1. ENGINE MODE CODES

2. Engine Number Engine number is punch­marked on the position as
illustrated.
Name plate shows vehicle model, chassis number, and
engine model.
1 Vehicle model
2 Chassis number
3 Engine model

3. Engine Name Plate
The engine name plate is attached to the position shown
in the illustration.
The following items are indicated.
1 Engine model
2 Valve clearance
3 Firing order
4 Fuel injection timing

4. SPECIFICATIOS

6. 1 Rocker 2 Valve cap 3 Valve cotter 4 Upper retainer
5 Outer valve spring
6 Inner valve spring
7 Lower retainer
8 Valve
9 Camshaft
10 Tappet
11 Push rod
12 Valve guide
13 Valve stem seal
14 Rocker shaft bracket
15 Lock nut
16 Adjusting screw
17 Rocker cover
The valve stem seal 13 is fitted onto the valve 8 to control
he amount of lubricant flowing onto the sliding surfaces
of the valve and valve guide 12.
The valve springs 5, 6 are unevenly pitched to prevent
abnormal vibration at high speeds. To prevent the inner
and outer springs from meshing with each other, the springs
are wound in opposite directions.
To facilitate removal and reinstallation of the camshaft 9
from the rear end of the crankcase, the diameter of each
camshaft bearing is smaller toward the front of the engine.

7. CYLINDER LINER REMOVEL AND INTALLATION

8. CYLINDER LINER

9. PISTONS AND CYLINDER LINERS SIZES
PİSTON SIZE MARK A B C
CYLINDER LINER MARK A B C
A, B, C arası fark 0,012mm dir.
D Over Size: 0,5, 0,75, 1.00 mm

10. CONNECTING RODS
1 Connecting rod bushing
2 Connecting rod
3 Upper connecting rod bearing
4 Connecting rod bolt
5 Lower connecting rod bearing
6 Connecting rod cap
a : Weight mark stamp
“A” to “H”, “J” to “M”
(where “A” indicates the greatest
connecting rod weight)
b : Alignment mark
c : Lug

11. PISTONS a : Part number b : Weight mark c : Size mark
Standard pistons are marked “A”, “B” or “C”
(where “C” indicates the greatest outside diameter).
d : Cooling cavity
e : Front mark “F” and “¬”
The pistons selected must bear the same size
marks as the cylinder liners.

12. TIMING GEARS

13. Disassembly sequence 1 Bolt
ROCKER COVER, CYLINDER HEAD AND VALVE MECHANISM
Disassembly sequence
1 Bolt
2 Injection nozzle
3 O­ring
4 Nozzle tip gasket
5 Bolt
6 Bushing
7 Insulator
8 Rocker cover gasket
9 Rocker cover
10 Bolt
11 Rocker and bracket assembly 12 O­ring
13 Cylinder head bolt (short)
14 Cylinder head bolt (long)
15 Cylinder head and valve assembly 16 Cylinder head gasket
17 Push rod
18 Side cover
19 Tappet
A: Locating pin
X: Non­reusable part

14. CYLINDER HEAD AND VALVE ASSEMBLY
[Removal]
Before loosening the cylinder head bolts 13, 14, make sure all the valve springs
are free by loosening the adjusting screw C on rocker A in case this is compressing
its valve spring B due to the action of its push rod 17.

15. cylinder head bolt should be loosened a little at a time.
LOOSEN AND REMOVE THE CYLINDER HEAD BOLTS
Loosen and remove the cylinder head bolts 13, 14 in the sequence shown. Each
cylinder head bolt should be loosened a little at a time.

