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    2K views205 pages

    Toyota 4Y Engine Book

    Uploaded by

    marjan43
    engine manual

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    © All Rights Reserved
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    TOYOTA FORKLIFT REPAIR MANUAL TOYOTA MOTOR CORPORATION = FOREWORD This repair manual describes the description, construction, trouble shooting, removal, disassembly, inspection and repair, assembly and installation of the various components of the 4Y model engine equipped on the Toyota Forklift Trucks. You are encouraged to become thoroughly familiar with this manual so as to make the most of the outstanding performance and durability features of these vehicles mounted with the 4Y engine and to perform the proper servicing to maintain them in tip-top running condition. | This repair manual contains the latest information available as of August 1986. For any changes thereafter, you are asked to consult the Parts & Service News. Toyota reserves the right to make changes in specifications and descriptions with- out incurring any obligation and without previous notice. TOYOTA MOTOR CORPORATION SECTION INDEX — “STARTING SYSTEM _ _CHARGING SYSTEM _ -SSTLIST _ "SERVICE STANDARL GENERAL Page ENGINE VIEWS 2.0.0.0... 0. 0ccece eee eee eee eee ee 02 ENGINE PERFORMANCE CURVES 03 SPECIFICATIONS 05 ABBREVIATIONS . 06 TIPS FOR OPERATION .............00.00ee essere 06 STANDARD BOLT AND NUT TIGHTENING TORQUES . 07 0-2 ENGINE VIEWS AY Engine Exterior Views KAS426 ~6- ENGINE PERFORMANCE CURVES 0-3 Engine horsepower 40} 30} 16.5/1800 a 4/2100 ? 200/200 14 18 22 Engine speed (rom) 28 ww E na € a 2 10 egrn} 260 y Fuel consumption ratio 180 (alps) x10? 4Y Engine Performance Curves (11.75 ton) ~7- KANT ~ ee ~ g Z g women cnesvonsunvesjons 2 ee £22 8 § 8 8 8 ee hE 28 68/1800 sarzaoo NJ 70 12 18 cr Engine speed (pm) 4Y Engine Performance Curves {2-3 ton) semodossoy aui6ug 0-5 SPECIFICATIONS [ 1 ton series 2,3 ton series Engine model | ay - Type Gesoling © Gyele a . No, of oylinders and arrangement Indine 4 oylinders, longitudinal arrangement Starting method Self-starting = Combustion chamber type ‘Wedge type - Valve mechanisin ~ OHV, Chain drive = Bore x Stroke mmm fin.) | 97.0 x 86.0 (3.58 x 3.39) = Total displacement 6 (eu:in} 2237 (138) + Compression ratio 92 = Compression pressure kg/cm? {psi)/rem 12.5 (178)/280 « Rated horsepower PS/iom 45/2100 54/2400 Maximum torque kom (feibi/rm 16. (11ei/rom « secede MEET tosh tem) | 200 (2000) | 195 (2300) Engine dimensions | S76xsI2x 707 (length x width x height) me tin) | (96.6 x 20,2 x 27.8) - Service weight kg fib) | 134 (295) e Number of piston rings Beam Reason ings < . Open ag? BTDC | - Intake valve timing Close 40° ABDC = ~ | Open 54° BEDC - Exhaust vatve timing = Close & ATDC ~ intake 0 (Self adjusting) | « Valve clearance - + - - Exraust | , | = Idle speed rom 850 # 60 - No-load maximum governed speed rpm | 7300 # 60 2600 # 60 PCV system type Closed type + 0-6 ABBREVIATIONS Abbreviation Abbreviation {cociel Meaning code} Meaning ASSY Assembly ois Oversize ABDC After bottom dead center 3) OPT Option ATDC After top dead center RH Right hand BB0C Before bottom dead center cpm | Revolutions per minute BTDC Before top dead center Sst Special service tool BDC Bottom dead center sTo ‘Standard EX Exhaust SUB-ASSY Sub-assembly vA Integrated ignition assembly Ts Tightening torque IN Intake us Undersize LH Left hand GENERAL RULES OF SERVICING WORK PREPARATION BEFORE DISASSEMBLY 1. Prepare mechanic tools, necessary measuring instruments and SST before starting operation. 