2) Be careful not to leave out the thrust plate when installing the camshaft. After setting this shaft in place, with its thrust plate pro: perly fitted, turn the shaft by hand to be sure it rotates smoothly, 1. Gamshafsthrurt plato arm Shafts ly engine oil to rocker arms and rocker shafts. | rocker arms, springs and rocker arm rocker-arm shafts are identical, there Fe need to distinguish between the two. = each shaft takes but one position in below figure. Ge inlet side, the stepped end @ comes side. Be exhaust side, the stepped end fon rear side 4, Benaust vawe se Stopped aa 5. Front sie (Camenat pullay sie) 3. Imveke velve side 6, Rear aide (Flynhee! side) 3) After Installing rocker arms, springs, and rocker arm shafts as shown in below figure, tighten rocker arm shaft screws to specifiod torque, Tightening torque 9=12Nm for rocker arm shaft 0.9 — 1.2 ka-m screws 7.0 —8.5 Ib-ft NOTICE: Valve clearance is adjusted after all parts are atsombled. So it is not adjusted at this point Leave rocker arm adjusting screw as loose as can be.1. Gamanatt pulley soe Water Inlet Pipe Install water inlet pipe and its new gasket to cylinder block. Be sure to angle it as shown in below figure, yy Intake Manifold and Carburotor 1] Install intake manifold gasket to cylinder head. Use new gasket, NOTICE: Clean cylinder head mating surface with gasket before installation. 2) Install intake manifold with carburetor to cylinder head. 3) Tighten manifold bolts and nuts to specified torque. 18-23 Nm 18-23 kom 13.5 - 165 Tightening torque for manifold bolts and nuts Ze Water Pump 1] Install water pump gasket to cylinder block. Use new gasket NoTICE Clean cylinder block mating surface with gasket before installation. 2) Install water pump to cylinder block. 3) Tighten bolts and nuts to specified torque. Tightening torque 9-12Nm for water pump, 0.9 ~ 1.2 kg-m bolts and nuts 7.08.5 lb-ft -s, ey Timing Belt Inside Cover Bolts Two bolts (1), need BOND No. 1215, because the bolt holes for the two extend into the in terior of cylinder head. Apply the BOND No. 1215 to the threads of these screws before running them in,Timing Belt Inside Cover, Belt Pulleys, Tensioner, Timing Bolt and Outside Cover 1) Install timing belt inside cover. o-12Nm | 0.9~ 1.2 kam 70-B5ib4 | Tightening torque for timing bolt inside cover bolt and nut 2) Install crankshaft timing belt guide, key and pulley Refer to below figure for proper installation of these parts. Install timing belt guide in such a way that its concave side faces oil pump. When installing pulley, direct its punch marked side to timing belt outside cover side. 3) Install key and camshaft timing belt pulley When installing pulley, direct its punch: marked side to timing belt outside cover side, Tighten pulley bolt to specified torque with special tool applied as shown in below figure. 50 — 60 Nin 5.0 —6.0 ke-m 365-430 | Tightening torque for pulley bolt (8): Camshaft lack holder (Special tool) 1 Vien 2. camshett timing belt pulley 3. Ting belt insige cover 4)Put tensioner and spring together before installing them as one to the timing belt cover. Tighten the bolts to the extent that the tensioner can be moved by hand easily. 1. Timing betpuley 3, Punchrourk 2. Guide5) Before installing timing belt to camshaft pulley and crankshaft timing belt pulley, loosen all valve adjusting screws of intake and exhaust rocker arms fully, or check to ensure they are loose This is to permit free rotation of camshaft for the following reason; when installing timing belt to both pulleys, belt should be correctly tensed by tensioner spring force, If camshaft does not rotate freely, beit will not be correctly tensed by tensioner. 1, Valve auntie sere 2 Leck rut 6) Turn camshaft pulley clockwise and align punch-mack © on camshaft pulley with embossed mark @) on timing belt inside cover 4 Purch-mark 2, Emboanod rar, 7) Turn crankshaft clockwise and align punch- mark @ (key way) on crankshaft timing belt pulley with embossed mark @on timing belt inside cover. 