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    Tham gia ngày:
    5/10/12
    Số km:
    83
    Được đổ xăng:
    39
    Mã lực:
    41
    Xăng dự trữ:
    344 lít xăng
    GENERAL
    GENERAL
    SPECIFICATIONS
    Description Standard Limit
    General
    Type In-line OHC
    Number of cylinders 4
    Bore 75.5 mm (2.97 in.)
    Stroke 82 mm (3.23 in.)
    Total displacement 1,468 cc (89.6 cu.in.)
    Compression ratio 9.4
    Firing order 1 - 3 - 4 - 2
    Basic ignition timing Refer to emission control
    information label on car
    Valve timing
    Intake valve
    Opens (BTDC) 18.5°
    Closes (ABDC) 51.5°
    Exhaust valve [MPI] [FBC]
    Opens (BBDC) 51.5° 47.50
    Closes (ATDC) 18.5° 14.50
    Compression pressure 1.32 MPa (13.5 kg/cm2,
    192 psi)/250 rpm
    Valve clearance-Hot engine
    Intake valve 0.15 mm (0.006 in.)
    Exhaust valve 0.25 mm (0.010 in.)
    *Jet valve 0.25 mm (0.010 in.)
    Cylinder head
    Warpage of lower face of head Within 0.05 mm (0.002 in.)
    Clearance with camshaft 0.05-0.09 mm (0.002-0.0035 in.)
    Oversize rework dimension of valve seat hole
    Intake 0.3 mm (0.102 in.)
    0.6 mm (0.024 in.)
    Exhaust 0.3 mm (0.012 in.)
    0.6 mm (0.024 in.)
    Oversize rework of valve guide hole
    (both intake and exhaust)
    0.05 mm (0.002 in.)
    0.25 mm (0.010 in.)
    0.50 mm (0.020 in.)
    Camshaft
    Height of cam lobe
    Intake
    Exhaust
    39.3-39.325 mm (1.5472-1.5482 in.)
    39.6-39.625 mm (1.5590-1.5600 in.)
    34.3-34.325 mm (1.3504-1.3514 in.)
    34.6-34.625 mm (1.3622-1.3632 in.)
    0.1 mm (0.004 in.)
    End play
    13.05-13.068 mm (0.5135-0.5145 in.)
    13.25-13.268 mm (0.5216-0.5224 in.)
    13.50-13.518 mm (0.5315-0.5323 in.)
    38.909 mm (1.5318 in.) -0.5 mm (-0.020 in.)
    38.974 mm (1.5344 in.) [MPI] -0.5 mm (-0.020 in.)
    38.648 mm (1.5216 in.) [FBC] -0.5 mm (-0.020 in.)
    0.05-0.20 mm (0.002-0.008 in.) 0.4 mm (0.016 in.)
    * : FBC only
    2 0 - 2
    GENERAL
    Description Standard Limit
    Valve
    Stem O.D.
    Intake
    Exhaust
    Thickness of valve head (Margin)
    Intake
    Exhaust
    Clearance with valve guide
    Intake
    Exhaust
    Valve guide
    Installed dimension
    Oversize
    Valve seat insert
    Width of seat contact
    Seat angle
    Oversize
    Valve spring
    Free length
    Load
    Installed height
    Squareness
    *Jet valve
    Stem O.D.
    Seat angle
    *Jet valve spring
    Free length
    Load
    Cylinder block
    Cylinder bore
    6.6 mm (0.26 in.)
    6.6 mm (0.26 in.)
    1.0 mm (0.039 in.) 0.7 mm (0.028 in.)
    1.5 mm (0.059 in.) 1.0 mm (0.039 in.)
    0.03-0.06 mm (0.0012-0.0024 in.) 0.10 mm (0.004 in.)
    0.05-0.09 mm (0.0020-0.0035 in.) 0.15 mm (0.006 in.)
    13.7-14.3 mm (0.5394-0.5630 in.)
    0.05 mm, 0.25 mm, 0.50 mm
    (0.002 in., 0.010 in., 0.020 in.)
    0.9-1.3 mm (0.035-0.051 in.)
    45°
    0.3 mm, 0.6 mm (0.012 in., 0.024 in.)
    44.6 mm (1.756 in.)
    24 kg/27.3 mm (53 lb./1.075 in.)
    36 mm (1.417 in.)
    1.5° or less
    4.3 mm (0.1693 in.)
    45°
    -1.0 mm (-0.039 in.)
    +1 mm (+0.039 in.)

    29.60 mm (1.1654 in.)
    3.5 kg/21.5 mm (5.5 lb/0.846 in.)
    75.50-75.53 mm (2.9724-2.9736 in.)
    Out-of-roundness and taper of cylinder bore Within 0.02 mm (0.0008 in.)
    Clearance with piston 0.02-0.04 mm (0.0008-0.0016 in.)
    Piston
    O.D.
    Oversize
    75.47-75.5 mm (2.9713-2.9724 in.)
    .25 mm, 0.50 mm, 0.75 mm, 1.00 mm
    (0.010 in., 0.020 in., 0.030 in., 0.039 in.)
    Piston ring
    Side clearance
    No.1 0.03-0.07 mm (0.0012-0.0028 in.) 0.15 mm (0.006 in.)
    No.2 0.02-0.06 mm (0.0008-0.0024 in.) 0.12 mm (0.005 in.)
    End gap No. 1 and No .2 0.20-0.35 mm (0.008-0.0138 in.) 0.8 mm (0.031 in.)
    Oil ring 0.20-0.70 mm (0.008-0.028 in.) 1.0 mm (0.039 in.)
    Oversize 0.25 mm, 0.50 mm, 0.75 mm, 1.00 mm
    (0.010 in., 0.020 in., 0.030 in., 0.039 in.)
    * : FBC only
    2 0 - 3
    GENERAL
    Description Standard Limit
    Connecting rod
    Bend
    Twist
    Side clearance
    Connecting rod bearing
    Oil clearance
    Undersize
    Crankshaft
    Pin O.D.
    Journal O.D.
    Bend
    Out-of-roundness, taper of journal and pin
    End play
    Undersize rework dimension of pin
    0.25 mm (0.010 in.)
    0.50 mm (0.020 in.)
    0.75 mm (0.030 in.)
    Undersize rework dimension of journal
    0.25 mm (0.010 in.)
    0.50 mm (0.020 in.)
    0.75 mm (0.030 in.)
    Flywheel
    Out-of-roundness
    Engine oil pressure
    At engine idle speed
    Oil pump
    Outer gear
    Clearance between outer circumference
    and front case
    Clearance between addendum and crescent
    End play
    Inner gear
    Clearance between addendum and crescent
    End play
    Relief spring
    Free height
    Load
    0.05 mm (0.0020 in.) or less
    0.10 mm (0.0039 in.) or less
    0.10-0.25 mm (0.004-0.010 in.) 0.4 mm (0.016 in.)
    0.014-0.044 mm (0.0006-0.0017 in.)
    0.25 mm, 0.50 mm, 0.75 mm
    (0.01 in., 0.02 in., 0.03 in.)
    42 mm (1.6535 in.)
    48 mm (1.8898 in.)
    Within 0.03 mm (0.0012 in.)
    Within 0.01 mm (0.0004 in.)
    0.05-0.18 mm (0.002-0.007 in.) 0.25 mm (0.0098 in.)
    41.73541.750 mm (1.6431-1.6437 in.)
    41.48541.500 mm (1.6333-1.6339 in.)
    41.235-41.250 mm (1.6234-1.6240 in.)
    47.73547.750 mm (1.8793-1.8799 in.)
    47.48547.500 mm (1.8695-1.8701 in.)
    47.23547.250 mm (1.8596-1.8602 in.)
    Within 0.13 mm
    (0.005 in.)
    78 kPa (0.8 kg/cm2, 11 psi) or more
    [Engine oil temperature 75-90°C (167-190°F)]
    0.1-0.2 mm (0.0039-0.0079 in.)
    0.22-0.34 mm (0.0087-0.0134 in.)
    0.04-0.10 mm (0.0016-0.0039 in.)
    0.21-0.32 mm (0.0083-0.0126 in.)
    0.04-0.10 mm (0.0016-0.0039 in.)
    46.6 mm (1.835 in.)
    6.1 kg/40.1 mm (13.4 lb/1.579 in.)
    2 0 - 4
    GENERAL
    TIGHTENING TORQUE
    Nm kg.cm lb.ft
    Cylinder Block
    Front engine support bracket bolt
    Front roll stopper bracket bolt
    Rear roll stopper bracket bolt
    Left engine support bracket bolt
    Oil pressure switch
    Cylinder head
    Cylinder head bolt-cold engine
    -hot engine
    Intake/exhaust manifold bolts or nuts
    Rocker cover bolt
    Rocker arm shaft bolt
    Camshaft bolt
    Rear plate bolt
    *Jet valve
    Main Moving
    Connecting rod cap nut
    Crankshaft bearing cap
    Flywheel (manual transaxle) bolt
    Drive plate (automatic transaxle) bolt
    Timing Belt
    Crankshaft pulley bolt
    Crankshaft sprocket bolt
    Camshaft sprocket bolt
    Timing belt tensioner bolt
    Timing belt cover bolt
    Front case bolt
    4 9 - 6 9 500-700 3 7 - 5 0
    5 4 - 7 4 550-750 4 0 - 5 4
    108-127 1100-1300 8 0 - 9 4
    29-41 300-420 2 2 - 3 0
    15-21 150-220 1 1 - 1 5
    6 9 - 7 4 700-750 5 1 - 5 4
    7 8 - 8 3 800-850 58-61
    1 5 - 2 0 150-200 1 1 - 1 4
    1.5-2.0 1 5 - 2 0 1.1-1.4
    2 0 - 2 6 200-270 1 4 - 2 0
    2 0 - 2 6 200-270 1 4 - 2 0
    8 - 1 0 8 0 - 1 0 0 5.8-7.2
    1 8 - 2 2 180-220 1 3 - 1 6
    3 1 - 3 4 320-350 2 3 - 2 5
    4 9 - 5 3 500-540 3 6 - 3 9
    127-137 1300-1400 94-101
    127-137 1300-1400 94-101
    1 2 - 1 5 120-150 8.7-11
    6 9 - 9 8 700-1000 5 1 - 7 2
    6 4 - 7 4 650-750 4 7 - 5 4
    2 0 - 2 6 200-270 1 4 - 2 0
    1 0 - 1 2 100-120 7.2-8.7
    1 2 - 1 5 120-150 8.7-11
    * : FBC only
    2 0 - 5
    GENERAL
    Nm kg.cm lb.ft
    Engine Mounting
    Left mounting insulator (large) nut
    Left mounting insulator (small) nut
    Left mounting bracket to engine nuts and bolts
    Transaxle mount insulator nut
    Transaxle insulator bracket to side member bolts
    Transaxle mount bracket to automatic transaxle nut
    Rear roll stopper insulator nut
    Rear roll stopper bracket to center member bolts
    Front roll stopper insulator nut
    Front roll stopper bracket to center member bolts
    Center member to body bolts
    Roll rod to engine bolt
    Roll rod to roll rod bracket nut
    Roll rod bracket to body bolts
    Oil filter
    Oil pan bolts
    Oil pan drain plug
    Oil screen bolts
    Timing belt upper cover bolts
    Timing belt lower cover bolts
    Surge tank to inlet manifold nuts and bolts
    8 8 - 1 0 8 900-1100 6 5 - 8 0
    4 9 - 5 9 500-600 3 6 - 4 3
    4 9 - 6 4 500-650 3 6 - 4 7
    8 8 - 1 0 8 900-1100 6 5 - 8 0
    2 9 - 3 9 300-400 2 2 - 2 9
    8 8 - 1 0 8 900-1100 6 5 - 8 0
    4 4 - 5 9 450-600 3 3 - 4 3
    4 4 - 5 9 450-600 3 3 - 4 3
    4 4 - 5 9 450-600 3 3 - 4 3
    2 9 - 3 9 300-400 2 2 - 2 9
    5 9 - 7 8 600-800 4 3 - 5 8
    5 4 - 6 4 550-650 4 0 - 4 7
    4 4 - 5 9 450-600 3 3 - 4 3
    6 9 - 9 3 700-950 5 1 - 6 5
    1 1 - 1 3 110-130 8 - 9 . 4
    6 - 8 6 0 - 8 0 4 - 6
    3 4 - 4 4 350-450 2 5 - 3 3
    1 5 - 2 2 150-220 1 1 - 1 6
    1 0 - 1 2 100-120 7 - 9
    1 0 - 1 2 100-120 7 - 9
    1 5 - 2 0 150-200 1 1 - 1 4
    2 0 - 6
    SELECTION OF LUBRICANTS
    Engine Oil
    Recommended API classification : SF, SF/CC OR SG
    Recommended SAE viscosity grades :
    Temperature range
    anticipated before
    next oil change
    Recommended SAE viscosity number
    *1. Restricted by driving conditions and climate conditions.
