ENGINE (SOHC) SUBARU. 1992 SERVICE MANUAL M MECHANISM AND FUNCTION .. 1. General 2, Timing Bett 3, Belt Tension Adjuster 4. Belt Cover 5, Valve Rocker ASSY 6. Hydraulic Lash Adjuster 7. Camshaft . 8. Cylinder Head . 9. -Cylinder Block 10. Crankshaft . 11. Piston .. $ SPECIFICATIONS AND SERVICE DATA A: SPECIFICATIONS B: SERVICE DATA © COMPONENT PARTS 1, Timing Belt .. 2, Cylinder Head and Camshaft... 3, Cylinder Head and Valve ASSY . 4, Cylinder Block 5. Crankshaft and W_ SERVICE PROCEDURE . General Precautions... . Timing Belt . Camshaft. . Cylinder Head... . Cylinder Block Pg Ree T TROUBLESHOOTING . 1. Engine Trouble 2, Engine Noise . Valve Rocker ASSY ton General‘3a_{M100) ENGINE (SOHC) M MECHANISM AND FUNCTION 1, General The engine is made from aluminum alloy and is hor'- zontally opposed. It is a 4-stroke cycle, water-cooled, SOHC 16-valve engine. Aummary of the major construction and function fea- tures is as follows: ‘¢ The cylinder head is a center-plug type that utilizes pentroof combustion chambers. The four-valve design is provided with two intake valves and two exhaust valves per cylinder. The intake and exhaust ports are arranged © The vaive rocker arm has @ built-in hydraulic lash adjuster which eliminates the need for valve clearance adjustment, © A single timing belt drives two camshafts on the left ‘and right banks and the water pump on the left bank. Belt tension is automatically adjusted to eliminate main- tenance. © The crankshaft is supported by five bearings to pro- vide high rigidity and strength, © The cylinder block is made from aluminum diecast which is integrated with cast-iron cylinder liners, — A Intake ave eka mal Hydraulic " i — 5p aecae Pockr that suppor ae: = = 6) | > aig Extn abe Soark ug camanatt H coe inde hee ae =f Rocker shaft Piston seore Fig. 1 tENGINE (SOHC) IM300]_2. 2. ing Belt Asingle timing belt drives two camshafts (one in the left bank and one in the right bank). The back of the belt also drives the water pump. ‘The timing belt teeth have a spec profile to provide quiet operat lly designed round |. The timing belt is composed of a strong and inflexible core wire, a wear- resistant canvas and heat-resistant rubber material. A hydraulic belt-tension adjuster constantly maintains specified belt tension to properly drive the camshafts, as well as to provide a “maintenance-free” advantage. ‘Timing indiestor (For timing mark of erenksheft pulley). Allgnment mark Alignment mark **Piston ‘pottion mark Paton ‘potition mack Camshaft sprocket LM ‘5-4 piston ie set at TOC whan piston-poution mark on Crankahatt sprocket i aligned with mark on cylinder block, {#1 piston lsat at TDC on compreasion stroke when pitton- otition mark on camthatt sprocket is aligned with mark on Delt cover 82077 Fig. 2 3. Belt Tension Adjuster ‘The belt tension adjuster provides a constant value of tension for the timing belt. Proper belt tension is main- tained using a rod to push the tension pulley. The loca- tion of the tensioner pulley shaft center is offset in rela- tion to the center of the pulley’s outside diameter. ‘The tensioner adjuster rod provides a rotary movement for the tensioner pulley by both tension of the spring housed in the adjuster. 1) Belt tension action ‘The tensioner adjuster rod is moved to the left by the force of the main spring. This causes silicon oil (which is held to constant pressure by compression-spring ten- sion inside the reservoir chamber) to push the check ball so that sifeon ol owe Into the of-pressure cham er. ‘The momentum which forces the adjuster rod out acts upon the tensioner atm so that the pulley is turned counterclockwise. Thus, timing belt tension is properly maintained. 2) Balance to belt tension When the timing belt reaction force is balanced by the main spring tension (to push the adjuster rod), the arm is held stationary to maintain constant belt tension. When the timing belt reaction force increases to such an extent that the belt will be too tight, a small quantity of oil in the oll-pressure chamber gradually returns to the reservoir chamber via the adjuster body-to-rod clearance. This return of oil continually moves the rod until the reaction force of the timing belt balances with main spring force and oil pressure inside the oil-pres- ‘sure chamber. Thus, belt tension is constantly main- tained,2-3a_Im4oo] ENGINE (SOHC) “Tension orm: ‘Tieng belt Adjuster rod Stopper Piston Compression spring { i | } Ze ‘it pressure chamber Oi reservoir chamber (Sticon of Ol seat 2078 4. Belt Cover ‘The belt cover is made of synthetic resin molding which is lightweight and heat resistant. It has a totally enclosed design that utilizes rubber packing at the mat- ing surface of the cylinder block. This eliminates the chance of dust and water from entering the interior. A floating design is utilized by placing rubber mounting between the cylinder block and belt cover to prevent ‘the transmission of noise and vibration. The front belt cover has @ graduated line for ignition- timing confirmation, 5. Valve Rocker ASSY ‘A metal bushing is press-fitted to the rocker arm at the tocker shaft location and a sintered alloy chip casting is used at the frictional surface of the cam. ‘The valve side of the rocker arm is provided with a hydraulic lash adjuster to maintain a “zero” valve clearance, as well as to provide quiet operation and eliminate valve clearance adjustment. The rocker arm on the exhaust valve side has a “Y"- letter design and operates two exhaust valves. The rocker shaft has an oil passage in it. One side of, shaft end is provided with e built-in relief valve. Figt portion S Intake valve roeker armENGINE (SOHC) 6. Hydraulic Lash Adjuster ‘The hydraulic lash adjuster is built into each rocker arm on the valve side. A total of sixteen lash adjusters are employed. ~s vals oe oy Rotetion foree SS) bet dij a Let UKE] e 82.080 {M700]_2-3a 7. Camshaft ‘The cam nose part is finished with “chill” treatment to increase weer resistance and anti-scuffing property, ‘The right- hand camshaft is supported by three journals. inside the cylinder head while the left-hand camshaft is supported by four journals. The flanges of these cam- shafts are also supported by the camshaft support ends to receive thrust force, by thrust force 2.081 Fig. 62-3a_ [M800] ENGINE (SOHC) 8, Cylinder Head “The eylinder head gasket is made from carbon materia} : : {not asbestos). Its core is metal provided with metal Combustion chambers in the cylinder heed ae hooks to increase resistance to both heat and wet compact, center plug, pentroof types which feature a The inner sie maga fo of grommets used in the eylinder bore wide “squish” area for increased combustion eff 46 reinforced with wire to withstand both high com. ciency. Four valves (two intake and two exhaust}, wi bustion pressure and temperature. arranged in a cross-flow design, are used per cylinder. ears Fig. 7 9. Cyl The cylinder block is made from aluminum diee ‘The cylinder perimeter has an open-deck design whi is lightweight, highly rigid and has superb cooling effi ciency. The cylinder liners are made from cast iron and are dry types which are totally cast