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8 mm (1.0031 inch) .002 inch 0.48.2583 .0063 inch) 31.9 mm (0.0.0.098 MPa(1.31.331 inch) 0.0055 inch) 0.980 mm (1.0.075 mm (0.2 mm (2.2 % Ignition timing Idle speed CO/HC concentrations BTDC°/rpm rpm CO concentration HC concentration 350 rpm STD Minimum Difference between cylinders 5 ± 2/950 950 ±50 1.045 .16 mm (0.0.0035 .0.2591 inch) 47.14 mm (0.1 mm 2 2 Compression pressure Timing belt pulley Wear limit (Minimum limit-) Oil clearance Camshaft Crankshaft Front STD Center STD Rear STD Camshaft Reference Journal diameter Front Center Rear Cam lobe height Intake Minimum limit Exhaust Minimum limit Runout [Bend] Uneven wear of camshaft journal Maximum limit Cylinder head Flatness Cylinder block side Intake manifold side Exhaust manifold side Valve seat angel Intake Exhaust Valve guide bushes Oil clearance Intake Exhaust 45° 0.7 .47.0024 .0.0016 .4 i 4.0016 .19 mm (0.960 .1.8 mm (1.0.028-0.06 .0018 .SERVICE SPECIFICATIONS CB-41 Coolant capacity Pickup Van Oil capacity Without oil filter With oil filter Valve clearances (HOT) Intake Exhaust Spark plug gap 4.1.5 kgf/cm ) 0.02 mm (0.040 .09 .05 mm/0.0.6 I 2.0.0.415 .031-0.7 .270 inch) 59.8 mm (0.05 mm/0.8 .0.8656 .9 mm (4.04 .8 mm (0.035 inch) NIPPONDENSO W16EXR-U 0.002 inch CHAMPION RN9YC 0.5669 inch) 39.0.1 I 0.0075 inch) 0.8665 inch) 48.0012 inch) 0.031 inch) 5±2/900 900 ±50 Not to exceed 0.0030 inch) 0.5 % Not to exceed 1000 ppm Not to exceed 100 ppm 2 LISMPa^kgf/cm ) 1.0kgf/cm ) 119.410 mm (1.03 mm (0.0078 ± 0.031 inch) CB-42 NGK BPR5EY 0.03 MPa (10.028 .0.5669 inch) 0.2 ± 0.080 mm (0.9 I 3.1.385 .9061 .0008 inch) 0.0.440 mm (1.0078 ± 0.2 ± 0.9071 inch) 39.

955 mm (0.02 . 1 No.2734 .0.028 inch) 0.002 inch) 101.49 mm (0.0.6.0.12 mm (0.65 mm (4.01 mm (0.0.0. 2 Oil Piston.0012 .002 inch) 43.0019 inch) 0.25 .5 mm (0.0024 inch) 1.03 mm (2.65 mm (4.47 -1.3.30 mm (0.0039 inch) Cylinder 0.008 .0024 inch) 0.0028 inch) 0.000 -16.028 inch) 0.0587 inch) 0.07 mm (0.03 .0006 .2 -1.0020 inch) 0. piston pin and piston rings Piston ring groove-to-piston ring side clearance Piston ring thickness No.070 mm (0.50 Piston.03 .2740 inch) 6.012 .0020 .20 .0118 .035 .6.0.071 inch) 6.0035 inch) 16.53 mm (3.043 inch) 0.9 kg 25. 2 No.0008 .0394 .50 .7 kg 0.047 .70 mm (0. 