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Toyota 7 k engine repair manual 2

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Toyota 7k engine repair manual

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Toyota 7 k engine repair manual 2

  1. 1. J . ' @TOYOTA .. } REPAIR MANUAL Jul., 1995 ;. ·,
  2. 2. .. • • j; •• .. INTRODUCTION ENGINE IGNITION SYSTEM STARTING SYSTEM CHARGING SYSTEM .. ··:- ......., ..~ ~ d '¥ • -:_,.,.., ,..;:/·..:_~,.r;t.:
  3. 3. . '· •• ~' . ' 0 • • .. • 0 ©1995TOYOTA MOTOR CORPORATION All rights reserved. This book may not be reproduced or copied, in whole or in part, withtlut the written permission of Toyota "..- ~- ,.. FOREWORD This repair manual has been prepared to provide informatio" · covering general service repairs for the 7K engine equipped in the TOYOTA TUV. Applicable models: KF42, 52 series Please note that the publica lions below have a!so been prepared as relevant service manuals for the components and system in this engine. All information in this manual is based on the latest product in- formation at the time of publication. However, specifications and procedures are subject to change without notice. TOYOTA MOfOR CORPO{Ul.TION
  4. 4. • • IN-1 INTRODUCTION HOW TO USE THIS MANUAL ·················· IN- 2 fii'~ IDENTIFICATION INFORMATION ··············· IN- 4 ii.!fJ.:i!!t GENERAL REPAIR INSTRUCTIONS ············ IN- 4 ABBREVIATIONS USED IN THIS MANUAL ·••···•••·•·•······•·········•··············· IN- 7 STANDARD BOLT TOROUE SPECIFICATIONS···································· IN- B
  5. 5. IN-2 INTRODUCTION - HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist y.:OtJ in finding your way through the manual, the Section Title and major heading are given at the top of every page. GENERAL DESCRIPTION At the beginning of each section, a General Description is given that rertains to all repair operations contained in that section. Read these precautions before starting any repair task. TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagn.::se the problem and find the causA. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains·the purp-ose of each one. REPAIR PROCEDURES r Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: --------------------------------------------------~ Oil Pump Body +Cotter Pin __.., ~ ~ -~ -~ ~ -~ ~.., ~- I ~ ~ -I -- ~( Relief Valve DriJ.n Rotor-@Volve Spring I Srring Retainor I ~ ~JP Oil Pump Covor [B·m lkgf·cm, ft·lbf) i : Specified torque I 1./ I J Drive Rotor----J"b.'- f ) ~ + Non~reusable part P2537J '-------------------------------------------------------~~
  6. 6. -. , INTRODUCTION HOW TO USE THIS MANUAL The procedures are presented in a step-by-step format: • The illustration shows what to do and where to do it. • The task heading tells what to do. • The detailed text tells how to do the task and gives other information such as specifications and warnings. Example: This. format provides the experienced technician with a FAST TRACK to the information neaded. The upper case task heading can be read at a glance when necessary, and tho text below it provides detailed information. Important specifications and warnings always stand out in bo:d type. REFERENCES References have been kept to a minimum. However, when they are required you are £ivan the page to refer to. SPECIFICATIONS Specifications are presented in bold type throughout the text where needAd. You never have to leave the procedure to look up your specifications. They are also found at the end of each sectio:1, for quick reference. . CAUTIONS, NOTICES, HINTS: • CAUTIONS are presented in bold type, and indicate ther9 is a possibility of injury to you or other people. • NOTICES are also presented in bold type, and indicate the possibility of damage to thr components being repaired. • HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently.
  7. 7. 11'1-4 INTRODUCTION·- GENERAL REPAIR INSTRUCTIONS Sf UNIT The UNITS given in this manual are primarily expressed according to the SI.UNIT(International System of Unit); and alternately expressed in the metric system and in the Epglbh System. Example: Torque: 30 N·m (31 0 kgf-cm. 22 ft·lbf) IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block as shown. GENERAL REPAIR INSTRUCTIONS 1. 2. 3. I JfOrl-tf Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in th6 appropri~t•• order to. facilitate reassembly. ' Observe the fo!lowing: (a) Before doing electrical work. disconnect the neg- ative cable from the battery terminal. (b) If it is necessary to disconnect the battery for in.spection or repair, always disconnect the cable from the negative(-) terminal which is grounded to the vehicle body. . (c) To prevent damagll to the battery terminal post. lcosen tho terminai nut and rais~ the cabl<:l strai- ght up without twisting or pryin9 it. (d) Cle.an th9 battery terminal posts and cable t<~rmi­ nals with a clean shop rag. Do not scrape them with a file or other abrasivs object~. (e) Install the cable terminal ~o the battery post with the nut loose, and tighten the nut after installa- tion. Do not use a hammer to tap the terminal onto the post. (f) Be sure the cover for the positive (+) terminal is .properly in place. 4. Check hose and wiring connectors to m?'<e sure that they are socuro and correct. f
  8. 8. s-~···· ' .. • - INTRODUCTION - GENERAL REPAIR INSTRUCTION:'; IN-5 5. Non- reusable parts (a) Always replace cotter r-ins. gaskets, 0-rings and oil seals etc. with new ones. (b) Non-reusable parts a~e indieated in the compo- nent illustrations by the ••• symbol. _j--------------------- Seal Lock Adhes:ive 6. Precoated parts Precoated parts are belts and nuts. etc. that 1re coated with a seal lock adnasive at the factory. (a) If a precoated part is retightenod. loosened or caused to move in any way, it must be recoated with the specified adhesive. Fuse Equal Amperage Rating ' ( 10 8F1J&& Illustration ~ B£5694 ~ BE56S~ 1-· ~ B£5690 I / BE5597 GY BES598 ' (b) When reusing precoatsd parts. clean off the old adhesive and dry with compre~sed air. Then apply the specified ssallock adhe~il(e to the bolt, nut or threads. (c) Precoated parts are indicated in the component illustrations by the "*"symbol. 7. When necessary, use a sealer on gaskets to prevent le~ks. 8. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. 9. Use of SST and SSM may be required. depending on the nature of the repair. Bs sure to Ulje SST and SSM where specified and follow the prooer work proce- dure. A list of SST and SSM can he found in the preparation ;:>art at tho front o~ eacn section in this manual. 10. When replacing fustJ·s. be sure the new fuse ha~ the correct amperag(> rating. DO NOT exceed tha rating or use one with a lower rating. ~" ·-r·------, Symbol Part Nnme Abbrevintion - -~- FUSE ..WQJ8S 1 --<0"'o-I MEDIUM CURRENT FuSE IM-FIJSE w-JoJee j -~-- HIGH CURRENT FUSE H-FUSE INOl07 -~ FUSIBLE LINK FL IN0307 -8-- 'I CIRCUIT 6iii:AKER co INOJ68 """".
  9. 9. ·· IN-6 INTRODUCTION - GENERAL REPAIR INSTRlJ.;TIONS WHONG CORRECT IN0253 IL---------------------~==~. WRONG CORRECT ,/ l IN0262 Exampie I '""""' I 11. Care· must be taken when jacking up and supporting the 'lehicle. Be sure to lift and support the vehicle at 1 the proper locations. (a) If the vehicle i~ to be jacked up only at the front or rear end. be sure to block the whesls at the opposite end in order to ensure s'afety~ (b) After the vehicle is jacked up. be sure to support it on stands. It is extremely dangerous to do any work on a vehicle raised on a jack alone. even for a small job that can be finished quickly. , 12. Observe these precautions to avoid damage to the parts: (a) Do not open tho cover or case of the ECU unless ·absolutely necessary. (If the IC terminals are tou- ched. t:1o IC may be destroyed by static electric· ity.) (b) To disconnect vacuum hoses. pull on the end. not the middle of the hose. (c) To pull apart electrical connectors. pull on the connector itself. not the wires. (d) Be careful not to drop electrical components. such as sensors or relays. If they are dropped on a· hard floor. they should be ~eplaced and not reused. (e) When steam cleaning an engine, protect the elec.- tronic components. &ir filter. and emissions relat- • ed components from water. (f) Never use an impact wrench to remove or install temperature switches or temperature sensors. (g) When checking continuity at the wire connector. insert the testGr probe carefully to !Jrsvont termi- nals from bending. (h) When using a vacuum g<:lJge. never force the hose onto a connector that is· too large. Usa a stllp ·-down adapter instead. Once the ho$e h~.s b'3en stretched, it may ldak. 13. Tag hosas before disconnecting them: (a) When disconr.ec!ing vacuum hoses, use tags to identify how they should be reconnected. (b) After -::omple~ing a job, double check that the vacuum hoses are properly connected. A label under the hood shows the proper layout. 14. Unless otherwise stated. all resistance is measured at an ambient temperature of 2o•c (68°F). Because the resistance m9y be out;ide specifications if measured at high temperatures .immediately after the vehicle has been running. measurements should be made when the engine has cooled down.
  10. 10. ' INTRODUCTrON - ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL A/G Air Conditioner Approx. Arproxlmatelv BOG Bottom Oe11d Center FIPG Formed In Placa Guket MP Multipurpoa.:J C/S Oversized PGV Positive Crnnkca~e Vflntil~tion SSM Special SOrvice Meteriela SST Special Service Tools STO Standard SW Switch TOG Top Dead Center TEMP. Temperature U/S Undersize vsv Vacuum Switching Velva W/ With w/o Without IN-/ --· ,. -- ~
  11. 11. IN-8 IN.TRODUCTIO'I'< -STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS ' --w HOW TO DETERMINE BOLT STRENGTH ~--~ --------- Mark Class ------ Mark l Class Hexaqon 4- 4T Hexagon ~ head bolt 5- ST flange boll 4 Protruding 9T Boll G- GT wl washer lines ()'head No._ 7- 7T hexagon bo,lt 8- ST Hexagon ~ 9- 9T flange boll 5 10- 10T Protruding 10T w/ Y!asher lines 11- 11T · hexagon boil - -. 0 Hexagon ~ flange boll 6 No mark 4T Prolr!:Jding 11T w/ washer lines hexagon bolt Hexagon 0 Slud boll No mark flange bolt No mark 4T Iw/ w~sher hexagon bolt I 4T Hexagon CD I + I head boll 2 I 0 ProtrtJding ST L I linas J 1- r·,·~:·Hexagon !( 0 2ll•.nge boll IQl ::.:"';~ "lI w/ wacher I GT hb'<agon be-lt I -I I I I - _j__ I HexaqtJn l'ead boll ~ 3 I ~ Protruding n Welded boll lines ~Hexagon ~ 4T head bolt 4 Protruding ST lines
  12. 12. .- ... IN-9 INTIC!ODUCTION -STANDARD i'lOLT TORQUE S,_P-"E-"C::_IF~!'-'C'-'A"-T'-'Ic:O:..cN-"S"-------- SPECIFIED TORQUE FOR STANDARD BOLTS Class 4T 5T 6T 7T ~ 8T t'T lOT 11T Specified torque Diameter Pitch Hexegon head bolt He."'"9on flonge bolt m;n :nm N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf 6 1 5 55 48 in.·lbf 6 60 52 in.·lbi 8 1.25 12.5 130 9 ~4 145 10 10 1.25 26 260 19 29 290 21 12 1.25 47 480 35 53 540 39 14 1.5 74 760 55 84 850 61 16 1.5 115 1.150 83 - - - 6 1 6.5 65 56 in.·lbf 7.5 75 65 in.·lbf 8 1.25 15.5 160 12 17.5 175 13 10 1.25 32 330 24 3€ 360 26 12 1.25 59 600 43 65 670 48 14 1.5 91 930 67 100 1,050 76 16 1.5 140 1,400 101 - - - 6 1 8 80 69 in.·lbf 9 90 78 in.·lbf 8 1.25 19 195 14 21 210 15 10 1.25 39 400 29 44 440 32 12 1.25 71 730 53 80 810 59 14 1.5 110 1,100 80 125 1,250 90 ' 16 1.5 170 1,750 127 - - - 6 1 10.5 1I0 8 12 120 9 8 1.25 25 260 19 28 290 21 10 1.25 52 530 38 58 590 43 12 1.25 95 970 70 105 1,050 76 14 1.5 145 1,500 108 165 1,700 123 16 ~ 230 2.30ti) 156 -- - ~8 T 1.25 I 29 300 22 33 330 10 1 1.25 I 61 .620 45 68 690 50 I12 I 1.25 110 1,100 00 120 1,250 90 .. 6 i. 7.5 I 34 .340 25 .17 380 27 I 7C ..10 1.25 51 7B710 790 o7 12 1.25 125 ,,30(1 94 1 140 1.450 105 +----------------r----------·-----1 8 1.25 38 10 1.25 78 12 1.25 140 8 1.25 42 10 1.25 87 12 1.25 155 390 28 42 430 31 800 1,450 430 890 1,600 58 105 31 64 I 16 88 155 47 97 175 890 1,600 480 990 1,800 64 116 35 72 130 -
  13. 13. .. ' . I " '. tG-1 ENGINE ENGINE MECHANICAL .PREPARATION ....................................... EG- 2 AIR elLTER INSPECTION AND CLEANING ·························•·•·········· ··· EG- 6 IDLE CO CHECK AND ADJUST .....•......;.. EG- 6 COMPRESSION CHECK ····•····••···•·•·······•·· EG- 9 VALVE CLEARANCE INSPECTION AND ADJUSTMENT······································ EG- 10 IGNITION TIMING INSPECTION AND ADJUSTMENT······································· EG- 11 IDLE SPEED INSPECTION AND ADJUSTMENT······································· EG-11 CYLINDER HEAD ................................. .-.. EG- 1r TIMING CHAIN ....................................... EG- 27 CYLINDER BLOCK ................................. EG- 34 SERVICE SPECIFICATIONS ........................ EG- 55 FUEL SYSTEM PREPARATION .................................,..... EG- 60 PRECAUTION ........................................,. EG- 60 ON-VEHICLE INSPECTION ..................... EG- 6! CARBURETOR ....................................... EG- 61 FUEL PUMP ........................................... EG- 76 SERVICE SPECIFICATIONS........................ EG- 78 COOLING SYSTEM PREPARATION ....................................... EG- 79 COOLANT CHECK AND REPLACEMENT ... EG-- 80 WATER PUMP ...............................;....... EG- 81 THERMOSTAT ....................................... EG- 85 RADIATOR ............................................. EG- 87 SERVICE SPl:CIFICATIONS........................ EG- 88 LUBRICAT!ON SYSTEM PREPARATION ....................................... EG- 89 OIL PRESSURE CHECK ........................... EG- 90 OIL AND FILTER REPLACEMENT ............ EG- 91 OIL PUMP ............................................. EG- 92 SERVICE SPECIFICATIONS ........................ EG- 96
