ISU2U KB - SERIES WORKSHOP MANUAL SECTION 6 PETROL ENGINE DIAGNOSIS. Hard Starting .. . Unstable Idling . Insufficient Power }. Abnormal Combustion .. . Excessive Oil Consumption . Overheating PS Ernowayn a . Flat Spot .. TROUBLESHOOTING 6-1 SECTION 6 TROUBLESHOOTING TABLE OF CONTENTS . Excessive Fuel Consumption .........000sssesseeeeececececeecceeeseseeeeseetenees 6-14 Oil Pressure Does Not Rise Abnormal Engine Noise .6—2 TROUBLESHOOTING Refer to the following troubleshooting charts to quickly pinpoint and repair engine problems. 1. This Section is divided into ten Sub-Sections. 2. Each troubleshooting chart has three headings arranged from left to right. Example: 3. INSUFFICIENT POWER ‘Checkpoint ‘Trouble Cause Countermeasure | fetta NG | Fuel ter oro donee tapas ft ar | t t—* Fuel line clogged onl ‘Glan the fuel line | LS | cs | Foe! pump Defective fuel pump -« F-—+_—_—Replace the fuel pump 3. Easily checked areas are presented at the beginning of the troubleshooting chart. Procedures become more complex as the chart progresses. 4. It is suggested that you work from the beginning of the troubleshooting chart. Do not start from the middle. 5. Itis possible that a seemingly apparent engine problem is not related to the engine. For example, the engine may appear to have insufficient power. This could be caused by dragging brakes or a slipping clutch instead of an engine malfunction. Refer to the other troubleshooting charts if required. 6. Optional equipment and vi ns are included in the troubleshooting charts. If the vehicle you are servicing is not equipped with a particular option or variation noted in the “Checkpoint” frame, disregard the frame and move on to the next one.TROUBLESHOOTING 6-3 aon Checkpoint 1. HARD STARTING 1. STARTER INOPERATIVE Trouble Cause Countermeasure Battery [NG _| Loose battery cable terminals | Clean and/or retighten the bat- | |] Poor connections due to rusting tery cable terminals } | | | ] -— NG | gattery discharged or weak | —|_ Recharge or replace the battery I | [| | | tT | KS Fan belt loose or broken |-—1_ Adjust or replace the fan beit | | | | | ox | l 1 - no | . | Mein fuse | Mase shored F-—} else the mn fase L L al — ox | _ | | na | | Starter switch Defective starter switch Replace the starter swich | Le | OK ] ] ‘Starter motor uid Defective magnetic switch ‘epair or replace the magnetic | switch | i ne Defective starter motor Repair or replace the starter motor |6—4 TROUBLESHOOTING 2. STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER Checkpoint Trouble Cause Countermeasure | r 1 | Battery NG_| Loose battery cable terminals Clean and/or retighten the bat- Poor connections due to rusting tery cable terminals L i ee ne | | Battery discharged or weak © | Recharge or replace the battery | ok | - NG | Starter motor Defective pinion ring gear Replace the pinion gear NG OK | Brush wear ‘Weak brush spring Replace the brush and/or the brush spring Distributor cap Continued on the next page NG Leaking Replace the distributor capTROUBLESHOOTING 6-5 parts Checkpoint Trouble Cause Countermeasure Continued from the previous page OK | ns Ignition coil {SZ _etectve ignition cat | —]_ Replace the ignition colt Jt J Poor connections in the primary | NG Reconnect the primary and and/or secondary ignition coil | Reconnect the primary and ee secondary ignition coil circuits | LV | | 7 | NG_| Primary ignition coil circuit «primary ignition coi open Replace the primary igniti il | LC) LU OK ] ] | ey NG_| Disconnect or broken high | Reconnect the high tension cable | a | tension cable | “| Replace the high tension cable J ~ T ox _| ] 1 | ve | eee Spark plugs Diny or defective spark plugs ~——— the gaps | | Replace the spark plugs | OK 1 I | ition tii NG : i , sen \gnition timing Incorestignton timing |-—__ Aalst the ignition timing | \ \ i J OK — tf 1 1 NG | Piston, crankshaft bearing Repair or replace the related | Engine seizure, or other damage | |6-6 TROUBLESHOOTING 150103 3. ENGINE TURNS OVER BUT DOES NOT START FUEL IS NOT BEING DELIVERED TO THE CARBURETOR Checkpoint Trouble Cause Countermeasure NG Fuel Fuel tank is empty —— Fill the fuel tank OK | f | , Repair or replace the fuel ines logged or dam: TT Fuel pining NG_| Clogged or damaged fuel lines |___ Retighten the fuel line ‘008e fuel line connections | connections , u OK | } Fuel filter NG. Clogged fuel filter J Replace the fuel filter | | l ne Water in the fuel line Bleed the fuel line OK NG Fuel pump LNs | Defective fuel pump |] Replace the fuel pump OK ‘ 1 t { | | Carburetor ae Defective carburetor }-——_ Repair or replace the carburetor i | NG_| Incorrect fuel level in float chamber Continued on the next page Adjust the float level armTROUBLESHOOTING 6: Checkpoint Continued from the previous page Trouble Cause Countermeasure | Adjust or replace the choke | Carburetor Choke valve inoperative mechanism | sono10202 FUEL IS BEING DELIVERED TO THE CARBURETOR | Fuel LNG | Use ofthe wrong fuel = Use the correct fuel | | L | — | NG Li | Water particles in the fuel Charge the fuel |6—8 TROUBLESHOOTING 2. UNSTABLE IDLING Checkpoint Trouble Cause Countermeasure i nc_| | Idling system Idling speed improperly adjusted |——1___ Adjust the idling speed oK , no | | Choke system Choke system out of adjustment ‘Adjust the choke system | ok - NG . Float chamber fuel level Fuel level too high or too low | —! Adjust the float level | j ok NG. Jet Jets clogged or damaged | __— Overhaul the carburetor. | T oK | | Mixture (If so equipped) NS] Detective mixture contol vave}——| Replace the mincure control valve , l ok { | ] ee NG _| Coasting fuel system not Adjust the coasting richer system | ea functioning properly and the coasting fuel cut system ok EGR valve (iso equipped) | NS_| Defective EGR valve || Replace the EGR valve | | Continued on the next pageTROUBLESHOOTING ———————————— crea Checkpoint Continued from the previous page ox_| Trouble Cause Countermeasure Thermal vacuum valve NG_| Thermal vacuum vaive does not . Replace the thermal vacuum valve {If so equipped) ‘operate