2-1

ENGINE OVERHAUL (4Y-M)

Page 0
SST TO BE USED .............................................. 2-2
1
ENGINE ATTACHMENTS.................................. 2-4
REMOVAL·INSPECTION·INSTALLATION ................ 2-4
2
CYLINDER HEAD .............................................. 2-7 3
COMPONENTS........................................................... 2-7
4
DISASSEMBLY·INSPECTION·REASSEMBLY........ 2-10
TIMING GEAR .................................................. 2-19 5
COMPONENTS......................................................... 2-19 6
DISASSEMBLY·INSPECTION·REASSEMBLY........ 2-22
CYLINDER BLOCK.......................................... 2-31
7
COMPONENTS......................................................... 2-31 8
DISASSEMBLY·INSPECTION·REASSEMBLY........ 2-33
9
ENGINE ADJUSTMENT................................... 2-42
V-BELT INSPECTION·ADJUSTMENT ..................... 2-42
10
INSPECTION·ADJUSTMENT OF 11
IGNITION TIMING .................................................. 2-43
INSPECTION·ADJUSTMENT OF 12
IDLE-UP SPEED .................................................... 2-43
INSPECTION·ADJUSTMENT OF
13
IDLE SPEED .......................................................... 2-44
14
NO LOAD MAXIMUM
SPEED INSPECTION AND
ADJUSTMENT ....................................................... 2-44
15
COMPRESSION INSPECTION................................. 2-44 16
17
18
2-2

SST TO BE USED
Illustration Part No. Part name

09032-76001-71
Oil pan seal cutter
(09032-00100)

09201-76006-71
Valve guide bushing remover & replacer
(09201-60011)

09202-76002-71
Valve spring compressor
(09202-70020)

09215-76004-71
Camshaft bearing remover & replacer
(09215-00101)

09216-76001-71
Belt tension gauge
(09216-00020)

09221-76002-71
Piston pin remover & replacer
(09221-25018)

09228-76001-71
Oil filter wrench
(09228-06501)

09270-76001-71
Rocker arm support tool set
(09270-71010)
 2-3

Illustration Part No. Part name

09276-76001-71
Valve lifter tool
(09276-71010)
0
1
09320-23000-71 Bearing remover
2
3
09950-76014-71
(09950-40011)
Puller B set 4
5
09950-76018-71
Replacer set
6
(09950-60010)
7
8
09950-76019-71
Replacer B set
(09950-60020)
9
10
09950-76020-71
(09950-70010)
Handle set
11
12
13
14
15
16
17
18
2-4

ENGINE ATTACHMENTS
REMOVAL·INSPECTION·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]

13

T = 17.5 (178) [12.9]

4

T = 20 (204) [14.8]

7
11 12
8
1 9

T = 21 (214) [15.5]

T = 49 (500) [36.2]

T = 19 (194) [14.0]
T = 18 (183) [13.2] 2
T = 25 (255) [18.4]

Removal·Installation Procedure
The installation procedure is the reverse of the removal procedure.
No. Item Removal Inspection Installation
1 Fan, Pulley, V-belt See P2-42 See P2-42
2 Alternator
3 Intake pipe
4 Spark plugs
5 Accelerator wire
6 Carburetor
7 Air governor
8 Fuel pump
9 Intake·Exhaust manifolds [Point 1] [Point 2]
10 Oil level gauge
11 Oil filter [Point 3] [Point 5]
12 Water pump
13 Distributor [Point 4]
 2-5

[Point 1]
Removal:
The intake manifold and exhaust manifold are to be removed
at the same time.

0
1
[Point 2]
2
Inspection:
Using a straight edge ruler and a thickness gauge, measure
3
the amount of distortion of the intake manifold.
Limit: 0.40 mm (0.0157 in.) 4
5
6
Inspection:
Using a straight edge ruler and a thickness gauge, measure
the amount of distortion of the exhaust manifold. 7
Limit: 0.40 mm (0.0157 in.)
8
9
10
[Point 3]
SST Removal: 11
Use the SST to remove the oil filter.
SST 09228-76001-71
(09228-06501)
12
13
14
[Point 4]
Installation: 15
Install the distributor.
1. Align the TDC mark of the crank pully with the notch of the 16
timing gear cover.

17
18
2-6

2. Set the position of the groove in the oil pump driveshaft at

about 30° when seen from above.

