1 9 92 CONTENTS: F Mazda General Information oe Cesare Tn B2600i fet 32200 Workshop Lubrication System Manual Cooling System Fuel and Emission | Carburetor Control Systems Eq) FOREWORD Engine Electrical System This workshop manual is intended for use by service technicians of Authorized Mazda | Clutch ‘Dealers to help them service Mazda vehicles. Fot ‘proper repair and maintenance, a | Manual thorough familiarization with this manualisim- | Tranemission portant, and it should always be kept in a han- dy place for quick and easy reference. | Teanater.Cese Al the contents of this manual, including drawings and spectications, are the latest avai able al the {ime of printing. As modifications | Automatic affecting tepair or maintenance occur, relevant | Transmission Carona information supplementary to this volume will be made available at Mazda dealers. This Transfer Case manual should be kept up-to-date. Propeller Shaft Mazda Motor Corporation reserves the right to alter the specifications and contents of this _| Front and Rear Axles manual without obligation or advance notice. esering Allrights reserved. No part of this bookmay | Steering System be reproduced or used in any form or by any | means, electronic or mecharical—inclucing _Br@king System photocopying and recording and the use of | Wheels and Tires any kind of information storage and retrieval system—without permission in writing, ‘Suspension Mazda Motor Corporation HIROSHIMA, HIMA, JAPAN | Gody Electrical System APPLICATION: This manual is applicable to vehicles beginning | Heater and Alr Conditioner Systems with the Vehicle Identification Numbers (VIN) | Teghnical Data shown on the following page. Special Tools Parts index Wiring Diagram {bere gopcany © 1991 Mazda Motor Corporation PRINTED IN USA, JUL. ‘91 1269-10-91G (8999-95-022B-92)VEHICLE IDENTIFICATION NUMBERS (VIN) JM2UF123 «NO 250001 ~ JM2UF223 «NO 250001 ~ JM2UF323 «NO 250001 ~ JM2UF113 *NO 250001 ~ JM2UF213 «NO 250001 ~ ‘JM2UF313 «NO 250001 ~ JM2UF114«NO 250001 ~ ‘JM2UF314%NO 250001 ~ JM2UF414*NO 250001 ~ JM2UF614*NO 250001 ~ JM2UF514%NO 250001 ~ ‘JM2UF223+NO 250001 ~ a =FGENERAL INFORMATION IMPORTANT INFORMATION BASIC ASSUMPTIONS. SAFETY RISK. POSSIBLE LOSS OF WARRANTY WARNING ON LUBRICANTS AND GREASES. HOW TO USE THIS MANUAL. PROTECTION OF THE VEHICLE .. A WORD ABOUT SAFETY esse PREPARATION OF TOOLS AND MEASURING EQUIPMENT ... SPECIAL TOOL! REMOVAL OF PARTS.. DISASSEMBLY . REASSEMBLY ADJUSTMENTS RUBBER PARTS JACK AND SAFETY STAND (RIGID POSITIONS. a VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS. TOWING.. WITH MANUAL TRANSMISSION, WITH AUTOMATIC TRANSMISSION CHASSIS NUMBER LOCATION. ENGINE MODEL AND NUMBER LOCATION .. ABBREVIATIONS CAUTION ELECTR TOOLS .. CAUTION WITH ELECTRICAL PARTS. ‘ssvarcoat Gl PO onGl IMPORTANT INFORMATION IMPORTANT INFORMATION BASIC ASSUMPTIONS This workshop manual assumes that you have certain special tools that are necessary for the safe and eff cient performance of service operations on Mazda vehicles and that you know how to use them properly Italso assumes that you are familar with automobile systems and basic service and repair procedures. You should not attempt to use this manual unless these assumptions are correct and you understand the conse- ‘quences described below. SAFETY RISK This manual contains certain notes, warnings, and other precautionary information that you should carefully read and follow to reduce the risk of personal injury to yourself or others and the risk of improper service that may damage the vehicle or render it unsafe. If there is no such information in regard to any specific service method, this does not mean there is no possiblity that personal safety or vehicle safety will be jeopardized by the use of incorrect methods o tools. POSSIBLE LOSS OF WARRANTY ‘The manufacturer's warranty on Mazda vehicles and engines can be voided if improper service or repairs are performed by persons other than those at an Authorized Mazda Dealer. WARNING ON LUBRICANTS AND GREASES Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated uring service (e.g., engine sump ails) are more irritating and more likely to cause serious effects, including skin cancer, in the event of gross and prolonged skin contact. ‘Wash skin thoroughly after work involving oil. Protective hand cleaners may be of value provided they can be removed from the skin with water. Do not use gasoline, paraffin, or other solvents to remove oil from the skin. Lubricants and greases may be slightly irritating to the eyes. Repeated or prolonged skin contact should be avoided by wearing protective clothing if necessary. Particu lar care should be taken with used oils and greases containing lead. Do not allow work clothing to be con- taminated with oil. Dry clean or launder such clothing at regular intervals. sntusoc 002 GI-2 } SYGl HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL PREPARATION PREPARATION points cut the needed SST for the service operation that follows. Itis best to gather al necessary SST before beginning work. Gl Example: N ie-Rop END BOOT AND STEERING GEAR BOOT ‘SST NUMBER, ‘TIE-ROD END BOOT AND STEERING GEAR BOOT ‘ssT NAME SST ILLUSTRATION omveixoas REPAIR PROCEDURE 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and visual parts inspections. If a damaged or worn partis found, repair or replace it ‘as necessary. 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview istration, 8, Pages related 10 service procedures are shown under the illustration. Refer to this information when ser- vicing the related part. Example: sows Fao sows 5 ee Rae | |e. ea a n | ae = Wy oe Bohr |\ a eee Ne Se mexaasy | ORG UT 2 lode See, ee ‘shows § Seerpg et tee INSPECTION RELATED Sis INFORMATION te ee rapt sins a eh waa Sats sence fA BEY“ Keuanent ot hog ‘pepe nae a fl The numbering (ex@)y shows service procedure. *2: Units shown in Nm (m-kg, ft-lb) unless otherwise specified. GI-3GI How To usE THIs MANUAL/FUNDAMENTAL PROCEDURES SYMBOLS There are 6 symbols for oil, grease, and sealant. These show the points of applying oil, grease, or sealant during servicing. a = = Wawa Wow rg o'r geo 2 eprptte Sou oe i oo 1. _— — ee ere ao o Apply petroleum jelly Appropriate petroleum jelly a Note When special oil or grease is needed, this is shown in the illustration. NOTES, CAUTIONS, AND WARNINGS {As you fead through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each ‘one is there for a specific purpose. NOTES give you added information that will help you to complete @ particular procedure, CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause per- sonal injury. The following list contains some general WARNINGS you should follow when you work on a vehicle, saavancoss FUNDAMENTAL PROCEDURES PROTECTION OF THE VEHICLE Always be sure to cover fenders, seats, and floor areas be- fore starting work. mEFUNDAMENTAL PROCEDURES Gl ava TOT ‘A WORD ABOUT SAFETY The folowing precautions must be folowed when jacking up the vehicle, 1. Block the wheels, 2. Use only the specied jacking postions 3. Support the vehicle wih safety stands Start the engine only after making certain the engine compart- ment is clear of tools and people. PREPARATION OF TOOLS AND MEASURING EQUIPMENT Be sure that all necessary tools and measuring equipment are available before starting any work ‘SPECIAL TOOLS Use special tools when they are required. REMOVAL OF PARTS While correcting @ problem, try also to determine its cause. Begin work only after first learning which parts and subassem- blies must be removed and disassembled ior replacement or repair. DISASSEMBLY IWthe disassembly procedure is complex, requiring many parts to be disassembled, al parts shouid be disassembled ina way that will not affect their performance or external appearance {and identified so that reassembly can be periormed easly and efficiently GI-5FUNDAMENTAL PROCEDURES 1. Inspection of parts When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems. ra 2. Arrangement of parts All disassembled parts should be carefully arranged for re- assembly, Be sure fo separate or otherwise identity the parts to be replaced from those that will be reused. mae Cleaning parts for reuse Al parts to be reused should be carefully and thoroughly cleaned in the appropriate method. REASSEMBLY Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. Refer to STANDARD BOLT AND NUT TIGHTENING TORQUE in Section TD for tightening torques not mentioned in the main text If removed, these parts should be replaced with new ones: 4. Oil seals 2. Gaskets 3. Orings 4, Lock washers 55. Cotter pins 6. Nylon nuts RARER Depending on location: 1. Sealant should be applied to gaskets. 2. Oil should be applied to the moving components of pats. 3. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly. mao Gi-6FUNDAMENTAL PROCEDURES Gl ADJUSTMENTS Use suitable gauges and/or testers when making adjustments. RUBBER PARTS AND TUBING Prevent gasoline or ol from getting on rubber parts or tubing. GI-7Gl JACK AND SAFETY STAND (RIGID RACK) POSITIONS JACK AND SAFETY STAND (RIGID RACK) POSITIONS FRONT et Jack position: Safety stand positions: : At the center of the crossmember On both sides of the Jack point L EGO EROS \ 2 REAR Safety stand positions: Jack position: ‘On both sides of the ‘At the center of the differential diferential oy area oo Gi-8VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS Gl VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS FRONT Jack point: On both sides of the jack point AR Oo aq. TL % ie ; \ Bry BAY \ SA Eo Gi-9| gtategrleteee FOR au SEr THE REMOTE FREE WHEEL SYSTEM YO FREE MODE BUR TOWING TOWING Proper towing equipment is necessary to prevent damage to the vehicle during any towing operation. Laws and regulations applicable to vehicles in tow must always be observed. Release the parking brake, place the shift lever in neutral, anc set the ignition key in the ACC position. As a rule, towed vehi cles should be pulled with the driving wheels off the ground, WITH MANUAL TRANSMISSION If the transmission, rear axle, and steering system are not damaged, the vehicle may be towed on all four wheels, it any of these components are damaged, use a towing dally WITH AUTOMATIC TRANSMISSION If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use a wheel dolly. With all 4 wheels on the ground, the vehicle may be towed only forward. In this case, do not exceed the following towing speed andlor distance or transmission damage could result we wa Toving speed 5 tanh G6 mph] | 66 ev 85 my “Towing tans 8 em (10-rites) —| 58 kr 5 rls) Ittowing speed andor distance will excead above-mentioned specifications, use one of three methods: 1, Place the rear wheels on a dolly 2. Tow with the rear wheels off the ground, 3. Disconnect the propeller shaft. (4x4: rear propeller shat) Ifthe transmission or rear axle is inoperative, tow the vehicle with its rear wheels off the ground or have the propeller shatt disconnected, CAUTION a) The power assist for the brakes is inoperable while the engine is off. b) When either of the towing hooks Is used, pull the cable or chain straight away from the hook and do not apply any sideways force to It. To further help prevent damage, do not take up slack too quickly in the cable or chain. ©) The rear towing hook should be used only in an emergency situation (for example, to pull the vehi- cle from a ditch, snow, or mud).CHASSIS & ENGINE NUMBER LOCATION/UNITS/ABBREVIATIONS. Gl CHASSIS NUMBER LOCATION UNITS Tm (kg Wb). Torque i Pareions per mine A Ampere(s) : von a Ot (estiance) 168 Want po) Prose (ual poet) mmtig (a He)... Presne (ety nog) Ie w Wa rm tenet Ta ENGINE MODEL AND NUMBER LOCATION ABBREVIATIONS Basoo! ETRBUTER 777 Se 186... Aer bolo dead car ABS. Antec eke avn & A0Attuootas & AiG AF conten, AV At conte A062 Aker op ea eer Mino Altona anarosen AE Alora aramid Sn Bypoo ar come BBD.” Bee oti Sead conor | Bio. Bote top das senor ECAT Ecvencabyconued sromate avarice EOU. Engi eae anh ED. Enegeaive ere conta oan EGR nnn Beha go touton Eu Emorgerby log eer EIR Beste Reg nae Bee ena Fg we PR Hiroe convoed erate weccicase HUA ou OE Lh eo heap cheat fac (ne Nam ane aR IN torment 180. sped cont So Rare 16. Lina a rete Was" our ade een Wi Mate ede nt A" Mant pera NF Macartney todo OB Ot agree OF Sten Se Sth on FEV Proeniing by pase vas Po polar sakes venoaion PB Power desing FEW" Ronee ee hoa hub Bee Riek han Sa Sete Ta te aut crow Toe top aed bance FPS eto toy iene aUaKoR Gi-11CAUTION ke aero “Se VOLTMETER aaa BaEKOe aca Gi-12 CAUTION ELECTRICAL TROUBLESHOOTING TOOLS Test Light ‘The test light, as shown in the figure, uses a 12V bulb. The two lead wires should be connected to probes. ‘The test light is used for simple voltage checks and for check ing for short circuits. Caution When checking the control unit, never use a bulb over 3.4W. Jumper Wire ‘The jumper wite is used for testing by shorting across switch terminals and ground connections. Caution Do not connect a jumper wire from the power source line to a body ground; this may cause burning or oth- er damage to harnesses or electronic components. Voltmeter The DC voltmeter is used to measure of circuit voltage. A vol meter with a range of 15V or more is used by connecting the postive (+) probe (red lead wire) to the point where voltage is to be measured and the negative (-) probe {black lead wire) to a body ground, Ohmmeter ‘The ohmmeter is used to measure the resistance between two points ina circult and also to check for continuity and diagno- sis of short circuits. Caution Do not attempt to connect the ohmmeter to any cir- cuit to which voltage is applied; this may burn or other- wise damage the ohmmeter. CAUTION WITH ELECTRICAL PARTS Battery Cable Before disconnecting connectors or replacing electrical parts, disconnect the negative battery cable.CAUTION Gl eee = ra se ow » a EB RTT Connectors Removal of connector Never pull on the wiring harness when disconnecting con- neciors. Connectors can be removed by pressing or pulling the lock lever as shown, Locking of connector When locking connectors, make sure to listen for @ click that will indicate they are securely locked. Inspection When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wire harness side, Terminals Inspection Pull lightly on individual wires to check that they are secured in the terminal GI-13aaa \ CAUTION Replacement of terminals Use the appropriate tools to remove the terminal as shown. When installing the terminal, be sure to insert it until it locks Gay securely. Insert @ thin piece of metal from the terminal side of the con- nector, and then. with the terminal locking tab pressed down, pull the terminal out from the connector. Same as the female type. Wiring Hamess Wiring color codes Two-color wires are indicated by a two-color code symbol The firs letter indicates the base color ofthe wire and the sec- cond the color of the stripe. ~ (CODE ‘coLon cope | COLOR : 3 Bleck ° Orange BR Brown P Pok | 6 Green a Rea oy Gray v Vile t Bue w wre | 18 ont Bue ¥ Yellow is Light Green 7 = Sensors, Switches, and Relays Handle sensors, switches, and relays carefully. Do not drop them or strike them against other parts.BUS Eero CAUTION Gl Fuse Replacement 1. When replacing a fuse, be sure to replace it with one of specified capacity |'a fuse again fails after it hes been replaced, the circuit probably has @ short circuit and the wiring should be ‘checked. 2. Be sure the negative battery terminat is disconnected be- fore replacing a main fuse (804), 8. When replacing a pull out fuse, use the fuse puller supplied in the fuse box cover. GI-15PRE-DELIVERY INSPECTION AND SCHEDULED MAINTENANCE SERVICES PRE-DELIVERY INSPECTION .. PRE-DELIVERY INSPECTION TABL! SCHEDULED MAINTENANCE SERVI (USA)... « ‘SCHEDULE 4 {NORMAL DRIVING CONDITION) 82600) SCHEDULE 1 (NORMAL DRIVING CONDITION) 82200... A= 7 SCHED! (eNIovE ‘CaN CONDITION) B2600i.. SCHEDU (UNIQUE ‘DAIVING CONDITION) 82200 eos A> SCHEDULED MAINTENANCE SERVICES (CANADA) aesPRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE Following items may be done at any time prior to delivery to your customer. [4 EXTERIOR + INSPECT and, necessary, ADJUST the folowing tems to specications: 12 Gis, exarior bright metal, and paint for damage Gi Wheel tug nuts Nowsted 88-118 Ne» (0-120 mrtg, 6587 fe) Styiod! 118147 Nev (12.0—18.0 ekg, 87-106 tb) ‘Al waathorstips for damage ox detachment Overaton of haod release and lock 1D Operston 0! tua id opener (I eaupped) 5 Door oporeton and algnment 1 Heaigne arn * INSTALL tho folowing parts: i Wheel cantor caps ft equipped) 5 Outside rearview meron) 2. UNDER HOOD—ENGINE OFF * INSPECT and, necessary, ADJUST the folowing items 1 spectations: 1D Fue), coolant anc hydraulic ines, ftings, connections, and ‘components for leaks. Engine oF leve! 1 Ollfeval in steering gearbox 5 Power stoering fud level equipped) 1 Brake ana clutch master cylinder td levels 1D Windehlald washer resarvor fic level 1D Headlight cleaner reservor fd level (if equippec) 1D Raciator coolant level D Tightness of batiory terminals 3. INTERIOR = INSTALL the following pans: 1 Rubber stopper for inside rearview mirror © CHECK the operations of the folowing roms: 1D Seat coniros (siding and recining) and head rest 1D Boor Socks: 1D Foe-Down rear seats (Cab Pius only) ‘© Seat bets and warning system 5 Igaiton switch and steering iook Sartor interlock switch (MPT only) 5B Shitiock systen and inhibitor sutch (AIT only) D Al iat, Incucing warring anc incicator its (equipped) I Horn, windshield wipers, and washers (f equipped) 1D Headlight cloaner ( equipped) 5) Radio and antenna (i equipoec) 1 Cigaratie lighter and clock (f equippsc) INTERIOR (cont'd) i Healer, dose, and al conditioner at iferent modest eqarped + GREEK he folowing tems: D Fresence of spare fase 1 Upotsery and miro rich Following items must be done just before the delivery 1D Load test battery and charge if necessary vate 1B Adjust ire pressure tothe specification {Pater to Section Q) © Ciean outside of vehicie A-2 '» CHECK and, # necessary, ABMUST the folowing items: 1 Pedal ne ght Wah earoed and ree piay 0! breke and clutch pedal Pada heght mm Te] Free play mm (a) Caioh [BEBO [91207 (7527.8 ; pec) eze00 Her—rar g.1e=75q) °° $0028 Brake pedal 160185 (7 08—7.28)| 407.0 16-028) 1 Peting 660K wanna. 