when cold | ok i NG Air cleaner Clogged air cleaner element Replace the air cleaner element | J oK_| ug | Loose carburetor intake Retighten the intake manifold | Carburetor fitting manifold Replace the intake manifold Defective manifold gasket gasket | ok | [ne Ignition timing [SS incorrect ignition timing Adjust the ignition timing J OK. r | r ee [_NG_| Valve clearance incorrectly Adjust the vatve clearance adjusted OK NG. Valve seating Valve incorrectly seated Correct the valve seating T OK _| Fn ng | Blown out cylinder head gasket Compression pressure Worn cylinder liner Replace the applicable parts Piston ring sticking or broken6-10 TROUBLESHOOTING 3. INSUFFICIENT POWER Checkpoint Trouble Cause Countermeasure NG Clean the fuel pipe and/or Fuel system Clogged fuel pipe and filter races SDA ia NG Water particles in the fuel Replace the fuel Use of wrong fuel Use fuel of the specified octane rating ok | No | Fuel pump Defective fuel pump + _ Replace the fuel pump | oK NG. . Carburetor Fuel level too low or too high Adjust the float level NG Overhaul the carburetor nea Clean the jet ok {If so equipped) Defective mixture control valve Replace the mixture control valve | Continued on the next pageCheckpoint Continued from the previous page OK Air vent valve Trouble Cause NG _| Defective air vent solenoid valve TROUBLESHOOTING 6—11 Countermeasure Replace the air vent solenoid Valve ok Fuel pump not breathing suft- | | NG _| ciently due to clogged | Fuel tank. ee — Clean the fuel tank | evaporative emission control | | circuit | L — ok _| 1 f | | Replace or clean the air cleaner Ar cleaner NS, Clogaed ar cleaner element -——_ Free or clean the air cleaner | | \ J ok 1 —- | | NG_| Loose carburetor fitting Replace the carburetor gasket | a aaa Defective gasket Retighten the carburetor | } ok 1 1 \ , is NG_| Kinked or flattened air intake | Straighten or replace the air Air intake hose hose | intake hose , | l J ok | |g | Diny spark plug Clean or replace the spark plug Spark plug Spark plug heat range F— Instal spark plugs ha | inadequate i adequate heat range | J | } ox | . Ignition timing [NG | incorrect ignition timing L_—1__Ajust the ignition timing J6—12 TROUBLESHOOTING soso. 4. ABNORMAL COMBUSTION 1, MIXTURE TOO LEAN Checkpoint Trouble Cause Countermeasure NG Jet Jet clogged Overhaul the carburetor OK Carburetor intake manifold ne) Defective gasket tr Replace the gasket NG oK | Loose intake manifold. |__| Tighten the intake manifold Fuel supply NG_| insufficient fuel being delivered to the carbretor Replace the fuel pump Replace the fuel filter Clean the fuel pipe Slow cut solenoid valve NG Broken slow cut solenoid valve Replace the siow cut solenoid valveTROUBLESHOOTING 6-13 ‘50102 2. MIXTURE TOO RICH Checkpoint Trouble Cause Countermeasure r 1 | | i Choke valve NG_| choke valve does not open fully ——| Repair or adjust the choke valve | | { contro! - J ox | 5 NG | Air jet a Air jet clogged Overhaul the carburetor | ox | j 1 | re | Carburetor float Fuel level to0 high or too low | Adjust the float level | i j | ok ] 7 Le | | i r Air cleaner LNG | Clogged air cleaner element || _Reblace or clean the air cleaner | element | | | ok NG_| Carbon deposits in the combus- Combustion chamber ees Remove the carbon deposits | ok No | Dirty spark plug Clean or replace the spark plug Spark plug [Spark plug heat range Install spark plugs having an | aces adequate heat range J} — y Ok {Nc | Ignition timing Incorrect ignition timing -—}_Adjust the ignition timing |4 TROUBLESHOOTING 5. EXCESSIVE FUEL CONSUMPTION Checkpoint Trouble Cause Countermeasure | NG | Repair or replace the applicable Fuel system ro Fuel leakage [——] parts ox i | rl NG_| Engine misfire due to exces- Refer to “ABNORMAL eo) sively lean fuel mixture CONSUMPTION” ——___— NG Refer to “ABNORMAL cxcesivey eh et monre | Began ox | | sion vt ns et | anton ding Inorectigntion timing || Adjust he ignition ting | ox _ , Ns | ling speed ling peed 10 high Aust hein seed ) ox ‘Accelerator control NG_| Accelerator pedal return Adjust or repair the accelerator Sugai pedal nkape | ox Valve clerance NG | Vane cleranceincorecty |__| paietne ah crane Continued on the next pageTROUBLESHOOTING Checkpoint Continued from the previous page oK | Trouble Cause Countermeasure Blown out cylinder gasket | | Worn cylinder finer I | Compression pressure |-NS_! piston ring sticking or broken | Replace the appiicable parts | Improper seating between the | | | valve and the valve seat | ok | | } 7 | | ne | \ Valve spring [4 Weakened or broken vaive spring }——|_Replace the valve spring | | i ot | | l J | ok | | ] } i ne | Adjust the clutch control system | Cluteh Cluteh slipping [| Replace the clutch driven plate | | | | . ue ox | Brake drag Broken brake return spring Brake return spring out of position OK Adjust the brake lining clearance | Install or replace the brake return spring LW Transmission gear shift selection Caution operator on gear selection | | Wrong gear selection L J6 TROUBLESHOOTING 6. EXCESSIVE OIL CONSUMPTION Checkpoint Trouble Cause Countermeasure | Engine oil LNG | Wrong grade of engine oil Replace the engine oil | | a Too much engine oil Reduce the engine oil volume | OK r Ft. or Rr. oll seals and gaskets NG_ Oil leakage from the oil seals | and/or the gaskets gasket | OK Oil pressure unit ok | Oil pressure switch NG_| Loose or broken oil pressure unit - Retighten or replace the oi! pressure unit, Retighten or replace the oil pressure switchTROUBLESHOOTING 6-17 7. OVERHEATING Checkpoint Trouble Cause Countermeasure ; ; 1 1 ] N_| | | Coolant LNS | Insufficient coolant Replace the coolant, | ok | Cooling fan coupling NG | Oil leakage from the cooling i 1s | the cooli i reareeeel eee Replace the cooling fan coupling L ; u J J ok | | Fan belt ee) /-—__ Adjust or replace the fan belt | causing slippage 1 l l — OK NG | Defective radiator cap Replace the radiator cap Sacto | Clogged radiator core Clean the radiator core OK | | Water pump NS Defective water pump Repair or replace the water pump | u ] oK | 