SECTION 3

ENGINE
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CONTENTS

3-1. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2. ENGINE SERVICES NOT REQUIRING ENGINE REMOVAL . . . . . . 3-5

3-3. ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-4. ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3-5. INSPECTION OF ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . 3-17

3-6. ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3-7. ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

3-8. ENGINE MAINTENANCE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

3-9. RECOMMENDED TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3-58

3-1
3-1. GENERAL DESCRIPTION
1) Engine
The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its S.O.H.C (Single
overhead camshaft) valve mechanism arranged for “V’‘-type valve configuration.
This single overhead camshaft is mounted over the cylinder head; it is driven from crankshaft through
timing belt, and no push rods are provided in the valve train system.

Fig. 3- I- 1

3-2
2) Engine Lubrication
The oil pump is of a trochoid type, and mounted on the crankshaft at the crankshaft pulley side.
Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter.
The filtered oil flows into two paths in cylinder block.
In one path, oil reaches the crankshaft journal bearings.
Oil from the crankshaft journal bearings is supplied to the connecting rod bearings by means of intersect-
ing passages drilled in the crankshaft, and then injected from a small hole provided on the big end of
connecting rod to lubricate piston, rings, and cylinder wall.
In another path, oil goes up to the cylinder head and lubricates rocker arms, valves and camshaft, etc.,
after passing through the internal oilway of rocker arm shafts.

An oil relief valve is provided on the oil pump. This valve starts relieving oil pressure when the pressure
comes over about 3.0 kg/cm2 (42.7 psi, 300 kPa). Relieved oil drains back to the oil pan.

Fig. 3- 1-2
3-3
 3) Cylinder Head and Valve Train
The cylinder head is made of cast aluminum alloy and has four combustion chambers arranged in-line.
Each combustion chamber has an intake and an exhaust ports.
Moreover, as shown in Figure 3-l-3, the air induction nozzle is provided near each intake valve. During
intake stroke of the engine, air/fuel mixture enters into the combustion chamber from carburetor through
intake manifold and intake valve. At the same time, air flows to the air induction nozzle through carbure-
tor and air induction passage in the intake manifold, and jets into the combustion chamber.
The air jetted into the combustion chamber accelerates the mixture swirl to improve the combustion
efficiency.

A single overhead camshaft driven by the crankshaft through the timing belt is mounted on the cylinder
head. The camshaft has eight cams, and each cam operates the intake or exhaust valve through rocker arm.
The valve lash can be adjusted by turning the adjusting screw on the rocker arm after loosening the lock
nut.

2-

1. Intake valve
2. Exhaust valve
3. Rocker arms
4. Camshaft
6. Air induction nozzle
6. Air induction passage
7. Intake manifold
a. Carburetor
-. - _- - ._ . . . . .
Fig. 3- 7-3 Cylinder head and valve train

4) Cylinder Block
The cylinder block is made of cast aluminum alloy and has 4 cylinders arranged “In-Line”. A cylindrical
cast iron sleeve is installed in each cylinder.

5) Crankshaft and Main Bearings

A monoblock casting crankshaft is supported by 5 main bearings which are of precision insert type. Four
crank pins on the crankshaft are positioned 180” apart.

6) Pistons, Rings, Piston Pins and Connecting Rods

The piston is cast aluminum alloy, and has two compression rings and one oil ring.
Among two compression rings (top and 2nd rings), the top ring is plated with hard chromium for improve-
ment in abrasion resistance.
The oil ring consists of two rails and one spacer.
The piston pin is offset. 0.5 mm towards the major thrust side. This allows a gradual change in thrust
pressure against the cylinder wall as the piston travels its path. Pins are chromium steel and have a floating
fit in the pistons. They are retained in the connecting rods by a press fit. The connecting rods are made of
forged steel, and the rod bearings are of precision insert type.

3-4
3-2. ENGINE SERVICES NOT REQUIRING ENGINE REMOVAL
The following parts of components do not require engine removal to receive services (replacement, inspec-
tion or adjustment):

Part or Component Nature of Service 1

1. Spark plug Replacement or inspection
2. Distributor Replacement, inspection or adjustment
1 3. Exhaust manifold 1 Replacement or inspection I
I 4. Oil filter 1 Replacement I
1 5. Oil pressure unit ( Replacement
6. Cylinder head cover 1 Replacement I
I 7. Rocker shaft 1 Replacement or inspection I
8. Rocker-arm Replacement or inspection
I
9. Rocker-arm spring Replacement or inspection
10. Cam shaft Replacement or inspection (Cylinder head removal required)
11 Cylinder head Replacement or inspection

I 12. Radiator

13. Cooling fan

Replacement or inspection (Cooling fan and fan shroud
removal required)
Replacement
I

14. Camshaft timing belt pulley Replacement or inspection

15. Crankshaft timing belt pulley 1 Replacement or inspection

I 16. Timing belt

17. Fuel pump

Replacement or inspection (Cooling fan and fan shroud
removal required)
Replacement
18. Carburetor Replacement, inspection or adiustment
19. Intake manifold 1 Replacement I
20. Alternator Replacement or inspection
21. Starter motor Replacement or inspection
22. Fan belt Replacement, inspection or tension adjustment
23. Water pump Replacement (Cooling fan and fan shroud removal required)
24. Pulleys (crank, generator, fan) Replacement
25. Timing belt cover ) Replacement (Cooling fan and fan shroud removal required)
26. Water hose Replacement or inspection
27. Oil pan, oil strainer, and oil pump Replacement or inspection
Replacement or inspection (Cylinder head and oil pan
28. Piston and connecting rod
removal required)

3-5
 3-3. ENGINE REMOVAL
1) Disconnect negative (-) and positive (+)
cords from battery terminals.
‘) From starter motor terminals, disconnect
black/yellow lead wire and positive (+)
battery cord.
3) Disconnect coupler and white lead wire
from alternator terminals.
4) Disconnect lead wires from water tempera-
ture gauge and thermal switch. The gauge
and switch are on intake manifold.
Disconnect earth lead wire from intake
manifold. Fig. 3-3- 1
5) Disconnect couplers of carburetor fuel cut
solenoid valve, vent solenoid valve and
mixture control solenoid valve, and dis-
connect couplers from TWSVS and VSV.
6) Remove warm air hose.
) Disconnect breather hose from air cleaner
case.
,) Remove air intake case from carburetor
body and air inlet hose.
1) Disconnect accelerator cable from carbure-
tor.
10) Disconnect vacuum hoses of TCAC and
canister from intake manifold.
11) Remove fuel tank filler cap to release fuel
vapor pressure in fuel tank. After releasing,
reinstall it. Disconnect fuel feed and return Fig. 3-3-2
hoses from fuel pump.
12) Disconnect lead wire from oil pressure unit
terminal and oxygen sensor lead wire at the 16) Disconnect heater hoses from heater unit
coupler. outlet pipe and intake manifold.
13) Disconnect lead wires of back-up light
switch and fifth switch at their couplers.
14) Disconnect distributor lead wire at the
coupler.
15) Pull off high-tension cord from ignition coil.
16) Loosen radiator drain plug to drain cooling
water,
17) Disconnect water hoses from thermostat
cap and water inlet pipe. After removing
cooling fan & clutch and fan shroud, remove
radiator.

Fig. 3-3-3

3-6
19) Disconnect brake booster vacuum hose from 26) Disconnect clutch cable from engine mount-
pipe. ing bracket and clutch release lever.
20) Disconnect coupler of lead wire (black) 27) Loosen drain plug to drain transmission
from distributor gear case. oil.
21) Remove 4 bolts fastening gear shift lever 28) Remove propeller shaft interconnecting
boot No. 2 and move the boot upward. transmission case and transfer case.
29) By using a chain block, hold engine so
that the engine is kept from falling.

NOTE:

engine at two hooks provided, one on inlet-

manifold side and the other on exhaust-mani-
fold side.

30) Remove exhaust center pipe mounting

bracket and 4 transmission mounting bolts.

Fig. 3-3-4

22) Move gear shift lever boot No. 1 to upper

side of shift lever.
23) Loosen 3 bolts tightening gear shift lever
case cover and take shift lever out of lever
case.

Fig. 3-3-6

31) Remove the pipe connected to chassis

under the transmission case.

Fig. 3-3-5

24) Raise vehicle.

25) Sever exhaust manifold from muffler by
undoing joint.

Fig. 3-3-7

3-7
32) Lower vehicle and remove 4 bolts securing
right and left engine mounting brackets
(body side).

Fig. 3-3-10

34) Remove clutch lower plate.

35) Separate transmission from engine.
Fig. 3-3-8

CAUTION: Throughout this MANUAL, 4 cylinders of

Before lifting engine and transmission, engine are identified by numbers: No. 1, No. 2,
recheck to ascertain all hoses, electric wires No. 3 and No. 4 as counted from front end.
and cables are disconnected from engine
and transmission.

33) Take down engine by operating a hoisting

means.

Fig. 3-3-11

Fig. 3-3-9

3-8
3-4. ENGINE DISASSEMBLY 3) Remove distributor assembly.

NOTE:
l Observe critically before starting to remove a
component or part by loosening bolts, nuts
and the like. What you may find before and
during disassembly is valuable information
necessary for sucessful reassembly.
l Be careful in .handling aluminum-alloy parts.
They are softer than steel or cast-iron parts
and their finished surfaces more easily- take
scratch marks.
l Have trays and pans ready for setting aside
disassembled parts in an orderly manner.
Place parts in trays and pans in such a way _.
that they can be readily identified. Put match Fig. 3-4-3
marks or tags on them, as necessary, so that
they will go back to where they came from. 4) Remove the fuel pump and rod.
Carry out engine disassembly in the following NOTE:
sequence : When removing pump and distributor gear case,
place waste or receiver under gear casa.
1) Loosen drain plug and drain out engine oil.

Fig. 3-4-4
Fig. 3-4- 1
5) Take down distributor case.
2) Remove clutch cover and clutch disc.

Fig. 3-4-2 (A) Flywheel holder (Special tool Fig. 3-4-5

09924- 17810)
 6) Take down alternator and water pump
pulley.

Fig. 3-4,9 (A) Flywheel holder (Special tool

09924-17810)
Fig. 3-4-6
8) Remove outside cover on timing belt.

Fig. 3-4-7 Fig. 3-4- 10

7) Remove crankshaft pulley by removing 4 9) Loosen tensioner bolt and stud, and remove
pulley bolts, with special tool (A) hitched to belt from crank timing belt pulley and cam-
flywheel so that crankshaft will not turn. shaft pulley after pushing up tensioner
The crank timing belt pulley bolt at the plate fully by finger as shown in Figure
center needs not to be loosened. 3-4-l 1.