  14. 14. EG-2. ENGINE·..:. ENGINE MECHANICAL ENGINE MECHANICAL PREPARATION SST (SPECIAL SERVICE TOOLS) 09201-10000 Valva Guido Bushing Remover & AopiGcor Sot ··············. ··························· (09201-01080) Valve Guide Bushing Remover & Replacer B 09~02 -70020 Valva Spring Compressor •-•~u . ...................................,....................................................................................................................._.. (09202-00010) Attochmont (09202-01010) A•m .......................; .......... ······································································································································· ·································· (09202-01020) Set Bolt · ·· ·i9ois4·:::iiooii4) 5~·;~::; ················· ······ · ············ ······· ···· ····· ·I ~ I 1 ~-----------------------------~------- I09213-14010 Cranksh_aft Pulley Hol.ding Tool ----, ,~ I II I (~1651-60665) Bolt 09215-00101 Camchsft Dearing Remover & Roplecer Sot ..g ················· ............................................................................................................... (09?15-001?1) Gote "A" (09215-00130) Bolt .... I f
  15. 15. ' ·. -I .-- ." J ENGINE - ENGINE MECHANICAL EG-3 (09215-00141) Nut (09215 -00150) Shalt "A• (09215-00161) P;n (09215-00211) P.omovor & Aflplacor (09215-0022l) Remover & Aoplacor (09215-00231) Remover & Rop/occr 09221-25025 Piston Pin Romovor & Raplacor ········································································································ ·························-·························· (09221-00020) .Body (09221-00030) Sp,;ng -I I i ..........................................................................................................,.................................................. (09221-00170) Gu;de "J' .......... ················· ················· ........................................................................................................................................... (09221- "n10) Gu;de ·M· 09223 15020 Oil Seal & Bearing Replacer ~ 09223 46011 ~::~~:~;11 Front 0;1 Sool J ~--------------------------------_l____________
  16. 16. EG-4 ENGINE -.ENGINE MECHANICAL 09330 00021 Companion Flange Holding Tool ......................... (09330-00030) Pin 09950-4o'01 0 Puller BSet Crankshaft pulley Crankshaft pulley Crankrhdt sprocket ·····················cosgs2·~::o4o·io>····s·lid~-;.,~-~---················· -·····-·-··--····-···-···········... ··································································· .......... ......:........ .. .....· ····· ... ·· ·.. ..io99s4·::·a4ciiiii...;.,;;,..is· ·.... · ................ ·· ........................................................................................ .. ························ .························cii99ss·::·a4iii'iii···r;,;:;,·;;~:·;·.....................................................................................................................:::- ~~ <o995.7 :.:o4ii·;o)···:.;:;;;·~·h·;;;;·~·;· ..··.......·................··...........................................·..............·........................... 09g5o 50010 Pullor C $et Crankshaft pulley Crankshaft sprocket .......................... ·················· ...........~ ......io995·i·::·a5oi.iii ··fi~~~~; i5Ci....................................................................................................................... ···.................. ···......··············· .................iii99s·2::osiiiii)···-s;;'d~·;.:·;;,··...................:................................[.................................................................. [@ITQJ ~..................iii&s5i·:·o5ii2ii,· ··e:~-~-;~;-'0·~·;;·;·-sc;·· .........................................................................·.............................. ···········..····..··············..·...····....········....····cu9iis4·::·oso2o) ..-;;;;·;;·N~::;· ........·............................................·...........................................·..................... ~~ · 09950 70010 Hondle Set .............................io995.i =o7i5ii). ··fi~~di~·;-s'O......................................................................................................................... ,,. I i , i: •I{ ! t '
  17. 17. • ENGINE - ENGINE MECHANICAL EG-5 09960:...10010 Variob/o Pin Wronch Set Camshaft cprcekot (09962-01000) Vor;oblo p;n Wrench Arm A"y ............... ························· ······· ................................................ (09963-01000) Pin 10 tECOMMENDED TOOLS .- • -.:OUiPMENT . • Caliper gauge . CO/HC meter Compression gauge ·connecti!lg rod aligner Cylind~r gauge Dial indicatCJr Dye· penetrant Engine tune-up taater HH&ter 'Megnetie flngnr Mlcromet&r Pilt,Jn ring 'JI')ftlprenor -------P1ston tinQ a)(pr;Fld~r Plaatig11J90 -~recision atraight edpe SQft bruah -~~ring tester ..steel square •Tachometer Therml')meter Timing light Torque wrench "Valva seat cutter Vernier calipers ,, . 09200-00010 Enpino Adjust Kit. 09258-00030 Hose Plug Set. - - Valve 1prlng Val'la spring Plug for the vacuum hose, fuel hose etc, ' - --
  18. 18. EG-6 ENGINE - ENGINE MECHANICAL SSM (SPECIAL SERVICE MATERIALS) -···~ Seal Packing Black or equivalent (FIPG) Timing chain cover. oil pan and .., rear oil sear retainer [ 08826-00080 - - - - - - - - - - L - - - - ~711 = AIR FILTER INSPECTION AND GLEANING 1. REMOVE AIR FILTER . ,, NOTICE: Use care to prevent dirt or other foreign matter from entering into the carburetor. 2. INSPECT AIR FILTER Visually check that the element is not excessively dirty, damaged or oily. 3. CLEAN AIR FILTER 4. Blow dirt off in the element with' compressed air from the inside. If element is torn or excessively dirty, replace the air filter. REINSTALL AIR FILTER IDLE CO CHECK AND ADJUST 1. VISUALLY INSPECT CARBURETOR _..,.M~~ (a) Check for loose screws or a loose mounting to the manifold. (b) Chnck for wear in the linkage, missing snap rings 01 axcessive looseness in the throttle shaft, Correct any problems found. 2. INITIAL CONDITIONS (a) Air· cleaner installed. (b) Normal operating coolant temperatura. (c) Ali accessories switched off. (d) Ali vacuum lines connected. (e) Ignition timing set correctly. (f) Transmission in the "N" range. (g) CO meter operates normally. 3. CONNECT TACHOMETER TO ENGINE Connect the test probe of a tachometer to the ignition coil negative{-) terminaL • • "
  19. 19. ·. • . .. .·. ENGINE - ENGINE MECHANICAL EG-7 NOTICE: • NEVER allow the tachomotl3r terminal to touch grourid as it could result in damage to tho igniter and/or ignition coil. • As some tachometers erll not compotible with this ignition system. we recommend that you confirm the compatibility of yow· unit befor~ use. 4. INSPECT IDLE SPEED Idle speed: 750 ±50 rpm If not a·s specified, adjust accroding to these proce- dure: CAUTION: • Always use a CO motor when ~djusting the idle mixture. It is not noce.n:s11ry to adjust with the idle mixture adjusting screw in most vehicles if thoy are in good condition. If a CO meter is r>ot available, £9 NOT ATTEMPT TO ADJUST WITH THE SCREW. • If a CO meter is not available and it is absolutely necessary to edjust with the Idle mixture adjusting screw. use the alternative method. 5. CHECK AND ADJUST CO CONCENTRATION AT IDLE A. Method with CO meter (a) Start the engin9. (b) Using a CO meter to measure the CO concentration in the exhaust. turn the idle speed and idle mixture adjusting screws to obtain the speclfied concentra- tion value at idle speed. ,Idle speed: ' 750 ±50 rpm (c) Check that the CO meter is properly calibrated. (d) Race the engine 30-60 seconds at about 2,000 rpm before measuring concentration. (e) Wait 1-3 minutes after rucin!l the engine to allow the ccncentration to stabilize. (f) lnsort a testing probe at least 40 em (1.3 ft) into the tailpipe, and measure the concentration ~vithin a short time. Idle CO concentretion: 1.0 ± 0.5 % • If the CO concentration is within specification • this adjustment is complete. If the CO concentration is not within specifica- tion, turn the idle mixture adjusting screw to obtain the specified concentration valt..e. • If the CO concentration cannot be corrected by adjusting the idle mixture, see tacle below for other possible causes. -~ •· ,.
  20. 20. EG-8 co 1-!C Normal High Low High -- High High ENGINE '- ENGINE· MECHANICAL<· .. TROUBLESHOOTING Problems Causes Rough idle 1. Faulty ignition: • Incorrect timing • Fouled,shorted or Improperly gapped plugs • Open or crossed Ignition wires • Cracked distributor cap 2. Leaky exhaust valves 3. Leaky cylinder Rough Idle 1. Vacuum leak: • Vacuum hose (Fluctuating HC reading) • Intake manifold • PCV line - ' • Carburetor base Rough idle 1. Restricted air filter 2. Plugged PCV valve (Black smoke from exhaust) 3. Faulty carburetlon: • Incorrect float setting • Leaking needle or seat . • Leaking power valve B. Altsrnstive method (a} Start the engine. """' (b) Set to the maximum speed by turning the id!e mixture adjusting screw. (c) Set to the idle mixture spaed by turning the idle speed adjusting screw. Idle mixture ap~ed: BOO rptn (d) Before moving to the next step continue adjust~ents (b) and (c) until the maximum speed will not rise any further no matter how much the idle mixture adjusting screw is adjusted. (e) Set to the idle spe~d by screwing in the idle mixture adjusting screw. Idle speed: 750 rpm This is Lean Drop Method for setting idle speed and mixture. •
  21. 21. ENGINE - ENGINE·MECHANIGAL ·COMPRESSION CHECK lG--·1 HINT: lfthere is lack of power, excessive oil consump- tion or poor fuel economy, measure the compre:;sion pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating • temperature. ~2. DISCONNECT DISTRIBUTOR WIRE 3. DISCONNECT HIGH-TEiISION CORDS FROM SPARK PLUGS 4. REMOVE SPARK PLIJGS 5. CHECK CYLINDER COMPRESSION PRESSURE (a) Insert a ccmpression gauge into the spark plug hole. (b) Fully open the throttle. (c) While cranking the engine, measure the compression pressure. HINT: Always use n fully chargsd battery to obtain engine speed of 250 rpm or more. - (d) Repeat steps (a) through (c) for each cylinder. .- NOTICE: This moasurement must be done In ss s.,ort a - time u possible. ., ' Compression prOsaure: 931 kPa (9.5 kgf/cm'. 135 psi) or mora .· Minimum pressure: 785 kPa (9.0 kgf/cm', 128 psi) " Difference betweon each cylinder: 98 kPe (1.0 kgf/cm', 14 psi) or lass ;· ~? (e) If tha cylinder compression in 1 or rnore cylinders is low, pour a small nmount of engine oil into the cylin- der through the spark plug hole and repeat steps (a) · through (c) for cylinders with iow compression. • If adding oil helps the compression, chances ara that the piston rings and/or ~ylindElr bore are .worn or damage. .. If pressure stays low, a valv& r:1ay be stickinr, or seating is improper, or there may be leakage past the gasket. 6. REINSTALL SPARK PLUGS Torque: 17.5 N·m (180 kgf·cm, 13 ft-lbf) 7. RECONNECT HIGH-TENSION CORDS TO SPARK . t· PLUGS B. RECONNECT DISTRIBUTOR WIRE . -
  22. 22. ''3-10 ENGINE -·ENGINE MECHANICAL ' .. Front -+- No.1 No.2 VALVE: CLEARANCE INSPECTION AND ADJUSTMENT [GI.OM•OI HINT: Inspect and adjust the valve c!aarance when the engine is cold. 1. REMOVE CYLINDER HEAD COVER (See step 8 in cylinder head removt~l) 2. SET N0.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley, and align its groove with the timing mark ·o· of the timing chain cover. (b) Check that the rocker arms on the No.1 cylinder are ''''l~ll ~nd mr,h, nrrr1.~ on fhij NoA r:ylill(lllr hill titllol. If not, turn the crankshaft one revolution (360°) and align the marks as above. 3. INSPECT AND ADJUST VALVE CLEARANCE (a) Measure only the valves indicated by arrows. Valve clearance (Cold): Intake 0.13 mm (0.005 ln.) Exhl!ust 0.23 mm (().009 in.) • Using a feeler g'luge, measure the valve clear- ance between· the valve stam and rocker arm. Loosen the lock nut "nd tum the adjusting screw to set the proper clearance. Hold the adjusting screw in position and tighten the lock nut.. • Rec:heck :he val•1e ·clearance. Tha fAster g3ugo 1 should slide with a very slight drag. Front +- =,J No.2 No.3 No.4 EX IN IN EX + +--+-+~ ~0 0 0 0 0 -- .t'Sl:.>J.I (b) Turn the crankshaft one revolution (360°) and align the mark above. 4. Adjust Qnly the valves indicated by arrows. REINSTALL CYLINDERJlEAD COVER. ., ·, ' (Seo step 5 in cylinder hoad ir.;;tallation) ·'' ~.r~>:...
  23. 23. "' ..:.' . ' " ·:..... I . .ENGINE ·ENGINEMECHANICAL tG-11 IGNITION TIMING INSPECTION AND ADJUSTMENT 1 '. 2. WARM L.:P ENGINE Allow the engine to warm up to normill operating temperature. CONNeCT TACHOMET[;R TO ENGINE (See step 3 in idle CO check and adjust) 3. INSPECT DWELL ANGLE 4. Check the dwell angle at tho engine idling. Dwell anglo: 52±6@ idle If the dwell angle is not specified, adjust the rubbing block gap. (See distributor assembly in Ignition System) DISCONNECT VACUUM HOSE (a) Disconnect the vacuum hose from the distributor. (b) Connect a plug to the vacuum hose. 5. CONNECT TIMING LIGHT TO ENGiNE 6. INSPECT AND ADJUST IGNITION TIMING With the engine idling as specified, u~e atiming light to check the timing. Ignition timing: 5±2• BTDC @.Idle If necessary, loosen the distributor bolt and turn the distributor to align the marks. R~check the timing after tightening the distributor bolt. Torque: 12 N·m (120 kgf·cm, 9 ft.fl!f) _ 7. RECONNECT VACUUM HOSE a. RECHECK IGNIT!ON T:M!NG .. With th8 engine idling as specified, us~ a timing t~:t, check the timing. ''/' Ignition timing: 12±3°BTDC@ idle 9. DISCONNECT TACHOMETER AND TIMING LIGHT IDLE SPEE'J INSPECTION AND ADJUSTMENT (See steps 1 to 4 in idle CO check and adjust) -·- ·.~:f~; .