2. When disassembling a complicated assembly, put punch or matching marks at places not affecting function to facilitate reassembly operation. When repairing an electrical system, start operation after disconnecting the cable from the battery negative terminal. INSPECTION DURING DISASSEMBLY 1. Each time a part is removed, check the part installed state, deformation, damage, roughening state and seratching, ORDERLY ARRANGEMENT OF DISASSEMBLED PARTS 1. Disassembled parts shall be arranged orderly, Distinguish the parts to be replaced from the parts to be reused, CLEANING OF DISASSEMBLED PARTS 1, Parts to be reusad shall be cleaned and washed thoroughly. INSPECTION AND MEASUREMENT 1. Detaited inspection and measurement shail be carried out as required for parts to be reused. INSTALLATION 1. Install good parts according to the correct procedure and observing the determined standards (tighten- ing torques, adjustment values, etc.) 2. Always use genuine parts for replacement of existing parts. 3. Always use new packings, gaskets and cotter pins because they are not meant for reuse. 4. Coat seal packing on gaskets depending on the places, coat oil on the sliding contact places, coat oi or grease at specified places, and coat MP grease on oil seal lips before reassembly. ADJUSTMENTS AND OPERATION CHECK 1. Adjust to thé service standard values by using gages, a multimeter, etc. —10- 0-7 STANDARD BOLT AND NUT TIGHTENING TORQUE JUDGEMENT Standard bolt and nut tightening torques are not indicated; therefore tightening torque must be judged as below: 1. Find out the type of the bolt from the tist below. Then, find the bolt tightening torque frorn the table. 2. The nut tightening torque can be judged from the bolt type. (See the table.) LIST OF BOLT TYPES AND STRENGTH 1. Sudging by pert 2. Judging by part No. Shape and description Type Hexagon bolt "Number in reief or | 2727 |] Semple number | hallmark on the 91111-40610 Hexegon ea 6=6T o61¢ bolt prea ye7t Standard T Length (mom): A bottom surface I Diameter (mm): B No mark. at I Type Hexagon T | bolt | {Collared No mark at CR Te Hexagon ! 1 (Standora I Two relief lines on sr A bottom the head \ | bottom) surface) Y Hexagon at ‘ Two relief lines on er ‘clare bottom) the head Stud bolt i Hexagon | Three relief lines on |p bolt I the head Sample number 92132-40614 | L Welded we la Length om): A Diameter (mm): B ! Type Welding | No mark 4T 1 Ts bolt Ll LUUUUUUY Q aes Stud Stuc | Approximately 2mm 1 (0.08 in.)hollowon | 6T either or both ends a BAHS28 BAHS25 -We 0-8 STANDARD BOLT TIGHTENING TORQUE Precoated bolts (bolts and nuts coated with seal lock agent on threaded parts) 1. Do not use precoated bolts in any of the fol: lowing cases: (1) When a precoated bolts is removed. {2) When a precoated bolts is removed as result of tightening check, etc. (When it is loosened or tightened) Note: Check the torque with the lower limit of the tightening torque. If it moves, retighten it, according to the following procedure: 2, Method for reuse of precoated bolts (1) Clean the bolt and threaded hole. Clean the threaded hole when the bolt is to be replaced (2) Dry the cleaned parts thoroughly by air blowing. (3) Coat the specified seat lock agent on the threaded part of the bolt. Standard tightening torque gem (ft-/b) b Diameter Pisch a San yee andar eat wi 6 10 55 ( 4.0) 60 { 43) 8 1.25 130 ( 9.4) 145 (10.5) 30 1.25 260. 8.8) 290 (20.9) aT 12 1.28 480 (34.7) 540, {39.0} 14 15 760 (54.9) 850 (61.4) 16 16 1,150 {83.0) _ 6 10 65 (4.7) _ 8 1.26 160 (11.6) - 10 1.25 330 (23.8) | oT 12 1.28 600 (43.3) ~ 14 1S 930 (67.1) _ | 16 15 4,400 (101.1) _ 6 1.0 80 ( 5.8) 90 ( 6.5) 8 | 1.25 195 (14,1) 210 (16.2) 6T 10 | 1.25 400 (28.9) 440 (31.8) 12 | 1,25 730 (52.7) 810 (58.5) 44 15 1,100 (79.4) i 1,260 (90.3) 6 10 110 ( 7.9) 120 ( 8.7) 8 1,25 (260 (18.8) 290 (20.9) 10 1.25 530 (38.3) 590 (42.6) uv 2 1.28 970 (70.0) 1,050 (75.8) a4 15 1,500 (108.3) 1,700 (122.7) i6 16 2,300 (166.1) BAHS6 ~12- Seal locking eaterial 84460 ENGINE TUNE-UP COOLANT INSPECTION . ENGINE OIL INSPECTION...............