ENE'NETUNE.

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CONTENTS
ENGINM E A I N T E N A N .C: .E. . . . . . . . . ET- 2 SERVICEDATA .AND
Beforeenginestart . ET. 2 SPEC|F|CATIONS.... ... ET-11
After enginewarm-up ET. 5 Enginemaintenance..,. ET-1l
Emi'sslon
controlsystem ET-10
 E N G I N EM A I N T E N A N C E

ENGINE
MAINTENANCE
B E F O R EE N G I N ES T A R T The belts should not touch the bottom 3. Adjust belt tensionas follows:
of the pulley groove.
CHECKINGAND ADJUSTING
Fan and alternatorbelt
DRIVE BELTS 2. Checkbelt tensionby pushing.
1. Loosen the upper and lower alter-
l. Visually inspect for cracks or The belts should deflect by the spec-
nator securingbolts until the alterna-
damage. ified amount.
tor can be moved slightly.
2. Move the alternator with a prying
Adjust deflection Set deflection bar until the belt tension is within the
Drive belt deflection of new belt
of usedbelt specifiedrange.Then tighten the bolts
securely.
8-10 ).) - /.)
Coolingfan mm (in)
( 0 . 3 1- 0 . 3 9 ) (0.2r1- 0.29s)
belt
Air conditionercomPressor
Air conditioner 7 - 10.5 7- 8
mm tln, 1. Loosenthe idler pulley lock nut.
compressor (0.28-0.413) ( 0 . 2 8- 0 . 3 1 )
2. Adjust the adjustingbolt until the
Applied pushingforce N (kg, lb) 98 (t0,22) belt tension is within the specified
amount.
3. Tighten the idler pulley lock nut
securely.
Alternator
Fan pulley
R E P L A C I N GA I R C L E A N E R
CompressorPulleY FILTER
a. The viscouspaper type air cleaner
filter doesnot requireany cleaning
operationbetweenrenewal.
b. Replace air cleaner filter at the
specified maintenance intervals.
c. When replacing,install air cleaner
filter with "UP" mark facing up-
Crank pulleY ward.
Idler PulleY

Checkingpoint of drive
belt deflection
SMA337A

SMA712

ET.2
 E N G I N EM A I N T E N A N C E

C H E C K I N GF U E L L I N E S
(Hoses,piping, connections,etc.) To fuel tank From fuel tank
1 1
1. Check fuel line for leaks,particu.
iarll- around connection of fuel pipe Fuel damper
and fuel hose.
L Retighten loose connections and
replace any damaged or deformed
pans.

regulator -
Pressure Fuel pipe assemblY

CAUTION:
a. Do not reusefuel hose clamp after
loosening.
b. Tighten high pressurerubber hose
clamp so that clamp end is 3 mm
(0.12 in) from hose end or screw
position (wider than other portions
of clamp)is flush with hoseend.
Tighteningtorque specificationsare
$ Furl ho clamps
the samefor all rubber hoseclamps. 1 . 0- 1 5 N . m
When tighteninghoseclamp,ensure (0.10- 0.15 kg-m,
that screwdoes not come into con- 0.7 - 1.1 ft-lbl trFV/b

tact with adjacentparts.

R E P L A C I N GF U E L F I L T E R CHANGINGENGINECOOLANT
a. Before replacing,releasefuel pres-
sure. (Refer to Section EF for WARNING:
fuel pressure.)
releasing To avoid the dangerof being scalded,
b. Be carefulnot to spill fuel overen- never attempt to changethe coolant
gine compartment.Place a rag to when the engineis hot.
absorbfuel.
And plug openingof fuel hoseim- When changing engine coolant, set
mediately. heater"TEMP" control lever at fully
"HOT" position.

