>E>D>C>C>B>A


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REMOVAL SERVICE POINTS CONNECTING ROD CAPREMOVAL

Mark the cylinder number on the side of theconnecting rod big end as a guide for reassembly.

PISTON PIN REMOVAL

The special tool Piston pin setting tool (MD998780),

consists of the elements shown in the drawing.

1. Insert the tool element, Push rod, into the pistonfrom the front mark side, then attach the element,Guide C, to the push rod.

2. Place the piston and connecting rod assembly onthe element, Base, with the front mark facing up.

3. Use a press to remove the piston pin.NOTE: Keep the disassembled pistons, piston

pins and connecting rods cylinder by cylinder.

INSTALLATION SERVICE POINTS>>A


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NOTE: The piston size mark is located on the

piston top surface.

2. Measure the following dimensions: A: Piston pin insertion hole length

B: Distance between piston bosses

C: Piston pin length

D: Connecting rod small end width3. Obtain dimension L from the measurements using

the following formula.

L = [(A-C) (B-D)] 24. Insert the tool element, Push rod, into the piston

pin and attach the element, Guide A, to the push

rod end.5. Assemble the connecting rod with the piston with

their front marks facing in the same direction.6. Apply engine oil to the outside surface of the

piston pin.

7. Insert the assembly of piston pin, Push rod, andGuide A (put together in step 4.) into the pistonholes from the front mark side.

8. Screw the tool element, Guide B, into the toolelement, Guide A until the gap between both theelements is equal to the dimension L (obtained instep 3.) plus 3 mm.

9. Place the piston and connecting rod assemblyonto the element, Piston setting base, with thefront marks facing up.

10.Install the piston pin using a press. If the requiredpress force is less than the standard value,replace the piston and piston pin assembly or theconnecting rod, or both.

Standard value: 7,350 17,100 N

Cylinder bore size mark Piston size mark

I A

II No mark

III C

AK202784

Connecting rod

PistonPiston pin

D C

B A

AD

AK301480

3 mm + L

Guide AGuide BAC

AK305971

P

AC

PPush rod

Front mark

Front mark

Base

Guide A

Guide B


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>>B>C


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>>D


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>>F>G


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2. Install a piston ring or oil ring side rail into thecylinder bore and force it down with the head of apiston until the ring is at right angles to thecylinder wall. Measure the end gap with athickness gauge.NOTE: If the end gap is excessive, replace the

piston ring.

Standard values:No. 1 ring: 0.20 0.30 mmNo. 2 ring: 0.30 0.45 mmOil ring: 0.10 0.40 mm

Limits:No. 1 ring: 0.8 mmNo. 2 ring: 0.8 mmOil ring: 1.0 mm

CRANKSHAFT PIN OIL CLEARANCE(PLASTIC GAUGE METHOD)1. Wipe off oil from the crankshaft pin and

connecting rod bearing.2. Cut a piece of plastic gauge whose length is

equivalent to the width of the bearing and place it

on the crankshaft pin in parallel with its axis.3. Install the connecting rod cap carefully and tighten

the nuts to the specified torque 20 2 N m + 90 to 94 .

4. Remove the nuts, then remove the connecting rodcap carefully.

5. Measure the largest width of the crushed plasticgauge using the ruler printed on the bag of theplastic gauge.

Standard value: 0.03 0.05 mmLimit: 0.1 mm

AK301481 ADPiston ring Piston ring gap

Push in bypiston

AK202848


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CRANKSHAFT AND CYLINDER BLOCKENGINE OVERHAUL 11D-62

CRANKSHAFT AND CYLINDER BLOCKREMOVAL AND INSTALLATION

M1113008700875

AK400305 AB

6

3

14

1113

8

12

5

9

4

10

1

7

2

25 2 N m + 90

11 1 N m

9.0 1.0 N m

132 5 N m

11 1 N m


Removal steps1. Flywheel bolt2. Flywheel3. Rear plate4. Bell housing cover

>>F>E>D>D>C>C>B>A


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REMOVAL SERVICE POINTS OIL JET REMOVAL

CAUTION

Be extremely careful not to give damage to thecylinder wall.Use a suitably long metal rod to drive out the oil jet.



