CHAPTER 3} ENGINE we crs 4 BS. 36. a7 +8. a 310. an, SPECIFICATIONS AND SERVICE DATA COMPONENT PARTS ON-CAR SERVICES DISMOUNTING AND REMOUNTING . REMOVAL .. DISASSEMBLY INSPECTION AND ADJUSTMENT ASSEMBLY . INSTALLATION TROUBLESHOOTING . SPECIAL TOOLSENGINE 3-1. Specifications and Service Data 1, Entire Engine Specifications Non TURBO FURBO 700 1800 1600 or ar AF Rosawd | aw> | Nonawo | 4D “ow Tree Torzontallyoppoted, qld cold, yds, ¢soke gale enpne ‘abe aangement Ovetead wpe oe 80 ; ore Soke mmo | 21 92461 0.624264) Paton Sec eeaiiass Baton ann mr Cecuin) | hE a5) 4.781 (781, 2086 Compresion aio 30 u aa Compression 1.206 presrekP Giglem?, sD Lim a29,.7 350 w=) «23,195, and.156 ‘Nero piston ings reste ing: 2, OWng 1 Opening ag wroc 16 soc Intake vale ining Gosng oo nae GARDE ABE Opening 6 wae pnDe nat valve ing Closing zor ATO Vavecearnees | Snake 0250010) 0) =| (chen egies at) rm Gay | Besa 038 010) = 8 z 650100 5 | sane seed = | (Atneutral pm Gapend) 700 + 100 800 = 100 © | (Cor) of B positior Kutta Gespeed) Tereth | 419.0650) “7066 410638) 523,009) Eee dimensions Twigs | 701 @7.60) 72h 76 G56) Hee 07390) 554 03.59) » [ri of eine witoue via ain [2218S [ors ro aan | E2E® | 2.3800) ttasmision gy | 12104 229 | Fou as) | 12108 2D | ss aon) | 1°58 G09) | 107 a6) (Gian colat ate nines) 3:06 229) 2 | 5:98 05) i cleaner element Vieour ope la @ fF: O2aa) 2209). g000 a tnnioncoseiosn (OOOH BESSA VOSS Dog akz LBS 2 OF P3 ®@BO® "3 OO ing order 3-2-4 wipe 1650 pm ect) woe leon nig aa BTDC "700 = Lie £700 9m Get) sas vain 73; Coma 4 4S wd Cana nn @: Ondatoneatae” @:ECR Al 3-22. Lubrica' ENGINE mn System Specifications SUBARU 1800 SUBARU 1600 Lubrication method Forced feed, fll low filtration, splash type Pump wpe Trochoid type ‘4.09/mnin 3.08min Discharge ~ Pressure | (4.2 US qtimin, 3.5 mp qt/min) G.2 US quimin, 2.6 Imp qt/mia) Desctae ox more = 3463 kPa 3.5 kalem?, 50 ps) | ormore ~ 245 kPa (2.5 kglem’, 36 ps) performance 1 ‘Speed 500 rm Oi temperature 75 ~ 85°C (67 —185°F) 21.0emin 15.08min Discharge ~ Pressure | (22.2 US qt/min, 18.5 imp qtinin) (15.9 US qt/min, 13.2 tmp quan) Oitpamp | Discs (ot more ~ 392 KPa (6.0 talem’, $7 psi) | or more — 392 kPa (3.0 kelom, $7 ps) petformance 1 Speed 2,500 rpm Ol temperature 75 -35°C sT — s"F) ‘Oitcciet | Pressure a whieh 2 EPeruieps on nies 392 - 441 kPa (4.0 ~4.5 kglem’, $7 64 pst) Oil by-pass_ | Pressure at whieh 7 et irks eo 147 kPa (Ls kglem*, 21 sty 98 KPa (1.0 ke/om, 14 pe) Type Paper, eartidge 776 i titer Futwation area 01s 6a ‘408 358 eden (42 US gt, 3.5 tmp at) G7 US at,3.1 imp a0 Engine oi capacity ape 308 258 G.2 US qt,2.6 tmp a) Gs us qt, 2.2 imp qvENGINE Engine Oil Flow Diagram 1 #3 cylinder 2 See [Soom = ' 1 Main gallery et & #3 cyt] [at a #3 cyto ae vabve Liter] ™| der pas rods Vatve rocker fcrnkeae [=L craneanast. | [#24 #3 con * necting rod tunso Fig. 31 ase 4. Engine Oil Cooling System 1) Specifications of Oil Cooler © Core size 200 x $5 x 32. mm (7.87 x 2.17 x 1.26 in) © Core pitch + 2mm (0.08 in) © Fins 2 Corrugated fin type © Radiation capacity: 2.326 KW (2,000 keal/h, 7,936 BTU/A) © Oilftow 1OR/min (2.6 US gal/min, 2.2 tmp gal/min) © Wind velocity 8 m/sec (26 ft/sec) at | © Temperature difference between oil and air 75°C (167°F) ‘© Oil temperature 110°C (230°F) 2) Component Parts Arachment ot m3 Gosker Ze T2_]Union serew Tighacing toraues Wan (eee, RB) Te ASSY (in) Tis 29:4 +49 GOD 280,260 = 43) alae "12 36.3 49 G60 = 80,304 = 43) age ae Ta: 7.4 = 20 (75 20, 65 = 17) [re assosass5.27r4a1 | icaseeaecy 3 Fig. 2 87904) Description Engine oil passing through the filter ix branched before itis supplied. When the temperature of engine oil is lower than a certain value, the thermo valve opens the circuit allowing engine cil to lubricate the working parts of the turbocharger and return to the engine. When the temperature of engine oil reaches certain value, the thermo valve closes. At this point, the engine oil pass through the oil cooler to lubricate the working parts of the turbocharger, returning to the engine. Although the temperature of engine ‘ll rises to operate the cooler, if a pressure difference between @ and @© is higher than the certain value, the safety valve wil open. At this point, engine oll bypasses the cooler and is supplied to the turbocharger. 5} Inspection of Thermo Valve Checking method Measure dimension A shown in figure on the right when thermo valve reaches room temperature. Next, dip thermo valve in hot water (67 — 73°C (153 ~ 163°F)] and, while holding it, measure dimension A. Check the difference between the two measurements above to make sure itis approximately $ mm (0.20 in). If it is too different, replace thermo valve. ENGINE pump Asay Fig. 33 ‘Thermo valve ‘Valve lifting amount is § mm (0.20 in) characteristics at 67 — 73°C (153 ~ 163°F) Safety valve ‘Starts operating atoll temperature of 100°C (212°F) characteristics | and at pressure difference of 226 kPa (23 kalom 38 ps) Fig. 34 =ENGINE 5. Cooling System Specifications TonTUREO TURES 160 ie 100 Goolng ome Tics an + Forced soling wer creation yom Total coolant pacity Saab USGLA7 Impad 558 58 US 9h 68 imp a Tire Cento eter pe Dak Tainin (7 US amin, 6:2 ip quinn ox mare ee ame at inp revorne | RR 1000 rpm = 0.29 m Aa (95 Aa) 7 WC GST — 18 F) Oem 03.2 US al, 1.0 inp ea or more wae pomp 4.000 rm ~ 5.0m Aq (164 fe Ag) Water empersar BawC0e SH impel diameter Gam GAB) ‘Namber of impeller vanes 5 Pomp plleycimeter Bnm Gam Wan Gam ee Waxpele ape Senso open Weise as. ‘tremosat [Fay opens TOC aIFF) Valve lift Sum (31) Vatre bor 3mm (122 in) Tye Wax paint ope = treme i : Ten uly dome Fercaia3eF 7 Fay ope ae FCUT #367) = Teme LON. BePCGo ITER sect [OF 31 FC036236R) Mow 126 Works src fan Finda BO ram LBP wD Tree Crom ow, pesue wre ATAMDAT, oy : aan 43 a A Tota mistion area sam sisam lap, 19 e Cee] ada eam Others: 590 m" (635 af) “AT a GWD-AT: 473 BW Gre kealmin SontUlnin 31.7 kW 4wD: 42.9 kW . (455 kcaliin, (sis tealmin, 11805 BTUimi SAoB Timi | 2690 BTUmind ones rw Radiation capacity cartel, satistor SABO + Waa tow “se/min SEEPS cau, 9.9 mp cumin a |e Temperate diference between Toole nd ambien simorpie: 65°C (145°F) shires: Bliec 6 fee SUBARU 1800 AT & 40-4 Coredimensons mm (in) BATT as.1260 625 «3432 Others: $80 x 334 x 32 (22.83 x 13.15 1.26) (2461 6 13.15 6 1.26) Radnor pacity 1.98 (20 US gt 1.7 npg Pressure range in which cp vibe Mow 88 10 4Ps 0.9 + 0-1 glem*, 13=14 pe isopen Below oh. 10 =10 KPa 005 1-0. glen” s-0.) = 1.4 psd Fins Covrgaied fn ve 38ENGINE t 6. Coolant NOTE: ‘SUBARU COOLANT % Avoid using any coolant o¢ only It is recommended to use “SUBARU (net 18 titer) water other than this designated genuine coolant” when replacing or Parts No. 000016218 ‘ype to prevent corrosion, refilling the engine coolant, §, SUBARU's engine is aluminum This coolant is antifieeze, antic Hloy, and so recat Can corrosive ethylene glycol coolant, and UO and $0 special care is neces. ‘is especially made for SUBARU vehi- fed dle. SUBARU Coolant specifications are as follows: (Coolant Specifications | SUBARU Specific gravity anticipated temperature | water ratio aioe | a20e | aczore | acaore | aesorc Freeing point Lowest aimospherie cootanto- Wolume) | sorry | Gey | em | coer | az amecwere [#0 | tom | som [wwe | aoe | aan * Wis recommended that digtiled water be wed, 7. Coolant Flow Diagram eS ae Sinai] [Gama ieee Lf See pL rector ef SHY Liste Lit J] said Sin] [Sina eet bal ets fe) “LS soeeme Le inane ar hI oe Potal iertuees oy fremo} acess 1. Radiator intet hose 2 Water by-pass hose 3 Thermonat cover 4 Thermostat Water by-pass hose 6 Water by-pass pipe 7 Water by-pass hose 8 Sway cock 9 Water by-pass hose 10 Ineake manifold 11 Water by-pass pipe 12 Water by-pass hose 13 Radiator outlet hose 14 Water pump 15 Thermo switch 16 Electric fan 17 Thermo valve 18 Water by-pass hor‘The operation of the cooling system is 2s follows 1) Cooling with thermostat closed When the coolant temperature is under the specified degrees, coolant flows only through the by-pass passage. This limited coolant circulation reduces cooling action, thus shortening engine ‘warm-up time. By-pas pasage: a. Intake manifold > Carburetor ~ Thermo valve = Water by pass bat and pipe + Water pump When the environmental tempera: ture around thermo valve exceeds the specified degrees, the coolant pasmge from carburetor to water by-pas pipe ie shutoff by means of thenmo "valve so that the fel in carburetor isnot heated, 8. Automatic Transmission Flui: ». Intake manifold ——+ Thermostat case Baway Cock —z Water by-pass hose 4 ‘and pipe Heater t Water pump To ragiator ong 2) Cooling with thermostat open ‘When the coolant temperature exceeds the specified degrees, thermostat begins to open and coolant flows through radiator and by-pass passage, increasing the cooling function, 3) Cooling with electric fan in opera- tion ‘When the coolant temperature exceeds the specified degrees, the thermo- switch turns on to operate the electric Fig. 36 Cross section of thermo valve fan. wax asso Cooling System ‘Automatic transmission fluid | cooling system (SUBARU 1800 AT & 4WD-AT) 1,570 KW (1,350 keal/h, 5,357 BTU/h) Radiation © Ol flow: capacity |, | # Waters ‘68/min (1.6 US gal/min, 1.3 Imp gal/min) 202/min (5.3 US gal/min, 44 Imp gal/min) © Temperature difference between water inlet and oil inlet: 30°C (86°F) The Auld cooling system of automatic transmission consists of an cooler built in radiator, pipes and hoses to circulate fMuid between torque converter and cooler, Heated uid circulating through torque converter retuins to cooler and is cooled by coolant, thereby being ‘maintained at an adequate temper ture. a © 2 11 Outlethoe 3 Hose camp 12 Inbthow 4 Cooler 13 Camp 5 Radia 14 Gip 6 Side frame Fig. 3-7 Component parts of auto- ‘matic transmission fluid cooling system 38ENGINE 9. Service Data Head surface warpage Limit | 0.05 mm (0.0020 in) Head surface grinding Limit | 0.5 mm (0.020 in) Standard height 1600 89.6 mm 6.528 in) 3 1800 90.6 eo (3.567 in) 2 | vate seat Refacing angle 90°, 150° 3 Contacting width Intake | 0.7 - 13mm (0.028 ~ 0.051 in) 2 Exhaust | 1.0-18mm — (0.039-0071in) é Wear limit 0.5 mm (0.020 in) Valve guide Inner diameter 8000-8015 mm (0.3150 - 0.3156 in) Protrusion Intake | 175- 185mm (0.689 - 0.728 in) Exhaust | 225-23.5mm (0.886 - 0.925 in) Valve overall length Intake 109.5 mm G31 in) Exhaust 1093 mm (4.30 in) Valve head edge thickness Intake std | 1.5mm (0.059 in) Limit | 0.5 mm (0.020 in) Exhaust st? | 13mm (0.051 in) g Limit | 08mm (0.031 in) = | Stem diameter Intake 7.950 7.965 mm (0.3130 - 0.3136 in) Exhaust 7945-7960mm (0.3128 - 0.3134 in) Stem oil clearance Intake STD | 0.035 -0.065 mm (0.0014 - 0.0026 in) Limit | 0.15 mm (0.0059 in) Exhaust STD | 0,040-0.070mm (0.0016 ~ 0.0028 in) Limit | 0.15 mm (0.0059 in) ‘© With solid valve lifter Free length. Outer spring | 45.3 mm (1.783 in) nner spring | 48.8.mm (1921 in) Tension/spring height Outerspring | 146.1 — 169.7N/39.5 mm (149 ~ 17.3 kg/39.5 mm, 32.9 ~ 38.1 16/1.555 in) 500.2 — 568.8 N/30.5 mm (51.0 ~ $8.0 kg/30.5 mm, s 112.5 ~ 127.9 Ib 1.201 in) = i Inner spring | 843-98. N/37.5 mm 2 (8.6 — 10.0 kg/37.5 mm, = 19.0 ~ 22.1 Ib/1.476 in) 185.6 — 214.8 N/285 mm (18.9 — 21.9 kg/28.5 mm, 41.7 — 48.3 1b/1.122 in) Squareness Outer spring | 2.0mm orless (0.079 in or less) Inner spring | 21 mmoriess (0.083 inor less) © With hydraulic valve lifter Free length Outer spring | 48.5 mm (1.909 in) Inner spring | 53.0 mm (2.087 in) 39ee EN ‘Tension/spring height Outerspring | 228.5 ~ 261.8.N/39.5 mm (23.3 — 26.7 kg/39.5 mm, 51.4 ~ 589 Ib/1.555 in) 3 518.8 — $99.2 N/32.0mm g (829 ~ 61.1 kg/32.0mm, 116.6 ~ 134.7 Ib/1,260 in) & Inner spring | 115.7 ~ 133.4N/37.5 mm = (11.8 = 13.6 &9/37.5 mm, 7 26.0 — 30.0 Ib/1.476 in) 2 201.0 - 230.5 N/30.0 mm 3 @05 - 23.5.kg/30.0mm, 45.2 — 51.81b/1.181 in) Squareness Ovterspring | 2.1 mmorless (0,083 in or less) Inner spring | 23mmorless. (0.091 inor ess) eg] Inet diameter of rocker arm 18.016 — 18.034 mm (0.7093 = 0.7100 in) JSS] Outer diameter of rocker shaft 17.982 — 18.003 mm (0.7080 — 0.7088 in) 7 Rocker arm to rocker shaft clearance 0.013 - 0.052 mm (0.0005 — 0.0020 in) © Solid valve lifter Lifter hole inner diameter of crankcase 21.000 ~ 21.021 mm (0.8268 — 0.8276 in) Outer diameter of lifter 20.949 — 20.970 mm (0.8248 — 0.8256 in) g | Lifter to lifter hole clearance STD | 0030-0072 mm (0.0012 — 0.0028 in) s Limit | 0.100 mm (0.0039 in) 2 | > Hydcautic valve titer © | Lifter hole inner diameter of crankease 20.988 ~ 21.040 mm (0.8263 ~.0,8283 in) ‘Outer diameter of lifter 20.950 — 20.968 mm (0.8248 — 0.8255 in) Lifter to lifter hole clearance STD | 0.020-0.090mm (0.0008 - 0.0035 in) Limit] 0.100 mm (0.0038 in) Overall length 1600 (Kaucting: 2) 219-219.4mm (8.62 — 8.64 in) 1800 with solid valve 230.7-231.1mm (9.08 -9.10 in) lifter (Kauring: 1) 1800 with hydraulic valve ter | 231.7-2322 mm (9.12 -9.14 in) ‘(Knurling: nothing) (Stee! tube) Deflection at center 04mm (0.016 in) or less Cylinder bore Diameter 91.985 — 92.015 mm (3.6214 — 3.6226 in) (Both 1800 and 1600) Taper STD | 0.015 mm (0.0006 in) Limit | 0.050mm (0.0020 in) Out of roundness STD | 0.010mm (0.0004 in) . Limit} 0.050 mm (0.0020 in) + Cylinder to piston clearance STD. | 0.010-0.040 mm (0.0004 — 0.0016 in) Limit } 0.060 mm (0.0024in) Enlarging init of cylinder inner diameter | 0.50 mm (0.0197 in) Inner diameter difference limit between cylinders | 0.05 mm (0.0020 in) Case surface warpage (mating with head) Limit | 0.05 mm (0.0020 in) Protrusion of stud bolt from mating surface 1800 ] 915-935mm (3,602 - 3.681 in) 1600 | 905-92.5mm (3.563 ~ 3.642 in) 3-10ENGINE Crankshaft (0.03 mm (0.0012 in) US 0.05 mm (0.0020 in) US 0.25 mm (0.0098 in) US 1600 Front & rear STD 0.03 mm (0.0012 in) US (0.05 mm (0.0020 in) US 0.25 mm (0.0098 in) US Center STD 0.03 mm (0.0012 in) US 0.05 mm (0.0020 in) US 0.25 mm (0.0098 in) US | Piston outer diameter STD | 91.960 -91.990 mm (3.6205 — 3.6216 in) 8 0.25 mm (0.0098 in) OS | 92.210 - 92.240 mm (3.6303 — 3.6315 in) & 0.50 mm (0.0197 in) OS | 92.460 — 92.490 mm (3.6402 — 3.6413 in) J | Piston pin hole inner diameter of piston 20,999 — 21,009 mm (0.8267 — 0.8271 in) § ] Piston pin outer diameter 20.992 — 21.000 mm (0.8265 — 0.8268 in) | 2 | Piston pin to hole in piston clearance 0.004 0.010 mm (0.0002 - 0.0004 in) Piston ring gap Topring = STD | 0.20-0.35mm (0.0079 -0.0138 in) Limit | 10mm (0.039 in) Second ing STD | 0.20-035mm (0.0079 ~ 0.0138 in) Limit | 10mm (0.039 in) 2 Oilsingrail = STD | 020-090mm — (0.0079 — 0.0354 in) 5 Limit | 15mm (0.059 in) Z | Piston ring to piston ring groove clearance Top ring STD | 0.04-0.08mm (0.0016 - 0.0031 in) Limit | 0.15 mm (0.0059 iny Second ring STD | 003-0.07mm — (0.0012~0.0028 in) Limit | 0.15 mm (0.0059 in) Oi ing ° Distance between big end and small end hole 1800 | 11695 ~ 117.05 mm (4.6043 — 4.6083 in) 3 1600 | 109.95 ~ 110.05 mm (4.3287 ~ 4.3327 in) f | Bend or twist per 100 aun (3.94 in) in length Limit | 0.10 mm (0.0039 in) & | Theust clearance STD | 0070-0330mm (0.0028 - 0.0130 in) i Limie | 040mm (0.0157 S | Piston pin to bushing clearance 00.022 mm (0 - 0.0009 in) Bushing bore 21.000 ~ 21.016 mm (9.8268 - 0.8274 in) BE] Thickness at center stD | 1477-1485 mm (0.0581 - 0.0585 in) a 0.05 mm (0.0020in) US | 1.505—1510mm (0.0593 —0.0594 in) 33 0.25 mm (0.0098 in) US} 1.605—1.610mm (0.0632 - 0.0634 in) Bend limit 0.035 mm (0.0014 in) Crankpin and erank journal Outofcoundness 0.03 mm or tess (0.0012 in or less) Taper limit 007 mm (0.0028 in) Grinding iit 0.25 mm (0.00898 in) ‘Thrust clearance STD | 001~0.095 mm — (0.0004 — 0.0037 in) Limit | 030mm (0.0118 in) Crank journal outet diameter 1800 STD | 54955 ~ $4970 mm (2.1636 — 2.1642 fa) 54.925 — 54.940 mm (2.1624 — 2.1630 in) 54.905 ~ $4,920 mm (2.1616 — 2.1622 in) 54.705 — 54.720 mmm (2.1537 ~ 2.1543 in) 49.957 — 49.970 mm (1,9668.