1 1 7 [NG | Defective seating cap resulting | in inder — 1 sealing c Cylinder head and cylinde: intaaiae osksoe Replace the sealing cap | OK i — | Thermostat NS; defective thermostat Replace the thermostat Continued on the next page6—18 TROUBLESHOOTING Checkpoint Trouble Cause Countermeasure Continued from the previous page OK _ _ | nell | | Cooling system Cooling system clogged Clean the cooling system | L l l } OK | | | | Ignition timing (SS tncoreectigniion ming -—-]__ Aas he ignition timing | | l __ J ok — , | | NG_} Wrong grade of engine cil Replace the engine oil Engine oll Insufficient engine oil Add engine oil ok __ | i Bor NG_| Excessive back pressure in the |__| Clean the exhaust system i exhaust system Replace the defective parts t ok | | Fuel mixture: ne Mixture too lean. ;-———|_ Refer to “MIXTURE TOO LEAN” ok_| Mixture control valve NG (if so equipped) ; Control valve does not close Replace the control valve |TROUBLESHOOTING 6-19 8. OIL PRESSURE DOES NOT RISE Checkpoint Trouble Cause Countermeasure / { ] in NG_| wrong grade of engine oi! Replace the engine oil Engine oil Insufficient engine oil | at engine ot | | | | 4 | ok | — Oil pressure unit or gauge Defective oll pressure unit or gauge Repair or repiace the oil pressure unit and gauge ok f | 1 NG ’ Replace the oil fiter element | oil fiter LNs | Clogged ot fter 4 arece acl tai | l | J | | ; | - ox | is | Regulating valve x Regulating vaive sticking Replace the regulating valve | | J ox _ | Ne 1 ot pump Clogged oil pump strainer Clean the oil pump strainer l ! | | NG Replace the applicable cil ou ‘place the applicable oll pump Worn oil pump parts tas L — ok — 1 Inet | | Rocker arm shaft Pr Worn rocker arm Replace the rocker arm | | J | Continued on the next page6-20 TROUBLESHOOTING Checkpoint Trouble Cause Countermeasure Continued from the previous page ok | vector arm Replace the camshaft the rocker Camshaft NS Worn camshaft and rocker ar arm shaft bracket, and the shaft bracket j eylinder head ok } Crankshaft and crankshaft bearing NG Worn crankshaft and crankshaft bearing Replace the crankshaft and the crankshaft bearingTROUBLESHOOTING 6-21 9. ABNORMAL ENGINE NOISE 1. ENGINE KNOCKING sso Checkpoint Trouble Cause Countermeasure Allow the engine to warm up before beginning the troubleshooting procedure. | Fuel NS} octereratngtooiow |_| Repaceshei | — OK — | 1 { | ignvon iia «ss LNS 4 incrrctignon timing Adjust the otion timing | OK | _ ] [ | | Install spark plugs having an | Spark pug LNG | soak pus heat range Inadequate lesel spark pugehaving an | | | OK ” Replace the head gasket and/or smoression pressure NG, Broken piston rng solace the Compression pressure rt Blown out head gasket 1 eee | oK | _ ) oF | | | Combustion chamber LNG_| Carbon deposits in the i}, Remove the carbon deposits | combustion chamber ial |6—22 TROUBLESHOOTING 10002 Checkpoint 2. GAS LEAKAGE NOISE Trouble Cause Allow the engine to warm up before beginning the troubleshooting procedure. Countermeasure NG_| Loosely connected exhaust pipe Tighten the exhaust pipe Exhaust pipe “ies pictlineasas connection a Replace the exhaust pipe ok ng | Loosely connected exhaust Tighten the exhaust manifold | Exhaust manifold LNS | imanifoid connection | Loose spark plug Tighten the spark plug ok. Cylinder head gasket | NS_)_pammaged cylinder head gasket Replace the cylinder head gasketTROUBLESHOOTING 6-23 ay 3. CONTINUOUS NOISE it Trouble Cause Countermeasure Checkp Allow the engine to warm up before beginning the troubleshooting procedure. Fan belt ne Loose fan belt Adjust the fan belt tension ok | Cees NG_| Worn or damaged water pump Replace the water pump bearing bearing unit unit J T OK - r f - NG | Alternator Defective alternator [—| _ Replace the alternator | | ok ss Valve clearance [NG Valve clearance incorrectly —{ Adjust the vaive clearance adjusted J6—24 TROUBLESHOOTING Checkpoint Allow the engine to warm up before beginning the troubleshooting procedure. 4. SLAPPING NOISE Trouble Cause Countermeasure NG_| Valve clearance incorrectly Valve clearance Ls | areal Adjust the vaive clearance OK | | NG Rocker arm Damaged rocker arm ;——_ Replace the rocker arm oK | Valve stem and valve guide ns Seized valve stem Pee ee rca reco Seen oe valve guide OK , NG Valve spring Broken valve spring 1 _ Replace the valve spring OK NG Lap the vaive seat Ive Incorrect valve seatin Valve seat correct valve seating Rape eee 1 OK. Rocker arm and camshaft NG_| Wom or pitted contact faces | Replace the camshaft and the contact faces rocker arm is — ne | | Flywheel “ Loose flywheel bolt 4 __Retighten the flywheel boit Continued on the next pageTROUBLESHOOTING 6-25 Summ Checkpoint Trouble Cause Countermeasure Continued from the previous page ok 1 | [_NG_| Worn or damaged crankshaft Replace the crankshaft and the cea aaa and/or thrust bearing thrust bearing | ~ J ok | _ Crankshaft and connection rod |_NG_| Worn or damaged crankshaft Replace the connecting rod and _| bearing ‘and/or connecting rod bearing the connecting rod bearing ok , —_ | i NG_| Worn or damaged connecting | Replace the connecting rod Connecting rod and piston pin |" 44 and piston pin and the piston pin ok _ NG_| Worn or damaged piston and Rebore the cylinder and replace omer evened I cylinder | the piston6-26 TROUBLESHOOTING Checkpoint Allow the engine to warm up before beginning the troubleshooting procedure. OTHER NOISE Trouble Cause Countermeasure Water pump NG_/_ Defective water pump bearing Replace the bearing unit oK Air pump (If so equipped) NG vee CI) Replace the air pump t rr NG. “S_ Relief vaive leakage Replace the relief valve ok | | " NG i a ‘ Air pump drive belt NS Air pump drive belt slipping Adjust the drive belt tensionTROUBLESHOOTING 6-27 10. FLAT SPOT 001 1. FLAT SPOT DURING HIGH SPEED OPERATION Checkpoint Trouble Cause Countermeasure | | ir [ne _| { Carburetor main jet i Clogged main jet 1-—__ Clean or replace the main jet J l | ok | | | NG Power valve Clogged power valve | | Clean or replace the power valve | J ok ] oT re | |, Clean the vacuum port Jn NG_| Sagged diaphragm spring Replace the diaphragm, the ec orearean Clogged vacuum port diaphragm spring, and the | | throttle body6-28 TROUBLESHOOTING 2. FLAT SPOT DURING ACCELERATION Checkpoint Trouble Cause Countermeasure NG i i ‘ ‘al Idling speed Idling speed too high ‘Adjust the idling speed J} OK. |_NG_| Detective air vent solenoid Replace the air vent solenoid Air vent solenoid valve valve valve OK. } Accelerator pump NG_| Excessive play inthe pump = |_!