toyota 7k engine repair manual.pdf

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REPAIR MANUAL Jul., 1995

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INTRODUCTION ENGINE

IGNITION SYSTEM STARTING SYSTEM CHARGING SYSTEM

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©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 information at the time of publication. However, specifications and procedures are subject to change without notice.

TOYOTA MOfOR CORPO{Ul.TION

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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 TO ROUE

SPECIFICATIONS···································· IN- B

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./

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Drive Rotor----J"b.'-f )

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+ Non~reusable part P2537J

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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.

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 straight up without twisting or pryin9 it.

(d) Cle.an th9 battery terminal posts and cable t<~rminals 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 installation. 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.

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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

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(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 procedure. A list of SST and SSM can he found in the preparation ;:>art at tho front o~ eacn section in this manual.

1 0. 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.

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Symbol Part Nnme Abbrevintion -

-~- FUSE .. WQJ8S 1

--<0"'o-I MEDIUM CURRENT FuSE I M-FIJSE w-JoJee j

-~-- HIGH CURRENT FUSE H-FUSE INOl07

-~ FUSIBLE LINK FL IN0307

-8-- 'I CIRCUIT 6iii:AKER co INOJ68

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·· IN-6 INTRODUCTION - GENERAL REPAIR INSTRlJ.;TIONS

WHONG CORRECT

IN0253 I L---------------------~==~.

WRONG CORRECT

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l IN0262

Exampie

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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 touched. 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 terminals 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.

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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

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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 I w/ w~sher

hexagon bolt I 4T

Hexagon

CD I

+ I

head boll 2 I

0 ProtrtJding ST L

I lin as

J 1- r·,·~:· Hexagon ! ( 0 2 ll•.nge boll

I Ql ::.:"';~ "l I

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

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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

1 2 1.25 47 480 35 53 540 39

14 1.5 74 760 55 84 850 61

16 1.5 1 1 5 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

1 2 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 1 2 1.25 71 730 53 80 810 59 14 1.5 1 10 1,100 80 125 1,250 90

' 16 1.5 170 1,750 127 - - -

6 1 10.5 1 I 0 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 I 12 I 1.25

1 10 1,100 00 120 1,250 90 .. 6 i. 7.5 I 34 .340 25 .17 380 27

I 7C ..

10 1.25 51 7B 710 790 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

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ENGINE

ENGINE MECHANICAL .PREPARATION ....................................... EG- 2

AIR elL TER 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


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


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~-----------------------------~------- I 09213-14010 Cranksh_aft Pulley Hol.ding Tool ----,

,~ I

I I I

(~1651-60665) Bolt

09215-00101 Camchsft Dearing Remover & Roplecer Sot .. g

················· .............................................................................................................. . (09?15-001?1) Gote "A"

(09215-00130) Bolt

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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

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.......................................................................................................... , ................................................. . (09221-00170) Gu;de "J'

.......... ················· ················· .......................................................................................................................................... . (0922 1- "n10) Gu;de ·M·

09223 15020 Oil Seal & Bearing Replacer

~ 09223 46011 ~::~~:~;11 Front 0;1 Sool J ~--------------------------------_l ___________ _

EG-4 ENGINE -.ENGINE MECHANICAL

09330 00021 Companion Flange Holding Tool

......................... (09330-00030) Pin

09950-4o'01 0 Puller B Set

Crankshaft pulley

Crankshaft pulley Crankrhdt sprocket

·····················cosgs2·~::o4o·io>····s·lid~-;.,~-~---················· -·····-·-··--····-···-··········· ... ···································································

.......... ...... :........ .. . .... · ····· ... ·· · .. ..io99s4·::·a4cii iii ... ;.,;;, .. 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 ........................................................................................................................ .

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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,

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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

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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 procedure: 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 concentration 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 specification, 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.

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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.

•

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-TEi\ISION 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

. -

''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 clearance 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)

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.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 a timing 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~ ; .

EG-12 ENGINE -, .. ENGINE MECHANICAL·

CYLINDER HEAD COMPONENTS --.. I

Seal Washer---~ f.------Seal Washer

\---Cylinder Head

+ 0-Ring

Spar~ Plug

Spark Plug I Tube ---....__ \

Water Outlet Hosing ~ / Assembly "'""-, J

Clamp~-· <V'-~-·

(

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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

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n olds a d L n Carbureto· A : . .

ENGINE

• ssembly ·

E.:l-13

• Intake Manifold

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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. 1 C. 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.

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(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 screwdriver. 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.

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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.

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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 cylinder head.

B. Inspect for cracks Using a dye pe~etrant, check the combustion chamber, intake ports, exhaust ports and cylinder block side surface for cracks. If cracked, replace the cylinder head.

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 - 1 OO"C ;176

- 212"F).

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' 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 diameter 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 .

. 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.

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ENGINE - ENGINE MECHANICAL EG-Z1

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Width

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(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.

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EG-22

I I

ENGINE - ENGINE MECHANICAL

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. (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.

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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



( 1) (2)

. 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 run out exceeds the maximum, replace the push rod.

12. INSPECT INTAKE AND EXHAUST MANIFOLDS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage:

0.20 mm (0.008 in.)

If warpage is greater than maximum, correct or replace 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)

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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 !NST ALLAT!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 1 0 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.

EG-26 ENGINE I:NGINI'. MCCII-1\NICI\L

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(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

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ENGINE - ENGINE MECHANICAL .

TIMING CHAIN COMPONENTS FOR REMOVAL AND INSTALLATION

Timing Chain COVM Water Pump Pulley

I I

~ Crankshaft Pulley

l'ming Chain

+Gasket

--; .......... I

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EG-27

\ --------- Distributor

-- Assembly

Valve Lifter .

,_ __

Camshaft Sprocket

Thrust Plale

.. -:::::~--- ,----- ----~:11 --d)"--- Chain Tensioner ',,'" __ _

~~j ---- , +Gasket \

---- 1/JP ' ----- ""

Crankshaft Sprocket

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Vibration Damper

JN·m (kgf·cm, ft·lbf)J: Specified torque + Non-reusable part

+Gasket---.;,

Drain Plug---~::>

~ I t----+O·Ring .,

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.

·, . ' ·~

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ENGINE :_·ENGINE MECHANICAL EG-29

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Cylinder Head Bolt

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·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.)

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 run out 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, replace 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)

•

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:

'

ENGINE ::...· EN.GJNE MECHANICAL· EG-31

"''"'

4." INSPECT THRUST PLATE (a) Install the thrust plate and camshaft sprocket to the

cam's haft . (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.

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 tension or with oil before installation.

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.

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ENGINE - ENGINE MECHANICAL. I:G-33

""''"

5. (a)

(b)

6.

7. (a)

(b)

INSTALL TIMING CHAIN COVER Place a naw 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)

EG-34 ENGIN'E- ·ENGINE-MECHANICAL

CYLINDER BLOCK COMPONENTS

-·IZ

~- -------====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•

'=

~ :.' '- -

•.•

•

- j~

.[ • 1

i '


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 assembly 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, replace the connecting rod assembly. If nocessa;y, replace the crankshaft.

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 .connecting 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, f 8 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 crankshaft.

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

I 0/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 1 0 main bearing cap bolts in several passes, in the sequence shown.

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 washers (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 washers 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 bearings, 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 crankshaft.

.· ~·· ..

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. ' 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. J 201 - 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 lnR

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. I 2~ 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.

~ ~

~~.. • i ..

r;. EG-40 11:). 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.

., .

-' .-

...

Cf'j Front,._ \: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 DlSASSEMBL Y

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.

.~· . '-,, 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.

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 directions. {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 between· 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.

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 connecting 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 connecting rod assembly.

. • • ' •

--

•J . _,

I - ' '

'- J 1

About 20mm

ENGINE -'ENGINE MECHANICAL t\;·4b

rc67'8

B. Inspect connecting rod bolts Using vernier calipers. measure tile minimum diameter 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 run out at t .1e

center journal. Maximum clrclo runout:

0.03 mm (0.0012 ln.)

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 clearance (S.ee steps 3 and 6 in cylinder block disassembly). If necessary, grind or replace the crankshaft.

(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 maximum, 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 undersized bearings .

•

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:-

,·

. .

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 camshaft.

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)

· EG-48 . '·

No.1 No.2 No.3

•···

ENGINE- ENGINE :MECHANICAL

No.4

500291

ZI~J I

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.

·' ..

•

'

•

-.

0 C: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)

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 compression 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.

-.

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·-

~, .

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~

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-/ ~""'"' "" t1r h h

L o If(/ o ' It= ~ r- 0 or> }-

~ ~- J\l~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 a light 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.

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 ALTERN A TOR 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)

•

I .

Front Mark (Protru!_!:s~io~n:.!)~~~~

Fro~~ I I I .---.,.--,i;*:~~ Painted ') Mark ,

.i

.__I _______ ____:_:.__;.


: 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 1 0 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)

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-SERVICE SPECIFICATIONS· SERVICE OAT A

Compression at 250 rpm STD

. pressure Minimum

Difference of pressure botweon onch cylinder

Valve at cold Intake . Exhaust clearance

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.)

I 00.1 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 (0.00 1 6 in.)

0.30 mm (0.0 11 B in.)

I 21.387- 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.)

I 0.10 mm (0.0039 in.} ----'

I I I

I I

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

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.CO 12 - 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 (0.0 11 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,) I I 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,9c 19 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.)

.-.

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

ENGINE ENGINE MECHANICAL EG-59

·-·IU TORQUE 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 &;

..

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.

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 INST ALLATICN

+Gasket

+ Non-reusable part IN·m (kgf·cm, ft·fbtJl: Specified torque

r P25715

'

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.

•

•

- :

·' ·- -

•

EG-63

. COMPONENTS FOR DISASSEMBLY AND-•-N

ASSEMB.L Y

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 1 \jJ "'-._

Needle Valve~ '"'~ J: [·~ "'-._~Spring ~ : ~ Pcwer Piston

Neodle Valve+-~ I : • ;?"h SpringTI ____.....--- / : ~ ·----Float

PlungertJ--{j Needle Valve I~ Wire --<:; Assembly 1

1 <:::::::.:::.----Pivot Pin I

---~ .AI - ' .,_ L'

+ Non-reusable part · I -----------~

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

--·-,-------

. . .

"

-.j . .I

? ...... ~.~-- ....... ' "·: ., ...

•

Pivot Pin

ENGINE - FUEL SYSTEM EG-65.

CARBURETOR DI~ASSEMBL Y ........ ...

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.

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

,,._· ... , .... ~, ... ,,,., , ....

"" .

,.

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 ventui-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

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.

·~··· , .... ,, ..... ·~·· .. ~···- ·--

...

(+)

'- ~ 8EB

ENGINE:..:: FUEL SYSTEM·· EG-69. '

T P25816

3; · INSPECT POWER VALVE ·check for faulty opening and clo~ing action.

4. INSPECT FUEL CUT SOLENOID VALVE (a) Connect the connector tArminals to the battery termi

nals: (b) You should feel a "click" from the sola·noid valva when

the battery power is connected and disco;~nected. If the solenoid valve is not operating proparly, replace it.

CARBURETOR ASSEMBLY

HINT: Use new gaskets and 0-rini;s throughout.

Carburetor Body Assembly

1. ASSEMBLE CARBURETOR BODY AND FLANGE (a) Assemble the flanga and body together with a r·.ew

insulator. (b) Install the 2· bolts. (c) Install the 2 passage screws together with the spring

washers.

2. 3.

INSTALL IDLE MIXTURE ADJUSTING SCREW INSTALL IDLE SPEED ADJIJSTING SCREW

(a) Install idle speed adjusting screw and spring. (b) Hook the back spring to the arm, and install the arm

with the bolt. 4. INSTALL FUEL CUT SOLENOID

Install fuel cut solenoid and wire clamp.

I

. t:G·/0 ·

Snap Ring

-_:>,,' ~~-

. ~ ';t! ----

ENGINE- F.UEL SYSTEM

""""

S002(<;

,..,,

5. INSTALL~ECONDARY THROTTLE VALVE DIAPHRAGM

(a) Co.nnect. t.he diaphragm link with the snap ring and washer.

(b) Install the throttle valve diaphragm with the 2 screws. (c) Connect t~e vacuum hose to the body.

6. INSTALL SMALL VENTURIS

7. (a)

(b)

8. 9.

10. (a) (b)

Install 2 new gaskets and the pnmary, secondary venturis with the 4 screws.

