ENGINE MECHANICAL serous IMI PRECAUTIONS. Parts Requiring Angular Tightening Liquid Gasket Application Procedure. PREPARATION ‘Special Service Tools Commercial Service Tools ‘OUTER COMPONENT PARTS COMPRESSION PRESSURE. Measurement of Compression Pressure. OIL PAN Removal, Installation TIMING CHAIN. Removal, Inspection Installation OIL SEAL REPLACEMENT CONTENTS ‘ACCEL-DRUM UNIT. CYLINDER HEAD Removal, Disassembly. Inspection Assembly Installation ENGINE REMOVAL... Removal Installation... CYLINDER BLOCK. Disassembly. Inspection Assembly. SERVICE DATA AND SPECIFICATIONS (S.D.S.) General Specifications, o Inspection and Adjustment. BR oF ELGroove Bott hole sewarso| PRECAUTIONS Parts Requiring Angular Tightening ‘Some important engine parts ere tightened using an angu- lar-tightening method rather than a torque setting method. If these parts are tightened using a torque setting method, dispersal of the tightening force (axial bolt force) will be two or three times that of the dispersal produced by using the correct angular-tightening method Although the torque setting values (described in this man- val) are equivalent to those used when bolts and nuts are tightened with an angular-tightening method, they should be used for reference only. To assure the satisfactory maintenance of the engine, bolts and nuts must be tightened using an angular-tightening method Before tightening the bolts and nuts, ensure that the thread and seating surfaces are clean and then coated with engine oil The bolts and nuts which require the angular-tightening method are as follows: (1)Cylinder head bolts (2)Main bearing cap bolts (3)Connecting rod cap nuts. Liquid Gasket Application Procedure Before applying liquid gasket, use a scraper to remove all traces of old liquid gasket from mating surfaces and grooves, and then completely clean any oil stains from these portions. Apply a continuous bead of liquid gasket to mating sur- faces. (Use Genuine Liquid Gasket or equivalent.) © Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in) wide (for oll pan). ‘© Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) wide (in areas except oil pan). Apply liquid gasket to inner surface around hole perimeter area. (Assembly should be done within 5 minutes after coating.) Wait at least 30 minutes before refilling engine oll and engine coolant. EM-2PREPARATION Special Service Tools Too! number (Kent-Moore No.) Too! name Description 'ST0501S000 c-) Engine stand assembly @ 8705011000 (-) Engine stand @ 8705012000 (-) Base Disassembling and assembling KVv10106500 (-) Engine stand shaft Kvi0116900 c-) Engine sub-attachment ‘sT10120000 (02423901) Cylinder head bolt wrench ‘Loosening and tightening cylinder hhead bolt Kvi016200, (126006-A) Valve spring compressor @ Kv10115900 (126996-20) ‘tachment Disassembling valve mechanism (338958) Valve oil seal drift Kvi0107902 (38059) Valve oil seal puller Displacement valve EM-3 seal WA ci EF& eCPREPARATION Special Service Tools (Contd) Too! number (Kent-Moore No.) Tool name Description 1«v10116700 (36967) Dial gauge stand ‘Adjusting shims 103470000 (v8037) Piston ring compressor Installing piston assembly into eylin- “2 der bore Kv10107400 (426365-12, 26366) Piston pin press stand @ Kvt0107310 (-) Center shatt @ sT13040020 (-) Stand ® ST 13040030 (-) Spring @ Kv10107320 ) Cap © ST 19040050 (=) Deitt ‘Disassembling and ‘assembling piston pin Kv10111100 (37228) Seal cutter lemoving oll pan 1w338980000 c-) Tube presser Pressing the tube of liquid gasket, Kvi0112100 (=) ‘Angle wrench Tightening bolts for be ‘cap, cylinder head, etc. EM-4Too! name ‘Spark plug wrench ing spark plug Q Tem 5 (0.5319) PREPARATION Commercial Service Tools Description Removing and inst Valve seat cutter set Finishing valve seat dimensions Piston ring expander Removing and installing piston ring a Valve guide drift ee Intake & Exhaust A= 9.5 mm (0374 I). B= 50 mm (0.197 In) Valve guide reamer Reaming valve guide @ or hole for oversize valve guide @ ® o, Unit: mm (in) ia. @ 6.0 (0.286) | 10.175 (0.4006) db, Front oll seal deft, Installing front oil seal Rear oil seal drift, Installing rear oil seal EM-5 aT Fa HAOUTER COMPONENT PARTS [0] Rear to “tnstataton in 6-7 (16-24, 219) Mar-s0 (038-051, 27-3 —@ Fs.2 eee ec * 12, 12-16) WJss-03 [°* (oes - 098, a6) “8 @ nan —— Tra ass [ew 48-69 y [20-26 0-27, 14-29) DD): nem teg-m,t0) TB Aeon tts ast. ©® Oiltiler cep ® EGR & canister control solenoid Engine coolant temperature sen- ® Rocker cover valve 5 ® POV. valve ® Knock sensor ® Thermostat housing @® arition cot @ Oil filter bracket ® Air rliet plug @® Crankshatt position sensor built «Ol catcher ® Thermostat into distributor ® Oil fiter ® Starter motor © Power transistor ® Water inlet © Power stering cil pump aust @ Intake marifolé supports ® Thermal transmitter ng bar © Power steering oil pump bracket@8000 Injector Pressure regulator Intake manifold EGR tube EGR temperature sensor OUTER COMPONENT PARTS © EGA valve ® PAIRC-solenoid valve Oa hoa - an ® EGRC-BPT valve @ Intake manitold collector ® Pod EM-7 lnm oom, ® Accel-drum unit @ Throttle position sensor ® Throttle body @ |Acvair regulator ® IACV-AAC valve 24-108 (0.86 - 11, 62-80) 1) semosse Ez HA aOUTER COMPONENT PARTS i“ 4 A nee Fe tee saan 12-15)" FD: Nem (ka-m, fb) T= Ao xi onset sesr70 @ it level gauge © Drain plug ® Exhaust manitolé @® Alternator adjusting bar @® Resonator Heated oxygen sensor @ Compressor bracket @ Oil separator ® Exhaust manifold cover @ Alternator bracket @ PAIR valve ® PAIR valve tube © Water outlet EM-8COMPRESSION PRESSURE seusreo] — 20 ram (0.79 in) Use compressor tester whose ond (rspber Porton) fs less than 20 mm (0.79 in) ia Otherwise, it may be caught By cylinder head during removal Measurement of Compression Pressure Fi 2. 3. om xo oe 10. Warm up engine. Turn ignition switch off. Release fuel pressure. Refer to “Releasing Fuel Pressure” in section EF & EC. Remove all spark plugs. Disconnect distributor center cable. Attach a compression tester to No. 1 cylinder. Depress accelerator pedal fully to keep throttle vaive wide ‘open. Grank engine and record highest gauge indication. Repeat the measurement on each cylinder as shown above. Always use a fully-charged battery to obtain specified engine speed. Compression pressure: kPa (kg/cm?, psi)/300 rpm Standard 4,226 (12.5, 178) Minimum 4,030 (10.5, 149) Difference limit between cylinders 98 (1.0, 14) It cylinder compression in one or more cylinders is low, pour a small amount of engine oil into cylinders through spark plug holes and retest compression. If adding oil helps compression, piston rings may be worn or damaged. If so, replace piston rings after checking pis- ton. if pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and to S.D.S,) If valve or valve seat is damaged exc replace them. it compression in any two adjacent cylinders Is low and it adding oll does not help compression, there Is leakage past the gasket surface. If so, replace cylinder head gasket. Fa RA BR BF HA aOIL PAN Rime eannny esr Bi A009 tic ons FN ies (0.19 - 028, 14-14) NN | N Rotor to “Installation” 64-75 (085 - 076, 47 - 5) ® Side gallery battle plate @® Aluminum oft @ Rear cover plate @ Drain plug © Steel oil pan Removal Remove engine under cover. Drain engine oil. Remove stee! oil pan bolts. Remove steel oil pan. Insert Too! between aluminum oi pan and steel oil pan. Be careful not to damage aluminum mating surface. Do not insert screwdriver, or oll pan flange will be deformed. EM-10OIL PAN Removal (Cont'd) (2) Slide Tool by tapping on the side of the Too! with a ham- mer. (3) Remove steel oil pan. 5. Remove baffle plate. cra ec 6. Remove front tube. 7. Set a suitable transmission jack under transaxle and hoist gg engine with engine slinger. 8 Remove center member. 