Maintenance Specifications -- Engine

Submitted by xjcdadmin on Tue, 06/09/2009 - 12:30

Model(s)

A, Engine

1 a. b.	Cylinder head Volume Warp limit		22.7 cc < 0.03 mm (0.0012 in) > *Lines indicate straightedge measurement
2. a. b. c. d.	Cylinder Material Bore Size Taper Limit Out-of-round Limit	Aluminum alloy with cast iron sleeve 63.0 mm (2.480 in) <0.05mm (0.0020 in)> <0.01 mm (0.0004 in)>
3. a. b. c. d.	Camshaft Drive Method Cam Cap Inside Diameter Camshaft Outside Diameter Shaft-to-cap Clearance	Chain drive Center 25^+0.021_-0 mm (0.98^+0.0008-0 in) 25^-0.020_-0.33 mm (0.98^-0.0008-0.0013 in) 0.020 ~ 0.054 mm (0.0008 - 0.0021 in)
e.		Cam Dimensions Intake Exhaust	"A" "B" "C" "A" "B" "C"	35.50 mm (1.398 in) 28.00 mm (1.102 in) 7.50 mm (0.295 in) 35.50 mm (1.398 in) 28.00 mm (1.102 in) 7.50 mm (0.295 in)
f.		Valve Timing Intake: Open Close Exhaust: Open Close Over Lap	B.T.D.C. 28° A.B.D.C. 48° B.B.D.C. 53° A.T.D.C. 23° 51°
9.		Camshaft Runout Limit	0.06 mm (0.0024 in)
h. i.	Cam Chain Type/Number of Links Cam Chain Adjustment Method	BUSH-CHAIN/120 Automatic

4.	Valve, Valve Seal, Valve Guide
a.	Valve Clearance (Cold) IN. EX.	0.11 *- 0.15 mm (0.0043 - 0.0059 in) 0.16 - 0.20 mm (0.0063 -0.0079 in)
b.	Valve Dimensions

	"A" Head Dia. IN. EX.		33 ± 0.1 mm (1.30 ± 0.0039 in) 28 ± 0.1 mm (1.10 ± 0.0039 in)
	"B" Face Width IN. EX.		2 3 mm (0.091 in) 2.3 mm (0.091 in)
	"C" Seat Limit Width IN. EX.		1 ± 0.1 mm (0.0394 ± 0.039 in) 1 ± 0.1 mm (0.0394 i 0 039 in)
	"D' Margin Thickness Limit IN. EX.		0.7 mm (0.028 in) 0.7 mm (0.028 in)
c.	Stem Outside Diameter IN. EX.		7^-0.10_-0.025mm (0.2756 ^-0.0004_-0.0010 in) 7^-0.25_-0.040 mm (0.2756 ^-0.0010_-0.0016 in)
d	Guide Inside Diameter IN. EX.		7^+0.12_-0. mm (0.2756 ^-0.0005_-0. in) 7^+0.12_-0. mm (0.2756 ^-0.0005_-0. in)
e.	Stem-to guide Clearance IN. EX.		0.010- 0.037 mm (0.004- 0.0015 in) 0.025 - 0.052 mm (0.0010 - 0.0020 in)
f.	Stem Runout Limit		<0.03mm (0.0012 in) >
g-	Valve Seat Width Standard < Limit >		1.0 mm (0.039 in) < 2.0 mm (0.080 in) >
6. Valve Spring
a.	Free Length Inner Spring IN. EX. Outer Spring IN. EX.		35.9 mm (1.413 in) 35.9 mm (1.413 in) 39.5 mm (1.555 in) 39.5 mm (1.555 in)
b.	Spring rate Inner Spring IN. EX. Outer Spring IN. EX.		2.36 kg/mm (132 lb/in) 2.36 kg/mm (132 lb/in) 4.58 kg/mm (256 lb/in) 4.58 kg/mm (256 lb/in)
c.	Compression Length (Valve Closed) Inner Spring IN. EX. Outer Spring IN. EX.		31,0 mm (1.220 in) 31.0 mm (1.220 in) 34,0 mm (1.339 in) 34,0 mm (1.339 in)
d.	Compression Force (Valve Closed) Inner Spring IN. EX. Outer Spring IN. EX.		9.0 kg (20 lb) 9.0 kg (20 lb) 19.1 kg (42.1 lb) 19.1 kg (42.1 lb)
e.	Tilt Limit, all springs:		2.5°
f.	Direction of Winding (Top View)		Intake	Exhaust