with aluminum cylinder block. Five main journal block designs are employed to increase stiffness and quiet operation. The oil pump located in the front center of the cylinder block and the der water pump is located at the front of the left-cylinde Block bank. At the rear of the right-cylinder block is a separa ‘tor which eliminates oil mist contained in the blow-by} gas.ENGINE (SOHC) 10, Crankshaft ‘The crankshaft is supported by five bearings to provide high rigidity and strength. The corners of the crankshaft journals and webs, as well as the crank pins and webs, [M100] 2-3a are finished with fillet-roll work to increase stifiness, The five crankshaft bearings are made from aluminum alloy and the No. 3 bearing Is provided with a flanged metal to receive thrust force. ” #2 e 2.084 ‘The piston skirt has a “slipper” design to reduce weight id sliding. The oll control ring groove utilizes a slit i n. The Nos. 1 and 3 pistons are offset in the lower direction while the Nos. 2 and 4 pistons are offset in the upper direc- tion, The piston heed is recessed for both the intake and exhaust valves. It also has symbols used to identify the locetion and the direction of installation. ‘Three piston rings are used for each piston-two com- pression rings and one oil ring, The top piston ring has an inner-bevel design and the second piston ring has an interrupt design to reduce oil consumption. Identification mark (Pieton sie) ‘Location mark (Engin front side) Location mark a interrupt) a Pion one = ‘Upper rait ~~ Lower ra vy Fig. 92-3a_[SOAQ] ENGINE (SOHC) S_ SPECIFICATIONS AND SERVICE DATA A: SPECIFICATIONS orton a a ro TF soa =it [= eater Least fie A Sas one Sara Than oe NTN ceaxn ffl tiisiam waxes H eirbalene mm (ind (a.at8 x 2.08) | (3.62%2.98) 87.0 x 76 (8.461 x 2.96) (3.481 x 2.581) i Piston displacomanm® (ou in)| 2.212 (134.98) | 1,994 (121.671 7,820 (111.08) 1,887 (87.46) Conse a 5 as 7 Conpanien pews | iano aa | ae ae Peer teo—tae, | fet | gg RE ny ‘kPa (kg/em?, psi)| 186 —~ 185) 166 — 195) aa een ra Pasme ing a Bet | lexan [imesh [openne | Peroe [eae a ore ing [Closing 60" ABDC 52" ABDC, ‘58° ABDC 51° ABDC Secs format er toc! i] Ha voce a brenoe timing [Closing 16° ATOC 12° ATOC 12° ATDC & ATOC en oe) reser iio ita need awereore | eostone | “aseea” | wstecean | wets [At neutral (on N} positionypm | load) load) AT: 800 100 vacuum vacuum feces | owen | eden Finger ervey) Wigs | wae | aeon forioe ning erbetpm| zeerorsoo | arasoreco | “aac” | garwcenen | semwrcars ax-20 oro] Marea | MienSTD: Standard 1D: Inner diameter OD: Outer diameter 9 ENGINE (SOHC) {S080} B: SERVICE DATA Eke Protrusion of adjuster rod 154 — 18.4 mm (0.608 — 0.046. adjuster oe rt Spacer Ob Team eam [Tensioner bushing ID 16.16 mm (0.6362 in) Tae if ocean ‘STD [o.117— 0.180 mm (0.0046 — 0.0071 inp fertersione: |Clenaee between epacor and bushing sae coe nae st) |oa7— 08mm (001 — 0uR13 ee ee Linnit 8 mm {0.081 in) ae rotor ST>_|o020— a61 min (0008 — 98032 arm Eomebtelemanieebenutee ter Limit 0.10 mm. (0.0039 in) Bend limit 0.025 mm_ {0.0019 in) SiS |o.020 — 0380 mm (00012 — 9aT08 a Limit 0.35 mm {0.0138 in) S10 |s200—manomm 0am — 1a eee Wear limit _|0.3 mm_ {0.012 in) S10 |sasea— aaa mm (1272 — 12781 on be reo eel ‘Wear limit [0.3 mm {0.012 in) 1800cc STO 32.495 — 32.695 mm _(1.2783 — 1.2833 in) Camas 100s [Wo tao mm (waa in ot uur [319986 -— 31880 mm (14878 — 12879 eamerat |mx [eon ——]in [cantor [arate = rato mm ae = tana aor Front [27906 — 87980 mm (14006 — 14041 ip ‘Someta Front Rear 32.005 — 82.025 mmm (1.2600 — 1.2608 in) ouneitoe [aH [Comer]. Centr | 97.505— 97596 min (1a700— 1.4774 in) 0 Rear Front 38.005 — 38.025 mm (1.4963 — 1.4970 in) STD 0.085 — 0.080 mm {0.0022 — 0.0036 in) eet Limit 0.10 mm. {0.0039 in) Suraco worpago ek 0 mm (002 ir ‘Cylinder head | Surface grinding {imtt 0.1 rom {0.004 in) Standard hight 503 mm (2970) Refacing argo ac STO 0.7 mm (0.028 in) Valve sat ie: Limit 1.4mm (9.056 in). conxcting wisn Exhoust STO. 4.0 mm (0.039 in) Limit 4.8mm (0.071 in) ‘veguae ar aamate 6.000 = 602 mm (07382 — 02967) ‘guide [Protusion above head 17.5 — 18.0 mm (0.689 — 0.709 in) 31 [rom (0.009) itso Tink [os mm (o031 i) fre nee ee sTO 4.2. {0.047 in) Lint o.¢ mm (0091) psssinasns irako [5.060 — 65 mm (02300 — 02900) Valve ee Exhaust 5.945 — 6.960 mm (0.2341 — 0.2346 in) Go [iti oas5 = 052 mm (oan — 0.0028 n |Stom oil clearance Exhoust_ 9.040 — 0.067 mm {0.0016 — 0.0026 in) Limit : 0.15 mm {0.0088 in) inka | 104.9 rm (2976 ere Exhaust 104.2 mm (3.984 in)2-3a_[S0BO} ENGINE (SOHC) renege EAP PTS COTn ise ee SS SS Toe length fee mm Tamm Saurorse 28, Lem (cor awe sa toa = aeky 8 — 49.4 0/870 mm 57) Tension/spring height 401.1 — 401.9 N (40.9 — 47.1 kg, 00.2 — 103.9 by 2am 801) aca pigs a Tg wh ended” —— 025 mm saa Satie gag Oe [a (3.8161 — 3.6166 in) 220000 (3.6148 — 3.8181 In) (Setat= 350 Sige seals (aeaae = 98726) Cylinder bore /2000c0 (91,995 — 92.005 mm_ (3.6216 — 3.6222 in) (91.985 — 91.995 mm_ {3.6214 — 3.6218 in) Cylinder 19800ce (87,905 — 87.915 mm_ (3.4608 — 3.4612 In) 4 toa tecee Srase = a7a08 nm oasoa — sano (87.806 — 07.805 mm, (8.4600 — 3.4604 in} a dotE nm (Sao06 = 0.050 mm_ {9.0020 in) S00 (oo200 enone 0,050 mm_ {0.0020 in) 3010 = 0 {cot = OHHH penny denen, 0.060 mm {0.0024 In) ring Bag ES os (so2s ' x (96.685 — 06.086 mm (3.8144 — 3.6148 in) i so |e Seer esas mm ————(Rolso— 2.0044 zaotee ¢ Sees cous nm ———_(ueloo seein 5 a NG LOS fons wes mm nando = naar Seon orev pos [erste ergs nm an —sen0 7m etae— ote nm ae = serie so fb States mm (eat = a0atei) on (Oe | zone ¢ Stee stot mm een seatt i (0.25 min (0.0088 in} OS 92.225 — 92.235 mm_ {3.6300 — 3.6313 in) See mn OaTeT AOS — [¥E.06— v2.5 nm (6107 —aeaTt my A sao 0788 mm (000 94804 ee ee ere —a7si8 mm foo — 24000 eos fe S1als = e7sTe mm faasoa= aa TE ONG HOS Toni wa. mm fa4006 = 2000 eee arar eos — [an s76= wn mm (a47ea 24707 ‘Standard inner diemeter of piston pin hole [23.000 — 23.008 mm_ (0.9055 — 0.9067 in) ae di Frou = zoo mm owes — cates ruton on [Sat Seatac aban Sion Ga ond Tab aon [0081 — 0818 (cooind = a0on5 sage atom ma a Wed Fo postion win ub 8 20 {68°F). y SO [on0 =o cosmo, roe in Limit 41.0 mm {0.039 in) ane vecond ring [ST 0.20 — 088 mm (0.0070 — 6.0738 6) eit tani Second ting Tit 4.0 mm {9.038 in) aa vag (ST fa0— 6mm (soon — Ome eadaid onring [mit 15mm. (0.089 in) i Tong [St lo =a (Soote — ORT Crna tn tin [oxs am (ean | frac pon in oor Sb Jou — oso (poor = ome second ng [Epa ——[o5 (90086 \ caaag ani am: aut —— [ovo (por I Conestne OO comune S10 ore = oa (oom = OTS i tino (Gore i , 8 STD: Stondard OS: OversizeENGINE (SOHC) [S080] 2-3a mi = = eente aaa [act — 0008 ram (eaece— omen] A tint [008 mm (00 in ett 5 1482 — i80t mm (G0567 — coset my rod beng 03 mim (OOOTe 510 1618 = Thickness at corer porton [202 (00072 njUS | 1610— 1819 mm (0664 — ate nh 9.06 mm (0.0020 in) US__[1.520— 1.623 mm (0.0508 — 0.0600 in) | 225 mm (00090 m) US __|1.820—1.829 mm (20688 — ost in) comeing [og sn pin end vsning [2 [= 0822 mm (0— ato in) [fee usta [enrerce between ston nt [ume [0.080 mm {0.012 inp Bend int 056 mim (0014 in Oitchrcundioss 0.090 mm (08012 rove Crankpin and rank journal an : Grinding limit 0.260 mm {0.0098 in) sTO | 51.984 — 52.000 mm, (2.0466 — 2.0472 in) Cronin ter amore [22 100012) US |61.054— 61.670 mm (eove4 — 20461 np H 9.05 mm (9.0020 in) US 81.934 — 51.950 mm (2.0446 — 2.0453 in) 025 mm (20088 nj us [81.788 61.780 mm (2.0068 — 2.0974 ry S10 58964 — 60.000 mm (22616 — 2.3822 ny Cranahett [crank journal outer tame. [08 min (OO017 nj US] 50988 — GoTo mm (at0¢ — 2.3610 Fy tor 0.06 mm (0,0020 in} US 59.934 — 59,950 mm {2.3596 — 2.3602 in) 22 mm (020068 ny US| 69.704 — 69750 mm (23617 — 2.624 S70 0080 — 0.18 mm (00012 — aces ‘Thrust clearance ‘ in) Lin 028 mm (06008 inh ne PD [e010 — 008 mm (00004 — aaora ny a | Linnit 0.040 mm {0.0016 in) 01 clemanco rarans [SD [0010 — 0080 mm (00004 — aor? np E Limit }0.035 mm (0.0014 in) S10 [1988 — 2011 mm (0.0787 — aurea wy 0.09 rm (corn) |2017—2.020 mm (0.0786 ~ 0078 rb bs ne 9.05 mm (20020 ny |2.027— 2.050 mm (2.0766 — acres in) bs 25 mm foaoHe ny | 2.127 — 2.150 mm (00657 — acces in) cranshat bs Crankshat bearing tichr boating ee [sto 2.000 — 2.013 mm (0.0787 — 00768 i 0.08 rm foootz'y | 2018— 2022 mm (00785 — 00786 in) ls #2, #3, na 1005 mm (o.c0z0 ry |2.020— 2.082 mm (00799 — ace00 np us 025 mm (0090 im) |2.t20—2.182 mm (00838 — 00888 n) us eee eee STD: Standard US: Under size "2-3a_{C100) ENGINE (SOHC) C COMPONENT PARTS 41. Timing Belt Tightening torque: Nem (kg-m, ft-lb) Ti: 74 — 83 (7.5 — 85, 54 — 61) Ta: 35 — 43 (BS — 44, 26 — 32) TB: 23 — 26 (23 — 27, 17 — 20) Ta: 5 (0.5, 3.6) TS: 103 — 113 (105 — 11.8, 76 — 83)ENGINE (SOHC) [C200] 2-3a 2. Cylinder Head and Camshaft @IsPFI and carburator) ‘ee? (MRED [=] 1 Rocker cover (RH) 2 Rocker cover gxtket 3 Camuheft support (RH) eal Cynder heed (FH 40. Cylinder hoed asker 11 Oytinder heed (LH) 418. Camshaft support (LH) 16 Ollseat 17 OU filer cop. 18 Guiket 19 Oli filler pipe ‘o-ring 21. locker goaket 22 Rocker cover (CH) 23 Oil ave! 24 Oxing ‘Tightening torque: Nom (kgm, feb) Ti: Refer to (W5E1] 72: 16 (1.6, 12) T3: 10 (1.0,7) T4: 5 (05, 3.6) Bes64 Fig. 11ENGINE (SOHC) > 3. Cylinder Head and Valve ASSY 1 Exhaust valve 2 Intake valve 13 tnnake valve ol! sat 4 Valve spring 8 Rewiner & Retainer key 7 Exhaust valve olf sal & Rocker shafe support 9 Rocker shaft support 130 Rocker shaft support 11. locker shaft \\ \ 14 Exhaust valve rocker arm 16 Spring Pere eee yoo eee \ ‘Tightening torque: Nem (kgm, feb) TH: 5 (0.5, 3.6) ‘T2: 12 (1.2, 9)ENGINE (SOHC) {C400]_2-3a 4. Cylinder Block 1. Ol prenure switen 2 Cylinder block (RH) 13. Water pump 3 ser te 4. ‘72: 23 ~ 26 (2,3 ~2.7, 17-20) TS: 6.4 (0.65, 4.7) Ta: 6 (0.5, 3.8) TB: 10 (1.0, 7) ‘T6: 62 - 76 (6.3 ~7.7, 48 — 68) TH: Fit 10-14 (1.0~1.4,7~10) Second 10 — 14 (1.0 ~ 1.4, 7 - 10) Fig. 132-3a_[c500) ENGINE (SOHC) , : 5. Crankshaft and Piston —_——_—______—_. Tightening torque: Nem (kgm, ft1b) Th: 69-75 (7.0 —7.6,51 — 55) TR: 43-46 (4,4—4,7, 32-34)ENGINE W SERVICE PROCEDURE 1. General Precautions 1) Before disassembling engine, install on ENGINE STAND. ENGINE STAND ADAPTER. RH (498487000) {LH (498457100) ENGINE STAND (499817000. 2.001 Fig. 15 2. Timing Belt A: REMOVAL 1. CRANKSHAFT PULLEY AND BELT COVER (SOHC) 2) All parts should be thoroughly ol cial attention to the engine oil p: Pistons and bearings, 3) Rotating parts and sliding parts such as piston, bear- ing and gear should be coated with il prior to assem- bly. 4) Be careful not to let oil, grease or coolant contact the timing belt, clutch disc and flywheel. 5) All removed parts, if to be reused, should be stalled in the original positions and directions. 6} Gaskets and lock washers Must be replaced with new ones. Liquid gasket should be used where speci- fied to prevent leakage. 7) Bolts, nuts and washers should be replaced with new ones as required, 8) Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks, Fig. 16 1) Remove V-belt, 82.001 2} Remove pulley bolt. To lock crankshaft, use Special Tool2-3a_[W2A2} ENGINE (SOHC) 3) Remove crankshaft pulley. 4) Remove left-hand belt cover. 8) Remove right-hand belt cover. 6) Remove front belt cover. ' Fig. 17 2. TIMING BELT 4 2.003 Fig. 18 1) If alignment mark and/or arrow mark (which indi- cates rotation direction) on timing belt fade away, put new marks before removing timi as follows: (1) Turn crankshaft, and align alignment marks on crankshaft sprocket, and left and right camshaft sprockets with notches of belt cover and cylinder block. ‘Special tool: CRANKSHAFT SOCKET (499987500)ENGINE (SOHC) [W2A2]_2-3a Fig. 19 {2} Using white paint, put alignment and/or arrow marks on timing belts in relation to the sprockets.2-3a_[W2A3] ENGINE (SOHC) 2) Loosen tensioner adjuster mounting bolts. 4) Remove belt idler No. 2 3) Remove belt idler. 5) Remove timing belt. 3. BELT TENSIONER AND IDLER 82.008 Fig. 27 1) Remove belt idler. 3) Remove belt tension adjuster. 2) Remove belt tensioner and spacer. 4, SPROCKETENGINE (SOHC) 1) Remove left-hand camshaft sprocket. Fig. 23 2) Remove right-hand camshaft sprocket. To lock camshaft, use CAMSHAFT SPROCKET WRENCH. 3) Remove crankshaft sprocket. 4) Remove left-hand belt cover No. 2. 5) Remove right-hand belt cover No. 2 6) Remove tensioner bracket. 1. TIMING BELT 1) Check timing belt teeth for breaks, cracks, and wear Hf any fault is found, replace belt. 2) Check the condition of back side of belt; if any crack is found, replace belt. 2. Be careful not to let oll, grease or coolant contact the belt. Remove quickly and thoroughly if this hap- pens, b, Do not bend the belt sharply. [The bending radius must be greater than 60 mm (2.36 in).] fa.36 i / 2.092 Fig. 24 2, BELT TENSION ADJUSTER 1) Visually check oil seals for leaks, and rod ends for ‘abnormal wear or scratches. If necessary, replace faulty Parts. a [W284] 2-3a Slight traces of oil at rod’ oil seal does not indicate a problem. 2) While holding tensioner with both hands, push the rod section against floor or wall with a force of 147 to 490 N (16 to 60 kg, 33 to 110 Ib) to ensure that the rod section does not move. If it moves, replace tension adjuster with a new one. 3) Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one. Fig. 25 Rod extension H: 15.4 — 16.4 mm (0.606 — 0.646 in) 3, BELT TENSIONER 1) Check mating surfaces of timing belt and contact point of tension adjuster rod for abnormal wear or scratches, Replace belt tensioner if faulty. 2) Check spacer and tensioner bushing for wear. 4, BELT IDLER Check idler for smooth rotation. Replace if noise or excessive play is noted.2:38 [w2Ci] ENGINE (SOHC) C: INSTALLATION 1, SPROCKET - ki 8 5 acuta Ts Nem kgm, fib) 32.008 Fig. 26 1) Install right-hand belt cover No. 2. 6) Install left-hand camshaft sprocket, 2) Install left-hand belt cover No. 2, Do not confuse loft- and right-hand camshaft sprock- 3) Install tension 3 trata tension ets during instollation. The leftthand camshaft 5) Inetall right-hand camshaft sprocket Se reimee Cee er ere To. lock camsheft, use CAMSHAFT SPROCKET 3 WRENCH,ENGINE (SOHC) 2. BELT TENSIONER AND IDLER [w2c2]_2-3a NS ow Ne van @Qyr et ( oer eae TE Nm thom, {38 ~ 44,26 —32). @ om, fttb) eae Fig. 27 1) Installation of belt tensioner adjuster. rt stopper pin 1.5 mm (0.059 in) dia. into while pushing tension adjuster rod into body ing a press, Push unt ‘, Do not allow press pressure to exceed 9,807 N shee hele (1,000 kg, 2,205 Ib). b, Do not relesse press pressure until stopper pin is completely inserted. ©, Push tension adjuster rod vertically. (2) Temporarily tighten bolts while tension adjuster is pushed all the way to the right. 