ENGINE /

CONTENTS

SPECIFICATIONS ............................................... 2 COMPONENT SERVICE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
GENERAL SPECIFICATIONS ....................... 3 ENGINE ‘MOUNTING .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SERVICE SPECIFICATIONS ......................... 7 ENGINE AND TRANSMISSION
TORQUE SPECIFICATIONS ........................... 7 ASSEMBLY *........**........................*............*.... 19
LUBRICANT .................... .;. ............................ 8 TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. . 2?
SEALANT AND ADHESIVE ?.......................... 8 ROCKER ARMS, ROCKER ARM SHAFTS,
CAMSHAFT . . . . . . . . . .. . . .. . . .. . . . . . . .. . . .. .. . . . . .. . . . . . . . . . . . . . 26
m
SPECIAL TOOLS ................................................ 9 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . ..*................... 30
VALVES AND VALVE SPRINGS . . . . . . .. .. . . .. . 32
TROUBLESHOOTING ........................................ 11
JET VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *..* . . . . . . . . . . . 37
SERVICE ADJUSTMENT PROCEDURES ........ 14 SILENT SHAFTS AND OIL PUMP . . . . . . . . . . . . . 39
RETORQUING OF CYLINDER HEAD PISTONS AND CONNECTING RODS . . . . . . . . . 43,
BOLTS ............................................................. 14 CRANKSHAFT .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SILENT SHAFT DRIVE CHAIN TENSION CYLINDER BLOCK .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
ADJUSTMENT PROCEDURE ........................ 14
ENGINE OIL LEVEL GAUGE ...................... 15

9-l
 .
..
ED.. SPECIFICATIONS

G54B ENGINE

.\1 *.’ 5EN116

. .. .

. .

9-2
 SPECIFICATIONS
.
El...
GENERAL SPECIFICATIONS

Description Specifications

General
No. and arrangement of cylinders 4, in-line, vertical
Combustion chamber type Hemispherical
Valve arrangement Overhead valve type
Camshaft arrangement Overhead camshaft type
Total displacement cc (cu.in .) 2,555 (155.9)
Bore x stroke mm (in.) 91.1 x98 (3.59 x 3.86)
Compression ratio 8.2
Valve timing
Intake valve and jet valve open/close 25’BTDC/59”ABDC
Exhaust valve open/close 64’BBDC/20°ATDC
Firing order l-3-4-2 ’
Valve clearance at hot engine mm (in.) 0.15 (.006) -intake
0.25 (.OlO) -exhaust and jet
Timing chain
Type Double roller
No. of links 102
Pitch mm (in.) 9.5 (.375)
Timing chain “BY for silent shaft drive
Type Single roller
No. of links 90
Pitch mm (in .) 8.0 (.315)
Crankshaft sprocket
Material Ferrous sintered alloy
No. of teeth 19
Crankshaft sprocket “B”
Material Cast iron
No. of teeth 34
Camshaft sprocket
Material Cast iron .
No. of teeth 38
Silent shaft and oil pump sprocket
Material Steel
No. of teeth 17
Rocker arm
Material Aluminum die casting
Slipper made from special sintered alloy
I.D. mm (in .) 18.9 (.744)
Oil clearance mm (in.) 0.01-0.04 (.0004-.0016)

9-3
 SPECIFICATIONS

- Specifications
Description .
I!
II
Camshaft
Driven by .. Chain
Material . I Cast iron, cam surface chilled
Cam height mm (in.) 42.5 (1.673) ,
Valve lift mm (in.) .., 10.5 (.413)
Cam diameter for fuel pump drive mm (in.) 37 (1.457)
Journal diameter mm (in.) 34 (1.339)
Oil clearance mm (in.) 0.05-0.09 (.002-.004) ,
Identification mark 6 ‘_
Cylinder head
Material Aluminum alloy ’ ’ .
Deflection of gasket surface mm (in.) Less than 0.05 (.002)
Valve guide hole diameter mm (in.)
0.05 (.002) 0s. 13.050-13.068 (.5138-.5145)
0.25 (.OlO) O.S. 13.250-13.268 (.5217-.5224)
0.50 (.020) O.S. 13.500-13.518 (.5315-.5422)
Intake valve seat ring hole diameter mm (in.)
0.3 (.012) 0s. 47.30047.325 (1.8622-1.8632) ’
0.6 (.024) O.S. 47.60047.625 (1.8740-.1.8750) ’
Exhaust valve seat ring hole diameter . mm (in.)
0.3 (.012) O.S. 40.300-40.325 (1.5866-l .5876)
0.6 (.024) O.S. ’ 40.60040.625 (1.5984-l .5994)
Valve guide installation height mm (in.) 14 (.551)
Intake valves ‘1 /
Material Special heat-resistant steel
Treatment Sur-sulf .,
Valve diameter mm (in.) 46(1.811)
Stem diameter mm (in .) 8.0 (.3150)
Clearance (stem-to-guide) mm (in.) 0.03-0.06 (.0012-.0024)
Margin mm (in .) 1.2 (.047)
Identification mark N
Exhaust valves
Material Special heat-resistant steel
Valve face padded with stellite
Treatment Tufftriding
Valve diameter mm (in.) 38 (1.496)
Stem diameter ‘mm (in.) 8.0 (.3150)
Clearance (Stem to guide) mm (in:) 0.05-0.09 (.0020-.0035)
Margin mm (in .) 2.0 (.079)
-- -
Identification mark .. N

9-4
 SPECIFICATIONS
.
El...
Description Specifications

Valve springs
Free height mm (in .) 47.5 (1.870)
Load N (lbs)/mm (in.) 275 (62)/40.4 (1.59 1)
Square Less than 1.5”
Identification color Blue
Right silent shaft
Driven by Chain,
Material Steel
Rear journal diameter mm (in.) 43 (1.693).
Oil clearance mm (in.) 0.06-0.10 (.0024-.0039)
Left silent shaft
Driven by Chain
Material Steel
Front journal diameter mm (in.) 23 (.906)
Rear journal diameter mm (in.) I43 (1.693 1.
Oil clearance mm (in.)
Front 0.02-0.06 (.OOOS-.0024)
Rear 0.06-0.10 (.0024-.0039)
Piston
Material Special aluminum alloy
Type Autothermic
(Steel strut used for 4G54)
Diameter (Standard) mm (in .) 91.1 (3.587)
Clearance (Piston-to-cylinder) mm (in.) 0.02-0.04 (.OOOS-.0016)
Pistons for service mm (in .) 0.25 (.OlO), 0.50 (.020),
0.75 (.030), 1.OO (.040), oversize
Piston rings
No. of rings per piston
No. of compression rings
No. of oil rings
Compression ring type
No. 1 ring Barrel type, special cast iron, chrome face
No. 2 ring Taper type, special cast iron, chrome face
Gil ring type 3-piece steei rail, chrome face
Ring gap mm (in .)
No. 1 ring 0.30-0.45 (.012-.018)
No. 2 ring 0.25-0.40 (.OlO-.015)
Oil ring 0.3-0.6 (.012-.024)
Ring side clearance mm (in.)
No. 1 ring 0.05-0.09 (.002-.004)
No. 2 ring 0.02-0.06 (.OOl-.002)
Rings for service mm (in.) 0.25 (.OlO), 0.50 (.020),
0.75 (.030), 1.OO (.040), oversize

