ENGINE - ENGINE DISASSEMBLY AND SERVICING

11. Crankshaft and flywheel have their own reference hole on the mating surface. When installing the crankshaft and the flywheel, align the holes.

Notes

Notes

When installing the main bearing case cover, the "UP" mark on it should be at the highest position so that its holes are aligned with the holes of the cylinder block.

10. Tighten the outer bolts (3) first, then tighten the inner bolts (2). M8

23.6 ~ 27.4 N•m

2.4 ~ 2.8 kgf-m 17.4 ~ 20.2 ft-lb

If the flywheel is turned from the original position and then installed, the bolts cannot be tightened. Align the installation reference holes (arrow

ENGINE - ENGINE DISASSEMBLY AND SERVICING

12. When installing the flywheel bolts, apply the oil on them and tighten them with a hand until they are handtightened. Then, tighten them with a torque wrench to the specified torque. Tighten the bolts diagonally in several steps.

Notes

It is recommended to insert a long bolt (M8, pitch

1. The crank pin metal bearing (1) should be aligned with the mating notch of the connecting rod (2) or connecting rod cap (3) before installation.

• Apply sufficient amount of oil to the bearing before and after the installation.

2. The crankshaft metal bearing 2 (4) should be aligned with the notch of the main bearing case and main bearing case cap (6).

• Apply sufficient amount of oil to the bearing before and after the installation.

3. The side metal 1 (19) and side metal 2 (20) can only be installed to the main bearing case cover assembly (21), which is right next to the flywheel.

• Apply sufficient amount of oil before and after the installation.

IMPORTANT

• The oil groove of the side metal 1, 2 should face outward. In other words, the oil groove should be seen after the side metal is installed to the main bearing case.

• If it is installed backwards, it can cause engine stall.

• The protrusion part of the side metal 2 (20) should face doward.

Notes

Install the bearing case and cap to the crankshaft immediately after installing the crankshaft bearing and side metal to prevent the misplace of the bearing.

7.20 FLYWHEEL AND CRANKSHAFT CHECK

7.20.1. FLYWHEEL DEFLECTION AND CRANKSHAFT END PLAY

7.20.3. CRANKSHAFT JOURNAL AND BEARING 1 OIL CLEARANCE

1. Set a dial indicator with its tip on the rear friction face of the flywheel near the edge.

2. Turn the flywheel to measure the deflection or the uneven wear.

3. If the measured value exceeds the allowable limit, remove the flywheel and check the mating faces of the crankshaft and flywheel.

4. If it is scored or worn excessively, regrind the surface of the flywheel or replace the flywheel.

5. Measure the end play while moving the crankshaft with flywheel back and forth to each end.

6. If the end play exceeds the allowable limit, replace the side bearing.

1. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer.

2. Measure the O.D. of the crankshaft journal with an outside micrometer.

3. If the clearance exceeds the allowable limit, replace the crankshaft metal bearing.

7.20.2. CRANKSHAFT DEFLECTION

1. Place the crankshaft on V blocks with its journals supported and set a dial indicator with its tip on the intermediate journal.

2. Measure the eccentricity (half of the measured value) while turning the crankshaft on the V blocks.

3. If the eccentricity exceeds the allowable limit, replace the crankshaft.

7.20.4. CRANKSHAFT METAL BEARING 1 REPLACEMENT

(1) SEAM

1. Press out the crankshaft metal bearing 1 (1) using the replacing tool.

1. Place a plastigauge in lengthwise on the center of the journal.

2. Install the bearing cap, tighten the bolts to the specified torque once and remove the cap again.

2. Clean a new crankshaft metal bearing 1 (1) and bore and apply the engine oil on them.

3. Press in a new bearing 1 (1) using a pressing-in tool while checking the seam of the metal bearing (1) is facing the exhaust manifold.

ENGINE - ENGINE DISASSEMBLY AND SERVICING HYDRAULIC SYSTEM ELECTRIC & DIAGNOSIS

3. Measure the amount of the flatness with a scale and get the oil clearance.

4. If the clearance exceeds the allowable limit, replace the bearing.

4. Press in the metal bearing for 4.2 ~ 4.5 mm (A) deeper than the cylinder block.

TRANSMI SSION HST 3-82 DR72-W00

7.20.6. CRANK PIN AND CONNECTING ROD BEARING 2 OIL CLEARANCE

1. Place a plastigauge in lengthwise on the center of the crankpin.

2. Install the connecting rod, tighten the bolts to the specified torque once and remove the cap again.

3. Measure the amount of the flatness with the scale and get the oil clearance.

4. If the clearance exceeds the allowable limit, replace the bearing.

7.21 CYLINDER BORE CHECK

1. Check the worn condition of the honing groove on the bore.

(A) AXIAL DIRECTION (B) TRANSVERSE DIRECTION

2. Check the bore for scuffing or scoring.

3. Measure the cylinder liner I.D. at six locations as shown in the figure to find the largest worn area.

ENGINE HYDRAULIC SYSTEM ELECTRIC & DIAGNOSIS

- ENGINE DISASSEMBLY AND SERVICING TRANSMI SSION HST 3-83 DR72-W00

ENGINE - ENGINE DISASSEMBLY AND SERVICING

7.22 OIL PUMP, OIL FILTER, RELIEF VALVE AND OIL STRAINER

7.22.1. RELIEF VALVE OF ENGINE OIL

7.22.2. OIL PUMP CHECK

► CLEARANCE BETWEEN ROTOR AND LOBE CLEARANCE OF OIL PUMP

(1) RELIEF VALVE BALL (2) RELIEF VALVE SEAT (3) RELIEF VALVE SPRING

1. Remove the oil pump.

2. Drain the engine oil and remove the oil filter to check it.

3. Check the relief valve for dirt. Check the seat (2) and ball (1) for damage.

4. If they are damaged, replace them.

5. Check the free length of the spring (3).

6. If it is less than the allowable limit, replace the spring.

Caution

• Install the relief valve cover with the mark (▲) faces upside.

1. Measure the clearance between the outer rotor and inner rotor with a feeler gauge.

2. Measure the clearance between the outer rotor and the housing with a feeler gauge.

3. If the clearance exceeds the allowable limit, replace the pump.

Clearance between outer rotor and housing in)

Specified value 0.11 ~ 0.19 mm (0.0043 ~ 0.0075 in)

Allowable limit 0.25 mm (0.0098 in)

► END CLEARANCE OF ROTOR IN OIL PUMP

7.23 THERMOSTAT

T46W2F0A

(1) THERMOSTAT (2) THERMOSTAT COVER

1. Place a plastigauge on the rotor and assemble the pump.

2. Disassemble the pump and measure the amount of the flatness with a scale to get the clearance.

3. If the clearance exceeds the allowable limit, replace the pump.

► REMOVAL

1. Remove the thermostat cover (2).

2. Pull out the thermostat (1).

► INSTALLATION

• Apply the liquid gasket (Three Bond 1215 or equivalent) on the gasket. (The paper gasket can be used for some models.)

►

1. Suspend the thermostat in the water by a string with its end inserted between valve and seat.

2. While heating the water slowly, read the temperatures when the valve starts to open and when the valve opens for approx. 8 mm.

T46W2F2A HYDRAULIC SYSTEM ELECTRIC & DIAGNOSIS

ENGINE - ENGINE DISASSEMBLY AND SERVICING TRANSMI SSION HST 3-85 DR72-W00