7.	Piston
a.	Piston Size/ Measuring Point (A)		63.0 mm (2.48 in)/ 7.5 mm (0.295 in) (From bottom line of piston skirt)
b.	Clearance between Piston & Cylinder < Limit >		0.03 - 0.05 mm (0.0012 -0.0020 in) <0.1 mm (0.0049 in) >
c.	0versize 1st 2nd 3rd 4 th		--- 63.50 mm (2.50 in) --- 64.00 mm (2.52 in)
d.	Piston Pin Hole Off-Set		0.5 mm (0.02 in) / lnside
8.	Piston Ring
a.	Sectional Sketch
		Top Ring	B = 1.2^-0.01_-0.03 mm (0.47^-0.0004_-0.0012ⁱⁿ) T = 2.6 ± 0.1 mm (0.102 ± 0.004 in)
		2nd Ring	B = 1.5^-0.01_-0.03 mm (0.59^-0.0004_-0.0012ⁱⁿ) T = 2.8 ± 0.1 mm (0.110 ± 0.004 in)
		Oil Ring	B = 2.5mm (0.098 in) T = 2.8 ± 0.15 mm (0.110 ± 0.0059 in)
b.	End Gap (Installed) Limit Top Ring 2nd Ring Oil Ring		0.15- 0.35 mm (0.0059 - 0.0138 in) < 1.0 mm (0.039 in) > 0.15-0.35 mm (0.0059-0.0138 in) < 1.0 mm (0.039 in) > 0.3-0.9 mm (0.012 ~ 0.035 in) < 1.5 mm (0.059 in) >
c.	Side Clearance Top Ring Limit 2nd Ring Limit		0.03-0.07 mm (0.0012- 0.0028 in) <0.15mm (0.0059 in)> 0.02-0.06 mm (0.0008-0.0024 in) <0.15mm (0.0059 in) >
d	Plating or Coating Top Ring 2nd Ring Oil Ring		Chrome plated. Ferox coating ---- Chrome plated. Ferox coating
9. a. b.	Connecting Rod Oil Clearance Color Code		0.03-0.09 mm (0.0012- 0.0035 in) 1. Blue, 2. Black, 3. Brown, 4. Green
10.	Crankshaft
a.	Crank Width "A"		A¹ = 56.15 mm (2.21 in) A² = 59.2 mm (2.33 in) A³ = 60.45 mm (2.38 in) A⁴= 56.45 mm (2.22 in)
b.	Assembly Width "B"		341.4 ±0.6 mm (13.44± 0.024 in)
c.	Deflection Limit "C"		<0.04mm (0.0016 in)>
d.	Big End Side Clearance "D"		0.16-0.27 mm (0.006-0.011 in)
e.	Journal Oil Clearance		0.020-0.044 mm (0.0008-0.0017 in)
f.	Color Code _ Corresponding Size Blue		1.5^+0.006_+0.002mm(0.0591^+0.00024_+0.00008in)
	Black		1.5^+0.002_-0.002mm(0.0591^+0.00008_-0.00008in)
	Brown		1.5^-0.002_-0.006mm(0.0591^-0.00008_-0.00024in)
	Green		1.5^-0.006_-0.010mm(0.0591^-0.00024_-0.00039in)
	Yellow		1.5^-0.010_-0.014mm(0.0591^-0.00039_-0.00055in)

11. a. b. c. d. e. f. g. h. i. i	Clutch Friction Plate Thickness/Quantity Wear Limit Clutch Plate Thickness/Quantity Warp Limit Clutch Spring Free Length Minimum Length Primary Reduction Gear Backlash Tolerance Primary Drive Gear Backlash Number Primary Driven Gear Backlash Number Clutch Release Method	3.0 ±0.1 mm (0.12 ± 0.004 in)/8 pcs. <2.8mm (0.11 rn)> 1.6 mm (0.06 in)/7 pcs. < 0.05 mm (0.002 in)> 42.8 mm (1.69 in) 41.8 mm (1.65 in) 118 87-91 27-32 Rack & Pinion pull. Outer pull
12. a.	Transmission Main Axle Run-out Limit	<0.08mm (0.0031 in) >
13. a.	Shifter Shifter Type	Cam drum
14. a. b. c. d. e. f. g. h. j. k, l. m. n. o. p. q. r.	Carburetor Type/Manufacturer/Quantity I.D. Mark Throttle Valve Size Venturi Size Main Jet (M.J.) Main Air Jet (M.A.J.) Jet Needle (J.N.I Needle Jet (N.J.) Throttle Valve (Th.V.) Pilot Jet (P.J.) Pilot Air Jet (P.AJ.) Pilot Screw (turns out (P.S.) Pilot Outlet Size (P.O.) Starter Jet (G.S.) Valve Seat Size (V.S.) Fuel Level (F.L.) Float Height (F.H.) Engine Idling Speed Vacuum Pressure at Idling Speed	BS30/MIKUNI/4pcs. 16G0O 30 mm (1.18 in) 26.4 mm (1.04 in) #127.6(For#1.#4cyl.). #132.6 (For #2, #3cyl.) #70 4DPS39 O-6 (#318) 14° #35 #170 Preset 0.8 #30 1.2 2 ± 1 mm (0.08 ± 0.04 in) 17.5 ± 0.5 mm (0.7± 0.02 in) 1,050 ± 50r/min Above 185 mmHg (7.28 inHg)
15. a. b. c. d. e.	Turbocharger Model/Manufacturer Turbine Diameter Compressor Diameter Maximum RPM. Wastegate Valve	TC0306A/MITSUBISHI 40 mm (01.58 in) 40 mm (0 1.58 in) 210.000 r/min Yes

16.

