ENGINE

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GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE MOUNTlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0
ENGINE AND TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . 2 5
TIMING BELT TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ROCKER ARMS AND ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 35
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
VALVE AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
JET VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
FRONT CASE, OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
PISTON AND CONNECTlNG ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 0
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
OIL PRESSURE SWlTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
GENERAL
SPECIFICATIONS

Description Standard Limit

General
Type In-line OHV, OHC
Number of cylinders 4
Bore 75.5 mm (2.97 in.)
Stroke 82 mm (3.23 in.)
Total displacement 1,468 cc (89.6 cu.in.)
Compression ratio 9.4
Firing order 1-3-4-2
Basic ignition timing Refer to emission control
information label on car
Valve timing
Intake valve
Opens (BTDC) 15°
Closes (ABDC) 53°
Exhaust valve
Opens (BBDC) 53°
Closes (ATDC) 15°
Jet valve
Opens (BTDC) 15°
Closes (ABDC) 53°
Valve overlap 30°
Intake valve duration 248°
Exhaust valve duration 248°
Jet valve duration 248°
Compression pressure 1.12 MPa (11.4 kg/cm2,
164 psi)/250 rpm
Valve clearance-Hot engine
Intake valve 0.15 mm (0.006 in.)
Exhaust valve 0.25 mm (0.010 in.)
Jet valve 0.25 mm (0.010 in.)
Cylinder head
Warpage of lower face of head Within 0.05 mm (0.002 in.) 0.1 mm (0.004 in.)
Clearance with camshaft 0.05-0.09 mm (0.002-0.0035 in.)
Oversize rework dimension of valve seat hole
Intake 0.3 mm (0.102 in.) 39.3-39.325 mm (1.5472-1.5482 in.)
0.6 mm (0.024 in.) 39.6-39.625 mm (1.5590-1.5600in.)
Exhaust 0.3 mm (0.012 in.) 34.3-34.325 mm (1.3504-1.3514 in.)
0.6 mm (0.024 in.) 34.6-34.625 mm (1.3622-1.3632 in.)
Oversize rework of valve guide hole
(both intake and exhaust)
0.05 mm (0.002 in.) 13.05-13.068 mm (0.5135-0.5145 in.)
0.25 mm (0.010 in.) 13.25-13.268 mm (0.5216-0.5224 in.)
0.50 mm (0.020 in.) 13.50-13.518 mm (0.5315-0.5323 in.)

20-2
Description Standard Limit

Camshaft
Height of cam lobe
Intake 38.1 mm (1.500 in.) -0.5 mm (-9.020 in.)
Exhaust 38.2 mm (1.504 in.) -0.5 mm (-0.020 in.)
End play 0.05-0.20 mm (0.002-0.008 in.)
Valve
Stem O.D
Intake 6.6 mm (0.26 in.)
Exhaust 6.6 mm (0.26 in.)
Thickness of valve head (Margin)
Intake 1.0 mm (0.039 in.) 0.7 mm (0.028 in.)
Exhaust 1.5 mm (0.059 in.) 1.0 mm (0.039 in.)
Clearance with valve guide
Intake 0.03-0.06 mm (0.0012-0.0024 in.) 0.10 mm (0.004 in.)
Exhaust 0.05-0.09 mm (0.0020-0.0035 in.) 0.15 mm (0.006 in.)
Valve guide
Installed dimension 13.7-14.3 mm (0.5394-0.5630 in.)
Oversize 0.05 mm, 0.25 mm, 0.50 mm
(0.002 in., 0.010 in., 0.020 in.)
Valve seat insert
Width of seat contact 0.9-1.3 mm (0.035-0.051 in.)
Seat angle 45°
Oversize 0.3 mm, 0.6 mm (0.012 in., 0.024 in.)
Valve spring
Free length 44.6 mm (1.756 in.) -1.0 mm (-0.039 in.)
Load 24 kg/27.3 mm (53 lb./.469 in.)
Installed height 36 mm (1.417 in.) +1 mm (+0.039 in.)
Squareness 1.5° or less 3°
Jet valve
Stem O.D. 4.300 mm (0.1693 in.)
Seat angle 45°
Jet valve spring
Free length 29.60 mm (1.1654 in.)
Load 3.5 kg/21.5 mm (5.5lb/0.846 in.)
Cylinder block
Cylinder bore 75.5 mm (2.972 in.)
Out-of-roundness and taper of cylinder bore Within 0.02 mm (0.0009 in.)
Clearance with piston 0.02-0.04 mm (0.0008-0.0016 in.)
Piston
O.D. 75.5 mm (2.972 in.)
Oversize 0.25 mm, 0.50 mm, 0.75 mm, 1.00 mm
(0.010 in., 0.020 in., 0.030 in., 0.039 in.)

20-3
 GENERAL

Description Standard Limit

Piston ring
Side clearance
No. 1 0.03-0.07 mm (0.0012-0.0028 in.) 0.15 mm (0.006 in.)
No. 2 0.02-0.06 mm (0.0008-0.0024 in.) 0.12 mm (0.005 in.)
End gap No. 1 and No. 2 0.20-0.35 mm (0.008-0.0014 in.) 0.10 mm (0.039 in.)
Oil ring 0.20-0.70 mm (0.008-0.028 in.) 0.10 mm (0.039 in.)
Oversize 0.25 mm,0.50 mm, 0.75 mm, 1.00 mm
(0.010 in., 0.020 in., 0.030 in., 0.039 in.)
Connecting rod
Bend 0.05 mm (0.0020 in.) or less
Twist 0.10 mm (0.0039 in.) or less
Side clearance 0.10-0.25 mm (0.004-0.010 in.)
Connecting rod bearing
Oil clearance 0.01-0.06 mm (0.0004-0.0024 in.)
Undersize 0.25 mm, 0.50 mm, 0.75 mm
(0.01 in., 0.02 in., 0.03 in.)
Crankshaft
Pin O.D. 42 mm (1.6535 in.)
Journal O.D. 48 mm (1.8898 in.)
Bend Within 0.03 mm (0.0012 in.)
Out-of-roundness, taper of journal and pin Within 0.01 mm (0.0004 in.)
End play 0.05-0.18 mm (0.002-0.007 in.)
Undersize rework dimension of pin
0.25 mm (0.010 in.) 41.735-41.750 mm (1.6431-1.6437 in.)
0.50 mm (0.020 in.) 41.485-41.500 mm (1.6333-1.6339 in.)
0.75 mm (0.030 in.) 41.235-41.250 mm (1.6234-1.6240 in.)
Undersize rework dimension of journal
0.25 mm (0.010 in.) 47.735-47.750 mm (1.8793-1.8799 in.)
0.50 mm (0.020 in.) 47.485-47.500 mm (1.8695-1.8701 in.)
0.75 mm (0.030 in.) 47.235-47.250 mm (1.8596-1.8602 in.)
Flywheel
Out-of-roundness Within 0.13 mm (0.005 in.)
Oil pump
Outer gear
Clearance between outer circumference 0.1-0.2 mm (0.0039-0.0079 in.)
and front case
Clearance between addendum and crescent 0.22-0.34 mm (0.0087-0.0134 in.)
End play 0.04-0.10 mm (0.0016-0.0039 in.)
Inner gear
Clearance between addendum and crescent 0.21-0.32 mm (0.0083-0.0126 in.)
End play 0.04-0.10 mm (0.0016-0.0039 in.)
Oil pressure at idle
At idle speed 78 kPa (0.8 kg/cm2, 11 psi)
At 3,000 rpm 441-539 kPa (4.5-5.5 kg/cm2, 64-78 psi)
Relief spring
Free height 47 mm (1.850 in.)
Load 4.3 kg/40 mm (9.5 lb/1.575 in.)

20-4
 GENERAL

SERVICE STANDARD

Standard value
Belt deflection 7-9 mm (0.28-0.35 in.)
Clearance between timing belt and seal line Approx. 14 mm (0.55 in.)
Piston pin press in load 4,900-14,700 N (1,102-3,306 lb)
Flywheel runout 0.1 mm (0.004 in.) max.
Oil pressure gauge unit
Current flow
at 0 kPa (0 psi, 0 kg/cm2) 0 mA
at 392 kPa (57 psi, 4 kg/cm2) 84 mA
at 785 kPa (114 psi, 8 kg/cm2) 110 mA

TIGHTENING TORQUE

Nm kg-cm Ib.ft

Cylinder Block
Front engine support bracket bolt 59-78 600-800 43-58
Front roll stopper bracket bolt 54-69 550-700 40-51
Rear roll stopper bracket bolt 59-78 600-800 43-58
Left engine support bracket bolt 29-39 300-400 22-29
Oil pressure switch 15-21 150-210 11-15
Cylinder Head
Cylinder head bolt-cold engine 69-74 700-750 51-54
-hot engine 78-83 800-850 58-61
Intake/exhaust manifold bolt or nut 16-19 160-190 12-14
Rocker cover bolt 1.5-2.0 15-20 1.1-1.4
Rocker arm shaft bolt 20-26 200-270 14-20
Camshaft bolt 20-26 200-270 14-20
Rear plate bolt 7.8-9.8 80-100 5.8-7.2
Jet valve 18-22 180-220 13-16
Main Moving
Connecting rod cap nut 31-34 320-350 23-25
Crankshaft bearing cap 49-53 500-540 36-39
Fly wheel (manual transmission) bolt 127-137 1,300-1,400 94-101
Drive plate (automatic transmission) bolt 127-137 1,300-1,400 94-101
Timing Belt
Crankshaft pulley bolt 12-15 122-150 8.7-11
Crankshaft sprocket bolt 69-98 700-1,000 51-72
Camshaft sprocket bolt 64-74 650-750 47-54
Timing belt tensioner bolt 20-26 200-270 14-28
Timing belt cover bolt 9.8-12 100-120 7.2-8.7
Front case bolt 12-15 120-150 8.7-11