1. Timing belt
2. Tensioner plate
1. Crankshaft pulley
3. Tensioner bolt
2. Crankshaft pulley bolt
3. Crank timing belt pulley bolt
Fig. 3-4- 11 4. Tensioner stud
Fig. 3-4-8
3-10
10) Remove timing belt tensioner, tensioner 13) Remove crankshaft timing belt pulley key.
plate, and tensioner spring. 14) Remove timing belt inside cover.
11) Remove camshaft timing belt pulley by lock-
ing camshaft (insert general rod into the cam-
shaft hole) as shown below.

Fig. 3-4- 14

15) Remove water pump.

1. Wrench
2. Camshaft timing belt pulley
3. Timing belt inside cover
4. General rod

Fig. 34 12

12) Using flywheel holder (A) (Special tool),

remove crankshaft timing belt pulley bolt,
pulley and timing belt guide with crank-
shaft locked.

Fig. 3-4- 15

16) Remove exhaust manifold cover.

17) Take off exhaust manifold and its gasket.

1. Crankshaft timing belt pulley

2. Pulley bolt
3. Timing belt guide

Fig. 3-4-13

Fig. 3-4- 16

3-11
18) Using special tool (C), remove oil filter. 22) Remove water inlet pipe.
NOTE:
Be careful not to spill oil when removing filter.

Fig. 3-4120

Fig. 3-4- 17 (C) Oil filter wrench (099 15-473 10) 23) Take off cylinder head cover.

19) Draw water hoses off water pump inlet pipe.

Fig. 3-4-2 1

Fig. 3-4- 18
24) Loosen 8 valve adjusting screws fully. Leave
20) Disconnect PCV (Positive crankcase venti- screws in place.
lation valve) hose from cylinder head cover.
21) Take down intake manifold with carburetor.

Fig. 3-4-22

3-12
25) Loosen rocker arm shaft securing screws 28) Remove cylinder head.
(10 PCS).

____
Fig. 3-4-26
Fig. 3-4-23

a) Use valve lifter (D), (E) to compress valve

26) While drawing out rocker arm shaft, separate spring in order to free valve cotter pieces
valve rocker arms and rocker arm springs. for removal. In this way, remove valve
spring and valves.

Fig. 3-4-24

27) Draw camshaft out toward rear end (trans-

mission case side).

(D) Valve lifter

(Special tool 09916-14510)
(El Valve lifter attachment
(Special tool 0991648210)
Fig. 3-4-27

Fig. 3-4-25
3-13
 b) Remove valve stem oil seal from valve guide, NOTE:
and then valve spring seat. Place disassembled parts except valve stem seal
NOTE: and valve guide in order, so that they can be
Do not reuse oil seal once disassembled. Be installed in their original positions.
sure to use new oil seal when assembling.
29) Remove flywheel, using special tool (A)
as shown.

1. Valve stem oil seal

2. Blade screw driver
3. Valve spring seat
Fig. 3-4-28 Fig. 3-4-30 (A) Flywheel holder (Special tool
09924- 17810)

c) Using special tool (F), drive valve guide 30) Remove oil level gauge guide from oil pump.
out from combustion chamber side to valve
spring side (Figure 3-4-29).

NOTE:
Do not reuse valve guide once disassembled.
Be sure to use new valve guide (Oversize) when
assembling.

Fig. 3-4-3 1

(F) Valve guide remover (Special tool 09916-44511)

Fig. 3-4-29

3-14
31) Take down oil pan. 34) Install guide hose over threads of rod bolts.
This is to prevent damage to bearing journal
and cylinder wall when removing connecting
rod.

Fig. 3-4-32

32) Remove oil pump strainer.

1. Guide hoses

Fig. 3-4-35

35) Decarbon top of cylinder bore, before

removing piston from cylinder.
36) Push piston and connecting rod assembly
out through the top of cylinder bore.
1
CAUTION:
l Before pulling piston out, scribe cylinder
number on its crown.
l Be sure to identify each bearing cap for
its connecting rod by using cylinder
Fig. 3-4-33 number. Set cap and rod aside in combi-
nation.
33) Remove connecting rod bearing caps.
a) Using piston ring expander, remove two
compression rings (Top and 2nd) and oil
ring from piston.
b) Remove piston pin from connecting rod.
Fit piston and connecting rod assembly to
special tool (Fig. 3-4-36), and then press
piston pin out of connecting rod by using
arbor press (Fig. 3-4-37).

Fig. 3-4-34

3-15
 a) Remove oil pump rotor plate.

Piston
Arrow mark
Piston pin remover and installer
(Special tool 09910-38210)

Fig. 3-4-36 1. Rotor plate

Fig. 3-4-39
Press 1. Driver handle
2. Piston
3. Piston pin
a 4. Piston pin guide b) Remove outer rotor and inner rotor.
:..: 5. Base
n 1
.:: ,. 6. Support
NOTE:
Itema 1,4, and 5 are in Special tool
1 (09810-38210).

7
I+4-b6
,
////I / 1. Outer rotor
2. Inner rotor
Fig. 3-4-37 Fig. 3-4-40

37) Remove oil pump assembly.

Fig. 3-4-38

3-16
38) Remove oil seal housing. 3-5. INSPECTION OF ENGINE
COMPONENTS

NOTE:
During and immediately after disassembly,
inspect cylinder block and head for evidence
of water leakage or damage and, after washing
them clean, inspect more closely.
Wash all disassembled parts clean, removing
grease, slime, carbon and scales, before
inspecting them to determine whether repair
is necessary or not. Be sure to de-scale water
jackets.
Use compressed air to clear internal oil holes
Fig. 3-4-4 1 and passages.
Do not disturb set combinations of valves,
bearings and bearing caps, etc. Have the
sets segregated and identified.
39) Remove crankshaft bearing caps, and take
out crankshaft.
Cylinder Head
l Remove all carbon from combustion cham-
bers.

NOTE:
Do not use any sharp-edged tool to scrape off
the carbon. Be careful not to scuff or nick
metal surfaces when decarboning. This applies
to valves and valve seats, too.

Fig. 3-4-42

Fig. 3-5 1

l Check cylinder head for cracks in intake and

exhaust ports, combustion chambers, and
head surface.

3-17
 l Flatness of gasketed surface: l Distortion of manifold seating faces:
Using a straightedge and thickness gauge, Check seating faces of cylinder head for
check surface at a total of 6 locations. If the manifolds, using a straightedge and thickness
limit stated below, is exceeded, correct gauge, in order to determine whether these
gasketed surface with a surface plate and faces should be corrected or cylinder head
abrasive paper of about # 400 (Waterproof replaced.
silicon carbide abrasive paper): place paper on
and over surface plate, and rub gasketed
surface against paper to grind off high spots.
I Limit of distortion 0.10 mm (0.004 in.) I
Should this fail to reduce thickness gauge
readings to within the limit, replace cylinder
head.
Leakage of combustion gases from this
gasketed joint is often due to a warped
gasketed surface; such leakage results in
reduced power output.

Limit of distortion 0.05 mm (0.002 in.)

Fig. 3-5-4 In take manifold seating face

Fig. 3-5-2

Fig. 3-5-5 Exhaust manifold seating face

Fig. 3-5-3

3-18
Rocker-Arm Shaft and Rocker Arms
0 Shaft-to-arm clearance (IN & EX):
Using a micrometer and a bore gauge, measure

The difference between two readings is the

specified.
If the limit is exceeded, replace shaft or arm,

I Item Standard Limi t I

Rocker arm 16.000 - 16.018 mm
I.D. (0.629 - 0.630 in.)
Rocker arm 15.973 - 15.988 mm
Shaft dia. (0.628 - 0.629 in.)
Arm-to-Shaft 0.012 - 0.045 mm 0.08 mm
clearance (0.0005 - 0.0017 in.) (0.0035 in.) Fig. 3-5-7

0 Wear of rocker-arm and adjusting screw:

If the tip @ of adjusting screw is badly worn,
replace screw. Arm must be replaced if its
cam-riding face @I is badly worn.

Fig. 3-5-6

1. Adjusting screw
2. Rocker arm
l Runout of rocker-arm shaft: 3. Cam-riding face
Using “V” blocks and dial gauge, check Fig. 3-5-8
runout. If runout exceeds the limit, replace
rocker arm shaft.
Valve Guides
I
I
Runout limit 1 0.12 mm (0.004 in.) 1
I I
Using a micrometer and bore gauge, take dia-
meter readings on valve stems and guides to
determine stem clearance in guide. Be sure to
take a reading at more than one place along
the length of each stem and guide.

3-19
 Item Standard Limit
6.965 - 6.980 mm
Valve In
(0.2742 - 0.2748 in.)
stem
diameter Ex 6 . 9 5 0 -6 . 9 6 5 m m
(0.2737 - 0.2742 in.)
In 7 . 0 0 0 -7 . 0 1 5 m m
Valve (0.2756 - 0.2761 in.)
guide
I.D. 7 . 0 0 0 -7 . 0 1 5 m m
Ex’ (0.2756 - 0.2761 in.)
0.020 - 0.050 mm 0.07 mm
Stem-to- In (0.0008 - 0.0019 in.) (0.0027 in.)
guide
clearance Ex 0.035 - 0.065 mm 0.09 mm
(0.0014 - 0.0025 in.) (0.0035 in.)

Fig. 34 10

Valves
l Remove all carbon from valves.
l Inspect each valve for wear, burn or distor-
tion at its face and stem and replace as neces-
sary.
l Measure thickness of valve head. If measured
t h i c k n e s s e x c e e d s i t s l i m i t s p e c i f i e d b e l o w,
replace valve.

Fig. 3-5-9 I Valve head thickness I

Standard Limit
1 .O mm In 0.6 mm (0.023 in.)
If bore gauge is not available, check end deflec- (0.039 in.) Ex 0.7 mm (0.027 in.)
tion of the valve stem in place with a dial
gauge rigged.
fvlove stem end in the directions @ and @ to
measure end deflection.
If deflection exceeds its limit, replace valve stem
and valve guide.

Valve stem end In 0.14 mm (0.005 in.)

deflection limit Ex 0.18 mm (0.007 in.)

