Repair Manual for

Overhaul of Engine
 Contents
Chapter I 4A92 Engine ................................................................................................................................. 1
Section I Overhaul of Engine .................................................................................................................. 1
Instructions ...................................................................................................................................... 1
Overview ......................................................................................................................................... 2
Maintenance Specifications ............................................................................................................. 3
Sealing ............................................................................................................................................. 4
Special Tools ................................................................................................................................... 4
Inspection and Adjustment of Drive belt tension ............................................................................ 4
Inspection and Adjustment of Valve Clearance ............................................................................... 7
Compression Pressure Inspection .................................................................................................... 9
Disassembly and Installation of Crank Shaft Pulley ..................................................................... 10
Disassembly and Installation of Camshaft .................................................................................... 11
Disassembly and Installation of Oil Pan ....................................................................................... 17
Disassembly and Installation of Oil Seal of Crank Shaft .............................................................. 19
Section II Major Overhaul of Engine .................................................................................................... 22
Maintenance Specifications ........................................................................................................... 22
Specification of Tightening Torque ............................................................................................... 24
Sealing ........................................................................................................................................... 26
Special Tools ................................................................................................................................. 27
Disassembly and Installation of Engine and Ignition System ....................................................... 28
Disassembly and Installation of Fuel Injection Parts .................................................................... 30
Disassembly and Installation of Intake Manifold .......................................................................... 33
Disassembly and Installation of Exhaust Manifold ....................................................................... 36
Disassembly and Installation of Oil Pan and Timing Chain Case ................................................. 38
Disassembly and Installation Inspection of Timing Chain ............................................................ 42
Disassembly and Assembly Inspection of Camshaft ..................................................................... 48
Disassembly and Installation Inspection of Cylinder Cover and Valve ........................................ 52
Disassembly and Installation Inspection of Piston and Connecting Rod ...................................... 57
Disassembly and Installation Inspection of Crank Shaft and Cylinder Block ............................... 64
 Chapter I 4A92 Engine

Instructions
Maintenance steps
(1) Get to know the installation status of parts according to the profile maps on the parts.
(2) Use the number of parts to express the operation steps and indicate the parts that can not

be used any more (use ) and tightening torque.

Distinguishing of maintenance guidelines

Standard values and the usage of special tools should be described in details as maintenance
guidelines.

Marks of lubricating oil, sealant and adhesive

Indicate the positions where lubricating oil, sealant and adhesive are applied or replenished on
the maps of parts and components
Disassembly steps: the numbers in the maps of parts and components correspond to the
specific parts, indicating the disassembly steps.
Installation steps: installation steps should be indicated in case that the steps opposite against
the disassembly steps are not allowed, but if it is allowed, the installation steps can be
omitted.

Diagrams
<<A>>: means there are disassembly or dismantling guidelines.
>>A<<: means there are assembly or installation guidelines.

……lubricating grease: refers to multi-use lubricating grease in case of no special

description

……sealant or adhesive

……engine oil or gear lubricating oil

Overhaul of Engine—overview

Overview
Name of Model Model of Displacement Specification
vehicles engine mL
A series 4A92-S 1,590 Dual overhead camshaft, 16 air
valves

General Specifications

Item 4A92-S
Total displacement mL 1,590
Bore diameter × stroke mm 75.0 × 90.0
Compression ratio 10.5
Combustion chamber Lend-to roof
Number of cylinders 4
Number of air Intake 8
valves
Exhaust 8
Air valve timing Intake valves open BTDC 31°-ATDC1 9°
Intake valves close ABDC 21°-ABDC 71°
Exhaust valves BBDC 39°
open
Exhaust valves ATDC 5°
close
Rocker Not equipped
Automatic slack adjuster Not equipped
Fuel injection system Electronic-controlled multi-point fuel injection (MPI)
system
Ignition system Electronic-controlled, 4-coil
Generator Generator (equipped with built-in IC adjuster)
Starter Directly driven
Overhaul of Engine—maintenance specifications

Maintenance Specifications

Item Standard Operating limit

value value
Driving belt tension of generator and air Vibration 140 - 171 -
conditioner (in inspection) frequency Hz
Tension N 392 - 588 -
Deviation mm (for 10.9 - 16.5 -
reference)
Driving belt tension of generator and air Vibration 148 - 164 -
conditioner (in adjustment) frequency Hz
Tension N 441 - 539 -
Deviation mm (for 11.9 - 14.6 -
reference)
Driving belt tension of generator and air Vibration 198 - 221 -
conditioner (in replacement) frequency Hz
Tension N 784 - 980 -
Deviation mm (for 6.3 - 7.6 -
reference)
Compression pressure (when the speed of engine is 300 1,550 Minimum 1,100
r/min) kPa
Difference of compression pressure of cylinders kPa - Maximum 98
Overhaul of Engine—sealing, special tool

Sealing
Item Specification of sealant Remarks
Timing chain tensioner cover LOCTITE 5971 or equivalent Semi-dry sealant
Valve cover disassembly
Oil pan of engine
Installation of rear oil seal of crank shaft

Flywheel bolt LOCTITE 2701 or equivalent

Special Tools
Tool Parts No. Name Application

Joint of torque Disassembly and installation of V.V.T.,

MB991992
wrench installation bolt of chain wheel component

MD998727 Oil pan remover Disassembly of oil pan of engine

MD998781 Flywheel stopper Fixed flywheel component

Front oil seal

MB991993 conduit of crank
shaft
Installation of front oil seal conduit of
crank shaft
Installer of oil seal
MB990699
of crank shaft
Overhaul of Engine—inspection and adjustment of diving belt tension
Inspection of Driving Belt Tension of
Generator and Air Conditioner
Inspect driving belt tension according to the following steps.
Standard value:
Vibration frequency Hz 140 - 171

Tension N 392 - 588

Deviation mm (for reference) 10.9 - 16.5

● The surface temperature of belt should be close to

normal temperature as far as possible
●
microphone.
● If strong wind blows over the microphone or there
is any noise near the microphone, the measured
Notice
value may deviate from actual value.
● In case that the microphone contacts with the belt
in measurement, the measured value of
microphone may not be accurate.
● Measurement is never allowed during the
operation of vehicle engine.

Generator
Tension pulley <Use of Tension Gauge>
gauge
Use a belt tension gauge to determine whether belt tension lies
Water pump pulley
in the range of standard values.
Pulley of air
condition
compressor

Crank shaft pulley

Remarks Disassemble oil rule conduit before inspection.

Generator <Belt Deviation Inspection>

pulley
Impose about 100 N force (on the position indicated by the
arrow) in the middle of belt to determine whether the deviated
Water pump pulley
Deflection
value is within the standard range.
Pulley of air
condition
compressor

Crank shaft pulley

Overhaul of Engine—inspection and adjustment of diving belt tension
Adjusting bolts
Adjustment of Driving Belt Tension of
Adjusting nuts
Generator and Air Conditioner
1. Loosen the nuts on the pivot bolt of engine.
2. Loosen the adjusting nut of engine.
Pivot nuts of generator 3. Use adjusting bolt to adjust deviation between the belt
tension and tension to standard value.
Standard value:
Item Adjustment Replacement
Vibration frequency Hz 148 - 164 198 - 221
Tension N 441 - 539 784 - 980
Deviation mm (for reference) 11.9 - 14.6 6.3 - 7.6
4. Tighten the nuts on the pivot bolt of engine.
Tightening torque: 39.5 ± 4 N·m
5. Tighten the adjusting nut of engine.
Tightening torque: 20 ± 2 N·m
6. Tighten the adjusting bolt.
Tightening torque: 5.0 ± 1.0 N·m
Overhaul of Engine—Inspection and Adjustment of Valve Clearance

Inspection and Adjustment of Valve Clearance

Inspect and adjust valve clearance in the
Remarks
cooling state of engine.

1. Remove all ignition coil

2. Remove valve cover.

Notice Rotate the crank shaft clockwise.

Timing mark 3. Rotate the crank shaft clockwise and align it with the
timing mark on the chain wheel of exhaust cam shaft
opposite against the cylinder cover (as shown in the
drawing). At this time, No.1 cylinder moves to upper
dead center of the compression travel.

4. Use thickness gauge to measure the valve clearance

Exhaust valve side
indicated by the arrow in the drawing. Record the
valve clearance if it fails to comply with the
specification.
Standard value:
Intake valve 0.22 ± 0.04 mm
Exhaust valve 0.30 ± 0.04 mm
Intake valve side

Timing mark
5. Rotate the crank shaft 360o clockwise and place the
timing mark on the position indicated in the
drawing. At this time, No.4 cylinder moves to the
upper dead center of the compression stroke.
Overhaul of Engine—Inspection and Adjustment of Valve Clearance
6. Inspect the valve clearance indicated by the arrow
Exhaust valve side
according to step 4.
7. Remove camshaft and valve lifter if the valve
clearance fails to comply with the specification.

Intake valve side

8. Use a micrometer to measure the thickness of the

Wall thickness removed valve lifter.