712 Nolchos!196N (20 kg, 44 Ib) UNDER HOOD—ENGINE RUNNING AT OPERATING TEMPERATURE 4 CHECK the falowing Heme: 5 Trois sere (€) 1 Operation of loleu system for. = Airconditoner and automete tranemission (Carburetor) 1D Automate transmission uid leve Ci Operation of dashpot (Carburetor & Carburetor oat level intial igntlon tering: 6 & 1° BTDC (82200) & Idle speed: 800 “Y rpm AT; in P range (82200) © Operation of EGR contral valve (Carburetor) 1D Operation of lole switch (Carburetor) ‘ON HOIST ‘CHECK tne folowing tems: B Operation of remota freewhee! (4x4 only) 5 Manuel varemiesion of level 1G Transfer oo89 ol love (4x4 oni) 1D Front ade a level (x4 only). 1 Rear axe oll evel 1H Underside fuel, coolant and hydraulic nes tings, connec- ‘ions and components for leaks 1D Tres for cuts or bruisos| U Stosting Invage, suspension, exhaust sytem and all under- side harcware for looseness or damage 6, ROAD TEST © CHECK ihe folowing tems: 1D Brake oporaton © Clutch operation 5) Steering control 1D Operation of metere and gauge 1D Squeaks, ratles of unusual noises | Emergency lock relractore 5 Cruse contol eyetom (it equippec) 1B Operation of ranster caso (4x4 ony) 7 AFTER ROAD TEST = CHECK for necessary owner's information material, tool ‘and spare te in vehicle to your customer. 1D Install fuses tor accessories [U1 Remove seat and foor mat protective covers 1D Vacuum and clean interior of vehicle 1B Inspect instalation of option pans with invelce eeuaaccozSCHEDULED MAINTENANCE SERVICES (USA) owo}ed eq O32 Tei PuewuIOD9: am “JOADMO}, "BWLOMED Klooxe SaIES Ife PUE ’pBUED 40} Poulnbe: S| coUEUEIUIEL SIL ¢, IOeINUEW 10 @BErGAOD AIUELsEM UO|SSHWWE 10} KtBSSBOSU JOU SI “OASMOH| "EPZEW Aq PapUeWUIOOEI s| BOUEUOINTEW SL ZL “SQUBUSTUIB PACLOSEp OY 167 sOTPO;PUY UOHOUNIEWY 94 ‘9IOIYOA BIUIOWED 10) OOK] L HO} 94) 910U “ueYD BOUEUO|UIEL SIM UI SWOY PEW , 10} Sy 10} 01 enuyuaD "(w4 000'96) SAIL OOO‘OR 40 SYUOW O9 JOMY TOMEWO ‘NO S8LUOO 1 41 ‘S9)tU O0'DR PU SA! 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(Inspect, and if necessary replace...Air cleaner element 2200 only) R: Replace or change T: Tighten L! Lubricate Clean Aiter 60 months or 96,000 km (60,000 miles), continue to follow the described maintenance items and inter- vals periodically ‘As for *marked items in this maintenance chart, pleace pay attention to the following points. "1: Replacement of the timing belt is required at every 96,000 km (60,000 miles) Failure to replace the timing belt may result in damage to the engine. * 2: This maintenance operation is recommended by Mazda, However, this maintenance is not neces- sary for emission warranty coverage or manufacturer recall lability *3: The Maltunction Indicator Light (MIL) comes ON at every 96,000 km and 128,000 km, If it comes ON, foliow the described maintenance. PauonoisENGINE (B2200) TROUBLESHOOTING GUIDE .. ENGINE TUNE-UP PROCEDURE DRIVE BELT. HLA TROUBLESHOOTING GUIDE . COMPRESSION COMPRESSION .. ON-VEHICLE MAINTENANCE. TIMING BELT wessseu CYLINDER HEAD GASKET .. FRONT OIL SEAL. REAR OIL SEAL. REMOVAL .... PREPARATI ENGINE STAND INSTALLATION. PREPARATION INSTALLATION DISASSEMBLY. PREPARATION. AUXILIARY PARTS .. TIMING BELT CYLINDER HEAD. CYLINDER BLOCK CYLINDER BLOCK INSPECTION AND REI PREPARATION ASSEMBLY. PREPARATION... CYLINDER BLOCK T.... CYLINDER BLOCK IT CYLINDER HEAD. TIMING BELT AUXILIARY PARTS ENGINE STAND REMOVAL .. REMOVAL... INSTALLATION, PREPARATION B1| B1 INDEX INDEX \ ~ i Goes Caouennies 1 mpethcnc pace Bes ve cowpneseion Wee] SOME N ae 10 We} STANDARD; 1,197 KPa (12.2 kglem’, 173 psi300 rpm L eee etre aati : RAS Ay 2-02 EET ey de : a it i a FRSINE boon INSPECTION, SEONEESSRENN ® — exene on nsrecron, | SSN SeOCRTD ORVE BELT ADJUSTING, PAGE BI=S DEFLECTION a cave aT a =) | ERO —| wees RET) | woo saw || 1 a ‘AIG COMPRESSOR | 10.0—12.0 (0.99--0.47) | 120—14.0 (0.47055) — | 1. engine 2.Timing belt | Removal page 81-20 TEOMA wusseencennenncnsnnn POD BI 8 : Bieaesoribiy page B1-24 instalation fege BI10 he Inspection and Repair ee page B1-34 Inspection sesssssessssareney PAGE BI-A4 } P a i Assembly....... page B1-46 3. Cylinder head gasket i Installation age 61-69 Romovel snsnnemsnee page 61-18 instalation page BI1-15 Bi-2 SeOUTLINE, TROUBLESHOOTING GUIDE Bi OUTLINE SPECIFICATIONS: == Es a en aa i [ie in Fa a aay ota i ofa eared cone wp J ‘ies Sie tain [Banaras aaa Ba Gg Soon ae SMO cabasat eaze ee Tea —— = Gun BS = | oe Close ABDC Ea aaa lex Open BBDC 58° rear — se ie ry iN mm (ny 0; Maintenance free ra aeeee xX mmm (in) 0; Maintenance free — ver a a wae ise [Pm [AIT range) 30028 770 20 zt a TROUBLESHOOTING GUIDE Problem | Possible Cause Remedy Page Dita ering | Wainstn a one ra combo Bas reo ss Sa an eo oe Bae [aes eine es Bs Nseon ol aon par nF Msarton festa sien fb for rg Hefner of nested onsen iter ees ep Mee tet cot Become | BH ra Sr na fs a | anette fie 6 SOF li slong st Faro Sea Scene ad ——] bron Seamct | SUNTETETE acne erste oon emo | Rca sie DBS ee REE | ofete wong own Sexes sie av Mi eh ase ies a Oi sap Fa an B1-3: TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page TInsutficient power | insufficient compression Malfunction of HLA Replace e140 CComoression Isakage from valve seat Repair BI27 Seized valvo stem Foplace 51-35 ‘Weak o° broken valve spring Ropiace 51-38 Faies eyindor head gacket Replace 81-13 Cracked or distorted cylinder head Replace Bias Sfcking, damaged, of worn piston ring Replace Bie Cracked of worn piston Replace Bie [Matfunction of fuel system Reter fo Sections Ft, F2 Malfunction of ignition system Reler ta Section G ‘Others Sipping clutch Reler ta Section Dragging brakes eter to Section P Wrong siz fires Fate: to Section O ‘Abnormal Malfunction of engine-related components ‘eombustion Malfunction of HLA Replace B40 Steking or burned valve Replace 81-35 ‘Weak or broken valve spring Replace 1-38 ‘Carbon secumulaion in combustion chamber Eliminate carbon = Maitunction of fuel system Fler to Sections FY, F2 Malfunction of ignition system lar to Section G Engine noise ‘Crankshaft oF bearing related parts Excessive main bearing oll clearance Replace or repair Bi-a9 Main bearing seized or heat-damaged Replace Bias Excessive crankshait end play Replace or repair 1-50 Exceceve connecting rod beeting al clearance Replace or repait Bist Gonnscting rod boating seized or heat-damaged Repiace Bias iston-related parts Worn eyinger Foplaco oF repair Bio Wom piston oF piston pin Replace Bis Seized piston Replace Bia Damaged piston ting Replace B14 Bent connecting rod Replace a1-43 Valves of timing-related parte Malfunction of HLA" Replace BI-40 Broken valve spring Replace Bi-33 Excessive valve guide clearance Repiace I-35 Insufciet Movication of rocker arm Repiace 8140 Malfunction of cooling system ater to Section E ‘Malfunction of fuel system Fifer to Sections F1, F2 Others Malfunction of water pump bearing Refer to Section E Improper dtve-belt tension Adjust Bis Mattunction of alternator bearing | Refer to Section G Exhaust gas leakage Fifer to Sections Ft, F2 Maltunetion of timing belt tensioner Replace Bin 8 od = Tappet noige may occur the engine is not operated for an extended period. The noise shoud disappear ater the engine has reached normal operating temperaire. Bi-4 featsENGINE TUNE-UP PROCEDURE B1 ENGINE TUNE-UP PROCEDURE DRIVE BELT 1. Check the drive bells for wear, cracks, or fraying; replace if necessary. 2, Check the drive belt deflection by applying moderate pres- sure (98 N, 10 kg, 22 1b) midway between the pulleys shown in the figure. Adjust if necessary aaa Deflection mm (i ‘PrS OWL PUMP: ADJUSTING BOLT ao Dave bet New eet | ane lees 88 _(028-031) (031-035) 70-80 30-90 P98 ol pump 025-031) (031025 os 700-720 720140 AIG comoresio 29-047) (047058) 3. Check the drive belt tension with the tension gauge, . Note ee aera cot Belt tension can be measured among any pulleys. \ Mest No.) Dive bat New T Used 31580 320-481 | Aerator ose tociey | ao sabe t110) 2s—294 198-25 mounma 80uT PIS of pump (25-20, 55-05) | 20-25, 4455) 441540 348 —aat ‘AVC compressor cama (ass, 99-129 | @5—95, 77-29) Adjustment (1) Alternator belt lf necessary, loosen the aiternator bolts and adjust the belt deflection, Tightening torque Bolt A: 31—46 Nm (3.2—4.7 m-kg, 23-34 ft-lb) Bolt B: 3752 Nm (3.8—5.3 m-kg, 27—38 ft-lb) (2) PIS oil pump belt lf necessary, loosen the locknut and adjust the bett deflection by turning the adjusting bot Tightening torqu 37-52 Nm (3.8—5.3 m4 27—38 ft-lb) Bi-5HLA TROUBLESHOOTING GUIDE ENGINE TUNE-UP: PROCEDURE, COMPRESSION | (8) AIC compressor bett If necessary, loosen the mounting bolts and adjust the bbelt defiection by turning the adjusting bot. Tightening torque: ‘37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb) 2 5 Problem Possible Cause ‘ion |]. [temo wen oname s sed Hamedaay [Ol eatage nol) Fin angie wt 20005000 ron is | Getot's chanaes passage Foe slope after 2 sacord—10 minutes’, HLA s A | 2, Nose unten engine i tated after seting formal APG LE. aprox one ay. Wek replace HLA Lo. [Nese when encira is sarod afer cank- | Ol eakageir” | Tyme requied for enging oo cree TPee Te eee neato re me {it ncuvos tera for engine of conten ard 1 4, Noise when engine is started after new ambient temperature. Aas [2 NtA‘sineated 3 Hows contmucs more fan 10 minutes | (reuicant of | Check a pressure. (ler Secton 0) pressure Ilower then specication, Shock fr cause Oli pressure; 304—402 KPa (G14. kgfer, 44—58 ps!)-3000 rpm Fauly WA] (Raa to pane 82-69) Pree down fecker art by hand ihe moves, place HLA {Ft ases not move, HLA nora ‘Meanie vave sosrance. tinove than Bram (0) replace HLA 3. Nal casas danny Wo aor Fgh opeed | Wcorec Gt | Check of Fal runing amour Bran of ed ol as neces Bateraior oF | Check ot quality W Seer. ace wn sects yp ad aro oot Tar Tnoearor COMPRESSION tt the engine exhibits iow power, poor fuel economy, or poor idle, check the following: 1. Ignition system (Refer to Section G.) 2. Compression 3. Fuel system (Refer to Sections F1, F2.) COMPRESSION 1. Check that the battery is fully charged. Recharge it if necessary, 2. Warm up the engine to the normal operating temperature. 3. Tum it off for about 10 minutes to allow the exhaust mani: fold to cool. 4, Remove all spark plugs. 5, Disconnect the primary wire connector from the ignition coil ,COMPRESSION B1 6. Connect a compression gauge to the No.1 spark plug hole, 7. Fully depress the accelerator pedal and crank the engine, 8. Note the maximum gauge reading. 9. Check each cylinder. Compression: 1,197 kPa (12.2 kg/em?, 173 psi)-300 rpm Minimum: a 834 kPa (8.5 kg/cm’, 121 psi)-300 rpm ty SaTORT Possible Cause i.compression i iow, pour heavy a int tho onder and tun fe erankshait sovra mes i hack compression ance more I Is compression increased? 1, Wor piston ot piston rings 2 Worn eyinder wi 1. Delecive oyinder head gasket No 2 Boned Sno head | eS ves : : Ts canpesson in aden der? no 1 tapope sao wong | 2 Wipe Si guce 3. Defective cyinder head gasket wae B1-7| Bi ON-VEHICLE MAINTENANCE (TIMING BELT) ||| ON-VEHICLE MAINTENANCE TIMING BELT |, Removal 1. Disconnect the negative battery cable. | 2. Drain the engine coolant |. 3. Remove in the order shown in the figure referring to the Removal note, TSO <4) 1.Cooling fan 7, Crankshaft pulley 2 Radiator cowiing 8. Timing belt cover upper 8. Alternator drive belt 9. Timing belt cover lower 4, Cooling fan pulley 40. Timing belt tensioner and spring 5. Cooling fan bracket 11. Timing belt 6. Secondary air pipe assembly (Carburetor) Bi-8ON-VEHICLE MAINTENANCE (TIMING BELT) Bi DIRECTION ARROW Removal note Timing belt tensioner 1. Tum the crankshaft to align the $1 mark of the camshaft pulley with the front housing matching mark 2, Remove the tensioner and spring, Timing belt Mark the timing belt rotation for proper reinstallation if itis reused. Caution Be careful not to allow oil, grease, or water on the belt. Inspection Inspection of timing belt related parts. (Refer to page B1-44,) seunero%e B1-9ON-VEHICLE MAINTENANCE (TIMING BELT) Installation Install in the reverse order of removal referring to the Installation note. oe Caution After radiator cowling installation, rotate the cooling fan by hand and verify that the fan blade does not touch the radiator cowling. If the fan touches the cowling, adjust the radiator cowling mounting position. Note a)Position the hose clamp in the original location on the hose. b)Squeeze the clamp lightly with large pliers to ensure a good fit. if |, Torque Specifications b I | onan (7O=100 cart, 6187 i) (as 73, 9-19) en ook mb) TBUOBI CTS B1-10aa ON-VEHICLE MAINTENANCE (TIMING BELT) Bi Installation note Timing belt 1. Check that the mark on the timing belt pulley is aligned with the matching mark. 2. Check that the #11 mark of the camshaft pulley is aligned with the matching mark. If tis not aligned, turn the came shatt to align, 8. Install the timing belt tensioner and spring. Temporarily se- ‘cure it with the spring fully extended, 4. Install the timing belt so that there is no looseness at the water pump pulley and idler pulley side. Caution 9) if the timing belt is being reused, it must be rein- stalled to rotate in the original direction. b) Check that there is no oil, grease, or dirt on the tim- ing belt. Note Remove all spark plugs for easier rotation. 5. Tum the crankshatt twice clockwise in the direction of ro- tation. 6. Check that the matching marks are correctly aligned. If not, repeat the above-mentioned procedure. 7. Loosen the tensioner lock bolt and apply tension to the belt Bi-11nea B1-12 ON-VEHICLE MAINTENANCE (TIMING BELT) 8, Tighten the timing belt tensioner lock bot. Tightening torque: 37—52 Nan (3.8—5.3 m4 27-38 ft-lb) 9, Turn the crankshaft twice in the direction of rotation and align the matching marks. 10. Check the timing belt deflection, If the deftection is not cor- rect, repeat the adjustment from step § above, Timing belt deflection/98 N (10 kg, 22 Ib) New : 8.0—8.0mm (0.31—0.35 in) Used: 8.0—10.0mm (0.35—0.39 in) Caution Be sure not to apply tension other than that of the ten- sloner spring. Spark plug 1. Install the spark plugs Tightening torque: 15—23 Nm (1.5—2.3 m , 11-17 ftlb) Steps After Installation 1. Adjust the drive belt tension. (Refer to page B1-5.) 2. Add engine coolant to the specified levels. 3. Connect the negative battery cable. 4, Start the engine and do the following: (1) Check for leakage of engine coolant. (2) Perform engine adjustments if necessary. (8) Recheck the coolant leveis. souosroreON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) Bi CYLINDER HEAD GASKET Removal Warning: Release the fuel pressure. (Refer to Sections F1, F2.) 1, Disconnect the negative battery cable, 2. Remove the engine undercover. 3. Drain the engine coolant. 4, Remove in the order shown in the figure referring to the Removal note (CARQURETOR ® 1. Air cleaner assembly (Carburetor) 2. Air intake hose (EG) 3. Cooling fan.and radiator cowiing 4, Accelerator cable 5. Fuel hoses 6. Fuel pump (Carburetor M/T) 7. Heater hoses 8. Brake vacuum hose 9. Three-way solenoid valve assembly 10. Duty solenoid valve assembly 11. Canister hoses 12, Engine harriess 18. High-tension leads and spark plugs 14. Distributor Ser, | REPLACE, Eo 18. Secondary air pipe assembly (Carburetor) 16. Radiator hose, upper 17. Water by-pass hose 18. Intake manifold assembly 19, Exhaust manifold insulator 20. Exhaust manifold 21. Timing bett cover, upper 22. Timing belt tensioner and spring 23, Timing belt 24. Engine ground 25. Cylinder head cover 26. Cylinder head bolt 27. Cylinder head 28, Cylinder head gasket B1-13B1 ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) [GARQURETOR a @. © @ g TORT Removal note Fuel hose Note a) Cover the hose with a rag because fuel will spray out when disconnecting. b)Keep sparks and open flame away from the fuel area. Plug the disconnected hoses to avoid {uel leakage. Timing belt 1. Before removing the timing bett, turn the orankshaftto align the 41 mark of the camshaft pulley with the front housing matching mark. 2, Loosen the timing belt tensioner lock bolt 3, Shit the tensioner outward as far 2s possible, then temporer- ily tighten it 4, Remove the timing bet and secure it out of the way to pre- vent damage during removal and instalation of the cylin- der heed. Cylinder head bolt Loosen the cylinder head bolts in two or three steps in the order shown in the figure.ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) B1 ] Disassembly of Cylinder Head | Refer to page B1-28. Inspection of Cylinder Head Refer to page 81-34, Assembly of Cylinder Head Reter to page B1~56. wea Installation Install in the reverse order of removal referring to the Installation note. Caution Alter radiator cowling installation, rotate the cooling fan by hand and verify that the fan blade does not touch the radiator cowling. If the fan touches the cowling, adjust the radiator cowling mounting position. Note a) Position the hose clamp in the original location on the hose. b)Squeeze the clamp lightly with large pliers to ensure a good fit. Torque Specifications (20110 crag, 6525 in) 12s (18F6, 419)Bi ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) Installation note | Cylinder head | 1 Thoroughiy remove all dir and oi from the top of the eylin- ax der block with a rag. 2, Place a new cylinder head gasket in postion. 3. Set the cylinder head in place. 4. Apply engine oll to the bolt threads and seat faces, 5, Tighten the cylinder head bolts in two or three steps in the order shown in the figure, Tightening torque: '80—B6 Nm (8.2. .8 m-kg, 59—64 ft-b) Cylinder head cover +1. Apply engine oll ta the valves and rocker arms. 2 Apply silicone sealant to the shaded areas shown in the figure 3. Install the cylinder head cover. aes Tightening torque: 2.93.9 Nim (30—40 cm-kg, 26—36 in-lb) mae Timing belt + Align the 441 mark ofthe camshaft pulley with the front hous: 19 matching mark 2. Install the timing bet. (Refer to page B1-10.) Distributor 4. Apply engine cil to the new O-ring, and position it on the distributor. 2. Apply engine oll to the distributor driven gear. 3. Align the distributor housing and driven gear marks. 