  24. 24. EG-12 ENGINE -,..ENGINE MECHANICAL· CYLINDER HEAD COMPONENTS - -.. I Seal Washer---~ f.------Seal Washer ---Cylinder Head + 0-Ring Spar~ Plug Spark Plug ITube ---....__ Water Outlet Hosing ~ / Assembly "'""-, J Clamp~-· <V'-~-· ( '' Cover Rocker Arm and l.ll.<;~-----shaft Assembly See e EG·25 1•1 29.5 (300, 22) 2nd Turn go• 3rd Turn go• Cylinder Head X6 lntake,Exhaust Manifolds and Carburetor Assembly ,,.,., - ,.
  25. 25. ' . ·• . lntak - ENGINE ME e, Exhaust Ma If . CHANICA' n olds a d Ln Carbureto· A : . . ENGINE • ssembly · E.:l-13 • Intake Manifold ; "-
  26. 26. EG-14 ' ENGINE - ENGINE MECHANICAL l I.,.,.,I CYLINDER HEAD REMOVAL 1. DRAIN ENGINE COOLANT 2. DISCONNECT HIGH-TENS10i4 CORDS FROM SPARK PLUGS 3. REMOVE SPARK PLUGS ·--·· 4. REMOVE SPARK PLUG TUBES AND 0-RINGS 5. DISCONNECT FUEL HOSE AND VACUUM HOSES (a) Disconnect the fuel hose and vacuum hoses. ,.. (b) Remove the fuel pipe .and vacuum hose from the clamp. 6. REMOVE INTAKE, EXHAUST MANIFOLDS AND CARBURETOR ASSEMBLY (a) Disconnect the PCV hose from the cylinder head cover. (b) Remove the 6 nutR holding the manifolds to the cylin- der head. -·(c) Remove the intake, exhaust manifolds. carburetor as- sam bly and gasket. 7. DISCONNECT WATER BYPASS HOSE 8. REMOVE CYLINDER HEAD COVER Remove the 2 cap nuts. seal washers, cylinder head cover and gasket. 9. REMOVE ROCKER ARM AND SHAFT ASSEMBLY. (a) Uniformly loosen and ramove the 6 bolts and 2 nuts in several passes, in tha sequence sho)!Vn. (b) Remove the rocker arm and shaft assembly. 1C. REMOVE PUSH RODS Remove tho 8 push rods in o;der, begi11ning from tho No.1 push rod. NOTE: Arrange the push rods in correct order• 11. REMOVE CYLINDER HEAD (a) Uniformly loosen and remove the 3 head bolts in several passes. in the sequence shown. CAUTION: Head werpage or cracking could result from removing out of sequence. .:::·
  27. 27. P149SO P149Sl ENGINE - ENGINE MECHANICAL EG-15 ZI6SJS (b) Uniformly loosen and remove the 11J head bolts in several passes, in the sequence shown. CAUTION: Hond wnrpngo or cracking could result from removing out of sequence. (c) Lift the cylinder head from the dowels on the cyli;,der block and· place the head on wooden blocks on ~ bench. HINT: If the cylinder head is difficult to lift off, pry betwee;, the cylinder head and block with a screw- driver. CAUTION: Be careful not to damage the cylinder head or· b!ock surface on the cylinder haad gasket sides. CYLINDER HEAD DISASSEMBLY 1. REMOVE WATER OUTLET ~lOUSING AND REAR PLATE (a) Remove the 2 bolts, clamp. watGr outiet. housing ar~d gasket. (b) Remove the 4 bolts, rear plate ar.d ga3ket. 2. REMOVE VALVES (a) Using SST. compress the valve spring and remove the 2 keepers. SST 09202-70020 (09202-00010, 09202-01010. 09202-01020, 90 154-80004) (b) Remove the spring retainer, vaive sprir>g and valve. ~ .Ifj:~ ·:, -i~,. ffl .i!li. .. -··•j,..,. ~=· ;E(:L .....~·; ••
  28. 28. EG-16 ENGINE - ENGINE MECHANICAL (c) Using. needle- nose pliers. remove the B oil seals. (d) Remove the B spring seats. ·HINT: Arrange the valves, v.alve springs, spring seats and· spring· retainers in correct order. CYLINDER HEAD COMPONENTS INSPECTION. CLEANING AND REPAIR combustion chambers. -...... NOTICE: Be careful not to aeratch the cylinder block contact surface. '
  29. 29. ENGINE - ENGINE MECHANICAL EG-17 l t ' ' l ~~ ') ~~ ""'" .' ., ' ,• ! -.---------------------------~ ' . P2.t961 P2498l """' C. Clean valve guide bushings Using a valve guide bushing brush .and solvent, claan all the guide bushings. D. Clean cylinder head Using a soft brush and sclvent, thoroughly clean the cylinder head. - . 3. INSPECT CYLINDER HEAD A. Inspect for flatness Using a precision straight edge and thickness gauge, measure the surfaces contacting the cylinder hlock and the manifolds for warpage. Maximum warpage: Cylinder block side: 0.05 mm {0.0020 ln.) Manifold side: 0.10 mm (0.0039 ln.) If warpage is greater than maximum, replace the cylin- der head. B. Inspect for cracks Using a dye pe~etrant, check the combustion cham- ber, intake ports, exhaust ports and cylinder block side surface for cracks. If cracked, replace the cylinder head.
  30. 30. EG-18 + ENGINE - ENGINE MECHANICAL ' . 4. CLEAN VALVES (a) L!sing a gasket scraper. chip off any carbon from the • valve head. j. '''''" (b) Using a wire brush, thoroughly clean the valvo. 5. INSPECT VALVE STEMS AND GUIDE BUSHINGS (a) Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 8.010 - 8.030 mm (0.3154 - 0.3161 in.) (b) Using a micrometer, measure the diameter of the valve stem. V6lve stem diameter: Intake 7.951 - 7.991 mm (0.3130- 0.3146 in.) Exhaust 7.960 - 7.986 mm (0.3134- 0.3144 ln.) (c) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Oil clearance: - Intake Exh!USt O.OT9 - 0.079 mm 0.024 - 0.075 mm Standard (0.0007 - 0.0031 ln.) (0.0009 - 0.0030 ln.) Meximum 0.08 mm (0.0031 in.) - 0.10 mm (0•.0039 ln.) If the clearance iE greater than maximum, r13plactl ln9 valve and guide bushing. 6. IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS '(a! Using a chisel and hammer, break the valve guide bushings. (b) G•adually heat th·e cylinder head to SO - 1OO"C ;176 - 212"F). '. ' .
  31. 31. < I " <I.. .·. ., ., 'ENGINE - ENGINE MECHANICAL EG-19 Both intake and exhaust Bushing bore diameter mm '(in.) Bushing size 13.000- 13.027 Use STD (O.S118- 0.5129) 13.050- '13.077 Use 0/S 0.05(0.5138- 0.5148) V07105 Sharp 8 mm Reamer (b) · Using SST and a hammer. tap out the guide bushing. SST 09201 -1 0000 (09201 -01 080). 09950-70010 (09951-07150) (c) Using a caliper gauge, measure the bushing bore di- ameter of the cylinder head. (d) Select a new guide bushing (STD size or 0/S 0.05). If the bushing bore diameter of the cylinder head is greater than 13.027 mm (0.5129 in.). machine the bushing bore to these dimension: 13.050- 13.077 mm (0.5138- 0.5148 in.) If the bushing bore diameter of the cylinder head is greater than 13.077 mm (0.5148 in.). replace the cylinder head. , (s) Gradually heat the cylinder head to 80 -· 10o•c (176 - 212.F). (f) Using SST and a hammer, tap in a new guide bushing until the snap ring makes contact with the cylinder head. · SST 0920i -10000 (09201-01 080), 09950-70010 (09951-·07150)- (g) Using a sharp 8 mm reamer. ream the guide bushing to obtain the standard specified clearance (See step 5) between the guide bushing and valve stem.
  32. 32. . EG-20 CM0254 £M018C. ENGINE:- ENGINE'MECHANICAL 7. ·INSPECT AND·GRIND VALVES (a) (b) Grind the valve enough to remove pits and carbon. Check· that the valva i~ ground to the correct valve face angle. Valva face angle: 44.5° (c) Check' the valva head margin thickness. Stand&rd margin thickness: Intake: . 1.0 - 1.6 mm (0.039 - 0.063 ln.) Exhaust: 1.2 - 1.8 mm {0.047 - 0.071 ln.) Minimum margin thickness: Intake: 0.8 mm (0.031 ln.) Exhaust: 0.9 mm (0.035 ln.) If the margin thicknar.s is Jess than minimum, replace the valve. (d) Check the valve overall length. " Overall length: Overall Lenyth - Intake Exhi'IUSt Standard 99.90 mm 100.10 mm (3.933 ln.) (3.941 ln.) Minimum 99.4 mm (3.913 ln.) 99.6 mm (3.921 ln.) If the overall length is less than minimum, replace the valve. (e) Check the surface of the valve stem tip for wear. · If the valve stem tip is worn, resurface tho tip with a grindar or replace the valve. NOTICE: Do not grind off more than ,;inlmum. 8. INSPECT AND. CLEAN VALVE SEATS (a) Using a 45" carbide cutter, resurface the valve seats. Remove only enough metal to' clean the seats. :: ..
  33. 33. 0 EMI)186 -~ ,. .. EM01BS I I I., --] -.I Deviation -If- .::;s;; ENGINE - ENGINE MECHANICAL EG-Z1 ss• Zl6545 Width ZIOW (b) .Checl( the valve seating position. Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve <Jgainst the seat. Do not rptate valve. (c) Check the -valve face and seat for th.,so: • If blue appears 360° around the face, the valve is concentric. If not, replace the valve. • If blue appears 360" around the valve seat, the guide and face are concentric. If not, resurface the saat. • Check that the seat contact is i11 the middle of the valve face with these width: Intake 1.1 - 1.7 mm (0.043- 0.067 in.) Exhaust 1.2- 1.8 mm (0.047- 0.071 in.) If not. correct the valve se,ts as follows: (1) If the seating is too high on the valve face, uss 45" and 65" cutters to correct the seat. (2) If the seating is too low on the valve face, use 45" and 30" cutters to correct.the seat. (d) Hand-l<lp the valve and valve seat with an abrasive compnund. (e) After hand-lapping, <;!san tha valve and valve seat. 9. INSPECT VALVE SPRINGS (a) Using a steel square, measure the sc;uareness of the valve spring. Maximum squareness: 1.6 mm (0.063 ln.) If the deviation is greater than maximum, replace the valve spring. ~ ~-
  34. 34. EG-22 II ENGINE - ENGINE MECHANICAL """'' EM0281 EMT~JO I £MOOU . (b) I· (c) ·Using vemier calipers. measure the free length of the valve spring. Fr"".l.,ngth: -46~5 mm (1.831 in.) . If the free length is not as specified. replace the valve spring. Using a "Pring tester. measure the tension of the valve spring at the spe"cified installed length. lnstall9d tension: At 38.4 mm (1.512 in.): 2g6 -- 328 N (30.2 - 33.4 kgf. 66.6 - 73.6 lbf) If the instal.led tension is not as specified. replace the valve spring. 10. INSPECT ROCKER ARM AND SHAFT (a) Inspect the valva contacting surface of the rocker arm ' for wear. Correct or replace if necessary. (b) Inspect the rocker arm to the shaft· clearance by moving each rocker arm as shown in the figure. Little or no movement should be possible. If movement is felt. disassemble afld inspect. (c) Disassemble th~ ·,alva rockor shaft <~ssembly. HINT: Arrange th6 rocker arms and rocker supports in correct order. .. If the valve contacting surface of the rocker arm is worn. resurface it with a valve refacer and oil stone or ' replace the rocker arm. •
  35. 35. ,....,.. . ~ ..•.•,,,_,,,.,••:·.-·r,· ''". ~,., ' ..... Valve Rocker Shaft V&lv.o Recker Support (1) Valve Rocker Arm No.1 {2) ENGINE - ENGINE MECHANICAL. EG-23 ·Inspect the oil clearance between the rocker arm and shaft. , • Using a caliper gauge. measure the inside diarne- . tar of the rocker arm. , Rocker arm inside diameter: 16.00 - 16.02 mm (0.6299 - 0.6307 in.) • Using a micrometer, measure the diameter of the rocker shaft. Rocker shaft diameter: 15.97 - 15.99 mm (0.6287 - 0.6295 in.) • Subtract the rocker shaft diameter measurement from the inside diam<'lter measurement of the rocker arm. Standard oil clearance: 0.02 - 0.04 mm (0.0008 - 0.0016 in.) Maximum oil clearance: 0.04 mm (0.0016 In.) If the clearance exceeds maximum. rsplace the rocker arm and shaft. (e) Assemble the valve rocker shaft ~ssembly as shown. (2) (1) (2) Valve RoGkAr Shaft As$ambly • ~onf Valve Rocker Arm Compression Spring Valve Rocker Arm No.2 Valve Rocker Arm No.1 (1) (2)
  36. 36. . EG-24 ENGINE·- ENGINE MECHANICAL: 0.30 mm l_·------------------------~n~~~ SST 1"24951 11. INSPECT PUSH RODS (a) Place the push rod on V- blocks. (b) Using a dial indicator, measure the circle runout at the · center of the push rod. Maximum circle runout: 0.30 mm (0.0118 in.) !f the circle runout exceeds the maximum, replace the push rod. 12. INSPECT INTAKE AND EXHAUST MANIFOLDS Using a precision straight edge and feeler gauge, mea- sure the surface contacting the cylinder head for war- page. Maximum warpage: 0.20 mm (0.008 in.) If warpage is greater than maximum, correct or re- place the manifolds. CYLINDER HEAD ASSEMBLY --· HINT: • Thoroughly clean all parts to be assembled. • Before installing the parts, apply new engine oil to ..all sliding and rotating surfaces. • Replace all gaskets, 0-rings and oil seals with new ones. 1. INSTALL VALVES (a) Install 8 new oil seals with your hand. (b) Install theso parts: (1) Valve (2) Spring seat (3) Valve spring (4) Spring retainer (c) Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202-70020 (09202-01010. 09202-01020, 90154-80004) .· '"
  37. 37. " ". P2S379 ~24951 4 2 5 ENGII~E - ENGINE MECHANICAL Z16537 (d) Using a plastic-faced hammer, lightly tap the valve stem tip to assure proper 'fit. 2. INSTALL WATER OUTLET HOUSING AND ENGINE REAP. PLATE ' (a) Place a new gasket and install the engine rear plate with 4 boi ts. Torque: 8 N·m (80 kgf·cm, 61i ln.·lbf) (b) Place a new gasket and install the water outlet hous- .I§. ing with 2 bolts. Torquo: 19 N·m (195 kgf-cm, 14 ft·lbf) CYLINDER HEAD !NSTALLAT!ON 1. INSTALL CYLINDER HEAD A. Place cyiincler head on cylinder block (a) Place a new cylinder head gasket in position on the cylinder block. NOTICE: Be careful of the lnstollution direction. (b) Place the cylinder head in position on the cylinder head gasket. B. Install 12 pointed head cylii1dt~r head bolts HINT: • The cylinder head bolts are tightened in 2. pr~­ gressive steps (steps (b) and (d)).' • If any bolt is broken or deformed, replace it. . ia) Apply a light coat of engine oil on the thrllads tnd under the heads of the cylinder hGad b.:>Its. (b) Install and uniformly tighten the 10 cylinder head bolts on each cylinder head, in several passes, in the sequence shown. Torque: 29.6 N·m (300 kgf·cm, 22 ft·lbf) If any of the cylinder head bolts does not meGt the torque specification, replace the cylinder head bolt. (c) Mark the front of the cylinder head bolt head with paint.