-..2200005 BATTERY ELECTROLYTE LEVEL AND SPECIFIC GRAVITY INSPECTION . AIR CLEANER INSPECTION AND CLEANING ...... CLOGGING WARNING SYSTEM INSPECTION ....... V-BELT INSPECTION AND ADJUSTMENT .......... IGNITION PLUG CLEANING AND GAP INSPECTION & ADJUSTMENT ................05 IGNITION TIMING INSPECTION AND ADJUSTMENT . 2.22.06. 0 2 eee eee cee eens IDLE-UP SPEED INSPECTION AND ADJUSTMENT IDLE SPEED INSPECTION AND ADJUSTMENT |. NO-LOAD MAXIMUM GOVERNED SPEED INSPECTION AND ADJUSTMENT COMPRESSION PRESSURE INSPECTION .. =13- Page 12 12 1:3 13 1-4 15 15 1-2 COOLANT INSPECTION 1. Coolant Inspection (See Section 5.) Standard: The coolant jevel in the radiator reservoir tank shall be between the FULL and LOW lines. The LLC concentration shall be 30% (50% in frigid zone) or more, and the coolant shall not be contaminated with oil, etc. ENGINE OIL INSPECTION 1, Engine Oil inspection Standard The oil level shall be between F and L on the dipstick. The oil shall not be heavily contaminated, and the viscosity shall be proper. Neither coolant nor light oi shall exist in the engine oil. BATTERY ELECTROLYTE LEVEL AND SPECIFIC GRAVITY Inspecting the Coolant KAHS109 INSPECTION Inspecting the Engine Oil Luos09 1. Battery Electrolyte Level Inspection Standard: The electrolyte level shall be between UPPER LEVEL and LOWER LEVEL. The specific gravity shall be 1.28 (at 20°C). Caution: If the battery electrolyte is insufficient, add | distilled water. Inspecting the Battery Electrolyte Level Kausso4 AIR CLEANER INSPECTION AND CLEANING 1, Air Cleaner Element Inspection and Cleaning (1) Check the air cleaner element for da- mage, dirt and clogging. (2) Use compressed air to clean the air cleaner element, Caution: The air pressure shall be 7 kg/em? (99 psi) or less. Cleaning the Air Cleaner Elernent 1 KaHstit 1. Air Cleaner Case Cleaning (1) Clean the inner and outer surfaces of the case with cloth CLOGGING WARNING SYSTEM INSPECTION 1. Inspection on vehicle (1) Check that the air cleaner warning lamp ‘on the instrument panel comes on when the key switch is set to ON, and that it goes off when the engine starts. 2. Individual inspection (1) Check current conduction when a nega- tive pressure is applied to the vacuum switch Standard: Approx. 50 mmHg or above: Conduction Approx. 35 mmHg or less: No conduction Ceution: Do not apply a negative pressure exceeding 75 mmHg to the vacuum switch. V-BELT INSPECTION AND ADJUSTMENT 1. Vehelt Inspection (1) Check that the belt is correctly installed. (2) If squealing or slipping exists, check the belt surface in contact with the pulley for wear, damage and scratches, and the pulley for surface defects. (3) Push the center of the belt between the alternator and water pump with a force of 10kg (22 Ib) and measure the flexure. Standard V belt flexure: New belt canto) (0.26-0.35) [Freese 9 eaten Caution: © Always measure the belt flexure at be- ‘tween the specified pulleys. AIR CLEANER | Warning Lemp KAds2 Inspecting the Vacuum Switch KAHS125 aN Pushing force: NS TOkg (22 Io) / | Straight edge e Cc J Fexure Inspecting the V-belt Flexure KAISI ~B- 14 © When replaced with @ new belt, adjust the flexure to the central value of the stan: dard range for the new belt. © When inspecting a belt used for 5 minutes ‘or more, apply the standard for general inspection, © When reinstalling a belt used for S minutes