Service Manual Toyota 7K — Isi Lengkap 151 Halaman
Halaman 1
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@TOYOTA
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REPAIR MANUAL
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·,
Jul., 1995
INTRODUCTION ENGINE IGNITION SYSTEM STARTING SYSTEM CHARGING SYSTEM
Halaman 2
INTRODUCTION | IN
ENGINE | EG
IGNITION SYSTEM | IG
STARTING SYSTEM | ST
CHARGING SYSTEM | CH
INTRODUCTION ENGINE IGNITION SYSTEM STARTING SYSTEM CHARGING SYSTEM
Halaman 3
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FOREWORD
This repair manual has been prepared to provide informatio"
· covering general service repairs for the 7K engine equipped in
the TOYOTA TUV .
•
• ~'
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Please note that the publica lions below have a!so been
prepared as relevant service manuals for the components and
system in this engine.
All information in this manual is based on the latest product in-
formation at the time of publication. However, specifications
and procedures are subject to change without notice.
0
•
•
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0
©1995TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be
reproduced or copied, in whole or in part,
withtlut the written permission of Toyota
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Applicable models: KF42, 52 series
TOYOTA MOfOR CORPO{Ul.TION
INTRODUCTION
Halaman 4
•
•
IN-1
INTRODUCTION
HOW TO USE THIS MANUAL ·················· IN-
2
fii'~
IDENTIFICATION INFORMATION ··············· IN-
4 ii.!fJ.:i!!t
GENERAL REPAIR INSTRUCTIONS ············ IN-
4
ABBREVIATIONS USED IN THIS
MANUAL ·••···•••·•·•······•·········•··············· IN-
7
STANDARD BOLT TO ROUE
SPECIFICATIONS···································· IN-
B
INTRODUCTION
Halaman 5
IN-2
INTRODUCTION -
HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired.
To assist y.:OtJ in finding your way through the manual, the Section Title and major heading are
given at the top of every page.
GENERAL DESCRIPTION
At the beginning of each section, a General Description is given that rertains to all repair
operations contained in that section.
Read these precautions before starting any repair task.
tables are included for each system to help you diagn.::se the problem and
find the causA.
PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and
SSM (Special Service Materials) which should be prepared before beginning the operation and
explains· the purp-ose of each one.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and
shows how the parts fit together.
Example:
~
r
Oil Pump Body
+Cotter Pin
~
~
(
Relief Valve
DriJ.n Rotor-@
Volve Spring I
Srring Retainor I ~
~JP
I
1./
Drive Rotor----J"b.'-f
[B·m lkgf·cm, ft·lbf) i : Specified torque
+ Non~reusable part
P2537J
'~~
__ ..,
~ -
~ -
~
~ -
~
~ - I
--
~..,
~-
I
~
Oil Pump Covor
I
J
)
~
INTRODUCTION
Halaman 6
INTRODUCTION
HOW TO USE THIS MANUAL
The procedures are presented in a step-by-step format:
-.
•
The illustration shows what to do and where to do it.
•
The task heading tells what to do.
•
The detailed text tells how to do the task and gives other information such as specifications
,
and warnings.
Example:
This. format provides the experienced technician with a FAST TRACK to the information neaded.
The upper case task heading can be read at a glance when necessary, and tho text below it
provides detailed information. Important specifications and warnings always stand out in bo:d
type.
REFERENCES
References have been kept to a minimum. However, when they are required you are £ivan the
page to refer to.
SPECIFICATIONS
Specifications are presented in bold type throughout the text where needAd. You never have to
leave the procedure to look up your specifications. They are also found at the end of each sectio:1,
for quick reference .
. CAUTIONS, NOTICES, HINTS:
•
CAUTIONS are presented in bold type, and indicate ther9 is a possibility of injury to you or
other people.
•
NOTICES are also presented in bold type, and indicate the possibility of damage to thr
components being repaired.
•
HINTS are separated from the text but do not appear in bold. They provide additional
information to help you perform the repair efficiently.
GENERAL REPAIR INSTRUCTIONS
Halaman 7
11'1-4
INTRODUCTION·- GENERAL REPAIR INSTRUCTIONS
Sf UNIT
The UNITS given in this manual are primarily expressed according to the SI.UNIT(International
System of Unit); and alternately expressed in the metric system and in the Epglbh System.
Example:
Torque: 30 N·m (31 0 kgf-cm. 22 ft·lbf)
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
The engine serial number is stamped on the engine
block as shown.
GENERAL REPAIR INSTRUCTIONS
JfOrl-tf
Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
During disassembly, keep parts in th6 appropri~t••
order to. facilitate reassembly.
'
Observe the fo!lowing:
(a)
Before doing electrical work. disconnect the neg-
ative cable from the battery terminal.
(b)
If it is necessary to disconnect the battery for
in.spection or repair, always disconnect the cable
from the negative(-) terminal which is grounded
to the vehicle body.
.
(c)
To prevent damagll to the battery terminal post.
lcosen tho terminai nut and rais~ the cabl<:l strai-
ght up without twisting or pryin9 it.
(d)
Cle.an th9 battery terminal posts and cable t<~rmi
nals with a clean shop rag. Do not scrape them
with a file or other abrasivs object~.
(e)
Install the cable terminal ~o the battery post with
the nut loose, and tighten the nut after installa-
tion. Do not use a hammer to tap the terminal
onto the post.
(f)
Be sure the cover for the positive ( +) terminal is
. properly in place.
4.
Check hose and wiring connectors to m?'<e sure that
they are socuro and correct.
1.
2.
3.
f
I
GENERAL REPAIR INSTRUCTIONS
Halaman 8
s-~····
INTRODUCTION -
GENERAL REPAIR INSTRUCTION:';
IN-5
5.
Non- reusable parts
(a)
Always replace cotter r-ins. gaskets, 0-rings and
oil seals etc. with new ones.
(b)
Non-reusable parts a~e indieated in the compo-
'
..
nent illustrations by the ••• symbol.
_j
6.
Precoated parts
Precoated parts are belts and nuts. etc. that 1re
coated with a seal lock adnasive at the factory.
(a)
If a precoated part is retightenod. loosened or
caused to move in any way, it must be recoated
with the specified adhesive.
Seal Lock Adhes:ive
(b)
When reusing precoatsd parts. clean off the old
adhesive and dry with compre~sed air. Then
apply the specified ssallock adhe~il(e to the bolt,
nut or threads.
(c)
Precoated parts are indicated in the component
illustrations by the "*" symbol.
7.
When necessary, use a sealer on gaskets to prevent
•
le~ks.
8.
Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
9.
Use of SST and SSM may be required. depending on
the nature of the repair. Bs sure to Ulje SST and SSM
where specified and follow the prooer work proce-
dure. A list of SST and SSM can he found in the
preparation ;:>art at tho front o~ eacn section in this
manual.
1 0. When replacing fustJ·s. be sure the new fuse ha~ the
correct amperag(> rating. DO NOT exceed tha rating or
use one with a lower rating.
Fuse
Equal Amperage Rating
' (
10
8F1J&&
·-r·------,
Symbol
Part Nnme
Abbrevintion
-
Illustration
~
B£5694
~
BE56S~
1-·
-~-
FUSE
..
WQJ8S 1
--<0"'o-I
MEDIUM CURRENT FuSE
I
M-FIJSE
~
B£5690
-
-~--
HIGH CURRENT FUSE
H-FUSE
I /
BE5597
GY
BES598
-~ FUSIBLE LINK
FL
IN0307
-8--
'I CIRCUIT 6iii:AKER
co
INOJ68
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w-JoJee j
INOl07
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.
GENERAL REPAIR INSTRUCTIONS
Halaman 9
·· IN-6
INTRODUCTION -
GENERAL REPAIR INSTRlJ.;TIONS
11. Care· must be taken when jacking up and supporting
the 'lehicle. Be sure to lift and support the vehicle at 1
the proper locations.
(a)
If the vehicle i~ to be jacked up only at the front
or rear end. be sure to block the whesls at the
opposite end in order to ensure s'afety~
(b)
After the vehicle is jacked up. be sure to support
it on stands. It is extremely dangerous to do any
work on a vehicle raised on a jack alone. even for
a small job that can be finished quickly.
,
12. Observe these precautions to avoid damage to the
parts:
(a)
Do not open tho cover or case of the ECU unless
·absolutely necessary. (If the IC terminals are tou-
ched. t:1o IC may be destroyed by static electric·
ity.)
(b)
To disconnect vacuum hoses. pull on the end. not
the middle of the hose.
(c)
To pull apart electrical connectors. pull on the
connector itself. not the wires.
(d)
Be careful not to drop electrical components.
such as sensors or relays. If they are dropped on
a· hard floor. they should be ~eplaced and not
reused.
(e)
When steam cleaning an engine, protect the elec.-
tronic components. &ir filter. and emissions relat- •
ed components from water.
(f)
Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(g)
When checking continuity at the wire connector.
insert the testGr probe carefully to !Jrsvont termi-
nals from bending.
(h)
When using a vacuum g<:lJge. never force the
hose onto a connector that is· too large. Usa a
stllp ·-down adapter instead. Once the ho$e h~.s
b'3en stretched, it may ldak.
13. Tag hosas before disconnecting them:
(a)
When disconr.ec!ing vacuum hoses, use tags to
identify how they should be reconnected.
(b)
After -::omple~ing a job, double check that the
vacuum hoses are properly connected. A label
under the hood shows the proper layout.
14. Unless otherwise stated. all resistance is measured at
an ambient temperature of 2o•c (68°F). Because the
resistance m9y be out;ide specifications if measured
at high temperatures .immediately after the vehicle
has been running. measurements should be made
when the engine has cooled down.
WHONG
CORRECT
IN0253 I
~==~.
WRONG
CORRECT
,/
l
IN0262
Exampie
I
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GENERAL REPAIR INSTRUCTIONS
Halaman 10
INTRODUCTrON -
ABBREVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS
MANUAL
'
A/G
Air Conditioner
Approx.
Arproxlmatelv
BOG
Bottom Oe11d Center
FIPG
Formed In Placa Guket
MP
Multipurpoa.:J
C/S
Oversized
PGV
Positive Crnnkca~e Vflntil~tion
SSM
Special SOrvice Meteriela
SST
Special Service Tools
STO
Standard
SW
Switch
TOG
Top Dead Center
TEMP.
Temperature
U/S
Undersize
vsv
Vacuum Switching Velva
W/
With
w/o
Without
IN-/
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GENERAL REPAIR INSTRUCTIONS
Halaman 11
IN-8
INTRODUCTION — STANDARD BOLT TORQUE SPECIFICATIONS
STANDARD BOLT TORQUE SPECIFICATIONS
HOW TO DETERMINE BOLT STRENGTH
| Mark | Class | Mark | Class |
| :------------------------------------------------- | :---- | :------------------------------------------------- | :---- |
| **Hexagon head bolt** | | **Hexagon flange bolt** | |
| Bolt head No. 4 | 4T | **w/ washer hexagon bolt**<br>4 Protruding lines | 9T |
| Bolt head No. 5 | 5T | 5 Protruding lines | 10T |
| Bolt head No. 6 | 6T | 6 Protruding lines | 11T |
| Bolt head No. 7 | 7T | | |
| Bolt head No. 8 | 8T | | |
| Bolt head No. 9 | 9T | | |
| Bolt head No. 10 | 10T | | |
| Bolt head No. 11 | 11T | | |
| | | | |
| **Hexagon flange bolt**<br>**w/ washer hexagon bolt**<br>No mark | 4T | **Stud bolt**<br>No mark | 4T |
| | | | |
| **Hexagon head bolt**<br>2 Protruding lines | 5T | **Grooved** | 6T |
| | | | |
| **Hexagon flange bolt**<br>**w/ washer hexagon bolt**<br>2 Protruding lines | 6T | **Welded bolt** | 4T |
| | | | |
| **Hexagon head bolt**<br>3 Protruding lines | 7T | | |
| | | | |
| **Hexagon head bolt**<br>4 Protruding lines | 8T | | |
GENERAL REPAIR INSTRUCTIONS
Halaman 12
IN-9
INTIC!ODUCTION -STANDARD i'lOLT TORQUE S,_P-"E-"C::_IF~!'-'C'-'A"-T'-'Ic:O:..cN-"S"--------
SPECIFIED TORQUE FOR STANDARD BOLTS
\
Specified torque
Diameter
Pitch
Hexegon head bolt
He."'"9on flonge bolt
m;n
:nm
Class
N·m
kgf·cm
ft·lbf
N·m
kgf·cm
ft·lbf
6
1
5
55
48 in.·lbf
6
60
52 in.·lbi
8
1.25
12.5
130
9
~4
145
10
10
1.25
26
260
19
29
290
21
4T
1 2
1.25
47
480
35
53
540
39
14
1.5
74
760
55
84
850
61
16
1.5
1 1 5
1.150
83
-
-
-
6
1
6.5
65
56 in.·lbf
7.5
75
65 in.·lbf
8
1.25
15.5
160
12
17.5
175
13
10
1.25
32
330
24
3€
360
26
1 2
1.25
59
600
43
65
670
48
14
1.5
91
930
67
100
1,050
76
16
1.5
140
1,400
101
-
-
-
5T
6
1
8
80
69 in.·lbf
9
90
78 in.·lbf
8
1.25
19
195
14
21
210
15
10
1.25
39
400
29
44
440
32
1 2
1.25
71
730
53
80
810
59
14
1.5
1 10
1,100
80
125
1,250
90
'
16
1.5
170
1,750
127
-
-
-
.-
...
6T
6
1
10.5
1 I 0
8
12
120
9
8
1.25
25
260
19
28
290
21
10
1.25
52
530
38
58
590
43
12
1.25
95
970
70
105
1,050
76
14
1.5
145
1,500
108
165
1,700
123
16
~
7T
230
2.30ti)
156
--
- ~
8 T 1.25 I
29
300
22
33
330
10
1
1.25
I
61
.620
45
68
690
50
I
12 I 1.25
1 10
1,100
00
120
1,250
90
..
~
8T
6
i. 7.5 I 34
.340
25
.17
380
27
I
7C
..
10
1.25
51
7B
710
790
o7
t'T
12
1.25
125
,,30(1
94
1 140
1.450
105
r----------·-----1
8
1.25
38
10
1.25
78
12
1.25
140
390
28
42
430
31
800
1,450
lOT
8
1.25
42
10
1.25
87
12
1.25
155
430
890
1,600
11T
-
58
105
88
155
890
1,600
64
116
31
64
47
97
175
480
990
1,800
35
72
130
I 16
ENGINE
Halaman 13
ENGINE
..
ENGINE MECHANICAL
' .
.PREPARATION ....................................... EG-
2
AIR elL TER INSPECTION AND
CLEANING ·························•·•·········· ··· EG-
6
IDLE CO CHECK AND ADJUST .....•...... ; .. EG-
6
COMPRESSION CHECK ····•····••···•·•·······•·· EG-
9
VALVE CLEARANCE INSPECTION AND
ADJUSTMENT······································ EG- 10
IGNITION TIMING INSPECTION AND
ADJUSTMENT······································· EG- 11
IDLE SPEED INSPECTION AND
ADJUSTMENT······································· EG-11
CYLINDER HEAD ................................. .-.. EG- 1r
TIMING CHAIN ....................................... EG- 27
I
"
CYLINDER BLOCK ................................. EG- 34
SERVICE SPECIFICATIONS ........................ EG- 55
FUEL SYSTEM
PREPARATION ................................. , ..... EG- 60
PRECAUTION ........................................ ,. EG- 60
ON-VEHICLE INSPECTION ..................... EG- 6!
CARBURETOR ....................................... EG- 61
FUEL PUMP ........................................... EG- 76
'.
SERVICE SPECIFICATIONS ........................ EG- 78
COOLING SYSTEM
PREPARATION ....................................... EG- 79
COOLANT CHECK AND REPLACEMENT ... EG-- 80
WATER PUMP ............................... ; ....... EG- 81
THERMOSTAT ....................................... EG- 85
RADIATOR ............................................. EG- 87
SERVICE SPl:CIFICATIONS ........................ EG- 88
LUBRICAT!ON SYSTEM
PREPARATION ....................................... EG- 89
OIL PRESSURE CHECK ........................... EG- 90
OIL AND FILTER REPLACEMENT ............ EG- 91
OIL PUMP ............................................. EG- 92
SERVICE SPECIFICATIONS ........................ EG- 96
tG-1
ENGINE MECHANICAL
Halaman 14
EG-2
ENGINE — ENGINE MECHANICAL
# ENGINE MECHANICAL
## PREPARATION
## SST (SPECIAL SERVICE TOOLS)
| Part Number | Description |
| :---------------- | :---------------------------------------------- |
| 09201-10000 | Valve Guide Bushing Remover & Replacer Set |
| (09201-01080) | Valve Guide Bushing Remover & Replacer B |
| 09202-70020 | Valve Spring Compressor |
| (09202-00010) | Attachment |
| (09202-01010) | Arm |
| (09202-01020) | Set Bolt |
| (90154-30004) | Screw |
| 09213-14010 | Crankshaft Pulley Holding Tool |
| (91651-60865) | Bolt |
| 09215-00101 | Camshaft Bearing Remover & Replacer Set "A" |
| (09215-00121) | Gate "A" |
| (09215-00130) | Bolt |
ENGINE MECHANICAL
Halaman 15
ENGINE - ENGINE MECHANICAL EG-3
| Image | Part Number | Description |
| :--------------------------------------- | :------------------ | :--------------------------------- |
|  | (09215-00141) | Nut |
|  | (09215-00150) | Shaft "A" |
|  | (09215-00161) | Pin |
|  | (09215-00211) | Remover & Replacer |
|  | (09215-00221) | Remover & Replacer |
|  | (09215-00231) | Remover & Replacer |
|  | 09221-25025 | Piston Pin Remover & Replacer |
|  | (09221-00020) | Body |
|  | (09221-00030) | Spring |
|  | (09221-00040) | Bushing "A" |
|  | (09221-00170) | Guide "J" |
|  | (09221-^0210) | Guide "M" |
|  | 09223-15020 | Oil Seal & Bearing Replacer |
|  | 09223-46011 | Crankshaft Front Oil Seal Replacer |
ENGINE MECHANICAL
Halaman 16
EG-4
ENGINE — ENGINE MECHANICAL
| | | |
| :---------------- | :----------------------------- | :---------------------------------- |
| 09330-00021 | Companion Flange Holding Tool | Crankshaft pulley |
| (09330-00030) | Pin | |
| 09950-40010 | Puller B Set | Crankshaft pulley Crankshaft sprocket |
| (09952-04010) | Slide Arm | |
| (09954-04010) | Arm 25 | |
| (09955-04010) | Claw No.1 | |
| (09957-04010) | Attachment | |
| 09950-50010 | Puller C Set | Crankshaft pulley Crankshaft sprocket |
| (09951-05010) | Hanger 150 | |
| (09952-05010) | Slide Arm | |
| (09953-05020) | Center Bolt 150 | |
| (09954-05020) | Claw No.2 | |
| 09950-70010 | Handle Set | |
| (09951-07150) | Handle 150 | |
ENGINE MECHANICAL
Halaman 17
ENGINE -
ENGINE MECHANICAL
EG-5
09960:...10010
Variob/o Pin Wronch Set
Camshaft cprcekot
(09962-01000) Vor;oblo p;n Wrench Arm A"y
............... ························· ······· ............................................... .
(09963-01000) Pin 10
tECOMMENDED TOOLS
09200-00010
Enpino Adjust Kit.
09258-00030
Hose Plug Set.
.-
• -.:OUiPMENT
.
• Caliper gauge
.
CO/HC meter
Compression gauge
•
·connecti!lg rod aligner
Cylind~r gauge
Dial indicatCJr
Dye· penetrant
Engine tune-up taater
HH&ter
'Megnetie flngnr
Mlcromet&r
Pilt,Jn ring 'JI')ftlprenor
-------
P1ston tinQ a)(pr;Fld~r
Plaatig11J90
-
-
-~recision atraight edpe
SQft bruah
-
~~ring tester
.. steel square
•Tachometer
Therml')meter
Timing light
Torque wrench
" Valva seat cutter
,, .
Vernier calipers
Plug for the vacuum hose, fuel
hose etc,
'
-
--
Valve 1prlng
Val'la spring
ENGINE MECHANICAL
Halaman 18
EG-6
ENGINE -
ENGINE MECHANICAL
SSM (SPECIAL SERVICE MATERIALS)
-···~
08826-00080
Seal Packing Black or equivalent
(FIPG)
[
AIR FILTER INSPECTION AND
GLEANING
1.
REMOVE AIR FILTER
. ,,
NOTICE: Use care to prevent dirt or other foreign matter
from entering into the carburetor.
2.
INSPECT AIR FILTER
Visually check that the element is not excessively
dirty, damaged or oily.
3.
CLEAN AIR FILTER
4.
~711
IDLE CO CHECK AND ADJUST
1.
VISUALLY INSPECT CARBURETOR
(a)
Check for loose screws or a loose mounting to the
manifold.
(b)
Chnck for wear in the linkage, missing snap rings 01
axcessive looseness in the throttle shaft, Correct any
problems found.
2.
INITIAL CONDITIONS
(a)
Air· cleaner installed.
(b)
Normal operating coolant temperatura.
(c)
Ali accessories switched off.
(d)
Ali vacuum lines connected.
(e)
Ignition timing set correctly.
(f)
Transmission in the "N" range.
(g)
CO meter operates normally.
3.
CONNECT TACHOMETER TO ENGINE
Connect the test probe of a tachometer to the ignition
coil negative{-) terminaL
=
Timing chain cover. oil pan and
..,
rear oil sear retainer
Blow dirt off in the element with' compressed air from
the inside.
If element is torn or excessively dirty, replace the air
filter.
REINSTALL AIR FILTER
•
_..,.M~~
•
"
ENGINE MECHANICAL
Halaman 19
ENGINE -
ENGINE MECHANICAL
EG-7
NOTICE:
•
NEVER allow the tachomotl3r terminal to touch
·.
grourid as it could result in damage to tho igniter
and/or ignition coil.
•
As some tachometers erll not compotible with this
ignition system. we recommend that you confirm
the compatibility of yow· unit befor~ use.
4.
INSPECT IDLE SPEED
Idle speed:
•
750 ±50 rpm
If not a·s specified, adjust accroding to these proce-
dure:
CAUTION:
•
Always use a CO motor when ~djusting the idle
mixture. It is not noce.n:s11ry to adjust with the idle
mixture adjusting screw in most vehicles if thoy are
in good condition. If a CO meter is r>ot available, £9
NOT ATTEMPT TO ADJUST WITH THE SCREW.
•
If a CO meter is not available and it is absolutely
necessary to edjust with the Idle mixture adjusting
screw. use the alternative method.
5.
CHECK AND ADJUST CO CONCENTRATION AT
IDLE
A.
Method with CO meter
(a)
Start the engin9.
(b)
Using a CO meter to measure the CO concentration in
the exhaust. turn the idle speed and idle mixture
adjusting screws to obtain the speclfied concentra-
tion value at idle speed.
,Idle speed:
'
750 ±50 rpm
(c)
Check that the CO meter is properly calibrated.
(d)
Race the engine 30-60 seconds at about 2,000 rpm
before measuring concentration.
(e)
Wait 1-3 minutes after rucin!l the engine to allow the
ccncentration to stabilize.
(f)
lnsort a testing probe at least 40 em (1.3 ft) into the
tailpipe, and measure the concentration ~vithin a short
time.
Idle CO concentretion: 1.0 ± 0.5 %
•
If the CO concentration is within specification
. ..
. ·.
this adjustment is complete .
If the CO concentration is not within specifica-
tion, turn the idle mixture adjusting screw to
obtain the specified concentration valt .. e.
•
If the CO concentration cannot be corrected by
adjusting the idle mixture, see tacle below for
other possible causes.
•
-~
•·
,.
ENGINE MECHANICAL
Halaman 20
EG-8
ENGINE '- ENGINE· MECHANICAL<· ..
co
1-!C
Problems
Causes
Normal
High
Rough idle
1. Faulty ignition:
Low
High
Rough Idle
1. Vacuum leak:
(Fluctuating HC reading)
• Intake manifold
• PCV line
-
'
• Carburetor base
--
High
High
Rough idle
1. Restricted air filter
2. Plugged PCV valve
\
(Black smoke from exhaust)
3. Faulty carburetlon:
B.
Altsrnstive method
(a}
Start the engine.
(b)
Set to the maximum speed by turning the id!e mixture
adjusting screw.
(c)
Set to the idle mixture spaed by turning the idle speed
adjusting screw.
Idle mixture ap~ed:
BOO rptn
(d)
Before moving to the next step continue adjust~ents
(b) and (c) until the maximum speed will not rise any
further no matter how much the idle mixture adjusting
screw is adjusted.
(e)
Set to the idle spe~d by screwing in the idle mixture
adjusting screw.
Idle speed:
750 rpm
This is Lean Drop Method for setting idle speed and
•
• Incorrect timing
• Fouled,shorted or Improperly gapped plugs
• Open or crossed Ignition wires
• Cracked distributor cap
2. Leaky exhaust valves
3. Leaky cylinder
• Vacuum hose
• Incorrect float setting
• Leaking needle or seat
.
• Leaking power valve
"""'
mixture.
ENGINE MECHANICAL
Halaman 21
ENGINE -
ENGINE·MECHANIGAL
·COMPRESSION CHECK
lG--·1
HINT: lfthere is lack of power, excessive oil consump-
tion or poor fuel economy, measure the compre:;sion
pressure.
1.
WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating
•
temperature .
~
2.
DISCONNECT DISTRIBUTOR WIRE
3.
DISCONNECT HIGH-TEi\ISION CORDS FROM
SPARK PLUGS
4.
REMOVE SPARK PLIJGS
5.
CHECK CYLINDER COMPRESSION PRESSURE
(a)
Insert a ccmpression gauge into the spark plug hole.
(b)
Fully open the throttle.
(c)
While cranking the engine, measure the compression
pressure.
HINT: Always use n fully chargsd battery to obtain
engine speed of 250 rpm or more.
-
(d)
Repeat steps (a) through (c) for each cylinder.
.-
NOTICE: This moasurement must be done In ss s.,ort a
-
time u possible.
.
, '
Compression prOsaure:
931 kPa (9.5 kgf/cm'. 135 psi) or mora
.·
Minimum pressure:
785 kPa (9.0 kgf/cm', 128 psi)
"
Difference betweon each cylinder:
98 kPe (1.0 kgf/cm', 14 psi) or lass
;·
~?
(e)
If tha cylinder compression in 1 or rnore cylinders is
low, pour a small nmount of engine oil into the cylin-
der through the spark plug hole and repeat steps (a) ·
through (c) for cylinders with iow compression.
•
If adding oil helps the compression, chances ara
that the piston rings and/or ~ylindElr bore are
. worn or damage.
..
If pressure stays low, a valv& r:1ay be stickinr, or
seating is improper, or there may be leakage past
the gasket.
6.
REINSTALL SPARK PLUGS
Torque: 17.5 N·m (180 kgf·cm, 13 ft-lbf)
7.
RECONNECT HIGH-TENSION CORDS TO SPARK
. t·
PLUGS
B.
RECONNECT DISTRIBUTOR WIRE
. -
ENGINE MECHANICAL
Halaman 22
''3-10
ENGINE -·ENGINE MECHANICAL
' ..
VALVE: CLEARANCE INSPECTION
AND ADJUSTMENT
[GI.OM•OI
HINT: Inspect and adjust the valve c!aarance when
the engine is cold.
1.
REMOVE CYLINDER HEAD COVER
(See step 8 in cylinder head removt~l)
2.
SET N0.1 CYLINDER TO TDC/COMPRESSION
(a)
Turn the crankshaft pulley, and align its groove with
the timing mark ·o· of the timing chain cover.
(b)
Check that the rocker arms on the No.1 cylinder are
3.
INSPECT AND ADJUST VALVE CLEARANCE
(a)
Measure only the valves indicated by arrows.
Valve clearance (Cold):
Front
-+-
No.1
No.2
•
Using a feeler g'luge, measure the valve clear-
ance between· the valve stam and rocker arm.
Loosen the lock nut "nd tum the adjusting screw
to set the proper clearance. Hold the adjusting
screw in position and tighten the lock nut ..
•
Rec:heck :he val•1e ·clearance. Tha fAster g3ugo
1
should slide with a very slight drag.
