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OUTER COMPONENT PARTS CD

CD17

Dust eover

Exhaust manifold.

f.C!J 9.1 11.8 (o.93 1.2, 6.7 8.7)

Compressor A 89. n (7.o. a.o. s1 sa>


A 39 49 < . s..o. a . 38)

~ M10 31 ~
(3.2 U, 23 27) ,,-,
MI 16 21 ~-
(U 2.1, 12 15) ~

A 13 .1a <1.3. u. 9 -13}~


A 49 59 (s.o &.o. 43)

A .: Nm (kgm. ftlb}
SEM708A

EM-195
CD
OUTER COMPONENT PARTS

CD20 - Right side

rRJ 16 21

":L
(t.6. 2.1,

~ : Nm (kg-m. ftlb)

SEM571D

EM-196
OUTER COMPONENT PARTS CD

CD20 - Left side

o
-~

LA .....(1.8 - 2.2,
A 11 21 ~ - 11>
(1.1 - 2.1,
12 - 15)
--Exhal.lst manifold

A : Nm {kg-m. ft-lbl

SEM5720

EM-197
COMPRESSION PRESSURE CD

1. Warm up engine sufficiently.


2. Disconnect injection tubes on nozzle side and toosen
injection tubes on pump side. Release clamps on injection
tu bes.
Use two wrenches to prevent delivery holder on pump slde
from loosening.

SEM5000

SEM5010

3. Remove spill-tube assembly.


To prevent splll tube from breaklng, remove lt by grlpplng
nozzle holder.

4. Remove all injection nozzles using a suitable tool.

5. Disconnect fuel-cut solenoid valve connector.

SEM5040

EM-198
COMPRESSION PRESSURE CD

6. Fit compression gauge to cylinder head.

SEMS050

7. Crank engine and read compression gauge indication.


Cranking speed: 200 rpm
Compresslonpressure: kPa (bar, kg/cm2, psi)
Standard
2,942 - 3,236 (29.4 - 32.4,
30 - 33, 427 - 469)
Llmlt
2,452 (24.52, 25.0, 356)
Limit of dlfference between cyllnders
490 (4.90, 5.0, 71)
8. lf the pressure appears low, pour about 3 me
(0.11 lmp fl oz)
of engne oil through nozzle holes and repeat test.
For indications of test, refer to the following table.

__________ ,,,,,,,,,,.,_,,,,,,, _
Gauge ndication durng tests Trouble diagnosis

'--..-..-- Second
First--""'--..r readng
reeding

Piston rings are worn or damaged.

lncreased
reading

lf two adjacent cylinders are low, gasket is damaged.


Valve is sticking.
Valve seat or valve contact surface is incorrect.
Seme
reading
maintained

EM-199
COMPRESSION PRESSURE CD

9. Replace nozzle gaskets and re-nstall injection nozzles.


@ Nozzle aide
New nozzle gaskets must be lnstalled In the dlrectlon shown .
Nozzle to cyllnder head:
~: 59- 69 Nm
(6 - 7 kg-m, 43 - 51 ft-lb)

SEM5110

10. lnstall spill tube by holding nozzle holder.


Splll tube nut:
A: 39-49 Nm
(4 - 5 kg-m, 29 - 36 ft-lb)

11. lnstall njection tubes using two wrenches as shown.


lniection tubes:
[q]: 22 - 25 Nm
(2.2 - 2.5 kg-m, 16 - 18 ft-lb)

SEM5000

EM-200
OIL PAN CD

Removal
1. Drain oil.
2. Remove oil pan using tool as illustrated.
1) lnsert Tool between oil pan and cylinder block.
Do not drive seal cutter lnto oil pump or rear oil seal
retainer portlon, or alumlnum mating surfaces will be
damaged.
Do not insert screwdriver, or oll pan flange will be de-
formed.

2) Slide Tool by tapping it with a hammer, and remove oil pan.

lnstallation
1. Before installing oil pan, remove all traces of liquid gasket
from mating surtace using a scraper.
Also remove traces of liquid gasket from mating surface of
cylinder block.

Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)


Wide.
Use GenuineLiquid Gasketor equlvalent.

~---J
Cut here.

Uquid gnket

SLC906

2. Apply liquid gasket to inner sealng surface as shown at left.

Bolt hole
SEM909B

EM-201
CD
OIL PAN
lnstallation (Cont'd)
3. Apply liquid gasket to il pan front oil seal and rear oil sea!.

0 : Seeling point
SEM8948

4. Apply a continuous bead of liquid gasket to mating surface


of oil pan.
Attaching should be done within 5 minutes after coating.

5. lnstalt oil pan and tighten bolts in the order shown in the
figure.
Walt at least 30 minutes before refllltng engine oll.
011 pan bolts:
tc?J:
CD17 5 - 7 Nm (0.5 - 0.7 kg-m, 3.6 5.1 ft-lb)
CD20 7 - 8 Nm (0.7 0.8 kg-m, 5.1 - 5.8 ft-lb)


SEM3690

EM-202
TIMING BELT CD

Camshaft Timlng Belt - CD17


CAUTION:
a. Do not bend or twist timing belt.
b. After removing timing belt, do not turn crankshaft and camshaft separately because valves will strike
plston heads.
c. Ensurethat tlming belt, camshaft sprocket, crankshaft sprocket and belt tensioner are clean and free
from oil and water.

Timlng belt
cover

~
rRJaz.40
(3.3 4.1,
2'. 30)

Cl'lll'* pulley rRJ: Nm (kg-m, ft-lb) SEM2320

REMOVAL
1. Set No. 1 cylinder at T.D.C. on its compression stroke.

2. Remove timing belt.


(1) Loosen tensioner pultey bolt. turn tensioner pulley counter-
clockwise then tighten bolt.

EM-203
CD
TIMING BELT
Camshaft Timlng Belt - CD17 (Cont'd)
(2) Aemove idler pulley.

(3) Remove timing belt with crankshaft sprocket.

INSPECTION
Refer to page EM-208. (CD20 engine)

INSTALLATION
1. lnstall sprocket plate in correct direction.

2. Confirm that No. 1 piston is set at T.D.C. on its compression


stroke.

EM-204
TIMING BELT CD
Camshaft Timing Belt - CD17 (Cont'd)
3. lnstall tensioner and return spring.
Temporarlly tlghten bolts so that tensloner Is set at the fully
outslde posltlon.
4. lnstall idler and tighten bolt to the specified torque.
5. Check tensioner and idler for smooth turning.

6. lnstall timing belt with crankshaft sprocket.


a. Allgn whlte Unes on timing belt with punchmarks on cam-
shaft sprocket and crankshaft sprocket.
b. Point arrow on timing belt toward belt cover.

7. Adjust timing belt tension.


1) Loosen tensioner lock bolt to apply tension to timing belt.
2) Rotate crankshaft clockwise two turns to apply the specified
tension to timing belt.
3) Tighten tensioner lock bolt while holding tensioner pulley
with hexagon wrench.

EM-205
TIMING BELT CD !
Camshaft Tlmlng Belt - CD20
CAUTION:
a. Do not bend or twist tlming belt.
b. After removing tlming belt, do not turn crankshaft and camshaft separately because valves wlll strlke
plston heads.
c. Ensure that timlng belt, camshaft sprocket, crankshaft sprocket and belt tensioner are clean and free
from oU and water.

Belt eover center


(Engine rnounting bracket)

tqJ : Nm {kg-m. ft-lb)


fl : Locking sealant
SEM8520
~===::::==::::==;==::;:===""'i,?===:;--;=-:;-:;-::;;:-:-;-:-;------- __ , ,,,,,, __ ,,,,,, --
REMOVAL
Remove engine front mountng bracket.
When removing, support front portion of engine with trans-
misslon jack or hoist.

. Remove starter motor, and install ring gear stopper using


mounting bolt holas.
Remove crank pulley bolt.
Remove crank pulley using puller.
Be sure to securely attach puller jaws. Attach jaws only to
the rear slde of pulley.

SEM681D

EM-206
TIMING BELT CD

Camshaft Timlng Belt - CD20 (Cont'd)


1. Set No. 1 cylinder at T.D.C. on its compression stroke.

2. Remove timing belt.


(1) Loosen tensioner pulley bolt, turn tensioner pulley counter-
clockwise then tighten bolt.
(2) Remove camshaft sprocket plate.

(3) Remove idler pulley.

(4) Remove timing belt with crankshaft sprocket.

SMA398A

EM-207
TIMING BELT CD
Camshaft Timlng Belt - CD20 (Cont'd)
INSPECTION
Timing belt
Visually check the condition of timing belt.
Replace if any abnormality is found.

ltem to check Problem Cause


Tooth is broken/tooth Camshaft jammng
root is cracked. Distributor jamming
Damaged camshaft/crankshaft oil seal

SEM394A

Back surface is Tensioner jamming


cracked/worn. Overheated engine
lnterference with belt cover

SEM395A

Sde surface is wom. lmproper nstallation of belt


Malfunctioning crankshaft pulley plate/timing
belt plate

Belt corners are worn and round.


Wcks are frayed and comng out. SEM396A

Teeth are worn. Poor belt cover sealng

/1/bl!I
Coolant leakage at water pump

.... ...
Camshaft not functionlng properly
Distributor not functioning properly
Excessive belt tension

Rotating direction

Canvas on tooth tace is worn down .


. Canvas on tooth is flufly, rubber !ayer is
worn down and faded white, or weft is worn
down and Invisible. SEM397A

Oil, coolant or water is Poor ol sealng of each ol seal


stuck to belt. Coolant leakage at water pump
Poor belt cover sealing

EM-208
TIMING BELT CD
Camshaft Tlmlng Belt - CD20 (Cont'd)
Belt tensioner, tensloner spring and idler
1. Check belt tensioner and idler for smooth turning.
2. Check condition of tensioner spring.

-~-
SEM558

Crankshaft sprocket and front camshaft sprocket


Check teeth for abnormal signs.

INSTALLA TION
1. lnstall crankshaft sprocket plate in correct direction.

2. Confirm that No. 1 pisten is set at T.D.C. on its compression


stroke.

3. lnstall tensioner and return spring.


Temporarlly tighten bolts so that tensioner Is set at the fully
outside positlon.
4. lnstall idler and tighten bolt to the specified torque.

SEM5180

EM-209
TIMING BELT CD
Camshaft Tlmlng Belt - CD20 (Cont'd)
5. lnstall timing belt with crankshaft sprocket.
a. Allgn whlte llnes on timlng belt with punchmarks on eam-
shaft sprocket and crankshaft sprocket.
b. Polnt arrow on tlming belt toward belt cover.
6. lnstall camshaft sprocket plata and secure screws with
locktite.

7. Adjust timing belt tension.


1) Loosen tensioner lock bolt to apply tension to timing bell
2) Rotate crankshaft clockwise two turns to apply the specified
tension to timing belt.
3) Tighten tensioner lock bolt while holding tensioner pulley
with hexagon wrench.
Belt tenston:
147.124.5 N (152.5 kg, 33.1 5.5 lb)

SEM5200.

lnjection Pump Tlming Belt

J@ , .
Tensioner spring
Timlng belt Tensloner

~ 18 - 21
f.1, 12 11)

o
/~ 0
/ lnjection pu~ sprocket

Rear camshaft
sprocket

1
,..._~~~-
~
-~~--~~~~~
: N,m (kg-m. ft-lb) SEMS21DI

REMOVAL
1. Set No. 1 cylinder at T.D.C. (white paint mark) on its
compression stroke.
2. Remove air duct with resonator and timing belt cover.

EM-210
TIMING BELT CD

lnjection Pump Timing Belt (Cont'd)


3. Remove timing belt
1) Loosen tensioner lock nut and turn tensioner clockwise to
free belt frorn tension. Then temporarily tighten tensioner
nut.
2) Rernove tirning belt.

r------
1njecton pump pulley INSTALLATION
Mark 1. Confirm that No. 1 piston is set at T.D.C. on its compression
stroke.
Key lf injection purnp pulley was removed, confirm that it is
re-installed as illustrated.
ldentlficatlon of alignment
CD17 No mark
CD20 Use mark "A"

SEM6790

2. Set timing belt.


a. Align white Unes on tlming belt wlth punchmarks on cam-
shaft sprocket and injectlon pump sprocket.
b. Polnt arrow on tlmlng belt toward belt cover.

3. Adjust belt tension.


1) Loasen tensioner lock nut to apply tension to timing belt.
2) Rotate crankshaft clockwise two turns.
Do not turn crankshaft by camshaft sprockets.
3) Tighten tensioner lock nut while holding tensioner with a
screwdriver.
Belt tenslon:
CD17 25549 N (265 kg, 5711 lb)
CD2014749 N (155 kg, 3311 lb)

INSPECTION
Refer to page EM-208.

INJECTION TIMING ADJUSTMENT


Refer to EF & EC section.

EM-211
OIL SEAL REPLACEMENT CD

VAL VE OIL SEAL


1. Remove both timing belts.
2. Remove camshaft sprockets and back covers.
3. Remove camshaft brackets by loosening bracket nuts from
center to outside in two or three stages.
4. Remove camshaft oil seals and camshaft.

5. Remove valve lifters and mark order No. on each lifter.


6. Replace valve oil sea! according to the following procedure.
When replaclng valve oll seal, set the correspondlng plston at
T.D.C. Fallure to do so causes the valve to drop into the
cylinder.
1) Set No. 1 cylinder at T.D.C.
2) Remove valve springs and valve oil seals for No. 1 and No.
4 cylinders. Valve spring seats should not be removed.
3) lnstall new valve oil seals for No. 1 and No. 4 cylinders as
illustrated. Reinstall valve springs. (narrow pitch sde to-
ward cylinder head)
4) lnstall valve spring retainers on intake valves and valve
rotators on exhaust val ves, and remount valve assembly.
5) Set No. 2 cylinder at T.D.C.
6) Replace valve ol seals for No. 2 and No. 3 cylinders
according to steps 2) and 3).
7) lnstall valve lifters in original positons.

1.0
(0.039)

Unt: mm (In) SEM2390

SEM5120

CAMSHAFT AND CRANKSHAFT OIL SEAL INSTALLING


DIRECTION AND MANNER
When installlng camshaft and crankshaft oll seals, be

.--+. . .
careful to instan them correctly, as shown In the figure.
Apply englne oil to oil seal llp, outer face, camshaft and
Engine --11 Engine bracket.
inside outslde
Wlpe off excess oll after lnstalllng oil seal.
Oil ... lllp Dust seal llp

SEM7l5A

EM-212
OIL SEAL REPLACEMENT CD

CAMSHAFT OIL SEALS


1. Remove timing belts, sprockets and back covers.
2. Pull out oll seal with a suitable tool.

3. lnstall new ol seals with a suitable tool.


Confirm turnlng direction of both oll seals and camshaft.

CRANKSHAFT FRONT OIL SEAL


1. Remove valve timing beft and crankshaft sprocket.
2. Remove ol sea! with a suitable tool.

3. Apply engne oil to new oil seal and install ol seal using a
sutable tool.

CRANKSHAFT REAR OIL SEAL


1. Remove transaxle assembly. (Refer to MT/AT section.)
2. Remove flywheel (drive plate).
3. Remove rear ol seal with a suitable tool.

EM-213
OIL SEAL REPLACEMENT CD

4. Apply engine oil to new o seal and install oil seal using a
suitable tool.

EM-214
CYLINDER HEAD CD

CD17

Rocker cover
rRJ 92 102 (9.4 10.4, 68 75)
A 3.7 s.o co.38 o.s1. 2.1 3.7)

Rear t>ack cover

Spring retainer
Valve stem seal

Front camshaft sprocket Vatve seat


~ 92 102 (9.4 10.4, 68 75)

rRJ : Nm {kg-m. ft-lbl

SEM709A

EM-215
CYLINDER HEAD CD

CD20

Rocker cover gasket G


_.o_,/

camshaft

Hydnwlic valve llfter

Spring retainer

Valve stem seal

Selective
cylinder head
gas.ket O
Valve seat

~ : Nm (kg-m, ft-lb)

IRJ 17 107 (8.9 1o.t, 84 79)

SEM5240
For hydraulic valve lifter
Before starting engine, make sure that valve does not hit piston when rotating crankshaft by hand.
When bleeding air out from hydraulic valve lifter, run engine at more than 2,400 rpm for 20 minutes
or more.

EM-216
CYLINDER HEAD - Removal CD

1. Drain coolant and dtsconnect front exhaust pipe from


manifold.
2. Reinove water hoses, air duct and intake manifold.
3. Remove heat shield and exhaust manifold.
4. Remove rocker cover and injection tubes.

5. Remove both timing belts.


Set No. 1 cylinder at T.D.C.on its compression stroke. Refer
to "Replacing Timing Belt".
After timlng belts have been removed, do not rotate crankshaft
and/or camshaft separately as valves wlll hit plston heads.

6. Remove cylinder head.

EM-217
CYLINDER HEAD - Disassembly CD

1. Remove front camshaft sprocket plate, front and rear


sprockets using suitable tools and front back cover.

2. Remove camshatt brackets in order from outside to inside.


Loosen camshaft bracket nuts in two or three stages.
3. Remove camshaft and oil seals.

4. Remove valve lifters.


For hydraulic valve llfter - CD20
Do not set hydraulic valve llfters as Ulustrated as air will
enter valve llfter causlng malfunctlon.
Do not dlsassemble hydraullc valve llfters.
Attach tags to valve lifters to prevent mlxlng them up.
Valve llfters must be pul in englne oll after removal.

SEM715B

5. Remove valve component parts using special service tool


or a suitable tool.
Keep each valve and lts components together and mark
them so they can be reassembled In thelr original posltlons.

6. Remove valve oil seals using special tool.

EM-218
CYLINDER HEAD - lnspectlon CD

CYLINDER HEAD DISTORTION


1. Visually check for cracks and deformation.
2. Check cylinder head for distortion.
Head surface flatness:
Less than 0.1 mm (0.004 in)
lf beyond the specified limlt, replace or resurface cylinder
head.
Resurfacing limit:
The resurfacing llmit of the cylinder head Is related to the
amount of resurfacing of the cyllnder block.
W1,pep of 111ff11et1: When:
.._ th1n 0.1 mm (0.004 inl "A" Is the amount of resurfaclng needed for the cytfnder head
and "B" Is the amount of resurfaclng needed for the cyllnder
block, the maximum limlt is determined by
A + B = 0.1 mm (0.004 in)
After resurfacing cylinder head, check that camshaft rotates
freely by hand. lf resistance is felt, the cylinder head must be
replaced.
Nominal height of cylinder head:
CD17 116.6 117.0 mm (4.591 - 4.606 In)

SEM595A

VALVE GUIDE CLEARANCE


1. Measure deflection across the cyfinder head as iflustrated.
Valve deflectlon limlt (dial gauge readlng):
0.1 mm (0.004 In)

2. lf exceeding the limit, check valve-to-guide clearance.


a) Measure valve stem diameter and valve guide inner diam-
eter as illustrated.
b) Check that clearance is within the specification.
Valve stem to valve guide clearance limlt:
0.1 mm (0.004 In)
e) lf exceeding the limt, replace valve or valve guide.

VALVE GUIDE REPLACEMENT


1. Heat cylinder head in oil to 150 to 160C (300 to 320F).
2. Orive out valve guide using a press or hammer and a
suitable tool.

SEM871

EM-219
CYLINDER HEAD - lnspectlon CD

3. Ream cylinder head valve guide bore.


Reaming bore (servlce part):
11.185 - 11.196 mm (0.4404- 0.4408in)

4. Heat cylinder head to 150 to 160C (302to 320F)and press


service valve guide onto cylinder head.
5. Ream valve gulde.
Final size:
7.000 - 7.015 mm (0.2756 - 0.2762In)
H: CD17
13.8 mm
(0.543 In)
CD20
10.3 mm
(0.<406 In)
SEM2460

VALVE SEATS
1. Check valve and valva seat for contact.
Coat the valve tace with prussian red lead. lf contact is
wrong, correct valve seat. lf the valve red lead appears 360
around face, the vatve stem and tace are concentrlc. lf not,
repair or replace valve.

N.G. N.G.
SEM722B

2. Check valve seats for any evidence of pitting on valve


contact surface, and reseat or replace if worn out exces-
sively.
Correct valve seat surface.
When repalrlng valve seat, check valve and valve guide for
wear beforehand. lf worn, replace them. Then correct valve
seat.

EM-220
CYLINDER HEAD - lnspectlon CD

VALVE SEAT REPLACEMENT


1. Bore out old seat until it collapses.
The machina depth stop should be set so that boring cannot
continue beyond the bottom face of the seat recess in
cylinder head.
2. Ream the cylinder head recess.
Reamlng bore for servlce valve seat
[Overslze 0.5 mm (0.020 In)]:
CD17
lntake 38.44 0.01 mm (1.5134 0.0004 In)
......_ s_EM_1_9s......
A Exhaust 34.46 0.01 mm {1.3567 0.0004 In)
CD20
lntake 40.943 0.011 mm (1.6119 0.0004 In)
Exhaust 34.943 0.011 mm (1.3757 0.0004 In)
Reaming should be done to the concentrlc clrcles around the
valve guide center so that valve seat will have the correct flt.
3. Heat cylinder head to a temperatura of 150 to 160C (302 to
320F) and press fit seat until it seats on the bottom.
4. lnstall valve seats.
When replaclng valve seat, valve should be replaced as well.