20-5
 Nm kg.cm Ib.ft

Engine Mounting
Left mounting insulator (large) nut 59-78 600-800 43-58
Left mounting insulator (small) nut 29-39 300-400 22-29
Left mounting bracket to engine nut 49-64 500-650 36-47
Transmission mount insulator bolt 59-78 600-800 43-58
Transmission insualtor bracket to side member bolt 29-39 300-400 22-29
Transmission mount bracket to automatic transmission nut 59-78 600-800 43-58
Rear roll insulator bolt 29-39 300-400 22-29
Rear roll stopper bracket to crossmember bolt 29-39 300-400 22-29
Front roll rod upper bolt 29-39 300-400 22-29
Front roll rod lower bolt 54-69 550-700 40-51

SELECTION OF LUBRICANTS
Engine Oil
Recommended API classification : SF OR SF/CC
Recommended SAE viscosity grades :

*1. Restricted by driving condition and dealing area.

*2. Mot recommended for sustained high speed vehicle operation.

For best perfornamce and for maximum protection of all engines for all types of operation, select only those lubricants
which:
1. Conform to the requirements of API classification.
2. Have proper SAE grade number for expected ambient temperature range.
Lubricants which do not have both an SAE grade number and an API service classification on the container should
not be used.

20-6
 GENERAL

SPECIAL TOOLS

20-7
 GENERAL

20-8
GENERAL
 GENERAL

Tool
Illustration Use
(Number and name)

09391-21101 Inspection for FBC system

Harness connector for FBC

20-10
 GENERAL

TROUBLESHOOTING

Symptom Probable cause Remedy

Misalignment of suspension Bent engine mount bracket Replace bracket

Deformed engine roll stopper and roll bracket Replace bracket
Broken insulator in engine roll stopper Replace insulator
Deformed engine mount pipe Replace pipe
Deformed transmission mount bracket Replace bracket

Vehicle will not move Broken engine front mount bracket Replace bracket
Broken engine rear mount bracket Replace bracket
Broken rod in engine mount bracket Replace bracket or rod
Broken transmission mount bracket Replace bracket

Noise occurs when accelerating Loose engine front mount bracket Retighten bolt
or decelerating Loose engine rear mount bracket Retighten bolt
Loose engine roll stopper bracket Reighten bolt
Loose transmission mount bracket Retighten bolt

Body vibration Broken engine mount insulator Replace insulator

Broken transmission mount insulator Replace insulator

Loose transmission mount Loose bolt tightening transmission mount Reposition mounting
bracket parts

20-11
 GENERAL

20-12
20-13
RETORQUING OF CYLINDER HEAD BOLTS
1. When cylinder head bolts are retorqued, first slightly loosen
and then tighten to specified torque.
2. Be sure to follow the specific torquing sequence.
3. After cylinder head bolts have been tightened to specified
torque, run engine until normal operating temperature is
reached, allow it to cool down, and then retorque bolts to
specification for best results.

Tightening torque
Cold engine.. . . . . . 69-73 Nm (704-745 kg.cm, 51-54 Ib.ft)
Hot engine . . . . . . . 79-83 Nm (806-847 kg.cm, 58-61 Ib.ft)

ENGINE OIL LEVEL GAUGE

1. The oil level gauge is located on the forward side of the engine.
2. Maintain engine oil level within the marking lines on the oil
level gauge. The oil level in the oil pan may read at the “MAX”
mark line (upper limit) after the engine has been standing for
several hours, but when the engine is started the oil level will
drop somewhat due to filling of oil passage, etc.
3. When the oil level is at or below the “MIN” mark line (lower
limit) on the level gauge, add 1 liter (1 U.S. quart). The oil should
never be allowed to remain below the lower limit.
CAUTION:
Do not overfill crankcase. This will cause oil aeration and loss
of oil pressure.

OIL FILTER
Filter Selection
All Hyundai Motor Company engines are equipped with high
quality, full flow throwaway oil filter. This filter is recom-
mended as a replacement filter in service on all vehicles.
The quality of replacement filter varies considerably. Only high
quality filter should be used to assure most efficient service.

Replacing Oil Filter

1. Use filter wrench or the like to remove oil filter. Clean the
mounting surface on the block carefully.
2. Apply a thin film of engine oil to the surface of the new gasket
before screwing filter on.
3. Then tighten filter enough by hand.
4. Start and run engine and check for engine oil leaks.
5. After stopping engine, check oil level and replenish as neces-
sary.

20-14
 GENERAL

TIMING BELT AND TIMING BELT TENSIONER INSTA-

LLING PROCEDURE
1. Assemble rocker arm adjusting screw in tentative state.
Then screw must protrude within 1.5 mm (0.06 in.)
NOTE
(a) Take special care not screw to be below arm end, other-
wise valve stem would rust thread part.
(b) In case of protruding too much, tension of belt would be
excessive.

2. Tentatively fasten timing belt tensioner at such position as to

place it’s pulley nearest to water pump (pulley may touch water
pump body).

3. After installing flange, crankshaft sprocket and camshaft

sprocket match timing mark of each sprocket as shown in
illustration.
As a result of this, get piston in No. 1 cylinder at top dead center
on compression stroke.

CAUTION
(a) Take special care of installing direction of flange. (Cham-
fered part shows front of engine).
(b) When installing camshaft sprocket, make sure that
knock pin and camshaft fits small hole in pulley.

20-15
 GENERAL

NOTE
Allow tensioner to remain in assemble state must be installed
temporarily as follows.
o Tentatively tighten tensioner at position as shown in illus-
tration, in state that one extended end of spring tensioner
is assembled to bend of tensioner bracket as imaginary
line (wheel spring tensioner is inoperative and not loaded).
o Then set extended end of tensioner spring at front case
with drive etc.

4. Install timing belt so as not to give slack to tension side. Then

make sure all timing marks are at correct position respectively
with tension side in strained state by applying force to camshaft
sprocket in reversing (counterclockwise) direction.

20-16
 GENERAL

TIMING BELT TENSION ADJUSTMENT PROCE-

DURE
If any unusual noise is caused by improperly adjusted timing
belt tension, use the following procedure to readjust the
tension.

1. Remove timing belt upper cover and water pump pulley.

2. Check the belt for cracking, peeling or other damage. Be sure to
carefully check the entire length of the belt.
3. Set the engine so that the No. 1 cylinder is at the compression
top dead center. In other words, align the timing mark on the
camshaft sprocket with that on the cylinder head.
Note that the crankshaft should be turned clockwise, not in
reverse. Turning the crankshaft counterclockwise will cause
the tension to become improperly adjusted.

4. Remove the timing belt lower cover.

5. Loosen the tensioner mounting bolts 1 and 2 in that order as
shown to give the timing belt only spring tension.

6. Check the belt to ensure that it is not out of position.

20-17
7. Tighten the tensioner attaching bolts 2 and 1 in that order as
shown. If the bolt 1 is tightened first, the tensioner will move
with the bolt and cause the belt to become overtightened.

8. Give the crankshaft one turn in operating direction (clockwise)

and realign crankshaft sprocket timing mark with the top dead
center position.
CAUTION:
Do not turn the crankshaft in a reverse direction. The crank-
shaft should be turned smoothly clockwise.
9. Loosen the tensioner attaching bolts 1 and 2 in that order as
shown.
10. Retighten the tensioner attaching bolts 2 and 1 in that order as
shown to the specified torque.

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-26 Nm (200-270 kg.cm, 14-20 Ib.ft)

11. Then recheck the belt tension. Verify that when the tensioner
and the tension side of the timing belt are pushed in horizon-
tally with a moderate force [approx. 49 N (11 lb)], the timing
belt cog end is approx. 1/2 of the tensioner mounting bolt head
radius (across flats) away from the bolt head center.

20-18
 GENERAL

TENSION MEASURING PROCEDURE (When using

tension gauge)
1. Rotate crankshaft in direction of irregular rotation (counter
clockwise) to position of 90 degrees before top dead center as
shown in illustration under condition that adjusting screw,
rocker arm is adjusted regularly (where valve clearance is
adjusted).
2. Measure the belt tension in the middle of tension side span us
ing tension gauge. (BOROUGHTS BT-33-73F TYPE)

Torque valve of timing belt tension (In cool condition)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96-107 lb.

CAUTION
(a) Put arm on bottom of belt teeth. And put spindle on the
middle of belt back surface.
(b) Keep hand off from indicating part.