— 1.9673 in) 49.927 — 49.940 mm (1.9656 — 1.9661 in) 49.907 — 49.920 mm (1.9648 — 1.9654 in) 49.707 — 49.720 mm (1.9570 — 1.9575 in) 49.970 — 49 982 mm (1.9673 ~ 1.9678 in) 49.940 — 49.952 mm (1.9661 — 1.9666 in) 49.920 — 49.932 mm (1.9654 — 1.9658 in) 49.720 — 49.732 mm (1.9575 — 1.9579 in) feENGINE 0.05 mam (0.0020 in) US 0.25 mm (0.0098 in) US Center sTD 0.03 mm (0.0012 in) US ' (0.05 mm (0.0020 in) US Crank journal ollclearance 1800 Front & rear STD. | 0.010 ~0.030 mm (0.0004 — 0.0012 in) * Limit | 0.055 mm (0.0022 in) Center STD | 0.010-0.025 mm (0.0004 — 0.0010 in) z Limit | 0.045 mm (0.0018 in) a 1600 Front & rear STD | 0.010 ~0.035 mm (0.0004 0.0014 in) z Limit) 0.055 mm (0.0022 in) ae Center STD | 0.010-0.030mm (0.0004 — 0.0012 in) 2 Limit | 0.045 mm (0.0018 in) Z| Crankpin outer diameter STD | 44.995 ~ 45.010 mm (1.7715 — 1.7720 in) § 0.05 mm (0.0020in) US| 44.945 — 44.960 mm (1.7695 — 1.7701 in) (0.25 mm (0.0098 in) US | 44.745 — 44.760 mm (1.7616 - 1.7622 in) Crankpin oll clearance STD | 0.020-0.070rmm (0.0008 — 0.0028 in) Limit | 0.1mm (0.0039 in) Thickness at center 1800 Front& rear STD_ | 2.015 2.019 mm (0.0793 — 0.0795 in) 0.03 mm (0.0012 in) US | 2.030-2.034mm (0.0799 — 0.0801 in) 0.05 mm (0.0020 in) US | 2.040-2.044 mm (0.0803 — 0.0805 in) 0.25 mm (0.0098 in) US | 2.140-2.144:mm (0.0843 — 0.0844 in) Center STD | 2.015—2.028 mm (0.0793 — 0.0798 in) # 0.03 mm (0.0012 in) US | 2.030-2.043 mm (0.0799 0.0804 in) 3 : 0.05 mm (0/0020 in) US | 2.040-2.053 mm (0.0803 ~ 0.0808 in) 7 i 0.25 mm (0.0098 in) US | °2.140-2.153 mm (0.0843 — 0.0848 in) 3 1600 Front & rear STD_ | 2.001-2.008 mm (0.0788 — 0.0791 in) i ee 5 2.022 ~ 2.035 mm 2.122 — 2.135 mm 2.003 ~ 2.015 mm 2.017 — 2.030 mm 2.022 ~ 2.035 mun (0.0796 — 0.0801 in) (0.0835 — 0.0841 in) (0.0789 — 0.0793 in) (0.0794 — 0.0799 in) (0.0796 — 0.0801 in) 0.25 mm (0.0098 in) US | 2.122-2.135 mm (0.0835 — 0.0841 in) Cam lobe height STD | *1: 32.24 ~ 32.34 mm (1.2693 — 1.2732 in) "2: 35.90 ~ 36.00 mm (1.4134 — 1.4173 in) Wearlimit | 0.15 mm (0.0059 in) Bend limit 0.05 mm (0.0020 in) ‘Thrust clearance STD | 0.020—0.090 mm (0.0008 — 0.0035 in) Limit | 020mm (0.0079 in) ‘Camshaft journal outer diameter Front & center 1600 | 25.959 — 25.975 mm (1.0220 ~ 1.0226 in) 1800 | 31.959 — 31.975 mm (1.2582 ~ 1.2589 in) Rear 35.959 ~ 35.975 mm (1.4157 — 1.4163 in) ‘Camshaft journal to cam bore clearance STD | 0.025~0.059mm (0.0010 ~ 0.0023 in) Limit | 0.100 mam (0.0039 in) Run out i Limit | 025mm (0.0098 in) (Crankshaft gear to cam gear backlash STD | 0.010-0.050mm (0.0004 — 0.0020 in) Limit | 010mm (0.0039 in) "ag 2 Wit yratc vae iter : Sin EE 312ENGINE ll pump Drive gear outer diameter Rotor outer diameter Drive gear to rotor tip clearance Rotor to case and gear to case axial clearance Rotor to case radial clearance Relief valve spring =~ By-pass valve spring > i filter filteation area sTD Limit STD Limit STD Limit Free length Installed length, Load when installed Free length Installed length Load when installed 1600 1800 1600 1800 1600 1800 29.70 29.74 mm 40,53 — 40.56 mm (1.1883 = 1.1709 1 © (1.5957 ~ 15968 ny 0.02-0.12mm (0.0008 - 0.0047 in) 02mm (0.008 in) ale 0.03 -0.13mm (0.0012 0.0051 in) 02mm (0.008 in) 0.15-021mm (0.0059 — 0.0083 in) 0.25 mam, (0.0098 in) 47.1 mm (1.854 in) 33.5 mm (1319 in) 38.05 — 41.97N (B.88 — 4.28 kg, 8.56 - 9.44 Ib) 40.7 mm (1.602 in) 37. mm (1.461 in) 311mm (1.224 in) 25.1 mm (0.988 in) 3.580 -3.972N (0.365 — 0.405 kg, 0.805 ~ 0.893 Ib) 5.178 ~ 6.159 N (0.528 ~ 0.628 kg, 1.164 — 1.385 Ib) 0.15 m* (1.6 sq.ft) ¥ENGINE 3-2. Component Parts 1. Crankcase Thread se Toraue TOrmm [59-47 Nem WO-48 berm, 29-35 Fe) ‘@mm | 23-26Nem (23-27 kgm, 17-20 fb) Bom [44-54 Nem (045 -O.55 kg, 3.3-4.0 ib) liquid gasket (Fuji Bond C or © Aaply lauid gasket {Fujf Bond C or equlvaent) ewithe thread 1 Crankeate asembly 1S Gasket 262x315 x1 mm) 2 Sted bolt 16 Gankease plug 3 Bolt 10 108 x 28 mm) 17 Gankease O-ring . 4 Bott AB. Back up ring 5 Washer 19 Bolt & washer (613.213 mm) 6 Bolt (0x 145 x28 mm) D Cip 7 Washer 10.5 x 18 x 2 mm) DY Grankease plug - 8 Main gallery plug 22 Gasket 06.244 x1 mm) 9 Bott 23. Caankease sembly 10 Crankease front hanger 24. Nat (10x 8mm) ‘itachi carburetor) 2S Bolt 10x 135% 28mm) 11 Nut 26 Sud bolt (10 x 120 26 mm) 12 Bolt (10x70 x28 mm 27 Bott 13 Bolt 28 Crankeawe front hanger 14 Washer 29 Crankease front a cues : (CW carburetor) asses aENGINE 2. Cylinder Heads 1 Valve guide 2 Osea 3 Cylinder head (1,600 ce) 4 Cylinder head (1,800 ce) 5 Cylinder head gasket 6 Cylinder heed 2 (1,600 c2) 7 Cylinder head 2 (1,800 ee) lanes poNe Baa AR) Frdsag $9 Nm Digsa, <2) [aessep 4nn 185 com, 47 fb) | 8 Washer 9 Nat 10 Bolt (11x 16234 mm) 11 Stud bot 12 Pug . Apply sealant “Three Bord 1201" or equivalent 13 Gasket veil f0 both sides of cylinder head gasket 14 Stud bolt with a beat, Asseo Fig. 29 Cylinder headsi 3. Flywheel Housing and Fittings (CTihionng eau Wn ie OT] ENGINE Th 46- 94147-5534: 40) "72"20-27 120-28, 14-20) ‘Coat with quid gasket (Three Bond 1215 oF ‘quivalent) on mating surface and dry the ‘omed surface for 5 to 10 minutes before installation. Flywheet housing CP Sud OB wal (10 x 87x 8.5 mm) me Fig. 3-10 Flywheel housing and fittings Balt 1S. Stitfener 2 Balt 16 Accelerator cable bracket Bolt (CW earbureto:) Washer 17 Gp Washer 18 Washer Spring washer 19° Spring washer Spring washer 20 Nut 21 Bolt 6-781 3-16ENGINE 4. Crankshaft and Related Parts ee 5 Oded {Distributor drive gear 7 Woodratt key 8 Crankshart 3 Woodrutl key 430 Crankshaft gear 11 Crankshaft bearing st 12 Center bearing set 13 Connecting rod CP 34 Nat 15 Connecting rod bearing set 16 Piston ring et 21 Bole (aT) 22 Converter back plate (AT) 23 Converter drive pate (AT) 24 Connecting rod bolt 25 Connecting rod bushing 73 Tighiening torquet Nom (eg, RB) Ti 41-45 (42 12: 39-4260) ‘+ Any engine ot on the thaad. T3:49-53160-5. 4 Abo liquid gasket (Thee Gon 1215 or equivalent) on the Harge seat. s reer eee ee Ts 64774 (65-75,47-88) Fig. 3-11 Crankshaft and related parts Asesr a7ENGINE 5. Valve System Tightening wrquer New kom UB) T3-4103-04,22-29) een 1 Boke 9 Vale ring 36 Camshaft gear 2 Valve rocker cover sal washer 20. Valve spring 2 47 Camshaft pate 3 Vabve rocker cover 11 Intake wade. 18 Valve rocker ASSY 44 Valve rocker coves gasket 12 Vale pus rod 19 Camshaft, 5. Va rocker ASSY R.A.) 33 Vale liter 20 Woodruff key 6 Exhaus valve 14 Bot 21 Hydraulic vave titer 7. Valve spring retainer key 35 Lock washer 22, Push tod (for hydraulic valve liter) 8. Valve spring retainer + Fig. 3:12 Valve system assessFig, 3-13. Valve rocker ENGINE Rocker shaft spring washer Rocker shaft supporter Valve rocker arm CP Rocker shaft spacer Valve rockor shaft a L GB i ” 18 ro ied ave rocker arm CP 2 Vane cocker ASSY (Lift) Vale rocker ASSY (RH) Rocker shaft spacer Valve rocker shaft Valve cocker ASSY (LiL) Valve rocker arm ‘atv rocker arm 2 Lock washer (only for Inydranlic valve lifter)2 fission Control Equipment *. 1) Hitachi Carburetor Type (1) 1 als coment {California and 49-state non-4WD) Govedaieaat 3. Vacuum swith 1 4 Bolt & washer 5. EGR pipe cover 6 EGR pipe 8 Oxygen sensor 9 Nut 10 Washer 17 Bolt washer 18 Solenoid valve 1 19 Thermo vacuum valve It 27 Carburetor procector 28 Carburetor prowetor 2 29 Solenoid vave (49-Stae only) 8 as-702 Fig. 3-14-1 3-20ENGINE 2) Hitachi Carburetor Type (2) (Canada and 49-state 4WD) Hose clamp Hose Nat Spring washer 10 EGR valve aSsY Howe 1 2 3 4 S Antiafter burning valve 6 7 8 ° 27 Bolt & washer 28 Temperature vive ASSY 29 Revolution sensor 30 Solenoid vave 1 asa02 Fig. 3-142ENGINE 3) C-W Carburetor Type 1 Akitude compensator 2 Vacuum switeh 1 3. Vacuum switeh 1 4 Bolt d washer 5. EGR pipe cover 6 EGR pipe 7. Solenoid valve 1 19. Solenoid valve 1 20 Tenition relay 5793 Fig! 3-15 Emission contro! equipment (C-W carburetor type)ENGINE 4) EGI-TURBO Engine System (1) 2 3 Olldelivery pipe CP 44 Union serew 3 Bolt & Union screw tock plate 7. Fuel injection control unit 8 22 Temperature sensor ASSY 23 Thermo vacuum valve 28 0, sensor 29 Knock senor Fig. 3-165) EGI-TURBO Engine System (2) eENGINE 8. Intake Manifold 1) Hitachi Carburetor Type 3 Tahasina rave: Wim (earn, feb) Ti 18-221-8-22, 13-18) 1 Nut 2 Al cleaner 3 Air cleaner bracket 4 Warner 5 Bolt & wather Carburetor bolt 7 3 9 ‘Air cleaner gasket Carburetor or power steering vehicle) Insulator 29. Vacuum hose clam 30 say 31 Washer 49-796 Fig, 3-18 Intake manifold (Hitachi carburetor type)ENGINE 2) C-W Carburetor Type “Tagiening woraue! New Tig RT 22(18-22 13-16) Nut ‘Ais cleaner ‘Air cleaner bracket Washer Bolt & washer ‘ering pin Boe ‘Spring wather Fuel hove stay Bolt Intake manifold gasket Intake manifold ‘Vacuum hose clamp Stud bolt 18 Bolt & washer 19 Sty 20 Stay? 2k Washer 22 Ais cleaner bracket 23 Carburetor 25 Nat 26 Carburetor gasket 2 27 Connector 28 Camp 29 Hose 30 Bolt 33. Carburetor spacer 34 Ait cleaner bracket (or power stering) 8596 Fig, 3-19 Intake manifold (C- carburetor type}1 Hose camp 2 Hose 3 Sockerboit 4 Spring washer 5 Twwotte switch ASSY 6 Hose 7 Hose clamp 8 Screw & washer ASSY 9. Tarottle body ASSY 10 Howe LL Throtte body gasket 12. Spat plus cond supporter 13. Spring washer 18 Spark plug cord stay AS. Spark plug cord supporter 16 Bolt 17 Boit 18 Hose 19 Nut 20 Spring washer 21 Throttle lever 29 late adjusting sew 30. Dash put holder 31 Washer 32 Screw A washer ASSY 33. Dashpot 34 Gip 35. Spark plug cord supporter 36 Clip 37 Pate 38 Collar 39 Spring hoider B 40 Couar 41 Collar B 42 Sleeve 43° Spring colar 44 Spring holder A 45: Bott Fig. 3-20 45-797ENGINE ~~~ 4) EGI-TURBO Engine System (2) 1 Bolt & washer ASSY 2 Intake manifold CP 3 Ful pipe CP (RED 4 Fuel pipe CP (LAD 5 Ful injector hoider 6 Ful injector pate 7. Ful injeetor insulator 8 Fuel injector seal 9. Fael pressure regulator ASSY 10 Fuel injector ASSY 11 Vacuum pipe CP 12 Hose clamp 1s 16 Bolt & washer ASSY 17 Chip 18 Gp 19 Wather Rg he Fig. 321ENGINE Pan, Oil Filler Duct and Fittings “Tigranina torauel_ Wer tae, FBT Ti_23-26(23-27, 17-20) 222-27 (22-28, 16-20), Ta 44-84 (045-058, 5 1 Od evel gauge 2 OU Mller duce 3 Olt fillercap CP 4 Gasket 5. Air breather duct gasket 6 OM Mer duce stay (SUBARU 1800) 7 Oiler duce say (SUBARU 1600) Fig. 9:22 Oillstainer stay ving Oi strainer Be Spring washer Nut Oi srainer stay 2 Bolt & washer Odpan gasket Bolt & washer il pan CP Pog Gasket (Oi filer duct stay (TURBO) Oil evel gauge (TURBO) 8798ENGINE oa" 10. Oil Pump (1800 ce engine) + apoly tauis gecket (Fuji Bord Cor squivatent) tothe treed. in + Apply thin coat ofa [Fiafiening woraue Nem team, Fo) Th 31-37 (02-38,23-2) Tz 22-27 (22-28, 16-20) 73: 298.0, 321 (1600 ce engine) “Tightening torque Nm ke, RTO) Th: 81-397 G2 -38,23— 2 T2: 22-27 22-28, 16-20) * Apply liquid goskat ‘Ful'Gord Cor feunatenl fete tired. DB - sopiy 5 tnin com of oo A ‘the seat ea rubber. ” 18 19 20 2 n 23 * 26 n » 30 31 04 pump assembly Ou reel valve Relief valve spring Washer Washer Pug ning (Oi pump rotor (0d pump drive gear (Oi pump body holder Pan bead screw Plug (Models without pressure gauge) (OW pressure switeh (Models without pressure gauge) Phug (18°) (Models with pressure gauge) ‘Oil pump body gasket Oring Oring Oi fter Bolt Bolt Washer 8 pressure gauge (odels with pressure gauge) Stay Oring Thermo valve Attachment Connector (04 pump assembly Ou relief vate Relic vale spring Washer Washer Plug Oning 8 pump rotor (il pump drive gear (0d pump body holder Pan head sew Plug (Models without pressure gauge) Bal ‘By-puss vale spring Oring (Oi pressure switch ‘Models without pressare gauge) ‘Oi pump body gasket i fiter Bott Bott Washer O-ring ‘lug (Models with pressure gauge) (Oi pressure gauge (Mtodes with pressure gouge) Suy nateENGINE 141. Engine Cooling System NOTE: There are