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    02 - Engine Mechanical PDF

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    Vitor Jordao

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    EM-1 ENGINE MECHANICAL Page TROUBLESHOOTING EM-2 ENGINE TUNE-UP EM-4 COMPRESSION CHECK .. EM-15 TIMING BELT cess EMA16, ‘Components ceetetttteeeeeeeres EMAG: Removal of Timing Belt sna EM-16 Inspection of Components ........ cece EMA9 Installation of Timing Belt .......... EM-21 CYLINDER HEAD ooo... ccc ceceeeeeee eee EMRE Components .2.2 06.6 ce cece ceceeeeee eres EMA26 Removal of Cylinder Head... veces EM-27 Disassembly of Cylinder Head. seeeees EM-30 Inspection, Cleaning and Repair of Cylinder Head Components .. vey EM-31 Assombly of Cylinder Mead .............-..-. EM-38 Installation of Cylinder Head - EM-40 CYLINDER BLOCK enestead EMA45 Components be etece teers EMOMB Préparation for Disassembly EM-46 Disassembly of Cylinder Block EM-48 Inspection of Cylinder Block ... EM-52 Disassembly of Piston and Connecting Rod Assemblies e..0.-sccsevseererrecsess EMOBS Inspection of Piston and Connecting Rod Assemblies ...--..0.0- see ceceesees EMBO Boring of Cylinders ....-... ceceereees EMB7 Inspection of Grankshaft ... ceeeesees EMPBB Replacement of Oil Seal . eit v EM-59 Assembly af Pistan and Connecting Rod Assemblies. teeeeereeee EMGT Installation of Crankshaft, Piston and Connecting Rod Assemblies ..,,,...-..-.-. EM-62 Assembly of Cylinder Block ........2.2.0.0.. EMA64 EM-2 ENGINE MECHANICAL — Troubleshooting TROUBLESHOOTING Problem Possibte cause Remedy Page overheats | Cooling system Fauly Troubleshoot costing system 0-2 Incorrect ignition timing Reset timing ewe Engine will not crank | Starting system faulty | Troubleshoot starting systamn [st2 “or etanks siovity | Engine wil not start) | No fuel supply #0 earburetor Choek tut ine her to srt Certurotor problems Troubleshaot ust system Fu, Igoition problems Troubleshoot ignition system 162 Vacuum teake Repair a2 necessary © HIC tne © PCV tine © lntake manifold 1 Compression low Cheek compcession MAIS Rough ide or stalls | Vacuum enka "| Repair as necessary HH tne \ | # Peviine | © intake monitord | tgnition probiams Troubleshoot ignition ayatam | 10-2 Carburetor probloms Troubleshoot fuok system Fu2.9 HAL system fauity Check HA! system | Engine ovecheots Troubleshoot cooling system | CO-2 Compression low ‘Check compression EMS Engine hesitates! | Ignition problems Troubleshoot ignition system 162 oor acceleration | vacuum leaks Repair as necessary | HIE ne ' © PCV ine | * intake manifold | © carouretor noses | air ctooner clogged check air ftor jee Fuel line clogged | heck fuel line ‘Sexburetor problems ‘Troubleshoot fuel system FUL2, 3 Emission contro! system problem “* HAL system always on Check HAI system thot engine? | Engine overhests Troubleshoot cooling system coe | ere nr | Shc commas amis ENGINE MECHANICAL — Troubleshooting EM-3 TROUBLESHOOTING (Cont'd) Frobiem Possible cause Remedy Page Engine diesaing Carburetor problems “Troublesheot fuel system Fu-2 8 (rane after ignition Incorrect ignition timé Roset timing EM-S switch is turned off) . “~ ‘Muffler oxpiosion DP system teulty ‘Check OF system Eig steer feed on Daceleraion Fual cut evstem always aff | Check fuel cut system deceleration only | Muffier explosion ‘Air claaner clogged . (Check alr iter Ma {after fiel all the | Choke system faulty Cheek choke system time (K type carburetor oni) | incorrect ignition timing Reset timing EMG Engine backfires | Choke valve open (cold nginel Check chake system tT {iC type carburetor only} Carburetor vacuum feck Chock hoses and repair | se necoccary Ingufficiant fuel thre Troubleshoot fue! system 7-23 Incorrect ignition timing Reset timing Enis Excessive oll Oil teak Reais as necessary corsumation PCV line clogged hack PCM system Piston ring wrom or damaged Check rings Valve stem won Check valves and guides a-32 | Valve stem oif seal worn er damaged Check eit sea Poor fuehmivage | Ful leak Repair as necessary : Air eleanor clogged Check sir titer ems Jgnition problems Troubleshoat gation system | 16-2 Corburetor problems Troubleshoot fual systern Fu, ‘Compression low heck compression eves Tees impropertyintated Inflate tres to proper pressure Clutch sip Troublachootaluteh Brakes dog Troubleshoot brakes | ENA ENGINE MECHANICAL — Engine Tune-up ENGINE TUNE-UP CHECK OIL LEVEL The vik level should be between the L and F maks an the lovel gauge. If low. check for leakage and add oil up to the F mark, INSPECT AIR FILTER {a} Visually check that the air cleaner element is not oxcossively dirty, damaged or oily, tb) Clean the element with compressed air. First blow from the back side thoroughly. Then blow off the front side of the element. INSPECTION OF HIGH TENSION CORD 4. CAREFULLY REMOVE HIGH TENSION CORD BY RUBBER BOOT FROM SPARK PLUGS. CAUTION: Pulling on or bent damage the conductor Inside. ‘the cords may 2. INSPECT RESISTANCE OF HIGH TENSION CORD WITH DISTRIBUTOR CAP Using on ohmmeter, eheck that the resistance dos not exceed the maximum, Maximum resistance: Less than 25 k{/eord Hf more than maximum, check the terminals, and replace the high tension cord and/ar distributer cap as required ENGINE MECHANICAL — Engine Tune-up EMS INSPECTION AND ADJUSTMENT OF VALVE CLEARANCES NOTE: Inspect and adjust the valve clearance after engine has reached normal operating temperature. 1. . REMOVE AIR CLEANER COVER 2. REMOVE CYLINDER HEAD COVER (See step 3 on page EM-16) SET NO. 1 CYLINDER TO TDC/COMPRESSION (a) Tum she crankshaft pulley and align its groove with the “0” mark an the No, 1 timing belt cover. (bl Check that the rocker arms on Ne. 1 eylinder are loose and the rackers on No. 4 are tight. IF not, turn the crankshaft one complete revolution and align the marks as above. INSPECT AND ADJUST VALVE CLEARANCE fe) Measure only those valves indicated, Valve clearance (hot): 0.20 mm (0,008 {o) Using 9 fesler gauge, measure the gap between the eam and rocker arm. Loosen the lock nut and turn the: adjusting screw te the specified clearance. Hold the: adjusting screw in position and tighten the lock nut fol Recheck clearance. The feeler gauge should move with a very slight drag, (dl Turn the crankshaft one revolution and adjust the other valves. INSTALL CYLINDER HEAD COVER (See step 10 on page EM-24) INSTALL AIR CLEANER COVER Spark plug — no | NGK | iececi W20EXR-U 2E IEC! WDE Others | W2OEX-U ‘SPROEY v1 | aPREEYHY Beery Tachometee ey * a = seh Conventional Type = ‘Tachomater ENGINE MECHANICAL Engine Tune p INSPECTION OF SPARK PLUG 4, CLEAN AND INSPECT SPARK PLUGS la) Clean the spark plugs with a spark plug cleaner or wire brush th) Inspect the spark plugs for electrode wear, thread damage and insulator damage, If a problem is found, replace the plugs. 