9. Calculate the thickness of the valve lifter newly

Recognition mark assembled through the following equation.
A: Thickness of the valve lifter newly assembled
B: Thickness of the valve lifter removed.
C: Measured valve clearance
Equation
Intake valve: A = B + (C - 0.22 mm)
Exhaust valve: A = B + (C - 0.30 mm)
The thickness of valve lifter lies in the range
of 2.70 - 3.30 mm and the difference among
different models (31) is 0.02 mm. The
Remarks thickness of decimal-point section should be
printed on the back of valve lifter.
For example, when the thickness is 2.90 mm,
print “90” on the back.
10. Select valve lifter to be assembled and place it on the
position of camshaft as per step 9.
11. Clean away the residual liquid sealant on the valve
cover, timing chain case and the forepart of cylinder.
12.
Timing chain should be assembled within 3 min
Notice
after liquid sealant is used.
Use 4 mm-continous beaded liquid sealant as the drawing
shows.
Specification of sealant: LOCTITE 5971 or
equivalent.
13. Install and tighten the valve cover to 9.0 ± 1.0 Nm
14. Install ignition coil.
Overhaul of Engine—Compression Pressure Inspection

Compression Pressure Inspection

1. Set the vehicle to pre-inspection state before the

inspection.
2. Remove all ignition coils and spark plug.
3. Remove all oil nozzle joint.
● The joint should be kept away from the
Oil nozzle joint spark plug bore in rocking-turn.
● When water, engine oil or fuel are used to
Notice measure the compression amount incurred
by the rocking-turn of cylinder, they will be
heated and erupted from the spark plug,
which is very dangerous.
4. Cover the spark bore with a towel or the like. Inspect
whether there is any foreign matter stuck to the towel
Pressure gauge after the rocking-turn of engine.
5. Place the compression pressure gauge on the spark
plug bore.
6. Rotate the engine and measure compression pressure
when the air damper is completely opened.
Standard value (engine speed 300 r/min): 1,550 kPa
Limit value (engine speed 300 r/min): 1,100 kPa
7. Measure the compression pressure of cylinder and
inspect whether the pressure difference of the cylinder
is lower than the limit value.
Limit value: maximum value 98 kPa
8. In case that the compression pressure or compression
pressure differences of an cylinder exceeds limit value,
drop a little engine oil via the spark plug and then
repeat the step 5 to step 7.
(1) If the compression pressure rises after the addition of
engine oil, the failure is caused by piston ring or
internal surface abrasion or damage of cylinder.
(2) If the compression pressure does not rise after the
addition of engine oil, it is indicated that the valve seat
is burnt out or is in bad condition or the pressure is
leaked from the gasket.
9. Connect position sensor joint of crank shaft.
10. Install ignition coil and spark plug.
11. Use scanning tool to clean diagnostic trouble code.
Disconnected oil nozzle joints will generate
Remarks
diagnostic trouble code.
Overhaul of Engine—Disassembly and Installation of Crank Shaft Pulley

Disassembly and Installation of Crank Shaft

Pulley

Disassembly steps
<<A>> 1. Driving belt
<<B>> >>A<< 2. Bolt of crank shaft pulley
>>A<< 3. Washer of crank shaft pulley
>>A<< 4. Crank shaft pulley <4A90U>
>>A<< 5. Damping pulley of crank shaft <4A91/92U>
Overhaul of Engine—Disassembly and Installation of Crank Shaft Pulley

Disassembly and Installation of Camshaft

Apply engine oil on all

mobile parts before
installation

Engine oil

Engine oil
Overhaul of Engine—Disassembly and Installation of Crank Shaft Pulley
Disassembly steps of camshaft
· Air cleaner and intake hose
· Ignition coil
1. Venting hose
2. PCV hose
3. Oil nozzle joint
4. Control harness lathedog
5. Assembly of oil rule and conduit
6. O-ring
<<A>> >>E<< 7. Assembly of valve cover
Valve clearance adjustment <only refers to installation)
>>D<< 8. Timing chain tensioner screw
9. Timing chain tensioner
<<B>> >>C<< 10. Chain wheel of camshaft
<<B>> >>C<< 11. V.V.T. chain wheel assembly
<<B>> >>C<< 12. Front bearing cover of camshaft
<<B>> >>C<< 13. Bearing cover of camshaft
<<B>> >>C<< 14. Camshaft
Disassembly step of oil control valve
15. Oil control valve joint
<<C>> >>B<< 16. Oil control valve
>>B<< 17. O-ring
18. Bolt on cleaner of oil control valve
19. Seal ring
<<C>> >>A<< 20. Cleaner of oil control valve
Overhaul of Engine—Disassembly and Installation of Crank Shaft Pulley
Key points of disassembly and
maintenance
<<A>> Disassembly of valve cover
assembly
Unscrew the fixed bolt of the valve cover assembly
according to the sequence in the drawing.
Front of engine

Strap <<B>> Disassembly of camshaft

Timing chain
chain wheel/ V.V.T. chain wheel
assembly/ front bearing cover of
camshaft/ bearing cover of
camshaft/ camshaft
Chain wheel of
1. Fix camshaft chain wheel or timing chain with
camshaft lathedog or similar tool.

Hexagon area of
exhaust camshaft

2. Fix hexagon area of exhaust camshaft with wrench

or similar tools and unscrew fixed bolt of camshaft
chain wheel

Fixed bolts of camshaft chain wheel

Hexagon area of
exhaust camshaft

3. Fix hexagon area of exhaust camshaft with wrench

or similar tools and unscrew the fixed bolt of V.V.T.
Fixed bolts of V.V.T.
chain wheel assembly chain wheel assembly with special tool—torque
wrench joint (MB991992).
Overhaul of Engine—Disassembly and Installation of Crank Shaft Pulley
4. Unscrew fixed bolt of front bearing cover of
Front of engine camshaft and then loosen fixed bolts of front
Front bearing cover of camshaft bearing cover of camshaft one by one according to
the order in the drawing. Remove the front bearing
Bearing cover of camshaft cover of camshaft and the bearing covers of each
camshaft.
5.
Never rotate crank shaft when removing the
Notice camshaft chain wheel assembly with timing
chain.
Raise the exhaust camshaft with camshaft chain wheel
and timing chain on the cylinder slightly, remove the
fixed bolts of camshaft chain wheel and remove the
Bearing cover of camshaft camshaft chain wheel and timing chain assembly from
the exhaust camshaft.
6. Remove the V.V.T. chain wheel assembly and
timing chain assembly on the exhaust camshaft, as
the step 5 shows.
7.
Camshaft chain wheel and timing
chain assembly Remove the camshaft chain wheel and V.V.T.
chain wheel assembly (with timing chain) on
Notice the camshaft. Never misplace the camshaft
chain wheel, V.V.T. chain wheel assembly and
Exhaust camshaft timing chain.
Place the camshaft chain wheel and timing chain
Fixed bolts of camshaft assembly, V.V.T. chain wheel assembly and timing chain
chain wheel
assembly on the assembly of timing chain case after
disassembly.
<<C>> Disassembly of engine oil
control valve/ cleaner of engine oil
control valve
Prevent dust or other matter entering the
engine oil circuit of cylinder cover after
Notice
removing the engine oil control valve and the
cleaner of engine oil control valve.

Key points of installation and

maintenance
>>A<< Installation of cleaner of
engine oil control valve
Avoid foreign matters from sticking to the
cleaner and avoid the damage / transformation
Notice
of cleaner when installing the cleaner of
engine oil control valve.

>>B<< Installation of O-ring/

engine oil control valve
Overhaul of Engine—Disassembly and Installation of Crank Shaft Pulley
1. Cover the engine oil sump of oil control valve with
paperboard.
2. Apply engine oil to the O-ring and install the ring
onto the engine oil control valve. Don't damage
O-ring.
3. Apply engine oil to the O-ring and install the
engine oil control valve onto the cylinder cover.
Don't damage O-ring.

V.V.T. chain wheel assembly >>C<< Installation of camshaft/

Dowel pin
bearing cover of camshaft/ front
bearing cover of camshaft/ V.V.T.
chain wheel assembly / camshaft
chain wheel
Locating
hole Intake camshaft
1. Raise the V.V.T. chain wheel assembly and timing
chain assembly of camshaft chain wheel. After that,
align the dowel pin of admission camshaft with the
Chain wheel of camshaft Dowel pin
bore on the V.V.T. chain wheel assembly, fit the
admission camshaft and V.V.T. chain wheel
assembly together and tighten fixed bolts
temporarily.
2. Raise the chain wheel, V.V.T. chain wheel assembly
Groove
and timing chain assembly of camshaft. And then
Exhaust camshaft
align dowel pin on exhaust camshaft with the
groove of the camshaft chain wheel, fit exhaust
camshaft and camshaft chain wheel. Tighten fixed
Front of engine
bolts temporarily.
Front bearing cover of camshaft
3. Place the admission camshaft and exhaust camshaft
on the installation place of cylinder cover.
Bearing cover of camshaft
4. Tighten the bolts on the bearing cover of each
camshaft to standard torque and then tighten the
fixed bolts on the front bearing cover of camshaft.
Tightening torque:
11 ± 1 N·m
(Fixed bolts of bearing cover of camshaft)
20 ± 1 N·m
(Fixed bolts of front bearing cover of camshaft)

Bearing cover of camshaft

Overhaul of Engine—Disassembly and Installation of Crank Shaft Pulley
5. Fix hexagon area of exhaust camshaft with wrench
Hexagon area of
intake camshaft or similar tools and tighten the fixed bolts of V.V.T.
chain wheel assembly to standard torque with
special tool, torque wrench joint. Calculate the
tightening torque as per the following formula for
fixed bolts of V.V.T. chain wheel assembly are
Fixed bolts of
V.V.T. chain wheel tightened with special tool (MB991992).
assembly
Tightening torque: (65 ± 5) × {L ÷ (L + 150)} N·m
65 ± 5: V.V.T. tightening torque of fixed bolts of chain
wheel assembly (Unit: N·m)
L: distance between the center of a torque wrench
and the center of its handle (Unit: mm)
150: length of special tool (Unit: mm)
6. Fix the hexagon area of exhaust camshaft with
Hexagon area of wrench or similar too and tighten the fixed bolts of
exhaust camshaft
Fixed bolts of camshaft camshaft to standard torque.
chain wheel
Tightening torque: 88 ± 10 N·m
>>D<< Installation of timing chain
tensioner screw
Apply standard sealant on the screw
Install timing chain tensioner screw onto the timing
chain case assembly
Tighten it to standard torque.
Tightening torque: 54 ± 15 N·m