two manufacturers of fa ASSY. One is Hitachi and the o ‘Mitsuba, Each is exclusively composed, so there is no interchangeability ‘between two manufacturers. Ground core Tapping srew Hose camp Flange aut Flange bolt Shroud Radiator inet how ‘Thermo switch Packing Radiator outlet hose Radiator assembly [Trgrrening raver Nm arn, Fb [Histienina oraue:_Nim thon, feb] 710-1811 -8,7—13) BRURO RUNES SECRET ORE Sees mueune ¥ i ose som Hose clamp Tapping screw cooler pipe damp Ot cooler hove 4 cooler pipe complete Oitcooter pipe clamp Spring washer Batt 9 Clip Fig. 3-25. Engine cooling system (Oil cooler {AT}ENGINE 12. Water Pump and Relative Fittings 1) Non-TURBO Vehicle Fig. 3:26. Engine cooling system (Water pump and relative fittings) gv 3-32 Bott & washer ‘Thermostat cover Bolt & washer Hove camp Hose (For CW carburetor) Thermostat cover (For power stcezing) Water by-pass pipe Protector say Warer pump gasket Water pump Bolt & washer Bolt & washer Howe calmp Hose Hose Thermostat ‘Thermostat cover gasket Solenoid valve bracket Hose ‘Water pump impeller ase76ENGINE 2) TURBO VehicleENGINE 13. Exhaust System 1) Non-TURBO Vehicle Tighten torque! Non tag Ra] Tie 42-53 (63-83,31-281 72: 10-18 11.0 T3: 25-29 (26 Ta: 14-22 (1.42.2, 10-16) TS: 25-30 (25-35, 18-26) Rear exhaust pipe ASSY (Canada and 49-nate 4¥D) ‘Seltock aut Exhaust gasket Bolt Exhaust cushion Exhaust pipe hanger bracket Front exhaust pipe ASSY Gasket Washer Gasket Selttock mut eas exhaust pipe ASSY (49-state non-4WD) Flange bolt Fagor eae As-e00 3-34ENGINE 2) TURBO Vehicle ‘Tightening torque: Nm legen, Ra] Th 42-52 43-83,31-38) 7210-18 (1.0-18, 7-13) 73: 25-34 (25-35, 19-25) Ts" 25-29 (26-30, 19-22) Fig. 3.29 ‘all pipe cutter Exhaust cushion Mame aSSY. Bolt Exhaust gasket Self lock aut chau pipe nanger brackat Exhaust cushion Rear exhaust pipe ASSY Flange boit Spring Exhaust gasket Cover T bracket Flange our Self lock aut Bolt & washer ASSY Bracket Bole Center exhaust pipe ASSY Flange elt Flange bolt ‘Turbo IN gasket Seud bole Upper cover CP Flange nue Lower cover Converter cover Flange boit Under cover Nat Washer Gasket Front exhaust pipe ASSY Bracket Flange boit Flange bolt ‘Turbo OUT gasket Flange bolt Flange nut Rear exhaust pipe ASSY (California mode) SeeseevesesesyRes asaotinet ENGINE 14. Turbocharger F308ENGINE 3-3. On-car Services Also after reassembling and remount: ing the engine, perform the following checks and adjustments. NOTE: a. Upon completion of the ot adjustments, check the oil ‘coolant level, Add up coolant if necessary. b. Check to see if there is any leakage of the engine oil or coolant, eCheck the wiring cords, pipes, hoses, ete. for undesirable interfer: ence, 4. If ane or bath of the cylinder heads ‘are removed in engine disassembly, tmaver fail to perform the retighten- ing of the cylinder head nuts & bolts and intake manifold bolts and ad ‘il and for about 10 minutes and cooled down to ambient temperature. 1. Ignition Timing Perform inspection and/or adjustment Of ignition timing according to the following procedures {nition timing (8TDC) Without racuuok advance fanction, and with gear in neutial position (MT) 0: N (OF position (AT), and lights off Fig. 3:31 Plugging vacuum hose For TURBO vehicles, disconnect the black connector (2pole connector) between distributor and knock control wit. To check the ignition timing, connect 4 timing light to #1 cylinder spark plug cord, adjust the engine idle speed to the specification and illuminate the timing mark with the timing If the timing is not correct, proceed to the next paragraph for adjustment. [espeea] 8 = 2°1650 mm 1600 fae [speed | 8:¢2"/700 om sees st | s27/700—m 1300 at | 8: 7°/800 0m jturso {1800} ar |ts + 2°/800 pm 1) Checking Ignition Ti Before adjusting ignition timing, dis connect the pressure hose of advancer from the distributor to stop the vacu- ‘um advance function of the distribu- tor, and, while checking ignition tim- ing, plug the end of the pressure hose with small rd. Fig. 3:32 Checking ignition timing 2). Adjusting Ignition Timing 1) Loosen the 6mm bolt on the mounting plate of the distributor. 2). Turn the distdbutor housing, The timing is advanced when the distrib tutor housing is turned clockwise and 's cetarded when turned counterclock- wise. 3) Tighten the bolt and make sure that the teing i corect Fig, 3-33. Adjusting ignition timing 2. Engine Compression 1) After warming up the engine, turn off the ignition starter switch. 2) Make sure that the battery is fully charged. 3) Remove all the spark plugs. 4) Fully open the throttle valve. 5) Check the starter motor for satis- factory performance and operation. 8) Crank the engine by means of the starter motor, and read the maximum value on the gauge when the pointer is steady. Note: Hold the compression gauge tight against the spark plug hale. 7) Perform at least two measure ments per cylinder, and make sure that the values are correct. [Non TURBO) |_ see — TER sane Lo nae nes -roma.062TURBO] h 10790, 180 cpg an 5 Bom i Gomme HOR NTI Fig. 3:34 Compression pressure ENGINE Fig. 3:38 Measuring compression Fig. 3:36 Measuring vacuum Tina hg Intake Manifold 5) Keep the engine a the ile sped iferencebe: [Oe A 28 pai facuum land read the vacuum gauge indication, tween cylinders Fo By observing the gauge needle 1) Warm up the engine. . movement, the internal condition of 2) Disconnect the vacuum hose and the engine can be diagnosed a install the vacuum gauge to the hose described in Table below. fiting on the manifold. Diagnosis of engine condition by measurement of manifold vacuum ‘Vacuum gauge indiation Possible engine condition 1, Needle is steady but lower than normal position. This tendency becomes more evident as engine temperature rises. Leakage around intake manifold gasket or carburetor gasket. 2. When engine speed is reduced slowly from higher speed, needle stops temporarily when it is Towering or becomes steady above normal position, Back pressure too high, of exhaust muffler clogged. 3. Needle intermittently drops to position lower than normal position. Leakage around cylinder. 4, Needle is steady but slightly lower than normal position. Retarded ignition clearances. timing or insufficient valve 5. Needle is steady but slightly higher than normal ‘Advanced ignition timing. begins to vibrate rapidly at certain speed, and then vibration increases as engine speed increases. position, 6. Ned rope sil and inemitentiy fom | Leaking aes or feu vale carne normal position. 7, Needle drops suddenly and intermittently from Sticky valves. ‘normal position. 8. When engine speed is gradually increased, needle ‘Weak or broken valve springs. 9. Needle vibrates above and below normal position in narrow range. Defective ignition system or incorrect carburetor idle adjustment, 3-38 anesHot Air Control System Inspect the hot air control system periodically as follows. In warm weather, it is difficult 10 find out malfunction of the hot air control system. In cold weather, how- ever, malfunction of the air conteol valve due to disconnection or deterio- ration of the vacuum hose between the intake manifold and vacuum motor and insufficient durability of the air ENGINE control valve will cause insufficient automatic control operation for iatake air, and result in engine disorders: 1) Stall or hesitation of engine oper ation, 2) Increase in fuel consumption, and. 3)_Lack of power. ‘These phenomena reveal malfunc- tion of hot air control system. If these Phenomegs should occu, check the hhot air edttcol system for the follow- ing items before carrying out inspec ton of the earburetor. Vacuum motor Tempecature sensor ‘Throttle valve Intake manifold Vacuum hose Ag store Au ince hove Air control ralve Air hom (Scorkel tube) 1 Vacuum motor 2 Temperature sensor Fig. 3-37 Hot air contral system 339 1) Vacuum Hoses Check each hose for cracks and proper connections. 2) Vacuum Motor nD the engine stopped, place a mirror at the end of the air cleaner inlet pipe as shown in the figure, and check to see if the air control valve is in correct position, asces Fig. 3:38 Inspecting valve position ‘The air control valve is in correct position if its under hood air inlet is ‘open and hot air inlet is closed. Check the condition of the air control valve Linkage, 2) Disconnect the vacuum motor inlet vacuum hose, and connect an- ther hose to the inlet to apply vacu- lum to the vacuum motor. Vacuum ean be applied by sucking at the hose end as shown in the figure. Place a mirror at the end of the air cleaner inlet pipe, and check to see if the air control valve is in correct Position. Fig. 3:39 Inspecting valve position Correct position of the air control valve is the reverse of that described in 1) above, The air control valve is in correct position if the under hood air inlet is closed, and the hot air inlet is open.ENGIN 3) With the hot air inlet in open 3) Temperature Sensor 3) Check that the air control valve position, as described in 2), pinch the gradually moves to open the under vacuum hose with fingers so that the ‘Check temperature sensor for prop: hhood air inlet as the engine warms up. When the environmental temperature around the temperature sensor is low, spend more time for engine warming up operation to facilitate smooth oper- ation of the air control valve air does not enter the vacuum motor. _¢f function by proceeding as follows. In this condition, check that the air Be sure to keep the engine cold before control valve maintains the condition starting this test. described in 2) for more than 30) With the engine stopped, check seconds, and that the hot air inlet is the position of the air contzol valve, In ‘open, If the diaphragm spring actuates thls case, underhood air inlet should the ait control valve by its spring force _@ open. Use a mirror for inspection as to open the under hood air inlet. 2)~ 1) within 30 seconds, replace the vacuum 2) Start the engine and keep it motor as an assembly since this may idling. Immediately after engine start- Check the rubber plate for sticki- fave resulted from air leek at the Mi check the alr control valve for pers ‘vacuum motor diaphragm. ‘correct position as described above, In this case, the correct position of the 5) ic contiol valve is the reverse of 4) Rubber Plate Intake Hose i 2)-1); the under hood air inlet ig Check the air intake hose for dam- Glosedand the het st let isopen, age and ns connections freak ; Operation of a onl vie an eso ave ! Under hood a Sensor ae ; a Vien snmcmmatcipingn | Azenmiteopaien| SR Below 5.3 kPa (40 mmHg, 1.57 inHg) Coo! air admission Below 38°C (100°F) Close ‘bow 1604P4(120 nmi 472 nti) | Hot at odmision 38—S3°C (0100-1277) uae Cootand hot amie | ey Above 53°C (127°F) —— Cool air admission Open 5S. Engine Idle Speed and Idle Mixture 1. ENGINE IDLE SPEED intake system, are tight and secure, ‘Nott (2) The engine has warmed up ‘& Make sure that the ignition timing sufficient and 02 sensor has and valve clearances correctly also be& warmed up at an adjusted prior to this inspection. engine speed of 2,500 rpm for 'b. Set the gear position at “Neutral” approximately one minute for MT, or “P” or “N" for AT. ‘after engine warm-up. © Before inspecting the engine idle (G) Clog the purge hose to the ‘speed, ensure that: intake manifold after (1) Vacuum hoses, blow-by hoses, necting it rocker cover, oil filler cap, etc, which are connected to. the a 7 aeENGINE [Ren TGRBO venice] © Troubleshooting Fy Engine idle speed (rpm) Faulty “Rony Degraded catalyst 1 isiion ectsynes facet 4speed | 650100 sysem Ty fiaae ‘anal ! Faulty se of leaded Speed injector eee a Faulty exhaust pipe MT i eel Fay mater AT 800 = 100 ile CO z fae: Incorrect ave (TERBOwehiele] a> Gs Semen imgcoper sismae steed 1). Before inspection, ensue that the compen auxiliary ai valve i completely closed. prestre 2) Adjust the idle speed by using the idle adjusting serew located on the Fig. 342 een *L: Check the EGI system. : Connect a jumper wite and check to see ifthe ECS lamp fickers with the Tle speed (cpm) | 800+ 100 ‘engine at idle. If it does, the EGI system is Functioning properly. CO contents (%) | O.l.max. Chek halen Remove the fuel injector and diect air at a pressure of approximately 196 kPa HC contents (ppm) | 200, max. (Kafer? 28 si) to see if ac leaks at the nozzle tp. Uf ar leaks, ceplace the injector. bb: The injector is faulty. Fig. 341 3) Inspecting the exhaust gas, 4 Alter adjusting both ignition timing and idling speed, check both the idle CO and HC contents in the exhaust $35, NOTE: ‘The CO content adjusting screw ofthe flow meter need not be adjusted as the air-fuel ratio is feedback con- ‘trolled. b. IF the CO and HC contents are outside specifieations, check and correct the problem using the following chart as a guide. oa; ENGINE 2. ENGINE IDLE MIXTURE Non-TURBO) NOTE: Perform the idle mixture adjustment only when dismounting carburetor from engine or disassembling carbu- retor, And after completion of adjust- ment, be sure to press spring pin into the hole in thrattle chambe 1) For 49-state Non-4WD and Californi Perform the engine idle mixture adjustment according to the following diagram. . Warm up engine | . Does the pointer of duty meter swing |, ‘dling speed = N normally? (ie. Is duty ratio controlled?) Duty ratio = 2 lain speed = N Duty ratio ‘Adjust duty atio. |) is Yes Keep engine seed within 2,000 3,000 a ‘Ware up engine oy sm for? ~ 3 minutes. nvang ound for No ima Z See Troubleshooting Cam Doeg the pointer of auy nese ing | Yep in Capers Daginto=2 romally? ie dry ratio controled?) dye 650 100 rpm (1600 ce 4spnd) End Xo += [ 100 £100 pm (160 ce Sapent ant 1800 ec #1) 800 = 100 rpm (1800 ee AT) See Troubieshooting in Chapter 5 ae ‘Vehicle with Vehicle with HITACHI carburetor CW eaburetor Standard value Dury ao =Z 13580315 deg) ie ‘NOTE: 2 Perform the above adjustment a Zits constant both main and stow duty solenoid er | | asses of te valve by using check terminal. ead lau 'b, Adjustment method by using dwell ameter is as follows. is, (1) Set the range switch to “four oe cycle — four cylind = = (2) Adjust the idle adjusting screw Weer leaom so thet the needle points out Z is determined according to ‘secarding to the following cal- ee altivude, ) . culation, a 90 a 806 (245 dep) Dwell (deg) = =x Duty (%) oases Sea Paine -208 18 den °* Adjust ile adjusting erew so that duty meter indicates 35 + 10%. 