__agiust or replace the linkage linkage L NG_| Pump is not supplying sufficient tse er ——_ Replace the accelerator pump NG Clogged pump strainer. |! _ Clean or replace the strainer ok. NG i ini Main jet Clogged main jet Clean or replace the main jet | ok. [LNG Vacuum hole Clogged vacuum hole Clean the vacuum hole ok. NG. Fuel pump Defective fuel pump Replace the fuel pump LENGINE MECHANICAL 6A~1 SECTION 6A ENGINE MECHANICAL TABLE OF CONTENTS Main Data and Specifications ..........- 06-2. 22s cece ee ener tenet ene nee eee een eres Torque Specifications .....6....ccceeeecseseeecceeeeeeeeeeeeeeeeeteeeereeeeeeeees Standard Bolts Flare Nuts .. Special Parts Fixing Nuts and Bolts . Recommended Liquid Gasket . Loctite Application Procedure . Servicing .. . General Description Removal and Installation Engine Repair Kit Engine Overhaul Disassembly Inspection and Repair . Reassembly Lubricating System .6A-2 ENGINE MECHANICAL MAIN DATA AND SPECIFICATIONS (CARBURETTOR TYPE) Item Engine model azci 4zZE1 Engine type ‘Combustion chamber type Timing train system No. of cylinders - bore x stroke No. of piston rings Total piston displacement Compression ratio (to 1) Compression pressure Engine weight (Dry) Firing order Ignition timing (BTDC) Idling speed Valve clearance (At cold) Intake Exhaust Valve clearance (At hot) Intake Exhaust Intake valves Open at (BTDC) Close at (ABDC) Exhauxt valves Open at (BBDC) Close at (ATDC) Ignition system Distributor type Diatributor advance type Spark plug type Spark lug gap co(in*) kg/orn*(psi/kPa) kg{lb) deg/rpm pm mn(in) mm(in) mmi(in) mmi(in) deg deg deg deg 0.7-0.8 (0.02 Cent Four-cycle, water cooled, crossflow with single overhead camshaft Hemispherical Belt drive 4-88.0x82.0 4-92.6x95.0 (3.46x3.23) (3.64x3.74) Compression rings: 2/OiI ring:t 1,994 (121.7) 2,559 (156.2) 8.0 8.3 12.0 (170.6/1,177.2) Approx. Approx, 135 (297.7) 149 (328.5) 1-3-4-2 10/800 6/800 800 800 0.15 (0.006) 0.25 (0.010) 0.20 (0.008) 0.30 (0.012) 24 65 55 20 Fully transistorized battery ignition Contract pointless trifugal and vacuum BPRGES-11 or BP6ES or W20EXR-U or BPR6ES 1.0-1.1 (0.040-0.043) for catalytic conventer vehicle 031) Except catalytic conventer vehicleENGINE MECHANICAL 6A-3 Engine model Item azct 4zE1 Lubricating system Lubricating method Full flow pressure circulation Specified engine oil (API grade) SE, or SF Oil pressure kg/om’(psi/kPa)rpm 4.0-5.0 (56.9-71.1/392.4-490.5)/4,000 [SAE 10W-30/API SC grade] engine oil after warm-up il pump type Trochoid Oil filter type Cartridge, full flow Oil capacity lit. (US/UK gal.) 4.9 (1.24, 1.08) 5.5 (1.45, 1.21) Cooling system Radiator type Corrugated fin with reserve tank Coolant capacity lit, (US/UK gal.) 8.6 92.2, 1.9) [| 9.02.3, 2.0) Water pump type Centrifugal Thermostat type Wax pellet with jiggle valve Fuel system Carburetor type Stomberg 2-barrel 2-stage Fuel pump type Mechanical Fuel pressure kglom’(psi/kPa)rpm 0.25 (3.56/24.50) for HITACHI CARB Fuel filter type Air cleaner type Battery Alternator capacity Starter motor output TypelV-A x No. of units V-A(W) VW 0.24 (8.4/23.5) for NIPPON KIKAI CARB Cartridge paper element Dry paper element or Oil wetted (viscous) paper element 34B19R (12/33) 46B24R (12/45) 50D20R (12/50) 12-55 (660) 12-1.0 124.26A—4 ENGINE MECHANICAL TORQUE SPECIFICATION [] stanparo Botts The torque values given in the following table should be applied whenever a particular torque is not specified. kg-mllb AUN.) Sermons 4.8 (47) (77) 8.8 | 9.8 (9T) Bott Refined | Non-Refined Identification | | ot No mark — | Diameterx | Pitch (mm) M 6x10 10.6020.20 0.7520.25 = (4.9321.44/5.8821.96) (6.432 1.80/7.3522.45) MBX 1.25 1.752055 2400.70 (aac 90) (12 664.00/17.1525.39) (17.3625.06/23.5226.86) Mio x 1.25 2.8020.70 3.7520.95 5.1021.30 (20.2835.06/27.4426 86) (27 1246,87/36,7529.31) | (96.0929.40/49.983:12.74) M12 x 1.25 6.2521.25, | 77521.55 9.6521.95, (45.2129.04/61.25212.25) (56.06211.21/75.95215.19) (69.80214.10/94,57219.11) M14 x15, 9.7521.95 11.8522.35 14505290 (70.52214.10/95,55219.11) (85.71217.00/116.13223.03) (104.88:21.00/142.10228.42) M6 x 1.5 13302270 17302350 20.4024.10 (96.202 19.53/10 34%:26.46) (125 13225.32/169.54=34.30) (147.55229.66/199.92=40.18) Mia x 1.5 19.203.80 24.90=5.00 29:3035.90 (138.87227.49/188.16:37.24) (180,10 36.17/244,0249.00) (211.93242.67/287.14257.82) M20 x 1.5 26.305.30 34 4026.90 40.4038.10 (190.23238.33/257.74251.94) (248.82: 49.41/337.1267.62) (292.21258.59/396.92279.38) M22 x 1.5 | 33.9028.30 46.2529.25 54.10:10.80 (245.20260.03/332.22:81 34) (334.532.66.91/453 2590.65) 78.12/530.182105.84) M24 x 20 45.8029.20 58.202 14.30 70.60214.10 (331,27266.54/448,84-90.16) (420.962 103.43/570.362140.14) (610.65: 101:99/691.882138.18) smo x 15 2.70+0.70 3.7020.90 4.9021.20 (19.5315.06/26.4626.86) (26.76:6.50/36,26+8.82) (95.44:8.68/48.02211.76) oz x15 5.8021.20 7.2021.40 9.10+1.80 (41.95:8.68/56 84211 76) (62.082 10.13/70.56413.72) (65.82::13,02/89.1817.64) ona x 2.0 9.1021.80 1.202220 13,602.70 (65.8213.02/89.1817.64) (81.01215.91/109.76221.56) (98.372 19.53/133.28+26.46) “M16 x 2.0 12.702250 16.5023.30 19802390 (91.86 18.08/124 46+24 50) (119.34223.87/161.70232.34) (141.04:28.21/191.10:38.22) An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft ma- terials such as casting. Those shown in parentheses in the strength class indicate the classification by the old standard. FLARE NUTS kgsmilbt/Neem) Pipe diameter mmiin) Torque | Pipe diameter mmiin) Torque 4.76 (0.187) 1.852025 (11.22 1.8/15.222.45) 10.00 (0384), 5.50205 (39.723,6/53.9524.90) 6.35 (0.250) 27020,30 (19.522.1/26.4822.96) 