82 Engine - General Repair Procedures Vato 3. Wash off the lapping paste with 4. Sard thevalve unt races of carbon _—_—timaune 4 ADDY an aT i artes a erm engne ate eae sis SENT tnge Cattle othe Beet zntat pie eheen iye grinding should Aesombly pe iano de ‘in the reverse ocder of rummoval ‘memceramsto van eel eae ete ZAfeFsanding.tap the operations. NOME ARR ie Coram Fh mevae spire angie ee sa Peecnes siete oreo pee cee eeaeer : oe Fi hp vane nate Eshaus vale. ofay-re6h ASKBaIy'2 Thin layer Of lapping, identification mer - gece Exo! vie... Opti ayo Ca Foe Donat allow the lapping pasieto. | = = | Fret we amedium ait | Baste (i 120-150), cae | Sha ten a fing lapping j = | Bast (it over 200 Fer unfom apatcaton vivesoing | fubbing poste sold sac : mitre paste wih som amour of Frit Fo eas . | aunty a ol a _ seen c) Use » puller to compress the spring aay nin ho set net rove the orneer seraper exp TS will resuitin increased on: ifthe spring is o ‘ihe valve guide Do may reat against the oil seal ot installa Used ol sual td damage a epecial ool | eves 4) Ghesk te correct installation of e eackate ar romoving ne 2 loon ote ito ie ies Care aout eee ao Sao Legiot Autodata www.autodata.ru www.motordata.raEngine - General Repair Procedures Piston and connecting rod Removal and dsassembiy + The gar are removed in the order of ‘umber nicted i he Sour Removing hainstaling te piston and comvesting od Note: operations for somoving and ‘stalieg tho poy nae gon Ino ‘Reparstosecon + Whoa remoting pars, pay attention io the ogeration of remove tho connecting Waring: Be caraful when nan emeuing Be en an cornet rot ‘Seco rl h hm conned od ') Mark the vinger number on the side ios ofthe craeing rand capt fecitte subsequent assembly. 6) Arrange the removed pars (Connecting reds, stone, net, ek) inthe Checking Piston and iston pin Alteran the piston ane piston (eSpecially on the mating Surfacoe}. Replace the piston iferacks 2° 7 ty insert the piston pin force""At thie’ Samié time, rosigance shoul be fet. Reolace ‘thé hele orf there is significant play, Piston rings: ‘prion pean 6 lens wi 3 new Gne, the plson rings must noe ace win ones 1. Check the pision rings for damage, kinks or 2.check ne coarance between he psn “usasire he gep between the iton ng sb potan gen. Fi tte gap score smu porte ‘py meaning, then replace the > Bare tahing measure jaasure the pap betweer the rng ‘ana the piston grcove along he entre Sroumence as nermg aoe BREA suctace of Saves 83, Te gn tte ne compres ng a 003-007 4. Csok th gap the ing lak 2) inset the pst tag nb he jane. Move't dawn the piston ‘tin such a may that the rng is ‘ores postloned at 3 rat andl io ‘he eylender wal). 5) Measre the 999 the piton lock the fisting witha fal screw. If Ring lack gap: tah Gtseperlio Maximum pemiccbie value: Compression rs oon Ne 10:20mn piston and connecting fed. 1 nul, 2 Tawer ewer connecting rod pearing shell, 4- piston and onneating tad assembly, 5 -uopor conrecting ro3 bearing shel, § compression ‘ing Ne, 7 compression rig No.2. 6 of scraper nq, 9 stan ® raph. iOpiston 11 soneecing ad 2 Flt fiaually check tho cordon fing shell (uneven contact, sipes, soratches, seuting ste) eve are opin ett, repoce te connect od Logion-AutoetaEngine - General Repair Procedures 4) Using 2 press, remove the piston pin Note: a achat further aszaribly, Koop disasserblod regatta special ods tho folowing valuos: fisonpln inthe dance betaeen Plena: Dietnowstnorine PO ) Screw the guide sieeve “3 Ii Uw guide Sloove Aso iere’ie'a'aistance equal to the value “L” measured in eub- _t I) Place the pion and connoeting rod ‘agater wih te Wont mares aera mm) Press the pushor rod win a the force developed during pm scomiy andor eamacting ressing of the piston ried outa room| re ep a peers a 9} Detorming tha valve of the folowng formula L=(a-c)-ce-0n2 9) Pace the piston pen the Sleeve *A* onto the end of the rostagether wih te ros mares ‘ing pon the base of he a using Inserthe assriiyipustvod Sseemaleaae mebisnnp ete eee 85 ©) Chock that he pcton move ‘Shootty without sting. f stalator of parts i cae outio re reverse crdoe of romova “When instaling parts. pay attention ual ener Dail at arse te 12S aus tatt gen iron an ooo Scone seen nena New pats (expander and Scrapers) are color coded ee corresponding tabie).b) inal te apr ssaper oF To inet tne upper scrape. st Instr ona end ine scfaper tone Br the scraper wih your Faget ‘Waring: Do not use an expander Distr gs, Urake otter piston sng paris, the of ‘un 06,1868 ans Paro i Table. Oil ring size color codes. Pajero Mini Thorne rapa = vest