INSTALL PRIMARY AND SECONDARY MAIN JETS Install the primary and secondary main jets with 2'

' new gaskets. Install the primary and secondary passage plugs with 2 new gaskets. INSTALL POWER VALVE INSTALL SLOW JET

INSTALL CHECK BALLS FOR ACCELERATION Install the plunger small ball. Using tweezers. install the ball re_tainer.

(c) Install the plunger spring. (d) Install the pump discharge large ball. spring and

weight.

'

;

' ENGINE - FUEL SYSTEM . EG-71·

L---------------~·-·--------~~

Air Horn Assembly

1. INSTALL POWER PISTON lnstall.the spring and power pistun .with the retainer and screw.

2. INSTALL. NEEDLE VALVE SEAT Install the valve seat together with a new gasket.

3. ADJUST FLOAT LEVEL (a) Insert the needle valve. spring and r:unger into the

needle valve seat. HINT: After adjusting the float levet install the clip

. onto the needle valve.

(b) Install the float with the pivot pin.

(c) Allow the· float to hang down by its own weight. Using SST, measure the clearance b~tweon the float tip and air horn. SST 09240-00014 Float level (Raised po•iti~n):

6.5 mm (0.256 ln.)

HINT: This maasurement should be made without a gasket on the air hctn.

(d) Adjust by bending the portion of the float !ip marked A.

•

., ..

..

EG-72

B

.,.~ \._.-'

' ENGINE '- FUEL-SYSTEM

P25700

Pivot Pin

(e) Lift up·tha flqat. Using SST. measure the clearance between the needle 'Valve plunger and float lip. SST 09240-00020 Float level (Lowered position):

1.5·- 1.7 mm (0.060- 0.067 ln.)

(f) Adjust by bending the position of the float lip marked

B. (g) After adjusting the float level. remove the float, plung

er, spring and needle valve.

(h) Assemble the clip onto the needle valve. 4. INSTALL NEW AIR HORN GASKET

Place the air horn gasket on the a'ir horn. 5. INSTALL ACCELERATION PUMP PLUNGER

Install a new ·boot and the pump plunger.

6. INSTALL NEEDLE VALVE AND FLOAT (a) Hook the needle valv9 clip to the lip portion of the

float.

(b) Install the float and secure it with the pivot pin.

.

•

.

-'

. . .

..

Snap Ring .,.,

ENGINE·. FUEL SYSTEM EG-73

7: INSTALL AIR HORN ASSEMBLY (.a) Place the air horn in the carburetor body. (b) Install theso parts with the 7 scr&ws:

( 1) ·Accelerator cable b~acket (2) Wire clamp (3) Fuol pipe bracket

(c) Connect the fuel cut solenoid connector to the wire clamp .

(b) Install the retur'l spring to the accalerator bracket and flange.

8. INSTALL THERMOSTATIC VALVE (a) Install the thermostatic valve and Nc. !Jiate with the 2

screws. (b) Connect the 2 vacuum hoses to the carburetor.

9. INSTALL ACCELERATION PUMP ARM (a) Connect the pump connecting link to the throttle

lever .

(b) Connect the pump arm to tho pump plunger. (c) Install the pump arm with the pivot bolt. (d) Secure the link with the snap rir.g and washer. 10. CHECK FOR SMOOTH OPERATION OF EACH PART

CARBURETOR ADJUSTMENT

HINT: Ustl SST 09240-00014 to make adjustment. 1. CliECK AND ADJUST THROTTLE V..ALVE OPENING (a) Check the full opening angle of the ;>rimary throttle

v&lv~.

Standarci n1gle: so• from horilontsl

(b) Adjust.by bending the primary throttle stop lever.

m

EG-74

Secondary Throtlle Stop Lever

YP2S7W

~gle Gauge_,-------,r-r

For 59·_/ 31"

70mm (2. 76 in.)

I 30mm (1.18 in.)

YP251'59

ENGINE - FUEL SYSTEM .

·(c). Check -th·e full opening ·an·gle of the secondary throttle. valve. · S:anderd .angle:

80° from horizontal

(d) Adjust by bending the secondary throttle stop lever.

2. CHECK AND ADJUST KICK-UP SETTING (a) With the primary throttle valve fully opened, check ·

the opening angle of the seconda~y throttle valve. Standard angle:


(b) Adjust by bending the secondary throttle kick-up lever.

3. CHECK AND ADJUST SECONDARY TOUCH ANGLE (a) Make an angl~ gauge as shown in the illustration.

.·

·-

Idle Speed Adjusting Screw

ENGINE - FUEL SYSTEM .. EG-75

y P25r.i7

y P?-;7'57

y P25761

{b) Check the primary throttle valve opening angle at the same -time the primary throttle touch lever just tou·ches·the· secondary throttle touch lt.ver. Standard angle:


{c) Adjust by bending the primary throttle touch laver.

4. ·CHECK AND ADJUST ACCELERATION PUMP {a) Rotate the throttle shaft and check that tho length of

the stroke. Standard stroke:

3.25 -3.75 mm (0.128- 0.143 in.) (b) Adjust the pump stroke by bending the connecting

link.

5. PRESET IDLE SPEED ADJUSTING SCREW (a) Check the primary throttle valve angle.

Standard angle:

13.5° from horizontal

(b) Adjust by turning the idle speed adjusting screw.

I EG-76 ENGlNE'- FUEL SYSTEM.·

r-------:::::;-;;::::::----, . 6.· PRESET IDLE;MIXTURE ADJUSTING SCREW l

Fuel Ou:let Hose

J

~-m {kgf·cm, fl'lbf)l: Specified torque • Non-reusable part

If the idle mixture adjusting screw has been removed.' ' fully- screw it in and then unscrew it the following amount. · Standard: ,

Return 3.76 turns from fully closed position NOTICE: Use care not to· screw It In too tightly and damage the screw tip.

7. CHECK FOR SMOOTH OPERATION OF EACH PART a. INSTALL CABURETOR STUD BOLT

CARBURETOR INSTALLATION

Installation is in the reverse ordl3r of removal.

FUEL PUMP COMPONENTS FOR REMOVAL AND INSTALLATION

TP258:20:

. ,

•

Outlet Pipe

ENGINE •-'- FUEL:SYSTEM .. · • EG-77

· FUEL;PUMP REMOVAL . ;

. 1: 2.

DISCONNECT FUEL HOSES I=ROM FUEL PUMP REMOVE FUEL PUMP Remove ·the 2 nuts, fuel pump, gasket, insulator and

gasket. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

INSTALLATION HINT: Use 2 new gaskets.

-...x-•• FUEL PUMP INSPECTION (Airtight Test)

PRECHECK Before doing these ch~cks on the fuAI pump:

(a) Run soma fuel through the pump to insure that the check valves seal tightly (a dry cher;k valve may not seal properly).

(b) Without blocking off any pipes, operate the rocker arm and check the amount of force necessary for (lperation and the amount of arm play. This same amount of force should be used in the checks.

1. CHECK INLET VALVE Block off the outlet pipe with your finger and ch~ck that there is an increasa in rocker arr~· play and that the rocker arm moves freely (no reaction force) .

2. CHECK OUTLET VALVE !nlet Pipe Block off the inlet pipe with your finger and check that

the rocker arm locks (does not operats with same amount of force used in the precheck above). HINT: Never use more force than that used in the precheck. This opplies to chocks 3 and 4 also:

·---------------, 3. CHECK DIAPHRAGM

Outlet Pipe Block off the inlet, outlet pipe and ch~ck that the rocker arm locks. HINT: If all three of these checks are net as specified, the caulking (sealing) of the body and upper casing is defective.

.m :~:

, .

' i j i

I

EG-76 ENGINE--' FUEL SYSTEM· ·.

SERVICE SPECIFICATIONS SERVICE DATA

Carburetor Part. No.

Float level

Throttle valve opening engle

Secondary throttle valve

Kickup flngle

Secondary touch engle

Acculeration pump stroke

Idle speed !ngla

Idle mixture adjusting screw .

TORQUE SPECIFICATIONS Part tightened

tor x lnta~e manifold Carbure

Fuel pu

Inlet pip

mp x Cyli;.der Mock

e x Curburotor .

4. CHECK OIL SEAL Block off the vent hole with your finger and check that the rocker arm locks.

FUEL PUMP INSTALLATION

Installation is in the reverse order of removal.

21100-13870

Raised positiion 6.5 mm (0.256 in.)

Lowered po!:ition 1.5 - 1.7 mm (0.060 - 0.067 in.)

Primary 90° from horizontal ·,

Secondary so· from horizontal

23• from horizontal

59'" from horizontal

3.25 - 3.75 mm (0.128 - 0.148 in.)

Pre-setting 13.5• from horizontal

Pre-setting Return 3.75 turns from fulley closed position ----~

-, N·m kgf·cm ft.Jbf

19 195 - 14

18 185 13

24 240 17 i ----

..

·-···· ·-·· --· ..

. ENGINE -.COOLING SYSTEM EG-79

COOUNG SYSTEM · ·

:. PREPARATION .. ......

• .· :· SST (SPECIAL SERVICE TOOLS)

... ' -... 09236-00101 Water Pump Overhaul Tool Sot

. ... (09236-1501 0) Beedng.S~•Y

I ..............................................................................................................................

(09237-00010) Water Pump Soaring Remover &

Roplacer

....................... ,

...................................... : .. : ......................................................................................................................... .. (09237 -00020) Boadng Stay

(09237 -00030) Beadng Stay

(09237-00050) Shaft ·a·

EQUIPMENT

Heater Thermostat ~

-R.-d~-or-ca--pte-sto-,--~·-------------------------------~·-------·-------------------------ThermometBr Thermostat ---Torque wrench

COOLANT

r-------=r ltt>m Capac:hy ~ Cla.ssilication

1 Ethylenc.-glycol base ( Enoine coola~t -5.7 Htors (6,0 US qts, 5.0 Imp. qt:;)

SSM (SPECIAL SERVICE MATERIALS)

08826-00100 Soal Paoking 12828. THREE BONO 12820 or equivalent

(FIPG)

Wator pump

J

l.:I.:HlU

Drain Cock

ENGINE:-<CO.Ol!NGSYSTEM.

COOLANT CHECK AND REPLACEMENT

t.M.U-11

1. GHECK ENGINE COOLANT LEVEL AT RESERVOIR' TANK The coolant level sh0uld be between'the "LOW" and "FULL" lines, when the engine is cold. If low, check for leaks and add coolant up to the · •• "FULL" line.

2. CHECK ENGiNE COOLANT QUALITY There should not be any excessive deposits of rust or scales around the radiator cap or radiator filler hole, and radiator cap or radiator filler hole, and the coolant should be free from oil. If excessively dirty, replace the coolant.

3. REPLACE ENGINE COOLANT {a) Remove the radiator cap.

CAUTION: To avoid the danger of being bu,ned, do not

remove it while the engine and radiator are still hot, as

fluid and steam can be blown out under pressure.

{b) Drain the .coolant from the radiator drain cock and engine drain cock. {Engine drain cock at the front of engine block.)

{c) Close the drain cocks. Torque (Engine drt~in cock):

25 N·m (250 kgf.cm, 18 ft·lbf)

{d) Slowly fill the system with coolant. • Use a good brand of ethylene-glycol base cool

ant and mix it according to the manufacturer's directions.

• Using coolant which includes more than 50 % ethylene-glycol {but not more than 70 %) is recommended.

NOTICE:

• Do no~ use a alce>hol type coolant .

~ The coolant chould be mixed with demineralizad

wator or distilled water.

Capacity:

6. 7 lltlilr• (6.0 US qts, 5.0 imp. qts)

(e) Reinstall the radiator cap. (f) Warm up the engine and check for leaks. (g) Recheck the coolant level and refill as necessary.

..

. '

..

"'\--

•.

'

. '

191195, 141

Fan

ENGINE:- COOLING SYSTEM

WATER PUMP COMPONENTS FOR REMOVAL AND INSTALLATION

+Gasket

Water Puf'J)P

Water Pump Pulley

EG-81

Fluid <..OlJDHJlQ Drive Belt

j N·m (kgf·cm, ft-lbf) I : Specified torque + Non-reusable part

P>$461

WATER PUMP REMOVAL

1. DRAIN ENGINE COOLANT 2. REMOVE DRIVE BELT, FAN, FLUID

(a)

(b)

(c) (d)

3. (a)

(b)

COUPLING AND WATER PUMP PULLEY Stratch the belt and loosen th~ 'Rn pulley mounting nuts. Loosen the pivot and adjusting bolts of the alternntor, and remove the drive bait. Remove the 4 nuts, fan with fluid coupling and p:~/Jey. Remove the 4 nuts and fan from tho fluid coupling. REMOVE WATER PUMP Disconnect the water bypass hose from the water pump. Remove the 4 bolts, adjusting bar, water pump afld gasket.