12.00 10.472) 9.00::1.0 (65.0:7.2/88.29:9.80) 8.00 (0.315) 4.5020.50 (32.523.6/44 142490) 15.00 (0591) 107821 25 (77 7:8.0/108 4512.26)ENGINE MECHANICAL 6A-5 SPECIAL PARTS FIXING NUTS AND BOLTS Cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket kg-milb.ft/N-m) 20 0. (16.0 # 1.8 / 21.6 + 2.5) ‘Nut 25 2.20 0: (16.0 + 1.8 / 21.6 + 2.5) Bolt 0.75 20.15 (58+ 1.4/7822.0) [1st step 2nd step | 8 (67.8 78.5) 1027 (72.3 7.2/ 98.1 = 9.8) L { Apply engine oil to the threadsGA—6 ENGINE MECHANICAL Crankshaft Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper Pulley, Flywheel, and Oil Pan kg-milb.ft/N-m) 521 (36.2 + 7.2 / 49.0 + 9.8) 1021 (72.3 10.8 / 98.0 = 14.7) | Apply engine oil to the |__threads and seating face 6.0 20.2 4ZE1 | (43.4+1.4/58.8 +20) 45202 (32.5 £1.46 / 44.1 £1.96) 4azai 6.0205 (43.4 +3.6 / 58.8 +4.9) ‘Apply LOCTITE or equivalent to the threads 18205 For 4x4, and 4ZE1 For 4x2 (Except 42E1) (13.0 + 3.6 / 17.6 + 4.9) 1 Bt 2/728 + 98) (57.8 # 7. +05 117.6 + 4.9)ENGINE MECHANICAL 6A—-7 Timing Cover, Camshaft, and Timing Pulley kg-mi(lb.ft/N-m) 0.6+0.2 ] (43+ 1.4/5.9 + 2.0) 7 £10 (58.7 = 7.2 | 75.6 + 9.8) ‘Apply LOCTITE or equivalent to the threads 0.6 +0.2 (4.32146A—8 ENGINE MECHANICAL ron Cooling and Lubricating System kg-m(Ib.ft/N-m) 1.9405 (13.7 +36 / 18.6 + 4.9) 1.9205, (13.7 + 3.6 / 18.6 + 4.9) | 2.7405 (19.5 2 3.6 / 26.5 = 4.9) 2.2403 > |15.9427/21.6 +29)ENGINE MECHANICAL 6A~9 Intake and Exhaust System kg-m(lb.ft/N-m) 2.2 +03 ] (15.9 + 2.2/21.6 + 2.9) 1.9 +05 (13.7 +3.6/18.6 + 4.9) 4.5 +05 (32.5 + 3.6/54.1 + 4.9) 0.8 + 0.2 (5.8 = 1.4/7.8 + 2.0) 020423-0016A-—10 ENGINE MECHANICAL aoa Ql Engine Electricals kg-m(lb.ft/N-m) 875219 (63.3 + 14.5 / 85.28 2 18.0) 1.9405 (13.7 + 36 / 18.6 + 49) g®ENGINE MECHANICAL 6A-116A—12 ENGINE MECHANICAL ezoetaon Engine Mounting Bracket and Engine Stiffener kg-m(Ib.ft/N-m) (40.5 + 5.8 / 54.9 + 7.8) 28207 (20.3 + 5.1 / 27.4 6.7) : (29.6 + 4.3 / 40.2+5.9) Zee 84208 | |__ (60.8 $5.8 / 82.4 £78) 3.78 + 0.95 (21.7 + 69 / 36.8 + 9.3)ENGINE MECHANICAL 6A—13 RECOMMENDED LIQUID GASKET Type Brand Name Manufacturer Remarks RTV* ThreeBond 12078 Three Bond Silicon Base ThreeBond 1207C Three Bond Water Base ThreeBond 1141E Three Bond ThreeBond 1104 Three Bond BelcoBond 4 Isuzu Solvent BelcoBond 401 Isuzu BeleoBond 402 Isuzu , LOCTITE 515 Loctite Recommended for earn [__ Loctite 518 Loctite transaxle repairs \ * RTV : Room Temperature Vulcanizer Note: 1, Itis very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle. 2, Be careful to use the specified amount of liquid gasket. Follow the manufacturer's instructions at all times. 3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying the liquid gasket. The connecting surfaces must be perfectly dry. 4, LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface. Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater ‘than 0.25 mm (0.01 in). Poor adhesion will result.GA—14 ENGINE MECHANICAL 1700 LOCTITE APPLICATION PROCEDURE LOCTITE Type | LOCTITE Color Application Steps 1. Completely remove all lubricant and moisture from the bolts and the female threaded surfaces of the parts to be joined. LOCTITE 242 Blue The surfaces must be perfectly dry. 2. Apply LOCTITE to the bolts. LOCTITE 262 | Red -— Apply LOCTITE to at least 1/3 of the bolt’s ‘threaded area. LOCTITE 270 Green 3. Tighten the bolts to the specified torque. 4. Wait at least one hour before continuing the installation procedure. LOCTITE 271 Red 1. Completely remove lubricant and moisture from the con- necting surfaces. ‘The surfaces must be perfectly dry. 2. Apply a 2.0 — 2.5 mm (0.08 — 0.10 in.) bead of LOCTITE to one of the connecting surfaces. There must be no gaps in the bead. Loctite Enlarged area | Bead width 2-25 mm LOCTITE 515 Violet (0.08 - 0.10 in) \Y) Bead width 2 mm (0.08 in) 3. Tighten the bolts to the specified torque. 4. Let the joined parts set for at least thirty minutes.ENGINE MECHANICAL 6A~15 SERVICING Servicing refers to general maintenance procedures to be performed by qualified service personnel. 02, crane ce 030203 oxczoan MODEL IDENTIFICATION Engine Number The engine number is stamped on the protrusion at the reat left hand side of the cylinder block. AIR CLEANER Oil Wetted (Viscous) Type Paper Element The air cleaner has an oi! wetted paper element. No servicing is required until the replacement interval is reached, Never attempt to clean the element, no matter how it may appear. The element is designed to provide normal filtering efficiency until it becomes due for re- placement. Dry Type Paper Element Apply compressed air to the inside of the element as you rotate it with your hand, This will blow the dust free. Compressed Air Pressure kg/cm?(psi/kPa) 4—5 (56.9—71.1/392.3—-490.3) Do not bang the element against another object in an attempt to clean it. Damage to the element will result.6A—16 ENGINE MECHANICAL 0304-028 To carburetor 4 2 LUBRICATING SYSTEM Oil Filter Replacement Procedure Loosen the drain plug © to drain the engine oil. Wait a few minutes and then retighten the drain piug with new gasket. Loosen the used oil filter by turning it counterclock- wise with the filter wrench. Clean the oil filter adapter fitting face. This will allow the new oil filter to seat properly. 5. Apply a light coat of engine oil to the O-ring. 6. Turn in the new oil filter until the filter O-ring is fitted against the sealing face. 7. Use the filter wrench to turn in the filter an addi- tional 1 turn. Filter Wrench : 5-8840-0203-0 8 Check the engine oil level and replenish to the spe- cified level if required. 