20-19
 ENGINE MOUNTING

ENGINE MOUNTING
COMPONENTS

20-20
 ENGINE MOUNTING

REMOVAL
Attach a cable or chain to the engine hooks, and then lift
enough so that there is no pressure on the insulators.

Engine Mounting
1. Remove the engine mount insulator bolts.
2. Remove the engine mount bracket from the engine.

Transmission
1. For vehicles with a 5-speed manual transmission, remove the
select control valve.
2. Remove the transmission mount bolt.

3. Detach the cap from the inside of the right fender shield,
remove the transmission mounting bolts.
4. Remove the transmission bracket.

Front Roll Stopper

1. Remove the front roll stopper upper and lower bolts.
2. Remove the front roll rod assembly.
 ENGINE MOUNTING

Rear Roll Stopper

1. Remove the bolt from the rear roll stopper.
2. Remove the rear roll stopper from the No. 2 crossmember.

INSPECTION ITEMS

Transmission mounting Engine mounting Front roll stopper Rear roll stopper

BUSHING REPLACEMENT
Removal
1. Press out the bushings from the front roll stopper by using
special tools.

20-22
 ENGINE MOUNTING

2. Press out the bushing from the rear roll stopper by using special
tools.

NOTE
Before removing the rear roll stopper bushing, mark the rear
roll stopper for reference in bushing installation.

Installation
1. Press fit the bushings into the front roll rod by using special
tools.

2. Press fit the bushings into the rear roll stopper by using special
tools.

20-23
 ENGINE MOUNTING

NOTE
When the bushings are installed, observe the following dimensions.

Front roll stopper Rear roll stopper

NOTE
When installing the front roll stopper lower bolt, tighten the bolt
with its projection inserted into the slot.

20-24
 ENGINE AND TRANSMISSION ASSEMBLY

ENGINE AND TRANSMISSION ASSEMBLY

REMOVAL
1. Remove the battery.
2. Detach the air cleaner.
3. Disconnect the connectors for the backup lamp and engine
harness.
4. For vehicle with a 5 speed manual transmission disconnect
the select control valve connector.

5. Disconnect the connectors for the alternator harness and the

oil pressure gauge wiring.
6. Drain the engine coolant.
7. For vehicles with an automatic transmission, disconnect the
transmission oil cooler hoses.
NOTE
When disconnecting the hoses, make identification marks
to avoid making any mistakes in reconnecting them.
CAUTION
Be careful not to spill any of the oil or fluid out of the hoses,
and the openings to prevent the entrance of foreign material.

8. Disconnect the radiator upper and lower hoses on the engine

side, and then remove the radiator assembly.
9. Disconnect the high tension cable and all wires to the distribu-
tor from the ignition coil section.
10. Disconnect the engine ground.
11. Disconnect the brake booster vacuum hose.
12. Remove the fuel main, return and vapor hoses from the engine
side.

13. Disconnect the heater hoses (inlet and outlet) on the engine
side.
14. Disconnect the accelerator cable at the engine side.
15. For vehicles with a manual transmission, remove the clutch
cable from the transmission.
16. For vehicles with an automatic transmission, remove the con-
trol cable from the transmission.

20-25
 ENGINE AND TRANSMISSION ASSEMBLY

17. Disconnect the speedometer cable form the transmission.

18. Disconnect the air conditioner mounting bracket.

19. Jack up the vehicle.

20. Drain the transmission oil (or fluid).
21. Disconnect the front exhaust pipe from the manifold.
NOTE:
Use wire to suspend the exhaust pipe from the bottom of
the vehicle.
22. For vehicles with a manual transmission, remove the shift
control rod and extension rod.
23. Remove the lower arm ball joint bolts and the strut bar at the
point where it is mounted to the lower arm.
24. Remove the drive shafts from the transmission case.

CAUTION
(a) Plug up the holes of the transmission case to prevent
entry of foreign material.
(b) The circlips on the drive shafts should be replaced at
each removal.
25. Hang the lower arm and drive shaft from the body with a
string.
26. Attach a cable to the engine, and use a chain block to lift the
engine only enough to pull cable tight.

27. Remove the front roll stopper.

28. Separate the rear roll stopper and the No. 2 crossmember.

20-26
 ENGINE AND TRANSMISSION ASSEMBLY

29. Remove the engine mounting insulator bolts.

30. Remove the engine mounting bracket from the engine.

31. Slowly raise the chain block (to the extent that the engine and
transmission weights are not applied to the mounting por-
tions) and temporarily hold it in the raised condition.
CAUTION
Confirm that all of the cables, hoses, harnesses, connectors
etc., are disconnected from the engine.
32. Remove the blind cover from inside the right fender shield and
remove the transmission mount bracket bolts.
33. Remove the left mount insulator bolt.
While directing the transmission side downward, lift the
engine and transmission assembly up and out of the vehicles.

20-27
 ENGINE AND TRANSMISSION ASSEMBLY

INSTALLATION
1. While checking the connections of the harnesses, pipes, hoses,
etc., and making sure that none of them are being caught,
damaged, etc, install the engine and transmission assembly.
2. When the engine and transmisson assembly is installed to the
front roll stoppers, first tighten temporarily.
3. Then, after the weight of the engine and transmission assembly
has been put on each insulator, tighten to specified torque.
4. Reassemble all of the components removed during disassem-
bly. Be especially careful to properly secure all components,
including fuel, electrical and fluid pipe connections.
5. Replenish the coolant and check for leakage.
6. Replenish the transmission fluid, test the operation, and check
for leakage.
7. Check the operation of the transmission control cable and
accelerator cable, and adjust as necessary.
8. Check the operation of each of the various meters.

20-28
 TIMING BELT TRAIN

TIMING BELT TRAIN

COMPONENT

TORQUE : N m (kg-cm. Ib.ft)

The timing belt train is driven by a cogged belt. The timing belt
drives the camshaft. The timing belt is fully covered to keep out
stones, water, sand and dust. Do not drive the vehicle with the
timing belt covers removed.

DISASSEMBLY
1. Remove the fan, spacer, water pump pulley and belt.
2. Remove the timing belt cover.
3. Move the timing belt tensioner fully toward the water pump and
temporarily secure it.
4. Remove the timing belt from the camshaft sprocket.
5. Remove the camshaft sprocket.
6. Remove the crankshaft pulley.
7. Remove the timing belt. If the timing belt is to reused, make an
arrow mark indicating the turning direction (or the front of
the engine) to make sure that the belt is reinstalled in the
same direction as before.
8. Remove the crankshaft sprocket bolts and remove the crank-
shaft sprocket and flange.
9. Remove the timing belt tensioner.

20-29
 TIMING BELT TRAIN

INSPECTION
Sprockets and Tensioner
1. Check the camshaft sprocket, crankshaft sprocket and ten-
sioner for abnormal wear, cracks damage and replace as
necessary.
2. Inspect tensioner for easy and smooth pulley rotation and check
for play or noise. Replace as necessary.

Timing Belt
1. Check the belt for oil or dust deposits and replace if necessary.
The slight deposit should be wiped away with a dry cloth or
paper. Do not clean with a solvent.
2. When the engine is overhauled or belt tension adjusted, check
the belt in detail. If the following flaws are evident, replace the
belt with a new one.

Description Flaw conditions

1. Hardened back surface rubber Back surface glossy. Non-elastic and so hard that even if a finger
nail is forced into it, no mark is produced.

2. Cracked back surface rubber

3. Cracked or separating canvas

20-30
 TIMING BELT TRAIN

Description Flaw conditions

4. Badly worn teeth (initial stage) Canvas on load side tooth flank worn
(Fluffy canvas fibers, rubber gone and color changed to white, and
unclear canvas texture)
Flank worn
(On load side)

5. Badly worn teeth (last stage) Canvas on load side tooth flank worn down and rubber exposed
(tooth width reduced)

6. Cracked tooth bottom

7. Missing tooth

8. Side of belt badly worn

NOTE
Normal belt should have precisely cut sides as if produced by a
9. Side of belt cracked sharp knife.

20-31
 TlMING BELT TRAlN

REASSEMBLY
1. Install the flange and crankshaft sprocket as shown, while
paying heed to their mounting directions.
Tightening torque
Crankshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69-98 Nm (700-1,000 kg.cm, 51-72 Ib.ft)

2. Install the camshaft sprocket and tighten the bolt to the speci-
fied torque.
Tightening torque
Crankshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64-74 Nm (650-750 kg.cm, 47-54 Ib.ft)

3. Align the timing marks of the camshaft sprocket and crankshaft

sprocket, with the piston in the No. 1 cylinder placed at top dead
center on compression stroke.

20-32
 4. To install the timing belt tensioner, first mount the tensioner,
spring and spacer and temporarily tighten the bolts. Next,
temporarily tighten the tensioner long hole side washer and
bolts. Install the bottom end of the spring in the position of the
front case as shown in illustration.

5. Secure the tensioner to the position nearest the water pump.

6. Install the timing belt on the crankshaft sprocket
7. Install the timing belt on the camshaft sprocket.
When the timing belt is installed on the camshaft sprocket,
make sure that the tension side is tight. Then, check to ensure
that when the tension side is tightened by turning the cam-
shaft sprocket in a reverse direction, all timing marks are in
line.