1 No.9921 .5° 0.0059 .0.0118 inch) 0.12 mm (0.49 mm (0.0118 inch) Cylinder bore diameter STD (When over size piston is O/S 0.0.018 mm (0.0.0012 inch) 0.8 mm (0.2738 inch) 101.05 mm (0.06 mm (0.2732 .1 mm (0.0709 inch) 45. piston pin and piston rings Piston-to-piston pin oil clearance Maximum limit Piston pin-to-connecting rod interference fit Connecting rod Big end thrust clearance Maximum bend Maximum twist Crankshaft Crankshaft bend Uneven wear of main journal and crankpin journal Main and crankpin journal oil clearance Crankshaft thrust clearance .0579 .0008 .76.0008 .019 mm (0.05 mm (0.0.0587 inch) 1.150 .0.25 used) O/S 0.0.0047 inch) 0.70 mm (0.02 .3.1.0047 inch) 76.47 -1.0012 .0.10 mm (0.0027 inch) 0.0.9933 inch) 76.059 inch) 1.0.06 mm (0.960 mm (0.03 mm (0.9 mm Valve rocker arm and valve rocker shaft STD Minimum limit CB-42 1.0.0.0.0.984 mm (0.020 .30 mm (0.09 mm (0.20 .76.7047 inch) 29. 2 Piston ring end gap No.940 .0.0.6306 inch) 15.6293 inch) 33 mm (1.008 .0.6283 .945 .0020 inch) 0.0.0.9 -1. 1 No.0004 inch) 0.0579 .0.8 mm (0.0130 inch) 0.958 -15.0.00 .3 mm (1.0031 inch) 76.0.6299 .008 .016 .299 inch) Oil clearance between rocker arm and rocker shaft Valve rocker arm inner diameter Vaive rocker shaft outer diameter Valve rocker arm spring Cylinder block Minimum free length Flatness cylinder head gasket attaching surface Oil clearance between piston-tc-cylinder STD Maximum limit STD Maximum limit 0.28 mm (3.76.CB-41 Valves Contact width with valve seat Valve face angle Valve stock thickness Intake Exhaust Valve stem outer diameter Overall length Intake Exhaust Intake Exhaust Vaive spring Free length Installed tension at 34.0.2.0.20 -1.0005 .0.0 .

0.0.0813 .25 bearing Undersize 0.756 mm (0.631 mm (0.2 mm (2.0.50 bearing Bearing center thickness STD Oversize 0.0039 inch) 119.0078 inch) 0.0.1.0.115 mm (0.270 inch) 59.506 mm (0.0.0862 .256 mm (0.611 -1.0831 .2.0.2.25 bearing Undersize 0.2.0.0.131 mm (0.190 .0764 .2.50 bearing Crankpin journal bearing (Connecting rod bearing) Crankshaft thrust bearing Bearing center thickness Replacement STD bearing Undersize 0.0691 inch) 1.0882 inch) PEM00079O0000 Crankshaft main journal Bearing center thickness Replacement bearing STD bearing Undersize 0.006 mm (0.736 -1.236 .0.0010 .0683 .9 mm (4.0012 .331 inch) 0.240 mm (0.0642 inch) 1.CB-41 Balance shaft Balance shaft thrust clearance Balance shaft bearing oil clearance Timing belt pulley Camshaft timing belt pulley outer diameter Minimum limit Crankshaft timing belt pulley outer diameter Minimum limit Fly wheel Run out Maximum limit CB-42 0.03 .025 .0839 inch) 2.0782 .50 bearing .0.0783 inch) 2.0634 .111 -2.0880 .986 .0593 inch) 1.0585 .990 mm (0.486 -1.0790 inch) 2.0888 inch) 1.940 .0.0.10 mm (0.0039 inch) 1.0833 inch) 2.065 .20 mm (0.1 mm (0.25 bearing Oversize 0.

