ENG'NET{TECH

AT\I'CA
T,

CONTENTS
ENGINE COMPONENTS(Outerparts) . . EM- 2 C Y L I N D E RB L O C K ,C R A N K S H A F T
C Y L I N D E RH E A D EM-4 ANDPISTON .. ... EM.9
Cylinderheaddisassembly . EM. 4 Pistonandconnectingrod ..... EM-10
V a l v eg u i d e EM- 5 Crankshaft ....EM-1l
Valveseatinserts EM- 6 J a c ks h a f t a n dj a c ks h a f tb u s h i n g. . , . . . E M - 1 2
Camshaftand.canrshaft bearing. ., . . . . EM- 6 Cylinderblock. . EM-12
Valve EM- 6 Frontcover .... EM-13
V a l v es o r i n o EM- 6 Flywheel EM-13
.)?

Valvelifter. ...... EM- 6 O i ls e a l .. EM-13

^ . , . + , . :
CyIiridfi ilead assemb ly EM- 6 Distributor'...., .EM-13
CAMSHAFT AililD JACK SHAFT ' ,, SERVICEDATA AND
DRIVE ....",i , ,r';,. EM. 8 SPECIFICATIONS . EM-14
Valvetirningr....:-. ..i,, EM- 8 G e n e r as lp e c i f i c a t i o n s . . . EM-14
Chaintensio . .n. e
. .r . ; . . : : . . . , ' .. . . EM-8 I n s p e c t i o n a n d a d j u s .t .m e n t . . . . E M - 1 4
I
T i g h t e n i ntgo r q u e EM-18
l!!,
S P E C I A LS E R V I C ET O O L S .. .. EM.19

'l:1

,-t.,'

0.;i !,t*;
 ENGINE COMPONENTS{Outerparts)

(Outerparts)
ENGINECOMPONENTS

g- O zo.zs (2.0.3.0,14-221
B
T
\

Distributor

W.ter pump

@ nst
6.3- 8.3
{0.64.0.85,
4.6' 6.1)
M8:
16-21
l 1 . q- 2 . 1 ,
1 ?- 1 5 1

Fs--
Y
bbw O o.s'a'a
(0,64- 0.85,
4.5.6.1)

147. 196fi5.0, ?0.0,108- 1451

Oil pressure
switch

@ r e- z r i . r . 6 . 2 . 1 , 1 2 - 1 5 1 e s - s9 (4.s- 6.0,39- 431

O r e - z t 1 1 .-62 . 1 , 1 2- 1 5 1

O aa- ss (4.s- G.0,gt - 431

@ : N.m (kg-m, ft-lb)

EM.2
 (Outerparts)
ENGINECOMPONENTS

o 30 - tto
(3.1- 4.1,
22 -301
Intake manifold
Throttle valve

ogzd
(0.38- 0.51,
@!-qz
13.2'4'3,
2 3. 3 1 ) P
2.7 -3.71 I
O to-zt
( 1 . 6- 2 . 1 , Throttle chamber
12.151 f-^revelgauge
O g . r- r r . e Thermostat
{
(0.93.1.2,

O r o -- z r
1 1 . 6 2 . 1 , 1 2-

@r e - z r
1 1 . 6 . 2 . 1 , 1 2t 5
-l

@ : N.m ftg-m, ft-lb)

EM-3
 " ,CYL,INOER'fl€AD

CYLINDEfiHEAD
Valve rocker cover
Cylinder head bolt
@ s , r - 1 t . g{ 0 . 9 3- 1 . 2 , 6 . 7- B . t l - 13O,87- 941
o 118- 727112.0
; Camshaft(Intake)

Camshaft(Exhaust)
O r+.189.4-i.8,to.1sl
l

Valve lifter

O s.s- e.s
(0.64. 0.85,4.6- 6.11

Rubber plug
Applv sealant.-g!.

.u"Sb
I
O r e . 2 r ( 1 . 6 2- . 1 , 1 2 - l l l
@ : N-m (kg-m, ft-lb1 :,
'
.:
,
,
.t1: ,.
. "!'SEMEO8
, i

C Y L I N D E RH E A D Be cdsful not to drop chain tensioner

DISASSEMBLY sleerc ard spring.
6. Removecamshaft spioakets.
CAUTION:
a Do not rotate omnkshaft and cam-
shaft separately,becausevalveswill
hit piston heads.
o Always use new cylinder head
gasket.

5. Remove chain tensioner A cover

and chain tensioner A.

.a| i i:.1,

CYLINDERHEAD REMOVAL Support tiniing chain with a propel

wire so it doesnot fall.
1. Removeouter parts attachedto
cylinderhead.
2. Turn crankshaftuntil No. I piston
is at top dead centeron its compres-
sionstroke.
3. Scribemarkson timing chainand
camshaftsprocketswith paint before
removal.
4. Loosen camshaftsprocketbolts.