8. install the crankshaft pulley. In this case, make sure that the
crankshaft sprocket pin fits the small hole in the pulley.
Tightening torque
Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8-12 Nm (100-120 kg.cm, 7.2-8.7 Ib.ft)

9. Loosen the tensioner mounting bolts 1 and 2 in that order as

shown to give the timing belt only spring tension. Check the
belt to ensure that it is not out of position.
10. Tighten the tensioner tightening bolts 1 and 2 in that order-If
the bolt 1 is tightened first, the tensioner will move with the
belt in the direction that the belt is tightened.
11. Give the crankshaft one turn in operating direction (clockwise)
and realign crankshaft sprocket timing mark with the top dead
center position.

20-33
 TIMING BELT TRAIN

CAUTION
Do not turn the crankshaft in a reverse direction.
The crankshaft should be turned smoothly clockwise.
12. Loosen the tensioner attaching bolts 1 and 2 in that order.
13. Tighten the tensioner attaching bolts 2 and 1 in that order to
the specified torque.
Tightening torque
Tensioner attaching bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-26 Nm (200-270 kg.cm, 14-20 Ib.ft)

14. Then recheck the belt tension. Verify that when the tensioner
and the tension side of the timing belt are pushed in horizon-
tally with a moderate force [approx. 49 N (11 lb)], the timing
belt cog end end is approx. 1/2 of the tensioner mounting bolt
head radius (across flats) away from the bolt head center.
15. Install the timing belt cover.
16. Install the fan belt and adjust the belt tension.

20-34
 ROCKER ARMS AND ROCKER SHAFT

REMOVAL
1. Remove the breather hose between the air cleaner and the
rocker cover.
2. Remove the air cleaner.
3. Remove the timing belt cover.
4. Remove the rocker cover.
5. Loosen the rocker shafts mounting bolts and remove the rocker
shafts, rocker arms and rocker shafts springs as an assembly.
6. Remove the bolts, the rocker arms and rocker shafts springs
from the rocker shafts.

INSPECTION
1. Check the rocker arm face that contacts the cam lobe and the
adjusting screw end that contacts the valve stem. If badly worn
or damaged, replace rocker arm and/or adjusting screw(s).
2. Check the rocker arm shafts for damage. Replace as necessary.

20-35
 ROCKER ARMS AND ROCKER SHAFT

INSTALLATION
1. Install the rocker arms and rocker shafts springs to the rocker
arm shafts. Install the rocker arm shafts to the cylinder head.
Tighten the rocker shafts mounting bolts to the specified
torque.
Tightening torque
Rocker arm shafts mounting bolt . . . . . . . . . . . . . . . . . . . . . . . .
20-26 Nm (200-270 kg.cm, 14-20 Ib.ft)

2. When installing the rocker arms, shafts and springs, note the
difference between the RH and LH parts. The RH springs (those
for exhaust side) are approx. 47 mm (1.85 in.)free length, while
the LH springs (those for intake) are approx. 77 mm (3.03 in.)
free length.

3. Install the rocker cover and tighten the bolts to the specified
torque.
Tightening torque
Rocker cover bolt.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5-2.0 Nm (15-20 kg.cm, 1.1-1.4 Ib.ft)

4. Install the timing belt cover.

Tightening torque
Timing belt cover bolt.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8-12 Nm (100-120 kg.cm, 7.2-8.7 Ib.ft)

5. Install the air cleaner.

6. Install the breather hose.

20-36
 CAMSHAFT

CAMSHAFT
COMPONENTS

64-74 (650-760.47-54)
TORQUE : Nm (kg.cm, Ib.ft)

REMOVAL
1. Disconnect the breather hose and the secondary air hose.
2. Remove the air cleaner.
3. Remove the timing belt cover.
4. Move the timing belt tensioner fully toward the water pump
and temporarily secure it.
5. Remove the timing belt from the camshaft sprocket. Since the
crankshaft pulley need not be removed, the timing belt should
be left installed on the crankshaft sprocket.
6. Remove the camshaft sprocket.
7. Remove the rocker cover.
8. Remove the rocker shafts assembly. Refer to “Rocker Arm and
Rocker Arm Shaft”.
9. Remove the cylinder head rear cover.
10. Remove the camshaft thrust case tightening bolt.

20-37
 CAMSHAFT

11. Remove the camshaft thrust case and camshaft toward the
transmission side of the cylinder head.

INSPECTION
1. Check the camshaft journals for wear. If the journals are badly
worn, replace the camshaft.
2. Check the cam lobes for damage. If the lobe is damaged or
worn excessively, replace the camshaft.
Cam height
[Standard dimension]
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.1 mm (1.500 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . 38.2 mm (1.504 in.)
[Limit]
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . -0.5 mm (-0.020 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . -0.5 mm (-0.020 in.)

3. Check the cam surface for abnormal wear or damage, and

replace if required. The fuel pump drive eccentric cam should
also be checked.
4. Check the distributor drive gear tooth surfaces. If abnormal
wear is evident, replace the camshaft.
5. Check each bearing for damage. If the bearing surface is
excessively damaged, replace the cylinder head assembly.
6. Oil Seal (camshaft front)
(1) Check the lips for wear. If lip threads are worn, replace.
(2) Check the oil seal lip contacting surface of camshaft. If it is
worn in stages, replace camshaft.

INSTALLATION
1. Install the crankshaft thrust case and thrust plate to the cam-
shaft end and firmly tighten the bolt. Check the camshaft end
play.
If the end play is too large, replace the thrust case and recheck
the end play. If the end play is still too large, check the rear end
of camshaft rear journal for wear. If it is badly worn, replace
the camshaft.
End play of camshaft [Standard value]. . . . . . . . . . . . . . . . . . . . .
0.05-0.20 mm (0.002-0.008 in.)

20-38
 CAMSHAFT

2. After lubricating the journal and thrust portions of the camshaft

with engine oil, insert the camshaft from the transmission side
of the cylinder head. Insert the camshaft thrust case with the
threaded hole uppermost, align the threaded hole with the bolt
hole in the cylinder head, install and firmly tighten the bolt.
3. Install the rear cover and gasket and tighten the bolts.

4. Using special tools, Camshaft Oil Seal lnstaller(09221-21000)

press fit the camshaft oil seal. Be sure to apply engine oil to the
external surface of the oil seal.
Insert the oil seal along the camshaft front end and install by
driving the installer with a hammer until the oil seal is fully
seated.

5. Install the camshaft sprocket and tighten the bolts to the speci-
fied torque.
6. Install the rocker arm and shafts.
Refer to “Rocker Arm and Rocker Arm Shafts”.
7. Align the camshaft sprocket and crankshaft sprocket timing
marks. The piston in the No. 1 cylinder will then be at the top
dead center on the compression stroke.

Tightening torque
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64-74 Nm (650-750 kg.cm, 47-54 Ib.ft)

8. Temporarily set the valve clearance to specification with the

engine cold. See “Valve Clearance Adjustment Procedure”.

Valve clearance (cold engine) [Standard value]

Jet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.17 mm (0.007 in.)
Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mm (0.003 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . 0.17 mm (0.007 in.)

20-39
 CAMSHAFT

9. Install a gasket in the rocker cover groove.

10. Temporarily install the rocker cover.
11. Start the engine and run at idle.
12. After warming the engine to normal operating temperature
[80 to 95°C (176 to 203°F) coolant temperature], adjust the
valve clearance to specification. See “Valve Clearance Adjust
ment Procedure”
13. Install the rocker cover and tighten the bolts to the specified
torque.

Tightening torque
Rocker cover bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5-2.0 Nm (15-20 kg.m, 1.1-1.4 Ib.ft)

14. Install the timing belt cover.

20-40
 CYLINDER HEAD

CYLINDER HEAD
COMPONENTS
The cylinder head is an aluminum alloy casting into which the
jet pieces, valve guides and valve seats are press fitted.
1. The combustion chamber is hemispherical type. The jet pieces,
jet valves, intake valves, exhaust valves and spark plugs are
arranged as shown in illustration.
2. There are three camshaft bearings machined as a unit with the
cylinder head at the top center of the cylinder head.
3. The exhaust manifold with a built-in catalytic coverter is on the
right side of the cylinder head. The intake mainfold, fuel pump
and distributor are on the left side.

REMOVAL
1. Drain the coolant and disconnect the upper radiator hose.
2. Remove the breather hose (between the air cleaner and the
rocker cover)
3. Remove the air cleaner.
4. Remove the vacuum hose, fuel hose and water hose.
5. Remove the cables from the spark plugs. The cables should be
removed by holding their boot portions.

20-41
 CYLINDER HEAD

6. Remove the distributor.

7. Remove the carburetor.
8. Remove the intake manifold.
9. Remove the heat cowl and exhaust manifold assembly.
10. Remove the timing belt cover.
11. Move the timing belt tensioner fully toward the water pump
and temporarily secure it.
12. Remove the timing belt from the camshaft sprocket. Since the
crankshaft pulley need not be removed, the timing belt should
be left on the crankshaft sprocket.
13. Remove the rocker cover.

14. Remove the cylinder head assembly. The cylinder head bolts
should be removed by using a Special Tool, Cylinder head Bolt
Wrench (09221-11000), in the sequence as shown in
illustration.
15. Remove the gasket pieces from the cylinder block top surface
and cylinder head bottom surface.
NOTE
Make sure that the gasket pieces do not fall in the engine.