9. Remove A/T shift control cable. (A/T only) aT Fa RA 10. Remove compressor gussets. BR ST oF ‘Compressor bracket ‘Roar compressor \ \ heel Senosso} He 11. Remove rear cover plate. a EM-11OIL PAN Kvr0111100 (us7228) Removal (Cont'd) 12. Remove aluminum oil pan bolts. 18. Remove the two engine to transaxle bolts and refit them into vacant holes as indicated. Tighten bolts to release aluminum oil pan from cylinder block. 14. Remove aluminum oil pan, (1) Insert Too! between cylinder block and aluminum oil pan. ¢ Be careful not to damage aluminum mating surtace. © Do not insert screwdriver, or oll pan flange will be deformed. (2) Slide Tool by tapping on the side of the Tool with a ham- mer. (3) Remove aluminum oil pan. 15. Remove the two engine to transaxle bolts previously installed in aluminum oil pan. EM-12OIL PAN on here, 7 eam (028 In) Liquid gasket | ‘Groove tok hole senosao] Installation 4. Install aluminum oil pan. (1) Before installing aluminum oil pan, remove all traces of liquid gasket from mating surfaces using a scraper. © Also remove traces of liquid gasket from mating surface of cylinder block and front cover. (2) Apply a continuous bead of liquid gasket to mating surface of aluminum oil pan. © Use Genuine Liquid Gasket or equivalent. © Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in) wide. © Attaching should be done within 5 minutes after coating. © For areas marked with ““k”, apply liquid gasket to the outer side of the bolt hole. (3) Install aluminum oil pan. © Install bolts in the reverse order of removal ® - © bolts: : 16 - 19 Nem (1.6 - 1.9 kg-m, 12 - 14 ft-lb) 1, ® bol 16.4 - 7.5 Nem (0.65 - 0.76 kg-m, 4.7 - 5.5 ft-lb) 2. Install the two engine to transaxle bolts, 3. Install rear cover plate. EM-13 WA Le Fe [4 FE a wr aT Fa AB BR st BF HA ELOIL PAN {Ti* Sracust [TT | ReSinneet ose Sol Tear compressor gusset ON Cat here guid casket a 7 mm (028 in) » ers Bott hole senorse| Tighten In numereal order. senosso] Installation (Cont'd) 9. a) (3) . Install compressor gussets. Install A/T shift control cable. (A/T only) Install center member Install front tube. install battle plate. Install steel oil pan. Before installing steel oil pan, remove all traces of liquid gasket from mating surfaces using a scraper. Also remove traces of liquid gasket from mating surface of aluminum oil pan. Apply a continuous bead of liquid gasket to mating surface of steel oil pan. Use Genuine Liquid Gasket or equivalent. Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.187 in) wide. Attaching should be done within 5 minutes after coating. Install steel! oil pan. Install bolts in the reverse order of removal together with heated oxygen sensor harness bracket. Wait at least 30 minutes before refilling engine oil. EM-14TIMING CHAIN qN Fa PP) 1s-19019-19,9-19 ae “ : BR Cas. 75 085-076, 47-55) st Tas 108 19 FD stem oem, 2) oF seo © oytinder block © Chain guide ® Crankshat sprocket ry @ Chain guide © Front cover @ Chain guide @ RH, camshat sprocket @ Crank pulley © Timing chain @ Chain tensioner © Oit pump spacer @ LH, camshatt sprocket nh EM-15TIMING CHAIN PAIR valve il separator Loosen in numerical ardor otake mantle support CAUTION: After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. When installing sliding parts such as rocker arms, camshafts, chain tensioner and oil seal, be sure to apply new engine oil on their sliding surfaces. When tightening cylinder head bolts, camshaft sprocket bolts, crankshaft pulley bolt and camshaft bracket bolts, apply new engine oil to thread portions and seat surfaces of bolts. Removal 1 18. 14 Release fuel pressure. Refer to “Releasing Fuel Pressure” in section EF & EC. Remove engine under covers. Remove front R.H. wheel and engine side cover. Drain coolant by removing cylinder block drain plug and radiator drain cock. Remove radiator. Remove air duct to intake manifold. Remove drive belts and water pump pulley. Remove alternator. Remove power steering oil pump. ). Remove vacuum hoses, fuel hoses, wires, harness, con- nectors and so on. . Remove all spark plugs. . Remove PAIR valve and resonator. Remove rocker cover and oil separator. Remove intake manifold supports. EM-16TIMING CHAIN Removal (Cont'd) 15. Remove oil filter bracket and power steering oil pump bracket @ WA eM 46. Set No. 1 piston at T.D.C. on the compression stroke by rotating crankshaft. lc a ec FE cL © Rotate crankshaft until mating mark on camshaft sprocket is set at position indicated in figure at left. iw ar FA RA 17. Remove chain tensioner. BR st HA 18. Remove distributor. Do not turn rotor with distributor removed. EL EM-17TIMING CHAIN Removal (Cont'd) 19. 20. 2 2 Remove timing chain guide. Remove camshaft sprockets. Remove camshafts, camshaft brackets, oll tubes and baffle plate, .. Remove the following water hoses. Water hose for cylinder block. Water hoses from heater. Remove starter motor. EM-18TIMING CHAIN Removal (Cont'd) 24, Remove water pipe bolt . Remove cylinder head outside bolts. . Remove cylinder head bolts. Bolts should be loosened in two or three steps. . Remove cylinder head completely with intake and exhaust manifolds. Remove oil pans. aT Refer to “Removal” in “OIL PAN”. FA RA . Remove oil strainer and baffle plate. BR st BF Ha Remove crankshaft pulley. EM-19‘Transmission yack sensecc} TIMING CHAIN Removal (Cont'd) 31. Seta suitable transmission jack under main bearing beam. 32. Remove front engine mounting. 33, Remove front cover. 34. Remove timing chain guides and timing chain, Inspection Check for cracks and excessive wear at roller links. Replace chain if necessary.TIMING CHAIN Installation 1. Install crankshaft sprocket on crankshaft. ton a WA Ceankshatt sprocket eM 2. Position crankshaft so that No. 1 piston is set at T.D.C. (Keyway at 12 o'clock-mating mark at 4 o'clock approx) fit iming chain to crankshaft sprocket so that mating mark is LC in line with mating mark on crankshaft sprocket. © Mating mark color on timing chain. wr 20 tes tng na Wr at \ / Fa 3. Install timing chain and timing chain guides. BR BF guide) XA semoeac| HA 4. Before installing front cover, remove all traces of liquid gasket from mating surface using a scraper. ‘® Also remove traces of liquid gasket from mating surface of cylinder block. a sucaons EM-21TIMING CHAIN Installation (Cont'd) 5. Apply a continuous bead of liquid gasket to mating surface of front cover. © Use Genuine Liquid Gasket or equivalent. 5 Giaws ot 20-30 mm {0.079 - 0.18 tn) Never apply qu ‘gasket to this 6. Install oil pump drive spacer and front cover. © Wipe off excessive liquid gasket 7. Install front engine mounting, EM-22TIMING CHAIN Installation (Cont'd) 8. Install crankshatt pulley. 9. Set No. 1 piston at T.D.C. on its compression stroke. a ma ca 10. Install oil strainer and baffle plate. 11, Install oil pan. le Refer to “Installation” in “OIL PAN”. Fa ec FE cL 12, Before installing cylinder head gasket, apply a continuous bead of liquid gasket to mating surface of cylinder block. yer aT FA RA ‘yinder head a 49. Install cylinder head completely with intake and exhaust manifolds. BR CAUTION: The cylinder head bolts can be reused providing dimension “A” is not exceeded. Dimension “ 188.2 mm (6.228 In) a“ OF senazso Ha Tightening procedure: Tighten all bolts to 39. N-m (4.0 kg-m, 29 ft-Ib). & Tighten all bolts to 78 N-m (8.0 kg-m, 58 ft-Ib). Loosen all bolts complete! Tighten all bolts to 34 to 44 Nem (3.5 to 4.5 kg-m, 25 to 33, ft-lb). eee ° Tighten in numerical order. EM-23TIMING CHAIN Installation (Cont'd) @ Method A: Turn all bolts 90 to 100 degrees clockwise with Tool or suitable angle wrench. Method B: If angle wrench Is not available, mark the side of each cylinder head bolt with a paint mark facing the front of the engine, then turn all bolts 90 to 100 degrees clockwise. ® Turn all bolts 90 to 100 degrees clockwise. @ Ensure that paint mark on each bolt faces the rear of the engine. (Method B only) Do not turn any bolt 180 to 200 degrees clockwise all at once. om ee Ee sees Be saBe $38 Wem kgm, FB) 3 Tightening torque Nem kor, fH) 38 (60, 2) 78.80, 58) 00.0) 3045 (40205, 286206) 90718 degrees 08 ejelslojelo 14, Install cylinder head outside bolts. 