KIJANG 7K Engine Repair Book

. ' ENGINE - ENGINE MECHANICAL · · · .EG-39. . ·- .
' ~

... ·: '• ... ·HINT: If l'!Sing ·a standard bearing, replace with one

. .. 1:'/0,3 r=-. having the same number. If the number of the bearing·
No!~'{t":r;::...· ~'"' · ' , ~/.%" c2nnot be determined, select a be·aring from the table
..~·· j~ ;---. LjJ """ 0 Mark according to the numbers imprinted on tf':q r.vlinder
6,7or8
. ·s·.block· and·crankshaft. ThtJre are 5 sizes of standard·

bearings, marked "3", "4", "6" ond "7" accordingly.

NumbP.r marked ~~
678
Cylinder block 1 213 t 12 3 1 2 3
Crankshaft 5 4i3 6!5 4 7 6 5
Use bear!ng

EXAMPLE: Cylinder block "6'' - Crankshaft "2"
= Total number 4 (Use bearing "4")

P25&51 \).\)>:::;;;>Mark Reference:
P25584 3,4,5,6 or 7 Cylinder block main Journal bore diamotAr:

P25681 ZI6SJS Mark 6 54.004 - 54.012 mm (2. J201 - 2.1265 in.}
"! Mark 7 54.012- 54.020 mm (2.1255- 2.1268 in.)
Mark 8 54.020- 54.028 mm (2.1268- 2.1271 ln.)
•.
Crankshaft Journal diamEltor:

Mark 1 49.976 49.984 mm (1.9796- 1.9679 in.)
Mcrk 2 49.984 49.992 mm (I .967~ - 1.9682. in.J·
Mark 3 49.992 50.000 mm.(l.9d82 - 1.96851o.)
u;s o.25 49.733 - 49.743 mm t1.958Cl- 1.9584 in.)
U/S 0.50 49.483 - 49A03 mm (!.9481 - 1.9485 in.)

Standard :oizod bearing cent'er Wfl!l.t:hicKnoss:

Mark 3 - - -I.990 - 1.994 mm (0.0703 - 0.0785 ln.l

Mark 4 1.994·- !.9S8 mm (0.0785 - 0.0787 ln.)
1.998 2.002 mm. (_O.o787 -· 0.0708 l n R
,_f~rk. s·

Mark B 2.002 - 2.006 mm (0.07ell - 0.0790 ln.) ;

~- ----··Made 7 2.006- 2.0!0 mrn (0.07PO- 0.0791 in.) •
IJJ,..,. 0•2•r.:l:
' -2.112 - 2. I2~ m:n t0.0~3 I - 0.0835 lr.J 1

L:u;so.so 2.237 - 2.247 mm (O.OU8l - 0.0885 _ln.) J

(k) Corupletely remove tha Plastig~ge.

.7. - REMOVE CRANKSHAFT
(a) ·Lift out the crankshaft.
(b)· Remove the upper bearings and· upper thrust washers

from·.the cylinder block.
HINT: Arrange the main bearing caps, bearbgs and
thrust washers in correct order.

~~.. • i ..
r;. EG-40
11:). I .. ENGINE :.-·.ENGINE MECHANICAL ,..

,-------------------~~~~~~~~~~~~~~~---------------
..--11
. CYLINDER· BLOCK INSPECTION

:· ,... " ... ··.: . ,...

1- CLEAN·CYLINDER BLOCK

A. Remove gasket material

· Using a gasket scraper, remove all the gasket material
from the top surface of the cylind~r block.

B. Clean cylinder block

Using a soft. brush and solvent; thoroughly clean the

cylinder block.

2. INSPECT TOP SURFACE OF CYLINDERBLOCK FOR .
FLATNESS
Using a precision straight edge and thickness gauge,
measure the surfaces contacting the cylinder head
gasket for warpage.
Maximum warpago:
0.05 mm (0.0020 ln.)
If warpage is greater than maximum, replace the cylin-.
der block.

·--

o o·o o·o o·o o

~ 'rf- '\9!: ~ ~

P25!'i2J ~~\-~. ./
f'25524'
\_

3. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If dMp sc.ratc.hes ar& pr&sent. re&CJrll IJ(( th6 ~ l.fill,·
ders. If necessary, replace the cylinder block.

---:="""'

4... INSPECT' CYLINDER BORE DIAMETER

HINT:· There are 3 sizes of the stanqard cylinder bore

diameter; marked *1*, *2* and ·a• ·accordingly. The

mark is stamped on the top of the .cylinder block.

ENGINE - ·ENGINE'MECHANICAL· ·· · EG-41

Front,._ \C:1f']j CD Thrust •Using ..a ·cylin.der gauge, m·easure the cylinder bore
diameter at positions A, B and C in the thrust and axial
Direction directio(ls.
Standard diameter:
<VAxial

Direction

.., STD:Merk 1 80.500- 8C.b10 mm 13.1693··- 3:16971n.)
STD Mark 2 60.51 0 - 80.520 mm .(3.1697 3.1701 in.)
STD Mark 3 80.520-80.530 mM (3.1701 - 3.1705 in.)
81.000 - 81.030 mm (3.1890 - 3.1902 i,,,)
0/S 0.50

Moxlmum diomotor: 80.728 mm (3.178~ in.)
---'-----1
STD
0/S 0.50 81.228 mm (3.1g79 i.1.)

If the diameter is greater than maximum, rebore ""the

4 r:ylindars. If necessary, replace the cylinder bioci<.

-.-'

5. REMOVE CYLINDER RIDGE

... If the wear is Jess than 0.2 mm (0.008 in.), using a
ridge reamer, grind the top of the t;:YI!nder.

......._"

PISTON AND CONNECTING ROD ASSY
DlSASSEMBLY

1. CHECK FIT BETWEEN PISTON AND PJSTON.Pm

Try to move the piston back and f~rth on the pi~ton

p!n.
If any movbm~nt is felt, replace the pi3ton and ·pin cS'
a sat.

2. · · REMOVE PISTON RINGS
(a) Using a piston ring expander, remov& the 2 compres-

sion rings.

,.,~· EG-42 .'- ENGINe·~. ENGINe·MECH-ANIC>AL ·
(b) ·"Remove· the 2 side rails· and oil·ring by hand.
.. ,HINT: · .Arrange the rings in correct order only.

P'Z5527

3. DISCONNECT CONNECTING ROD FROM PISTON
Using SST. press out· the piston pin from the piston.
Remove the connecting rod.
SST 09221-25025 {09221-00020, 09221-00030.
09221-00040.09221-00170. 09221-00210)
HINT:

• The piston and pin are a matched set.
• Arrange the pistons. pins. rings, connecting rods

and bearings. in correct order.

PISTON AND CONNECTING ROD
INSPECTION

1. CLEAN PISTON
{a) Using a gasket scraper, remove the carbon· from the

piston top.

{b) Using a groove cleaning tool or broken ring, clean the
piston ring grooves.

{c). Using. solvent and a brush. thoroughly clean the
piston.
NOTICE: Do not use a wire brush.

l:

t EG-43'· ·
i - ENGINE "-: ENGINE MECHANICAL

. ...Front Mark ' .... ' .·· ; ~ ., 2: · 'JNSPECT'PISTON
A. 'Inspect piston oil clearance
, 2 or3 HINT: There are three sizes of tha standard. piston
diameter, marked 1, "2" and "3" accordingly:'The mark-
is stamped on the piston top.

.'•

{a) Using a micrometer, measure the piston diameter at
ring angles to the piston hoad side, 8 mm (0.31 in.)
from the piston pin center line.
Piston diameter:

-. I STO Mark 1 80.358 - 80.368 mm (3.1637 - 3.1641 In,)
80.308 - 80.378 mm (3.1641 - 3.1645 in.)
,, i STO Mark 2 80.378 - 80.388 mm i2.1645 - 3.1649 in.)
80.858 - 80.888 mm (3.1 &34 - 3.1846 in.)
. I STD Mark 3
I 0/S 0.50
•
(b) Measure the cylinder bore diameter in the thrust di-
.- rections.
{See step 4 in cylinder blo~k inspectionf
,_
(c) Subtract the piston diameter measurement from the
cylinder bore diameter measurement.
Standard oil clearance:

0.132 -·0.152 mm (0.0052- 0.(1060 lr..)

If the oil clearance is greater thnn maximum. replace
all the 4 pistons and rebore all the 4 cylinders. If
necessary, replace the cylir)der block.
HINT (Use new cylinder block): Use a piston with the
· same· number· mark as the cylinder bore diameter
marked on the cylinder blo~k.

P2Si1& 216541
P2$5SS

.B; Inspect piston ring groove clearance

Using ··a· thickness gauge, measure thA clearance be-

tween· new piston ring and the wall of the piston ring
groove.