ET.3

Coolingwater capacity:
Unit: liters (Imp qt)
With heater e.o(7-718)
Without heater 8 . 3( 7 - 1 1 4 )
When usinganti-freezecoolant,follow
instructions attached to anti-freeze
containerfor mixing ratio.
C H E C K l N GC O O L | N G S Y S T E M .
H O S E SA N D C O N N E C T I O N S
Check hoses and fittings for loose
connections or deterioration. Re-
tiglrten or replaceifnecessary.
Checkingradiatorcap
Using cap tester, check the radiator
cap reliefpressure.
If the pressuregaugedrops rapidly and
ercessively,replacethe radiator cap.
Caprelief pressuro:
88 kPa (0.88 bar, 0.9 kg/cm2
Checting cooling systemfor leaks
,{:tach pressuretesterand pump tester
:i ihe specifiedpressure.
fhe;k for drop in pressure.
I: lhe pressuredrops, check for leaks
:::rr hoses,radiator,or water PumP.
I: no external leaks are found, check
..elrercore,block and head.
E N G I N EM A I N T E N A N C E
C H A N G I N GE N G I N E O I L A N D
OIL FILTER
WARNING:
Be carefulnot to burn yourself,asthe
engineoil may be hot.
A milky oil indicatesthe presence
of cooling water. lsolatethe cause
and take correctivemeasure.
An oil with extremelylow viscosity
indicatesdilution with gasoline.
Smeara little engineoil on rubber
gasketof new oil filter,
SMAOl O
o Oil filter should be tightened by
hand.
DO NOT use a wrench to tighten
the filter.
Oil capacity:
Unit: liters(Imp qt)
With oil filter 4.1(4-rl8)
Withoutoil filter 4.2(3-314)
o When checkingoil level, park the
vehicleon a levelsurface,
ET.4
C H E C K I N GE N G I N E
COMPRESSION PRESSURE
This inspectionshouldbe perform-
ed while engineis hot.
b . Disconnectall injector connectors
beforeinspection.
,-/sMA34'lA
pressure:
Compression
Unit: kPa(bar, kg/cm2,psi)/rpm
1 , 1 1 (71 1 . 7,7
Standard
12.0,tlt)1350
9 8 1( 9 . 8 1 ,
Minimum
10.0,r42)1350
If cylinder compressionin one or more
cylindersis low, pour a smallquantity
of engineoil into cylinders.
o If addingoil helpsthe compression
pressure,chancesare that piston
ringsare worn or damaged.
o If pressurestayslow, valve may be
stickingor seatingimproperly.
o If cylinder compressionin any two
adjacent cylinders is low, and if
adding oil does not help the com-
pression,there is leakagepast the
gasketedsurface.
Oil and water in combustioncham-
berscan result from this problem.
 E N G I N EM A I N T E N A N C E

C H E C K I N GA N D R E P L A C I N G
SPARK PLUGS
l Clean plugs in sandblast cleaner.
And inspect insulator for cracks or
chips. If they are excessivelyworn,
replacewith new spark plugs.
2. Using feeler gauge, check spark
plug gap.
If it is not within specifiedrange,set
gap by bendingsideelectrode.
Side electrode
A F T E R E N G I N EW A R M . U P A D J U S T I N GI N T A K E A N D
EXHAUST VALVE CLEARANCE
C H E C K I N GT O R O U E O F
CYLINDER HEAD BOLTS, Adjustment should be made while
MANIFOLD AND EXHAUST engineis hot.
TUBE NUTS l. Start engine and warm up engine
Cylinderheadbolt until water temperature indicator
points to the middle of gauge, then
The inspection should be performed
while engineis hot. stop engine.
Valve clearanceadjustmentcannot be
madewhile engineis in operation.

ft
2. Removevalverocker cover.
G a p : 1 . 0- 1 . 1 m m 3. Set No. I piston at top dead
(0.039- 0.043 inl
centeron its compressionstroke.

SMA343A

sMAOI9

Sparkplug:
Standardtype:
BP6ES-1 1
o @ o @ @
o o o o o SMA345A
Gold type:
BPTES-1 1
o o o o o
@: Sparkplug o @ @ @ @ 4. Measurevalve clearanceand write
20 - 29 N.m it down.
(2.0 - 3.0 ks-m, (Hot)
Valveclearance
14-22ft.tb1 I ntake
SMA344A
All cablesare marked to identify their 0 . 3 0 m m ( 0 . 0 1 2i n )
original locations, Exhaust
Q: Cylinderheadbolt
1 1 8- 1 2 7N ' m 0 . 3 5 m m ( 0 . 0 1 4i n )
C H E C K I N GI G N I T I O NW I R I N G ( 1 2 . 0- 1 3 . 0k g m ,
87 - 94 ft-tb)
l. Visually check wiring for cracks,
and damagedand burned terminals.
2. Using an ohmmeter, measurethe
resistancebetween cable terminal on Manifold and exhausttube nut
the spark plug side and corresponding
electrodeinsidecap. WARNING:
Shake the wire while measuringre- You should not check the exhaust
sistance to check for intermittent system until it has been cooled off.
brakes. Otherwise,you may burn yourself.