30°

Oil pump
driveshaft groove

3. Align the housing groove with the drill mark of the gear, and
insert the distributor.
Note:
• Do not confuse the drill mark and the straight pin.
Housing groove • When installing the distributor, align the screw hole for
attaching the block with the center of the groove in the
flange to install.
• After installation, adjust the ignition timing. (See P2-43)

Straight pin Drill mark

[Point 5]
Installation:
After cleaning the attachment surface of the oil filter, fit an O-
ring to the oil filter and tighten the oil filter to the bracket by
hand first, and then use the SST to further tighten by 3/4 turn.
SST 09228-76001-71
(09228-06501)
Caution:
• Apply a small amount of engine oil to the O-ring.
• Clean the surface to which the O-ring will be attached.
 2-7

CYLINDER HEAD
COMPONENTS
1104
2-8

1302
 2-9

1701
2-10

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]

T = 5.0 (51) [3.7] 2

T = 88 (900) [65.1]

5 4

T = 24 (244) 6
[17.7]

10
8
T = 19.1 (195) [14.1]

Disassembly·Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
No. Item Disassembly Inspection Reassembly
1 Remove parts in procedures 1 to 13 on page 2-4.
2 Cylinder head cover
3 Rocker shaft ASSY [Point 1] [Point 2] [Point 18]
4 Valve stem cap [Point 3]
5 Valve push rod [Point 4] [Point 5] [Point 17]
6 Cylinder head bolt [Point 6] [Point 16]
7 Cylinder head gasket [Point 7] [Point 15]
8 Valve spring and valve [Point 8] [Point 9] [Point 14]
9 Valve stem oil seal [Point 13]
10 Valve guide bushing [Point 10] [Point 11] [Point 12]
 2-11

Point Operations
[Point 1]
Disassembly:
Evenly loosen the support set bolts in two or three times,
following the order shown in the illustration.

1 3 5 4 2

[Point 2]
Inspection:
Inspect for wear or damage to the contact surface for the
rocker arm valve stem cap.
If there is a slight damage, correct it by polishing with oil stone,
Contact surface and replace if there is a considerable wear or damage.

Inspection:
Move the rocker arm as shown in the illustration, and inspect
the clearance between the rocker arm and the shaft. If the
clearance is large, disassemble and inspect it.

Inspection:
Inspect the oil clearance between the rocker arm and the
rocker shaft.
1. Measure the rocker arm inside diameter with a caliper gauge.
Standard: 18.500 to 18.515 mm (0.7283 to 0.7289 in.)

2. Measure the rocker shaft outside diameter with a micrometer.

Standard: 18.474 to 18.487 mm (0.7273 to 0.7278 in.)
Calculate the oil clearance by the difference between the arm
inner diameter and the shaft outer diameter.
Standard: 0.013 to 0.041 mm (0.0005 to 0.0016 in.)
Limit: 0.08 mm (0.0031 in.)
If it exceeds the limit, replace the rocker arm or the rocker
shaft.
2-12

[Point 3]
Inspection:
Inspect the valve stem cap.
1. Measure the wall thickness of the valve stem cap.
Standard: 1.31 to 1.49 mm (0.0516 to 0.0587 in.)
2. If there is a slight scratch on the contact surface with the rocker
arm, correct it by polishing with oil stone, and if there is
considerable wear or damage, replace with a new one.

[Point 4]
Disassembly:
Store the removed push rods carefully so that their order will
not be mixed up during reassembly.

1 2 3 4 5 6 7 8

[Point 5]
Inspection:
Inspect the push rod.
1. Inspect the runout in the push rod.
Limit: 0.30 mm (0.0118 in.)
If it exceeds the limit, replace the push rod.
2. Inspect for blockage of the push rod oil hole.
If there is a blockage, remove it with an air gun.

[Point 6]
6 1 2 3 5
8 13 11 Disassembly:
Loosen the cylinder head bolts in two or three times, following
the order shown in the illustration.

Front
4 10 12 9 7

[Point 7]
Inspection:
Use a straight edge ruler and a thickness gauge to measure
the distortion of the lower surface of the cylinder head and the
attachment surface of the manifold.
Limit
Cylinder head lower surface: 0.15 mm (0.0059 in.)
Manifold attachment surface: 0.10 mm (0.0039 in.)
If it exceeds the limit, grind or replace.
 2-13

Inspection:
Inspect for cracking in the cylinder head.
With color check (dye penetrant inspection), inspect the
combustion chambers, the intake ports, the exhaust ports, and
the lower and upper faces of the heads.

[Point 8]
SST
Disassembly:
Use the SST to disassemble the valve spring and valve.
SST 09202-76002-71
(09202-70020)
Disassembly:
Store the removed parts by sorting them out for each cylinder.

[Point 9]
Inspection:
Inspect the oil clearance between the valve guide bushing and
the valve stem.
1. Measure the valve guide bushing inside diameter with a caliper
gauge.
Standard
IN: 8.010 to 8.030 mm (0.3154 to 0.3161 in.)
2. Measure the outside diameter of the valve stem.
Standard
IN: 7.970 to 7.985 mm (0.3138 to 0.3144 in.)
EX: 7.965 to 7.980 mm (0.3136 to 0.3142 in.)
3. Calculate the oil clearance.
Standard
IN: 0.025 to 0.060 mm (0.0010 to 0.0024 in.)
EX: 0.030 to 0.065 mm (0.0012 to 0.0026 in.)
Limit
IN: 0.10 mm (0.0039 in.)
EX: 0.12 mm (0.0047 in.)
If it exceeds the limit, replace the valve stem or the valve guide
bushing. Also, if necessary, grind the inside surface by using a
reamer to correct the oil clearance between the valve guide
bushing and the valve stem within the standard range.
2-14

Inspection:
Inspect the valves.

