SECTIONEM

ENGINE
rcDEL MECHANICAT
13, 1 6 SERIES
HGIIIES

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EngineMechanical

GENERAL
DESCRIPTION

CONTENTS
J 1 3J, ] 5 A N D J 1 6 E N G I N E S EM2 CANISHAFT EM-3
CYLINDEHBLOCK EIV].3 ROCKERSHAFT EM.4
CFANKSHAFT Etvt-3 VALVE I\4ECHANISI\4 EM4
PISTON A N D C O N N E C T I NRGO D . EM3 ]\4ANIFOLDS EM.4
CYLINDER NEAD EM.3

J 1 3 , t 1 5 A N DJ 1 6
, rrENGll{ES
.. . mechanism
r. O.tt.V.typ" valve
, , r De€pski , cast'ironcylinderblock
with cast.incylinders
. Csst-hon cylinder head including
bathtubtype combustion chambers
. Fully counterbalancedcrankhaft
jourMls
with 3 mainbearing exlaust manifold ls equippedwiti the
. 2-banel,downdraftcarburetorfor
thorough air-fuelmixing Sinceth€ Jls is a bored.outversion
of the J13, and the Jl6 is a length-
The exhaust manifold is of semi. ened.veion of the Jl5. The way in
for the bonnettype
dual construction which they are serviced is seldom
models.For caballtype models,the different except that some iechnical
datemustbe adjusted.

Enginemejordrtr

BngineModel Jl3 Jl5 J16

Diiplacement cc (cu in) | 299(19.3) (90.5)

1,483 (9s.6)
1,557
Bore x stroko mm (il) 73x7't.6(2.81x 3n6) 78x 71,6 (3.0'lx 3,06) 18x 82Qn1 x 3.23)
Ratio
Compression 8.2 8,3 8.3

Isnition timins
-
B-.T-D,C.
rPm 8o/600 8Y600 8o/600

EIM.2

Fig. EM-l Croessectionaloieo (J16 enEine'bonnettlpe nodeb)
CYLINDERBLOCK
The crankshaftis a fully counter
baianced,3.bearingtype desjgnedto
turn out smooth,dependable pow€r.
Wate! is forced through the wrter
jackeh to depdve the cylindersof
unwanted combustion h€at. The
engineidertificationmarks"T0i" for
the Jls and Jl6 and "B34" for the
J13 areembossed on the right rearol
ihe engineblock.
Fic. EM-2 Cllinder bloch
CRANKSHAFT
The cranLshaftis of sp€cialsteel
forginSwith 3 main bearingjournals.
To providebalance,4 counterOal-
ance)weightsarc providedjust op'
posite t}Ie crants. The main bearing
joumalsand connectingrod joumals
(crank pins) are case hardened and
linished to extreme smoothnessfor
Engine Mechanical
cylinder walls are lubricatedby oil
squirtedfiom the oil jets locatedat
the corn€ctingmd big erds.
Fig. DM-4 Pi|ton
JGF Il5,ll5
0
increased wear resistance.
The crank.
shaft has drilled passages through
which oil can flow to the mainbear-
ingsto lubricateandat the sametime
K o -
The centermain
to cool the bearings. Fig. EM"5 Connectingrod
beadng is equipped ivith thrust
washersto take up end thnst of the
crankshaft.
CYLII{DER HEAD
The cylinderh€adis madeof steel
casting. It contains baihtub type
combustlon chambers. A specialsinte!"
ed alloy valveseatis installedon the
€xhaustvalve.It is press-fiit€d.
FE. EM-3 Crdnkshaft
PISTON AND
CONNECTING ROD
EM-345
The pistonsaremadeof aluminum
Fig. EM-6 Cylin.t r hed.l
aloy casting.Itis Autothermictypeto
assurcperfectroundness whenheated
to operatingtemperature. The piston
pin is a full floaling fit to th€ piston
CAMSHAFT
while it is pr€ssfitted to the con- The camshaftis of specialste€l
necting rod snall end. The connecting casting and is supportedby 3 rnain
rod is a specialsteelforging.On the bearings.The cam lobes are cas€
J13, the piston pin is bolted to tlle hardened and finished to extreme
snall end to preYentit from wo*ing $noothness for inu€asedwear resist-
out of place during operation.The
:.
EIM.3
 E n g i n eM e c h a n i c a l

springtype, innerand outer.Only for MAI{IFOLDS

the A321models,the valv€springis of
single type. The valve oil seal iing is Cast-i.onmanifolds are used 1o
carrythe exhaustgases awayfrom the
cylindersand to admit fie ai.fuel
mixture to the combustionchambe..
The exhaustmanifoldis of seni-dual
constructionfor bonnettype mod€ls
and is equippedwith a heat control
valvefor caballtypemodels.Theseare
Iig. EM-7 CdnshLft bolted to the cylinderheadwirh the
gasketsinse(ed in between.The €x-
haust pipe is flangemountedto the
ROCKERSHAFT
Fie. EM-g Voluemechanism
The rockershaftis madeofcarbon
steel: it is also case hardenedfor
jncreas€d dumbility.The valverocker
arms are lubricatedby leakrgeof oil
from th€ oil passagedriled in the
rockershaft.

Fur bonnerryfc nrodel!

EM349
Fig. EM-8 Ro.ker shoft a$embly

VALVEMECHANISM
The valve train consistsof the
camshaft,pulh rod, v?iverockerarm,
and valve; motion h transmitted
throughthesefour partsin rhe order
listed.Th€ valvespringis of doubie Fi!. EM la Exhaust& Ihtohe manifods

ENGINEDISASSEMBLY

CONTENTS
P B E L I M I N A RCYL E A N I N G
AND PISTON
A N D C O N N E CNTG B O D EN/t,7
I N S P E CI T
NG EN,45 C Y L I N D E RH E A D EM.7
D SASSEI/]BLY El/l-5 V A L V E R O C K E RA S S E M B L Y EM.7
i

Et\,14
 E n g i n eM e c h a n i c a l
PRELIMINARY rcmoveoil filter, useOil Filter Wrench
CLEAIING AND sT19320000.
I1{SPECTING
Beforedisassembling engine,note
the fo owing:
l. Fu€l, oil or water may leakpast
cylind€r head and block. Prior to
disassembling,check cylinder head,
front chain cover,oil pan afld oil {ilter
gasketsand crankshaftand water FE. EM-14 Re ovingboterpunp
pump sealsfor signsof leatagepast
theirgasketed surfaces.
11. Back off bolts securingcarnk.
2. Checkcarburetorand fuel pump
Fig.EM-l1 EnEineonenginestand shaftpulleyin position:removecrank.
for condition;fuelhosesfor deteriora-
shaftpuney.
tion, cracksor leakageof fuel pasi
thei(jointedor conflectedsurfaces. 4. Removefan andfan pulley.
3. Removeeir cleaner,alternator, 5. Disconnect carburetor ffom
distributorand starter,and plug up intakemanifold.
carburetor air-hom add distributor 6. Remov€boih intakeandexbaust
hole to prevent entry of foreign maf manifoldsiogetllerwith gaskets.
ter.
4. Wipedudtandmud offengine.
5. Inspectblock,rockercover,front
chaincover,oil panandall otherouter
partsfor vbualdefectsandbrokenor
missingparts suchasboltsandnuh. EM35A

6. Test all pipings and electrical crcnhpuller

circuih for discontinuityor brokenor
&msgedinsulation.
DISASSEMBI.Y
To removeengin€ from vehicle,
rcfer to relatedtopic under "Engine
Removaland Installation"in Chassis
and BodySe iceManual,SectionER.
l. Removetransrnisslon from enBine
completewith clutch.
2. Thoroucldy drain €n8in€oil and
coolantbyremoving bottomplugs.
3. In succession, r€movethe follow"
rn8pa|ls:
. Hightensioncables
. Sparkptugs
. Rightenginemouniingbracket
. Oil filter bracket and oil filter
. Oil pressureswitch
. Oil levelgause
. Fanbelt
After above st€pshave been com-
plet€d, attach Engine Attachment
5T05280000to dght sid€of engine.
With the useof an overheadhoist and
lifting cable, hoist engine up away
frorn the engin€ cari€r and place it
down in Engirc StandSm501S000.
The engineattachment is commonto
the J13, J15 and J16 €ngines.To
Fig. EM-12 Bemouingintake dnd
eth.utt manifolds
1 . Removefuel pump.
Iig. EM-L3 Reno\inq fuel PumP
8. Back off bolts and removeleft
handenginemountingbracket.
9. Back off bolts securingwater
outlet; removewater outlet and i}Ier'
10. Removelrater pump together
withSasket.
EiTS
Fi.. EM'16 Removine
12. Applying suitablewrench,un-
screwboits which hoid timing chain
coverin place;takeoff covertogether
with gasket.
13. Remov€timing chainlensioner.
14. Back off bolh which secure
camshaftgear to camshaft;remove
camshaftwasher.At the sametime,
iake out oil thrower on crankshaft
side.
15. Removecamshaftand crank-
shaft gea6 with cham hung around
gearteeth-It is good practiceto use
CrankshaftCear Pullef 5T16530000.
FA.EM-16 Fenouing timing chain

16. Renove camshaftand cranl-
shaftkeysfro k€y,ways in gea( (two
for crantshaftandone for camshaft).
17. Straightcntabsof lock wishers
andbackoffbolis sccuring flywheelto
flanse erd of crankshaflrcar. Fiy-
wheel can dren be take oul. Be
carefulrot to drop it- At thissiagcof
disrssembly, removeenginerearplaie
togetherwith gasket.
18. Back off bolts which hold
rocker cover 10 the to! of cylinder
head; renove rocker coyer together
with gaskerundercover.
19. Back off valve rocker shaft
brrcket bolls ard cylinderherd stud
nuts in two or threeprogressilc sleps
ard in sequenceshown.
Fig. EM-17 Rocher shdft btochel
boLtdnd.cyliidet hcdd
trut loosenihg sequence
10. Tlkc off valvc rocker shan !s
semblyftorr cylinder head.
2 1 . L i f t o u t p u s hr o d sf r o m h o l e si n
c y l i n d c rh c a d .
22. Lift cylinder herd strright up
away irom cngineblock togetherwilh
saskct undcr hcad. Every caution
shouldbe taken not to damagethreads
of stud bohswhile head is beinglilled.
Fig. EM tB RPnaling.!Lindet hedd
23- Invert engnreblock 180" so that
oil pan is facing u!; renove bolts
which secureoil lan to engineblock.
Remove oit pan togetherwith Basket.
E n g i n eM e c h ainc a l
24. Rernove oil pum! with oi1 can be reinslaled in their original
sirainerassemblyand oil pump drive
sljndle by backingoff bolis which
Fig. EM-21 Withtlrouingpiston and
cannectinqrod oseftblr
Fie. EM-19 R.mouine oiLpump ond
oilpump driuespitdle 30. Rlck off bolls lolding crank-
slnll beuing c!ps to engine block
saddlcs:scprr te crps ofi srddles !o"
g c l h e r w i L h t h n r s l w a s h e r sa n d b e a r -
2 5 . F r € e c a n l s h a f tl o c a f i r g p h t c ; n l g s .l l i s n c c c s s a r1yo u s c C r r n k s h N l t
withdraw crmshaft towLlrd thc lio l M r n r B c a r i n g( l a p I ' u l l c rS f i 6 5 l l 0 0 0
of engine.When renrovi|8 shrft. cxcr. w h e n r e m o v i n gc c n t e ra n d r c i r b c a r i r g
c i s e c a r e n o t ! o d L u n a g cc r s h x J l
bcarings as woll rs crnr lobes, rvhich
w o L r l dm r k e t h e m u f i i f o r f L r ( | c l
Fig. EM 22 Rehauing rnaih
Deonhg caP
31. Renovc crankshrfl ald mair
Fig. EM-2a Withdnung conlshoft
bearings.Makesureto placeihern in
corfecl o.der ir pats fack, so-that
they can be instatledin their original
16. Pull oui valvclifters from block.
:7. Renovc ffont plate by backnrg
offbolts seou|ingii to engineblock.
18. Rotate engin€ block on engine
standfor easyaccessto pistons_
29. Remove bolts which hold con
necting rod caps ifl placet separate
connecting rod caps iogether wirh
bedring hserts. Push con ecting rod
and piston assemblyout to! of cyl,
inder with lr bar or hmdle end of a
hanner. Avoid danaging piston .ings
wher removingpiston and connecring
rcd. Phce all disassenbledparis in
paft rack in corect order so that rhey FE. EM'23 Remouine.runk\haft
ENrt.6