1. Valve head thickness

2 . 45
Fig. 3-S 11

3-20
l Check end face of each valve stem for wear. The pattern produced on seating face of valve
This face meets rocker arm intermittently must be a continuous ring without any break,
‘in operation, and might become concaved or and width 6@ of pattern must be within
otherwise irregular. As necessary, smoothen stated range as follows.
the end face with an oil stone and, if this
grinding removes the end stock by as much as
0.5 mm (0.0196 in.) (as measured from the width revealed 1.3- 1.5 mm
original face), replace the valve. (0.0512 - 0.0590 in.)

Limit on stock allowance 0.5 mm

of valve stem end face (0.0196 in.)

l Check each valve for radial runout with a

dial gauge and “V” block. To check runout,
rotate valve slowly. If runout exceeds limit,
replace valve.

I Limit on valve head

radial runout
0.08 mm (0.003 in.)
I

Fig. 3-5-13

Fig. 3-612

Valve Seats

CAUTION :
Valves to be checked and serviced for seat- @ Valve seat contact width

ing width and contact pattern must be those Fig. 3-5-14

found satisfactory in regard to stem clearan-
ce in the guide and also requirements stated
on preceding page under valves.

l Seating contact width:

Produce contact pattern on each valve in the
usual manner, namely, by giving uniform coat
of marking compound to valve seat and by
rotatingly tapping seat with valve head.
Valve lapper (tool used in valve lapping)
must be used.

3-21
l Valve seat repair: 2) INLET VALVE SEAT: Cutting sequence is
Valve seat not producing uniform contact the same as for exhaust valve seats but the
with its valve or showing width @ of seating second angle is (60” ).
contact that is off the specified range must be
repaired by regrinding or by cutting and Seat width @I for 1.3- 1.5mm
regrinding and finished by lapping. inlet valve seat (0.0512 - 0.0590 in.)I
1) EXHAUST VALVE SEAT: Use a valve seat
cutter to make three cuts as illustrated in Fig.
3-5-16. Three cutters must be used: the first
for making 15” angle, the second for making
75” angle and the last for making 45” Seat
angle. The third cut must be made to produce
desired seat width @I!).

Seat width @ for 1.3- 1.5 mm

exhaust valve seat (0.0512 - 0.0590 in.)

Fig. 3-5- 17 Valve seat angles for in take valve

3) VALVE LAPPING. Lap valve on seat in two

steps, first with coarse-size lapping com-
pound applied to its face and the second with
a fine-size compound, each time using a valve
lapper according to usual lapping method.

1. Valve seat CUtter

Fig. 3-S 15 Valve seat cutting

Fig. 3-5- 18 Applying lapping compound to

valve face

NOTE:
l After lapping, wipe compound off valve face
and seat, and produce contact pattern with
marking compound. Check to be sure that
contact is centered widthwise on valve seat
Fig. 3-5- 16 Valve seat angles for exhaust valve
and that there is no break in contact pattern
ring.
a Be sure to check and, as necessary, adjust
valve clearance after reinstalling cylinder
head and valve mechanism.

3-22
Fig. 3-5-19 Contactpattern @ uniform in width
Fig. 3-5-21 Measuring spring preload

Valve Springs
l Referring to the criterion-data given below,
l Spring squareness:
check to be sure that each spring is in sound Use a square and surface plate to check each
condition, free of any evidence of breakage or spring for squareness in terms of clearance
between the end of valve spring and square.
weakening. Remember, weakenedvalve springs
Valve springs found to exhibit a larger clea-
can be the cause of chatter, not to mention
rance than specified limit must be replaced.
the possibility of reducing power output due
to gas leakage caused by decreased seating
Valve springs
2.0 mm (0.079 in.)
squareness limit

Valve spring for 41.5 mm for 41.5 mm

preload (54.7 - 64.3 lb/ (50.2 lb/
1.63 in.) 1.63 in.)

Fig. 3-5-22 Measuring spring squareness

Fig. 3-5-20 Measuring free length of spring

3-23
 Camshaft l Journal wear:
l Runout of camshaft: Measure journal diameter in two directions at
Hold camshaft between two “V” blocks, and two places (total of 4 readings) on each
measure runout by using a dial gauge. journal as shown in Fig. 3-5-25, and also by
If runout exceeds its limit, replace camshaft. using bore gauge, measure journal bore in
cylinder head as shown in Fig. 3-5-26 (i.e. 4
I Runout limit 1 0.10 mm (0.0039 in.) 1 readings on each journal).
Subtract journal diameter measurement from
journal bore measurement to determine
journal clearance.
If journal clearance exceeds its limit, replace
camshaft, and as necessary, cylinder head, too.

I I Standard 1 I
Journal
0.050 - 0.091 mm
clearance
(0.0020 - 0.0036 in.)
limit

Camshaft journal dia. Journal bore dia.

Fig. 3-5-23 @ 44.125 -44.150 mm 44.200 - 44.216 mm
(I.7372 - 1.7381 in.) (1.7402 - I .7407 in.)
@ 44.325 -44.350 mm 44.400 44.416 mm
0 Cam wear: (1.7451 - 1.7460 in.) (I .7480 - I .7486 in.)
Using a micrometer, measure height (H) of 0 44.525 -44.550 mm 44~600 -44.616 mm
cam (lobe). If measured height is less than (1.7530 - I .7539 in.) (I .7560 - I .7565 in.)
respective limits, replace camshaft.

Cam height Standard Limit

37.500 mm 37.400 mm
Intake cam
(I .4763 in.) (1.4724 in.)

I
,
37.500 mm 37.400 mm
Exhaust cam
(I .4763 in.) (I .4724 in.) I
r
Fuel pump 40.000 mm 39.600 mm
drive cam (I .5748 in.) (1.5590 in.)

Fig. 3-5-24 Fig. 3-5-25

3-24
 l Cylinder bore dia. exceeds its limit.
l Difference of measurements at two positions
exceeds taper limit.
l Difference between thrust and axial measure-
ments exceeds out-of-round limit.

Fig. 3-5-26 NOTE:

If any one of four cylinders has to be rebored,
rebore all four to the same next oversize. This is
Cylinder Block necessary for the sake of uniformity and balance.
l Distortion of gasketed surface:
Using a straightedge and a thickness gauge,
check gasketed surface for distortion and, if
result exceeds specified limit, correct it.

Standard Limit

I
I
0.03 mm 0.06 mm
Flatness
(0.0012 in.) (0.0024 in.) I

1. 50mm (1.96in.j
2. 95 mm (3.74 in.)

Fig. 3-5-28 Positions to be measured

Fig. 3-5-27

l Cylinder bore:
1) Inspect cylinder walls for scratches, roughness,
or ridges which indicate excessive wear. If
cylinder bore is very rough or deeply scratch-
ed, or ridged, rebore cylinder and use oversize Fig. 3-5-29 Measuring cylinder bore with
piston. cylinder gauge
2) Using a cylinder gauge, measure cylinder bore
in thrust and axial directions at two positions
as shown in Fig. 3-5-28.
If any of the following conditions exists,
rebore cylinder.
3-25
 l Honing or reboring cylinders: Piston and Piston Rings
1) When any cylinder needs reboring, all other Clean carbon from piston head and ring grooves,
cylinders must also be rebored at same time. using a suitable tool.
2) Select oversized piston according to amount Inspect piston for faults, cracks or other damage.
of cylinder wear. Damaged or faulty piston should be replaced.
0 Piston diameter:

I Size I Piston diameter As indicated in Fig. 3-5-31, piston diameter

should be measured at the height of 15 mm
O/S 0.25 7 4 . 2 2 0- 7 4 . 2 3 0 mm
(0.59 in) from piston skirt end in the direc-
(2.9220 - 2.9224 in.)
tion perpendicular to piston pin.
o / s 0.50 7 4 . 4 7 0- 7 4 . 4 8 0 mm
(2.9318 - 2.9322 in.) 73.970 - 73.990 mm
Standard
(2.9122 - 2.9129 in.)
Oversize:
3) Using micrometer, measure piston diameter. Piston 0.25 mm 7 4 . 2 2 0- 7 4 . 2 3 mm
0
diameter (2.9220 - 2.9224 in.1
(0.0098 in.)
0.50 mm 74.47 - 74.48 mm
(0.0196 in.) (2.9319 - 2.9322 in.)

1. 15 mm (0.59 in.)

Fig. 3-5-30 Measuring piston diameter

4) Calculate cylinder bore diameter to be rebor- 1. 15 mm (0.59 in)

ed.
Fig. 3-5-3 1 Measuring piston diameter
D=A+B-C with micrometer
D : Cylinder bore diameter to be rebored.
A : Piston diameter as measured.
8 : Piston clearance = 0.02 - 0.04 mm l Piston clearance:
(0.0008 - 0.0015 in) To calculate piston clearance, measure cylin-
C : Allowance for horning = 0.02 mm der bore diameter and piston diameter. The
(0.0008 i n ) piston clearance is difference between cylinder
5) Rebore and hone cylinder to calculated dimen- bore diameter and piston diameter. Piston
sion. clearance should be within specification as
follows.
NOTE: If it is out of specification, rebore cylinder and
Before reboring, install all main bearing caps in use oversize piston.
place and tighten to specification to avoid
distortion of bearing bores. 0.02 - 0.04 mm
Piston clearance
(0.0008 - 0.0015 in.)
6) Measure piston clearance after honing.

NOTE:
Cylinder bore diameters measured in thrust
direction at two positions as shown in Fig.
3-528 should be used for calculation of piston
clearance.

3-26
0 Ring groove clearance:
Before checking, piston grooves must be
clean, dry and free from carbon.
Fit new piston ring into piston groove, and
measure clearance between ring and ring land
by using thickness gauge.
If the clearance is out of specification, replace
piston.

1. Cylinder block
Ring groove 2. Feeler gauge
clearance ti1 3. Piston ring
4 . 12Omm
(4.72 in.)

Fig. 3-5-33 Measuring piston ring end gap

Piston Pins
l Piston pin must be fitted into piston bore
with an easy finger push at normal room
temperature.
l Check piston pin and piston bore for wear or
damage. If pin or piston bore is badly worn or
damaged, replace pin or piston, or both.

1. Piston ring
2. Thickness geuge
Connecting Rods
l Big-end side clearance:
Fig. 3-5-32 Measuring ring groove clearance Check big end of connecting rod for side
clearance, with rod fitted and connected to
its crank pin in the normal manner. If clea-
0 Piston ring end gap: rance measured is found to exceed its limit,
To measure end gap, insert piston ring into replace connecting rod.
cylinder: bore, locating it at the lowest part of
bore and holding it true and square; then Item Standard Limi t
use a feeler gauge’to measure gap. If the gap Big-end side 0.10 - 0.20 mm 0.35 mm
exceeds its limit, replace ring. clearance (0.0039 - 0.0078 in.) (0.0137 in.)
NOTE:
Decerbon and clean top of cylinder bore,
before inserting piston ring.