9. Start the engine and check for oil leakage from the drain plug and main oil filter, then turn it off. After several minutes, recheck the engine oil level. FUEL SYSTEM Fuel Filter Replacement ih 2 Remove the fuel filter © from the filter clip @. Disconnect the inlet and outlet fuel hoses © from the fuel filter. Connect the inlet and outlet fuel hoses to the new fuel filter. Be sure to connect the fuel hoses in their correct positions. Install the fuel filter to the filter clip. Start the engine. Check for fuel leakage from the fuel hoses.ENGINE MECHANICAL 6A—17 9, o90e0014 Mixing ratio (%) Carburetor Float Level Inspection and Adjustment Check the float level against the float level mark on the float chamber (Nikki) ©, and float level glass (Hitachi) ©. If required, adjust the float level by carefully bending the float seat, COOLING SYSTEM Coolant Level Check the coolant level and replenish the radiator surge tank as necessary. If the coolant level falls below the “MIN” line, carefully check the cooling system for leakage. Then add enough coolant to bring the level up to the "MAX" line. Note: Do not overfill the reserve tank. Remove the radiator filler cap only when absolutely necessary. Always check the coolant level when the engine is cold. Always refer to the chart at the left to determine the correct cooling water to antifreeze solution mixing ratio. Cooling System Inspection Install a radiator filler cap tester to the radiator. Apply testing pressure to the cooling system to check for leak- age. The testing pressure must not exceed the specified pressure. Testing Pressure kg/cm? (psi/kPa) 2 (28.45/196)6A—18 ENGINE MECHANICAL 308.016 080s, 9305-015 Radiator Cap Inspection The radiator filler cap is designed to maintain coolant pressure in the cooling system at 1.05 kg/om? (15 psi/ 103 kPa). Check the radiator filler cap with a radiator filler cap tester. The radiator filler cap must be replaced if it fails to hold the specified pressure during the test procedure, Radiator Filler Cap Pressure Pressure Valve kg/cm? (psi/kPa) 0.9 = 1.2 (12.8 — 17.1/88 — 118) Negative Valve (Reference) kg/om? (psi/kPa) 4 (0.14 0), Drive Belt Adjustment Check the drive belt tension. Depress the drive belt mid-portion with a 10 kg (22 Ib/ 98 N) force. Drive Belt Deflection mm(in) Except power steering 10 (0.39) Only power steering 14 (0.55) Check the drive belt for cracking and other damage. Crankshaft pulley Alternator pulley Cooling fan pulley Compressor idler pulley Compressor pulley Air pump pulley Power steering oil pump pulley 8Q@6e8080 Cooling Fan Pulley Drive Belt Fan belt tension is adjusted by moving the alternator. Depress the drive belt mid-portion with a 10 kg (22 Ib/ 98 N) force. ® Crankshaft pulley ® Alternator pulley ® Cooling fan pulleyENGINE MECHANICAL 6A—19 02 05-018 | | Compressor Pulley Drive Belt Move the idler pulley to adjust the compressor drive belt tension. Depress the drive belt mid-portion with a 10 kg (22 Ib/ 98 N) force. ® Crankshaft pulley @ Compressor pulley @ Idler pulley Power Steering Oil Pump Pulley Drive Belt Move the oil pump to adjust the oil pump pulley drive belt tension. Depress the drive belt mid-portion with a 10 kg (22 Ib/ 98 N) force. © Crankshaft pulley ® Oil pump pulley Air Pump Pulley Drive Belt Move the air pump to adjust the air pump pulley drive belt tension. © Crankshaft pulley ® Air pump pulley ® Cooling fan pulley ENGINE CONTROL Idling Speed and Mixture Adjustment Preparation 1. Set the parking brake and chock the drive wheels. 2. Place the transmission in neutral 3. Start the engine and allow it to warm up. 4 Check that all the accessory switches are off and that the choke vaive is fully open. 5. Seta tachometer to the engine. 6. Check the ignition timing and adjust it if required. Ignition Timing (BTOC) degitpm, From ‘91, switzerland & Sweden (4ZD1) | 6/900 Other 6/8006A—20 ENGINE MECHANICAL Throttle chamber Idling Speed Adjustment (Nikki Carburetor) 1, Disconnect the distributor vacuum hose and plug the hose end. 2. Bend the attached rubber hose to close off the thermo valve vacuum line. 3. Set the throttle adjusting screw © to the specified idling speed. 4, Turn the idle adjusting screw @ to peak the engine speed. Idle screw adjuster (If required); 8-9421-6632-0 5. Reset the throttle adjusting screw to lower the idling speed to 20 rpm below the specified level. 6. Turn the idle adjusting screw counterclockwise to raise the idling speed to the specified level. Engine Idling Speed rpm 800 7. Reconnect the distributor vacuum hose and the idle compensator vacuum hose to the carburetor after completing the adjustment procedure. Idle Mixture Adjustment (Hitach carburetor) (Until 99 Swiss & Sweden, and From ‘92 Chili mod- els) 1, Remove the air cleaner. 2. Tag each of the vacuum hoses leading to the car- buretor. 3. Disconnect the harness connectors and the vacuum hoses at the carburetor. 4, Remove the carburetor assembly. Drill a hole in seal plug with proper tool, 5. Remove the idle adjusting screw from the throttle chamber. 6. Inspect the idle adjust If the adjusting screw head has been damaged by the drill, the screw must be replaced with a new one. If the adjusting screw taper is excessively worn or stepped, the screw must be replaced with a new one. g screw.10. " 12. 13. 14, 15. 16. 1”. 18. ENGINE MECHANICAL 6A-21 Reinstall the idle adjusting screw to the throttle chamber, Fully screw the idle adjusting screw into the throttle chamber. Do not overtighten the screw. Back off the idle adjusting screw 3 turns. Reinstall the carburetor. Reconnect the vacuum hoses and the harness con- nectors to the carburetor. Pay close attention to the tags applied at removal. Refer to "REMOVAL AND INSTALLATION” of the carburetor 6C. Reinstall the air cleaner. Start the engine and allow it to idle until the cooling water reaches normal temperature. Make sure that the choke valve is fully open. If the choke valve is not fully open, open it. Make sure that the air conditioning system is off (if so equipped) Move the front wheels to the straight ahead posi- tion (power steering equipped vehicle only). Disconnect and plug the distributor line. Disconnect and plug the canister purge line.6A-22 ENGINE MECHANICAL 19. Disconnect and plug the EGR vacuum line. 20. Bend the attached rubber hose to close off the idle compensator vacuum line. 2 Engine Idling Speed rpm 800 Use the throttle adjusting screw to adjust the idling. 22. Adjust the setting of the idle adjusting screw ® to ob- tain the maximum speed. 