----~

EG-82 ENGINE..:.: COOLING SYSTEM· ·

WAT:ER PUMP COMPONENTS INSPECTiON

1. INSPECT WATER PUMP Turn the pulley seat and check that the water pump bearing is not rough or noisy. If necessary, replace the water pump bearing.

2. INSPECT FLUIP COUPLING Check the fluid coupling for damage and silicon oii leakage. If necessary, replace the fluid coupling.

lOUt-eo

COMPONENTS FOR DISASSEMBLY AND

ASSEMBLY

--------------------------------------------~-------------------, 10.3 (105, 81

Plate

~.av y I

+ Gasket

+ Rotor

+Seal Set

I Water Pump Body

I + Ae!ring

Pulley Seat

I N·m (kgf·cm, it·lbfl : Specified torque

+ Non~rcusable part

• .,. I

•

•

• .

·-

I

ENGINE.- CO.OLING SYSTEM EG-83

WATER PUMP DISASSEMBLY . . .

1. REMOVE PUMP PLATE Remove the 3 screws. pump plate and gasket.

Z. REMOVE PULI.EY SEAT Using SST and a pross, pross thP Lonring sh~ft and remove the pulley seat. SST 09236-00101 (09237-00010, 09237-00050)

3. REMOVE WATER PUMP BEARING AND ROTOR (a) Gradually heat the water rump body to 75 - as•c

(167 - 1as· F). (b) Using SST and a press, press the shaft of the bearing

and remove the bearing and rotor. SST 09236-00101 (09237 -00010, 09237- 00050j

4. REMOVE SEAL SET Using SST and a press. press out 1he seal set.

S~ SST 09236-00101 (09236-15010)

. IL-----------------------·~~~~"J

P25111

~ .. -.. '

WATER PUMP ASSEMBLY

HINT: Always assemble the water pump with a new seal set.

1. INSTALL WATER PUMP BEARING (a) Gradually heat the water pump boc'{ :o 75 - ss•c

( 167 - las· FJ. (b) Using SST and a press, install the bearing hto the

water pump body.

EG-84 . ENGINE _:_' COOLING SYSTEM ' ..

,..------------......:...--;·.; .. SST09236~00101 (09237-00020)

SST

P257l<l I

P2'".)~WI ·-------- ------'-"~

NOTICE: The bearing and face should be flush with the body top surface.

2. INSTALL SEAL SET (a) Apply a seal set packing to a·new seal and pump body.

Seal packing: Part No. 08826-00100 or equivale~t

(b) Using SST and a press, install the seal set. SST 09236-00101 (09237-00030)

3. INSTALL PULLEY SEAT Using SST and a press, press in the pulley seat on the water pump bearing shaft to 89.3 - 90.7 mm (3.516 . - 3.571 in.) form the installation surface of the pump body. SST 09236-00101 (09237 -00020) -

4. INSTALL ROTOR Using ?. press, press in a new rotor on the water pump bearing shaft te 0.3 - 1.1 mm (0.0 1 - 0.04 in.) from the installation surface of the pump body. N011CE: As shown In the figure, the rotor and fa<:e should be flush with the bearing snaH top ~"rfaot.

5. INSTALL PUMP PLATE Install a new gasket <Jnd the pump body with the 3 screws. Torque: 10.3 N.-m (105 kgf·cm, 8 ft·lbf) NOTICE: After Installing, maka sura that tho rotor is not In contact with tho water pump plate.

6. CHECK WATER PUMP ROTATES SMOOTHLY

' '

. ' .... ' -

,.·

J19{1~~ I

+Gaskel-0

Thermostat~

~ I I I I I I I I

I

'CNGINE - COOLING SYSTEM EG-85

--·· WATER PUMP INSTALLATION

1. INSTALL WATER PUMP (a) Temporary install the adjusting bar to the alternator

with the adjusting bolt . (b) Install a new gasket and water pl!mp with the 3 bo!ts.

Torque: 19 N-m (195 kgf-cm. 14 ft·ibf)

, ______ :;~

2. INSTALL WATER PUMP PULLEY. FAN, FLUID ~~ COUPLING AND DRIVE BELT

"""'' (a) Install the fan to the fluid coupling with the 4 nuts. (b) , Tempornry install the water pump-pulley and fan with

fluid coupling with the 4 nuts. (c) Install and adjust the belt.

(Se& on -vehicle inspecticn in Charging System) (d) Stretch the belt tight and tighien the 4 nuts.

Torque: 5.5 N-m (55 kgf-cm, 49 Jn.-lbf)

3. FILL WITH ENGINE COOLANT 4. START ENGINE AND CHECK FOR LEAKS

THERMOSTAT COMPONENTS FOR REMOVAL AND !NST ALLA TION

·. l<·m (kgl·om, ft•lbOI' Spoo;nod ,,:- \ ~\ j + Non-reusable part u~ T P25557

EG-86

J

COOJOO Z\6616

ENGINE - cooLING SYSTEM

THERMOSTAT REMOVAL •

HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficJen.;y, • Do not remove the thermostat, even if the engi,ne tends to overheat.

1. DRAIN ENGINE COOLANT

2. REMOVE WATER OUTLET AND THERMOSTAT (a). Remove the 2 bolts and water o•Jtlflt from the water

outlet housing. (b) Remove the thermostat 3nd gasket.

THERMOSTAT INSPECTION

INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature.

(a) !mmerse· tho thermostat in water and gradually heat the water.

(b) Check the valva opening temperature. Vnlve opening temperature:

80- 84•::: (176- 133.F)

If ths valve oper.ing temperature is not as specifia&, replace the thermostat.

(c) Check the valve lift. Valve lift:

At gs•c (203.F): 8 mm (0.31 in.) or more

If the valve lift is not as specified, replace the thermostat.

(d) Check that the valve is fully closed when the thermostat is at low temperatures (below 4o•c (1 04.F)). If not closed, replace the thermostat.

~

•

.·

I Ra1iator Cap

COOQJ(

ENGINE'·-·coOLING·SYSTEM ·· EG-87

THERMOSTAT INSTALLATION

1. INSTALL THERMOSTAT AND WATER OUTLET (a) Install a new gasket to th.; th~rmostat.

· (b) ·Align the jiggle valve of the thermostat with right side of the ·mar~. and insert the thermostat in the water outlet housing. HINT: The jiggle valve may be set-within 10° of either side of the prescribed position.

(c) Install the water outlet with the 2 bolts. Torque: 19 N·m (19!; kgf-cm. 14 ft·lbf)

2. FILL WITH ENGINE COOLANT 3. START ENGINE AND CHECK FOR COOLANT

Li:AKS

RADIATOR. RADIATOR CLEANING

IOUI-11

Using water or a steam clean·er, remov~ any rnud and dirt from the radiator core. NOTICE: If using a high pre83ure type-ciBaner. be careful not to deform the fin• of the radiator core. (i.e. Maintain a distan'ce between the cleanP.r noz"'le.and radiat~r cor~.t)

RADIATOR INSPECTION

1. REMOVE RADIATOR CAP CAUTION: To avoid the donger of bolng burned, do not rom eve tha radiator cap whilft the engine ancf·radiator ore "itm hot. a: fiuid an-i 'iteam can be blown out under

pras£ure.

2. INSPECT RADIATOR CAP NOTICE: If the radiotor cap has r.<>ntarninetions, always rinse it with water.

Using a radiator cap tester, pump the taster and measure the vacuum valve opening pressure. Standard oponing pressure:

74- 103 kPa (0.75- 1.05 kgf/cm', 10:7- 14.9 psi)

Minimum opening pressure:

59 kPa (0.6 kgf/cm'. 8.5 psi)

HINT: Use the tester's maximum reading as the opening pressure.

~~

~· EG-8B ENGii'.fE ~· COOLING SYSTEM ..

SERVICE SPECIFICATIONS SERVIGE DATA

Therm.,stat Valve opaning temperature

Velvb lift 1-·-·

Radiator cap Vecuvm veive opening pressure

·TORQUE SPEC!F!CATIONS Part tightened

Drain plllg x Cylinder ~leek

Water rump body ~ Pump p!ete

Fluid coupling x \Vater pump

Water pump x Cyiinder block

Water outlet x Water I)Utlet ho:.using

•

If the opening pre.ssure is less than minimum, replace, the radiator cap.

3. INSPECT COOLING SYSTEM FOR LEAKS (a) Fill the radiat..;~ ~'ld engine with coolant, and attach a ·

radiator cap tester to the water filler. (b) Warm up the engine. (c) Pump it to 11 B kPa (1.2 kgf/cm2

, 17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks a're. found, check the heater core, cylinder block and cylinder head.

4. REINSTALL RADIATOR CAP

&00'7\.-U

eo- s4•c 111e- 1B3'FJ I ot 95'C (203'F) 8 mm (0.31 in.) or more

STD 74- 103 kPo (0.75- 1.05 kgf/em', 10.7- 14.9 psi)

Minimum 59 kPa (0.6 kgf/em', 8.5 psi)

N·m kgf-cm ft-lbf

25 250 18 •

10.3 105 8

5.5 55 49 in.·lbf

19 195 14

19 195 14

0 •

ENGINE - LU.BRICATION SYSTEM

, LUBRICATION·SYSTEM :. i

PREPARATION MU\1··

SST (SPECIAL SERVICE TOOLS)

... --

~ 09228 22020 Oil Filter Wrench

09816-30010 Oil Pressure Switch Socket

0 ,.. .. ., __

RECOMMENDED TOOLS 09200-00010 Engin~t Adjus~ Kit.

EQUIPMENT

Oil pressure gauge ~-Straight edge

~T~or=q~u.~.w:=re=n~ch~--------------------------~----+------------------------ . _,,.,_ ..

LUBRICANT

Item Cap~city C/ossificllltlon -

En;ine oil API grade SG, SH or !LSAC owltigrade

Dry fill 3,9 liters (4.1 US qts, 3.4 Imp. qts) engbe oli

Drain and refill

I w/ Oil filter charge 3.7 litero (3.9 US qts, 3,3 Imp. qts)

w/o Oil filter change 3.4 liters (3,6 US qts, 3.0 Imp. qts) -SSM {SPECIAL SERVICE MATERIALS)

08826-00080 Soa/ Pecking Black ar equlvo.lent (FIPG)

Oil ran

. r-------------------~~~==~--~~~--------------~------------------~ 08833-00080 Adhesive 1344, Oi•11ressure switch THREE BOND 1344, LOCTJTE 242 or equivalent

EG-90 ENGINE:... 'LUBRICATION SYSTEM. -..

OIL PRESSU'RE CHECK 1. CHECK ENGINE OIL QUALITY

Check 'the oil for det-erioration, entry of water, dis- ' · coloring or thinning. If oil quality is visibly poor. replace ft.

2. CHECK ENGINE OIL LEVEL ! ·· The oi: level should be between the "L" and "F" marks

on the dipstick

=

~'25m

Adhesive

J~ ......_____

•

If low, check for leakage and add oil up to ·r:· mark. 3. REMOVE OIL PRESSURE SWITCH

4. 5.

6.

7. 8. (a)

(b)

9.

Using SST. remove the oil pressure switch. SST 09816-30010

INSTALL OIL PRESSURE GAUGE START ENGINE Start the engine and warm it up to normal operating temperature. MEASURE OIL PRESSURE Oil pressure: At idle:

29 kPa (0.3 kgf/cm', 4.3 psi) or more At 3,000 rpm:

245 - 490 kPa (2.5 - 5.0 kgfjcm', 36 - 7l psi)

REMOVE OIL PRESSURE GAUGE REINSTALL OIL PRESSURE SWITCH Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive:

Part No. 03833- 00080, THRF.E BOND 134-4,

LOCTITE 242 or equivalent

Using SST, install the oil pressure switch. SST 09816-30010 Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)

START ENGINE AND CHECK FOR LEAKS

.'

.,

·.

ENGINE- LUBRICATION SYSTEM. EG·91

LU0490

·OIL ·AND FILTER REPLACEMENT

CAUTION:

.• Prolonged and repeated contact with mineral oil will

result in the removal of natural fats from the skin, leading to dryness, irritation end dermatiti~. In addi-

tion, used engine oil contains rotentially harmful contaminants which may cause skin cai1eer. Ade- ~·

quate means of skin protection and washing facilit· ios should ba provided.