Ring groove clearance:

No.1: 0.030 - 0.070 mm (0.001 2 - 0.0028 in.)
No.2: 0.020 - 0.060 mm {0.0008 - 0.0024 in.)

If the clearance is greater thon m2ximum, replace the

piston.

EG-44' .. · ENGINE·:-.·ENGINE MECHANICAL.
. ·. ·.... ...:·

.c. · lnspect,piston..ring end gap

(a). lnsert..thecpiston ring into the cylinder bore.
· · ·· (b) Using a piston, push the piston ring·· a little beyond the .·

· bottom of.the ring tr~vel, 125 inm (4.92 ·in.} from the
top of the cylinder block.

125 mm

(c) Using a thickness gauge, measure the end gap.
End gap:

Item' Standard Maximum

. 0.23 - 0.33 mm
No.1 0.33 mm (0.0130 ln.)

(0.0091 - 0.0130 ln.)

0.33 - 0.48 mm
No.2 0.48 mm (0.01_89 in.)

(0.0 130 - 0.0189 in.)

Oil (Side roil) 0.18- 0.38mm 0.38 mm (0.0150 in.)
(0.0071 -0.0150 ln.)

If the and gap "is greater than maximum, replace the

piston ring. If the end gap is greater than maximum,
even with a new piston ring, reb'ore all the 4 cylinders

or replace the cylinder block.

3. INSPECT CONNECTING ROD.

. A. Inspect connecting rod alignment

Using a rod aligner and thickness gauge, check the

connecting rod alignment. -
• Che~k for bend.

