Thông số ford laser overhaul manual (2001MY)

CONTENTS Title General Information 2001 LASER Overhaul Manual D ENGINE D MANUAL TRANSAXLE FOREWORD This Manual explains the disassembly, inspection, repair, and reassembly procedures for the aboveĆindicated engine and manual transaxle In order to these procedures safely, quickly, and correctly, you must first read this manual and any other relevant service materials carefully The information in this manual is current up to FEBRUARY 2001 Any changes that occur after that time will not be reflected in this particular manual Therefore, the contents of this manual may not exactly match the mechanism that you are currently servicing Parts & Service AsiaĆPartner Export Office Hiroshima, Japan Section GI FS Engine B3 G15M-R Manual transaxle J2 Technical Data TD Special Tools ST 2001 Ford Japan Limited PRINTED IN AUSTRALIA, FEB 2001 F173-20-01B GENERAL INFORMATION GI GI HOW TO USE THIS MANUAL GI-2 RANGE OF TOPICS GI-2 SERVICING PROCEDURE GI-2 SYMBOLS GI-4 ADVISORY MESSAGES GI-4 UNITS GI-5 UNITS TABLE GI-5 FUNDAMENTAL PROCEDURES GI-6 PREPARATION OF TOOLS AND MEASURING EQUIPMENT GI-6 SPECIAL SERVICE TOOLS GI-6 DISASSEMBLY GI-6 INSPECTION DURING REMOVAL, DISASSEMBLY GI-6 ARRANGEMENT OF PARTS GI-7 CLEANING OF PARTS GI-7 REASSEMBLY GI-7 ADJUSTMENT GI-8 RUBBER PARTS AND TUBING GI-8 HOSE CLAMPS GI-8 TORQUE FORMULAS GI-9 VISE GI-9 ELECTRICAL SYSTEM GI-10 CONNECTORS GI-10 NEW STANDARDS GI-14 NEW STANDARDS TABLE GI-14 ABBREVIATIONS GI-16 ABBREVIATIONS TABLE GI-16 GI–1 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL RANGE OF TOPICS Z4F201000001101 • This manual contains procedures for performing all required service operations The procedures are divided into the following five basic operations: — Removal/Installation — Disassembly/Assembly — Replacement — Inspection — Adjustment • Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of parts, jacking, vehicle lifting, cleaning of parts and visual inspection) have been omitted End Of Sie SERVICING PROCEDURE Z4F201000001102 Inspection, Adjustment • Inspection and adjustment procedures are divided into steps Important points regarding the location and contents of the procedures are explained in detail and shown in the illustrations WGIWXX0009E Repair Procedure Most repair operations begin with an overview illustration It identifies the components, shows how the parts fit together, and describes visual part inspection However, only removal/installation procedures that need to be performed methodically have written instructions Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration In addition, symbols indicating parts requiring the use of special service tools or equivalent are also shown GI–2 HOW TO USE THIS MANUAL Procedure steps are numbered and the part that is the main point of the procedure is shown in the illustration with the corresponding number Occasionally, there are important points or additional information concerning a procedure Refer to this information when servicing the related part WGIWXX0010E End Of Sie GI–3 GI HOW TO USE THIS MANUAL SYMBOLS Z4F201000001103 • There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent These symbols show application points or use of these materials during service Symbol Meaning Kind Apply oil New appropriate engine oil or gear oil Apply brake fluid New appropriate brake fluid Apply automatic transaxle/transmission fluid New appropriate automatic transaxle/transmission fluid Apply grease Appropriate grease Apply sealant Appropriate sealant Apply petroleum