Specifications c Ignition Timing ENGINE TIMING CONNECTIONS pre Game 20 Niet Spark Pug Connect Reg Ciip to Ponte (+ Battery Terminal Connect Back Clip fos Good Ground aresser2 ‘The correct ignition timing is: Gasdline and dual fuel gear LP fuel 18°BTC NOTE: For engine timing accuracy, the vacuum advance hove must be disconnected from the distributor vacuum advance valve and plugged. See ignition Timing Check and ‘Adjustment in Testing And Adjusting. The No. 1 cylinders, toward the fywhee! end of the engine. Ignition Sequence (Firing Order) © intaxe vatves EXHAUST VALVES erozz7P2 The firing order is 19-42, NOTE: Front end of engine is opposite to fywhee! end. No. + oyfinder isthe rear cylinder of the engine. Spark Plug organs Gap for spark plugs: Gas 0.6 mm (.024 in) P 0.4 to05mm (016 to 020in) Dual Fue! (0.6 mm (.024in} Torque for spark plug... 225t025.0Nem (16 $0 18.0 bt) 2.0 Liter (XN1P) Gasol Engine SpecificationsFuel Filterlock Gas/LP Carburetor sresries 3 ee (1) Fuel outiet port (to converter 2) Tigien to a maximum torque ot @) Fitter element (4) Tighten to a torque ot (8) Fuel niet poet (rom fue tank 25Nem (181 ft) 40t055 Nem (300 401 ft) Fuelock NOTE: The fuslock is used on LP fuel systems which have a separate fue! fite. The fuelock and fuel titer replace the fterock that is used on earlier machines. (1) Fue init port. @) Fuel outet port. ‘The fuetock must open against 1034 KPa (150 psi at 9V and room temperature of 25°C (78°F) 1 co 702061 (1), Gasatine ful inet. 2) LP tuct init (3) Idle mixture adjustment screw. See the topic lole Mixture ‘Screw Adjustment in the Testing And Adjusting section (4) Velocity governor, High ite rpm T25D-TC40D; v250.VC400 2400+ 100 rpm ‘T40D-TG600; v400-VO500 2500 1001pm TAQE, TSOE, VAOE, VEOE 2800 100rpm ‘See the topic High idle Adjustment in the Testing And ‘Adjusting section. (8) High idle stop (©) Low idle spoed setscren. Low idle spoed 850: 01pm See the topic Low lile Adjustment in the Testing And ‘Adjusting section, 2.0 Liter (XN1P) Gasoline Engine SpecificationsLP Fuel Converter Current - 701189, 7E9725 Earlier - 2W4392 areca (1) Screws that fasten the cover to the main body. Tighten all sorens (1) until contacts mace wth tne ‘cover. Then tighten screws thorough from one side to the opposite side until all screws (1) have a good seat ‘There should be no air leaks for ten minutes when 725 KPa (120 psi) is applied to the converter. See the topic Converter Pressure Test in the Testing And Adjusting section. (1) Starting and ice adjustment screw. Turn clockwise to increase ide speed. (2) Fuel outlet port (to carburetor) (@)_ Vacuum port (to inlet marifole, (4) Water inlet port. (6) Water outet port (6) Fuel nit port (trom fiterlock) 2.0 Liter (XN1P) Gasoline Engine 86 SpecificationsFuel Pump Oil Pan erode (1) Put 983268 Thread Lock on ott, torque for 16 bolts (not shown) 10.0Nem (80 in) () Put 983269 Thread Lock on 2 studs (nt shown), torque for nuts 10.0Nem (80 0) (8) Torque for oil rain lug .... 95 t0 40 Nem (26 0 30 bt) 3 eraesses Oil Filter (1) Electrical power connection. Operation vatage 1010 16V0C Maximum curren a 12 VBC 148 @ Fue out 7 ‘Maximum outlet pressure at zero_ | dalvery 31.01062.1 kPa (4.5109 psi) (8) Foal inet Maximum seltgiing it 487 mm (18in) ‘The pump delivery, when the pressure is controlled, is as follows (at 12 VDC} Delivery when the pressure is 5 KPa (73 psi)..... MOL (28.1 gain) Delivery when the pressure is 18 KPa (2.18 psi)... 75L/h (19.8 gain) Delivery when the pressure is 25 KPa (3.63 psi)... 