MODEL D4B

SHOP MANUAL
(FOR INDUSTRIAL USE)
 FORWORD

We would like to express our sincere gratitude to the patrons who have given us unwavering encouragement.
This manual covers shop manual and parts catalog in one volume for an easy reference of parts list, as
well as contains the accurate and efficient service procedures for HYUNDAI D4B industrial engine.

This manual includes specifications, troubleshooting, removal, installation, disassembly and assembly in
each group and presents component illustrations and descriptions for an easy reference.

Accordingly, thoroughly read this manual, rapidly purchase the required parts and service the engine in
proper methods to extend its life and benefit.

Improper service methods and procedures may shorten the engine life resulting from its low performance.
Hyundai genuine parts are designed and built to provide the best performance in your engine. If your claim
is caused by using non-Hyundai genuine parts or servicing at places not recommended, your warranty is
not available.

Hyundai Motor Co., Inc. makes efforts to enhance quality and build better parts and service data for you.
We want to assist you in every way possible with this manual and your purchase of HYUNDAI engine is
highly appreciated.

March 2004

Hyundai Motor Co., Inc.

Industrial Engine Development Team
(TEL 82-52-280-8221~8223)

O.E.M Parts Export Team

(TEL 82-2-746-0291~0299)

NOTE: Contents and specifications are subject to change according to design changes without notice.
 IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all en-
gines as well as the personal safety during work. This manual provides general directions for the efficient service
methods and procedures.

There are numerous variations in procedure, techniques, tools and parts for servicing engines, as well as in the skill
of the individual technician.
This manual cannot possibly anticipate all such variations and provide advice or cautions as to each.
Accordingly, anyone who departs from the instructions provided in this manual must establish that he comprises
neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts.

NOTE, CAUTION, WARNING

NOTE : Information needed in reference to a repair service.

CAUTION: Information about an activity that could cause damage to the vehicle.

WARNING : Information about an activity that could cause injury or damage to the driver, occupants or
repairman.

[SAFETY INFORMATION]
The following list contains some general warnings that you should follow when you work on an engine.

Always wear safety glasses for eye protection.

Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure.

Operate the engine only in a well-ventilated area to avoid the danger carbon monoxide poisoning.

Keep yourself and your clothing away from moving parts when the engine is running, especially the drive belt.

To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,
catalytic converter and muffler.

Do not smoke while working on an engine.

To avoid injury, always remove rings, watches, loose hanging jewelry and loose clothing before beginning to
work on an engine.

Keep hands and other objects clear of the radiator fan.

The fan can be operated with the ignition key in the OFF position. Therefore necessarily disconnect the radiator
fan motor connector.
 CONTENTS

1. GENERAL 1-1

2. ENGINE MECHANICAL SYSTEM 2-1

3. LUBRICATION SYSTEM 3-1

4. COOLING SYSTEM 4-1

5. INTAKE AND EXHAUST SYSTEM 5-1

6. ENGINE ELECTRICAL SYSTEM 6-1

7. FUEL SYSTEM 7-1

 CHAPTER 1 GENERAL INFORMATION

1. GENERAL ............................................................................. 1- 1

2. ENGINE IDENTIFICATION NUMBER ..................................... 1- 6

3. TIGHTENING TORQUE OF STANDARD PARTS.................... 1- 7

4. RECOMMENDED LUBRICANTS AND CAPACITIES .............. 1- 8

5. SPECIFICATIONS .................................................................. 1- 9

6. TORQUE SPECIFICATIONS .................................................. 1- 13

7. SPECIAL TOOLS ................................................................... 1- 15

8. TROUBLESHOOTING ........................................................... 1- 18

9. CHECKING POINT ................................................................. 1- 20

 GENERAL 1-1

1. OVERALL
1) ENGINE
Cylinder head is made of aluminum alloy and combustion chamber is a swirl type.
Valve is a SOHC type and the camshaft is operated by the Cog type timing belt.
Cylinder block is made of special cast iron and dry cylinder liner is press-fitted in the cylinder. Water jacket is a Siamese type
and piston is made of aluminum alloy and connected with connecting rod by full floating piston pin.
Oil ring no.1 of the piston ring is made of steel, no.2 of special cast iron, piston ring no.1 of barrel face, no.2 of taper face and
oil ring of bevel cutter and coil expander is attached.

ENGINE ASSEMBLY

KD4BB01A

Crankshaft is made of forged steel and supported with main bearing. Pulley attached with torsional damper is installed in the
front of crankshaft and flywheel in the rear of it. Silent shaft is installed to both ends of the cylinder block, operated with cog
belt and rotated at a double speed of crankshaft.
1-2 GENERAL

Timming belt train

KD4BB02A
 GENERAL 1-3

2) LUBRICATION SYSTEM
It is a forced lubrication system and the forced oil by the oil pump is sent to the engine compartment through the oil cooler and
oil filter as shown in the illustration and directly operated by the crank shaft.
Maximum oil pressure is controlled by the reducing valve.

Rocker arm shaft

Camshaft
Main
passage

Oil filter
Left silent shaft
To oil pan

Reduing pressure
Crank shaft
Vaccum pump
Right silent shaft

Oil jet
KD4BB03A
1-4 GENERAL

Oil filter is a combined type and full flow filter and bypass filter are built in it. The bypass filter in the full flow filter uses a thick
multi-fiber media to filter dirt (soot).
If oil enters the oil filter, filtered oil from the full flow filter passes through the main passage and the filtered oil from the bypass
filter returns to the oil pan.

Bypass filter

Gasket
Flow filter
From oil pump

To oil pan
Valve

To main passage

KD4BB04A
 GENERAL 1-5

3) COOLING SYSTEM
Engine is cooled with the circulated coolant forced by the water pump.
This illustration shows the flow of coolant.

Cold engine
From heater

To heater
Thermostat

Water pump
Water pipe

From heater
Hot engine
Heater
Thermostat

Water pump
Water pipe

KD4BB05A
1-6 ENGINE IDENTIFICATION NUMBER

2. ENGINE INDENTIFICATION NUMBER

1) ENGINE IDENTIFICATION NUMBER LOCATION
The engine identification number is stamped on the right front
side of the top edge of the cylinder block.
Engine
identification
number

2) DESCRIPTION OF ENGINE IDENTIFICATION KAXD010C

NUMBER

D 4 B B 2 0 0 0 0 0 0

Engine fuel
- D : diesel

Engine range
- 4 : In line 4 cycle 4 cylinder

Engine development order

- B : 4D56

Engine capacity
- F : 2476 cc TC
- H : 2476 cc TCI
- B : 2607 cc NA

Production year
- 1 : 2001
- 2 : 2002
- 3 : 2003
- 4 : 2004

Engine production sequence number

- 000000 ~ 999999
 TIGHTENING TORQUE TABLE OF STANDARD PARTS 1-7

3. TIGHTENING TORQUE TABLE OF STANDARD PARTS

Bolt nominal Torque (kg m)

Pitch (mm)
diameter (mm) Head Mark 4 Head Mark 7

EADA010R EADA010S EADA010T EADA010U

M5 0.8 0.3 ~ 0.4 0.5 ~ 0.6

M6 1.0 0.5 ~ 0.6 0.9 ~ 1.1
M8 1.25 1.2 ~ 1.5 2.0 ~ 2.5
M10 1.25 2.5 ~ 3.0 4.0 ~ 5.0
M12 1.25 3.5 ~ 4.5 6~8
M14 1.5 7.5 ~ 8.5 12 ~ 14

NOTE
1. The torques shown in the table are standard values under the following conditions.
. Nuts and bolts are made of steel bar, and galvanized.
. Galvanized plain steel washers are inserted.
. All nuts, bolts and plain washers are dry.

2. The torques shown in the table are not applicable.

. When spring washers, toothed washers and the like are inserted.
. If plastic parts are fastened.
. If self-tapping screws or self-locking nuts are used.

3. If you reduce the torques in the table to the percentage indicated below, under the following conditions,
it will be the standard value.
. If spring washers are used : 85%
. If threads and bearing surfaces are stained with oil : 85%
1-8 LUBRICANTS CAPACITES

4. LUBRICANTS CAPACITES
Description Capacities Specified oil

Oil pan 0.7 l

Oil filter 0.5 l Above API CD or SG

Engine oil (10W/30 or 1500W/40)
Oil cooler 9.5 l

Total 0.7 l

Coolant Antifreeze for aluminum

CAUTION
For the best performance and maximum protection of all types of operation, select only those lubricants
which :
1. Satisfy the requirements of the API classification.
2. Have the proper SAE grade number for expected ambient temperature range.Lubricants which do not
have both an SAE grade number and an API service clasification on the container should not be used.
 SPECIFICATIONS 1-9

5. SPECIFICATIONS
Description Specification Limit

Type Diesel engine

Number of cylinders 4
Valve system OHC
D4BB D4BF, D4BH
Total displacement
2607cc 2476cc

Cylinder bore 91.1 mm 91.1 mm

General Cylinder stroke 100 mm 95 mm

Comprssion ratio 22 21
Intake valve
- OPEN 20° BTDC
- CLOSE 48° ATDC
Valve timing
Exhaust valve
- OPEN 54° BTDC
- CLOSE 22° ATDC

Firing order 1-3-4-2

Flatness of gasket surface 0.05 mm 0.2 mm
Flatness of manifold mounting surface 0.15 mm 0.3 mm
Overall height 94.0 ~ 94.1 mm
Oversize of valve guide hole
0.05 13.050 ~ 13.068 mm
Cylinder head Rework dimensions
0.25 13.250 ~ 13.268 mm
(both intake and exhaust)
0.50 13.500 ~ 13.518 mm
Oversize rework dimen-
sions of intake valve seat 0.30 43.300 ~ 43.325 mm
hole 0.60 43.600 ~ 43.625 mm
Oversize rework
dimensions of exhaust 0.30 37.300 ~ 37.325 mm
valve seat hole 0.60 37.600 ~ 37.625 mm
Intake 37.05 mm 36.55 mm
Cam height
Exhaust 37.05 mm 36.55 mm