=,J
(b) Turn the crankshaft one revolution (360°) and align
Front
+-
No.2
No.3
No.4
EX
IN
IN EX
+
+--+-+~
~
--
.t'Sl:.>J.I
4.
Adjust Qnly the valves indicated by arrows.
REINSTALL CYLINDERJlEAD COVER
.
.,
·, '
(Seo step 5 in cylinder hoad ir.;;tallation)
''''l~ll ~nd mr,h, nrrr1.~ on fhij NoA r:ylill(lllr hill titllol.
If not, turn the crankshaft one revolution (360°) and
align the marks as above.
Intake 0.13 mm (0.005 ln.)
Exhl!ust 0.23 mm (().009 in.)
the mark above.
~.r~>: ...
·''
ENGINE MECHANICAL
Halaman 23
·:\.....
I.
.ENGINE
·
tG-11
IGNITION TIMING INSPECTION AND
ADJUSTMENT
1 ' .
WARM L.:P ENGINE
Allow the engine to warm up to normill operating
temperature.
CONNeCT TACHOMET[;R TO ENGINE
(See step 3 in idle CO check and adjust)
3.
INSPECT DWELL ANGLE
"' .. :.'
2 .
. '
Check the dwell angle at tho engine idling.
Dwell anglo:
52±6@ idle
If the dwell angle is not specified, adjust the rubbing
block gap.
(See distributor assembly in Ignition System)
DISCONNECT VACUUM HOSE
(a)
Disconnect the vacuum hose from the distributor.
(b)
Connect a plug to the vacuum hose.
4.
5.
CONNECT TIMING LIGHT TO ENGiNE
6.
INSPECT AND ADJUST IGNITION TIMING
With the engine idling as specified, u~e a timing light
to check the timing.
Ignition timing:
If necessary, loosen the distributor bolt and turn the
distributor to align the marks. R~check the timing
after tightening the distributor bolt.
Torque: 12 N·m (120 kgf·cm, 9 ft.fl!f)
_
7.
RECONNECT VACUUM HOSE
a.
RECHECK IGNIT!ON T:M!NG
..
With th8 engine idling as specified, us~ a timing t~:t,
check the timing.
''/'
Ignition timing:
9.
DISCONNECT TACHOMETER AND TIMING LIGHT
IDLE SPEE'J INSPECTION AND
ADJUSTMENT
(See steps 1 to 4 in idle CO check and adjust) -·-
"
5±2• BTDC @.Idle
·.~:f~
; .
12±3°BTDC@ idle
ENGINE MECHANICAL
Halaman 24
EG-12
ENGINE -, .. ENGINE MECHANICAL·
CYLINDER HEAD
COMPONENTS
--.. I
Seal Washer---~
f.------Seal Washer
\---Cylinder Head
+ 0-Ring
Spar~ Plug
Spark Plug
I
Tube
---....__
\
Water Outlet Hosing
~
/
Assembly
"'""-,
J
' '
Clamp~-·
<V'-~-·
(
Cover
Rocker Arm and
l.ll.<;~-----shaft Assembly
See
e EG·25
1•1 29.5 (300, 22)
2nd Turn go•
3rd Turn go•
Cylinder Head
X6
- ,.
lntake,Exhaust Manifolds and
Carburetor Assembly
,,.,.,
ENGINE MECHANICAL
Halaman 25
# ENGINE — ENGINE MECHANICAL E3-13
## Intake, Exhaust Manifolds and Carburetor Assembly
* Intake Manifold
* Gasket
* 19 (195, 14)
* ⊗X 3
* Carburetor
* ⊗X 4
* Insulator
* Exhaust Manifold
## Valve Rocker Shaft Assembly
* Valve Rocker Shaft
* (4)
* (1)
* (3)
* (2)
* Conical Spring (6)
* Spring Retainer (5)
* (1)
* (3)
* (2)
* Compression Spring (4)
* Valve Rocker Support (3)
| Valve Rocker Arm |
| :--------------- |
| No.1 |
| (1) |
| No.2 |
| (2) |
S00297
S00298
N·m (kgf·cm, ft·lbf): Specified torque
◆ Non-reusable part
ENGINE MECHANICAL
Halaman 26
EG-14 '
ENGINE -
ENGINE MECHANICAL
CYLINDER HEAD REMOVAL
1.
DRAIN ENGINE COOLANT
2.
DISCONNECT HIGH-TENS10i4 CORDS FROM
SPARK PLUGS
3.
REMOVE SPARK PLUGS
4.
REMOVE SPARK PLUG TUBES AND 0-RINGS
5.
DISCONNECT FUEL HOSE AND VACUUM HOSES
(a)
Disconnect the fuel hose and vacuum hoses.
, ..
(b)
Remove the fuel pipe .and vacuum hose from the
clamp.
6.
REMOVE INTAKE, EXHAUST MANIFOLDS AND
CARBURETOR ASSEMBLY
(a)
Disconnect the PCV hose from the cylinder head
cover.
(b)
Remove the 6 nutR holding the manifolds to the cylin-
der head.
-·
(c)
Remove the intake, exhaust manifolds. carburetor as-
sam bly and gasket.
7.
DISCONNECT WATER BYPASS HOSE
8.
REMOVE CYLINDER HEAD COVER
Remove the 2 cap nuts. seal washers, cylinder head
cover and gasket.
l
9.
REMOVE ROCKER ARM AND SHAFT ASSEMBLY.
(a)
Uniformly loosen and ramove the 6 bolts and 2 nuts in
several passes, in tha sequence sho)!Vn.
(b)
Remove the rocker arm and shaft assembly.
1 C. REMOVE PUSH RODS
Remove tho 8 push rods in o;der, begi11ning from tho
No.1 push rod.
NOTE: Arrange the push rods in correct order •
I
.,.,.,I
11. REMOVE CYLINDER HEAD
(a)
Uniformly loosen and remove the 3 head bolts in
several passes. in the sequence shown.
CAUTION: Head werpage or cracking could result from
removing out of sequence.
·--··
.:::·
ENGINE MECHANICAL
Halaman 27
ENGINE -
ENGINE MECHANICAL
EG-15
(b)
Uniformly loosen and remove the 11J head bolts in
several passes, in the sequence shown.
CAUTION: Hond wnrpngo or cracking could result from
removing out of sequence.
P149SO
P149Sl
ZI6SJS
(c)
Lift the cylinder head from the dowels on the cyli;,der
block and· place the head on wooden blocks on ~
bench.
HINT: If the cylinder head is difficult to lift off, pry
betwee;, the cylinder head and block with a screw-
driver.
CAUTION: Be careful not to damage the cylinder head or·
b!ock surface on the cylinder haad gasket sides.
CYLINDER HEAD DISASSEMBLY
1.
REMOVE WATER OUTLET ~lOUSING AND REAR
PLATE
(a)
Remove the 2 bolts, clamp. watGr outiet. housing ar~d
gasket.
(b)
Remove the 4 bolts, rear plate ar.d ga3ket.
2.
REMOVE VALVES
(a)
Using SST. compress the valve spring and remove the
2 keepers.
SST 09202-70020 (09202-00010, 09202-01010.
09202-01020, 90 154-80004)
(b)
Remove the spring retainer, vaive sprir>g and valve.
~
.If
j:~
·:,
-i~ ,.
ffl
.i!li
. ..
-··•j,..,. ~=·
;E(:L
..... ~·;
••
ENGINE MECHANICAL
Halaman 28
EG-16
ENGINE -
ENGINE MECHANICAL
(c)
Using. needle- nose pliers. remove the B oil seals.
(d)
Remove the B spring seats.
·HINT: Arrange the valves, v.alve springs, spring seats
and· spring· retainers in correct order.
CYLINDER HEAD COMPONENTS
INSPECTION. CLEANING AND REPAIR
combustion chambers.
NOTICE: Be careful not to aeratch the cylinder block
contact surface.
'
-.. ....
ENGINE MECHANICAL
Halaman 29
ENGINE -
ENGINE MECHANICAL
EG-17
l
t
C.
Clean valve guide bushings
Using a valve guide bushing brush .and solvent, claan
all the guide bushings.
'
'
l ~~
') ~~
""'"
D.
Clean cylinder head
Using a soft brush and sclvent, thoroughly clean the
cylinder head .
. '
. ,
,•
! - .~
' .
'
3.
INSPECT CYLINDER HEAD
A.
Inspect for flatness
Using a precision straight edge and thickness gauge,
measure the surfaces contacting the cylinder hlock
and the manifolds for warpage.
Maximum warpage:
0.10 mm (0.0039 ln.)
If warpage is greater than maximum, replace the cylin-
der head.
P2.t961
P2498l
"""'
B.
Inspect for cracks
Using a dye pe~etrant, check the combustion cham-
ber, intake ports, exhaust ports and cylinder block
side surface for cracks.
If cracked, replace the cylinder head.
- .
Cylinder block side:
0.05 mm {0.0020 ln.)
Manifold side:
ENGINE MECHANICAL
Halaman 30
ENGINE -
ENGINE MECHANICAL
' .
EG-18
4.
CLEAN VALVES
(a)
L!sing a gasket scraper. chip off any carbon from the •
valve head.
j.
(b)
Using a wire brush, thoroughly clean the valvo.
5.
INSPECT VALVE STEMS AND GUIDE BUSHINGS
(a)
Using a caliper gauge, measure the inside diameter of
the guide bushing.
Bushing inside diameter:
+
(b)
Using a micrometer, measure the diameter of the
valve stem.
V6lve stem diameter:
7.951 -
7.991 mm (0.3130- 0.3146 in.)
Exhaust
7.960 -
7.986 mm (0.3134- 0.3144 ln.)
(c)
Subtract the valve stem diameter measurement from
the guide bushing inside diameter measurement.
Oil clearance:
'''''"
If the clearance iE greater than maximum, r13plactl ln9
valve and guide bushing.
6.
IF NECESSARY, REPLACE VALVE GUIDE
BUSHINGS
'(a!
Using a chisel and hammer, break the valve guide
bushings.
(b)
G•adually heat th·e cylinder head to SO -
1 OO"C ;176
-
212"F).
'.
8.010 -
8.030 mm (0.3154 -
0.3161 in.)
' .
Intake
-
Intake
Exh!USt
O.OT9 - 0.079 mm
0.024 - 0.075 mm
Standard
(0.0007 - 0.0031 ln.)
(0.0009 - 0.0030 ln.)
Meximum
0.08 mm (0.0031 in.)
- 0.10 mm (0 •. 0039 ln.)
ENGINE MECHANICAL
Halaman 31
'
ENGINE -
ENGINE MECHANICAL
EG-19
(b) · Using SST and a hammer. tap out the guide bushing.
< I
SST 09201 -1 0000 (09201 -01 080).
" <I.
.
(c)
Using a caliper gauge, measure the bushing bore di-
ameter of the cylinder head.
(d)
Select a new guide bushing (STD size or 0/S 0.05).
If the bushing bore diameter of the cylinder head is
greater than 13.027 mm (0.5129 in.). machine the
bushing bore to these dimension:
13.050- 13.077 mm (0.5138- 0.5148 in.)
If the bushing bore diameter of the cylinder head is
greater than 13.077 mm (0.5148 in.). replace the
cylinder head.
,
.·
Both intake and exhaust
.
Bushing bore diameter
mm '(in.)
Bushing size
13.000- 13.027
Use STD
(O.S118- 0.5129)
13.050- '13.077
Use 0/S 0.05
(0.5138- 0.5148)
.,
(s)
Gradually heat the cylinder head to 80 -· 10o•c (176
-
212.F).
V07105
(f)
Using SST and a hammer, tap in a new guide bushing
until the snap ring makes contact with the cylinder
head.
·
SST 0920i -10000 (09201-01 080),
Sharp 8 mm Reamer
(g)
Using a sharp 8 mm reamer. ream the guide bushing
to obtain the standard specified clearance (See step 5)
between the guide bushing and valve stem .
. ,
09950-70010 (09951-07150)
09950-70010 (09951-·07150)-
ENGINE MECHANICAL
Halaman 32
. EG-20
ENGINE:- ENGINE'MECHANICAL
7. ·INSPECT AND·GRIND VALVES
(a)
(b)
Grind the valve enough to remove pits and carbon.
Check· that the valva i~ ground to the correct valve
face angle.
Valva face angle:
CM0254 £M018C.
(c)
Check' the valva head margin thickness.
Stand&rd margin thickness:
Intake: . 1.0 -
1.6 mm (0.039 -
0.063 ln.)
Exhaust: 1.2 -
1.8 mm {0.047 -
0.071 ln.)
Minimum margin thickness:
Intake: 0.8 mm (0.031 ln.)
Exhaust: 0.9 mm (0.035 ln.)
If the margin thicknar.s is Jess than minimum, replace
the valve.
(d)
Check the valve overall length.
"
Overall length:
Standard
99.90 mm
100.10 mm
(3.933 ln.)
(3.941 ln.)
Minimum
99.4 mm (3.913 ln.)
99.6 mm (3.921 ln.)
Overall Lenyth
If the overall length is less than minimum, replace the
valve.
(e)
Check the surface of the valve stem tip for wear. ·
If the valve stem tip is worn, resurface tho tip with a
grindar or replace the valve.
NOTICE: Do not grind off more than ,;inlmum.
8.
INSPECT AND. CLEAN VALVE SEATS
(a)
Using a 45" carbide cutter, resurface the valve seats.
Remove only enough metal to' clean the seats.
:: ..
44.5°
-
Intake
Exhi'IUSt
ENGINE MECHANICAL
Halaman 33
ENGINE -
ENGINE MECHANICAL
EG-Z1
(b) . Checl( the valve seating position.
Apply a light coat of prussian blue (or white lead) to
the valve face. Lightly press the valve <Jgainst the
seat. Do not rptate valve.
(c)
Check the -valve face and seat for th.,so:
•
If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
•
If blue appears 360" around the valve seat, the
guide and face are concentric. If not, resurface
the saat.
•
Check that the seat contact is i11 the middle of the
valve face with these width:
Intake
1.1 -
1.7 mm (0.043- 0.067 in.)
Exhaust
1.2- 1.8 mm (0.047- 0.071 in.)
If not. correct the valve se,ts as follows:
(1)
If the seating is too high on the valve face, uss
45" and 65" cutters to correct the seat.
ss•
EMI)186
-
Zl6545
,.
..
~
(2)
If the seating is too low on the valve face, use
45" and 30" cutters to correct.the seat.
0
Width
EM01BS
ZIOW
I I
(d)
Hand-l<lp the valve and valve seat with an abrasive
compnund.
(e)
After hand-lapping, <;!san tha valve and valve seat.
I
.,
9.
INSPECT VALVE SPRINGS
(a)
Using a steel square, measure the sc;uareness of the
valve spring.
Maximum squareness:
1.6 mm (0.063 ln.)
If the deviation is greater than maximum, replace the
valve spring.
--]
Deviation -If-
-.I
.::;s;;
~
~-
ENGINE MECHANICAL
Halaman 34
EG-22
ENGINE -
ENGINE MECHANICAL
.
(b)
"""''
I· (c)
EM0281
10. INSPECT ROCKER ARM AND SHAFT
(a)
Inspect the valva contacting surface of the rocker arm
'
for wear.
Correct or replace if necessary.
EMT~JO
(b)
Inspect the rocker arm to the shaft· clearance by
moving each rocker arm as shown in the figure.
Little or no movement should be possible.
If movement is felt. disassemble afld inspect.
(c)
Disassemble th~ ·,alva rockor shaft <~ssembly.
HINT: Arrange th6 rocker arms and rocker supports in
correct order.
..
I
I
If the valve contacting surface of the rocker arm is
worn. resurface it with a valve refacer and oil stone or
'
replace the rocker arm.
I
£MOOU
·Using vemier calipers. measure the free length of the
valve spring.
Fr"" .l.,ngth:
-46~5 mm (1.831 in.) .
If the free length is not as specified. replace the valve
spring.
Using a "Pring tester. measure the tension of the valve
spring at the spe"cified installed length.
lnstall9d tension:
At 38.4 mm (1.512 in.):
2g6 -- 328 N (30.2 - 33.4 kgf. 66.6 - 73.6 lbf)
If the instal.led tension is not as specified. replace the
valve spring.
•
ENGINE MECHANICAL
Halaman 35
, . ...,.. .
~ ..•.• ,,,_,,,., •• :·.-·r,· ''". ~,.,
'
ENGINE -
ENGINE MECHANICAL.
EG-23
·Inspect the oil clearance between the rocker arm and
shaft. ,
•
Using a caliper gauge. measure the inside diarne-
. tar of the rocker arm. ,
Rocker arm inside diameter:
•
Using a micrometer, measure the diameter of the
rocker shaft.
Rocker shaft diameter:
15.97 - 15.99 mm (0.6287 - 0.6295 in.)
•
Subtract the rocker shaft diameter measurement
from the inside diam<'lter measurement of the
rocker arm.
Standard oil clearance:
0.02 - 0.04 mm (0.0008 -
0.0016 in.)
Maximum oil clearance:
0.04 mm (0.0016 In.)
If the clearance exceeds maximum. rsplace the rocker
arm and shaft.
(e)
Assemble the valve rocker shaft ~ssembly as shown.
Valve Rocker
Shaft
V&lv.o Recker
Support
{2)
( 1)
~onf
Compression
Spring
.....
Valve Rocker
Arm No.2
Valve Rocker
Arm No.1
16.00 - 16.02 mm (0.6299 - 0.6307 in.)
(2)
(2)
Valve RoGkAr Shaft
As$ambly •
( 1)
Valve Rocker Arm
Valve Rocker
Arm No.1
( 1)
(2)
ENGINE MECHANICAL
Halaman 36
. EG-24
ENGINE·- ENGINE MECHANICAL:
11. INSPECT PUSH RODS
(a)
Place the push rod on V- blocks.
(b)
Using a dial indicator, measure the circle runout at the
· center of the push rod.
Maximum circle runout:
0.30 mm
0.30 mm (0.0118 in.)
!f the circle run out exceeds the maximum, replace the
push rod.
12. INSPECT INTAKE AND EXHAUST MANIFOLDS
Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head for war-
page.
Maximum warpage:
0.20 mm (0.008 in.)
If warpage is greater than maximum, correct or re-
place the manifolds.
l_·~n~~~
CYLINDER HEAD ASSEMBLY
--·
HINT:
•
Thoroughly clean all parts to be assembled.
•
Before installing the parts, apply new engine oil
to .. all sliding and rotating surfaces.
•
Replace all gaskets, 0-rings and oil seals with
new ones.
1.
INSTALL VALVES
(a)
Install 8 new oil seals with your hand.
(b)
Install theso parts:
(1) Valve
(2) Spring seat
(3) Valve spring
(4) Spring retainer
(c)
Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202-70020 (09202-01010. 09202-01020,
SST
1"24951
.· '"
90154-80004)
ENGINE MECHANICAL
Halaman 37
ENGII~E -
ENGINE MECHANICAL
(d)
Using a plastic-faced hammer, lightly tap the valve
stem tip to assure proper 'fit.
2.
INSTALL WATER OUTLET HOUSING AND ENGINE
REAP. PLATE
'
(a)
Place a new gasket and install the engine rear plate
with 4 boi ts.
Torque: 8 N·m (80 kgf·cm, 61i ln.·lbf)
(b)
Place a new gasket and install the water outlet hous- .I§.
ing with 2 bolts.
Torquo: 19 N·m (195 kgf-cm, 14 ft·lbf)
CYLINDER HEAD !NST ALLAT!ON
"
1.
INSTALL CYLINDER HEAD
A.
Place cyiincler head on cylinder block
(a)
Place a new cylinder head gasket in position on the
cylinder block.
NOTICE: Be careful of the lnstollution direction.
(b)
Place the cylinder head in position on the cylinder
head gasket.
B.
Install 12 pointed head cylii1dt~r head bolts
HINT:
•
The cylinder head bolts are tightened in 2. pr~
gressive steps (steps (b) and (d)).'
•
If any bolt is broken or deformed, replace it. .
ia)
Apply a light coat of engine oil on the thrllads tnd
under the heads of the cylinder hGad b.:> Its.
(b)
Install and uniformly tighten the 1 0 cylinder head
bolts on each cylinder head, in several passes, in the
sequence shown.
Torque: 29.6 N·m (300 kgf·cm, 22 ft·lbf)
If any of the cylinder head bolts does not meGt the
torque specification, replace the cylinder head bolt.
4
2
5
P2S379
~24951
Z16537
(c)
Mark the front of the cylinder head bolt head with
paint.
".
ENGINE MECHANICAL
Halaman 38
EG-26
ENGINE
I:NGINI'. MCCII-1\NICI\L
(d)
Retighten the cylinder head bolts by so• in \he numer-
ical order shown.
-
(e)
Retighten the cylinder head bolts by an additional so•.
(f)
Check that the painted mark is now facing rearword.
c.
(a)
Install recessed head cylinder head bolts
Apply a light coat of engine oil on the thn:.ads and
ur.dor the heads of the cylinder head bolts.
Install the cylinder head boits. as shown.
Torque: 19 N-m (1 95 kgf-crn. 14 ft·lbf)
INSTALL PUSH RODS
Install the 8 push rods.
~44lfiJ
(f$JJ:~
{b)
~QJ·JQ
~-J '---,
:; 3 ?'
I/ I \_f
~
P255~J
............. ~
16543
2.
INSTALL VALVE ROCKER SHAFT ASSEMBLY
Place the rocker shaft assembly on tha cylinder head.
Install and uniformly tighten the 6 bolts and 2 nuts in
several passes. in the sequence :;hov.;n.
Torque: 21 N·m (210 kgf-cm, 16 ft·lbf)
CHECK AND ADJUST VALE CLEARANCE
(See valve clearance inspection and adjustment)
INSTALL CYLINDER HEAD COVER
(a)
Install the gasket to the cylinder head cover.
(b)
Install the cylinder head cover with 2 seal washers
and cap nuts.
Torque: 2 N-m (25 kgf-cm, 18 in.-lbf)
6.
INSTALL INTAKE. EXHAUST MANIFOLDS AND
CARBURETOR ASSEMBLY
(a)
Install a new gasket, the intake, exhaust manifolds
and carburetor assembly with the 6 nuts.
Torque: 49 N-m (50_0 Y.gf-crn, 36 ft-lbf)
(b)
Connect the PCV hose to the cylinder head cover.
7.
CONNECT WATER BYPASS HOSE ,
8.
CONNECT FUEL HOSE ANO VACUUM HOSES
9.
INSTALL SPARK PLUG TUBES AND 0-RINGS
(a)
Install 4 new 0-rings to the spark plug tubes.
(b)
Install the spark plug tubes to the cylinder head.
10. INSTALL SPARK PLUGS
3.
(a)
(b)
4.
5.
P249<CS
216"..44
Torque: 17.5 N-m (180 kgf·cm, 13 ft-lbf)
11. CONNECT HIGH-TENSION CORDS TO SPARK
PLUGS
12. FILL WITH ENGINE COOLANT
13. START ENGINE AND CHECK ·FoR LEAKS
14. CHECK ENGINE OIL LEVEL
. .
..
'
-.
•.
ENGINE MECHANICAL
Halaman 39
ENGINE -
ENGINE MECHANICAL .
TIMING CHAIN
COMPONENTS FOR REMOVAL AND
INSTALLATION
"
~
Timing Chain COVM
Water Pump Pulley
.<
·.
Fan
I
I
~
Crankshaft
Pulley
,.
Camshaft
Sprocket
·'
Thrust Plale
..
-:::::~---
,----- ---
.,
-~:11 --d)"---
Chain Tensioner ',,'" __ _
~~j
---- ,
+Gasket
\
----
1/JP
' ---
--
""
,_ __
•
I
Vibration Damper
Crankshaft
Sprocket
+Gasket---.;,
Drain Plug---~::>
JN·m (kgf·cm, ft·lbf)J: Specified torque
+ Non-reusable part
EG-27
l'ming Chain
+Gasket
--;
..........
I
......................
I
I
I
I
. __ J
--
\
---
------ Distributor
--
Assembly
Valve Lifter .
I
t----+O·Ring .,
~
ENGINE MECHANICAL
Halaman 40
EG-28
ENGINE'-· ENGINE MECHANICAL·.
,
TIMING CHAIN AND CAMSHAFT
.REMOVAL
1 .. REMOVE WATER PUMP PULLEY AND DRIVE BELT.
{See water pump removal in Cooling System)
2.
REMOVE CYLINDER HEAD
{See cylinder head removal)
3.
REMOVE DISTRIBUTOR
(See distributor removal in Ignition System)
4.
REMOVE FUEL PUMP
{See fuel pump removal in Fuel System)
5.
REMOVE OIL PAN
(See-oil pump remove! in Lubrication System)
6.
REMOVE CRANKSHAFT PULLEY
{a)
Using SST, remove the pulley bolt.
SST 09213-1401 0 (91651-60865),
. 09330-00021 (09330-00030)
{b)
Remove the crankshaft pulley.
HINT: If necessary, remove the pulley with SST.
SST 09950-4001 0 (09957 -0401 0),
7.
REMOVE TIMING CHAIN COVER
(a)
Remove the 8 bolts and nut.
(b)
Using a
pl~stic faced hammer, remove the timing
chain covor and gaskat.
8.
INSPECT TIMING CHAIN SLACK
Mensure the timing chain slack.
Minimum slack:
13.5 mm (O.G31 ln.)
If the sla.ck is lass than minimum, replace the timing
chain and sprockets.
--·1
·,
. '
·~
-· j •
'
. :
'
09950-50010 (09951-0501 o. 09952-05010,
09953-05020, 09954-050:.10)
At 98 N (1 0 kgf, 22 lbf) tanslon:
ENGINE MECHANICAL
Halaman 41
ENGINE :_·ENGINE MECHANICAL
EG-29
·l:l~ · ;REMOVE CHAIN TENSIONER AND VIBRATION
DAMPER
10. REMOVE TIMING CHAIN AND CAMSHAFT
SPROCKET
(a) ·Using SST, remove the camshaft sprocket set bolt .
. SST 09960-10010 (09962-01000, 09963-01 000)
(b)
Remove the timing chain and camshaft sprocket'to~
gather.
.. : ..
11. REMOVE CRANKSHAFT SPROCKET
Using a screwdriver, remove the crankshaft sprocket.
If the crankshaft sprocket can not b~ removod with a
screwdriver, use SST.
SST 09950-40010 (09952 -04010, 09954-0401 0,
09955-04010, 09957-0401 0),
09950-50010 (09951 -0501 0, 09953-05020)
12. REMOVE VALVE LIFTERS
HINT: Keep the valve lifters in correct order.
--
13. REMOVE THRUST PLATE AND CAMSHAFT
(a)
Remove the 2 bolts and thrust plate .
(b)
Temporarily install the cylinder headibolt to the cam-
shaft.
(c)
While turni11g the camshaft, slowly pull out so as not
to damage the bearing.
••
Cylinder
Head
Bolt
-, '-----·---------...::.:.""'::=::..J'
I
TIMING CHAIN AND CAMSHAFT
COMPONENTS INSPECTION
1-;zsj.-:j.\':j.·:;::;::j::~f--1 -r=
I~
--~
1.
(a)
INSPECT TiMING CHAIN AND SPRPCKETS
Measure the length with the chain fully stretched.
Maximum o:hain Glongatlom
Lc:::
J
272.2 mm (1 0.736 ln.)
If the elongation is greater than meximum, replace tho
chain.
HINT: Make the same measurements pulling at 3 or
more places selected at random.
Warp the chain around the sprocket.
Using vernier calipers, measure the sprocket diameter
with the chain.
NOTICE: Vernier calipers must contact the chain rollers
for measuring.
Minimum sprocket diameter (w/chaln):
.'---, --~
(b)
(c)
Crankshaft: 69.4 mm (2.339 ln.)
Camshaft: 113.8 mm (4.480 ln.)
ENGINE MECHANICAL
Halaman 42
EG-30
ENGINE- ENGINE MECI;JANJCAL
Chain tensinner: 12.0 mm (0.472 in.)
Vibration damper: 4.0 mm (0.157 in.)
If the diameter is less than minimum. replace the chair
tensioner and/or vibration damper.
3.
INSPECT CAMSHAFT
A.
Inspect camshaft for runout
(a)
Place the camshaft on V- blocks.
(b)
Using a dial indicator. measure the circle run out at the
center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle run out is greater than maxirnurr:. replace
the camshaft.
B.
Inspect cam lobes
EM2011
c.