2, ADJUST ELECTRODE GAP Carefully bend the outer electrode to obtain the correct electrode gap Electrode gap: W20EXR-U — BPRGEY 0.8 mm (0.031 in} W20EX-U BPGEY = 0.8 mm (0.031 In} W20EXR-U11 BPRGEY11 1.1 mm (0.043 in} INSPECTION AND ADJUSTMENT OF IGNITION TIMING 1, CONNECT TACHOMETER AND TIMING LIGHT TO ENGINE {Conventional Type): Connect the tachameter positive (+) terminal to the igni- tion coil negative (-} terminal. HA Type! Remove the rubber cap and connect the test probe of a tester to the service connector at the distrinutor. CAUTION: © NEVER allow tho ignition coil terminals to touch ground as it could result in damage to the igniter and/or ignition © As some tachometers are not compatible with this ignition system, it is recommended that you congult with the manufacturer. 2. WARN UP ENGINE Allow the engine to reach normal operating temperature. 3. CHECK DWELL ANGLE (Conventional Type only) Dwell angle: 52 + 6° (ab With the engine idling mak sure the divell angle-is within the specified range. If angle is tao fargo, set the rubbing block gap closer. i199 small, inerease the gap. tb) ENGINE MECHANICAL — Engine Tune-up. 4, EM-7 CHECK IGNITION TIMING ec) tb Disconnect the vacuum hose from the distributor sub-diaphragm and plug the hose end. (6) With the engi idling a8 specified, use a timing light to check the timing, Ignition timing: fa 5° BTDC @ Max. 950 rpm HF necessary, loosen the distributor bolts and turn the distributor to align the marks. Recheck the timing after tightening the distributor, Torque: 175 kg-em (13 ftlb, 17 Nem) Reconnect. cern (Reconnect the vacuum hose to the distributor. le Check the ignition timing. Ignition thmi 12 ~ 18° BTDC NOTE: Check the ignition timing with the electric cooling fan off (General) i) ‘With the engine idling as specified, us6 a timing light to check the timing, Ignition timing: 5° BTDEC (85 RON version! 10° BTDC (80 RON version) Fesfer to the information label under the engine hood. NOTE: Check the ignition timing with the electric ccoling fan off. te Hf necessary, loosen the distributer belt and turn the distributor to atign the marks. Recheck the timing after tightening the cistributar Torque: 176 kg-om (13 ft-lb, 17 Nem} EM-8 ENGINE MECHANICAL — Engine Tune-up CHECK AND ADJUSTMENT OF IDLE SPEED AND IDLE MIXTURE NOTE: Check and adjust the idle speed and idle mixture with the electric caoling fan off, | CONNECT TACHOMETER TO ENGINE 2. WARM UP ENGINE ‘Allow the engins to reach normal operating temperature. 3. CHECK IDLE SPEED Idle speed: M/T 800 rom AIT 850 rpm W not as specified, adjust according to the following pra- cedure: CAUTION: © Always use a CO mater when adjusting the idle mix: ture, It is nat necessary to adjust with the idle mix- ture adjusting serow in most wehictes If they are in gaod condition. © Hf a CO mater is not available and it is absolutely necessary to adjust with the idle mixture adjusting screw, use the alternative methed (See page EM- 101. A, METHOD WITH CO METER VISUALLY INSPECT CARBURETOR {a} Check for loose screws or a loose mounting to the manifold, fo) Check tor wear in the linkage, missing snap rings or excessive looseness in the throttle shaft. Comect any problems found 2. INITIAL CONDITIONS {o) Initial conditions © Air clesner installed # Normal operating coolant temperature © Choke valve fully aben IK type carburetor anyt # All accessories switched off © All vacuum lines connected © ‘nition timing set eorrectiy . © Trensmission in M range © CO meter operates normatiy © Use SST it necessary SST 08243-00020 ENGINE MECHANICAL —~ Engine Tune-up Emo {b} Disconnect the HIC hose and plug the hose ends, TERE (EX EG) o's. aD ausT IDLE SPEED la) Start the engine. (b) Tum the idle speed adjusting serew to obtain the specified speed, Idle speed: M/F 800 rom AIT 850 rpm. ite nicure’”—SdhvStIN Serer Adjusting Screw ones [2E (EG), BEC Tato tantra coy, Adjusting Screw die Speed } LL _Aaiusting Screw sane "] 4 MEASURE CO CONCENTRATION -Focherastar fo) Make suré the CO meter is praperiy calibrated, ib) Race the engine for 30 — 60 seconds at about 2,000, 7 'pm before measuring the concentration, {ch Woit about 3 minutes after racing the engi 5) the concentration ta stabilize rm: Id) Insert a testing probe at least 40 Gm (1.3 41 into the: {oilpipe, and measure the concentration with 9 short fime. Idle CO concentration: TE, 26 (Ex. EC) 2.0 + 06 % 2E (EC), 2€-C 15 £05 % ® If the CO concentration is within specification, this adjustment is complete to allow ® If the-CO concentration is not within spacification, turn the idle mixture adjusting screw te abtain the specified concentration value. © If the CO concentration cannot be corrected by idle mixtura adjustment, refer to the following table for other possible causes, ‘TROUBLESHOOTING ENGINE MECHANICAL — nging Tune-up co Norma’ Probloms | Rough ile Causes 1, Faulty ignition: 1 Iocomeet timing Fouled, shorted or improperly gapped plans # Gpen or crossed ignition wires © Gracked distributor can Ineorect valve clearance ‘Lasky exhaust valves: Leaky eylinger Low High | Roush idle Fluctating HE reading Rough tale | ft0ek smote tom eust Vaeuurt leak: © Vacuum hose © Intake mantel © FCW ling © Corburetor base 1. Restricted air falter 2. Plugged PCM valve 3. Faulty carburetion Feulty choke action # Incorrect float setting 4 Leaking needle or saat * Leaking power valve 5. RECONNECT HIC HOSE B, ALTERNATIVE METHOD To be used only if CO meter is not available. 4. VISUALLY INSPECT CARBURETOR (a) (by Check for loose screws or a loose mounting to the manifold Check for wear in the linkage, missing snap rings or excessive looseness in-the throttle shaft, Correct any problems found. 2. INITIAL CONDITIONS ta) Initisl conditions: © Air cleaner instaliod © Normal operating caotant temperature © Choke valve fully open (K type carburator only] © All accessories switched off All vacuum lines connected @ Ignition t ig st correctly ‘© Transmission in N range # Use SST if necessary ‘SST 09243-00020 ENGINE MECHANICAL — Engine Tund-up Eha-i7 ©) Disconnect the Hic: hose and slug the hose ends, 3, ADJUST IDLE SPEED AND IDLE Mixruné 2) Start the engine. (2) Set to the maximum speed by turning the IDLE MIX. TURE ADJUSTING SCREW. lel Set to the idle mixtura speed by turing the IDLE SPEED ADJUSTING SCREW, Idle mixture spec: YE, 2E (Ex. EC) M/T 850 rpm tte Speed dle Mixture Acjusting Scrove Agjusting Screw AIT 900 rpm a ea 2E (EC), 2E-C M/T 860 rpm — AIT 910 rpm {dl Before moving to the next step, continue adjust ments tb) and fe) until the maximum speed will not ise any further na matter howe much tha IDLE Mike TURE ADJUSTING SCREW is adjusted, (eh Sat to the idle speed By screwi TURE ADJUSTING SCREW. Idle speed: M/T 800 rpm AIT 850 rpm Feconnect the HIC hose, in the IDLE Wax ar Iie Spood = Adjusting Sere th aul INSPECTION AND ADJUSTMENT OF FAST IDLE SPEED 18, 26 (Ex. EC) 1. WARM UP AND STOP ENGINE 2, REMOVE AIR CLEANER Plug the HIC hose. 3, CONNECT TACHOMETER 4 FULLY PULL OUT CHOKE KNOB 5. INSPECT AND ADJUST FAST IDLE SPEED fa} Start the engine (b} Fully open the choke valve, (cl Cheek the tast idle speed. Fast idle speed: 1B 4,809 + 200 tpm 2E 3,400 = 200 mpm EM-12 ENGINE MECHANICAL — Engino Tune-up (a) Agjust the fast idle speed by turning the FAST IDLE ADJUSTING SCREW. (e) Recheck the fast idle speed. 