ENGINE 2-3

SUBARU M MECHANISM AND FUNCTION . . . .... . . . . . . . . .. . . . .... . . . . .. . . . . . . . . . 2

Page

1 . General ... . . . ..... . ...... . . . . . . . . . . . . . . .. . . . . . ... . . . . . . ..... . . . .... . . .... . . . .. . . . . 2

2. Timing Belt . ... . . . .... . . . . . .. . . . . . . .... . . . . .... . . . . . . . ... . . . .... . . . . ... . . ... . . . 3

SVX 3. Belt Tension Adjuster . . . . . . ...... . . .... . . . . . . . ... . . . ..... . . . .... . ... . . . 4
4. Belt Cover . .... . . .... . . . . . . . .. . . . . . . .... . . . . .... . . . . . .. ... . . . .... . . . . ... . . ... . . . 5 .
5. Camshaft . . . . .... . . . .... . . . . . .. . . . . . . .... .. . . .... . . . . . . . ... . . . ..... . . . .... . ... . . . 5
6. Hydraulic Lash Adjuster . . .... . . . . .... . . . . . .. ... . . . .... . . . . ... . . ... . . . 6

1992 7. Cylinder Head . . . .... . . . . . .. . . . . . . ...... . . .... . . . . . . . ... . . . ...... . . .... . ... . . .
8. Cylinder Block . . .. . . . . . . . .. . . . . . . .... . . . . .... . . . . . . . ... . . . .... . . . . .... . .. . . . .
7
8
9. Crankshaft . . ... . . .... . . . . . . . .. . . . . . . .... . . . . .... . . . . . . . ... . . . .... . . . . ... . . ... . . . 9
10. Piston . ... . . . . . . . . . . . .. . . . . . . . .. . . . . . . .. .. . . . . ... . . . . . . . . . . . . . . .... . . . . ... . . .. . . . . 9
S SPECIFICATIONS AND SERVICE DATA . . . . .... . . . . .. . . . .. . . . . 10
A : SPECIFICATIONS . . . . . . . . . . . .. .... . . . . .. . . . . . . . . .. . . . . . .... . . . . .. . . . .. . . . . 10
B : SERVICE DATA .. . . . . . . . . . . . . . .. .... . . . . .... . . . . . .. . . . . . . . ... . . . . .. . . . .. . . . . 11
C COMPONENT PARTS . . . . . . . . . . .... . . . . .... . . . . . .. . . . . . . .... . . . . ... . . .. . . . . 15
1 . Timing Belt . .. . . .... . . . . . . . .. . . . . . . .... . . . . .... . . . . . ... . . . . . .... . . . . .. . . . .. . . . . 15
2. Cylinder Head and Camshaft . . .... . . . . . . . . .. . . . .... . . . . .... . ... . . . 16
3. Cylinder Head and Valve ASSY . . . . . . . . ... . . . .... . . . . .... . ... . . . 17
4. Cylinder Block . . .... . . . . . . . . . . . . . .. . . . . . . .... . . . . . . . .. . . . . .. .. . . . . .... . ... . . . 18
5 . Crankshaft and Piston . . . . . . .... . . . . .... . . . . . . . ... . . . .... . . . . .... . ... . . . 19
W SERVICE PROCEDURE .. . . . . . . .... .. . . .. .. .. . . . . . ... . . . .. .. . . . . . ... . . .. . . . 20
1 . General Precautions . ... . . . . . .. .... . . . . .... . . . . . . .. . . . . . .... . . . . .. . . . .. . . 20
2 . Timing Belt . .. . . . . . . . . . . . . . . .. . . . . . . . .. .. . . . . .. .. . . . . . . .. . . . . . .... . . . . .. . . . .. . . 21
3. Camshaft .. . . . .... . . . . .. . . . . . ... . . . . . . . .... .. . . .... . . . . . . .. . . . . . .... . . . . .. . . . ... . 31
4. Cylinder Head . . . . . ... . . . . ... . . . . . . . .... .. . . .... . . . . . . .. . . . . . .... . . . . .. . . . ... . 45
5 . Cylinder Block . . . . ... . . . . . .. . . . . . . . . ... . . . . .. . . . . . . . . .. . . . . . .... . . . . .. . . . ... . 56
T TROUBLESHOOTING . . . . ... . . . . . . . .... .. . . .. .. . . . . . . .. . . . . . .... . . . . .. . . . ... . 76
1 . Engine Trouble in General .... . . . . .... . . . . . . .. . . . . . .... . . . . .. . . . ... . 76
2. Engine Noise . . . . .. .. . . . . . ... . . . . . .. .... . . . . .... . . . . . . .. . . . . . .... . . . . .. . . . ... . 79
2-3 JIV11001 ENGINE

M MECHANISM AND FUNCTION

1 . General * The exhaust camshafts on the left and right banks are
driven by a single timing belt, and a gear on the exhaust
The Subaru 3300cc, 6-cylinders engine is made from
aluminum alloy and is horizontally opposed . It is a side camshaft engages with a gear on the intake side
4-stroke cycle, water-cooled, DOW 24-valve engine . camshaft to drive it .
The fuel system utilizes an MPFI (multiple fuel injection) o A single timing belt drives two camshafts on the left
design. and right banks and the water pump on the right bank.
A summary of the major construction and function Belt tension is automatically adjusted to eliminate main-
features is given below. tenance .
0 The cylinder head is a center-plug type that utilizes The crankshaft is supported by seven bearings to
pentroof combustion chambers . The four valve design provide high rigidity and strength .
is provided with two intake valves and two exhaust o The cylinder block is made from aluminum diecast
valves per cylinder. The intake and exhaust ports are which is integrated with cast-iron cylinder liners .
arranged in a cross-flow design .

C2-184

Fig. 1

2
 ENGINE [nn2ool 2-3

2. Timing Belt composed of a strong and inflexible core wire, a wear-

resistant canvas and heat-resistant rubber material .
A single timing belt drives two exhaust camshafts (one
in the left bank and one in the right bank). The back of A hydraulic belt-tension adjuster constantly maintains
the belt also drives the water pump . specified belt tension to properly drive the camshafts,
The timing belt teeth have a specially designed round as well as to provide a "maintenance-free" advantage .
profile to provide quiet operation . The timing belt is

Alignment mark

Alignment mark
Alignment mark (oil pump)
(crank sprocket)
Top mark Alignment
Alignment mark mark
Belt tensioner

Belt tension
o adjuster
V \

Alignment mark
Alignment mark (belt cover)
(belt cover)- I~LJII V I~OO~ COY
O O Alignment mark
(camshaft sprocket)
Alignment mark
(camshaft sprocket) Top mark

O ~) ° I 0 o
o
J o
Top mark
~U °
Idler Camshaft sprocket LH
Camshaft sprocket RH
Idler No . 2
Timing belt
Water pump pulley

C2-185
Fig. 2

3
2-3 [M3001 ENGINE

3 . Belt Tension Adjuster wise, giving tension PB to the belt.

(2) Action for balancing the belt tension
The belt tension adjuster provides a constant value of
When tension PB is given to the belt and the belt tension
tension for the timing belt. Proper belt tension is main-
reaches the normal level, the belt generates the reaction
tained using a rod to push the tension pulley. The
location of the tensioner pulley shaft center is offset in TB, which works as the reaction P at the pressure cone
relation to the center of the pulley's outside diameter . apex of the rod . Since the reaction force pushes the rod
The tensioner adjuster rod provides a rotary movement to the right, the check ball in the oil pressure chamber is
for the tensioner pulley by both tension of the spring closed . When the rod is pushed to the left by the oil
housed in the adjuster . inflow, the balance between the rod and arm is main-
(1) Action when the belt is loose tained to stop the arm, and the belt tension is main-
When the belt is loose, the force between the arm and tained at the fixed level.
rod is unbalanced so that the rod is pushed out to the (3) Action when the belt is too tight
left by the force of the main spring . Then, the oil When the timing belt reaction force increases to such an
pressure in the reservoir compressed by the pressure of extent that the belt will be too tight, the arm force P is
the main spring is increased more than in the oil pres- larger than the rod thrust F. Consequently, the oil in the
sure chamber, and the oil in the reservoir pushes past oil pressure chamber passes through the clearance
the check ball to flow into the oil pressure chamber . In between the adjuster body and rod and is returned to
this way the rod is pushed to the left until the force the reservoir in small amounts. This oil return is stopped
between the arm and rod is balanced . Since the thrust F when the rod thrust F and arm force P are balanced to
works to the arm, the pulley is rotated counterclock- maintain tension at the fixed level .

Fig. 3

4
 ENGINE [M500] 2-3

4 . Belt Cover 5. Camshaft

The belt cover is made of synthetic resin molding which The DOHC engine uses four camshafts in all ; intake and
is lightweight and heat resistant . It has a totally enclosed exhaust camshafts on the RH bank and intake and
design that utilizes rubber packing at the mating surface exhaust camshafts on the LH bank.
of the cylinder block. This eliminates the chance of dust Each camshaft has a gear which allows the exhaust
camshaft to drive the intake camshaft . The intake cam-
and water from entering the interior .
shaft also has a sub gear for eliminating gear backlash,
A floating design is utilized by placing rubber mounting
thereby reducing gear noise.
between the cylinder block and belt cover to prevent The cam nose part is finished with "chill" treatment to
the transmission of noise and vibration . increase wear resistance and anti-scuffing properties .
The front belt cover has a graduated line for ignition- Each camshaft is supported by four journals with three
timing confirmation . camshaft caps and a front camshaft cap . Each camshaft
flange is supported by a groove provided in the cylinder
head to receive thrust force.

camshaft cap LH Sub gear (Non-backlash gear)

Portion affected Driven .geer

Left hand intake camshaft
by thrust force
/t roil passage Intake camshaft cap

l/ ~ Iy~J.l I) r Hexagonal portion for wrench Cylinder No .

O

Journal -J / ~LJou
Snap ring) {=} ~Camshaft .gear spring
DfIVB 988'

7111A~(I I,~I~
Left hand exhaust camshaft Exhaust camshaft cap
Oil passage
Hexagonal portion for wrench Cylinder No .
O
Oil pool

1L.W--J
O
Journal Sub gear
(Non-backlash gear)
Portion affected
by thrust force Driven gear /-Snap ring Front camshaft cap RH
//T Portion affected
Right hand intake camshaft
by thrust force
Intake camshaft cap Oil passage-,

Cylinder No .

0
-journal -'- Journal
Z
Hexagonal portion for wrench
gear spring
Right hand exhaust camshaft
Exhaust camshaft cap gear
Oil passage,
0 Cylinder No.

11 pool

\
0
k X",
oii R Journal
~ Looms I
'-Hexagon.1 portion for wrench L_7 Portion affected
journal -tom by thrust force

C2-187

Fig. 4

5
2-3 [M600] ENGINE

6. Hydraulic Lash Adjuster the high pressure chamber is compressed in a very

short time, almost no change occurs in the oil quantity
The hydraulic lash adjuster is located between the
inside the high pressure chamber. Accordingly, the
camshaft and valve stem. The top surface of the hydrau-
bucket, plunger and adjuster body work as an integral
lic lash adjuster is always in contact with the cam face.
unit to push down the valve stem to open the valve . The
The cam directly pushes the lash adjuster to open or
close the valve . passage for supplying oil from the cylinder head to the
The engine oil flows through the cylinder head and goes lash adjuster is closed during this period, and no oil
into the lash adjuster so as to always maintain zero flows into the lash adjuster.
valve clearance . 3) Action when the valve stops lifting
1) Action when the valve starts to lift When the cam completes its lash adjuster pressing
When the cam begins to push the lash adjuster, the stroke, the passage for supplying oil from the cylinder
bucket and plunger are pushed down . At the same time, head to the lash adjuster opens, allowing oil to flow
the body is pushed up by the reaction from the valve from the cylinder head into reservoir II of the lash
stem . This causes the high pressure chamber to com- adjuster . Since the pressure in the high pressure cham-
press, increasing the oil pressure in the high pressure ber is lower than the pressure in reservoir Il,the check
chamber. ball is pushed down by the oil pressure in reservoir II .
2) Action while the valve is lifted Accordingly, oil flows into the pressure chamber until
As long as the cam is pushed by the lash adjuster, the oil the oil pressure becomes equal between the high pres-
pressure in the high pressure chamber is held high . The sure chamber and reservoir II . Under the action of this
oil in the high pressure chamber leaks through a very oil pressure, the body is pressed against the valve stem
small clearance between the plunger and body. Since and the bucket against the camshaft .

2)

Overflow recess Reservoir II

Bucket
Plunger

Body
Clip i
Reservoir 1
Oil feed hole
Sleeve
Retainer
ring \II Ball cage
Plunger
Check ball - `spring Load
High pressure chamber Check ball spring

1) 3)

C) C)

-crTv
F Pressure in - Expanded
chamber is
increased
C2-188

Fig . 5

6
 ENGINE [Wool 2-3

7 . Cylinder Head The cylinder head gasket is made from carbon material
(not asbestos) . Its core is metal provided with metal
Combustion chambers in the cylinder head are com-
hooks to increase resistance to both heat and wear.
pact, center plug, pentroof types which feature a wide
"squish" area for increased combustion efficiency. The inner side of grommets used in the cylinder bore
Four valves (two intake and two exhaust), which are are reinforced with wire to withstand both high com-
arranged in a cross-flow design, are used per cylinder. bustion pressure and temperature .