or more, adjust the flexure to the central value of the standard range for general inspection. (4) When the belt tension gauge is available, apply the gauge at the center between the alternator and water pump to measure the tension of the V-belt SST 09216-00020 \Vebelt tension standard: For new belt kg io) | 38-62 (84-137) For general inspection ‘eo (iby | 90-50 (66-110) 2. Vebelt Flexure Adjustment (1) Loosen fixing bolts A and B. (2) Turn adjusting bolt C to adjust the flexure. (3) Tighten fixing bolts 8 and A in this ‘order. (4) Check the belt tension {flexure or tension) IGNITION PLUG CLEANING, AND GAP INSPECTION & ADJUSTMENT 1. Gap Inspection and Adjustment (1) Inspect the gap and adjust it if the stan- dard is not satisfied Standard: 0.7 - 0.8mm (0.028 ~ 0.031 in.) (See page 7-3) ce Adjusting the V+ Inspecting the Ignition Plug ~16= iG0089 IGNITION TIMING INSPECTION AND ADJUSTMENT 1. Engine warm up Standard: Coolant temperature: 75 ~ 85°C Engine oil temperature: 70°C or more Hydraulic oil temperature: 50°C or more 2. Tachometer and timing light installation (1) Disconnect the test connector and con- ect the tachometer measuring lead to the black wire, 3. Idle speed inspection Standard: 650 £50 rpm 4, Ignition timing inspection and adjustment (1) Disconnect the vacuum hose from the Distributor (IIA), “Test conhector (black wire) Installing the Tschometer KASS (2) Use the timing fight and inspect the ignition timing, Standard: 7° BTDC/650 mpm (3) If the standard is not satisfied, loosen the’ distributor set boit and turn the distributor for adjustment to the stan: dard value. (4) Tighten the set bolt and recheck the ignition timing T= 1.85 kom (18.4 ftb) (5) After ignition timing adjustment, seal the distributor set bolt by using the sealing tape. IDLE-UP INSPECTION AND ADJUSTMENT 1, Engine warm up Standard: Coolant temperature: 75 ~ 85°C Engine oil temperature: 70°C or more Hydraulic oil temperature: 50°C or more ‘Tachometer installation (See above.) 3. Idle-up speed inspection and adjustment (1) Start the engine, Disconnect the vacuum hose @) from the idleup actuator ©) , andl measure the engine speed. Standard: Clutch model: 1350+ 25 rpm Torque converter model: 1280 + 25 rpm If the standard is not satisfied, turn the adjusting screw @ for adjustment. Caution: Clockwise turn of the adjusting screw in- _gjusting the Idle-up Speed KAL209 creases the engine speed. n -W- 1-6 IDLING SPEED INSPECTION AND ADJUSTMENT 1. Engine warm up Standard: Coolant temperature: 76 — 85°C Engine oil temperature: 70°C or more Hydrautic oil temperature: 50°C or more 2, Tachometer and vacuum gauge installation (1) install the tachometer. (See page 1-5.) (2) Remove the intake manifold plug @ and connect the vacuum gauge 3. Idle speed inspection and adjustment (1) Start the engine. Alternately turn the throttle adjusting screw C) and idle adjusting screw @) to maximize and stabilize the vacuum while maintaining the specified idle speed (2) When engine idle spead does not return to the normal (preset) speed due to the imterference or contact between the idle-up adjusting screw and the idleup actuator rod, loosen the idle-up adjusting screw. (See page 15) Standards: Idle speed: 660 + 60 rpm Vacuum: 400 mmHg NO LOAD MAXIMUM GOVERNED! SPEED INSPECTION AND AD- JUSTMENT (See page 3:34) COMPRESSION PRESSURE INSPECTION Note: Measuring the Compression Pressure emai, If output reduction, excessive oil consump- tion or extremely bad fuel consumption ratio is observed, measure the cylinder com- pression pressure. 