Haima S5 1.5T. Service Manual - part 3

 

Engine block 1A-29 

 

 

 

 

3.  Mark every bolt head.   

4.  According to the bolt-tightening sequence 

(Step 2) illustrated in the figure, 

Each bolt 

with a reference mark, rotated by 90 °, then 
rotated 90 °.

 (see the figure).   

 

Explanations on the camshaft mounting   

Notice 

 

Since the camshaft’s mounting clearance is 

small, make sure that the camshaft journal is 
closely attached to the bearing seat during the 
mounting process, or the contact surface 
between the shaft and bearing will incur 
excessive pressure and in turn suffer damage. 
To avoid foresaid situation, regulations below 
shall be observed:   

1.  Smear some oil onto the camshaft journal and 

bearing seat.   

2.  Mount the camshaft into camshaft bearing 

seat, making camshaft journal closely 
attached to the bearing seat.   

3.  Mount the camshaft bearing cover onto 

corresponding journal according to the 
sequence.  

4.  Tighten the bolts according to the sequence 

illustrated in the figure: first, tighten every 
camshaft cover bolt, and then tighten the front 
camshaft bearing cover bolt.   

 

Explanations on the VVT mounting   

1.  Rotate the camshaft to make the dowel pin 

keep upward.   

2.  Smear some oil onto the VVT assembly’s 

inserting part, align the VVT assembly 
location hole to the camshaft dowel pin, and 
mount the VVT assembly slowly.   

3.  Lock the camshaft’s hexagon part with a 

wrench (see the figure), so as to tighten 
VVT’s fixing bolts.   

 

 

Paint mark place 
after Step 4 

Initial paint mark

VVT assembly location 
hole (align camshaft 
dowel pin) 

VVT assembly 
inserting part (smear 
some oil around) 

 

Engine block 1A-30 

 

1.10.2 Valve Mechanism Dismantling/ 
Mounting 

1.  Dismantle cylinder head(see the cylinder head 

dismantling).  

2.  Dismantle parts according to sequence 

illustrated in the figure. .   

3.  Mount the parts according to the sequence 

reverse to the dismantling process.   

 

 

   

1 

Valve Half (see dismantling/mounting 
explanations) 

2 

Valve spring upper seat   

3 

Valve spring (see the mounting 
explanations) 

4 

Valve spring lower seat   

5 

Valve (see the mounting explanations)

6 Valve 

oil 

seal 

 

Explanations on dismantling of valve 
keeper 

Use special tool valve spring pressure, remove the 
valve keeper. 

 

Explanations on inspection of valve 
clearance 

1.  Dismantle the cylinder head hood (see 

cylinder head hood dismantling part).   

2.  Confirm if the engine has been cooled.   

3.  Measure valve clearance.   

(1)  Rotate the crankshaft along the clockwise 

direction, making the piston located at the 
stopping place on No.1 Cylinder, namely, gas 
distribution mark shall be adjusted to the 
position indicated in the right figure.   

       

 

 

(2)  Use plug gauge to measure valve clearances 

of all cylinders at Mark A indicated in the 
figure.  

 

★

  Note:If the valve clearance exceeds the 

standard value, replace the tappet(see the 
valve clearance’s adjustment)valve 
clearance’s standard value (when engine is in 
cooling state): 

 

Engine block 1A-31 

 

Intake:0.18～0.26mm 
Exhaust:0.26～0.34mm 

(3)  Rotate the crankshaft for 360 degrees along 

the clockwise direction, making the piston 
located at the stopping place on No.4 
Cylinder, namely, gas distribution mark shall 
be adjusted to the position indicated in the 
figure below.   

 

(4)  Use plug gauge to measure valve clearances 

of all cylinders at Mark B indicated in the 
figure above.   

★

  Note:If the clearance exceeds standard value, 

tappet shall be replaced(see the valve 
clearance’s adjustment) 

Valve clearance’s standard value (when the engine 
is in cooling state): 

ON:0.18～0.26mm 

OFF:0.26～0.34mm 

4.  Mount cylinder head hood (see the timing 

chain, cylinder head hood mounting part).   

Explanations on the valve clearance’s 
adjustment  

To adjust the valve clearance, operation steps 
below shall be observed: 

1.  Dismantle camshaft (see the camshaft 

dismantling part).   

2.  Take out the tappet at the place where the 

valve clearance shall be adjusted.   