Fig. 6

7
2-3 [M8001 ENGINE

8 . Cylinder Block block. Seven main journal block designs are employed
to increase stiffness and quiet operation . The oil pump
The cylinder block is made from aluminum diecast . The
cylinder perimeter has an open-deck design which is is located in the front center of the cylinder block and
lightweight, highly rigid and has superb cooling effi- the water pump is located at the front of the left-cylinder
ciency . bank. At the rear of the right-cylinder block is a separa-
The cylinder liners are made from cast iron and are dry tor which eliminates oil mist contained in the blow-by
types which are totally cast with aluminum cylinder gas .

Oil separator cover

I
"'ms
t a
i~ ~1~~

o ` \ - 10 ~/ o

`®v --o ,
Cylinder block (RH)

Uo
'+V
a0

Cylinder block (LH)

C2-190

Fig . 7

8
 ENGINE [nn1ooo1 2-3

9. Crankshaft and webs, are finished with fillet-roll work to increase

strength . The seven crankshaft bearings are made from
The crankshaft is supported by seven bearings to pro-
vide high rigidity and strength. The corners of the aluminum alloy and the No. 5 bearing is provided with a
crankshaft journals and webs, as well as the crank pins flanged metal to receive thrust force.

C2-191
Fig. 8

10 . Piston The piston head is recessed for both the intake and
exhaust valves . It also has symbols used to identify the
The piston skirt has a "slipper" design to reduce weight
and sliding . The oil control ring groove utilizes a slit location and the direction of installation .
design. Three piston rings are used for each piston-two com-
The piston pin is located in an offset position. The Nos . pression rings and one oil ring. The top piston ring has
1, 3 and 5 pistons are offset in the lower direction while an inner-bevel design and the second piston ring has an
the Nos . 2, 4 and 6 pistons are offset in the upper interrupt design to reduce oil consumption .
direction .

Location mark
(Engine front side) (I nner-bevel)
Location mark
Identification (Engine front side)
mark (Piston size)
Top ring

Second ring
Identification mark (Interrrupt)
(Piston size)
Upper rail

Oil ring Spacer

Lower rail

C2-192
Fig. 9

9
2-3 [SOA01 ENGINE

S SPECIFICATIONS AND SERVICE DATA

f A: SPECIFICATIONS

Type Horizontally opposed, liquid cooled, 6-cylinder, 4-stroke gasoline engine

Valve arrangement Belt driven, double over-head camshaft, 4-valve/cylinder
Bore x Stroke mm (in) 96 .9 x 75 (3 .815 x 2 .95)
Piston displacement cm3 (cu in) 3,318 (202 .46)
Compression ratio 10 .0
Compression pressure kPa (kg/cm2, psi) 1,177 - 1,422 (12 - 14 .5, 171 - 206)
(at 200 - 300 rpm)
Number of piston rings Pressure ring : 2, Oil ring : 1
ENGINE
Opening 4° BTDC
I nta ke val ve tim i ng
Closing 52° ABDC
Opening 55° BBDC
E x h aust va lve t i m i ng
Closing 9° ATDC
Idling speed [At N or D
rpm 610± 100 (No load)
position]
Firing order 1-6-3-2-5-4
Ignition timing BTDC/rpm I 20± 8°/610

10
 ENGINE [SOSO] 2-3

~B: SERVICE DATA

Unit : mm (in)

Belt tension
Adjuster rod protrusion 15 .4 - 16 .4 (0 .606 - 0 .646)
adjuster
Spacer O .D . 16 (0 .63)
Tensioner bush I .D . 16 .16 (0 .6362)
STD 0. 117 - 0 .180 (0 .0046 - 0 .0071)
Belt tensioner Clearance between spacer and bush
Limit 0.230 (0 .0091)
STD 0.37 - 0 .54 (0 .0146 - 0.0213)
Side clearance of spacer
Limit 0.8 (0.031)
Bend limit 0.02 (0 .0008)
STD 39 .05 - 39.15 (1 .5374 - 1 .5413)
Intake
Limit 38 .90 (1 .5315)
Cam lobe height
STD 39 .85 - 39 .95 (1 .5689 - 1 .5728)
Exhaust
Limit 39 .70 (1 .5630)
#1 31 .946 - 31 .963 (1 .2577 - 1 .2584)
Camsh a ft journal OD
Camshaft #2, #3, #4 27 .946 - 27 .963 (1 .1002 - 1 .1009)
STD 0.03 - 0 .09 (0 .0012 - 0.0035)
Inta k e
Limit 0.13 (0 .0051)
Thrust clearance
STD 0.02 - 0.08 (0 .0008 - 0.0031)
Exhaust
Limit 0.12 (0 .0047)
STD 0.037 - 0 .072 (0 .0015 - 0 .0028)
Oil clearance
Limit 0.10 (0 .0039)
STD 0.029 - 0.175 (0 .0011 - 0.0069)
Backlash
Camshaft gear Limit 0 .30 (0 .0118)
Free distance between camshaft spring ends 24 .88 - 28 .88 (0 .9795 - 1 .1370)
Surface warping limit 0 .05 (0 .0020)
Cylinder head Surface grinding limit 0 .30 (0 .0118)
Standard height 127.5 (5 .020)
Refacing angle 90°
STD 1 .0 (0 .039)
Intake
Valve seat Limit 1 .7 (0 .067)
Contacting width
STD 1 .5 (0 .059)
Exhaust
Limit 2 .2 (0 .087)
Inner diameter 6 .000 - 6.012 (0 .2362 - 0 .2367)
Valve gui de
Height above head 8 .5 (0 .335)
STD 0 .8 (0 .031)
I ntake
Limit 0 .6(0 .024)
H ead ed ge t hic kness
STD 1 .0 (0 .039)
Va lve Ex h aust
Limit 0 .8 (0 .031)
Intake 5.955 - 5.970 (0 .2344 - 0.2350)
Stem di ameter
Exhaust 5 .945 - 5.960 (0 .2341 - 0.2346)

STD : Standard ID : Inner diameter OD : Outer diameter

11
2-3 [SOBO1 ENGINE
Unit : mm (in)

STD 0.030 - 0.057 (0 .0012 - 0.0022)

Intake
Limit 0 .10 (0.0039)
Stem o il c l earance
STD 0 .040 - 0 .067 (0 .0016 - 0.0026)
Va l ve Ex haust
Limit 0 .10 - (0 .0039)
Intake 90 .00 (3 .5433)
Overa ll l eng th
Exhaust 90 .85 (3 .5768)
Outer spring 36 .4 (1 .433)
F ree l ength
Inner spring 34 .9 (1 .374)
Outer spring 2 .5°, 1 .6 (0 .063)
Squareness
Valve spring Inner spring 2 .5°, 1 .5 (0 .059)
124 .5 - 142 .2 N (12.7 - 14.5 kg, 28 .0 - 32 .0 Ib)/29 (1 .14)
Outer spring
308 .9 - 356 .0 N (31 .5 - 36.3 kg, 69 .5 - 80.0 Ib)/21 .1 (0 .831)
Tensi on/spr i ng height
58 .8 - 66 .7 N (6 - 6 .8 kg, 13 .2 - 15 .01b)/27.5 (1 .083)
Inner spring 147 .1 - 168 .7 N (15 - 17 .2 kg, 33.1 - 37 .9 Ib)/19 .6 (0.772)
Outer diameter 32 .965 - 32 .975 (1 .2978 - 1 .2982)
Hydraulic lash Bush I .D . 33 .009 - 33 .031 (1 .2996 - 1 .3004)
adjuster STD 0.028 - 0 .078 (0.0011 - 0.0031)
Oil c l earance
Limit 0.110 (0 .0043)
Surface warpage limit (mating with cylinder head) 0.05 (0.0020)
Surface grinding limit 0.4 (0 .016)
A 96 .905 - 96 .915 (3 .8151 - 3 .8155)
Cylinder bore STD B 96 .895 - 96 .905 (3 .8148 - 3 .8151)
C 96 .885 - 96 .895 (3 .8144 - 3 .8148)
STD 0.015 (0 .0006)
Cy li nd er bl oc k Taper
Limit 0.050 (0 .0020)
STD 0.010 (0 .0004)
Ou ter-of-roun d ness
Limit 0.050 (0 .0020)
STD 0.010 - 0 .030 (0.0004 - 0.0012)
Pi s ton c learance
Limit 0.060 (0 .0024)
Enlarging (boring) limit 0.5 (0 .020)
A 96 .885 - 96 .895 (3 .8144 - 3 .8148)
STD B 96 .875 - 96 .885 (3 .8140 - 3 .8144)
Piston Outer diameter C 96 .865 - 96 .875 (3 .8136 - 3 .8140)
0 .25 mm (0.0098 in) OS 97 .125 - 97 .135 (3 .8238 - 3 .8242)
f 0 .50 mm (0.0197 in) OS 97 .375 - 97 .385 (3 .8337 - 3 .8340)

STD : Standard ID : Inner diameter OS : Over size

12
 ENGINE ISOBOI 2-3

Unit : mm (in)

Standard clearance between piston pin and hole in piston 0.004 - 0 .008 (0 .0002 - 0 .0003)
Piston pin Piston pin must be fitted into
Degree of fit position with thumb at 20°C (68°F) .
STD 0.20 - 0 .30 (0.0079 - 0.0118)
Top ring
Limit 0.5 (0.020)
Second LTD 0 .37 - 0 .52 (0.0146 - 0.0205)
Piston ring gap ring Limit 1 .0 (0.039)
STD 0 .20 - 0 .60 (0.0079 - 0.0236)
Piston ring Oil ring
limit 1 .5 (0.059)
STD 0 .04 - 0 .09 (0 .0016 - 0 .0035)
Top ring
Clearance between piston ring Limit 0 .15 (0 .0059)
and piston ring groove STD 0 .03 - 0 .07 (0 .0012 - 0 .0028)
Second
ring Limit 0 .15 (0 .0059)
Bend twist per 100 mm (3.94 in) length Limit 0 .10 (0 .0039)
Connecting
STD 0.070 - 0.330 (0.0028 - 0.0130)
rod Side clearance
Limit 0 .4 (0.016)
STD 0 .020 - 0.046 (0.0008 - 0.0018)
Oil clearance
Limit 0 .05 (0 .0020)
Connecting STD 1 .486 - 1 .498 (0.0585 - 0.0590)
rod bearing 0.03 mm (0.0012 in) U .S . 1 .496 - 1 .509 (0.0589 - 0 .0594)
Thickness at center portion
0 .05 mm (0.0020 in) U .S . 1 .506 - 1 .519 (0.0593 - 0.0598)
0.25 mm (0.0098 in) U .S . 1 .606 - 1 .619 (0.0632 - 0 .0637)
Connecting STD 0 - 0 .018 (0 - 0 .0007)
Clearance between piston pin and bushing
rod bushing Limit 0 .030 (0 .0012)
Bend limit 0 .035 (0 .0014)
Out of roundness 0 .03 (0 .0012) or less

51.934 - 51.950 (2.04 6 - 2.0453)

Crank pin and crank journal Taper limit 0 .07 (0 .0028)
Grinding limit 0 .25 (0 .0098)
STD 51 .984 - 52 .000 (2 .0466 - 2 .0472)
0 .03 mm 51 .954 - 51 .970 (2 .0454 - 2 .0461)
(0.0012 in) U.S .
Crankpin outer diameter 0 .05 mm
rankshaft (0.0020 in) U .S .
0 .25 mm 51 .734 - 51 .750 (2 .0368 - 2 .0374)
(0.0098 in) U .S .
STD 59.992 - 60 .008 (2 .3619 - 2 .3625)
0 .03 mm 60 .022 - 60 .038 (2 .3631 - 2 .3637)
(0.0012 in) U.S .
Crank journal outer diameter 0 .05 mm 60 .042 - 60 .058 (2 .3639 - 2 .3645)
(0.0020 in) U .S .
0 .25 mm 60 .242 - 60 .258 (2 .3717 - 2 .3724)
(0.0098 in) U .S .

STD : Standard U .S. : Undersize

13
2-3 [SOB01 ENGINE
Unit: mm (in)

STD 0.030 - 0.115 (0 .0012 - 0.0045)

Thrust clearance
Limit 0.25 (0 .0098)
#1, #3, #7 0 .005 - 0.035 (0 .0002 - 0 .0014)
Crankshaft STD #2, #4, #6 0 .013 - 0.038 (0 .0005 - 0 .0015)
Oil clearance #5 0 .013 - 0.034 (0 .0005 - 0 .0013)
#1, #2, #6, #7 0 .045 (0.0018)
Limit
#3, #4, #5 0 .040 (0.0016)
STD 1 .998 - 2 .011 (0 .0787 - 0 .0792)
0.03 mm 2 .017 - 2 .020 (0 .0794 - 0 .0795)
(0.0012 in) U .S .
#1, #3, #7 0 .05 mm
2 .027 - 2 .030 (0 .0798 - 0 .0799)
(0.0020 in) U .S .
0 .25 mm
2 .127 - 2 .130 (0 .0837 - 0 .0839)
(0.0098 in) U .S .
STD 2 .000 - 2 .013 (0 .0787 - 0 .0793)
0 .03 mm
2,019 - 2 .022 (0 .0795 - 0 .0796)
(0.0012 in) U .S .
C ran ksh a ft
Crankshaft bearing thickness #2, #4, #6 0 .05 mm
bearing 2.029 - 2.032 (0 .0799 - 0.0800)
(0.0020 in) U.S .
0 .25 mm 2 .129 - 2 .132 (0 .0838 - 0 .0839)
(0.0098 in) U .S .
STD 2 .000 - 2 .013 (0 .0787 - 0 .0793)
0 .03 mm
2 .019 - 2 .022 (0 .0795 - 0 .0796)
(0.0012 in) U .S .
#5 0 .05 mm 2 .029 - 2 .032 (0 .0799 - 0 .0800)
(0.0020 in) U .S .
0 .25 mm
2 .129 - 2 .132 (0 .0838 - 0 .0839)
(0.0098 in) U .S .