(a)
£M25J8
!f the·diam13ter is Jess than minimum, replace the cha
and 2 sprockets.
2.
INSPECT CHAIN TENSJONER AND VIBRATION
DAMPER
·;, Using vernier calipers, measure the diameter of eac.
.
.
tensioner and vibration damper.
Minimum thickness:
Using a micrometer, measure' the cam lobe height.
Standard cam lobe height:
'
·
Intake:
36.47 -
36.57 mm (1.4358 -
1.4397 in.)
Exhaust: 36.37- 36.47 mm (1.4318- 1.4358 in.)
Minimum cam lobe height:
Intake: 36.17 mm (1.4240 ln.)
Exhaust: 36.07 .mm (1.4201 ln.)
If the cam lobe height is greater than minimum, re-
place the camshaft.
Inspect camshaft journals
Using a micrometer, measure the journal diameter.
Journal diameter (from front side):
STD No.I
43.209 - 43.225 m.;, (1.7011 -.1.7018 in.)
STD No.2.
42.954- 42.970 mm (1.6911 -
1.6917 in.)
STD No.3
4:1.704- 4:1.720 mm (1.8873- 1.68t9ln.)
STD No.4
42.459- 42.475 mm (1.6716- 1.6722 in.)
UfS 0.125 No.1
43.085 - 43.095 mm (t .6963 -
1.6967 in.)
U/S 0.125 No.2
42.837- 42.647 mm (1.6865- 1.6969 i~-y--
U/S 0.125 No.3
42.587 - 42.597 rnm (1.6767 -
1.6770 in.)
U/S 0.125 No.4
42.337- 42.347 mm (1.6669- 1.6672ln.)
U/S 0.25 No.I
42.960- 42.970 mm (1,6913- 1.6917 in.)
U/S 0.25 No.2
42.712-42.722 mm (1.6816- 1.6920 ln.)
U/S 0.25 No.3
42.462- 42.472 mm (1.6717- 1.6721 i~.)
U/S 0.25 No.4
42.212-42.222 mm (1.6619- 1.6623 in.)
If the journa! diameter is not as specified, check the oil
clearance.
(See camshaft and camshaft bearing inspection and
repair in cylinder block)
ENGINE MECHANICAL
Halaman 43
ENGINE ::...· EN.GJNE MECHANICAL·
EG-31
4."
INSPECT THRUST PLATE
(a)
Install the thrust plate and camshaft sprocket to the
cam's haft .
(b)
Install and torque the set bolt.
Torque: 59 N·m {600 kgf.cm, 44 ft.Jbf)
(c)
Using a feeler gauge, measure the camshaft thrust
clearance betwe<Jn the thrust p!ate and camshaft.
Thrust clearance:
•
0.3 mm (0.012 in.)
If clearance is gre<:ter than the maximrJm, replace the
thrust plate and/or' sprocket .
..
CRANKSHAFT FRONT OIL SEAL
REPLACEMENT
:
'
HINT: There are 2 methods (A and 13) to replace the oil
seai which are as follows:
REPLACE CRANKSHAFT FRONT OIL SEAL
A.
If timing chain cover is removed from cylinder block:
(a)
Using a screwdriver, pry out the oil seal. .
(bi
Using SST and a hammer, tnp in a new oil seal unti: its
S!Jrface is flush with the timing chain co.ver edge.
SST 09g2;3-46011
(c)
Apply MP grease to the oil seal lip.-
B.
If timing chain cover is installed to the cylinder
block:
(a)
Using a screwdriver, pry out the oil s&al.
NOTICE: Se careful not to damage the ~rankshaft. Tape
ihe. screwdriver tip.
"''"'
STD:
0.07 -
0.14 mm (0.0028 -
0.0055 in.)
MS)dmum:
TIMING CHAIN INSTALLATION
Halaman 44
EG-32
ENGINE .,-.·EN.GINE.MECHANICAL
(b)
Apply tvjP grease to a new oil seal lip.
(c)
Using S!)T and a hammer, tap in the oil seal until its •
surface is flush with the timing chain cover edge.
SST 09223..:.46011
-....,..,1
TIMING CHAIN INSTALLATION
1.
INSTALL CAMSHAFT AND THRUST PLATE
(a)
Apply light coat of engine oil of the camshaft.
(b)
Temporary install the cylinder head bolt to the cam-
shaft.
(c)
Install the. camshaft, using care not to damage the
camshaft bearing.
(d)
Install the thrust plate with 2 bolts as shown in the
Front
<?
illustration.
Torque: 8 N-m (80 kgf-cm, 69 ln.·lbf)
INSTALL CRANKSHAFT SPROCKET
(a)
Apply light coat of engine oil on the shaft portion of
the crankshaft sprocket.
3.
INSTALL TIMING CHAIN AND CAMSHAFT
SPROCKET
(a)
Set the No.1 position to TDC.
(b)
Align the camshaft dowel pin nearb·r the mark on the
thrust plate.
2.
(c)
Install tho camshaft sprocket to tha timing chain.
HINT: Align the timing chain and camshaft sprocket
timing marks.
(d)
Install the timing chain to the crarrkshaft sprocket.
HINT: Align the timing chain and crankshaft sprocket
timing r.1arks.
(e)
Install the camshaft sprocket with the timing chain.
(f)
Using SST, install the bolt to the camshaft sprocket.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 59 N-m (GOO !lgf-cm, 43 ft-lbf)
4.
INSTALL CHAIN TENSIONER AND VIBRATION
DAMPER
Install the chain tensioner :-;,d vibration damper with
4 bolts.
Torque: 8 N·m (80 kgf-cm, 69 ln.-lbf)
NOTICE: Apply tho tension or with oil before installation.
TIMING CHAIN INSTALLATION
Halaman 45
ENGINE -
ENGINE MECHANICAL.
I:G-33
5.
(a)
INSTALL TIMING CHAIN COVER
Place a naw gasket to the front end plate.
Install the timing belt cover with fl'bolts ,and nut.
Torque:
'
(b)
0 .,
" .
10 mm head: 8 N·m (80 kgf-cm, 69 in.·lbf)
12 mm head: 19 N·m (19S kgf-cm. ·14 ft-ibf)
INSTALL VALVE LIFTER
HINT: Apply light coat of engine oil of tha valve lifter. l,i
6.
""''"
7.
(a)
INSTALL CRANKSHAFT PULLEY
Install the crankshaft pulley.
Using SST, install and torque the pulley bolt.
SST 09213--14010 (91651-60865),
(b)
09330-00021 (09330- 00030)
Torque: 88 N-m (900 kgf.cm, 65 ft·lbf)
8.
INSTALL OIL PAN
(See oil pump installation in Lubrication System)
g_
INSTALL FUEL PUMP
(See fuel pump installation in Fuel System)
10. INSTALL DISTRIBUTOR
.-
(See distributor installation in Ignition System)
11. INSTALL CYLINDER HEAD
;
'
(See cylinder head installation)
12. INSTALL WATER PUMP PULLEY AND DRIVE BELT
(See water pump installation in Cooling System)
TIMING CHAIN INSTALLATION
Halaman 46
EG-34
ENGIN'E- ·
CYLINDER BLOCK
COMPONENTS
Oil Filter and
Piston Ring_r-_§
Bracket Assembly
(Side Rail)
~
Piston Ring (Expander)
RH Engine M~unting ~
0
Piston Pin
Bracket
~
'GI,)
~~
Upper Main Bearing---·
Crankshaft-----------..,!~
Lower Crankshaft _______ -----..
Thru~~~:::h:_r ---
~4
+ Gasket---?\l; ~
<V~~-z;'.\1~;'·
.
' 6
Oil Strainer
+ Non-reusable part.
* Precoated part
[ffffiJkgf·cm, ft·lbf)j: Specified torque
-·IZ
~-
-------====Piston Ring (No.1 Compression)
~Piston
Ring (No.2 Compresskm)
See page EG-53
111 24.5 (250, 18)
2nd Tum so•
+Gasket
'oil Pan
'=
PREPARATION FOR DISASSEMBLY
Halaman 47
ENGINE -
ENGINE MECHANICAL
PREPARATION FOR DISASSEMBLY
1.
REMO'vt: FLYWHEEL
2.
REMOVE REAR END PLATE
3.
INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY
4.
REMOVE CYLINDER HEAD
(See cylinder heed removal)
5.
REMOVE WATER PUMP
(See water pump removal in Cooling System)
6.
REMOVE ALTERNATOR AND BRACKET
7.
REMOVE TIMING CHAIN
(See timing chain removal)
8.
REMOVE OIL PUMP
(See oil pump removal in Lubri.::stion System)
9.
REMOVE N0.2 ENGINE HANGER
10. REMOVE OIL DIPSTICK
11. REMOVE OIL FILTER BRACKET AND FILTER
~ :.'
'- -
ASSEMBlY
Remove the 2 bolts. the oil filter br<~c:ket. filtGr assem-
bly and gasket.
12. REMOVE ENGINE DRAIN COCK
13. REMOVE FRONT END PLATE
•.•
Remove the 2 bolts, front end plete' and gaske·t
14. REMOVE ENGINE MOUNTING ERACKETS ·
CYLINDER BLOCK DiSASSEMBLY
1.
REMOVE REAR OIL SEAL RHAINER
Remove the 5 bolts. retainer and gasket.
2.
CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance
while moving tho connecting rod back and forth .
Standard thrust clearance:
•
0.150 -
0.330 mm (0.0059 -
O.C130 in.)
Maximum thrust clearance:
- j~
.[
•
1
i
'
0.30 mm (0.0118 ln.)
If the thrust clearance is greater than maximum, re-
place the connecting rod assembly. If nocessa;y, re-
place the crankshaft.
EG-35
PREPARATION FOR DISASSEMBLY
Halaman 48
EG-LJS
ENGINE.- 'ENGINE· MECHANICAL
3.
REMOVE CONNECTING ROD CAPS AND CHECK
OIL CLEARANCE
··(a)
Check the matchmarks on the connecting rod and cap
to ensure correct reassemi.:y.
(b)
Remove the 2 connecting rod cap bolts.
I
(c)
Using the 2 removed connecting rod bolts, remove the
connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT: Keep the lower bearing inserted with the .con-
necting rod cap.
(d)
Clean the crank pin and bearing.
(e)
Check the crank pin and bearing for pitting and scrat~ ·
ches.
If the crank pin or bearing is damaged, replace the
bearings. If nece:;sary, grind or replace the crankshaft ..
(f)
Lay a strip of Plastigage across the crank pin.
(g)
Install the connecting rod cap with the 2 bolts.
(See step B in cylinder block assembly)
Torque:·
,..-,--·
Plastigage
1st: 24.5 N·m (250 kgf·cm, f 8 ft-Jbf)
2nd: Turn go•
NOTICE: Do not turn til<. cronbhaft.
(hj
Ramovo the 2 bolts and connecting rod cap.
(Sa~ procedure (b) and (c) abova)
(i)
Measur~ the Plastigage at its widest point.
Standard oil c!oarance:
·. O.o19 - 0.068 mm (0.0007 - 0.0022 ln.)
Maximum oil clearance:
If the oil'. clearance is greater than maximum, replace .
the bearings. If necessary, grind or replace the crank-
shaft.
STD:
0.020 - 0.048 mm (0.0008 -
0.0019 ln.)
U/S 0.25, U/S 0.50 end U/S 0.75:
0.08 mm (0.0031 ln.)
PREPARATION FOR DISASSEMBLY
Halaman 49
ENGINE MECHANICAL
EG-37
ENGINE
Mark
~
1, 2 or 3
(
I
M••
-,~'·'"''
HINT: If using a standard bearing. replace it with one
having the same number marked r,n the connocting
·rod cap. There are three sizes of standard hearings,
marke<1 '1", "2" and '3" accordingly.
Standard sized bearing cantor well thickness:
STD-Mark ~
1.488 -
1.490 mm (0.05S5 - 0.0587 ln.)
STD Mark 2
1.490 -
1 .494 mm (0. 0587 - 0.0588 in.)
STD Mork 3
1.494 -
1.498 mm (0.0588 - 0.0590 ln.)
u;s o.25
1.807 -
1.813 mni (0.0833 - 0.0835 in.)
u;s o.so
1.732 -
1.738 mm (0.0682 - 0.0684 in.)
u;s o.75
1.857 -
1.883 mm (0.07 ~ 1 - 0.0733 ln.)
(Protrusior.)
Ul
4.
Completely remove the Plastigage.
REMOVE PISTON AND CONNECTlNf> ROD
ASSEMBLIES
Using a ridge reamer, remove the all carbon from·the
top of the cylinder.
Cover the connecting rod bolts with a short piece of
hose to protect the crankshaft from daml'ige.
Push the piston, connecting rod assembly and upper
bearing through the top of the cylindGr bloc;k.
HINT:
•
Keep the bearings, connecting rod and cap to-
gather.
•
Arrange the piston a11d conn&cting rod al;sernbl-
ies in correct order.
CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance
while prying the crankshaft back ~nd forth with a
screwdriver.
Standard thruat clearance:
(a)
(b)
'
(c)
• ..
-•
'
5.
0.040 - 0.242 mm (0.0016 - 0.0095 ln.)
MGxlmum thrust clearance:
0.30 mm (0.0118 ln.)
If the thrust clearance is greater than maximum, re-
plaol' tha thrust washers as a sat.
Thruot washer thlckne .. :
STD
2.430 - 2.480 mm (O.OU57 - 0.0978 ln.)
1 I
0/S 0.126
2.490 - 2.540 mm (0.0980 - 0.1 000 ln.)
6.
-
2
REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
Uniformly loosen and remove the 1 0 main bearing cap
bolts in several passes, in the sequence shown.
~
(a)
··• .. ~
PREPARATION FOR DISASSEMBLY
Halaman 50
EG-38
ENGIN'E '-' ENGINE MECHANICAL
(b)
Using the'removecl main bearing· cap bolts. pry the •
main bearing cap back and forth. and remove the main ·
bearing caps. lower bearings and lower thrust wash-
ers (No:3 main bearing cap only) ..
HINT:
•
Keep the lower bearing. and main bearing cap
together.
•
Arrange the main bearing caps and lower thrust
washers in correct ord.er.
(c)
Lift out the crankshaft.
HINT: Keep the upper bearing and upper thrust wash-
ers together with the cylinder block.
(d)
Clean each main journal and bearing.
(e)
Check each main journal and bear.ing for pitting and
scratches.
If the journal or bearing is damaged, replace the bear-
ings, If necessary, grind or repiace the crankshaft.
(f)· Place the crankshaft on the cylinder block.
(g)
Lay a strip of Plastigage across each journal.
(h)
Install the 5 main bearing caps witb the 10 bolts.
(Soe step 4 in cylinder block assembly)
Torq·uo: 59 N·rn (600 kgf.cm. 43 ft·lbf)
NOTICE: Do not turn the crankshaft.
Plastigage
(i)
Remove the 10 bolts and 5 main bearing caps.
(See procedure (a) and (b) above)
(j)
Measure the Plastigage at its widest point.
Standard clearance:
STD
0.016 - 0.040 mm (0.0006 - 0.0016 in.)
U/S typo
0.017 -
0.071 mm (0.0007 - 0.0028 in.)
Maximum:
If the oil clearance is greater than maximum. replace
the bearings. If necessary. grind or replace the crank-
shaft.
-
0.10 mm (0.0039 in.)
PREPARATION FOR DISASSEMBLY
Halaman 51
. '
ENGINE -
ENGINE MECHANICAL · · ··
EG-39 . ·- .
.
' .
~
. : '• ... · ..
.
..
1:'/0,3 r=-.
·HINT: If l'!Sing ·a standard bearing, replace with one
having the same number. If the number of the bearing·
c2nnot be determined, select a be·aring from the table
according to the numbers imprinted on tf':q r.vlinder
No!~'{t"
'"' · ' , ~/.%"
Mark
~
:r;::..
0
6,7or8
j~ ;---. LjJ """
.
.·
block· and·crankshaft. ThtJre are 5 sizes of standard·
bearings, marked "3", "4", ·s·. "6" ond "7" accordingly.
~·· ..
Cylinder block
6
7
8
Crankshaft
1 213 t 12 3
1 2
Use bear!ng
5 4i3 6!5 4
7
6
EXAMPLE: Cylinder block "6'' -
Crankshaft "2"
= Total number 4 (Use bearing "4")
\).\)>:::;;;>Mark
Reference:
3,4,5,6 or 7
P25&51
P25584
P25681
Mark 6
54.004 - 54.012 mm (2. J 201 - 2.1265 in.}
ZI6SJS
"!
Mark 7
54.012- 54.020 mm (2.1255- 2.1268 in.)
Mark 8
54.020- 54.028 mm (2.1268- 2.1271 ln.)
Mark 1
49.976
49.984 mm (1.9796- 1.9679 in.)
•.
Mcrk 2
49.984
49.992 mm (I .967~ -
1.9682. in.J·
Mark 3
49.992
50.000 mm.(l.9d82 -
1.96851o.)
u;s o.25
49.733 - 49.743 mm t1.958Cl- 1.9584 in.)
U/S 0.50
49.483 - 49A03 mm (!.9481 -
1.9485 in.)
---
Mark 4
1.994·- !.9S8 mm (0.0785 - 0.0787 ln.)
Mark 3
I .990 -
1.994 mm (0.0703 - 0.0785 ln.l
,_f~rk. s·
1.998
2.002 mm. (_O.o787 -· 0.0708 lnR
Mark B
2.002 - 2.006 mm (0.07ell - 0.0790 ln.)
;
~-
IJ , .. 0 2r.:: ----··
'
J., ••
l
2.112 - 2. I 2~ m:n t0.0~3 I - 0.0835 lr.J
L:u;so.so
-2.237 - 2.247 mm (O.OU8l - 0.0885 _ln.)
Made 7
2.006- 2.0!0 mrn (0.07PO- 0.0791 in.)
•
(k)
Corupletely remove tha Plastig~ge .
. 7. - REMOVE CRANKSHAFT
(a) ·Lift out the crankshaft.
(b)· Remove the upper bearings and· upper thrust washers
from·.the cylinder block.
HINT: Arrange the main bearing caps, bearbgs and
thrust washers in correct order.
NumbP.r marked
~
~
3
5
Cylinder block main Journal bore diamotAr:
Crankshaft Journal diamEltor:
Standard :oizod bearing cent'er Wfl!l.t:hicKnoss:
1 J
PREPARATION FOR DISASSEMBLY
Halaman 52
~~..
• i ..
r;. EG-40
11:).
I
.. ENGINE :.-·.ENGINE MECHANICAL , ..
,~~~~~~~~~~~~~~~
:· . CYLINDER· BLOCK INSPECTION
, ... " ... ··.: . , ...
1-
CLEAN·CYLINDER BLOCK
A.
Remove gasket material
· Using a gasket scraper, remove all the gasket material
from the top surface of the cylind~r block.
B.
Clean cylinder block
Using a soft. brush and solvent; thoroughly clean the
cylinder block.
2.
INSPECT TOP SURFACE OF CYLINDERBLOCK FOR .
FLATNESS
Using a precision straight edge and thickness gauge,
measure the surfaces contacting the cylinder head
gasket for warpage.
Maximum warpago:
·--
o o·o o·o o·o o
rf- '\9!: ~ ~ '
~~\-~. ./
~
\_
P25!'i2J
f'25524'
3.
INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If dMp sc.ratc.hes ar& pr&sent. re&CJrll IJ(( th6 ~ l.fill,·
ders. If necessary, replace the cylinder block.
---:="""'
4 ... INSPECT' CYLINDER BORE DIAMETER
--11 ..
0.05 mm (0.0020 ln.)
If warpage is greater than maximum, replace the cylin-.
der block.
HINT:· There are 3 sizes of the stanqard cylinder bore
diameter; marked *1*, *2* and ·a• ·accordingly. The
mark is stamped on the top of the .cylinder block.
PREPARATION FOR DISASSEMBLY
Halaman 53
ENGINE - ·ENGINE'MECHANICAL· · · ·
EG-41
Cf'j
Front,._ \:1]
CD Thrust
Direction
<VAxial
Direction
STD:Merk 1
80.500- 8C.b10 mm 13.1693··- 3:16971n.)
STD Mark 2
60.51 0 - 80.520 mm .(3.1697
3.1701 in.)
., .
STD Mark 3
80.520-80.530 mM (3.1701 - 3.1705 in.)
0/S 0.50
81.000 - 81.030 mm (3.1890 - 3.1902 i,,,)
0/S 0.50
-' .-
5.
REMOVE CYLINDER RIDGE
If the wear is Jess than 0.2 mm (0.008 in.), using a
ridge reamer, grind the top of the t;:YI!nder .
...
.... ... _"
PISTON AND CONNECTING ROD ASSY
DlSASSEMBL Y
1.
CHECK FIT BETWEEN PISTON AND PJSTON.Pm
Try to move the piston back and f~rth on the pi~ton
p!n.
If any movbm~nt is felt, replace the pi3ton and ·pin cS'
a sat.
2. · · REMOVE PISTON RINGS
(a)
Using a piston ring expander, remov& the 2 compres-
sion rings.
•Using .. a ·cylin.der gauge, m·easure the cylinder bore
diameter at positions A, B and C in the thrust and axial
directio(ls.
Standard diameter:
Moxlmum diomotor:
80.728 mm (3.178~ in.)
---'-----1
81.228 mm (3.1g79 i.1.)
STD
If the diameter is greater than maximum, rebore ""the
4 r:ylindars. If necessary, replace the cylinder bioci<.
PREPARATION FOR DISASSEMBLY
Halaman 54
.~·
. '-
,, EG-42
ENGINe·~. ENGINe·MECH-ANIC>AL ·
(b) ·"Remove· the 2 side rails· and oil·ring by hand .
.. ,HINT: · .Arrange the rings in correct order only.
P'Z5527
3.
DISCONNECT CONNECTING ROD FROM PISTON
Using SST. press out· the piston pin from the piston.
Remove the connecting rod.
SST 09221-25025 {09221-00020, 09221-00030.
PISTON AND CONNECTING ROD
INSPECTION
1.
CLEAN PISTON
{a)
Using a gasket scraper, remove the carbon· from the
piston top.
{b)
Using a groove cleaning tool or broken ring, clean the
piston ring grooves.
{c). Using. solvent and a brush. thoroughly clean the
piston.
NOTICE: Do not use a wire brush.
09221-00040.09221-00170. 09221-00210)
HINT:
•
•
The piston and pin are a matched set .
Arrange the pistons. pins. rings, connecting rods
and bearings. in correct order.
PREPARATION FOR DISASSEMBLY
Halaman 55
l :
t i
- ENGINE "-: ENGINE MECHANICAL
EG-43'·
·
., 2: · 'JNSPECT'PISTON
' .... ' . ·· ... ;
~ .
Front Mark
A. 'Inspect piston oil clearance
, 2 or3
'• .
{a)
Using a micrometer, measure the piston diameter at
ring angles to the piston hoad side, 8 mm (0.31 in.)
from the piston pin center line.
Piston diameter:
I
i
I
I
-.
STO Mark 1
80.358 - 80.368 mm (3.1637 -
3.1641 In,)
STO Mark 2
80.308 - 80.378 mm (3.1641 -
3.1645 in.)
STD Mark 3
80.378 -
80.388 mm i2.1645 -
3.1649 in.)
0/S 0.50
80.858 -
80.888 mm (3.1 &34 -
3.1846 in.)
,,
(b)
Measure the cylinder bore diameter in the thrust di-
rections.
{See step 4 in cylinder blo~k inspectionf
(c)
Subtract the piston diameter measurement from the
cylinder bore diameter measurement .
Standard oil clearance:
.
•
. -
0.132 -·0.152 mm (0.0052- 0.(1060 lr..)
If the oil clearance is greater thnn maximum. replace
all the 4 pistons and rebore all the 4 cylinders. If
necessary, replace the cylir)der block.
HINT (Use new cylinder block): Use a piston with the
· same· number· mark as the cylinder bore diameter
marked on the cylinder blo~k.
,_
P2Si1&
P2$5SS
216541
. B;
Inspect piston ring groove clearance
Using ··a· thickness gauge, measure thA clearance be-
tween· new piston ring and the wall of the piston ring
groove.
Ring groove clearance:
No.1: 0.030 -
0.070 mm (0.001 2 -
0.0028 in.)
No.2: 0.020 -
0.060 mm {0.0008 -
0.0024 in.)
If the clearance is greater thon m2ximum, replace the
piston.
HINT: There are three sizes of tha standard. piston
diameter, marked 1, "2" and "3" accordingly:'The mark-
is stamped on the piston top.
PREPARATION FOR DISASSEMBLY
Halaman 56
EG-44' .. ·
ENGINE·:-.·ENGINE MECHANICAL .
. ·. · .... ... :·
.c. · lnspect,piston .. ring end gap
(a). lnsert..thecpiston ring into the cylinder bore.
· · ··
(b)
Using a piston, push the piston ring·· a little beyond the .·
125 mm
(c) Using a thickness gauge, measure the end gap.
End gap:
3.
INSPECT CONNECTING ROD .
. A.
Inspect connecting rod alignment
Using a rod aligner and thickness gauge, check the
connecting rod alignment.
-
•
Che~k for bend.
Maximum bond:
0.05 mm (0.0020 ln.) per 100 mm (3.94 ln.)
I
I
I
~~~~0~35~£~M~0,~88~--------·------~
· bottom of.the ring tr~vel, 125 inm (4.92 ·in.} from the
top of the cylinder block.
Item'
Standard
Maximum
.
0.23 - 0.33 mm
No.1
(0.0091 - 0.0130 ln.)
0.33 mm (0.0130 ln.)
0.33 - 0.48 mm
No.2
(0.0 130 -
0.0189 in.)
0.48 mm (0.01_89 in.)
0.18- 0.38mm
Oil (Side roil)
(0.0071 -0.0150 ln.)
0.38 mm (0.0150 in.)
"
If the and gap is greater than maximum, replace the
piston ring. If the end gap is greater than maximum,
even with a new piston ring, reb'ore all the 4 cylinders
or replace the cylinder block.
If bend is greater than maximum, replace the connect-
ing rod assembly.
•
. Check for twist
Maximum twist:
0.05 mm (0.0020 ln.) per 100 mm (3.94 ln.)
If twist is greater than maximum, replace the connect-
ing rod assembly.
PREPARATION FOR DISASSEMBLY
Halaman 57
ENGINE -'ENGINE MECHANICAL
t\;·4b
B.
Inspect connecting rod bolts
Using vernier calipers. measure tile minimum diame-
ter of the compressed bolt at tho measuring point ..
Standard diameter:
About
20mm
rc67'8
CYLINDER BORING
HINT:
•
Bore all the six cylindars for the oversized piston
outside diameter.
o
Replace all the piston rings with ones to match
the oversized pistons.
SELECT OVERSIZED PISTONS
Oversized piston diameter:
0/S 0.50
1.
. • •
80.858 -
80.888 mm (3.1834 -
3,1846 in.)
CALCULATE AMOUNT TO BORE CYLINDERS
Using a micrometar, measure the p'iston diamet3r at
right angles to the piston head side, 8 mm (0.31 in.)
from the piston pin center line.
Calculate the amount of each cylinder is to be rebored
as follows:
Size to be reborod = P + C ·- H
P = Pi•ton diameter
2.
(a)
' •
--
(b)
C = Piston clearance
0.040 -
0.060 mm (0.0016 -
0.0024 in.)
H = Allowance for honing
0.20 mm (0.0008 ln.) or lft$1
3.
BORE AND HONE CYLINDER TO O:ALCULATED
DIMENSIONS
Maximum honing:
0.02 mm (0.0008 in.)
NOTICE: Exce .. honing will dastroy the flniohad round-
neal.
•J
. _,
-1'-IC
CRANKSHAFT INSPECTION AND REPAIR
I
- ' '
1.
INSPECT CRANKSHAFT FOR RUNOUT
(a)
Place the crankshaft on V-blocks.
(b)
Using a dial indicator, measure the circle run out at t .1e
center journal.
Maximum clrclo runout:
'-J 1
8.860 -
9.000 mm (0.3488 -
0.3543 in.)
Minimum diameter:
8.60 mm (0.3386 in.)
If the diameter is Jess than minimum, repl2ce the ~£
connecting rod bolt.
0.03 mm (0.0012 ln.)
PREPARATION FOR DISASSEMBLY
Halaman 58
EG-46 ·
ENGINE-~ ENG.INE.MECHANICAL
If the circle runout. is greater than maximum, replace
the crankshaft.