Item Standard Limi t

Top ring 0 . 2 0 -0 . 3 3 m m 0.7 mm
Piston (0.0079 - 0.0129 in.) (0.0275 in.)
ring 2nd 0.20 - 0.35 mm 0.7 mm
ring
end (0.0079 - 0.0137 in.) (0.0275 in.)
QaP 0.20 - 0.70 mm 1.8 mm
Oil riilg
(0.0079 - 0.0275 in.) (0.0708 in.)

Fig. 3-5-34 Measuring side clearance

3-27
 l Connecting rod alignment: l Rod bearing clearance :
Mount connecting rod on aligner to check 1) Before checking bearing clearance, clean
it for bow and twist and, if either limit is bearing and crank pin.
exceeded, replace it. 2) Install bearing in connecting rod and bear-
ing cap.
Limit on bow 0.05 mm (0.0020 in.) 3) Place a piece of gaging plastic the full width

I Limit on twist ) 0.10 mm (0.0039 in.) 1 of the crankpin as contacted by bearing

(parallel to the crankshaft), avoiding the oil
hole.
4) Install rod bearing cap to connecting rod.
Crank Pin and Connecting Rod Bearings When installing cap, be sure to point arrow
l Inspect crank pin for uneven wear or damage. mark on cap to crankshaft pulley side, as
Measure crank pin for out-of-round or taper indicated in Fig. 3-5-36. Tighten the cap
with a micrometer. If crank pin is damaged, nuts to the specified torque, DO NOT turn
or out-of-round or taper is out of limit, crankshaft with gaging plastic installed.
replace crankshaft or regrind crank pin to
undersize and use undersize bearing. torque 33 - 37 N-m

I
for rod bearing cap 3.3 - 3.7 kg-m
Connecting
Crank pin diameter 24.0 - 26.5 lb-ft
rod bearing size I

I Standard

0.25 mm (0.0098 in.)

41.982 - 42.000 mm
(1.6529 - 1.6535 in.) I
41.732 - 41.750 mm
.

undersize (1.6430 - 1.6437 in.)

Out-of-round and e
0.01 mm (0.0004 in.)
taper limit

3
l Rod bearing:
Inspect bearing shells for signs of fusion, 0
pitting, burn or flaking and observe contact
pattern. Bearing shells found in defective
condition must be replaced. Rod bearing cap
Two kinds of rod bearing are available; Arrow mark
Crankshaft pulley side
standard size bearing and 0.25 mm under- Cap nut
size bearing. To distinguish them, 0.25 mm
undersize bearing has stamped number ’ Fig. 3-5-36 Installing bearing cap
(USO25) on its backside as indicated in Fig.
3-5-35, but standard size one has no such
number.

Fig. 3-5-35 0.25 mm undersize bearing

3-28
c
5) Remove cap and using scale on gaging bIastic l Crankshaft thrust play :
envelope, measure gaging plastic width at Measure this play with crankshaft set in
the widest point. cylinder block in the normal manner, that is,
If the clearance exceeds its limit, use a new with thrust bearing fitted and journal bearing
standard size bearing and remeasure clea- caps installed. Tighten bearing cap bolts to
rance. specified torque.
Use a dial gauge to read displacement in axial
(thrust) direction of crankshaft.
If the limit is exceeded, replace thrust bearing
with new standard one or oversize one to
obtain standard thrust play.

Item Standard Limit

Crankshaft 0.11 - 0.31 mm 0.38m m
thrust play (0.0044- 0.0122i n . ) (0.0149 in.)

-.
Thickness of
crankshaft
thrust bearing
1. Gaging plastic
2. Scale

Fig. 3-5-37 Measuring rod bearing clearance

6) If clearance can not be brought to within

limit even by using a new standard size bear-
ing, regrind crankpin to the undersizeand use
0.25 mm undersize bearing.

Crankshaft
l Crankshaft runout:
Using a dial gauge, measure runout at center
journal. Rotate crankshaft slowly. If runout
exceeds limit, replace crankshaft.

Limit on runout 0.06mm (0.0023 in.)

1, Thrust bearing

Fig. 3-5-39 Thrust bearings

Fig.3-5-38 Measuring runou t

3-29
 Crankshaft Main (Journal) Bearings
General informations:
l Service main bearings are available in standard-
size and 0.25 mm (0.0098 in) undersize, and
each of them has 5 kinds of bearings differ-
ing in tolerance.
l The upper half of bearing has oil groove as
indicated in Fig. 3~5-42. Install this half with
oil groove to cylinder block.

Fig. 3-5-40 Measuring thrust play of crankshaft

l Out-of-round and taper (uneven wear):

An unevenly worn crankshaft journal shows
up as a difference in diameter at a cross
section or along its length (or both). This
difference, if any, is to be determined from
1. Cylinder block
micrometer readings. 2. Upper half of bearing
If any of journals is badly damaged or if the 3. Oil groove
amount of uneven wear in the sense explained Fig. 3-5-42 Upper half of bearing installation
above exceeds its limit, regrind or replace the
crankshaft.
l On each main bearing cap, arrow mark and

I
number are embossed as indicated in Fig.
Limit on out-of-round
0.01 mm (0.0004 in.) 3-5-43.
and taper
When installing each bearing cap to cylinder
block, point arrow mark toward crankshaft
pulley side and install each cap from crank-
shaft pulley side to flywheel side in ascending
order of numbers @,a, 0, @ and 0. Tigh-
ten cap bolts to specified torque.

Fig. 3-5-4 1 Checking uneven wear

2. Flywheel side

Fig. 3-5-43 Bearing caps ins talla tion

3-30
2) Next, check bearing cap bore diameter with- 3) There are five kinds of standard bearings
out bearing. differing in thickness. To distinguish them,
On mating surface of cylinder block, five they are painted in following colors at the
alphabets are stamped as shown in Fig. position indicated in Fig. 3-5-47.
3-5-46. Each color indicates the following thicknesses
Three kinds of alphabets (“A”, “B” and at center of bearing.
“C”) represent following cap bore diameters.
Color painted Bearing thickness
1
Alphabet Bearing cap bore diameter
stamped (without bearing)
49.000 - 49.006 mm)
A
(1.9292 - 1.9294 in.)

B
49.006 - 49.012 mm
(1.9294 - 1.9296 in.) I Colorless
(no paint)
2.002 - 2.006 mm
(0.0788 - 0.0789 in.) I

I C
49.012 - 49.018 mm
(1.9296 - 1.9298 in.) I

The first, second, third, fourth and fifth (left

to right) stamped alphabets indicate the cap
bore diameter of bearing caps “1”, “2”, “3”,
“4” and “5” respectively.
For example, in Fig. 3-5-46, the first (leftmost)
alphabet “8” indicates that the cap bore dia. of
bearing cap @ is within 49.006 - 49.012 mm,
and the fifth (rightmost) alphabet “A” indicates
that the cap bore dia. of cap @ is within 49.000
- 49.006 mm.

r-l 1. Paint

Fig. 3-5-47 Paint on standard bearing

4) From the numeral stamped on crank webs of

No. 2 and No. 3 cylinders and the alphabets
stamped on mating surface of cylinder block,
determine new standard bearing to be install-
ed to the journal, by referring to the table
shown below.
For example, if numeral stamped on crank
web is “1” and alphabet stamped on mating
surface is “8”, install new standard bearing
Fig. 3-5-46 Stamped alphabets on cylinder painted in “Black” to its journal.
block

3-31
2) Next, check bearing cap bore diameter with- 3) There are five kinds of standard bearings
out bearing. differing in thickness. To distinguish them,
On mating surface of cylinder block, five they are painted in following colors at the
alphabets are stamped as shown in Fig. position indicated in Fig. 3-5-47.
3-5-46. Each color indicates the following thicknesses
Three kinds of alphabets (“A”, “B” and at center of bearing.
“C”) represent following cap bore diameters.

I Black
1.999 - 2.003 mm
(0.0787 - 0.0788 in.) I

I Colorless
(no paint)
2.002 - 2.006 mm
(0.0788 - 0.0789 in.)
2.005 - 2.009 mm
I
9

Yellow
(0.0789 - 0.0790 in.)

The first, second, third, fourth and fifth (left

to right) stamped alphabets indicate the cap
I Blue
2.008 - 2.012 mm
(0.0790 - 0.0791 in.) I

bore diameter of bearing caps “l”, “2”, “3”,

“4” and “5” respectively.
For example, in Fig. 3-5-46, the first (leftmost)
alphabet “B” indicates that the cap bore dia. of
bearing cap @ is within 49.006 - 49.012 mm,
and the fifth (rightmost) alphabet “A” indicates
that the cap bore dia. of cap @ is within 49.000
- 49.006 mm.

1. Paint

Fig. 3-5-47 Paint on standard bearing

4) From the numeral stamped on crank webs of

No. 2 and No. 3 cylinders and the alphabets
stamped on mating surface of cylinder block,
determine new standard bearing to be install-
ed to the journal, by referring to the table
shown below.
For example, if numeral stamped on crank
web is “1” and alphabet stamped on mating
surface is “B”, install new standard bearing
Fig. 3-5-46 Stamped alphabets on cylinder painted in “Black” to its journal.
block

3-32
 Numerals stamped on crank
webs (Journals diameter)
1 2 3
Alphabets A Green Black Colorless
stamped B Black Colorless Yellow
on mating
surface c Colorless Yellow Blue
New standard bearing to be installed.

1
5) Using gaging plastic, check bearing clearance 1. Paint
with new standard bearing selected.
If clearance still exceeds its limit, use next Fig. 3-5-48 Faints on undersize bearing
thicker bearing and recheck clearance.
6) When replacing crankshaft or cylinder block . l If crankshaft journal is necessary to be
due to any reason, select new standard reground to undersize, regrind the journal and
bearings to be installed by referring to the select undersize bearing to be used as follows.
numerals stamped on new crankshaft or the
alphabets stamped on the mating surface of 1) Regrind journal to following finished dia-
new cylinder block. meter.

