MAINTENANCE SECTION MA CONTENTS PREPARATION Meeaticit PRE-DELIVERY INSPECTION ITEMS GENERAL MAINTENANCE... PERIODIC MAINTENANCE RECOMMENDED FLUIDS AND LUBRICANTS ... ENGINE MAINTENANCE CHASSIS AND BODY MAINTENANCE .... SERVICE DATA AND SPECIFICATIONS (§Too! number Too! name. Description PREPARATION ‘SPECIAL SERVICE TOOLS Engine application ‘SR2ODE GAT6DE 1£G17650301 Radiator cap tester adapter Lba0-i KV10115800 il fiter cap wrench {65 mm (2.86 in) dia. Removing oil fiter KV10106250 il fer cap wrench iemoving oil fier KV10105600 il fiter cap wrench Removing oil fitor| MA-2PRE-DELIVERY INSPECTION ITEMS ‘Shown below are Pre-delivery ins Items required for the new vehicle. It is recommended that necessary items other than those listed here be added, paying due regard to the conditions in each country. Perform applicable items on each model. Consult text of this section for specifications. UNDER HOOD (front) — engine off 1 Radiator coolant level and coolant hose con- nections for leaks Battery fluid level, specific gravity and condi- tions of battery terminals Brake and clutch reservoirs fiuid level and fluid lines for leaks Windshield and rear window washer and headlamp cleaner reservoir fluid level BNDSR HOOD (interior) — engine off Drive belts tension 1 Fuel filter for water or dust, and fuel lines and connections for leaks Power steering reservoir fluid level and hose ‘connections for leaks Engine oil level and oil leaks INSIDE AND OUTSIDE [| Remove front spring/strut spacers. Lift up front of vehicle to remove them easily. evwaoae Do not drive at speeds higher than 8 knvh (5 miles/h) before spacers have been removed. ‘The handling of the car can be affected seri- ‘ously. 1 Operation of all instruments, gauges, lights and accessories 1 Operation of horn(s), wiper and washer Steering lock for operation 1 Air conditioner for gas leaks Front and rear seats, and seat belts for ope- ration All moldings, trims and fittings for fit and alignment Al windows for operation and alignment Hood, tailgate, door panels for fit and align- ment Latches, keys and locks for operation Weatherstrips for adhesion and fit Headlamp aiming 1 Tighten wheel nuts 1 Tire pressure (Inc. spare 1) Check front wheels for toe 1 Check rear wheels for toe-in (RS. models only) 1 Install clock/room lamp fuse. Remove wiper blade protectors (It necessary) UNDER BODY © Manual transmission/transaxle and differen- tial gear oil level 1 Brake and fuel lines and oil/fluid reservoirs for leaks Tighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shaits ROAD TEST © Clutch operation "Parking brake operation 5 Service brake operation 1. Steering control and returnability © Engine performance Squeaks and rattles ENGINE OPERATING AND HOT Adjust idle mixture and speed (and ignition timing) 1 Engine idling and stop knob operation (Diesel only) FINAL INSPECTION Install necessary parts (outside mirror, wheel covers, seat belts, mat, carpet or mud flaps) 1 Inspect for interior and exterior metal and paint damage 1. Check for spare tire, jack, tools and literature 1 Wash, clean interior and exterior MA-3GENERAL MAINTENANCE General maintenance includes those items which should be checked during the normal day-to-day ‘operation of the vehicle. They are essential if the vehicle is to continue operating properly. The owners ‘can perform the checks and inspections themselves or they can have their NISSAN dealers do them at a nominal charge. tem, Reference pages ‘OUTSIDE THE VEHICLE ‘The maintenance items listed here should be performed from time to time, unless other- wise specified Tires Check the pressure with a gauge periodically when at a service station, including the spare, and adjust to the specified pressure it necessary. Check carofully for damage, - Cuts or excessive wear. ‘Windshield wiper blades Check for cracks or wear if they do not wipe propery. = ‘Doors and engine hood Check that all doors, the engine hood, the trunk lid and back door ‘operate properly. Also ensure that all latches lock securely. Lubricate if necessary. Make sure that the secondary latch keeps the hood from opening when the primary latch is : MAa7 ‘When driving in areas using road salt or other corrosive materials, check for lubrication frequently. Tire rotation Tires should be rotaled every 10,000 km (6,000 miles). MAB INSIDE THE VEHICLE ‘The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc. Lights Make sure that the headights, stop lights, tail ights, turn signal lights, and other lights are all operating property and installed securely. Also check headlight aim. ‘Warning lights and buzzers/chimes Make sure that all waming lights and buzzers/chimes are operating propery. Steering wheel Check for change in he steering conditions, such as excessive tree play, hard steering or strange noises, st Free play: Less than 35 mm (18 in) UNDER THE HOOD AND VEHICLE ‘The maintenance items listed here should be checked periodically €.9. each time you check the engine ol or refuel ‘Windshield washer fluid Check that there is adequate fluid in the tank. = Engine coolant level Check the coolant level when the engine is cold MAA11, MA-23 & MAST see Check the level alter parking the vehicle on a level spot and uring Oa 47 saa.os & ALSO Brake and clutch fluid level Make sure that the brake fluid level is between the "MAX" and "MIN" lines on the reservoir. el Battery Check the fluid level in each cell t should be between the MAX” and "MIN" = lines.PERIODIC MAINTENANCE ‘The following tables show the normal maintenance schedule. Depending upon weather and atmospheric conditions, varying road surfaces, individual driving habits and vehicle usage, additional or more frequent maintenance may be required. Periodic maintenance beyond the last period shown on the tables requires similar maintenance. Engine Oil & Minor Service (Gasoline engine) Abbrevations:R~ Replace 1 Inspect. Corec or rplace it necessary, TaNTEUNEE FELTON TaRTEANSE TERT es oa RENT, Mee kk | | = omevson 9 0) 4) wo cH eoces= S| a sows au eo nus Tecra Ere een oe EE “So RD Eos le Rr PNP ST RRR | ii oe a at fe re a aa HGRA UO STI) senor = Sati SeeNOTED! Tea R AR NOTE: (1) For GA series engines periodic adjustment is not necessary. However, inspoct valve clearances Ifthe valve noise increases. @) Maintenance Rem with "#” should be performed more frequently according to "Maintenance under severe driv- ocho” (@) Non-catalizer models only. Engine Oil & Minor Service (Diesel engine) ‘Abbreviations: R= Repace | = Inpect_A = Adjust Conect or epace i nacenssy. MAINTENANCE OPERATION MAINTENANCE INTERVAL Porm ona manage basa tut on eservarruns MMBXNOD «4S «AS SAS SRS GD__Relrrce page Besgnten drvnglesstan 8000 ies (0D4m) nx 1.000) @.8) 18) 2S) GO) (7S) US) (528) (6) ones Monin sew 4 wo 6 2 Tigre ol soniew) “Engine sompariner ond wnoer ven Engine ol (Use APIGE oi oni oe ne ee Tako Engine ol are Seoncre@ A RA A AAA OR re Drive bate (or tnsion) i ie trot ange on ce (ine service Engine compare ‘seo 7 0 T T waa Dre bots 0 0 r o re Intake ard exhaust valve Oeerance a ” a - MA98 NOTE: (1) Use dual element type (Part No. 15208-40100) for engines with E.G.R. system. (2) Maintenance ae wit "shoul be permed more requenty ecorsng to “Maintenance under severe civ MA-5PERIODIC MAINTENANCE Major Service Abbreviations: Al = Replace _| = Inspect Correct or replace if necessary ( ): At the specified mileage only. ‘MAINTENANCE OPERATION MAINTENANCE INTERVAL Reterence pages Perform on an annual basis, but on a mileage basis Months a SR GA LD when driving more than 18,000 miles (30,000 km) in Miles x 1,000 8 6 St 72 ‘series series series aoe tam x 1,000) ___(80)__(60)_(80)_(120) ENGNE Trdeteonet and under erie Dive bel See NOTE GY oer ATO WADE NASD Engine an eoze coolant (Eons gyal Base) See NOTE @) MAT MA2S NAST Costing system ro MATS MAB WAS Foal nos 1 1 MAIS MAZE MAS ‘Ar cleaner er (Vas008 paper Wale a R MAIS WA25 WAS6 Fue ar a MANS MAZE — 9 a ee Senor A AAA MTG MAZ_— 3 LATINUME TIPPED type Tr cave models ® ATG MA25—— gion aad (Esco tox Sweden) 1 = z Poste crankcase vention (PCV) aR T =e MAIO MAZE — G [Vac noses ard connects" =e MAO MAZ3_— Extaust gas sensor (Except or Sweden) "2 i 1 Mazi AZO _— Vapor ines "2 See NOTE) 7 1 ARO MA23— ul Feet mere ® ® = 3 S[imecton nowos Soa NOTE) = wae 5 GilTiming belt tor camshatt and injection pump “ = = EM 114 {CHASSIS ANO BODY Tnerborne! and vader vehicle Brake & coh ad =a CSS Brake Rule ® ® MAS Bake Boosey vadaun Rone, Connestons & check valve 1 1 waa Power stern fad & Ines agra | a ake 8 euch syst ae MAST Manual wanemisor/vansane & Gandara aeertal gear oe a MA «2 Limited sip dfovental (5.0) gear ol exoot viscous Woe) iA Ma, 8 Steering gear & Inkage, axle & suepension par, propeller shal & exhalat ; 7 RA, 46, FA, systems Baa Dive sete ———— Faia ae —_—— ‘Wee algnmnont (fnecessary, rate & bance wheal) eee Whats, FRE ARS Brake pecs, des & cher brake conporenisx ieeieealiel Wasa Blake nings, dns & other bake components ae ST AAS Heaclane wimg jen eels th Foot brake, parking bake & Guich (For fos pay, svoke & operator) Sin aE GR, 28 Oca Body corenion ely ass NOTE: (1) After 24 months or 96,000 miles (60,000 kr), check every 12 monthe or 18,000 miles (90,000 km) {@) Change at 60 month or 54,000 miles (60,000 km), then every 24 months or 36,000 miles (60,000 km). {@) For Sweden parform at mileage interval only. {@) For Sweden perform at th first 80,000 km (54,000 miles), and then every 60,000 km (36,000 miles) or 24 months, Whichever comes first. (6) tt ongine power decreases, black exhaust smoke Is emitted or engine noise increases, chock and, it necessary, ‘adjust the fuel injection nozate's starting pressure and the fuel spray patter. (© Haltenance name wth "shou be performerd more requeiyeecording to "Martanance uncer severe ci- Conditions". ‘1: Noncatalyzer models only °2: Catalyzer models MA-6PERIODIC MAINTENANCE Maintenance Under Severe Driving Conditions The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance must be performed on the following items as shown in the table. SEVERE DRIVING CONDITIONS A —Driving under dusty conditions B_ —Driving repeatedly short distances © —Towing a trailer D —Extensive idling E —Driving in extremely adverse weather conditions or in areas where ambient temperatures are either extremely low or extremely high F —Driving in high humidity areas or in mountainous areas G —Driving in areas using salt or other corrosive