DYNAJ05CENGREPAIRMANUALDR137E

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FOREWORD
TOYOTA MOTOR CORPORATION
This repair manual has been prepared to provide information covering general service repairs for the J05C
engine equipped on the TOYOTA DYNA. 2003 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be repro-
Applicable models: XZU420, 430 series duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
Please note that the publications below have also been prepared as relevant service manuals for the
components and systems in this vehicles.
Manual Name Pub. No.
S DYNA Repair Manual RM1008E
S DYNA Repair Manual Supplement (Draft) DR129E
All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.
CAUTION
This manual does not include all the necessary items about repair and service. This manual is made
for the purpose of the use for the persons who have special techniques and certifications. In the
cases that non--specialized or uncertified technicians perform repair or service only using this manu-
al or without proper equipment or tool, that may cause severe injury to you or other people around
and also cause damage to your customer’s vehicle.
In order to prevent dangerous operation and damages to your customer’s vehicle, be sure to follow
the instruction shown below.
S Must read this manual thoroughly. It is especially important to have a good understanding of
all the contents written in the PRECAUTION of ”IN” section.
S The service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use tools spe-
cified and recommended. If using non--specified or recommended tools and service method,
be sure to confirm safety of the technicians and any possibility of causing personal injury or
damage to the customer’s vehicle before starting the operation.
S If part replacement is necessary, must replace the part with the same part number or equivalent
part. Do not replace it with inferior quality.
S It is important to note that this manual contains various ”Cautions” and ”Notices” that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improper service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is
important to warn of all the possible hazardous consequences that might result from failure to
follow these instructions.
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MAIN INDEX: DYNA J05C

ENG REPAIR MANUAL DR137E
INTRODUCTION 1
PREPARATION 2
SERVICE SPECIFICATIONS 3
FUEL 11
INTAKE 13
ENGINE MECHANICAL 14
EXHAUST 15
COOLING 16
LUBRICATION 17
STARTING & CHARGING 19
ALPHABETICAL INDEX
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INTRODUCTION
HOW TO USE THIS ENGINE
REPAIR MANUAL . . . . . . . . . . . . . . . . . . . . . . 01--1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 01-1/3
REPAIR INSTRUCTION FOR ENGINE
REPAIR MANUAL . . . . . . . . . . . . . . . . . . . . . . 01--4
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4/6
TERMS FOR ENGINE REPAIR MANUAL . . . 01--7
ABBREVIATIONS USED IN THIS MANUAL . . . . 01-7/11
GLOSSARY OF SAE AND TOYOTA TERMS . . 01--12/14

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01--1
INTRODUCTION -- HOW TO USE THIS ENGINE REPAIR MANUAL
HOW TO USE THIS ENGINE REPAIR MANUAL

GENERAL INFORMATION
0108J--03
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting
3. Final Inspection
(c) This manual explains ”Removing and Installing, Replacing, Disassembling, Installing and Checking,
Adjusting”, but ”Final Inspection” is omitted.
(d) The following essential operations are not written in this manual, however these operations must be
done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be
repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repairing condition. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed as the section or title when necessary.
(b) Illustrations of the parts catalog are placed as the ”disassembled parts drawing” so that it enables you
to understand the fitting condition of the components.
(c) Non--reusable parts, grease applied parts, precoated parts and tightening torque are specified in the
components drawing.
Example:
OVERHAUL Camshaft,
No. 3 Camshaft Sub--assy
Camshaft Drive Gear
Camshaft Timing Tube Assy
7.5 (80, 66 in.·lbf)

No. 2 Camshaft,
Seal Washer No. 4 Camshaft Sub--assy
z Camshaft Setting Oil Seal Camshaft Driven Main Gear

Screw Plug
78 (790, 58)
15 (150, 11) Wave Washer Camshaft Timing Gear

Bolt Washer
Camshaft Sub Gear
N·m (kgf·cm, ft·lbf) : Specified torque Snap Ring
z Non--reusable part A54988
J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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01--2
(d) Tightening torque, oil applying position, and non--reusable parts are described as important points in
the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In that case, all the
information such as torque, oil, etc. are described in the illustration.
(e) Installing procedure of operation items is performed in the reverse order of the removing, and only the
important points are described.
(f) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notice are placed.
(g) There may be a case where the illustrations of similar models are used. In that case the details may
be different from the actual vehicle.
(h) The procedures are presented in a step--by--step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
Illustration: Task heading: what to do
what to do and where
Detailed text:
Set part No. Component part No. how to do task
A59974
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for a quick reference.
6. TERMS DEFINITION
CAUTION Indicate the possibility of injury to you or other people.
NOTICE Indicate the possibility of damage to the components being repaired.
HINT Provide additional information to help you perform the repair efficiently.

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01--3
7. SI UNIT
(a) The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys-
tem of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N⋅m (310 kgf⋅cm, 22 ft⋅lbf)

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01--4 INTRODUCTION -- REPAIR INSTRUCTION FOR ENGINE REPAIR
MANUAL
REPAIR INSTRUCTION FOR ENGINE REPAIR MANUAL

PRECAUTION
0108K--03
1. TO PREVENT FROM ENTERING FOREIGN SUBSTANCES

(a) When foreign substances such as dust, grain of sand or metallic dust enter inside of engine, it often
causes functional failure of the engine.
(1) Precaution before disassembly.
S Remove adequately all sand and mud adhere to the outside of engine.
(2) Precaution at reassembly.
S Protect disassembled parts from dust by using vinyl sheet to cover.
2. TO PREVENT SCRATCHES ON THE PARTS
(a) The existence of scratches on the contact and revolving surfaces often causes oil leak and seisure.
(1) Precautions at disassembly and reassembly.
S When disassemble the contact surface of the parts, use plastic hummer striking lightly. (Do
not pry out by screwdriver).
S When fix the parts to the vise, do not directly catch it in the vise. Fix the parts through alumi-
num bar.
3. TO CLEAN AND WASH THE PARTS
(a) Each parts needs to be well cleaned, washed, and dried by air, and apply specified oil before reas-
sembly.
(1) Cleaning and washing by alkaline solvent is prohibited:
S Parts made of aluminum and rubber. (ex. cylinder head cover gasket etc.)
(2) Cleaning and washing by flushing oil (ex. kerosene, white gasoline etc.) is prohibited:
S Parts made of rubber. (ex. cylinder head cover gasket etc.)
4. POSITION AND DIRECTION OF EACH PARTS
(a) Each parts needs to be reassembled as the same position and direction as it disassembled.
(1) Precautions at disassembly and reassembly.
S Follow the directions when the manual designates to mark the matchmark and/or direction
mark.
S Disassembled parts needs to be put in order as disassembled, not to change position and/
or direction.
S Follow the directions when the manual instructs the position and direction.
5. INSTALL ENGINE ASSEMBLY TO OVERHAUL STAND WHEN OVERHAUL THE ENGINE
6. PUT THE DISASSEMBLED PARTS IN ORDER AS THEY DISASSEMBLED
7. APPLY ENGINE OIL TO THE SLIDING AND ROTATING SURFACES
8. NON--REUSABLE PARTS SUCH AS GASKET AND SEAL NEEDS TO BE CHANGED TO THE NEW
PARTS
9. BASIC REPAIR HINT
(a) Precoated Parts:
(1) Precoated parts are bolts, nuts, etc. that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(3) When reusing precoated parts, clean off the old
Seal Lock Adhesive
adhesive and dry with compressed air. Then apply
Z11554 the specified seal lock adhesive to the bolt, nut or
threads.

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INTRODUCTION -- REPAIR INSTRUCTION FOR ENGINE REPAIR 01--5
MANUAL
NOTICE:
Do the torque checking with the lower limit value of the torque tolerance.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) Gaskets:
When necessary, use a sealer on gaskets to prevent leaks.
(c) Bolts, Nuts and Screws:
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
(d) Torque When Using Extension Tool with Torque Wrench:
(1) In case of tightening by extending the entire length
L1 L2
of the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the read-
D02612 ing of the torque wrench by the formula.
(3) Formula T’ = T x L2/(L1 + L2)
T’ Reading of torque wrench {N⋅m (kgf⋅cm, ft⋅lbf)}
L1 L2 T Torque {N⋅m (kgf⋅cm, ft⋅lbf)}
L1 Length of SST or tool (cm)
L2 Length of torque wrench (cm)
D01201
L1 L2
D01202
10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS

(a) Place for Removing and Installing Fuel System Parts:
(1) Place with good air ventilation and without anything flammable such as welder, grinder, drill, elec-
tric motor or stove in the surroundings.
(2) Never work in a place like a pit or nearby pit as there is a possibility that vaporized fuel fills those
places.
(b) Removing and Installing of Fuel System Parts:
(1) Prepare a fire extinguisher before starting the operation.
(2) For prevention of the static electricity, install a ground on the fuel changer, vehicle and fuel tank,
and do not spray much water so as to prevent slipping.

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01--6 INTRODUCTION -- REPAIR INSTRUCTION FOR ENGINE REPAIR
MANUAL
(3) Never use any electric equipment like an electric motor or a working light as they may cause
spark or high temperature.
(4) Never use an iron hammer as it may cause spark.
(5) Dispose the shop lag separately from any fuel deposit.
11. REMOVAL AND INSTALLATION OF ENGINE INTAKE
PARTS
(a) If any metal tip is mixed in the inlet pass, that may give a
bad effect to the engine and turbo charger.
(b) When removing and installing of the inlet system parts,
close the opening of the removed inlet system parts and
the engine with a clean shop lag or gum tape.
(c) When installing the inlet system parts, check that there is
D01563 no mixing of a metal tip.
12. HANDLING OF HOSE CLAMPS

Flat Spring Clamp
(a) Before removing the hose, check the depth of inserting
portion and the clamp position to restore it surely.
(b) Change a deformed or dented into a new one.
(c) In case of reusing the hose, install the clamp on the hose
where it has a clamp track.
(d) For a flat spring type clamp, make it adjust by adding force
Clamp Track to the arrow mark direction after the installation.
D25081

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01--7
INTRODUCTION -- TERMS FOR ENGINE REPAIR MANUAL
TERMS FOR ENGINE REPAIR MANUAL

ABBREVIATIONS USED IN THIS MANUAL
0108H--03
Abbreviations Meaning
ABS Anti--Lock Brake System
A/C Air Conditioner
AC Alternating Current
ACC Accessory
ACIS Acoustic Control Induction System
ACSD Automatic Cold Start Device
A.D.D. Automatic Disconnecting Differential
A/F Air--Fuel Ratio
AHC Active Height Control Suspension
ALR Automatic Locking Retractor
ALT Alternator
AMP Amplifier
ANT Antenna
APPROX. Approximately
ASSY Assembly
A/T Automatic Transmission (Transaxle)
ATF Automatic Transmission Fluid
AUTO Automatic
AUX Auxiliary
AVG Average
AVS Adaptive Variable Suspension
B+ Battery Voltage
BACS Boost Altitude Compensation System
BAT Battery
BDC Bottom Dead Center
B/L Bi--Level
B/S Bore--Stroke Ratio
BTDC Before Top Dead Center
BVSV Bimetallic Vacuum Switching Valve
CB Circuit Breaker
CCo Catalytic Converter For Oxidation
CD Compact Disc
CF Cornering Force
CG Center Of Gravity
CH Channel
CKD Complete Knock Down
COMB. Combination
CPE Coupe
CPS Combustion Pressure Sensor
CPU Central Processing Unit
CRS Child Restraint System
CTR Center
C/V Check Valve
CV Control Valve
CW Curb Weight
DC Direct Current
DEF Defogger
DFL Deflector

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01--8
DIFF. Differential
DIFF. LOCK Differential Lock
D/INJ Direct Injection
DLC Data Link Connector
DLI Distributorless Ignition
DOHC Double Overhead Cam
DP Dash Pot
DS Dead Soak
DSP Digital Signal Processor
DTC Diagnostic Trouble Code
ECAM Engine Control And Measurement System
ECD Electronic Controlled Diesel
ECDY Eddy Current Dynamometer
ECT Electronic Control Transmission
ECU Electronic Control Unit
ED Electro--Deposited Coating
EDU Electronic Driving Unit
EDIC Electric Diesel Injection Control
EFI Electronic Fuel Injection
E/G Engine
EGR Exhaust Gas Recirculation
EGR--VM EGR--Vacuum Modulator
ELR Emergency Locking Retractor
ENG Engine
ESA Electronic Spark Advance
ETCS Electronic Throttle Control System
EVAP Evaporative Emission Control
EVP Evaporator
E--VRV Electric Vacuum Regulating Valve
EX Exhaust
FE Fuel Economy
FF Front--Engine Front--Wheel--Drive
F/G Fuel Gauge
FIPG Formed In Place Gasket
FL Fusible Link
F/P Fuel Pump
FPU Fuel Pressure Up
FR Front
F/W Flywheel
FW/D Flywheel Damper
FWD Front--Wheel--Drive
GAS Gasoline
GND Ground
HAC High Altitude Compensator
H/B Hatchback
H--FUSE High Current Fuse
HI High
HID High Intensity Discharge (Head Lamp)
HSG Housing
HT Hard Top
HWS Heated Windshield System

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01--9
IC Integrated Circuit
IDI Indirect Diesel Injection
IFS Independent Front Suspension
IG Ignition
IIA Integrated Ignition Assembly
IN Intake (Manifold, Valve)
INT Intermittent
I/P Instrument Panel
IRS Independent Rear Suspension
ISC Idle Speed Control
J/B Junction Block
J/C Junction Connector
KD Kick--Down
LAN Local Area Network
LB Liftback
LCD Liquid Crystal Display
LED Light Emitting Diode
LH Left--Hand
LHD Left--Hand Drive
L/H/W Length, Height, Width
LLC Long--Life Coolant
LNG Liquified Natural Gas
LO Low
LPG Liquified Petroleum Gas
LSD Limited Slip Differential
LSP & PV Load Sensing Proportioning And Bypass Valve
LSPV Load Sensing Proportioning Valve
MAP Manifold Absolute Pressure
MAX. Maximum
MIC Microphone
MIL Malfunction Indicator Lamp
MIN. Minimum
MP Multipurpose
MPI Multipoint Electronic Injection
MPX Multiplex Communication System
M/T Manual Transmission
MT Mount
MTG Mounting
N Neutral
NA Natural Aspiration
NO. Number
O2S Oxygen Sensor
O/D Overdrive
OEM Original Equipment Manufacturing
OHC Overhead Camshaft
OHV Overhead Valve
OPT Option
O/S Oversize
P & BV Proportioning And Bypass Valve
PCS Power Control System
PCV Positive Crankcase Ventilation

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01--10
PKB Parking Brake
PPS Progressive Power Steering
PS Power Steering
PTO Power Take--Off
P/W Power Window
R&P Rack And Pinion
R/B Relay Block
RBS Recirculating Ball Type Steering
R/F Reinforcement
RFS Rigid Front Suspension
RRS Rigid Rear Suspension
RH Right--Hand
RHD Right--Hand Drive
RLY Relay
ROM Read Only Memory
RR Rear
RRS Rear--Wheel Drive
RWD Rear--Wheel Drive
SDN Sedan
SEN Sensor
SICS Starting Injection Control System
SOC State Of Charge
SOHC Single Overhead Camshaft
SPEC Specification
SPI Single Point Injection
SRS Supplemental Restraint System
SSM Special Service Materials
SST Special Service Tools
STD Standard
STJ Cold--Start Fuel Injection
SW Switch
SYS System
T/A Transaxle
TACH Tachometer
TBI Throttle Body Electronic Fuel Injection
TC Turbocharger
TCCS TOYOTA Computer--Controlled System
TCV Timing Control Valve
TDC Top Dead Center
TEMP. Temperature
TEMS TOYOTA Electronic Modulated Suspension
TFT Toyota Free--Tronic
TIS Total Information System For Vehicle Development
T/M Transmission
TMC TOYOTA Motor Corporation
TMMK TOYOTA Motor Manufacturing Kentucky, Inc.
TRC Traction Control System
TURBO Turbocharge
TWC Three--Way Catalyst
U/D Underdrive
U/S Undersize

TO MODEL INDEX
01--11
VCV Vacuum Control Valve
VENT Ventilator
VIN Vehicle Identification Number
VPS Variable Power Steering
VSC Vehicle Skid Control
VSV Vacuum Switching Valve
VTV Vacuum Transmitting Valve
VVT--i Variable Valve Timing--intelligent
W/ With
WGN Wagon
W/H Wire Harness
W/O Without
1ST First
2ND Second
2WD Two Wheel Drive Vehicle (4 x 2)
3RD Third
4TH Fourth
4WD Four Wheel Drive Vehicle (4 x 4)
4WS Four Wheel Steering System
5TH Fifth

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01--12
GLOSSARY OF SAE AND TOYOTA TERMS

0108I--03
This glossary lists all SAE--J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE TOYOTA TERMS
SAE TERMS
ABBREVIATIONS ( )----ABBREVIATIONS
A/C Air Conditioning Air Conditioner

ACL Air Cleaner Air Cleaner, A/CL
AIR Secondary Air Injection Air Injection (AI)
AP Accelerator Pedal --
B+ Battery Positive Voltage +B, Battery Voltage
BARO Barometric Pressure HAC
CAC Charge Air Cooler Intercooler
CARB Carburettor Carburettor
CFI Continuous Fuel Injection --
CKP Crankshaft Position Crank Angle
CL Closed Loop Closed Loop
CMP Camshaft Position Cam Angle
CPP Clutch Pedal Position --
CTOX Continuous Trap Oxidizer --
CTP Closed Throttle Position LL ON, Idle ON
DFI Direct Fuel Injection (Diesel) Direct Injection (DI)
DI Distributor Ignition --
DLC1 Data Link Connector 1 1: Check Connector
DLC2 Data Link Connector 2 2: Total Diagnosis Comunication Link (TDCL)
DLC3 Data Link Connector 3 3: OBD II Diagnostic Connector
DTC Diagnostic Trouble Code Diagnostic Code
DTM Diagnostic Test Mode --
ECL Engine Control Level --
ECM Engine Control Module Engine ECU (Electronic Control Unit)
ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW)
Electrically Erasable Programmable Read Only Memory
EEPROM Electrically Erasable Programmable Read Only Memory (EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV)
EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR)
EI Electronic Ignition TOYOTA Distributorless Ignition (TDI)
EM Engine Modification Engine Modification (EM)
EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)
EVAP Evaporative Emission Evaporative Emission Control (EVAP)
FC Fan Control --
Flash Electrically Erasable Programmable
FEEPROM --
Read Only Memory
FEPROM Flash Erasable Programmable Read Only Memory --

FF Flexible Fuel --
FP Fuel Pump Fuel Pump
GEN Generator Alternator
GND Ground Ground (GND)

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01--13
HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S)

IAC Idle Air Control Idle Speed Control (ISC)
IAT Intake Air Temperature Intake or Inlet Air Temperature
ICM Ignition Control Module --
IFI Indirect Fuel Injection Indirect Injection (IDL)
IFS Inertia Fuel--Shutoff --
ISC Idle Speed Control --
KS Knock Sensor Knock Sensor
MAF Mass Air Flow Air Flow Meter
Manifold Pressure
MAP Manifold Absolute Pressure
Intake Vacuum
Electric Bleed Air Control Valve (EBCV)
MC Mixture Control Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDP Manifold Differential Pressure --
MFI Multiport Fuel Injection Electronic Fuel Injection (EFI)
MIL Malfunction Indicator Lamp Check Engine Lamp
MST Manifold Surface Temperature --
MVZ Manifold Vacuum Zone --
NVRAM Non--Volatile Random Access Memory --
O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S)
OBD On--Board Diagnostic On--Board Diagnostic System (OBD)
OC Oxidation Catalytic Converter Oxidation Catalyst Convert (OC), CCo
OP Open Loop Open Loop
PAIR Pulsed Secondary Air Injection Air Suction (AS)
PCM Powertrain Control Module --
PNP Park/Neutral Position --
PROM Programmable Read Only Memory --
PSP Power Steering Pressure --
Diesel Particulate Filter (DPF)
PTOX Periodic Trap Oxidizer
Diesel Particulate Trap (DPT)
RAM Random Access Memory Random Access Memory (RAM)

RM Relay Module --
ROM Read Only Memory Read Only Memory (ROM)
RPM Engine Speed Engine Speed
SC Supercharger Supercharger
SCB Supercharger Bypass E--ABV
SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection
SPL Smoke Puff Limiter --
SRI Service Reminder Indicator --
SRT System Readiness Test --
ST Scan Tool --
TB Throttle Body Throttle Body
Single Point Injection
TBI Throttle Body Fuel Injection
Central Fuel Injection (Ci)
TC Turbocharger Turbocharger
TCC Torque Converter Clutch Torque Converter

TO MODEL INDEX
01--14
TCM Transmission Control Module Transmission ECU, ECT ECU

TP Throttle Position Throttle Position
TR Transmission Range --
Bimetallic Vacuum Switching Valve (BVSV)
TVV Thermal Vacuum Valve
Thermostatic Vacuum Switching Valve (TVSV)
Three--Way Catalytic (TWC)

TWC Three--Way Catalytic Converter Manifold Converter
CCRO
TWC+OC Three--Way + Oxidation Catalytic Converter CCR + CCo
VAF Volume Air Flow Air Flow Meter
VR Voltage Regulator Voltage Regulator
VSS Vehicle Speed Sensor Vehicle Speed Sensor
WOT Wide Open Throttle Full Throttle
WU--OC Warm Up Oxidation Catalytic Converter --
WU--TWC Warm Up Three--Way Catalytic Converter --
3GR Third Gear --
4GR Fourth Gear --

TO MODEL INDEX
PREPARATION
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--1
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--1
INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--2
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--2
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . 02--3
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--3/5
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--6
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--6
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--7
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--7/8
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--9
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--9
STARTING & CHARGING . . . . . . . . . . . . . . . . . 02--10
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--10/11

TO MODEL INDEX
02--1
PREPARATION -- FUEL
FUEL
022Q3--01
PREPARATION
Equipment
Brass brush
dial gauge
Injection nozzle tester
Torque wrench

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02--2
PREPARATION -- INTAKE
INTAKE
022Q4--01
PREPARATION
Recomended Tools
09200--00010 Engine Adjust Kit INTAKE MANIFOLD (J05C)
Equipment
Precision straight edge