1. Measure the wall thickness of the valve head.

Standard
IN: 1.0 to 1.4 mm (0.039 to 0.055 in.)
EX: 1.3 to 1.7 mm (0.051 to 0.067 in.)
Limit
IN: 0.5 mm (0.020 in.)
EX: 0.8 mm (0.031 in.)

2. Measure the total length of the valves.

Standard
IN: 108.2 mm (4.260 in.)
EX: 108.5 mm (4.272 in.)
Limit
IN: 107.7 mm (4.240 in.)
EX: 108.0 mm (4.252 in.)

Inspection:
Inspect the valve seat.

1. Apply red lead primer thinly to the valve face.

2. Insert the valve into the valve guide bushing, and press the
valve onto the valve seat. Do not rotate the valve while it is
pressed onto the valve seat.
3. Inspect the width of the contact surface to see whether it is
within the standard along the entire circumference.
Standard
Contact width: 1.2 to 1.6 mm (0.047 to 0.063 in.)
If the width is not within the standard, replace the valve or
correct the valve seat.
4. Correct the valve seat.
Caution:
• Use a carbide tip cutter for the EX side.
• Cutting should be performed while constantly checking
the contact point and contact width of the valve.
• In order not to create steps, gradually reduce the force
towards the end of cutting.
• Make corrections after inspecting the valve guide
bushing.
 2-15

(1) Grind the valve seat with a 45° valve seat cutter.
(2) If the contact position is on the outward side, grind using
30° a 30° cutter.
45°

Contact surface

(3) If the contact position is on the inward side, grind using a

IN side: 60° 60° cutter on the IN side, and a 65° cutter on the EX side.
EX side: 65°
45°

Contact surface
Inspection:
2.0 mm (0.079 in.) Inspect the valve spring.

1. Measure the squareness at the top end of the spring.

Limit IN·EX: 2.0 mm (0.079 in.)

2. Measure the free length.

Standard
IN·EX: 46.0 mm (1.81 in.)
Limit
IN·EX: 45.5 mm (1.79 in.)

[Point 10]
Disassembly:
Remove the valve guide bushing.
Valve guide
bushing 1. Use a bar and hammer to break off the valve guide bushing.
Snap ring 2. Remove the snap ring.
2-16

3. Gradually warm the cylinder head to between 80 and 100°C

(176 to 212°F).

4. Use the SST and a hammer to tap out the valve guide bushing.
SST 09201-76006-71
(09201-60011)
SST

[Point 11]
Inspection:
Use a caliper gauge to measure the inside diameter of the
bushing bottom hole, then select the bushing to be used.
Bushing inside diameter (mm) [in.] Bushing size
13.000 to 13.027 (0.5118 to 0.5129) STD bushing
13.027 (0.5129) or more O/S 0.05 bushing

If the bushing bottom hole inside diameter is 13.027 mm

(0.5129 in.) or more, correct the inside of the bushing bottom
hole with a reamer.
Bushing bottom hole inside diameter:
13.050 to 13.077 mm (0.5138 to 0.5148 in.)
If the bushing bottom hole inside diameter is 13.077 mm
(0.5148 in.) or more, replace the cylinder head.
[Point 12]
Reassembly:
SST Install the valve guide bushing.

Snap ring 1. Gradually warm the cylinder head to between 80 and 100°C
(176 to 212°F).
2. Use the SST and a hammer to tap the bushing in until the snap
ring makes contact with the head.
SST 09201-76006-71
(09201-60011)
 2-17

[Point 13]
Oil seal
Reassembly:
Apply engine oil to the valve stem oil seal lip portion and to the
valve stem, and reassemble them.
Reassemble according to the dimensions shown in the
14.5 mm
illustration on the left.
(0.571 in.)
SST 09201-76005-71
(09201-58010)

[Point 14]
SST
Reassembly:
Use the SST to reassemble the valve spring and valve.
SST 09202-76002-71
(09202-70020)

[Point 15]
Front side Gasket Reassembly:
Check the direction of the gasket and install the gasket.

[Point 16]
8 13 12 11 9
6 1 3 Reassembly:
Tighten the cylinder head bolts in two or three times, following
the order shown in the illustration.

Front
10 4 2 5 7

[Point 17]

SST Reassembly:
Use the SST to position and install the push rod.
SST 09270-76001-71
(09270-71010)
2-18

[Point 18]
Reassembly:
Evenly tighten the support set bolts in two or three times,
following the order shown in the illustration.