15. Install water pipe bolt. EM-24casket fas, camshat Sy ee "ey No.1 to brackets bracket _sencoeo| TIMING CHAIN Installation (Cont'd) 46. Install starter motor. @ my 17. Install the following water hoses. a © Water hose for cylinder block. u © Water hoses for heater. EF a EC fe a 18. Before installing L.H. camshaft end bracket remove all traces of liquid gasket from mating surface. ww © Also remove traces of liquid gasket from mating surface of cylinder head. 19. Apply a continuous bead of liquid gasket to mating surface jy of LH. camshaft end bracket. © Use Genuine Liquid Gasket or equivalent. FA RA 20. Install camshafts, camshaft brackets, oil tubes and baffle plate. © Position camshatt. © LH. camshaft key at about 12 o'clock ‘© RH. camshaft key at about 10 o'clock HA a EM-25‘Mating mark O “¢—™\ | 1 7™~ RM, camshaft sprocket LH. camshat sprocket ‘seen TIMING CHAIN Installation (Cont'd) © Tightening procedure ‘STEP 1: R.H. camshaft Tighten bolts @ - {@ in that order then tighten bolts @ - © in that order. 1: 2 Nem (0.2 kg-m, 1.4 feb) LH. camshaft Tighten bolts 4} - @ in that order then tighten bolts @) - (in that order. (O): 2 Nem (0.2 kg-m, 1.4 ft-lb) STEP 2: Tighten bolts in the specified order. (0): 6 Nem (0.6 kg-m, 4.3 ft-Ib) STEP 3: Tighten bolts in the specified order. : 9.0 = 11.8 Nem (0.92 - 1.2 kg-m, 6.7 - 8.7 f-1b) Bolt type ® ® (): 18 - 25 Nem (1.8 - 2.6 kg-m, 13 - 19 ft-b) +» Bolt type © 21. Install camshaft sprockets. Line up mating marks on timing chain with mating marks on camshaft sprockets. © Lock camshafts as shown in figure and tighten to specified torque. (O): 197 - 157 Nm (14.0 - 16.0 kg-m, 101 - 116 ft-Ib) 22. Install timing chain guide. EM-26a Fotar head positon * oylinder at TOC) TIMING CHAIN Installation (Cont'd) 23. Install distributor. ‘@ Make sure that position of camshaft is as shown in figure. ‘© After installing, confirm that distributor rotor head is set as ‘shown In figure. te ia 24, Install chain tensioner. Make sure the camshaft sprockets are tightened completely. jr Pr stopper down and “press: eve until hook can be engaged on pin. When tensioner is bolted in position the hook will release automatically. Ensure arrow “A” faces the ar front of the engine. FA A BA sT BF HA 25. Install oil filter bracket and power steering oil pump bracket. FA EM-27intake marsfld supports setae Unit: mm Cn) Engine font 30012) Buca gasket 30 (038) 10 (039) ‘senaseo} ‘mm (0:12 v4 BA Lavi gasket ‘nt lon in numerical order. _sewsaso| TIMING CHAIN Tnstallation (Conta) 26. Install intake manifold supports. 27. Before installing rocker cover, remove all traces of liquid gasket from mating surface of rocker cover gasket to cylin- der head. 28. Apply a continuous bead of liquid gasket to mating surface of rocker cover gasket and cylinder head. © Use Genuine Liquid Gasket or equivalent. 29. Install rocker cover and oil separator. Rocker cover tightening procedure: (1) Tighten nuts @ - 4 - { - @ - ® in that order to 4 N: (0.4 kg-m, 2.9 ft-lb). (2) Tighten nuts @ to as indicated in figure to 8 to 10 N-m 8 to 7.2 ft-lb). 30. Install PAIR valve and resonator. 31. Refit spark plugs and leads. 32. Install vacuum hoses, fuel heses, wires, harness, connec- tors and so on 33. Install power steering oil pump and alternator. 34. Install water pump pulley and drive belts 35. Refit air duct to intake manifold. 36. Install radiator. 37. Refit hoses and refill with coolant. Refer to MA section. 38. Install engine side cover and front R.H. wheel. 39. Install engine under covers. EM-28OIL SEAL REPLACEMENT VALVE OIL SEAL 1. Remove accelerator cable. 2. Remove rocker cover and oil separator. 3, Remove camshafts and sprockets. Refer to “Removal” in “TIMING CHAIN”. a Remove spark plugs. Install air hose adapter into spark plug hole and apply air pressure to hold vaives in place. Apply a pressure of 490 MA kPa (5 kg/cm’, 71 psi). 6. Remove rocker arm, rocker arm guide and shim. ci 7. Remove valve spring with Tool. Piston concerned should be set at T.D.C. to prevent valve from 1c falling. 8 Remove valve oil seal. aT Fa 9. Apply engine oil to new valve oil seal and install it with Tool. BR oF HA FRONT OIL SEAL 4. Remove the following parts: a © Engine under cover © Front R.H. wheel and engine side cover © Drive belts © Crankshaft pulley 2, Remove front oil seal. Be careful not to scratch front cover. EM-29OIL SEAL REPLACEMENT Engin inside + 0 sea Engine outside Dust sea ip 3. Apply engine oil to new oil seal and install it using a suit- able tool. REAR OIL SEAL 1. Remove transaxle. (Refer to MT or AT section.) 2. Remove flywheel or drive plate. 3. Remove rear oil seal. Be careful not to scratch rear oil seal retainer. Enno cule oF sa ust slp NOS 4. Apply engine oil to new oil seal and install it using a suit- able tool EM-30wen ciosed — Z ban tn ‘When fully opened Adjusting sorew VereH Stopper lever Lock nut Turn adjusting screw 3 rotations socks, {aE 40-54 wm (oat = 058 kp 20-40 1) ACCEL-DRUM UNIT Adjust accel-drum unit whenever any of the following parts (new or old) are installed: © Accel-drum unit Throttle body Install accel-drum unit and throttle body. . © Rod (Always replace with a new one after removal.) 1 2. Apply grease all over the inside of the rod couplings. Use genuine Nissan grease or equivalent. 3. Insert each one coupling to ball links of throttle body and accel-drum unit. 4, Loosen lock nut. 5. Loosen adjusting screw enough. 6. Manually turn accel-drum until throttle valve is fully open. © Check that stopper lever is not touching adjusting screw. If it is, loosen adjusting screw to maintain clearance between the two 7. Turn adjusting screw until it touches stopper lever. 8 Back off accel-drum. 9. Turn adjusting screw 3 rotations clockwise. 10. Tighten lock nut EM-31 Wa ci Le Fe ec FE ch aT FA RA BR T eL8690080 CYLINDER HEAD nee ee mee — Lm DES OA NAT ca err ent 63 Q ~— an Refer to “installation” in “TIMING CHAIN". 12] Refer to “nstattion” in Sime CHAI" Ds nem xg, tb) Aon taut guste 497-197 (14-16, 101 - 190) seen it titer cap @® Camshat sprocket ® Valve spring seat Rocker cover @® Camshatt @® Valve spring Rocker arm guide @ Camshat bracket ® Valve spring retainer Rocker arm eles ® Valve collet im ater outlet @® Spark plug Hydraulic lash adjuster ® Cylinder head elgtecieen Chain tensioner ® Valve EM-32CYLINDER HEAD 8 © smal eee) ‘him / fT bern e ena LBosen ln numeral order. seusero] ‘CAUTION: © When installing sliding parts such as rocker arms, cam- shaft and oil seal, be sure to apply new engine oil on their sliding surfaces. © When tightening cylinder head bolts, camshaft sprocket bolts and camshaft bracket bolts, apply new engine oil to thread portions and seat surfaces of bolts. © a hydraulic lash adjuster is kept on its side, there is a risk of air entering it. After removal, always set hydraulic lash adjuster straight up, or when laying it on its side, have it ‘soak in new engine oil. ¢ Do not disassemble hydraulic lash adjusters. ¢ Attach tags to lash adjusters so as not to mix them up. Removal © This removal is the same procedure as those for timing chain. Refer to “Removal” in "TIMING CHAIN”. Disassembly 1. Remove rocker arms, shims, rocker arm guides and hydraulic lash adjusters from cylinder head. CAUTION: Koop parts In or nal positions during positions.) 60 that they can be inetalled in their origi- mbly. (Install parts in their original 2, Remove throttle body with accel-drum unit. 3, Remove EGR tube. 4. Remove exhaust manifold cover. 