5 Key way 8) You now have the two pulleys correetly re leted to each other in angular sense. Under this condition, put on timing belt in such a way that portion of belt indicated as @ (drive side of belt) is free of any slack. NOTICE: When installing timing bolt, match arrow mark (=>) on timing belt with rotating direction of crankshatt, 6. Drive side of siting bale9) After putting belt, hook spring on the water pump bolt and tensioner as shown in below figure, The spring, with its own ten- sion, acjusts belt tension to the specified value, Rotate cranksheft clockwise fully twice and tighten bolt @ first and then bolt @) to the specified torque. 15 -23N-m | 1.6 -2.3 ka-m ft ightening torque [fer tensioner bolts | | caurion: | After setting belt tensioner, turn crankshaft 2 rotations in clockwise direction to see if | locate themselves on | the same straight line, If they do not line lp straight, the foregoing procedure must | | be reposted to satsy this requirement. 2. Embosed mak 5. Bolt 5. Punchomare 7. Bot 10) Inetal\ timing belt outside cover: 3-4Nm | 0.3 0.4 kg-m 25 bf Tightening torque for outside cover bolt Oil Filter Install oil filter. i CAUTIOI For oil filtar installation, refer to P.1-5 of this manual. Exhaust Manifold and Cover 1] Install exhaust manifold gasket to cylinder head Use new gasket. NOTICE Clean cylinder head mating surface with gasket before installation, 2) install exhaust manifold to cylinder head. 3) Tighten bolts and nuts to specified torque: 18-23 Nm 1.8-2.3 kgm 13.5 ~ 165 Ib ft Tightening torque for bolts and nuts 4) install exhaust manifold cover. Crankshaft Pulley, Water Pump Pulley & Cooling Fan and Alternator 1) Install crankshaft pulley. Fit keyway on pulley to key of crankshaft timing belt pulley, and tighten bolt to speci- fication, with flywheel holder (special tool) hitched to flywheel so that crankshaft will not turn Tightening torque for pulley bolt 5.06.0 kgm | 365-430 ibft (A): Flywhool holder [Special 00% 1. Grankinat p 2. Builey bol2) Install water pump pulley, spacer and coo- ling fan to water pump. 8—12Nm Tightening torque for cooling fan 0.8 = 1.2 ka-m bolt 60-85 Ibi | 3) Install alternator assembly and water pump drive belt. ‘The water pump drive belt, by which the altemater too is driven, must be tensioned to the specification after the alternator is installed. Check the tension at the middle point of the belt between water pump pull ey end alternator pulley. To vary the tension for adjustment, displace the alternator in place, For belt tension specification, refer to “MAINTENANCE SERVICE” of SECTION 1 in this manual, Rate * Distributor Gear Case Install distributor gear case and its nev’ gasket to cylinder block. Be sure to apply 8OND No. 1215 to the thread of cave securing bolts luteh Disc and Cover Install clutch disc and cover For installation, refer to p. 11-7 of SECTION 11 CLUTCH in this manual and torque each bolt to specification. Transmission Assembly and Starter Motor 1)Check to make sure that 2 pins (are fitted to cylinder block. 2) Attach ‘transmission assembly to engine cylinder block and tighten nuts. 4) Install starter motor to transmission case and tighten bolts. Distributor Install distributor to case For installation, be suro to refer to SECTION 8 IGNITION SYSTEM in this manual.NOTICE: ‘© Before installing distributor, fill distributor gear case with about 30 cc (1.02/1.06 US/ Imp 02) engine oil. '* Check and adjust ignition timing with engine installed to car body and after installing and connecting all necessary parts. For procedure, refer to SECTION 8 IGNITION SYSTEM in this manual. ‘Valve Lash (Clearance) Adjustment ‘Adjust valve lash of all intake ond exhaust Valves to specification, referring to description on vaive lash on p. 3.48 of this manual, Cylinder Head Cover Install cover to cylinder head and tighten bolts to specified torque. 4-5N.m 04-05 kgm [Tightening torave for eylinder head cover boits 3-7. ENGINE INSTALLATION 1) Raise engine with transmission into vehicle, and tighten engine mounting member bolts (right and left) and transmission mounting bracket bolts to specification, Refer to p. 3-52. 2) Reverse removal procedures for installation of remainder. © Adjust accelerator cable play, choke cable play and cluich cable play © Adjust gear shift control cables so that gear shift lever is shifted to each position smoothly. Refer to SECTION 12 GEAR SHIFT CONTROL SYSTEM in this manual. 