Camshaft Journal O.D. 29.935 ~ 29.950 mm

Oil clearance 0.05 ~ 0.08 mm
End play 0.1 ~ 0.2 mm
I.D 18.910 ~ 18.928 mm
Rocker arm
Rocker arm - to -guide clearance 0.012 ~ 0.050 mm
1-10 SPECIFICATIONS

Description Specification Limit

O.D. 18.878 ~ 18.898 mm

Rocker shaft
Length 451.5 mm

Intake 136.5 mm
Over length
Exhaust 136.5 mm

Intake 7.960 ~ 7.975 mm

Stem diameter
Exhaust 7.930 ~ 7.950 mm

Valve Fage angle 45° ~ 45° 3 0 ”

Thickness of valve head Intake 2 mm 1.0 mm

(Margin) 2 mm
Exhaust 1.0 mm

Stem-to-guide clear- Intake 0.03 ~ 0.06 mm

ance Exhaust 0.05 ~ 0.09 mm
Free height 49.1 mm
Valve spring Load/Installed N kg/mm 276/40.4
height Out-of squareness Max 2°
Intake 71 mm
Over length
Exhaust 74 mm
I.D. 8.000 ~ 8.018 mm
Valve guide
O.D. 13.06 ~ 13.07 mm
Press temperature Ordinary temperature
Seat angle 45°
Valve seat Valve contack widht 0.9 ~ 1.3 mm
Sinkage 0.2
Right

- Front 18.300 ~ 18.467 mm

- Rear 42.975 ~ 42.991 mm
Journal diameter
Silient shaft Left
- Front 18.959 ~ 18.980 mm
- Rear 49.975 ~ 42.991 mm

Front 0.02 ~ 0.06 mm

Oil clearance
Rear 0.05 ~ 0.09 mm
 SPECIFICATIONS 1-11

Description Specification Limit

O.D. 79.0 ~ 79.2 mm

TC NA
Piston-to cylinder clearance 0.04 ~ 0.06 0.03 ~ 0.05
Piston
No. 1 ring 2.601 ~ 2.603 2.02 ~ 2.04

Ring groove width No. 2 ring 2.100 ~ 2.102 2.07 ~ 2.09

Oil ring 4.010 ~ 4.035 3.01 ~ 3.035

No. 1 ring 0.35 ~ 0.50 0.25 ~ 0.40 0.8 mm

End gap No. 2 ring 0.41 ~ 0.54 0.45 ~ 0.60 0.8 mm

Oil ring 0.25 ~ 0.45 0.20 ~ 0.40 0.8 mm

Piston ring
Ring-to-ring No. 1 ring 0.056 ~ 0.076 0.03 ~ 0.07 0.15 mm
groove No. 2 ring 0.046 ~ 0.066 0.08 ~ 0.12 0.15 mm
clearance Oil ring 0.02 ~ 0.065 0.02 ~ 0.065 0.1 mm
Piston pin O. D. 28.994 ~ 29.000 mm
Big end center-to small end center length bend 157.95 ~ 158.05 mm
Bend 0.05
Connecting rod
Twist 0.1
Bing end side clearance 0.1 ~ 0.25 mm

End play 0.05 ~ 0.18 mm 0.2 mm

Journal O.D. 66 mm 0.3 mm
Pin O.D. 53 mm

Out of roundness of journal and pin 0.05 mm less than

Out-of taper of journal and pin 0.015 mm less than

Oil clelarance of journal 0.02 ~ 0.05 mm 0.1 mm

Crank shaft Oil clearance of pin 0.02 ~ 0.05 mm

0.25 U.S. 65.735 ~ 65.750 mm

Journal 0.50 U.S. 65.485 ~ 65.500 mm

0.75 U.S. 65.235 ~ 65.250 mm

0.25 U.S. 52.735 ~ 52.750 mm

Pin 0.50 U.S. 52.485 ~ 52.500 mm

0.75 U.S. 52.235 ~ 52.250 mm

1-12 SPECIFICATIONS

Description Specification Limit

O. D. 91.10 ~ 91.13 mm
Cylinder block Flatness of gasket surface 0.05 mm 0.1 mm

Overall height 318.45 ~ 318.55 mm

Flywheel Run out 0.13 mm 0.13 mm

Inner gear 0.22 ~ 0.35 mm 0.5 mm

Tip clearnace
Outer gear 0.12 ~ 0.22 mm 0.4 mm

Oil pump Body clearnace Side clearance 0.04 ~ 0.10 mm 0.15 mm

Inner gear 0.03 ~ 0.09 mm 0.15 mm

Side clearance
Outer gear 0.12 ~ 0.22 mm 0.30 mm

Cooling system Water-cooled forced circulation system

Drive Belt V Belt
Water pump type Centrifugal impeller
Fan clutch type Bimetal thermostat type
Thermo type Wax type
Coolant temperature gauge unit Thermister type
Thermo switch(113°C, A/con) Thermister type

Cooling system Drive belt 10 ~ 13 mm

Valve opening
76.5 2°C / 82 2°C
temperature
Thermostat
Fulley opening
95°C
temperature
Repeat amount 8 or not less than

Coolant temperature 90.5 ~ 117.5 /70°C

Coolant tempera-
ture gauge unit gauge element 21.3 ~ 26.3 /115°C
Resistance
Glow control 22.3 ~ 27.3k /-20°C
element 2.92 ~ 3.58k /20°C

Intake & Air cleaner Paper filter type

Exhaust Muffler Expansion resonance type
 TORQUE SPECIFICATIONS 1-13

6. TORQUE SPECIFICATIONS

Deseription Standard (kg m)

Crankshaft pulley bolt 17 ~ 19

Crankshaft sprocket bolt 6.5 ~ 7.5

Timing belt tensioner bolt 2.2 ~ 3.0

Injection pump sprocket nut 8~9

Silent shaft sprocket nut 3.4 ~ 4.0

Timing belt tensioner “ B ” nut 2.2 ~ 3.0

Rocer cover bolt 0.5 ~ 0.7

Rocker arm shft bolt 1.9 ~ 2.1

Cold engine 10.5 ~ 11.5

Cylinder head bolt
Hot engine 11.5 ~ 12.5

Oil pan bolt 0.6 ~ 0.8

Oil pan drain plug 6~8

Front case bolt (upper, lower) 1.2 ~ 1.5

Silent shaft driven gear bolt 3.4 ~ 4.0

Silent shaft plug gap 2.0 ~ 2.7

Silent shaft gear cover bolt 1.5 ~ 1.8

Connecting rod cap nut 4.5 ~ 4.8

Flywheel bolt 13 ~ 14

Crankshaft bearing cap bolt 7.5 ~ 8.5

Silent shaft chamber cover bolt 0.5 ~ 0.7

Oil relief valve plug 3.0 ~ 4.5

Oil pump cover bolt 0.9 ~ 1.4

Oil pressure switch 0.8 ~ 1.2

Oil filter bracket 1.2 ~ 1.5

Oil cooler by-pass valve 5.0 ~ 6.0

Oil jet check valve 3.0 ~ 3.5

Water pump bolt 1.2 ~ 1.5

Water pump pulley bolt 1.0 ~ 1.2

1-14 TORQUE SPECIFICATIONS

Deseription Standard (kg m)

Water outlet fitting attaching bolt 1.0 ~ 1.3

Coolant tempeature gauge unit 3.0 ~ 4.0

Thermo switch (113°) 0.9

Alternator brace bolt 1.2 ~ 1.5

Adjust rocker arm 1.2 ~ 1.5

Alternator support bolt nut 2.0 ~ 2.5

Intake fitting bolt 1.0 ~ 1.3

Intake manifold bolt 1.5 ~ 2.0

M6 0.8 ` 1.0
Heat protector bolt
M8 1.2 ~ 1.5

Oil return pipe bolt 0.8 ~ 1.0

Exhaust fitting nut 5.0 ~ 7.0

Turbo charger nut 5.0 ~ 7.0

Exhaust manifold nut 1.5 ~ 2.0

SEALANTS

Description Sealants Amount

Half circle packing 3M ATR P/No. 8660 or equivalent As required

Oil pan gasket 3M ATR P/No. 8660 or equivalent As required

Coolant gauge unit 3M nut rocking P/No. 4171 or equivalent As required

Thermo switch (113°, A/con) Threebond No.2440 or equivalent As required

 SPECIAL TOOLS 1-15

7. SPECIAL TOOLS

Tool (Number and name) Illustration Use

Silent shaft bearing puller Removal of silent shaft rear bearing

(09212-43100)

B1243100

Silent shaft bearing installer Installation of silent shaft rear bearing

(09212-43200)

B1243200

Bearing installer stopper Removal of Right silent shaft rear bear-

(09212-43300) ing

B1243300

Crank shaft front oil seal installer Installation of crankshaft front oil seal
(09214-32000)

B1432000

Crankshaft front oil seal guide Guide for installation of crank shaft front
(09214 - 32100) oil seal

B1621100

Connecting - rod small - end busing Replacement of connecting - rod small -

replacement tool end bushing
(09214-43000)

B1443000

Camshaft oil seal installer Installation of camshaft oil seal

(09221-21000)

ECLA002I
1-16 SPECIAL TOOLS

Tool (Number and name) Illustration Use

Cylinder head bolt wrench Loosening and tightening of cylinder

(09221-32000) head bolt

ECLA002A

Valve seat cutter pilot Correction of valve seat

(09221-43200)

ECLA002B

Valve seat cutter 45° Correction of valve seat

(09221-43300)

ECLA002C

Valve seat cutter 65° Correction of valve seat

(09221-43400)

ECLA002D

Valve seat cutter 30° Correction of valve seat

(09221 - 43500)

ECLA002E

Valve spring compressor Compression of valve spring

(09222-21000)

B2221000

Valve stem seal installer Installation of valve stem seal

(09222-32100)

B2232100
 SPECIAL TOOLS 1-17

Tool (Number and name) Illustration Use

Valve guide installer Removal and Installation of valve

(09222-32200) guide

ECLA002F

Silent shaft drive gear oil seal guide Installation of silent shaft drive oil seal
(09222-43200)

B2243200

Crankshaft rear oil seal installer Installation of crankshaft rear oil seal
(09232-32000)

B3132000

Oil pressure switch wrench Removal and Installation of oil pres-

(09260-32000) sure switch

B6032000

Injection pump sprocket puller Removal of injection of pump sprocket

(09314-43000)

C1443000
1-18 TROUBLESHOOTING

8. Troubleshooting

Symptom Probable cause Remedy

Low compression Blown cylinder head gasket Install new head gasket

Worn or broken piston rings Hone cylinder bores and install new rings

Warped or pitted valves Install new valve

Excessive run-out of valve seats on valve faces Reconditioning valve seats and valves

Noisy valves Incorrect of valve cleanrance Adjust as standard and valve

Worn valve guides Install new valves and/or new valve guides with O.S.