• Care should be taken, therofo>re, whan changing engine oil. tc minimize the frequency and length of

time your sk!n is exposed to used engine oil. Pro'i:ec-:

tive clothing and gloves, that carmot be penetrated

by oil, should be worn. Wash your'skin ~horoughly with soap and water. or use water-l~ss h.and clean

er, to remove any usod engine oiL Do not use gasoline. thinners. or solvents.

• In order to preserve the environment, used oil snd

used oil filter must be disposed of •mly at d~signated · disposal sites.

1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil drain plug. and drain the oil into a

contain~r.

2. REPLACE OIL FILTER (a) Using SST, remove the oil filter.

SST 09228-22020 (b) Clean the oil filter contact surface on the oil filt~r

mounting. (c) Lubricate the filter rubber ga£ket with cJe;,n omgina

oil.

(d) Tighten filter until the gasket contacts seat of the filter mounting. Then using SST, give it an additional 3/4 turn lo seat the filter. SST 09228-22020

EG-92 ENGINE:"'- LUBRICAT.JON;SYSTEM ,

R ex>mmended Viscosity (SAE:) • · e

·~: 2nw.,o

15V/-40

' 10W-30 > '

I I II II : SW-30

'C ·29 -18 -7 4 16 27 38 'F -~0 0 20 40 60 80 100· TEMPERATURE RANGE .~NTICIPATED BEFORE NEXT OIL CHANGE T :1'23182 -----

+Gasket

Oil Pan

I

I + Gasket--e

Drain Plug-~

[}G"n lkaf·cm, ft·lbf) j Specified torque

'3.·; FIL)-·WITH l;i'IGINE OIL (a) Clean and ·install the oil drain plug with a new gasket·.

Torque: .. 25 N·m (250 kgf·cm. 18 ft·lbf)

(b) · Fill with new engine oil. Oil grade:

API grade SG, SH or ILSJI.C multigrade engine oil.

Recommended vi•cosity is as shown in the

.illustration.

Capacity:

Drain and ref111

w/ Oil filter change

3.7 liters (3.9 US qt;, 3.3 Imp. qts)

w/o Oil filter change

3.4 liters (3.6 US qts, 3.0 Imp. qts)

(c) Reinstall the oil filler cap. 4. START ENGINE AND CHECK FOR LEAKS 6. CHECK ENGINE OIL LEVEL

