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@TOYOTA
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REPAIR MANUAL Jul., 1995 ;.
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.. INTRODUCTION ENGINE IGNITION SYSTEM STARTING SYSTEM CHARGING SYSTEM
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FOREWORD
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This repair manual has been prepared to provide informatio" · covering general service repairs for the 7K engine equipped in the TOYOTA TUV .
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Applicable models: KF42, 52 series Please note that the publica lions below have a!so been prepared as relevant service manuals for the components and system in this engine. All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice.
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TOYOTA MOfOR CORPO{Ul.TION
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©1995TOYOTA MOTOR CORPORATION All rights reserved. This book may not be reproduced or copied, in whole or in part, withtlut the written permission of Toyota
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IN-1
INTRODUCTION • HOW TO USE THIS MANUAL ·················· IN- 2 IDENTIFICATION INFORMATION ··············· IN- 4 GENERAL REPAIR INSTRUCTIONS ············ IN- 4 ABBREVIATIONS USED IN THIS MANUAL ·••···•••·•·•······•·········•··············· IN- 7 STANDARD BOLT TO ROUE SPECIFICATIONS···································· IN- B
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IN-2
INTRODUCTION - HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist y.:OtJ in finding your way through the manual, the Section Title and major heading are given at the top of every page.
GENERAL DESCRIPTION At the beginning of each section, a General Description is given that rertains to all repair operations contained in that section. Read these precautions before starting any repair task.
TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagn.::se the problem and find the causA.
PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains· the purp-ose of each one.
REPAIR PROCEDURES
r
Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: --------------------------------------------------~
Oil Pump Body
__ ..,
+Cotter Pin
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~..,
(
~
Srring Retainor
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~JP
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-
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-DriJ.n Rotor-@
Relief Valve Volve Spring
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Oil Pump Covor I I
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1./
Drive Rotor----J"b.'-
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[B·m lkgf·cm, ft·lbf)
i : Specified torque
+ Non~reusable part P2537J '-------------------------------------------------------~~
INTRODUCTION
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,
The • • •
HOW TO USE THIS MANUAL
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.
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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 negative cable from the battery terminal. (b) If it is necessary to disconnect the battery for in.spection or repair, always disconnect the cable from the negative(-) terminal which is grounded to the vehicle body. . (c) To prevent damagll to the battery terminal post. lcosen tho terminai nut and rais~ the cabl<:l straight up without twisting or pryin9 it. (d) Cle.an th9 battery terminal posts and cable t<~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 installation. Do not use a hammer to tap the terminal onto the post. (f) Be sure the cover for the positive ( +) terminal is . properly in place. 4. Check hose and wiring connectors to m?'
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INTRODUCTION -
5.
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IN-5
GENERAL REPAIR INSTRUCTION:';
6.
Seal Lock Adhes:ive
• 7.
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 component illustrations by the ••• symbol. 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. When necessary, use a sealer on gaskets to prevent
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le~ks.
8.
Fuse Equal Amperage Rating
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10
8F1J&&
Symbol
Illustration
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Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. 9. Use of SST and SSM may be required. depending on the nature of the repair. Bs sure to Ulje SST and SSM where specified and follow the prooer work procedure. A list of SST and SSM can he found in the preparation ;:>art at tho front o~ eacn section in this manual. 10. When replacing fustJ·s. be sure the new fuse ha~ the correct amperag(> rating. DO NOT exceed tha rating or use one with a lower rating.
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B£5694
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-~-B£5690
GY
BES598
FUSE
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M-FIJSE
HIGH CURRENT FUSE
H-FUSE
FUSIBLE LINK
FL
CIRCUIT 6iii:AKER
co
INOl07
-~ BE5597
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MEDIUM CURRENT FuSE
w-JoJee
Abbrevintion
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WQJ8S 1
--<0"'oBE56S~
·-r·------, Part Nnme
IN0307
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INOJ68
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·· IN-6
INTRODUCTION -
GENERAL REPAIR INSTRlJ.;TIONS
11. Care· must be taken when jacking up and supporting
WHONG
CORRECT
IN0253
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WRONG
CORRECT
,/
l IN0262
Exampie
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the 'lehicle. Be sure to lift and support the vehicle at 1 the proper locations. (a) If the vehicle i~ to be jacked up only at the front or rear end. be sure to block the whesls at the opposite end in order to ensure s'afety~ (b) After the vehicle is jacked up. be sure to support it on stands. It is extremely dangerous to do any work on a vehicle raised on a jack alone. even for a small job that can be finished quickly. , 12. Observe these precautions to avoid damage to the parts: (a) Do not open tho cover or case of the ECU unless ·absolutely necessary. (If the IC terminals are touched. t:1o IC may be destroyed by static electric· ity.) (b) To disconnect vacuum hoses. pull on the end. not the middle of the hose. (c) To pull apart electrical connectors. pull on the connector itself. not the wires. (d) Be careful not to drop electrical components. such as sensors or relays. If they are dropped on a· hard floor. they should be ~eplaced and not reused. (e) When steam cleaning an engine, protect the elec.tronic components. &ir filter. and emissions relat- • ed components from water. (f) Never use an impact wrench to remove or install temperature switches or temperature sensors. (g) When checking continuity at the wire connector. insert the testGr probe carefully to !Jrsvont terminals from bending. (h) When using a vacuum g<:lJge. never force the hose onto a connector that is· too large. Usa a stllp ·-down adapter instead. Once the ho$e h~.s b'3en stretched, it may ldak. 13. Tag hosas before disconnecting them: (a) When disconr.ec!ing vacuum hoses, use tags to identify how they should be reconnected. (b) After -::omple~ing a job, double check that the vacuum hoses are properly connected. A label under the hood shows the proper layout. 14. Unless otherwise stated. all resistance is measured at an ambient temperature of 2o•c (68°F). Because the resistance m9y be out;ide specifications if measured at high temperatures .immediately after the vehicle has been running. measurements should be made when the engine has cooled down.
INTRODUCTrON - ABBREVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS MANUAL '
A/G
Air Conditioner
Approx.
Arproxlmatelv
BOG FIPG
Bottom Oe11d Center
IN-/
--· --
Formed In Placa Guket
MP
Multipurpoa.:J
C/S PGV SSM
Oversized
Special SOrvice Meteriela
SST
Special Service Tools
STO
Standard
Positive
Crnnkca~e Vflntil~tion
SW
Switch
TOG
Top Dead Center
TEMP.
Temperature
U/S
Undersize
vsv
Vacuum Switching Velva
W/
With
w/o
Without
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IN-8
IN.TRODUCTIO'I'< -STANDARD BOLT TORQUE SPECIFICATIONS
STANDARD BOLT TORQUE SPECIFICATIONS
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HOW TO DETERMINE BOLT STRENGTH
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--------Hexaqon head bolt
( ) ' h e a d No._ 7-
7T
8-
ST
9-
9T
10-
10T
11-
11T
0
w~sher
Hexagon
CD
head boll
0
I J
w/ wacher hb'
~
wl washer hexagon bo,lt
Hexagon flange boll
~
w/ Y!asher · hexagon boil
~
flange boll
4T
No mark
w/ washer hexagon bolt
II I
0
~
9T
Protruding lines
5
10T
Protruding
-
lines
6 Prolr!:Jding lines
11T
4T
r·,·~:·
2
I
3 Protruding
n
I
+
L
ST
lin as
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4
I I II
2 ProtrtJding
Class
No mark
4T
No mark
1Ql ::.:"';~ "l
!(
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Hexagon head bolt
ST
Hexagon flange boll
Slud boll
hexagon bolt
I
5-
GT
0
Hexagon flange bolt
Hexagon ll•.nge boll
4T
l
Mark
Hexagon
-.
w/
4G-
Boll
------
Class
Mark
GT I
I
_j__ Welded boll
-
I
I
lines
4 Protruding
lines
ST
~
4T
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
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Specified torque Class
Pitch :nm
Diameter m;n
N·m
4T
5T
.-
...
6T
7T
~ 8T
t'T
He."'"9on flonge bolt
Hexegon head bolt kgf·cm
ft·lbf
kgf·cm
6 29 53 84
60 145 290 540 850
10 21 39 61
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6 8 10 12 14 16
1 1.25 1.25 1.25 1.5 1.5
5 12.5 26 47 74 1 15
55 130 260 480 760 1.150
6 8 10 12 14 16
1 1.25 1.25 1.25 1.5 1.5
6.5 15.5 32 59 91 140
65 160 330 600 930 1,400
12 24 43 67 101
17.5 3€ 65 100
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6 8 10 12 14 16
1 1.25 1.25 1.25 1.5 1.5
8
19 39 71 1 10 170
80 195 400 730 1,100 1,750
69 in.·lbf 14 29 53 80 127
9 21 44 80 125
90 210 440 810 1,250
6
1 1.25 1.25 1.25
8 19 38 70 108 156
8 10 12 14 16 8 10 12
10.5 25 52 95
48 in.·lbf
9 19 35 55 83
~4
7.5
56 in.·lbf
-
1.5
145
T ~I
230 29 61 1 10
300 .620 1,100
22 45 00
33 68 120
330 690 1,250
34 7C
.340 710 ,,30(1
25 51 94
.17 7B 1 140
380 790 1.450
1
I
1.25 1.25
6
i. 7.5
10
1.25
12
1.25
I
I I
125
105 165
--
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58
65 in.·lbf 13 26 48 76
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120 290 590 1,050 1,700
12 28
52 in.·lbi
75 175 360 670 1,050
1I0 260 530 970 1,500 2.30ti)
1.25
ft·lbf
N·m
78 in.·lbf 15 32 59 90
9 21 43 76 123
~I
.
50 90
27 .. o7 105
+----------------r----------·-----1 lOT
11T
8 10 12 8 10 12
1.25 1.25
-
1.25
38 78 140
390 800 1,450
28 58 105
42 88 155
430 890 1,600
31 64 116
1.25 1.25 1.25
42 87 155
430 890 1,600
31 64 I 16
47 97 175
480 990 1,800
35 72 130
tG-1
ENGINE
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ENGINE MECHANICAL .PREPARATION ....................................... EG- 2 AIR elLTER INSPECTION AND CLEANING ·························•·•·········· ··· EG- 6 IDLE CO CHECK AND ADJUST .....•...... ; .. EG- 6 COMPRESSION CHECK ····•····••···•·•·······•·· EG- 9 VALVE CLEARANCE INSPECTION AND ADJUSTMENT······································ EG- 10 IGNITION TIMING INSPECTION AND ADJUSTMENT······································· EG- 11 IDLE SPEED INSPECTION AND ADJUSTMENT······································· EG-11 CYLINDER HEAD ................................. .-.. EG- 1r TIMING CHAIN ....................................... EG- 27
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CYLINDER BLOCK ................................. EG- 34 SERVICE SPECIFICATIONS ........................ EG- 55
FUEL SYSTEM PREPARATION .................................,..... EG- 60 PRECAUTION ........................................ ,. EG- 60
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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~·;~::;
················· ······ · ············ ······· ··· · ·····
~
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~-----------------------------~------09213-14010 Cranksh_aft Pulley Hol.ding Tool ----,I
1 ,~ I
I I
(~1651-60665)
Bolt
09215-00101
Camchsft Dearing Remover & Roplecer Sot ..g
·················
...............................................................................................................
(09?15-001?1) Gote "A"
I (09215-00130) Bolt
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ENGINE -
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EG-3
ENGINE MECHANICAL
(09215-00141)
Nut
(09215 -00150)
Shalt "A•
.-(09215-00161) P;n
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.
(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
,
.......................................................................................................... ................................................. . (09221-00170) Gu;de "J'
-I
I
i
J
..........
················· ················· ........................................................................................................................................... (0922 1 - "n10) Gu;de ·M·
09223
~
15020
09223 46011
Oil Seal & Bearing Replacer
~::~~:~;11 Front 0;1 Sool
~--------------------------------_l
J ____________
,,. EG-4
I
i
ENGINE -.ENGINE MECHANICAL 09330 00021
Companion Flange Holding Tool
Crankshaft pulley
, i: •
I {
.........................
!
(09330-00030) Pin
09950-4o'01 0
t' Crankshaft pulley
Puller B Set
Crankrhdt sprocket
·····················cosgs2·~::o4o·io>····s·lid~-;.,~-~---·················
.......... ...... :........
..
..... ·
-·····-·-··--····-···-···········... ···································································
····· ... ·· · .. ..io99s4·::·a4cii iii ... ;.,;;,..is· ·.... · ................ ·· ........................................................................................
.. ························ ························ cii99ss·::·a4iii'iii···r;,;:;,·;;~:·;· ..................................................................................................................... :::.
~~
:.:o4ii ·;o) · ·:.;:
09g5o 50010
;;;·~·h·;;;;·~·;·
..··.......·................··...........................................·..............·...........................
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,·
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······ ····.. ····.. ···· ······· ··.. ·... ····.... ····· · ·.... ····cu9iis4·::·oso2o) .. -;;;;·;;
·N~::;·
......................................................................... ·............................. .
........ ·............................................ ·........................................... ·.................... .
~~ · 09950 70010
Hondle Set
.......................... ...io995.i =o7i5ii). ··fi~~di~·;-s'O........................................................................................................................ .
EG-5
ENGINE - ENGINE MECHANICAL 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
.
CO/HC meter Compression gauge
•
·connecti!lg rod aligner Cylind~r
gauge
Dial indicatCJr Dye· penetrant
Engine tune-up taater HH&ter
'Megnetie flngnr
-
Mlcromet&r
Pilt,Jn ring 'JI')ftlprenor
------P1ston tinQ a)(pr;Fld~r Plaatig11J90
-~recision
-
atraight edpe
-
-
SQft bruah ~~ring
tester
..steel square
•Tachometer
Therml')meter Timing light
Torque wrench " Valva seat cutter
Vernier calipers
,,
.
Valve 1prlng
Val'la spring
--
EG-6
ENGINE - ENGINE MECHANICAL -···~
SSM (SPECIAL SERVICE MATERIALS) 08826-00080
Seal Packing Black or equivalent (FIPG)
[
Timing chain cover. oil pan and rear oil sear retainer
..,
----------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. REINSTALL AIR FILTER
4.
•
~711
IDLE CO CHECK AND ADJUST _..,.M~~
1. (a) (b)
2. (a) (b) (c) (d) (e) (f) (g) 3.
=
VISUALLY INSPECT CARBURETOR Check for loose screws or a loose mounting to the manifold. Chnck for wear in the linkage, missing snap rings 01 axcessive looseness in the throttle shaft, Correct any problems found. INITIAL CONDITIONS Air· cleaner installed. Normal operating coolant temperatura. Ali accessories switched off. Ali vacuum lines connected. Ignition timing set correctly. Transmission in the "N" range. CO meter operates normally. CONNECT TACHOMETER TO ENGINE Connect the test probe of a tachometer to the ignition coil negative{-) terminaL
• "
ENGINE -
EG-7
ENGINE MECHANICAL
NOTICE: • NEVER allow the tachomotl3r terminal to touch grourid as it could result in damage to tho igniter
·.
•
and/or ignition coil. As some tachometers erll not compotible with this ignition system. we recommend that you confirm the compatibility of yow· unit befor~ use.
•
4.
INSPECT IDLE SPEED Idle speed: 750 ±50 rpm If not a·s specified, adjust accroding to these procedure: CAUTION:
•
Always use a CO motor when
~djusting
the idle
mixture. It is not noce.n:s11ry to adjust with the idle
.
..
•
mixture adjusting screw in most vehicles if thoy are in good condition. If a CO meter is r>ot available, £9 NOT ATTEMPT TO ADJUST WITH THE SCREW. If a CO meter is not available and it is absolutely
necessary to edjust with the Idle mixture adjusting screw. use the alternative method.
5.
A. (a) (b)
(c) (d) (e) (f)
.·.
CHECK AND ADJUST CO CONCENTRATION AT IDLE Method with CO meter Start the engin9. Using a CO meter to measure the CO concentration in the exhaust. turn the idle speed and idle mixture adjusting screws to obtain the speclfied concentration value at idle speed. ,Idle speed: ' 750 ±50 rpm Check that the CO meter is properly calibrated. Race the engine 30-60 seconds at about 2,000 rpm before measuring concentration. Wait 1-3 minutes after rucin!l the engine to allow the ccncentration to stabilize. lnsort a testing probe at least 40 em (1.3 ft) into the tailpipe, and measure the concentration ~vithin a short time. Idle CO concentretion: 1.0 ± 0.5 % • If the CO concentration is within specification this adjustment is complete . • If the CO concentration is not within specification, turn the idle mixture adjusting screw to obtain the specified concentration valt.. e. • If the CO concentration cannot be corrected by adjusting the idle mixture, see tacle below for other possible causes.
-~ •·
,.
EG-8
ENGINE '- ENGINE· MECHANICAL<· ..
TROUBLESHOOTING
•
co
1-!C
Normal
High
Rough idle
1. Faulty ignition: • Incorrect timing • Fouled,shorted or Improperly gapped plugs • Open or crossed Ignition wires • Cracked distributor cap 2. Leaky exhaust valves 3. Leaky cylinder
Low
High
Rough Idle
1. Vacuum leak: • Vacuum hose • Intake manifold • PCV line • Carburetor base
Causes
Problems
(Fluctuating HC reading) '
-High
High
Rough idle
-
1. Restricted air filter
(Black smoke from exhaust)
2. Plugged PCV valve 3. Faulty carburetlon:
.
\
• Incorrect float setting • Leaking needle or seat • Leaking power valve
"""' B.
Altsrnstive method
(a} (b)
Start the engine. 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 consumption or poor fuel economy, measure the compre:;sion pressure. WARM UP AND STOP ENGINE 1. Allow the engine to warm up to normal operating temperature . 2. DISCONNECT DISTRIBUTOR WIRE 3. DISCONNECT HIGH-TEi\ISION CORDS FROM SPARK PLUGS 4. REMOVE SPARK PLIJGS 5. CHECK CYLINDER COMPRESSION PRESSURE (a) Insert a ccmpression gauge into the spark plug hole. (b) Fully open the throttle. (c) While cranking the engine, measure the compression pressure. HINT: Always use n fully chargsd battery to obtain engine speed of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTICE: This moasurement must be done In ss s.,ort a time u possible. Compression prOsaure:
931 kPa (9.5 kgf/cm'. 135 psi) or mora Minimum pressure: 785 kPa (9.0 kgf/cm', 128 psi) Difference betweon each cylinder: 98 kPe (1.0 kgf/cm', 14 psi) or lass (e) If tha cylinder compression in 1 or rnore cylinders is low, pour a small nmount of engine oil into the cylinder 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
•
.
. t·
.-
~
;·
''3-10
' ..
ENGINE -·ENGINE MECHANICAL
VALVE: CLEARANCE INSPECTION AND ADJUSTMENT [GI.OM•OI
HINT: Inspect and adjust the valve c!aarance when the engine is cold. REMOVE CYLINDER HEAD COVER
1.
(See step 8 in cylinder head
2.
removt~l)
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.
INSPECT AND ADJUST VALVE CLEARANCE
3.
Front
-+-
(a)
No.1
Measure only the valves indicated by arrows.
No.2
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 clearance between· the valve stam and rocker arm. Loosen the lock nut "nd tum the adjusting screw to set the proper clearance. Hold the adjusting screw in position and tighten the lock nut .. Rec:heck :he val•1e ·clearance. Tha fAster g3ugo should slide with a very slight drag.
=,J Front
+-
No.2
No.3
No.4
EX
IN
IN EX
+
+--+-+~
~
0
0
0
--
0
0
.t'Sl:.>J.I
(b) Turn the crankshaft one revolution (360°) and align the mark above. Adjust Qnly the valves indicated by arrows. 4. REINSTALL CYLINDERJlEAD COVER ·, ' . ., (Seo step 5 in cylinder hoad ir.;;tallation) ·''
.
~.r~>:
·:\.....
.ENGINE
tG-11
I.
·ENGINEMECHANICAL
IGNITION TIMING INSPECTION AND ADJUSTMENT '.
WARM L.:P ENGINE
2.
CONNeCT TACHOMET[;R TO ENGINE
1
..:.'
"'
.'
Allow the engine to warm up to normill operating temperature. (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. Connect a plug to the vacuum hose.
(b)
5. 6.
CONNECT TIMING LIGHT TO ENGiNE INSPECT AND ADJUST IGNITION TIMING With the engine idling as specified, u~e timing light
a
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. 7. a.
Torque: 12 N·m (120 kgf·cm, 9 ft.fl!f) RECONNECT VACUUM HOSE RECHECK IGNIT!ON T:M!NG
With th8 engine idling as specified, check the timing.