5. Cut or grind valve seat using a suitable tool at the specified


dimenslons as shown in S.D.S.
The cutting should be done with both hands to obtaln a unlform
and concentrlc finlsh.

SEM876

6. Apply a small amount of fine grinding compound to the


valve's contacting tace and put the valve lnto its guide.
Lap valve against its seat until proper valve seating is
obtained.

SEM877

7. Check valve seating condition.

)
W: Refer to S.D.S.
SEM635A

EM-221
CYLINDER HEAD - lnspectlon CD

VALVE DIMENSIONS
1. Check dimensions of each valve. For dirnenslons. refer to
S.D.S.
2. Corrector replace any valve that is faulty.

L
SEM188A

3. Valve face or valve stem end surface should be retaceo by


using a valve grinder.
When valve head has been worn down to 0.5 mm (0.020 in) in
margln thlckness, replace the valve.
Grlndlng allowance for v~lve stem tlp is 0.5 mm (0.020 In) or
less.

VALVE SPRING SQUARENESS


Check valve spring for squareness using a steel square and flat
surface plate.
lf spring is out of square "S" more than specified limit, replace
with new one.
Out-of-square:
Outer
Less than 2.1 mm (0.083 In)
lnner
Less than 1.9 mm (0.075 In)
SEM333

VALVE SPRING PRESSURE LOAD


Measure the free length and the tension of each spring. lf the
measured value exceeds the specified lirnit, replace spring.
Refer to S.D.S.

EM113

VALVE LIFTER
CD17: Valve llfter
CD20: Hydraullc valve llfter
1. Check contact and sliding surfaces for wear or scratches.

SEM723B

EM-222
CYLINDER HEAD - lnspection CD

2. Check diameter of valve lifters.


Outer diameter:
34.959 - 34.975 mm (1.3763 - 1.3770 in)

SEM724B

3. Check valve lifter gude bore.


CD17
Bore diameter
34.988 - 35.013 mm (1.3775 - 1.3785 In)
Standard clearance
0.013 - 0.054 mm (0.0005 - 0.0021 In)
CD20
Bore dlameter
34.998 - 35.018 mm (1.3779 - 1.3787 in)
Standard clearance
0.023 - 0.059 mm (0.0009 - 0.0023 In)

COMBUSTION CHAMBER REPLACEMENT


Usually combustion chambers should not be removed.
However, if they show cracks or extenslve damage, they should
be replaced.
1. Remove glow plug connecting plate, glow plugs and injec-
tion nozzle.
2. Heat cylinder head in oil to between 150 and 160C (302 and
320F). .
3. Remove cornbustlon chamber so that cylinder head will not
be damaged.
SEM720B
Be careful not to scratch lnslde of nozzle hole.
4. lnstall combustion chamber.
a. Heat cylinder head 150 to 160C (302 to 320F) in oil.
b. Align combustion chamber knock pin wlth cyfinder head
notch, and install it nto cylinder head using a plastlc-ttp
hammer.

SEM721B

CAMSHAFT VISUAL CHECK


Check camshaft for scratches, seizure and wear.
CAMSHAFT END PLAY
1. lnstall camshaft in cylinder head.
2. Tighten bracket bolts to the specified torque.
3. Measure camshaft end play.
Camshaft end play: Standard
CD17 0.06 - 0.17 mm (0.0024 0.0067 In)
CD20 0.115 - 0.188 mm (0.0045 - 0.0074 In)
SEM726BI

EM-223
CYLINDER HEAD - lnspection CD

CAMSHAFT RUNOUT
1. Measure camshaft runout at the center journal.
Runout (Total indlcator readlng):
Llmlt O.OS mm (0.0020 In)
2. lf it exceeds the limit. replace camshaft.

CAMSHAFT CAM HEIGHT


1. Measure camshaft cam height.
Cam helght. Standard
Unit: mm (in)

--------
CD17 CD20
44.45 44.50 49.20 - 49.30
lntake
(1.7500 1.7520) (1.9370 - 1.9409)
45.45 - 45.50 49.15 - 49.25
Exhaust
(1.7894 - 1.7913) (1.9350 1.9390)

2. lf wear is beyond the limit, replace camshaft.

CAMSHAFT JOURNAL CLEARANCE


Using mlcrometer
1. Measure the inner diameter of camshaft bearings.
Standard inner dlameter:
30.000 - 30.021 mm (1.1811 - 1.1819 In)
Tlghten bracket bolts to the speclfied torque.

2. Measure the outer diameter of camshaft journals.


Standard outer diameter:
29.935 - 29.955 mm (1.1785 - 1.1793 In)
lf clearance exceeds the limit. replace camshaft and/or cylinder
head.
Standard clearance:
0.045 - 0.086 mm (0.0018 - 0.0034 In)
Llmlt: 0.1 mm (0.004 In)

EM-224
CYLINDEA HEAD - lnspectlon CD

Uslng plastlgage
1. Wlpe off oil from camshaft journal bracket caps and brack-
ets.
2. lnstall camshaft in journal bracket caps and put plastigage
on each camshaft journal.
3. lnstaH cam bracket caps and tlghten cam bracket cap nuts
in the correct order to the speclfled torque.
~: 18 - 22 Nm (1.8 2.2 kg-m, 13 .. 16 ft-lb)

4. Remove cam bracket caps and measure maximum width of


plastigage.
Camshaft bearlng clearance:
Llmlt
0.1 mm (0.004 In)
5. lf clearance appears to exceed the limit, replace camshaft
or cylinder head.
Which parts to be replaced should be decided upon after
measuring the diameters of the parts concerned.

EM ..225
CVLINDER HEAD - Assembly CD

1. tnstall valva component parts.


Instan valve sprlng wlth lts narrow pitch slde toward cyllnder
head slde.
Painted side
Always install new valve oll seals.
Refer to oll seal replacement.
Before lnstalllng oll seal, instan valve-sprlng seat.
When lnstalllng valve, apply englne oil on the valve stem
and llp of valve oll seal.
Check whether the valve face Is free from foreign matter.

SEM202

CD17 For CD17


lnstall valve llfter plate.
Adjust valve clearance.

SMA409A

CD20 For CD20


lnstall valve spring retainers on the intake side and valve
IN. rotators on the exhaust slde.
Valve rotators cannot be dlsassembled.

EX.

number 2. lnstall camshaft and brackets and tighten bracket nuts to


llghtenlng sequence the specified torque in two or three stages.
!B.(
Camshaft-bracket nuts:

1~
@ ~: 18 - 22 Nm (1.8 - 2.2 kg-m, 13 - 16 ft-lb)
Tlghten bracket from center to outstde.
tw @ @


Apply sealant to brackets No. 1 and No. 5.
When lnstalllng brackets, set camshaft so that the pin of
camshaft front head Is uppermost.
Facing front of engine lnstall new camshaft oil seals.
(positlon 2) Refer to oll seal replacement.
SEM5280

13.0 (0.512)

No. 1 joomal bracket No. 5 joumal bracl<et


Unt: mm (In} SEM676D

EM-226
CYLINDER HEAD - lnstallatlon CD

1. lnstall cylinder head gasket.


a. When replaclng only cyllnder head gasket, Instan same
grade gasket as the one formerly used.
b. When replacing or repalrlng cyllnder block, plston, connect-
ing rod and crankshaft, select gasket referrlng to "Selectlng
cyllnder head gasket".
2. lnstall cylnder head and tghten cylinder head bolts accord-
ing to the following sequence.

Tightening procedure
1. Apply engine oil to threads and underhead seating face of
each bolt.
For CD20
2. Tighten bolts progressively in the following steps.
39 Nm (4.0 kg-m, 29 ft-lb)
885 Nm (9.00.5 kg-m, 65.1 3.6 ft-lb)
@ Return to O Nm (O kg-m, O ft-lb)
@ 39 Nm (4.0 kg-m, 29 ft-lb)
@ Tighten to 75 _+ ~
Jf it is difficult to check tightening angle of bolt, tighten to 83
CD20 to 93 Nm (8.5 to 9.5 kg-m, 61 to 69 ft-lb).
Nm (kg-m, ft-4b) For CD17
88:1.:5 2. Tighten bolts progressively in the following steps.
(9.0 0.5, (i) 39 Nm (4.0 kg-m, 29 ft-lb)
66.13.6)
@ 1035 Nm (10.50.5 kg-m, 763.6 ft-lb)
(4.0,29)
@ Return to O Nm (O kg-m, O ft-lb)
@ 39 Nm (4.0 kg-m, 29 ft-lb)
@ Tighten to 82 _+ ;:
O Nm (O kg-m. O ft-4b)
lf it is difficult to check tightening angle of bolt, tighten to 98
to 108 Nm (10.0 to 11.0 kg-m, 72 to 80 ft-lb).
SEM6730

Cylinder head bolt

EM-227
CYLINDER HEAD - lnstallatlon CD

3. lnstall rocker cover.


lnstall rocker cover in the sequence shown at left.

SEM6780

Apply sealing compound (THREE-BONDNo. 10 or equtva-


lent) to both ends of brackets No. 1 and No. 5.

Selectlng cyllnder head gasket - CD17


1. Set dial gauge and needle on cyllnder block surface.
2. Adjust scale to zero.
3. Move dial gauge assembly untll needle is set on the
measuring point of pistan.
4. Read scale.
5. Reset dial gauge on cylinder block and confirm that scale
indicates zero again.

Be sure to measure the projection at two points for each


cyllnder as shown.
Set each plston at lts T.D.C.

Front

SEM911

EM228
CYLINDER HEAD - lnstallatlon CD

6. Determine gasket grade.


(1) Calculate average value of projections for ali pistons.
(2) Determine gasket thickness. referring to the chart.
Unit: mm (in)
Average vatues
Number of
Grade for piston Gasket thlckness
indentatlons
projeetions

A
Less than 0.52
(0.0205)
1.15 (0.0453) ,
0.52 0.57
B 1.20 (0.0472) 2
(0.0205 0.0224)
More than 0.57
e (0.0224)
1.25 (0.0492) 3

(3) lf any one of the average values of each piston exceeds the
average value (Max.) for piston projections by more than
O.OS mm (0.0020 in), select a one grade thicker gasket than
that determined in step (2).
Example
Unlt: mm (In)

Re-
Step ~ 1 2 3 4
1 marks

M1 M2 M1 M2 M1 M2 M1 M2
1. Measured value 0.53 0.56 0.59 0.55 0.53 0.58 0.58 0.51
(0.0209) (0.0220) (0.0232) (0.021'7) (0.0209) (0.0228} (0.0228) (0.0201)
Average value of each
2. 0.545 (0.0215) 0.57 (0.0224) 0.555 (0.0219) 0.545 (0.0215)
plston
Average value of ali
3. 0.55375 (0.02180)
pistons
4. Rounded value 0.55 (0.0217)
Determinad gasket
5. thlckness 1.20 (0.0472} (Grade B)
{Temporary)
X: Maxlmum piston projection of selected gasket ... 0.57 (0.0224) + 0.05 (0.0020)
= 0.62 (0.0244)
6.
Y: Maximum of the average value of each piston = 0.57 (0.0224)
Result: Y < X 1
Determlned gasket
7. thlckness 1.20 (0.0472) (Grade B)
(Final)
1: lf Y > X [for example Y = 0.63 mm (0.0248 in)], use thlcker gasket grade C.

EM-229
CYLINDER HEAD - lnstallation CD

Selectlng cyllnder head gasket - CD20


When replaclng only cyllnder head gasket, lnstall the same
grade gasket as the one formerly used.
Step 1
Measure projection of piston to cylinder head surtace.
a) Set dial gauge and needle on cylinder block and adjust dial
gauge to zero.
b) Set dial gauge needle at measuring point on pisten. taking
care not to disturb its zero setting.
e) Rotate crankshaft around the top dead center position.

d) Read and write down the maximum value.


e) Reset dial gauge on cylinder block and confrm that zero
setting has not been disturbed during measurement.
f) Repeat steps b through d for all measuring points as
illustrated and for each cylinder.
Be sure that piston whose projectiori is being measured is
at its TDC.
Step 2
Calculate the average value of measurements taken for each
pistan.
Step 3
Calculate the average value of measurements for aU pistons
from the values obtained from step 2.
Step 4
Round of the value obtained.
Step 5
Determine required thickness of gasket, referring to chart A.

EM-230
CYLINDER HEAD - lnstallatlon CD

l
Relatlon between piston average projection and cyllnder head
gasket (Chart A)

Average value of
Gasket thickness
Grade piston projections Number ot notches
mm (in)
mm (In)
......
Less than 0.505 1.15 -ti:
A
(0.0199) co.0453 : ~.~m >
1

B
0.505 - 0.555 1.20 ~:i: 2
SEM5300
(0.0199 - 0.0219) (0.0472 : ~ g~~g )
e Ovar 0.555 (0.0219)
1.25 _.. ti: 3
(o.0492 : i g~~z > 1

Step 6
Check it the average value of each projection obtained from
step 2 is larger than the max. value of the standard projection
(of selected gasket) incremented by 0.05 mm (0.0020 in}.
lf so, use gasket that is 1 grade thicker. lf not so, use gasket as
selected in step 4.
Example
Unt: mm (in)

Step~No. 1 2 3 4
m
M1 M2 M3 M4 Ml M2 M3 M4 M1 M2 M3 M4 M1 M2 M3 M4
Measured
l. 0.53 0.56 0.53 0.56 0.59 0.55 0.59 0.55 0.53 0.58 0.57 0.54 0.58 0.51 0.52 0.57
value
(0.0209) (0.0220) (0.0209) (0.0220) (0.0232) (0.~17} (0.0232) (0.02171 (0.0209) (0.0228) (0.0224} (0.0213) (0.0228} (0.0201} (0.0205) {0.0224)
Average
0.545 0.57 0.555 0.545
2. varee of eacn
(0.0215) (0.0224) (0.0219} (0.0215}
pisten
Average
3. vaue Of all 0.55375(0.02180}
pistons
Round off
4. 0.554 (0.0218}"1
vaue

j
...........
Determined
5. gasket thck 1.20 (0.0472){Grade BI
ness (Tempo-
rarity)
X: Maximum vaue ot standard projection of setected gasket ... 0.555 (0.0219) (in cnart A) + 0.06 (0.0020} "' 0.605 (0.02381
6. Y: Maxlmum value in step 2 = 0.57 (0.0224)
The relationshipbetween X and Y is "X > Y". 2
Oetermined
7. gasket thlck 1.20 (0.0472) (Grade B}'2
ness (Finally}

t: 11 the average value of projectlons for ali plstons is, tor exampfe, 0.553(7) 5, as shown In the table above, 11 should be rounded off u followa:
lf the dlgft fn the forth decimal place (whlch is enc:tosed by a circle In thls case) Is smaller than 5, the avef'age value should be regarded as
0.553 mm (0.0218 In); if lt is larger than 5, the average value lhould be regarded as 0.554 mm (0.0218 In).
2: lf X < Y, then the thlctter grade C gasket must be used.

EM-231
ENGINE REMOVAL

~: Nm (kgm. 1't-lbl

SEM2480

EM-232
ENGINE REMOVAL CD

WARNING:
Sltuate vehlcle on a flat and solld aurface.
Place chocks at front and back of rear wheele.
Do not remove englne untll exhaust system has completely
cooled off. Otherwlae, you may burn yourself and/or fire
may break out In the fuel line.
For safety durlng subsequent steps, the tenslon of wfrea
should be alackened agalnst the englne.
Before removlng front axle from transaxle, place safety
stands under deslgnated front supporttng polnts. Refer to
GI sectlon for llftlng points and towlng.
Be sure to holst englne and transaxle In a safe manner.
For englnes not equlpped wlth englne sllngers, attach
proper slingers and bolts descrlbed In PARTS CATALOG.
CAUTION:
When Uftlng englne, be careful not to atrlke adjacent parta,
especlally accelerator wlre casing, brake Unes, and brake
master cyllnder.
In holsting the engine, always use englne allngers In a safe
manner.
In removlng drive shaft, be careful not to damage transaxle
oll seal.
1. Remove engine undercovers and splash covers.
2. Remove front exhaust tube.
3. Drain coolant and dlsconnect lower water hose from radl-
ator.
4. Drain transaxle oll.
5. Disconnect electrical wiring from radiator.
6. Aemove power steering mounting bolt.
7. Drain coolant from cytinder head.
8. Disconnectwater hoses and electrical wiring from radiator
and remove radiator.
Drain plug (Radiator)
9. Disconnectfuel tubes and vacuum tubes.
10. Ralease power steering belt adjustlng nut and remove
power steering pump from engine.
Bind pump properly to the vehicle.
11. Disconnect or remove electrical wlring where necessary.
12. Release clutch tever cable and accelerator cable.
13. Release tachometer cable from transaxle housing.
14. Remove front wheels.

SMA343C

SEM5310

EM-233
ENGINE REMOVAL CD

15. Remove brake caliper mounting bolts and bind caliper


properly to vehicle (coil spring) L.H. & R.H.

SEM5320

16. Remove lower ball joint nuts and release the upper hub
mounting bolts.
17. Release steering arm ball joint using a suitable tool.
Remove drive shafts from transaxle.
1) RH: Split drive shaft center thrust bearing.
2) RH & LH: Remove hub mounting bolts and remove drive
shaft carefully from transaxle.

SEM5330

18. Mount suitable slingers to cylinder head. Fit hoist with


studge and hoist engine to release force on engine rnount-
ings.

SEM534D

19. Remove upper mounting (Right side).

SEM5350

20. Release transaxle shift linkages.

SEM536D

EM-234
ENGINE REMOVAL CD

21. Release lower left engine mounting.

SEM5370

22. Remove center member from chassis.

SEM5380

23. Remove engine with transaxle as shown.

EM-235
CYLINDER BLOCK ! CD!

CD17

1

~
...
.,.:
o
e
...
1
o
1 j
i
1

..
'8
a:1
i -
:;

,.

i 1 i.
~

1
e.
=. i
e=

SEM8530

EM-236
CYLINDER BLOCK CD

CD20

Rear oil seal retainer

Cylinder block rRJa-93


(U. 9.5,
81 69)

Flywheel

Rear plate

Piston ring

eonne<.:tingrod

Pston pin Maln bearing cap

ecnnecting rod bearing

Angular tlghtening

~ : Nm (kg-m. ft-lb)
~~-M
(4.5 s.s. 33 - 40)

SEM7080

EM-237
CYLINDER BLOCK CD

ST0501SOOO Dlsassembly
KV10108101
PISTON AND CRANKSHAFT
1. Place engine on a work stand.
2. Drain coolant and oil.
3. Remove timing belt.
4. Remove water pump.
5. Remove oll pan and oil pump.
6. Remove cylinder head.
7. Remove pistons.

When dlsassembllng plston and connectf ng rod. heat plston to


60 to 70C (140 to 158F) or use piston pin press stand at room
temperature.

SEM3600

8. Remove bearing cap and crankshaft.


Place the bearlngs and caps in thelr proper order.
Upper bearlngs (cyllnder block side) have oil groove.

Loosen in numerical order.


9. Remove piston rings with a tool.

EM-238
CYLINDER BLOCK CD

lnspectlon
PISTON AND PISTON PIN CLEARANCE
1. Measure outer diameter of piston pin and inner diameter of
piston pin hole.
2. Calculate pisten to pistn pin clearance.
Pin dlameter:
CD17 23.994 - 24.000 mm (0.9446 - 0.9449 in)
CD20 24.994 25.000 mm (0.9840 - 0.9843 In)
Pin hole dlameter:
CD17 23.991 23.999 mm (0.9445 - 0.9448 In)
CD20 24.991 - 24.999 mm (0.9839 - 0.9842 In)
Clearance:
-0.004 to O mm (-0.0002 to O in)
(lnterference fit)
Servlce parts are available as a set of plston and piston pin.

PISTON RING SIDE CLEARANCE


Side clearance:

CD17

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

Standard limit
0.020 - 0.060
Top rng 0.20 (0.0079)
(0.0008 - 0.0024)
0.040 - 0.080
2nd ring 0.15 (0.0059)
(0.0016 - 0.0031)
0.030 - 0.070
Oil rng 0.10 (0.0039)
(0.0012 - 0.0028)

CD20
Unit: mm (in)

---------
Top ring
Standard
0.060 0.095
(0.0024 - 0.0037)
0.040 - 0.075
Limit

o. 10 (0.0039)

2nd rng 0.10 (0.0039)


(0.0016 - 0.0030)
0.030 - 0.070
Oil ring 0.10 (0.0039)
(0.0012 - 0.0028)

EM-239
CYLINDER BLOCK CD

lnspection (Cont'd)
PISTON RING GAP
Rlng gap:
Feeler
gauge

-----
CD17
Unit: mm (in)

Standard Limt
0.20- 0.35
Top ring 1.0 (0.039)
(0.0079 - 0.0138)

SEM599A 0.20 0.35


2nd ring 0.7 (0.028)
(0.0079 - 0.0138)

0.30 - 0.45
Oil rng 0.6 (0.024)
(0.0118 - 0.0177)

CD20
Unit: mm (in)

---------
Top rng
Standard
0.12 - 0.30
(0.0047 0.0118)
Limt

1.0 (0.039)

0.38 - 0.53
2nd rng 0.7 (0.028)
(0.0150 - 0.0209)

0.30 0.55
Ol ring 0.6 (0.024)
(0.0118 0.0217)

lf out of specification, replace piston ring. lf gap stllf exceeds the


limit even with a new ring, rebore the cylinder and use oversize
piston/piston ring assembly.
Refer to S.D.S.