Maximum bond:

~~~~0~35~£~M~0,~88~--------I·------~II 0.05 mm (0.0020 ln.) per 100 mm (3.94 ln.)
If bend is greater than maximum, replace the connect-
ing rod assembly.

• . Check for twist
Maximum twist:

0.05 mm (0.0020 ln.) per 100 mm (3.94 ln.)

If twist is greater than maximum, replace the connect-
ing rod assembly.

ENGINE -'ENGINE MECHANICAL t\;·4b

About B. Inspect connecting rod bolts
Using vernier calipers. measure tile minimum diame-
20mm ter of the compressed bolt at tho measuring point..
Standard diameter:
•. 8.860 - 9.000 mm (0.3488 - 0.3543 in.)

• Minimum diameter:

'• 8.60 mm (0.3386 in.)
If the diameter is Jess than minimum, repl2ce the ~£
-- rc67'8 connecting rod bolt.

.•_J, CYLINDER BORING

-I'' HINT:

'- J • Bore all the six cylindars for the oversized piston
outside diameter.
1
o Replace all the piston rings with ones to match
the oversized pistons.

1. SELECT OVERSIZED PISTONS
Oversized piston diameter:

0/S 0.50

80.858 - 80.888 mm (3.1834 - 3,1846 in.)
2. CALCULATE AMOUNT TO BORE CYLINDERS
(a) Using a micrometar, measure the p'iston diamet3r at

right angles to the piston head side, 8 mm (0.31 in.)
from the piston pin center line.
(b) Calculate the amount of each cylinder is to be rebored
as follows:

Size to be reborod = P + C ·- H

P = Pi•ton diameter

C = Piston clearance

0.040 - 0.060 mm (0.0016 - 0.0024 in.)
H = Allowance for honing
0.20 mm (0.0008 ln.) or lft$1

3. BORE AND HONE CYLINDER TO O:ALCULATED
DIMENSIONS
Maximum honing:
0.02 mm (0.0008 in.)
NOTICE: Exce.. honing will dastroy the flniohad round-

neal.

-1'-IC

CRANKSHAFT INSPECTION AND REPAIR

1. INSPECT CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V-blocks.
(b) Using a dial indicator, measure the circle run out at t .1e

center journal.

Maximum clrclo runout:

0.03 mm (0.0012 ln.)

EG-46 · ENGINE-~ ENG.INE.MECHANICAL

If the circle runout. is greater than maximum, replace
the crankshaft.
2. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using ..a .micrometer. measure the diameter of each
main journal and crank pin.

Diameter:

Item Main journal Cranck pin

STD 49.976 - 50.000 mm ~7.988 - 48.COO mm
(1.9676 - 1.9685 in.) (1.8893 - 1.8828 i.1.)
u;s 0.25 49.733 - 49.743 mm 47.738 - 47.750 ffiOI
u;s o.5o (1.9580 - 1.9584 in.) (1.8794 - 1.8780 in.)
49.483 - 49.493 mm 47.488 - 47.500 mm·
U/S 0.75 (1.9481 - 1.9485 in.) (1.8696 - 1.8701 in.)
47.238 - 47.250 mm
- (1.8598 - 1.8602 in.)

If thc.di.ameter is not as specified, check the oil clear-
ance (S.ee steps 3 and 6 in cylinder block dis-
assembly). If necessary, grind or replace the crank-
shaft.
(b) Check each main journal and crank pin for taper and
out-of-round as shown.
Maximum taper and out-of-round:

0.005 mm (0.0002 in.)

If the taper and out-of-round is greater than maxi-
mum, replace the crankshaft.
3. IF NECESSARY, GRIND AND HONE MAIN
JOURNALS AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to
the finished undersized diameter (See procedure in
step 2).
Install new main journal and/or crankshaft pin under-
sized bearings.

•

EG-47

ENGINE:- ENGiNE.MECHANICAL

--···cAMSHAFT AND CAMSHAF-T BEARING

iNSPECTiON AND REPAIR

1. INSPECT CAMSHAFT OIL CLEARANCE
(a) Using a 'cylinder .gauge. measure the inside diameter

of the camshaft bearing.

Bearing inside diameter (from front side):

• STD No.1 43.250- 4:;.275 mm 11.7028 - 1.7037 in.)

";; STD No.2 - -43.010 - 4:;,03:; m<r 11.5933 - I.G943 in.)
STD No.3
:- 42.750- 42.785 mm 11.6835- 1.6R44 in.)
STD No.4 42.500 - 42.525 mm 11.6732 -· 1.6742 in.)
,· U/S 0.125 No.I
·--
.. u;s 0.125 No.2
u;s 0.125 No.3 43.120 - 43.151 mm (1.6976 - 1.5989 in.)
u;s 0.125 No.4 42.890- 42.930 mm 11.6886- 1.6902 in.)
42.640 - 42.680 mm (1.6787 - 1.6803 in.)
U/S 0.25 No. I 42.390- 42.4~0 mm 11.6589 - 1.6705 in.)
U/S 0.25 No.2
U/S 0.25 No.3 . ~-
U/S 0.25 No.4 42.995 - 43.026 mm (1.6927 - 1.6939 ln.)
42.765 - 42.805 mm (1.6837 - 1.6852 in.)
42.515 - 42.555 mm (1.6738 - 1.6754 in.)
42.265 - 42.'30t: mm (1.6ti40 - 1.6655 in.)

(b) Subtract the journal diameter measurement (See stop
3 in timing chain and camshaft inspection) from the
bearing inside diameter measuremimt.
Standard oil ciearance:

STD

No.1 and No.4 0.025 - 0.066 mm 10.0010- 0.0028 in.)
0.040- 0.081 rnm 10.0016- 0.00321n.)
No.2 and No.3 0.025 - 0.066 mm 10.0010 - 0.0026 in.)
0.043 - 0.093 mm 10.0017 - 0.0037 in.)
U/S Typo No.1

'--- Oth~:~rs

Maximum oil clearanca:
0.10 mm (0.0039 ln.)

2. If the clearance is 9reatar than maximum, replace tha
camshaft bearings. If necessary, -rRplace the cam-
,..,. I A. shaft.

B. IF NECESSARY, REPLACE CAMSHAFT BEARINGS
Remove expansion plug
Using SST and a hammer, tap out the expa:-tsion plug.
SST 09215-00101 (09215-00130. 09215-00150,

09215-00211)
Remove camsha-ft bearings
Using SST, remove th~ camshaft bearings.
SST 09215-00101 (09215-00121. 09215-00130,

09215-00141,09215-00150,09215-00161,
. 09215-00221)

· EG-48 . '· ENGINE- ENGINE :MECHANICAL ·' ..

C. Install new camshaft bearings.
(a) Install ne'yV bearings in their proper location.

. ·.

No.1 No.2 No.3 No.4
•···
500291

(b) Align the oil holes of the bearing and cylinder block.

(c) Using SST, install the camshaft bearings.
SST 09215-00101 (09215-00121, 09215-00130,
09215-00141.09215-00150,09215-00161,
09215-00221)

D. Check camshaft oil clearance (See step 1 above)

E. Install expansion plug

(a) Apply liquid sealer to the expansion plug surface of

the cylinder block.

(b) Using SST and a hammer, drive in thoJ expansion plug

to 11 distance of 2 mm (0.08 in.) from the cylinder

ZI~J I block edge.
SST 09215-00101 (09215-00231)

VALVE LIFTERS AND VALVE LIFTER
BORES INSPECTION

INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the valve lif!er bore

diatneter.
Bore diameter:

21.417- 21.437 mm (0.8432- 0.8440 ln.)
(b) Using a micrometer, measure the valve lifter diameter.

. ENGINE-~· ENGINE MECHANICAL. EG-49

lifter diameter:
21.387- 21.404 mm (0.8420- 0,8427 ir>.)

{c) Subtract the valve lifter dbmetor measurement from
the valve lifter bore diameter m6asurement.
Standard oil clearance:

0.013 - 0.050 mm (0.0005 - 0.0020 in.)

Maximum oil clearance:
0.10 mm (0.003S in.)

__.If the oil clearance is greater thc:n maximum. replllce

the valve lifters.

CRANKSHAFT OIL SEALS REPLACEMENT

HINT: There are 2 methods {A and Bj to replace the oil

seal which are as follows:

1. REPLACE CRANKSHAFT FRONT OIL SEAL

{See crankshaft front oil seal replacement in timing

• chain)

' 2. REPLACE CRANKSHAFT REAR OIL SEAL

• """' A. If rear oil seal retainer is removed from cylinder

.- block:

0 {a). Using screwdriver and hammer, tap out the oH seal.

C:Jt Position {b) Using SST and a hammer, tap in a new oil seal until its

I~ =* surface is flush with the rear oii seal edge.

SST 09223-15020, 09608-30012 {096PB-04020)

(c) Apply MP grease to the oil seal lip.

B. If rear· oil seal retainer Is installed to .:ylinder block:

{a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.

NOTICE: Be careful not to damage ·tha cronk•haft. Tape

the screwdriver tip.

{c) Apply MP grease to a new cil seal lip.

{d) Using SST and a hammer, tap in the oil se~l until its

surface is flush with the rear oil seal retc:iner edge.

SST 09223-15030, 09608-30012 {09608-·04020)

EG-50 ENGINE ~-ENGINE MECHANICAL ...

PISTON.AND CONNECTING ROD co... '"
ASSEMBLY
Front fvhrk---~
(Cavity; J

Front Mark-----0~~~ 1. ASSEMBLE PISTON AND CONNECTING ROD
(Protrusion) (a). Coat the piston pin and. piston holes with engine oil.
(b) Align the front marks of the piston and connecting

rod.

(c) Using SST. press in the piston pin.
SST 09221-25025 (09221-00020, 09221-00030;
09221 -00040, 09221 -00170, 09221 -0021 0)'

2. INSTALL PIS"T:ON RINGS -.
(a) Install the oil ring expander and 2 side rails by hand.

pz:£/11

3/: (b) Using a piston ring expander, install the 2 compres-
sion rings with the code mark facing upward.
,:;~ Coda mark:
No.1
_"----------------·~LIP_>s._._,_.,._. 1N
No.2

2N

Side nail (c) Position tho piston rings so that the ring ends are as
(Upper) .shown.
