J @TOYOTA
.'
..
}
REPAIR MANUAL
Jul., 1995
;.
·,
\
..
• INTRODUCTION ..··:- ......., ~
.. d '¥ • -:_,.,..,
ENGINE ~
,..;:/·..:_~,.r;t.:
IGNITION SYSTEM
STARTING SYSTEM
CHARGING SYSTEM
•
j; ••
..
. '· 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
0
Please note that the publica lions below have a!so been
• prepared as relevant service manuals for the components and
system in this engine.
•
All information in this manual is based on the latest product in-
formation at the time of publication. However, specifications
and procedures are subject to change without notice.
TOYOTA MOfOR CORPO{Ul.TION
..
•0
©1995TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be
reproduced or copied, in whole or in part,
..w"it ht l ut the written permission of Toyota
- ,..
~-
IN-1
INTRODUCTION
•
HOW TO USE THIS MANUAL ·················· IN- 2 fii'~
ii.!fJ.:i!!tIDENTIFICATION INFORMATION ··············· IN- 4
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
Most repair operations begin with an overview illustration. It identifies the components and
shows how the parts fit together.
Example:
--------------------------------------------------~
r __..,Oil Pump Body
+Cotter Pin - - -~
~
~ ~
~
~
~..,
~-
( I
~
I ~ I
Relief Valve IJ -- -~
DriJ.n Rotor-@
Volve Spring I 1./
Oil Pump Covor
I ~Srring Retainor
~JP
Drive Rotor----J"b.'f-
)
~
i :[B·m lkgf·cm, ft·lbf) Specified torque
+ Non~reusable part P2537J
'-------------------------------------------------------~~
-. 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
f
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
I
1. JfOrl-tf
Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
2. During disassembly, keep parts in th6 appropri~t••
order to. facilitate reassembly. '
3. Observe the fo!lowing:
(a) Before doing electrical work. disconnect the neg-
ative cable from the battery terminal.
(b) If it is necessary to disconnect the battery for
in.spection or repair, always disconnect the cable
from the negative(-) terminal which is grounded
to the vehicle body. .
(c) To prevent damagll to the battery terminal post.
lcosen tho terminai nut and rais~ the cabl<:l strai-
ght up without twisting or pryin9 it.
(d) Cle.an th9 battery terminal posts and cable t<~rmi
nals with a clean shop rag. Do not scrape them
with a file or other abrasivs object~.
(e) Install the cable terminal ~o the battery post with
the nut loose, and tighten the nut after installa-
tion. Do not use a hammer to tap the terminal
onto the post.
(f) Be sure the cover for the positive (+) terminal is
.properly in place.
4. Check hose and wiring connectors to m?'<e sure that
they are socuro and correct.
s-~····
INTRODUCTION - GENERAL REPAIR INSTRUCTION:'; IN-5
5. Non- reusable parts
' (a) Always replace cotter r-ins. gaskets, 0-rings and
oil seals etc. with new ones.
.. (b) Non-reusable parts a~e indieated in the compo-
Seal Lock Adhes:ive _j nent illustrations by the ••• symbol.
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.
(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
Fuse torques. Always use a torque wrench.
Equal Amperage Rating 9. Use of SST and SSM may be required. depending on
' ( 10 the nature of the repair. Bs sure to Ulje SST and SSM
where specified and follow the prooer work proce-
dure. A list of SST and SSM can he found in the
preparation ;:>art at tho front o~ eacn section in this
manual.
10. When replacing fustJ·s. be sure the new fuse ha~ the
8F1J&& correct amperag(> rating. DO NOT exceed tha rating or
use one with a lower rating.
Illustration ~"Symbol Part Nnme ·-r·------,
~ B£5694 -~- - Abbrevintion
I WQJ8S 1
BE56S~ . FUSE
~ --<0"'o- MEDIUM CURRENT FuSE IM-FIJSE
- ~1-· w-JoJee j
-~-- HIGH CURRENT FUSE H-FUSE
B£5690 INOl07
/ -~ FUSIBLE LINK FL
I BE5597 IN0307 co
BES598
GY - 8 - - 'I CIRCUIT 6iii:AKER
INOJ68
' . """"
·· IN-6 INTRODUCTION - GENERAL REPAIR INSTRlJ.;TIONS
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. ,
WHONG 12. Observe these precautions to avoid damage to the
CORRECT parts:
(a) Do not open tho cover or case of the ECU unless
·absolutely necessary. (If the IC terminals are tou-
ched. t:1o IC may be destroyed by static electric·
ity.)
(b) To disconnect vacuum hoses. pull on the end. not
the middle of the hose.
IL---------------------~=IN=02~53. (c) To pull apart electrical connectors. pull on the
connector itself. not the wires.
(d) Be careful not to drop electrical components.
WRONG CORRECT such as sensors or relays. If they are dropped on
a· hard floor. they should be ~eplaced and not
,/ l
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
IN0262 temperature switches or temperature sensors.