4, Install the distributor into the front housing, 5, Loosely tighten the distributor mounting bolt. oe ERTSON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) B1 DST Spark plug 1. Apply ant-seize compound or molybdenum-based lubricant to the spark piug threads, 2. Install the spark plugs, Tightening torque: 15—23 Nem (1.52.3 m-kg, 11—17 ft-lb) Steps After Installation 1. Add engine coolant to the specified levels. 2. Connect the negative battery cable 3, Start the engine and do the following: (1) Check for leakage ot engine coolant (2) Perform engine adjustments if necessary. {@) Recheck the oil and coolant levels sezose B1-17Bi ON-VEHICLE MAINTENANCE (FRONT OIL SEAL) FRONT OIL SEAL |p. Preparation ssT 495120710 so 4011 101A ®) 4 | Holder, couping == | crankshatiock wed | ange tool # eam 4 aE TS Removal 1. Disconnect the negative battery cable. 2. Drain the engine ol. 3. Remove the timing belt. (Refer to page B18.) 4 Remove the timing belt pulley with the SST. 5. Remove the oil seal with @ screwdriver and a rag. Installation Install in the reverse order of removal referring to the instal lation note. Installation note Front oll seal +. Apply engine oil to the new seal lip. 2 Fit the oil seal onto the oll pump body. 8, Tap the oil seal in evenly using a suitable pipe. il seal outer diameter: 48mm (1.89 in) Caution The oil seal must be tapped in until itis flush with the edge of the oil pump body. Timing belt pulley Install the timing bett pulley with the SST. Tightening torque: 457—167 Nem (16.0—17.0 m-kg, 116-128 ft-lb) ‘Steps After Installation +. Add engine oil to the specified levels. 2.Connect the negative battery cable. 8 Start the engine and do the following: (1) Check for leakage of engine oil {2) Perform engine adjustments if necessary. {@) Recheck the oil levets. wearsON-VEHICLE MAINTENANCE (REAR OIL SEAL) B1 REAR OIL SEAL Preparation sst 49 E011 140 49 SE01 910 Ring gear brake " Clutch aise sel centering took BaD Bare Removal 1. Disconnect the negative battery cable. 2. Drain the engine oil ‘8. Remove the manual transmission, (Refer to Sections J1, J2, J3,) Remove the automatic transmission. (Refer to Sections K1, K2, K3.) 4. Remove the cluich cover, clutch dise, and flywheel with the SST. (Refer to Section H.) Remove the plate, drive plate, and adapter with the SST. (Refer to Sections Ki, K2, KS.) 5, Remove the oil seal with a screwdriver and a rag. Installation Install in the reverse order of removal reterting to the Installation note. Installation note Rear oil seal 1. Apply engine oil to the new oil seal lip. 2. Fit the oil seal onto the rear cover. 8, Tap the oil seal in evenly using a suitable pipe. Oil seal outer diameter: 140mm (4.33 in) Caution The oll seal must be tapped in until it is flush with the i edge of the rear cover, Steps After Installation 1. Add engine oil to the spectied levels 2. Connect the negative battery cable. 8. Start the engine and do the following: (1) Check for leakage of engine cil (2) Perform engine adjustments if necessary. (3) Recheck the oil levels, xno Bi-19B1 REMOVAL | |REMOVAL | | PREPARATION [| osst 49 wo2a 5054 ‘dus wronch — waa § | Warning: Release the fuel pressure. (Refer to Sections Ft, F2.) 1 | 4. Disconnect the negative battery cable. £ | 2, Remove the starter (Refer to Section G) and transmission. (Refer to Sections J1 U2, J3 and K1, K2, K3.) 3, Drain the engine oil and coolant. | 4. Remove in the order shown in the figure referring to the Removal note. | BI-201. Air cleaner assembly 2. Cooling fan and radiator cowling 3. Accelerator cable 4. Fuel hoses 5. Heater hoses 6. Brake vacuum hose 7. Three-way solenoid valve assembly 8. Vacuum solenoid valve assembly 9. Canister hoses 10. Engine harness [eARBURETOR Taso REMOVAL B1 11. Engine ground 12. Secondary air pipe assembly (Carburetor) 13, Radiator hoses 14. Radiator 15. Binaust pice 18. A/C compressor 17. PIS oil pump pulley 18. P/S oil pump 419. Engine mount ruts mento Removal note Fuel hose Warning 2) Cover the hose with a rag because fuel will spray ‘out when disconnecting. '»)Keep sparks and open flame away from the fuel area, Plug the disconnected hoses to avoid fuel leakage. P/S oil pump pulley Remove the PIS oil pump pulley with the SST. P/S oll pump, A/C compressor Remove the PIS oll pump and A/C compressor with the hoses stil connected to them; secure the pump and compressor as shown in the figure. Bi-21: Bi ENGINE STAND INSTALLATION [ENGINE STAND INSTALLATION REPARATION sst i 1 1] ss o1or ea ev TTD pg | eiterm 1 | env sana ang ge ) pa E sand Be | Por ot E Le |stoow * Lt oaee ae Pra i = Hee) ote zee 6 1 | eta Utes We E 49 LO10 140) 49 LO10 1A0) 49 LO10 1A0) ie : maar IPE | to10 108 Q | evo 08 TEE | oot = |i Sts oa Le | 8tiou0 sto v0 iH i}; INSTALLATION | |) 1, Remove the parts in the order shown in the figure. { } 2 Install the engine to the engine stand referring to the Installation Note. He + Ht | Hee | i eager, serve | | | | » l eee oS 1. Exhaust manifold insulator 4.01 vel gauge 2. Exhaust manifold 5. AIC compressor and P/S oil pump bracket 3 Engine mounts Bi-22ENGINE STAND INSTALLATION B1 Installation note Engine Hanger 1. Install the SST (arms) io the block holes as shown in the figure and loosely tighten SST (bolts A). 2. Assemble the SST (bolts, nuts, hooks and plate). 3. Install the SST assembly to the respective arms while ad- justing parallelism between the arms and plate by turning the bolts and nuts. Warning Use special caution while turning the engine stand handle to prevent hand injury. 4 Tighten the bolts and nuts to fix the SST. 2 5. Install the engine on the SST. FOE "ao Bi-23|, Bi DISASSEMBLY 4} | DISASSEMBLY q PREPARATION Sst Po [ae e011 140 49 0698 1004 49 G090 202 pe é te Seng er i 49 1285 O71 49 L011 OAD & 49 L011 001 ! WE SB) | Pater, bearing menif}—eres | Psion pin sting S} | suppor block | toa ea g mo RSS | Gala : Slot on 1 | | 49 vo1t 008 wrioroo 49 Lott 006 1 | seen ace Se io P| hose Canet tare 11) | ean ot ‘49 L011 0A0) 49 LO11 AO) © [SSS ono | il i || | 49011 008 49 Lott 010 | 49 tors on £ | aude a Centering tool Holder ono patel A jean 8 ~ £ [Ssh ono {Lott 010 $e Lots 010) aT 4, Code all identical parts (such as pistons, piston rings, connectings rads, and valve springs) so that they can be reinstalled in the cylinder from which they were removed 2. Clean the parts with steam; blow off any remaining water with compressed air. Note During the disassembly of any part or system, be sure to study ts order of assembly. Also, note any deformation, wear, or damage. smonzor? § g 1 RX 2DISASSEMBLY (AUXILIARY PARTS) B1 AUXILIARY PARTS Remove in the order shown in the figure. ‘CARBURETOR Ten 4. Distributor and high-tension leads 8. Alternator 2. Spark plugs 9. Alternator bracket and cooling fan bracket 3. Rear engine hanger 10. Fuel pump (Carburetor M/T) 4. Front engine hanger 11. Oi fiter 5, Thermostat cover 12. Oil pressure switch 6. Thermostat 13. Coolant bypass pipe Service ... Section E 14. Coolant inlet pipe 7. Intake maniiold assembly Bi-25; B1 DISASSEMBLY (TIMING BELT) TIMING BELT || |) 1. Remove in the order shown in the figure referring to the Disassembly note, oe i el {|} Inspect all parts and repair or replace as necessary. ; ieeenesae % \ va | - TRE 6. Timing belt idier pulley 7. Timing belt aan 8. Camshaft pulley 9. Timing belt pulley 1, Crankshaft pulley 2. Upper timing belt cover 3. Lower timing belt cover 4 Baffle plate 5. Timing bett tensioner and spring B1-26DISASSEMBLY (TIMING BELT) B1 TRI Tan Disassembly note Crankshaft pulley 1. Set the SST against the flywheel 2. Remo the crankshatt pulley. Timing belt 1. Looser the tensioner lock belt, and remove the tensioner spring, 2. Mark the timing belt rotation for proper reinstallation fis reused! 3. Removp the timing belt Cautic Be careful not to allow oll or grease on the belt. Camshaft pulley Remove the pulley lock bott using a screw driver to prevent the camshatt from turning, Timing belt pulley Remove he timing belt pulley with the SST. B1-27er | | Bi DISASSEMBLY (CYLINDER HEAD) CYLINDER HEAD 1. Remove in the order shown in the figure referring to the Disassembly note. 2. Inspect all parts and repair or replace as necessary. = 6 vawve sea, oa EE ®, SEAL CAP, REPLACE. 1. Cylinder head cover and gasket 9. Cylinder head gasket 2. Front housing 10. Valve keepers 3. Rocker arm and shatt assembly 11. Upper spring seat Inspection page 81-40 12. Valve spring, outer and inner 4. Hydraulic lash adjuster (HLA) Inspection : page B1-38 Inspection page B1-40 13, Lower spring seat 5. Seal cap 14. Valve 6. Camshaft Inspection... . page B1-35 Inspection nen page B1-39 18, Valve seal 7. Cylinder head bot Inspect for wear or damage 8 Cylinder head 16. Valve guide INSPOCtiON no page 81-34 inspection page B1-35 Replaceme: page 81-36 B1-28DISASSEMBLY (CYLINDER HEAD) B1 Disassembly note During disassembly, inspect the following. 1, Camshaft end play (Refer to page B1-40.) 2. Camshaft journal oil clearance (Refer to page 81-39.) Rocker arm and shaft assembly +. Loosen the bolts in two or three steps in the order shown in the figure. 2. Remove the rocker arm and shaft assembly together with the bolts. Caution ‘Do not mix up the parts of the rocker arm and shaft assembly. Hydraulic lash adjuster (HLA) Removethe HLA by hand. I this is diffcul, remiove it with pliers | Caution Do not remove the HLA unless necessary because oll leakage will occur if the O-ring Is damaged. hp aaa? Cylinder head bolt Loosen the cylinder head bolts in two or three steps in the order shown in the figure, a = Valve Remove the valves from the cylinder head with the SST. B1—29B1 DISASSEMBLY (CYLINDER BLOCK) CYLINDER BLOCK I 1, Remove in the order shown in the figure referring to the Disassembly note. 2. Inspect all parts and repair or replace as necessary. (GASKET. REPLACE GasKer, REPLACE 1. Clutch cover (MD, Backing plate (AT) 2. Clutch disc (MM), Drive plate (A/T) 3. Flywheel (M/), Adapter (A/T) 4. End piate 5.Oll pan Inspect tor damage ETS 6. Oil strainer 7. Stiffener 8. Rear cover 8. Water pump assembly Service Section 10. Oil pump assembly Service... Section D Disassembly note Clutch cover, flywheel (M/T) or drive plate (A/T) Remove the ciutch cover and flywheel (MIT), or drive plate (A/D) with the SST.DISASSEMBLY (CYLINDER BLOCK) B1 CYLINDER BLOCK II 1. Remove in the order shown in the figure referring to Disassembly note. 2. Inspect all parts and repair or replace as necessary, a sure 4. Connecting rod cap 5, Main bearing cap 2. Connecting rod bearing 6. Crankshatt Inspect for peeling, scoring, or damage Inspection page 81-43 8. Conneeting 10d, piston and piston pin Inspection pages B1—42, 43 4, Piston ring Inspection... neneeeenee PAGS BI~42 7. Pilot bearing (MT) 8. Main beating Inspect for peeling, scoring, or damage 9, Cylinder block Inspection... page B1~40 Bi-31DISASSEMBLY (CYLINDER BLOCK) Disassembly note Connecting rod and cap Before removing the connecting rod, clean the bearing, con- ee necting rod, and crankpin, and measure the following: 1. Connecting rod side clearance (Refer to page 81-51.) 2. Crankpin oil clearance (Refer to page B1-51.) Main bearing cap Before removing the main bearing caps, clean the bearings, main journals, and caps, and measure the following points. 1. Crankshaft end play (Refer to page 81~50.) 2. Main journal oil clearance (Refer to page B1—49,) Pilot bearing (M/T) 1. Before removing the pilot bearing, inspect for sticks or ex cessive resistance by turing the bearing while applying force in the axial direction, 2, Remove the pilot bearing from the crankshatt with the SST if necessary. Note When replacing and/or cleaning the crankshaft, re- move the pilot bearing. aaa Piston and connecting rod 1, Before disassembling the piston and connecting rod, check the oscillation torque as shown, Ifthe large end does not drop by its own weight, replace the piston or the piston pin. 2. Assemble the SST as shown ich—_——DISASSEMBLY (CYLINDER BLOCK) Bi ———— _ 3 Insert the SST No.2 into the piston pin as shown and fully Nee sorew in the SST No.1. oa | | \ = in Ce Ey 4, Mount the piston and connecting rod in the SST as shown. 5, Press out the piston pin. While removing the piston pin, check the pressure. if itis lower than 4,905 N (500 kg, 1,100 Ib), replace the piston ppin or connecting rod. Bi-33,B1 INSPECTION AND REPAIR || INSPECTION AND REPAIR PREPARATION sst 49 0221 2514 so L012 040 BE | «91012 002 jomiover | Instafer set, valve, Ir Nt 0) cane tao y) 49 L012 AO) 49 LO12 040) 1. Clean all parts, being sure to remove any gasket fragments, dir, oil or grease, carbon, moisture residue, or other foreign materials, || 2. Inspection and repairs must be performed in the order specified. Caution Do not damage the joints or friction surfaces of aluminum alloy components (such as the cylin- der head or pistons). Cylinder Head 1. Inspect the cylinder head for damage, cracks, and leakage of water or oi. Replace if necessary. 2 Measure the cylinder head distortion in the six directions shown in the figure. Distortion: 0.15mm (0.006 in) max. 3. Ifthe cylinder head distortion exceeds specification, grind the oylinder head surface lithe cylinder head height is not within specification, replace a Height: 91.95—92.05mm (3.620—3.624 in) Grinding: 0.20mm (0.008 in) max. Note Before grinding the cylinder head, first check the fol- towing. Replace if necessary. * Sinking of valve seat ‘* Damage of manifold contact surtace © Camshaft oil clearance and end play sasINSPECTION AND REPAIR B1 | wana THICKNESS VALVE FACE I ANGLE ase eu Enon VALVE GUIbE VALVE STEM 4. Measure the manifold contact surface distortion in the six directions shown in the figure. Distortion: 0.15mm (0.006 in) max. 5. If distortion exceeds specification, grind the surface or re place the cylinder head. Valve and Valve Guide 1. Inspect each valve for the following. Replace or resurface if necessary. (1) Damaged or bent stem (2) Roughness or damage to face (3) Damage or uneven wear of stem tip 2.Check the valve head margin thickness. Replace if necessary. 1.5mm (0.020 in) EX: 1.0mm (0.039 in) 3, Measure the valve length. Length ‘Standard IN: 111.89mm (4.4051 in) EX: 111.69mm (4.3972 in) Minimum IN: 111.49mm (4.3894 in) EX: 111.29mm (4.3815 in) 4, Measure the valve stem diameter, Diameter IN : 8.030—8.045mm (0.3161—0.3167 in) EX: 6.025—8.040mm (0.3159—0.3165 in) 5. Measure the valve guide inner diameter. Inner diameter IN : 8.07—8.09mm (0.3177—0.3185 in) EX: 8.07—8.09mm (0.3177—0.3185 in) 6. Measure the valve stem-to-guide clearance. (1) Method No.1 ‘Subtract the outer diameter of the valve stem from the inner diameter of the corresponding valve guide. B1-35,INSPECTION AND REPAIR (2) Method No.2 Measure the valve stem play at a point close to the valve guide with the valve lifted slightly off the vaive seat. Clearance IN : 0,025—0,060mm (0.0010—0.0024 in) EX: 0.030—0.065mm (0.0012—0.0026 in) ‘Maximum: 0.20mm (0.008 in) 7. lithe clearance exceeds the maximum, replace the valve andlor valve guide. 8. Check the valve guide projection height (dimension Ain the VALVE GUIDE figure). Replace it necessary. our Height: 19.1—19.6mm (0.752—0.772 in) Replacement of valve guide OO | Note [| Although the shapes of the intake and exhaust valve guides are different, use the exhaust valve guide on — J ih} NW x both sides as a replacement. Removal Remove the vaive guide from the side opposite the combus- tion chamber with the SST. EarINSPECTION AND REPAIR Q°0 ° Kar Sa ee SBC Installation 1, Assemble the SST so that the depth L is as specified. Depth L: 19,1—-19.6mm (0.752—0.772 in) 2, Tighten the locknut. 3, Tap a new valve guide in from the side opposite the com bbustion chamber until the SST contacts the cylinder head. 4, Check thatthe vaive guide projection height is within spect cation. 5. IF not within specification, repeat steps 1—4. Valve Seat 1. Inspect the contact surface of the valve seat and valve face for the following (1) Roughness: (2) Damage 2. Irnecessary, resurface the valve seat with a 45° valve seat cutter and/or resurtace the valve face. 8. Apply a thin coat of Prussian blue to the valve face. 4, Check the valve seating by pressing the valve against the seat (1) If blue does not appear 360° around the valve face, re- place the valve. @ If blue does not appear 360° around the valve seat, resurface the seat. 5. Check the seat contact width. Width: 1.2—1.6mm (0.047—0,063 in) B1-37Bi INSPECTION AND REPAIR 6. Check that the valve seating position is at the center of the valve face. (1) Ifthe vaive seating position is too high, correct the valve seat with a 60° cutter. (Ifthe vaive seating position is too low, correct the valve seat with @ 25° (IN) or 15° (EX) cutter. 7. Seat the valve to the valve seat with a lapping compound, VALVE SEAT wioTs (amy 8. Check the sinking of the valve seat, Measure protruding length (dimension L) of each valve stem, Dimension L. IN: 46.5mm (1.831 in) EX: 46.5mm (1.831 in) (1) if Lis as below, it can be used as it is. IN : 46.5—47.0mm (1.831—1.850 in) EX: 46.5—47.0mm (1.831—1.850 in) (2) IfLis as below, insert a spacer between the spring seat and cylinder head to adiust. IN: 47.0—48.0mm (1.850—1.890 in) EX: 47.0—48.0mm (1.850—1.890 in) (8) If Lis more than as below, replace the cylinder head, IN: 48.0mm (1.890 in) EX: 48.0mm (1.890 in) aaa 7 Valve Spring 1. Inspect each valve spring for cracks or damage. 