NOTICE: Do not align the ring ends.
..Front
'
Froni: M;:Jrk
(Cavit·rl Side Rail
(lower)
No.i and
Expander P25537

)

ENGiNE -~ ENGlNE MECKANICAt· .. EG-51 ·

·- 3: INSTALL BEARINGS

.~, (a) Align·the bearing claw with the groove of the r.onnect-
ing rod or connecting cap.
P06443
P07010 (b) Install the bearings in the connecting rod and con-

riecting rod cap.

~­

iir~

105505

CYLINDER BLOCK ASSEMBLY

HINT:
• Thoroughly clean ail parts to be assembled.
-• Before installing the parts, apply new engine oil

to all slid!ng and rotating suriacas.
• Replace all gaskets, 0- rings and oil seals with

new parts.
1. INSTALL MAIN BEARINGS

HINT: Upper bearings have an oil groovo and oil holes.

l lower bearings do not.
(a) Align the bearing c!aw with the claw groove of the
cylinder block, and push in tha 5 upper b'earings.

(b) Align the bearing claw with the claw groow of the
main bearing cap, and push ir> the 5 lower bearings.
HINT: A number is marked on ~ach main bearing cap
to indicate the installation position.

EG_-_5_2_··-------"--·--=E:.:.:N:..::G:.:.:iNc.:.:E::..·_~_.E:::.:N.::G::..:I.:..:N.:::E..:.:·Mc:.:E::.:C:..c.:H.AN.:.:iC::.:.A.:.:t:.:.......:._ _ _ _ _ _ _ _ __

2; INSTALL UPPER THRUST WASHERS
lnstail· the 2 thru;;t washers under the No.3 journal
position of the· cylinder block with the oil grooves
f a c i n g .. o u t w a r d .

3. PLACE CRANKSHAFT ON CYLINDER BLOCK

4. INSTALL MAIN BEARING CAPS AND LOWER
THRUST WASHERS

A. Place main bearing cap and lower thrust washers on
cy!inder block

(a) Install th& 2 thrust washers on the No.3 bearing cap
with the grooves facing outward.

----------'-·---,,.----...::""c:.'::.:"....s
..

r"O\ rd- (b) Install the 5 main bearing caps in their proper loca-

tions. .

h/~- J\l~lf' ~ =If(/ ""L~""'"'t1r HINT: Each bearing cap has a nun;ber and front m·ark..
h
o ~ r- 0 or>
o ' It=
}- ~

;,cS; "' ~- :j \::. ~ Q..J

~
El17003

B. Install main bearing cep bolts .
a(a) Apply light coat of engine oil on the threads ar.d

uncier heads of tha main bearing .cap bolts.

(b) Install and unifo;mly tighten the 10 bolts of the main

bearing cap bolts in several passes, in the sr;quence

shown.

Torquo: 59 N·m (600 kgf-cm, 43 ft-lbi)

(c) Check that the crankshaft turns smoothly.

P25~04 (d) Check that the cra11kshaft thrust clearance.

'------------ (Sae ste:-- 5 in cylinder block disassembly)

5. INSTALL PISTON AND CONNECTING ROD

ASSEMBLIES

Using a piston ring compressor, push 'he correctly

numbered piston and connecting rod assemblies into

/ each cylinrler with t';a front mark of the piston facing

Front forward.

•

EG-54 ENG'INE:..: ENGINE' MECHANICAL CGOV••I

"- 'pOST ASSEMBLY

" L INSTALL ENGINE MOUI'iTING BRACKETS
Install the brackets with the 4 bolts.
,;·· Torque: 39 N-m (400 kgf-cm. 29 ft-lbf)

""""'

2. INSTALL FRONT END PLATE
Install a new gasket <ond front end plate with tho 2
bo!ts.
Torque: 19 1~-m (195 kgf-cm. 14 ft-lbf)

3. INSTALL ENGINE DRAIII! COC!<

1'155<2

4. INSTALL OIL FILTER BRACKET AND FILTER

ASSEMBLY

h1stall a new gasket. the oil filter·, bracket ,;nd filter

assembly with the 2 bolts.

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

5. INSTALL N0.2 ENGINE HANGER

Torque: 37 N-m (380 kgf·cm, 27 tt-lbf)

6. INSTALL OIL DiPSTICK

7. INSTALL OIL PUMP

(See oil pump installation in Lubricatior. System)

B. INSTALL TIMING CHAIN

(See timing chain instellatiem)

0 INSTALL ALTERNA TOR BRACKET

~-

·rorque: 26 N-m (270 kgf-cm, 20 ft·l~f)

10. INSTALL ALTERNATOR

1 ~. INSTALL WATER PUMP

(Sea water pump inst111lstion in Cooling System)
12. INSTALL CYLINDER HEAD

(See cylinder head installGtion)

13. REMOVE ENGINE STAND

14. INSTALL REAR END PLATE

· Torque: 8 N-m (80 kgf·cm, 69 ln.·lbf)

15. INSTALL FLYWHEEL

(a) Install the flywheel on the crankshaf~.

(b) Install and uniformly tighten the 6 mount bolts in '
several passes. in the sequence shown.

Torquo: 83 N-m (850 kgf-cm, 61 ft-lbf)

"""'

ENGINE - ENGINE MECHANICAL EG-53

Front Mark : 6. INSTALL CONNECTING ROD CAPS
(Protru!_!:s~io~n:.!)~~~~ A. Place connecting rod cap on connecting rod
(a) Match the numbered connecting rod cap with the
connecting rod.
(b) l!'lstall the connecting rod cap with the front mark
facing forward.

I• Fro~~ B. lnstoll connecting rod cop bolts
I I .---.,.--,i;*:~~ HINT:
• The connecting rod cap bolts are tightened in 2
Painted ') progressive steps (steps (b) and (d)).
• If any connecting rod bolt is broken or deformed.
Mark , replace it.

(a) Apply a light coat of engine oil on the threads and
under the heads of the connecting rod cap bolts.

(b) Install and alternately tighten the 10 bolts of the
connecting rod cap in several passGs.
Torque: 24.6 N·m (260 kgf.cm, 18ft·lbf)

If any one of the connecting rod cap bolts does not ·
meet the torque S!Jecification.' replace the connecting
rod cap bolt.
(c) Mark tho front of the connecting rod cap bolt with
paint.

{d) Retighten the connecting rod cap bolts 90" as shown.

.i (e) Check that the painted mark is now at a 90" angle to

I. the front. -

. _ _ I_ _ _ _ _ _ _ _ _ _ _ : _ : . _ _ ; . (f) Check that tha crankshaft turns smoothly.

(g) Chack that the connecting rod thrust clearance.

{See step 2 m cylinrlcr b!nck disassembiyl

7. INSTALL REAR OIL SEAL RETAINER
Install a new gasket and the retainer with the 5 bolts.
Torque: 8 N·m (80 kgf·cm, 69 ln.·lbf)

ENGINE - ENGINE MECHANICAL

-SERVICE SPECIFICATIONS·

SERVICE OATA

Compression at 250 rpm STD -

. pressure Minimum 931 kPa (9.5 kgf/cm', 135 psi) or more
795 kPa (9.0 kgl/cm'. 129 psi)
. Valve Difference of pressure botweon onch cylinder 98 kPa (1.0 kgf/cm', 14 psi) or loss
clearance at cold Intake 0.13 mm (0.005 in.)
Dwell angle 0.23 mm (0,009 in.)
Ignition timing Exhaust 46 sa·@ idle
Idle speed 9- 15" BlOC@ idle
Cylinder t".ead Engine at normal opera:ing temperature 700- 800 rpm

Valve guic!e Engine at normal operating temperature 0.05 mm (0,0020 in.)
0.1 0 mm (0.0039 in.)
. bushing Engine at normal operating temperature
ao·. 45•. 6s·
•• Warpage
45"
Valve Cylinder block side Maximum 1.1 - 1,7 mm (0.043 - 0.067 in.)
ManifOld side Maximum 1.2 - 1.9 mm (0.047 - 0.071 in.)
8.0 I 0 - 8.030 mm (0.3154 - 0.3161 in.)
Valve seat reiacing engle 13.000- 13.027 mm (0.5119- O.S129 in.)
13.050 - 13.077 mm (0.5138 - 0.5149 in.)
Contacting angle so- 1oo·c (176 -212"Fl
99,90 mm (3.933 in.)
Contar:ting width Intake

Exhaust

Inside diameter

Outside diameter (for repair part) STD

0/S 0.05

Replacing temperature (Cylinder head side)

Valve overall hmgth STD Intake

Minimum Exhaust I 00.1 0 mm (3.941 in.)
Intake 99.4 mr.: (3.913 in.)
99,6 mm (3.921 in.)
Exhaust 44.5·

Valve face angle

Stem diameter Intake 7.951 -7.991 mm (0.3130- 0.3146Jn.)

.,, Exhaust 7.960-7.986 mm (0.3134 ·- 0.3144 in.)

StiJm oil clearance STD Intake 0,019 - 0.1)79 mm (0.0007 - 0.0031 in.)

I • ExhauJO;t 0.024 - 0.075 mm (0.0009 - O.OC30 in.) I
0.08 mm (0.0031 in.l
I Maximum Intake I

I Exhaust 0.1 0 mm (0.0039 in.) I

I Margin thickness STD Intake 1,0 - 1.6 mrn \0.039 - 0.063 in.) I
Oavlation I
I Exhaust 1.2- 1.9 mm (0.047- 0.071 in.)

Valve spring Minimum !r.taba 0.9 """ (0.031 ln.)

· - --.Exho1.0st O.U mm (0.035 in.)
1.6 mm {0.083 in.)
Mox1mum

Fres length 46.~ mm (1.831 in.)
Installed tension
·. Arm· inside diameter at 38.4 mm (1.512 in.) 296 -· 328 N (30.2 - 33.4 kgf, 06.0 ·- 73.8 lbl)
Shaft die-meter
Valve rocKer Oil clearance · STD 16.00 - 16.02 mm !0.11299 - 0,6307 in.)
arm and Maximum
shaft Circle runout Ma'xlmum 15.97 - 15.99 mm (0.6287 - 0.62~9 in.)
Lifter diameter
.. Push rod Lifter bore diameter STO 0.02- 0.04 mm (0.0006- 0.0016 in.)
Valve lifter Oil clearance Maximum
0.04 mm (0.00 16 in.)
,.
0.30 mm (0.0 11 B in.) I
21.387- 21.404 mm (0.9420- 0.8427 in.)
21.417 - 21.437 mm (0.8432 - O.C440 in.j

0.013 - 0.050 mm (0.0005 - 0.00?.0 in.) I
0.10 mm (0.0039 in.}
----'

EG-56 F.NGINE'~. ENGINE: MECHANICAL·

Manifolds 'Narpage Maximum 0.20 mm (0:0078 in.). '
Camshaft Thrust clearance 5TD
0.07 0.14 mm (0.0028 - 0.0055 in.)
•
Maximum 0.3 mm (0.012 in.)
I