materials H_ — Driving on rough and/or muddy roads or in the desert |__—Driving with frequent use of braking or in mountainous areas f Pe = aterence page conan ‘tem “persion “enteral? sa | ca | ww sores_| cares | sree Engine ol eaniow 7 eo n& ol mer ‘Smarter wa = £308 mos (7.800 en) aed eee = Eos ae 7 aS cae a a et = me Bios lene ae = ia ee ee ee ee oo pemeeimaeas Om RSS Za arm pretty : Sa aoe PEST ey 5 go SS foie Sar aiom i zs See iss Se Sa poe . ia i Ps ; a a rae Maborarce operon: Chack = Check. Cores replace M necessary MA-7RECOMMENDED FLUIDS AND LUBRICANTS Fluids and Lubricants Capaty Apposnae) Taconnenand tis i Saas Sane Engine oil (Refill) ‘SR200E 39 6-7/8 pts ‘Wath oll iter ‘GAI6DE 35 6-1/8 pts Gasoline engines: Lo20- a7 10 pts eee Na) ‘Wate oer roo a7 spp Biren ‘oo are a Caan aon Tatacapacy, __sRaaoe ‘00 ‘rss (With reservoir tank) “GAT6DE 9.0 15-7/8 pts tee 130 Bram Ti area Sate 33 ea pe ee GAI6DE a3 14-518 “6 ca ee (Enyane gy tase) Tio ear ane —SRa00E as Ts SADE 7 : aa oH Taal sorsais pear ot RSEATIG = Aaa Fear areal od — aK HOA TSO) TS Since arog AP ee Coat tenia (C50) gear Use coy 50 puro RpLau's an Sar eovico2 aberrant Rar a aa WISE Fava seta Bad n 1385 “pe XRT Bia are ued = = DOT 4 BS FAVES Ro TH eee = = ACG No 2 oa aso) TE Ragga catia ens, SAE Veron Nuroar “2 ERE'G0'S accpistie'm amen lomportures above -18°(0'F) MA-8RECOMMENDED FLUIDS AND LUBRICANTS SAE Viscosity Number [Outside Temperature Range Anticipated Before Next Oil Change JASOLINE ENGINE OIL 20W20, TOWED, 7050 * Not recommended for sustained high speed driving Toons «For warm and cold areas: 10W-30 is prefera- ble for ambient temperatures above ~20°C (FA). «For hot areas: 20W-40 and 20W-50 are sul- table. ‘Outside Temperature Range Anticipated Before Next Oil Change DIESEL ENGINE OIL * Not recommended for sustained high speed dri Tio008 «For cold areas: 10W-30 is preferable. For hot and warm areas: 20W-40 and 20W-50 are suitable. MA-9 ‘Outside Temperature Range Anticipated Betore Next Oil Change ‘To00s 80W-90 is preferable for ambient tempera- tures below 40°C (104°).ENGINE MAINTENANCE (i) Drive Belt Check ae oo Bp to-211s-21, cea 12-15), a 12-15) ©): Nm tkg-m, 0) ee dew WARNING: Inspect drive belt deflections when engine is cold. When engine is hot, check deflections at least 30 minutes after engine has been switched off. 1, Inspect belts for cracks, fraying, wear or oil adhesion. It necessary, replace with new ones. 2, Inspect drive belt deflections by pushing on the belt midway between pulleys, as indicated with ¥. 3. Adjust belt deflection if it exceeds the li Belt deftection: nit mm ny Used belt detoction Sot Detlection of Limit ‘Adjust deflection | _new belt 13-15 95-115 cain qe (951-059) | (0.374- 0.453) Air conditioner ee 75-95 55-75 ‘compressor (0.295- 0.974) | (0.216 - 0.295) Power sieering 11-13 eit cil pump TSE (043-051) | (0.35 - 0.43) ‘Applied pushing 98 N (10 kg, 22 1b) forceENGINE MAINTENANCE ip) all, X \ = Cie ae = aa Changing Engine Coolant Cooling System Diagram Lo ae sp @ — 7 co cmmn)| \ifFao = @ fo Front ator ® “CES = war fy ) pump — I a ® @ © ® enor @ Front heater coolant filer cap ® Cylinder block drain plug ® Transparent hose @ Front heater air reliet cap ® Rear heater air relict cap Inner diameter: 7.5 mm (0.295 in) @ Fadator iter cap © ONOF vave Ung 1/200 me (7 2 in) @ Radiator drain plug @® Expansion tank cap 1S One wey ove WARNING: To avoid being scalded, never change the coolant when the engine is hot. 1, Move temperature control lever of the heater to the "HOT" position (from front and rear heater, if so equipped). 2, Remove engine under cover. 3. Tum the ON/OFF valve, situated in the outlet tube from the expansion tank, to the “ON” position, MA-31ENGINE MAINTENANCE a Changing Engine Coolant (Contd) ‘air relet cap es Nes = 4, 8. 6 Remove radiator drain plug. Remove radiator cap. Remove expansion tank cap. . Open both the air relief valve and filler apperture of the front heater. |. Remove the air relief cap of the rear heater. |. Disconnect hose leading from engine to expansion tank at engine side (as indicated with “D” in Cooling System Diagram), and plug hose. See illustration at left. |. Remove cylinder block drain plug. MA-32ENGINE MAINTENANCE {) Changing Engine Coolant (Cont'd) 11. Disconnect upper and lower hoses to rear heater, at loca- tions indicated with “A” and “B” in Cooling System Dia- gram 12. Disconnect upper radiator hose at location indicated with 'C” in Cooling System Diagram. 18. Drain cooling system completely. 14. Remove Reservoir tank and clean it. Re-install it temporarily. * Be careful not to allow coolant to contact drive belts. 15. Re-install radiator- and cylinder block drain plugs and ighten them securely. 16. Re-connect upper radiator- and rear heater hoses. 17. Connect a transparent tube to that position, where the hose from the expansion tank has been disconnected (position indicated with “D” in Cooling System Diagram). Dimensions transparent tube: — inner diameter: 7.5 mm (0.295 in) = length: 1,200 mm (49.24 in) 18. Place a tray under the air relief valve of the rear heater, in order not to spill any coolant. 19. Fill radiator with water and install radiator cap. 20. Fill cooling system further by pouring water into expansion tank, until water spills from air relief valve of rear heater. If no more air escapes from this air relief valve, close it «Tighten clamp securely. 21. Continue filling cooling system by pouring water into filler aperture of front heater, meanwhile monitoring fluid level in the transparent tube. MA-33,ENGINE MAINTENANCE Gp) 7 Front healer coolant fer Changing Engine Coolant (Cont'd) 22. When the level mentioned above is at the same hight as the filler aperture of the front heater, stop pouring water. 23. Close the filler aperture and the air relief valve of the front heater. ‘¢ Tighten clamps securely. 24. Remove the transparent tube and reconnect hose to ‘expansion tank. 25. Fill reservoir tank up to specified level. 26. Warm up engine at approx. 2000 rpm until radiator fans operate. Make sure that air conditioner switch is “OFF”. Monitor water temperature gauge, to check that engine does not overheat. 27. Stop engine and wait unti it has cooled down, 28. Repeat steps 4 through step 27 until clear water starts to drain trom radiator. 29. Drain water following steps 4 through 13. 30. Re-install reservoir tank. 81. Fill cooling system with coolant following steps 15 through 27. © Apply sealant to the thread of cylinder block drain plug. (0): 44 - 54 Nem (4.5 - 5.5 kg-m, 33 - 40 ft-lb) Follow instructions attached to anti-freeze container for mixing ratio of anti-freeze to water. Coolant capacity (with reservoir tank): 13.0 1 (2-7/8 imp pts) Coolant capacity with rear heater (without reservoir tank): 12.3 ¢ (21-5/8 imp pts) Coolant capacity without rear heater (without reservoir tank): 11.31 (19-7/8 imp pts) Reservoir tank for “H” level: 07 ¢ (1-1/4 Imp pts). Expansion tank: 2.14 (3-3/4 Imp pts) Pour coolant through coolant filler neck slowly to allow air in system to escape. 32. If necessary add coolant. 33, Turn the ON/OFF valve, situated in the outlet tube from the expansion tank, to the “OFF” position. MA-34ENGINE MAINTENANCE (a) suaszre] swasoa| Checking Cooling System (CHECKING HOSES Check hoses for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. RADIATOR CAP CHECK 1. Check relief pressure with cap tester. Radiator cap relief pressure: 78-98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm?, 11 - 14 psi) Replace radiator cap if pressure is not within the specified values. 2, Pull the negative-pressure valve to open it, and check that it closes completely when released. COOLING SYSTEM LEAK CHECK ‘Apply pressure to the cooling system with cap tester to check for leakage: Testing pressure: ‘98 kPa (0.98 bar, 1.0 kg/em?, 14 psi) CAUTION: Higher pressure than the specified value may cause damage to radiator. Fuel Line Check Inspect fuel lines and tank for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. If necessary, repair or replace malfunctioning parts. MA-35,ENGINE MAINTENANCE @) Air Cleaner Filter Replacement ‘The viscous paper type air cleaner filter does not require any cleaning operation between renewals. Water Draining, Fuel Filter Check and Replacement WATER DRAINING ‘Open drain cock at the bottom of fuel filter. FUEL FILTER CHECK Check fuel filter for {uel leakage, damage and other abnormal signs. FUEL FILTER REPLACEMENT 1. Disconnect water sensor connector and replace fuel fiter with a new one. Hand-tighten fuel fitter by about 2/3 tum after O-ring touches mounting surface, Follow the instructions on fuel filter. 2. Connect water sensor connector and bleed fuel system. FUEL SYSTEM AIR BLEEDING 1. Disconnect fuel retum hose at fuel injection pump. 2. Bleed air from fuel system with the priming pump until no bubbles corrie out of fuel return pipe of injection pump. 8. Securely connect fuel return hose, ie Oil Change Waming: Be careful not to burn yourself, as engine oil is hot. 1. Warm up engine, and check for oil leakage from engine ‘components. 2. Remove oil filler cap. 3. Remove oil drain plug and drain oil. MA-36ENGINE MAINTENANCE (i) ‘suas susor Engine Oil Change (Cont'd) 4, Tighten oil drain plug, 5. Fill with engine oil. Oil refill capacity: Unit: «(imp pis) Without ol fiter 5.2 (9-1/8) With ol fiter 527 (10) CAUTION: «Be sure to clean drain plug and install with new washer. Drain : (0}:29-39 Nem (8.0 4.0 kg-m, 22 - 29 fb) « Use recommended engine oil. Consult “RECOMMEND FLUIDS AND LUBRICANTS”. Confirm cil level and warm up en Recheck oil level and adjust it to ND level if necessary. Engine Oil Filter Change 1. Remove oil fier with Tool. WARNING: Be careful not to burn yourself, as engine and engine oil are hot. 2. Before installing new oil filter, wipe clean oil filter mounting surface on cylinder block, and apply a litle engine oil to rubber seal of oil filter. MA-37ENGINE MAINTENANCE {ea 2/9 of «turn i erro serssea| Engine Oil Filter Change (Cont'd) 3. Screw oil filter on until a slight resistance is felt, then tighten an additional 2/3 tum or more (1/2 turn for ‘models with EGR. system). 4. Warm up engine and check oil level. 5. Adjust oil level if necessary. Refer to Engine Oil Change. Injection Nozzle Check 1. Remove injection delivery tubes and fuel spill tube. 2. Remove nozzle with a suitable tool [span 27 mm (1.06 in)]. 