MAIN BEARING CLEARANCE


1. lnstall main bearings to cylinder block and main bearing
cap.
2. lnstall main bearing cap with bearing to cylinder block.
Tlghten all bolts In two or three stages.
caJ:
44 - 54 Nm (4.5 - 5.5 kg-m, 33 - 40 ft-lb)
3. Measure inside diameter "A" of main journal.

4. Measure outside diameter "Dm" of main journal of crank-


shaft
Journal dlameter:
Refer to S.D.S.
5. Calculate main bearing clearance.
Main bearing clearance = A - Dm
Standard:
0.039 - 0.065 mm. (0.0015 - 0.0026 in)
lf it exceeds the limit, replace the bearing.

EM-240
CYLINDER BLOCK CD
lnspection (Cont'd)
lf crankshaft main journal is worn or shows any abnormal-
ity, regrind crank journal and use undersized bearings to
maintain the specified oil clearance.
J eo..... Refer to S.D.S. for regrlnding crankshaft joumal dlameter
~ weight and avallable servlce parts.
When regrJndlng crankshaft journal, do not grlnd ffllet-roll.
Main journal~

Maintaln more tti.n


0.13 mm (0.0051 In) SEM566B

CD17 lf either bearing, crankshaft or cylinder block is replaced


with a new one, select main bearlng according to the fol-
lowing table. These numbers are punched in either Arabic
No. s or Roman numerals.
Main bearing housing grade number
o 1 2
~ Main bearing grade number
Crankshaft main [our-
o o 1 2
1 1 2 3
nal grade number
2 2 3 4
SEM680A

ldentlflcation color:

-----
Grade O
Grade 1
CD17
Black
Brown
CD20
Yellow
Green
Grade 2 Green Brown
Grade 3 Yellow Black
Grade 4 Blue Blue

SEM706D

. For example:
Main journal grade number: 1
No.5 Crankshaft journar grade number: 2
Main bearing grade number = 1 + 2 = 3
Maln bearlng thlckness:

Refer to S.D.S.

CONNECTING ROO BEARING CLEARANCE (Big end)


CD17: Non-selective connecting rod bearing
CD20: Selective connectlng rod bearlng
1. Jnstall connecting rod bearing to connecting rod and cap.
2. lnstall connecting rod cap with bearing to connecting rod.
Apply oll to the thread portion of bolts and seatlng surface of
nuts.
A= CD17 31 37 Nm (3.2 - 3.8 kg-m, 23 - 27 ft-lb)
CD20 37 45 Nm (3.8 - 4.6 kg-m, 27 33 ftlb)
3. Measure inside diameter "C" of bearing.

EM-241
CYLINDER BLOCK CD
lnspectlon (Cont'd)
4. Measure outslde diameter "Dp" ot crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearlng clearance = C - Dp
Counter Standard:
weight CD17 0.024 - 0.066 mm (0.0009 0.0026 In)
CD20 0.031 - 0.061 mm (0.0012 0.0024 in)
lf it exceeds the limit, replace the bearing.
lf crankshaft pin journal is worn or shows any abnormatity,
regrind crank pin and use undersized bearings to maintain
Mllintain more than the specified oil clearance.
.0.13 mm (0.0061 in)
--~~~~~~~~~~~~--'
seM3610 Refer to S.D.S. for regrindlng diameter of crankshaft pin
and avallable service parts.
When regrindlng crankshaft pin, do not grind flllet-roll.

For CD20 (Selectlve connecting rod bearlng)


lf either bearings or crankshaft are belng. replaced with
new ones, select connecting rod bearings according to the
following table. Grade numbers are punched in either Ara-
bic or Roman numerals.

Crankshaft pin journal grade number


o 2
Connecting roo baring grade num-
ber
o 2

ldentlficatlon color
Grade O: Black
Grade1: Yellow
Grade2: Blue

CONNECTING ROD AND PISTON PIN CLEARANCE


(Small end)
Clearance (D - d):
0.025 - 0.044 mm (0.0010 0.0017 in)
lf clearance exceeds the specif ications, replace the bear-
ing.

CleeranceD-d
SEM5758

EM-242
CYLINDER BLOCK CD

lnspectlon (Cont'd)
Bearlng replacement
1. Remove bearing with a suitable tool.
Do not scratch inner surface of connectlng rod.

2. lnstall new bearing with ol holes aligned correctly.


3. Ream bore using a suitable tool.
Ream bore:
CD17 24.025 - 24.038 mm (0.9459 - 0.9464 in)
CD20 25.025 - 25.038 mm (0.9852 0.9857 In)

CONNECTING ROD BEND AND TORSION


Bend and torsion [per 100 mm (3.94 in) length]:
CD17
Bend Less than 0.15 mm (0.0059 in)
Torsion Less than 0.30 mm (0.0118 In)
CD20
Bend Less than 0.025 mm (0.0010 in)
Torslon Less than 0.025 mm (0.0010 in)

EM133

A B CRANKSHAFT
1. Check crankshaft journals and pins for score, bias, wear or
cracks. lf faults are mnor, correct with fine crocus cloth.
X 2. Check journals and pins with a micrometer for taper and
out-ot -round.
Out-of-round (X - Y):
y
Less than 0.005 mm (0.0002 In)
Taper (A - B):
Taper: A- B Leas than 0.005 mm (0.0002 In)
Out-ofround: X - Y
.SEM3!6A

3. Check crankshaft runout.


Runout (Total indicator readlng):
Less than 0.05 mm (0.0020 In)

~
SEM601A

EM-243
CYLINDER BLOCK CD

lnspection (Cont'd)
CYLINDER BLOCK DISTORTION
Measuringpoints
Clean upper tace of cylinder block and measure the distortion.
Llmlt:
0.10 mm (0.0039 In)
lf out of specification. resurface it.
The resurfaclng Hmit of cylinder block Is determlned by cylinder
head resurfaclng in an englne.
Amount of cyllnder head resurfaclng Is A,,,
Amount of cyllnder block resurfaclng is "8".
The maximum limit Is as follows:
Warpage of surface:
A + B = 0.1 mm (0.004 In)
Lesa than 0.1 mm (0.004 In) lf necessary, replace cylinder block.

SEM655A

CYLINDER BORE
Moving the bore gauge
as shown, take the 1. Check for scratches or seizure. lf seizure is found, hone
mnimum readng. bore.
2. Using a bore gauge, measure cylinder bore for wear.
out-of-round or taper.
Standard bore dlameter:
CD17 80.000 80.050 mm (3.1496 - 3.1516 In)

-------
CD20 84.500 - 84.550 mm (3.3268 3.3287 In)
Unit: mm (in)
CD17 CD20
Bore wear limit 0.1 (0.004) 0.2 (0.008)
Out-ot-round standard 0.04 (0.0016) 0.015 (0.0006)
Taper (A - B) standard 0.04 (0.0016) 0.010 (0.0004)
y

lf it exceeds the limit, rebore all tour cylinders. Replace cylinder


block if necessary.
lf either cylinder block or plston Is replaced wlth a new one,
select the same plston as piston grade number punched on
1 co11: eo (2.38) co20: 10 (2.76) cyllnder block upper surfaces.
"2 CD17: 100 (3.94) CD20: 120 (4.72)
Unit: mm lin) SEM7040

Front.
0000
SEM1768

EM-244
CYLINDER BLOCK CD

Assembly
PISTON
Numbers stamped on connectlng rod and cap correspond
to each cylinder. Care should be. taken to avold a wrong
comblnation lncludlng bearlng and connectlng rod dlrec-
tion.

SEM7030

Instan new snap rlng on one slde of plston pin hole.


When assembling plston and connecting rod wlth plston
pin, heat plston to between 60 and SO"C (140 and 176F)and
install plston pin wlth a sultable tool.
Instan new snap rlng.
After assembllng, ascertaln that plston swlngs smoothly.
ICV1010?0$0

EM156

lnstall piston rings with a suitable too!.


CD20 selectlve top rlng; When installlng new top ring or
replaclng cylinder block, select top rlng to ad)ust ring gap.

Cylinder bore grade


---.-----
1, 2, 3 4, 5
Top ring grade No. No mark S

SEM2510

CRANKSHAFT
1. Set main bearings in the proper position on cylinder block
and main bearing caps.
lf elther crankshaft, cyllnder block or maln bearing la
reused agaln, lt Is necessary to measure maln bearlng
clearance.
Upper bearlngs (cylinder block slde) have oll groove.

EM-246
CYLINDER BLOCK CD

Assembly (Cont'd)
CD20 2. Apply engine oil to main bearing surfaces on crankshaft
journal side.
3. lnstall crankshaft and main bearing caps and main bearing
beam (CD20).
Maln bearing cap bolt:
[Cll: 44 - 54 Nm (4.5 - 5.5 kg-m, 33 40 ftlb)
4. Tighten main bearing cap bolts.
Arrange the parts so that the lndicated numbers on bearlng
caps are In a row from the front of engine.
Tlghten bearlng cap bolts gradually In two or three stages
and outwardly from center bearlng In sequence.
Alter securing bearlng cap bolts, ascertaln that crankshaft
tums smoothly.

Engne
front

L__-.~~~~~~~~~-S_E_M7_02_.0

5. Measure crankshaft free end play at center bearing.


Crankshaft free end play:
Standard
O.OS - 0.18 mm (0.0020 - 0.0071 in)
Llmlt
0.30 mm (0.0118 in)

PISTON WITH CONNECTING ROD


1. lnstall connecting rod bearings in the connecting rods and
connecting rod caps.
Confirm that correct size of bearings is used.
Refer to lnspection".
lnstall the bearings so that the oil hole in the connecting rod
aligns with the oil hole of the bearing.
Apply engine oil to connecting rod bearing surfaces on the
crankshaft journal side.
SEM159B

Set piston rings as shown.


CYLINDER BLOCK CD

Assembly (Cont'd)
2. lnstall pistons with connecting rods.
lnstall them into corresponding cylinder using Tool.
Be careful not to scratch cylinder wall with connectlng rod.
Apply englne oll to cyllnder wall, plston and bearlng.
A-rrange so that the front mark on plston head faces to the
front of engine.

3. lnstall connecting rod bearing caps.


Apply a little engine oil to the thread of connecting rod
bearing nut.
For CD17
tql: 31 - 37 Nm (3.2 - 3.8 kg-m, 23 - 27 fllb)
For CD20
(1) Tighten connecting rod bearing nut to 151 Nm (.50.1
kg-m, 10.80.7 ft-lb).
(2) Then tighten an additional 60 +_~. turns with an angular
tightening wrench .
.__ e_M_329_, tql: 15~) Nm (1.50.1 kg-m, 10.80.7 ftlb) plus
60 _0 or .
27 45 Nm (3.8 - 4.6 kg-m, 27 - 33 ft-lb)

4. Measure connecting rod side clearance.


Connectlng rod side clearance (Blg end play):
Llmit
0.3 mm (0.012 In)

FL YWHEEL RUNOUT
Runout (Total lndlcator reading):
Leas than 0.15 mm (0.0059 In)

EM-248
CYLINDER BLOCK CD

Assembly (Cont'd)
CYLINDER HEAD GASKET
Refer to "Selectlng cyllnder head gasket".
Whenreplacing or repalrlng cyllnder block, plston, connect-
lng rod and crankshaft, select gasket.

EM-249
SEAVICE DATA AND SPECIFICATIONS (S.D.S.) GA

General Speclflcatlons
GENERAL SPECIFICATIONS

Engne GA130S GA140S GA 16DS & GA 16DE

Classlticaton Gasoline

Cyllndef arrangement 4. ln-line


Displacement cm3 (cu in) 1.295 (79.02) 1.392 (84.94) 1.597 (97.45)

Bore x strok.e mm (In) 71.0 X 81.8 (2.795 X 3.220) 73.6 X 81.6 (2.898 X 3.220) 76.0 X 88.0 (2.992 X 3.465)

Valve arrangement D.O.H.C.

Firing order 1-3-42

Number of pston rings

Compression 2
Oil 1

Number of main bearlngs 5


Compression ratio 9.5 9.5 9.5, 9.6

Yalve timlng For Europe and Gulf standard

BDC

EM120
Unit: degree

a b e d e
GA13DS, GA16DS,
and GA 140S with 222 222 o 42 o 42
out E.G.R.
GA14DS with
214 214 2" 32 -12 46"
E.G.R.
GA16DE 222' 235 -2 ss o 42

EM-250
SERVICE DATA AND SPECIFICATIONS (S.D.S.) GA

lnspectionand Adjustment
ENGINE COMPRESSION PRESSURE CYLINDER HEAD
Unit: kPa (bar, kg/cm2 psi)/350 rpm Unit: mm (in)

Standard
Mnimum
Dfference limt between cylin-
ders
1.324 (13.24, 13.5, 192}
1,128(11.28. 11,5, 164)

98 (0.98. 1.0, 14)


--------
Head surface
flatness
,._,,.
Standard
Less than
0.03 (0.0012)
Limit

0.1 (OJJ04}

117.8- 118,0
Heght
(4.638 - 4.646) -

VALVE
Unit: mm (in)

i-----l ----

~-- -
Valve head dlameter "D"
""'"

lntake
GA13DS

26.4- 26.6
(1.039 1.047)
21.4 21.6
GA14DS

28.9 - 29.1
(1.138-1.146)
23.9 - 24.1
GA16DS
GA16DE
29.9 - 30.1
(1.177 - 1.185}
23.9- 24.1
SEM188

Exhaust
(0.843 - 0.850) (0.941 - 0.949) (0.941- 0.949)
lntake 92.00 - 92.5 (3.6220 3.6417)
Valve length "L"
Exhaust
- 92.37 - 92.87 (3.6366 3.6563)
lntake 5.465 - 5.480 (0.2152 0.2157)
Valve stem diameter "d" --,.............
Exhaust 5.445 5.460 (0.2144 0.2150)
...
Valve lace angle "n" 4515 4545
Valve margn "T" lirnlt 0.9 1.1 {0.035 - 0.043)
.....
Valve stem end surface grindng lmit Less than 0.2 (0.008)

Valve clearance
Unt: mm {in)

<. Hot
For adjusting
Cotct
....
For checkng

......
Hot

__
lntake
,,,,
0.32 0.40
(0.013 0.016)
0.37 0.45
0.25 0.33
(0.010 0.013)
0.32 0.40
0.21 0.49
(0.008 0.019)
0.30 0.58
Exhaust
(0.015 0.018) {0.013 - 0.016) (0.012 0.023)
': At a temperature of approx,mately 2oc (68.F)
Whenever valve ctearances are adjusted to cokl apeclficattons,
checkthat the clearancessatlsfy hot speclflcations and adjust agaln
if necessary.

EM-251
SERVICE DATA ANO SPECIFICATIONS (S.D.S.) GA
lnspection and Adjustment(Cont'd)
Available shims

Thckness mm (in} ldentfcatonmark


T
2.00 (0.0787) 200
2.02 (0.0795) 202
2.04 {0.0803) 204
2.06 (0.0811) 206
2.08 (0.0819) 208
2.10 (0.0827)
- 210
lndlcat
T = 2.800 mm
Shlm (0.1102 In)
2. 12 (0.0835) 212
SEM7490
2.14 (0.0843) 214
2.16 (0.0850) 216
2.18 (0.0858) 218
-
... .......
2.20 (0.0866) 220
2.22 (0.0874) 222
2.24 (0.0882) 224
2.26 (0.0890) 226
2.28 (0.0898) 228
2.30 (0.0906) 230
2.32 (0.0913) 2.32
...
2.34 (0.0921) 234
.
2.36 (0.0929) 236
2.38 (0.0937) 238
2.40 (0.0945) 240
2.42 (0.0953) 242
2.44 (0.0961) 244
2.46 (0.0969) 246
2.48 (0.0976) 248
2.50 (0.0984) 250
2.52 (0.0992) 252
2.54 (0.1000)
-- 254
2.56 (0.1008) 256
2.58 (0.1016) 258
2.60 (O. 1024) 260
2.62 (0.1031) 262
2.64 (O. 1039) 264
2.66 (0.1047) 266
------
2.68 (0.1055) 268
2.70 (0.1063) 270
2.72 (0.1071) 272
2.74 (0.1079) 274
2.76 {0.1087) 276
2.78 {0.1094) 278
2.80 (0.1102) 280
2.82 (0.1110) 282
2.84 (0.1118) 284

__
2.86 (0.1126) 286
.., 2.88 (0.1134) 288
2.90 (0.1142) 290
2.92 (0.1150) 292
2.94 (0. 1157) 294
2.96 (0.1165) 296
2.96 (O. 1173) 298

EM-252
SERVICE DATA AND SPECIFICATIONS (S.D.S.) GA

lnspe~ion and Adjustment (Cont'd)


Valve gulde
Unit: mm {in}

------------ -
Valve guide

Outer diameter
------- Sta~da<d

9.523 - 9.534
(0.3749 0.3754)
-==f
lntake

1
Service
--""'"

9.723 - 9.734
(0.3828 0.3632)
Standard

9.523 - 9.534
(0.3749 0.3754)
Exhaust

Servce

9.723 - 9.734
(0.3628 0.3632)
-

----..
Valve guide

lnner diameter
5.500 - 5.515 (0.2165 - 0.2171) 5.500 5.515 (0.2165 0.2171)
(Finished sizeJ

9.475 - 9.496 9.685 9.696 9.475 - 9.496 9.685 9.696


Cylinder head valve gude hole diameter
(0.3730 0.3739) (0.3813 0.3817) (0.3730 - 0.3739} (0.3813 - 0.3817)

0.027 - 0.059 0.027 0.049 0.027 0.059 0.027 - 0.049


lnterlerence lit of valve guide
(0.0011 0.0023) (0.0011 0.0019) {0.0011 - 0.0023) (0.0011 0.0019)
-
Stem to guide clearance 0.020 o.oso (0.0008 0.0020) 0.040 0.070 (0.0016 - 0.0028)
-----, ..-.._. .............. _, -
Valve deflecton limit
0.2 {0.008) 0.2 (0.008)
{Dial gauge reading)

Valve spring
Free height rnm n) 41. 19 {1.6217}

344.42 (35.12, 77.44)


Standard
Pressure N (kg. lb) at at 25.26 (0.9945)
.......
height mm (in) 323.73 (33.01, 72. 79)
Limit
at 25.26 (0.9945)

Out-of-square mm(in) Lesa than 1.80 (0.0709)

Valve lifter
Unit: mm (in)

Valve lifter outsde diameter 29.960 - 29.975 (1.1795 - 1.1801)

Lifter gude nside diameter 30.000- 30.021 (1.1811 - 1.1819)

Clearance between lilter and


0.025 0.061 {0.0010 0.0024)
lifter guide

EM-253
SERVICE DATA AND SPECIFICATIONS {S.D.S.) GA
lnspectlonand Adjustment(Cont'd)
Valve seat
Unit: mm (in)

EXHAUST
Standard

s.es (0.2224)

Oversize
Oversize

Cylindef l'lead machlnng data


SEM5730 SEM5740

Oia. GA13DS GA14DS GA16DS & GA16DE


@ 23.9 - 24.1 (0.941 - 0.949) ~ ..4 ~ 26.6 (1.039 1.047) 27.4 - 27.6 (1.079 - 1.087)
!'
@ 26.0 - 26.2 (1.024 - 1.031) 28.5 - 28.7 (1.122 - 1.130) 29.5 - 29.7 (1.161 - 1.169)

27.7 - 27.9 (1.091 - 1.098} 30.2 - 30.4 (1.189 - 1.197) 31.9- 32.1 (1.258 - 1.264)
@ 28.000 - 28.016 (1.1024 - 1.1030) 30.500 - 30.516 (1.2008 - 1.2014) 31.500 - 31.516 (1.2402 - 1.2408)

21.0 - 21.2 (0.827 - 0.835) 23.5 - 23.7 (0.925 - 0.933) 23.5 - 23.7 (0.925 - 0.933)

22.7 - 22.9 (0.894 - 0.902} 25.2 - 25.4 (0.992 - 1.000) 25.2 - 25.4 (0.992 - 1.000)

23.000 - 23.016 (0.9055 - 0.9061} 25.500 - 25.516 (1.0039 - 1.0046) 2s.soo - 2s.s16 0.0039 - 1.0046)

EM-254
SERVICE DATA AND SPECIFICATIONS (S.D.S.) GA

lnspection and Adjustment {Cont'd)


CAMSHAFTANO CAMSHAFT BEARING . CYLINDER BLOCK
Unit: mm (in)
Camshaft
Unit; mm (in)