2.
INSPECT MAIN JOURNALS AND CRANK PINS
(a)
Using .. a .micrometer. measure the diameter of each
main journal and crank pin.
Diameter:
If thc.di.ameter is not as specified, check the oil clear-
ance (S.ee steps 3 and 6 in cylinder block dis-
assembly). If necessary, grind or replace the crank-
shaft.
(b)
Check each main journal and crank pin for taper and
out-of-round as shown.
Maximum taper and out-of-round:
0.005 mm (0.0002 in.)
If the taper and out-of-round is greater than maxi-
mum, replace the crankshaft.
3.
IF NECESSARY, GRIND AND HONE MAIN
JOURNALS AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to
the finished undersized diameter (See procedure in
step 2).
Install new main journal and/or crankshaft pin under-
sized bearings .
•
Item
Main journal
Cranck pin
49.976 -
50.000 mm
~7.988 - 48.COO mm
STD
(1.9676 -
1.9685 in.)
(1.8893 -
1.8828 i.1.)
49.733 -
49.743 mm
47.738 -
47.750 ffiOI
u;s 0.25
(1.9580 -
1.9584 in.)
(1.8794 -
1.8780 in.)
49.483 -
49.493 mm
47.488 - 47.500 mm·
u;s o.5o
(1.9481 -
1.9485 in.)
(1.8696 -
1.8701 in.)
47.238 - 47.250 mm
U/S 0.75
-
( 1.8598 -
1.8602 in.)
PREPARATION FOR DISASSEMBLY
Halaman 59
ENGINE:- ENGiNE. MECHANICAL
EG-47
--··
·cAMSHAFT AND CAMSHAF-T BEARING
iNSPECTiON AND REPAIR
1.
INSPECT CAMSHAFT OIL CLEARANCE
(a)
Using a 'cylinder .gauge. measure the inside diameter
of the camshaft bearing.
Bearing inside diameter (from front side):
STD No.1
43.250- 4:;.275 mm 11.7028 -
1.7037 in.)
STD No.2
43.010 - 4:;,03:; m<r 11.5933 -
I.G943 in.) --
STD No.3
42.750- 42.785 mm 11.6835- 1.6R44 in.)
STD No.4
42.500 - 42.525 mm 11.6732 -· 1.6742 in.) ·--
U/S 0.125 No.I
43.120 -
43.151 mm (1.6976 -
1.5989 in.)
u;s 0.125 No.2
42.890- 42.930 mm 11.6886- 1.6902 in.)
u;s 0.125 No.3
42.640 - 42.680 mm (1.6787 -
1.6803 in.)
u;s 0.125 No.4
42.390- 42.4~0 mm 11.6589 -
1.6705 in.)
.
~-
U/S 0.25 No. I
42.995 - 43.026 mm (1.6927 -
1.6939 ln.)
•
U/S 0.25 No.2
42.765 - 42.805 mm (1.6837 -
1.6852 in.)
U/S 0.25 No.3
42.515 - 42.555 mm (1.6738 -
1.6754 in.)
";;
U/S 0.25 No.4
42.265 - 42.'30t: mm (1.6ti40 -
1.6655 in.)
:-
(b)
Subtract the journal diameter measurement (See stop
3 in timing chain and camshaft inspection) from the
bearing inside diameter measuremimt.
Standard oil ciearance:
STD
No.1 and No.4
0.025 -
0.066 mm 10.0010- 0.0028 in.)
No.2 and No.3
0.040- 0.081 rnm 10.0016- 0.00321n.)
U/S Typo
No.1
0.025 -
0.066 mm 10.0010 - 0.0026 in.)
'---
If the clearance is 9reatar than maximum, replace tha
camshaft bearings. If necessary, -rRplace the cam-
shaft.
2.
IF NECESSARY, REPLACE CAMSHAFT BEARINGS
A.
Remove expansion plug
Using SST and a hammer, tap out the expa:-tsion plug.
SST 09215-00101 (09215-00130. 09215-00150,
, .
., .. I
09215-00211)
B.
Remove camsha-ft bearings
Using SST, remove th~ camshaft bearings.
SST 09215-00101 (09215-00121. 09215-00130,
,·
. .
Oth~:~rs
0.043 -
0.093 mm 10.0017 - 0.0037 in.)
Maximum oil clearanca:
0.10 mm (0.0039 ln.)
09215-00141,09215-00150,09215-00161,
. 09215-00221)
PREPARATION FOR DISASSEMBLY
Halaman 60
· EG-48 . '·
ENGINE- ENGINE :MECHANICAL
C.
Install new camshaft bearings.
(a)
Install ne'yV bearings in their proper location .
No.1
No.2
No.3
No.4
•···
500291
(b)
Align the oil holes of the bearing and cylinder block.
(c)
Using SST, install the camshaft bearings.
SST 09215-00101 (09215-00121, 09215-00130,
D.
Check camshaft oil clearance (See step 1 above)
E.
Install expansion plug
(a)
Apply liquid sealer to the expansion plug surface of
the cylinder block.
(b)
Using SST and a hammer, drive in thoJ expansion plug
to 11 distance of 2 mm (0.08 in.) from the cylinder
block edge.
SST 09215-00101 (09215-00231)
ZI~J I
VALVE LIFTERS AND VALVE LIFTER
BORES INSPECTION
INSPECT VALVE LIFTER OIL CLEARANCE
(a)
Using a caliper gauge, measure the valve lif!er bore
diatneter.
Bore diameter:
21.417- 21.437 mm (0.8432- 0.8440 ln.)
(b)
Using a micrometer, measure the valve lifter diameter.
·' ..
. ·.
09215-00141.09215-00150,09215-00161,
09215-00221)
PREPARATION FOR DISASSEMBLY
Halaman 61
. ENGINE-~· ENGINE MECHANICAL.
EG-49
lifter diameter:
21.387- 21.404 mm (0.8420- 0,8427 ir>.)
{c)
Subtract the valve lifter dbmetor measurement from
the valve lifter bore diameter m6asurement.
Standard oil clearance:
CRANKSHAFT OIL SEALS REPLACEMENT
1.
REPLACE CRANKSHAFT FRONT OIL SEAL
{See crankshaft front oil seal replacement in timing
chain)
REPLACE CRANKSHAFT REAR OIL SEAL
If rear oil seal retainer is removed from cylinder
block:
Using screwdriver and hammer, tap out the oH seal.
Using SST and a hammer, tap in a new oil seal until its
surface is flush with the rear oii seal edge .
SST 09223-15020, 09608-30012 {096PB-04020)
•
2.
A.
"""'
'
{a).
{b)
•
-.
(c)
Apply MP grease to the oil seal lip.
0
B.
{a)
(b)
If rear· oil seal retainer Is installed to .:ylinder block:
Using a knife, cut off the oil seal lip.
Using a screwdriver, pry out the oil seal.
NOTICE: Be careful not to damage ·tha cronk•haft. Tape
the screwdriver tip.
I~ =*
C:Jt Position
{c)
{d)
Apply MP grease to a new cil seal lip.
Using SST and a hammer, tap in the oil se~l until its
surface is flush with the rear oil seal retc:iner edge.
SST 09223-15030, 09608-30012 {09608-·04020)
0.013 -
0.050 mm (0.0005 -
0.0020 in.)
Maximum oil clearance:
0.10 mm (0.003S in.)
If the oil clearance is greater thc:n maximum. replllce
the valve lifters.
__ ..
HINT: There are 2 methods {A and Bj to replace the oil
seal which are as follows:
PREPARATION FOR DISASSEMBLY
Halaman 62
EG-50
ENGINE ~-ENGINE MECHANICAL ...
PISTON.AND CONNECTING ROD
ASSEMBLY
Front fvhrk---~
(Cavity;
J
1.
ASSEMBLE PISTON AND CONNECTING ROD
(a). Coat the piston pin and. piston holes with engine oil.
(b)
Align the front marks of the piston and connecting
rod.
Front Mark-----0~~~
(Protrusion)
(c)
Using SST. press in the piston pin.
SST 09221-25025 (09221-00020, 09221-00030;
2.
INSTALL PIS"T:ON RINGS
(a)
Install the oil ring expander and 2 side rails by hand.
pz:£/11
3/:
,:;~
(b)
Using a piston ring expander, install the 2 compres-
sion rings with the code mark facing upward.
Coda mark:
No.1
1N
No.2
LIP_>s_ .. _,_.,_ .. _"·~
(c)
Position tho piston rings so that the ring ends are as
.shown.
Front ..
Side nail
(Upper)
NOTICE: Do not align the ring ends.
Froni: M;:Jrk
(Cavit·rl
No.i and
Expander
Side Rail
(lower)
P25537
co ... '"
09221 -00040, 09221 -00170, 09221 -0021 0)'
-.
2N
'
PREPARATION FOR DISASSEMBLY
Halaman 63
ENGiNE -~ ENGlNE MECKANICAt· ..
EG-51 ·
3:
INSTALL BEARINGS
(a)
Align·the bearing claw with the groove of the r.onnect-
ing rod or connecting cap.
(b)
Install the bearings in the connecting rod and con-
riecting rod cap.
·-
~, .
P06443
P07010
105505
CYLINDER BLOCK ASSEMBLY
HINT:
•
Thoroughly clean ail parts to be assembled.
-•
Before installing the parts, apply new engine oil
to all slid!ng and rotating suriacas.
•
Replace all gaskets, 0- rings and oil seals with
new parts.
1.
INSTALL MAIN BEARINGS
HINT: Upper bearings have an oil groovo and oil holes.
lower bearings do not.
(a)
Align the bearing c!aw with the claw groove of the
cylinder block, and push in tha 5 upper b'earings.
l
(b)
Align the bearing claw with the claw groow of the
main bearing cap, and push ir> the 5 lower bearings.
HINT: A number is marked on ~ach main bearing cap
to indicate the installation position.
)
~
iir~
PREPARATION FOR DISASSEMBLY
Halaman 64
EG_-_5_2_··-------"--·--=E:.:.:N:..::G:.:.:iNc.:.:E::..·_~_. E:::.:N.::G::..:I.:..:N.:::E..:.:·Mc:.:E::.:C:..c.:H.AN.:.:iC::.:.A.:.:t:.:.......:. _________ _
2;
INSTALL UPPER THRUST WASHERS
lnstail· the 2 thru;;t washers under the No.3 journal
position of the· cylinder block with the oil grooves
facing .. outward.
3.
PLACE CRANKSHAFT ON CYLINDER BLOCK
4.
INSTALL MAIN BEARING CAPS AND LOWER
THRUST WASHERS
A.
Place main bearing cap and lower thrust washers on
cy!inder block
(a)
Install th& 2 thrust washers on the No.3 bearing cap
with the grooves facing outward.
----------'-·---,,.----...::""c:.'::.:"....s
..
r"O\
rd-
(b)
Install the 5 main bearing caps in their proper loca-
tions.
.
HINT: Each bearing cap has a nun;ber and front m·ark ..
/
~""'"'
""
t1r
h
h
L
o If(/ o ' It=
~ r-
0
or>
}-
~
~- J\l~lf' ~ = ;,c
Q..J
S; "' ~- :j \::.
~
~
El17003
B.
Install main bearing cep bolts
.
(a)
Apply a light coat of engine oil on the threads ar.d
uncier heads of tha main bearing .cap bolts.
(b)
Install and unifo;mly tighten the 10 bolts of the main
bearing cap bolts in several passes, in the sr;quence
shown.
Torquo: 59 N·m (600 kgf-cm, 43 ft-lbi)
(c)
Check that the crankshaft turns smoothly.
(d)
Check that the cra11kshaft thrust clearance.
(Sae ste:-- 5 in cylinder block disassembly)
5.
INSTALL PISTON AND CONNECTING ROD
ASSEMBLIES
P25~04
'------------
Using a piston ring compressor, push 'he correctly
numbered piston and connecting rod assemblies into
each cylinrler with t';a front mark of the piston facing
forward.
/
Front
•
PREPARATION FOR DISASSEMBLY
Halaman 65
EG-54
ENG'INE:..: ENGINE' MECHANICAL
'pOST ASSEMBLY
L
INSTALL ENGINE MOUI'iTING BRACKETS
Install the brackets with the 4 bolts.
Torque: 39 N-m (400 kgf-cm. 29 ft-lbf)
""""'
2.
INSTALL FRONT END PLATE
Install a new gasket <ond front end plate with tho 2
bo!ts.
Torque: 19 1~-m (195 kgf-cm. 14 ft-lbf)
3.
INSTALL ENGINE DRAIII! COC!<
1'155<2
" -
4.
INSTALL OIL FILTER BRACKET AND FILTER
ASSEMBLY
h1stall a new gasket. the oil filter·, bracket ,;nd filter
assembly with the 2 bolts.
Torque: 19 N-m (195 kgf·cm, 14 ft-lbf)
5.
INSTALL N0.2 ENGINE HANGER
Torque: 37 N-m (380 kgf·cm, 27 tt-lbf)
6.
INSTALL OIL DiPSTICK
7.
INSTALL OIL PUMP
(See oil pump installation in Lubricatior. System)
B.
INSTALL TIMING CHAIN
(See timing chain instellatiem)
"
0
~-
INSTALL ALTERN A TOR BRACKET
·rorque: 26 N-m (270 kgf-cm, 20 ft·l~f)
10. INSTALL ALTERNATOR
1 ~. INSTALL WATER PUMP
(Sea water pump inst111lstion in Cooling System)
12. INSTALL CYLINDER HEAD
(See cylinder head installGtion)
13. REMOVE ENGINE STAND
14. INSTALL REAR END PLATE
· Torque: 8 N-m (80 kgf·cm, 69 ln.·lbf)
15. INSTALL FLYWHEEL
(a)
Install the flywheel on the crankshaf~.
(b)
Install and uniformly tighten the 6 mount bolts in '
several passes. in the sequence shown.
Torquo: 83 N-m (850 kgf-cm, 61 ft-lbf)
,;··
"""'
CGOV••I
PREPARATION FOR DISASSEMBLY
Halaman 66
ENGINE -
ENGINE MECHANICAL
EG-53
: 6.
INSTALL CONNECTING ROD CAPS
A.
Place connecting rod cap on connecting rod
(a)
Match the numbered connecting rod cap with the
connecting rod.
(b)
l!'lstall the connecting rod cap with the front mark
facing forward.
Front Mark
(Protru!_!:s~io~n:.!)~~~~
B.
lnstoll connecting rod cop bolts
HINT:
•
The connecting rod cap bolts are tightened in 2
progressive steps (steps (b) and (d)).
•
If any connecting rod bolt is broken or deformed.
replace it.
(a)
Apply a light coat of engine oil on the threads and
under the heads of the connecting rod cap bolts.
(b)
Install and alternately tighten the 1 0 bolts of the
connecting rod cap in several passGs.
Torque: 24.6 N·m (260 kgf.cm, 18ft·lbf)
If any one of the connecting rod cap bolts does not ·
meet the torque S!Jecification.' replace the connecting
rod cap bolt.
(c)
Mark tho front of the connecting rod cap bolt with
paint.
•
Fro~~
I I I .---.,.--,i;*:~~
Painted
')
Mark
,
{d)
Retighten the connecting rod cap bolts 90" as shown.
(e)
Check that the painted mark is now at a 90" angle to
the front.
-
(f)
Check that tha crankshaft turns smoothly.
(g)
Chack that the connecting rod thrust clearance.
{See step 2 m cylinrlcr b!nck disassembiyl
.i
I .
.__I _ _ _ _ _ _ _
____:_:.__;.
7.
INSTALL REAR OIL SEAL RETAINER
Install a new gasket and the retainer with the 5 bolts.
Torque: 8 N·m (80 kgf·cm, 69 ln.·lbf)
PREPARATION FOR DISASSEMBLY
Halaman 67
ENGINE -
ENGINE MECHANICAL
-SERVICE SPECIFICATIONS·
SERVICE OAT A
Compression
at 250 rpm
STD
.
pressure
Minimum
Difference of pressure botweon onch cylinder
Valve
at cold
Intake
.
Exhaust
clearance
Dwell angle
Engine at normal opera:ing temperature
Ignition timing
Engine at normal operating temperature
Idle speed
Engine at normal operating temperature
Cylinder t".ead
Warpage
Cylinder block side
Maximum
ManifOld side
Maximum
Valve seat
reiacing engle
Contacting angle
Contar:ting width
Intake
Valve guic!e
Inside diameter
bushing
Outside diameter (for repair part)
STD
.
• •
Replacing temperature (Cylinder head side)
Valve
Valve overall hmgth
STD
Intake
Minimum
Intake
Valve face angle
Stem diameter
Intake
.,,
StiJm oil clearance
STD
Intake
•
ExhauJO;t
Maximum
Intake
I
Exhaust
I
I
Margin thickness
STD
Intake
Exhaust
I
I
Minimum
!r.taba
Valve spring
Oavlation
. ·-
Mox1mum
Fres length
·.
Installed tension
at 38.4 mm (1.512 in.)
Valve rocKer
Arm· inside diameter
arm and
Shaft die-meter
shaft
Oil clearance
· STD
Maximum
..
Push rod
Circle runout
Ma'xlmum
Valve lifter
Lifter diameter
Lifter bore diameter
,.
Oil clearance
STO
Maximum
-
931 kPa (9.5 kgf/cm', 135 psi) or more
795 kPa (9.0 kgl/cm'. 129 psi)
98 kPa (1.0 kgf/cm', 14 psi) or loss
0.13 mm (0.005 in.)
0.23 mm (0,009 in.)
46
sa·@ idle
9- 15" BlOC@ idle
700- 800 rpm
0.05 mm (0,0020 in.)
0.1 0 mm (0.0039 in.)
ao·. 45•. 6s·
45"
1.1 -
1,7 mm (0.043 -
0.067 in.)
Exhaust
1.2 -
1.9 mm (0.047 -
0.071 in.)
8.0 I 0 - 8.030 mm (0.3154 -
0.3161 in.)
13.000- 13.027 mm (0.5119- O.S129 in.)
0/S 0.05
13.050 -
13.077 mm (0.5138 -
0.5149 in.)
so- 1oo·c (176 -212"Fl
99,90 mm (3.933 in.)
Exhaust
I 00.1 0 mm (3.941 in.)
99.4 mr.: (3.913 in.)
99,6 mm (3.921 in.)
Exhaust
44.5·
7.951 -7.991 mm (0.3130- 0.3146Jn.)
Exhaust
7.960-7.986 mm (0.3134 ·- 0.3144 in.)
0,019 -
0.1)79 mm (0.0007 -
0.0031 in.)
0.024 - 0.075 mm (0.0009 -
O.OC30 in.)
0.08 mm (0.0031 in.l
I I
I I I
0.1 0 mm (0.0039 in.)
1,0 -
1.6 mrn \0.039 -
0.063 in.)
1.2- 1.9 mm (0.047- 0.071 in.)
0.9 """ (0.031 ln.)
O.U mm (0.035 in.)
--1.6 mm {0.083 in.)
Exho1.0st
46.~ mm (1.831 in.)
296 -· 328 N (30.2 -
33.4 kgf, 06.0 ·- 73.8 lbl)
16.00 -
16.02 mm !0.11299 -
0,6307 in.)
15.97 -
15.99 mm (0.6287 -
0.62~9 in.)
0.02- 0.04 mm (0.0006- 0.0016 in.)
0.30 mm (0.0 11 B in.)
I
0.04 mm (0.00 1 6 in.)
21.387- 21.404 mm (0.9420- 0.8427 in.)
21.417 -
21.437 mm (0.8432 -
O.C440 in.j
0.013 -
0.050 mm (0.0005 -
0.00?.0 in.)
I
0.10 mm (0.0039 in.}
----'
PREPARATION FOR DISASSEMBLY
Halaman 68
EG-56
F.NGINE'~. ENGINE: MECHANICAL·
Manifolds
'Narpage
Maximum
0.20 mm (0:0078 in.).
'
Camshaft
Thrust clearance
5TD
0.07
0.14 mm (0.0028 - 0.0055 in.)
Journal oil clearance
5TD
No.1 end No . .4 1
0.025 - 0.066 mm (0.001 0 - 0.0026 ln.)
No.2 end tJo.3·'
O.CJ40- 0.081 mm (0.0016- 0.0032 in.)
U/5 Type
No.I .
0.025 - 0.066 mm (0.001 0 - 0.0026 in.)
Journal dbmflter (f;om front side)
·SiD
No.I
43.209- 43.225 mm (1.7011 -
1.70181n.)
U/5 0.125
No.I
43.085- 43.095 mm (1.6983- 1.6967 in.)
U/5 0.25
No.I
42.960- 42.970 mm (1,8gl3- 1.6917 in.)
Bea.ring inside diameter (from front side)
STD
No.I
43.250- 43.275 mm (1.7028- 1.7037 in.)
•
No.2
43.010 - 43.035 mm (1.693~ -
1.6943 in.)
U/S 0.125
No.I
43.120-43.151 mm (1.6976- 1.6989 in.)
.
No.3
42.640 - 42.680 mm (1.6787 -
1.6803 in.)
I
No.4
42.390 - 42.430 mm (1.6689 -
1.6705 in.)
U/5 0.25
No.I
42.995 - 43.026 mm (1.6927 -
1.6939 ln.)
Circle runout
Maximum
0.06 mm (0.0024 ln.)
Cam lobtt height
5TD
· Intake
36.47 - 36.57 mm (1.4358 -
1.4397 ln.)
I
Exhtual
36.37-- 30.47 """ (1.4318- 1.4358 ln.)
~--·~··
Minirnt:m
lntck&
26.17 mm (1.4240 ln.)
Chair. ::lock
--r·
end sprocket
e\ 98 N (I 0 kgf, 2.2 ibn tension
Minumurn
13.5 mm (O.G31 ln.)
Chain olongotion
Maximum
272.2 mm (I 0.736 in.)
CamShaft sprocket wear (w/ chain)
Minimum
113.8 mm (4.480 in.l,
Crankshaft li:procketr wear (w/ chain)
Minimum
69.4 mm (2.339 ln.)
Chein
Tenttion diameter
Minimum
12.0 mm (0.472 ln.)
tensioner end
Ol!lmper diornetoi
Minimum
4.0 mm (0.167 ln.)
vibration
c.Jamper
Maximum
0.3 mm (0.012 in.)
Others
0.043 - 0.093 mm (0.0017 - 0.0037 in.)
Maximum
0.10 mm (0.0039 in.)
No.2
42.954-42.970 mm (1.6911 -
1.0917 in.)
No.3
42.704-42.720 mm (1.6873- 1.6819 in.)
No.4
42.459-42.475 mm (1.8716- 1.6722 in.)
No.2
42.837-42.847 mm (1.8865- 1.68691n.)
No.3
42.587 - 42.597 mm (1.8767 -
1.6770 in.)
No.4
42.337- 42.347 mm (1.6668 -- 1.6672 in.)
No.2
42.712- <!2.722 mm (1.6616- 1.6820 ln.)
No.3
42.462- 4:<:.472 mm (1.6717- 1.6721 ln.)
'
No.4
42.212-42.222 mm (1,8619- 1.6623 in.)
No.3
42.760- 42.785 mm (1,6635 -
1.6844 ln.)
No.4
42.500 - 42.525 mm (1.6732 -
1.8742 in.)
No.2
42.890 - 42.930 mm (1.6866 -
1.6902 in.)
No.2
42.766 - 42.805 mm (1.6837 -
1.6852 in.)
No.3
42.515 - 42.555 mm (1.6738 -
1.6754 ln.)
No.4
42.265 - 42.305 mm (1.6649 -
1.6655 ln.)
Exhaust ·.
36.07 mm (1.4201 h)
PREPARATION FOR DISASSEMBLY
Halaman 69
ENGINE·- "ENGINEMECHANI.CAL
..
l
Cylinder block
Cylinder head surfecttwarpege
..
Maximum
0.05 mm (0.0020 in.)
Cylinder bore diameter
STD
Mark 1
80.500 -
80.51 0 mm {3.1693 -
3.16~7 in.)
Maximum STD
80.728 mm (3.1783 ln.)
Cylinde!' block main journal bore diameter
STD Mark 6
54.004- 54.012 mm (2.1281 -
2.1265 in.)
Pistori and
Piston diameter
STD Mark 1
80.358 - 80.368 mm (3.1537 - 3.1641 in.)
piston ring
Mark 2
80.368 - 80.378 rnm (3.1641 - 3.1645 ln.)
0/S 0.50
80.858 - 80.888 mm (3.1834 - 3.1846 in.)
Piston oil clearance
0.132 - 0.152 mm (0.0052 - 0.0060 ln.)
,,
Piston ring groove clearance
No.1
0.030 - 0.070 mm (O.CO 12 - O.C028 in.)
Piston ring end gap
STD
No.1
0.23 - 0.33 mm (0,0091 - 0.0130 in.)
Oil (sido rail)
0.18 - 0.38 mm (0.0071 - 0.0 ISO io.)
Maximum No.I
0.33 mm (0.0 130 in.)
Oil (side rail)
0.38 mm (0.0150 ln.)
Connecting
Thrust cleerance
STD
0.150-0.330 mm(0.0059 -.0.0130 in.)
rod
Maximum
0.30 mm (0.0 11 8 ln.)
Connecting rod bearing center w~ll thickness
Mark 2
1.490 -
1.494 mm (0.0587 -
0.058~ ln.)
..
STD Mark 1
1.486 -
1.490 mm (0.0585- O.OS8i in.)
U/S 0.25
1.007 -. 1.613 mm (0.0833 - 0.0835 ln.)
I
I
U/S 0.60
1.732 -
1.738 mm (0.0&82 - 0.0684 in,)
I
I
U/S 0.75
1.857 -
1.883 mm (0.0731 - 0.0'133 in.)
Connecting rod oi! clearenca
STD
0.020 - 0.048 mm (0.0008 - o,9c 19 lr..)
U/S Type .
0.019 - 0.058 mm (0.0007 - O.O•J22 ln.)
Maxlroum
O.C8 mm (0,0031 ln.)
!
Rod ~ut-~of-a!ignment
M8xlmvm per 100 mm (3.941n.)
0.05 mm (0.0020 ln.)
HQd twist
Maximum per 100 mm {3.S4 ln.)
0.05 mm {0.0020 ln.)
Connecting rod bolt outcl~e dl11metor
STD
8.880 - 9.000 mm (0.34aO - 0.3543 in.)
Minimum
8.60 mm (0.3388 ln.)
.-.
Mark 2
80.510- 80.520 mm (3,1897- ~.1701 ln.l
Mark 3
80.520 - 80.530 mm (3.1701 -
~.1705 in.)
0/S 0.50
81.000- 81.030 mm (3.1890- 3.1902 in.)
0/S 0.50
81.228 inm (3.1979 in.)
Mark 7
54.012 - 54.020 rnm (2.1285 -
2.1268 in.)
Mark 8
54.020- 64.028 mm (2.1288- 2.1271 ln.)
Mark 3
80.378 - 80.388 mm (3.1645 - 3.1349 in.)
No.2
0.020 - 0.080 mm (0.0008 - 0.0024 in.)
No.2
0.33-0.48 mm (0.0130- 0.018g io.)
No.2
0.48 mm (0.01 89 ln.)
.
Ml!llrk 3·
1.494 -
1.498 mm (0.0588 - 0.0590 in.)
PREPARATION FOR DISASSEMBLY
Halaman 70
EG-58
ENGINE- ENGINE MECHANICAL.
Crtmkshaft
Thrust clearanco
Thru~t wa:;her thickness
Main jo:.Jrnal oil cJegrance
STD Mark 1
Main journal diameter
Main bearing center wall thickness
STD
Mark 3
Crank pin diameter
Circle runout
Maximum I 0.06 mm (0.0024 in.}.
Main journal taper and out-of-round
Maximum
0.02·mm (0.0008 in.)
'Crank pin taper and out-of-round
Maximum I 0.005 mm (0.0002 in.)
~~~------~----~------~--------__J
STD
0.040 -
0.242 mm ~0.00 t 6 -
0.009.5 in.}
0.30 mm {0.0 1 t 8 in.)
2.430·- 2.480 mm ·(0.0957 - 0.0976 in.)
Maximum
STD
0/50.125
2.490-; 2.540 mm (0.0976- 0.1000 in.)
0.016 -' 0.040 mm (0.0006 -
0.0016 in.)