3. Install injector to pressure tester. 4. Check initial injection pressure by pumping tester handle slowly (one time per second). Injection i Pressure: 12,259 - 19,299 kPa (122.6 - 132.4 bar, 125 - 135 kg/em’, 1,778 - 1,920 psi) 5. Check fuel spray pattern by pumping tester handle quickly (4 or 6 times per second). 6. If injection nozzle is not in normal condition, replace or correct. Refer to EF & EC section for injection pressure adjustment. 7. Install all injection nozzles and securely connect fuel spill tube and delivery tubes. 8. Bleed air from fuel system and check for fuel leakage with engine running. MA-38,ENGINE MAINTENANCE eto speed adjusting screw uo injection pum suaszoc| m Idle Speed Check Inspection should be carried out with gears in “Neutral” and with air conditioner and other electrical loads off. 1. Warm up engine to normal operating temperature. 2. Attach a diesel tacho tester. 3. Race engine two or three times and check idle speed. Idle Speed: Unit: 1pm +50 Idle speed 700 7 5 idle speed with air conditioner + 50 ON" 00 4. If itis out of specification, adjust idle speed with idle speed adjusting screw. Securely lock the adjusting serew with lock nut. Timing Belt Replacement Refer to EM section. Adjusting Intake and Exhaust Valve Clearance ‘Adjustment should be made while engine is warm but not run- ning. 1. Remove valve rocker cover. 2. Set No. 1 cylinder at top dead center on its compression stroke and adjust valve clearance @, @), @ and ©. 3. Set No. 4 cylinder at top dead center on its compression stroke and adjust valve clearance @ Valve clearance: (Hot) Exnoos Intake 0.25 mm (0.010 in) Exhaust 0.30 mm (0.012 in) (Cold) Intake 0.18 mm (0.007 in) Exhaust 0.25 mm (0.010 in) MA-39ENGINE MAINTENANCE D) Adjusting Intake and Exhaust Valve Clearance (Cont'd) 1) Loosen pivot lock nut and turn valve rocker pivot until spec- ified clearance is obtained. 2) After adjustment, tighten pivot lock nut using Tool and recheck clearance. ©): 49-59Nm (6.0 - 6.0 kg-m, 36 - 43 fb) MA-40SERVICE DATA AND SPECIFICATIONS (S. Engine Maintenance (Cont'd) INSPECTION AND ADJUSTMENT TIGHTENING TORQUE Drive belt deflection Unit Nm kgm ft Luni mm (in) “Aerator, power stserng W-51 38-52 27-98 Used bot deacon] eo ae = detection ‘Aerator, power steering Limit | A908 tee | “ot new bot Neer set 16-21 12-15 aaa voen| 2% | ees (Winder biock drain plug 44-84 45-55 93-40 (051-059) | (0374 -0.459) Engine ollpan drain plug 29-99 30-40. 22-20 Arconditonercom |; 4x] 75-85 | 55-75 Injector (To nea 59-69 60-70 43-51 pressor (0295 -0.374)| (0216-0295) wale oils ckaae tae Power siaenng a Te an oe 16058) | ads eye Gias 0m) Delivery tube, 22-25 22-25 16-18 a 981 (10 kg, 2210) Coolant capacity (Refill capacity) Lunt ¢ (imp pis) 123 e188) 71.3 (18778) 07 (F-1m) 216-34) Cooling system check nt: KPa oar, gle? 78 - 98 (0.78 - 098, 08- 1.0, 11-14) Radiator testing pressure 98 (0.98, 1.0, 14) Radiator cap relief pressure Engine oil capacity (Refill capacity) Unt: «(imp pis) Without ol fitter 5.2 (9-1/8) With of iter 57 (30) Injection nozzle Unit: KPa (bar, Kole’ Inia ijeeson pressure ne Oias tas, 1800-2085) cae ‘as oe, 78 1800) Idle speed Unit pm Idle speed with Aircondtioner “ON MA-51ENGINE MECHANICAL SECTION E M jem EM. 2 EM 5 CONTENTS PRECAUTIONS PREPARATION .. SR OUTER COMPONENT PARTS ... COMPRESSION PRESSURE OIL PAN .. TIMING CHAIN OIL SEAL REPL CYLINDER HEAD ... ENGINE REMOVAL ... CYLINDER BLOCK = GA OUTER COMPONENT PARTS ... COMPRESSION PRESSURE . OIL PAN TIMING CHAIN OIL SEAL REPLACEMENT CYLINDER HEAD .... VALVE CLEARANCE ENGINE REMOVAL. CYLINDER BLOCK a EM- 10 EM- 13 a EM: 14 EM. 19 EM. 32 EM- 34 EM. 45 EM. 48 EM- 60 EM. 64 EM- 65 EM. 67 EM. 77 . EM- 79 EM. 87 EM- 90 EM- 93 OUTER COMPONENT PARTS COMPRESSION PRESSURE (On-vehicle service) OIL PAN (On-vehicle service) . TIMING BELT (On-vehicle service) OIL SEAL REPLACEMENT (On-vehicle service) CYLINDER HEAD ...... : ENGINE REMOVAL .. CYLINDER BLOCK EM-107 EM-109 EM-112 EM-114 EM-119 EM-122 . EM-136, EM-139 ——— SERVICE DATA AND SPECIFICATIONS (S.D.S. .» EM-152Tentication mark of sodkum-iled exhaust valve seuoseo| Black ion color Siver calor Unit: ment) semosec| et ae senaeoc] PRECAUTIONS Special Cautions to Ensure the Safe Disposal of Sodium-filled Exhaust Valves (SR20DE Engines) The handling and disposal of sodiumfilled exhaust valves requires special care and consideration. Under conditions such as breakage with subsequent exposure to water, the sodium metal which lines the inner portion of the exhaust valve will react violently, forming sodium hydroxide and releasing hydro- gen gas which may result in an explosion or fire. A sodium-filled exhaust valve is identified on the top of its stem as shown in illustration. DEALER DISPOSAL INSTRUCTIONS CAUTION: ‘© Use approved shatter-resistant eye protection when per- forming this procedure. * Perform this and all subsequent disposal work procedures in an open room, away from flammable liquids. Keep a fire extinguisher, rated at least 10 ABC, in close proximity to ‘the work area. ‘Be sure to wear rubber gloves when performing the follow- ing operations. Clamp valve stem in a vice. 2. The valve has a specially-hardened surface. To cut through. it, first remove a half-round section, approximately 30 mm. (1.18 in) long. Use an air-powered grinder until the black iron color is removed and the silver-colored metal appears. 3. Use a hacksaw to cut through approximately half the diam- eter of the valve stem. Make the serration at a point 40 mm (1.57 in) from the end of the stem. EM-2seneerg PRECAUTIONS Special Cautions to Ensure the Safe Disposal of Sodium-filled Exhaust Valves (SR20DE Engines) (Cont'd) 4. Cover the serrated end of the valve with a large shop towel. Strike the valve face end with a hammer, separating it into two pieces. 5, Fill a bucket (such as a 20 coil can) with at least 10 ¢(2-1/4 Imp gal) of water. Carefully place the already-cut (serrated) valves into the water one-at-a-time using a set of large tweezers and quickly move away at least 2.7 m (9 ft). The valves should be placed in a standing position as shown in the illustration to allow complete reaction of the sodium with the water. The major portion of the resultant chemical reac- tion lasts 1 to 2 minutes. After the bubbling action has subsided, additional valves can be placed into the bucket allowing each subsequent chemical reaction to subside. However, no more than 8 valves should be placed in the ‘same 10 ¢ (2-1/4 Imp gal) amount of water. The complete ‘chemical reaction may take as long as 4 to 5 hours. Remove the valves using a set of large tweezers after the ‘chemical reaction has stopped. Afterwards, the valves can be mixed with ordinary scrap metal. CAUTION: Make sure the resultant (high alkalinity) waste water does not contact your skin. If the waste water does contact you, wash the contacted area immediately with large quantities: of water. Dealers should check their respective country and local regulations concerning any chemical treatment or waste water discharge permits which may be required to dispose of the resultant (high alkalinity) waste water. Parts Requiring Angular Tightening * Some important engine parts are tightened using an angu- lar-tightening method rather than a torque setting method. « Ifthese parts are tightened using a torque setting method, dispersal of the tightening force (axial bolt force) will be two or three times that of the dispersal produced by using the correct angular-tightening method. + Although the torque setting values (described in this man- ual) are equivalent to those used when bolts and nuts are tightened with an angular-tightening method, they should be used for reference only To assure the satisfactory maintenance of the engine, bolts and nuts must be tightened using an angular-tightening method. Before tightening the bolts and nuts, ensure that the thread ‘and seating surfaces are clean and then coated with engine oil. EM-3PRECAUTIONS Parts Requiring Angular Tightening (Cont'd) «The boltsand nuts which require the angular-tightening method are as follows: (1) Cylinder head bolts ..... SR, GA, LD (2) Main bearing cap bolts ..... SA (3) Connecting rod cap nuts ..... SR, GA uid Gasket Application Procedure ‘a. Before applying liquid gasket, use a scraper to remove all > traces of old liquid gasket from mating surface and groove, and then completely clean any oil stains from these por- | tone b. Apply a continuous bead of liquid gasket to mating sur- faces. (Use Genuine Liquid Gasket or equivalent.) Groowe «Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in) en wide for SR engine and 3.5 to 4.5 mm (0.138 to 0.177 in) wide for GA and LD engine (for oil pan). seusric] Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) wide (in areas except oil pan). ¢. Apply liquid gasket to inner surface around hole perimeter area. (Assembly should be done within 5 minutes after coating.) d. Wait at least 30 minutes before refilling engine oil and ‘engine coolant. EM-4PREPARATION SPECIAL SERVICE TOOLS *: Special tool or commercial equivalent Tool number Description Engine application Tool name Sia =eA-1-u: STOSOTSOOO Disassembing and assombing Engine stand assembly D @ $705011000 Engine stand @ 705012000 ce ites sia Base KV10106500 Engine stand shaft V10118300 Engine sub-attachment Engine attachment assembly @® KV10106500 Engine attachment @® Kv10113300 ‘Sub-attachmont ‘When overhauling engine '$710120000 Loosening and tightening cylinder Cylinder head bolt head bolt wrench Kv10116200 Valve spring compressor @ Kv10115900 ‘Attachment Disassembling valve mechanism EM-5PREPARATION +: Special tool or commercial equivalent ‘Tool number Tool name KV10109250 Valve spring ‘compressor @ Kv10109210 Compressor @ Kv10109220 Adapter Description Disassembling valve ‘mechanism Engine application SR ry KV10115600 Valve oil seal drit Installing valve oi seal inako Exhaust sR | Sdoa | Sido 8 ‘Sido A KVv10107902 Valve ol seal puller @ Kv10116100 Holder (Holder design diflers between KV10107900 and, Kv10107902,) Displacement valve lip seal KV10115700 Dial gauge stand ‘Adjusting shims Kvi0115180 Liter stopper set @ Kvror1s110 Camshat piers @ kv10115120 Liter stopper ‘Changing shims = EM03470000 Piston ring compressor Installing piston assembly into cyinder bore EM-6PREPARATION *: Special tool or commercial equivalent Tool number Description Engine application Tool name sf | GA] 1D Kv 