Cylinder cover assembly >>E<< Installation of Valve Cover

Timing
chain case
assembly Assembly
Area 1. Remove sealant from the marked area of valve
cover, valve cover assembly and timing chain case
assembly.
2. Apply standard sealant on the marked area of valve
cover assembly and timing chain case assembly and
then install the valve cover assembly onto the
cylinder cover assembly within 3 min.
Specification of sealant: LOCTITE 5971 or accurate
equivalent.
3. Tighten fixed bolts of valve cover assembly to
standard torque according to the order in the
Front of engine drawing.
Standard torque: 9.0 ± 1.0 N·m
Overhaul of Engine—Disassembly and Installation of Oil Pan

Disassembly and Installation of Oil Pan

Before disassembly After installation

● ● Install damping pulley of crank shaft

● ● Re-inject engine oil

Disassembly steps
· Engine oil gauge
1. Bell-shaped shell cover
2. Oil drainer of oil pan
3. Oil drainer gasket of oil pan
<<A>> >>B<< 4. Oil pan
>>A<< 5. Oil filter
>>A<< 6. O-ring
Overhaul of Engine—Disassembly and Installation of Oil Pan
Key points of disassembly and
maintenance
<<A>> Disassembly of oil pan
1. Disassemble the fixed bolts of oil pan.
2. Remove the oil pan with special tool, remover of oil
pan (MD998727).

Key points of installation and

O-ring maintenance
>>A<< Installation of O-ring/
Engine oil collector
and cleaner engine oil collector and cleaner
Confirm O-ring is safely fixed in the groove of engine oil
collector and cleaner without any twist or damage and
Groove then install it on the engine oil collector and cleaner.

>>B<< Installation of oil pan

Rear edge of oil pan 1. Remove sealant from the oil pan and cylinder block
surface.
2.
Oil pan
Engine oil may leak from the both ends of
Notice the oil pan of engine, thus standard sealant
should be applied, as the drawing shows.
Apply continuous beaded standard sealant on the flange
of oil pan and then install the oil pan on the cylinder
block within 3 min.
Specification of sealant: LOCTITE 5971 or
equivalent.
3.
The engine should not be started and engine
Notice oil or cooling liquid should be contact with
the surface within at least one hour.
Tighten fixed bolts of oil pan to standard torque.
Tightening torque: 7.6 ± 0.6 N·m
Overhaul of Engine—Disassembly and Installation of Oil Seal of Crank Shaft
Disassembly and Installation of Oil Seal of
Crank Shaft

Disassembly steps of front oil seal of crank shaft

· Damping pulley of crank shaft
>>C<< 1. Front oil seal of crank shaft
Disassembly steps of rear oil seal of crank shaft
· Clutch cover and disk
· Oil pan
<<A>> >>B<< 2. Flywheel bolt
>>B<< 3. Flywheel assembly
>>A<< 4. Assembly of rear oil seal housing of crank shaft
Overhaul of Engine—Disassembly and Installation of Oil Seal of Crank Shaft
Key points of disassembly and
maintenance
<<A>> Disassembly of flywheel
bolt
1. Fix the flywheel assembly with special tool –
Cylinder block flywheel stopper (MD998781)
2. Remove the flywheel bolts.

Flywheel
Key points of installation and
maintenance
>>A<< Installation of assembly of
rear oil seal housing of crank shaft
Area 1. Remove sealant on the surface of cylinder.
2. Apply a little engine oil on the area surrounding oil
seal.
Engine oil

Assembly of rear oil seal housing

of crank shaft

3. Apply continuous beaded standard sealant on the

matching surface of rear oil seal housing assembly
of crank shaft and cylinder.
Specification of sealant: LOCTITE 5971 or
equivalent.
4.
Install rear oil seal housing assembly of
Cylinder block Notice crank shaft without damage of rear oil seal
of crank shaft.
Section A-A
Section B-B
Install rear oil seal housing assembly of crank shaft onto
cylinder and tighten fixed bolts to standard torque within
3 min after standard sealant is applied.
Tightening torque: 7.6 ± 0.6 N·m

>>B<< Installation of flywheel

Overhaul of Engine—Disassembly and Installation of Oil Seal of Crank Shaft
assembly / flywheel bolt
Cylinder block
1. Remove sealant, engine oil and other attached
matters from installation surface of flywheel
assembly, bolt bore of crank shaft and flywheel bolt.
2. Install flywheel assembly onto the crank shaft.
3. Fix the flywheel assembly with special tool –
flywheel stopper (MD998781) in the same manner
Flywheel
with disassembly.
4. Apply a little engine oil on the bolt surface of
flywheel and bolt bore of crank shaft.
5. Apply standard sealant on the screw thread of bolts
of the flywheel.
Specification of sealant: LOCTITE 2701 or
equivalent.
6. Tighten flywheel bolts to standard torque.
Tightening torque: 100 ± 5 N·m

>>C<< Installation of front oil seal

Crank shaft
of crank shaft
1. Apply a little engine oil around the conduit of front
oil seal of crank shaft (special tool) (MB991993)
Engine oil and install the conduit on the crank shaft.
2. Apply a little engine oil on the whole inner ring
around the oil seal.
Oil seal
3.
Don’t damage front oil seal of crank shaft
Notice
before installing it.
Push the oil seal to the assembly of timing chain case
with special tool, installer of oil seal of crank shaft
(MB990699).
Major Overhaul of Engine—Maintenance Specifications

Section II Major Overhaul of Engine

Maintenance Specifications
Item Standard Limit
value value
Timing chain
Valve clearance mm Intake 0.22 -
Exhaust 0.30 -
Camshaft
Height of camshaft mm Intake 4A92U 44.71 44.21
Exhaust 4A92U 44.28 43.78
Cylinder cover and valve
Flatness of back surface of cylinder cover mm 0.03 max. 0.2
Grinding limit of lower surface of cylinder cover (total grinding - 0.2
amount of cylinder cover and cylinder block)
Total height of cylinder cover mm 112.9 - 113.1 -
Thickness of valve (border) mm Intake 1.35 0.85
Exhaust 1.85 1.35
External diameter of valve stem Intake 4.965 - 4.980 -
Exhaust 4.955 - 4.970 -
Plane angle 45°- 45.5° -
Radial clearance of valve and conduit Intake 0.020 - 0.047 0.10
Exhaust 0.030 - 0.057 0.15
Valve length mm Intake 89.61 89.11
Exhaust 90.94 90.44
Protrusion of valve stem mm Intake 38.46 38.96
Exhaust 38.49 38.99
Free length of valve spring mm 43.1 42.1
Loan of valve spring/ installation length N/mm 152/33.4 -
Deflection of valve spring 2° max. 4°
Valve contact width of valve seat mm 1.1 - 1.5 -
Internal diameter of valve conduit mm 5 -
Installation height of valve conduit mm 7.7 - 8.3 -
Piston and connecting rod
Major Overhaul of Engine—Maintenance Specifications

External diameter of piston mm 75 -

Item Standard Limit
value value
Edge clearance of piston ring mm No. 1 0.03 - 0.07 0.1
No. 2 0.02 - 0.06 0.1
Terminal opening of piston ring mm No. 1 0.15 - 0.30 0.8

No. 2 0.30 - 0.50 0.8

Oil ring 0.10 - 0.40 1.0
External diameter of piston pin mm 18 -

Pressing-in load of piston pin (room temperature) of piston pin N 5,000 - -

11,000

Oil film clearance of crank pin mm 0.014 - 0.059 0.1

Big-end clearance of connecting rod mm 0.10 - 0.35 0.4

Crank shaft and cylinder block

End-to-end backlash of crank shaft mm 0.09 - 0.27 0.3

External diameter of crank shaft journal 46 -

External diameter of crank shaft pin mm 40 -

Oil film clearance of crank shaft journal mm 0.014 - 0.034 0.1

Flatness of upper surface of cylinder block mm 0.05 0.1

Grinding limit of upper surface of cylinder cover (total grinding - 0.2

amount of cylinder cover and cylinder block)

Total height of cylinder block mm 280 -

Internal diameter of cylinder block mm 75 -

Cylindricity of cylinder hole mm 0.007 max. -

Clearance of piston and cylinder mm 0.010 - 0.035 -

c
Major Overhaul of Engine—Specification of Tightening Torque
Specification of Tightening Torque
Item N·m
Generator and ignition system
Spark plug 25 ± 5
Bolts of ignition coil 8.4 ± 0.6
Bolts of damping pulley of crane shaft 190
Bolt of water pump pulley 8.4 ± 0.65
Adjusting bolts 5.0 ± 1.0
Bolts of generator support bracket 36.0 ± 3.6
Nuts of generator (M8) 20 ± 2
Nuts of generator (M10) 40 ± 3
Bolts of conduit of engine oil gauge 7.6 ± 0.6
Parts of fuel and waste gas emission
Bolts of exhaust pipe and fuel injector assembly 18.4 ± 1.4
Bolts of absolute pressure (MAP) sensor of manifold 6.0 ± 0.5
Bolts of throttle body 6.0 ± 0.5
Bolts of magnetic valve 7.6 ± 0.6
Bolts of engine support bracket 18.4 ± 1.4
Intake manifold
Bolts of inlet pipe 10 ± 2
Bolts of accessories of water inlet 10 ± 2
Temperature sensor of engine coolant 29.4 ± 9.8
Bolts of angle sensor of crank shaft 8.4 ± 0.6
Position bolts of camshaft 8.4 ± 0.6
Bolts of knock sensor 20.0 ± 1.6
Bolts of engine oil pressure switch 10 ± 2
Bolts of intake manifold bracket 18 ± 1
Bolts of intake manifold 18 ± 1
Exhaust manifold
Bolt A of support seat of exhaust manifold 20 ± 1
Bolt B of support seat of exhaust manifold 35 ± 6
Nuts of exhaust manifold 35 ± 2
Bolts of thermostat 6.0 ± 1.0
Item N·m
Major Overhaul of Engine—Specification of Tightening Torque
Oil pan and timing chain case