Connecting rod Excessive camshaft end play Reconditioning valve seats and valve
noise
Insufficient oil supply Correct end play

Low oil pressure Check engine oil level

Check engine oil level

Thin or diluted oil Inspect oil relief valve and spring

Excessive bearing clearance Change oil to correct viscosity

Connecting rod journals out-of-roundness Measure bearings for correct clearance

Misaligned connecting rods Replace crankshaft or regrind journals

Replace bent connecting rods

Crankshaft Insufficient oil supply Check engine oil level

Bearing noise Low oil pressure Check engine oil level

Inspect oil relief valve and spring.

Thin or diluted oil Change oil to correct viscosilty

Excessive end play Measure bearings for correct clearances

Crankshaft journal out-of-roundness worn Replace crankshft or regrind journals

Loosen flywheel Tighten to correct torque

Piston noise Excessive clearance due to cylinder wear Correct cylinder wear

Piston or piston pin worn Replace piston

Burnt piston Install new piston

Piston ring damaged Install new rings

 TROUBLESHOOTING 1-19

Symptom Probable cause Remedy

Oil leak Oil pan drain plug loose Tighten to torque

Oil pan mounting bolt loose Tighten to torque

Oil pan gasket broken Install new oil seal

Crankshaft front oil seal defective Install new oil seal

Crankshaft front oil seal defective Install new oil seal

Rocker cover gasket broken Install new oil seal

Oil filter loose Tighten to torque

Oil filter gasket broken Install new oil seal

Oil consumption Worn, scuffed, or broken rings Hone cylinder bores and install new rings

Carbon in oil ring slot Install new rings

Ring fitted too tight in grooves Remove the rings. Check grooves. If groove

width is not , proper width, replace pistion.

Faulty valve stem seals Install new valve stem selas

Overheat Low oil level Check engine oil level

Slow idle speed Set idle speed to specification

Faulty oil pressure switch Install new switch

Colgged oil filter Install new oil filter

Worn parts in oil pump Replace worn parts or pump

Thin or diluted oil Change oil to correct viscosity

Excessive bearing clearance Measure bearings for correct clearance

Oil relief valve stuck Remove valve and inspect, clean and reinstall

Oil pump cover bent or cracked Install new oil pump

Oil screen loose or clogged Clean or replace screen

Insufficent coolant Radiator leakage Correct or replace

Loose or damage radiator hose, heater hose Retighten or replace

Themostat water pump leakage Retighten or replace

Radiator clogged Coolant dirty Replenish

Damaged radiator cap Replace

High coolant tem- Damaged themostat Replace
perature
Loose or broken belt Correct or replace
1-20 CHECKING POINT

9. CHECK POINT
CHECKING COOLANT RESERVIOR
1. Use an adapter to attach the cap to the tester.

2. Increase the pressure until the gauge stops moving. Check

that the pressure level is maintained at or above the limit.

Main valve opening pressure 0.75 ~ 1.05 kgf/cm2

Main valve closing pressure 0.65 kgf/cm2

3. Replace the radiator cap if the reading does not remain at or

above the limit.

NOTE
Be sure that the cap is clean before testing, since rust
or other foreign material on the cap seal will cause
an incorrect reading.

CHECKING COOLANT
1. Check that the coolant level of the reservoir tank is between
FULL and LOW marks.

2. Check that the coolant is not mixed with oil.

3. The standard coolant concentration range is as below.

Standard 30 ~ 60% (normal range)

CAUTION
If the concentration of coolant falls below 30% or
above 60%, vapor corrosion is not inhibited, cool-
ing is not efficient or the engine part could become
damaged or not work properly.

3. Antifreeze ratio

Delivery Freezing Coolant quantity (9.5l )

condition temperature(°C) Mixture ratio(%) Antifreeze
quantity(l)
-15 30 10

40% -20 35 2.45

-25 40 2.80
 CHECKING POINT 1-21

REPLACE COOLANT
1. Loosen and remove the drain plug.

2. Remove the reservoir tank and drain coolant.

3. After draining the coolant, pour water into the coolant reser-
voir cap and clean the coolant passage.

4. Securely tighten the radiator drain plug.

5. Install the reservoir tank.

6. Fill the reservoir tank up to FULL line with coolant.

3.9l Engine capacity

Coolant
quantity Overall capacity including
9.5l
the reservoir tank and radiator

7. Securely install the coolant reservoir cap.

8. Check the coolant quantity after warming up the engine and

add coolant.
CAUTION
Do not open the coolant reservoir cap when it is hot.
Steam and scalding liquids released from a hot cool-
ing system can burn you badly.

CHECKING ENGINE OIL LEVEL

1. Pull out the engine oil indicator(dipstick) and wipe it clean
with clothing.

2. Insert the indicator into the oil level gauge guide. Good

3. Remove the indicator carefully and check that the oil level is
between LOW and HIGH marks as shown in the illustration. HIGH

CAUTION LOW
• Make sure the vehicle is on a level ground. KCMB018A
• If the engine is running, turn the engine off and
wait a few minutes before checking.

4. If the oil level is below the LOW mark, add enough recom-
mended oil.

Engine oil Diesel Above API CD SAE 10W30

CAUTION
Oil levels above the HIGH mark may cause engine
damage.

5. After starting the engine, let it idle for a few minutes, stop the
engine and recheck the engine oil level is within the normal
range.
1-22 CHECKING POINT

REPLACING ENGINE OIL

CAUTION
When replacing engine oil and oil filter, do not drop
engine oil in the alternator. Engine oil placed in the
alternator may harm the alternator.
Drain plug

1. After warming up the engine, remove the oil filler cap.

Front
KD4B1001
2. Remove the drain plug and drain oil.

CAUTION
Protect yourself from the hot oil.

3. Tighten the drain plug.

4. Add new oil to the oil filler.

CHECKING AND ADJUSTING DRIVE BELT

Belt
TENSION Water pump

1. Inspect tension by pressing in the middle of belt with 10 kg

f as shown in the illustration.
Standard
Alternator

Alternator 10 ~ 13 mm

Crank shaft KD4B1002

CHECKING AND ADJUSTING DRIVE BELT Alternator

TENSION
CAUTION Alternator bolt
Inspect tension after rotating the engine to one turn
counterclockwise.
Alternator pully
Alternator
support bolt
Crankshaft pulley or pulley
KCMB020B
 CHECKING POINT 1-23

BELT ADJUSTMENT Alternator brake bolt

1. Loosen the alternator support nut.
Water pump
pully
2. Loosen the alternator brace bolt.
Alternator
3. Move the alternator to increase the belt tension to the stan- pully
dard value. Crank shaft
pully
Standard 10 ~ 13 mm Alternator
support bolt
KCMB020E

4. When using a tension gauge, move the alternator to the stan-

dard tension value. 10kg.m
·
Water pump
Standard pully
Alternator
50 ~ 70 kg pully

Standard 40 kg
Crank shaft
pulley

KCMB020F

VALVE CLEARANCE ADJUSTMENT

1. Warm up the engine until the coolant temperature reaches
80~90°C.

2. Measure the valve clearance at arrow positions shown in

the illustration.
NO.1 NO.2 NO.3 NO.4
Description Hot engine

Exhaust valve 0.25 mm

Intake valve 0.25 mm

Intake valve
Èí±â¹ëºê
Exhaust valve
¹è±â¹ëºê
KD4B1003
1-24 CHECKING POINT

3. If the measured value exceeds the standard, loosen the

locker arm nut and adjust clearance with the adjust screw Cygnus
turning using a thickness gauge. gauge

4. Tighten the lock nut to the specified torque with the adjust-
ing nut fixed not to rotate using a screwdriver.

5. Rotate the crankshaft to 360° place the cylinder no.4 to

the dead point.

KD4B1004

6. Measure valve clearance at arrow positions shown in the

illustration.
NO.1 NO.2 NO.3 NO.4
( ) : Cold engine

Item Hot engine

Exhaust valve 0.25 (0.15) mm

Intake valve 0.25 (0.15) mm

Intake valve
Exhaust valveÈí±â¹ëºê
¹è±â¹ëºê
7. If the measured value exceeds the standard, adjust it as the KD4B1005
procedures (6)~(7).

8. Inspect clearance of the intake and exhaust valves and ad-

just it if required.
Feeler gauge

Standard 0.25 mm

KCMB020G

VALVE CLEARANCE ADJUSTMENT

Pressure gauge
1. Check the engine oil, starter and battery for normal operation.

2. Warm up the engine until the coolant temperature reaches

80~90°C.