9-5
 SPECIFICATIONS

Description Specifications

Connecting rod
Length (Center to center) mm (in.) 166 (6.535)
Piston pin bore diameter mm (in.) 21.974-21.985 (.8651-.8655)
Side clearance (Big end) mm (in.) 0.1-0.25 (.004-.OlO)
Crankshaft
Material Steel
Main bearing journal diameter mm (in.) * - 60 (2.362)
Connecting rod journal diameter mm (in.) 53 (2.087)
Maximum allowable out-of-round and/or taper of journal mm (in.) 0.01 (.0004) ’
Oil clearance mm (in.)
Main bearing journal 0.02-0.05 (.OOOS-.0020)
Connecting rod journal 0.02-0.06 (.OOOS-.0024)
Thrust taken by No. 3 main bearing
End play mm (in.) 0.05-0.18 (.0020-.0071)
Bearings for service available in standard size and 0.25 (.OlO), 0.50 (.020), 0.75 (.030)
following undersizes mm (in.)
Cylinder block
Material Cast iron
Water jacket Siamese type
Cylinder bore mm (in.) 91.1 (3.587)
Out-of-round and taper mm (in.) Less than 0.02 (.OOOS)
Maximum allowable oversize (Cylinder bore) mm (in .) 1.oo (.039)
Oil pump
/ Gear
Type
Driven by Chain
Oil pressure at idle kPa (psi) 49 (7.1) or more
Relief valve opening pressure kPa (psi) 392 (57)
Oil filter
Type Cartridge, full flow
Size (Diameter x Length) mm (in.) 90 x 100 (3.54 x 3.94)
Engine oil
Capacity including that of oil filter liters (U.S.qts., Im:p.qts.)
Rear-wheel drive models 5.0 (5.2,4.4)
4-wheel drive models 5.8 (6.1,5.1)
Recommended oil (API classification) SE or SF

9-6
 SPECIFICATIONS

SERVICE SPECIFICATIONS

Standard value
’ Valve clearance - Hot engine mm (in .) . .’
Intake valve : 0.15 (.006)
Exhaust valve 0.25 (.OlO)
Jet valve 0.25 (.OlO)
Piston pin press-in load N (lbs.) 7,35517,162 (1,653-3,858)
Flywheel runout mm (in.) 0.1 (.004) max.
Oil pressure gauge unit
Current value mA
at 0 kPa (0 psi) 0
at 392 kPa (57 psi) 84
at 785 kPa (114 psi) 110

TORQUE SPECIFICATIONS Nm (ft.lbs.)

Front engine mounting

Engine support front insulator to engine 13-20 (9- 14)
Front insulator stopper to heat protector 6-10 (4-7)
Engine support front insulator to engine mounting bracket 30-40 (22-29)
Rear engine mounting
Vehicles with a manual transmission
Engine support rear insulator to No. 2 crossmember 18-25 (13-18)
Engine support rear insulator to transmission 18-25 (13-18)
No. 2 crossmember to frame 55-75 (40-54)
Frame to plate 18-25 (13-18)
Transfer support insulator to transfer mounting bracket 18-25 (13-18)
Transfer support insulator to plate 18-25 (13-18)
Transfer mounting bracket to transfer 18-25 (13-18)
Vehicles with an automatic transmission
Engine support rear insulator to No. 2 crossmember 30-42 (22-30)
Engine support rear insulator to transmission 17-23 (12- 17)
No. 2 crossmember to frame 55-75.(40-54)
Frame to plate 18-25 (13-18)
Transfer support insulator to plate 18-25 (13-18)
Transfer mounting bracket to transfer 18-25 (13-18)
Transfer mounting bracket to pipe 30-42 (22-30)
Cylinder head bolts - cold engine
Nos. 1 through 10 89-98 (65-72)
No. 11 15-21 (11-15)
Cylinder head bolts - hot engine
Nos. 1 through 10 98-107 (73-79)
No.11 . 15-21 (11-15)
Camshaft bearing cap bolts 17-20 (14-15)
Camshaft sprocket bolt 49-58 (37-43)

9-7
 SPECIFICATIONS

Rocker cover bolts 5-6 (4-5)

Heater joint 20-39 (15-28)
Intake and exhaust manifold nuts or bolts 15-19 (11-14)
Rocker arm adjusting nuts 12-17 (9-13) t ,
Main bearing cap bolts 74-83 (55-61)
Connecting rod cap nuts 45-47 (33-34) ”
Crankshaft pulley bolts 108-127 (80-94) ‘.
Oil pump sprocket bolt 30-39 (22-28)
Silent shaft sprocket bolt 30-39 (22-28)
Silent shaft chamber cover bolts 4-5 (3-4)
Flywheel bolts 128-137 (94-101) ( .
Drive plate bolts 128-137 (94-101) ‘, ‘.
‘. .
Engine support’bracket bolts .- 4049 (29-36).
Chain guide “B” bolt (upper) 8-9 (6-7) >
Chain guide “B” bolt (lower) 15-21 (11-15)
Chain guide access hole cover bolts 10-l 1.5 (7.5-8.5)
Oil pump cover bolt 10 -11 (7-8)
Oil pump assembly mounting bolt i’ 8-9 (6-7)
Oil pressure switch and gauge unit 8 15-21 (11~15)
Oil pan bolt 6-7 (4.5-5.5)
Oil pan drain plug 59-78 (44-57)
oil filter _ 11-12 (8-9) -
Oil filter stud 50-58 (3743) .’ : 1
Oil relief valve plug 4049 (29-36)
Water temperature gauge unit 30-39 (22-28)

’
LUBRICANT :
Specified lubricant Quantity I

Engine oil (including oil filter API clas,sification 4.5 liters (4.5 U.S. qts., 3.7 Imp. $9.)
and cooler) SE or higher

SEALANT AND ADHESIVE ,’

: ‘..
Specified sealant and adhesive Quantity

Top of cylinder head circular 3M Super Weather Strip adhesive As required

packing 8001 or equivalent
Threaded portion of oil pressure 3M Liqtiid Gasket 8959 or As required
gauge unit equivalent

:
- I

,9-8
 SPECIAL TOOLS

Tool (Number and name) Use Tool (Number and name) Use ,

MD998115 dD998148 “D”

Valve guide installer Ialve seat cutter pilot

MD99 8 173 “D” tiD998377 Use with valve spring seat

Valve seat cutter falve stem seal installer
[30” - O.D. 40 mm (1.57 in.)]

MD9981 75 “D” MD99 83 03 “*” May also be used for

Valve seat cutter u’alve spring compressor MA904
[30° - O.D. 44 mm (1.73 in.)]

MD9981 58 “D” UD998 184 “*”

Valve seat cutter Piston pin setting tool
[45’ - O.D. 40 mm (1.57 in.)]

MD9981 59 “D” MD99825 1 “*” For rear bearing

Valve seat cutter Silent shaft bearing puller
[45” - d.D. 44 mm (1.73 in.)]

MD998165 “D” MD998250 “*” For rear bearing

Valve seat cutter Silent shaft bearing installer
[65” - O.D. 44 mm (1.73 in.)]

‘- w. _
“*“, “D” see page 2 for instructions.
9-9
 SPECIAL TOOLS

Tool (Number and name) Use Tool (Number and name) Use

MD998376 “*” MD998054

Crankshaft rear oil seal installer Oil pressure switch wrench t

MD998308 MD998310
Jet valve stem seal installer Jet valve socket wrench

MD998309
Jet valve spring pliers

“*” see page 2 for instructions. .i,

,

9-10
 TROUBLESHOOTING

Symptom Probable cause Remedy

NOISY ENGINE
Knocking of crankshaft and Loose main bearing Replace
bearing
Seized bearing Replace

Bent crankshaft Replace

Excessive crankshaft end play Replace thrust bearing

Piston and connecting Loose bearing Replace

rod knocking
Seized bearing Replace

Loose piston pin Replace piston and pin or

connecting rod

Loose piston in cylinder Recondition cylinder

Broken piston ring Repair or replace

Improper connecting rod alignment Realign

Camshaft knocking Loose bearing Replace

Excessive end play Replace

Broken cam gear Replace

Timing chain noise Improper chain tension Adjust or replace

Worn and/or damaged chain Replace

Worn sprocket Replace

Worn and/or broken tension adjusting mecha- Replace

nism

Excessive camshaft and bearing clearance Replace

Camshaft and valve Improper valve clearance Adjust

mechanism knocking
Worn adjusting screw Replace

Worn rocker face Replace

(Loose valve stem in guide (Replace guide

Weakened valve spring Replace

’ Seized valve Repair or replace

Water pump knocking Improper shaft end play Replace water pump assembly

Broken impeller Replace water pump assembly

9-11
 TROUE3LESHOOTING

Symptom Probable cause Remedy

OTHER MECHANICAL
TROUBLE
Stuck valve in guide Improper valve clearance Adjust

Insufficient clearance between valve stem and Clean stem or ream guide
I guide
’ I Weakened or broken valve spring Replace
I.L Damage to valve stern Replace

Valve stuck on seat Improper valve cleamnce Adjust

I Weakened valve spring Replace

’
Thin valve head edge Replace valve
>
Narrow valve seat Reface

Overheating ’ Repair or replace

Excessive engine speed Drive at proper speed

Stuck valve guide Repair or replace

.’