Exampie (g) When checking continuity at the wire connector.
insert the testGr probe carefully to !Jrsvont termi-
nals from bending.
(h) When using a vacuum g<:lJge. never force the
hose onto a connector that is· too large. Usa a
stllp ·-down adapter instead. Once the ho$e h~.s
b'3en stretched, it may ldak.
13. Tag hosas before disconnecting them:
I (a) When disconr.ec!ing vacuum hoses, use tags to
'""""' I 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.
INTRODUCTrON - ABBREVIATIONS USED IN THIS MANUAL IN-/ ,.
ABBREVIATIONS USED IN THIS --·
MANUAL
- -' A/G Air Conditioner
Approx. Arproxlmatelv
BOG Bottom Oe11d Center
FIPG Formed In Placa Guket
MP Multipurpoa.:J
C/S Oversized
PGV Positive Crnnkca~e Vflntil~tion
SSM Special SOrvice Meteriela
SST Special Service Tools
STO Standard
SW Switch
TOG Top Dead Center
TEMP. Temperature
U/S Undersize ~
vsv Vacuum Switching Velva
W/ With
w/o Without
IN-8 IN.TRODUCTIO'I'< -STANDARD BOLT TORQUE SPECIFICATIONS
STANDARD BOLT TORQUE SPECIFICATIONS '
--w
HOW TO DETERMINE BOLT STRENGTH
~-----------~ Mark Class ------ Mark l Class
Hexaqon
head bolt 4- 4T Hexagon ~ 4 9T
5- ST flange boll
GT Protruding
Boll G- wl washer
( ) ' h e a d No._ 7- 7T lines
8- ST hexagon bo,lt
9T
9- 10T Hexagon ~ 5 10T
10- 11T flange boll
Protruding -
w/ Y!asher lines
· hexagon boil
11-
0-. ~Hexagon 6 11T
No mark Prolr!:Jding
flange boll lines
4T w/ washer
hexagon bolt
Hexagon Slud boll No mark
flange bolt
0 No mark I4T
w/ w~sher I
hexagon bolt 4T
I I
I ! (CD 1- r·,·~:·+JHexagon I
ll•.nge boll
IQl ::.:"';~ "lIw/ wacher
hb'<agon be-lt
Hexagon
Lhead boll
2 ST
ProtrtJding
0 lin as
0 2 GT
I _j__HexaqtJn I I I
~ -l'ead boll - I I
I 3 n Welded boll
Protruding
I~ lines
~ 4T
Hexagon ~ 4 ST
head bolt Protruding
lines
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
Specified torque
Class Diameter Pitch Hexegon head bolt He."'"9on flonge bolt
:nm
m;n 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 12.5 130 145 10
10 1.25 26 260 9 ~4
4T 12 1.25 47 480 19 290 21
14 1.5 74 760 35 29 540 39
16 1.5 115 1.150 55 53
83 84 850 61
- --
5T 6 1 6.5 65 56 in.·lbf 7.5 75 65 in.·lbf -
8 1.25 15.5 160 175 13
.- 10 1.25 32 330 12 17.5 360
12 1.25 59 600 24 3€ 26
6T 14 1.5 91 930 43 65 670
16 1.5 140 1,400 67 100 1,050 48
... 101
6 1 8 80 - - 76
8 1.25 19 195 69 in.·lbf
10 1.25 39 400 14 9 -
12 1.25 71 730 29 21
14 1.5 110 1,100 53 44 90 ' 78 in.·lbf
16 1.5 170 1,750 80 80 210 15
127 125 440 32
810 59
- 90
1,250
-
-
61 10.5 1I0 8 12 120 9
8 1.25 25 260 19 28 290 21
7T 10 1.25 52 530 38 58 590 43
~ 12 1.25 95 970 70 105 1,050 76
8T 14 1.5 145 1,500 108 165 1,700 123
2.30ti) 156 ~I-- -
t'T T ~I16 230
300 22 33 330
lOT 8 1.25 29 .620 45 68 690 50
1,100 00 .120 1,250 90
I10 1 1.25 I 61
12 1.25 110
I6
i. 7.5 34 .340 25 .17 380 o2..77
10 1.25 I 7C 710 51 7B 790
12 1.25 125 ,,30(1 94 1 140 1.450 105
+----------------r----------·-----1
8 1.25 38 390 28 42 430 31
10 1.25 78 800 58 88 890 64
12 1.25 140 1,450 105 155 1,600 116
8 1.25 42 430 31 47 480 35
11T 10 1.25 87 890 64
1.25 155 1,600 I 16 97 990 72
12
175 1,800 130
tG-1
ENGINE
.. ENGINE MECHANICAL
.PREPARATION ....................................... EG- 2
.'