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02--3
PREPARATION -- ENGINE MECHANICAL
ENGINE MECHANICAL
022PZ--01
PREPARATION
SST
09201--41020 Valve Stem Oil Seal Replacer CAMSHAFT HOUSING AND
CYLINDER HEAD(J05C)
09202--70020 Valve Spring Compressor CAMSHAFT HOUSING AND

CYLINDER HEAD(J05C)
09960--10010 Variable Pin Wrench Set CAMSHAFT HOUSING AND

CYLINDER HEAD(J05C)
(09962--01000) Variable Pin Wrench Arm Assy CAMSHAFT HOUSING AND

CYLINDER HEAD(J05C)
(09963--01000) Pin 10 CAMSHAFT HOUSING AND

CYLINDER HEAD(J05C)
S0940--21480 Press sub--Assy PISTON, CRANKSHAFT AND

CYLINDER BLOCK(J05C)
S0940--71030 Oil Seal Press CRANKSHAFT FRONT END, OIL

PAN, FLYWHEEL AND FLYWHEEL
HOUSING(J05C)
S0940--71040 Oil Seal Press CRANKSHAFT FRONT END, OIL

HOUSING(J05C)
S0942--01720 Sylinder liner puller PISTON, CRANKSHAFT AND

S0942--01731 Oil Seal Puller CRANKSHAFT FRONT END, OIL

HOUSING(J05C)
S0942--01742 Oil Seal Puller CRANKSHAFT FRONT END, OIL

HOUSING(J05C)
S0944--41630 Gauge PISTON, CRANKSHAFT AND


TO MODEL INDEX
02--4
S0947--21210 Bar CAMSHAFT HOUSING AND

CYLINDER HEAD(J05C)
S0947--21620 Tool PISTON, CRANKSHAFT AND

S0948--11170 Guide PISTON, CRANKSHAFT AND

S0948--11340 Guide CRANKSHAFT FRONT END, OIL

HOUSING(J05C)
S9001--24262 Check Bolt PISTON, CRANKSHAFT AND

S9800--06100 Steel Ball CAMSHAFT HOUSING AND

CYLINDER HEAD(J05C)
Recomended
09200--00010 Engine Adjust Kit CAMSHAF HOUSING AND CYL-
INDER HEAD
09905--00013 Snap Ring Pliers TIMING GEAR
SSM
08826--00080 Seal Packing Black or equivalent CAMSHAFT HOUSING AND CYL-
(FIPG) INDER HEAD
INTAKE MANIFOLD
CRANCKSHAFT FRONT END, OIL
HOUSING
08833--00070 ”Adhesive 1324,” TIMING GEAR
THREE BOND 1324 or equivalent
Equipment
Abrasive compound
Bolt
Connecting rod aligner
Cylinder gauge
Dial gauge
Dye penetrant
Heater

TO MODEL INDEX
02--5
Micrometer
Piston ring compressor
Piston ring expander
Press
Press Sliding hammer
Soft brush
Solvent
Spring tester
Steam cleaner
Steel square
Straight edge
Torch
Torque wrench
Valve guide bushing brush
Valve seat cutter
V--block
Vernier calipers
Wire brush

TO MODEL INDEX
02--6
PREPARATION -- EXHAUST
EXHAUST
022Q5--01
PREPARATION
Recomended Tools
09200--00010 Engine Adjust Kit EXHAUST MANIFOLD(J05C)
Equipment

TO MODEL INDEX
02--7
PREPARATION -- COOLING
COOLING
022Q6--01
PREPARATION
SST
09236--00101 Water Pump Overhaul Tool Set WATER PUMP ASSY(J05C)
(09236--15010) Bearing Stay WATER PUMP ASSY(J05C)
(09237--00020) Bearing Stay WATER PUMP ASSY(J05C)
(09237--00050) Shaft ”B” WATER PUMP ASSY(J05C)
09238--47012 Water Pump Bearing Remover & WATER PUMP ASSY(J05C)

Replacer
09950--50013 Puller C Set WATER PUMP ASSY(J05C)
(09951--05010) Hanger 150 WATER PUMP ASSY(J05C)
(09952--05010) Slide Arm WATER PUMP ASSY(J05C)
(09953--05010) Center Bolt 100 WATER PUMP ASSY(J05C)
(09954--05021) Claw No.2 WATER PUMP ASSY(J05C)
S0942--01820 Puller ASSY WATER PUMP ASSY(J05C)
Recomended Tools
09905--00013 Snap Ring Pliers WATER PUMP ASSY(J05C)

TO MODEL INDEX
02--8
PREPARATION -- COOLING
Equipment
Vernier calipers
Torque wrench

TO MODEL INDEX
02--9
PREPARATION -- LUBRICATION
LUBRICATION
022Q7--01
PREPARATION
Equipment
Dial gauge
Micrometer
Torque wrench
Vise

TO MODEL INDEX
02--10
PREPARATION -- STARTING & CHARGING
STARTING & CHARGING

022Q8--01
PREPARATION
SST
09285--76010 Injection Pump Camshaft Bearing GENERATOR ASSY(J05C)
Cone Replacer
09286--46011 Injection Pump Spline Shaft GENERATOR ASSY(J05C)

Puller
09820--00021 Alternator Rear Bearing Puller GENERATOR ASSY(J05C)
09820--00031 Alternator Rotor Rear Bearing GENERATOR ASSY(J05C)

Replacer
09820--63010 Alternator Pulley Set Nut Wrench GENERATOR ASSY(J05C)

Set
(09820--06010) Alternator Rotor Shaft Wrench GENERATOR ASSY(J05C)
(09820--06020) Alternator Pulley Set Nut 22 mm GENERATOR ASSY(J05C)

Wrench
09950--60010 Replacer Set STARTER ASSY(J05C)

GENERATOR ASSY(J05C)
(09951--00260) Replacer 26 STARTER ASSY(J05C)
(09951--00390) Replacer 39 STARTER ASSY(J05C)
(09952--06010) Adapter STARTER ASSY(J05C)
09950--70010 Handle Set GENERATOR ASSY(J05C)

TO MODEL INDEX
02--11
PREPARATION -- STARTING & CHARGING
(09951--00270) Replacer 27 GENERATOR ASSY(J05C)
(09951--07100) Handle 100 GENERATOR ASSY(J05C)
Recomended Tools
09082--00040 TOYOTA Electrical Tester STARTER ASSY
GENERATOR ASSY
Equipment
Cylinder indicator Commutator
Micro meter Starter clutch
Plastic hammer
Pull scale Brush spring
Sandpaper Commutator
Torque wrench
Vernier calipers Commutator, Brush, Rotor (Slip ring)
Vise

TO MODEL INDEX
SERVICE SPECIFICATIONS
STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . . 03--1
HOW TO DETERMINE BOLT STRENGTH . . . . 03--1
SPECIFIED TORQUE
FOR STANDARD BOLTS . . . . . . . . . . . . . . . . . 03--2
HOW TO DETERMINE NUT STRENGTH . . . . . 03--3
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--4
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--4
TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . 03--5
INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--6
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--6
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . 03--7
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--7/10
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--12
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--12
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--13
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--13
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--14
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--14
STARTING & CHARGING . . . . . . . . . . . . . . . . . 03--15
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--15

TO MODEL INDEX
03--1
SERVICE SPECIFICATIONS -- STANDARD BOLT
STANDARD BOLT
HOW TO DETERMINE BOLT STRENGTH 03096--07
Bolt Type
Hexagon Head Bolt Class
Stud Bolt Weld Bolt
Normal Recess Bolt Deep Recess Bolt
4 4T
No Mark No Mark No Mark
5 5T
6 6T
w/ Washer w/ Washer
7 7T
8 8T
9 9T
10 10T
11 11T
B06431

TO MODEL INDEX
03--2
03097--08
SPECIFIED TORQUE FOR STANDARD BOLTS

Specified torque
Diameter Pitch
Class Hexagon head bolt Hexagon flange bolt
mm mm
N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf
6 1 5 55 48 in.·lbf 6 60 52 in.·lbf
8 1.25 12.5 130 9 14 145 10
10 1.25 26 260 19 29 290 21
4T
12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 115 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 36 360 26
5T
12 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 -- -- --
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
6T
12 1.25 71 730 53 80 810 59
14 1.5 110 1,100 80 125 1,250 90
16 1.5 170 1,750 127 -- -- --
6 1 10.5 110 8 12 120 9

8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
7T
12 1.25 95 970 70 105 1,050 76
14 1.5 145 1,500 108 165 1,700 123
16 1.5 230 2,300 166 -- -- --
8 1.25 29 300 22 33 330 24

8T 10 1.25 61 620 45 68 690 50
12 1.25 110 1,100 80 120 1,250 90
8 1.25 34 340 25 37 380 27
9T 10 1.25 70 710 51 78 790 57
12 1.25 125 1,300 94 140 1,450 105
8 1.25 38 390 28 42 430 31
10T 10 1.25 78 800 58 88 890 64
12 1.25 140 1,450 105 155 1,600 116
8 1.25 42 430 31 47 480 35
11T 10 1.25 87 890 64 97 990 72
12 1.25 155 1,600 116 175 1,800 130

TO MODEL INDEX
03--3
03098--07
HOW TO DETERMINE NUT STRENGTH

Nut Type
Present Standard Old Standard Hexagon Nut Class
Hexagon Nut Cold Forging Nut Cutting Processed Nut
4N
No Mark
5N (4T)
No Mark (w/ Washer) No Mark (w/ Washer) No Mark
6N
6N
7N (5T)
8N
8N
10N (7T)
10N
No Mark
11N
11N
12N
12N
*: Nut with 1 or more marks on one side surface of the nut.

B06432
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more

TO MODEL INDEX
03--4
SERVICE SPECIFICATIONS -- FUEL
FUEL
031KA--01
SERVICE DATA
Pre--lift 0.097 to 0.133 mm (0.0044 to 0.0058 in.)
First opening pressure New nozzle 15.88 to 17.45 MPa (162 to 178 cm2, 2,300 to 2,528 psi)
Old nozzle 15.39 to 16.96 MPa (157 to 173 cm2, 2,229 to 2,457 psi)
Injection nozzle
Spray pattern
Shudders at a certain pumping speed New nozzle 30 to 60 times per minuite
Old nozzle 15 to 60 times per minuite

TO MODEL INDEX
03--5
SERVICE SPECIFICATIONS -- FUEL
030OA--03
TORQUE SPECIFICATION
Part tightened N·m kgf·cm ft·lbf
Nozzle retaining nut x Nozzle holder body 63.7 650 47
Adjust screw x Nuzzle holder cap nut 54 550 40

TO MODEL INDEX
03--6
SERVICE SPECIFICATIONS -- INTAKE
INTAKE
030NN--04
SERVICE DATA
Intake manifold Warpage Maximum 0.20 mm (0.0079 in.)

TO MODEL INDEX
03--7
SERVICE SPECIFICATIONS -- ENGINE MECHANICAL
ENGINE MECHANICAL
030NP--04
SERVICE DATA
Valve clearance at cold Intake 0.30 mm (0.012 in.)
Exhaust 0.45 mm (0.018 in.)
Timing gear Main idler gear

Outside diameter of main idler gear shaft STD 56.94 to 56.97 mm (2.2422 to 2.2430 in.)
Inside diameter of main idler gear bushing STD 57.00 to 57.03 mm (2.2441 to 2.2453 in.)
Oil clearance between bushing and shaft STD 0.030 to 0.090 mm (0.0012 to 0.0035 in.)
Maximum 0.20 mm (0.0079 in.)
Thrust clearance STD 0.114 to 0.160 mm (0.0045 to 0.0063 in.)
Maximum 0.30 mm (0.0118 in.)
Sub idler gear

Outside diameter of sub idler gear shaft STD 49.950 to 49.975 mm (1.9665 to 1.9675 in.)
Inside diameter of sub idler gear STD 50.000 to 50.025 mm (1.9685 to 1.9695 in.)
Maximum 0.20 mm (0.0079 in.)
Maximum 0.30 mm (0.0118 in.)
Camshaft idler gear

Outside diameter of camshaft idler gear shaft STD 33.950 to 33.975 mm (1.3366 to 1.3376 in.)
Minimum 33.80 mm (1.3307 in.)
Inside diameter of camshaft idler gear STD 34.000 to 34.015 mm (1.3386 to 1.3392 in.)
Maximum 34.02 mm (1.3394 in.)
Maximum 0.20 mm (0.0079 in.)
Maximum 0.30 mm (0.0118 in.)
Backlash
Crankshaft gear x Main idler gear STD 0.030 to 0.167 mm (0.0012 to 0.0064 in.)
Maximum 0.30 mm (0.0118 in.)
Main idler gear x Injection pump drive gear STD 0.030 to 0.218 mm (0.0012 to 0.0086 in.)
Maximum 0.30 mm (0.0118 in.)
Injection pump drive gear x PS pump gear STD 0.030 to 0.183 mm (0.0012 to 0.0072 in.)
Maximum 0.30 mm (0.0118 in.)
Main idler gear x Sub idler gear STD 0.030 to 0.162 mm (0.0012 to 0.0064 in.)
Maximum 0.30 mm (0.0118 in.)
Sub idler gear x Oil pump gear STD 0.030 to 0.131 mm (0.0012 to 0.0052 in.)
Maximum 0.30 mm (0.0118 in.)
Sub idler gear x Camshaft idler gear STD 0.030 to 0.303 mm (0.0012 to 0.0119 in.)
Maximum 0.30 mm (0.0118 in.)
Camshaft timing gear x Camshaft idler gear STD 0.028 to 0.168 mm (0.0011 to 0.0066 in.)
Maximum 0.30 mm (0.0118 in.)
Sub idler gear x Vacuum pump gear STD 0.029 to 0.187 mm (0.0011 to 0.0074 in.)
Maximum 0.30 mm (0.0118 in.)
Cyliner head Warpage STD 0.04 mm (0.0016 in.) or less for longitudinal direction
0.03 mm (0.0012 in.) or less for lateral direction
Cylinder head bolt Length (Bolt number position: See page 14--2)
Maximum No. 1, 2, 7, 8, 9, 10, 15, 16, 17 126.5 mm (4.9803 in.)
No. 4, 5, 12, 13 156.5 mm (6.1614 in.)
No. 3, 6, 11, 14, 18 187.5 mm (7.3819 in.)

TO MODEL INDEX
03--8
Valve Valve seat angle Intake 30˚00’ to 30˚15’

Exhaust 45˚00’ to 45˚15’
Valve face angle Intake 29˚30’ to 30˚00’
Exhaust 44˚45’ to 45˚00’
Valve sink dimension STD Intake 0.55 to 0.85 mm (0.0217 to 0.0335 in.)
Exhaust 1.30 to 1.60 mm (0.0512 to 0.0630 in.)
Maximum Intake 1.10 mm (0.0433 in.)
Exhaust 1.85 mm (0.0728 in.)
Valve stem diameter STD Intake 6.957 to 6.977 mm (0.2739 to 0.2747 in.)
STD Exhaust 6.957 to 6.977 mm (0.2739 to 0.2747 in.)
Minimum Intake 6.92 mm (0.2724 in.)
Exhaust 6.84 mm (0.2693 in.)
Valve stem oil clearance STD Intake 0.023 to 0.058 mm (0.0010 to 0.0022 in.)
Maximum Intake 0.12 mm (0.0047 in.)
Exhaust 0.15 mm (0.0059 in.)
Valve spring Deviation Maximum 2.0 mm (0.079 in.)

Free length STD Inner 64.6 mm (2.543 in.)
Outer 75.7 mm (2.980 in.)
Minimum Inner 61.6 mm (2.425 in.)
Outer 72.7 mm (2.862 in.)
Installed tension Inner at 44.8 mm (1.764 in.) 128.5 N (13.1 kgf, 28.9 lb)
Outer at 46.8 mm (1.843 in.) 313.8 N (32.0 kgf, 70.5 lb)
Manifold Warpage Maximum 0.20 mm (0.0079 in.)

Camshaft Cam lobe height STD Intake 51.328 mm (2.0208 in.)
Exhaust 52.185 mm (2.0549 in.)
Minimum Intake 51.248 mm (2.0176 in.)
Exhaust 52.115 mm (2.0518 in.)
Journal diameter STD 39.959 to 39.975 mm (1.5732 to 1.5738 in.)
Minimum 39.85 mm (1.5689 in.)
Inside diameter of camshaft bearing STD 40.00 mm (1.5748 in.)
Maximum 40.15 mm (1.5807 in.)
Oil clearance STD 0.020 to 0.063 mm (0.0008 to 0.0024 in.)
Maximum 0.010 mm (0.0039 in.)
Circle runout Maximum 0.10 mm (0.0039 in.)
Maximum 0.30 mm (0.0118 in.)
Camshaft gear Length 30.0 mm (1.181 in.)
bolt
Valve rocker arm Valve rocker arm bushing inside diameter STD 22.00 to 22.050 mm (0.8661 to 0.8681 in.)
and shaft Maximum 22.08 mm (0.8693 in.)
Valve rocker arm shaft outside diameter STD 21.959 to 21.980 mm (0.8645 to 0.8654 in.)
Minimum 21.92 mm (0.8630 in.)
Oil clearance STD 0.030 to 0.101 mm (0.0012 to 0.0040 in.)
Maximum 0.15 mm (0.0059 in.)
Injection nozzle Protrusion STD 2.25 to 2.75 mm (0.0886 to 0.1083 in.)
Maximum 2.75 mm (0.1083 in.)
Connecting rod Rod bent Maximum per 100 mm (3.94 in.) 0.05 mm (0.0020 in.)
Rod twist Maximum per 100 mm (3.94 in.) 0.05 mm (0.0020 in.)
Bushing inside diameter STD 37.00 mm (1.4567 in.)
Maximum 37.10 mm (1.4606 in.)
Bushing oil clearance STD 0.015 to 0.036 mm (0.0006 to 0.0014 in.)
Maximum 0.08 mm (0.0031 in.)
Rod big end inside diameter (w/o bearing) STD 68.985 to 69.000 mm (2.7159 to 2.7165 in.)
Maximum 69.06 mm (2.7189 in.)
Rod big end inside diameter (w/ bearing) STD 64.985 to 65.000 mm (2.5585 to 2.5591 in.)
Maximum 65.06 mm (2.5614 in.)
Rod big end oil clearance STD 0.031 to 0.082 mm (0.0012 to 0.0032 in.)
Maximum 0.20 mm (0.0079 in.)
Maximum 1.00 mm (0.0393 in.)

TO MODEL INDEX
03--9
Connecting rod Length 82.5 mm (3.2480 in.)

bolt
Piston and piston Piston pin diameter STD 36.989 to 37.000 mm (1.4563 to 1.4567 in.)
ring Minimum 36.96 mm (1.4551 in.)
Piston diameter STD 113.920 to 113.944 mm (4.4850 to 4.4859 in.)
Minimum 113.920 mm (4.4860 in.)
Piston oil clearance STD 0.056 to 0.080 mm (0.0022 to 0.0031 in.)
Maximum 0.15 mm (0.0059 in.)
Piston pin boss inside diameter STD 36.987 to 37.003 mm (1.4562 to 1.4568 in.)
Minimum 37.05 mm (1.4587 in.)
Clearance between piston pin boss and piston pin STD 0.013 (T) to 0.014 (L) mm (0.0051 (T) to 0.0055 (L) in.)
Maximum to0.05 mm (to0.0020 in.)
Piston ring groove width STD 1st 2.55 to 2.57 mm (0.1004 to 0.1012 in.)
2nd 2.03 to 2.05 mm (0.0799 to 0.0807 in.)
Oil 4.01 to 4.03 mm (0.1579 to 0.1586 in.)
Maximum 1st 2.70 mm (0.1063 in.)
2nd 2.20 mm (0.0866 in.)
Oil 4.10 mm (0.1614 in.)
Piston ring thickness STD 1st 2.47 to 2.49 mm (0.0972 to 0.0980 in.)
2nd 1.97 to 1.99 mm (0.0776 to 0.0783 in.)
Oil 3.97 to 3.99 mm (0.1563 to 0.1571 in.)
2nd 1.90 mm (0.0748 in.)
Oil 3.90 mm (0.1535 in.)
Piston ring groove clearance STD 1st 0.06 to 0.10 mm (0.0024 to 0.0039 in.)
2nd 0.04 to 0.08 mm (0.0016 to 0.0031 in.)
Oil 0.02 to 0.06 mm (0.0008 to 0.0023 in.)
2nd 0.30 mm (0.0118 in.)
Oil 0.20 mm (0.0079 in.)
OilPiston ring end gap STD 1st 0.30 to 0.40 mm (0.0118 to 0.0157 in.)
2nd 0.50 to 0.65 mm (0.0197 to 0.0255 in.)
Oil 0.15 to 0.30 mm (0.0059 to 0.0118 in.)
2nd 1.20 mm (0.0472 in.)
Oil 1.20 mm (0.0472 in.)
Crankshaft Crank pin diameter STD 64.940 to 64.960 mm (2.5567 to 2.5575 in.)
Minimum 63.80 mm (2.5118 in.)
Circle runout Maximum 0.15 mm (0.0059 in.)
Main journal diameter STD 79.94 to 79.96 mm (3.1472 to 3.1480 in.)
Minimum for repair 79.80 mm (3.1417 in.)
for use 78.80 mm (3.1024 in.)
Main journal oil clearance STD 0.051 to 0.102 mm (0.0020 to 0.0040 in.)
Maximum 0.20 mm (0.0079 in.)
Maximum 0.50 mm (0.0197 in.)
Cylinder block Warpage STD 0.05 mm (0.0020 in.) or less

Maximum 0.20 mm (0.0079 in.)
Main bearing bore diameter (w/o bearing) STD 84.985 to 85.000 mm (3.3459 to 3.3465 in.)
Maximum 85.20 mm (3.3543 in.)
Main bearing bore diameter (w/ bearing) STD 80.00 mm (3.1496 in.)
Maximum 80.30 mm (3.1614 in.)
Main bearing cap Length STD 106.80 mm (4.2047 in.)
bolt Maximum 108.00 mm (4.2520 in.)