6. INSTALL AIR CLEANER ones Pe Fost lobe Adjusting La Screw 2E (EC), 28-6 1, WARM UP AND STOP ENGINE ——————> 2. CUT OPERATION OF EGR SYSTEM (2E-C only) Disconnect the vacuum hese from the EGR valve and plug the hose end, 3. CONNECT TACHOMETER 4, INSPECT AND ADJUST FAST IDLE SPEED NOTE: Inspect and adjust the fast idle speed with the electric cooling fan off. la} Start the engine. (bl) While holding the throttle valve slightly opén, set thé fast idle adjusting cam, and release the thrattle valve, |e) Check the fast idle spead. Fast idle spead: 3,600 + 200 rpm [db Adjust the fast idle speed by tuming the FAST IDLE ADJUSTING SCREW. (el Recheck the fast idle speed, 8. CONNECT EGR SYSTEM (2E-C only! Connect the vacuum hose to the EGR velve. ENGINE MECHANICAL er Engine Tun 9 EM-13 INSPECTION AND ADJUSTMENT OF DASH POT (DP] SYSTEM 1 2. 3 WARM UP ENGINE CHECK IDLING SPEED AND ADJUST IF NECESSARY CONNECT TACHOMETER OUT OPERATION OF EGR SYSTEM (2E-C only! Disconnect the vacuum hose from the EGR valve and plug the hose end, INSPECT AND ADJUST DASH POT SETTING SPEED. NOTE: Inspect and adjust the dash pot setting speed with the electric cooling fan off {1E, 2E (Ex. EI fo)" Disconnect the vacuum hose from the dash pot and plug the vacuum hose end. (6) Maintain the engine speed at 3,000 rpm. fc] Relense the throttle valve. Id) Check the dash pot setting speed DP setting speed: 2,000 + 200 rpm EM-14 fg Dash Pot Adjusting Screw gee I not at spec ENGINE MECHANICAL — Engine Tune-up spead, adjust with the dash pot adjust- ing screw. | fe) Reconnect the vacuum hose to the dash pot, Ete BE tec) >» (E (EC), 2€-C) fa} Disconnect the vacuum hose from tha dash pot and plug the vacuum hose end. to) Maintain the engine speed at 2,000 rpm (o) Release the throttle valve ld Check the dosh pot setting speed. DP setting speed: 2,000 + 200 rpm Bash Pot Adjusting Screw PEE ae ee = (of Reconnect the vacuum hose to the dash pol, ce Ye CONNEGT EGR SYSTEM (2E-C oniy) If not at specified speed, adjust with dash pot adjusting screw, Connect the vacuum hose to the EGR valve. ENGINE MECHANICAL — Compression Check EM-15 COMPRESSION CHECK NOTE: If there is lack of power, excessive ail consump- tion or poor fuel milage after engine tune up, measure the eylinder compression pressure. WARM UP ENGINE REMOVE FOUR SPARK PLUGS DISCONNECT DISTRIBUTOR CONNECTOR MEASURE CYLINDER COMPRESSION PRESSURE lal Insert a compression gauge into the spark plug hole. {b) Fully open the throttle. lel While cranking the engine, measure the compression Pressure NOTE: Always usé 4 fully charged battery to insure that at feast 250 mm can be attained fa} Repest steps (ab theough (ct For each cylinder. Comprossion pressure: BE IEC), 2E-¢ 13.0 kg/em (184 psi, 1270 kPal Others 12.0 kgfom? (171 pet, 1180 kPal Minimum pressure: 10.0 kg/cm? (142 psi, 981 kPa) Diffetence between each cylinder Less than 1.0 eafom? (14 psi, 98 kPa) {eH compression af one or mare cylinder is low, pour a small amount of engine oil inte that cylinder through the spark plug hole and repeat steps fal through fo} for the eylinder with low compression. © If adding of helps the compression, chances are that the piston rings andar eylinder bare are worn or damaged, © If pressure rom: tow, a valve may be sticking or seated improperly, ar there may be leakage past the gasket surface. EM-16. IGINE MECHANICAL ing Bett TIMING BELT COMPONENTS ‘Cammabaft Tining Pulley ‘Taming Belt oi Purp Paey eo. Spring. Crankshaft Timing Pulley Ting de Gute No. 1 Timing Bott Cover Cramkshatt Pulley [ig-CRTETE Wil] = Specitina torque REMOVAL OF TIMING BELT 1. IF VEHICLE HAS AIR CONDITIONING, REMOVE DRIVE BELT 2. REMOVE ALTERNATOR DRIVE BELT Loosen the alternator pivat nut, fock bolt and remove the alternator drive belt, Altarnator Pivot Nut 3. REMOVE CYLINDER HEAD COVER [Disconnect the PCV hose from PCV valve, tb) Remove the two nuts and cylinder head cover with gasket. ENGINE MEGHANICAL — Timing Bolt eMn7 4, 6 SET NO. 1 GYLINDER TO TOC/COMPRESSION Tum the crankshaft pulley and align its groove with the 0" mark on tha Na. 1 timing belt cover. NOTE: Check that the rocker arms on the No. 1 eylindes are loose. If not, tun the ¢rankshaft pulley ane complete revolution. REMOVE CRANKSHAFT PULLEY (a) Install the SST to the crankshaft pulley. SST 08212-14010 ol Using SST to hold the crankshaft pulley, remove the pulley bolt, SST 09330.90020 fl Using SST. remove the pulley, SST 09213-31021 REMOVE TIMING BELT COVERS Ramave the six bolts and the No. 1 and No. 2 timing belt covers, REMOVE TIMING BELT GUIDE EM-18 ENGINE MECHANICAL — Timing Belt a a W 12, REMOVE TIMING BELT AND NO. 1 IDLER PULLEY CAUTION: Bo NOT turn the camshatt or crankshaft while the timing belt is removed as this will desynchronize the timing of the piston head with the subintake valve. NOTE: If reusing the timing belt, draw @ direction arrow: ‘on the lett lin diréction of engine revolution), end place matchmarks an the pulleys and bolt as shown in the ‘figure. (a) Loosen the idler pulley bolt and pustvit left as far as it will go and than temporarily tighten it (b) Remove the belt, (c) Remove the ilar pulley bolt, pulley and tension spring. REMOVE NO. 2 IDLER PULLEY REMOVE CRANKSHAFT TIMING PULLEY If the timing pulley cannot be removed by hand, use two screwoirivers. NOTE: Position shop rags as shown ta prevent damage, REMOVE CAMSHAFT TIMING PULLEY Hold the eomshott with the wranch, and ramove the pulley sot bolt and timing pulley REMOVE OIL PUMP PULLEY Using SST to hold the pulley, remove the pulley nut end pulley, SST 09612-24012 ENGINE MECHANICAL — Timing Belt EM.19 INSPECTION OF COMPONENTS No! 1. INSPECT TIMING BELT CAUTION: * Do not bend, twist er turn the belt inside out. * Do not allow the belt to come into cantact with oil, water or steam. * Do not utitize belt tension whan installing or remov- ing the sot bolt ef the camshaft timing pulley. H there are defacts as shown in the figures, check the following points and replace the timing belt if necessary. la) Premature severance © Check for proper installation. (b) if the bolt teeth are cracked or damaged, cheek to see if the camshaft or oll pump is lacked. (c} IF thera is notieasble weer oF cracks on the belt face, chock ta soe if thara are nicks on one side of the idler pulley lock | tal If there is wear or damage on only one site of the ball, check the belt guide and the alignment of each pulley EM-20 ENGINE MECHANICAL — Timing Belt le) If there is noticeable wear on the belt teeth, check the ning cover for damage. Check for foreign materials ‘an the pulley teeth. 2. INSPECT NO. 1 IDLER PULLEY Check the tuming smoothness of the timing belt idler pulleys. HW necessary, replace the idler pulley. 