Journal oil clearance 5TD No.1 end No.4 1 0.025 - 0.066 mm (0.001 0 - 0.0026 ln.)
~--·~·· O.CJ40- 0.081 mm (0.0016- 0.0032 in.)
end sprocket No.2 end tJo.3·' 0.025 - 0.066 mm (0.001 0 - 0.0026 in.)
Chein
tensioner end U/5 Type No.I .
vibration
c.Jamper Others 0.043 - 0.093 mm (0.0017 - 0.0037 in.)

Maximum 0.10 mm (0.0039 in.)

Journal dbmflter (f;om front side) ·SiD No.I 43.209- 43.225 mm (1.7011 - 1.70181n.)

No.2 42.954-42.970 mm (1.6911 - 1.0917 in.)

No.3 42.704-42.720 mm (1.6873- 1.6819 in.)

No.4 42.459-42.475 mm (1.8716- 1.6722 in.)

U/5 0.125 No.I 43.085- 43.095 mm (1.6983- 1.6967 in.)

No.2 42.837-42.847 mm (1.8865- 1.68691n.)

No.3 42.587 - 42.597 mm (1.8767 - 1.6770 in.)

No.4 42.337- 42.347 mm (1.6668 -- 1.6672 in.)

U/5 0.25 No.I 42.960- 42.970 mm (1,8gl3- 1.6917 in.)

No.2 42.712- <!2.722 mm (1.6616- 1.6820 ln.)

No.3 42.462- 4:<:.472 mm (1.6717- 1.6721 ln.)

No.4 42.212-42.222 mm (1,8619- 1.6623 in.) '

Bea.ring inside diameter (from front side) .

STD No.I 43.250- 43.275 mm (1.7028- 1.7037 in.)
No.2 43.010 - 43.035 mm (1.693~ - 1.6943 in.)

No.3 42.760- 42.785 mm (1,6635 - 1.6844 ln.)

No.4 42.500 - 42.525 mm (1.6732 - 1.8742 in.)

U/S 0.125 No.I 43.120-43.151 mm (1.6976- 1.6989 in.)

No.2 42.890 - 42.930 mm (1.6866 - 1.6902 in.)

No.3 42.640 - 42.680 mm (1.6787 - 1.6803 in.)
I No.4 42.390 - 42.430 mm (1.6689 - 1.6705 in.)

U/5 0.25 No.I 42.995 - 43.026 mm (1.6927 - 1.6939 ln.)

No.2 42.766 - 42.805 mm (1.6837 - 1.6852 in.)

No.3 42.515 - 42.555 mm (1.6738 - 1.6754 ln.)

No.4 42.265 - 42.305 mm (1.6649 - 1.6655 ln.)

Circle runout Maximum 0.06 mm (0.0024 ln.)

Cam lobtt height 5TD · Intake 36.47 - 36.57 mm (1.4358 - 1.4397 ln.)

Exhtual 36.37-- 30.47 """ (1.4318- 1.4358 ln.)
Minirnt:m lntck& 26.17 mm (1.4240 ln.)

Chair. ::lock Exha-ust-·. r· 36.07 mm (1.4201 h)

e\ 98 N (I 0 kgf, 2.2 ibn tension Minumurn 13.5 mm (O.G31 ln.)

Chain olongotion Maximum 272.2 mm (I 0.736 in.)

CamShaft sprocket wear (w/ chain) Minimum 113.8 mm (4.480 in.l,

Crankshaft li:procketr wear (w/ chain) Minimum 69.4 mm (2.339 ln.)

Tenttion diameter Minimum 12.0 mm (0.472 ln.)

Ol!lmper diornetoi Minimum 4.0 mm (0.167 ln.)

ENGINE·- "ENGINEMECHANI.CAL

Cylinder block .... Maximum 0.05 mm (0.0020 in.) l

Cylinder head surfecttwarpege I

Cylinder bore diameter STD Mark 1 80.500 - 80.51 0 mm {3.1693 - 3.16~7 in.) I
Mark 2 80.510- 80.520 mm (3,1897- ~.1701 ln.l

Mark 3 80.520 - 80.530 mm (3.1701 - ~.1705 in.)

0/S 0.50 81.000- 81.030 mm (3.1890- 3.1902 in.)

Maximum STD 80.728 mm (3.1783 ln.)

0/S 0.50 81.228 inm (3.1979 in.)

Cylinde!' block main journal bore diameter

STD Mark 6 54.004- 54.012 mm (2.1281 - 2.1265 in.)

Mark 7 54.012 - 54.020 rnm (2.1285 - 2.1268 in.)

Mark 8 54.020- 64.028 mm (2.1288- 2.1271 ln.)

Pistori and Piston diameter STD Mark 1 80.358 - 80.368 mm (3.1537 - 3.1641 in.)
piston ring
Mark 2 80.368 - 80.378 rnm (3.1641 - 3.1645 ln.)
,,
Mark 3 80.378 - 80.388 mm (3.1645 - 3.1349 in.)

0/S 0.50 80.858 - 80.888 mm (3.1834 - 3.1846 in.)

Piston oil clearance 0.132 - 0.152 mm (0.0052 - 0.0060 ln.)

Piston ring groove clearance No.1 0.030 - 0.070 mm (O.CO 12 - O.C028 in.)

No.2 0.020 - 0.080 mm (0.0008 - 0.0024 in.)

Piston ring end gap STD No.1 0.23 - 0.33 mm (0,0091 - 0.0130 in.)

No.2 0.33-0.48 mm (0.0130- 0.018g io.)

Oil (sido rail) 0.18 - 0.38 mm (0.0071 - 0.0 ISO io.)

Maximum No.I 0.33 mm (0.0 130 in.)
0.48 mm (0.01 89 ln.)
No.2 .

Oil (side rail) 0.38 mm (0.0150 ln.)

Connecting Thrust cleerance STD 0.150-0.330 mm(0.0059 -.0.0130 in.)
rod
Maximum 0.30 mm (0.0 11 8 ln.)
..
Connecting rod bearing center w~ll thickness
I
STD Mark 1 1.486 - 1.490 mm (0.0585- O.OS8i in.)
!
Mark 2 1.490 - 1.494 mm (0.0587 - 0.058~ ln.)

Ml!llrk 3· 1.494 - 1.498 mm (0.0588 - 0.0590 in.)

U/S 0.25 1.007 -. 1.613 mm (0.0833 - 0.0835 ln.)

U/S 0.60 1.732 - 1.738 mm (0.0&82 - 0.0684 in,)

I U/S 0.75 1.857 - 1.883 mm (0.0731 - 0.0'133 in.)
Connecting rod oi! clearenca STD
0.020 - 0.048 mm (0.0008 - o,9c 19 lr..)

U/S Type . 0.019 - 0.058 mm (0.0007 - O.O•J22 ln.)

Maxlroum O.C8 mm (0,0031 ln.)

Rod ~ut-~of-a!ignment

M8xlmvm per 100 mm (3.941n.) 0.05 mm (0.0020 ln.)

HQd twist Maximum per 100 mm {3.S4 ln.) 0.05 mm {0.0020 ln.)

Connecting rod bolt outcl~e dl11metor STD 8.880 - 9.000 mm (0.34aO - 0.3543 in.)

Minimum 8.60 mm (0.3388 ln.)

.-.

EG-58 ENGINE- ENGINE MECHANICAL.

Crtmkshaft Thrust clearanco STD 0.040 - 0.242 mm ~0.00 t 6 - 0.009.5 in.}
Maximum 0.30 mm {0.0 1 t 8 in.)

Thru~t wa:;her thickness STD 2.430·- 2.480 mm ·(0.0957 - 0.0976 in.)

0/50.125 2.490-; 2.540 mm (0.0976- 0.1000 in.)

Main jo:.Jrnal oil cJegrance STD 0.016 -' 0.040 mm (0.0006 - 0.0016 in.)

U/S Type 0.017 _; 0.071 mm (0.0007- OC0028 in.)

Maximum 0.10 mm (0.0039 in.)

Main journal diameter STD Mark 1 49.976 - 49.984 mm (1.9796 - 1.9~79 in.)

Mark 2 49.984 - 49.992 mm (1.9679 - 1.9682 in.)

Mark 3 49.992 - 50.000 mm (1.9682 - 1.9685 in.)

U/S 0.25 49.733 - 49.743 mm (1.9580 - 1.9584 in.)

U/S 0.50 49.483 - 49.493 mm (1.9481 - 1.9485 in.)

Main bearing center wall thickness STD Mark 3 1.990 - 1.994 mm (0.0783 - 0.0785 in.)

Mark 4 1.994 - 1.998 mm (0.0785 - 0.0787 in.)

Mark 5 1.998 - 2.002 mm (0.0787 - 0.0788 in.)

Mark 6 2.002 - 2.006 mm (0.0788 - 0.0790 in.)

Mark 7 2.006- 2.010 mm (0.0790- 0.0791 in.)

U/S 0.25 2. 11 2 - 2.122 mm (0.0831 - 0.0835 in.)

U/S 0.50 2.237 - 2.247 mm (0.0881 - 0.0885 in.)

Crank pin diameter STD 47.988 - 48.000 mm (1.8893 - 1.fl808 in.)

U/S 0.25 47.738 - 47.750 mm (1.8795 - 1.8799 in.)

U/S 0.50 47.488 - 47.500 mm (1.86.96 - 1.8701 in.)

Circle runout IU/S 0.75 47.238- 47.250 mm (1.859~- 1.8602 in.)

Maximum 0.06 mm (0.0024 in.}.

Main journal taper and out-of-round Maximum 0.02·mm (0.0008 in.)
IMaximum 0.005 mm (0.0002 in.)
'Crank pin taper and out-of-round
~----------L-------~----------------------~------~----~------~--------__J

ENGINE ENGINE MECHANICAL EG-59

TORQUE SPECIFICATIONS ·-·IU

Part tightened N·m kgf-cm . ft·lbf

Spark plug x Cylinder head 17.5 180 13
0;-:tributor x Cylinder block 12 120 9
29.5 300
-. Cylinder head x Cylincfer block 12 Pointed head 1st 22
2nd Turn so• Turn so• Turn so•
3rd Turn so•
Turn go• •. Turn so•
Recessed head t9 195
21 210 14
2 25
Rocker arm assembly x Cylinder head 8 80 16
Cylinder head cover x Cylinder h3ad 19 195
Reer ple1e x Cylinder head 39 400 18 in.-lbf
W21ter Outlet housing x Cylinder heed 8 80
Manifolds x Cylinder head 59 600 69 !n.-lbf
Thrust plate x Cylinder block 8 80
Camshaft sprocket x Camshaft 80 14
Chain tensioner x Cylinder block 3 80 29
Vibration damper x Cylinder block 8 195
Timing chain cover x Cylinder block 19 900 69 in.·lbf
89 250
Crankshaft pulley x Crankshaft 24.5 Turn go• 43
Connecting rod cap x Connecting rod 600
Turn go• 195 69 in.·lbf
Main bearing c~tp x Cylinder block 59 80
Front end plate x Cylinder block 19 400 69 in.·lbf
Rear oil seal retainer x Cylinder block 195
Engin~ mounting bracket x Cylinder block 10 mm head bolt 8 80 69 in.·lbf
Oil filter bracket x Cylinder block 12 mm heed bolt 39 380
Rear end plate x Cylinder block 19· 270 14
No.2 engin& hanger x Cylinder block 1st 8 850
Alter011tor bracket x Cylinder block 2nd 37 65
26
Flywheol x Crankshaft 83 18
Torn go•

43

14

- 69 in..lbf

29

14

69 in.-lbf

27

I' 20

&;

..

EG-60 ENGINE - F.UEL ~YSTEM

FUEL SYSTEM

PREPARATION --

SST (SPECiAL SERVICE TOOLS) __ .,

~ 09240-00014 Carburetor Adjusting Gauge Set ·,
~
~

~ 09240-00020 Wire Gauge Set·

~;l!'~!!l!ih ~

RECOMMENDED TOOLS

~~. 09082-00050 TOYOTA Electrical Tester Set.

-~--"="'
~~

~:!· 09200-00010 Engine Adjust Kit .•

-~ 09860-11011 C.!rburetor Drivor Set.

::;::<'

""·'--===--

EQUIPMENT

Torque wrench
LT_w_ee_ze_rs_ _ _,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _

PRECAUTION

1. Before working on the fuel system, disconnect the cable from the negative battery ter~i';a'i.
2. When working on the fuel system, keep away from possible fire hazards ana do not smoke.
3. Keep gasoline off rubber or leather parts.
4. Work on only one component group at a time to help avoid confusion between similar looking

parts.