25L/h (8 oan) 025901 (1) Put 983268 Thread Lock on bolts. Torque for bolts is 13.0Nem (10.0164) 2.0 Liter (XN1P) Gasoline Engine 7 Specifications(2) Wipe clean the fiter adapter inthe area thatthe new filter makes contact. Put clean engine oll on the new fiter gasket. install iter unti contact is made, then tighten 3/4 turn more (@) Torque for oil pressure switch 40Nem (01 ft) Oil Pump 2702401 (1) Tighten botts to a torque of 10.0Ner (80 in) Intake Manifold 2702091 Exhaust Manifold Put §P3931 Anti Seize Compound on stud threads. (71) Torque tor nuts that tasten exhaust manos to cytinoer| head '20t025Nem (15to 18) (2) Torque for 2 nuts (not shown) 55+ 10Nem (40710) Cylinder Head 70683 (1), Cylinder head thickness: New 92.50.15 mm (3.642 006 in) Minimum after machining 92.10 mm (3.626in) (@) Maximum permissible amount of bow (aut of (1) Torque for 5 bolts and 3 nuts (not shown) that fasten intake manifold to cylinder head 201025 Nem fat) oor oa (1510 18) (2) Torque for 2 nuts (not shown) that fasten carburetor to manifold 10t0 15Nem @.0t0 11.0 1H) 2.0 Liter (XN1P) Gasoline Engine Specificationsc Head Bolt Tightening Procedure 11. Ifa bot turns at less than 50 Nem (37 Ib ft in Step 10, repeat Steps 7 through 10. 412, Tighten the rocker shaft nuts in letter sequence to a torque of 18 Nem (11 loft), See the ilstration fr nut Fdenitication. 18. Set the intial valve clearance. When a new head gasket is installed the initia valve clearance is sat at. Exhaust (0.30.mmn (012 in) Intake (0.18 mm (006 in}, 14, Run the engine at 2000 rpm and ne load for 10 minutes 15. Tighten bolts + through 10 in sequence an additional 20° (he of a complete turn) with an 873082 Degree Turn Inceator 16. Let the engine cool @ minimum of 2 hours. or unti the engine temperature is a maximum of 15°C (27°F) above crosses ‘ambient. Then check bolts 1 through 10 for minimum torque of 80 Nem (37 Ib), 17. Ita bolt turns at less than 80 Nem (37 b ft) in Step 16 Use the procedure that corresponds to the engine serial No, lnosen all bots and repeat Steps 8 through 17, NOTE: The following procedures are for the original Check the valve clearance (engine cold) and adjust i ‘production parts. I paris are interchanged these procedures ‘required. The speciied valve clearances are! are not correct, Exhaust (0.251mm (010 in) Intake (0.10 mn (004 in), Engine Serial No. 1ABNO - 12820 she Engine Serial No. 1ABNO13321 - 42860 Teast — = =o area Pass Cara Sa aca Pas aston Toa Ga et Fl CS Ge a : FES ope 7 LR Sere TE bape Tam ST ; 1. Pace anew neha gasket nha ck and on Peseta 2. nse 60474 Cnr He Ge (vy paced Re lietss 2. rsa wo 108738 Cynder Heed Ges (ve spaces) 2. Pace the wars on cir ad bt anda 6V4876 Molykote Paste Lubricant to the threads, ‘3. Apply 6V4876 Molykote Paste Lubricant to the threads of ee oot 4. ete cynder has athe nc ac Al ie ea ees Ceca nae tabs cece ee Seca ae eee peratt Saif cain needs eee ae ee eae 5 Toten ote and 21 atau of 10256 Nm 7 4 1). See the illustration for bolt identification. 5. Med to ean fae sequence ea forcve of 50+ el dara ee peor 6. Token ronaining botsinsequrcetosd=sNme@r | EMMI SABI = 4'b ft). See the ilustation for Dot identification 6. Loosen all he bolts in number sequence. Loosen, in number sequence, bots 8 through 10, 7. Tighten all the bolts again in number sequence to a torque Tighten bolts 1 through 10 in sequence to torque of 20, of 20 5 Nem (15 = 4 lo ft). 