GA13DS,
GA16DS, and GA140Swth
Engine model GA16DE
GA14DS with E.G.R.
E.G.R.
-
39.880 - 40.070
.. '"""
40.600 - 40.790 39.380 - 39.570
1 H

Cam
height
lntake (1.5701
1.5776}
(1.5984
1.6059) _____
(1.5504
,, 1.5579)

.. A'' 39.880 - 40.070 39.880 40 070 39.380 39.570


Ex- ~
(1.5701 (1.5701 {1.5504
haust Cranl(shaft
1.5776} 1.5776} 1.5579) center
SEM1710
Cam wear limit 0.20 (0.0079)
GA16DS
GA13DS GA14DS
GA16DE Limit
Standard
~
Less than 0.1
Surface tlatness
0.03 (0.0012) (0.004)

Height "H" (nomi-


nalJ
213.95 - 214.05
(8.4232 - 8.4271} -
-
Standard

lnner diameter
1
71.000 73.600 76.000
Grade 71.010 73.610 76.010
No. 1 (2.7953 - (2.7986- (2.9921

-------
Camshaft bearlng 2.7957} 2.8980} 2.9925)
Unit: mm (in)
71.010 73.610- 76.010 -

____ Grade

___
71.020 73.620 76.020 0.2

__ __
Standard
.........., Limil
~ ... No.2 (2.7957 (2.8980 (2.9925- (0.008)
Camshafl journal to bearing 0.045 0.086 ,,, 2.7961) 2.8984) 2.9929)
0.15 (0.0059)
clearance (0.0018,, 0.0034)
,,, ___
""
,,,

28.000 28.021
- Grade
71.020 -
71.030
73.620
73.630
76.020
76.030
lnner diameter No. 1
(1.1024 1, 1032) No. 3 (2.7961 (2.8984 - (2.9929
ol camshaft - 2.7965) 2.8988) 2.9933)
b&aring No. 2 to 24.000 24.021 - Less than
No.5 (0.944~ 0.9457) Out-of-round
(X--Y) 0.015 (0.0006)
-
No. 1
27.935 27.955 ..
Outer diameler Less than
ol camshatt
(1.0998 1.1006)
- Taper (A- BJ
0.010 (0.0004)
-
journal No. 2 to 23.935 23.955 """""""""
No.5 (0.9423 0.9431} Diflerence in nner
0.2
diameter between 0.05 (0.0020)
Less than (0.008)
Camshalt runout (T.I.R.'J 0.1 (0.004} cytnders
0.02 (0.0008)

0.070 0.143
Camshalt end play 0.20 (0.0079)
(0.0028 0.0056)
': Total indicator readmg

EM-255
SERVICE DATA ANO SPECIFICATIONS {S.D.S.) GA
lnspectionand Adjustment(Cont'd)
PISTON, PISTON RING AND PISTON PIN Piston ring
Unt: mm (in)
Piston

----------
Unit: mm (in) Standard Limit
0.040 0.080
Top
Sde (0.0016 0.0031)
....... 0.2 {0.008)
crearance 0.030 - 0.070
2nd
(0.0012
_,, 0.0026)

[O]
0.20- 0.35
Top
(0.0079 0.0138)
0.37 - 0.52
End gap 2nd 1.0 (0.039)
{0.0146 0.0205}
A
11
- Oil
0.20 - 0.60
(0.0079 - 0.0236)

SEM6580

GA13DS GA14DS
GA16DS Piston pin
~ GA16DE Unit: mm (in)
Piston skirt diameter
18.989 19.001
"A" Piston pn outer diameter
{0.7476 0.7481)
Standard
Pston pin to pistn clearance
-0.004 to o
70.975 73.575 75.975- (-0.0002 to O)
70.985 73.585 75.985
Grade No. 1
(2.7943- (2.8966- (2.9911-
Piston pin to connectng roe, 0.005 - 0.017
bushing clearance (0.0002 0.0007)
2.7947) 2.8970) 2.9915)
70.985- 73.585 75.985-
70.995 73.595 75.995
Grade No. 2
(2.7947- (2.8970 (2.9915-
2.7951) 2.8974) 2.9919)
CONNECTING ROD
Unit: mm {in)
70.995- 73.595 75.995-
71.005 73.605 76.005 140.45- 140.55
Grade No. 3 Center distance
(2.7951- (2.8974- (2.9919 (5.5295 - 5.5335)
2.7955} 2.8978) 2.9923)
Bend limit [per 100 (3.94)] 0.15 {0.0059)
71.475- 74.075 76.475-
0.5 {0.020)ovar- 71.505 74.105 76.505 Torsion lmit {per 100 (3.94)1 0.3 (0.012)
size (servce) (2.8140 {2.9163- (3.0108- Connecting rod bushng inner 19.000 19.012
2.8152) 2.9175) 3.0120) dameter" (small end) (0.7480 - 0.7485)
71.975 - 74.575 76.975- Connecting rod big end nner 43.000 43.013
1.0 (0.039)over- 72.005 74.605 77.005 diameter {1.6929 - 1.6934)
size (servce) (2.8337- (2.9360- (3.0305
'Sde clearance
-
2.8348) 2.9372) 3.0317)
"a" dimension 9.5 (0.374) Standard 0.20 0.47 (0.0079 0.0185)

Piston pin hole inner Llmit 0.52 (0.0205)


18.987- 18.999 (0.7475 - 0.7480)
dameter : After mstalling m connecting rod
Pston pin outer di-
18.989- 19.001(0.7476 0.7481)
ameter
Piston to bore olear-
0.015 0.035 (0.0006 0.0014)
anee

EM-256
r'
SERVICE DATA AND SPECIFICATIONS (S.D.S.) GA

lnspectlonand Adjustment(Cont'd)
CRANKSHAFT MAIN BEARING
Unit: mm (in)
Standard
GA16DS

-------------
GA13DS GA14DS Thickness "T"
GA16DE Grade No. ldentificaton color
mm(n)
Man journal da. "Dm"
Grade No. O 1.826 - 1.830
49.956 - 49.964 (1.9666 - 1.9671) o (0.0719 - 0.0720)
Black
Grade No. 1 49.948 - 49.956 (1.9665 - 1.9668)
1.830 - 1.834
Grade No. 2 49.940 - 49.948 (1.9661 - 1.9665) 1 Brown
(0.0720 - 0.0722)
Pn joumal da. "Dp"
1.834 - 1.838
Grade No. O 39.968 - 39.974 (1.5735 - 1.5736) 2 Green
(0.0722 - 0.0724)
Grade No. 1 39.962 - 39.966 (1.5733 1.5735)
1.838 - 1.842
Grade No. 2 39.956 - 39.962 (1.5731 - 1.5733) 3 Yellow
(0.0724 0.0725)
40.85 - 40.85- 43.95 -
1.842 1.846
40.95 40.95 44.05 4 Blue
Center distance "r" (0.0725 - 0.0727)
(1.6083 - (1.6083 - (1.7303 -
1.6122) 1.6122) 1.7342)
Out-o-round (X - Y)
Standard Less than 0.005 (0.0002)
Undersize
Taper (A-B)
Unt: mm (in)
Standard Less than 0.002 (0.0001)
.
Runout [T.1.R.'J Thickness 'T'
Standard Less than o.os (0.0020) 0.25 (0.0098) 1.957 1.965 (0.0770 - 0.0774)
Free end play
0.50 (0.0197) 2.082 - 2.090 (0.0620 - 0.0823}
Standard 0.060 - 0.180 (0.0024 - 0.0071)
Limt 0.3 (0.012)

: Total ndicator reading

AVAILABLE CONNECTING ROO BEARING


Connecting rod bearing
Unt: mm (in)

Grade No. Thickness ldentflcaton color or number

o 1.505 - 1.508 (0.0593 - 0.0594) -


Standard 1 1.508 - 1.511 (0.0594 0.0595) Brown

2 1.511 - 1.514 (0.0595 - 0.0596) Green


0.08 (0.0031) 1.542 - 1.546 (0.0607 0.0609) 8
Underslze 0.12 (0.0047) 1.562 1.566 (0.0615 - 0.0617) 12
0.25 (0.0098) 1.627 - 1.631 (0.0641 - 0.0642) 25

Beartng clearance MISCELLANEOUS COMPONENTS


Unt: mm (in} Unt: mm (in)

Main bearing clearance Flywheel


Less than 0.15 (0.0059)
Runout {T.I.R.'J
0.018 - 0.042
Standard
(0.0007 - 0.0017) ': Total indicator reading

Limit 0.1 (0.004)

Connecting rod bearing otear-


ance
0.010 0.035
Standard
{0.0004 0.0014)

Limt AII 0.1 (0.004}

EM-257
SERVICE DATA ANO SPECIFICATIONS (S.D.S.) SR

General Specifications
-c-y-1in_d_e_r a-r-ra-ng_e_m_e-nt--------,n--l-in_e _4___ COMPRESSION PRESSURE
Unt: kPa (bar, kg/cm2, psi)/300 rpm
Displacement cm3 (cu in} 1.998 (121.92)

Bore and stroke


Valve arrangement
Firing order
mm (in) 86 X 86 (3.39
0.0.H.C.
1-3-4-2
X 3.39)

.
---------
Standard
SR20DE

1.275
(12.75, 13.0, 185)
. SR20DET

1,128
{11.28. 11.5, 164)

1,079 932
Number ol piston rngs Minimum
(10.79. 11.0. 156) (9.32. 9.5. 135)
Compression 2
....... -
Differential limit be-
98 (0.98, 1.0. 14)
Ol tween cylnders
Number of man bearings 5
Compression ratio
SR200E 10.0

SR20DET 8.3

EM-258
SERVICE DATA AND SPECIFICATIONS (S.D.S.) SR

tnspectionand AdJustment
CYLINDER HEAD VALVE
Unit: mm (in) Unit: mm (in)

Standard Limit
T
Lessthan
Head surface distor1ion 0.1 (0.004)
0.03 (0.0012)

----L ----t
SEM188

Nominal cytinder head height; Valve head diameter "D"


H ::::: 136.9 137.1 (5.390 - 5.398)
lntake 34.0 - 34.2 (1.339 - 1.346)
SEM956C
Exhaust 30.0 30.2 (1.181 - 1.189)

Valve length "L".


lntake
101.19 - 101.61
SR20DE
(3.9839 - 4.0004)
101.845 - 102.355
SR20DET
(4.0096 4.0297)
Exhaust
102.11 - 102.53
SR20DE
(4.0201- 4.0366)
102.765 - 103.275
SR20DET
(4.0459 4.0659)
Valve stem diameter "d"
ln!ake 5.965 - 5.980 (0.2348 0.2354)
Exhaust 6.945 - 6.960 (0.2734 - 0.2740)

Valve seat angle "a"


lntake
4515 - 45"45'
Exhaust
Valve margln "T"
lntake
SR20DE 1.1 (0.043)
SR20DET 1.3 (0.051)

Exhaust
SR200E 1.3 (0.051)
SR20DET 1.5 (0.059)
Valve margln ''T" limt More than 0.5 (0.020)
Valve stem end surface
Less !han 0.2 (0.008}
grnding lmt

EM-259
SERVICE DATA AND SPECIFICATIONS (S.D.S.) SR

lnspection and Adjustment(Cont'd)


Valve spring

-------------
SR200ET
SR200E.
lnner Outer

Free height mm (in) 49.36 (1.9433) 40.49 {1.5941) 47.74 (1.8795)

Pressure
N (kg, lb) at height mm (in}

569.00 641.57 154.95 174.76 451.51 504.18


Standard (58.02- 65.42, 127.93 144.25) (15.8 17.82, 34.84 39.29) (46.04 - 51.41, 101.52 - 113.36)
at 30.0 (1.181) at 20.6 (0.811) at 27.9 (1.098)

549.2 (56.0, 123.5) 147.1 (15.0, 33.1) 428.6 (43.7, 96.4)


Limit
at 30.0 (1.181) at 20.6 (0.811) at 27.9 (1.098)

Out-ol-square mm (in) Less than 2.2 (0.087) Less than 1.8 (0.071) Less lhan 2.1 (0.083)

Hydraulic lash adjuster (H.L.A.) Valve guide


Unit: mm (in) Unit mm (in)

16.960 - 16.993
H.L.A. outer diameter
(0.6685 - 0.6690)

17.000 17.020
H.L.A. gulde inner diameter
(0.6693 - 0.6701}

Ctearance between H.L.A. and H.L.A. 0.007 - 0.040


guide (0.0003 - 0.0016)

SEM0830

Standard Service
-
Valve guida

10.023 - 10.034 10.223 10.234


lntake
O u ter (0.3948 0.3950) (0.4025 0.4029)
diameter i:x- 11.023- 11.034 11.223 - 11.234
haust (0.4340 0.4344} (0.4418 - 0.4423}

Valve guide

lnner di- lntake 6.000 - 6.018 (0.2362 0.2369)


a meter
(Finished Ex 7.000 - 7.018 (0.2756 0.2763)
size) haust

9.975 - 9.996 10.175 10.196


Cylinder head lntake
(0.3927 - 0.3935) (0.4006 - 0.4014)
valve guide
hole diameter Ex- 10.975 10.996 11.175 - 11.196
haust (0.4321 0.4329) (0.4400 0.4408)

lnterlerence fit ot valve


0.027 - 0.059 (0,0011 - 0.0023)
gude

Standard Umit

0.020 0.053
lntake 0.1 {0.004)
Stem to guide (0.0008 0.0021)
clearance Ex- 0.040 0.073
0.1 (0.004)
haust (0.0016 - 0.0029)

Valve detlection limlt 0.2 (0.008)

Projecton length L" 14.0 - 14.2 (0.551 0.559)

EM-260
SERVICE DATA AND SPECIFICATIONS (S.D.S.) SR
lnspection and Adjustment(Cont'd)
Valve seat
Unit: mm (n}

~rhead

H
------o

Standard Standard

h
___ 29.35 - 29.65 1
(1.1555 1.1673)1
=+=== 1
31,4 - 31.6 (1.236 1.244) ie---- 26.8 'O.O (1.055 1.063)
44o53, - 450()7' 44o53, - 45o07'
33,6 33.8 ....., d 29,4 - 29.6 (1.157 1.165)
-..., d (1.323 1.331)

Contactlng width (W): 1.4 - 1.7 Contaetlng width (W): 1.7 2.0 (0.067 0.079)
(0.055 0.067)

OVersize OVersize

31.4 31.6 (1.236 - 1.244) ---- '26.8 - V.O (1.055 1.063)


'4453' 45o07' 1 44o53, - 450()7'
'33.6 - 33.8 J *29.4 29.6 (1.157 1.165)
..-d (1.323- 1.331) 1 i."-----d
Contactingwidth (W): 1.4 - 1.7
Contactng width (W): 1.7 - 2.0 (0.067 - 0.079)
(0.055 0.067) : Machlning data
SEM6510

Standard Service
In. 35.000 35.016 (1.3780 1.3786) 35.500 - 35.516 (1.3976 - 1.3983)
Cylinder head seat recess diameter (D)
Ex. 31.000 - 31.016 (1.2205 - 1.2211) 31.500 31.516 (1.2402 1.2408)
_,,,,....__.. ...

In. 0.064 - 0.096 (0.0025 0.0038)


Valve seat interference lit
Ex. 0.064 - 0.096 (0.0025 - 0.0038)
..
In. 35.080 35.096 (1.3811 1.3817) 35.580 - 35.596 (1.4008 1.4014)
Valve seat outer diameter (d) ...
Ex . 31.080 31.096 (1.2236 1.2242) 31.580 - 31.596 (1.2433 - 1.2439)
........ -
In. 6.25 (0.2461)
Depth (Hl
Ex . 6.25 (0.2461)
.........-.- ..,- .... """"""""""""
Height (h) 6.2 - 6.3 (0.244 - 0.248) 5.4 5.5 (0.213 0.217)

EM-261
SERVICE DATA AND SPECIFICATIONS (S.D.S.) SR

lnspection and AdJustment(Cont'd)


Valve clearance adjustment(For. SR20DE)
Unit: mm (in)
Rocker arm
Valve clearance gulde

lntake O (O)
Exhaust O (O)
Valve clearance
Adjustment valva limit ...Q.025 (--0.0010} ::i
(T)- (T,)""' [(T) - (T 1)1 ~ 0.025 (0.0010) Valve Valve

SEM0950

Available shims (For SR20DE)


T
Thickness mm (in) ldentification mark

28
2.800 (0.1102)
00

28
2.825 (0.1112)
25
lndlcete
2.850 (O. 1122)
28 T= 2.800 mm
50 (0.1102 In)
28 SEM0960
2.875 (0.1132)
75
29
2.900 (0.1142)
00
- 29
2.925 (0.1152)
25
-
29
2.950 (0.1161)
50
29
2.975 (0.1171)
75
30
3.000 (0.1181)
00

30
3.025 (0.1191)
_,, 25
30
3.050 (O. 1201)
50
30
3.075 (0.1211)
75
31
3.100 (0.1220)
00

31
3.125 (0.1230)
25
31
3.150 (0.1240)
50

31
3.175 (O. 1250)
75
32
3.200 (0.1260)-
00

EM-262
SERVICE DATA AND SPECIFICATIONS (S.D.S.) SR

lnspectionand Adjustment(Cont'd)

------
Valve clearance adjustment(For SR20DET)
Unlt: mm (in)

Hot Cold
Valveclearance
0.30- 0.35 0.21 0.26
lntake & Exhaust
{0.012 - 0.014) (0.008 - 0.010)
..................
Camshaltclearance
0.20 0.23 0.14- 0.17
lntake & Exhaust
(0.008 - 0.009) (0.006 - 0.007)
Shim Rocker arm
': Ata temperature of approximately 20c (68.FJ guide
Whenever valve ctearances are adjusted to cold speclflcatlona,
checkthat the clearances satlsly hot apecfflcatlon& and adjus1 agaln .___ .....,_ ..,_,
lfnecenary.

Available shlms and rocker arm guldes (For SR20DET)

Thckness ldentfcation Thickness ldentifcation Thickness ldentfcation


mm (in) mark mm(in) mark mm(n) marlc
""""""'
1.50 (0.0591) 1 2.175 (0.0856) 28 2.85 (0.1122) 55
1.525 (0.0600) 2 2.20 (0.0866) 29 2.875 (0.1132) 56
.. ..,.,......
_...,

1.55 (0.0610) 3 2.225 (0.0876) 30 2.90 (0.1142) 57


"'""
1.575 (0.0620} 4 2.25 {0.0886) 31 2.925 (0.1152) 58
1.60 (0.0630) 5 2.275 (0.0896) 32 2.95 (0.1161) 59

__ ... 1.625 (0.0640)


1.65 (0.0650)
6
7
2.30 (0.0906}
2.325 (0.0915)
33
34
2.975 (0.1171}
3.00 (0.1181)
60
61
..
1.675 (0.0659) 8 2.35 (0.0925) 35 3.025 (O.1191) 62
1.70 (0.0669) 9 2.375 {0.0935) 36 3.05 (0.1201) 63
1.725 (0.0679) 10 2.40 (0.0945) 37 3.075 (0.1211} 64
1.75 (0.0689) 11 2.425 (0.0955) 38 3.10 (0.1220) 65
1.775 (0.0699) 12 2.45 (0.0965) 39 3.125 (0.1230) 66
""""
1.80 (0.0709) 13 2.475 (0.0974) 40 3.150 (0.1240) 67
1.825 (0.0719) 14 2.50 (0.0984) 41 3.175 (0.1250) 68
1.85 (0.0728) 15 2.525 (0.0994) 42 3.20 (0.1260) 69
1.875 (0.0738) 16 2.55 (0.1004) 43 3.225 (0.1270) 70
- 1.90 (0.0748) 17
""
2.575 (0.1014) 44 3.25 {0.1280} 71
....
........
1.925 (0.0758) 18 2.60 (0.1024) 45 3.275 (0.1289) 72
......
1.95 (0.0768) 19 2.625 (0.1033) 46 3.30 (0.1299} 73
1.975 {0.0778) 20 2.65 (0.1043) 47 3.325 (0.1309) 74
2.00 {0.0787) 21 2.675 (0.1053) 48 3.35 (0.1319) 75
-
2.025 (0.0797) 22 2.70 (0.1063} 49 3.375 (0.1329} 76
-
i
2.05 (0.0807) 23 2.725 (0.1073) 50 3.40 (0.1339) 77
- - 78
2.075 (0.0817) 24 2.75 (0.1083) 51 3.425 (0.1348)
! ..
2.10 (0.0827) 25 2. 775 (0.1093) 52 3.45 (0.1358) 79
2.125 (0.0837) 26 2.80 (0.1102) 53 3.475 (0.1368) 80
2.15 (0.0846) 27 2.825 (0.1112} 54 3.50 (0.1378)
- 81

EM-263
SERVICE DATA AND SPECIFICATIONS (S.D.S.) SR

lnspection and Adjustment(Cont'd).