3, INSPECT TENSION SPRING to) Check the free length of the spring Free length: 38.4 mm (1.542 ind} Ib) Check the tension of the spring at the specified installed length. Installed tension: — reviage = TE 4.71 kg (10.4 Ib, 46 N) at 50.2 nm (1.976 2E 5.11 kg (11.3 Ib, 60 N) at 61.8 mm (2.028 nu If not specified, raplace the spring. Comshate Knock Pin —{ wa N= ENGINE MECHANICAL — Ti Beanng Cap Merk oo L \ Beit, EM-21 INSTALLATION OF TIMING BELT (See page EM-16) 1, INSTALL OIL PUMP PULLEY Using SST to hold the pullay, tighten the nut SST 09612-24012 Torque: 270 kg-cm (20 ft-tb, 26 nem} 2 INSTALL CAMSHAFT TIMING PULLEY (a) Align the camshaft knock pin with the No, 4 camshaft bearing cap mark as shown in tha figure, (o) Align the camshaft knack pin with the camshaft time ing pully #8 shown in the figure. NOTE © Check thot tha Mo. 1 bearing cap mark ang center of the small hole an the comshaft timing pulley align, # On 1E engine mount the timing pulley with te No. 1 hole over the beating Gap merk. on 2E engine align the No. 2 hole over the mark {e) Hold the camshaft with # wrench, and tighten the pullay sot bolt Torque: Bolt wio washer B10 kg-om (37 ft-lb, SO Nem) Bolt w/ washer 650 kg-cm (47 ft-lb, G4 Nim) NOTE: Remove any oll or water on the camshaft timing pulley and keep it clean, INSTALL CRANKSHAFT TIMING PULLEY Install the crankshaft timing pulley and align the TOC ‘marks on the oil purnp bady and crankshaft timing pulley NOTE: Remove-sny oil or water on the cranksha‘t timing pulley ond keep it clean, INSTALL TIMING BELT IDLER PULLEYS {a} Install the Na. 1 idler puley and tension spring, (b} Pry tha No, 1 idlor pulley toveard the lett as far as it vill go snd temporarily tighten it {c)_ Install the No. 2 idler pulley, Torque: 200 kg-em {14 ft-tb, 20 N-m) NOTE: Remove any oil or water on the idlar pulleys: and keep them clean, INSTALL TIMING BELT NOTE: If reusing the timing belt, during removal and install the belt in the Girection af engine revolution. ign the points marked ith the arrow painting INSPEGT VALVE TIMING AND TIMING BELT TEN SION fa) Loosen the timing belt No. 1 idler pulley set bolt {bh Temporarily instell the crankshaft pulley bolt and turn ihe erankshelt hue. ravelutions from TDC to TOC. NOTE: Always turn the crankshaft clockwise. ENGINE MECHANICAL — Timing Bett Em-23 fe] Check that axeh pulley 'y aligns with the marks as shown in the figure, (4) Tighten the No. 1 idler pulley set bolt Torque: 185 kg-cm (13 ft-Ib, 18 N-mb {e] | Make sure that there is belt t tension at the position indicated in the figure, INSTALL TIMING BELT GUIDE INSTALL TIMING BELT Covers Install the No. 1 and No, 2 timing belt covers with the six bolts. a 10. W ENGINE MECHANICAL — Timing Belt INSTALL CRANKSHAFT PULLEY 4a) Align the pulley set key with the key groove of the pulley fb) Install the SST to the crankshaft pulley, SST 09213-14010 (c) Using SST to hold the crankshaft pulley, install and torque the pulley bolt SST 09330-00020 Tarque: 1,000 ~ 1,500 kg-em {73 = 108 feb, 99 — 147 Nem NOTE: Apply a light coating of engine oll on the bolt Unweads and under the bolt head before installing INSTALL CYLINDER HEAD COVER fa) Apply seal packing black (Part No, 08826-00080) or equivalent to the cylinder head as shown in the figure. NOTE: Install the head caver as soon as the seal packing is applion (oh to) Install the gasket and head cover with the two nuts Connect the PCV hase to the POV valve, INSTALL ALTERNATOR DRIVE BELT 12, IF VEHICLE HAS AIR CONDITIONING, INSTALL DRIVE BELT ENGINE MECHANICAL — Timing Belt EM-25 13. ADJUST DRIVE BELTS fer Drive belt deflection with 10 kg (22.1 Ib, 98 Ny) | New belt A 3.5~4.5 mm (0.138 — 0.177 in} B 5.5 —7.0 mm (0.217 — 0.276 in} Used belt A 5.0~ 6.0 mm {0.197 ~ 0.236 ind rar PUM Altemator Cranishatt i B 7.0= 85 mimi Empress (0.276 ~ 0.335 i — [Reference] i : Using SST. check the V-tibbed type drive bell tension. oe SST A 08216-00020 SBT 8 og216.00080 Drive belt tension: Avssra Now belt C85 ~65 kg ay B55 — esky Used belt © 25 — 40 kg f Ey B 35-45 kg | Nore '* “New belt” refers to anew belt which has never been used * “Used belt” refers to a belt which has been used on a running engine for 5 minutes or more, , '* After installing the crive belt, chock that it fits properly | in the ribbed grooves. * Check by hand to confinn thot the belt has not slipped Sormect WHORG © OvRoNa Out af the groove om the bottom of the crankshaft pulley. © After installing the bell, run the engine for about 5 ‘minutes and then recheck the dedl ENGINE MECHANICAL CYLINDER HEAD COMPONENTS PV vilwe > ‘Cylinder Head Cover ————a— & ——-Comsialt Bearing Cop %— (ieee, 10 we Camshaft Bearing =a eg saran $04 Seg” . ae Pump so 7 No. 2 Engine Hanger a ee Valve Rocker Arm : | Valve Spring @ Valve Rocker Arm Spring Valve Keeper Intake Manifold Valve Stem OH Saal Valve Gude“ Valve Spring Retainer ‘as (Caer, eat) sooner 0 De a AY Cylinder Head pa 2) | vaive * cast 5? \y 6 a td af —-Pessstontas 3 nay? 2 * [kgecm ft-lb, Rem] : Specified torque ee No. 7 Engine Hanger 4 Non-reuseble part + : Precoated part ENGINE MECHANICAL — Cylinder Head EM.27 REMOVAL OF CYLINDER HEAD (See page EM-26} 1. REMOVE DISTRIBUTOR (Conventional Typel +l) Disconnect the vacuum hoses, “tbl Remove the distributor hald-down bolts. Remove the ‘tutor from the eylinder head with the cap and conds attaches. (WA Type} te) Disconnect the vacuum hoses, tb) Remove the twe distributar hold-down bolts. Remove the distributor from the eylinder head with the cap and cords attached. 2 REMOVE WATER OUTLET HOUSING {a} Disconnect the water hase. (Ol Remove the bolt, two nuts and water outlet housing from the eylinder head. ~) 3. REMOVE EXHAUST MANIFOLD (a) Remove the three bolts and No, # heat insulator ib) Remove the six nuts, exhaust manifold, tera gaskets and Na. 2 heat insulator, 4. REMOVE FOUR SPARK PLUGS EM-28 ENGINE MECHANICAL — Cylinder Head 5, REMOVE FUEL PUMP fal Disconnect the fusi hases. tb) Remave the two nuts, fuel pump and ingulatar with the two gaskets, 6, REMOVE CARBURETOR ASSEMBLY (See page FU-8) 7. REMOVE VACUUM PIPES [EC only] anaea 8 REMOVE INTAKE MANIFOLD. {al Disconnect the water hose from the manifold. {0} Remove the five bolts, two nuts and manifold with the gasket, 9, REMOVE TIMING BELT AND CAMSHAFT TIMING PULLEY {See stops 1 to 8 and 11 on pages EM-16 to 18) 10, MEASURE CAMSHAFT THRUST CLEARANCE Using 2 diat gauge, measure the thrust clearance while maving the camshaft back and forth, Standard thrust elearanes: 0.08 - 0.18 mm (6.0031 = 0.0071 in} Maximum thrust clearance: 0.25 mm (0.0088 in.) If clearance is greater then the maximum, replace the head and/or camshaft. pus 41, REMOVE BEARING CAPS AND CAMSHAFT {al Loosen each bearing cap bolts a little ata time andl in the sequence shown in the figure. (bl Remove the camshaft, cil sest and camshaft bearing aps. ENGINE MECHANICAL — Cylinder Head EM-29 + 12, 13. {01 Arrange the camshaft bearing