5Nem (15 + 41 ft. ‘8. Then tighten each bolt again in number sequence an 8, Then tighin bots 1 through 10 in sequence an akon autneel 180° thor a Sara aan 120° (i of complete turn) with an 873052 Degree Turn Dagtbe Tun oaeete ee am Inciator 9. Tighten the rocker shat nuts in eter sequence toa torque 10. Check batts 1 trough 10 fora minimum torque of $0 of 15 Nem (11 Bf). See the lustration for bat Nem (37 Ib identication 2.0 Liter (XN1P) Gasoline Engine 89 Specifications10. Set the intial valve clearance. When a new head gasket 'S instaled the intial valve clearance is set at Exhaust (030.mm (012in), Intake 0.15 mm ( 006}. 111, Fun the engine at 2000 rpm and no load for 15 minutes. 412, Tighten each head bolt again in number sequence an ‘adaitional 30° (Vs of a complete turn) with an 873052 Degree Turn indicator. 48. Check the valve clearance (engine coi) and adjust it required, The speciied valve clearances are: Exnaust 0.25 mm (010i Intaxe (0.10 mm (.004in}, Engine Serial No. 1ABNO42861 - UP Tools Needed GVAGTE Molykote Paste Lubricant ‘BT3052_ Degree Torn Indicator 7 1, Place a new cylinder head gasket on the block and align the coolant flow holes. 2. Apply 6V4876 Molykote Paste Lubricant tothe threads of the cylinder head bots 13 Place the eyinder head on the cylinder block. Align the ‘oot holes and instal al the head bolts. Begin threading the bolts by hand, 4, Tighten the bolts in number sequence to a torque of 60 = 5 Nem (44 + 4 lo Mt), See theilustration for bolt identitiation. 5 Wait one minute. Then one bolt ata time do the following thee staps in number sequence 1. Loosen the bolt b, Tighten the bot to a torque of 20 Nem (15 1 ft, €, Tighten the bolt an additional 300 + 5° with an 813052 Degree Turn Indicator. 6. Tighten the rocker shaft ruts in letter sequence to a toque (of 15 Nem (11 Ib ft), See the illustration for bot identification. 7. Set the inital valve clearance, When a new head gasket is installed the intial valve clearance is set at: Exhaust (0.0mm (012in). Intake (0.18 mm (008 in), {8 Run the engine at 2000 rpm and no load for 10 minutes ‘This is an operational check ofthe engine. 9, Check the valve clearance (engine cold) and adjust i required. The speciieg vale clearances are: Valve Clearance 70201 NOTE: The engine must be cold to acust the valve clearance. (1) Clesrance for exaust valve (e0ls) 0.25 mm (10 in) (2) Clearance for intake valve (cold)... 0.40 mm (.004 in) (@) Torque for valve clearance adjustment nuts 12510 17.5Nem @to 13 1b) Torque for rocker arm cover bolts (not shown)... 10Nem (loin) Valves (1) Intake and Exhaust valve spring: Exhaust (0.25mm (010i Length under test force 388mm (1.57 in} Intake (0.10 ram (004 n, Test force 169 (36 lbs) Free length atte: test “44 mm (1.73in) Color blue (@) Exhaust valve stem dameter 802mm (3187 in) () Intake valve stem diameter 800mm (315in) 2.0 Liter (XN1P) Gasoline Engine 920 ‘Specifications(4) Length of exhaust valve (5) Length of intake valve 112.0:mm (4.409 in) 118.25 mm (4.656in) (©) Angle of exhaust valve face a (7) Diameter of exhaust valve head 355mm (1.40in) (8) Diameter of intake valve head 425mm (1.67 in) Angie of intake valve face 30° (10) Valve guide inner diameter: Intake Exhaust 8.04:mm (3165 in) 806mm (3173in) NOTE: Valve guide must be reamed to fit valve stem after instalation. Valve guide to valve stem clearance: Intake (0.02 to 0.06 mm (.0008 to 0024 in) Exhaust (0.04 to 0.08 mm (0016 to.0031 in) (11) Diameter of valve guide and bore. * Outside ciameter of valve guide: New First oversize ‘Second oversize ‘Diameter of bore in cylinder end 1397 mm ($50 in) 14.20 mm (863 in) 4450 mm (571 in) New 14.02 mm (552 in) First oversize .. 