jelly Appropriate petroleum jelly Replace part O-ring, gasket, etc Use SST or equivalent Appropriate tools End Of Sie MESSAGES ADVISORY Z4F201000001104 • You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this manual Warning • A Warning indicates a situation in which serious injury or death could result if the warning is ignored Caution • A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored Note • A Note provides added information that will help you to complete a particular procedure Specifications • The values indicate the allowable range when performing inspections or adjustments Upper and Lower Limits • The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments End Of Sie GI–4 UNITS UNITS GI UNITS TABLE Electrical current Electric power Electric resistance Electric voltage Length Negative pressure Number of revolutions Z4F201200002101 A (ampere) W (watt) Ω (ohm) V (volt) mm (millimeter) in (inch) kPa (kilo pascal) mmHg (millimeters of mercury) inHg (inches of mercury) rpm (revolutions per minute) kPa (kilo pascal) Positive pressure Torque Volume Weight kgf/cm2 (kilogram force per square centimeter) psi (pounds per square inch) N·m (Newton meter) kgf·m (kilogram force meter) kgf·cm (kilogram force centimeter) ft·lbf (foot pound force) in·lbf (inch pound force) L (liter) US qt (U.S quart) imp qt (Imperial quart) ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce) N (Newton) g (gram) oz (ounce) Conversion to SI Units (Système International d'Unités) • All numerical values in this manual are based on SI units Numbers shown in conventional units are converted from these values Rounding Off • Converted values are rounded off to the same number of places as the SI unit value For example, if the SI unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8 Upper and Lower Limits • When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is an upper limit and rounded up if the SI unit value is a lower limit Therefore, converted values for the same SI unit value may differ after conversion For example, consider 2.7 kgf/cm2 in the following specifications: 210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi} 270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi} • The actual converted values for 2.7 kgf/cm2 are 265 kPa and 38.4 psi In the first specification, 2.7 is used as an upper limit, so the converted values are rounded down to 260 and 38 In the second specification, 2.7 is used as a lower limit, so the converted values are rounded up to 270 and 39 End Of Sie GI–5 FUNDAMENTAL PROCEDURES FUNDAMENTAL PROCEDURES PREPARATION OF TOOLS AND MEASURING EQUIPMENT • Be sure that all necessary tools and measuring equipment are available before starting any work Z4F201400004101 WGIWXX0023E End Of Sie SPECIAL SERVICE TOOLS • Use special service tools or equivalent when they are required Z4F201400004102 WGIWXX0024E End Of Sie DISASSEMBLY Z4F201400004103 • If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be marked in a place that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently WGIWXX0027E End Of Sie DURING REMOVAL, DISASSEMBLY INSPECTION Z4F201400004104 • When removed, each part should be carefully inspected for malfunction, deformation, damage, and other problems GI–6 FUNDAMENTAL PROCEDURES GI WGIWXX0028E End Of Sie ARRANGEMENT OF PARTS • All disassembled parts should be carefully arranged for reassembly • Be sure to separate or otherwise identify the parts to be replaced from those that will be reused Z4F201400004105 WGIWXX0029E End Of Sie OF PARTS CLEANING • All parts to be reused should be carefully and thoroughly cleaned in the appropriate method Z4F201400004106 Warning • Using compressed air can cause dirt and other particles to fly out causing injury to the eyes Wear protective eye wear whenever using compressed air WGIWXX0030E End Of Sie REASSEMBLY • Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts • If removed, these parts should be replaced with new ones: — Oil seals — Gaskets — O-rings — Lockwashers — Cotter pins — Nylon nuts Z4F201400004107 WGIWXX0031E GI–7 FUNDAMENTAL PROCEDURES • Depending on location: — Sealant and gaskets, or both, should be applied to specified locations When sealant is applied, parts should be installed before sealant hardens to prevent leakage — Oil should be applied to the moving components of parts — Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly WGIWXX0032E End Of Sie ADJUSTMENT • Use suitable gauges and/or testers when making adjustments Z4F201400004108 WGIWXX0033E End Of Sie RUBBER PARTS AND TUBING • Prevent gasoline or oil from getting on rubber parts or tubing Z4F201400004109 WGIWXX0034E End OfCLAMPS Sie HOSE Z4F201400004110 • When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit WGIWXX0035E GI–8 FUNDAMENTAL PROCEDURES End Of Sie TORQUE FORMULAS Z4F201400004111 • When using a torque wrench-SST or equivalent combination, the written torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench Recalculate the torque using the following formulas Choose the formula that applies to you Torque Unit N·m kgf·m kgf·cm ft·lbf in·lbf Formula N·m × [L/(L+A)] kgf·m × [L/(L+A)] kgf·cm × [L/(L+A)] ft·lbf × [L/(L+A)] in·lbf × [L/(L+A)] A : The length of the SST past the torque wrench drive L : The length of the torque wrench WGIWXX0036E End Of Sie VISE • When using a vise, put protective plates in the jaws of the vise to prevent damage to parts Z4F201400004112 WGIWXX0037E End Of Sie GI–9 GI MANUAL TRANSAXLE 5TH/REVERSE GEAR AND HOUSING PARTS ASSEMBLY Assemble in the order shown in the figure Z4F511201029106 Z4F5112M089 Clutch housing (See J2–41 Clutch Housing Assembly Note) Control rod J2–40 Control end 1st/2nd shift fork MANUAL TRANSAXLE 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Control lever Interlock lever 3rd/4th shift fork Clutch hub Synchronizer keys Clutch hub sleeve Synchronizer key springs Differential differential component Secondary shaft gear component (See J2–42 Primary Shaft Gear Component and Secondary Shaft Gear Component Assembly Note) Primary shaft gear component (See J2–42 Primary Shaft Gear Component and Secondary Shaft Gear Component Assembly Note) Spring Steel ball Shift fork and shift rod component (See J2–42 Shift Fork and Shift Rod Component Assembly Note) Crank lever component (See J2–43 Crank Lever Component and Crank Lever Shaft Assembly Note) Crank lever shaft (See J2–43 Crank Lever Component and Crank Lever Shaft Assembly Note) Pin 5th/reverse shift rod end (See J2–43 5th/Reverse Shift Rod End and 5th/ Reverse Shift Rod Assembly Note) 5th/reverse shift rod (See J2–43 5th/Reverse Shift Rod End and 5th/ Reverse Shift Rod Assembly Note) Reverse idle gear (See J2–43 Reverse Idle Gear and Reverse Idle Shaft Assembly Note) 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Reverse idle shaft (See J2–43 Reverse Idle Gear and Reverse Idle Shaft Assembly Note) Magnet Transaxle case component (See J2–43 Transaxle Case Component Assembly Note) Neutral switch Back-up light switch Lock bolt, ball and spring Guide bolt Lock bolt Secondary 5th gear (See J2–44 Secondary 