STD : Standard U .S . : Under size

14
 ENGINE [Clool 2-3

C COMPONENT PARTS
1 . Timing Belt

Crank shaft sprocket

Right-hand belt cover No . 2
Left-hand belt cover No . 2
Right-hand camshaft sprocket
Belt idler
Belt tensioner bracket
Belt tensioner
Belt idler No. 2
Belt tension adjuster
Left-hand camshaft sprocket
Timing belt
Right-hand belt cover
Front belt cover
Left-hand belt cover
Crank shaft pulley

~v \'\ l'
Tightening torque : N .m (kg-m, ft-Ib)
T1 : 147 - 167 (15 - 17, 108 - 123)
T2 :4.4-5.4(0 .45-0.55,3.3-4 .0)
T3 : 35 - 43 (3 .6 - 4.4, 26 - 32)
T4 : 23-26 (2 .3-2 .7, 17-20)
T5 : 108 - 127 (11 - 13, 80 - 94)

C2-193
Fig . 10

15
2-3 [C200] ENGINE

2 . Cylinder Head and Camshaft

1 Cylinder head cover (RH) 12 Exhaust camshaft (RH)

2 Cylinder head cover gasket (R H) 13 Camshaft oil seal
Tightening torque : N .m (kg-m, ft-Ib)
3 Intake camshaft cap 14 Cylinder head bolt (short)
T1 : Refer to [W4E1 ] .
4 Exhaust camshaft cap 15 Cylinder head bolt (long)
T2 :9 .1-10 .5(0 .93-1 .07,6 .7-7 .7) 5 Front camshaft cap (R H) 16 Intake valve guide
T3 :4 .4-5 .4(0 .45-0 .55,3 .3-4 .0) 6 Intake camshaft (R H) 17 Exhaust valve guide
7 Camshaft gear spring 18 Cylinder head (RH)
8 Sub gear 19 Cylinder head gasket (RN)
T3
9 Wave washer 20 Cyolinder head gasket (LH)
10 Snap ring 21 Cylinder head (LH)
11 Camshaft plug 22 Intake camshaft (LH)
23 Exhaust camshaft (LH)
\T~ 24 Intake camshaft cap
i 25 Exhaust camshaft cap
t
i 26 Front camshaft cap (LH)
i
27 Cylinder head cover gasket (LH)
i 28 Cylinder head cover

T2 -~ \'

C2-194
Fig . 11

16
 ENGINE (C3001 2-3

3 . Cylinder Head and Valve ASSY

"

1
Exhaust valve
2
Intake valve
3 Valve spring seat
4 Intake valve oil seal
5 Inner valve spring
6 Outer valve spring
7 Retainer
8 Retainer key
9 Hydraulic lash adjuster
10 Exhaust valve oil seal

C2-195
Fig . 12

17
2-3 [C4001 ENGINE

4. Cylinder Block

1 Water pipe
2 Oil pressure switch
"' Cylinder block (RH)
Service hole plug
Gasket
Oil separator cover
Oil pump
Front oil seal
ear oil seal
-ring
Service hole cover
Cylinder block (LH)
13 Water pump
uffle plate
Oil strainer
Gasket
Oil pan
Oil drain plug
Gasket
Oil level gauge guide
Oil level gauge
Water by-pass pipe
eater pipe

Tightening torque : N-rn (kg-m, ft-1b)

T1 : Refer to M5021
17 - 20)
.3 - 5.1)
).55, 3.3 - 4.0)
6.5 - 8 .0)
46 - 56)
.3-5 .1)
.3 - 5.1)
,7-10)
. 8.7 - 11 .6)
C2-196
Fig . 13

18
 ENGINE [C5001 2-3

5 . Crankshaft and Piston

T1

e 0
® e
00

1 Drive plate
2 Reinforcement
3 Top ring
4 Second ring
5 Oil ring
6 Piston
7 Piston pin
8 Circlip
9 Connecting rod bolt
10 Connecting rod
11 Connecting rod bearing
12 Connecting rod cap
13 Crank shaft
14 Woodruff key
15 Crank shaft bearing #1, #3, #7
16 Crank shaft bearing #2, #4, #6
17 Crank shaft bearing #5

Tightening torque : N-m (kg-m, ft-Ib)

T1 : 69-75 (7 .0-7 .6,51-55)
T2 :43-46(4 .4-4 .7,32-34)

C2-197
Fig. 14

19
2-3 [w100) ENGINE

W SERVICE PROCEDURE
1 . General Precautions 3) All parts should be thoroughly cleaned, paying spe-
cial attention to the engine oil passages, pistons and
1) Before disassembling engine, install on ENGINE
bearings .
STAND .
4) Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly .
5) Be careful not to let oil, grease or coolant contact the
timing belt.
6) All removed parts, if to be reused, should be rein-
stalled in the original positions and directions.
7) Gaskets and lock washers must be replaced with
new ones . Liquid gasket should be used where speci-
fied to prevent leakage .
8) Bolts, nuts and washers should be replaced with
new ones as required .
9) Even if necessary inspections have been made in
rig. 10 advance, proceed with assembly work while making
rechecks.
2) Since the engine is very heavy, be sure to use more
than four persons when lifting the engine .
Never hold ENGINE STAND REINFORCEMENT when
lifting the engine.

20
 ENGINE [w2A2] 2-3

2. Timing Belt 4) Remove power steering pump bracket .

5) Remove A/C belt tensioner bracket .
6) Remove A/C compressor.
A: REMOVAL 7) Remove A/C compressor bracket .

1 . RELATED PARTS
1) Remove V-belts .
(Refer to 1-5 Drive Belts [01B1].)
2) Remove power steering pump.
3) Remove alternator and V-belt cover bracket .
2. CRANKSHAFT PULLEY AND BELT COVER

® . h

,-
`I`~\
.,

OO

C2-200
Fig. 16
1) Remove pulley bolt. To lock crankshaft, use Special J

Tool.
D Oa ° ~r_

- O
® -

® . .~ 0
L CRANKSHAFT STOPPER
(49849 7200)
C2-284
Fig . 18

2) Remove crankshaft pulley .

rig. 7 / 3) Remove left-hand belt cover.
4) Remove right-hand belt cover .
5) Remove front belt cover.

21
2-3 [W2A3] ENGINE
3. TIMING BELT

O \- ;,, ;,/ ice .\~

C ~ -. r \ ~i . ,
r(
\ \
~" \, C ~
\ ~ e
> r

o C2-202

Fig . 19
1) If alignment mark and/or arrow mark (which indi- sprockets with marks of belt cover and cylinder block.
cates rotation direction) on timing belt fade away, put
new marks before removing timing belt as follows : Special tool : CRANKSHAFT SOCKET (499987500)
(1) Turn crankshaft, and align alignment marks on
crankshaft sprocket, and left and right camshaft

Alignment mark Alignment Alignment mark

.\I~I _,, mark

o ~ \~

C2-387

Fig. 20

22
 ENGINE [w2A4] 2-3

(2) Using white paint, put alignment and/or arrow 2) Loosen tensioner adjuster mounting bolts.
marks on timing belts in relation to the sprockets . 3) Remove belt idler.
4) Remove belt idler No. 2
5) Remove timing belt.

Fig. 2 7

4. BELT TENSIONER AND IDLER

10

0 0
0 c2_208
Fig . 22
1) Remove belt idlers . 2) Remove belt tensioner and spacer.

23
2-3 [W2A5] ENGINE

3) Remove belt tension adjuster .

5. SPROCKET

OO

~k /© ~~f'I U/

t~ J
0 ~ (\\

C2-2o9
Fig. 23
1) Remove left-hand camshaft sprocket . If unable to remove crankshaft sprocket, tap two holes
in crankshaft sprocket, and remove using PULLER and
BOLT.
But this PULLER has no holes to fit crank shaft
sprocket holes.
Therefore drill two holes in PULLER to fit crankshaft
sprocket holes to following dimensions:

Hole center - to - hole center (Pitch) :

41 mm (1.61 in)
Hole diameter:
10 mm (0.39 in)

rig . L4 Recommended tap

Thread diameter 8mm (0.31 in)
2) Remove right-hand camshaft sprocket . To lock cam-
Thread pitch 1 .25 mm (0.0492 in)
shaft, use CAMSHAFT SPROCKET WRENCH .
3) Remove crankshaft sprocket.

24
 ENGINE [W2B4] 2-3

Cut thread using

tap. ®O imm
.36 h
D
i
PULLER
(89952 1421)
Crankshaft sprocket
M8 bolt

Crankshaft 82-092
BOLT (49952 5500) --
Fig . 26
2. BELT TENSION ADJUSTER
1) Visually check oil seals for leaks, and rod ends for
abnormal wear or scratches . If necessary, replace faulty
parts .
Slight traces of oil at rod' oil seal does not indicate a
problem.
2) While holding tensioner with both hands, push the
rod section against floor or wall with a force of 147 to
490 N (15 to 50 kg, 33 to 110 lb) to ensure that the rod
section does not move . If it moves, replace tension
adjuster with a new one.
3) Measure the extension of rod beyond the body. If it
is not within specifications, replace with a new one .
C2-211
Fig . 25
4) Remove left-hand belt cover No. 2.
5) Remove right-hand belt cover No . 2.
6) Remove tensioner bracket .

B : INSPECTION

1 . TIMING BELT
1) Check timing belt teeth for breaks, cracks, and wear.
If any fault is found, replace belt.
C2-212
2) Check the condition of back side of belt; if any crack
Fig . 27
is found, replace belt.
a. Be careful not to let oil, grease or coolant contact
the belt . Remove quickly and thoroughly if this hap- Rod extension H :
pens . 15.4 - 16.4 mm (0 .606 - 0.646 in)
b. Do not bend the belt sharply. [The bending radius
3. BELT TENSIONER
must be greater than 60 mm (2.36 in).]
1) Check mating surfaces of timing belt and contact
point of tension adjuster rod for abnormal wear or
scratches . Replace belt tensioner if faulty .
2) Check spacer and tensioner bushing for wear.

4. BELT IDLER
Check idler for smooth rotation . Replace if noise or
excessive play is noted .

25
2-3 [W2C1] ENGINE

C: INSTALLATION

1 . SPROCKET

T 4 .4 - 5 .4
(0 .45-0 .55,
3 .3 - 4 .0) ~I
05 /\~ it \1'~L ~

~kT

o
T 23 - 26
® (2 .3-2 .7,
17-20) ~, 3O

T 4.4 - 5.4
(0.45 - 0.55, 3.3 - 4.0)
T : N-m (kg-m, ft-Ib) T 108 - 127
(11 - 13,80 - 94) C2-213
Fig. 28
1) Install tensioner bracket . To lock camshaft, use CAMSHAFT SPROCKET
2) Install right-hand belt cover No. 2 . WRENCH .
3) Install left-hand belt cover No . 2. 6) Install left-hand camshaft sprocket .
4) Install crankshaft sprocket. Do not confuse left- and right-hand camshaft sprockets
during installation. The left-hand camshaft sprocket is
5) Install right-hand camshaft sprocket .
identified by a projection used to monitor cam-angle
sensor .

26
 ENGINE [w2C2] 2-3

2. BELT TENSIONER AND IDLER

T 35-43
o "'
(3 .6-4 .4,26-32)
11

T 35-43 O O
(3 .6-4 .4,26-32)
T 23-26(2.3-2 .7,17-20)

T : N -m (kg-m, ft-Ib)
T 35- 43 O
(3 .6-4 .4,26-32)
C2-214

Fig. 29
1) Installation of belt tension adjuster .
(1) Insert stopper pin 1 .5 mm (0.059 in) dia . into
place while pushing tension adjuster rod into body
using a press. Push until
a. Do not allow press pressure to exceed 9,807 N these hole:
are aligned.
(1,000 kg, 2,205 lb).
b. Do not release press pressure until stopper pin is
completely inserted .
c. Push tension adjuster rod vertically.
(2) Temporarily tighten bolts while tension adjuster
is rv lehorl nil thu %eiw to thn rinht
q00

Stopper pin

I
V
I

. --

C2-216
Fig. 31
2) Install belt tensioner .
3) Install belt idlers .

27
2-3 IW2C3I ENGINE

3. TIMING BELT

/-

T 35-43 V T N-m (kg-m, ft-Ib)

(3 .6-4 .4,26-32)
C2-217
Fig. 32
1) Installation of timing belt
(1) Using SPROCKET WRENCH, turn sprockets and
align their alignment marks with marks of belt covers
and oil oumn .

28
 ENGINE IW2C3I 2-3

(2) While aligning alignment mark on timing belt with Ensure belts rotating direction is correct .
marks on sprockets, position timing belt properly .

53 tooth length 53 tooth length

\~ ),~c/
© OO

Alignment mark Alignment mark

Alignment mark -
_ .o

\\
\ ICI \\

C2-223

Fig. 34

2) Install belt idler No. 2. 5) After ensuring that the marks on timing belt and
3) Install belt idler. sprockets are aligned, remove stopper from tension
4) Loosen tension adjuster attaching bolts and move adiuster_

y\\~
Stopper pin

/ -"
,c~\
C2-225
7g. 36
Fig . 35

29
2-3 [W2C4] ENGINE
4. CRANKSHAFT PULLEY AND BELT COVER

~h \I

OO ~ I I°
T 147 - 167
(15-17,108-123) /
T 4.4 - 5.4 , T : N-m (kg-m, ft-Ib)
(0 .45 - 0.55,
3 .3-4 .0) C2-226

Fig. 37

1) Install front belt cover .