Bolts of timing chain case (M10) 39.5 ± 3.0

Bolts of timing chain case (M6) 8.4 ± 0.6
Water pump bolts 8.4 ± 0.6
Bolts of engine oil collector and cleaner 11.5 ± 1.1
Oil pan bolts 7.6 ± 0.6
Support of engine oil cleaner 20±8
Valve cover bolts 9.0 ± 1.0
Discharge cock 39 ± 5
Timing chain
V.V.T. chain wheel bolts 64.5 ± 5.5
Bolts of camshaft chain wheel 88 ± 10
Bolts of tensioner lever assembly 23.5 ± 4.5
Bolts of chain guide rail assembly 10 ± 2
Plug screw 54 ± 15
Bolts of timing chain tensioner assembly 8.4 ± 0.6
Camshaft
Bolts of oil control valve (OCV) 7.6 ± 0.6
Bolts on cleaner of oil control valve (OCV) 44 ± 5
Bolts of bearing cover of camshaft (M6) 11 ± 1
Bolts of bearing cover of camshaft (M8) 20 ± 1
Cylinder cover and valve
Cylinder cover bolts 24.5 ± 2.0 → +180° to 184°
Piston and connecting rod
Bolts of connection rod cap 15 ± 2 → +90° to 94°
Crank shaft and cylinder block
Screw of induction ring of crank shaft 9.0 ± 1.0
Bolts of bearing cover 35 ± 2 → +60° to 64°
Bolts of oil seal housing 7.6 ± 0.6
Bolts of bell-shaped shell cover 7.6 ± 0.8
Flywheel bolts 100 ± 5
Major Overhaul of Engine—Sealing
Sealing
Key points Specification of sealant
Clamping surface of rear oil seal of cylinder block LOCTITE 5971 or equivalent
Plug screw LOCTITE 5971 or equivalent
Oil pan LOCTITE 5971 or equivalent
Valve cover LOCTITE 5971 or equivalent
Timing chain case LOCTITE 5971 or equivalent
Clamping surface of angle sensor of crank shaft of the cylinder block LOCTITE 5971 or equivalent
Flywheel bolts LOCTITE 2701 or equivalent
Engine oil pressure switch LOCTITE 565 or equivalent
Temperature sensor of engine coolant LOCTITE 262 or equivalent

Sealant (FIPG)
Use sealant on many parts of the engine. Please be careful in using sealant to ensure the suitability of
sealant.
The most important points are the dimension of bead-shaped sealant, continuity and position. Too little
sealant may lead to leakage and too much sealant may incur oil circuit blocking or narrowing. Therefore, in
order to avoid leakage of joint surface, it is necessary to apply proper amount of continuous beaded sealant
evenly without any disconnection.
FIPG in engine may harden due to the reaction with moisture in atmosphere, therefore it is generally used
on the metal end face.

Disassembly
Parts assembled by FIPG can be easily disassembled without any special methods. But in certain conditions,
a mallet or similar tool should be used to slightly knock the part and break down the sealant on the mating
surface, or a smooth and thin sealant scraper should be used to cut into the mating surface slightly; make
sure that the mating surface should not be damaged.

Sealing surface cleanup

Clean the sundries on the sealing surface with sealant scrapper or wire brush; ensure that the FIPG surface
is smooth without any grease or foreign matter; don’t forget to remove the sealant used on the screw hole.

Main points of sealant applying

Apply continuous beaded FIPG of standard dimension without crack. Enclose screw hole with continuous
beaded sealant. Remove the sealant having not hardened. Install the part on specified position when the
sealant is wet (within 3 min). Prevent sealant from contacting with any other unnecessary place in
installation. Neither apply oil on the parts applied with sealant nor wet or start the engine within sufficient
time (about 2 hours). Apply sealant on different positions according to the steps specified.
Major Overhaul of Engine—Special Tools
Special Tools
Tool Number Name Use

MD998781 Flywheel stopper Fix flywheel

MD998727 Oil pan remover Disassemble oil pan

Installer of front oil seal of

MB990699 Install front oil seal
crank shaft

Front oil sealing conduit of

MB991993 Install chain case
crank shaft

MB992000 Guide sleeve of crank shaft Rotate crank shaft

MD999597 Compressor of valve spring Compress valve spring

Install valve stem oil seal

Installer of valve stem oil
MB991994 (use special tools stamped with
seal
"MB991994A”)

MD998780 Installation tool of piston

Install/ disassemble piston pin

MB991659 Conduit D

Tighten bolts of bearing cover of

MB991614 Angle gauge
cylinder block
Major Overhaul of Engine--Disassembly and Installation of Engine and Ignition System
Disassembly and Installation of Engine and
Ignition System

Disassembly steps
1. Conduit of engine oil gauge
2. Engine oil gauge
3. O-ring
4. Generator
5. Generator support bracket
6. Water pump pulley
<<A>> >>A<< 7. Bolt of crank shaft pulley
>>A<< 8. Seal ring
>>A<< 9. Damping pulley of crank shaft
10. Ignition coil
11. Spark plug
Major Overhaul of Engine--Disassembly and Installation of Engine and Ignition System

Key points of disassembly and

Cylinder block maintenance
<<A>> Disassembly of bolts of crank
shaft chain wheel
1. Fix the flywheel with special tool – flywheel stopper
(MD998781).
Flywheel
2. Remove the crank shaft bolts.

Key points of installation and

maintenance
Cylinder block >>A<< Installation of crank shaft
chain wheel/ seal ring/ bolts of crank
shaft chain wheel
1. Fix the flywheel with special tool – flywheel stopper
(MD998781).

Flywheel

2. Clean up the screw hole of crank shaft.

Crank shaft pulley 3. Clean up crank shaft chain wheel.
Wash
Washer Remove the oil stain when necessary to avoid
Remarks the reduction of the friction between the chain
wheel belt surface.

4. Install crank shaft chain wheel.

Bolt of crank 5. Apply a little engine oil on the screw thread section.
shaft pulley Engine oil Crank shaft
6. Clean the seal ring.
7. Tighten bolts of crank shaft to tightening torque: 190
N·m.
Major Overhaul of Engine--Disassembly and Installation of Fuel Injection Parts
Disassembly and Installation of Fuel Injection
Parts

Disassembly steps
1. Vacuum rubber pipe 10. Insulator
2. Vacuum rubber pipe 11. Fuel injector support
3. Electromagnetic valve 12. O-ring
4. Engine lifting bracket 13. Oil nozzle
5. Supper hose clamp of radiator 14. O-ring
>>D<< 6. Throttle body 15. Fuel oil distributing pipe
>>C<< 7. Gasket of throttle body
>>B<< 8. Absolute pressure (MAP) sensor of manifold

>>A<< 9. Fuel oil distributing pipe assembly

Major Overhaul of Engine--Disassembly and Installation of Fuel Injection Parts
Key points of installation and
maintenance
>>A<< Installation of Fuel Oil
Distributing Pipe Assembly
Prevent engine oil from flowing into the fuel
Notice
oil distributing pipe.
1. Apply new engine oil to the O-ring of oil nozzle slightly.
Insert the oil nozzle to the fuel oil distributing pipe
slightly other than aslant.
2. Ensure stable rotation of oil nozzle. If it fails, remove
the oil nozzle to confirm whether the O-ring is damaged.
Replace the oil nozzle if necessary. After that, re-install
the oil nozzle and verify whether the oil nozzle rotates
smoothly.
3. Install oil nozzle support.

4. Install fuel oil distributing pipe assembly onto the

cylinder cover.
Ensure stable rotation of oil nozzle. If it fails, remove the oil
nozzle to confirm whether the O-ring is damaged. Replace
the oil nozzle if necessary. After that, re-install the oil nozzle
and verify whether the oil nozzle rotates fluently.
Align the center of oil nozzle of fuel oil distributing pipe with
the projection section.
5. Align the oil nozzle with the projection section by
rotating the nozzle.
6. Tighten fuel oil distributing pipe assembly to tightening
torque: 18.4 ± 1.4 N·m.
>>B<< Installation of absolute
pressure sensor of manifold
● Prevent the MAP sensor from shocking
in installation.
Notice
●
MAP sensor falls to the floor.

