EM-38 ENGINE
TIMING GEAR AND CAMSHAFT
Disassembly
<D4AE, D4AF, D4AL>
5
9
4
Damper pulley (for bus)
60kg·m
Disassembly sequence
1. Crankshaft pulley
2. Timing gear case
3. Oil seal
4. Ider gear
5. Idler shaft
6. Camshaft gear
7. Thrust plate NV ... Nominal Valve
8. Camshaft L ... Limit
9. Front plate
CUBEM019
TIMING GEAR AND CAMSHAFT EM-39
<D4DA, D4DB>
T= 30 N·m Injection
(3 kgf·m) pump gear
4 Camshaft
10 18
9
18
5 13
17
7
Oil pump gear Crankshaft gear
13 Injection pump gear
12
16
Crankshaft gear
2 15
11
24 N·m
(2.4 kgf·m) 14
Front oil seal slinger
3 Key
600 N·m 1
(60 kgf·m)
Disassembly sequence
1. Dumper pulley(for bus) 7. Vacuum pump assembly 13. Idler gear assembly
2. Crankshaft pulley 8. Front oil seal 14. Idler gear push
3. Bolt 9. Bearing 15. Idler gear
4. Engine revolution sensor 10. Timing gear case 16. Idler shaft
5. O-ring 11. Bolt 17. O-ring
6. O-ring 12. Thrust plate 18. Power steering oil pump
NOTE
Remove front oil seal and bearing only when it is damaged.
JCW20108
EM-40 ENGINE
Disassembly of Camshaft
<D4DA, D4DB>
12
11
13
10
8 9
2
6
1 7
5
4
3
Disassembly sequence
1. Bolt 8. No.1 Camshaft bush
2. Camshaft assembly 9. No.2 Camshaft bush
3. Bolt 10. No.3 Camshaft bush
4. Camshaft gear 11. No.4 Camshaft bush
5. Thrust plate 12. Seal cap
6. Key 13. No.5 Camshaft bush
7. Camshaft
NOTE
Do not remove camshaft gear when it is not bad. JCW20109
TIMING GEAR AND CAMSHAFT EM-41
1. If the crankshaft pulley flange or crankshaft pulley are hard to
remove, use the special tool(09431-83100)
09431-83100
Crankshaft pulley
D4AF0152
2. Do not remove oil seal unless abnormal condition is evident.
Timing gear case
Oil seal D4AF0153
3. Measurement of backlash
Measure the backlash between gears and replace if the limit is
exceeded.
NOTE
1. For a pair of gears, the backlash must be measured at
more than three points to determine the condition.
2. When measuring the backlash in injection pump gears,
D4AF0153
keep the pump fixed onto the front plate.
4. Measurement of end play
Measure the end play of the idler gear and camshaft with a
thickness gauge or dial indicator. If the measurements exceed
the limit, replace the parts.
D4AF0155
EM-42 ENGINE
5. Removal of camshaft gear <D4AE, D4AF, D4AL>
Thrust plate
attaching bolt
1) Accessing through the holes in camshaft gear, loosen the
thrust plate attaching bolts. Then, remove the gear together
with the camshaft.
Camshaft gear
D4AF0157
<D4DA, D4DB>
Bolt
Camshaft gear
Camshaft
JCW20115
2) To remove, use the special tool(09431-83100).
CAUTION
1. Do not remove the gear unless defect is evident.
2. For removal, never attempt to tap the gear with a
hammer. Plug
09431-83100
D4AF0158
Inspection
1. With the idler gear Inner Diameter(I.D) and idler shaft Outer
Diameter(O.D),calculate the clearance. If the limit is exceeded,
replace the bushing in the idle gear.
D4AF0161
D4AF0162
TIMING GEAR AND CAMSHAFT EM-43
2. Replacement of Idler Gear Bushing Removal Installation
Using the special tool(09246-41000), replace the idler gear
bushing. See illustration for procedure.
09246-41000
NOTE Bushing
1. When installing the bushing, align the oil hole in bush- oil hole
ing with that in idler gear. Idler gear
2. After installation, make sure that the bushing to idler
shaft clearance is within nominal value. If the clear- Idler gear bushing Idler gear oil hole
D4AF0163
ance is below specification, ream the bushing.