caps in order. REMOVE ROCKER ARMS While lifting the top of the spr screwdriver fing, pry off with NOTE: Arrange the rocker arms, REMOVE CYLINDER HEAD (al Remove and loosen the head bolts gradually in three asses in the numerical order shown. CAUTION: Head warpage or cracking could result from removing out of arder. NOTE: Some engines include head bolts with a smoothly grinded head surfaces, (bo) Lift the cylinder head from the dowels on the eylindar block and place it on the wooden blocks on @ bench, If the cylinder head is difficult to lift off, pry with a bar between the head and block projectian. CAUTION: Be careful not damage the cylinder head and black surfaces of the cylinder head gasket side. } EM-30 ENGINE MECHANICAL — Cylinder Head DISASSEMBLY OF CYLINDER HEAD (See page EM-26) REMOVE VALVES (al Using SST, piéss the valve spring and remove the two keepers SST 09202-79010 (b) Remove the spring retainer (or valve rotator), vaive spring, seat and valve, (c)_ Pull out the oll seal. thi NOTE: Arrange the disassembled parts in order. ENGINE MECHANICAL — Cylinder Head EM. INSPECTION, CLEANING AND REPAIR OF CYLINDER HEAD COMPONENTS 1. CLEAN TOP OF PISTONS AND TOP OF CYLINDER. BLOCK (3) Turn the crankshaft and bring each piston to top dead center. Using a gasket scraper, remove all the carbon from the piston taps, (b} Using 2 gasket scraper, remove all gasket material from the tom of the block. Blaw cation and oil from the bolt hales. WARNING: Protect your eyes when using high pressure air, 2, REMOVE GASKET MATERIAL Using 2 gasket seraper, remove all gasket material from the head and manifola surfaces, CAUTION: Be careful not to seratch the surfaces, 3. CLEAN COMBUSTION CHAMBER Using a wire brush, remave alt the carbon from the com- ‘bustion chambers. CAUTION: Be careful not to scratch the head gasket contaet surface, {Apgar 4 CLEAN VALVE GUIDE susHines: t Using a valve guide brush and sotvent, clean all the vaive guide bushings. 5. CLEAN CYLINDER HEAD Using a soft brush and solvent, throughly glean the head, EM-32 ENGINE MECHANICAL — Cylinder Head 6 INSPECT CVLIDER HEAD FOR FLATNESS: Using 2 precision straight edge and fecter gauge, measure the surfaces contacting the cylinder block end manifold for warpage Maximum warpage: Cylinder blosk side 0.05 mm (0.0020 in. Manifold. side 9.05 mm (0.0020 in.) If werpage i groster than maximum, replace the cylider head INSPECT CYLIDER HEAD FOR CRACKS: Using a dye penetrant, check the combustion chamber, intake and exhaust por's, heed surface and the tap of the head for cracks, Hf cracked. replace the head. CLEAN VALVES (a) Using a gasket scraper, chip any carbon from the valve, {o) Using # wire brush, thoroughly clean the valve. INSPECT VALVE STEM AND GUIDE BUSHINGS la) Using a csliper gauge, measure the inside diameter of the valve guide, Gulde inside diameter: 6.01 — 6.03 mm (0.2366 — 0.2374 in} ENGINE MECHANICAL — Cylinder Hoad 10, Both intake and exhaust i000 11.027 Use St, asst oat | Owr7i.027 Jonroe vas] ei Use 08 008 Bushing bose man fm) ee 2 {b) Using a micrometer, measure the ciamete: Valve stem. Stam diameter intake 6.970 - 5.985 mm (0.2350 ~ 0.2366 in} 5.965 ~ 5.980 mm (0.2348 — 0,2854 in} ‘Subtract the valve stem measurement from the valve Suids measurement. ‘Standard stom oil clearance: Intake 0,025 ~ 0.060 mm {0.0010 — 9.0024 in) Exhaust 0.030 = 0,065 mm (0.0012 - 0.0026 in) Maximum stem ail clearane intake 0.08 mm (0.0031 in) Exhaust 0.10 mm (0.0039 in) Hf the clearance is greater than the maximum, replace the valve and guide Exhaust ‘el If NECESSARY, REPLACE VALVE GUIDE BUSHINGS (a) Using SST and hammer, bushing. 8ST 09201-70010 drive out the valve guide tb) * coliper gauge, measure the vaive guide bore of the cytinder head, {c)_ Select # new velve guide bushing If the valve guide bushing bore of the cylinder head is ‘mare than 11.027 mm (0,434) in}, machine the bore 10 the following dimension, Rebored valve guide bushing bore dimension: 11.050 — 11,077 mm (6.4360 ~ 0.4361 in) EM.34 ENGINE MECHANICAL — Cylinder Head (a) Using SST and a hammer, drive in a new valve guide to where thore ig 13.3 — 14,1 mim (0.6236.0.5551 in} protuding from the eylinder head, SST 09201-70010 (el Using a sharp 6 mn roamer, ream the waive guide to obtain the standard specified clearance (See page FM-32) between the valve quide and new valve stem. __—_]_ 11. INSPECT AND GRIND VALVES | {3 Grind the valve only enough to remove pits and car | ton (i) Check thot the valves are ground ta the carrat valve face engl Valve face angle: 445° (c) Check the vaive head margin thicknass. Standard margins thick 1.0 mm (0.039 in} Minimum margin thickness: 0.8 mm (0.031 in] If the valve head margin thickness ig less than mini¢iurh Feplace the vatve, (dl Check the valve everall length Standard overall length: Intake (Main) 92.26 mm (3.6323 in (Sub) 98.50 mm (3.8779 int Exhaust, 92,26 mm (3.6323 in} Minimum overall length: Intake (Main) 91.76 mm (3.6126 in) (Sub) 98.00 mm (3.8683 in) i Exhaust 91.76 mm (3.6126 in.) if the wolve overall Jenath is tess than minumum, replace the valve, ENGINE MECHANICAL — Cylinder Head EM-35 fol Check the surface of the valve start tip for wear. If the valve stem tip is worn, regrind it with grinder or rep- lace the valve if necessary. CAUTION: Do not grind off more than the minimum overall length (See page EM-34), 12, INSPECT AND CLEAN VALVE SEATS. (al Using » 45° carbide cutter, resurface the valve seats, Remove only enought metal to clean thé aéats. lb) Check the valve seating position ‘Apply 2 thin cost of pruseion blue (oe white toad to the valve face. Install the valve, Lightly press the valve against the seat. Da not rotate the valve, Check the valve {266 and seat for the following: ‘If blue appears 360° araund the face, the valve is Cancantric. If not, replace the valve, If blue appears 360° sround the valve seat, the guide and seat are concentric. If not, resurface the sei © Cheek that the seat contact is on the middie of the valve face with the following width, 1.2 — 1.6 mm (0.047 = 0,963 in) el If not, correct the waive seat 3¢ fotlows: i 1] If seating is too high on the valve face, use 30° i and 45° utters to correct tho seat : ih (2) If seating is tao low on the valve face, use 75° (IN), 60" (EX) and 45° cutters to correct the ‘seat 13, 14, ENGINE MECHANICAL — Cylinder Head {dl Hand-lap the valve and valve coat with an abrasive compound. INSPECT VALVE SPRINGS (Using 2 steel square, measure the squareness of the valve springs. Maximum squareness: 2.0 mm {0.079 in} I squarenass is grestar than maximum, replace the valve spring, (b} Using ealipers, measure the free length of the valve spring Free length: 41.52 mm (1.6346 In} If the free length is not within specification, replace the valve spring. {ch Using @ spring tester, measure the tension of the valve spring at the specified instalted length, Installed tension: 15.91 kg (35.1 Ib, 156 N) at 36.16 mm (1.3842 