3. Engage the gauge adapter and install the preheat plug to the
pressure gauge.

KCMB025A
 CHECKING POINT 1-25

4. Crank the engine and measure the pressure.

Limit (250rpm) 19.2 kg/cm2

5. Check that the measured value of each cylinder is within the

limit.

Limit 3.0 kg/cm2

CHECKING COMPRESSED PRESSURE

1. Disassemble the timing belt upper cover. Timing mark

2. Rotate the crankshaft clockwise to place the cylinder no.1 to

the dead point. Check that the timing mark on the sprocket is
aligned.
No.1 cylinder dead
point

KCMB026A

3. Loosen the spiral bolt to a turn and the groove nut to 1-2
turns.
Groove bolt

Spiral bolt

KCMB026B

4. Rotate the crankshaft clockwise to the second gear of the

camshaft sprocket. Cam shaft sprocket
5. Fix the tensioner groove bolt and tighten the spiral bolt to the
specified torque.

Tightening torque 2.2 ~ 3.0 kg m

Second gear

KCMB026C
1-26 CHECKING POINT

6. Rotate the crankshaft counterclockwise to align it to the tim-

ing mark.

7. Check the belt tension by pressing the middle of cam sprocket

and injection pump sprocket with hand.

Standard 4 ~ 5 mm

8. Assemble the timing belt upper cover.

ECLA005E

ADJUSTING TIMING BELT "B" TENSION

1. Disassemble the timing belt upper cover.

2. Rotate the crankshaft clockwise to place the cylinder no.1 to

the dead point.

KCMB026F

3. Remove the access cover.

Access cover

KCMB026D

4. Loosen the spiral bolt to a turn and the groove nut to 1-2
turns.

5. First tighten the tensioner groove bolt and then the spiral bolt
to the specified torque. Spiral bolt

Tightening torque Groove nut

Bolt 2.0 ~ 2.7 kg m

Nut 2.2 ~ 3.0 kg m

KCMB026E
6. Assemble the access cover.

7. Install the timing belt upper cover.

 CHECKING POINT 1-27

CHECKING INJECTION TIMING

1. Stop the cold starting advance angle function. Insert a screw-
driver into the lever lower groove and turn it as shown in the
Spacer
illustration. Accelerator (10mm)
lever
Rod
CAUTION
Do not turn the lever too much.

Driver
ECLA005H

2. Insert the spacer (thickness: 10mm) between the rod and ad-
justing screw.

3. Remove the screwdriver.

CAUTION
When checking and adjusting to replace the injection
pump, stop the advance angle function not to result
in lack of power.

WAX TYPE COLD STARTING EQUIPMENT

This unit is adopted at low temperature to properly correct the fuel injection timing according to the engine coolant temperature.

Wax type cold starting equipment

KCLA006A
1-28 CHECKING POINT

STRUCTURE
1. Wax is sealed in the cold starting equipment, so the piston
rod is operated according to the engine coolant temperature.

Piston Wax

KCLA006B

2. The lever is rotated by the piston and the roller puller is oper- Timer
ated by pin(B) to control the injection timing in retard or Piston
Adjusting bolt
advance. The torsion spring pushes the piston to the injec-
tion timing advance angle direction.
Pin (A)
Idle control bolt
Lever (1)
Pin (B)
Outut side lever
Spring
Pump sie lever
KCLA006C

3. According to the engine coolant temperature except for the

injection timing, the rod connected in the accelerator lever
adjusts the engine idle speed.
Accelerator lever

Pin(A) Lever (1)

KCLA006D
 CHECKING POINT 1-29

ADJUSTING INJECTION TIMING

Notch Timing indicator
CAUTION
Adjust the injection timing with the engine stopped.

1. Rotate the crankshaft to place the cylinder no.1 to the com-

pression dead point.
Crank pully

KCLA003G

2. Loosen the four union nuts in the injection pump side injec-
tion pipe and temporarily tighten them. Fix the distribution Distribution
holder
holder using a spanner not to be turned during loosening the
union nut. Nut

KCLA003H

3. Loosen the injection pump mounting nut and temporarily

tighten it.

Injection (4)

Bolt (2)

Nut (2)

KCLA003I

4. Remove the timing check plug from the injection pump.

Timing check plug

KCLA003J
1-30 CHECKING POINT

5. Before installing the special tool, check that the push rod is
jutted out about 10mm. Protrusion of the push rod is adjusted
by the inner nut. Push rod 09301-43000
09310 - 43000
Nut

10mm
10 mm

KCLA003K

6. Install the dial gauge by installing the special tool to the injec-
tion pump.

Dial gauge

KCLA003L

7. Align the crank pulley to 30° front of the cylinder no.1 com-
Approx
30˚30° 0
pression dead point.

8. Set the dial gauge to read '0'.

9. Slightly move the crank pulley notch left and right and check
that the pointer moves away from 0 position.
If the pointer is unstable, realign the notch position to 30°
front of the dead point

KCLA003M

10. Rotate the crankshaft to the right to place the pulley notch to
5°. 1 10.03
± 0.03
mmmm

Normal injection timing ATDC 5°

Recheck the dial gauge is within the standard.

Standard 1 0.03 mm

KCLA003N
 CHECKING POINT 1-31

11. If the pointer of dial gauge is out of the standard values, move
the injection pump body left or right to correct and tighten the
injection pump mounting nut and bolt to the specified torque. Front View 10.03 mm or more
1±0.03

12. After adjusting, repeat the procedures (7) and (10) to check
that the adjustment is correct.

10.03 mm or less
1±0.03

KCLA003O

13.Detach the dial gauge and special tool and install the gasket
and plug.

14. Install the injection pipe nut.

Fix the spanner not to turn the distribution holder together.

15. Install a new gasket and tighten the plug to the specified Dial gauge
torque.
Plug
Tightening torque 2.3 ~ 3.7 kg m
KCLA003P

CHECKING AND ADJUSTING ENGINE IDLE Idle adjusting screw

SPEED
Speed up
Accelerator Lock nut
CAUTION
lever
Only use the idle speed adjusting screw.

1. Before checking and adjusting

• Engine coolant temperature: 80~90°C

2. Check the injection timing and valve clearance and adjust KCLA004A

them if required.

3. Install the idle speedometer.

4. Measure the engine idle rpm.

Standard 750 100 mm

5. If the measure the value is out of the standard, loosen the

lock nut and adjust it within the standard values by turning
the adjusting screw.

6. After adjusting, tighten the lock nut.

CHAPTER 2. ENGINE MECHANICAL SYSTEM

1. CYLINDER HEAD ASSEMBLY .............................................. 2- 1

2. TIMING SYSTEM ................................................................... 2- 14

3. FRONT CASE ........................................................................ 2- 25

4. MAIN MOVING SYSTEM ....................................................... 2- 31

5. CYLINDER BLOCK ............................................................... 2- 41

 CYLINDER HEAD ASSEMBLY 2-1

1. CYLINDER HEAD ASSEMBLY

1) LOCKER ARM & CAM SHAFT
COMPONENTS

0.5 ~ 0.7kg·m

3
3.5 ~ 4.0kg·m
4 10

6
7
16
9
15
8 14
13
1.9 ~ 2.1kg·m
17

12

11

<Disassembly>
1. Breather hose 10. Adjust screw
2. Oil filler cap 11. Camshaft oil seal
3. Rocker cover 12. Camshaft bearing cap - Front
4. Rocker cover gasket 13. Camshaft bearing cap No.2
5. Packing 14. Camshaft bearing cap No.3
6. Rocker shaft 15. Camshaft bearing cap No.4
7. Rocker arm, Intake 16. Camshaft bearing cap - Rear
8. Rocker arm, Exhaust 17. Camshaft
9. Rocker shaft spring
KCMB800A
2-2 CYLINDER HEAD ASSEMBLY

INSPECTION
CAMSHAFT
1. Visually inspect the camshaft journals and replace them if
they are damaged and burned.
If the camshaft journals have burned, check the cylinder head
bearing for damage and the cylinder head oil passage for
Journal
clogging.

KCMB810A

2. Measure the camshaft diameter and bearing inner diameter

and if the oil clearance exceeds the limit value, replace the
camshaft, cylinder head or both.

Standard 0.05 ~ 0.08 mm

Limit 0.13 mm

KCMB100H

3. Check the cam surface for abnormal wear or damage and

replace it if required.
Measure the cam height (bigger diameter) and replace it if it
exceeds the limit.

Standard 37.05 mm

Limit 36.55 mm

ROCKER ARM
1. Check the contact surface with the cam and replace the rocker
arm if it damaged and burned.

2. Visually check the inside for damage or burn and replace it if

required.

3. Measure the inner and outer diameters and if the oil clear-
ance exceeds the limit, replace the rocker arm, shaft or both.

Standard 0.01 - 0.04 mm

Limit 0.08 mm
 CYLINDER HEAD ASSEMBLY 2-3

ROCKER SHAFT
1. Check the oil passage for clogging and clean it if required.

2. Check the rocker arm assembly for damage or burn and

replace it if required.

ASSEMBLY
CAM SHAFT
1. Measure A and B, calculate the end play, and if the value
exceeds the limit, replace parts.

B - A = End play

Standard 0.01 - 0.04 mm

A B
Limit 0.08 mm ECLA019C

2. Install the camshaft with the dowel pin upward to the cylinder
head.
Dowel pin

Camshaft

KCMB820A

CAM SHAFT BEARING CAP

Assemble the camshaft bearing cap in sequence of the identifi-
cation number engraving on the upper surface of bearing cap.
2-4 CYLINDER HEAD ASSEMBLY

CAM SHAFT OIL SEAL

09221--21000
09221 21000
1. Using the special tool, press-fit a new camshaft oil seal to the
front bearing cap portion. Cam shaft

2. Apply oil to the oil seal lip portion.

Oil seal
KCMB820B

ROCKER ARM (EXHAUST, INTAKE)

Take care not to make mistakes of the identification numbers.

