S E C T I O NE M

ENGINE
MECHANICAL
11, L1 6 & L l A S E R T E S

I)ESSRIPTIOII IM-2
G[I{[RAI.
DISASSEMBI-Y Ilt|.5
INGII'|I
II{SPICTION
ANORIPAIR tll|- 8
il,{0rNt . ....
Asst|||Bty rM.23
OAIA
SIRVICT A|'|O
sPEClFlCATl0l{S tnr'zd
rRo|JBr.r
0tA0il0sts tM.35
NISSAN AI{DCORRICIIONS

NISSANMOTOR
CO.,LTD.
TOKYO, JAPAN
 ENGINEMECHANICAL

G E N E R A LD E S C R I P T I O N

CONTENTS
1 1 4 ,1 1 6 A N D 1 1 8 E N G N E EM-2 CAN/]SHAFT E[,14
CYLINDER BLOCK EM3 V A L V E M E C H A NS M EM.4
C F A NK S H A F T EM3 CAMSHAFTDRIVE Etvl-4
PISTONAND CONNECT
NG BOD EM3 [,,lANlFOLDS EM.4
CYL]NDERHEAD E[,1-3

L14, L16 AND 118

ENGINE
The 510 seriesmodelsarepoweEd
by ihe L14 andL16 engines. TheLl6
enginejs also utilized to power the
610. For the 510, the Ll8 engineis
alsoavailable
for faster,halderuseon
highways and streets.The engines
feature O.H.C. valves,wedge,shaped
combustionchamber,alminumheads
and fully baltnced s-b€aringorank"
shaftto turn out smooth,dependabl€
power.The cylind€rblock is castin a
singleunit, featuringdeepskining.
SU type carburetoris used to
provideproperair-fuelmixingfor the
Ll6 and Li8 engines.Theseengines
arealsoequipp€dwith single,2-barrei,
downdraftcarburetor. TheL14 €ngine
uses only the same single,2'barrel
carburetorthat is usedon th€ L16 and
Li8 engine.

Fig. EM-1

EM.2
 ENGINEMECHANICAL

Main specifications

Lt4 Ll6 Ll8

Singlecarb. Singlecarb. Twin carb. Singiecarb. Twin carb.

Displacement
1,428(87.14) 1,595(97.33) 1 , 7 7(0r 0 8 . 0 r )
cc Gu in)

83x66 83 x'73.7 85x78

nn (in) (3.268x 2.s98) (3.268x 2302) (3.346x 3.071)

Comprcssion
ratio 9.0 8.5 9.5 9.5

Ignitiontimingfor
M/T B.T.D.C. l00/600 em l401650rpm i0o/600rpm l4ol6s0rpm
80/600rpm
(for A/T) (650) (700) (6s0) (700)

M/T: ManualTransmissionA/T: AutomaticTransmission

Notei On vehiclesequipped with afl
air conditioner, increas€engine
speedby 150rpm higherthan that
indicated whil€ F.I.C.D. is in
operation.
CYLINDERBLOCK
The cylinderblock, which is of a
monoblockspecialcastingstructurc,
adophfive.bearing-supporl systemfor
quietness andhigherdurability.
The cylinderboresare surrounded
by cooling jackets and machined
dilecily in the block.The oil waysin
the block are a angedso rhat the
full.flow oil 6lter is directlyaitached
to thedghthandsideof the block.
The L18 engineuseseightbalancc
weights, wbilethe othelsusefour,
Mai[beadngsgainlubricationfrom
oil pump€d through th€ main oil
gallaryand the oil holeswhich run in
parallelwith cylinderbores.Thereare
drilled oilwaysin ihe 0rankshaftfor
the lubricatingoil. The cenler nrain
bearing is equipped wilh thrusl
washersto take up end thrust of thc
crankshaft.
Fie.EM"3 Cruntuhaft(Lt4 andLt6)
ringsand one cornbinedoil rjng.Th€
Ll6 engine equipped wjth twin
carburetors,and the Ll4 englne
equippedwith singlecarburetoruse
the flat head pistonsand othersLNe
slightlydishedpistons.The phton pin
is a specialhollow steelshaft. lt is
full.floltingfit to the pistonandpress
fit 1othe connecting rods.
The connectingrods rre speciel
forged steel. Oil js directedto th€
connectingrod small ends lhrough
d lled passgesnr fie largecnds of
rod. Oil holesin ihe conncctingrods
rre locatedso as lo insureoplimum
lubricationunderhcaly lord.
ccax)9<KD
IFXT
-'-;
l|-\ !_a

u
Fis. EM-5 Piston dn 1.conne.ting rod

Fis. EM 4 Oanhthoft (LI8)

fie. EM-2 Cylinder btoch CYLINDERHEAD

CRANKSHAFT
The crankshaft is a special steel
forgins.Fuly balanced,it turns olli
snooft, dependablepower at high
spe€d-
PISTONAND
CONNECTINGROD
The pistons are special alminum
castingwit}l struts lo control thermal
exDansionand have two comDression
The cylinde.headis madeof light
and stmngrluminumalloy witi good
coolingefficiency;it containswedge
type combustionchambers. A special
aluninumbronzevalveseatisusedon
the intakevalve,whilea heatresistant

EIV-3

installedon the
exhaust valve. These
pressfilted.
EMOAl
F iC.-EM'6 Cr linde r hea.l
CAMSHAFT
Camshaftis made of speoialcast
iron and loclted insiderockercover,
Four aluminumalloybrackets support
crmshaft. Camshaft bearings ar€
lubricatodfrom oil boles'rhich leadto
the main oil galleryof the cyltnder
head.
The concentricpassages arc ddlled
in thc froni and resr part of the
camshaft.
Th€ oil lo eachcamlobeh supplied
thmughdn oil holeddlledin the base
circle of each ]obe. Lubricani is
$rppliedlo lhe front oil gdlery from
2nd camshaftbearingand to the lear
oil gailelyfrom 3rd camshafib€aring.
Theseholeson the basecircleof lobe
supply lubricant to th€ cam pad
surfaceof ihe rockerarm and to thc
valvetip end.
Iie. EM-7 camehaft
ENGINEMECHANICAL
VALVE MECHANISM
The vaive system has a pivol lYPe
rocker arm that is aciivateddireclly by
tlle cam mechanism,and thh hasmade
its moving parts considerably lighter
and provides an ideal highspeed
Only the Ll4 engineusesrhe single
type v ve springs int*e valve only
and al1other enginesuse the dual type
valvesprings.
EMOA5
s*k Fig. EM-10 Chaindriring sy9tem
MANIFOLDS
#$ftc The intake maniibld is made of
casted aluminum alloy. The twin-
carbufeloftype enginesuse the one
wjth an indopend€ntdesignfor each
$ +
It d!
carbLrrcto!,
fold.
whilethe singl€crrburetor
type engiresus€ monoblockmani-
T|e exhaustmanifold,identicalin
dcsignon both cnginctypcsis a dual
Fie.EM.8 Valuenechanbm (LI1) cxlraustsystemintendedto preveni
decrcase in 0utput due to exhsust
intcrferenc€and 10 increaseoutput
B-k
thl(nrghthe in€rtiascavengingaction.
It is connccicdto cxhaustpipcsby
AeaE
nanges, whichinsurecompl€t€ abs€nce
oi exhiustlciks.
BWOF
4,fi
c! c)
Fis. EM I Vdl&
( L 1 6 o n dL t 8 ) FE. EM-|1 Manifolrk for sinele
CAMSHAFT DRIVE
Camsluft is diven by a doublc row
roller chrin driven by cran-kshaft.The
tension of the chain i cortroiled by a
chain tenslonerwhich is operated by
spring and oil pressue. The rubber
shoe type lensionerinsuhies vibration
of the chain and controls teision of FiE.EM-12 Manifoldsfor tain
EN].4
 ENGINEMECHANICAT

E N G I N ED I S A S S E M B L Y
CONTENTS
P FE L I M I N A R C
YL E A N ] N G A N D PISTONS
AND CONNECTING
BODS EM.6
INSPECT]ON EM5 CYL NDERHEAD EM.1
DISASSE[4BLY EM5

PRELIMINARY
CLEANINGAND (3) Removeoil filter using special 9- Removerockercover.
INSPECTION tooi "Oil FilterWrenchST19320000." 10. RemovecIlrburetot.
Before disrssenbling engine, (4) Removeoil pressure swirch. 1l- Remove intake and exhust
observe the followingitems: (5) Install engine rttachmcnr to
1. Fuei, oil or water may leakpast cylinder block using boli holes
cylinder head and block. Prior to securingallernatorbracketand water
disassembling, check cylinder head, drain plug.
front chaincover,oil panandoil filter (6) Selengineon the stand.
gasketsand crankshaft and watei "EngineAttachment
ST05260001"
pump seahlor sign ol leak postthoir "EngineStandST05015000"
gaskeiedsurfaces.
2. Checkcarburetorand fuel pump
for condition;fuel hosesfor deteriora.
tion, cracksor otherwiseleakageof
fuel past their.ioinled or oonnecled
Fig.EM-16 Remouinq
monifolds
3. Remove ir cle ner, alternator, sT050rs000
dislributor and stsrter, and plug up
carbureto! air.horn and distributor
hol€ to prevent entry oI foreign 12. RemoveenginemountingL.H.
matier, 13. Remov€crankpulley.
4. Wipedustandmudoffengine. 14. R€movewal€rpump.
5. Inspectblock,rock€rcover,fiont t 5. Remov€fuelpump.
clain cov€r,oil panandall otherouter Fig. EM-13 Enciae on enginestdnn 16. R€rnoye
fu€lpumpdrivecan.
partsfor visualdef€ctsandbrokenor 17. Rcmovecamshaftsprocker.
missing partssuchasboltsandnuts.
6. Test ali pipings and electrical 4. Removeoil levelgaug€.
5. Removeclutchassernbly.
circuitsfor discontinuiiyor brokenor
damaged insulation. 6. Removehightensioncable-
7. Removesparkplugs.
8. Removcthernostathousing.
DISASSEMBLY
To removeengine lron vehicle,
r€fer to relativeiopic under"Engine
Renovaland Installation"in Chassis
and BodyService Manual,SectionER. Fie. EM-16 Remouinecamshdft
1 Remove tnnsmission fron spfocRe.
engine.
2- Thorougbly drain engineoil and
coolantby .ernoving drainplugs. 18. Removecylinder headassembly.
3. Place engine assemblyon the Use special tool "Cylinder Head Bolt
Wrcnch 5T10120000" to removecyl,
(l) Removefan andfan pulley. Fig- EM- 14 Il.nouine them@tat inder head bo1ts. Loosen bolts from
(2) Renove ensine mounting R.H. houst\g O to @ as shown in Figu.e EM-l?.