PISTOI{ AND
OONI{ECTIIIGROD,
l. Removepiton ringsfrom around
piston using Pislon Ring Expander
EM03500000.
Note: Exercise caution in renovirg
piston rings. Excessiverpreadingof
rings wil cau3edarnsgeand render
them unJit for furthe( servicedile
to br€akageor relaxedtemion,
FE. EM-24 Renouins pistot ring
2. Removeplston pin with Piston
Pln Prers Stand ST13060000under
pr€ss(Jl5 andJ16).
(J15,Jl
sTl3060000
Fig. EM-26 Eenoving piltton pin
(J16 ontl J16)
Engine Mechanical
3. Using suitable wrench, back off
bolt secuiingpiston pin in place.Using:
Pision Pin PiessStand 5T13040000,
removepin underpress(Jl3).
FE. EM-27 Renouing ualve
EM365
fE. EM"26 Remoolng pirton pin
bolt (J13)
VALVE ROCXER ASSEMBLY
Withdrawcotterpinr from€achend
ol rockerslnfti removevalverocker,
Note: Be sure to place removedpins
valve rocker bra4ket and sprlng ln
in conect ord€r in pad rack so that
orderListed.Therearmodbracketll,s
they csn be r€install€din ihe same
a s€tgcrewwhichlecureSrockershaft
pbtoff from which lhey ve.e re-
ln plsceto preventit frofi worklng
loosedu ngoperaiion,
CYLINDER HEAD
Compress valvespringswith Valve
Ufter 5T12070000. Removerubber A
Ws N
rings, valve colleh, springrotainers, \@ \
valve springs,valve oil seal rings
EM36?
(option) and valver.Placermoved
parh in correctorderin partsrackso Fig, EM-28 Dkastembling rccher
that they can b€ ninstrlled in their 6oemblr
odginallocations.
El\4-7
 Engine Mechanical

AND REPAIR
INSPECTION

CONTENTS
PREPARATION FOR NSPECTION .,,,... Et1 I c y L N D E BB O RN G . . . . . . . . . . . . . . EM'16
C Y LN D - R - f ^ D A \ D V A V t EM-8 P I S T O NP,] S T O N
PN AND
H E A DI V A TN G
C H E C K L NCGY L ] N D E R p t S T O NR T N G S . EM-17
E M 8 C O N N E C TR TOND G. . . . . . . . . . . . . . . . . ENI-19
v A - v r -^ , v B lY . . . . . . . . . ... E M 8 CFANKSHAFT .,.... EIV].19
V A t v r - | r r . FA \ D D U S H qOD..... Etvt-I B U S H I NAGN D B E A R I N.G .............. - E|\,,1-21
VALVI SPPING E[/]- 9 MEASUBE]\4ENT OF CONNECT NG ROD
ROCKEFARIV]AND VALVE B E A R T NCGL E A R A N C. E . . . . . . .. Etvt_2l
R O .< E c o t v o T EM-10 MEASUFEMEN OT F I \ 4 A I NB E A RN G
V A IV E C U I D f E M1 O CLEARANCE . . EM'21
VALVI SIAT EM,]2 FlrrlNG BEABNG " ev-zz
CAMSHAFT AND CAMSHAFT M I S C E L L A N E OCUOSf u 1 P O N E N T S , . ., . . , EM.23
B | - A B T N C . . . .. . EM.]3 C B A N K S H A FSTP F O C K EATN D
(AVS*A_ BEAE.NC G- ^ C A \ ' E . , EIV].13 C A M S H A FSTP B O C K E, T .,, ,,,,,,, EM.23
VA-VF TI\,1INC EM.14 C H A I NA N D C H A I NT E N S I O N E. B , . , . EM.23
C A I I S H AIL A I I C\ V t N EM-14 F L Y W H E .E. L. . . . . . . . . . . .. . . . . . . . . . EM'23
C Y L I N D EBF- O C < , EM.15 F R O N TC O V E FO L S E A L. . . , , , , . , , , , EM'23
NOWTO N4EASU FE CYLINDER
EM.15

PREPARATIONFOR Headsurfaceflatn€ss
INSPECTION
L Bciorc clcaning,checkfor signs Maximumallowable
standrrd mm (in)
ofwaterandoit Leaks in cylinderblock limit nun(in)
andhead.
2. Clean o and cafton deposits Transversc
warpage on
gasket
0.r(0.0039) 0.2(0.00?9)
from all parts.Th€y shouldbe clcan lhce
contacting
fromgaskero! sealant.
3. Cleana[ oil holeswith solvent Surface
Brindinglimii 1.5(0.0s9r)
ard dry with compressed air. Make
surethri lh€y arenot resiricted.

Surfacegrindinglirnit
CYLINDERHEAD The grindinglimit of cylinderhead
AND VALVE is availableby the cylinder block
grindingin an engine..
CHECKINGCYLINDERHEAD Depth of cylinderheadgrindingis
MATINGFACE
1. Make a visual checkfor cracks Depth of cylinder block grinding is

2- Measuretnc surfaceof cylinder Thelimit is fo owing;

head (on cylinder block side) for A+B= 2.0 mm (0.0784in)
waryage.If it is found to be beyond
the limit designated
below,regrindthe VALVE ASSEMBLY
affectedsurface grinder.
with a surface
Fig. EM 29 Checkikecrlinder h.dd
suta.e 1. Check each iniake and exhaust
EMA
 Engine Mechanical

valve for worn, darnagedor deformed VALVELIFTER AND

valvecap3or stems.Conector replace PUSH ROD

2. Valve face or valve ltem end Valve lilter

surfaceshouldbe refacedby usinga
valve8rinder. Check valve lifiers for excessive
Fig. EM30 Intahe and erhawt ualue wear on the face that contactswitl
cam lobe.The end that contactspush
rod shouldalso be smootl. Replace
Unit: mn (in) with new onesif wom beyondrepai..
Corroci valve lifter to lifter hole
34.8to 35.0
In. clearanceis 0.016 to 0.052 mm
(1.370to 1.378)
(0.0006to 0.0020in).
J13
299 to 30.1
Ex,
( 1 . 1 7t7o 1 . 1 8 5 )
valve head Pu3h rod
37.8to 38.0
In, l lnspect push rod tbr excessive
(1.488to 1.496)
wear on the face that contactswith
J16 valverockerbal end Gphericalface).
31.9to 32.1
The facethat contaclswith valvelifter
(1.2s6ro 1.264)
shouldalsobe smooth,replacing those
wom or damaged beyondrepair.
109.35to 109.65
In. 2. Checkpushrod for bendor twist
(4.30s1to 4.3169)
lvith a dial gaugeor on a surfaceplat€.
J13
to 10835
108.55
L Valvelength (42736to 4.28s4)

J15 In.& to 109.6s Unit: mrn(in)

109,35
Jt6 (4.30s1
to 4.3169)

Valvestem 8.680to 8.693

D In & Ex' (0 341'7to 0,3422')
diam€ter
0.2(0.00?9)
valveceatangle ln. & Ex. 45030'

Grinding allowance for the !"lve

sten €ndsurfac€is0.5 mm (0.0197
in) or les,
VALVESPR]NG
L Checkvalvespringfor squareness
usinga steeisquareandsurtac€plate.
If slring is out ofsquare"S" in Figure
8M.33 beyondspeciliedlimit, replace

Fig.EM 31 Medsuring
stemdbmeter

Note: Wh€nvalveheadhasb€enworn
down to 0.s mn (0.0197in) in
thickn€ss,replacethe valv€. FE. EM.32 Reetinding DstDefdce

Ell,l€
l' Engine Mechanical
I Valre sprin$Aecifi cations
A32l
J13,J15andJl6 J 1 3a n d J l 5
Valvespringlengtn Double
sprhgtrT,€ Singlespringtype
Outer nm (in) s2(2.U7)
Inner mm(in) s0(1.969)
47.r(r.8s4)
Valvespringpressedlength (valveopen)
Outer 'nm/ks(in/lb) 30.7 .8(r .2091l0s)
147
Inner mrn/ks(in/b) 30.'tl7o.6(t .2o91156)
(\.r30l4't)
28.712r.3
Valvespringassembled
height (r"tve ctose)
Orter rnm/ks(in/lb) .0(1.s3t164)
38.9129
lnner run/kg (in,{b) (1.0t6/?8)
38.9/3s.4
(t.453129)
36.9113.1
("S")
Outof square
Outer ftn (in) r.6(0.063)
Innor rnrn(in) 1.6(0.063)
1.2(0.047)

2. Measur€froe length and teNion
of eachspring.lf the messured value
€xceedsthe specified llrdt, replace
spdng.
lwiih pushrodshouldalsobe inspected
placing those worn or damaged
beyond llfiits. Correct oil clearance
betweenrockorarln and rocker ghaftis
0Ol io 0.05 mm (00004 ro 0,0020
m).
2. Check rocker arm for wear or
damageto the endthat contactswith
valvestemend.The facethat contacts
for roughness,Replaceil wom of
damaged beyondrepat.
the worn parieor both valveandvalve
guide.
In this case,it is esseniial
to doier.
nine if such s clearancehas been
cauledby e wom or bentvalvestemor
by a worn valveguide.

-rtffi VALVEGUIDE
rig. EM-38 M.aludns sprw M€asureclearoncebetwoenvalve
EM36A
guide and valve!tem. If iie cleaonc€
Fig. EM.35 Intdke andexhoust uatue
exce€dsihe designaied limit, r€place
Euidedi,ne6iot,, ( for Sevice)

Valveguidedinensions(for Seryice)
Unit: ftn (in)

Valveguide 7.6to 7.A

Dr In. & Ex.
(0.299to 0.30?)
Fig. EM-34 Medsving spring t.tuio4
Valveguide 14.313to 14326
D2 In.& Ex.
outer diam€ter (0.s63sto 0.s640)
ROCKERARIII AI{D
VA.LVEROGKERPIVOT In. 47.6(r.874)
Valvesuide
L
l. Checkrockerarmfor signofwear length
oi damageto rocker slnft hole, r€. Ex. s6nQ.20s)
Et\4-10
 Engine Mechanical

- €mergencyexpedient, push (0.003ein). Max.alowabtedeflecxon

i valve guide and move to the
he right. If its tip deflects
0, mm (0.0079in) or more,
&drace betw€enstem and guide
tle maximumlimit of 0.1 mm
0.2nn (0.0079in)
Note: Valve should be moved in 3 0n m ( 1 . 1 8 1 i n )
paralel with rocker arn. (Gen€tal-
ly, a largeamountof w€aroccus in
this ditection..)