5. Remove exhaust manifold. EM-33 @ WA Le Fa ee FE or aT Fa RA BA T oF HACompressor assembly /Ataenmert SSP" seneoen CYLINDER HEAD Di 40. " assembly (Cont'd) Remove fuel tube assembly. Refer to “Injector Removal and Installation” in EF & EC section, Remove intake manifold. Remove intake manifold collector from intake manifold. Remove water outlet. Remove water connector. Remove thermostat housing with water pipe. . Remove valve components with Tool. EM-34sentaasc] CYLINDER HEAD Disassembly (Cont'd) 13. Remove valve oil seal with a suitable tool. a WA ial Inspection CYLINDER HEAD DISTORTION Le Head surface flatness: Standard fe Less than 0.03 mm (0.0012 in) EC Limit 0.1. mm (0.004 in) rn If beyond the specified limit, replace or resurface. Resurfacing limit: The resurfacing limit of cylinder head Is determined by the cyl- cj inder block resurfacing in an engine. Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. wr The maximum limit is as follows: A + B = 0.2 mm (0.008 in) After resurfacing cylinder head, check that camshaft rotates aT freely by hand. If resistance is felt, cylinder head must be replaced, ‘Nominal cylinder head height: Fa 136.9 - 137.1 mm (5.390 - 5.398 In) Ra CAMSHAFT VISUAL CHECK Check camshaft for scratches, seizure and wear. BR ST oF HA CAMSHAFT RUNOUT 1, Measure camshaft runout at the center journal. a Runout (Total indicator reading): Standard Less than 0.02 mm (0.0008 in) Limit 0.1 mm (0.004 in) 2. If it exceeds the limit, replace camshaft. EM-35‘senszse) CYLINDER HEAD. Inspection (Cont'd) CAMSHAFT CAM HEIGHT 1. Measure camshaft cam height. ‘Standard cam height: Intake: 38.408 - 38.598 mm (1.5121 - 1.5196 in) Exhaust, 37.920 - 38.110 mm (1.4929 - 1.5004 in) Cam wear limit: Intake & Exhaust 0.2 mm (0.008 in) 2. If wear is beyond the limit, replace camshaft. CAMSHAFT JOURNAL CLEARANCE 1. Install camshaft bracket and tighten bolts to the specified torque. 2. Measure inner diameter of camshaft bearing. ‘Standard inner diameter: 28.000 - 28.021 mm (1.1024 - 1.1032 in) 3. Measure outer diameter of camshaft journal. Standard outer diameter: 27.935 - 27.955 mm (1.0996 - 1.1006 in) 4. Ifclearance exceeds the limit, replace camshaft and/or cyl- inder head. ‘Camshaft journal clearance: Standard 0.045 - 0.086 mm (0.0018 - 0.0034 in) Limit 0.12 mm (0.0047 in) CAMSHAFT END PLAY 1. Install camshaft in cylinder head. 2. Measure camshaft end play. ‘Camshaft end play: ‘Standard (0.055 - 0.139 mm (0.0022 - 0.0055 in) Limit 0.20 mm (0.0079 in) CAMSHAFT SPROCKET RUNOUT 4. Install sprocket on camshaft. 2. Measure camshaft sprocket runout. Runout (Total indicator reading): Limit 0.25 mm (0.0098 in) 3. If it exceeds the limit, replace camshatt sprocket. EM-36CYLINDER HEAD Inspection (Cont'd) VALVE GUIDE CLEARANCE 1. Measure valve deflection in a parallel direction with rocker arm. (Valve and valve guide mostly wear in this direction.) Valve detlection limit (Dial gauge reading): Intake & Exhaust a 0.2 mm (0.008 in) WA ci 2. If it exceeds the limit, check valve to valve guide clearance. a, Measure valve stem diameter and valve guide inner diam- eter. b. Check that clearance is within specificati Valve to valve guide clearance: a Standard ee Intake 0.020 - 0.053 mm (0.0008 - 0.0021 in) Exhaust 0.040 - 0.073 mm (0.0016 - 0.0029 in) ps Limit Intake & Exhaust 0.1 mm (0.004 in) ¢. If it exceeds the limit, replace valve or valve guide, a VALVE GUIDE REPLACEMENT 1, To remove valve guide, heat cylinder head to 110 to 130°C WT (230 to 26°F). aT Fa RA 2. Press out valve guide or use a hammer and suitable tool. BR sT BF Ha 3. Ream cylinder head valve guide hole. Valve guide hole diameter a (for service parts): Intake & Exhaust 10.175 - 10.196 mm (0.4006 - 0.4014 in) EM-37Lu 1 Reces siometer CYLINDER HEAD Inspection (Contd) 4. Heat cylinder head to 110 to 130°C (230 to 266°F) and press service valve guide onto cylinder head. Projection “L"; 14.0 - 14.2 mm (0.551 - 0.559 in) 5. Ream valve guide. Valve guide inner diameter: Intake & Exhaust 6.000 - 6.018 mm (0.2362 - 0.2369 in) VALVE SEATS Check valve seats for any evidence of pitting at valve contact surface, and reset or replace if it has worn out excessively. © Before repairing valve seats, check valve and vaive guide for wear. If they have worn, replace them. Then correct valve seat. © Cut with both hands to uniform the cutting surface. REPLACING VALVE SEAT FOR SERVICE PARTS 1. Bore out old seat until it collapses. The machine depth stop should be set so that boring cannot continue beyond the bottom face of the seat recess in cylinder head. 2. Ream cylinder head recess. Reaming bore for service valve seat Oversize [0.5 mm (0.020 in)]: Intake — 35.500 - 35.516 mm (1.3976 - 1.3983 in) Exhaust 31.500 - 31.516 mm (1.2402 - 1.2408 in) Reaming should be done in circles concentric to the valve guide center so that valve seat will have the correct fit 3. Heat cylinder head to 110 to 130°C (280 to 26°F). 4. Press fit valve seat until it seats on the bottom. EM-387 (Margin thickness) +" eR > {_ ian |—+|}+—8 (out-ot-equare) CYLINDER HEAD Inspection (Contd) 5. Cut or grind valve seat using a suitable tool at the speci- fied dimensions as show S.D.S. 8. After cutting, lap valve seat with abrasive compound. 7. Check valve seating condition. Seat face angle “a”: 44°53" - 45°07" Contacting width “W": Intake 1.4 = 4.7 mm (0,085 - 0.067 in) Exhaust 1.7 - 2.0 mm (0.067 - 0.079 in) VALVE DIMENSIONS Check dimensions in each valve. For dimensions, refer to S.Ds. When valve head has been worn down to 0.5 mm (0.020 in) in margin thickness, replace valve, Grinding allowance for valve siem tip Is 0.2 mm (0.008 in) or less. VALVE SPRING Squareness 1. Measure “S” dimension. Out-of-squar Less than 2.2 mm (0.087 in) 2. If it exceeds the limit, replace spring. Pressure Check valve spring pressure. Pressure: N (kg, Ib) at height mm (in) Standard 569.00 - 641.57 (58.02 - 65.42, 127.93 - 144.25) at 30.0 (1.181) Limit More than 549.2 (56.0, 123.5) at 30.0 (1.181) It it exceeds the limit, replace spring. HYDRAULIC LASH ADJUSTER 1. Check contact and sliding surfaces for wear or scratches. EM-39 uc EFa eC FE cL wTCYLINDER HEAD Inspection (Cont'd) 2. Check diameter of lash adjuster. Outer diameter: 4 16.980 - 16.993 mm (0.6685 - 0.6690 in) sevsee| 3. Check lash adjuster guide inner diameter. Inner diameter: 17.000 - 17.020 mm (0.6693 - 0.6701 in) Standard clearance between lash adjuster and adjuster guid. 0.007 - 0.040 mm (0.0003 - 0.0016 in) 4 Rocker arm ROCKER ARM, SHIM AND ROCKER ARM GUIDE Check contact and sliding surfaces of rocker arms, shims and rocker arm guides for wear or scratches. ssemesso} Assembly Install water connector. 1 (1) Before installing water connector, remove all traces of liq- tid gasket from mating surface using a scrarer TT Yq 1 vc past ¢ Also remove traces of liquid gasket from mating surface of < cylinder head. ae 20-30mm | (2) Apply a continuous bead of liquid gasket to mating surface wate CTS 85 of water connector. © Use Genuine Liquid Gasket or equivalent 2. Install thermostat housing with water pipe. © Tightening procedure: (1) Tighten bolt @ to 2-5 Nem (0.2 - 0.5 kg-m, 1.4 - 3.6 ft-lb. (2) Tighten bolt © to 16 - 21 Nem (1.6 - 2.1 kg-m, 12 - 15 ft-lb). (3) Tighten bolt ® to 16 - 21 Nem (1.6 - 2.1 kg-m, 12 - 15 ft-lb). (4) Tighten bolt ® to 16 - 21 Nem (1.6 - 2.1 kg-m, 12 - 15 ft-b) ‘© Perform steps (2) through (4) after installing cylinder head ‘on cylinder block. ‘sensaro} EM-40‘Trratie boay CYLINDER HEAD bly (Cont'd) Install water outlet. Before installing water outlet, remove all traces of liquid gasket from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of cylinder head. Apply a continuous bead of liquid gasket to mating surface of water outlet. Use Genuine Liquid Gasket or equivalent. Install intake manifold collector to intake manifold. Install intake manifold, Install fuel tube assembly. Refer to “Injector Removal and Installation" in EF & EC section, Install exhaust manifold. Install exhaust manifold cover. Install EGR tube. ). Install throttle body with accel-drum unit. |. Adjust accel-drum unit. Refer to “ACCEL-DRUM UNIT”. EM-41 @ aT FAentiication mark seusoso] Wide pitch Narrow pitch alot mark finder head side senceso} Rocker arm gue. Focker arm CYLINDER HEAD ‘Assembly (Contd) 12. Install valve component parts. © Install valves, noting their identification marks as indicated in the table below. Identifca Intake valve 53 Exhaust ay yn mark © Always use new valve oil seal. Refer to OIL SEAL REPLACEMENT. © Before installing valve oil seal, install valve spring seat. ‘Install valve spring (uneven pitch type) with its narrow pitched side toward cylinder head side (paint mark). ‘© Affer installing valve component parts, use plastic hammer to lightly tap valve stem tip to assure a proper fit. 48. Check hydraulic lash adjusters. (1) When rocker arm can be moved at least 1 mm (0.04 in) by pushing at hydraulic lash adjuster location, it indicates that there is air in the high pressure chamber. Noise will be emitted trom hydraulic lash adjuster is started without bleeding air. engine (2) Remove hydraulic lash adjuster and dip in a container filled with engine oil. While pushing plunger as shown in figure, lightly push check ball using a thin rod. Air is completely bled when plunger no longer moves. Air cannot be bled from this type of lash adjuster by running the engin 14, Install rocker arms, shims, rocker arm guides and hydrau- lic lash adjusters. CAUTION: Install all parts in their original positions. EM-42res = Roa (ZS ) ma CYLINDER HEAD ‘Assembly (Cont'd) 45. Select a suitable shim when replacing valve, cylinder head, shim, rocker arm guide and/or valve seat with new one(s), as follows: 1) Install valve component parts to cylinder head (Except shim), © Always replace rocker arm guide with a new one. 2) Remove hydraulic lash adjuster. 3) Install Too!" into hydraulic lash adjuster fixing hole. * Tool [KV10115700 (J38957)] is screwed into magnetic stand rod used with dial gauge. 2:00 mm (o.t102 i) 4) Measure difference in level (T,) between sliding surface of rocker arm guide against rocker arm and valve stem end ‘on shim side with vaive, valve spring, collet, retainer and rocker arm guide installed to the head (Except shim), When measuring, lightly pull dial indicator rod toward you to eliminate play in Too! [KV10115700 (J38957)]. 5) Select a shim having a thickness (T) that makes ~0.025 mm (0.0010 in) 5 [(T) ~ (T,)] & 0.025 mm (0.0010 in). © Shims are available in 17 different thicknesses ranging from 2.800 mm (0.1102 in) to 3.200 mm (0.1260 in) in incre- ments of 0.025 mm (0.0010 in). Installation ¢ This installation is the same procedure as those for timing chain. Refer to “Installation” in “TIMING CHAIN”. EM-43 a Le Fe ec FE io wr aT Fa Ra BR 7 OF HAENGINE REMOVAL Apis TD: Norm tag, tb) 100, 57-72) @® Rear engine slinger @ Rear insulator © Front engine stinger @® Front engine mounting @® Center member @® Rear engine mounting (Fluid type) @ Mounting bracket (Fluid type) @ Mounting bracket EM-44ENGINE REMOVAL WARNING: Situate vehicle on a flat and solid surte Place chocks at front and back of rear wheels. Do not remove engine until exhaust system has completely cooled off. a Otherwise, you may burn yourself and/or fire may break out in fu For safety during subsequent steps, the tension of wires jj, should be slackened against the engine. Before disconnecting fuel hose, release fuel pressure from a fuel line. Refer to “Releasing Fuel Pressure” in section EF & EC. Be sure to hoist engine and transaxle in a safe manner. 9. For engines not equipped with engine singers, attach LC proper slingers and bolts described in PARTS CATALOG. CAUTION: oa © When lifting engine, be careful not to strike adjacent parts, EC especially accelerator wire casing, brake lines, and brake master cylinder. ‘© Inhoisting the engine, always use engine slingers ina safe FE manner. cL Removal 1, Remove engine under cover and hood. ci 2. Drain coolant from both cylinder block, and radiator. 3. Drain engine oil from drain plug of oil pan. . 4. Remove vacuum hoses, fuel hoses, wires, harness and AT connectors and so on. 5. Remove exhaust tubes, ball joints and drive shafts. 6. Remove radiator and fans. FA 7. Remove drive belts. & Remove alternator, compressor and power steering oll .. pump from engine. RR 9 Set a suitable transmission jack under transaxle. Hoist engine with engine slinger. aR 10. Remove center member. st BF Ha 11. Remove engine mounting bolts from both sides and then slowly lower transmission jack. a EM-45ENGINE REMOVAL Removal (Contd) 12. Remove engine with transaxle as shown. senosso| Installation 1. Install engine mounting bracket and fixing bolts, Be sure that insulators are correctly positioned on the brack- ets. 2. Carefully lower the engine onto engine mounting insula- tors. When installing the engine, adjust the height of the engine EM-46©8888 S88e CYLINDER BLOCK [A Rotor to “Assembly” “eheasrs we “P)19-28 ie (019 - 025, 14-18) B cnmigm nm ears ‘ a (088 878, Tae tau gaske aR @ seusore Rear oil seal retainer ® Piston rings @® Stee! oit pan Cylinder block © Piston @ Bale plate Water pump ® Piston pin @ Side gallery bate plate Power sleering oll pump adlust- Connecting rod @ Main bearing team I batho ® Connecting rod bearing @ Main bearing cap ‘ront cover with ofl pump ® Battle plate @ Flywheel or drive plate ® Aluminum oil pan @ Rear plate ® Rear cover plate @ Main bearing Crankshatt @ Drain plug Connecting rod bushing EM-47‘sewarre} CYLINDER BLOCK CAUTION: © When installing sliding parts such as bearings and pistons, be sure to apply new engine oil on the sliding surfaces. © Place removed parts such as bearings and bearing caps in their proper order and direction. When tightening connecting rod bolts and main bearing cay bolts, apply engine oil to thread portion of bolts and seat- ing surface of nuts. Disassembly PISTON AND CRANKSHAFT 4. Remove engine. Refer to "ENGINE REMOVAL”. 2. Remove cylinder head. Refer to “Removal” in “TIMING CHAIN”. 3. Remove oil pan. Refer to “Removal” in “OIL PAN” 4, Remove timing chain. Refer to "Removal “TIMING CHAIN”. 5. Remove pistons with connecting rod, © When disassembling piston and connecting rod, remove snap ring first, then heat piston to 60 to 70°C (140 to 158°F) or use piston pin press stand at room temperature. 6. Remove rear oil seal retainer. 7. Remove bearing beam, bearing cap and crankshatt. © Before removing bearing cap, measure crankshaft end play. ‘© Bolts should be loosened in two or three steps. Inspection PISTON AND PISTON PIN CLEARANCE 1. Measure inner diameter of piston pin hole “dp”. Standard diameter “dp’ 21.987 - 21.999 mm (0.8656 - 0.8661 in) EM-48CYLINDER BLOCK Mcrometer PF Prese:tt (ol le Measuring point Inspection (Cont'd) 2. Measure outer diameter of piston pin “Dp” Standard diameter “Dp’ 21.989 - 22.001 mm (0.8657 - 0.8662 in) 3. Calculate piston pin clearance. dp — Dp = -0.004 to 0 mm (-0.0002 to 0 in) @ It it exceeds the above value, replace piston assembly with © pin, wa PISTON RING SIDE CLEARANCE Side clearance: Top ring id 0.045 - 0.080 mm (0.0018 - 0.0031 in) 2nd ring we 0.030 - 0.065 mm (0.0012 - 0.0026 in) ec Max. limit of side clearance: 0.2 mm (0.008 in) Fe If out of specification, replace piston and/or piston ring assem- bly. PISTON RING END GAP End gap: Pa Top ring 0.20 - 0.30 mm (0.0079 - 0.0118 in) 2nd ring 0.35 - 0.50 mm (0.0138 - 0.0197 in) Oil ring 0.20 - 0.60 mm (0.0079 - 0.0236 in) ay Max. limit of ring gat 1.0 mm (0.039 in) If out of specification, replace piston ring. If gap still exceeds fg the limit even with a new ring, rebore cylinder and use over- sized piston and piston rings. Refer to S.0.S. Ra CONNECTING ROD BEND AND TORSION Bend: BR Limit 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion: oT Limit 0.30 mm (0.0118 in) per 100 mm (3.94 in) length If it exceeds the limit, replace connecting rod assembly. BF HA CYLINDER BLOCK DISTORTION AND WEAR 1. Clean upper face of cylinder block and measure the distor- gj, tion. 1n 0.03 mm (0.0012 in) Limit: 0.10 mm (0.0039 in) 2. If out of specification, resurface it. The resurfacing limit is determined by cylinder head resur- facing in engine. EM-49214.25 - 211.35 mm (2.3169 - 0.3208 la) -seueoeo) o Bis ogiNte? a 100; CYLINDER BLOCK Inspection (Contd) Amount of cylinder head resurfacing Is ‘A’ Amount of cylinder block resurfacing is “B”. ‘The maximum limit is as follows: A + B = 0.2 mm (0.008 in) Nominal cylinder block height from crankshaft center: 211.25 - 211.35 mm (8.3169 - 8.3208 in) 3. If necessary, replace cylinder block. PISTON-TO-BORE CLEARANCE 1. Using a bore gauge, measure cylinder bore for wear, out- of-round and taper. Standard inner diameter: 86.000 - 86.030 mm (3.3858 - 3.3870 in) Wear limit: 0.20 mm (0.0079 in) Out-of-round limit: 0.015 mm (0.0006 in) Taper limit: 0.010 mm (0.0004 in) If it exceeds the limit, rebore all cylinders. Replace cylin- der block if necessary. 