DA4G13-.6L/DASGI8-6L conbestng 8] nea] G) PutSST ( tools ) into piston pin then fix the (4) When install piston and connecting, ther fro TENO42 Smmu mre eens B aide sleeve A TENO#3 (5) Pat engine ol on the piston pin outer circular. (6) Start from guide sleeveA, pur guide sleeve A. piston pin,SST pressure into pistons front mark side. (1) Screw guide sleeve B into guide sleeve A,the distance between the two is 3mm plus L. Engine Check And Repair Manual ‘puide sleeve A (t00ks). wnt mark should be inthe same side (8) Inthe condition that the piston front mark is down,put piston and co-rod onto the ston pin pedestal (9) Use the pressure machine to install piston.If the loading pressure is out of rules,you should should chang the piston pin.piston assy Standard No: 1000+ 500 kg « f “11 and co-rod,or change the both.DA4G13-.6L/DASGI8-6L Engine Check And Repair Manual ses guide seve B > B 4 the assembing of oil ring 7ENO90 (1) Put oil ring into piston ring.then fix the above and underside steel slice ring, steel sie Hing Ring 8 1enoo77 Notice: 1. Ring and steel slice ring may be fixed various directions.there are no difference between the above and underside steel slice ring, 2, The color code of the ring and steel slice ring as follows: Size Colour Sundard Ne. Tnorease 050mm Blue Inorease 100mm Yellow (2) In order to assemble steel slice ring,put one side of slice ring into the slot, then press other parts to its position. -72-DA4GI3-6L/DA4GI8-6L. Engine Check And Repair Manual Stet plat ring side surice Notice: Do not use piston ring dilator to install steel ring.or they will be break. (3) Alter fixing up the steel slice ring,check whether they can move smooth toward two directions. >C4_ The fixing of second piston ring/tirst piston Use piston expansion machine, fix up the secondpiston ring and! first piston ring, their recognized mark should be upward(at the top side of piston) recognized mark: First piston ring : 1 ‘Second piston ring: 27 piston ing dilator Ennis Notice: The piston ring is engraved the following size mark: ‘Size ‘Size mark ‘Standard No Increase 0.50mm 50. Tnerease 1.0mm 100 Preagia mark “21 eunie mk mesure nk te De The assembling of piston and connecting assy (1) Put engine oil onto the piston, piston ring and piston pin. (Q)AS the pic shows,aims at the air ring and oil ring's openings. -73-DA4G13-6L/DA4GI8-6L. Engine Check And Repair Manual te ~y ae + ito in VN 2at ing and ete te sng cose (Gy Ria te piston one eran markt te Teter sepress the piston anil connsting assy imo sy tinder atthe hea of slider (4) Use proper piston rng pressure tools pes the ring Kght.then press the piston and connecting tngether into the pliner Do not kml piston witha ch foreeor te piston ing ni cack ald connec aes Ne the cache PE The assembling of cone bearng bush Please confirm the rast shown as plcture al the Mente mark onthe con-odseles Dearing bush ss fllowing. Crnkshatt ently mark | Con-rod Wentily mark Dearing bash identify mark] White 1. Yellow No ‘Yellow White No ‘Yellow White No. Yellow -74-DA4G13-.6L/DASGI8-6L Engine Check And Repair Manual cok postion No. , 3 Noe recognizable mark postion . Not 4 oor joe ° ar pa one recognizable color eno = “Sa teNo402 >F4 The assembling of connecting rod cover (1) Aims the mark when disassembling, put the con-rod axes cover onto the connecting, If the con-rod is new,no mark,then must make axes cover lock up gap at the same side. a5DAGGI3-GL/DASGI8-6L Engine Check And Repair Manual slider NO. lock gap DeNoos (2) Check whether the con-rod big part side gap is accord with rules. Standard :0.10.0.25mm > G4 the assembling of con-rod nut Notice : If you have fix up the cylinder cover before fixing the con-rod nut,then you should knock down the spark plug. (2) Use the con-rod bolt and nuts