82012] e201 2) Install belt tensioner. 3) Install belt idler. Fig. 292-3a_[W2c3] ENGINE (SOHC) 3, TIMING BELT It 38—43N-m 186-44 hoe, 26 —32 fib Bao Fig. 30 1) Installation of timing belt. (1) Using SPROCKET WRENCH, turn sprockets so that their alignment marks come to top positions. ‘lignrant mak Se ° Fig. 32 === | 2) Install belt idler No. 2, 3) Install belt idler. = 4) Loosen tension adjuster attaching bolts and move Fig. 31 adjuster (2) While aligning alignment mark on timing belt with marks on sprockets, position timing belt properly. Ensure bott’s rotating direction Is correct. the way to the left. Tighten the bolts.ENGINE (SOHC) [W2c4) 2-34 6) After ensuring thet the marks on timing belt and After properly installing timing belt, remove rocker sprockets are aligned, remove stopper from tension cover and ensure that the valve lash adjuster contains Fig. 34 ho air. T 103-143 (105 — 11.8, 76—@3) Te Nem (kgm, fe) Beate Fig. 35 1) Install front belt cover. 2) Install right-hand belt cover. 3) Install left-hand belt cover. 4) Install crankshaft pulley. 5) Install pulley bolt. 6) Install V-belt, 252-3a_IWsao} ENGINE (SOHC) 3. Valve Rocker ASSY ‘A; REMOVAL Fig. 36 1) Disconnect PCV hose and remove rocker cover. Locate valve rocker ASSY with alr vent (en rocker 2) Removal of valve rocker ASSY facing upward or dip it in engine oil after {1) Remove bolts @through @in numerical temoval. sequence. See Figure. See Figure. Lesve two or three threads of bolt @engaged to retain valve rocker ASSY. (2) Equally loosen bolts @through @all the way, being careful that dowel pin is not gouged. (3) Remove valve rocker ASSY.ENGINE (SOHC) B: DISASSEMBLY iwace], 2020 Fig. 39 1) Remove bolts which secure rocker shaft. 2) Extract rocker shaft. Remove valve rocker arms, springs and shaft supports from rocker shaft. Arrange all removed parts in order so that they can be Installed in their original positions. Locate rocker arms with air vente facing upward. 3} Remove valve lash adjuster from valve rocker. Do not remove valve lash adjuster unless it requi bleeding or replacement. If valve lash adjuster Is hard to remove by hand, use pliers. Be careful not to scratch valve lash adjuster. Dip lash adjuster in engine oil after removal. 6 air C: INSPECTION 1. VALVE LASH ADJUSTER 1) Bleed air from valve lash adjuster es described below: (1) While dipping vaive lash adjuster in engine oil, 25 shown in Figure, push check ball in using a 2 mm (0.08 in) dia, round bar (2) With check ball pushed in, manually move plunger up and down at one-second intervals until air bubbles disappesr. 8) After air bubbles disappear, remove round ber and quickly push plunger in to ensure itis locked. If plunger does not lock properly, replace valve lash adjuster. Leave lash adjuster (after air is bled) in engine oif until it is ready for installation. Fig. 40 2) Replace valve lash adjuster with a new one if valve contact surface is scratched. 2, VALVE ROCKER ARM 1) Measure inside diameter of valve rocker arm and ‘outside diameter of valve rocker shaft, and determine the difference between the two (= oil clearance). Clearance between arm and shaft: Standard 0.020 — 0.081 mm (0.0008 — 0.0032 in) Limit 0.10 mm (0.0039 in) If oil clearance exceeds specifications, replace valve rocker arm or shaft. 27}a_{W3C3] Use the following table as a guide in determi combination rocker shaft, rocker arm and support. Toa det [ feo __Svppon aad (No Mark "—" (No mark) vei ware [ME np am 2) Ifcam or valve contact surface of valve rocker arm is worn or dented, repair by removing the minimum nec- essary amount. If worn heavily, replace valve rocker arm. D: ASSEMBLY ENGINE (SOHC) 3. VALVE ROCKER SHAFT Visually check oil relief valve of shaft end for any of the following abnormalities. Breaks in check ball bod} Foreign particles caught in valve spring © Oil leaks at check ball Repair or replace valve rocker shaft as necessary. Vn Booz Fig. 41 1) After bleeding air from valve lash adjuster, position valve lash adjuster in valve rocker arm while dipping in 1e oil, (Ref. to [W2C1].) Fill rocker arm oil reservoir chamber with engine oil. Install new valve lash adjuster O-ring, being careful not to scratch it. Do not attempt to rotate valve lash adjuster during installation. 2) Arrange valve rocker arms, springs and shaft sup- ports in assembly order and insert valve rocker shaft. Ensure that cutout portion of rocker shaft faces oil holes in shaft supports. Valve rocker arme, rocker shaft and shaft supports have identification marks. Ensure parts with seme markings are properly essembled. 3) Install valve rocker shaft securing bolts while align- ing shaft “lock” holes with bolts.ENGINE (SOHC) (W3E0]_2-3a 8 E: INSTALLATION To Wen than. fe) Fig. 42 1) Installation of vaive rocker ASSY {1) Temporarily tighten bolts @through @equally (a8 shown in Figure, Do not allow vaive rocker ASSY to gouge dowel pins. (2) Tighten bolts @through @to specified torque, (8) Tighten bolts @through @to specified torque. 2} Install rocker cover and connect PCV hose.2-3a_[W4A1] ENGINE (SOHC) 1. RELATED PARTS 4, Camshaft 1) Remove timing belt, camshaft sprockets and related ‘A: REMOVAL parts, (Ref. to 2. Timing Belt {W2A0}.) 2) Remove valve rocker ASSY. (Ref. to 3. Valve Rocker ASSY [W3A0],) 2, CAMSHAFT LH Fig. 44 1) Remove cam-angle sensor. (Except carburetor 4) Remove O-ting. model) 5) Remove camshaft LH. 2), Remove oil level gauge guide attaching bott. 6) Remove oil seal. 3) Remove camshaft support LH. Do not remove oil seal unless necessery. 3. CAMSHAFT RH 82988 Fig. 45 1) Remove distributor [SPFI and Carburetor]. 3) Remove camshaft support RH. 2) Remove rotor [SPF]. 4) Remove O-ring. 30a ENGINE (SOHC) 5) Remove camshaft, 6) Remove oil seal. Do not remove oil seel unless necessary. INSPECTION 4, CAMSHAFT : 41) Measure the bend, and repair or replace if neces- sary, Limit: (0.025 mm (0.0010 in) (wap) 2-3 Fig. 46 2) Check journal for damage and wear. Replace if faulty. 3) Measure outside diameter of camshaft journal and inside diameter of cylinder head journal, and determine the difference between the two (= oil clearance). if oll clearance exceeds specifications, replace camshaft or cylinder head as necessary. 4) Check cam face condition; remove minor faults by grinding with oil stone. Measure the cam height H; replace if the limit has ‘Standard cam height “H” 2200¢¢ ‘32.390 — 32.490 mm (1.2752 — 1.2791 in) 2000ce ‘32.364 — 32.464 mm (1.2742 — 1.2781 in) 1800co, 1600ce 32,495 — 82.595 mm (1.2783 — 1.2633 in) Wear tim 0.3 mm (0.012 in) ‘Unit om fn) = Righthend camshaft Front Center Roar of Lefichand camaheft Fear ‘Gorter Front [Standard (0.056 — 0090 (0.0022 — 00086) Clearonce et journal Limit 0.10 {0.0080 ) 31.035 — 31.060 37.436 — 37450 37.998 — 37.050 Camshaft journal 0.0. (12573 — 1.2579) (14790 — 1.4744) (1.4955 — 1.4941) 32.005 — 32.025 37.508 — 37.525 38.008 — 38.026 isananlnlan? {4.2600 — 1.2608) (1.4760— 1.4774) (1.4963 — 1.4970) N ‘2a men (1.10 i) 2.008] 31 Fig. 472-3a_[W4B2] ENGINE (SOHC) 2. CAMSHAFT SUPPORT Measure the thrust clearance of camshaft with dial | gauge. If the clearance exceeds the limit, replace cam- shaft support. Standard: ‘0.03 — 0.26 mm (0.0012 — 0.0102 in) Limit: 0.35 mm (0.0138 in)ENGINE (SOHC) [wacy _2-3a C: INSTALLATION 4, CAMSHAFT LH T 10010,7) T+ Nem kgm, fe4b) Fig. 49 1) Apply # coat of engine oil to camshaft journals and install camshaft LH. 2} Install O-ring to camshaft support, 3) Install camshaft support. 