CAMSHAFT AND CAMSHAFT BEARING Valve tming
Unit: mm {in)

Standard Limit

Camshaft journal to bear- 0.045 - 0.066


0.12 (0.0047)
ng clearance (0.0018 - 0.0034}
lnner diameter ol cam- 28.000 28.021
shaft bearing (1.1024 - 1.1032)
Outer diameter of cam- 27.935 27.955
shaft journal (1.0998 - 1.1006)
Less than
Camshalt runout (T.I.R.'J 0.1 (0.004)
0.02 {0.0008)

Camshaft sprocket runout Less lhan EM120


[T.1.R.'] 0.25 (0.0098} a.o.e. Unit: degree

0.055 - 0.139 a b e d e
Camshaft end play 0.20 (0.0079}
(0.0022 0.0055)
SR20DE 240 248' 9 59 9 51
SR20DET 248' 248 14 54 a so

EM671

Cam height "A''

lntake

SA20DE 38.408 - 38.598 (1.5121 - 1.5196)


SR20DET 38.648 38.838 (1.5216 - 1.5291)
Exhaust

SR20DE 37.920 38.110 (1.4929 1.5004)


SR20DET 38.648 - 38.838 (1.5216 - 1.5291)
Wear limit of cam height 0.2 (0.008)
Valve Hft

lntake

SR20DE &
10.0 {0.394)
SR20DET
Exhaust

SR20DE 9.2 (0.362)


SR200ET 10.0 (0.394)
*Total indicator reading

EM-264
SERVICE DATA AND SPECIFICATIONS (S.D.S.) SR

lnspectlon and AdJustment (Cont'd)


CYLINDER BLOCK PISTON, P-ISTON RING ANO PISTON PIN
Unit: mm (in)
Available piston
Unt: mm (in)

a
SEM0080
y

SEM750C

Plston skirt diameter "A"

Standard
Grade No. 1 85.980 85.990 (3.3850 3.3854)
Grade No. 2 85.990 86.000 (3.3854 3.3858)
SEM6860 Grade No. 3 86.000 - 86.010 (3.3858 - 3.3862)
Surface ffatness 0.20 (0.0079) over-
86.180 86.210 (3.3929 3.3941)
sze (Service)
Standard Less than 0.03 (0.0012)
"a" dirnension 14.0 (0.551)
Limit 0.10 (0.0039)
Plston clearance to cylin-
Cylinder bore 0.010 - 0.030 (0.0004 0.0012)
der block
lnner dameter
Pston pin hole dlameter 21.987 21.999 (0.8656 0.8661)
Standard

Grade No. 1 86.000 - 86.010 (3.3858 3.3862)


Grade No. 2 86.010 86.020 (3.3862 3.3866)

Grade No. 3 86.020 - 86.030 (3.3866 - 3.3870)

Wear limit 0.20 (0.0079)


Out-ot-round (X - Y) Less than 0.015 (0.0006)
Taper(A- B-C) Less than 0.010 (0.0004)
Difference in lnner di-
ameter between cylin-
ders

Limit Less than O.OS (0.0020)


Main journal nner
diameter

Grade No. O 58.944 58.950 (2.3206 - 2.3209)

Grade No. 1 58.950 - 58.956 (2.3209 - 2.3211)

Grade No. 2 58.956 58.962 (2.3211 - 2.3213)

Grade No. 3 58.962 - 58.968 (2.3213 2.3216)

EM-265
SERVICE DATA AND SPECIFICATIONS (S.D.S.) SR

lnspectlonand Adjustment(Cont'd)
Piston rlng CONNECTING ROD
Unt: mm (in} Unit: mm (in)

Side clearance Center distance 136.30 (5.3661)

Top Bend, torson [per 100


(3.94)]
Standard
0.045 o.oso
(M018 0.0031} Lmit 0.15 {0.0059)

Limit 0.2 (0.008) Torson [per 100 (3.94)]


2nd Lmit 0.3 (0.0012)

0.030 - 0.065 Connecting rod small end


Standard 24.980 25.000 (0.9835 - 0.9843)
(0.0012 - 0.0026) inner diameter
-
Lmit 0.2 (0.008) Piston pin bushing nner
22.000 22.012 (0.8661 0.8666)
dlameter"
Ring gap
Conneclng rod big end
Top 51.000 - 51.013 {2.0079 2.0084)
inner diameter
Standard 0.20 0.30 (0.0079 0.0118)
Sde clearance
Lmit 1-0 (0.039)
Standard 0.20 0.35 (0.0079 0.0138)
2nd
Limit 0.5 (0.020)
Standard 0.35 - 0.50 (0.0138 0.0197)
After mstalhng in connectmg rod
Limit 1.0 (0.039)

Oil

Standard 0.20 0.60 (0.0079 0.0236)

Lmit 1.0 (0.039)

Piston pin
Uoit: mm (in)

Piston pin outer dameter 21.989 22.001 (0.8657 0.8662)

lnterference fit of piston pin


O 0.004 (O 0.0002)
to piston

Pston pin to connectng


rod bushng clearance

Standard 0.005 0.017 (0.0002 0.0007)

Limit 0.023 (0.0009)

Values measured at ambent temperature of 2oc (68.F)

EM-266
SERVICE DATA AND SPECIFICATIONS (S.D.S.) SR

lnspectionand Adjustment(Cont'd)
CRANKSHAFT AVAILABLE MAIN BEARING
Unt: mm (in}

Main journal dia. "Om"


Grade No. O 54.974 - 54.980 (2.1643 - 2.1646)
Grade No. 1 54.968 - 54.974 (2.1641 - 2. 1643)
Grade No. 2 54.962 - 54.968 (2.1639 - 2.1641)
Grade No. 3 54.956 - 54.962 (2.1636 - 2.1639}
Pin journal dla. "Dp''
Grade No. O 47.968 - 47.974 (1.8885 - 1.8887)
Grade No. 1 47.962 - 47.968 (1.8883 - 1.8885)
Grade No. 2 47.956 - 47.962 (1.8880 - 1.8883)
Center distance "r" 42.96 - 43.04 (1.6913 - 1.6945)
SEM6850
Out-ot-round (X - Y)
Standard
SR200E
Less than 0.005 (0.0002}
(Main & pin journal)
Maln bearlng (Standard)
SR20DET (Maln journal) Less than 0.005 (0.0002)
Unit: mm (in)
SR20DET (Pin journal) Less than 0.0025 (0.0001)
Taper (A- B) Grade ldentification
Thickness "T" Width"W"
Standard number color (mark)

SR20DE 1.977 - 1.980


(Main & pin Journal)
Less lhan 0.005 (0.0002) o (0.0778 0.0780)
Black (A)

SR20DET (Man journal) Less than 0.005 (0.0002) 1.980 - 1.983


1 Brown (B)
SR20DET (Pin journal) Less than 0.0025 (0.0001) (0.0780 0.0781)
Runout [T.1.R.J 1.983 - 1.986
2 Green (C)
Standard Less than 0.025 {0.0010) {0.0781 - 0.0782)

Umit Less than O.OS (0.0020) 1.986 1.989 18.9 - 19.1


3 Yellow (O)
Free end play (0.0782 - 0.0783) (0.744 - 0.752)

Standard 0.10 - 0.26 (0.0039 - 0.0102) 1.989 - 1.992


4 Blue (E)
{0.0783 0.0784)
Limit 0,30 (O.O 118)
1.992 - 1.995
Dm 5 Pink (F}
(0.0784 0.0785)

1.995 - 1.998
6 No color (G)
(0.0785 - 0.0787}

Maln bearing (Undersize)


Unit: mm (in)
Dp Main journal
Undersize Thickness ''T"
dlameter "Dm"
SEM954C
Out-of-round X- Y Grind so that bear-
Teper A-B 2.109-2.117
0.25 (0.0098) ing clearaoce is the
{0.0830 - 0.0833)
specfied value.
A B

EM715

EM-267
SERVICE DATA AND SPECIFICATIONS (S.D.S.) SR
lnspectionand AdJustment (Cont'd)
AVAILABLECONNECTING ROD BEARING MISCELLANEOUS COMPONENTS
Unt: mm {in)
Connecting rod bearlng
Camshaft sprocket runout limt
Standard slze {T.I.R.]
0.25 (0.0098)
Unt: mm {in}
Flywheel runout limit [T.I.R.J 0.1 (0.004)

Thickness "T" Identifica


Grade
Width "W" ton
number SA200ET
SR20DE color (mark)

1.500 1.503 1.495 - 1.498


o {0-0591 {0.0589 - No color (A)
0.0592) 0.0590)

1.503 - 1.506 1.498 1.501 16.9 17.1


1 (0.0592 (0.0590 (0.665 Black (B}
0.0593) 0.0591) 0.673)

1.506 - 1.509 1.501 1.504


2 (0.0593 (0.0591 Brown (C)
0.0594) 0.0592)
!

Undersize
Unit: mm (in)

Thlckness 'T" Crank po


Undersize journal diame-
SR20DE SA20DET ter "Dp"
. ..
1.541 - 1.549 1.536 - 1.544
0.08 {0.0031) (0.0607 - (0.0605
0.0610) 0.0608)
Grind so that
1.561 - 1.569 1.556 - 1.564 bearing crear-
0.12 (0.0047) (0.0615 (0.0613 anee is the
0.0618) 0.0616) specfed
--- value.
1.626 - 1.634 1.621 - 1.629
0.25 (0.0098) (0.0640 (0.0638-
0.0643) 0.0641)

Bearing clearance
Uot mm {In)

Man bearing clearance

Standard 0.004 - 0.022 (0.0002 - 0.0009)

Lmit 0.05 (0.0020)

Connecting rod bearing clear-


ance

Standard

SR20DE 0.020 - 0.045 (0.0006 0.0018)

SR20DET 0.030 0.055 (0.0012 0.0022)

Limit 0.09 (0.0035)

EM-268
SERVICE DATA ANO SPECIFICATIONS (S.D.S.)

General Speclfications
Cylinder arrangement 4, n-lne
Dsplacement cm3 (cu in) 988 (60.29}

Bore and stroke mm (in} 73 X 59 (2.87 X 2.32}


Valve arrangement S.O.H.C.
Firlng creer 1-3-~2

Number of piston Compresson 2


rings Ol 1
Number of main bearings 5
Compression ratio 9.0

lnspection and Adjustment


ENGINE COMPRESSION PRESSURE VALVE
Unit: kPa (bar, kg/cm2, psi)f350 rpm Unit: mm {n)

1,245 (12.45, 12.7,


Standard T
181)

Mnimum 981 (9.81, 10.0. 142}


Difference limit between cylinders 98 (0.98. 1-0. 14) Q

--------
CYLINDER HEAD
Unit: mm (in)

Standard Llmit i.----- L ---


less than
-
Headsurtace flatness o. 1 (0.004) SEM188
0.03 (0.0012)
119.9 120.1 Valve head dame- lntake 35 (1.38)
Height
(4.720 - 4.728} - ter "D" 29 (1.14)
Exhaust
....,_,_ ~---
118.98 - 119.28
lntake
(4.6842 4.6961)
vaive length "L"

__ ,,,,
Exhaust
118.28 118.88
(4.6567 4.6803}
6.970 6.985
lntake
Valve stem diame- (0.2744 0.2750)

___
ter "d" 6.945 - 6.960
Exhaust
,,_ _..,, __ (0.2734 0.2740)

Valve seat angle lntake


4515' - 4545
.. a." Exhaust
Valve margin "T" Limit 0.5 (0.020)
Valve stem end surtace grinding lmit 0.2 (0.008)
.
0.28 (0.011)
lntake
Valve clearance ro.22 (0.009)]
(Hot) [' 1 Cold] 0.28 (0.011)
Exhaust
ro.22 (0.009)1
: Used as approxmate values during engine assembly, olear-
ances should ultimately be adjusted to the above hot values.

EM-269
SERVICE DATA AND SPECIFICATIONS (S.D.S.)
lnspection and Adjustment(Cont'd)
Valve spring Valve seat
Unit: mm (in)
Free heght mm (in) 46.70 (1.8386)
Pressure
N (kg. lb) at heght mm {in) INTAKE
568.8 {56.0, 127.9) 30
Standard
at 30.2 (1.189)
521.7 (53.2, 117.3) 45
Urnit 50
at 30.2 (1.189)
Out-ct-square "S" mm (in} 2.0 (0.079)

1 32.4 32.6 (1.2756 1.2835) dia.


.. 1
Valve guide 34.5 34.7 {1.3583 1.36611 dia.
Unit: mm (in) 1

---------
37 .500 37 .516 (1.4764 -1.47701 dia.

Standard Servce
1

Valve gude
SEM737
12.033 12.044 12.256 12.274
Outer diameter EXHAUST
(0.4737 - 0.4742) (0.4825 0.4832)
lnner diameter
7.005 7-020 (0.2758 0.2764)
(Finished sizeJ
Cylinder head valve 11.970 11.988 12.200 12.211 45
guide hole diameter (0.4713 0.4720) (0.4803 0.4807)
lnterference flt of valve 50
0.045 - 0.074 {0.0018 0.0029)
gude
Standard Max. tolerance
0.02 0.05
lntake
Stem to gude (0.0008 0.0020)
0.10 (0.0039) 28.5-28.7
clearance Ex- 0.045 0.075
11.122 - 1.130) da.
haust (0.0018 0.0030)
Valve deflecton limil 31.600 -31.51111.2402 1.24061 da.
0.2 (0.008)
{Dial indicator readng) SEM738

Cylinder head machining data


for 0.5 (0.020) oversze

Rocker shaft and rocker arm


Unit: mm (in)

Rocker sha1t
19.979 20.000
Outer diameter
(0.7866 0.7874)
Rocker arm

___ lnner diameter


,,,,,

Clearance between roeker arm


,
20.007 20.028
(0.7877 - 0.7885)
0.007 0.049
_
and rocker shaft (0.0003 0.0019)

EM-270
SERVICE DATA AND SPECIFICATIONS (S.D.S.)
lnspectlon and Adjustment (Cont'd)
CAMSHAFT ANO CAMSHAFT BEARING JACKSHAFT ANO JACKSHAFT BUSHING

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

Standard . Max. tolerance


---- Standard Max. tolerance
0.035 0,076
No. 0.020 - 0.098
(0.0014 - 0.15 (0.0059} Jackshaft [ournat FA
Camshafl jour- 1. 3. 5 (0.0008 0.0039)
0.0030) to bushing olear- 0.20 (0.0079)
nal to bearing 0.020 - 0.098
0.078-0.119 anee RR
clearance No. (0.0008 0,0039)
2,4
(0.0031 -
0.0047}
0.20 (0.0079}
FR 32.020 - 32.085 (1.2606 - 1.2632}
-
lnner diameter of
42.000 42.025 jackshatt bushng AR 28.620 - 28.685 (1.1268 - 1.1293)
lnner dameter ot camshatt
(1.6535 - -
bearing
1.6545} Outer diameter of FR 31.987 - 32.000 (1.2593 - 1.2598)
jackshaft journal RR 28.587 28,600 (1.1255 1.1260)
INo.
41.949 - 41.965 ---- ..
1, 3. 5
(1.6515
Jackshaft end play
0.045 0.105 ...._
Outer diame- 1.6522) (0.0018 0.0041)
ter of camshaft
41.906 41.922
- Fuel pump cam
journal No.
(1.6498 -
2, 4
1.6505)
---- Less than
Camshaft bend {T.I.A."J 0.1 (0.004)
0.02 (0.0008)
"A"
0.15 - 0.29
Camshaft end play (0.0059 0.4 (0.016)
0.0114)

SEM734
27.7 27.8 ..... ,
Cam height "A"
(1.091 1.094)

CYLINDER BLOCK
Un!: mm (in)
EM671

Cam heght lntake 35.71 35.96 (1.4059 1.4157)


"A"
~-~--....._-~---+---~
cam
Wear lmit of
Exhaust

height
35.43 - 35.68 (1.3949 1.4047)

0.2 (0.008)

'Total ndicator readng

Valve timing

SEM378B

Standard Less than 0.05 (0.0020)

__..
Surface flat-
ness
--
, ..... Limt 0.10 (0.0039}

Height "H" 188.95 189.05 (7.4390 7.4429)


-
lnner diameter 73.00 73.05 (2.8740 - 2.6760)

Out-ot-round
Cylinder bore Less than 0.02 (0.0008)
(X-Y)
.
Taper (A- B) Less than 0.015 (0.0006)

Difference in inner diameter


EM120 Less than 0.05 (0.0020)
B.D.C. Unit: degree between cyllnders

a b e d e
237" 236 39 o 57'

EM-271
SERVICE DATA AND SPECIFICATIONS (S.D.S.) E

lnspectlonand AdJustment(Cont'd)
PISTONRING AND PISTON PIN Pistonpin
Unlt: mm (n)
Piston
Unt: mm {In) 17.445 17.450
Piston pin outer dameter
(0.6868 0.6870)
0.006 0.010
Pston pin to piston clearance
(0.0002 0.0004)
loterference fit of pston pin to 0.017 0.038
connecting rod (0.0007 0.0015)

CONNECTINGROO
Unlt: mm (in)

Center dstance 1s1.5 (s.1n2


Bend, torsion
Limit 0.05 (0.0020)
[per 100 (3.94)]
SEM646
17.412 17.428
72.967 73.017 Pston pin bore dla.
Standard (0.6855 0.6861)
{2.8727 2.8747)
Piston skrt Standard 0.1 0.37 (0.0039 0.0146)
0.25 73.217 73.287 Big end play
diameter
Oversze {0.0098) (2.6826 - 2.8853) Limit 0.5 (0.020)
"A"
for servce o.s 73.467 - 73.517
{0.020) (2.8924 - 2.8944)
"a" dlmension 10.6 (0.417)
17.452 - 17.459
Piston pin hole dameter
(0.6871 0.6874)
0.023 0.043
Piston clearance to cylinder block
(0.0009 0.0017)

Plston ring
Unit: mm (In)

---------
Side
ctear-
Top
Standard
0.040 0.073
(0.0016 0.0029)
Limit

0.2
(0.008)
anee 0.030 - 0.063
2nd
(0.0012 0.0025)
Type 1: 0.14 0.26
(0.0055 0.0102)
Top
Type 2: 0.20 0.30
(0.0079 0.0118)
Type 1: 0.28 0.37
1.0
Ring gap (0.0110 0.0146)
2nd (0.039)
Type 2: 0.15 0.25
(0.0059 0.0098)
0.20- 0.60
Ol
(0.0079 0.0236)
{rall ring)

Type 1, Type 2: Refer to page EM-90.