UNDERSIZE BEARING (0.25 mm):

l 0.25 mm undersize bearing is available in 5
kinds differing in thickness.
I Finished diameter
44.732 -44.750 mm
(1.7612 - 1.7618 in.) I

To distinguish them, each bearing is painted

in following colors at position indicated in 2) Using micrometer, measure reground journal
Fig. 3-5-48. diameter. Measurement should be carried out
Each color indicates following thickness at in two directions perpendicular to each other
center of bearing. in order to check for out-of-round.
3) From the journal diameter measured above
and the alphabets stamped on mating surface
Color painted Bearing thickness of cylinder block, select the undersize bearing
I
2.121 - 2.125 mm to be installed by referring to the table
Green & Red
I
(0.0835 - 0.0836 in. ) I shown below.
I
2.124 - 2.128 mm Check bearing clearance with undersize
Black & Red bearing selected.
(0.0836 - 0.0837 in.)
2.127 - 2.131 mm
Red only
(0.0837 - 0.0838 in.) I
2.130 - 2.134 mm
Yellow & Red
(0.0838 - 0.0839 in.)
2.133 - 2.137 mm
Blue & Red
(0.0839 - 0.0840 in.) I

3-33
 Measured journal diameter

44.744 - 44.750 mm 44.738 - 44.744 mm 44.732 - 44.738 mm

(1.7616 - 1.7618 in.) (1.7614 - 1.7616 in.) (1.7612 - 1.7614 in.)

Green & Red Black & Red Red only

Alphabets stamped I A
on mating surface B Black & Red Red only Yellow & Red
of cylinder block
C Red only Yellow & Red Blue & Red
Undersize bearing to be installed.

Rear Oil Seal

Carefully inspect oil seal for wear or damage. If
its lip is worn or damaged, replace oil seal.

Fig. 3-5-50 Measuring runou t

1. Rear oil seal

Fig. 3-5-49 Rear oil seal Oil Pump

1) Inspect oil seal lip for fault or other damage.
Replace as necessary.
Flywheel 2) Inspect outer and inner rotors, rotor plate,
l If ring gear is damaged, cracked or worn, and oil pump case for excessive wear or
replace flywheel. damage.
l If surface contacting clutch disc is damaged,
or excessibly worn, replace flywheel. l Radial clearance:
l Check flywheel for face runout with a dial Check radial clearance between outer rotor
and case, using thickness gauge.
wge.
If runout is out of limit, replace flywheel. If clearance exceeds its limit, replace outer
rotor or case.
Limit on runout 0.2 mm (0.0078 in.)

Outer rotor and case 0.310 mm (0.0122 in.)

3-34
 3-6. ENGINE REASSEMBLY

NOTE:
l All parts to be used in reassembly must be
perfectly clean.
l Oil sliding and rubbing surfaces of engine
parts just before using them in reassembly.
Use engine oil (Refer to page l-8).
l Have liquid packing ready for use. SUZUKI
BOND NO. 1215 is specified for it. Use it
wherever its use is specified in order to
ensure leak-free (oil and water) workmanship
of reassembly.
l There are many running clearances. During
the course of engine reassembly, be sure to
check these clearances, one after another,
as they form.
l Gaskets, “0” rings and similar sealing mem-
Fig. 3-5-51 Radial clearances bers must be in perfect condition. For these
members, use replacement parts in stock.
l Tightening torque is specified for impor-
l Side clearance:
tant fasteners - mainly bolts and nuts -of
Using straight edge and thickness gauge, the engine and other components. Use torque
measure side clearance. wrenches and constantly refer to the specified
Limit on side values given on p. 3-58.
0.15 mm (0.0059 in.) l Do not disregard match marks provided on
clearance
parts. Some of them are those given at the
time of disassembly.
l There are many sets of parts. Crankshaft
bearings, connecting rods, pistons, etc., are
in combination sets. Do not disturb such
combinations and make sure that each part
goes back to where it came from.

Engine reassembly is the reverse of engine disas-

sembly as far as sequence is concerned, but
there are many reassembling steps that involve
measures necessary for restoring engine as close
to factory-assembled condition as possible. Only
those steps will be dealt with here.

Fig. 3-5-52 Side clearance measurement

Timing Belt end Tensioner

l Inspect timing belt for wear or crack. Replace
it as necessary.
l Inspect tensioner for smooth rotation.

3-35
Crankshaft 3) Install thrust bearings to cylinder block
1) Install main bearings to cylinder block. between No. 2 and No. 3 cylinders. Face oil
NOTE: groove sides to crank webs.
If main bearing replacement is necessary, select
such bearing as to allow proper clearance as
described on p. 3-30 and install it in place.

Between two halves of main bearing, one

side has oil groove. Install this half with oil
groove to cylinder block, and another half
without oil groove to bearing cap.
Make sure that two halves are painted with
same color.

r
2
1. Thrust bearing
2. Oi I groove

Fig. 3-6-3 Ins tatting thrust bearing

4) Install crankshaft to cylinder block.

5) Oil crankshaft journals.
6) When fitting bearing caps to journals after
setting crankshaft in place, be sure to point
arrow mark (on each cap) to crankshaft
pulley side. Fit them sequentially in ascend-
1. Cylinder block
2. Upper half of bearing
ing order, 1, 2, 3, 4 and 5, starting from
3. Oil groove pulley side.

Fig. 3-6- 1 Installing bearing half with oil groove Tightening torque 50 - 57 N-m
for main bearing 5.0 - 5.7 kg-m
cap bolts 36.5 - 41 .O lb-ft
2) Be sure to oil crankshaft journal bearings as
shown. Gradual and uniform tightening is important for
bearing cap bolts. Make sure that five caps
become tight equally and uniformly specified
torque.
NOTE:
After tightening cap bolts, check to be sure that
crankshaft rotates smoothly when turned by
hand.

Fig. 3-6-2

3-36
 Oil Pump
n
NOTE:
Reassemble components of oil pump assembly
according to following procedure, if disassem-
bled.
a) Wash, clean and then dry all disassembled
parts.
b) Apply thin coat of engine oil to inner and
outer rotors, oil seal lip portion, and inside
surfaces of oil pump case and plate.
c) Install outer and inner rotors to pump case.
d) Install gear plate. Tighten 5 screws securely.
U
e) After installing plate, check to be sure that
1. Crankshaft pulley side
gears turn smoothly by hand.
2. Arrow mark

Fig. 3-6-4 Ins tailing main bearing caps 1) Install two oil pump pins and oil pump gasket
to cylinder block. Use new gasket.
2) To prevent oil seal lip from being damaged or
Oil Seal Housing upturned when installing oil pump to crank-
Install oil seal housing and its gasket. shaft, fit oil seal guide (special tool) to
Install new gasket. Do not reuse gasket removed crankshaft, and apply engine oil to it.
in disassembly. Apply oil to oil seal lip before
installing. Tighten housing bolts to specifi-
cation.
After installing oil seal housing, gasket edges
might bulge out; if so, cut off edges to flush
with cylinder block and oil seal housing.

lo- 13 N-m
Tightening torque
l.O- 1.3 kg-m
for housing bolts
7.5 - 9.0 lb-ft

1. Crankshaft
2. Oil seal guide (Vinyl resin) (Special tool
09926-18210)
3. Oil pump pin

Fig. 3-6-6 Special tool (Oil seal guide)

ins talla tion

Fig. 3-6-5 Cutting off edges of gasket

3-37
 3) Install oil pump to crankshaft and cylinder Piston, Connecting Rod and Piston Rings
block. install No. 1 and No. 2 bolts as shown NOTE:
in Fig. 3-6-7, and tighten them to specified Two sizes of piston are available as standard size
torque. spare part so as to ensure proper piston-to-
After installing oil pump, check to be sure cylinder clearance. When installing a standard
that oil seal lip is not upturned, and then size piston, make sure to match piston with
remove special tool. cylinder as follows.

a) Each piston has a stamped number 1 or 2 as

shown depending on its outer diameter.

or 2
2

Piston
2

Fig. 3-6-9

b) There are also stamped numbers of 1 and 2

1. N O. 1 bolts (short) on cylinder block as shown below. First
2. No. 2 bolts (long) number indicates inner diameter of No. 1
Fig. 3-6-7 cylinder, second number of No. 2 cylinder,
third number of No. 3 cylinder and fourth
number of No. 4 cylinder.
4) Edge of oil pump gasket might bulge out: if
it does, cut bulge off with a sharp knife, No. 1 Cylinder
making edge smooth and flush with end No. 2 Cylinder
No. 3 Cylinder
faces of the pump case and cylinder block. No. 4 Cylinder

Crank

Cylinder block

Fig. 3-6- 10

Fig. 3-6-8 Cutting the edge of gaske t

3-38
cl Use a number 2 stamped piston for installa-
tion if cylinder is identified with number 2
and a number 1 piston for cylinder with
number 1.
Crankshaft pulley side

1. Piston
2. Arrow mark
3. Connecting rod
4. Oil hole

(Oil hole should come on

intake side)

Fig. 3-6- 12 Fitting connecting rod to piston

@ Place piston on piston pin remover and

Fig. 3-6- 11 installer (special tool) as indicated in Fig.
3-6-13, and press piston pin into piston and
connecting rod (Fig. 3-6-14).
Piston Cylinder Piston-to-
cylinder
Number ck?arancE
NWtlber
a;$;r$p Outside diameter Bore diameter
(mar kb

0.02 - 0.04mm
73.96 - 73.99mm 7 4 . 0 1 74.02mm ~0.0009 -
1 (2.9126 - 2.9130in.) ’ (2.9138 - 2.9142in.l 0.0016in.)

0.02 - 0.04mm
73.97 - 73.96mm 74.00 - 74.01 mm (0.0008 -
2 2 (2.9134 - 2.9138in.l
(2.9122- 0.0016in.l

Also, a letter A, 6, C etc., is stamped on piston

head but ordinarily it is not necessary to dis-
criminate each piston by this number.

1) Install connecting rod to piston.

@ After applying engine oil to piston pin holes
2. Arrow mark
in piston and connecting rod, fit connecting
3. Piston pin remover and installer
rod to piston as prescribed in Fig. 3-6-12. (Special tool 0991 O-3821 0)

Fig. 3-6- 13 Fitting piston to special tool

3-39
 2) Install piston rings to piston.
l As indicated in Fig. 3-6-16, 1st and 2nd
rings have “R” or “T” mark. Installing these
piston rings to piston with marked side of
each ring faced foward top of piston.
l 1st ring differs from 2nd ring in thickness,
shape and color of the surface contacting
cylinder wall.
Distinguish 1st ring from 2nd ring by refer-
NOTE:
1 kerns 1, 5,6, 7 and 6 are in ring to Fig. 3-6-16.
special tad (09910-36210). l When installing oil ring, install spacer first
and then two rails.