Etvt-5
 ENGINEMECHANICAL
28. Remoyemainbearingcaps.
Use specialtool "CrankshaftMain
BearingCap Puller 3T16515000"to
removecenterand rearmain bearing
caps.Keepthemin ordei.

sT1651S000

Fig.EM'17
' Cylinderheqtlbolt
looseniag
sequeace
Not€: For the conv€ni€nce of cylinder FiC-EM-20 RemouinC chointensioner
head replacement,sp€ciol tool anI timingchdin
"Chain Stopp€r 5T17420001"is
24. Remove tining chain.
prepar€dto supporttining chain
25. Removeoil tirowcr. crankshaft
during the serviceoperation.By
worn gearandchaindrivesprocket. Fie. EM-24 Renoving rcat hoin
using this tool, timi g marks on
cnflkshaft sprockel and timing
chain will be unchanged. So the
work for aligningtiming mffks will \ I r.]i 29, Remove
iearoil seal,
be s€vedso fnuch. -
/ )i-
-i :,
v?r-eI
sTl?420001 'a'J/
Fig. EM-21 Remouingch.in dtne

Fig. EM-25 Remoring rcar oil seal

i0. Renrovecrankshafi.
31. Remove buffle phte and cyl.
Fig. EM-18 Suppo ing timine.hain

19. .lnvertengjne.
20. Removeoil panand oil strain€r.

Fig. EM 22 RemoDinepiiton and

connectingro.l @embl!
27. Removellywheel. Be carefulnor
to drop rt.

Fie. EM 26 Remo,ine buffteptatu and

net
FiE. EM-tg Remouineoil strdiner

21. Removeoil pump and its drive PISTONSAND

spindle. CONNECTINGRODS
22. RemoveIront cover. l. Removepistonringswith a ring
23. RemDvechaintensioner. Fig. EM-23 EeaotiaE flyuheel

Et\,1-6
 ENGINEMECHAN!CAL

CYLINDERHEAD 3. Rernov€valvesusing specialtool

"Va1v€Lifter
l Loosenvalve rocker pivot lock STI 2070000."
nut andremoverockerarmby pressing

Fig. EM-27 Remooingpbton ring

2. Pressout pistonpin with special
tool "Phton Pin Press Stand Fig.EM-31 Removing
ualue
sT13030001." 4, Takecarenot to losevalvespring
rocherom
I'ig.EM-29 Remouing seat, oil seal,valvecollei, and lalve
Note: Take care not to lose vah€ rockerguide.
rockerguide. 6
€ o
{n g
2. Removecamshaft.
6
sTr3030001 H
U
I
F
Fig.EM-28 Remouinspbtotpin ? $
t!
<)
3, Keep the disa$embledparB in
Fie. EM-32
EM105

Fis. EM-30 Renouing cdffihdft Notes:

Notei At thfu time, take carenot to
dsmagec.msh.ft besrings andc.m
lobe3.
N. B€ surc to l€avecamshaftbearing
intrct. Becaus€the bearingc€nteris
liable to be out ot rlignrnent.
b. Only the Ll4 engineusesthe single
type Bpringfor intake r?lve,

EM7
 ENGINEMECHANlCAL

I N S P E C T I O NA N D R E P A I R

CONTENTS

PREPABA OTN F O F N S P E C T I O-N. ,. , . . EM.8 P S T O N S ,P I S T O N P N S A N D P S T O N

C Y LN D E FH E A DA N D V A L V E, , . . , , , . , E M .8 R r N G. S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EN/l-17
Checkin c yg l l f d ehr e a dm a t i nfga c e . . . . . . . . EI\4.8 CONNEC N TG F O D . . . . . . . . . . . . . . . . . . . . E M1 8
Valvea$embly E[/'l-8 CRANKSHAFT .,,.,, E[/],18
V a l vsep r i n.g. . .. . . . . . - . Et\4.9 B U S H T NAGN D B E A F | N .G. . . . _ . . . . . . . . . . . E[/],20
R o c k e r a ra' n d v a l v e r o c k e r p i. v. .o. t. . . . Et\4-'l0 Measur-"ment oi main boaring
vatv-gL,de.... ElvtI0 c l e a r a n c e. . . . . . . . . . . . . . . . . . . . ... EM.20
Valveseatinserts EM.]1 Measurementof connectingrod
CAMSHAFT AND CANISHAFT bearin ce s . r a n c. .e. . . . . . . . . . . . . . . . . . . . . , EM'20
B E AN R G. . . . . . . . . . . . EN/l-
13 F i l { i n gb e a r i n g s .... ENI-20
Camshaft bear ng clearanc Etit-13 M I S C E L L A N E O U SC O M P O N E N T,S, , , . , , , , , , ENI"22
V a l v e t i m .i n . .g. . . . . . . Et/t-13 Crankshaft sDrock-"1, camsh€f1
C a m s h a fi tg n m e n, ,l , . , E[/]-14 s p r o c k € t. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-22
C Y L I N D E8FL O C K . , , . EM.14 C h a i lne n s i o naefrd c h a i q nlide............ EM-22
H o w t o m € a s u r e c y l i n d e r b o r e , , , , , , , . E[/]-15
,.,.. F l w v h e. .. l. . . . . . . . . . .. . . . . . . . . . . . . . . . . EM-22
Cyllrdefborlag E[/]-15 F r o n c! o l e a r n dr - b ao r s e a l. . . . . . . . . . . . . . . EM-23

PREPARATIONFOR Note: Never remove canrhall llead surfacellatnese

INSPECTION b€6ring! unl$s you hlve a suitable
l. BeforccLeaning, checkfor signof rMchin€ for boring camshaft
water and oil leaksin cylinderblock bearingin line. If you oncerernore
6ndhead. comshaftbearings,bearing clnters
will be out of llignment ald lessthan0.05
2. Clean oil nnd carbon deposiis nn (0.0020in)
from aU pafts.They shouldbe clean reconditioningis very difiicull
from gasketor sealant, withoutcenterborings.
3. Clean dI oil holeswilh solvenr
and dry with comprcssed aL. Makc
surethat theyarenot restrict€d. l. Mrko a visual checkfor cncks Yalve assembly
andllnws. l. Check erch of rhe intrk€ and
2. M€lsure the surfaceof cylinder erihaust valve for worn. damagedor
CYLINDERHEAD head (on cylinder block side) fof dctonned vrlve capsoI slems.Correct
AND VALVE waryagc.If it is found to be beyond or replace the valve that is defective.
the limli designated
below,regind de l. Valve face or valvc stem end
Checkingcylinder head affecledsurfacewilh a suribcegrinder. iurface should be rcfaced by using a
mating face Yalvegnnder.

Fis. EM 34 Chechinccrlinalerhead FE. EM 35 Intake dnI eehaustuotue

FiS, EM 33 Ctlin.Ier head sutace dineBioN

Etvl-8
 ENGINEMECHANICAL
Not€: Whenvalveheadhasbeenwom
In. 38.0to 38.2(i.496to 1.s04) down to 0.s mm (0.0197in) in
Lt4 thicknass.replacethe valve.
Ex. 33.0to 33.2(1.299to 1.307) Gindiry allowance for the valv€
sten endsurfaceis 0.s mm (0.0197
Valve headdiameter In. 42.0to 42.2(1.654to 1.661) in) or less.
H Lt6
33.0to 33.2(1.299to 1.307) Valve spring
In. 42.oto 42.2(t.6s4ro 1.661) 1. Checkvalvespringfor squareness
L18 usinga steelsq areandsudaccp1ale.
Ex. 3s.0ro3s.2(1.378 If springis out of squar€norc than
to 1.386)
1.6 mm (0.063ln), replacewith new
In. I 1 5 . 6t o 1 1 s .(94 . s stl o 4 . s 6 2 )
Lt4 2. l\reirsufethe free lengthand lhe
Ex. I15.7to I 16.0(4.555to 4.567) tensi()nofeachspring.lfthe measurcd
Vrlvelength vnllre exceedsthe specificd limit,
L mm (in)
In. 114.9 (4.524
to 115.2 to 4.535) rcplacespri g.
L16
L18
115.7 (4.ss5to 4.567)
to 116.0

Valvestemdiameter
Ll4 In, 7.965to ?.Y80(0.3136ro 0.3I42)
D Ll6
mm (in)
Ll8 (0.3128
Ex. 7.945ro7.960 ro0.1134)

cl ValveseatangleIn. & Bx. 45o30'

=ffi
Fig. EM-38 Meosuring sprine .quarcness

Fie.8M-36 Chechineualuestem
.liameter Fig. EM.37 ReqrindinEualuefdce I'ig. EM 39 Medsutine sprine tehsion