INSPECTION
1. Check the cylinder head for cracks, damage and water
leakage.
2. Remove scale, sealing compound and carbon deposits com-
pletely. After cleaning oil passages, apply compressed air to
make certain that the passages are not clogged.
3. Check the jet air passage and EGR gas passage for clogging.

20-42
 CYLINDER HEAD

4. Check the cylinder head gasket surface for flatness by using a

straight edge in the direction of A, B, . . . as shown.
If flatness exceeds service limit in any direction, either replace
cylinder head or lightly machine the cylinder head gasket
surface.
Flatness of cylinder head gasket surface
[Standard dimension]. . . . . . . Less than 0.05 mm (0.002 in.)
[Limit]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.004 in.)

INSTALLATION
1. Clean all gasket surfaces of cylinder block and cylinder head.
2. Install new cylinder head gasket and cylinder head assembly.
Do not apply sealant to the gasket and do not reuse cylinder
head gasket.
3. Install the cylinder head bolts. Starting at top center, tighten all
cylinder head bolts in sequence as shown in illustration, using
the Cylinder Head Bolt Wrench (09221-11000). Repeat the
procedure, retightening all cylinder head bolts to the specified
torque.
Tightening torque
Cylinder head bolt
When cold.. . . . . 69-74 Nm (700-750 kg.cm, 51-54 Ib.ft)
When hot . . . . . . 78-83 Nm (800-850 kg.cm, 58-61 Ib.ft)

4. Move the timing belt tensioner fully toward the water pump and
temporarily secure it.
5. Install the timing belt on the camshaft sprocket, making sure
that the tension side is tight. Check to ensure that when the
tension side is tightened by turning the camshaft sprocket in
reverse, all timing marks are in alignment.
6. Adjust timing according to “Timing Belt Train”.
7. Install the rocker cover and tighten the bolts to the specified
torque.
Tightening torque Rocker cover bolt.
. . . . . . . . . . . . . . . . . . . . . 1.5-2.0 Nm (15-20 kg.cm, 1.1.1.4 Ib.ft)

20-43
 CYLINDER HEAD

8. Install the timing belt cover.

9. Install the new intake manifold gasket and the intake manifold,
and tighten the nuts and bolts to the specified torque.

Tightening torque
Manifold nuts and bolts.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(both intake and exhaust)
16-19 Nm (160-190 kg.cm, 12-14 Ib.ft)

10. Install the new exhaust manifold gasket and the exhaust
manifold. Tighten the exhaust attaching nuts to the specified
torque.
11. Install the carburetor and tighten the nuts.
12. Install the distributor.
13. Connect the vacuum hose, fuel hose and water hose.
14. Install the air cleaner and breather hose.

20-44
 VALVE AND VALVE SPRINGS

VALVE AND VALVE SPRINGS

The intake and exhaust valves are made of heat resistant steel
and arranged in the form of the letter V with the camshaft in the
center.
The valve stem seal, installed on the upper part of the valve
guide, serves to prevent the oil from working down through the
clearance between the valve stem and the valve guide.

1. Cylinder head 7. Valve spring

2. Camshaft 8. Valve stem seal
3. Exhaust valve guide 9. Intake valve
4. Exhaust valve 10. Intake valve guide
5. Retainer lock 11. Exhaust valve seat
6. Valve spring retainer 12. Intake valve seat

REMOVAL
Remove the cylinder head. Refer to “Cylinder Head”

DISASSEMBLY
1. Using Special Tool, Valve Spring Compressor (09222-21001),
remove the retainer lock.
Then remove the spring retainer, valve spring, spring seat and
valve.
NOTE
Keep these parts in order so that they can be reinstalled in
their original positions.
2. Remove valve stem seals with pliers and discard.
NOTE
Do not reuse the valve stem seals.

20-45
 VALVE AND VALVE SPRINGS

INSPECTION
Valves
Check each valve for wear, damage and deformation of head
and stem at B. Repair or correct excessively worn, damaged or
deformed valves.
If stem top A has been pitted, correct with an oil stone or other
means. This correction must be limited to a minimum. Also
reface the valve.
Replace the valve if the face margin has decreased to less than
the service limit.
Margin
[Standard dimension]
Intake.............................1.0mm(0.039in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.059 in.)
[Limit]
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 mm (0.028 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.039 in.)

Valve Springs
1. Check the valve spring free length and tension. If they exceed
the service limit, replace the spring.
2. Using a square, test the squareness of each spring. If the spring
is excessively out of square, replace it.
Valve spring
[Standard Value]
Free height . . . . . . . . . . . . . . . . . . . . . . 44.57 mm (1.755 in.)
Load . . . . . . . . . . . . 24.2 kg at 37.3 mm (54 lb at 1.479 in.)
Out of square . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5° or less
[Limit]
Free height . . . . . . . . . . . . . . . . . . . . . . -1.0 mm (-0.039 in.)
Out of square. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3°

Valve Guides
Check the valve stem-to-guide clearance. If the clearance
exceeds the service limit, replace the valve guide with next
oversize part.’
Valve stem-to-guide clearance
[Standard dimension]
Intake . . . . . . . . . . . . . . 0.03-0.06 mm (0.0012-0.0024 in.)
Exhaust . . . . . . . . . . . . 0.05-0.09 mm (0.0020-0.0035 in.)
[Limit]
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm(0.004in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)

20-46
 VALVE AND VALVE SPRINGS

Valve Guide Oversizes

Cylinder head hole size
Size mm (in.) Size mark
mm (in.)
0.05 (0.002) O.S 5 12.105-12.115
(0.4766-0.4770)
0.25 (0.010) O.S 25 12.305-12.315
(0.4844-0.4848)
0.50 (0.020) O.S 50 12.555-12.565
(0.4943-0.4947)

Valve Seat Insert

1. Check the valve seat for evidence of overheating and improper
contact with the valve face. Correct or replace the seat if
necessary.
When correcting, check the valve guide for wear. Replace the
worn guide, and then correct the seat ring.
Recondition the valve seat with a seat grinder or cutter. The
valve seat contact width should be of the specified size at the
center of the valve face.
To correct the exhaust valve seat, use Valve Seat Cutter and
Pilot.
After correction, the valve and valve seat should be lapped
lightly with a lapping compound.

2. Check valve seat insert sinkage. If the sinkage exceeds the

service limit, replace the insert with an oversize part as des-
cribed below.
Measure the installed height of spacing between the spring seat
and the retainer with the valve spring seat, spring retainer and
retainer lock installed. The amount of sinkage can be judged
from the measured value.
lnatalled height of spring A (both intake and exhaust)
[Standard dimension] . . . . . . . . . . . . . . . . . 36 mm (1.417 in.)
[Limit]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +1 mm (+0.039 in.)

20-47
 VALVE AND VALVE SPRINGS

Valve Seat Insert Replacement Procedure

1. Any valve seat insert that has been worn over the service limit
should be removed at normal temperature after cutting away
most of the insert wall, using valve seat cutters, as shown in
Fig. “A”.

Valve Seat Insert Oversizes

Description Size mm (in.) Size mark Seat insert height H mm (in.) Cylinder head I.D. mm (in.)

Intake valve 0.3 (0.012) O.S 30 7.6 (0.299) 36.30-36.33 (1.429-1.430)

Seat insert 0.6 (0.024) O.S. 60 7.9 (0.311) 36.60-36.63 (1.441-1.442)
Exhaust valve 0.3 (0.012) O.S. 30 7.5 (0.295) 32.30-32.33 (1.272-1.273)
Seat insert 0.6 (0.024) O.S. 60 7.8 (0.307) 32.60-32.63 (1.283-1.285)

2. After removing the seat insert, machine the seat insert bore by
a reamer or a cutter uniformly to the size shown in the table.
3. Heat the cylinder head to about 250°C (480°F) and press in the
oversize seat insert. The oversize seat insert should be at nor-
mal room temperature for installation. After the installation of a
new valve seat, correct the valve seat surface by the valve seat,
correct the valve seat surface by the same procedure as para-
graph 1. in Valve Seat Insert.

20-48
 VALVE AND VALVE SPRINGS

Valve Guide Replacement Procedures

The valve guide is press fitted. Using a Valve Guide installer
(09222-21200) or suitalbe tool, replace the valve guide by the
following procedure.
1. Using the push rod of the Valve Guide Installer, push the valve
guide out of position toward the cylinder bolck with a press.
2. Machine the valve guide insert hole in the cylinder head to the
oversize of valve guide.

3. Using the Valve Guide Installer or suitable tool, press fit the
valve guide. The use of the valve guide installer makes it possi-
ble to press fit the valve guide to a predetermined height. The
valve guide should be installed from the top of the cylinder
head. Note that the intake and exhaust valve guides are differ-
ent in length [44 mm (1.73 in.)for intake and 49.5 mm (1.95 in.)
for exhaust).
4. After the valve guides have been installed, insert new valves
and check their sliding condition.
5. When the valve guides have been replaced, check for valve
contact and correct the valve seats as necessary.