2) Install right-hand belt cover.
3) Install left-hand belt cover .
4) Install crankshaft pulley .
5) Install pulley bolt. To lock crankshaft, use CRANK-
SHAFT PULLEY WRENCH .
5. RELATED PARTS
1) Install A/C compressor bracket .
2) Install A/C compressor .
3) Install A/C belt tensioner bracket .
4) Install power steering pump bracket.
5) Install alternator and V-belt cover bracket .
6) Install power steering pump.
7) Install V-belts .
(Refer to 1-5 Drive Belts [01 B1] .j

30
 ENGINE [w3A2I 2-3

3 . Camshaft

A: REMOVAL

1 . RELATED PARTS
1) Remove timing belt, camshaft sprockets and related parts
(Refer to Timing Belt [MAO] .)
2) Disconnect cam angle sensor connector .
3) Disconnect ignition coil connectors .
2. CAMSHAFTS LH

~~7 '1 C~`h

c2-227
Fig. 38
1) Remove cam angle sensor with bracket . 3) Disconnect blow-by hose and remove cylinder head
2) Remove ignition coils . cover and gasket .
Fully loosen ignition coil mounting bolts, and pull the 4) Remove front camshaft cap .
bolt head using pliers . 5) Remove camshaft oil seal and plug .
Be careful not to pull any harness by mistake . 6) Removal of intake and exhaust camshafts .
Since the camshaft thrust clearance is small, the cam-
shaft must be removed by holding it parallel to the
cylinder head . If the camshaft is not parallel to the
cylinder head, the cylinder head thrust bearing portion
may be damaged by the camshaft . To avoid this,
proceed as follows :

31
2-3 [W3A2] ENGINE
(1) Rotate the intake camshaft (upper) and exhaust
camshaft (lower) so that the notch at the front end of
each camshaft faces directly downward, by applying
a wrench to the hexagonal portion of the camshafts .

C
Match 0
O mark
C
I
v

e
l~ ® o
Match
mark
I

O 0 v Face the notch

downward .

/-( -

®I 0

C2-229

Fig . 40
(3) Install a service bolt to the sub-gear mounting
bolt hole of the intake camshaft gear to secure the
C2-22s sub-gear and driven gear.

Fig. 39 Recommended service bolt:

(2) See the rear side of the camshaft gears, and make Thread diameter
sure that the match marks of the intake camshaft gear 6 mm (0 .24 in)
(driven gear) and exhaust camshaft gear (drive gear) Thread pitch
are aligned . 1.0 mm (0.039 in)
Bolt length
16 - 20 mm (0.63 - 0.79 in)

Fig . 41

32
 ENGINE [W3A2] 2-3

When removing camshafts, make certain that the tor- the exhaust camshaft clockwise .
sional spring force of the sub-gear has been eliminated Arrange the camshaft caps in correct order.
by the above operation. (6) Loosen six bolts of three exhaust camshaft caps
(4) Loosen six bolts on three intake camshaft caps equally, a little at a time, in the numerical sequence as
equally, a little at a time, in the numerical sequence as illustrated .
illustrated .

v o c~ uou e~ ~ I

~~ 0

C2-231 Fig. 44
Fig . 42 Make sure that, as the bolts are loosened, the clear-
Make sure that, as the bolts are loosened, the clear- ance between the camshaft journal and the cylinder
ance between the camshaft journal and the cylinder head journal bearing increases evenly at three places. If
head journal bearing increases evenly at three places . If not, tighten the bolts by reversing the illustrated nu-
not, tighten the bolts by reversing the illustrated nu- merical sequence, and then repeat step (6) above.
merical sequence, and then repeat step (4) above.

Fig. 45
Fig . 43 (7) Remove the camshaft cap while holding the ex-
(5) Remove the camshaft cap while holding the in- haust camshaft with one hand, and then remove the
take camshaft with one hand, and then remove the camshaft .
camshaft . If it is hard to remove the camshaft, rotate Arrange the camshaft caps in correct order.
33
2-3 [W3A3) ENGINE
7) Remove hydraulic lash adjusters .
Arrange the hydraulic lash adjusters in order so that
they can be installed in their original positions .
®O

Face the notch 0

upward . wJ I r

I
C2-235 ® I ~-
Fig . 46 O ,O

3. CAMSHAFTS RH
Operation precautions are the same as those for the LH
camshafts, except the method for aligning the cam-
shaft gear match marks before removing camshafts .
1) Remove ignition coils .
2) Disconnect blow-by hose and remove cylinder head
cover and gasket .
3) Remove front camshaft cover .
4) Remove camshaft oil seal and plug .
C2-236
5) Removal of intake and exhaust camshafts
(1) Rotate the intake camshaft (upper) and exhaust Fig. 47
camshaft (lower) so that the notch at the front end of
each camshaft faces directly upward .

34
 ENGINE [W3A3] 2-3

(2) Seethe rear side of the camshaft gears, and make Make sure that, as the bolts are loosened, the clear-
sure that the match marks of the intake camshaft gear ance between the camshaft journal and the cylinder
(driven gear) and exhaust camshaft gear (drive gear) head journal bearing increases evenly at three places . If
are aligned . not, tighten the bolts by reversing the illustrated nu-
merical sequence, and then repeat step (4) above.
(5) Remove the camshaft cap while holding the in-
0 take camshaft with one hand, and then remove the
camshaft . If it is hard to remove the camshaft, rotate
the exhaust camshaft counterclockwise .
C Arrange the camshaft caps in correct order.
(6) Loosen six bolts of three exhaust camshaft caps
equally, a little at a time, in the numerical sequence as
illustrated .
o Math
I mark

-v
C

J%~` Match
' mark

I
Fig . 50

Make sure that, as the bolts are loosened, the clear-

ance between the camshaft journal and the cylinder
head journal bearing increases evenly at three places. If
C2-237
not, tighten the bolts by reversing the illustrated nu-
Fig . 48 merical sequence, and then repeat step (6) above.
(3) Install a service bolt to the sub-gear mounting (7) Remove the camshaft cap while holding the ex-
bolt hole of the intake camshaft gear to secure the haust camshaft with one hand, and then remove the
sub-gear and driven gear. camshaft .
(4) Loosen six bolts on three intake camshaft caps Arrange the camshaft caps in correct order.
equally, a little at a time, in the numerical sequence as
6) Remove hydraulic lash adjusters .
illustrated .
Arrange the hydraulic lash adjusters in order so that
they can be installed in their original positions .

Fig . 49

35
2-3 [W3B1I ENGINE

B : DISASSEMBLY

1 . INTAKE CAMSHAFT

Fig. 51
1) Removal of snap ring
(1) Secure the shaft portion of the camshaft in a vice
using a rag .
a. Never attempt to hold the cam lobe or journal in the
vice.
b. Pay attention not to damage the cam lobe and
journal .

Fig. 53
(3) Remove snap ring using CAMSHAFT GEAR PLI-
ERS.

Fig. 52

(2) Turn the sub-gear clockwise using CAMSHAFT

GEAR WRENCH, and remove service bolt.

fig . 54

36
 ENGINE [W3C1] 2-3

2) Remove wave washer .

Unit : mm (in)
3) Remove camshaft sub-gear.
4) Remove camshaft gear spring . ,
Arrange the camshaft sub-gears and gear springs .

H
C: INSPECTION

1 . CAMSHAFT
1) Visually check the camshafts for scratches flaking
and wear. 28 mm (1 .10 in)
2) Measurement of the camshaft bend .
(1) Place the camshaft on V-blocks at the No. 2 and B2-098

No.4 journal . Fig . 56

(2) Measure the camshaft runout at the No .3 journal .
5) Visually check the camshaft caps for scratches, flak-
ing and wear.
If the camshaft caps are damaged, replace the camshaft
caps and cylinder head as a set.
6) Measurement of the thrust clearance of camshaft
Measure the clearance of each camshaft.
(1) Install camshaft without installing valve lash ad-
justers.
(Refer to [W3E1].j
Be sure to install the camshaft at the specified position .
(2) Measure the thrust clearance of the camshaft .

Fig . 55

Limit :
0.02 mm (0 .0008 in)

(3) If it exceeds the limit, replace camshaft .

3) Measure outside diameter of the camshaft journal . If
the journal diameter is not as specified, check the oil
clearance .
Camshaft journal outer diameter fig. 57
#1 #2, #3, #4
31 .943 - 31 .963 mm 27 .946 - 27 .963 mm
Standard
(1 .2576 - 1 .2584 in) (1 .1002 - 1 .1009 in)

4) Measure the cam height H.

If it exceeds the limit, replace camshaft.

Standard cam height H:

Intake : 39.05 - 39.15 mm (1 .5374 - 1 .5413 in)
Wear limit
38.90 mm (1.5315 in)
Exhaust : 39.85 - 39.95 mm (1 .5689 - 1.5728 in)
Wear limit
39.70 mm (1 .5630 in) '

37
2-3 [W3C2] ENGINE

Standard camshaft thrust clearance:

2. CAMSHAFT GEAR
Intake :0 .03 - 0 .09 mm (0 .0012 - 0.0035 in) 1) Inspection of camshaft gear backlash .
Wear limit (1) Install the intake and exhaust camshafts without
0.13 mm (0.0051 in) installing hydraulic lash adjusters .
Exhaust:0.02 - 0.08 mm (0 .0008 - 0.0031 in) (Refer to [W3E1].)
Wear limit Do not install the intake camshaft sub-gear.
0.12 mm (0.0047 in) (2) Measure the backlash using dial gauge. If the
backlash exceeds the limit, replace the intake and
exhaust camshafts as a set.
(3) If the thrust clearance exceeds the limit, replace
Standard camshaft gear backlash:
the camshaft caps and cylinder head as a set. If
0.029 - 0.175 mm (0.0011 - 0 .0069 in)
necessary, replace the camshaft .
Limit :
7) Measurement of the camshaft journal oil clearance
0.30 mm (0.0118 in)
(1) Clean the bearing caps and camshaft journals .
(2) Place the camshafts on the cylinder head . (With-
out installing lash adjuster .)
(3) Place plastigauge across each of the camshaft
journals .
(4) Install the bearing caps.
(Refer to CW3E1].)
Do not turn the camshaft .
(5) Remove the bearing caps .
(6) Measure the widest point of the plastigauge on
each journal .
If the oil clearance exceeds the limit, replace the
camshaft . If necessary, replace the camshaft caps
and cylinder head as a set .
Hg. 59
Standard oil clearance:
0.037 - 0.072 mm (0 .0015 - 0.0028 in)
2) Measure the free distance between the camshaft
Limit:
gear spring ends .
0.10 mm (0.0039 in)
If the free distance is not as specified, replace the gear
spring .

Free distance :
24.88 - 28.88 mm (0.9795 - 1.1370 in)

Free distance

Fig . 58

(7) Completely remove the plastigauge .

C2-248
Fig. 60

38
 ENGINE [W3D11 2-3

D: ASSEMBLY
1 . INTAKE CAMSHAFTS

Fig . 61
1) Install camshaft gear spring .
2) Install camshaft sub-gear.
3) Install wave washer .
4) Install snap ring using CAMSHAFT GEAR PLIERS .

Fig. 63
(2) Turn the sub-gear clockwise and align the holes
of the camshaft driven gear and sub-gear using
CAMSHAFT GEAR WRENCH, and install service bolt.
r-1g. Uz
T 6-7N .m I
(0 .6 - 0.7 kg-m, 4.3 - 5.1 ft-Ib)
5) Installation of service bolt CAMSHAFT GEAR WRENCH
(1) Secure the shaft portion of the camshaft in a vice (49920 7200)
urr O
using a rag .
a. Never attempt to hold the cam lobe or journal in the U

vice. f ~ O
b. Pay attention not to damage the cam lobe and
journal .

C2-250
Fig . 64

39
2-3 [W3E1I ENGINE

[ E: INSTALLATION

1 . CAMSHAFTS LH

y1

T 9 .1 - 10 .5
c-it
(0.93-1.07,6.7-7 .7)
4.4 - 5.4
O ~_//-T (0 .45 - 0.55,
3.3 -4 .0)

^. \ 3
6

T : N-m (kg-m, ft-Ib)

T 9.1 - 10 .5
(0 .93 - 1 .07, 6.7 - 7.7)

C2-251

Fig . 65
Since the camshaft thrust clearance is small, the cam-
shaft must be installed by holding it parallel to the
cylinder head . If the camshaft is not parallel to the
cylinder head, the cylinder head thrust bearing portion
may be damaged by the camshaft . To avoid this,
proceed as follows :
1) Installation of exhaust camshaft
(1) Apply a coat of engine oil to the hydraulic lash
adjuster surface and insert hydraulic lash adjusters .
(2) Apply a coat of engine oil to the camshaft jour-
nals.
(3) Set the exhaust camshaft on the cylinder head
with the front end notch of the camshaft facing
directly downward . Then attach three camshaft caps Fig. 66
to the correct positions, and fully hand-tighten the
cap bolts . Make sure that, as the bolts are tightened, the clear-
Hold the camshaft with one hand so that it will not ance between the camshaft journal and the cylinder
drop while tightening the camshaft caps. head journal bearing decreases evenly at three places.
(4) Tighten six bolts on three exhaust camshaft caps If not, loosen the bolts by reversing the illustrated
equally, a little at a time, in the numerical sequence as numerical sequence, and then repeat step (4) above.
illustrated .