Efi/f-4
 C Y L I N D E RH E A D

7. Remove camshaftbrackets and

chain guideA in the sequence
below.
Keepthe remov€d
bracketsin order,

@ @

Valve
lifter

S E M 8 15

@ @
Valve lifter can be removedeasierby If beyond the specifiedlimit, correct
usingmagnetor suction rubber. with a surfacegrinder.

8 . Remove camshafts. Surfacegrindingtimit:

(2) Remove valves and springs using
9 . Remove chain guide C upper bolt. The grindinglimit of rylinder head is
Tool.
determined by the cylinder block
grinding.
Depthof cylinderheadgrindingis ,?,,
sTl 2315000 Depthof cylinderblock grindingis ,,8',
The limit is asfollows:
A + B - 0.2 mm (0.008in)

VALVE GUIDE
s E M 8 16 VALVE GUIDECLEARANCE
l- Measure the diameter of valve
Pay particularattention not to damage stem with a micrometer in three
10. Loosencylinderheadboltsin two valvelifter guidehole.
places;top, centerandbottom.
or threestages. 2. Measurevalve guide bore using
(3) Remove valve oil sealsusing Tool. insidedial gauge.
3. Subtract the highest reading of
valve stem diameter from valve guide
KVl0107900 bore to obtain the stem to guide clear-
o @ @ o @ ance.
o o o o o
Stem to guide clearance:
I ntake
o o o o o 0.025 - 0.055 mm
@ @ @ @ @ (0.0010- 0.0022inl
Exhaust
0.040 - 0.077 mm
SEM814 (0.016- 0.0030in)

11. Removecylinderhead. (4) Removevalve spring seats.

12. Disassemblecylinder head.
Keep the disassembledparts in order.
(l) Removevalvelifters and caps.
CYLINDERHEAD DISTORTION
Warpageof surface:
Lessthan0.1 mm (0.004in)

EM-5
 C Y L I N D E RH E A D

VALVE SEAT INSERTS CAMSHAFTBEND

Check valve seat inserts for any evi Camshaftbend:
dence of pitting at valve contact sur- L i m i t 0 . 0 5 m m ( 0 . 0 0 2 0i n )
face, and reseat if worn out exces-
sively.
Correct valve seat surface with Tool
and grind with a grinding compound.
a When repairing valve seat, check
valve and valve guide for wear
beforehand. Then correct valve
SEM333
seat.
. The cutting should be done with
both handsfor uniform cutting.
2. Measurethe free leneth and the
tensionof eachspring.
R e f e rt o S . D . S .

CAMSHAFTEND PLAY
VALVE LIFTER
E n dp l a y :
1. lVleasure outsidediameterof valve
L i m i t 0 . 3 m m ( 0 . 0 1 2i n )
litier and insidediameterof valvelifter
g u i d eh o l e .

SEM823
Valvelifter clearance:
0.025- 0.075 mm
( 0 . 0 0 1 0 - 0 . 0 0 3i0n )

CAMSHAFTAND CAMSHAFT h \ )
z1 \\
BEARING / \
\-.\\\ \
C A M S H A F TB E A R I N G C L E A R - \ \
ANCE lh
\=, \ (,
l. Clean camshaftjournal and bear- \ A t ' A
\/i,'-^{tL.r
ing.
2. Placeplastigageacrossjournal.
3. Install capsand tighten.
@:1a-18N.m
( 1 . 4- 1 . 8 k s - m ,
VALVE
10- 13ft-tb)
o When valve head has been worn
4. Remove caps and measureplasti- down to 0.5 mm (0.020 in) in-
gage. margin-thickness,
replacethe valve. C Y L I N D E RH E A D A S S E M B L Y
Max. toleranceof camshaftbearing l. Installvalveand valvespring.
clearance: (1) Install valve spring seat and valve
0 . 1 m m ( 0 . 0 0 4i n ) oil sealusineTool.

VALVE SPRING KV10108800

l Check valve spring for squareness
using a steel squareand surfaceplate.
Out of square("S"):
Outer
Limit 2.0 mm (0.079in)
Inner lO.74A- O.772inl
L i m i t 1 . 8 m m ( 0 . 0 7 1i n )