AIR elLTER INSPECTION AND
I" CLEANING ·························•·•·········· ··· EG- 6
'. IDLE CO CHECK AND ADJUST .....•......;.. EG- 6
COMPRESSION CHECK ····•····••···•·•·······•·· EG- 9
VALVE CLEARANCE INSPECTION AND
ADJUSTMENT······································ EG- 10
IGNITION TIMING INSPECTION AND
ADJUSTMENT······································· EG- 11
IDLE SPEED INSPECTION AND
ADJUSTMENT······································· EG-11
CYLINDER HEAD ................................. .-.. EG- 1r
TIMING CHAIN ....................................... EG- 27
CYLINDER BLOCK ................................. EG- 34
SERVICE SPECIFICATIONS ........................ EG- 55
FUEL SYSTEM
PREPARATION .................................,..... EG- 60
PRECAUTION ........................................,. EG- 60
ON-VEHICLE INSPECTION ..................... EG- 6!
CARBURETOR ....................................... EG- 61
FUEL PUMP ........................................... EG- 76
SERVICE SPECIFICATIONS ........................ EG- 78
COOLING SYSTEM
PREPARATION ....................................... EG- 79
COOLANT CHECK AND REPLACEMENT ... EG-- 80
WATER PUMP ...............................;....... EG- 81
THERMOSTAT ....................................... EG- 85
RADIATOR ............................................. EG- 87
SERVICE SPl:CIFICATIONS ........................ EG- 88
LUBRICAT!ON SYSTEM
PREPARATION ....................................... EG- 89
OIL PRESSURE CHECK ........................... EG- 90
OIL AND FILTER REPLACEMENT ............ EG- 91
OIL PUMP ............................................. EG- 92
SERVICE SPECIFICATIONS ........................ EG- 96
EG-2. ENGINE·..:. ENGINE MECHANICAL
ENGINE MECHANICAL f
PREPARATION •-•~u
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
_...................................,..................................................................................................................... ..
(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 (~1651-60665) Bolt
I 09215-00101 Camchsft Dearing Remover &
Roplecer Sot ..g
I
················· .. . I...............................................................................................................
I
(09?15-001?1) Gote "A"
(09215-00130) Bolt
ENGINE - ENGINE MECHANICAL EG-3
(09215-00141) Nut
·. -I
(09215 -00150) Shalt "A•
.--
(09215-00161) P;n
.
(09215-00211) P.omovor & Aflplacor
"
' (09215-0022l) Remover & Aoplacor
(09215-00231) Remover & Rop/occr
09221-25025 Piston Pin Romovor & Raplacor
········································································································ ·························-··························
(09221-00020) . Body
(09221-00030) Sp,;ng
,.......................................................................................................... ................................................. . -I
(09221-00170) Gu;de "J'
I
i
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 I
09330 00021 Companion Flange Holding Tool Crankshaft pulley i
......................... ,
(09330-00030) Pin
i: •
I
{
!
t'
09950-4o'01 0 Puller B Set 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.......................................................................................................................
i i9 s·2: osi i i)· ·-s; 'd~·;.:·; ,····.................. ···......··············· ................. ...................:................................[..................................................................
[@ITQJ
~..................iii&s5i·:·o5ii2ii,· ··e:~-~-;~;-'0·~·;;·;·-sc;··......................................................................... ·..............................
······ ····..····..··········· ··..·...····....······ ·....····cu9iis4·::·oso2o) ..-;;;;·;;·N~::;· ........·............................................ ·...........................................·.....................
~~
· 09950 70010 Hondle Set
.............................io995.i =o7i5ii). ··fi~~di~·;-s'O.........................................................................................................................
ENGINE - ENGINE MECHANICAL EG-5
09960:...10010 Variob/o Pin Wronch Set Camshaft cprcekot
(09962-01000) Vor;oblo p;n Wrench Arm A"y
............... ························· ······· ................................................
(09963-01000) Pin 10
tECOMMENDED TOOLS
09200-00010 Enpino Adjust Kit.
.- 09258-00030 Hose Plug Set. Plug for the vacuum hose, fuel
hose etc,
.• -.:OUiPMENT --
'
.• Caliper gauge Valve 1prlng
CO/HC meter Val'la spring - --
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
,,
EG-6 ENGINE - ENGINE MECHANICAL
SSM (SPECIAL SERVICE MATERIALS) -···~
08826-00080 Seal Packing Black or equivalent Timing chain cover. oil pan and ..,
rear oil sear retainer
(FIPG)
[
----------L----
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
Blow dirt off in the element with' compressed air from
the inside.
If element is torn or excessively dirty, replace the air •
filter.
4. REINSTALL AIR FILTER
~711
IDLE CO CHECK AND ADJUST
_..,.M~~
1. VISUALLY INSPECT CARBURETOR
(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
ENGINE - ENGINE MECHANICAL EG-7 -~
·. NOTICE: •·
,.
• • NEVER allow the tachomotl3r terminal to touch
. ..
grourid as it could result in damage to tho igniter
.·.
and/or ignition coil.
