Installation

•Installthebearingsusingthespecialtool.

1Root109913-70210:Bearinginstallerset

NOTE:

Thestampedmarksideofthegearshiftshaftbearingfacesout•

side.

•Installtheoilseal.

•Installthegearshiftcamwiththebearing.

NOTE:

Thestampedmarksideofthegearshiftcambearingfacesout•

side.

_\

•Installthegearshiftforksandtheirshaftsasshown._@

G)For3rd/4thdrivegears

~For6thdrivengear

@For5thdrivengear

•ApplyasmallquantityofTHREADLOCK"1342"tothebearingretainerscrewsandtheshiftforkshaftretainerbolt.

^{•Tightenthemtothespecifiedtorque.}

~99000-32050:THREADLOCK"1342"

(!)Bearingretainerscrew:10N·m(1.0kgf·m,7.0lb-ft}Gearshiftforkshaftretainerbolt:19N·m

(1.9kgf·m,13.7lb-ft}

OILJETRemoval

^{•RemovethepistoncoolingoiljetsG)fromtheuppercrank•}

_case.

_l

_•

•Removetheoiljet(fortransmission)fromthelowercrankcase.

Inspectionandcleaning

•Checktheoiljetsforclogging.

•Iftheyareclogged,cleantheiroilpassagewithaproperwireandcompressedair.

G)Pistoncoolingoiljet

~Oiljet(#14)(Fortransmission)

Installation

•Fitthenew0-ringsG)toeachpistoncoolingoiljetasshownandapplyengineoiltothem.

IACAUTIONI

Usethenew0-ringstopreventoilpressuredown.

NOTE:

Besuretofacetheoilholes®oneachpistoncoolingoiljettothetopwheninstallingthem.

•Installeachpistoncoolingoiljetwiththebolts.

NOTE:

ApplyasmallquantityofTHREADLOCK"1342"totheboltsandtightenthemtothespecifiedtorque.

tfE99000-32050:THREADLOCK"1342"

(!JPistoncoolingoiljetbolt:10N·m(1.0kgf·m,7.0lb-ft)

-

•Installtheoiljets(fortransmission).

PLUGS

•Installeachplug.

(!JG)Waterjacketplug:9.5N·m(0.95kgf·m,6.9lb-ft)(Z'Oilgalleryplug(lowercrankcase):

_{35N·m(3.5kgf·m,25.3lb-ft)}

NOTE:

Applytheenginecoolanttothe0-ring.

CRANKSHAFTANDCONROD

CRANKSHAFTRUNOUT

•Supportthecrankshaftwith''V"blocksasshown,withthetwoendjournalsrestingontheblocks.

•Setupthedialgauge,asshown.

•Rotatethecrankshaftslowlytoreadtherunout.

•Replacethecrankshaftiftherunoutisgreaterthanthelimit.

!T'OR!09900-20606:Dialgauge(1/100mm,10mm)

09900-20701:Magneticstand

09900-21304:V-block(100mm)

RCrankshaftrunout:

ServiceLimit:0.05mm(0.002in)

CONRODSMALLENDl.D.

•Usingasmallboregauge,measuretheinsidediameteroftheconrodsmallend.

1RXiti09900-20602:Dialgauge(1/1000mm,1mm)

09900-22401:Smallboregauge(1o-18mm)

RConrodsmallend1.0.:

ServiceLimit:15.040mm(0.5921in)

•Iftheinsidediameteroftheconrodsmallendexceedsthelimit,replacetheconrod.

CONRODBIGENDSIDECLEARANCE

•Inspecttheconrodsideclearancebyusingathicknessgauge.

•Iftheclearanceexceedsthelimit,removetheconrodandin•

specttheconrodbigendwidthandthecrankpinwidth.

•Ifthewidthexceedthelimit,replaceconrodorcrankshaft.

- Conrodbigendsideclearance:ServiceLimit:0.30mm(0.012in)

dooti09900-20803:Thicknessgauge

~Conrodbigendwidth:

Standard:19.95-20.00mm(0.7854-0.7874in)

!MOLi09900-20205:Micrometer(0-25mm)

RCrankpinwidth:

Standard:20.10-20.15mm(0.7913-0.7933in)

1ER109900-20605:Dialcalipers(1/100mm,10-34mm)

CONROD-CRANKPINBEARINGINSPECTION

•Inspectthebearingsuriacesforanysignoffusion,pitting,burn,orflaws.Ifany,replacethemwithaspecifiedsetofbearings.

CONROD-CRANKPINBEARINGSELECTION

•Placetheplastigaugeaxiallyalongthecrankpin,avoidingtheoilhole,asshown.

!TMI09900-22301:Plastigauge

•Tightentheconrodcapboltstothespecifiedtorque,intwostages.(c:::73-68)

IACAUTIONI

*Applyengineoiltotheconrodcapbolt.

*Neverrotatethecrankshaftorconrodwhenapieceofplastigaugeisinstalled.

'm~

!dW==:111111::1t11~

-

_Rear

•Removethebearingcapsandmeasurethewidthofthecom•pressedplastigaugeusingtheenvelopescale.Thismeasure•mentshouldbetakenatthewidestpartofthecompressedplastigauge.

~Conrodbigendoilclearance:

Standard:0.032-0.056mm(0.0013-0.0022in)ServiceLimit:0.080mm(0.0031in)

•Iftheoilclearanceexceedstheservicelimit.selectthespeci•

fiedbearingsfromthebearingselectiontable.

•Checkthecorrespondingconrod1.D.codenumber("1"or"2")

_®·

•Checkthecorrespondingcrankpin0.D.codenumber("1"."2"or"3")@.

aBearingselectiontable

CrankpinO.D.®

Code1²³

_Conrod 1^{GreenBlackBrownl.D.@2BlackBrownY}ellow

DConrodl.D.

Code^{l.D.specification}

1

35.000-35.008mm

(1.3780-1.3783in)

_{35.008-35.016mm}

_1~=

^@

²_{(1.3783-1.3786in)}

[ECrankpinO.D.

Code^{O.D.specification}

1

30.992-31.000mm

(1.2202-1.2205in)

2

30.984-30.992mm

(1.2198-1.2202in)

3

30.976-30.984mm

(1.2195-1.2198in)

1-looti09900-20202:Micrometer(25-50mm)

~Bearingthickness

Color(PartNo.)Thickness

Green1.480-1.484mm

(12164-39FOO-OAO)(0.0583-0.0584in)

Black^{1.484-1.488mm}

(12164·39FOO-OBO)^{(0.0584-0.0586in)}

Brown1.488-1.492mm

(12164-39FOO-OCO)(0.0586-0.0587in)

Yellow1.492-1.496mm

(12164-39FOO-ODO)(0.0587-0.0589in)

IACAUTIONI

IThebearingsmustbereplacedasaset.

Colorcode

CRANKSHAFTJOURNALBEARING