Fie- EM-36 Measutinq cledra\ce

betueen odluestem
an l vahreguide

E* luide s?ecilicstions

Intake Exhaust Wearlimit

14.2811o14.300
valve guidehole diameter mm (in)
(0.5622
to 0.5630)

Cuideto suidehole 0.013to 0.045

nrmllni
(0.000sto 0.0018)

Valvequideinner 8.732to 8.745 8.144$8.751

.. : mmtrn,
(0.3438to 0.3443) (0.3443to 0.3448)

Valvestemouter 8.680
to 8.693
.- mmttn,
(0,3411roO.3422)

0.039to 0.065 0.051to 0.077

Guideto stemclearance mm (in) 0.r0(0.0039)
(0.0015to 0.0026) (0.0020ro 0.0030)

R.pl.cem.nt of valva gulde 2. New guidesshouldbe installedto

t. To remov€old guides,usea drift
and drive them out of combustion
chamber sid€ toward rocker cover.
Heating cylinder head wil facilitate
Fig. EM-37 Drioing elue Ei.i.te
ort frcm crlintler heod
proper depth and ream€dto size of
nomal room temperatures. Standard (0.610!o0.626in)
diamet€!of hole io which guideis
fitted is 14281to 14.300mm (0.5622
ro 0.5630in).
3. Wheninstaling new guideswith
an arborpress,it is recommended to
heat cylioder head to about 80oC
(176oF).Then,pressthem into place
in valveguide holes from rocker cover
side. Guides must be installed to
proper depth so tlat height abov€
valvespring$at is 15.5to 15.9mm FA- EM-38 l@taUtne ualueSuide
(0.6t 0 to 0 .626in) asshownin Figure
EM-38. Int€rfer€nce between valve
guide and guide hole should be held
witlin 0.013to 0.045lnm (0.0005to
0O018in). 4. Ream the bore with valveSuide
pressedin, using Valve Guide Reamer
HTs6900870.
EIIIl
 EngineMechanical

Valveguideinner diam€ter
Unitl lnm (in) -! dia.

4.-"...s"
8]32 to 8.145
(0.3438to 0.3443)

8.744to 8.75'7
l"tC rios"
ls"
(0.3443to 0.34a3)
I'
Unit: mm(ir)
J13 J l 5 ,J l 6
tT569008?0
Intak€ A 40 (1.575) 40(r.s75)
B 34.5(1.358) 37.5(t.4'76t
C 32.2(t .268) 35.2(1.386)
0,2 to 0.4 0.2to 0.4
D (0.0079to 0.0157)
(0.0079 io 0.01s7)

Exhaust 32.s(r.280) 3 5( 1 . 3 7 8 )
B 29.4(1.t57) 31.6(1.244\
EM37] c 26.8(l.os5) 29.0(1.t42)
1 . 0t o 1 . 2 O.2to 0.4
FE. EM-39 Redninc uolvesuAe D (0.0079
(0.0394 to 0.0472) to 0.0157)

5. Correct valv€ seat surfacewilh
newvaiveguideasthe axis.
VALVE SEAT
when a valveseatis badlydamaged
or wom excessiv€ly to a poini wher€
pmper valvefunction is impaked,ii
nust be refac€dwith Valve Seat
CoutterST11600001. Valveseatinsert
of 0.5 mm (0.0197 in) oversizeis
availablefor service exhaustvalve.
in
Rogrlnding v.lve seatt
l- Wh€nvalveseatis found to be
wide b€yondspecificarions,
ir should
grinding
b€ narrowedwith a 45.d€gr€e
2. Width of valveseats,\ouldthen
be adjusted10 1.6 to 1.7 mm (0.053
to 0.067 in) by making upper and
lower cutsasshownin FigureEM42-
To do this, use a ls-degre€grinding
EM375
Fig. EM-41 Voloe sedt dime$io@
3. Apply snal amountoffine grind-
ing compoundto valvecontacting face
and put valveinto guide.Lap valve
aga,rst its seat until propei valve
seatingis obrained.Removevalveand
thencleanvalveandvalveseat.
Repleclng valvo Beal In.ort
1. Old in$it can be removedby
boring out until it collapses.The
machinedepth stop shouldbe s€t so
that boring cannotcontinuebeyond
the bottom fac€of the ins€rtrecess
in

ooo
cylinderhead.
2. Selecla suitablevalveseatinsert
sT1600001 andcheckits outsidediameter.
3. Machinecylinderh€ad recessto
ihe concentriccirclesof valveguide

x x o
c€nter so that insert will have th€

4. Reamthe cylinderheadrecess
at

Fig. EM40 value seot contactinq FE. EM42 Cti4ding uolue6eat 5. Pressins€rte$uring that it beds
face uith Srin lina cutter on the bottomfaceofits recess.
-12
Et\r
 Engine Mechanical

- 6. Valve seatsnewly fitted shouldbe 7. Lap valveagainstits seat,follow- CAMSHAFT AND

cut or ground at the specilieddirnen-
sionsasshownin Figur€8M41.
32,5?0ro 32.580
( 1 , 2 8 2t o 1 . 2 8 1 )d i a ,
2 6 . 8( r . 0 s 5 d
) ia.
Fie. EM.43 Standordethouttalue seat.lim2 rcn'
Cylirder herd r€c$s diametd
ingabovernentioned
procedure. CAMSHAFT BEARING
CAMSHAFT BEARING
35.0?0to 35,080 GLEARAI{CE
( 1 . 1 8 0t o 1 . 1 8 1 d
) ia.
Joumaldiameters shouldbe check-
ed with a micrometerand bearings
with an inside dial gauge.Measure-
ments should then be compared to
determinewhether bearlngsare worn.
29 (r.1,42tdi^, If found worn beyond 0.18 mm
(0.00?in), replacewith new ones.ln
.Ir5,J16 pr€ss-fittinga new bearing, make
certain that oil holes in block and
bearingareproperlyaligned.
: Unit: mm (in)

J13 J l 5 a n dJ l 6

32.500to 32.516 35.000to 35.016

For standard
insert
(l,2195ro 1,2802)(1.3780
to L3786)
Exhaust
For servic€
insert
33.00to 33.016 35.500 to 35.516
(1.2992to r.2998)(1.3976
to 1,3983)

fit nrn (in) I Exhaust| 0.054to 0.080(0.0021

Interference to 0.0031)

Crmshaftjournrl to beedngcleannct Unitr mm (in)

Frcnt Cenier Rear

journaldiameter 45.434to 45.447 43.891to 43.910 4l .218to 4l .231

Camshaft (1.?887 (r .7282to 1.7287) (1.6228to | .6233)
to 1.7892)

45.474 to 4s.484 43.948to 43.961 4l .257to 4l,267

Bearlnginnerdiameter (1,6243to | .6247)
(r ,7903to 1,1901) (1.7302to 1.7307)

0.027to 0.050 0.038to 0.064 0.026to 0.049

Beadngclearance (0.0015 (0.0010
(0.0011to 0.0020) to 0.0025) to 0.0019)

Bearingclearancelimlt 0.18(0.007r)

Camshaftjoumal to beirlng sp€cifications Unit: mm (in)

Beadng Camshaftjournal
Size Bearingthickness
position outer diameter

1 . 5 ?t o l 5 9 45.43to 45.45
Standard (0.0618to 0.0625) (1.7886to 1.7894)

o.25 1.69to l.?l 45.tab 45.20

(0.0098) (0.0665to 0.0673) (I ;7787to 1.779s)
Front
0.s0 1.82to I .84 44.93to 4495
Under size (o.o7r'7to 0.0724) (r.7689to 1.7697)
(0.0197)

o.75 l.94Io 1.96 44.6ato 44.70

(0o295) 64 ro O.0'7'72)
<O.O'7 (1.7s91
to 1.?s98)

EM-I3
 EngiineMechanical

Bearing Bearingthickness Camshaftj oumal

Size
position

1.57to 1.59 43.89to 43.91

St ndard (0.0618to 0.0626) (r ;1279to 1.128'7)

o.25 1.59to 1.71 43.64to 43.66

(0.0098) (0.0665to 006?3) ( 1 . 7 1 8 111.o7 1 8 9 )
Center
0.50 1.82to 1.84 43.39to 43.41
Und€rsize (1.7083to l.?091)
(0o197) (O.0117
roO.0724)

0.75 L94to 196 43.14to 43.16

(0o29s) (o.o764ro 0.0112) (1.6984to 1.@92)

1.57to 1.59 41.21to 41.23

Standard (0.0618to 0.0626) (t .6224to 1.6232)

0,25 L69to 1.?1 40.96to 40.98

(0.0098) (0.0665
to 0.0673) (1,6126
to 1.6134)
Rear
0.50 1,82to I .84 40,7| to 40.73
Under size (0.0197) (O.O117 (1.6028io 1.6035)
to 0.0724)

0.75 1.84to 1.96 40.46to 40.48

(0.0295) (0.0754to 0.0772) (1.s929to 1.s937)

VALVErl ll{G 3. Csmsh{ftendplay canbe check.

ed by lnstalllng camshaft, camshaft
This diagramwtll apply to a[ cyl. locatlng plate and cam$aft gear in
ind€rs,If any valveis found beyond their respectiveposiiions.Bnd play
speclfl@tiom,one possibilitylr that will thenbe indicatedwlth a dialgauge
cam lobe is worn or damag€dexc$- or a feelergaugB. If end play €xceeds
sively,calling for replacementof cam.
0.35mm (0.0138in), replacelocatinS
shaft. plate.

Fig. EM-44 VolveE ning dia$sm

& b d f

Jl3 244 244 t4 50 t2 52

J 1 5J, l 6 252 252 18 54 16 56

FE.EM46 Me6uing .omthoft end

CAMSHAFT ALIGI{MENT
1. Checkcamshaft,camshdtjournal
and cafi surfac€ for bend, wear or
damage.If ilefects are beyond limits,
replaceaffectedpafts.
2. A bent valve is one-half of the
reading obtain€d when camshaft is
tumed one tull revolution witll a dial
joumat.
gaugeapp&q(a th! .c,e!t-el Fig. EM45 Measurine .amshaft betd
Etv.14
 E n g i n eM e c h a n i c a l

Canshaft specificatioB

Standard

Canshaftbend nm (in) Lessthan0.03(0.0012) 0.05(0.oo2o)

J13 37.60lo37.70(1.4803
to 1.4842) 37.40(.1.4724\
Camshaftlobe hcight mn (in)
J15
3?.605io 37.650(1.4805
ro 1.4823) 37.3s(l.470s)
Jl6

endplay
Camshaft mm (in) 0.05to 0.29(0.0020
to 0.0114) 0.3s(0.0138)

CYLINDER BLOCK HOW IO MEASURE

CYLINDERBORE
1. Check flatnessof block gasket
surfacewith a straightedge and a A bore gaugc is used. Measure
feelergaugert lwo diagonaland five cylinder borc ri top, middlc and
positions.
longirudinal bottom positionstoward A rnd B
2. Plac€ ihe straigh! edse alons dnectionsas shorvnin FigureEM-49
diagonallinesof block planeand the ondrccordlhe measuredvalues.
longihrde,and inspectfor levelusinga
feelergauge.
Fig. EM-48 Measurihgcttin.ler bote