  38. 38. EG-26 ENGINE I:NGINI'. MCCII-1NICIL ~44lfiJ(f$JJ:~ ~QJ·JQ~-J '---, :; 3 ?' I/ I _f ~P255~J .............~ 16543 P249<CS 216"..44 (d) Retighten the cylinder head bolts by so• in he numer- ical order shown. - (e) Retighten the cylinder head bolts by an additional so•. (f) Check that the painted mark is now facing rearword. c. (a) {b) 2. 3. (a) (b) 4. 5. Install recessed head cylinder head bolts Apply a light coat of engine oil on the thn:.ads and ur.dor the heads of the cylinder head bolts. Install the cylinder head boits. as shown. Torque: 19 N-m (1 95 kgf-crn. 14 ft·lbf) INSTALL PUSH RODS Install the 8 push rods. INSTALL VALVE ROCKER SHAFT ASSEMBLY Place the rocker shaft assembly on tha cylinder head. Install and uniformly tighten the 6 bolts and 2 nuts in several passes. in the sequence :;hov.;n. Torque: 21 N·m (210 kgf-cm, 16 ft·lbf) CHECK AND ADJUST VALE CLEARANCE (See valve clearance inspection and adjustment) INSTALL CYLINDER HEAD COVER (a) Install the gasket to the cylinder head cover. (b) Install the cylinder head cover with 2 seal washers and cap nuts. Torque: 2 N-m (25 kgf-cm, 18 in.-lbf) 6. INSTALL INTAKE. EXHAUST MANIFOLDS AND CARBURETOR ASSEMBLY (a) Install a new gasket, the intake, exhaust manifolds and carburetor assembly with the 6 nuts. Torque: 49 N-m (50_0 Y.gf-crn, 36 ft-lbf) (b) Connect the PCV hose to the cylinder head cover. 7. CONNECT WATER BYPASS HOSE , 8. CONNECT FUEL HOSE ANO VACUUM HOSES 9. INSTALL SPARK PLUG TUBES AND 0-RINGS (a) Install 4 new 0-rings to the spark plug tubes. (b) Install the spark plug tubes to the cylinder head. 10. INSTALL SPARK PLUGS Torque: 17.5 N-m (180 kgf·cm, 13 ft-lbf) 11. CONNECT HIGH-TENSION CORDS TO SPARK PLUGS 12. FILL WITH ENGINE COOLANT 13. START ENGINE AND CHECK ·FoR LEAKS 14. CHECK ENGINE OIL LEVEL .. .. ' -. •.
  39. 39. " ~ .< ·. ,. ·' ., Fan ENGINE - ENGINE MECHANICAL . TIMING CHAIN COMPONENTS FOR REMOVAL AND INSTALLATION Timing Chain COVM Water PumpPulley I I ~ Crankshaft Pulley l'ming Chain +Gasket --;.......... I ...................... I I I I . __ J -- EG-27 --------- Distributor -- Assembly Valve Lifter . ,___ Camshaft Sprocket Thrust Plale .. -:::::~--- ,----- ----~:11 --d)"--- Chain Tensioner ',,'"___ ~~j ---- , +Gasket ---- 1/JP ' --- -- "" Crankshaft Sprocket • I Vibration Damper JN·m (kgf·cm, ft·lbf)J: Specified torque + Non-reusable part +Gasket---.;, Drain Plug---~::> ~ I t----+O·Ring .,
  40. 40. EG-28 ENGINE'-· ENGINE MECHANICAL·. , TIMING CHAIN AND CAMSHAFT .REMOVAL --·1 1.. REMOVE WATER PUMP PULLEY AND DRIVE BELT. {See water pump removal in Cooling System) 2. REMOVE CYLINDER HEAD {See cylinder head removal) 3. REMOVE DISTRIBUTOR (See distributor removal in Ignition System) 4. REMOVE FUEL PUMP {See fuel pump removal in Fuel System) 5. REMOVE OIL PAN (See-oil pump remove! in Lubrication System) 6. REMOVE CRANKSHAFT PULLEY {a) Using SST, remove the pulley bolt. SST 09213-1401 0 (91651-60865), . 09330-00021 (09330-00030) {b) Remove the crankshaft pulley. HINT: If necessary, remove the pulley with SST. SST 09950-4001 0 (09957 -0401 0), 09950-50010 (09951-0501 o. 09952-05010, 09953-05020, 09954-050:.10) 7. REMOVE TIMING CHAIN COVER (a) Remove the 8 bolts and nut. (b) Using a pl~stic faced hammer, remove the timing chain covor and gaskat. 8. INSPECT TIMING CHAIN SLACK Mensure the timing chain slack. Minimum slack: At 98 N (1 0 kgf, 22 lbf) tanslon: 13.5 mm (O.G31 ln.) If the sla.ck is lass than minimum, replace the timing chain and sprockets. ·, . ' ·~ -· j • '. : '
  41. 41. ENGINE :_·ENGINE MECHANICAL EG-29 .. : .. -- •• Cylinder Head Bolt -, '-----·---------...::.:.""'::=::..J' I 1-;zsj.-:j.':j.·:;::;::j::~f--1-r= I~ --~ .'---,--~ Lc::: J ·l:l~ · ;REMOVE CHAIN TENSIONER AND VIBRATION DAMPER 10. REMOVE TIMING CHAIN AND CAMSHAFT SPROCKET (a) ·Using SST, remove the camshaft sprocket set bolt. . SST 09960-10010 (09962-01000, 09963-01 000) (b) Remove the timing chain and camshaft sprocket'to~ gather. 11. REMOVE CRANKSHAFT SPROCKET Using a screwdriver, remove the crankshaft sprocket. If the crankshaft sprocket can not b~ removod with a screwdriver, use SST. SST 09950-40010 (09952 -04010, 09954-0401 0, 09955-04010, 09957-0401 0), 09950-50010 (09951 -0501 0, 09953-05020) 12. REMOVE VALVE LIFTERS HINT: Keep the valve lifters in correct order. 13. REMOVE THRUST PLATE AND CAMSHAFT (a) Remove the 2 bolts and thrust plate. (b) Temporarily install the cylinder headibolt to the cam- shaft. (c) While turni11g the camshaft, slowly pull out so as not to damage the bearing. TIMING CHAIN AND CAMSHAFT COMPONENTS INSPECTION 1. (a) (b) (c) INSPECT TiMING CHAIN AND SPRPCKETS Measure the length with the chain fully stretched. Maximum o:hain Glongatlom 272.2 mm (1 0.736 ln.) If the elongation is greater than meximum, replace tho chain. HINT: Make the same measurements pulling at 3 or more places selected at random. Warp the chain around the sprocket. Using vernier calipers, measure the sprocket diameter with the chain. NOTICE: Vernier calipers must contact the chain rollers for measuring. Minimum sprocket diameter (w/chaln): Crankshaft: 69.4 mm (2.339 ln.) Camshaft: 113.8 mm (4.480 ln.)
  42. 42. EG-30 ENGINE- ENGINE MECI;JANJCAL EM2011 £M25J8 !f the·diam13ter is Jess than minimum, replace the cha and 2 sprockets. 2. INSPECT CHAIN TENSJONER AND VIBRATION DAMPER ·;, Using vernier calipers, measure the diameter of eac.. .tensioner and vibration damper. Minimum thickness: Chain tensinner: 12.0 mm (0.472 in.) Vibration damper: 4.0 mm (0.157 in.) If the diameter is less than minimum. replace the chair tensioner and/or vibration damper. 3. INSPECT CAMSHAFT A. Inspect camshaft for runout (a) Place the camshaft on V- blocks. (b) Using a dial indicator. measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle run out is greater than maxirnurr:. replace the camshaft. B. Inspect cam lobes c. (a) Using a micrometer, measure' the cam lobe height. Standard cam lobe height: ' · Intake: 36.47 - 36.57 mm (1.4358 - 1.4397 in.) Exhaust: 36.37- 36.47 mm (1.4318- 1.4358 in.) Minimum cam lobe height: Intake: 36.17 mm (1.4240 ln.) Exhaust: 36.07 .mm (1.4201 ln.) If the cam lobe height is greater than minimum, re- place the camshaft. Inspect camshaft journals Using a micrometer, measure the journal diameter. Journal diameter (from front side): STD No.I 43.209 - 43.225 m.;, (1.7011 -.1.7018 in.) STD No.2. 42.954- 42.970 mm (1.6911 - 1.6917 in.) STD No.3 4:1.704- 4:1.720 mm (1.8873- 1.68t9ln.) STD No.4 42.459- 42.475 mm (1.6716- 1.6722 in.) UfS 0.125 No.1 43.085 - 43.095 mm (t .6963 - 1.6967 in.) U/S 0.125 No.2 42.837- 42.647 mm (1.6865- 1.6969 i~-y-- U/S 0.125 No.3 42.587 - 42.597 rnm (1.6767 - 1.6770 in.) U/S 0.125 No.4 42.337- 42.347 mm (1.6669- 1.6672ln.) U/S 0.25 No.I 42.960- 42.970 mm (1,6913- 1.6917 in.) U/S 0.25 No.2 42.712-42.722 mm (1.6816- 1.6920 ln.) U/S 0.25 No.3 42.462- 42.472 mm (1.6717- 1.6721 i~.) U/S 0.25 No.4 42.212-42.222 mm (1.6619- 1.6623 in.) If the journa! diameter is not as specified, check the oil clearance. (See camshaft and camshaft bearing inspection and repair in cylinder block)
  43. 43. • .. : ' ENGINE ::...· EN.GJNE MECHANICAL· EG-31 "''"' 4." INSPECT THRUST PLATE (a) Install the thrust plate and camshaft sprocket to the cam'shaft. (b) Install and torque the set bolt. Torque: 59 N·m {600 kgf.cm, 44 ft.Jbf) (c) Using a feeler gauge, measure the camshaft thrust clearance betwe<Jn the thrust p!ate and camshaft. Thrust clearance: STD: 0.07 - 0.14 mm (0.0028 - 0.0055 in.) MS)dmum: 0.3 mm (0.012 in.) If clearance is gre<:ter than the maximrJm, replace the thrust plate and/or' sprocket. CRANKSHAFT FRONT OIL SEAL REPLACEMENT HINT: There are 2 methods (A and 13) to replace the oil seai which are as follows: REPLACE CRANKSHAFT FRONT OIL SEAL A. If timing chain cover is removed from cylinder block: (a) Using a screwdriver, pry out the oil seal. . (bi Using SST and a hammer, tnp in a new oil seal unti: its S!Jrface is flush with the timing chain co.ver edge. SST 09g2;3-46011 (c) Apply MP grease to the oil seal lip.- B. If timing chain cover is installed to the cylinder block: (a) Using a screwdriver, pry out the oil s&al. NOTICE: Se careful not to damage the ~rankshaft. Tape ihe. screwdriver tip.
  44. 44. EG-32 Front <? ENGINE .,-.·EN.GINE.MECHANICAL (b) Apply tvjP grease to a new oil seal lip. (c) Using S!)T and a hammer, tap in the oil seal until its • surface is flush with the timing chain cover edge. SST 09223..:.46011 -....,..,1 TIMING CHAIN INSTALLATION 1. INSTALL CAMSHAFT AND THRUST PLATE (a) Apply light coat of engine oil of the camshaft. (b) Temporary install the cylinder head bolt to the cam- shaft. (c) Install the. camshaft, using care not to damage the camshaft bearing. (d) Install the thrust plate with 2 bolts as shown in the 2. illustration. Torque: 8 N-m (80 kgf-cm, 69 ln.·lbf) INSTALL CRANKSHAFT SPROCKET (a) Apply light coat of engine oil on the shaft portion of the crankshaft sprocket. 3. INSTALL TIMING CHAIN AND CAMSHAFT SPROCKET (a) Set the No.1 position to TDC. (b) Align the camshaft dowel pin nearb·r the mark on the thrust plate. (c) Install tho camshaft sprocket to tha timing chain. HINT: Align the timing chain and camshaft sprocket timing marks. (d) Install the timing chain to the crarrkshaft sprocket. HINT: Align the timing chain and crankshaft sprocket timing r.1arks. (e) Install the camshaft sprocket with the timing chain. (f) Using SST, install the bolt to the camshaft sprocket. SST 09960-10010 (09962-01000, 09963-01000) Torque: 59 N-m (GOO !lgf-cm, 43 ft-lbf) 4. INSTALL CHAIN TENSIONER AND VIBRATION DAMPER Install the chain tensioner :-;,d vibration damper with 4 bolts. Torque: 8 N·m (80 kgf-cm, 69 ln.-lbf) NOTICE: Apply tho tensionor with oil before installation.