• As some tachometers erll not compotible with this
ignition system. we recommend that you confirm
the compatibility of yow· unit befor~ use.
4. INSPECT IDLE SPEED
Idle speed:
750 ±50 rpm
If not a·s specified, adjust accroding to these proce-
dure:
CAUTION:
• Always use a CO motor when ~djusting the idle
mixture. It is not noce.n:s11ry to adjust with the idle
mixture adjusting screw in most vehicles if thoy are
in good condition. If a CO meter is r>ot available, £9
NOT ATTEMPT TO ADJUST WITH THE SCREW.
• If a CO meter is not available and it is absolutely
necessary to edjust with the Idle mixture adjusting
screw. use the alternative method.
5. CHECK AND ADJUST CO CONCENTRATION AT
IDLE
A. Method with CO meter
(a) Start the engin9.
(b) Using a CO meter to measure the CO concentration in
the exhaust. turn the idle speed and idle mixture
adjusting screws to obtain the speclfied concentra-
tion value at idle speed.
,Idle speed:
' 750 ±50 rpm
(c) Check that the CO meter is properly calibrated.
(d) Race the engine 30-60 seconds at about 2,000 rpm
before measuring concentration.
(e) Wait 1-3 minutes after rucin!l the engine to allow the
ccncentration to stabilize.
(f) lnsort a testing probe at least 40 em (1.3 ft) into the
tailpipe, and measure the concentration ~vithin a short
time.
Idle CO concentretion: 1.0 ± 0.5 %
• If the CO concentration is within specification
this adjustment is complete.
• If the CO concentration is not within specifica-
tion, turn the idle mixture adjusting screw to
obtain the specified concentration valt.. e.
• If the CO concentration cannot be corrected by
adjusting the idle mixture, see tacle below for
other possible causes.
EG-8 ENGINE '- ENGINE· MECHANICAL<· ..
TROUBLESHOOTING •
co 1-!C Problems Causes
Rough idle
Normal High 1. Faulty ignition:
Rough Idle • Incorrect timing
Low High (Fluctuating HC reading) • Fouled,shorted or Improperly gapped plugs
• Open or crossed Ignition wires
-- ' • Cracked distributor cap
High High Rough idle 2. Leaky exhaust valves
(Black smoke from exhaust) 3. Leaky cylinder
1. Vacuum leak: -
• Vacuum hose
• Intake manifold
• PCV line
• Carburetor base
1. Restricted air filter \
2. Plugged PCV valve
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.
. t·
(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
PLUGS
B. RECONNECT DISTRIBUTOR WIRE
''3-10 ENGINE -·ENGINE MECHANICAL ' ..
Front VALVE: CLEARANCE INSPECTION
AND ADJUSTMENT
-+-
[GI.OM•OI
No.1 No.2
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.)
1 • Using a feeler g'luge, measure the valve clear-
=,J ance between· the valve stam and rocker arm.
Loosen the lock nut "nd tum the adjusting screw
to set the proper clearance. Hold the adjusting
screw in position and tighten the lock nut..
• Rec:heck :he val•1e ·clearance. Tha fAster g3ugo
should slide with a very slight drag.
Front (b) Turn the crankshaft one revolution (360°) and align
the mark above.
+- Adjust Qnly the valves indicated by arrows.
No.2 No.3 No.4 4. REINSTALL CYLIND.ER.,JlEAD COVER·, '
(Seo step 5 in cylinder hoad ir.;;tallation)
EX IN IN EX
.·''
~+ +--+-+~
~.r~>:
00000
-- .t'Sl:.>J.I
·:\..... I. tG-11
.ENGINE ·ENGINEMECHANICAL
."' .:.' IGNITION TIMING INSPECTION AND
.' ADJUSTMENT
" .'1 WARM L.:P ENGINE
Allow the engine to warm up to normill operating
temperature.
2 . CONNeCT TACHOMET[;R TO ENGINE
(See step 3 in idle CO check and adjust)
3. INSPECT DWELL ANGLE
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)
4. 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
aWith the engine idling as specified, u~e timing light
to check the timing.
Ignition timing:
5±2• BTDC @.Idle
·.~:f~
;.
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)
EG-12 ENGINE -,.. ENGINE MECHANICAL·
CYLINDER HEAD - -.. I
COMPONENTS
Seal Washer---~ f.------Seal Washer
\---Cylinder Head
Cover
+ 0-Ring Rocker Arm and
l.ll.<;~-----shaft Assembly
Spar~ Plug
See e EG·25
Spark Plug I 1•1 29.5 (300, 22)
2nd Turn go•
Tube ---....__ \ 3rd Turn go•
Water Outlet Hosing ~J/ Cylinder Head
Assembly "'""-,
''
Clamp~-·
<V'-~-·
X6
- ,.
( lntake,Exhaust Manifolds and
Carburetor Assembly
,,.,.,
' . ENGINE E.:l-13
. lntake, Exhaust Ma If . - ENGINE MECHANICA'
·• n olds and Carbureto•· Asse:m.bly. · L
• Intake Manifold
;
"-
EG-14 ' ENGINE - ENGINE MECHANICAL
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.