plastic distortion stretcl-tight way to screw down , ‘you must check whether the bolt is seratched when use it suse hand to screw down the nut to pass. ‘Through the whole length of screw thread when nut can Wrest smoothly, it shows there is no cut in the screw thread part, or you will change bolt. (2) before assembling the nut, spread to engine oil onto it's screw thread and the bottom . () put the nut omto the bolt, use finger screw them tightly, after this you must screw nut tight, alternately 10 make sure the right assembling way of con-rod cover. (4) The nut tighting moment is 16.7 + 2.0NM. (5) As the picture show make the painting mark at each nut's top. T int fark % (6) From the ping mark in mt to lock-wisedieston 90° —94* make the pnkng mark at the bolt (9) Revolving nut the paki mark of olin atthe pining math of nul, NOTICE: (D if he revolving angle i ss than 90+ the comectng cover i ack of ighinss, @ I te revolving angle s more tan 94” ,oF you shut lose them and ressrew them according to the stp above. -16-DAAGL. /DASGI8-6L. Engine Check And Repair Manual 7.3.10 Crankshaft and cylinder block Hien oe \ 5 Xn ohn oN zn ‘Assembly and disassembly step: 1. flywheel bolt 7. lower protect board B13. main axes cover (lower) 3. flywheel »D4 8. crankshaft rear oil sal 14, crankshaft 6. upper protect board 9. crankshaft rear oil eal body BAIS. main axes covex{upper) > C4 11. axletree cover bolt *C-412.main axes axletree cover. A> A416, engine oil pressure starter 17. eylinder block. encore Disassembling essentials: 4 Ap engine oil pressure starter's disassembling (1). take off the engine oil pressure port. (Q). use special tool to disassembling engine oil pressure starter -T1-DA4G13-6L/DA4GI8-6L. Engine Check And Repair Manual sy -rwveons NOTICE: there is seal on the screw thread, please do not bend it when you knock down engine oil pressure starter. >A The assembling of engine oil pressure ,paint seal glue onto the screw thread ,then use special tool to assemble the engine oil pressure start as the picture show. Mpeo8ose i \ ‘push direction The ordered teal glue Notice : 1. when paint seal glue ,do not make glue crush out of screw thread, 2. please do not screw engine oil pressure starter tightly .moment:15-22Nm > B4 the assembling of crankshaft cover (2) According to recognizable mark of crankshaft or color size ,choose axes cover (refer to the following table ) if they can not recognize .you should measure crankshaft diameter, and choose the correlative axes 10 match it, Crack shaft and shaft neck Anke cover range | Color] Recowaie | grat nek 's camer econize mark T 47.995 ee 7395, 2 3 47.988 = 2 |aanaic | 2 Bie) 3 r 47.982 . 3 [Mics 3 ae. t -78-DA4G13-6L/DA4GI8-6L. Engine Check And Repair Manual WK vaso Diamser fran} lane fron 2 frst main darter of shat 12323 Lutt iets Thin in a Sveth ain ameter sat t. arr | series crack shaft amor |series crack shaft Tiina bene coli block shat La} mect’s hole diameter ENO505, From front to behind 5. 4, 3, 2. 1 cylinder diameter of shaft grade 2) mean cylinder block bearing shell hole diameter identity code is carved on the shown position by front no. lof engine ,must select and install shaft shell based on these identity code, -79-DA4G13-6L/DA4GI8-6L. Engine Check And Repair Manual tenoao2 ). based on step (1) and step (2) checking identity code ,select shaft shell from above table For example 1. if checked shaft neck is 48.00mm ,it is equal to first classification of above table. 