Et\4-9
 MECHANI

Bocker arm and valve

rocker pivot
Check pivot head and cam contact
Ll6 andLl8
and pivot contact surlacesof rocker
armfor damage,or wear.Ifdefectsar€
Twincarb.
found, replacexhem.A defectivepivot
necessitaterils rcplacement togetier
Valve springfree
witl the correspondingrocker srfn.
length
'r'm (in)
oirt., 49.98(1.958)
Intak€ 49.0(r.929)
Irmer 44.85(1.?66) Valve guide
Outer 49.98 49.98(1.968) Moasurethe clearanc€between
0.e68) valve guide and valve steh. If the
Brftaust
Inner (t.166)
44.8s 44.8s0.?66) clearanceexc€€dsthedesignated limlt,
replacethe wom prrts or both valve
Valvespdng and v,Ive guide. [n this cas€,it is
Pressurod length essentialto detemine if ruch a
(vrlre open)'
ciearanc€hasboencausod by a wom
or bentvslv€stemor by o nom valv€
30.0147.7 29,5149.O guide.
(1.181/r05.2) 0.16u,0E)
30.0/60.0
(l.r8l/132.3)
25.0124.9 u.5125.s Exhausl
(0.984154.9) (0.96s1s6.2)

3O.0147.7
Outer (1,181i
29.s149.0 29.5149.O
10s.2) (r.r5l/l08) (1.16U108)
Bxhaurt 12,023to 12.034dla.
25.0124.9 24.sW.s Ls"roltir " 0,+l:ai
(0.984/54.e) (0.96s
1s6.2) (0.96s1s6.2,
Valv6spring
assembl.dheiSht (0.3150to 0.3r57)
(0.3?4)
(vdecloro)
; 10.8(0.425) | .. .
mm/kg(in/lb) 59.0(2.123)----J unn: mmun,
40.Ol2r.3 EM,14
Outor (t.57sw.0)
4O.O128.4 FE. EM-40 Stundafi ualveeltld.
lntake
(r.s75162.6) '
35.0112.3
(r.3181n.r)

40.o12r.3
Outer
0.57si0.839)
ExhDxat
3s.01t2.3
(r378/0.484)

Etvl-10
 ENGINEMECHANICAL

Exhaust valve

Stem to grlide L11 0.020to 0.053 0.040to 0.073

cleamncemln (in) Ll6, L18 (0.0008to 0.0021) (0.0016to 0.0029)

Max.tolerance
of
AII 0.1 (0.0039)
mm (in)

As an einergency expedient. a valve

is pulhedin valveeuid€and movedto
the left and the fight at which point if
its tip deflectsabout0.2 mm (0.0079
in) or nore, ii wili be known that the
olearancebelween stem and guide
€xce€ds the muimum limii of0.1 mm
(0.0039in).
Note: Valve should be rhoved in
paralel with rocker arm. (G€neral
ly, a largeamount of wesr occursin
thisdir€ction.)
Max, allowdblcdcn€ction
0.2inm (0.0079in)
I \
3 0 m m( l . l 8 l i n )
t v
EM115
Fig. EM-41 Meosuting.ledtunce
betaeen uoluestem
dnd ualw gulle
Guideholeinner
dianeter"a" mm (in)
Replacement
of valveguide
l To removeold guides,usea drift
nnda press(undera 2{on prcssure)
or sTl103s000
Drive them out from oombustion
chamberside toward rocker cover.
Heatedcylinderheadwill facilitatethe
operation,
2. Ream cytinder head sidc guide
holeut roomtemp€rature. f-
Fig. EM-43 Reaming uolueguide
10.6 4. Rean the bore wilh valveguide
pressedin, usingspeciaL tool "Valve
GuideReame! SetSTI1035000."
Reaming bore:
8.000to 8.018mm
(0.3150 to 0.3157in)
5. Correct valve seat surfacewit]I
newvalveguideastheaxis.
EM 1 1 6
Fig. 8M.42 valoeSuidehole
Valve seat inserts
Check valve seat insertslbr any
L 1 4 L, l 6 a n dL l 8
evidenceof pitting aa valv€contact
surface,and reseatof replaceif wom
11.9851o I 1.996
(o.4719to 0.4723)
Valveseatinsertof0.s mm (0.0197
in) oveNizeis availablefor servicein
1 2 . 1 8t5o 1 2 . 1 9 6
thisL series
engine.
(0.4797to 0.4802)

3. Pressnew valveguideirto valve Valveguideof 0.2 mm (0.0079in)

carefuly so that it will fit smootirly oversize diameter is availablefor
afterheatingcylinderheadto 1506to
2oooc(3020to 392oF).

Ll4, Ll6 andLl8

lnterference fit of yalve 0.027to 0.049

guide to guidehole mm (in) (0.0011to 0.0019) Fig EM 44 Carreatineualueseot

E[41I
 E N G I N EM E C H A N I C A L

L l 6 a n dL l 8

lntake 7.5(0.295) 1.1(.0.303)

34 O.339)dia. 3 8 ( l - 4 9 6 )d i a .
4 1 1 04 1 . 1 1 3( 1 . 6 1 4 1 0i . 6 1 9 ) d i a . 4 l r o4 1 . 1 1 3( 1 - 6 1 l4o 1 . 6 1 9d)i r ,

L14andLl6 Lt8

\io l t . 6 l ] . 2 8 1 5 )d h .
7.5(0.29s1
Exiaust
7.5(0.29s)
I
3 0 ( 1 . 1 8 1d)i a . l 0 ( 1 . l 8 1 dl i a ,

( 1 . 4 5 9 11o. 4 6 0 ) d 3 7 . 0 8 0
3 7 . 0 8 0 13o7 . 0 9 6 ( 1 . 4 5 9t o 1 . 4 6 0d) i a .
r o3 7 . 0 9 6

FE Elr-45 Sto\dart ualwseat

Cylinderheadreceesdiametcr Rcplacing valve s€at inserl

Unit: nm (in)
L Oid jnsert cun be romovcdby
Lt4 L l 6 a n dL l 8 boring out until it collapses.The
nuchine d€pth stop shouldbc scl so
to 41.016 45.000
41,000 io 45.016 lhrt horing cannotcontinuebeyond
For standard
insert
(1,6142 (1.7717
to 1.6148) to 1.7723) rhebottom faoeof the insertlecess
in
Intake cylindefhead.
4 1 . 5 0t0o4 1 . 5 1 6 45.500
to 45.515 L Sclccta suitabl€valvesealinse
(1.6339 to 1.6345) (1.7913
to 1.7920) rnd checkits oulsidedianetcr.
3. Machire cylinderhead rcccssto
Ll4, Ll6 andLl8 rhe conccntic circlcsto valveguid€
center so thdt nNert will havc thc
insert
For standard to 37.016
37.000 (1.4557
to L4s73)
Exhaust .1- Reamthe cylinderheadrccessrt
37.500 (1.4764
to 37.516 to 1.4770)
5. He rylinderhcadto x tempera-
iure of 150' to 200oC (3020 to
r9loF).
6. Fit insencnsuingthat it bedson
0.081to 0.113(0.0032
to 0.0044) Ihe bortom lace of its recess,and
lit rnm (in) cnulkmorethan4 points.
0.064to 0.096(0.002sto 0.0038) 7. Valveseatsnewlyfitled shouldbe
cut or ground at the specified
dimensions asshownin FigurcEM'46.
8. Apply snrll amount ()1-line
grindingcompoundto valvecontacling
face and put valve into guide. Lap
valveagainstits seatrntil propervrlve
sertingis obtained.Renovevalveand
tlen clemvalveandvalveseat.

EM-12
 ENGINEMECHANICAL

Lt4 Ll6 andLl8

)tllv
//w1,,"
// rY
Inlake t,,l"y"\/(
,/['ffiZ-r'r.r ur.r-rssrr
/F:_=FF\-' (14961)dia
l -l -F3+91. 68
4 l ( 1 . 6 1 4 2d) i a . ( 1 . 5 5 9 rd) i a .
ll4s i;t;4 1.8(r.645
7)d"

L14andLl6 Lr8

l| ll, ' lt il/ t

!,LI]IU
Exhaust

1 . 7( 0 . 0 6 6 9 ) / l/;I> *"-r_ , ) ,n ,( ,,,

,/ al=::l:fi
l0 (1.l8l),ik. f------r30 (l.l8lt) dir.
ir 1r,r5rfrlz'o ai'
tr'rsrsr - --32,6 {1.2835)did.
r_-- 34,6 0.3622)dia.
E37(t.4s6?);1n
eM121

Fig. EM-46 VolDeBedt dimen$ions

CAMSHAFTAND journal to bealingcleararrce

Camshafl.
CAMSHAFTBEARING
Camshaftbearins Standdrd
clearance 0.038to 0.067
Oil clearance
mn (in) 0.1(0.0039)
l. Measurethe inside diarneterof (0.001s100.0026)
c,rn$haftbcaringwith an nrsidedial
gaugeand ihc outside diamererof Inn€rdiameterof cam 48.000to 48.016
cnmshaft journalwith a micfomeler.If sh,tftbearinsmm (in) (1.8898to 1.8904)
wear is fotrnd insidebrncket,replace
cylirderheadass€nbly.

Valve timing
This diagram will apply to all
cylinders.Il any valveis lbund "out of
specifications."one possibilily is that
crm lobe is worn or drnnged, calling
for rcplacementof camshaft.

FiE. EM.47 Chechtng aumshoft beanng

Fig, EM 4a Value timinq diaeram

EI!1,13
 ENGINEMECHANICAL
Unitr degree Camshaft alignment
1. Check carnshaft,camshaftjournal
d md cam sufrce for bend, wear or
danage. lf defects are beyond th€
Lt4 240 )32 8 18 50 limits, replace the affected parts.
2. A bend wlv€ is on€-half of the
Single 248 240 12 48 l8 reading obtained when camshaft is
Lt6 turned one ful revolution with a dial
Twin 248 248 T6 52 l8 gaugeto 2nd and 3rdjournals.