5 3 1 2 4

Reassembly:
Check the direction of the rocker arm shaft, then use the SST
Facing to position the rocker arm and install the rocker arm ASSY.
upward
SST SST 09270-76001-71
Projecting outward
(09270-71010)
Front side

Projecting outward
 2-19

TIMING GEAR
COMPONENTS
1106
2-20

1302
 2-21

1303
2-22

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]

T = 21 (214) [15.5]
11
T = 21 (214) [15.5]
3

15
13
T = 21 (214) [15.5]
9
T = 140 (1427) [103.2]

T = 90 (917) [66.3]
10
16

T = 21 (214) [15.5]

8
9
T = 19 (194) [14.0]

14

Disassembly·Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
No. Item Disassembly Inspection Reassembly
1 Fan pulley, V-belt, alternator See P2-42 ← ←
2 Cylinder head ASSY* See P2-10 ← ←
3 Crankshaft pulley
4 Crank position sensor
5 Timing gear cover and gasket
6 Crankshaft bearing [Point 1] [Point 19]
7 Pump drive sprocket and drive chain, crankshaft sprocket [Point 2] [Point 18]
8 Chain tensioner [Point 3]
9 Timing chain, crankshaft sprocket, camshaft sprocket [Point 4] [Point 17]
 2-23

No. Item Disassembly Inspection Reassembly

10 Chain vibration damper [Point 5]
11 Valve lifter [Point 6] [Point 7]
12 Oil pan [Point 8] [Point 16]
13 Thrust plate and camshaft [Point 9] [Point 10] [Point 15]
14 Timing gear case
15 Front oil seal [Point 11] [Point 14]
16 Camshaft bearing [Point 12] [Point 13]

* If you remove the parts other than the camshaft, you do not need to remove the cylinder head.
Point Operations
SST(1)
[Point 1]
Disassembly:
Use the SST to remove the crankshaft bearing.
SST 09950-76014-71 ..................(1)
(09950-40011)
09950-76018-71 ..................(2)
SST(2) (09950-60010)

[Point 2]
Disassembly:
Use the SST to remove the bearing (case side).
SST
SST 09320-23000-71

Disassembly:
Use the SST to remove the bearing (gear side).
SST 09950-76014-71 ..................(1)
SST(1) (09950-40011)
09950-76018-71 ..................(2)
(09950-60010)
SST(2)

[Point 3]
Tensioner
Inspection:
Use a vernier caliper to measure the tensioner.
Standard: 15.0 mm (0.591 in.)
Limit: 12.5 mm (0.492 in.)
2-24

[Point 4]
Inspection:
Chain Inspect the timing chain.
Tension the chain to 49 N (5 kgf) [11.0 lbf], then measure the
chain length in at least 3 places at random to inspect the
stretch of the chain.
Limit: 291.4 mm (11.472 in.)

Inspection:
Inspect the timing gear.
Measure the outside diameter of the sprocket with the chain
on.
Limit
Crankshaft: 59 mm (2.32 in.)
Camshaft: 114 mm (4.49 in.)

[Point 5]
Inspection:
Use a vernier caliper to measure the thickness of the damper.
Standard: 6.6 mm (0.260 in.)
Limit: 5.0 mm (0.197 in.)

[Point 6]
Disassembly:
Use a wire with the end bent into an L shape to remove the
valve lifter.
Note:
• Bend the end of the wire about 1 mm (0.04 in.), and insert
the wire into the center hole of the valve lifter to hook the
valve lifter.
• Clean the wire thoroughly first.

• Line the removed valve lifters up in number order. Always

store them with standing up with the hole facing upwards.
• Do not disassemble the valve lifters.

8
6 7
5
3 4
1 2
 2-25

[Point 7]
Inspection:
Inspect the oil clearance of the valve lifter.
1. Measure the outside diameter of the valve lifter.
Standard: 21.387 to 21.404 mm (0.8420 to 0.8427 in.)

2. Measure the inside diameter of the cylinder block bottom hole.

Standard: 21.417 to 21.443 mm (0.8432 to 0.8442 in.)
3. Calculate the oil clearance of the valve lifter.
Standard: 0.012 to 0.056 mm (0.0005 to 0.0022 in.)
Limit: 0.10 mm (0.0039 in.)
If it exceeds the limit, replace the valve lifter.

Inspection:
Valve lifter leak down test
1. Bleed the air from the valve lifter.
Immerse the valve lifter in a container full of diesel oil, and use
the SST to move the plunger up and down several times.
SST 09276-76001-71
(09276-71010)
Caution:
The diesel oil is used only for the test. When installing the
valve lifter, perform bleeding again in engine oil.
2. Use a tester and apply 196 N (20 kgf) [44.1 lbf] of force to the
Plunger
plunger of the air-bled lifter. After the plunger has dropped
Tester about 2 mm (0.08 in.), measure the time taken for the plunger
dropping a further 1 mm (0.04 in.).
3. Measure 3 times, shifting the position of the plunger 120° each
time, and find the average value.
Lifter body Standard: 7 to 28 sec./1 mm (0.04 in.)
(oil temperature 20°C [68°F])

[Point 8]
Disassembly:
Do not deform the flange section of the oil pan during the
operation.
SST 09032-76001-71
(09032-00100)
Caution:
• Do not use the SST on the timing gear case side.
• Do not pry with a screwdriver.
2-26

[Point 9]
Disassembly:
Remove the camshaft.
Caution:
When pulling out the camshaft, pull it out straight to avoid
damaging the camshaft bearing.