8 1.39.15.5 .0 .8 .4.7 3.15.1 29.9 7.15.7-28.13.2 1.7-28.7 .1 14.4 .8 .0 .0-1.0 29.7-32.6 5.3 29.3.5 0.4-22.0-1.5 1.4 39.3.8 -11.1 .15.2 .4 .8 .3 21.47.3 .1.21.6.5 0.8 -15.9 .9 4.2 0.5.0 .6.2 9.6 14.1 7.5 21.7 2.5 3.2-11.0 2.8 .9 .0.2 24.5 .4 5.2 .7-21.5 .0 9.5 10.3 .6 14.0.2 .8 .8 17.5-2.8.1 33.1 -25.0.3 .0 .6.3.5 2.7 2.0 .2 ft-lb 10.6 53.6 9.15.21.4-44.2 0.98.4.0 .0 1.TIGHTENING TORQUE Tightening components N-m Cylinder head x Spark plug Cylinder head x Cylinder block Cylinder head cover x Cylinder head M8 M6 Timing belt cover Crankshaft bearing cap x Cylinder block Cylinder block x Oil pan Cylinder block x Balance shaft thrust plate Connecting rod x Connecting rod cap Flywheel x Crank shaft Crankshaft pulley x Crankshaft Camshaft timing belt pulley x Camshaft Timing belt tensioner x Balance gear cover Cylinder block x Oil pump Water pump x Water pump pulley Cylinder head x Intake manifold Cylinder head x Exhaust manifold Balance shaft gear cover x Cylinder block Balance shaft weight x Balance shaft Oxygen sensor x Exhaust manifold Coolant temperature sensor x Cylinder head Intake air temperature sensor x Intake manifold Coolant temperature sender x Intake manifold Delivery pipe x Intake manifold 14.9 .0 5.9 .9 18.9 .17.4.5 3.1 4.0 3.7 23.2 65.4-44.0-1.5 3.5 21.3.7 .6 21.8 2.9 39.6 3.8.8.2.4-2.8 -14.4 .9 7.6 0.72.36.0 .2 -10.0 88.8 .9 2.9 9.7-32.6 Tightening torque kgf-m 1.39.10.7-32.9 .2 1.9 53.5.7-21.34.6.6 .2.5-2.7 7.5 .6 1.7 1.4.4.2 5.42.5 .5 .3-44.0 21.9 39.2 .8.4 28.8 .64.4 .4.1 .0 .9 10.7 .5 10.0.0 .0 10.30.49.8 14.63.5-2.21.9 .4 .9 1.7 29.

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5 0.HW-15 WIRE HARNESS CONNECTING TABLE ENGINE Item Dim-Dip relay (2) Headlight LH (Lo) Headlight RH (Lo) Meter (charge) Back-up lamp SW Oil pressure SW Meter (temp.85 0. engine) Connect to L1-L2 Connect to L1-L2 Connect to L1-L2 PYC heater Main fuse J/B (Ignition ST) Main fuse J/B (Ignition SW (IG)) Distributor (-) Connect to N5-N6 Connect to N3-N4 Ignition coil (+) Ignition coil (-) Connect to N5-N6 Choke SW (-) A25 A3 A4 D1 G1 H1 H3 K1 L1 L1 L1 L22 Ml M3 N1 N3 N5 N5 N3 N22 N6 N5 06 Circuit | A35 | A37 i A38 D2 G2 H2 H4 K2 L2 L3 L6 L21 L23 M2 M4 N2 N4 N6 N11 N20 N23 N24 N25 010 Item Dim-Dip resister (-) Dim-Dip resister (LH) Dim-Dip resister (RH) IC alternator (L) Back-up lamp (+) Meter (oil) Water temp.25 Z 0.85 0. sensor Back-up lamp SW Fuel cut solenoide IC alternator (IG) Carburetor (outer vent V/V) Water temp.5 0.85 0.5 0.5 L R-G R-B LW RY YW YL LB WR WR WR WR LR WR BY W BL BR BR BL BW BR BR Y-B HWO0033-OO0OO .5 1.5 0.5 0.) J/B (Fuse.5 0.5 0.5 0. SW (PXC) Water temp. heater) J/B (Fuse.85 3 2 3 Z 0. SW(PXC) Starter (B) Starter (ST) IC alternator (B) Ignition coil (B) Ignition coil (-) F/C amp. SW (choke) Wire size & color 0.5 0. Distributor (+) Condenser Resister (+) Resister (-) Water temp.85 0.85 0.85 0.