Single 248 240 12 4a l8 54

Ll8
Twin 248 248 t6 52 18

bend
Camshaft 0.0s(0.0020)
mm (in)
Fig. EM-49 Chechingcdmjhaft bend

Singlecarb. Twincarb,

Lt4 L l 6 a n dL l 8 L l 6 a n dL l 8

39.951040.00
Intake
(l.5728to I.5718)
Standnrd height 39.951040.00 40.30to 40.35
of carn mm (in) (1.5?28to 1.3?48) (l.5866to 1.5886)
40.30to 40.35
Exlausr (1.s866to 1.s886)

Wearlimit of carnhcight
0.2s(0.00e8)
mm (in)

in diameter
Allowabledifference
betweenmax.worn andmin. 0.0s(0.0010)
worn partsof camshaftjournal
nln (ir)

Maxirnumtoleranccin journal
0.1 (0.0039)
diarnet€r mrn (in)

Camshaftend play mrn (in) 0.08to 0.38(0.0031

to 0.0ls0)

CYLINDERBLOCK
l. Visuallycheckcylinderblock for

2. Measure the top ofcylinderblock

0.10(0.0039) (cylinder head mating fice) for
warpage.If warpageexceeds thelimil,

Et\l-14
 ENGINEMECHANICAL
cylinder borc at top, middle and
bottom positions towad A and B
dilections as showo in Figure EM-52
and record the measuredvalues.

Fie.EM-50 CheehinC c! linderbloch

sutoce
J. Using_a bore gauge measure
cylindcr bore for but.of'round or
tapcr. If, oui-of.round or taper is
excessiv€,rebor€the cylinderwallsby
me:nsof a boringmailine. Measure-
ment shouldbe takehslongbor€sfor
taper lnd arcund boresJoi oufof-
round.SeeFigufeEM.52.
0utof.round X.Y
Tap€r A.B
[ig. EM 5t Me6utinecr lindetborc
4. Whenwear,taperof oufof-round
is miror andwilhin rhe limir, remove
the step rt the topnrostportion oI
cylinderusingr ridgereamefor other
si ilar tool.
How to measure Fig. EM-52 Cllincler bore medsuring
cylinder bore positions
A bore gauge is Lrsed.Me sure

Standard
Wearlimit
Lt4, Ll6 Ll8

83,000to 83.050 85.000

to 85.050
(3.2677to 3.2697) (3.3165 0.2(0.0079)
to 3.3484)
Cylinderbore
mm (in) 0.0rs (0.0006)
Taper 0.0rs (0.0006)

cylinderbore rnm(in)
Difference 0.0s(0.0020) 0.2(0.0079)

Oversizepistonsspecifibstione
Cylinder boring
Ll4 rnd Ll6 l. When lny of cylinders needs
boring. all other cyljndersmust also be
Piston diameter nm (in) bored at th€ sameiimc.
82.985to 83.035 84.985to 85.035 2. Dctcltnire piston oversize ac-
Slandard cordjng Lo ihe amourt of wear of
(3.2671to 3.2691) (3.3459to 1.3478)
cylinder.
0.2s(0.0098) 83.215to 83.265
Oversize (3.2762to3.2'781)

0.s0(0.0197) 83.455to 83.s1s 85.465to 85.515

Oversne (3.2860to 3.2880) (3.3648to 3.3667)

0.7s(0.0295) 83.715io 83.765

Oversise (3.2959ra 3.29'78)

r.00(0.0394) 83.965to 84.015 to 86.015

86.965
(3.3057to 3.307?) (3.42381o3.3864)

1.2s(0.0492) 84.465to 84.515

(3.3254ro 3.3274,

Et\,l15

3. The sizeto which cylindersmust
be honedis determinedby addingto
th€ largestpistondiameter(at piston
skirt in thrust dftection) piston,to,
ENGINEMECHANICAL
Reboredste calculatio. springbalancehookedon feelergauge,
D = A + B - C = A + [0.005to 0.025 measuringthe anount of force rc-
Inn1(0.0002to 0.0010in)l quircd to pull out gaugefrom between
pistotrandcylinder.
D: Horeddiameter
A: Skirtdiamet€rasmeasured Noter:
B: Piston-to-wal
clearunce a. When m€asurinsthe clearance,
C: Machininsallowance(0.02 mnt slowly pull the feelergaugest.aighl
(0.0008in)
Note: To prcYentstnin dueto cutting b. lt is rccomm€nded that pistonand
heat,borethe cylindenin th€ order cylind€rbe heatedto 20oC(68oF).
of 24-l-3.

4. Do not cut too much our of

cylinderbore nl a time, but cut 0.05
Fig. EM" 53 Maaswine piston.liame teI nxn (0,0020in) or soat a rirne.
5. Measuremenlof cylinder bore
just machinedrequires the utmostcare
sinceit is expmdedby cuttingheal.
6. As u final step,cylind€r!should
ie honedto sizc.
7. Measure thc finished cylinde!
borelof out-of"round or taperedpart.
8. MeAsure phton to cylinderclear-

lhis clearancecan be checked

Fig:.EM-54 Me$uring piston shirt easilyby usinga feelergaugeand , Fig.EM-55 Measuingpiston fit
in.rlinder

Notei If cylirder bor€ has worn

L l 4 , L l 6 a n dL l 8 beyondthe wearlimit, usecylinder
liner.
Siandardclearano€ mm (in) 0.025ro 0.045(0.0010
.o o.o0l8) Und€rsizecylind€rlinersare lviil"

Feelergauge mn (in) 0.04(0.00

r6) Interferenc€fit of cylind€rliner in
cylinder block shouldbe 0.08 to
E\tractingfqrce kB(lb) 0.2ro 1.5(0.44to 3.31) 0.09mrn(0.0031to 0.0035in).

Cylinder liner for servrce Uflir: mm (in)

Ll4, Ll6 andLl8

"---
Outsidediameter I lnnerdiameter

4.0(0.rs?5) 87.00io 87.05

Undersize 13.42s2to 3.4272)

4.s(0.1772) 87.500to 87.55 82.45to 82-60

Undersize (3.4M9 to 3.4468) (3.2461to 3.2s20)

5.0(0.1969) 88.00lo 88.05

(3.4646to 3.4665)

Et\416
 ENGINEMECHANICAL
PISTONS, PISTON
PINS AND
P I S T O NR I N G S
l. Removocarbontiom pistonand
ringgrooveswith a carbonscraper and
a curvedsteelwire. The wife will be
usefulin cleaninsbottom land of ring
groove.Cleanout oil slotsin bottom
landofoil ringgroove.
2. Checkfor damage,scratches and {ig. EM 56 Meosutingpisto4ing
wear. Replaceif such a defect is side cleoraace
detecled.
3. M€asurethe side clearanceof
a. When pistotr ing only is to be
dngs in ring groovesas each ring is
rcplaced,without cylinder bore
inslalled.Clearancewith new pislons
4. Push ring into cylinder with a b€ingcorrected,measureth€gapat
andringsshooldbe asfollows.
piston so ns to placeit squarelyin th€ bottom of cylinderwhereth€
cylinder; measurering gap with a
gauge.
fe€1er b. Oversizepiston rings rrc available
Ring shouldbe placed1odiameter for xrvice. [0,5 mm (0.0197in),
rt upperor lowerlimit oi ring tr vel. 1.0mm (0.0394in) oversiz€l

Side clearance mm (in)

Standard

Ll4 L16 Lr8

Top ring
0.040ro 0.080 0,040to 0.080 0.045to 0.08
(0.0016to 0.0031) (0.0016io 0.0031) (0.0018to 0.0031)
0.1 (0.0039)
0.030to 0.070 0.030to 0.070 0.030to 0.070
Secondring
(0.0012to 0.0028) (0.0012to 0.0028) (0.0012to 0.0028)

OiJring

Ring gap nrn {'n)

Siandard
Wearlimit
Lt4 Lt6 L18

0.23 to 0.38 0.25to 0.40 0.35to 0.55

Top ring
(0.0091 to 0.01s0) (0.0098to 0.0157) (0.0138to 0.0217)

0.15to 0.30 0.15to 0.30 0.30lo0-50

Secondring 1.0(0.0394)
(0.00s9to 0.0118) (0.0059ro 0.0118) (0.0118
to 0.0197)

0.30to 0.90 0.3to 0.9 0.3to 0.9

Orl ring
(0.0118to 0.0354) (0.0118to 0.0354) (0.118ro 0.03s4)

Et\l-17
 ENGINEMECHANICAL
5. Measure piston pin hole in pin into piston pin CONNECT]NG
ROD
relaiion io the outer dianeter of pin. extent that it can be finger pressedat
Ifwear exceedsihe limit, replacesuch This piston pin 1. If a connectingrod has any flaw
piston pin together with piston on must be a tight on both sidesof the lhrust face and
thc largeend,cor|gctor replaceit.
which it is installed.
6. Determine the fitting of piston

Fig. EM'58 Pbton pin Iitting
Fig.EM-60 Cheching
rod aLiennent
2. Checkconnecting rod for bendor
EM132
lo$ion usinga connectingrod aligner,
Fb. EM-59 Measuingpbton Pi^ lf bcnd or torsionexceeds the limit,
di4metet

3. When replacingconnectingrod,
Unit: mm(in) selectrod so that weight difference
betweennew and old onesis within 5
Ll4, Ll5 andLl8 gr (0.18 oz) for the L14 engine,T gr
(0.25oz) for the Ll6, L18 engines.
Pistonpin outsidediameler 20.995 (0.8265
!o 21.000 to 0.8268) 4. Install connectingrods with
bearingson to corresponding cr nk
Pistonpin holediarnerer (0.82677
21.000to 21,005 to 0.82697\ pinsand mcasure the thrustcleafance.
lf the measuredvalue exceedsthe
Pistonpinto pistonclearanc€0.001to 0.013(0.00004
to 0.00051) limir, rcplaoesuchconnccting rod.

l-itof pision
lnterterence
pin to connecting
0.015to 0.033(0.00059
to 0.00130)
rod

Model Standard Maximum '

,.-t\r.(
q)rl
Connecting rod bend
or torsionGef 100mm
or 3.94in length)
Lr4
Lt6
0.02s(0.00r0)