ROCKER ARM SHAFT

1. Assemble the oil passage side shown in the illustration, fac-
ing it downward. Front

2. The shaft having one oil passage should be assembled in the

front.

One oil passage Two oil passages

KCMB820C

PACKING
Apply sealant to the marked portion in the illustration.

Specified sealant 3M P/No. 8660 or equivalent

Apply sealanat

KCMB820D
 CYLINDER HEAD ASSEMBLY 2-5

ADJUSTING VALVE CLEARANCE

Timing
1. Rotate the crankshaft clockwise to align the camshaft sprocket Camshaft mark
sprocket
with the timing mark.

KCMB820E

2. Adjust the valve clearance at the arrow position shown in the

illustration.

Ex. In. In. Ex.

KCMB280F

3. Loosen the adjusting screw mounting nut.

4. Adjust the valve clearance by turning the adjusting screw.

Standard (Cold engine)

Intake 0.15 mm

Exhaust 0.15 mm

5. Fix the adjusting screw not to turn using a screwdriver and

install the adjusting nut

ECLA019J
2-6 CYLINDER HEAD ASSEMBLY

6. Rotate the crankshaft to one turn clockwise to place the cyl-

inder no.4 to the compression dead point.

7. Follow the procedures (2), (3) and (4) to adjust the valve
clearance.

Standard (Hot-engine)

Intake 0.25 mm

Exhaust 0.25 mm

8. After installing the engine assembly to the vehicle, inspect

the valve clearance with hot engine and adjust it if required.

Ex. In. Ex. In.

KCMB280G
 CYLINDER HEAD ASSEMBLY 2-7

2) CYLINDER HEAD & VALVE

COMPONENTS

4
5
10
6
1
7
Cold engine : 10.5~11.5 kg·m
11 Hot engine : 11.5~12.5 kg·m
12

13
14
8

[DISASSEMBLY]
1. Cylinder head bolt 10. Valve stem seal
2. Cylinder head 11. Intake valve guide
3. Cylinder head gasket 12. Exhaust valve
4. Valve spring retainer lock 13. Intake valve seat
5. Valve spring retainer 14. Exhaust valve
6. Valve spring
7. Spring seat
8. Intake valve
9. Exhaust valve
KCMB750A
2-8 CYLINDER HEAD ASSEMBLY

DISASSEMBLY
CYLINDER HEAD BOLT
Using the special tool, Cylinder Head bolt Wrench (09221-32000),
loosen 18 Cylinder head bolts and remove them. Loosen the bolts
09221 - 32000
in the sequence shown and in two to three steps.

ECLA018B

6 14 16 8
1 10 18 12 4

5 13 15 7 3
2 9 17 11

KCDA052A

VALVE SPRING RETAINER LOCK

1. Using a valve spring compressor (09222 - 21000), compress 09222 - 21000
the spring and fit the retainer lock in position.

2. The valve spring, if compressed excessively, causes the bot-

tom end of retainer to be in contact with, and damages, the
stem seal.

ECLA018D

INSPECTION
CYLINDER HEAD
1. Before cleaning the cylinder head, check for water and oil
leaks, damage, or cracks.

2. Remove oil, scale, sealant, and carbon deposits completely.

After cleaning the oil passages, apply compressed air to en-
sure that the passages are not clogged.
 CYLINDER HEAD ASSEMBLY 2-9

3. If there is gas leak from the cylinder head gasket surface,

measure the surface flatness. If distortion exceeds the limit,
replace the cylinder head.

Standard value 0.05 mm less than

Limit L 0.2 mm

4. Visually check the camshaft bearing internal surfaces for dam-

age or seizure. If defects are evident, replace the bearing.

INTAKE VALVE, EXHAUST VALVE

1. If the valve stem develops wear (taper wear) or damaged,
replace. If there is a dent in the stem end face (the surface in
contact with the rocker arm adjust screw), replace.
Contact
Margin

KCMB770A

2. Check the valve face for contact. If the contact is not proper,
correct with a valve refacer. The contact pattern with the valve
seat must be even at the center of valve face.

3. Replace if the margin (valve head thickness) exceeds the limit.

Contact
Standard value 2.0 mm Margin

Limit 1.0 mm

KCMB770A

VALVE SPRING
1. Measure the free height of spring and replace if the limit is ˚
exceeded.

Standard value 49.1 mm

Free height
Limit 48.1 mm

2. Measure the squareness of the spring and, if the limit is

exceeded, replace.
KCMB100B

Standard value 2° less than

Limit 4°
2-10 CYLINDER HEAD ASSEMBLY

VALVE GUIDE
Measure the valve guide to stem clearance and, if the measure-
ment exceeds the limit, replace the valve guide or valve, or both.

Exhaust 0.05 ~ 0.09 mm

Standard value
Intake 0.03 ~ 0.06 mm
Intake 0.10 mm
Limit
Exhaust 0.15 mm KCA9281D

RECONDITIONING VALVE SEAT

1. When reconditioning the valve seat, inspect clearance be-
tween the valve guide and valve and replace the valve guide
if required.
Special tool
2. Using the special tool or valve grinder, correct the seat width
and angle to the specified value. Cutter

VALVE SEAT CUTTER

Cutter angle Parts number 0.9 - 1.3 mm

45° 09221-43300 65˚

65° 09221-43400 65˚

30° 09221-43500
45˚
ECLA018E

3. Apply compound to the valve and seat.

VALVE SEAT REPLACEMENT PROCEDURE

0.5 - 1mm
1. Cut the valve seat to be replaced from the inside to thin the
wall thickness. Then, replace the valve seat.

2. Rebore the valve seat hole in cylinder head to the oversize Cutting portion
valve seat diameter.
0.5 - 1mm
Intake valve 0.30 O.S. 43.300 ~ 43.325mm
seat ring hole
diameter 0.60 O.S. 43.600 ~ 43.625mm
KCMB100D
Exhaust valve 0.30 O.S. 37.300 ~ 37.325mm
seat ring hole
diameter 0.60 O.S. 37.600 ~ 37.625mm
 CYLINDER HEAD ASSEMBLY 2-11

3. Before fitting the valve seat, either heat the cylinder head up
to approximately 250°C (482°F) or cool the valve seat in liq-
uid nitrogen to prevent the cylinder head bore from abrasion.

4. After installation, recondition the valve seat.

Height of valve seat

Over size I.D.

KCMB100E

VALVE GUIDE REPLACEMEMT PROCEDURE

1. Using the push rod of Valve Guide installer (09222 - 32200)
and apress, remove the valve guide forward cylinder block.
2. Rebore valve guide hole to the new oversize valve guide out-
side diameter.

0.05 O.S. 13.050 ~ 13.068 mm

0.25 O.S. 13.250 ~ 13.268 mm

0.50 O.S. 13.500 ~ 13.518 mm

CAUTION
Do not reassemble the same size of valve guide.

3. Using Valve Guide Installer (09222-32200), press-fit the valve

guide, working from the cylinder head top surface.

CAUTION
Take care not to change the exhaust and intake valve Push rod
guides because both lengths are not equal. 09222 - 32200
Valve guide
Cylinder head

KCMB770C

Vavle guide Valve guide

(Intake valve) (Exhaust valve)

71mm 74mm

KCMB770D
2-12 CYLINDER HEAD ASSEMBLY

4. After installing valve guides, insert new valves in them to check

for sliding condition. Vavle guide Valve guide
(Intake valve) (Exhaust valve)
5. When replacing the valve guides, inspect valve contact and
correct the valve seat if required.

71mm 74mm

KCMB770E

INSTALLATION
VALVE STEM SEAL
1. Using Valve Stem Seal Installer (09222 - 32100), install the 09222 - 32100
valve stem seal into the valve guide.

CAUTION
• The valve stem seal must be not reused.
• The special tool must be used for the installation
of the valve stem seal. Improper installation could
result in oil consumption through valve guide.
Valve spring seat

KCMB780A

VALVE SPRING
Direct the valve spring end with identification color to the therocker Spring
Identification
arm.

Retainer

Stem seal

KCMB100F
 CYLINDER HEAD ASSEMBLY 2-13

VALVE SPRING RETAINER LOCK

Using a valve spring compressor (09222 - 21000), compress the 09222 - 21000

spring and fit the retainer lock in position.

CAUTION
The valve spring, if compressed excessively, causes the
bottom end of retainer to be in contact with, and damages,
the stem seal.
ECLA018D

CYLINDER HEDA GASKET

1. Clean contact surfaces between the cylinder head and cylin-
der block gasket.

2. Assemble the gasket facing upward the marking portion in

the illustration.

CYLINDER HEAD BOLT

1. Scrape off gasket adhered to cylinder head assembly.

2. Tighten in the numerical order indicated in the diagram in two

13 5 3 11
or three groups with special tool. 17 9 1 7 15

Specified torque 16
14 6 4 12
18 10 2 8
Limit 11.5 ~ 12.5 kg·m

Cold engine 10.5 ~ 11.5 kg·m KCMB780B

2-14 TIMING SYSTEM

2. TIMING SYSTEM
1) TIMING BELT
COMPONENTS

11 8
2.2 ~ 3.0kg·m
6.5 ~ 7.5kg·m

4 9

8 ~ 9kg·m

12

17 ~ 19kg·m 7
1 13 10

2 3 6

[DISASSEMBLY]
1. Crank shaft pully bolt 8. Timing belt tensioner
2. Washer 9. Tensioner speacer
3. Crank shaft pully 10. Timing belt
4. Timing belt upper cover 11. Camshaft sprocket
5. Timing belt lower cover 12. Injection pump sprocket
6. Acess cover 13. Crank shaft sprocket
7. Flange

KCMB850A
 TIMING SYSTEM 2-15

REMOVAL
TIMING BELT
1. Remove the cooling fan, water pump, crankshaft pulley and
timing belt cover.