3422) For 49-state 4WD and Canada Adjust engine idle mixture as follows: 1) Start engine and warm up suff ciently, 2) Inspect idle speed and CO per- centage in exhaust gas with secondary 1600 otter | ata |2-D00r] ‘than | sWD- |Haten- at | at | back STD 700 | 800 | 650 {ate speed (cpm) | L199 | s100 | 100 co Without | 29 | 1s | 20 se. fants | cto | aio | Ato . is fe | ono re 3) Disconnect sie suction hose be- tween ai suction valve and secondary sic cleaner, 4) Clog aic suction pipe with cubber cop or the ike. 5) Inspect idle speed and CO per- centage in exhaust gas without second- ay ai 6) If necessary,-adjust idle speed and CO percentage in exhaust gas while clogging air aiction pipe 2. Adjust both throtle adjusting screw and ile mixture adjusting serew to obtain the specified idle speed and CO percentage without secondary air . Remove the plug clogging air suction pipe, and connect the pipe to secondary air cleaner hose. c. With secondary air, recheck that idle speed and CO percentage satisfy the specifications. TURBO ‘This adjustment is not recommendable. 6. Radiator Check radiator, hoses and their con- nections for damage, clogging or leakage. ENGINE A. Testiipof radiator cap CCheck the valve, spring and packing in the cap for damage. Check rubber seal on cap for tears, ‘racks or deterioration after cleaning it. Install the cap on a tester and if cap does not hold or does not release the specified pressure, replace cap. Standard pres- sue at which via valve sarts to | 9 kelem®, 13 ps) open Fig. 3-43. Testing the cop 8. Testing of radiator leakage Inspect radiator for leakage using a cap tester and applying a presuce of 187 kBa(1.6 kafem?, 23 psi). Lf a leakage is détected, repair or replace the radiator. Fig. 3-44 Testing the radiator 7. Hydraulic Valve Lifter 1) Replacement The hydraulic valve lifter can be replaced even when the engine is ‘mounted on the vehicle as follows: aw 1). Disconnect both the biow-by and PCV hoses. 2) Remove the valve rocker cover. 3) Using the special tool Socket Wrench: 899988607), loosen the valve ‘cocker ASSY and remove the push rod. 4) Raise the vehicle body with a jack and support it on a safety stand. 5) Remove the nuts which secure the front engine mounting and slightly raise the engine using a floor crane. ©) Remove the drain plug to drain the engine oil completely. Detach the oil pan. 7) Remove the hydraulic valve lifter. Use of a magnet facilitates removal as-678 Fig. 3-45 8) The valve lifter ean be installed in the reverse order. 2) Adjustment 1) Perform adjustment in cold con- dition (coolant, temperature: 20 to 40°C (68 to 104°F)]. 2). Retighten cylinder head nuts and bolts previously if necessary. 3) Adjust hydraulic valve liter with the following procedures: a, Perform adjustment in two (2) sequences, ‘Sequence (I) —————— Position #1 cylinder at TDC (Compression), and adjust the valve lifters for intake and exhaust valves on #1 cylinder, for exhaust valve on #3 cylinder and for intake valve on #4 cylinder.ENGINE i Sequence (11) ———— fs Position #2 eylinder at TDC (Compression), and agjust all the others, ie. for intake and exhaust valves on #2 cylinder, for intake valve on #3 cylinder ‘and for exhaust valve on #4 cylinder. b, Raise up the bend of lock washer, loosen the lock nut, and then turn the valve rocker’ screw clock- wise by approx. four (8) tums using Valve Clearance Adjuster 498767000. . Valve opens. t ie CEs Serew by approx. 4 turns. > 45-700 Fig. 346 ¢. Leave it with the valves opened for approx. 15 minutes, ‘Leave for approx. "Teminuter then pressure chamber ‘Solume becomes ‘Valve moves 1) clone tte. a 8-701 Fig. 347 : 4. Unserew -the valve rocker “screw gradually, Then, the rocket arm stops moving due to the closing of valve. This condition is called + "Zero Point”. + Fig. 348 Unseraw gradi 8-702 fe. Moreover, unscrew the valve rocker screw counterclockwise by 1.5 tums. lysate valve ters adjusted OA 0 = sO} Unscrew by 1.5 tens.) f, Tighten the Jock nut, and bend the lock washer. 8. Exhaust System 1) After installing, the exhaust sys- tem, check all clesrances to ensure that they exceed the specified values 2) If a clearance is small at any Particular point, loosen all connections, then readjust clearances by utilizing fiee play existing at each bolt location unt correct clearances are obtained. Finally, tighten all connections. 0 the specified value. NOTE: It muffler or exhaust pipe clearance is excessively smail due to a deformed or broken exhaust cover, repair or replace : 45709 the cover, and adjust the clearance ee correctly. [Noa-TURBO] . Front erosmember Crossmember fr manual ansmisson b, Apply engine oil to the reamer guide is torn, the edge of the reamer should be slightly ground guide becomes lustrous and the reamerdoes not cut chips, use @ ‘new reamer or remedy the reamer. h. Recheck the contact condition between valve and valve seat after replacing valve guide. 4. Intake Valve Oil Seal Replace oil seal with new one, if lip is damaged or spring is out of place, or when the surfaces of intake valve and valve seat are reconditioned ‘or intake valve guide is replaced, Press in oil seal to the specified dimension indicated in the figure, using Oi Seal Installer (898858600). 1 Oi Seal installer «#98858600) 2 Cylinder Head Table (699765101) Fig. 3-108 Installing oit seat 8-201 23.2 mm {03913 nl Fig. 3-109. Installed position of oi! ‘se! NOTE: Apply oil to the oil seal prior to pressing 5S. Intake and Exhaust Valves 1) Inspect the flange and stem of valve, and replace if damaged, worn, for deformed, or if “H” is less than the specified limit W Stangars | Limit T tam | 0.5mm Imake | (0.039im) | (0.020 a) Pismm | osm Exhaust | co.0st iny | (0.051 iny = 03 mm (0.012 i) Fig. 3-110 Valve head dimensions Intake valve Exhaust valve Angle of valve surface oo that contacts valve seat 0 Valve overall length 109 mm (4.29 in) 109.3 mm (4.30 in) oe 2) If the contact surface of valve is ‘damaged, ofthe stem end is recessed, corect with a valve refzcer, grinding 3-60 as little as possible. The contact sur- face should be at right angle with the valve axis.ENGINE Specifications of valve spring with solid valve lifter Outer spring Inner spring Free length 45.3 mm (1.783 in) | 488 mm (1.921 in) 146.1 = 169.7. N 843 -98.1N (14.9 — 173 kg, 86 ~ 10.0 kg, 32.9 ~ 38.1 bb)/ 190-221 by 39.5 mm (135 in) | 37.5 mm(1.476 in) ieiif aeuaie ‘Tension/spring height tig eee 500.2 - $68.8.N 1854-2148. 1.0 - 58.0 kg, (18.9 = 21.9 kg, 3) Put a small amount of grinding N25 ~ 127.9 bby 41.7 — 48.3 by compound on the seat surface and lap 305 mm (1201 in) | 28.5 mm (1.122 in) the valve and seat surface, Also refer to 2. Cylinder Head 3) at this time. 2.0 mm (0.079 in) 2.1 mm (0.083 in) Install a new intake valve oil seal after | Sausveness or less geles lapping. ae eee asec ee Specifications of valve spring with hydraulic valve lifter Outer spring tne: spring 6. Valve Springs Free length 48.5 mm (1.909 in) (53.0 mm (2.087 in) Check valve springs for damage, free length, and tension. Replace 228.5 ~2618N 115.7 -133.4N valve spring if itis not to the specif. (233 - 26.7 kg, (118 ~ 13.6 kg, cations presented below. S14 — 58.9 tb) 26.0 — 30.0 iby) 39.5 mm (1.535 in) (37.5 mm (1.476 in) NOTE: ‘Tension/spring height ‘To measure the squareness of the valve 518.8 — 599.2N 201.0-2305N ‘spring, stand the spring on a surface G29— 61.1 kg, (20.5 23.5 kg, piste tnd memtore es deflection et ahe 166-1347 by | 452-518 by top using a try square. 32.0. mm (1.260 in) | 30.0 mm (1.181 in) 2.1mm (0.083 in) | 2.3 mm (0.091 in) Squareness or less orless * 7. Valve Rocker 1) Inspect the inner surface of valve Replace valve rocker arm or shaft ocker arm and the outer surface of if defective. rocker shaft for wear. 2) If the cocker arm surface that A5.062 contacts the stem head is noticeably worn, replace the rocker arm. If worn Fa 3112 Checking ring auareness | Cesanes | oo13oasamm | slthtly ina stepped shape, use a valve peewees eck**| (0.0005 — 0.0020 in) refacer and correct the surface, grind- ing as ltie as possible Toner diameter | 18.016 ~ 18.034 mum ‘of rocker arm_ | (07093 ~ 0.7100 in) ‘Outer diameter| 17.982 ~ 18.003 mm . of shaft | (0.7080 — 0.7088 in) 3-61ENGINE 3) Replace rocker shaft ‘washers if worn excessively, spring Fig. 3-113 Correcting valve rocker arm 8. Valve Lifter 1) Solid Valve Lifter Specifications for lifter an¢ lifter hole Standard inner diameter of : lifter hole 21.000 ~ 21.021, mm (0.8268 ~ 0.8276 in) ‘ Standard outer diameter of 20.949 — 20,970 mm (0.8248 ~ 0.8256 in) (0.030 — 0.072 mm (0.0012 ~ 0.0028 in) : lifter i Clearance between | Standard { lifter and lifter j hole Limit 0.100 mm (0.0039 in) 1) Check valve lifters for wear and damage, and replace or correct if defective 2) Check the lifter holes in the crankcase for damage, etc., and correct or replace as necessary. 2) Hydraulic Valve Lifter anos Fig. 3-114 Checking lifter hole Hydraulic valve lifter and lifter hole Standard inner diameter of lifter hole 20,988 ~ 21.040 mm (0.8263 ~ 0.8283 in) ‘Standard outer diameter of, lifter 20.950 — 20.968 mm (0.8248 — 0.8255 in) 0.020 ~ 0.090 mm (0.0008 — 0.0035 in) Lifter wo ster hole | Standart cleargge ar 0.100 mm (0.0039 in) NOTE: Be extremely careful to prevent any foreign matter from getting into the valve lifter as it is machined to a high degree of precision. 1). Measure the outer diameter of the vaive lifter. If itis outside the specified value, replace it. Also check it for wear or damage and replace it as necessary. 2) Measure the bore diameter in the crankcase atthe vabe liter location. If the clearance between the bore diameter and outer diameter of the lifter exceeds the specified limit, replace the lifter. 3) Forcibly insert the push rod seat with push rod to see if the seat moves into the valve body. If it does, check the following reasons and repair it as follows: © Air is sucked into the pressure chamber. © Plungertotbody clearance is too large. © Foreign matter and/or damage exists around check ball and plunger. a. Remove the following parts in the order indicated, ° Clip © Push rod seat © Plunger © Check ball, check ball spring and check ball retainer © Plunger spring NOTE: a, Never mix up plunger, push rod saat and valve body amoung valve lifters. Use a wire to facilitate removal of the plu 2-3 mm, (0.08"0.12 in} asa Fig. 3-115 8 Sr RRR i i 5 i “regent rnin mr aceacemgrn ener sc apse naeb, Cleam alt disassembled parts. cc. Install the check ball, check ball spring and check ball’ retainer on the plunger, being careful not to tit them, Plunger Fig. 3-116 eet 4. Install the plunger spring in the valve body and fl the body with clean engine oil. «. Insert plunger into valve body and push check ball with drift pin fouter 32 mm (1/8 in) dia) until the plunger comes into contact with ‘the body while making an ‘opening between the check ball and plunger. & Insert a suitable pin into the oil hole in the body and remove the eit pin, oe ~ azine a. orien). wsios |asti.3e oe eat 2511/10) ia. ~/ iB Unie: mam Gnd Fig. 2117 = 8. After refiling with clean engine oil, insert the push rod seat, install the clip in place and remove the pin h. Again make sure that the push rod seat does not move into the valve body when forcibly pushing the seat with the push rod TE it does, replace the valve lifter with a new one. ENGINE 9. Push Rod 1) Check for any sign of bending or damage, and replace if defective, Deflection of center 0.4 mm (0.016 in) or less 2). Check the oil hole in push tod for clogging and clean if necessary, 219 - 219.4 mm (8.62 ~ 8.64 in) For 1600 (Kaurling: 2) For 1800 with solid Overall | valve lifter length | (Knurling: 1) For 1800 with hydrau- lic valve lifter (Kaurling: nothing) 230.7 ~ 231.1 mm (9.08 ~ 9.10 in) B17 mm (9.12 — 9.14 in) Fig. 3-118 Checking push rod for bending 10. Crankcase Chece crankcase for the follox- ing items, and corcect or replace if detective. 1) Check for cracks and damage visually. Especially, inspect important parts by means of red check. 2) Check the oil pasages for clog- ing. 3) Check stud bolts on the crankcase for loosenes.{f any stud boli ioe, corset or replace. If itis bent, covet so that the cylinder head ‘can be installed smoothly Use Stud Bolt Wrench (898878600) to screw the stud bolt into crank- case. NOTE: Coat the stud bolt threads with 2 torqueholding sealant (Loctite 270 or 271, oF equivalent) before installation. asa Fig. 2-119 Installing cylinder head stud bolt 4) Inspect the crankcase surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary. Warping limit | 0.05 mm (0.0020 in) Stud Bott 1,800 ce 1,600 ee - 915-935 mm 90.5 ~92.5 mm Leng (602-3681) | 9.563 ~ 3.682) 34 4Nem Torque (GS-43 kgm, 25 — 33 felb) 3-6311. Cylinder and Piston 1) Measure the inner diameter of each cylinder in both the thrust and ENGINE 2). Boring and honing 2. If the value of taper, out-ofxound- ness, or cylinderto-piston clearance measured exceeds the specified piston pin directions at the heights shown in the figure, using a cylinder bore gauge. Cinder hee mating arte a 0 Ym 10.28 inl 7, Nore: f = 7 y When any of the cylinders needs rebor- 4 Y ing, all other cylinders must be bored at the same time, and use oversize AA: Tat direction Paton pin direction limit or if there is any damage on the cylinder wall, rebore it to use ‘an oversize piston, ‘A507 Fig. 3-128 Measuring piston diameter pistons. Do not perform boring on one wer only, nor use an oversize Piston outer diameter wecvon piston for one cylinder only. : z | 91.960 91990 mm Standard | 1600 | 30mm Clem pe oe srnn pena (3.6205 ~ 3.6216 in) 1.800 a [335 mm (1319 ip measure the outer diameter of each [O35 a Fig 3120 Positions for cylinder bore piston at the height shown in the | | 92210-92240 mm Fe r20 reasorement Figure. (Thrust direction) (0.0098 i) "(3.6303 — 3.6315 in) bade 050mm Mossurament should be performed at Goria) | 92460-92490 mm temperature of 20°C (68°F). tvesae | 2402 3.6813) NoTe: Q 2samm Measurement should be performed at frase a temperature of 20°C (68°F). ~ ¢. If the cylinder inner diameter ex- ceeds the following erfarging limit Georg after boring and honing replace the rankexse. 