  45. 45. ' 0 ., " . .- ; ' ENGINE - ENGINE MECHANICAL. I:G-33 ""''" 5. (a) (b) 6. 7. (a) (b) INSTALL TIMING CHAIN COVER Place anaw gasket to the front end plate. Install the timing belt cover with fl'bolts ,and nut. Torque: 10 mm head: 8 N·m (80 kgf-cm, 69 in.·lbf) 12 mm head: 19 N·m (19S kgf-cm. ·14 ft-ibf) INSTALL VALVE LIFTER HINT: Apply light coat of engine oil of tha valve lifter. l,i INSTALL CRANKSHAFT PULLEY Install the crankshaft pulley. Using SST, install and torque the pulley bolt. SST 09213--14010 (91651-60865), 09330-00021 (09330- 00030) Torque: 88 N-m (900 kgf.cm, 65 ft·lbf) 8. INSTALL OIL PAN (See oil pump installation in Lubrication System) g_ INSTALL FUEL PUMP (See fuel pump installation in Fuel System) 10. INSTALL DISTRIBUTOR (See distributor installation in Ignition System) 11. INSTALL CYLINDER HEAD (See cylinder head installation) 12. INSTALL WATER PUMP PULLEY AND DRIVE BELT (See water pump installation in Cooling System)
  46. 46. EG-34 ENGIN'E- ·ENGINE-MECHANICAL CYLINDER BLOCK COMPONENTS - · I Z ~- -------====Piston Ring (No.1 Compression) ~Piston Ring (No.2 Compresskm) Oil Filter and Piston Ring_r-_§ Bracket Assembly (Side Rail) ~ Piston Ring (Expander) RH Engine M~unting ~ 0 Piston Pin Bracket ~ 'GI,) ~~ Upper Main Bearing---· Crankshaft-----------..,!~ Lower Crankshaft _______ -----.. Thru~~~:::h:_r- - - ~4+ Gasket---?l;~ <V~~-z;'.1~;'· . ' 6 Oil Strainer + Non-reusable part. *Precoated part [ffffiJkgf·cm, ft·lbf)j: Specified torque +Gasket 'oil Pan See page EG-53 111 24.5 (250, 18) 2nd Tum so• '=
  47. 47. ~ :.' '- - •.• • - j~ .[ • 1 i ' ENGINE - ENGINE MECHANICAL PREPARATION FOR DISASSEMBLY 1. REMO'vt: FLYWHEEL 2. REMOVE REAR END PLATE 3. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY 4. REMOVE CYLINDER HEAD (See cylinder heed removal) 5. REMOVE WATER PUMP (See water pump removal in Cooling System) 6. REMOVE ALTERNATOR AND BRACKET 7. REMOVE TIMING CHAIN (See timing chain removal) 8. REMOVE OIL PUMP (See oil pump removal in Lubri.::stion System) 9. REMOVE N0.2 ENGINE HANGER 10. REMOVE OIL DIPSTICK 11. REMOVE OIL FILTER BRACKET AND FILTER ASSEMBlY EG-35 Remove the 2 bolts. the oil filter br<~c:ket. filtGr assem- bly and gasket. 12. REMOVE ENGINE DRAIN COCK 13. REMOVE FRONT END PLATE Remove the 2 bolts, front end plete' and gaske·t 14. REMOVE ENGINE MOUNTING ERACKETS · CYLINDER BLOCK DiSASSEMBLY 1. REMOVE REAR OIL SEAL RHAINER Remove the 5 bolts. retainer and gasket. 2. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving tho connecting rod back and forth. Standard thrust clearance: 0.150 - 0.330 mm (0.0059 - O.C130 in.) Maximum thrust clearance: 0.30 mm (0.0118 ln.) If the thrust clearance is greater than maximum, re- place the connecting rod assembly. If nocessa;y, re- place the crankshaft.
  48. 48. I EG-LJS ,..-,--· Plastigage ENGINE.- 'ENGINE· MECHANICAL 3. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE ··(a) Check the matchmarks on the connecting rod and cap to ensure correct reassemi.:y. (b) Remove the 2 connecting rod cap bolts. (c) Using the 2 removed connecting rod bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted with the .con- necting rod cap. (d) Clean the crank pin and bearing. (e) Check the crank pin and bearing for pitting and scrat~ · ches. If the crank pin or bearing is damaged, replace the bearings. If nece:;sary, grind or replace the crankshaft.. (f) Lay a strip of Plastigage across the crank pin. (g) Install the connecting rod cap with the 2 bolts. (See step B in cylinder block assembly) Torque:· 1st: 24.5 N·m (250 kgf·cm, f8 ft-Jbf) 2nd: Turn go• NOTICE: Do not turn til<. cronbhaft. (hj Ramovo the 2 bolts and connecting rod cap. (Sa~ procedure (b) and (c) abova) (i) Measur~ the Plastigage at its widest point. Standard oil c!oarance: STD: 0.020 - 0.048 mm (0.0008 - 0.0019 ln.) U/S 0.25, U/S 0.50 end U/S 0.75: ·. O.o19 - 0.068 mm (0.0007 - 0.0022 ln.) Maximum oil clearance: 0.08 mm (0.0031 ln.) If the oil'. clearance is greater than maximum, replace . the bearings. If necessary, grind or replace the crank- shaft.
  49. 49. ENGINE Mark ~1, 2 or 3 ( I M•• -,~'·'"'' (Protrusior.) Ul 4. (a) (b) ' (c) •.. -• ' 5. 6. - 2 ~ (a) ··• ..~ ENGINE MECHANICAL EG-37 HINT: If using a standard bearing. replace it with one having the same number marked r,n the connocting ·rod cap. There are three sizes of standard hearings, marke<1 '1", "2" and '3" accordingly. Standard sized bearing cantor well thickness: STD-Mark ~ 1.488 - 1.490 mm (0.05S5 - 0.0587 ln.) STD Mark 2 1.490 - 1.494 mm (0.0587 - 0.0588 in.) STD Mork 3 1.494 - 1.498 mm (0.0588 - 0.0590 ln.) u;s o.25 1.807 - 1.813 mni (0.0833 - 0.0835 in.) u;s o.so 1.732 - 1.738 mm (0.0682 - 0.0684 in.) u;s o.75 1.857 - 1.883 mm (0.07~ 1 - 0.0733 ln.) Completely remove the Plastigage. REMOVE PISTON AND CONNECTlNf> ROD ASSEMBLIES Using a ridge reamer, remove the all carbon from·the top of the cylinder. Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from daml'ige. Push the piston, connecting rod assembly and upper bearing through the top of the cylindGr bloc;k. HINT: • Keep the bearings, connecting rod and cap to- gather. • Arrange the piston a11d conn&cting rod al;sernbl- ies in correct order. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back ~nd forth with a screwdriver. Standard thruat clearance: 0.040 - 0.242 mm (0.0016 - 0.0095 ln.) MGxlmum thrust clearance: 0.30 mm (0.0118 ln.) If the thrust clearance is greater than maximum, re- plaol' tha thrust washers as a sat. Thruot washer thlckne..: STD 2.430 - 2.480 mm (O.OU57 - 0.0978 ln.) 1 I0/S 0.126 2.490 - 2.540 mm (0.0980 - 0.1 000 ln.) REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE Uniformly loosen and remove the 10 main bearing cap bolts in several passes, in the sequence shown.
  50. 50. EG-38 Plastigage ENGIN'E '-' ENGINE MECHANICAL (b) Using the'removecl main bearing· cap bolts. pry the • main bearing cap back and forth. and remove the main · bearing caps. lower bearings and lower thrust wash- ers (No:3 main bearing cap only).. HINT: • Keep the lower bearing. and main bearing cap together. • Arrange the main bearing caps and lower thrust washers in correct ord.er. (c) Lift out the crankshaft. HINT: Keep the upper bearing and upper thrust wash- ers together with the cylinder block. (d) Clean each main journal and bearing. (e) Check each main journal and bear.ing for pitting and scratches. If the journal or bearing is damaged, replace the bear- ings, If necessary, grind or repiace the crankshaft. (f)· Place the crankshaft on the cylinder block. (g) Lay a strip of Plastigage across each journal. (h) Install the 5 main bearing caps witb the 10 bolts. (Soe step 4 in cylinder block assembly) Torq·uo: 59 N·rn (600 kgf.cm. 43 ft·lbf) NOTICE: Do not turn the crankshaft. (i) Remove the 10 bolts and 5 main bearing caps. (See procedure (a) and (b) above) (j) Measure the Plastigage at its widest point. Standard clearance: STD 0.016 - 0.040 mm (0.0006 - 0.0016 in.) U/S typo 0.017 - 0.071 mm (0.0007 - 0.0028 in.) Maximum: 0.10 mm (0.0039 in.) - If the oil clearance is greater than maximum. replace the bearings. If necessary. grind or replace the crank- shaft.
  51. 51. .· ~·· .. "! •. . ' ENGINE - ENGINE MECHANICAL · · ·· EG-39 . ·- .. ' .~ . : '• ... ·.. . .. 1:'/0,3 r=-. No!~'{t"'"' · ' , ~/.%" Mark ~ :r;::.. 0 6,7or8 j~ ;---. LjJ """ . P25&51 P25584 P25681 ).)>:::;;;>Mark 3,4,5,6 or 7 ZI6SJS ·HINT: If l'!Sing ·a standard bearing, replace with one having the same number. If the number of the bearing· c2nnot be determined, select a be·aring from the table according to the numbers imprinted on tf':q r.vlinder block· and·crankshaft. ThtJre are 5 sizes of standard· bearings, marked "3", "4", ·s·."6" ond "7" accordingly. NumbP.r marked Cylinder block 6 7 8 Crankshaft 1 213 t 12 3 1 2 Use bear!ng 5 4i3 6!5 4 7 6 EXAMPLE: Cylinder block "6'' - Crankshaft "2" = Total number 4 (Use bearing "4") Reference: Cylinder block main Journal bore diamotAr: Mark 6 54.004 - 54.012 mm (2. J201 - 2.1265 in.} Mark 7 54.012- 54.020 mm (2.1255- 2.1268 in.) Mark 8 54.020- 54.028 mm (2.1268- 2.1271 ln.) Crankshaft Journal diamEltor: Mark 1 49.976 49.984 mm (1.9796- 1.9679 in.) Mcrk 2 49.984 49.992 mm (I .967~ - 1.9682. in.J· Mark 3 49.992 50.000 mm.(l.9d82 - 1.96851o.) u;s o.25 49.733 - 49.743 mm t1.958Cl- 1.9584 in.) U/S 0.50 49.483 - 49A03 mm (!.9481 - 1.9485 in.) Standard :oizod bearing cent'er Wfl!l.t:hicKnoss: Mark 3 I.990 - 1.994 mm (0.0703 - 0.0785 ln.l 3 5 ---Mark 4 1.994·- !.9S8 mm (0.0785 - 0.0787 ln.) ,_f~rk. s· 1.998 2.002 mm. (_O.o787 -· 0.0708 l n R Mark B 2.002 - 2.006 mm (0.07ell - 0.0790 ln.) ; Made 7 2.006- 2.0!0 mrn (0.07PO- 0.0791 in.) • ~- IJ ,.. 0 2r.:: ----··' J., ••l 2.112 - 2.I2~ m:n t0.0~3 I - 0.0835 lr.J L:u;so.so - 2.237 - 2.247 mm (O.OU8l - 0.0885 _ln.) (k) Corupletely remove tha Plastig~ge. .7. - REMOVE CRANKSHAFT (a) ·Lift out the crankshaft. 1 J (b)· Remove the upper bearings and· upper thrust washers from·.the cylinder block. HINT: Arrange the main bearing caps, bearbgs and thrust washers in correct order. ~~
  52. 52. ~~.. • i .. r;. EG-4011:). I .. ENGINE :.-·.ENGINE MECHANICAL ,.. ,-------------------~~~~~~~~~~~~~~~--------------- P25!'i2J f'25524' ·-- o o·o o·o o·o o rf- '9!: ~ ~ '~~-~. ./ ~ _ ---:="""' :· . CYLINDER· BLOCK INSPECTION ,... " ... ··.: . ,... 1- CLEAN·CYLINDER BLOCK A. Remove gasket material --11 .. · Using a gasket scraper, remove all the gasket material from the top surface of the cylind~r block. B. Clean cylinder block Using a soft.brush and solvent; thoroughly clean the cylinder block. 2. INSPECT TOP SURFACE OF CYLINDERBLOCK FOR . FLATNESS Using a precision straight edge and thickness gauge, measure the surfaces contacting the cylinder head gasket for warpage. Maximum warpago: 0.05 mm (0.0020 ln.) If warpage is greater than maximum, replace the cylin-. der block. 3. INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches. If dMp sc.ratc.hes ar& pr&sent. re&CJrll IJ(( th6 ~ l.fill,· ders. If necessary, replace the cylinder block. 4... INSPECT'CYLINDER BORE DIAMETER HINT:· There are 3 sizes of the stanqard cylinder bore diameter; marked *1*, *2* and ·a•·accordingly. The mark is stamped on the top of the .cylinder block.
  53. 53. ., . -'.- ... Cf'jFront,._ :1] ENGINE - ·ENGINE'MECHANICAL· ·· · EG-41 CD Thrust Direction <VAxial Direction 5. •Using ..a ·cylin.der gauge, m·easure the cylinder bore diameter at positions A, B and C in the thrust and axial directio(ls. Standard diameter: STD:Merk 1 80.500- 8C.b10 mm 13.1693··- 3:16971n.) STD Mark 2 60.51 0 - 80.520 mm .(3.1697 3.1701 in.) STD Mark 3 80.520-80.530 mM (3.1701 - 3.1705 in.) 0/S 0.50 81.000 - 81.030 mm (3.1890 - 3.1902 i,,,) Moxlmum diomotor: STD 0/S 0.50 80.728 mm (3.178~ in.) ---'-----1 81.228 mm (3.1g79 i.1.) If the diameter is greater than maximum, rebore ""the 4 r:ylindars. If necessary, replace the cylinder bioci<. REMOVE CYLINDER RIDGE If the wear is Jess than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the t;:YI!nder. ......._" PISTON AND CONNECTING ROD ASSY DlSASSEMBLY 1. CHECK FIT BETWEEN PISTON AND PJSTON.Pm Try to move the piston back and f~rth on the pi~ton p!n. If any movbm~nt is felt, replace the pi3ton and ·pin cS' a sat. 2. · · REMOVE PISTON RINGS (a) Using a piston ring expander, remov& the 2 compres- sion rings.
  54. 54. .~· .'- ,, EG-42 ENGINe·~. ENGINe·MECH-ANIC>AL · P'Z5527 (b) ·"Remove· the 2 side rails· and oil·ring by hand. .. ,HINT: · .Arrange the rings in correct order only. 3. DISCONNECT CONNECTING ROD FROM PISTON Using SST. press out· the piston pin from the piston. Remove the connecting rod. SST 09221-25025 {09221-00020, 09221-00030. 09221-00040.09221-00170. 09221-00210) HINT: • • The piston and pin are a matched set. Arrange the pistons. pins. rings, connecting rods and bearings. in correct order. PISTON AND CONNECTING ROD INSPECTION 1. CLEAN PISTON {a) Using a gasket scraper, remove the carbon· from the piston top. {b) Using a groove cleaning tool or broken ring, clean the piston ring grooves. {c). Using. solvent and a brush. thoroughly clean the piston. NOTICE: Do not use a wire brush.