2. Cheok the tree length and out of square. Replace it necessary. Free length Standard Outer: 52.0mm (2.047 in) Inner: 44.0mm (1.732 in) Minimum Outer: 50.4mm (1.984 in) Inner: 42.7mm (1.681 in) Out of square ‘Outer: 1.8mm (0.07 in) max. Inner: 1.5mm (0.06 in) max. VARIATION FROM PERPENDICULAR, BUST OsINSPECTION AND REPAIR B1 Camshaft 1. Set the front and rear journals on V-blacks, Check the camshatt runout. Replace it necessary. eS Runout: 0.03mm (0.0012 in) max. 2. Check the cam for wear or damage. Replace i necessary. | 3, Check the cam lobe height at the two points as shown, Height IN : 38.059mm (1.4984 in) © EX: 38.059mm (1.4984 in) Minimum IN : 37.859mm (1.4905 in) + EX: 37.859mm (1.4905 in) aaa 4. Measure the journal diameters in X and Y directions at the two points (A and B) as shown, Diameter No.1 and No.5: 31,940—31.965mm (1.2575—1.2584 in) No.2, No.3 and No.4: 31.910—31.935mm (1.2563—1.2573 in) Out-of-round: 0.05mm (0.002 in) max. wusi7 —_§, Measure the oil clearance of the camshaft and camshaft eee eae eee et (1) Remove any oil, or dirt from the journals and bearing surface. (2) Set the camshaft on the cylinder head. (3) Position the Prastigauge on top of the journals in the axial direction (4) Place the camshaft caps and rocker arm shatts in pos- tion; then tighten them to the specified torque. Tightening torqu 18—26 Nem (1.8—2.7 m-kg, 13—20 fib) uma (6) Remove the camshaft caps and measure the oil clear- ance at each cap. Oil clearance No.1 and No.5: 0.035—0.085mm (0.0014—0.0033 in) No.2, No.3 and No. 0.065—0.115mm (0.0026—0.0045 in) Maximum: 0.15mm (0.006 in) (6) I the oll clearance exceeds the maximum, replace the ma cylinder head Bi-39 aLwine TET INSPECTION AND REPAIR 6. Measure the camshaft end play. fit exceeds the maximum, replace the camshaft or the cylinder head, End play: 0.08—0.16mm (0.0031—-0.0063 in) Maximum: 0.20mm (0.008 in) Rocker Arm and Rocker Arm Shaft 1. Check for wear or damage to the contact surfaces of the rocker arm shaft and the rocker arm. Replace if necessary. 2. Check the oil clearance between the rocker arm and shaft. Replace if necessary. (1) Measure the rocker arm inner diameter. Diameter: 18.000—16.027mm (0.6300—0.6310 in) (2) Measure the rocker arm shaft diameter. Diameter: 15.966—15.984mm (0.6286—0.6293 in) (@) Subtract the shaft diameter from the rocker arm di- ameter. clearance: 0.016—0.061mm (0.0006—0.0024 in) Maximum: 0.10mm (0.004 in) Hydraulic Lash Adjuster (HLA) ‘Check the HLA face for wear or damage. Replace if necessary. Caution ‘Do not remove the HLA unless necessary because oil leakage will occur if the O-ring is damaged. Cylinder Block 1. Check the cylinder block. Repair or replace if necessary. (1) Leakage damage (2) Cracks ) Scoring of wall 2. Measure the distortion of the top surtace of the cylinder block in the six directions as shown in the figure. Distortion: 0.1mm (0.006 in) max.INSPECTION AND REPAIR Bi 3, Ifthe distortion exceeds the maximum, repair by grinding, ‘0 replace the cylinder block. Height: 301.5mm (11.87 in) Grinding: 0.20mm (0.008 in) max. CFO ? v & 4 os eo | alles igs aaa seve 4. Measure the cylinder bore in X and ¥ directions at three levels (A, B, and C) in each cylinder as shown. SE S55 Tae | Olinger pore m9) a “ : Bore i: Sims Diameter a a Sandra 36.005 58.08 6. 3856—B.5606) owas eee 0.25 (0010) oversze | _ 66250—06.260 (9.:957—a.5064) y T 0.50 (0.020) oversize 36.500~86 519 (640663 4065) (1) Ifthe cylinder bore exceeds the maximum, rebore the cylinder to oversize. @) Kf the difference between the measurements A and C exceeds the maximum taper, rebore the cylinder to oversize. ‘Taper: 0.019mm (9.0004 in) max. @ If the difference between the measurements X and Y exceeds the maximum out-of-round, rebore the cylin- der to oversize, Out-of-round: 0.010mm (0.0004 in) max. Caution ‘The boring size should be based on the size of an over- size piston and be the same for all cylinders. 5. If the upper part of the cylinder wall shows uneven wear, remove the ridge with a ridge reamer. B1-41B1 INSPECTION AND REPAIR: Piston 1. Inspect the outer circumferences of all pistons for seizure or scoring. Replace if necessary. * 2, Measure the outer diameter of each piston at a right angle (80°) to the piston pin, 18.0mm (0.709 in) below the oil ring iand lower edge. OL ANG ‘GROOVE orn, Ch Piston diameter a Goren oaweren [S20 Piston Diameter i [Standard | 5.944—25.964 @.3696—3.3844) | sania — F925 (0.010) averize 86. 194— 86.214 @.9995~3.3842) a ‘0150 (0.020) oversize 26 aad—06 464 (4053-84081) 3, Check the piston-to-cylinder clearance, Clearance: 0.043—0.062mm (0.0017—0.0024 in) _ Maximum: 0.15mm (0.006 in) 4, Ifthe clearance exceeds the maximum, replace the piston or rebore the cylinders to fit oversize pistons. —[Fcurarance| ee If the piston Is replaced, the piston rings must also be replaced. Piston and Piston Rings 1. Measure the piston ring toring land clearance around the == entire circumference by using a new piston ring. Clearance (Top and Second): 0.03—0.07mm (0.0012—0.0028 in) Maximum: 0.5mm (0.006 in) Ifthe clearance exceeds the maximum, replace the piston Inspect the piston rings for damage, abrormal wear, oF breakage. Replace it necessary. [ol] 4, Insert the piston ring into the cylinder by hand and use the : piston to push it fo the botiom of the ring travel 7 [PISTON AING '5. Measure each piston ring end gap with a feeler gauge. Re- i place if necessary. End gap Top: 0.20—0.35mm (0.008—0.014 in) Second: 0.15—0.30mm (0.006—0.012 in) Oil rail :_0.20—0.70mm (0.008—0.028 in) ce Maximum: 1.0mm (0.039 in) TaLOET IINSPECTION AND REPAIR B1 Tae Waa Piston and Piston Pin 1, Measure the piston pin hole diameter in X and Y directions at four points. Diameter: 21.988—21.998mm (0.8657—0.8661 in) 2. Measure the piston pin diameter in X and Y directions at four points. Diameter: 21.974—21.980mm (0.8651—0.8654 in) 3. Check the piston pin-to-piston clearance. Clearance: 0.008—0.024mm (0.0003—0.0009 in) 4. ifthe clearance exceeds the specification, replace the pis- ton and/or piston pin, Connecting Rod 1, Measure the connecting rod small end bore. Diameter: 1.943—-21.961mm (0.8640—0.8646 in) 2. Check the interference between the small end bore and pis- ton pin, Interference: 0.013—0.037mm (0.0005—0.0015 in) 8. Check each connecting rod for bend. Repair or replace if necessary, Bend: 0.24mm (0.0094 in) max. Length (Center to Center): 158.45—158.55mm (6.2382—6.2421 in) I the connecting rod is replaced, the connecting rod cap and bolts must also be replacced because they are a matched set. Crankshaft 1. Check the journals and pins for damage, scoring, or oil hole clogging. 2, Set the crankshaft on Veblocks. 8. Check the crankshaft runout at the center journal. Replace it necessary. Runout: 0.03mm (0.0012 In) max. B1-43We Sao (CARANKPIN JOURNAL MAIN JOURNAL Sa FILLET ROLL. Taco wT INSPECTION AND REPAIR 4, Measure each journal diameter in X and Y directions at two places. Main journal Diameter: 59.937—59.955mm (2.3597—‘ Out-of-round: 0.05mm (0.0020 in) max. 3604 in) Crankpin journal Diameter: 50.940—50,955mm (2.0055—2.0061 in) ‘Out-of-round: 0.05mm (0.0020 in) max. 5, Ifthe diameter is below the minimum, grind the journals to maich an undersize bearing, Undersize bearing: 0.25mm (0.010 in), 0,50 mm (0.020 in), 0.75mm (0.030 in) Main Journal diameter undersize men fo) Bearing 828) “Joural ameter 0.25 (@.ot0)| No12a5 | _Sa6as—59.711 (2s601—2 3508) undersize [Nos '59.687—59.706 (2.24082, 3506) 0.50 (0.020)| Nai2.45 | __s0.449—60.461 (2.9409—2.3410) vundetsize [Nos 39,437—59.455 (2.5400—2.3407) f.75 (0.030)| No.12,48 | 59.193—88.211 (2.8904—2.911) ungersize [Nod 59,167—65.205 @.3902—2.3009), Crankpin journal diameter undersize arn Tourtal Tames 56 5B0—50 705 (1.99571 9965), 150 440-50 455 (1 9858—1.9964), 50.190 50.206 (7,9760—1.9768), Bearing 825, 025. (.010) undsrae (0.50 (0.020) undersze (0.75 (0.030) undersze Caution Do not grind the fillet roll. Main Bearing and Connecting Rod Bearing ‘Check the main bearings and the connecting rod bearings for peeling, scoring, or other damage. Timing Belt 1. Replace the timing belt if there is any oil or grease on it 2. Check the timing belt for damage, weer, peeling, cracks, or hardening. Replace #f necessary.INSPECTION AND REPAIR B1 Ne< Las (1.0 9) min maar Eo waa sa Caution a) Never forcefully twist turn inside out, or bend the timing belt. b)Be careful not to allow oil or grease on the belt. Timing Belt Tensioner and Idler Pulley Check the timing bett tensioner and idler pulley for smooth rotation and abnormal noise. Replace if necessary. Caution Do not clean the tensioner with cleaning fluids. If necessary, use a soft rag to wipe it clean, and avoid scratching it. Timing Belt Tensioner Spring Check the tree length of the tensioner spring. Replace if necessary, Free length: 63.0mm (2.480 In) Timing Belt Pulley and Camshatt Pulley Inspect the pulley teeth for wear, detormation, or other dam- age. Replace i necessary. Caution Do not clean the pulley with cleaning fluids. If neces- ary, use a rag to wipe it clean. Timing Belt Cover (lower and upper) Inspect the timing belt covers for damage or cracks. Replace if necessary, B1-45B1 ASSEMBLY | | ASSEMBLY f PREPARATION | Sst ' 1 r |] ao.011 010 491.011 001 | 8 ly 11 ch 49.011 08 | | Piston pin seting ‘Support block | |_| suppor block | | foto RS | By feud | RO a ee SS ® SS © | ao Lor ono) £8 L011 040) {| 49 toit ooo | 49 L011 005 49 L011 006 EAN) sore Stopper bot Puller & instar oo || are fara Gavel i eae) Re, | Etat one Sie) > ul fy: | | 49L011 008 49 LO11 010 49. LO1T O11 f a | | Guide ‘Centering tool Holder || eats S Gara Rea ee 8 © [SSS om Sots ono, SS tott ox eit it | | aocons 140 49 L012 010 aE | 49.012 001 — were o@cBie lee QUCDB (|s view ae Can't ~ | ave gave (ote oan | | | ae vote 2 45 1012 008 450598 1008 £ | @an of Pant of ® titer . | | Stoke oso {eo Loke oxo) et | aT | |e coso 222 so se01 310 ff | Pivot, valve Centering tool, U1 Soioine seer ase i t |; ; | 1. Clean all parts before reinstallation. | | Z.Rbpy new engine of to al siding and rotting pats E | 3. Replace plain bearings if they are peeling, burned, or otherwise damaged. {| 4. Tighten all bolts and ruts to the specitied torques. | Caution {| Do not reuse gaskets or oil seals. B1-46ASSEMBLY (CYLINDER BLOCK) B1 CYLINDER BLOCK I Torque Specifications Connecting Rod 1, Assemble the SST as shown. B1-473, Tighten the locknut. B1 ASSEMBLY (CYLINDER BLOCK) | 2. Set the stopper bolt (49 L011 005) so that the depth L is | as specified. if a Depth L: 59.5—59.7mm (2.342—2.450 in) 4, Insert the SST No.2 into the piston pin as shown and fully sorew in the SST No.1 5. Apply engine oil to the piston pin. : Bina ei 6. Set the piston on the SST with the F mark facing upward. : on, HOLE 7. Align the oil hole of the large end of connecting rod and | iF T F mark on the piston as shown in the figure. 8, Press the pision pin into the piston and connecting rod un- {il the SST contacts the stopper bot. 9, While inserting the piston pin, check the pressure force. If itis less than speciied, replace the piston pin or the con necting rod. Ste Pressure force: 4,905—14,715 N (500—1,500 kg, 1,100—3,300 Ib) 10. Check the oscillation torque of the connecting rod. (Refer to page 81-32,) BNE Piston Ring 1. Install the three-piece oll rings on the pistons. (1) Apply engine oil to the oil ring spacer and ral, (@) Install the oil ring spacer so that the opening faces upward. (G) Install the upper rail and lower ral Note any 2) The upper rail and lower rail are the same. b) Each rail can be installed with either face upward. wasn Bi-48ASSEMBLY (CYLINDER BLOCK) B1 SPACER TANG ‘SPACER ENDS PISTON UPPER Rat coe BERS ae lL Ne UPPER RAIL eo ou ne cia ‘SPACER ad oi aN SECOND TOWER RAL Ng ame ‘CENTER MAIN BEARING, ON THE a SIDE III VIDIYD )INDER BLOCK uae se Plasriaauae A] 2. Check that both rails are expanded by the spacer tangs ‘as shown in the figure by checking that both rails turn smoothly in both directions, 8. Install the second ring to the piston first; then install the top ring. Use a piston ring expander. Caution a) The ring must be installed so that the “R”” marks face upward. b) The second ring must be installed with the scraper face downward. 4. Apply a liberal amount of clean engine oil to the second and top piston rings. 5. Position the opening of each ring as shown in the figure. Crankshaft 4. Before installing the crankshaft, inspect the main bearing oil clearances as described, Note ‘The center main bearing on the cylinder block side has thrust shoulders. Oil clearance inspection (1) Remove any foreign material and oil from the journals and bearings. (2) Install the upper main bearings in the cylinder block. (@) Set the crankshatt in the cylinder block (4) Postion the Plastigauge on top of the journals in the axial direction Bi-49ASSEMBLY (CYLINDER BLOCK) (©) Install the main bearing caps along with the lower main earings according to the cap number and ¢ mark. ( Tighten the caps in two or three steps in the order in the figure. Tightening torque: 82—88 Nan (8.4—9.0 m-kg, 61—65 ft-lb) Caution Do not rotate the crankshaft when measuring the oil clearances. (7) Remove the main bearing caps, and measure the Plastigauge at each journal at the widest point for the smallest clearance, and at the narrowest point for the largest clearance. if the oll clearance exceeds specification, grind the crankshaft and use undersize main bearings. (Refer to page 81-44.) Oil clearance No.1,2,4,5: 0.025—0.043mm (0.0010—0.0017 in) No.3: 0.031—0.04amm (0.0012—0.0019 In) aussi «Maximum: 0.08mm (0.0031 in) 2, Apply a liberal amount of engine oil to the main bearings and main journals, 8. Install the crankshaft and the main bearing caps accord- ing to the cap number and + mark Co 4, Verify that the crankshatt rotates smoothly by hand. 6. Inspect the crankshaft end play. End play: 0.08—0.18mm (0,0031—0.0071 in) ‘Maximum: 0.30mm (0.0118 in) 6. If the end play exceeds specification, grind the crankshaft and use an undersize center main bearing. ‘ Center main bearing width i ‘Standard: 27.94—27.99mm (1.1000—1.1020 in) i (0.25mm (0.040 in) undersize: 28.04—28.09mm (1.1040—1.1059 in) 0.50mm (0.020 in) undersize: 28.12—28.17mm (1.1071—1.1091 in) ‘more 0.76mm (0,030 in) undersize: oe 28.20—28.25mm (1.1102—1.1122 in) rust width Is available only in undersize cen- bearing rasASSEMBLY (CYLINDER BLOCK) B1 Pilot Bearing 1. Apply engine oil o the outer citcumference of the bearing. 2. Seta piece of pipe (outer diameter 30—-S4mm, 1.181.834 in) against the outer race of the bearing; then tap it evenly into the crankshatt. 3. Lubricate the bearing with grease Piston and Connecting Rod Assembly 1. Apply a liberal amount of clean engine oil to the oylinder walls, pistons, and rings. 2. Check the piston rings for the end gap alignment 3. Insert each piston assembly into the cylinder block with the F mark facing the front of the engine. Use a piston installer tool (commercially available). Connecting Rod Cap 1. Check the connecting rod bearing clearances using the ‘same procedure as used for the main bearing oil clearance, Connecting rod cap tightening torque: 65—69 Nin (6.6—7.0 m-kg, 48—51 ft-tb) Oil clearance: 0.027—0.067mm (0.0011—0.0026 in) ‘Maximum: 0.10mm (0.004 in) Caution Align the matching marks on the cap and on the con- necting rod when Installing the connecting rod cap. 2, Ithe oil clearance exceeds specification, grind the crank shaft and use undersize bearings. (Refer to page B1-44,) 3. Check the side clearance of each connecting rod without the cap installed. Side clearance: 0.110—0.262mm (0.0043—0.0103 in) Maximum: 0.30mm (0.012 in) IW the clearance exceeds the maximum, replace the con- ecting rod, B1-51Bi ASSEMBLY (CYLINDER BLOCK) 4. Apply a liberal amount of engine oil to the crankpin journal ‘and connecting rod bearing. 5. Install the connecting rod cap with the alignment marks ~ aligned. Tightening torque: ‘@5—69 Nm (6.6—7.0 m-kg, 4851 ft-lb) 6. Verity that the crankshaft rotates smoothly by hand. aE |CYLINDER BLOCK TI [Torque Specifications 70-12m (0120 emg, 69104 nie) L 10-26 (1-27, 13-20) (10120 emg, 61—108 i) No og,ASSEMBLY (CYLINDER BLOCK) B1 SST Ba Rear Cover 1. Apply engine oil to the rear cover and new oil seal lip. 2. Fit the oil seal onto the rear cover. ‘3. Press the oil seal in evenly using & suitable pipe Oil seal outer diameter: 110mm (4.33 in) Caution The oil seal must be pressed in until it is flush with the edge of the rear cover. 4. Install the rear cover and a new gasket. Tightening torque: 7.8—12 Nm (80—120 cm-kg, 69—104 in-tb) 5. Cut away the portion of the gasket that projects out from the rear cover assembly toward the oil pan side. Caution Do not scratch the rear cover assembly. End Plate Install the end plate, Tightening torque: 19—30 Nm (1.9—3.1 m-kg, 14-22 ft-lb) oil Pump 41. Apply engine cil 1o the oil pump body and new oil seal lip. 2. Fit the oil seal onto the ol pump body, 4. Press the oll seal in evenly using a suitabie pipe. Oil seal outer diameter: 48mm (1.89 in) Caution The oil seal must be pressed in until it is flush with the edge of the oil pump body, B1-53ASSEMBLY (CYLINDER BLOCK) 4. Apply engine oil to the oil seal lip. 5, Remove any dirt or other material from the contact surfaces, 6. Apply a continuous bead of silicon sealant to the contact surface of the oil pump. 7. Install a new O-ting into the pump body. Caution Do not allow any sealant to get into the oil hole. 8. Install the oil pump. Tightening torque @: 18-25 Nm (1.92.6 m-kg, 14—19 ftb) ©: 37—52 Nm (3.8—5.3 m-kg, 27—38 ftb) 9. Remove any sealant which has been squeezed out. Stiffener 4, Remove any dirt or other material from the contact surface. 2. Apply a continuous bead of silicone sealant to the stiffener along the inside of the bolt holes, and overlap the ends. 3. Install the stitfener. Tightening torque: 6.9—12 Nin (70—120 cm-kg, 61—104 In-b) Caution After the sealant is applied, the oil pan must be se- ‘cured within 30 minutes. Oil Strainer Install the oil strainer and a new gasket. Tightening torque: 7.8—12 Nin (80—120 cm-kg, 69-104 1b) Oil Pan 1. Apply @ continuous bead of silicone sealant to the ol pan ‘around the inside of the bolt holes and overlap the ends. 2. Install the cil pan, Tightening torque: 6.9—12 Nam (70—120 om-kg, 61—104 in-Ib)ASSEMBLY (CYLINDER BLOCK) B1 Flywheel (M/T), Drive Plate (A/T) 1, Remove any old sealant from the bolts and bolt holes. If ald sealant cannot removed from the bolt, replace it 2. Apply sealant to the bolt threads. (Mm) 3, Install, and tighten the fywheel with the SST. Tightening torque: 96—103 Nan (9.8—10.5 m-kg, 71—76 ft-lb) an, 4, Install, and tighten the drive plate adapter, drive plate, and backing plate with the SST. Tightening torque: ‘96—103 Nm (9.8—10.5 m-kg, 71—76 ft-lb) Clutch Disc and Clutch Cover (M/T) Install the clutch disc and clutch cover using the SST. (Refer to Section 1) Tightening torque: 18—26 Nm (1.8—2.7 m-kg, 13—20 ft-lb) Water Pump 1. Remove all din, grease, and other material from the water pump mounting surface. 2. Place a new gasket in position B1-55ASSEMBLY (CYLINDER HEAD) 3, Install the water pump. Tightening torque: 19—25 Nm (1.92.6 m-kg, 14—19 ft-lb) Tame 23-290m Go40 ema, 26-95 nb) GASKET, REPLACE CS ay 3 8 & beASSEMBLY (CYLINDER HEAD) B1 Valve Seal . 