_
..
us~ a timing t~:t, ''/'
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 Spar~
Spark Plug Tube ---....__ Water Outlet Hosing "'""-, Assembly
Plug
Rocker Arm and Assembly
l.ll.<;~-----shaft
See e EG·25 1•1 29.5 (300, 22) 2nd Turn go•
I
3rd Turn go•
\
~/ J ''
Clamp~-·
Cylinder Head
X6
- ,.
(
lntake,Exhaust Manifolds and Carburetor Assembly
,,.,.,
' . lntak
·•
.
ENGINE - ENGINE ME . CHANICA' n olds a n d Carbureto·• Assembly L :. . ·
e, Exhaust Ma If
Intake Manifold
•
;
"-
E.:l-13
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 cylinder head. (c) Remove the intake, exhaust manifolds. carburetor assam 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 I
9.
REMOVE ROCKER ARM AND SHAFT ASSEMBLY. Uniformly loosen and ramove the 6 bolts and 2 nuts in several passes, in tha sequence sho)!Vn. (b) Remove the rocker arm and shaft assembly. 1 C. REMOVE PUSH RODS Remove tho 8 push rods in o;der, begi11ning from tho No.1 push rod. NOTE: Arrange the push rods in correct order• (a)
.,.,.,I
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
(b)
~
EG-15
.If j:~ ·:, -i~
Uniformly loosen and remove the 11J head bolts in several passes, in the sequence shown.
,.
ffl .i!li . ..
CAUTION: Hond wnrpngo or cracking could result from removing out of sequence.
-··•j,..,.
~=·
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.....
~·;
••
P149SO P149Sl
ZI6SJS
(c)
Lift the cylinder head from the dowels on the cyli;,der block and· place the head on wooden blocks on ~ bench. HINT: If the cylinder head is difficult to lift off, pry betwee;, the cylinder head and block with a screwdriver. CAUTION: Be careful not to damage the cylinder head or· b!ock surface on the cylinder haad gasket sides.
CYLINDER HEAD DISASSEMBLY
(a)
REMOVE WATER OUTLET ~lOUSING AND REAR PLATE Remove the 2 bolts, clamp. watGr outiet. housing ar~d
(b)
gasket. Remove the 4 bolts, rear plate ar.d ga3ket.
2. (a)
REMOVE VALVES Using SST. compress the valve spring and remove the
(b)
2 keepers. SST 09202-70020 (09202-00010, 09202-01010. 09202-01020, 90 154-80004) Remove the spring retainer, vaive sprir>g and valve.
1.
EG-16
ENGINE -
ENGINE MECHANICAL
(c) (d)
Using. needle- nose pliers. remove the B oil seals. 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
l l
t
EG-17
C.
Clean valve guide bushings Using a valve guide bushing brush .and solvent, claan all the guide bushings.
D.
Clean cylinder head Using a soft brush and sclvent, thoroughly clean the cylinder head .
' '
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~~ ""'"
.'
-
.
., ,•
'
! - .---------------------------~ '
.
3. A.
INSPECT CYLINDER HEAD Inspect for flatness Using a precision straight edge and thickness gauge, measure the surfaces contacting the cylinder hlock and the manifolds for warpage. Maximum warpage: Cylinder block side: 0.05 mm {0.0020 ln.) Manifold side: 0.10 mm (0.0039 ln.) If warpage is greater than maximum, replace the cylinder head.
B.
Inspect for cracks Using a dye pe~etrant, check the combustion chamber, intake ports, exhaust ports and cylinder block side surface for cracks. If cracked, replace the cylinder head.
P2.t961
P2498l
"""'
EG-18
ENGINE -
' .
ENGINE MECHANICAL
4.
CLEAN VALVES
(a) (b)
L!sing a gasket scraper. chip off any carbon from the • valve head. 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.
j.
'.
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:
Standard
Meximum
Intake
Exh!USt
O.OT9 - 0.079 mm
0.024 - 0.075 mm
(0.0007 - 0.0031 ln.)
(0.0009 - 0.0030 ln.)
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! (b)
Using a chisel and hammer, break the valve guide bushings. G•adually heat th·e cylinder head to SO - 1OO"C ;176
- 212"F).
.
' ENGINE - ENGINE MECHANICAL <
"
(b) · Using SST and a hammer. tap out the guide bushing.
I
SST 09201 -1 0000 (09201 -01 080). 09950-70010 (09951-07150)
(c)
.· . .,
Using a caliper gauge, measure the bushing bore diameter of the cylinder head.
(d)
Both intake and exhaust Bushing bore diameter Bushing size mm '(in.) 13.000- 13.027 Use STD (O.S118- 0.5129) 13.050- '13.077 (0.5138- 0.5148) Use 0/S 0.05 V07105
Sharp 8 mm Reamer
.,
EG-19
Select a new guide bushing (STD size or 0/S 0.05). If the bushing bore diameter of the cylinder head is greater than 13.027 mm (0.5129 in.). machine the bushing bore to these dimension: 13.050- 13.077 mm (0.5138- 0.5148 in.) If the bushing bore diameter of the cylinder head is greater than 13.077 mm (0.5148 in.). replace the cylinder head. , (s) Gradually heat the cylinder head to 80 -· 10o•c (176 - 212.F). (f) Using SST and a hammer, tap in a new guide bushing until the snap ring makes contact with the cylinder head. · SST 0920i -10000 (09201-01 080), 09950-70010 (09951-·07150)-
(g)
Using a sharp 8 mm reamer. ream the guide bushing to obtain the standard specified clearance (See step 5) between the guide bushing and valve stem .
. EG-20
ENGINE:- ENGINE'MECHANICAL 7.
·INSPECT AND·GRIND VALVES
(a)
Grind the valve enough to remove pits and carbon. Check· that the valva i~ ground to the correct valve face angle.
(b)
Valva face angle: 44.5°
::
CM0254 £M018C.
(c)
Check' the valva head margin thickness. Stand&rd margin thickness: Intake: . 1.0 - 1.6 mm (0.039 - 0.063 ln.) Exhaust: 1.2 - 1.8 mm {0.047 - 0.071 ln.) Minimum margin thickness: Intake: 0.8 mm (0.031 ln.) Exhaust: 0.9 mm (0.035 ln.)
If the margin thicknar.s is Jess than minimum, replace the valve. (d) "
Check the valve overall length. Overall length:
Overall Lenyth
Standard
Minimum
Intake
Exhi'IUSt
99.90 mm
100.10 mm
(3.933 ln.)
(3.941 ln.)
99.4 mm (3.913 ln.)
99.6 mm (3.921 ln.)
If the overall length is less than minimum, replace the valve. (e)
Check the surface of the valve stem tip for wear. · If the valve stem tip is worn, resurface tho tip with a grindar or replace the valve. NOTICE: Do not grind off more than ,;inlmum.
8.
INSPECT AND. CLEAN VALVE SEATS
(a)
Using a 45" carbide cutter, resurface the valve seats. Remove only enough metal to' clean the seats.
.
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
ss•
Exhaust 1.2- 1.8 mm (0.047- 0.071 in.)
If not. correct the valve se,ts as follows: If the seating is too high on the valve face, uss 45" and 65" cutters to correct the seat.
(1) EMI)186
Zl6545
-
~
(2)
..
,.
If the seating is too low on the valve face, use 45" and 30" cutters to correct.the seat.
0
Width EM01BS
ZIOW
I
(d)
I
(e)
Hand-l
.,I
--]
Deviation - I f -
9. (a)
INSPECT VALVE SPRINGS Using a steel square, measure the sc;uareness of the valve spring. Maximum squareness:
-.I
.::;s;;
1.6 mm (0.063 ln.)
If the deviation is greater than maximum, replace the valve spring.
EG-22
ENGINE - ENGINE MECHANICAL .
(b)
·Using vemier calipers. measure the free length of the valve spring. Fr"" .l.,ngth: -46~5 mm (1.831 in.) .
If the free length is not as specified. replace the valve spring.
"""''
I·
(c)
Using a "Pring tester. measure the tension of the valve spring at the spe"cified installed length. lnstall9d tension: At 38.4 mm (1.512 in.): 2g6 -- 328 N (30.2 - 33.4 kgf. 66.6 - 73.6 lbf)
If the instal.led tension is not as specified. replace the valve spring. EM0281
10. INSPECT ROCKER ARM AND SHAFT
(a)
Inspect the valva contacting surface of the rocker arm ' for wear. Correct or replace if necessary.
(b)
Inspect the rocker arm to the shaft· clearance by moving each rocker arm as shown in the figure. Little or no movement should be possible. If movement is felt. disassemble afld inspect. Disassemble th~ ·,alva rockor shaft <~ssembly. HINT: Arrange th6 rocker arms and rocker supports in .. correct order.
EMT~JO
(c)
I
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.
I
£MOOU
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' EG-23
ENGINE - ENGINE MECHANICAL.
·Inspect the oil clearance between the rocker arm and shaft. , • Using a caliper gauge. measure the inside diarne. tar of the rocker arm. , Rocker arm inside diameter: 16.00 - 16.02 mm (0.6299 - 0.6307 in.)
•
Using a micrometer, measure the diameter of the rocker shaft. Rocker shaft diameter: 15.97 - 15.99 mm (0.6287 - 0.6295 in.) • Subtract the rocker shaft diameter measurement from the inside diam<'lter measurement of the rocker arm. Standard oil clearance: 0.02 - 0.04 mm (0.0008 - 0.0016 in.) Maximum oil clearance:
(e)
0.04 mm (0.0016 In.) If the clearance exceeds maximum. rsplace the rocker arm and shaft. Assemble the valve rocker shaft ~ssembly as shown.
Valve Rocker Shaft
(2) (2)
Valve RoGkAr Shaft As$ambly • V&lv.o Recker Support
( 1) {2)
~onf
( 1)
.....
Valve Rocker Arm No.1
Valve Rocker Arm
Compression Spring Valve Rocker Valve Rocker Arm No.1 Arm No.2 (1)
(2)
. EG-24
ENGINE·- ENGINE MECHANICAL: 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.
0.30 mm
Maximum circle runout: 0.30 mm (0.0118 in.)
.· '"
!f the circle run out exceeds the maximum, replace the push rod.
12. INSPECT INTAKE AND EXHAUST MANIFOLDS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.20 mm (0.008 in.)
If warpage is greater than maximum, correct or replace the manifolds.
l_·------------------------~n~~~
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)
SST
1"24951
Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202-70020 (09202-01010. 09202-01020, 90154-80004)
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) (b) Place a new gasket and install the water outlet housing with 2 bolts. Torquo: 19 N·m (195 kgf-cm, 14 ft·lbf)
"
CYLINDER HEAD !NST ALLAT!ON 1. A.
(a)
INSTALL CYLINDER HEAD
Place cyiincler head on cylinder block 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.
Install 12 pointed head cylii1dt~r head bolts HINT: • The cylinder head bolts are tightened in 2. pr~ gressive steps (steps (b) and (d)).' • If any bolt is broken or deformed, replace it. . ia) Apply a light coat of engine oil on the thrllads tnd under the heads of the cylinder hGad b.:> Its. (b) Install and uniformly tighten the 1 0 cylinder head bolts on each cylinder head, in several passes, in the sequence shown.
B.
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.
4
2
5
P2S379 ~24951
Z16537
(c)
".
Mark the front of the cylinder head bolt head with paint.
.I§.
EG-26
I:NGINI'. MCCII-1\NICI\L
ENGINE
(d)
Retighten the cylinder head bolts by so• in \he numerical order shown.
(e) (f)
-
Retighten the cylinder head bolts by an additional so•. Check that the painted mark is now facing rearword.
.
~44lfiJ (f$JJ:~
~QJ·JQ :;
~-J '---, P255~J
I/
I \_f
3
c.
Install recessed head cylinder head bolts Apply a light coat of engine oil on the thn:.ads and ur.dor the heads of the cylinder head bolts. {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. (a)
?'
~
~
.............
16543
3. (a) (b)
4.
P249
.
216"..44
5. (a) (b)
6. (a)
(b) 7. 8. 9. (a) (b) 10.
11. 12.
13. 14.
INSTALL VALVE ROCKER SHAFT ASSEMBLY Place the rocker shaft assembly on tha cylinder head. Install and uniformly tighten the 6 bolts and 2 nuts in several passes. in the sequence :;hov.;n. Torque: 21 N·m (210 kgf-cm, 16 ft·lbf) CHECK AND ADJUST VALE CLEARANCE (See valve clearance inspection and adjustment) INSTALL CYLINDER HEAD COVER Install the gasket to the cylinder head cover. Install the cylinder head cover with 2 seal washers and cap nuts. Torque: 2 N-m (25 kgf-cm, 18 in.-lbf) INSTALL INTAKE. EXHAUST MANIFOLDS AND CARBURETOR ASSEMBLY 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) Connect the PCV hose to the cylinder head cover. CONNECT WATER BYPASS HOSE , CONNECT FUEL HOSE ANO VACUUM HOSES INSTALL SPARK PLUG TUBES AND 0-RINGS Install 4 new 0-rings to the spark plug tubes. Install the spark plug tubes to the cylinder head. INSTALL SPARK PLUGS Torque: 17.5 N-m (180 kgf·cm, 13 ft-lbf) CONNECT HIGH-TENSION CORDS TO SPARK PLUGS FILL WITH ENGINE COOLANT START ENGINE AND CHECK ·FoR LEAKS CHECK ENGINE OIL LEVEL
.. ' -.
•.
EG-27
ENGINE - ENGINE MECHANICAL .
TIMING CHAIN COMPONENTS FOR REMOVAL AND INSTALLATION
" .<
~
Timing Chain COVM Water Pump Pulley
Fan
·.
I
l'ming Chain +Gasket
Crankshaft Pulley
I
~
.......... ......................
--;I I I
I
. __ JI
\
-----
------ Distributor -Assembly
Valve Lifter .
~
,. Camshaft Sprocket
·'
Thrust Plale
..-~:11 -:::::~---
.,
~~j
,_ __
--
--d)"---
,-----
---
Chain Tensioner ',,'" __ _ ---- , +Gasket
----
\
1/JP
' ---
"" •
I
Vibration Damper Crankshaft Sprocket
+Gasket---.;, JN·m (kgf·cm, ft·lbf)J: Specified torque
+ Non-reusable part
Drain
Plug---~::>
I t----+O·Ring .,
EG-28
ENGINE'-· ENGINE MECHANICAL·.
,
TIMING CHAIN AND CAMSHAFT .REMOVAL
--·1
1 . . REMOVE WATER PUMP PULLEY AND DRIVE BELT. {See water pump removal in Cooling System) 2. REMOVE CYLINDER HEAD {See cylinder head removal) 3. REMOVE DISTRIBUTOR (See distributor removal in Ignition System) 4. REMOVE FUEL PUMP {See fuel pump removal in Fuel System) 5. REMOVE OIL PAN (See-oil pump remove! in Lubrication System) 6. REMOVE CRANKSHAFT PULLEY {a) Using SST, remove the pulley bolt. SST 09213-1401 0 (91651-60865), . 09330-00021 (09330-00030) {b) Remove the crankshaft pulley.
HINT: If necessary, remove the pulley with SST. SST 09950-4001 0 (09957 -0401 0), 09950-50010 (09951-0501 o. 09952-05010, 09953-05020, 09954-050:.10)
7. (a) (b)
REMOVE TIMING CHAIN COVER Remove the 8 bolts and nut. Using a pl~stic faced hammer, remove the timing chain covor and gaskat.
8.
INSPECT TIMING CHAIN SLACK Mensure the timing chain slack. Minimum slack: At 98 N (1 0 kgf, 22 lbf) tanslon: 13.5 mm (O.G31 ln.) If the sla.ck is lass than minimum, replace the timing chain and sprockets.
·, .' ·~
-· j •
'
. :
'
ENGINE :_·ENGINE MECHANICAL ·l:l~
EG-29
· ;REMOVE CHAIN TENSIONER AND VIBRATION
DAMPER 10. REMOVE TIMING CHAIN AND CAMSHAFT SPROCKET (a) ·Using SST, remove the camshaft sprocket set bolt . . SST 09960-10010 (09962-01000, 09963-01 000) (b) Remove the timing chain and camshaft sprocket'to~ gather.
.. : .
11. REMOVE CRANKSHAFT SPROCKET Using a screwdriver, remove the crankshaft sprocket. If the crankshaft sprocket can not b~ removod with a screwdriver, use SST. SST 09950-40010 (09952 -04010, 09954-0401 0, 09955-04010, 09957-0401 0), 09950-50010 (09951 -0501 0, 09953-05020) 12. REMOVE VALVE LIFTERS HINT: Keep the valve lifters in correct order.
--
13. REMOVE THRUST PLATE AND CAMSHAFT (a) Remove the 2 bolts and thrust plate . (b) Temporarily install the cylinder headibolt to the camshaft. (c) While turni11g the camshaft, slowly pull out so as not to damage the bearing.
••
Cylinder Head Bolt
-, '-----·---------...::.:.""'::=::..J'
I
TIMING CHAIN AND CAMSHAFT COMPONENTS INSPECTION
1-;zsj.-:j.\':j.·:;::;::j::~f--1 Lc::: I~ --~ .'---,--~ -r=
J
1.
INSPECT TiMING CHAIN AND SPRPCKETS Measure the length with the chain fully stretched. Maximum o:hain Glongatlom 272.2 mm (1 0.736 ln.) If the elongation is greater than meximum, replace tho chain. HINT: Make the same measurements pulling at 3 or more places selected at random. (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.) (a)
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, measure . the diameter of eac. tensioner and vibration damper.
.
Minimum thickness:
Chain tensinner: 12.0 mm (0.472 in.) Vibration damper: 4.0 mm (0.157 in.)
If the diameter is less than minimum. replace the chair tensioner and/or vibration damper. 3.
INSPECT CAMSHAFT
A. (a) (b)
Inspect camshaft for runout Place the camshaft on V- blocks. Using a dial indicator. measure the circle run out at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.)
B.
If the circle run out is greater than maxirnurr:. replace the camshaft. 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
c. (a)
If the cam lobe height is greater than minimum, replace the camshaft. Inspect camshaft journals Using a micrometer, measure the journal diameter. Journal diameter (from front side): STD No.I
£M25J8
43.209 - 43.225 m.;, (1.7011 -.1.7018 in.)
STD No.2.
42.954- 42.970 mm (1.6911 - 1.6917 in.)
STD No.3
4:1.704- 4:1.720 mm (1.8873- 1.68t9ln.)
STD No.4
42.459- 42.475 mm (1.6716- 1.6722 in.)
UfS 0.125 No.1
43.085 - 43.095 mm (t .6963 - 1.6967 in.)
U/S 0.125 No.2
42.837- 42.647 mm (1.6865- 1.6969 i~-y--
U/S 0.125 No.3
42.587 - 42.597 rnm (1.6767 - 1.6770 in.)
U/S 0.125 No.4
42.337- 42.347 mm (1.6669- 1.6672ln.)
U/S 0.25 No.I
42.960- 42.970 mm (1,6913- 1.6917 in.)
U/S 0.25 No.2
42.712-42.722 mm (1.6816- 1.6920 ln.)
U/S 0.25 No.3
42.462- 42.472 mm (1.6717- 1.6721
U/S 0.25 No.4
42.212-42.222 mm (1.6619- 1.6623 in.)
i~.)
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· 4."
EG-31
INSPECT THRUST PLATE
(a)
Install the thrust plate and camshaft sprocket to the cam's haft . (b) Install and torque the set bolt. Torque: 59 N·m {600 kgf.cm, 44 ft.Jbf) (c) Using a feeler gauge, measure the camshaft thrust clearance betwe
•
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. (a)
If timing chain cover is removed from cylinder block: 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 Apply MP grease to the oil seal lip.-
(c)
B. (a)
If timing chain cover is installed to the cylinder block: 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
(b) (c)
Apply tvjP grease to a new oil seal lip. 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 Front
1. (a) (b)
INSTALL CAMSHAFT AND THRUST PLATE Apply light coat of engine oil of the camshaft. Temporary install the cylinder head bolt to the camshaft. (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)
(d)
(e)
(f)
4.
Install tho camshaft sprocket to tha timing chain. HINT: Align the timing chain and camshaft sprocket timing marks. Install the timing chain to the crarrkshaft sprocket. HINT: Align the timing chain and crankshaft sprocket timing r.1arks. Install the camshaft sprocket with the timing chain.
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) 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.
5.
'
(a) 0
.
"
(b)
.,
I:G-33
INSTALL TIMING CHAIN COVER Place naw gasket to the front end plate. Install the timing belt cover with fl'bolts ,and nut.
a
Torque:
6.