.:::·
l 9. REMOVE ROCKER ARM AND SHAFT ASSEMBLY.
(a) Uniformly loosen and ramove the 6 bolts and 2 nuts in
I
several passes, in tha sequence sho)!Vn.
.,.,.,I (b) Remove the rocker arm and shaft assembly.
1C. REMOVE PUSH RODS
Remove tho 8 push rods in o;der, begi11ning from tho
No.1 push rod.
NOTE: Arrange the push rods in correct order•
11. REMOVE CYLINDER HEAD
(a) Uniformly loosen and remove the 3 head bolts in
several passes. in the sequence shown.
CAUTION: Head werpage or cracking could result from
removing out of sequence.
ENGINE - ENGINE MECHANICAL EG-15 ~
(b) Uniformly loosen and remove the 11J head bolts in .If
several passes, in the sequence shown. j:~
CAUTION: Hond wnrpngo or cracking could result from ,.·:,
-i~
removing out of sequence.
ffl
..i.!.li
-··•j,..,. ~=·
;.E....~(·:L;
••
P149SO ZI6SJS
P149Sl
(c) Lift the cylinder head from the dowels on the cyli;,der
block and· place the head on wooden blocks on ~
bench.
HINT: If the cylinder head is difficult to lift off, pry
betwee;, the cylinder head and block with a screw-
driver.
CAUTION: Be careful not to damage the cylinder head or·
b!ock surface on the cylinder haad gasket sides.
CYLINDER HEAD DISASSEMBLY
1. REMOVE WATER OUTLET ~lOUSING AND REAR
PLATE
(a) Remove the 2 bolts, clamp. watGr outiet. housing ar~d
gasket.
(b) Remove the 4 bolts, rear plate ar.d ga3ket.
2. REMOVE VALVES
(a) Using SST. compress the valve spring and remove the
2 keepers.
SST 09202-70020 (09202-00010, 09202-01010.
09202-01020, 90 154-80004)
(b) Remove the spring retainer, vaive sprir>g and valve.
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.
ENGINE - ENGINE MECHANICAL EG-17
lt C. Clean valve guide bushings
' Using a valve guide bushing brush .and solvent, claan
all the guide bushings.
l '
~~
~~')
""'"
D. Clean cylinder head
Using a soft brush and sclvent, thoroughly clean the
cylinder head.
.' - .
.,
,•
!' .- .---------------------------~ 3. INSPECT CYLINDER HEAD
A. Inspect for flatness
'
Using a precision straight edge and thickness gauge,
measure the surfaces contacting the cylinder hlock
and the manifolds for warpage.
Maximum warpage:
Cylinder block side:
0.05 mm {0.0020 ln.)
Manifold side:
0.10 mm (0.0039 ln.)
If warpage is greater than maximum, replace the cylin-
der head.
P2.t961 """'
P2498l
B. Inspect for cracks
Using a dye pe~etrant, check the combustion cham-
ber, intake ports, exhaust ports and cylinder block
side surface for cracks.
If cracked, replace the cylinder head.
EG-18 ENGINE - ENGINE MECHANICAL '.
+ 4. CLEAN VALVES j.
(a) L!sing a gasket scraper. chip off any carbon from the •
'.
valve head.
(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
Standard O.OT9 - 0.079 mm 0.024 - 0.075 mm
(0.0007 - 0.0031 ln.) (0.0009 - 0.0030 ln.)
Meximum 0.08 mm (0.0031 in.) - 0.10 mm (0•.0039 ln.)
If the clearance iE greater than maximum, r13plactl ln9
valve and guide bushing.
6. IF NECESSARY, REPLACE VALVE GUIDE
BUSHINGS
'(a! Using a chisel and hammer, break the valve guide
bushings.
(b) G•adually heat th·e cylinder head to SO - 1OO"C ;176
- 212"F).
ENGINE - ENGINE MECHANI'CAL EG-19
<I (b) · Using SST and a hammer. tap out the guide bushing.
SST 09201 -1 0000 (09201 -01 080).
" <.I. 09950-70010 (09951-07150)
(c) Using a caliper gauge, measure the bushing bore di-
ameter of the cylinder head.
.· Both intake and exhaust (d) Select a new guide bushing (STD size or 0/S 0.05).
If the bushing bore diameter of the cylinder head is
. Bushing bore diameter greater than 13.027 mm (0.5129 in.). machine the
mm '(in.)
Bushing size bushing bore to these dimension:
13.050- 13.077 mm (0.5138- 0.5148 in.)
13.000- 13.027 Use STD
., (O.S118- 0.5129) If the bushing bore diameter of the cylinder head is
13.050- '13.077 Use 0/S 0.05 greater than 13.077 mm (0.5148 in.). replace the
(0.5138- 0.5148)
cylinder head. ,
V07105 (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)-
Sharp 8 mm Reamer (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 ENGINE:- ENGINE'MECHANICAL :: .