5. Keep work area claan to avoid contamination of the c·arburetor and components.

S. Be careful not to mix up or lose clips or springs.

ENGINE --, FUEL SYSTEM. I:::G-'31
'

• . ON- VEHICLE INSPECTION

_- 1. REMOVE INTAKE AIR CONNECTOR FROM CARBURETOR

. ' 2. INSPECT CARBURETOR AND LINKAGE

• (a) Check that the various set screws. plugs and union bolts are tight nnd correc'tly installed.

(b) Check the linkage for excessive wear and missing snap rings.
(c) Check that the throttle valvas open fully when the accelerator pedal is fully depre~sed.

,.. : . 3. INSPECT ACCELERATION PUMP

Open the throttle valve, and check that gasoline spurts out from the acceloration nozzle.

4. CHECK AND ADJUST IDLE SPEED AND IDLE MIXl Ur1c .

(See idle CO check end adjust in Engine Mechanical)

CARBURETOR

:.. ~ COMPONENTS FOR REMOVA!- AND

INSTALLATICN

+Gasket

j24(24Q, 17) I

+ Non-reusable part

IN·m (kgf·cm, ft·fbtJl: Specified torque

r P25715

EG-62 ENGINE - FUEL SYSTEM '.

CARBURETOR REMOVA.L IM... II

1. DISCONNECT ACCELEflATOR CABLE FROM
CARBURETOR

2. DISCONNECT CARBURETOR CONNECTOR

3. DISCONNECT FUEL INLET PIPE FROM
CARBURETOR
Remove the union bolt and 2 gaskets, and disconnect
the inlet pipe from the carburetor.

Torque: 24 N-m (240 kgf-cm, 17 ft·lbf)

INSTALLATION HINT: Use 2 new gaskets.
4. DISCONNECT VACUUM HOSE AND PCV HOSE
(a) Disconne.ct the distributor vacuum hose from the car-

buretor.
(b) Disconnect the PCV hose from the insulator.
5. REMOVE CARBURETOR
(a) Remove the 4 nuts holding the carburetor to the ·

intake manifold.

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

(b) Lift out the carburetor.
(c) Remove the insulator and gaskets assembly.
(d) Cover the inlet hole of the intake manifold with a

cloth.

INSTALLATION HINT: Uso a new insulator.

'

•

EG-63

• . COMPONENTS FOR DISASSEMBLY AND-•-N
ASSEMB.LY

-:

·' ·- - Accelerator Cable r~ / Wire Clamp

Bracket ~ Accelerati0n
//PumpArm
' ""~~--
'I
l 0 1 - - - Plunger - .,_---~.AI
8 Boot '
"""'"';k! 7"~~ V<tCUUrl) L'
I@
~"
Snap Ring

Thermostatic
Valve

Air Horn

Vacuum Hose Valve~ '"'~ [·~"'-._r~SpringNeedle

1:11' 'tl,, ) 'I .

11 • • __ Ac::eleratlon
Pump Plunger
+ Gasket ~

J:1 1 ~\ j J
Seat--.... ~ "'-._
:
Valve+-~• I ;?"h :Neodle Pcwer Piston

: ~ ·----Float
I~SpringTI ____.....--- /
PlungertJ--{j Needle Valve
Wire --<:; Assembly 1

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

•

I+ Non-r-eusable p-art ---------~·

--·-,-------

ENGINE -'- FUEL' SYSTEM

Primary
Small Venturi

,, Fuel Cut Solenoid
Wire Clip,
II
Secondary
II
Small V:::nturi

I Discharge Slow Jet
I I •I Weight
II I
I1 I
I'
+Gasket
ir
0
+Gasket

I

I
I

Secondt:lry I
T~rottle Valve Diaphragm.:

l,

I'

I

Ring--~A I
Snap ,)"@ 1

,_,I

lnsu

Return

+ Non-reusable part

?......~.~--....... ' "·: .,... ENGINE - FUEL SYSTEM EG-65.

• CARBURETOR DI~ASSEMBLY ...........

. .. HINT: These instructions are organized so that you

..-.Ij will work only one component group ai " time.

This will help you avoid confusion between similar

looking parts from different subassemblies being on

your workbench at the same time. fi§F
(a) To facilitate reassembly, arrang3 parts in order.

(b) 8e careful not to mix up or lc.se balls, clips or springs.

Air Horn Disassembly

1. REMOVE CARBURETOR STUD BOLT
2. REMOVE ACCELERATION PUMP ARM
(a) Remove the snap ring from the pump connecting link.
(b) Remove the pivot bolt.
(c) Disconnect the pump arrn 'irono the pump plunger.
(d) Disconnect the pump connecting !ink and washer

from the throttle li!ver and remove the pump arm with
pump connecting link.
3. REMOVE THERMOSTATIC VALVE
(a) Disconnect 2 vacuum hoses from t~o carburetor.
(b) Remove the 2 screws, No. plato, tha thermostatic
valve and vacuum hosgs assembly.

"

Pivot Pin 4. REMOVE AIR HORN ASSEMBLY

(a) Rsmove the rsturn spring from tha accelerator cable
bracket and flange.

(b) Disconnect the fuel cut solenoid colmector from the
wire clamp.

\~) R9move ~ha 7 screws and ihase parts:
(1) Acc~lorator c;;bla bracket
(2) Wire clamps
(3) Fuel pipe bracket

(b) Lift off the air hom assembly together with ths air
horn gasket.

6. REMOVE FLOAT AND NEEDLE VALVE

Remove the float pivot pin, float and needle valv9
subassembly.

ENGIN·E ..;- FUEL SYS'fEM

·c. REMOVE ACCELERATION PUMP PLUNGER

Remove the pump plunger and boot.
7. REMOVE AIR HORN GASKET
8. REMOVE NEEDLE VALVL. S!=AT

Remove the ne.edle valve seat and g~sket.
9. REMOVE POWER PISTON

Remove the screw. retainer, power piston and spring.

,.,.,,

.----------------, .Carburetor Body Disassembly

1. REMOVE CHECK BALLS FOR ACCELERATION
PUMP

(a) Remove the pump discharge weight, spring and large
ball. ·

(b) Remove the plunger spring.

(c) Using tweezers. remove the ball retainer.
(d) Remove the small ball.

--~

2. REMOVE SLOW JET

3. REMOVE POWER VALVE

... ....,,._· , ~,...,,,., ,.... ENGINE' c:.. FUEL SYSTEM EG-67 ·
"" .
4. · REMOVE PRIMARY AND SECONUARY MAIN JETS
(a) Remove the 2 passage plugs ar:d gaskets.
(b) Rein'ove the primary and secondary main jets 'and

gaskets.

5. REMOVE SMALL VENTURIS

Remove the 4 screws. primary, secondary small ven-
tui-is and gaskets.

6•. REMOVE SECONDARY THROTTLE VALVE

,. DIAPHRAGM
(aj Disconnect the vacuum hose from' ;he body.
(b) Remove the snap ring and washer from the diaphragm
link.
(c) Remove the 2 screws and throttle valve diaphragm.

Snap Ring

7. REMOVE FUEL CUT SOLENOID
(a) Remove the wire clip from the fuel cut solenoid.
(b) Remove the fuel cut solenoid and gasket.

8•. REMOVE IDLE SPEED ADJUSTING SCREW
(a) Remove the bolt and arm.
(b) Remove the idle speed adjusting screw and sprinf'.
9. REMOVE IDLE MIXTURE ADJUSTING SCREW

EG-61! ENGINE.-. FUEL. .SYSTEM
.10.. ·SEPARAJ.E CARBURETOR BODY AND FLANGE

. (a) ·Remove .the 2 passage screws and spring washers.

0'25707

(b) Remove,the 2 bolts.
(c) Separate the hody and flange.
(d) Remove the insulator.

I GENERAL CLEANING PROCEDURE

Ir CLEAN DISASSEMBLED PARTS BEFORE INSPECTION
(a) With a soft brush wash and clean the cast parts in
e
carburetor cleaner.
(5)-g (b) Clean off the carbon around the throttle valve.
(c) Wash the other parts thoroughly in carburetor clean-
l"·~-(3!--Q
er.
(d) Blow all dirt and other foreign material from the jets,

fuel passages and restrictions in the body.

·INSPECTION OF CARBURETOR

1. INSPECTFLOAT AND NEEDLE_vALVE
(a) lnspoct the pivot pin (1) for scratches and excessive·

wear.
(b) Inspect the float (2) fer broken !ips and wear in the

pivot pin holes.
(c) Inspect the spring (3) for breaks and deformation.
(d) Inspect the needle valve (4) and plunger (5) for wear or

damage.
(e) Inspect the strainer (6) for rust and breaks.
2. INSPECT POWER PISTON

Check that the power piston moves smoothly.

.... ..... .., ,, ·--·~···
·~·· ~···-

... ENGINE:..:: FUEL SYSTEM·· EG-69. '

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

8EB T P25816

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

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

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

CARBURETOR ASSEMBLY

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

Carburetor Body Assembly

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

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

washers.

2. INSTALL IDLE MIXTURE ADJUSTING SCREW

3. INSTALL IDLE SPEED ADJIJSTING SCREW

(a) Install idle speed adjusting screw and spring.

(b) Hook the back spring to the arm, and install the arm

with the bolt.

4. INSTALL FUEL CUT SOLENOID

Install fuel cut solenoid and wire clamp. I

. t:G·/0 · ENGINE- F.UEL SYSTEM
5. INSTALL~ECONDARY THROTTLE VALVE
Snap Ring DIAPHRAGM
(a) Co.nnect. t.he diaphragm link with the snap ring and
washer.
(b) Install the throttle valve diaphragm with the 2 screws.
(c) Connect t~e vacuum hose to the body.

6. INSTALL SMALL VENTURIS
Install 2 new gaskets and the pnmary, secondary
venturis with the 4 screws.

""""

7. INSTALL PRIMARY AND SECONDARY MAIN JETS

(a) Install the primary and secondary main jets with 2'

new gaskets. '