2. Turn the crankshaft to bring the piston in No. 1 cylinder to the

top dead center on the compression stroke.

3. Mark an arrow on the back of the timing belt and timing belt B
with a chalk to indicate the direction of rotation. This ensures
that the belt is installed in the same direction for reuse.

CAUTION
Stained belts with water or oils may be highly short
enedtheir life. So, the removed timing belt, sprocket
and tensioner should not be washed off, as well as
not be stained with oils. If the belts are seriously
stained, replace them.

ECLA020B

4. The piston in No. 1 cylinder is at the top dead center on the

compression stroke when all timing marks at the three places
are aligned as shown.

KCMB860A

5. Slightly loosen the two bolts securing the tensioner. Then,

slide the tensioner toward the water pump and tighten the Slide toward water pump

bolts temporarily to secure the tensioner in place.

KCMB860B
2-16 TIMING SYSTEM

CAMSHAFT SPROCKET
1. Loosen the bolt securing the camshaft sprocket and remove
the camshaft sprocket.

2. Remove the sprocket nut.

CAUTION
Use care not to give shock to the fuel injection pump
shaft, as it could result in defective fuel injection
KCMB860C
pump. Using Injection Pump Sprocket Puller (09314 -
43000) or suitable tool, remove the sprocket from in-
jection pump.

3. Remove the tensioner and tensioner spring.

INSPECTION
TIMING BELT
Carefully inspect the belt and replace it with a new one if there
are damages presented as below.

1. Hardened back surface of rubber

Back surface is glossy, Non-elastic and so hard that, when
your fingernail is pressed into it, no mark is produced.
ECA9200B

2. Cracked back surface of rubber

Crack Crack
3. Cracked or separating canvas

4. Badly worn out teeth (initial stage)

Separation
5. Badly worn out teeth (last stage) Crack

Crack
KCMB870A
 TIMING SYSTEM 2-17

6. Side of belt cracked

Normal belt should have precisely cut side as if produced by
a sharp knife.
Separation
Rounded belt side

Abnormal wear
KCMB100J

7. Cracked tooth bottom

Initial state: Canvas worn (swollen canvas fiber, low quality of
Rubber exosed
rubber, discolored with white, and bad clearness)
Latter state: Canvas worn and rubber exposed (tooth width
narrowed)
Fiber exposed
8. Missing tooth

KCMB100K

TIMING BELT TENSIONER

1. Check it for smooth rotation and abnormal noise and replace
it if required.

2. Check it for clicking sound and rolling and replace it if required.

KCMB870B

TIMING BELT COVER

1. Check it for deformation and crack and replace it if required.

2. Check the seal for wear and damage and replace the timing
belt if required.
2-18 TIMING SYSTEM

INSTALLATION
Crank shaft
CRANKSHAFT SPROCKET
1. Mount the crankshaft sprocket to the crankshaft noting the
direction of the sprocket as well as the flange. Oil pump gear
drive shaft
2. Mount the camshaft sprocket and tighten the flange bolts to
specified torque. Sprocket
Sprocket “ B ”
3. Be careful of the flange installation direction. Flange
KCMB880A

TIMING BELT TENSIONER

1. Install the tensioner, tensioner spring and tensioner spacer.

2. The tensioner moved all the way to the water pump, tempo-
rarily tighten bolt.

CAUTION
When installing, face the short end of tensioner spring
toward the water pump.
KCMB870B

TIMING BELT Camshaft

sprocket Separation
1. Correctly line up timing marks on three sprockets.

2. While ensuring that the tension side of timing belt is not slack,
Injection
install belt onto the crankshaft sprocket, injection pump pump sprocket
sprocket, tensioner and camshaft sprocket, in that order.
Tensioner
CAUTION Separation
• When installing the belt onto the injection pump
sprocket, keep the sprocket in position, as it tends Crankshaft sprocket KD4B2010

to turn by itself at the timing mark alignment

position.
• If the belt is to be reused, make sure that the ar-
row mark made during disassembly faces to the
correct direction at reassembly.
 TIMING SYSTEM 2-19

3. Check if all timing marks are aligned correctly.

Bolt A

Bolt B

KCMB870B

4. Back off tensioner bolt A, that have previously been secured

to the water pump side, one to two turns to give tension to the
Camshaft sprocket
belt using tensioner spring tension.

5. Confirm that the timing belt is correctly engaged with three

sprockets.

CAUTION Crank shaft

Turn crankshaft clockwise by the two teeth of the cam-
shaft sprocket and keep the position.
KCMB880C

6. Tighten bolt A.
Deflection
7. Tighten bolt B.

CAUTION
If the bolt B is tightened first, the tensioner should be
turned together, causing an undue tension to be ap-
plied to the timing belt.

8. Turn the crankshaft in the direction of backward rotation to

line up timing marks. KCMB880E

9. In this condition, ensure that the deflection when the center

of belt is pushed by the index finger.

Standard 4 ~ 5 mm
2-20 TIMING SYSTEM

FLANGE INSTALLATION
Notch for timing
adjustment
Note that bolt holes in the flange and those in the injection pump Sprocket
sprocket are offset positioned at one place. When assembling, Offset
position the jlange and sprocket as shown.
Flange

KCMB880F
 TIMING SYSTEM 2-21

2) TIMING "B"
COMPONENTS

9
7

3.4 ~ 4.0kg·m

8 2 3 4 5

2.2 ~ 3.0kg·m
3.4 ~ 4.0kg·m

10

1
6

1. Flange
2. Gasket
3. Tensioner spacier
4. Tensioner spring B
5. Timing belt tensioner B
6. Timing belt B
7. Silent shaft sprocket-right
8. Silent shaft sprocket-left
9. Spacier
10. Crank shaft sprocket B

KCMB900A
2-22 TIMING SYSTEM

REMOVAL
TIMING BELT "B"
1. Remove the timing belt.

2. Using chalk or the like, put an arrow on the back of the timing
belt "B" to indicate the direction of drive.

ECLA021B

3. Slightly loosen the bolts and nuts securing the tensioner. Then,
slide the tensioner toward the water pump and tighten the
nuts to secure the tensioner in place temporarily.

4. Remove the timing belt "B".

5. Remove the crankshaft sprocket "B".

6. Remove the two silent shaft sprockets.

SILENT SHAFT SPROKCET(LEFT, RIGHT)

Screw driver [shaft dia. Wrench extension
When loosening the nut and bolt for two silent shaft sprockets, be 8 mm (0.31 in.) bar or similar size rod
sure to lock the silent shaft as shown.

CAUTION
Water, oil, or grease on the belt shortens its life
Slient shaft,
drastically. Use special care to ensure that the re- left
Silent shaft,
moved timing belt, sprockets, and tensioner are free right
from oil and grease.
Right side

Remove this plugh and insert a screwdriver

Remove cover and inseft bar

KCMB910A
 TIMING SYSTEM 2-23

INSTALLATION Crank shaft

1. Mount the crankshaft sprocket "B"to the crankshaft, noting

the direction of the sprocket "B".
Oilpump gear
drive shaft

Sprocket “ B ”
KCMB920A

2. The spacer must be installed with its chamfered end facing

toward the silent shaft. If the spacer is installed in the wrong Spacier
direction, damage to oil seal will result. Silent shaft

Tapper

KCMB920B

TIMING BELT "B" TENSIONER Water pump

1. Install the tensioner spring and spacer, with the tensioner
moved all the way to the water pump.
Bolt
2. Tigh ten the nut. Tighten the bolt not fully put finger tight.

Nut
A

Spacier

Tensioner A-A

Gasket

Front lower
case
Tensioner spring “ B ”
KCMB920C
2-24 TIMING SYSTEM

TIMING BELT "B"

Timing mark
1. Line up timing marks on the crankshaft sprocket B, and right
Tensioner "B"
and left silent shaft sprockets.
Timing mark
2. With the timing belt B installed, ensure that its tension side is
not slack. Tension
Timing belt "B"
CAUTION
If the belt is to be reused, make sure that the arrow
mark made during disassembly faces to the correct Crank shaft sprocket "B"
KCMB920D
direction at reinstallation.

3. With the tension side of timing belt B kept tight by pushing

Timing mark
the slack side (indicated by A in illustration) with a finger,
make sure that the timing marks are properly aligned with Timing mark
each other.
Tension

Tension
KCMB920E

4. Back off tensioner B nut, that have previously been secured

to the water pump side, one to two turns to give tension to the
belt using tensioner spring tension.

5. First tighten the timing belt "B" tensioner mounting nut and
then the bolt.
Bolt
CAUTION Nut
If the bolt is tightened first, the tension B should be Tensioner
spring "B"
turned together, resulting in reduced timing belt B
tension. KCMB920F

6. Ensure that the deflection is 4 to 5 mm (0.0394 to 0.1969 in.)

Silent
when the belt is pushed by the index finger at the position
indicated by and arrow.

Belt deflection 4 ~ 5 mm Belt deflection

Crank shaft
sprocket "B"
KCMB920G
 FRONT CASE 2-25

3. FRONT CASE
1) FRONT CASE, SLIENT SHAFT, OIL PAN
COMPONENTS

21

19

1.5 ~ 1.8kg·m

11 15
3.4 ~ 4kg·m 16

18 N

17

9
2.0 ~ 2.7kg·m 13 N

20
12

14

19
1.2 ~ 1.5kg·m 21

8N
2N
7
1.2 ~ 1.5kg·m

6
[DISASSEMBLY] 1
1. Oil drain plug 6 ~ 8kg·m
2. Oil drani plug gasket 0.6 ~ 0.8kg·m
3. Oil pan 3
4. Oil screen
5. Oil screen gasket
6. Front upper case
16. Silent shaft driven gear
7. Oil seal
17. Silent shaft driven gear
8. Front upper case gasket
18. Oil seal
9. Plug Cap
19. Silent shaft, right
10. O-ring
20. Silent shaft, left
11. Flange bolt
21. Bearing, rear
12. Flange lower case
13. Flange lower case gasket [Remarks]
14. Front oil seal Assembly is the reverse of disassembly.
15. Silent shaft gear cover Do not reuse N marking parts.
N
KCMB150A
2-26 FRONT CASE

REMOVAL
OIL PAN
Remove the oil pan by tapping the oil pan bottom edge or drain
plug with a soft hammer.