1. Engine warm up Standard: Coolant temperature: 78 —85°C Engine oil temperature: 60°C or more 2. Remove of all ignition plugs 3. Distributor connector disconnection 4, Compression pressure measurement Caution: Run the starting motor to discharge foreign matters from cylinders before the com- Pression pressure measurement, (1) Insert the compression gauge to the ignition plug hole. (2) Fully open the throttle, (3) Crank the engine by the starting motor and measure the compression pressure. Standard: 12.5 kg/cm? (178 psi) Limit: 8.0 kg/em* (128 psi) Caution: Always use 2 fully charged battery to keep the engine speed at 250 rpm or above. (4) Repeat steps (1) to (3) above for all cylinders and inspect the pressure dif ference. Pressure difference limit: 1.0 kg/cm? (14 psi) (5) If the compression pressure is below the limit or if the compression pressure in any cylinder is deviated beyond the pressure difference limit, add engine oil slightly through the ignition plug hole, and repeat steps (1} 10 (3) @ if the pressure rises after the oil ad- dition, the piston rings and/or cy- Tinder bore may be worn or damaged. @_ If the pressure is still low after the oi addition, valve seizure, valve contact defect or pressure leak from the gasket may be the reason. 5. Distributor connector reconnection 6. Ignition plug instatlation T= 1.8 kom (13.0 ft-lb) -19- ~20- ENGINE OVERHAUL ENGINE SECTIONAL VIEWS............--200--005 CYLINDER HEAD .... TIMING GEAR & CAMSHAFT ...........-.-----++ CYLINDER BLOCK =21- 21 Page 22 24 2-25 . 241 2-2 ENGINE SECTIONAL VIEWS AY Engine Longitudinal Sectional View Laois, ~22- 4Y Engine Transverse Sectional View LAOLs =23- 24 CYLINDER HEAD COMPONENTS Peres 7 10. oe (Cylinder head cover SUB-ASSY Seal washer Cytinder head cover gaskat il filer cap SUB-ASSY Gasket Gylinder head SUB-ASSY Intake valve guide bush Exhaust valve guide bush Shaft snap ring Plug Gasket 12 13. 14. 16. 16. 17, 18. 19, 20. 21 22. Intake valve ceat Exhoust valve seat Ignition plug hote Gasket Cylinder head gasket Gasket Head rear plate Valve rocker arm, No. 2 Saring Valve rockerarm, No. 1 Volve push rod 23, 24. 28. 27. 28, 30. 31 32. 33, Value lifter Stud bott Stud belt Valve rocker shaft No. 1 Valve spring retainer tock Valve spring retainer Valve spring Valve stern oil seal Spring seat Intake velve Exhaust valve Cylinder Head Components ~24— KAJMS ‘Manifold Components —25— KAsM4 2-8 CYLINDER HEAD REMOVAL. 1. Fan, fan pulley and V-belt removal (1} Loosen alternator fixing bolts (2 pes.) and the adjusting bolt (2) Fan (3) Fan puliey (4) Vebelt 2. Alternator removal (1) Fixing bolts (2 pes.) (2) Adjusting bolt (3) Alternator Removing the Alternator (2) = 26~ Katia 3. Air cleaner connector disconnection (1). Disconnect ventitation hose No. 3. (2) Disconnect the connector to governor hose. (3) Remove set bolts {2 pos.), and remove the air cleaner connector. Disconnecting the Air Gleaner Connector KAJI1.23. 4. Carburetor removal (1) Disconnect vacuum hoses (4 pes.) Note: Attach identification tags to the vacuum hoses before disconnection. (2) Disconnect the water hose. (3) Disconnect the fuel piping, (4) Remove set nuts (2 pes.), and remove the carburetor. 5. Governor removal (1) Disconnect ventilation hose No, 1 (2) Disconnect the water hose. (2) Remove the air governor. (4) Remove the heat insuletor and fuel insulator plate, Removing the Air Governor KASI1.36 -27- 2-8 6. Water outlet pipe removal (1) Union bolt (2) Set bolts (2 pes.} (3) Water bypass hose disconnection (4) Water outlet pipe 7. Ignition plug and tube removal {1} Use an ignition plug wrench and remove ignition plugs (4 pes.