40
 ENGINE [w3E1] 2-3

Match mark
1 © J-

o~ L

o ® o
o C ~ I
o 0

l~ O

~° C
Face the notch
Match mark
downward

C2-385
Fig. 67 Fig. 68
(5) Tighten each bolt to the specified torque in the (4) See the rear side of the camshaft gears, and make
sequence explained in step (4) . sure that the match marks of the camshaft gears are
2) Installation of intake camshaft aligned . If not, re- assemble the camshaft using pro-
Each intake and exhaust camshaft gear has match cedure (3) again.
marks at two places . Accordingly, if the match marks
are incorrectly aligned, the cam timing will be mis-
aligned by 180° between the intake side and exhaust
side. To avoid this, be sure to use the following method
when assembling the camshafts.
(1) Apply a coat of engine oil to the hydraulic lash
adjuster surface and insert hydraulic lash adjusters .
(2) Apply a coat of engine oil to the camshaft jour-
nals.
(3) Align the intake camshaft match mark with the
match mark of the exhaust camshaft which is already
installed . In this case, make sure that the notch on the
front end of the intake camshaft and that of the
exhaust camshaft are facing the same direction (fac-
ing downward) . After that, install the three camshaft
caps at the specified positions, and fully hand-tighten
the bolts.
Be sure to hold the camshaft with one hand so that it
will not drop while installing the camshaft caps.

41
2-3 [W3E1] ENGINE

C
Match C /
mark
,
I
\\

C
v

Match
mark

`1'
i

C2-229

Fig. 69 Fig. 71
(5) Tighten six bolts of three intake camshaft caps (6) Tighten each bolts to the specified torque in the
equally, a little at a time, in the numerical sequence as sequence explained in step (5) .
illustrated . (7) Remove the sub-gear securing service bolt from
the intake camshaft gear.

Fig . 70
Fig . 72
Make sure that, as the bolts are tightened, the clear-
ance between the camshaft journal and the cylinder 3) Installation of front camshaft cap
head journal decreases evenly at three places . If not, (1) Apply fluid packing for mating surface of front
loosen the bolts by reversing the illustrated numerical camshaft cover.
sequence, and then repeat step (5) above. Use only enough fluid packing to avoid its entrance
into the camshaft oil hole.

42
 ENGINE [w3E2] 2-3

Fluid packing

C2-257
Fig . 73 Fig. 76

(2) Install front camshaft cover. (3) Install cylinder head cover and gasket .
4) Apply a coat of grease to oil seal lips and install oil (4) Connect blow-by hose .
seal . 7) Install ignition coils.
Use a new oil seal. 8) Install cam angle sensor .
2. CAMSHAFT RH
Operation precautions are the same as those for the LH
camshafts, except the method of aligning the camshaft
gear match marks.
1) Installation of exhaust camshaft
(1) Apply a coat of engine oil to the hydraulic lash
adjuster surface and insert hydraulic lash adjusters .
(2) Apply a coat of engine oil to the camshaft jour-
nals.
(3) Set the exhaust camshaft on the cylinder head
with the front end notch of the camshaft facing
directly downward . Then attach three camshaft caps
to the correct positions, and fully hand- tighten the
Fig. 74
cap bolts.
Hold the camshaft with one hand so that it will not
5) Install camshaft plug.
drop while tightening the camshaft caps .
(4) Tighten six bolts on three exhaust camshaft caps
equally, a little at a time, in the numerical sequence as
illustrated .

c
o ~) ; t ~~>>
CAMSHAFT PLUG ^
INSTALLER I,
(49803 7100)
C2-259

Fig . 75

6) Installation of cylinder head cover

(1) Completely remove excess fluid packing from
Fig. 77
location (& in the figure.
(2) Apply soapy water over ® and ® shown in the
figure .

43
2-3 [W3E2] ENGINE

Make sure that, as the bolts are tightened, the clear-

ance between the camshaft journal and the cylinder
head journal decreases evenly at three places. If not,
Face the notch
loosen the bolts by reversing the illustrated numerical upward ~ o Match mark
sequence, and then repeat step (4) above.
m
(5) Tighten each bolt to the specified torque in the 40
sequence explained in step (4) . `I O
2) Installation of intake camshaft
Each intake and exhaust camshaft gear has match o -~
marks at two places. Accordingly, if the match marks
are incorrectly aligned, the cam timing will be mis- 0 0 r " ~~ ~ IJ
o
aligned by 180° between the inside and exhaust side .
To avoid this, be sure to use the following method i
when assembling the camshafts.
(1) Apply a coat of engine oil to the hydraulic lash
adjuster surface and insert hydraulic lash adjusters . o O
Io ' v
(2) Apply a coat of engine oil to the camshaft jour-
nals . w
(3) Align the intake camshaft match mark with the
match mark of the exhaust camshaft which is already Uc
-` I Match mark
installed . In this case, make sure that the notch on the
front end of the intake camshaft and that of the
exhaust camshaft are facing the same direction (fac-
ing upward) . After that, install the three camshaft
caps at the specified positions, and fully hand-tighten
the bolts .
Be sure to hold the camshaft with one hand so that it
c2-sss
will not drop while installing the camshaft caps.
Fig . 78
(4) See the rear side of the camshaft gears, and make
sure that the match marks of the camshaft gears are
aligned . If not, re-assemble the camshaft using pro-
cedure (3) again .

44
 ENGINE [W4A1] 2-3

3) Installation of front camshaft cap

(1) Apply fluid packing for mating surface of front
camshaft cap .
Use only enough fluid packing to avoid its entrance
into the camshaft oil hole .
C (2) Install front camshaft cover.
4) Apply a coat of grease to oil seal lips and install oil
seal .
Use a new oil seal.
Match 5) Install camshaft plug.
I mark 6) Installation of cylinder head cover
(1) Completely remove excess fluid packing from
location ® in the figure .
C (2) apply soapy water over ® shown in the figure .

Match
' mark

C2-237
Fig . 81
Fig. 79
(5) Tighten six bolts of three intake camshaft caps
(3) Install cylinder head cover and gasket .
equally, a little at a time, in the numerical sequence as (4) Connect blow-by hose .
illustrated. 7) Install ignition coils .
3. RELATED PARTS
1) Connect ignition coil connectors .
2) Connect cam angle sensor connector .
3) Install camshaft sprockets, timing belt and related
parts.
(Refer to Timing Belt UW2C0] .)

4. Cylinder Head

A: REMOVAL

1 . INTAKE MANIFOLD
Fig. 80
1) Remove timing belt, camshaft sprockets and related
parts.
Make sure that, as the bolts are tightened, the clear-
(Refer to 2 Timing Belt [W2A0] .)
ance between the camshaft journal and the cylinder
2) Remove EGR valve, EGR pipe and BPT .
head journal bearing decreases evenly at three places .
3) Disconnect auxiliary air control valve connector .
If not, loosen the bolts by reversing the illustrated 4) Disconnect blow-by hoses .
numerical sequence, and then repeat step (5) above . 5) Disconnect auxiliary air control valve hose .
(6) Tighten each bolt to the specified torque in the 6) Disconnect PCV hose from connector PCV.
sequence explained in step (5) . 7) Disconnect two water hoses from throttle body.
(7) Remove the sub-gear securing service bolt from 8) Remove collector and intake manifold ASSY and
the intake camshaft gear. gaskets.
45
2-3 [w4A1] ENGINE

Fig . 82
9) Remove exhaust manifold and gasket .
10) Remove cylinder head covers, camshafts and re-
lated parts .
(Refer to 3 Camshafts [W3A0] .j

46
 ENGINE [W4A21 2-3

2. CYLINDER HEAD

C2-263

Fig. 83

1) Remove oil level gauge guide. 4) While tapping cylinder head with a plastic hammer,
2) Remove heater pipe. separate it from cylinder block. Remove bolts 6@ or
3) Remove cylinder head bolts in numerical sequence to remove cylinder head.
shown in Figure . 5) Remove cylinder head gasket .
Leave bolts 5@ or ® engaged by three or four threads 6) Similarly, remove right-hand cylinder head.
to prevent cylinder head from falling.

Fig . 84

47
2-3 [w4BO] ENGINE

B : DISASSEMBLY

,~~-rlnl 6~RN~

C2-2s5
Fig. 85
1) Remove hydraulic lash adjusters . a. Mark each valve to prevent confusion.
Arrange the hydraulic lash adjusters in order so that b. Use extreme care not to damage the lips of the
they can be installed in their original positions. intake valve oil seals and exhaust valve oil seals .

C2-235
Fig . 86 ,y .

2) Compress the valve spring and remove the valve

spring retainer key . Remove each valve and valve
spring .

48
 ENGINE [W4C3] 2-3

tive or when valve guides are replaced.

C: INSPECTION
W:
Intake
1 . CYLINDER HEAD Standard
1) Make sure that no crack or other damage exists . In 1 .0 mm (0.039 in)
addition to visual inspection, inspect important areas by Limit
means of red check. 1 .7 mm (0.067 in)
2) Measure the warping of the cylinder head surface Exhaust
that mates with crankcase by using a straight edge and Standard
thickness gauge . 1 .5 mm (0.059 in)
If the warping exceeds 0.05 mm (0.0020 in), regrind the Limit
surface with a surface grinder. 2.2 mm (0.087 in)

Warping limit:
0.05 mm (0.0020 in)
Grinding limit :
0.30 mm (0.0118 in)
Standard height of cylinder head:
127 .5 mm (5 .020 in)

Uneven torque for the cylinder head nuts can cause

warping. When reassembling, pay special attention to
the torque so as to tighten evenly .

Straight edge
i

O
Fig. 89
g ~ °
° op o ° - 0
3 . VALVE GUIDE
1) Check the clearance between valve guide and stem .
The clearance can be checked by measuring the outside
u diameter of valve stem and the inside diameter of valve
i guide with outside and inside micrometers respectively .
CYLINDER HEAD ~'
TABLE (49826 7500) Thickness Clearance between the valve guide and valve stem :
gauge Standard
Intake
0.030 - 0.057 mm (0.0012 - 0.0022 in)
Exhaust
o CD o 0 o B 0.040 - 0.067 mm (0.0016 - 0.0026 in)
Limit
0.10 mm (0 .0039 in)
U® ~ pl-J Valve guide inner diameters:
JU
6.000 - 6.012 mm (0.2362 - 0.2367 in)
Valve stem outer diameter:
Intake
1~- 5.955 - 5.970 mm (0.2344 - 0.2350 in)
Exhaust
5.945 - 5.960 mm (0.2341 - 0.2346 in)

C2-27o
2) If the clearance between valve guide and stem ex-
Fig . 88
ceeds the specification, replace guide as follows :
2. .VALVE SEAT (1) Place cylinder head on CYLINDER HEAD TABLE
Inspect intake and exhaust valve seats, and correct the with the combustion chamber upward so that valve
contact surfaces with valve seat cutter if they are defec- guides enter the holes in CYLINDER HEAD TABLE.
49
2-3 [W4C3] ENGINE
(2) Insert VALVE GUIDE REMOVER into valve guide
and press it down to remove valve guide .

VALVE GUIDE REMOVER

(49976 7200)

VALVE GUIDE
ADJUSTER
(79976 7600)
Fig . 90

(3) Turn cylinder head upside down and place

VALVE GUIDE ADJUSTER as shown in the figure .

CYLINDER HEAD TABLE

(49826 7500)

C2-273
Fig. 92
(6) Check the valve guide height .

Valve guide height : L

8.5 mm (0.335 in)
Fig. 91

(4) Before installing a new valve guide, be certain (7) Ream the inside of the valve guide using VALVE
that the valve guide bore in the cylinder head is not GUIDE REAMER (499767400) . Apply engine oil to the
scratched, pitted or damaged . reamer, insert it into the guide and with light down-
(5) Coat a new valve guide with oil and insert it into ward pressure, rotate the reamer clockwise . Continue
the bore. Place the VALVE GUIDE REMOVER into the rotating until the reamer is completely through the
valve guide, and press the guide into the cylinder guide . Remove the reamer by rotating clockwise,
head until the upper end of the guide is flush with the while pulling upward . After reaming, clean the guide
upper edge of the VALVE GUIDE ADJUSTER. with engine oil to remove chips.
If the reamer is glazing the inside of the guide, sharpen
or replace the reamer .

50
 ENGINE Iw4C5l 2-3

VALVE GUIDE REAMER

(49976 7400)

4\ go 1

90 .+1

0* +1
9

C2-274 B2-106
Fig . 93 Fig . 94
(8) Coat the face of the valve with talcum powder, 2) Put a small amount of grinding compound on the
and lightly rotate the valve against the seat to inspect seat surface and lap the valve and seat surface . Also
for proper valve seating . refer to Cylinder Head 4) at this time. Install a new intake
valve oil seal after lapping .
4. INTAKE AND EXHAUST VALVE
1) Inspect the flange and stem of valve, and replace if 5. VALVE SPRINGS
damaged, worn, or deformed, or if "H" is less than the 1) Check valve springs for damage, free length, and
specified limit . tension . Replace valve spring if it is not to the specifi-
cations presented below.
H: 2) To measure the squareness of the valve spring,
Intake stand the spring on a surface plate and measure its
Standard
deflection at the top using a try square .
0.8 mm (0 .031 in)
Limit
0.6 mm (0.024 in)
Exhaust
Standard
1 .0 mm (0 .039 in)
Limit
0.8 mm (0.031 in)
Valve overall length :
Intake 90.00 mm (3 .5433 in)
Exhaust 90.85 mm (3.5768 in)

I B2-1081
Fig. 95

51
2-3 Iw4C6] ENGINE

Outer spring Inner spring

i
Free length 36.4 mm (1 .433 in) 34 .9 mm (1 .374 in)

124 .5-142 .2N (12.7- 58 .8-66 .7N(6-

6 .8 kg, 13.2 - 15 .6Nor-
14 .5 kg, 28 .0 - 32.0
Tension/ mal Control Ib)/
Ib)/29 mm (1 .14 in)
spring 27 .5 mm (1 .083 in)
height 308 .9 - 356.0 N (31 .5 - 147 .1 - 168 .7 N (15 -
36 .3 kg, 69.5 - 80.0 lb)/ 17.2 kg, 33.1 - 37 .9 lb)/
21 .1 mm (0.831 in) 19 .6 mm (0.772 in)
Square- 2,5°, 1 .6 mm (0 .063 in) 2 .5°, 1 .5 mm (0.059 in)
ness

6. INTAKE AND EXHAUST VALVE OIL SEAL

C2-276
Replace oil seal with new one, if lip is damaged or Fig. 97
spring out of place, or when the surfaces of intake valve
and valve seat are reconditioned or intake valve guide is 2) Measure the hydraulic lash adjuster diameter.
replaced .
Press in oil seal to the specified dimension indicated in Diameter D:
the figure, using OIL SEAL INSTALLER . 32.965 - 32.975 mm (1 .2978 - 1.2982 in)
a. Apply engine oil to oil seal before force-fitting.
b. Be sure to press by hand, never hammer on the
special tool.
c. Differentiate between intake valve oil seal and ex-
haust valve oil seal by noting their difference in color.