8208 Fig, 3.122 Postion for measuring Fig, 3-121 Measuring cylinder bore biston diameter ‘Enlarging Unit z etevinaer | 0,50 mm (0.0197 m) inner diameses ‘ linder bore a NOTE: 9198s ~92015 Immediately after reboring, the, cy- ‘Standard diameter (Both 1800 and 1600) (36214~ 36226 in) inder diameter may differ from its real z diameter due to temperature rise Standard 0.015 mm (0.0006 in) Ane ne sttemlen ts ee fo : measuring the cylinder diameter. : Limit 0.050 mm (0.0020 in) 4. Inspect the cylinder bore for taper, outofiroundness, and diameter di Standard 0.010 mam (0.0004 in) ferences, Outof roundness Limit 0.050 mm (0.0020 in) Diameter difference | 0.050 mm between cylinders | (0.0020) oss oe 0.010 — 0.040 mm - seaaece (0.0004 ~ 0.0016 in) Cylinder to piston clearance Note: at 20°C (68°F) ee = 0.060 mm Measure the ianer diameter of. the ae (0.0024 in), oye when the temperature is 20°C i ee 3-64ENGINE 12. Piston and Piston Pin 1) Check pistons and piston pins for damage, etacks, and wear and the piston cing grooves for wear and dam- age. Replace if detective, 2) Measure the piston-to-ylinder clearance at exch cylinder a3 instructed in 11. Cylinder and fiston. 1 any of the clearances is not to specification, replace the piston or bore the cylinder to use an oversize piston. 3) Make sure that piston pin can bee inserted into the piston pin hole with a thumb at 20°C (68°F), Replace if detective 13. Piston Ring 1) If piston cing is broken, dam- aged, or worn, or if its tension is insufficient, or when the piston is replaced, replace piston ting with a new one of the same size as the piston. Note: a. “R” or “N” is marked an the end af the top and second rings, When installing the rings to the piston, face this mark upward. asor2 Fig, 3-124 Mack on piston ring ‘4. The oil ring is a combined ring coa- sisting of two rails and a spacer in between. When installing, be careful ‘at to make misassembly. Specifications for piston and piston pin ‘Standard outer diameter of piston pin ‘Standard inner diameter of piston pin 20,992 to 21.000 mm (0.8265 t0-0.8268 in) 20.999 to 21.009 mm and hole in connecting rod tent Fig. 3-125 Cross section of piston rings (Riken Piston Ring) vom EB es notin GF Es, Fin 3108 Craton peette iter Pee a 2) Sausy pc gto en oe inks tnd mene te pce ge with a thickness gauge, NOTE: If the cylinder is not corrected or it eng hole (0.826710 08271in) ‘Standard clearance between piston pin 0.004 to0.010 mm 4. and hole in piston (0.0002 t0 0.0004 in) > ‘Standard clearance between piston pin 0.005 to 0.040 mm (0.0002 to 0.0016 in) 8-296 Fig. 3-127 Measuring piston ring gap 3) Measure the clearance between piston ring and piston ring groove witha thickness gauge. NOTE: Before measuring the clearance, clean ‘the piston ring graove and piston ring. replaced one, measure the piston fi asors gap at the hottom of the cylinder, Fig. 3-128 Meesuring piston ring where the wear is litte, ‘groove clearance Standard Limit a 020-035mm | 10mm Bee (0.0079 -0.0138 in) | (0.039 in) ae 020 -0.35 mm 10mm Piston ringgap | Second ring | (9.9979 —0.0138 in) | (0.039 in) 1 020-090mm | 15mm Oil ring rail | (9 0979 — 0.0354 in) | (0.059 in) 3-65keting anki canna ENGINE Standard Limit Tense | gore 003! m) oa0s3 =) puto megane | 46) os —ognaeim) | (059. Oilring ° o 14. Connecting Rod 1) Replace connecting rod, if the large or small end thrust surface is damaged. 2) Check for bend or twist using a connecting rod aligner. Replace con- necting rod if bend or twist exceeds the limit, Limit of bend or ‘twist per 100 mm (3.94 in) in length 0.10 mm (0.0039 in) 1 Thickness pruge N 2 Connecting rod asov7 : aso7e 1 Connecting rod 2 Thickness gaoge Fig. 3-129° Measuring piston ring ‘groove clearance 3) Install connecting rod fitted with bearing to crankshaft and measure the side clearance (thrust clearance). Re- place connecting rod if the side clearance exceeds the specified limit, Fig. 3-130 Measuring side clearance Connecting rod side clearance 0.070 — 0.330 mm Standard | (9.0928 — 0.0130 in) Limit |- 0.4mm (0.016 in) 4) Inspect connecting rod bearing for scar, peeling, seizure, melting, wear, etc. 5) Measure the oil clearance on in- dividual connecting rod bearings by ‘means of plastigauge according to the AS-080 Fig. 3-131 Measuring connecting rod oil clearance a. Wipe off oil, dust, etc. on the sur- faces to be measured b. Cut the plastigauge to the width of the beuring, place it on the crank- pin parallel with the crankshaft axis, and install connecting rod. Tighten connecting rod nuts to 41.Nem (4.2 kgm, 30 fib), NOTE: During this measurement, do not allow relative movement between the crank- and connecting rod. cc. Remove connecting rod and mea- sure the width of the plastigauge with the scale printed on the plastigauge case, If any oil clearance is not within specification, replace the defective bearing with a new one of standard size of undersize a5 necessary, and replace or recondition the crank- shaft as necessary. (See. the table below.) 6) Inspect bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at the connecting rod small following procedure Connecting rod oil clearance Standard 0.020 — 0.070 mm (0.0008 — 0.0028 in) Limit 0.10 mm (0.0039 in) 3-86 none E : i iENGINE Replacement procedure is as fol ¢, Make two 3mm (0.12in) holes in 3) Inspect the crank journal and lows. bushing. crankpin for wear. If not to specifica. a. Remove bushing from connecting d. Ream the inside of bushing, tions, replace bearing with an under- rod with Remover & Replaccr « size one, and replace or recondition (499037000) and px crankshaft as necessary. When grinding - Pret bathing, with Remover & | nghore| 24000-21016 mm] rank journal or erankpin, bh them Replacer (499037000) after apply. /Bushing bore! 968 _ 9.8074 iny | to the specified dimensions according ing oil on the periphery of bushing. to the undersize bearing to be used. (See the table.) 116.95 ~ 117.05 mm 1800 ce Distance between big end and small (6.6043 ~ 4.6083 in) end hole 1600 c¢ | 109.95 ~ 110.05 mm (4.3287 ~ 4.3327 in) , After completion of reaming, clean NOTE: bushing to remove chips. When measuring, place both the front and rear journals on blocks located on a surface plate, and apply a dil gauge to the center journal, Fig. 3-193 Checking wear of crank journal 15. Crankshaft and Crankshaft Bearing 1) Clean crankshaft completely and check for cracks by means of red check etc,, and ceplace if defective, (Crankpin and crank journal 2) Measure the crankshaft bend, and correct or replace if it exceeds the Outef | 0.03 mm 0.0012 in) limit roundness | or less - Taper limie | 0.07 mm (0.0028 in) 0.035 mm Crankshaft bend timit | (Ot a) 0.25 mm (0.0098 in) Fig. 3-132 Checking crankshaft bend Dimensions of crankpin, bearing and bearing bore Part : : Connecting rod bearing in CCeankpin diameter | Connecting rod bearing thicknes at center eee 44995 — 45.010 mm ~ 1.477 = 1.485 mm Standard 1 (771s — 1.7720 in) (0.0581 — 0.0585 in) 005 mm 44.945 — 44960 mm 1505 ~ 1510mm (0.0020 in) , 48.000 - 48.019 mm Gade | (7698 — 1.7701 in) (0.0593 ~ 0.0594 in iaasoe esas} Goose yy | 44745 ~ 44.760 mm 1.605 ~ 1.610 mm seek) | 7616 = 17622 iny (0.0832 0.0634 in) 3-87NGINE AS. Dimensions of crankpin, crank journal and bearing ‘Crank journal outer diameter Bear ize eer cunt 1,800 cc engine 1,600 cc engine ne diameter ee : = Front, enter and Rear | Front and Rear Center : 44395-45010am | s4955-sastomm | 49987 —49970mm | 49970-49982 mm emu ams-1770 | ares-aue2m | csees—i96r.) | ase 196m 0 mm sasis~s4stomm | 49927-49.900mm | 49940-49952 mim @aaiziny nm —21630im) | asese—r96eiian | c96si ~ 19666 im ir mm 44.945 — 44,960 mm 54.905 ~ 54.920 mm 49.907 — 49.920 mm 49.920 ~ 49.932 mm Cogozei) | ress error) | asere-24622in | 5 a.96es—196s4iny | 96419658) ont 44.745 ~ 44.760 mm 54,705 ~ 54.120 mm 49.707 — 49.120 mm 49.720 — 49.732 mm geese) | reie—irezzin | qassr—2asaain | agsi0—19s7si) | agers —19sr0m 4) Measure the thrust clearance of crankshaft at center bearing. If the clearance, eXageds the limit, replace ‘bearing, © * (Crankshaft thrust clearance 0.010 — 0.095 mm Standard | (6.9004 — 0.0037 in) Limit 0.3 mm (0.0118 in) 1 Thickness gauge 2 Center bearing part = Fig.3-134 Checking thrust clearance 5) Inspect individual crankshaft bear- ings for signs of flaking, seizure, ‘melting, and wear. 6) Measure the oil clearance on each crankshaft bearing by means of plasti= ‘gauge as follows: 1. Wipe off oil, dust, etc. on the sur- faces to be measured. Install bearings in crankcase and set crankshaft in position. . Cut the plastigzuge to the bearing width and place it on journal parallel with the crankshaft axis. Be careful not to put it on the oil hole for groove. Bring together the crank- case halves and tighten bolts to the specified torque. NOTE: ‘During the work, the crankshaft must not be turned nor the crankcase 4. Remove all bolts and separate ‘crankcase. Measure the plastigauge ‘width with the scale printed on the pilastigauge case, inverted. tf Asoee ‘Thread size Torque Fig. 3-135 Measuring oil clesrance of ‘crank journal 39-47Nm 10mm 40-48 kgm, 29-35 ft-lb) Nii 23-26Nm 8mm (232.7 kem, 17-20 felb) If the measurement is not within 44-S4Nm the specification, replace defec- 6mm | (045-055 kgm, tive bearing with an undersize one, 3.3 — 4.0 felb) and replace or recondition crank- shaft as necessary. 3-68. 7 OTTER i i iee eee eee eae Ue ENGINE z 4 In case that the oil clearance of NOTE: * bf you use undersize bearings, please crankshaft bearings does not reach a, When selecting crankshaft bearings, confirm that the crankshaft can be the limit and the engine knocking the following combination can be turned smoothly by hand [at noise is generated, select under size as well as using same size torque of 15N-m (1.5kom, 11 bearings in sutable size to minimize bearings for both right and left fb) or les], to prevent the bear. the of clearance within the stand- crankease halves: ings from seizuring after assembling acd tange as shown in the following The following table summarizes the ‘the crankcase just before installing table "Crankshaft oil clearance”. amaunts of reduction in oil clear- ‘the pistons. anee for various combination of hearing halves, Combination of crankshaft bearing Left side crankcase Crankshaft bearing size 0.03 min (0.0012 in) | 0.05 mm (0.0020 in) eee undersize undersize Standard Omm (in) 0.015 mm (0.0006 in)'} Not recommended 0.03 mm (0.0012 in) a i Right side 0.015 mm (0.0096 in) | 0.03 mm (0.0012 in) | 0.04 mm (0.0016 in) ee underize ‘ee oe 2.5 rm (0.0020 in) | Noerecommended | 0.04 mmm (0.0016 in) | 0.05 mm (0.0020 in) Crankshaft oil clearance Engine 1,800 ce 1,600 ce a sore ana aeons ‘ (0.0004 — 0.0010 in) (0.0004 - 0.0012 in) Standard 35 0.010 “6.030 mm ob 0.010 - 0.035 mm ieee (0.0004 — 0.0012 in) _ (0.0008 — 0.0014 in) Center 0.045 mim (0.0018 in) . Limit 4 Front & Rear 0.055 mm (0.0022 in)— ENGINE Dimensions of bearing Thickness of bearing at center Crankshaft ; preronie 1800 cc engine 1,600 cc engine Front & Rear Center Front & Rear Center eeucy 2015-2019mm | 2015-2028mm | 2001-2.008mm | 2003-2015 mm anda (0.0793 - 0.0795 in) | (0.0793-0.0798 in) | (0.0788 - 0.0791 in) | (0.0789 0.0793 in) oorziay | /2030-2036mm | 2030-2043mm | 2017-2.030mm | 2017 - 2.030 mm ends (0.0799 - 0.0801 in) | (0.0799 - 0.0804 in) | (0.0794 — 0.0799 in) | (0.0794 — 0.0799 in) omnis) 2040-2.044mm | 2040-2.053mm | 2022~2035mm | 2022-2035 mm Ae (0.0803 — 0.0805 in) | (0.0803 —0.0808 in) | (0.0796 — 0.0801 in) _| (0.0796 — 0.0801 in) (ase 2.140-2.144mm | 2.140-2.153mm | 2.122—2438mm | 2192-2135 mm (00088 =) | (0.0843 — 0.0844 in) | (0.0843 — 0.0848 in) | (0.0835 — 0.0841 in) | (0.0835 — 0.0841 in) 7) Inspect the crankshaft gear teeth and the surface on which oil seal slides for wear, damage, etc., and replace if defective. 