in) I the installed tension is not a8 specified, replace the valve spring, INSPECT CAMSHAFT fal Place the camshaft on W-blocks end, using 2 dial indicator, messure the circle runout at the center journal Maximum circle runout: 0,04 mm (0.0016 in.) IU the eirele runout is greater than the maximum, replace the camshaft ENGINE MECHANICAL — Cylinder Head, Em-37 1 6) Using a micrometer, measure the cam lobe height, | Standard cam lobe height: 1E Intake (Main) 36.35 - 35,45 mm (1.2917 ~ 1.3957 in) (Sub) 34.91 ~ 35.01 mm (1.3794 — 1.3783 int Exhaust 35.83 — 35.93 mm (1.4108 = 1.4148 in) 2e Intake (Main) 35,87 — 35.97 mm {1.4122 = 1.4181 in) Front "oN (Sub) 35.38 — 35.48 mm Bx Min) at) 41.2929 ~ 1.3968 in) - ~ tay | Exhaust 38.83 — 36,93 mm Imai | fsa | 41.4106 — 1.4146 in) A Minimum cam lobe height: 16 Intake (Main) 35.15 mm (1.3838 ind iv le (Sub} 34.71 mm {1.3685 ind (Sub | acd Exhaust 36.63 mm (1.4028 In] be 2E (doing Ose Intake (Mainl 35.67 mm (1.4043 int (Sub] 35:18 mm (1.3850 Exhaust 35.63 mm (1.4028 in.) | the cam lobe height is legs than minimum, replace the camshaft, (cl Using a micrometer, measure the journal diamoter. Standard diameter: 26.979 — 26.995 mm (1.0622 ~ 1.0628 in} If the journal diameter ig tess than speci camshatt sd, replace the 15. INSPECT CAMSHAFT OIL CLEARANCE (a) Clean the bearing cops and camshofe journel {0} Pisce the camshaft in the cylinder head. (cl Lay a strip af Plastigage across each joumal, {d)_Ploce the bearing caps with the top of the number on the cap painting toward the front and in numerical order from the frant side. fel Torque the cap bolts groduslly from the inside in three nasses. Torque: 140 kg-em (10 Ftlb, M4 Nom) NOTE: Do not tum the carhshaft while the Plastigage is in place. EM.36 ENGINE MECHANICAL — Cylinder Head (Remove tha caps and measure the Plastigage at its widest point Standard olf clearance: 0.037 — 0.073 mm (0.0018 ~ 0.40289 ind Maximum oll clearance: 0.10 mm (0.0039 in.) If clearance is greater then the ma: cylinder hens andor camshaft ah Clean aut the pieces of Plastigage from the besring caps and journals. um, replace the 16. INSPECT ROCKER ARMS. Check the contact surface of the valve rocker arm and valve stem end and/er camshaft lobe. Ht the contact surface of the valve stem end and/or camshaft lobe is wore excessively, replace the rocker arm. 17, INSPECT INTAKE AND EXHAUST MANIFOLDS Using @ precision strsight edge and teeler gauge, check the surfaces contacting the cylinder head for warpage. Maximum warpage Intake manifold 0,20 mm (0.0079 in.) Exhaust manifold 0.30 mm (0.0148 in} ASSEMBLY OF CYLINDER HEAD (See page Em.261 NOTE © Thoroughly clean all parts to be assembled, © Befor installing the parts, apply new engine oil all sliding and rotating surfaces, © Replace all gaskets and oil seals with new ones. INSTALL VALVES fa) Install new oil seals om the valve guide bushings. ENGINE MECHANICAL — Cylinder Head EM.39 Mb) Insert the vaives in the sylinder head velve guide ‘bushing. Moke sure the valves are installed in the cor- ect order, ‘c) Install tha seats, springs and spring retsiners on the cylinder heod. fd) Using SST. compress the valve retainers and place twa keepers around the valve stem. SST 09202-70010 (e) Top the stem lightly to assure propor fit INSTALLATION OF CYLINDER HEAD (See page EM-26) 1. INSTALL CYLINDER HEAD {a} Placa new cylinder head gasket on the cylinder block CAUTION: Be careful of the installation direction. Sb] Place the cylinder head on the cylinder head gasket 2. TIGHTEN CYLINDER HEAD BOLTS NOTE: © The Gylinder head bolts are tighten in thrae progressive stops. “* If any of the bolts break or deform, repiece them, fol Apply a light coat of engine Under the cylinder head bolts, ‘an the threads and {bi First, uniformly tighten the ten eylinior head bolts in Several passes ond in the sequence shown Torque: 300 kp-ern (22 flb, 29 Nom) fc) Second, uniformly tighten the ten cylinder head bolts in sequence shown, Torque: 500 kg-em [36 ft-lb, 48. Nem) |f any one of the bolts doas not mest the torque specifica: tion, raplaes the bolt ENGINE MECHANICAL — Cylinder Head 3, (a) Third rotighten the cylinder head bolts an additional 80° in order, as shown above left INSTALL ROCKER ARMS NOTE: Use e brass bar and hammer to install the waive rocker arm pivot ante the cylindar head. lo) Bafore installing the rocker arm, cheek that adjusting screw is ag shown in the illustration Io} Using a screwdriver, press the bottom lip of a new rocker erm saring until it fits inte the groave on the rocker arm pivot, NOTE: Put the valve adjusting serew in the rocker anm pivot fel_Using a serawariver. pry the racker arm spring on to the racker arm pivot ENGINE MECHANICAL — Cylinder Head bo sss EM-41 NOTE: Put the edge of the rocker arm spring into the rocker erm groove |) Pulling the rocker arm up and down, check that there spring tension on the rocker arm ond that the rocker dogs not rattle frealy INSTALL CAMSHAFT AND OIL SEAL NOTE: To prevent the cub intake valve ond the piston ead from damege perform step (e) and c) below. fal Sat Mo. 1 cylinder to TDC/compression. fo} Cost elf bearing journals with engine cil fc] With the keock pin in the 12 o’elock pasition, place the camshaft on the oylinder head. (ol Placa No. 2, 3 and 4 beating cans on each jaumal with the arrows pointing toward the frat te) Apply MF grease to the oil seal EM-42 ENGINE MECHANICAL — Cylinder Head {8 Install the oil seat NOTE: Be careful not te install the oil seal stontuise. {o) Apply seot packing tpart No. 08826-00080) or equivalent to the No. 1 beating caps as shown in the figure. NOTE: install the No. 1 beating caps im-mediately efter applying the seal packing, h} Place the No. 1 beering caps on the eylinder head. (Torque each bearing cap bolt a little at a time in the Sequence shaven in the figure. Torque: 140 kg-cm (10 fb, 14 Nmt (Cheek the camshaft thrust clearance. (See page Ekl- 28) Standard clesranco: 0.08 — 0.18 mm (0.0031 = 0.0071 ind wum Glearance: 0.25 mm (0.0098 in) ma} INSTALL GAMCHAFT TIMING PULLEY AND TIMING BELT See steps 2 and 4 to 13 on pagos EM-21 te 25) ADJUST VALVE CLEARANCE (See page EM-5) INSTALL INTAKE MANIFOLD (a) Install a new gasket end the manifold with the five bolts and two nuts. Tighten the bolts and nuts Torque: 198 kg-em (14 ft-lb, 19 Nem! ENGINE MECHANICAL — Cylinder Heat Ew-a3 {h} Conneet the water hose to the intake manifold, & INSTALL VACUUM PIPES (EC only) 9, INSTALL CARBURETOR ASSEMBLY (See page FU-21) or 1 10. INSTALL FUEL PUMP (a) Install (wo new gaskets, insulptor and fue! pump with, the two nuts. (t) Connect the fuel noses. 