Usage:
1. Group Classification
This manual is organized into several groups classified according to the engine basic elements.
NOTE: Each group starts with page 1.
2. General Precautions for Servicing
Before starting the service procedures, check the vehicle for total time driven, use conditions, and user's complaints and requests to know exactly the engine conditions. Record information where necessary.
To ensure you are doing correct and efficient service jobs, observe the following precautions.
(1) Before performing the service procedures given in this manual, know the trouble spots and isolate the possible cause to determine whether the removal or disassembly procedure is required.
(2) Select a flat surface for the service job.
(3) When servicing the electrical system, be sure to disconnect the negative cable from the battery.
(4) Carefully check parts for oil leaks before cleaning. After cleaning, it may become difficult to spot defective areas.
(5) Ready and make the most of the special tools required for servicing. Use the right tools (specified special tools) in the right place to prevent damages to parts and personal injury.
(6) Make alignment marks and keep disassembled parts neatly arranged to ensure that they are reassembled into the right positions.
- * Special care must be taken for assemblies involving a number of parts, similar parts, or parts identical at right- and left-hand sides to ensure correct reassembly.* For alignment and punching markings, select a position that would not mar the appearance and function.* Clearly distinguish parts to be replaced from those reused.
(7) The oil seals, packings, O-rings, and other rubber parts, gaskets, and split pins must be replaced with a new one whenever they are removed.
(8) Apply the specified grease to U-packings, oil seals, dust seals, and bearings before installation.
(9) When work requires an assistant or two, always make sure of the safety each other. Never play with switches and levers.
(10) Make sure that your shoes are free from grease and oil especially when working on a heavy item.
(11) When checking or changing lubricants, wipe off grease and oil from parts immediately with a waste.
(12) Special care must be taken in handling sensors and relays which are suspectible to shocks and heat.
(13) Use care so that hands and fingers are not injured by sharp edges or corners of the parts.
(14) Wear safety goggles whenever handling a grinder or welding machine. Wear gloves as required to ensure utmost safety.
3. Terms and Units
The following terms and units are used throughout the entire tests of this manual.
(1) Front and Rear
The terms "front" is the fan side and "rear" the flywheel side of the engine.
(2) Right and Left
The terms "right" and "left" shall be used to indicate the side as viewed from the flywheel side of the engine.
(3) Service Standard Terms
* Nominal value
Shows the nominal dimensions, dimension of an individual part, standard clearance between parts in an assembly, or the standard performance of an assembly.
* Limit
Shows the value of a part at which the part is no longer serviceable from the performance as well as strength viewpoints, requiring replacement or repair.
(4) Tightening Torque
Over- or undertightening of bolts and nuts has critical effects on performance and functions. Tightening torque is therefore specified for some tightening points.
All tightening torque specifications may be considered as "dry" unless "wet" is specified.
Where no tightening torque is specified, use a torque value specified in the general bolts and nuts tightening torque table.
(5) Units
For length, weight, area, and volume, the SI unit (International System of units) is used with the metric notation jointly shown in parentheses.
Temperature is shown in centigrade (°C).
4. Table of Conversion Rate for Foot-pound Units into SI Units
5. Reading the Illustration
(1) Illustrations (exploded views and assembly drawings) show a typical service procedures if it is identical among various types of available systems and units.