TO MODEL INDEX
03--10
Cylinder liner
Protrusion STD 0.01 to 0.007 mm (0.0004 to 0.0028 in.)

Maximum 0.08 mm (0.0031 in.)
Inside diameter
STD 113.988 to 114.012 mm (4.4877 to 4.4887 in.)
Maximum 114.15 mm (4.4941 in.)
Flywheel Grind limit 1.00 mm (0.0394 in.)

Maximum deflection 0.04 mm (0.0016 in.)
Warpage STD 0.05 mm (0.0020 in.) or less
Maximum 1.00 mm (0.0394 in.)
Sliding surface play Maximum 0.15 mm (0.0059 in.)

TO MODEL INDEX
03 -- 11
030O8--04
Rear end plate bolt 55 560 41
Oil pump x Cylinder block 28.5 290 21
Sub idler gear shaft x Cylinder block 108 1,100 80
Main idler gear shaft x Cylinder block 172 1,750 127
Camshaft gear x Camshaft 59 + 90˚ 600 + 90˚ 44 + 90˚
Camshaft idler gear shaft x Cylinder head 108 1,100 80
Cylinder head x Cylinder block (Bolt number position: See page 14--2)
M12 bolt No. 1, 2, 7, 8, 9, 10, 15, 16, 17 59 + 90˚ + 90˚ 600 + 90˚ + 90˚ 44 + 90˚ + 90˚
No. 4, 5, 12, 13 59 + 90˚ + 135˚ 600 + 90˚ + 135˚ 44 + 90˚ + 135˚
No. 3, 6, 11, 14, 18 59 + 90˚ + 180˚ 600 + 90˚ + 180˚ 44 + 90˚ + 180˚
M10 bolt No. 19, 20, 21 59 600 44
Camshaft bearing cap x Cylinder head 31 320 23
Valve rocker support x Cylinder head 28.5 290 21
Valve rocker arm x Adjusting screw 25 250 18
Valve bridge x Valve bridge adjusting screw 25 250 18
Injection nozzle clamp bolt 25 250 18
Injection pipe nut (both end nipples) 34.3 350 25
Heater plug 25 250 18
Cylinder head cover x Cylinder head 28.5 290 21
Oil jet x Cylinder block 22 220 16
Main bearing cap x Cylinder block 1st 69 700 51

2nd Loosen Loosen Loosen
3rd 69 + 90˚ + 45˚ 700 + 90˚ + 45˚ 51 + 90˚ + 45˚
Connecting rod cap x Connecting rod 69 + 90˚ + 45˚ 700 + 90˚ + 45˚ 43 + 90˚ + 45˚
Flywheel x Crankshaft 1st 186 1,900 137

2nd Loosen Loosen Loosen
3rd 186 1,900 137
Oil pan bolt 28.5 290 21
Crankshaft pulley x Crankshaft 118 1,200 87
Drain plug 41 420 30

TO MODEL INDEX
03--12
SERVICE SPECIFICATIONS -- EXHAUST
EXHAUST
030O3--03
SERVICE DATA
Exhaust manifold Warpage Maximum 0.20 mm (0.0079 in.)

TO MODEL INDEX
03--13
SERVICE SPECIFICATIONS -- COOLING
COOLING
030O4--05
SERVICE DATA
Water Pump Water Pump bearing Dimension 5 mm (0.20 in.)
Water Pump pulley Dimension 14.2 mm (0.56 in.)
Thermostat Valve opening temperature Standard 74.5 to 78.5˚C (166 to 173˚F)

Valve lift at 90˚C (194˚F) 10 mm (0.39 in.) or more

TO MODEL INDEX
03--14
SERVICE SPECIFICATIONS -- LUBRICATION
LUBRICATION
030O5--05
SERVICE DATA
Oil pump Backlach Standard 0.073 to 0.207 mm (0.0029 to 0.0081 in.)
Maximum 0.30 mm (0.0118 in.)
Shaft diameter Driven gear shaft 18.00 mm (0.7087 in.)
Inside diameter Driven gear bush 18.00 mm (0.7087 in.)
Driven gear clearance Standard 0.040 to 0.083 mm (0.0016 to 0.0032 in.)
Minimum 0.15 mm (0.0059 in.)
Oil cooler Oil cooler element Test pressure 59 N⋅m (6 kgf/ cm2, 85.3 psi)
Test time 1 minute

TO MODEL INDEX
03--15
SERVICE SPECIFICATIONS -- STARTING & CHARGING
STARTING & CHARGING

030O6--03
SERVICE DATA
Starter Commutator
Diameter Standard 32.0 mm (1.260 in.)
Minimum 30.0 mm (1.181 in.)
Undercut depth Standard 0.7 mm (0.028 in.)
Brash length Standard 18.0 mm (0.709 in.)
Spring installed load Standard 42.2 to 51.0 N (4.3 to 5.2 kgf, 9.3 to 11.2 lbf)
Minimum 22.5 N (2.3 kgf, 4.9 lbf)
Magnetic switch
Resistance (M -- C) Standard 0.16 to 0.19 Ω
Resistance (M -- body) Standard 0.84 to 0.94 Ω
Starter clutch
Outside diameter Standard: A 26.0 mm (1.024 in.)
Standard: B 12.1 mm (0.476 in.)
Minimum: A 25.88 mm (1.019 in.)
minimum: B 12 mm (0.472 in.)
Starter drive housing
Inside diameter Standard 26 mm (1.024 in.)
Minimum 26.2 mm (1.031 in.) or more
Starter motor housing
Inside diameter Standard 12.1 mm (0.476 in.)
Minimum 12.3 mm (0.484 in.) or more
Commutator end frame
Inside diameter Standard 12 mm (0.472 in.)
Alternator Rotor coil resistance at 20˚C (68˚F) Open circuit 11.8 to 12.2 Ω
Ground 10 MΩ at more
Slip ring diameter Standard 14.2 to 14.4 mm (0.559 to 0.567 in.)
Brush exposed length Standard 9.5 to 11.5 mm (0.374 to 0.453 in.)
Voltage regulator Regulating voltage at 115˚C (239˚F) 27.7 to 28.7 V

TO MODEL INDEX
03--16
SERVICE SPECIFICATIONS -- STARTING & CHARGING
030O7--03
Motor housing x Starter drive housing 15 153 11
Magnetic switch x Starter drive housing 14.7 150 11
Commutator end frame x Starter drive housing 14.7 150 11
Commutator end frame x Brush holder 4.3 44 38 in.·lbf
Bearing retainer x Drive end frame 2.0 30 26 in.·lbf
Rectifier end frame with cord clip x Drive end frame Nut A 4.5 46 40 in.·lbf
Nut B 5.4 55 48 in.·lbf
Alternator pulley x Rotor 110.5 1,125 81

Generator holder w/ rectifier x Rectifier end frame 2.94 30 26 in.·lbf
Voltage regulator x Rectifier end frame 2.0 20 18 in.·lbf
Generator brush holder assy x Voltage regurator 2.0 20 18 in.·lbf
Rear end cover x Rectifier end frame Nut 4.4 45 39 in.·lbf

Bolt 3.85 39 34 in.⋅lbf
Terminal insulator x Rectifier holder 4.1 42 36 in.·lbf

TO MODEL INDEX
FUEL
NOZZLE HOLDER AND NOZZLE SET
(J05C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--1
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--1
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--2/6

TO MODEL INDEX
11--1
FUEL -- NOZZLE HOLDER AND NOZZLE SET (J05C)
NOZZLE HOLDER AND NOZZLE SET (J05C)

110JO--02
COMPONENTS
Nozzle Holder Body
Second Pressure Adjusting Shim
Joint Bolt
Nozzle Holder Cap Nut z Gasket
Pre--Lift Adjusting Shim
Second Pressure Spring z Gasket
Nozzle Assy Adjusting Screw

Spring Seat
First Pressure Spring
Push Rod
63.7 (650, 47)
Nozzle Retaining Nut
N⋅m (kgf⋅cm, ft⋅lbf) : Specified Torque

z Non--Reusable Part A84877

TO MODEL INDEX
11--2
110W1--01
OVERHAUL
1. REMOVE NOZZLE ASSY
(a) Remove the nozzle holder retaining nut.
NOTICE:
When disassembling the nozzle, be careful not to drop the
inner parts.
(b) Disassemble the nozzle holder and nozzle set, and re-
move the nozzle assy.
A71018
2. CLEAN NOZZLE ASSY

(a) In order to clean the nozzle, use a wooden stick and brass
brush. Wash them in clean diesel fuel.
HINT:
Do not touch the nozzle mating surfaces with your fingers.
A71019
(b) Using a wooden stick, remove the carbons adhering to

the nozzle needle tip.
A71020
(c) Using a brass brush, remove the carbons from the exteri-
or of the nozzle body (except lapped surface).
A71021

TO MODEL INDEX
11--3
(d) Check the seat of the nozzle body for burns or corrosion.
(e) Check the nozzle needle tip for damage or corrosion.
If any of these conditions are present, replace the nozzle assy.
A71022
3. INSPECT NOZZLE ASSY

1/3 Of Its Length (a) Wash the nozzle in clean diesel fuel.
HINT:
Do not touch the nozzle mating surfaces with your fingers.
(b) Tilt the nozzle body about 60 degrees and pull the needle
out about 1/3 of its length.
60_
(c) When released, the needle should fall into the body vent
smoothly by its own weight.
A74295
(d) Repeat this inspection, rotating the needle slightly each

time. If the needle does not fall smoothly, replace the
nozzle assy.
A71024
4. CHECK AND ADJUST PRE--LIFT

Spring Seat It is necessary to clean each part to avoid a measurement error
Spacer (G) (F) caused by a foreign object or something whenever an adjust-
ment is done.
Nozzle (1) Replace the nozzle assembly D, and then install the
assembly spring seat F and spacer G.
(D)
(2) Turn the tip of nozzle retaining nut upward, and then
put the nozzle assembly on the nozzle retaining nut
which will be used as a pedestal.
Retaining
Nut
B72171

TO MODEL INDEX
11--4
Spring Seat (F) (3) Apply a dial gauge onto the upper end of spring seat
F and make it 0 point. This time, the shim for an ad-
0 Point
justment of the pre--lift should be removed before-
hand.
Nozzle Needle
B72170
Pre--Lift (4) Assemble the shim E for an adjustment of the pre--

lift that has been set when disassembled, and then
Sh im measure the pre--lift.
(E)
If the pre--lift is not as specified below, select the shim for an ad-
Pre--Lift justment of the pre--lift and then adjust the amount of the pre--
lift.
PRE--LIFT:
0.097 to 0.133 mm (0.0044 to 0.0058 in.)
B72169 Adjusting shim:Thick shims = increase the pre--lift
Thin shims = decrease the pre--lift
NOTICE:
S The thicker the shim be, the more the pre--lift be.
S The thinner the shim be, the less the pre--lift be.
5. ADJUSTMENT OF FIRST OPENING PRESSURE

Second Pressure
Adjusting Shim Nozzle Holder (a) Attach the second opening pressure adjusting shim, se-
Second cond pressure spring and adjusted parts of the bottom of
Pressure the nozzle holder.
Spring Seat Spring
(b) Using a wrench, tighten the retaining nut.
Pre--Lift Nozzle
Adjusting Shim NOTICE:
Assembly
S Adjust the first opening pressure. Then the second
Retaining opening pressure is adjusted at the same time.
Nut
B72166 S Exchange parts is nozzle assembly and opening
pressure adjusting shim. Do not exchange other
parts.
Torque: 64 N·m (650 kgf·cm2, 47 ft·lbf)
(c) Insert the push rod and first pressure spring to the nozzle
Cap Nut holder body. Tighten the adjusting screw.
Gasket (d) Assemble the new gasket, tighten temporarily the cap
Adjusting Screw nut.
First Pressure Spring
Push Rod
Nozzle Holder
B72165

TO MODEL INDEX
11--5
Nozzle Hand (e) Mount the above stated nozzle holder on the nozzle hand
Tester tester to determine the pressure at the start of injection.
This value is used as the first opening pressure. The ad-
justing screw is tightened or loosened to keep this value
within a set range.
First opening pressure:
Old Nozzle 15.39 to 16.96 kPa (157 to 173 kgf/ cm2, 2.229 to 2.457 psi)
New Nozzle 15.88 to 17.45 kPa (162 to 178 kgf/ cm2, 2.300 to 2.528 psi)
B72167 HINT:
Tightening the adjusting screw ... increases pressure
Loosening the adjusting screw ...decreases pressure
(f) After adjustment, a gasket is installed and the cap nut is
tightened down to anchor the adjusting screw.
Cap Nut
NOTICE:
Gasket Make sure that the adjusting screw does not turn at the
Adjusting Screw same time.
Torque: 54 N·m (550 kgf·cm2, 40 ft·lbf)
B72168
6. INSTALL NOZZLE ASSY

(a) Assemble the nozzle holder body, adjusting shim, capsule sub--assembly, adjusting shim, No. 1 pres-
sure spring, distance piece, 2 straight pins and nozzle sub--assembly, and finger--tighten the retainer
nut.
HINT:
S Align the holes of the nozzle body, distance piece and nozzle holder body.
S When the thickness of the originally used adjusting shim is unclear, use a shim with 1.5 mm (0.56 in.)
thickness instead.
(b) Using a 19 mm deep socket wrench, tighten the retaining
nut.
Deep Torque: 63.7 N⋅m (650 kgf⋅cm, 47 ft⋅lbf)
Socket NOTICE:
Over--torquing could cause the nozzle deformation and the
needle adhesion or other defects.
A71025

TO MODEL INDEX
11--6
7. INSPECT NOZZLE HOLDER AND NOZZLE SET

(a) Check for leaks.
(1) While maintaining pressure at the value equal to the
difference between the No.1 opening pressure and
value A, check that there is no dripping from the in-
jection hole or around the retaining nut for 10 se-
conds.
Good Faulty No.1 Opening Pressure:
A74296 Old Nozzle 15.39 to 16.96 kPa (157 to 173 kgf/ cm2, 2,229 to 2,457 psi)
New Nozzle 15.88 to 17.45 kPa (162 to 178 kgf/ cm2, 2,300 to 2,528 psi)
Value A:
981 to 1961 kPa (10 to 20 kgf/ cm2, 142 to 284 psi)
If there is dripping within 10 seconds, replace the nozzle assy
or clean and overhaul it.
(b) Check the spray pattern.

(1) The injection nozzle shudders at a certain pumping
speed.
Standard:
Old Nozzle 15 to 60 times per minute
New Nozzle 30 to 60 times per minute
(2) Check the spray pattern while the injection nozzle
Good Faulty Faulty Faulty is shuddering.
A74297 If the injection nozzle has faulty spray pattern while shuddering,
replace or clean the nozzle.

TO MODEL INDEX
INTAKE
INTAKE MANIFOLD (J05C) . . . . . . . . . . . . . . . 13--1
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--1

TO MODEL INDEX
13--1
INTAKE -- INTAKE MANIFOLD (J05C)
INTAKE MANIFOLD (J05C)

1305Z--02
INSPECTION
1. INSPECT INTAKE MANIFOLD
HINT:
Clean the intake manifold with a commercial cleaning agent be-
fore the inspection.
(a) Using a dye penetrate, check the intake manifold for
cracks.
If cracks are found, replace the manifold.
A84792
(b) Using a precision straight edge and feeler gauge, mea-

sure the surface touching the cylinder head for warpage.
Maximum warpage: 0.20 mm (0.0079 in.)
If warpage is greater than the maximum, replace the intake
manifold.
(c) Visually check the seal surface of the intake manifold for
deformation or wear.
If damage such as deformation and wear is excessive, replace
A84793 the manifold.

TO MODEL INDEX
ENGINE MECHANICAL
CAMSHAFT HOUSING
AND CYLINDER HEAD (J05C) . . . . . . . . . . . 14--1
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 14--1
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14--2/23
CRANKSHAFT FRONT END, OIL PAN,
FLYWHEEL AND FLYWHEEL HOUSING
(J05C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14--24
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 14--24/26
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14--27/34
TIMING GEAR (J05C) . . . . . . . . . . . . . . . . . . . . 14--35
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 14--35
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14--36/41
PISTON, CRANKSHAFT
AND CYLINDER BLOCK (J05C) . . . . . . . . . 14--42
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 14--42
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14--43/62

TO MODEL INDEX
14--1
ENGINE MECHANICAL -- CAMSHAFT HOUSING AND CYLINDER HEAD (J05C)
CAMSHAFT HOUSING AND CYLINDER HEAD (J05C)

140X0--02
COMPONENTS
Oil Filler Cap

28.5 (290, 21)
Cylinder Head Cover

Spacer Sub--assy
z Gasket
Camshaft
Camshaft Bearing
Timing Gear 59 (600, 44) + 90_
Valve Rocker Shaft
Knock Pin
Camshaft
25 (250, 18)
28.5 (290, 21) Valve Rocker Support

Valve Rocker Arm
Valve Bridge Adjusting Screw

Lock Nut 25 (250, 18) See Page 14-- 2
Adjusting Screw Valve Bridge 59 (600, 44) + 90_+ 90_or 135_or 180_
Valve Spring Retainer

Valve Spring Seat Upper
Valve Spring Outer 25 (250, 18)
Valve Spring Inner
Valve Spring seat Lower 31 (320, 23)
Plug
z Valve Stem Seal
Valve Plug
Cylinder Head
Sub--assy
z Gasket
Heater Plug
N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque

TO MODEL INDEX
14--2
140X1--02
OVERHAUL
1. REMOVE CYLINDER HEAD COVER SUB--ASSY
NOTICE:
Thoroughly clean the cylinder head cover before removing
it to prevent foreign particles from getting in.
A84810
2. REMOVE INJECTION PIPE SET

(a) Loosen the 8 union nuts on the 4 injection pipe set.
(b) remove the 2 union bolts.
NOTICE:
After removing the fuel pipe, put it in a plastic bag and bind
the opening bag with a rubber band to prevent foreign ob-
jects from getting on the injection nozzle inlet.
A84811
3. REMOVE NOZZLE LEAKAGE PIPE NO.1

(a) Remove the 5 joint bolts, fuel return pipe and 5 gaskets.
A83819
4. REMOVE INJECTION NOZZLE SUB--ASSY

(a) Loosen the injection pipe nut.
(b) Remove the injection pipe seal together with the injection
pipe from the cam housing.
(c) Remove the nozzle clamp bolt.
(d) Pull out the nozzle holder assembly, avoiding any interfer-
ence.
A70961

TO MODEL INDEX
14--3
(e) Remove the O--ring.

NOTICE:
O--ring Replace the O--rings with a new one.
Nozzle Holder
Assembly
A70960
5. LOOSEN VALVE CLEARANCE ADJUSTING SCREW

(a) Loosen the lock nut at the top of the rocker arm, then wind
up the adjusting screw completely.
Lock Nut HINT:
Adjusting Screw If the adjusting screw is left unwound, the rocker shaft may bend
when the rocker arm support is loosened.
A83820
Rocker Arm Support 6. REMOVE VALVE ROCKER ARM ASSY

(a) Remove the rocker arm support bolts in the order as
shown in the illustration.
(b) Remove the valve bridge.
NOTICE:
When the rocker arm assembly is removed, be careful that
the rocker arm and support do not come off the rocker
shaft.
A83821
7. REMOVE CAMSHAFT
(a) Remove the cam bearing cap bolt.
(b) Remove the camshaft together with the gear.
NOTICE:
Be extremely careful not to drop any part into the interior of the engine.
8. REMOVE CYLINDER HEAD SUB--ASSY
(a) Remove the cylinder head bolts in the order as shown in
the illustration.
(b) Lift the cylinder head and remove it from the cylinder the
block.
A60050

TO MODEL INDEX
14--4
NOTICE:
S Place a piece of wood between the cylinder head and
table.
S When removing the cylinder head together with the
injection nozzle, be careful that the injection nozzle
does not touch the piece of wood.
S Check that there is no oil, water or gas leakage in the
cylinder head gasket if overheated or not.
A16376
A16082 A83822
9. REMOVE CAMSHAFT TIMING GEAR

(a) Using SST, remove the timing gear.
SST 09960--10010 (09962--01000, 09963--01000)
SST
A63492
10. REMOVE CAMSHAFT IDLER GEAR

(a) Remove the idler shaft bolt
(b) Remove the idler gear together with a snap ring from the cylinder head
11. REMOVE VALVE
SST
(a) Using SST, compress the valve spring, then remove the
valve spring retainer.
SST 09202--70020
A64525

TO MODEL INDEX
14--5
(b) Remove the valve spring seat upper, valve spring outer
and inner.
(c) Remove the intake and exhaust valves from the cylinder
head.
NOTICE:
S Do not remove the valve guide and valve spring seat
lower unless they need to be replaced.
S Align the removed parts in the order of the cylinder
A63493 No.
12. CLEAN CYLINDER HEAD SUB--ASSY

(a) Remove the gasket material.
(1) Using a gasket scraper, remove all the gasket mate-
rial from the cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(b) Clean the intake and exhaust ports.
A63449 (1) Using a wire brush, remove all the carbons and dust
from the intake and exhaust ports.
NOTICE:
Be careful not to scratch the valve contact surface.
(c) Clean the valve guide.
(1) Using a valve guide brush and solvent, thoroughly
clean the valve guide.
(d) Clean the cylinder head.
(1) Using a soft brush and solvent, thoroughly clean the
cylinder head.
13. INSPECT CYLINDER HEAD SUB--ASSY
(a) Inspect for cracks.
(1) Using a dye penetrant, check the intake ports, ex-
haust ports and the surface touching the cylinder
block.
If cracks are found, replace the cylinder head.
A63451

TO MODEL INDEX
14--6
(b) Inspect for flatness.

(1) Using a precision straight edge and a feeler gauge,
measure warpage of the surfaces that touch the cyl-
inder block and the manifolds.
Standard warpage:
Longitudinal direction 0.04 mm (0.0016 in.) or less
Lateral direction 0.03 mm (0.0012 in.) or less
If the warpage is greater than the maximum, replace the cylin-

der head.
A63450
14. CLEAN VALVE

(a) Using a gasket scraper, chip off any carbons from the
valve head.
(b) Using a wire brush, thoroughly clean the valve.
A63452
15. INSPECT VALVE

(a) Visually check the valves for damage, burns, carbons or
warpage, and check the valve heads, valve stems and
valve stem grooves for cracks.
If wear, burns, warpage or cracks are excessive, replace the
valves.
(b) Check the valve seating condition.
(1) Lightly apply red lead marking compound to the
A63494 valve face.
(2) Tap and rotate the valve against the seat.
(3) Check the seating condition of the valve face and
valve seat.
When the red lead mark is not concentric or the compound is
scattered all around the valve face or seat, correct the valve
face or the valve seat.