OIL PUMP COMPONENTS FOR REMOVAL AND INSTALLATION

~~~.-;1:::.-. ~~~1 / .. ~ .. -- I L~.-~1 I

Oil Pump·-------1~'-' 1 I I

. I

+Gasket I I ~~~ I

.-:sb r~~~~~~~~~ I

+ Non-rcusabie parl P'25649

----~--------------------------------------------~=

•

. -

·.

ENGI1'~i: - LUBRICATION SYSTEM EG-93

OIL PUMP REMOVAL

HINT;. When repairing the oil pump, the oil pan and

strainer should be removed and cleaned .

1. DRAIN ENGINE OIL 2. REMOVE OIL PAN

Remove the 22 nuts. oil pan and gasket.

3. REMOVE OIL STRAINER AND OIL PUMP I (a) Remove th~ 3 bolts, oil strainer and gasket. (b) Remove the bolt and oil pump.

. ron•~u

COMPONENTS FOR DISASSF.MBL Y AND ASSEMBLY

Oil Pump Body __ .,

~ I + Cotter Pin

· Relief Valve

Valve Spring

[}Tm (kgf·cm, f:·lbf) \ : Specified torque + Non-reusable part

t (

~..,

I I

r -- . ({It?) Dri~en Rotor---c:.J

I I I

I )

I I I I I I I

. I

~& ~:;_;YI

Drive Rotor----1

I II I I 11 1

I J I ! I ( I f

I ~) Q' : : .;"'"" ~ I

;, ~ r--c-::- ~;;--] £ L &.9i/0,6tl~

OIL PUMP DISASSEMBLY

1. REMOVE RELIEF VALVE (a) Remove the cotter pin.

ASSEMBLY HINT: Use a new cotter pin. (b). Remove the retainer, spring and relief valve.

EG-94. ENGINE:- lUBRICATION:SYSTEM.-.

,----------------:--. '· · 2 · REMOVe: DRIVE AND DRIVEN ROTORS

( 1'25368

. .,...,

l '---

~J

.... f'7.>X6

RemovB the 3 bolts. oil pump cover, the drive and driven rotors. Torque:. 6.9 N·m (70 kgf·cm, 61 in .. Jbf)

ASSEMBLY HINT: Install the rotors so that the mark are facing thB pump cover side (upward), as shown.

I<:IU-01

OIL PUMP INSPECTION

1. INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its ow,, weight. If the valve does not fall smoothly, replace the valve or oil pump assembly.

2. INSPECT DRIVE AND DRIVEN ROTORS A. Inspect rotor body clearance

Using a thickness gauge, measure the clearance be-tween the driven rotor and body. StDndard body ci.,Dronco:

v.li)O- 0.160 mm (0.0039- 0.0063 in.) Maximum body claar.,nca:

0.20 mm (0.0070 in.)

If the clearance is greater than the maximum, repl;3ce the rotors as a sst or pump assembly.

B. Inspect .rotor tip clearance Using a thickness gauge, measure the clearance be-tween the drive and driven rotor tips. Standard tip claarar.ce:

0.040 - 0.160 mm (0.0016 - 0.0063 in.) Maximum tip cloarance:

0.20 mm (0.0079 in.) If the tip clearance is greater than maximum. replace the rotor set.

.

'

..

ENGINE- 'LUBRrCATION'SYSTEM · EG-95

C: ··Inspect rotor:side clearance Using ·a thickness gauge and precision straight edge,

· measure the clearance between the rotor::; ·and preci

sion straigt.: c:'ge'. Standard side clearance:

0.030 - 0.090 mm (0.0012 ;... 0.0035 ln.) Maximuin side clearance:.

0.15 mm (0.0059 in.) If the side clearance is _greDter thar. maximum. replace the rotors set or pump assembly.

OIL PUMP ASSEMBLY

Assembly is in the reverse order of disass .. mbly.

OIL PUMP OPERATION CHECK ··--CHECK PUMP OPERATION (a) Using a screwdriver, immerse the suction end of the

shaft clockwise. Oil shoul.d come out the discharge hole.

(b) Using a screwdriver, close the discharge hole with your thumb and turn the shaft as before. The shaft shou!d be difficult to turn.

OIL PUMP INSTALLATION

1. INSTALL OIL PUMP AND STRAINER (a) Align the oil pump shaft slot of the oil pump with the

governor shaft protrusion of the distributor. (b) Install the oil pump with the bolt.

· Torque: 19 N-m (195 kgf·cm. 14 ft·lbf)

EG-96 ENGIN.E- LUBRICATION.SYSTEM ·


(c)·· Install· a new gasket and the oil strainer with the 3 • bolts. Torque: 8 N-m (80 kgf-cm, 69 in.-lbf)

2. :fo.!~TALL OIL PAN (a) Remove any old packing (FIPG) mateJial and be care·

ful not to drop any oil on the contact surfaces of the oil pan and cylinder block.

(b) Apply seal packing to the timing chain cover, cylinder block and rear oil seal retainer as shown in the illustra· tion. Seal packing:

Part No. OBe26-00080 or equivaleOJt

(c) Place a new gasket to the engine. (d) Install the oil pan with the 22 nuts.

Torque: 9 N-m (90 kgf-cm, 78 ln.-lbf)

3. FILL WITH ENGINE OIL 4. START ENGINE AND CHECK FOR LEAKS 5. RECHECK ENGINE OIL LEVEL

Oil pres!lure At Idle sp~ed (normal Ciperating temperature) 29 kPa (0.3 kgf/cm', 43 psi) or more

At 3,000 rpm {normal operating temperature) :245 - 490 kPe (2.5 - 5.0 kgf/cm', 36 - 71 psij

Oil pump Body c/earar.ce STD 0.1 oo - 1.160 mm ·co.oo39 - 0.0063 in.)

Maximum 0.20 mm (0.0079 n.)

Tip clearenco STD 0.040 - 0.160 mm (0.00 16 •• 0.0063 in.)

I I . Maximum 0.20 mm (0.0079 n.)

L ___ ~de clearance STD 0.030 •• 0.090 mm (0.00 12 - 0.0035 in.)

Maximum 0.15 mm (0.0059 n.)

TORQUE SPECIFICATIONS

~ \ · Part tightened I I I ft-1bl I Nm

' kgf-cm

-~fil.er bracket x 011 lirGssuro sw1tch 15 150 11 --------

in plog x Oil pan 25 250 18

I Oi! p~mp cover x Oil pump body 6.9 70 61 ln.·lbf --------·

Oil pump x Cylinder block 19 195 14

Oil strainer x Cylinder block, Oil pump 8 80 69 in.-lbf

Oil pen x Cyl!ndor block, Timing ch"in ccvcr. Roar oil ~;onl retainer 9 90 78 ln.-lbf

•

-· .

·-

,_

New 0-Ring

--~

IGNITION SYSTEM - DISTRIBUTOR IG-1 3

r 1 I( """'

. 2. INSTALLDISTRIBUTOR (a) Install a new 0-ring to the distributor·housing. (b) Apply a light coat of engine oil on. the 0-ring.

(c) Align the center line of the slot at the top end of the oil pump shaft against the mark (oil hole) at the top side of the oil pump body.

(d)

(e)

(f)

(g)

3.

4. 5.

6.

7.

Position the distributor rotor toward the right sids of No.3 plug tube, and insert the distributor housing. When the housing is inserted, the rotor should ba point near the centar of No.2 plug tube. Turn the ignition switch to ON, but do not crank the.

· starter motor. Rotate the distributor body counterclockwise until a spark jumps between the points and tigntan the clamp bolt in that position. INSTALL ROTOR, PACKING AND :::JISTRIBUTOfl CAP INSTALL DISTRIBUTOR WlRE CONNECT HIGH-TENSI01J CORDS TO DiSTRIBUTOR CAP CONNECT VACUUM HOSES TO VACUUM ADVANCER CHECK IGNITION TIMING (Sea ignition timing inspection and scijustment in Engine Mechanicalj

IG-14·------- IGNITION SYSTEM- SERVICE SPECIFICATIONS


H.igh-tension I Res:istaLlc.e

cord ~ Spark plug . Recommended spark plug

Correct electrode gap

~~ition coil Piima:y coil resistance

. Sacondnry co:l r(;sistance

Resistor resistanCe

Distributor Rubbing block gap

D:ampin~. spring gap

TORGUE SPECIFICATIONS

Part t:ghtened

Spark plug x Cylinder head

Distributor x Cylinder head

Maximum

NO

NGK

at cold

at hot

at cold

at hot

at cold

at hot

25 k 0 pur ~ord

W16Ex-u·

BP5EY

0.8 mm (0.03 1 in.)

1.35 - 2.09 ()

1.71 - 2.46 (i

8.5- 14.5 kO

10.7- 17.1 kO

0.8 - 1.3 0

1.05 - 1.52 0

0.4 - 0.5 mm (0.0 1 6 ·- 0.020 in.)

0.05 - 0.45 mm (0.002 - O.ot 8 in.)

N·m kgf.cm

17.5 180

12 120

--

·•

ft·lbf

13

9 . .

-·

IG-1

IGNITION SYSTEM

.-PREPARATION ....................................... IG- 2

-- ON-VEHICLE INSPECTION ....................... ·IG- 2

DISTRIBUTOR •••·•·••·•····•·••······••··· •·•·•••••••·• iG- 7 SERVICE SPECIFICATIONS ........................ IG- 14 I

IG-2 ·IGNIT-ION SYSTEM - ON~VEHICLE 'li~SPECTION

PREPARATION RECOMMENDED TOOLS

.. 090B2 -oooso

~<>? ~~~-~ ~""""" ~£ c

09200-00010

= ~ ~~

EQUIPMENT

-·-liD TOYOTA Eloetrict~l Tost~r Sot .

Engine Adju~t Kit .

M<9gger insulation resistance meter ~~~--------------~--------------------------~ Spark plug cleaner

------------------------r-----------------------·--~ Torque wrench

ON- VEHICLE INSPECTION SPARK TEST

CHECK THAT SPARK OCCURS (a) Disconnect the high-tension cords from the spark

plugs. (b) Remove the spark plugs. (c) Install the SJ:.>ark plugs toeach high -tension cord. (d) Ground the spark plug. (e) Che.;k if spNk occurs while engine is being cranked.

NOTICE: To prevent excess fuel being Injected from the

injectors during this test, do not crank the engine for more 5 - 10 seconds at time.

If the spark does not occur, do the test as follows:

•

·.

-·

:CNITION SYSTEM - ON-VEHICl-E INSPECTION. IG-3 ----------~~~~~~~==~~~~--------

I SPARK TEST I I NO

CHECK CONNECTION OF IGNITION COIL I ·J Connect securely. I AND DISTRIBUTOR CONNECTOR BAD t OK

CHECK RUBBING BLOCK GAP OF DISTRIBUTOR

I )See page IG-61 Rubbing block g<lj): 0.4- 0.5 mm (0.016- 0.020 ln.) BAD

Check and adju:;tlhe gap.

I OK CHECK RESISTANCE OF HIGH-TENSION CORD

~BAD l (See page IG-3) Replace the cor,; (s). Mal<imum resistance: 25 kO per cord

I OK 0

CHECK POWER SUPPLY TO IGNITION COIL t.Turn ignition switch to ON. Check wiring between ignition switch 2.Check that there Is bat!ery voltage at BAD to ignitcn coil.

igniton coil positive (+) terminal.

I OK CHECK RESISTANCE OF IGNITION COli... AND

""'"""" ,,.,., '"'· ~ RESISTOR !See page IG-41 Resistance: Coil Primary

Secondary . Resistor

I I I...__ .

Cold Hot 1.35·2.090 1.i1-2.460 BAD 8.5 ·14.50 10.7-17.1k0

·o.a -1.30 1.05 ° 1.520

I

~·

HIGH- TENSION CORDS INSPECTION

1. DISCONNECT HIGH-TENSION CORDS

(a) Disconnect the high - tension cords at the rubbor boot

(b) Disconnect the high-tension cord from the distributor cap and ignition coil.

DO NOT ;>ull on the cords. NOTICE: Pulling on or bonding the cords rnay damage the conductor ins:ide.

2. INSPECT HIGH-TENSION CORD RESISTANCE

Using an ohmmeter, measure the resistance. Maximum resistance:

25 kQ per cord

If the resistance is greater than m~ximum, check the tormb:;~\s .. !f riocessary, roplacs the high ~ Tensbn cord.

3 .. RECONNECT HIGH-TENSION CORDS

'-----===:: f?JJ:..-< J

SPARK PLUGS INSPECTION

2.

DISCONNECT HIGH-TENSION COflDS FROM SPARK PLUGS REMOVE SPARK PLUGS

Using a 16 mm plug wrench, remov~ the spark plug.

.. ;q-4. · :GNI"fiON SYSTEM·- ON-VEHICLE INSPECTION

.--------------,

IGOSCJ Zt6411

;j. CLEAN SPARK PLUGS Using a spark plug cleaner or wire brush, clean the spark plug.

Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap:

0.8 mm (0.031 ln.)

6. REINSTALL SPARK PLUGS Torque: 17.5 N·m (180 kgf·cm, 13 ft·lbf)

7. RECONNECT HIGH-TENSION CORDS TO SPARK PLUGS

IGNITION COIL INSPECTION

NOTICE: "Cold" end •Hot" In these sentences express the temperature of the co!ls themselves. ·cord· Is from -1 o•

. C (14°F) to so•c (122.F) snd··Hot"ls from so•c (122°F) to 100°C {2~:;('f-}.

1. DISCONNECT HIGH-TENSION CORD FROM IGNITION COiL

2. INSPECT PRIMARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the + and - terminals. Primary coil resistance: ·

Cold: 1.35 - 2.09. 0 · Hot: 1.71 - 2.46 0

If the electric resistance is not as specified, replace the ignition coil.

. .

-.

IG0585

IG-5 IGNITION SYSTEM ... -'- ON-VEHICLE INSPECTION-------

Ohmmeter

T::-I['J

'----Hoi 0 Zl6412

Ohmmeter

l.:.n.:J

'-----roe;:_~l 216•113

Voltmeter

DC]

~0 e

I

:3. INSPECT SECONDARY COIL RESISTANCE

4.

Using. an· ohmmeter, measure the resistance botween the Band high-tension terminals. Secondary co!' raslstance:

Cold: 8.5 - 14.5 kQ Hot: 10.7- 1'1.1 kQ

If the electric resistance is not 2s specified, replace the ignition ::oil.

INSPECT RESISTOR RESISTANCE Using an ohmmeter. measure tha resistance between the B and + terminals. Resistor resistance:

Cold: 0.8 - 1.3 Q

Hot: 1.05 - 1.52 0

If the electric resistance is not· as spocified, replace the ignition coil.

5. INSPECT ?OWER SOURCE LINE (a) With the ignition switch an ON and using a v.oltmeter.

connect the positive ( +) probe to the B tarminal and the negative (-) probe to body ground. Voltage: Approx. 12V

L'~Go::"='-------------~-~-· -----~ (b) With the ignition switch as ·sr ART' and using a

voltmeter, connect the positive ( +) probe to the + terminal and the negative(-) probe to body ground. Voltage: Approx. 12V

If abnormal, check tha ignition switch and wire harness.

c. RECONNECT HIGH-TENSION CORD TO IGNITION COiL

IG-6. • IGNITION SYSTEIVI ,_.,ON-VEHICLE INSPECTION

~I

DISTR!BUTOR INSPECTION

1. REMOVE DISTRIBUTOR CAP WITH .H'GH.,-TENSION CORDS

2. REMOVE ROTOR· 3. INSPECT BREAKER POINT

Using a feeler gauge. measure the gap between the cam and rubbing block. Rubbing block gap:

0.4 - 0.5 mm (0.016 - 0.020 in.)

If the gap is not within specification, adjust the gap. (See distributor assarnbly)

4. INSPECT DAMPING SPRING

Using a feeler gauge, measure the gap between the cam and damping spring. Damping spring gap:

0.05- 0.45 mm (0.002- 0.018 in.)

. If the gap is not within specification, adjust the gap. (See distributor assembly)

5. INSPECT VACUUM ADVANCER (a) Disconnect the vacuum hoses from the vacuum ad-

vancer. (b) Apply vacuum to the port A or B and check that the

vacuum advancer moves. If the vacuum advancer do_es not work, repair or replace as necessary.

6. INSPECT GOVERNOR ADVANCE (a) Turn the rotor clockwise, release it and check that the