4) Apply a coat of grease to oil seal lips and install oil seal on camshaft support. Use a new oil seal. Fig. 60 5) Install olf level gauge guide bolt. 6) Install cam-angle sensor. (Except carburetor model) 33ENGINE (SOHC) 5 1 1 » 2) 3) bi 2 Fig. 51 1) Apply a coat of engine oil to camshaft journals and install camshaft RH. 2) Install O-ring to camshaft support. us9807000) 3) Install camshaft support. 4) Install rotor [SPF]. 7 5) Install distributor [SPF1 and Carburetor). 6) Install oil seal. Use a now oil seal. F » 1499587100) a 2.107, R Fig. 62 7 3, RELATED PARTS ‘iy 1) Install vaive rocker ASSY, sh (Ref. to 3. Valve Rocker ASSY [W3E0],) le 2) Install timing belt, camshaft sprockets and related to parts. a (Ref. to 2, Timing Belt [W2C0}.)ENGINE (SOHC) 5. Cylinder Head 4) Remove hoses and tubes from cyli : 2. 5} Disconnect each connector and/or remove connec- A: REMOVAL tor bracket, 6) Remove crank angle sensor, cam angle sensor and 1. INTAKE MANIFOLD knock sensor [SPFI and MPF]. 4) Remove V-belt 7) Remove intake manifold ASSY and gasket, Sr ee omer ance 8) Remove water pipe [MPF]. 3) Remove alternator, air conditioner compressor and brackets. 2, CYLINDER HEAD Be02e Fig. 63 1) Remove timing belt, camshaft sprocket and related Parts, (Ref. to 2. Timing Belt [W2A0}.) 2) Remove oil level gauge guide attaching bolt (left hand only). 3} Remove cylinder head bolts in numerical sequence | shown in Figure. Leave bolts @ and @ engaged by three or four threads to prevent cylinder head from falling. 4) While tapping cylinder head with a plastic hammer, separate it from cylinder block, Remove bolts Mand @to remove cylinder head. ee77t 5) Remove cylinder head gasket, Fig. 64 6) Similarly, remove right-hand cylinder head. 35ENGINE (SOHC) Fig. 55 41) Remove rocker cover. 2) Remove valve rocker ASSY. (Ref. to 3. Valve Rocker ASSY {W3A0],) 3) Remove camshaft and support. (Ref. to 4. Camshaft [W4A0].) 4) Compress the valve spring and remove the valve spting retainer key. Remove each valve and valve spring. a, Mark each valve to prevent confusion. b, Use extreme care not to damage the lips of the intake valve oil seals and exhaust valve oil seals. 36 VALVE SPRING ‘REMOVER (499718000) Fig. 56 5) Removal of plug (cylinder head LH). Do not remove plug unless necessary.2-3a_[W5C4] ENGINE (SOHC) Valve guide protrusion: L eeu ‘17.5 — 18.0 mm (0.689 — 0.709 in} [REMOVER (490767200) fa Fig. 59 {3) Turn cylinder head upside down and place VALVE GUIDE ADJUSTER as shown in the figure, 2-104 Fig. 60 {4}, Before installing new valve guide, make sure that neither scratches nor damages exist on the inside surface of the valve guide holes in cylinder head. (6) Putnew valve guide, coated with sufficient oil, in cylinder, and insert VALVE GUIDE REMOVER into valve guide. Press in until the valve guide upper end is flush with the upper surface of VALVE GUIDE ADJUSTER. VALVE GUIDE REMOVER (498787200) VALVE GUIDE | ADJUSTER (498767000). CYLINDER HEAD. ‘TABLE (498261200) Fig. 61 (6) Check the vaive guide protrusion. (7) Ream the inside of valve guide with VALVE GUIDE REAMER (499767400). Gently rotate the reamer clockwise while pressing it lightly into valve guide, and return it also rotating clockwise. After saming, clean valve guide to remove chips. ®. Apply engine oll to the reamer when reaming. b. If the inner surface of the valve guide is torn, the edge of the reamer should be slightly ground with an oil stone. . If the inner surface of the valve guide becomes lus- trous and the reamer does not chips, use a new reamer or remedy the reamer. {8) Recheck the contact condition between valve and valve seat after replacing valve guide. 4, INTAKE AND EXHAUST VALVE 1) Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if “H” is less than the specified timit, Inteke Stenderd 1.0 mm (0.039 in) Limit 0.8 mm (0.081 in) Exhaust Standard 1.2 mm (0.047 in) Limit 0.8 mm (0.081 in) Valve overall tength: Intake 101.0 mm (3.976 in) Exhaust 101.2 mm (3.084 in)ENGINE (SOHC) [WsC3]_2-3a INSPECTION 4. CYLINDER HEAD 1) Make sure that no crack or other damage exists. In addition to visual inspection, inspect important areas by means of red check. 2) Measure the warping of the cylinder head surface that mates with crankcase by using a straight edge and thickness gauge, Ifthe warping exceeds 0.05 mm (0.0020 in), regrind the surface with a surface grinder. se Warping limit: Hi Fig. 58 0.05 mm (0.0020 Grinding limit: 3, VALVE GUIDE 0.3 mm (0.012 in) 1) Check the clearance between valve guide and stem, Standard height of cylinder head: 98.3 mm (3.870 in) Uneven torque for the cylinder head nuts can cause werping. When reassembling, pay special attention to the torque 80 a8 to tighten evenly. ‘TABLE (498267200) Fig. 57 2, VALVE SEAT Inspect intake and exhaust valve seats, and correct the contact surfaces with valve seat cutter if they are defec- tive or when valve guides are replaced. Inteke Standard 0.7 mm (0.028 in) Limit 1.4 mm (0.085 in) Exhaust Standard 1.0 mm (0,039 in} Limit 4.8 mm (0.071 in) The clearance can be checked by measuring the out- side diameter of valve stem and the ide with outside and Clearance between the valve guide and valve stem: Standard Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in) Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in) Limit 0.15 mm (0.0059 in) Valve guide inner diameters: 6.00 — 6.012 mm (0.2362 — 0.2367 in) Valve stem outer diameter: Intake 5,950 — 5.965 mm (0.2343-0.2348 in) Exhaust 5,945 — 5.960 mm (0.2341 — 0.2346 in) 2) If the clearance between valve guide and stem exceeds the specification, replace guide as follows: (1) Place cylinder head on CYLINDER HEAD TABLE with the combustion chamber upward so that valve guides enter the holes in CYLINDER HEAD TABLE. (2) Insert VALVE GUIDE REMOVER into valve guide and press it down to remove valve guid 37ENGINE (SOHC) Iwsce] _2-3a a Eh _ ic} 2-38 Fig. 62 2) Put a small amount of grinding compound on the seat surface and lap tho valve and seat surface, Also refer to Cylinder Head 3) at this time. Install a new intake valve oil seal after lapping. 5. VALVE SPRINGS 1) Check valve springs for damage, free length, and tension. Replace valve spring if it is not to the specifi cations presented below. 