TO MODEL INDEX
14--7
16. REPAIR VALVE SEAT

(a) Grind the valve and seat.
HINT:
S Grinding of valves should only be performed when hand--
lapping, does not result in proper seating.
S When hand--lapping, always recheck the seating condi-
tion.
CAUTION:
When grinding, metal particles tip may fly off on impact.
Wear safety glasses to protect your eyes.
Valve seat angle:
Intake 30˚00’ to 30˚15’
Exhaust 45˚00’ to 45˚15’
Valve face angle:

Intake 29˚30’ to 30˚00’
30˚ 45˚
Exhaust 44˚45’ to 45˚00’
Intake Exhaust
A16293
A16206 A63496
(b) Hand--lap the valve and valve seat.

(1) Lightly apply lapping compound to the valve face.
Tap and rotate the valve against the seat.
HINT:
S After hand--lapping, remove any lapping compound from
the valves and valve seats.
S When hand--lapping, always recheck the seating condi-
tion.
A63495
17. REMOVE VALVE SEAT

Block Brass
Hammer (a) Cut the 3 places on the circumference of an unwanted
Valve Seat
valve and weld it to the valve seat.
NOTICE:
To protect the lower surface of the cylinder head from weld-
Electric welding
Valve ing spatters, be sure to apply grease before welding.
applied
Grind this point (b) Place a block brass on the top of the valve stem and strike
with a grinder it with a hammer to remove the valve seat.
A63497 CAUTION:
When striking, metal particles may fly off on impact. Wear
safety glasses to protect your eyes.

TO MODEL INDEX
14--8
18. INSTALL VALVE SEAT

(a) Machine the valve seat according to the tables below.
Cylinder head dimension:
Intake (A) 41.000 to 41.016 mm (1.6142 to 1.6148 in.)
Intake (B) 9.400 to 9.600 mm (0.3701 to 0.3780 in.)
Exhaust (A) 39.000 to 39.016 mm (1.5354 to 1.5361 in.)
C C Exhaust (B) 8.600 to 8.800 mm (0.3386 to 0.3465 in.)

Intake Exhaust Valve seat dimension:
A63498
Intake (C) 41.085 to 41.100 mm (1.6175 to 1.6181 in.)
Intake (D) 7.000 to 7.200 mm (0.2756 to 0.2835 in.)
Exhaust (C) 39.120 to 39.135 mm (1.5402 to 1.5407 in.)
Exhaust (D) 6.000 to 6.200 mm (0.2362 to 0.2441 in.)
(b) Heat the cylinder head to 80 to 90˚C (176 to 194˚F) with

hot water. Cool the valve seat with dry ice for approxi-
mately 30 minutes.
(c) Hold the seat with pincers and place it on the heated cylin-
der head. The valve seat can be easily made to fit by light-
ly hitting it.
HINT:
When grinding the valve, always recheck the seating condition.
A63499 CAUTION:
S Never touch the cooled valve seat with your bare
hands.
S When striking, metal particles may fly off on impact.
Wear safety glasses to protect your eyes.
19. INSPECT VALVE SINK
Standard dimension:
Intake 0.55 to 0.85 mm (0.0217 to 0.0335 in.)
Valve Seat Maximum dimension:

Intake 1.10 mm (0.0433 in.)
Valve Sink
Dimension Cylinder Exhaust 1.85 mm (0.0728 in.)
Valve
Head HINT:
A63500
S If the valve heads are protruding from the cylinder head
surface, the valve heads may hit the pistons while the en-
gine is running.
S When replacing the valve and valve seat, always recheck
the seating condition.

TO MODEL INDEX
14--9
20. INSPECT VALVE STEM AND VALVE GUIDE

(a) Using a micrometer, measure the diameter of the stem.
Standard valve stem diameter:
6.957 to 6.977 mm (0.2739 to 0.2747 in.)
Minimum valve stem diameter:
Intake 6.92 mm (0.2724 in.)
Exhaust 6.84 mm (0.2693 in.)
If the stem diameter is less than the minimum, replace the valve.
A63453
(b) Using a cylinder gauge, measure the inside diameter of

the valve guide.
90˚ (c) Calculate the oil clearance between the valve stem and
valve guide.
Standard oil clearance:
Intake 0.023 to 0.058 mm (0.0010 to 0.0022 in.)
Maximum oil clearance:
A63456
Intake 0.12 mm (0.0047 in.)
Exhaust 0.15 mm (0.0059 in.)
If the oil clearance is greater than the maximum, replace the
valve or valve guide.
21. REMOVE VALVE GUIDE
(a) Remove the valve stem seal.
(b) Using a brass bar and hammer, strike the valve guide.
CAUTION:
A63501
Exhaust
22. INSTALL VALVE GUIDE
Intake
(a) Press--fit a new valve guide straight allowing it to protrude
as shown in the illustration.
HINT:
Lightly apply engine oil to the valve guide outer circumference
before the installation.
A83823
23. REMOVE VALVE STEM SEAL

(a) Replace the valve stem seal when the valve guide is replaced or when seal clearance is excessive
or the stem seal has been worn or damaged.

TO MODEL INDEX
14--10
24. INSTALL VALVE STEM SEAL

Valve Stem Seal
(a) Install the lower spring seat and valve to the cylinder head
Valve Spring Seat SST (for guide of SST), then apply engine oil to the lip of the
Lower
stem seal and strike the guide with SST.
SST 09201--41020
CAUTION:
When striking, a metal particles may fly off on impact. Wear
Valve A63488
HINT:
Coat Oil S After installing the valve stem seal, make sure that gaps
(A) and (B) appears shown in the illustration.
S Do not use the SST if its surface touching the valve spring
lower seat is deformed.
S Check that the seal has not been deformed or cracked af-
ter the installation.
A63489
25. INSPECT VALVE SPRING

Deviation (a) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.079 in.)
If the deviation is greater than the maximum, replace the valve
spring.
EM0988
(b) Using vernier calipers, measure the free length of the

valve spring.
Standard free length:
Inner spring 64.6 mm (2.543 in.)
Outer spring 75.7 mm (2.980 in.)
Minimum free length:
EM0801
If the free length is less than the minimum, replace the spring.
(c) Using a spring tester, measure the tension of the valve

spring at the specified installed length.
Tension:
Turn Item Setting Height Tension
128.5 N
(13.1 kgf, 28.9 lbf)
313.8 N
(32.0 kgf, 70.5 lbf)
EM0281
If the installed tension is not as specified, replace the spring.

TO MODEL INDEX
14--11
26. INSPECT VALVE SPRING SEAT

(a) Visually check the contact surface of the upper and lower
valve spring seats.
If damage such as wear and scratches is excessive, replace the
valve spring seat.
A63503
27. INSPECT CYLINDER HEAD COOLANT GALLERY FOR LEAKS

(a) Close all coolant holes and apply air pressure of about 2.5 kgf/cm2 (36 psi) to one of the coolant holes.
Immerse the cylinder head into the water, then check for air leakage.
If any leakage is found, replace the cylinder head.
28. REMOVE NOZZLE SLEEVE
(a) Engage a tap to the nozzle sleeve from the bottom of the
cylinder head.
(b) Screw in an appropriate bolt.
(c) Strike the bolt head using a hammer and drive out the
nozzle sleeve.
CAUTION:
A63447 safety glasses to protect your eyes.
29. INSTALL NOZZLE SLEEVE

Cylinder Head (a) Install a new O--ring to the nozzle sleeve insert hole of the
cylinder head.
O--ring NOTICE:
Be sure to install a new O--ring. Reused O--rings may cause
Nozzle Sleeve water or gas leakage and lead to overheating or cracked
heads.
(b) Apply seal packing to the bottom of a new nozzle sleeve.
A63486 Seal packing: Part No. 08826--00080 or equivalent
(c) Insert it into the nozzle sleeve insert hole of the cylinder
head.
(d) Using SST, caulk the nozzle sleeve.
Nozzle SST S0947--21210, S9800--06100
SST
Sleeve
Cylinder
Head
SST
A63487

TO MODEL INDEX
14--12
(e) Install the injection nozzle to the cylinder head.

(f) Using vernier calipers, measure the protrusion of the in-
jection nozzle from the lower surface of the cylinder head.
Protrusion:
Standard 2.25 to 2.75 mm (0.0886 to 0.1083 in.)
Cylinder Head
Maximum 2.75 mm (0.1083 in.)
If the protrusion is greater than the maximum, replace the injec-

tion nozzle.
Protrusion
A63504
30. INSPECT OIL CLEARANCE BETWEEN CAMSHAFT

IDLER GEAR SHAFT AND IDLER GEAR BUSH
(a) Using a micrometer, measure the shaft diameter of the
idler gear shaft.
Shaft diameter:
Minimum 33.80 mm (1.3307 in.)
If the diameter is less than the minimum, replace the idler gear
A83824 shaft.

the idler gear bush.
Inside diameter:
Maximum 34.02 mm (1.3394 in.)
If the inside diameter is greater than the maximum, replace the

idler gear.
(c) Calculate the oil clearance between the idler gear shaft
A64526 and idler gear bush.
Oil clearance:
Maximum 0.20 mm (0.0079 in.)
If the clearance is greater than the maximum, replace the idler

gear shaft and/or idler gear bush.
31. INSPECT CAMSHAFT

(a) Visually check the camshaft surface for wear and
scratches.
A64098

TO MODEL INDEX
14--13
(b) Using a micrometer, measure the cam lobe height.

Standard cam lobe height:
Intake 51.328 mm (2.0208 in.)
Exhaust 52.195 mm (2.0549 in.)
Minimum cam lobe height:

Intake 51.248 mm (2.0176 in.)
Exhaust 52.115 mm (2.0518 in.)
If the lobe height is less than the minimum, replace the cam-
EM2011
shaft.
(c) Measure the oil clearance of the camshaft journal.

(1) Using a micrometer, measure the journal diameter
of the camshaft.
Journal diameter:
Minimum 39.85 mm (1.5689 in.)
If the journal diameter is less than the minimum, replace the

camshaft.
EM2538
(2) Using a cylinder gauge, measure the inside diame-

ter of the camshaft bearing.
Inside diameter:
Standard 40.00 mm (1.5748 in.)
Maximum 40.15 mm (1.5807 in.)
If the diameter is greater than the maximum, replace the cam-

shaft bearing.
(3) Calculate the oil clearance from the above mea-
A63491 surement.
Oil clearance:
Maximum 0.10 mm (0.0039 in.)

camshaft or camshaft bearing.
(d) Inspect the camshaft for circle runout.

(1) Place the camshaft on V--blocks.
(2) Using a dial gauge, measure the circle runout at the
center journal.
Maximum circle runout: 0.10 mm (0.0039 in.)
If the circle runout is greater than the maximum, replace the
camshaft.
A84844

TO MODEL INDEX
14--14
32. INSPECT OIL CLEARANCE BETWEEN VALVE

ROCKER ARM AND SHAFT
(a) Using a cylinder gauge, measure the inside diameter of
the rocker arm bushing.
Inside diameter:
Maximum 22.080 mm (0.8693 in.)
If the diameter is greater than the maximum, replace the bush-

A84845 ing.
HINT:
When installing a bush into the rocker arm, align the bush with
the oil hole of the rocker arm.
(b) Using a micrometer, measure the outside diameter of the
rocker arm shaft.
Shaft diameter:
Minimum 21.920 mm (0.8630 in.)
If the outside diameter is less than the minimum, replace the

rocker arm.
(c) Calculate the oil clearance between the rocker arm bush
A64101 and rocker arm shaft.
Oil clearance:
Maximum 0.15 mm (0.0059 in.)

rocker arm bush.
33. INSPECT VALVE ROCKER ARM AND VALVE BRIDGE

(a) Visually check the contact surface between the rocker
arm and valve bridge.
Replace the rocker arm and the valve bridge if damage such as
wear and scratches is excessive. If there is only a minimal
amount of wear, correct the surface using a resurfacer.
(b) Visually check the adjusting screw thread.
HINT:
A64102 Replace the adjusting screw if damage such as wear and
scratches is excessive.
34. INSTALL VALVE
SST
(a) Apply engine oil to the intake and exhaust valve stems.
Then insert them to the valve guide installed to the cylin-
der head.
(b) Install the valve inner and outer springs and valve spring
seat upper.
(c) Using SST, compress the valve spring, then securely fit
the valve spring retainer.
A64525 SST 09202--70020

TO MODEL INDEX
14--15
HINT:
When reusing any parts are reused, be sure to install them to
their original positions.
NOTICE:
S Be sure to apply engine oil to the contact surface of
the parts before the assembly.
S Be sure to place each valve in its original position.
S When the valve spring is compressed, be careful that
the upper seat will not damage to the stem seal.
S As this valve spring is evenly pitched, it can be
installed with either end up.
35. INSTALL CAMSHAFT IDLER GEAR
(a) Install the idler gear with the snap ring side facing the cyl-
inder head.
(b) Install the cam idler gear shaft through a thrust plate, with
the oil filler facing downward.
(c) Tighten the idler gear shaft bolt to the torque specified be-
low.
Torque: 108 N⋅m (1,100 kgf⋅cm, 80 ft⋅lbf)
A83825
36. INSPECT CAMSHAFT IDLER GEAR THRUST CLEARANCE

HINT:
After installing the idler gear, measure the clearance between the cam idler gear and thrust bearing by using
a dial gauge.
Thrust clearance:
Maximum 0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum, replace the thrust bearing.
37. INSTALL IDLER GEAR COVER

(a) Clean the cylinder head mounting surface of the idler gear cover.
(b) Apply seal packing to the idler gear cover, then install it to the cylinder head within 20 minutes.
Seal packing: Part No. 08826--00080 or equivalent
Coating width: 1.5 to 2.5 mm (0.059 to 0.098 in.)
HINT:
If they are left more than 20 minutes, clean the liquid gasket completely and reapply seal packing
38. INSTALL CAMSHAFT TIMING GEAR
(a) Measure the length of the camshaft gear bolt.
Maximum length (A): 30.0 mm (1.181 in.)
If the length is greater than the maximum, replace them with
new bolts.
(b) Make sure there is no dirt or scratch on the camshaft gear
A or tightening surface of the camshaft.
A64099

TO MODEL INDEX
14--16
(c) Apply clean engine oil to the bolt seating and bolt thread,
then tighten the bolt to the specified torque below.
90˚ (d) Retighten them by 90_ (1/4 turn).
HINT:
When adding torque, never untighten the nuts, even if they
have been over tightened.
A64100
39. INSTALL CYLINDER HEAD GASKET

Seal Ring HINT:
S Do not reuse the head gasket for any reason, because
Gear Case Printed Seal
this will cause the engine damage.
S Before installing the cylinder head gasket, remove dirt,
moisture and oil from the cylinder head and cylinder block
surface.
S The 8 water hole seal rings between the bores are easily
damaged. Do not touch them with your hands or other ob-
jects. Mark sure that the seal rings are not loose or dam-
Seal Packing A aged.
A
Application point S As a silicon material is used for the gear case print seal,
make sure that there is no peeling before assembly.
(a) Install the cylinder head gasket on the cylinder block and
flywheel housing.
(b) Fill the hole at the back of the cylinder head gasket with
Print Seal seal packing.
Seal Packing
Application point Seal packing: Part No. 08826--00080 or equivalent
Cylinder Head Seal Packing HINT:
Cylinder Make sure that the seal packing surface is flush with the cylin-
Flywheel Housing
Block der head gasket upper surface.
Clearance CORRECT
Rear End 40. INSTALL CYLINDER HEAD SUB--ASSY
Plate POOR
Clearance Clearance
PROTRUDING
A--A Section
A16193
A16194 A83826
41. INSTALL CYLINDER HEAD BOLT

(a) Preparation
(1) Measure the length of the M12 head bolts.
Maximum length:
A Bolt Number
A
126.5 mm (4.9803 in.) 1, 2, 7, 8, 9, 10, 15, 16, 17
156.5 mm (6.1614 in.) 4, 5, 12, 13
187.5 mm (7.3819 in.) 3, 6, 11, 14, 18
A64106

TO MODEL INDEX
14--17

new bolts.
(2) Make sure that no dirt or scratch is on the tightening
surface of the cylinder head bolt.
(3) Apply clean engine oil to the bolt surface and bolt
threads.
HINT:
As these cylinder head bolts are unique to this engine, do not
substitute ordinary bolts for them.
(b) Tighten the cylinder head bolts.
(1) Tighten No. 1 to No. 18 (M12) bolts in the order
(2) After tightening the No. 18 bolt, check the torque
again all through the bolts from No. 1 to No. 18.
A84043
(3) Mark the bolts with paint to indicate the same direc-
tions as shown in the illustration.
(4) Turn the No. 1 to No. 18 bolts by 90_ (1/4 turn).
90_ (5) Make sure that all paint marks face the same direc-
tion.
HINT:
When adding torque, never untighten the nuts even if they have
been overtightened.
A83975
(6) Tighten the head bolts again (M12 bolts only) to

their respective tightening angles in the same se-
90˚ quence.
90˚
or Tightening Angle Head Bolt No.
135˚ 90_ 1, 2, 7, 8, 9, 10, 15, 16, 17
or
135_ 4, 5, 12, 13
180˚
180_ 3, 6, 11, 14, 18
HINT:
been overtightened.
(7) Tighten the No. 19 to No. 21 (M10) bolts in the order
A16198 A64108

TO MODEL INDEX
14--18
42. INSTALL CAMSHAFT

(a) Install the camshaft into the cam housing so that the ar-
row stamped on the front of the camshaft gear faces up-
Scale ward and that the lower line is level.
HINT:
Incorrect installation may damage the engine.
A64109
43. INSTALL CAMSHAFT BEARING CAP

(a) Install the camshaft bearing cap to the cam housing.
Make sure that there is no dirt or scratch on the tightening
surfaces.
(b) Apply clean engine oil to the bolt seating and bolt thread,
then tighten the bolt to the torque specified below.
(c) Install the valve bridge assy.
A64110 (1) Check that the valve bridge is properly installed on
each valve.
NOTICE:
S To check the proper installation of the valve bridge,
move it right and left by hand. If you hear a click sound
at this time, it means that the valve bridge is properly
installed.
S If the valve bridge is installed off the valve, it will push
the upper seat. This will cause the valve to slip off.
44. INSPECT BACKLASH OF CAMSHAFT GEAR AND
CAMSHAFT IDLER GEAR
(a) Using a dial gauge, measure the backlash between the
camshaft gear and camshaft idler gear.
Backlash:
Maximum 0.030 mm (0.0118 in.)
If the backlash is greater than the maximum, replace the cam-
A64111 shaft gear.
45. INSPECT CAMSHAFT THRUST CLEARANCE

(a) Using a feeler gauge, measure the thrust clearance be-
tween the camshaft and camshaft bearing.
Thrust clearance:
Maximum 0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum, replace the

camshaft.
A64112

TO MODEL INDEX
14--19
46. INSTALL VALVE ROCKER ARM ASSY

(a) Make sure of the correct direction of the rocker arm sup-
port and assemble the rocker arm assembly.
HINT:
Wrong mounting of the rocker arm support causes faulty lu-
brication, resulting in seizure of the valve mechanism.
(b) Wind up the adjusting screw of the rocker arm completely.
HINT:
A84939 If the adjusting screw is left unwound, the rocker shaft may be
bent when the rocker arm support is tightened.
(c) Install the valve rocker arm assy to the cylinder head
.Make sure that the cross head is on each valve.
Torque: 28.5 N⋅m (290 kgf⋅cm, 21 ft⋅lbf)
HINT:
If the valve bridge is assembled off the valve, the valve may fall
off, which results in engine damage.
A64102
47. INSTALL INJECTION NOZZLE SUB--ASSY

Valve Spring Injection (a) Install a new O--ring into the groove of the cylinder head.
Pipe Unit (b) Make sure that there is no dirt or foreign particles on the
sealing part between the nozzle holder and related parts
(O--ring, nozzle sleeve and injection pipe seal), and on
the connecting part between the nozzle holder and nut of
Rocker
Arm
the injection pipe.
(c) Insert the nozzle holder so that it does no touch the valve
spring as shown in the illustration.
Injection
NOTICE:
Pipe Seal
Apply clean engine oil to the O--ring and be careful that the
O--ring is not caught.
Leakage (d) Cover the end of the injection pipe seal with the nozzle
Pipe holder as shown in the illustration figure and tighten the
bolts to fasten the injection pipe seal to the cam housing.
Nozzle Clamp
Bolt
(e) Tighten the nut of the injection pipe provisionally.
Tighten the nozzle clamp bolt to the specified torque.
NOTICE:
After tightening the bolt, make sure that the rocker arm
moves smoothly.
(f) Tighten the nut of the injection pipe to the specified
O--Ring torque.
Nozzle Holder Assy (g) Install the leakage pipe.
Cylinder Head
A70965

TO MODEL INDEX
14 -- 20
48. INSPECT VALVE CLEARANCE

(a) Turn the crankshaft to align mark 14 on the outer periph-
ery of the flywheel with the pointer of the flywheel hous-
ing.
A64169
(b) Check that the No. 1 piston is at the TDC of the compres-
sion stroke when the arrow marks on the camshaft point
up and the underline is horizontal.
If not, turn the crankshaft one revolution (360˚) and align the
marks as indicated above.
A64434
(c) Check only those valves indicated in the illustration.