rotor re.turns quickly counterclockwise. (b) Check that the rotor is not excessively loose. 7. REINSTALL ROTOR . 9. REINSTALL DISTRIBUTOR CAP

•

.· ' '~

High-Tension ---rCord

®@~0-. Dislribulor -1 j • • • Wire Dislribulor ----<<L•

.. + 0-Ring----~cp

I L---

+ Non-reusable part

IGNITION SYSTEM _; DISTRIBUTOR IG-7

--

· DIS'fRJBl:JTOR COMPONENTS FOR REMOVAL AND •.

INSTALLATION

---

I I I I I ....

DISTRIBUTOR REMOVAL

1. DISCONNECT HIGH-TENSION CORDS FROM DISTRIBUTOR CAP

2. DISCONNECT VACUUM HOSES FROM VACUUM ADVANCER

3. REMOVE DISTRIBUTOR WIRE 4. REMOVE DISTRIBUTOR (a) Remove the mounting bolt, and pull out tha distribu-

tor. (b) Remove the 0- ring from the distributor housing.

IG·B IGNITION SYSTEM __: DISTRIBUTOR···

r--_ PieceB --...J

Rotor------@

w 11 LeodWirc~ .·· I

Holder- ~ I I I .~ Damping

Sprin~ I- -1--" ---"--

l,

Breaker Plate

+Non-reusable part

P25~

COMPONENTS FOR DISASSEMBLY AND"-~ ASSEMBLY

!-----Grease Stopper

!----Governor Spring

Packing

Distributor Housing Assembly

+ Driven Gear~

+Straight Pin -=t;1 Vacuum Advancer

DISTRIBUTOR DISASSEMBLY

,_

2. (a) (b)

(c)

3.

4.

REMOVE DISTRIBUTOR CAP, ROTOR, AND PACKING REMOVE DISTRIBUTOR TERMINAL Remove the nut and spring washer. Disconnect the lead wires of the condenser and breaker point. Remove the 2 terminal insulators and terminal.

REMOVE BREAKER POINT Remove the 2 screws and breaker point. REMOVE DAMPER SPRING Remove the screw and damper spring.

-. ' ..

•

- l

'·

IG-9 IGNITION SYSTEM - DISTRIBUTOR '.

·~I

5, REiv'IOVE VACUUM ADVANCER (a) . R.i~ove the screw and condenser. (b) Using a s~niwdriver, remove the snap ring and pull out

the vacuum advancer.

6. REMOVE BREAKER PLATE (a) Remove the 2 screws, lead wir~ and holder. (b) Remove the breaker plate.

7. REMOVE GOVERNOR SPRINGS Using needle- nose pliers, remove the 2 springs.

8. REMOVE CAM (a) Remove the grease stopper. (b) Remove the screw at the end of tho governor shaft. (c) Pull out ths cam.

9. REMOVE GOVERNOR WEIGHTS Using a small screwdriver, remove th~ snap ring and pull out the 2 weights.

.. IG-1 0 .IGNITION SYSTEM -:- DiSTRIBUTOR

.,,..I r-----------------------~

I

____ Pm»j

"' 154/G014T Z16'1l~

. DISTRIBlJTOR IN3PECTION

1. INSPECT BREAKF.R PLATE Turn the breaker plate and check that it has a slight • drag .. If it sticks or strongly resists, replace the breaker plate.

2. INSPECT GOVERNOR SHAFT (a) Turn the governor shaft and check that it is not rough

or worn. If it feels rough or worn, replace the distributor housing assembly .

(b) Using a feeler gauge, measure the governor shaft thrust clearance. Thrust clearance:

0.15 - 0.50 mm (0.0059 - 0.0197 in.) If the thrust clearance is not as specified, rep/aced the distributor housing assembly.

3. INSPECT CAM lnstaU the cam to the governvr shaft and check that they fit correctly. .

If they don't fit, replace the cam and/or distributor houl.'ing assemblv.

DRIVEN GEAR REPLACEMENT

1. REMOVE DRIVEN GEAR (a) Using a grinder, grinc the driven gear and straight pin.

CAUTION: Be careful .,ot to damage the governor shaft.

(b) Mount the driven gear in a vise. (c) Using a pin punch and hammer, tap out the straight

pin. (d) Remove ihe drive gear and washer.

. .

' .

. -

IG-11 IGNITION SYSTEM - DISTRIBUTOR

--~-------~~~~~~~~----~---

P25567

Drill Mark-·--..__. I L ___ ___,_, :=..~"'""

2. INSTALL NEW DRI\(EN GEAR {a) · Place the driven gear onto the governor sh,ft. {b) Install the new straight pin .

{c) Sacure the ends of the straight pin in a vise.

DISTRIBUTOR ASSEMBLY

1. INSTALL GOVERNOR WEIGHTS Using l)eedle- nose pliers, install the 2 weights with the snap ring.

2. INSTALL CAM {a) Lightly coat the governor shaft with high-t~mpera-·

tum grease, {b) Place the cam on the governor shaft. {c) Po.sition the &ill m~rk on the driven gear and cutout

as ~hown. {d) Install ths screw.

(d) Pack high-temperature grease into the c"m. {e) Push on the grease stopper with your finger. 3. INSTALL GOVERNOR SPRINGS

Using needle- nose pliers, in~tall the 2 springs.

IG-1:.!.

~··,

~--

IGNITION SYSTEM - DISTRIBUTOR

.. . . <l • INSTALL BREAKER PLATE {a) Align tl.a 4 clips on the breaker plate with the cutout

parts of the housing and insert the breai<er plate. (b) lnstali the 2 holders. lead wire and 2 screws. 5. INSTALL VACUUM ADVANCER {a) Insert the vacuum advancer into the housing connect-

ing the pivot pin to the link. {b) Usir:g needle-nose pli;;rs, install the snap ring. {c) Install the condenser with the screw.

6. INSTALL AND ADJUST BREAKER POINT (a) Clean the contact surfaces of the points with a piece

of cloth saturated in solvent. (b) Apply high--temper<tture grease to the rubbing block. (c) Temporary install the breaker point and lead wire with

the 2 screws. {d) Adjust the gap between the c<:m and rubbing block.

Rubbing block gap: 0.45 mm {0.018 in.) (d) Tighten the 2 screws and recheck the rubbing block

gap. 7. INSTALL AND ADJUST DAMPER SPRING {a) Apply high-temperature grease to the heel of the

damper spring. (b) Temporary install the damper spring with the screw. (c) · Adjust thfl gap between the cam and damper spring ..

Damper spring gap: 0.25 .mm (0.01 0 ln.) (d) Tighten the screw and recheck the damper spring gap.

8. INSTALL DISTRIBUTOR TERMINAL (2). Install the 2 insulators and terminal to the housing. (b) Connect the lead wires of the breaker point and con-

denser to the terminal. (s) lnst~JI thtJ spring wash.:r Dnd nut.

DISTRIBUTOR INSTALLATION

1. SET N0.1 CYLINDER TO TDC/COMPRESSION (a) Remove the No.1 spark plug. {b) Place your finger over the hole of the No.1 spark plug

and rotate the crankshaft clockwise to TDC. If pressure is felt on your finger, this is TOG/compression of the No.1 cylinder. If not, repeat the process.

(c) Install the No.1 ~park plug.

•

. . " , ~-

... ,. .. l~ew o-Ring

. -

.. -;

\ .

IGNITION SYSTEM '--- DISTRIBUTOR

2. ·INSTALL DISTRIBUTOR

(a) Install a new 0- ring to the disiributor housingc (b) Apply a light coat of engine oil on the 0-ring.

IG-13

(c) Align the center line of the slot at the top end of the oil pump shaft against the mark (oil hole) at the top side of the oil pump body .

(d) Position the distributor rotor toW3rd the right side of · No.3 plug tube, and insert the distributor housing .

(e) When the housing is inserted, tho rotor should be point near the center of No.2 plug tube.

(f) Turn the ignition swit,ch to ON, but do not crank the starter motor.

(g) Rotate the distributor body counterclockwise untir" a spark jumps between the points and tighten the clamp bolt in that position.

3. INSTALL ROTOR, PACKING AND !:JISTRIBUTOR CAP

4. INSTALL DISTRIBUTOR WIRE 5. CONNECT HIGH-TENSION CORDS TO

DISTRIBUTOR CAP 6. CONNECT VACUUM HOSES TO VACUUM

ADVANCER 7. CHECK IGNITION TIMING

(Sea Ignition timing inspection ond adjustment in Engine Mechonlcel)

IG-14 IGNITION SYSTEM

SERVICE SPECIFICATIONS SERVICE OAT A

. TORQUE SPECIFICA JtON~,~. ; .. ,: r-·

Part tightened

Spark plug X Cylinder hood

Distributer x Cylinder head

SERVICE SPECIFICATIONS

Maximum ! 25 kO per cord

" I w"~-o NGK BP5EY

0.8 mm (0.031 in.)

at cold 1.35 - 2.09 0

nt hot 1.71 - 2.46 0

at cold 8.5 - 14.5 kO

at hot 10.7- 17.1 kO

at cold 0.8 - 1.3 0

ot hot 1.05 - 1.52 0

O.A - 0.5 mm (0.0 16 - 0.020 in.)

0.05 - 0.45 mm (0.002 - O.Q18 in.)

N-m kgf·cm

17.5 180

12 120

og01t•OO

ft·lbf

13

9

•

ST-1

STARTING SYSTEM ..

?REPARATION ······································· ST- 2

STARTER ·················································sr- 3 SERVICE SPECIF:CATIONS··········· ............. ST-- I~

' .

ST-2 STARTING S'(STEM -·PREPARATION

PREPARATION SST (SPECIAL SERVICE TOOLS) •

I 09221 -25025 Piston Pin Remover & Replacer

I

....... ···································································· ·················· ················ ··································································· (09221 -00090) Gu;de ·c· Center besring

•

noor-or

=tECOMMENDED TOOLS

09082-00050 TOYOTA Electdcel Tester Set.

09804-00010 Expondor Set.

:OUIPMENT Micromet9r Planetary aheft

Caliper gauge

Dial indicator Comm11tator -Magnetic finger

Pullacale Brush spring

Sandpaper Commutator

l'>rqu.t wronch - __ -==:J v block

.. Vtrmer eaupe._r_•---------~-----·---..L..:C::o:::":::'m::_u::t::•:::to::_r•:_:B::r.:u::•h:_ _________ , ____ j

•

·•

. . '

-.

. .

STARTING: SYSTEM-. STARTER ST-3

STARTER COMPONENTS FOR DJSASSEMBL Y AND--~

ASSEMBLY

Magneti~ Switch Cover ®@~~Covetfr . l $~ e

Magnetic Switch Starter Housing

Drive Lever

· Stop Co/l;;r Plate Washer ·1

· Shock(}) Absorber l ""~@®--Snap Ring

Planetary Gear~Pianetary Sha~ (j/fff\ ~~~Starter Clutch

loi 'fi ~ ~ I Snap Rmg

Plate rQ;\ ~ ~ Plate Washer I Center Bearing ~ I Internal Gear

Plate Washer Brush Holder ' ~-Armature

comm"'"" Eo' '"m' -.;:-- "- to +o-"'"' ~ ~-~- l Field Frame

<l>' - __ < + 0-Ring

~Non-reusable part ~ +O-Ring --~ '(j---oust Protector _JI

--------------~--------~

STARTER D!SASSEMBL Y

1. REMOVE MAGI'IETlC SWITCH CO\'Efl 2. REMOVE MAGNETIC SWITCH

(a) Remove the nut and magnetic switch ccwer, (b) Remove the nut, and c::;~connact the l&ad wire from

the magnetic switch terminal. (c) Loosen the 2 nuts holding the magnetic switch to the

starter housing . (d) ·Pull the magnetic switch and while lifting the front

part of the magnetic switch. release tho plunger hook from the drive levar, then release the magnetic switch.

(e) Remove th;; plunger r.over. 3. REMOVF. FIELu FRAME AND ARMATURE

Remove the 2 through bolts, and pull out tho fi6ld frame together with the armature.

.. :

·:T-4 .STARTING. SYSTEM -STARTER

ST0728

t ;v~

ST~711 ------------------

1\0252 (1 J Z00210

. 4. R:;MOVE COMMUTATOR END FRAME Remove· the 2 screws with 0-rings and commutator end frame, and hold down the lead wire while releas-ing the commutator end frame. NOTICE: To avoid interference between the brush holder

and the dust protector, pull the commutator end frame

away at flO angle.

. 5. REMOVE BRUSH HOLDER (a) Using a screwdriver, hold the spring back and discon·

nect the brush holder. (b) Disconnect the 4 brushes, and remove the brush

holder. 6. REMOVE ARMATURE FROM FIELD FRAME 7. REMOVE 2 0-RINGS FROM FIELD FRAME

8. REMOVE DRIVE LEVER AND STARTER CLUTCH ·wiTH SHOCK ABSORBER FROM STARTER HOUSING

9. REMOVE PLANETARY GEARS Ramcve these parts from the shock absorber. (1) Plzte '

· (2) 3 planetary goars (3) Plate washar

10. REMOVE STARTER CLUTCH (a) Usi! .g a screwdriver, tap in the stop collar towards the

sta"ter clutch. (b) Using a screwdriver, pry off the snap ring.' (c) Remove the stop collar and starter clutch from the

planetary shaft.

.•

. '

.r

'--------------~~--~~S~T~A~R~T~I~N~G~-s~v~:s~T~E~M~-~-~S~T~A~R~TE~R~--------------------s_T_-_5

SICISSil

c;ontinuity

-,:J)J~E-=· ::1=·1 =

-;~]~_" --0~· ___;,j

11.' REMOVE P-lANETARY SHAFT AN~ INTERNAL GEAR

(a) Using snap ring plierz. remove the snap ring and plate washer. ·

(b) Removo the planetary shaft and plat'l washer.

STARTER INSPECTION AND REPAIR Armature Coil

1. INSPECT COMMUTATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity bet\~een the ;;egments of the commutator. If there is no continuity between any segments, replace the umature.

2 •. INSPECT COMMUTATOR FOR GROUND Using an ohmmeter, check that there is no cc-.ntinuity between the commutator and armature coil core. If there is continuit-y, replace the armature.

Commutator

1. INSPECT COMMUTATOR FOR'DIRTY AND BURNT SURFACES If the surface is dirt-y or burnt, correct with sandpapsr (No.400) or a lathe.

2. INSPECT COMMUTATOR CIRCLE RUNOUT (a) Piace tha <•om mutator on V -0!ccics. (b)-· Usin;J a dial gauge, measure tha circle run out;

3.

Mexlmum circle runout: 0.05 mm (0.0020 ln.)

If the circle runout is greater1h1m maximum, correct it on a lathe.

INSPECT COMMUTATOR DIAMETER Using vernier calipers, measure the commutator diameter. Standard diameter:

28 mm (1.10 ln.) Minimum diameter:

27 mm (1.06 ln.) If the diameter is less than minimum, replace the armature.

~ i '

I :I

ST-6

Continuity

No coiitinuit\'

STARTING SYSl'EM -STARTER

ST0040 1

l

4. INSPECT UNDEi)C:..'T DEPTH Check that the undercut depth is clean and free of foreign materials. Smooth out the edge. Standard undercut depth:

0.6 mm (0.024 in.)

Minimum undercut depth:

0.2 mm (0.008 in.)

If the undercut depth is less than minimum. correct it wi~h a hacksaw blade.

Field Frame (Field Coil)

1. INSPECT FIELD COIL FOR OPEN CIRCUIT Using an ohmmeter. check that there is continuity between the lead wire and field coil brush lead. If> there is no continuity, r~place the field frame.

2. INSPECT FIELD COIL GROUND Using an ohmmeter, check that there is no continuity between the field coil end and field frame: If there .is continuity, repair or replace tho field frame.