Gmenon S10) _|_scale (080mm) _| scale (1.00 mm) Peloro Min «08 1086 Release perbd | Naina Ta eae meseli) laz0 610) eaio (0.25 mm) _ [an85. chSeaner agin Samenay ‘} Chock the correct intaliation orsnts of tres pare. When ‘Montes sores Pealenps ieee eee VERY 2 netattion of compression Aras his No 2 Eipandr ts cmornson NB: tana No. 2 with te identification rneacng ue Ess comprossion ang an idantteaion tines. When tating, the mart son 00 entrain Mare Rg -Thoszn aoupor hie cororessin ring is Engine - General Repair Procedures Nominal (ST) _1 No ropa (625 09m) 25 repair (0.50 min) 89 Se esa oi lable “Selection of connoct ‘3 Boarng hale" n aceon Maine aurkchat can soca eynetcao, Gymbsicrmatis) and ne {raring on Ysa Sel She grup ner marks) ‘tortion the ernkshah ennortrg rod joumal sae mark ‘Son solents pa eerily '3, Selection of comecting 10d bearing determined aacarding he lable | 5 Moanin ot | he ee S- ESRULEEEILE Ts aR. g8T etnies Taz aaa ad 71.357 2.000) a 0 44,006, Te 7.996 -1.957 ae ga.902- 99998 [at 4,000 = 44,012. Tete 7.957 -2,000) | evita aa a4 012-4016. eran 2000-2008 Make sate that he cranks gi Using an arate inca. 5, Instalaton af he earkne ol seat - urtenrgeentoon LBSig a speci! ord naa | tec te ai cera te Ont 080.18 rm if Bolts are ightened to an angle Troximumparmenbie, .,.,. asm flees tan 6 then he fasting ea tthe carkshal bed willbe InauFient = tine bots are tightened to an angle of fore than 6D" ther Unsere the Bre epsat ie ahtonng proconae om gett 5 repre sia the a ae | fh ifthe gap exceeds the | 400HC engines netalan of 6) Make suo ne oaraatah ‘he axa olearanoe of ‘raat te knee Shaft ono the eyinde lock otha he arsw or his San Isto one une betes. ‘als earn oto sank Non «008-0: mm ©) Apply sma amount ot ‘Maximum permissibia.. 0:28 mm otto eset ona ts ‘ol sealon tho clack Fre ana te Bas Soca «(ral the sal ous tin 1S martes nu et ‘Mer icaling te ol sat hous, at atleast an hour betore pamengibaangre 6) Apaly engine ol the bot © Tighten the mount tals aie plate tegen enonsaine ‘Snr sarporeing paragon inne sence shown nt fue een Son nana carat as ie paegisions! tin Rechper Mar «ae Legion AutodataPowertrain supports note tints rte blogs, with SOHC «anaes icrovb endl insteing HRSiSH ES HST an Btn ssgpensn sin Rea ‘Removel end instalation procedures _ Checking ‘The ont ans + Cheok the engine mounts gerne eon ata x ana ran woe poo aes tox and rant Ne sotgrate (Pajero Junior ‘and Pajero Mini unt 08.1388) 4, starthe engine, warm i = Unless absolutely pio a coca femperatre of ieessary, donot Buch the (Der age nd he fnteryaquementsron Cleaning the throttle body engine. 2 Disconnectthe airhose 2 Poth bea po "ithe factory este of he Winme vas ‘Aitention: do not allow cleaning ‘rextn By mistake; tien ‘agent o et into the frocedure bulow. 1. Rak 58 the pedal eae tension 2 Goosen mo locenst of me factory Sentient sever een SASS 4, Spry ihe recommended ceanin: Sa inside the treste body ae Three bond 6601 roteThne bond B60 ating cio omen Soe sees (Grae met rons ne - eee Fee bets Pape Ose eliaviogdicey ache (ease Sturn licen adherens opine tte wave corte geen "tte Cae aes red SASS atten uni sees oul ave ber mn 4" and"S".7, Open the bypass Promitis positon: ighien te screw fevers rin Who halaing the factory adustment 8. Connect he ar intaka Screw trem fuming, hose tthe trate body fighien the locknutseceraly. i odes om tp nieces Sere eg =a tetas sone BESS Biren mecca Secon 8. Adjust the accelerator pedal cable ‘alan (eeothe coresporling subeacton, ‘Adjst ne base 4. Chock that the thre vesigs le with tho specifod valu. Base Frequency Adjustment lle spoed “~Bastidle speed tle speed is adjusted at the factory with the idle Speca dement soo (SAS) During operation, additonal ‘sdustnentis usualy tot raquirod 419 =f, by mistake, the factory setting Was vlad (he postin of the SAS sorew was charged), then the ile speed may te the engine (br example, ‘nen the aiecenationng Compressors tured on). “Hadsiment te sil Secessary, ion Setore string work, chek the spark lugs Ijecors. le spoea "aed servemeton 1. Before staring the inspecton and Saher Siedonae Ui te lowing fine te dreotiorar Ste chock it he sare aie ‘Tate automatic taremisin selector Sant up ins engine Ub eable {coolant amperature Keece'td "38° 0 Thesterng whe iste nthe Teese tO ree 2 Cameet te ner the dagroisc Gomes (uhencomacing beh the’ ‘positicn), 5 {Pact for Pp Min sioca 081858 ay inset a paperct inte the 1-cin onriector (blue) located of the rare compare a0 es Pajero Junior ) Gonnect the tachometer test load tothe poper cp natalie tho Legion-Audate