1. Assemble the SST as shown so that the depth L is as ‘specified. Depth L: 21.6—22.0mm (0.850—0.866 in) 2. Install a new valve seal onto the valve guide. 3. Install the SST onto the valve seal. 4, Tap the valve seal in until the SST contacts the cylinder head. Valve and Valve Spring 1. Install the lower spring seat 2. Install the valve. a 3. Instal the valve springs (outer and innef) and the upper spring seat. OO Note Install the outer valve spring with the closer pitch to- © ward the cylinder head, CYLINDER HEAD SIDE sae 4, Compress the valve spring with the SST; then install the valve keepers. 5. Tap the end of the vaive stem lightly two or three times with a plastic hammer to confirm that the keepers are all fully seated sau Bi-57ASSEMBLY (CYLINDER HEAD) me OL RESERVOIR Cylinder Head 1. Thoroughly remove all dirt oi, or other material from the top of the cylinder block. 2, Place the new cylinder head gasket in position 8, Install the cylinder head. 4, Apply engine oil to the bolt threads and seat faces. 5, Tighten the cylinder head botts in two or three steps in the Tightening torque: ‘80—86 Nm (6.2—8.8 m-kg, 59—64 ft-lb) Camshaft 1. Apply a liberal amount of engine oil to the journals and bearings, 2. Place the camshatt in position with the dowel pin facing straight up. ~ Hydraulic Lash Adjuster (HLA) 4. Pour engine oil into the oll reservoir in the rocker arm, 2. Apply engine oil to the new HLA, 8. Carefully install the HLA into the rocker atm. Caution Be careful not to damage the O-ring when installing the HLA. ‘Camshaft Gap, Rocker Arm and Shaft Assembly 1. Assemble the rocker arm and shaft assembly as shown in the figure. Caution Be sure that rocker arm shaft oil holes (in the center camshaft cap) face each other. Note Use the installation bolts for alignment.~ ASSEMBLY (CYLINDER HEAD) B1 2. Apply silicone sealant to the shaded areas shown in the figure. 3. Apply liberal amount of clean engine oil to the cam lobes, and journals. 4, Install the rocker arm and shaft assemblies. Tighten the bots in two or three steps in the order shown in the figure. ALA) ree oe Nin (82.7 mkg oc) Are }8—26 Nm (1.8—2.7 mkg, 13-20 ft ue Front Housing 1. Apply engine oil to the front housing and a new oil seal. 2. Press the oil seal into the front housing. 3. Apply engine oil to the oil seal lip. 4. Install the front housing and a new gasket. Tightening torque: 19-25 Nam (1.9. 6 mekg, 14—19 ft-lb) Cylinder Head Cover 1. Apply silicon sealant to the shaded areas shown in the figure. 2. install the cylinder head cover. Tightening torque 2.9-3.9 Nm (3 40 cm-kg, 26—35 in-Ib) B1-59BI TIMING BELT Torque Specifications ASSEMBLY (TIMING BELT) 05 Ne (70—100 cokg, 6187 ins) (16.017. 116-125) eo, 5575, 19, en (ag, 0) ea01E 700 Camshaft Pulley 1. Install the camshaft pulley on the carnshaft with the dowel Pin fit into the hole at the #1 mark. = 2. Tighten the camshaft pulley lock bolt. Tightening torque: 47—65 Nm (4.86.6 m-kg, 35—48 ft-lb) Lh poco TOTASSEMBLY (TIMING BELT) B1 TENSIONER, Taso 8. Align the #1 mark on the pulley with the matching mark on the front housing, Timing Belt Pulley 1. Reverse the direction of the SST. (Refer to page B1-55.) 2. Install the crankshaft key. 3. Install the timing belt pulley on the crankshatt. Tightening torque: 187—167 Nam (16.0—17.0 m-kg, 116—123 ft-lb) 4. Release the ring gear brake 5. Align the timing belt pulley and the oil pump body match: ing marks. Timing Belt Idler Pulley Install the timing bett idler pulley. Tightening torque 37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb) Timing Belt Tensioner 1. Install the timing belt tensioner and tensioner spring 2. Tentatively secure the tensioner with the spring fully ex- tended, Timing Bett 1. Install the timing bet. (keep the tension side of bettas tight as possible.) Caution a) If the timing belt is being reused, it must be rein- stalled to rotate in the original direction. b) Check that there is no oil, grease, or dirt on the tim- ing belt. 2. Turn the crankshaft twice in the direction of rotation. 3. Check that the matching marks are correctly aligned. If not aligned, remove the timing belt and tensioner, and repeat the above-mentioned procedure. 4. Loosen the tensioner lock bolt and apply tension to the bet. Bi-61ASSEMBLY (TIMING BELT) 5. Tighten the timing belt tensioner lock bolt. Tightening torque ae 37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb) 6. Tum the crankshaft twice in the direction of ratation and align the matching marks. 7. Check the timing belt deflection. Ifthe deflection is not correct, loosen the tensioner lock bolt and repeat steps 3—5 above. Replace the tensioner spring if necessary. BECO” Paint Belt deflection/98 N (10 kg, 22 Ib) | New : 8.0—9,0mm (0.31—0.35 in) | Used: 9.0—10.0mm (0.35—0.39 in) amo Baffle Plate Position the baffle plate on the timing belt pulley ‘Timing Belt Cover Install the lower timing bett cover, upper timing bett cover, and. new gaskets, a Tightening torque: 6.99.8 Nm (70—100 cm-kg, 61—87 in-Ib) Crankshaft Pulley Install the crankshatt pulley. Tightening torqu 12—17 Nam (1.25—1.75 m-kg, 9—13 ft-lb)ASSEMBLY (AUXILIARY PARTS) B1 AUXILIARY PARTS Torque Specification 39-25 (19-24, 14-19) < GASKETS, REPLACE \ 13-20 do, ae Tat asker, cosa eands, 09) REPLACE REECE Ne (mg, | Oil Pressure Switch Install the oit pressure switch. Tightening torque: 12—18 Nm (1.2—1.8 m-kg, 8.7—13 ft-lb) Oil Fitter 1. Apply a small amount of engine oil to the rubber seal of the new filter. 2. Install the oil fiter and tighten it by hand until the rubber seal contacts the base. ——amsiem — 3. Then tighten the filter 1-1/6 turn with a wrench. B1-63ASSEMBLY (AUXILIARY PARTS) Coolant Inlet Pipe and Bypass Pipe 1 Install the coolant inlet pipe with a new gasket Tightening torque: 19-25 Nm (1.9—2.6 m-kg, 14—19 ft-lb) 2. Apply vegetable oil to the new O-ring. 3. Install the coolant bypass pipe. Tightening torque: 19-25 Nim (1.92.6 mekg, 14—19 ft-b) Fuel Pump (Carburetor M/T) 1. Apply engine oil to the fuel cam contact surface. 2. Install the fuel pump with the insulator and new gaskets. Tightening torqui 19-25 Nm ( 2.6 m-kg, 14—19 ft-lb) Seal Cap 1. Apply slicone sealant to the new seal cap. 2 Install the seal cap into the cyiinder head. Engine Hanger Install the front and rear engine hangers. Tightening torque: 19—30 Nm (1.9—3.1 m-kg, 14—22 ft-lb)ASSEMBLY (AUXILIARY PARTS) B1 Sue Cooling Fan Bracket Install the cooling fan bracket. Tightening torque: ‘63-93 Nam (6.4—9.5 m-kg, 46—69 fb) Alternator and Alternator Bracket 1. Install the altemator bracket. Tightening torqu 3763 Nm (3.8—6.4 m-kg, 27—46 ft-lb) 2. Install the alternator. Tightening torque Bolt A: 31—46 Nm (3.2—4.7 m-kg, 23—34 ft-1b) Bolt B: 37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb) Intake Manifold Assembly 1. Place the new gasket in position. 2. Install the intake manifold assembly. 3. Tighten the bolts and nuts in two or three steps. Tightening torqui 19—25 Nm (1.9—2.6 m-kg, 14—19 ft-lb) Thermostat and Thermostat Cover 1. Install the thermostat into the water outlet with the jiggle pin at the top. 2. Position a new gasket with the printed side facing the wa- ter outlet 8. install the thermostat cover. Tightening torque 19—25 Nin (1.9—2.6 m-kg, 14—19 ft-lb) Spark Plug 1, Apply antseize compound or molyodenurr-based lubricant to the spark plug threads 2. Install the spark plugs. Tightening torque: 15—23 Nem (1.5—% 3 m-kg, 11—17 ft-lb) B1-65| BI ASSEMBLY (AUXILIARY PARTS) Distributor 1. Verify that the crankshaft pulley timing mark (yellow) is aligned with the matching mark on the timing belt cover. 2. Apply engine oil to the O-ring and install it onto the is- tributor. 3. Apply engine oil to the distributor driven gear. 4. Align the marks and install the cistrisutor. 5, Loosely tighten the distributor mounting bolt. High-tension Lead Install the high-tension leads.ENGINE STAND REMOVAL B1 ENGINE STAND REMOVAL REMOVAL 1. Remove the engine from the engine stand, 2. Remove the SST from the engine. 3. Install in the following sequence. Torque Specifications oe Ne (mg 8) eae 18 AIC Compressor and P/S Oi! Pump Bracket Install the A/C compressor and P/S oll pump bracket. Tightening torque: 37-63 Nm (3.86.4 m-kg, 27—46 ft-lb) UT B1-67EE Fa ENGINE STAND REMOVAL Engine Mount Install the right and left engine mounts Tightening torque: 37—63 Nm (3.8—6.4 m-kg, 27—46 ft-lb) Exhaust Manifold 1. Install the exhaust manifold with a new gasket. 2. Tighten the nuts in two or three steps. Tightening torque: 22—28 Nim (2,2—-2.9 mekg, 16—21 ft-lb) Exhaust Manifold Insulator Install the exhaust manifold insulator. Tightening torque: 19—25 Nan (1.9—2.6 m-kg, 14—19 ft-b)INSTALLATION B1 INSTALLATION PREPARATION SsT 49 woes 5854 Aust wonch — Warning: Be sure the vehicle is securely supported. 1. Install in the reverse order of removal referring to the Installation note. 2. Tighten all bolts and nuts to the specified torque. Caution After radiator cowling installation, rotate the cooling fan by hand and verify that the fan blade does not touch the radiator cowling. If the fan touches the cowling, adjust the radiator cowling mounting position. Note ‘@) Position the hose clamp In the original location on the hose. 'b)Squeeze the clamp lightly with large pliers to ensure a good fit. ZS ‘CABLE OEFLECTION = = EER Po) ais CO Torque Specifications Me oe peu 087 B1-69INSTALLATION Installation note P/S Oil Pump 1. Instail the PYS oil pump. Tightening torqu 31—46 Nm (3. 7 m-kg, 23—34 ft-lb) 2. Install the PIS oil pump pulley with the SST. Tightening torque: ‘49—59 Nm (5.0—-6.0 m-kg, 36—43 ft-lb) Accelerator Cable Install the accelerator cable. i a Pee eeeeee Cable deflection: 13mm (0.039—0.118 in) fo ye) Nn iC p 7 ie A aimee 26 a Drive Belt TNC COMPRESSOR Install and adjust the drive belt deflection. (Refer to page 81-5.) Note Alternator drive belt can be adjusted after cooling fan installation. / \ ALTERNATOR rs lL PUMP Engine Oit ‘Add the specified amount and type of engine oil. (Refer to Section D.) Coolant ‘Close the drain plug; then fil the radiator and reservoir tank with the specified amount and type of coolant. (Refer to Section E.) Transmission Install the manual transmission. (Refer to Section J.) Install the automatic transmission. (Refer to Section K.) Starter Install the starter. (Refer to Section G.) ‘Check Engine Condition 1, Check tor leaks. 2. Connect the negative battery cable. 8. Perform engine adiustments if necessary. 4, Perform a road test 5. Recheck the oll and coolant levels. couwarore B1-70SPECIFICATIONS TROUBLESHOOTI IDE ENGINE TUNE-UP PROCEDURE . DRIVE BELT. HLA TROUBLE: COMPRESSION... INSPECTION ‘ON-VEHICLE MAINTENANCE, TIMING CHAIN PREPARATION INSTALLATION DISASSEMBLY, PREPARATION AUXILIARY PARTS, CYLINDER HEAD. CHAIN CASE AND lL PAN BALANCER CHAIN AND TIMIN CYLINDER BLOCK vessoee INSPECTION AND REPAIR PREPARATION CYLINDER BLOCK’... BALANCER CHAIN AND TIMING CHAIN CHAIN CASE AND OIL PAN... CYLINDER HEAD AUXILIARY PARTS, ENGINE STAND REMOVAL REMOVAL. INSTALLATION PREPARATION. B2INDEX HYDRAULIC LASH AGJUSTER (HLA) INSPECTION, PAGE B2—6 COMPRESSION INSSECTION, PAGE B2— STANDARD: 1.258 kPa (12.8 Hal, 182 psl}270 rpm ae maN Set KPa (100 Kalen, 42 pe-280 pm EXHAUST MANIFOLD TONTENING TOROUE aoa gate) intake MANIFOLD “TGHTEWNG TORAU! 19-25 (19-28, 118) Bp { _ENGINE COOLANT KISPECTION, 'SEAVIGE, SECTION E ENGINE OIL INSPECTION, 2) SERVICE, SECTION D DRIVE BELT ADJUSTING, PAGE B2—5 DEFLECTION mm (r98 N (10 ke, 22) DRIVE BELT NEW. USED, iNT qo.0—120 70-180 16 auTennaToR | ose—oa7 | (49-051) (08) 66-72 72-80 10 PISO PUMP | @2s-o20 | (028-051) (039) ne 35—100 x00-115 16 compressor (oss—osy | (.90-048) 059) a aaa 4. Engine 2. Timing chain Removal page B2-24 Removal... page B2- 9 Disassembly .. vreau age B2-29 Installation, page 82-10 Inspection and Repair... Page B2~39 Inspection .e.esn page B2-51 Assembly. ar www Dage B2-52 3. Cylinder head gasket Installation ...vrsenneeen page 82-79 Removal a page B2-14 Installation. page B2-17 B2-2OUTLINE, TROUBLESHOOTING GUIDE B2 OUTLINE ‘SPECIFICATIONS = are : a are Ta Tn a [intr ree ‘ee Sana aa Tata ae ma mas onsosot a Spas seme ae aa TAT Toor a ie Ses — ae = oe ‘Open BBDC Ca [se sre} > es a a Aca patsaed x mm (in) 0; Maintenance free Tiss fa ioe Roa fe pony om Tet ae eon ig ng (Cd Sah rere — a TROUBLESHOOTING GUIDE = Penis Ge a Oia ring Wain otros ooo re a teva Fees cn nw oan BE anger | aby Hamat i a Motion sao ie a Ht ot ae ie arb eae a wonton pose es Ae ca rae [Bowne | resis [se a Maifunction of fuel system | Reter to Sootion F2 a a mean Mn Sy BEE ome | Sy ivan oe serene fesse ear ge Pa ND B2~31 B2 TROUBLESHOOTING GUIDE Problem Possible Cause |___ Remedy insufficient power | Insufficient compression ~ | Maltneton ot HLA Replace 2-45 | Compression leakage from valve seat Fepar Bo42 Seveed vave som Repace 82-40 Weak or broken valve epsng Repace e213 Falled yimder head gasket Replace | peta Grackod or cistorted cyinde head | Replace | seo Staking, damages, or wer pion rng | Replace Boar Graoket of worn giston Replace __| bear Malfunction of fuel systom Refer to Section F2 / Others | Stoni cltcn Refer o Section H Braacing takes Fier to Seaton P ae Wrong 220 tree Reterto Secon | “Abnormal aitunction of engine-elated components combustion Matuncton of HUA | Replace Stoking of burned valve | Repiace Weak or broken valve sping Repco | avon aooumuaion rcombustion chamber Elmina carbon ae [ Matfunetion of fuel system Rots to Secon F2 Engine noise Crankshaft or bearing related paris Excessive main bearing oil clearance Replace or repair | B2-56 Man boating sazed o Neal dameged Repace | s249 Sreeselve crontchat end pay Repace o rept 82.6 Excenive connecting 108 bearing ol clearance Fepiace oF ropa 82-87 | Ecrnetng oa bout sezee ot Feskcemapee __ | Repace B28 Balance shaft related parts. 1 Improper balanestchein torsion Adjust e203 Eroeeeive alence srt bushing ol laaranco Replace 32-50 | Branco en tuhingcezoa oMewtdaraged ___| ple 82-50 Piston-related parta ‘Worn eylinder Replace or reper | 82-45 Worn geton or piston pin | Replace | aad Sozed peton | Replace bear Semaged prion rg Replace bo—7 Bent conngcing 10d Replace 52-48 Valves or timing-rlated parts | Malncton of HLA 225 | Broken valve song BS Excessive valve gude clearance Bot | Kaatuneton of enan auster aaa Boe attunetion of cooling system I jeysten selon | Malfunction of fuel system, Taster to Secon F2 Refer to Section E | tmproper ervetbet tension pou a2 5 atunaton of atornator beeing Fate to Seaton @ Exhaust gas leakage Fier to Section F2 coo + Tappet noise may ooour if the engine is not operated fox an extended paiod, The nose shod ape ater the engine has reached normal operating temperature,ENGINE TUNE-UP PROCEDURE B2 [ALTERNATOR LTE _— LOCK BOLT BRR ADJUSTING BOLT _—Locknur ENGINE TUNE-UP PROCEDURE DRIVE BELT 1. Check the drive belts for wear, cracks, or fraying; replace if necessary. 2, Cheok the drive belt deflection by applying moderate pres- sure (98 N, 10 kg, 22 Ib) midway between the pulleys Note 2) Measure the belt deflection between the specified pulleys. b)A belt Is considered “New” if it has been used on @ running engine for less than five minutes. Set the deflection specified below accordingly. ©) Check the belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. 8. the deflection is not within specification, adjsut i Deflection Lookxtr ne CouueResson| mete) [Dine ot Tar Ta ee pemmema a eae ae eee | Alter (039-047) _|_@43—051) os | sgara | Saree e Peete | oie-a2) | @m-0%) | om _| a tei00 3 (wecommessce ee) ree 3S, Se omer | 65.8% os) Drive belt tension check Note @)Belt tension can be checked in place of belt deflection. b)Belt tension can be measured between any two pulleys. 4. Check the drive belt tension with the tension gauge. Tension N (kg, Ib) SS [Gre ar wa Tin ed auonar | eonee | aibe 8iaiio | sase=n |e fica | aaa] 5 rsctrne | aa | ‘en wee | reas | 240 | 3-38 | ieee ee ee ee we raidig) | 1085 18g |e Adjustment Caution Ifa new belt is used, adjust belt deflection at the mid- Point of “New” belt specification. A belt is considered “New” if ithas been used on a running engine for less than five minuetes. (1) Alternator belt lt necessary, loosen the alternator bolts and adjust the belt deflection by tuning the adjusting bolt Tightening torque Bolt A: 19-25 Nm (1.9—2.6 m-kg, 14—19 ft-1b) Bolt B: 3752 Nm (3.8—5.3 m-kg, 27—38 ft-lb) B2-5ENGINE TUNE-UP PROCEDURE, COMPRESSION (2) PIS oil pump belt if necessary, loosen the locknut and adjust the belt deflection by turning the adjusting bot. Tightening torque: '37—52 Nam (3.8—5.3 m-kg, 27—38 ft-lb) (@ AIC Compressor belt If necessary, loosen the locknut and adjust the belt deflection by turning the adjusting bolt Tightening torque: 37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb) SES WH an! HLA TROUBLESHOOTING GUIDE Problem T Possible Cause ‘Retion. TNs when enaine is stariad immediately | Oi feskage in of Run engine at 2000 2000 fort alter otis changes. passage 1 noise stops after 2 aecond—10 minutes, HLA is 2, Noise when engine Is started after setting ‘normal approx. ane day. ___} Hrmot, replace HLA. | 5 Rec chen Engine W Hare afer Gank | OF eakage in | * Time requiod fs engine of fe croatia within ene ing for 8 seconds or more. HLA ‘gine, includes tolerance far engine oil condition and 14, Noise when engine is started after new ‘smibient temperature, HLA ig installed 'B Noise conlinues more than TO minutes. | Insufficient ol ‘Check oF pressure, (Reler to Section D) pressure | Wiower than specication, check for cause. ‘Oil pressure; 304—402 kPa (@.1—4.1 kglom?, 44—58 psi)-3000 rpm. Fauty ALA (idler to page 82-69) Press down rocker atm by hand, IR moves, replace HLA. Fit does not move, HLA Is normal ‘Measure vaive clearance. more than Omm (0 in), replace HLA. aa & Noise occurs during ide aiter high-speed | Tnoorrect of ‘Check ai level running amount Drain or add cil 2s necessary, Deteriorated of} Chock oil quality. If deteriorated, replace with specified type and amount ot ol. COMPRESSION INDICATOR eg Ifthe engine exhibits low power, poor fuel economy, oF poor idle, check the following: + Ignition system (Refer to Section G.) 2. Compression 8. Fuel system (Refer to Section F2.) INSPECTION 1. Check that the battery is fully charged. Recharge it if necessary. TaCEE ORPossible Cause COMPRESSION B2 2. Warm up the engine to the normal operating temperature. 