EM.6
 C Y L I N D E RH E A D

(2) Install valve,valve spring inner and 3rd (Retightenafter loosening @ : Camshaftsprocketbolt
outer, valvespringretainer,usingTool. to 1st torque) 1 2 7- 1 7 7 N . m
1 1 8- 1 2 7N ' m (13.0-18.0 kg-m,
a. When installingvalve,apply engine
(12.O- 13.0 ks-m, 94 - 130 ft{b}
oil on valvestemand lip of valveoil
87 - 94 ft-lb)
seal.
8. Install chain tensionerA.
b. Check whether valve face is free
4. Tighten chain guide B upper bolt.
from foreign matter. @ : ChaintensionerA bolt
5. Install camshaftsand tighten cam-
6 . 3- 8 . 3 N ' m
(3) Install valvecap and valvelifter. shaft bracket nuts with chain guide A (0.64- 0.85 kg-m,
a. Pay particular attention not to in the reverseorder of removal in two 4.6 - 6.1 ft-tb)
damagevalvelifter guidehole. or three stages.
b. Apply engineoil on valvecap and @ : Camshaftbracketnut Beforeinstallation,fill chaintensioner
outer wall of valvelifter. 1 4- 1 8 N . m A with engineoil.

%h
(4) Check valve lifter for smooth ( 1 . 4- 1 . 8 k s - m ,
rotation. 10 - 13ft-tb)

a. lnstall camshafts so that No. 1

camsare at top deadcenter,

sEM831

SEM829

9. Install chain tensionercover.

10. Install rubber plug with sealant.
b. Apply engineoil on cam, camshaft I 1. Install valverocker cover.
journal,camshaftbearingand valve @ : Valve rocker cover bolt and nut
lifter upper surface. 9 . 1 - 1 1 . 8N . m
(0.93- 1.2 ks-m,
6. Adjust intake and exhaust valve
2. Install cylinder headonto cylinder 6.7 - 8.7 ft-tbl
clearance.Refer to Adjusting Intake
block.
And Exhaust Valve Clearancein sec-
Always usenew gasket. tion ET. a. Rocker cover bolts should be
tightenedin criss-cross
fashion.
3. Tighten cylinder head bolts in the Valveclearance[Cold] :
b. Always use new rocker cover
reverseorder of remova-. I ntake gasket.
@ : Cylinderheadbolt 0.23 mm (0.009in)
Exhaust 12. Install outer parts.
lst
49 - 59 N'm 0 . 3 2 m m ( 0 . 0 1 3i n )
(5.0 - 6.0 kg-m, Valve clearancesshould ultimately be
36 - 43 ft-tb) adjustedto the hot values.
2nd 7 . Set timing chain on camshaft
1 1 8- 1 2 7N . m sprockets by aligrring each mark
(12.0- 13.0 ks-m, scribed before removal. Then, install
87 - 94 ft-lb) camshaftsprocketsto camshafts.

EM.7
 CAMSHAFTAND JACK SHAFT DRIVE

AND JACK SHAFTDRIVE

CAMSHAFT
C a m s h a f t( I n t a k e )

ChainguideA

Timing chain A

Camshaft sprocket (Intake)

A n7 - fl7 lls.o - 18.0,94 - r3oll

l e s . s - 8 . 3( 0 . 6 4- 0 . 9 s , 4 . 6
- 6.11

ChainguideU-a.,
tr
Jack shait
tC- \
Chaintensioner
o
\D- Locating plate
-fiI \\
O (6.3-8.3 tr- ).1 CamshaftsProcket(Exhaustt
0 . 6 4 . 0 . 8 s ,-46. .61 1 f
6
(D 7 6- e s( 7 . 8 - 1 0 . 0 , s' 762 1 - ^ A [
6y

^.
z \-chain guidec
@-/ / {-
\- e 1 6 - 2 1 ( 1 . 6- 2 . 1, 1 2 . 1 s l
Jackshaftsprockett7 /
Jackshaftsprocket^--€. Timing chain B
Crankshaftsprocket : N.m (kg-m,ftlb)
!
ChaintensionerB
@ o . a- e . e( 0 . 6 4- 0 . 8 5 . 4 . 6 - 6 . i ) - \
SEM832

V A L V ET I M I N G CHAINTENSIONER
Chnin tensioner A
tensionerbodv
TChan
,6-(
(6--.1
-',of-*j4Jq7;sv'^c
:
-t" *@@rr^

-";:fr
SEM847

sEM833 sEM848

EM.8
 CYLINDER BI.OCK,CRANKSHAFTAND PISTON

BLOCK,CRANKSHAFT
CYLINDER AND PISTON
o When installingslidingpartssuchas on the slidingsurfaces. . Be carefulnot to damageoil seal.
bearings,be sureto apply engineoil o Usenew packingsand oil seals.

O s.z- s.o(0.38
- o.sl

Rear oil sealretainer

J
: 1 6 - 2 1|
: 6.3- 8.3

6.3- 8.3
(0.64- 0.8r
@ rsz- rsz
(14.0- 16.0,101 .