2. Check for scratches and seizure. If seizure is found, hone it, © If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block upper surface. 3, Measure piston skirt diameter. Piston diameter “A”: Refer to S.D.S. Measuring point “‘a” (Distance from the bottom): 11.0 mm (0.433 in) 4, Check that piston-to-bore clearance is within specification, Piston-to-bore clearance ““B”: 0.010 - 0.030 mm (0.0004 - 0.0012 in) 5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to S.D.S. 6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter “A”. Rebored size calculation: D=A+B-C where, D: Bored diameter A: Piston diameter as measured B: Piston-to-bore clearanc €: Honing allowance 0.02 mm (0.0008 in) 7. Install main bearing caps, and tighten to the specified torque to prevent distortion of cylinder bores in final assembly. EM-50CYLINDER BLOCK Inspection (Cont'd) 8 Cut cylinder bores. © When any cylinder needs boring, all other cylinders must also be bored. © Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so In diameter at a time. 9. Hone cylinders to obtain specified piston-to-bore clear- ance. 10. Measure finished cylinder bore for out-of-round and taper. i © Measurement should be done after cylinder bore cool down. a} rary CRANKSHAFT Lt 1. Check crankshaft main and pin journals for score, wear or LG cracks. I x | 2. With a micrometer, measure journals for taper and out- of-round. ea ee tt Out-of-round (X - ¥): \ Y Less than 0.005 mm (0.0002 in) Taper (A - B): FE Taper: A- 8 Less than 0.005 mm (0.0002 in) LJ omoteouna: x=¥ xuove a 3. Measure crankshaft runout. Runout (Total indicator reading): iw Less than 0.05 mm (0.0020 in) aT FA RA 7. BEARING CLEARANCE ee NS © Either of the following two methods may be used, however, BA method “A” gives more reliable results and is preferable. Method A (Using bore gauge & micrometer) UY Main bearing at Ww 1. Set main bearings in their proper positions on cylinder block and main bearing cap. eF J2L0Y / 2. Install main bearing cap and main bearing beam to cylin- der block. a Tighten all bolts in correct order in two or three stages. 3. Measure inner diameter “A” of each main bearing. EM-51CYLINDER BLOCK Inspection (Cont'd) 4, Measure outer diameter journal. 5. Calculate main bearing clearance. Main bearing clearance = A - Dm ‘Standard: 0.004 - 0.022 mm (0.0002 - 0.0009 in) Limit: 0.050 mm (0.0020 in) 6. If it exceeds the limit, replace bearing. 7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bear- ing. ‘Dm" of each crankshaft main a. When grinding crankshaft journal, confirm that “L" dimen- sion in fillet roll is more than the specified limit. “L": 0.1 mm (0.004 in) b. Refer to S.D.S. for grin vice parts. 19 crankshaft and available ser- see 8 If crankshaft is reused, measure main bearing clearances and select thickness of main bearings. If crankshaft is replaced with a new one, it is necessary to select thickness of main bearings as follows: a. Grade number of each cylinder block main journal is punched on the respective cylinder block. senso Fe saan jure grade conbor b. Grade number of each crankshaft main journal is punched on the respective crankshaft. Neos ¢. Select main bearing with suitable thickness according to the following table. How to select main bearings hot hoa | (Identification mark and color) Crankshaft Main journal grade number Journal grade number ° 1 2 3 Crankshaft 0 7 5 5 kd severe ° (A, slack) | (6, Brown) | (©, Green) | (0, Yellow) oo 1 2 3 4 ee ‘ (8.Brown) | (6. Green) | (0, Yellow) | _(E, Bive) No. 5 journal 2 3 4 5 2 (6. Green) | (0. Yellow) | (€. Blue) | _(F, Pink) 3 3 4 5 6 (0. Yellow) | (€.Blue) | _(F. Pink) | (G, No color) For example: Main journal gra Crankshaft journal g Main bearing grade number 3 (D, Yellow) EM-52sesso] Nos No.4 (Crankshaft ont view seworso} CYLINDER BLOCK Inspection (Cont'd) Connecting rod bearing (Big end) 1 2. Install connecting rod bearing to connecting rod and cap. Install connecting rod cap to connecting rod. Tighten bolts to the specified torque. 3. Connecting rod bearing grade number: Measure inner diameter “C" of each bearing. Measure outer diameter “Dp” of each crankshaft pin jour nal. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C ~ Dp Standard: 0.020 - 0.045 mm (0.0008 - 0.0018 in) Limit: 0.090 mm (0.0035 in) It it exceeds the limit, replace bearing. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bear- ing. Refer to step 7 of “BEARING CLEARANCE — Main bearing” If crankshatt is replaced with a new one, select connecting rod bearing according to the following table. a Connecting od bearing ora 0 0 1 1 2 2 Identification color: Grade 0; No color Grade 1; Black Grade 2; Brown Method B (Using plastigage) CAUTION: © Do not turn crankshaft or connecting rod while plastigage is being inserted. When bearing clearance exceeds the specified limit, ‘sure that the proper bearing has been installed. Then if excessive bearing clearance exists, use a thicker main bearing or undersized bearing so that the specified bear- ing clearance is obtained. EM-53 aT FA RA BR Hasemisie| ‘ion ssenes2A) CYLINDER BLOCK Inspection (Cont'd) CONNECTING ROD BUSHING CLEARANCE (Small end) 1, Measure inner diameter “C' of bushing. 2. Measure outer diameter “Dp” of piston pin. 3, Calculate connecting rod bushing clearance. Connecting rod bushing clearance = C - Dp Standard: (0.005 - 0.017 mm (0.0002 - 0.0007 in) Limit: 0.023 mm (0.0009 in) It it exceeds the limit, replace connecting rod assembly or ‘connecting rod bushing and/or piston set with pin. REPLACEMENT OF CONNECTING ROD BUSHING (Small end) 1. Drive in small end bushing until it is flush with end surface of rod Be sure to align the oil holes. 2. After driving clearance between connecting rod bushing and piston pin is the specified value. Clearance between connecting rod bushing and piston pin: 0.005 - 0.017 mm (0.0002 - 0.0007 in) FLYWHEEL/DRIVE PLATE RUNOUT Runout (Total indicator reading): Flywheel (M/T model) Less than 0.10 mm (0.0039 in) Drive plate (A/T mode!) Less than 0.20 mm (0.0079 in) EM-54 ‘small end bushing, ream the bushing so that‘8 ing expander Sf = Front 0 2.950 (0.1161) 2 Dearing clearance (00018-00004) 1200047) Inner diameter of cart 28,000 = 28021 = 2078 01179) = San bearing (iro 3 a ZI s05 27.955 ‘A 000 (03189) = (owe 108) = Cama runout Than 01 (0.008 @ rrr 002 (00008) aA Sees eaten 2% ‘Camshalt sprocket ‘Loss than _ @ eu TAR 025 (00000) 3.080 (01200) aR = 0058 - 0.189 2 Camshat end play gate gta) 02000079) 23075 (03211) 5 a 8T 24100 (0.1220) A 8.125 (0.1230) 4 BF a 2.150 (0.1240) “ wh 9.175 (0.1250) * ‘ ” 78 emer 2200 0.1280) ae am height a oo Intake 38.408 - 38,596 (1.5121 - 1.5196) Exhaust 7.920 98.110 (14909-15006), Wear tint of ame height 02 (0.008) Valve it Intake 100 0.306 Exhaust #2 096 ota ciate ending EM-61SERVICE DATA AND SPECIFICA’ INS (S.D.S. Inspection and Adjustment (Cont'd) CYLINDER BLOCK Unit: mm ans - 211.8 sevue 3 8 Sac a standard Loss tan 08 (20012 Lint 0 (000 Grn bore Inerclanetr Standard Grade Ho. 86000-26010 (3208-282 Grado No.2 86010-06000 (82862-3808) {Grade No.3. 