0.03(0.00r2)
0.0s(0.0020) Fie. EM 61
7
mm (in) L18

CRANKSHAFT
L Whenevercranlshaft is rcmoved
Lt4, L16andLl8 liom enSine,it should be cleaned
thoroughlyin a suitablesolvcnt.After
0.2to 0.3 cleaningcheckcrankshrftjournaland
Bigendplay mm(in) 0.6(0.0118)
(0.0079to 0.0118) cranh pin for scorc, birs wear or
cracks.Repairor replaceas required.
lf Cefectsare minor, dresswith fine

Et\,ll8
 ENGINEMECHANICAL
19.5(0.768) 32(t.260)
\-\ t9.5(0.768)

rr\ I--r
27(1.063)

-t
fTt-t
\l_--./ r i\
s
L13

5 4 . c 4rl or 4 9 5 5 l 2 . l 6 l lo 2 . l 6 l 5 , - - EM136

Fiq. EM.62 Cronhshdftand journnl

4 9 9 6 1 r o 4 9 . 9 7 4d i r . ( 1 . 9 6 6 I9o L a 6 7 5 l dimensions(L14 and L16 engine)

2. Checkwith a micrometerjounals lfjournalsor crankpinsaretapercd Note: Wh€n measuringbend, use a

and crmk pins for taperand out"of.
round.Measuremenl shouldbe taken
alongjournalsfor taper and round
journah for outof-round.SecFigu€
EM'62for detailinformation.
Outof-round
Taper
t9.s(0.?68)-
unit hn rinr(i.iir
or out-of.roundbeyondlimits,replace dial gauge.Bendvalre is a half of
with a newshaft. the readingobtainedwhen crank-
shaft is twned one full revolution
3. Crankshaftcan be check€dbof
with . dial gaugeartach€dto its
bcnd by placingit on V.blocksand
cent€rjoumal.
usinga dial gauge'rith its indiciting
x-Y fingerrestingon ccntcrjournal.
A.B
4. Afler r€gfinding crankshaft,
finish
it to the necessary
siz€indicaicdin rhe
Iist on page EM-21 by using an
adequateundersizebearingaccording
1.othe€xtentolrequir€dfepair.
5. Install crankshaft in cylindel
block andmeasure cnnkshaftfreeend
play.

Fig. EM-64 Chechingctunkshaftbehd

Fig. EM-63 Cranhshoftanrljoutnal
.timeasions (L I I engine)

Ll4, L16andL18 Maxinunl

Taperandout-of'round Fig. EM-65 Chechingctunhshaftend

ofjournalandcrankpin 0.03(0.0012) pto!
0.01(0.0004)
mm (in)

Ll4, L15andLl8 MLrinrum

Crankshaftbend mm (in) 0.r0(0.0039)

0.05(0.0020)

Et\,1-19

Crantshaft f.ee end
play mm (in)
6. At tne rear end of crankshaft,
check crankshaftpilot bushing for
wear or damage.Replaoeit, if any
defectis detected.
To replacecrankshaftrear pilot
bushingproceedasfbllowsi
(l) Pull out bushinsusing special
tool "Pilot Bushing Puller
sTI6510001."
ST
Fig. EM-66 Pulling out pilot
bwhing
(2) Betoreinstauinga new bushing,
thoroughlycleanbushinghole. Pr€ss
iit bushing90 that its height above
flangeend is 4.5 to 5.0 mm (0.18 to
0.20in). Do not oilbushi4g
( 0 . 1 8i o 0 . 2 0i i )
PILO'T
BUSHING
Fie. EM-67 Prcsrfitting neu pilot
bushing
BUSHING
AND BEARING
Measurement of
main bearing clearance
1 Thorougily clean all bearings
check for scfatches, n1elt, scor€ of
Replace b€arings,if any defect is
det€cted.
E N G I N EM E C H A N I C A L
Not€: Do not tum crankshaft while
the plastigageis b€ing inserted.
0.05to 0.18 5. Remove cap, and compafewidth
0.3(0.0118)
(0.0020to 0.0071) of the plastigageat its widest part wiih
the scale printed in the plastigage
2. Crankshaftjournaisand beariiss
shoddbe cleanandfreefron dustand
dirt beforeoil clearance
is measured.
FE. EM-69 Measurincbeatiag
FE. EM-68 Plostisase
Measurementof
connectingrod
3. Setmajnbearingon capblock. bearingclearance
4. Cut i plastigage to rh€ rvidrhof l. l\.{eusureoonnectingrod bearing
b€aring and plnoeit in parallelwith in thesarnenannerasabove,
clcarnnce
crankpin, geltingclearof theoilhole. Tightcningiorquel
Installcrp on ihc assemblyandlighlen 3.2to 3.8kg-m
thcm iogetherto the speciljedtorque. (23to 28 ftlb)
Tighteningtorque: for Ll6
4.5to 5.5kg-m 4.5 to 5.5 kg-nl
(33 to 40 ftlb) (33 t0 40 frlb)
t b r L l 4 a n dL l 8
Ilearingoil clearance
L l 4 , L l 6 a n dL l 8
Mainbearingclearance 0.010to 0.061
0.12(0.004?)
mm (in) (0.0008to 0.001.r)
Conneciing
rodbearing 0.015ro 0.055
0.12(0.0047)
(0.m10ro 0.0022)
2. If cleaianceexceedsihe specil-ied
valve, replace bearingwith dn undeF
size bearing and srind the cnnkhafr
journal adequately-
Fitting bearings
Bearings arc manufacturcd with
crushto makebearingssnugdown into
its boft. To neasure this, proceed as
folows: Fic. EM-70 Che.htngbearinsctush
ENt.20
 ENGINEMECHANICAL
l. Set main bcarin8in main bearing Bearing crush
cap recessor cylider block bearing

2. Lock the one side end of bearing Li4, LJ6andLr8

and press the other side until the
AII mainbearing rnm (in.) 0 to 0.03(0 to 0.0012)
bearing back surface touches the
AI connecting
rod bearinsmm (in) 0.01sto 0.04s(0.0006
to 0.0018)
3. Then,measure beanngcrush,,H,,
wiih a feelergruge.SeeFiSureEM-70.
The standardbearingcrusl vaiueis Main bearingundersize
listedbelow.- Unit:
4. Handleconnecting rod bearingin Ll4, Ll6 andLl8 Bearingtop thickness Crankjournaldiameter
the gamemannerasabove.
1.822to 1.835 54.942to 54.955
STD
(o-O'111
to 0.0722) (2.1631\o 2.1636)

0.2s(0.0098) 1.947ro |.960 54.692to 54.705

Undersize (0.0?67to 0.0772) ( 2 . 1 5 3t2a 2 . t s 3 7 )

0.s0(0.0197) 2.072to 2.085 54.442to 54.455

Undersize (0.0816to 0.0821) (2.1434to 2,1439\

0.75(0.029s) 2.197to 2.210 54.192to 54.205

Undefsiz€ (0.0665to 0.08?0) (2.1335to 2.1341)

r.00(0.0394) 2.322
to 2.335 53.942to 53,955
Undenize (0.09I4to 0.0919) (2.1237to 2.1242)

Connectingrod be*ring undersize Unit: mm (in)

Bearingtop ihickness Crankpin diameter

Ll4, I-16andLl8 L l 4 , L l 6 a n dL l 8

STD 1.493to 1.506 49.96t Io 49.974

(0.0588to 0.0s93) (l.9670to 1.967s)

0.6 (0.0236)UndersiTe 1 . 5 2t3o 1 . 5 3 6 49.901t0 49.914

(0.0600 to 0.060s) ( 1.9646
to l.96sl)

0. | 2 (0.0047)Undersize l-553to 1.566 49.841to 49.854

(0.061Ito 0.0617) (1.9622ro 1.9628)

0.25(0.0098)Undenize 1 . 6 1 t8o i . 6 3 1 49.711 to 49.124

(0.0637to 0.0642) (l.9571to 1.9576)

0.50(0.0197) l-?43to 1.756 49.461to49.4'74

Undersize
(0.0686to 0.0691) (l.9473to 1.9478)

0.75(0.024s) 1.868to 1.881 49.211ro49.22.4

Uns€iz€
(0.00?35to 0.0741) 11.9374to1.93'79)

l00 (0.0394)Underste 1.993to 2.006 48.961to 48.9'14

(0.078sto 0.0790) (1.9276to 1.9281)

Etvl-21
 ENGINEMECHANICAL
2. Insta[ pistonrings
Instalitop andsecondringsin right
position,with the markedsideup-
a. Top dng is chromium-plated on
liner contactingface.
b. Secondring haslargertapersurface
than top ring.
c. In the combinedoil ring, upperrail
is the sameaslower one.
Fie.EM-83 A$enbtine c!linde. h.dd
FiE. EM-81 lnstalti^g vabe /1

a. Checkwhetherthevalvefaceis fre€
ftom foreignmstt€fi.
b. On th€ L14 engine,the int*e valve
springsalonear€ of a singletYPe.
Otherengines usedoubletype valve
spdngs.
2. Valverockerpivol assembly
Scrcw valve rocker pivots joined
with lock nulsinlo pivot bushing.
3. Canrshaft assembly
Set locaiingplale and installcam"
shdt in cylinderhead carefuly. Do
not damagethe bearinginside.Thc
oblonggrooveof locatingplatc must
be direciedtowrrd the front side of
engine.
4. lnst ll carnshaft sprocketon 0 m-
shafiund lighte, it togelherwith fuel
pumposmto the specified torque.
Tight€ninglorque:
l2 to 16kg'm
(86 to 116ftlb)
A1 this iime, checkcrnshaft end
pl,ty.
P I S T O NA N D
CONNECTING ROD
l-1/
1. Assemble pistons.pistonpinsand :EJ
conrlectingrods to the dcsiSnated
cylinder.
Fig-EM-86 l$talLinePistonrinq
3. Fix bearingson connectingrod
rod cap.
andconnecting
Note: Cleanthe back sideof bearing
sr1303000r carefully.
E N G I N EA S S E M B L Y
L The tlrs! slepin engineassembly
is ro boli spccial rool "Engine
Atr!,rhn)€n!5T05260001" 1o righi
Fig. 8M"84 lkstollinepiston pi^
hand sidc of cylinder block, In
succcssion,inslall block in another
special tool "Enginc Stand
ST05015000" with €nginebottomup,
L Sct mrirt bcaringsat the ProPer
portionof cylinderbLock.