10 mm head: 8 N·m (80 kgf-cm, 69 in.·lbf) 12 mm head: 19 N·m (19S kgf-cm. ·14 ft-ibf) INSTALL VALVE LIFTER HINT: Apply light coat of engine oil of tha valve lifter.
""''" 7. (a) (b)
INSTALL CRANKSHAFT PULLEY Install the crankshaft pulley. Using SST, install and torque the pulley bolt.
SST 09213--14010 (91651-60865), 09330-00021 (09330- 00030)
.;
'
Torque: 88 N-m (900 kgf.cm, 65 ft·lbf) 8. INSTALL OIL PAN (See oil pump installation in Lubrication System) g_ INSTALL FUEL PUMP (See fuel pump installation in Fuel System) 10. INSTALL DISTRIBUTOR (See distributor installation in Ignition System) 11. INSTALL CYLINDER HEAD (See cylinder head installation) 12. INSTALL WATER PUMP PULLEY AND DRIVE BELT (See water pump installation in Cooling System)
l,i
EG-34
ENGIN'E- ·ENGINE-MECHANICAL
CYLINDER BLOCK -·IZ
COMPONENTS
~-
-------====Piston Ring (No.1 Compression)
~Piston Ring (No.2 Compresskm)
Oil Filter and Bracket Assembly RH Engine Bracket
Piston Ring_r-_§ (Side Rail) ~
M~unting ~
Piston Ring (Expander)
0
Piston Pin
~
'GI,)
~~
See page EG-53
111 24.5 (250, 18) 2nd Tum so•
Upper Main Bearing---· Crankshaft-----------..,!~
Lower Crankshaft _______ - - - - - . .
~4
Thru~~~:::h:_r
---
+ Gasket---?\l;~
'
6
+Gasket
Oil Strainer
+ Non-reusable part. Precoated part
*
[ffffiJkgf·cm, ft·lbf)j: Specified torque
'oil Pan
'=
ENGINE - ENGINE MECHANICAL
EG-35
PREPARATION FOR DISASSEMBLY
~
'-
:.' -
1. 2. 3.
4. 5. 6. 7. 8. 9. 10. 11. •.•
12. 13. 14.
REMO'vt: FLYWHEEL REMOVE REAR END PLATE INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY REMOVE CYLINDER HEAD (See cylinder heed removal) REMOVE WATER PUMP (See water pump removal in Cooling System) REMOVE ALTERNATOR AND BRACKET REMOVE TIMING CHAIN (See timing chain removal) REMOVE OIL PUMP (See oil pump removal in Lubri.::stion System) REMOVE N0.2 ENGINE HANGER REMOVE OIL DIPSTICK REMOVE OIL FILTER BRACKET AND FILTER ASSEMBlY Remove the 2 bolts. the oil filter br<~c:ket. filtGr assembly and gasket. REMOVE ENGINE DRAIN COCK REMOVE FRONT END PLATE Remove the 2 bolts, front end plete' and gaske·t REMOVE ENGINE MOUNTING ERACKETS ·
CYLINDER BLOCK DiSASSEMBLY
• - j~
.[ •
1
i '
1.
REMOVE REAR OIL SEAL RHAINER Remove the 5 bolts. retainer and gasket.
2.
CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving tho connecting rod back and forth . Standard thrust clearance: 0.150 - 0.330 mm (0.0059 - O.C130 in.) Maximum thrust clearance: 0.30 mm (0.0118 ln.)
If the thrust clearance is greater than maximum, replace the connecting rod assembly. If nocessa;y, replace the crankshaft.
EG-LJS
ENGINE.- 'ENGINE· MECHANICAL 3.
··(a) (b)
REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE Check the matchmarks on the connecting rod and cap to ensure correct reassemi.:y. Remove the 2 connecting rod cap bolts.
I
,..-,--· Plastigage
(c)
Using the 2 removed connecting rod bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted with the .connecting rod cap.
(d) (e)
Clean the crank pin and bearing. 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) (g)
Lay a strip of Plastigage across the crank pin. Install the connecting rod cap with the 2 bolts. (See step B in cylinder block assembly) Torque:· 1st: 24.5 N·m (250 kgf·cm, f 8 ft-Jbf) 2nd: Turn
go•
NOTICE: Do not turn til<. cronbhaft. (hj Ramovo the 2 bolts and connecting rod cap. (Sa~ procedure (b) and (c) abova) (i) Measur~ the Plastigage at its widest point. Standard oil c!oarance: STD: 0.020 - 0.048 mm (0.0008 - 0.0019 ln.) U/S 0.25, U/S 0.50 end U/S 0.75: ·. O.o19 - 0.068 mm (0.0007 - 0.0022 ln.) Maximum oil clearance: 0.08 mm (0.0031 ln.) If the oil'. clearance is greater than maximum, replace . the bearings. If necessary, grind or replace the crankshaft.
ENGINE MECHANICAL
ENGINE
HINT: If using a standard bearing. replace it with one having the same number marked r,n the connocting ·rod cap. There are three sizes of standard hearings, marke<1 '1", "2" and '3" accordingly. Standard sized bearing cantor well thickness:
I-,~'·'"'' Mark 1, 2 or 3
EG-37
~ (
M••
STD-Mark
(Protrusior.)
~
1.488 - 1.490 mm (0.05S5 - 0.0587 ln.)
STD Mark 2
1.490 - 1.494 mm (0. 0587 - 0.0588 in.)
STD Mork 3
1.494 - 1.498 mm (0.0588 - 0.0590 ln.)
u;s o.25
1.807 - 1.813 mni (0.0833 - 0.0835 in.)
u;s o.so
1.732 - 1.738 mm (0.0682 - 0.0684 in.)
u;s o.75
1.857 - 1.883 mm (0.07 ~ 1 - 0.0733 ln.)
Completely remove the Plastigage. REMOVE PISTON AND CONNECTlNf> ROD ASSEMBLIES (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 togather. Arrange the piston a11d conn&cting rod al;sernblies 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, replaol' tha thrust washers as a sat. Thruot washer thlckne ..:
Ul 4.
'
..
•
•
•-
•
'
-
2
6.
~
(a) ··•
..
~
STD
2.430 - 2.480 mm (O.OU57 - 0.0978 ln.)
0/S 0.126
2.490 - 2.540 mm (0.0980 - 0.1 000 ln.)
1
I
REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE Uniformly loosen and remove the 1 0 main bearing cap bolts in several passes, in the sequence shown.
EG-38
ENGIN'E '-' ENGINE MECHANICAL
(b)
Using the'removecl main bearing· cap bolts. pry the • main bearing cap back and forth. and remove the main · bearing caps. lower bearings and lower thrust washers (No:3 main bearing cap only) .. HINT:
• •
Keep the lower bearing. and main bearing cap together. Arrange the main bearing caps and lower thrust washers in correct ord.er.
(c)
Lift out the crankshaft. HINT: Keep the upper bearing and upper thrust washers together with the cylinder block.
(d) (e)
Clean each main journal and bearing. Check each main journal and bear.ing for pitting and scratches. If the journal or bearing is damaged, replace the bearings, If necessary, grind or repiace the crankshaft.
Place the crankshaft on the cylinder block. 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: (f)·
Plastigage
(g)
STD
0.016 - 0.040 mm (0.0006 - 0.0016 in.)
U/S typo
0.017 - 0.071 mm (0.0007 - 0.0028 in.)
-
Maximum: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum. replace the bearings. If necessary. grind or replace the crankshaft.
ENGINE -
.'
.: .
..
1:'/0,3 r=-.
~··
..
...
·..
~
j~ ;---. LjJ """
0
~
·HINT: If l'!Sing ·a standard bearing, replace with one having the same number. If the number of the bearing· c2nnot be determined, select a be·aring from the table according to the numbers imprinted on tf':q r.vlinder block· and·crankshaft. ThtJre are 5 sizes of standard· bearings, marked "3", "4", "6" ond "7" accordingly.
No!~'{t" :r;::..
'"' · ' , ~/.%"
.·
'•
EG-39. . ·-' . .
ENGINE MECHANICAL · · ·
Mark 6,7or8
·s·.
.
~ ~
NumbP.r marked Cylinder block
8
7
6
Crankshaft
1
213
Use bear!ng
5
4i3 6!5 4
t 12
3
1 2
3
6
5
7
EXAMPLE: Cylinder block "6'' - Crankshaft "2" = Total number 4 (Use bearing "4") \).\)>:::;;;>Mark
Reference:
3,4,5,6 or 7
Cylinder block main Journal bore diamotAr:
P25&51
P25584
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
Mcrk 2
49.984
49.992 mm (I .967~ - 1.9682. in.J·
Mark 3
49.992
50.000 mm.(l.9d82 - 1.96851o.)
49.984 mm (1.9796- 1.9679 in.)
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.)
,_f~rk.
---
s·
1.998 2.002 mm. (_O.o787 -· 0.0708 l n R 2.002 - 2.006 mm (0.07ell - 0.0790 ln.) ;
Mark B IJJ., , .. 0 •• 2r.::l
2.006- 2.0!0 mrn (0.07PO- 0.0791 in.) -- --·· 2.112 - 2. I m:n I - 0.0835 lr.J
L:u;so.so
2.237 - 2.247 mm (O.OU8l - 0.0885 _ln.)
~'
(k)
Made 7
-
2~
Corupletely remove tha
t0.0~3
•
1
J
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:).
.. ENGINE :.-·.ENGINE MECHANICAL ,..
I
,-------------------~~~~~~~~~~~~~~~---------------
:·
.
CYLINDER· BLOCK INSPECTION , ... " ... ··.: . , ... 1-
--11
..
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-
~ P25!'i2J f'25524'
'\9!:
~ ~
~~\-~.
'
./
\_ 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.
EG-41
ENGINE - ·ENGINE'MECHANICAL· · · ·
Front,._
Cf'j \:1]
•Using .. a ·cylin.der gauge, m·easure the cylinder bore diameter at positions A, B and C in the thrust and axial directio(ls.
CD Thrust Direction
Standard diameter:
Direction
STD:Merk 1
.,
.
80.500- 8C.b10 mm 13.1693··- 3:16971n.)
STD Mark 2
60.51 0 - 80.520 mm .(3.1697
STD Mark 3
80.520-80.530 mM (3.1701 - 3.1705 in.)
0/S 0.50
81.000 - 81.030 mm (3.1890 - 3.1902 i,,,)
3.1701 in.)
Moxlmum diomotor: STD
80.728 mm (3.178~ in.)
0/S 0.50
81.228 mm (3.1g79 i.1.)
---'-----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 DlSASSEMBL Y 1.
......._"
CHECK FIT BETWEEN PISTON AND PJSTON.Pm Try to move the piston back and f~rth on the pi~ton p!n. If any movbm~nt is felt, replace the pi3ton and ·pin cS' a sat.
2. · · REMOVE PISTON RINGS (a) Using a piston ring expander, remov& the 2 compression 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. {a)
CLEAN PISTON Using a gasket scraper, remove the carbon· from the piston top.
{b)
Using a groove cleaning tool or broken ring, clean the piston ring grooves.
{c). Using. solvent and a brush. thoroughly clean the piston. NOTICE: Do not use a wire brush.
l
: t
i
- ENGINE "-: ENGINE MECHANICAL
Front Mark
' .... '
. ··...
;
~
. , 2 or3
EG-43'·
., 2: · 'JNSPECT'PISTON A. 'Inspect piston oil clearance HINT: There are three sizes of tha standard. piston diameter, marked 1, "2" and "3" accordingly:'The markis 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
i
STO Mark 2
80.308 - 80.378 mm (3.1641 - 3.1645 in.)
I
STD Mark 3
80.378 - 80.388 mm i2.1645 - 3.1649 in.)
0/S 0.50
80.858 - 80.888 mm (3.1 &34 - 3.1846 in.)
I
,,
(b)
.
•
(c)
.-
80.358 - 80.368 mm (3.1637 - 3.1641 In,)
Measure the cylinder bore diameter in the thrust directions. {See step 4 in cylinder blo~k inspectionf 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& P2$5SS
216541
. B;
Inspect piston ring groove clearance Using ··a· thickness gauge, measure thA clearance between· new piston ring and the wall of the piston ring groove. Ring groove clearance: No.1: 0.030 - 0.070 mm (0.001 2 - 0.0028 in.) No.2: 0.020 - 0.060 mm {0.0008 - 0.0024 in.)
If the clearance is greater thon m2ximum, replace the piston.
·
EG-44' .. ·
ENGINE·:-.·ENGINE MECHANICAL . .
·. ·.... ... :·
.c. ·
lnspect,piston.. ring end gap (a). lnsert..thecpiston ring into the cylinder bore. (b) Using a piston, push the piston ring·· a little beyond the .· · 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: Standard
Item' .
0.23 - 0.33 mm
No.1
(0.0091 - 0.0130 ln.) 0.33 - 0.48 mm
No.2
(0.0 130 - 0.0189 in.) 0.18- 0.38mm
Oil (Side roil)
(0.0071 -0.0150 ln.)
Maximum 0.33 mm (0.0130 ln.) 0.48 mm (0.01_89 in.) 0.38 mm (0.0150 in.)
"
If the and gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, reb'ore all the 4 cylinders or replace the cylinder block.
3. . A.
I
I
~~~~0~35~£~M~0,~88~--------·------~
I
INSPECT CONNECTING ROD.
Inspect connecting rod alignment Using a rod aligner and thickness gauge, check the connecting rod alignment. Che~k for bend. • Maximum bond: 0.05 mm (0.0020 ln.) per 100 mm (3.94 ln.)
If bend is greater than maximum, replace the connecting rod assembly. • . Check for twist Maximum twist: 0.05 mm (0.0020 ln.) per 100 mm (3.94 ln.)
If twist is greater than maximum, replace the connecting rod assembly.
ENGINE -'ENGINE MECHANICAL
B.
t\;·4b
Inspect connecting rod bolts Using vernier calipers. measure tile minimum diameter of the compressed bolt at tho measuring point .. Standard diameter: 8.860 - 9.000 mm (0.3488 - 0.3543 in.) Minimum diameter: 8.60 mm (0.3386 in.)
If the diameter is Jess than minimum, repl2ce the ~£ connecting rod bolt.
About 20mm rc67'8
CYLINDER BORING HINT:
•
1. .
•
•
'
Bore all the six cylindars for the oversized piston outside diameter. o Replace all the piston rings with ones to match the oversized pistons. SELECT OVERSIZED PISTONS Oversized piston diameter: 0/S 0.50 80.858 - 80.888 mm (3.1834 - 3,1846 in.)
2.
•
(a)
--
(b)
CALCULATE AMOUNT TO BORE CYLINDERS Using a micrometar, measure the p'iston diamet3r at right angles to the piston head side, 8 mm (0.31 in.) from the piston pin center line. Calculate the amount of each cylinder is to be rebored as follows: Size to be reborod = P + C ·- H P = Pi•ton diameter C
=
Piston clearance
0.040 - 0.060 mm (0.0016 - 0.0024 in.) H = Allowance for honing 0.20 mm (0.0008 ln.) or lft$1
3.
BORE AND HONE CYLINDER TO O:ALCULATED DIMENSIONS Maximum honing: 0.02 mm (0.0008 in.) NOTICE: Exce .. honing will dastroy the flniohad roundneal. -1'-IC
•J ._,
CRANKSHAFT INSPECTION AND REPAIR
-I''
1. (a) (b)
'- J
1
INSPECT CRANKSHAFT FOR RUNOUT Place the crankshaft on V-blocks. 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-~
2. (a)
ENG.INE.MECHANICAL
If the circle runout. is greater than maximum, replace the crankshaft. INSPECT MAIN JOURNALS AND CRANK PINS Using .. a .micrometer. measure the diameter of each main journal and crank pin. Diameter: Item
STD
u;s 0.25 u;s o.5o U/S 0.75
(b)
Main journal
49.976 - 50.000 mm
Cranck pin ~7.988
- 48.COO mm
(1.9676 - 1.9685 in.)
(1.8893 - 1.8828 i.1.)
49.733 - 49.743 mm
47.738 - 47.750
(1.9580 - 1.9584 in.)
(1.8794 - 1.8780 in.)
49.483 - 49.493 mm
47.488 - 47.500 mm·
(1.9481 - 1.9485 in.)
(1.8696 - 1.8701 in.)
-
47.238 - 47.250 mm
ffiOI
( 1.8598 - 1.8602 in.)
If thc.di.ameter is not as specified, check the oil clearance (S.ee steps 3 and 6 in cylinder block disassembly). If necessary, grind or replace the crankshaft. 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.)
3.
•
If the taper and out-of-round is greater than maximum, replace the crankshaft. IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/OR CRANK PINS Grind and hone the main journals and/or crank pins to the finished undersized diameter (See procedure in step 2). Install new main journal and/or crankshaft pin undersized bearings .
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
STD No.3
42.750- 42.785 mm 11.6835- 1.6R44 in.)
--
STD No.4
42.500 - 42.525 mm 11.6732 -· 1.6742 in.)
U/S 0.125 No.I
43.120 - 43.151 mm (1.6976 - 1.5989 in.)
u;s 0.125 No.2 u;s 0.125 No.3 u;s 0.125 No.4
42.890- 42.930 mm 11.6886- 1.6902 in.)
42.390-
U/S 0.25 No. I
42.995 - 43.026 mm (1.6927 - 1.6939 ln.)
U/S 0.25 No.2
42.765 - 42.805 mm (1.6837 - 1.6852 in.)
U/S 0.25 No.3
42.515 - 42.555 mm (1.6738 - 1.6754 in.)
U/S 0.25 No.4
42.265 - 42.'30t: mm (1.6ti40 - 1.6655 in.)
·--
42.640 - 42.680 mm (1.6787 - 1.6803 in.) 42.4~0
mm 11.6589 - 1.6705 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 No.2 and No.3
U/S Typo '---
0.025 - 0.066 mm 10.0010- 0.0028 in.) 0.040- 0.081 rnm 10.0016- 0.00321n.)
No.1
0.025 - 0.066 mm 10.0010 - 0.0026 in.)
Oth~:~rs
0.043 - 0.093 mm 10.0017 - 0.0037 in.)
Maximum oil clearanca: 0.10 mm (0.0039 ln.)
If the clearance is 9reatar than maximum, replace tha camshaft bearings. If necessary, -rRplace the camshaft.
,..,. I
2.
IF NECESSARY, REPLACE CAMSHAFT BEARINGS
A.
Remove expansion plug Using SST and a hammer, tap out the expa:-tsion plug. SST 09215-00101 (09215-00130. 09215-00150, 09215-00211) 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)
B. ,·
..
· EG-48 . '·
ENGINE- ENGINE :MECHANICAL C. (a)
Install new camshaft bearings. Install ne'yV bearings in their proper location . . ·.
No.1
•···
No.2
No.3
No.4 500291
(b)
(c)
Align the oil holes of the bearing and cylinder block.
Using SST, install the camshaft bearings. SST 09215-00101 (09215-00121, 09215-00130, 09215-00141.09215-00150,09215-00161, 09215-00221)
D. E. (a)
ZI~J I
Check camshaft oil clearance (See step 1 above) Install expansion plug Apply liquid sealer to the expansion plug surface of the cylinder block. (b) Using SST and a hammer, drive in thoJ expansion plug to 11 distance of 2 mm (0.08 in.) from the cylinder block edge. SST 09215-00101 (09215-00231)
VALVE LIFTERS AND VALVE LIFTER BORES INSPECTION (a)
INSPECT VALVE LIFTER OIL CLEARANCE 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.
"""' '
•
.-
0
REPLACE CRANKSHAFT REAR OIL SEAL
A.
If rear oil seal retainer is removed from cylinder block: {a). Using screwdriver and hammer, tap out the oH seal. {b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oii seal edge . SST 09223-15020, 09608-30012 {096PB-04020) (c) Apply MP grease to the oil seal lip.
B. {a) (b)
If rear· oil seal retainer Is installed to .:ylinder block: Using a knife, cut off the oil seal lip. Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage ·tha cronk•haft. Tape the screwdriver tip.
C:Jt Position
I~
=* {c)
{d)
Apply MP grease to a new cil seal lip. Using SST and a hammer, tap in the oil se~l until its surface is flush with the rear oil seal retc:iner edge. SST 09223-15030, 09608-30012 {09608-·04020)
EG-50
ENGINE
Front
~-ENGINE
PISTON.AND CONNECTING ROD ASSEMBLY
fvhrk---~
(Cavity;
MECHANICAL ...
J
co... '"
1. ASSEMBLE PISTON AND CONNECTING ROD (a). Coat the piston pin and. piston holes with engine oil. (b) Align the front marks of the piston and connecting rod.