4 Tighton bolts ‘and nuts to specified torque. For individual specification, refer to each section. 3) Fill specified amount of specified trans- mission oil, engine oil and cooling water. For the detail, refer to SECTION 1 MAIN: TENANCE SERVICE of this manual 4) Before starting engine, check again to ensure that all parts once disassembled or discon- nected are back in place securely. 5)Start engine and check ignition timing. If it is not to specified timing, adjust it, referr ing to SECTION 8 of this manual 6) After ongine is started, check for oil leak, ‘abnormal noise and other malcondition, ‘Also, check each part for operation.3-8. ENGINE MAINTENANCE SERVICE Fan Belt Adjust belt tension as outlined in SECTION 1 MAINTENANCE SERVICE (p. 1.4). Ignition Timing Refer to SECTION 8 IGNITION TIMING [p. 88). Carburetor Adjustments to be made are detailed in SEC TION 4. Valve Lash (Clearance) Valve lash specifications: Valve lash refers to gap between rocker arm adjusting serew and valve stem. Use a thickness gauge to measure this gap (@) Ir —— Valve lash igap ‘A) specification Exhaust | (0.005 ~0.007 in.) OLD} | 2. Screw ek nut Checking and adjusting procedures NOTICE: © Refer 10 page 3-8 of SECTION 3 for cylinder numbers (No. 1, No. 2, No. 3 and No, 4) mentioned in this section, 1) Remove cylinder head cover, 2)Remove ignition timing check window rubber plug from clutch housing of trans. mission case. 3)Turn crankshaft clockwise (viewing trom crankshaft pulley side) to the extent that line @ above “‘T" mark punched on fly wheel is aligned with match mark (on transmission case as shown below, i.2. No. 1 cylinder piston reaches TDC position. TJ 4) Remove distributor cap and check that rotor is positioned as shown in figure. If rotor is out of place, twin crankshaft clockwise ‘once (360°). In this state, check valve lashes at valves (1), and @, Rotate crankshaft exactly one tum, and check the same at valves ©, @,@and @ NOTICE: '® When adjustment becomes necessary in step 4), loosen adjusting screw lock nut and then make adjustment by turning adjusting screw, After adjustment, tidhten lock nut to specifi- ed torque while holding adjusting screw stationary with straight headed screwdriver, and then make sure again that gap A) is within specification,5] Upon completion of check and adjustment, install cylinder head cover and torque bolts to specification Tightening torque 4-5Nm for cylinder heed 0.4 — 0.5 kg-m cover bolts 3.0 — 3.5 lb-ft 6) install distributor cap and connect blow-by gas hose to cylinder head cover. Engine Oil Refer to SECTION 1 (p. 1-6) of this manual Engine Oil Filter For removal and installation of filter, refer to SECTION 1 (p. 1.5) of this manual. Engine Coolant This subject iS covered in SECTION 6 ENGINE COOLING SYSTEM Exhaust Line and Muffler Inspect each exhaust line connection far tight ness, and examine muffler and other parts for evidence of breakage and leakage of gases, Repair or replace defective parts, if any, Compression Pressure Measurement Check compression pressure on all four cylinders as follows 1) Warm up engine, 2) Stop engine after warming up 3) Remove all spark plugs and disconnect high tension cord from ignition coil 4) Install compression gauge (special tool) into spark plug hole.5) Disengage clutch (to lighten starting load on engine), and depress accelerator pedal all the way to make throttle full-open 6) Crank engine with fully charged battery, and read the highest pressure on compression gauge. — [Compression pressure | I — | wed 13.5 kg/em? (102.0 psi)/ | Std Sennen Limit 12.0 ke/em? (1700 psid/) Lint 300 rein | ox tron se eereno | Lokat’ 142s) 7) Carry out steps 4) through 6) on each cylin: der to obtain four readings. NOTICE. Compression pressure value is measured by using compression gauge (Special tool 09915-64510). Oil Purnp Discharge Pressure Measurement NOTICE: Prior to checking oil pressure, check the follow ing. © Oil level in oil pan. If level is low, add oil up to Full level line on il lovel gauge. © Oil quality. If ol is discolored, or deteriorated, change oil. For particular oil to be used, refer to table on p 1-6 of SECTION 1. * Oil leak. If leak is found, repair it 1) Disconnect switch, lead wire from oil pressure 2) Remove oil pressure switch from cylinder block. 