2) To measure the squareness of the valve spring, stand the spring on a surface plate and measure its deflection at the top using a try square. (Outer spring Free length 42.99 mm (1.6026 In) 1903 — 219.7 N (194 — 224 kg, 42.0 — 494 Iby 37.0 mm (1.487 ‘Tensiow/epring bsighe| Be-108! Fig. 63 6. INTAKE AND EXHAUST VALVE OIL SEAL Replace oil seal with new one, if lip is damaged or spring out of place, or when the surfaces of intake valve ‘and valve seat are reconditioned or intake valve guide is replaced. Press in oil seal to the specified dimension indicated in the figure, using VALVE OIL SEAL GUIDE. ‘8. Apply engine oil to oil seal before force-fitting. b. Differentiate between intake valve oil soal snd ‘exhaust valve oil seal by noting their difference in color. Color of rubber part: Intake [Black] Exhaust [Brown] Color of spring part: Inteke [White] Exhaust [White] VALVE OIL SEAL 7 GUIDE (4958871001 ‘CYLINDER HEAD TABLE (498267200) Fig. 64 39ENGINE (SOHC) Nem gen, ib) Fig. 65 41) Install plug (cylinder head LH). Special tool: OIL SEAL INSTALLER (499587100) —— 2) Installation of valve spring and valve. (1) Coat stem of each valve with engine oil and insert valve into valve guide. When inserting valve into valve guide, use special care not to damage the oil seal lip. (2) Install valve spring and retainer. Be sure to install the valve spr coiled end facing the seat on the cylinder hea: (3) Compress valve spring and fit valve spring retainer key. VALVE SPRING REMOVER (499718000) 2.092] Fig. 66 (4) After installing, tap valve spring retainers lightly with wooden hammer for better seating. 3) Install camshaft and support. (Ref. to 4, Camshaft [W4C0}.) 4) Install vaive rocker ASSY. (Ref. to 3. Valve Rocker ASSY [W3E0]) 8) Install rocker cover.ENGINE (SOHC) (WSE1]_2-3a E: INSTALLATION 1. CYLINDER HEAD Fig. 67 1) Install cylinder head and gaskets on cylinder block. Use new cylinder head gaskets. 2) Tighten cylinder head bolts. (1) Apply a coat of engine oil to washers and bolt threads. {2) First, tighten bolts to 29 Nem (3.0 kg-m, 22 ft-lb) in the order shown in the Figure. After this, tighten them further to 69 Nem (7.0 kg-m, 51 ft-lb) in the same order. (3) Back off ali bolts by 180°, After this, back them off another 180°, (4) Tighten bolts and @to 34 Nem (3.5 kg-m, 25 ft (6) Tighten bots @, @, @ and © to 15 Nem (1.5 kgom, 11 felb). (6) Tighten all bolts by 80 to 90° in numerical sequence. Do not tighten bolts more then 90°. (7) Further tighten all bolts by 80 to 90° in numerical sequence. Ensure that the total “restightening angle” (steps (6) and (7) above) do not exceed 180°. Fig. 68 3) Install oil level gauge guide attaching bolt (left hand only) 4) Install timing belt, camshaft sprocket and related parts. (Ref, to 2. Timing Belt [W2C0}) a2-3a_[WSE2I ENGINE (SOHC) 2. INTAKE MANIFOLD 4) Connect each connector and/or install connector 1) Install water pipe [MPF]. orcs a ae eee oh ivan eakets: connect hoses and tubes to cylinder blocs 2} inotall Intake manifold, {6} Install brackets, alternator and eir conditioner com- pressor. Use new gaskets, 7) Install power steering pump. 3) Install crank angle sensor, cam angle sensor and 8) install V-belt. knock sensor [SPFI and MPF. Use dry compressed alr to remove foreign particles before installing sensors.ENGINE (SOHC) 6. Cylinder Block 1. RELATED PARTS ‘A: REMOVAL ! H Remove ‘timing belt, camshaft sprocket and related (Ref, to 2. Timing Belt (W2A0},) 2) Remove intake manifold and cylinder head, (Ref. to §. Cylinder Head |.) 2° OIL PUMP AND WATER COMP RZ IW6A2} 2-3a2, 1) Remove housing cover, 2) Remove flywheel or drive plate. To lock crankshaft, use CRANKSHAFT STOPPER. IW6A2] ENGINE (SOHC) Fig. 71 7) Removal of oil pan. (1) Turn eylinder block with #2 and #4 piston sides facing upward. (2) Remove bolts which secure oil pan to cylinder block, (3) Insert a oil-pan cutter blade between cylinder block-to-oil pan clearance and remove oll pan. Do not use 2 screwdriver or similar toot in place of oll-pan utter blade, 3) Remove oil separator cover. 4) Remove water pipe 5) Remove water pump. 6) Remove oil pump from cylinder block. Use a standard screwdriver as shown in Figure when removing oil pump. Be careful not to scratch the mating surface of cylinder block end of! pump. Fig. 72 8) Remove oll strainer stay. 8) Remove oil strainer. 10) Remove bafile plate, 11) Remove oil filter,ENGINE (SOHC) B: DISASSEMBLY NECTING BOLT 1. PISTON PIN AND CYLINDER BLOCK CON- [WeB1]_2-3a 2087 Fig. 73 using hexagon wrench (14 mm), hole of #1 and #2 cylinders. 1) Remove service hole cover and service hole plugs 2) Rotate crankshaft to bring #1 and #2 pistons to BDC Position, then remove piston circlip through service Fig. 75 4) Similarly remove piston pins from #3 and #4 pis- tons. 5) Remove bolts which connect cylinder block on the side of #2 and #4 cylinders. Fig. 74 3) Draw out piston pin from #1 and #2 pistons. 8) Back off bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns. Be careful not to confuse original combination of Piston, piston pin and cylinder. 452-3a [WeB2] ENGINE (SOHC) 2. CYLINDER BLOCK 1) Set up cylinder block so that #1 and #3 cylinders are ‘on the upper side, then remove cylinder block connect- left-hand and right-hand cylinder blocks, ‘When separating cylinder block, do not allow the con- necting rod to fall and damage the cylinder block. 3) Remove rear oil seal. 4) Remove crankshaft together with connecting rod. 5) Remove crankshaft bearings from cylinder block by hand, Do not confuse combination of crankshaft bearings. Press bearing st the end opposite to locking lip. 6) Draw out each piston from cylinder block using wooden bar or hammer handle, Do not confuse combination of piston and cylinder.ENGINE (SOHC) 3. CRANKSHAFT AND PISTON (wec2] 2-3a Fig. 77 1) Remove connecting rod cay 2) Remove connecting rod bearing, Arrange removed connecting rod, connecting rod cap ‘and bearing in order to prevent confusion. 3) Remove the piston rings using the piston ring ‘expander, 2123 (1) Standard sized pistons are classified into three grades, “A”, “B” and “C”. These grades should be used as a guideline in selecting a standard piston. (2) When piston is to be replaced due to general or cylinder wear, determine a unitable sized piston by ‘measuring the piston clearance, 4) Remove the oil ring by hand. Arrange the removed piston rings In good order to Prevent confusion, 5) Remove circlip. C: INSPECTION 1, CYLINDER BLOCK 1) Check for cracks and damage visuslly. Especially, inspect important parts by means of red check. 2) Check the oil passages for clogging. 3) Inspect crankcase surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary. Warping limit: 0.05 mm (0.0020 in) Grinding limi 0.4 mm (0.016 in) ee 2. CYLINDER AND PISTON. 1) The cylinder bore size is stamped on the cylinder Mein ourel see mark Gytinder block RH-LH ‘combination mark teats #4 oylinder bore size mark #2 cylinder bore size mark +1 eylinder bore size mark 49 cylinder bore size mark. 2210] block's front upper surface. 