    *2. Not recommended for sustained high speed vehicle operation.
    For best performance and for maximum protection of all engines for all types of operation, select only those lubricants
    which:
    1. Conform to the requirements of API classification.
    2. Have proper SAE grade number for expected ambient temperature range.
    Lubricants which do not have both a SAE grade number and an API service classification on the container should
    not be used.
    2 0 - 7
    GENERAL
    SPECIAL TOOLS
    Tool
    (Number and name)
    09214-21000
    Crankshaft front oil seal
    installer
    Illustration Use
    Installation of the crankshaft front oil seal
    (use with 09214-21100)
    09214-21100
    Crankshaft front oil seal
    guide
    Installation of the crank shaft front oil
    seal (use with 09214-21000)
    09216-21000
    Mount bushing remover and
    installer arbor
    Removal and installation of the front roll
    rod upper bushing (use with 09216-
    21100 and 09216-21000)
    09216-21100
    Mount bushing remover and
    installer base
    Removal and installation of the roll rod
    upper bushing (use with 09216-21000)
    09221-11001
    Cylinder head bolt wrench
    Removal and tightening of the cylinder
    head bolt
    Camshaft oil seal installer with 09221-21100)
    Valve spring compressor exhaust valve
    2 0 - 8
    GENERAL
    Tool
    (Number and name)
    09222-21100
    Valve stem oil seal installer
    09222-21200
    Valve guide installer
    Illustration Use
    Installation of the valve stem oil seal
    Removal and installation of the valve
    guide
    09231-21000
    Crankshaft rear oil seal
    installer
    1. Installation of the engine rear oil seal
    2. Installation of the crankshaft rear oil
    seal
    09234-21000
    Piston pin setting tool
    09260-11000
    Oil pressure switch wrench
    Removal and installation of the piston pin
    Removal and installation of the oil
    pressure switch
    09222-21300
    *Jet valve socket wrench
    09222-21400
    *Jet valve spring plier
    Removal and installation of jet valve
    For assembling and reassembling jet
    valve
    09222-21500 Installation of the jet valve stem oil seal
    *Jet valve stem seal installer
    * : FBC only
    2 0 - 9
    GENERAL
    TROUBLESHOOTING
    Symptom
    Low compression
    Probable cause
    Blown cylinder head gasket
    Worn or damaged piston rings
    Worn piston or cylinder
    Worn or damaged valve seat
    Remedy
    Replace gasket
    Replace rings
    Repair or replace piston
    and/or cylinder block
    Repair or replace valve
    and/or seat ring
    Oil pressure drop Low engine oil level Check engine oil level
    Faulty oil pressure switch Replace
    Clogged oil filter Replace
    Worn oil pump gears or cover Replace
    Thin or diluted engine oil Change and determine cause
    Oil relief valve stuck (open) Repair
    Excessive bearing clearance Replace
    High oil pressure Oil relief valve stuck (closed) Repair
    Excessive engine rolling and Loose engine roll stopper (front, rear) Re-tighten
    vibration Loose transaxle mount bracket Re-tighten
    Loose engine mount bracket Re-tighten
    Loose center member Re-tighten
    Broken transaxle mount insulator Replace
    Broken engine mount insulator Replace
    Broken engine roll stopper insulator Replace
    Noisy valves Thin or diluted engine oil (low oil pressure) Change
    Worn or damaged valve stem or valve guide Replace
    Connecting rod and/main lnsufficient oil supply Check engine oil level
    bearing noise Thin or diluted engine oil Change and determine cause
    Excessive bearing clearance Replace
    Timing belt noise Incorrect belt tension Adjust belt tension
    2 0 - 1 0
    GENERAL
    CHECKING ENGINE OIL
    1. Position the vehicle on a level surface.
    2. Warm up the engine.
    NOTE
    If a vehicle that has been out of service for a prolonged
    period of time, warm up the engine for approximately 20
    minutes.
    3. Stop the engine, and wait 2 or 3 minutes, then check the
    oil level after engine oil drains to the oil pan.
    4. Check that the engine oil level is within the level range
    indicated on the oil dipstick. If the oil level is found to have
    fallen to the lower limit (the MIN mark), refill to the “MAX”
    mark.
    NOTE
    When refilling, use the same type of engine oil as the one
    currently being used.
    5. Check that the oil is not dirty or contaminated with coolant
    or gasoline, and that it has the proper viscosity.
    REPLACING OIL FILTER
    Filter Selection
    All Hyundai engines are equipped with a high quality,
    throw-away oil filter. This filter is recommended as a
    replacement filter on all vehicles. The quality of replacement
    filters varies considerably. Only high quality filters should be
    used to assure the most efficient service. Make sure that the
    rubber gasket from the old oil filter is completely removed from
    the mating surface on the engine block, before installing the new
    filter.
    Replacing Oil Filter
    1. Use a filter wrench to remove the oil filter.
    2. Before installing the new oil filter on the engine, apply clean
    engine oil to the surface of the rubber gasket.
    3. Tighten the oil filter to the specified torque.
    Tightening torque
    Oil filter . . . . 11-13 Nm (110-130 kg.cm, 8-9.4 lb.ft)
    4. Run the engine to check for engine oil leaks.
    5. After stopping the engine, check the oil level and add oil as
    necessary.
    Part number
    2 0 - 1 1
    GENERAL
    CHANGING ENGINE OIL
    1. Run the engine until it reaches normal operating temperature.
    2. Stop the engine.
    3. Remove the oil filler cap (on rocker cover) and the drain plug
    (on the oil pan). Drain the engine oil.
    4. Re-install and tighten the drain plug to the specified torque.
    Tightening torque
    Drain plug . . 34-44 Nm (350-450 kg.cm, 25-33 Ib.ft)
    5. Fill the crankcase with fresh engine oil through the oil filler
    cap opening.
    Dry fill . . . . . . . . . . . . . . 3.4 lit (3.59 U.S.qts., 2.99 Imp.qts.)
    Drain and Refill
    Without oil filter; 2.6 lit (2.74 U.S.qts., 2.28 Imp.qts.)
    With oil filter; 3.0 lit (3.17 U.S.qts., 2.64 Imp.qts.)
    6. Install the oil filler cap.
    7. Start and run the engine.
    8. Stop the engine and then check the oil level. Add oil if
    necessary.
    TIGHTENING CYLINDER HEAD BOLTS
    1. When retorquing cylinder head bolts, slightly loosen and
    then tighten to the specified torque.
    2. Be sure to follow the specified torquing sequence.
    3. After the cylinder head bolts have been tightened to the
    specified torque, run the engine until normal operating
    temperature is reached. Allow it to cool down, then re-torque
    the bolts to specification for best results.
    Tightening torque
    Cold engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    69-73 Nm (704-745 kg.cm, 51-54 lb.ft)
    Hot engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    79-83 Nm (806-847 kg.cm, 58-61 lb.ft)
    Cylinder head bolt tightening sequence
    2 0 - 1 2
    GENERAL
    CHECKING COMPRESSION PRESSURE
    1. Before checking compression, check the engine oil level.
    Make sure the starter motor and battery are in normal
    operating condition.
    2. Start the engine and wait until engine coolant temperature
    reaches 80-95°C (176-205°F).
    3. Stop the engine and disconnect the spark plug cables.
    4. Remove the spark plugs.
    5. Crank the engine to remove any foreign objects in the
    cylinders.
    6. Attach the compression gauge to the spark plug hole.
    7. Depress the accelerator pedal to fully open the throttle.
    8. Crank the engine and read the gauge.
    Standard value : 13.5 kg/cm2 (1.32 MPa, 192 psi)
    [250-400 rpm]
    Limit : 12.0 kg/cm* (1.18 MPa, 171 psi)
    [250-400 rpm]
    9. Repeat steps 6 through 8 on all cylinders, making sure that
    the pressure differential for each of the cylinders is within
    the specified limit.
    Limit : Max. 1.0 kg/cm2 (100 kPa, 14 psi) between cylinders
    10. If a cylinder’s compression or pressure differential is below
    the specification, add a small amount of oil through the spark
    plug hole and repeat steps 6 through 9.
    1) If the addition of oil brings the compression up, it is
    possible that there is wear between the piston ring and
    cylinder wall.
    2) If compression remains the same, valve seizure, poor
    valve seating or a compression leak from the cylinder
    head gasket are all possible causes.