[Point 10]
Inspection:
Measure the thrust clearance of the camshaft.
Standard: 0.07 to 0.22 mm (0.0028 to 0.0087 in.)
Limit: 0.3 mm (0.012 in.)

Inspection:
Measure the height of the cam.
Standard
IN: 38.620 to 38.720 mm (1.5205 to 1.5244 in.)
EX: 38.629 to 38.729 mm (1.5208 to 1.5248 in.)
Limit
IN: 38.26 mm (1.5063 in.)
EX: 38.27 mm (1.5067 in.)

Inspection:
Inspect the bending of the camshaft.
Bending = runout of the dial gauge/2
Limit: 0.06 mm (0.0024 in.)

Inspection:
Inspect the oil clearance of the camshaft bearing.
1. Measure the outside diameter of the camshaft journal.
Standard
No.1: 46.459 to 46.475 mm (1.8291 to 1.8297 in.)
No.2: 46.209 to 46.225 mm (1.8192 to 1.8199 in.)
No.3: 45.959 to 45.975 mm (1.8094 to 1.8100 in.)
No.4: 45.709 to 45.725 mm (1.7996 to 1.8002 in.)
No.5: 45.459 to 45.475 mm (1.7897 to 1.7904 in.)
 2-27

2. Measure the inside diameter of the camshaft bearing.

Standard
No.1: 46.500 to 46.540 mm (1.8307 to 1.8323 in.)
No.2: 46.250 to 46.290 mm (1.8209 to 1.8224 in.)
No.3: 46.000 to 46.040 mm (1.8110 to 1.8126 in.)
No.4: 45.750 to 45.790 mm (1.8012 to 1.8028 in.)
No.5: 45.500 to 45.540 mm (1.7913 to 1.7929 in.)
3. Calculate the oil clearance.
Standard: 0.025 to 0.081 mm (0.0010 to 0.0032 in.)
Limit: 0.1 mm (0.0039 in.)
If it exceeds the limit, replace the bearing.
[Point 11]
Disassembly:
SST(2) Use the SST to tap out the oil seal.
SST 09950-76018-71 ..................(1)
SST(1)
(09950-60010)
09950-76020-71 ..................(2)
(09950-70010)

[Point 12]
Disassembly:
Remove the camshaft bearing.
SST
1. Remove the oil pump w/ strainer. (See P8-6)
2. Use the SST to remove the rear tight plug.
SST 09215-76004-71
(09215-00101)

3. Use the SST to remove the camshaft bearing.

SST 09215-76004-71
(09215-00101)
SST
2-28

Note:
Each bearing has a different outside diameter, so take care
No.1 No.2 No.3 No.4 No.5 when removing and reinstalling them.

[Point 13]
Disassembly:
Install the camshaft bearing.
1. Align the oil holes of the cylinder block and the bearing.
No.5
No.4
No.3
No.2
No.1

Front 2. Use the SST to install the bearing.

SST 09215-76004-71
(09215-00101)
3. Use a new tight plug to apply ThreeBond 1386 to the outer
SST circumference, and drive the tight plug into the cylinder block
until the surface is even.
SST 09215-76004-71
(09215-00101)

[Point 14]
Reassembly:
SST(2) Using the SST, drive the oil seal into the timing gear cover until
the surface is even.
SST 09950-76018-71 .....................(1)
SST(1)
(09950-60010)
09950-76020-71 .....................(2)
(09950-70010)

[Point 15]
Reassembly:
Take care as the thrust plate has a direction.

Front
 2-29

[Point 16]
Reassembly:
Apply FIPG to the seal section of the oil pan.
FIPG: 08826-76001-71
(For handling of FIPG, See P0-19)

FIPG

[Point 17]
Mark
Reassembly:
Camshaft key Install the timing chain, camshaft sprocket, and crankshaft
sprocket.
1. Position the crankshaft key exactly at the top.
2. Align the camshaft key with the upper mark on the thrust plate.

Crankshaft key

3. Assemble the timing chain, camshaft sprocket, and crankshaft

Timing mark sprocket at the same time.
Caution:
Be sure to align the marks of each sprocket with the marks on
Mark the timing chain.

Mark

Timing mark
2-30

[Point 18]
Gear side SST(1) Case side
Reassembly:
(2) Use the SST to install the bearing.
SST(2)
SST 09950-76018-71 .....................(1)
(1) (09950-60010)
09950-76020-71 .....................(2)
(09950-70010)

[Point 19]
Reassembly:
Tap the bearing inner race evenly around with a bar to fit it.