3. Usinga bore gauge,measure cyl-

Surface Lessthan inderborefor out.of-round
or tAper.lf
flatness 0.05 oufof'round or tap€r is cxcessive,
mm (in) (0.0020) r€borethc cylindcrwallsby melnsof
a boringmachine.Measurement should
be t ken along bores for iaper and
Surfacegrindinglinit around bores fof out.of'round.S€c
The grindinglimit ofcylinderblock FigureEM-49.
is availableby thecylinderh€adgrind-
ing in an cngine. Outof-round X.Y
Taper A-B
Depth of cylinderheadglindingis
U n i r :$ D ( i n )
4. Wl1enwear,trper or oui ot-round
Depihof cylindefblockSfindinsis is minor andwithin the limit, removc
"B"
the stcp at th€ topmostportion of
Thelinit is: cylinderusinga ridgereameror other
A+B=2.0inn(0.0784in) Fig. EM-49 Cllinler borc measwing
similartool. po$non3

Fie. EM-47 Chechinecrlindet bloch

Bytace
Et\,1-15
 E n g i n eM e c h a n i c a l

Cylinderbore sp€cifications

Standard

J13 J 1 5J, l 6

73.000io 73.050 77.950to 78.000

Innerdiameter
(2.8'740to 2.8760) (3.0689to 3.0709)
0.r5(0.005e)
Cyljnderbore
nm (in) Oufol-round 0.020(0.0008)

Taper 0.02(0.0008)
0.1(0.0039)
Diilerencecylinder
borebetw€encylindcrs mm (in) 0.02(0.0008)

CYLINDERBORING
L Whenany cylinderneedsboring, cording to the amount of wear of
all othercylindersmust alsobe bored 2. Detemine piston ovenize ac- cylinder.

pistonsspecifi
Ovelsize cations Unit: mm(in)

Jl3 Jl5,Jt6

Siandardsize 72.987lo 73.037

(2.8735to 1.8755) 77.935to 77.98s(3.0683
to 3.0703)

0.50(0.0r97) 73.467to 73.5L7 ().8924to I 8944) 78.415to 78.465(3.0872!o 3.0892)

Ov€rsiz€ .00(0.0394) 13.961ro 14.011(.2.9t21 ta 2.9140) 78.91s (3.1069

to 78.s65 to 3.1089)

1.s0(0.0s91) 74.461 (.2.9315

ro 74.517 to29337) 79.41sto 79.465(3.1266to 3.1285)

3. The sizeto which cylindcrsmust Note: To prevenistrah dueto cutting

be honedis determinedby adding1o heat,borethe cylindersin the oder
the laryestpistondiameier(at piston of 2-41-3.
skit in thrust directjon) piston-to-
9tt
a b o u t2 0 n m ( 0 . 7 8 7 4i n )
4. Do not cut too much out of
cylinderbore at one time. Cut 0.05
mm (0.0020in) or soai a time.
5. Measurementof cylinder boro
just machjn€d requires
the utmostcare
FiC.DM 51 MeosutihApbton Ekirt sinceit is expanded
by cuttingheat.
didneter 6. As a final sre!, cylindersshould
Reboredsizecalculation
D= -{ + B C = A + [ 0 - 0 0 5r o 0 . 0 2 5 7. Measure the finished cylinder
ffm (0.0002 to 0.0010 in)l borefor out-otuoundor taperedpart.
8. Measur€pistonto cylinderclear'
D: Honed diameier
Ar Skirt diametefasmeasured This cleamncecan be checked
B: Piston to-wxll clearance easilyby usinga feelerSaugeand a
C: Machinins alowanc€ [0.02 sping balancehookedon feelergauge,
Fig. EM-'0 Measutingpxton d.idtueter !m (0.0008 in)l measuringthe arnountof forcerequi!-
Efu'I.16
 E n g i n eM e c h a ni c a l

ed to pull oui gaugefrom beiween Note: ff cylinder bor€ h3s wom

pistonandcylinder. beyond the wear limit, us€{ylind€r
liner.
Undersizecylinderlinersare avail-
a. When measudg the clearanc€, able.
slowly pul the feelergaugestraight Interferenc€fit of cylind€r liner in
cylind€r block should be 0.08 to
that pislonand I
b. It is recommended 0.09mm (0.0031to 0.0035in).
cylinderbe heatedto 20oC(68oF).

Fig. EM 52 MedsurinEpiston fit

I
in cYlinder

JI5,Jt6

0.023to 0.043 0.025to 0.045

mn (in) (0.0009to 0.0017) (0.0010to 0.0018)

Fe€lerBauge
0.04(0.0016)
mm (in)

Exlractingforc€
kc0b) 0.s1o1.5(1.1to 3.3)

Cylind€rliner for service Unir: mm('n)

Jl3 J1 5 J, l 6

Oursid€diamete! Inncrdiame!€r Ouhidediameter

'77 ta 77.Os
4.0(0.ts7s) .OO 8L95 to 82.00
Undersizc (3.031sio 3.0335) (3.2254\o 3.2283)
'12.45 'l'l.45to'77.55
4.5(0.1772') 17.soto 1'1.SS to72.55 82.45to 82.50
Undersize (3.0512to 3.0531) (2.8524
to 2.8s63) (3.2461to 3.2480) (3.0492 to 3.0s31)

5.0(0.r969) 78.00to 78-05 82.95ro 83.00

Undersize (3.0709to 3.0728) (3.265'7
ta 3.2677)

Ring should be placed !o diamerer

PtsToN, P|STON P|NS at upper or lower limit of ring travel.

AND PISTON RII{GS

1. Removecarbonfrom pistonand
ling grooveswith a carbonscraperand
a curvedsteelwire. The wire will be
usefulin cleaning bottom landof ring
groove.Cleanout oil slotsin bottom
landof oil rins groove.
2. Checkfor damage,scratches and Fig. EM-5s Me$uriag ptston ring
wear. Replaceif such a defect is sitl. .ledtunce
detected-
3. Measur€the side clearanceof 4. Push ring inlo cylinder with a
rings in rhg groovesas each ring is piston so as ro place it squarely in
installed.Clearance with new pistons cylinder; measure ring gap with a
andringsshouldbe a!fo]1ows. feelergauge. FiC- EM-s! Meosuring ing Eop
E[/],17
 Engine Mechanical
Sidecleamnc€ Unit: rnm(in)
Notes:
a. l{hen piston dng obly is to be Standard
replnced, without cylindg bore Wearlimit
beitrg corr€cted,m€asurethe gapat Jl3, J15andJ16
th€ bottom of cytnder where the
Top dng 0.036to 0.076(0.0014to 0.030)
Properdng fit in ring grooYeis very 0.r (0.0039)
important for propet performance Secondring 0.036to 0.076(0.0014to0.030)
and long life. A sticky ring ca$es
blow"by ot oil.up, iesulting in
prenature wear on ring and cyl- Ring gap Unit: mm (in)
inder wall. ff it is too loose, this
acceleratB w€ar on sid€s of ring Standard
grooveto aggramt€ring play. Wearlimit
b. Oversizepiiton rings are available. J13 J l 5 ,J t 6
[0.5 mn (0,0197 in), 10 nn
(00394 in) orcruizel, 0.20to 0.33 0.20to 0.35
Top rlng
(0.0079xo0.0130)(0.00?9
to 0.0138)

0.20to 0.33 0.14to 0.29

dng
Second
(0.0079 1.0(0.0394)
to 0.0130)(0.0055to 0.01l4)

Oil ring
0.30to 0.90 0.3to 0.9
(0.0118io 0.0354)(0.0118
to 0.0354)

Ov€$izeplstonringout€ralitmeter Unit: mrn(in)

---------.-.'.--
113 Jl5,J15.

St.ndard 13.00(2.8740) 1't.95(3.0689)

0.50(0,0197) 73.sO(2.8937) 78.4s(3.0886)

Over
size
1O0(0.0394) 14.00Q.9t34) (3.1083)
78.9s
1.s0(0.0591) 74.s0(2,933r) 19,4s(3.1279)

Fig"8M"66 Pitton pin fltti^e

5. Measurepiston pin hole in rela" 6. Determinethe fitting ol piston

tion to the out€r diameterof pin. lf
wear exceedstlle limit, replacepiston
pin tog€therwith piston on which it is
insta ed.
pin into piston pin hole to such an
€xtent that it canbe {inger press€dat
room temperature. This piston pill
must be a tight pr€ss fit into con-
n€ctingrod.
FiC. EM-56 Measwing piston pin
diametet

Etll,18
 Engine Mechanical

Unit: mm (in)

J13 J 1 5 J, l 6

Pistonpin outsidediameter 17.44'7to I7 .452(0.6869to O.6811) 20.993to 20.998(0.826sto 0.8267)

Pistonpin hole diameter 17.453 (0.68?lto 0.6874)

to 1?.460 21.001 (0.8268
ro21.008 to 0.82?1)

Pistonpjn to pistonclearance 0.001to 0.013(0.00004

to 0.000s) 0.003to 0O15(0.00012to 0.00059)

fit of piston
Interference 0.01sto 0O33(0.000s9
to 0.00130)
Bolt clamp
pin to connectingrod

CONNECTINGROD
J l 3 ,J l 5 a n dJ 1 6 Maximum
l. If a connecting rod hasany flaw
on bolh sidesof the thust faceand Connecting rod bend
it.
the largeend,corrector replace or torsion(per I 00
0.03(0o012) 0.1(0.0039)
mm or 3.94in length)
mm (in)

Connecling
rod big 0.20to 0.3
0.5(0o197)
endplay mm (in) (0.0079
to 0.0118)

EM133
Fig. EM67 Chechingrcd otign ent
2. Checkconnecting rod for bendor
torsion usingconnectingrod aligner.If
bend or torsion exceodsthe limit,
3. When replacingconnectigrod,
s€l€ct rod so that weiSht differ€nce
betwe€nnew and old onesis within 6
sr (0.2116oz),
4. lnstallconnectilgrodswit]bear"
ings on to conespondingcrnnk Pins
and measurcthe thrust clearance.If
the measuiedvalue€xceeds the limit,
replaceconnectingrod.
CRAI{KSHAFT
s
L Whenevercrarlshaft is remov€d J 1 3 J, l 5 3 8 . 8( 1 , 5 2 8 )
from engine, thor'
it shouldbe cleaned 41.00.646)
oughly in a suitablesolvent.Afier
cleaning,checkcrankshaft joumaland
crank pin for score,bias wear or 41.640to 41,652 dia.
( 1 . 8 7 5t6o 1 . 8 7 6 1 )
cracks.Repairor replaceas required,
If defectssre mjnor, dresswith fine 50.813to 50.825dia
crocuscloth, .0005102.0010)
2. Checkwith micrometerjournals
and crank pins for taperand outof'
mund. Measurement shouldbe talen
along joumals for taper and around
journalsfor out-of-round.SeeFigure
EM-59for detailedinformation.