Piston ring

Piston
e g.z-s.o
-
(0.38 0.51,
l
Connecting
rod

43 - 471

IR
SN\ G
Fg- oilstrainer
- 2.1.12- 1o-<-l
O rs- zr 11.6 \- ynin bearingcap
\ 9 4

$-" -0.7.3.6-s.l1
5-7 (o.E

@ : N.m (kg-m, ft-lb)

EM-9
 CYLINDER BLOCK, CRANKSHAFTAND PISTON

PISTONAND CONNECTING Pistonpin to pistonpin hole

ROD clearance:
-0.005 - 0.004 mm
o Piston can be easily removed by
(-0.0002 - 0.0002 in) at
scraping carbon off top face of
cylinderwith a scraper. 20'c (68'F)
o Numbers are stamped on the
3. Measure cylinder bore diameter
connectingrod and cap correspond- and piston skirt diameter.
ing to eachcylinder. Careshould be
Pistonto cylinderwall clearance:
taken to avoid a wrong combina-
0.050 - 0.070 mm
tion includingbearing.
(0.0020 - 0.0028 in)
Arrange so that the front mark on
piston head faces to the front of 4. Check connectingrod for bend or
engine. torsion using a connecting rod aligner.
Arrange so that oil hole of connect- Install piston rings so that stamped If bend or torsion exceedsthe limit,
ing rod big end is directed toward markon ringfacesupward. correct or replace.
the right sideof cylinderblock. Bend and torsion
lper lfi) mm (3.94 in! lensthl:
Lessthan 0.05 mm (0.0020 inl
C=
a7
a/

sEM566

sEM844

. Set piston ringsas shown below.

PISTONRING
Measurethe side clearanceof ringsin 5. Measurethe thrust clearance. If
ring groovesaseachring is installed. the measuredvalueexceedsthe limit,
Max.tolerance
of sideclearance: replacesuchconnecting
rod.
0.1 mm (0.004inl

PISTON, PISTON PIN AND

C O N N E C T I N GR O D
l. Measure inside diameter of
connecting rod small end bearing and
outer diameterof piston pin.
EM129
Connectingrod smallend bearing
GAUTION:
clearance:
o Connecting rod with same weight
0.004 - 0.017 mm
Measurering gap with a feeler gauge, tolerance is availableonly as a set
(0.0002 - 0.0007 in) at
placing ring squarely in cylinder using of four.
piston at upper or lower part of cylin-
2o"c(68"F)
der. 2. Measure inner diameter of piston
Max. toleranceof ring gap: pin hole and outer diameter of piston
1.0 mm (0.039in) pin.

EM-10
 C Y L I N D E RB L O C K .C R A N K S H A F TA N D P I S T O N

. C O N N E C T I N GR O D B E A R I N G
Measure connecting rod bearing No.5
clearanceusing plastigage.
l. Removeconnectingrod caps No. 2
2. Clean crankshaft journal and
bearing.
3. Placeplastigageacrossjournal.
4. Install capsand tighten.

@ : Connectingrod bearingcap
59 - 64 N.m EM757 SEMA35
(6.0 - 6.5 kg-m,
43 - 47 tt-tb'l

5. Remove cap and measure plasti-

2. Install main bearing cap and
gage. CRANKSHAFT
RUNOUT tightenboltsto specified
torque.
Checkcrankshaftrunout. . Arrangethe partsso that the figure
Max. toleranceof connecting
rod bearingclearance:
on bearingcap facestoward the
0.10 mm (0.0039in)
waterpump,
Prior to tightening bearing cap
bolts, place bearing cap in proper
CAUTION:
position by shifting crankshaft in
Do not tutn crankshaftor connecting
' the axialdirection.
rod while the plastigageis being in-
Tighten bearingcap bolts gradually
serted.
in separatingtwo to three stages
and in sequenoeoutwardly from
centerbearing,
(Total indicator readingl:
Le$ than 0.08 mm (0.0020in) EM7t6 Tighten in numerical order.
Loosenin reverseorder.

t-----\@- Ot----\@
(J / \ , t

l@l
t l
lol l@l
t l | | t l
MAIN BEARING l@l
-
l"l l"l
Measuremain bearing clearanceusing , , @ . , 6'----.,B
plastigage.

@ : Main bearingcap
83 - 98 N.m
(85 - 10.0 ks-m, o After securing bearing cap bolts,
61 - 72 ft-tb) ascertain that crankshaft turns
CRANKSHAFT Max. tolerance of main bearing smoothly by hand.
CRANK JOURNAL AND PIN dearane: 3. Measure crankshaft free end play
0.10 mm (0.fi)39 in) at the centerbearing.
l Check crankshaft journals and
pins for score,bias, wear or cracks.If Crankshaftfree end play limit:
faults are minor, correct with fine 0 . 3 0m m ( 0 . 0 1 1 8i n )
crocuscloth.
2. Check journals and crank pins
with a micrometer for taper and out- CRANKSHAFT INSTALLATION
of-round. Measureme4t should be 1. Set upper main bearings in the
taken along journals for taper and proper position on cylinder block.
around j ournals for out-of-round.
o Only center bearing (No. 3) is a
If out-of-round or taper exceedsthe
flangetype.
specifiedlimit, replaceor repair.
o Front bearing (No. 1) is also the
Out-of-round(X-Y) and same type as rear bearing (No. 5).
Taper(A-B): a Other inter bearings,ex@pt center
Lessthan 0.01 mm (0.0004 in) bearing,are the sametype.