10107400 @ Disassembling and Piston pin press stand ‘assembling piston pin @ kvi0107310 Genter shaft @ st13040020 Stand @ ST13040080 Spring @® Kvt0107320 Cap © ST13040050 Dat V11100300" Nozzle holder socket V10111700 Seal cutter Removing oll pan wS39930000 ‘Tube presser Pressing the tube of liquid gasket KVv10112100 Tightening bots for bearing cap, V11102900" Pulley puller ‘Angle wrench cylinder head, etc. thew EM-7PREPARATION. + Special tool or commercial equivalent Tool number Description Engine application Too! name SA tc) KV 10105650 ® Ring goar stopper ) animes Quo Adapter rai re * @ Kv10105610 uy) Plate assembly = Spark plug wrench | Removing and instaling spark plug a) r 1 x * > Sie (osaim Valve seat cuter sat | Finishing valve seat dimensions mh all x Piston fing expander | Removing and instaling piston Weg) aN ; x} x] x Valve guide drt Femoving and insaling valve guide —P Ae \ so x Sh lute Steet A - smn Bart GA Intake & Exhaust A = 95 mm (0.374 in) dia. B= 55mm (0217 im) dla, EM-8PREPARATION *: Special tool or commercial equivalent Tool number Too! name Description Kvi0104180 Grankshatt main bearing cap puller @ Crankshaft main bearing puller @ Adapter @ Adapter Engine application sa | Ga | iD 8710640001 Pivot adjuster (valve clearance) Tool number Too! name Description COMMERCIAL SERVICE TOOLS Engine application Valve guide reamer Reaming valve guide @ or hole SA | GA | 1D for oversize valve guide @) o = er = gt a >, ah ee 4 pe nim ma Ly oy Trake & 70.178 = Exhaust sin eed (0.4008) Take & cas oa Exhaust PREM), (0.3813) Front of weal dit Tnstaling front oll seal Kelle Mes A= 15mm 295 in i. 82 Bim{tarin as. ear ol seal cit Instaling rear ol seal i ae ps ea ee A 0mm (99 mga arm isin oe EM-9OUTER COMPONENT PARTS: to) [Bh eter ons o7-19 ® Water pipe @ Oi cooler @ Glow pug @ To water pump © Oifitor @ Metalic pipe @ Injection nozzle @ Injection pump @ Engine siinger @® Spill tube © Injection tube @ Oitcoller gaskot ® Oitcooier @ Glow plug connecting plate EM-107OUTER COMPONENT PARTS \ Setar *% el &. Or onan -co see -@ # | Ste = eas | Spe sia om | ee Sf By a4 5449-5, 00-40) » te bo ney 16-22 4 (18-22, 12-16) ee (14-97, 10-12) (@0- 40,21 -29) TB vm agen) cemoes @ Water outiet @ Back cover @ Tensioner pulley @ Thermostat ® Timing belt 2 Dust cover ‘Thermostat housing @ Camshatt pulley @ Alternator $ ‘Water temperature sensor @ Idler pulley @ Compressor bracket @ Intake manifold @ Cranktiming pulley @ Compressor ® Exhaust manitols @ Injection pump pulley. @ EGR tube @ Exhaust manifold cover @ Crank damper pulley ® EGA vane EM-108COMPRESSION PRESSURE (On-vehicle service) 1. Warm up engine sufficiently. 2. Disconnect injection tubes on nozzle side and loosen injec- tion tubes on pump side. Release clamps on injection tubes. Use two wrenches to prevent delivery holder on pump side from loosening. 3. Remove spill-tube assembly. «To prevent spill tube from breaking, remove it by gripping nozzle holder. 4. Remove all injection nozzles using a suitable tool. 5. Disconnect fuel-cut solenoid valve connector.COMPRESSION PRESSURE (On-vehicle service) 6. Fit compression gauge to cylinder head. 7. Crank engine and read compression gauge indication. Cranking speed: 200 rpm ‘Compression pressure: kPa (bar, kg/em?, psi) Standard 3,138 (31.4, 32, 455) Limit 2,482 (24.52, 25.0, 356) Limit of difference between cylinders 490 (4.90, 5.0, 71) 8. Ifthe pressure appears low, pour about 3 m¢(0.11 Imp fl oz) of engine oil through nozzle holes and repeat test. For indications of test, refer to the following table. Gauge indication during tests Trouble diagnosis }» Piston rings are wom or damaged. J» If two adjacent cylinders are low, gasket is damaged. Je Valve is sticking Je Valve seat or valve contact surface is incorrect, EM-110COMPRESSION PRESSURE (On-vehicle service] a) 9. Replace nozzle gaskets and re-install injection nozzles. New nozzle gaskets must be installed in the direction shown. Nozzle to cylinder head: (9): 59-69 (6-7 kg-m, 43 - 51 fttb) 10. Install spill tube by holding nozzle holder. Spill tube nut: 1D: 39-49 Nm (4-5 kg-m, 29-36 ftb) 11. Install injection tubes using two wrenches as shown. Injection tubes: Oy: 22-25 Nm (22-25 kg-m, 16 - 18 fb) EM-111OIL PAN (On-vehicle service) Removal 4. Drain oil. 2. Remove oil pan using tool as illustrated. 1) Insert Tool between oil pan and cylinder block. © Do not drive seal cutter into oll pump or rear oil seal retainer portion, or aluminum mating surfaces will be da- maged. * Do not insert screwdriver, or oil pan flange will be deformed. 2). Slide Too! by tapping it with a hammer, and remove oil pan. 3. Remove adaptor plate and oil strainer. Installation 1. Before installing oil pan, remove all traces of liquid gasket from mating surface using a scraper. * Also remove traces of liquid gasket from mating surface of cylinder block «Be sure liquid gasket is 4.0 to 4.5 mm (0.157 to 0.177 in) wide. Use Genuine Liquid Gasket or equivalent. EM-112OIL PAN (On-vehicle service) aay 4 eee SGT cro Installation (Cont'd) 2. Apply liquid gasket to oil pan front cil seal and rear oil seal, at the locations as shown in the illustration. 3. Apply liquid gasket to inner sealing surface as shown at left. 4. Apply a continuous bead of liquid gasket to mating surface of oll pan. + Attaching should be done within 5 minutes after coating. 5. Install adaptor plate and oil strainer. F plate bolts: : 7-9 Nem (0.7 - 0.9 kg-m, 5.1 - 6.5 ftb) strainer bolts: ): 16 - 20 Nem (1.6 - 2.0 kg-m, 12 - 15 fb) 6. Install oil pan and tighten bolts in the order shown in the figure. Wait at least 30 minutes before refilling engine oil. Oil pan bolts: ©: 7-8 Nm (0.7- 0.8 kg-m, 5.1 - 5.8 fb) EM-113TIMING BELT (On-vehicle service) @ CAUTION: ‘a. Do not bend or twist timing belt. b, After removing timing belt, do not turn crankshaft and camshaft separately because valves will strike piston heads. ¢. Ensure that timing belt, camshaft sprocket, crankshaft sprocket and belt tensioner are clean and free coolant. bf ® 31-99 mgm, (a2-40,23-29) (14-16, 101-118) Estos f Removal 1 Remove engine; refer to “ENGINE REMOVAL”. 2 Set No. 1 cylinder at T.D.C. on its compression stroke. EM-114OIL PAN (On-vehicle service) (a) Installation (Cont'd) 2. Apply liquid gasket to oil pan front oil seal and rear oil seal, at the locations as shown in the illustration. 3. Apply liquid gasket to inner sealing surface as shown atleft. 4. Apply a continuous bead of liquid gasket to mating surface of oil pan. Attaching should be done within 5 minutes after coating. 5. Install adaptor plate and oil strainer. r : 7 = 9 Nem (0.7 - 0.9 kg-m, 5.1 -6.5 ftb) strainer bolts: ©: 16 - 20 Nem (1.6 - 2.0 kg-m, 12 - 15 ft-lb) 6. Install oil pan and tighten bolts in the order shown in the figure. Wait at least 30 minutes before refilling engine oil. Oil pan bolts: (): 7-8 Nem (0.7 - 0.8 kg-m, 5.1 - 5.8 ft4b) EM-113TIMING BELT (On-vehicle service) on) CAUTION: a. Do not bend or twist timing belt. b ‘After removing timing bel, do not turn crankshaft nd camshe seperately because vaies wil trie c Eves Sat toi bol cami rock ef ashal wh teeta ali Sopsionar Wa leat na ee from oil and coolant. (08-07,43-51) Q Ph eee (135-148, 98 - 108), B99 @ Mt 57 (14-16, 101-196) BD Nm tiem 1-0) Removal 1 Remove engine; refer to “ENGINE REMOVAL”. 2 Set No. 1 cylinder at T.D.C. on its compression stroke. EM-114TIMING BELT (On-vehicle service) REMOVAL (Cont'd) + Remove starter motor, and install ring gear stopper using mounting bolt holes. «Remove crank pulley bolt Remove crank pulley using puller. Be sure to securely attach puller jaws. Attach jaws only to the rear side of pulley. «Remove belt covers. 2. Remove timing belt. (1) Loosen tensioner pulley bolt, turn tensioner pulley counter- clockwise and re-tighten bolt. (2) Remove timing belt with crankshaft sprocket. EM-115TIMING BELT (On-vehicle service) Inspection TIMING BELT Visually check the condition of timing belt. Replace if any abnormality is found. Item to check Problem Cause Tooth is brokenvtooth [* Camshait jamming ‘oot is cracked. '* Injection pump jamming /* Damaged camshalvcrankshatt oil seal semsoaa Back surface is '¢ Tensioner jamming cracked/worn '* Overheated engine }¢ Interference with belt cover ‘SEMGS5A ‘Side surfage is war. tye /* Belt corners are worn and round, /¢ Wicks are trayed and coming out. _SEMG06A (Improper installation of belt Maltunctioning crankshatt pulley plateltiming bolt plate Teeth are worn. a ing direction /* Canvas on tooth face is wom down. /* Canvas on tooth is futty, rubber layer is worn down and faded white, or welt is worn down and invisible. SEMS97A oor belt cover sealing Coolant leakage at water pump ‘Camshaft not functioning properly Distributor not functioning properly Excessive belt tension (Oil, coolant or water is stuck to belt Poor oil sealing of each oll seal Coolant leakage at water pump Poor belt cover sealing EM-116ING BELT (On-vehicle service) Inspection (Cont'd) Belt tensioner, tensioner spring and idler 1. Check belt tensioner and idler for smooth turning. 2. Check condition of tensioner spring. Crankshaft sprocket and front camshaft sprocket Check teeth for abnormal signs. Installation 1, Install crankshaft sprocket plate in correct direction. 2. Confirm that No. 1 piston is set at T.D.C. on its compres- sion stroke. 3, Install tensioner and return spring. ‘Temporarily tighten bolts so that tensioner is set at the fully outside position. 4. Install idler and tighten bolt to the specified torque. (GO): 44-54 Nem (4.5 - 5.5 kg-m, 33 - 39 ft-lb) EM-117TIMING BELT (On-vehicle service) (2) ata (Cont'd) Install timing belt with crankshaft sprocket. ‘. Align white lines on timing belt with punchmarks on cam- shaft sprocket, injection pump sprocket and crankshaft b. Point arrow on timing belt toward belt cover. 6. Agiust timing belt tension. 1) Loosen tensioner lock bolt to apply tension to timing belt. 2) Rotate crankshaft clockwise two tus to apply the specified tension to timing belt. 3) Tighten tensioner lock bolt while holding tensioner pulley with hexagon wrench. Belt tension: 147.1£24.5 N (1522.5 kg, 33.1£5.5 Ib) 7. Install lower and upper belt covers. Belt cover: 1: 7-9.N'm (0.7 -0.9 kg-m, 5.1 - 65 fib) 8. Install crankshaft pulley and thighten crank pulley bolt, (O): 137 - 157 Nem (14 - 16 kg-m, 101 - 116 ft-4b) INJECTION TIMING ADJUSTMENT Refer to EF & EC section. EM-118OIL SEAL REPLACEMENT (On-vehicle service) VALVE OIL SEAL 1, Remove timing belt, refer to “Removal” in “TIMING BELT”. 