2 Shortage of engine oil Add or change oil

Clean crankcase, change oil and

replace oil filter element

Use proper oil

Repair or replace

Repair or replace

Improper piston rin,g clearance Replace

Clean air cleaner and replace filter,

Clean or replace carburetor choke

Over choking Repair or replace choke assembly

Damaged connecting rod Add or change oil

Check oil level on daily basis

Correct

Use proper oil

Grind or replace

Clean

9-12
 TROUBLESHOOTING

Symptom Probable cause Remedy

Damaged connecting rod Bearing worn or eccentric Replace

(continued)
Bearing improperly assembled Correct or replace

Loose bearing Replace

Incorrect connecting rod alignment Repair or replace

Damaged crankshaft bearing Shortage of engine oil Add or change oil

Check oil level on daily basis

Low oil pressure Adjust or repair

Poor quality engine oil Use proper oil

Worn or out-of-round crankshaft journal Repair or replace

Clogged oil passage in crankshaft Clean

Bearing worn or eccentric Replace bearings and check

engine oil lubrication system

Bearing improperly assembled Repair or replace

Non-concentric crankshaft or bearing Replace

Excessive vibration Loose engine mounts Tighten or replace

Silent shaft bearings damaged Replace

Improper phase of silent shafts Adjust

9-13
 .....
Erl A SERVICE ADJUSTMENT PROCEDURES

RETORQUING OF CYLINDER HEAD BOLTS

I. When cylinder head bolts are retorqued, first slightly
loosen and then tighten to specified torque. 0 Front of engine
2. Be sure to follow the specified torquing isequence.
(5EN016)

Cylinder head bolt tightening sequence

3. After cylinder head bolts have been tightened to specified

torque, run engine untii”n0rnx-J operating tem:perature is
reached, allow it to cool down, and then retorque bolts to
specification for best results.

Tightening torque .
Cylinder head bolt (No. 1 to 10)
. Cold engine . . .... . . . . 89-98 Nm (65-72 ft.lbs.)
Hot enging . . . .... .!. . 98- 107 Nm (73-79 ft.lbs:)
Cylinder head bolt (No. 11) . . . . -. . . . . . . 15:‘) 1 Nm
(1 1-15 ftlbs.)

SILENT SHAFT DRIVE’ CHAIN TENSION’ ADJUST-

MENT PROCEDURE _:
When a loose silent shaft drive chain is suspected 4s the proba-
ble cause of abnormal noise, the tension must be readjusted.
Tension of silent shaft drive chain can be adjusted without
removing timing chain cover as follows:
1. Remove cover from access hole provided a t center of
chain case (under water pump).

\ I 5EN07:

2. Loosen special bolt “B”. 1

3. Using your finger push projection on chain guide “B”
in direction of arrow. Do not push projection with a Chain guide “B”

screwdriver or other tool. Improperly chain tension

bolt “B”
will cause abnormal noise. (5EN007)
4. Tighten special bolt “B’,.
5. Install cover. Do not reuse damaged gasket. ’

Cover bolt tightening torque .................

10-l 1.5 Nm (7.5-8.5 ft. lbs.)
Projection

5EN007

9-14
 SERVICE ADJUSTMENi PROCEDURES

ENGINE OIL LEVEL GAUGE

The oil level gauge is located on the right side of the engine. Upper limit Lower limit
Maintain engine oil;level within the marking lines on the oil
level gauge. (DGEOOS)
The oil level in the oil pan may read at the “MAX” mark line
(upper limit) after the engine has been standing for several
hours. When the engine is started the oil level drop some- ( MAX
what due to filling of oil passages, etc.
When the oil level is at or below the “MIN” mark line (lower
limit) on the level gauge, add 1 liter (1 U.S. qt., 0.9 Imp.
qt.). The oil should never be allowed to remain below the
lower limit.
I DGEOOS
Caution
Do not overfill crankcase. This will cause oil aeration and
loss of oil pressure.
 COMPONENT SERVICE-ENGINE MOUNTI’NG

.
COMPONENTS I_- Front mounting

Rear mounting
Vehicles with a manual transmission

1. Heat protector 01 W502

2. Front insulator stopper
3. Engine support front insulator
4. No. 2 crossmember Vetiicles with an automatic transmission
5. Engine support rear i&ulator 10 6 F
6. Transfer mounting bracket
7. Transfer support insulator
8. Plate
9. Stopper
10. Pipe

Nm fLlbs.

A 13-20 9-14
B 6-10 4-7
C 3040 22-29
D 18-25 13-18
E 55-75 40-54
F 3042 22-30
G 17-23 12-17

9-16
 COMPONENT SERVICE-ENGINE MOUNTING

REMOVAL
Front .Mounting
1. Remove the heat protector from the front ‘insulator
stopper.
2. Remove the engine mounting nuts and bolts from the
front insulators. (OlW501)
3. Attach a chain to the. engine hangers.
4. Using a chain block and tackle, raise the engine and
remove the insulators.
‘Caution
Avoid applying a strain on the radiator, fuel hoses or cables
by raising the engine too high.

Rear Mounting shicles with a manual’ Vehicles with an automatic

ansmission i transmission
1. Support the transfer with a jack.
2. After the transfer mounting bracket and transfer support
insulator have been separated, remove the plate from the
side frame. (09W507, 09W508)
3. Detach the transfer mounting bracket from the transfer.
(09W507,09W508)

4. Support the transmission with a jack.

5. Detach the engine support rear insulator from the engine.
(SO902O,OlW5 19)

6. For vehicles with an automatic transmission, detach the

cross select shaft from the No. 2 crossmember. (Refer to
GROUP 2 1.)
7. Remove the No. 2 crossmember mounting bolts.
(OOW530)
8. Remove the engine support rear insulator from the No. 2
crossmember.
 .
tn. COMPONENT SERVICE:ENGINE MOUNTING

INSPECTION ,
1. Check insulatdrs for cracks, separation or deformation.
2. Check transfer mounting bracket for deformation or
corrosion.
3, Check plate for deformation or corrosion. .~,
4. Check No: 2 crossmember for deformation or, corrosion.

21.7 f.85)
1

mm (in.) OlW5OL

INSTALLATION
Front Insulator
Make sure that the locating boss and hole are in alignment.
Caution‘
Do not distort rubber portions, and never stain ml&x por-
tions with fuel or oil.

9-18
 COMPONENT SERVICE-ENGINE AND TRANSMISSION ASSEMBLY

REMOVAL
1. Disconnect the ground cable from the battery terminal.
2. Remove the hood. (Refer to GROUP 23.)
3. Remove the air cleaner.
4. Disconnect the heater hoses. (0 1W.5 14)
5. Disconnect the brake booster vacuum hose. (0 lW.5 14)

6. Disconnect the fuel hoses. (OlW526)

7. Disconnect the accelerator cable. (Refer to GROUP 14.)

8. For vehicles equipped to meet California regulations

(can also be sold in Federal States), disconnect the air
temperature sensor connector, throttle position sensor
connector and the carburetor control wiring harness
connector.