STD
U/S Type
0.017 _; 0.071 mm (0.0007- OC0028 in.)
Maximum
0.10 mm (0.0039 in.)
49.976 - 49.984 mm (1.9796 -
1.9~79 in.)
Mark 2
49.984 -
49.992 mm (1.9679 -
1.9682 in.)
Mark 3
49.992 -
50.000 mm (1.9682 -
1.9685 in.)
U/S 0.25
49.733 - 49.743 mm (1.9580 -
1.9584 in.)
U/S 0.50
49.483 - 49.493 mm (1.9481 -
1.9485 in.)
1.990 -
1.994 mm (0.0783 - 0.0785 in.)
Mark 4
1.994 -
1.998 mm (0.0785 -
0.0787 in.)
Mark 5
1.998 -
2.002 mm (0.0787 - 0.0788 in.)
Mark 6
2.002 -
2.006 mm (0.0788 -
0.0790 in.)
Mark 7
2.006- 2.010 mm (0.0790- 0.0791 in.)
U /S 0.25
2. 11 2 -
2.122 mm (0.0831 - 0.0835 in.)
U/S 0.50
2.237 -
2.247 mm (0.0881 -
0.0885 in.)
STD
47.988 -
48.000 mm (1.8893 -
1.fl808 in.)
U/S 0.25
47.738 - 47.750 mm (1.8795 -
1.8799 in.)
U/S 0.50
47.488 - 47.500 mm (1.86.96 -
1.8701 in.)
47.238- 47.250 mm (1.859~- 1.8602 in.)
U/S 0.75
PREPARATION FOR DISASSEMBLY
Halaman 71
ENGINE — ENGINE MECHANICAL
EG-59
**TORQUE SPECIFICATIONS**
| Part tightened | | N·m | kgf·cm | ft·lbf |
| :--------------------------------- | :-------------- | :---- | :------- | :--------- |
| Spark plug x Cylinder head | | 17.5 | 180 | 13 |
| Distributor x Cylinder block | | 12 | 120 | 9 |
| Cylinder head x Cylinder block | 12 Pointed head | 29.5 | 300 | 22 |
| | 1st | Turn 90°| Turn 90° | Turn 90° |
| | 2nd | Turn 90°| Turn 90° | Turn 90° |
| | 3rd | Turn 90°| Turn 90° | Turn 90° |
| | Recessed head | 19 | 195 | 14 |
| Rocker arm assembly x Cylinder head| | 21 | 210 | 16 |
| Cylinder head cover x Cylinder head| | 2 | 25 | 18 in·lbf |
| Rear plate x Cylinder head | | 8 | 80 | 69 in·lbf |
| Water outlet housing x Cylinder head| | 19 | 195 | 14 |
| Manifolds x Cylinder head | | 39 | 400 | 29 |
| Thrust plate x Cylinder block | | 8 | 80 | 69 in·lbf |
| Camshaft sprocket x Camshaft | | 59 | 600 | 43 |
| Chain tensioner x Cylinder block | | 8 | 80 | 69 in·lbf |
| Vibration damper x Cylinder block | | 3 | 80 | 69 in·lbf |
| Timing chain cover x Cylinder block| 10 mm head bolt | 8 | 80 | 69 in·lbf |
| | 12 mm head bolt | 19 | 195 | 14 |
| Crankshaft pulley x Crankshaft | | 89 | 900 | 65 |
| Connecting rod cap x Connecting rod| 1st | 24.5 | 250 | 18 |
| | 2nd | Turn 90°| Turn 90° | Turn 90° |
| Main bearing cap x Cylinder block | | 59 | 600 | 43 |
| Front end plate x Cylinder block | | 19 | 195 | 14 |
| Rear oil seal retainer x Cylinder block | | 8 | 80 | 69 in·lbf |
| Engine mounting bracket x Cylinder block | | 39 | 400 | 29 |
| Oil filter bracket x Cylinder block| | 19 | 195 | 14 |
| Rear end plate x Cylinder block | | 8 | 80 | 69 in·lbf |
| No.2 engine hanger x Cylinder block| | 37 | 380 | 27 |
| Alternator bracket x Cylinder block| | 26 | 270 | 20 |
| Flywheel x Crankshaft | | 83 | 850 | 61 |
PREPARATION FOR DISASSEMBLY
Halaman 72
EG-60
ENGINE -
F.UEL ~YSTEM
FUEL SYSTEM
PREPARATION
SST (SPECiAL SERVICE TOOLS)
09240-00014
~
~
~
Carburetor Adjusting Gauge Set
~
09240-00020
Wire Gauge Set·
~;l!'~!!l!ih ~
RECOMMENDED TOOLS
09082-00050
TOYOTA Electrical Tester Set.
~~.
-~--"="'
~~
09200-00010
Engine Adjust Kit .•
~:!·
~
-
::;::<'
09860-11011
C.!rburetor Drivor Set.
""'-==-
·-=-
EQUIPMENT
Torque wrench
Tweezers
L_ ______ , _________________ __
PRECAUTION
1.
Before working on the fuel system, disconnect the cable from the negative battery ter~i';a'i.
2.
When working on the fuel system, keep away from possible fire hazards ana do not smoke.
3.
Keep gasoline off rubber or leather parts.
4.
Work on only one component group at a time to help avoid confusion between similar looking
parts.
5.
Keep work area claan to avoid contamination of the c·arburetor and components.
S.
Be careful not to mix up or lose clips or springs.
--
__ .,
·,
VEHICLE INSPECTION
Halaman 73
ENGINE --, FUEL SYSTEM.
I:::G-'31
. ON- VEHICLE INSPECTION
•
_-
1.
. ' 2.
REMOVE INTAKE AIR CONNECTOR FROM CARBURETOR
INSPECT CARBURETOR AND LINKAGE
'
Check that the various set screws. plugs and union bolts are tight nnd correctly installed.
Check the linkage for excessive wear and missing snap rings.
Check that the throttle valvas open fully when the accelerator pedal is fully depre~sed.
INSPECT ACCELERATION PUMP
Open the throttle valve, and check that gasoline spurts out from the acceloration nozzle.
CHECK AND ADJUST IDLE SPEED AND IDLE MIXl Ur1c
.
(See idle CO check end adjust in Engine Mechanical)
• (a)
(b)
(c)
,..
: . 3.
4.
CARBURETOR
COMPONENTS FOR REMOVA!- AND
INST ALLATICN
: .. ~
+Gasket
j24(24Q, 17) I
+ Non-reusable part
IN·m (kgf·cm, ft·fbtJl: Specified torque
r P25715
'
VEHICLE INSPECTION
Halaman 74
EG-62
ENGINE -
FUEL SYSTEM
' .
CARBURETOR REMOVA.L
1.
DISCONNECT ACCELEflATOR CABLE FROM
CARBURETOR
2.
DISCONNECT CARBURETOR CONNECTOR
3.
DISCONNECT FUEL INLET PIPE FROM
CARBURETOR
Remove the union bolt and 2 gaskets, and disconnect
the inlet pipe from the carburetor.
Torque: 24 N-m (240 kgf-cm, 17 ft·lbf)
INSTALLATION HINT: Use 2 new gaskets.
4.
DISCONNECT VACUUM HOSE AND PCV HOSE
(a)
Disconne.ct the distributor vacuum hose from the car-
buretor.
(b)
Disconnect the PCV hose from the insulator.
5.
REMOVE CARBURETOR
(a)
Remove the 4 nuts holding the carburetor to the ·
intake manifold.
Torque: 19 N-m (195 kgf·cm, 14 ft·lbf)
(b)
Lift out the carburetor.
(c)
Remove the insulator and gaskets assembly.
(d)
Cover the inlet hole of the intake manifold with a
cloth.
INSTALLATION HINT: Uso a new insulator.
'
IM ... II
•
VEHICLE INSPECTION
Halaman 75
. COMPONENTS FOR DISASSEMBLY AND-•-N
•
ASSEMB.L Y
-
:
Wire Clamp
r
~ /
Accelerati0n
~
//PumpArm
'
·' ·- -
Accelerator Cable
Bracket
'
""~~--
I
l
~
V<tCUUrl)
"""'"';k! 7"~
~"
I@
Thermostatic
Valve
11
,
•
__ Ac::eleratlon
''l r
+ Gasket
11 ~
Pump Plunger
Vacuum Hose
:1 t, )
•
.
Seat
--....
1 1 \jJ
"'-._
Needle Valve~ '"'~ J: [·~ "'-._~Spring
~
:
~
Pcwer Piston
Neodle Valve+-~ I
:
•
;?"h
SpringTI
____.....--- /
: ~
·----Float
PlungertJ--{j Needle Valve I~
Wire
--<:;
Assembly
1
1
<:::::::.:::.----Pivot Pin
I
•
+ Non-reusable part
· I
-----------~
EG-63
---~ .AI
-
' .,_
L'
01---Plunger
8
Boot
Snap Ring
Air Horn
' I
VEHICLE INSPECTION
Halaman 76
EG-64
ENGINE — FUEL SYSTEM
* Primary Small Venturi
* Gasket
* Secondary Small Venturi
* Gasket
* Idle Speed Adjusting Screw
* Arm
* Spring
* Secondary Throttle Valve Diaphragm
* Snap Ring
* Insulator
* Return Spring
* Carburetor Flange
* Fuel Cut Solenoid
* Wire Clip
* Discharge Weight
* Spring
* Slow Jet
* Plunger Spring
* Retainer
* Power Valve
* Check Ball (Small)
* Check Ball (Large)
* Gasket
* Primary Main Jet
* Gasket
* Plug
* Gasket
* Secondary Main Jet
* Gasket
* Idle Mixture Adjusting Screw
* Spring
* Non-reusable part
P25919
VEHICLE INSPECTION
Halaman 77
? ...... ~.~--....... ' "·: ., ...
ENGINE -
FUEL SYSTEM
EG-65.
•
CARBURETOR DI~ASSEMBL Y
HINT: These instructions are organized so that you
will work only one component group ai " time.
This will help you avoid confusion between similar
looking parts from different subassemblies being on
your workbench at the same time.
(a)
To facilitate reassembly, arrang3 parts in order.
fi§F
(b)
8e careful not to mix up or lc.se balls, clips or springs.
. . .
Air Horn Disassembly
REMOVE CARBURETOR STUD BOLT
REMOVE ACCELERATION PUMP ARM
(a)
Remove the snap ring from the pump connecting link.
(b)
Remove the pivot bolt.
(c)
Disconnect the pump arrn 'irono the pump plunger.
(d)
Disconnect the pump connecting !ink and washer
from the throttle li!ver and remove the pump arm with
pump connecting link.
3.
REMOVE THERMOSTATIC VALVE
(a)
Disconnect 2 vacuum hoses from t~o carburetor.
(b)
Remove the 2 screws, No. plato, tha thermostatic
valve and vacuum hosgs assembly.
1.
2.
-.j . .I
"
4.
REMOVE AIR HORN ASSEMBLY
(a)
Rsmove the rsturn spring from tha accelerator cable
bracket and flange.
(b)
Disconnect the fuel cut solenoid colmector from the
wire clamp.
\~) R9move ~ha 7 screws and ihase parts:
(1)
Acc~lorator c;;bla bracket
(2)
Wire clamps
(3) Fuel pipe bracket
(b)
Lift off the air hom assembly together with ths air
horn gasket.
6.
REMOVE FLOAT AND NEEDLE VALVE
Remove the float pivot pin, float and needle valv9
subassembly.
Pivot Pin
........ ...
VEHICLE INSPECTION
Halaman 78
ENGIN·E ..;- FUEL SYS'fEM
·c.
REMOVE ACCELERATION PUMP PLUNGER
Remove the pump plunger and boot.
7.
REMOVE AIR HORN GASKET
8.
REMOVE NEEDLE VALVL. S!=AT
Remove the ne.edle valve seat and g~sket.
9.
REMOVE POWER PISTON
,.,.,,
.,
. Carburetor Body Disassembly
1.
REMOVE CHECK BALLS FOR ACCELERATION
PUMP
(a)
Remove the pump discharge weight, spring and large
ball.
·
(b)
Remove the plunger spring.
(c)
Using tweezers. remove the ball retainer.
(d)
Remove the small ball.
--~
2.
REMOVE SLOW JET
3.
REMOVE POWER VALVE
Remove the screw. retainer, power piston and spring.
VEHICLE INSPECTION
Halaman 79
,,._·
... , ....
~, ... ,,,., , ....
ENGINE' c:.. FUEL SYSTEM
EG-67 ·
4. · REMOVE PRIMARY AND SECONUARY MAIN JETS
(a)
Remove the 2 passage plugs ar:d gaskets.
(b)
Rein'ove the primary and secondary main jets 'and
"" .
5.
6 •. REMOVE SECONDARY THROTTLE VALVE
DIAPHRAGM
(aj
Disconnect the vacuum hose from' ;he body.
(b)
Remove the snap ring and washer from the diaphragm
link.
(c)
Remove the 2 screws and throttle valve diaphragm.
,.
Snap Ring
7.
REMOVE FUEL CUT SOLENOID
(a)
Remove the wire clip from the fuel cut solenoid.
(b)
Remove the fuel cut solenoid and gasket.
8 •. REMOVE IDLE SPEED ADJUSTING SCREW
(a)
Remove the bolt and arm.
(b)
Remove the idle speed adjusting screw and sprinf'.
9.
REMOVE IDLE MIXTURE ADJUSTING SCREW
gaskets.
REMOVE SMALL VENTURIS
Remove the 4 screws. primary, secondary small ven-
tui-is and gaskets.
VEHICLE INSPECTION
Halaman 80
EG-61!
ENGINE.-. FUEL. .. SYSTEM
.10 .. ·SEPARAJ.E CARBURETOR BODY AND FLANGE
.
(a) ·Remove .the 2 passage screws and spring washers.
0'25707
(b)
Remove,the 2 bolts.
(c)
Separate the hody and flange.
(d)
Remove the insulator.
GENERAL CLEANING PROCEDURE
CLEAN DISASSEMBLED PARTS BEFORE INSPECTION
(a)
With a soft brush wash and clean the cast parts in
carburetor cleaner.
(b)
Clean off the carbon around the throttle valve.
(c)
Wash the other parts thoroughly in carburetor clean-
er.
(d)
Blow all dirt and other foreign material from the jets,
fuel passages and restrictions in the body.
·INSPECTION OF CARBURETOR
I
I r
e
1.
INSPECTFLOAT AND NEEDLE_vALVE
(a)
lnspoct the pivot pin (1) for scratches and excessive·
wear.
(b)
Inspect the float (2) fer broken !ips and wear in the
pivot pin holes.
(c)
Inspect the spring (3) for breaks and deformation.
(d)
Inspect the needle valve (4) and plunger (5) for wear or
damage.
(e)
Inspect the strainer (6) for rust and breaks.
2.
INSPECT POWER PISTON
Check that the power piston moves smoothly.
(5)-g
(3!--Q
l"·~-
VEHICLE INSPECTION
Halaman 81
·~··· , .... ,, ..... ·~·· .. ~···- ·--
...
ENGINE:..:: FUEL SYSTEM··
EG-69. '
3; · INSPECT POWER VALVE
·check for faulty opening and clo~ing action.
T P25816
4.
INSPECT FUEL CUT SOLENOID VALVE
(a)
Connect the connector tArminals to the battery termi-
nals:
(b)
You should feel a "click" from the sola·noid valva when
the battery power is connected and disco;~nected.
If the solenoid valve is not operating proparly, replace
it.
(+)
'-
~
8EB
CARBURETOR ASSEMBLY
HINT: Use new gaskets and 0-rini;s throughout.
Carburetor Body Assembly
1.
ASSEMBLE CARBURETOR BODY AND FLANGE
(a)
Assemble the flanga and body together with a r·.ew
insulator.
(b)
Install the 2· bolts.
(c)
Install the 2 passage screws together with the spring
washers.
2.
3.
INSTALL IDLE MIXTURE ADJUSTING SCREW
INSTALL IDLE SPEED ADJIJSTING SCREW
(a)
Install idle speed adjusting screw and spring.
(b)
Hook the back spring to the arm, and install the arm
with the bolt.
4.
INSTALL FUEL CUT SOLENOID
Install fuel cut solenoid and wire clamp.
I
VEHICLE INSPECTION
Halaman 82
. t:G·/0 ·
ENGINE- F.UEL SYSTEM
5.
INSTALL~ECONDARY THROTTLE VALVE
DIAPHRAGM
(a)
Co.nnect. t.he diaphragm link with the snap ring and
washer.
(b)
Install the throttle valve diaphragm with the 2 screws.
(c)
Connect t~e vacuum hose to the body.
Snap Ring
6.
INSTALL SMALL VENTURIS
Install 2 new gaskets and the pnmary, secondary
venturis with the 4 screws.
""""
7.
(a)
INSTALL PRIMARY AND SECONDARY MAIN JETS
Install the primary and secondary main jets with 2'
'
new gaskets.
Install the primary and secondary passage plugs with
2 new gaskets.
INSTALL POWER VALVE
INSTALL SLOW JET
(b)
8.
9.
-_:>,,'
~~-
. ~
';t!
----
S002(<;
10.
(a)
(b)
INSTALL CHECK BALLS FOR ACCELERATION
Install the plunger small ball.
Using tweezers. install the ball re_tainer.
,..,,
(c)
Install the plunger spring.
(d)
Install the pump discharge large ball. spring and
weight.
VEHICLE INSPECTION
Halaman 83
'
ENGINE -
FUEL SYSTEM .
EG-71·
Air Horn Assembly
'
1.
INSTALL POWER PISTON
lnstall.the spring and power pistun .with the retainer
and screw.
2.
INSTALL. NEEDLE VALVE SEAT
Install the valve seat together with a new gasket.
~·-·--------~~
3.
ADJUST FLOAT LEVEL
(a)
Insert the needle valve. spring and r:unger into the
needle valve seat.
HINT:
After adjusting the float levet install the clip
. onto the needle valve.
(b)
Install the float with the pivot pin.
;
(c)
Allow the· float to hang down by its own weight.
Using SST, measure the clearance b~tweon the float
tip and air horn.
SST 09240-00014
Float level (Raised po•iti~n):
6.5 mm (0.256 ln.)
HINT: This maasurement should be made without a
gasket on the air hctn.
(d)
Adjust by bending the portion of the float !ip marked
A.
., ..
..
•
VEHICLE INSPECTION
Halaman 84
EG-72
'
ENGINE '- FUEL-SYSTEM
(e)
Lift up·tha flqat.
Using SST. measure the clearance between the needle
'Valve plunger and float lip.
SST 09240-00020
Float level (Lowered position):
P25700
(f)
Adjust by bending the position of the float lip marked
B.
(g)
After adjusting the float level. remove the float, plung-
er, spring and needle valve.
B
(h)
Assemble the clip onto the needle valve.
4.
INSTALL NEW AIR HORN GASKET
Place the air horn gasket on the a'ir horn.
5.
INSTALL ACCELERATION PUMP PLUNGER
Install a new ·boot and the pump plunger.
6.
INSTALL NEEDLE VALVE AND FLOAT
(a)
Hook the needle valv9 clip to the lip portion of the
float.
.,.~
\._.-'
(b)
Install the float and secure it with the pivot pin.
Pivot Pin
.
1.5·- 1.7 mm (0.060- 0.067 ln.)
VEHICLE INSPECTION
Halaman 85
ENGINE·. FUEL SYSTEM
EG-73
-
'
7:
INSTALL AIR HORN ASSEMBLY
(.a)
Place the air horn in the carburetor body.
(b)
Install theso parts with the 7 scr&ws:
( 1) ·Accelerator cable b~acket
(2) Wire clamp
(3)
Fuol pipe bracket
(c)
Connect the fuel cut solenoid connector to the wire
clamp .
(b)
Install the retur'l spring to the accalerator bracket and
flange.
8.
INSTALL THERMOSTATIC VALVE
(a)
Install the thermostatic valve and Nc. !Jiate with the 2
screws.
(b)
Connect the 2 vacuum hoses to the carburetor.
•
.
. .
.
..
9.
INSTALL ACCELERATION PUMP ARM
(a)
Connect the pump connecting link to the throttle
lever .
(b)
Connect the pump arm to tho pump plunger.
(c)
Install the pump arm with the pivot bolt.
(d)
Secure the link with the snap rir.g and washer.
10. CHECK FOR SMOOTH OPERATION OF EACH PART
Snap Ring .,.,
CARBURETOR ADJUSTMENT
HINT:
Ustl SST 09240-00014 to make adjustment.
1.
CliECK AND ADJUST THROTTLE V..ALVE OPENING
(a)
Check the full opening angle of the ;>rimary throttle
v&lv~.
Standarci n1gle:
(b)
Adjust.by bending the primary throttle stop lever.
m
so• from horilontsl
VEHICLE INSPECTION
Halaman 86
EG-74
ENGINE -
FUEL SYSTEM .
·(c). Check -th·e full opening ·an·gle of the secondary throttle.
valve. ·
S:anderd .angle:
(d)
Adjust by bending the secondary throttle stop lever.
Secondary Throtlle
Stop Lever
YP2S7W
2.
CHECK AND ADJUST KICK-UP SETTING
(a)
With the primary throttle valve fully opened, check ·
the opening angle of the seconda~y throttle valve.
Standard angle:
(b) Adjust by bending the secondary throttle kick-up
lever.
~gle
Gauge_,-------,r-r
3.
CHECK AND ADJUST SECONDARY TOUCH ANGLE
(a)
Make an angl~ gauge as shown in the illustration.
For 59·_/
I
30mm
(1.18 in.)
31"
70mm
(2. in.)
YP251'59
80° from horizontal
23° from horizontal
VEHICLE INSPECTION
Halaman 87
.·
ENGINE -
FUEL SYSTEM ..
EG-75
{b)
Check the primary throttle valve opening angle at the
same -time the primary throttle touch lever just tou-
·ches·the· secondary throttle touch lt.ver.
Standard angle:
{c)
Adjust by bending the primary throttle touch laver.
y
P25r.i7
4. ·CHECK AND ADJUST ACCELERATION PUMP
{a)
Rotate the throttle shaft and check that tho length of
the stroke.
Standard stroke:
3.25 -3.75 mm (0.128- 0.143 in.)
(b)
Adjust the pump stroke by bending the connecting
link.
y P?-;7'57
5.
PRESET IDLE SPEED ADJUSTING SCREW
(a)
Check the primary throttle valve angle.
Standard angle:
·-
(b)
Adjust by turning the idle speed adjusting screw.
Idle Speed
Adjusting Screw
y P25761
59° from horizontal
13.5° from horizontal
VEHICLE INSPECTION
Halaman 88
I EG-76
ENGlNE'- FUEL SYSTEM.·
r-------:::::;-;;::::::----, . 6.·
PRESET IDLE;MIXTURE ADJUSTING SCREW
l
If the idle mixture adjusting screw has been removed.' '
fully- screw it in and then unscrew it the following
amount. ·
Standard:
,
Return 3.76 turns from fully closed position
NOTICE: Use care not to· screw It In too tightly and
damage the screw tip.
7.
CHECK FOR SMOOTH OPERATION OF EACH PART
a.
INSTALL CABURETOR STUD BOLT
CARBURETOR INSTALLATION
Installation is in the reverse ordl3r of removal.
FUEL PUMP
COMPONENTS FOR REMOVAL AND
INSTALLATION
Fuel Ou:let Hose
J
~-m {kgf·cm, fl'lbf)l: Specified torque
• Non-reusable part
TP258:20:
VEHICLE INSPECTION
Halaman 89
ENGINE •-'- FUEL:SYSTEM .. · •
EG-77
· FUEL;PUMP REMOVAL
. ;
. 1:
2.
DISCONNECT FUEL HOSES I=ROM FUEL PUMP
REMOVE FUEL PUMP
Remove ·the 2 nuts, fuel pump, gasket, insulator and
gasket.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
INSTALLATION HINT: Use 2 new gaskets.
-...x-••
FUEL PUMP INSPECTION (Airtight Test)
PRECHECK
Before doing these ch~cks on the fuAI pump:
(a)
Run soma fuel through the pump to insure that the
check valves seal tightly (a dry cher;k valve may not
seal properly).
(b)
Without blocking off any pipes, operate the rocker
arm and check the amount of force necessary for
(lperation and the amount of arm play. This same
amount of force should be used in the checks.
1.
CHECK INLET VALVE
Block off the outlet pipe with your finger and ch~ck
that there is an increasa in rocker arr~· play and that
the rocker arm moves freely (no reaction force) .
Outlet Pipe
•
. ,
2.
CHECK OUTLET VALVE
!nlet Pipe
Block off the inlet pipe with your finger and check that
the rocker arm locks (does not operats with same
amount of force used in the precheck above).
HINT: Never use more force than that used in the
precheck. This opplies to chocks 3 and 4 also:
·, 3.
CHECK DIAPHRAGM
Outlet Pipe
Block off the inlet, outlet pipe and ch~ck that the
rocker arm locks.
HINT: If all three of these checks are net as specified,
the caulking (sealing) of the body and upper casing is
defective.
.m
:~:
, .
VEHICLE INSPECTION
Halaman 90
EG-76
ENGINE--' FUEL SYSTEM· ·.
4.
CHECK OIL SEAL
Block off the vent hole with your finger and check that
the rocker arm locks.
' i
j
i
I
FUEL PUMP INSTALLATION
Installation is in the reverse order of removal.
SERVICE SPECIFICATIONS
SERVICE DATA
Carburetor
Part. No.
Float level
Raised positiion
6.5 mm (0.256 in.)
Lowered po!:ition
1.5 -
1.7 mm (0.060 -
0.067 in.)
Throttle valve opening engle
Primary
90° from horizontal
·,
Secondary
so· from horizontal
Secondary throttle valve
Kickup flngle
Secondary touch engle
Acculeration pump stroke
Idle speed !ngla
Pre-setting
13.5• from horizontal
Idle mixture adjusting screw
.
Pre-setting
Return 3.75 turns from fulley closed position
TORQUE SPECIFICATIONS
Part tightened
tor x lnta~e manifold
Carbure
Fuel pu
mp x Cyli;.der Mock
Inlet pip
e x Curburotor
.
..
21100-13870
23• from horizontal
59'" from horizontal
3.25 - 3.75 mm (0.128 - 0.148 in.)
----~
-,
N·m
kgf·cm
ft.Jbf
19
195
-
14
18
185
13
24
240
17
i
----
VEHICLE INSPECTION
Halaman 91
ENGINE — COOLING SYSTEM EG-79
# COOLING SYSTEM
## PREPARATION
### SST (SPECIAL SERVICE TOOLS)
| Part Number | Description |
| :------------ | :-------------------------------------- |
| 09236-00101 | Water Pump Overhaul Tool Set |
| (09236-15010) | Bearing Stay |
| (09237-00010) | Water Pump Bearing Remover & Replacer |
| (09237-00020) | Bearing Stay |
| (09237-00030) | Bearing Stay |
| (09237-00050) | Shaft "B" |
### EQUIPMENT
| Item | |
| :----------------- | :----------- |
| Heater | Thermostat |
| Radiator cap tester| |
| Thermometer | Thermostat |
| Torque wrench | |
### COOLANT
| Item | Capacity | Classification |
| :------------- | :---------------------------------- | :------------------- |
| Engine coolant | 5.7 liters (6.0 US qts, 5.0 Imp. qts) | Ethylene-glycol base |
### SSM (SPECIAL SERVICE MATERIALS)
| Part Number | Description | Application |
| :---------- | :------------------------------------------------------ | :---------- |
| 08826-00100 | Seal Packing 1282B, THREE BOND 1282B or equivalent (FIPG) | Water pump |
VEHICLE INSPECTION
Halaman 92
l.:I.:HlU
ENGINE:-<CO.Ol!NGSYSTEM.
COOLANT CHECK AND
REPLACEMENT
t.M.U-11
1.
GHECK ENGINE COOLANT LEVEL AT RESERVOIR'
TANK
The coolant level sh0uld be between'the "LOW" and
"FULL" lines, when the engine is cold.
If low, check for leaks and add coolant up to the
· ••
"FULL" line.
2.
CHECK ENGiNE COOLANT QUALITY
There should not be any excessive deposits of rust or
scales around the radiator cap or radiator filler hole,
and radiator cap or radiator filler hole, and the coolant
should be free from oil.
If excessively dirty, replace the coolant.
3.
REPLACE ENGINE COOLANT
{a)
Remove the radiator cap.