16. G : Socket H : Rod J : Rod (extension)
TIGHTEN THE CYLINDER HEAD BOLTS
Before fitting any cylinder head bolt 13, 14, check the
punch marks D on its head. Do not use the bolt if there are
more than two punch marks.
The punch marks indicate the number of times each bolt has
been tightened using the plastic area tightening method. Any
bolt that already has three punch marks must be replaced.
Tighten the cylinder head bolts 13, 14 to the specified
torque (180 N·m {18 kgf·m}) in the sequence shown
and then confirm that the bolts 1, 2 and 3 are correctly
tightened to 180 N·m {18 kgf·m}. (If the torque is
insufficient, tighten them additionally.) After that,
turn the bolts further in accordance with the following
procedure.
G : Socket
H : Rod
J : Rod (extension)

17. CYLINDER HEAD AND VALVE MECHANISM

18. VALVE COTTERS REMOVAL

19. VALVE SPRINGS

20.  Disassembly sequence
ROCKER AND BRACKET ASSEMBLY
 Disassembly sequence
1 Thrust plate
2 Rocker assembly <Inlet>
3 Rocker assembly <Exhaust>
4 Lock nut
5 Adjusting screw
6 Rocker bushing
7 Rocker
8 Rocker shaft bracket
 Assembly sequence
Follow the disassembly sequence
in reverse.

21. SERVICE PROCEDURE Rocker bushing [Removal] J : Rocker Bushing Puller
[Installation]
Set the components as illustrated
such that the oil hole A in the
rocker bushing 6 is aligned with
the oil hole B in the rocker 7.
C : Seam of bushing
D : Chamfered side of rocker
Using the J Rocker Bushing Puller,
install the rocker bushing 6 into the
rocker 7 until the puller touches the
chamfered side D of the rocker.

22. VALVE GUIDES REMOVAL AND INSTALLATION
Exhaust : mm Limit: 0.2 mm
Inlet : mm Limit: 0.2 mm
If any clearance exceeds the specified limit,
replace the defective part(s).

23. THE VALVE STEM SEALS

24. INJECTION NOZZLE TUBE REMOVAL AND INSTALLATION

25. THE CONNECTING ROD BUSHING REMOVAL AND INSTALLATION

26. ADJUSTMENT VALVE CLEARANCES

27. When taking measurements using the J Feeler Gauge, the gauge should be
ADJUSTMENT VALVE CLEARANCES
NOTE
When taking measurements using the J Feeler Gauge, the gauge should be
able to move in the clearance with some resistance. Accurate measurements
can not be taken if the gauge moves loosely in the clearance.

28. TIGHTENING TORQUE 1- TORK DEĞERLERİ 180 Nm veya 18Kgfm (Islak)
2- AÇI DEĞERİ 90
YENİDEN SIKMA
1000 Km-Yeni araç =>10º
4000 Km-Bakımdan Sonra =>10º

30. Removal sequence 1 Nut 2 Lower connecting rod bearing
3 Connecting rod cap
4 Upper connecting rod bearing
5 Piston and connecting rod assembly 6 O­ring
7 O­ring
8 Rubber packing
9 Cylinder liner
*a: Oil pan L Gr12
*b: Crankcase L P11­56
X: Non­reusable part
Installation sequence
Follow the removal sequence in reverse.

32. PISTON PROJECTION Service procedure Pre­disassembly inspection
(1)Piston projection from crankcase top surface
NOTE
The piston projections affect engine performance
and must therefore be checked.
Measure the projection of each piston at four points
and calculate the average of the four values.
A : Front of engine
If the average value is out of specification, check
the clearances between all relevant parts.

33. CYLINDER LINER FLANGE PROJECTION

34. CONNECTING ROD END PLAY

35. Pre­disassembly inspection
Crankshaft end play
Before removing the main bearing
caps, measure the extent of crankshaft
end play.
If the measurement exceeds the specified
limit, replace the thrust plates with
oversize ones.

36. CRANKSHAFT THRUST PLATES AND MAIN BEARING CAPS

37. MAIN BEARING CAPS

38. CRANKSHAFT RECTIFICATION SIZES

39. MAIN BEARING CAPS
11-60

40. CRANKSHAFT MAIN BEARINGS
[Installation]
Install the main bearings 7, 16 such that their lugs A fit into the corresponding
grooves.
The upper main bearing 16 has an oil hole B. The lower main bearing 7 has no oil hole.
Take care not to confuse the upper and lower parts.

42. CAMSHAFT BUSHINGS
Disassembly sequence
6, 5, 4, 3, 2, 1, 7
Assembly sequence
5,4,3, ,

43. CAMSHAFT BUSHING REMOVAL

44. CAMSHAFT BUSHING INSTALLATION