    Tightening torque
    Spark plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    20-30 Nm (204-306 kg.cm, 15-21 lb.ft)
    VALVE CLEARANCE ADJUSTMENT
    Refer to GROUP 10 Lubrication and Maintenance.
    Compression gauge
    2 0 - 1 3
    GENERAL
    TIMING BELT AND TIMING BELT
    TENSIONER INSTALLATION PROCEDURE
    1. Assemble rocker arm adjusting screw in tentative state.
    Then screw must not protrude more than 1 mm (0.04 in.)
    NOTE
    1) Take special care not screw to be below arm end,
    otherwise valve stem would rust thread part.
    2) In case of protruding too much, tension of belt would
    be excessive.
    2. Tentatively fasten timing belt tensioner at such position as
    to place it’s pulley nearest to water pump (pulley may touch
    water pump body).
    3. After installing the tensioner, the crankshaft sprocket and
    the camshaft sprocket, match timing mark of each sprocket
    as shown in illustration.
    Rotate the crankshaft until the piston in No.1 cylinder is at
    top dead center on the compression stroke.
    CAUTION
    1) Be sure to install the flange in the correct direction.
    (Chamfered part shows front of engine).
    2) When installing the camshaft sprocket, make sure that
    the pin on the camshaft fits small hole in pulley.
    Chamfered
    2 0 - 1 4
    GENERAL
    NOTE
    Allow tensioner to remain in assemble state must be
    installed temporarily as follows.
    1) Tentatively tighten tensioner at position as shown in
    illustration, in state that one extended end of spring
    tensioner is assembled to bend of tensioner bracket as
    imaginary line (wheel spring tensioner is inoperative
    and not loaded).
    2) Then set extended end of tensioner spring at front case
    with drive etc.
    4. Install the timing belt so as not to allow slack to the tension
    side. Make sure that all timing marks are at their correct
    position with the tension side in a strained state by applying
    force to the camshaft sprocket in a reversing (counterclockwise)
    direction.
    TIMING BELT TENSION ADJUSTMENT
    PROCEDURE
    The timing belt has an automatic tension adjusting mechanism.
    Adjustment can be made by the following procedure:
    1. Turn the steering wheel fully counter-clockwise.
    2. Apply a wood block under the engine oil pan and carefully
    raise the engine.
    CAUTION
    Jack up only slightly to prevent undue stress on parts.
    3. Remove the engine left mount bracket.
    2 0 - 1 5
    GENERAL
    4. Remove the water pump pulley.
    5. Remove the timing belt upper cover.
    6. Check the belt for cracking, peeling or other damage. Be sure
    to carefully check the entire length of the belt.
    7. Rotate the crankshaft so that the No. 1 piston is at top dead
    center of the compression stroke. In other words, align the
    timing mark on the camshaft sprocket with that on the
    cylinder head.
    Note that the crankshaft should be turned clockwise, not
    counterclockwise. Turning the crankshaft counterclockwise
    will cause the tension to become improperly adjusted.
    8. Remove the timing belt lower cover.
    9. Loosen the tensioner mounting bolts 1 and 2 in that order
    as shown to give the timing belt spring tension.
    2 0 - 1 6
    GENERAL
    10. Check the belt to ensure that it is not out of position.
    11. Tighten the tensioner attaching bolts 2 and 1 in that order
    as shown. If the bolt 1 is tightened first, the tensioner will
    move with the bolt and cause the belt to become
    overtightened.
    12. Give the crankshaft one turn in operating direction
    (clockwise) and realign crankshaft sprocket timing mark with
    the top dead center position.
    CAUTION:
    Do not turn the crankshaft in a counterclockwise
    direction.
    13. Loosen the tensioner attaching bolts 1 and 2 in that order
    as shown.
    14. Retighten the tensioner attaching bolts 2 and 1 in that order
    as shown to the specified torque.
    Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    20-26 Nm (200-270 kg.cm, 14-20 lb.ft)
    2 0 - 1 7
    GENERAL
    15. Recheck the belt tension, When the tensioner and the
    tension side of the timing belt are pushed in horizontally with
    a moderate force [approx. 49 N (11 lb)], the timing belt cog
    end is approx. ½ of the tensioner mounting bolt head radius
    (across flats) away from the bolt head center.
    TENSION MEASURING PROCEDURE
    (When using a tension gauge)
    1. Rotate the crankshaft counterclockwise to position 90
    degrees before top dead center as shown in the illustration.
    2. Measure the belt tension in the middle of the tension side
    span using the tension gauge. (BORROUGHS BT-33-73F
    TYPE)
    Timing belt tension (In cool condition). . . . . . . . . . . . . . . . .
    14.5-21.5 kg (32-47 lb)
    CAUTION
    Place the arms on the bottom of the belt teeth. Place the
    spindle against the middle of the back surface of the belt.
    2 0 - 1 8
    ENGINE MOUNTING
    TORQUE : Mm (kg.cm, lb.ft)
    ENGINE MOUNTING
    Roll rod (Vehicle with a manual transaxle)
    TORQUE : Nm (kg.cm, lb.ft)
    REMOVAL
    Attach an engine hoist to the engine hooks, and raise it just enough
    so that there is no pressure on the insulators.
    Engine Mounting
    1. Remove the engine mount insulator bolts.
    2. Remove the engine mount bracket from the engine.
    Transaxle
    1. For vehicles with a 5-speed manual transaxle, remove the
    select control valve.
    2. Remove the transaxle mount bolt.
    2 0 - 2 0
    ENGINE MOUNTING
    3. Detach the cap from the inside of the right fender shield,
    remove the transaxle mounting bolts.
    4. Remove the transaxle bracket.
    Front Roll Stopper
    Remove the front roll stopper bracket from the center member.
    Rear Roll Stopper
    Remove the rear roll stopper from the center member.
    Center member
    1. Remove the under cover (R.H.).
    2. Remove the front roll stopper mounting bolts.
    3. Remove the rear roll stopper mounting bolts.
    4. Remove the center member from the body.
    ENGINE MOUNTING
    Roll Rod (Manual Transaxle only)
    Before removal, place a piece of tape as illustrated to the bottom
    side of the roll rod for identification.
    INSPECTION ITEMS
    Transaxle mounting Engine mounting Front roll stopper Rear roll stopper
    Cracks, peeling
    and damage
    Cracks, peeling,
    and damage
    Center member
    Cracks and damage
    Roll rod (Manual Transaxle only)
    Cracks, peeling
    and damage
    2 0 - 2 2
    ENGINE AND TRANSAXLE ASSEMBLY
    ENGINE AND TRANSAXLE ASSEMBLY
    REMOVAL
    1. Remove the battery.
    2. Detach the air cleaner.
    3. Disconnect the connectors for the backup lamp and engine
    harness.
    4. For a vehicle with a 5-speed manual transaxle, disconnect
    the select control valve connector.
    5. Disconnect the connectors for the alternator harness and the
    oil pressure gauge wiring.
    6. Drain the engine coolant.
    7. For vehicles with an automatic transaxle, disconnect the
    transaxle oil cooler hoses.
    NOTE
    When disconnecting the hoses, identify their location to
    avoid making any errors during reassembly.
    CAUTION
    Be careful not to spill any oil or fluid from any of the
    openings. Also take care in preventing the entrance of
    foreign material.
    8. Disconnect the radiator upper and lower hoses on the engine
    side, and then remove the radiator assembly.
    9 . Disconnect the high tension cable and all wires to the
    distributor from the ignition coil section.
    10. Disconnect the engine ground.
    11. Disconnect the brake booster vacuum hose.
    12. Remove the main fuel line, and the return and vapor hoses
    from the engine side.
    CAUTION
    To reduce the residual pressure in the hoses, refer to
    Group Fuel System “Fuel filter replacement” [For MPI
    System].
    13. Disconnect the heater hoses (inlet and outlet) on the engine
    side.
    14. Disconnect the accelerator cable at the engine side.
    15. For vehicles with a manual transaxle, remove the clutch
    cable from the transaxle.
    16. For vehicles with an automatic transaxle, remove the control
    cable from the transaxle.
    ENGINE AND TRANSAXLE ASSEMBLY
    17. Disconnect the speedometer cable from the transaxle.
    18. Disconnect the air conditioner from the mounting bracket.
    19. Jack up the vehicle.
    20. Drain the transaxle oil (or fluid).
    21. Disconnect the front exhaust pipe from the manifold.
    NOTE:
    Use wire to suspend the exhaust pipe from the bottom of
    the vehicle.
    22. For vehicles with a manual transaxle, remove the shift
    control rod and extension rod.
    23. Remove the lower arm ball joint bolts and the strut bar at
    the point where it is mounted to the lower arm.
    24. Remove the drive shafts from the transaxle case.
    CAUTION
    1) Plug the holes of the transaxle case to prevent entry
    of foreign material.
    2) Install new circlips on the drive shafts when
    reassembling.
    25. Hang the lower arm and drive shaft from the body with a
    string.
    26. Attach a cable to the engine, and use a chain hoist to lift
    the engine only enough to pull the cable tight.
    27. Remove the front roll stopper.
    28. Separate the rear roll stopper.
    29. For vehicles with a manual transaxle, remove the roll rod.
    2 0 - 2 4
    30. Remove the engine mounting insulator bolts.
    31. Remove the engine mounting bracket from the engine.
    32. Slowly raise the engine (to the extent that the engine and
    transaxle weights are not applied to the mounting portions)
    and temporarily hold it in the raised condition.
    CAUTION
    Check that all of the cables, hoses, harnesses, connectors
    etc. are disconnected from the engine.
    33. Remove the caps from inside the right fender shield and
    remove the transaxle mount bracket bolts.
    34. Remove the left mount insulator bolt.
    While directing the transaxle side downward, lift the engine
    and transaxle assembly up and out of the vehicles.
    2 0 - 2 5
    INSTALLATION
    1. While checking the connections of the harnesses, pipes,
    hoses, etc., and making sure that none of them are being
    caught, damaged, etc., install the engine and transaxle
    assembly.
    2. When the engine and transaxle assembly is installed
    temporarily tighten the front roll stopper.
    3. The front and rear center member rubber bushings and
    collars are different.
    4. After the weight of the engine and transaxle assembly has
    been put on each insulator, tighten to specified torque.
    5. Reassemble all of the components removed during disassembly.
    Be especially careful to properly secure all
    components, including fuel, electrical and fluid pipe
    connections.
    6. Refill the coolant and check for leaks.
    7. Refill the transaxle fluid, test its operation, and check for
    leaks.
    8. Check the operation of the transaxle control cable and
    accelerator cable. Adjust as necessary.