3.  Select an apposite tappet. New tappet’s 

thickness =old tappet’s thickness + measured 
valve clearance － standard valve clearance. 
(standard valve clearance: ON, 0.22mm; OFF, 
0.30mm) 

4.  Mount the selected tappet into the tappet hole.   

5.  Confirm the valve clearance again (see valve 

clearance, valve clearance inspection).   

 

Notice: 

  If the valve clearance will be adjusted when 

there is not timing chain, make the crankshaft 
dowel pin towards side face, in order to 
prevent the valve from colliding with the 
piston top during the valve clearance 
adjustment process.   

  Mark the tappet thickness inside the tapper 

with 3 digits, see figure below:   

 

 

1.10.3 Cylinder Head Inspection /Repair   

 

 

1.  Inspect the cylinder head’s defect. If 

Thickness mark

 

Engine block 1A-32 

 

necessary, replace the cylinder head.   

2.  Inspect the following items, repair and 

replacement shall be conducted if necessary.   

(1).  If there is indentation at the valve seat.   

(2).  If the camshaft journal clearance and end gap 

is excessive.   

3.  Use the Straight Edge Ruler and plug gauge 

to inspect if the cylinder head is distorted 
along six directions, see the figure.   

Maximum distortion:

 0.03mm 

4.  If the cylinder head’s distortion exceeds the 

maximum value, inspect the cylinder head’s 
height. If the height stays beyond the standard 
value, replace the cylinder head.   

Standard height:112.9-113.1mm 

5.  If the cylinder head’s distortion exceeds the 

maximum value, and the height stays within 
the standard value, grind the height or replace 
the cylinder head.   

Maximum grinding volume:0.20mm 

6.  Use the Straight Edge Ruler and plug gauge 

to measure the cylinder head intake/ exhaust 
manifold flange’s distortions along different 
directions, see the figure.   

Maximum distortion: 

0.15mm

 

 

 

7.  If the distortion measured in Step 6 exceeds 

the maximum value, grind the surface or 
replace the cylinder head.   

Maximum grinding volume: 0.20mm 

1.10.4 Inspection of Valve and Valve 
Guide 

1.  Measure thickness of every valve’s head rim. 

If necessary, replace the valve. 

Standard thickness: intake valve: 1.35mm; exhaust 
valve: 1.85mm.   

Minimum thickness: intake valve: 0.85mm; 
exhaust valve: 1.35mm.   

 

2.  Measure every valve’s length. If necessary, 

replace the valve.   

Standard length   

Intake valve:

89.51～90.01mm

 

Exhaust valve:

90.69～91.19mm

 

Minimum length   

Intake valve: 

89.31mm 

Exhaust valve: 

90.49mm

 

 

3. Measure every valve’s rod diameter 

respectively at A, B, C point (see the figure) 

Brim th

ic

knes

s

 

Engine block 1A-33 

 

along X and Y direction. If necessary, replace 
the valve.   

Standard diameter 

Intake valve: 4.965～4.980mm 

Exhaust valve: 4.955～4.970mm 

Minimum diameter 

Intake valve: 4.915mm 

Exhaust valve: 4.905mm 

4.  Measure every valve guide’s inner diameter 

respectively at A, B, and C point along X and 
Y direction (see the figure). If necessary, 
replace the valve guide.   

Standard inner diameter 

Standard:5.0～5.012mm 

 

5.  When there is not valve spring’s lower seat, 

measure every valve guide’s extrusion height 
(Size A). If necessary, replace the valve 
guide.  

Standard height:12.7～13.3mm 

   

1.10.5 Explanations on inspection of valve 
seat 

1. S

urface painted with a method to measure the 

valve seat contact width. If necessary, use a 44 
° valve seat cutter reworked valve or valve 
seat surface. 

     

Standard width: 1.1 ~ 1.5mm 

 

2. 

Check valve seat depression. Measure the 
valve stem projecting length (size L). If 
necessary, replace the cylinder head.   
Standard size L 

Intake: 38.16 ~ 38.76mm   
Exhaust: 38.16 ~ 38.76mm 

 

1.10.6 Explanations on inspection of valve 
spring 

1.  Use the special tools to exert pressure on the 

valve spring, and inspect the spring height. If 
necessary, replace the valve spring. Exert 
pressure on the valve spring, and compress 
the spring to a given height, when the 
pressure value exceeds the specified range, 
the valve spring shall be replaced.   

When the height is 33.4mm, the pressure is 142.2～
161.8N{14.51～16.51kgf}; 

When the height is 24.9mm, the pressure is 
293.4～324.4N{29.94～33.10kgf}.  