Front Mark-----0~~~ (Protrusion)
(c)
Using SST. press in the piston pin. SST 09221-25025 (09221-00020, 09221-00030; 09221 -00040, 09221 -00170, 09221 -0021 0)'
2. (a)
INSTALL PIS"T:ON RINGS Install the oil ring expander and 2 side rails by hand.
(b)
Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Coda mark: No.1 1N
-.
pz:£/11
3/:
,:;~
No.2 2N
_"----------------·~
LIP_>s_.._,_.,_ ..
(c)
Side nail (Upper)
..
Position tho piston rings so that the ring ends are as .shown. NOTICE: Do not align the ring ends.
Front
'
Froni: M;:Jrk
(Cavit·rl
No.i and Expander
Side Rail (lower) P25537
)
ENGiNE
-~
ENGlNE MECKANICAt· ..
EG-51 ·
3: INSTALL BEARINGS (a)
Align·the bearing claw with the groove of the r.onnecting rod or connecting cap. (b) Install the bearings in the connecting rod and conriecting rod cap.
·-
~,
.
~ iir~
P06443 P07010
105505
CYLINDER BLOCK ASSEMBLY
1.
l
(a)
(b)
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. INSTALL MAIN BEARINGS HINT: Upper bearings have an oil groovo and oil holes. lower bearings do not. Align the bearing c!aw with the claw groove of the cylinder block, and push in tha 5 upper b'earings.
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;
3.
4. A. (a)
INSTALL UPPER THRUST WASHERS lnstail· the 2 thru;;t washers under the No.3 journal position of the· cylinder block with the oil grooves facing .. outward. PLACE CRANKSHAFT ON CYLINDER BLOCK
INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS Place main bearing cap and lower thrust washers on cy!inder block Install th& 2 thrust washers on the No.3 bearing cap with the grooves facing outward.
----------'-·---,,.----...::""c:.'::.:"....s
..
rd-
r"O\ /
h
L
o
If(/
~""'"' h o ' It=
"" r-
~
:j
\::.
Install the 5 main bearing caps in their proper locations. . HINT: Each bearing cap has a nun;ber and front m·ark ..
B. (a)
Install main bearing cep bolts . Apply light coat of engine oil on the threads ar.d uncier heads of tha main bearing .cap bolts. Install and unifo;mly tighten the 10 bolts of the main bearing cap bolts in several passes, in the sr;quence shown.
t1r 0
}-
~- J\l~lf' ~ =;,c S; "' ~-
(b)
or>
~
Q..J
~
~
El17003
a
(b)
Torquo: 59 N·m (600 kgf-cm, 43 ft-lbi) P25~04
'------------
Check that the crankshaft turns smoothly. Check that the cra11kshaft thrust clearance. (Sae ste:-- 5 in cylinder block disassembly) INSTALL PISTON AND CONNECTING ROD ASSEMBLIES Using a piston ring compressor, push 'he correctly numbered piston and connecting rod assemblies into each cylinrler with t';a front mark of the piston facing forward.
(c) (d)
5.
/
Front
•
EG-54
ENG'INE:..: ENGINE' MECHANICAL
'pOST ASSEMBLY
CGOV••I
L
INSTALL ENGINE MOUI'iTING BRACKETS Install the brackets with the 4 bolts. Torque: 39 N-m (400 kgf-cm. 29 ft-lbf)
2.
INSTALL FRONT END PLATE Install a new gasket
""""'
3.
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 ALTERN A TOR BRACKET ~·rorque: 26 N-m (270 kgf-cm, 20 ft·l~f) 10. INSTALL ALTERNATOR 1 ~. INSTALL WATER PUMP (Sea water pump inst111lstion in Cooling System) 12. INSTALL CYLINDER HEAD (See cylinder head installGtion) 13. REMOVE ENGINE STAND 14. INSTALL REAR END PLATE · Torque: 8 N-m (80 kgf·cm, 69 ln.·lbf) 15. INSTALL FLYWHEEL (a) Install the flywheel on the crankshaf~. (b) Install and uniformly tighten the 6 mount bolts in ' several passes. in the sequence shown. Torquo: 83 N-m (850 kgf-cm, 61 ft-lbf)
"
,;··
"""'
EG-53
ENGINE - ENGINE MECHANICAL : 6.
INSTALL CONNECTING ROD CAPS
A. (a)
Place connecting rod cap on connecting rod Match the numbered connecting rod cap with the connecting rod. (b) l!'lstall the connecting rod cap with the front mark facing forward.
Front Mark (Protru!_!:s~io~n:.!)~~~~
B.
lnstoll connecting rod cop bolts HINT:
•
•
I
The connecting rod cap bolts are tightened in 2 progressive steps (steps (b) and (d)). • If any connecting rod bolt is broken or deformed. replace it. (a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. (b) Install and alternately tighten the 10 bolts of the connecting rod cap in several passGs. Torque: 24.6 N·m (260 kgf.cm, 18ft·lbf) If any one of the connecting rod cap bolts does not · meet the torque S!Jecification.' replace the connecting rod cap bolt. (c) Mark tho front of the connecting rod cap bolt with paint.
Fro~~ Painted Mark
I I .---.,.--,i;*:~~ ') ,
.i
I.
{d) Retighten the connecting rod cap bolts 90" as shown. (e) Check that the painted mark is now at a 90" angle to the front. (f) Check that tha crankshaft turns smoothly. (g) Chack that the connecting rod thrust clearance. {See step 2 m cylinrlcr b!nck disassembiyl
-
. _ _ I_ _ _ _ _ _ _ _ _ _ _ : _ : . _ _ ; .
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 OAT A
.
STD
at 250 rpm
Compression
Minimum
pressure
at cold
Valve
clearance Dwell angle
Intake
0.13 mm (0.005 in.)
Exhaust
0.23 mm (0,009 in.)
Engine at normal opera:ing temperature
46
Ignition timing
Engine at normal operating temperature
Idle speed
Engine at normal operating temperature
700- 800 rpm
Cylinder t".ead
Warpage
Maximum Maximum
ManifOld side
Valve seat
Intake
Exhaust Inside diameter
bushing
Outside diameter (for repair part)
STD
STD
13.000- 13.027 mm (0.5119- O.S129 in.) 13.050 - 13.077 mm (0.5138 - 0.5149 in.) so- 1oo·c (176 -212"Fl
Intake Exhaust
Minimum
Intake Exhaust
Valve face angle Intake
.,,
I
I I
Valve spring
Oavlation
·.
..
7.960-7.986 mm (0.3134 ·- 0.3144 in.) 0,019 - 0.1)79 mm (0.0007 - 0.0031 in.)
•
ExhauJO;t
Maximum
Intake
0.08 mm (0.0031 in.l
Exhaust
0.1 0 mm (0.0039 in.)
STD
0.024 - 0.075 mm (0.0009 - O.OC30 in.)
I
Intake
1,0 - 1.6 mrn \0.039 - 0.063 in.)
Exhaust
1.2- 1.9 mm (0.047- 0.071 in.)
!r.taba
0.9 """ (0.031 ln.)
Exho1.0st
O.U mm (0.035 in.)
I I
I I
. ·- --1.6 mm {0.083 in.)
Mox1mum
46.~
at 38.4 mm (1.512 in.)
mm (1.831 in.)
296 -· 328 N (30.2 - 33.4 kgf, 06.0 ·- 73.8 lbl)
Valve rocKer
Arm· inside diameter
16.00 - 16.02 mm !0.11299 - 0,6307 in.)
arm and
Shaft die-meter
15.97 - 15.99 mm (0.6287 -
shaft
Oil clearance
Push rod
Circle runout
Valve lifter
Lifter diameter
· STD
Oil clearance
0.62~9
in.)
0.02- 0.04 mm (0.0006- 0.0016 in.)
Maximum
0.04 mm (0.00 1 6 in.)
Ma'xlmum
0.30 mm (0.0 11 B in.) 21.387- 21.404 mm (0.9420- 0.8427 in.) 21.417 - 21.437 mm (0.8432 - O.C440 in.j
Lifter bore diameter
,.
7.951 -7.991 mm (0.3130- 0.3146Jn.)
Intake
Fres length
Installed tension
99,6 mm (3.921 in.)
Exhaust
Minimum
I
I 00.1 0 mm (3.941 in.) 99.4 mr.: (3.913 in.)
STD
I
Margin thickness
99,90 mm (3.933 in.)
44.5·
Stem diameter StiJm oil clearance
1.2 - 1.9 mm (0.047 - 0.071 in.)
0/S 0.05 Replacing temperature (Cylinder head side)
Valve overall hmgth
1.1 - 1,7 mm (0.043 - 0.067 in.)
8.0 I 0 - 8.030 mm (0.3154 - 0.3161 in.)
Valve guic!e
Valve
0.1 0 mm (0.0039 in.)
45"
Contacting angle
•
0.05 mm (0,0020 in.)
ao·. 45•. 6s·
reiacing engle
Contar:ting width
•
sa·@ idle
9- 15" BlOC@ idle
Cylinder block side
.
795 kPa (9.0 kgl/cm'. 129 psi) 98 kPa (1.0 kgf/cm', 14 psi) or loss
Difference of pressure botweon onch cylinder
.
-
931 kPa (9.5 kgf/cm', 135 psi) or more
STO Maximum
0.013 - 0.050 mm (0.0005 - 0.00?.0 in.) 0.10 mm (0.0039 in.}
I I
----'
EG-56
F.NGINE'~.
Manifolds
'Narpage
Camshaft
Thrust clearance
ENGINE: MECHANICAL· 0.20 mm (0:0078 in.).
Maximum
5TD
0.07
0.3 mm (0.012 in.)
Maximum Journal oil clearance
No.1 end No..4
5TD
0.025 - 0.066 mm (0.001 0 - 0.0026 ln.)
1
O.CJ40- 0.081 mm (0.0016- 0.0032 in.)
No.2 end tJo.3·'
U/5 Type
No.I .
0.025 - 0.066 mm (0.001 0 - 0.0026 in.) 0.043 - 0.093 mm (0.0017 - 0.0037 in.)
Others
Maximum ·SiD
Journal dbmflter (f;om front side)
U/5 0.125
U/5 0.25
'
0.14 mm (0.0028 - 0.0055 in.)
0.10 mm (0.0039 in.)
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.)
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.)
No.I
42.960- 42.970 mm (1,8gl3- 1.6917 in.)
No.2
42.712-
No.3
42.462- 4:<:.472 mm (1.6717- 1.6721 ln.)
No.4
42.212-42.222 mm (1,8619- 1.6623 in.)
No.I
43.250- 43.275 mm (1.7028- 1.7037 in.)
'
Bea.ring inside diameter (from front side)
STD
•
U/S 0.125
I U/5 0.25
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.)
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.)
No.4
42.390 - 42.430 mm (1.6689 - 1.6705 in.)
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.)
Maximum
Circle runout
5TD
Cam lobtt height
I
0.06 mm (0.0024 ln.)
· Intake
36.47 - 36.57 mm (1.4358 - 1.4397 ln.)
Exhtual
~--·~··
end sprocket
Chein tensioner end vibration
c.Jamper
Minirnt:m
Chair. ::lock e\ 98 N (I 0 kgf, 2.2 ibn tension Chain olongotion
36.37-- 30.47 """ (1.4318- 1.4358 ln.)
lntck&
26.17 mm (1.4240 ln.)
Exhaust ·.
36.07 mm (1.4201 h)
-- r·
Minumurn
13.5 mm (O.G31 ln.)
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.)
Minimum
4.0 mm (0.167 ln.)
Ol!lmper diornetoi
.
ENGINE·- "ENGINEMECHANI.CAL
.. Cylinder block
Cylinder head surfecttwarpege
..
Maximum
STD
Cylinder bore diameter
0.05 mm (0.0020 in.)
Mark 1
80.500 - 80.51 0 mm {3.1693 -
3.16~7
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
in.)
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.)
l
Cylinde!' block main journal bore diameter
STD Mark 6
Pistori and
Piston diameter
Mark 7
54.012 - 54.020 rnm (2.1285 - 2.1268 in.)
Mark 8
54.020- 64.028 mm (2.1288- 2.1271 ln.)
STD Mark 1
80.358 - 80.368 mm (3.1537 - 3.1641 in.)
Mark 2
80.368 - 80.378 rnm (3.1641 - 3.1645 ln.)
Mark 3
80.378 - 80.388 mm (3.1645 - 3.1349 in.)
piston ring
0/S 0.50 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.)
STD No.1
Piston ring end gap
No.2
0.33-0.48 mm (0.0130- 0.018g io.) 0.18 - 0.38 mm (0.0071 - 0.0 ISO io.)
No.I
0.33 mm (0.0 130 in.)
No.2
0.48 mm (0.01 89 ln.)
Oil (side rail)
0.38 mm (0.0150 ln.)
STD
Thrust cleerance
Maximum
rod
Connecting rod bearing center
w~ll
..
!
I Connecting rod oi! clearenca Rod
0.150-0.330 mm(0.0059 -.0.0130 in.) 0.30 mm (0.0 11 8 ln.) 1.486 - 1.490 mm (0.0585- O.OS8i in.) 0.058~ ln.)
Mark 2
1.490 - 1.494 mm (0.0587 -
Ml!llrk 3·
1.494 - 1.498 mm (0.0588 - 0.0590 in.)
U/S 0.25
1.007 -. 1.613 mm (0.0833 - 0.0835 ln.)
I
U/S 0.60
1.732 - 1.738 mm (0.0&82 - 0.0684 in,)
I
U/S 0.75 STD
1.857 - 1.883 mm (0.0731 - 0.0'133 in.) 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.)
~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
Minimum
.-.
.
thickness
STD Mark 1
I
0.23 - 0.33 mm (0,0091 - 0.0130 in.)
Oil (sido rail)
Maximum
Connecting
80.858 - 80.888 mm (3.1834 - 3.1846 in.) 0.132 - 0.152 mm (0.0052 - 0.0060 ln.)
Piston oil clearance
,,
54.004- 54.012 mm (2.1281 - 2.1265 in.)
8.880 - 9.000 mm (0.34aO - 0.3543 in.) 8.60 mm (0.3388 ln.)
EG-58 Crtmkshaft
ENGINE- ENGINE MECHANICAL. STD
Thrust clearanco
0.040 - 0.242 mm
Thru~t
STD
2.430·- 2.480 mm ·(0.0957 - 0.0976 in.) 2.490-; 2.540 mm (0.0976- 0.1000 in.)
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 jo:.Jrnal oil cJegrance
Main bearing center wall thickness
STD
1.9~79
Mark 1
49.976 - 49.984 mm (1.9796 -
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.)
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 Crank pin diameter
- 0.009.5 in.}
0/50.125
wa:;her thickness
Main journal diameter
~0.00 t 6
0.30 mm {0.0 1 t 8 in.)
Maximum
in.)
2.237 - 2.247 mm (0.0881 - 0.0885 in.)
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.)
U/S 0.75
47.238- 47.250 mm (1.859~- 1.8602 in.)
Circle runout
Maximum
Main journal taper and out-of-round
Maximum
I I
0.06 mm (0.0024 in.}. 0.02·mm (0.0008 in.)
'Crank pin taper and out-of-round Maximum 0.005 mm (0.0002 in.) ~----------L-------~----------------------~------~----~------~--------__J
ENGINE
EG-59
ENGINE MECHANICAL
TORQUE SPECIFICATIONS N·m
kgf-cm
Spark plug x Cylinder head
17.5
180
0;-:tributor x Cylinder block
12
120
9
29.5
300
22
Part tightened
Cylinder head x Cylincfer block
-.
12 Pointed head
1st 2nd
Turn
so•
Turn
3rd
Turn
go•
Turn
Recessed head Rocker arm assembly x Cylinder head
so• so•
ft·lbf 13
so•
Turn •.
Turn so•
t9
195
14
21
210
16
Cylinder head cover x Cylinder h3ad
2
25
18 in.-lbf
Reer ple1e x Cylinder head
8
80
69 !n.-lbf
19 39
195 400
29
W21ter Outlet housing x Cylinder heed Manifolds x Cylinder head
14
Thrust plate x Cylinder block
8
80
69 in.·lbf
Camshaft sprocket x Camshaft
59
600
43
Chain tensioner x Cylinder block
8
80
69 in.·lbf
Vibration damper x Cylinder block
3
80
69 in.·lbf
10 mm head bolt
8
80
69 in.·lbf
12 mm heed bolt
19
195
14
89
900
65
Timing chain cover x Cylinder block Crankshaft pulley x Crankshaft Connecting rod cap x Connecting rod
1st 2nd
Main bearing
c~tp
x Cylinder block
Front end plate x Cylinder block Rear oil seal retainer x Cylinder block
24.5 Turn
go•
250 Turn
18
go•
Torn
go•
59
600
43
19
195
14
8
80
39
400
Oil filter bracket x Cylinder block
19·
195
14
Rear end plate x Cylinder block
8
80
69 in.-lbf
Engin~
..
.
·-·IU
mounting bracket x Cylinder block
-
69 in..lbf
29
No.2 engin& hanger x Cylinder block
37
380
27
Alter011tor bracket x Cylinder block
26
270
20
Flywheol x Crankshaft
83
850
'
I
&;
EG-60
ENGINE - F.UEL
~YSTEM
FUEL SYSTEM PREPARATION
--
SST (SPECiAL SERVICE TOOLS)
~
~
09240-00014
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 LTweezers __ _ _ _ _ _ ,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _
PRECAUTION 1. 2. 3. 4. 5. S.
Before working on the fuel system, disconnect the cable from the negative battery ter~i';a'i. When working on the fuel system, keep away from possible fire hazards ana do not smoke. Keep gasoline off rubber or leather parts. Work on only one component group at a time to help avoid confusion between similar looking parts. Keep work area claan to avoid contamination of the c·arburetor and components. Be careful not to mix up or lose clips or springs.
ENGINE --, FUEL SYSTEM.
•
I:::G-'31 '
. ON- VEHICLE INSPECTION
REMOVE INTAKE AIR CONNECTOR FROM CARBURETOR INSPECT CARBURETOR AND LINKAGE ' installed. Check that the various set screws. plugs and union bolts are tight nnd correctly (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)
_- 1. . ' 2. • (a)
,..
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
' . IM ... II
CARBURETOR REMOVA.L 1. 2.
3.
DISCONNECT ACCELEflATOR CABLE FROM CARBURETOR DISCONNECT CARBURETOR CONNECTOR
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)
4. (a) (b) 5. (a)
INSTALLATION HINT: Use 2 new gaskets. DISCONNECT VACUUM HOSE AND PCV HOSE Disconne.ct the distributor vacuum hose from the carburetor. Disconnect the PCV hose from the insulator. REMOVE CARBURETOR Remove the 4 nuts holding the carburetor to the · intake manifold. Torque: 19 N-m (195 kgf·cm, 14 ft·lbf)
(b) (c) (d)
Lift out the carburetor. Remove the insulator and gaskets assembly. Cover the inlet hole of the intake manifold with a cloth.
INSTALLATION HINT: Uso a new insulator.
' •
EG-63
. COMPONENTS FOR DISASSEMBLY AND-•-N
•
ASSEMB.L Y
-
:
r~ /
Accelerator Cable
·' ·-
Bracket
'
""~~--
Accelerati0n
~
//PumpArm
I
'
~
Wire Clamp
l V
"""'"';k!
7"~
----~' .,_ .AI
01--- Plunger 8 Boot
L'
I@
~"
Snap Ring
Thermostatic Valve
Air Horn Vacuum Hose
r 'I
:1 t, )
+ Gasket
Needle Seat
Neodle
•
''l 11 , • 11 ~
Pump Plunger
Valve~ '"'~ J: [·~"'-._~Spring --....
1
~
:
1 \jJ
~
"'-._
Valve+-~• I ;?"h : ~
SpringTI
PlungertJ--{j Wire
.
_ _ Ac::eleratlon
--<:;
____.....--- /
Needle Valve Assembly
:
Pcwer Piston
·----Float
I~
1
1 I
<:::::::.:::.----Pivot Pin
• +
Non-reusable part
·
I
-----------~
--·-,------ENGINE -'- FUEL' SYSTEM
Primary Small Venturi
Fuel Cut Solenoid
,,
Secondary Small V:::nturi
I
I
I
I
I
1
0
I I
Secondt:lry
I
T~rottle Valve Diaphragm.:
l,
'
I
I Ring--~A
I
1
,)"@ ,_,I
lnsu
+ Non-reusable part
•I I
I
'
+Gasket I
Return
I
I I I I
ir
I
+Gasket
Snap
Wire Clip,
Discharge Weight
Slow Jet
?......~.~-- ....... ' "·: .,...