    9. Check for proper operation of each of the various gauges.
    2 0 - 2 6
    TIMING BELT
    TIMING BELT
    COMPONENT
    TORQUE : Nm (kg.cm, lb.ft)
    REMOVAL
    1. Remove the fan, spacer, water pump pulley, and belt.
    2. Remove the timing belt cover.
    3. Move the timing belt tensioner pulley toward the water
    pump, and temporarily secure it.
    4. Remove the timing belt from the camshaft sprocket.
    5. Remove the camshaft sprocket.
    6. Remove the crankshaft pulley.
    7. Remove the timing belt.
    NOTE
    If the timing belt is reused, make an arrow mark indicating
    the turning direction (or the front of the engine) to make
    sure that the belt is reinstalled in the same direction as
    before.
    8. Remove the crankshaft sprocket bolts. Remove the crankshaft
    sprocket and flange.
    9. Remove the timing belt tensioner.
    2 0 - 2 7
    TIMING BELT
    INSPECTION
    Sprockets and Tensioner
    1. Check the camshaft sprocket, crankshaft sprocket and
    tensioner for abnormal wear, cracks, or damage. Replace as
    necessary.
    2. Inspect the tensioner for easy and smooth pulley rotation and
    check for play or noise. Replace as necessary.
    Timing Belt
    1. Check the belt for oil or dust deposits. Replace if necessary.
    Small deposits should be wiped away with a dry cloth or
    paper. Do not clean with solvent.
    2. When the engine is overhauled or belt tension adjusted,
    check the belt in detail. If the following flaws are evident,
    replace the belt with a new one.
    Description
    1. Hardened back surface rubber
    Flaw conditions
    Back surface glossy. Non-elastic and so hard that even if a finger
    nail is forced into it, no mark is produced.
    2. Cracked back surface rubber
    3. Cracked or separating canvas
    2 0 - 2 8
    TIMING BELT
    Description
    4. Badly worn teeth (initial stage)
    Flaw conditions
    Canvas on load side tooth flank worn
    (Fluffy canvas fibers, rubber gone and color changed to white, and
    5. Badly worn teeth (last stage)
    unclear canvas texture)
    Flank worn
    (On load side
    Canvas on load side tooth flank worn down and rubber exposed
    (tooth width reduced)
    Rubber exposed
    6. Cracked tooth bottom
    7. Missing tooth
    8. Side of belt badly worn
    9. Side of belt cracked
    Rounded belt side
    NOTE Abnormal wear (fluffy canvas fiber)
    Normal belt should have precisely cut sides as if produced by
    a sharp knife.
    2 0 - 2 9
    TIMING BELT
    INSTALLATION
    1. Install the flange and crankshaft sprocket as shown. Pay
    close attention to their mounting directions.
    Tightening torque
    Crankshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    69-98 Nm (700-1,000 kg.cm, 51-72 lb.ft)
    2. Install the camshaft sprocket and tighten the bolt to the
    specified torque.
    Tightening torque
    Crankshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    64-74 Nm (650-750 kg.cm, 47-54 lb.ft)
    3. Align the timing marks of the camshaft sprocket and
    crankshaft sprocket, with the No.1 piston placed at top dead
    center on its compression stroke.
    2 0 - 3 0
    TIMING BELT
    4. To install the timing belt tensioner, first mount the tensioner,
    spring, and spacer. Temporarily tighten the bolts. Next,
    temporarily tighten the tensioner long hole side washer and
    bolts. Install the bottom end of the spring against the front
    case as shown in the illustration.
    5. Secure the tensioner, positioned towards the water pump.
    6. Install the timing belt on the crankshaft sprocket.
    7. Install the timing belt on the camshaft sprocket.
    When the timing belt is installed on the camshaft sprocket,
    make sure that the tension side is tight. Then, check to
    ensure that when the tension side is tightened by turning
    the camshaft sprocket in a reverse direction, all timing marks
    are in line.
    8. Install the crankshaft pulley. In this case, make sure that the
    crankshaft sprocket pin fits the small hole in the pulley.
    Tightening torque
    Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    10-12 Nm (100-120 kg.cm, 7.2-8.7 lb.ft)
    9. Loosen the tensioner mounting bolts 1 and 2 in that order
    as shown. This will apply spring tension to the timing belt
    only. Check the belt to ensure that it is not out of position.
    10. Tighten the tensioner tightening bolts 1 and 2 in that order.
    If the bolt 1 is tightened first, the tensioner will move with
    the belt in the direction that the belt is tightened.
    11. Rotate the crankshaft one revolution in a clockwise direction.
    Realign the crankshaft sprocket timing mark with the top
    dead center position.
    TIMIMG BELT
    CAUTION
    Do not turn the crankshaft in a counterclockwise
    direction. The crankshaft should turn smoothly.
    12. Loosen the tensioner attaching bolts 1 and 2 in that order.
    13. Tighten the tensioner attaching bolts 2 and 1 in that order
    to the specified torque.
    Tightening torque
    Tensioner attaching bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    20-26 Nm (200-270 kg.cm, 14-20 lb.ft)
    14. Recheck the belt tension. Verify that when the tensioner and
    the tension side of the timing belt are pushed in horizontally
    with a moderate force [approx. 49 N (11 lb)], the timing belt
    cog end is approx. ½ of the tensioner mounting bolt head
    radius (across flats) away from the bolt head center.
    15. Install the timing belt cover.
    Tightening torque
    Timing belt cover bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    10-12 Nm (100-120 kg.cm, 7.2-8.7 lb.ft)
    16. Install the fan belt and adjust the belt tension.
    2 0 - 3 2
    ROCKER ARMS AND ROCKER ARM SHAFTS
    COMPONENTS [MPI]
    C : Marked 1-3
    TORQUE : Nm (kg.cm, lb.ft) D : Marked 2-4
    REMOVAL
    1. Remove the breather hose between the air cleaner and the
    rocker cover.
    2. Remove the air cleaner.
    3. Remove the timing belt cover.
    4. Remove the rocker cover.
    5. Loosen the rocker arm shaft mounting bolts and remove the
    rocker arm shaft, rocker arms and rocker arm shaft springs
    as an assembly.
    6. Remove the bolts, the rocker arms and rocker arm shaft
    springs from the rocker arm shaft.
    INSPECTION
    1. Check the roller surface. Replace there are any dents,
    damage or evidence of seizure.
    2. Check rotation of the roller. If it does not rotate smoothly or
    if looseness is evident, replace it.
    3. Check the inside diameter. If damage or seizure is evident
    replace the roller.
    4. Check the areas marked with arrows for wear and damage.
    If considerable wear or damage is evident, replace the roller.
    2 0 - 3 3
    ROCKER ARMS AND ROCKER ARM SHAFTS
    ROCKER ARMS AND ROCKER ARM SHAFTS
    COMPONENTS [FBC]
    TORQUE : Nm (kg.cm, lb.ft) A, C : Marked 1-3
    B, D : Marked 2-4
    REMOVAL
    1. Remove the breather hose between the air cleaner and the
    rocker cover.
    2. Remove the air cleaner.
    3. Remove the timing belt cover.
    4. Remove the rocker cover.
    5. Loosen the rocker arm shaft mounting bolts and remove the
    rocker arm shaft, rocker arms and rocker arm shaft springs
    as an assembly.
    6. Remove the bolts, the rocker arms and rocker arm shaft
    springs from the rocker arm shaft.
    INSPECTION
    1. Check the rocker arm face that contacts the cam lobe and
    the adjusting screw end that contacts the valve stem. If badly
    worn or damaged, replace rocker arm and/or adjusting
    screws.
    2. Check the rocker arm shaft for damage. Replace as
    necessary.
    2 0 - 3 4
    ROCKER ARMS AND ROCKER ARM SHAFTS
    INSTALLATION
    1. Install the rocker arms and rocker arm shaft springs to the
    rocker arm shafts. Install the rocker arm shafts to the
    cylinder head.
    Tighten the rocker arm shaft mounting bolts to the specified
    torque.
    Tightening torque
    Rocker arm shaft mounting bolt. . . . . . . . . . . . . . . . . . . . . . .
    20-26 Nm (200-270 kg.cm, 14-20 lb.ft)
    2. When installing the rocker arms, shafts and springs, note the
    difference between the RH and LH parts. The RH springs
    (exhaust) are approx. 44.2 mm (1.74 in.) free length, while
    the LH springs (intake) are approx. 77 mm (3.03 in.) free
    length.
    3. Install the rocker cover and tighten the bolts to the specified
    torque.
    Tightening torque
    Rocker cover bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    1.5-2.0 Nm (15-20 kg.cm, 1.1-1.4 Ib.ft)
    4. Install the timing belt cover.
    Tightening torque
    Timing belt cover bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    10-12 Nm (100-120 kg.cm, 7.2-8.7 lb.ft)
    5. Install the air cleaner.
    6. Install the breather hose.
    2 0 - 3 5
    CAMSHAFT
    COMPONENTS
    TORQUE : Nm (kg.cm, lb.ft)
    REMOVAL
    1. Disconnect the breather hose and the secondary air hose.
    2. Remove the air cleaner.
    3. Remove the timing belt cover.
    4. Move the timing belt tensioner pulley toward the water pump
    and temporarily secure it.
    5. Remove the timing belt from the camshaft sprocket. Since
    the crankshaft pulley need not be removed, the timing belt
    should be left installed on the crankshaft sprocket.
    6. Remove the camshaft sprocket.
    7. Remove the rocker cover.
    8. Remove the rocker arm shaft assembly. Refer to “Rocker
    Arms and Rocker Arm Shafts”.
    9. Remove the cylinder head rear cover.
    10. Remove the camshaft thrust case tightening bolt.
    11. Remove the camshaft thrust case and camshaft toward the
    transaxle side of the cylinder head.
    2 0 - 3 6
    CAMSHAFT
    INSPECTION
    1. Check the camshaft journals for wear. If the journals are
    badly worn, replace the camshaft.
    2. Check the cam lobes for damage. If the lobe is damaged or
    worn excessively, replace the camshaft.
    Cam height
    [Standard] [MPI]
    Intake. . . . . . . . . . . . . . . . . . . . . . 38.909 mm (1.5318 in.)
    Exhaust. . . . . . . . . . . . . . . . , . . . . 38.947 mm (1.5344 in.)
    [Standard] [FBC]
    Intake. . . . . . . . . . . . . . . . . . . . . . 38.909 mm (1.5318 in.)
    Exhaust. . . . . . . . . . . . . . . . . . . . 38.648 mm (1.5216 in.)
    [Limit]
    Intake . . . . . . . . . . . . . . . . . . . . . . . . -0.5 mm (-0.020 in.)
    Exhaust. . . . . . . . . . . . . . . . . . . . . -0.5 mm (-0.020 in.)
    3. Check the cam surface for abnormal wear or damage, and
    replace if necessary.