Brushes

INSPECT BRijSIJ LENGTH Using vernfer calipers, measure the brush length. Stondord length:

14.0 mm (0.551 ln.)

Minimum longth: 9.0 mm (0.354 in.)

ff thq Jqngth k Jqu lh;m minimum. mplilGii !hr. /;ru~l. holder and filed frame.

Brush Springs

INSPECT BRUSH SPRING LOAD ·Take the pull scale reading the instant the brush spring separates from the brush. Spring installed load:

8.8'- 17.7 N (0.9 - 1.8 kgf, 2.0 - 4.0 lbf)

r ..

-·

<

. STARTING.SYSTEM- STARTER

__ ; •. ------------'-~--, -.

•. ! •' -· .

,. . •

i;

No continuity

---------------""'-" I

Contjnuity

STOC:67

Terminal 50

Terminal C

P10134

Brush'Hoider

INSPECT BRuSH HOLDER INSULATION Usin·g an ohmmeter, check that there is no continuity between the positive{+) and negative(-) brush holders. If there is continuity, repair or replace the brcsh holder.

. Clutch and Gears

1.

2 .

INSPECT GEAR TEETH Check the gear teeth on tha planetary gear.- internal gear and starter clutch for woar or damage. If tl;le gear is damaged, repiBce it. If the starter clutch teeth are damaged; replace the starter clutch and also inspect the fl~wheel ring gear for wear or damage.

INSPECT STARTER CLUTCH Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion gear counterclockwise and check that it locks. If necessary, replace the starter clutch.

Magnetic Switch

1. INSPECT PLUNGER Push in the plunger and replace it. Check that it returns quickly to it:? original position. If necessary, replace the magnetic> swit!:h.

2. DO PULL--'I.N COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity. replace the magnetic switch.

·t.

' . ~ 'i f I:

.,•,.

ST-8 STARTING SYSTEM·,... STARTER.

~ -----------------

~ST e:i--~ "-- Yf I '- -

~" fy)

/ '

3. DO .HOLD....., IN COIL OPEN CIRCUIT TEST . I • •

Using M ohmmeter, check that there is continuity between terminal 50 and the switch body. · If there is no continuity, replace the magnetic switch. ·

. ,

Planetary Shaft and Center Bearing

1. INSPECT PLANETARY SHAFT AND CENTER BEARING

(a) Using a micrometer, measure the outer diameter of the, surface in contact with the center bearing of the planetary shaft. Standard shaft diameter:

14.980- 15.000 mm (0.5898- 0.5906 in.)

(b) Using a caliper gauge, measure the inside diameter of the center bearing. Center boadng Inside diameter:

15.008 - 15.050 mm (0.5908 - 0.5925 in.) (c) Subtract the planetary shaft diameter from the bear

ing inside diameter measurement. Standard center bearing oil clearance:

0.01 - 0.06 mm (0.0004 - 0.0024 in.) Maximum cantor bearing oil cloarance:

0.2 mm (0.0078 ln.)

If the clearance is greater than maximum, replace the planet carrier shaft and center bearing.

2. lF NEC!:SSARY, REPLACE CENTER BEARING (a) Using SST and .Press, press out the center bearing.

SST 09221-25025 (09221-00090)

(b) Using SST and a press, press in a new center bearing to the posi.tion shown in the illustration.

•

....

·-

SST 09221-25025 (09221-00071) •

•

' - '

• •

·'

-

STARTING. SYSTEM:....· STARTER· ST-9

' '

Shock Absorber

Hollow

Protrusion

SToo-17

· liollow

STC647

(j Planetar~· Shaft

f Plate Washer

)671 Zl~l

sroon

·(c) Align the hollow of tha internal gear with the protrusion inside the shock absorber, and remove the interrial gear. ·

STARTER ASSEMBLY

1.

HINT: Use high temperature-resistant grease to lubricate the bearings and sliding parts when assembling the starter. INSTALL INTERNAL GEAR AND PLANETARY SHAFT

(a) Apply grease to the internal gear touching the sock absorber and planetary gears.

(b) Align the hollow of the internal gear with the protrusion inside the shock absorber.

(c) Insert and turn the internal gear 5o that it interlocks with the shock absorber.

(d) (e)

(f) (g)

: 2. (a)

(b)

Apply turbine oil with additives to thA c&nter bearing. Apply grease to the plate washer. and install it to the plar.atary shaft Install the·planetary shaft to the shock absorber. Using snap ring plior~. install the plato washer and snap ring.

INSTALL STARTER CLUTCH Apply grease to the bushing and splir.e of the starter clutch and stop collar. Place the starter clutch an·d stop collar on the plano· tary shaft.

..

ST-10 STARTJNG.SYSTEM - STARTEtl

ST007J

t :

··~. ST07<11

(c) Apply. grease to the snap ring, and instal! it to the planetary .shaft gro.ove.

(d) Using a vise, compress the snap ring.

(e) Hold the starter clutch, tap the planetary shaft and install the stop collar onto the Sflap ring with a plastic -facod hammer.

3. INSTALL PLANETARY GEARS (a) Apply grease to the planetary. gears and flange pin

parts of the planetary shaft. (b) Install the plate washer and 3 planetary gears. (c) Align the cutout of the plate With the protrusion insida

the shock absorber, and install the plate.

4. INSTALL DRIVE LEVER AND STARTER CLUTCH WITH SHOCK ABSORBER

(a) Apply turbine cil with additives to tlie bearing ot 1he starter housing.

(b) Apply grease to th& drive levor touching the starter pivot part of the drive levsr.

(c) Install tho drive lever to the starter clutch.

(d) Align the protrusion of the shock absorber with the 0utout of the starter hol!sing and install them.

. . •

..

.·

•

.• . ... .. . . .

·.

i

iT0727

R I 88.(

STARTING SYSTEM - STAR.TER ST-11

"""

Protrusion

=

I I

ST0742

5. 6. 7.

INSTALL 2 NEW 0-RJNGS TO FJELD FRAME PLACE ARMATURE INTO FIELD FRAME INSTALL BRUSH HOLDER

(a) Place the brush holder in position on ths armature. (b) Using a screwdriver. hold the brush spring back. a.1d

connect the brush into tho brush holder. ' Connect the 4 ·brushes. HINT: Check that positive(+) lead wires are not grounded.

8. INSTALL COMMUTATOR ENO FRAME (a) Apply turbine oil with additives to t~e bearing of the

end frame. (b) Install the end frame with 2 new screws with 0-:-

rings. NOTICE: To avoid interference between tho brush holder and tho dust protector, pull tho commutator ~rid frame away at an angle.

9. INSTALL FIELD FRAME AND ARMATURE ASSEMBLY

(a) Align the cutout of the field frame with the protrusion of the shock absorber.

(b) Install tho field frame and arrnaturo assnmbly with the 2 through bolts.

10. (a)

(b)

(c) (d)

INSTALL MAGNETIC SWITCH Install the plunger cover to the magnet:c switch. Ha11g the pltrnpE!r ol tho magn~ti.:: ,~witch to the drive levsr from the upper side. Install ths magnetic switch with the 2 nuts .. Connect the lead wire to th~ terminal, And install the nut.

(e) Install the magnetic switch cover with the nut. 11. INSTALL MAGNETIC SWITCH COVER

STARTER PERFORMANCE TEST

NOTICE: Thaso tests must be dono within 3 to!> seconds to avoid burning out tho coil:

1. DO PULL-IN TEST (a) Disconnect the field coil lead from terminal C. (b) Connect the battery to the magnetic switch as shown.

Check that the clutch pinion gear mo·ves outward.

,.;

·:··

ST-12 STARTING SYSTEM- STARTER

Di~connect

"'""'

'---- ------------'-"""="'-1

If the clutch pinion gear does not move, repiace the • magnetic switch. ·

2. DO HOLD-IN TEST

3.

With the battery connected as above and with the clutch pinion gear .:>Ut disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear remains out. If the clutch pinion gsar returns inward, replace the magnetic switch.

INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative (-) le.ad from the switch body.

- . •

Check that the clutch pinion gear returns inward. " If the clutch pinion gear does not return, replace the !'\lagnetic switch.

4. INSPECT CLUTCH PINION GEAR CLEARANCE (a) Connect the battery to the magnetic switch as shown.

(b) Move the pinion gear toward ths armature to remove slack and maasure the ci<Jarance between tha pinion goar end am! stop co!!a~. St~and11rd ~lesranee;

7 - ~ m'm (0.04 ·- 0.16 in.)

5. DO NO-LOAD PERFORMANCE TEST (a) Connect the field coil lead to terminal C.

Make sure the lead is not grounded. (b) Connect the battery a·nd ammeter to the starter as

shown. (c) Check that the starter rotates smoothly and steadily

with the clutch pinion gear moving out. Check that the ammeter r!3ads the•specified current. RnAl"':ifiArf r.:m"r"Ant!

•

•

••

'.

STARTING SYSTEM -SERVICE SPECIFICATIONS


Starter 1 RBted voltage and output puwer

No-load characteristics

Brush len9th

Spring instal:ed load

Ccmmutator

Diameter

Undercut dApth

Circle runout

Planetary shaft diametor

Center bearing

Inside diamoter

Oil clearance

12 V 0.8 kW

Current 90 A or less at 11. 5 V

rpm 3,000 rpm or more

STD

Minimum

STD

Minimum

14.0 mm (0.551 in.)

9,0 mm (0.354 in.)

8.8 - 17.7 N (0.9 ·· l.B kgf, 2.0 - 4.0 lbf)

26 mm (1.10 in.)

27 mm ( 1.06 in.)

STD 0.6 mm (0.024 in.)

Minimum 0.2 mm (0.008 in.)

Maximum 0.05 mm (0.0020 in.)

STD 14.980 - 15.000 mm (0.5898 - 0,5906 in.)

STD

Maximum

15.008 - 15.050 mm (0.5908 ·- 0.5925 in,)

O.GI - 0.08 mm (0.0004 - C.0024 in.)

0.2 mm (0.0078 in.)

ST-13

.........

l

L ____________ l_P~i~n~io~n~c~lo~o~,,~n~c~e------------·--------~S~T~D~~I_:-~4~m~m~(0~.04~~-~~0.~1~6~in~.~)------------·----·--_J

CH-1

,- CHARGING SYSTEM

•

PRECAUTION .......................................... CH- 2

PREPARATION ····························-·······; .. CH- 2' ON-VEHICLE INSPECTION ..................... CH- 3

ALTERNATOR ............................ _ .......... CH- 5

ALTERNATOR REGULATOR,_,_,_,,, ......... CH-13

SERVICE SPECIFICATIONs ........................ CH- 14

'.

' I i

I I I

CH-2 CHARGING SYSTEM - PREPARATION

PRECAU;!ON

1. Check that the battery r.aoles are connected to the correct terminals. 2. Disconnect the battery cables when the battery is given a quick charge. 3. Do not perform tests with a high voltage insulation resistance tester. 4. Never disconnect the battery while the engine is running.

PREPARATION SST (SPECIAL SERVICE TOOLS)

09286-46011 Injection Pump Spiino Shaft Pullor

09950-60010 Replacer Set

(0995 I -00220) Replacer 22

(09951-00400) Replacer 40

Roto:~r roar bearing

Rotor front bearing

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RECOMMENDED TOOLS

TOYOTA Electrical Testor Set. L_ 09082-00050

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EQUIPMENT ----

Batt&r'f' specific gravity gauge

Torque wrench --

Vernier calipors Rotor (Slip ring)

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CORRECT

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Water Pump

CHARGING SYSTEM - ON-VEHICLE INSPECTION CH-3

WRONG

MAOOJS

Allernator

1 "''"'

ON- VEHICLE INSPECTION

1. CHECK BATTERY SPECIFIC GRAVITY AND ELECTROLYTE LEVEL

(a) Check the electrolyte quantity of each cell. if insufficient, refill with distilled (or purified) water.

{b) Check the specific gravity of each ceil. Standard specific gravity:

At 2o·c (sa·FJ: NS40l: 1.27 - 1.29

Othors: 1.25 - 1.27

If the gravity is less than $pacification, charg~ tho battery.

2. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES

(a) Check that the battery terminals aro not loose or . corroded.

(b) Check the fusible link and fuses for continuity. 3. INSPECT DRIVE BELTS (a) Visually check the drive belt for craeks, oiliness cr

wear. Check that the belt does not to:.~ch the bottom of the pulley groove. If necessary, replace the driva bel:.

{b) Check the drive belt deflection by pressing on the belt at the points indicated in the illustration with 98 N {1 0 kgf, 22 lbf) of pressure; Drive belt deflection:

New belt: 11 - 15 mm (0.43 - 0.59 in.) Used belt: 15 - 20 mm {0.59 - ().79 in.)

If neces.sary, adjust the drive bolt deflection. HINT: • "New belt" refers tc a belt which has bGen usod

less than 5 minutes or. a running sngina. • "Used belt" refers to a bolt which ha$ been used

on a running enginll for 5 minutas or more. • After installing a new belt, run the engine for

about 5 minutes and recheck the deflection. 4. VISUALLY CHECK ALTERNATOR WIRING AND

LISTEN FOR ABNORMAL NOISES (a) Check that the wiring is in good conclition. (b) Check that there is no abnormal nois~ from the alter

nator while the engino is runnin8. 5. INSPECT DISCHARGE WARNING LIGHT SIRCUIT (a) Turn the ignition switch "ON". Check that the dis

charge warning light comes on. (b) Start the engine. Check•that the light goes off.

If the light cloes not operate as specified, troubleshoot the discharge warning light circuit.

CH-4 CHARGING SYSTEM.- ON-VEHICL:E INSPECTION

Plm / ...._,..__~·,...., ~meter

CH0008

QQI17 I

· 6, . INSPECT CHARGING CIRCUIT WITHOUT LOAD , . HINT: If a batteryjalte~nator teste'r is available, con- • nect the tester to the charging circuit as per the manufacturer's instructions.

(a) If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows: • ·Disconnect the wire from terminal 8 of the altar

nator and cc.nnect it to the negative (-) lead of the ammeter.