47 Fig. 783a_[W6C2] (3) Proper combination of pistons and cylinders ENGINE (SOHC) cylinder Piston Piston clesrance 20° Bore sie symbol_[ Cylinder bore dia_| Piston grade eymbol | Standard pistor dla (oor F) i 96.905 — 98.915 mm i 96.886 — 96.898 mm (3.8161 — 3.8185 in) (3.8144 — 3.6148 in) "96.895 — 96.905 mm 96.876 — 06.886 mm] 0.01 — 0.03 mm 220000 7 (3.8148 — 3.8181 in) = (3.6140 — 3.8144 in} | (0.0004 — 0.002 in) c 96.888 — 96.895 mm e 96.865 — 96.875 mm (3.8146 — 3.8148 in) (3.6136 — 3.8140 in) 7 7 91.985 — 91.995 mm (e214 — 3.6216 in) 200006 8 B 91.905 — 91.995 mm . (3.6214 — 3.6218 in) = 7 7.905 — 67.915 mm 7 (3.4606 — 3.4812 In) 1800ce 7 “67.885 — 87.905 mm 7 n ‘160066 {3.4604 — 3.4806 ia) (2.4846 — 3.4800 in) 7 ‘7.886 — 67.898 mm A 97.805 — 87.878 mm {3.4600 — 3.4808 in) (2.4862 — 3.4566 in) 2) Measure the inner diameter of each cylinder in both 2200¢e the thrust and piston pin directions at the heights shown in the figure, using a cylinder bore gauge. Measurement should be performed at @ temperature 20°C (68°F). petit Fig. 79 Taper: Standard 0.015 mm (0.0008 in) Limit 0.080 mm (0.0020 in) Out-of-roundness: Stenderd 0.010 mm (0.0004 in) Limit 0.050 mm (0.0020 in) Cylinder to piston clearance at 20°C (68°F): Standard 0.010 — 0.030 mm (0.0006 — 0.0012 in) Limit 0,080 mm (0.0024 in} Standard diameter: ‘A 96.905 — 96.915 mm (3.8151 — 3.8155 in) B 96.895 — 96.905 mm {3.8148 — 2.8151 in) © 96.885 — 96.895 mm (3.8144 — 3.8148 in) 20006 ‘A.92.005 — 92.015 mm (3.6222 — 3.6226 in) B 91.995 — 92.005 mm (8.6218 — 3.6222 in) € 81.985 — 91.995 mm {3.6214 — 3.6218 in) 1800cc, 1600¢¢ ‘A.87.905 — 87.915 mm {3.4608 — 3.4612 in) 8 87.895 — 87.905 mm {3.4604 — 3.4608 in) © 87.885 — 87.895 mm {3.4600 — 3.4604 in) 3) Boring and honing (1) If the value of taper, out-of-roundness, or eylin- der-to-piston clearance measured exceeds the spec- ified limit or if there is any damage on the cylinder wall, rebore it to use an oversize piston. When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use ‘oversize pistons. Do not perform boring on one oylin- der only, nor use an oversize piston for one cylinder only.ENGINE (SOHC) [weca] a (2) Get four of the oversize pistons and measure the outer diameter of each piston at the height shown in the figure. (Thrust direction) ‘Measurement should be performed et a temperature of 20°C (68°F). Standard ‘A 96.885 — 96.895 mm (3.8144 — 3.8148 in) B 96.875 — 96.885 mm (3.8140 — 3.8144 in) C 96.865 — 96.875 mm (3.8136 — 2.8140 in} 0.25 mm (0.0088 in) oversize 97.125 — 97.135 mm (3.8238 — 3.8242 in) 0.50 mm (0.0197 in) oversize 97.375 — 97.385 mm (3.8337 — 3.8340 in) 15 mm (3.6214 — 3.6218 in) B 91,975 — 91.885 mm (3.6211 — 3.6214 in) C 91.965 — 91.975 mm (3.6207 — 3.6211 in) 0.25 mm (0.0088 in) oversize 92.225 — 92.235 mm (3.6309 — 3.6313 in) 0.50 mm (0.0197 in) oversize 92.475 — 92.485 mm {3.6407 — 3.6411 in) 1800c¢, 1600cc Standard ‘A87.885 — 87.805 mm (3.4600 — 3.4604 in) B 87.875 — 87.885 mm (3.4596 — 3.4600 in) C 87.865 — 87.875 mm (3.4592 — 3.4596 in) 0.25 mm {0.0098 in) oversize 88,125 — 88.135 mm (3.4695 — 3.4699 in) 0.50 mm (0.0197 in) oversize ‘88.375 — 88.385 mm (3.4793 — 3.4797 in) fh 2.0mm (2.047 In) Fig. 80 (3) If the cylinder inner diameter exceeds the limit after boring and honing, replace the crankcase. Immodistely after reboring, the cylinder diameter may differ from its real diameter dus to temperature rise. Thus, pay attention to this when measuring the cy! dor diameter. Limit of cylinder enlarging (boring): 0.3 mm (0.012 in) 3, PISTON AND PISTON PIN 1) Check pistons and piston pins for damage, cracks, ‘and wear and the piston ring grooves for wear and damage. Replace if defective. 2) Measure the piston-to-cylinder clearance st each cylinder as instructed in CYLINDER AND PISTON. If any of the clearences is not to specification, replace the pis- ton or bore the cylinder to use an oversize piston. 3) Make sure that piston pin can be inserted into the piston pin hole with a thumb at 20°C (68°F). Replace if defective. Stendard clearance between piston pin and hole in piston: 0.001 — 0.013 mm (9.00004 — 0.00051 in) Standard clearance between piston pin and hole in connecting rod: 0 — 0.022 mm (0 — 0.0008 In) 4, PISTON RING 1) If piston ring is broken, damaged, or worn, of if its tension Is insufficient, or when the piston is replaced, replace piston ring with a new one of the same siz the piston, “RY or “N" is marked on the end of the top and second rings. When installing the rings to the piston, face this mark upward. Bate combined ring consisting of two rails ‘and a spacer in between. When installing, be careful not to make misassembly. 49ENGINE (SOHC) Unie in) ‘Standard 7 ‘0104 — 0.08 Cleerance | ToP ing {0.0018 | 0.16 (0.0060) ‘between piston 0.0081 ) ring and piston eT ing groove | Second ring, 0.0012 — | 0.16 {0,0059) Oil rng 2-115} Fig. 62 2) Squarely place piston ring and oil ring in cylinder, ‘and measure the piston ring gap with @ thickness gauge. Un: rn) — ‘Standard Limit | 0.20 — 0.36 Top ing (ooo7a— | 1.0(0039) 00136) Fig. 84 020— 035 fon taoriing | natant | sommes) | & CONNECTING ROD bal 0.0138) 1) Replace connecting rod, if the large or small end 320070 thrust surface is damaged. oiiageas | o0a70— | 180050) } 2) Check for bend or twist using a connecting rod 0.0276) ml aligner. Replece connecting rod if the bend or twist ‘exceeds the limit. oe Limit of bend or twist per 100 mm (3.94 in) in length: ‘0.10 mm (0.0039 in) PO PRE hn Fig. 83 3) Measure the clearance between piston ring and pis- ton ring groove with a thickness gauge. Bofore measuring the clearance, clean the piston ring greove and piston ring.2 Connecting rod 1 Connecting rod 2 Thicknoss gauge B2119| ring to crank- shaft and measure the side clearance (thrust clearance). Replace connecting rod if the side clearance exceeds the specified limit, Connecting rod side clearance: Standard 0.070 — 0.330 mm (0.0028 — 0.0130 in) Limit 0.4 mm (0.016 in) 51 ENGINE (SOHC) IW6C5]_2-3a 4) Inspect connecting rod bearing for scar, peeling, seizure, melting, wear, ete. 5) Measure the oil clearance on individual connecting rod bearings by means of plastigauge. if any oil clear- ‘ance is not within specification, replace the defective bearing with a new one of standard size or undersize as necessary, necessary. (See the table below.) Connecting rod oil clearance: Standard 0.015 — 0.045 mm (0.0008 — 0.0018 in) Limit 0.05 mm (0.0020 in} Unit: mm (in) Bearing ake (Tick | Outer diameter of Bearing ‘Ress at center) crank pin 1492 1501 | 61.964 — 62.000 ard (0.0567 — 0.0591) | (2.0466 — 2.0472) 15101519 | 51.964 —61970 Ces undersize | 0.0604 — 0.0596) | (2.0664 — 2.0461) 1820— 1873 | 61.494 — 61.980 ee {0.0598 — 0.0800) 1.620 1.678 (0.0086 — o.0eem) 6) Inspect bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at the connecting rod small end. Clearance between piston pin and bushing: Standard — 0.022 mm (0 — 0.0008 in} Limit 0.030 mm (0.0012 In) Replacement procedure is as follows. (1) Remove bushing from connecting rod with REMOVER & REPLACER and press, (2) Press bushing with REMOVER & REPLACER after applying oil on the periphery of bushing.[wsce] ENGINE (SOHC) CONNECTING ROI BUSHING REMOVER S& REPLACER (499037100) Betis] Fig. 87 (3) Make two 3mm (0.12 in) holes in bushing. Ream the inside of bushing. (4) After completion of reaming, clean bushing to remove chips. 6. CRANKSHAFT AND CRANKSHAFT BEARING 41) Clean crankshaft completely and check for eracks by means of red check etc., and replace if defective. 