    4. Check the distributor drive gear tooth surfaces. If abnormal
    wear is evident, replace the camshaft.
    5. Check each bearing for damage. If the bearing surface is
    excessively damaged, replace the cylinder head assembly.
    6. Oil Seal (camshaft front)
    1) Check the lips for wear. If lip threads are worn, replace.
    2) Check the oil seal lip contacting surface of camshaft. If
    it is worn in stages, replace the camshaft.
    7. Check the camshaft end play.
    If the end play is too large, replace the thrust case and
    recheck the end play. If the end play is still too large, check
    the rear end of camshaft rear journal for wear. If it is badly
    worn, replace the camshaft.
    End play of camshaft [Standard value] . . . . . . . . . . . . . . . . . .
    0.05-0.20 mm (0.002-0.008 in.)
    INSTALLATION
    1. Install the crankshaft thrust case and thrust plate to the
    camshaft end and firmly tighten the bolt.
    2 0 - 3 7
    2. After lubricating the journal and thrust portions of the
    camshaft with engine oil, insert the camshaft from the
    transaxle side of the cylinder head. Insert the camshaft
    thrust case with the threaded hole at the top. Align the
    threaded hole with the bolt hole in the cylinder head. Install
    and tighten the bolt.
    3. Install the rear cover and gasket and tighten the bolts.
    4. Using special tools, Camshaft Oil Seal Installer (09221-
    21000), press fit the camshaft oil seal. Be sure to apply
    engine oil to the external surface of the oil seal.
    Insert the oil seal along the camshaft front end and install
    by driving the installer with a hammer until the oil seal is
    fulley seated.
    5. Install the camshaft sprocket and tighten the bolts to the
    specified torque.
    6. Install the rocker arm and shafts.
    Refer to “Rocker Arms and Rocker Arm Shafts”.
    7. Align the camshaft sprocket and crankshaft sprocket timing
    marks. The piston in the No. 1 cylinder will then be at the
    top dead center on the compression stroke.
    Tightening torque
    Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    64-74 Nm (650-750 kg.cm, 47-54 lb.ft)
    8. Temporarily set the valve clearance to specification with the
    engine cold. See “Valve Clearance Adjustment Procedure”.
    Valve clearance (cold engine) [Standard value]
    Intake valve . . . . . . . . . . . . . . . . . . . . . 0.07 mm (0.003 in.)
    Exhaust valve . . . . . . . . . . . . . . . . . . . 0.17 mm (0.007 in.)
    Jet valve [FBC only] . . . . . . . . . . . . . . 0.17 mm (0.007 in.)
    2 0 - 3 8
    CAMSHAFT
    9. Install a gasket in the rocker cover groove.
    10. Temporarily install the rocker cover.
    11. Start the engine and run at idle.
    12. After warming the engine to normal operating temperature
    [80 to 95°C (176 to 205°F) coolant temperature], adjust the
    valve clearance to specification. See “Valve Clearance
    Adjustment Procedure”.
    13. Install the rocker cover and tighten the bolts to the specified
    torque.
    Tightening torque
    Rocker cover bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    1.5-2.0 Nm (15-20 kg.cm, 1.1-1.4 lb.ft)
    14. Install the timing belt cover.
    2 0 - 3 9
    CYLINDER HEAD
    CYLINDER HEAD
    COMPONENTS
    TORQUE : Nm (Kg.cm, lb.ft)
    REMOVAL
    1. Drain the coolant and disconnect the upper radiator hose.
    2. Remove the breather hose (between the air cleaner and the
    rocker cover).
    3. Remove the air cleaner.
    4. Remove the vacuum hose, fuel hose and water hose.
    5. Remove the cables from the spark plugs. The cables should
    be removed by holding their boot portions.
    2 0 - 4 0
    CYLINDER HEAD
    6. Remove the distributor.
    7. Remove the surge tank.
    8. Remove the intake manifold.
    9. Remove the heat cowl and exhaust manifold assembly.
    10. Remove the timing belt cover.
    11. Move the timing belt tensioner pulley toward the water
    pump and temporarily secure it.
    12. Remove the timing belt from the camshaft sprocket. Since
    the crankshaft pulley need not be removed, the timing belt
    should be left on the crankshaft sprocket.
    13. Remove the rocker cover.
    14. Remove the cylinder head assembly. The cylinder head bolts
    should be removed by using Special Tool, Cylinder Head Bolt
    Wrench (09221-11001), in the sequence as shown in the
    illustration.
    15. Remove the gasket pieces from the cylinder block top surface
    and cylinder head bottom surface.
    NOTE
    Make sure that the gasket pieces do not fall in the engine.
    INSPECTION
    1. Check the cylinder head for cracks, damage and coolant
    leakage.
    2. Remove scale, sealing compound and carbon deposits
    completely. After cleaning oil passages, apply compressed air
    to make certain that the passages are not clogged.
    3. Check the EGR gas passage for clogging.
    And for FBC system, also check the jet air passage for
    clogging.
    2 0 - 4 1
    CYLINDER HEAD
    4. Check the cylinder head gasket surface for flatness by using
    a straight edge in the direction of A, B, . . . as shown.
    If flatness exceeds service limit in any direction, either
    replace the cylinder head, or lightly machine the cylinder
    head gasket surface.
    Flatness of cylinder head gasket surface
    [Standard dimension] . . . . . Less than 0.05 mm (0.002 in.)
    [Limit]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.004 in.)
    INSTALLATION
    1. Clean all gasket surfaces of the cylinder block and the
    cylinder head.
    2. Install a new cylinder head gasket onto the cylinder head
    assembly. Do not apply sealant to the gasket and do not
    reuse the old cylinder head gasket.
    3. Install the cylinder head bolts. Starting at top center, tighten
    all cylinder head bolts in sequence as shown in illustration,
    using the Cylinder Head Bolt Wrench (09221-11001).
    Repeat the procedure, retightening all cylinder head bolts to
    the specified torque.
    Tightening torque
    Cylinder head bolt
    Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    69-74 Nm (700-750 kg.cm, 51-54 lb.ft)
    Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    78-83 Nm (800-850 kg.cm, 58-61 lb.ft)
    4. Move the timing belt tensioner pulley toward the water pump
    and temporarily secure it.
    5. Install the timing belt on the camshaft sprocket, making sure
    that the tension side is tight. Check to ensure that when the
    tension side is tightened by turning the camshaft sprocket
    in reverse, all timing marks are in alignment.
    6. Adjust the timing according to “Timing Belt”.
    7. Install the rocker cover and tighten the bolts to the specified
    torque.
    Rocker cover bolt Tightening torque . . . . . . . . . . . . . . . . . . . . .
    1.5-2.0 Nm (15-20 kg.cm, 1.1-1.4 lb.ft)
    2 0 - 4 2
    CYLINDER HEAD
    8. Install the timing belt cover.
    9. Install the new intake manifold gasket and the intake
    manifold. Tighten the nuts and bolts to the specified torque.
    Tightening torque
    Manifold nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    (both intake and exhaust)
    15-20 Nm (150-200 kg.cm, 11-14 lb.ft)
    10. Install the new exhaust manifold gasket and the exhaust
    manifold. Tighten the exhaust manifold attaching nuts to the
    specified torque.
    11. Install the surge tank and tighten the nuts and bolts to the
    specified torque.
    For carburetor type, install the carburetor and tighten the
    bolts to the specified torque.
    Tightening torque
    Surge tank to inlet manifold nuts and bolts . . . . . . . . . . .
    15-20 Nm (150-200 kg.cm, 11-14 lb.ft)
    Carburetor to intake manifold bolts. . . . . . . . . . . . . . . . . . .
    15-20 Nm (150-200 kg.cm, 11-14 lb.ft)
    12. Install the distributor.
    13. Connect the vacuum hose, fuel hose and water hose.
    14. Install the air cleaner and breather hose.
    2 0 - 4 3
    VALVES AND VALVE SPRINGS
    VALVES AND VALVE SPRINGS
    TORQUE : Nm (kg.cm, lb.ft)
    REMOVAL
    1. Using Special Tool, Valve Spring Compressor (09222-
    21001), remove the retainer lock.
    Next remove the spring retainer, valve spring, spring seat
    and valve.
    NOTE
    Keep these parts in order so that they can be reinstalled
    in their original positions.
    2. Remove the valve stem seals with pliers, and discard.
    NOTE
    Do not reuse the valve stem seals.
    2 0 - 4 4
    VALVES AND VALVE SPRINGS
    INSPECTION
    Valves
    Check each valve for wear, damage and distortion of head and
    stem at B. Repair or correct if necessary.
    If stem end A is pitted or worn, resurface as necessary. This
    correction must be limited to a minimum. Also resurface the
    valve face.
    Replace the valve if the margin has decreased to less than the
    service limit.
    Margin
    [Standard dimension]
    Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.039 in.)
    Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.059 in.)
    [Limit]
    Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 mm (0.028 in.)
    Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.039 in.)
    Valve Springs
    1. Check the valve spring free length and tension. If they
    exceed the service limit, replace the spring.
    2. Using a square, test the squareness of each spring. If the
    spring is excessively out of square, replace it.
    Valve spring
    [Standard Value]
    Free height . . . . . . . . . . . . . . . . . . . . . 44.6 mm (1.756 in.)
    Load . . . . . . . . . .24 kg at 27.3 mm (53 lb at 1.075 in.)
    Out of square . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 or less
    [Limit]
    Free height . . . . . . . . . . . . . . . . . . -1.0 mm (-0.039 in.)
    Out of square . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3°
    Valve Guides
    Check the valve stem-to-guide clearance. If the clearance
    exceeds the service limit, replace the valve guide with next
    oversize part.
    Valve stem-to-guide clearance
    [Standard dimension]
    Intake . . . . . . . . . . . . . . 0.03-0.06 mm (0.0012-0.0024 in.)
    Exhaust . . . . . . . . . . . . 0.05-0.09 mm (0.0020-0.0035 in.)
    [Limit]
    Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.004 in.)
    Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
    2 0 - 4 5
    VALVES AND VALVE SPRINGS
    Valve Guide Oversizes
    Size mm (in.) Size mark
    Cylinder head hole size
    mm (in.)
    0.05 (0.002) O.S 5 12.105-12.115
    (0.4766-0.4770)
    0.25 (0.010) O.S 25 12.305-12.315
    (0.4844-0.4848)
    0.50 (0.020) O.S 50 12.555-12.565
    (0.4943-0.4947)
    Valve Seat Insert
    Check the valve seat for evidence of overheating and improper
    contact with the valve face. Recondition or replace the seat if
    necessary.
    Before reconditioning the seat, check the valve guide for wear.
    If the valve guide is worn, replace it, then recondition the seat.