Lubrication System:

a.
b.
c.

d.
e.
f.
g.

Oil Filter Type
Oil Pump Type
Rotor Thickness
Delivery pump
Turbo scavenger pump
Tip Clearance
Side Clearance
Bypath Valve Setting Pressure
Relief Valve Operating Pressure

Paper filter
Trochoid pump

18⁺⁰_-0.02 mm (0.709⁺⁰_-0.0008 in)
5⁺⁰_-0.02 mm (0.197⁺⁰_-0.0008 in)
0.03 ~ 0.09 mm (0.001- 0.004 in)
0.03~0.08mm (0.01 ~ 0.003 in)
1.0±0.2 kg/cm (14.2 ± 2.8 lb/in)
5.0 ±0.6 kg/cm (7.2 ± 8.5 lb/in)

h. Lubrication Diagram

17.	Middle Gear Backlash	0.1 ~ 0.2 mm (0.0039 - 0.0079 in)
18.	Final Gear Backlash	0.1- 0.2 mm (0.0039-0.0079 in)
19.	Crankcase Tightening Sequence

Tightening torque:

..... 8 mm bolt: 24 Nm (2.4 m-kg. 17.5 ft-lbl

..... 6 mm bole 12 Nm (1.2 m-kg, 8.7 ft-lbl

20. Tightening Torque
Part to be tightened	Part name	Thread size	Q'ty	Tightening torque			Remarks
Part to be tightened	Part name	Thread size	Q'ty	Nm	m-kg	1Mb	Remarks
ENGINE
Cylinder head	Nut	M10 P1 .25	12	36	3.6	25	Apply oil.
Cylinder head cover	Bolt	M6 P1.0	20	1.0	1.0	7.2
Spark plug	-		4	20	2.0	14
Cylinder	Nut	M8 P1.25	2	20	2.0	14	Cam chain case Front & Rear
Cylinder holding bolt	Stud bolt Bolt	M10P1.25 M10 P1.25	7 5	20 20	2.0 2.0	14 14	Apply oil
Cam shaft cap	Bolt	M6 P1.0	20	10	1.0	7.2	Tighten in 3-stages.
Cam sprocket	Bolt	M7 P1.0	4	20	2.0	14
Cam chain tensioner end plug		M11 P1.0	1	15	1.5	11
Cam chain tensioner securing bolt	Bolt	M6 P1.0	2	10	1.0	7.2
Connecting rod	Nut	M7 P0.75	8	25	2.5	18
Generator (rotor)	Bolt	M10 PI .25	1	55	5.5	40
Drain plug	Bolt	M14 P1.5 M8 PI.25	1 1	43 24	4.3 2.4	31 17	Crankcase drain
Oil filter	Bolt	M20 P1.5	1	15	1.5	11
Pump cover	Screw	M6 P1.0		7	0.7	5.1
Strainer cover	Bolt	M6 P1.0	13	10	1.0	7.2
Crankcase	Flange Bolt	M8 P1.25 M6 P1.0	12 27	24 12	2.4 1.2	17 8.7
Clutch boss	Nut	M20 P1.0	1	72	7.2	52
Clutch spring screw	Bolt	M6 P1.0	5	10	1.0	7.2
Change Pedal	Bolt	M6 P1.0	1	10	1.0	7.2
Neutral Switch	-	M10 P1.25	1	20	2.0	14
Exhaust Pipe	Nut	M6 P1.0	8	10	1.0	7.2
Oil cooler	Joint Nut	M22 PI.5	2	45	4.5	32
SHAFT DRIVE:
- Middle Gear -
Drive Shalt	Nut	M34 PI .5	1	110	11	80	Stake.
Mount cover	Screw	M8 PI.25	4	25	2.5	18	Stake.
Driven shaft	Nut	M14 Pl.5	1	120	12	85	Use LOCTITE: Stake
Bearing cap	Flange Bolt	M8 P1.25	4	25	2.5	18
- Final Gear-
Drive Shaft	Nut	M14 P1.5	1	110	11	80
Bearing housing	Flange Bolt	M10 P1.25	2	23	2.3	17
Bearing housing	Nut	M8 P1.25	6	23	2.3	17
Oil mount screw	Plug	M14 P1.5	1	23	2.3	17
Oil drain screw	Plug	M14 P1.5	1	23	2.3	17
Bearing retainer		M65 P1.5	1	110	11	80	Left hand screw

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