35
Servicing Engine
This sub-section is organized to show a thorough pro-
gression of steps to completely service engine compo-
nents. For efficiency, however, it may be preferable to
focus only on those components needing service. Also,
some components may vary from model to model. The
technician should use discretion and sound judgment.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this engine
section.
NOTE: When indicated for use, each special tool
will be identified by its specific name, as shown in the
chart below, and capitalized.
NOTE: Special tools are available from the Service
Department.
Specifications
Description p/n
Ball Hone
Common Tool
Flywheel Puller Kit
0744-083
Piston Pin Puller
Common Tool
V Blocks
Common Tool
Drive Clutch Spanner Wrench
0644-136
Ring Compressor
Common Tool
Spark Plug Tool
TBD
Valve stem seal protective sleeve for a 5.5 mm valve
shaft
Aftermarket Tool
Cam Timing Tool
6 mm square bar
CRANKSHAFT
Connecting Rod (max.)
(small end inside diameter)
18.017 mm
Connecting Rod (big end side-to-side) 0.10-0.30 mm
Connecting Rod (max.)
(rod parallelism upper to lower axis)
0.05 mm
Crankshaft (web-to-web)
(inside cylinder crankcase)
63.950-64.050 mm
0.15-0.30 mm
Crankshaft Runout (max.) 0.03 mm
Crankshaft Main Bearing Play 0.030 to 0.060 mm
Conrod Big End Bearing Play 0.025 to 0.050 mm
VALVES AND GUIDES
Valve Face Diameter (max.) (intake)
(exhaust)
37 mm ± 0.2
32 mm ± 0.2
Valve Guide/Stem Clearance 0.030-0.056 mm
Valve Guide Inside Diameter 5.500-5.012 mm
Valve Head Thickness (min.) 2.7 mm
Valve Seat Angle 45°
Valve Spring Free Length (min.) 30.28 mm ± 0.03 mm
Valve Spring Tension @ 31.5 mm 32.5 mm/180 N ± 9 N
CAMSHAFT AND CYLINDER HEAD
Camshaft Journal Bores at Head 24.005-24.026 mm
Camshaft Journal Outside Diameter 23.970-23.983 mm
Cylinder Head Surface to Cylinder (max.)
Crankcase
0.04 mm
CYLINDER, PISTON, AND RINGS
Piston Skirt/Cylinder Clearance (max.) 0.041-0.074 mm
Cylinder Bore 94.000-94.015 mm
Piston Diameter at height of uncoated
window 9.1 mm from skirt end
93.950 ± 0.009 mm
Bore x Stroke 94 x 86 mm
Cylinder Trueness (max.) 0.02 mm
Piston Ring End Gap — Installed (1st/2nd) 0.35 mm ± 0.15 mm
0.5mm ± 0.25 mm
Piston Ring Groove Width (1st/2nd) 1.21-1.24 mm
1.22-1.24 mm
Piston Ring Thickness (1st/2nd) 1.17-1.19 mm
Piston Pin Bore (max.) 18.005-8.011 mm
Piston Pin Outside Diameter (min.) 17.995-18.000 mm
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