23, Reset the throttle adjusting screw to 850 rpm. 24. Turn the idle adjusting screw clockwise (lean) until the engine idle speed is down to 800 rpm. 25. Remove the air cleaner. 26. Replace the idle adjusting screw plug. Tap the new plug in until it is flush with the car- buretor surface. 27. Reinstall the air cleaner.ENGINE MECHANICAL 6A-23 Torowle chamber Idle Speed and Mixture Adjustment (Hitach carbure- tor) (From ‘91 Swiss, Sweden & From ‘92 Germany mod- els) 1. Remove the air cleaner. 2. Tag each of the vacuum hoses leading to the car- buretor. 3. Disconnect the harness connectors and the vacuum hoses at the carburetor. 4. Remove the carburetor assembly. Drill a hole in seal plug with proper tool. 5. Remove the idle adjusting screw from the throttle chamber. Inspect the idle adjusting screw. © If the adjusting screw head has been damaged by the drill, the screw must be replaced with a new one. * If the adjusting screw taper is excessively worn or stepped, the screw must be replaced with a new one. 7. Reinstall the idle adjusting screw to the throttle chamber. 8. Fully screw the idle adjusting screw into the throttle chamber. Do not overtighten the screw. 9. Back off the idle adjusting screw 3 turns. 10. Reinstall the carburetor. 11. Reconnect the vacuum hoses and the harness con- nectors to the carburetor. Pay close attention to the tags applied at removal. Refer to “REMOVAL AND INSTALLATION” of the carburetor 6C.6A-24 ENGINE MECHANICAL 12. 13. 14. 15. 16. 7. 18. 19. 20. Reinstall the air cleaner. Start the engine and allow it to idle until the cooling water reaches normal temperature. Make sure that the choke valve is fully open. If the choke valve is not fully open, open it. Make sure that the air conditioning system is off (if so equipped). Move the front wheels to the straight ahead posi- tion (power steering equipped vehicle only). Disconnect and plug the distributor line. Disconnect and plug the canister purge line. Disconnect and plug the EGR vacuum line. Bend the attached rubber hose to close off the idle compensator vacuum line.ENGINE MECHANICAL 6A-25 Primary throttle shaft 4 Throttle adjust fever speedup | controller Speed-up screw adjusting serew 21. Use the throttle adjusting screw to adjust the idling. Engine Idling Speed rpm 900 22. Use a dwell meter to measure the dwell Connect the positive side of the meter to the moni- tor lead @ and the negative side of the meter to ground. After confirming dwell or duty to vary, ad- just setting of idle adjusting screw @ to obtain an average dwell or duty as specified. Dwell Deg. Dwell Meter Reading (4-Cylinder Scale) Average 36 The dwell reading specified is the average of the most constant vibration. 23. Use the throttle adjusting screw to reset the engine idling speed. Engine Idling Speed rpm 900 24, Remove the air cleaner. 25. Replace the idle adjusting screw plug. Tap the new plug in until it is flush with the car- buretor surface. 26. Reinstall the air cleaner. Idle Up Adjustment (if equipped) 1. Start the engine and allow it to warm up. 2. Turn “ON” airconditioner. 3. Turn the speed-up screw to 900 rpm.6A-26 ENGINE MECHANICAL 0305-018 Fast Idling Speed Adjustment Preparation 1. Set the parking brake and chock the drive wheels. 2. Place the transmission ‘in neutral. 3. Remove the air cleaner and while holding the throttle slightly open, push the choke the valve closed, and hold it closed as you release. 4. Disconnect the vacuum hose @ from the choke pis- ton and plug the hose end. 5. Disconnect the EGR system thermal vacuum hose @ from the carburetor and plug the hose end. 6. Check that all the accessory switches are off. Fast Idling Speed Adjustment 1. Start the engine and allow it to warm up. Do not depress the accelerator pedal. 2. Set a tachometer to the engine. 3. Check the fast idling speed. Fast Idling Speed rpm 2,700 — 3,000 If the fast idling speed is outside the specified range, adjust it with the fast idle adjusting screw. 4. Reconnect the vacuum hose to the choke piston and install the air cleaner after completing the ad- justment procedure.2059, o20602014 | \es 0305.021 0308.022, ENGINE MECHANICAL 6A—27 Engine Control Adjustment Accelerator Pedal Adjustment Adjustment of the accelerator pedal height is not re- quired. 1. Loosen the pedal stopper bott lock nut ©. 2. Tighten the pedal stopper bolt ® to prevent it from interfering with the accelerator pedal. Engine Control Cable Adjustment 1. Fully close the throttle valve. 2. Turn the adjusting nut @ to adjust the engine con- trol inner cable play ©. Engine Control Inner Cable Play mm(in) Approximately 2 — 3 (0.079 — 0.120) 3. Connect the engine control cable to the throttle hol- der @. . Install the engine control cable to the bracket ®. 5. Tighten the lock nut @. 6. Fully open the throttle valve. 7. Adjust the clearance between the stopper bolt pad © and the accelerator pedal ©. Accelerator Pedal and Bolt Pad Clearance mmi(in) 0-3 (0—0.12) 8. Fully depress the accelerator pedal. Check that the throttle valve is fully open when the pedal is fully depressed. CYLINDER HEAD BOLT Cylinder Head Bolt Tightening Torque Inspection Use the torque wrench to check the cylinder head bolt tightening torque in the sequence shown in the illustra- tion before adjusting the valve clearances. Head Bolt Wrench: 9-8511-4209-0 Cylinder Head Bolt Torque 1(72.3 + 7.2/98.0 + 9.8)6A~28 ENGINE MECHANICAL VALVE CLEARANCE ADJUSTMENT 1 Rocker Arm Shaft Bracket Nut Torque _k; Check the rocker arm shaft bracket nuts for loose- ness. Tighten any loose rocker arm shaft bracket nuts be- fore adjusting the valve clearance. (Ib. Ft/N-m) 2.2 + 0.25 (16.0 + 1.8/21.6 + 2.5) Bring the piston in either the No. 1 cylinder to TDC ‘on the compression stroke by turning the crankshaft until the crankshaft pulley TDC line is aligned with the timing mark. If the No. 1 cylinder is at TDC, there will be play in the No. 1 cylinder valve rocker arms. Adjust the valve clearances in the following manner using a feeler gauge. Feeler gauge should move with a very slight drag. Valve Clearance mm(in) Nelve Gearence ____mfin) AtCold | —_AtHot Intake 0.15 (0.006) 0.20 (0.008) 4 5. Exhaust |__0.25 (0.010) 0.30 (0.012) Adjust the clearance of the vaive (arrowed) Turn the crankshaft one full turn (360 degrees) and adjust the clearances of the valves (arrowed).ENGINE MECHANICAL 6A—29 gn car2018 IGNITION TIMING Ignition Timing Inspection 1. Start the engine and allow it to idle for warm up. 2. Set the engine tachometer. 