14.195 t0 14.225 mm ($589 0.5600 in) Second oversize 14.495 to 14.527 mm (5707 10.5719in) (12) Distance from bottom of exhaust valve guide to bottom ‘of valve seat 1.3mm ( 846n) (13) Distance trom the bottom of intake valve guide to bottom of valve seat B.S (1.24in) (14) Angle of exhaust valve seat 4s (15) Dameter of exaust valve seat and bore. '* Outside diameter of exhaust valve seat New First oversize ‘Second oversize 37.01 mm (1.457 in) ‘37.31 mm (1.4689 in) 37.51 mm (1.4768 in) ‘Diameter of bore in cylinder head! New ‘37.0 mm (1.4567 in) First oversize $37.30 mm (1 4685 in) Second oversize 37.50 mm (1.4764in) (16) Diameter of intake valve seat and bore. ' Outside diameter of intake valve seat New Fist oversize ‘Second oversize ‘Diameter of bore in cylinder head: 4851 me (1.713) 48.85 mm (1.728 in) 44.01 mm (1.7827 in) New 43.50 mm (1.7126 in) First oversize 43.80 mm (1.7244in) Second oversize 44,00 mm (1.7323 in) (17) Angie of intake valve seat 30° 2.0 Liter (XN1P) Gasoline Engine a ‘SpecificationsCylinder Block ersesse1 (1) Inside diameter of bearing surtace bore for camshatt Front 48.0 to 48,039 mm (1.8898 to 1.8913 in) Center 46,0 to 48,039 mm (1.8110 to 1.8126in) Rear 44400 44,039 mm (1.7323 to 1.7338 in) @) Distance from oll pan mating surface to the top of the block 285.9 0.15 mm (11.257 + 006in) (@) Distance from oil pan mating surface to the centerine of the crankshatt bores ... 76.0+0.15 mm (2992 + 006 in) Distance between the cylinder liner locating lange and the top surface ofthe block (not ShOWN) sn 69.985 to 90.045 mm (3.5427 to 3.5451 in) (4) Main bearing bore sizes: ear main 158,731 +0.018mm (2312 + 0006 in) Fear interior main ~. 59.97 + 0.015 mm (2.361 +0006 in) Center main {61.00 + 0.015 mm (2.402 0006 in) Front interior main 62.384 0.015mm (2.456 = 0006 in} Front main 63.227 + 0.015 mm (2.489 0006 in) 2.0 Liter (XN1P) Gasoline Engine 92 ‘SpecificationsCamshaft (1) Torque for retainer and thrust pate bolt A7Nem (25m) End play for camshatt 0.05 100.14 mm (002 to.0055 in) Clearance between camshatt journals and block (0.08 to 0.124 mm (.0024 to ,0049 in) (@) Outside ciameter of tront bearing surface 47.815 to 47.94 mm (1.8864 to 1.8874 in) (8) Outside aiameter of center bearing surface 445.915 1045.94 (1.8077 to 1.8087 in) (4) Outside diameter of rear bearing surface 43.915 to 43.94 (1.7289 0 1.7299 in) TAT 742097 | (6). Height of camshatt lobes (be it}: To find obe it, use the procedure that follows: ‘A. Measure camshatt lobe height (6) B. Measure base circle (7), . Subtract base ccle (Step 8) trom the lobe height (Step A). The difference is actual lobe it (6) D. Spectted camshatt lobe lit is: Exhaust lobe Intake lobe 58mm (228in) 58mm (228in) 2.0 Liter (XN1P) Gasoline Engine SpecificationsCrankshaft 1 2 ‘ srr 5 6 7 8 9 RAESHAFT JOURNAL DETER Tour searing cap Jour eg Dareter ame ‘SaorBoae niga ameter 2Snmeeaem @ Fatman a Bue Beavrws0aremm | W049 88 118mm Gauewsaem Gambwasenn @ | Fonte nana Wie 5850805857 mm] Sage 08272 (aos we som aan wesc @ Car ma aa Gen B,781087 189mm | 887410 88880 rm Gaowsaiem aarwsseern) @ Fear nator nah a Re $6,1401088:168 mn] $8840 8868 mm Gawweatn Geioseios tear) a Fear ural Toor 54905084829 mm | 84605 0 4620 nm (eisai taiteo wane) a Comeding od areal Tea 198040 50000 mm | #8684 0 700m (isto 96661) (isso earn) Tera rain bering cap Bs (SoH) TSNeM ——_() Teaue for ranksat ply nu... TONE (1251019 ee (8) Torque for counterweight bolts 67.5 Nem (50 Ib ft) Tera for connteting rod ap bat rt sown) dann (@) End play for crankshaft 0.08 100.20 mm (.003 to .008 in) Tera fr el etaring blot shown) GSN raya en ply cetemind by4 hal st washers 2 J ‘on each side of the rear main bearing. Main bearing runing clearance. 