  55. 55. l : t i '• . -. ,, ,_ .• .- Front Mark P2Si1& P2$5SS ' ....' . ··...; ~ . - ENGINE "-: ENGINE MECHANICAL EG-43'· · , 2 or3 216541 ., 2: · 'JNSPECT'PISTON I i I I A. 'Inspect piston oil clearance HINT: There are three sizes of tha standard. piston diameter, marked 1, "2" and "3" accordingly:'The mark- is stamped on the piston top. {a) Using a micrometer, measure the piston diameter at ring angles to the piston hoad side, 8 mm (0.31 in.) from the piston pin center line. Piston diameter: STO Mark 1 80.358 - 80.368 mm (3.1637 - 3.1641 In,) STO Mark 2 80.308 - 80.378 mm (3.1641 - 3.1645 in.) STD Mark 3 80.378 - 80.388 mm i2.1645 - 3.1649 in.) 0/S 0.50 80.858 - 80.888 mm (3.1 &34 - 3.1846 in.) (b) Measure the cylinder bore diameter in the thrust di- rections. {See step 4 in cylinder blo~k inspectionf (c) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.132 -·0.152 mm (0.0052- 0.(1060 lr..) If the oil clearance is greater thnn maximum. replace all the 4 pistons and rebore all the 4 cylinders. If necessary, replace the cylir)der block. HINT (Use new cylinder block): Use a piston with the · same· number· mark as the cylinder bore diameter marked on the cylinder blo~k. .B; Inspect piston ring groove clearance Using··a· thickness gauge, measure thA clearance be- tween· new piston ring and the wall of the piston ring groove. Ring groove clearance: No.1: 0.030 - 0.070 mm (0.001 2 - 0.0028 in.) No.2: 0.020 - 0.060 mm {0.0008 - 0.0024 in.) If the clearance is greater thon m2ximum, replace the piston.
  56. 56. EG-44' .. · ENGINE·:-.·ENGINE MECHANICAL. . ·. ·.... ...:· .c. · lnspect,piston..ring end gap (a). lnsert..thecpiston ring into the cylinder bore. · · ·· (b) Using a piston, push the piston ring·· a little beyond the .· 125 mm I · bottom of.the ring tr~vel, 125 inm (4.92 ·in.} from the top of the cylinder block. (c) Using a thickness gauge, measure the end gap. End gap: Item' Standard Maximum . 0.23 - 0.33 mm No.1 (0.0091 - 0.0130 ln.) 0.33 mm (0.0130 ln.) 0.33 - 0.48 mm No.2 (0.0 130 - 0.0189 in.) 0.48 mm (0.01_89 in.) 0.18- 0.38mm Oil (Side roil) (0.0071 -0.0150 ln.) 0.38 mm (0.0150 in.) "If the and gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, reb'ore all the 4 cylinders or replace the cylinder block. 3. INSPECT CONNECTING ROD. . A. Inspect connecting rod alignment Using a rod aligner and thickness gauge, check the connecting rod alignment. - • Che~k for bend. Maximum bond: 0.05 mm (0.0020 ln.) per 100 mm (3.94 ln.) I I ~~~~0~35~£~M~0,~88~--------·------~ If bend is greater than maximum, replace the connect- ing rod assembly. • .Check for twist Maximum twist: 0.05 mm (0.0020 ln.) per 100 mm (3.94 ln.) If twist is greater than maximum, replace the connect- ing rod assembly.
  57. 57. . • • ' • -- •J._, I-' ' '-J 1 About 20mm ENGINE -'ENGINE MECHANICAL t;·4b rc67'8 B. Inspect connecting rod bolts Using vernier calipers. measure tile minimum diame- ter of the compressed bolt at tho measuring point.. Standard diameter: 8.860 - 9.000 mm (0.3488 - 0.3543 in.) Minimum diameter: 8.60 mm (0.3386 in.) If the diameter is Jess than minimum, repl2ce the ~£ connecting rod bolt. CYLINDER BORING 1. 2. (a) (b) HINT: • Bore all the six cylindars for the oversized piston outside diameter. o Replace all the piston rings with ones to match the oversized pistons. SELECT OVERSIZED PISTONS Oversized piston diameter: 0/S 0.50 80.858 - 80.888 mm (3.1834 - 3,1846 in.) CALCULATE AMOUNT TO BORE CYLINDERS Using a micrometar, measure the p'iston diamet3r at right angles to the piston head side, 8 mm (0.31 in.) from the piston pin center line. Calculate the amount of each cylinder is to be rebored as follows: Size to be reborod = P + C ·- H P = Pi•ton diameter C = Piston clearance 0.040 - 0.060 mm (0.0016 - 0.0024 in.) H = Allowance for honing 0.20 mm (0.0008 ln.) or lft$1 3. BORE AND HONE CYLINDER TO O:ALCULATED DIMENSIONS Maximum honing: 0.02 mm (0.0008 in.) NOTICE: Exce.. honing will dastroy the flniohad round- neal. -1'-IC CRANKSHAFT INSPECTION AND REPAIR 1. INSPECT CRANKSHAFT FOR RUNOUT (a) Place the crankshaft on V-blocks. (b) Using a dial indicator, measure the circle runout at t .1e center journal. Maximum clrclo runout: 0.03 mm (0.0012 ln.)
  58. 58. EG-46 · • ENGINE-~ ENG.INE.MECHANICAL If the circle runout. is greater than maximum, replace the crankshaft. 2. INSPECT MAIN JOURNALS AND CRANK PINS (a) Using..a .micrometer. measure the diameter of each main journal and crank pin. Diameter: Item Main journal Cranck pin 49.976 - 50.000 mm ~7.988 - 48.COO mm STD (1.9676 - 1.9685 in.) (1.8893 - 1.8828 i.1.) 49.733 - 49.743 mm 47.738 - 47.750 ffiOI u;s 0.25 (1.9580 - 1.9584 in.) (1.8794 - 1.8780 in.) 49.483 - 49.493 mm 47.488 - 47.500 mm· u;s o.5o (1.9481 - 1.9485 in.) (1.8696 - 1.8701 in.) 47.238 - 47.250 mm U/S 0.75 - (1.8598 - 1.8602 in.) If thc.di.ameter is not as specified, check the oil clear- ance (S.ee steps 3 and 6 in cylinder block dis- assembly). If necessary, grind or replace the crank- shaft. (b) Check each main journal and crank pin for taper and out-of-round as shown. Maximum taper and out-of-round: 0.005 mm (0.0002 in.) If the taper and out-of-round is greater than maxi- mum, replace the crankshaft. 3. IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/OR CRANK PINS Grind and hone the main journals and/or crank pins to the finished undersized diameter (See procedure in step 2). Install new main journal and/or crankshaft pin under- sized bearings.
  59. 59. • ";; :- ,· . . ENGINE:- ENGiNE.MECHANICAL EG-47 ,..,..I --···cAMSHAFT AND CAMSHAF-T BEARING iNSPECTiON AND REPAIR 1. INSPECT CAMSHAFT OIL CLEARANCE (a) Using a 'cylinder .gauge. measure the inside diameter of the camshaft bearing. Bearing inside diameter (from front side): STD No.1 43.250- 4:;.275 mm 11.7028 - 1.7037 in.) STD No.2 43.010 - 4:;,03:; m<r 11.5933 - I.G943 in.) --STD No.3 42.750- 42.785 mm 11.6835- 1.6R44 in.) STD No.4 42.500 - 42.525 mm 11.6732 -· 1.6742 in.) ·-- U/S 0.125 No.I 43.120 - 43.151 mm (1.6976 - 1.5989 in.) u;s 0.125 No.2 42.890- 42.930 mm 11.6886- 1.6902 in.) u;s 0.125 No.3 42.640 - 42.680 mm (1.6787 - 1.6803 in.) u;s 0.125 No.4 42.390- 42.4~0 mm 11.6589 - 1.6705 in.) . ~- U/S 0.25 No. I 42.995 - 43.026 mm (1.6927 - 1.6939 ln.) U/S 0.25 No.2 42.765 - 42.805 mm (1.6837 - 1.6852 in.) U/S 0.25 No.3 42.515 - 42.555 mm (1.6738 - 1.6754 in.) U/S 0.25 No.4 42.265 - 42.'30t: mm (1.6ti40 - 1.6655 in.) (b) Subtract the journal diameter measurement (See stop 3 in timing chain and camshaft inspection) from the bearing inside diameter measuremimt. Standard oil ciearance: STD No.1 and No.4 0.025 - 0.066 mm 10.0010- 0.0028 in.) No.2 and No.3 0.040- 0.081 rnm 10.0016- 0.00321n.) U/S Typo No.1 0.025 - 0.066 mm 10.0010 - 0.0026 in.) '--- Oth~:~rs 0.043 - 0.093 mm 10.0017 - 0.0037 in.) Maximum oil clearanca: 0.10 mm (0.0039 ln.) If the clearance is 9reatar than maximum, replace tha camshaft bearings. If necessary, -rRplace the cam- shaft. 2. IF NECESSARY, REPLACE CAMSHAFT BEARINGS A. Remove expansion plug Using SST and a hammer, tap out the expa:-tsion plug. SST 09215-00101 (09215-00130. 09215-00150, 09215-00211) B. Remove camsha-ft bearings Using SST, remove th~ camshaft bearings. SST 09215-00101 (09215-00121. 09215-00130, 09215-00141,09215-00150,09215-00161, . 09215-00221)
  60. 60. · EG-48 . '· No.1 No.2 No.3 •··· ENGINE- ENGINE :MECHANICAL No.4 500291 ZI~JI C. Install new camshaft bearings. (a) Install ne'yV bearings in their proper location. .·. (b) Align the oil holes of the bearing and cylinder block. (c) Using SST, install the camshaft bearings. SST 09215-00101 (09215-00121, 09215-00130, 09215-00141.09215-00150,09215-00161, 09215-00221) D. Check camshaft oil clearance (See step 1 above) E. Install expansion plug (a) Apply liquid sealer to the expansion plug surface of the cylinder block. (b) Using SST and a hammer, drive in thoJ expansion plug to 11 distance of 2 mm (0.08 in.) from the cylinder block edge. SST 09215-00101 (09215-00231) VALVE LIFTERS AND VALVE LIFTER BORES INSPECTION INSPECT VALVE LIFTER OIL CLEARANCE (a) Using a caliper gauge, measure the valve lif!er bore diatneter. Bore diameter: 21.417- 21.437 mm (0.8432- 0.8440 ln.) (b) Using a micrometer, measure the valve lifter diameter. ·' ..
  61. 61. • ' • -. 0C:Jt Position I~ =* . ENGINE-~· ENGINE MECHANICAL. EG-49 """' lifter diameter: 21.387- 21.404 mm (0.8420- 0,8427 ir>.) {c) Subtract the valve lifter dbmetor measurement from the valve lifter bore diameter m6asurement. Standard oil clearance: 0.013 - 0.050 mm (0.0005 - 0.0020 in.) Maximum oil clearance: 0.10 mm (0.003S in.) If the oil clearance is greater thc:n maximum. replllce the valve lifters. __.. CRANKSHAFT OIL SEALS REPLACEMENT 1. 2. A. {a). {b) (c) B. {a) (b) {c) {d) HINT: There are 2 methods {A and Bj to replace the oil seal which are as follows: REPLACE CRANKSHAFT FRONT OIL SEAL {See crankshaft front oil seal replacement in timing chain) REPLACE CRANKSHAFT REAR OIL SEAL If rear oil seal retainer is removed from cylinder block: Using screwdriver and hammer, tap out the oH seal. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oii seal edge. SST 09223-15020, 09608-30012 {096PB-04020) Apply MP grease to the oil seal lip. If rear· oil seal retainer Is installed to .:ylinder block: Using a knife, cut off the oil seal lip. Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage ·tha cronk•haft. Tape the screwdriver tip. Apply MP grease to a new cil seal lip. Using SST and a hammer, tap in the oil se~l until its surface is flush with the rear oil seal retc:iner edge. SST 09223-15030, 09608-30012 {09608-·04020)
  62. 62. EG-50 ENGINE ~-ENGINE MECHANICAL ... Front fvhrk---~ (Cavity; J Front Mark-----0~~~ (Protrusion) pz:£/11 3/:,:;~ LIP_>s_.._,_.,_.._"----------------·~ Side nail (Upper) Front ..Froni: M;:Jrk (Cavit·rl No.i and Expander Side Rail (lower) P25537 PISTON.AND CONNECTING ROD ASSEMBLY 1. ASSEMBLE PISTON AND CONNECTING ROD co... '" (a). Coat the piston pin and. piston holes with engine oil. (b) Align the front marks of the piston and connecting rod. (c) Using SST. press in the piston pin. SST 09221-25025 (09221-00020, 09221-00030; 09221 -00040, 09221 -00170, 09221 -0021 0)' 2. INSTALL PIS"T:ON RINGS (a) Install the oil ring expander and 2 side rails by hand. (b) Using a piston ring expander, install the 2 compres- sion rings with the code mark facing upward. Coda mark: No.1 1N No.2 2N (c) Position tho piston rings so that the ring ends are as .shown. NOTICE: Do not align the ring ends. -. '
  63. 63. ·- ~, . P06443 P07010 ) ENGiNE -~ ENGlNE MECKANICAt· .. EG-51 · 105505 l 3: INSTALL BEARINGS (a) Align·the bearing claw with the groove of the r.onnect- ing rod or connecting cap. (b) Install the bearings in the connecting rod and con- riecting rod cap. CYLINDER BLOCK ASSEMBLY HINT: • Thoroughly clean ail parts to be assembled. -• Before installing the parts, apply new engine oil to all slid!ng and rotating suriacas. • Replace all gaskets, 0- rings and oil seals with new parts. 1. INSTALL MAIN BEARINGS HINT: Upper bearings have an oil groovo and oil holes. lower bearings do not. (a) Align the bearing c!aw with the claw groove of the cylinder block, and push in tha 5 upper b'earings. (b) Align the bearing claw with the claw groow of the main bearing cap, and push ir> the 5 lower bearings. HINT: A number is marked on ~ach main bearing cap to indicate the installation position. ~­ iir~
  64. 64. EG_-_5_2_··-------"--·--=E:.:.:N:..::G:.:.:iNc.:.:E::..·_~_.E:::.:N.::G::..:I.:..:N.:::E..:.:·Mc:.:E::.:C:..c.:H.AN.:.:iC::.:.A.:.:t:.:.......:.__________ ----------'-·---,,.----...::""c:.'::.:"....s .. r"O rd- / ~""'"' "" t1rh h L o If(/ o ' It= ~ r- 0 or> }- ~ ~-Jl~lf' ~ =;,c Q..J S; "' ~- :j ::. ~ ~ El17003 P25~04 '------------ / Front 2; INSTALL UPPER THRUST WASHERS lnstail· the 2 thru;;t washers under the No.3 journal position of the· cylinder block with the oil grooves facing..outward. 3. PLACE CRANKSHAFT ON CYLINDER BLOCK 4. INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS A. Place main bearing cap and lower thrust washers on cy!inder block (a) Install th& 2 thrust washers on the No.3 bearing cap with the grooves facing outward. (b) Install the 5 main bearing caps in their proper loca- tions. . HINT: Each bearing cap has a nun;ber and front m·ark.. B. Install main bearing cep bolts . (a) Apply alight coat of engine oil on the threads ar.d uncier heads of tha main bearing .cap bolts. (b) Install and unifo;mly tighten the 10 bolts of the main bearing cap bolts in several passes, in the sr;quence shown. Torquo: 59 N·m (600 kgf-cm, 43 ft-lbi) (c) Check that the crankshaft turns smoothly. (d) Check that the cra11kshaft thrust clearance. (Sae ste:-- 5 in cylinder block disassembly) 5. INSTALL PISTON AND CONNECTING ROD ASSEMBLIES • Using a piston ring compressor, push 'he correctly numbered piston and connecting rod assemblies into each cylinrler with t';a front mark of the piston facing forward.