2.  Measure the valve spring verticality, and if 

the verticality goes beyond the standard, the 

Valve guide

Cylinder head 

 

Engine block 1A-34 

 

valve spring shall be replaced.   

Valve spring’s maximum verticality:1.50mm 

 

1.10.7 Explanations on the inspection of 
camshaft 

1.  Place the camshaft’s No. 1 and No. 5 journals 

onto the V-shaped block to measure the 
camshaft’s radial run-out. If necessary, 
replace the camshaft.   

Radial run-out: 0.03mm 

 

 

2.  Measure heights of the two convex parts (see 

the figure). If necessary, replace the camshaft.   

Standard height   

Intake side: 

44.5mm

 

Exhaust side: 

43.8mm

 

Minimum height   

Intake side: 

44.2mm

 

Exhaust side: 

43.5mm

 

 

3.  Measure the journal diameter respectively at 

A and B point along X and Y direction. If 
necessary, replace the camshaft.   

Standard diameter:

25.945～25.96mm

 

Minimum diameter: 

25.915mm

 

 

4.  Dismantle the tappet, and measure camshaft 

journal clearance according to steps below: 

(1). Remove all oil on the journal and bearing 

seat’s internal surface.   

(2).  Put the camshaft into the bearing seat.   

(3). Make the plastic gauge match the bearing 

width (see the figure), and then put it on the 
top of journal along the axial direction.   

(4).  Mount the camshaft cover (see cylinder head 

dismantling/mounting, camshaft mounting 
attentions).  

 

Notice 

Point A

Point B 

Axial direction 

Plastic gauge 

 

Engine block 1A-35 

 

  When measuring the clearance, do not rotate 

the camshaft 

(5).  Dismantle camshaft cover (see cylinder head 

dismantling/mounting, camshaft dismantling 
attentions).  

(6). Use the scale on the plastic gauge bag to 

measure the widest point on the plastic 
gauge’s extruded part, and then calculate out 
the journal clearance.   

If necessary, replace the cylinder head and 
camshaft cover.   

Standard journal clearance:0.040～0.076mm 

 

5.  Mount the camshaft cover (see cylinder head 

dismantling/mounting, camshaft mounting 
attentions).  

6.  Mount the dial gauge, push camshaft forward 

or backward at the end of camshaft (see the 
figure), and measure the camshaft end gap. If 
necessary, replace the cylinder head or 
camshaft.  

Caution 

  Do not push the camshaft at the cam part, so 

as to prevent the cam from being damaged.     

Standard end gap:0.08～0.20mm 

Maximum end gap:0.21mm 

 

1.10.8 Explanations on inspection of 
tappet hole and tappet 

1.  Measure every tappet mounting hole’s inner 

diameter respectively at A and B Point (see 
the figure) along X and Y direction.   

Standard inner diameter:31.000～31.025mm 

 

2.  Measure every tappet’s diameter respectively 

at the A and B point (see the figure) along X 
and Y direction.   

Standard diameter:30.964～30.980mm 

 

3.  Calculate the clearance between tappet and 

corresponding tappet hole. If necessary, replace 
the tappet or cylinder head.   

Standard clearance:0.020～0.061mm 

Maximum clearance:0.180mm 

 

 

 

 

 

 

Engine block 1A-36 

 

1.11 Flywheel, clutch 

 

1.11.1 Flywheel and Clutch Dismantling/Mounting 

1.  If the crankshaft’s back cover needs to be dismantled, oil sump body shall be dismantled at first (see 

lubricating system, oil sump body dismantling and mounting).   

2.  Dismantle parts according to sequence illustrated in the figure. .   

3.  Mount the parts according to the sequence reverse to the dismantling process.   

 

 

 

 

1 

clutch pressure disc 

(see dismantling explanations/see mounting explanations) 

2 

Clutch friction disc (see dismantling explanations/see mounting explanations) 

3 

flywheel 

(see dismantling explanations/see mounting explanations) 

4 

Crankshaft’s back cover 

(see the rear oil seal dismantling explanations /see rear oil seal 

mounting explanations /see mounting explanations) 

5 Transmission’s 

baffle 

plate 

 

 

 

 

 

 

 

Engine block 1A-37 

 

1.11.2 Explanations on Clutch Pressure 
Disc/Friction Disc Dismantling   

1.  Use the special tools to lock the flywheel, and 

locate the clutch(see the figure).   

2.  Loosen the bolt in a disposable manner 

according to the sequence of right-angled 
intersection till the diaphragm spring’s 
pressure is released.   