025 0.976 mn (.0010 to .0030 in) Connecting rod bearing running clearance (0,018%00.081 mm (.0007 to.0020n) 2.0 Liter (XN1P) Gasoline Engine 94 ‘SpecificationsThrust washer thickness (not show), 5 sizes available 2.0mm (0906 in) 2.35 mm (.0925 in) 2.40 mm ((0945 in) 2.45 mm (.0965 in) 2.50. (0984 in) NOTE: Install two 2:30 mm (0906 in) ha thust washers towards the inside of the engine (place the thrust washer side with the lubrication grooves against the crankshaft) Install {wo half thrust washers to produce the desired end play toward the outside ofthe engine 2.0 Liter (XN1P) Gasoline Engine 95 SpecificationsPistons PISTON to LINER MATCHING Pion ent Pion Ter [Panter tert) ameter Bore | “Cerance x B7aB5 w 87998 ne Boom | Guster sascom (aaesoo 30507) 3 873981 8.947 3801) t 88.022 rm 0.06 19 008 mm (accowesaezsn) | (Basso saeseny | (Boss 00st) (9.8825 to 3.4629 in) c 7.947 to 87 958mm | Ss Notchos 186.022 to 88.083 mm (9.485¢ to 3.4659 in) (2.4629 1034630in) | 0 17.958 10 97.969mm | 4 Notches 736.083 to 68.084 mm (9.4859 03.4663 n) PISTON to PISTON PIN MATCHING. Piston Piston ent Pin Number] Piston Pin dent. |__Piston Pin @ Bore Color | __ Diameter + | POE to 78.058 mam | Bue | D901 19 28.008 mam (057 to 9059 in) (2086 to. 2058 in) 2 | 23.000 fo 28.005 mm | White | 22.996 10 23.001 mm (055 to 9057 ny (2054 to 9056 in) 3 [22996 to 28.000 mm| Red | 22.992 to 22.996 mm (2053 to.9058 ny (2052 to 8054 i) reser 6 NOTE: The size ofthe piston must match the size ofthe Cylinder iner and the size ofthe piston pin. The top of the piston has markings (1), (2) and (3) for matching the piston to the piston pin and liner. (1) The arrow must point tothe front ofthe engine when installed (2) The letter (piston identification) must agree withthe number of notches on the cylinder liner. See Cylinder Liner for the location of the notches. See the Piston to Liner Matching chart. (@) The number (piston identification) must agree with the Coicrof the piston pin. See the Piston to Piston Pin Matching chart NOTE: it may be necessary to heat the piston in boling water to instal the piston pin. © (4) Compression ring: Thickness 1.5mm (.0591 in) End gap {6:40 16 0.88 mm (016 to.022in) © (8) Oil seraper ring: Thickness 2.0mm (0787 in) End gap 1614016 0.85 mm (016 t0.022in) © (6) it controt rng: Thickness 3.96 mm (.1558in) End gap 10.38 191.40 mm (01510 §8in) NOTE: When installing piston rings, the marked face of the ring goes up. Position the top two rings so thatthe ring gap is 129° apart, Position the ol control rings so that the ring (gap is 20 to 50 mm (.787 to 1.969 in) apart. 2.0 Liter (XN1P) Gasoline Engine SpecificationsCylinder Liner ‘CYLINDER LINER GASKET SELECTION Liner Projection Gasket (1) Gasket (1) wo tion” | SRetoase Gaia woos | Bue sige] a0 mn tonnes ore Gao | (oe 1 (0.018 10 0.038 mm Red strips | 0.12 mm GC toocr 2 soy ee | faarh, 0008 040018 mm | ~Nesipe “1 08 | coomre'acorn | “Bee | Ban "Use eres vaio a res.vdin Sep? 2 B74Ba2P1 3 ot NOTE: The size ofthe cylinder liner and the piston must ‘match. A liner and piston must be installed asa matched par. (1) The upper flange of the liner is marked with notches at this location. The number of notches must agree with the Piston denttication letter. See Pistons and the Piston to Liner Matching chart. 2) Overat height @) Locating height 135.2 to 196.2 mm (§.82t05.36in) 89.950 t0 90.000 mm (25413 t0 35433 in) (4) The lower locating diameter not aN H Z Y Y Y Y H y howe 308510 02m (658103662) N/ Cylinder Liner Projection Procedure NY Taira N 3700S The Poi at Sep 7 Y ETOH? Ln Caen tal oe “i TOSSA Ler ty Se Gem teen STOO Ta {or Enotes 1ABNO TSE On Braseaer ‘he cpr ine rojcion mut be cored pro Iaaaon te syn inos ote ie eno ine czas tein ence soos ne Se Then net ang beck aiog eine er ean 29 tec any og mate tae ae oe moe 2.0 Liter (XN1P) Gasoline Engine 97 Specifications1. Put the liners in position in the block. Fats (2) on the top ftange of eyindars 1 and 2 and cylinders 3 and 4 must be in alignment NOTE: The pistons and liners are matched assemblies. 