CM0254 £M018C. 7. ·INSPECT AND·GRIND VALVES
(a) Grind the valve enough to remove pits and carbon.
" (b) 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:
- Intake Exhi'IUSt
Overall Lenyth Standard 99.90 mm 100.10 mm
(3.933 ln.) (3.941 ln.)
99.6 mm (3.921 ln.)
Minimum 99.4 mm (3.913 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.
ENGINE - ENGINE MECHANICAL EG-Z1
(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.
ss• • Check that the seat contact is i11 the middle of the
Zl6545 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
EMI)186 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.
~
,.
0
EM01BS Width
I ZIOW
I (d) Hand-l<lp the valve and valve seat with an abrasive
compnund.
(e) After hand-lapping, <;!san tha valve and valve seat.
.,I 9. INSPECT VALVE SPRINGS
--] Deviation -If- (a) Using a steel square, measure the sc;uareness of the
valve spring.
-.I .::;s;;
Maximum squareness:
1.6 mm (0.063 ln.)
If the deviation is greater than maximum, replace the
valve spring.
EG-22 ENGINE - ENGINE MECHANICAL
I . (b) ·Using vemier calipers. measure the free length of the
valve spring.
I Fr"" .l.,ngth:
-46~5 mm (1.831 in.) .
If the free length is not as specified. replace the valve
spring.
"""''
I· Using a "Pring tester. measure the tension of the valve
(c) 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.
EM0281
10. INSPECT ROCKER ARM AND SHAFT
(a) Inspect the valva contacting surface of the rocker arm
for wear. '
Correct or replace if necessary.
EMT~JO
(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.
I 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.
£MOOU •
,....,.. . ~ ..•.• ,,,_,,,.,••:·.-·r,· ''". ~,.,
'
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.)
Valve Rocker • Using a micrometer, measure the diameter of the
Shaft 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)
(2)
Valve RoGkAr Shaft
As$ambly •
V&lv.o Recker (1)
Support
{2)
~onf(1) Valve Rocker Arm
Compression
Spring
..... Valve Rocker Valve Rocker Valve Rocker
Arm No.1
Arm No.1 Arm No.2
(1) (2)
. EG-24 ENGINE·- ENGINE MECHANICAL:
0.30 mm
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.
l_·------------------------~n~~~ 12. INSPECT INTAKE AND EXHAUST MANIFOLDS
Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head for war-
page.
Maximum warpage:
0.20 mm (0.008 in.)
If warpage is greater than maximum, correct or re-
place the manifolds.
CYLINDER HEAD ASSEMBLY --·
HINT:
• Thoroughly clean all parts to be assembled.
• Before installing the parts, apply new engine oil
to ..all sliding and rotating surfaces.
• Replace all gaskets, 0-rings and oil seals with
new ones.
1. INSTALL VALVES
(a) Install 8 new oil seals with your hand.
(b) Install theso parts:
(1) Valve
(2) Spring seat
(3) Valve spring
(4) Spring retainer
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202-70020 (09202-01010. 09202-01020,
90154-80004)
SST 1"24951
ENGII~E - ENGINE MECHANICAL
(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)
.I§." (b) Place a new gasket and install the water outlet hous-
ing with 2 bolts.
Torquo: 19 N·m (195 kgf-cm, 14 ft·lbf)
CYLINDER HEAD !NSTALLAT!ON
1. INSTALL CYLINDER HEAD
A. Place cyiincler head on cylinder block
(a) Place a new cylinder head gasket in position on the
cylinder block.
NOTICE: Be careful of the lnstollution direction.
(b) Place the cylinder head in position on the cylinder
head gasket.
B. Install 12 pointed head cylii1dt~r head bolts
HINT:
• The cylinder head bolts are tightened in 2. pr~
gressive steps (steps (b) and (d)).'
• If any bolt is broken or deformed, replace it. .
ia) Apply a light coat of engine oil on the thrllads tnd
under the heads of the cylinder hGad b.:>Its.
(b) Install and uniformly tighten the 10 cylinder head
bolts on each cylinder head, in several passes, in the
sequence shown.
Torque: 29.6 N·m (300 kgf·cm, 22 ft·lbf)
If any of the cylinder head bolts does not meGt the
torque specification, replace the cylinder head bolt.
425 Z16537
P2S379 (c) Mark the front of the cylinder head bolt head with
paint.
~24951
".
EG-26 ENGINE I:NGINI'. MCCII-1\NICI\L
(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.
..
(~~~-Jf4Q'---$,4JJl·fJJi::; 3JQ~?' c. Install recessed head cylinder head bolts
P255~J I/ I \_f ~~............. 16543
(a) Apply a light coat of engine oil on the thn:.ads and
P249<CS 216"..44 ur.dor the heads of the cylinder head bolts. ..