•
ENGINE - FUEL SYSTEM
CARBURETOR DI~ASSEMBL Y
.
..
(a) (b)
EG-65.
........
...
HINT: These instructions are organized so that you will work only one component group ai " time. This will help you avoid confusion between similar looking parts from different subassemblies being on your workbench at the same time. To facilitate reassembly, arrang3 parts in order. 8e careful not to mix up or lc.se balls, clips or springs.
Air Horn Disassembly 1. 2. (a) (b) (c) (d)
-.j
3.
..I
(a) (b)
REMOVE CARBURETOR STUD BOLT REMOVE ACCELERATION PUMP ARM Remove the snap ring from the pump connecting link. Remove the pivot bolt. Disconnect the pump arrn 'irono the pump plunger. Disconnect the pump connecting !ink and washer from the throttle li!ver and remove the pump arm with pump connecting link. REMOVE THERMOSTATIC VALVE Disconnect 2 vacuum hoses from t~o carburetor. Remove the 2 screws, No. plato, tha thermostatic valve and vacuum hosgs assembly.
" 4. (a)
Pivot Pin
REMOVE AIR HORN ASSEMBLY 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.
fi§F
ENGIN·E ..;- FUEL SYS'fEM
·c.
REMOVE ACCELERATION PUMP PLUNGER
Remove the pump plunger and boot. 7. 8.
REMOVE AIR HORN GASKET REMOVE NEEDLE VALVL. S!=AT
Remove the ne.edle valve seat and 9.
g~sket.
REMOVE POWER PISTON
Remove the screw. retainer, power piston and spring.
,.,.,, .----------------,
. Carburetor Body Disassembly 1.
REMOVE CHECK BALLS FOR ACCELERATION PUMP
(a) (b)
Remove the pump discharge weight, spring and large ball. · Remove the plunger spring.
(c) (d)
Using tweezers. remove the ball retainer. 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) (b)
Remove the 2 passage plugs ar:d gaskets. Rein'ove the primary and secondary main jets 'and gaskets.
5.
REMOVE SMALL VENTURIS
.
Remove the 4 screws. primary, secondary small ventui-is and gaskets.
6 •. REMOVE SECONDARY THROTTLE VALVE DIAPHRAGM
,.
(aj (b) (c)
Disconnect the vacuum hose from' ;he body. Remove the snap ring and washer from the diaphragm link. Remove the 2 screws and throttle valve diaphragm.
7.
REMOVE FUEL CUT SOLENOID
(a) (b)
Remove the wire clip from the fuel cut solenoid. Remove the fuel cut solenoid and gasket.
Snap Ring
8 •. REMOVE IDLE SPEED ADJUSTING SCREW
(a) (b)
Remove the bolt and arm. 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.
GENERAL CLEANING PROCEDURE CLEAN DISASSEMBLED PARTS BEFORE INSPECTION
(a)
With a soft brush wash and clean the cast parts in carburetor cleaner. (b) Clean off the carbon around the throttle valve. (c) Wash the other parts thoroughly in carburetor cleaner. (d) Blow all dirt and other foreign material from the jets, fuel passages and restrictions in the body.
I
I r
·INSPECTION OF CARBURETOR
e
1.
(5)-g
(a)
(3!--Q
l"·~-
INSPECTFLOAT AND NEEDLE_vALVE
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.
·~···
,
.... ,,..... .. ·~··
~···-
·--
...
EG-69. '
ENGINE:..:: FUEL SYSTEM··
3; · INSPECT POWER VALVE ·check for faulty opening and
clo~ing
action.
T P25816
(+)
4. (a)
(b)
'- ~
8EB
INSPECT FUEL CUT SOLENOID VALVE Connect the connector tArminals to the battery terminals: 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. (a)
ASSEMBLE CARBURETOR BODY AND FLANGE Assemble the flanga and body together with a r·.ew insulator. (b) Install the 2· bolts. (c) Install the 2 passage screws together with the spring washers.
2. 3. (a) (b)
4.
INSTALL IDLE MIXTURE ADJUSTING SCREW INSTALL IDLE SPEED ADJIJSTING SCREW Install idle speed adjusting screw and spring. Hook the back spring to the arm, and install the arm with the bolt. INSTALL FUEL CUT SOLENOID Install fuel cut solenoid and wire clamp.
I
. t:G·/0 ·
ENGINE- F.UEL SYSTEM 5.
(a) (b) (c)
INSTALL~ECONDARY THROTTLE VALVE DIAPHRAGM Co.nnect. t.he diaphragm link with the snap ring and washer. Install the throttle valve diaphragm with the 2 screws. Connect t~e vacuum hose to the body.
Snap Ring
6.
INSTALL SMALL VENTURIS Install 2 new gaskets and the pnmary, secondary venturis with the 4 screws.
7.
INSTALL PRIMARY AND SECONDARY MAIN JETS Install the primary and secondary main jets with 2' ' new gaskets. Install the primary and secondary passage plugs with 2 new gaskets. INSTALL POWER VALVE INSTALL SLOW JET
"""" (a) (b)
8. 9.
-_:>,,' ~~-
'.;t!
~
----
S002(<;
10. INSTALL CHECK BALLS FOR ACCELERATION (a) Install the plunger small ball. (b) Using tweezers. install the ball re_tainer.
,..,, (c) (d)
Install the plunger spring. Install the pump discharge large ball. spring and weight.
' . ENGINE - FUEL SYSTEM
'
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.
•
' ENGINE '- FUEL-SYSTEM
EG-72
(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)
B
Adjust by bending the position of the float lip marked
B. (g)
After adjusting the float level. remove the float, plunger, spring and needle valve.
(h) 4.
Assemble the clip onto the needle valve. INSTALL NEW AIR HORN GASKET Place the air horn gasket on the a'ir horn. INSTALL ACCELERATION PUMP PLUNGER Install a new ·boot and the pump plunger.
5.
.,.~\._.-
6. (a)
INSTALL NEEDLE VALVE AND FLOAT 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 (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.
INSTALL ACCELERATION PUMP ARM 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 9. (a)
.. Snap Ring
.,., CARBURETOR ADJUSTMENT 1. (a)
HINT: Ustl SST 09240-00014 to make adjustment. CliECK AND ADJUST THROTTLE V..ALVE OPENING Check the full opening angle of the ;>rimary throttle v&lv~.
Standarci n1gle: so• from horilontsl
(b)
Adjust.by bending the primary throttle stop lever.
m
EG-74
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. (a)
CHECK AND ADJUST KICK-UP SETTING With the primary throttle valve fully opened, check · the opening angle of the seconda~y throttle valve. Standard angle: 23° from horizontal
~gle For
Gauge_,-------,r-r
I
59·_/
30mm (1.18
in.)
31"
70mm (2. 76
in.) YP251'59
(b)
Adjust by bending the secondary throttle kick-up lever.
3. (a)
CHECK AND ADJUST SECONDARY TOUCH ANGLE Make an angl~ gauge as shown in the illustration.
.· ENGINE - FUEL SYSTEM ..
{b)
EG-75
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)
y
Adjust by bending the primary throttle touch laver.
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.
5.
PRESET IDLE SPEED ADJUSTING SCREW
y P?-;7'57
(a)
Check the primary throttle valve angle. Standard angle: 13.5° from horizontal
·-
(b)
Idle Speed
Adjusting Screw y P25761
Adjust by turning the idle speed adjusting screw.
I l
EG-76
ENGlNE'- FUEL SYSTEM.·
r-------:::::;-;;::::::----, .
6.·
7.
a.
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. CHECK FOR SMOOTH OPERATION OF EACH PART 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 • Non-reusable part
TP258:20:
ENGINE •-'- FUEL:SYSTEM .. · •
EG-77
.m
:~:
· FUEL;PUMP REMOVAL
.;
. 1: 2.
DISCONNECT FUEL HOSES I=ROM FUEL PUMP REMOVE FUEL PUMP Remove ·the 2 nuts, fuel pump, gasket, insulator and gasket. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) INSTALLATION HINT: Use 2 new gaskets.
-...x-••
FUEL PUMP INSPECTION (Airtight Test)
Outlet Pipe
•
PRECHECK Before doing these ch~cks on the fuAI pump: (a) Run soma fuel through the pump to insure that the check valves seal tightly (a dry cher;k valve may not seal properly). (b) Without blocking off any pipes, operate the rocker arm and check the amount of force necessary for (lperation and the amount of arm play. This same amount of force should be used in the checks. 1. CHECK INLET VALVE Block off the outlet pipe with your finger and ch~ck that there is an increasa in rocker arr~· play and that the rocker arm moves freely (no reaction force) .
,. .,
2.
CHECK OUTLET VALVE 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 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.
!nlet Pipe
·---------------, Outlet Pipe
EG-76
ENGINE--' FUEL SYSTEM· ·.
4.
'i
..
CHECK OIL SEAL
Block off the vent hole with your finger and check that the rocker arm locks.
j i
I FUEL PUMP INSTALLATION Installation is in the reverse order of removal.
SERVICE SPECIFICATIONS SERVICE DATA 21100-13870
Part. No.
Carburetor
Float level
Raised positiion
Lowered po!:ition Throttle valve opening engle
Primary Secondary
6.5 mm (0.256 in.) 1.5 - 1.7 mm (0.060 - 0.067 in.) 90° from horizontal
so·
·,
from horizontal
Secondary throttle valve Kickup flngle
.
23• from horizontal
Secondary touch engle
59'" from horizontal
Acculeration pump stroke
3.25 - 3.75 mm (0.128 - 0.148 in.)
Idle speed !ngla
Pre-setting
13.5• from horizontal
Idle mixture adjusting screw
Pre-setting
Return 3.75 turns from fulley closed position ----~
TORQUE SPECIFICATIONS Part tightened Carbure tor x
lnta~e
manifold
-,
N·m
kgf·cm
19
195
ft.Jbf
-
14
Fuel pu mp x Cyli;.der Mock
18
185
13
Inlet pip e x Curburotor
24
240
17
.
----
i
·-···· ·-·· --· .. EG-79
. ENGINE -.COOLING SYSTEM
COOUNG SYSTEM
· ·
PREPARATION
:.
. ......
• .· :· SST (SPECIAL SERVICE TOOLS) 09236-00101
...
Water Pump Overhaul Tool Sot
... ' -
....
(09236-1501 0)
Beedng.S~•Y
I .............................................................................................................................. (09237-00010)
.......................
Water Pump Soaring Remover & Roplacer
...................................... : .. : ......................................................................................................................... .. (09237 -00020) Boadng Stay
(09237 -00030) Beadng Stay
(09237-00050) Shaft ·a·
EQUIPMENT Heater
Thermostat
ThermometBr
Thermostat
~
-R.-d~-or-ca--pte-sto-,--~·-------------------------------~·-------·--------------------------Torque wrench
-------=r
COOLANT
r
( Enoine
ltt>m
coola~t
Capac:hy
5.7 Htors (6,0 US qts, 5.0 Imp. qt:;)
~
Cla.ssilication
1 Ethylenc.-glycol base
SSM (SPECIAL SERVICE MATERIALS) 08826-00100
Soal Paoking 12828. THREE BONO 12820 or equivalent (FIPG)
Wator pump
J
,
l.:I.:HlU
ENGINE:-
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.
Drain Cock
{b)
Drain the .coolant from the radiator drain cock and engine drain cock. {Engine drain cock at the front of engine block.) Close the drain cocks.
{c)
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 coolant 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) (f) (g)
Reinstall the radiator cap. Warm up the engine and check for leaks. 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. 2.
P>$461 •.
'
DRAIN ENGINE COOLANT 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, 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.
• .,.
lOUt-eo
COMPONENTS FOR DISASSEMBLY AND ASSEMBLY
--------------------------------------------~-------------------, 10.3 (105, 81
•
Plate
~.av I
+ Gasket + +Seal Set
y
I
I
Water Pump Body
+ Ae!ring
Pulley Seat
I N·m (kgf·cm, it·lbfl +
Non~rcusable
part
Rotor
: Specified torque
•
I
EG-83
ENGINE.- CO.OLING SYSTEM .WATER . . PUMP
•
DISASSEMBLY
1.
REMOVE PUMP PLATE Remove the 3 screws. pump plate and gasket.
Z.
REMOVE PULI.EY SEAT Using SST and a pross, pross thP Lonring
.
sh~ft
and
remove the pulley seat.
SST 09236-00101 (09237-00010, 09237-00050)
3. (a)
·-
(b)
4. S~
REMOVE WATER PUMP BEARING AND ROTOR Gradually heat the water rump body to 75 - as•c (167 - 1as· F). Using SST and a press, press the shaft of the bearing and remove the bearing and rotor. SST 09236-00101 (09237 -00010, 09237- 00050j
REMOVE SEAL SET Using SST and a press. press out 1he seal set. SST 09236-00101 (09236-15010)
I
. IL-----------------------·~~~~"J ~
WATER PUMP ASSEMBLY
1. (a) (b) P25111
.. -..
HINT: Always assemble the water pump with a new seal set. INSTALL WATER PUMP BEARING Gradually heat the water pump boc'{ :o 75 - ss•c ( 167 - las· FJ. Using SST and a press, install the bearing hto the water pump body.
'
EG-84
. ENGINE _:_' COOLING SYSTEM
,..------------......:...--;·.;
..
SST09236~00101 (09237-00020)
2. (a)
(b)
' ..
NOTICE: The bearing and face should be flush with the body top surface. INSTALL SEAL SET Apply a seal set packing to a·new seal and pump body. Seal packing: Part No. 08826-00100 or equivale~t
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)
-
P257l
I 4.
5.
·--------
P2'".)~WI
------'-"~
6.
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. INSTALL PUMP PLATE Install a new gasket
,______
'CNGINE - COOLING SYSTEM
WATER PUMP INSTALLATION '
:;~
EG-85
--··
' 1. (a)
. ' -.... '
(b) 2. I
"""''
(a) (b) (c) (d) 3. 4.
,.·
INSTALL WATER PUMP Temporary install the adjusting bar to the alternator with the adjusting bolt . Install a new gasket and water pl!mp with the 3 bo!ts. Torque: 19 N-m (195 kgf-cm. 14 ft·ibf) INSTALL WATER PUMP PULLEY. FAN, FLUID ~~ COUPLING AND DRIVE BELT Install the fan to the fluid coupling with the 4 nuts. , Tempornry install the water pump-pulley and fan with fluid coupling with the 4 nuts. Install and adjust the belt. (Se& on -vehicle inspecticn in Charging System) Stretch the belt tight and tighien the 4 nuts. Torque: 5.5 N-m (55 kgf-cm, 49 Jn.-lbf) FILL WITH ENGINE COOLANT 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
Thermostat~
~\
u~
·. l<·m (kgl·om, ft•lbOI' Spoo;nod , , : - \ j + Non-reusable part
T P25557
EG-86
ENGINE - cooLING SYSTEM
THERMOSTAT REMOVAL
1.
HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficJen.;y, • Do not remove the thermostat, even if the engi,ne tends to overheat. DRAIN ENGINE COOLANT
J 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
(d)
COOJOO
Z\6616
•
If the valve lift is not as specified, replace the thermostat. Check that the valve is fully closed when the thermostat is at low temperatures (below 4o•c (1 04.F)). If not closed, replace the thermostat.
~
•
ENGINE'·-·coOLING·SYSTEM ··
EG-87
THERMOSTAT INSTALLATION 1. (a)
INSTALL THERMOSTAT AND WATER OUTLET Install a new gasket to th.; th~rmostat.
~
~
· (b) ·Align the jiggle valve of the thermostat with right side of the ·mar~. and insert the thermostat in the water outlet housing. HINT: The jiggle valve may be set-within 10° of either side of the prescribed position. (c) Install the water outlet with the 2 bolts. Torque: 19 N·m (19!; kgf-cm. 14 ft·lbf) 2. FILL WITH ENGINE COOLANT 3. START ENGINE AND CHECK FOR COOLANT Li:AKS
RADIATOR. RADIATOR CLEANING
IOUI-11
Using water or a steam clean·er, remov~ any rnud and dirt from the radiator core. NOTICE: If using a high pre83ure type-ciBaner. be careful not to deform the fin• of the radiator core. (i.e. Maintain
.·
a distan'ce between the cleanP.r noz"'le.and radiat~r cor~.t)
RADIATOR INSPECTION 1.
REMOVE RADIATOR CAP CAUTION: To avoid the donger of bolng burned, do not rom eve tha radiator cap whilft the engine ancf·radiator ore hot. a: fiuid an-i 'iteam can be blown out under
"itm
pras£ure.
2.
INSPECT RADIATOR CAP NOTICE: If the radiotor cap has r.<>ntarninetions, always rinse it with water.
Using a radiator cap tester, pump the taster and measure the vacuum valve opening pressure. Standard oponing pressure: 74- 103 kPa (0.75- 1.05 kgf/cm', 10:7- 14.9 psi)
I Ra1iator Cap COOQJ(
Minimum opening pressure:
59 kPa (0.6 kgf/cm'. 8.5 psi) HINT: Use the tester's maximum reading as the opening pressure.
~·
EG-8B
ENGii'.fE ~· COOLING SYSTEM ..
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/cm 2, 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
1-·-·
Radiator cap
Velvb lift Vecuvm veive opening pressure
I
eo- s4•c 111e- 1B3'FJ
Valve opaning temperature
ot 95'C (203'F)
STD Minimum
8 mm (0.31 in.) or more
74- 103 kPo (0.75- 1.05 kgf/em', 10.7- 14.9 psi) 59 kPa (0.6 kgf/em', 8.5 psi)
·TORQUE SPEC!F!CATIONS Part tightened Drain plllg x Cylinder
~leek
N·m
kgf-cm
ft-lbf
25
250
18
Water rump body ~ Pump p!ete
10.3
105
8
Fluid coupling x \Vater pump
5.5
55
49 in.·lbf
Water pump x Cyiinder block
19
195
14
19
195
14
Water outlet x Water I)Utlet ho:.using
•
0
•
•
ENGINE - LU.BRICATION SYSTEM
, LUBRICATION·SYSTEM
:. i
PREPARATION MU\1··
SST (SPECIAL SERVICE TOOLS)
... --
~
09228 22020
Oil Filter Wrench
09816-30010
Oil Pressure Switch Socket
0 ..
,.. ., __
RECOMMENDED TOOLS 09200-00010
Engin~t Adjus~
Kit.
EQUIPMENT ~-
Oil pressure gauge Straight edge
~T~or=q~u.~.w:=re=n~ch~--------------------------~----+------------------------
.
_,,.,_..
LUBRICANT En;ine oil
-
Cap~city
Item
C/ossificllltlon
API grade SG, SH or !LSAC owltigrade
Dry fill
3,9 liters (4.1 US qts, 3.4 Imp. qts)
engbe oli
Drain and refill
w/ Oil filter charge w/o Oil filter change
I
3.7 litero (3.9 US qts, 3,3 Imp. qts)
-
3.4 liters (3,6 US qts, 3.0 Imp. qts)
SSM {SPECIAL SERVICE MATERIALS) 08826-00080
Soa/ Pecking Black ar equlvo.lent
Oil ran
(FIPG)
. r-------------------~~~==~--~~~--------------~------------------~ 08833-00080
Adhesive 1344, THREE BOND 1344,
LOCTJTE 242 or equivalent
Oi•11ressure switch
EG-90
ENGINE:... 'LUBRICATION SYSTEM. -..
OIL PRESSU'RE CHECK 1.
2. ! ··
3.
CHECK ENGINE OIL QUALITY Check 'the oil for det-erioration, entry of water, dis- ' · coloring or thinning. If oil quality is visibly poor. replace ft. CHECK ENGINE OIL LEVEL The oi: level should be between the "L" and "F" marks on the dipstick If low, check for leakage and add oil up to ·r:· mark. REMOVE OIL PRESSURE SWITCH Using SST. remove the oil pressure switch. SST 09816-30010
= 4.
~'25m
Adhesive ......_____
J~
INSTALL OIL PRESSURE GAUGE 5. START ENGINE Start the engine and warm it up to normal operating temperature. 6. MEASURE OIL PRESSURE Oil pressure: At idle: 29 kPa (0.3 kgf/cm', 4.3 psi) or more At 3,000 rpm: 245 - 490 kPa (2.5 - 5.0 kgfjcm', 36 - 7l psi) 7. REMOVE OIL PRESSURE GAUGE 8. REINSTALL OIL PRESSURE SWITCH (a) Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 03833- 00080, THRF.E BOND 134-4, LOCTITE 242 or equivalent (b) Using SST, install the oil pressure switch. SST 09816-30010 Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) 9. START ENGINE AND CHECK FOR LEAKS
.'