Color of rubber part :

Intake [black]
Exhaust [brown]
Color of spring part:
Intake [white]
Exhaust [white]

VALVE OIL SEAL

GUIDE (49885 7100) rig. YU

3) Measure the hydraulic lash adjuster bush inner di-

ameter .
Valve -
oil seal Inner diameter:
33.009 - 33.031 mm (1 .2996 - 1 .3004 in)

CG 1

9
1

CYLINDER HEAD TABLE (49826 7500) '

C2-275
0
Fig . 96
0
7. HYDRAULIC LASH ADJUSTER
1) Visually, check the contact and sliding surface for r°1--I1 h! Y L2,nm Caliper gauge
--Measuring- /
wear or scratches . (0.08 in)
point

Meas uring 2311111,

mm (0 .91 in)
Jp oint

a Valve side
C2-278
Fig . 99

52
 ENGINE IW4Do] 2-3

4) Subtract the hydraulic lash adjuster diameter from Standard oil clearance :
the hydraulic lash adjuster bush inner diameter mea- 0.028 - 0.078 mm (0.0011 - 0.0031 in)
surement . The oil clearance can be calculated . If the oil Limit:
clearance exceeds the limit, replace cylinder head. 0.110 mm (0.0043 in)

~ D: ASSEMBLY

Fig. 100
1) Installation of valve spring and valve
(1) Coat stem of each valve with engine oil and insert
valve into valve guide .
When inserting valve into valve guide, use special care
not to damage the oil seal lip .
(2) Install valve spring and retainer .
Be sure to install the valve springs with their close
coiled end facing the seat on the cylinder head.
(3) Compress valve spring and fit valve spring re-
tainer key .

t-/g. 1U1

(4) After installing tap valve spring retainers, lightly

with wooden hammer for better seating.
2) Apply a coat of engine oil to hydraulic lash adjuster
sliding surface and insert hydraulic lash adjusters .

53
 2-3 IW4E1] ENGINE

f E: INSTALLATION

1 . CYLINDER HEAD

T 14 .2 - 17 .2
(1 .45-1 .75,10 .5-12 .7)

/~ T 14 .2 - 17 .2
® I 3 s~ (1 .45-1 .75,10 .5-12 .7)

"
11
U J
J

~ 7

L ~G ~~ I ' ~
'I ( ~
n \ fl \

- V

Mark (S)

O Mark (L

T : N-m (kg-m, ft-1b) Mark (L)

~ Mark (S)
C2-280

Fig . 102
1) Install cylinder head and gaskets on cylinder block.
6 1 4
Use new cylinder head gaskets.
2) Tighten cylinder head bolts.
(1) Apply a coat of engine oil to washers and bolt a o 0 0_ I~o o
threads. 0 0 0 0 0
(2) Tighten all bolts to 29 Nom (3.0 kg-m, 22 ft-Ib) in ~ v
I
the numerical order shown in Figure . Q 0 O) o,
(3) Tighten all bolts to 69 Nom (7.0 kg-m, 51 ft-Ib) in 0 00 ~o~ ~~Q
the numerical order shown in Figure .
(4) Back off all bolts by 180°. 0o
(5) Further back off all bolts by 180°.
(6) Tighten all bolts to 27 N-m (2 .8 kg-m, 20 ft-Ib), in 7
5 3 2 C2-281
the numerical order shown in Figure .
(7) Re-tighten bolts 10, ©, 3) and ® by 80° - 90° in Fig . 103
the numerical order shown in Figure .
3) Install heater pipe .
Do not tighten bolts more than 90°.
4) Install oil level gauge.
(8) Re-tighten bolts 5), ©, 70 and ® to 44 N-m (4.5
kg-m, 33 ft-Ib) in the numerical order shown in Figure .
(9) Further tighten all bolts by 80° - 90° in the numer-
ical order shown in Figure .
Ensure that the total "re-tightening angle" (Steps (7)
and (9) above) does not exceed 180".

54
 ENGINE [W4E21 2-3

2. INTAKE MANIFOLD
Use dry compressed air to remove foreign particles
before installing sensors .
1) Install camshafts, cylinder head covers and related
pa rts .
(Refer to 3 Camshafts [W3E0] .)
2? Install exhaust manifold and gasket.
3) Install collector and intake manifold ASSY and gas-
kets.

T 23 - 26 N-m Collector and intake manifold

(2 .3 - 2.7 kg-m, ASSY
17 - 20 ft-Ib)
I®

r
~~ 1

r -
I`

^~ e Gasket

j
jam. 0 1

~~ F~n~'J-
f~
,Pi;
I r ~J

C2-282
Fig . 104
4) Connect two water hoses to thotttle body.
5) Connect PCV hose to connector PCV.
6) Connect auxiliary air control valve hose.
7) Connect blow-by hoses.
8) Connect auxiliary air control valve connector.
9) Install EGR valve, EGR pipe and BPT.
10) Install camshaft sprockets, timing belt and related
parts.
(Refer to 2 Timing belt [W2C0] .)

55
2-3 [W5A1) ENGINE

5. Cylinder Block (Refer to 2 Timing belt [MAO].)

2) Remove cylinder head covers and camshafts and
related parts .
A: REMOVAL (Refer to 3 Camshafts CW3A0] .)
3) Remove intake manifold, cylinder head and related
1 . RELATED PARTS parts .
1) Remove timing belt, camshaft sprockets and related (Refer to 4 Cylinder head CW4A0].)
parts. 4) Remove crank angle sensor and knock sensors .
2. OIL PUMP AND WATER PUMP

C2-283

Fig . 105

56
 ENGINE [W5A2] 2-3

1) Remove drive plate. 7) Removal of oil pan .

To lock crankshaft, use CRANKSHAFT STOPPER (1) Turn cylinder block with #2, #4 and #6 piston
sides facing upward .
(2) Remove bolts which secure oil pan to cylinder
CJ o o block.
s (3) Insert a oil-pan cutter blade between cylinder
o block-to-oil pan clearance and remove oil pan .
Do not use a screwdriver or similar tool in place of

®. o D ' sc
oil-pan cutter blade.

CRANKSHAFT STOPPER
(49849 7200) C2-284

Fig . 106

2) Remove oil separator cover .

3) Remove water by-pass pipe.
4) Remove water pipe .
5) Remove water pump and gasket.
I Oilpan
cutter
6) Remove oil pump from cylinder block. Use a stan-
C2-286
dard screwdriver as shown in Figure when removing oil
pump . Fig. 108
Be careful not to scratch the matching surface of
cylinder block and oil pump. 8) Remove oil strainer .
9) Remove baffle plate .
10) Remove oil filter .

Fig . 107

57
2-3 [W5B1/ ENGINE

B: DISASSEMBLY

1 . PISTON PIN AND CYLINDER BLOCK CONNECTING BOLT

2
O

C2-287

Fig. 109
1) Remove service hole cover and service hole plugs
using hexagon wrench (14 mm) .
2) Rotate crankshaft to bring # 1 and #2 pistons to BDC
position, then remove piston circlip through service ~ n r, ~f
C

hole of #1 and #2 cvlinders.

I l
IL- ^

PISTON PIN REMOVER

(49909 7500)
C2-289
Fig . 111

.ly .

3) Draw out piston pin from #1 and #2 pistons .

Be careful not to confuse original combination of pis-
ton, piston pin and cylinder.

58
 ENGINE Iw5B1) 2-3

4) Rotate crankshaft to bring #3 and #4 piston to BDC 6) Rotate crankshaft to bring #5 and #6 pistons BDC
position, then remove piston circlip through service position, then remove piston circlip through service
hole of #1 and #2 cylinders with PISTON CIRCLIP hole of #5 and #6 cylinders .
PLIERS . 7) Draw out piston pin from #5 and #6 pistons .
8) Remove bolts which connect cylinder block on the
side of #1, #3 and #5 cylinders .
9) Back off bolts which connect cylinder block on the
side of #2, #4 and #6 cylinders two or three turns .

Fig. 112
5) Draw out piston pin from #3 and #4 pistons through
service hole of #1 and #2 cylinders .

59
2-3 [W5B2] ENGINE
2. CYLINDER BLOCK 1) Set up cylinder block so that #2, #4 and #6 cylin-
ders are on the upper side, then remove cylinder block
connecting bolts .
Be sure to remove small connecting bolt in the crank-
case.

Fig. 114

2) Separate left-hand and right-hand cylinder blocks .

When separating cylinder block, do not allow the
connecting rod to fall and damage the cylinder block.
3) Remove rear oil seal .

o a
o 4) Remove crankshaft together with connecting rod .
5) Remove crankshaft bearings from cylinder block by
hand .
Do not confuse combination of crankshaft bearings .
I Press bearing at the end opposite to locking lip.
4 l 6) Draw out each piston from cylinder block using
wooden bar or hammer handle .
Do not confuse combination of piston and cylinder .

a
\.. \~ I

o \ I
2 \ ~~
I I I ' /,, ~r
l~a.

5,~~`~ll".r
I J I

C2-291

Fig. 113

60
 ENGINE [W5C21 2-3

3. CRANKSHAFT AND PISTON

O2
®,

C2-293
Fig. 115
1 ) Remove connecting rod cap . (2) When piston is to be replaced due to general or
2) Remove connecting rod bearing. cylinder wear, determine a suitable sized piston by
Arrange removed connecting rod, connecting rod cap measuring the piston clearance .
and bearing in order to prevent confusion.
3) Remove the piston rings using the piston ring ex-
pander .
4) Remove the oil ring by hand.
Arrange the removed piston rings in good order to
r
prevent confusion.
5) Remove circlip . l

~ C: INSPECTION Main journal '

size mark
1 . CYLINDER BLOCK Cylinder block RH-LH
1) Check for cracks and damage visually. Especially, ~r
-~---
r /
combination mark

inspect important parts by means of red check . #7

2) Check the oil passages for clogging . L-J L-J

3) Inspect the crankcase surface that mates with cylin-

YY
I Ir-~ r-~ 1 -~
r

der head for warping by using a straight edge, and

L-.J L- .'
#5

$j:5 Cylinder bore size mark

correct by grinding if necessary . #4 iL .J
3 L
#6 Cylinder bore size mark
# J L~~ L-r

Warping limit : 2 ~N---4

# Cylinder bore size mark
# J l.-J L-J
0.05 mm (0.0020 in)
#1 J-L -J L J I -~~ #2 Cylinder bore size mark
Grinding limit :
-{ #1 Cylinder bore size mark
0.4 mm (0.016 in)
#3 Cylinder bore size mark
Front

2. CYLINDER AND PISTON

i
1) The cylinder bore size is stamped on the cylinder
block's front upper surface .
(1) Standard sized pistons are classified into three
C2-294
grades, "A", "B" and "C" . These grades should be
used as a guideline in selecting a standard piston . Fig. 116

61
2-3 [W5C2] ENGINE
(3) Proper combination of pistons and cylinders

Cylinder Piston Piston clearance

Bore size symbol Cylinder bore dia . Piston grade symbol Standard piston dia . 20°C (68° F)
96 .905 - 96 .915 mm A 96 .885 - 96 .895 mm
(3.8151 - 3 .8155 in) (3 .8144 - 3.8148 in)
B 96 .895 -96 .905 mm B 96 .875 - 96 .885 mm 0 .01 - 0 .03 mm
(3.8148 - 3 .8151 in) (3 .8140 - 3.8144 in) (0 .0004 - 0 .0012 in)
C 96 .885 - 96 .895 mm C 96.865 - 96 .875 mm
(3.8144 - 3 .8148 in) (3 .8136 - 3.8140 in)

2) Measure the inner diameter of each cylinder in both 3) Boring and honing
the thrust and piston pin directions at the heights shown (1) If the value of taper, out-of-roundness, or
in the figure, using a cylinder bore gauge. cylinder-to-piston clearance measured exceeds the
Measurement should be performed at a temperature specified limit or if there is any damage on the
20°C (69°F). cylinder wall, rebore it to use an oversize piston .
When any of the cylinders needs reboring, all other
cylinders must be bored at the same time, and use
oversize pistons. Do not perform boring on one cylin-
der only, nor use an oversize piston for one cylinder
only .
a0mo
n: Team ai-i . . (2) Get six of the oversize pistons and measure the
outer diameter of each piston at the height shown in
B: vinon pin dkmlen

Cy11nOn heed rti,InY _,aei

the figure . (Thrust direction)

1 n 10 .191

a Measurement should be performed at a temperature of

20°C (68°F) .
I 90
11 .151

115
1. .511
Piston outer diameter :
Standard
B2-111 A 96 .885 - 96 .895 mm
Fig . 117 (3 .8144 - 3.8148 in)
B 96.875 - 96.885 mm
(3 .8140 - 3.8144 in)
Taper : C 96 .865 - 96 .875 mm
Standard (3 .8136 - 3.8140 in)
0.015 mm (0.0006 in) 0.25 mm (0 .0098 in) oversize
Limit 97.125 - 97.135 mm (3.8238 - 3.8242 in)
0 .050 mm (0.0020 in) 0.50 mm (0.0197 in) oversize
Out-of-roundness : 97.375 - 97.385 mm (3.8337 - 3.8340 in)
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in) h : 52 .0 mm
(2.047 in)
Cylinder to piston clearance at 20°C (68°F) :
Standard
0.010 - 0.030 mm (0.0004 - 0.0012 in)
Limit
0.060 mm (0.0024 in)
Standard diameter:
A 96.905 - 96.915 mm
(3.8151 - 3.8155 in)
B 96.895 - 96.905 mm
(3.8148 - 3.8151 in)
C 96.885 - 96.895 mm 82-112
(3.8144 - 3.8148 in) Fig. 118

62
 ENGINE [W5C4] 2-3

(3) If the cylinder inner diameter exceeds the limit

RorNmark
after boring and honing, replace the crankcase .
Immediately after reboring, the cylinder diameter may Top ring

differ from its real diameter due to temperature rise. -R or N mark

Thus, pay attention to this when measuring the cylin-
Second ring
der diameter.