  65. 65. EG-54 "- " ,;·· ENG'INE:..: ENGINE' MECHANICAL """"' 1'155<2 """' 'pOST ASSEMBLY CGOV••I L INSTALL ENGINE MOUI'iTING BRACKETS Install the brackets with the 4 bolts. Torque: 39 N-m (400 kgf-cm. 29 ft-lbf) 2. INSTALL FRONT END PLATE Install a new gasket <ond front end plate with tho 2 bo!ts. Torque: 19 1~-m (195 kgf-cm. 14 ft-lbf) 3. INSTALL ENGINE DRAIII! COC!< 4. INSTALL OIL FILTER BRACKET AND FILTER ASSEMBLY h1stall a new gasket. the oil filter·, bracket ,;nd filter assembly with the 2 bolts. Torque: 19 N-m (195 kgf·cm, 14 ft-lbf) 5. INSTALL N0.2 ENGINE HANGER Torque: 37 N-m (380 kgf·cm, 27 tt-lbf) 6. INSTALL OIL DiPSTICK 7. INSTALL OIL PUMP (See oil pump installation in Lubricatior. System) B. INSTALL TIMING CHAIN (See timing chain instellatiem) 0 ~- INSTALL ALTERNATOR BRACKET ·rorque: 26 N-m (270 kgf-cm, 20 ft·l~f) 10. INSTALL ALTERNATOR 1~. INSTALL WATER PUMP (Sea water pump inst111lstion in Cooling System) 12. INSTALL CYLINDER HEAD (See cylinder head installGtion) 13. REMOVE ENGINE STAND 14. INSTALL REAR END PLATE · Torque: 8 N-m (80 kgf·cm, 69 ln.·lbf) 15. INSTALL FLYWHEEL (a) Install the flywheel on the crankshaf~. (b) Install and uniformly tighten the 6 mount bolts in ' several passes. in the sequence shown. Torquo: 83 N-m (850 kgf-cm, 61 ft-lbf)
  66. 66. • I. Front Mark (Protru!_!:s~io~n:.!)~~~~ Fro~~ I I I.---.,.--,i;*:~~ Painted ') Mark , .i . _ _ I_ _ _ _ _ _ _ _ _ _ _ : _ : . _ _ ; . ENGINE - ENGINE MECHANICAL EG-53 : 6. INSTALL CONNECTING ROD CAPS A. Place connecting rod cap on connecting rod (a) Match the numbered connecting rod cap with the connecting rod. (b) l!'lstall the connecting rod cap with the front mark facing forward. B. lnstoll connecting rod cop bolts HINT: • The connecting rod cap bolts are tightened in 2 progressive steps (steps (b) and (d)). • If any connecting rod bolt is broken or deformed. replace it. (a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. (b) Install and alternately tighten the 10 bolts of the connecting rod cap in several passGs. Torque: 24.6 N·m (260 kgf.cm, 18ft·lbf) If any one of the connecting rod cap bolts does not · meet the torque S!Jecification.' replace the connecting rod cap bolt. (c) Mark tho front of the connecting rod cap bolt with paint. {d) Retighten the connecting rod cap bolts 90" as shown. (e) Check that the painted mark is now at a 90" angle to the front. -(f) Check that tha crankshaft turns smoothly. (g) Chack that the connecting rod thrust clearance. {See step 2 m cylinrlcr b!nck disassembiyl 7. INSTALL REAR OIL SEAL RETAINER Install a new gasket and the retainer with the 5 bolts. Torque: 8 N·m (80 kgf·cm, 69 ln.·lbf)
  67. 67. • • .,, ·. .. ,. ENGINE - ENGINE MECHANICAL -SERVICE SPECIFICATIONS· SERVICE OATA Compression at 250 rpm STD . pressure Minimum Difference of pressure botweon onch cylinder Valve at cold Intake . Exhaustclearance Dwell angle Engine at normal opera:ing temperature Ignition timing Engine at normal operating temperature Idle speed Engine at normal operating temperature Cylinder t".ead Warpage Cylinder block side Maximum ManifOld side Maximum Valve seat reiacing engle Contacting angle Contar:ting width Intake Exhaust Valve guic!e Inside diameter bushing Outside diameter (for repair part) STD. 0/S 0.05 Replacing temperature (Cylinder head side) Valve Valve overall hmgth STD Intake Exhaust Minimum Intake Exhaust Valve face angle Stem diameter Intake Exhaust StiJm oil clearance STD Intake • ExhauJO;t I Maximum Intake I Exhaust I Margin thickness STD Intake Exhaust I I Minimum !r.taba Exho1.0st Valve spring Oavlation . ·-Mox1mum Fres length Installed tension at 38.4 mm (1.512 in.) Valve rocKer Arm· inside diameter arm and Shaft die-meter shaft Oil clearance · STD Maximum Push rod Circle runout Ma'xlmum Valve lifter Lifter diameter Lifter bore diameter Oil clearance STO Maximum -931 kPa (9.5 kgf/cm', 135 psi) or more 795 kPa (9.0 kgl/cm'. 129 psi) 98 kPa (1.0 kgf/cm', 14 psi) or loss 0.13 mm (0.005 in.) 0.23 mm (0,009 in.) 46 sa·@ idle 9- 15" BlOC@ idle 700- 800 rpm 0.05 mm (0,0020 in.) 0.1 0 mm (0.0039 in.) ao·. 45•. 6s· 45" 1.1 - 1,7 mm (0.043 - 0.067 in.) 1.2 - 1.9 mm (0.047 - 0.071 in.) 8.0 I 0 - 8.030 mm (0.3154 - 0.3161 in.) 13.000- 13.027 mm (0.5119- O.S129 in.) 13.050 - 13.077 mm (0.5138 - 0.5149 in.) so- 1oo·c (176 -212"Fl 99,90 mm (3.933 in.) I00.1 0 mm (3.941 in.) 99.4 mr.: (3.913 in.) 99,6 mm (3.921 in.) 44.5· 7.951 -7.991 mm (0.3130- 0.3146Jn.) 7.960-7.986 mm (0.3134 ·- 0.3144 in.) 0,019 - 0.1)79 mm (0.0007 - 0.0031 in.) 0.024 - 0.075 mm (0.0009 - O.OC30 in.) 0.08 mm (0.0031 in.l 0.1 0 mm (0.0039 in.) 1,0 - 1.6 mrn 0.039 - 0.063 in.) 1.2- 1.9 mm (0.047- 0.071 in.) 0.9 """ (0.031 ln.) O.U mm (0.035 in.) --1.6 mm {0.083 in.) 46.~ mm (1.831 in.) 296 -· 328 N (30.2 - 33.4 kgf, 06.0 ·- 73.8 lbl) 16.00 - 16.02 mm !0.11299 - 0,6307 in.) 15.97 - 15.99 mm (0.6287 - 0.62~9 in.) 0.02- 0.04 mm (0.0006- 0.0016 in.) 0.04 mm (0.0016 in.) 0.30 mm (0.011 B in.) I21.387- 21.404 mm (0.9420- 0.8427 in.) 21.417 - 21.437 mm (0.8432 - O.C440 in.j 0.013 - 0.050 mm (0.0005 - 0.00?.0 in.) I0.10 mm (0.0039 in.} ----' I II I I
  68. 68. EG-56 F.NGINE'~. ENGINE: MECHANICAL· Manifolds 'Narpage Maximum 0.20 mm (0:0078 in.). ' Camshaft Thrust clearance 5TD 0.07 0.14 mm (0.0028 - 0.0055 in.) Maximum 0.3 mm (0.012 in.) Journal oil clearance 5TD No.1 end No..4 1 0.025 - 0.066 mm (0.001 0 - 0.0026 ln.) No.2 end tJo.3·' O.CJ40- 0.081 mm (0.0016- 0.0032 in.) U/5 Type No.I . 0.025 - 0.066 mm (0.001 0 - 0.0026 in.) Others 0.043 - 0.093 mm (0.0017 - 0.0037 in.) Maximum 0.10 mm (0.0039 in.) Journal dbmflter (f;om front side) ·SiD No.I 43.209- 43.225 mm (1.7011 - 1.70181n.) No.2 42.954-42.970 mm (1.6911 - 1.0917 in.) No.3 42.704-42.720 mm (1.6873- 1.6819 in.) No.4 42.459-42.475 mm (1.8716- 1.6722 in.) U/5 0.125 No.I 43.085- 43.095 mm (1.6983- 1.6967 in.) No.2 42.837-42.847 mm (1.8865- 1.68691n.) No.3 42.587 - 42.597 mm (1.8767 - 1.6770 in.) No.4 42.337- 42.347 mm (1.6668 -- 1.6672 in.) U/5 0.25 No.I 42.960- 42.970 mm (1,8gl3- 1.6917 in.) No.2 42.712- <!2.722 mm (1.6616- 1.6820 ln.) No.3 42.462- 4:<:.472 mm (1.6717- 1.6721 ln.) ' No.4 42.212-42.222 mm (1,8619- 1.6623 in.) Bea.ring inside diameter (from front side) STD No.I 43.250- 43.275 mm (1.7028- 1.7037 in.) • No.2 43.010 - 43.035 mm (1.693~ - 1.6943 in.) No.3 42.760- 42.785 mm (1,6635 - 1.6844 ln.) No.4 42.500 - 42.525 mm (1.6732 - 1.8742 in.) U/S 0.125 No.I 43.120-43.151 mm (1.6976- 1.6989 in.) . No.2 42.890 - 42.930 mm (1.6866 - 1.6902 in.) No.3 42.640 - 42.680 mm (1.6787 - 1.6803 in.) I No.4 42.390 - 42.430 mm (1.6689 - 1.6705 in.) U/5 0.25 No.I 42.995 - 43.026 mm (1.6927 - 1.6939 ln.) No.2 42.766 - 42.805 mm (1.6837 - 1.6852 in.) No.3 42.515 - 42.555 mm (1.6738 - 1.6754 ln.) No.4 42.265 - 42.305 mm (1.6649 - 1.6655 ln.) Circle runout Maximum 0.06 mm (0.0024 ln.) Cam lobtt height 5TD · Intake 36.47 - 36.57 mm (1.4358 - 1.4397 ln.) I Exhtual 36.37-- 30.47 """ (1.4318- 1.4358 ln.) ~--·~·· Minirnt:m lntck& 26.17 mm (1.4240 ln.) Exhaust ·. 36.07 mm (1.4201 h) Chair. ::lock --r· end sprocket e 98 N (I 0 kgf, 2.2 ibn tension Minumurn 13.5 mm (O.G31 ln.) Chain olongotion Maximum 272.2 mm (I 0.736 in.) CamShaft sprocket wear (w/ chain) Minimum 113.8 mm (4.480 in.l, Crankshaft li:procketr wear (w/ chain) Minimum 69.4 mm (2.339 ln.) Chein Tenttion diameter Minimum 12.0 mm (0.472 ln.) tensioner end Ol!lmper diornetoi Minimum 4.0 mm (0.167 ln.) vibration c.Jamper
  69. 69. ENGINE·- "ENGINEMECHANI.CAL .. l Cylinder block Cylinder head surfecttwarpege .. Maximum 0.05 mm (0.0020 in.) Cylinder bore diameter STD Mark 1 80.500 - 80.51 0 mm {3.1693 - 3.16~7 in.) Mark 2 80.510- 80.520 mm (3,1897- ~.1701 ln.l Mark 3 80.520 - 80.530 mm (3.1701 - ~.1705 in.) 0/S 0.50 81.000- 81.030 mm (3.1890- 3.1902 in.) Maximum STD 80.728 mm (3.1783 ln.) 0/S 0.50 81.228 inm (3.1979 in.) Cylinde!' block main journal bore diameter STD Mark 6 54.004- 54.012 mm (2.1281 - 2.1265 in.) Mark 7 54.012 - 54.020 rnm (2.1285 - 2.1268 in.) Mark 8 54.020- 64.028 mm (2.1288- 2.1271 ln.) Pistori and Piston diameter STD Mark 1 80.358 - 80.368 mm (3.1537 - 3.1641 in.) piston ring Mark 2 80.368 - 80.378 rnm (3.1641 - 3.1645 ln.) Mark 3 80.378 - 80.388 mm (3.1645 - 3.1349 in.) 0/S 0.50 80.858 - 80.888 mm (3.1834 - 3.1846 in.) Piston oil clearance 0.132 - 0.152 mm (0.0052 - 0.0060 ln.) ,, Piston ring groove clearance No.1 0.030 - 0.070 mm (O.CO12 - O.C028 in.) No.2 0.020 - 0.080 mm (0.0008 - 0.0024 in.) Piston ring end gap STD No.1 0.23 - 0.33 mm (0,0091 - 0.0130 in.) No.2 0.33-0.48 mm (0.0130- 0.018g io.) Oil (sido rail) 0.18 - 0.38 mm (0.0071 - 0.0 ISO io.) Maximum No.I 0.33 mm (0.0 130 in.) No.2 0.48 mm (0.01 89 ln.) . Oil (side rail) 0.38 mm (0.0150 ln.) Connecting Thrust cleerance STD 0.150-0.330 mm(0.0059 -.0.0130 in.) rod Maximum 0.30 mm (0.011 8 ln.) Connecting rod bearing center w~ll thickness STD Mark 1 1.486 - 1.490 mm (0.0585- O.OS8i in.) Mark 2 1.490 - 1.494 mm (0.0587 - 0.058~ ln.) .. Ml!llrk 3· 1.494 - 1.498 mm (0.0588 - 0.0590 in.) U/S 0.25 1.007 -. 1.613 mm (0.0833 - 0.0835 ln.) I I U/S 0.60 1.732 - 1.738 mm (0.0&82 - 0.0684 in,) II U/S 0.75 1.857 - 1.883 mm (0.0731 - 0.0'133 in.) Connecting rod oi! clearenca STD 0.020 - 0.048 mm (0.0008 - o,9c19 lr..) U/S Type . 0.019 - 0.058 mm (0.0007 - O.O•J22 ln.) ! Maxlroum O.C8 mm (0,0031 ln.) Rod ~ut-~of-a!ignment M8xlmvm per 100 mm (3.941n.) 0.05 mm (0.0020 ln.) HQd twist Maximum per 100 mm {3.S4 ln.) 0.05 mm {0.0020 ln.) Connecting rod bolt outcl~e dl11metor STD 8.880 - 9.000 mm (0.34aO - 0.3543 in.) Minimum 8.60 mm (0.3388 ln.) .-.