CAUTION: To avoid the danger of being bu,ned, do not
remove it while the engine and radiator are still hot, as
fluid and steam can be blown out under pressure.
Drain Cock
{b)
Drain the .coolant from the radiator drain cock and
engine drain cock. {Engine drain cock at the front of
engine block.)
{c)
Close the drain cocks.
Torque (Engine drt~in cock):
25 N·m (250 kgf.cm, 18 ft·lbf)
{d)
Slowly fill the system with coolant.
•
Use a good brand of ethylene-glycol base cool-
ant and mix it according to the manufacturer's
directions.
•
Using coolant which includes more than 50 %
ethylene-glycol {but not more than 70 %) is
recommended.
NOTICE:
•
Do no~ use a alce>hol type coolant .
~
The coolant chould be mixed with demineralizad
wator or distilled water.
Capacity:
6. 7 lltlilr• (6.0 US qts, 5.0 imp. qts)
(e)
Reinstall the radiator cap.
(f)
Warm up the engine and check for leaks.
(g)
Recheck the coolant level and refill as necessary.
..
VEHICLE INSPECTION
Halaman 93
ENGINE:- COOLING SYSTEM
. '
WATER PUMP
COMPONENTS FOR REMOVAL AND
INSTALLATION
. '
+Gasket
Water Puf'J)P
191195, 141
..
Fan
"'\--
Water Pump Pulley
Fluid <..OlJDHJlQ
Drive Belt
j N·m (kgf·cm, ft-lbf) I : Specified torque
+ Non-reusable part
WATER PUMP REMOVAL
1.
DRAIN ENGINE COOLANT
2.
REMOVE DRIVE BELT, FAN, FLUID
COUPLING AND WATER PUMP PULLEY
Stratch the belt and loosen th~ 'Rn pulley mounting
nuts.
Loosen the pivot and adjusting bolts of the alternntor,
and remove the drive bait.
Remove the 4 nuts, fan with fluid coupling and p:~/Jey.
Remove the 4 nuts and fan from tho fluid coupling.
REMOVE WATER PUMP
Disconnect the water bypass hose from the water
pump.
Remove the 4 bolts, adjusting bar, water pump afld
gasket.
(a)
(b)
P>$461
(c)
(d)
3.
(a)
•.
'
(b)
----~
EG-81
VEHICLE INSPECTION
Halaman 94
EG-82
ENGINE..:.: COOLING SYSTEM· ·
WAT:ER PUMP COMPONENTS INSPECTiON
1.
INSPECT WATER PUMP
Turn the pulley seat and check that the water pump
bearing is not rough or noisy.
If necessary, replace the water pump bearing.
2.
INSPECT FLUIP COUPLING
Check the fluid coupling for damage and silicon oii
leakage.
If necessary, replace the fluid coupling.
lOUt-eo
COMPONENTS FOR DISASSEMBLY AND
ASSEMBLY
~,
Plate
~.av
y
I
+Seal Set
I
Water Pump Body
I
+ Ae!ring
Pulley Seat
I N·m (kgf·cm, it·lbfl
: Specified torque
+ Non~rcusable part
• .,.
I
10.3 (105, 81
•
+ Gasket
+ Rotor
•
VEHICLE INSPECTION
Halaman 95
ENGINE.- CO.OLING SYSTEM
EG-83
WATER PUMP DISASSEMBLY
. .
.
1.
REMOVE PUMP PLATE
Remove the 3 screws. pump plate and gasket.
• .
Z.
REMOVE PULI.EY SEAT
Using SST and a pross, pross thP Lonring sh~ft and
remove the pulley seat.
SST 09236-00101 (09237-00010, 09237-00050)
3.
REMOVE WATER PUMP BEARING AND ROTOR
(a)
Gradually heat the water rump body to 75 -
as•c
(167 -
1as· F).
(b)
Using SST and a press, press the shaft of the bearing
and remove the bearing and rotor.
SST 09236-00101 (09237 -00010, 09237- 00050j
·-
4.
REMOVE SEAL SET
Using SST and a press. press out 1he seal set.
S~
SST 09236-00101 (09236-15010)
I
. ·~~~~"J
~ .. -.. '
WATER PUMP ASSEMBLY
HINT: Always assemble the water pump with a new
seal set.
1.
INSTALL WATER PUMP BEARING
(a)
Gradually heat the water pump boc'{ :o 75 -
ss•c
( 167 -
las· FJ.
(b)
Using SST and a press, install the bearing hto the
water pump body.
P25111
VEHICLE INSPECTION
Halaman 96
EG-84
. ENGINE _:_' COOLING SYSTEM
' ..
,..------------......:...--;·.; ..
SST09236~00101 (09237-00020)
NOTICE: The bearing and face should be flush with the
body top surface.
2.
INSTALL SEAL SET
(a)
Apply a seal set packing to a·new seal and pump body.
Seal packing:
Part No. 08826-00100 or equivale~t
(b)
Using SST and a press, install the seal set.
SST 09236-00101 (09237-00030)
SST
3.
INSTALL PULLEY SEAT
Using SST and a press, press in the pulley seat on the
water pump bearing shaft to 89.3 -
90.7 mm (3.516 .
-
3.571 in.) form the installation surface of the pump
body.
SST 09236-00101 (09237 -00020)
-
P257l<l I
4.
INSTALL ROTOR
Using ?. press, press in a new rotor on the water pump
bearing shaft te 0.3 -
1.1 mm (0.0 1 -
0.04 in.) from
the installation surface of the pump body.
N011CE: As shown In the figure, the rotor and fa<:e
should be flush with the bearing snaH top ~"rfaot.
5.
INSTALL PUMP PLATE
Install a new gasket <Jnd the pump body with the 3
screws.
Torque: 10.3 N.-m (105 kgf·cm, 8 ft·lbf)
P2'".)~WI
·-------- ------'-"~
NOTICE: After Installing, maka sura that tho rotor is not
In contact with tho water pump plate.
6.
CHECK WATER PUMP ROTATES SMOOTHLY
VEHICLE INSPECTION
Halaman 97
'CNGINE -
COOLING SYSTEM
EG-85
--··
WATER PUMP INSTALLATION
' '
1.
INSTALL WATER PUMP
(a)
Temporary install the adjusting bar to the alternator
with the adjusting bolt .
(b)
Install a new gasket and water pl!mp with the 3 bo!ts.
Torque: 19 N-m (195 kgf-cm. 14 ft·ibf)
. ' ....
' -
2.
INSTALL WATER PUMP PULLEY. FAN, FLUID
~~
COUPLING AND DRIVE BELT
"""''
(a)
Install the fan to the fluid coupling with the 4 nuts.
(b) , Tempornry install the water pump-pulley and fan with
fluid coupling with the 4 nuts.
(c)
Install and adjust the belt.
(Se& on -vehicle inspecticn in Charging System)
(d)
Stretch the belt tight and tighien the 4 nuts.
Torque: 5.5 N-m (55 kgf-cm, 49 Jn.-lbf)
3.
FILL WITH ENGINE COOLANT
4.
START ENGINE AND CHECK FOR LEAKS
I
,.·
THERMOSTAT
COMPONENTS FOR REMOVAL AND
!NST ALLA TION
J19{1~~
~
I
I
I
I
I
I
I
I
I
+Gaskel-0
Thermostat~
·. l<·m (kgl·om, ft•lbOI' Spoo;nod ,,:- \ ~\
j + Non-reusable part
u~
T P25557
, ______ :;~
VEHICLE INSPECTION
Halaman 98
EG-86
ENGINE -
cooLING SYSTEM
THERMOSTAT REMOVAL
•
HINT: Removal of the thermostat would have an ad-
verse effect, causing a lowering of cooling efficJen.;y, •
Do not remove the thermostat, even if the engi,ne
tends to overheat.
1.
DRAIN ENGINE COOLANT
J
2.
REMOVE WATER OUTLET AND THERMOSTAT
(a).
Remove the 2 bolts and water o•Jtlflt from the water
outlet housing.
(b)
Remove the thermostat 3nd gasket.
THERMOSTAT INSPECTION
INSPECT THERMOSTAT
HINT: The thermostat is numbered with the valve
opening temperature.
(a) !mmerse· tho thermostat in water and gradually heat
the water.
(b)
Check the valva opening temperature.
Vnlve opening temperature:
80- 84•::: (176- 133.F)
If ths valve oper.ing temperature is not as specifia&,
replace the thermostat.
(c)
Check the valve lift.
Valve lift:
At gs•c (203.F): 8 mm (0.31 in.) or more
If the valve lift is not as specified, replace the thermo-
stat.
(d)
Check that the valve is fully closed when the thermo-
stat is at low temperatures (below 4o•c (1 04.F)).
If not closed, replace the thermostat.
COOJOO
Z\6616
~
•
RADIATOR
Halaman 99
ENGINE'·-·coOLING·SYSTEM ··
EG-87
THERMOSTAT INSTALLATION
1.
INSTALL THERMOSTAT AND WATER OUTLET
(a)
Install a new gasket to th.; th~rmostat.
· (b) ·Align the jiggle valve of the thermostat with right side
of the ·mar~. and insert the thermostat in the water
outlet housing.
HINT: The jiggle valve may be set-within 10° of either
side of the prescribed position.
(c)
Install the water outlet with the 2 bolts.
Torque: 19 N·m (19!; kgf-cm. 14 ft·lbf)
2.
FILL WITH ENGINE COOLANT
3.
START ENGINE AND CHECK FOR COOLANT
Li:AKS
RADIATOR.
RADIATOR CLEANING
Using water or a steam clean·er, remov~ any rnud and
dirt from the radiator core.
NOTICE: If using a high pre83ure type-ciBaner. be careful
not to deform the fin• of the radiator core. (i.e. Maintain
a distan'ce between the cleanP.r noz"'le.and radiat~r cor~.t)
.·
RADIATOR INSPECTION
1.
REMOVE RADIATOR CAP
CAUTION: To avoid the donger of bolng burned, do not
rom eve tha radiator cap whilft the engine ancf·radiator ore
"itm hot. a: fiuid an-i 'iteam can be blown out under
pras£ure.
2.
INSPECT RADIATOR CAP
NOTICE: If the radiotor cap has r.<>ntarninetions, always
rinse it with water.
Using a radiator cap tester, pump the taster and meas-
ure the vacuum valve opening pressure.
Standard oponing pressure:
74- 103 kPa
(0.75- 1.05 kgf/cm', 10:7- 14.9 psi)
I
Minimum opening pressure:
59 kPa (0.6 kgf/cm'. 8.5 psi)
HINT: Use the tester's maximum reading as the open-
ing pressure.
Ra1iator Cap
COOQJ(
~
~
IOUI-11
RADIATOR
Halaman 100
~·
EG-8B
ENGii'.fE ~· COOLING SYSTEM ..
If the opening pre.ssure is less than minimum, replace,
the radiator cap.
3.
INSPECT COOLING SYSTEM FOR LEAKS
(a)
Fill the radiat..;~ ~'ld engine with coolant, and attach a ·
radiator cap tester to the water filler.
(b)
Warm up the engine.
(c)
Pump it to 11 B kPa (1.2 kgf/cm 2, 17.1 psi), and check
that the pressure does not drop.
If the pressure drops, check the hoses, radiator or
water pump for leaks. If no external leaks a're. found,
check the heater core, cylinder block and cylinder
head.
4.
REINSTALL RADIATOR CAP
SERVICE SPECIFICATIONS
SERVIGE DATA
eo- s4•c 111e- 1B3'FJ
I
ot 95'C (203'F)
8 mm (0.31 in.) or more
Therm.,stat
Valve opaning temperature
Velvb lift
1-·-·
Radiator cap
Vecuvm veive opening pressure
Minimum
59 kPa (0.6 kgf/em', 8.5 psi)
·TORQUE SPEC!F!CATIONS
Part tightened
Drain plllg x Cylinder ~leek
Water rump body ~ Pump p!ete
Fluid coupling x \Vater pump
Water pump x Cyiinder block
Water outlet x Water I)Utlet ho:.using
•
&00'7\.-U
STD
74- 103 kPo (0.75- 1.05 kgf/em', 10.7- 14.9 psi)
N·m
kgf-cm
ft-lbf
25
250
18
•
10.3
105
8
5.5
55
49 in.·lbf
19
195
14
19
195
14
0
•
RADIATOR
Halaman 101
ENGINE -
LU.BRICATION SYSTEM
, LUBRICATION·SYSTEM
:. i
PREPARATION
MU\1··
SST (SPECIAL SERVICE TOOLS)
09228 22020
Oil Filter Wrench
... --
~
09816-30010
Oil Pressure Switch Socket
0
,.. .. ., __
RECOMMENDED TOOLS
09200-00010
Engin~t Adjus~ Kit.
EQUIPMENT
Oil pressure gauge
~-
Straight edge
~T~or=q~u.~.w:=re=n~ch~~
.
_,,.,_ ..
LUBRICANT
Item
Cap~city
C/ossificllltlon
-
En;ine oil
API grade SG, SH or !LSAC owltigrade
Dry fill
3,9 liters (4.1 US qts, 3.4 Imp. qts)
engbe oli
Drain and refill
I
w/ Oil filter charge
3.7 litero (3.9 US qts, 3,3 Imp. qts)
w/o Oil filter change
3.4 liters (3,6 US qts, 3.0 Imp. qts)
-
SSM {SPECIAL SERVICE MATERIALS)
08826-00080
Soa/ Pecking Black ar equlvo.lent
(FIPG)
. r~~~==~--~~~--------------~~
08833-00080
Adhesive 1344,
Oi•11ressure switch
THREE BOND 1344,
LOCTJTE 242 or equivalent
Oil ran
RADIATOR
Halaman 102
EG-90
ENGINE:... 'LUBRICATION SYSTEM. -..
OIL PRESSU'RE CHECK
1. CHECK ENGINE OIL QUALITY
Check 'the oil for det-erioration, entry of water, dis- ' ·
coloring or thinning.
If oil quality is visibly poor. replace ft.
2.
CHECK ENGINE OIL LEVEL
! ··
The oi: level should be between the "L" and "F" marks
on the dipstick
If low, check for leakage and add oil up to ·r:· mark.
3.
REMOVE OIL PRESSURE SWITCH
Using SST. remove the oil pressure switch.
SST 09816-30010
=
4.
5.
INSTALL OIL PRESSURE GAUGE
START ENGINE
Start the engine and warm it up to normal operating
temperature.
MEASURE OIL PRESSURE
Oil pressure:
At idle:
29 kPa (0.3 kgf/cm', 4.3 psi) or more
At 3,000 rpm:
245 -
490 kPa (2.5 -
5.0 kgfjcm', 36 - 7l psi)
REMOVE OIL PRESSURE GAUGE
REINSTALL OIL PRESSURE SWITCH
Apply adhesive to 2 or 3 threads of the oil pressure
switch.
Adhesive:
6.
~'25m
7.
8.
(a)
Adhesive
J~
......_____
Part No. 03833- 00080, THRF.E BOND 134-4,
LOCTITE 242 or equivalent
Using SST, install the oil pressure switch.
SST 09816-30010
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
START ENGINE AND CHECK FOR LEAKS
(b)
9.
•
.'
OIL AND FILTER REPLACEMENT
Halaman 103
ENGINE- LUBRICATION SYSTEM.
EG·91
·OIL ·AND FILTER REPLACEMENT
CAUTION:
.•
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation end dermatiti~. In addi-
tion, used engine oil contains rotentially harmful
contaminants which may cause skin cai1eer. Ade-
~·
quate means of skin protection and washing facilit·
ios should ba provided.
•
Care should be taken, therofo>re, whan changing
engine oil. tc minimize the frequency and length of
•
In order to preserve the environment, used oil snd
used oil filter must be disposed of •mly at d~signated ·
disposal sites.
1.
DRAIN ENGINE OIL
(a)
Remove the oil filler cap.
(b)
Remove the oil drain plug. and drain the oil into a
contain~r.
2.
REPLACE OIL FILTER
(a)
Using SST, remove the oil filter.
SST 09228-22020
(b)
Clean the oil filter contact surface on the oil filt~r
mounting.
(c)
Lubricate the filter rubber ga£ket with cJe;,n omgina
oil.
.,
(d)
Tighten filter until the gasket contacts seat of the
filter mounting. Then using SST, give it an additional
3/4 turn lo seat the filter.
SST 09228-22020
·.
LU0490
time your sk!n is exposed to used engine oil. Pro'i:ec-:
tive clothing and gloves, that carmot be penetrated
by oil, should be worn. Wash your'skin ~horoughly
with soap and water. or use water-l~ss h.and clean-
er, to remove any usod engine oiL Do not use gaso-
line. thinners. or solvents.
OIL AND FILTER REPLACEMENT
Halaman 104
EG-92
ENGINE:"'- LUBRICAT.JON;SYSTEM ,
'3.·; FIL)-·WITH l;i'IGINE OIL
R ex>mmended Viscosity (SAE:) • ·
e
·~: 2nw.,o
(a)
Clean and ·install the oil drain plug with a new gasket·.
Torque: .. 25 N·m (250 kgf·cm. 18 ft·lbf)
(b) · Fill with new engine oil.
15V/-40
'
10W-30
>
'
I I II II
: SW-30
Oil grade:
API grade SG, SH or ILSJI.C multigrade engine oil.
Recommended vi•cosity is as shown in the
.illustration.
Capacity:
Drain and ref111
w/ Oil filter change
3.7 liters (3.9 US qt;, 3.3 Imp. qts)
w/o Oil filter change
'C ·29
-18
-7
4
16
27
38
'F -~0
0
20
40
60
80
100·
TEMPERATURE RANGE .~NTICIPATED
BEFORE NEXT OIL CHANGE
T :1'23182
-----
3.4 liters (3.6 US qts, 3.0 Imp. qts)
(c)
Reinstall the oil filler cap.
4.
START ENGINE AND CHECK FOR LEAKS
6.
CHECK ENGINE OIL LEVEL
OIL PUMP
COMPONENTS FOR REMOVAL AND
INSTALLATION
+Gasket
Oil Pan
I
I
+ Gasket--e
Drain Plug-~
[}G"n lkaf·cm, ft·lbf) j
Specified torque
+ Non-rcusabie parl
P'2564
----~~=
•
~~~.-;1:::.-.
~~~1
/ .. ~ .. --
I
L~.-~1
I
Oil Pump·-------1~'-'
1
I
I
. I
+Gasket
I
I
~~~ I
.-:sb r~~~~~~~~~
I
OIL AND FILTER REPLACEMENT
Halaman 105
ENGI1'~i: -
LUBRICATION SYSTEM
EG-93
OIL PUMP REMOVAL
HINT;. When repairing the oil pump, the oil pan and
strainer should be removed and cleaned .
1.
DRAIN ENGINE OIL
2.
REMOVE OIL PAN
Remove the 22 nuts. oil pan and gasket.
3.
REMOVE OIL STRAINER AND OIL PUMP
I
(a)
Remove th~ 3 bolts, oil strainer and gasket.
(b)
Remove the bolt and oil pump.
.
ron•~u
COMPONENTS FOR DISASSF.MBL Y AND
ASSEMBLY
. -
Oil Pump Body
~
I
+ Cotter Pin
t
· Relief Valve
·.
Valve Spring
Drive Rotor----1
[}Tm (kgf·cm, f:·lbf) \ : Specified torque
+ Non-reusable part
OIL PUMP DISASSEMBLY
1.
REMOVE RELIEF VALVE
(a)
Remove the cotter pin.
ASSEMBLY HINT: Use a new cotter pin.
(b).
Remove the retainer, spring and relief valve.
__ .,
I
I
I
~..,
I
I
r --
. ({It?)
(
Dri~en Rotor---c:.J
I
I
I
I
I
I
I
.
I
~&
I
)
~:;_;YI
I
II
I
I
11
1
I
J I
!
I
(
I
f
I
~)
Q' :
:
.;"'""
~ I
;, ~ r--c-::- ~;;--] £
L &.9i/0,6tl~
OIL AND FILTER REPLACEMENT
Halaman 106
EG-94.
ENGINE:- lUBRICATION:SYSTEM.-.
,:--. '· ·
2 · REMOVe: DRIVE AND DRIVEN ROTORS
RemovB the 3 bolts. oil pump cover, the drive and
driven rotors.
Torque:. 6.9 N·m (70 kgf·cm, 61 in .. Jbf)
ASSEMBLY HINT: Install the rotors so that the mark
are facing thB pump cover side (upward), as shown.
(
1'25368
I<:IU-01
OIL PUMP INSPECTION
1.
INSPECT RELIEF VALVE
Coat the valve with engine oil and check that it falls
smoothly into the valve hole by its ow,, weight.
If the valve does not fall smoothly, replace the valve or
oil pump assembly.
. .,...,
l
'---
2.
INSPECT DRIVE AND DRIVEN ROTORS
A.
Inspect rotor body clearance
Using a thickness gauge, measure the clearance be-
tween the driven rotor and body.
StDndard body ci.,Dronco:
v.li)O- 0.160 mm (0.0039- 0.0063 in.)
Maximum body claar.,nca:
~J
0.20 mm (0.0070 in.)
If the clearance is greater than the maximum, repl;3ce
the rotors as a sst or pump assembly.
B.
Inspect .rotor tip clearance
Using a thickness gauge, measure the clearance be-
tween the drive and driven rotor tips.
Standard tip claarar.ce:
0.040 -
0.160 mm (0.0016 -
0.0063 in.)
Maximum tip cloarance:
0.20 mm (0.0079 in.)
If the tip clearance is greater than maximum. replace
the rotor set.
....
f'7.>X6
.
'
..
OIL AND FILTER REPLACEMENT
Halaman 107
ENGINE- 'LUBRrCATION'SYSTEM ·
EG-95
C: ··Inspect rotor:side clearance
Using ·a thickness gauge and precision straight edge,
· measure the clearance between the rotor::; ·and preci-
sion straigt.: c:'ge'.
Standard side clearance:
0.030 -
0.090 mm (0.0012 ;... 0.0035 ln.)
Maximuin side clearance:.
0.15 mm (0.0059 in.)
If the side clearance is _greDter thar. maximum. replace
the rotors set or pump assembly.
OIL PUMP ASSEMBLY
Assembly is in the reverse order of disass .. mbly.
OIL PUMP OPERATION CHECK
··--
CHECK PUMP OPERATION
(a)
Using a screwdriver, immerse the suction end of the
shaft clockwise. Oil shoul.d come out the discharge
hole.
(b)
Using a screwdriver, close the discharge hole with
your thumb and turn the shaft as before. The shaft
shou!d be difficult to turn.
OIL PUMP INSTALLATION
1.
INSTALL OIL PUMP AND STRAINER
(a)
Align the oil pump shaft slot of the oil pump with the
governor shaft protrusion of the distributor.
(b)
Install the oil pump with the bolt.
· Torque: 19 N-m (195 kgf·cm. 14 ft·lbf)
OIL AND FILTER REPLACEMENT
Halaman 108
EG-96
ENGIN.E- LUBRICATION.SYSTEM ·
(c)·· Install· a new gasket and the oil strainer with the 3 •
bolts.
Torque: 8 N-m (80 kgf-cm, 69 in.-lbf)
2.
:fo.!~TALL OIL PAN
(a)
Remove any old packing (FIPG) mateJial and be care·
ful not to drop any oil on the contact surfaces of the
oil pan and cylinder block.
(b)
Apply seal packing to the timing chain cover, cylinder
block and rear oil seal retainer as shown in the illustra·
tion.
Seal packing:
Part No. OBe26-00080 or equivaleOJt
(c)
Place a new gasket to the engine.
(d)
Install the oil pan with the 22 nuts.
Torque: 9 N-m (90 kgf-cm, 78 ln.-lbf)
3.
FILL WITH ENGINE OIL
4.
START ENGINE AND CHECK FOR LEAKS
5.
RECHECK ENGINE OIL LEVEL
SERVICE SPECIFICATIONS
SERVICE DATA
Oil pres!lure
At Idle sp~ed (normal Ciperating temperature)
29 kPa (0.3 kgf/cm', 43 psi) or more
At 3,000 rpm {normal operating temperature)
:245 - 490 kPe (2.5 -
5.0 kgf/cm', 36 -
71 psij
Oil pump
Body c/earar.ce
STD
0.1 oo -
1.160 mm ·co.oo39 -
0.0063 in.)
Maximum
0.20 mm (0.0079 n.)
Tip clearenco
STD
0.040 -
0.160 mm (0.00 16 •• 0.0063 in.)
I
I .
Maximum
0.20 mm (0.0079 n.)
L ___ ~de
clearance
STD
0.030 •• 0.090 mm (0.00 12 - 0.0035 in.)
Maximum
0.15 mm (0.0059 n.)
TORQUE SPECIFICATIONS
~
\ ·
Part tightened
I
I
I
ft-1bl
I
Nm
'
kgf-cm
-
~fil.er bracket x 011 lirGssuro sw1tch
15
150
11
--------
in plog x Oil pan
25
250
18
I Oi! p~mp cover x Oil pump body
6.9
70
61 ln.·lbf
--------·
Oil pump x Cylinder block
19
195
14
Oil strainer x Cylinder block, Oil pump
8
80
69 in.-lbf
Oil pen x Cyl!ndor block, Timing ch"in ccvcr. Roar oil ~;onl retainer
9
90
78 ln.-lbf
•
-· .
·-
IGNITION SYSTEM
Halaman 109
IGNITION SYSTEM -
DISTRIBUTOR
IG-1 3
. 2.
(a)
Install a new 0-ring to the distributor·housing.
(b)
Apply a light coat of engine oil on. the 0-ring.
,_
New 0-Ring
(c)
Align the center line of the slot at the top end of the oil
pump shaft against the mark (oil hole) at the top side
of the oil pump body.
(d)
Position the distributor rotor toward the right sids of
No.3 plug tube, and insert the distributor housing.
When the housing is inserted, the rotor should ba
point near the centar of No.2 plug tube.
Turn the ignition switch to ON, but do not crank the.
· starter motor.
Rotate the distributor body counterclockwise until a
spark jumps between the points and tigntan the clamp
bolt in that position.
INSTALL ROTOR, PACKING AND :::JISTRIBUTOfl
CAP
INSTALL DISTRIBUTOR WlRE
CONNECT HIGH-TENSI01J CORDS TO
DiSTRIBUTOR CAP
CONNECT VACUUM HOSES TO VACUUM
ADVANCER
CHECK IGNITION TIMING
(Sea ignition timing inspection and scijustment in
Engine Mechanicalj
--
(e)
(f)
~
r 1
I(
(g)
"""'
3.
4.
5.
6.
7.
IGNITION SYSTEM
Halaman 110
IG-14 IGNITION SYSTEM — SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
SERVICE DATA
| Category | Item | Condition/Type | Value |
| :---------------- | :-------------------------- | :------------- | :---------------------------------- |
| High-tension cord | Resistance | Maximum | 25 kΩ per cord |
| Spark plug | Recommended spark plug | ND | W16EX-U |
| | | NGK | BP5EY |
| | Correct electrode gap | | 0.8 mm (0.031 in.) |
| Ignition coil | Primary coil resistance | at cold | 1.35 – 2.09 Ω |
| | | at hot | 1.71 – 2.46 Ω |
| | Secondary coil resistance | at cold | 8.5 – 14.5 kΩ |
| | | at hot | 10.7 – 17.1 kΩ |
| | Resistor resistance | at cold | 0.8 – 1.3 Ω |
| | | at hot | 1.05 – 1.52 Ω |
| Distributor | Rubbing block gap | | 0.4 – 0.5 mm (0.016 – 0.020 in.) |
| | Damping spring gap | | 0.05 – 0.45 mm (0.002 – 0.018 in.) |
TORQUE SPECIFICATIONS
| Part tightened | N·m | kgf·cm | ft-lbf |
| :-------------------------- | :--- | :----- | :----- |
| Spark plug x Cylinder head | 17.5 | 180 | 13 |
| Distributor x Cylinder head | 12 | 120 | 9 |
IGNITION SYSTEM
Halaman 111
IG-1
# IGNITION SYSTEM
* PREPARATION .................................................. IG- 2
* ON-VEHICLE INSPECTION .............................. IG- 2
* DISTRIBUTOR ................................................. IG- 7
* SERVICE SPECIFICATIONS ............................. IG- 14
---
*Stamp details (partially legible):*
DETROIT
ELEMENT
MANUFACTURE
1942
SAKAN
IGNITION SYSTEM
Halaman 112
IG-2
·IGNIT-ION SYSTEM -
ON~VEHICLE 'li~SPECTION
PREPARATION
RECOMMENDED TOOLS
..