3.  Dismantle the clutch pressure disc and 

friction disc.   

 

Explanations on flywheel dismantling   

1.  Use the special tools (see the figure) to lock 

the flywheel.   

2.  Follow the right-angled intersection sequence 

to evenly dismantle the mounting bolt (see the 
figure), and dismantle the flywheel.   

 

Explanations on Rear Oil Seal 
Dismantling/Mounting 

1.  Use the screwdriver, wrapped with protective 

cloth, to dismantle the oil seal(see the figure) 

Notice 

  Normally, there is no need to dismantle the oil 

seal, unless being replaced.     

2.  Add clean oil onto the oil seal opening.   

3.  Mount the oil seal with hands.   

4.  Use the special tools and hammer to compress 

the oil seal.   

Compression depth:0～0.5mm 

 

 

 

Explanations on the crankshaft’s back 
cover mounting   

1.  Smear evenly sealant onto indentation of the 

crankshaft’s back cover (see the figure). 

Sealant diameter:Φ1.5～Φ2.5mm 

 

Explanations on the flywheel mounting 
/inspection  

1.  Mount the flywheel onto the crankshaft.   

2.  Clean the thread and hole before mounting the 

bolt.  

3.  Smear evenly the sealant onto the thread.   

Notice 

  There is no need to smear the sealant when 

using new bolt 

 

4.  Tighten the flywheel bolt with hands.   

5.  Mount special tools onto the flywheel (see the 

figure).  

6. Follow the sequence of right-angled 

Protective 
cloth 

Smear sealant 

Clutch plate setting tool 

Gear ring fixture unit

Gear ring fixture unit

 

Engine block 1A-38 

 

intersection to tighten the flywheel bolt little 
by little.   

 

7.  Mount the dial gauge onto the cylinder body.   

8.  Rotate the flywheel and measure the 

flywheel’s end-on circle run-out. If it exceeds 
the standard, replace the flywheel.   

Maximum end-on circle run-out:0.13mm 

 

1.11.3 Explanations on the clutch friction 
disc inspection /mounting   

Use the vernier caliper to measure rivets on both 
sides and the friction disc surface’s depth.   

If it exceeds the standard, replace the clutch 
friction disc 

Minimum depth:0.3mm 

 

Use the dial gauge to measure the clutch friction 
disc’s end-on circle run-out.   

If it exceeds standard, replace the clutch 
friction disc 

Maximum end-on circle run-out:0.7mm 

 

Use the special tools to secure the clutch friction 
disc’s position (see the figure).   

 

1.11.4 Explanations on the clutch pressure 
disc inspection/mounting 

1.  Measure the diaphragm spring’s abrasion.   

If it exceeds standard, replace the clutch 
pressure disc 

Maximum height: 0.6mm 

 

2.  Use the Straight Edge Ruler and plug gauge 

to measure the pressure disc’s flatness.   

If it exceeds standard, replace the clutch 
assembly.  

Maximum clearance: 0.05mm 

Gear ring fixture 
unit 

Clutch disc 
locator 

 

Engine block 1A-39 

 

 

3.  Use the special tools to lock the flywheel, and 

locate the clutch(see the figure).   

 

4.  Follow the right-angled intersection sequence 

to evenly tighten bolts.   

5.  Mount the dial gauge onto the cylinder body, 

and rotate the flywheel to inspect the 
diaphragm spring’s radial run-out.   

If it exceeds standard, replace the clutch 
pressure plate 

Maximum radial circle run-out:0.6mm 

 

1.12 Cylinder body, Crank 
Connecting Rod Mechanism   

1.12.1 Cylinder Body, Crank Connecting 
Rod Mechanism Dismantling/Mounting 

1.  Dismantle the cylinder head (see the cylinder 

head part), oil sump, oil pump, and timing 
chain case assembly (see lubricating system 
part) and crankshaft’s back cover (see 
flywheel, clutch part).   

2.  Dismantle parts according to sequence 

illustrated in the figure. .   

3.  Mount parts according to the sequence 

reverse to the dismantling process.     

 

 

 

1 

connecting rod 
cover (see the 
mounting 
explanations) 

7 

connecting rod 

2 

connecting rod 
bearing  

8 

Main bearing cover 
(see the mounting 
explanations) 

3 

piston ring(see the 
mounting 
explanations) 

9 thrust 

bearing 

Clutch disc setting tool

Gear ring fixture unit

Smear oil 
before 
mounting 

⑩

Smear oil 

before 
mounting 

②

Smear oil 

before mounting

 

Engine block 1A-40 

 

4 

Piston pin retainer 

10 Crankshaft 

bearing 

5 

Piston pin (see the 
mounting 
explanations) 

11 

Crankshaft 

6 piston 

12 

Cylinder 

body 

Explanations on connecting rod cover 
dismantling  

Inspect the connecting rod end gap (see connecting 
rod inspection part).   

