em(4), Y61
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//-->ENGINE MECHANICALSECTIONMODIFICATION NOTICE:¼¼¼¼Engine mounting parts have been modified.Models with three way catalyst have been introduced for the Middle East.TB48DE engine has been introduced for Europe. For information and specifications other than those notdescribed here, refer to Y61 series Service Manual, Supplement-V 1st Revision (Publication No. SM1E-Y61EG1).TD42Ti engine has been introduced for Australia. For information and specifications other than those notdescribed here, refer to Y61 series Service Manual, Supplement-III 3rd Revision (Publication No. SM9E-Y61CG3).GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELSEIDXCONTENTSTB45E & TB45SENGINE REMOVAL.........................................................2TB48DEPREPARATION................................................................3Special Service Tools ..................................................3Commercial Service Tools ...........................................3OUTER COMPONENT PARTS.......................................5POWER VALVE ACTUATOR..........................................8COMPRESSION PRESSURE..........................................9Measurement of Compression Pressure.....................9OIL PAN.........................................................................10Removal.....................................................................10Installation..................................................................12TIMING CHAIN..............................................................15Components...............................................................15Removal.....................................................................16Inspection...................................................................19Installation..................................................................19OIL SEAL.......................................................................24Replacement..............................................................24ENGINE REMOVAL.......................................................26CYLINDER BLOCK.......................................................27Assembly ...................................................................28TD42TiPREPARATION..............................................................30OUTER COMPONENT PARTS.....................................31TURBOCHARGER.........................................................33Removal and Installation ...........................................34Inspection...................................................................34CHARGE AIR COOLER................................................38CYLINDER HEAD..........................................................39Removal.....................................................................40Inspection...................................................................40CYLINDER BLOCK.......................................................41Inspection...................................................................42SERVICE DATA AND SPECIFICATIONS (SDS)..........43Inspection and Adjustment ........................................43EM-1ENGINE REMOVALTB45E & TB45SSEM959GSEM060HEM-2PREPARATIONSpecial Service ToolsTool numberTool nameKV10111100Seal cutterDescriptionTB48DEGIMARemoving steel oil pan and timing chain caseLCNT046KV101056S0Ring gear stopper1 KV10105630Adapter2 KV10105610PlatePreventing crankshaft from rotatingECFENT617a: 3 (0.12)b: 6.4 (0.252)c: 2.8 (0.110)d: 6.6 (0.260)e: 107 (4.21)f: 14 (0.55)g: 20 (0.79)h: 14 (0.55) dia.Unit: mm (in)CLMTATTFPDFARACommercial Service ToolsTool nameSpark plug wrenchDescriptionRemoving and installing spark plugNT047Valve oil seal driftInstalling valve oil seala: 25 (0.98) dia.b: 14.4 (0.567) dia.c: 11.8 (0.465) dia.d: 10 (0.39)e: 11 (0.43)f: 9 (0.35)Unit: mm (in)BRSTRSBTHANT602Valve guide driftRemoving and installing valve guideNT015Intake & Exhausta = 10 mm (0.39 in) dia.b = 6.5 mm (0.256 in) dia.ELSEIDXEM-3PREPARATIONCommercial Service Tools (Cont’d)Tool nameValve guide reamerDescriptionTB48DEReaming valve guidekor hole for oversize1valve guidek2NT016Intake & Exhaustd1= 7.000 mm (0.2756 in) dia.d2= 11.19 mm (0.4406 in) dia.Valve seat cutter setFinishing valve seat dimensionsNT048Front oil seal driftInstalling front oil sealNT049a = 80 mm (3.15 in) dia.b = 58 mm (2.28 in) dia.Piston pin driftRemoving and installing piston pinNT074a = 22.5 mm (0.886 in) dia.b = 12.5 mm (0.492 in) dia.Piston ring expanderRemoving and installing piston ringNT030EM-4OUTER COMPONENT PARTSTB48DEGIMALCECFECLMTATTFPDFARABRSTRSBTHAELSEIDXSEM822GBEM-5
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