•
EG·91
ENGINE- LUBRICATION SYSTEM.
·OIL ·AND FILTER REPLACEMENT CAUTION:
.•
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation end
dermatiti~.
In addi-
tion, used engine oil contains rotentially harmful contaminants which may cause skin cai1eer. Ade-
•
quate means of skin protection and washing facilit· ios should ba provided. Care should be taken, therofo>re, whan changing engine oil. tc minimize the frequency and length of time your sk!n is exposed to used engine oil. Pro'i:ec-:
tive clothing and gloves, that carmot be penetrated
by oil, should be worn. Wash your'skin
~horoughly
with soap and water. or use water-l~ss h.and cleaner, to remove any usod engine oiL Do not use gasoline. thinners. or solvents. •
In order to preserve the environment, used oil snd
used oil filter must be disposed of •mly at d~signated · disposal sites.
1. (a) (b)
DRAIN ENGINE OIL Remove the oil filler cap. Remove the oil drain plug. and drain the oil into a contain~r.
2.
REPLACE OIL FILTER (a) Using SST, remove the oil filter. SST 09228-22020 (b) Clean the oil filter contact surface on the oil filt~r mounting. (c) Lubricate the filter rubber ga£ket with cJe;,n omgina oil.
(d)
.,
·. LU0490
Tighten filter until the gasket contacts seat of the filter mounting. Then using SST, give it an additional 3/4 turn lo seat the filter. SST 09228-22020
~·
EG-92
ENGINE:"'- LUBRICAT.JON;SYSTEM , '3.·; FIL)-·WITH l;i'IGINE OIL (a) Clean and ·install the oil drain plug with a new gasket·.
Reex>mmended Viscosity (SAE:) • ·
2nw.,o
·~:
Torque: ..25 N·m (250 kgf·cm. 18 ft·lbf)
15V/-40
'
10W-30
' : SW-30
'C ·29 'F
-~0
I
I II II
>
-18
-7
4
16
27
38
0
20
40
60
80
100·
(b) · Fill with new engine oil. Oil grade: API grade SG, SH or ILSJI.C multigrade engine oil. Recommended vi•cosity is as shown in the .illustration. Capacity: Drain and ref111 w/ Oil filter change 3.7 liters (3.9 US qt;, 3.3 Imp. qts) w/o Oil filter change 3.4 liters (3.6 US qts, 3.0 Imp. qts)
TEMPERATURE RANGE .~NTICIPATED BEFORE NEXT OIL CHANGE
T :1'23182 -----
(c) 4. 6.
Reinstall the oil filler cap. START ENGINE AND CHECK FOR LEAKS CHECK ENGINE OIL LEVEL
•
OIL PUMP COMPONENTS FOR REMOVAL AND INSTALLATION
+Gasket
Oil Pan
~~~.-;1:::.-.
/ .. ~ ..--
~~~1
I
I
L~.-~1
Oil Pump·-------1~'-'1
I
+ Gasket--eI Drain
I
+Gasket
Plug-~
~~~
I
I . I
I I
.-:sb r~~~~~~~~~ I
[}G"n lkaf·cm, ft·lbf) j +
Non-rcusabie parl
Specified torque P'2564
9
----~--------------------------------------------~=
ENGI1'~i: -
EG-93
LUBRICATION SYSTEM
OIL PUMP REMOVAL
.-
1. 2.
3. (a) (b)
HINT;. When repairing the oil pump, the oil pan and strainer should be removed and cleaned . DRAIN ENGINE OIL REMOVE OIL PAN Remove the 22 nuts. oil pan and gasket. REMOVE OIL STRAINER AND OIL PUMP Remove th~ 3 bolts, oil strainer and gasket. Remove the bolt and oil pump. .
ron•~u
COMPONENTS FOR DISASSF.MBL Y AND ASSEMBLY
Oil Pump Body
__
+ Cotter Pin
.,
~
I
I
t
I
I ~..,
I
(
·.
I
r --
· Relief Valve
. ({It?)
Dri~en Rotor---c:.J
Valve Spring
I
I
I I
I
I
)
I
I I
Drive Rotor----1
f
;,
[}Tm (kgf·cm, f:·lbf) \ : + Non-reusable part
~
I
~& ~:;_;YI II I
I
11
1
I I
J I ( I
!
~)
I :
.
.;"'""
r--c-::-
Q' :
~
~;;--]
I
£
L &.9i/0,6tl~
Specified torque
OIL PUMP DISASSEMBLY 1. (a) (b).
REMOVE RELIEF VALVE Remove the cotter pin. ASSEMBLY HINT: Use a new cotter pin. Remove the retainer, spring and relief valve.
I
EG-94.
ENGINE:- lUBRICATION:SYSTEM.-.
, - - - - - - - - - - - - - - - - : - - .'··
2 · REMOVe: DRIVE AND DRIVEN ROTORS RemovB the 3 bolts. oil pump cover, the drive and driven rotors. Torque:. 6.9 N·m (70 kgf·cm, 61 in .. Jbf)
ASSEMBLY HINT: Install the rotors so that the mark are facing thB pump cover side (upward), as shown.
( 1'25368
OIL PUMP INSPECTION 1.
.
I<:IU-01
INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its ow,, weight. If the valve does not fall smoothly, replace the valve or oil pump assembly.
.
.,..., '
l '---
~J
2.
INSPECT DRIVE AND DRIVEN ROTORS A. Inspect rotor body clearance Using a thickness gauge, measure the clearance between the driven rotor and body. StDndard body ci.,Dronco: v.li)O- 0.160 mm (0.0039- 0.0063 in.) Maximum body claar.,nca: 0.20 mm (0.0070 in.) If the clearance is greater than the maximum, repl;3ce the rotors as a sst or pump assembly. B. Inspect .rotor tip clearance Using a thickness gauge, measure the clearance between the drive and driven rotor tips. Standard tip claarar.ce: 0.040 - 0.160 mm (0.0016 - 0.0063 in.) Maximum tip cloarance: 0.20 mm (0.0079 in.)
....
f'7.>X6
If the tip clearance is greater than maximum. replace the rotor set.
..
ENGINE- 'LUBRrCATION'SYSTEM ·
EG-95
C: ··Inspect rotor:side clearance Using ·a thickness gauge and precision straight edge, · measure the clearance between the rotor::; ·and precision straigt.: c:'ge'. Standard side clearance: 0.030 - 0.090 mm (0.0012 ;... 0.0035 ln.) Maximuin side clearance:.
0.15 mm (0.0059 in.) If the side clearance is _greDter thar. maximum. replace the rotors set or pump assembly.
OIL PUMP ASSEMBLY Assembly is in the reverse order of disass .. mbly.
OIL PUMP OPERATION CHECK
··--
CHECK PUMP OPERATION (a) Using a screwdriver, immerse the suction end of the shaft clockwise. Oil shoul.d come out the discharge hole.
(b)
Using a screwdriver, close the discharge hole with your thumb and turn the shaft as before. The shaft shou!d be difficult to turn.
OIL PUMP INSTALLATION 1.
INSTALL OIL PUMP AND STRAINER Align the oil pump shaft slot of the oil pump with the governor shaft protrusion of the distributor. (b) Install the oil pump with the bolt. · Torque: 19 N-m (195 kgf·cm. 14 ft·lbf) (a)
EG-96
ENGIN.E- LUBRICATION.SYSTEM ·
(c)·· Install· a new gasket and the oil strainer with the 3 • bolts. Torque: 8 N-m (80 kgf-cm, 69 in.-lbf)
2. (a)
(b)
:fo.!~TALL OIL PAN Remove any old packing (FIPG) mateJial and be care· ful not to drop any oil on the contact surfaces of the oil pan and cylinder block. Apply seal packing to the timing chain cover, cylinder block and rear oil seal retainer as shown in the illustra· tion.
-·
.
Seal packing: Part No. OBe26-00080 or equivaleOJt
(c) (d)
Place a new gasket to the engine. Install the oil pan with the 22 nuts. Torque: 9 N-m (90 kgf-cm, 78 ln.-lbf)
3. 4. 5.
FILL WITH ENGINE OIL START ENGINE AND CHECK FOR LEAKS RECHECK ENGINE OIL LEVEL
SERVICE SPECIFICATIONS SERVICE DATA Oil pres!lure
At Idle
sp~ed
(normal Ciperating temperature)
29 kPa (0.3 kgf/cm', 43 psi) or more
At 3,000 rpm {normal operating temperature) Oil pump
Body c/earar.ce
:245 - 490 kPe (2.5 - 5.0 kgf/cm', 36 - 71 psij STD
Maximum Tip clearenco
L___ I
STD
Maximum
I .
~de
STD
clearance
Maximum
0.1 oo - 1.160 mm ·co.oo39 - 0.0063 in.) 0.20 mm (0.0079 n.)
·-
0.040 - 0.160 mm (0.00 16 •• 0.0063 in.) 0.20 mm (0.0079 n.) 0.030 •• 0.090 mm (0.00 12 - 0.0035 in.) 0.15 mm (0.0059 n.)
TORQUE SPECIFICATIONS ~
I
\·
I
Part tightened
~fil.er
bracket x 011 lirGssuro sw1tch -------in plog x Oil pan
I
Oi!
p~mp
cover x Oil pump body
Oil pump x Cylinder block
--------·
Oil strainer x Cylinder block, Oil pump Oil pen x Cyl!ndor block, Timing ch"in ccvcr. Roar oil
•
~;onl
retainer
Nm
-
I
'
kgf-cm
I
ft-1bl
15
150
11
25
250
18
6.9
70
61 ln.·lbf
19
195
14
8
80
69 in.-lbf
9
90
78 ln.-lbf
IGNITION SYSTEM - DISTRIBUTOR . 2.
IG-1 3
INSTALLDISTRIBUTOR
(a) (b)
Install a new 0-ring to the distributor·housing. Apply a light coat of engine oil on. the 0-ring.
(c)
Align the center line of the slot at the top end of the oil pump shaft against the mark (oil hole) at the top side of the oil pump body.
,_
New 0-Ring
(d) Position the distributor rotor toward the right sids of
--
No.3 plug tube, and insert the distributor housing. When the housing is inserted, the rotor should ba point near the centar of No.2 plug tube. (f) Turn the ignition switch to ON, but do not crank the. · starter motor. (g) Rotate the distributor body counterclockwise until a spark jumps between the points and tigntan the clamp bolt in that position. 3. INSTALL ROTOR, PACKING AND :::JISTRIBUTOfl
(e)
~
r1 I( """'
4. 5. 6.
7.
CAP INSTALL DISTRIBUTOR WlRE CONNECT HIGH-TENSI01J CORDS TO DiSTRIBUTOR CAP CONNECT VACUUM HOSES TO VACUUM ADVANCER CHECK IGNITION TIMING
(Sea ignition timing inspection and scijustment in Engine Mechanicalj
IG- 14 · - - - - - - - IGNITION SYSTEM- SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS SERVICE DATA H.igh-tension
I
~
cord Spark plug .
Maximum
Res:istaLlc.e Recommended spark plug
NO NGK
Piima:y coil resistance
. Sacondnry co:l r(;sistance
at cold
BP5EY 1.35 - 2.09 ()
at hot
1.71 - 2.46 (i 8.5- 14.5 kO
at cold at hot
Distributor
--
W16Ex-u·
at cold
at hot Resistor resistanCe
~ord
0.8 mm (0.03 1 in.)
Correct electrode gap
~~ition coil
25 k 0 pur
10.7- 17.1 kO 0.8 - 1.3 0 1.05 - 1.52 0
Rubbing block gap
0.4 - 0.5 mm (0.0 16 ·- 0.020 in.)
D:ampin~. spring gap
0.05 - 0.45 mm (0.002 - O.ot 8 in.)
·•
TORGUE SPECIFICATIONS N·m
kgf.cm
ft·lbf
Spark plug x Cylinder head
17.5
180
13
Distributor x Cylinder head
12
120
9
Part t:ghtened
.
-·
.
IG-1
IGNITION SYSTEM .PREPARATION
--
....................................... IG- 2
ON-VEHICLE INSPECTION ....................... ·IG- 2 DISTRIBUTOR •••·•·••·•····•·••······••··· •·•·•••••••·• iG- 7 SERVICE SPECIFICATIONS ........................ IG- 14
I
IG-2
·IGNIT-ION SYSTEM - ON~VEHICLE 'li~SPECTION
PREPARATION
-·-liD
RECOMMENDED TOOLS ..
~<>?
090B2
-oooso
TOYOTA
Eloetrict~l Tost~r
Sot.
~~~-~
~"""""
=
~£
~~
c
09200-00010
Engine
Adju~t
Kit .
~
EQUIPMENT M<9gger insulation resistance meter Spark plug cleaner
Torque wrench
~~~--------------~--------------------------~
------------------------r-----------------------·--~
•
ON- VEHICLE INSPECTION SPARK TEST CHECK THAT SPARK OCCURS
(a)
Disconnect the high-tension cords from the spark plugs. (b) Remove the spark plugs. (c) Install the SJ:.>ark plugs toeach high -tension cord. (d) Ground the spark plug. (e) Che.;k if spNk occurs while engine is being cranked. NOTICE: To prevent excess fuel being Injected from the injectors during this test, do not crank the engine for more 5 -
10 seconds at time.
If the spark does not occur, do the test as follows:
·.
:CNITION SYSTEM - ON-VEHICl-E INSPECTION. IG-3 ----------~~~~~~~==~~~~--------
I SPARK TEST
I
NO I CHECK CONNECTION OF IGNITION COIL AND DISTRIBUTOR CONNECTOR OK t CHECK RUBBING BLOCK GAP OF DISTRIBUTOR )See page IG-61 Rubbing block g
.
I BAD·J Connect securely. BAD
~BAD
I
I
Check and adju:;tlhe gap.
Replace the cor,; (s).
l
0
BAD
BAD
Check wiring between ignition switch to ignitcn coil.
""'"""" ,,.,., '"'· ~ ~·
HIGH- TENSION CORDS INSPECTION
-·
I
I I...__
.
'-----===::
f?JJ:..-<
I
1. (a)
DISCONNECT HIGH-TENSION CORDS Disconnect the high - tension cords at the rubbor boot
(b)
Disconnect the high-tension cord from the distributor cap and ignition coil. DO NOT ;>ull on the cords. NOTICE: Pulling on or bonding the cords rnay damage the conductor ins:ide.
2.
INSPECT HIGH-TENSION CORD RESISTANCE Using an ohmmeter, measure the resistance. Maximum resistance: 25 kQ per cord
If the resistance is greater than m~ximum, check the tormb:;~\s .. !f riocessary, roplacs the high ~ Tensbn cord. 3 . . RECONNECT HIGH-TENSION CORDS
J
SPARK PLUGS INSPECTION
2.
DISCONNECT HIGH-TENSION COflDS FROM SPARK PLUGS REMOVE SPARK PLUGS Using a 16 mm plug wrench, remov~ the spark plug.
..
;q-4.
· :GNI"fiON SYSTEM·- ON-VEHICLE INSPECTION ;j.
CLEAN SPARK PLUGS Using a spark plug cleaner or wire brush, clean the spark plug.
.
Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 0.8 mm (0.031 ln.)
6.
REINSTALL SPARK PLUGS Torque: 17.5 N·m (180 kgf·cm, 13 ft·lbf)
7.
RECONNECT HIGH-TENSION CORDS TO SPARK PLUGS
IGNITION COIL INSPECTION NOTICE: "Cold" end •Hot" In these sentences express the temperature of the co!ls themselves. ·cord· Is from -1 o• . C (14°F) to so•c (122.F) snd··Hot"ls from so•c (122°F) to 100°C
.--------------,
{2~:;('f-}.
1.
DISCONNECT HIGH-TENSION CORD FROM IGNITION COiL
2.
INSPECT PRIMARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the + and - terminals. Primary coil resistance: · Cold: 1.35 - 2.09. 0 · Hot: 1.71 - 2.46 0
If the electric resistance is not as specified, replace the ignition coil. IGOSCJ
Zt6411
.
IGNITION SYSTEM...-'- ON-VEHICLE INSPECTION------:3.
INSPECT SECONDARY COIL RESISTANCE Using. an· ohmmeter, measure the resistance botween the Band high-tension terminals. Secondary co!' raslstance: Cold: 8.5 - 14.5 kQ Hot: 10.7- 1'1.1 kQ
Ohmmeter
T::-I['J '----Hoi
IG-5
If the electric resistance is not 2s specified, replace the ignition ::oil.
0 Zl6412
4.
Ohmmeter
Resistor resistance: Cold: 0.8 - 1.3 Q
l.:.n.:J
'-----roe;:_~l IG0585
INSPECT RESISTOR RESISTANCE Using an ohmmeter. measure tha resistance between the B and + terminals.
Hot:
1.05 - 1.52 0
If the electric resistance is not· as spocified, replace the ignition coil.
216•113
Voltmeter
5. (a)
INSPECT ?OWER SOURCE LINE With the ignition switch an ON and using a v.oltmeter. connect the positive ( +) probe to the B tarminal and the negative (-) probe to body ground. Voltage: Approx. 12V
(b)
With the ignition switch as ·sr ART' and using a voltmeter, connect the positive ( +) probe to the + terminal and the negative(-) probe to body ground.
DC]
~0 e I
L'~Go::"='-------------~-~-·-----~
Voltage: Approx. 12V
c.
-.
If abnormal, check tha ignition switch and wire harness. RECONNECT HIGH-TENSION CORD TO IGNITION COiL
IG-6. •
IGNITION SYSTEIVI ,_.,ON-VEHICLE INSPECTION
DISTR!BUTOR INSPECTION 1. 2. 3.
•
REMOVE DISTRIBUTOR CAP WITH .H'GH.,-TENSION CORDS REMOVE ROTOR· INSPECT BREAKER POINT
Using a feeler gauge. measure the gap between the cam and rubbing block. Rubbing block gap: 0.4 - 0.5 mm (0.016 - 0.020 in.)
If the gap is not within specification, adjust the gap. (See distributor assarnbly)
4.
INSPECT DAMPING SPRING
Using a feeler gauge, measure the gap between the cam and damping spring. Damping spring gap: 0.05- 0.45 mm (0.002- 0.018 in.)
. If the gap is not within specification, adjust the gap. (See distributor assembly) 5.
INSPECT VACUUM ADVANCER
(a)
Disconnect the vacuum hoses from the vacuum advancer. (b) Apply vacuum to the port A or B and check that the vacuum advancer moves. If the vacuum advancer do_es not work, repair or replace as necessary.
6. (a)
(b) 7. 9.
INSPECT GOVERNOR ADVANCE
Turn the rotor clockwise, release it and check that the rotor re.turns quickly counterclockwise. Check that the rotor is not excessively loose. REINSTALL ROTOR . REINSTALL DISTRIBUTOR CAP
~I
.·
'
'~
IGNITION SYSTEM _; DISTRIBUTOR
IG-7
· DIS'fRJBl:JTOR COMPONENTS FOR REMOVAL AND •. INSTALLATION
High-Tension ---rCord
®@~0-. -1
Dislribulor j ••• Wire Dislribulor ----<
.. I
I I I
+ 0-Ring----~cp
.... ----
I
I
L---
+ Non-reusable part DISTRIBUTOR REMOVAL 1. 2. 3.
4. (a) (b)
DISCONNECT HIGH-TENSION CORDS FROM DISTRIBUTOR CAP DISCONNECT VACUUM HOSES FROM VACUUM ADVANCER REMOVE DISTRIBUTOR WIRE REMOVE DISTRIBUTOR
Remove the mounting bolt, and pull out tha distributor. Remove the 0- ring from the distributor housing.
IG·B
IGNITION SYSTEM __: DISTRIBUTOR···
COMPONENTS FOR DISASSEMBLY AND"-~ ASSEMBLY
!-----Grease Stopper
!----Governor Spring
r-_ PieceB
-
-...J
Packing
Rotor------@
w
11
LeodWirc~I .·· HolderDamping
Sprin~
~
I I I
.~ I- -
1--" ---"-Distributor Housing Assembly
l,
Breaker Plate
+ Driven Gear~ +Straight Pin -=t;1
+Non-reusable part
Vacuum Advancer
DISTRIBUTOR DISASSEMBLY
,_ 2.
(c)
Remove the nut and spring washer. Disconnect the lead wires of the condenser and breaker point. Remove the 2 terminal insulators and terminal.
3.
REMOVE BREAKER POINT
(a) (b) P25~
REMOVE DISTRIBUTOR CAP, ROTOR, AND PACKING REMOVE DISTRIBUTOR TERMINAL
Remove the 2 screws and breaker point.
4.