EM-272
SERVICE DATA AND SPECIFICATIONS (S.D.S.) E

lnspection and Adjustment(Cont'd)


CRANKSHAFT Main bearing size

-----
Unit: mm (in) Unit; mm (in)

Man journal da. "Om''


49.940 49.964
{1.9661 -1.9671)
---- Thickness

1.620 1.840
Standard
39.961 39.974 (0.0717 0.0724}
Pin journal dia. "Dp"
(1.5733 - 1.5738)
1.943 1.949
Undersze 1 0.25 (0.0098}
{0.0765 0.0767)
Center distance "r" 29.5 (1.1614)

Out-of-round Standard Less than 0.01 (0.0004)


{X-Y) and
taper (A- B) Limit 0.03 (0.0012)
Connecting rod bearing size
Standard Less than 0.04 (0.0016)
Bend {T.1.A.*J Unit: mm (in)
Limit 0.08 (0.0031)
Thlckness
Standard 0.05 - 0.165 (0.0020 0.0065}
Free end play
Limit 0.30 (0.0118) 1.499 1.508
Standard
(0.0590 - 0.0594)

1.615 1.623
Undersize 1 0.25 {0.0098) {0.0636 0.0639)

r
MISCELLANEOUS COMPONENTS
Unt: mm {in)

Camshaft pulley
Less than 0.1 (0.004)
Runout [T.I.R.')
SEM645 Flywheel
Outof-round X - Y Less than 0.15 (0.0059)
Taper A-B
Runout {T.I.R.
: Total indicator reading

A B

EM715

': Total lndicator readng

BEARING

-----
Bearing clearance
Unit: mm (in)

Standard Limit

Main bearing clear-


anee

0.031 0.056 0.10


No. 1, 3, 5
(0.0012 0.0022) (0.0039)

0.031 0.092
No.2,4
(0.0012 0.0036)

Connectlng rod bear- 0.016 0.052 0.12


ng clearance (0.0007 0.0020} (0.0047)

EM-273
SERVICE DATA ANO SPECIFICATIONS (S.D.S.) CD I
lnspection and Adjustment - CD17
COMPRESSION PRESSURE VALVE
Unit kPa (bar, kg/cm2, psi) at 200 rpm Unit mm (in)

Standard 3, 138 (31.4. 32. 455) T


Limt 2,452 (24.5, 25. 356)
Difference limit
between cyllnders
490 (4.9, s. 71) Q

CVLINOER HEAO
Unt: mm (in)

Head surface flatness


----L
Standard Less than 0.05 (0.0020}
SEM188
Limit 0.1 (0.004)
Va!ve head diameter "D"
Nominal cylinder nead
116.6- 117.0 (4.591 4.606) lntake 38.00 (1.4173)
height
Exhaust 31.00 (1.2205)

Valve length "L"


CAMSHAFT ANO CAMSHAFT BEARING lntake & Exhaust
100.55 100.85
Unt: mm (in) (3.9587 3.9705)

Standard Max. toterance Va!ve stem diameter "d"

Camshaft journal 0.045 - 0.086 6.965 6.980


0.1 (0.004)
lntake
clearance (0.0018 0.0034) (0.2742 02748)

lnner dameter of 30.000 30.021 6.945 6-.960


Exhaust
camshaft bearing (1.1811 - 1.1819) (0.2734 0.2740)
Valv seat angle "(X" 4530
Outer diameter of 29.935 29.955
camshaft journa! (1.1785- 1.1793} Valve margin "T" limlt 0.5 (0.020)
Less than Valve stem end surface grindng
Camshaft runout
0.02 (0.0008)
o.os {0.0020) 0.5 (0.020)
limit
0.06 0.17 Va!ve seat contact width
Camshatt end play 0.17 (0.0067)
(0.0024 0.0067).
lntake 1.7 (0.067)
Exhaust 1.8 (0.071)

EM671

Cam height "A"

lntake 44.45 44.50 (1.7500 1.7520)


Exhaust 45.45 45.50 (1,7894 1.7913)
Wear limit of cam heght

lntake 44.300 (1.7441)

Exhaust 45.300 (1.7835)

EM ..274
SERVICE DATA AND SPECIFICATIONS (S.D.S.) CD
lnspectlon and Adjustment - CD17 (Cont'd)
Valve spring Valve seat fesurfacing
Unt: mm (in)
Free height mm (in}
fnlake
Outer 46.40 (1.8268)
lnner 43.20 (1.7008) Standard IOriginel)

Standard Limit

Assembled heght
mm/N (mm/kg, in/lb)

39.51150.0 39.51125.5
Ouler (39.5115.3, (39.5112.8.
1.555/33.7) 1.555/28.2)
36.0/85.3 36.0/71.6 35.6 35.8 (1.402 1.409}
lnner (36.0/8.7, (36.017.3,
1.417/19.2) 1.417116.l) 0.5 (0.0201 O\lel'$lze
Out-ot-square "S" A0.3 0.5
mm (in) 0.012 0.020)
38.43 38.45 (1.5130 1.5138!
Outer 2. 1 (0.083)

lnner 1.9 {0.075)

Valve guide 11.t


Unil: mm (in) 10.437)

Standard Service
2.8:t0.05 I l
Valve guide (O. t 102t0.0020) __ 35_.6__3_5.8_1_.402
__ _1._409_
11.023 11.034 11.223 11.234 : Cylinder had machinng dllta
Outer diameter
(0.4340 0.4344} (0.4418 0.4423)
SEM917
vaive guide
Exhaust
lnner diameter 7.000 - 7.015
{Finished sue) {0.2756 0.2762) Standard (Original!
Cylinder head valve 10.975 - 10.996 11.185 11.196
guide hole diameter (0.4321 0.4329) (0.4404 - 0.4408)
lnterference fil of valve 0.027 - 0.059
guide
~-~---~-~~~~
(0.0011 - 0.0023)

Max.
Standard tolerance

Stem to guide clear- 2.9:0.05


ance (0.1142:1:0.0020)..l,,,ii;jlt.-+-----+---

0.020 - 0.050 30.6 30.8 (1.205 1.213)


lntake 0.10 (0.0039)
(0.0008 0.0020}
0.5 (0.020) Oversize
0.040 0.070


Exhaust 0.10 (0.0039} R0.3 0.5
(0.0016 - 0.0028)
(0.012- 0.()20)
Valve deflection lmit 0.1 (0.004) 34A6 34.4711.3563 1.35711

11.4
(0.449)

2.9:1:0.0S
(0.11420.0020)......30.6- 30.S (1.205-1.213)
_
SEM918
: Cylinder hud machlning data

EM-275
SERVICE DATA ANO SPECIFICATIONS (S.D.S.) CD
lnspection and Adjustment- CD17 (Cont'd)
VALVE LIFTER CYLINDER BLOCK
Unit: mm (in) Unit: mm (in)

Valve lifter outer diameter


34,959 34,975
Standard
(1,3763 1,3770)
Cylinder head valve lifter hole 34.988 35.013
diameter (1.3775 1.3785)
Clearance
0.013 0.054
Standard
(0.0005 0.0021)
Limit 0.1 (0.004)

SEM902
Standard Limit
Surface flatness Less than O.OS (0,0020) O. 10 (0,0039)
Grade No. 1
80.000 - 80.010
(3.1496 3,1500)
Grade No. 2
80.010 80.020
(3.1500 3.1504)
Grade No, 3
lnner
diameter 80.020 80.030 -
(3.1504 3.1508)
Cylinder Grade No. 4
bore 80.030 80.040
(3.1508 3,1512)
Grade No, 5
80,040 80.050
(3, 1512 3, 1516)
Out-ot-
round Less than 0,02 (0.0008) 0.04 (0.0016)
(X- Y)
Taper
Less than 0.02 {0.0008) 0.04 (0.0016)
{A- B)
Difference In lnner
diameter between Less than O.OS (0,0020) 0.2 (0.008)
cylinders
Piston to cylinder o.os- 0.07
-
cearance (0.0020 - 0.0028)
Feeler gauge extract-
ing force {with gauge
thickness 0,06 mm
7.8 14.7
(0.8 1.5. 1.8 3.3) -
(0.0024 in)] N (kg. lb)
Grade No. O
56,654 56.663
(2,2305 2.2308)
Grade No. 1
Main journal inner
diameter 56.663 56.672 -
(2.2308 - 2.2312)
Grade No, 2
56,G72 56.680
(2.2312 2.2315)

EM-276
SERVICE DATA AND SPECIFICATIONS (S.D.S.) CD
lnspeclionand Adjustment- CD17 (Cont'd)
PISTON, PISTON RING AND PISTON PIN Piston pin
Unt: mm (in)
Piston
Unit: mm {in) 23.994 - 24.000
Piston pin outer dameter
(0.9446 - 0.9449)
Grade No. 1 79.94 79.95 (3.1472 3.1476)
lnter1erence fil o pston pin to
Grade No. 2 79.95 - 79.96 (3.1476 - 3.1480)
O - 0.004 (O 0.0002)
piston

Standard Grade No. 3 79.96 79.97 (3.1480 - 3.1484) Pistan pin to connectng roe 0.025 - 0.044
Pston
clearance (0.0010 0.0017)
skirt Grade No. 4 79.97 79.98 (3.1484 - 3.1488)
diam- Grade No. 5 79.98 79.99 (3. 1488 - 3.1492)
eter
Standard 79.96 80.01 (3.1480 - 3.1500)

Oversize 0.5 (0.020) 80.44 80.49 (3.1669 - 3.1689)


CONNECTING ROD
Unt: mm (in)
,.o (0.039) 80.94 80.99 (3.1866 3.1886)
Measure position (From Top) 60 (2.36) Bend [per 100 mm (3.94 in}]

23.991 23.999 Standard Less than 0.15 (0.0059)


Piston pin note dlameter
(0.9445 - 0.9448) Torson

Standard Less than 0.30 (0.0118)

24.025 24.038
Piston pin bore dia.
Plston ring (0.9459 0.9464)
Unit: mm (in} Bg end play

Side clearance
Lmit 0.3 (0.012}

Top

Standard 0.020 - 0.060 (0.0008 0.0024)

limit 0.20 (0.0079)


CRANKSHAFT
Unit: mm (in}
2nd

Standard 0.040 - 0.080 (0.0016 - 0.0031) Grade No. O


52.967 - 52.975
limt 0.15 (0.0059) (2.0853 2.0856)
Oil Grade No. 1
Main journal da. 52.959 - 52.967
Standard 0.030 - 0.070 (0.0012 - 0.0028) (2.0850 2.0853)
Lmit 0.10 (0.0039) Grade No. 2
52.951 52.959
Ring gap
(2.0847 2.0850)
Top 44.961 44.974
Pin journal da.
Standard 0.20 - 0.35 (0.0079 - 0.0138) (1.7701 1.7706)

Limit 1.0 (0.039) Out-of-round (X - Y) and


taper (A - B)
2nd
Standard Less than 0.005 (0.0002)
Standard 0.20 - 0.35 (0.0079 - 0.0138)
Limit 0.03 (0.0012)
Lmit 0.7 (0.028)
Runout
Oil
Standard Less than 0.05 (0.0020)
Standard 0.30 0.45 (0.0118 - 0.0177)
Lmlt 0.03 (0.0012)
Llmit 0.6 (0.024)
Free end play

Standard 0.05 0.18 (0.0020 - 0.0071)

Llmit 0.3 (0.012)

EM-277
SERVICE DATA AND SPECIFICATIONS (S.D.S.) CD
lnspection and Adjustment- CD17 (Cont'd)
AVAILABLE MAIN BEARINGS
No. 1, No. 2, No. 4 and No. 5 main bearings

Grade number Thickness "T" mm (in) Wldth "W" mm (in) ldentificatlon color
o 1.816 1.820 (0.0715 - 0.0717) Black
1.820 1.824 (0.0717 0.0718) Brown
2 1.824 1.828 (0.0718 0.0720) 22 (0.87) Green
3 1.828 1.832 (0.0720 0.0721) Yellow
4 1.632 1.836 (0.0721 0.0723) Blue

No. 3 main bearlngs

Grade number Thickness T" mm (in) Width w" mm (in) ldentitication color
o 1.816 1.820 (0.0715 0.0717) Black
1.820 1.824 (0.0717 0.0718) Brown
2 1.624 1.828 (0.0718 - 0.0720) 24 {0.94) Green
3 1.828 1.832 (0.0720- 0.0721) Yellow
4 1.832 1.836 (0.0721 0.0723) Blue

Main bearing undersize Bearing clearance


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

Crank journal dlameter Main bearog clearance


52.951 52.975 0.039 0.065
STO Standard
(2.0847 2.0856} (0.0015 0.0026)
52.701 52.725 Limt 0.12 (0.0047)
0.25 (0.0098} undersize
(2.0748 2.0758)
Connectng rod bearng clearance
0.024 0.066
Standard
(0.0009 0.0026)
Connecting rod bearlng undersize Umit 0.12 (0.0047)
Unt: mm (in)

Crank pin diameter


44.961 44.974 MISCELLANEOUS COMPONENTS
STO Unt: mm (in)
(1.no1 - 1.11001
44.881 44.894
0.08 {0.0031) undersize Camshaft sprocket
(1.7670 1.7675)
Runout fT.I.R!J Less than 0.1 (0.004)
44.841 44.854
0.12 (0.0047) undersze
(1.7654 1.7659) Flywheel
44.711 44.724 Runout [T.I.R!) Less than O, 15 (0.0059}
0.25 {0.0098) undersize
(1.7603 1.7608)
: Total indcator readlng

EM-278
SERVICE DATA ANO SPECIFICATIONS (S.D.S.) CD

lnspection and Adjustment- CD20


COMPRESSION PRESSURE VALVE
Unit: l<Pa (bar, kgtcm2, psi} at 200 rpm Unt: mm (In)

Standard 3, 138 (31.4. 32, 455)


T
Umit 2,452 (24.5, 25, 356)
Diflerence limit
490 (4.9, 5, 71)
between cylinders Q

CYLINDER HEAD
Unit mm (in)

Head surlace flatness i-----L


Standard Less than O.OS (0.0020)
SEM188
limit 0.1 (0.004)
Valve head dameter "D"
Nominal cylinder head 137.9 - 138.1
height (5.429 - 5.437) lntake 39.0 - 39.2 ( 1.535 - 1.543)
Exhaust 32.0 - 32.2 (1.260 - 1.268)
Valve length "L"
CAMSHAFT ANO CAMSHAFT BEARING lntake
100.53 - 100.97
Unt: mm (In) (3.9579 - 3.9752)

Max. tolerance 100.38 - 100.82


Standard Exhaust
(3.9520 - 3.9693)
Camshafl journal 0.045 - 0.086
0.1 (0.004) Valve stem diameter "d"
clearance (0.0018 - 0.0034)
lnner diameter ol 30.000 30.021
6.965 - 6.980
lntake
camshaft bearng (1.1811-1.1619} (0.2742 - 0.2748)

Outer dlameter ol 29.935 29.955 6.945 - 6.960


Exhaust
camshaft journal (1.1785 1.1793} (0.2734 - 0.2740)
----- ..-- Valve seat angle "o:" 4530'
Less than
Camshaft runout 0.05 (0.0020)
0.02 (0.0008) Valve margin "T" lmit 0.5 (0.020)
---------------- ..---------
0.115 - 0.188 Valve stem end surface grinding
Camshaft end play 0.5 (0.020)
(0.0045 0.0074) lmit

EM671

Cam heght "A"


lnlake 49.20 - 49.30 (1.9370 - 1.9409)

Exhaust 49.15 - 49.25 {1.9350 - 1.9390)

EM-279
SERVICE DATA AND SPECIFICATIONS (S.D.S.) CD

lnspectlon and AdJustment - CD20 (Cont'd)


Valve sprlng Valve seat resurfaclng
Unlt: mni (in)
Free height mm (In)
lntake
Outer 43.2 (1.701)
lnner 38.2 (1.504)
Standard

Assembled height
mm/N (mm/kg. in/lb)

Outer 36.1/164.8 (36.1/16.8, 1.421/37.0)


lnner 32.6/78.5 (32.6/8.0, 1.283/17.6)
Out-ol..,square "S"
mm(in) 36.636.811.402 1.4081

Outer 2.1 {0.083) O.S (0.o:IO) Owenin


lnner 1.9 (0.075) "R0.3 0.5
0.012 0.0201
"38.43. 38.46 U.5130 1.&138)

Valve gulde
Unlt: mm {in)

Standard Serv ce
11.1
Valve gude IO.A37)
11.023 11.034 11.223 11.234
Outer dlameter
(0.4340 0.4344) (0.4418 0.4423)
2.8~.06
Valve gude (0.1102~.00201 36.6-36.8 (1.4021.4091
lnner diameter 7.000 7.015 : CVllnderhnd machining dita
(Fnished size) (0.2756 0.2762)
SEM917
Cylinder head valve 10.975 10.996 11.185 11.196
Exhaust
guide hole dlameter (0.4321 0.4329) (0.4404 0.4408)
lnterference fil of valve 0.027 0.059 Stendlrd (OrlgiMI)
gude (0.0011 0.0023)
Standard Max. toeranee
Stem to guide clear-
anee

0.020 0.050
lntake 0.10 (0.0039)
(0.0008 0.0020)
0.040 0.070
Exhaust 0.10 (0.0039)
(0.0016 0.0028) 30.6 30.8 (1.206 1.213)
Valve deflecton limil 0.1 (0.004}
0.5 (0.020) Oveflize
R0.3 0.5
,0.012 .0.020,
34..45 34.47 (1.3663 1.357l

11.4
(0.449)

fo~~.i:o.0020) 30.6 30.8 (1.206 -1.213t


SEM9l8
: Cylindef hnd mec:hining data

EM-280
SERVICE DATA AND SPECIFICATIONS (S.D.S.) CD
lnspectionand Adjustment- CD20 (Cont'd)
VALVE LIFTER CYLINDER BLOCK
Unt: mm (in) Unit: mm (in)

Valve lifter outer diameter


34.959 34.975
Standard
(1.3763 1.3770)
Cylinder head valve li1ter hole 34.988 35.018
dameter ( 1.3775 1.3787)
Clearance
0.023 0.059
Standard
(0.0009 0.0023)
Lmt 0.1 (0.004)

SEM902
Standard Lmit
Surlace flatness Less than 0.05 (0.0020) 0.10 {0.0039}
Grade No. 1
84.500 - 84.510
(3.3268 3.3272)
Grade No. 2
84.510 84.520
(3.3276 3.3279)
Grade No. 3
lnner
dlameter
84.520 84.530 -
(3.3276 3.3279)
Cylnder Grade No. 4
bore 84.530 84.540
{3.3279 - 3.3283)
Grade No. 5
84.540 84.550
(3.3283 3.3287)
Out-of-
round Less than O.o15 (0.0008) 0.04 (0.0016)
(X-Y)
Taper
Less than 0.010 {0.0004) 0.04 (0.0016)
(A- B)
Plston to cylinder 0.025 0.045
clearance (0.0010 0.0018) -
Feeler gauge extract
ing force [wth gauge 7.8 - 14.7
thckness 0.06 mm (0.8 1.5. 1.8 - 3.3)
-
(0.0024 in)) N (kg, lb)
Grade No. O
56.654 56.663
(2.2305 2.2308)
Grade No. 1
Main journal nner
diameter 56.663 56.672 -
(2.2308 2.2312)
Grade No. 2
56.672 56.680
(2.2312 2.2315)

EM-281
SERVICE DATA AND SPECIFICATIONS (S.D.S.) CD

lnspectionand Adjustment- CD20 (Cont'd)


AVAILABLE MAIN BEARINGS
No. 1, No. 2, No. 4 and No. 5 main bearlngs

Grade number Thickness "T" mm (In) Width "W" mm (in) ldentification color
o 1.816 1.820 (0.0715 0.0717) Yellow
1.820 - 1.824 (0.0717 - 0.0718) Green
20.0 (0.787)
2 1.824 1.828 {0.0718 - 0.0720) Brown
17.8 (0.701)*
3 1.828 - 1.832 (0.0720 - 0.0721) Black
4 1.832 - 1.836 (0.0721 - 0.0723) Blue
: Contacling width

No. 3 maln bearings

Grade number Thlckness "T" mm (in) Width "W" mm (in) ldentification color
o 1.816 - 1.820 (0.0715 - 0.0717) Yellow
1.820 - 1.824 (0.0717 - 0.0718) Green
27.95 (1.1004)
2 1.824 - 1.828 (0.0718 - 0.0720) Brown
20.8 (0.819)'
3 1.828 - 1.832 (0.0720 - 0.0721) Black
4 1.832 1.836 (0.0721 0.0723) Blue
: Contacting wdth

Main bearing undersize Bearing clearance


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

Crank journal dameter Man bearing clearance


52.951 - 52.975 0.039 - 0.065
STO (2.0847 - 2.0856)
Standard
(0.0015 - 0.0026)

52.701 - 52.725 Connecting rod bearing clearance


0.25 {0.0098) undersize
(2.0748 - 2.0758)
0.031 0.061
Standard
(0.0012 0.0024)

Connecting rod bearlng undersize


Unit: mm (in) MISCELLANEOUS COMPONENTS
Unit: mm (in)
Crank pin diameter
49.968 - 49.974 Flywheel
Grade O Black
(1.9672 1.9675}
Runout [T.I.R.'J Less than 0.15 (0.0059)
49.961 - 49.968
STO Grade 1 Yellow
(1.9670 1.9672)
": Total ndicator reading

49.954 49.961
Grade 2 Blue
(1.9667 1.9670)
49.874 - 49.894.
0.06 (0.0031} undersize
(1.9635 1.9643)
49.834 - 49.854.
O. 12 (0.0047) underslze
(1.9620 1.9628)
49.704 - 49.724.
0.25 (0.0098) undersize
(1.9568 1.9576)
': Reterence value

EM-282
SERVICE DATA AND SPECIFICATIONS (S.D.S.) CD
lnspectionand Adjustment - CD20 (Cont'd)
PISTON, PISTON RING AND PISTON PIN Piston pin
Unit: mm (in>
Piston
Unit: mm (in) 24.994 - 25.000
Pi.ston pin outer diameter
(0.9840 - 0.9843)
84,465 - 84.475
Grade No. 1 lnterference lit of pisten pin to
(3.3254 - 3.3258) O 0.004 (O 0.0002)
piston
84.475 - 84.485
Grade No. 2 Piston pin to connecting rod 0.025 0.044
(3.3258 - 3.3262}
clearance (0.0010 - 0.0017)
84.485 - 84.495
Standard Grade No. 3
(3.3262 - 3.3266)
Pis ton
skirt 84.495 - 84.505
Grade No. 4
ciam- (3.3266 3.3270) CONNECTING ROO
eter Unit: mm (in)
84.505 84.515
Grade No. 5
(3.3270 - 3.3274)
Bend [per 100 mm (3.94 in)J
84.715 84.765
0.25 (0.0098) Standard Less than 0.025 (0.0010)
(3.3352 3.3372)
Oversize
84.965 85.015 Torsion
0.5 (0.020)
(3.3451 - 3.3470)

_
Standard Less than 0.025 (0.0010)

------
Measure position (From Top) 62 (2.44)
Piston pin bore dia.
25.025 - 25.038
24.991 24.999 (0.9852 - 0.9857)
Piston pin hole diameter
(0.9839 0.9842} Big end play

Umit 0.3 (0.012}


Piston ring
Unil; mm (in)