8. Tum it off for about 10 minutes to allow the exhaust mani {old to cod, 4, Remove ail spark plugs. 5. Disconnect the primary wire connector from the ignition col & Connect a compression gauge to the No. 1 spark plug hole. 7, fully depress the accelerator pedal and crank the engine, 8. Note the maximum gauge reading, 9. Check each cylinder. Compression: 1,255 kPa (12.8 kg/em’, 182 psi}-270 rpm Minimum: 981 kPa (10.0 kg/em?, 142 psi)-280 rpm ‘Chock compression once mate G,carpPression is low, pour heavy oil into the cylinder and turn the erankshat several bes 1 S 's compression inereasaq? YES J Worn pion o piston ings 2 Worn cyinder wal | No eee 1. Detective cyinger head gasket 2. Distorted cylinder head yt 's compression in adjacent eyinder low? FS. [No | + improper valve seatng 2. Valve sticking in quids 3. Defective cyinder head gaskot a waa/B2 ON-VEHICLE MAINTENANCE (TIMING CHAIN) ON-VEHICLE MAINTENANCE TIMING CHAIN Preparation sst 49 8120710 Hoe, counting === flange Pre-inspection Timing chain 4. Cheek the chain tension; ithe sleeve protrudes 13 notches or more, replace the timing chain. 2. Push the chain lever in the direction of the arrow. Ifthe ex- coseive movernent exists, there will be a chain adjuster mal- funelion or worn chain lever, chain guide, camshaft pulley and timing gear. Inspect and replace it necessary. 3. Push the chain adjuster sleeve in the direction of the arrow. Itit moves back. the ratchet wil be faulty. Replace the chain adjuster. Balancer chain Note Balancer chain must be replaced if chain guide © bottoms at point F when adjusting. eroON-VEHICLE MAINTENANCE (TIMING CHAIN) Release the fuel pressure. (Refer to Section F2.) 1. Disconnect the negative battery cable. 2. Drain the engine oil and coolant 3. Remove the radiator cowiing and cooling fan. (Reter to Section E.) ‘4. Remove the cylinder head. (Refer to page B2~-14.) 5. Remove the ail pan. (Refer to Section D.) 6. Remove in the order shown in the figure referring to the Removal note. B2 1. Drive belts 12. Chain guides 2. Water pump pulley 18. Idler sprocket assembly 3. Alternator and bracket 414, Crankshaft sprocket 4. PIS oil pump and bracket 18. Balancer chain 5. AIC compressor and bracket 16. Chain adjuster 6. Water pump 1?. Camshaft pulley 7. Coolant bypass pipe 18. Timing chain and timing gear 8 Crankshaft pulley 19. Key 9. Chain cover 20. Chain lever 10. Spacer 21. Chain guide 11. Idler sprocket assembly lock bolt POETS B2-9| B2 ON-VEHICLE MAINTENANCE (TIMING CHAIN) Removal note Crankshaft pulley Remove the crankshaft pulley with the SST. | 5 Inspection | j Inspection of siving chain relates pars, (efor to page B2-51) | F Ingpection of balancer chain related parts. (Refer to page B2-51,) | Installation | Insta in the reverse order of removal referring to the Installation note. . Note | a) Position the hose clamp in the original location on the hose: b)Squeeze the clamp lightly with large pllers to ensure a good fit. Torque Specifications t aneON-VEHICLE MAINTENANCE (TIMING CHAIN) B2 Installation note Timing chain 1. Install the key onto the crankshatt 2. Insiail the timing chain and the timing gear as shown, Camshaft pulley 1. Assemble the camshaft pulley to the timing chain so that the mark on the pulley aligns with the white link on the chain, 2. Secure the pulley and the chain with a wire to prevent dis. engagement. Chain adjuster 1. Insert the pin into the lever hole to hold the sleeve, 2. Install it onto the cylinder block. Tightening torque: 7.8—11 Nm (0—110 cm-kg, 6995 in-tb) Note Do not forget to remove the retaining pin betore in- stalling the service cover. Balancer chain related parts (Refer to page B2-60,) Chain cover 1. Insiall the chain cover with new gaskets. Tightening torque: 19-25 Nem (1.9—2.6 m-kg, 14—19 ft-lb) 2. Tighten the oi strainer stay bot. Tightening torque: 7.8—11 Nm (80—110 cm-kg, 69—95 in-ib) B2-11i & B2 ON-VEHICLE MAINTENANCE (TIMING CHAIN) Water pump: Install the water pump with a new gasket 2.6 m-kg, 14—19 ft-1b) Coolant bypass pipe ‘Apply vegetable oil fo the new O-ring and instal the coolant bypass pipe. Tightening torque: '37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb) Crankshaft pulley instal the crankshaft pulley with the SST. Tightening torqui 177—196 Nm (18.0—-20.0 m-kg, 180—145 ft-lb) il pan +7. Apply a continuous bead of silicone sealant to the oll pan ‘along the inside of the bolt holes, and overlap the ends. 2. Instal the oil pan. Tightening torque: Fig—-11 Nem (80—110 cm-kg, 69-95 In-Ib) Cylinder head gasket {Thoroughly remove all dirt and oil from the top of the cylin: der block with a rag 2. Apply silicone sealant to the shaded area. 3. Place a new oylinder head gasket in position.ON-VEHICLE MAINTENANCE (TIMING CHAIN) B2 Cylinder head 1. Set the cylinder head in place. 2. Apply engine oil to the bolt threads and seat faces, 8. Tighten the cylinder head bolts in two or three steps in the order shown. Tightening torque: 80—86 Nm (8.2—8.8 m-kg, 59—64 ft-1b) 4. Tighten the remaining small cylinder head bolts @). Tightening torque: 16-23 Nm (1,642.3 m-kg, 12—17 ft-b) Steps After Installation 1. Install the radiator cowiing and cooling fan, Refer to Section E,) 2. Adjust the drive belt tension. (Refer to page B2-5) 8. Add engine cil and coolant to the specified levels, 4. Connect the negative battery cable. 5, Start the engine and do the following: (1) Check tor leakage of engine oil and coolant, 2) Perform engine adjustments if necessary. sams (3) Recheck the ail and coolant levels. B2-13ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) | PYLINDER HEAD GASKET 1H | Preparatior 2. Drain the engine cool 3. Remove in the order ant. chown in the figure referring to the Removal note. | B2-14 TanON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) B2 1. Accelerator cable 2. Air intake pipe and resonance chamber 3. AIC drive belt and idier 4. High-tension lead and spark plug 5. Radiator upper hose 6. Brake vacuum hose 7. Oil cooler water hose 8. Canister hose 9. Fuel hose 10. Oxygen sensor connector 11. Solenoid valves (008 em (3.7 in a ste oR 12. Emission hamess connectors 13. Cylinder head cover 14. Distributor 18. Distributor drive gear 16, Camshaft pulley 17. Intake manifold bracket 18, Exhaust pipe and bracket 19. Cylinder head bolt 20, Cylinder head 21. Cylinder head gasket ouvoscose Removal note Fuel hose Note 4) Cover the hose with a rag because fue! will spray ‘out when disconnecting. b)Keep sparks and open flame away from the fuel area. Plug the disconnected hoses to avoid fuel leakage, Distributor 1. Turn the crankshaft pulley until the timing mark of the cam- shaft pulley is 99° degrees to the right as shown, 2, Check that the crankshaft pulley timing mark (yellow) is aligned with the indicator pin 8. Remove the distributor. Caution Do not turn the crankshaft during removal and instal. lation. Distributor drive gear 1. Lock the crankshatt pulley with the SST. 2, Remove the distributor drive gear, Camshaft pulley 1. Remove the service cover on the chain cover. 2. Push the chain adjuster sleeve in toward the left and insert the pin as shown into the lever hole to hold it Caution Be especially careful that the pin does not fall. * B2-15ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) 2, Secure the camshaft pulley and the chain with a wire 2s shown. 4, Remove the camshaft pulley off the camshaft dowel pin. Cylinder head bolt 1, Remove the bots ®. 2. Logsen the remaining cylinder head bolts in two or three steps in the order shown in the figure.ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) B2 Installation Install in the reverse order of removal referring to the Installation note. Note Position the hose clamp In the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit. Torque Specifications 1e23 6-25, 2219 re2s1.9-46, 19)B2 ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) Installation note Cylinder head gasket 1. Thoroughly remiove all dirt and oil from the top of the eylin- ~ der block with a rag. 2. Apply silicone sealant to the shaded area. 3, Place a new cylinder head gasket in postion, Cylinder head 1. Set the cylinder head in place. 2. Apply engine oil to the bolt threads and seat faces. 3, Tighten the cylinder head bolts in two or three steps in the ‘order shown in the figure. Tightening torque: ‘80—86 Nm (8.2—8.8 m-kg, 59—64 ft-lb) 4, Tighten the remaining small cylinder head bolts @. Tightening torque: 16—23 Nem (1.6—2.3 m-kg, 12—17 ft-lb) ‘Camshaft pulley 1. Install the camshaft pulley onto the camshaft dowel pin. 2, Remove the wite securing the camshaft pulley and the chain. 3, Remove the retaining pin from the chain adjuster. 4, Install the service cover with a new gasket. Tightening torque Bolt: 7.811 Nm (80—110 cm-kg, 69—95 in-Ib) Nut: 6.99.8 Nan (70—100 cm-kg, 61—87 in-Ib)ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) B2 Distributor drive gear 1. Install the distributor drive gear with a new washer and lock bolt. 2. Hold the camshaft with a screwdriver as shown in the figure. 3. Tighten the lock bolt Tightening torque: 49-61 Nm (6.0—6.2 m-kg, 36—45 ft-lb) 4. Apply sealant to the shaded area as shown, and install the new seal cover. Distributor 1. Verify that the timing mark on the camshaft pulley is 90 degrees to the right, as shown, 2. Verily that the crankshaft pulley timing mark (yellow) is aligned with the indicator pin. 3. Apply engine oil to the new O-ring and install it onto the dis. tributor. 4. Apply engine oil to the distributor driven gear. 5. Align the marks and install the distributor. 6. Loosely tighten the distributor mounting bolt. Cylinder head cover 4. Apply engine oi to the valves, rocker arms and timing chain, 2. Remove all old silicone sealant from the cylinder head and cover, 8. Coat a new gasket with silicone sealant, and install onto the cylinder head cover, 4. Apply silicone sealant to the shaded areas shown in the figure. 5. Install the cylinder head cover. Tightening torque: 8.98.8 Nm (60—90 cm-kg, 52—78 in-tb) B2-19aanae oe 4.1G coil 5. Injector harness 2. Distributor 6. Intake air thermosensor 3, Water thermosensor 7. Oxygen sensor 4, Heat gauge unit 8 Idle switch rk plug Install the spark plugs. Tightening torque: 15—23 Nan (1,5—2.3 m-kg, 11—17 ft-lb) Steps After Installation {. Add engine coolant to the specilied levels 2 Connect the negative battery cable. 3, Start the engine and do the following (1) Check for leakage of engine cootan. (2) Perform engine adjustments if necessary. {3} Recheck the oil and cooiant levels aON-VEHICLE MAINTENANCE (FRONT OIL SEAL) B2 FRONT OIL SEAL Preparation ssT 49 8120 710 Holder, couping ==, flange wana Removal 1, Disconnect the negative battery cable, 2. Drain the engine oi. 3, Remove in the order shown in the figure referring to the Removal note. ® 7.811 em (80110 om, #995 inh) zx | — | “WT seus | en (vg, 0) aECaN 1. Radiator cowling 2. Cooling fan 3. Drive belis AUSIMERE eer Page B2-5 4. Water pump pulley 5. Crankshaft pulley 6. Front oil seat B2-21ON-VEHICLE MAINTENANCE (FRONT OIL SEAL) Removal note Crankshatt pulley a Remove the crankshaft pulley with the SST. : Front ail seal Remove the front oil seal with a screwdriver as shown, Installation instal in the reverse order of removal referring to the Installation note. Caution ‘After radiator cowling installation, rotate the cooling fan by hand and verity that the fan blade does not ‘touch the radiator cowling. Ifthe fan touches the cowling, adjust the radiator cowl ing mounting position. Note Position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers =, to ensure a good fit. Installation note Front oil seal 1. Apply engine oil to the new oil seal lip. 2. Fit the oll seal onto the chain cover. ‘3, Tap the oil seal in evenly using a suitable pipe. Ol seal outer diameter: 60mm (2.36 In) Caution The oll seal must be tapped in until itis flush with the ‘edge of the chain cover. Crankshaft pulley instal the crankshaft pulley with the SST. Tightening torque: 477-196 Nm (18.0—20.0 m-kg, 130—145 ft-lb) Steps After Installation +. Add engine oll to the specified levels. 2. Connect the negative battery cable. os 3. Stan the engine and do the following (1) Check for leakage of engine oil @) Perform engine adjustments it necessary. {@) Recheck the oil levels.ON-VEHICLE MAINTENANCE (REAR OIL SEAL) B2 REAR OIL SEAL Preparation ssT 49011 140 49 E011 105 49 E011 108 ing goar brake ‘Stopper Shatt : set Part of (Pan of eS 49 E011 1A0) 49 £011 140) URES 49 E011 104 49 SE01 310A, Collar Clutch dse (Part of centering too! 49 E011 1A) are Removal 1. Disconnect the negative battery cable. 2. Drain the engine oil, ‘3. Remove the transmission. (Refer to Section J2.) 4. Remove the clutch cover, clutch disc, and | flywheel with the SST (49 E011 10) or equivalent and (49 SEO1 310A) Reter to Section H.) 5, Remove the oil seal with a screw driver and a rag. Installation the reverse order of removal referring to the ion note, Installation note Rear oil seal 1. Apply engine cil to the new oil seal lip. 2. Fit the oil seal onto the rear cover. 8. Tap the oil seal in evenly using a suitable pipe. Oil seal outer diameter: 110mm (4.33 in) Caution The oil seal must be tapped in untit itis flush with the edge of the rear cover. Steps After Installation 1, Add engine oil to the specified levels. 2. Connect the negative battery cable. 8. Start the engine and do the following (1) Check for leakage of engine oil (2) Perform engine adjustments if necessary. (8) Recheck the oll fovela, omvorece5| B2~23REMOVAL |] 2 |) 49 woes 5360 i] ft ween Qe Ve S SEE { | orm Release the fuel pressure. (Refer to Section F2.) Disconnect the negative battery cable and remove the battery. Remove the starter Refer to Section G) and transmission. (Refer to Section J2.) | |B. Drain the engine oil and coolant. | | Remove in the order shown in the figure referring to the Removal note. > STEP 4 { TaeREMOVAL B2 4. Undercover 8. Accelerator cable 2. Solenoid valve 9. Air cleaner 3. Cooling fan and radiator cowiing 10. Resonance chamber assembly 4. Drive belts 11. Canister hose 5. Upper and lower radiator hoses 12. Brake vacuum hose 8. Of cooler hose (A/T) 13, Heater hoses 7. Radiator 14. Fuel hoses ceuoegon3 STEP 2 eum 1. Emission harness connectors 5. PIS oll pump 2. Ground wire 6. Exhaust pipe and bracket 3. AIC compressor 7. Lett engine mount nut 4. PIS oll pump ‘pulley 8.Right engine mount nut B2-25| REMOVAL Removal note Fuel hose Warning 2) Cover the hose with a rag because fuel will spray out when disconnecting. p)Keep sparks and open flame away from the fuel area. Plug the disconnected hoses to avoid fuel leakage. P/S oil pump pulley Remove the PIS oll pump pulley with the SST. P/S oil pump, A/C compressor Remove the PIS oll pump and A/C compressor with the hoses til connected to them; secure the pump and compressor as shown in the figure. ~ENGINE STAND INSTALLATION B2 ENGINE STAND INSTALLATION PREPARATION SST 49 0107 6808 Engine stand 49 L010 180 ‘Hanger, engine & Plate oe Be | ata | Sisto 0 Cee 49 L010 101 49 Loto 102 49 Lo10 105, 49 L010 104 Arms Hooks Nuts 6 (an of (Past of ar of 49 LOt0 1A0) 49 L010 140) 49 LO1O 140) TREO Botts Botts (Par of | ar ot “91010 140) qa oe [i INSTALLATION 4. Exhaust manifold insulator 2. Exhaust manifold 3. Engine mount 4. Oil level gauge 1. Remove the parts in the order shown in the figure. 2. Install the engine to the engine stand referring to the Installation note. 5. Oil level gauge pipe and stay 6. A/C compressor bracket 7. Coolant bypass pipe 8. Cooiant inlet pipe B2-27(62h) ENGINE: BOLTS 198mm ‘Ga3 in) | Er eo” } i ae 01 TeSinm_ ) ENGINE STAND INSTALLATION ef] are Daw WASHER Hoo | | Bout Nor [SS THaw Zorn (@.79 in OES “awe Installation note Engine hanger +. install the SST (arms) to the block holes as shown in the figure and loosely tighten the SST (bolts A). 2, Assembie the SST (bolts, nuts, hooks and plate). 8 instal the SST assembly to the respective arms while ad- justing parallelism between the arms and plate by turning the bolts and nuts. Warning Use special caution while turning the engine stand handle to prevent hand Injury. | 4 Tighten the bots and nuts to fx the ssr. 5. Install the engine on the SST.DISASSEMBLY B2 DISASSEMBLY PREPARATION ssT 40011 40 | 29 e011 105 w 49 £011 108 fra oer bake aoe out, SO ECr 140) SEO 180) 49.01% 104 490636 1008 sonora 82 ator tio spina iter SET 140) ] sv eorz012 s9.012 019 49 6012014 Boxy Foot Leck rut Cates (ato ( (fart So'8612 ong fo 5012 0x fo's012 09g 7 7 49 1285 071 ssrorio 491011 oot S ge a | 3 ates tool sot a both | 2 SS Gato | FS | ST one 49 Lor 002 aororioe 49 Lov 006 Suppo Bock 3 sew Pale & tater nee RS (ear of at of SI | BIS ono fe Lott oe OTST o80) 48.011 069 40.014 010 so.oir on as > leper bq ee 8 eet > | Gar oe 48 L011 080) 49 LOTT OAD) 89 L011 040) 1. Code all identical parts (such as pistons, avo piston rings, connecting rods, and vaive springs) so that they Gan be reinstalled in the cylinder from which they were removed 2. Clean the parts with steam; Note During the disassembly of any part or system, wear, or damage. any deformation, blow off any remaining water with compressed air. ‘be sure to study its order of assembly. Also, note ceuoa20%9 B2-29B2 DISASSEMBLY (AUXILIARY PARTS) | RUXILIARY PARTS ‘Remove in the order shown in the figure ou 4. Distributor and high-tension lead 8, Alternator 2. Spark plug 9. Altemator bracket and strap 3. Rear engine hanger 40. PIS oil pump bracket 4. Front engine hanger 14. 01 fiter 5. Thermostat and thermostat cover 12. Oil cooler Servic seen Section E 13. Oil pressure switch 6. Water outlet 14, AIC idler bracket 7. Intake manifold assembly 15. PIS idler bracket B2-30DISASSEMBLY (CYLINDER HEAD) CYLINDER HEAD B2 }; Remove in the order shown in the figure referring to the Disassembly note. 2. Inspect all parts and repair or f | L 1. Cylinder head cover and gasket 2.Seal cover 3. Distributor drive gear Inspect for wear or damage 4. Rocker arm and shaft assembly IN8POCtION «reine 5. Hydraulic lash adjuster (HLA) Inspection mun 6 Service cover 7. Camshaft Inspection ..., 8. Timing chain cover 9. Cylinder head bolt 10. Cylinder head Inspection page B2~45 age B2-45 Page B2-44 19 boit ovens PAGE B2-B9 place as necessary Tae 11. Cylinder head gasket 12. Valve keepers 13. Upper spring seat 14. Valve spring Inspection... 