  70. 70. EG-58 Crtmkshaft ENGINE- ENGINE MECHANICAL. Thrust clearanco Thru~t wa:;her thickness Main jo:.Jrnal oil cJegrance Main journal diameter Main bearing center wall thickness Crank pin diameter STD Maximum STD 0/50.125 STD U/S Type Maximum STD Mark 1 Mark 2 Mark 3 U/S 0.25 U/S 0.50 STD Mark 3 0.040 - 0.242 mm ~0.00 t 6 - 0.009.5 in.} 0.30 mm {0.0 1 t 8 in.) 2.430·- 2.480 mm ·(0.0957 - 0.0976 in.) 2.490-; 2.540 mm (0.0976- 0.1000 in.) 0.016 -' 0.040 mm (0.0006 - 0.0016 in.) 0.017 _; 0.071 mm (0.0007- OC0028 in.) 0.10 mm (0.0039 in.) 49.976 - 49.984 mm (1.9796 - 1.9~79 in.) 49.984 - 49.992 mm (1.9679 - 1.9682 in.) 49.992 - 50.000 mm (1.9682 - 1.9685 in.) 49.733 - 49.743 mm (1.9580 - 1.9584 in.) 49.483 - 49.493 mm (1.9481 - 1.9485 in.) 1.990 - 1.994 mm (0.0783 - 0.0785 in.) Mark 4 1.994 - 1.998 mm (0.0785 - 0.0787 in.) Mark 5 1.998 - 2.002 mm (0.0787 - 0.0788 in.) Mark 6 2.002 - 2.006 mm (0.0788 - 0.0790 in.) Mark 7 2.006- 2.010 mm (0.0790- 0.0791 in.) U/S 0.25 2. 11 2 - 2.122 mm (0.0831 - 0.0835 in.) U/S 0.50 2.237 - 2.247 mm (0.0881 - 0.0885 in.) STD U/S 0.25 U/S 0.50 U/S 0.75 47.988 - 48.000 mm (1.8893 - 1.fl808 in.) 47.738 - 47.750 mm (1.8795 - 1.8799 in.) 47.488 - 47.500 mm (1.86.96 - 1.8701 in.) 47.238- 47.250 mm (1.859~- 1.8602 in.) Circle runout Maximum I 0.06 mm (0.0024 in.}. Main journal taper and out-of-round Maximum 0.02·mm (0.0008 in.) 'Crank pin taper and out-of-round Maximum I 0.005 mm (0.0002 in.) ~----------L-------~----------------------~------~----~------~--------__J
  71. 71. ENGINE ENGINE MECHANICAL EG-59 ·-·IUTORQUE SPECIFICATIONS Part tightened N·m kgf-cm . ft·lbf Spark plug x Cylinder head 17.5 180 13 0;-:tributor x Cylinder block 12 120 9 Cylinder head x Cylincfer block 12 Pointed head 1st 29.5 300 22 -. 2nd Turn so• Turn so• Turn so• 3rd Turn go• Turn so• •. Turn so• Recessed head t9 195 14 Rocker arm assembly x Cylinder head 21 210 16 Cylinder head cover x Cylinder h3ad 2 25 18 in.-lbf Reer ple1e x Cylinder head 8 80 69 !n.-lbf W21ter Outlet housing x Cylinder heed 19 195 14 Manifolds x Cylinder head 39 400 29 Thrust plate x Cylinder block 8 80 69 in.·lbf Camshaft sprocket x Camshaft 59 600 43 Chain tensioner x Cylinder block 8 80 69 in.·lbf Vibration damper x Cylinder block 3 80 69 in.·lbf Timing chain cover x Cylinder block 10 mm head bolt 8 80 69 in.·lbf 12 mm heed bolt 19 195 14 Crankshaft pulley x Crankshaft 89 900 65 Connecting rod cap x Connecting rod 1st 24.5 250 18 2nd Turn go• Turn go• Torn go• Main bearing c~tp x Cylinder block 59 600 43 Front end plate x Cylinder block 19 195 14 Rear oil seal retainer x Cylinder block 8 80 69 in..lbf - Engin~ mounting bracket x Cylinder block 39 400 29 Oil filter bracket x Cylinder block 19· 195 14 Rear end plate x Cylinder block 8 80 69 in.-lbf No.2 engin& hanger x Cylinder block 37 380 27 Alter011tor bracket x Cylinder block 26 270 ' 20 Flywheol x Crankshaft 83 850 I &; ..
  72. 72. EG-60 ENGINE - F.UEL ~YSTEM FUEL SYSTEM PREPARATION SST (SPECiAL SERVICE TOOLS) ~ 09240-00014 ~~ ~ 09240-00020 ~;l!'~!!l!ih ~ RECOMMENDED TOOLS ~~. -~--"="' ~~ ~:!· ~ -::;::<' ""'-==-·-=- EQUIPMENT Torque wrench Tweezers 09082-00050 09200-00010 09860-11011 Carburetor Adjusting Gauge Set Wire Gauge Set· TOYOTA Electrical Tester Set. Engine Adjust Kit.• C.!rburetor Drivor Set. L_______,___________________ PRECAUTION -- __., ·, 1. Before working on the fuel system, disconnect the cable from the negative battery ter~i';a'i. 2. When working on the fuel system, keep away from possible fire hazards ana do not smoke. 3. Keep gasoline off rubber or leather parts. 4. Work on only one component group at a time to help avoid confusion between similar looking parts. 5. Keep work area claan to avoid contamination of the c·arburetor and components. S. Be careful not to mix up or lose clips or springs.
  73. 73. ENGINE --, FUEL SYSTEM. I:::G-'31 . ON- VEHICLE INSPECTION • _- 1. . ' 2. • (a) (b) (c) ,.. : . 3. 4. :.. ~ REMOVE INTAKE AIR CONNECTOR FROM CARBURETOR INSPECT CARBURETOR AND LINKAGE 'Check that the various set screws. plugs and union bolts are tight nnd correctly installed. Check the linkage for excessive wear and missing snap rings. Check that the throttle valvas open fully when the accelerator pedal is fully depre~sed. INSPECT ACCELERATION PUMP Open the throttle valve, and check that gasoline spurts out from the acceloration nozzle. CHECK AND ADJUST IDLE SPEED AND IDLE MIXl Ur1c . (See idle CO check end adjust in Engine Mechanical) j24(24Q, 17) I CARBURETOR COMPONENTS FOR REMOVA!- AND INSTALLATICN +Gasket + Non-reusable part IN·m (kgf·cm, ft·fbtJl: Specified torque r P25715 '
  74. 74. EG-62 ' ENGINE - FUEL SYSTEM ' . CARBURETOR REMOVA.L 1. DISCONNECT ACCELEflATOR CABLE FROM CARBURETOR 2. DISCONNECT CARBURETOR CONNECTOR 3. DISCONNECT FUEL INLET PIPE FROM CARBURETOR IM... II Remove the union bolt and 2 gaskets, and disconnect the inlet pipe from the carburetor. Torque: 24 N-m (240 kgf-cm, 17 ft·lbf) INSTALLATION HINT: Use 2 new gaskets. 4. DISCONNECT VACUUM HOSE AND PCV HOSE (a) Disconne.ct the distributor vacuum hose from the car- buretor. (b) Disconnect the PCV hose from the insulator. 5. REMOVE CARBURETOR (a) Remove the 4 nuts holding the carburetor to the · intake manifold. Torque: 19 N-m (195 kgf·cm, 14 ft·lbf) (b) Lift out the carburetor. (c) Remove the insulator and gaskets assembly. (d) Cover the inlet hole of the intake manifold with a cloth. INSTALLATION HINT: Uso a new insulator. •
  75. 75. • - : ·' ·- - • EG-63 . COMPONENTS FOR DISASSEMBLY AND-•-N ASSEMB.LY Accelerator Cable Bracket ' ""~~-- Wire Clamp r~ / Accelerati0n ~ //PumpArm ' I l ~ V<tCUUrl) """'"';k! 7"~ 01---Plunger 8 Boot ~" I@ Thermostatic Valve Vacuum Hose 'I Snap Ring Air Horn :1 t, ) • . 11 , • __ Ac::eleratlon''l r+ Gasket 11 ~ Pump Plunger Seat --.... 1 1jJ "'-._ Needle Valve~ '"'~J: [·~"'-._~Spring ~ : ~ Pcwer Piston Neodle Valve+-~ I :• ;?"hSpringTI ____.....--- / : ~ ·----Float PlungertJ--{j Needle Valve I~ Wire --<:; Assembly 1 1 <:::::::.:::.----Pivot PinI ---~ .AI - ' .,_L' + Non-reusable part · I -----------~
  76. 76. ENGINE -'- FUEL'SYSTEM Secondary Small V:::nturi +Gasket Primary Small Venturi ,,I I I I I 1 I I I I 0 Secondt:lry I T~rottle Valve Diaphragm.: l, 'I I I Snap Ring--~A 1 ,)"@ I ,_, Return + Non-reusable part lnsu I I I •I I I I I ' ir+Gasket Fuel Cut Solenoid Wire Clip, Discharge Weight Slow Jet --·-,-------
  77. 77. . . . " -.j ..I ?......~.~--....... '"·: .,... • Pivot Pin ENGINE - FUEL SYSTEM EG-65. CARBURETOR DI~ASSEMBLY ........... HINT: These instructions are organized so that you will work only one component group ai " time. This will help you avoid confusion between similar looking parts from different subassemblies being on your workbench at the same time. (a) To facilitate reassembly, arrang3 parts in order. fi§F (b) 8e careful not to mix up or lc.se balls, clips or springs. Air Horn Disassembly 1. 2. REMOVE CARBURETOR STUD BOLT REMOVE ACCELERATION PUMP ARM (a) Remove the snap ring from the pump connecting link. (b) Remove the pivot bolt. (c) Disconnect the pump arrn 'irono the pump plunger. (d) Disconnect the pump connecting !ink and washer from the throttle li!ver and remove the pump arm with pump connecting link. 3. REMOVE THERMOSTATIC VALVE (a) Disconnect 2 vacuum hoses from t~o carburetor. (b) Remove the 2 screws, No. plato, tha thermostatic valve and vacuum hosgs assembly. 4. REMOVE AIR HORN ASSEMBLY (a) Rsmove the rsturn spring from tha accelerator cable bracket and flange. (b) Disconnect the fuel cut solenoid colmector from the wire clamp. ~) R9move ~ha 7 screws and ihase parts: (1) Acc~lorator c;;bla bracket (2) Wire clamps (3) Fuel pipe bracket (b) Lift off the air hom assembly together with ths air horn gasket. 6. REMOVE FLOAT AND NEEDLE VALVE Remove the float pivot pin, float and needle valv9 subassembly.
  78. 78. ENGIN·E ..;- FUEL SYS'fEM ,.,.,, .----------------, --~ ·c. REMOVE ACCELERATION PUMP PLUNGER Remove the pump plunger and boot. 7. REMOVE AIR HORN GASKET 8. REMOVE NEEDLE VALVL. S!=AT Remove the ne.edle valve seat and g~sket. 9. REMOVE POWER PISTON Remove the screw. retainer, power piston and spring. .Carburetor Body Disassembly 1. REMOVE CHECK BALLS FOR ACCELERATION PUMP (a) Remove the pump discharge weight, spring and large ball. · (b) Remove the plunger spring. (c) Using tweezers. remove the ball retainer. (d) Remove the small ball. 2. REMOVE SLOW JET 3. REMOVE POWER VALVE
  79. 79. ,,._· ...,....~, ...,,,., ,.... "" . ,. Snap Ring ENGINE' c:.. FUEL SYSTEM EG-67 · 4. · REMOVE PRIMARY AND SECONUARY MAIN JETS (a) Remove the 2 passage plugs ar:d gaskets. (b) Rein'ove the primary and secondary main jets 'and 5. gaskets. REMOVE SMALL VENTURIS Remove the 4 screws. primary, secondary small ven- tui-is and gaskets. 6•. REMOVE SECONDARY THROTTLE VALVE DIAPHRAGM (aj Disconnect the vacuum hose from' ;he body. (b) Remove the snap ring and washer from the diaphragm link. (c) Remove the 2 screws and throttle valve diaphragm. 7. REMOVE FUEL CUT SOLENOID (a) Remove the wire clip from the fuel cut solenoid. (b) Remove the fuel cut solenoid and gasket. 8•. REMOVE IDLE SPEED ADJUSTING SCREW (a) Remove the bolt and arm. (b) Remove the idle speed adjusting screw and sprinf'. 9. REMOVE IDLE MIXTURE ADJUSTING SCREW
  80. 80. I I r EG-61! e (5)-g (3!--Q l"·~- ENGINE.-. FUEL. ..SYSTEM 0'25707 .10.. ·SEPARAJ.E CARBURETOR BODY AND FLANGE . (a) ·Remove .the 2 passage screws and spring washers. (b) Remove,the 2 bolts. (c) Separate the hody and flange. (d) Remove the insulator. GENERAL CLEANING PROCEDURE CLEAN DISASSEMBLED PARTS BEFORE INSPECTION (a) With a soft brush wash and clean the cast parts in carburetor cleaner. (b) Clean off the carbon around the throttle valve. (c) Wash the other parts thoroughly in carburetor clean- er. (d) Blow all dirt and other foreign material from the jets, fuel passages and restrictions in the body. ·INSPECTION OF CARBURETOR 1. INSPECTFLOAT AND NEEDLE_vALVE (a) lnspoct the pivot pin (1) for scratches and excessive· wear. (b) Inspect the float (2) fer broken !ips and wear in the pivot pin holes. (c) Inspect the spring (3) for breaks and deformation. (d) Inspect the needle valve (4) and plunger (5) for wear or damage. (e) Inspect the strainer (6) for rust and breaks. 2. INSPECT POWER PISTON Check that the power piston moves smoothly.

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