9. Disconnect the Starter motor wiring harness. (0 1W507)

10. Remove the clutch release cylinder from the transmission.
(Refer to GROUP 21.)
 COMPONENT SERVICE-ENGINE AND TRANSMISSION ASSEMBLY

11. Disconnect the alternator wiring harness.

12. Disconnect the engine ground cable.

13. Disconnect the fuel cu’t solenoid valve and bowl vent
valve connector.

14. Disconnect the high-tension cable. (OlW516) ;

15. Disconnect the water temperature gauge connector.
(OlW516)
16: Remove the power steering pump. (Refer to C:ROUP 19.)

OlW516

17. For vehicles equipped to meet California regulations

(can also be sold in Federal States), disconnect the water
temperature sensor.

9-20
 COMPONENT SERVICE-ENGINE AND TRANSMISSION ASSEMBLY

18. Disconnect the vapor hose.

19. Disconnect the purge hoses from the purge control valve.

20. For vehicles equipped to meet California regulations

(can also be sold in Federal States), disconnect the
Oxygen sensor connector.

2 1. Disconnect the oil pressure switch harness. (0 1W5 18)

22. Remove the radiator assembly. (Refer to GROUP 7.)
23. Remove the front exhaust pipe. (Refer to GROUP 11.)
24. Remove the transfer case protector. (Refer to GROUP
21.)
25. Disconnect the speedometer cable. (Refer to GROUP 2 1.)
26. Disconnect the back-up light switch harness and 4-wheel
drive indicator light switch harness. (Refer to GROUP 2 1.)
27. Remove the front and rear propeller shafts. (Refer to
GROUP 16.)
28. Remove the transmission gear-shift lever (vehicles with a
manual transmission) or transmission selector lever
(vehicles with an automatic transmission) and transfer
shift lever.
29. For vehicles with an automatic transmission, remove the
oil cooler hoses and tubes. (Refer to GROUP 7.)
30. Remove the engine mounting. (Refer to p. 9-l 7.)
31. Using a chain block and tackle, raise and remove the
engine and transmission assembly diagonally out of the
engine compartment.

9-21
 COMPONENT SERVICE-EN(:INE AND TRANSMISSION ASSEMBLY

INSTALLATION
1. Supply coolant to the coohng system. (Refer to GROUP
7.)
2. Supply transmission and transfer case fluid.’ (Refer to
GROUP 21.)
3. Supply engine oil. (Refer to.p. 9-8.)
4. Adjust the clutch control system. (Refer to GROUP 6.)
Adjust the accelerator cable. (Refer to GROUP 14.)
Adjust the hood alignment. (Refer to GROUP 23.)
5. Torque all parts to specifications during assembly.

9-22
 .+,
*.

COMPONENT SERVICE-TIMING CHAIN

.
COMPONENTS

7
-8
1. Crankshaft pulley bolt
2. Special washer
3. Pulley
4. Flange bolt - 8x68 (8)
5. Flange bolt - 8x73
6. Flange bolt - 8x58 (2)
7. Timing chain case
a. Chain case gasket (R 1 .
9. Chain case gasket (L)
10. Flange bolt - 6x18 (2)
11. Cover
12. Gasket
13. Oil seal
14. Flange bolt - 10x15 (2)
15. Special bolt “B” 1
16. Special bolt “A”
17. ‘Spring washer,
18. Chain guide “B”
19. Flange bolt - 6x60
20. Flange bolt - 6x45
21. Chain guide “A”
22. Flange bolt - 6x45
23. Flange bolt - 6x32
24. Chain guide “C”
25. Chain “B”
26. Crankshaft sprocket “B”
27. Sprocket “B” (2)
28. Spacer
29. Bolt w/washer - 14x70
30. Plain washer
31. Distributor gear
32. Timing chain
33. Crankshaft sprocket
34. Camshaft sprocket
35. Spring pin
36. Tensioner
37. Rubber sheet
38. Spring
39. Flange bolt - 6x10
40. Tension side chain guide
41. Flange bolt - 6 x 10 (2)
42. Loose side chain guide
43. Flange bolt (2)
44. Sprocket holder

NOTE
-32
Numbers show order of disassembly.
For reassembly, reverse order of disassembly.

Nm ft.lbs.

108127 80-94
12-14 9-l 0.5
15-21 11-15
a-9 6-7
59-68 44-50
49;58 37-43

9-23
 .
.
Em .
. COMPONENT !SERVlCE-TIMING CHAIN

TIMING CHAIN INSTALLATION PROCEDURE

1. Install sprocket holder and chain guides.
2. Turn crankshaft until piston of No.1 cylinder is at top
dead center.
3. Install tensioner spring, sleeve and rubber sheet to oil
pump.
4. Line up plated links of timing chain and timing marks on
sprockets as chain and’sprockets are assembled.
5. While sliding crankshaft sprocket onto crankshaft, install Sprocket holder

chain and sprocket. Place camshaft sprocket on sprocket Chain guide, right
holder. Tensioner slee

..

5ENO(

6. Install crankshaft sprocket “B” (for driving silent shafts)

on crankshaft.

Front

Crankshaft sprocket’“B” \

Crankshaft sprocket

5ENOO:

7. Assemble silent shaft sprockets to chain “B”. Make sure

that timing marks are in alignment with plated links. e Front a Front
Use care not to confuse right and left sprockets, as they
are installed in opposite directions.

When sprocket When sprocket

is installed to oil is installed to .
pump drive gear left silent shaft

Right side Left side 5EN004

9-24
 COMPONENT SERVICE- TIMING CHAIN

8. Holding assembled sprockets and chain “B”, align timing

mark on crankshaft sprocket “B” with that on chain “B”,
and install sprockets to oil pump drive gear and left silent
shaft. Partially tighten bolt. Chain guide “6”

9. Temporarily install chain guides “A”, “B” and “C”. Cylinder block
Special bolt “A”
10. Tighten silent shaft sprocket bolts to specified torque.
1 1. Tighten chain guide “A” mounting bolts firmly. Section Y - Y
12. Tighten chain guide “C” mounting bolts firmly. Special bolt “B” Timing mark Plated
v \ link

Chain guide “B”

Section X - X

Timing X
mark A,

Chain
/ guide

Chain buide w” 4 glated link

1 Timing mark

5EN005

13. Rotate both silent shaft sprockets slightly to position

chain slack at point P.
14. Adjust position of chain guide “B” so that when chain is
l-3.5 mm
pulled in direction of arrow with finger tips, clearance be- (.04-.I4 in.)
tween chain guide “B” and links of chain “B” will be 1 to
#,@&
3.5 mm (.04 to .14 in.) and tighten special bolts “A” and Chain guide “B

“B”. Section P- P

Tightening torque Special bolt “A”

Special bolt “A” . . . . . . . . 8-9 Nm (6-7 ft.lbs.)
Special bolt “B” . . . . 15-21 Nm (1 l-15 ft.lbs.)

* 5ENOO

9-25
 COMPONENT SERVICE-ROCKER ARMS, ROCKER ARM SHAFTS, CAMSHAFT

COMPONENTS r ‘_.

1 .; Oil filler cap

2. Bolt - 8x40 (2)
3. Washer (2)
4. Oil seal (2)
5. -Rocker cover
6. Rocker cover.gasket
7. PCV valve
8. Semicircular packing
9. Flange bolt (10)
10. Flange bolt - 8x25 (2)
11. Rocker arm and shaft assembly
-1 Bearing cap, front
-2 Wave washer (2)
3 Rocker arm “A” (4)
4 Adjusting screw (4)
-5 Nut (4)
-6 Adjusting screw (8) -
-7 Nut (8)
-8 Rocker arm “C” (4)
-9 Bearing cap No. 2
-10 Rocker arm spring (6)
-11 Bearing cap No. 3
-12 Bearing cap No. 4
-13 Bearing cap, rear
-14 Rocker arm shaft left
-15 Rocker arm shaft right
12. Circular packing
13. Camshaft

NOiE
Numbers show order of disassembly.
For reassembly, reverse order of disassembly.

Nm ft.lbs.