8) Inspect distributor drive gear for tooth surface damage, and proper fit of woodruff key, and replace if defective, + Fig. 3-136 Checking camshaft bend 2) Measure the thrust clearance between camshaft and camshaft plate. If it exceeds the limit, remove cam 16. Camshaft sear and replace plate 1) Measure the camshaft bend, and correct or replace if it exceeds the limit. Camshaft thrust clearance 0.020 — 0.090 mm NOTE: Standard | (@ 9908 — 0.0035 in) When the camshaft is replaced, the valve filters also must replaced. Limit 0.2 mm (0.008 in) Bend limit | 0.05 mm (0.0020 in) 3-70 1 Camshaft plate 3, Camshaft 2 ‘Thickness gauge 4 Cam gear Fig. 3-137 Measuring thrust clesrance 3) Inspect the journals, and refer if damaged or worn. 4) Inspect the cam surface for dam- age, and measure the total height of the cam, Replace camshaft, if damaged noticeably or worn beyond the limit. If damaged only to 2 minor degree, grind and correct with an oil stone. provided with taper cof 4 minutes to cause the valve lifter to rotate. Be sure to retain this taper. nent RESIN RHEE POH PNET EOE EN RPE DENI TSEENGINE Specifications of cam lobe height (intake and exhaust) With solid Standard 3224-3234 mm (1.2693 ~ 1.2732 in) (Dimension “H”) With solid 35.90 - 36.00 mm (14134 ~ 14173 in) Wear limit 0.1 im (0.0059 in) 8) Measure the backlash between cam gear and crankshaft gear, by using Magnet Base (498247001) and Dial Gauge (498247100). Replace cam gear if the measurement exceeds the specified limit, Backlash between crankshaft gear and cam gear With conventional valve lifter 27 mm (1.06 in) 0.010 —0.050 man s tandard | (0.0004 — 0.0020 ia) Dimension With hydraulic valve lifter 31 mm (1.22 in) or aseas b. If a new cam is used, check its if defective. , Whenever the camshaft i replaced : because ofits abnormality, replace peed the vat lifters with new ones too 3) Inspect the fit of woodruff key G x 65 x 20 mm) in the camshaft Key groove and cam gear key groove, ; and if defective replace Key or gear, ot correct the key groove. 6) aspect camshaft and cam gear contact surfaces for cracks of other Peg nears damage, and the cam gear tooth surface for wear. Replace cam gear 7) Measure the cam gear run-out, and replace cam gear if the run-out ‘exceeds the limit, Limit of run-out 0.25 mm (0.0098 in) Datil “A” for hdratie valve itter - Fig. 3-139 Cam identification Limit 0.10 mm (0.0039 in)}\ ENGINE 32.000 — 32.018 mm ce 1.800 ce (1 2598 ~ 1.2605 in) Front & Center } as ‘Standard inner diameter : of camshaft journal bores 26.000 ~ 26.018 mm 6.0236 ~ 1.0243 in) 1,600 ce (0.4173 ~ 1.4180 in) ott Sk a 1,800 cc (1.2582 — 1.2589 in) fg ; ete A eal Ss ters L me 36.000 ~ 36.018 mm Ott set (Front) [ E : : i of camshaft journal 1,600 ec | (1/9220 — 1.0226 in) L 1.959 — 35.975 mm eeereec fe eer Gia tenets Fig. 2-143 Oil seal 0.025 — 0.059 mm Clearance between i seateaha (0.0010 — 0.0023 in) camshaft journal and NOTE: "| journal bore 0.100 mm The oil seal (Front) can be detached ae (0.0039 in) by separating the erankcase. Reinstl- lation is performed by using Oil Seal . Installer (499067000). B 18. Oi Pump ; Remove Set i mT GR Wash the disassembled parts, check eS them for the following items, and a repair ot replace if defective. ' “as.001 1) Oil pump drive gear and rotor 1 Mage toe 3 Ca 2. Check the outside diameter of the eee jauge q. 3-142 Installis shaft portion, and replace oil pur 2 Crankshaft gar asezerion — F18 9242 Inseating cam goar @iapar aa tae Fig, 3141 Messure backlash considerably. (1200 17. Oil Seals Shaft orion i NOTE: i When replacing the cam gear, use Inspect cil seal fitted in flywheel Remover Set (899714110). housing and the oil seal fitted at the Measure the vast clearance as crankshaft front end for lip wear, deseibed in 2) after replacement, and damage, hardeningcet., and seplace if i adjust to the specification. defective, = be len (1600 ee Oil sal 1,800 ec 1,600 ce i rom | 38x39x9 mm 38 x55x9 mm i ca (1.50 x 2.32 x 0.35 in) (1.50 x 2.17 x 0.35 in) 76 x93 x 10mm 70 x 87x85 mm Rear (2.99 x 3.66 x0.39 in) (2.76 x 34.3 x0.335 in) scot Fig, 3.148ENGINE b. Check both the gear and rotor and (1800 ce engine) replace if worn or damaged consid- erably. Thickness swvae ‘Ouvide diameter] 29.70 29.74mm ] Thickness ofdevegest | (2.1693 1.1709in) | Je ‘Ouuide diameter] 40.53 - 40.36 mm of rotor 13957 ~ 1.5968 im neal Fig, 3-147 Measuring rotor-tocase clearance 2) Oil relief valve and elie? valve ip clearance between put 1600 ce engine spring © Besa at om Cee Measure the tip clearance and re- ® ‘tion and damage, and the relief valve plaes both the drive gear and rotor spring for damage and deterioration. as a set if the clearance exceeds the 4 Replace the parts if defective, ae .) é Relief valve spring Deve [staré] 0.02 - 0.12 am aie 41mm searto- [art {(.0008 — 0.9047 im) ene (1.854 iny ‘ptor tip 28-008 cleans | init | 02mm (0.008 im | 1 staight edge Installed 33.5 mm ee Tenge (2.319 in) Fig. 3-146 Measuring rotorto-case a ard geortecselerance | Load when | 2805~4197 realird (6.88 - 4.28 kg, . 8.56 -9.44 1b) ¢. Radial clearance between pump ® rotor and pump case Replace either the rotor or case as necessary if the clearance exceeds the limit, : 2 Rotor A508 e010 1 Onze ave 2 Rell ave spring Fig. 3-145 Measuring drive georto- Roroeto: [stand] 045 -0.2tmm | Fig. 3-148 Oil relief valve and spring rotor clesrance ease [aed {0.0059 — 0.0083 in) a 3) By-pass valve and spring clearance | tit | 025 mm (0.0098 a) |’ The checking method is as same as that of paragraph 2). 4. Side clearance between pump ease By-pass valve spring and pump cotor and between pump : case and drive gear 1,800 ee 1,600 ce Measure the side clearance and re- Place either the rotor or case as 37.1 mm 40.7 mm necessary if the clearance exceeds Free length (1.461 in) (1.602 in) the limit 25.1 mm 311mm Installed tengeh (0.988 in) (1.224 in) Rowero- |Sand] 0.03 — 0.3 mm eweand | ard (0.0012 - 0.0051 ia) 5.178 ~ 6.159 N 3.580 -3972N a omaha (0.528 - 0628 ks, (0.365 — Clearance | Limit | 0.2mm (0.008 i) aa 1.164 — 1.385 Ib) 0,805 - 01 73 a4) Ol pump holder Check the pump shaft hole for wear, and other surfaces for damage. 5) Oil pump case Check the oil pump case for clogged cil passage, wom rotor chamber, cracks, and other faults. 19. Water Pump NOTE: Clean all the ‘thoroughly. 1) Inspect the pump shaft for wear, damage, and operation. P a 21 Water pump shaft 2 Water pump impeller Fig, 3-149 Shafe and impelier bled parts 2) Inspect the impeller surface that ‘contacts the mechanical seal for wear and damage. 3-8. Assembly 1. Precautions 1) All parts should be thoroughly cleaned, paying special attention to ‘the engine oil passages, pistons and bearings. 2) Rotating parts and sliding parts such as piston, bearing and gear should be coated with oll prior to ASSY. 3) All removed parts, ito be reused, should be reinstalled in the original positions and directions. 4) Gaskets and lock washers must be replaced with new ones. Liquid gasket should be used where specified to ‘prevent leakage. 5) Bolts, nuts and washers should be replaced with new ones as required. ENGINE 3). Inspect the other parts for crack, wear and damage, and replace if defective 20. Thermostat Replace the thermostat if the valve does not close completely at an ambient temperature or if the follow- ing test shows unsatisfactory results. Immerse the thermostat and a thermo- meter in water, Raise water tempera: ture gradually, and measure the tem- perature and valve lift when the valve begins to open and when the valve is fully opened. During the test, agitate the water for even temperature distri- bution. The measurement should be 10 the specification. Fig. 3-160 Temperature test for thermostat 6) Even if necessary inspections have bbeen made in advance, proceed with ASSY work while making rechecks. NOTE: In the following procedures, items ‘with * mark should be rechecked. 2. Intake Mai Assembly 1. NON-TURBO VEHICLE 1) Hitachi Carburetor Type 1) Install thermostat and thermostat cover with new gasket. NOTE: Install it with the jiggle pin upward aut 21. Thermo Valve Connect vinyl tubes to output ports of thermo valve Soak the valve in cool water (approx. 10°C (50°F)] for some time, and then heat the water. Blow air into the valve through one vinyl tube, and confirm that the valve opens ot closes in response to the specified temperature. (Refer to page 3.8) Vinyl hose 007 Fig. 3-151 Fig. 3-152 asne0 2) Install the following parts. a. Thermo vacuum valve Il 23-26Nm (23-2.7 kem, 17 = 20 fib) Torquewor! a. Apply liquid gasket (Three Bond 1201 -P/N 004403008, or equiv- alent) on the thread. b. Install thermo valve with its pipe outiet facing outsi b. Stay & clip, clip and actuator ASSY {AiC only). c, Solenoid valve 1, bracket and pro- tector stay 4, Thermosensor. NOTE: Be careful not to bend the terminal. ¢, Accelerator eable bracket. £ PCV valve 23-26Nm tomue | 3-27 kgm, 17 =20 fe) to = o- 79 Fig, 3-153 3) Install carburetor with two gaskets ‘and an insulator, and connect hoses, 4) Install EGR. valve with gasket and connector clamp, and connect hose, ENGINE NOTE: Apply liquid gasket (Fuji Bond C or equivalent) on the thread. Thermo vacuum valve 23-26Nm 3-27 kgm, 17 ~20 ft-lb) Torque NOTE: Install thermo valve with its pipe autlet facing forward. fh Vacuum pipe CP with carburetor protector 3, and vacuum hoses. i. Controi air cleaner, PCY. hose, uty solenoid valves, carburetor protector 2 and hoses. i. Heater hose and purge hose. 1 Thermo vacuum vaiveIt*2 2 Thermostat cover 3. Solenoid valve brackee*3 4 Protector stay 5. Solenoid valve (*3 ‘ 1 8 9 Theemorensor PCV valve Thermo vacuum valve E Vacuum pipe CP Carburetor protector: 11 Duty solenaid valve 12 Carburetor protector 2*1 13. Thermo vate t¥*2 14 Bracket? 15 frautatoc2 1S Antiafterbuning pipet? Except 48-state 4WD and Canada 49:state WD snd Canada 49state non4WD and California, 49sate 4WD, Canada AT and $WD AT 5) Attach lectic wiring harness, connect electric connectors, and then clip harness. 2) CW Carburetor Type 1) Install thermostat and thermostat cover with new gasker. NOTE: Install it with the jagle pin upward. 2) Install the following parts a. Stay & clip. ». Clip. ¢. Gasket, thermostat caver, solenoid valve [ and bracket, and connect ote, 4, Thermosensor. 1 nat to bend the terminal, ©. PCV. valve, 23-26Nm | Torque | @3-2.7kgm, 17 =20 felby Apply ‘ts equivalent) £. Thermo vacuum valve I 1 EGR valve 2 Connector clamp ia oat Fig, 3.184 ¢ 3-75 23-26Nm Torque (23-2.7 kgm, 17 = 20 ft-lb) NOTE: Install the valve with its pipe facing ‘outside, . Vacuum pipe CP and vacuum hoses.Fig. 3-155 3) Install carburetor with two gaskets and an insulator, and connect hoses. 4) Install the following pars. a. EGR vabe with gasket, and hose. b. Heater hose. ©. PCY, hose ASSY. 4. (A/C only) FICD actuator and hose. ‘Actuator (AIC only) Fig. 3-156 5) Attach electric wiring hamess, connect electric connectors, and then clip harness. IGINE ‘Thermostat cover Solenoid valve bracket Solenoid vale 1 ‘Thermosensor ‘Thermo vacaum valve 1 ‘Vacuum pipe CP PCV wake 2. TURBO VEHICLE 1) Attach the following parts to the intake manifold: ‘Thermometer ‘Thermo valve Vacuum pipe | cp Coolant thermosensor ‘Thermostat cover and gasket ‘Auxiliary air valve and gasket “Thnotue body and gasket EGR valve and gasket cr 376 Aseoe © Thermometer 2522Nm Torque | @520.2 kgm, 18.1214 fp) Coolant thermosensor 2545 Nm Torque | @5205kem, 18.1 £36 feb) © Thermostat, ‘© Thermostat cover and gasket NOTE: ‘Also attach the spark plug cord stay and hose. © Auxiliary air valve and gasket © Air relief valve 69-98Nm Torque (7=10 kg, 51-72 fell) NOTE: Apply a coat of liquid packing to threaded areas. © PCV valve 2522Nm Torque (2.5 £0.2 kgm, 18.1 # 1.4 felby NOTE: Apply 2 coat of liquid packing to ‘threaded areas. © Throttle body and gasket 157 215Nm Torque | (1620.15 kei, 11.6 £ 1.1 feb) © EGR valve and gasket 15.7 £15 Nm Torque | (1620.15 kgm, 11.6 41.1 ftby © Thermo valve 2522Nm Torque | 25202 kgm, 18.1 21.4 felb)3. Valve Rocker ‘Always install the valve with is nipple facing 45-dagree upwar ieuubatilas @ Vacuum pipe NOTE; @ EGR pipe a. Pay special attention to the direc- 2) Connect the various hoses. tion of the rocker shaft, 3 © Water preheating hose of throttle cer shaft, the posi- of the spring washers, the body number of plain washers, the di ference between the rocker arms, and the marks on the spacer. 4) Connect the wiring harness. Before asembting apply a generous © Auxiliary aie valve amount of oit to the sliding surface © Throttle switch of each part. 4 FICD solenoid vale Thermometer © Coolant themmosensor Vas roster asembiy Ground tenminal . Tighten togeth- ‘er with the pressure cegulator stay 1.pao.ce | 1,600 ce & 1806 mm | 176.9 am Fig. 3-168 GLa) | (6.96 in © Heater hose & 358mm | 342am 409 ia) | (1346 im © Blow-by hose. 409 im) | G.346im) © Vacuum hoses b 348mm | 332mm NoTe (1.370% | (1307 ny Refer ta the label for piping instrue- acaaaaee tions or parts catalogue @e a 3) Installing the pressure regulator. a tei er : e763 Park on spacer] Op fa Fig. 3-160 ‘an rag b. Do not use bolt to fasten the stay NOTE: ‘together with the graund terminal. See Parts catalogue for the clip «. Connecthoses with presure postions and clip band facings of the regulator. wiring harness. 3-77| | 1,800 ce angine 1,800 ec engine wit BEM) \ a as-eoa 1 Valve rokoer ASSY (RH) AL Valve rocker arma CP 2 2 Snap ring 32. Valve rocker ASSY (LH) 3 Nat 13 Valve rocker ASSY (RH) @ Waser 14 Rocker shaft spacer 5 Valve rocker sew 1S. Valve rocker shaft 6 Rocker shaft spring washer 16 Valve rocker 7. Rocker shaft supporter 17 Valve rocker am 8 Valve rocker arma CP 18 Valve rocker arm 2 9) Rocker shaft spacet 19 Lock washer (only for 10. Valve rocker shaft Fig. 3-161 Assembling valve rocker parts 4. Cylinder Head 1) Press oll seal onto intake valve Buide. NOTE: Apply oi to the oil seal prior to 2). Apply oil to stems of intake and exhaust valves prior to installation. 3) Install intake and exhaust valves with inner and outer valve springs, valve spring retainers and retainer keys on cylinder head by using Valve Spring Press (899724100). 