    Recondition the valve seat with a valve seat grinder or cutter.
    The valve seat contact width should be within specifications and
    centered on the valve face.
    Valve Seat Insert Replacement Procedure
    1. Any valve seat insert that has been worn over the service
    limit should be removed at normal temperature after cutting
    away most of the insert wall, using valve seat cutters, as
    shown in Fig. “A”.
    2 0 - 4 6
    VALVES AND VALVE SPRINGS
    Valve Seat Insert Oversizes
    Description Size mm (in.) Size mark Seat insert height H mm (in.) Cylinder head I.D. mm (in.)
    Intake valve 0.3 (0.012) O.S 30 7.0-7.2 (0.276-0.283) 36.30-36.33 (1.429-1.430)
    seat insert 0.6 (0.024) O.S 60 7.3-7.5 (0.287-0.295) 36.60-36.63 (1.441-1.442)
    Exhaust valve 0.3 (0.012) O.S 30 7.4-7.6 (0.291-0.299) 32.30-32.33 (1.272-1.273)
    seat insert 0.6 (0.024) O.S 60 7.7-7.9 (0.303-0.311) 32.60-32.63 (1.283-1.285)
    2. After removing the seat insert, machine the seat insert bore
    using a reamer or a cutter. Cut to the size shown in the table.
    3. Heat the cylinder head to about 250°C (480°F) and press in
    the oversize seat insert. The oversize seat insert should be
    at normal room temperature for installation. After installation
    of a new valve seat insert, resurface the valve seat using
    the same procedure as in paragraph 1. in Valve Seat Insert.
    2 0 - 4 7
    VALVES AND VALVE SPRINGS
    Valve Guide Replacement Procedures
    The valve guide is installed using a press fit. Using a Valve Guide
    Installer (09222-21200) or suitable tool, replace the valve guide
    by the following procedure.
    1.
    2.
    3.
    4.
    5.
    Using the push rod of the Valve Guide Installer, push the
    valve guide out toward the cylinder block with a press.
    Machine the valve guide insert hole in the cylinder head to
    the specified oversize of the new valve guide.
    Using the Valve Guide Installer or suitable tool, press fit the
    valve guide. The use of the valve guide installer makes it
    possible to press fit the valve guide to a predetermined
    height. The valve guide should be installed from the top of
    the cylinder head. Note that the intake and exhaust valve
    guides are different in length [44 mm (1.73 in.) for intake
    and 49.5 mm (1.95 in.) for exhaust].
    After the valve guides have been installed, insert new valves
    and check the clearance.
    Whenever valve guides are replaced, check for valve to seat
    contact and recondition the valve seats as necessary.
    2 0 - 4 8
    VALVES AND VALVE SPRINGS
    INSTALLATION
    CAUTION
    1) Clean each part before assembly.
    2) Apply engine oil to sliding and rotating parts.
    1. After installing the spring seat, fit the stem seal onto the
    valve guide.
    To install, fit the seal in by lightly tapping the Special Tool,
    Valve Stem Oil Seal Installer (09222-21100).
    The seal’ is installed in the specified position by means of
    the special tool. Incorrect installation of the seal will
    adversely affect the lip I.D. and eccentricity, resulting in oil
    leakage down the valve guides. When installing, therefore,
    be careful not to twist the seal. Do not reuse old stem seals.
    2. Apply engine oil to each valve. Insert the valves into the
    valve guides. Avoid inserting the valve into the seal with
    force.
    After insertion, check to see if the valve moves smoothly.
    3.
    4.
    5.
    Install springs and spring retainers.
    Valve springs should be installed with the enamel coated
    side toward the valve spring retainer.
    Using Special Tool, Valve Spring Compressor (09222-
    21001), compress the spring. Be careful that the valve stem
    seal is not distorted by the bottom of the retainer. Then
    install the retainer locks. After installation of the valves,
    make certain that the retainer locks are properly installed.
    Install the cylinder head. Refer to “Cylinder Head”.
    JET VALVE (FBC)
    JET VALVE
    COMPONENTS
    REMOVAL
    1. Remove the rocker arms and shafts. Refer to Rocker Arm and
    Rocker Arm Shaft.
    2. Remove the valves, using Special Tool, Jet Valve Socket
    Wrench (09222-21300).
    CAUTION
    When the jet valve socket wrench is used, make certain that
    the wrench is not tilted with respect to the center of the jet
    valve. If the tool is tilted, the valve stem might be bent by
    the force exerted on the valve spring retainer, resulting in
    defective jet valve operation or a damaged tool.
    2 0 - 5 0
    JET VALVE (FBC)
    3. When disassembling the jet valve, compress the spring with
    the Special Tool, Jet Valve Spring Pliers (09222-21400)
    remove the valve spring retainer lock, and then remove the
    valve spring retainer and valve spring.
    CAUTION
    Do not mix up the combination of the jet valve body after
    the disassembly of the jet valve assembly, otherwise gas
    leakage and malfunctioning may result.
    4. Pull off valve stem seals with pliers and discard.
    INSPECTION
    1. Make sure that the jet valve slides smoothly in the body and
    has no play.
    Combination of the jet valve and jet body should not be
    disturbed and the jet valve and jet body should be replaced
    as an assembly.
    2. Check the valve head and valve seat for damage of seizure.
    3. Check the spring for sag, cracks or breakage.
    [Standard value]
    Diameter of jet valve stem 4.300 mm (0.1693 in.)
    Angle of valve face and seat . . . . . . . . . . . . . . . . . . . . . . 45°
    Jet valve spring
    Free length . . . . . . . . . . . . . . . . . . . 29.60 mm (1.165 in.)
    Load . . . . . . . . . . . . . . 3.5 kg/21.5 mm (5.5 lb/0.846 in.)
    INSTALLATION
    1. Using the Special Tool, Jet Valve Stem Seal Installer
    (09222-21500). drive the valve stem seal into the jet body.
    CAUTION
    1) The valve stem seal is not reusable.
    2) Use Special Tool, otherwise valve stem seal will be
    improperly installed and oil will work down.
    2. Apply engine oil to the jet valve stem when installing it to
    the jet body. Take care not to damage the valve stem seal
    lip. Make sure that the jet valve stem slides smoothly in the
    body.
    3. Compress the spring with the Special Tool, Jet Valve Spring
    Pliers (09222-21400) and install it together with valve
    spring retainer, and install the retainer lock.
    Be careful not to damage the valve stem seal with bottom
    of the retainer while installing.
    4. Install new O-ring in the jet valve body groove and apply a
    thin coat of engine oil to it.
    2 0 - 5 1
    JET VALVE (FBC)
    5. Install the jet valve assembly, assembled as described in 1
    thru 4 above, using Special Tool, Jet Valve Socket Wrench
    (09222-21300).
    Tighten to the specified torque below. While installing, apply
    engine oil to the threaded portion and seating surface of the
    jet body.
    CAUTION
    1) Install the jet valve assembly, finger-tighten and finally
    tighten to the specified torque with torque wrench.
    2) Keep the socket of wrench aligned with the jet valve
    stem to prevent it from forcing the stem sidewise or
    to keep it from dropping.
    Tightening torque
    Jet valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    18-22 Nm (180-220 kg.cm, 13-16 lb.ft)
    6. Install the rocker arm shaft assembly and rocker cover. Refer
    to “Rocker Arm Shaft Assembly”.
    JET VALVE CLEARANCE ADJUSTMENT
    CAUTIONS
    1) The misadjustment of the jet valve clearance not only
    2)
    3)
    1.
    2.
    3.
    4.
    5.
    affects the exhaust gas level but also may cause some
    engine trouble. So, be sure to make adjustment as follows:
    Adjust the jet valve clearance before the adjustment of the
    intake valve clearance. Readjust it after additional
    tightening of cylinder head bolts.
    Loosen fully the adjusting screws while making jet valve
    clearance adjustment.
    Warm up the engine until the temperature of the coolant
    rises to 80 to 95°C (176 to 205°F).
    With the piston in the cylinder positioned at TDC on the
    compression stroke, adjust in the following sequence.
    Back off the adjusting screw for the intake valve 2 or more
    turns.
    Loosen the lock nut on the adjusting screw for the jet valve.
    Turn the adjusting screw for the jet valve counterclockwise
    and insert a 0.25 mm (0.010 in.) feeler gauge between the
    jet valve stem and adjusting screw.
    Jet valve clearance (hot engine)
    [Standard value]. . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
    2 0 - 5 2
    JET VALVE (FBC)
    6. Tighten the adjusting screw until it touches the feeler gauge.
    Since the jet valve spring is weak in tensile strength, use
    special care not to force the jet valve in. Be careful
    particularly when the adjusting screw is hard to turn.
    7. Tighten the lock nut securely while holding the rocker arm
    adjusting screw with a screwdriver to prevent it from turning.
    8. Make sure that a 0.25 mm (0.010 in.) feeler gauge can be
    easily inserted.
    9. Adjust the intake valve clearance.
    10. Check for idle CO and R.P.M. and adjust if necessary.
    INTAKE AND EXHAUST VALVE CLEARANCE
    ADJUSTMENT PROCEDURE
    CAUTIONS
    1) Adjust the jet valve clearance before adjusting intake valve
    clearance.
    2) The valve clearance should be adjusted after additional
    tightening of the cylinder head bolts.
    1. Warm up the engine until the temperature of the coolant
    rises to 80 to 95°C (176 to 205°F).
    2. With the piston positioned at TDC on the compression stroke,
    adjust as follows:
    3. Loosen the lock nut.
    4. Adjust the valve clearance by turning the adjusting screw
    while measuring the clearance with a feeler gauge.
    Valve clearance (hot engine) [Standard value]
    Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
    Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
    5. Tighten the lock nut securely while holding the rocker arm
    adjusting screw with a screwdriver to prevent it from turning.
    6. Check for idle CO, HC and R.P.M. and adjust if necessary.
    2 0 - 5 3
    FRONT CASE, OIL PUMP
    FRONT CASE, OIL PUMP
    COMPONENTS
    TORQUE : Nm (kg.cm, lb.ft)
    REMOVAL
    1. Remove the timing belt. Refer to “Timing Belt”.
    2. Remove all the oil pan bolts.
    3. Remove the oil pan.
    4. Remove the oil screen.
    5. Remove the front case assembly.
    2 0 - 5 4
    FRONT CASE, OIL PUMP
    6.
    7.
    8.
    Remove the oil pump cover.
    Remove the inner and outer gears from the front case. The
    mating marks on the inner and outer gears indicate the
    direction of installation. Make sure that the inner and outer
    gears are installed as shown.
    Remove the plug and remove the relief spring and relief
    valve.
    INSPECTION
    Front Case
    1. Check the front case for cracks or damage. Replace as
    necessary.