“R” or” T”
1. Driver handle
2. Piston pin
3. Piston
4. Connecting rod
5. Piston pin guide
6. Guide spring
7. Spring retainer
8. Base
9. Support

Fig. 3-G 14 Ins tatting piston pin

1. 1st ring (“A” 1.2 mm)
2. 2nd ring (“6” 1.5 mm)
3. Oil ring
@ Press piston pin until line marked on driver
handle is flush with flat surface of piston Fig. 3-6- 16 Piston rings installation
(Fig. 3-6-l 5).

l After installing 3 rings (lst, 2nd and oil

rings), distribute their end gaps as shown
in Fig. 3-6-l 7.
5

1. Driver handle
2. Line
3. Piston
4. Piston pin

1. Arrow mark
Fig. 3-6- 15 Line marked on driver handle I\, 2. 1 st ring end gap
6 3. 2nd ring end gap
4. Oil ring rail gaps
5. lnta ke side
6. Exhaust side
7. 450
8. Oil ring spacer gap

Fig. 3-6- 17 Piston ring end gaps positions

3-40
 3) install piston and connecting rod assembly @ Use piston ring compressor (Special tool) to
into cylinder bore. compress rings. Guide connecting rod into
@Apply engine oil to pistons, rings, cylinder place on the crankshaft.
walls, connecting rod bearings and crank- Using a hammer handle, tap piston head to
pins. install piston into bore. Hold ring compres-
@Put guide hoses over connecting rod bolts as sor firmly against cylinder block until all
shown in Fig. 3-6-18. These guide hoses piston rings have entered cylinder bore.
protect crankpin and thread of rod bolt
from damage during installation of connect-
ing rod and piston assembly.

1. Piston ring compressor

(Special tool 09916-77310)

Fig. 3-6-20 Installing piston to cylinder

1. Guide hoses
4) Install connecting rod bearing cap.
When installing cap to rod, point arrow mark
Fig. 3-6- 18 Guide hoses installation on cap to crankshaft pulley side.
Tighten cap nuts to specification.

@When installing piston and connecting rod Tightening torque 33 - 37 N-m

assembly into cylinder bore, point arrow for rod bearing 3.3 - 3.7 kg-m
mark on each piston head to crankshaft cap nuts 24.0 - 26.5 lb-ft
pulley side.

1. Crankshaft pulley side

2. Flywheel side

Fig. 3-6- 19 Direction of arrow mark on 1. Bearing cap

piston head 2. Arrow mark
3. Crankshaft pulley side
4. Cap nut

Fig. 3-6-21 Ins tailing bearing cap

3-41
 Oil Pump Strainer 2) Install oil pan to cylinder block.
Install seal in the position shown in Fig. 3-6-22. After fitting oil pan to block, run in secur-
Tighten strainer bolt first and bracket bolt to ing bolts and start tightening at the center:
specified torque. move wrench outward, tightening one bolt
at a time.
Tightening torque 9 - 12 N.m Tighten bolts to specified torque.
for bolts 0.9 - 1.2 kg-m
6.5 - 8.5 lb-ft Tightening torque 9- 12 N-m
for oil pan bolts 0.9 - 1.2 kg-m
7.0 - 8.5 lb-ft

3) Install gasket and drain plug to oil pan.

Tighten drain plug to specified torque.

Tightening torque 30 - 40 N.m

for drain plug 3.0 - 4.0 kg-m
22.0 - 28.5 lb-ft

4) Install guide seal to pump case and then oil

level gauge guide.

1 . Seal
Fig. 3-6-22 Installing seal 2. Strainer
3. Bracket

Oil Pan
1) Clean mating surfaces of oil pan and cylinder
block. Remove oil, old sealant, and dusts
from mating surfaces.
After cleaning, apply silicon type sealant to
oil pan mating surface continuously as
shown in Fig. 3-6-23.

1. Oil pump
2. Oil level gauge guide
3. Guide bolt
4. Guide seal

Fig. 3-6-24 Oil level gauge guide

Flywheel
Sealant MOOO-31150) Install flywheel to crankshaft.
Using special tool, lock flywheel, and tighten
flywheel bolts to specification.
Fig. 3-6-23 Applying sealant to oil pan
Tightening torque 5 7 - 6 5 N-m
for flywheel bolts 5.7 -6.5 kg-m
41.5 - 47 lb-ft

3-42
 b) Install valve guide to cylinder head.
Heat cylinder head uniformly at a tempe-
rature of 80 to 100°C (176 to 212”F),
using care not to distort head, and drive new
valve guide into hole with special tools.
Refer to Fig. 3-6-27.
Drive in new valve guide until valve guide
installer(Special tool) contacts cylinder head.
After installation, make sure that valve
guide protrudes by 14 mm from cylinder
head (Fig. 3-6-27).

1. Flywheel holder (Special tool 09924-l 7810)

2. Flywheel bolts
3. Input shaft end bearing
4. Locating pin

Fig. 3-6-25

Cylinder Head

NOTE:
l Do not reuse valve guide once disassembled.
Install new valve guide (Oversize). 1. Valve guide installer attachment (Special tool 09917-88210)
l Intake and exhaust valve guides are identical. 2. Valve guide installer handle (Special tool 09916-57321)
3. Valve guide protrusion (14 mm)

Fig. 3-6-27 Valve guide installation

cl Ream valve guide bore with 7 mm reamer

1) Install new valve guide into cylinder head. (Special tool).
a) Before installing new valve guide into After reaming, clean bore.
cylinder head, ream guide hole with 12 mm
reamer (Special tool) to remove burrs, mak-
ing sure that guide hole diameter after
reaming comes within specified range.

Valve guide hole 12.030 - 12.048 mm

Dia. (In & Ex) (0.4736 - 0.4743 in.)

1. Valve guide
2. 7 mm reamer (Special tool 09916-34520)

Fig. 3-6-28 Reaming valve guide bore

1. 12 mm reamer (Special tool 09916-37310)

Fig. 3-6-26 Reaming guide hole

3-43
 2) Install valve spring seat to cylinder head.
3) Install new valve stem seal to valve guide.
After applying engine oil to seal and spindle
of valve stem seal installer (special tool), fit
oil seal to spindle, and then install seal to
valve guide by pushing special tool by hand.
After installation, check to be sure tha t
seal is properly fixed to valve guide.
NOTE:
l Do not reuse oil seal disassembled. Be sure to
install new oil seal.
l When installing, never tap or hit special tool
with a hammer or else. Install seal to guide
only by bushing special tool with hand.
Tapping or hitting special tool may cause
damage on seal. Fig. 3-6-30 Valve installation

7 i
5) Install valve spring and spring retainer.
Each valve spring has top end (large-pitch
end) and bottom end (small-pitch end)
Be sure to position spring in place with its
bottom end (small-pitch end) down to valve
spring seat side.

1. Valve stem seal installer (Special tool 09917-98210)

2. Valve stem seal

Fig. 3-6-29 Valve stem seal installation

4) Install valve to valve guide.

Before installing valve to valve guide, apply 4 1. Large-pitch
2. Small-pitch
engine oil to stem seal, valve guide bore, 3. Valve spring retainer side
and valve stem. 4. Valve spring seat side

Fig. 3-6-3 1 Valve spring installation

3-44
 6) Using special tool (Valve lifter), compress 8) Install cylinder head onto cylinder block.
valve spring and fit two valve totters to Tighten cylinder head bolts gradually with a
groove provided in valve stem. torque wrench, following sequence in
Fig. 3-6-34. Finally tighten bolts to specified
torque.

Tightening torque for 63- 70 N-m

cylinder head bolts 6.3 - 7.0 kg-m
46.0 - 50.5 lb-ft

1. Valve lifter (Special tool)

2. Forceps (Special tool 1
3. Valve totters
4. Valve spring retainer

Fig. 3-6-32 Valve totters installation Fig. 3-6-34 Tightening sequence of cylinder
head bolts

7) Be sure that locating pins @ are in place and

then install new head gasket as shown in Camshaft
Fig. 3-6-33, namely in such a way that 1) Apply engine oil to cams and journals on
“TOP” mark provided on the gasket comes camshaft, and oil seal on cylinder head.
on top side (toward cylinder head side) 2) Install to cylinder head from transmission
and on crankshaft pulley side. case side.

Fig. 3-6-35 Camshaft installation

1. Cylinder head gasket
2. Crankshaft pulley side
3 Flywheel side
4. Locating pin

Fig. 3-6-33 Cylinder head gasket installation

3-35
Rocker-Arm Shafts
1) Apply engine oil to rocker arms and rocker
arm shafts.
2) install rocker arms, springs and rocker arm
shafts.
The two rocker arm shafts are not identical.
To distinguish between the two, dimensions
of their stepped ends differ as shown in
Fig. 36-36. Install intake rocker arm shaft,
facing its stepped end to camshaft pulley
side, and exhaust rocker arm shaft, facing 1. Intake side
its stepped end to distributor side (rear side). 2. Exhaust side

Fig. 3-6-37

Water Inlet Pipe

Install water inlet pipe to cylinder block.
Make sure to fit seal ring @(O-ring) to inlet
5 6 pipe before installation.

b 0 10 0 0

/
3 I
o-
3
I “7

1. Intake rocker arm shaft

2. 14 mm (0.55 in)
3. Exhaust rocker arm shaft
4. 15 mm (0.59 in)
5. Camshaft pulley side
6. Distributor side

Fig. 3-6-36 Rocker arm shafts installation

Fig. 3-6-38
3) After installing rocker arms, springs, and
rocker arm shafts as shown in Fig. 3-6-37,
tighten rocker arm shaft screws to specified Intake Manifold and Carburetor
torque. 1) Install intake manifold gasket to cylinder
head. Use new gasket.
Tightening torque 9 - 12 N.m
NOTE:
for rocker arm shaft 0.9 - 1.2 kg-m
Clean cylinder head mating surface with gasket
screws 7.0 - 8.5 lb-ft
before installation.
2) Install intake manifold with carburetor to
NOTE: cylinder head.
Valve clearance is adjusted after all parts are 3) Tighten manifold bolts and nuts to specified
assembled. So it is not adjusted at this point torque.
Leave rocker arm adjusting screw as loose as
can be.
Tightening torque ~.m kg-m lb-ft
for manifold bolts
and nuts 18 - 28 1.8 - 2.8 13.5-20.0

3-46
 Water pump
1) Install water pump gasket to cylinder block.
Use new gasket.
NOTE:
Clean cylinder block mating surface with gasket
before installation.
2) Install water pump to cylinder block.
3) Tighten bolts and nuts to specified torque.