(1) Using a feeler gauge, measure the clearance be-
tween the adjusting screw on the valve rocker arm
and the valve bridge.
(2) Record the measurements of the valve clearance
that is out--of--specification.
Valve clearance (Cold):
No. 1 No. 1 No. 2 No. 3 Intake 0.30 mm (0.012 in.)
IN EX IN EX A84512
Exhaust 0.45 mm (0.018 in.)
If the clearance is out of the standard range, adjust the valve

clearance.
(d) Turn the crankshaft one revolution (360˚) and align the
marks as indicated at step (a).
(e) Check only the valves indicated in the illustration.
Measure the valve clearance (See step (c)).
No. 2 No. 3 No. 4 No. 4

EX IN IN EX A84512

TO MODEL INDEX
14--21
49. ADJUST VALVE CLEARANCE

(a) Completely loosen the adjusting screw and nut of the
valve bridge.
Loosen Adjusting
Screw HINT:
Loosen S The adjusting screw must protrude by 10 mm (0.3931 in.)
or more from the valve bridge upper surface.
Valve S Unless the adjusting screw is completely loose to the
Bridge
Hold valve stem, the following adjustments may be adversely
A84513 affected.
(b) Insert a 30 mm (0.012 in.) feeler gauge for the intake or

0.45 mm (0.018 in.) feeler gauge for the exhaust between
Turn Adjusting the rocker arm and valve bridge. Adjust the clearance with
Screw the adjusting screw of the rocker arm. Tighten the lock
Lock
Valve nut.
Rocker Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf)
0.30 or Slide Arm
0.45mm HINT:
Feeler The feeling of the feeler gauge during the clearance adjustment
Gauge A84514 is the same as before.
(c) With the feeler gauge inserted, loosen the adjusting

screw of the valve bridge. Make sure that the feeler gauge
is not felt loose.
Loosen
Adjusting HINT:
Screw If it is loose, repeat the following steps.
Slide (d) Tighten the adjusting screw of the valve bridge until the
Valve feeler gauge does not move.
Bridge (e) While loosening the adjusting screw of the valve bridge
A84515 gradually, adjust the valve clearance. Tighten the lock nut
of the valve bridge when the feeler gauge is felt correct.
Feeler Gauge Adhesion HINT:

Start S The feeling of the feeler gauge during the clearance ad-
No Nut Fixing Position justment is the same as before.
Movement
S Do not over--loosen the adjusting screw because this will
Proper cause the valve bridge to come off from the valve stem.
Contact
The feeler gauge may have excessive clearance be-
Feeling is same tween the adjusting screw of the valve bridge and the
Loosening Amount
valve. This does not allow the correct adjustment.
of Adjusting Screw = > Large
A64442

TO MODEL INDEX
14--22
S The adjustable valve clearance, when either the No. 1 or

No. 4 piston is at the TDC of the compression stroke, is
shown in the following chart. After completing the valve
clearance adjustment when the No. 1 piston is at the TDC
of the compression stroke, turn the crankshaft one com-
plete revolution and place the No. 4 piston at the TDC of
the compression stroke (The arrow marks on the cam-
shaft point down and the underline is horizontal) and ad-
A64443 just the rest of the valve clearances.
(f) Finally, tighten all the lock nuts of the rocker arm and the
Rocker Arm Valve Bridge cross head with the following torque and make sure that
they are all tight (the nuts do not turn).
HINT:
Never over--tighten them with more than the following torque.
A64444
50. INSTALL CYLINDER HEAD COVER SUB--ASSY

Head Cover (a) Install the cylinder plugs at the front and rear ends of the
cam housing. Clean the cylinder plugs and the mounting
surface of the cam housing.
Cylinder Head Cylinder Plug

A64116
(b) Apply seal packing to the front and rear half circles of the
cam housing, then install the cylinder plug within 20 min-
utes.
Seal packing: Part No. 08826--00080 or equivalent
A HINT:
S If they are left more than 20 minutes, remove the seal
packing completely and reapply the seal packing.
A64117 S Make sure to wipe off excessive seal packing.
(c) Apply seal packing to plug corner A at the front and rear
ends of the cam housing.
(d) Install the cylinder head cover gasket into the gasket
groove at the head cover lower surface.
(e) Insert the spacer from the head cover to the cam housing.
(f) Install the cylinder head cover to the cam housing im-
mediately before mounting the head cover.
HINT:
If they are left more than 20 minutes, remove the seal packing
completely and reapply the seal packing.

TO MODEL INDEX
14--23
(g) Tighten the mounting bolt of the head cover through the
silent block and fix the head cover on the cylinder head.
Silent Block Torque: 28.5 N⋅m (290 kgf⋅cm, 21 ft⋅lbf)
A64162

TO MODEL INDEX
14--24 ENGINE MECHANICAL -- CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL
AND FLYWHEEL HOUSING (J05C)
CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND

FLYWHEEL HOUSING (J05C)
141EW--01
COMPONENTS
Oil Seal Retainer
Flywheel Housing
Rear End Plate
zGasket
zGasket L 55 (560, 40)
Flywheel 186 (1,900, 137)

Ring Gear
Knock Pin Crankshaft
Gear
Crankshaft
Crankshaft Oil Seal
Crankshaft Pulley
Crankshaft Rear
Oil Seal
118 (1,200, 87)
N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque

z Non--reusable part
A84812

TO MODEL INDEX
ENGINE MECHANICAL -- CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL 14--25
See page 14-- 27

69 (700, 43) + 90˚+ 45˚
Liner
Oil Jet
Valve 22 (220, 16)
z Gasket
Upper Oil Pan
28.5 (290, 21)
171.5 (1,750, 127)
97 (990, 70.7)
z Gasket
Low Oil Pan

Oil Level Gauge
Gasket z and guide
28.5 (290, 21)
Drain Plug
41 (418, 30)
N·m (kgf·cm, ft·lbf) : Specified torque

A83965

TO MODEL INDEX
Piston Pin
Piston
Retainer Ring
z Connecting Rod Bushing

Camshaft
Connecting
108 (1,100, 80)
Rod
172 (1,750, 127)
See page 14-- 27
69 (700, 43) + 90˚+ 45˚
Main Idler Gear

Connecting Rod Bearing Cylinder Liner
Cylinder Block
Oil Jet
See page 14-- 27 Valve 22 (220, 16)
Key
69 (700, 51) + 90˚+45˚
Crankshaft Crankshaft Gear
Crankshaft Pulley
Oil Seal
Flywheel
186 (1,900, 137)

Crankshaft Main Bearing
pilot bearing
Ring Gear
L Precoated part
A83976

TO MODEL INDEX
141EX--01
OVERHAUL
1. REMOVE CRANKSHAFT PULLEY
A64128
2. REMOVE OIL PAN AND OIL STRAINER
A70969
3. REMOVE FLYWHEEL SUB--ASSY

(a) Remove the pilot bearing.
A64129
(b) Remove the flywheel mounting bolts.

(c) Hold a copper rod through the starter hole against the fly-
wheel and drive the rod lightly with a hammer to remove
the flywheel from the crankshaft while rotating the crank-
shaft.
CAUTION:
The flywheel is heavy. When removing, be careful not to
drop it on your feet.
A60052

TO MODEL INDEX
14 -- 28 ENGINE MECHANICAL -- CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL
4. REMOVE CRANKSHAFT OIL SEAL

(a) Using SST, remove the crankshaft oil seals.
SST S0942--01731 (Front), S0942--01742 (Rear)
(1) Place SST (plate) at the crankshaft end with the
crank pulley mounting bolts (front) or the flywheel
mounting bolts (rear).
SST
A83966
(2) Install SST (hook) to the crankshaft end with the

Hook supplied bolt.
HINT:
Engage the hook with the oil seal notch.
(3) Remove the bolt installed in step (1).
Remove after
Hook Installation
SST
A83967
(4) Install SST (center bolt) and tighten it to remove the

Center oil seal.
Bolt
A83968
5. REMOVE FLYWHEEL HOUSING

(a) Remove the 2 front mounting bolts of the flywheel hous-
ing.
(b) Remove the rear mounting bolts of the flywheel housing.
Vacuum HINT:
Pump Before removing the flywheel housing, be sure to loosen bolt A.
Bolt A
A60053

TO MODEL INDEX
(c) Using a plastic--faced hammer, remove the flywheel

housing by lightly striking it.
A60054
CAUTION:
The flywheel housing is heavy. When removing, be careful
not to drop it on your feet.
A60055
6. REMOVE OIL SEAL RETAINER
A63426
7. INSPECT CRANKSHAFT PULLEY

HINT:
Clean the torsional damper with a commercial cleaning agent
before inspection. Use a cleaning agent that dose not damage
gum.
(a) Check if there are any cracks in the damper rubber sec-
tion.
If cracks are excessive, replace the pulley.
A64130
8. INSPECT FLYWHEEL SUB--ASSY

(a) Check the friction surface for damage.
(b) Check the friction surface for distortion.
(c) Grinding and replacement should be performed as nec-
essary.
Maximum deflection: 0.04 mm (0.0016 in.)
Grind limit: 1.00 mm (0.0394 in.)
If the flywheel is ground over the limit, replace it with a new one.
A64131

TO MODEL INDEX
9. INSPECT PILOT BEARING

(a) Rotate the bearing lightly by hand, and check whether
there is any abnormal noise or clatter and whether the
balls run smoothly.
If there is any fault, replace the pilot bearing.
A64132
10. INSPECT FLYWHEEL RING GEAR

(a) Visually check the flywheel ring gear.
If damage such as wear and scratches is excessive, replace the part.
11. REMOVE FLYWHEEL RING GEAR
(a) Using a torch, heat the ring gear evenly to about 200_C
(392_F). Insert the ring gear periphery lightly using a
cushion bar to remove the gear.
CAUTION:
Never touch the ring gear or flywheel with your bare hands
when they are hot.
A64133
12. INSTALL FLYWHEEL RING GEAR

(a) Using a torch, heat the ring gear evenly to about 200_C (392_F). Insert the ring gear into the flywheel
so that the chamfered side faces upward.
NOTICE:
Do not overheat the ring gear.
13. INSTALL OIL SEAL RETAINER
(a) Clean the cylinder block mounting surface of the oil seal
retainer.
Seal Packing
(b) Apply seal packing to the oil seal retainer, then install it to
the cylinder block within 20 minutes.
Seal packing: Part No. 08826to00080 or equivalent
A64134 completely and reapply the seal packing.

TO MODEL INDEX
ENGINE MECHANICAL -- CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL 14 -- 31
14. INSTALL FLYWHEEL HOUSING

(a) Clean the rear end plate mounting surface of the flywheel
housing.
Matching Face with Rear End Plate (b) Apply seal packing to the flywheel housing, then install it
to the rear end plate within 20 minutes.
Seal packing: Part No. 08826to00080 or equivalent
Seal Packing Coating width: 1.5 to 2.5 mm (0.059 to 0.098 in.)
Bolt A
completely and reapply the seal packing.
NOTICE:
Before installing the flywheel, be sure to tighten bolt A.
B
Be sure to apply seal packing to the flywheel housing.
Be sure to assemble the stud bolt on the block side.
CAUTION:
The flywheel is heavy. When installing, be careful not to
A63432
15. INSTALL CRANKSHAFT OIL SEAL

SST (a) Clean the edges and surface of the crankshaft and SST.
Guide
(b) Insert a new crankshaft oil seal onto SST (guide of oil seal
press).
SST S0940--71030 (Front), S0940--71040 (Rear)
New
Oil Seal A64135
Edge of Crankshaft HINT:

Felt Side of Pay attention to the orientation of the oil seal (The felt side
Oil Seal
should face the outside of the cylinder block).
Guide Bolt
Guide
A64136
(c) Apply a little amount of engine oil to the seal portion of the
shaft oil seal.
(d) Attach SST (oil seal press guide) with the oil seal onto the
crankshaft with SST (attached guide bolt).
Guide Bolt
A83971

TO MODEL INDEX
(e) Insert the oil seal press by adjusting the oil seal press hole
Press to the guide bolt.
Center (f) Press the crankshaft oil seal inside by attaching the ac-
Bolt
companying center bolt onto the oil seal press and tighten
it until it stops.
A83972
16. INSTALL FLYWHEEL SUB--ASSY

(a) Make sure that there are no burns or dirt on the contact
surface or in the threaded hole of the crankshaft or fly-
wheel.
SST (b) Insert SST into the crankshaft.
SST S0948--11340
HINT:
Place one guide bar on one side of the collar knock and another
on the opposite side of the collar knock.
(c) Insert the flywheel slowly until it touches the collar knock
in order to prevent impact on the guide bar. Adjust the
position, then insert it completely.
CAUTION:
The flywheel is heavy. When installing, be careful not to
A64137
(d) Apply clean engine oil to the threads of the flywheel bolt
Tightening order
Crankshaft collar and the flywheel bolt seat. Be sure to tighten 2 or 3
threads provisionally by hand. Then, tighten the flywheel
bolts (1) to (8) using a low--torque impact wrench.
(e) Pull out the guide bar and tighten the other 2 flywheel
bolts provisionally as in step (d).
(f) Tighten the flywheel bolts in the order shown in the il-
lustration.
A84813 Torque: 186 N⋅m (1,900 kgf⋅cm, 137 ft⋅lbf)
(g) Loosen all bolts and tighten them again.

TO MODEL INDEX
(h) Measure the sliding surface play of the flywheel.

(1) Using a dial gauge, measure the runout of the fly-
wheel.
Maximum runout: 0.15 mm (0.0059 in.)
If the runout is greater than the maximum, resurface the sliding
surface.
A63435
(i) Install the pilot bearing.
A63436
17. INSTALL OIL PAN

Seal Packing (a) Make sure that there is no deformation, impact marks or
(2 Parts Each) foreign particles on the mounting surface and stiffener
surface of the upper oil pan.
(b) Place a guide pin of 70 mm (2.76 in.) or longer in the cylin-
der block.
(c) Apply seal packing to the front and back ends of the cylin-
der block lower surface.
A63437 Seal packing: Part No. 08826--00080 or equivalent
(d) Install the upper oil pan gasket so that the protrusion is on
the flywheel housing side and the print seal surface is at
the cylinder block side.
Oil Pan Lower
(e) Install the upper oil pan.
HINT:
Oil Pan Gasket Lower
Oil Pan Upper
S Install the upper oil pan along the guide pin.
Bolt Tightening
S If they are left more than 20 minutes, remove the seal
Direction packing.
(f) Tighten the upper oil pan installation bolts in the order 1
-- 2 -- 3 -- 4 as shown in the illustration.
Rear Side Torque: 28.5 N⋅m (290 kgf⋅cm, 21 ft⋅lbf)
(g) Make sure that there is no deformation, impact marks or
Front Side
foreign particles on the mounting surface and stiffener
Lobe
surface of the lower oil pan.
Oil Pan Gasket Upper
(h) Finish tightening the bolts in the order shown in the il-
Oil Strainer
lustration.
HINT:
Intake Port Side A84035 Make sure that the washer is not on the flange.

TO MODEL INDEX
18. INSTALL CRANKSHAFT PULLEY

(a) Apply clean engine oil to the threads of the crankshaft
pulley bolt. Be sure to tighten 2 or 3 threads provisionally
by hand. Then, tighten the 6 crankshaft pulley bolts with
a low--torque impact wrench.
(b) Tighten the crankshaft pulley bolts in the order shown in
the illustration.
(c) Loosen all bolts and tighten them again.
A64128 Torque: 118 N⋅m (1,200 kgf⋅cm, 87 ft⋅lbf)

TO MODEL INDEX
14--35
ENGINE MECHANICAL -- TIMING GEAR (J05C)
TIMING GEAR (J05C)

140X4--02
COMPONENTS
Camshaft Timing Gear
Main Idler Gear Camshaft Idler Gear
Sub Idler Gear
Vacuum Pump Gear

Power Steering
Pump Gear
Oil Pump Drive Gear
Injection Pump
Drive Gear
Crankshaft Timing
Gear
Camshaft Idler Gear

Rear End Plate Crankshaft
Idler Gear Thrust Plate
Sub Idler Gear 108 (1,100, 80)
Supply 172 (1,750, 127)

Pump Gear
z Gasket
Idler Gear Shaft
L 55 (560, 41)
Idler Gear
z Gasket Thrust Plate
N·m (kgf·cm, ft·lbf) : Specified torque Main Idler Gear

L Precoated part A83977

TO MODEL INDEX
14--36
140X5--02
OVERHAUL
1. REMOVE MAIN IDLER GEAR
(a) Remove the mounting bolt of the main idler gear shaft.
(b) Remove the main idler gear.
A60057
(c) Using a sliding hammer, drive out the main idler gear
shaft.
(1) Check the teeth on each gear for wear and pitching.
If there is damage, replace the gear.
A64446
2. REMOVE SUB IDLER GEAR

(a) Remove the mounting bolt of the sub idler gear shaft.
(b) Remove the sub idler gear.
A83978
(c) Using a sliding hammer, drive out the sub idler gear shaft.
(1) Check the teeth on each gear for wear and pitching.
If there is damage, replace the gear.
A64447

TO MODEL INDEX
14--37
3. REMOVE OIL PUMP ASSY
A84021
4. REMOVE REAR END PLATE

(a) Using a socket wrench, remove 2 torx bolts adjacent to
the supply pump drive shaft mounting section.
Rear End Plate
A16731
A16705 A84022
5. INSPECT OIL CLEARANCE BETWEEN MAIN IDLER

GEAR BUSH AND SHAFT
(a) Using a micrometer, measure the diameter of the main
idler gear shaft.
Standard shaft diameter:
56.94 to 56.97 mm (2.2422 to 2.2430 in.)
A63423

the main idler gear bush.
Standard inside diameter:
57.00 to 57.03 mm (2.2441 to 2.2453 in.)
(c) Calculate the clearance from the above measurement.
Oil clearance:
Maximum 0.20 mm (0.0079 in.)
A63422

TO MODEL INDEX
14--38

main idler gear shaft and/or main idler gear bush.
6. INSPECT OIL CLEARANCE BETWEEN SUB IDLER
GEAR BUSH AND SHAFT
(a) Using a micrometer, measure the diameter of the sub idler
gear shaft.
Standard shaft diameter:
49.950 to 49.975 mm (1.9665 to 1.9675 in.)
A63425

the sub idler gear bush.
50.000 to 50.025 mm (1.9685 to 1.9695 in.)
(c) Calculate the oil clearance from the above measurement.
Oil clearance:
Maximum 0.20 mm (0.0079 in.)
A63424 If the oil clearance is greater than the maximum, replace the sub
idler gear shaft and/or sub idler gear bush.
7. INSTALL REAR END PLATE

(a) Insert a new gasket between the block and plate.
Rear End Plate (b) Apply adhesive to threads of 2 torx bolts.
Adhesive:
Part No. 08833--00070, THREE BOND 1324 or equiva-
lent.
(c) Using a socket wrench, tighten 2 torx bolts adjacent to the
supply pump drive shaft mounting section to the torque
specified below.
(d) Tighten the 3 bolts to the torque specified below as
HINT:
S Be careful that the gasket should not be moved off the
proper place.
S Always use a new gasket.
A16705
A16731
A84023

TO MODEL INDEX
14--39
8. INSTALL OIL PUMP ASSY

(a) Apply oil to the pump case and bearings of the block
(hatched area) before installing the oil pump.
HINT:
Not applying oil may cause oil suction failure at startup, result-
ing in seizure and abnormality.
(b) To prevent misalignment of the gasket, apply engine oil
to the gasket matching face of the block. Then, place and
fix the gasket.
(c) Tighten the oil pump mounting bolts provisionally in the
Apply Oil (Hatched Area)
order as shown in the illustration. Then retighten them.
(d) Check that the gear rotates smoothly by hand after the
installation.
A63428 HINT:
Be sure to observe the tightening order of the bolts, otherwise
the oil pump will be damaged.
Thrust Plate
Camshaft Timing Gear

Main Idler Gear Cylinder Oil Hole
Camshaft Idler Gear Block C--C Section
C C
A Sub Idler Gear
B B
Vacuum Pump Gear
Power Steering
Pump Gear Oil Pump Drive Gear
Injection Pump A Oil Hole

Drive Gear
Cylinder
Block
Crankshaft Timing Gear B--B Section
Thrust
Plate
Match-
Match-
mark
mark
(2)
(1)
Oil Hole
Cylinder
A16237 Block
A16238
A--A Section
A16125 A16235 A84024

TO MODEL INDEX
14--40
9. INSTALL SUB IDLER GEAR

(a) Install the sub idler gear shaft through the thrust plate so
that the lubrication hole faces downward.
(b) Install the sub idler gear.
(1) Apply engine oil to the seat and thread of the bolt.
(c) Tighten the mounting bolts of the sub idler gear shaft.
A63430
Thrust 10. INSPECT SUB IDLER GEAR THRUST CLEARANCE

Clearance (a) Using a dial gauge, measure the clearance between the
sub idler gear and thrust bearing.
Thrust clearance:
Thrust
Maximum 0.30 mm (0.0118 in.)
Bearing
Cylinder thrust bearing.
Block A84025
11. INSTALL MAIN IDLER GEAR

(a) Install the main idler gear shaft through the thrust plate so
that the lubrication hole faces downward.
(b) Install the main idler gear.
HINT:
S Apply engine oil to the contact surface of the idler gear
and idler gear shaft before installation.
S Adjust the timing of the main idler gear to align with the
A63431 supply pump gear.
(c) Tighten the mounting bolts of the main idler gear shaft to
the torque specified below.
Thrust 12. INSPECT MAIN IDLER GEAR THRUST CLEARANCE

Clearance (a) Using a dial gauge, measure the clearance between the
main idler gear and thrust bearing.
Standard thrust clearance:
Thrust Standard 0.114 to 0.160 mm (0.0045 to 0.0063 in.)
Bearing Maximum 0.30 mm (0.0118 in.)
Move If the thrust clearance is greater than the maximum, replace the
Cylinder
Block thrust bearing.
A84026

TO MODEL INDEX
14--41
13. INSPECT TIMING GEAR BACKLASH

(a) Using a dial gauge, measure the backlash between the gears.
Backlash:
Item Standard Backlash Maximum Backlash
Crankshaft x Main idler 0.030 to 0.167 mm (0.0012 to 0.0066 in.)
Main idler x Injection pump 0.030 to 0.218 mm (0.0012 to 0.0086 in.)
Injection pump x PS pump 0.030 to 0.183 mm (0.0012 to 0.0072 in.)
Main idler x Sub idler 0.030 to 0.162 mm (0.0012 to 0.0064 in.)
0 30 mm (0
0.30 (0.0118
0118 in
in.))
Sub idler x Oil pump 0.030 to 0.131 mm (0.0012 to 0.0052 in.)
Sub idler x Camshaft idler 0.030 to 0.303 mm (0.0012 to 0.0119 in.)
Camshaft idler x Camshaft timing 0.030 to 0.168 mm (0.0012 to 0.0066 in.)
Sub idler x Vacuum pump 0.029 to 0.187 mm (0.0011 to 0.0074 in.)
If the backlash is greater than the maximum, replace the gears.