5-6.8 3.7-5.0
19-20 14-15
20-26 15-19
8-9.5 6-J
12-17 9-13

5EN074

9-26
 COMPONENT SERVICE-ROCKER ARMS, ROCKER ARM SHAFTS, CAMSHAFTS

REMOVAL
:l. Before rocker arm and rocker shaft are removed, make
sure that piston in No. 1 cylinder is at top dead center on
compression stroke.
2. Illustration shows position of camshaft sprocket timing
mark when piston in No. 1 cylinder is placed at top dead
center on compression stroke. (5EN075)

5EN075

INSPECTION
Rocker Arm
1. Check for wear of portions A, B and C, and replace if
following conditions are evident. (1 EN01 2)
(1) Portion A dented or worn
(2) Portion B eccentric
(3) Portion C (inside diameter) excessively loose on shaft
2. Check to ensure that oil holes are clear. (rocker arm with
oil holes only)

lEN012

Rocker Arm Shaft

1. Check to ensure that rocker arm mounting portion is not
worn.
2. Check to ensure that oil holes are clear. (SEN063) Oil holes

Camshaft
1. If the following areas of the camshaft are badly worn or
damaged, replace. ( 1EN0 19)
(1) Journals
(2) Cam lobes
(3) Fuel pump drive cam
(4) Distributor drive gear teeth
(5) Oil seal contacting surface
2. If camshaft bearing is badly worn, replace cylinder head.
3. If oil seal lip is worn, replace.

1 ENOl!

9-27
 COMPONENT SERVICE-ROCKER ARMS, ROCKER ARM SHAFTS, CAMSHAFT

INSTALLATION
Rocker arm “C”
There are two kinds of rocker arms: rocker arm “A” and for exhaust
rocker arm “C”. 1
Rocker arm “A” drives intake valves and jet valves.
Rocker arm ‘C” drives exhaust valves.

Rocker arm “A”-

for intake
5EN076 I

1. Insert the left and right rocker shafts into the front
bearing cap. The rear end of left (intake) ‘rocker arm
shaft has a notch as shown in 5EN077.
2. Align the mating mark of the rocker arm shaft front
end to the mating mark of the front bearing cap. Then
:
A Front

insert the bolts to hold shafts in bearing cap.

Rocker arm shaft (left)

for intake

Notch

3. Install the waved ‘washer in the direction shown in the

illustration. Rocker arm

t
Front bearing cap

4. Assemble the rocker arm shaft so that the alignment

mark at the front end matches the alignment rnark of the Mating marks
front bearing cap. (5ENO12) 13 mm t.12 in.) dia. hole]

5. Install the rocker arms; shafts, caps, etc., as shown in

illustration before installation to the cylinder head.
Insert the bolts to hold parts in position. (5EN079)

Mating marks‘
[2 mm t.08 in.) dia. embossing]

-. 5EN012

9-28
 COMPONENT SERVICE-ROCKER ARMS, ROCKER ARM SHAFTS, CAMSHAFT

Identification
8 1 1
mark
I
, 1

1. Rocker arm “C”

2. Rocker arm “A”
3. Front bearing cap
4. No. 2 bearing cap
5. No. 3 bearing cap
(Inscribed mark 3 on top surface)
6. No. 4 bearing cap
(Rocker screw hole on top surface) 3 24252627'
7. Rear bearing cap
8. Waved washer
5FNn74

6. Apply engine oil to the journals of camshaft and install it

to cylinder head. Rear bearing cap Apply sealant

7. Coat the sealant to the O.D. of circular packing and install

the circular packing to cylinder head as shown in 5EN080.
8. Install the rocker arms, shafts and bearing caps assembly
to the cylinder head, and tighten the bearing cap bolts to
specified torque.
9. Adjust the valve clearance. See “Lubrication and Mainte-
nance”, Group 0, for detailed procedure.

10. Install the semi-circular packing to the front of cylinder

head and apply sealant to top of semi-circular packing.
Apply sealant
Recommended adhesive . . . . . . . . . . . . . . . . . . . . .
3M Super Weather Strip Adhesive 800 1 or equivalent
10mm
I.4 in.)
11. Install the rocker cover gasket and rocker cover.
Caution
Make sure that rocker cover bolts are tightened to specified Semi-circular Dackina
torque. Cylinder head

If they are overtorqued, a deformed rocker cover or oil leak-

age could result.
I 6EN013

Tightening torque
Rocker cover bolts . . . . . . 5-6 Nm (3.7-5.0 ft.lbs.)

9-29
 COMPONENT SERVICE-CYLINDER HEAD

COMPONENTS

/I

1. Nut (8)
2. Plain washer (7)
3. Exhaust manifold
4. Exhaust manifold gasket
5. Nut (9)
6. Spring washer (9)
7. Intake manifold
8. Intake manifold gasket
9. Flange bolt (2)
10.: Cylinder head bolt (101,
11. Washer (10)
12. Cylinder head
13. Cylinder head gasket

NOTE
Numbers show order of disassembly.
For reassembly, reverse order of disassembly.

Nm ft.lbs.

A Cold engine 89-98 65-72

Hot engine‘ 98-107 73-79
B 15-21 11-15
C 15-19 ‘11-14

5EN086

1. Remove cylinder head bolts in sequence shown in illustra-

tion. (5ENO15)
2. Cylinder head bolts can be loosened with ordinary socket @ Front of engine

wrench or special tool MD99805 1.

5ENOl!

9-30
 COMPONENT SERVICE-CYLINDER HEAD

: INSPECTION
Cylinder Head
1. Check cylinder head gasket surface for warping by using
a straight edge in directions of A, B, . . . as shown in
illustration. (5EN064)
2. If warping exceeds 0.1 mm (.004 in.) in any direction,
either replace cylinder head or lightly machine cylinder
head gasket surface.

5EN06L

INSTALLATION
Cylinder Head Gasket
1. Clean gasket surfaces of cylinder head and cylinder
block.
2. Install gasket surface with identification mark toward
cylinder head. (5EN069)
Caution
Do not apply sealant to cylinder head gasket.

Front of engine

5EN06E

3. Before cylinder head gasket is installed, apply sealant to

top surface (indicated by arrows in illustration) of each
butt joint between cylinder block and chain case.

Cylinder Head
1. Install cylinder head assembly.
2. Install cylinder head bolts.
3. Starting at top center, tighten all cylinder head bolts to
l/2 of specified torque in the sequence shown in illustra-
tion. (5EN016)
4. Torque all cylinder head bolts to the specifications in
the same sequence.

Cylinder head bolt (Nos. 1 through 10) tightening

torque
Cold engine . . . . . . . . . . 89-98 Nm (65-72 ft.lbs.)
Hot engine . . . . . . . . . . 98- 107 Nm (73-79 ft.lbs.)
Cylinder head bolt (No. 11) tightening torque
15-21 Nm (11-15 ft.lbs.) 5ENOlt
 COMPONENT SERVICE-VALVES AND VALVE SPRINGS

COMPONENTS

1. Lock (8)
2. Retainer (4)
3. Spring (4)
4. Seat (4)
5. Intake valve (4)
6. Valve stem seal (4)
7. Intake valve guide (4)
8. Intake valve seat (4)
9. Lock (8)
10. Retainer (4)
11. Spring (4) 6
12. Seat (4)
13. Exhaust valve (4)
14. Valve stem seal (4)
15. Exhaust valve guide (4)
16. Exhaust valve seat (4)
17. Cylinder head

NOTE
Numbers show order of disassembly.
For reassembly, reverse order of disassembly.

5EN017

Disassembled parts, such as valves, valve springs, should be

grouped in accordance with their cylinder numbers.