REMOVE DAMPER SPRING
Remove the screw and damper spring.
...
•
'
IGNITION SYSTEM - DISTRIBUTOR 5,
IG-9
'.
REiv'IOVE VACUUM ADVANCER
(a) . R.i~ove the screw and condenser. (b) Using a s~niwdriver, remove the snap ring and pull out the vacuum advancer.
- l
6. (a) (b)
7.
REMOVE BREAKER PLATE
Remove the 2 screws, lead Remove the breaker plate.
wir~
and holder.
REMOVE GOVERNOR SPRINGS Using needle- nose pliers, remove the 2 springs.
'·
REMOVE CAM
8. (a) (b) (c)
Remove the grease stopper. Remove the screw at the end of tho governor shaft. Pull out ths cam.
9.
REMOVE GOVERNOR WEIGHTS
·~I Using a small screwdriver, remove pull out the 2 weights.
th~
snap ring and
.. IG-1 0
.IGNITION SYSTEM -:- DiSTRIBUTOR
. DISTRIBlJTOR IN3PECTION 1.
INSPECT BREAKF.R PLATE
Turn the breaker plate and check that it has a slight • drag .. If it sticks or strongly resists, replace the breaker plate.
2.
INSPECT GOVERNOR SHAFT
(a)
Turn the governor shaft and check that it is not rough or worn. If it feels rough or worn, replace the distributor housing assembly .
(b)
Using a feeler gauge, measure the governor shaft thrust clearance.
.,,..I r-----------------------~
.
.
Thrust clearance:
0.15 - 0.50 mm (0.0059 - 0.0197 in.) If the thrust clearance is not as specified, rep/aced the distributor housing assembly.
'
3.
INSPECT CAM
lnstaU the cam to the governvr shaft and check that they fit correctly. . If they don't fit, replace the cam and/or distributor houl.'ing assemblv.
I
_ _ _ _Pm»j DRIVEN GEAR REPLACEMENT 1.
(a)
REMOVE DRIVEN GEAR
Using a grinder, grinc the driven gear and straight pin. CAUTION: Be careful .,ot to damage the governor shaft.
(b) (c)
"'
154/G014T
Z16'1l~
(d)
Mount the driven gear in a vise. Using a pin punch and hammer, tap out the straight pin. Remove ihe drive gear and washer.
.
IGNITION SYSTEM -
IG-11
DISTRIBUTOR
--~-------~~~~~~~~----~--2.
INSTALL NEW DRI\(EN GEAR
{a) · Place the driven gear onto the governor sh,ft. {b) Install the new straight pin .
.P25567
{c)
Sacure the ends of the straight pin in a vise.
DISTRIBUTOR ASSEMBLY 1.
INSTALL GOVERNOR WEIGHTS
Using l)eedle- nose pliers, install the 2 weights with the snap ring.
2.
INSTALL CAM
Lightly coat the governor shaft with high-t~mpera-· tum grease, {b) Place the cam on the governor shaft. {c) Po.sition the &ill m~rk on the driven gear and cutout {a)
Drill Mark-·--..__.
I
as
~hown.
{d)
Install ths screw.
(d) {e)
Pack high-temperature grease into the c"m. Push on the grease stopper with your finger.
3.
INSTALL GOVERNOR SPRINGS
L _ _ ____,_,:=..~"'""
Using needle- nose pliers,
in~tall
the 2 springs.
IG-1:.!.
IGNITION SYSTEM - DISTRIBUTOR
..
..
{a) (b) 5. {a) {b) {c)
INSTALL BREAKER PLATE Align tl.a 4 clips on the breaker plate with the cutout parts of the housing and insert the breai
6.
INSTALL AND ADJUST BREAKER POINT Clean the contact surfaces of the points with a piece of cloth saturated in solvent. (b) Apply high--temper
~··,
~--
8. INSTALL DISTRIBUTOR TERMINAL (2). Install the 2 insulators and terminal to the housing. (b) Connect the lead wires of the breaker point and condenser to the terminal. (s) lnst~JI thtJ spring wash.:r Dnd nut.
DISTRIBUTOR INSTALLATION 1. (a) {b)
(c)
SET N0.1 CYLINDER TO TDC/COMPRESSION Remove the No.1 spark plug. Place your finger over the hole of the No.1 spark plug and rotate the crankshaft clockwise to TDC. If pressure is felt on your finger, this is TOG/compression of the No.1 cylinder. If not, repeat the process. Install the No.1 ~park plug.
•
IGNITION SYSTEM '--- DISTRIBUTOR 2.
(a) (b)
.. ,
...
IG-13
·INSTALL DISTRIBUTOR
Install a new 0- ring to the disiributor housingc Apply a light coat of engine oil on the 0-ring.
"
,. . ~-
l~ew
o-Ring
(c)
Align the center line of the slot at the top end of the oil pump shaft against the mark (oil hole) at the top side of the oil pump body .
.-
.. -
(d)
;
(e) (f) (g)
3. 4. 5. 6. 7.
\
.
Position the distributor rotor toW3rd the right side of · No.3 plug tube, and insert the distributor housing . When the housing is inserted, tho rotor should be point near the center of No.2 plug tube. Turn the ignition swit,ch to ON, but do not crank the starter motor. Rotate the distributor body counterclockwise untir" a spark jumps between the points and tighten the clamp bolt in that position. INSTALL ROTOR, PACKING AND !:JISTRIBUTOR CAP INSTALL DISTRIBUTOR WIRE CONNECT HIGH-TENSION CORDS TO DISTRIBUTOR CAP CONNECT VACUUM HOSES TO VACUUM ADVANCER CHECK IGNITION TIMING (Sea Ignition timing inspection ond adjustment in Engine Mechonlcel)
IG-14
IGNITION SYSTEM
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
og01t•OO
SERVICE OAT A Maximum
! 25 kO per cord
" Iw"~-o
NGK
BP5EY
0.8 mm (0.031 in.) at cold
1.35 - 2.09 0
nt hot
1.71 - 2.46 0
at cold
8.5 - 14.5 kO
at hot
10.7- 17.1 kO
at cold ot hot
0.8 - 1.3 0 1.05 - 1.52 0 O.A - 0.5 mm (0.0 16 - 0.020 in.)
0.05 - 0.45 mm (0.002 - O.Q18 in.)
. TORQUE SPECIFICA JtON~,~. ;.. ,:
r-· Spark plug
Part tightened X
Cylinder hood
Distributer x Cylinder head
N-m
kgf·cm
ft·lbf
17.5
180
13
12
120
9
•
ST-1
STARTING SYSTEM
.. ?REPARATION ······································· ST- 2 STARTER ·················································sr- 3 SERVICE SPECIF:CATIONS··········· ............. ST-- I~
'
ST-2
.
STARTING S'(STEM -·PREPARATION
PREPARATION SST (SPECIAL SERVICE TOOLS)
I
09221 -25025
•
Piston Pin Remover & Replacer
I
.......
···································································· (09221 -00090) Gu;de ·c·
··················
················ ··································································· Center besring
• noor-or
=tECOMMENDED TOOLS 09082-00050
TOYOTA Electdcel Tester Set.
09804-00010
Expondor Set.
:OUIPMENT Micromet9r
Planetary aheft
Caliper gauge Dial indicator
-Magnetic finger
Comm11tator
Pullacale
Brush spring
Sandpaper l'>rqu.t wronch
v block
-
Commutator
__-==:J
.. Vtrmer eaupe._r_•---------~-----·---..L..:C::o:::":::'m::_u::t::•:::to::_r•:_:B::r.:u::•h:__ _ _ _ _ _ _ _ _ ,_ _ _ _ j
•
ST-3
STARTING: SYSTEM-. STARTER
·•
STARTER COMPONENTS FOR DJSASSEMBL Y AND--~
. .'
ASSEMBLY Magneti~
Switch Cover
®@~~Covetfr $~
.
l
e
Starter Housing
Magnetic Switch Drive Lever ·
Stop Co/l;;r
·
Shock(}) Absorber
Gear~Pianetary Sha~ (j/fff\ loi 'fi ~~
Planetary
Plate
rQ;\ ~ ~I
Plate Washer
comm"'"" Eo' '"m'
Brush Holder
-
__ <
--~
~Non-reusable
part
Snap Rmg
'
~-Armature
+o-"'"'
-.;:-- "-
'
~
I
I
to ~ ~-~l
.-
+O-Ring
+ 0-Ring
Ring
~~~Starter Clutch
Plate Washer Center Bearing Internal Gear
~
·1
l ""~@®--Snap
Plate Washer
Field Frame
'(j---oust Protector
_JI
--------------~--------~
STARTER D!SASSEMBL Y 1.
2. (a)
REMOVE MAGI'IETlC SWITCH CO\'Efl REMOVE MAGNETIC SWITCH Remove the nut and magnetic switch ccwer,
Remove the nut, and c::;~connact the l&ad wire from the magnetic switch terminal. (c) Loosen the 2 nuts holding the magnetic switch to the starter housing . (d) ·Pull the magnetic switch and while lifting the front part of the magnetic switch. release tho plunger hook from the drive levar, then release the magnetic switch. (e) Remove th;; plunger r.over. (b)
..
3.
REMOVF. FIELu FRAME AND ARMATURE Remove the 2 through bolts, and pull out tho fi6ld frame together with the armature.
.. :
·:T-4
.STARTING. SYSTEM -STARTER . 4.
R:;MOVE COMMUTATOR END FRAME Remove· the 2 screws with 0-rings and commutator end frame, and hold down the lead wire while releasing the commutator end frame.
.•
NOTICE: To avoid interference between the brush holder and the dust protector, pull the commutator end frame away at
flO
angle.
ST0728
. 5. (a)
(b) 6. 7.
REMOVE BRUSH HOLDER Using a screwdriver, hold the spring back and discon· nect the brush holder. Disconnect the 4 brushes, and remove the brush holder. REMOVE ARMATURE FROM FIELD FRAME REMOVE 2 0-RINGS FROM FIELD FRAME
8.
REMOVE DRIVE LEVER AND STARTER CLUTCH ·wiTH SHOCK ABSORBER FROM STARTER HOUSING
9.
REMOVE PLANETARY GEARS Ramcve these parts from the shock absorber. (1) Plzte ' ·(2) 3 planetary goars (3) Plate washar
t
;v~ ------------------
1\0252
(1 J
ST~711
Z00210
10. REMOVE STARTER CLUTCH (a) Usi! .g a screwdriver, tap in the stop collar towards the sta"ter clutch. (b) Using a screwdriver, pry off the snap ring.' (c) Remove the stop collar and starter clutch from the planetary shaft.
.
'
.r
'--------------~~--~~S~T~A~R~T~I~N~G~-s~v~:s~T~E~M~-~-~S~T~A~R~TE~R~--------------------s_T_-_5 11.' REMOVE P-lANETARY SHAFT AN~ INTERNAL GEAR (a) Using snap ring plierz. remove the snap ring and plate washer. · (b) Removo the planetary shaft and plat'l washer.
SICISSil
STARTER INSPECTION AND REPAIR Armature Coil 1.
c;ontinuity
INSPECT COMMUTATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity bet\~een the ;;egments of the commutator. If there is no continuity between any segments, replace the umature.
2 • . INSPECT COMMUTATOR FOR GROUND Using an ohmmeter, check that there is no cc-.ntinuity between the commutator and armature coil core. If there is continuit-y, replace the armature.
Commutator 1.
INSPECT COMMUTATOR FOR'DIRTY AND BURNT SURFACES If the surface is dirt-y or burnt, correct with sandpapsr (No.400) or a lathe. 2. INSPECT COMMUTATOR CIRCLE RUNOUT (a) Piace tha <•om mutator on V -0!ccics. (b)-· Usin;J a dial gauge, measure tha circle run out; Mexlmum circle runout: 0.05 mm (0.0020 ln.) If the circle runout is greater1h1m maximum, correct it on a lathe.
-,:J)J~E-= ·
3.
=
::1=·1
-;~]~_"--0~·___;,j
INSPECT COMMUTATOR DIAMETER Using vernier calipers, measure the commutator diameter. Standard diameter:
28 mm (1.10 ln.) Minimum diameter: 27 mm (1.06 ln.)
If the diameter is less than minimum, replace the armature.
~ i' I
:I
ST-6
STARTING SYSl'EM -STARTER 4.
INSPECT UNDEi)C:..'T DEPTH
Check that the undercut depth is clean and free of foreign materials. Smooth out the edge. Standard undercut depth: 0.6 mm (0.024 in.) Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum. correct it wi~h a hacksaw blade.
ST0040 1
Field Frame (Field Coil) 1.
INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter. check that there is continuity between the lead wire and field coil brush lead. If> there is no continuity, r~place the field frame.
r..
Continuity
2.
INSPECT FIELD COIL GROUND
Using an ohmmeter, check that there is no continuity between the field coil end and field frame: If there .is continuity, repair or replace tho field frame.
No coiitinuit\'
l
Brushes INSPECT BRijSIJ LENGTH
Using vernfer calipers, measure the brush length. Stondord length: 14.0 mm (0.551 ln.) Minimum longth: 9.0 mm (0.354 in.)
ff thq Jqngth k Jqu lh;m minimum. mplilGii !hr. holder and filed frame.
/;ru~l.
Brush Springs INSPECT BRUSH SPRING LOAD
·Take the pull scale reading the instant the brush spring separates from the brush. Spring installed load: 8.8'- 17.7 N (0.9 - 1.8 kgf, 2.0 - 4.0 lbf)
-·
·t.
. '~
<
. STARTING.SYSTEM- STARTER
-.
Brush'Hoider
No continuity
INSPECT BRuSH HOLDER INSULATION
Usin·g an ohmmeter, check that there is no continuity between the positive{+) and negative(-) brush holders. If there is continuity, repair or replace the brcsh holder.
!
•' -· .
---------------""'-" I
.
Clutch and Gears 1.
INSPECT GEAR TEETH
Check the gear teeth on tha planetary gear.- internal gear and starter clutch for woar or damage. If tl;le gear is damaged, repiBce it. If the starter clutch teeth are damaged; replace the starter clutch and also inspect the fl~wheel ring gear for wear or damage.
,.
.•
2.
INSPECT STARTER CLUTCH
Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion gear counterclockwise and check that it locks. If necessary, replace the starter clutch.
Magnetic Switch 1.
INSPECT PLUNGER
Push in the plunger and replace it. Check that it returns quickly to it:? original position. If necessary, replace the magnetic> swit!:h.
STOC:67
2. Terminal 50
i;
Terminal C
Contjnuity
P10134
f
I:
__ ; •. ------------'-~--,
•.
'i
DO PULL--'I.N COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity. replace the magnetic switch.
.,•,.
ST-8
STARTING SYSTEM·,... STARTER. 3.
DO .HOLD....., IN COIL OPEN CIRCUIT TEST . I • •
Using M ohmmeter, check that there is continuity between terminal 50 and the switch body. · If there is no continuity, replace the magnetic switch. ·
.,
•
....
Planetary Shaft and Center Bearing 1.
INSPECT PLANETARY SHAFT AND CENTER BEARING
(a)
Using a micrometer, measure the outer diameter of the, surface in contact with the center bearing of the planetary shaft.
·-
Standard shaft diameter: 14.980- 15.000 mm (0.5898- 0.5906 in.)
(b)
Using a caliper gauge, measure the inside diameter of the center bearing. Center boadng Inside diameter: 15.008 - 15.050 mm (0.5908 - 0.5925 in.)
(c)
Standard center bearing oil clearance: 0.01 - 0.06 mm (0.0004 - 0.0024 in.) Maximum cantor bearing oil cloarance: 0.2 mm (0.0078 ln.)
~
-----------------
~ST
"--
e:i--~ '-
Yf-
Subtract the planetary shaft diameter from the bearing inside diameter measurement.
I
2. (a)
If the clearance is greater than maximum, replace the planet carrier shaft and center bearing. lF NEC!:SSARY, REPLACE CENTER BEARING Using SST and .Press, press out the center bearing. SST 09221-25025 (09221-00090)
~" fy) (b)
/
Using SST and a press, press in a new center bearing to the posi.tion shown in the illustration. SST 09221-25025 (09221-00071)
•
•
STARTING. SYSTEM:....· STARTER· ·(c)
''
- ''
•
ST-9
Align the hollow of tha internal gear with the protrusion inside the shock absorber, and remove the interrial gear. ·
Hollow •
Protrusion
SToo-17
STARTER ASSEMBLY
1.
·'
(a)
(b) (c) · liollow
HINT: Use high temperature-resistant grease to lubricate the bearings and sliding parts when assembling the starter. INSTALL INTERNAL GEAR AND PLANETARY SHAFT Apply grease to the internal gear touching the sock absorber and planetary gears. Align the hollow of the internal gear with the protrusion inside the shock absorber. Insert and turn the internal gear 5o that it interlocks with the shock absorber.
STC647
(d) (e)
Shock Absorber
(j
Planetar~·
Shaft
(f) (g)
f
Apply turbine oil with additives to thA c&nter bearing. Apply grease to the plate washer. and install it to the plar.atary shaft Install the·planetary shaft to the shock absorber. Using snap ring plior~. install the plato washer and snap ring.
Plate Washer
-
)671
Zl~l
: 2. (a)
(b)
sroon
INSTALL STARTER CLUTCH Apply grease to the bushing and splir.e of the starter clutch and stop collar. Place the starter clutch an·d stop collar on the plano· tary shaft.
..
ST-10
STARTJNG.SYSTEM - STARTEtl
(c) (d)
Apply. grease to the snap ring, and instal! it to the planetary .shaft gro.ove. Using a vise, compress the snap ring.
.
. •
ST007J
(e)
3.
INSTALL PLANETARY GEARS
(a)
Apply grease to the planetary. gears and flange pin parts of the planetary shaft. Install the plate washer and 3 planetary gears. Align the cutout of the plate With the protrusion insida the shock absorber, and install the plate.
(b) (c)
4.
t
(a) (b)
:
··~.
Hold the starter clutch, tap the planetary shaft and install the stop collar onto the Sflap ring with a plastic -facod hammer.
(c)
.
.·
INSTALL DRIVE LEVER AND STARTER CLUTCH
WITH SHOCK ABSORBER Apply turbine cil with additives to tlie bearing ot 1he starter housing. Apply grease to th& drive levor touching the starter pivot part of the drive levsr. Install tho drive lever to the starter clutch.
ST07<11
(d)
Align the protrusion of the shock absorber with the 0utout of the starter hol!sing and install them.
•
STARTING SYSTEM - STAR.TER
.•
. . ..
5.
...
6.
..
7. (a) (b)
iT0727
"""
8. (a) (b)
ST-11
INSTALL 2 NEW 0-RJNGS TO FJELD FRAME PLACE ARMATURE INTO FIELD FRAME INSTALL BRUSH HOLDER Place the brush holder in position on ths armature. Using a screwdriver. hold the brush spring back. a.1d connect the brush into tho brush holder. ' Connect the 4 ·brushes. HINT: Check that positive(+) lead wires are not grounded. INSTALL COMMUTATOR ENO FRAME Apply turbine oil with additives to t~e bearing of the end frame. Install the end frame with 2 new screws with 0-:-rings. NOTICE: To avoid interference between tho brush holder and tho dust protector, pull tho commutator ~rid frame away at an angle.
9.
Protrusion
(a) (b)
R I 88.(
INSTALL FIELD FRAME AND ARMATURE ASSEMBLY Align the cutout of the field frame with the protrusion of the shock absorber. Install tho field frame and arrnaturo assnmbly with the 2 through bolts.
=
II ·. ST0742
10. INSTALL MAGNETIC SWITCH (a) Install the plunger cover to the magnet:c switch. (b) Ha11g the pltrnpE!r ol tho magn~ti.:: ,~witch to the drive levsr from the upper side. (c) Install ths magnetic switch with the 2 nuts .. (d) Connect the lead wire to th~ terminal, And install the nut. (e) Install the magnetic switch cover with the nut. 11. INSTALL MAGNETIC SWITCH COVER
STARTER PERFORMANCE TEST i
1. (a) (b)
NOTICE: Thaso tests must be dono within 3 to!> seconds to avoid burning out tho coil: DO PULL-IN TEST Disconnect the field coil lead from terminal C. Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear mo·ves outward.
,.;
·:··
ST-12
STARTING SYSTEM- STARTER
If the clutch pinion gear does not move, repiace the • magnetic switch. · 2.
DO HOLD-IN TEST
-
With the battery connected as above and with the clutch pinion gear .:>Ut disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear remains out. If the clutch pinion gsar returns inward, replace the magnetic switch.
Di~connect
"'""' 3.