2. if idemtity code of eylinder shaft shell is then select shaft shell with identity code 2. (4). except middle shaft shell, all upper bearing shell have slots ,middle shaft shell has supporting convex edge upper and below of middle shaft shell is same (5). All below shat shell has no slot. ‘wth slot without shoe upper fat shell blow shat tell an 4 3) Ce. 45) pm without sot uperteon shat sbeNanyNoty 4 ENOQKT > CC main shaft cover's installation (2). On each main bearing cover there is main shaft cover NO. and arrow. From timing belt side in sill main shaft cover according to number sequence arrow must point to timing belt side ‘Shaft shel ‘Arrow show afront of engine (Q), After installing main shaft sell, measuring crankshaft 's axial clearance .if measurement data is above stipulated at mast limit, then change crankshaft shell. -80-DAGGI Engine Check And Repair Manual 1eNa280 Standard: 0,05-0.18mn_ »D¢ rear oil seal installation Use the tool, press install rear oil seal oil seal ¥ Mpo9e0t cil seal house 1EN0273| -81-DA4G13-6L/DA4GI8-6L. Engine Check And Repair Manual 7.4 Check and maintenance operation: 1) alternator and ignition system 2) timing belt 1. timing belt. Check timing belt carefully, if the following deficit occur then change new belt. (1). Back rubber harden (back rubber smooth without elasticity and hardened to that no vestige occur when using nail to scratch .) (2). Back rubber’s surface has erack G). canvas mangle and canvas separate from rubber. (4). tooth side has crack. (5). belt side has erack SB ee WS toot rot with crack eee (©). Belt side has wearing hard. BENDO6E ge round angle y weaving hard (core exposing) ‘8ENO067 Note: if belt side is sharp like knife cutting .belt is normal. (D. Teeth wearing hard Start phase (loosing canvas fiber ,rubber structure disappear, white color fade, canvas structure is hard fo recognize ) -82-DA4G13-6L/DA4GI8-6L. Engine Check And Repair Manual (2) clean all machine oil, water dirt, seal glue and carbon. After cleaning oil passage, blow compressed air into oil passage to confirm no blockage. (3) use ruler and gap gauge to check whether cylinder cover washer is deformed, iff deformed above utmost limit, grind and scrape washer surface. washer surface deformed Standard:0.03mm below. Cylinder head height (new):120 £0.1mm Note: on contact surface of eylinder head and cylinder block the grinding volume > valve Pot more than 0.2mm. valve (1). check whether valve surface is contacted correctly ,if contact is not even or complete ,base surface should be repaired (Q). If edge thickness is less than stipulated data valve should be changed. (amuse a the centre of surface.) ede thicknes. eeNost2 Standard: ‘utmost limit: air intake valve:1.35mm air intake valve:0.85mm ‘Air exhaust valve:1.85mm air exhaust valve:1.35mm ). measure valve whole length-if measured result is less than stipulated data, valve should be changed. ‘Standard : ‘utmost limi intake valve:111.06mm exhaust valve:114.21mm wake valve:111.56mm, 4.7Lmm air ir exhaust valve: 3. valve spring (1), measure valve spring free height. If measured result is less than stipulated data, valve spring should be changed. Standard : 50.87 ‘utmost limt:50.37 2), measure valve spring verticality, if measured result is above stipulated ‘utmost limit ,valve spring should be changed. Standard : 2° utmost limt:4° -83-DA4G13-6L/DA4GI8-6L. Engine Check And Repair Manual Verticality a reNo2s4 4. valve guide pipe ‘measure space of valve guide sleeve and valve bar if this space is above stipulated data, one or two parts should be changed. Standard: air intake valve guide pipe sleeve: 0.020-0.036mm Air exhaust valve guide sleeve: 0.030-0.045mm ‘Utmost limit: air intake valve guide pipe sleeve: 0.10mm, Air exhaust valve guide sleeve: 0.15mm valve guide Pipe valteber outer diameter valve pide pipe mer diate NDR 3. valve base Install valve then measure protruding height of valve bar to valve spring base surface. if measurement result is above utmost limit ,valve base should be changed Standard: ‘utmost limit: air intake valve:53.21mm air intake valve:53.71mm