EM.11
 C Y L I N D E RB L O C K ,C R A N K S H A F TA N D P I S T O N

JACK SHAFT AND JACK der using a ridge reamer or other

SHAFT BUSHING similartool.

JACK SHAFT BUSHING

CLEARANCE
Journal diameters should be checked C Y L I N D E RB O R I N G
with a micrometer,and bushingswith When any cylinder needs boring, all
an inside dial gauge. Measurements other cylindersmust also be bored at
should then be comparedto determine the sametime.
whether bushingsareworn.
Max. toleranceof jack shaft
D e t e r m i n i nbgo r es i z e
bushingclearance:
0 . 1 5m m ( 0 . 0 0 5 9i n ) 1. Determinepiston oversizeaccord-
If beyond the specifiedlimit, correct ing to amountof cylinderwear.
with surfacegrinder. R e f e rt o S . D . S .
Surfacegrindinglimit: 2, The size to which cylinder must
The grindinglimit of cylinder block is be honed is determined by adding
determinedby the cylinderheadgrind- piston-to-clLinder clearance to the
ing. p i s t o ns k i r t d i a m e t e r .
Depthof cylinderheadgrindingis A
Depthof cylinderblock grindingis B
The limit is as follows:
A * B = 0.2 mm (0.008inl

SEM837
Using a bore gauge,measurecylinder
bore for wear, out-of-round or taper.
Referto S.D.S.

Out-of-round ....... X-Y

R E P L A C I N GJ A C K S H A F T Taper. ...... A-B
BUSHING
o Align cylinder block oil hole and
bushingoil hole. Rebored
sizecalculation
. Checkbushingclearance. D=A+B_C
o Install welch plug into cylinder = A + [0.030to 0.050mm
block,applyingsealant. (0.0012to 0.0020inll
where,

t
D ; Honeddiameter
A : S k i r td i a m e t ear s
measured
Unit: mm tin) \l--,2 'EM'4B B : Piston-to-wall clearance
C : Honingallowance
0.02 mm (0.0008in)
l-*

sEM838

Boring

C Y L I N D E RB L O C K sEM549 l. Install main bearingcapsin place,

and tighten to the specifiedtorque to
CYLINDER BLOCK DISTORTION prevent distortion of the cylinder
AND WEAR boresin final assembly.
When wear, taper or out-of-round is
Warpageof surface: minor and within the limit, remove the 2. Hone the cylinders to the required
Lessthan 0.1 mm (0.004inl step at the topmost portion of cylin- sizereferrinsto S.D.S.

EM.12
 C Y L I N D E RB L O C K ,C R A N K S H A F TA N D P I S T O N

F R O N TC O V E R OIL SEAL
Before installing front cover, align lo- r lt is good practiceto renewoil seal
catins notches. wheneverengineis overhauled.

Front cover Check front, and rear oil seals for

worn or folded over sealinglip and oil
leakage.When installing a new front or
rear seal,pay attention to its mounting
direction.
lCrankshaft
sprocket
sLc39 1

DISTRIBUTOR
l. Make sure No. I piston is at top
FLYWHEEL dead center.
Measure runout of the clutch disc 2. Align distributor gear with the
contact surfacewith a dial gauge. sEM839
mark on the shaft.

Runout
(Total indicatorreadingl:
Lessthan 0.1 mm (0.004inl
When installing oil seal retainer,
give coatingof engineoil to mating
shaft to preyent scratchesand fold-
ed lip. Also apply coatingof oil to
peripheryof oil seal.

KE
Install oil sealin the directionthat
dust seal lip facesto the outsideof
crankcase.

A P P L Y I N GS E A L A N T
Then, turn rotor shaft clockwise on
Use sealantto eliminate water and oil distributor cap sideabout 12 degree.
leaks.Do not apply too much sealant. 3. Install distributor and tighten
Check tooth surfacesof ring gear for Part requiring sealantis: fixing plate bolt.
flaws or wear.
Install ring gear on fly wheel, heating
ring gear to about 180 to 220"C (356
to 428"F)

EM-13
 SERVICEDATA AND' SPECIFICATIONS

SERVICEDATAAND SPECIFICATIONS
G E N E R A LS P E CFI I C A T I O N S VALVE
Unit: mm (in)
E n g i n em o d e l FJ2O

Cylinderarrangement 4, in-line

Displacement cma (cu in) 1 , 9 9 0( 1 2 1 . 4 3 )

Boreand stroke mm (in) 8 9 x 8 0 ( 3 . 5 0x 3 . 1 5 )

Valve arrangement D.O.H.C.