• Connect the positive ( +) lead of the ammeter to terminal 8 of the alternator.

• Connect the positive(+) lead of the voltmeter to terminal 8" of the alternator.

• Ground the negative(-) lead of the voltmeter. (b) . Check the chargi!lg circuit as follows:

With the engine running frorr: idle to 2,000 rpm, ch.eck the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage:

At20"C(68"F): 13.8 -14.8V

At 60"C (140"F): 13.3- 15.5 V

"If the voltmeter reading is more than standard voltage, adjust the regulator or replace it.

7. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the

high beam headlights and place th.e heater blower switch at "HI".

(b) Check the reading on the ainmete~r. Standard amperage: 30 A or mare

If the ammeier reading is less than standard amperage, repair the alternator. HINT: If the battery is fully charged, the indica·tio;1 will somatiml3s be :!Jss than st<JnJard amperage.

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40A Type

Pulley

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50A Type

P2~56 P25J57

Spacer Coller

CH·5 CHARGING SYSTEM ALTERNATOR

ALTERNATOR COMPONENTS FOR . , ASSEMBLy DISASSEMBLy AND_,_"

Stator

. Front Bearing

Onve Elld Frnme

Rotor

Spacer Coller

Fan

Insulator Washer

Brush Spring . I

Rear End Cover

Rectifier End F rame

Fran~ Bearin Drive End F. 1• 9 Rotor

• ffime j Spacer Coller 1 I ~ . "" !:? I "'""' "'"" ~ -~-'· " . _., _,_ -, ,QI ~ ,'t;). - I ,.:,. ~--~ ' Rear Bearing

TP.rminallnsulator

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Condenser

~Rectifier End F -~ rame ' .

Conectamea! Housing

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I N·m (kgf·cm, ft·lbfl : Specified torque

CH-6 CHARGING SYSTEM- ALTI::RNATOR

r-·--------------~·--~-------~

40A Type

@---j-(11 ~--J-(2)

(3)

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ALTERNATOR DISASSEMBLY

1. REMOVE DRIVE END FRAME AND ROTOR ASSEMBLY FROM STATOR

(a) Remove the 3 through screws.

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(b) Using a screwdriver. pry the flnd frame and remove it together with the rotor. CAUTION: Do not pry on the coil wires.

2. REMOVE PULLEY AND FAN (a) . Mount the t"otor in a soft jaw vise. (b) Remove the nut and these parts:

(I) Spring washer (2) Spacer collar (3) Pul:ey (4) Fan (5) Spacer collar

3. REMOVE ROTOR (a) Using a pn'lss, press ou·t the rotor. (b) 40A Type:

Remove the spacer ring and snap ring. (c) 50 A Type:

Remove the spacer ring.

4. REMOVE RECTIFIER END FRAME A. 40A Type: (a) Remove the 4 nuts, condenser, cord clip and 2 termi

nal insulators. (b) Remove the nut and rear end cover from the rectifier

end frame. (c) Removs the rectifier end frame from the rectifier

holder.

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___________ C::.H:..:.:..:.:ARGING SYSTEM- ALTERNATOR CH-7

soA Type l

SOA Type

No Conlinuily

B. 50A Type: (a). Remove the 4 nuts. condenser and 2 terminal insula

tors . (b) Remove the rectifier end frame from the rectifier

holder . (c) Remove the insulator washer from the rectifier holder.

5, REMOVE RECTIFIER HOLDER H<'ld the rectifier terminal with needie-nose pliers and unsolder the lead wires. CAUTION: Protect the rectifiers trorn heat .

6. 50A Type: REMOVE CONECTAMEAL HOUSING Using an un·solder, remove the conectameal housing from the rectifier holder. CAUTION: Protect the rectifiers from heat.

Clocu.,.-•1

ALTERNATOR INSPECTION AND REPAIR Rotor

1. INSPECT ROTOR rCR OPEN CIRCUIT Using an ohmmeter, chock that there is continuity · between the slip rings. Standard resistance:

At 2o•c {61l.F): 3.9- 4.1 o If there is no continuity, replace the rotor.

· z: INSPECT ROTOR FOR GROUND Using an ohmmeter. check that there is no continuity between the slip ring and rotor. If there is continuity, replace ·the rotor.

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. -. CHARGING SYSTEM.- ALTERN A TOR

Ohmmeter

Q_/ \ - I No cantinu!ty P24939

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3. INSPECT SLii= RINGS

(a). Check that the slip rings are not rough or scored. If rough or scored, replace the rotor.

• ' (b)· Using vernier calipers. measure the slip ring diameter ...

Standard diameter: 32.3 - 32.5 mm {1.272 - 1.280 in.)

Minimum diameter: 32.1 mm {1.264 in.)

If the diameter is less than minimum, replace the rotor.

Stator

1. INSPECT STATOR FOR OPEN CIRCUIT Using an ohmmeter, chsck that there is continuity between the coil leads.

, NOTICE: At this time, th& meeting wires should be connected with soldered.

If there is no continuity, replace .the stator.

2. INSPECT STATOR FOR GROUND Using an ohmmeter, check that there is no continuity between the coil leads and stator coni. If th11m i~ r;rmtin11ity, nip11lr.ll thll ~tfll'lr.

Brushes

• '. INSPECT EXPOSED BRUSH LENGTH Using a scale. measure the exposed !:irush length. Stand~~rd exposed length:

12.5 mm {0.492 ln.) Minimum exposed length:

5.5 mm {0.2171n.)

If the exposed length is less than minimum, replace the brush.

2. lF 'NECESSARY, REPLACE BRUSHES

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(a) Unsolder and remove the brush and spring. • (b) Run the wire of a new brush through the spring and

the hole in the brush holder, and insert the spring and brush into the brush holder.

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40A Type

50A Type

40A Type

Negative Terminal

SOA Type

CHARGING SYSTEM- ALTERNATOR CH-9

Positive i+) Terminal

mm

Zl66<l7

Negative (-) Terrryinal

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fc) Solder the brush wire to the brush holder at specified exposed length .

. Exposed len;Jth:

t 2.5 mm (0.492 in.)

(d) Check that the brush moves smoothly in the brush holder.

{e) Cut off the excess wire. (f) Apply insulation .paint to the soldered area.

Rectifiers (Rectifier Holder)

1. (a)

INSPECT POSITIVE RECTIFIER lc'fi . ........

Using an ohmmeter, connect one tester probe to the positive (+)terminal and the other to each rectifier terminal.

(b) Reverse the polarity of the tester probes and repeat step (a).

(c) Check that one shows continuity and the other shows no continuity . If continuity is not as specified, replace the rectifier holder,

2. INSPECT NEGATIVE RECTIFIER (a) Using an ohmmeter, connect one tester probe to saC'h

negative (-) terminal and tha other to each rectifiilr terminal.

(b) Reverse the polarity of the tester probes and repeat stop (a). · ·

(c) Check that one shows continuity and th" other shows no continuity. If continuity is not as specified, replace the rectifier holder.

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CH-1 0 CHARGING SYSTEM - ALTERNATOR

Bearings

1. INSPECT FRONT BEARING

Check that the bearing_ is not rough or worn. 2. IF NECESSARY. REPLACE FRONT BEARING {a) Remove the .3 screws.

{b) Using SST and a press, press out the bearing. SST 09950-6001 0 (09951 -00220. 09952-0601 0)

(c) Using SST and a press, press in a new bearing. SST 09950-6001 0 (09951 - 00400)

(d) Install the 3 screws.

3. INSPECT REAR BEARING Chock that tho bearing is not rough or worn.

4. IF NECESSARY, REPLACE REAR BEARING (a) Using SST, remove the bearing.

SST og286-46011

{b) Using a press, press in a new bearing.

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SOA Type

40A Type

40A Type

.~;;;® SOA Type ::- -1

r1sJs<~

P15J5S

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CH.ARGING SYSTEM- ALTERNATOR CH-11

P2<93J

P249~

ALTERNATOR ASSEMBLY

1. 50A Type: INSTALL CONECTAMEAL HOUSiNG s·older the conectameal housing to the rectifier hold~r . CAUTION: P:·otect t~e rectifiers from heat.

2. INSTALL RECTIFIER HOLDER TO STATOR Hold the rectifier terminal with needle-pliers while soldering t~e lead wires. CAUTION: Protect the rectifiers from heat.

3. INSTALL RECTIFIER END FRAME TO RECTIFIER HOLDER

A. (a)

40A Type: Pla~e the 2 insulator washers on the positive studs )f the 'rectifier holder.

(b) Pla9e the rectifier end fran1e on the rectifier holder.

(c)

(d)

(e)

(f)

(g)

B. (a)

(b)

(c)

Place the rear end cover on the rectifier end frame. Place the 2 terminal insulators on the positive studs on the rectifier holder . Install nut. Torque: 4.4 N·m (45 kgf.r.m, 39 in •. lbf)

Install the cord clip and condenser with the 4 nuts. Torquo: 4.4 .N·m (45 kgf.cm, 39 in.·lbf)

Check that the lead wires are not touching the rectifier end frame.

50A Type: Place the insulator washer on ths positive studs of the rectifier holder. Place tho rectifier end frame on the rectifier holcJAr. Place the 2 terminal insulators on tho positive studs on the rectifier holder.

(d) Install the condenser with the 4 nuts. Torque: 4.4 N·m (45 kgf·cm, 39 ;, .. Jbf)

(e) Check that the lead wires are not touching the rectifier e!ld frame.

4. INSTALL ROTOR (a) 40A Typd;

Place the snap nng and spacer ring onta the rotor shaft.

(b) 50A Type: Place the spa cor ring onto the rotor shaft.

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CH-12 CHARGING SYSTEM- ALTERNATOR

00311

(51 141 131

(21

( 1 1 11&117

L---------------------~-0~~~

50A Typo

Seal

(c) Using a press, press in the rotor.

5. INSTALL FAN AND PULLEY (a) Mount the rotor in S'Jft jaw vise. (h) Install these parts with the nut on the rotor shaft:

( 1) Spacer collar (2) Fan (3) Pulley (4) Spacer collar (5) Spring washer Torque: 61.3 N·m (625 kgf·cm, 45 ft·lbf)

6. INSTALL DRIVE END FRAME ASSEMBLY AND RECTIFIER END FRAME ASSEMBJ_ Y

(a) Bend the rectifier lead wires back to clear the rotor. (b) Using a curved tool, push tha brushes in as far as they·

will go and hold them in placo by inserting a stiff w'ire through the accass hole in· the access hole in the rectifier end frame.

(c) Assemble the drive end frame and the rectifiar arid frame by inserting the r&ar bflaring on the rotor shaft into the rectifier end frame.

(d) Install the 3 through screws. Torque: 5.9 N-m (60 kgf·cm, 52 in .. Jbf)

(e) Remove the stiff wire from the access hole.

7. CHECK THAT ROTOR ROTATES SMOOTHLY (a) Che"k that the rotor rotates r<moothly. (b) 50A Type:

Seal the access hole.

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-1 GHARGING SYSTEM - ALTERN A TOR REGULATOR CH-13

Regulator

-----------'---Relay

ALTERNATOR REGULATOR · tocoeu~"

ALTERNATOR REGULATOR INSPECTION

1. REMOVE ALTERNATOR REGULATOR AND COVER

2. INSPECT ALTERN A TOR REGULATOR

A. :nspect point surfaces for seizure and damage If defective, replace the regulator(

B. {a)

Inspect resistance between terminals Regulator:

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Using an ohmmeter, measure the resistance between 1'1 terminals IG and F. Resistance:

· At rest: 0 Q

Pulled in: Approx. 1 1 Q

{b) Relay:

(c)

Using an ohmmeter, measure the resistance between terminals E and L. Resistance:

At rest: 0 0 Pulled i11: Approx. 100 Q

Relay:

Using an ohmmoter. measure tho resistance between terminals 8 and E. Resistance:

At rest: infinity Pulled In: Approx. 100 Q

{d) Relay: Using an ohmmeter. measure the resistance bot\veen terminals 8 and L. Resistance:

At rest: Infinity .

fulled In: 0 0

{e) Using an ohmmeter, measure the resistance between terminals N and E. Resistance: Approx. 23 0 If any of the above checks are not positive, replace the alternator regulator.

3. REINSTALL ALTERNATOR REGULATOR AND

COVER

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CH-14 · CHARGING SYSTEM - SERVICE SPECIFICATIO::.:N..:cS::.._ _________ _

00158


ALTERNATOR REGULATOR VOLTAGE c .........

ADJUSTMENT

.1. REMOVE ALTERNATOR REGULATOR AND COVER 2. ADJUST ALTERNATOR REGULATOR

A. Adjust voltage regulator

Bend the regulator adjusting arm to adjust. Regu!ating voltage:

At 2o•c (68.F): 13.8- 14.8 v

B. Adjust voltage relay

Bend the relay adjusting arm to adjust. Relay actuating voltage: 4.0 - 5.8 V

3. REINSTALLALTERNATORREGU~ATORAND

COV.ER

I

Battery Specific gravity at 2o•c (6B"Fl NS40L !.27 - !.29

Others 1.25 - !.27 ' Alternator Rated output

I 12 V 40 A. 50 A

Rotor coil resistance 3.9-4.1 0

Slip ring diameter STD 32.3 mm - 32.5 mm ( t .27'2 - 1.280 in.} I

Minimum 32.1 m'll (1.254 in.)

Brush exposed length STD 17..5 mm (0,492 in.) \

Minimum 5.5 mm (0.217 in.)

AltE"rrlator Regulating voltage at 20" C (68- F) 1J.8- 1•i.BV

Regulator Relay actuating voltage 4.0- 5.8 v

TORQUE SPECIFICATIONS Pert tightened N·m kgf·cm . ft·lbf

Rear end cover x Rectifier end frame 4.4 45 39 in.·lbf

Rectifier end frame x Rectifier holder {SOA Type) 4.4 45 39 in.·lbf

Cc,densar X Rectifier end frame 4.4 45 39 in.·!bf

Cord clip x R")ar and covor 4.4 45 39 in..lbf

Alternator pullay x Rotor 61.3 625 45 -·

Rectifier end frame x Drive end frame I 5.9 60 52 in.·lbf

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