Air exhaust valve:54.10mm air exhaust valve:54.60mm, ‘ave bar terminal surface salve prong bei 3 Valve base amendment operation, (1), before amending valve base check the space of valve guide sleeve and valve, if necessary valve guide pipe should be changed (2). Use suitable tool or valve base grinder to amend valve base, in order (0 ‘meet stipulated base width and angle. -84-DA4G13-.6L/DASGI8-6L Engine Check And Repair Manual (2). after amending valve base, use colathar grind valve and valve base .then check valve bar protruding height (refer to front valve base check process). Taam 1eNoIO Valve base change operation (1). In order to reduce wall thi then dismantle valve base cut the changed valve base from inner part ZZ INN (2), Grind cylinder head valve hole in order to match enlarged diameter valve base. take base hole diameter: 30.42 Air intake base hole diameter: 30,725-30,745mm, air exhaust base hole diameter:28.4 air exhaust base hole diameter: 28. 45mm 45mm 45mm, 1425-2 vave base height Inner damier of 9 enlarged hole sewnors (3). Avoid eylinder head hole to seratch valve base by liquidized nitrogen before pressing assembl ly. (A). Amend valve base in order to meet stipulated width and angle Valve guide pipe changing operation. (1), Use forcing press to push valve guide pipe to cylinder block side. -85-DA4G13-6L/DA4GI8-6L. Engine Check And Repair Manual (2). Grind eylinder head valve guide pi valve guide pipe Nove: don’t install same size valve guide sleeve Valve guide pipe hole diameter: Enlarge 0.05: 10.605-10615mm EnlargeO.25: 10,805-10.815mm Enlarge 0.50: 11.055-11,065tmm. G). press valve guide pipe to make ‘its protruding beight to meet stipulated data Standard; 23.0 mm ¢ hole in order to match enlarged ERO 06 Note: 1. valve guide pipe must be installed from the top of eylinder head 2. For valve guide pipe of air intake and exhaust the length is different 3. After pressing of guide pipe valve, thrust new valve, and check whether it slide smoothly 8), machine oil pump and oil pa, 1, Machine oil pump: (1) Install rotator into front cover. (2). Use gauge to check tooth space. Standard: 0.06-0.18mm ). Use ruler and gauge space ‘Standard: 0,04-0. 11mm,DA4G13-6L/DA4GI8-6L. Engine Check And Repair Manual (4). use gauge to check house space, ‘Standard : 0.10-0.18mm utmost limit:0.35mm 9), Piston and connecting rod 1. piston ring, (2). check piston ring side space .if this space is above stipulated, piston ring or piston should be changed Standard: ‘utmost limit: first ring :0.03-0.07mm first ring :0.1mm Second ring :0.02-0.06mm second ring:0. Imm 7enoss Put piston ring into cylinder hole and use piston push them down , top of piston must contact piston ring. The angle of ring and cylinder wall is 90°C then use gauge to measure opening space of ring.if opening space is too big. Piston ring should be changed. Standard: Ist ring: 0.20-0.35mm 2nd ring: 0.35-0,50mm il ring: 0.10-0.40mm Utmost fit Ist ring : 0.80 mm 2nd ring: 0.80 mm Oil ring: 1.0 mm -87-DA4G13-6L/DA4GI8-6L. Engine Check And Repair Manual Z 7 Ze piston Hing oping space 7ENOA7E 2.con-rod shat shell space (plastic thread gauge) ‘(), wipe con-rod shaft neck and con-rod shaft shell's machine ol. (Q). put plastic thread gauge on the con-rod shaft neck .it is cutted to same length with shaft shell. plastic thread gauge must be put atthe center of conrad shaft neck, and be in parallel with axis, (3). Put con-rod cover on the position slowly ,and tighten bolt to stipulated vorque. (4). dismantle bolt, dismantle con-rod cover slowly. (3). Use ruler that is printed on plastic thread gauge to measure pressed part of plastic thread ‘gauge on the widest point ‘Standard: 0.02-0,04 mam Unnost limit: 0.1 mm 10). Crankshaft and eylinder block |. crankshaft space use plastic