5th Gear Assembly Note) Gear sleeve 5th gear 5th synchronizer ring 5th/reverse clutch hub component (See J2–44 5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note) 5th/reverse shift fork (See J2–44 5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note) Reverse synchronizer ring Primary reverse synchronizer cone Reverse synchronizer gear sleeve Spacer Locknut (secondary shaft) (See J2–44 Locknut Assembly Note) Locknut (primary shaft) (See J2–44 Locknut Assembly Note) Rear cover Clutch Housing Assembly Note Assemble the SST Assembly clutch housing on the SST Z4F5112M003 J2–41 J2 MANUAL TRANSAXLE Primary Shaft Gear Component and Secondary Shaft Gear Component Assembly Note Install the primary shaft gear component and the secondary shaft gear component together Z4F5112M090 Shift Fork and Shift Rod Component Assembly Note Shift to 2nd gear and position the shift fork and shift rod component as shown Z4F5112M091 Insert the spring seat and spring into the reverse lever shaft, install the steel ball, and place a scraper so that it contacts the steel ball With the edge of the control end against the scraper, when the control end is pushed in the direction of the arrow in the figure so that the ball goes into the shaft, the rod will at the same time line up with the shift rod coupling hole in the clutch housing Z4F5112M092 Set each clutch hub sleeve to the neutral position, and tap the shift rod from above so that the steel ball goes into the center groove (of the three grooves in the control end) Pull the ball part of the control end forward so that the steel ball goes into the detent in the groove Z4F5112M093 J2–42 MANUAL TRANSAXLE Crank Lever Component and Crank Lever Shaft Assembly Note Fit the crank lever between the change arm and the control end, and connect the crank lever shaft to the crank lever Aligh the pin holes of the crank lever shaft and the clutch housing, and insert a new pin J2 Z4F5112M094 5th/Reverse Shift Rod End and 5th/Reverse Shift Rod Assembly Note Note • The mark (indicated by the arrow in the figure) and the shift rod end mounting bolt hole must be aligned Install shift rod end and the shift rod 2, and tighten the gate mounting bolt Tightening torque 11.8—13.7 N·m {120—140 kgf·cm, 105—121 in·lbf} Z4F5112M095 Reverse Idle Gear and Reverse Idle Shaft Assembly Note Install the reverse idle gear and the reverse idler shaft Attach the magnet to the clutch housing Aligh the end of the interlock sleeve with the control lever (arrow), and at the same time, face the reverse idle shaft screw hole in the direction shown in the figure Z4F5112M096 Transaxle Case Component Assembly Note Apply a thin coat of sealant to the contact surfaces of the clutch housing and transaxle case, and tighten the transaxle case installation bolts to the specified torque Tightening torque 37.3—52.0 N·m {3.8—5.3 kgf·m, 28—38 ft·lbf} J2–43 MANUAL TRANSAXLE Install the SSTs through the drive shaft and joint shaft hole Z4F5112M097 Secondary 5th Gear Assembly Note Install the secondary 5th gear as shown Z4F5112M098 5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note Install the 5th/reverse clutch hub component and the 5th/reverse shift fork together Z4F5112M099 Locknut Assembly Note Shift to 1st gear Lock the primary shaft using the SST Tighten new lock nuts onto the primary and secondary shafts Tightening torque 127.5—205.8 N·m {13.0—20.0 kgf·m, 95—144 ft·lbf} Stake the locknuts Z4F5112M100 J2–44 MANUAL TRANSAXLE Measure the 5th gear thrust clearance using a dial indicator • If not as