TO MODEL INDEX
14--42 ENGINE MECHANICAL -- PISTON, CRANKSHAFT AND CYLINDER
BLOCK (J05C)
PISTON, CRANKSHAFT AND CYLINDER BLOCK (J05C)

140X6--02
COMPONENTS
Piston Pin
Piston Piston Ring
Retainer Ring
z Connecting Rod Small End Bush Camshaft
108 (1,100, 80)

Connecting Rod
z Connecting Rod Cap 172 (1,750, 127)
See Page 14-- 43

69 (700, 43) + 90_ + 45_
Main Idler Gear
Cylinder Liner
Connecting Rod Bearing
Cylinder Block
Crankshaft Bearing Cap Oil jet

See Page 14-- 43 Valve
69 (700, 51) + 90_ + 45_ 22 (220, 16) Knock Pin
Crankshaft Gear
Crankshaft
Crankshaft Pulley Oil Seal
108 (1,100, 80)

Flywheel
186 (1,900, 137)

L
Crankshaft Bearings
N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Ring Gear
z Non--reusable part L Non--reusable part A16127

TO MODEL INDEX
ENGINE MECHANICAL -- PISTON, CRANKSHAFT AND CYLINDER 14--43
BLOCK (J05C)
141EY--01
OVERHAUL
1. REMOVE PISTON AND CONNECTING ROD
(a) Remove the connecting rod bearing cap mounting bolts
and pull out the pistons along with the connecting rods
from the cylinder block upper side.
A64172
HINT:
S Before pulling out the pistons, remove carbon deposits
from the upper end inside the cylinder liner using a scrap-
er or an emery paper (recommended: No.150), working
in a circular direction.
S When pulling out the pistons, be careful that the insides
of the cylinder liners are not damaged by the connecting
rod big ends.
A64171 S When pulling out the pistons, be careful that the nozzle of
the cooling jet should not be deformed. If it is deformed,
replace or correct it.
S When pulling out the pistons, be careful not to drop the
connecting rod bearings from the connecting rod big
ends, which may cause deformation or damage.
S Arrange the removed parts in the order of the cylinder
numbers. Be careful not to change the combination of the
connecting rod and cap.
S 2 pistons can be removed at a time (Nos. 1 and 4, Nos.
2 and 3).
2. REMOVE CRANKSHAFT
(a) Remove the bearing cap mounting bolts.
(b) Remove the crankshaft.
A64173

TO MODEL INDEX
BLOCK (J05C)
3. REMOVE CYLINDER LINER

HINT:
Before removing the piston, put alignment marks on the cylin-
der liner and cylinder block using a marking pen. The cylinder
liner is bent by ”runtoin”. When reusing the cylinder liner, mis-
alignment with the cylinder block may concentrate stress on the
thin part of the cylinder liner and it may break.
A70971
(a) Remove the cylinder liner.

If this is difficult, use the SST.
SST S0942 -- 01720
HINT:
SST Arrange the removed parts in the order of the cylinder numbers.
A64175
4. CLEAN CYLINDER BLOCK SUB--ASSY

(a) Rinse the cylinder block in a hot commercial alkaline solution and remove oil from the cylinder block.
(b) Remove the alkaline solution from the cylinder block using a steam cleaner.
(c) If the water jacket is dirty, clean it as follows.
(1) Rinse the cylinder block in a commercial acid solution.
(2) After rinsing the cylinder block for a while, immerse it in the solution for approximately 30 minutes.
(3) Pull out the cylinder block. After the solution has drained off, re--immerse the cylinder block in
the solution and leave it for approximately 10 minutes.
(4) Repeat step 3 until deposits are removed.
(5) Remove the acid solution with hot water.
(6) Immerse the cylinder block in the alkaline solution to neutralize the acid.
(7) Finish cleaning using a steam cleaner.
(d) When the cooling water passage and oil passage are cleaned completely, dry the cylinder block,
press--fit a new blank cap and apply seal packing.
5. REMOVE CONNECTING ROD

(a) Using snap ring pliers, remove the retainer rings from
both ends of the piston pin.
CAUTION:
Removing the retainer rings may cause the retainer rings
to fly up. Be sure to wear protective goggles.
(b) Using a hammer, apply the reinforcing plate to the piston
pin and punch out the piston pin.
A64177 CAUTION:
Never touch the piston with your bare hands when it is hot.
HINT:
If it is difficult to punch out the piston pin, first immerse the piston
and piston pin in hot water 80 to 90_C (176 to 194_F) for
approximately 5 minutes to facilitate removal.

TO MODEL INDEX
BLOCK (J05C)
6. REMOVE PISTON RING

(a) Using a piston ring expander, remove the piston ring.
HINT:
S Carefully handle the piston rings because they are made
of a special casting which is easily broken.
S Arrange the piston rings in the order of the cylinder num-
bers.
A84031
7. INSPECT CONNECTING ROD

(a) Using dye penetrate examination or magnetic examina-
tion, check the connecting rod for cracks or damage.
If there are any cracks or damage, replace the connecting rod
with a new one.
A64178
(b) Check that there is no clogging in the lubrication passage

to the connecting rod small end.
If there is any clogging, blow air through the lubrication passage
using an air gun or clean the passage by inserting a wire.
A64179
(c) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If the bend is greater than the maximum, replace the connecting
rod.
A64180
(2) Check for twist.

Maximum twist:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum, replace the connecting
rod.
A64181

TO MODEL INDEX
14 -- 46 ENGINE MECHANICAL -- PISTON, CRANKSHAFT AND CYLINDER
BLOCK (J05C)
8. INSPECT PISTON PIN

(a) Using a micrometer, measure the piston pin diameter.
Standard pin diameter:
Standard 36.989 to 37.000 mm (1.4567 in.)
Minimum 36.96 mm (1.4551 in.)
If the diameter is less than the minimum, replace the piston pin.
HINT:
Never grind the piston pin, because the surface is coated with
A64182 a special material.
9. INSPECT CONNECTING ROD SMALL END BUSH

(a) Using a cylinder gauge, measure the connecting rod bush
inside diameter.
Maximum 37.10 mm (1.4606 in.)

connecting rod bush with a new one.
A64183 (b) Calculate the oil clearance between the piston pin and
piston pin bush.
Standard oil clearance:
Maximum 0.08 mm (0.0031 in.)
If the oil clearance is greater than the maximum, replace the pis-
ton with a new one.
10. INSPECT CONNECTING ROD BIG END
(a) After tightening the connecting rod cap without bearing
using a cylinder gauge, measure the inside diameter of
the connecting rod big end to calculate the roundness.
Maximum inside diameter 69.06 mm (2.7189 in.)
HINT:
For tightening of the connecting rod cap, see step 34.
connecting rod big end with a new one.
A16307
A16309 A64184

TO MODEL INDEX
BLOCK (J05C)
11. INSPECT CRANKSHAFT PIN AND BEARING

(a) Using a micrometer, measure the crankshaft pin diame-
ter.
Standard crankshaft pin diameter:
Minimum crankshaft pin diameter 63.80 mm (2.5118 in.)
If the crankshaft pin diameter is less than the minimum, replace

the crankshaft pin with a new one.
X
Y Y’
X’
A16433
A16310 A64185
(b) Using a cylinder gauge, measure the connecting rod

bearing inside diameter.

connecting rod bearing with a new one.
(c) Calculate the clearance between the crank shaft pin and
connecting rod bearing.
Standard clearance:
Maximum clearance 0.20 mm (0.0079 in.)
If the clearance is greater than the maximum, replace the con-

necting rod bearing with the correct one.
Undersize machining dimension: 2 sizes below
Undersize machined dimension:
0.25 mm (0.0098 in.) 0.50 mm (0.0197 in.)
A16307
A16308 A64186
HINT:
Machined dimension of filet R
Crankshaft pin: 5.0 to 5.5 mm (0.20 to 0.21 in.)
CORRECT WRONG
A64217

TO MODEL INDEX
BLOCK (J05C)
12. INSPECT PISTON AND CYLINDER LINER

HINT:
Before the measurement, remove carbon deposits from the up-
per end inside the cylinder liner using a scraper or an emery pa-
per (recommended: No.150), working in a circular direction.
Make sure that there is no scratches inside the cylinder liner.
A64171
(a) Using a micrometer, measure the piston diameter at the

illustration points.
Standard piston diameter:
Minimum piston diameter 113.92 mm (4.4850 in.)
If the piston diameter is less than the minimum, replace the pis-
ton with a new one.
Outside
Diameter
(0.83 in.)
21 mm
A16311
A16312 A64187
(b) Using a cylinder gauge, measure the cylinder liner inside

diameter at the 4 points in the piston boss and thrust
direction as shown in the illustration.
Standard 114.00 mm (4.4882 in.)

cylinder liner with a new one.
A64188 HINT:
S Use the value measured at the most worn point as the cyl-
inder liner inside diameter.
S If the cylinder liner is heavily worn. If only the piston ring
must be replaced, correct the corrugation at the top of the
cylinder liner.

TO MODEL INDEX
BLOCK (J05C)
(c) Measure the clearance between the piston and cylinder
160 (6.30)
20 (0.79)
40 (1.57)
80 (3.15)
liner.
Standard clearance:
Maximum clearance 0.15 mm (0.0059 in)
If the clearance is greater than the maximum, replace the cylin-

der liner and/or piston with a new one.
mm (in.) HINT:
A64189 Use the value measured at the most worn point as the cylinder
liner inside diameter.
13. INSPECT PISTON PIN BOSS
(a) Using a cylinder gauge, measure the piston pin boss in-
side diameter.
Standard piston pin boss inside diameter:
36.987 to 37.003 mm
Standard
(1.4562 to 1.4568 in.)
Maximum piston pin boss inside diameter 37.05 mm (1.4587 in.)

A64190 piston with a new one.
(b) Calculate the clearance between the piston pin and the
piston pin boss.
Maximum oil clearance --0.05 mm (0.0020 in.)
HINT:
If the clearance is less than the maximum, replace the piston or
piston pin.
14. INSPECT PISTON RING AND PISTON RING GROOVE
(a) Insert the piston ring into the piston ring groove.
(b) Using a feeler gauge, measure the clearance between
the piston ring and piston ring groove.
Clearance:
Item Standard Maximum
0.06 to 0.10 mm
1st ring 0.30 mm (0.0118 in.)
(0.0024 to 0.0039 in.)
A64191 0.04 to 0.08 mm
2nd ring 0.30 mm (0.0118 in.)
(0.0016 to 0.0031 in.)
0.02 to 0.06 mm
Oil ring 0.20 mm (0.0079 in.)
(0.0008 to 0.0023 in.)
If the clearance is greater than the maximum, measure the

width of the piston ring and piston ring groove individually and
replace any parts that do not meet the limit with new ones.

TO MODEL INDEX
BLOCK (J05C)
Groove width:
2.55 to 2.57 mm
1st ring 2.70 mm (0.1063 in.)
(0.1004 to 0.1012 in.)
2.03 to 2.05 mm
2nd ring 2.20 mm (0.0866 in.)
(0.0799 to 0.0807 in.)
4.01 to 4.03 mm
Oil ring 4.10 mm (0.1614 in.)
(0.1579 to 1587 in.)
If the groove width is greater than the maximum, measure the

Ring thickness:
Item Standard Minimum
2.47 to 2.49 mm
1st ring 2.40 mm (0.0944 in.)
(0.0972 to 0.0980 in.)
1.97 to 1.99 mm
2nd ring 1.90 mm (0.0748 in.)
(0.0775 to 0.0783 in.)
3.97 to 3.99 mm
Oil ring 3.90 mm (0.1535 in.)
(0.1562 to 0.1570 in.)
A70972 If the ring thickness is less than the minimum, measure the
15. INSPECT PISTON RING GAP

(a) Fit the piston ring into the cylinder liner.
(b) Using a feeler gauge, measure the end gap of the piston
ring matching point.
Clearance:
0.30 to 0.40 mm
1st ring 1.50 mm (0.0590 in.)
(0.0119 to 0.0157 in.)
A64192 0.50 to 0.65 mm
2nd ring 1.20 mm (0.0472 in.)
(0.0197 to 0.0255 in.)
0.15 to 0.30 mm
Oil ring 1.20 mm (0.0472 in.)
(0.0059 to 0.0118 in.)
If the end gap is greater than the maximum, replace the piston
ring.

TO MODEL INDEX
ENGINE MECHANICAL -- PISTON, CRANKSHAFT AND CYLINDER 14 -- 51
BLOCK (J05C)
16. INSPECT CRANKSHAFT

HINT:
Before the inspection, clean the crankshaft with a commercial
cleaning agent and clean the lubrication passage using an air
gun.
A64193
(a) Performing the dye penetrate test, check the crankshaft

for cracks.
HINT:
Pay special attention to the finished R section and oil hole of the
crankshaft journal and crankpin.
(b) Visually check the condition of the crankshaft journal and
pin for damage or wear.
If any damage are found, replace the crankshaft.
A64194
(c) Inspect for circle runout.

(1) Place the crankshaft on V--blocks.
(2) Using a dial gauge, measure the circle runout of the
crankshaft at the center journal.
Maximum circle runout: 0.15 mm (0.0059 in.)
If the circle runout is greater than the maximum, replace the
crankshaft with a new one.
A64214
17. INSPECT CRANKSHAFT BEARING CAP

(a) After tightening the main bearing caps without bearing us-
ing a cylinder gauge, measure the inside diameter of the
main bearing caps to calculate the roundness.
Inside diameter:
Maximum 85.20 mm (3.3543 in.)
If the inside diameter is greater than the maximum, carry out
boring after overlay welding or replace the cylinder block with
a new one.
HINT:
S When installing the main bearing caps, make sure to re-
turn them to the original positions according to the num-
ber stamped on the caps. The main bearing caps together
with the cylinder block are round.
S For tightening of the main bearing caps, see step 28.
A16435
A16317
A64216

TO MODEL INDEX
BLOCK (J05C)
18. INSPECT CRANKSHAFT JOURNAL AND BEARING

(a) Using a micrometer, measure the main journal outside di-
ameter.
Standard journal diameter:
Minimum journal diameter:
Repair 79.80 mm (3.1417 in.)
Use 78.80 mm (3.1024 in.)
X If the diameter is less than the minimum for use, replace the
crankshaft with a new one.
Y Y’
X’
A16436
A16310 A64197
(b) After installing and tightening the bearing caps using a

cylinder gauge, measure the bearing inside diameter.
Inside diameter:
Maximum 80.30 mm (3.1614 in.)

bearing with a new one.
HINT:
S When installing the bearing caps, make sure to return
them to the original positions according to the number
stamped on the caps. The bearing caps together with the
cylinder block are round.
S For tightening of the bearing cap, see step 28.
(c) Calculate the oil clearance between the crankshaft jour-
nal and bearing.
Pin outside diameter:
STD 64.940 to 64.960 mm (2.5567 to 2.5575 in.)
A16435
A16317
U/S 0.25 64.690 to 64.710 mm (2.5468 to 2.5476 in.)
A64216 U/S 0.50 64.440 to 64.460 mm (2.5370 to 2.5378 in.)
Journal outside diameter:

STD 79.940 to 79.960 mm (3.1472 to 3.1480 in.)
U/S 0.25 79.690 to 79.710 mm (3.1374 to 3.1382 in.)
U/S 0.50 79.440 to 79.460 mm (3.1276 to 3.1283 in.)
Oil clearance:
Maximum 0.20 mm (0.0079 in.)
Undersize machined dimension:

0.25 mm (0.0098 in.) 0.50 mm (0.0197 in.)

TO MODEL INDEX
BLOCK (J05C)

bearing.
HINT:
Make sure to replace the top and bottom main bearings as one
set. The top and bottom main bearings must be round.
HINT:
Machined dimension of filet R
Crankshaft pin: 5.0 to 5.5 mm (0.1969 to 0.2165 in.)
CORRECT WRONG Crankshaft journal: 5.0 to 5.5 mm (0.1969 to 0.2165
in.)
A64217
19. INSPECT CYLINDER BLOCK SUB--ASSY

(a) Remove the water gallery plug and visually check the
condition of the worn hole.
If the wear is excessive, replace the part with a new one. Also
inspect the inside of the cylinder block and clean the cylinder
block main body with a commercial cleaning agent as required.
(b) Check the cylinder for cracks.
(1) Check the cylinder block for cracks and perform the
dye penetrate test.
If any checks are found, replace the cylinder block with a new
one.
(c) Check the flatness of the cylinder block upper surface.
(1) Using a straight edge and feeler gauge, measure
the warpage of the surfaces toucting the cylinder
head.
Standard warpage:
Standard 0.05 mm (0.0020 in.) or less
Maximum warpage 0.20 mm (0.0079 in.)
A16318
A16291 A64308 If the warpage is greater than the maximum, replace the cylin-
der block with a new one.
20. REMOVE CHECK VALVE AND OIL JET

(a) Remove the 4 check valves and 4 oil jets.
A64513

TO MODEL INDEX
BLOCK (J05C)
21. INSPECT CHECK VALVE

(a) Using a wooden stick, push the valve to check if it is stuck.
If stuck, replace the check valve.
Push
A64514
22. INSPECT OIL JET

(a) Check the oil jet for damage or clogging.
If necessary, replace the oil jet.
A64515
23. ADJUST OIL JET

(a) Align the pin of the jet with the pin hole of the cylinder
Oil Jet
block.
(b) Install the jet with SST.
SST S9001--24262
SST
(c) Connect a commercial oil pump (hydraulic pressure: 196
kpa (2 kgf/cm2 28 psi.)) to SST using a hose.
Oil Hose
A64198
(d) Set SST on the cylinder block upper surface against the
SST dowel pin.
SST S0944--41630
Cylinder Block
A64309

TO MODEL INDEX
ENGINE MECHANICAL -- PISTON, CRANKSHAFT AND CYLINDER 14 -- 55
BLOCK (J05C)
(e) Start the oil pump, let the engine oil spray out the oil jet
to check that the center of the jet flow is within the ø 7 mm
(ø 0.27 in.) reference line of the gauge as well as to judge
Spray Target whether the jet flow is good based on the figure.
NOTICE:
S Use new engine oil.
S Engine oil is flammable.
Abnormal Abnormal Normal Normal
S This spray test should be done in a well ventilated
room and away from any open flames or electric
Spray Pattern sparks.
Spray
Oil Jet
Abnormal
A16248
A16319 A64310
If the center of the jet flow is out of the ø 7 mm (ø 0.27 in.) refer-
ence line of the gauge, adjust the jet sight using the SST.
(f) Remove the checking bolt after inspection.
SST S0947--21620
SST
A64311
24. INSTALL CHECK VALVE AND OIL JET

(a) Align the pin of the jet with the pin hole of the cylinder block.
(b) Install the jet with the check valve. Install the 4 oil jet and 4 check valves.
Torque: 22 N·m (220 kgf·cm, 16 ft·lbf)
NOTICE:
S Always install the soft washer.
S When installing the piston, make sure that the oil jet is not struck by the piston when at bottom
dead center.
25. REPLACE CONNECTING ROD SMALL END BUSH
Press (a) Using SST and a press, press out the bush.
SST S0940--21480
SST
SST SST
A84864

TO MODEL INDEX
BLOCK (J05C)
Press S9191--08252 (b) Install a new bush.

(1) Attach the bush to SST with the ball of SST inside
the oil hole of the bush.
SST S0940--21480, S0948--11170
Oil Hole SST
(2) Fully coat the bore in the connecting rod with new
Bush
engine oil.
(3) Align the oil holes of a new bush and the connecting
rod.
A84865 (4) Using a press, press in the bush.
(c) Inspect the bush positioning after installation.

(1) Make sure that the oil hole of the bush and the oil
path of the connecting rod are suitably aligned al-
lowing a 6 mm (0.24 in.) diameter rod to penetrate.
HINT:
Misalignment can lead to insufficient lubrication, which may re-
sult in seizure.
(2) Make sure that the bush can be rotated smoothly by
A84866 hand with a new piston pin inserted in the piston.
26. INSTALL CYLINDER LINER

Marks of Liner HINT:
S When assembling the cylinder liner with the cylinder
block, clearance can be set to 3 levels.
S When using a new cylinder liner, the upper surface and
side surface of the cylinder block are stamped A, B or C.
Insert a matching cylinder liner having the same symbol.
A84038
S When reusing a cylinder liner, install it according to the

alignment marks that are put during the removal. The cyl-
inder liner is bent by ”run--in”. When reusing the cylinder
liner, misalignment with the cylinder block may concen-
trate stress on the thin part of the cylinder liner and it may
break.
A70971
27. INSPECT PROTRUSION OF CYLINDER LINER

SST (a) Install SST onto the cylinder block.
SST S0942--01720
(b) Tighten the center bolt to the torque specified below to set
the cylinder liner in the normal installation condition.
Torque: 9.8 N·m (100 kgf·cm, 87 in.·lbf)
A64204

TO MODEL INDEX
BLOCK (J05C)
(c) Using a dial gauge, measure the protrusion of the cylinder

Pressure: 4,903 N (500 kgf, 1,100 lbf) liner.
Standard protrusion:
Maximum protrusion 0.07 mm (0.0028 in.)
Protrusion
If the protrusion is greater than the maximum, replace the cylin-

der liner.
A76112
28. INSTALL CRANKSHAFT

(a) Install the main bearings onto the cylinder block and main
bearing caps.
HINT:
S When reusing a bearing, make sure to reassemble the re-
moved bearing as it was originally installed.
S Install the bearing with the oil hole on the block side and
install the bearing without the oil hole on the cap side.
A64206 S Match the bearing protrusion with the notch of the block
or cap.
S After the installation, apply engine oil to the journal sur-
faces of the bearings.
(b) Install the crankshaft onto the cylinder block.
A64176

TO MODEL INDEX
BLOCK (J05C)
(c) Install the thrust washers onto the 4 points of the No. 2
journal of the cylinder block and either side of the bearing
caps.
HINT:
S When reusing a bearing, make sure to reassemble the re-
moved bearing as it was originally installed.
S Install the thrust washers with the groove side (front) to-
ward the crankshaft arm and with the part number stamp
(back) toward the main bearing cap or cylinder block.
S Apply engine oil or grease to the back of the bearing to
prevent loosening during installation.
S Fit the bearing to the mounting groove of the block and
cap side.
(d) Install the bearing cap.
HINT:
Facing the arrow mark stamped on the cap forward, install in the
order of the stamped numbers.
A64312
(1) Measure the length of the bearing cap bolts.