Explanations on piston pin dismantling   

1. The piston pin retainer with the tool removed. 

2.Hand push the piston pin, which was pushed out.     

Explanations on main bearing cover 
dismantling  

1.  Inspect the crankshaft end gap (see the 

crankshaft inspection /repair part).   

2.  Loosen the main bearing cover’s bolt 

according to steps illustrated in the figure.   

 

Explanations on the crankshaft 
dismantling  

Inspect the main journal clearance (see the 
crankshaft inspection /repair part).   

Explanations on the main bearing cover 
mounting  

1.  Measure every bolt’s length. If the length 

exceeds the standard value, replace the bolt.   

Standard length: 74.15～74.85mm 

Maximum length: 75.05mm 

 

2.  Tighten main bearing cover’s bolt to specified 

torque by steps according to the sequence 
illustrated in the figure, as well as mark every 
bolt head. Tightening torque:

33 ～

37N·m{3.357～3.784kgf·m} 

3.  according to the bolt-tightening sequence 

(Step 2) illustrated in the figure, rotate every 
bolt for 60°～64° from the mark.   

 

Explanations on the piston pin mounting   

1. Removing the piston, piston pin into the ring at 

one end. 

2. The clean oil applied to the piston pin. 

3. Place the piston and connecting rod to press-fit 

the stage, piston "→" on the mark side and 
the link "HMA" or logo side, as shown. 

4. The piston pin into the piston, connecting rod 

assembly, to be assembled in place, on the 
other side of the piston pin into the piston 
rings. 

Explanations on the piston ring mounting   

1.  The following figure, the first spiral spring 

loaded oil ring body support groove Connect 
with the latch pin connector.     

2. The oil ring was placed in an oil ring groove. 

3. The support spring connectors and oil ring body 

openings staggered 180 °. 

 

Engine block 1A-41 

 

 

 

4.  Use the piston ring dilator to mount the No. 2 

and No.1 piston ring. 

5. Keep the marker side upward during the 

mounting process.   

6.  Align all rings’ opening locations (see the 

figure).  

 

Explanations on piston connecting rod 
assembly mounting   

1. 

Pistons forward flag "          " for the front of 
the engine. 

 

 

Explanations on the connecting rod cover 
mounting  

1.  The bolt can be reused, but when the outer 

diameter difference at the two points 
illustrated below exceeds 0.1mm, the bolt 
shall not be further used.   

 

2.  Tigthen the connecting rod bolt to specified 

torque by steps according to the sequence 
illustrated in the figure.   

Tightening torque:

18.0 ～ 22.0N·m{1.84 ～

2.45kgf·m} 

 

3.  Mark every bolt head.   

4.  According to the bolt-tightening sequence 

(Step 2) illustrated in the figure, rotate every 
bolt for 90°～94° from its marker.   

1.12.2 Cylinder Body Inspection /Repair   

1.  Use the Straight Edge Ruler and plug gauge 

Piston ring dilator 

Outer 

diam

eter  

Outer 

diam

eter  

    In 

Front

Row

 

Engine block 1A-42 

 

to measure the distortion on the cylinder 
body’s upper surface along six directions 
illustrated in the figure.   

Cylinder body’s maximum distortion:0.1mm 

 

2.  If the distortion on the cylinder body’s upper 

surface exceeds the maximum value, inspect 
the cylinder body’s height. If the height stays 
beyond the standard value, replace the 
cylinder body.   

 

Cylinder body 

Standard height:204.95～205.05mm 

3.  If the cylinder body’s distortion goes beyond 

the maximum value and the height stays 
within the standard value, grind the height or 
replace the cylinder body.   

 

Maximum grinding volume: 0.20mm 

4.  Use the inside dial indicator to measure the 

cylinder’s inner diameter at the place 60mm 
away from upper surface along the X and Y 
direction (see the figure).     