20-49
 VALVE AND VALVE SPRINGS

REASSEMBLY
CAUTION
(a) Clean each part before assembly.
(b) Apply new engine oil to sliding and rotating parts.
1. After installing the spring seat, fit the stem seal onto the valve
guide.
To install fit the seal in by lightly tapping the Special Tool, Valve
Stem Oil seal Installer (09222-21100).
The seal is installed in the specified position by means of the
specical tool. Incorrect installation of the seal will adversely
affect the lip I.D. and eccentricity, resulting in oil leakage down
the valve guides. When installing, therefore, be careful not to
twist. Do not reuse old stem seals.
2. Apply engine oil to each valve. Insert valves into the valve
guides. Avoid inserting the valve into the seal with force.
After insertion, check to see if the valve moves smoothly.
3. Install springs and spring retainers.
Valve springs should be installed with the enamel coated side
toward the valve spring retainer.
4. Using Special Tool, Valve Spring Compressor (09222-21001),
compress the spring with the Valve Spring Compressor, be
careful that the valve stem seal is not pressed by the bottom of
the retainer. Then start installing the retainer lock. After instal-
lation of valves, make certain that retainer locks are positively
installed.
5. Install the cylinder head. Refer to “Cylinder Head”.

20-50
 JET VALVE

JET VALVE
COMPONENTS

REMOVAL
1. Remove the rocker arms and shafts. Refer to Rocker Arm and
Rocker Arm Shaft.
2. Remove the valves, using Special Tool, Jet Valve Socket
Wrench (09222-21300).

CAUTION
When the jet valve socket wrench is used, make certain that
the wrench is not tilted with respect to the center of the jet
valve. If the tool is tilted, the valve stem might be bent by the
force exerted on the valve spring retainer, resulting in defec-
tive jet valve operation or a damaged tool.

20-51
3. When disassembling the jet valve, compress the spring with the
Special Tool, Jet Valve Spring Pliers (09222-21400), remove
the valve spring retainer lock, and then remove the valve spring
retainer and valve spring.
CAUTION
Do not mix up the combination of the jet valve body after the
disassembly of the jet valve assembly, otherwise gas leakage
and malfunctioning may result.
4. Pull off valve stem seals with pliers and discard.

INSPECTION
1. Make sure that the jet valve slides smoothly in the body and has
no play.
Combination of the jet valve and jet body should not be dis-
turbed and the jet valve and jet body should be replaced as an
assembly.
2. Check the valve head and valve seat for damage of seizure.
3. Check the spring for sag, crakcs or breakage.
[Standard value]
Diameter of jet valve stem 4.300 mm (0.1693 in.)
Angle of valve face and seat.. . . . . . . . . . . . . . . . . . . . . . . . 45°
Jet valve spring
Free length . . . . . . . . . . . . . . . . . . . . . . 29.60 mm (1.165 in.)
Load . . . . . . . . . . . . . . . . 3.5 kg/21.5 mm (5.5lb/0.846 in.)

INSTALLATION
1. Using the Special Tool, Jet Valve Stem Seal Installer (09222-
21500). drive the valve stem seal into the jet body.
CAUTION
(a) The valve stem seal is not reusable.
(b) Use Special Tool, otherwise valve stem seal will be
improperly installed and oil will work down.
2. Apply engine oil to the jet valve stem when installing it to the jet
body. Take care not to damage the valve stem seal lip. Make
sure that the jet valve stem slides smoothly in the body.
3. Compress the spring with the Special Tool, Jet Valve Spring
Pliers (09222-21400) and install it together with valve spring
retainer, and install the retainer lock.
Be careful not to damage the valve stem seal with bottom of the
retainer while installing.
4. Install new O-ring in the jet valve body groove and apply a thin
coat of engine oil to it.

20-52
 JET VALVE

5. Install the jet valve assembly, assembled as described in 1

thru 4 above, using Special Tool, Jet Valve Socket Wrench
(09222-21300).
Tighten to the specified torque below. While installing, apply
engine oil to the threaded portion and seating surface of the jet

CAUTION
(a) Install the jet valve assembly, finger-tighten and finally
tighten to the specified torque with torque wrench.
(b) Keep the socket of wrench aligned with the jet valve
stem to prevent it from forcing the stem sidewise or to
keep it from dropping.
Tightening torque
Jet valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18-22 Nm (180-220 kg.cm, 13-16 Ib.ft)

6. Install the rocker arm shaft assembly and rocker cover. Refer to
“Rocker Arm Shaft Assembly”.

JET VALVE CLEARANCE ADJUSTMENT

CAUTIONS
(a) The misadjustment of the jet valve clearance not only
affects the exhaust gas level but also may cause some
engine trouble. So, be sure to make adjustment as
follows:
(b) Adjust the jet valve clearance before the adjustment of
the intake valve clearance. Readjust it after additional
tightening of cylinder head bolts.
(c) Loosen fully the adjusting screws while making jet valve
clearance adjustment.
1. Warm up the engine until the temperature of the coolant rises
to 80 to 90°C (170 to 190°F).
2. With the piston in the cylinder positioned at TDC on the com-
pression stroke, adjust in the following sequence.
3. Back off the adjusting screw for the intake valve 2 or more
turns.
4. Loosen the lock nut on the adjusting screw for the jet valve.
5. Turn the adjusting screw for the jet valve counterclockwise and
insert a 0.25 mm (0.010 in.) feeler gauge between the jet valve
stem and adjusting screw.
Jet valve clearance (hot engine)
[Standard value] . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)

20-53
 6. Tighten the adjusting screw until it touches the feeler gauge.
Since the jet valve spring is weak in tensile strength, use
special care not to force the jet vavle in. Be careful particularly
when the adjusting screw is hard to turn.
7. Tighten the lock nut securely while holding the rocker arm
adjusting screw with a screwdriver to prevent it from turning.
8. Make sure that a 0.25 mm (0.010 in.) feeler gauge can be
easily inserted.
9. Adjust the intake valve clearance.
10. Check for idle CO and R.P.M. and adjust if necessary.

INTAKE AND EXHAUST VALVE CLEARANCE AD-

JUSTMENT PROCEDURE
CAUTIONS
(a) Adjust the jet valve clearance before adjusting intake
valve clearance.
(b) The valve clearance should be adjusted after additional
tightening of the cylinder head bolts.
1. Warm up the engine until the temperature of the coolant rises
to 80 to 90°C (170 to 190°F).
2. With the piston positioned at TDC on the compression stroke,
adjust as follows:
3. Loosen the lock nut.
4. Adjust the valve clearance by turning the adjusting screw
while measuring the clearance with a feeler gauge.
Valve clearance (hot engine) [Standard value]
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)

5. Tighten the lock nut securely while holding the rocker arm
adjusting screw with a screwdriver to prevent it from turning.
6. Check for idle CO, HC and R.P.M. and adjust if necessary.

20-54
 FRONT CASE, OIL PUMP

FRONT CASE, OIL PUMP

COMPONENTS

TORQUE : Nm (kg.cm, lb-ft)

FRONT CASE
The front case contains the gear type oil pump and oil relief
valve and has the oil screen on its underside.

Removal
1. Remove the timing belt. Refer to “Timing Belt Train.“.
2. Remove all the oil pan tightening bolts.
3. Strike a corner of the oil pan with a soft hammer to separate
from the cylinder block, and then remove the oil pan.
NOTE
Prying the oil pan by use of the screwdriver will deform the
oil pan.
4. Remove the oil screen.
5. Remove the front case assembly.

20-55
 FRONT CASE, OIL PUMP

OIL PUMP
The oil pump is a gear type and is mounted in the front case and
driven directly by the crankshaft. The relief valve is located in
the upper right of the front case. When the specified delivery
pressure is exceeded, the valve opens, allowing excess oil to
flow into the oil pan.

Removal
Remove the front case assembly.
Refer to “Front Case”.

Disassembly
1. Remove the oil pump cover.
2. Remove the inner and outer gears from the front case. The
mating marks on the inner and outer gears indicate the direc-
tion of installation. Make sure that the inner and outer gears
are installed as shown.
3. Remove the plug and remove the relief spring and relief valve.

INSPECTION
Front Case
1. Check the front case for cracks and damage and replace as
necessary.
2. Check the front oil seal for worn or damaged lips. Replace if
defective.

20-56
 FRONT CASE, OIL PUMP

Oil Pan and Oil Screen

1. Check the oil pan for failure, damage and cracks.
Replace if defective.
2. Check the oil screen for failure, damage and cracks and replace
if defective.

Front Case and Oil Pump Cover

Worn (especially stepped) or damaged surfaces contacting
gears.

Oil Pump Gears

1. Worn or damaged gear tooth surfaces.
2. Clearance between outer gear and front case.
Outer gear
Clearance between outer circumference and front case.. . .
. . . . . . . . . . . . . . . . . . . . . . . . . 0.1-0.2 mm (0.0039-0.0079 in.)
Clearance between addendum and crescent . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 0.22-0.34 mm (0.0087-0.0134 in.)
End play . . . . . . . . . . . . . .0.04-0.10 mm (0.0016-0.0039 in.)
Inner gear
Clearance between addendum and crescent . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 0.21-0.32 mm (0.0083-0.0126 in.)
End play . . . . . . . . . . . . . . 0.04-0.10 mm (0.0016-0.0039 in.)