Out-of-round x-Y 3 4( 1 . 3 3 9 )
Taper A.B
t 8 . 7( 0 , ? 3 6 2 )

/n tr-l
\l7I{
Fig.EM-59 Croftshdft andiourtul
.lime6ion

Ifjournalsor crankpinsaretapered
or out-of-roundbeyondlirnits;repiace

EM.lS

Fig- EM-60 MeasutiaCjou dl diometpr
3. Crankshafican
bend by piacingit
J 1 3 ,J l 5 a n dJ l 6
Taperandourof"round
ofjorunalandcrankpin
0.01(0.0004)
mm (in)
JI 3 ,J 1 5
Crankshaft
bend
(in)
mm
Noter When measurinS bend, us€ a
djal gauge.Bendvalueishaf ofthe
readingobtainedwhencrankshaft is
turned one full revolutionwith a
dinl guageattahcedto its center
journal.
4. After regrinding crankshaft,finish
it to the necessary
sizeindicaiedin dre
list on pag€EM-21by ushg an ade-
quate undersizebearingaccordingto
theextentof requiredrcpair.
5- After grindingjournalsor crank-
pins,crankshaftshouldbe checked for
end play-This canbe doneby instail.
ing shaft in engineblock with main
bearingsand bearingcapstorquedto
10 to l1 kg'rn (72 to 80 fi-lb).
Wilhout disiurbingabovesetting,bar
Crankshaftfreeend 0.05to 0.20
play mrn(in) (0.0020to 0.0079)
E n g i n eN 4 e c h a n i c a l
using a dial gaugewith its indicating
finser rcstingon centerjoumal.
Fig. EM 61 Chechingctunhshaftbend
Maximum
0.01(0.00r2)
Standard
0.0s(0.0020)
cranksluftas far €ndwiscas posiblc
and inserta feelcrgaugein cleanncc
bctwe€nbiock and centerrnainbear-
'nc.
Fig. EM 62 Chechinscrcnhshaftend
0 . 3( 0 . 0 1 r 8 )
Er\,1-20
If end play exceedsseflice limits
above, replace thrusi washerswith
thosethat give propercranlshafiend
ptav.
Thrusrwasherthickness
(upperandlowet mm (in)
2.235Ia 2.286
(0.0880to 0.0900)
2.286ro 2.337
(0.0900to 0.0920)
:.337to 2.388
(0.09:0 to 0.09210)
2.388io 2.438
(0.0940ro 0.0960)
6. At the rear end of crankshaft,
check crankshaft pilot bushing for
w c x r o r d a n a g e .R e p l a c ei t i l d c f c c ti s
To replace crnnkshaft rear pilot
b u s h i n g! r o c e e da si o L l o w s l
(l) PulL out bushins usins Pild
B u s h i n gP u l l € rS T l 6 6 l 0 0 0 l .
\ r'uuronn'
Fis. EM-63 Pulling out pilot
bwhing
(2) Before installing a new bushing,
rhoroughly clean bushing holc. Press
fit bushing so thai its heisht above
tlangecnd js 8.0 to 8.3 mn (0.315 to
0 - 3 2 7i n ) . D o n o t o i l b u s h i n g .
( 0 . 3 1 t o0 , 3 3i n )
Fig, EM-61 Presefitting netupilot
bwhirg
 E n g i n eM e c h a n i c a l

BUSt{t]{c Al{D w€ar,scorssor pitting,replacing

those (3) Loosen bolts securingcap in
BEARIl{G foundbeyondmaximu,nlinits. place.Compareflatlenedwidth with a
MEASUREMENT OF 2. Measurecleamncebetweencon- specialscalesuppliedwith the plas-
CON}IECTING ROD BEARING nectins rod journal and bearinsto ti8aseenvelope. If difference
between
CLEARANCE deternine jf it is within specified maximumand mirimun width in a
1. Checkconnecting
rodbearing
for limits. strip exce€ds 0.03 lnm (0.0012in), it
is an indicationlhal journal is wom
locally,callingfor furtherse.vice.
Brrring oil clearsnce Noter Do not tum crankshaftwith
plastigage
installed.
Maximurn
3. If measurement revealsthat oil
Connecting rod
0.011lo 0.052 clearanceexceeds0.10 mm (0.0039
ciearance(bigend) 0.10(0.0039)
(0.0004to 0.0020) in). usecorreclundersiz€
bearing.
mln (in)

To measureclearance,proceedas (2) Placea sirip ofplastisase lensth-

folows: wise on journal. Instal bearingon
(1) Beforemeasuring, journah and joumal and right€nto 2.5 to 3,5 kg.m
bearingsshouldbe wiped cleanof oil (18to 25 frlb).

Connecting andjoumalspecifications
rod bearing
Unitr mm(in)

rodjoumal
Connecling
Bearing
rhickness
outerdianreter(crsnkpin)

L83 ro l 84 4l.64 ro4'7.65

Standard
(0.0720lo0.0724) (l.8756to 1.8?60)

0.08 1.8610L87 47.58to 41.59

(0.0031) (0.0732to 0.0736) (1.8732
to 1.8736)
0.l2 t.89 to l 90 4'7.51ro 4'7.53
(0.0047) (0.0744to 0.0748) ( 1 . 8 7 0 9 1Lo8 7 1 3 )

0.25 1.95to l.9a) 47.40ro1'7.41

(0.0098) (0.0768to 0.0772) (1.8661
!o 1.866s)
Undersize
0.50 2.08to 2.09 4'7.t4ra4'7.ts
(0.0197) (0.0819to 0.0823) ( l . 8 5 5r9o 1 . 8 5 6 3 )

0.75 2.2410o2.2r 46.90to 46.91

(0.0295) (0.0866to 0.0870) (l.8465to 1.8468)

1.00 2.33to 2.14 216.64to 46.65

(0.0394) (0.0917to 0.0921) ( 1 . 8 3 6 2r o 1 . 8 3 6 6 )

Note: Since bearinssare of precision
insert type, it is not necessaryto
file bearingcapsor to gdnd b€aring
surfac€swith an emery cloih to
conect b€aringclearance.
MEASUREMENTOF MAIN
BEARINGCLEARANCE
Thoroughly clean all beatings.
Check for scratches.
r€phcing those found beyond limits.

Etv-2l
 Engine M echanical

Bearingoil clearance Whennew bearingsare us€d,bear-

ins fit, or mor€ specifically,
oil clear-
anceshouldalwaysbe inspected. If if
exceeds0.10 mm (0.0039in) (maxi-
Main b€aring cl€arance 0.02to 0.05 mun), corr€ct undersize bearings
0.10(0.0039) shouldbe selected or journalsshould
mm (m) (0.0008to 0.0020i
be groundto fit next unde.size bear'
proceedasfollows:
To measureoil clearance, mgs.

1. Crankshaftjournalsand bearings Note Do not turn crankshaftwhile Note: Sincebearingsare of pr€cision

shouldbe wipedcleanof oil andalty plastigageis install€d. insert type, it is not n€cessaryto
oaherforeign materialssuch as dust file bea.ingcapsor to grind bearing
and dirt beforethey canbe neasu.ed surfa€€swith an em€ry cloth to
conectb€aringclearanc€.
2. Use plastigage, placingit length-
wise on joumal. lnstal bearingand
bearingcapin positionandtightento
10 to 11 kg.m(72 ro 80 ftlb) t€nsio..
3. Removecap and measurewidth
of plastigageflattenedby comparing
with a specialscal€print€d on plas. Fig.8M.65 Measwingmdin beoring
tigageenvelope,

Main bearingandjoumal specifications Unir: mm(in)

j ournaI
Crankshaft
Bcaringthickncss

1.822
to 1.83s 50.81
to 50.82
Standard (2.000
(0.o711roO.o722, to 2.001)

L947to 1.960 50.57to 50.59

0.25(000e8) (O.O'767
ta O.O7
72) ( l . 9 9 1t o 1 . 9 9 2 )

2.0721(l
2.085 50.31to 50.33
(0.0re7)
0.s0 (0.0816
to 0.0821) ( 1 . 9 8 0t7o l 9 8 1 s )
Undersize
2.197to 2.210 50.07 to 50.09
0.75(0.029s)
(0.086sto 0.0870) (t .9'7| to I .9'72)

2.322to 2.335 49.81to 49.83

1.00(0.0394)
(0.0914to 0.0919) (1.961to 1.962)

FIITING BEARINGS back surface is completely flush

Bearingsare manufaciuredwith
crush io nahe them fit snugly into
their bores.To measurelhis, proceed
1- Properlysetmainb€aringin mair
beadngcap recessor cylinderblock
2. Lock one sideof rhe bearingand
press i]Ie ofher side ti11ihe bearing
Pressweight:
abou!500kg (1,100lb)
3. Then,measure bearingc sh "H"
with a feelergauge.SeeFigureEM{6.
Th€ standardbearingcrush%lueis 0
ro 0.0smn] (0 to 0.0020in). Fig. EM-66 Cheching bedrinc crBh
EM22

MISCELLANEOUS
COMPONENTS
CRANKSHAFT SPROCKET
AND GAMSHAFT SPROCKET
1. Chcckcrankshaft and camshaft
sprockets
for wearor scores
onsprock-
et teeth. Replaceif wom or damaged
b e y o n dI i m i t s .
2. lnstall camshaft sprocket and
cleck to determinethat geafrur out is
held withfi 0.1 Jn'n (0.0039 in). If
CHAIN AND CHAIN
TENSIONER
i. Chcck chain for stcppcdw€ar,
scratchcsor othcr problcmsto roller
links.Replaceilnecessary.
2. Chcck chain tensioncrfor wear,
brerkag€or rny other defectswhich
would intcrfcrc wilh proper chrin
functbn. Replace if necessrry.
FLYWHEEL
1. Cheokring gcar. Ii found to bc
worn or danagedcxocssiycly,rcplace.
2. Clutch contactingface of fly-
wheelshouldbc smooth.lf it is wo|n,
d nagedo! roughcncdbcyondlimits.
PRECAUTION
C Y L\ D ' R A D .. . . . , . . .
P I S T OANN D C O N N E C T JFNOGD. . . , , , , .
PRECAUTION
Before dssemblingcnginc, obscrve
the fo]lowing precautions:
1. Clean all disasscnbledparls with
clean solvent- Al1 oil holes in crant-
shaft, camshaft.valverocker shaft. etc.
should be cleaned thorcugHy to re-
move all traces of grinding chips or
lint. Always use cleansolvent.
2. In genelal,uscd gaskets,packings
E n g i n eM e c h a ni c a l
3. Measure flywheel for run out.
This can b€ checkedwiih a dial gauge,
by iotaiing jl in either direction with
indicating finger resting on flywheel
facc la hest from center. If 'un out
exceeds0.05 mn (0.0020 in), replac€
flywhee1.
FiC.EM-67 Measurinqflydheel tun
Noter Removal and installationof
ringgearrequiresuseofa hydmulic
presr. It is also nec€ssaryto heat
ring gearas thh expandsit, thus
facililatingremoval0ndinstallation.
Do not heatring gearto morethan
300oC (572oF). To do so could
resultin inpaired hardness of ring
gerr.
ENGINEASSEMBLY
CONTENTS
EM 23 V A L V ER O C K ESRI ] A F TA S S E M B L Y , ,, .
EM 24 A S S E N 4 B LE
I NNG
G I N.E. , , . . , , , , . . - . . . . . .
EM 24
and oil sealsshoutd be rcplacedwith
3. Under no cncunsrances should
lockwashersbe reused.
,1. Place bolts. nuts and washers
back in their originrl parts or places
ffom which they were removed.
5. Most packings serve best when
Liquid packing is applied to iheif
sealingsurfaces.When designated,use
suitable liquid packing io elimjnate
EM.23
FROI{TCOVER
OIL SEAL
First check front cover of oil seal
for deflected wiping edge or oil
leakag€.If it is denec&d or the'e it
any sign ol oil teak,replacelvith a n€w
seal. When insraling a new sea1,pay
pariicular atlention to mounting direc
Fig. EM'68 InstaUineoil seal
Noi€s:
a. It is goodpnctice to renewoil serl
when€ver engin€is overhauled.
b. Apply lithiumgrease to wipingedge
of oil s€al.
EM.24
EN,1.25
possibiliiyof watcr, oil and gasleak.
6. Prior to assembling, all sliding
surfacesshouldbe oilcdlibera11y.
7. Propertighteningis essentialto
successful pefomancc of all vehicte
repairs.It is alsoimpodanlto lbllow
correctsequence of lighieningin pul-
ingup cylinderhead.Beon the aleriat
a]l tines to th€ amountof cleannce