thread gauge to measure crankshaft space, In order to measure crankshaft by plastic thread gauge, make the following process: (1). wipe crankshaft shaft neck and bearing inner surface’ s machine oil, (2). Install bearing. (3). Cut plastic thread gauge (o meet width of bearing ,then put it on-the shaft neck through shaft neck's axis. Plastic tha gauge (4), Install crankshaft shell cover slightly ,and tighten bolt to stipulated torque. (5). Dismantle bolt and crankshaft shaft shell cover slightly. -88-DA4G13-6L/DA4GI8-6L. Engine Check And Repair Manual (6) Use ruler that is printed plastic thread gauge to measure pressed part of plastic thread gauge on the widest point Standard :0.02-0.04 mam Utmost limit: 0.1mm, ‘Not: con-rod shaft neck of rankshalt must be rolling pressed no weed to process to educe dimension, renova 2. cylinder block (1), Check crack corrosion by eye, use reagent to check cylinder block sepair deficit ‘or change cylinder block (2), These is no washer fragment and other dying material on the top use ruler and gauze to check cylinder block's deformation. ‘Standard :0.03 mm below Utmost limit: 0.1mm below a (8). check whether cylinder wall has erack and scuffing of cylinder bore . if deficit is obvious , all cylinder should be grinded to enlarged dimension or change eylinder block. (4), use gauge to measure each cylinder hole and coluran degree if and cylinder wear seriously all cylinder should be grinded to larged size and change piston and piston ring accordingly measurement point sce pictur, Standard : Cylinder hole diameter: 7.0 mm -89-DA4G13-6L/DA4GI8-6L. Engine Check And Repair Manual cylindriaty degree :below 0.01mm 3. grind cylinder hole. (1), Use maximum hole diameter 's cylinder hole to confirm enlarged piston 2). Such as follo @. . (. ©. enlarged piston:0.25 mm, 0.50mm, 0.75mm and 1.00 mm.measare all piston’s diameter .After grinding eylinder hole the space of piston and cylinder meet standard after grinding cylinder, measure piston diameter as per picture. spray seal Bision outer diameter) | glue EN0554 calculate grinded hole diameter according piston diameter : ¢ [grinded diameter] = [piston outer diameter] + [space between piston and cylinder (0.02-0.04)mm}- [grinder volume(0.02:m)]. sgrind each cylinder to calculate grinder dimension Note: in order to avoid deformation because of grinding caused beat. Grind cylinder to final dimension(piston outer diameter +piston and cylinder 's space) check space of piston and eylinder Standard: 0.02-0.04mm. -90-SC72A3 Gearbox Using And Repair ManualSC72A3 Gearbox repair namual Chapter 8 The instruction of SC72A3 gearbox ‘The structure of gearbox, as figure-1 show: D Figl-1 The structure of gearbox 8.1 Basic Parameter of SC72A3 gearbox Speed I " tL W v R Rate | 3,967 | 2.136 | 1.36 1 0.856 | 3.578 Gearbox centre distance: 72mm, 8.2 The inspect standard of SC72A3 gearbox: Inspect Item Inspect Standard Gear side clearance of Ist shaft (00.06, adjuse by shaft snap ring Clearance between Ist shaft and its seat (0~0.1, adjust by shim Site clearance of Gnd and th peed synchronizer (0 ~0.08, adjust by shaft snap ring Mid shaft rear bearing clearance (00.05, adjust by shim -92-Chapter 9 Repair SC72A3 gearbox 9.1 Gearbox oil level inspect: Open drain plug of gearbox, drain all oil, tighten drain plug in certain torque, 30~35Nm. Fill gearbox through oil filler hole, brand hyperbola gear oil SAE85/90, meet APE GL-4, oil mass 2.2L. Tighten oil filler hole to certain torque, torque" 30 ~30Nm. 1 ining pag MI6X 18 ($C-1701008) Drainplag assy K72-1701070) rig 24 oil,drain plug fiu 9.2 Replace rear case oil seal: As Fig 2-2 show replace rear case oil seal, separate drive shaft from rear case, unload anti-dust oil seal sleeve, unload oil seal in flathead screwdriver, then