Side clearance CRANKSHAFT


Unit: mm (in)
Top

Standard 0.060 0.095 (0.0024 0.0037) Grade No. O


52.967 - 52.975
Limit o. 10 (0.0039)
(2.0853 - 2.0856)
2nd Grade No. 1
Main journal da, 52.959 52.967
Standard 0.040 0.075 (0.0016 - 0.0030)
(2.0850 - 2.0853)
Umit o. 10 (0.0039) Grade No. 2
52.951 52.959
OH
(2.0847 - 2.0850)
Standard 0.030 - O.Q70 (0.0012 - 0.0028)
Grade
-----
No. O
Ring gap 49.968 49.974
(1.9672 - 1.9675)
Top
Grade No.1
Standard Pin journal dia. 49.961 - 49.968
(1.9670 1.9672)
Bore grade 1, 2, 3 0.20 - 0.30 (0.0079 - 0.0118)
Grade No. 2
Bore grade 4, 5 0.12 - 0.22 (0.0047 0.0087) 49.954 49.961

2nd
--------------- ..- ..--..--. (1.9667 1.9670)

Out-of-round (X - Y) and
Standard 0.38 - 0.53 (0.0150 0.0209)
taper (A- B)
Oil
Standard Less than 0.005 (0.0002)
Standard 0.30 - 0.55 (0.0118 0.0217)
Runout

Standard Less than 0.05 (0.0020)

Free end play

Standard 0.05 - 0.18 (0.0020 0.0071)


Limit 0.3 (0.012)

EM-283
SERVICE DATA AND SPECIFICATIONS (S.D.S.) CD

TlghteningTorque
ENGINE OUTER PARTS ENGINE BODY PARTS

Unit Nm . kg-m ft-lb Unit Nm kg-m fl(b


Adjusling bar to CD17 16 21 1.6 - 2.1 12 - 15 011 pan drain plug 29- 39 3.0 - 4.0 22- 29
engine mounting CD20 21 - 26 2.1 - 2.7 15 - 20
Rocker cover C017 1 -3 0.1 0.3 0.7 - 2.2
Alternator to braeket 37 - 51 3.8 5.2 27 38 CD20 2-4 0.2- 0.4 1.4-2.9
Front dust cover 3-5 0.3 - 0.5 2.2- 3.6 Water pump to cylinder
16 - 21 1.6- 2.1 12 15
block
ldler pulley nut
19 - 25 1.9 2.6 14 19
(For air conditioner) Water draln plug 54 74 5.5 - 7.5 40-54
lnjecton pump rear
24 27 2.4 - 2.8 17 20
bracket (to cylnder block}
lnjecton pump rear
49 59 5.0- 6.0 36-43
bracket
lnjeclion pump to rear
24 - 27 2.4 - 2.8 17 - 20
bracket
lnjecton pump sprocket
59 69 6.0 - 7.0 43 51
nut

EM-284
ENGINE LUBRICATION &
----- COOLING SYSTEMS

SECTIONLC
---- - --------- -- ------ - ,_ - -- ..---'

CONTENTS
PRECAUTION LC- 2
PREPARATION LC- 3

---~~-~~-~---__.GA,SR,CD.__ __.
ENGINE COOLING SYSTEM LC- 4

.__ __,GA,SR,E,CD.__ ~---'


ENGINE COOLING SYSTEM LC- 6

GA
ENGINE LUBRICATION SYSTEM LC-10
ENGINE COOLING SYSTEM LC-14
RADIATOR FAN MOTOR ELECTRICAL CIRCUIT LC-21

SR
ENGINE LUBRICA TION SYSTEM LC-29
ENGINE COOLING SYSTEM LC-36

E
ENGINE LUBRICA TION SYSTEM LC-42
ENGINE COOLING SYSTEM LC-46
RADIATOR FAN MOTOR ELECTRICAL CIRCUIT LC-50

CD
ENGINE LUBRICATION SYSTEM LC-53
ENGINE COOLING SYSTEM LC-59
RADIATOR FAN MOTOR ELECTRICAL CIRCUIT LC-65

~-----------~GA,SR,E,CD--------------
SERVICE DATA ANO SPECIFICATIONS (S.D.S.) LC-66
PRECAUTION

;J.}
LIQUID GASKET APPLICATION PROCEDURE
a. Before applylng llquld gasket, use a scraper to remove all
traces of old llquld gasket from matlng surface.
ift[, b. Apply a contlnuous bead of liquld gasket to mating sur-
lnner
side faces. (Use Genuine Llquid Gasket or equlvalent.)
Be sure llquld gasket Is specified wldth (for oll pan).
SR: 4.0 to 5.0 mm (0.157 to 0.197 In)
GA, E, CD: 3.5 to 4.5 mm (0.138 to 0.1n in)

L
8~-t-ho_~~~~~
Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 In)
Groow- wide {in areas except oil pan).
SEM37lCI c. Apply liquid gasket to lnner seallng surface around hole
perlmeter area.
(Assembly should be done wlthln 5 minutes after coatlng.)
d. Walt at least 30 minutes before refllllng englne oll and
engine coolant.

LC-2
PREPARATION

SPECIAL SERVICE TOOLS


': Special tool or commercial equivalent

Tool number Engine application


Description
Tool name GA SR E CD
ST25051001
Oil pressure gauge
X X X X

a
r>
ST25052000 Adapting oil pressure gauge
Hose to cylinder block
X X X X

WS39930000 Pressng the tube of liquid


Tube presser gasket
X X X X

EG17650301 Adapting radiator cap tester


Radiator cap tester
adapter

u T to radiator filler neck

'
X X X X

KV99103510 lnstalllng radiator upper


Radiator plate and lower tanks

--
)
pliers A
~-::::J X X X X

KV99103520 Removing radiator upper


Radator plate and lower tanks
pliers B
E! X X X X

LC..3
ENGINE COOLING SYSTEM GA,SR,CD

RefillingEngine Coolant
1. Set heater temperature control lever to Maximum Hot
position.
2. Remove radiator filler cap, air relief plug and air bleeder
cap.

3. Fill radiator with coolant and fill reservoir tank to Max line
with coolant.
Air relief plug is reinstalled once coolant spills from the air
relief hole during refill.
Then fil! radiator and reservoir tank with coolant.
4. Reinstall air bleeder cap.

5. lnstall a temporary radiator filler cap which allows air and


- Radiator filler cap
coolant in cooling system to be directed into reservor tank
Negatve pressure regardless of pressure.
valve lnstall a suitable steel wire between negativa pressure
valve and its seat as shown in the picture.
6. Warm up engine to normal operating temperatura.
7. Run engine at 2,500 rpm for 10 seconds and return to idle
speed.
Repeat2 or 3 ti mes
Watch coolant temperature gauge so as not to overheat the
SLC57SA englne.
8. Stop engine and cool lt down.
Oool down using a tan to reduce the time.
9. Removethe temporary radlator filler cap and check coolant
level.
lf necessary, refill radiator up to filler neck with coolant.
10. Refill reservoir tank to Max line with coolant.
11. Repeat step 7 through step 10 two or more times.

LC-4
ENGINE COOLING SYSTEM GA,SR,CD

RefillingEngine Coolant(Cont'd)
12. lnstall a proper radiator filler cap. (Original radiator filler
Radiator filler cap
cap)
Negatlve pressure 13. Warm up engine, and check for sound of coolant flow while
valve running engine from idle up to 4,000 rpm with heater
temperature control lever set at severa! positions between
COOL and HOT.
Sound may be noticeable at heater water cock.
14. GA and CD engines:
lf sound is heard, bleed air from cooling system by repeat-
ing steps 5 through 10 until coolant leve! no longer drops.
SLC576A SR engine:
lf sound is heard, bleed air from cooling system according
to the following steps.
1) Cool engine down and remove air bleeder cap on heater
inlet hose.

2) Attach a suitable transparent hose at air bleeder pipe and


put the opposite end of the hose into coolant of reservoir
tank.
3) lnstall the temporary radiator cap and check for proper
connection of ali coolant related hoses.
4) Start engine and check for bubbles in reservoir tank.
5) Set heater temperature control lever to max ''COOL" posi-
tion in order to bypass coolant through the transparent
hose.
6) Run engine up to 2,300 rpm until bubbles disappear in the
SI.C473A transparent hose.
Do not run engine over 2,300 rpm because engine may be
damaged dueto reduced coofant flow.
7) After removing bubbles, set heater temperature control
lever to max "HOT'' postion and check for sound of coolant
flow.
8) lf sound is heard, repeat step 5) through step 7).
15. Stop engine and coof it down.
16. lnstall a proper radiator cap. (Original radiator cap)
17. Aemove the transparent hose and install air bleeder cap.
18. Check any removed parts for secure reinstallation.

LC-5
ENGINE COOLING SYSTEM GA,SR,E,CD

Radiator {Alumlnum type)

V
O-rlng~
, w
Lower tank
Ol cooler
, e

o
A/T model onty

SLC892

Aluminum radlator can be disassembled by using special


procedures and special service tools.

DISASSEMBL Y
1. Remove tank with Tool.

Grip the crimped edge and bend it upwards so that Tool


slips off.
Do not bend excessively.

*
SL~

LC-6
ENGINE COOLING SYSTEM GA,SR,E,CD
Radiator(Aluminumtype) (Cont'd)

1
In areas where Tool cannot be used, use a screwdriver to
bend the edge up.
Be careful not to damage tank.

SLC930

2. Make sure the edge stands straight up.


3. Remove oil cooler from tank. (A/T models only)

ASSEMBLY
1. lnstall oil cooler. (A/T models only)
Pay attentlon to directlon of con leal washer.

Sl.C894

2. Clean contact portion of tank.

SLC932

3. lnstall sealing rubber.


When installing sealing rubber, select the correct one accord-
ing to the table below.

ldentification hole Applicable sealing rubber


Yes (on the side ___
of radator
,,_, core} ......- Square shaped sealng rubber _
No Circle shaped sealng rubber

SLC638A

LC-7
ENGINE COOLING SYSTEM GA,SR,E,CD
Radiator (Aluminum type) (Cont'd)
Push lt In with flngers.
Be careful not to twlst seallng rubber.

4. Attach a 1.5 mm (0.059 In) thick spacer to the tip of Tool..


(Square shaped sealing rubber only)

Unit: mm (in)
SLC553A

5. Caulk tank in specified sequence with Too!.

Keep tool perpendeUlar to


the radator.
X
!Grip is nsuffcient.l SLC896

Use pliers in the locations where Tool cannot be used.

SLC897

LC-8
ENGINE COOLING SYSTEM GA,SR,E,CD
Radiator (Alumlnum type) (Cont'd)
6. Make sure that the rim is completely crimped down.
Standard height "H":
Square shaped sealing rubber
8.0 8.4 mm (0.315 - 0.331 in)
Circle shaped sealing rubber
9.5 - 9.9 mm (0.374 - 0.390 in)
7. Confirm that there is no leakage.
Refer to lnspection.

INSPECTION
EG17650301
Apply pressure with Tool.
Speclfled pressure value:
'157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
WARNING:
To prevent the rlsk of the hose coming undone whlle under
pressure, securely fasten lt down wlth a hose clamp.

~J
1
Attach a hose to the oll cooler as well. (A/T models only)
1

.....____ =--~~--_)-

LC-9
ENGINE LUBRICATION SYSTEM GA

Lubricatlon Clrcult

Oil passage

Oil 9allery in cyllnder block

By-pass passage
o~ pump Orain
1
L.l
,_,,, Oistl'lbutor -]
1
r cOUJ)llng

j
Oil
.__ _ p==--- ,
___.
. o~
pan
: Except tor GA160E only

SLC496A

011 Pressure Check


WARNING:
Be careful not to burn yourself, as the englne and oll may
be hot.
Ol pressure check should be done In "Neutral" gear
posltion.

1. Checkoil level.
2. Removeol pressure switch.

LC-10
ENGINE LUBRICATION SYSTEM GA
Oil Pressure Check (Cont'd)
Engine speed Approximate discharge pressure
rpm kPa (bar, kg/cm2 psi)
ldle speed 49 - 186 (0.49 - 1.86, 0.5 - 1.9. 7 27)
ST25051001 -----. ,-. . . . . ,------1---------------
3.000 343 - 441 (3.43 - 4.41. 3.5 - 4.5, 50 - 64)

3. lnstall pressure gauge.


4. Start engine and warm it up to normal operating tempera-
ture.
"ST25052000 5. Check oil pressure with engine running under no-load.
SLC926
lf difference is extreme, check oil passage and oll pump for oll
leaks.
6. lnstall oil pressure switch with sealant.

LC-11
ENGINE LUBRICATION SYSTEM GA

011 Pump
rl Liquld gasket

Froot cover slde

~ : Nm (kg-m, ft-lb}
.O:-.~
Oil pump eover side SLC497A

(!) Screw @ Front cover


Oil pump cover (l) Regulator valve
@ Bolt @ Spring
@ loner gear @ Washer
@ Outer gear @) Plug

REGULATOR VALVE INSPECTION


Spring 7 1. Visually inspect componentsfor wear and damage.
2. Check oil pressure regulator valve sliding surface and
Regulator valve spring.
val ve 3. Apply regulator valve with engine ol and check that it falls
I
smoothty into the valve hole by its own weight.
lf damaged, replace regulator valve set or oil pump assembly.

t1LC172A

OIL PRESSURE RELIEF VALVE INSPECTION


lnspect ol pressure relief valve for movement, cracks and
breaks by pushingthe ball. lf replacementis necessary,remove
valve by prying it out with suitable tool.
lnstall a new valve in place by tapping it.

SLC418A

LC-12
ENGINE LUBRICATION SYSTEM GA
Oil Pump (Cont'd)
DISASSEMBL Y AND ASSEMBL Y
Always replace oil seal with a new one.
When installlng oil pump, apply englne oil to gears.
Make sure that Oring is fltted properly.
OIL PUMP INSPECTION
Using a feeler gauge, check the following clearance.
Unit: mm (in)
Body to outer gear clearance G) o. 110 - 0.200 (0.0043 - 0.0079)
lnner gear to crescent clearance @ 0.217 - 0.327 (0.0085 - 0.0129}
Outer gear to crescent clearance @ 0.21 - 0.32 (0.0083 - 0.0126)
Body to inner gear clearance (~ 0.05 - 0.09 (0.0020 - 0.0035)
Body to outer gear clearance @ 0.05 - o. 11 (0.0020 - 0.0043)
lnner gear to brazed portion of
0.045 - 0.091 (0.0018 - 0.0036)
housing clearance @

lf the tlp clearance (@) exceeds the limlt, replace gear set.
Feeler gauge
lf body to gear clearances ( (j) , @ , @ , @ , @ ) exceed the
SLC419A limit, replace front cover assembly.
------------

lnner gear
b
SLC222A

LC-13
ENGINE COOLING SYSTEM GA

CoollngClrcult
I CARBURETOR MODEL
.... Thermolat: OPl:k

~ Tl,ermc>tal: CI.OSEO

Raiato, Reservolr tan =1

Thermosto!
""""9
Wat~ outlet

wa101 xmp

Cyl'inder bJock

CY"""' hetd

SLC421A

EXCEPT CARSURETOR MODEL


... Therrnottat. OPEN

~ The<m<ta1. CLOSEO

Rac.tiator

Water inle1

The,mostat
i
L._. __J:==~
hOUSing

' water outtet

w.,., pllml)
Heater

----------------- ------ .... --------------------'


SLC498C

LC-14
ENGINE COOLING SYSTEM GA

System Check
WARNING:
Never remove the radiator cap when the engine Is hot; serlous
burns could be caused by high pressure fluid escaplng from the
radlator.
Wrap a thick cloth around cap and carefully remove the cap by
turning it a quarter turn to allow bullt-up pressure to escape and
then tum the cap ali the way off.

CHECKING COOLING SYSTEM HOSES


Check hoses for mproper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.

CHECKING RADIATOR CAP


To check radiator cap, apply pressure to cap with a tester.
Radlator cap reUef pressure:
78 98 kPa
(0.78 0.$8 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)

Pull the negative pressure valve to open it. Check that it closes
completely when released.

CHECKING COOLING SYSTEM FOR LEAKS


To check for leakage, apply pressure to the cooling system with
a tester.
Testlng pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Higher than the specifled pressure may cause radlator damage.

LC-15
ENGINE COOLING SYSTEM GA

Water Pump

Water pump

~ 6.3 - 8.3 {0.64. 0.85, 4.6. 6.1)

Water pump pulley


A : Nm (kg-m. ftlbJ SLC423A

CAUTION:
When removlng water pump assembly, be careful not to gel
coolant on timlng chain.
Water pump cannot be dlsassemblecl and should be re-
placed as a unlt.
After lnstalllng water pump, connect hose and clamp se-
curely, then check for leaks uslng radlator cap tester.

REMOVAL
1. Drain cootant from radiator and cylinder block.
2. Remove drive belts for compressor, power steering pump
and alternator.
3. Remove water pump pulley.
4. Remove water pump.

INSPECTION
1. Check for badly rusted or corroded body assembly and
vane.
2. Check for rough operation due to excessive end play.

Sl.C162A

LC-16
ENGINE COOLING SYSTEM GA

Water Pump (Cont'd)


INSTALLATION
Before installing water pump, remove liquid gasket from
mating surface of water pump using a scraper.
Be sure liquld gasket In grooves is also removed.
Rernove liquid gasket from mating surface of front cover.
Remove ali traces ot liquid gasket using white gasoline.

Apply liquid gasket to mating surface of pump housing as


shown.

~ Uquidgasket, Thermostat
Thermostat housing-, \, INSPECTION
1. Check for valve seating condition at ordinary temperatures.
Thermostat- s:s ~
lt should seat tightly.
Water inlet~) ~~.r

,~ / ~rPJ
1-( ~
6.3 8.3
Liquid gasket (0.64 0.85,
CJ 4.6 - 6.1)
({} A 6.3 a.3 <o.64 - o.85, 4.6. 6.1,

........~~~~~~~~-
~ : Nm (kg-m, ftlb) SLC427A

Jigglevalve
(top sdeJ
Up

Sl.C499A

l 2. Check valve opening temperatura and maximum valve lift.


Valve opening temperature e (F) 76.5 (170)
Max. valva lift mmlC (inlF) 8/90 (0.31/194)

3. Then check if valve closes at 5C (9F) below valve opening


temperature.
After lnstallatton,run engine for a few minutes, and check
for leaks.

SLC343

LC-17
ENGINE COOLING SYSTEM GA
Thermostat(Cont'd)
INSTALLATION
When installing water inlet apply liquid gasket as shown.

Water Outlet
INSPECTION
Visually inspect for water leaks. lf there is leakage, apply liquid
gasket.

INSTALLATION
When installing water outlet, apply liquid gasket as shown.

-'*111"- 2.0 3.0 mm


(0.079 0.118 In) cfie.

SLC430A

\.C-18
ENGINE COOLING SYSTEM GA

-- Radiator.
-------

l
,,

___ ,,,,,,, ,,,,,,,,_.,_,, , _ SLC500A

(j) Reservoir tank @ Mounting rubber


Reservor tank bracket @ Oil cooler hose {A/T models)
@ Radiator cap @) Radiator
@ Mounting bracket ~j)Lower hose
@ Upper hose @ Fan
@ Washer @ Fan motor
(!) Oran plug

CAUTION:
Whenfilling radlator wlth coolant, refer to MA sectlon.

Electrical Coollng Fan


For schematlc and wirlng diagram of electrlcal cooling fan,
refer to pages LC-21,22 and 23.

LC-19
ENGINE COOLING SYSTEM GA

Thermoswltch {GA13DS, GA14DS & GA16DS)


INSPECTION
1. Drain about one liter of coolant.
2. Remove thermoswitch.
3. Check thermoswitch for proper operation.
Operatlng temperature:

_J 1
Except for A/T models for hot areas
OFF -" ON 82 88C (180 190F)
Except for A/T models for A/T models for hot areas
A/T models hol areas
..._f_o_r_ho_t _rea
__s ------ SLCS11A OFF ..... ON G) 82 - 88C (180 190F)
@ 102 - 108C (216 - 226f)

LC-20
RADIATOR FAN MOTOR ELECTRICAL CIRCUIT GA

Schematic
Except A/T model for Middle East

IGNITION SWITCH
BATTERY ON or START
@: A/T mcde I far
hot areas
<@): Exept@
@: Models with air
cond1t1oner

g
1-
ru
1
<t >-
..... <t
OZ..J
<t<tW
a:1.1..a:

To air
condltioner-..---1-.-.-------J.-------'
system
...

z<t z<( z<1 z;


LI..
c.
o
eo
.... lL
a:
lL
<I

~~ ..... '-+' E o
<t
C\J
a:
o ....1
M ~ el: 1- 1 M 1- 1 1-
....c:r a: ..,..... l"'I C)
a: ..... a:
<t ro "O.., <l <l
HO
o 1-
o e C11 H o o
<l o
1-
o oo:::-- o 1- o ....