>>C<< Installation of throttle body

gasket
Install throttle body gasket to make the projection section
Gasket located in the position in the drawing.
Major Overhaul of Engine--Disassembly and Installation of Fuel Injection Parts
>>D<< Installation of throttle body
Install throttle body on the manifold by connecting the
groove of throttle body with the projection of manifold.
Major Overhaul of Engine--Disassembly and Installation of Intake Manifold
Disassembly and Installation of Intake Manifold

Disassembly steps
>>F<< 1. Support seat of intake manifold
2. Intake manifold
3. Gasket of intake manifold
>>E<< 4. Engine oil pressure switch
5. Knock sensor
6. Position sensor of camshaft
>>D<< 7. Angle sensor of crank shaft
>>C<< 8. Temperature sensor of engine coolant
9. Accessories of water inlet
>>B<< 10. Temperature saver
11. Water pipe
12. Water pipe
>>A<< 13. Water pipe assembly
14. Gasket of water pipe assembly
Major Overhaul of Engine--Disassembly and Installation of Intake Manifold
Key points of installation and
maintenance
>>A<< Installation of gasket of water
pipe assembly
Install gasket of water pipe assembly on the cylinder block
with the projection in the direction shown in the drawing
Projection

>>B<< Installation of temperature

saver
Install the temperature saver on the cylinder block with the
oscillating valve on the upper position.

Oscillating
valve
>>C<< Installation of temperature
sensor of engine coolant

1. Remove the residual sealant (if any) on the temperature

sensor of engine coolant or screw hole of cylinder cover.
● Use tools carefully. Never damage the
Notice connecting parts (made of resin) of the sensor.
● Do not overly tighten the sensor
2. Apply sealant on the screw thread (as the drawing shows)
of the sensor.
Specification of sealant: LOCTITE 262 or equivalent.
>>D<< Installation of angle sensor of
crank shaft
1. Remove any residual sealant (if any) on the angle sensor
or the installation surface of cylinder block.

● Apply sealant properly to prevent sealant from

Notice being squeezed out from screw holes.
● Do not overly tighten the sensor

2. Apply continuous beaded sealant with the diameter of 1.7

± 0.5 mm on the cylinder block as the drawing shows.
Specification of sealant: LOCTITE 5971 or equivalent.
3 Install angle sensor of crank shaft on the cylinder block
and tighten it to the specified torque: 8.4 ± 0.6 N·m.
Major Overhaul of Engine--Disassembly and Installation of Intake Manifold

>>E<< Installation of engine oil

pressure switch
1.
● Apply sealant properly to prevent sealant from
being squeezed out from the end of screw
Notice
hole.
● Do not overly tighten the sensor
Remove any residual sealant (if any) on engine oil pressure
switch or the screw hole of cylinder block.
2. Apply sealant on the screw thread of engine oil pressure
switch, as the drawing shows.
Specification of sealant:
LOCTITE 565 or equivalent
3. Install engine oil pressures switch on the cylinder block
and tighten it to the torque: 10 ± 2 N·m.

>>F<< Installation of Support Seat

of Intake Manifold
Inspect and confirm the support seat of intake manifold
closely contacts with intake manifold and cylinder block
before installation and then install the support seat of intake
manifold and tighten it to the torque: 18 ± 1 N·m
Major Overhaul of Engine--Disassembly and Installation of Exhaust Manifold
Disassembly and Installation of Exhaust
Manifold

Disassembly steps
>>B<< 1. Support B of exhaust manifold
2. Exhaust manifold cover
3. Heat insulating pad
4. Exhaust manifold
>>A<< 5. Gasket of exhaust manifold
6. Support A of exhaust manifold
Major Overhaul of Engine--Disassembly and Installation of Exhaust Manifold
Key points of installation and
maintenance
>>A<< Installation of gasket of
exhaust manifold
Install the gasket of exhaust manifold with the projection in
the direction shown in the drawing.

>>B<< Installation of support B of

Projection
exhaust manifold
Inspect and confirm that support B of exhaust manifold
closely contacts with the exhaust manifold and support A
of exhaust manifold and then install support B and lock it
to the torque: 35 ± 6 N·m.
Major Overhaul of Engine--Disassembly and Installation of Oil Pan and Timing Chain Case

Disassembly and Installation of Oil Pan and Timing Chain Case

Disassembly steps
1. Venting hose <<A>> >>F<< 8. Engine oil cleaner
2. PCV hose >>E<< 9. Plug screw
3. PCV valve >>D<< 10. Valve cover
4. PCV valve washer 11. Valve cover gasket
5. Engine oil filling cover <<B>> >>C<< 12. Oil pan
6. Oil drainer 13. Engine oil collector and cleaner
7. Oil drainer gasket 14. Gasket of engine oil cleaner
15. Water pump
16. O-ring
>>B<< 17. Timing chain case
Major Overhaul of Engine--Disassembly and Installation of Oil Pan and Timing Chain Case
>>A<< 18. Front oil seal
19. O-ring
20. Support of engine oil cleaner
21 Support gasket of engine oil cleaner

Key points of disassembly and

maintenance
<<A>> Disassembly of cleaner
Disassemble the cleaner with cleaner wrench

<<B>> Disassembly of oil pan

1. Disassemble bolts of oil pan
2. Use special tool—oil pan remover ((MD998727)
between the oil pan and cylinder block.

Key points of installation and

maintenance
Oil seal
Timing chain cover >>A<< Installation of front oil seal
Install front oil seal in the timing chain case with the special
tool, oil seal installer of crank shaft (MB990699).

>>B<< Installation of timing chain

case
1. Remove the sealant residue on the timing chain case,
cylinder block and cylinder cover.
2. Install the special tool, oil seal conduit (MB991993) on
the crank shaft.
Major Overhaul of Engine--Disassembly and Installation of Oil Pan and Timing Chain Case
3.

Complete the installation of timing chain case

Notice
within 3 minutes after liquid sealant is used.

Apply continuous beaded liquid sealant (Ф2.0 ± 0.5 mm) on

the position A on timing chain case and apply continuous
beaded liquid sealant (Ф1.5 ± 0.5 mm) on the position B, as
the drawing shows.
Specification of sealant: LOCTITE 5971 or equivalent.
4. Install timing chain case

Tightening bolts vary in length. Please ensure

Remarks
bolts are properly used on each position.

5. Tighten the bolts of timing chain case to standard

torque.
Tightening torque:
M6 8.4 ± 0.6 N·m
M6 8.4 ± 0.6 N·m
M10 (support bracket) 39.5 ± 3.0 N·m
M10 (pillar) 36 ± 3.6 N·m

>>C<< Installation of oil pan

1. Remove the sealant residue on the timing chain case,
cylinder block and oil pan.
Complete the installation of oil pan within 3 min
Notice
after liquid sealant is applied.
2. Apply continuous beaded liquid sealant (Ф4.0 ± 0.5
mm) on the position A on oil pan and apply continuous
beaded liquid sealant (Ф2.0 ± 0.5 mm) on the position
B, as the drawing shows.
Specification of sealant: LOCTITE 5971 or equivalent.
3. Tighten bolts to the torque: 7.6 ± 0.6 N·m.
Major Overhaul of Engine--Disassembly and Installation of Oil Pan and Timing Chain Case
>>D<< Installation of valve cover
1. Clean away the residual liquid sealant on the valve
cover, timing chain case and air cylinder.
2. Apply Ф4 mm continuous beaded liquid sealant as the
drawing shows.
Specification of sealant: LOCTITE 5971 or equivalent.

Complete the installation of timing chain within

Notice
3 min after liquid sealant is used.

3. Tighten the bolts of valve cover to 9.0 ± 1.0 N·m

according to the steps in the drawing.

Direction of timing chain

>>E<< Installation of plug screw

Install timing chain tensioner screw onto the timing chain
case assembly
Tighten it to standard torque.
Tightening torque: 54 ± 15 N·m

>>F<< Installation of engine oil

cleaner
1. Clean the installation surface of the cleaner on the
cylinder block.
2. Apply engine oil on the gasket of engine oil cleaner as
the drawing indicates.

3.
Tighten the engine oil cleaner with cleaner
wrench. Oil leakage may occur if the cleaner is
Notice
tightened manually because the specified torque
cannot be achieved.
Tighten engine oil cleaner until the O-ring contacts with the
installation surface. Rotate the cleaner for 3/4 ring or to the
torque of 11 ± 1 N·m with cleaner wrench.
Major Overhaul of Engine--Disassembly and Installation Inspection of Timing Chain

Disassembly and Installation Inspection of

Timing Chain

Disassembly steps
>>D<< 1. Assembly of timing belt chain tensioner
2. Assembly of tension regulating stem
3. Assembly of chain guide rail
>>C<< 4. Timing chain
<<A>> >>B<< 5. Bolts of camshaft chain wheel
6. Chain wheel of camshaft
<<B>> >>A<< 7. V.V.T. chain wheel bolts
8. V.V.T. chain wheel assembly
Major Overhaul of Engine--Disassembly and Installation Inspection of Timing Chain
Key points of disassembly and
maintenance
<<A>> Disassembly of bolts of
camshaft chain wheel
Screw the hexagon parts of the camshaft with a wrench to
remove the bolts of camshaft chain wheel.

<<B>> Disassembly of bolts of V.V.T.

chain wheel
Screw the hexagon parts of the camshaft with a wrench to
remove the bolts of V.V.T. chain wheel.

Key points of installation and

maintenance

>>A<< Installation of bolts of V.V.T.

V.V.T. chain
wheel chain wheel
1. Apply small amount of engine oil on the following
positions.
● End of camshaft
● Patchhole of V.V.T. chain wheel (internal and external
V.V.T. chain wheel bolts Camshaft surface)
● Screw thread and nuts of bolts of V.V.T. chain wheel
● Bearing surface of bolts of V.V.T. chain wheel
2. Install V.V.T. chain wheel on the camshaft.
3. Ensure that the V.V.T. chain wheel is installed on the
camshaft. Screw the hexagon parts of the camshaft with
a wrench to check whether V.V.T. chain wheel rotates.
4. Screw the hexagon parts of the camshaft with a wrench
tightly to tighten the bolts of camshaft chain wheel to
the torque: 64.5 ± 5.5 N·m.