Tighteningtorque:
Distributor cap
Unit N.m kg-m ft-lb

High tension cable Intake

manifold
3 r - 4 2 3 . 2- 4 . 3 2 3 - 3 1

Exhaust
Resistance:
L 6 - 2 1 r.6 - 2.1 1 2 - 1 5
manifold
Less than
30,000C, Exhaust
tube 2 6 - 3 6 2 . 7- 3 . ' l 2 0 - 2 7
SM4342A SM4347A

ET.5
 E N G I N EM A I N T E N A N C E

5. Set No. 4 piston at top dead (5) Removecamshaftsprockets.

centeron its compressionstroke.
6. Measurevalve clearanceand write
it down.

(10) Calculateoptimum thicknessof

valvecap.
SM4348A
Support timing chain by a properwire I ntake:
to ensureit doesnot drop. t = t t + T 1- 0 . 3 0( m m )
Exhaust:
(6) Remove camshaft brackets and
t = tE + Te - 0'35 (mm)
7. If out of specification, adjust chain guide A in the sequencebelow.
t 1 , t g : M e a s u r evda l v e
valveclearance.
c a pt h i c k n e s (sm m )
(l) Reset No. I piston at top dead
centeron its compressionstroke. O @ o @ @
T 1 ,T E : M e a s u r evda l v e
clearance (mm)
(2) Scribemarks on timing chain and
camshaftsprocketswith paint.
n
BJ
P1
hJ
( 1 1 ) P i c k o u t p r o p e rv a l v ec a p f r o m
(3) Loosencamshaftsprocketbolts.
the list of valve cap thicknessesin
S.D.S.
n
El| Before installation,it is necessary
to
checkthicknessof new valvecap.
e @ @ @ @
(1 2) Install valvecap and valvelifter.
SEM812
a. Apply engineoil on valve cap and
outer wall of valvelifter.
Keepremovedbracketsin order. b. Pay particular attention not to
damagevalvelifter guidehole.
(7) Removecamshafts. c. Check valve lifter for smooth rota-
(8) Removevalvelifter and cap. tion.

(4) Removechain tensionercoverand

chain tensionerA.

(13) Install camshafts and tighten

o Valve lifter can be removed easily camshaft bracket nuts with chain
by usingmagnetor suction rubber. guideA in the reverseorder of removal
S E M 8 1O o Keepvalvelifter and cap in order, in two or three stages.

@: Camshaftbracketnut
(9) Measure thickness of removed 14- 18 N.m
Be careful not to drop chain tensioner valve cap using surface plate and dial ( 1 . 4 ' 1 . 8k g ' m ,
sleeveand spring. gauge,and write it down. 10 - 13 ft-rb)

ET-6
 E N G I N EM A I N T E N A N C E

wd:
a. Install camshaftsso that No. 1 cams C H E C K I N GA N D A D J U S T I N G
are at top deadcenter. I D L E R P M , I G N I T I O NT I M I N G
AND MIXTURE RATIO
Preparation

b. Apply sealant on cam, camshaft
journal, camshaftbearingand valve
lifter upper surface.
(14) Set timing chain on camshaft
sprockets by aligning each mark
scribed before removal. Then, install
camshaftsprocketsto camshafts.
@: Camshaftsprocketbolt
1 2 7- 1 7 7 N . m
( 1 3 . 0- 1 8 . 0k s - m ,
94 - 130 ft-rb)
N SEM831
(16) Install chain tensionercover.
(17) Install rubber plug with sealant.
(18) Install valverocker cover.
@ : Valve rocker cover bolt and nut
9 . 1 - 1 1 . 8N . m
t0.93 - 1.2k1-m,
6.7 - 8.7 ft-rb)
Rocker cover bolts should be
tightenedin crisscrossfashion.
b. Always use new rocker covel
gasket.
1. Make surethat the following parts
air in good order.
. Battery
o lgnition system
o EFI harnessconnectors
o Vacuum hoses
o Air intake system
o Oil filler cap,oil levelgaugeetc.
2. Connect engine tachometer and
timing light in their properpositions.
3. On air conditionerequippedme
dels, checks should be carried out
while the air conditioneris "OFF".
WARNING:
a. When inspecting idle speed,apply
parking brake and block both front
and rear wheelswith chocks.
b. After the inspectionhasbeenmade,
removewheel chocks.