Firingorder 1-34-2

Numberof compression 2
pistonrings
Oil 1

Numberof mainbearings 5 sEM841

Valve head
Intake 34.5 (1.358)
Compression
ratio 9.1
"D"
diameter
Exhaust 30.011.181)

lntake - 4.!4.11
r25.01- 125.5114.922
INSPECTION AND ADJUSTMENT Valvelength"L"
Exhaust l2as' - 125.46(4.920- 4.939)
CYLINDERHEAD
unit: mm (in) Intake 6.$0 - 6.975 10.2740- 0.27461
Varvestem
diameter!'d, " - 0;.2740l,
Standard Limit Exhatrst 5-Sl8 - 6.$0 10.2731
Lessthan lntake
Headsurfaceflatness 0.1(0.004) Valvestemend
0.05 (0.0020) 5.572- 5.590rc.21!A- 0.22011
diameter"dr"
E nrr".
"e"
Valve seat angle 45" 15' - 45"45'

Valveclearance Inake 0.30(0.012)

(Hot)
Exhanst 0.35{0.014)

Valveclearance lnoke 0.23(0.009)

(Cold)*
Exhaust 0.32(0.0131
*Cold: Usedasapproximateydues dJring engineassembly,
clearancesshould ultirnacly be adiustedto fie abovehot
values;refer to sectkrnET for procedure.

Valve lifter
Unit: mm (in)

Standard Limit

Valvelifter 3.950 - 33.97s

outer diameter - 1.3376)
(1.3ti|66

Cylinder head valve

34.000- 34.025
guide hole inner
- 1.3396)
(1.3ri!86
diameter

Valvelifter guide
0.025- 0.075
hole clearance (0.0010- 0.0030)
IOil clearance]

EM.14
 SERVICEDATA AND SPECIFICATIONS

. Valvespring Valve seat

Unit: mm (in)

Standard

Outer 45.07(1.77441
Freelength mm (in)
I nner 41 .66 n.6402l.

29.O1318.7
Outer
Pressure
height 1.142171.7|
Q9.0132.5,
mm/N (mm/kg,in/lb)
26.51159.27
Inner
Q6.5| 16.24,1.043/35.81)

37.5/150.0
Outer
Assemblyheight rc7.5| 15.3.1.476133.71
mm/N (mm/kg,in/lb)
Inner
35.0170.O2 Contacting face angle "o" 45"
135.Ol7.14. 1.378115.74l,
contacting width
lntake 1.63 (0.0642t
Outer 2 . 0( 0 . 0 7 9 ) 'w"
Out of square mm (in) Exhaust 1.55 (0.0610)
I nner 1 . 8( 0 . 0 7 1 )
33.9- 34.1
Intake
( 1 . 3 3 -51 . 3 4 3 )
F i n i s h e dd i a m e t e r " d "
Valveguide 29.4 - 29.6
Exhaust
. U n i t : m m( i n ) ( 1 . 1 5 -7 1 . 1 6 5 )

36.780- 36.796
I ntake
11.4480- 1.4487l.
Outerdiameter"D"
33.080- 33.096
17.7- 18.3 Exhaust
- 1.30301
11.3024
(0.697- 0.720)
36.700- 36.716
Intake
Cylinder headseat 11.4449- 1.4455)
recessdiameter
33.000- 33.016
Exhaust
(.2992 - 1.2998)

Interferencefit of seatinsert
0.064.0.096
(0.0025- 0.0038)

Valve guide 1 2 . 0 3 -3' t 2 . U 4

Outer diameter 10.4737 - O.4742't

Valve guide 7 . 0 0 0- 7 . 0 1 5
I n n e r d i a m e t e r ( F i n i s h e ds i z e l (0.2756- 0.2762l.

Cylinderheadvalveguidehole 1 1 . 9 7 0 -1 1 . 9 8 8
diameter (0.4713- 0.47201

Interference fit of valve guide

0.045- 0.074
(0.0018- o.oo29)

I ntake
0.025- 0.055
(0.0010- 0.0022)
Stemto guide
clearance
Exhaust
0.040- 0.077
(0.0016- 0.oo30)

EM-15
 SE.RVICEDATA. AND SPECIFICATIONS

CAMSHAFTAND CAMSHAFTBEARING JACK SHAFT AND JACK SHAFT BUSHING

Unit: mm (in) Unit: mm (in)