3. Check the clearance between the outer gear addendum and

crescent.

4. Check the clearance between the inner gear addendum and

crescent.

20-57
 FRONT CASE, OIL PUMP

Relief Valve and Spring

1. Check sliding condition of relief valve inserted in the front case.
2. Inspect for deformed or broken relief spring.
[Standard value]
Free height . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 mm (1.850 in.)
Load . . . . . . . . . . . . . . . . 6.1 kg/40.1 mm (13.4 lb/1.579 in.)

Oil Seal
1. Inspect for worn, deformed or damaged lips.
2. Check for elongated spring ring.
Press seal into the front case with Special Tool, Crankshaft
Front Oil Seal Installer (09214-21000) Crankshaft Front Oil
Seal Guide (09214-2100), until the front end of the front case
is even with the front of the oil seal.

REASSEMBLY
Front Case
1. Install the front case assembly with gasket, and tighten the
bolts to the specified torque.
Front case tightening bolt . . . . . . . . . . . . . . 12-14 mm (9-10 in.)
Body length (A) . . . . . . . . . . . . . . . . . . . . . . . . . . 20 mm (0.79 in.)
(B). . . . . . . . . . . . . . . . . . . . . . . . . . . 30 mm (1.18 in.)
(C). . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.36 in.)
Tightening torque . . . 12-15 Nm (120-150 kg.cm, 8.7-11 Ib.ft)

2. Install Special Tool, Crankshaft Front Oil Seal Guide (09214-

21100), to front end of crankshaft. Apply engine oil to outer
surface of oil seal guide, and install new oil seal along guide by
hand until it toughes front case. Make sure that oil seal is
replaced at each reassembly.

3. Use Special Tool, Crankshaft Front Oil Seal Installer (09214-

21000), to install oil seal.
4. Install the crankshaft sprocket, timing belt and crankshaft pul-
ley. Refer to “Timing Belt Train”.
5. Install the oil screen.
6. Clean both gasket surfaces of oil pan and cylinder block.

20-58
 FRONT CASE. OIL PUMP

7. Apply sealant into groove of oil pan flange as shown.

CAUTIONS
(a) Apply sealant approx. 4 mm (0.16 in.) in thickness.
(b) After application of sealant, do not exceed 15 minutes
before installing the oil pan.
8. Install the oil pan and tighten the bolts to the specified torque.
Tightening torque
Oil pan bolt . . . . . . . 5.9-7.8 Nm (60-80 kg.cm, 4.3-5.8 Ib.ft)

Oil Pump
1. Install the outer and inner gears into the front case. Make sure
that the inner and outer gears are installed in the same direc-
tion as shown.
2. Install the oil pump cover and tighten the bolts to the specified
torque. After the bolts have been tightened, check to ensure
that the gear turns smoothly.
Tightening torque
Oil pump cover bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8-8.8 Nm (80-90 kg.cm, 5.8-6.5 Ib.ft)

3. Install the relief valve and spring and tighten the plug to the
specified torque. Apply engine oil to the relief valve.
Tightening torque
Relief valve plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29-39 Nm (300-400 kg.cm, 22-29 Ib.ft)

20-59
 PISTON AND CONNECTING ROD

PISTON AND CONNECTING ROD

COMPONENTS

DISASSEMBLY
1. Remove the cylinder head assembly. Refer to “Cylinder Head”.
NOTE
Make the connecting rods and caps before disassembly to
avoid accidental mixed up.
2. Remove the oil pan and then remove the oil screen.
3. Remove the connecting rod cap and withdraw the piston and
connecting rod assembly from the cylinder. Keep the connect-
ing rod bearings in order by cylinder number.
4. Using Special Tool, Piston Pin Setting Tool (09234-21000),
disassemble the piston from the connecting rod as follows:
(a) Remove piston rings.
(b) Make certain that the front mark on the top of the piston is
faced upward when the assembly is set on the press.
(c) Remove the piston pin by using a press.

20-60
INSPECTION
Piston and Piston Pins
1. Check each piston for scuffing, scoring, wear and other defects.
Replace any piston that is defective.
2. Check each piston ring for breakage, damage and abnormal
wear. Replace the defective rings. When the piston requires
replacement, its rings also should be replaced.
3. Check the piston pin fit in the piston pin hole. Replace any
piston and pin assembly that is defective.
The piston pin must be smoothly pressed by hand into the pin
hole at room temperature.

Piston Rings
1. Measure the piston ring side clearance. If the measured value
exceeds the service limit, insert a new ring in a ring groove to
measure the side clearance. If the clearance still exceeds the
service limit, replace the piston and rings together. If it is less
than the service limit, replace the piston rings only.
Piston ring side clearance
No. 1 . . . . . . . . . . . . . . . . .0.03-0.07 mm (0.0012-0.0028 in.)
No. 2 . . . . . . . . . . . . . . . . . .0.02-0.06 mm (0.0008-0.0024 in.)
[Limit]
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
No. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)

2. To measure the piston ring end gap, insert a piston ring into the
cylinder bore. Correctly position the ring at right angles to the
cylinder wall by gently pressing it down with a piston. Draw the
piston up and out, then measure the gap with a feeler gauge. If
the gap exceeds the service limit, replace the piston ring.
Piston ring end gap No. 1 and No. 2
[Standard dimension]. . . . . . 0.2-0.35 mm (0.008-0.014 in.)
[Limit] . . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.039 in.)
Oil ring side rail end gap
[Standard dimension]. . . . . . . 0.2-0.7 mm (0.008-0.030 in.)
[Limit] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.039 in.)

When replacing the ring only without correcting the cylinder

bore, check the gap with the ring positioned at the lower part of
cylinder that is less worn.

20-61
 PISTON AND CONNECTING ROD

When replacing a ring, be sure to use a ring of the same size.

Piston ring service size and mark
STD..............................................None
0.25mm(0.010in.)O.S.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
0.50 mm (0.020 in.) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
0.75 mm (0.030 in.) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.00mm(0.039in.)O.S.. . . . . . . . . . . . . . . . . . . . . . . . . . . 100

NOTE
The mark can be found on the upper side of the ring next to
the end.

Connecting Rods
1. When connecting rod cap is installed, make sure that cylinder
numbers put on rod end cap at disassembly match.
When new connecting rod is installed, make sure that notches
for holding bearing in place are on same side.

2. Replace the connecting rod damaged on the thrust faces at

either end, and also that has step wear in, or severely rough
surface of, the inside diameter of the small end.
3. Using a connecting rod aligner, check the rod for bend and
twist. If the measured value is close to the repair limit, correct
the rod by a press. Any connecting rod that has been severely
bent or distorted should be replaced.
Bend of connecting rod . . . . . . . . 0.05 mm (0.0020 in.) or less
Twist of connecting rod . . . . . . . . . 0.1 mm (0.0039 in.) or less

REASSEMBLY
1. Using Special Tool, Piston Pin Setting Tool (09234-21000),
assembly the piston to the connecting rod by the following
procedure.
(a) Apply engine oil to the outer surface of the piston pin and
the small end bore of the connecting rod.

20-62
 PISTON AND CONNECTING ROD

(b) Set the connecting rod and piston with the front mark facing
up and insert the piston pin assembly.
Front mark
Piston side: Indented mark
Connecting rod side: Numberal, embossed.
(c) Using a press, press the piston pin into the pin hole with the
specified pressure applied through the push rod to the pin
end.
Piston pin pressing-in pressure (At normal temperature)
[Standard value] . . . . . 4,900-14,700 N (1,102-3,306 lb)

If more pressure than the specified pressure is required to

press the piston pin into the pin hole, complete the follow-
ing procedure.
(d) Turn the push rod a half turn, and dismount the piston
connecting rod assembly from the support.
(e) After pressing in the piston pin, make sure that the connect-
ing rod slides lightly and moves freely.

2. Install piston rings on the piston in the following sequence.

(a) Install the 3-piece oil ring. install the spacer expander,
upper side rail and lower side rail in that order. When the
side rails are installed, do not expand their gaps with the
piston ring expander as with other piston rings. The side
rails might be broken if such a method is employed. To
install the side rail, first put one end of the side rail between
the piston ring groove and spacer expander, hold it down
firmly, and then press down the portion which is to be
inserted into the groove with a finger as illustrated. In this
manner, the side rail can be easily installed. Make sure that
the upper side rail is installed first and the lower side rail
installed next.
CAUTION
(a) After the 3-piece oil ring has been installed, check to
ensure that both upper and lower side rails can be turned
smoothly.
(b) Make sure that the spacer expander gap is intalled more
than 45° apart from the side rail gaps.
 PISTON AND CONNECTING ROD

(b) Install the No. 2 piston ring and then install the No. 1 piston
ring.
CAUTION
(a) Install the piston rings in such a way that the size mark
and maker stamped on the ring surface will face the
piston top.
(b) The No. 1 and No. 2 piston rings have the same thick-
ness. Use care to prevent confusion. The No. 1 and No. 2
piston rings are different in cross sectional shape.