>>B<< Installation of bolts of

camshaft chain wheel
Screw the hexagon parts of the camshaft with a wrench
tightly to tighten the bolts of camshaft chain wheel to the
torque: 88 ± 10 N·m.
Major Overhaul of Engine--Disassembly and Installation Inspection of Timing Chain
>>C<< Installation of timing chain
Timing mark Fasteners (blue) 1. Install the timing chain with the two close blue fasteners
of timing chain
of timing chain located in the upper parts and the other
Timing blue fastener of timing chain which is far from the other
mark
of two aligning with the side of crank shaft.
camsha Timing
ft chain mark of
As the drawing shows
wheel V.V.Y. chain
wheel

Timing mark

Fasteners (blue)
Timing mark of crank of timing chain
shaft chain wheel

2. Install timing chain on the crank shaft chain wheel and

align the blue fastener with the mark on the chain wheel

Timing mark

3. Install timing chain on the V.V.T chain wheel and align

Timing mark
the blue fastener with the mark on the chain wheel

Timing mark
4. Install a chain on the camshaft chain wheel and align the
blue fastener with the mark on the chain wheel
At this time, rotate one or two gears of V.V.T. chain wheel or
camshaft chain wheel to align the blue fastener with the mark
on the chain wheel.
5. Confirm the three groups of timing marks are aligned
6. Install chain guide rail and tensioner lever
Major Overhaul of Engine--Disassembly and Installation Inspection of Timing Chain
>>D<< Installation of timing chain
tensioner
1. Insert a pin to lock the plunger when pressing the
plunger of timing chain tensioner, as the drawing shows.
2. Install timing chain tensioner on the cylinder block.

3. Remove the pin from the tensioner. Tighten the timing

chain through the tensioner lever.
Major Overhaul of Engine--Disassembly and Installation Inspection of Timing Chain
Inspection
Measurement of valve clearance
Groove
Measure the valve clearance as the drawing shows.
Dowel pin
Install the bolts and washer of damping pulley of crank shaft
with a special tool, guide sleeve of crank shaft (MB992000).

Bolts and gasket of crank shaft chain wheel

1.
Timing mark
Notice Crank shaft should keep rotating clockwise.
Rotate the crank shaft clockwise until the mark on the camshaft
chain wheel is aligned with the mark on the upper surface of
cylinder cover (place No.1 cylinder on the upper dead center of
compression stroke).

Direction of timing chain 2. Measure the clearance of the valve indicated by the arrow.
Exhaust

Intake

3. Measure the clearance between the base circle of the

camshaft and the valve lifter.
Standard value (cooling state):
Intake valve 0.22 ± 0.04 mm
Exhaust valve 0.30 ± 0.04 mm
4. Record the measured value if it fails to comply with the
standard value.
5. Rotate crank shaft clockwise until the timing mark on the
camshaft chain wheel is rotated to the position in the
drawing. At this time, No. 4 cylinder is on the upper dead
Timing mark center of the compression stroke.
Major Overhaul of Engine--Disassembly and Installation Inspection of Timing Chain
6. Measure the clearance of the valve indicated by the
Direction of timing chain
Exhaust arrow.
7. Record the measured value if it fails to comply with
the standard value.
8. Replace valve lifter if the valve clearance exceeds
the standard value.
There are 31 groups of dimension of valve
Intake
Remarks lifter. The interval of the dimension from
2.70-3.30 mm is 0.02 mm.

9. Select valve lifter in the following method.

Wall thickness (1) Remove valve lifter and measure its thickness.
(2) Clculate correct thickness of new valve lifter
according to the following method to meet standard
valve clearance.
A: Thickness of the new valve lifter
B: Thickness of the old valve lifter
C: Measured valve clearance
Equation:
Intake valve: A = B + (C - 0.22 mm)
Exhaust valve: A = B + (C - 0.30 mm)
Major Overhaul of Engine--Disassembly and Assembly Inspection of Camshaft

Disassembly and Assembly Inspection of

Camshaft

Apply engine oil to all

movable parts before
installation

Disassembly steps
>>D<< 1. Oil control valve (OCV)
>>D<< 2. O-ring
3. Bolt on filter of oil control valve
4. Washer
>>C<< 5. Filter of oil control valve
<<A>> >>B<< 6. Front bearing cover of camshaft
<<A>> >>B<< 7. Bearing cover of camshaft
>>B<< 8. Intake camshaft
>>B<< 9. Exhaust camshaft
<<B>> >>A<< 10. Valve lifter
Major Overhaul of Engine--Disassembly and Assembly Inspection of Camshaft
Key points of disassembly and
maintenance
<<A>> Disassembly of front bearing
cover of camshaft/ bearing cover of
camshaft
Remove the front bearing cover of camshaft first and then
remove the fixed bolts on the bearing cover of each camshaft in
the order indicated in the drawing.

<<B>> Disassembly of valve lifter

Add a tag to each removed valve lifter to indicate the position so

as to help re-installation.
Key points of installation and
maintenance
>>A<< Installation of valve lifter
Install valve lifter on the correct position indicated on the tag.
>>B<< Installation of camshaft /
bearing cover of camshaft
1. Install each camshaft and confirm that the dowel pin is in
Dowel pin
the direction indicated in the drawing.

v
Major Overhaul of Engine--Disassembly and Assembly Inspection of Camshaft
2. No. 2 to No. 5 bearing covers of intake and exhaust
camshaft have different shape. Install them correctly
Identification mark according to relevant identification marks.
No. Identification marks (attach marks to No. 2 and No. 5
bearing covers)
I: Intake
E: Exhaust
3. Tighten bolts of bearing cover of each camshaft first
according to the number sequence in the drawing and then
tighten bolts of front bearing cover of the camshaft.

>>C<< Installation of filter of oil

control valve

Check whether there is any attached foreign matter,

Notice flaw or transformation and then install filter of oil
control valve.

>>D<< Installation of oil control valve

1.
● Don’t reuse O-ring.
Gummed tape ● Wrap the oil circuit of oil control valve with
Notice soft gummed tape before installation of O-ring
to protect the ring from being damaged.
Damaged O-ring may incur oil leakage.
Apply a little engine oil on the O-ring of oil control valve.
2. Install oil control valve on the cylinder cover.
3. Tighten oil control valve to standard torque: 7.6 ± 0.6 N·m.
Major Overhaul of Engine--Disassembly and Assembly Inspection of Camshaft
Inspection
Camshaft
Measure the height of camshaft. Replace the camshaft if the
measured height exceeds limit value.
Standard value:
Intake: 44.71 mm
Exhaust: 44.28 mm
Limit value:
Intake: 44.21 mm
Exhaust: 43.78 mm

Valve lifter

1. Measure valve lifter (as the drawing shows). Replace

Wall thickness
the valve lifter according to the identification marks
and the following table if the measure value is not
coincident with the specified value.

2. Each valve lifter is provided with an identification

mark attached on the position shown in the drawing.

There are 31 groups of dimension of valve lifter. The

interval of the dimension from 2.70-3.30 mm is 0.02 mm,
as the following table shows.

Thickness Thickness Thickness

Recognition Recognition Recognition
mm mm mm
Identification mark mark mark mark
mm mm mm
2.70 70 2.92 92 3.14 14
2.72 72 2.94 94 3.16 16
2.74 74 2.96 96 3.18 18
2.76 76 2.98 98 3.20 20
2.78 78 3.00 00 3.22 22
2.80 80 3.02 02 3.24 24
2.82 82 3.04 04 3.26 26
2.84 84 3.06 06 3.28 28
2.86 86 3.08 08 3.30 30
2.88 88 3.10 10
2.90 90 3.12 12
Major Overhaul of Engine--Disassembly and Installation Inspection of Cylinder Cover and
Valve

Disassembly and Installation Inspection of

Cylinder Cover and Valve

Apply engine oil to all

movable parts before
installation

Disassembly steps
>>C<< 1. Cylinder cover bolts 12. Exhaust valve
2. Bolt washer of cylinder cover >>A<< 13. Valve oil seal
3. Cylinder cover assembly 14. Spring seat of valve
4. Cylinder gasket >>A<< 15. Valve oil seal
<<A>> >>B<< 5. Valve locker 16. Spring seat of valve
6. Fixer of valve spring 17. Valve conduit
7. Valve spring 18. Valve conduit
8. Intake valve 19. Intake valve seat
<<A>> >>B<< 9. Valve locker 20. Exhaust valve seat
10. Fixer of valve spring 21. Cylinder cover
11. Valve spring 22. Exhaust valve
Major Overhaul of Engine--Disassembly and Installation Inspection of Cylinder Cover and
Valve

Key points of disassembly and

maintenance
<<A>> Disassembly of valve locker
Compress the valve springs and remove valve locker with the
special tool, compressor of valve spring (MD999597).
Valve springs and other disassembled parts
Remarks should be placed orderly and marked to help
re-installation.

Key points of installation and

maintenance
>>A<< Installation of valve oil seal
Oil seal of
valve stem 1. Install spring seat of valve.
2. Apply engine oil on the valve oil seal.
● Don’t reuse valve oil seal.
●
Notice
a special tool to prevent engine oil from
seeping into the combustion chamber.
3. Push new valve oil seal into the valve conduit with the
special tool—installer of valve oil seal.