Standard Max. tolerance Standard Max, tolerance

C a m s h a f ti o u r n a l t o 0.025- 0.085 o.o25- 0,089 (0.00591

(0.0010- 0.0033) 0.1{0.004} Jack shaft Front
(0.0010- 0.00351 o.15
bearing clearance journal to
bushing
Innerdiameterof -32.021
32.OOO o.o20- o.o74
camshaftbearing (1.2598
- 1.26,071 clearance Rear
(0.0008- 0.0029) 0.15(0.0059)
Outer diameterof 32.936- 32.975 Front
y.o25 - 34.064
camshaftjournal - 1.29A21
11.2967 Inner diameter (1.3396- 1.3411l|
of jack shaft
Camshaftbend bushing 29.020- 29.053
Lessthan 0.05 (0.0020) Rear
lTotal indicatorreading] 11.1425- 1.1438)

Camshaftend play Lessthan 0,3 (0.012) :l:1.975- 34.000

Outer diameter Front
lt.:!:176- 1.33861
of jack shaft
Journal 28.979 - 29.000
Rear ( 1 . 1 4 G-t r . 1 4 1 7 1

Jack shaft end play 0.045 - 0.1(F (0.0018- 0.0041)

CYLINDERBLOCK
Unit: mm (inl
EM671

Camheight"A" 42.835-42.865(1.6864- 1.6876)

Wearlimit of cam height 0.1(0.004)

Valvetiming

Stardard Limit
€Mr20
a.o. c.
Lessthan
Surfaceflatness 0.1 10.0039)
0.(E10.00201
Unit: degree
Cylinderbore
a b c o e
Inner diameter
89.(xn - 89.050
256" 256" 29" 47" 11" 650
{35(B9-3.5(F91
Out-of-round lX-Y) Lessthan 0.015 {0.0006}

Taper(A-B) Lessthan0.015(0.00061

Differencein inner
diameter between 0.05(0.00201
cylinders

EM.16
 S E R V I C ED A T A A N D S P E C I F I C A T I O N S

P I S T O N ,P I S T O N R I N G A N D P I S T O N P I N Connectingrod
Piston
Unit: mm (in)
Centerdistance 1 4 0 . 0( 5 . 5 1)

Bend,torsion
l p e r 1 0 0( 3 . 9 4 ) l
Standard 0.025(0.0010)
Limit 0.05(0.0020)
P i s t o n p i n b u s h i n gd i a m e t e r 22.013 (0.8661-0.8667)
22.OOO-

Big end play

Standard 0.2- 0.3(0.008- 0.012)
Limit 0.6(0.024)

Pistonskirt diameter "A

Standard 88.940- 88.990(3.5016- 3.50351 CRANKSHAFT

Oversize for service

89.440- 89.490(3.5213-3.52321 M a i nj o u r n a ld i a . " D m " 54.942- 54.955(2.1631- 2.1636)
t0.5(0.020)l
"a" P i n j o u r n a ld i a . " D p " 49.961 - 49.974 .'1.9670- 1.96751
dimension 1 1 . 0( 0 . 4 3 3 )

Piston pin hole diameter 21.991- 22.000(0.8658- 0.8661) C e n t e r d i s t a n c e" r " 40 11.57l.

Piston clearance to Out-of-round (X-Y) and

cylinder block
0.050- 0.070(0.0020
- 0.00281 taper (A-B)
Limit Lessthan 0.01 (0.00041

Bend (total indicator

Pistonring reading)
Unit: mm (in) Lim it Lessthan 0.05 (0.0020)
Standard Limir Freeend play

Side clearance
Standard 0.05 - 0.18 (0.0020- 0.0071)
0.03- 0.07
Top
(0.0012- 0.002s) 0.1(0.004) Limit Lessthan 0.3 (0.012)

2nd
0.03- 0.07
(0.0012- 0.0028) 0.1 (0.004)

oil

Ringgap
0.3- 0.5
Top
(0.012- 0.020) 1 . 0( 0 . 0 3 9 )

2nd
o.3- 0.5
(0.012- 0.020) 1 . 0( 0 . 0 3 9 )

O u t - o f- r o u n d X-Y
Oil (rail ring) 0.3 - 0.9
1.0 (0.039) Taper A-B
{0.012- 0.o3sl

Pistonpin

Unit: mm (in)

Pistonpin outer diameter 21.991- 22,000(0.8658- 0.8661)

Piston pin to piston -0.005 - 0.004(-0.0002- 0.0002)

clearance at 2OoC[68oF] EM7I5

Pistonpin to connecting 0.004 - 0.017 (0.0002- 0.00071

rod clearance at 20"C [6g0F]

EM.17
 S E R V I C ED A T A A N D S P E C I F I C A T I O N S

BEARING
Unit N m Kg-m ft-lb
Bearingclearance
Unit: mm (in) F a n c o u p l i n gb o l t A ? _ q ? 0.64 - 0.85 4.6.6.1