Length (A):
Standard 106.80 mm (4.2047 in.)
Maximum 108.00 mm (4.2520 in.)
new bolts.
(2) Apply clean engine oil to the bolt seat and bolt
threads.
A64313
(3) Tighten the bolts in the order shown in the illustra-

tion.
(4) Loosen all bolts.
Front
(5) Tighten the bolts as in step (3).
A64314
(6) Mark the bolts with paint to indicate the same direc-
Paint Mark tion.
(7) Tighten the bolts by 90˚ (1/4 turn) in the same order
as in step (5).
(8) Finally, retighten the bolts by 45˚ (1/8 turn) as in
step (7).
(9) Make sure that all paint marks face the same direc-
tion.
A64315

TO MODEL INDEX
BLOCK (J05C)
HINT:
been over--tightened.
(10) After tightening, using a plastic--faced hammer, tap
the front and back ends of the crankshaft to make
complete fit.
29. INSPECT CRANKSHAFT THRUST CLEARANCE

(a) Using a dial gauge, measure the crankshaft thrust clear-
ance.
Thrust clearance:
Maximum 0.50 mm (0.0197 in.)
thrust bearing with the oversized one of 0.25 mm (0.0098 in.).
A64207
30. INSTALL CONNECTING ROD

Piston Identification Sym- HINT:
bol
S Before assembling the piston with the connecting rod,
check whether the piston is specified for this engine
74 S Check should be performed using the engine compatible
identification code on the top of the piston.
Engine compatible identification code: 74
(a) Install a new retainer ring onto one end of the piston boss.
Top View A84037 HINT:
Installing the retainer ring may cause it to fly up. Be sure to wear
protective goggles.
(b) Immerse the piston in hot water (80 to 90˚C (176 to
194˚F)) for approximately 5 minutes.
(c) Assemble the piston with the O mark being opposite to

O Mark Piston
the connecting rod alignment mark.
CAUTION:
Never touch the piston with your bare hands while it is hot.
Oil Hole
Match Marks
A64317

TO MODEL INDEX
BLOCK (J05C)
(d) Insert the piston pin into the piston.

HINT:
Insert the piston pin from the piston boss attached to the retain-
er ring so that the ring groove is not damaged.
(e) Install a new retainer ring to the other end of the piston
boss.
CAUTION:
Installing the retainer ring may cause it to fly up. Be sure
A64316 to wear protective goggles.
HINT:
S When using an oversized piston, hone the liner so that the
clearance between the cylinder liner and the piston be-
comes the standard value.
S Prevent parts from damage by covering them with cloth
while they are being installed onto the cylinder block.
S Measure the entire length of the connecting rod bolt.
(see step 34)
31. INSTALL PISTON RING
Ring Upper Face (a) Facing the identification marks on the piston ring upper
surface, install them in the order of the oil ring, 2nd ring
and 1st ring using a piston ring expander.
HINT:
S Never change the combination of the coil and oil ring.
Identification S Connect the joint of the coil expander for the oil ring and
Mark install it inside the piston ring. Assemble the ring with the
joint 180˚opposite to the matching point of the ring.
1st Ring 2nd Ring Oil Ring
Joint
Gap
GapA64209
HINT:
Top Ring Position the matching points of the piston ring at an even dis-
O Mark
tance. Be careful not to position at the piston boss.
Oil Ring 2nd Ring

A64318

TO MODEL INDEX
BLOCK (J05C)
32. INSTALL CONNECTING ROD BEARING

NOTICE:
S When reusing the bearing, make sure to reassemble
the removed bearing as it was originally installed.
S Install the bearing with the oil hole on the connecting
rod side and install the bearing without the oil hole on
the cap side.
S Match the bearing protrusion with the notch of the
A64210 connecting rod or cap.
33. INSTALL PISTON AND CONNECTING ROD

(a) Using a piston ring compressor and a hammer handle, in-
sert the piston through the connecting rod assembly into
the cylinder block.
HINT:
S Before the installation, apply engine oil to the piston pin,
piston ring, cylinder liner and connecting rod bearing.
A64211 S Recheck the matching point of each piston ring.
S When inserting the piston, be careful that the oil jet is not
struck by the connecting rod. If struck, make sure to re-
check the condition of the oil jet.
Oil Jet
A64319
S Make sure that the O mark on the piston on at the exhaust

Exhaust Port Side O Mark
side.
S Do not damage the inside of the liner.
Intake Port Side A64320
34. INSTALL CONNECTING ROD CAP
A64212

TO MODEL INDEX
BLOCK (J05C)
(a) Measure the length of the bolts.

Maximum length (A): 82.5 mm (3.2480 in.)
new bolts.
A (b) Apply clean engine oil to the nut seat surface and bolt
thread of the connecting rod cap.
A64321
(c) Tighten the connecting rod nut to the torque specified be-
Paint Mark low in the order shown in the illustration.
(1) Tighten the connecting rod nuts 1 and 2 temporarily,
dividing into small amount.
(d) Mark the cap nut with paint to indicate the same direction.
(e) Tighten the cap nut by 90˚ (1/4 turn) in the same order as
in step (c).
A64322 (f) Tighten the cap nut by turning 45˚ (1/8) turn as in step (e).
(g) Make sure that all the paint marks face the same direc-
tion.
(h) Turn the crankshaft to make the piston in the bottom dead
center, and then check that the piston and oil jet nozzle
of the block do not interfere with each other.
HINT:
When adding torque, never loosen the nuts even if they have
been over--tightened.
35. INSPECT CONNECTING ROD THRUST CLEARANCE

(a) Using a dial gauge, measure the clearance between the
connecting rod and crankshaft pin end surface.
Standard thrust clearance:
Maximum thrust clearance 1.00 mm (0.0393 in.)

connecting rod.
A64213

TO MODEL INDEX
EXHAUST
EXHAUST MANIFOLD (J05C) . . . . . . . . . . . . . 15--1
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15--1

TO MODEL INDEX
15--1
EXHAUST -- EXHAUST MANIFOLD (J05C)
EXHAUST MANIFOLD (J05C)

1508L--02
INSPECTION
1. INSPECT EXHAUST MANIFOLD
HINT:
Clean the exhaust manifold with a commercial cleaning agent
before the inspection.
(a) Using a dye penetrate, check the exhaust manifold for
cracks.
If cracks are found, replace the manifold.
A71648
(b) Using a precision straight edge and feeler gauge, mea-

sure the surface touching the cylinder head for warpage.
Maximum warpage: 0.20 mm (0.0079 in.)
If the warpage is greater than the maximum, correct the exhaust
manifold by grinding it so that the warpage is within 0.1 mm
(0.004 in.) per 2 flanges or 0.1 mm (0.004 in.) per a flange.
If damage such as deformation and wear is excessive, replace
the manifold.
A64097

TO MODEL INDEX
COOLING
WATER PUMP ASSY (J05C) . . . . . . . . . . . . . . 16--1
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--1/3
THERMOSTAT (J05C) . . . . . . . . . . . . . . . . . . . . 16--4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--4

TO MODEL INDEX
16--1
COOLING -- WATER PUMP ASSY (J05C)
WATER PUMP ASSY (J05C)

160O4--01
OVERHAUL
1. REMOVE WATER PUMP ROTOR
(a) Using SST, remove the rotor from the shaft.
SST SST S0942--01820
B58339
2. REMOVE WATER PUMP PULLEY SEAT

(a) Using SST, remove the water pump pulley seat.
SST 09950--50013 (09951--05010, 09952--05010,
SST 09953--05010, 09954--05021)
B58340
3. REMOVE WATER PUMP BEARING & SHAFT

SUB--ASSY
(a) Using snap ring pliers, remove the snap ring.
B58341
(b) Using SST and a press, press out the bearing and shaft
from the case.
SST SST 09236--00101 (09237--00050)
B58342

TO MODEL INDEX
16--2
4. REMOVE WATER PUMP SEAL SET

(a) Using SST and a press, press in the seal set.
SST SST 09236--00101 (09236--15010)
B58343
5. INSTALL WATER PUMP BEARING & SHAFT

SUB--ASSY
(a) Using a press, press in the bearing and shaft, as shown
in the illustration.
Dimension: 5 mm (0.20 in.)
B58344
(b) Using snap ring pliers, install the snap ring.
B58341
6. INSTALL WATER PUMP SEAL SET

(a) Using SST and a press, press in the seal set.
SST SST 09236--00101 (09237--00020)
B58345
7. INSTALL WATER PUMP ROTOR

(a) Using a press, press in the water pump rotor flush with the
end of the shaft.
B58346

TO MODEL INDEX
16--3
8. INSTALL WATER PUMP PULLEY SEAT

(a) Using SST and a press, press in the pulley seat, as shown
SST 09238--47012
Dimension: 14.2 mm (0.56 in.)
SST
B58347

TO MODEL INDEX
16--4
COOLING -- THERMOSTAT (J05C)
THERMOSTAT (J05C)
160O5--01
INSPECTION
1. INSPECT THERMOSTAT FUNCTION
Stirring Rod
Thermostat (a) Place the thermostat in hot water and check the valve
opening temperature and valve lift.
Thermometer CAUTION:
Never touch hot water and heated thermostat with your
bare hands. This can result in personal injury.
Heater
A84028
T1: Valve Opening Temperature (b) Using a coolant temperature gauge, measure the valve
10 mm T2: Valve Opened Temperature opening temperature.
(0.4 in.)
Standard: 74.5 to 78.5˚C (166 to 173˚F)
Lift →
NOTICE:
Check that the thermostat valve opening temperature (T1)
is engraved on the thermostat seat.
If the value opening temperature is not as specified, replace the
0˚C 10˚C Temp. → thermostat.
T1˚C T2˚C A84029
(c) After immersing the thermostat in hot water,

90_C(194˚F), for 5 minutes, measure the valve lift using
vernier calipers.
Standard value lift: 10 mm (0.3937 in.) or more
If the value does not meet the standard value, replace the ther-
L1: When Cold mostat.
L2: When (T2)˚C
A A: Valve Lift (d) Immerse the thermostat that is open in water at normal
L1 temperature.
L2 If it completely closes within 5 minutes, it is normal.
A84030
If it remains slightly open, it is defective and must be replaced.

TO MODEL INDEX
LUBRICATION
OIL PUMP ASSY (J05C) . . . . . . . . . . . . . . . . . . 17--1
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--1
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--2/4
OIL COOLER ASSY (J05C) . . . . . . . . . . . . . . . 17--5
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--6

TO MODEL INDEX
17--1
LUBRICATION -- OIL PUMP ASSY (J05C)
OIL PUMP ASSY (J05C)

170AU--02
COMPONENTS
Oil Cooler with Oil Filter
24.5 (250, 18)
z Gasket
z O--Ring
24.5 (250, 18)
z Gasket Oil Pump 28 (290, 20.7)
Driven Gear
Relief Valve
Relief Valve Spring
Seat
Seat
z Cotter Pin
z O--Ring
28 (290, 20.7)
Oil Strainer
z Non--reusable part B72281

TO MODEL INDEX
17--2
170GG--01
OVERHAUL
1. REMOVE OIL PUMP DRIVEN GEAR
(a) Remove the driven gear from the oil pump.
NOTICE:
Since the driven gear is a press--fit type, it can not be disas-
sembled.
B58348
2. REMOVE OIL PUMP RELIEF VALVE

(a) Pull out the cotter pin, and remove the 2 seats, relief valve
spring and relief valve.
CAUTION:
Removing the cotter pin may cause 2 seats and the relief
valve spring to pop out. Be sure to wear protective goggles.
3. INSPECT OIL PUMP ASSY
(a) Visually check each part of the oil pump for damage or
B58375 wear.
If damage of wear is excessive, replace the oil pump assy with
a new one.
(b) Inspect the backlash between the drive gear and driven
gear.
(1) Using a vise, fix the oil pump assy.
(2) Using a dial gauge, measure the backlash between
the drive gear and driven gear.
Backlash:
Maximum 0.30 mm (0.0118 in.)
B58376 If the backlash is greater than the maximum, replace the oil
pump assy with a new one.

TO MODEL INDEX
17--3
(c) Inspect the clearance between the diameter of the driven

gear shaft and the inside diameter of the driven gear
bush.
(1) Using a micrometer, measure the diameter of the
driven gear shaft.
Shaft diameter: 18.00 mm (0.7087 in.)
B58377
(2) Using a dial gauge, measure the inside diameter of

the driven gear bush.
Inside diameter: 18.00 mm (0.7087 in.)
(3) Calculate the difference between the diameter of
the driven gear shaft and the inside diameter of the
driven gear bush.
Clearance:
B58378 Maximum 0.15 mm (0.0059 in.)
If the oil clearance is greater than the maximum, replace the oil
pump assy or the driven gear bush.
(d) Visually check each part for damage or wear.
If damage of wear is excessive, replace the relief valve with a
Relief Valve
new one.
Relief Valve If the spring is flattened, replace the relief valve with a new one.
Spring NOTICE:
Before inspection, be sure to clean metal parts using
Seat 1 treated oil.
Seat 2
B58379
4. INSTALL OIL PUMP RELIEF VALVE

(a) Attach the relief valve, relief valve spring and 2 seats to
Relief Valve
the oil pump.
Relief Valve
Spring
Seat 1
Seat 2
B58379

TO MODEL INDEX
17--4
(b) Using a plastic--faced hammer, lightly tap the cotter pin.
B58375
5. INSTALL OIL PUMP DRIVEN GEAR

(a) Install the driven gear to the oil pump.
B58348

TO MODEL INDEX
17--5
LUBRICATION -- OIL COOLER ASSY (J05C)
OIL COOLER ASSY (J05C)

170GH--01
COMPONENTS
Oil Cooler Assy
z Gasket
z O--Ring
Oil Cooler Case
Oil Filter Element
z Non--reusable A69537

TO MODEL INDEX
17--6
LUBRICATION -- OIL COOLER ASSY (J05C)
INSPECTION
170AT--02
1. INSPECT OIL COOLER

NOTICE:
Before the inspection, please refer to the following items.
S Be sure to clean the oil cooler element and oil passage using commercial cleaning agent.
S Clean the metal parts using treated oil.
(a) Carry out a pneumatic test for the oil cooler element.
Test pressure: 59 N⋅m (6 kgf/ cm2, 85.3 psi)
Test time: 1 minute
If defective, replace the oil cooler element.
(b) Visually check each part for damage or wear.
If the damage or wear is excessive, replace the relief valve with
a new one.
If the spring is flattened, replace the relief valve with a new one.
B58455

TO MODEL INDEX
STARTING & CHARGING

STARTER ASSY (J05C) . . . . . . . . . . . . . . . . . . 19--1
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--1
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--2/9
GENERATOR ASSY (J05C) . . . . . . . . . . . . . . . 19--10
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--10
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--11/19

TO MODEL INDEX
19--1
STARTING & CHARGING -- STARTER ASSY (J05C)
STARTER ASSY (J05C)

190BK--02
COMPONENTS
Lead Wire
Starter Magnetic Switch Assy

4.3 (44, 38 in.·lbf)
z O--Ring
14.7 (150, 11)
Starter Brush Holder Assy
Starter Yoke Assy (Field Coil)
14.7 (150, 11)
Starter Commutator End Frame Assy
z Felt
Brush
Washer
Starter Armature Assy
z Felt (Commutator)
Washer
Spring
Holder
z Dust Protector Cap

Starter Pinion Drive Lever
Pin Motor Housing
Amature Bearing
z Starter Dust Protector
Pinion Gear 15 (153, 11)

z Snap Ring zRubber Seal
Plate
Starter Clutch Sub--assy
Drive Housing Bush
Drive Housing
z Non--reusable part B72338

TO MODEL INDEX
19--2
190PK--01
OVERHAUL
1. REMOVE STARTER YOKE ASSY
Lead Wire M
Terminal M (a) Move the cap of terminal M, then remove the nut and lead
(Cap) wire M.
Terminal C
(Cap) (b) Move the cap of terminal C, then remove the bolt and lead
wire C.
Lead Wire C
B58381
(c) Remove the 2 through bolts and pull out the starter yoke
together with the armature coil.
HINT:
Hold the starter by hand so that it will not fall or drop.
B58382
2. REMOVE STARTER COMMUTATOR END FRAME

ASSY
O--ring
(a) Remove the 2 bolts, 2 O--rings and commutator end
frame.
HINT:
Commutator Holding lead wire M, remove the commutator end frame by tak-
Lead Wire M End Frame ing it upward.
B58383
3. REMOVE STARTER BRUSH HOLDER ASSY

Spring
(a) Holding the spring tank using a screwdriver, disconnect
the brush from the brush holder.
(b) Disconnect the 4 brushes and remove the brush holder.
B70858
4. REMOVE STARTER ARMATURE ASSY

(a) Pull out the field frame.
(b) Remove the armature from the starter yoke.
(c) Remove the felt and washer from the armature.

TO MODEL INDEX
19--3
5. REMOVE MAGNET STARTER SWITCH ASSY

A
(a) Loosen the 2 bolts holding the magnet switch to the drive
housing.
(b) Pull out the magnet switch in direction B by tilting the up-
per part of the magnetic switch in direction A, as shown
B
B58385
6. REMOVE MOTOR HOUSING

(a) Remove the bolt and motor housing.
(b) Remove the plate, spring and rubber seal from the starter drive housing.
7. REMOVE ARMATURE BEARING
SST
(a) Using SST, press out the bearing.
SST 09820--36010
B58386
8. REMOVE PINION GEAR

(a) Using a vise, lightly fix the pinion, place 2 screwdrivers to
the both sides of the retainers opening port and then re-
move the retainer by lightly tapping those handles ends
using a plastic hammer.
(b) Remove the pinion gear.
B58387
9. REMOVE STARTER CLUTCH SUB--ASSY

(a) Remove the starter clutch together with the drive lever
Holder from the starter drive housing.
Lever 10. REMOVE STARTER PINION DRIVE LEVER
Rod (a) Remove the lever and shaft assembly from the pinion
case at the same time.
(b) Pull out the rod and remove the holder from the lever.
Shaft Assembly
B58388
11. REMOVE STARTER DUST PROTECTOR

(a) Remove the protector by prying it with a screwdriver.

TO MODEL INDEX
19--4
Ohmmeter 12. INSPECT STARTER ARMATURE ASSY

Continuity
(a) If the surface of the commutator is dirty or burned, polish
the surface using sandpaper (#400) or replace the arma-
ture.
(b) Check the commutator open circuit.
(1) Using an ohmmeter, check that there is continuity
between the segments of the commutator.
If there is no continuity between any segments, replace the ar-
B58389 mature assy.
Ohmmeter No Continuity
(c) Check the commutator ground.
(1) Using an ohmmeter, check that there is no continu-
ity between the commutator and armature coil core.
If there is continuity, replace the armature assy.
B58390
(d) Check the commutator diameter.

(1) Using vernier calipers, measure the commutator di-
ameter.
Standard Minimum
32.0 mm (1.260 in.) 30.0 mm (1.181 in.)
If the diameter is less than the minimum, replace the armature

assy.
B58391
(e) Measure the undercut depth of the commutator.

Standard Minimum
0.7 mm (0.028 in.) 0.2 mm (0.008 in.)
If the undercut depth is less than the minimum, correct it using

a hacksaw blade.
HINT:
Check that there is no foreign objects in the undercut and
smooth out the edge. Then, check the depth of the undercut.
B58392
13. INSPECT STARTER YOKE ASSY (FIELD COIL)

Continuity
(a) Using an ohmmeter, check that there is continuity be-
tween the lead wire and field coil brush lead.
Ohmmeter If there is no continuity, replace the starter yoke assy.
B58393

TO MODEL INDEX
19--5
(b) Inspect for ground.