18. Lower spring seat 16. Valve Inspection 17. Valve seal Inspect for wear or damage 18. Valve guide Inspection... Replacement. - Page B2-43 page B2-40 page 82-40 Page B2-41 B2-31B2 DISASSEMBLY (CYLINDER HEAD) Disassembly note During disassembly, inspect the following. +. Camshaft end play eter to page B2-45,) 3. Gamshait journal ol clearance (Refer to page B2-44,) Distributor drive gear oat the SST or equivalent against the flywheel (MIT) or drive plate (A/T). 2, Remove the distributor drive gear. Rocker arm and shaft assembly + Loosen the boits in two or three steps in the order shown in the figure. 2. Remove the rocker arm and shaft assembly together with the bolts, Caution Do not mix up the parts of assembly. the rocker arm and shaft Hydraulic lash adjuster (HLA) Remove the FILA by hand. Ithisis dificult, remove it with pliers. Caution ‘Do not remove the HLA unless necessary because oll Teakage will occur if the O-ring is damaged. | | Camshatt 7. Remove the service cover on the chain cover 2. Push the chain adjuster sleeve in toward the eft and insert the pin as shown into the lever hole to hold it Caution Be especially careful that the PN Ee ny ieee aa 3. Remove the camshaft mace pin does not fall. Cylinder head bolt 1. Remove the boit @ 2. Loosen the remaining cylinder head bolts in two or three steps in the order shown in the figure.DISASSEMBLY (CHAIN CASE AND OIL PAN) B2 Valve Remove the valves from the cylinder head with the SST. CHAIN CASE AND OIL PAN 2. Remove in the order shown in the figure referring to the Disassembly note. 2 Inspect all parts and repair or replace as necessary [ ioe 1. Water pump pulley 4. Oil pan 2. Water pump Inspect for damage SENVICE oeeenniertee -» Section E 5, Chain cover 3. Crankshaft pulley 6. Oil strainer 7: Vibration reducing stifener (VRS) B2-33DISASSEMBLY (BALANCER CHAIN AND TIMING CHAIN) EO BALANCER CHAIN AND TIMING CHAIN +1, Remove in the order shown in the figure 2. Inspect all pants and repair or replace as necessary, 4. Spacer 2 Idler sprocket assembly look bolt 3. Chain guide A Inspect for wear or damage 4. Chain guide 8 Inspect for wear or damage 5. Chain guide C Inspect for wear or damage 6. Crankshaft sprocket inspect for wear or damage: 7. Balancer chain Inspect for wear or damage 8. Left balance shaft assembly Inspection | 2-34 Disassembly note Crankshaft pulley +. Set the SST of equivalent against the flywhee! (M/T) or drive plate (A/T). 2. Remove the orankshatt pulley. referring to the Disassembly note. coo 9. Right balance shaft assembly Inspection ee 40. Chain adjuster Inspection 11. Camshait pulley Inspect for wear or damage 42, Timing chain and timing gear Inspection on : 13. Key 14, Chain lever Inspect for wear or damage 48. Chain guide Inspeet for wear or demage page B2-50 page B2- 8 page 82-51 .. page B2-50DISASSEMBLY (BALANCER CHAIN AND TIMING CHAIN) B2 Disassembly note Idler sprocket assembly lock bolt Loosen the idler sprocket assembly lock bol, before remov- ing the chain guides. Left and right balance shatt assembly 1. Remove the thrust plate lock bolts 2. Pull out the balance shaft assembly, Caution Do not damage the bal ing when pulling out the ice shaft journal and bush- sssembly. 3. Disassemble the balance shaft assembly. Caution Do not use a vise on the journals during disassembly. 4. Distinguish the left and right balance shaft for correct as- sembly because the both shafis and the thrust plates are shaped the same, B2-35' ' | : ' : } ||P Remove in the order shown in I B2 DISASSEMBLY (CYLINDER BLOCK) YLINDER BLOCK | the figure reterring to the Disassembly note. | inspect all parts and repair of replacs WASHER, Restace ae aU 4. Clutch cover (MT), Plate (A/T) 40, Main bearing cap 2 Clutch disc (MIT), Drive plate (AT) 41. Crankshaft 3, Flywheel (MIT), Adapter (A/T) Inspection .. page B2-49 4. End plate 42. Pilot beating (MI) 6. Rear cover 43, Main bearing 6 Connecting rod cap inspect for peeling, scoring, or damage 7, Connecting rod bearing 14, Oil jet Inspect for peeling, scoring, or damage 45. Balance shaft bushing 8. Connecting rod, piston and piston pin Replacement page B2-50 Inspection... pages B2-47, 48 16. Blind plug and screw 9. Piston ring Replacement osone--emnnnss Page B2-B1 Ingpection... ss vnnes PAge B2-AT 47. Cylinder block Inspection. sneenes page B2-45 Disassembly note Clutch cover and flywheel (M/T) or drive plate Remove the clutch cover and flywheel (MT), or drive plate (AT) with the SST or equivalent. B2-36DISASSEMBLY (CYLINDER BLOCK) B2 MEASURING PLACE aan Ne Now — Connecting rod and cap Before removing the connecting rod, clean the bearing, con- ecting rod, and crankpin, and measure the following: 1. Connecting rod side clearance (Refer to page B2-58.) 2. Crankpin oil clearance (Refer to page 82-57 ) Main bearing cap Before removing the main bearing caps, clean the bearings, main journals, and caps, and measure the folowing points, 1. Crankshaft end play (Refer to page B2-56.) 2. Main journal oll clearance (Refer to page B2-56.) Pilot bearing 1. Before removing the pilot bearing, ingpect for sticks or ex- cessive resistance by turning the bearing while applying force in the axial direction 2, Remove the pilot bearing from the crankshaft with the SST if necessary. lacing and/or cleaning the crankshaft, re- ‘move the pilot bearing. Piston and connecting rod 1. Before disassembling the piston and connecting rod, check the oscillation torque as shown, Ifthe large end does not drop by its own weight, replace the piston or the piston pin, 2. Assemble the SST as shown. B2-37DISASSEMBLY (CYLINDER BLOCK) 3. Insert the SST No.2 into the piston pin as shown and fully screw in the SST No.1. 4, Mount the piston and connecting rod in the SST as shown, 5. Press out the piston pin. While removing the piston pin, check the pressure. If itis ower than 4,905 N (500 kg, 1,100 Ib), replace the piston ppin or connecting rodINSPECTION AND REPAIR B2 INSPECTION AND REPAIR PREPARATION ‘SST 1. Clean all parts, being sure or other foreign materials, 2. Inspection and repairs must be performed Caution Do not damage the joi der head or pistons). ints or friction surte Saar 3 49 0248 0104, 49 L012 AO LF | 49.012 002 Romover & Installer set, valve B,® | Beay installer, = sed 8 vag Remove the SST from the engine. 1). Inetall in the following sequence. : Torque Specifications m20 (22-28, 16-21) 4-61 (44-92, 32-49) | : to-an 9a, 20 § ee ae 37-82 (9.853, 27-3) aaa OSES —| Coolant Inlet Pipe and Bypass Pipe 1. Install the coolant inlet pipe with @ new gasket Tightening torque: 19—25 Nim (1.92.6 m-kg, 14—19 ft-lb) | 1 | 1 i | | | | t | ' 1 t | 1 | i i ' | | { | | | | | i | aaa | |ENGINE STAND REMOVAL. B2 EEE 2. Apply vegetable oil to the new O-ring, 3. Install the coolant bypass pipe. Tightening torque: 37—52 Nem (3.8—5.3 m-kg, 27—38 ft-1b) 4. Tighten the intake manifold nut Tightening torque: 19—25 Nm (1.9—2.6 m-kg, 14—19 ft-lb) 6. Tighten the bot Tightening torque: 19-25 Nm (1.9—2.6 m-kg, 14—19 ft-lb) 6. Connect the water hose to the BAC valve. AIC Compressor Bracket Install the AIC compressor bracket Tightening torque ‘37-52 Nm (3.8—5.3 m-kg, 27—38 ft-lb) Oil Level Gauge Pipe and Left Engine Mount 1. Tap in the oil level gauge pipe. 2. Slide the oil level gauge stay over the gauge pipe. 3. Apply sealant to the shaded area in the figure. 4. Install the left engine mount and gauge stay. Tightening torque: 43—61 Nim (4.4—6.2 m-kg, 32—45 fb) 5. Install the oil level gauge. B2-77ENGINE STAND REMOVAL Right Engine Mount Install the right engine mount. Tightening torque: ‘43—61 Nim (4.4—6.2 m-kg, 32—45 ft-lb) Exhaust Manifold 4. Install the exhaust manifold with a new gasket. 2. Tighten the nuts in two or three steps. Tightening torque: 22—28 Nm (2.22.9 m-kg, 16—21 fb) Exhaust Manifold Insulator Install the exhaust manifold insulator. Tightening torque: 19-30 Nm (1.9—3.1 m-kg, 14—22 ft-Ib) ~INSTALLATION INSTALLATION PREPARATION ‘SST 49 Wo2s 585A, Adu wrench TS Tighten all botts and nuts to the specified torques. Warning: Be sure the vehicle is securely supported. STEP 1 Torque Specitications 20-29 20-40, 1-29) ‘TO PREVENT EXCESSIVE NOISE AND VIBRATION, CHECK THAT THE BUSHINGS ARE NOT TWISTED OF OFFSET. B2 Ne og, “aoe B2-79INSTALLATION Engine 1, Suspend the engine horizontally. 2. Install the engine in the engine compartment being careful not to damage the piping. 8. Tighten the engine mount nuts, Tightening torque 34—49 Nm (3! .0 mekg, 25—36 ft-lb) Exhaust Pipe and Bracket 1. Install the exhaust pipe Tightening torque Nut: 34—49 Nn (3.5—5.0 m-kg, 25—36 ft-lb) 2. Tighten the bracket bolt. Tightening torque Bolt; 21—27 Nm (2.1—2.8 m-kg, 15—20 ft-Ib) PIS Oil Pump 1. Install the PIS oll pump. Tightening torque: 31—46 Nan (3.2—4.7 m-kg, 23—34 ftb) 2. Install the P/S oil pump pulley with the SST. 6.0 m-kg, 29—43 ft-lb) AIC Compressor Insta the AIC compressor. Tightening torque: '39—54 Nm (4,0—5.5 m-kg, 29—40 ft-lb)INSTALLATION B2 Emission Harness Connectors aaaeT 1.1G coil 6. Intake air thermosensor 2. Distributor 7. Oxygen sensor 3. Water thermosensor 8. Idle switch 4. Heat gauge unit 9. Oil pressure switch 5. Injector harness 10. Alternator B2-81| 32 STEP 3 ‘orque Specifications GABLE DEFLECTION, INSTALLATION 19-25 (1.9026, 1419) FUEL HOSE “mn (.089—0.178 i) al za-m0 (2-03, 16-23) Brake Vacuum Hose Connect the brake vacuum hose. 71911 Yen (60-110 cg, 6225 Hn) en ka. i)INSTALLATION B2 Heater Hose Conneot the heater hoses. Canister Hose Connect the canister hose. oma Fuel Hoses Connect the fuel hoses. Solenoid Valve 1. Install the solenoid valve, Tightening torque: 7.8—11 Nm (80—110 cm-kg, 68—95 in-Ib) 2. Connect the emission harness connector. B2-83INSTALLATION Resonance Chamber Assembly Install the resonance chamber assembly. Tightening torque Bolt A: 7.8—11 Nam (80—110 cm-kg, 69—95 in-lb) Bolt B: 19—25 Nm (1.9—2.6 m-kg, 14—19 ftb) Cleaner 1. Install the air cleaner. Tightening torque: 7.8—11 Nm (80—110 om-kg, 69—95 intb) 2. Connect the airflow meter connector. Accelerator Cable Install the accelerator cable. Cable deflection: 13mm (0.039—0.118 in) Drive Belt Install and adjust the drive belt deflection. (eler to page 82-5) Note Alternator drive bett can be adjusted after cooling tan installation. Radiator 1. Install the radiator, Tightening torque: '22—30 Nm (2.2—3.1 m-kg, 16—22 ft-lb) 2. Connect the radiator harness, and coolant reservoir hose. 3, Connect the oli cooler hoses. (A/T) TEINSTALLATION B2 4. Connect the upper and lower radiator hoses. Note 4) Position the hose clamp in the original location on the hose. b)Squeeze the clamp lightly with large pliers to en- sure a good omuoee 249 Cooling Fan and Radiator Cowling Install the cooling fan and radiator cowiing, Tightening torque: 7.8—11 Nm (80—110 cm-kg, 69—95 in-Ib) Caution After radiator cowling installation, rotate the cooling fan by hand and verify that the fan blade does not touch the radiator cowling. Itthe fan touches the cowling, adjust the radiator cow!- a ing mounting position. Engine Olt ‘Add the specified amount and type of engine oil. (Refer to Section D.) ‘Transmission Install the manual transmission. (Refer to Section J2.) Install the automatic transmission, (Refer to Section K2.) Starter Install the starter. (Refer to Section G.) Check Engine Condition 1. Check for leaks. 2, Perform engine adjustments i necessary. 3. Pertorm a road test 4, Recheck the oil and coolant levels. B2-85LUBRICATION SYSTEM INDEX. OUTLINE. SPECIFICATIONS. TROUBLESHOOTING GUIDE. ON-VEHICLE INSPECTION... PREPARATION. ENGINE OIL... OIL PRESSURE. ON-VEHICLE MAINTEN, ENGINE OIL. OIL FILTER’ OIL COOLE} OIL PAN... OIL PUMP... PPPPPPPPPPPPPP ee oBucoxoo1INDEX dINDEX 182200 (F2 ENGINE) HYDRAULIC LASH ADJUSTER (HLA) SERVICE, SECTION BY i ENGINE OL sPecincaTion — | ® ® APISERVICE 86 (EC) ‘TOTAL capaciTy Seis (05 US ct 4.0 Imp ad : BK 1. 04 pump 4, Oil pan Removal page D-11 Removal page D- 8 Installation ... page D-15 Installation page D-10 Disassembly “page D-12 —§. Oil pressure Assembly. page D-14 Inspection. page D- 6 Inspection: page D-14 6. Engine oil 2.0il strainer Inspection. page D- 5 Removal and Installation... page D=11 Replacement page D- 7 8. Oil fiter Replacement sve page D= 7 D-2INDEX D a 1826001 (@6 ENGINE) HYDRAULIC LASH ADJUSTER (HLA) ‘SERVICE, SECTION 82 WL CONTROL PUG: ow ver SERVICE, ‘SECTION 82 \, ENGINE OIL SPECIFICATION [API SERVICE 50 (ECiT) TAL CAPs "ACT. 5 ters (6.8 US at, 4.8 Imp a) oo 1. Oil pump 4. il cooler Removal 7 page D-12 Removal and Installation... pago D- 7 Installation page D-iS 5. 0il pan Disassembly page 0-13 Removal pages D- 8, 9 ABSSEMIY nnn page D-14 instalation Page 0-10 Inspection page D-14 6. Oil pressure 2. Ol strainer Inspection. page D- 6 3. Gi iter 7. Engine oil Replacement, page D~ 7 Inspection. page D- 5 Replacement wo page D- 7 D-3iD OUTLINE — OUTLINE SPECIFICATIONS F2 ENGINE | Lubrication eystem Force/ed type | Tp Tread gear {| 01 pure Reet prema kPa Io. eh 734002 0-40. 8-57) “pe Fulton, pape denen {Jo mer { al prot ioral KPa elo, pa 75118 08-12 1-1) I Oll pressure switch activation pressure kPa (kg/om’, psi) 2-25 (0.02—-0.25, 0.28—3.60) k Tota (ry engine) fos US ah mp a 4669.40) Oteapecty [oirpan tos 8 at iro a) 3 n.8a) Otter Ber US at npg 022 (028, 018) Eng ol 7? onice 86 Energy Consrving HEC H) |}.G6 ENGINE {TY Laercation system Foroeed (ype | pe Teechid gear es |] 0 pure ) i at presse Wa Walon ed 32401 40-80, 6771) il Type Fudlfiow, paper element joie = cE - ole pesos cirtal KPa fain? pe) 7e—119 (08-1811) Ol pressure switch activation pressure kPa (kgicm*, psi) 29 (0.3, 4.3) Tova fy engine) Hore (US a imp a 356848 | ol capacity Oil pan Iters (US at, imp.qt) 4.5 (4.8, 4.0) Oi fr ier 08 a mp a) 02 (028, 0.19) 1 [enone ot AP sevice 86 Eneray Gonsoreng HEC H) ! aa || Recommended SAE Viscosity i a ee er ee er |] | Temperature a ae i ee ee ee Engine oil GED i THs t ae smunoeens | peaTROUBLESHOOTING GUIDE, ON-VEHICLE INSPECTION (ENGINE. OIL) D TROUBLESHOOTING GUIDE ON-VEHICLE INSPECTION PREPARATION ssT 49.0187 280 Otrpressure ‘gauge ENGINE OIL Problem Possible Cause Remedy Page Engine hard starting | improper ongine ol Replace D7 Insufficient engin of Ads ol o-7, Excessive ol! ‘ll working up or down Refer to Section ‘consumption 81 (2 engine) or 2 (G6 engine) Oil leakage Repair - Oil preesure drop | Insuficient of ‘had of DT Oil leakage Repair s ‘Worn and/or damaged oll pump gear Repiace D2, 13 Worn plunge (inside ol pum) or weak spring Replace D4 Clogged of strainer Coan es Excosave main bearing or connecting rod beating Fer to Socton loarance 1 (2 engine) or B2 (G6 engine) Waring tamp ‘Ol pressure drop ‘As desctibad above = Muninates white Malfunction of ol pressure switch Ree to Section T engine is running | Walunction of electrical systom Feter to Section T TSO mae 1. Be sure the vehicle is an level ground. 2. Warm up the engine to normal operating temperature and stop it 3. Wait for five minutes. 4, Remove the oiMevel gauge and check the oil level and con- dition. 5. Add or replace oil if necessary, Note ‘The distance between the L and F marks on the level gauge represents 1.0 liter (1.06 US qt, 0.88 Imp qt).D ON-VEHICLE INSPECTION (OIL PRESSURE) I [OIL PRESSURE I | i i | | | i | | i 1, Remove the oil pressure switch 2. Screw the SST inio the pressure switch installation hole, 3. Warm up the engine to normal operating temperature. 4, Run the engine at 3,000 rpm, and note the gauge reading, Oil pressure kPa (holon, ps) Engine Fe 66 71000 Be 147245 (15—2.5, 21-36) 105-206 (1.12.1, 16-80) 3.000 v0 ‘oa--382 (20-400, 42-87) 304-402 @.1—4.1, 44-58) 1. If the pressure is not as specified, check for the cause, and repair. (Refer to Troubleshooting Guide.) F2 ENGINE, OS NY ea (TAN G6 ENGINEON-VEHICLE MAINTENANCE (ENGINE OIL, OIL FILTER, OIL COOLER) D 4 Oe Ieee c i “ oS suo ON-VEHICLE MAINTENANCE ENGINE OIL Replacement 1. Warm up the engine to the normal operating temperature and stop i 2. Remove the oil filler cap and the oil pan drain plug. 3. Drain the ail inio a suitable container. Warning Be careful when draining; the oil is hot. 4. Install the drain plug and a new gasket. Tightening torque: 29—41 Nm (3,0—4.2 m-kg, 22—30 ft-b) 5. Refil the engine with the specified type and amount of en- gine oil 6. Refit the oil filer cap. Oil pan capacity: 3.9 liters (4.1 US gt, 3.4 Imp qt) 4.5 liters (4.8 US qt, 4.0 Imp qu 7, Recheck the oil level after the engine has been run. OIL FILTER Replacement 1. Remove the oil fiter with a suitable wrench, 2. Use a clean rag to wipe off the mounting surface on the engine. 3. Apply a small amount of engine oil to the rubber seal of the new filter. 4. Install the oil fiter until the rubber seal contacts the base, and then tighten the filter 1-1/6 turn with a wrench. 5, Start the engine and inspect for leaks around the filter seal 6. Check the il level and add oil if necessary. Oil filter capacity: (0.22 liter (0.23 US qt, 0.19 Imp qt OIL COOLER (G6 ENGINE) Removal and Installation Remove in the order shown in the figure. Install in the reverse order of removal 1. Water hose 2. Oi Titer 3. Nut 4. Oil cooler Nut tightening torque: 29—39 Nm (3.0—4.0 m-kg, 22~29 ft-lb)my D ON-VEHICLE MAINTENANCE (OIL PAN) OIL PAN | Removal 1. Disconnect the negative battery cable. || 21 Drain the engine oi, | 3. Remove the undercover. UG. Remove the front dlfferential assembly (G6 Engine: Refer to Section M) and center link (Refer to Section N). |. Remove in the order shown in the figure, referring to the Removal note, 6, Inspect all parts and repair or replace as necessary. F2 ENGINE | a) 1 | 711 Wm (60-170 ears, 6998 nse) G 29-41 80-42, 22-20) tHe (vt 0) aoa 4. Gusset plate 4, Drain plug 2. Clutch undercover Inspect for damage to threads 3. Oil pan Inspect for cracks, deformation, or damageON-VEHICLE MAINTENANCE (OIL PAN) D G6 ENGINE 78-11 he (20-110 emg, 69-95 in) heal Ny ms 1. Gusset plate 3. Drain plug yoee Inspect for damage to threads Inspect for cracks, deformation, or damageON-VEHICLE MAINTENANCE (OIL PAN) Ea D-10 aU Removal note Oil pan 1. Remove the oil pan mounting bots. 2 Insert a scraper or a suitable tool between the oil pan and the cylinder block to separate them. 3, Remove the oil pan. Caution Do not bend the oll pan when prying it loose. Installation Install in the reverse order of removal referring to the instal- lation note. Installation note Oil pan 1. Remove any old sealant from the bolts and bolt holes. If the old sealant can not be removed, replace the bolts as necessary. 