HOW TO USE THIS MANUAL
MAINTENANCE OPERATION EXPLANATION
This manual describes important items for installation, removal, assembly, inspection, repair and failure diagnosis.
Caution:
A general description of a visual inspection and cleaning of disassembled parts has generally been omitted. However, when reusing the parts, make sure to perform visual inspection and cleaning as necessary.
CONFIGURATION COMPONENTS, OPERATION CONTENTS & PROCEDURES
The configuration components, operation contents and procedures are shown after the title of each operation. Preparation standards and important operation points such as parts which can not be used again, tightening torque and lubrication locations are also indicated.
Configuration components & Operation contents
The operations for installation, assembly and disassembly are indicated by the part name. This description is used when the ideal procedure can not be determined or there are many types of components. [Point] is used to indicate the operation procedures which are necessary.
STRUCTURAL PARTS DIAGRAM AND OPERATIONAL SEQUENCE
The name of the parts required for the operations are shown. The operation sequence must be followed in the order shown. Assembly is the reverse of disassembly except when otherwise indicated.
ENGINE OVERHAUL
OVERHAUL CAUTIONS
(1) Disassembly
- Use correct and suitable tools when possible and make sure to carry out safe procedures.
- Care must be taken with operations on mating surfaces and sliding surfaces to prevent loss of surface accuracy.
- Arrange disassembled pars by making marks to organize for easy faults detection and precise assembly.
- Loosen nuts and bolts in a diagonal direction from outside. Care must be taken to follow the numerical order when indicated.
(2) Inspection, repairand replacement
- Replace or repair after completing parts inspection following the inspection procedures. Perform same inspection for the new parts and replace parts as necessary.
(3) Assembly
- Always use a torque wrench to tighten nuts and bolts to specific tightening torque.
- Tighten nuts and bolts from centre to outside diagonal direction, gradually in two or three successive stages. Follow the numeric order when indicated.
- Replace gasket, packing, oil seals and O-rings with new ones in principle.
- Clean each part thoroughly and blown off with compressed air. In particular, check that oil and water passages are not clogged or obstructed.
- Care must be taken not to scratch or damage sliding or mating surfaces. Clean off all dust, debris or foreign objects. Lubricate all sliding surface with an adequate coating oil.