3. Measure the base circle diameter and lobe height of each cam.
If the difference between them is below the limit, replace. Measurement point
NOTE
Since the taper cam is used, ensure that the measurement Cam lobe
Front height
is taken at the location indicated in illustration.
A B A B Basic diameter
D4AF, D4AE, D4AL 5.5mm 5.5mm
D4DA, D4DB 6.5mm 6.5mm D4AF4101
4. Measure the camshaft journal Outer Diameter(O.D) and crank-
case Inner Diameter(I.D) If the limit is exceded, replace the
bushing in the crankcase.
D4AF4102
D4AF2398
EM-44 ENGINE
5. Replacement of Camshaft Bushing
Camshaft
To remove the bushing, first remove the sealing cap through bushing
09212-41200
the camshaft hole in the rear-end face of the crankcase. Then,
using the special tool(09212-41200), remove camshaft bushing
1) D4AF, D4AE, D4AL
Bushing No.
(From the Stamped number Outer diameter D4AF0165
front of engine)
No.1 1 ø58.5 Number is stamped here
No.2 3 ø58
No.3 5 ø57
2) D4DA, D4DB
Bushing No.
(From the Stamped number Outer diameter
front of engine)
D4AF0166
No. 1 1 58.5mm
No. 2 2 58.25mm Make camshaft
bushing end face
No. 3 3 58.0mm Camshaft bushing flush with
crankcase
No. 4 4 57.75mm 09212-41200 end face.
No. 5 5 57.0mm
6. When installing the bushing, identify bushings with a unique
Oil hole (ø8)
number stamped on the external surface, indicating the instal- Align with oil
hole in crankcase D4AF0167
lation position.
If the number is illegible, determine by mesuring theInner Diameter
(I.D) and width.
1) D4AF, D4AE, D4AL
Bushing No.
(From the No.1 No.2 No.3
front of engine)
Inner diameter 54.5mm 54.5mm 53mm
Width 41mm 21mm 21mm
Stamped number 1 3 5
2) D4DA, D4DB Unit : mm
Bushing No.
(From the No.1 No.2 No.3 No.4 No.5
front of engine)
Inner diameter 54.5 54.5 54.5 54.5 53
Width 33 21 21 21 21
Stamped number 1 2 3 4 5
Then, using the special tool(09212-41200), press-fit the
bushings.
TIMING GEAR AND CAMSHAFT EM-45
7. Measure the bend of camshaft. If the limit is exceeded, replace.
NOTE
Rotate the camshaft a turn and read the deflection of the
D4DA, D4DB
dial indicator pointer.
One half of the reading is bent.
Standard valve : 0.02 mm(0.0008 in.) or less
Camshaft bend measurement
D4AF0168
Reassembly <D4DA, D4DB>
“F” mark
1. Install the thrust plate with the oil hole for the gear. Washer
Camshaft gear
Thrust plate
Camshaft
CW20-126
2. Installation of Camshaft Gear <D4DA, D4DB> Push
“2”
After mounting the thrust plate, install the camshaft gear with
its number marking side facing outward. Camshaft gear
NOTE
Install camshaft gear after checking the key (D4DA , D4DB Camshaft
Key
engine)
JCW20127
3. Check the camshaft end play. Then, install the camshaft into
the crankcase.
D4AF0172
4. Installation of the idler gear <D4AE, D4AF, D4AL>
Idler gear
When installing the idler gear, keep the surface which is printed Injection pump
Camshaft
gear
numbers on outward and assemble the crankshaft “1”, the cam- gear
shaft “2” and the injection pump “3”.
Camshaft
gear
CUBEM101
EM-46 ENGINE
<D4DA, D4DB>
Idler gear
Camshaft Injection pump
gear gear
Camshaft
gear
CUBEM102
5. Check gears for backlash. <D4AE, D4AF, D4AL>
Oil seal
CUBEM103
6. Apply lithium-base grease to the oil seal lips. <D4DA, D4DB>
Oil seal
CUBEM104
7. Assembly of the timing gear case <D4AL, D4AF, D4AE>
Fix up the case within three minutes after putting a seal on the
ø1mm
assembly-surface as illustrated. Sealant
CAUTION
Do not switch on the ignition within one hour after the
assembly.
CUBEM105
<D4DA, D4DB>
ø1~1.5mm
Sealant
CUBEM106