2, Remove any dit or other material from the contact surfaces. 3. (With gasket) ‘Apply sealart to the shaded areas shown in the figure (6 engine). Then install a new gasket. (Without gasket) Apply sealant continuously to the oil pan around the inside (of the bolt holes and overlap the ends. Caution a) Do not apply sealant to both the cylinder block side and oil pan side. b) After the sealant Is applied, the oll pan must be se- cured within 30 minutes. 4, Apply locking agent to the bo threads. (G6 engine) Note New bolts of the G6 engine do not need extra locking agent because they come with it already applied. 5. Install the oil pan. Tightening torque: 6.9—12 Nm (70-120 cm-kg, 61—104 in-b) 7.8—11 Nm (80-110 em-kg, 69—95 in-tb).. . F2 Engine .. G6 Engine Step After Installation 1. Add engine oll to the specified leve's. 2. Connect the negative battery cable. 3, Start the engine and do the following: (1) Check for leakage of engine oil 2) Perform engine adjustments if necessary. 8) Recheck the oil levels. suusoro%0ON-VEHICLE MAINTENANCE (OIL PUMP) D lL PUMP Preparation sst 49 $120 710 Holder, coupling <._—_-¢=: flange — SORTS Removal F2 Engine 1. Remove the engine. (Refer to Section B1,) 2, Remove in the order shown in the figure, referring to the Removal note. 1981926, 19 | arse asa, 27am ‘O-FING REPLACE LO=12 W (00-120 emg, 68104 indy 85-12 Nem (0120 ems, 61—104 nay ‘2041 (90-42, 22-20) Non nk, ay UOT 1. Timing belt (Refer to Section B1) 4. Oil strainer 2. Timing belt pulley 6. Stiffener 3. Oil pan 6. Oil pump D-11ON-VEHICLE MAINTENANCE (OIL PUMP) Removal note Crankshaft pulley lock bolt Hold the crankshaft pulley with the SST and remove the look bot Removal || G6 Engine 1. Remove the engine. (Refer to Section B2.) 2. Remove the chain case, referring to Section B2 (TIMING CHAIN ON-VEHICLE MAINTENANCE), Disassembly || Disassemble in the order shown in the figure. | Fe ENGINE FACE, THE DIMPLE TOWARD SAE Pum COVER WHEN ASSEMBLING aOR 1, Pump cover 4, Pressure relief valve 2. Outer rotor 5. Oil seal 3. Inner rotor 6. Oil pump body D-12ON-VEHICLE MAINTENANCE (OIL PUMP) D G6 ENGINE FACE THE DIMPLE TOWARD THE PUMP COVER WHEN ASSEMBLING en ekg, 0) ‘oMUeOK Ces 1. Pump cover 4. Pressure relief valve 2. Outer roior 5. Oil soai 3. Inner rotor 6. Oil pump body 7. Water inlet pipe gasket D-13‘Dp ON-VEHICLE MAINTENANCE (OIL PUMP) Inspection 1. Check the following and replace any faulty parts. (1) Distorted or damaged oil pump body or cover, (2) Worn or damaged plunger @) Weak or broken plunger spring Free length: 46.4mm (1.827 In) 2. Measure the following clearances. F2 ENGINE 06 ENGINE Taare Side clearance: Tooth tip clearance: Outer rotor to pump body: 0.10mm (0.0039 In) max. (0.18mm (0.0071 in) max. 0.20mm (0.0078 in) max. Assembly ‘Assemble in the reverse order of disassembly, referring to the Assembly note. ‘Assembly note Oil seal 1. Apply engine oil to the pump body and new oil seal lip. 2, Press the oil seal in evenly using a suitable pipe Ol seal outer diameter: 48mm (1.89 in)... F2 Engine 60mm (2.36 In)... G6 Engine Caution ‘The oll seal must be pressed in until itis flush with the edge of the oil pump body.ON-VEHICLE MAINTENANCE (OIL PUMP) Installation lation note. Installation note Crankshaft pulley lock bolt Tightening torqu wmoxee Steps After Installation {install he crankshatt lock bolt with the SST. D Install in the reverse order of removal, referring to the Instal- 187—167 Nm (16.0—17.0 m-kg, 116—123 ft-lb) 1. Add engine oil and coolant to the specified levels. 2. Connect the negative battery cable 3. Start the engine and do the following: (1) Check for leakage of engine oil or coolant. (2) Perform engine adjustment it necessary. (3) Recheck the oil and coolant levels. D-15COOLING SYSTEM INDEX. OUTLINE SPECIFICATIONS TROUBLESHOOTING GUIDE... ON-VEHICLE INSPECTION PREPARATION .. ENGINE COOLANT. REPLACEMENT AIR BLEEDING ANI RADIATOR CAP COOLING FAN. eo ON-VEHICLE MAINTENANCE... RADIATOR... WATER PUMP THERMOSTATPep EY E INDEX INDEX a ae 182200 (F2 ENGINE) ‘CARBURETOR To HEATER ENGINE COOLANT ® |) | Win HEATER: 7.5 thors (7.9 US at, 661 Imp at) {[} | WTHOUT HEATER: 7.0 Hers (7.4 US at, 62 Imp ad) omnEToE 1. Radiator 3. Water pump Removal, Inspection, and Removal, Inspection, and Installation. page E- 7 Installation orev page E- 8 2. Cooling fan 4, Thermostat ‘Removal and Installation .. page E- 7 Removal, page E~10 Inspection snus page E~ 6 Inspection page E~i1 Installation page E-11 5, Coolant reservoir e-2B2600i (G6 ENGINE) on cooten SERVICE, SEGTION D INDEX BAC VatvE sence, SecTionF ENGINE COOLANT 68 ites (72 US Mt, 60 Imp at RENTS 41. Radiator 3, Water pump Removal, Inspection, and Femoval, Inspection, and Installation... page E- 7 Installation pages E~ 8, 9 2.Cooiing fan 4, Thermostat Removal and Installation page E~ 7 Removal. sree Page E~10 lnspection page E- 6 Inspection .ccnnnnnnnns page E-11 Instafation “page E~11 5. Coolant reservoirE OUTLINE, TROUBLESHOOTING GUIDE DUTLINE BPECIFICATIONS be a Engine model 5 as Cooing system Watecacled, forced srculston With boster 7578, 68) 7579.66) Coola capacity — Hers (US at Imp ct) Without heater 6973.61) 6973.61) | Tyee Centritugal Water pump Winer 20a) Urifed mechanical seat Type Wox Wax, wostage | Opening temperature coer | 9ss-a9s re6—109) | Nam 985808 (188-199 Thexmestat Fultopen temperature soe) 00 72) 100 32) Fullopen itt smn ¢o) 8.5 (0.3) min. ar oo oe mn Type Corugeted fin Radiator Cap valve epering Proeae A os) 74108 (0751.05, 11-18) Type Thermo-modblaod T ae Me 55-65 (191140) Hew | 68-92 (154-106)... NCO [OFF ON CCA ar 65-75 (149-167). linear | — Cosi fan wi 7 2 Number of blades ar 3 7 Outer dameter of lado | MT Seneca ao ren (6) | at 410 (18.4) = oo TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page ‘Overheating Ineufiet coolant ‘de 8 Godan lnekage Repair 7 Redieo: fins cogged Green e7 Raclstor cap matron Replace £6 Cosing fan malfunction Replace a STrerotatmafuncton piace E10 Water pessage cogged Cioan a Wate: pump malunction Repl E68 Corrosion Impurities in coolant epiace Les IGORON-VEHICLE INSPECTION (ENGINE COOLANT) E ON-VEHICLE INSPECTION PREPARATION ssT 49 9200 145 49 9200 146 49 9200 147 pecan hesous sears ee a Ose a ES ey a waa RIDE ENGINE COOLANT Bo Coolant Level (Engine cold) 1. Check that the coolant level is near the radiator inlet port, 2. Check that the coolant level in the coolant reservoir is be- tween the FULL and LOW marks. ‘Add coolant if necessary. Warning a) Never remove the radiator cap while the engine is hot. b) Wrap a thick cloth around the cap when removing It. Coolant Quality 11. Check that there is no build up of rust or scales around the radiator cap or radiator filler neck, 2. Check that coolant is free of oll 3. Replace the coolant it necessary. Coolant Leakage 1. Connect a tester and SST to the radiator inlet port 2. Apply 103 kPa (1.05 kg/em’, 15 psi) pressure to the system, 8. Check that the pressure is held, IF not, check for coolant leakage. Warning When removing either the radiator cap or the tester, loosen it slowly until the pressure in the radiator is released, and then remove it.+004 BOB B BiBuihy By iSoriocicn ‘COOLANT TEMPERATURE °C (7) REPLACEMENT, AIR BLEEDING AND REFILLING SYSTEM Coolant Protection Caution a) Do not use alcohol- or methanol-based coolant. b)Use only soft (demineralized) water in the coolant mixture. +. Measure the coolant temperature and specific gravity with a thermometer and a hydrometer. 2, Determine the coolant protection by referring to the graph shown. if the coolant protection is not proper, add water or coolant. Antifreeze solution mixture percentage coon SE a ee REPLACEMENT Warning a) Never open the radiator cap while the engine is hot. b) Wrap a thick cloth around the cap when loosening. ¢) When removing the radiator cap, loosen it slowly to the first stop until the pressure in the radiator is released, and then remove it. )Use caution when draining hot coolant. Caution a) Do not use alcohol- or methanol-based coolant. b) Use only soft (demineralized) water in the coolant mixture. ¢) Before loosening the radiator drain plug, verify that the radiator drain hose faces straight down. 4. Remove the radiator cap and loosen the drain plug. 2. Drain the coolant into @ suitable container. 3 Fill with the proper amount and mixture of ethylene glycol based coolant. AIR BLEEDING AND REFILLING SYSTEM When the coolant is drained, bleed the cooling system after refiling it ‘| Slowly pour the coolant into the radiator up to the coolant filler port Filling pace: 2 ¢ (2.1 US gt, 1.8 Imp qt)/min. max. 2. Fill the coolant reservoir up to the FULL level. 53 Install the radiator cap securely and start the engine. LCE O0RADIATOR CAP, COOLING FAN E 4. Run the engine at idle speed untl it reaches normal oper- ating temperature. Caution If the temperature increase beyond normal, there is excessive air in the system. Stop the engine, allow the engine to cool, and repeat Steps 1—3. 5. Run the engine above idle several times as specified, Speed: 2,200—-2,800 rpmx5 sec, o 6. Stop the engine and wait tl the system is cooled down, Remove the radiator cap and check the coolant level tithe coolant level has dropped, repeat the operation from Step 1 RADIATOR CAP Radiator Cap Valve 1. Remove foreign material (such as water residue) from be- tween the radiator cap valve and the valve seat. 2. Attach the radiator cap to a tester with the SST. Apply pres- ‘sure gradually to 74—103 kPa (0.75—1.05 kg/em’, 11—15 psi). 3, Wait about 10 seconds; then check thal the pressure has not decreased. En Negative Pressure Valve 1. Pul the negative-pressure valve to open it. Check that it closes completely winen released 2. Check for damage on the contact surfaces and fo cracked oF deformed seal packing 8. Replace the raciator cap i necessary a — ames COOLING FAN Inspection 1. Inspect the following tems. Replace if necessary, (1) uid teakage from the fan-dtive clutch (2) Detormation of the bimetal (G) Excessive play of the cooling tan bearing (2) Grease leakage from the cooling fan bearing 2, When the engine is warm, turn the cooling fan by hand and heok that resistance is felt. Replace the far-drive clutch if necessary. E-7= ON-VEHICLE MAINTENANCE (RADIATOR) N-VEHICLE MAINTENANCE jADIATOR - jemoval, Inspection and Installation . Drain the engine coolant. 2 Remove in the order shown in the figure. Inspect all parts and repair or replace as necessary. 4. Install in the reverse order of removal. Caution After radiator cowling installation, rotate the cooling fan by hand and verify that the fan blade does not touch the radiator cowling. It the fan touches the cowling, adjust the radiator cowling mounting position. Note Position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit. | CHECK FOR ‘THe FOLLOWING AND REPAIR OR REPLACE TF NECESSARY 1. GRACKS, DAMAGE, OR WATER LEAKAGE 2, BENT FINS (REPAIR WITH ‘A SOREWDAWER) 9. DISTORTED Of BENT“ RADIATOR WET ey ao io eg, 2-25 fo) S/ a | Ne eta, sac a "aUOECOR ae 1. Upper and lower radiator hoses 4, Cooling fan and radiator cowling 2. Coolant reservoir hose 5. Radiator 3. ATF hose (A/T) E-8ON-VEHICLE MAINTENANCE (WATER PUMP) E WATER PUMP Removal, Inspection, and Installation 1. Disconnect the negative battery cable. 2. Turn the crankshaft so that the No.1 cylinder is at TOC of compression. (F2 Engine) 3. Drain the engine coolant. 4. Remove in the order shown in the figure, 5. Inspect all parts and repair or replace as necessary. 6. Install in the reverse order of removal After radiator cowling installation, rotate the cooling fan by hand and verity that the fan blade does not touch the radiator cowling, If the fan touches the cowling, adjust the radiator cowling mounting position. B Note Do not disassemble the water pump. if a problem is found, replace the pump as a unit. F2 ENGINE asker, @RePLACE 1825 (10-126, 1499) Nor (vag, to) a Teer 1. Timing belt Reter to Section B1,) 3. Water pump 2. Timing belt idler pulley Inspect for body cracks and damaged gasket surface 4. GasketEe Wi E ON-VEHICLE MAINTENANCE (WATER PUMP) G6 ENGINE EY ras um | (O70 em, 6325 in) aaa 4. Drive belt 4. Water pump Adjustment... Section B2 Inspect body cracks and damaged gasket 2. Cooling fan and radiator cowiing surface 3. Water pump pulley 5. Gasket Steps After Installation 4. Add engine coolant to the specified levels. 2. Connect the negative battery cable. cae 3. Start the engine and do the following: * (1) Check for leakage of engine coolant. (2) Perform engine adjustments if necessary. (@) Recheck the coolant levels. | E-10 SU aaa ‘yoexc00|ON-VEHICLE MAINTENANCE (THERMOSTAT) E THERMOSTAT Removal 1. Drain the engine coolant. 2, Remove in the order shown in the figure. F2 ENGINE THE JIGGLE PIN SHOULD BE ‘ON THE UPPER SIDE G6 ENGINE THE JIGGLE PIN SHOULD BE ON THE UPPER SIDE SEAL PRINT SibE FacING | THE CYLINDER HEAD oe vs / mite? J th | wes B aaster gf (> Carew” — SBe Nev (mg, 4) BUEN? 1. Upper radiator hose 3. Thermostat Inspection... page E-12 2. Thermostat cover E-11E ON-VEHICLE MAINTENANCE (THERMOSTAT) 2 ENGINE Inspection Check the thermostat and replace if necessary. 1, Visually cheok that the vaive is airtight. 2. Place the thermostat in water with a thermometer. Increase the water temperature, and check the following. Installation Install in the reverse order of removal. Note Ta Eton] re ce Inia opening 365-895 [Main 86.589. (188~109) temperase eC (°F) | (185-199) [Sub : 65.5865 (182—188) Fulkopen Fuhopen ec ory | 10221) 100 212) Fuikopen it Main: 60 31) min nm (ay | 88 (039m. | su: 1.5 (0.08) in Position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit. | Steps After installation 1. Add engine coolant to the specified levels. | 2, Connect the negative battery cable. 3, Start the engine and do the following: (1) Check for leakage of engine coolant. (2) Perform engine adjustments if necessary. (3) Recheck the coolant levels, E-12 muoeKo2sFUEL AND EMISSION CONTROL SYSTEMS (CARBURETOR) F1 Fin 2 Fie 6 Fi- 6 Fi 7 VACUUM HOSE ROUTING DIAGRAM. F1— 10 SPECIFICATIONS Fie 12 ‘TROUBLESHOOTING GUIDE. Fin 13 HOW TO USE THIS SECTION. FI 13 DIAGNOSTIC INDEX Fi 15 SYMPTOM TROUBLESHOOTING... F1— 16 FEEDBACK SYSTEM... Fi- 52 PREPARATION Fin 52 ‘SYSTEM INSPECTION’... AIRIFUEL (A/F) SOLENOID OXYGEN SENSOR... ILE, CLUTCH, NEUTRAL, AND AIR-CONDITIONER SIGNALS AIR INJECTION SYSTEM SYSTEM INSPECTION No.1 AIR CONTROL V/ No.2 AIR CONTROL VALVE REED VALVE 7 ACV SOLENOID VALVE. EXHAUST GAS RECIRCULATION (EGR) SYSTEM SYSTEM INSPECTION’ EGR CONTROL VALVE... EGR POSITION SENSOR .... Fi 63 DUTY SOLENOID VALVE. Fi 63 DECELERATION CONTROL SYSTEM... F1— 65 SYSTEM INSPECTION 66 ‘SLOW FUEL CUT SOL VALVE. Fi— 67 COASTING RICHER SOLENOID VALVE F1— 67 VACUUM SOLENOID VALVE. MIXTURE CONTROL VALVE.. DASHPOT (FOR MIT). EVAPORATIVE EMISSION CONTRO! (EEC) SYSTEM. SYSTEM INSPECTION No.1 PURGE CONTROL VALVE... No.2 PURGE CONTROL VALVE No PURGE CONTROL VALVE WATER THERMOVALVE, CHECK-AND-CUT VALVE. AIR VENT SOLENOID VALVE PURGE SOLENOID VALVE CATALYTIC CONVERTER... INSPECTION ssrenesee PTC HEATER SYSTEM PTC HEATER. PIC HEATER Rél os FI~ 61 Fi 62 ALTITUDE COMPENSATION SYSTEM... F1— 76 HIGH-ALTITUDE COMPENSATOR ...... F1— 76 AIR INTAKE TEMPERATURE CONTROL, SYSTEM, I-77 FI- 7 Fi- 78 Fi- 78 Fie 78 IDLE COMPENSATOR ACCELERATOR CABLE. FI 79 FI 79 Fim 80 Fi— 80 Fi 80 VACUUM CONTROL VALVE AIR CLEANER.. AIR CLEANER ELEMENT FUEL SYSTEM. FUEL PUMP & FUEL PUMP (MECHANICAL TYPE). FUEL PUMP CONTROL UNI FUEL FILTER, FUEL TANK,, FUEL CHECK VALVI FUEL CUT VALVE CARBURETOR CONTROL SYSTEM. PREPARATION TROUBLESHOOTING WITH ‘SELF-DIAGNOSIS CHECKER .. WATER TEMPERATURE SWITCH IDLE SWITCH. CLUTCH SWITCH NEUTRAL SWITCH . INHIBITOR SWITCH INTAKE AIR THERMOSENSOR EGR POSITION SENSOR OXYGEN SENSOR ENGINE CONTROL IDLE ADJUSTMENT IDLE SPEED. IDLE MixTURE. IDLE-UP SYSTEM. IDLE-UP FOR Aft OR AIC. HOLE UP FOR AIT WITH Al (DUAL SERVO DIAPHRAGM) IDLE-UP SOLENOID VALVE MALFUNCTION INDICATOR LIGHT (MiL)..INDEX Fi 1. ACV solenoid vaive 20. No.1 Air control valve Inspection page F1— 60 Inspection page F1- 59 2. Air cleaner element 21. No.1 purge control vaive Inspection. s page F1— 80 Inspection page Fi- 70 3. Air vent solenoid vaive 22, No.2 Air control vaive Inspection : page Fi— 72 Inspection. page Fi- 60 4. Airftual (IF) solenoid vaive 23, No.2 purge control valve Inspection page F1- 54 Inspection... page F1~ 71 5. Atmospheric pressure sensor 24, No.3 purge control valve Inspection... .. page F1-106 inspection page F1~ 71 6. Clutch switch 25. Oxygen sensor Inspection .. .. page F1~105 Inspection... page F1— 55 7. Coasting richer solenoid valve 26. PCV valve Inspection .- page Fi- 67 Inspection... page F1- 79 8. Dashpot (lor MT) 27. PTC heater Inspection page F1- 68 Inspection : . page FI- 75 9. Duty solenoid valve 28. Purge solencid valve” Inspection - page Fi— 63 Inspection ... page F- 72 10. EGR control valve 29. Rear catalytic converter Inspection .. ‘i page Fi- 62 Inspection .. 11. EGR postion sensor 30. Reed valve inspection page F1~ 63 Replacement. 12, Engine control unit 31, Servo diaphragm Precaution page F1-109 Adjustment. page FI~114 Inspection nn page F1-109 32. Siow fuel cut solenoid 13. Front catalytic converter InSB2CtiOM wenn page F1~ 67 Inspection ssone Page FI- 74 — 83, Vacuum control valve 14. High-altitude compensator Inspection page Fi— 80 Inspection... page Fi- 76 34. Vacuum sensor 16. Idle compensator Inspection page F1-107 Inspection page FI- 78 35, Vacuum solenoid valve 16. Idle switch Inspection page F1— 67 Inspection page F1-105 36. Water temperature switch 17. Intake air thermosensor Inspection page F1~105 Inspection page F1-107 37. Water thetmosensor 18. Mixture control valve Inspection ... page F1-106 Inspection page FI- 68 38, Water thermovaive 19, Neutral switch Inspection page F1— 71 Inspection .- page F1-105 avon Fi-3