2. Remove camshaft sprockets, injection pump, tensioner pul- ley and idler pulley. If itis hard to remove pulleys, use a puller, 3. Remove rocker cover and ventilation hose. 4. Remove valve rocker spring. 5. Remove valve rocker arm and valve rocker arm guide. 6. Remove camshaft brackets and camshaft. 7. Replace valve oil seal according to the following procedure. When replacing valve oil seal, set the corresponding piston at T.D.C. Failure to do so causes the valve to drop into the cylin- der. 1) Set No. 1 cylinder at T.D.C. 2) Remove valve springs and valve oil seals for No. 1 and No. 4 cylinders. Kv10109210. v10111200 3) Install new vaive oil seals for No. 1 and No. 4 cylinders as illustrated. Reinstall valve springs. (narrow pitch side towards cylinder head) 4) Set No. 2 cylinder at T.D.C. 5) Replace valve oil seals for No. 2 and No. 3 cylinders according to steps 2) and 3). EM-119OIL SEAL REPLACEMENT (On-vehicle service) CAMSHAFT AND CRANKSHAFT OIL SEAL INSTALLING DIRECTION AND MANNER «When installing camshaft and crankshaft oil seals, be care- ful to install them correctly, as shown in the figure. ¢ Apply engine oil to oil seal lip, outer face, camshaft and bracket. Engine «¢ Engine me nas e Wipe off excess oil after installing oil seal. ot sap unt al tp sevri CAMSHAFT OIL SEALS 1. Remove timing belts, sprockets and back covers. 2. Pull out oil seal with a suitable tool. 3. Install new oil seals with a suitable tool. Confirm that arrowmarks on oil seals match with rotating direc- tion of camshaft. CRANKSHAFT FRONT OIL SEAL 1. Remove valve timing belt and crankshaft sprocket. 2. Remove crankshaft sprocket cover. 3. Remove oil seal with a suitable tool. 4. Apply engine oil to new oil seal and install oil seal using a suitable tool. senaai EM-120OIL SEAL REPLACEMENT (On-vehicle service) CRANKSHAFT REAR OIL SEAL 1. Remove transaxle assembly. (Refer to MT section.) 2. Remove flywheel and rear plate. 3. Remove rear oil seal with a suitable tool. 4. Apply engine oil to new cil seal and install oil seal using a suitable tool. EM-121CYLINDER HEAD 3 croenti A ® _Q=@ @G22 a ay ee BL bron ney = ® Rocker cover gasket @ Intake vave @ Oil seat ® Valve rocker arm @ Vaive guide @ Spacer ® Vave rotate @ Exraust valve @ Camsratt @ Valve cotter @ Combustion chamber @ Injection pump bracket 9 tee enie @ Valve seat @ Rocker cover 2 enema @ Cylinder head @ Cylinder head gasketCYLINDER HEAD — Removal Gp) 1. Drain coolant and disconnect front exhaust pipe from ma- nifold. Remove water hoses, air duct and rocker cover. Remove timing belt, refer to “Removal” in “TIMING BELT”. Remove camshaft sprockets and camshaft, refer to “VALVE OIL SEAL" in “OIL SEAL REPLACEMENT”. Sop Remove E.G.R. valve and -tube. Remove heat shield from exhaust manifold. Remove intake manifold. aoe 8. Remove exhaust manifold and thermostat assembly. 9. Disconnect injection tubes, refer to “COMPRESSION PRESSURE”. 10. Remove cylinder head. Loosen in numerical order. ‘The bolts should be loosened in two or three steps. EM-123CYLINDER HEAD — Disassembly 1. Remove glow plug connecting plate. 2. Remove valve component parts using special service tool. Keep each valve and its components together and mark them so they can be reassembled in their original posi- tions. 3. Remove valve oil seals using special tool. EM-124Warpage of surface: CYLINDER HEAD — Inspection = 3 ° i SC ee 18 mm 2 (0.59 In) Ci ¢ CYLINDER HEAD DISTORTION 1. Visually check for cracks and deformation. 2. Check cylinder head for distortion. Head surface flatness: Less than 0.1 mm (0.004 in) If beyond the specified limit, replace or resurface cylinder head. Resurfacing limit: The resurfacing limit of the cylinder head is related to the amount of resurfacing of the cylinder block. When: “A” is the amount of resurfacing needed for the cylinder head and ‘“B” is the amount of resurfacing needed for the cylinder block, the maximum limit is determined by ‘A + B = 0.1 mm (0.004 in) After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, the cylinder head must be replaced. ‘Nominal height of cylinder head: 89.4 - 89.6 mm (3.520 - 3.528 in) VALVE GUIDE CLEARANCE 1. Measure deflection across the cylinder head as illustrated. Valve deflection limit (dial gauge reading): 0.1 mm (0.004 in) 2. If. exceeding the limit, check valve-to-guide clearance. a) Measure valve stem diameter and valve guide inner diam- eter as illustrated. b) Check that clearance is within the specification. Valve stem to valve guide clearance limit: ‘0.1 mm (0.004 in) ©) If exceeding the limit, replace vaive or valve guide. VALVE GUIDE REPLACEMENT 1. Heat cylinder head in oil to 150 to 160°C (300 to 320°F). 2. Drive out valve guide using a press or hammer and a suit- able tool. EM-125CYLINDER HEAD — Inspection 3. Ream cylinder head valve quide bore. Reaming bore (service part): 12.223 - 12.234 mm (0.4812 - 0.4817 in) 4. Heat cylinder head to 150 to 160°C (802 to 320°F) and press service vaive guide onto cylinder head, 5. Ream valve guide. Final size: 8,000 - 8.018 mm (0.3150 - 0.3157 in) VALVE SEATS 1. Check valve seats for any evidence of pitting on valve con- tact surface, and reseat or replace if worn out excessively. Correct valve seat surface. When repairing valve seat, check valve and valve guide for wear beforehand. if worn, replace them. Then correct valve ‘Seat. 2. Check valve and valve seat for contact. Coat the valve face with prussian red lead. If contact is wrong, correct valve seat. If the valve red lead appears 360° around face, the valve stem and face are concentric. If not, repair or replace valve. EM-126CYLINDER HEAD — Inspectior %: tote Exhwoet 103 '98:0.15 (03740:0.0058) 15 (0.3976:0.0088) x Unit: mm ‘uewoor seve sewa77 W: Referto 5.05, semss5al VALVE SEAT REPLACEMENT 1. Bore out old seat until it collapses. The machine depth stop should be set so that boring can- not continue beyond the bottom face of the seat recess in oylinder head, 2, Ream the cylinder head recess. Reaming bore for service valve seat Intake 38.6 ~ 38.8 mm (1.520 - 1.528 in) Exhaust 31.6 - 31.8 mm (1.244 - 1.252 in) Reaming should be done to the concentric circles around the valve guide center so that valve seat will have the correct fit. 3. Heat cylinder head to a temperature of 150 to 160°C (302 to 320°F) and press fit seat until it seats on the bottom. 4. Install valve seats. When replacing valve seat, valve should be replaced as well. 5. Cut or grind valve seat using a suitable tool at the speci- fied dimensions as shown in S.0.S. ‘The cutting should be done with both hands to obtain a uni- form and concentric finish. 6. Apply a small amount of fine grinding compound to the valve's contacting face and put the valve into its guide. Lap valve against its seat until proper valve seating is obtained, Clean valve and vaive seat. 7. Check valve seating condition. Valve seat contact “W": Intake 1.91 mm (0.0752 in) Exhaust 1.63 mm (0.0642 in) EM-127CYLINDER HEAD — Inspection (Margin thickness) eu: seurz06| VALVE DIMENSIONS 1. Check dimensions of each valve. For dimensions, refer to SDS. 2. Correct or replace any valve that is faulty. 3. Valve face or valve stem end surface should be refaced by using a valve grinder. When vaive head has been worn down to 0.5 mm (0.020 in) in margin thickness, replace the valve. Grinding allowance for valve stem tip is 0.5 mm (0.020 in) or less. VALVE SPRING SQUARENESS Check valve spring for squareness using a steel square and flat surface plate. If spring is out of square “S” more than specified limit, replace with new one. Out-of-squa Less than 2.2 mm (0.087 in) VALVE SPRING PRESSURE LOAD Measure the free length and the tension of each spring. If the measured value exceeds the specified limit, replace spring. Refer to S.D.S. COMBUSTION CHAMBER REPLACEMENT Usually combustion chambers should not be removed. However, if they show cracks or extensive damage, they should be replaced. 1. Heat cylinder head in oil to between 150 and 160°C (302 and 320°F). 2. Remove combustion chamber taking care not to damage cylinder head. Be careful not to scratch inside of nozzle hole. EM-128CYLINDER HEAD — Inspection a=] sew7216| ews] 3. Install combustion chamber. a. Heat cylinder head to 150 to 160°C (302 to 320°F) in oil. b. Align combustion chamber knock pin with cylinder head notch, and install it into cylinder head using a plastic-tip hammer. ‘* Before installing combustion chamber, clean auxiliar chanal, as shown at left CAMSHAFT VISUAL CHECK Check camshatt for scratches, seizure and wear. (CAMSHAFT END PLAY 1. Install camshaft in cylinder head. 2. Tighten bracket bolts to the specified torque. 3, Measure camshaft end play. ‘Camshaft end play: Standard 0.08 - 0.38 mm (0.0031 - 0.0150 in) CAMSHAFT RUNOUT 1. Measure camshaft runout at the center journal Runout (Total indicator reading): Limit 0.05 mm (0.0020 in) 2. fit exceeds the limit, replace camshaft. CAMSHAFT CAM HEIGHT 1. Measure camshaft cam height. ‘Standard cam height: Intake 39.95 - 40.00 mm (1.5728 - 1.5748 in) Exhaust 40.30 - 40.35 (1.5866 - 1.5886 in) Wear limit of cam height: (0.15 mm (0.0059 in) 2. If wear is beyond the limit, replace camshaft. EM-129CYLINDER HEAD — Inspection CAMSHAFT JOURNAL CLEARANCE Using micrometer 1, Measure the inner diameter of camshaft bearings. Standard inner diameter: 48.000 - 48.016 mm (1.8898 - 1.8904 in) Tighten bracket bolts to the specified torque. 2. Measure the outer diameter of camshaft journals. ‘Standard outer diameter: ‘47.949 - 47,962 mm (1.8878 - 1.8883 in) If clearance exceeds the limit, replace camshaft and/or cylinder head. Standard clearance: 0.038 - 0.067 mm (0.0015 - 0.0026 in) Limit: 0.1 mm (0.004 in) Do not remove camshaft brackets. If they have been removed, check camshaft for smouth rotation after brackets have been reinstalled. EM-130CYLINDER HEAD — Assembl @) Printed side Cylinder hea si Nacrom piten’ Wide pitch enced] 1. Install valve component parts. Install valve spring with its narrow pitch side toward cylinder head side. «Always install new vaive oil seals. Rewfer to oil seal Before installing oil seal, install valve-spring seat. « When installing valve, apply engine oil on the valve stem and lip of vaive oil seal. «Check whether the valve face is free from foreign matter. 