specified, reassemble the transaxle Clearance 0.100—0.220 mm {0.0039—0.0087 in} Maximum 0.270 mm {0.0106 in} J2 Z4F5112M101 End Of Sie J2–45 TECHNICAL DATA TD TECHNICAL DATA TD-2 ENGINE TD-2 MANUAL TRANSAXLE TD-5 TD–1 TD TECHNICAL DATA TECHNICAL DATA ENGINE Z4F931001001101 Item Engine type Cylinder head Height Distortion Grinding Valve and valve guide Specification FS (mm {in}) Standard (mm {in}) Maximum (mm {in}) Maximum IN EX Standard IN Minimum Valve length (mm {in}) Standard EX Minimum Standard IN Minimum Valve stem diameter (mm {in}) Standard EX Minimum Valve guide inner diameter (mm {in}) Valve guide protection height (mm {in}) Standard Valve seat Seat contact width (mm {in}) Standard IN Seat angle EX Standard IN Maximum Seat sinking (mm {in}) (Valve protection height) Standard EX Maximum Valve spring Pressing force at valve H:36.5 mm (N {kgf, lbf}) Standard spring height H {1.44 in} IN Out-of-square (mm {in}) EX Camshaft Camshaft runout (mm {in}) Maximum Standard IN Minimum Lobe height (mm {in}) Standard EX Minimum Standard No.1,5 Minimum Journal diameter (mm {in}) Standard No.2,3,4 Minimum Standard Camshaft bearing oil (mm {in}) clearance Maximum Standard Camshaft end play (mm {in}) Maximum Tappet Tappet bore diameter (mm {in}) Standard Tappet diameter (mm {in}) Standard Standard Tappet-to-tappet bore (mm {in}) clearance Maximum Margin thickness TD–2 (mm {in}) 124.45—124.55 {4.8996—4.9035} 0.10 {0.004} 0.15 {0.006} 1.10 {0.0433} 1.20 {0.0472} 89.49—90.09 {3.524—3.546} 89.28 {3.515} 89.79—90.39 {3.536—3.558} 89.38 {3.519} 5.970—5.985 {0.2351—0.2356} 5.940 {0.2339} 5.965—5.980 {0.2349—0.2354} 5.935 {0.2337} 6.01—6.03 {0.2367—0.2374} 13.5—14.1 {0.532—0.555} 0.90—1.30 {0.036—0.051} 45° 45° 39.0 {1.535} 39.6 {1.559} 39.0 {1.535} 39.6 {1.559} 177.1—200.0 {18.05—20.40, 39.71—44.88} 1.54 {0.061} 1.54 {0.061} 0.03 {0.012} 43.7014 {1.7205} 43.5914 {1.7162} 43.2061 {1.7010} 43.0961 {1.6967} 25.940—25.965 {1.2013—1.0222} 25.890 {1.0193} 25.936—25.965 {1.0212—1.0222} 25.886 {1.0191} 0.035—0.081 {0.0014—0.0031} 0.15 {0.006} 0.08—0.20 {0.0032—0.0078} 0.21 {0.008} 30.000—30.025 {1.1812—1.1820} 29.959—29.975 {1.1795—1.1801} 0.025—0.066 {0.00099—0.00259} 0.180 {0.0071} TECHNICAL DATA Item Cylinder block Height Distortion Grinding Cylinder bore diameter Wear limit Piston Piston diameter Measure at 90° to pin bore axis and 16.5 mm {0.650 in} below oil ring groove Piston-to-cylinder clearance Specification (mm {in}) Standard (mm {in}) Maximum (mm {in}) Maximum Standard (mm {in}) 0.25 {0.01} oversize 0.50 {0.02} oversize (mm {in}) 261.4—261.6 {10.292—10.299} 0.05 {0.002} 0.20 {0.008} 83.000—83.019 {3.2678—3.2684} 83.250—83.269 {3.2776—3.2783} 83.500—83.519 {3.2874—3.2881} 0.15 {0.006} Standard (mm {in}) 0.25 {0.01} oversize 0.50 {0.02} oversize 82.953—82.975 {3.2659—3.2667} 83.203—83.225 {3.2758—3.2765} 83.453—83.475 {3.2856—3.2864} Standard Maximum 0.039—0.065 {0.0016—0.0025} 0.15 {0.006} Top Second (mm {in}) Oil Maximum Top Second (mm {in}) Oil Maximum 0.035—0.065 {0.0014—0.0025} 0.030—0.065 {0.0012—0.0025} 0.022—0.065 {0.0009—0.0025} 0.20 {0.008} 0.15—0.25 {0.006—0.009} 0.15—0.30 {0.006—0.011} 0.20—0.70 {0.008—0.027} 1.0 {0.039} (mm {in}) TD Piston ring Piston ring-to-ring groove clearance End gap (Measured in cylinder) Piston pin Diameter Connecting rod-to-piston pin clearance Piston-to-piston pin clearance Crankshaft Crankshaft runout (mm {in}) 18.988—19.000 {0.7476—0.7480} (mm {in}) 18.943—19.961 {0.7458—0.7858} (mm {in}) 18.974—18.980 {0.7471—0.7472} (mm {in}) Maximum Standard Main journal