2) Measure the crankshaft bend, and correct or replace ifit exceeds the limit. Ifa suitable V-block is not available, install #1 end #5 crankshaft bearing on cylinder block, position crank- shaft on these bearings and measure crankshaft bond using a dial gauge. Ciankshaft bend limit: 0.035 mm (0.0014 in) 2.120) Fig. 88 3) Inspect the crank journal and crankpin for weer. If not to specifications, replace bearing with an undersize one, and replace or recondition crankshaft as neces- sary. When grinding crank journal or crankpin, finish them to the specified dimensions according to the undersize bearing to be used. Crankpin and crank journal: ‘Out-of-roundness 0.03 mm (0.0012 in) or less Teper limit 0.07 mm (0.0028 in) Grinding limit (0.25 mm (0.0098 in)ENGINE (SOHC) [wece} 2-3a Unit mm (ny Crank jour i aim Wat 7" rank pin O.D, ae ‘ase —e0.0c0 | sosee— e000 | s9.see— e000 | 61.908 —é2000 snaps : 22616— 2.9622) | (2asie— 22622) | @aeis—2s6za | (2.0486— 2.0872) Bearing sea 1908— 2011 | 2000-2018 | 2000-2013 | 1482— 1510 {Thickness at cent |_(a.0787—o.07ea) | (0.0767 —o07es) | (00787 — 0.0789) | (0.0867 — 0.058) 60.064 — 69.070 51.064 — 61.970 00 Journal 0.0, (2.2004 — 2.2610) ia 7 (2.0464 — 2.046%) ndorsico Bearing sie zo17—2020 | 2019-202 | 2010-202 | 1510—1819 (Thickness at center) | (0.0704 — 0.0796) | (0.0796 — 0.079) | (o07~s— 0.0706) | (0.0568 — 0.0506) 39.958 — 69.960 61.984 — 61.950 008 Journal 0.0, (2.3860 — 2.600) i a (2.0446 — 2.0483) undersiza ‘20a7— 2000 |” 2oe—20% | 2009-208 | 1520— 1873 (0.0760 — 00709) | (0.0788 — 0.0200) | (2.0789 — o,0800)_| (0.0580 — 0.0800) 50.734 — 60760 . 51.794— 61.750 028 ene (2.3617 — 2.3524) i z ndersizo (Bearing sie 2a27— 2.190 | 21202192 (Thickness at coreer) | (0.0837 — 0.0830) | (0.0838 — 0.0839) (0.0838 — 0.0830) 2.121 2 posi Fig. 89 4) Measure the thrust clearance of crankshaft at center bearing. f the clearance exceeds the limit, replace bear- ing. Crankshaft thrust clearance: ‘Standard 0.030 — 0.115 mm (0.0012 — 0.0048 in) Limit 0.25 mm (0.0088 Fig. 90 5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear. 6) Measure the oil clearance on each crankshaft bear- ing by means of plastigauge. If the measurement is not within the specification, replace defective bearing with ‘an undersize one, and replace or recondition crankshaft as necessary. Uns mm Gn) Crankshaft of clearance ‘2.010 080 bichad {o.0004 — 0.0012) eee 0.010 — 0.030 #2,93.44 | cocoa — 00012) ws 0.040 (0.0016) Limit 2B 0.096 (0.0016)2-3a_[W6D1] ENGINE (SOHC) D: ASSEMBLY 1. CRANKSHAFT AND PISTON 1 42-48 Nm (64—47 kom, 3238 b) Fig. 97 1) Install connecting rod bearings on connecting rods and connecting rod caps. Apply oil to the surfaces of the connecting rod bear- ings. 2) Install connecting rod on crankshaft. Position each connecting rod with the side marked fac- ing forward. 3) Install connecting rod cap with connecting rod nut. Ensure the etrow on connecting rod cap faces the front, during installation. ‘8. Each connecting rod hes its own mating cap. Make ‘sure that they are assembled correctly by checking their matching number. ‘b: When tightening the connecting rod nuts, apply oil ‘on the threads. 4) Installation of piston rings and oil ring. (1) Install oil ring spacer, upper reil and lower rail in this order by hand. Then install second ring and top ring with a piston ring expander. {2) Position the gaps of the piston rings and oil ring as shown in the figure. 5) Install circlip. Install circlips in piston holes located opposite service holes in eylinder block, when positioning all pistons in the corresponding cylinders. ‘attach to hole. Topi my Tdentiication mark {RH or LH} ou ag lower rit Second cing ring spacer Fig. 92ENGINE (SOHC) {Web2]_2-3a 2. CYLINDER BLOCK 1) Install ENGINE STAND to cylinder block, then install crankshaft bearings. Remove oil the mating surface of bearing and cylinder block before installation. Also apply a coat of engine ae oil to crankshaft pins. 3- 2) Position crankshaft on the #1 & #3 cylinder block. ® 3) Apply fluid packing to the mating surface of #1 & #3 cylinder block, and position the #2 & #4 cylinder block on #1 & #3 cylinder block, + m2 oA t | Bi%.17-20 | Fluid packing: EO. . ‘Three-bond 1215 or equivalent 4 Do not allow fluld packing to Jut Into O-ring grooves, bhi oil passages, bearing grooves, etc. Fuld packing Oing groove v Fig. 95 4) Temporarily tighton #2 & #4 cylinder block side con- Ss S necting bolts to 20 Nem (2 kg-m, 14 ft-lb). | 5) Turn cylinder block so that itis horizontal. Tighten all cylinder block connecting bolts to specified torque, starting with bolts on the #1 & #3 cylinder block side. 6) Install rear oil seal. seas] Fig. 96 Fig. 94ENGINE (SOHC) BNAND PISTON PIN (#1.and #2) ag Ses ' te 9 2061 Fig. 97 1) Installing piston Caan TraAAToNoE oy noe cylinder block so that #1 and #2 cylinders | SCS) 44900171001 (2) Turn crankshaft so that #1 and #2 connecting rods are set at bottom dead center. (3) Apply @ coat of engine oil to pistons and cylin- ders and insert pistons in their cylinders. Fig. 99 {2) Apply a coat of engine oil to piston pin and insert piston pin into piston and connecting rod through service hole, (3) Install cirelip.. Si es 2200 (49874730) 000 oO TDD 06 498747000) por Fig. 98 2) Installing piston pin (1) Insert the PISTON PIN GUIDE into service hole to lign piston pin hole with connecting rod small end. Apply # coat of engine oil to PISTON PIN GUIDE before insertion,ENGINE (SOHC) [Ws04] 2-3a (4) Install service hole plug and gasket. Use a new gasket and apply a coat of fluid packing to it before installation, ee Fluid packing: ‘Three-bond 1105 4. PISTON AND PISTON PIN (#3 and #4) T 2-76 63-727, ot T 64 (065, 4.7) 2S Tt Nem tkgm, fib) Fig. 107 Turn cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install pistons and piston pins. 572-3a_[W6Et] ENGINE (SOHC) E: INSTALLATION 1, OIL PUMP AND WATER PUMP T ‘ T Nem (kgm, tb) Fig. 102 eerENGINE (SOHC) [W6E1]_2. 4) Install battle plate, and O-ring 3} ise ol strainer stay, packing to matching surfaces and install Fluid packing: ‘Three-bor iive ‘OIL SEAL INSTALLE} yoe-bond 1207C or equivalent OL SEAL IN ud pack 2088 Fig. 105 (2) Apply fluid packing to matching surface of oil pump. Fluid pecking: Three-bond 1215 or equivalent 52.067] Fig. 103 wh 5) Apply fluid packing to matching surfaces and install eS cil saparator cover. c Fluid packing: @ Three-bond 1215 or equivalent yee a nace 17d packing Fig. 106 (3) install oil pump on cylinder block. Be careful not to damage oil seal during installation. ‘, Do not forget to install O-ring and seal when install- i) ing ofl pump. | b. Align flat surface of oil pump’s inner rotor with crankshaft before installation. 9) Install water pump and gasket. £2097] 9, Bo sure to use a now gasket. Fig. 104 b, When installing water pump, tighten bolts in two 6) Install flywheel or drive plate. stages, in the numerical sequence shown in figure. 7) Install housing cover. 59ENGINE (SOHC) 10) Install water pipe. 11) Install oi! fiter. 2. RELATED PARTS. 1) Install cylinder head and intake manifold. (Ref. to 5. Cylinder Head [W5EO],) 2) Install timing belt, camshaft sprocket and related Peat Poossel parts, (Ref. to 2. Timing Belt [W2C0].) Fig. 107