(b) Install the primary and secondary passage plugs with

2 new gaskets.

8. INSTALL POWER VALVE

-_:>,,' 9. INSTALL SLOW JET

~~-

';t!. ~

- - - - S002(<;

10. INSTALL CHECK BALLS FOR ACCELERATION
(a) Install the plunger small ball.
(b) Using tweezers. install the ball re_tainer.

,..,,

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

weight.

ENGINE - FUEL SYSTE' M . EG-71·

Air Horn Assembly

'

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

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

L---------------~·-·--------~~

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

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

(b) Install the float with the pivot pin.

; ., ..

..

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

6.5 mm (0.256 ln.)

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

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

A.

•

EG-72 ENGINE '- FUEL'-SYSTEM

B (e) Lift up·tha flqat. .

Using SST. measure the clearance between the needle

'Valve plunger and float lip.
SST 09240-00020
Float level (Lowered position):

1.5·- 1.7 mm (0.060- 0.067 ln.)

P25700

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

B.

(g) After adjusting the float level. remove the float, plung-
er, spring and needle valve.

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

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

Install a new ·boot and the pump plunger.

.,.~ 6. INSTALL NEEDLE VALVE AND FLOAT
\._.- (a) Hook the needle valv9 clip to the lip portion of the
'
float.

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

Pivot Pin

ENGINE·. FUEL SYSTEM EG-73

- 7: INSTALL AIR HORN ASSEMBLY

' (.a) Place the air horn in the carburetor body.
(b) Install theso parts with the 7 scr&ws:
•
(1) ·Accelerator cable b~acket
. .. . (2) Wire clamp
(3) Fuol pipe bracket
..
m(c) Connect the fuel cut solenoid connector to the wire
clamp.
(b) Install the retur'l spring to the accalerator bracket and

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

screws.

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

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

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

Snap Rin.g,.,

CARBURETOR ADJUSTMENT

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

v&lv~.

Standarci n1gle:

so• from horilontsl

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

EG-74 ENGINE - FUEL SYSTEM .

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

S:anderd .angle:
80° from horizontal

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

Secondary Throtlle

Stop Lever

YP2S7W

2. CHECK AND ADJUST KICK-UP SETTING

(a) With the primary throttle valve fully opened, check ·
the opening angle of the seconda~y throttle valve.

Standard angle:

23° from horizontal

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

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

For 59·_/ I

31" 30mm

70mm (1.18 in.)

(2. 76 in.) YP251'59

.·

ENGINE - FUEL SYSTEM .. EG-75

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

Standard angle:
59° from horizontal

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

y P25r.i7

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

the stroke.

Standard stroke:

3.25 -3.75 mm (0.128- 0.143 in.)

(b) Adjust the pump stroke by bending the connecting
link.

y P?-;7'57

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

Standard angle:

13.5° from horizontal

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

Idle Speed

Adjusting Screw

y P25761

I EG-76 ENGlNE'- FUEL SYSTEM.·

l r-------:::::;-;;::::::----, . 6.· PRESET IDLE;MIXTURE ADJUSTING SCREW
If the idle mixture adjusting screw has been removed.' '

fully- screw it in and then unscrew it the following

amount. ·

Standard: ,

Return 3.76 turns from fully closed position

NOTICE: Use care not to· screw It In too tightly and

damage the screw tip.

7. CHECK FOR SMOOTH OPERATION OF EACH PART

a. INSTALL CABURETOR STUD BOLT

CARBURETOR INSTALLATION

Installation is in the reverse ordl3r of removal.

FUEL PUMP

COMPONENTS FOR REMOVAL AND
INSTALLATION

Fuel Ou:let Hose

J

~-m {kgf·cm, fl'lbf)l: Specified torque TP258:20:
• Non-reusable part

ENGINE •-'- FUEL:SYSTEM ..· • EG-77 .m
:~:

· FUEL;PUMP REMOVAL

.;

. 1: DISCONNECT FUEL HOSES I=ROM FUEL PUMP

2. REMOVE FUEL PUMP
Remove ·the 2 nuts, fuel pump, gasket, insulator and

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

INSTALLATION HINT: Use 2 new gaskets.

-...x-••

FUEL PUMP INSPECTION (Airtight Test)

PRECHECK

Before doing these ch~cks on the fuAI pump:

(a) Run soma fuel through the pump to insure that the

check valves seal tightly (a dry cher;k valve may not

seal properly).

(b) Without blocking off any pipes, operate the rocker

arm and check the amount of force necessary for

(lperation and the amount of arm play. This same

amount of force should be used in the checks.

Outlet Pipe 1. CHECK INLET VALVE

Block off the outlet pipe with your finger and ch~ck
that there is an increasa in rocker arr~· play and that

• the rocker arm moves freely (no reaction force).

,.

.,

!nlet Pipe 2. CHECK OUTLET VALVE
Block off the inlet pipe with your finger and check that
the rocker arm locks (does not operats with same
amount of force used in the precheck above).
HINT: Never use more force than that used in the
precheck. This opplies to chocks 3 and 4 also:

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

EG-76 ENGINE--' FUEL SYSTEM· ·. ..

'i 4. CHECK OIL SEAL
j
i Block off the vent hole with your finger and check that

I the rocker arm locks.

FUEL PUMP INSTALLATION

Installation is in the reverse order of removal.

SERVICE SPECIFICATIONS
SERVICE DATA

Carburetor Part. No. 21100-13870
Float level
Raised positiion 6.5 mm (0.256 in.)
Lowered po!:ition
1.5 - 1.7 mm (0.060 - 0.067 in.)
Primary
Throttle valve opening engle Secondary 90° from horizontal ·,

so· from horizontal

Secondary throttle valve Pre-setting 23• from horizontal
Kickup flngle Pre-setting 59'" from horizontal
3.25 - 3.75 mm (0.128 - 0.148 in.)
Secondary touch engle 13.5• from horizontal
Acculeration pump stroke
Idle speed !ngla Return 3.75 turns from fulley closed position

. Idle mixture adjusting screw ----~

TORQUE SPECIFICATIONS -,

Part tightened N·m kgf·cm ft.Jbf
Carbure tor x lnta~e manifold
Fuel pump x Cyli;.der Mock -19 195 14

Inlet pipe x Curburo.tor 18 185 13

i24 17
-24-0 - -

·-···· ·-·· --· .. EG-79

. ENGINE -.COOLING SYSTEM

COOUNG SYSTEM · ·

:. PREPARATION . ......

• .· :· SST (SPECIAL SERVICE TOOLS)

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

.... ,I
(09236-1501 0) Beedng.S~•Y
.......................
..............................................................................................................................

(09237-00010) Water Pump Soaring Remover &
Roplacer

......................................:..: ...........................................................................................................................

(09237 -00020) Boadng Stay

(09237 -00030) Beadng Stay

(09237-00050) Shaft ·a·

EQUIPMENT

-HRe.a-tedr~-or-ca--pte-sto-,--~·--------------------------T-h-e-r-m-o~s·ta-t------·-------------------------~
- - -ThermometBr Thermostat

Torque wrench

-------=rCOOLANT Capac:hy ~ Cla.ssilication J

r ltt>m - 1 Ethylenc.-glycol base

( Enoine coola~t 5.7 Htors (6,0 US qts, 5.0 Imp. qt:;)

SSM (SPECIAL SERVICE MATERIALS)

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

(FIPG)

l.:I.:HlU ENGINE:-<CO.Ol!NGSYSTEM.
Drain Cock
COOLANT CHECK AND •·•
REPLACEMENT
..
t.M.U-11

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

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

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

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

remove it while the engine and radiator are still hot, as
fluid and steam can be blown out under pressure.

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

{c) Close the drain cocks.

Torque (Engine drt~in cock):