Bar
 2-31

CYLINDER BLOCK
COMPONENTS
1105
2-32

1301
 2-33

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]

4 5

12
8
3

T = 18 (183)
[13.2]

7 11

T = 78 (795) [57.5]
T = 49 (500) [36.2] T = 44 (448) [32.4]
T = 12.5 (127) [9.2]

Disassembly·Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
No. Item Disassembly Inspection Reassembly
1 Cylinder head ASSY See P2-10 ← ←
2 Timing gear-related See P2-22 ← ←
3 Oil pump ASSY W/ oil strainer
4 Rear oil seal retainer W/ oil seal [Point 1] [Point 14]
5 Rear oil seal
6 Measuring the thrust clearance of the connecting rod [Point 2]
7 Connecting rod cap W/ bearing [Point 3] [Point 13]
8 Piston W/ connecting rod [Point 4] [Point 12]
9 Piston disassembly [Point 5] [Point 6] [Point 11]
10 Measuring the thrust clearance of the crankshaft [Point 7]
11 Crankshaft cap, bearing, thrust washer [Point 8] [Point 10]
12 Crankshaft [Point 9]

Caution:
Be sure that the parts for each cylinder are assembled in their correct combinations.
2-34

Point Operations
[Point 1]
Disassembly:
Use a screwdriver and a hammer to tap out the oil seal.

[Point 2]
Inspection:
Move the connecting rod back and forth to measure the thrust
clearance.
Standard: 0.016 to 0.312 mm (0.0063 to 0.00123 in.)
Limit: 0.35 mm (0.0138 in.)

[Point 3]
Inspection:
Measure the oil clearance of the connecting rod bearing.
Perform the measurement with a Plastigage, and tighten the
connecting rod cap set nut to the specified torque.
Do not turn the crankshaft during the measurement.
Standard: 0.020 to 0.051 mm (0.0008 to 0.0020 in.)
Limit: 0.10 mm (0.0039 in.)

Caution:
6, 7 or 8 • When using STD bearings, use a bearing with the same
reference number (6, 7, 8) as that punched into the
connecting rod cap.
• Remove the Plastigage completely after measuring.

[Point 4]
Vinyl hose Disassembly:
Attach a vinyl hose or similar to the connecting rod bolt to
protect the cylinder inner wall and the crankshaft.
 2-35

Note:
Sort the removed pistons, connecting rod caps, and bearings
into the order of the cylinders.

1 2 3 4

[Point 5]
Disassembly:
Disassemble the piston and the connecting rod.
1. Remove the piston ring and the oil ring.

2. Use the SST and a press to push out and remove the piston
Piston pin pin.
Piston pin
SST 09221-76002-71
(09221-25018)
Note:
• The removal should be performed at room temperature.

SST

• Sort out the removed parts for each cylinder, and be sure
not to mix them up during reassembly.

1 2 3 4

[Point 6]
Inspection:
Inspect the cylinder block.
1. Inspect for any distortions on the upper face of the cylinder
block.
Limit: 0.05 mm (0.0020 in.)
Check that there are no considerable scratches on the cylinder
wall surface. If there are scratches, rebore the cylinder.
2-36

2. Measure the six points shown in the left illustration, and find
the difference between the maximum and minimum values.
Crank axle
Front direction Limit: 0.05 mm (0.0020 in.)

Thrust
direction
10 mm
(0.39 in.)
Center
10 mm
(0.39 in.)

3. Measure the piston clearance.

24 mm (1) Measure the outside diameter of the piston.
(0.94 in.)
Measurement position:
Measure the diameter at the place in a position 24 mm
(0.94 in.) from the top of the piston and orthogonal to
the piston pin.
Standard
STD: 90.925 to 90.955 mm (3.5797 to 3.5809 in.)
O/S 0.5: 91.425 to 91.455 mm (3.599 to 3.601 in.)

(2) Measure the cylinder bore and calculate the piston

clearance.
Crank axle
Front direction Standard: 0.065 to 0.085 mm (0.0026 to 0.0033 in.)

Thrust If the value exceeds the limit, replace the piston or rebore
direction the cylinder and install an O/S piston.
10 mm Note:
(0.39 in.) Boring dimension = P + C - H
Center
P: Outside diameter of the piston C: Piston clearance
10 mm H: Honing margin (0.02 mm [0.0008 in.] or less)
(0.39 in.)

Inspection:
Inspect the piston and the connecting rod.
1. Measure the gap between the piston ring and the ring groove
along the entire circumference.
Standard: 0.03 to 0.07 mm (0.0012 to 0.0028 in.)

2. Press the piston ring into the sliding section of the piston, and
measure the piston ring gap.
Standard
No.1: 0.23 to 0.48 mm (0.0091 to 0.0189 in.)
No.2: 0.16 to 0.44 mm (0.0063 to 0.0173 in.)
Oil ring: 0.13 to 0.47 mm (0.0051 to 0.0185 in.)
 2-37

Reassembly:
Install the piston ring.
1. Install the oil ring expander.
2. Install the oil ring side rail using the piston ring tool.
There is no difference between the top and bottom sides of the
Punch mark oil ring side rail.
3. Install each compression ring with the punch mark at the top
using the piston ring tool.
Punch mark
Top ring: 1T
Second ring: 2 T

Compression Upper side

4. Align the ring gaps as shown in the illustration.
ring No.2 rail

Front

Lower side Compression

rail ring No.1 and
Expander

[Point 7]
Inspection:
Measure the thrust clearance of the crankshaft.
Standard: 0.020 to 0.220 mm (0.0008 to 0.0087 in.)
Limit: 0.30 mm (0.0118 in.)
If it exceeds the limit, replace the thrust washer.