8. Cleanliness of toolsor partssu€h
as work bench usedin makinga repan
is essential.When setting up a job
every pr€cautionshould be taken tiat
toolsor partsarefreeofdirt, mudand
oil. Do not work in dustandgrit, for
they are pdmary causeof w€ar in any
engine.
CYLINDER HEAD
Use Velve Lifter 5T12070000,1o
install intake and exhaustvalves,valve
springs, valv€ spring retainers, valve
colletsand rubber rings to cylind€r
hesdin the orderlisted.
Not$;
a. Do not intercha$ge\alvesbetween
cylind€rs,for th€lr slidingor seating
su acer haveundergonewearing-in
or hsve been hpped at s$lembly,
forning specific coniact with their
matingpart3.
b. Ch€ck to be sule thlt valv$ are
properly seatedon valveseatswith-
out for€rgn padicles stuck in be.
FE.EM-69 IrctauingDalue
PISTON AND
CONNECTINGROD
l. Heat pistonto 20oC (68oF);as-
sembleconnectingrod, piston pir and
pistonto8€therby hand.On the J13,
tiShten connectingrod s.nallend bolt
to 2.s to 3.s ks-m (18 to 2s ftlb)
usinga suitabletorque wrench.
Engine Mechanical
sT13050000o15.J16)
Iie. EM-70 ln6tdlli4Spitton p 1
EM365
Fe. EM-71 IiShteninssnotten4
bott ( 3)
EM32I
Fis.EM"72 Astemblingpietondnd
connectingrod
Notes:
a. For the Jls and Jl6 engine pbton
is pr€$ed into connecting rod, and
fitting forceis from 0.5 to 1.5tons;
the aid of Piston Pin hess Stand
ST13050000 (Jls, J16) or
STl30OO00(J13)b nec€ssary.
When pressingpiston pin in con-
n€ctingrod, apply engineoil to pin
and smallendof connectingrod.
b. A[ pistonsarc marftedwith a notch
in piston head and "F" ma*
around pislon pin hole. B€ sureto
install pistons in cylind€n with
thes€ markslacing toward front of
engrne.
c. Cotrnectingrod shouldbe instaled
with bottotn oil jet placrd on right
slle.
d. Do dot givedirect hanEn€rblows to
pidon pin whenfitting it hto place
in pi*on.
EM.24
2. To install pistonwith piston dngs
properly spacedarourd it, usePistor
Ring ExpanderEM035m000.BYery
€ution should be taken that dngs are
not interchangedbetweenring groov€s
in piston.
Be sureto install compressionrings
with surfaces having marked end
towardpistonhead:
Notes:
a. Top ring is chromim-plated on
linercontactingface.
b. Secondring haslargertapersurface
than top ring.
c. In the combinedoil ring, upperrail
is the ssmeaslowerone,
EMI68
Fis. EM-73 ttutalling pbton rine
3. Installconnectingrod bushingin
btg end half and cap.M&kesurethat
dust and dirt arc not ca.ried ln bo-
lween iheir matingcl€aronce.
VALVE ROCKER SHAFT
ASSEMBLY
Install parts, as shown in'Figure
EM-74,in placeon rocker slEft; secure
with cotter pins on both €nals of
rocker shaft. Instrll set screwin hole
in rearmost bncket and tighien to
prevent shaft from working loose
duringoperation.
, b \
FiC.EM-74 ksembling Mlue rochq
shoft d*emblr
 Engine Mechanical

.ASSEMBLING 4. Cleanmain bearingshells,bearing Note: Apply liquid prcking to bearing

E1{GINE
l. The first stepin €ngnrcassembly
is to bolt Engine Attaclunert
5T05280000 to dght hand side of
cylinder block. Next, instal anotlrcr
EngineStand ST0501S000 in block.
2. Thorougt y clean groove in oil
sealhousingof oankslBft rearbearing;
placeofl sealin groovewith finger and
thumb. Usine an oil seal replacer
Guide), lighdy tap with a harnmer
until oil seal is installed coffectly.
T.im seal flush with ends of housing
block. Install oil seal in rear bearing
saddlesand bearing caps. Place slpll
hrtves in b€arjng Naddlesin cylinder
blo€k; place other hlves in bearing
caps. Next, install thrust washerson
each side of center b€arh8. Make
ceriain that lug on eachhalf of shell
fits in a notch in bearing saddleand
bearingcap.
Notei Thrust washels should be in"
stauedwiih side oil gloov€sfacing
towaid outer sid€of bearingc$p.
saddletouching ends of r€{r main
b$ring csp.
7. tnstal rcar bearing side s€al and
front seal. Prior io installing, apply
aalhesiveto theseseals.B€ careful not
Xo damag€ sealing lips which could
result in oil leak.

FiE.8M.79 DtiuinSrcn be&ins

EM3A7
FE.8M.77 Mdin bedringcdps
dd beaing.

5. Liberally apply cleanengineoll to

EM3A5
Fig.EM-76 INtaUinE crunhahaftrc.r
oll eeol
3. Apply a light coat of engin€oil io
sliding surfccesof velve lifters; lnsert
lifters in holos in clinder block. To
inatell camshaft,be sureto coat sliding
surfacesof camslEft bushingswith a
Ilght cost of englno oll. Insert cam"
shaft in cylinder block from f$nt side
of €ngine, exercising carc not to
darnage camshaft bushtngs. Toque
locatingplate 1o 0.5 to 0.8 kg-rn(3.5
to 53 fdb) using a suitable torque
bearing shelk; place cranlshaft on
shellsin cylinderblock.
6. To instal main bearingcaps,be
rure that arrow mark in cap head h a
placedtowardlront of engine,Install
thrust lrasherson each sid€ of center
Fig. EM40 INto ing frcnt Beal
main bearingcap. Main bearingcap
bolis should be tightened In the
equenceasshownandin threeto four 8. Install engine rear plate and
st€psgraduaUy. After abovestepshave Sasketand tightenbolts to specifiod
been completed,checkto dotermine torque.
tlat cnnl(shaft tums fr€ely.
Mainbeadngcaptighteningtorque: 3.0 to 4.0 kg"m
10 to 1l kg-m 9/16" bolt
Q2 ro 29 rt.lb)
(72 to 80 ftlb)
09 to 1.5kg-rn
(6.5toll ft-lb)

9. Position fl]^vheel in place on

llange end of crantshaft; instull and
tighten attaching bolis to 4.0 to 5.0
EM4O4 ks-m (29 to 36 ftlb). Bend ends of
FiC. EM-78 Toryue equence of lockwash€rsup aSain$ sides of at-
Fig. EM-76 lastolling lo@tinA pldte cop bohs tachingbolts to secureinsta ation.
Elt4-25

Fig. EM-81 Installins flyuheel
Note: Always use new lockwashers
and tight€n them up againstbolts
10. Using Piston zung Compressor
EM03470000,install pistonsso they
are below top of cylinders.Notesin
inslallingpistons:
(1) Marking "F" in piston head F ie. EM-84 T iehtenine.onnecting tod
shouldbe placedtowardthe front ol
cngine.
11. lnstall engine fiont platc with
(2) Eachconn€ciingrod is number- gasket under jt and tighten bolls to
ed, beginingat the front of engine, specifiedtorque.
Pistonand connectingrod &ssemblies
shouldbe installedin respeclivecyl"
inder so that number on rod cor-
respond!with cylindernunber,
(3) Piston ring end gapsshouldbe
strggered l80o apad from €achoiher,
being careful not to locatc them in
thrustandpistonpin directions.
Se.6nd rinA_
Fig.EM 82 Pistoning diection
(4) Numberson connecting rod and
bearingcap must be on the sameside
with oiljets properlypoiried. Referto
Note "c" underihe paragraph "Piston
and ConnectingRod." Instan con-
nectingrod capswith light engineoil
on both joumal and bushingcontact-
ing surfaces. Draw tiem up to 2.8 to
3.5 ks-m (20 to 25 ftlb); insta pal
t nutsto secure the iflstallation,
4
Engine Mechanical
(2) After abovestephasbeencom.
pleted, instail crankshaft sprocket,
chainand camshaftsprocketwith their
markingsproperlyaligned.Oil sprock-
et t€eth and chain wlth liSht engine
oil. Tightencamshaftsprocketbolt to
4.0 to 5.0 kg-m (29 to 36 ft-lb) by
meansofa suitableiorquewrench,
F is. Elll-83 tnsLollingphton
Fig.EM-86 Aligningmothings
EM166
13. lnstall chain tensioner.Correct
cop proj€clion"L" ot spindleis bclow 15
mm (0.591 in). Rephcespindlewh€n
it is foundlo be overthisiimit.
0.5to 1.0kg-m
7116"bol\
(3.6 to 7.2 fr"lb)
0.9to L5 kg.m
l/2" bolt
(6.stollft.lb)
12. Installclankshaftsprocket, cam-
EM334
shaftsprockelandchainin t|e follow-
Fig.EM'87 In'ta|ing chaihtensionr
ingmanner:
(1) Insert keys in keyways.Tem-
porarily install both crankshaftand
14. Install oil ttuower in froni of
camshaftsprocketsand checkto s€c camshaflsprocketcorrectly.
thai th€y are flushwith eachother.If
differencein height falls below 0.5
mm (0.020 in), place a 0.15 mm
(0.00s9 in) washerund€r crankhaft
FE. EM-88 Imtalling oil thrcber
ls. Instal froni (chain)coverwith
gasketinsededin between.At this
Fie. EM-85 Meaturingspto.ket heiSht time, coat gasketsurfaceand Saskei
Etvl-26