5 1. sensor (+)) A/C amp.5 0. 2) Connect to L1-L2 Main fuse (B) IG SW (ST) Connect to M3-M4 Main fuse (L) Connect to N1-N2 Connect to N11-N5 Connect to N1-N2 J/B (IG coil B) A/C amp.0 4.) Connect to H6-H7 J/B (Fuse: wiper) Front wiper SW (+1) Front washer motor (-) Front wiper SW (+2) Connect to I1-I2 Rear wiper SW (washer) Rear wiper SW (+) Connect to I1-I9 Connect to I1-I9 J/B (Intermittent wiper relay: S) Connect to K5-K6 J/B (Fuse: Deffoger (L)) Deffoger SW (-) J/B (Fuse: Heater (L)) Heater blower SW (Hi) Heater blower motor (-) Heater blower SW (Me) Heater blower SW (Lo) J/B (Fuse: Heater (L)) A/C SW (-) Connect to K5-K6 Connect to K5-K6 A/C amp.0 4.5 0. SW (B) Meter combination (choke) H4 Circuit H5 H7 Item Meter combination (oil pressure) (Coolant temp.0 K6 K8 K9 K11 0.0 1.5 1.5 1.5 0.5 0.0 K13 K14 K16 K17 K18 K21 K55 K60 K32 K12 K65 K56 L1 L1 N34 L1 M1 K25 K30 K33 K58 K69 K83 L2 L7 L11 0.5 1.5 0.5 0.0 0.0 L12 M2 M4 M3 M3 N1 N1 N11 N1 N17 N11 M5 | N2 N3 N4 N6 N8 N15 N15 N16 N31 2.5 0. gauge (7V) A/C amp.5 1.5 0. 2) Alternator (L) Choke SW (-) Choke SW (+) Wire size & color 0.5 4.5 1.5 .5 0.0 1.0 0. (3) A/C amp.5 0.0 0. (5) A/Camp. (10) Idle up VSV (+) Connect to K12-K13 Condenser fan relay (M-) A/C amp.0 I15 I17 J K2 K4 I16 J K1 K3 K5 K7 K8 K10 K12 K36 K15 K5 K5 K54 0. (14) IG SW (IG) Connect to N7-N45 IG SW (IG2) Meter combination (charge) Engine coolant temp.0 H6 H6 I1 I3 I5 I7 I1 I10 I12 I1 I1 W-Y Y-L Y-L H8 | I2 I4 I6 I8 I9 I11 I13 I14 L-R V-Y L L-B L-R L-W V-Y L-R L-R L-W L-B B-R L L-B L-W L-W V-B L L-B V-Y L-B L-B R L-R Y L-B L B O W-R W-R W-R W-R W-L B-Y B-Y jW W B-R W 0. (8) Condenser cooling fan motor (-) Fuse. (coolant temp. A/C (L) Radiator cooling fan motor (+) Fuel pump relay (+B) Alternator (IG) Dim-Dip relay (7) Starter (B) Starter (ST) Fuel pump relay (ST) J/B (IG SW (B)) IG SW (B) Fuel pump relay (IG pulse) Alternator (B) IG coil (B) Ignition coil (-) J/B (IG SW (IG)) J/B (IG SW (IG)) Fuse holder (Fuse: Engine No.0 B B-R N7 N7 B B W-L W-G Y-B Y-R N30 03 O10 07 04 06 08 4.5 0.5 4. (4) A/C amp.0 1.5 4.HW-17 Item Oil pressure SW (+) Meter combination.5 0.5 1.5 0.0 0.5 2.5 0.5 0.5 1.0 1. (9) Front wiper motor (+) Front wiper motor (+1) Front wiper SW (washer) Front wiper motor (+2) Front washer motor (+) Rear washer motor (-) Rear wiper motor (-) Rear wiper motor (+) Rear washer motor (+) Front wiper motor (S) Connect to K36-K14 Deffoger SW (+) Deffoger (+) Heater blower motor (+) Heater blower motor (-) Heater resister (Hi) Heater resister (Me) Heater resister (Lo) A/C SW (B) Dual pressure SW (+) Back lamp SW (+) Meter combination (+B) Idle up VSV (-) Compressor magnet clutch (+) Water temp.5 0.0 4.5 0.5 0.5 0.5 2. (6) J/B (Fuse: Engine (L)) Connect to L1-L2 J/B (Fuse: Engine No.5 4.