9-32
 COMPONENT SERVICE-VALVES AND VALVE SPRINGS

INSPECTION
Valves
1. Check each valve for wear, damage or deformation of
head and stem at “B”. Repair or replace excessively
worn, damaged or deformed valves.
2. If stem tip “A” is pitted, correct by grinding. This
correction must be limited to a minimum. Also reface
valves with a valve grinder.
3. Check valve stem-to-guide clearance, Replace valve
and/or valve guide if necessary.
45”
1 EN034

4. Replace valve if the margin of the face has decreased to

less than 0.5 mm (.02 in.). (6EN020)
5. Valve seat contact should be made at center of valve face.
6. Using marking compound, check for even contact with

1
valve seat.
7. If inadequate contact with valve seat is evident, correct
valve seat and/or reface valve. Valve seat
contact

f+ Margin

6EN020

Valve Springs
1. Check free height of each valve spring and replace if
necessary. (1 EN03 5)
2. Using a square, test squareness of each valve spring. If
spring is excessively deformed, replace it.
--I Free height

I 1 EN035

Valve Seats
1. Check valve seats for evidence of overheating or impro
per contact with valve face. Correct or replace seat if
necessary.
2. Valve seat contact width should be as specified. (Refer to
p. 9-32.) (lEN033)
 COMPONENT SERVIC,E-VALVES AND VALVE SPRINGS

VALVE STEM SEAL REPLACEMENT

1. Remove valve stem seal with pliers and discard it.
Caution
Do not reuse valve stem seal.

2. Install spring seats.

.3. Lightly tap seal into place with special tool. (5EN081)
NOTE
Incorrect installation of seal will adversely aff&ct lip and
eccentricity, resulting in oil leakage past valve guides. Valve stem seal

5EN08’

VALVE SEAT RECONDITIONING

‘1. When correcting, check valve guide for wear. Replace
guide if worn, and then’correct seat.
2. To correct valve seat, use special tools.
(lEN036, lEN037)

Contact width
Exhaust . . . . 1. . . . . 1.2-l .6 mm (.047-‘.063 in.)
Intake . . . . . . . . . . . . 0.9-1.3 mm (.035:.051 in.)

3. After correction, valve and valve seat should be lapped

with a lapping compound.
1 EN03(

1 EN037

9-34
 COMPONENT SERVICE-VALVES AND VALVE SPRINGS

VALVE SEAT INSERT REPLACEMENT PROCEDURE

1. When seat insert is to be removed, cut away excess metal
from inside of insert with cutter before removal.

Cylinder head

I 1 EN03

2. Grind valve insert bore in cylinder head to match the

outside diameter and height of oversize seat insert.
(lEN039)
3. Before insert is installed, heat cylinder head proper to
approx. 250” C (480” F).
Caution
If seat insert is installed at room temperature, cylinder head
will be ground and seat ring will not tightly fit.
4. Press-fit insert quickly in hole provided in cylinder head.
5. After installation, recondition valve seat with seat cutter.
See “Valve Seat Reconditioning”.
1 EN035

VALVE GUIDE REPLACEMENT PROCEDURE

Replace the valve guide as follows.
1. Using special tool, press valve guide out toward cylinder
head lower surface. (1 EN040)
2. Machine valve guide hole in cylinder head to outer
-MD9981 15
diameter of oversize valve guide.
Valve guide Cylinder head

1 EN040

3. Using special tool install the valve guide. Use of valve

guide installer makes it possible to press the valve guide
to a predetermined height. Valve guide should be installed
from top of cylinder head. ( lEN041)
Caution
If valve guide of standard size has been removed, do not
reinstall a standard size valve guide. Be sure to install valve
guide at room temperature.
4. After valve guides have been installed, insert new valves Valve guide
and check for free movement.
5. When valve guides have been replaced, check for valve
face-toseat contact and correct valve seats as necessary.
I 1 EN041

9-35
 COMPONENT SERVlCiE-VALVES AND VALVE SPRINGS

REASSEMBLY - .’
.l. Apply engine oil to each valve. Insert valves into, guides.
Avoid inserting valve into seal with force. After insertion, Identification color
check to see if valve moves smoothly.
2. Valve springs should be installed with identifica.tion color
side toward valve spring retainer. (1 EN043)

Identification color . . . ; . . . . . . . . . . . . . . . . . . Blue

3. .Use valve spring compressor or suitable tool to comp-

ress spring and install retainer lock. (3EN 127)
4. After installation of valves, make certain that retainer
locks are positively installed.
Caution
When spring is compressed with Valve Spring Compressor
or suitable tool, check to see that the bottom of r&ainer does
not contact the valve stem seals.

3EN12;

.A

9-36
 COMPONENT SERVICE-JET VALVES

COMPONENTS

1. Retainer lock
2. Spring retainer
3. Spring
4. Jet valve
5. Valve stem seal
6. O-ring
7. Jet body

NOTE
Numbers show order of disassembly.
For reassembly, reverse order of disassembly.

EC1 084

REMOVAL
1. Remove the jet valve assembly with special tool.
Caution Jet valveMDggf \
When using the jet valve socket wrench, make certain that
the wrench is not tilted with respect to the center of the jet
valve. If the tool is tilted, the valve stem might be bent by
the force exerted on the valve spring retainer, resulting in
defective jet valve operation.

2. Remove the jet valve spring retainer lock with special tool
and remove the valve spring retainer and valve spring.

1 EMOOE
 COMPONENT SERVICE-JET VALVES

INSPECTION
1. Check to ensure that the jet valve slides smoothly with no
play in the jet body. Do not attempt to adjust the fit of
the jet valve in the jet body. Replace the jet valve and jet
body as an assembly.
2. Check the face of the jet valve and the jet bo’dy seat for
seizure or damage. If defective, replace the jet valve and
jet body as an-assembly.
3. Check the jet valve spring for deterioration,, cracks or
damage, and replace if defective.

INSTALLATION
1. Install the jet valve stem seal with the special toeol.
( 1EM006)
Caution
Do not reuse old. valve stem seal.
2. Apply engine oil to the stem of the jet valve before insert-
ing the jet valve into the jet body. When inserting the
valve, use care to prevent damage to the new valve
stem seal lips. After installation, check to ensure that the
valve slides smoothly.

3. Mount the jet valve spring and jet valve spring retainer.
Then compress the spring with the special tool, and
install the retainer lock. When compressing the spring
with pliers, use care not to avoid damaging the valve stem
with the bottom of the spring retainer.

4. Install a new O-ring into the groove around the jet body
and apply engine oil to the O-ring. Apply engine oil to
the jet body threaded area and seat surface. (llEM007)
5. Screw the jet valve assembly into the cylinder head by
hand, and tighten to the specified torque with special
tool. Hold the jet valve socket wrench firmly to make
sure that it is not tilted with resp‘ect to the center of the
jet valve.
Tightening torque
Jet valve assembly . . . . . 18-21 Nm (13-15 ft.lbs.)
Apply engine oil

9-38
 COMPONENT SERVICE- SILENT SHAFTS AND OIL PUMP

COMPONENTS

1. Oil drain plug

2. Oil drain plug gasket
3. Bolt (24)
4. Oil pan
5. Gasket
16
6. Bolt (2)
7. Oil screen
8. Oil screen gasket 23
9. Flange bolt - 6x22
10. Flange bolt - 6x38
11. Flange bolt - 6x45
12. Flange bolt - 6x16
13. Oil pump assembly
-1 Screw
-2 Oil pump cover
-3 Oil pump drive gear
4 Oil pump driven gear
-5 Plug
-6 Relief spring
-7 Relief valve
-8 Pin (2)
-9 Oil pump body
14. Oil pump gasket
15. Flange bolt
16. Silent shaft, right
17. Woodruff key
18. Flange bolt (2)
19. Thrust plate
20. O-ring
21. Silent shaft, left
22. Woodruff key
23. Oil filter

NOTE
Numbers show order of disassembly.
For reassembly, reverse order of disassembly.

Nm ft.lbs.