 

5.  If the cylinder’s inner diameter goes beyond 

the abrasion limit, replace the cylinder body, 
and install the corresponding piston, in order 
to make it accord with the standard clearance 
between piston and cylinder. Abrasion limit: 
0.135mm 

Size Diameter 

Standard 

74.8～74.815 

1.12.3 Piston, Piston Ring, and Piston Pin 
Inspection  

1. Along the vertical direction of piston pin hole’s 
axial line, measure the piston’s diameter at the 
place that is 19.38mm below the lower rim of the 
oil control ring groove   

 

Piston diameter 

   (mm) 

Size Diameter 

Standard 

74.7625～74.7775 

Calculate the clearance between piston and 
cylinder. If necessary, replace the piston.   

Standard clearance

:0.0225～0.0525mm

 

Maximum clearance: 0.10mm 

2.  If replacing the piston, piston ring shall be 

replaced as well.   

Cylinder body’s upper surface 

 

Engine block 1A-43 

 

3.  Use the plug gauge to measure the clearance 

between piston ring and ring slot along the 
entire perimeter (see the figure). If necessary, 
replace the piston and piston ring.   

 

Standard clearance 

Ring 1:   

0.040～0.085mm

 

Ring 2:   

0.030～0.070mm

 

Oil ring: 

 0.020～0.060mm 

Maximum clearance   

Ring 1, Ring2:    0.15mm 

Oil ring:  0.15mm.  

4.  Put the piston ring into cylinder with hands, 

and use the piston to push the piston ring to 
the bottom of the cylinder bore stroke.   

 

5.  Use the plug gauge to measure every piston 

ring’s opening clearance. If necessary, replace 
the piston ring.   

Standard opening clearance: 

Ring 1: 

 0.20～0.35mm

 

Ring 2:   

0.40～0.60mm

 

Oil Ring:   

0.20～0.40mm

 

Maximum opening clearance:1.0mm 

6. Respectively at A, B, C, and D point along X 
and Y direction, measure every piston pin hole’s 
diameter.  

Standard diameter:

17.996～18.000mm

 

 

7. Respectively at A, B, C, and D point along X 
and Y direction, measure every piston pin’s 
diameter 

Standard diameter:

18.004～18.010mm

 

 

8. Calculate out the clearance between piston pin 
and piston pin hole. If necessary, replace the piston 
or piston pin.   

Standard clearance:

0.004～0.014mm 

9.  Measure the connecting rod’s small head 

diameter (see connecting rod inspection), and 
calculate the clearance between connecting 
rod’s small head and piston pin. If necessary, 
replace the connecting rod or piston pin. 
Standard clearance:

-0.010～-0.027mm.

 

1.12.4 Connecting Rod Inspection   

1.  Use the plug gauge to measure the connecting 

rod’s end gap. If necessary, replace the 
connecting rod and connecting rod cover.   

 

Engine block 1A-44 

 

 

Standard clearance

:0.10～0.30

mm 

Maximum clearance:0.40mm 

2.  Measure the crank pin journal clearance 

according to steps below.   

(1). Remove all oil on the journal and bearing 

seat’s internal surface. 

(2). Make the plastic gauge match the bearing 

width and then put it on the top of journal, 
keeping parallel with the axial line.   

(3).  Mount the connecting rod cover (see piston 

and connecting rod mounting part).   

(4). Dismantle the connecting rod cover’s bolt, 

and slowly take off the connecting rod cover.   

(5). Use the plastic gauge scale to measure the 

widest point on the plastic gauge’s extruded 
part, and then calculate out the journal 
clearance. If the clearance exceeds the 
maximum value, replace the crankshaft and 
corresponding connecting rod bearing to 
ensure the standard clearance.   

Standard clearance

:0.024～0.056mm 

 

Maximum clearance:0.10mm 

Rod bearing matching table            mm 

Crank pin diameter  Rod bearing thickness

φ43.979～φ43.986

blue 

1.489～1.494

 

φ43.986～φ43.993

yellow 

1.486～1.491

 

43.993～φ44.000

 

red 

1.483～1.488

 

3. As shown in X and Y direction of each of the 

connecting rod small end diameter 
measurement. 

Standard diameter:

 18.010～18.023mm 

 

 

 

1.12.5 Inspection of Piston Connecting 
Rod Assembly   

Inspect the swaying torque (see the figure). If the 
big head fails to drop down by virtue of its own 
weight, replace the piston or piston pin.   

 

1.12.6 Crankshaft Inspection /Repair   

1.  Mount the dial gauge, use the screwdriver to 

push the crankshaft frontward and backward, 
and measure the crankshaft end gap (see the 
figure). If the end gap surpasses the maximum 
value, replace the thrust bearing or crankshaft 
to fit the standard end gap.   

Drop down by virtue 
of its own weight