Use the special tool with the part number of

Remarks
MB991994A

>>B<< Installation of valve locker

Compress the valve springs and install valve locker with the
special tool, compressor of valve spring (MD999597).
>>C<< Installation of bolts of cylinder
cover
1. Inspect all reused bolts of cylinder cover according to the
following steps.
(1) Measure the external diameter of the position indicated in
the drawing (arrow “A”).
(2) Measure the smaller external diameter of the position
indicated in the drawing (arrow “B”).
(3) Replace the bolts of cylinder cover if the difference
between the external diameters (arrow “A” and “B”). of
the two positions exceeds standard value. Standard
value: 0 - 0.15 mm.
2. Install bolts of cylinder cover and washer assembly on the
cylinder cover.
Major Overhaul of Engine--Disassembly and Installation Inspection of Cylinder Cover and
Valve
Direction of timing chain 3. Tighten the bolts to standard torque: 24.5 ± 2 N·m as per
the installation order.
4. Ensure the bolts meet standard torque.

5. Make applying marks on the bolt caps and the cylinder, as

Applying mark
the drawing indicates.
6.
● Bolts of cylinder cover may loosen if they are
screwed by less than 180o. Thus, please screw
bolts correctly.
Notice
Applying mark ●
completely and re-screw as per specified
steps if they are screwed by over 184o.

Screw the bolts of cylinder cover by 180o ~184o as per correct

order.
Inspect whether the applying marks on the bottle caps and
cylinder cover are aligned.
Major Overhaul of Engine--Disassembly and Installation Inspection of Cylinder Cover and
Valve

Inspection
Cylinder cover
1. Check whether the coolant or exhaust gas in the
cylinder cover leaks or whether there is any damage
before cleaning.
2. Remove oil, furr, sealant, carbon deposit and other
residue. Clean and blow the oil circuit with
compressed air.
3.
The combined grinding limit value of cylinder
Notice
cover and cylinder block is 0.2mm.
Measure the flatness of bottom surface of the cylinder cover
with straight scale and thickness gauge. Correct the flatness
through grinding if it exceeds the limit value.
Distortion of bottom surface
Standard value: maximum 0.03 mm
Limit value: 0.2mm
Grinding limit value: 0.2mm
Valve Height of cylinder cover
(standard value of new parts): 113.0 mm
1. Finish the valve seat with tools if the surface of valve
seat is not flat or continuous.
2. Measure the valve edge. Replace new valve if the
Contact of the bottom of measured value exceeds limit value.
valve seat and the surface
Standard value:
Edge Intake: 1.35 mm
Exhaust: 1.85 mm
Limit value:
Intake: 0.85 mm
Exhaust: 1.35 mm E
3. Measure the total length of valve. Replace the valve if
the measured value exceeds limit value.
Standard value:
Intake: 89.61 mm
Length
Exhaust: 90.94 mm
Limit value:
Intake: 89.11 mm
Exhaust: 90.44 mm
Major Overhaul of Engine--Disassembly and Installation Inspection of Cylinder Cover and
Valve

Valve spring
1. Measure the free height of the valve spring. Replace
Verticality the spring if the measured value exceeds limit value.
Standard value: 43.1 mm
Limit value: 42.1 mm
Free height 2. Measure the verticality of the valve spring. Replace
the spring if the measured value exceeds limit value.
Standard value: less than 2°
Limit value: 4°

Valve conduit
Measure the clearance between the valve conduit and
valve lifter. Replace the valve conduit or/ and the valve if
the measured value exceeds the limit value.
Valve conduit Standard value:
Intake 0.020 - 0.047 mm
Exhaust 0.030 - 0.057 mm
Conduit diameter Limit value:
Internal diameter of conduit
Intake: 0.10 mm
Exhaust: 0.15 mm

Valve seat
Combine the valves and measure the projection of valve
End of the valve lifter
lifter between the end of valve lifter and the surface of
Projection of valve stem spring seat. Replace the cylinder cover assembly if the
measured value exceeds the limit value.
Surface of spring seat Standard value:
Intake: 38.46 mm
Exhaust: 38.49 mm
Limit value:
Intake: 38.96 mm
Exhaust: 38.99 mm
Major Overhaul of Engine--Disassembly and Installation Inspection of Piston and Connecting
Rod

Disassembly and Installation Inspection of

Piston and Connecting Rod

Apply engine oil to

all movable parts
before installation

Disassembly steps
>>G<< 1. Bolts of connection rod cap
<<A>> >>F<< 2. Connecting rod cap
>>E<< 3. Connecting rod bearing
>>D<< 4. Piston and connecting rod assembly
>>E<< 5. Connecting rod bearing
>>C<< 6. No.1 piston ring
>>C<< 7. No.2 piston ring
>>B<< 8. Oil ring
<<B>> >>A<< 9. Piston pin
10. Piston
11. Connecting rod
Major Overhaul of Engine--Disassembly and Installation Inspection of Piston and Connecting
Rod
Key points of disassembly and
maintenance
<<A>> Disassembly of connecting
rod cap
Mark corresponding cylinder number on the side of the
connecting rod to ensure correct installation.

Conduit A: 17.9mm <<B>> Disassembly of piston pin

Push rod Conduit B
Setting means of piston pin (MD998780), a special tool,
consists of the parts in the drawing. The special
Conduit A: 18.9mm
tool--conduit D (MB991659) can also be used for
Conduit C disassembling.

Conduit A: 20.9mm
Conduit D

Conduit A: 21.9mm

1. Insert the push rod (special too) into the piston from
the side with forward mark of the piston bottom.
Install conduit D on the other side.
Push rod 2. Install the piston and connecting rod assembly on
the piston pin base (special tool) with a tool and
Piston pin
ensure that the forward mark of the piston is
upward.
3. Disassemble the piston pin with pressure.
Forward mark
Place the disassembled piston, piston pin and
Remarks
connecting rod as per the cylinder number.
Conduit D

Base
Major Overhaul of Engine--Disassembly and Installation Inspection of Piston and Connecting
Rod
Key points of installation and
maintenance
>>A<< Installation of piston pin
1. Insert the special tool (push rod) into the piston pin
and then install conduit A.
2. Install the piston and connecting rod together and
Forward mark
confirm their forward marks are aligned.
3. Paint engine oil around the piston pin.
4. Insert the combined piston pin in step 1 into the
piston pin seat. The end of conduit A of piston pin
should be inserted to the forward mark of the pin
seat.
5. Insert conduit B into conduit A with the clearance L
Conduit B Conduit A of 2.25 mm.

6. Insert the piston and connecting rod assembly on the

piston pin base (special tool) with a tool and ensure
Push rod that the forward mark of the piston is upward.
7. Press in the piston pin with pressure. Replace the
piston pin (piston assembly) or/and connecting rod
Piston pin
if the pressure is lower than the standard value.
Standard value: 5,000 - 11,000 N

Forward mark

Conduit A

Base

Conduit B

>>B<< Installation of oil ring

Major Overhaul of Engine--Disassembly and Installation Inspection of Piston and Connecting
Rod
1. Install the main ring of oil ring into the groove of
piston ring and then install upper and lower doctor
blade.
Distinguish new main ring and doctor blade
Remarks
as per the following identification colors:

Dimensions Identification color

Standard No mark
0.25 mm oversize Dual blue
2.
Don’t use the expander of piston ring in
Notice installing doctor blade, or the doctor blade
may be damaged.
Insert one end of the doctor blade into the piston groove
and then press the doctor blade into the correct position
with fingers.
3. Install the doctor blade on the piston and check
whether the doctor blade can move flexibly in both
Lower
Upper
doctor
doctor directions.
blade
blade 4. The opening of the doctor blade should be set on the
opening
opening
position indicated in the drawing.
>>C<< Installation of No.2 piston
Spring opening
ring/ No.1 piston ring
Install No.1 and No.2 piston rings with the expander of
piston ring. The identification mark of piston ring should
be upward.

Expander of piston
ring

Identification mark: No. 1 ring: R No.2 ring: 2R

Dimension mark of piston ring is as follows:

Identification mark
Dimension mark
Dimensions Dimension mark
Standard No. 1 ring No mark

No. 2 ring No mark

0.25 mm oversize 25

>>D<< Installation of piston and

connecting rod assembly
1. Paint engine oil around the piston, piston ring and
Major Overhaul of Engine--Disassembly and Installation Inspection of Piston and Connecting
Rod
oil ring.
Doctor blade 2. Arrange piston ring and oil ring opening as the
drawing indicates (doctor blade and oil ring)
3. Insert the piston and connecting rod assembly into
Piston pin the cylinder hole and ensure that the forward mark
on the top of the piston faces the camshaft chain
wheel.
Doctor blade
4.
Never knock piston and connecting rod
Notice assembly fiercely, otherwise, the piston ring
may be easily damaged.
Fix piston ring with compression tools of piston ring and
then install the piston and connecting rod assembly into
the cylinder block.
>>E<< Installation of connecting
rod bearing
1. The identification mark of connecting rod bearing is
made on the position indicated in the drawing.
Select connecting rod bearing as per the following
table.
Connecting rod bearing
Upper bearing Lower bearing
Identification color Blue Red
Red Blue
Yellow Yellow
For example: if upper bearing is blue, the lower bearing
should be red.
2. Install selected bearing on the big end of the
connecting rod and the bearing cover.
3. Measure the position indicated in the drawing. The
error should be less than 0.5 mm.
>>F<< Installation of connecting
rod cap
1. Install correct bearing cover on corresponding
connecting rod as per the marks made in
disassembly.
Cylinder number

Forward mark
2. Confirm that the side clearance of the big end of
connecting rod complies with specified values.
Standard value: 0.10 - 0.35 mm
Major Overhaul of Engine--Disassembly and Installation Inspection of Piston and Connecting
Rod
Limit value: 0.4 mm

>>G<< Installation of bolts of

connecting rod cap
1. Inspect all reused bolts of connecting rod according
to the following steps.
(1) Measure the external diameters on the positions 15
mm/30mm from the end of the bolts of connecting
rod in the drawing.
(2) Replace the bolt of connecting rod if the difference
between the external diameters (measured value on
the position 15mm/30mm from the end) exceeds the
standard value.
Standard value: 0 - 0.1 mm
2. Paint engine oil on the screw thread and the bearing
surface of nuts.
3. Install connecting rod cap correctly and screw the
bolts loosely with fingers.
4. Tighten bolts to the standard torque: 15 ± 2 N·m as
per the steps.
5. Make painting marks on the front part of bolts as the
drawing indicates.
Applying mark Applying mark 6. Make another painting mark on the front part of bolts
(from 90o to 94o) oriented from the first painting
mark to the screwing direction.
7.
● tened
because bolts may loosen if it is screwed
less than 90o.
Notice
● Unscrew bolts completely and then
repeat all the steps if they are
tightened over 94o.