FE.EM-85 As.mbliagPistonand
0 ffi ftl u
ffl
tl't \!t
.on4ecungr@ n D D l') T1
L ]

(rJ t tr
tr /B
g
fil
a. Piston is pressedinto conn€ct-irs
rod, and firting force is fron 0.5 to
t1t
t t l t\ {
1.5 tonsand the aid of special
"Piston
tool tE \J9 \p
Pin Press Stard t1 t2 t1
is n€c€slary.
#s
ST13030001,"
When pressingpiston pin in con- Fig. EM-87
nectingrod, apply engineoil lo pin
Fig.EM 82 Installingcamshaft 3. Irstdl baffle phte includingcyl-
andsmauendofconnectiryrod.
8proc4e.
b. Anange s that oil jet of con-
5. Irstdl rocker arms by pressing necting lod big end is dtuected
downvalvespnngswith a screwdriver. toward the ighl side of cylinder a. Only c€nter b€aring (No. 3) is a
6. lnstal valverockersprings. block. flangedtype.
7. Afier assembling cylinder head, c. Be sur€to instal piston in cylinden (No.2 andNo 4)
b. Atl inter-bearings
tum camshaftuntil No. 1 pistonis at with notch m.k of piston head arethe sametype.
stroke.
T.D.C.on its compression toward the lrort of eneine. c. Front bearins(No. l) is also th€

EM.24
 ENGINEMECHANICAL
sametype as rearb$ring (No. s). RingComprcssor
EM03470000."
The differenceis that an oil hol€ is
providedin the front bearing.
d. All bearingsexceptNo. I bearing tM03470000
have a interchangeability between
upp€randlowerbearings,

4. Apply engineoil to mainbearing

surfaceson both sides of cylindel
blockandcap.
Installerankshaft.
5. Install main bearing cap and ITig-EM-89 Chechingcrunhshd[tend
tightenbolh to specjfied
torque. pLar FiE. EM-92 Inndlting pirton-rc.|

Tightcningtorque: ?. lnstall sidc oil sealsinto reaf main

4.5 ro 5.5kg-m bcaring cnp. Prior ro nrsiilling, apply
a. jlpply engineoil to slidingparts.
(32.s1o39.8ft"lb) sealantto thesesedh.
b. Arange so that the notchmark on
piston head facesto th€ fronl of
a. Apply sealantto eachsideof rear €ngme.
main bearing cap and each corner c. Installpistonringsat l80o to each
of cylinder blopk ss showr in oth€r, avoiding th€ir fit in the
Figur€8M79. thrustandpistonpin directiors.
b, Arrangeth€ partsso that the anow
5 .- ro! rin8
rnark on bearingc.p fRcestoward
t-\ oiri,ns
tlle front of engin€. q\(\
c. Prior to tighteningb€aring cap
bolts, placeb€aringcap in proper E \'
! \
position by shifting cEnkstuft in F I
the axialdirection. ai,""a"/
d. Tightenb€aringcapboltsgradually
rig. EM-90Dtiuirg sideoilsedl
in separotingtwo to thr€e stages
8. Install rcar oil s.rl usingspecirl
and outwardlyfrom c€nterb€aring
tool "CrankshaftRear Oii SealDrift
in the s€quence as shownin Figure Fig.EM-93 Pistontingdirc.tion
STi5310000." Applya lirhiunrgrcase
EM"88,
to seahtglip ofoil serl. 12. Installconnectingrod caps.
€. After securingbearingcap bolts,
ascertain that crankshaft tum Tighteninstorque:
srnoothly. 3.2 L03.8kg-m
(23 io 28 fr-lb)
for Lt6
sT1s310000 4.5 105.5kg-n)
(33 Lo40 il-lb)
for L14andLI8

Fic. EM 91 Instolling rcor oil BeqL

9. Install rerf end plrle.
Fig. EM-88 Torque sequenceof cap 10. Install tlywheel securely, and
botis ghren botts io specifiedtorqle.
Fie. 8M"94 Ihstallinecohnectinero.I
6. Makesuroihal th€reexistsproper TighLenirgtorque: cap
endplayat crankshaft. 14 to 16 kg-m Note: Anange connecting rods and
endphy:
Crankshaft ( 1 0 1t o I 1 6 f t - l b )
connecting rod caps so that the
0.05io 0.18mm il. Insert pislons in coiiesponding cylinder numbem face jn the same
(0.0020to 0.0071in) cylinder using special tool "Piston

EI\,125

13. Mak€ sure that there exists
prcperend play at connecting
rod bjg
bigen.lPtoY
FiC.EM-95Chechine
Bigondplay:
0.2 to 0.3 nm
(0.00?9 to 0.0118in)
14, Install cylinderhead assembly.
sequence
Fig.EM-96 Tightening
(1) Tholoughlycieancylinderblock
andheadsurface.
Do not apply sealantto any other
part of cylinder block and head
Do not applyit to anyotherpart of
cylinderblockandheadsurface.
(2) Turn crankshaftuntil No. I
pistonis at T.D.C.on ils compression
(3) Make sure that camshrft
sprockei location notch and plate
oblong groove are aligned at then
(4) When instaningcylinder head,
make sure that all valves are apart
liom headofpisto.s.
(s) Do not rotate crankshaf.and
camshaftseparately,becausevalves
will hit headolpistons.
(6) Temporarily tighten two bolts
(O, @) shownin FigureEM-96.
Tightening torque:
2 kg-m(14.sftlb)
15. Insta crankshaltsprocketand
disrributor drive gear and flt oil
ENGINEMECHANICAL
Note: Make sure that the mating
marks of crankshaftsprocketfrces
to the front.
16. Installtimingchain.
Notes:
a. I{ake sure that crankshaft and
camshaft keyspoint upwards.
Figi EM-99 Insta\ine front coaer
I lucl punp diive cam Not€s:
a. Apply s€alantto front side of
cylinder block nnd front cover
gasketas lhown in FigureEM-78.
b. Apply sealantonly to th€ top of
front cover as sho*n in Figur€
EM-78.
c. lnstallfront coverwith headg0sk€t
Fic.EM-97 IrctollingtiminEchoin in place.
b. Set timing chain by making its d. Ch€ck the height differencebe-
matingmarksalign with thoseof twe€n cylinder block upper face
crankshaft sprocket and camshaft and front cover upper face. Ih
sprocketat the right hand side. diff€r€ncemust be lessthan 0,15
Ther€ .re forty-two chain links mm (0.0059in).
betw€en two msting marks of e. Not€ that diff€renttyp€sof bolts
timingchain.
c. No. 2 hol€ is factory adjusred, f, Apply a lithiumgre{seto s€aling
lip
Wh€n chain str€tchesexcessively, of oil seal.
odjustcamshaftsprccketat No 3
hole.
d. Use a s€t of timing mtrks ond
locationholenumbers.
17. Instali chain Suid€to cylind€r
block.
18. Installchaintensioner.
Note: Adjust the protrusionof chain Irig.EM'100 Ftunt couerbolts
spindleto 0 mm (0 in).
tensioner
Tightening rorque:
SizeM8
(0.315in)
a.&
1.0to 1.6kg-n b. AI
(7.2to 11.6ttlb)
SizeM6
(0.236in)
0.4to 0.8kg-rn 23.
(2.9to s.8 ft-lb) ddvin
TiS
21. Instal crankshaft pulley md
I
Fig. EM-98 Installingchain tensioner warerpump, then sei No. I pistoflat
I
stmke.
T.D.C.on its compression
19. Pressnew oil sealin front cover-
(front coveroil sealshouldbe repiaced Crantshaftpulleynut
whenfront coveris disassembled.) nghteningtorque:
20. Installfront coverwith gaiketin 12to l6 kg-m 3pd
(86.8to 115.7ft'lb) mark
Et\,1-26
 qNGINEMECHANICAL
b. Installoil pumptogetherwith drii€
spindleso that rheprojecrionon its a. Apply sealantto the step portions
top is located in :25 a.m. at foul rnating surfacesassho\ln in
position, at this time, the sma er
FigureEM-80.
bo*-shape wi be placed toward
b. Tightening oil pan should be
thefront. p€rformedin criss-croi,pattem and
c. Do not foget to insta gask€t.
finaly to 0.6 to 0.9 kg-m (4.3 to
6.5ft-lb) torque.