86620-06000 (3208- 3670) iar iit 020,007 Sarat OV 5 han 0015 (086) T 8 than 0.070 (0.0008) ) Ditorence in inner clameter between cylin- ore Limit ‘Lees than 0.05 (0.0020) Main joural inner diameter Grade No. 0 58.044 - 8.050 (28208 - 23200) Grade No. 1 58.950 - 58.956 (2.200 - 2.011) Grade No. 2 58.956 - 58.962 (2.8211 - 28218) Grade No. 3 58.962 - 58.968 (2.8219 - 23216) PISTON, PISTON RING AND PISTON PIN Available piston Unit nm in) Piaton aki diameter "A Standard 85.980 - 85.990 (3.9680 - 9.9854) 25.900 - 86.000 (2.3654 - 9.9858) Grade No. 3 26.000 - 86.010 (2.3858 - 9.3862) 020 (0.078) over. ee 26.180 - 86.210 (2.3629 - 3.3641) ion 110 0-89) (2.010 - 0.090 (.00c4- 0.0012) Piaton pin hole diameter 21.887 - 21.968 (0.8656 - 0.8661) Piston ring Unit am (in) ‘Standard Limit Side clearance x 2.045 - 0080 iD (0.0018 - 0.0031), 22 (0.008) ond 0.000 - 0.085 (o.0012 0.0026) End gap 10 020-020 eZ (20079 0.0118) 035-080 one oorse-oorem | 191008) 020-060 (i (eat rng) rcaratonzse) EM-62Piston pin SERVICE DATA AND SPECIFICATIONS (S.D-.S. Inspection and Adjustment (Cont'd) CRANKSHAFT Unit mm in) Unit: mm in) Platon pin outor dlametor 721001 (0.8657 - 0.8662) Main joural dia. “Om 0 ot piston rae No, 54.900 (2.1688 - 2.1646) Taran fon >. 0008 (000002) Grade No.0 ‘4.974 ~ 94.90 (2.1689 21046) te piston Grade No. 1 (54.968 - 54.974 (2, 1641 - 2.1643) ea Grade No.2 ‘962 - 54.968 (2.1690 -2 1041) Standard 0.005 - 0.017 (0.0002 - 0.0007) Grade No 9 CL AS) — same in journal di. "Dp ‘measired at ambient temperature of 20°C (68°F) Grade No.0 peace emcee rade No. 1 7962-47 988 (1.883 - 1.885) ‘CONNECTING ROD Grade No. 2 47.956 - 47.962 (1.8880 - 1.8883) Unit mm (o) “Cantar tance“ 72 (1858) ‘Contr ditance 19690 (696) ‘Outtround = ¥) Bend, torsion per 100, Standard Les tan 0006 (0.002) gen Taper (8) Limit esa Standard Less than 0.005 (0.0002) Torsion [por 10 880) anon | os eon Standard Less than 0325 (0.0010) Connecting rea smalioné | 24.999. 25.00 (0.9895 - 0.9843) Ui ‘ess than 006 (00020) Foun pa bang ear] Free ond Piston pn bushing ier 7 diameter ee eee, Standard 0.10 - 0.26 (0.0039 - 0.0102) Connecting ra big end Umi 030 00118) inner diameter ‘Side clearance Standard mit ‘51.000 - 51.013 (20078 - 2.0084) 020-035 (0.0079 - 0.0136) (05 (0020) "Biter ating Ta Connecting Fo EM-63 elo! ews EFA Ec FE cL FA RA BR st BF ELSERVICE DATA AND SPECIFICATIONS (S. Inspection and Adjustment (Cont'd) AVAILABLE MAIN BEARING ‘Olt hole: at oes sees Main bearing (Standard) (Giase | canoes “T° | wianw~ | Wenileaton © | coorra sre ck (a) + | otro: oarey brown (8) 2 | soive core area 9 9 | oraz cores | reson | Yoon) + | ours oor) Bue €) 5 | coorat-o07es) Pink © | aes corn we eet Main bearing (Undersize) oxscocom | 2-280, | no cnrancn ota speaied ton AVAILABLE CONNECTING ROD BEARING Connecting rod bearing Standard size Unit mm tn) rade : | aenticaon umber | THekness “7 wath “we color (mark) 1500-1508 0 | ghia No color (A) | sss | 69-171 | gece (0.0592 - 0.0593) | (0.685 - 0.673) ome 1.508 1908 2 | eoosss - 10564) ome Undersize Unit mmm) Undersize Thickness, ee Tea Ce) (0.0607 - 0.0610) Grind so tat boar- rr 012 o0047) : Ing clearance the 40.0615 - 0.0618) ‘specified value. 1128-634 025 (0.0088) | 20540-0645) Bearing clearance Unt me a) ‘Main bearing clearance Standard ‘0.008 - 0.022 (2.0002 - 0.0009) us 0.05 (0.0020) ‘Connecting rod Bearing ch Standars (0.020 - 0.045 (0.0008 - 0.0018) iit 0.09 (0.0035) MISCELLANEOUS COMPONENTS Unit mem (in| “Camshaft sprocket runout init ry 025 (0.0088) Flywheel runout limit (TR 0.3 (0.008) Drive plate runout init (TLR) 02 (0.008) EM-64ENGINE LUBRICATION & COOLING SYSTEMS sero PRECAUTION. Liquid Gasket Application Procedure PREPARATION. Special Service Tools ENGINE LUBRICATION SYSTEM. Lubrication Circuit, Oil Pressure Check. ll Pump, ENGINE COOLING SYSTEM. Cooling Circuit CONTENTS System Check Cooling System Inspection. Water Pump. Thermostat Water Outlet Radiator. Refilling Engine Coolant. SERVICE DATA AND SPECIFICATIONS (S.0.S,) Engine Lubrication System. Engine Cooling System 10 1" 1" 12 oN 14 14 iyLiquid Gasket Application Procedure Before applying liquid gasket, use a scraper to remove all traces of old liquid gasket from mating surface and grooves, and then completely clean any oil stains from these portions. Apply a continuous bead of liquid gasket to mating sur- faces. (Use Genuine Liquid Gasket or equivalent.) © Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) wide (for oil pan). © Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) wide (in areas except oil pan). Apply liquid gasket to inner surface around hole perimeter a bly should be done within 5 minutes after coating.) Wait at least 30 minutes before refilling engine oil and engine coolant. Lc-2PREPARATION Special Service Tools ‘Tool number (Kent-Moore No.) Too! name Description 'S725051001 (025695-1) Oil pressure gauge '$725052000 ‘Adapting oll pressure gauge (425695-2) to cylinder block Hose ws39920000 Pressing the tube of liquid on) gasket Tube presser EG17650301 ‘Adaating radiator cap tester (-) Radiator cap tester adapter to radiator filer neck Lc-3 BF Ha aENGINE LUBRICATION SYSTEM Lubrication Circuit Pee a Feed Oit strainer a {Taree f= ot gue SS 04 pasar SS sxcsean| Oil Pressure Check WARNING: © Be careful not to burn yourself, as the engine and oil may be hot. © Oil pressure check should be done in “Neutral position”. 1. Check oil level 2. Remove oil pressure switch. Lc-4ENGINE LUBRICATION SYSTEM Oil Pressure Check (Cont'd) 3. Install pressure gauge. 4, Start engine and warm it up to normal operating tempera- ture. 5. Check oil pressure with engine running under no-load. Engine speed ‘Approximate discharge pressure ‘om kPa (kg/em’, psi) idle speed ‘More than 76 (08, 11) 3,200 314-392 (32-40, 46-67) If difference is extreme, check oll passage and oil pump for oil leaks. 6. Install oil pressure switch with sealant. Oil Pump REMOVAL 1. Remove drive belts. 2. Remove cylinder head. (Refer to EM section.) 3. Remove oil pans. (Refer to EM section.) 4, Remove oil strainer and baffle plate. 5. Remove front cover assembly. DISASSEMBLY AND ASSEMBLY . oO ar-e0 fess Shay 27-an - A fia out = e ent N ® 01 pup cover > Benne 8 toes ] a\ 4 se . @ opus ne ee \ \p Peek Taon ara ® Soe . ‘8 Oe Fi-wasina 8 Re (0) 99-68 (40-70, 29-51) ie Da: nem (haem, tt) Always replace oil seal and O-ring with new ones. © When installing ol! pump, apply engine oll to inner and outer gears. © Be sure that O-rings are properly fitted. Lc-5 a wa 2] Era eC Fe ck aT aT FA RA BR st oF HAENGINE LUBRICATION SYSTEM. ‘Oil Pump (Cont'd) INSTALLATION ‘¢ Before installing front cover assembly, remove all traces of liquid gasket from mating surface using a scraper. ‘© Also remove traces of liquid gasket from mating surface of cylinder block. sxcaosa] 1. Apply a continuous bead of liquid gasket to mating surface of front cover assembly. Use Genuine Liquid Gasket or equivalent. Installation is the reverse order of removal. EC gtskat to ie groove. WS G-O=® scm xcevon| LC-6ENGINE LUBRICATION SYSTEM Oil Pump (Cont'd) INSPECTION Using a feeler gauge, check the following clearances: Unit: mm (in) Body to outer gear clearance @ (0.114 - 0.200 (0.0045 - 0.0078) Inner gear to outer gear tip clearence Reece y MA Body to inner gear clearance @ 0.05 - 0.09 (0.0020 - 0.0035) dy acute gear clearance @ 005-01 (00020-0004 ler gat a brazed orton of M9945 996 (061-050) © taetponeara yeaa ee ma ap oero Al Mf body to gear clearances (D, @, @, ©) exceed thi limit, replace front cover assembly. a FE co REGULATOR VALVE INSPECTION Spring — 4. Visually inspect componen's for wear and damage. it Regulator 2. Check oil pressure regulator valve sliding surface and vate vee valve spring. 