Limit of cylinder enlarging (boring) :

Upper rail
0.3 mm (0.012 in)
Oil ring Spacer

3. PISTON AND PISTON PIN ~3--Lower rail

1) Check pistons and piston pins for damage, cracks, B2-115]

and wear and the piston ring grooves for wear and Fig . 120
damage. Replace if defective .
2) Measure the piston-to-cylinder clearance at each 2) Squarely place piston ring and oil ring in cylinder
cylinder as instructed in CYLINDER AND PISTON . If any using piston, and measure the piston ring gap with a
of the clearances is not to specification, replace the thickness gauge.
Unit : mm (in)
piston or bore the cylinder to use an oversize piston .
3) Make sure that piston pin can be inserted into the Standard Limit
0.20-0.30
piston pin hole with a thumb at 20°C (68°F) . Replace if
Top ring (0,0079- 0.5 (0.020)
defective. 0.0118)
0.37-0.52
Standard clearance between piston pin and hole in Piston
Second ring (0 .0146- 1 .0 (0.039)
ring gap
piston : 0.0205)
0.004 - 0.008 mm (0.0002 - 0.0003 in) 0.20-0.60
Oil ring rail (0 .0079- 1 .5 (0.059)
Standard clearance between piston pin and hole in 0 .0236)
connecting rod :
0 - 0.018 mm (0 - 0.0007 in)
Cylinder block top surface

4. PISTON RING _ 30 mm
1) If piston ring is broken, damaged, or worn, or if its hi kess / (1 .18 in)
tension is insufficient, or when the piston is replaced, ~
\ ~lgauge
0

replace piston ring with a new one of the same size as i

the piston.
II o 0
"R" is marked on the end of the top and second rings .
When installing the rings to the piston, face this mark :.~~
upward .

\\ r C2-390
Fig . 121

C2-408
Fig. 119

The oil ring is a combined ring consisting of two rails

and a spacer in between . When installing, be careful
not to make misassembly .
63
2-3 [w5C5] ENGINE

3) Measure the clearance between piston ring and

piston ring groove with a thickness gauge .
Before measuring the clearance, clean the piston ring
groove and piston ring.
Unit :mm (in)

^V
Standard Limit
0 .04-0 .09
Clearance be- Top ring (0.0016 - 0.15 (0 .0059) 3
tween piston 0.0035) o.
ring and piston W
0 .03-0 .07
ring groove Second ring (0.0012 - 0.15 (0 .0059)
0 .0028)
1 Thickness gauge
2 Connecting rod

1 I

11

ness gauge
B2-117
1 Connecting rod j
Fig . 122 2 Thickness gauge
B2-118

Fig . 123
5. CONNECTING ROD
3) Install connecting rod fitted with bearing to crank-
1) Replace connecting rod, if the large or small end
shaft and measure the side clearance (thrust clearance) .
thrust surface is damaged .
Replace connecting rod if the side clearance exceeds
2) Check for bend or twist using a connecting rod
the specified limit.
aligner . Replace connecting rod if the bend or twist
exceeds the limit . Connecting rod side clearance :
Standard
Limit of bend or twist per 100 mm (3.94 in) in length : 0.070 - 0.330 mm (0 .0028 - 0.0130 in)
0 .10 mm (0.0039 in) Limit
0.4 mm (0.016 in)

Fig . 124

64
 ENGINE [W5C61 2-3

4) Inspect connecting rod bearing for scar, peeling, 6. CRANKSHAFT AND CRANKSHAFT BEARING
seizure, melting, wear, etc . 1) Clean crankshaft completely and check for cracks by
5) Measure the oil clearance on individual connecting means of red check etc ., and replace if defective .
rod bearings by means of plastigauge . If any oil clear- 2) Measure the crankshaft bend, and correct or replace
ance is not within specification, replace the defective if it exceeds the limit.
bearing with a new one of standard size or undersize as If a suitable V-block is not available, install #1 and #5
necessary, necessary . (See the table below.) crankshaft bearing on cylinder block, position crank-
shaft on these bearings and measure crankshaft bend
Connecting rod oil clearance: using a dial gauge.
Standard
Crankshaft bend limit :
0.020 - 0 .046 mm (0.0008 - 0.0018 in)
0.035 mm (0.0014 in)
Limit
0.05 mm (0.0020 in)

Unit: mm (in)

Bearing size (Thick- Outer diameter of

Bearing
ness at center) cran k pin
1 .486 - 1 .498 51 .984 - 52 .000
Standard
(0 .0585 - 0 .0590) (2.0466 - 2 .0472)
1 .520 - 1 .524 51 .954 - 51 .970
0.03 undersize
(0 .0598 - 0 .0600) (2.0454 - 2 .0461)
1 .540 - 1 .544 51 .934 - 51 .950
0.05 undersize
(0 .0606 - 0 .0608) (2.0446 - 2 .0453)

0 .25 Undersize 1 .740 - 1 .744 51 .734 - 51 .750

(0 .0685 - 0 .0687) (2 .0368 - 2 .0374)

6) Inspect the bushing at connecting rod small end for

Fig. 125
wear or damage .
Also measure the piston pin clearance at the connecting 3) Inspect the crank journal and crankpin for wear . If not
rod small end . to specifications, replace bearing with an undersize one,
If not within specifications, replace connecting rod and and replace or recondition crankshaft as necessary.
connecting rod cap as a set. When grinding crank journal or crankpin, finish them to
the specified dimensions according to the undersize
Clearance between piston pin and bushing : bearing to be used .
Standard
0 - 0.018 mm (0 - 0.0007 in) Crankpin and crank journal :
Limit Out-of-roundness
0.030 mm (0.0012 in) 0 .03 mm (0.0012 in) or less
Taper limit
0.07 mm (0.0028 in)
Grinding limit
0.25 mm (0.0098 in)

65
2-3 (w5C6] ENGINE
Unit : mm (in)

Crank journal
Crank pin O .D .
#1, #3, #7 #2, #4, #6 #5
59 .992 - 60 .008 51 .984 - 52 .000
Journal O.D .
2 .3619 - 2.3625 f 2 .0466 - 2 .0472
Standard
Bearing size 1 .998 - 2 .011 2 .000 - 2 .013 2 .000 - 2 .013 1 .492 - 1 .510
Thickness at center 0 .0787 - 0.0792 0.0787 - 0.0793 0 .0787 - 0 .0793 0 .0587 - 0 .0594
59 .962 - 59 .978 51 .954 - 51 .970
Journal O.D .
0.03 (0 .0012) 2 .3607 - 2.3613 `- 2 .0454 - 2 .0461
undersize Bearing size 2 .017 - 2 .020 2 .019 - 2 .022 2 .019 - 2 .022 1 .510 - 1 .513
Thickness at center 0 .0794 - 0.0795 0.0795 - 0.0796 0 .0795 - 0 .0796 0 .,0594 - 0 .0596
59 .942 - 59 .958 51 .934 - 51 .950
Journal O.D .
0.05 (0 .0020) (2 .3599 - 2 .3605 2 .0446 - 2 .0453
undersize Bearing size 2 .027 - 2.030 2 .029 - 2 .032 2 .029 - 2 .032 1 .520 - 1 .523
Thickness at center 0 .0798 - 0.0799 0.0799 - 0 .0800 0 .0799 - 0 .0800 0 .0598 - 0 .0600
59 .742 - 59 .758 51 .734 - 51 .750
Journal O.D .
0.25 (0 .0098) (2 .3520 - 2 .3527 2 .0368 - 2 .0374
I undersize I Bearing size 2 .127 - 2.130 2 .129 - 2 .132 2 .129 - 2 .132 1 .620 - 1 .623
(Thickness at center) (0 .0837 - 0.0839) (0 .0838m - 0.0839) (0 .0838 - 0.0839) (0 .0638 -0.0639)
Il l

5) Inspect individual crankshaft bearings for signs of

flaking, seizure, melting, and wear.
6) Measure the oil clearance on each crankshaft bear-
ing by means of plastigauge . If the measurement is not
within the specification, replace defective bearing with
an undersize one, and replace or recondition crankshaft
as necessary.
Unit :mm (in)

Crankshaft oil clearance

0.005 - 0 .035
#1, #3, #7
(0 .0002 - 0 .0014)
0.013 - 0 .038
Standard #2, #4, #6 (0.0005 - 0 .0015)
rig . 7Zb 0.013 - 0 .034
#5
4) Measure the thrust clearance of crankshaft at #5 (0 .0005 - 0 .0013)
bearing . If the clearance exceeds the limit, replace #1, #2, #6, #7 0.045 (0 .0018)
Li mi t
bearing . #3, #4, #5 0.040 (0 .0016)

Crankshaft thrust clearance :

Standard
0.030 - 0.115 mm (0.0012 - 0.0045 in)
Limit
0.25 mm (0.0098 in)

Fig . 128

~ o
1) f Thickness gauge

C2-299
Fig . 127

66
 ENGINE [W5D1] 2-3

D: ASSEMBLY
1. CRANKSHAFT AND PISTON

O
T 43 - 46
(4 .4 - 4.7, 32 -:734 ® I /~-

Side
mark O
T : N-m
(kg-m, ft-1b)
C2-300

Fig . 129
1) Install connecting rod bearings on connecting rods Identification mark
and connecting rod caps. (RH or CHI
R' Oil ring
2) Install connecting rod on crankshaft. lower rail
Oil ring upper rail
a. Apply oil to the surfaces of the connecting rod
30°
bearings . 25*
b. Position each connecting rod with the side marked
facing forward . Bend over pawl
of upper rail and
3) Install connecting rod cap with connecting rod nut . attach to hole . 3 , 30°
Ensure the arrow on connecting rod cap faces the front
during installation . Top ring _' Second ring
a. Each connecting rod has its own mating cap. Make oil ring spacer
sure that they are assembled correctly by checking
82-056
their matching number.
b. When tightening the connecting rod nuts, apply oil Fig. 130
on the threads. 5) Install circlip .
4) Installation of piston rings and oil ring. Install new circlips in piston holes located opposite
(1) Install oil ring spacer, upper rail and lower rail in service holes in cylinder block, when positioning all
pistons in the corresponding cylinders .
this order by hand. Then install second ring and top
ring with a piston ring expander.
(2) Position the gaps of the piston rings and oil ring
as shown in the figure.

Fig. 131

67
2-3 [W5D2] ENGINE
2. CYLINDER BLOCK 1) Install ENGINE STAND to cylinder block, then install
crankshaft bearings .
Remove oil the mating surface of bearing and cylinder
block before installation. Also apply a coat of engine oil
to crankshaft pins.
2) Position crankshaft on the #1, #3 £t #5 cylinder
block.
3) Apply fluid packing to the mating surface of # 1, #3 It
#5 cylinder block, and put 0-rings on the grooves of
#1, #3 ft #5 cylinder block, and then position #2, #4 £r
#6 cylinder block on it.
J
Fluid packing :
Three-bond 1215B or equivalent
r
S
o
Do not allow fluid packing to jut into O-ring grooves,
oil nassanes_ bearinn nrooves_ etc-

0 O
"' ~T6tC - 7 N-m
l.
\ r (0.6 - 0.7 kg-m,
4.3 - 5.1 ft-Ib)

J ,y .
2 `
q
4) Tighten #2, #4 £r #6 cylinder block side connecting
c
bolts to 15 N "m (1 .5 kg-m, 11 ft-Ib) in the numerical
sequence shown in figure ..