CAUTION
Do not insert a chisel or screwdriver between the oil
pan flange and cylinder block to remove the oil pan.
It may deform the oil pan flange surface. ECLA007H

FLANGE BOLT REMOVAL

Cylinder block right
1. Remove the plug on the right side of the cylinder block.

Plug

KCMB160A

2. Insert a screwdriver (cross slotted) into the plug hole not

to turn the silent shaft.
Driver
3. Remove the flange bolt.

Silent shaft right

KCMB160B
 FRONT CASE 2-27

INSPECTION
SILENT SHAFT
1. The oil holes must be free from clogging.

2. Check journal for seizure, damage, and contact with the

bearing. If defects are evident, replace the silent shaft, bearing,
or front case assembly.

3. Check the silent shaft for oil clearance. If wear is excessive,

ECLA007K
replace the silent shaft bearing, silent shaft, or front case
assembly.

STANDARD VALUE

Front left 0.02 ~ 0.6 mm

Front right 0.02 ~ 0.05 mm
Rear 0.05 ~ 0.09 mm

FRONT UPPER CASE, FRONT LOWER CASE

Check them for damage and crack.
Replace them if required.

OIL PAN
Check the gasket surface for deformation and replace it if required.

REPLACEMENT
SILENT SHAFT
09212-43300
1. Use Bearing Installer Stopper (special tool) only for removal
and reinstallation of the right bearing.

ECLA008A
2-28 FRONT CASE

2. Using Bearing Installer Stopper and Silent Shaft Bearing Puller

(09212 - 43300, 09212 - 43100), remove two rear bearings 09212 - 43100 Bearing
from the cylinder block.

09212 - 43300

KCMB180B

3. Using Bearing Installer Stopper and Silent Shaft Bearing Puller

(09212 - 43300, 09212 - 43100), remove two rear bearings 09212 - 43200
from the cylinder block. Bearing

Apply
09212 - 43300 oil

KCMB180C

4. When press-fitting the right bearing, align the bearing oil hole
with the cylinder block oil hole. Bearing oil hole

Silent shaft bearing

Plug

Cylinder block
Oil hole
KCMB180D

INSTALLATION Oil seal

Socket
OIL SEAL
Install special tools in drive gear and apply to engine oil to drive
gear shaft.

KCMB190A
 FRONT CASE 2-29

SILENT SHAFT GEAR

Silent shaft
1. Apply engine oil to the gear.
Mating
2. Align the mating marks on the silent shaft drive gear and driven marks
gear and assemble them to the front lower case

KCMB190B

Drive gear
Front lower case

09222 - 43200

Oil seal

KCMB190C

FRONT LOWER CASE

Front lower case
When tightening the bolts, be sure to secure the silent shaft in L = 55
position. L = 25
L = 75

L = 65 L = 25

L = 55 L = 65
L = bolt screw length (mm)
KCMB190D

FRONT OIL SEAL Oil seal Front lower case

1. Install the special tool guide to the crankshaft and apply en- Crank shaft
gine oil to the outer surrounding.
Oil pump
2. Using the special tool, assemble the front oil seal to the case. driver shaft

09214 - 32000
(Apply oil to outer
surrounding) 09214 - 32100
KCMB190E
2-30 FRONT CASE

FLANGE BOLT
1. Insert a screwdriver (cross slotted) into the plug hole not to
turn the silent shaft(right).

2. Assemble the flange bolt and tighten it to the specified torque.

KCMB190F

KCMB190G

OIL PAN
1. Remove the sealant attached in the cylinder block and oil
pan gasket surface.

2. Apply sealant to the oil pan flange to the thickness of 4mm.

3. After applying sealant, assemble the oil pan and tighten the
bolt to the specified torque in 15 minutes.

Tightening torque 0.6 ~ 0.8 kg·m

 MAIN MOVING SYSTEM 2-31

4. MAIN MOVING SYSTEM

1) CRANK SHAFT & FLY WHEEL
COMPONENT

13 ~ 14 kg·m

5 1

8
9

7
10 6

14

13

12

11

7.5 ~ 8.5 kg·m

1. Fly wheel assembly 8. Bearing cap

2. Rar plate 9. Crank shaft bearing-Lower
3. Bell housing cover 10. Crank shaft
4. Oil sela case 11. Crank shaft bearing-Upper
5. Gasket [Remarks]
6. Oil separator (1) Assembly is the reverse of disassembly
7. Rear oil seal (2) Do not reuse N marking parts.

KCMB200A
2-32 MAIN MOVING SYSTEM

INSPECTION
CRANKSHAFT
1. Visually inspect the journals and pins for damage and replace
them if required.

2. Measure the journal O.D. and main bearing I.D. and if the
clear ance exceeds the limit, replace the main bearing (and
crank shaft if required).
Or, grind the crankshaft to undersize and replace it with the ECLA009B
undersize main bearing.

Standard 0.02 ~ 0.05 mm

Limit 0.01 mm A
1 2
B

KCMB210A

3. When grinding the crankshaft to undersize, ensure correct

2.5 mm R
fillet radius dimensions in journals and pins.

2.5 mm R

2.5 mm R

KCMB210B

CRANKSHAFT OIL CLEARANCE (PLASTIGAGE

Plastic gauge
METHOD)
1. Wipe crankshaft O.D. and bearing I.D. clean of oil.

2. Install the crankshaft.

3. Put a strip of Plastigage lengthwise in the center of the journal.

KCMB210C
 MAIN MOVING SYSTEM 2-33

4. Replace the main bearing cap carefully and tighten bolts to

specification.

5. Remove bolts and carefully remove the main bearing cap.

6. Using the scale printed on the bag of plastigage, measure

the amount the Plastigage has been flattened (the widest
point).

ECLA009F

CRANKSHAFT FRONT AND REAR OIL SEALS

1. Wear and damage in oil seal lips.

2. Deteriorated or hardened rubber.

3. Cracks or damage on oil seal case.

RING GEAR
1. If the ring gear teeth are worn, damaged, or broken, replace Fly wheel
Ring gear
the ring gear.

2. If the teeth are damaged or broken, check the starting motor

pinion.

3. To remove the ring gear for replacement, tap its outer rim one
place after another. Heating the gear makes it impossible to
remove. To install the ring gear onto the flywheel, heat it up to
KCMB210D
260-280°C (500-536°C) : it is a shrink fit in the flywheel.

FLYWHEEL
1. Visually inspect the flywheel clutch disc surface for wear and
damage and replace it if required

2. If the clutch disc surface rolling exceeds the limit, replace it.

Limit 0.13 mm
2-34 MAIN MOVING SYSTEM

DRIVE PLATE (AUTOMATIC TRANSAXLE)

Check the drive plate for deformation, damage and crack and
replace it if required.

INSTALLATION Without oil hole With oil hole

1. Install the upper crankshaft bearing to the cylinder block.

There is oil hole in the upper crankshaft bearing. Upper bearing
Lower bearing (No. 1. 2. 4. 5)
(No. 1.2.4.5)
2. Install the lower crankshaft bearings to each bearing cap and (No.(No.
1. 2. 4. 5)
1.2.4.5) Without oil hole
apply engine oil to the bearing surface.

Upper & lower

bearning(middle)
KCMB220A

BEARING GAP
Main bearing cap direction
1. Install the main bearing to the cylinder block. Ensure the cor-
rect cap number and arrow mark direction.
Arrow
(Display engine forward)
Engine direction

No.
Cap No.

KCMB220B

2. Check to ensure that the crankshaft turns smoothly and there

is an adequate end play.

Standard 0.05 ~ 0.18 mm

Limit 0.25 mm

ECLA009J
 MAIN MOVING SYSTEM 2-35

OIL SEAL CASE

Using special tool, press-fit a new crankshaft rear oil seal into the
oil seal case.

09231 - 32000

KCMB210C

OIL SEPARATOR
Push oil separator into the oil seal case. Make sure that the oil
hole in the separator comes at the bottom (indicated by an arrow
in illustration.)

Oil hole
KCMB220C
2-36 MAIN MOVING SYSTEM

2) PISTON
COMPONENTS

6
7
9
8

11

10
5
13

12

[DISASSEMBLY]
1. Nut
2. Connect rod cap
3. Connect rod bearing
4. Piston & connecting rod assembly
3
5. Connect rod bearing
6. Bolt
7. Piston ring No.1
8. Piston ring No.2 2
9. Oil ring
10. Piston
11. Snapring 1
12. Piston rod 4.5 ~ 4.8 kg·m
13. Connect rod [Remark]
14. Bushing (1) Assembly is the reverse of disassembly
KCMB250A
 MAIN MOVING SYSTEM 2-37

INSPECTION
PISTON
1. Check each piston for scuffing, scoring, wear and other
defects. Replace any piston that is defective.

2. Check that the piston pin fits in the piston pin hole.

CAUTION
Replace the piston and piston pin as an assembly.

3. Replace any piston and pin assembly that is defective.

4. The piston pin must be smoothly pressed by hand into the

pin hole (at room temperature).

PISTON RING
1. Check each piston ring for breakage, damage and abnormal
wear. Replace the defective rings.

2. When the piston requires replacement, its ring should also

be replaced.

Item TC NA
No.1 0.056 ~ 0.076 0.03 ~ 0.07
Standard No.2 0.046 ~ 0.066 0.08 ~ 0.12
OIL 0.02 ~ 0.065 0.02 ~ 0.065 ECLA010B

No.1 0.15
imit No.2 0.15
OIL 0.1

3. Measure the clearance between piston ring and ring home.

Thickness
Piston gauge

ECLA010C
2-38 MAIN MOVING SYSTEM

4. Place a piston ring in the cylinder bore and set it square by

pushing it down with piston.