1 Outer vale spring 4 Valve spring retainer 2 Inner vate spring § Valve stem 3 Rewiner key Fig. 3-162 Installing valve and related parts 378 nyésaulic valve ite) NOTE: 2, Take care not to damage the lips of the intake valve oil seals when installing the intake valves, b. Place the inner and outer valve springs with the paint mark toward the valve spring retainer, or with’ ‘the close coil side toward the cyl inder head. seating of the valve,ENGINE 39-42.Nm Teg Gono HE coarests | 2931 Ret) ‘ with of on threads NK 2 Note: Wie hao 2. Position each connecting rod with the side marked @ facing forward, 1 Valve sping cetainer } Goecatse ssaas ve voce cio { assne Fig. 2-163 Installed direction of valve ‘ering 4) InstagM¥acer with gasket for air injection fE. bb. Each connecting rad has its own ‘mating cap. Make sure that they are assembled correctly by checl their matching number, ‘& When tightening the connecting rod ‘nuts, apply oil on the threads, * Side clearance and oil clearance Discrimination mack on spacer 1600 |, *Forghchand | Engine | side(#1 & 3) | evlindechead | 1800 a Engine Forlefehand sde(#2& | #4) cylinder head Only for 49-seate (except 4WD & 4WD-AT) S. Crankshaft D) Install connecting rod bearings on connecting rods and connecting rod caps, NOTE: Apply oil to the surfaces of the connecting rod bear 2) Install connecting rods and con- necting rod caps on crankshaft with connecting rod bolts and nuts. Matching number fe Fig, 3-164. Instaling cannecting rods 6. Camshaft Install woodruff key on camshaft, Place camshaft plate in position and install cam gear by using Remover Set (899714110). Remove Sat (909714110) ‘Asoat Fig. 3-165 Installing cam gear 3-79 NOTE: a, Pay attention to the assembling” rection of camshaft plate and cam ae 1,800 ce ersine 1,800 c= angine asa29 Fig. 3-168 Camshaft plate and cam gear Place the camshaft. journal on Remover Set (899714110) when Dressing the cam gear. + Thrust clearance Piston 1) Inseall follows. Install oil ring spacer, upper sail and lower rail in this order by hand. ‘Then install second ring and top. ring with a piston ring expander, fon rings on pistons as ne — secondo —— Oeng 1 sexe Leh tenet “sora Fi 3-167 Cross section of piston 2 tings (ikon Piston ira)| spacer asora Fig, 3-168 Cross section of piston rings (Nippon Piston Ring) tion the gaps of the rings, Stopper pin (Oi ring une: 88990 Fig. 3-169. Piston ring gap position ‘Install oil figure. ing as shown in the (Riken Piston Ring) Upper side ait SF — span rT Stopper pin’ Tower sie rail ana (Nippon Piston Ring) Piston Spacer expand Stopper pin ane Upper sae ral Asan Fig. 3-170 Installation of oil ring ENGINE «. Position stopper pins. Rear Stoope pin Fig. 3-171 Stopper pin position asso9 4. The top and second rings are pro- vided with “R” or “N" mark as shown in Figs, 5-84 and 5-85. Be sure to install the rings with this ‘mark facing upward. ‘Ring to groove clearance 2) Insert piston pin circlip into the stopper pin side of the piston, NOTE: a, The installed circlip should be directed as shown in the figure. Girelio Asan Fig. 3-172 Installed direction of cirelip 1 If the piston pin hole has burrs made by the citclip end during its ‘emoval, correct s0 that the piston can be inserted smoothly into ‘the piston pin hole with fingers. 8. Oil Pump NOTE: Replace washers and O-rings with.new ‘ones, 1) Assemble oil relief valve, spring, two washers and phig in pump body. 3-80 2). Assemble ball, by-pass valve spring and O-ring in pump body. 3) Assemble oll pump rotor, drive gear, O-ring and pump body holder in pump body. 4) Install oil filter. 9. Water Pump NOTE: 12, Replace the mechanical seal with a new one, tb. Apply liquid gasket where required, 1) Install the water pump shaft into Pump body with a press. NOTE: 4, Before pressing, heat the pump body to 80 to 100°C (176 to 212°F), b, Do not press the shaft, or the bearings will be damaged. Press the Fig. 3-173 Pressing water pump shaft 2) Apply liquid gasket (Fuji Bond D ‘or equivalent) to the periphery of the mechanical seal and press the seal into the pump body with the carbon ‘washer of the seal facing the impeller. 3) With s thin coat of oil on the shaft surface, install the impeller fonto the pump shaft with a press. Fig. 3-174 Inscalling impellerNOTE: ‘Apply coolant on the sliding surface between mechanical seal and impel Check for the following clearance after installation and corcect if defec- tive, Clearance berween impeller and pump body cg ¢ \ \As 0.5-0.7 mm (0.020 — 0.028 in) itarance berwoon Srapeior ana pump food 25 ~ 0.7 mm (0.020 ~0.028 in) 1 Mechanial sea 2 Pump body 3. Impeter Aro89 Fig. 3-175. Impeller clearances 3-9. Installation 1. Precautions 1) All parts should be thoroughly cleaned, paying special attention to the engine oil passages, pistons, cyl- inders and bearings. 2) Rotaning parts and sliding parts such as the piston, cylinder, bearing and gear should be coated with oil Prior to reinstailation, 3) All removed parts, if to be reused, should be reinstalled in the original Positions and directions, 4) Oi seal lips should be coated with grease before reinstallation. ) Gaskets and lock washers rust be replaced with new ones. Liquid gasket ‘should be used where specified to pre- ‘ent leakage. ENGINE Fig. 3-176 Checking impeller-topump body clearance 4) Support the impeller side of che pump shaft end and install the pulley by using @ press until the distance “L” between the pump body surface, which mates with the gasket, and the center, of belt groove of the pulley ‘becomes specified value, ‘Non TURBO) arso1 Fig. 2.177 6) Bolts, nuts, washers, and cotter pins should be replaced with new ones as required. 7) Even if necessary inspections have been made in advance, proceed with reinstallation work while making rechecks. 8) If one or both of the cylinder heads are removed in engine disassem- bly, perform the retightening of the cylinder head nuts and intake manifold bolts and the adjustment of the valve clearances (except engine with hydraulic valve lifter) after the engine has been assembied, mounted ‘on thie car, run for about 10 minutes, and cooled down to ambient tempera. Pee 1800 ce Engine | 1600 cc Engine 611-61.7mm | 64.1 - 6.7mm (2.406 - 2.429 in | (2.824 — 2.5478) NOTE: Befare pressing, apply oil on the pump shaft, TURBO as767 Fig. 3-178 7 92.1 -92.7 mm (8.626 ~ 3.650 in) NOTE: In the following procedures, items with * mark should be rechecked. 2. Non-TURBO Vehicle 1) [nstall Engine Stand (399814300) toeach crankcase half. Engiea Stand (39981400) as.296 Fig. 3-179 Installing engine stand2). Install oil pressure switch (Vehicle without pressure gauge) or plug (Vehicle with pressure gauge) on crankcase. Before installation, apply liquid gasket (Fuji Bond C or equiva ent) to the threads of pressure switch body or plug body. 22-27 (22-28 kes 16 — 20 ft-lb) Torque 3) Install crankshaft bearings on crankcase, -Grankanate bearings = Fig, 3-180. Installing crankshaft bearings 4) Insest valve lifters into the lifter holes in crankcase and hold them on #1 and #3 cylinder side by using ‘Valve Lifter Clip 899804100 (only for hydraulic valve lifter). NOTE: Apply oil to the valve lifters before instalation. 5) Install crankshaft and camshaft on the crankcase half having #2 and #4 cylinders. NOTE: & Apply oil to the camshaft and ‘crankshaft bearings before installa- tion. . One of the bolt holes in the erank- shaft gear has’ a larger chamfer ‘than others. Install the crankshaft ‘so that the punch mark on the cam (gear can be seen through this bolt ‘hole in the crankshaft gear. cc. Whenever the camshaft is replaced because of its abnormality, replace the valve lifters with new ones'too. ‘% Oil clearance of crankshaft Vt WAN 1 Crankshaft gear 3 Punch 45-337 > Lampectamter 4 Comat par Fig. 2-181 Aligning crankshaft and ‘camshaft gears, 6) Install O-ring and backup ting ‘on the crankcase half having #2 and #4 cylinders. 4] rorquétor crankcase bolts and nut 9) Bring together the crankcase hhalves and tighten the crankcase bolts and nut with a plain washer to the specified torques ang in the specified sequence, ‘Thread size Torque 39-47Nm 0-48 kgm, 29-35 ft-lb) 10mm 23-26Nm 8mm..2.| 03-27 kgm, =| 7-20 ft) | ) 44-54Nm (045 ~055 kem, 33 — 40 fb) 6mm Fig. 3-182 Installing O-ring and ‘backup ring 7) Apply liquid gasket (Fuji Bond C of equivalent) on the mating surface of erfikease. NOTE: Before applying liquid gasket, clean the mating surfaces of the crankcase 0 that they are free of oil, grease and ‘dust by using thinner or the like. sone Fig, 3-183 Aoptyingliauid gasket 8) Put Vale Lifter Clips (899804100) between valve lifters in the crankcase half having the #1 and #3 cylinders, 10 prevent lifters from assur 1 Ollstrainer say 5. Spring washer 2 Owing 6 Nut 3 Olstaine 7 Oilstralner say? 4 Bolt 8 Bolt and washer Fig. 3-191 stalling of strainer stayENGINE 16) Install a new cylinder head nox. fasket, #2 — #4 cylinder head, valve rods and also valve rocker as ‘Tollows. a, Install a new cylinder head gasket. NOTE: a, Before installing the cylinder head ‘gasket, clean the mating surfaces of ‘the cylinder head and crankcase so ‘that they are free of oil, grease and ‘dust by using thinner or the like. b, Apply head gasket sealant THREE BOND 1201 (004403008) or DOW CORNING 242-026 evenly to both sides of the new cylinder head gasket with a brush. Do not apply ‘excessive sealant. Install the gasket ‘on to the crankcase quickly after ‘apelying sealant. b, Install #2 — #4 cylinder head. NOTE: The cylinder head installing direction is as in the figure. Fig. 3-192 Installed position of cylinder heads ¢. Take out Valve Lifter Clip 1899804100 (for hydraulic valve lifter), and insert valve push rods in alignment with vale lifters. NOTE: ‘Do not misuse the push rod. _ = Number of Knurlings 1600 2 1800 with solid valve ' liner 1800 with hydraulic valve lifter asl] 4. Insal valve rocker. When tightening nuts and bolts, apply oil to the threads and tighten them in two of three successive steps until the final tightening is at the ‘specified torque, In each step, tighten them in the specified sequence Nm ststep | G0 kgm, 22 fb) : 59m 2edste> | (6.0 kgm, 43 fb) 3rd (fina) | 64m step (65 kgm, 47 fb) NOTE: a, When tightening ©, © auts, use Socket Wrench (489987006). . After tightening all the cylinder head mts and bolts, retighten the center nut © to insure itis eorrect- ty torqued. €. Do not use washers in installing valve rocker. 4. Moke sure that the valve rocker is correctly assembled. a84 17) Install #1 ~ #3 SVfinder head with a new gasket and push rods and valve rocker assembly (RH) in the ‘same way as instructed in 16). 18) Press oil seal (Rear) into the flywheel housing if oil seal has been removed. NOTE: 7 a, Apply oil on the circumference of the oil seat prior to pressing. b. Git seal dimensions. 1,800 ee ... 76 x 83 x 10. mm (2.99 x 3.66 x 0.39 in) 1,600 ec... 70 87 x 8.5 mm (2.76 3.43 x0.335 in) 19) Install flywheel housing to crankcase with the mating surface coated with liquid gasket [THREE BOND 1215 (PIN Qg4g03007) o: equivalent). 20ST Nm Torue | @0-28kem, 14 — 20 Fb) Fig 3-195 Installing flywheel housing ‘NOTE: + a. Cloan the mat surfaces of the fiywhes! housing and crankcase so ‘that they are free of oil, grease: and dust by using thinner or the like boofore applying fiquid gasket. b. Be careful net to damage the oil seal lip and not to detech the spring ‘when instatling the flywheel hous: iENGINE ¢. When using THREE BOND 1218, dry the coated surface for § to 10 minutes before instalation, 4, Remove Vahe Lifter Cl (899804100) before installing 20) pan, Install crankcase oil pan, oil pan gasket and transmission cover {1 (un. Torque (Oil pan) 4.4 -5.4Nm (0.43 - 0.55 kgm, 334.0 Rb) (SUBARU 1800) Fig. 3-197 installing crankcase hanger 2) Kastall Aywheel with O-cing (MT) oF converter drive plate with back Plate and O-ring (AT) on the crank- shaft gear, Apply liquid gasket [THREE BOND 1215 (P/N 004403007)] to the ? threads of the bolts. at Mr Torque 49-. so 36) S3.Nm | 41-45 Nm 5.4 kgem,|(4.2 4.6 keen 39.) | 30-33 Fb) 1 Transmission cover I (MT) 2 Oilpan Asan Fig. 3-196 Installing oll pan 21) Install pitching stopper bracket and crankease rear hanger, if it has been removed, to Aywheel housing On C-W carburetor, install accelerator cable bracket with hanger, NOTE: Do not misplace the washer, Nut Bote Spring washer CCrankease cer hanger Pitching stopper bracket Timing hole hanger Bole ‘Timing hole hanger Stifener RH (4D) Stiffenee LH (SD) Accelerator cable bracket (CW carburetor) ‘6900 NoTE: a. The flywheel or drive plate and back plate can be installed only in n sinca nat all the bolt Positioned at equal holes intervals. b. When installing back plate, align sthe mark on back plate and the hole in drive plate. (AT) Fig. 3-198 installing drive plate and back plate (AT) & When using THREE BOND 1215, dry the bolts coated with it for § to 23) Install clutch disc and clutch cover with bolts and spring washers, aligning clutch disc With flywheel by inserting Clutch Dis. Guide (499747000) into needle bearing Atted in fywheel. MT) ey Torque 16 Nem (Clutch cover) |(1.6 kgm, 12 feb) __ asase Fig. 3-199 imagen = ee : the clutch cover so that the "0" marks on the flywheel and clutch cover are spaced 120° or more, 24) Install water pump, hose, pipe compl and heater hose as an assembly and install another hoseaseoe Fig. 3-200 Installing water pump 25) After assembling of) filter and coll pump, install it with O-ring and cil pump gasket. Fig. 3-201 Installing oil pump Nort ‘a. Use new gaskets and O-rings, fb. When installing, aliga the rotor shaft with the groove in the cam- shaft er 26) Install oil seal (Front) on the crankshaft front end by using Oil ‘Seal Installer (499067000). Fig. 3-202, Installing oit seat 27) Anstall crankshaft pulley on crankshaft with flange bolt. 64 -74Nen Torque (65~75 kgm, 47 — 54 ftlb) ENGINE NOTE: ‘, When tightening the bolt, insert a screw driver through the timing hole into the hole in the drive plate (AT) or flywheel! (MT) to prevent the crankshaft from turning. Fig. 3-203 Installing crankshaft pulley '. Apaly engine ail on the thread, and fiquid gasket (THREE BOND 1215 of the equivalent) on the flange seat, . Pulley dia. is as follows. 