diameter (mm {in}) 0.25 {0.01} under size Main journal out-of-round (mm {in}) Standard Crankpin diameter (mm {in}) 0.25 {0.01} under size Crankpin out-of-round (mm {in}) Maximum Standard Main journal oil clearance (mm {in}) Maximum Standard Crankshaft end play (mm {in}) Maximum Connecting rod and connecting rod bearing Length (Center to center) (mm {in}) Bending (mm {in}) Distortion (mm {in}) Standard Connecting rod bearing oil clearance (mm {in}) Maximum Standard 0.25 {0.01} Connecting rod bearing thickness (mm {in}) under size 0.50 {0.02} under size Standard Connecting rod side clearance (mm {in}) Maximum 0.03 {0.0012} 55.937—55.955 {2.2022—2.2029} 55.687—55.705 {2.1924—2.1931} 0.05 {0.002} 47.940—47.955 {1.8874—1.8879} 47.690—47.705 {1.8776—1.8781} 0.05 {0.002} 0.024—0.050 {0.0010—0.0019} 0.067 {0.0026} 0.080—0.282 {0.0032—0.0111} 0.30 {0.012} 129.15—129.25 {5.0847—5.0885} 0.05 {0.020} max./50 {1.97} 0.05 {0.020} max./50 {1.97} 0.024—0.061 {0.0010—0.0024} 0.067 {0.0026} 1.509—1.524 {0.05941—0.05999} 1.629—1.637 {0.06414—0.06444} 1.754—1.762 {0.06906—0.06936} 0.110—0.262 {0.005—0.010} 0.30 {0.012} TD–3 TECHNICAL DATA Item Specification Tensioner spring Free length Oil pump Inner rotor tooth tip to outer rotor clearance Outer rotor body clearance Side clearance (mm {in}) 36.6 {1.44} Standard Maximum Standard (mm {in}) Maximum Standard (mm {in}) Maximum 0.130—0.206 {0.0051—0.0081} 0.30 {0.012} 0.113—0.186 {0.0045—0.0073} 0.22 {0.009} 0.035—0.095 {0.0014—0.0037} 0.14 {0.006} Standard Maximum Standard (mm {in}) Maximum Standard (mm {in}) Maximum 46.7—47.3 {1.839—1.862} 48.0 {1.890} 67.7—68.3 {2.666—2.688} 69.0 {2.717} 104.2—104.8 {4.103—4.125} 105.5 {4.154} (mm {in}) Bolt Connecting rod bolt length Main bearing cap bolt length Cylinder head bolt length (mm {in}) Plunger spring Pressing force at plunger spring height H (N {kgf, lbf}) End Of Sie TD–4 H: 33.50 mm {1.319 in} 97.68—107.48 {9.96—10.96, 21.91—24.11} TECHNICAL DATA MANUAL TRANSAXLE Z4F931001029101 Item (mm {in}) (mm {in}) (mm {in}) (mm {in}) (mm {in}) (mm {in}) (mm {in}) (mm {in}) (mm {in}) (mm {in}) Specification G15M-R 0.05—0.28 {0.002—0.011} 0.33 {0.013} 0.18—0.46 {0.007—0.018} 0.51 {0.020} 0.05—0.20 {0.002—0.007} 0.25 {0.010} 0.17—0.37 {0.007—0.014} 0.42 {0.017} 0.100—0.220 {0.0040—0.0086} 0.270 {0.0106} (mm {in}) 39.500—39.525 {1.555—1.556} (mm {in}) 39.445—39.470 {1.553—1.554} (mm {in}) 0.030—0.080 {0.002—0.003} (mm {in}) 35.015—35.035 {1.378—1.379} (mm {in}) 34.945—34.905 {1.376—1.374} (mm {in}) 0.05—0.09 {0.002—0.003} (mm {in}) 36.000—36.025 {1.417—1.418} (mm {in}) 35.945—35.970 {1.415—1.416} (mm {in}) 0.030—0.080 {0.001—0.003} (mm {in}) 31.000—31.025 {1.220—1.221} (mm {in}) 30.945—30.970 {1.218—1.219} (mm {in}) 0.030—0.080 {0.001—0.003} (mm {in}) 34.000—34.025 {1.3386—1.3395} (mm {in}) 33.945—33.970 {1.3365—1.3373} (mm {in}) (mm {in}) 0.030—0.080 {0.0012—0.0031} 0.10—0.45 {0.004—0.017} Maximum (mm {in}) 0.95 {0.037} Standard (mm {in}) 0.10—0.40 {0.004—0.015} Maximum (mm {in}) 0.90 {0.035} Standard (mm {in}) 0.10—0.36 {0.004—0.014} Maximum (mm {in}) 0.86 {0.034} Standard (mm {in}) 1.50 {0.059} Maximum (mm {in}) 0.80 {0.031} Standard (mm {in}) 0.10—0.35 {0.004—0.013} maximum (mm {in}) 0.85 {0.033} Transaxle type 1st gear 2nd gear Thrust clearance 3rd gear 4th gear 5th gear 1st gear 2nd gear Oil clearance 3rd gear 4th gear 5th gear Clearance between 1st/2nd shift fork and hub sleeve Clearance between Shift fork and hub 3rd/4th shift fork and sleeve hub sleeve Clearance between 5th shift fork and hub sleeve Clearance between