2, Measure and record liner projection (X) at 4 equally spaced places (&-B-C.D) around each cyinde. NOTE: The maximum aitference between the 4 places (A.B: (CD) must not exceed 0.04 mm (0016 in). If not corect, remove the liner and check for dit or foregn material. The liner and piston may be switched to another cylinder to meet the specication '3, Mark the positon ofthe liners in the block and remove the lines, 4, Use the measurements recorded in Step 2 and the Cylinder Liner Gasket Selection chart to determine the Correct cylinder liner gasket. ‘The correct gasket gives @ liner projection at the highest point BNO? - 42860... 0.07 190.14 mm (008 0.006 in) {ABNO42861 - UP... 0.080 0.10 mm (6012 to 004n), NOTE: Only use one gesket for each cyinder erase 5, Install dry gasket (1) on the liner 6, Reinstall the liners as per Step 3. NOTE: Be sure the cylinder block and liner mating suraces are clean and tre of foreign material 7. Install the eylinder liner hold down tooling resus 8. Measure and record liner projection (x) at 4 equally spaced places (&-B-CD) around each cylinder Liner projection (is: YABNOT » 42860 ..... 0.07 100.14 mm (003 0.006 in) ABNO42861 - UP 0.080 0.10 mm (6042 to 004 in} ‘The maximum difference inner projection between adjacent liners is, 10.04 mm (0016 in) ‘The maximum difference inline projection around any one oylinder is (0.04 mm (0016 in) 2.0 Liter (XN1P) Gasoline Engine 98 SpecificationsConnecting Rod Engine Timing eresucrs (1) Inside diameter of connecting rod sma end 24.35 to 24,68 mm (9587 t0.9717 in) Outside diameter of small ena bushing 24.373 10 24.476 mm (.9596 to 9636 in) Inside diameter of bushing (installeg) 23.005 to 23.018 mm (9057 to 9082 in) NOTE: The bushing is supplied undersize and must be reamed to size after installation, (2) Distance between center af piston pin bore (small end) and crankshaft bore (big end)... 131,880 182.07 mm (6.1941 t0 5.1996 in} (3) Inside diameter of connecting rod big end 531655 to §3.674 mm (2.1126 102.1131 in) NOTE: Bearings are available for a crankshatt rod journal undersize of 030mm (~012 in) () Torave for connecting rod nuts ‘40Nem (306 ft) reese ‘See ignition Timing Check And Adjustment in Testing And Adjusting forthe timing procedure, (1) Torque for camshaft retainer bolt (@) Torque for plate retainer bolts 17 Nem (13.016 11) 10N+m (7.016) raas7es Camshatt (2) and crankshaft sprocket (4) must be in alignment as shown to install te timing chain Timing marks on chain and sprockets must be in alignment as shown, 2.0 Liter (XN1P) Gasoline Engine 99 ‘Specifications(6) Torque for camshaft sprocket bolts Zann Engine Mounting Groups T25D-TC40D; V25D-VC40D Models eraasert (1) Flywheel housing. 2) Frame, (8) Torque for two bolts a74asert 100% 15Nem (7511 Bf) (6) Torque for chain tensioner bolts... 