1600 ce: 109 mm (4.29 in) 1800 ce: 119 mm (4.69 in) 28) install oil filler duct, oil filler duct stay and gasket on crankcase, (On 4WD, install ol filler duct, stffen- er 2, and gasket on crankcase Fig. 3-204 Installing oil filler duct 29) Install generator bracket compl., bracket 2 and bracket 3 as follows a, Temporarily connect bracket compl. © and bracket 3, @ until the spring washer is deformed 2 lice. ». Install the sub-assembled bracket prepared” in a onto the engine by tightening bolts @ @ temporarily At frst tighten fully the two bolts @® and after that tighten the bolt @ to the specified torque. 4, Tighten fully the two bolts @ to.the specified torque. fe. After loosening the bot @ by two tums or more, tighten it again to the specified torque Temporarily install bracket 2.) 13-19Nm Torque | (13-19 Kem, 9-14 ft-lb) 0®2® © © 1 Bracket CP 2 Bracket § Bolts 3 Bolts Bracket 2 Fig. 3-205 Installing gonerator brackers 4 Bott NoTe: Be sure to use the Gyligoit for the generator bracket 2. ¥ Others are @ ones. 30) (Except engine with hydraulic valve lifter) Adjust the valve clearances. 2 Exhaust valves 4 Valve Clearance 2 Intake valves Adjuster 3 Thickness euge _” (498767000) Fig. 3-206 Adjusting valve clearance Valve clearance (Cold) 023 - 0.27 mm Inake | (0.009 - 0.011 in) Exhaust teatore: Ue T.D.C. marking on pally. [38) Install valve rocker covers with valve rocker cover gaskets, seal washers and bolts. 29-39Nm Torque | (0300.40 kem, 29 flb) 32) Install spark plugs with gaskets. 18 -24Nam Torque (13-24 kgm, 13-17 felb) 33) Install the intake manifold as sembly prepared before as follows. ‘a {nstall the intake manifold as- sembly with intake manifold gasket, air eleaner bracket. fuel hose stay, and EGR pipe. And connect water by-pass hoses. 18 -22Nm Torque (18-22 kgm, 13 — 16 felb) NOTE: Discrimination kaurfing for €.G.R. pipe. ENGINE 34) Tighten E.G, pipe. 35) Install battery cable bracket and AS.V. bracket [vehicle without power steering for Canada and 49-state (except 1600 ec)] or oif pump bracket (vehicle with power steering). Fig. 3-207 ["Vehieie Kaurling 1600 ce 2 CW carburetor type 3 Except the above Nothing b. Connect the hamess lead to oil Pressure gauge o oil pressure switch, and clip it. © Connect the PCV. hose to rocker cover and clip it atthe upper portion. Nore: For further particulars of vacuum hose, wiring harness, water hose hose, refer to label ina hood, and Parts 4. Be sure to connect E.C.M. (Elec- ‘onic Control Madule) earth at right front bolt. ye om, Fig. 2-209 38) Install atemator on the genésa- toc brackets with air cleaner beacket, spark plug cord stay and drive bet Fig, 3-210 Installing alternator with NOTE: ‘elative parts 8. After aligning the air cleaner bracket and air cleaner, secure the bracket. 'b. Do not forget tightening fully the bolt for generator bracket 2, Drive belt tension 13 14mm 51 - 0.55 iny/ 98 N (10 ke, 22 Ib) When replacing with new one, the tension is (10 ke, 22 sen Gots. 22001 \ Crank shalt Fig. 3.211 Drive belt tension 1b). 13414mm (051-088 in) 10mm (0.39 in)/98N Alternator omer 39) Install distributor as follows. a. Set #1 piston at its top dead ‘center in the compression stroke. b. Align the distributor matching marks, ‘\ | { t i | i | .. Anstall distributor plate on crank- NIPPON Matening marks OENSO HITACHI as-208 Fig. 3-212 Aligning oistributor ‘matching marks 4. Apply oil to the circumference of distributor shaft and gear, e. Install distribucor into crankcase taking care not to damage distributor gear and O-ring. 3. TURBO Vehic! engine as far as 28) are the same as those for Non-TURBO vehicles except 25) installing the oi! pump. f. Connect vacuum hoses to dis. tributor. Clip the distributor lead wire, NOTE: Be careful that the holes in the distributor plate and crankcase are correctly lined up. 40) Connect spark plug cords to spark plugs and cord supporters and Alistibutor cord to cord supporter. 41) Install oil level gauge if it has been removed. 42) Install earburetor protector. [For 49 States (except 4WD & 4WD-AT) and California] 43) Remove (399814300). Engine Stands 25) Install ol pump together with attachment and oil filter as follows: 1 Anachment 2 Union screw 3 Gasket 4 Pipe 5 Oring 6 Connector 7 Owing 8 Bolt d& washer AL Detvery pipe 12 Union serew 13 Gasker 14 Thermo vale 15 Oil pump. Tigivening worques Wen tegen, Rab) Fig. 3.213 "F: 59 Nem 16 keen, 43 (810) 5-708 42. Install pipe @ to attachment @ with union serews @ and gaskets ® 34Nm Torque | (3.5 kgm, 25 felby b, Set O-ring © in attachment O. (Apply oil) «. Install connector © into attach. ment ©. 4. Set O-ring @ in attachment . (Apply of) «. Assemble oil pump @ and attach. rent (D by temporally tightening connector ©. f. Insall pipe @ to crankease by temporarily tightening boit ®. g. Tighten connector © to the speci fied torque 2m G kgm, 22 feb) Torque hh. Tighten bolt @ to the specified torque. 26Nm Torque | 7 gem, 20 feb) i. Install oil fier @. J Install off delivery pipe with union serew (@ and gaskets © 16Nm | Foraye | (16 kgm, 12 feb) NOTE: Replace union screw and gasket with new ones. 29) Installing the injector ——————— 1.03 —1 | Tightening | (0.105 0.155 kg-m, | beta 0.76 ~ 1.12 feb) Fig. 3-214 oe30) Installing the knock sensor Use a 27 mm deep socket. |; 2-27Nm | 2-38. i 16 20 felb) 31) Installing the alternator bracket. 30-36 Nm B.1-3.7 kgm, = 27 felb) el 32) Installing the power steering pump bracket, T etesig | LENO Taken |g 22tgm ss 13 = 16 felb) Fig. 3-216 33) Installing the inteke manifold, 4 Use four longer bolts to install : 18 22Nm eene | (182.2 kee, 13 = [6 fetb) '. Install the fuel pipe to the injector. ENGINE NOTE: Replace the fuel hose clamp with a ew ane. . Tighten the fuel pipe along with the intake manifold. Tightening an i eee fae 13 = 16 fe-lb) NOTE: Mount the spark plug cord stays on sides #2 and 24. 4. Tighten the EGR pipe plug. NOTE: a. If the alternator ASSY is hard:to install, drive out the si b. The 35) Installing the distributor, a. Install the plate. b. Bring #1 cylinder to TDC on che compression stroke. Put #1 cylinder in an electefied state, Adjust the notch to the punched mark on the pinion, 4. Install the distributor and fix it to the plate with 6 mm bolt. gum | 337m Rene | 6223. igm, 7 23 - 27 felb) € Connect the air vent hose. £ Connect the lead wires of the oil pressure switch and injector, NOTE: Clamp the lead wires after connecting them. oo itt Fig. 2217 aan Connect the blow-by hose and vacuum hose. Ih. Put the EGR pipe cover in place. 34) Knstallng the alternator, Temporarily install the ASSY to the bracket. alternator Fig. 3-218 3-88 Fig. 3219 ©. Connect the vacuum hose. f. Connect the lead wires. © Knock sensor © Ground terminal Fig. 3-220 g. Connect the plug cords and high- tension cord. 36) Removing the ENGINE STAND. 37) Installing the front exhaust pipe. NOTE: Before installation, ensure that the exhaust pipe is free of all foreign matter. 38) Install the oil pipe stay.ENGINE 3-10. Troubleshooting 1. Turbocha: Trouble Diagnosis If the turbocharger system fails, any of the following phenomena can occur. @ Excessively high supercharging pressure Engine knocking © Air is intermittently relieved from air relief valve ® Excessively low supercharging pressure: Lack a engine power © Poor acceleration performance Considerable fuel consumption ® Oil leak from turbocharger: ‘Excessive oil consumption © White exhaust smoke (#: Phenomenon) 1) How to Diagnose ® and @ Gowever, the phenomena @ can also result from other causes, such as ait leakage from the intake’ system, ex- hhaust. system leakage ot obstruction incorrect ignition timing, malfunction ing knock control system, defects in the EGI control system.) {Checking supercharging presure] # Disconnect the rubber hose from the presse switch, and attach 2 branch connector, Lead the rubber hose into the passenger compart- ment, and connest it t0 the positive pressure gauge. © After warming up the engine, make 2 test ran, Read the sopercharging pressure on the positive pressure juge when the vehicle is running at approximately 2,600 rpm with a fullopen throttle. © At this time, check for air being intermittently relieved from the relief valve (This would be detect- able by aloud, hissing sound), [Judgment] (© The turbocharger is in normal con- dition if the supercharging pressure i in the range of 48.0% 4.0%Pa G60 £30 mmHg, 14.17 £1.18 in Hg) and the relief valve is not leaking air. © The air relief valve is defective when the supercharging pressure is below the upper limit of 52.0 KP: (G90 mmHg, 15.35 inl) and air is being relieved from the relief valve. Replace the air relief valve. © When the supercharging pressure ‘exceeds the upper limit of 52.0 kPa (390 mrmtig, 15.35 ing), © Check the rubber hose that con- ols the waste gate valve for cracks and disconnection. Re- place the rubber hose or correct the connection, © If the waste gate valve is not ‘operating and remains closed. replace the turbocharger. ‘© When the supercharging pressure is below the lower limit of 44.0 kPa (G30 mmHg, 12.99 ing), the turbo- charger is defective. Replace the turbocharger. 2) How to Diagnose @ ‘© Oil leaks from the exhaust gas side (Cusbine side) © Remove the center exhaust pipe and examine the turbocharger from the exhaust gas side. As shown in the figure on the Fight, if there are excessive car- toon deposits on the turbine exhaust side, oil is leaking from the turbine. {An this case, off may also be leaking from between the tur. bine chamber and bearing cham- Fig. 3-221 anime © Oil Teaks from the inlet side (blower side) © The turbocharger is not neces- sarily leaking oll when oil is present on the blower side. The oll is likely to have come from cil mists contained in the blow. by gases flow in the inlet system. (© When oil is leaking from the inlet system, it is accompanied by@ ratte from the turbocharger shaft when it moves in an axial ‘or radial direction, Remove the turbocharger from the engine and determine if the shaft rattles. (Limit of rating: Measure with a dial gauge.) a Axial rating: (0.09 mm (0.0035 ind b. Radial rating 0.17 mm (0.0067 in) when the turbine side and blower side of the shaft are moved cixcumferentialy at the same time. If anything wnusual is found, replace the turbocharger. NOTE: ‘a. The turbocharger proper cannot be isassembled or adjusted. b, When removing and installing the ‘turbocharger, do not allow dirt and dust to enter the inlet and outlet ‘openings of the turbine and blower, Any foreign matter allowed to ‘enter, will undoubtedly damage the ‘turbine and blower blades as soon as the turbocharge goes into opers- tion again, Likewise, cover the open end of the front exhaust pipe. If foreign matter is allowed to enter, the turbine blades will be instantane- usly destroyed when the turbo- charger is put into operate. © Visually inspect the connections of ‘the oil delivery pipe with the turbo- charger and oil pump. If oll is leaking, replace the washer of the union screw and tighten it to the specified tightening torque. 147-17.7Nm amen® | (150 1.80 kgm, 7 10.8 ~ 13.0 f-tb) |3-11. Special Tools re a 899724100 899768602 898878600 ENGINE STAND. ‘SPRING PRESS VALVE GUIDE ADJUSTER ‘STUD BOLT WRENCH. Crankease Valve spring Exhaust valve guide Crankeas stud bolt | iM DN Fig. 9222 ase | Fa 9-226 nares [ig 3290 sae | Fi. 2206 ase 399524100 899714110 399768603 499067000, PULLER SET REMOVER SET VALVE GUIDE ADJUSTER| OIL SEAL INSTALLER Cranishatt pulley Cam shaft lotake waveguide 0 seal (erankcae) Pater (890521411) a= ED y 9 | CoE eo eonszre12 Fig. 9.223 asses | Fig, 3227 area Fig. 2297 nave | Fig. 9.295 Asam 359098310 399765101 899768105 398744300 PISTONPIN REMOVER | CYLINDER HEAD TABLE | VALVEGUIDEREAMER | _PISTONGUIDE Peston pin Cylinder head Valve guide Paton G Fig, 3-224 asia | Fig, 3.228 asnas | Fig. 3232 asso | Fig. 3-296 asass 899804100 899764104 398858600 399284300 VALVE LIFTER CLIP VALVE GUIDE REMOVER | _ OIL SEAL INSTALLER PISTONPINGUIDE | a | eines ee 3102ENGINE sa 499987006 499747000 498767000 499037000 ET WRENCH CLUTCH DISC GUIDE VALVE CLEARANCE. Scala a ORISTER: REMOVER & REPLACER Colinder head nuts Clutch dise Intake and exhaust valves | Connecting rod bushing — e = LE S Fig, 2.208 sr.oae | Fig. 3.209 anova | Fig 3.240 sroas| Fig. 3247 As.aco| 499990100 926040000 SOCKET SOCKET Oxygen (03) sensor (0; sensor (TURBO) D € ©. & “7 Fig, 9-242 avoriaa| Fig 3-263 atone 3-103EA-81 STOCK ENGINE Maximum Output 85 hp @ 4800 mpm Maximum Torque 13 kg-m @ 2400 rpm With 1.84: 1 Reduction 24 kg-m @ 3500 rpm Minimum Fuel Consumption 205 9 /hp-h 2 4a 28 2 | a 19434 a 22 110 42 20 100 419 18 90 47 7 4g TORQUE 80 4 ois (kg-m) “4 70 43 Torque 60 41 Shaft 10 HP 50 40 20 4 400 Fuel 20, 4 200 FUEL (9 / hp -hy” 10 4 0 ° isesiegeesee [atta peace sce fae tees tarde tiie RPM (X 1000) i“ Tes arvenors ROTE na Fal oapre fnenmalze to horsepower, 0 fr h kg-m = 7.26 [normalized 1ohorsep ite 2 450g Graph courtasy of: Welburn Galt you toca Dave Johnson REDUCTIONS Box 16, Grp. 15, RR 1 Dugald, Manitoba CANADA ROE oko 204.853.7998,AirSoob: EA-81 Engine Service Manual Excerpts to assist you in ordering genuine Subaru parts, these pages provided by Courtesy Subaru 3155 Stevens Creek Blvd. San Jose, CA 95117 408-984-2001 (ask for Subaru Parts) "Note: For those that want to order parts via UPS directly from Courtesy, any ofthe parts people are aware ‘of our application and can assist you without knowing “what kinda car do you have”. Just mention you are ‘part of this group, the Soob-powered Airplane guys, tll them you have a parts manual in front of you, and they will understand. I was asked NOT to give out the pasts manager's name, for fear you might only ask for him, but if there is any confusion about parts for our application, his name is Robert, and he is the Soob “god” there. But try to use whoever handles your cal first, before bailing out to Robert. ‘Our motors are refered to by the Soob people as the “1800 Direct Drive Motor” or “1800 Pushrod Motor.”