Item TC NA
No.1 0.30 ~ 0.50 0.25 ~ 0.40
Standard No.2 0.41 ~ 0.54 0.45 ~ 0.60
OIL 0.25 ~ 0.45 0.20 ~ 0.40

Limit 0.8 Piston Eng gap

ring
KCMB260A

CONNECTING ROD BEARING

1. Check the bearing surfaces for uneven contact pattern,
streaks, scratches, and seizure. If defects are evident, replace.
If the surfaces are seriously nicked and seized, check also
the crankshaft. If the crankshaft is also damaged, replace the
crankshaft or grind to undersize for reuse.

ECLA010E

2. Measure the connecting rod bearing I.D. and crankshaft pin

O.D. If the clearance (oil clearance) exceeds the limit, replace
the bearing and, if necessary, the crankshaft. Or, grind the
crankshaft to an undersize and, at the same time, replace the
bearing with an undersize.

Standard 0.02 ~ 0.05 mm

Limit 0.1 mm

ECLA010F

CONNECTING ROD BUSHING Pull out

1. Pull out the bushing using the special tool.

09214 - 43000

Pull out
ECLA010G
 MAIN MOVING SYSTEM 2-39

2.. Press-fit the bushing using the special tool.

At this time, align the busing with connecting rod small end
oil hole.
09214 - 43000
Apply oil
Bushing

Align to the Chamfer side

oil hole

ECLA010H

3. Adjust the busing inner diameter within the standard values.

Standard 29.015 ~ 29.025 mm

ECLA010I

CAUTION
1. Insert the piston pin, following the front mark.
Front mark

Front mark

KCMB260B

2. Install the snap ring in the following direction.

ECLA010K
2-40 MAIN MOVING SYSTEM

INSTALLATION
No. 1
PISTON RING INSTALLATION
No. 2
1. Install the oil ring expander and oil ring to the piston.
Oil
2. Then, install No.2 piston ring and No.1 piston ring, in that
order. Make sure that the ring side, on which manufacturer
and size marks are stamped, faces to the piston crown.

KCMB270B

PISTON & CONNECTING ROD ASSEMBLY

Upper side rail
No. 1
1. Apply engine oil to the piston surface, piston ring and oil ring.

2. Adjust gap between the piston ring and oil ring as shown in
the illustration. Piston pin

No. 2 Lower side rail

KMBC270B

3. Insert the piston and connecting rod assembly from above

the top of cylinder. Ensure that the front mark on piston crown
and that (ID mark) on the connecting rod face toward the front
of engine (to the crank pulley side).

4. Clamp firm the piston rings with the ring band and install the
piston assembly into cylinder. Do not strike it hard into the
piston, as broken piston ring or damaged crank pin could
result.
ECLA010N

5. When assembling, align the bearing cap with the connecting

rod.
If parts are new ones, align notches in the same direction.

6. Make sure the clearance of connecting rod big end side.

Standard 0.10 ~ 0.25 mm

Limit 0.4 mm

ECLA010O
 CYLINDER BLOCK 2-41

5. CYLINDER BLOCK
1) CYLINDER BLOCK
COMPONENTS

5
4 ~ 5 kg·m

N 2 1

6 5 ~ 6 kg·m 4 0.5 ~ 0.7 kg·m

[DISASSEMBLY]
1. Cover
2. Packing
3. Engine bracket, right
4. Engine bracket, left [Remarks]
5. Cylinder sleeve (1) Assembly is the reverse of disassembly
6. Cylinder block (2) Do not reuse N marking parts

KCMB030A
2-42 CYLINDER BLOCK

INSPECTION
CAUTION
• Before inspection and repair, clean parts to re-
move dirt, oil, carbon, deposits, and scale.
• Before cleaning the cylinder block, be sure to
check for evidences of water leaks and damage.
• Romove contaminants from oil holes with com-
pressed air and, at the same time, make sure that
they are not blocked.

CYLINDER BLOCK C D E
A F
1. Check for scratches, rust, and corrosion. Use also a flaw -
detecting agent for the check. If defects are evident, correct B G
or replace.

2. Using a straightedge and thickness gauge, check the cylin-

der block top surface for flatness. Lay the straightedge
longways and crossways as indicated by A, B,... in illustration.
If flatness is not within the limit, replace the cylinder block. At
ECLA007B
measurement, ensure that the cylinder block top surface is
free from any traces of gasket material.

Standard 0.05 mm

Limit 0.1 mm

3. Check cylinder wall for scratches and seizure. If defects are

evident, correct (to oversize) or replace.

4. Using cylinder gauge, measure the cylinder bore. If it wears

out excessively, bore the cylinder to oversize and replace
the piston and piston rings. Measurement points are as
shown.

Standard 91.10 ~ 91.13 mm

Middle

Bottom

KCMB040A
 CYLINDER BLOCK 2-43

BORING OF CYLINDER
1. Using the maximum cylinder bore as a basis, determine the
oversize piston to be used.
There are four oversize pistons available :

Size Identification mark

0.25 mm(0.01 in.) O.S. 0.25

0.50 mm(0.02 in.) O.S. 0.50
0.75 mm(0.03 in.) O.S. 0.75
1.00 mm(0.04 in.) O.S. 1.00

CAUTION
Sizes are marked on the pistons.

2. Based on the piston O.D. measured, calculate the boring

dimension.

• Boring dimension
Piston O.D. + 0.04 to 0.06 mm
(piston to cylinder clearance) - 0.02 mm (0.0008 in.)
(honing margin).

Piston O.D.

4. Bore cylinders to obtain the calculated boring dimension.

KCMB040B

CAUTION
To prevent thermal distortion due to temperature rise
during boring operation, bore cylinders in the se-
quence of No. 2, 4, 1 and 3.

5. The cylinders must be honed to finish dimension.

6. Check clearance between piston and cylinder.

TC NA
Clearance
0.02 ~ 0.08 mm 0.03 ~ 0.05 mm

CAUTION
1. When boring cylinders, finish all of four cylin
ders to the same oversize.
2. Don't bore only one cylinder to oversize.
2-44 CYLINDER BLOCK

2) REPLACING CYLINER SLEEVE

REMOVAL
Face the rounded
side toward the block
1. Fix the cylinder block with a boring machine before centering.
Centering should be done in the lower part of the cylinder
sleeve where has little abnormal wear. Thin cylinder
sleeve
2. Bore the sleeve until the thickness is 0.5mm.

KD4B2001

3. Insert the processed screwdriver as shown in the illustration

between the cylinder sleeve and cylinder block and remove
the cylinder sleeve by tapping on the screwdriver slightly. Be
careful not to damage the cylinder block wall.
Attach a round piece
to the screwdriver

KD4B2002

INSPECTION
1. After removing the cylinder sleeve, inspect the cylinder block
sleeve hole surface.

2. If there are damages, scuffing, abnormal wear and other

defects, bore the cylinder block sleeve hole to oversize.

3. Measure the cylinder sleeve O.D. and cylinder block sleeve

Y direction
hole I.D. with a gauge placed as shown in the illustration.
Measure D1, D2 and D3 in the directions of X and Y and if the Xdirection
average value is below 0.12mm, bore the sleeve hole to 0.
5mm oversize and press-fit the oversized sleeve into the sleeve
hole. 12mm D1
Middle D2
CAUTION
Bottom D3
Be sure when boring the cylinder, all sleeves should
KD4B2003
be removed from all cylinders not to make mistakes
during rounding.
 CYLINDER BLOCK 2-45

PRESS-FIT Hydraulic press

1. Without boring cylinder block sleeve hole Cylinder sleeve

1) Apply press oil to the cylinder block sleeve hole surface

and sleeve outer surface.

2) Put a flat rounded plate on the sleeve top end and press-
fit it with a hydraulic press.

Press-fit load 2200kg or more

KD4B2004

3) Press-fit the sleeve until the sleeve top end surface is

flush with the block top surface.
Press-fit it toward the chamfer as shown in the illustration.
Upper part
Lower part

KD4B2005

4) To prevent the cylinder sleeve and cylinder block top sur- No slice
faces from roughness and bump, cut the cylinder block
top surface.
Difference between them should be '0' as possible. (The
limit: 0.2mm) Cylinder
sleeve Cylinder
block

KD4B2006

5) Chamfer the cylinder sleeve top end as shown in the

illustration. 1mm Cylinder sleeve

30

KD4B2007
2-46 CYLINDER BLOCK

6) Cylinder sleeve I.D. is processed with 90.08~90.10mm,

after press-fitting the sleeve, hone the bore to be within
the standard value.

Cylinder bore 91.10~91.13mm

Honing surface formation 2~4

Honing rendering angle (Cross-hatch) 15~25°

Cylinder bore perpendicularity 0.05mm

2. Boring cylinder sleeve hole

1. Prepare a 0.5mm oversized cylinder sleeve.

2. Hone the cylinder block sleeve hole to 94.025~94.050mm.

3. Press-fit the cylinder sleeve and render the bore.

For press-fit and process procedures, refer to "Without
boring block sleeve hole".

INSPECTION AFTER ASSEMBLY

Protrusion Piston
Cylinder block
1. After assembling the crankshaft and piston, inspect protru-
sion of the piston.
If the protrusion is out of the limit, replace the piston inserted
into thin one to be the protrusion within the limit.

2. After procedure 1, if the protrusion is not within the limit, re-

place the cylinder block.

KD4B2008
Limit 1.1 mm
 CHAPTER 3. LUBRICATION

1. OIL FILTER ............................................................................ 3- 1

2. OIL PAN ................................................................................. 3- 5

3. OIL PUMP .............................................................................. 3- 7