2. Install valve rocker pivot assembly. Screw valve rocker pivots joined with lock nuts inte pivot bushing. EM-131CYLINDER HEAD — Installation () ‘Unt: me (in) (1.19, (058) (0.98) seus200 1. Install cylinder head gasket ‘a. When replacing only cylinder head gasket, install same grade gasket as the one formerly used. b, When replacing or repairing cylinder block, piston, con- necting rod and crankshaft, select gasket as follows: Selecting cylinder head gasket When only replacing cylinder head gasket, install the same grade gasket as the one formerly used. Step 1 Measure projection of piston to cylinder head surface. a) Set dial gauge and needle on cylinder block and adjust dial gauge to zero, b) Set dial gauge needle at measuring point on piston, taking care not to disturb its zero setting. ©) Rotate crankshaft around the top dead center position. d) Read and write down the maximum value. e) Reset dial gauge on cylinder block and confirm that zero setting has not been disturbed during measurement. 1) Repeat steps b through e for all measuring points as illus- trated and for each cylinder. «Be sure to measure the projection at 4 points for each cyl- inder as shown. Step 2 Calculate the average value of measurements taken for each piston. Step 3 Calculate the average value of measurements for all pistons from the values obtained from step 2. Step 4 Round of the value obtained. Step 5 Determine required thickness of gasket, referring to chart A. EM-132CYLINDER HEAD — Installation (] Nolen Relation between piston average projection and cylinder head gasket (Chart A) = ‘Average value of or) Grade_| piston projections | GAS%et Tienes? | numer of notones BOG mm (in) = | bessiman 0505 [1.15 288 j YY; (0.0199) (0.0453 *° 38530 ) 5 (0.505 - 0.555 7.20 2098, 3 ‘oniewn| (0.0199 - 0.0219) | (0.0472 *°0%%e0 ) c Over 0.555, 1.25 29955, 3 (o.car9) | (0.0492 “ome, Step 6 Check if the average value of each projection obtained from step 2 is larger than the max. value of the standard projection (of selected gasket) incremented by 0.05 mm (0.0020 in). If so, use gasket that is 1 grade thicker. If not so, use gasket as selected in step 4. Example ial opments 1 2 <= 4 se A fave ass [oss [oss | oss [ose | oss | os | oss | 059 | ose | os7 | ose | osm | ost | ose | osr > [avenge ae] a5 Ee oss os sss oss a [iteame | oer Rune a 5 «om ose ovemrad s eaaetmi. 120 Gade fan Pe Manin aoa of Hann pen alec gate OSE fo Chan A) 7 OS = ODS «|r Maximon vate sop 2 = 057 ne retoncip beoeonX and Vi") ¥""2 Seed oa 7. fet cess 1.20 (rage 872 tay “tH average value of projection fora pistons i, for example, 0.59 (7) 5 a8 show nthe able above, It should be rounded ofa ok lowe: Ie ig in tne tort decimal plae (wtih e enclosed by cle nti ose ie smal than 5, the average valve shout be regarded tu 05st rts lnsger tran avrags van aud be roarded a 8 34 me “2: HHL, tam te chr gro © geket mun be Uood EM-133CYLINDER HEAD — Installation a2o® re a amas ® OO — Wem em) igi tro o ® fo 0,20} © ® Cwm hem ORB) oo) 2. Place cylinder head on cylinder block (with correct gasket), and install cylinder head bolts as shown in illustration. Make sure that no. 1 cylinder is in T.D.C. 3. Install camshaft and camshatt brackets into cylinder head. ‘* Be carefull not to damage the inner surfaces of camshaft bearings. © Make sure that no. 1 cam of camshaft is at T.D.C. on its compression stroke. 4. Tighten cylinder head bolts according to the sequence as. shown at left. Tightening procedure 1. Apply engine oil to threads and underhead seating face of each bolt. 2. Tighten bolt progressively in the following steps. 39 N-m (4.0 kg-m, 29 ft-lb) 118 - 127 Nem (12 - 13 kg-m, 87 - 94 ft-lb) Return to 0 N'm (0 kg-m, 0 ft-lb) 39 N:m (4.0 kg-m, 29 ft-b) Tighten to 100 +2 If itis difficult to check tightening angle of bolt, tighten to 118 to 127 Nim (12 to 13 kg-m, 87 to 94 ft-lb). OOOO, EM-134CYLINDER HEAD — Installation 3. Install valve rocker arm and valve rocker spring. 4, Apply approximately 1 mm (0.04 in) thick coating of seal- ant to groove in rocker cover gasket, and install gasket. 5. Install rocker cover. Be sure to apply a coat of sealant {approximately 1 mm (0.04 in) thiok and 3 mm (0.12 in) wide] to corners of front cam bracket before installation. Rocker cover bolt @:5-9Nm (05 - 0.9 kg-m, 3.6 - 6.5 ft-lb) EM-135ENGINE REMOVAL ® Mounting bracket @® Bracket ® Bracket ® Rear engine mounting © Member ® Front engine singer ® Insulator @ Insulator @ Rear engine singer EM-136ENGINE REMOVAL [i] WARNING: a. Situate vehicle on a flat and solid surface. b. Place chocks at front and back of rear wheels ©. Donotremove engine until exhaust system has completely cooled off. Otherwise, you may burn yourself. d. For safety during subsequent steps, make sure transmis- sion jack is set securely. . Before disconnecting fuel hose, place a tray to catch over- flow of fuel or use shop towels. {, Be sure to hoist engine and transmission in a safe manner. CAUTION: «When lowering engine, be careful not to strike adjacent parts, especially accelerator wire casing and idling control ‘electrical wires and brake lines. Always use engine supports in a safe manner. When removing drive shafts, be careful not to damage oil seals of transmission. Engine cannot be removed seperately from transmission. Remove engine with transmission. Removal . Remove engine under cover Drain engine oil from drain plug of oil pan. Drain coolant from both cylinder biock, and radiator. Remove alternator, compressor, power steering oil pump. 7. Disconnect vacuum hoses, fuel hoses, water hoses, elec- trical connections, accelerator and idling control wires. 8. Support engine/transmission assembly by placing suitable transmission jacks under transmission and engine. 9. Remove center member and mounting brackets from engine. EM-137ENGINE REMOVAL (i) Removal (Cont'd) 10. Remove engine with transmission as shown. SS ee Eq) SEMO?0E Installation ‘When installing the engine, tighten the lock bolts to the speci- fied torque. «Installation is the reverse order of removal EM-138CYLINDER BLOCK (2) Disassembly PISTON AND CRANKSHAFT Place engine on a work stand. Drain remainder of coolant and oil. Remove timing belt. Remove water pump. Remove oil pan and oil pump. Remove cylinder head. Remove pistons. Negsene When disassembling piston and connecting rod, heat piston to 60 to 70°C (140 to 158°F) or use piston pin press stand at room temperature. Remove bearing caps using Special Service Tool, Place the bearings and caps in the proper order. Upper bearings (cylinder block side) have oil groove. Only center bearing has protrudings. Front and rear bearings are the same. Remaining center bearings are the same. Remove crankshaft. eeaere 10. Remove piston rings. EM-140CYLINDER BLOCK @ Inspection (Cont'd) + If either bearing, crankshaft or cylinder block is replaced with a new one, select main bearing according to the fol- lowing table. These numbers are punched in either Arabic or Roman numerals. Main bearing housing grade number o 1 = ‘Main bearing grade number Crankshaft main jour | _0 0 1 2 nal grade number 1 7 2 3 Identification color: Grade 0: Black Grade 1: Brown Grade 2: Green Grade 3: Yellow For example: Main journal grade number: 4 Crankshaft journal grade number: 2 Main bearing grade number = 1 + 2 =3 Main bearing thickness: Refer to S.D.S. Using plastigage 1. Wipe off oil from crankshaft main journal and main bearing inner surface. 2. Install crankshaft and put plastigage on each crankshaft main journal 3. Install crankshaft main bearing caps with main bearings and tighten nuts to the specified torque: (D): 69 - 83 Nem (7.0 - 8.5 kg-m, 51 - 61 ftb) 4. Remove main bearing caps and measure maximum width of plastigage. * Do not turn crankshaft while the plastigage has been applied. * When bearing clearance exceeds the specified limit, ensure that the proper bearing has been installed. if exces- sive bearing clearance exists, use thicker main bearing or undersized bearing, so that the specified clearance is obtained. EM-143Counter Pin journal Maintain moro than: 0.13 men (0.0051 in) ‘No. 1 pn journal grade number sses7aso] Clearance = 0-4 $5758) CYLINDER BLOCK jan) Inspection (Cont'd) CONNECTING ROD BEARING CLEARANCE (Big end) 1. Install connecting rod bearing to connecting rod and cap. 2. Install connecting rod cap with bearing to connecting rod. Apply oil to the thread portion of bolts and seating surface of nuts, (: 44 - 64 Nem (4.5 - 5.5 kg-m, 33 - 40 ft-b) 3. Measure inside diameter “C” of bearing. 4. Measure outside diameter “Dp” of crankshaft pin journal. 5. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C — Dp Standard: 0.024 - 0.066 mm (0.0009 - 0.0026 in) If it exceeds the limit, replace the bearing. + If. crankshaft pin journal is wom or shows any abnormality, regrind crank pin and use undersized bearings to maintain the specified oil clearance. «Refer to S.DS. for regrinding diameter of crankshaft pin and available service parts. When regrinding crankshaft pin, do not grind fillet-roll. «If either bearings or crankshaft are being replaced with new ones, select connecting rod bearings according to the following table. Grade numbers are punched in either Ara- bic or Roman numerals. Crankshatt pin joumal grade number 0 1 2 ‘Connecting rod baring grade num er ° 1 2 CONNECTING ROD AND PISTON PIN CLEARANCE (Small end) Clearance (D — a): 0.025 - 0.044 mm (0.0010 - 0.0017 in) * If clearance exceeds the specifications, replace the bear- ing. EM-144ewra9] sen! CYLINDER BLOCK Inspection (Cont'd) Bearing replacement 1. Remove bearing with a suitable tool. Do not scratch inner surface of connecting rod. 2. Install new bearing with oil holes aligned correctly. 3. Ream bore using a suitable tool. Ream bore: 25.025 - 25.038 mm (0.9852 - 0.9857 in) CONNECTING ROD BEND AND TORSION ee en ee eee ey Tse than 0.05 mm (0.0020 in) Torsion Less than 0.05 mm (0.0020 in) CRANKSHAFT 1. Check crankshaft journals and pins for score, bias, wear or cracks. If faults are minor, correct with fine crocus cloth. 2. Check journals and pins with a micrometer for taper and out-of-round, Out-of-round (K — Y): Less than 0.03 mm (0.0012 in) Taper (A ~ B): Less than 0.03 mm (0.0012 in) 3, Check crankshaft runout. Runout (Total indicator reading): ‘Less than 0.05 mm (0.0020 in) EM-145Measuring points SSN ai Warpage of surface: Semessa| jean lean mane i" toe oa ve ety ssewroso) Unt: me (io) Piston grade number snl CYLINDER BLOCK 2) Inspection (Cont'd) CYLINDER BLOCK DISTORTION Clean upper face of cylinder block and measure the distortion. Limit: 0.10 mm (0.0039 in) If out of specification, resurface it. ‘The resurfacing limit of cylinder block is determined by cylin- der head resurfacing in an engine. Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B The maximum limit is as follows: A + B = 0.1 mm (0.004 in) If necessary, replace cylinder block. CYLINDER BORE 1. Check for scratches or seizure. If seizure is found, hone bore. 2. Using a bore gauge, measure cylinder bore for wear, out- of-round or taper. Standard bore diameter: 85,00 - 85.050 mm (3.3465 - 3.3484 in) Bore wear limit 0.2 mm (0.008 in) Out-of-round (X - ¥) limit: 0.020 mm (0.0008 in) Taper (A - B, A- C, B-C) limit: 0.020 mm (0.0008 in) It it exceeds the limit, rebore all four cylinders. Replace cylin- der biock if necessary. Hf either cylinder block or piston is replaced with a new one, select the same piston as piston grade number punched on cylinder block upper surfaces. EM-146CYLINDER BLOCK [iD] Inspection (Cont'd) Reboring 1. The size to which cylinders must be honed, is determined by adding piston-to-cylinder clearance to the piston skirt diameter “A”. Dimension ‘Approximately 60 mm (2.44 in) Rebored size calculation D=A+B~C =A + [0.03 to 0.05 mm (0.0012 to 0.0020 in)} Honed diameter Skirt diameter as measured Piston-to-wall clearance Machining allowance 0.02 mm (0.0008 in) 2. Install main bearing caps in place, and tighten to the spe- cified torque to prevent distortion of the cylinder bores in final assembly. 3. Cut cylinder bores in the order of 1-3-4-2. Do not cut too much out of the cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time. Hone the cylinders to the required size referring to S.D.S. Use clean sharp stones of proper grade. Cross-hatch pattern should be approximately 45°. Measure the finished cylinder bore for out-of-round and taper. Measurement of a just machined cylinder bore requires utmost care since it is expanded by cutting heat. PISTON TO CYLINDER WALL CLEARANCE Using micrometer 1. Measure piston and cylinder bore diameter. Piston diameter ‘A’ thick ns 6s (Distance from the bottom): 62 mm (2.4 in) Measuring point (Distance from the top): ‘Approximately 60 mm (2.36 in) 2, Check that piston clearance is within the specification, Piston clearance (D — A): 0.050 - 0.070 mm (0.0020 - 0.0028 in) Using feeler gauge 1. Set piston and feeler gauge with spring scale. 2, Measure extracting force while pulling up scale slowly. Feeler gauge used: 0.06 mm (0.0024 in) Extracting force: 5.9- 11.8 N (0.6 - 1.2 kg, 1.3- 26 Ib) a1Oloh sev EM-147Kv10107050 Sev2s10) eemor4 seme] CYLINDER BLOCK Assembly PISTON «Numbers ‘on connecting rod and cap correspond to each cylinder. Care should be taken to avoid a wrong combination including beering and connecting rod direc * Install new snap ring on one side of piston pin hole. ‘When assembling piston and connecting rod with piston pin, heat piston to between 60 and 80°C (140 and 176°F) and install piston pin with a suitable tool. ‘2 Install new snap ring. After assembling, ascertain that piston swings smoothly. Install piston rings with a suitable tool. a) When installing pistong rings, make sure that stamped mark “TOP” is facing top of position. b) When installing new top ring or replacing cylinder block, ‘select top ring to adjust gap. Top ring grade No. ©) Align teflon tube with gap of oil ring. d) Align gaps of piston rings with intervals of 120°, as shown in illustration. CRANKSHAFT 1. Set main bearings in the proper position on cylinder block and main bearing caps. If either crankshaft, cylinder block or main bearing is reused again, it is necessary to measure main bearing clearance. EM-148CYLINDER BLOCK LD Assembly (Cont'd) Upper bearings (cylinder block side) have oil groove. Only center bearing has protrudings. Front and rear bearings are equal. Remain two center bearings are the same. evar: 2. Apply engine oil to main bearing surfaces on both sides of ‘oylinder block and cap. . Install crankshaft and main bearing caps. Arrange bearing caps so that the indicated numbers are in ‘order from the front of the engine. 4. Tighten main bearing cap bolts. 69- 83 Nem (7.0 - 8.5 kg-m, 51 - 61 fb) «Tighten bearing cap bolts gradually in two or three stages and outwardly from center bearing in sequence. After securing bearing cap bolts, ascertain that crankshaft ‘tums smoothly. seurozo ‘5. Measure crankshatt free end play at center bearing. Crankshaft free end play: ‘Standard 0.05 - 0.18 mm (0.0020 - 0.0071 in) Limit 0.30 mm (0.0118 in) PISTON WITH CONNECTING ROD 1, Install connecting rod bearings in the connecting rods and connecting rod caps. «Confirm that correct size of bearings is used. Refer to “inspection”. ‘+ Install the bearings so that the oil hole in the connecting rod aligns with the oil hole of the bearing + Lubricate connecting rod bearings and crankshaft journals sewrsee} "with engine oil. —EM-149eeword CYLINDER BLOCK i) Assembly (Cont'd) «Set piston rings in the positions as shown in the illustration at left. Install pistons with connecting rods. Install them into corresponding cylinder using Tool. Be careful not to scratch cylinder wall with connecting rod. Apply engine oll to cylinder wall, piston and bearing. ‘Arrange so that the front mark on piston head faces to the front of engine. Install connecting rod bearing caps. Apply a little engine oil to the thread of connecting rod bearing nut. Tighten connecting rod bearing nut in two stages: Tighten connecting rod bearing nut to 15 to 16 N-m (1.5 to 1.6 kg-m, 14 to 12 ft-lb). Then tighten an additional 60 ‘§: tums with an angular tightening wrench. ©): 15 to 16 N'm (1.5 to 1.6 kg-m, 11 to 12 ft-lb) plus: 60 5 or, if an angular tightening wrench is not available, 37 to 45 Nm (3.8 to 4.6 kg-m, 27 to 33 ft-lb) Measure connecting rod side clearance. Connecting rod side clearance (Big end play): Limit 0.3 mm (0.012 in) REPLACEMENT OF PILOT BUSHING 1. Extract pilot bushing using SST. «Before installing new bushing clean contact surfaces of bushing and crankshaft. EM-150CYLINDER BLOCK (5) Ku101 ose Assembly (Cont’ 2. Drive in pilot bushing by using appropriate tool. FLYWHEEL Installation 1. Install flywheel and tighten flywheel bolts to the specified torque: (2): 137 - 157 Nem (14 - 16 kg-m, 101 - 116 ftb) Flywheel runout Runout (Total indicator reading): Less than 0.15 mm (0.0059 in) EM-151SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment COMPRESSION PRESSURE Unit: KPa (bar. kplem*, pl) at 200 rpm Standard 8.198 (314, 92, 485) mit 2,452 (245, 25, 356) Diterance limit between 490 (4, 8,71 cylinders ve deh CYLINDER HEAD Unit: rm (i) ‘Head surface fainess Standard Loss than 0.05 (0.0020) Lim 0.1 (0.008 cylinder head heigt 4 - 896 (9.520 - 3528) VALVE Unit: mm (ny -T (Margin thickness) seme Valve hoad diameter "D" Intake 30.20 - 30.24 (1.543 - 1.545) ‘CAMSHAFT AND CAMSHAFT BEARING Exhaust 32.0 - 32.2 (1.260 - 1.268) UE 60) Va gat eam en Siete rink 11659. 116.62 (4.5001 - 45019) t= 8087 Exhaust 196.1 1164 (45700-45827) (00015-00026) 9 08) Vale siom dametor% Inner Gamat ofan 48000-48016 = cans a (1806 - 18908) Exhaust 7.945 -7,960 (03128 - 0.3194) ‘utr diameter of a7.940-47 950 : camehafoumal (1.8878 - +8883) Waive seat angie" 1520018 ave margin "Tk 0 ‘Camshaft runout Anes ten Di 0.05 (0.0020) Nate ety Te 2B 20). (0.0008), Vale som end wurace a) ‘Camshalt ond pay (0108 - 0.38 (0.003% - (0.0150) ringing mit Valve clearance Unit mm én) er cad ink 025 (0010) | _018 (0.007) Einav 330 (0012) | 025 0010) evs ‘am penta irate 99.95 - 40.00 (15728 - 15748) Exhaust 40.90 «40.35 (35966 - 15806) EM-169SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment (Cont'd) Valve seat resurfacing Valve spring Free height om Gr) 7077 (19504) Stan Presse bag 30,0812.9 (900823, 1.1637 iN (meg it) ‘esorbied height feria nm) 40.0228 40.029, 1.87851) ‘utatsquare "Ss" mm (in) 22 (0087) Valve guide Lait mm Gn) Stanaers Service Valve gue v2023- 1200 12223-12208 Suse saree (0.4733 - 0.4738) (0.4812 - 0.4817) Vane use Inner cameter 6000-8018 (Fished sce) (03180 -0:3157) ‘Cylinder head valve ‘11985-11906 12.185- 12,106 Guide hole diameter (0.4718 -0.4723) (0.4797 - 0.4802 Interterenes fit of valve 0027 - 0.089 guide (0.0011 - 0.0019) Standard ‘Stom to guide clear 0.020 - 005 Intake (ooves J ooeery 0-19 (0.0009) 0.040 - 0.0073 Exhaust oat6 feoza) 8.10 0.0088) Valve defection writ 07 (0.008) Unit: mm (ny 28:05 Exhaust ‘Standard (Origa) 163 (6.0842) 2910.05 38.638. (1.520-1.528) SEMO17 800215) {0.1142+0.0020) EM-170 semoieSERVICE DATA AND SPECIFICATIONS (S.D.S. CYLINDER BLOCK Inspection and Adjustment (Cont'd) ‘Unit: me (in) iv hx soo Standard iit Surface fainoss [Loss than 005 (0.0020) | 0.70 (0.0088) Grade No.1 85.000 - 85.010 (3.3468 - 33468) Grade No.2 85.010 - 85.020 (3468 - 3.3472) nner [67800 No.3 es: 85,020 - 85.030 - (as472- 3.3478) [Grade No. inde 85.090 - 85.040 ore (29476 - 3.3480) Grade No.5 85.040 - 65.050 (3.3880 - 3.3488) lower round | Less han 0.020 (0.0008) | 0.020 (0.0008) oY) Taper (48. | os man 020 (0.0008) | 0.020 (0.008) Bc) Piston eylnder (00080-0070 = etoarance {0.0020 - 0.0028) Feeler gauge exrac- ing fore [with gauge 59-118 thickness 0.06 mm (0.0024 in] N (kg, | (06-12,13-261) Main journal innor Grade No.0 55.545 - BS.654 (25057 - 25061) (Grade No. 1 63.654 - 63.663 (25061 - 25064) Grade No. 2 63.663 - 63.672 (25064 - 25068) EM-171SERVICE DATA AND SPECIFICATIONS (S.D. PISTON, PISTON RING AND PISTON PIN Piston Inspection and Adjustment (Cont'd) Piston pin Unit me (op 724.908 - 25.000 Piston pin outer ameter as Interence ft of plson pin to vane 0 0.008 (0 - 0.0002) Piston pin te connecting vod - cee 0.025 - 0.044 (0.0010 - 0.0017) CONNECTING ROD ‘Unit mn) 94-6495 iaeacs Peet (9.3441 - 3.9445) 84.95 26.05 eee te. (3.3445 - 3.449) 2496-9497 - eerie Bo (6.3449 - 3.3453) 2497-0490 ues amen s (99483-33457) ameter 84.90 - 4.99 eae io (8.3457 - 3.3461) 84.96- 85.01 See (3.3449 - 3.3468) 95.44 25.49 oversize [0:8 (0.020 eee cae 85.94 25.99 fee) (3.3835 - 3.3854) ‘Measure postion (Fom Top) 62 (244) 24.901 - 24.990 Piston pinhole dameter toes Piston ring na) Sie clearance Tor Standard 0.060 - 0.100 0.0028 - 0.0008) Lieit 0.20 (0.0079) Bad Standard 0.040 - 0.080 (0.018 - 0.0031) Lit 0.15 (0.0089) om Standard 0090-0.070 (0.0012 - 0.0028) Lt 010 (2.0099) Ring asp Top (wineut“S") 0.20 -0.29,0.0078- 00114) Stardera (win) 0.14 -022 (0.0058 - 0.0087) Lt 0.6 (0024) rd Standard 0.20 - 0.35 (0.0079 - 00138) mat 0.8 (0031) oF Stardars 030-048 (00118 - 0.0177) Umit 1.0 (0.090) Unit: mm én) ‘Bond [per 100 mm (3.94 in} ‘Standart and limit Less than 0.05 0.0020) Torsion ‘Standard and iit ‘Loss than 0.05 (0.0020) 25,025 - 25.008 Piston pin bore dia. ool oer Big end play it 05 (0028) CRANKSHAFT Unt: Grade No. 0 159.949 - 58.956 (2.3602 - 2.3605 ‘Main journal ca. ae 59.942 - 59.949 (2.3590 - 2.3602) 49961 - 4 enemst (1.9670 - 1.9675) ‘Outtotround OV) and taper (8) Standard Less than 0.01 (0.0004) Limi .03 (0.0012) Funout Standard ‘Less than 0.05 (0.0020) Limit 0.10 (0.000) Free end play Standard 0.05 - 0.18 (0.0020 - 0.0071) Umit 03 (0012) EM-1728 SERVICE DATA AND SPECIFICATIONS (S.D.S.] Inspection and Adjustment (Cont'd) AVAILABLE MAIN BEARINGS 5 main bearing (with oil groove) ‘Thickness “Tram (in) Wath 0" me Cn) *Part number entication color 1.622 - 1.826 (0.0717 - 0.0719) 12215-68500 | Black 1.826 - 1.890 (0.0719 - 0.0720) sor 12215-48501 | Brown 1.830 - 1834 (0.0720-0.0722) | (0.885 + 0.008) 12215-08802 | Green 1.834 - 1.836 (0.0722 - 0.0724) 12215-48503 | Yellow No. 1 and No. § main bearing (without oil groove) ‘Grade number Thickness “Tm Gp ‘Wiem "Wem (in) | “Parnumber | entiation coir ° Tae2- 1808 0717-00715) 12220-05500 [Back 1 26 1.800 (00719 00720) 22203 2000-68601 | Brown 2 ego 1834 (0.0720 00722) | (0866 + 0.004) 2z30.08502 | Green 3 1834. 