(15) Install chain tensionerA.

@: ChaintensionerA bolt (19) Start engine and warm it up

6.3 - 8.3 N.m
(0.64 - 0.85 ks-m,
4.6. 6.1 ft-tb)
Before installation,fill engineoil
in chaintensionerA.
until water temperature indicator
points to the middle of gauge, then
stop engine.
(20) Remove valve rocker cover and
recheckvalveclearance.

ET-7
 ENGINE MAINTENAN.CE

Checklng'and adjusting procedure

engineand warm up engineuntil water

temperatureindicator points to the middle

o Openenginehood.
o Run engineat about 2,000 rpm for about
2 minutesunderno-load.

Run engineat idling speed.

Disconnectdistributor vlcuu+ hosqfrom

distributor vacuum controller, and plug hose
with proper plug.

Raoeenginetwo or three times under no-

Ioad.
Then run enginefor one minute at idle
speed.

SMA3SOA

Check ignition timing with tfuninCliCht.

4' r 1" B.T.D.C.

Adjust ignition timing by turning distributor

after looseningbolts which securedistributor.

Reconnectdistributor vacuum hose.

ET.8
 E N G I N EM A I N T E N A N C E

Raceenginetwo or three times under no-

load.
Then run enginefor one minute at idle
speed.

SMA35OA

Adjust idle speedby turning idle speed

adjustingscrew.

Stop engineand disconnectthe throttle

valveswitch harnessconnector.

Connecta lead wire, as shown between

terminals No. 24 and No. 30 of the throt-
tle valve switch harnessconnector.

Start engineand race enginetwo or three

times under no-load,then run engineat SMA3844
idle.

Adjust mixture ratio with enginespeedset

at maximumby turning air by-passscrew.

Stop engine,removethe lead wire and

SMA353A reconnectthe throttle valveswitch harness
to the throttle valveswitch.

Raceenginetwo or three times under no-

load, then run engineat idle.

Check idle speed and ignition timing.

ldle speed: 900 t 50 rpm

lgnition timing: 20o r 5' B,T.D.C,

SMA35OA

Adjust idle speedby turning idle speed

adjustingscrew.

ET-9
 EI\}@$NEUI'AI'NTE]NANC
E

EMISSIONCONTROLSYSTEM CheckingP.C.V.valve

CHECKINGPOSITIVECRANKCASEVENTILATION(P.C.V.)SYSTEM With engine running at idle, remove

the ventilator hose from P.C.V. valve
'
if the valve is working, a hissing noise
Baffle plate will be heard as air passesthrough the
valve and a strong vacuum should be
felt immediately when a finger is
placed over valve inlet.

P.C.V.Valve
SMA354A
ChedringYentilationhoses
1. Checkhosesandhoseconnections
for leaks.
2. Disconnect all hoses and clean
with compressedair.
If any hosecannotbe free ofobstruc-
tions,replace.
Enzure that flame arresteris surely
insertedin hosebetweenair pipe and
rockercover.