26. Adjust valv€ clearancero the

FiC.EM-101 tnstattingcnnhshoft specified
dimensions.
pullet anduoterpump Specialrool .?ivot Adjusrer
22. Fift ly tightenheadbottsro the sT10640001."
specifiedtorque in rhree steps ac, Tightenjngtorque:
cordingto the tighteningsequenceas 5.0 to 6.0 kg-m
shownin FigureEM-96. (36,2to 43.4ft-tb)
Note that two types ot bolts ufe
used. Fig. EM-103 SetIinEdistributol
Specialtool "CylinderHeadBolt driuing Bpindle a. First set cleamnceto the cold
Wrench ST1012000.,' specifications.
Tightening lorque:
lst turn
4.0 kg-m(28.9frtb)
2ndturn
6.0 kg.m(43.4frlb)
3rd turn
6.5 to 8.5kg-rn
(47.0to 61.5ft"lb)

Fig. EM-104 Instaltinl oitputnp

Fig.EM.105A.tjustingudluectearunce
24. Install luel pump. wa|er inlet
elbowand front engineslingerjn their b. After €ngine has been assembled,
run it for at leastseveratminutes,
Fuelpumptightening torquel finally adjust th€ cleamncero th€
1.2to 1-8kg-m warm specifications.
(8.7to 13.0tuib)
Note: Do rof forg€t to instalt fuel 2?. Insiail rear enginestinger,ex^
Fig. EM-j02 Cylinderhead bol16 pump spacerand packingsinserted haustmanifoldand inlak€ manifold.
Detween spacer and btock, fuel Tighteninglorq e:
pump. 0.8 to 1.2kg-rn
a. Be sur€ to righten two $nall bolts
b. After enginehasb€enoperatedfor 25. Installoil slraincr,oil pangasket (s.8 to 8.7 tu1b)
several minutes; if necessary, andoil pan.
retighten.
23. Installoii pumpand djstributor
drivingspindleinto front cover. Ll4, Ll6 andLl8
Tightenjng torque: .
rd t.l to 1.5kg-m Intake 0.2(0.0079)
(8.0to 10.8tulb) Cold
Exhaust 0.2s(0.0098)
mm (in)
{ Assemble oil punp and drive 0.25(0.0098)
spindle, inaking driving spindle
nnfk faceto oil pumphole. Exlaust 0.30(0.01r8)

EM.27
 ENGINEMECHANICAL
Note: Bond gasketto rocker cover
using sealant.Then, install rocker
coverto cylinder head.
33. Instdl sparkplugs.
34. Connectdistributorto plughigh
35. Installenginernountbrackelon
leit hand sido.
36. lnstallcluichassembly.
Fie- EM 106 l\stollinq mdnifolds Specialtool "ClutchAligningBar
28. Instal distributorassembly. sT20600000."
29. Install carburetorass€mbly and Tighteningtorquei
carburetorinsulatorwilh stampfacing 1.2to 2.2 kg-ft
(8.7to 15.9ft"lb)
upward.Tighteningrorque3.6 107.2
kg"m(26 to 52 tulb).
30. Instdl fuel pipes and vacuum
fron enginestandand tien down onto
engine cader. Install alternator
bracket,adjustingbar, altematof,fan
pull€y,fan and fan belt in this order.
Then,checkto,be sur€that deflection
of fan belt is held wiihin 8 to 12 nm
(0315 ro 0.472 in) when thumb
pressureis appliedmidway between
pullcys(A pressed lorceis aboutl0 kg
(22.01b)).
{,q
(22.2lb)
( u , l l 5 0t o 0 . 4 7 2 i4n )

All pipes and hoses should be

clampedsecurely, beingcarefulnot to
allow them to intederewith adjacent
or suroundingpa$s.
3l. lnstall thefmostut housing,
thermostatond water outlet in their
positioff. Do not forget to install
gasKer.
32. Instailrocke!cover'
FE.EM-107I ^stolling.tu tchassembU
37. Using an overh€adhoist and
lifting cable.hoist engineup a way
FE. EM-108 Fon bett tbnsion
38, Insiull engine mount bracket
Gight hand), oil fiiter, oil pressure
switch,oil lcvclgaugeand watefdfain
plug. When installingan oil filler,
faslenit on cylinderblockby hand.
Note: Do not overtighten filter, or oil
leakagemayoccur,
39. Powerengineoil up to specified

S E R V I C ED A T AA N D S P E C I F I C A T I O N S
GENERALSPECIFICATIONS
Model L18 ST
Cylinderarrangement 4, in line

Displacementcc(cu in) 1,428(87.t4) 1,s95(61.80) r.7?0(108.01)

Boreandstrokemm (in) 83x 66.0(3.2611 \ 2.90168s x 78(3.346st 3.0709)
x 2.5984 a3x't3.7(3.1611
o.H.c.
Firingorder
Singlecarb. crrb.
Single Twincarb. Singlecarb. Twin carb.
Engineidle rpm
M/T 600 600 6s0 600 650
A/T 6s0 650 700 650 700
9.0 8.5 9.5 8.5 9.5
Engineidle manifold *qso(n .l) 4soi1.7) 400(15.7) 4s0(t'7.'7) 4oo(1s.7)
nmHg (irHg) ai idlerpm
Oil pressure
(Wann^at2,000 rprn) 3.5 to 4.0 (49-8to 56.9)
kgi cmz (psi)
M/T: ManualTnnsmission A/T: AutonaticTmnsmission

EM.28
 ENGINEMECHANICAL

TIGHTENING
TOROUE
Model L18

Cylinderheadbolts 3rd Turn

1stTum4.0(28.9) 2nd Turn6.0 (43.4)
kg-m (tulb) 6.5to 8.5(47.0to 61.5)
Connectingrod bigendnuts 4.5to 5.5(33to 40) 3.2 to 3.8 (23 to 27) 4.5 to 5.5 (33 to 40)
ks-n (f b)
Flywheeifixingbolts
1 4t o l 6 ( 1 0 1t o 1 1 6 )
kg-n (ft"1b)
Mainbearingcapbolts
4.5to s.s (33to 40)
ks-m (ft'lb)
Camshaft sprocketbolt
12to 16(86.8to I l6)
kg-n (ft-lb)
oil panbdts kg-n (ft.lb) 0.6to 0.9(4.3106.5)
oil Durf; bolts ks-mfft.lb) 1.1to l.s (8.01o10.8)
Oil.pandrainplug 2,0to 3.0(14.5to 21.?)
ks.m(tulb)
Rockerpivotlock nuts s.01o6.0(36.2to 43,4)
kg-m(ftlb)
Camshafilocatingplatebolts
ti
0.6ro 0,9(4.3to 6.5) ,,1.4
kg-m(fflb)
nuts kg-m(fi-lb)
Carburetor 3.6 to 7.2 (26 1052)
Manifoldnuts kg-m(ft.lb) 0.8to 1.2(5.8to 8.7)
Fuelpumpnuts kg-m(ftJb) 1.2to 1,8(8.7to 13.0)
Crankpullqyboli 12.0to 16.0(86,8to 115.?)
k8-m(tulb)

SPECIFICATIONS
Model

a) Valvernechanisrn

valve clearanc€(warm)
In.0.25(0.0098) Ex.0.30(0.0118)
n'rn (in)
(cold)
valveclearance
In. 0.20(0.0079) Ex. 0.2s(0.0098)
mm (in)
Valveheaddia.
mm (in)
3 8( 1 . s 3 6 1 ) 42(1.6s35) 42(r.653s)
33(1.2992\ 33(1.2992) 3s (1.3780)

7.965io ?.980(0.3136
to 0.3142)
?.945to 7.960(0.3128
to 0.3134)

Etvt-29
 ENGINEMECHANICAL

L18

Valvelength
'nm (in) 1 1 5 . t6o 1 1 5 . 9 114.9to 115.2
(4.sstb a.562) (4.s2a
b 4.s3s)
115.7to 116.0 1 1 5 . t7o 1 1 6 . 0
(4.ss5to 4.s67) (4.sssto4.s67\

Valve lift carb. Twincarb. Single

SinSle carb. Twin cflrb.
mmIin)
10.0(0.394) 10.0(0.394) 10.5(0.4r3) 10.0(0.394) 10.5(0.413)
10.0(0.394) r0.5(0.4i3) 10.5(0.413)10.5(0.413)r0.s(0.413)
Valve springfree length
mm (in)
-Outer 49.98(1.968)
Intake 49.0(1.929)
-lnner 44.85(1.766)
-Outer 49.98(1.968) 4e.98(r.968)
Bxhaust
44.8s(1.766) 44.8s(1.766)
Valvespringpressufed
lengtl (valveopen) Single carb. Twinc8rb,
mm (in)
-OuteI 30.0147.7 29.5149.0.
( r . l 8 l / r 0 s . 2( 1) . 1 5 1 / 1 0 8 )
Intake 30.0/60.0
(1.r81/132.3)
-Inner 25.0124.9 24,s12s.5
(o.984 | s4.9) (0.965| s6.2)
-Outer (l.l8r/r05.2)
30.0/47.7 29.s149.0 29.s149.0
( r . r 6 r / 1 0 8 )( i . 1 6 1 / t 0 e )
tsxhaust
-Inner | 24.9(0.984| 54.9)
25.0 24.Sl2S.s 24.sl2S.s
(0.96sls6.2)(0.96s1s6.2)
height
Valv€springassembled
(valveclose)
nm/kg (in/lb)
Outer .3(1.s7s147
40.0121 .0)
Intake 28.4(1.s'7
4O.Ol 5| 62.6)
Inner 35| t2.3(t .3' 78121
.t)

-Outer .3(t .s75147

40.012.1 .O)
Exhaust
3s.ol 12.3(t.378127.t\

Valve springetf€clive aurns

lnn (in)
Outer 4.5 5.0
tntake
Inner 5.5

Et\4.30
 ENGINEMECHANICAL

Ll8

5.0
Bxhaust
5.5

Valvespringwire dia.
mln (ln)
_ -Outer 4.4(0.1723) 4.0(0.r575)
Intake
-lnner 2.9(0.1t42)

-Outer 4.0 (0.1575)

Exha st
-IMer 2.9(0.rt42)

Valvesprtngcoil dia.
mrn(ln)
-Outer (1.r81)
30.0 29.4(1.1s0)
Intake
-Inner 2t.9 (0.862)

-Out€r 29.4(1.1s0)
-lnner 2r.9(0.862)

Valveguidelengih
mm (in)
-Inteke s9.0(2.323)
_Exhoust s9.0(2.323)
Valveguideheight from
headsurface 10.6(0.4r7)
ffn (in)
Valveguideinner dia.
mm (in)
8.000
to 8.018(0.3150
to 0.3154)
(0.3150
8.000to 8.018 to 0.31s4)
Valveguideouterdia.
run (in)
-Intake 12.023to 12.034(0.47s3to 0.4738)
-Exhaust 12.023to 12.034(0.4133to 0.4'738)
Valv€ guide to siem cleamnce
mm (in)

-Intake 0.020to 0.053

(0.0008to 0.0021)

Et -31
 ENGINEMECHAN!CAL

Model I-18

0.040to 0.073
Exhaust
(0.0016ro 0.0029)
Valv€seatwidth
lnn (in)
lntake 1 . 8( l . 1 0 2 4 ) 1.4(0.0ssl)
Exhdusl r.7 (1.0630) 1.3(0.0s
i 2)

Intake
tsxhaust 450
Valveseatinlederencefil
nm (in)
-Iriake 0.081to 0.113 (0.0032lo 0.0044)
-Exhausi 0.064to 0.096(0.0025to 0.0038)
Valveguidejnterference
fit
mm (in)
0.027to 0.tX9(0.011100.0019)

b) Camshrftandtining chain
Camshaft efldplay
mflr(in) 0.08ro0.38(0.001r
ro0.0r50)
Singlecarb. Singlecarb- Twin carb. Singlecarb. Twincarb.