Fs411 0
` 3
v

-( ~ \ ~--r
\_ , I ~?I
o o~ o

® C~oO ~O
~l 1 =/

© o 0 C2-306
Fig . 134
C2-302
5) Tighten small bolt in the crank case.
Fig . 132

68
 ENGINE [W5D3] 2-3

3. CYLINDER BLOCK CONNECTING BOLT

T 23 - 26N-m
(2.3 - 2.7 kg-m,
17 - 20 ft-Ib)

C2-304

Fig . 135
1) Turn cylinder block so that it is horizontal. 2) To confirm tightening torque on the #2, #4 and #6
Tighten cylinder block connecting bolts to 15 N"m (1 .5 cylinder block side connecting bolts re-tighten connect-
kg-m, 11 ft-Ib) on the #1, #3 and #5 cylinder block side ing bolts to 15 N"m (1 .5 kg-m, 11 ft-Ib), in the numerical
in the numerical sequence shown in Figure . sequence shown in figure .

J) T
J.
o o o m
L o °~ o q o

'o o ,o u o
®
I
l
© O O C2-305
© 20 C2-306
Fig. 136 Fig. 137

3) Re-tighten connecting bolts by 90°- 110° on the #2,

#4 and #6 cylinder block side in the numerical se-
quence shown in figure .

69
2-3 [w5D4] ENGINE
4) Re-tighten connecting bolts by 90°- 110° on the #1,
#3 and #5 cylinder block side in the numerical se-
quence shown in figure .
5) Tighten other cylinder block connecting bolts to
specified torque.
6) Install rear oil seal .

Flywheel attaching bolt ' aoilseal

Re

OIL SEAL INSTALLE t ~~ S

o
(499587200)\/ \

o
OIL SEAL GUIDE
(499597100)
j~2-060

Fig . 138

4. PISTON AND PISTON PIN (#3 and #4)

U
C. G

v,1 ~ ' I

.!I
1 r1 `

a
C2-307

Fig. 139

70
 ENGINE [W5D4] 2-3

1) Installing piston . (2) Apply a coat of engine oil to piston pin and insert
(1) Turn cylinder block so that #1 and #2 cylinders piston pin into piston and connecting rod through
face upward . service hole.
(2) Turn crankshaft so that #3 and #4 connecting (3) Install new circlip with PISTON CIRCLIP PLIERS .
rods are set at bottom dead center .
(3) Apply a coat of engine oil to pistons and cylinders
and insert #3 and #4 pistons in their cylinders .
CRANKSHAFT SOCKET
(49998 7500)

PISTON GUIDE
(49874 7100)

C2-308

Fig . 140
2) Installing piston pin .
(1) Insert the PISTON PIN GUIDE into service hole to
align piston pin hole with connecting rod small end .
Apply a coat of engine oil to PISTON PIN GUIDE before
insertion.

Fig. 142

Fig. 141

71
2-3 [W5D5] ENGINE

5. PISTON AND PISTON PIN (#1 and #2)

T 62 - 76 N-m (6 .3 - 7 .7 kg-m, 46 - 56 ft-Ib)

0
O

\~ U ~

~ I" I

I
C2-310

Fig. 143
1 ) Installing piston (2) Apply a coat of engine oil to piston pin and insert
(1) Turn cylinder block so that #1 and #2 cylinders piston pin into piston and connecting rod through
face upward . service hole.
(2) Turn crankshaft so that #1 and #2 connecting (3) Install new circlip .
rods are set at bottom dead center .
(3) Apply a coat of engine oil to pistons and cylinders PISTON CIRCLIP
and insert pistons in their cylinders . PLIERS
(49989 7200 )
2) Installing piston pin
(1) Insert the PISTON PIN GUIDE into service hole to
align piston pin hole with connecting rod small end . ~ v r \ ~U ~~

Apply a coat of engine oil to PISTON PIN GUIDE before

insertion . i

CRANKSHAFT SOCKET
(49998 7500)

PISTON PIN GUIDE

(49901 7100 ) C2-316
Fig . 145

(4) Install service hole plug and gasket .

Use a new gasket.

C
C2-311
Fig . 144

72
 ENGINE [w5D61 2-3

6. PISTON AND PISTON PIN (#5 and #6)

T 62-76 T 6-7
(6 .3-7 .7,46-56) (0 .6-0 .7,4 .3-5 .1)

4 e
° 4

~" 10-1'41
T : N.m (kg-m, ft-Ib)

C2-312

Fig. 146
Turn cylinder block so that #5 and #6 cylinders face
upward . Using the same procedures as used for #1 and
#2 cylinders, install pistons and piston pins.

73
2-3 IW5E1I ENGINE

E : INSTALLATION

1 . OIL PUMP AND WATER PUMP

~T 6-7(0.6-0.7,4 .3-5 .1)

T 69 - 75
(7 .0-7 .6,51-55)

)
o
~ o ooh o
S'*
o

T 6-7 © r, (('' QQ

(0 .6-0 .7,
4.3 -5 .1),

,0

-~ ,l ! T 6-7
(0 .6 - 0.7, 4.3 - 5.1)

F, 4

T 10 - 14 -
(1 .0-1 .4,7-10)

T 12-16 O
(1 .2-1 .6,9-12) T 4.4 - 5.4
(0 .45 - 0.55, 3.3 - 4.0)
T 9-11
(0 .9-1 .1,
6.5-an)

T : N-m (kg-m, ft-Ib)

T 4.4 - 5 .4
(0 .45 - 0.55, 3.3 - 4.0)
C2-313

Fig. 147

1) Install baffle plate.

2) Install oil strainer and O-ring
3) Apply fluid packing to matching surface and install
oil pan .

Fluid packing :
Three-bond 1207F or equivalent

74
 ENGINE [W5E2] 2-3

(2) Apply fluid packing to matching surface of oil

pump .

Fluid packing :
Three-bond 1215B or equivalent

0
0 Fluid packing
O Ito p O
t-1g . 7 4d \ ~~ I

4) Apply fluid packing to matching surfaces and install o4 Oo

oil separator cover. oh

Fluid packing :
Three-bond 1215B or equivalent C2-321
Fig . 151

(3) Install oil pump on cylinder block . Be careful not

U o Fluid packing
to damage oil seal during installation.
(Referto2-4 ENGINE LUBRICATION SYSTEM [W1E0] .)
a. Do not forget to install O-ring and seal when install-
ing oil pump.

U
0
b. Align flat surface of oil pump's inner rotor with
crankshaft before installation .
7) Install water pump and gasket .
After tightening all bolts to the specified torque, tighten
o O
all bolts to specified torque again .
0 (Refer to 2-5 ENGINE COOLING SYSTEM CW2C0] .)
B2-037
Be sure to use a new gasket .
Fig . 149 8) Install water pipe .
9) Install water by-pass pipe.
5) Install drive plate. 10) Install oil filter with OIL FILTER WRENCH.
6) Installation of oil pump.
(1) Discard front oil seal after removal . Replace with 2. RELATED PARTS
a new one . 1) Install cylinder head and intake manifold .
(Refer to Cylinder Head [W4A0] .)
2) Install camshaft and related parts .
(Refer to Camshaft [W3A0].)
3) Install camshaft sprocket, timing belt and related
parts.
(Refer to Timing Belt [W2A0] .)

Ng. 15U

75
2-3 [T100] ENGINE

T TROUBLESHOOTING
1 . Engine Trouble in General
Symbols shown in the chart refer to No . TROUBLE
the possibility of reason for 1 Starter does not turn.
the trouble in order ("Ver y often" to "Rare ly ") --
O- Very often 2 Engine will Initial combustion does not occur .
0- Sometimes 3 not start . Initial combustion occurs .
D- R are ly
4 Engine stalls after initial combustion .
5 Rough idle and engine stall .
6 Low output, hesitation and poor acceleration.
7 Surging .
8 Engine does not return to idle .
9 Dieseling (Run-on) .
10 After burning in exhaust system .
11 Knocking .
12 Excessive engine oil consumption .
13 Excessive fuel consumption .
TROUBLE No.
POSSIBLE CAUSE
1 2 3 4 5 6 7 8 9 10 11 12 13
STARTER
0 a Defective battery-to-starter harness .
D Defective starter switch .
D Defective inhibitor switch .
0 A Defective starter .
BATTERY
O e Poor terminal connection .
O e Run-down battery .
0 e Defective charging system .
O O O O O O O O O O O MPFI SYSTEM (See Chap . 2-7 .)
IGNITION SYSTEM
0 0 0 O O O O O O O O e Incorrect ignition timing .
0 O 0 0 0 e Disconnection of ignition coil connector .
0 d 0 0 e Defective ignition coil .
0 0 L A e Defective cord or wiring .
0 0 0 0 O a Defective spark plug .
0 0 0 O 0 O A 0 0 * Incorrect cam timing .
1 2 3 4 5 6 7 8 9 10 11 12 13

76
 ENGINE ITioo] 2-3

TROUBLE No .
POSSIBLE CAUSE
1 2 3 4 5 6 7 8 9 10 11 12 13
INTAKE SYSTEM
0 0 O 0 0 O 0 0 O 0 Improper idle adjustment .
0 O O O L O * Loosened or cracked intake boot.
0 O O O L O e Loosened or cracked intake duct.
O O O L O 0 e Loosened or cracked blow-by hose.
O 0 O O 0 O 0 Loosened or cracked vacuum hose .
0 0 O O 0 Defective air cleaner gasket.
O 0 0 0 0 O * Defective intake manifold gasket.
0 0 0 0 0 O * Defective throttle body gasket.
d 0 0 0 0 0 * Defective PCV valve .
0 0 0 L 0 L e Loosened oil filler cap .
O 0 0 O " Dirty air cleaner element.
FUEL LINE
O D L 0 0 e Defective fuel pump .
O D d 0 0 e Clogged fuel line .
0 0 0 0 L e Lack of or insufficient fuel .
BELT
0 0 0 e Defective.
0 0 0 L 0 0 0 0 0 0 Defective timing .
FRICTION
d Seizure of crankshaft and connecting-rod bearing .
D Seized camshaft.
D Seized or stuck piston and cylinder .
COMPRESSION
D D L 0 0 0 0 L 0 e Worn or broken lash adjuster.
0 L 0 0 L L L 0 Loosened spark plugs or defective gasket.
0 0 A L L 9 Loosened cylinder head nuts or defective gasket .
D D A 0 0 A 0 0 0 Improper valve seating.
O D L L IL IL L O L e Defective valve stem .
0 0 0 0 0 IL L A e Worn or broken valve spring .
0 L L 0 0 * Worn or stuck piston rings, cylinder and piston.
0 0 0 0 O O O 0 0 " Incorrect valve timing .
0 0 O 0 0 0 9 Improper engi ne oil (low viscosity) .
1 2 i 3 4 5 6 7 8 9 10 11 12 13

77
2-3 [Tioo1 ENGINE

TROUBLE No.
POSSIBL E CAUSE
1 2 3 4 5 6 7 8 9 10 11 12 13
LUBRICATION SYSTEM
0 0 9 Incorrect oil pressure .
0 0 Loosened oil pump attaching bolts and defective gasket.
0 0 Defective oil filter seal .
0 0 Defective crankshaft oil seal .
d 0 0 Defective rocker cover gasket.
0 0 Loosened oil drain plug or defective gasket .
0 * Loosened oil pan fitting bolts or defective oil pan .
COOLING SYSTEM
D d 0 0 O e Overheating .
D d D e Over cooling .
OTHERS

A d 0 Malfunction of Evaporative Emission Control System . (See

O O Chap . 2-1 .)
0 O 0 Stuck or damaged throttle valve .
0 0 0 0 Accelerator cable out of adjustment.
1 1 2 ( 3 4 5 6 7 8 9 10 11 12 13

78
 ENGINE [T200) 2-3

2 . Engine Noise
Valve lash adjusters may make clicking noise once engine starts. It is normal if clicking noise ceases after a few
minutes .
If clicking noise continues after a few minutes, check engine oil level and add oil if necessary. Warm up engine for
five minutes, then drive it at approximately 3,000 rpm for twenty minutes . If noise still exists, conduct
troubleshooting procedures in accordance with the following table .

Type of sound Condition Possible cause

Valve mechanism is defective
Broken and worn lash adjuster .
Sound increases as engine speed
Regular clicking sound. Worn camshaft .
increases . Broken valve spring .
Worn lash adjuster guide.
Worn crankshaft main bearing .
Oil pressure is low . Worn connecting rod bearing (big end) .
Heavy and dull metallic knock .
0 Loose flywheel mounting bolts.
Oil pressure is normal a Damaged engine mounting .
Ignition timing advanced .
High-pitched metallic knock . (En- Sound is noticeable when accel- 0 Accumulation of carbon inside combustion chamber .
gine knocking) erating with an overload . a Wrong spark plug .
Improper gasoline .
Metallic knock when engine Sound is reduced when spark e Worn crankshaft main bearing .
speed is medium (1,000 to 2,000 plug in noisy cylinder is short- e Worn bearing at crankshaft end of connecting rod .
rpm) . ened out.
Sound is reduced when spark a Worn cylinder liner and piston ring .
plug in noisy cylinder is short- 0 Broken or stuck piston ring .
Knocking sound when enginei is ened out. * Worn piston pin and hole at piston end of connecting rod .
operating under idling speed and
engine is warm . Sound is not reduced if each * Unusually worn valve lifter .
spark plug is shortened out in o Worn cam gear .
turn . * Worn camshaft journal bore in crankcase.
Squeaky sound . - * Insufficient alternator lubrication .
Rubbing sound . - * Defective alternator brush and rotor contact.

-
Type of sound Condition Possible cause
Gear scream when starting en- _ e Defective ignition starter switch .
gine. 0 Worn gear and starter pinion .
Sound like polishing glass with a _ e Loose drive belt.
dry cloth. * Defective water pump shaft .
* Loss of compression.
Hissing sound . - e Air leakage in air intake system, hoses, connections or mani-
folds.
Loose timing belt.
Timing belt noise . 0 Belt contacting case/adjacent part.

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