    2. Check the front oil seal for worn or damaged lips. Replace
    if defective.
    Oil Pan and Oil Screen
    1. Check the oil pan for failure, damage or cracks.
    Replace if defective.
    2. Check the oil screen for failure, damage and cracks and
    replace if defective.
    Front Case and Oil Pump Cover
    Worn (especially stepped) or damaged surfaces contacting gears.
    Oil Pump Gears
    1. Worn or damaged gear tooth surfaces.
    2. Clearance between outer gear and front case.
    Outer gear
    Clearance between outer circumference and front case
    0.1-0.2 mm (0.0039-0.0079 in.)
    Clearance between addendum and crescent . . . . . . . . . . .
    0.22-0.34 mm (0.0087-0.0134 in.)
    End play . . . . . . . . . . 0.04-0.10 mm (0.0016-0.0039 in.)
    2 0 - 5 5
    FRONT CASE, OIL PUMP
    Inner gear
    Clearance between addendum and crescent . . . . . . . . . . .
    0.21-0.32 mm (0.0083-0.0126 in.)
    End play . . . . . . . . . . 0.04-0.10 mm (0.0016-0.0039 in.)
    3. Check the clearance between the outer gear addendum and
    crescent.
    4. Check the clearance between the inner gear addendum and
    crescent.
    Relief Valve and Spring
    1. Check sliding condition of the relief valve inserted in the
    front case.
    2. Inspect for distorted or broken relief valve spring.
    [Standard value]
    Free height . . . . . . . . . . . . . . . . . . . . . . .46.6 mm (1.835 in.)
    L o a d . . . . . . . . . . . . . . 6.1 kg/40.1 mm (13.4 lb/1.579 in.)
    lNSTALLATlQN
    Oil Pump
    1. Install the outer and inner gears into the front case. Make
    sure that the inner and outer gears are installed in the same
    direction as shown.
    2. Install the oil pump cover and tighten the bolts to the
    specified torque. After the bolts have been tightened, check
    to ensure that the gear turns smoothly.
    Tightening torque
    Oil pump cover bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    8-10 Nm (80-100 kg.cm, 6-7 lb.ft)
    2 0 - 5 6
    FRONT CASE, OIL PUMP
    3. Install the relief valve and spring. Tighten the plug to the
    specified torque. Apply engine oil to the relief valve.
    Tightening torque
    Relief valve plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    39-49 Nm (400-500 kg.cm, 29-36 lb.ft)
    Front Case
    Install the front case assembly with a new gasket, and tighten
    the bolts to the specified torque.
    Body length (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 mm (1.18 in.)
    (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 mm (0.79 in.)
    (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.36 in.)
    Tightening torque.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    12-15 Nm (120-150 kg.cm, 8.7-11 lb.ft)
    Oil Seal
    1. Inspect for worn, distorted or damaged lips.
    2. Check for elongated spring ring.
    3. Install Special Tool, Crankshaft Front Oil Seal Guide
    (09214-21100), to the front end of the crankshaft. Apply
    engine oil to the outer surface of the oil seal guide, and
    install the new oil seal along the guide by hand, until it
    toughes front case. Always use a new oil seal when
    reassembling.
    4. Use Special Tool, Crankshaft Front Oil Seal Installer
    (09214-21000), to install the oil seal.
    5. Install the crankshaft sprocket, timing belt and crankshaft
    pulley. Refer to “Timing Belt”.
    6. Install the oil screen.
    7. Clean both gasket surfaces of the oil pan and the cylinder
    block.
    FRONT CASE, OIL PUMP
    8. Apply sealant into the groove of the oil pan flange as shown.
    CAUTION
    1) Apply sealant approx. 4 mm (0.16 in.) in thickness.
    2) After application of sealant, do not exceed 15 minutes
    before installing the oil pan.
    9. Install the oil pan and tighten the bolts to the specified
    torque.
    Tightening torque
    Oil pan bolt. . . . . . . 6-8 Nm (60-80 kg.cm, 4-6 lb.ft)
    2 0 - 5 8
    PISTON AND CONNECTING ROD
    PISTON AND CONNECTING ROD
    COMPONENTS
    TOROUE : Nm (kg.cm, lb.ft)
    REMOVAL
    1. Remove the cylinder head assembly. Refer to “Cylinder
    l-lead”.
    NOTE
    Mark the connecting rods and caps before disassembly to
    avoid an accidental mix up during reassembly.
    2. Remove the oil pan and the oil screen.
    3. Remove the connecting rod cap and withdraw the piston and
    connecting rod assembly from the cylinder. Keep the
    connecting rod bearings in order by cylinder number.
    4. Using Special Tool, Piston Pin Setting Tool (09234-21000),
    disassemble the piston from the connecting rod as follows:
    1) Remove piston rings.
    2) Make certain that the front mark on the top of the piston
    is facing upward when the assembly is set in the press.
    3) Press the piston pin out.
    2 0 - 5 9
    PISTON AND CONNECTING ROD
    INSPECTION
    Piston and Piston Pin
    1. Check each piston for scuffing, scoring, wear, and other
    defects.
    Replace any piston that is defective.
    2. Check each piston ring for breakage, damage, and abnormal
    wear. Replace the defective rings. When the piston requires
    replacement, its rings also should be replaced.
    3. Check the piston pin fit in the piston pin hole. Replace any
    piston and pin assembly that is defective.
    The piston pin must push into the pin hole by hand at room
    temperature.
    Piston Rings
    1. Measure the piston ring side clearance. If the measured
    value exceeds the service limit, insert a new ring in a ring
    groove to measure the side clearance. If the clearance still
    exceeds the service limit, replace the piston and rings
    together. If it is less than the service limit, replace the piston
    rings only.
    Piston ring side clearance
    No.1 . . . . . . . . . . . . .0.03-0.07 mm (0.0012-0.0028 in.)
    No.2 . . . . . . . . . . . . .0.02-0.06 mm (0.0008-0.0024 in.)
    [Limit]
    No.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.004 in.)
    No.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.004 in.)
    2. To measure the piston ring end gap, insert a piston ring into
    the cylinder bore. Correctly position the ring into the cylinder
    by gently pushing it down with a piston. Remove the piston
    and measure the end gap with a feeler gauge. If the gap is
    not within the service limit, replace the piston ring.
    Piston ring end gap No.1 and No.2
    [Standard dimension] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    0.2-0.35 mm (0.008-0.014 in.)
    [Limit]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.039 in.)
    Oil ring side rail end gap
    [Standard dimension] . . 0.2-0.7 mm (0.008-0.030 in.)
    [Limit]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 mm (0.039 in.)
    When replacing the ring only, without correcting the cylinder
    bore, check the end gap with the ring positioned at the
    bottom of the ring travel.
    2 0 - 6 0
    PISTON AND CONNECTING ROD
    When replacing a ring, be sure to use a ring of the same
    size.
    Piston ring service size and mark
    STD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None
    0.25 mm (0.010 in.) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
    0.50 mm (0.020 in.) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . 50
    0.75 mm (0.030 in.) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . 75
    1.00 mm (0.039 in.) O.S . . . . . . . . . . . . . . . . . . . . . . . . 100
    NOTE
    The mark can be found on the upper side of the ring next
    to the end.
    Connecting Rods
    1. When reinstalling, make sure that cylinder numbers put on
    the connecting rod and cap at disassembly match.
    When a new connecting rod is installed, make sure that the
    notches for holding the bearing in place are on the same
    side.
    2.
    3.
    Replace the connecting rod if it is damaged on the thrust
    faces at either end. Also if step wear or a severely rough
    surface of the inside diameter of the small end is apparent,
    the rod must be replaced as well.
    Using a connecting rod aligning tool, check the rod for bend
    and twist. If the measured value is close to the repair limit,
    correct the rod by a press. Any connecting rod that has been
    severely bent or distorted should be replaced.
    Allowable bend of connecting rod.. . . . . . . . . . . . . . . . . . . . . .
    0.05 mm/100 mm (0.0020 in./3.94 in.) or less
    Allowable twist of connecting rod.. . . . . . . . . . . . . . . . . . . . . .
    0.1 mm/100 mm (0.0039 in./3.94 in.) or less
    INSTALLATION
    1. Using Special Tool, Piston Pin Setting Tool (09234-21000),
    assemble the piston to the connecting rod by the following
    procedure.
    1) Apply engine oil to the outer surface of the piston pin
    and the small end bore of the connecting rod.
    2 0 - 6 1
    PISTON AND CONNECTING ROD
    2) Set the connecting rod and piston with the front mark
    facing up and insert the piston pin assembly.
    Front mark
    Piston side : Indented mark
    Connecting rod side : Numeral, embossed.
    3) Using a install, press the piston pin into the pin hole with
    the specified pressure applied through the push rod to
    the pin end.
    Piston pin installation pressure (At normal temperature)
    [Standard value] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    4,900-14,700 N (1,102-3,306 lb)
    If more pressure than the specified pressure is required
    to press the piston pin into the pin hole, complete the
    following procedure.
    4) Turn the push rod a half turn, and dismount the piston
    connecting rod assembly from the support.
    5) After pressing in the piston pin, make sure that the
    connecting rod slides lightly and moves freely.
    2. Install the piston rings on the piston in the following
    sequence.
    1) Install the 3-piece oil ring. Install the spacer expander,
    upper side rail, and lower side rail in that order. When
    the side rails are installed, do not expand their gaps with
    the piston ring expander as with other piston rings. The
    side rails might be broken if such a method is employed.
    To install the side rail, first put one end of the side rail
    between the piston ring groove and the spacer expander.
    Hold the installed end in place. Working around the
    piston, press the rest of the rail into the groove with a
    finger as illustrated. Make sure that the upper side rail
    is installed first and the lower side rail installed last.
    CAUTION
    After the 3-piece oil ring has been installed, make sure
    that both the upper and lower side rails can be turned
    smoothly.
    Make sure that the spacer expander gap is installed more
    than 45° apart from either of the side rail gaps.
    2 0 - 6 2
    PISTON AND CONNECTING ROD
    2) Install the No.2 compression ring, followed by the No.1
    compression ring.
    CAUTION
    1) Install the piston rings in such a way that the size mark
    and maker stamped on the ring surface will face the
    piston top.
    2) The No.1 and No.2 compression rings have the same
    thickness. But these are different in cross sectional
    shape. Be very careful not to reverse them.
    3. Insert the piston and connecting rod assembly into the
    cylinder using a piston ring compressor. The piston mating
    mark must agree with the cylinder number, and with the
    arrow mark on the piston head directed toward the
    crankshaft pulley side of engine. It is advisable to install
    protective covers over the cap bolt threads in order to avoid
    causing damage to the cylinder bore and crank pin.