Standard Limit Spark plug ZU. ZY 2 . 0. 3 . 0 14-22

0.035- 0.075 C o m p r e s s o rb r a c k e t 't9 - 26

M a i n b e a r i n gc l e a r a n c e
(0.0014- 0.0030) 0.1 (0.004) 25-35 z.t) - J.b
bolt

C o n n e c t i n gr o d 0.035- 0.075 Compressorto bracket 36-50 3.7-5.1 27-37

b e a r i n gc l e a r a n c e (0.0014- 0.0030) 0 . 1( 0 . 0 0 4 )
Crank pulley bolt 147 IYb 1 5 , 0- 2 0 . 0 1 0 8- 1 4 5

Main bearingundersize Distributor support bolr 3 . 7- 5 . 0 0 . 3 8- 0 . 5 1 2 . 7- 3 . 7

Jnit: mm (in) Water outlet bolt 9.1 t t , 6 o . 9 3- 1 . 2 6 . 7- 8 . 7
Crank main journal diameter "Dm"

Standard 54.942- 54.955(2.1631- 2.1636) Engineinternalparts

U ndersize
54.692 - 54.705 12j532 - 2.15371 Unit N-m kg-m ft-lb
0.25 (0.0098)
Camshaft bracket bolt 14.18 1 . 4- 1 . 8 1 0 -1 3
C a m s h a f ts p r o c k e t b o l r 1 2 7 - 1 1 7 r 3 . 0- 1 8 . 0 94 - 130
MISCELLANEOUS
COMPONENTS 49.59 5.0-6.0
1st 36-43
Unit:mm (in)
uyr Inoer
2nd 1 1 8- 1 2 7 1 2 . 0 -1 3 . 0 87-gI
C a m s h a f tp u l l e y
Runout lTotal indicator reading] 0 . 0 8( 0 . 0 0 3 1 ) head
3rd (After
l o o s e n i n gt o 1 1 8- 127 12.O-' t3.O 87 -94
Flywheel 1st torque)
Runout [Total indicator reading] 0.1 (0.004)
M a i n b e a r i n gc a p b o l t 83 -98 8 . 5- 1 0 . 0 6 1- 7 2
Connectingrod nut 59-il 6 . 0- 6 . 5 43-47

Jack shaft locating

plate bolt o.J - 6.J 0.64 - 0.85 4.6- 6.1

TIGHTENING
TOROUE Jack shaft sprocket Solt 76-98 7.8 - r0.0 56-72
Engineouter parts
Chain guide bolt to - z l 1 . 6- 2 . 1 12-15
Un it N'm kg-m ftl b 6 . 3- 8 . 3
C h a i n t e n s i o n e rb o l t 0.64 - 0.85 4 . 6- 6 . 1
Alternator bracket bolt 44-59 4.5 - 6.0 33-43 Front cover bolr 16-21 1 . 6- 2 . 1 12-15
Alternator to adlusting R e a r o i l s e a lr e t a l n e r
16-21 1 . 6- 2 . 1 12-15 3 . 7- 5 . 0 0.38 - 0.51 2 . 7- 3 . 7
bar bolt bolt

Clutch cover fixing O i l s t r a i n e rb o l t 16 - 2' 1 1 . 6- 2 . 1

16-21 1 . 6- 2 . 1 12-15 12-15
bolt
Oil pan bolt 5-7 0.5- 0.7 3 . 6- s . 1
E n g i n em o u n t i n g
bracketto cylinder 30-40 3 . 1- 4 . 1 2 2 -3 0 Oil pan drainplug 35-47 3.6 - 4.8 26-35
block
Flywheel bolt 137 - 157 1 4 . 0- 1 6 . 0 t01 1 1 6
Intake manifold nut 31-42 3.2- 4.3 23 - 3'l
Intake manifold
30-40 3 . 1- 4 . 1 22-30
support bolt

Exhaustmanifold nut 16-21 1 . 6- 2 . 1 12-15

Throttle chamber bolt 16-21 1 . 6- 2 . 1 12-15

Water pump bolt 6.3- 8.3 0.64 - 0.85 4 . 6- 6 . 1

Cooling fan bolt 6.3- 8.3 0.64 - 0.85 4.6- 6.1

EM.18
 S P E C I A LS E R V I C ET O O L S

SPECIALSERVICE
TOOLS
Specialtool or a commercial equivalent

Tool number Tool name

sT0501s000 Enginestandassembly
@ srosorrooo Enginestand
@ srosorzooo Base

O rvroroosm Engine attachment

@ Kvlotos?oo

sTl2315000 Valve compressor

O rvtorozsoo Valvelip sealdrift

@ rvrorosgoo

KV10107900 Valvelip sealpuller

b#--*
d#\
KV30101000 Clutch aligning bar

t.
I
I
I
[1
il
EM.19 H
F