3) Install oi) pressure gauge (special tool) to vacated threaded hole. (N): Ou pressure gauge (Special too! 09915:77210) 4)Start engine and warm it up to normal ‘operating temperature. 5} After warming up, raise engine speed to 3,000 r/min and measure oil pressure. 3.0 — 4.5 kgicm* 42.7 — 63.9 psi at 3,000 r/min (rom) Oil pressure specification6) After checking oil pressure, stop engine and remove oil pressure gauge. 7) Before reinstalling oll pressure switch, be cure to wrap its screw threads with sealing tape and tighten switch to specified torque. 12-15 Nm [Tightening torque | loch peor po 18kom [awit | 80-08 NOTICE: «If sealing tape edge is bulged out from screw threads of switch, cut off edge. 8) After installing oil pressure switch, start engine and check switch for oil leakage, Vacuum Mozsurement Engine vacuum that develops in intake line is a ‘good indicator of engine condition. Vacuum checking procedure is as follows 1) Warm up engine to normal operating tempe: rature: 2} Install vacuum gauge (O) (09915-67310). as shown in below figure. Install engine tacho- meter, 3) Run engine at specitied idling speed and, under this running condition, read vacuum gauge. Vacuum should not be lower than 45 cm Hg (17.7 in. Ha). ‘A low vacuum reading means that any combi nation of following malconditions is the cause, which must be corrected before releasing machine to customer: (a) Leaky cylinder head gasket (b) Leaky inlet manifold gasket (c) Leaky valves [d) Weakened valve springs |e) Meledjusted valve clearance (f) Valve timing out of adjustment (g) Ignition mistimed (h) Carburetor improperly adjusted NOTICE Should indicating hand of the vacuum gauge oscillate violently, turn adjusting nut A to steady it | 45—50cmHe | d m Standard vacuum | Aeon Bae Hal (Sea level) at specified idling speed Pee ate 4) After checking, remove vacuum gauge. 5) Before reinstalling vacuum checking plus, be sure to wrap its screw threads with sealing tape and tighten plug. Oil Filler Cap The cap has @ packing, Be sure that packing is in good condition, free of any damage and signs of deterioration, and is tight in place: It is replacee- bie.3.9, RECOMMENDED TORQUE SPECIFICATIONS. Fastening parts Tightening torque Nm [kgm ibe 1._Gylinder head bolt 55 — 60 55-60 | 400-430 2. Cylinder head cover bolt 4-5 04-05 30-36 3. Spark plug 20-30 20-30 145-215 4. Distributor gear case bolt 18-28 | 18-28 13.5 —200 5. _Rocker arm shaft screw 9-72 | 09-12 70-85 6. Valve adjusting screw lock nut 15—19 15-19 “110-135 | [_7. Granksheft main bearing cap bolt [3-48 43-48 315-345 8. Oil filter stand 20-25 20-25 14.5 — 18.0 [ 9. Oil filter Ass'y 12-16 12-16 90-115 [10._Oil pressure switch 12-15 12-15 90-105 11, Oil drain plug - 20-25 20-25 | 146-180 12. Oil pan bolt 4-5 04-05 30-35 13._Oil pump strainer bolt 9-12 09-12 70-85 [14. Water pump bolt 9-12 0.9-1.2 70-85 18. Cooling fan bolt [08-12 60-85 16. Flywheel bolt 40-45 29.0 32. 17._ Oil al housing bolt 9-12 09-12 7.0- 85 18. Connecting rod bearing cap nut 28 — 32 28-32 | |19. Crankshaft pulley bolt 50 —60 50-60 = 430 20,_ Exhaust center pipe nut 35 — 45 35-45 255 — 325 21. Timing belt inside cover bolt and nut o-12 [70-85 22. Camshaft timing pulley bolt 50 —60 36.5 — 43.0 Z3._ Timing belt tensioner bolt 15-23 110-165 [24. Camshaft thrust plate screw 9-12 70-85 25. Oil pump case bolt 9-12 10-85 26._ Oil pump gear plate sere 9-12 70-85 27. Intake & exhaust manifold bolt and nut 18-23 135-165 | 28. Timing belt outside cover bolt 3-4 25 29._ Engine mounting member bolt | 30-40 220 ~ 28.5 30. Engine mounting bracket engine side bolt | __ 18 — 23 18-23 13.5 ~ 16.5 [ 31. Engine mounting nut 23-28 23-28 17.0 20.0 32._Transmission mounting bracket bolt | __18 23 18-23 135—165 33._Transmission mounting nut 23-28 23-28 17.0 — 20.0 34. Exhaust cenier pipe bolt [35-50 3.55.0 255-360 | NOTICE: If specified tightening torque for particular bolt or nut is not included here, refer to p 0-13 of this manual.