} and ignition plug tubes (4 pes.) 8. Oil Jevel gauge set bolt removal 9. Fuel pipe and hose removal {1) Disconnect the fuel pipe from the fuel pump, {2} Fuat pipe clamp set bolts (2 pes.) (3) Fuel pipe and hose ee S . Flomoving the Oil Level Gauge Set Bolt Disconnecting the Fuel Pipe and Hose 28 A320 10. Cylinder head cover removal (1) Cap nuts (3 pes.) (2) Seat washers (3 pes.) (3) Cylinder head cover (4) Gasket 11. Valve rocker shaft ASSY removal (1) Evenly loosen three valve rocker shaft set bolis and two nuts in the illustrated ‘order in several steps, and remove them. (2) Remove the valve racker shaft ASSY. Removing the Valve Rocker Shaft ASSY ewan? 42. Valve push rod removal Caution: Extracted push rods shail be arranged in the order of cylinders. 13. Manifold removal (1) Set nuts (8 pes.) (2) Manifold (3) Gasket Removing the Manifold KANS-27 2-10 14, Water pump ASSY removal (1) Water inlet hose disconnection {2} Set bolts (4 pes.) (3) Water pump ASSY 15, Cylinder head removal (1) Evenly loosen 13 cylinder head bolts in the illustrated order in several steps (2} Remove the set bolts and remove the rear engine hanger. (3) Remove the cylinder head from the cylinder block. Caution: Carefully prevent the cylinder head instatla- tion surface from any damage. CYLINDER HEAD DISASSEMBLY 1. Valve remaval {1} Set the SST to the vaive to compress the velve spring, and remove two retainer locks, SST 09202-43013 (2) Remove spring retainers, springs, seats, valves and oil seals. Caution: Removed parts shall be arranged orderly for each cylinders. Kasse Removing the Cylinder Head eM2416 sst | i | égé om BE =30 | 2-11 CYLINDER HEAD INSPECTION AND CLEANING 1 Piston and cylinder block top surface cleaning (2) Rotate the crankshaft to bring each piston to the top dead center. Use a gasket scraper and remove the carbon deposit on top of the piston, (2) Use the scraper and remove the gasket adhering on the cylinder block top sur face. (3). Use an air gun to blow off oil and foreign matters from bolt holes, Caution Use cloth to prevent splashing of oit Cylinder head gasket removal (1) Use the scraper and clean the cylinder head bottom surface and manifold in- stallation surface, Caution: Do not damage the cylinder head during cleaning. Cylinder head combustion chamber cleaning (7) Use @ wire brush to remove the carbon. from the combustion chambers Caution: Do not damage the surface to be in contact with the head gasket Valve guide bush cleaning (1) Use a solvent and clean the inner surface of the valve quide bush. Cleaning the Cylinder Block M2532 Soe SS 9, SE SOSO a a a SS Soe > x 0, a> 2. Ss = TOS ASC TV TV r Sena waar ez ‘Contact width Correcting the Valve Seat (2) M0185 Intake 60° Exhoust 65° . 45 S¢ Gohtact with M2535 Correcting the Valve Seat (31 so Se % 1G Se S S SRG eMo1E6 Lapping the Vaive —36— ew2400 14. Valve spring inspection (1) Use a straight edge and thickness gauge, Squareness —e}-=— ‘and measure the squareness at the top } end of the valve spring, Limit: 2.0 mm (0.079 in.) Replace the vaive spring if the limit is exceeded. ‘Measuring the Valve Spring Squareness M0988 (2) Use 2 vernier caliper and measure the free length of the valve spring Standard: 47.0 mm (1.85 in.) Meaturing the Valve Spring Free Length ENog07 (3) Use a spring tester and measure the in- stalled tension of the valve spring, Standard: 28.8-35.2 kg (63.5~77.6 |b} (When the installed length is 40.6 mm (1.598 in.)