Tightening torque N.m b-m I b-ft

for water pump
bolts and nuts 8 - 12 0.9 - 1.2 7.0 - 8.5
,

Fig. 3-6-39

4) Connect water hoses to water inlet pipe and

clamp each hose.

Oil Filter
Install oil filter.

CAUTION:
For oil filter installation, refer to P. 1-7 of
this manual.

Exhaust Manifold and Cover Fig. 3-6-40

1) Install exhaust manifold gasket to cylinder
head.
Use new gasket. 4) Install rubber seats 0; one between oil
NOTE: pump and water pump and the other be-
Clean cylinder head mating surface with gasket tween water pump and cylinder head.
before installation.
2) Install exhaust manifold to cylinder head.
3) Tighten bolts and nuts to specified torque.

Tightening torque N.m kg-m lb-ft

for bolts and nuts 18 - 28 1.8 - 2.8 13.5-20.0

4) Install exhaust manifold cover.

Fig. 3-6-4 1

3-47
 Timing Belt Inside Cover, Belt Pulleys,
Tensioner, Timing Belt and Outside Cover
1) install timing belt inside cover to cylinder
head.
2) Install crankshaft timing belt guide, key and
pulley.
Refer to Fig. 3-6-42 for proper installation
of these parts.
Install timing belt guide in such a way that
its concave side faces oil pump.
Tighten crankshaft timing belt pulley bolt to
specified torque by using flywheel holder
A (Special tool). inside cover
2. Camshaft pulley:
3. Pulley pin
4. Slot
5. Pulley bolt

Fig. 3-6-43 Pulley pin, slot and pulley bolt

1. Timing belt guide

2. Key
3. Crank timing belt pulley
4. Pulley bolt
(A) Flywheel holder
(09924-I 7810)

Fig. 3-6-42 Installing guide, key and pulley

1. Wrench
2. Camshaft timing belt pulley
3. Timing belt inside cover
4. General rod
3) Install camshaft timing belt pulley.
Fit pulley pin on camshaft into slot in
camshaft pulley. Tighten pulley bolt to Fig. 3- 6-44
specified torque with general rod applied as
shown in Fig. 3-6-44.

Tightening torque N-m kg-m lb-ft

for pulley bolt 56 - 64 5.6 - 6.4 41.0-46.0

3-48
4) Install timing belt tensioner plate to tensio- 6) Before installing timing belt to camshaft
ner. pulley and crankshaft timing belt pulley,
Insert lug of tensioner plate into hole of loosen all valve adjusting screws of intake
tensioner. and exhaust rocker arms fully, or check to
ensure they are loose.
This is to permit free rotation of camshaft
for the following reason; when installing
timing belt to both pulleys, belt should be
correctly tensed by tensioner spring force.
If camshaft does not rotate freely, belt will
not be correctly tensed by tensioner.

3w 4
1. Tensioner plate
2. Tensioner
3. L u g
4. H o l e

Fig. 3-645 Lug and hole

5) Install timing belt tensioner, tensioner plate

and spring. 1. Valve adjusting screw
2. Locknut
Do not tighten tensioner bolt and stud with
wrench yet. Fig. 3-6-47 Valve adjusting screw and lock nut
Hand tighten only at this time.
Be sure that plate movement in arrow
direction as shown in Fig. 3-6-46 causes the 7) After loosening all valve adjusting screws all
same directional movement of tensioner. the way, turn camshaft pulley clockwise and
If no associated movement between plate align timing mark on camshaft pulley with
and tensioner occurs, remove tensioner and “V” mark on belt inside cover as shown in
plate again and reinsert plate lug into tensio- Fig. 3-6-48.
ner hole.

1. Tensioner bolt
2. Tensioner stud
3. Tensioner plate 1. Camshaft timing pulley
4. Tensioner 2. Timing mark
5. Spring 3. “V” mark
6. Spring damper 4. Belt inside cover

Fig. 3-648 Timing marks

Fig. 3-646 Tensioner installation

3-49
8) Turn crankshaft clockwise, fitting 17 mm NOTE:
wrench to crankshaft timing belt pulley When installing timing belt, match arrow mark
bolt, and align punch mark on timing belt (+I on timing belt with rotating direction of
pulley with arrow mark on oil pump as crankshaft.
shown in Fig. 3-6-49. 10)To allow belt to be free of any slack, turn
crankshaft clockwise fully twice after install-
ing belt. After removing belt slack, tighten
tensioner stud first and then tensioner bolt
to 24 - 30 N.m (2.4 - 3.0 kg-m, 17,5 -
21.5 lb-ft).
Then confirm again that 4 marks are match-
ed.
9 - 1 2 N-m

1. Crankshaft timing belt pulley bolt

2. Punch mark
3. Arrow mark
4. Crankshaft timing belt pulley
Fig. 3-6-49 Timing marks

9) With 4 marks aligned, install timing belt on

two pulleys in such a way that drive side of
belt is free from any slack, and with tensio-
ner plate pushed up by finger.
NOTE:
In this state, No.4 piston is at top dead center 3. Tensioner plate

of compression stroke. Fig. 3-6-51 Tensioner bolt and nut

11) Install timing belt outside cover.

Tightening torque N.m lb-ft

km
for outside cover
bolts and nuts 9- 12 0.9 - 1.2 7.0 - 8.5

Crankshaft Pulley, Water Pump Pulley and

Alternator
1) Install crankshaft pulley.
Fit keyway on pulley to key of crankshaft
timing belt pulley, and tighten 4 bolts to
specification, with flywheel holder (special
tool 09924-17810) hitched to flywheel so
that crankshaft will not turn.

Tightening torque N.m kg-m lb-ft

for pulley bolts lo- 1 3 1.3 7.5-9.0
*

Direction of crankshaft
1. Drive side of belt

Fig. 3-6-50 Installing timing belt

3-50
 - 1. Key
‘3 2. Crankshaft pulley
3. Pulley bolt Fig. 3-6-53

Fig. 3-6-52 Installing crankshaft pulley

Fuel Pump
Install fuel pump rod, gasket and fuel pump to
2) Install alternator assembly.
cylinder head.
Tighten alternator ass’y securing bolts (3pcs)
Apply engine oil to rod @ before installation.
only to the extent to allow alternator to be
Use new gasket.
moved by hand. Don’t torque them tight.
NOTE:
Adjust water pump belt tension to specification
upon completion of installing engine ass’y to
body and then cooling fan and water pump
pulley. Make sure to refer to p. 1-5 of this
manual for adjusting procedure.

Distributor Case
1) Install distributor case O-ring to cylinder
head.
2) Install distributor case.
3) Tighten bolts to specified torque.

kg-m lb-ft Fig. 3-6-54 Fuel pump rod installation

T i g h t e n i n g t o r q u e N.m
for case bolts 8 - 12 0.8 - 1.2 6.0 -8.5

case with about 3Occ (1.02/1.05 US/Imp

3-51
Clutch Disc and Cover ? Valve Lash (Clearance) Adjustment
Install clutch disc and cover. Adjust valve lash of all intake and exhaust
For installation, refer to p. 11-7 of SECTION 11 valves to specification, referring to description
CLUTCH in this manual and torque each bolt to on valve lash on p. 3-53 of this manual.
specification.
Cylinder Head Cover
Install cover to cylinder head and tighten
Transmission Assembly bolts to specified torque.
1) Check to make sure that 2 pins @ are
fitted to cylinder block.

Fig. 3-6-55

2) Attach transmission assembly to engine

cylinder block and tighten bolts and nuts to
specified torque.

Tightening torque ~.m kg-m I b-ft

for transmission
,.aSe bolts an,-j nutS 22 - 35 2.2 - 3.5 16.0-25.0

Distributor
1) Install distributor to case.
For installation, besure to refer to SECTION
8 IGNITION SYSTEM in this manual.

NOTE:
Check and adjust ignition timing with engine
installed to car body and after installing and
connecting all necessary parts. For procedure,
refer to p. 8-9 of SECTION 8 IGNITION SYS-
TEM in this manual.

3-52
3-7. ENGINE INSTALLATION 3-8. ENGINE MAINTENANCE SERVICE
1) Lower engine with transmission into vehicle, Fan Belt
but do not remove lifting device. Adjust belt tension as outlined in SECTION 6
2) Tighten engine mounting bracket bolts ENGINE COOLING SYSTEM (p. 6-10).
(right and left) and transmission mounting
bolts to specification. Refer to p. 3-58. Ignition Timing
3) Remove lifting device. Refer to IGNITION TIMING, Page 8-9.
4) Reverse removal procedures for installation
of remainder. Carburetor
5) Adjust accelerator cable play and clutch fidjustments to be made are detailed in SEC-
cable play. TION 4 (p. 4-19).
6) Connect vacuum hoses securely. Refer to
section 5 “EMISSION CONTROL SYSTEM” Valve Lash (Clearance)
for correct connection. Valve lash specifications:
7) Connect wire harnesses and couplers secure- Valve lash refers to gap between rocker arm
IY. adjusting screw and valve stem. Use a thickness
8) Tighten bolts and nuts to specified torque. gauge to measure this gap @.
For individual specification, refer to each
When cold When hot
section. (Coolant tempe- (Coolant tempa-
9) Fill specified amount of specified trans- Valve lash
rature is 15 - 25% rature is 60 - 66’C
or 69 - 77’F) or 140 - 154’F)
mission oil and engine oil. For the detail, (gap A)
specif i- 0.13 - 0.17 mm 0.23 - 0.27 mm
refer to SECTION 1 PERIODIC MAINTE- cation Intake (0.0051 - 0.0067 in) (0.009 - 0.011 in)
NANCE SERVICE of this manual. 0.16 -0.20 mm 0.26 - 0.30 mm
Exhaust (0.0063 - 0.0079 in) (0.0102 - 0.0116 in)
10) After adjusting water pump belt tension to
specification, fill specified amount of engine
Screw lock nut 15 - 19 N.m
cooling water. (1.5 - 1.9 kg-m, 11 .O - 13.5 lb-ft)
11) Before starting engine, check again to ensure Adjusting screw
that all parts once disassembled or discon-
nected are back in place securely.
12)Start engine and check ignition timing. If
it is not to specified timing, adjust it, referr- 8

ing to SECTION 8 of this manual.