    CAUTION
    Check to ensure that the piston ring end gaps are
    positioned as illustrated.
    This will ensure that the piston rings are installed in such
    a way that their gaps will not coincide with the piston pin
    and thrust directions and that each gap will be positioned
    as far apart from the neighboring gaps as possible.
    Before attaching the piston ring compressor, apply engine
    oil around the piston and the piston rings.
    4. Install the connecting rod cap and tighten the connecting rod
    cap nuts to the specified torque. When the connecting rod
    cap is installed, make sure that the match mark (cylinder No.)
    stamped on the connecting rod big end and the match mark
    (cylinder No.) stamped on the cap are placed on the same
    side.
    Tightening torque
    Connecting rod cap nuts.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    31-34 Nm (320-350 kg.cm, 23-25 lb.ft)
    5. Check the connecting rod big end side clearance.
    Connecting rod big end side clearance
    [Standard] . . . . . . . . . . . . . . . 0.1-0.25 mm (0.004-0.01 in.)
    [Limit] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 mm (0.016 in.)
    6. Install the oil screen.
    7. Install the oil pan. Refer to “Front case” section.
    8. Install the cylinder head. Refer to “Cylinder Head”
    2 0 - 6 3
    CRANKSHAFT
    CRANKSHAFT
    COMPONENTS
    REMOVAL
    1. Remove the timing belt, front case, flywheel, cylinder head
    assembly and oil pan. For details refer to respective chapters.
    2. Remove the ‘rear plate and the rear oil seal.
    3. Remove the connecting rod caps.
    NOTE
    Mark the main bearing caps to permit reassembly in the
    original position and direction.
    4. Remove the main bearing caps and remove the crankshaft.
    Keep the bearings in order by cap number.
    INSPECTION
    Crankshaft
    1. Check the crankshaft journals and pins for damage, uneven
    wear and cracks. Also check oil holes for clogging. Correct
    or replace any defective part.
    2. Inspect out-of-roundness and taper of the crankshaft
    journals and pins.
    [Standard dimension]
    Crankshaft journal O.D . . . . . . . . . . . . 48 mm (1.8898 in.)
    Crank pin O.D . . . . . . . . . . . . . . . . . . . . 42 mm (1.6535 in.)
    Crankshaft journal pin out-of-roundness and taper.. . . .
    0.01 mm (0.004 in.) or less
    2 0 - 6 4
    CRANKSHAFT
    Main Bearings and Connecting Rod Bearings.
    Visually inspect each bearing for peeling, overheating, seizure
    and improper contact. Replace the defective bearings.
    Oil Clearance Measurement
    To check the oil clearance, measure the outside diameter of the
    crankshaft journal and the crank pin and the inside diameter of
    the bearing. The clearance can be obtained by calculating the
    difference between the measured outside and inside diameters.
    Journal oil clearance . . . . 0.02-0.07 mm (0.0008-0.0028 in.)
    Pin oil clearance . . . . . . . . 0.01-0.06 mm (0.0004-0.0024 in.)
    Tightening torque
    Main bearing cap bolt.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    49-53 Nm (500-540 kg.cm, 36-39 lb.ft)
    Connecting rod cap nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    31-34 Nm (320-350 kg.cm, 23-25 Ib.ft)
    Oil Clearance Measurement (Plastigauge Method)
    Plastigauge may be used to measure the clearance.
    1. Remove oil and grease and any other dirt from the bearings
    and journals.
    2. Cut the plastigauge to the same length as the width of the
    crankshaft journal and place it in parallel with the journal,
    away from oil holes.
    3. Install the bearings and caps and tighten them to the
    specified torque. During this operation, do not turn the
    crankshaft. Remove the caps. Measure the width of the
    plastigauge at the widest part by using a scale printed on
    the plastigauge package.
    If the clearance exceeds the repair limit, the bearing should
    be replaced or an undersize bearing be used.
    When installing a new crankshaft, be sure to use standard
    size bearings.
    Should the standard clearance not be obtained even after
    bearing replacement, the journal should be ground to a
    recommended undersize, and a bearing of the same size
    should be installed.
    Oil Seal
    Check the front and rear oil seals for damage or worn lips.
    Replace any seal that is defective.
    2 0 - 6 5
    CRANKSHAFT
    INSTALLATION
    1. Install the upper main bearing inserts in the cylinder block.
    When reusing the main bearings, remember to install them
    by referring to the location marks made at the time of
    disassembly.
    Oil holes in the bearings must match up with the oil holes
    in the block.
    2. Install the crankshaft. Apply engine oil to the journals.
    3. Install the bearing caps and tighten the bolts to the specified
    torque in the following sequence: No.3, No.2, No.4, No.1 and
    No.5.
    Cap bolts should be tightened evenly in 2 to 3 stages before
    they are tightened to the specified torque.
    The caps should be installed with the arrow mark directed
    toward the crank pulley side of engine. Cap numbers must
    be in order.
    Tightening torque
    Main bearing cap bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    49-53 Nm (500-540 kg.cm, 36-39 Ib.ft)
    4. Make certain that the crankshaft turns freely and has the
    proper clearance between the center main bearing thrust
    flange and the connecting rod big end bearing.
    5.
    6.
    7.
    8.
    9.
    Crankshaft end play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    0.05-0.18 mm (0.002-0.007 in.)
    Install the oil seal in the crankshaft rear oil seal case. Use
    Special Tool, Crankshaft Rear Oil Seal Installer
    (09231-21000) as shown. Press fit the oil seal all the way
    in, being careful not to misalign it.
    Install the rear oil seal case and gasket. Tighten the five
    bolts. Apply engine oil to the oil seal lips and crankshaft at
    the time of installation.
    Install the rear plate and tighten the bolts.
    Install the connecting rod caps. Refer to “Piston and
    Connecting Rods”.
    Install the flywheel, front case, oil pan and timing belt. For
    further details, refer to the respective chapters.
    2 0 - 6 6
    FLYWHEEL
    FLYWHEEL
    COMPONENTS
    TORQUE : Nm (kg.cm. Ib.ft)
    M/T : Manual Transaxle Vehicles
    A/T : Automatic Transaxle Vehicles
    REMOVAL
    1. Remove the transaxle and clutch.
    2. Remove the flywheel.
    INSPECTlON
    1. Check the clutch disc contacting surface of the flywheel for
    damage and wear. Replace the flywheel if excessively
    damaged or worn.
    2. Check the clutch disc contacting surface of the flywheel for
    run-out.
    Standard value
    Flywheel run-out . . . . . . . . . . . . . . . . . . . 0.1 mm (0.004 in.)
    3. Check the ring gear for damage, cracks and wear, and
    replace if necessary.
    INSTALLATION
    Install the flywheel assembly and tighten the bolts to the
    specified torque.
    Tightening torque
    Flywheel bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    127-137 Nm (1,300-1,400 kg.cm, 94-101 Ib.ft)
    2 0 - 6 7
    CYLINDER BLOCK
    CYLINDER BLOCK
    COMPONENTS
    TORQUE : Nm (kg.cm. Ib.ft)
    REMOVAL
    1. Remove the cylinder head, timing belt, front case, flywheel,
    piston and crankshaft.
    2. Using the special tool (09260-11000), remove the oil
    pressure switch.
    For further details, refer to the respective chapters.
    INSPECTION
    Cylinder Block
    I. Visually check the cylinder block for scratches, rust and
    corrosion. Also check for cracks or any other defects, using
    a flaw detecting agent (magnafluxing). Correct or replace the
    block if defective.
    2. Using a straightedge and feeler gauge, check the block top
    surface for warpage. Make sure that the surface is free from
    gasket chips and other foreign matter.
    Standard . . . . . . . . . . . . . . . . . . . 0.05 mm (0.0020 in.) or less
    Limit.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.0039 in.)
    2 0 - 6 8
    CYLINDER BLOCK
    3. Measure the cylinder bore with a cylinder gauge at three
    levels in the directions A and B. If the cylinder bores show
    more than the specified out-of-round or taper or if the
    cylinder walls are badly scuffed or scored, the cylinder block
    should be rebored and honed. New oversize pistons and rings
    must be fitted.
    Measuring points are as shown.
    Cylinder I.D.. . . . . . . . . . 75.5-75.53 mm (2.972-2.974 in.)
    Cylinder I.D. taper . . . . . . . . . . 0.02 mm (0.0008 in. or less)
    4. If a cylinder ridge exists, cut away with a ridge reamer.
    5. Oversize pistons are available in four sizes.
    Piston service size and mark mm (in.)
    0.25 (0.010) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25
    0.50 (0.020) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50
    0.75 (0.030) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75
    1.00 (0.039) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00
    6. When boring the cylinder bore to oversize, keep the specified
    clearance between the oversize piston and the bore, and
    make sure that all pistons used are of the same oversize.
    The standard measurement of the piston outside diameter is
    taken at a level 12 mm (0.47 in.) above the bottom of the
    piston skirt and across the thrust faces.
    Piston-to-cylinder wall clearance . . . . . . . . . . . . . . . . . . . . . . . .
    0.02-0.04 mm (0.0008-0.0016 in.)
    INSTALLATION
    Install the following parts by referring to the respective chapters.
    (a) Crankshaft
    (b) Flywheel
    (c) Piston
    (d) Cylinder head
    (e) Timing belt
    (f) Front case
    2 0 - 6 9
    OIL PRESSURE SWITCH
    OIL PRESSURE SWITCH
    The oil pressure switch is located at the center of the right-hand
    side of the engine. If the oil pressure in the lubricating system
    has dropped below 28 kPa (4 psi) during normal operation, the
    oil pressure warning light will come on. The hexagonal portion
    of this switch is 26 mm (1.024 in.) wide across the flats.
    REMOVAL AND INSTALLATION
    Using the special tool (09260-11000), install the oil pressure
    switch after applying sealant to the threaded area.
    Sealant.. . . . . . . . . . . . . . . . . . . . . . Threebond 1104 or equivalent
    NOTE
    Do not over torque the oil pressure switch.
    Tightening torque
    Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
    15-21 Nm (150-220 kg.cm, 11-15 Ib.ft)
    INSPECTION
    1. Check the continuity between the terminal and the body with
    an ohmmeter.
    If there is continuity, replace the oil pressure switch.
    2. Check the continuity between the terminal and the body
    when the fine wedge is pushed. If there is continuity even
    when the fine wedge is pushed, replace it.
    3. Or, if there is no continuity when a 50 kPa (70 psi) vacuum
    is applied through the oil hole, the switch is operating
    properly. Check to see that air doesn’t leak. If air leaks, the
    diaphragm is broken. Replace the switch.
    2 0 - 7 0
     

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