} If the standard is not satisfied, replace the valve spring, Rieasuring the Valve Spring Installed Tension - M0281 15, Valve rocker arm inspection (1) Inspect the rocker arm for the wear and damage of the surface in contact with the valve stem, (2) If slight surface defect is found, correct with an oil stone. ff heavily worn or damaged, replace the rocker arm, Inspecting the Valve Rocker Arm (1) M2399 ~37~ 2-18 (3) Move the rocker arm as illustrated, and inspect the clearance with the rocker arm shaft Standard: Almost no looseness shall be felt. If any looseness is felt, disassemble the rocker arm ASSY and inspect the oil clearance. Inspecting the Vaive Rocker Arm M2298 16. Rocker arm to rocker shaft oil clearance {1) Use a caliper gauge and measure the rocker arm inside diameter Standard: 18,500 ~ 18.515 mm (0.7283 — 0.7289 in.) ‘Measuring the Rocker Arm Inside Diameter EM2297, {2) Use a micrometer and measure the rocker shaft outside diameter. Standard: 18.474 — 18.487 mm (0.7273 ~ 0.7278 in.) (3) Calculate the difference between the rocker arm inside diameter and rocker shaft outside diameter. Standard: 0.013 — 0.041 mm ' (0.0005 — 0.0016 in.) Limit: 0.08 mm (0.0031 in.) If the limit fs exceeded, replace the Measuring the Rocker Sha Outside M2096 rocker arm and rocker shaft, Diameter No, 2 (4) Assemble the valve rocker shaft ASSY No.1 1 Check the direction of the rocker {A acm shatt rear end, assemble the Q rocker arms and springs as illustrated, and position them by using SSTs. Protrusion SST 09270-71010 Front With protrusion Positioning the Rocker Arms M2295 ~38~ 2-19 17. Push rod inspection (1). Inspect the push rod runout Runout fimit: 0.30 mm (0.0118 in.) If the limit is exceeded, replace the push rod. (2) Inspect the push rod end ail hole clog ging. If clogged, clean with an air gun, Inspecting the Push Rod M2536 18. Intake and exhaust manifold distortion in- spection (1) Use a straight edge and thickness gauge, and measure the distortion of the in- stallation surface to the cylinder head, Limit: 0.40 mm (0.0167 in.) If the limit is exceeded, regrind or re- place the manifold ASSY. eM2304 2-20 CYLINDER HEAD ASSEMBLY Notes © Thoroughly clean the parts to be assem: bled. © Coat engine oil on the sliding contact and rotating surfaces. Replace the gaskets and oil seals with new parts, 1. Valve assembly (1) Insert valve @) into the valve guide bush. (2) install valve spring seat @) and oil seat @ Coat engine ail on the valve stem and oit sea fp, (3) Install valve spring @ and spring re rwiner ©. Upwars wow: t The paint mark on the spring shall face the head. Paint mark Assembling te Valve () Eos 0476 (4) Use the SST to compress the valve Spring, and install spring retainer lock est | ©. | SST 09202-43013 2 (5) Tap the valve stem top fightly with a plastic hammer to settle the spring, alg Assembling the Valve (2) em2a13, CYLINDER HEAD INSTALLATION 1. Cylinder head installation (1) Install a new gasket 10 the cylinder block, paying attention to its direction, (2) Install the cylinder head. (3) Coat engine oil on cylinder head bolts. Installing the Cylinder Head Gasket em2393 -40- (4) Evenly tighten 13 cylinder head bots in the ilfustrated order in several steps, T= 9.0 kg-m (65 ft-lb} «Mi2} T= 1.95 kam (14 ft-lb) «is) Push rod and vaive rocker shaft ASSY in- stallation (1) Install each push rod @) at its original position before removat. {2}, Use the SST ond positfon the push rods as illustrated SST 09270-71010 Caution: Check that the push rod is surely in the lifter push rod seat portion. (3) Install the valve rocker shaft ASSY to ‘the cylinder head (4) Evenly tighten 3 bolts and 2 nuts in the illustrated order in several steps. 40 kg-mn (17 fttb} Caution: Keep the push rods from leaving the rocker arm, and tighten the bolts and nuts. Water pump ASSY installation (1) Install a new gasket, (2) Install the water pump ASSY. (3) Tighten 4 set bolts. T= 1.85 kg-m (13 ft-lb) (4) Install the waterinlet hose, 2-21 Botts eM2qi6 eM2302 Installing the Velve Rocker Shaft ASSY EM2a17, Instailing the Weter Pump ASSY

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