use tools knock the rear case oil seal into the rear case, please note oil seal load direction. Spread appointed gearbox oil on the lip of seal (Oi seal 36XS2X10(8C-1802504) Amidst set sleve(SC72-1802506) 22 -93-9.3. Disassembly and assembly the gearbox 9.3.1 Follow bellow picture disassembly gearbox in order. Fig 2-3 Figure 2-3 disassembly gearbox 1 backup lamp switch (SC72A3-1703030) backup lamp switch bracket (SC72A-1703008) bolt M8x55 (SC72-1703004) bracket (SC72A3-170440) locking plate of odometer seat (SC72A-1703024) bolt M6x13.5 (SC72a-1703025) odometer driven gear assy (SC72A2-1703020) bolt M8x110 (SC-1703-003) rear case assy (SC72A-1703000) 10 gasket (SC-1703-003) 9.3.2 Disassembly and rebuild the main cast ‘The order of disassembly and rebuild main case as Fig2-4: -94-M1 12 13 14 15 16 7 18 19 20 ag. Fig 2-4 disassembly gearbox locking plug M10x1.25x19 (SC-1702040) locking spring @1.1x7.5x18.4 (SC-1702403) steel ball (7.938 GB308) locking each other lock (SC-1702401) Ist / 2nd speed declutch shift shaft (SC72A-1702101) 3rd / 4th speed decluteh shift shaft (SC72A-1702201) Sth / reverse shifting fork (SC72A-1702302) pin (6x22 GB879) Sth / reverse declutch shift shaft (SC72A-1702301) O ring (SC72A-1704112)21 select shaft limiting pin (SC72A-1704109) 23 mut (SC72A-1704111) 25 select shaft assy (SC72A3-1704100) 27 Ist / 2nd shifting fork (SC72A-1702102) 29 3rd / 4th shifting fork (SC72A-1702202) 31 spring (SC72A-1704106) 22 aluminum gasket 12 (SC-1703031) 24 shift shaft assy (SC72A3-1704200) 26 select shaft oil seal (SC72A-1704203) 28 pin (5x22 GB879) 30 gasket (SC72A 1704103) 32 spring (SC72A3-1704105) 33 Sth / reverse speed return arm assy (SC724-1704108) 34 bolt M8x16 (SC-1701015) 36 clip (SC72A-1704107) 38 4-rods mechanism assy (SC72A-1704300) 40 3rd / 4th shifting block (SC72A-1702203) 35 lower cover plate (SC-1701011) 37 reverse lock assy (SC72A-1704310) 39 Sth / reverse shifting block (SC72A-1702303) 41 1st / 2nd shifting block (SC72A-1702104) 42 AS AAS 46 47 48 49 50¢4) 51S 53 54 55 565758 57) 5960 \\ ees \Wiew ) 6s a @ n\\ a) M170 69 68 67 Fig 2-5 Disassembly gearbox After upper disassembly, go on disassembly the main box, use special tools unload part 63 (rear bearing of mid shaft ). Use new spare parts when assembly part 62 (mid. shaft Jock nut), part 56 (2nd shaft lock nut), part 68 (reverse shaft lock nut ), part 67 (pin). -96-Go on disassembly and rebuild order as follow: 41 lock plate (SC-1701266) 43 screw M8x20 (SC1701267) 44 needle bearing 43x43x23 (SC-1701273) 45. reverse needle bearing bush (SC-1701274) 46 reverse driven gear (SC-1701271) 47 3rd / 4th synchronizer clip (SC-1701214) 48 Sth / reverse synchronizer (SC-1701282) 49 5th / reverser synchronizer block (SC-1701283) 50 Sth / reverse synchronizer ring (SC-1701281) 51 3rd / 4th / 5th synchronizer ring (SC-1701206) 52. 5th driven gear assy (SC-1701290) 53 needle bearing 40x35x32 (SC-1701293) 54 Sth needle bearing bush (SC-1701294) 55. thrust washer (SC-1701295) 56 locking nut (SC-1701297) 57 shaft check ring 28 (SC-1701203) 58 ball bearing 58x28x16 (SC-1701205) 59 shaft check ring 26.5 (SC72A-1701299) 60 odometer drive gear (SC72A2-1701298) 61 steel ball (4.762 GB308) 62 locking nut (mid shaft) (SC-1701432) 63. ball bearing 52x22x16 (SC-1701431) 64 5th drive gear (SC-1701405) 65 check ring (SC-1701405) 66 reverse drive gear (SC-1701420) 67 pin (4X32 GB91) 68 locking nut (reverse shaft) (SC-1701453) 69 thrust washer (SC-1701452) 70 reverse gear (SC-1701450) 71 needle bearing 26x22x17 (SC-1701451) 72. reverse shaft (SC-1701440) -97-Follow lower fig, go on disas -mbly and rebuild, before unload mid shaft, unload outer ring of the mild shaft and bearing, use special tools when unload inner ring of the bearing, or use new spare part when you rebuild. Bo 