Camshaft robelifi
rnm (in)
-Intake 16.65 1.00 6.6s 7.00
(0.2753) (0.25r
8) (0.2753)
6.6s(0.26r8) ]to.:er:l
Exhaust J7.00 ?.00 1.O0 7.00
l(0.27s3) (o.2ts3) (o.2'ts3) (0.2'7
s3)
Camshaftjournaldia.
mm (in) 47.949to 47.962(l.8877to 1.8883)
-2nd 47.949to 41.9O ( 1.8877 ro 1.8883\
-3rd 47.949ro 47.962(1.8877to |.8883)
-4th 47.949to 47.962( t.8a71rc |.Aaa3)
Canshaftbend
mn (in) 0.02(0.0007)
journalto bearing
Camshaft
0.038to 0.067(0.0015to 0.0026)
mm (in)
bearinginnerdia.
Camshaft
nn (rn) 48.000lo 48.016(1.8898
to 1.8904)
48.000to 48.016(1.8894
to 1.8904)
48.000to 48.016(1.8898
to 1.8904)
48.0001o48 016 (1.8898to 1.8904)
c) Rockerarm leverratio 1.5 1.45

EM.32
 ENGINEMECHANICAL

d) Connectins
rod
Center
distance
mm(in)
(s.3s)
136.6 I
(s.24)
133.0 I r:0.:s
1s.rrz1
Bearingnaterial F170

Beadng (S.T.D.)
thickness 1.493to 1.506
mm (in) (0.0588to 0.0593)
Bigendplay
0.20to 0.30(0.0079
ro0.01l8)
mm(in)
Connectingrod bearingclearance 0.0?5to 0.055
rnm(in) {0.0010to 0.0022)
Connecting rodbefldor torsion
(per100mmor 2,937in) (o.0olo)
lessthanO.O2s lessthan0.03(0.0012)
|
rnrn(in)
e) crankshaftandmainbeadng
Journal
dia.
to 54.955
54.942 Q.l631to 2.1636)
rnm(in)
Journal
iaper& out-of.round jessthan0.01(0.0004)
mm(in)
crankshaftfreeendplay
0.05to 0.18(0.0020to 0.0071)
mm(in)
limit of dittoedplay
Wear 0.3(0.0118)
mm(in)
Crankpindia,
4 (1.9610to | ,9675)
49.961to 49,97
nrn (in)
Crankpir iaper& out'of-round lessthan0.01(0.0004)
mm(in)

Mainbearing
mat€rial F770

Mainbearing (S.T.D:)
thickness
to 1.835
1.822
(o.O711too.o'722)
Mainbearingclearance 0.020to 0.062
mrn (in) (0.0008to 0.0024)
Wearlimit of dittotedclearance
0.12(0.004?)
rnm (in)
Crankshaftbend
0.0s(0.0019)
mn (in)

0 Pistion
Pistondia. STD 82.985to 83.03s 84.985to 85.035
m'n (in) (3.2671to 3.2591) (3.3459to 3.34?8)
0.2s(0.0098) 83.215 to 83.265
Ove.size (.3.27
62to 3.2781
)
 ENGINEMECHANICAL

Model Ll8

0.s0(0.0197) 83.465to 83-515 85.465to 85.515

(3.2860to 3.2880) (.3.3648ro 3.366'7
)
0.7s(0.029s) 83.715to 83.765
Oversize (3.2959to 3.2978,

1.00(0.0394) 83.965to 84.015 86.965to 86.015

Oversize (3.3057to 3.3077) (3.3844to 3.3864)
1.2s(O.O492) 84.465to 84.51s
Oversize (3.32s4to 3.3274)
Ellipsedifference 0.32to 0.35(0.013io 0.014)
mm (in)
Ringgroovewidih
-Top 2.0(0.0787
)
-Second 2.0(0.0787)
-oil 4.0(o.ls7s)
Pistonto boreclearance 0.025!o 0.045(0.0010
to 0 0018)
nm (in)
Pistonpin holeoff.sei
0.95to 1.05(0.0374
to 0.0413)
mm (in)
g) Pistonpin
Pindia. (0.8266
to 0.8268)
ro21.000
20.995
nm (in)
Pinl€nglh 72.00to 72.25 72.25to 73.00
mn (in) (2.8346to 2.844s) (2.8445to 2,8740)
Pistonpin to pistonclearance
0.001ro0.013(0.000M
lo (0,00051)
mrn(in)
lnlerferencefit ofpiston pin to
connecting rod bushing 0.015to 0.033(0.0006
to 0.0013)
mm (in)
h) Phtonrins
Ringheighi
nm (in) _Top 1.971(O.0178)
-Second t.9 t7 (0.0178)

mm (in) 0.040to 0.080 0.045to 0.080

-Top
(0.0016to 0.0031) (0.0018to 0.0031)
0.030to 0.070
-Second (0.0012to 0.0028)
Ring gap
nin (in) 0.23to 0.38 0.25to 0.40 0.35to 0.55
Top (0.0098to 0.0157) (0.0138to 0.0217)
(0.0091to 0.0150)
0.15to 0.30 0.l5 to 0.30 0.30to 0.50
-Second
(0.0059to 0.0118) (0.0059 to 0.01l8) (0.0118to 0.0197)

-oil 0.30to 0.90 0.30to 0.90 0.30to 0.90

(0.0118to 0.03s4) (0.0118to 0.0354) (0.01l8to 0.03s4)
 ENGINEMECHANICAL

T R O U B L ED I A G N O S E S
AND CORRECTIONS
Condition
L Nohy engine
Knockingof crantshaft loosemainbearing. Replace.
andbearing. Seized
bearing. Replace.
Bentcrankshaft. Repai.or replace.
Unevenwearofjournal. Correct.
Excessivecrankshaftend play. Replace
centerbearing.

Pistonandconnecting Loosebearing. Replace.

rod knocking Seized
bearing. Replace.
Loosepistonpin. pin or bushing.
Replace
l,oosepistonin cylinder. Recondition
cylinder.
Brokenpfutonring. Replace.
lmproperconnecting
rod llignment. Realign,

Camshaft
knocking Loosebearing. Replace.
axialplay,
Excessive beridngthrustplate.
Replace
Roughg€arteeth. Repair.
Brokencamgear. Replac€.

Timlngchainnolse Improperchaintengion, Adjust.

Wornand/ordamaged
chain. Replace.
Wornsprocket. Replace.
Worn and/or broken tensjon adjusting Replace.
mechanism,
Excessive
camshaft
sndbearing
clearance. Replace.

Camshaft
andvalve Impropervalveclearance. Adjust,
mechanismknocking Wornadjustingscrew. Replace.
Replace.
Loosevalvestemin guide. guid€.
Replaoe
We.lened valvespring. Replace.
Seized
valve.

Waterpurnpknocking shaftendplay.
L.nproper Replace.
Brokenimpeller. Replace.

IL Oth€rmechaniciltrout
Stickedvalve I Impropervalveclearance. Adjusi.
Insufiicient clearancebetween valve slem sten or reamguide.
Cllean
andguide.
Weakenedor broken valvesprins. Replace.
Biting or danageof valvestem.
Poorqualityof fuel. Usesoodfuel.

EM-35
 ENGINEMECHANICAL

Condition

Seized valve seat Impropervalveclearance. Adjust.

Weatened
v ve sprnrg. Replace.
Thinvalveheadedge. R€place
valve.

Overheat. Repairor replace.

Overspeeding. Driveunderproperspeed.
StickedvJveguide. Repft.

Excessively
worn Shortage
ofengineoil.
cylinderandpiston Dirly engineoil. Clean crankcase,rephce oil filter

PooLqualityof oil. U s er i 8 h to i l .
Overheat.
Wrongassemblyof pistolrwith connecting Repairor replace.
rod,
lrnproperpistonringclearance. Adjusr.
Brokenpislonring. Replace.
Drty air cleaner, Clean.
Mixturetoo rich. Adjusl.
B gineoverrun. Drivest propersp€eds.
Stickedchokevalve. Cleanandodjust.
Overchoking,

Defective of engineoil.
Shortnge Add oil.
connectingrod Low oil pressure. Correct.
Poofqualityof €ngineoil. Usenghi oil.
Roughsurfaceof crankshaft. Grind and replacebearing
o passnge.
Clogged Clean.
Wearor eccenlricityofb€ariflg. Replace.
Wrongassenblyolbcaring. Conect.
Loosebearing. Replace.
rod aliSnme
Conn€cting nl inconecL.

DefectivecranLshaft of engineoil.
Shortage
bearing Irw oil pressure. Correct,
Poorquality of engineoil. Usenghl oil.
journnl wornor out'of{ound.
Crankshaft Repair.
Cloggedoil passage
in crankshaft- 0ean.
Wearor eclentricityof bearing. Replace.
Wrongassembly
of b€aring. Corrcct.
or bearing.
Eccentriccrankshaft Replace. t{
N
Etlt.36