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3. The size mark of each crankshaft bearing isindicated by ink in the location shown in thedrawing.

4. Install bearing halves with oil grooves in thecylinder block bearing bores.

5. Install bearing halves with no oil grooves in thebeam bearing cap.

>>D


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CAUTION If the tightening angle is less than 90 , ade-

quate tightness could not be assured. If the tightening angle exceeds 100 , loosen

the bolt completely and then perform thetightening again beginning with the first step.

7. Turn clockwise the bolts 90 to 100

in theindicated tightening sequence to bring the mark

on each bolt head into alignment with that on thebearing cap.

8. After installing the beam bearing cap, measurethe end play of the crankshaft. If the end playexceeds the limit, replace the crankshaftbearings.


>>E>F


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CRANKSHAFT OIL CLEARANCE(PLASTIC GAUGE METHOD)This plastic gauge method is recommended as asimplest way of measuring the crankshaft oil clear-ance.Measure the crankshaft oil clearance using a plasticgauge as follows:1. Wipe off oil from the crankshaft journal surface

and the crankshaft bearing inner surface.2. Install the crankshaft.

3. Cut a piece of plastic gauge whose length isequivalent to the width of the bearing and place iton the crankshaft journal in parallel with its axis.

4. Install the crankshaft bearing cap carefully andtighten the bolts to the specified torque of 25 2N m + 90 to 100 .

5. Remove the bolts, then remove the crankshaftbearing cap carefully.

6. Measure the largest width of the crushed plasticgauge using the ruler printed on the bag of theplastic gauge.


CYLINDER BLOCK1. Visually check the cylinder block for scratches,

rust, and any other corrosion. Also check it forcracks using a flaw detecting penetrant.

If any defect is evident, replace the cylinder block.

2. Use a straightedge and thickness gauge to checkthe cylinder block top surface for warp.

Make sure that the surface is free from remaininggasket material and other foreign matter.

Standard value: 0.05 mmLimit: 0.1 mm

3. If the distortion is excessive, correct within theallowable limit or replace.

Grinding limit: 0.2 mm*Includes/combined with cylinder headgrindingCylinder block height (when new): 284 mm

4. Check cylinder walls for scratches and seizure.If defects are evident, rebore to oversize orreplace the cylinder block.

5. Use a cylinder gauge to measure the cylinderbore diameter and taper.

If the cylinder is worn badly, rebore it to anoversize and replace the piston and piston ringswith ones matched with the new bore size.

Standard value: 85.0 mmTaper: 0.01 mm

AK300203

Plastic gauging material

AD

AK300204

Plastic gauging material

AD

AK300205

AB

C D EFG

AK300206

12mm

AD

AB

Center

Bottom


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BORING CYLINDERS1. Select an oversize of the pistons to be used

based on the largest of the cylinder bores.

2. Oversize pistons are available in two oversizes:0.50 mm and 1.00 mm. Bore each cylinder to asize that provides the standard clearance whencombined with the selected piston. The reference

position for piston diameter measurement is asshown in the drawing.

3. Based on the piston diameter measurement,calculate the boring finish dimension.

Boring finish dimension = [Piston diameter] +[0.02 0.04 mm (clearance between piston andcylinder)] [0.02 mm (honing margin)]CAUTION

To prevent deformation of cylinder block thatwould result from the heat generated by boring,bore the cylinders in the following sequence: No.2 No. 4 No. 1 No. 3.

4. Bore all the cylinders to the calculated boringfinish dimension.

5. Hone the bored cylinders to the final finishdimension (piston diameter + clearance betweenpiston and cylinder).

6. Check the clearance between the piston andcylinder.

Standard value: 0.02

0.04 mm

AK300577AC

Thrustdirection

Piston outsidediameter

AD


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NOTES

4G63 Turbo Engine Overhaul Manual GR00003400-11D

Documents

Transcript of 4G63 Turbo Engine Overhaul Manual GR00003400-11D