1% 77 8 BM BL 73 4 15 16 17 18 79 80 81 82 83 84 85 3 2 1 9% » Bo) Fig 2-6 disassemly gearbox separate bearing assy(SH78-1602010) abnormity clip (SC-1602031) clutch separate shifting fork (SH78-1602020) Ist shaft shaft block (SC72A3-1701021) gasket (SC-1701024) oil seal 30x45x6 (SC-1701023) shaft check ring 35 (SELECT SC-1701115) zanjon ball bearing assy (SC-1701113) Ist shaft (SC72A3-1701110) bolt M10x42 (SC72-1602G09) clutch case (SC72A3-1602001) bearing case (SC72A2-1701001) double inner ring ball bearing (SC-1701264) -98-86 taper roller bearing 52x25x16.25 (SC-1701403) 87 2nd shaft assy (SC-1701200) 88 middle shaft (SC-1701401) 89 middle shaft front check ring (SC-1701402) 90 needle bearing © 28x20x20 (SC-1701116) 91 gasket (8 GB93) 92 nut (JK72-1702079) 93. threaded stud M8 (SC-1701017) Follow fig 2-7 disassembly 2nd shaft and rebuild 94 (SI) 47) 959697 AT) UST) 98 99) Lt ooo 100 / #007 (203) 110109 (205) 108 107 106 10S 104 103 102 101 Fig 2-7 Disassembly 2nd shaft assy 94 shaft check ring 32.8 (SELECT SC-1701202) 95 3rd / 4th synchronizer gear (SC-1701212) 96 3rd / 4th synchronizer block (SC-1701213) 97 3rd / 4th synchronizer tooth ring (SC-1701211) 98 Needle bearing & 40x35x29 (SC-1701233) 99 3rd driven gear assy (SC-1701230) -99-100 2nd shaft (SC72A-1701201) 106 Ist / 2nd synchronizer tooth ring (SC-1701251) 101 1st driven gear assy (SC-1701260) 107 Ist / 2nd synchronizer block (SC-1701253) 102 1st needle bearing bush (SC-1701263) 108 Ist / 2nd synchronizer gear (SC-1701252) 103 Needle bearing «48x43x30 (SC-1701243) 109 2nd synchronizer tooth ring (SC-1701244) 104 1st synchronizer tooth ring (SC-1701255) 110 2nd driven gear assy (SC-1701240) 105 1st /2nd synchronizer clip (SC-1701254) 9.3.3 Follow fig 2-8 install or uninstall the synchronizer, must note how to assembly the clip of the synchromiser, must have 120° angle. (A) Follow fig 2-8 (a) install or unstall Ist /2nd synchronizer and 3rd / 4th synchronizer.(B) The 5th / reverse synchromiser block as fig shows big head direction reverse . The direction of assembly Sth / reverse synchronizer is request as fig (2-9) show, don't assembly in wrong direction. (a) (b) Fig 2-8. sychromzer spring clip installation reverse <—— Fig 2-9 Sttvreverse synchroniser assy =100-4 Follow fig (2-10) install synchromiser tooth ring, install synchronizer tooth ring on speed gear tooth ring, keep distance "A", if clearance "A"over value, replace tooth ring and gear. Value: A=0.5mm Speed 1st / 2nd :A=1.35mm ~1.85mm Speed 3rd, 4th, Sth: A=1.25~1.75mm Fig 2-10 Clearance of tooth ring and shaft 9.3.5 When you install paper gasket, double spray seal glue on sides of paper gasket. 9.3.6 Every gear install request of locking steel ball and locking spring as fig(2-11), small end of locking spring on the steel ball, the other spring are same. Fig 2-11 Locking steel ball locking spring -101-Electrical appliance diagrammatic layout (Chapter 10)10.1 Power,Generator, Starter, Ignition, switch,diagnoseinterface 2 aa H+ generator = ignition switeh * f = T} sate battery! T I age : dl fee Tt -103-10.2 Engine lontrol a TITTY10.3 lamps, horn/alarm, front & rear wiper/washer 105.10.4 rear fog lamp,turnning lamp,head lamp,door lamp, brake lamp,rear defrost : » : cm = ats = = acest i = : ara sh uy SMa bells wea foloies . fesiolsistes i ww | i i . le i i} aie) Gli) | + i ry) Ue ye i al F] cq) ]ayeye | edi : i zl Teas ae oD lee a ee Ds leo lalla 106.10.5 combination meter, backward lamp,radio player : 8 2 AE oi rT " =) mom gE sense oe ices Le = rie | soe Fa |mntwome | EF PPT | LU myo | EEG i TL | | ; 7 F | s ¥ : | cpm | ddd dd | ad del | od ls i t i i | i qi | | i | i | EB B&B i | “ot a 107.10.6 A/C system 108:10.7 center lock,cigar lighter,power rear view mirror,glass regulator : = “ ism sm ism a is 109.