3, Coat regulator valve with engine oil and cheok that it falls aT = 1 smoothly into the valve hole by its own weight. tit M damaged, replace regulator valve set or oll pump cover. sucan RA 4. Check regulator valve to oil pump cover clearance. Clearance: aR ® : 0.040 - 0.097 mm (0.0016 - 0.0038 in) Wit exceeds the limit, replace oil pump cover. sxcasta) HA OIL PRESSURE RELIEF VALVE INSPECTION Inspect oil pressure relief valve for movement, cracks and gl, breaks. If damaged, replace oil filter bracket assembly. (6-7 kgm, 43-51 Mab) Lc-7ENGINE COOLING SYSTEM Cooling Circuit ee Thermoniat open <2 : Thamostt closed [fener] Throttle body ACV. rgulator Heater £c176¢0301 c toa ‘System Check WARNING: Never remove the radiator cap when the engine is hot; serious burns could be caused by high pressure fluid escaping from the radiator. Wrap a thick cloth around the cap and carefully remove it by turning it a quarter turn to allow built-up pressure to escape and then turn the cap all the way off. Cooling System Inspection CHECKING HOSES Check water hoses for proper attachment, leaks, cracks, damage, loose connections, chafing and deterioration, CHECKING RADIATOR CAP To check radiator cap, apply pressure to cap with a tester. Radiator cap relief pressure: 78 - 98 kPa (0.8 - 1.0 kg/em?, 11 - 14 psi) Pull the negative pressure valve to open it Check that it closes completely when released Lc-8ENGINE COOLING SYSTEM stceaa| Cooling System Inspection (Cont'd) CHECKING COOLING SYSTEM FOR LEAKS To check for leakage, apply pressure to the cooling system with a tester, Testing pressure: 157 kPa (1.6 kg/cm?, 23 psi) a CAUTION: Higher than the specified pressure may cause radiator dam- age. we EM Water Pump REMOVAL 4. Drain coolant from radiator 2. Remove cylinder block drain plug located at left front of EF & cylinder block and drain coolant. eC 3. Remove front R.H. wheel and engine side cover. 4. Remove drive belts FE 5. Remove front engine mounting, ch 6. Remove water pump. CAUTION: wt © When removing water pump assembly, be careful not to get coolant on drive belt. © Water pump cannot be disassembled and should be a7 replaced as a unit. © After installing water pump, connect hose and clamp securely, then check for leaks using radiator cap tester. Fi RA INSPECTION 1. Check for badly rusted or corroded body assembly. BA 2. Check for rough operation due to excessive end play. st aF AA INSTALLATION 1. Before installing water pump, remove all traces of liquid |, gasket from mating surface of water pump using a scraper. © Also remove traces of liquid gasket from mating surface of cylinder block Lc-9IE COOLING SYSTEM Water Pump (Cont'd) 2. Apply a continuous bead of liquid gasket to mating surface of water pump. Tduaud gasket | Use Genuine Liquid Gasket or equivalent. 20-30 mm (04079 - 0338 i) stcesual Thermostat es-03 ‘Ae relet pug, (084 085, 48 - 6.1) Sacer Ne , Ly ® ip Pis-2 > (18-23, 2-15 Lopes a (6-2 ‘Water it 2 FE): Nom team, tb) REMOVAL AND INSTALLATION 1. Drain engine coolant. 2, Remove lower radiator hose. 3, Remove water inlet, then take out thermostat 4, Install thermostat with jiggle valve or air bleeder facing upward. After installation, run engine for a few minutes, and check for leaks. Be careful not to spill coolant over engine compartment. Use a rag to absorb coolant. LC-10ENGINE COOLING SYSTEM Thermostat (Cont'd) INSPECTION 1. Check for valve seating condition at ordinary temperatures. It should seat tightly. 2. Check valve opening temperature and maximum valve lift. a Valve opening temperature “ocr 785 (170) Max. valve lit mimeo (arh)| 0700 (Os¥t94) WA 3. Then check if valve closes at 5°C (9°F) below valve open- ing temperature. eH Water Outlet INSPECTION Visually inspect for water leaks. If there is leakage, apply liq- uid gasket a ec FE cL INSTALLATION 1. Before installing water outlet, remove all traces of liquid {7 {gasket from mating surface of water outlet using a scraper. Also remove traces of liquid gasket from mating surface of cylinder head. a 2. Apply a continuous bead of liquid gasket to mating surface of water outlet. @ Use Genuine Liquid Gasket or equivalent. FA OE Laid gasket e085] Ly Radiator © Radiator ter cap @ Upper radiator hose @ Radiator drain plug 7 @ OF cooler hoses (AT modes) @ Radiator tan © Lower radiator hose © Raster shroud oF @ Rahat fan motor @ Reserve tae HA aL s.cossa|ENGINE COOLING SYSTEM Refilling Engine Coolant 1 6 7. Set heater temperature control lever to Maximum Hot posi: tion. Remove radiator filler cap, air relief plug and air bleeder cap. Fill radiator with coolant and fill reservoir tank fo Max line with coolant. Air relief plug is reinstalled once coolant spills from the air relief hole during refill Then fill radiator and reservoir tank with coolant. Reinstall air bleeder cap. Install a temporary radiator filler cap which allows air and coolant in cooling system to be directed into reservoir tank regardless of pressure. Install a suitable steel wire between negative pressure valve and its seat as shown in the picture. ‘Warm up engine to normal operating temperature. Run engine at 2,500 rpm for 10 seconds and return to idle speed. Repeat 2 or 3 times Watch coolant temperature gauge so as not to overheat the engine. 8 . 9. . 10. " Stop engine and coo! it down. Cool down using a fan to reduce the time. Remove the temporary radiator filler cap and check cool- ant level. if necessary, refill radiator up to filler neck with coolant. Refill reservoir tank to Max line with coolant. Repeat step 7 through step 10 two or more times. Le-12ENGINE COOLING SYSTEM. Rasator ter cap hose Reserve tank Radiator Transparent ‘Ar bieedor Ny sucara] Refilling Engine Coolant (Cont'd) 12. Install a proper radiator filler cap. (Original radiator filler cap) 19. Warm up engine, and check for sound of coolant flow while running engine from idle up to 4,000 rpm with heater tem- perature control lever set at several positions between COOL and HOT. @ Sound may be noticeable at heater water cock. 14. If sound is heard, bleed air from cooling system according. to the following steps. 1) Cool engine down and remove air bleeder cap on heater inlet hose 2) Attach a suitable transparent hose at air bleeder pipe and put the opposite end of the hose into coolant of reservoir tank. 3) Install the temporary radiator filler cap and check for proper connection of all coolant related hoses. 4) Start engine and check for bubbles in reservoir tank. 5) Set heater temperature control lever to max “COOL” posi- tion in order to bypass coolant through the transparent hose. 6) Run engine up to 2,300 rpm until bubbles disappear in the transparent hose. Do not run engine over 2,300 rpm because engine may be damaged due to reduced coolant flow. 7) After removing bubbles, set heater temperature control ever to max “HOT” position and check for sound of cool- ant flow, 8) If sound is heard, repeat step 5) through step 7). 45. Stop engine and cool it down. 16. Install a proper radiator filler cap. (Original radiator filler cap) 17. Remove the transparent hose and install air bleeder cap. 48. Check any removed parts for secure reinstallation LC-13 Era Fa AB BASERVICE DATA AND SPECIFICATIONS (; ) Engine Lubrication System Oil pressure check Engine epeed ‘Approximate discharge pm pressure KPa (kolem*, psi) Tale speed More than 78 (08, 11) 3,20 814 902 (82-40, 46-57) Regulator valve inspection ‘nit nm (in| ‘Regulator valve to oll pump eames eae, 0.040 - 0.097 (0.0018 - 0.0038) Oil pump inspection Unit mam in ‘Body to outer gear clearance toner (0.114 0:20 (0.0065 - 0.0079) year to out gear tip Boow 0.18 (0.0071) Body to Inner gear clearance 0.050.080.0020 - 0.0085) Body to outer gear clearance 0.05 0.11 0.0020 - 0.0043) Inner gear to brazed portion of housing clearance ee eee Engine Cooling System Thermostat Valve opening temperature ‘ecm| 78807) Max. valve i mmv'o tnrr)| 80 031/186 LC-14