Tighten bolts 90o-94o. The painting mark on the

connecting rod should align with that on the bolts.
Major Overhaul of Engine--Disassembly and Installation Inspection of Piston and Connecting
Rod

Inspection
Piston Ring
1. Measure the clearance between the piston ring and
ring groove. If the measured value exceeds the limit
value, the piston ring, or both of the piston ring and
piston should be replaced.
Standard value:
No.1 Channel 0.03 - 0.07 mm
No.2 Channel 0.02 - 0.06mm
Limit value: 0.1mm

2. Insert the piston ring into the cylinder hole. Place the
Push down the piston piston and push it down with piston head to ensure
the correct angel between the ring and the cylinder
wall. Measure the opening clearance with thickness
gauge: if the measured value exceeds limit value,
replace the piston ring.
Standard value:
No.1 Channel 0.15 - 0.30mm
Piston ring
Piston ring No.2 Channel 0.30 - 0.50mm
Oil ring 0.10 - 0.40 mm
Limit value:
No.1 Channel 0.8 mm
No.2 Channel 0.8 mm
Oil ring 1.0mm
Oil Film Clearance of Crank Pin
(In Plastic Gauge Materials)
1. Clean the oil film between crank pin and connecting
rod bearing.
Plastic gauge 2. Cut off the plastic gauge materials of the length
equal to the width of the bearing and place it on
crank pin in parallel.
3. Carefully install the connecting rod cap on the
plastic gauge and screw down the bolt to 15 ± 2 N·m
→ +90 to 94 degree.
4. Remove the bolt and the connecting rod cap slowly.
5. Measure the width of the pressed part (the widest
part) of the plastic gauge materials with the measure
gauge printed on the package.
Standard value: 0.014 - 0.059 mm
Plastic gauge Limit value: 0.1mm
 Disassembly and Installation Inspection of
Crank Shaft and Cylinder Block

Apply engine oil to all

movable parts before
installation

Disassembly steps
<<A>> >>G<< 1、 Flywheel bolt
2、 Flywheel
3、 Bell-shaped shell cover
>>F<< 4、 Oil-seal housing
>>E<< 5、 Bolt of crank shaft bearing cap
>>E<< 6、 Crank shaft bearing cap
>>D<< 7、 Crank shaft bearing, lower part
8、 Crank shaft
>>C<< 9、 Crank shaft bearing, upper part
>>B<< 10、 Thrust bearing
 >>A<< 11、 Induction ring of crank shaft
12、 Cylinder

Key points of disassembly and

maintenance
Cylinder
<<A>> Disassembly of flywheel bolt
1. Lock the flywheel with a special tool – flywheel stopper
(MD998781)
2. Disassembly the flywheel bolt
Flywheel

Key points of installation and

maintenance
>>A<< Installation of induction ring
of crank shaft
1. Apply engine oil to the induction ring screw of crank
shaft
Pin 2. Screw down the induction ring screw of crank shaft to
9.0 ± 1.0 N·m following the steps as indicated in the
drawing.

>>B<< Installation of thrust bearing

1. Install thrust bearing on No.4 bearing on the cylinder.
To facilitate the installation, engine oil may be applied
on the thrust bearing.
2. The thrust bearing must be installed with its groove
Groove
surface facing to the crank web of the crank shaft.

Side of timing chain >>C<< Installation of crank shaft

bearing (upper part)
1. Select crank shaft bearing (upper part) according to the
identification mark on the bottom surface of cylinder
and the table below.

Distinguish each crank shaft bearing (upper part) according

Groove to the identification color as indicated in the drawing
Cylinder block Identification
Identification Journal diameter color of crank
mark mm shaft bearing

1 50.000 - 50.005 Blue

Identification color
2 50.005 - 50.010 Yellow
 3 50.010 - 50.015 Red

2. Select and install the crank shaft bearing (upper part)

Install the working parts in the position as indicated in the
drawing.

>>D<< Installation of crank shaft

Production date

bearing (lower part)

1. Select the crank shaft bearing (lower part) according to
the identification mark (see the drawing) on the flange
(on the back of crank shaft) and the table below.
2. Distinguish each crank shaft bearing (lower part)
according to the identification color as indicated in the
drawing

Crank shaft Identification

Identification Journal color of crank
Identification color
mark diameter mm shaft bearing

P 46.024 - 46.029 Blue

Y 46.019 - 46.024 Yellow

N 46.014 - 46.019 Red

W 46.009 - 46.014 White

B 46.004 - 46.009 Purple

3. Select and install the crank shaft bearing (lower part)

No. Install the working parts in the position as indicated in the
drawing.

>>E<< Installation of crank shaft

bearing cap/bolt
 1. Install bearing cap as per the identification mark as
indicated in the drawing.
2. Before the installation of bearing bolt, ensure that the
length of the bolt is below the limit value; if not,
replace the bolt.
Handle length Standard value: 75.3 mm
3. Apply engine oil to the screw thread and the bearing
surface of the bolt.
4. Screw down the bearing cap bolt to the torque of 35 ± 2
N·m.
5.
● If the screw tightening of the bolt is less than
60 degrees, the bolt may be insecure. Ensure
that the bolt is screwed down.
Notice
● If the screw tightening of the bolt exceeds 64
degrees, completely unscrew the bolt and
then repeat the screwing steps.
Screw down bearing cap bolt to 60-64 degrees in specified
order with a special tool – angle gauge (MB991614).
6. Install bearing cap and inspect the clearance of crank
Handle length shaft end. If the measured value exceeds the limit
value, replace the crank shaft bearing.
Standard value: 0.09 - 0.27mm
Limit value: 0.30mm

Cylinder

>>F<< Installation of oil-seal housing

1. Clean the sealant residue on the oil-seal housing and
cylinder.
2、
Oil-seal housing should be assembled within 3
Notice
min after liquid sealant is used.
Apply continuous beaded liquid sealant of Ф2.0 ± 0.5 mm as
indicated in the drawing. Specification of the sealant:
LOCTITE 5971 or equivalent.
3. Install oil-seal housing and screw it down to the torque
of 7.6 ± 0.6 N·m.
>>G<< Installation of flywheel
1. Clean up the sealant residue on the flywheel or the
screwed hole of the crank shaft.
2. Apply sealant on the screwed part of flywheel bolt as
indicated in the drawing.
The sealant should be used correctly to prevent it
Notice
from being squeezed out of the screw thread.
 Specification of the sealant: LOCTITE 2701 or
equivalent.
Cylinder 3. Fix the flywheel to a proper place with a special tool –
flywheel stopper (MD998781).

Flywheel

4. Screw down the driver panel bolt to the specified

torque of 100 ± 5 N·m.
Check
Oil Film Clearance of Crank Journal
(By Plastic Gauge)
The film clearance can be easily measured with “plastic
gauge”.
Plastic gauge The “plastic gauge” can be used in the following way:
1. Remove the oil film from the surface of crank journal
and the internal surface of bearing.
2. Install crank shaft.
3. Cut off the plastic gauge materials of the length equal
to the width of the bearing and place it on the journal
in parallel.
4. Place the main bearing cap and screw down the bolt to
the specified torque.
5. Disassemble the bolt and the main bearing cap
carefully.
6. Measure the width of the pressed part (the widest part)
of the plastic gauge materials with the measure gauge
printed on the package.

Standard value: 0.014 - 0.034mm

Plastic gauge
Limit value: 0.1mm

Cylinder block
1. Inspect scratch, rust and corrosion visually. Inspect
crack with liquid detection agent. Replace the cylinder
block if there is a crack.
2. Measure the upper surface of the cylinder block with a
straight scale or thickness gauge. Ensure that
Standard value: 0.05mm
Limit value: 0.1mm
3. Inspect whether there are scratches or scrapes on the
cylinder hole; replace it if there is any scratch or scrap.
4. Measure the cylindricity of cylinder hole with
roundness gauge. If there is severe abrasion, replace
the piston and piston ring.
Standard value:
Inner diameter of cylinder 75.0 mm
Cylindricity of cylinder diameter 0.007 mm
 S300

Engine Repair Manual (4A92S)

1.6L (Aluminum Cylinder Block)

DAROU PAKHSH St.-KM17 KARAJ MAKHSOOS ROAD-TEHRAN