, A 59-78 44-57
B 6-7 4.5-5.5
C 1 o-1 1.5 7.58.5
D 59-68 44-50
E 89 6-7
F 3044 22-32
G 1 o-1 1.5 7.5-8.5
H 11-12 8-9

5EN118
f

9-39
 COMPONENT SERVICE- SILENT SHAFTS AND OIL PUMP

REMOVAL
When the thrust plate is to be removed, install 8 mm dia. Thrust plate
bolts into threaded holes of flange and turn bolts equally to
remove the thrust plate.
shaft, left

8mm’bolt

. 5EN02(

INSPECTION
Oil Pump
Tip clearance
1. Install drive gear and driven gear to oil pump. body and Side clearanc
measure clearance. Driven gear
2. Check for stepped wear of gear contacting surfaces of
body and cover.
3. If clearance is excessive, or if case or cover has stepped
wear, replace case and cover assembly, replace gears, or
both.

Side

Silent Shafts
1. Check journals for wear, damage or seizure. 1:fexcessive
damage or seizure is evident, check bearing also. If
necessary, replace silent shaft, bearing, or both.
2. Check oil hole passage for clogging. Clean or repair
if necessary.

5EN071 1

SILENT SHAFT BEARING REPLACEMENT PROCE-

DURE
1. Using special tool, remove silent shaft rear bearing.
Cylinder block

Cylinber block

9-40
 COMPONENT SERVICE- SILENT SHAFTS AND OIL PUMP

2. Using special tool, install silent shaft bearing to cylinder

block.
Caution
Before installing bearing, apply engine oil to outer surface
of bearing.

Cylinder block

I “E”l023

INSTALLATION
Left Silent Shaft
1. Apply engine oil to journal of left silent shaft. (ShN025)
2. Install left silent shaft into cylinder block carefully, to Apply engine oil

prevent damage to the bearing. CL

-- -

3. Install new O-ring into groove of thrust plate. (.5EN026)

4. Apply engine oil around O-ring.

New O-ring

5. Install two guides into threaded holes for mounting

thrust plate. Guides should be fabricated by cutting off
hexagonal heads of bolts 6 mm (.24 in.) in diameter and
50 mm (2 in.) long. (5EN027)
shaft
6. Install since thrust plate into cylinder block along guides.
Without use of guides, threaded holes will be hard to
align, turning to align holes might twist or damage the
O-ring, so make sure that thrust plate is correctly
I
installed by use of the guides. head
‘ader block
bolt with
 COMPONENT SERVICE.- SILENT SHAFTS AND OIL PUMP

Right Silent Shaft and Oil Pump

1. Install oil pump gears to oil pump body and align timing
marks. (5EN028)
Caution
If timing marks are out of .aligmnent, phase of s:ilent shaft Driven gear
will be out of phase, and vibration will result.
Timing marks
2. Install oil pump cover to,body and tighten screws.
Drive gear

3. After installing pump cover, position pump assembly in

same position as it was originally installed on engine and
put approx. 10 cc (0.6 cuin.) of clean engine oil in Apply 10 cc

0
0
delivery port. (SEN029) 00 (0.6 cu.in.)
engine oil
of

4. Install right silent shaft into oil pump driven gear.

5. Install driven gear and ‘silent shaft tightening bolt and
tighten to specified torque.
Q
0
6. Apply engine oil to journal of right silent shaft. e” o 0

7. Install silent shaft and oil pump as an assembly to cylinder

0000”
block. Use care to avoid damaging rear bearing as the
shaft is installed.
8. Tighten oil pump mounting bolts to specified torque.

Torque specification
Oil fitimp mounting bolts . . . . . . . . . . . . . . . . .
lo-lo.5 Nm (7.5-8.5 Ift.lbs.)

9-42
I
 COMPONENT SERVICE- PISTONS AND CONNECTING RODS

COMPONENTS

5
6
7

1. Nut (8)
2. Bearing cap (4)
3. Bearing (4)
4. Piston and connecting rod assembly (4)
-1 Bearing (4)
-2 Piston pin (4)
-3 Connecting rod (4)
-4 Bolt (8)
-5 No. 1 piston ring (4)
-6 No. 2 piston ring (4)
-7 Oil ring (4)
-8 Piston (4)

NOTE
Numbers show order of disassembly.
For reassembly, reverse order of disassembly.

Nm ft.lbs.

A 45-47 33-34

5EN120

REMOVAL
Connecting Rod Cap
1. Before connecting rod cap is removed, make the cylinder
number on the connecting rod and on the cap and big linder
end side surfaces. (DENOSO) mber
2. Keep bearings in order of corresponding connecting rods
(according to cylinder numbers) for proper reassembly.

DEN050

9-43
 COMPONENT SERVICE-PISTONS AND CONNECTING RODS

PISTON PIN REMOVAL AND INSTALLATION PROCE-

DURES
Push rod
Caution
Tools vary on different engine models.
1. Use the special tools illustrated to remove Ihd install 7
piston and connecting rod. 4G54
stamped

a
I

MD9981 84 90.5 mm
stamped
(3.563 in.)

5EN031

2. Set piston and connecting rod assembly in tool body SO

that the front mark (arrow mark of piston or identifica-
tion mark of connecting rod) is positioned upward.
3. Place connecting rod securely on tool body. Push rod
4. Insert push rod into piston pin and remove piston pin Connecting rod
Piston pin I I
with press. (lEN056)

Front mark
(arrow mark
Piston

5. Assemble piston pin, push rod and guide. (lENO.58)

6. Apply engine oil to outer surface of piston pin and
small end bore of connecting rod.
7. Set connecting rod and piston with front mark facing up.

1 FNWi8

8. Insert push rod, piston pin and guide as a unit into

piston pin hole and connecting rod small end hlole.
Body
9. Align the guide so that the two parallel surfaces are
positioned as shown in illustration. (lEN060)
10. Press piston pin into piston pin hole applying the
specified load with a press. If required installa.tion load is
not within specifications, .replace piston pin and/or
connecting rod.

Piston pin press-in load . . . . . . . . . . . . . . . . .,. . . . .

7,35517,162 N (1,653-3,858 lbs.) Gu’ide

9-44
 COMPONENT SERVICE- PISTONS AND CONNECTING RODS

11. Turn the push rod l/4 turn and separate the piston and
connecting rod assembly from the special tool.
12. After pressing in piston pin, make sure that connecting
rod turns and slides easily.
(identification mark)

1 EN059

PISTON RING INSTALLATION PROCEDURE

1. Install spacer.
Side rail

I 5EN082

2. Install upper side rail. To install side rail, first nut one I
end of side rail between piston ring groove and spacer,
hold it down firmly, and then press down the portion Side rail gap

which is to be inserted into groove with a finger as

illustrated. (lEN063) L&k.

Caution
Do not use piston ring expander when installing side rail.
3. Install lower side rail by same procedure as Step 2.

4. Using piston ring expander, installNo. 2 piston ring.

5. Install No. 1 piston ring. “Tl” mark stamped
6. Apply engine oil around piston and piston rings.
Barrel
type

“T2” mark stamped

Taper
we
 COMPONENT SERVICE- PISTONS AND CONNECTING RODS

INSTALLATION f
When installing the piston and connecting rod assembly into
I :
cylinder, be sure to check the following:
1. Position the ring gaps as far as possible ‘froni adjacent
‘gaps. Make sure that gaps are not positioned in thrust or
pin directions. ‘( l-EN065)
2. Use a piston ring compressor to hold the rings as they are I Front
c

installed into the cylinder.

,N,od;;~yJ
\
expander gap

I 1 EN065

3. Make sure that front mark of piston and front mark

(identification mark) of connecting rod are directed to
ward front of engine. (SEN121, 5EN067) Oversize mark

4. When connecting rod cap is installed, make sure that

cylinder numbers which were put on rod and cap at
disassembly match.

Identification mark

. .

Identification mark
(front mark)

5. When installing a new connecting rod, make sure that

the notches for holding the bearing in place ;are on the
same side.