11. INSTALL FOUR SPARK PLUGS Torque: 160 kg-om {13 tb, 18 Nem) he — 12. INSTALL EXHAUST MANIFOLD fa) Install the No, 2 haat insulator, two gaskets and manifold with the six nuts NOTE: Install the exhaust manifold gaskets with the mark facing outward (bl Tighten the six nuts. Torque: 426 kg-om (31 ft-lb, 42 N-mb 4g {c} Install the No. 1 heat insulater with three bolts, five EM-44. ENGINE MECHANICAL — Cylinder Head 13, INSTALL WATER OUTLET HOUSING fol Remove any old packing material and be careful not to drop any ail on the contacting curtaces af the water outlet housing and cylinder head. © Using 2 razor blade and gasket scraper, remove all the packing (FIPG} material from the: gasket sur- faces. © Thoroughly clean all campanents to remove oil the kaose material © Clean both sealing surfaces with a non-residue solvent. CAUTION: Do not use a solvent which will affect the painted surfaces. (b} Apply seal packing No, 1282-8 (Part No, 08826- 00100) or aquivalent to the water outlet housing a3 shown in the figure © Install a nozzle thet hag been cut toa 2 mm (0.08 in} opening. NOTE: Avoid applying an excess amount to the surface. Be especially careful near oil passagi © Ports must be assembled within 15 minutes of application Otherwise, the ‘material must be removed and ro-applied, ‘© Immediately remove nozzle from tube and reinstall ap. i) Install the water outlet housing with the bolt end two nts, {dl Connect the water hose. 14, INSTALL DISTRIBUTOR See page 16-14) 15. INSTALL VACUUM Hoses Fo] 16. INSTALL ENGINE HANGERS No.2 Engine Hengor —)} (3) Apply anasrobio auhasive and sealant [THREE BOND 1324 (Part No. 08833-00070} or equivalent] ta 2 or 3 threads of the bolt end (See page EM-68). NOTE: Cleaning end application instruction of adhesive and sealant See page EM-65. {b) Install the No. 1 and No. 2 engine hongers tighten the bolts. Torque: No.1 210 kg-em (18 ft-lb, 21 Nem} No.2 440 kg-cm [32 ft-lb, 43 tem) ENGINE MECHANICAL — Cylinder Block CYLINDER BLOCK ‘COMPONENTS E45 \ Gil Level Gauge ‘| oil Level ano ea. } Gouge Guide ee L © O-Ring sons Cranks Uppar Main Beoig Of Straine +08 ‘ o. ino = << Piston Pin Piston Connecting Rad [web We, aa connec ing Rod Beating Roar Oil Seal Ratainer Le enneting od C= —y 30 Crankshaft Upper Thrust Wesher Q CCronkshatt Grankshalt Bearing Cap aio) [ol Pan Gashat Caren HAE Wal) : Specified torque 4 Ron-rausabie part # : Preensted part vase EM.46 ENGINE MECHANICAL = Cylinder Block PREPARATION FOR DISASSEMBLY 1. REMOVE CLUTCH COVER AND DISCIMIT only] 2. REMOVE FLYWHEEL OR DRIVE PLATE 3, REMOVE REAR END PLATE 4. INSTALL ENGINE TO ENGINE STAND FoR DISASSEMBLY 5. REMOVE TIMING BELT {See steps 1 to 10 on page EM-16 to 18) 6. DISCONNECT WATER INLET HOSE FROM WATER OUTLET HOUSING 3. DISCONNECT WATER INTAKE MANIFOLD HOSE AND WATER BY-PASS HOSES FROM WATER PUMP AND INLET PIPE 8. REMOVE CYLINDER HEAD {See step 13 on page EM-29) 8. REMOVE WATER PUMP WITH BY-PASS PIPE 'Soe steps 2, 3 and 6 on pages C0-4 and 5) 10. REMOVE OIL PAN, STRAINER AND PUMP (See stops 2 to 7 on pages LU-4 and 5) 11. REMOVE ENGINE MOUNT RH DISASSEMBLY OF CYLINDER BLOCK (See page EM-45) 1. REMOVE REAR OIL SEAL RETAINER Remove four bolts, rear oil seal retainer. 2, MEASURE CONNECTING ROD THAUST CLEARANCE Using 2 dial indicator, measure the thrust clearance white moving the tad back and forth Standard thrust clearance: 0.15 ~ 0.85 mm 10,0059 — 0.0138 In} Maximum thrust clearance: 0.45mi {0.0177 int HW the clearance is greater than maximum, repioee the eon- acting rod assembly. If necessary repiace the crankshaft ENGINE MECHANICAL — Cylinder Block EM-47 3. REMOVE ROD CAPS AND MEASURE OIL srontatate CLEARANCE NOTE: If replacing the bearing, replace with one having / the same number 2s marked on the bearing cap, ate There aro three sizes of standard bearings supplied, REE » marked 1, 2 or 3 respectively hi, 20r8 la) Using» punch or numbering stamp, place the matchmarks on the rod snd cap to ensure comet assembly. It) Remove the red cap nuts. [cl Using a plastic-faced hammer, lightly tap the con- necting rod bolt and lift off the cap and lower b ing 4 NOTE: Keep the lower bearing inserted with the cap. Wee 3} C EH ()_ Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. = Cylinder Block fe} Clean the crank pin and besring, (8) Check the crank scratches. If the crank pin or beating are damaged, grind or raplace the crankshaft and raplace bearing, and bearing for pitting and () Lay a strip of Plastigage across the crankshaft pin. th) Aligh the punched marks on the rod and cap. Install and torque the cap outs alternately, in two or three passes. Torque: 400 kg-cm (29 ft-lb, 38 Nem NOTE: ‘© Bo not tum the crankshaft Apply a light coating of engine oll on the nut threads and under the nut before installation fi) Remove the rad cap. (See procedure Ib) and (ec) above) () Measure the Plastigage at its widest point Standard clearance: 0.016 ~ 0.048 mm (0.0006 = 0.0019 in.) Maximum clearance: 0.08 mm (0.0031 in.) If the clearance is graater than the maximum, replace the bearing. Grind the crankshaft pins or replace the crankshaft as required, (ki) Completely remove the Plastigage. PUSH OUT PISTON AND CONNECTING ROD ASSEMBLIES (al Remove all the carben from the piston ring ridge, ENGINE MECHANICAL — Cylinder Block eM.49 Ib} Cover the rod bolts with a short piece of hose to pro- tect the crankshaft from damage, (c)_ Push out the piston and connecting rod assembly and the upper bearing through the tap of the evlindsr block NOTE: @ Keap ths inserted beating, connecting rod and cap together. © Arrange the piston and connecting rad assemblies in order. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicstor, measure the thrust clearance while prying the erankshaft back and forth with a screwdriver, Standard thrust clearanea: 0.02 = 0.22 mm {0.0008 — 0.0087 in,) Maximum thrust clearance: 0.3 mm (0.012 in} If the clearance is greater than maximum, replace the thrust washers as 2 set. ‘Over size thrust washer: O/$ 0.126 REMOVE BEARING CAPS AND MEASURE OIL ‘CLEARANCE NOTE: lf replacing the bearing, replace with ene having the same numibar as marked on the evlinder block, There are threa sizes of standard bearings, marked with a 1. 2 or 3 accordingly. Be sure to recheck the oi clearance alter installing a new beering {a} Gradually loosen and remove the bearing cap bolts in theee passes and in the numerical order shown, ENGINE MECHANICAL (bh Using the remaved bearing cap bolts, pry the bearing cap fore and aft, and removeeit with the lower besring and thrust washers (No. 3 journal only} NOTE: © Keep the lower besring inserted with the cep, © Arrange the aps and lower thrust washers in correct onder. [o) Lift off the crankshaft NOTE: Keep the upper beorings and upper thrust \washers [for the No. 3 journal Only) inserted in the evlindér block, (a) Clean the journats and bearings (2) Check the journals and bearings fer pitting end serstiches. If the journat or bearing is damaged. grind or replace the crankshaft and replaces the bearing (f) Place the crankshaft om the eylinder block (gh Lay a strip of piastigage across each journal (rl Install the bearing caps with the lower beating and lower thrust washers, (Soe stop.4 on page EM-62} Torque: 580 kg-cm [42 fi-lb, 57 Nem) NOTE: Do