5 0.5 0.5 0.5 0.0 4.5 1.0 0.5 1.5 0.5 0.0 0. 2) Alternator (L) Choke SW (-) Choke SW (+) Cigarette lighter (+) Radio (+) J/B (IG SW (ACC)) Speaker (+) Speaker (-) Fuel pump motor (+) Body earth (Front LH) Meter combination (Earth) Courtesy SW (-) Wire size & coior 0.5 0.5 1.0 4.5 2.5 0.0 1.5 0.0 2.) Connect to H6-H7 J/B (Fuse: wiper) Front wiper SW (+1) Front washer motor (-) Front wiper SW (+2) Connect to 11-12 J/B (Intermittent wiper relay: S) Connect to K5-K6 J/B (Fuse: Heater (L)) Heater blower SW (Hi) Heater blower motor (-) Heater blower SW (Me) Heater blower SW (Lo) J/B (Fuse: Heater (L)) A/C SW (-) Connect to K5-K6 Connect to K5-K6 Connect to K12-K13 Connect to Z1-Z2 A/C amp.5 0.5 0.5 1.5 4.5 0.5 Y-G W-Y Y-L Y-L L-R V-Y L L-B L-R L-W L-B L-B L-W L-W V-B L L-B V-Y L-B L-B L W-B Y W-R W-R W-R W-R W-L B-Y B-Y W W B-R W B B LJM8 N15 N16 N20 N31 04 06 O8 R2 R4 R7 R15 R16 U12 Z2 Z3 Z4 B B-R W-L W-G Y-B Y-R ! L 1-° 0.0 0.0 0.5 4.0 0.0 0.5 0.5 4.5 0. sender (+) Thermistor (A/C) Front wiper motor (+) Front wiper motor (+1) Front wiper SW (Washer) Front wiper motor (+2) Front washer motor (+) Front wiper motor (S) K36-K14 Heater blower motor (+) Heater blower motor (-) Heater resister (Hi) Heater resister (Me) Heater resister (Lo) A/C SW (B) Dual pressure SW (+) Back lamp SW (+) Meter combination (+B) A/C amp.5 B-W R-Y B-Y L W-B W-B W-B .5 0.5 1. Fuse holder (Fuse: Engine No. A/C amp.5 4.5 0.0 1.HW-20 item Fuel level sender (+) Oil pressure SW (+) Meter combination (coolant temp.5 0. SW (B) Meter combination (choke) J/B (Fuse: ACC (L)) Connect to R1-R2 IG SW (ACC) Radio (speaker (+)) Radio (speaker (-)) Fuel pump relay (L) Body earth (Front RH) Connect to 21-Z2 Connect to Z1-Z2 H2 H4 H6 H6 11 13 15 17 11 116 J K5 K7 K8 K10 K12 K36 K15 K5 K5 K12 Z1 K60 L1 L1 N34 L1 M1 M3 M3 N1 N1 N5 N1 N17 l N7 N7 N5 N30 03 010 07 R1 R1 R6 R13 R14 U7 Z1 Z1 Z1 Circuit H3 H5 H7 H8 12 14 16 18 19 117 J K6 K8 K9 K11 K13 K14 K16 K17 K18 K58 K61 K70 L2 !_7 L11 | L12 M2 M4 M5 N2 N3 N4 N6 Item Meter combination (Fuel) Meter combination (oil pressure) Coolant temp.5 0. 2) Connect to L1-L2 Main fuse (B) IG SW (ST) Connect to M3-M4 Main fuse (L) Connect to N1-N2 Connect to B5-N20 Connect to N1-N2 J/B (IG coil (B)) IGSW(IG) Connect to N7-N15 IG coil (-) IG SW (IG2) Meter combination (charge) Engine coolant temp.5 0.5 1.5 0.0 4.5 2. J/B (Fuse: Engine (L)) Connect to L1-L2 J/B (Fuse: Engine No.5 0.5 0. Water temp gauge (7V) Radiator cooling fan motor (+) Fuel pump relay (+B) Alternator (IG) Dim-Dip relay (®) Starter (B) Starter (ST) Fuel Dump relay (ST) J/B (IG SW (B)) IG SW (B) Fuel pump relay (IG pulse) Alternator (B) IG coil (B) J/B (IG SW (IG)) J/B (IG SW (IG)) A/C amp.0 4.5 2.