Notches

9-46
 COMPONENT SERVICE-CRANKSHAFT

COMPONENTS

Vehicles with a manual transmission

1. Flywheel bolt (6)

,2. Flywheel
3. Ring gear
4. Ball bearing
5. Drive plate bolt (6)
6. Adapter plate
7. Drive plate assembly
8. Adapter plate
9. Crankshaft bushing
10. Flange bolt (2)
11. Rear plate
12. Flange bolt (2)
13. Bell housing cover
14. Flange bolt (5)
15. Oil seal case
16. Gasket Vehicles with an automatic transmission
17. Separator
18. Rear oil seal
19. Bolt (10)
20. Bearingcap (5)
21. Crankshaft bearing (5)
22. Crankshaft
23. Crankshaft bearing (5)

NOTE
Numbers show order of disassembly.
For reassembly, reverse order of disassembly.

Nm ft.lbs.

A 128-l 37 94-l 01
B 7483 55-61

5EN033

INSPECPON
Oil Clearance Measurement
1. After main bearing cap has been tightened to specified
torque, measure inside diameter of main bearing with a
cylinder gauge.

Tightening torque
Main bearing cap belt . . . . . . . . . . . . . . . . . . . . :
74-83 Nm (55-61 ft.lbs.)
 COMPONENT !3ERVICE-CRANKSHAFT

2. Measure outside diameter of crankshaft journal with a I

micrometer. (3EN056)
3. If oil clearance is excessive, replace main bearing.
4. Check bearing and journal for seizure or damage. If
necessary, replace bearing or crankshaft or machine
journal to undersize.

I 3EN05E

Oil Clearance Measurement (Plastigage Method)

1. Remove oil and dirt from bearings and journals.
2. Cut plastigage to same length as width of bearing and
install it parallel with journal, away from oil holes.
3. Install crankshaft, bearings and caps and tighten them to
specified torque. During this operation, do NOT turn
crankshaft. /
4. Remove caps. Measure width of plastigage at the widest
part with the scale printed on gauge envelope. (lEN067)

1 EN067

INSTALLATION
Grooveless
Main Bearing
1. Install grooved main bearing (upper bearing)’ ton cylinder
block side.
2. Install grooveless main bearing (lower bearing) on main Lower bearing
(for No. 1,2,4,5)
bearing cap side.
3. Both upper and lower bearings f&r center (thrust bearing)
are grooveless.

Upper and lower bearings

(for center)

1 EN068
Crankshaft
1. Install crankshaft. Apply engine oil to journ& and pins.
2. Caps should be installed with arrow mark directed toward
front of engine. Cap number must be correct.
3. Tighten cap bolts to specified torque in sequence of
center, No. 2, No. 4, front and rear caps. ’

’ Cap bolt tightening torque . . . . . . . . . . . . . .’ . . . . .

74-84 Nm (55-6 1 ftlbs.)

4. Cap bolts should be ‘tightened evenly in 2 to 3 stages

before they are tightened to specified torque.
5. Make certain that crankshaft turns freely and has proper
end play.

9-48
 COMPONENT SERVICE-CRANKSHAFT

Crankshaft Rear Oil Seal

1. Using special tool, install oil seal into oil seal case.

2. Push the oil separator into case, being sure that the 4 mm
(. 16 in.) diameter oil hole positioned at the bottom of Oil separator
Oil seal case
the case (oil pan mounting surface side).
3. Install the oil seal case to the engine block, install 7 bolt
and torque to specifications.

(.I6 in.)
Oil pan mounting dia. oil hole
surface

Flywheel
1. Install flywheel and tighten bolts to specified torque.
Check clutch mounting surface for runout.

1
Ring gear
Tightening torque . . . . . 128-137 Nm (94-101 ft.lbs.)
- Flywheel

Flywheel runout . . . . . . . . . . 0.1 mm (.004 in.) max. identification

mark

2. To install flywheel, use 26 mm (1.024 in.) bolts with

“11” marked on the heads. Do not use shorter bolts
for installing drive plate.
I
- Flywheel bolt

- Pilot bearing

Crankshaft
l- t

1 EN070
 COMPONENT SERVICE-CRANKSHAFT

Drive Plate
1. Install adapter plates and drive plate and tighten bolts to
specified torque.
2. Use bolts 21.5 mm (.846 in.) in length (“L”:) to install
Ring gear
drive plate.

Drive plate

Crankshaft bushing

Q
Crankshaft,
I

1 ENOi

9-50
 COMPONENT SERVICE-CYLINDER BLOCK

COMPONENTS

1. Bolt (4)
2. Engine support bracket
3. Engine support bracket
4. Cylinder block
5. Oil pressure switch
6. Oil pressure gauge unit
(if so equipped)

NOTE
Numbers show order of disassembly.
For reassembly, reverse order of disassembly.

Nm ft.lbs.

A 4049 29-36

5EN034

INSPECTION
Cylinder Block
1. Measure cylinder bore with a cylinder gauge at three
levels in directions of A and B. (3EN060)
Level 1: No. 1 piston ring position with piston at TDC
Level 2: Center of cylinder
Level 3: Bottom of cylinder
2. If cylinder bores show more than specified out-of-round
or taper, or if cylinder walls are badly scuffed or scored,
cylinder block should be rebored and honed, and new
oversize piston and rings fitted.
3EN06C

3. Check for damage and cracks.

4. Check top surface for distortion. If excessive distortion is
evident, grind to minimum limit or replace. (6EN053)

6ENO5:
 COMPONENT SERVICE-CYLINDER BLOCK

Oil Pressure Switch

1. If “OIL PRESSURE” indicating lamp lights when igni-
tion switch is set to “ON” and goes out when engine is
started and running at idle, then everything is in order. If
“OIL PRESSURE” lamp does not light when ignition
switch is set to “ON”, check switch, lamp and wiring.
2. If there is current flow when ignition switch is set to
“ON” and if there is no current flow when engine is run-
ning at idle, switch is good.
If switch is good, check lamp and wiring.

: GLUOOC

Oil Pressure Gauge Unit

1. Since bimetal type has constructional characteristics
which vary its resistance as it repeats ON-OFYF states, it
cannot be checked by measuring its resistance:
2. It can be checked by use of an AC type ammeter measur-
ing changes in current.

-. 6LUOO4

k-52
 .
in.
I CYLINDER BORING
COMPONENT SERVICE-CYLINDER BLOCK

1. Oversize of pistons to be used should be determined on

the basis of the largest cylinder bore. I
1
I _ I
f _ I
Size mark

I=4 0
0.25 mm (.Ol in.) O.S. .................. 0.25
Thrust
0.50 mm (.02 in.) O.S. .................. 0.50 direction
0.75 mm (.03 in.) O.S. .................. 0.75 Piston O.D.

1.00 mm (.04 in.) O.S. .................. 1.00 A

NOTE
Size mark is stamped on top of piston, 6EN05
2. Measure outside diameter of piston to be used at posi-
tion “A”, in thrust direction, as shown. (6EN054)
3. Based on measured piston O.D., calculate the boring
finish dimension.
Boring finish dimension = Piston O.D. + 0.01 to 0.03 mm
(.0004 to .0012 in.) (clearance between piston O.D. and
cylinder) - 0.02 mm (.OOOS in.) (honing margin)
4. Bore all cylinders to calculated bore finish dimension.
Caution
To prevent distortion that may result from temperature rise
during honing, bore cylinders in the following order: No. 2,
No. 4, No. 1, No. 3.
5. Hone to final finish dimension [piston O.D. + 0.01 to
0.03 mm (.0004 to .0012 in.)].
6. Check clearance between piston and cylinder.

Clearance between piston and cylinder . . . . . . . . . .

0.01-0.03 mm (.0004-.0012 in.)

NOTE
When boring cylinders, finish all four cylinders to same
oversize. Do not bore only one cylinder to an oversize.

INSTALLATION
1. Apply recommended sealant to threaded portion.

Recommended sealant . . . . . . . . . . . . . . . . . . . . .
3M Liquid Gasket 8959 or equivalent

2. Using special tool (MD998054), tighten switch to speci-

fied toruqe.

Tightening torque
Oil pressure gauge unit ..................
15-21 Nm (1 l-15 ft.lbs.)
6LUOl

9-53