{b) Install the cylinder head boits. as shown. '
Torque: 19 N-m (1 95 kgf-crn. 14 ft·lbf)
-.
2. INSTALL PUSH RODS
Install the 8 push rods. •.
3. INSTALL VALVE ROCKER SHAFT ASSEMBLY
(a) Place the rocker shaft assembly on tha cylinder head.
(b) 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)
4. CHECK AND ADJUST VALE CLEARANCE
(See valve clearance inspection and adjustment)
5. 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
ENGINE - ENGINE MECHANICAL . EG-27
TIMING CHAIN
COMPONENTS FOR REMOVAL AND
INSTALLATION
"~ Timing Chain COVM l'ming Chain
.< ·. Fan Water PumpPulley +Gasket
I Crankshaft
I Pulley
~ --;
.......... I
...................... I
I
I
-----. __JI
\ ------ Distributor
-- Assembly
Valve Lifter .
~ I,. t----+O·Ring .,
Camshaft
Sprocket
·' Thrust Plale
., .. -:::::~--- ,----- ---
-~:11 --d)"--- Chain Tensioner ',,'"___
~~j ---- , +Gasket
\
--,___ ---- 1/JP ' -""- -
Crankshaft •I
Sprocket
Vibration Damper
JN·m (kgf·cm, ft·lbf)J: Specified torque +Gasket---.;,
Drain Plug---~::>
+ Non-reusable part
EG-28 ENGINE'-· ENGINE MECHANICAL·. ,
TIMING CHAIN AND CAMSHAFT --·1
.REMOVAL
·,
1. . REMOVE WATER PUMP PULLEY AND DRIVE BELT.
{See water pump removal in Cooling System) .'
2. REMOVE CYLINDER HEAD -· ·~j •
{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.
ENGINE :_·ENGINE MECHANICAL EG-29
·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.
Cylinder SST 09950-40010 (09952 -04010, 09954-0401 0,
Head 09955-04010, 09957-0401 0),
Bolt 09950-50010 (09951 -0501 0, 09953-05020)
-, '-----·---------...::.:.""'::=::..J' 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.
I TIMING CHAIN AND CAMSHAFT
COMPONENTS INSPECTION
I1-;z~sj-.-:j.\':j.-·:-;::-;:~:j::~~f--1 J.'---,-Lrc=:::1. INSPECT TiMING CHAIN AND SPRPCKETS
(a) 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.
(b) Warp the chain around the sprocket.
(c) 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
!f the·diam13ter is Jess than minimum, replace the cha
and 2 sprockets.
2. INSPECT CHAIN TENSJONER AND VIBRATION
.DAMPER
·;, Using vernier calipers, measur.e 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
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.)
EM2011 If the cam lobe height is greater than minimum, re-
£M25J8
place the camshaft.
c. Inspect camshaft journals
(a) 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
U/S 0.125 No.3 42.837- 42.647 mm (1.6865- 1.6969 i~-y--
U/S 0.125 No.4
U/S 0.25 No.I 42.587 - 42.597 rnm (1.6767 - 1.6770 in.)
U/S 0.25 No.2 42.337- 42.347 mm (1.6669- 1.6672ln.)
U/S 0.25 No.3 42.960- 42.970 mm (1,6913- 1.6917 in.)
U/S 0.25 No.4 42.712-42.722 mm (1.6816- 1.6920 ln.)
42.462- 42.472 mm (1.6717- 1.6721 i~.)
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)
ENGINE ::...· EN.GJNE MECHANICAL· EG-31
• 4." INSPECT THRUST PLATE
(a) Install the thrust plate and camshaft sprocket to the
..
cam's h a f t .
: (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 ENGINE .,-.·EN.GINE.MECHANICAL
Front (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
illustration.
Torque: 8 N-m (80 kgf-cm, 69 ln.·lbf)
2. 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.
ENGINE - ENGINE MECHANICAL. I:G-33
' a5. INSTALL TIMING CHAIN COVER
0 ., (a) Place naw gasket to the front end plate.
(b) 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)
; l , i6. INSTALL VALVE LIFTER
HINT: Apply light coat of engine oil of tha valve lifter.
'
""''"
7. INSTALL CRANKSHAFT PULLEY
(a) Install the crankshaft pulley.
(b) 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 -·IZ
COMPONENTS
~- -------====Piston Ring (No.1 Compression)
~Piston Ring (No.2 Compresskm)
Oil Filter and Piston Rin g _ r~- _ §
Bracket Assembly (Side Rail)
Piston Ring (Expander)
RH Engine M~unting ~ 0 Piston Pin
Bracket ~
'GI,) See page EG-53
~~
111 24.5 (250, 18)
2nd Tum so•
Upper Main Bearing---· +Gasket
Crankshaft-----------..,!~ 'oil Pan
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
ENGINE - ENGINE MECHANICAL EG-35
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)
- j~ 5. REMOVE WATER PUMP
.[ (See water pump removal in Cooling System)
6. REMOVE ALTERNATOR AND BRACKET
•1 7. REMOVE TIMING CHAIN
i (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
Remove the 2 bolts. the oil filter br<~c:ket. filtGr assem-
bly and gasket.