[Point 8]
1 7 9 6 4
Disassembly:
Evenly loosen the cap set bolts in several times, following the
order shown in the left illustration.

3 5 10 8 2
2-38

Note:
Upper (on cylinder block side) Store the caps, bearings and washers in correct order in order
to reinstall them in the same position as when they were
removed.

Front

Lower (on bearing cap side)

[Point 9]
Inspection:
Measure the oil clearance of the crankshaft.
Do not turn the crankshaft during the measurement.
Standard: 0.02 to 0.051 mm (0.0008 to 0.0020 in.)
Limit: 0.10 mm (0.0039 in.)
If it exceeds the limit, replace the bearing. Or, if necessary,
replace the crankshaft.

Note:
When using STD bearings, replace with a bearing with the
same reference number (1 to 3) as that punched into the
cylinder block.

Number
Front

No.1 to 5

Inspection:
Inspect the bending of the crankshaft.
Inspect the bending when turning the crankshaft once.
Bending = runout of the dial gauge/2
Limit: 0.06 mm (0.0024 in.)
 2-39

Inspection:
Inspect for crankshaft wear.
1. Measure the outside diameters of all of the crankshaft journals
and pins.
Standard
Journal outside diameter: 57.985 to 58.000 mm
(2.2829 to 2.2835 in.)
Crank pin outside diameter: 47.985 to 48.000 mm
(1.8892 to 1.8898 in.)
2. Calculate the ellipticity and taper degree.
Limit Ellipticity: 0.02 mm (0.0008 in.)
Taper degree: 0.02 mm (0.0008 in.)
If it exceeds the limit, replace the crankshaft.
[Point 10]
Reassembly:
Install the bearing cap.
1. Install with the oil groove of the thrust washer facing the
crankshaft.
2. Check the front mark, and install in the same place as before
it was disassembled.
Oil groove

10 4 2 5 7 Disassembly:
Evenly tighten the bearing cap bolts in several times, following
the order shown in the illustration.

8 6 1 3 9
[Point 11]
Front mark
(Depression) Reassembly:
Reassemble the piston and connecting rod.
1. Align the front marks of the piston and the connecting rod.

Front mark
(Protrusion)
2-40

2. Apply engine oil to the piston pin and piston pin hole.
Piston pin Piston pin 3. Use the SST and a press to press fit the piston pin.
SST 09221-76002-71
(09221-25018)
Note:
The assembly should be performed at room temperature.

SST

[Point 12]
Reassembly:
Install the bearing.
Ensure that no foreign matter, oil, etc., becomes attached to
the contact surface between the bearing and the connecting
rod.
Apply engine oil to the inner surface of the bearing.
Assemble the upper bearing to the locking groove of the
connecting rod.
Install the lower bearing to the locking groove of the bearing
cap.
Reassembly:
Attach a vinyl hose or similar to the connecting rod bolt to
protect the cylinder inner wall and the crankshaft.

Vinyl hoses

Front mark Reassembly:

(Depression) When reinstalling the piston to the cylinder, be sure to install it
in the same cylinder from which it was removed.
Apply engine oil to the sliding sections of the connecting rod
and the piston.
Use a piston ring compressor to assemble with the front mark
Front facing front.
 2-41

[Point 13]
Reassembly:
Install the connecting rod cap.
1. Install with the front mark of the bearing cap facing the front of
the engine.
2. Align the punch marks of the connecting rod.
Note:
• There are several kinds of alphabet punch marks.
• Each of the rotation angles of the punched alphabet
marks differs. Be sure to align them when installing.
3. Make sure that no foreign matter or oil, etc., becomes attached
to the back surface of the bearing.
Front mark
4. Apply engine oil to the inner surface of the bearing.
5. Tighten the left and right bolts alternately in two or three times.

[Point 14]
Reassembly:
Use the SST to knock in the oil seal.
SST(2)
SST 09950-76019-71 ..................(1)
(09950-60020)
09950-76020-71 ..................(2)
SST(1) (09950-70010)
2-42

Pushing force 98 N (10 kgf) [22 lbf]

ENGINE ADJUSTMENT
Straightedge
V-BELT INSPECTION·ADJUSTMENT
V-belt Inspection
1. Check the belt for correct installation.
Deflection amount 2. Apply a pushing force of 98 N (10 kgf) [22 lbf] between the
alternator and the water pump and measure the amount of
deflection.
When installing a new part: 7 to 9 mm (0.28 to 0.35 in.)
When inspecting: 8 to 13 mm (0.31 to 0.51 in.)
Caution:
• Measurement of the belt deflection amount must be
performed between the specified pulleys.
• When replacing with a new belt, adjust the deflection to
the middle value of the standard "When installing a new
part".
• Apply the standard of "When inspecting" for the
inspection of the belt if it is used for five minutes or more.
• When reassembling the belt that is used for 5 minutes or
more, adjust to the mean value of the standard in "When
inspecting".