ET277

Er-'lo
 S E R V I C ED A T A A N D S P E C I F I C A T I O N S

SERVICEDATAAND SPECIFICATIONS
E N G I N EM A I N T E N A N C E Valve cap
INSPECTIONAND ADJUSTMENT
Part number T h i c k n e s sm m ( i n )
Basicmechanicalsystem
13229-AO200 1.25$.04921
Enginemodel FJ2O 13229-A0201 1 . 3 0( 0 , 0 5 1 2 )
V a l v e c l e a r a n c e( H o t ) mm (in)
13229-AO202 1 . 3 5( 0 . 0 s 3 )1
Intake 0 . 3 0( 0 . 0 1 2 ) 13229-AO203 1 . 4 0( 0 . 0 5 5 1 )
13229-AO204 1 . 4 5( 0 . 0 5 7 )1
Exhaust 0 . 3 5( 0 . 0 1 4 )
13229-AO205 1 . 5 0( 0 . 0 5 9 1 )
Adjust Set
Drive belt deflection mm (in) 13229-A0206 1 . 5 5( 0 . 0 6 1 0 )
deflection d e f l e c t i o n
of usedbelt o f n e w b e l t 13229-A0207 1.60 (0.0630)
13229-AO208 1.65(0.0650)
I -10 5 . 5- 7 . 5
C o o l i n gf a n ( 0 . 3 1- @ . 2 1 7- 13229-AO209 1 . 7 0( 0 . 0 6 6 9 )
0.39) 0.295) 13229-A0210 1 . 7 5( 0 , 0 6 8 9 )
7 - 10.5 7-8 13229.A0211 1 . 8 0( 0 . 0 7 0 9 )
Air conditioner comoressor ( 0 . 2 8- ( 0 , 2 8- 13229-AO212 1 . 8 5( 0 . 0 7 2 8 )
0.413) (0,31)
13229.AO213 1 . 9 0( 0 . 0 7 4 8 )
A p p l i e d p u s h i n gf o r c e N (kg, lb) 98 (10,22l, 13229-A0214 1 , 9 5( 0 . 0 7 6 8 )
E n g i n eo i l c a p a c i t y liter (lmp qt) 13229-AO215 2.00 (0.0787)
With oil filter 4.7 l4-118', 13229-AO216 2.05 (0,0807)
Without oil filter 4.2 {a-3141 13229-A0217 2.10 $.0827l-
13229.AO218 2 . 1 5( 0 , 0 8 4 6 )
Water capacity liter (lmp qt)
With heater LO 17-718], 13229-AO219 2.20 (0.0866)

Without heater
13229-AO220 2.25 (0.0886)
8.3 17-114l'
Radiator cap relief pressure
8 8 ( 0 . 8 80
, . 9 ,1 3 )
kPa (bar, kg/cm2, psi)

Coolingsystemleakage
testing lgnitionand fuel system
pressu
re 1 4 71 1. 4 7 ,1 . 5 , 2 1 l ,
kPa(bar,kg/cm2,psi) Ignition timing and engineidle speed

C o m p r e s s i o np r e s s u r e E n g i n em o d e l FJ2O
kPa (bar, kglcm2, psi)/rpm
Ig n i t i o n t i m i n g ( d e g r e e ) 4o t'1"
1,177
Standard
( 1 1 . 7 71, 2 , O , 1 7 1 1 . 1 3 0 0
ldle speed rpm 900r 50
Minimum 981
S p a r kp l u g
( 9 . 8 1 ,1 0 . 0 ,1 4 2 \ 1 3 5 0
Standard BP6ES-1
Type
Cold B P T E S -11

Gap mm (in) r . 0- 1 . 1( 0 . 0 3 -90 . 0 4 3 )

High tensioncable resistance (Ohm) Lessthan 30.000 O

D i s t r i b u t o r v a c u u m h o s e d i s c o n n e c t e da n d p l u g g e d .

ET-l1
 SENWES..EA.TAAN.fi}SPECI,FICATIONS

T|G}|TIN|NGToRoUE,',...:'i"'.ti.:.!;.l.i,.].''.i...::..'-]:'..

Unit N.m kg-m ft-lb

Cylinder head bolt 1 1 4- 1 2 7 1 2 . 0 -1 3 . 0 87-94,

Camshaft.bracket nut. 14-18 1 . 4- 1 . 4 . 1 0 -1 3

Camshaftsprocketbolt 1 2 7- 1 7 7 13"O:r
18.0 94 - 130

Chaintendiorierbolt 6 . 3- 8 . 3 0.64.0.85 4 . 6- 6 . 1

lntakemanifoldnut 31-42 3 . 2- 4 . 3 23-31

Exhaustmanifoldnut 't6 - 21 1,6.2.1 12-15

Sparkplug 20- 29 2'0: 3.0 14-22

Oil pan droin plug 35-47 3.6- 4,8 26-35

Et-1"9