No Continuity (1) Using an ohmmeter, check that there is no continu-
ity between the field coil end and starter yoke.
Ohmmeter If there is continuity, repair or replace the starter yoke assy.
B58394
14. INSPECT BRUSH

(a) Using vernier calipers, measure the brush length.
Standard Minimum
18 mm (0.709 in.) 12 mm (0.472 in.)
If the length is less than the minimum, replace the brush holder
assy and starter yoke assy.
B58419
15. INSPECT STARTER BRUSH HOLDER ASSY

Ohmmeter
No Continuity (a) Using an ohmmeter, check that there is no continuity be-
tween the positive (+) and negative (--) brush holders.
If there is continuity, repair or replace the brush holder assy.
B58420
(b) Using the pull scale, inspect the brush spring load when
the spring is separated from the brush.
Standard Minimum
42.2 to 51.0 N
22.5 N (2.3 kgf, 4.9 lbf)
(4.3 to 5.2 kgf, 9.3 to 11.2 lbf)
If the installed load is less than the minimum, replace the brush
springs.
B58421
16. INSPECT MAGNET STARTER SWITCH ASSY

(a) Check the pull--in coil.
M (1) Using an ohmmeter, check that there is resistance
between terminals M and C.
Standard resistance: 0.16 to 0.19 Ω
C C (b) Check the hold--in coil.
(1) Using an ohmmeter, check that there is resistance
between terminal C and the switch body.
B72235 Standard resistance: 0.84 to 0.94 Ω

TO MODEL INDEX
19--6
(c) Using an ohmmeter, check that there is continuity be-

Magnet Switch Assembly
M tween terminals B and M.
If there is continuity, replace the magnet switch.
(d) Push the magnetic switch assembly and check that there
is continuity between terminals B and M using an ohmme-
ter.
If there is no continuity, replace the magnet switch.
B
B58423
17. INSPECT STARTER CLUTCH SUB--ASSY

(a) With the clutch fixed, turn only the inner sleeve right and
Clutch
left.
(b) Check that the inner sleeve turns lightly in the arrow mark
direction but does not turn in the opposite direction.
Inner
Sleeve
B58424
(c) Using a micrometer, check each diameter of the starter

B A
clutch.
Diameter:
Standard Minimum
A: 26.0 mm (1.024 in.) A: 25.88 mm (1.019 in.)
B: 12.1 mm (0.476 in.) B: 12.0 mm (0.472 in.)
If the diameter is less than the minimum, replace the starter

clutch.
B58425
18. INSPECT DRIVE HOUSING

(a) Using a cylinder gauge, check the inside diameter of the
starter drive housing bush.
Inside diameter:
Standard Maximum
26.0 mm (1.024 in.) 26.2 mm (1.031 in.)
If the diameter is greater than the maximum, replace the drive

housing.
B58426
19. INSPECT MOTOR HOUSING

motor housing bush.
Inside diameter:
Standard Maximum
12.1 mm (0.476 in.) 12.3 mm (0.484 in.)
If the diameter is greater than the maximum, replace the motor
housing.
B58427

TO MODEL INDEX
19--7
20. INSPECT STARTER COMMUTATOR END FRAME

ASSY
end frame bush.
Standard Minimum
12.0 mm (0.472 in.) 12.2 mm (0.480 in.)
If the diameter is greater than the maximum, replace the com-

mutator end frame.
B58428
21. INSTALL STARTER BRUSH

22. INSTALL STARTER DUST PROTECTOR
SST
(a) Using SST and a plastic--faced hammer, tap in the protec-
tor.
SST 09950--60010 (09951--00260, 09951--00390,
09952--06010)
B58429
23. INSTALL STARTER PINION DRIVE LEVER

(a) Install the holder to the drive lever with the pin.
(b) Apply grease to the portions of the drive lever.
Apply Grease
B58430
24. INSTALL STARTER CLUTCH SUB--ASSY

(a) Apply grease to the portions of the starter clutch, and
install the drive lever together with the starter clutch to the
starter drive housing.
HINT:
Check that the starter clutch is in the depth and lightly slides
there.
Apply Grease
B58431
(b) Apply much grease until it would overflow from the reser-
voir of the start drive housing.
: Apply Grease B58432

TO MODEL INDEX
19--8
25. INSTALL PINION GEAR

(a) Install the pinion gear to the shaft by tapping it uniformly.
(b) Using pliers, pinch a new retainer and the shaft, then push
them in.
B58433
26. INSTALL ARMATURE BEARING

SST (a) Using SST and a press, press in the bearing.
SST 09820--36010
B58434
27. INSTALL MOTOR HOUSING

Rubber Seal
Spring (a) Apply grease to the parts as shown in illustration.
Plate (b) Install a new rubber seal, spring and plate.
(c) Install the motor housing with the bolt.
Apply Grease
B58435
28. INSTALL MAGNET STARTER SWITCH ASSY

A
(a) Attach the drive lever to the upper port of the magnetic
switch in direction A, then install it with the 2 bolts by in-
serting it direction B.
Torque: 14.7 N·m (150 kgf·cm, 11 ft·lbf)
B
B58385
29. INSTALL STARTER ARMATURE ASSY

(a) Apply grease to the portions of the armature as shown in
illustration.
(b) Install the armature to the motor housing.
Apply Grease
B58436

TO MODEL INDEX
19--9
30. INSTALL STARTER YOKE ASSY

(a) Align the cutout of the starter yoke with the cutout of the
motor housing.
(b) Install the starter yoke to the armature.
Cutout
B58437
31. INSTALL STARTER BRUSH HOLDER ASSY

(a) Place the brush holder in position on the armature.
(b) Holding the brush spring using a screwdriver, connect the
brush to the brush holder. Connect the 4 brushes.
B58439
32. INSTALL STARTER COMMUTATOR END FRAME ASSY

(a) Install the 2 end frame with the through bolts.
Torque: 14.7 N·m (150 kgf·cm, 11 ft·lbf)
(b) Install the 2 bolts with the new O--rings.
Torque: 4.3 N·m (44 kgf·cm, 38 in.·lbf )

TO MODEL INDEX
19--10
STARTING & CHARGING -- GENERATOR ASSY (J05C)
GENERATOR ASSY (J05C)

190BM--02
COMPONENTS
Generator Washer
Bearing Cover
Generator Rotor Assy
2.9 (30, 26 in.·lbf)
z Bearing (Front)
Drive End Frame
(Stator) z Bearing (Rear)
Bearing Cover
Generator Pulley
Bearing Retainer
Rear End Cover No. 2

110.5 (1,125, 81) 4.1 (42, 36 in.·lbf)
Rear End Cover
Terminal Insulator 2.0 (20, 18 in.·lbf)
Generator Brush
Holder Assy
5.4 (55, 48 in.·lbf)

3.85 (39, 34 in.·lbf)
Cord Clip Seal Plate
Brush Holder Cover

2.0 (20, 18 in.·lbf)
Plate Terminal
Voltage Regulator
x4 2.94 (30, 26 in.·lbf) 4.4 (45, 39 in.·lbf)

Generator Holder w/ Rectifier
Rubber Insulator
4.5 (46, 40 in.·lbf)
Rectifier End Frame


TO MODEL INDEX
19--11
190PL--01
OVERHAUL
1. REMOVE REAR END COVER NO. 2
2. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.
B58309
(b) Remove the 3 nuts, bolt, plate terminal, rear end cover
and brush holder cover.
B58310
3. REMOVE GENERATOR BRUSH HOLDER ASSY

(a) Remove the 2 screws, brush holder and seal plate.
4. REMOVE VOLTAGE REGULATOR
(a) Remove the 3 screws and voltage regulator.
B58312
5. REMOVE GENERATOR HOLDER W/RECTIFIER

(a) Remove the 4 screws and generator holder.
(b) Remove the 4 rubber insulators.
B58314

TO MODEL INDEX
19--12
SST (A)
6. REMOVE GENERATOR PULLEY
SST (B)
(a) Hold SST (A) with a torque wrench and tighten SST (B)
clockwise.
SST 09820--63010 (09820--06010, 09820--06020)
Turn (b) Check that SST (A) is secured to the rotor shaft.
B58316
(c) Mount SST (C) in a vise as shown in the illustration and

attach the pulley nut to SST (C).
(d) Turn SST (A) in the direction shown in the illustration to
loosen the pulley nut.
NOTICE:
SST (C) In order to prevent damage to the rotor shaft, do not loosen
Turn
the pulley nut more than one--half of a turn.
(e) Remove the generator from SST (C).
B58317 (f) Turn SST (B) and remove SST (A and B).
(g) Remove the pulley nut and pulley.
7. REMOVE RECTIFIER END FRAME
(a) Remove the 4 nuts and cord clip.
B58315
(b) Using SST, remove the rectifier end frame.

SST 09286--46011
(c) Remove the generator washer.
SST
B58319
8. REMOVE DRIVE END FRAME ASSY GENERATOR

TO MODEL INDEX
19--13
9. INSPECT VOLTAGE REGULATOR

(a) Using an ohmmeter, check the continuity between termi-
nals F and B.
Standard:
When the positive and negative poles between termi-
F nals F and B are exchanged, there is continuity in one
way but no continuity in another way.
B If the continuity is not as specified, replace the regulator.
A64727
(b) Using an ohmmeter, check the continuity between termi-

nals F and E.
E Standard:
When the positive and negative poles between termi-
nals F and E are exchanged, there is continuity in one
way but no continuity in another way.
F
A64728
10. INSPECT GENERATOR ROTOR ASSY

(a) Check the rotor for open circuit.
(1) Using an ohmmeter, check the resistance between
the slip rings.
Ohmmeter Standard resistance: 11.8 to 12.2 Ω at 20˚C (68˚F)
If the result is not as specified, replace the rotor assy.
Continuity
B58321
(b) Check the rotor for ground.

(1) Using an ohmmeter, check the resistance between
the slip ring and rotor.
Standard resistance: 10 MΩ or more
Ohmmeter If the result is not as specified, replace the rotor assy.
No Continuity
B58322
(c) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
(d) Using vernier calipers, measure the slip ring diameter.
Diameter:
If the diameter is less than the minimum, replace the rotor assy.
B58323

TO MODEL INDEX
19--14
11. INSPECT DRIVE END FRAME (STATOR)

(a) Check the stator for open circuit.
(1) Using an ohmmeter, check that there is continuity
Continuity
between the coil leads.
If there is no continuity, replace the drive end frame.
Ohmmeter
B58324
(b) Check the stator for ground.

(1) Using an ohmmeter, check that there is no continu-
ity between the coil lead and drive end frame.
No Continuity If there is continuity, replace the drive end frame.
Ohmmeter
B58325
12. INSPECT GENERATOR BRUSH HOLDER ASSY

(a) Using vernier calipers, measure the exposed brush
length.
Standard exposed length 9.5 to 11.5 mm (0.374 to 0.453 in.)
Minimum exposed length 1.5 mm (0.059 in.)
If the exposed length is less than the minimum, replace the

brush holder assy.
B58326
13. INSPECT GENERATOR HOLDER W/ RECTIFIER

(a) Check the positive (+) rectifier.
(1) Using an ohmmeter, connect one tester probe to the
positive (+) terminal and the other to each rectifier
terminal.
Positive (+) (2) Reverse the polarity of the tester probes and per-
Ohmmeter Terminal
form step (1) again.
Rectifier (3) Check that one shows continuity and the other
Terminal
B58327 shows no continuity.
If the continuity is not as specified, replace the rectifier holder
w/ rectifier.

TO MODEL INDEX
19--15
(b) Check the negative (--) rectifier.

(1) Using an ohmmeter, connect one tester probe to
Negative (--) each negative (--) terminal and the other to each
Terminal rectifier terminal.
(2) Reverse the polarity of the tester probes and per-
form step (1) again.
Ohmmeter
(3) Check that one shows continuity and the other
shows no continuity.
B58328 If the continuity is not as specified, replace the rectifier holder.
14. INSPECT BEARING
(a) Check that the bearing is not rough or worn.
If necessary, replace the bearing.
15. REPLACE BEARING (FRONT)
(a) Remove the bearing.
(1) Remove the 4 screws and bearing retainer.
B58329
(2) Using SST and a press, press out the bearing.

SST SST 09950--60010 (09950--70010, 09951--00270,
09951--07100)
B58330
(b) Install a new bearing.

(1) Using SST and a press, press in a new bearing.
SST
(2) Install the bearing retainer with the 4 screws.
B58331

TO MODEL INDEX
19--16
16. REPLACE BEARING (REAR)

SST (a) Remove the bearing.
(1) Using SST, remove the bearing cover (outside) and
bearing.
SST 09820--00021
NOTICE:
Be careful not to damage the fan.
(2) Remove the bearing cover (inside).
B58332
(b) Install a new bearing.

(1) Place the bearing cover (inside) on the rotor.
B58333
(2) Using SST and a press, press in a new bearing.

SST 09820--00031
SST
B58334
(3) Using SST, push in the bearing cover (outside).

SST 09285--76010
SST
B58335
17. INSTALL GENERATOR ROTOR ASSY

(a) Place the drive end frame on the pulley.
(b) Install the rotor to the drive end frame.

TO MODEL INDEX
19--17
18. INSTALL RECTIFIER END FRAME

(a) Place the generator washer on the rotor.
B58320
(b) Using a 30 mm socket wrench and press, slowly press in

30 mm the rectifier end frame.
Socket
Wrench
B58336
B (c) Install the cord clip and 4 nuts.

Torque:
4.5 N·m (46 kgf·cm, 40 in.·lbf) for A
A 5.4 N·m (55 kgf·cm, 48 in.·lbf) for B
A
A B58318
19. INSTALL GENERATOR PULLEY

SST (A)
SST (B)
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
(b) Hold SST (A) using a torque wrench, and tighten SST (B)
Turn clockwise to the specified torque.
SST 09820--63010 (09820--06010, 09820--06020)
(c) Check that SST (A) is secured to the pulley shaft.
B58316
(d) Mount SST (C) in a vise as shown in the illustration and

attach the pulley nut to SST (C).
(e) Turn SST (A) in the direction shown in the illustration to
torque the pulley nut.
Torque: 110.5 N·m (1,125 kgf·cm, 81 ft·lbf)
SST (f) Remove the generator from SST (C).
Turn (g) Turn SST (B) and remove SST (A and B).
B72276

TO MODEL INDEX
19--18
20. INSTALL GENERATOR HOLDER W/ RECTIFIER

(a) Install the 4 rubber insulators on the lead wires.
B58315
(b) Install the rectifier holder with the 4 screws while pushing
it.
Push
B58314
21. INSTALL GENERATOR BRUSH HOLDER AND

VOLTAGE REGULATOR
Upward (a) Install the generator regulator with the 3 screws.
Torque 2.0 N·m (20 kgf·cm, 18 in.·lbf)
(b) Place the seal plate on the rectifier end frame.
(c) Install the brush holder with the 2 screws.
NOTICE:
B58337 Be careful of the holder installation direction.
22. INSTALL REAR END COVER

(a) Place the brush holder cover on the brush holder.
B58311
(b) Install the rear end cover and plate terminal with the 2 nuts
and bolt.
Torque:
3.85 N·m (39 kgf·cm, 34 in.·lbf) for bolt
4.4 N·m (45 kgf·cm, 39 in.·lbf) for nut
B58310

TO MODEL INDEX
19--19
(c) Install the terminal insulator with the nut.

B58309
23. INSTALL REAR END COVER NO. 2

(a) Install the rear end cover with the 2 nuts.
24. INSPECT GENERATOR ASSY
(a) Check that the pulley rotates smoothly.

TO MODEL INDEX
00 -- 1
ALPHABETICAL INDEX (A-T)
PAGE 1 OF 2:
A L
Page Page
ABBREVIATIONS USED IN THIS MANUAL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--9
(TERMS FOR ENGINE REPAIR MANUAL) . . . . . . . . 01--7 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--14
C N
CAMSHAFT HOUSING NOZZLE HOLDER AND NOZZLE SET (J05C) . . . . . . . 11--1
AND CYLINDER HEAD (J05C) . . . . . . . . . . . . . . . . . . 14--1
COMPONENTS (CAMSHAFT HOUSING
AND CYLINDER HEAD (J05C)) . . . . . . . . . . . . . . . . . 14--1
O
COMPONENTS (CRANKSHAFT FRONT END,
OIL COOLER ASSY (J05C) . . . . . . . . . . . . . . . . . . . . . . . 17--5
OIL PAN, FLYWHEEL OIL PUMP ASSY (J05C) . . . . . . . . . . . . . . . . . . . . . . . . . . 17--1
AND FLYWHEEL HOUSING (J05C)) . . . . . . . . . . . . . 14--24
OVERHAUL (CAMSHAFT HOUSING
COMPONENTS (GENERATOR ASSY (J05C)) . . . . . . . 19--10 AND CYLINDER HEAD (J05C)) . . . . . . . . . . . . . . . . . 14--2
COMPONENTS (NOZZLE HOLDER
OVERHAUL (CRANKSHAFT FRONT END,
AND NOZZLE SET (J05C)) . . . . . . . . . . . . . . . . . . . . . 11--1 OIL PAN, FLYWHEEL
COMPONENTS (OIL COOLER ASSY (J05C)) . . . . . . . 17--5
AND FLYWHEEL HOUSING (J05C)) . . . . . . . . . . . . . 14--27
COMPONENTS (OIL PUMP ASSY (J05C)) . . . . . . . . . . 17--1 OVERHAUL (GENERATOR ASSY (J05C)) . . . . . . . . . . 19--11
COMPONENTS (PISTON, CRANKSHAFT
OVERHAUL (NOZZLE HOLDER
AND CYLINDER BLOCK (J05C)) . . . . . . . . . . . . . . . . 14--42 AND NOZZLE SET (J05C)) . . . . . . . . . . . . . . . . . . . . . 11--2
COMPONENTS (STARTER ASSY (J05C)) . . . . . . . . . . 19--1
OVERHAUL (OIL PUMP ASSY (J05C)) . . . . . . . . . . . . . 17--2
COMPONENTS (TIMING GEAR (J05C)) . . . . . . . . . . . . 14--35 OVERHAUL (PISTON, CRANKSHAFT
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--7
AND CYLINDER BLOCK (J05C)) . . . . . . . . . . . . . . . . 14--43
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--13 OVERHAUL (STARTER ASSY (J05C)) . . . . . . . . . . . . . . 19--2
CRANKSHAFT FRONT END, OIL PAN,
OVERHAUL (TIMING GEAR (J05C)) . . . . . . . . . . . . . . . 14--36
FLYWHEEL AND FLYWHEEL HOUSING (J05C) . . . 14--24 OVERHAUL (WATER PUMP ASSY (J05C)) . . . . . . . . . . 16--1
E P
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . 02--3
PISTON, CRANKSHAFT
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . 03--7
AND CYLINDER BLOCK (J05C) . . . . . . . . . . . . . . . . . 14--42
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--6
PRECAUTION (REPAIR INSTRUCTION
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--12
FOR ENGINE REPAIR MANUAL) . . . . . . . . . . . . . . . . 01--4
EXHAUST MANIFOLD (J05C) . . . . . . . . . . . . . . . . . . . . . 15--1 PREPARATION (COOLING) . . . . . . . . . . . . . . . . . . . . . . . 02--7
PREPARATION (ENGINE MECHANICAL) . . . . . . . . . . . 02--3
F PREPARATION (EXHAUST) . . . . . . . . . . . . . . . . . . . . . . 02--6
PREPARATION (FUEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--1
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--1 PREPARATION (INTAKE) . . . . . . . . . . . . . . . . . . . . . . . . . 02--2
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--4 PREPARATION (LUBRICATION) . . . . . . . . . . . . . . . . . . . 02--9
PREPARATION (STARTING & CHARGING) . . . . . . . . . 02--10
G
R
GENERAL INFORMATION (HOW TO USE
THIS ENGINE REPAIR MANUAL) . . . . . . . . . . . . . . . 01--1 REPAIR INSTRUCTION
GENERATOR ASSY (J05C) . . . . . . . . . . . . . . . . . . . . . . . 19--10 FOR ENGINE REPAIR MANUAL . . . . . . . . . . . . . . . . 01--4
GLOSSARY OF SAE AND TOYOTA TERMS
(TERMS FOR ENGINE REPAIR MANUAL) . . . . . . . . 01--12
S
H SERVICE DATA (COOLING) . . . . . . . . . . . . . . . . . . . . . . 03--13
SERVICE DATA (ENGINE MECHANICAL) . . . . . . . . . . . 03--7
HOW TO DETERMINE BOLT STRENGTH SERVICE DATA (EXHAUST) . . . . . . . . . . . . . . . . . . . . . . 03--12
(STANDARD BOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--1 SERVICE DATA (FUEL) . . . . . . . . . . . . . . . . . . . . . . . . . . 03--4
HOW TO DETERMINE NUT STRENGTH SERVICE DATA (INTAKE) . . . . . . . . . . . . . . . . . . . . . . . . 03--6
(STANDARD BOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--3 SERVICE DATA (LUBRICATION) . . . . . . . . . . . . . . . . . . 03--14
HOW TO USE THIS ENGINE REPAIR MANUAL . . . . . 01--1 SERVICE DATA (STARTING & CHARGING) . . . . . . . . . 03--15
SPECIFIED TORQUE FOR STANDARD BOLTS
(STANDARD BOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--2
I STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--1
STARTER ASSY (J05C) . . . . . . . . . . . . . . . . . . . . . . . . . . 19--1
INSPECTION (EXHAUST MANIFOLD (J05C)) . . . . . . . 15--1
INSPECTION (INTAKE MANIFOLD (J05C)) . . . . . . . . . . 13--1 STARTING & CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . 02--10
STARTING & CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . 03--15
INSPECTION (OIL COOLER ASSY (J05C)) . . . . . . . . . 17--6
INSPECTION (THERMOSTAT (J05C)) . . . . . . . . . . . . . . 16--4
INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02--2
INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03--6
INTAKE MANIFOLD (J05C) . . . . . . . . . . . . . . . . . . . . . . . 13--1

TO MODEL INDEX
00 -- 2
ALPHABETICAL INDEX (T - W)
PAGE 2 OF 2:
T
Page
TERMS FOR ENGINE REPAIR MANUAL . . . . . . . . . . . 01--7
THERMOSTAT (J05C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--4
TIMING GEAR (J05C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14--35
(ENGINE MECHANICAL) . . . . . . . . . . . . . . . . . . . . . . . 03--11
TORQUE SPECIFICATION (FUEL) . . . . . . . . . . . . . . . . . 03--5
(STARTING & CHARGING) . . . . . . . . . . . . . . . . . . . . . 03--16
W
WATER PUMP ASSY (J05C) . . . . . . . . . . . . . . . . . . . . . . 16--1
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What is the purpose of this repair manual?

What is the purpose of this repair manual?

What precautions should be taken when using this manual?

What precautions should be taken when using this manual?

BACK.

TO MODEL INDEX VIEW MAIN INDEX

S DYNA Repair Manual Supplement (Draft) DR129E

MAIN INDEX: DYNA J05C

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HOW TO USE THIS ENGINE REPAIR MANUAL

Camshaft Drive Gear

Camshaft Timing Tube Assy

7.5 (80, 66 in.·lbf)

z Camshaft Setting Oil Seal Camshaft Driven Main Gear

15 (150, 11) Wave Washer Camshaft Timing Gear

J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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REPAIR INSTRUCTION FOR ENGINE REPAIR MANUAL

1. TO PREVENT FROM ENTERING FOREIGN SUBSTANCES

J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS

J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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12. HANDLING OF HOSE CLAMPS

J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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TERMS FOR ENGINE REPAIR MANUAL

J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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GLOSSARY OF SAE AND TOYOTA TERMS

A/C Air Conditioning Air Conditioner

FEPROM Flash Erasable Programmable Read Only Memory --

J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S)

RAM Random Access Memory Random Access Memory (RAM)

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TCM Transmission Control Module Transmission ECU, ECT ECU

Three--Way Catalytic (TWC)

J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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J05C ENGINE REPAIR MANUAL (S.Africa) (DR137E)

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