3. Check that the engine is running stably at the speci- fied idling speed. If the vehicle is equipped with an air conditioner, the air conditioner switch must be in the “OFF” po- sition. Engine Idling Speed rpm From ‘91, Switzerland, Sweden & From "92, Germany Other 800 900 4. Disconnect the vacuum hose. 5. Attach the timing light cord to either the No. 1 or the No. 4 cylinder. 6. Aim the timing light at the crankshaft pulley Notched line to check the ignition timing. Ignition Timing (BTDC) deg/rpm From ‘91, Switzerland, Sweden & From ‘92, Germany cd Other | 6/800 l cat2.001 If the ignition timing differs from the specification, adjust it by moving the distributor. conaoie Ignition Timing Adjustment 1. Loosen the distributor fixing bolt. 2. Aim the timing light at the crankshaft pulley notched fine to check the ignition timing, | Moving the distributor to the left will advance the | timing. Moving the distributor to the right will retard the timing. 0312-003,6A—30 ENGINE MECHANICAL oa10-008 | COMPRESSION PRESSURE MEASURE- MENT Start the engine and allow it to idle for warm up. Set the engine tachometer. Stop the engine. Remove all of the spark plugs. Engage the starter and check that the cranking speed is at least 300 rpm. If the cranking speed is less than 300 rpm, the bat- tery must be replaced. 6. Set a compression gauge to the No. 1 cylinder spark plug hole. 7. Turn the engine over with the starter motor and take the compression reading Compression Pressure kg/cm?(psi/kPa) at 300 rpm Compression Pressure __kg/cm*{psi/kPa) at 300 rpm Standard Limit 12.0 (170.6/1,177.2) 8.0 (113.7/784.5) 8. Repeat the procedure (Steps 6 and 7) for the re- maining cylinders. gr EN > IGNITION SYSTEM If a problem in the ignition system is believed to be the cause of engine trouble, perform the following checks and make the required adjustments, repairs, and part re- placements. Distributor 1. Distributor Cap and Rotor Remove the distributor cap and check the following 1) Check the center electrode © and the side elec- trode ® for burning and corrosion. 2) Check the rotor @ for excessive wear and burning Replace the parts as required.ENGINE MECHANICAL 6A—31 cntaasoe ‘Vacuum 9313.01 2. Air Gap Use a feeler gauge to measure the clearance be- tween the signal generator @ and the distributor cam ®. if the measured value is outside the specified value, adjust the air gap by loosening the two screws @ and moving the bracket. Air Gap © mmi(in) 0.2 — 0.4 (0.008 — 0.016) Vacuum Adavancer 1. Disconnect the vacuum hose from the vacuum ad- vancer. 2. Connect a vacuum pump to the vacuum advancer diaphragm. 3. Apply a vacuum and check that the vacuum ad- vancer moves If the vacuum advancer does not move, repair or replace as necessary. Governor 1. Check the rotor shaft for excessive looseness. If the shaft is excessively loose, the governor is de- fective and must be replaced. 2. Turn the rotor shaft clockwise 1/4 of a turn and re- lease it. The rotor shaft should spring back. If the shaft does not spring back, the governor is defective and must be replaced. Ignition C Use a circuit tester to measure the resistance of the pri- mary coil and the secondary coil. If either of the measured values is outside the specified value, the ignition coil must be replaced. Ignition Coil Resistance TypeA | TypeB Primary Coil © - @ 11-1402 1.2 An Secondary Coll ©-@ 112.2- 1490] 86-1300 SPARK PLUG Insulation Resistance Inspection Use an ohmmeter to measure the insulation resistance. If the measured value is less than the specified value, the spark plug must be replaced. Insulation Resistance Ma More than 5)ENGINE MECHANICAL 313.012 ¥ wu l 0313-013, Insulation Resistance Inspection (Using a Spark Plug Tester) Use the spark plug tester to check for excessive carbon deposits, cracked insulation resulting in short circuiting, and terminal abrasion resulting in voltage surging. If any of these conditions are discovered, the spark plug must be replaced. Spark Plug Gap Adjustment Measure the spark plug gap and inspect the spark plugs. Adjust the spark plug gap if required. Spark Plug Gap Without catalytic ] 0.7-0.8 converter vehicle (0.028—-0.031) With catalyti 1.0-1.1 converter vehicle (0.040—-0.043) mea HIGH TENSION CABLE Check the cable for broken insulation. If there is broken insulation, the cable must be re- placed. 2. Check the terminals for corrosion and looseness. If the terminals are corroded or loose, the cable must be replaced. 3. Measure the cable resistance. lf the measured resistance deviates from the speci- fied value, the cable must be replaced Cable Resistance Ko/m 9.6 — 22.4 Note: The cable contains a synthetic conductor which is easily damaged. Never stretch or kink the cable. Never stick a needle or the pointed end of a probe into the cable during a timing check. An increase in resistance will occur at that point, causing the cable to burn.ENGINE MECHANICAL 6A-33 GENERAL DESCRIPTION (080100-003 ogo1028,os01020 The 4Z Series model engine, designed to meet the strictest emission control regulations, is used on TFR and TFS vehicles. This engine features aluminum alloy cylinder heads and hemispherical combustion chambers. The cross- flow intake and exhaust port valves have a “V" configuration A one-piece cast iron cylinder body is used. The oil pump and the water pump are built into the upper front of the cylinder body. The crankshaft is supported by five bearings for optimum stiffness. The counter weights are forged as part of the crankshaft. The timing train consists of the timing belt and the single overhead camshaft (SOHC)