Synchronizer ring synchronizer ring and flank surface of gear Clearance between Reverse idle gear and reverse idle gear reverse lever bushing and reverse lever Clearance Maximum Clearance Maximum Clearance Maximum Clearance Maximum Clearance Maximum 1st gear inner diameter Secondary shaft outer diameter Clearance 2nd gear inner diameter Secondary shaft outer diameter Clearance 3rd gear inner diameter Primary shaft outer diameter Clearance 4th gear inner diameter Primary shaft outer diameter Clearance 5th gear inner diameter Sleeve outer diameter Clearance Standard TD–5 TD TECHNICAL DATA Item Runout Bearing preload (mm {in}) (N·m {kgf·cm, in·lbf}) Primary shaft gear Preload adjust shims (mm {in}) Runout Bearing preload (mm {in}) (N·m {kgf·cm, in·lbf}) Secondary shaft gear Preload adjust shims (mm {in}) Differential bearing preload Differential Preload adjust shims Backlash of side gear and pinion gear End Of Sie TD–6 (N·m {kgf·cm, in·lbf}) (mm {in}) Standard (mm {in}) Specification 0.050 {0.0020}max 0.12—0.39 {1.2—4.0, 1.05—3.47} 0.20 {0.008}, 0.25 {0.010}, 0.30 {0.012}, 0.35 {0.014}, 0.40 {0.016}, 0.45 {0.018}, 0.50 {0.020}, 0.55 {0.022}, 0.60 {0.024}, 0.65 {0.026}, 0.70 {0.028} 0.015 {0.0006}max 0.2—0.3 {2.0—4.0, 1.8—3.4} 0.20 {0.008}, 0.25 {0.010}, 0.30 {0.012}, 0.35 {0.014}, 0.40 {0.016}, 0.45 {0.018}, 0.50 {0.020}, 0.55 {0.022}, 0.60 {0.024}, 0.65 {0.026}, 0.70 {0.028} 1.4—1.9 {14—20, 13—17} 0.1 {0.004}, 0.20 {0.008}, 0.25 {0.010}, 0.30 {0.012}, 0.35 {0.014}, 0.40 {0.016}, 0.45 {0.018}, 0.50 {0.020}, 0.55 {0.022}, 0.60 {0.024}, 0.65 {0.026}, 0.70 {0.028}, 0.75 {0.030}, 0.80 {0.031}, 0.85 {0.033}, 0.90 {0.035}, 0.95 {0.037}, 1.0 {0.039}, 1.05 {0.041}, 1.10 {0.043}, 1.15 {0.045}, 1.20 {0.047} 0.050—0.150 {0.0020—0.059} SPECIAL TOOLS ST SPECIAL TOOLS ST-2 ENGINE .ST-2 MANUAL TRANSAXLE ST-3 ST ST–1 SPECIAL TOOLS SPECIAL TOOLS ENGINE Z4F941001001101 49 0107 680A 49 L010 1A0 49 E011 1A0 Engine stand Engine hanger set Ring gear brake set 49 0636 100B 49 B012 0A2 49 S120 170 Valve spring lifter arm Pivot Valve seat remover 49 B012 005 49 L012 0A0A 49 L011 0A0B Valve guide remover & installer Valve seal & valve guide installer set Piston pin setting set 49 E011 001 49 E011 002 49 T012 0A0A Piston pin guide Screw Tapper holder set 49 B014 001 49 H010 401 49 G033 107A Oil seal installer Oil seal installer Dust cover installer 49 E301 144 Removing plate — End Of Sie ST–2 — SPECIAL TOOLS MANUAL TRANSAXLE Z4F941001029101 49 0107 680A 49 G019 0A0 49 0839 425C Engine stand Transaxle hanger set Bearing puller set 49 FT01 361 46 0636 145 498 G030 370 Bearing remover Fan pulley boss puller Removing plate 49 F401 366A 49 G030 795 49 G030 440 Plate Oil seal installer Primary shaft holder 49 B017 207 49 B017 208 49 B017 209 Attachment G Attachment H Attachment J 49 F401 331 49 F401 335A 49 F401 336B Body Attachment A Attachment B 49 G030 338 49 G030 380D 49 G017 202 Attachment E Shim selector set Preload adapter 49 B017 102 49 G030 455 Preload adapter Diff side gear holder ST — End Of Sie ST–3 ... GI-16 ABBREVIATIONS TABLE GI-16 GI–1 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL RANGE OF TOPICS Z4F201000001101 • This manual contains procedures for performing all required service...GENERAL INFORMATION GI GI HOW TO USE THIS MANUAL GI-2 RANGE OF TOPICS GI-2 SERVICING PROCEDURE GI-2 SYMBOLS GI-4 ADVISORY... parts requiring the use of special service tools or equivalent are also shown GI–2 HOW TO USE THIS MANUAL Procedure steps are numbered and the part that is the main point of the procedure is shown