090B2 -oooso
~<>?
~~~-~
TOYOTA Eloetrict~l Tost~r Sot .
~"""""
~£ c
09200-00010
=
~
~~
Engine Adju~t Kit .
EQUIPMENT
M<9gger insulation resistance meter
~~~--------------~~
Spark plug cleaner
r·--~
Torque wrench
ON- VEHICLE INSPECTION
SPARK TEST
CHECK THAT SPARK OCCURS
(a)
Disconnect the high-tension cords from the spark
plugs.
(b)
Remove the spark plugs.
(c)
Install the SJ:.>ark plugs toeach high -tension cord.
(d)
Ground the spark plug.
(e)
Che.;k if spNk occurs while engine is being cranked.
NOTICE: To prevent excess fuel being Injected from the
injectors during this test, do not crank the engine for
more 5 -
10 seconds at time.
If the spark does not occur, do the test as follows:
-·-liD
•
·.
IGNITION SYSTEM
Halaman 113
:CNITION SYSTEM -
ON-VEHICl-E INSPECTION.
IG-3
----------~~~~~~~==~~~~--------
I SPARK TEST
I
I
NO
CHECK CONNECTION OF IGNITION COIL
I
·J Connect securely.
I
AND DISTRIBUTOR CONNECTOR
BAD
t
OK
CHECK RUBBING BLOCK GAP OF DISTRIBUTOR
I
)See page IG-61
Rubbing block g<lj): 0.4- 0.5 mm (0.016- 0.020 ln.)
BAD
Check and adju:;tlhe gap.
~BAD
l
(See page IG-3)
Replace the cor,; (s).
Mal<imum resistance: 25 kO per cord
I
OK
CHECK RESISTANCE OF HIGH-TENSION CORD
I
OK
0
CHECK POWER SUPPLY TO IGNITION COIL
t.Turn ignition switch to ON.
Check wiring between ignition switch
2.Check that there Is bat!ery voltage at
BAD
to ignitcn coil.
igniton coil positive (+) terminal.
I
OK
CHECK RESISTANCE OF IGNITION COli... AND
RESISTOR !See page IG-41
Resistance: Coil
Primary
Secondary
.
Resistor
Cold
Hot
1.35·2.090 1.i1-2.460
BAD
8.5 ·14.50 10.7-17.1k0
·o.a -1.30
1.05 ° 1.520
HIGH- TENSION CORDS INSPECTION
-·
1.
DISCONNECT HIGH-TENSION CORDS
(a)
Disconnect the high -
tension cords at the rubbor
boot
(b)
Disconnect the high-tension cord from the distribu-
tor cap and ignition coil.
DO NOT ;>ull on the cords.
NOTICE: Pulling on or bonding the cords rnay damage the
conductor ins:ide.
2.
INSPECT HIGH-TENSION CORD RESISTANCE
Using an ohmmeter, measure the resistance.
Maximum resistance:
25 kQ per cord
If the resistance is greater than m~ximum, check the
tormb:;~\s .. !f riocessary, roplacs the high ~ Tensbn
cord.
3 .. RECONNECT HIGH-TENSION CORDS
'-----===::
f?JJ:..-< J
I
I
I I...__
.
SPARK PLUGS INSPECTION
DISCONNECT HIGH-TENSION COflDS FROM
SPARK PLUGS
REMOVE SPARK PLUGS
Using a 16 mm plug wrench, remov~ the spark plug.
2.
""'"""" ,,.,., '"'· ~
~·
IGNITION SYSTEM
Halaman 114
..
;q-4.
· :GNI"fiON SYSTEM·- ON-VEHICLE INSPECTION
;j.
CLEAN SPARK PLUGS
Using a spark plug cleaner or wire brush, clean the
spark plug.
Carefully bend the outer electrode to obtain the cor-
rect electrode gap.
Correct electrode gap:
0.8 mm (0.031 ln.)
6.
REINSTALL SPARK PLUGS
Torque: 17.5 N·m (180 kgf·cm, 13 ft·lbf)
7.
RECONNECT HIGH-TENSION CORDS TO SPARK
PLUGS
IGNITION COIL INSPECTION
NOTICE: "Cold" end •Hot" In these sentences express the
temperature of the co!ls themselves. ·cord· Is from -1 o•
. C (14°F) to so•c (122.F) snd··Hot"ls from so•c (122°F)
to 100°C {2~:;('f-}.
1.
DISCONNECT HIGH-TENSION CORD FROM
IGNITION COiL
.--------------,
2.
INSPECT PRIMARY COIL RESISTANCE
Using an ohmmeter, measure the resistance between
the + and -
terminals.
Primary coil resistance: ·
Cold: 1.35 -
2.09. 0 ·
Hot:
1.71 -
2.46 0
If the electric resistance is not as specified, replace
the ignition coil.
IGOSCJ
Zt6411
. .
IGNITION SYSTEM
Halaman 115
IG-5
IGNITION SYSTEM ... -'- ON-VEHICLE
:3.
INSPECT SECONDARY COIL RESISTANCE
Using. an· ohmmeter, measure the resistance botween
the Band high-tension terminals.
Secondary co!' raslstance:
Ohmmeter
Cold: 8.5 -
14.5 kQ
Hot: 10.7- 1'1.1 kQ
If the electric resistance is not 2s specified, replace
the ignition ::oil.
T::-I['J
'----Hoi 0
Zl6412
4.
INSPECT RESISTOR RESISTANCE
Using an ohmmeter. measure tha resistance between
the B and + terminals.
Resistor resistance:
Ohmmeter
l.:.n.:J
Cold: 0.8 -
1.3 Q
Hot:
1.05 -
1.52 0
If the electric resistance is not· as spocified, replace
the ignition coil.
'-----roe;:_~l
IG0585
216•113
5.
INSPECT ?OWER SOURCE LINE
(a)
With the ignition switch an ON and using a v.oltmeter.
connect the positive ( +) probe to the B tarminal and
the negative (-) probe to body ground.
Voltage: Approx. 12V
Voltmeter
DC]
~0
e
I
L'~Go::"='-------------~-~-· -----~
(b)
With the ignition switch as ·sr ART' and using a
voltmeter, connect the positive ( +) probe to the +
terminal and the negative(-) probe to body ground.
Voltage: Approx. 12V
If abnormal, check tha ignition switch and wire har-
ness.
c.
RECONNECT HIGH-TENSION CORD TO IGNITION
COiL
-.
IGNITION SYSTEM
Halaman 116
IG-6. •
IGNITION SYSTEIVI ,_.,ON-VEHICLE INSPECTION
DISTR!BUTOR INSPECTION
1.
REMOVE DISTRIBUTOR CAP WITH
.H'GH.,-TENSION CORDS
2.
REMOVE ROTOR·
3.
INSPECT BREAKER POINT
Using a feeler gauge. measure the gap between the
cam and rubbing block.
Rubbing block gap:
0.4 -
0.5 mm (0.016 -
0.020 in.)
If the gap is not within specification, adjust the gap.
(See distributor assarnbly)
4.
INSPECT DAMPING SPRING
Using a feeler gauge, measure the gap between the
cam and damping spring.
Damping spring gap:
0.05- 0.45 mm (0.002- 0.018 in.)
. If the gap is not within specification, adjust the gap.
(See distributor assembly)
5.
INSPECT VACUUM ADVANCER
(a)
Disconnect the vacuum hoses from the vacuum ad-
vancer.
(b)
Apply vacuum to the port A or B and check that the
vacuum advancer moves.
If the vacuum advancer do_es not work, repair or re-
place as necessary.
6.
INSPECT GOVERNOR ADVANCE
(a)
Turn the rotor clockwise, release it and check that the
rotor re.turns quickly counterclockwise.
(b)
Check that the rotor is not excessively loose.
7.
REINSTALL ROTOR
.
9.
REINSTALL DISTRIBUTOR CAP
~I
•
.·
'
'~
IGNITION SYSTEM
Halaman 117
IGNITION SYSTEM _; DISTRIBUTOR
IG-7
· DIS'fRJBl:JTOR
COMPONENTS FOR REMOVAL AND
•.
INSTALLATION
High-Tension ---r-
Cord
®@~0-.
Dislribulor -1 j
• • •
Wire
Dislribulor ----<<L•
..
I
I
I
I
I
....
+ 0-Ring----~cp
---
--
I L---
+ Non-reusable part
DISTRIBUTOR REMOVAL
1.
DISCONNECT HIGH-TENSION CORDS FROM
DISTRIBUTOR CAP
2.
DISCONNECT VACUUM HOSES FROM VACUUM
ADVANCER
3.
REMOVE DISTRIBUTOR WIRE
4.
REMOVE DISTRIBUTOR
(a)
Remove the mounting bolt, and pull out tha distribu-
tor.
(b)
Remove the 0-ring from the distributor housing.
IGNITION SYSTEM
Halaman 118
IG·B
IGNITION SYSTEM __: DISTRIBUTOR···
COMPONENTS FOR DISASSEMBLY AND"-~
ASSEMBLY
r--
_ PieceB
--...J
Rotor------@
w
11
LeodWirc~
.··
I
Holder-
~
I
I
I
.~
Damping
Sprin~
I-
-
1--"
---"--
l,
Distributor Housing
Assembly
Breaker Plate
+ Driven Gear~
+Straight Pin -=t;1
Vacuum Advancer
+Non-reusable part
DISTRIBUTOR DISASSEMBLY
,_
REMOVE DISTRIBUTOR CAP, ROTOR, AND
PACKING
REMOVE DISTRIBUTOR TERMINAL
Remove the nut and spring washer.
Disconnect the lead wires of the condenser and bre-
aker point.
Remove the 2 terminal insulators and terminal.
2.
(a)
(b)
(c)
P25~
3.
REMOVE BREAKER POINT
Remove the 2 screws and breaker point.
REMOVE DAMPER SPRING
Remove the screw and damper spring.
-
.
'
..
4.
!-----Grease Stopper
!----Governor Spring
Packing
•
IGNITION SYSTEM
Halaman 119
IG-9
IGNITION SYSTEM -
DISTRIBUTOR
'.
5,
REiv'IOVE VACUUM ADVANCER
(a) . R.i~ove the screw and condenser.
(b)
Using a s~niwdriver, remove the snap ring and pull out
the vacuum advancer.
- l
6.
REMOVE BREAKER PLATE
(a)
Remove the 2 screws, lead wir~ and holder.
(b)
Remove the breaker plate.
7.
REMOVE GOVERNOR SPRINGS
Using needle- nose pliers, remove the 2 springs.
'·
8.
REMOVE CAM
(a)
Remove the grease stopper.
(b)
Remove the screw at the end of tho governor shaft.
(c)
Pull out ths cam.
·~I
9.
REMOVE GOVERNOR WEIGHTS
Using a small screwdriver, remove th~ snap ring and
pull out the 2 weights.
IGNITION SYSTEM
Halaman 120
..
IG-1 0
.IGNITION SYSTEM -:- DiSTRIBUTOR
. DISTRIBlJTOR IN3PECTION
1.
INSPECT BREAKF.R PLATE
Turn the breaker plate and check that it has a slight •
drag ..
If it sticks or strongly resists, replace the breaker
plate.
2.
INSPECT GOVERNOR SHAFT
(a)
Turn the governor shaft and check that it is not rough
or worn.
If it feels rough or worn, replace the distributor hous-
ing assembly .
.,,..I
r~
(b)
Using a feeler gauge, measure the governor shaft
thrust clearance.
Thrust clearance:
0.15 - 0.50 mm (0.0059 -
0.0197 in.)
If the thrust clearance is not as specified, rep/aced the
distributor housing assembly.
3.
INSPECT CAM
lnstaU the cam to the governvr shaft and check that
they fit correctly.
.
If they don't fit, replace the cam and/or distributor
houl.'ing assemblv.
I
____
Pm»j
DRIVEN GEAR REPLACEMENT
1.
REMOVE DRIVEN GEAR
(a)
Using a grinder, grinc the driven gear and straight pin.
CAUTION: Be careful .,ot to damage the governor shaft.
(b)
Mount the driven gear in a vise.
(c)
Using a pin punch and hammer, tap out the straight
pin.
(d)
Remove ihe drive gear and washer.
"'
154/G014T
Z16'1l~
. .
' .
IGNITION SYSTEM
Halaman 121
IG-11
IGNITION SYSTEM -
DISTRIBUTOR
--~-------~~~~~~~~----~---
2.
INSTALL NEW DRI\(EN GEAR
{a) · Place the driven gear onto the governor sh,ft.
{b)
Install the new straight pin .
. -
P25567
{c)
Sacure the ends of the straight pin in a vise.
DISTRIBUTOR ASSEMBLY
1.
INSTALL GOVERNOR WEIGHTS
Using l)eedle- nose pliers, install the 2 weights with
the snap ring.
2.
INSTALL CAM
{a)
Lightly coat the governor shaft with high-t~mpera-·
tum grease,
{b)
Place the cam on the governor shaft.
{c)
Po.sition the &ill m~rk on the driven gear and cutout
as ~hown.
{d)
Install ths screw.
Drill Mark-·--..__.
I
L ___
___,_, :=..~"'""
(d)
Pack high-temperature grease into the c"m.
{e)
Push on the grease stopper with your finger.
3.
INSTALL GOVERNOR SPRINGS
Using needle- nose pliers, in~tall the 2 springs.
DISTRIBUTOR INSTALLATION
Halaman 122
IG-1:.!.
IGNITION SYSTEM -
DISTRIBUTOR
.. . . <l •
INSTALL BREAKER PLATE
{a)
Align tl.a 4 clips on the breaker plate with the cutout
parts of the housing and insert the breai<er plate.
(b)
lnstali the 2 holders. lead wire and 2 screws.
5.
INSTALL VACUUM ADVANCER
{a)
Insert the vacuum advancer into the housing connect-
ing the pivot pin to the link.
{b)
Usir:g needle-nose pli;;rs, install the snap ring.
{c)
Install the condenser with the screw.
6.
INSTALL AND ADJUST BREAKER POINT
(a)
Clean the contact surfaces of the points with a piece
of cloth saturated in solvent.
(b)
Apply high--temper<tture grease to the rubbing block.
(c)
Temporary install the breaker point and lead wire with
the 2 screws.
{d)
Adjust the gap between the c<:m and rubbing block.
Rubbing block gap: 0.45 mm {0.018 in.)
(d)
Tighten the 2 screws and recheck the rubbing block
gap.
7.
INSTALL AND ADJUST DAMPER SPRING
{a)
Apply high-temperature grease to the heel of the
damper spring.
(b)
Temporary install the damper spring with the screw.
(c) · Adjust thfl gap between the cam and damper spring ..
Damper spring gap: 0.25 .mm (0.01 0 ln.)
(d)
Tighten the screw and recheck the damper spring gap.
~··,
8.
INSTALL DISTRIBUTOR TERMINAL
(2).
Install the 2 insulators and terminal to the housing.
(b)
Connect the lead wires of the breaker point and con-
denser to the terminal.
(s)
lnst~JI thtJ spring wash.:r Dnd nut.
~--
DISTRIBUTOR INSTALLATION
1.
SET N0.1 CYLINDER TO TDC/COMPRESSION
(a)
Remove the No.1 spark plug.
{b)
Place your finger over the hole of the No.1 spark plug
and rotate the crankshaft clockwise to TDC. If pres-
sure is felt on your finger, this is TOG/compression of
the No.1 cylinder. If not, repeat the process.
(c)
Install the No.1 ~park plug.
•
IGNITION SYSTEM DISTRIBUTOR
Halaman 123
IGNITION SYSTEM '--- DISTRIBUTOR
2. ·INSTALL DISTRIBUTOR
(a)
Install a new 0- ring to the disiributor housingc
(b)
Apply a light coat of engine oil on the 0-ring.
. . "
,
~-
... ,. ..
l~ew o-Ring
(c)
Align the center line of the slot at the top end of the oil
pump shaft against the mark (oil hole) at the top side
of the oil pump body .
. -
.. -
(d)
Position the distributor rotor toW3rd the right side of
· No.3 plug tube, and insert the distributor housing .
(e)
When the housing is inserted, tho rotor should be
point near the center of No.2 plug tube.
(f)
Turn the ignition swit,ch to ON, but do not crank the
starter motor.
(g)
Rotate the distributor body counterclockwise untir" a
spark jumps between the points and tighten the clamp
bolt in that position.
3.
INSTALL ROTOR, PACKING AND !:JISTRIBUTOR
CAP
4.
INSTALL DISTRIBUTOR WIRE
5.
CONNECT HIGH-TENSION CORDS TO
DISTRIBUTOR CAP
6.
CONNECT VACUUM HOSES TO VACUUM
ADVANCER
7.
CHECK IGNITION TIMING
(Sea Ignition timing inspection ond adjustment in
Engine Mechonlcel)
;
\ .
IG-13
IGNITION SYSTEM DISTRIBUTOR
Halaman 124
IG-14 IGNITION SYSTEM – SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
SERVICE DATA
High-tension cord Resistance Maximum 25 kΩ per cord
| Component | Specification | Condition | Value/Range |
|:--------------|:--------------------------|:----------|:---------------------------------|
| Spark plug | Recommended spark plug | ND | W16EX-U |
| | | NGK | BP5EY |
| | Correct electrode gap | | 0.8 mm (0.031 in.) |
| Ignition coil | Primary coil resistance | at cold | 1.35 – 2.09 Ω |
| | | at hot | 1.71 – 2.46 Ω |
| | Secondary coil resistance | at cold | 8.5 – 14.5 kΩ |
| | | at hot | 10.7 – 17.1 kΩ |
| | Resistor resistance | at cold | 0.8 – 1.3 Ω |
| | | at hot | 1.05 – 1.52 Ω |
| Distributor | Rubbing block gap | | 0.4 – 0.5 mm (0.016 – 0.020 in.) |
| | Damping spring gap | | 0.05 – 0.45 mm (0.002 – 0.018 in.) |
TORQUE SPECIFICATIONS
| Part tightened | N·m | kgf·cm | ft·lbf |
|:----------------------------|:-----|:-------|:-------|
| Spark plug x Cylinder head | 17.5 | 180 | 13 |
| Distributer x Cylinder head | 12 | 120 | 9 |
STARTING SYSTEM
Halaman 125
ST-1
# STARTING SYSTEM
PREPARATION ................................... ST- 2
STARTER ....................................... ST- 3
SERVICE SPECIFICATIONS ........................ ST- 13
ST
STARTING SYSTEM
Halaman 126
ST-2
**STARTING SYSTEM — PREPARATION**
---
# PREPARATION
## SST (SPECIAL SERVICE TOOLS)
| Tool | Part Number & Description | Application |
| :---: | :--- | :--- |
|  | **09221-25025** Piston Pin Remover & Replacer | |
|  | **(09221-00071)** Guide "A" | Center bearing |
|  | **(09221-00090)** Guide "C" | Center bearing |
---
## RECOMMENDED TOOLS
| Tool | Part Number & Description |
| :---: | :--- |
|  | **09082-00050** TOYOTA Electrical Tester Set. |
|  | **09904-00010** Expander Set. |
---
## EQUIPMENT
| Equipment | Application / Component |
| :--- | :--- |
| Micrometer | Planetary shaft |
| Caliper gauge | |
| Dial indicator | Commutator |
| Magnetic finger | |
| Pull scale | Brush spring |
| Sandpaper | Commutator |
| Torque wrench | |
| V-block | |
| Vernier calipers | Commutator, Brush |
STARTING SYSTEM
Halaman 127
STARTING: SYSTEM-. STARTER
ST-3
·•
. . '
STARTER
COMPONENTS FOR DJSASSEMBL Y AND--~
ASSEMBLY
Magneti~ Switch Cover ®@~~Covetfr .
l
$~
e
Magnetic Switch
Starter Housing
·
Shock(})
Absorber l ""~@®--Snap Ring
Planetary Gear~Pianetary
Sha~ (j/fff\
~~~Starter
Clutch
loi
'fi
~ ~ I Snap Rmg
Plate
rQ;\ ~
~
Plate Washer I
Center Bearing
~ I
Internal Gear
comm"'"" Eo' '"m'
-.;:-- "- to
+o-"'"'
~
~-~-
l
Field Frame
<l>'
-
__ <
+ 0-Ring
-.
Plate Washer
Brush Holder
'
~-Armature
~Non-reusable part ~
+O-Ring
--~
'(j---oust Protector
_JI
--------------~--------~
STARTER D!SASSEMBL Y
1.
REMOVE MAGI'IETlC SWITCH CO\'Efl
2.
REMOVE MAGNETIC SWITCH
(a)
Remove the nut and magnetic switch ccwer,
(b)
Remove the nut, and c::;~connact the l&ad wire from
the magnetic switch terminal.
(c)
Loosen the 2 nuts holding the magnetic switch to the
starter housing .
(d) ·Pull the magnetic switch and while lifting the front
part of the magnetic switch. release tho plunger hook
from the drive levar, then release the magnetic switch.
(e)
Remove th;; plunger r.over.
3.
REMOVF. FIELu FRAME AND ARMATURE
Remove the 2 through bolts, and pull out tho fi6ld
frame together with the armature.
. .
Drive Lever
·
Stop Co/l;;r
Plate Washer
·1
.. :
STARTING SYSTEM
Halaman 128
·:T-4
.STARTING. SYSTEM -STARTER
. 4.
R:;MOVE COMMUTATOR END FRAME
Remove· the 2 screws with 0-rings and commutator
end frame, and hold down the lead wire while releas-
ing the commutator end frame.
NOTICE: To avoid interference between the brush holder
and the dust protector, pull the commutator end frame
away at flO angle.
ST0728
. 5.
REMOVE BRUSH HOLDER
(a)
Using a screwdriver, hold the spring back and discon·
nect the brush holder.
(b)
Disconnect the 4 brushes, and remove the brush
holder.
6.
REMOVE ARMATURE FROM FIELD FRAME
7.
REMOVE 2 0-RINGS FROM FIELD FRAME
t
;v~
8.
REMOVE DRIVE LEVER AND STARTER CLUTCH
·wiTH SHOCK ABSORBER FROM STARTER
HOUSING
ST~711
9.
REMOVE PLANETARY GEARS
Ramcve these parts from the shock absorber.
(1) Plzte '
· (2)
3 planetary goars
(3)
Plate washar
1\0252
(1 J
Z00210
10. REMOVE STARTER CLUTCH
(a)
Usi! .g a screwdriver, tap in the stop collar towards the
sta"ter clutch.
(b)
Using a screwdriver, pry off the snap ring.'
(c)
Remove the stop collar and starter clutch from the
planetary shaft.
.•
. '
STARTING SYSTEM
Halaman 129
.r
'--------------~~--~~S~T~A~R~T~I~N~G~-s~v~:s~T~E~M~-~-~S~T~A~R~TE~R~s_T_-_
5
11.' REMOVE P-lANETARY SHAFT AN~ INTERNAL
GEAR
(a)
Using snap ring plierz. remove the snap ring and plate
washer. ·
(b)
Removo the planetary shaft and plat'l washer.
SICISSil
STARTER INSPECTION AND REPAIR
Armature Coil
1.
INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity
bet\~een the ;;egments of the commutator.
If there is no continuity between any segments, re-
place the umature.
c;ontinuity
2 •. INSPECT COMMUTATOR FOR GROUND
Using an ohmmeter, check that there is no cc-.ntinuity
between the commutator and armature coil core.
If there is continuit-y, replace the armature.
Commutator
1.
INSPECT COMMUTATOR FOR'DIRTY AND BURNT
SURFACES
If the surface is dirt-y or burnt, correct with sandpapsr
(No.400) or a lathe.
2.
INSPECT COMMUTATOR CIRCLE RUNOUT
(a)
Piace tha <•om mutator on V -0!ccics.
(b)-· Usin;J a dial gauge, measure tha circle run out;
Mexlmum circle runout:
0.05 mm (0.0020 ln.)
If the circle runout is greater1h1m maximum, correct it
on a lathe.
3.
INSPECT COMMUTATOR DIAMETER
Using vernier calipers, measure the commutator diam-
eter.
Standard diameter:
28 mm (1.10 ln.)
Minimum diameter:
-,:J)J~E-=·
::1=·1 =
-;~]~_"
--0~· ___;,j
mm (1.06 ln.)
If the diameter is less than minimum, replace the
armature.
~ i '
I :I
STARTING SYSTEM
Halaman 130
ST-6
STARTING SYSl'EM -STARTER
4.
INSPECT UNDEi)C:..'T DEPTH
Check that the undercut depth is clean and free of
foreign materials. Smooth out the edge.
Standard undercut depth:
0.6 mm (0.024 in.)
Minimum undercut depth:
0.2 mm (0.008 in.)
If the undercut depth is less than minimum. correct it
wi~h a hacksaw blade.
ST0040 1
Field Frame (Field Coil)
1.
INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter. check that there is continuity
between the lead wire and field coil brush lead.
If> there is no continuity, r~place the field frame.
Continuity
2.
INSPECT FIELD COIL GROUND
Using an ohmmeter, check that there is no continuity
between the field coil end and field frame:
If there .is continuity, repair or replace tho field frame.
No coiitinuit\'
l
Brushes
INSPECT BRijSIJ LENGTH
Using vernfer calipers, measure the brush length.
Stondord length:
14.0 mm (0.551 ln.)
Minimum longth:
9.0 mm (0.354 in.)
ff thq Jqngth k Jqu lh;m minimum. mplilGii !hr. /;ru~l.
holder and filed frame.
Brush Springs
INSPECT BRUSH SPRING LOAD
·Take the pull scale reading the instant the brush
spring separates from the brush.
Spring installed load:
8.8'- 17.7 N (0.9 -
1.8 kgf, 2.0 - 4.0 lbf)
r
..
-·
STARTING SYSTEM
Halaman 131
<
. STARTING.SYSTEM- STARTER
__ ; •. ------------'-~--,
-.
•.
Brush'Hoider
No continuity
INSPECT BRuSH HOLDER INSULATION
Usin·g an ohmmeter, check that there is no continuity
between the positive{+) and negative(-) brush hol-
ders.
If there is continuity, repair or replace the brcsh
holder.
! •' -· .
""'-" I
.
Clutch and Gears
1.
INSPECT GEAR TEETH
Check the gear teeth on tha planetary gear.- internal
gear and starter clutch for woar or damage.
If tl;le gear is damaged, repiBce it.
If the starter clutch teeth are damaged; replace the
starter clutch and also inspect the fl~wheel ring gear
for wear or damage.
,.
.
•
2 .
INSPECT STARTER CLUTCH
Rotate the clutch pinion gear clockwise and check
that it turns freely.
Try to rotate the clutch pinion gear counterclockwise
and check that it locks.
If necessary, replace the starter clutch.
Magnetic Switch
1.
INSPECT PLUNGER
Push in the plunger and replace it.
Check that it returns quickly to it:? original position.
If necessary, replace the magnetic> swit!:h.
STOC:67
2.
DO PULL--'I.N COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity
between terminals 50 and C.
If there is no continuity. replace the magnetic switch.
Terminal 50
i;
Terminal C
Contjnuity
P10134
·t.
'
. ~
'i
f
I:
STARTING SYSTEM
Halaman 132
ST-8
STARTING SYSTEM·,... STARTER.
3.
DO .HOLD....., IN COIL OPEN CIRCUIT TEST
.
I
•
•
Using M ohmmeter, check that there is continuity
between terminal 50 and the switch body.
·
If there is no continuity, replace the magnetic switch. ·
Planetary Shaft and Center Bearing
1.
INSPECT PLANETARY SHAFT AND CENTER BEAR-
ING
(a)
Using a micrometer, measure the outer diameter of
the, surface in contact with the center bearing of the
planetary shaft.
Standard shaft diameter:
14.980- 15.000 mm (0.5898- 0.5906 in.)
(b)
Using a caliper gauge, measure the inside diameter of
the center bearing.
Center boadng Inside diameter:
15.008 -
15.050 mm (0.5908 -
0.5925 in.)
(c)
Subtract the planetary shaft diameter from the bear-
ing inside diameter measurement.
Standard center bearing oil clearance:
~
0.01 -
0.06 mm (0.0004 -
0.0024 in.)
Maximum cantor bearing oil cloarance:
0.2 mm (0.0078 ln.)
If the clearance is greater than maximum, replace the
planet carrier shaft and center bearing.