contact surface of engirc block with
suitable liquid packing before in-
ita ing gasket.Apply a littuum grease
to wiping edgeof front cover oil seal.
16. Instal and tighten crankshaft
puley to 12 to 14 kg-m (87 ro 101
ftlb) torque.Be sureto bendlocking
tab of lockwasherto s€curethe in.
stallation.
EM396
Fig.EM'89 Irctalling uantuhaft puller
17. Insiall oil pump &ive spindle
and oil pump assemblywith gasket
placedunderthem.Correcttightening
is l 2 to 1.8kg.m(8.7to 13tulb).
EM397
Pig.EM-90 Intd ing oil pump
18. At ihis stage,oil pan shouldbe
installed io fianged end of engine
blockwith gasketinsertedin b€rween.
Tightening should be performed in
criss"crosspattemto 0.5 to 1.0kg-m
(3.6to ?.2 ft.lb) tension.
19. The next step in engine as-
sembly is to install cylinder head and
rockershaftassernbly.
(1) Positioncylinderhead in place
on top of engineblock.Do not fo4et
to install gasketb€tweenhead and
block.
Note: Coat gasket surfac€ of engine
block with suitable liquid paddng
before imtaling gasket.Also apply
Engine Mechanical
same liquid packing to cylinder
head on surfacein which pushrod
holesarc castout.
(2) Insertpushrods.
(3) Position rocker shaft assembly
on top of cylinderhed.
(a) Tiehten cylinder head stud nuts
andvalverockershaftbfacketboltsar
FiC- EM-92 A.ljuiting &lue-tdppet
Cylinderhead 5.0 to 6.0kg.m
(36 to 43 ftlb)
21. Instflll sidecov€r.Tightenbotts
2.0 to 3.0kg-m which hold it in plae to 0.4 to 0.8
(ls to 22 tulb) kg-m(2.9to s.8 ft-lb) torque.
22, lnstall water pump assembly
In tightening,note the followingi with gask€t placed under it. Coat
Tighteningshouldbe madein two gasket surfacewith suitable liquid
or ihree steps,finally torquingto peckingbeforeinstalling grsket.lnstall
specificrtions. and tightenattachingbolts to specifi.
Tightnessof nuts andbolts should cations.lt shouldbe between1,2 and
b€ rcchecked afier enginehasbeen 1.8kg.m(8.7to 13 ft.lb).
operatedfor severalminutes;if
necessary,reiighten,
IiR. EM-93 lwtalling wdt$ pump
EM39A
Fig.EM-qI T@htening sequence 23. Install thermostatand water
outl€t.Do nol forgetto insta gasket.
20. Afier valv€nappet clearnace has
been adjustedproperly, instat valve
rocker covei. Correct valvelappet
clearance is 0.35 mm (0.0138in) for
both intakeand exhaustvalveswhen
engineis hot. To achievethis, first set
clearanceto 0.35 mm (0_0138in)
when engineis cold.Afrer engjnehas
been assembled, run it for at least
sevenlminutesand recheckclearance,
€M4oO
For d€tails,referto 'Adjustingintake
Fig. EM-94 l6taUing thetmutot
and exhausi valve clearance" in ET on l uoter outlet
24- Coat cylinder block to fuel
pump mountiag fac€s with suitable
Intakeand liquid packing and position gasketon
Exiaust Valves fuel pump mounting lace of block;
instal pump and tighten to 12 to l 8
kg,m (8.7 to 13 ft-lb) tensionusing a
0.3s(0.0138) suitable torque wr€nch. Heat shield ,.
plate shortd be installedsimultan€ous- .:itL
1y. ::.i

Fis.EM 95 Installingfuelpump
25. Position intake and exhaust
manifoidson cylinder block; install
bolts which secure manifolds and
torqueto 1.7 to 2.3 kg-n (12 to 17
ftlb). Next, instal carbureto!and air
clean€r.Engineslingerandai! cleaner
suplort shouldalso be tiShlenedto'
getherwiih manifolds.
Notes:
r. Carburetor gasketshould
insulating
be installedwith notch facingup.
b. Extl" caution shouldbe takento
pr€ventdust and sbrasiYes from
enteringcarbur€tor.
C{$uretornutstighteningtorque:
0.8 to 1.2kg"m
(s.8ro 8.7 ftlb)
Fig. EM-96 Instdlling mdnifoU
Fie. EM-97 Iastollingcdtburetor
Engine lvlechanical
26. Instaflalternatorbrack€l,adjust-
ing bar, alternator,fan pulley,fan and
fan belt in that order.Then,checkto
b€ surethal deflectionof fdn belt is
held wilhin 8 to 12 mm (0.315 to
0.472 in) when thumb lressure is
appliedmidwaybelw€enpul€ys.
( 0 . 1 1 5 r0o0 . 4 7 2 4
ini
Fig. EM-98 Meosuringdeflection of
fon belt
sTr9s50000
Fig.8M.99 Mountinq ditection of distibutordtiue spindle
30. Instal spark !1ugs,hish tension
cabl€s,oil pressur€switch and oil level
gauge.
31. Insrall fuel pipes and vacuum
At]. pipes and hoses should be
clampedsecurely,being careful not 1o
allow them to interfere with adjacent
El\l -28
27. Position oil filter brackei in
place with gasLetplaced under it;
tightento 1.6 to 2.4 kg-n (12 to 17
ftlb) usinga suitabletorquewrench.
28. Fastenoil lilter on oi1 filter
Note: Do not overtighten
filter, ot oil
lskag€may occur.
29. lnstall distributorin the fofow-
(1) Brins No. I pistonin T.D.C.on
its comlression
stroke,
(2) Driv€ spindleshouldbe located
as shownby usingDistlibutorDrive
SpindlePullerST19550000.
(3) Install distribuior bracket and
Note: Be carefulnot to d(op drive
spindleinto oil pan.
or surounding pads.
32. Fill with engine oil to specified
level.
33. Using an overhead hoist and
lifting cable, hoist engine up away
fiom enginestandand ihen down onto
enginecanier. Instal clutch assenbiy,
stading motor and enginemountings.
 Engine Mechanical

SERVICEDATAAND SPECIFICATIONS
GENERAL SPECIFICATIOI{S
Jl5 J16
4 in line 4 irl lin€
Disphcernent 1t99 (79.3)
,cc(cuir) -.....-......... r,483(90.s) | ,56't(95.6)
Bore x stroke rnln(in) .........,.........
73 x 77.6 78x 71.6 18 x 82.o
(3O7x 3.06) (391 x 3.23)
o.H.v. o.H.v.
t-3-4-2
Engineidle speed rpm .........................
600 600 500
Cofirpr$sion ratio ..,......,......,..8.2 8.3 8.3
Otl capacity(lncludingoil fllt€r)
Llt6$(U.S.qt,,Lnp.ql) ..,,..,.. 3.4to 4.4(3%, 4% to 4%, 3%)

EM-29
 Engine Mechanical

TIGHTENINGTORQUE

Model Jt6

Cylinderheadstudnut
s.0to 6.0(36to 43)
kg-m (ftlb)

Rockershaftbmcketbolt
kg-m (ft-lb)
2.0to 3.o(14to 22)

Connecting
rod bigendnuts
ks.m(tulh) 2.8to 3.5(20to 2s)

Connecting rod smal endbolt

2.5to 3.s(18to 2s)
kg-m (ft-1b)

Flywheelfiing bolts
4.0 to 5.0 (29 to 36)
ks-m(tulb)

Malnbearingcapbolts
10to 1l (72to 80)
kg.m (fr-lb)

Camshaft sprocketbolt
4.0 to 5.0 (29 1o36)
kg-m (ft.lb)

Oil panbolts
0.5to 1.0(3.6to 7.2)
ks.m (ftlb)

Oil pumpbolts
1.2to 1.8(8,7to 13)
ks-m (ft.lb)

Oil pandrainplug
2.0to 3.0(14.5to 21.7)
kg"m(ftlb)

Locatingplatebolh
ks'm (f b) 0.5ro 0.8(3.6to 53)

Carburetor nuts
0.8to 1.2(s.8to 8.7)
kg-m (ftlb)

Manifoldnuh
1.7ro 2.3(12ro l7)
kg.m (ft.lb)

Fueipumpnuts
1.2to 1.8(8.7to 13.0)
kg.rn (ft.lb)

Crankpulleybolt
l2 to l4 (87to 101)
ks-m (ftlb)

Enginefront plate bolts

kg-m (ftlb)
7/16"bolts 0.5to 09 (36 to 5.5)
l/2" bolts 0.9to 1.5(6.5to 11)
Enginerearplate bolts
ks-m (ftlb)
9/16" bolts 3.0to 4.0(22to 29)
l/2" bolts 0.9to 1.5(6.5to 11)
 Engine Mechanical

Waterpunp bolts 1.2to 1.8(8.7to 13)

kg'rn (tulb)

Oil iilter bolt! r.6 to 2.4(12to 1'7

kg-m (ftlb)
)

Sidecoverbolt
0.4to 0.8(2.9to 5.8)
ks-m ({t"lb)

SPECIFICATIONS
Model J16

a) VehE mechanbm

Valveclo.rance(hot)
lntak€ andexhaust . 0.3s(0.0138)
mm (in)

Valveheaddia.
mm (in)
-Intake 349(r.3740) 37.9(1.492t)
-Exhaust 3 0 . (01 . r 8 l l ) 32.0(t.2s98)

Valvestemdia.
mm (in)
Intake andexlaust 8.680to 8.693(0.341?
io 0.3422)

Valvelength
mm (in)
-lntake 109.35to 109.55 (4.305to 4.31?)
(4.305to 4.31?) to 109.65
109.35

-Exhaust 108.55to 10835 109.35 (4.305to 4.317)

to 109.65
(4.274to 4,28s)

Valve springfree lengih

Inm (in) Model620,T20 (J13,Jls andJ16) ModelA32l (JI3,Jls)
-Outer 52 Q.047)
-Inner s0 (1.969) 47.r (r854)

Valve springpressured
length (valveopen)
mn/kg (in/lb)
-Outer 30.714'7.8 (t .209ll0s) 30.717O.6
28.7l2t .3(t .130147 O 2Ae1156)
Inner )

Valvespringassembled
height
(valveclose)
nrn/ks (in/lb)
Outer 38sl29n
Q.s3r164) 38I135A (t s3r 178)
Inne! 369113.r
(r.4ssl29)

Etv,31
 Engine Mechanical

Model Jl6

Valve spdngeffectiveturns Model520,T20 (J13,Jl5 andJl6) ModelA321(J13,Jl5)

mrn (in)
-Outer 4.s(0.1772) 3.7s(0.14'76)
Inner 6.s(0.2ss9)
Vaivespringwire dia.
mm (in)
-Outer 4.0(0.1s75)
' 4.s(0.r772)
Inner 2.8(0.1102)

Valvespringcoil dia.
mm (in)
-Outer 2s.2(0.992r) 2s.2(09921)
-Inner 18.4(0,7244)

Valveguidelength
nm (in)
4'7.6 (1.874)
s6.0(2.20s)

Valveguideheightfrcm
heedsurface 15.5to 15.9(0.510
to 0.626)
rnm(in)

Valveguideinnerdia.
mm(n')
8.732to 8.745(0.3438
to 0.3443)
8.714to 8.751(0.3443
to 0.3/'48)

Valveguideouterdia.
mm (tn)
Intake andexlaust 14.313 (0.5535
to 14.326 to0.5640)

Valveguideio st€mclearance
mm (in)
-lniake 0.039to 0.065(0.0015
to 0.0026)
_Exlaust 0.051to 0.07?(0.0020
to 0.0030)

Valveguideinterferencefit
nJn (in) 0.013to 0.04s(0.000sto 0.0018)

Valve seatwidth
mm (in)
Intat€ andexiaust L6 to L7 (0.0630to 0.0669)

lntake andexiaust

fit
Valveseatinterference
lr)In (in)
0.054to 0.080(0.0021io 0.0031)

E[4-32
 E n g i n eM e c h a n i c a l

Model J16

b) canshaft and tinins chain

Camshaftendplay
0.05to 0.29(0.0020
to 0.0114)
mm (in)

Camshaftlobe height
6.15(0.242r)
mm (in)

Camshaft journaldia.
(standerdsize)
mn (in)
_F!ont 45.434to 45.441(l ;7887to I;7892)
-Center 43.89'lto 439lO(1.1282to | ,128'7)
-Rear 4l .218to 4t .231(1.622Ato | .6233)

Ca.rnshafibend
Lessthan0.03(0,0012)
mm (in)

journalto beartng
Camshaft

mm (in)
_Front 0.027to 0.050(0.0011
io 0.0020)
-Center 0.038to 0.064(0.0015
to 0,002s)
-Rear 0.026to 0.049(0.oo10
ro o.oo19)

Camshaftbearinginnerdia.
mm (in)
-Front 45.474 to 45,484(1,7903to 1.7907)
-Center 4.94a b 43.961 (1.1302 to 1,7307)
Rear 41.257Ia 4l .267(l .6243to 1,6247)

c) Rockerarm lev€rratio t.4

d) Connectingrod

Centerdistance
nrn (in) (s.51?)
t42.67 (5.s06)
13e.8s

Bearingmaterial F500 F770

(S.T.D.)
Bearinethickn€ss 83to 1.84(0.0720
to 0.0724)
mrn (in)

Bigendplay
0.20ro 0.30(0.0079ro 0.0118)
ffn (in)

Connectingrod bearingclearan
0.011to 0.052(0.0004to 0.0020)
mn (in)

Connectingrod bendor iorsion

(per 100lnm or 2.937in) l-e$ ihan0.03(0.0012)
nm (in)
 E n g i n eM e c h a n i c a l

Model J16

e) Crukshaft andnain bearing

Joumaldia.
s0.813to 50.825(2.0005
to 2.0010)
mn (in.)