3. Insert the piston and connecting rod assembly into the cylinder
using a piston ring clamp, with its mating mark agreeing with
the cylinder number, and with the arrow mark on the piston
head directed toward the crankshaft pulley side of engine. It is
desirable to install vinyl covers on cap bolts in order to avoid
causing damage to the cylinder bore and crank pin.
CAUTIONS
(a) Check to ensure that the piston ring gaps are positioned
as illustrated.
This will ensure that the piston rings are installed in such
a way that their gaps will not coincide with the piston pin
and thrust directions and that each gap will be positioned
as far apart from the neighboring gaps as possible.
(b) Apply engine oil around-the piston and the piston rings

4. Install the connecting rod cap and tighten the connecting rod cap
nuts to the specified torque. When the connecting rod cap is
installed, make sure that the match mark (cylinder No.) sta-
mped on the connecting rod big end and the match mark
(cylinder No.) stamped on the cap are placed on the same side.
Tightening torque
Connecting rod cap nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31-34 Nm (320-350 kg.cm, 23-25 Ib.ft)

5. Check the connecting rod big end side clearance.

Connecting rod big end side clearance . . . . . . . . . . . . . . . . . . . . .
0.1-0.25 mm (0.004-0.001 in.)

6. Install the oil screen.

7. Install the oil pan. Refer to “Front case” section.
8. Install the cylinder head. Refer to “Cylinder Head”

20-64
 CRANKSHAFT

CRANKSHAFT
COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

DISASSEMBLY
1. Remove the timing belt train, front case, flywheel cylinder head
assembly and oil pan. For details refer to respective chapters.
2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps.
NOTE:
Mark the main bearing caps to permit reassembly in the
original position and direction.
4. Remove the main bearing caps and remove the crankshaft.
Keep the bearings in order by cap number.

INSPECTION
Crankshaft
1. Check the crankshaft journals and pins for damage, uneven
wear and cracks. Also check oil holes for clogging. Correct or
replace any defective part.
2. Inspect out-of-roundness and taper of crankshaft journal and
pin.

[Standard dimension]
Crankshaft journal O.D. . . . . . . . . . . . . . . 48 mm (1.8898 in.)
Crank pin O.D. . . . . . . . . . . . . . . . . . . . . . . 42 mm (1.6535 in.)
Crankshaft journal pin out-of-roundness and taper
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01 mm (0.004 in.) or less

20-65
 CRANKSHAFT

Main Bearings and Connecting Rod Bearings.

Visually inspect each bearing for peeling, melt, seizure and
improper contact. Replace the defective bearings.

Oil Clearance Maesurement

To check the oil clearance, measure the outside diameter of the
crankshaft journal and the crank pin and the inside diameter of
the bearing. The clearance can be obtained by calculating the
difference between the measured outside and inside dia-
meters.
Journal oil clearance . . . . 0.02-0.07 mm (0.0008-0.0028 in.)
Pin oil clearance . . . . . . . . 0.01-0.06 mm (0.0004-0.0024 in.)

Tightening torque
Main bearing cap bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49-53 Nm (500-540 kg.cm, 36-39 Ib.ft)
Connecting rod cap nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31-34 Nm (320-350 kg.cm, 23-25 Ib.ft)

Oil Clearance Measurement (Plastigauge Method)

Plastigauge may be used to measure the clearance.
1. Remove oil and grease and any other dirt from bearings and
journals.
2. Cut plastigauge to the same length as the width of the bearing
and place it in parallel with the journal, off oil holes.
3. Install the crankshaft, bearings and caps and tighten them to
the specified torques. During this operation, do not turn the
crankshaft. Remove the caps. Measure the width of the plasti-
gauge at the widest part by using a scale printed on the gauge
package.
If the clearance exceeds the repair limit, the bearing should be
replaced or an undersize bearing be used.
When installing a new crankshaft, be sure to use standard size
bearings.
Should the standard clearance not be obtained even after bear-
ing replacement, the journal and pin should be ground to
undersize and a bearing of the same size should be installed.

Oil Seal
Check front and rear oil seals for damage or worn lips.
Replace any seal that is defective.

20-66
 CRANKSHAFT

REASSEMBLY
1. Install upper main bearing inserts in cylinder block.
When reusing the main bearings, remember to install them
by referring to location marks made at the time of dis-
assembly.
Install with care to oil holes in such a manner that the bearings
will not float.
2. Install the crankshaft. Apply engine oil to the journal and pin.
3. Install bearing caps and tighten cap bolts to the specified torque
in the sequence of the center, No. 2, No. 4 front and rear caps.
Cap bolts should be tightened evenly in 2 to 3 stages before
they are tightened to the specified torque.
Tightening torque
Main bearing cap bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49-53 Nm (500-540 kg.cm, 36-39 Ib.ft)

The caps should be installed with the arrow mark directed

toward the crank pulley side of engine. Cap numbers must be
corrected.
4. Make certain that the crankshaft turns freely and has the proper
clearance between the center main bearing thrust flange and
the connecting rod big end bearing.
Crankshaft end play
. . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05-0.18 mm (0.002-0.007 in.)

5. Install oil seal in the crankshaft rear oil seal case. Use Special
Tool, Crankshaft Rear Oil Seal Installer (09231-11000) as
shown, and press fit the oil seal all the way in without tilting it.
6. Install the rear oil seal case and gasket and tighten the five
bolts. Apply engine oil to the oil seal lips and crankshaft at the
time of installation.
7. Install the rear plate and tighten the bolts.
8. Install the connecting rod caps. Refer to “Piston and Connecting
Rods.”
9. Install the flywheel, front case, oil pan and timing belt train. For
further details, refer to the respective chapters.
 FLYWHEEL

FLYWHEEL
COMPONENTS

FOR M/T FOR A/T

TORQUE : Nm (kg.cm, Ib.ft)

M/T : Manual Transmission Vehicles

A/T : Automatic Transmission Vehicles

REMOVAL
1. Remove the transmission and clutch.
2. Remove the flywheel.

INSPECTION
1. Check the clutch disc contacting surface of the flywheel for
damage and wear. Replace the flywheel if excessively damaged
or worn.
2. Check the clutch disc contacting surface of the flywheel for
run-out.

Standard value
Flywheel run-out.. . . . . . . . . . . . . . . . . . . . 0.1 mm (0.004 in.)

3. Check the ring gear for damage, cracks and wear, and replace if
necessary.

REASSEMBLY
Install the flywheel assembly and tighten the bolts to the speci-
fied torque.
Tightening torque
Flywheel bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
127-137 Nm (1,300-1,400 kg.cm, 94-101 Ib.ft)

20-68
 CYLINDER BLOCK

CYLINDER BLOCK
COMPONENTS

DISASSEMBLY
Remove the cylinder head, timing belt train, front case, fly-
wheel, piston and crankshaft.
For further details, refer to the respective chapters.

INSPECTION
1. Visually check the cylinder block for scratches, rust and corro-
sion. Also check for latent cracks or any other defects by using a
flaw detecting agent (magnafluxing). Correct or replace the
block if defective.
2. Measure the cylinder bore with a cylinder gauge at three levels
in the directions to A and B. If the cylinder bores show more
than specified out-of-round or taper or if the cylinder walls are
badly scuffed or scored, the cylinder block should be rebored
and honed, and new oversize pistons and rings fitted.

20-69
 CYLINDER BLOCK

Measuring points are as shown.

1.5L engine
Cylinder I.D. . . . . . . . . . . . . . . . . . . . . . . . . 75.5 mm (2.972 in.)
Cylinder I.D. taper . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 in.)

3. If cylinder top ridge is worn in stages, cut away with ridge

reamer.
4. Oversize piston are available in four sizes.
Piston service size and mark mm (in.)
0.25 (0.010) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25
0.50 (0.020) O.S.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50
0.75 (0.030) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75
1.00 (0.039) O.S.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00

5. To rebore the cylinder bore to oversize, keep the specified clear-

ance between the oversize piston and the bore, and make sure
that all pistons used are of the same oversize.

The standard measurement of the piston outside diameter is

taken at a level 2 mm (0.08 in.) above the bottom of the piston
skirt and across the thrust faces.
Piston-to-cylinder wall clearance . . . . . . . . . . . . . . . . . . . . . . . . . .
0.02-0.04 mm (0.0008-0.0016 in.)

REASSEMBLY
1. Install the following parts by referring to the respective para-
graphs.
(a) Crankshaft
(b) Flywheel
(c) Piston
(d) Cylinder head
(e) Timing belt train
(f) Front case

20-70
 OIL PRESSURE SWITCH

OIL PRESSURE SWITCH

The oil pressure switch is located at the center of the right-hand
side of the engine. If the oil pressure in the lubricating system
has dropped below 28 kPa (4 psi) during normal operation, the
oil pressure warning light is lit. The hexagonal portion of this
switch is 26 mm (1.024 in.) wide across the flats.

REMOVAL AND INSTALLATION

To remove and install the oil pressure switch, use 1 inch 12 pt.
deep socket. When installing the switch, apply sealant to the
threaded portion.
After the oil pressure switch has been installed, make certain
that its electrical connectings are tight and secure.

INSPECTION
1. Check the oil pressure switch as illustrated. Replace the switch if
it does not satisfy the standard value.
Oil pressure switch activation pressure . . . . . . . . . . . . . . . . . . . .
28 kPa (4 psi, 0.29 kg/cm2)

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