4. (a)
•
INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative (-) le.ad from the switch body. Check that the clutch pinion gear returns inward. If the clutch pinion gear does not return, replace the !'\lagnetic switch.
" •
INSPECT CLUTCH PINION GEAR CLEARANCE Connect the battery to the magnetic switch as shown.
' - - - - ------------'-"""="'-1 (b)
Move the pinion gear toward ths armature to remove slack and maasure the ci
7 - ~ m'm (0.04 ·- 0.16 in.)
5. (a)
DO NO-LOAD PERFORMANCE TEST Connect the field coil lead to terminal C. Make sure the lead is not grounded. (b) Connect the battery a·nd ammeter to the starter as shown. (c) Check that the starter rotates smoothly and steadily with the clutch pinion gear moving out. Check that the ammeter r!3ads the•specified current. RnAl"':ifiArf r.:m"r"Ant!
.
•
STARTING SYSTEM -SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
.........
SERVICE DATA Starter
1
12 V 0.8 kW
RBted voltage and output puwer
No-load characteristics
Current rpm
••
Brush len9th
ST-13
STD Minimum
90 A or less at 11. 5 V 3,000 rpm or more
14.0 mm (0.551 in.) 9,0 mm (0.354 in.)
8.8 - 17.7 N (0.9 ·· l.B kgf, 2.0 - 4.0 lbf)
Spring instal:ed load Ccmmutator
Diameter
STD Minimum
Undercut dApth
Circle runout Planetary shaft diametor
26 mm (1.10 in.) 27 mm ( 1.06 in.)
STD
0.6 mm (0.024 in.)
Minimum
0.2 mm (0.008 in.)
Maximum STD
0.05 mm (0.0020 in.) 14.980 -
15.000 mm (0.5898 - 0,5906 in.)
15.008 -
15.050 mm (0.5908 ·- 0.5925 in,)
Center bearing Inside diamoter
Oil clearance
STD Maximum
O.GI - 0.08 mm (0.0004 - C.0024 in.) 0.2 mm (0.0078 in.)
L____________l_P~i~n~io~n~c~lo~o~,,~n~c~e------------·--------~S~T~D~~I_:-~4~m~m~(0~.04~~-~~0.~1~6~in~.~)------------·----·-_J
'.
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CH-1
,-
CHARGING SYSTEM
• PRECAUTION .......................................... CH- 2 PREPARATION ····························-·······;.. CH- 2' ON-VEHICLE INSPECTION ..................... CH- 3 ALTERNATOR ............................ _.......... CH- 5 ALTERNATOR REGULATOR,_,_,_,,, ......... CH-13 SERVICE SPECIFICATIONs ........................ CH- 14
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CH-2
CHARGING SYSTEM - PREPARATION
PRECAU;!ON 1. 2. 3. 4.
Check that the battery r.aoles are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running.
PREPARATION SST (SPECIAL SERVICE TOOLS) 09286-46011
Injection Pump Spiino Shaft
Roto:~r
roar bearing
Pullor
09950-60010
Replacer Set
..
Rotor front bearing
•• (0995 I -00220) Replacer 22
(09951-00400) Replacer 40
··········~···
······· ···
iii9352·~·a6iii'iii···:.;:d~~;~;·
...... ·· ····· · · ··· ···
···· ········ ............ ·· ·.................... · ... ·· ·
@ill~'~ RECOMMENDED TOOLS 09082-00050
TOYOTA Electrical Testor Set.
---------------------------
L_
EQUIPMENT
---Batt&r'f' specific gravity gauge Torque wrench
--
Vernier calipors
Rotor (Slip ring)
•
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CH-3
CHARGING SYSTEM - ON-VEHICLE INSPECTION
... '
ON- VEHICLE INSPECTION
.
1.
CHECK BATTERY SPECIFIC GRAVITY AND ELECTROLYTE LEVEL
(a)
Check the electrolyte quantity of each cell. if insufficient, refill with distilled (or purified) water. Check the specific gravity of each ceil.
{b)
Standard specific gravity:
At 2o·c (sa·FJ: NS40l: 1.27 - 1.29
CORRECT
:·
Othors: 1.25 - 1.27 If the gravity is less than $pacification, battery.
WRONG
MAOOJS
-
charg~
tho
2.
CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES
(a) (b)
Check that the battery terminals aro not loose or . corroded. Check the fusible link and fuses for continuity.
3.
INSPECT DRIVE BELTS
(a)
Water Pump
Allernator
"''"' 1
Visually check the drive belt for craeks, oiliness cr wear. Check that the belt does not to:.~ch the bottom of the pulley groove. If necessary, replace the driva bel:. {b) Check the drive belt deflection by pressing on the belt at the points indicated in the illustration with 98 N {1 0 kgf, 22 lbf) of pressure; Drive belt deflection: New belt: 11 - 15 mm (0.43 - 0.59 in.) Used belt: 15 - 20 mm {0.59 - ().79 in.) If neces.sary, adjust the drive bolt deflection. HINT:
• • •
"New belt" refers tc a belt which has bGen usod less than 5 minutes or. a running sngina. "Used belt" refers to a bolt which ha$ been used on a running enginll for 5 minutas or more. After installing a new belt, run the engine for about 5 minutes and recheck the deflection.
4.
VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES
(a) (b)
Check that the wiring is in good conclition. Check that there is no abnormal nois~ from the alter-
5.
INSPECT DISCHARGE WARNING LIGHT SIRCUIT
(a)
Turn the ignition switch "ON". Check that the discharge warning light comes on. Start the engine. Check•that the light goes off. If the light cloes not operate as specified, troubleshoot the discharge warning light circuit.
nator while the engino is runnin8.
(b)
CH-4
CHARGING SYSTEM.- ON-VEHICL:E INSPECTION
· 6, . INSPECT CHARGING CIRCUIT WITHOUT LOAD , . • HINT: If a batteryjalte~nator teste'r is available, connect the tester to the charging circuit as per the . manufacturer's instructions. (a) If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows: ·Disconnect the wire from terminal 8 of the altar• nator and cc.nnect it to the negative (-) lead of the ammeter. • Connect the positive ( +) lead of the ammeter to terminal 8 of the alternator. • Connect the positive(+) lead of the voltmeter to • terminal 8" of the alternator. • Ground the negative(-) lead of the voltmeter. • (b) . Check the chargi!lg circuit as follows: With the engine running frorr: idle to 2,000 rpm, ch.eck the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage:
...
Plm / ...._,..__~·,....,
~meter
CH0008
At20"C(68"F): 13.8 -14.8V At 60"C (140"F): 13.3- 15.5 V
QQI17
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"If the voltmeter reading is more than standard voltage, adjust the regulator or replace it. 7. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high beam headlights and place th.e heater blower switch at "HI". (b) Check the reading on the ainmete~r. Standard amperage: 30 A or mare If the ammeier reading is less than standard amperage, repair the alternator. HINT: If the battery is fully charged, the indica·tio;1 will somatiml3s be :!Jss than st
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CH·5 ALTERNATOR
CHARGING SYSTEM
.. '
ALTERNATOR COMPONENTS FOR DISASSEMBLy . , ASSEMBLy AND_,_"
-
Stator
40A Type
.
Rotor
Front Bearing
Onve Elld Frnme Spacer Coller
I
Fan Pulley
I
®®
~:
,(
i' .'>
Insulator Washer
Spacer Coller Brush Spring . I
Rear End Cover
Rectifier End Frame 50A Type
Fran~
Drive End F.
""
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Spacer Coller
1 !:?
~--~
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I "'~ ""' "'"" • 1
ffime
9
Rotor
j
~
-
_,_
-, I ,.:,.
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~-'·~ ,'t;). ".
,QI
Bearin
-
_.,
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Rear Bearing TP.rminallnsulator
,-·
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·:::·::: :~~:~ --~--______ ...
Condenser
~Rectifier -~ End Frame
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P2~56
P25J57
I N·m (kgf·cm, ft·lbfl
Conectamea! Housing : Specified torque
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CH-6
~
CHARGING SYSTEM- ALTI::RNATOR
ALTERNATOR DISASSEMBLY
-··· •CI-01
1. (a)
(b)
REMOVE DRIVE END FRAME AND ROTOR ASSEMBLY FROM STATOR Remove the 3 through screws.
Using a screwdriver. pry the flnd frame and remove it together with the rotor. CAUTION: Do not pry on the coil wires.
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• •
r-·--------------~·--~-------~
@---j-(11 ~--J-(2)
(3)
6J ----,
2. REMOVE PULLEY AND FAN (a) . Mount the t"otor in a soft jaw vise. (b) Remove the nut and these parts: (I) Spring washer (2) Spacer collar (3) Pul:ey (4) Fan (5) Spacer collar
3. (a) (b) (c)
40A Type
4. A. (a) (b) (c)
REMOVE ROTOR Using a pn'lss, press ou·t the rotor. 40A Type: Remove the spacer ring and snap ring. 50 A Type: Remove the spacer ring.
REMOVE RECTIFIER END FRAME 40A Type: Remove the 4 nuts, condenser, cord clip and 2 terminal insulators. Remove the nut and rear end cover from the rectifier end frame. Removs the rectifier end frame from the rectifier holder.
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1
CH-7
_ _ _ _ _ _ _ _ _ _ _C::.H:..:.:..:.:ARGING SYSTEM- ALTERNATOR soA Type
•'
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B.
l
50A Type:
(a). Remove the 4 nuts. condenser and 2 terminal insulators .
(b) (c)
5,
Remove the rectifier end frame from the rectifier holder. Remove the insulator washer from the rectifier holder.
REMOVE RECTIFIER HOLDER H<'ld the rectifier terminal with needie-nose pliers and unsolder the lead wires. CAUTION: Protect the rectifiers trorn heat .
• ••
6.
SOA Type
50A Type:
REMOVE CONECTAMEAL HOUSING Using an un·solder, remove the conectameal housing from the rectifier holder.
'
CAUTION: Protect the rectifiers from heat.
Clocu.,.-•1
ALTERNATOR INSPECTION AND REPAIR Rotor 1.
INSPECT ROTOR rCR OPEN CIRCUIT Using an ohmmeter, chock that there is continuity · between the slip rings. Standard resistance:
At 2o•c {61l.F): 3.9- 4.1
o
If there is no continuity, replace the rotor.
· z:
No Conlinuily
INSPECT ROTOR FOR GROUND Using an ohmmeter. check that there is no continuity between the slip ring and rotor. If there is continuity, replace ·the rotor.
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. CHARGING SYSTEM.- ALTERN ATOR 3.
INSPECT SLii= RINGS
Check that the slip rings are not rough or scored. •' If rough or scored, replace the rotor. (b)· Using vernier calipers. measure the slip ring diameter... (a).
Standard diameter: 32.3 - 32.5 mm {1.272 - 1.280 in.) Minimum diameter: 32.1 mm {1.264 in.)
If the diameter is less than minimum, replace the rotor.
Stator 1.
'
INSPECT STATOR FOR OPEN CIRCUIT
.I
Using an ohmmeter, chsck that there is continuity between the coil leads.
'
, NOTICE: At this time, th& meeting wires should be connected with soldered. If there is no continuity, replace .the stator.
2.
INSPECT STATOR FOR GROUND
Using an ohmmeter, check that there is no continuity between the coil leads and stator coni. If th11m i~ r;rmtin11ity, nip11lr.ll thll ~tfll'lr. Ohmmeter
Q_/ \ -
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No cantinu!ty P2 4939 L-------------------~~~.
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Brushes •'.
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INSPECT EXPOSED BRUSH LENGTH
Using a scale. measure the exposed !:irush length. exposed length: 12.5 mm {0.492 ln.) Minimum exposed length: 5.5 mm {0.2171n.) Stand~~rd
I
If the exposed length is less than minimum, replace the brush. 2.
lF 'NECESSARY, REPLACE BRUSHES
(a) (b)
Unsolder and remove the brush and spring. Run the wire of a new brush through the spring and the hole in the brush holder, and insert the spring and brush into the brush holder.
• •
I .
CHARGING SYSTEM- ALTERNATOR
fc)
CH-9
Solder the brush wire to the brush holder at specified exposed length . . Exposed len;Jth: t 2.5 mm (0.492 in.)
(d) mm
{e) (f)
Check that the brush moves smoothly in the brush holder. Cut off the excess wire. Apply insulation .paint to the soldered area.
Rectifiers (Rectifier Holder)
40A Type
1.
INSPECT POSITIVE RECTIFIER
(a)
Using an ohmmeter, connect one tester probe to the positive (+)terminal and the other to each rectifier terminal. (b) Reverse the polarity of the tester probes and repeat step (a). (c) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder,
- <
-.-. ..•
50A Type Positive i+)
Terminal
Zl66
2.
40A Type
(a)
INSPECT NEGATIVE RECTIFIER
Using an ohmmeter, connect one tester probe to saC'h negative (-) terminal and tha other to each rectifiilr terminal. (b) Reverse the polarity of the tester probes and repeat stop (a). · · (c) Check that one shows continuity and th" other shows no continuity. If continuity is not as specified, replace the rectifier holder.
Negative Terminal SOA Type
Negative (-) Terrryinal llfh46
lc'fi ........
.
CH-1 0
CHARGING SYSTEM - ALTERNATOR
Bearings 1. 2. {a)
{b)
7ffii
INSPECT FRONT BEARING Check that the bearing_ is not rough or worn. IF NECESSARY. REPLACE FRONT BEARING Remove the .3 screws.
Using SST and a press, press out the bearing. SST 09950-6001 0 (09951 -00220. 09952-0601 0)
5'&1
(c) (d)
3. 4. (a)
{b)
·•'
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Using SST and a press, press in a new bearing. SST 09950-6001 0 (09951 - 00400) Install the 3 screws.
INSPECT REAR BEARING Chock that tho bearing is not rough or worn. IF NECESSARY, REPLACE REAR BEARING Using SST, remove the bearing. SST og286-46011
Using a press, press in a new bearing.
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CH.ARGING SYSTEM- ALTERNATOR
CH-11
ALTERNATOR ASSEMBLY
SOA Type
•'
1.
... -
50A Type: INSTALL CONECTAMEAL HOUSiNG
s·older the conectameal housing to the rectifier hold~r . CAUTION: P:·otect
2.
t~e
rectifiers from heat.
INSTALL RECTIFIER HOLDER TO STATOR
Hold the rectifier terminal with needle-pliers while soldering t~e lead wires. CAUTION: Protect the rectifiers from heat.
3.
40A Type
A.
INSTALL RECTIFIER END FRAME TO RECTIFIER HOLDER 40A Type:
(a)
Pla~e
(b)
the 2 insulator washers on the positive studs )f the 'rectifier holder. Pla9e the rectifier end fran1e on the rectifier holder.
P2<93J
(c)
40A Type
(d)
••
(e)
Place the rear end cover on the rectifier end frame. Place the 2 terminal insulators on the positive studs on the rectifier holder. Install nut. Torque: 4.4 N·m (45 kgf.r.m, 39 in •. lbf)
(f)
Install the cord clip and condenser with the 4 nuts. Torquo: 4.4 .N·m (45 kgf.cm, 39 in.·lbf)
(g)
Check that the lead wires are not touching the rectifier end frame.
B.
50A Type:
(a)
Place the insulator washer on ths positive studs of the rectifier holder. Place tho rectifier end frame on the rectifier holcJAr. Place the 2 terminal insulators on tho positive studs on the rectifier holder. Install the condenser with the 4 nuts.
P249~
(b) (c)
(d)
Torque: 4.4 N·m (45 kgf·cm, 39 ;,.. Jbf)
(e)
.~;;;® SOA Type
::-
""" r1sJs<~
P15J5S
-1
,_/
J
..::; I
1'-V---L N
Check that the lead wires are not touching the rectifier e!ld frame.
4.
INSTALL ROTOR
(a)
40A Typd;
(b)
Place the snap nng and spacer ring onta the rotor shaft. 50A Type: Place the spa cor ring onto the rotor shaft.
. ,.
CH-12
CHARGING SYSTEM- ALTERNATOR (c)
Using a press, press in the rotor.
. ., .' ,,,-
1:.
00311
5.
INSTALL FAN AND PULLEY Mount the rotor in S'Jft jaw vise. (h) Install these parts with the nut on the rotor shaft: (1) Spacer collar (2) Fan (3) Pulley (4) Spacer collar (5) Spring washer Torque: 61.3 N·m (625 kgf·cm, 45 ft·lbf) (a)
(51 141 131 (21 ( 11 11&117
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6.
INSTALL DRIVE END FRAME ASSEMBLY AND RECTIFIER END FRAME ASSEMBJ_ Y (a) Bend the rectifier lead wires back to clear the rotor. (b) Using a curved tool, push tha brushes in as far as they· will go and hold them in placo by inserting a stiff w'ire through the accass hole in· the access hole in the rectifier end frame.
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L---------------------~-0~~~
(c)
(d) (e)
50A Typo
Seal
7. (a) (b)
Assemble the drive end frame and the rectifiar arid frame by inserting the r&ar bflaring on the rotor shaft into the rectifier end frame. Install the 3 through screws. Torque: 5.9 N-m (60 kgf·cm, 52 in .. Jbf) Remove the stiff wire from the access hole.
CHECK THAT ROTOR ROTATES SMOOTHLY Che"k that the rotor rotates r
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GHARGING SYSTEM - ALTERN A TOR REGULATOR
-1
CH-13
ALTERNATOR REGULATOR tocoeu~"
1. 2.
REMOVE ALTERNATOR REGULATOR AND COVER INSPECT ALTERN A TOR REGULATOR
A.
:nspect point surfaces for seizure and damage If defective, replace the regulator(
ALTERNATOR REGULATOR INSPECTION 0
B.
Regulator
{a)
I
0
Inspect resistance between terminals Regulator: Using an ohmmeter, measure the resistance between terminals IG and F.
1'1
-· I
{b)
Relay: Using an ohmmeter, measure the resistance between terminals E and L.
•;!•"
Resistance: At rest: 0 0 Pulled i11: Approx. 100 Q (c)
Relay: Using an ohmmoter. measure tho resistance between terminals 8 and E. Resistance: At rest: infinity Pulled In: Approx. 100 Q
{d)
Relay: Using an ohmmeter. measure the resistance bot\veen terminals 8 and L. Resistance: At rest: Infinity . fulled In: 0 0
{e)
Using an ohmmeter, measure the resistance between terminals N and E. Resistance: Approx. 23 0 If any of the above checks are not positive, replace the alternator regulator.
3.
REINSTALL ALTERNATOR REGULATOR AND COVER
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Resistance: · At rest: 0 Q Pulled in: Approx. 1 1 Q
-----------'--Relay
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CH-14 ·
CHARGING SYSTEM - SERVICE SPECIFICATIO::.:N..:cS::..__ _ _ _ _ _ _ _ __
ALTERNATOR REGULATOR VOLTAGE ADJUSTMENT .1. 2. A.
00158
B.
3.
c .........
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REMOVE ALTERNATOR REGULATOR AND COVER ADJUST ALTERNATOR REGULATOR Adjust voltage regulator Bend the regulator adjusting arm to adjust. Regu!ating voltage: At 2o•c (68.F): 13.8- 14.8 v
_..,,;;
""
Adjust voltage relay Bend the relay adjusting arm to adjust. Relay actuating voltage: 4.0 - 5.8 V
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REINSTALLALTERNATORREGU~ATORAND .\;
COV.ER
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SERVICE SPECIFICATIONS ('
SERVICE DATA
I
Battery
Alternator
Specific gravity
at 2o•c (6B"Fl NS40L
!.27 - !.29
Others
1.25 - !.27
Rated output
12 V 40 A. 50 A
STD
Minimum Brush exposed length
STD
Minimum AltE"rrlator
Regulator
Regulating voltage
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3.9-4.1 0
Rotor coil resistance Slip ring diameter
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at 20" C (68- F)
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32.3 mm - 32.5 mm ( t .27'2 - 1.280 in.}
32.1 m'll (1.254 in.) 17..5 mm (0,492 in.)
1J.8- 1•i.BV
4.0- 5.8
Relay actuating voltage
\
5.5 mm (0.217 in.)
v
TORQUE SPECIFICATIONS N·m
Pert tightened
kgf·cm .
ft·lbf
Rear end cover x Rectifier end frame
4.4
45
39 in.·lbf
Rectifier end frame x Rectifier holder {SOA Type)
4.4
45
39 in.·lbf
Cc,densar X Rectifier end frame
4.4
45
39 in.·!bf
Cord clip x R")ar and covor
4.4
45
39 in..lbf
61.3
625
45
5.9
60
52 in.·lbf
Alternator pullay x Rotor
-·
Rectifier end frame x Drive end frame
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