• Tension standard when using SST

SST 09216-76001-71
(09216-00020)
When installing a new part: 392 to 588 N (38 to 62 kgf)
[84 to 137 lbf]
When inspecting: 294 to 490 N (30 to 50 kgf)
[66 to 110 lbf]

Set bolt V-belt Deflection Adjustment

1. Loosen the fixing bolt.
Adjustment bolt 2. Loosen the set bolt, then turn the adjustment bolt to adjust the
tension.
3. Tighten the set bolt then re-check the belt tension.
4. Tighten the fixing bolt.
Caution:
Be careful not to apply too much tension to the belt.
Fixing bolt
 2-43

INSPECTION·ADJUSTMENT OF IGNITION
TIMING
1. Warm-up the engine.
Standard
Coolant temperature: 75°C (167°F) or above
Hydraulic oil temperature: 50°C (122°F) or above
Engine oil temperature: 60°C (140°F) or above
2. Install the rev counter and timing light.
Rev terminal Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).
3. Inspect the idle speed.
Standard: Refer to repair manual for each vehicle model.
4. Inspect and adjust the ignition timing.
(1) Disconnect the distributor vacuum hose.
(2) Use the timing light to inspect the ignition timing.
Standard: BTDC 7°/750 rpm
(3) If the value is outside of the standard, loosen the
distributor set bolt and rotate the distributor to adjust to
the standard value.
(4) Tighten the set bolt and inspect the ignition timing again.
T = 17.5 N·m (178 kgf·cm) [12.9 ft·lbf]
(5) If the ignition timing has been adjusted, seal the
distributor set bolt with sealing tape.
Idle up INSPECTION·ADJUSTMENT OF IDLE-UP
actuator
SPEED
1. Warm-up the engine.
Vacuum
hose Standard
Coolant temperature: 75°C (167°F) or above
Hydraulic oil temperature: 50°C (122°F) or above
Engine oil temperature: 60°C (140°F) or above
2. Install the rev counter. (Refer to above)
3. Start the engine, and measure the engine speed with the
vacuum hose removed from the idle-up actuator.
Standard
M/T: 1100 ± 30 rpm
T/C: 1000 ± 30 rpm
If the value is outside of the standard, adjust it by turning the
Adjusting adjusting screw.
screw
Caution:
If the adjusting screw is turned clockwise, the engine speed
increases.
4. After adjustment, connect the vacuum hose.
2-44

INSPECTION·ADJUSTMENT OF IDLE
SPEED
1. Warm-up the engine.
Standard
Coolant temperature: 75°C (167°F) or above
Hydraulic oil temperature: 50°C (122°F) or above
Engine oil temperature: 60°C (140°F) or above
2. Install the rev counter and vacuum gauge.
Vacuum hose
(1) Install the rev counter.
(2) Disconnect the vacuum hose from the vacuum advancer,
and connect the vacuum gauge.
3. Inspect and adjust the idle speed.
(1) Start the engine and alternately adjust the throttle
adjusting screw “A” and the idle adjusting screw “B”, to
adjust so that the vacuum is at a stable maximum at the
regulation idle speed.
(2) If the idle up adjusting screw is connected to the idle up
actuator rod and the idle speed does not reduce, loosen
the idle up adjusting screw. (See P2-43)
A Standard
B Idle speed: Refer to repair manual for each vehicle
model.
Vacuum: 400 mmHg or more
NO LOAD MAXIMUM SPEED INSPECTION
AND ADJUSTMENT
(See P4-24)

COMPRESSION INSPECTION
Note:
When there is a drop in power output or excessive oil
consumption, or if the fuel consumption is extremely high,
measure the compression pressure in the cylinders.
1. Warm-up the engine.
Standard
Coolant temperature: 75°C (167°F) or more
Hydraulic oil temperature: 50°C (122°F) or more
2. Remove all the spark plugs.
3. Disconnect the distributor connector.
4. Measure the compression pressure.
Caution:
Operate the starter before inspecting the compression in
order to expel foreign bodies from inside the cylinder.
 2-45

(1) Insert a compression gauge into the spark plug hole.

(2) Open the throttle up fully.
(3) Crank the engine with the starter to measure the
compression pressure.
Standard: 1225 kPa (12.5 kgf/cm2) [178 psi]
Limit: 883 kPa (9.0 kgf/cm2) [128 psi]
Caution:
In order to maintain the engine speed to more than 250 rpm,
use a fully charged battery.
(4) Carry out the above operations (1) to (3) on every
cylinder, and inspect the pressure difference.
Limit
Pressure difference between cylinders:
98 kPa (1.0 kgf/cm2) [14 psi]
(5) If some cylinders have a compression pressure less than
the limit, or if their pressure differences are more than the
limit, add a small amount of engine oil from the spark plug
hole, and repeat the above operations (1) to (3).
(a) If the pressure goes up by adding oil, there may be
wear or damage to the piston ring and the cylinder
wall.
(b) If the pressure remains low even if oil is added, there
may be a burnout of the valve, defect in valve
contact, or pressure leak from the gasket.
5. Connect the distributor connector.
6. Install the spark plugs.
T = 18 N·m (183 kgf·cm) [13.2 ft·lbf]