not turn the crankshaft. li Remove the bearing eaps with the lower bearing and lower thrust washers. (See procedure te) anc (b) abevel ENGINE MECHANICAL — Cylinder Block EM-51 Gl Measure the Plastigage at its widest point ‘Standard clearance: 0.016 — 0.049 mm {0.0006 — 0.0019 in Maximum clesrance: 0,08 mint (0.0031 in.) If the clesrance is greater than the maximum, repiaea the bbeerings. Grind the joumals or replace the crankshaft ag required (kt) Completely remove the plastigage from the bearing and journals, REMOVE CRANKSHAFT (ab Remove the crankshaft (tI Remove the upper beerings and upper thrust washers from the cylinder block NOTE: Arrange the caps, bearings and thrust washers in correct order, 52 ENGINE MECHANICAL — Cylinder Block INSPECTION OF CYLINDER BLOCK 1, REMOVE GASKET MATERIAL Using a gasket scrapes, remove all gasket material from the eylinder block surfaca, CLEAN CYLINDER BLOCK Using 8 soft brush and solvent, clean the block, 3. INSPECT TOP OF BLOCK Using precision straight edge and feeler gauge, check the surface contacting the eylinder head gasket for war- page. Maximum warpage: 0.05 mm (0.0020 ind If warpage is greater than maximum, replace the cylinder bieck 4. INSPECT CYLINDERS \Wisually inspect cylinders for vertical scratches. If daep scratches are present, rebore all four eyinders. ISee page EM-5 7} 5. MEASURE CYLINDER BORE DTurae Using a cyinde: micromater, moasure the eyliner bore at Front positions A. B and C in the thrust and axial directions. Pana Standord diameter | ; Cylinder bore am inh Ap 10am ston se # ey 70.60 = 70.83 ‘73.00 = 73.03 [Mise {a (2.7756 - 2.7766) | (2.8740 — 2.87521 Li. 10 mm | 7o7S- 07s | 7325-7378 | 10.38 in) sone O'S 0.25 | iggabd - 278661 | (2.8629 — 288801 Mavirmumn desmete orb Piston size 1E = | 81> [7073 7ad6) [7328 aes | “ois 076 | 7098 (2.7005) | 79.49 Ba929) If the diameter is greater than maximum, rebore all four cylinders. If necascary replace cylinder block, | ENGINE MECHANICAL — Cylinder Block EM.53. 8, REMOVE CYLINDER RIDGE If the wear is less than 02 ma 10.008 inJ, use a ridge Teamar te machine the piston ring ridge at the top of the ram oylinder, | DISASSEMBLY OF PISTON AND seek CONNECTING ROD ASSEMBLIES “ar 1. CHECK FIT BETWEEN PISTON AND PIN Try to mave the piston back and forth an thé piston pin _ If any movement is felt, replace the piston and pin as eet 2, REMOVE PISTON RINGS seep fel Using 2 piston ring expander, remove the compres- sion rings. (bh Remove the two side rails and olf ring expander by moat hand! 3 NOTE: Amange the rings in the correct order. a 52) a 50) 3, DISCONNECT CONNECTING ROD FROM PISTON — Using $87, press out the pin from the piston. am SST 09221-25018 i four EM-54 ENGINE MECHANICAL — Cylinder Block NOTE: Sen ease © The piston and pin are a matched sot, © Arrange the pistons, ping, rings, conneeting rods and bearing in comect arder. INSPECTION OF PISTON AND CONNECTING ROD ASSEMBLIES CLEAN PISTON (a) Using @ gasket seraper, remove the carbon from the Biston top. (0) Using a groave cleaning toot or broken ring, clean the ring grooves, (6) Using 4 soft brush and solvent, thoroughly clean the piston CAUTION: Do not damage the piston. MEASURE PISTON DIAMETER (2) Using a micromater and with the piston upside down, Measure the piston diarteter at right ongles to the Biston pin the indicated distance feom the top edge af the piston, 1E 21 mm (0.83 in} 2 23 mm (0.91 in) Piston diameter: 1E STD 70.41 ~ 7044 mm (2.4720 - 2.7732 in} OFS 0.25 70.66 - 70.69 mm (2.7819 = 2.7831 in, ENGINE MECHANICAL — Cylinder Block EM-55 2E STD 72.91 ~ 72.94 mm and (2.8705 - 2.8716 in) O/S 0.25 73.16 ~ 73.19 mm (2.8803 - 2.8815 in) 6 ——_—_—_—_—— tb} Measure the cylinder bara diameter in thrust direce Twat tions [See page EM-52) and subtmet the piston front Glametor mossurement from the cylinder nore ® woiat the Direction Standard oil clearance: Ag itm 0.08 ~ 0.10 mm (0.0031 — 0.0039 in) } AF oagin Moxinwim oil clearance: 0,20 mm (0.0079 in) 24 tiacie IF the oi clearance is. groster than maximum, replace all an eee four pistons. Regrind sil four eylindere ar replace the 98 ind se sylinder block if necessary. the the 3. INSPECT PISTON RING GROOVE CLEARANCE Using a teclar gauge, measure the clesrance between the nnewr piston sing and the ring land Piston ring groove clearance: No. 1 9.04 — 0.08 mm (0.0016 ~ 0.0031 in) No, 2 9.03 - 0.07 mm (0.0012 — 0.0028 ind wn, = It tne clearonco fe not within specification, replace the piston, EM-56 ENGINE MECHANIGAL — Cylinder Block [Se 4. INSPECT PISTON RING END CAP Top of {al Insert the piston ring into the eylinder. CHlingor Block ib) Using a piston, push the oiston ring a little beyond the bottom of the fing travel to the fallaving depth from the top of the eylinger block. Depth 1E 85 mm (3.38 in) 2E 100 mm 43.94 ind {cl Using » feoler gauge, measure the end gap. Piston ring end gap __mm (ind Standard ‘Mezienom Net | ‘0058 Piston ring and gap __mm (in) Stand | 10s ©0428) 3 10,0408) 1.43 (0.05631 If the gap exceeds the specified maximum, repiace the Pistan ring If the gap exceeds the specified maximum even with 2 new piston ring, rebore the cylinder and use an Q/S piston ring, INSPECT CONNECTING RODS: Using a rod fo) Check for bend, Maximum bend: 0.03 mm (0.0012 in) per 100 mm (3.94 in.) Wf bent is greater than maximum, roplace the connecting rod assambly ligner, check the connecting rod alignment, (b) Cheek for turst. Maximum 8.05 mm 10.0020 in) per 100 mm [3.94 ind If twist is greater than maximum, replace the connecting rod assembly NOTE: If replacing the connecting rods, raplace the same number af caanecting rod bearings ag that of naw connecting rod caps. ENGINE MECHANICAL — cylinder Block EM-57 BORING OF CYLINDERS NOTE '* Bore all faur cylinders for the oversized piston outside diameter. ‘* Reploce the piston rings with ones matching the pistons 1. SELECT OVERSIZED PISTON Oversized piston diameter: 16. 0/5 0.26 70.68 — 70.69 mm (2.7819 ~ 2.7831 ind 2E O/S 0.26 73.16 ~ 73.19 mm {2.8803 — 2.8815 in) Cee PEEL fa) Using 9 micrometer and with the nistan upside down, Measure tho piston diameter at a right angle to the 7 2. CALCULATE DIMENSION TO BORE CYLINDERS piston pin the indicated distanee fram the top edge the Of the piston, JE 21 mum (0.83 int he 2 23mm (0.91 in} ton (b) Calculate the size each eylinder is to bo rebored as ent allows, Size to be rabored = P+ —H P = piston diameter © = piston clearance 0.08 — 0.10 mm {0.0031 — 0.0039 in.) ting H = allowance far honing Less than 0.02 mm {0,008 in) 3. BORE AND HONE CYLINDERS TO CALCULATED DIMENSIONS: Amount of honing: 0.02 mm (0,0908 in,) maximum, CAUTION: Excess honing will destroy the finished roundness. sting + the EM-58 ENGINE MECHANICAL — Cylinder Block = INSPECTION OF CRANKSHAFT 1. MEASURE CRANKSHAFT FOR RUNOUT (a) Place the erankshatt on V-blocks, (b1 Using a diol indicator, measure the circle runaut at the

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