Journaltaper& oulof,round
mm (in)
LEss
than0.01(0.0004)

Crankshaftfreeend play
mm (in)
0.05to 0.20(0.0020
to 0.0079)

Wearlimit of dittoedplay
mm (in) 0.3(0.01r8)

Crankpin dia.
mm (in)
47.640to 47.652(1.8756
ro |.8761\

Crankpin taper& oufof-round

nm (in)
Lessthan0,01(0,0004)

Mainbearingnaterial F770

Mainbearingtlickness(S.T.D.)
mm (in)
1.822to 1.835(O.0717
to 0.0722)

Mainbearingclearance
mm (in)
0.02to 0.0s(0.0008
to 0.0020)

Wearlimit of dittoedclealanc€
mm (in) 0.10(0.0039)

Cranlchaft bend
mm (in) Lessihan0.03(0.0012)

f) Piston

Pistondia. -S.T.D. '72987

to73.037
mm (in) (2.873s ??.935 (3.Q583
to 77.98s to 3.0763)
to 2.8755)

0.s0(0.0197) 73.467
to73.517
Oversize (2.8924
to 2.8944) ?841sto 78.46s
(30871ro3.0892)

1.00(0.0394) '73.961
ro 74.017
Oversize (2.9r2rta 29140) 78.915 (3.1069
to 78.965 to 3.1089)

1.5(0.0s91) 74.467ta 74.517 '79.415

Oversize to '79.465(3.1266
to 3.1285)
Q.9318to 29337)
Elipsedifference
nm (in) 0.07to 0.17(0.0028to 0.0067)
 E n g i n eM e c h a n i c a l

Jl6

Ring groovewidth
2.0(0.0787)
2.0(0,0781)
4.0(0.rs7s)
Piston to bore cl€arance 0.023to 0.043
mm (in) (0.0009to 0.0017) 0.025to 0.04s(0.0010
to 0.0018)

Pistonpin hol€ off-sei 0

mm (in)
0.95to L05 (0.0374
to 0.0413)

Pisionpin hoiediameter 17.453to 17.460

mrn (in) (0.6871to 0.6874) 21.001 (0.8258
to 21.008 to 0.8271)

g) Plstonpin

Pin dia. I7 .141to 17.452

rnn (in) (0.6869 to 0.6871) 20.993to 20.998(0,8265
to 0.8267)

Pin length 65.23to 65.48

mrn (in) (2,5681 66,40to 66.sS(2,6t42to 2.6240)
ro 2,5780\

Pistonpin to phton clearance 0.001to 0.013

mm (in) (0.00004 0.003io 0.015(0.00012
to 0.00059)
to 0.00051)

fit of pistonpin
Interfer€nce
to conneciingfod bushing Bolt clarnp 0.015to 0,033(0.0006
to 0.0013)
mm(nr)

h) Pistonring

Ringheight
rnrn(in)
-ToP (0.0781)
1.984
-Second (0.0781)
1.984

Sideclealance
nm (in)
-Top 0.036to 0.076(0.0014
ro0.0030)
-'Secord 0.036to 0.076(0.0014
to 0.0030)

Ringgap
rnm (in)
0.20to 0.33
(0.0079to 0.0130) 0.20to 0.35(0.0079
to 0.0138)
0.20to 0.33
(0.0079to 0.0130) 0.14to 0.29(0.0055
to 0.0114)
0.30to 0.90(0.0118to 0.03s4)
 E n g i n eM e c h a n i c a l

AND CORRECTIONS
T R O U B L ED I A G N O S E S
Condition
I. Noisy engin€
Knocking of crankshafl Loosemarnbearing. Reptace.
andbearing. Seized
bearing. Replace.
Bent crankshafi. Repairor replace.
wearofjournal.
UneYen Corr€ct.
cranLshaftend play.
ExcessiYe centerbearing.
Replace

Pistonandconnecting Loosebea.ing. Replace.

rod knocking Seizedbearing. Replace.
l,oosepistonpin. pin or bushing.
Replace
lrose pistonin cylinder. Recondition
cylinder.
Brokenpistonfing. Replace.
rod alignment.
Improperconnecting Realign.

Camslnftknocking lrose bearing. Replace,

axiaiplay,
Excessive bearingthrustplate.
Replace
Roughgearteeth, Repair.
Brokencamgear, Replace.

Timingchalnnoise Improperchaintension. Adjust.

chain.
Worn.nd/or damag€d Replace.
Replac€,
Wom and/or broken iension adjusting Replace.

andb€aliogclearance-
camshaft
Excessive R€plac€.

Camshaftand valve Improperyalv€clearance. Adjust.

nechanismknocking Wornadjustingscrew. Replace.
Replace.
Loosevalvestemin guide. guide.
Replace
valvesprinS.
Weakened Replac€.
valve.
Seized Repairor replace.

Waterpunp knocking Impropershafi€ndplay. R€place.

Brokenimpeller. Replace.

lI. Other mechanic{ltrcubles

Stickingvalve- Irnpropervalveclearance. Adjust.
Insufficientclearancebetweenvalve stem Cleanstemor r€amguide.
andguide.
Weakened
or brokenvalvespring. Replace.
Seizedor damaged valvestem.
Poor fuel quality.

EM.36
 EngineMechanibal

Cordition Probabl€cause Co(ective action

Seiz€dvalveseat Improper valveclearance. Adjust.

W€alcnedvalvespring. R€place.
Ihin valveheadedge. ReplacevalYe.
Na-ffowvalveseat. Relace.
Overheating Repairor replace.
OYerspeeding. Ddve within proper speed.
Stickingvalveglide. Repair.

Excessiv€iy
worn Shortage
of engineoil. Addor replaceoil.
cylinderandpiston Drty engtneoil. Cleancrankcese,
r€place
element,
Poorqualityof oil. Usedghtoil.
Overheating. Repair
or replace.
Fallty asseftblyof pistonwith conneciing Repair
or replace.
rod.
lrnproper fristonringcleerance. Adjusi.
Broken pirtonrlng, Replace.
Dirty alr clean€r. Clean.
Toorichrni\ture. Adjust.
Engineoverrun, Driveat properspeeds.
Stickingchokevalve, Cloan,nd adjust.
Overchoking. Startcorrectly,

Dofective Shortoge of engineoil. Md oil.

confl€ctirurod I-owoil pressurc. Correct.
Poorqualityof engineoil. Useright oil.
Roughsurfaceof crar*shaft. Gdndandreplacebearing.
Cloggdd oil passage. Clean.
Dearlng wearor eccentdcity, Replace,
Improper bearinga$embly. Conect.
loosebearing. Replac€.
Corur€cting
rod alignm€ntincorrect. Repairor replace.

Def€ctlvecranlshsft Shortageof engin€oil. Add or replace.

bearing l,ow oil pressurc. Correct.
Poor quality of engineoil. Useright oil.
Gankshaft journal wom or out-of-round. Repair.
Cloggedoil passage
in crankshaJt. Cl€an.
Bearing*'ear or ecc€ntricity. Replace.
Improper beadngassembly. Correct,
EccentriccranlGhaftor bearing. Replsce.

EM.37
 E n g i n eM e c h a n i c a l

SPECIALSERVICETOOLS

Description pageor
No- & Uniti mn (in)
figureNo.

1. sTo501s000 Thisenginestandassembly is usedfor disassembling

or assembling All PageEM-5
engineblock or differential carrierthroughout360' in all PaseEM-25
Enginestand
dir€ctions. Fis.EI{-l1
?ssembly
I
fsTos011000
J Ensinestand
l1ST05012000
Base

2. sTo5280000 Thisengine
attachmentis installedto enginestandST05015000 J13 PageEM-s
or assembling
in dhass€mbling engifle. J15 PageEM"25
Engine
J16 Fig.EM'lI

3. sT13040000 installingthe pistonpin.

For removingand Jt3 PageEM-?
PaseEM.24
Plstonpin
pressstand

sT13060000 Thistool is us€dwitha prcsgto drivepin into, or out oi, connecf Jl5 PageEM-7
ng rod. l\6 Fig.EM-25
Pistonpin
L2OA PageEM-24
20 (0.?87)dia
Fis.EM-70

120(4.72)S
2 0 ( 0 . 7 8 7 d) i a ;

EM.38
 Engine Mechanical

For Reference
Desc.iption
No. & paceor
Unit: rrun (in)
figurc No.

5. sT12070000 This tool is usedto compressvalvespringby the combinedaction Alt PageEM-7

Valvelifter of its carnandlever,therebyfaciliiaiing the removalor installation models P^geEM-24
of collect(for generaluse). Fig. E[,]-69

6. sTt1600001 This valves€atcutter setis usedto or refinish a valveseat. Jl3 PageBM.l2

Valveseat J15 Fig.EM42
J16
P

sEl93

't.
sTl6s11000 Thistool fuus€dto removeihe cepfrommeinboaring.When J13 PageEM.5
Crankshaft usingthistoo1,tuin itr adapterlnto thethreaded
holein maln J15 F|E,8M.22
malnbearing Desrulgcap. Jt6
cappurcr AI
L.
Series
2 5 0( 9 . 8 )

2 8 0( 1 r . 0 )

8. sT16530000 This tool is usedto rcmovecamshaftand crankshaftsean with Jl3 PageEM"s

Crankshaft chainhung aroundgearte€th. J15
gearpul€r J16
H20
H30

Elvl-39
 Engine Mechanical

Tool number For Reference

Descdpiion
No. & pageoi
Unjt: nu (in)
luure No.

9. sTr661000r Thjsiool is usedtopushpjlot bushour ofplace. J13 PageEM"20

Pilotbush J15 Fig.EM-63
puuer J16
Ll3
Lt4
L16
L18
L2OA,
G18

10. sT19550000 Thislool is usedto removeandinstalldistributordrivesDindle. J13 Pag€EM-28

Distributor J15 Fig.EM-99
drivespindle J16
puller

ll. EM03500000 Thistool is us€dto rcmoveandinstallth€pistonrings. AII PageBM-1

Pision ring mod€ls PageEM'24
expand€r

t2. EM03470000 This tool is usedto compresspiston ringswhile piston is being A| Pag€
BM-26
Phtonring insertedinto cylinder. inodels

EM40
 Engine Mechanical

Toolnumber For
Desqiption
No. & pa€eor
Unit: mm (in)
figure No.

sT19320000 This tool is usedto take oil filter out of plsce.In tightening All PegeEM-5
the lilt€q do noi usethis filter, to pr€ventoxcesstightening. models
Oil lilt€r

sE197

14. Irts6900870 Ihe reamerisusedfor finisldngtheboreof newguide, Jl3 Fig.EM.39

Vrlveguide J15 P6geEM.l1
ftamer J16

EM.4I