2.
lF NEC!:SSARY, REPLACE CENTER BEARING
(a)
Using SST and .Press, press out the center bearing.
SST 09221-25025 (09221-00090)
~ST
e:i--~
"--
Yf
I
'-
-
~" fy)
(b)
Using SST and a press, press in a new center bearing
to the posi.tion shown in the illustration.
SST 09221-25025 (09221-00071)
•
/
'
.,•,.
•
....
. ,
·-
•
STARTING SYSTEM
Halaman 133
STARTING. SYSTEM:....· STARTER·
ST-9
·(c)
Align the hollow of tha internal gear with the protru-
sion inside the shock absorber, and remove the inter-
rial gear. ·
'
'
'
- '
Hollow
• •
Protrusion
SToo-17
STARTER ASSEMBLY
HINT: Use high temperature-resistant grease to lu-
bricate the bearings and sliding parts when assembl-
ing the starter.
INSTALL INTERNAL GEAR AND PLANETARY
SHAFT
(a)
Apply grease to the internal gear touching the sock
absorber and planetary gears.
1.
·'
(b)
Align the hollow of the internal gear with the protru-
sion inside the shock absorber.
(c)
Insert and turn the internal gear 5o that it interlocks
with the shock absorber.
· liollow
STC647
(j
(d)
(e)
Apply turbine oil with additives to thA c&nter bearing.
Apply grease to the plate washer. and install it to the
plar.atary shaft
Install the·planetary shaft to the shock absorber.
Using snap ring plior~. install the plato washer and
snap ring.
Shock Absorber
Planetar~· Shaft
f
Plate Washer
(f)
(g)
-
)671
Zl~l
: 2.
(a)
INSTALL STARTER CLUTCH
Apply grease to the bushing and splir.e of the starter
clutch and stop collar.
Place the starter clutch an·d stop collar on the plano·
tary shaft.
(b)
sroon
..
STARTING SYSTEM
Halaman 134
ST-10
STARTJNG.SYSTEM -
STARTEtl
(c)
Apply. grease to the snap ring, and instal! it to the
planetary .shaft gro.ove.
(d)
Using a vise, compress the snap ring.
ST007J
(e)
Hold the starter clutch, tap the planetary shaft and
install the stop collar onto the Sflap ring with a plastic
-facod hammer.
3.
INSTALL PLANETARY GEARS
(a)
Apply grease to the planetary. gears and flange pin
parts of the planetary shaft.
(b)
Install the plate washer and 3 planetary gears.
(c)
Align the cutout of the plate With the protrusion insida
the shock absorber, and install the plate.
t
:
··~.
4.
INSTALL DRIVE LEVER AND STARTER CLUTCH
WITH SHOCK ABSORBER
(a)
Apply turbine cil with additives to tlie bearing ot 1he
starter housing.
(b)
Apply grease to th& drive levor touching the starter
pivot part of the drive levsr.
(c)
Install tho drive lever to the starter clutch.
ST07<11
(d)
Align the protrusion of the shock absorber with the
0utout of the starter hol!sing and install them.
. .
•
..
.·
•
STARTING SYSTEM
Halaman 135
STARTING SYSTEM -
STAR.TER
ST-11
.• . ... .. .
. .
INSTALL 2 NEW 0-RJNGS TO FJELD FRAME
PLACE ARMATURE INTO FIELD FRAME
INSTALL BRUSH HOLDER
(a)
Place the brush holder in position on ths armature.
(b)
Using a screwdriver. hold the brush spring back. a.1d
connect the brush into tho brush holder.
'
Connect the 4 ·brushes.
HINT: Check that positive(+) lead wires are not gro-
unded.
8.
INSTALL COMMUTATOR ENO FRAME
(a)
Apply turbine oil with additives to t~e bearing of the
end frame.
(b)
Install the end frame with 2 new screws with 0-:--
rings.
NOTICE: To avoid interference between tho brush holder
and tho dust protector, pull tho commutator ~rid frame
away at an angle.
5.
6.
7.
iT0727
"""
9.
INSTALL FIELD FRAME AND ARMATURE
ASSEMBLY
(a)
Align the cutout of the field frame with the protrusion
of the shock absorber.
(b)
Install tho field frame and arrnaturo assnmbly with the
2 through bolts.
Protrusion
=
R I 88.(
I
I
INSTALL MAGNETIC SWITCH
Install the plunger cover to the magnet:c switch.
Ha11g the pltrnpE!r ol tho magn~ti.:: ,~witch to the drive
levsr from the upper side.
Install ths magnetic switch with the 2 nuts ..
Connect the lead wire to th~ terminal, And install the
nut.
(e)
Install the magnetic switch cover with the nut.
11. INSTALL MAGNETIC SWITCH COVER
10.
(a)
(b)
(c)
(d)
·.
ST0742
STARTER PERFORMANCE TEST
i
NOTICE: Thaso tests must be dono within 3 to!> seconds
to avoid burning out tho coil:
1.
DO PULL-IN TEST
(a)
Disconnect the field coil lead from terminal C.
(b)
Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear mo·ves outward.
,.;
STARTING SYSTEM
Halaman 136
ST-12
STARTING SYSTEM- STARTER
If the clutch pinion gear does not move, repiace the •
magnetic switch.
·
2.
DO HOLD-IN TEST
With the battery connected as above and with the
clutch pinion gear .:>Ut disconnect the negative (-)
lead from terminal C.
Check that the clutch pinion gear remains out.
If the clutch pinion gsar returns inward, replace the
magnetic switch.
Di~connect
"'""'
3.
INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (-) le.ad from the switch
body.
Check that the clutch pinion gear returns inward.
"
If the clutch pinion gear does not return, replace the
!'\lagnetic switch.
4.
INSPECT CLUTCH PINION GEAR CLEARANCE
(a)
Connect the battery to the magnetic switch as shown.
'---- ------------'-"""="'-1
(b)
Move the pinion gear toward ths armature to remove
slack and maasure the ci<Jarance between tha pinion
goar end am! stop co!!a~.
St~and11rd ~lesranee;
7 -
~ m'm (0.04 ·- 0.16 in.)
5.
DO NO-LOAD PERFORMANCE TEST
(a)
Connect the field coil lead to terminal C.
Make sure the lead is not grounded.
(b)
Connect the battery a·nd ammeter to the starter as
shown.
(c)
Check that the starter rotates smoothly and steadily
with the clutch pinion gear moving out.
Check that the ammeter r!3ads the•specified current.
RnAl"':ifiArf r.:m"r"Ant!
·:··
- .
•
•
•
STARTING SYSTEM
Halaman 137
STARTING SYSTEM -SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
SERVICE DATA
Starter
1
RBted voltage and output puwer
No-load characteristics
Current
90 A or less at 11. 5 V
••
Brush len9th
Minimum
Spring instal:ed load
Ccmmutator
Diameter
Minimum
Undercut dApth
Minimum
0.2 mm (0.008 in.)
Circle runout
Maximum
0.05 mm (0.0020 in.)
Planetary shaft diametor
Center bearing
Inside diamoter
Oil clearance
Maximum
L ____________ l_P~i~n~io~n~c~lo~o~,,~n~c~e------------·--------~S~T~D~~I_:-~4~m~m~(0~.04~~-~~0.~1~6~in~.~)------------·----·-- _J
'.
ST-13
.........
l
12 V 0.8 kW
rpm
3,000 rpm or more
STD
14.0 mm (0.551 in.)
9,0 mm (0.354 in.)
8.8 -
17.7 N (0.9 ·· l.B kgf, 2.0 - 4.0 lbf)
STD
26 mm (1.10 in.)
27 mm ( 1.06 in.)
STD
0.6 mm (0.024 in.)
STD
14.980 -
15.000 mm (0.5898 -
0,5906 in.)
15.008 -
15.050 mm (0.5908 ·- 0.5925 in,)
STD
O.GI - 0.08 mm (0.0004 - C.0024 in.)
0.2 mm (0.0078 in.)
STARTING SYSTEM
Halaman 138
CH-1
CHARGING SYSTEM
PRECAUTION ................................. CH- 2
PREPARATION ................................ CH- 2
ON–VEHICLE INSPECTION ................... CH- 3
ALTERNATOR ................................. CH- 5
ALTERNATOR REGULATOR ................... CH- 13
SERVICE SPECIFICATIONS................... CH- 14
STARTING SYSTEM
Halaman 139
CH-2
CHARGING SYSTEM -
PREPARATION
PRECAU;!ON
1.
Check that the battery r.aoles are connected to the correct terminals.
2.
Disconnect the battery cables when the battery is given a quick charge.
3.
Do not perform tests with a high voltage insulation resistance tester.
4.
Never disconnect the battery while the engine is running.
PREPARATION
SST (SPECIAL SERVICE TOOLS)
09286-46011
Injection Pump Spiino Shaft
Pullor
09950-60010
Replacer Set
(0995 I -00220) Replacer 22
(09951-00400) Replacer 40
··········~··· ······· ···
iii9352·~·a6iii'iii···:.;:d~~;~;· ...... ·· · ···· · · ··· · ··
···· ········ ............ ·· · .................... · ... ·· ·
@ill~'~
TOYOTA Electrical Testor Set. L_
RECOMMENDED TOOLS
09082-00050
EQUIPMENT
----
Batt&r'f' specific gravity gauge
Torque wrench
--
Vernier calipors
Rotor (Slip ring)
Roto:~r roar bearing
..
Rotor front bearing
••
•
•
I
CHARGING SYSTEM
Halaman 140
''
...
CHARGING SYSTEM -
ON-VEHICLE INSPECTION
CH-3
ON- VEHICLE INSPECTION
' .
1.
CHECK BATTERY SPECIFIC GRAVITY AND
ELECTROLYTE LEVEL
(a)
Check the electrolyte quantity of each cell.
if insufficient, refill with distilled (or purified) water.
{b)
Check the specific gravity of each ceil.
Standard specific gravity:
At 2o·c (sa·FJ:
NS40l: 1.27 -
1.29
Othors: 1.25 -
1.27
If the gravity is less than $pacification, charg~ tho
battery.
2.
CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(a)
Check that the battery terminals aro not loose or .
corroded.
(b)
Check the fusible link and fuses for continuity.
3.
INSPECT DRIVE BELTS
(a)
Visually check the drive belt for craeks, oiliness cr
wear. Check that the belt does not to:.~ch the bottom
of the pulley groove.
If necessary, replace the driva bel:.
{b)
Check the drive belt deflection by pressing on the belt
at the points indicated in the illustration with 98 N {1 0
kgf, 22 lbf) of pressure;
Drive belt deflection:
CORRECT
WRONG
MAOOJS
:· -
Water Pump
Allernator
New belt:
11 -
15 mm (0.43 -
0.59 in.)
Used belt: 15 -
20 mm {0.59 -
().79 in.)
If neces.sary, adjust the drive bolt deflection.
HINT:
•
"New belt" refers tc a belt which has bGen usod
less than 5 minutes or. a running sngina.
•
"Used belt" refers to a bolt which ha$ been used
on a running enginll for 5 minutas or more.
•
After installing a new belt, run the engine for
about 5 minutes and recheck the deflection.
4.
VISUALLY CHECK ALTERNATOR WIRING AND
LISTEN FOR ABNORMAL NOISES
(a)
Check that the wiring is in good conclition.
(b)
Check that there is no abnormal nois~ from the alter-
nator while the engino is runnin8.
5.
INSPECT DISCHARGE WARNING LIGHT SIRCUIT
(a)
Turn the ignition switch "ON". Check that the dis-
charge warning light comes on.
(b)
Start the engine. Check•that the light goes off.
If the light cloes not operate as specified, troubleshoot
the discharge warning light circuit.
1
"''"'
CHARGING SYSTEM
Halaman 141
CH-4
CHARGING SYSTEM.- ON-VEHICL:E INSPECTION
· 6, . INSPECT CHARGING CIRCUIT WITHOUT LOAD
, .
HINT: If a batteryjalte~nator teste'r is available, con-
•
nect the tester to the charging circuit as per the
manufacturer's instructions.
(a)
If a tester is not available, connect a voltmeter and
ammeter to the charging circuit as follows:
•
·Disconnect the wire from terminal 8 of the altar-
nator and cc.nnect it to the negative (-) lead of
the ammeter.
•
Connect the positive ( +) lead of the ammeter to
terminal 8 of the alternator.
•
Connect the positive(+) lead of the voltmeter to
terminal 8" of the alternator.
•
Ground the negative(-) lead of the voltmeter.
(b) . Check the chargi!lg circuit as follows:
Plm /
...._,..__~·,....,
~meter
CH0008
With the engine running frorr: idle to 2,000 rpm, ch.eck
the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage:
At20"C(68"F): 13.8 -14.8V
At 60"C (140"F): 13.3- 15.5 V
"If the voltmeter reading is more than standard voltage,
adjust the regulator or replace it.
7.
INSPECT CHARGING CIRCUIT WITH LOAD
(a)
With the engine running at 2,000 rpm, turn on the
high beam headlights and place th.e heater blower
switch at "HI".
(b)
Check the reading on the ainmete~r.
Standard amperage: 30 A or mare
If the ammeier reading is less than standard amper-
age, repair the alternator.
HINT:
If the battery is fully charged, the indica·tio;1
will somatiml3s be :!Jss than st<JnJard amperage.
QQI17 I
. ...
•
•
.. ,·
•
..
CHARGING SYSTEM ALTERNATOR
Halaman 142
CH·5
CHARGING SYSTEM
ALTERNATOR
.. -
ALTERNATOR
COMPONENTS FOR .
,
ASSEMBLy
DISASSEMBLy AND_,_"
'
40A Type
.
Front Bearing
Onve Elld Frnme
Spacer Coller
Fan
Pulley
I ~: ,(
®® i' .'>
Insulator Washer
Spacer Coller
Brush Spring
.
I
Rectifier End F rame
Fran~ Bearin
Drive End F.
1•
9
Rotor
•
ffime
j
50A Type
Spacer Coller 1
I
~
.
""
!:?
I "'""' "'""
~
-
~-'· " .
_.,
_,_
-,
,QI
~ ,'t;). -
I ,.:,.
~--~ '
Rear Bearing
~Rectifier End F
-~
rame
' .
P2~56
P25J57
I N·m (kgf·cm, ft·lbfl
: Specified torque
Stator
Rotor
I I
Rear End Cover
I
.I
I
TP.rminallnsulator
,-·
' ~
·:::·::: :~~:~ --~---
______ ...
Condenser
Conectamea! Housing
CHARGING SYSTEM ALTERNATOR
Halaman 143
CH-6
CHARGING SYSTEM- ALTI::RNATOR
ALTERNATOR DISASSEMBLY
1.
REMOVE DRIVE END FRAME AND ROTOR
ASSEMBLY FROM STATOR
(a)
Remove the 3 through screws.
(b)
Using a screwdriver. pry the flnd frame and remove it
together with the rotor.
CAUTION: Do not pry on the coil wires.
r-·--------------~·--~-------~
2.
REMOVE PULLEY AND FAN
(a) . Mount the t"otor in a soft jaw vise.
@---j-(11
(b)
Remove the nut and these parts:
(I) Spring washer
(2) Spacer collar
(3) Pul:ey
(4)
Fan
(5) Spacer collar
~--J-(2)
(3)
6J ----,
3.
REMOVE ROTOR
(a)
Using a pn'lss, press ou·t the rotor.
(b)
40A Type:
Remove the spacer ring and snap ring.
(c)
50 A Type:
Remove the spacer ring.
4.
REMOVE RECTIFIER END FRAME
A.
40A Type:
(a)
Remove the 4 nuts, condenser, cord clip and 2 termi-
nal insulators.
(b)
Remove the nut and rear end cover from the rectifier
end frame.
(c)
Removs the rectifier end frame from the rectifier
holder.
40A Type
.. , .. · ~
-.
-··· •CI-01
·'
...
•
•
•
.•
i
CHARGING SYSTEM ALTERNATOR
Halaman 144
___________
C::.H:..:.:..:.:ARGING SYSTEM- ALTERNATOR
CH-7
soA Type
l
B.
50A Type:
(a). Remove the 4 nuts. condenser and 2 terminal insula-
• '
...
tors .
(b)
Remove the rectifier end frame from the rectifier
holder .
(c)
Remove the insulator washer from the rectifier holder.
5,
REMOVE RECTIFIER HOLDER
H<'ld the rectifier terminal with needie-nose pliers
and unsolder the lead wires.
CAUTION: Protect the rectifiers trorn heat .
•
••
6.
50A Type:
REMOVE CONECTAMEAL HOUSING
Using an un·solder, remove the conectameal housing
from the rectifier holder.
CAUTION: Protect the rectifiers from heat.
SOA Type
'
Clocu.,.-•1
ALTERNATOR INSPECTION AND REPAIR
Rotor
1.
INSPECT ROTOR rCR OPEN CIRCUIT
Using an ohmmeter, chock that there is continuity ·
between the slip rings.
Standard resistance:
At 2o•c {61l.F): 3.9- 4.1 o
If there is no continuity, replace the rotor.
· z:
INSPECT ROTOR FOR GROUND
Using an ohmmeter. check that there is no continuity
between the slip ring and rotor.
If there is continuity, replace ·the rotor.
No Conlinuily
~
~l£:
•
CHARGING SYSTEM ALTERNATOR
Halaman 145
. -
. CHARGING SYSTEM.- ALTERN A TOR
3.
INSPECT SLii= RINGS
(a). Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
• '
(b)· Using vernier calipers. measure the slip ring diameter ...
Standard diameter:
32.3 -
32.5 mm {1.272 -
1.280 in.)
Minimum diameter:
32.1 mm {1.264 in.)
If the diameter is less than minimum, replace the rotor.
Stator
1.
INSPECT STATOR FOR OPEN CIRCUIT
Using an ohmmeter, chsck that there is continuity
between the coil leads.
, NOTICE: At this time, th& meeting wires should be con-
nected with soldered.
If there is no continuity, replace .the stator.
2.
INSPECT STATOR FOR GROUND
Using an ohmmeter, check that there is no continuity
between the coil leads and stator coni.
If th11m i~ r;rmtin11ity, nip11lr.ll thll ~tfll'lr.
Ohmmeter
Q_/
\
-
I
No cantinu!ty
P24939
L---
~~~.
I I I
I
Brushes
• '.
INSPECT EXPOSED BRUSH LENGTH
Using a scale. measure the exposed !:irush length.
Stand~~rd exposed length:
12.5 mm {0.492 ln.)
Minimum exposed length:
5.5 mm {0.2171n.)
If the exposed length is less than minimum, replace
the brush.
2. lF 'NECESSARY, REPLACE BRUSHES
(a)
Unsolder and remove the brush and spring.
•
(b)
Run the wire of a new brush through the spring and
the hole in the brush holder, and insert the spring and
brush into the brush holder.
'· .
'
.I
'
•
CHARGING SYSTEM ALTERNATOR
Halaman 146
I .
CHARGING SYSTEM- ALTERNATOR
CH-9
fc)
Solder the brush wire to the brush holder at specified
exposed length .
. Exposed len;Jth:
t 2.5 mm (0.492 in.)
(d)
Check that the brush moves smoothly in the brush
holder.
{e)
Cut off the excess wire.
(f)
Apply insulation .paint to the soldered area.
mm
Rectifiers (Rectifier Holder)
40A Type
INSPECT POSITIVE RECTIFIER
lc'fi
. ........
Using an ohmmeter, connect one tester probe to the
positive (+)terminal and the other to each rectifier
terminal.
(b)
Reverse the polarity of the tester probes and repeat
step (a).
(c)
Check that one shows continuity and the other shows
no continuity .
If continuity is not as specified, replace the rectifier
holder,
1.
(a)
-
<
. --.
..•
50A Type
Positive i+)
Terminal
Zl66<l7
2.
INSPECT NEGATIVE RECTIFIER
(a)
Using an ohmmeter, connect one tester probe to saC'h
negative (-) terminal and tha other to each rectifiilr
terminal.
(b)
Reverse the polarity of the tester probes and repeat
stop (a).
·
·
(c)
Check that one shows continuity and th" other shows
no continuity.
If continuity is not as specified, replace the rectifier
holder.
40A Type
Negative
Terminal
SOA Type
Negative (-)
Terrryinal
llfh46
CHARGING SYSTEM ALTERNATOR
Halaman 147
CH-1 0
CHARGING SYSTEM -
ALTERNATOR
Bearings
1.
INSPECT FRONT BEARING
Check that the bearing_ is not rough or worn.
2.
IF NECESSARY. REPLACE FRONT BEARING
{a)
Remove the .3 screws.
{b)
Using SST and a press, press out the bearing.
SST 09950-6001 0 (09951 -00220. 09952-0601 0)
7ffii
5'&1
(c)
Using SST and a press, press in a new bearing.
SST 09950-6001 0 (09951 - 00400)
(d)
Install the 3 screws.
3.
INSPECT REAR BEARING
Chock that tho bearing is not rough or worn.
4.
IF NECESSARY, REPLACE REAR BEARING
(a)
Using SST, remove the bearing.
SST og286-46011
{b)
Using a press, press in a new bearing.
·• '
.. '
'
CHARGING SYSTEM ALTERNATOR
Halaman 148
CH.ARGING SYSTEM- ALTERNATOR
CH-11
ALTERNATOR ASSEMBLY
SOA Type
• '
1.
50A Type:
INSTALL CONECTAMEAL HOUSiNG
s·older the conectameal housing to the rectifier hold~r .
CAUTION: P:·otect t~e rectifiers from heat.
2.
INSTALL RECTIFIER HOLDER TO STATOR
Hold the rectifier terminal with needle-pliers while
soldering t~e lead wires.
CAUTION: Protect the rectifiers from heat.
3.
INSTALL RECTIFIER END FRAME TO RECTIFIER
HOLDER
A.
(a)
... -
40A Type
40A Type:
Pla~e the 2 insulator washers on the positive studs )f
the 'rectifier holder.
(b)
Pla9e the rectifier end fran1e on the rectifier holder.
P2<93J
(c)
Place the rear end cover on the rectifier end frame.
Place the 2 terminal insulators on the positive studs
on the rectifier holder .
Install nut.
Torque: 4.4 N·m (45 kgf.r.m, 39 in •. lbf)
Install the cord clip and condenser with the 4 nuts.
Torquo: 4.4 .N·m (45 kgf.cm, 39 in.·lbf)
Check that the lead wires are not touching the rectifi-
er end frame.
40A Type
(d)
••
(e)
(f)
(g)
P249~
50A Type:
Place the insulator washer on ths positive studs of the
rectifier holder.
Place tho rectifier end frame on the rectifier holcJAr.
Place the 2 terminal insulators on tho positive studs
on the rectifier holder.
(d)
Install the condenser with the 4 nuts.
Torque: 4.4 N·m (45 kgf·cm, 39 ;, .. Jbf)
(e)
Check that the lead wires are not touching the rectifi-
er e!ld frame.
4.
INSTALL ROTOR
(a)
40A Typd;
Place the snap nng and spacer ring onta the rotor
shaft.
(b)
50A Type:
Place the spa cor ring onto the rotor shaft.
B.
(a)
(b)
(c)
.~;;;®
SOA Type
::-
-1
""" ,_/ J
..::; I 1'-V---L N
r1sJs<~
P15J5S
I
. ,.
CHARGING SYSTEM ALTERNATOR
Halaman 149
CH-12
CHARGING SYSTEM- ALTERNATOR
(c)
Using a press, press in the rotor.
00311
5.
INSTALL FAN AND PULLEY
(a)
Mount the rotor in S'Jft jaw vise.
(h)
Install these parts with the nut on the rotor shaft:
( 1) Spacer collar
(2)
Fan
(3)
Pulley
(4) Spacer collar
(5)
Spring washer
Torque: 61.3 N·m (625 kgf·cm, 45 ft·lbf)
(51
141
131
(21
( 1 1
11&117
6.
INSTALL DRIVE END FRAME ASSEMBLY AND
RECTIFIER END FRAME ASSEMBJ_ Y
(a)
Bend the rectifier lead wires back to clear the rotor.
(b)
Using a curved tool, push tha brushes in as far as they·
will go and hold them in placo by inserting a stiff w'ire
through the accass hole in· the access hole in the
rectifier end frame.
~-0~~~
(c)
Assemble the drive end frame and the rectifiar arid
frame by inserting the r&ar bflaring on the rotor shaft
into the rectifier end frame.
(d)
Install the 3 through screws.
Torque: 5.9 N-m (60 kgf·cm, 52 in .. Jbf)
(e)
Remove the stiff wire from the access hole.
7.
CHECK THAT ROTOR ROTATES SMOOTHLY
(a)
Che"k that the rotor rotates r<moothly.
(b)
50A Type:
Seal the access hole.
50A Typo
Seal
. ., . '
,,,-
1:.
,.
' ••
l
.•
•
CHARGING SYSTEM ALTERNATOR
Halaman 150
. '
-1
GHARGING SYSTEM -
ALTERN A TOR REGULATOR
CH-13
ALTERNATOR REGULATOR
·
tocoeu~"
ALTERNATOR REGULATOR INSPECTION
1.
REMOVE ALTERNATOR REGULATOR AND COVER
2.
INSPECT ALTERN A TOR REGULATOR
A.
:nspect point surfaces for seizure and damage
If defective, replace the regulator(
B.
{a)
Inspect resistance between terminals
Regulator:
Regulator
Using an ohmmeter, measure the resistance between 1'1
terminals IG and F.
Resistance:
· At rest: 0 Q
Pulled in: Approx. 1 1 Q
-----------'---
Relay
{b)
Relay:
Using an ohmmeter, measure the resistance between
terminals E and L.
Resistance:
At rest: 0 0
Pulled i11: Approx. 100 Q
Relay:
Using an ohmmoter. measure tho resistance between
terminals 8 and E.
Resistance:
At rest: infinity
Pulled In: Approx. 100 Q
{d)
Relay:
Using an ohmmeter. measure the resistance bot\veen
terminals 8 and L.
Resistance:
(c)
At rest: Infinity .
fulled In: 0 0
{e)
Using an ohmmeter, measure the resistance between
terminals N and E.
Resistance: Approx. 23 0
If any of the above checks are not positive, replace the
alternator regulator.
3.
REINSTALL ALTERNATOR REGULATOR AND
COVER
I
' .,
0 i·
I l
0
,.
I
. '
;
-·
I
•;!•"
•
CHARGING SYSTEM SERVICE SPECIFICATIONS
Halaman 151
CH-14 ·
CHARGING SYSTEM -
SERVICE SPECIFICATIO::.:N..:cS::.._ _________ _
ALTERNATOR REGULATOR VOLTAGE
ADJUSTMENT
.1.
REMOVE ALTERNATOR REGULATOR AND COVER
2.
ADJUST ALTERNATOR REGULATOR
A.
Adjust voltage regulator
Bend the regulator adjusting arm to adjust.
Regu!ating voltage:
At 2o•c (68.F): 13.8- 14.8 v
00158
B.
Adjust voltage relay
Bend the relay adjusting arm to adjust.
Relay actuating voltage: 4.0 -
5.8 V
3.
~ATORAND
COV.ER
SERVICE SPECIFICATIONS
SERVICE DATA
Battery
Specific gravity
at 2o•c (6B"Fl NS40L
!.27 -
!.29
Others
1.25 -
!.27
'
Alternator
Rated output
I
Rotor coil resistance
3.9-4.1 0
Slip ring diameter
STD
32.3 mm -
32.5 mm ( t .27'2 -
1.280 in.}
I
Minimum
32.1 m'll (1.254 in.)
Brush exposed length
STD
17..5 mm (0,492 in.)
\
Minimum
5.5 mm (0.217 in.)
AltE"rrlator
Regulating voltage
at 20" C (68- F)
1J.8- 1•i.BV
Regulator
Relay actuating voltage
4.0- 5.8 v
TORQUE SPECIFICATIONS
Pert tightened
N·m
kgf·cm .
ft·lbf
Rear end cover x Rectifier end frame
4.4
45
39 in.·lbf
Rectifier end frame x Rectifier holder {SOA Type)
4.4
45
39 in.·lbf
Cc,densar X Rectifier end frame
4.4
45
39 in.·!bf
Cord clip x R")ar and covor
4.4
45
39 in..lbf
Alternator pullay x Rotor
61.3
625
45
-·
Rectifier end frame x Drive end frame
I
5.9
60
in.·lbf
c .........
"
I
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•
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'.
I
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I i
12 V 40 A. 50 A
•