7ONer (631 in) NOTE: Be sure ol fiteris in postion in the oil galery behind the chain tensioner. raasert (7) Torque for timing case belts 1ONem (9018 in) 2.0 Liter (XN1P) Gasoline Engine ‘SpecificationsT40D-TC60D; V40D-VC60D; T40E & T50E; V40E & V50E Models Radiator Cap crogoser bo aa y/ f/ ( = 379497 Pressure valve must start to open 41.41055.8kPa (to8 ps) Vacuum valve must start to open (below atmospheric pressure) 0.0105.5kPa (010 8 psi) awaas7 Pressure valve must start to open 4481055. kPa (65t08 ps) Vacuum valve must open (maximum) (below atmospheric pressure) 5.0 kPa (Sps) 9yt791 Pressure valve must start to open 85t0 11OKPa VIEW FROM FRONT OF ENGINE (1210 16psi) Senesara Vacuum valve must open (maximum) (below atmospheric pressure) 5.0kPa (Sps) Install shims (1) as required so universal joint gap (A) does: Not exceed 1.5 mm (060 in). Check gap (A) in two positions 90° from each other. (2) Torque for two nuts on the fywhee! housing 160 20Nem (110 151 it) (@) Torque for four nuts that fasten the front mounts to the engine 25£TNem (185 bt) (4) Torque for four bolts that fasten the front mounts tothe frame 2527Nem (185 ib) 101 SpecificationsWater Temperature Regulator (Thermostat) Opening temperature 20°C (176°) Alternators NOTE: For complete alternator specications, see the Service Manual sted in the Alternator Coverage chart. "ALTERNATOR COVERAGE ‘Alternator Manufacturer? | Service Manual art Number ‘Series ‘Form Number er1193 Delco Remy/i0-SI SENSES7S erri95 eto Reny/I0-S1 ‘SENBESTS 7205510 | Delco Remy/OS-121 | _ SENBSS7S (805535 | Bosoh/Ki Enclosed | SENAGESS Delco Remy 10-SI Series anor 611193 - Delco Remy Number 1105076 Rated voltage 12v0ts Polarity is negative ground, Rotation can be either direction ‘Output at 5000 rpm (cold) 20amps Output voltage 14005 volts (1) Torque for battery terminal nut 36£08Nem (G27 bin) (2) Torque for pulley nut 707Nem (505 bt) {671195 - Delco Remy Number 1105074 Rated voltage 12 volts Polarity is negative ground, Rotation can be either direction (Output at 5000 rpm (cold) 36amos Output voltage 140205.olts (1) Torque for battery terminal nut 36208Nem @2+7 bin (2) Torque for puiley nut 707 Nem (50+5 bt) 2.0 Liter (XN1P) Gasoline Engine 102 SpecificationsDelco Remy CS-121 Series Bosch K1 Series 1 J] 2 1 a IAI oN oS ‘8C5510 - Delco Remy Number 1101291 Rated voltage 1avots Polarity is negative ground Rotation is clockwise. (Output a 6500 rpm (cold) 61amps Output voltage 14005 volts (1) Torque for battery terminal nut. 36+08Nem @ETIbin) (2) Torque for pulley nut 100-47 Nem (75: Sib tH) reese 805535 - Bosch Number 0 120 400 706 Rated voltage Yevols Poarty is negative ground Rolation is clockwise, ‘Output a 5000 rpm (eos) 29.amps Output voltage 14005 volts (1) Torque for pute nut 35:4 10Nem (257 bf) 2.0 Liter (XN1P) Gasoline Engine ‘SpecificationsTerminal torques: Be 36:08Nem (92+7 bin) D+, DOF 225 =0.25Nem (20.0% 2.210 in) Belt Tension 308302 NOTICE [Not loosening all alternator mounting bolts (1), can cause the ‘mounting ears of the alternator to break. Before adjusting the belt tension, loosen all alternator mounting bolts (1). The 3/8 alternator (fan) belt should be adjusted using a Bocroughs Tool Gauge No. BT-3397 or BT-33-95 (olde) ‘Check the belt tension half way between water pump pulley (2) and crankshatt puley (3). Gauge reading (new bet) Gauge reading (used belt) 445 22N (100: 516) 400 + 22N (9051) Starting Motors NOTE: For complete starting motor specications, see the service manual Nippondenso Reduction Starting Motors Form No, SENFG828 Nippondenso R1.4 Series c2res7e3 ‘378209 (Nippondenso Number 02800-9820) {617002 (Nippondenso Number 02800-0590) Rotation is clockwise when seen from drive end, ‘Minimum speed with no load 38001 Current consumption (dra) at no load Minimum with solenoid at 11.5 volt 90.amps (1) Torque for bolts that hold starting motor together Tio 12Nem (63t080 in) (2) Torque for 96-16 thread battery terminal... 810 14Nem (721090 bin) (@) Torque for 8.32 thread switch terminal .. 1.7 0.25Nem (152 1bin) Torque for three bolts that fasten the starting motor to the Aywheet housing (not shown)... 95:7 Nem (2651 t)