13) After engine is started, check for oil leak,
Valve stem
abnormal noise and other malcondition.
Also, check each part for operation.
Fig. 3-8-l

Checking and adjusting procedures:

NOTE:
l Refer to Fig. 3-3-11 of SECTION 3 for
cylinder numbers (No. 1, No. 2, No. 3 and
No. 4) mentioned in this section.
l When adjustment becomes necessary in step
4), loosen adjusting screw lock nut and then
make adjustment by turning adjusting screw.
After adjustment, tighten lock nut to specifi-
ed torque while holding adjusting screw
stationary with straight headed screwdriver,
and then make sure again that gap @ is
within specification.

3-53
 1) Remove cylinder head cover.
2) Remove ignition timing check window
rubber plug from clutch housing of trans-
mission case.
3)Turn crankshaft clockwise (viewing from
crankshaft pulley side) to the extent that
line @above “T” mark punched on fly-
wheel is aligned with match mark @ on
transmission case as shown below, i.e. No. 1
cylinder piston reaches TDC position.

EX

Fig. 3-8-4
-

Fig. 3-8-2 1. Match mark 2. ‘7” (TDC) mark

4) Remove distributor cap and check that rotor

is positioned as shown in figure. If rotor is Fig. 3-8-5 Measuring valve lashes
out of place, turn crankshaft clockwise
once (360”). In this state, check valve lashes 5) Upon completion of check and adjustment,
at valves @,@I, @and 0. Rotate cran kshaft
install cylinder head cover and torque bolts
exactly one turn, and check the same at
to specification.
valves 8, @, @ and @I.
Tightening torque N.,.,., b-m lb-ft
for cylinder head I
cover bolts 4-5 0.4 - 0.5 3.0 - 3.5*

6) Install distributor cap and connect blow-by

gas hose to cylinder head cover.

Camshaft Timing Belt

For checking procedures of damage, wear and
tension of camshaft timing belt, refer to SEC-
TION 1 (p. 1-5) of this manual.

Engine Oil
Fig. 3-8-3 Refer to SECTION 1 (p. I-7) of this manual.

Engine Oil Filter

For removal and installation of filter, refer to
SECTION 1 (p. I-7) of this manual.

3-54
Engine Coolant 5) Disengage clutch (to lighten starting load on
This subject is covered in SECTION 6 ENGINE engine), and depress accelerator pedal all
COOLING SYSTEM. the way to make throttle full-open.
6) Crank engine with fully charged battery, and
read the highest pressure on compression
Exhaust Line and Muffler
gauge.

3
Inspect each exhaust line connection for tight-
ness, and examine muffler and other parts for
evidence of breakage and leakage of gases. Compression pressure
Repair or replace defective parts, if any. 14.0 kg/cm2 (199.0 psi)
Standard
400 r/min
12.0 kg/cm2 (170.0 psi)
Limit
400 r/min
Max. difference
1 .O kg/cm2 (14.2 psi),
between any two
400 r/min
cylinders

7) Carry out steps 4) through 6) on each cylin-

der to obtain four readings.
NOTE:
Compression pressure value is measured by using
compression gauge (Special tool 09915-64510).

Oil Pump Discharge Pressure Measurement

Compression Pressure Measurement
Check compression pressure on all four cylinders NOTE:
as follows: Prior to checking oil pressure, check the follow-
1) Warm up engine. ing.
l Oil level in oil pan.
2) Stop engine after warming up.
3) Remove all spark plugs and disconnect If level is low, add oil up to Full level hole on
high tension cord from ignition coil. oil level gauge.
4) Install compression gauge (special tool) into 0 Oil quality.
spark plug hole. If oil is discolored, or deteriorated, change oil.
For particular oil to be used, refer to table on
p l-8 of SECTION 1.
l Oil leak.
If leak is found, repair it

1. Compression gauge (Special tool 09915-64510)

Fig. 3-8-7 Installing compression gauge

3-55
 1) Disconnect lead wire from oil pressure 6) After checking oil pressure, stop engine and
switch. remove oil pressure gauge.
2) Remove oil pressure switch from cylinder 7) Before reinstalling oil pressure switch, be
block. sure to wrap its screw threads with sealing
tape and tighten switch to specified torque.

NOTE:
l If sealing tape edge is bulged out from screw
threads of switch, cut off edge.

8) After installing oil pressure switch, start

engine and check switch for oil leakage.

Fig. 3-8-8 Oil pressure switch

Vacuum Measurement
Engine vacuum that develops in intake line is a
3) Install oil pressure gauge (special tool) good indicator of engine condition. Vacuum
to vacated threaded hole. checking procedure is as follows:

1) Warm up engine to normal operating tempe-

rature.
2) Install vacuum gauge @ (09915-67310), as
shown in Fig. 3-8-10. Install engine tacho-
meter.

1. Oil pressure gauge k+ecial tool O!Xil5-77310)

Fig. 3-8-9 Oil pressure gauge installation

4)Start engine and warm it up to normal

operating temperature. Fig. 3-8- 10
5) After warming up, raise engine speed to
3,000 r/min and measure oil pressure.

Oil pressure 3.0-4.2 kg/cm2

42.7- 59.7 psi
specification at 3,000

3-56
 3) Run engine at specified idling speed and, Oil Filler Cap
under this running condition, read vacuum The cap has a packing. Be sure that packing is in
gauge. Vacuum should not be lower than good condition, free of any damage and signs of
45 cm Hg (17.7 in. Hg). deterioration, and is tight In place: it is replacea-
A low vacuum reading means that any combi- ble.
nation of following malconditions is the cause,
which must be corrected before releasing
machine to customer:
(a) Leaky cylinder head gasket
(b) Leaky inlet manifold gasket
(c) Leaky valves
(d) Weakened valve springs
(e) Maladjusted valve clearance
(f) Valve timing out of adjustment
(g) Ignition mistimed
(h) Carburetor improperly adjusted

NOTE:
Should indicating hand of the vacuum gauge
oscillate violently, turn adjusting nut @I to
steady it
4

Standard vacuum 45- 55cm Hg

(sea level) (17.7 - 21.6 in. Hg)
BOO f 50 r/min (rpm)
Idling speed
(Take vacuum reading
specification
at this speed.)
L

4) After checking, remove vacuum gauge.

5) Before reinstalling vacuum checking plug,
be sure to wrap its screw threads with
sealing tape and tighten plug.

3-57
3-9. RECOMMENDED TORQUE SPECIFICATIONS

Tightening torque
Fastening parts
N-m kg-m lb-ft
1. Cylinder head bolt 1 63-70 1 6.3 - 7.0 1 46.0 - 5 0 . 5
2. Cylinder head cover bolt 4 - 5 0.4 - 0.5 3.0 - 3.5
3. Spark plug 20-30 2.0 - 3.0 14.5 - 21.5
4. Distributor gear case 8-12 0.8 - 1.2 6.0 - 8.5
5. Rocker arm shaft screw I 9- 12 I 0.9-1.2 1 7 . 0 - 8 . 5
6. Valve adjusting screw lock nut I 15- 19 1 1 . 5 - 1 . 9 I ll.O- 1 3 . 5
7. Crankshaft main bearing cap bolt 1 50- 57 1 5.0 - 5.7 1 36.5 - 41 .O
8. Oil filter stand I 20-25 -. 1 2.0 - 2.5 1 14.5 - 1 8 . 0
9. Oil filter Ass’y 12- 16 1.2 - 1.6 9.0 - 11.5
10. Oil pressure switch 12- 15 1.2 - 1.5 9.0 - 10.5
11. Oil drain plug I 30-40 I 3.0 - 4.0 1 22.0 - 28.5
12. Oil pan bolt and nut I 9- 12 I 0.9 - 1.2 I 7.0 - 8.5
13. Oil pump strainer bolt I 9- 12 I 0.9 - 1.2 I 7.0 - 8.5
14. Water pump bolt and nut I 9-12 I 0.9 - 1.2 I 7.0 - 8.5
15. Cooling fan nut I 8- 12 1 0.8- 1.2 1 6 . 0 - 8 . 5
16. Flywheel bolt I 57 - 65 I 5.7 - 6.5 I 41.5-47.0
17. Oil seal housing bolt I 9- 12 I 0.9 - 1.2 I 7.0 - 8.5
18. Connecting rod bearing cap nut 1 33-37 ( 3 . 3 - 3 . 7 1 24.0 - 2 6 . 5
19. Crankshaft pully bolt I lo- 13 I 1.0 - 1.3 I 7.5 - 9.0
20. Crankshaft timing belt pulley bolt I 65 - 75 I 6.5 - 7.5 1 47.5- 5 4 . 0
21. Timing belt cover bolt and nut I 9- 12 I 0.9- 1.2 1 7-O-8.5
22. Camshaft timing pully bolt I
I
56 - 64 1I 5.6 - 6.4 1I 41 .O - 46.0
23. Timing belt tension bolt 24 - 30 2.4 - 3.0 1 17.5 - 21.5
24. Timing belt tensioner stud I 9- 12 I 0.9 - 1.2 I 7.0 - 8.5
25. Oil pump case bolt I ‘9- 12 I 0.9- 1.2 1 7 . 0 - 8 . 5
26. Oil pump rotor plate screw I 9- 12 I 0.9-1.2 1 7-O-8.5
27. Inlet & exhaust manifold nut I 18-28 1 1 . 8 - 2 . 8 I 13.5 - 20.0
28. Fuel pump nut I lo- 16 1 1 . 0 - 1 . 6 I 7.0- 11.5
29. Engine mounting bracket frame side bolt 1 40 - 60 I ~~~4.0 - 6.0 1 29.0 - 43.0
30. Engine mounting bracket engine side bolt I 50 - 60 1 5 . 0 - 6 . 0 1 36.5 - 43.0
31. Engine mounting nut I
I
40-50 I
1
4.0 - 5.0 1 29.0 - 3 6 . 0
I

32. Transmission mounting bracket bolt 18-28 1.8 - 2.8 1 13.5 - 20.0
33. Transmission mounting bolt 18-28 1.8 - 2.8 13.5 - 20.0
34. Transmission mounting and frame bolt 18-28 1.8 - 2.8 13.5 - 20.0
35. Propeller shaft flange bolt and nut 23 - 30 2.3 - 3.0 17.0- 21.5
NOTE: If specified tightening torque for particular bolt or nut is not included here, refer to p O-12 of
this manual.

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