12. REMOVE ENGINE DRAIN COCK
13. REMOVE FRONT END PLATE
Remove the 2 bolts, front end plete' and gaske·t
14. REMOVE ENGINE MOUNTING ERACKETS ·
CYLINDER BLOCK DiSASSEMBLY
1. REMOVE REAR OIL SEAL RHAINER
Remove the 5 bolts. retainer and gasket.
2. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance
while moving tho connecting rod back and forth.
Standard thrust clearance:
0.150 - 0.330 mm (0.0059 - O.C130 in.)
Maximum thrust clearance:
0.30 mm (0.0118 ln.)
If the thrust clearance is greater than maximum, re-
place the connecting rod assembly. If nocessa;y, re-
place the crankshaft.
EG-LJS ENGINE.- 'ENGINE· MECHANICAL
I 3. REMOVE CONNECTING ROD CAPS AND CHECK
OIL CLEARANCE
,..-,--·
··(a) Check the matchmarks on the connecting rod and cap
Plastigage to ensure correct reassemi.:y.
(b) Remove the 2 connecting rod cap bolts.
(c) Using the 2 removed connecting rod bolts, remove the
connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT: Keep the lower bearing inserted with the .con-
necting rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scrat~ ·
ches.
If the crank pin or bearing is damaged, replace the
bearings. If nece:;sary, grind or replace the crankshaft..
(f) Lay a strip of Plastigage across the crank pin.
(g) Install the connecting rod cap with the 2 bolts.
(See step B in cylinder block assembly)
Torque:·
1st: 24.5 N·m (250 kgf·cm, 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 crank-
shaft.
ENGINE ENGINE MECHANICAL EG-37
IM1,a2rkor 3 ~( HINT: If using a standard bearing. replace it with one
having the same number marked r,n the connocting
-,~'·'"M'••' ·rod cap. There are three sizes of standard hearings,
marke<1 '1", "2" and '3" accordingly.
Standard sized bearing cantor well thickness:
(Protrusior.) STD-Mark ~ 1.488 - 1.490 mm (0.05S5 - 0.0587 ln.)
1.490 - 1.494 mm (0.0587 - 0.0588 in.)
STD Mark 2 1.494 - 1.498 mm (0.0588 - 0.0590 ln.)
STD Mork 3 1.807 - 1.813 mni (0.0833 - 0.0835 in.)
1.732 - 1.738 mm (0.0682 - 0.0684 in.)
u;s o.25 1.857 - 1.883 mm (0.07 ~ 1 - 0.0733 ln.)
u;s o.so
u;s o.75
Ul Completely remove the Plastigage.
4. REMOVE PISTON AND CONNECTlNf> ROD
ASSEMBLIES
(a) Using a ridge reamer, remove the all carbon from·the
top of the cylinder.
(b) Cover the connecting rod bolts with a short piece of
hose to protect the crankshaft from daml'ige.
(c) 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.
' 5. 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
0/S 0.126 2.490 - 2.540 mm (0.0980 - 0.1 000 ln.)
I
6. REMOVE MAIN BEARING CAPS AND CHECK OIL
-~ 2 CLEARANCE
(a) Uniformly loosen and remove the 10 main bearing cap
bolts in several passes, in the sequence shown.
··• ..~
EG-38 ENGIN'E '-' ENGINE MECHANICAL
Plastigage
(b) Using the'removecl main bearing· cap bolts. pry the •
main bearing cap back and forth. and remove the main ·
bearing caps. lower bearings and lower thrust wash-
ers (No:3 main bearing cap only)..
HINT:
• Keep the lower bearing. and main bearing cap
together.
• Arrange the main bearing caps and lower thrust
washers in correct ord.er.
(c) Lift out the crankshaft.
HINT: Keep the upper bearing and upper thrust wash-
ers together with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bear.ing for pitting and
scratches.
If the journal or bearing is damaged, replace the bear-
ings, If necessary, grind or repiace the crankshaft.
(f)· Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the 5 main bearing caps witb the 10 bolts.
(Soe step 4 in cylinder block assembly)
Torq·uo: 59 N·rn (600 kgf.cm. 43 ft·lbf)
NOTICE: Do not turn the crankshaft.
(i) Remove the 10 bolts and 5 main bearing caps.
(See procedure (a) and (b) above)
(j) Measure the Plastigage at its widest point.
Standard clearance:
STD 0.016 - 0.040 mm (0.0006 - 0.0016 in.)
U/S typo 0.017 - 0.071 mm (0.0007 - 0.0028 in.) -
Maximum:
0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum. replace
the bearings. If necessary. grind or replace the crank-
shaft.
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KIJANG 7K Engine Repair Book
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