1.008 (00722-00728) +2200.65509 __|Yolow No. 2 and No. 4 main bearing (with oil groove) ‘Grade number Thickness “T= rm fa) Wien -Wmm(n) | _“Pannumber | Kentiicaton coir ° Ye2e- 106 (00717-0071) 72231-45500 Jack 5 4261890 (0.0759 00720) wsos tzz31-05601 | Brown 2 1890 11884 (00720-00720) | (ase + 0.004) testasso2 | Groen 3 1894. 4.08 (0.0722 00728), 12231-08503 | Yotow No. 2 and No. 4 main bearing (without oil groove) (Grade number Thickness “7 mm Gr) Width “Wi mwm(n) | __ “Part number Iaenteation color ° 1822 - 1.626 (00717 - 0.0719) 12230-68500 Black 1 1.826 - 1890 (0.0719 - 0.0720), 2201 12200-65501 | Brown 2 11830 - 1834 (0.0720 -0.0722) | (0.856 + 0.004) 12230.c550 | Green 3 “84-1198 (0.0722 0.0726) 12299-65503 | Yllow SSS ES No, 3 main bearing (with oil groove) ‘Grade number Thickness “Tm fp Width -W'rom (a) | __ ‘Partnumber Teenttcation olor ° 1.822 - 1826 (00717-00710) ‘2247-48500 | Black 1 1828-1890 (0.0719-0.0720) | 31.2870-91.850 12247-65501 | Brown 2 1890-1834 (0.0720 -0.0722) | (1.2547 - 1.2579) 12247-65802 | Green 3 1.834 - 1.898 (0.0722 - 0.0728) 12247-65503 | Yolow No. 3 main bearing (without oil groove) (Grade number ‘Thickness "7" mm (in) Wet "W" men (in) “Part number dentiication color ° 1.822 - 1826 (0.0717 - 00710) 12285-65500 | Black 1 1.828 - 1.890 0.0719-0.0720) | 31.870 31,950 12286-68501 | Brown 2 1.890 - 1.634 (0.0720- 0.0722) | (1.2547 - 1.2578) 12256-45502 | Green 3 1.834 - 1.838 (0.0722 - 0.0728) 12255-65503 | Yalow EM-173SERVICE DATA AND SPECIFICATIONS (S. Main bearing undersize Inspection and Adjustment (Cont'd) BEARING CLEARANCE Lt: mm (ny ‘MAIN JOURNAL DIAMETER S002 - 50.956 ‘Standard (2.3509 - 2.3608) Uncorsize s0:602 - 59,708 025 (1.0000) (2.3801 - 2.3508) Available connecting rod bearing connecting rod bearing undersize Unit: mm) (CRANK PIN DIAMETER “Dp 29.961 - 49974 Standard (1.9670 - 1.9675) Underaize 49.901 - 49.914 005 (2.0028) (1.9646 - 1.9651) 48st - 49.854 0,12 0.0087) (1.9822: 1.9628) 49.711 -49.724 025 (1.0000) (1.9571 = 1.9578) nit: me Gn) ‘Main bearing clearance 10.036 - 0.063 (0.0014 - Standard aout Umit 0.12 (0.0047) ‘Connecting rod bearing clearance 0.024 - 0.086 aes (0.0009 - 0.0026) Lume 0.12 (0.0047) MISCELLANEOUS COMPONENTS: nit: min in) Flywheel RATA Less than 0.15 (0.0059) EM-174SERVICE DATA AND SPECIFICATIONS ( ) Tightening Torque ENGINE OUTER PARTS ENGINE BODY PARTS Ua vm mW Un Nn em Menai bact 09-39 30-40 22-25 Conmmctng od ay.sy 45-85 40 lmatr to adusting bar 16-21 16-21 12 eee Seachem bet Ak Se: Gyinder head bolt «118-127 12-1887 - 84 huawiaaies | accaetay sober Fiywhoot bot 197-187 14-16 101-116 ‘Crank pulley bolt 137-157 14.0- 16.0 101-116 Wai Reetng neh Be 88. moHee ‘Dust cover batt 3-5 03-05 22-36 eae ee BU AGe Rice ‘Back cover bolt 79 07-09 51-65 sate Shavit i an-08 841-88 Engine mounting bracket 29-99 20-40 22-29 CUPS: Ea SARE ea ‘Glow plug 20-25 20-25 14-18 Oil strainer boit 16-20 16-20 12-14 Glow plug comectng 10-15 01-018 07-14 Pivot lock nut 49-50 50-60 96-43 2 me Rocker cover bolt 5-9 05-09 36-65 Injection pump bracket 30-40 31-41 22-30 SS Injozton pump ceive gear 59-69 60-70 43-51 nut Injection pump nut 16-21 16-21 12-15 Injection tube flare nut «22-25 -2.2-25 16-18 Maniold Bolt and Nut Upper bolt (M10) 34-4 35-45 25-83 Lower nut & bolt(M8) 20-25 20-25 14-18 Injection nozzie S@-69 60-70 43-51 Oilcooler bracket bot «14-21 14-24 10-15 (il food pipe bor 19-25 19-28 ‘Oi pump bolt Me 06-08 43-58 ws 16-21 12-45 wor stooring pump 35-40 25-29 bracket bolt Spil tube nut 9-49 40-50 29-96 Tension pulley 32-40 83-41 24-20 Camshat puley bolt «132-142 135-148 98-108 loter putey bolt 44-54 45-55 33-40 Thermostat housing «15-20 «18-20 14-14 Vacuum pump pipe bot 20-25 20-25 14-18 ‘Water outlet bot 20-25 20-25 14-18 ‘water pump bolt MS 6-8 06-08 43-58 Me 16-21 16-21 12-15 —EM-175ENGINE LUBRICATION & COOLING SYSTEMS SECTION L C CONTENTS PRECAUTIONS sree LOHR. PREPARATIONS ...... LS SR ENGINE LUBRICATION SYSTEM .. A santcioes LA ENGINE COOLING SYSTEM ot area Le. 9 ENGINE LUBRICATION SYSTEM wo LOS, ENGINE COOLING SYSTEM ...... ew LOAD ENGINE LUBRICATION SYSTEM ...ssccssseststsessssestsseneenmnenetntsee 5 Lc-24 ENGINE COOLING SYSTEM ines Lc-29 ——= SAGA —— ENGINE ROOM FAN MOTOR ELECTRICAL CIRCUIT LC-33 ‘SR, GA, LD ‘SERVICE DATA AND SPECIFICATIONS (S.D.S.) .svssscscnseees onsets LOBEENGINE LUBRICATION SYSTEM (i) Lubrication Circuit LC-24ENGINE LUBRICATION SYSTEM jana) 728051001 728082000 s.ceee! Oil Pressure Check WARNING: Be careful not to burn yourself, as the engine and oll may be hot. ‘+ Oil pressure check should be done in “Neutral” gear posi- tion. 1. Check oil level. 2. Remove oil pressure switch. 3. Install pressure gauge. 4. Start engine and warm it up to normal operating tempera- ture. 5._Check oil pressure with engine running under no-load. ‘Approximate discharge pressure geen kPa (bar, kglem?, psi) ‘dle speed ‘More than 58 (0.58, 06, 8) 2,000 294 (29, 3, 43) 5,000 392 (3.8, 4, 57) If difference is extreme, check oil passage and oil pump for oil leaks. 6. Install oil pressure switch with sealant. Oil Pump REMOVAL 1. Remove timing belt (Refer to EM section). 2, Remove back covers of timing belt. 3. Remove oil pan (Refer to EM section). 4. Remove oil pump. LC-25ENGINE LUBRICATION SYSTEM a Oil Pump (Cont'd) DISASSEMBLY AND ASSEMBLY fe aset pee 90709 % Sur eae 5145) | Gasket 4 Beguator valve Sprng y = vs) c Ecos Fy wear c92s, 1215) Geet EL Nm inem, tb) excors| Always replace oil seal and O-ring with new ones. When installing oil pump, apply engine oil to inner and outer gears. «Be sure that O-rings are properly fitted. INSTALLATION 1. Install oil pump. Before installing oil pump assembly, remove all traces of liquid gasket from mating surface using a scraper. «Also remove traces of liquid gasket from mating surface of cylinder block. «Apply a continuous bead of liquid gasket to mating surface of front cover assembly. «Use Genuine Liquid Gasket or equivalent. «Installation is in reverse order of removal. LC-26ENGINE LUBRICATION SYSTEM Go) Lo017 vcore Oil Pump (Cont'd) INSPECTION Using a feeler gauge, check the following clearances: Unit mn (in) Body 10 0 clearance © (0:11 - 0.20 (0.0043 - 0.0079) Inner gearto crescent clearance @ 0.12 - 028 (0.0047 - 0.0081), Outer gear to crescent clearance (3) 0.21 - 0.32 (0.0083 - 0.0126) Housing toinnergear clearance @) 0.05 - 0.09 (0.0020 - 0.0085) Housing to outer gear clearance @) 0.05 -0.11 (0.0020 - 0.0043) ¢ If the tip clearance ((2)) exceeds the limit, replace gear set. If body to gear clearances ((1), (3), ©, (S)) exceed the limit, replace front cover assembly. REGULATOR VALVE INSPECTION 1, Visually inspect components for wear and damage. 2. Check oil pressure regulator valve sliding surface and valve spring. 3. Coat regulator valve with engine oil and check that it falls ‘smoothly into the valve hole by its own weight. Mf damaged, replace regulator valve set or front cover assem- bly. OIL PRESSURE RELIEF VALVE Inspect it for smooth operation by pushing the ball. If valve is sticky or damaged, replace oil filter bracket assembly. LC-27ENGINE LUBRICATION SYSTEM @ Oil Cooler Gy Ov tte beacxet Oi ceoer (4 ter & Asparegug 3 Oi cosie cover 1421 (1423 kom 1048 nit) excare REMOVAL AND INSTALLATION 1. Drain engine oil and coolant. 2. Remove oil cooler. 3. Installation is in the reverse order of removal. * Always replace gaskets with new ones. INSPECTION 1, Check oil cooler for cracks. 2. Check oil cooler for clogging by blowing through coolant inlet. If necessary, replace oil cooler assembly. LC-28ENGINE COOLING SYSTEM (i) Cooling Circuit i in 1 aah foe Seen J em Water Pump REMOVAL 6 Drain coolant from radiator. Remove under cover. Remove cylinder block drain plug located at left rear of cyl- inder block and drain coolant. Remove drive belts. Remove water pump pulley. Remove water pump. CAUTION: Water pump cannot be disassembled and should be replaced as a unit. After installing water pump, connect hose and clamp ‘securely, then check for leaks using radiator cap tester. LC-29ENGINE COOLING SYSTEM (2) Water Pump (Cont'd) INSPECTION 1. Check for badly rusted or corroded body assembly and vane 2. Check for rough operation due to excessive end play. INSTALLATION 1. Before installing water pump, remove alll traces of liquid gasket from mating surface of water pump using a scraper. * Also remove traces of liquid gasket from mating surface of cylinder block. 2, Install water pump gasket, apply a continuous bead of liq- id gasket to mating surface of water pump. 3. Install water pump and tighten bolts. Water pump securing bolts: (016-21 Nem (1.6 - 2.1 kg-m, 12 - 15 ft-lb) Thermostat ‘Water inet 1 2025 2025, 1410) Thomastat Themasich “Thermostat noveng ‘Water omperaure sonser Upper hese OS) comer a 2025 2025, 15185) Gasket 2. 6. ise a eg ® \ gy seas © 1520 (15:25, 1110) (1520, 144 Nm toe 0) ELcoes REMOVAL AND INSTALLATION 1. Drain engine coolant. 2. Remove lower radiator hose. 3. Remove water inlet, then take out thermostat. Lc-30