25 N·m (250 kgf.cm, 18 ft·lbf)

{d) Slowly fill the system with coolant.
• Use a good brand of ethylene-glycol base cool-
ant and mix it according to the manufacturer's
directions.
• Using coolant which includes more than 50 %
ethylene-glycol {but not more than 70 %) is
recommended.

NOTICE:

• Do no~ use a alce>hol type coolant.

~ The coolant chould be mixed with demineralizad
wator or distilled water.

Capacity:

6.7 lltlilr• (6.0 US qts, 5.0 imp. qts)

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

----~

ENGINE:- COOLING SYSTEM EG-81

. ' WATER PUMP

COMPONENTS FOR REMOVAL AND
INSTALLATION

.'

+Gasket
Water Puf'J)P

191195, 141

.. Fan

"'\--
Water Pump Pulley

Fluid <..OlJDHJlQ Drive Belt

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

+ Non-reusable part

WATER PUMP REMOVAL

1. DRAIN ENGINE COOLANT

2. REMOVE DRIVE BELT, FAN, FLUID

COUPLING AND WATER PUMP PULLEY

(a) Stratch the belt and loosen th~ 'Rn pulley mounting

nuts.

(b) Loosen the pivot and adjusting bolts of the alternntor,

P>$461 and remove the drive bait.

(c) Remove the 4 nuts, fan with fluid coupling and p:~/Jey.
•. (d) Remove the 4 nuts and fan from tho fluid coupling.

3. REMOVE WATER PUMP

(a) Disconnect the water bypass hose from the water

' pump.

(b) Remove the 4 bolts, adjusting bar, water pump afld

gasket.

EG-82 ENGINE..:.: COOLING SYSTEM· ·

WAT:ER PUMP COMPONENTS INSPECTiON

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

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

• .,. I

lOUt-eo

COMPONENTS FOR DISASSEMBLY AND

ASSEMBLY

--------------------------------------------~-------------------,

10.3 (105, 81

•

Plate

~.av + Gasket
yI + Rotor
I Water Pump Body
I + Ae!ring +Seal Set

Pulley Seat •

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

+ Non~rcusable part

ENGINE.- CO.OLING SYSTEM EG-83

.W. ATER .PUMP DISASSEMBLY

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

•.

Z. REMOVE PULI.EY SEAT
Using SST and a pross, pross thP Lonring sh~ft and

remove the pulley seat.

SST 09236-00101 (09237-00010, 09237-00050)

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

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

and remove the bearing and rotor.

SST 09236-00101 (09237 -00010, 09237- 00050j

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

S~ SST 09236-00101 (09236-15010)

I ~..-.. '

. IL-----------------------·~~~~"J

WATER PUMP ASSEMBLY

HINT: Always assemble the water pump with a new
seal set.
1. INSTALL WATER PUMP BEARING
(a) Gradually heat the water pump boc'{ :o 75 - ss•c
(167 - las· FJ.
(b) Using SST and a press, install the bearing hto the
P25111 water pump body.

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

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

NOTICE: The bearing and face should be flush with the

body top surface.

2. INSTALL SEAL SET

(a) Apply a seal set packing to a·new seal and pump body.
Seal packing:

Part No. 08826-00100 or equivale~t

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

SST

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

-SST 09236-00101 (09237 -00020)

IP257l<l

· - - - - - - - - ------'-P2'"".)~W~I 4. INSTALL ROTOR
Using ?. press, press in a new rotor on the water pump
bearing shaft te 0.3 - 1.1 mm (0.0 1 - 0.04 in.) from
the installation surface of the pump body.
N011CE: As shown In the figure, the rotor and fa<:e
should be flush with the bearing snaH top ~"rfaot.

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

6. CHECK WATER PUMP ROTATES SMOOTHLY

,______ :;~

'CNGINE - COOLING SYSTEM EG-85

WATER PUMP INSTALLATION --··

''

1. INSTALL WATER PUMP

(a) Temporary install the adjusting bar to the alternator

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

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

2. INSTALL WATER PUMP PULLEY. FAN, FLUID ~~

I COUPLING AND DRIVE BELT

"""'' (a) Install the fan to the fluid coupling with the 4 nuts.

(b) , Tempornry install the water pump-pulley and fan with

fluid coupling with the 4 nuts.

(c) Install and adjust the belt.

(Se& on -vehicle inspecticn in Charging System)

(d) Stretch the belt tight and tighien the 4 nuts.

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

3. FILL WITH ENGINE COOLANT

4. START ENGINE AND CHECK FOR LEAKS

,.· THERMOSTAT

COMPONENTS FOR REMOVAL AND

!NSTALLA TION

J19{1~~ ~
I
I I
I
I

I

I
I
I

+Gaskel-0 T P25557

Thermostat~

~\

·. l<·m (kgl·om, ft•lbOI' Spoo;nod , , : - \

u~j + Non-reusable part

EG-86 ENGINE - cooLING SYSTEM

J THERMOSTAT REMOVAL •~

COOJOO HINT: Removal of the thermostat would have an ad-

verse effect, causing a lowering of cooling efficJen.;y, •

Do not remove the thermostat, even if the engi,ne •
tends to overheat.

1. DRAIN ENGINE COOLANT

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

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

THERMOSTAT INSPECTION

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

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

(b) Check the valva opening temperature.
Vnlve opening temperature:
80- 84•::: (176- 133.F)
If ths valve oper.ing temperature is not as specifia&,
replace the thermostat.

(c) Check the valve lift.
Valve lift:
At gs•c (203.F): 8 mm (0.31 in.) or more
If the valve lift is not as specified, replace the thermo-
stat.

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

Z\6616

ENGINE'·-·coOLING·SYSTEM ·· EG-87

THERMOSTAT INSTALLATION

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

~~­

· (b) ·Align the jiggle valve of the thermostat with right side

of the ·mar~. and insert the thermostat in the water

outlet housing.

HINT: The jiggle valve may be set-within 10° of either

side of the prescribed position.

(c) Install the water outlet with the 2 bolts.

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

2. FILL WITH ENGINE COOLANT

3. START ENGINE AND CHECK FOR COOLANT

Li:AKS

RADIATOR.

RADIATOR CLEANING IOUI-11

.· Using water or a steam clean·er, remov~ any rnud and
dirt from the radiator core.
I NOTICE: If using a high pre83ure type-ciBaner. be careful

Ra1iator Cap not to deform the fin• of the radiator core. (i.e. Maintain

COOQJ( a distan'ce between the cleanP.r noz"'le.and radiat~r cor~.t)

RADIATOR INSPECTION

1. REMOVE RADIATOR CAP
CAUTION: To avoid the donger of bolng burned, do not

rom eve tha radiator cap whilft the engine ancf·radiator ore
"itm hot. a: fiuid an-i 'iteam can be blown out under

pras£ure.

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

rinse it with water.

Using a radiator cap tester, pump the taster and meas-
ure the vacuum valve opening pressure.

Standard oponing pressure:

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

Minimum opening pressure:

59 kPa (0.6 kgf/cm'. 8.5 psi)
HINT: Use the tester's maximum reading as the open-
ing pressure.

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

If the opening pre.ssure is less than minimum, replace,
the radiator cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiat..;~ ~'ld engine with coolant, and attach a ·
radiator cap tester to the water filler.
(b) Warm up the engine.
(c) Pump it to 11 B kPa (1.2 kgf/cm2, 17.1 psi), and check
that the pressure does not drop.
If the pressure drops, check the hoses, radiator or
water pump for leaks. If no external leaks a're. found,
check the heater core, cylinder block and cylinder
head.
4. REINSTALL RADIATOR CAP

SERVICE SPECIFICATIONS &00'7\.-U

SERVIGE DATA

Therm.,stat Valve opaning temperature ot 95'C (203'F) eo- s4•c 111e- 1B3'FJ I
Velvb lift STD 8 mm (0.31 in.) or more
1-·-· Vecuvm veive opening pressure 74- 103 kPo (0.75- 1.05 kgf/em', 10.7- 14.9 psi)
Radiator cap Minimum 59 kPa (0.6 kgf/em', 8.5 psi)

·TORQUE SPEC!F!CATIONS N·m kgf-cm ft-lbf

Part tightened 25 250 18 •
Drain plllg x Cylinder ~leek
10.3 105 8
Water rump body ~ Pump p!ete
5.5 55 49 in.·lbf
Fluid coupling x \Vater pump
Water pump x Cyiinder block 19 195 14
Water outlet x Water I)Utlet ho:.using
19 195 14

0•

•