L_.__
<l o,.,, < o <t o
a: .::.:: a: .::.:: 1-
a: .::.:: a: ::.:

__ ____
-:

,....... ,,,_,_,,_,,,,,,, __,,


,,,_,,,_,,_, __
,,_,,_,,,,,,,
, ,,,,
,,
,
, ,__,
SLC634A
---.
A/T modet for Middle East

BATTEAY IGNITION SWITCH


ON or START

FUSE

15
......
....1
<l
..... <t
>-
OZ...J
<I <l LU
0:ll..O:

....--+------

To ar
cond 1 t tener- ------
system
--1---.--------1--1--- -+----+---4---
:e
(.J

....
1-

3:
Cf)

i
IJ.j
r-

, ,,,_,,,,, __ ,,, ,, _
LC-21
RADIATOR FAN MOTOR ELECTRICAL CIRCUIT GA

Wiring Diagram
ExceptA/T model for Middle East
(1)
ro
Q) L.
L G)
ro N
:::,..
..> l""1
o ro
s: e, .
rl ro
MM
e,
Q
ro (.) a:
4)C!) .... .CC...C::(.!)
-0"0 +J (l)+J
-e-t e rl
0 0 ..-{,...... ..... ~ w121
EEOl0>4> 3:03: ~
u 'O 'O rl ...,
. ooo.oo.m ::J+J
OOEEEo..-1.,...-100.
ll)Q)'OQ).CQ.l
II(")'<:f- O'O C'O ..1 CJ
111
G) .,....'<-i'-.XOOO-rlX
e ..JO:IDZ<UIJ CJ::E s ur
t.
a>
s:
...
e
i

e
.......
>,O
C.+' @
eo
~=: --- S~I
t. .J
4)1.,J \..oH1,
.
3:
oc
Q., ...
@ Is1- ...1
"'
H a:
O
OZl-
4~0
a:: u.~

To alr conditioner system

@)
L/8-W
W/Gffl

(Engine
riarness)

@ SLC636A

LC-22
GA
RADIATOR FAN MOTOR ELECTRICAL CIRCUIT
Wirlng Diagram (Cont'd)
A/T model for Middle East

t ..J
<,
(I)


ii e O> a:i
(/,) m o.>,
e "O :J ..J
e(..
@
@
Q)
111 Cl)U
.J:.

....me 0*
1 ~

:m -
e
o
o
L.
G) U)
e v
... e
ii

CIH.
cm
!:! .J:.

B/W -..__ f -1
BR/W
W/G
r 1-
. ;! 15
I<.; CIZl-
L ~:i
g lu
BR ~
i' W/B...,
a:
o (\j
<(
....
>-
<(
1-
<t
1
a:
OZ.J
t <1:IU
a:u.a:
BR ~ 1
!
ozl:?
<ttO
W/B i--
a:u. :E
W/G
(ll
L
B/W i--~

bw1a
BR/W-..

B/W- ' w ~
BR 1 X
W/G o
1
..A
ltl

O]]
1 ~
a - ::,
u,

W/S
-BR/W

1 1 "'z
::t
W/G H

A
.. 8/W
w
...J
IU
.J
B ID
H

~ D=f1 U)
::,
1.1.

~ ::jJ
!
To air conditione~ sy stem ~

:,.
1 a:
1 W -c.J l:]:: GY .:::e} ~
I.O!L.J~-,1.. ~
FUSIBLE ~
LINK

SLC637A

LC-23
RADIATOR FAN MOTOR ELECTRICAL CIRCUIT GA

Trouble Diagnoses - Radlator Fan Motor (Cont'd)


.-------------~~--
~
r---~-----'-~-----
1) Turn ignition switch "OFF".
Hot areas 2) Check harness continuity be-
tween terminal G) and
ground.
Contlnulty should exlst.
lf N.G.. repar harness.

Replace water temperature


switch wth a new one.

SYMPTOM:
Even though the englne Is extremely hot [engine temperature is
above 1 OSC (221 F)], the radiator tan motor does not rotate at a
higher
" speed. (Only for A/T models for hot areas) ......;. -
This check should be performed alter the engine is warmed
up sufficiently.

CHECK POWER SUPPL Y. N.G. 1) Turn ignition switch "OFF".


1) Turo igntion switch "ON". 2) Disconnect radiator tan relay.
2) Check voltage between [41 3) Check voltage between
and ground. terminal and ground.
Battery voltage should exlst. Battery voltage ahould
eidst.
0.K.
lf N.G., check harness
continuity between bat-
tery $ terminal and ter-
minal(!).
0.K.

SLC513A
CHECK GROUND CIRCUIT. 1) Check radiator fan relay. lf
1) Turn ignition switch "OFF". N.G., replace with a new one.
2) Oisconnect radiator fan motor 2) Check harness continuity be-
hamess connector. tween radator tan relay ter-
3) Check harness continulty be- minal @ and radiator tan
tween @ and ground. motor harness connector ter-
Contlnuity should exisL minal G0.
lf N.G., repair hamess. lf N.G., repair harness.
jo.i<.--
Replace radiator fan motor with
a new one.
L.H.D. SLC513A

LC-26
.....i
RADIATOR FAN MOTOR ELECTRICAL CIRCUIT GA
Trouble Diagnoses - Radiator Fan Motor (Cont'd)
.--~~~~~~~~~~~~~~--,

liJ <>
1) Turn ignition switch "ON".
2} Check voltage between termi-
nal and ground.
Battery voltage should ex.lst.
lf N.G.. check the following
parts:
Harness continuity between
terminal @ and fuse
L.H.D. SI..C515A Fuse
O.K.

1) Connect radiator fan relay.


2) Disconnect water tempera-
tura switch harness connec-
tor.
11 3) Check voltage between
terminal (v and ground.
Battery voltage should
exlst.
lf N.G., check harness
SLC516A between terminal (v and
radiator fan relay termi-

L ------J nal.

A/T models li O.K.


tor hot 1) Turn ignition switch "OFF".
are as
2) Check harness continuty be-
tween terminal G) and
ground.
Continulty should exist
....~ N.G., repair harnes~:-........_ _J
SL_9509A r::--'."""" .L._. ,=:=]
.1 Replace water temperatura
. switch wth a new one.

LC-27
RADIATOR FAN MOTOR ELECTRICAL CIRCUIT GA

Trouble Diagnoses - Radiator Fan Motor (Cont'd)


.---------~--~-~~
SYMPTOM:
Even though the engine is cold, the radiator fan motor Is
rotatlng.

cJW
1) Turn igniton switch ''ON", N.G. 1) Disconnect radia- N.G.
2) Disconnect water tempera- tor relay. i----.ce
ture switch. Radlator tan me-
Radiator fan motor should tor should stop.
stop. O.K.
O.K.
L.H.D. SLC510A .-------"--------,
Replace water temperature Replace radiator fan
switch with a new one. relay with a new
one.

r,, ~ 1) Check voltage between terminal


and ground.
No voltage should exlst.
lf N.G.. check harness between ter-
minal and radiator fan motor
harness connector terminal @ for
shorting.

LC-28
ENGINE LUBRICATION SYSTEM SR

Lubrlcation Clrcuit
--------- .........,------------
SR20DE .. Return
Ol tube
<:::=, Feed
Camshaft

. Hydrauliclash adjuster

Oil cooler

os filter-
bracket

-oa pan

L SLC594A

ISR20DE +- : Ol gallery ...... - - : By-pass passage

~: Oil passage -- : To oil pan

Regulator valve
Conpump (Bultinto pumpcover)

. . _ - __~-
'"""" --- ;;; J
.---0-il -"c'-oo-1-er c~lief valve

1 ---- - ----.
~nbaaring Main gallery Chantensoner

I L___~:
~ecting
I1 rod bearing
"'l
_
Cylinder head oil
gallery
Timng chain

I Connecti~;-;;-==i

Hydrauliclash
adjuster
Piston and ~;;;;-:=] 1..------.r---__J

" l
SLC595A

LC-29
ENGINE LUBRICATION SYSTEM SR
LubrlcationCircult(Cont'd)
SR20DET .. Return
ou tube
<::==, Feed
!r-"1t~:lt\.. __. - Camsnaft

Oil cooler

Turbocharger
Oil filter bracket

Oil straner .::


SLC596A

sA20DET - - - : By-pass passage


.... ; Ollgallery

<:===i : Oil passage -:Tooil pan

Oil pan

Oil strainer
---------- ---
Regulator valve
011 pump (Built nto oil pump)

011 cooler
--Re-li-1~ -

Turbocharger Ol filter

Malo bearing Man gallery Chain tensioner

Timing chain
Conoecting rod bearng Cylinder head ol
gallery

Connecting rod

Camshaft Camshaft Rocker


surtace journal plVot
Pistenand cylinder

SLC597A

LC-30
ENGINE LUBRICATION SYSTEM SR

011 Pressure Check


Oil pressure switch WARNING:
Be careful not to burn yourself, as the engine and oll may
be hot.
Oil pressure check should be done in "Neutral" gear
posltlon.
1. Check oil leve!.
2. Remove oil pressure switch.
\
() ~608A

3. lnstall pressure gauge.


4. Start engine and warm lt up to normal operating tempera-
ture.
5. Check oil pressure with engine running under no-load.

Engine Approximate dlscharge pressure


rpm kPa (bar, kg/cm2, psi)
SR20DE: More than 98 (0.98, 1.0, 14)
ldle speed
SR20DET:More than 98 (0.98, 1.0, 14)
SR20DE:324 - 422 (3.24 - 4.22. 3.3 - 4.3, 47 61)
3,200
SR20DET:343 441 (3.43 4.41, 3.5 - 4.5, 50 - 64)

lf dlfference is extreme, check oll passage and oil pump for ol


leaks.
6. lnstall oil pressure switch with sealant.

011 Pump
REMOVAL
1. Remove drive belts.
2. Remove cylinder head. (Refer to EM section.)
3. Remove ol pans. (Refer to EM section.)
4. Remove oil strainer and baffle plate.
5. Remove front cover assembly.

LC-31
SR
ENGINE LUBRICATION SYSTEM
011 Pump (Cont'd)
DISASSEMBL Y ANO ASSEMBL Y
__ __
........, ,,,_,,,,,,,, , , ~

A 3.1 -s.e
(0.38 0.51, 2.7 3.7)
/ [t?J
j
6.4 7.5
.:: ~~ (0.65 0.76, 4.7 5.5)

... ~ Liquid gasket ft--_...... . 0

>

l 0-,;~ot -.
...........--~ 1

.>

~~- 1 , - (>

I ij
"-"---@
,'C-, -.............. 1
''-----j
'
!1 J.~ ~ 6.4 7.5
{0.65. 0.76, 4.7 5.5)

/ ~ rPJ 16 ~9 (1.6 1.9, 12 14/ ~


~ ~ l 4wo models . . .:-. -. . . . - . .- . .
(i)

Oil pump cover


Front cover
lnner gear
Outer gear
~rPJ 39 69 {4.0 7.0, 29 51)

'
'1

_ . ,-, "/ - ~

1,

@
@
(f)
Regulator valve
Spring
Washer ~
/ 6.4 - 7.5
lI ~:.=:::~
@ Plug (o.6s 0.16, 4.1 5.5) A .

@ __
,,,
Regulator valve set
Oil strainer
,,, ,
--- ..----------"""
rPJ : Nm (kg-m, ftlbJ ~ 16 19(1.6 1.9, 12 -~ SLC6l3A

Always replace oil seal and 0-rlng wlth new ones.


When instalUng oil pump, apply englne oll to lnner and
outer gear.
Be sure that 0-rlngs are properly fltted.

INSTALLATION
Before installing front cover assembly, remove ali traces of
liquid gasket from mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of
cylinder block.

SLC491A

1. Apply a continuous bead of lqutd gasket to mating surface


of front cover assembly.
Use Genulne Liquid Gasket or equivalent.
2. lnstallation is in reverse order of removal.
Never apply liqud
gasket to ths groove.

LC-32
ENGINE LUBRICATION SYSTEM SR

_,_,,,,_,,,,,_,,,
Oil Pump (Cont'd) __,

@,

L._ SLC49SA

.----------- ....

SLC4SOA

INSPECTION
Using a feeler gauge, check the following clearances:
Unit mm (in)

Body to outer gear clearance (1) 0.114 - 0.200 (0.0045 - 0.0079)


lnner gear to outer gear tip clearance Below 0.18 (0.0071)
Body to nner gear clearance @ 0.05 - 0.09 (0.0020 - 0.0035)
Body to outer gear clearance @ 0.05 - 0.11 (0.0020 - 0.0043)
lnner gear to brazed portien of housing
0.045 - 0.091 (0.0018 - 0.0036)
clearance@

H the tlp clearance ( ) exceeds the llmit, replace gear set.


H body to gear clearances ( (!), @, @, @) exceed the
limit, replace front cover assembly.

REGULATOR VALVE INSPECTION


1. Visually inspect components tor wear and damage.
2. Check oil pressure regulator valve sliding surface and
valve spring.
3. Coat regulator valve with engine oil and check that it falls
smoothly into the valve hole by its own weight.
lf damaged, replace regulator valve set or front cover assem-
bly.

SLC295

LC-33
ENGINE LUBRICATION SYSTEM SR
011 Pump (Cont'd)
4. Check regulator valve to oil pump cover clearance.
Clearance:
: 0.040 - 0.097 mm (0.0016 - 0.0038 In)
ff it exceeds the limlt, replace oll pump cover.

SLC451A

OIL PRESSURE RELIEF VALVE INSPECTION


(SR20DE)
lnspect ol pressure relief valve for movement, cracks and
breaks. lf damaged, replace oil filter bracket assembly.

SA20DET (SR20DET)
lnspect oil pressure relief valves for movement, cracks and
breaks by pushing the ball, lf replacement is necessary, remove
valve by prying it out with a suitable tool. lnstall a new valve in
place by tapping t.

OH pressure
relief valves
SLC615A

OH Jet (For piston)


INSPECTION
1. Blow through outlet of otl jet and make sure that air comes
out of inlet.
2. Push cut-o valva ot oil jet bolt with a clean resin or brass
rod and make sure that cut-off valve moves smoothly with
proper repulsion.

When lnstalHng oll Jet, allgn oil Jet's boas wlth hole on cyllnder
block.

LC-34
ENGINE LUBRICATION SYSTEM SR

011 Cooler
sRODE

Oil cooler l

Cootant
flow

0-rlng~

~ .--.,--r-
,<

-----~-
...)

Ol cooler assembly
~ 34 44 Nm (3.S 4.5 kg-m, 25 33 ftlb)
SLC632A

SR20DET
Gasket~

(l) Ol filter bracket


Oil cooter
@ Oil temperature sensor
011 flter
@ Ol pressure switch
~ : Nm (kg-m, ft-lb) SLC612A

REMOVAL ANO INSTALLATION


1. Drain engine ol and coolant.
2. Removeoil cooler.
3. lnstallation is in reverse order of removal.

INSPECTION
1. Check oil cooler for cracks.
2. Check oil cooler for clogging by blowing through coolant
inlet.
lf necessary, replace oil cooler assembly.

LC-35
ENGINE COOLING SYSTEM SR

CoolingClrcuit
+- Cooling circuit in cylinder head

~ Cooling circuit in cylinder block


Thermostat housing
- Cooling circuit in radiator and water gallery

Water pump

: Thermostat open

<:> ; Thermostat closed

Radiator
--------'
-.:-::::::::::.:::1 Reservoir tank C:.J : SR20DET engine only

Thermostat

Thermostat housing

Water pump Throttle chamber

Oil cooler Cylinder block Air regulator Heater

Water outlet ]4111111iiiiiiiiiiiiiiiL_Cyl~n~d::e:_r h~e~ad~


SLC599AI

System Check
WARNING:
Never remove the radlator cap when the englne is hot; serlous
burns could be caused by high pressure fluid escaping from the
radiator.
Wrap a thlck cloth around the cap and carefully remove it by
turnlng it a quarter turn to allow bullt-uppressureto escape and
then turn the cap all the way off.

LC-36
ENGINE COOLING SYSTEM SR

Cooling System lnspection


CHECKING HOSES
Check water hoses for proper attachment, leaks, cracks, dam-
age, loose connections, chafing and deterioration.

CHECKING RADIATOR CAP


To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 -1.0 kg/cm2, 11 - 14 psi)

\_
Pufl the negative pressure valve to open it.
Check that it closes completely when released.

SMA967Bj

CHECKING COOLING SYSTEM FOR LEAKS


To check for leakage, apply pressure to the cooling system with
a tester.
Testlng pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Hlgher than the speclfled pressure may cause radlator damage.

Water Pump
REMOVAL
1. Drain coolant from radiator.

LC-37
ENGINE COOLING SYSTEM SR
Water Pump (Cont'd)

2. Remove cylinder block drain plug located at left front of


cylinder block and drain coolant.

3. Remove drive belts.


4. Aemove water pump pulley.
5. Remove water pump.
CAUTION:
When removlng water pump assembly, be careful not to get
coolant on drlve belt.
Water pump cannot be disassembled and should be re-
placed as a unlt.
ttJJ 16 - 21 Nm ~
/ /
L Waterpump After lnstalllng water pump, connect hose and clamp se-
{U 2.1 kg-m, curely, then check for leaks uslng radlator cap tester.
12 15 ft-lb) SLC566A

INSPECTION
1. Check for badly rusted or corroded body assembly.
2. Check for rough operation due to excessive end play.

SLC408C

INSTALLATION
1. Before installing water pump, remove ali traces of liquid
gasket from mating surface of water pump using a scraper.
Also remove traces of llquid gasket from mating surface of
cylinder block .

SLC433A

LC-38
ENGINE COOLING SYSTEM SR

Water Pump (Cont'd)


...--=---------------,
SR20DE 2. Apply a continuous bead of liquid gasket to mating surface
of water pump.
Use Genuina Liquid Gasket or equivalent.

SLC617A

SLC601AI

Thermostat
------- ..-------------------

\A 1e. 21
A,.3. 8.3 ~ (U 2.1, 12 15)

Ar reliefplug\ 64 o.as, 4.6 61>


/
c>--. z- -~ ......
e;:

Waterinlet

~ Liquid gaske1
E';LiQud
gasket

2.0 3.0 (0.079 0.118)


2.0 3.0(0.079 0.118)

Unit : mm (In)
A : Nm (kgm, tt-lb) SLC579A
-----------'
LC-39
ENGINE COOLING SYSTEM SR
Thermostat(Cont'd)
REMOVAL AND INSTALLATION
1. . Drain engine coolant.
2. Remove lower radator hose.
3. Remove water inlet, then take out thermostat.

Upper 4. lnstall thermostat wth jiggle valve or air bleeder facing


upward.
After lnstallation, run engine for a few minutes, and check
for leaks.
Be careful not to splll coolant over englne compartment.
Use a rag to absorb coolant.

INSPECTION
1. Check for valve seatng condition at ordinary temperaturas.
lt should seat tightly.
2. Check valve opening temperatura and maxmum valve lift.

Valve opening temperature C ("F) 76.5 (170)

Max. valve lift mm/C (n/F) 8/90 (0.31/194)

3. Then check if valve closes at SC (9F) below valve opening


temperatura.

Water outlet
INSPECTION
Visually inspect for water leaks. lf there is leakage, apply liquid
gasket.

INSTALLATION
1. Before installing water outlet, remove all traces of liquid
gasket from mating surface of water outlet using a scraper.
Also remove traces of liquld gasket from mating surface ot
cylinder head. .
2. Apply a continuous bead of liquid gasket to mating surface
of water outlet.
Use Genuine Liquid Gasket or equivalent.
a Uquld gasket

SEM0860

LC-40
ENGINE COOLING SYSTEM SR

Radlator{Aluminumtype)

Models with air condltioner


5

(D Aeservoir tank

'
(V Aadiator fler cap
@ Upper radiator hose 6
Radator drain plug
@ Radiator 8
@ Lower radiator hose
1 (V Aadiator fan
@ Radiator shroud @
Radiator tan motor SLC606A

SR20DET

('

....._ ,, , __ __ ,_ SLC007A

LC-41
ENGINE LUBRICATION SYSTEM m
LubricationCircult

.
.
.l ...--Oil_l>U_"'l>_~=========~>I
...._~~-
Oilfll~ l'==....;;i\1>1 Moinoil
galle"'

._ ..

<::;= :o;,_
Note:

~ : 011 gollt<Y ;., oyliNle1' bloel<


----:ByPMS-

Oilpan

SLC486A

LC-42
ENGINE LUBRICATION SYSTEM

Oil Pressure Check


WARNING:
Be careful not to burn yourself, as the engine and oil may
be hot.
011 pressure check should be done in "Neutral" gear
posltlon.

1. Warm up engine.
2. Stop engine and remove oil pressure switch.

3. lnstall pressure gauge.


4. Start engine and warm it up to normal operating tempera-
ture.
5. Check ol pressure with engine running under no-load.
-ST25051001
Approximate dscharge pressure
Engine rpm
-------------- ,
kPa (bar, kg/cm2, psi) . __
ldle speed More than 59 (0.59, 0.6, 9)
363- 520
3,000
"ST25052000 (3.63 - 5.20, 3.7 - 5.3, 53 - 75)
SLC926

6. lnstall ol pressure switch.


011 pressure switch:
rPJ: 10 - 16 Nm
(1.0 - 1.6 kg-m, 7 - 12 ft-lb)

LC-43
ENGINE LUBRICATION SYSTEM

r---.--.--.- . Oil Pump

Pumpbody
J

tc!J : Nm (kgm, ft-lbl

L. , ,_, , _ SI.. C905

Do not dlsassemble inner rotor and drive gear.


Always replace gaskets with new ones.
When installlng oil pump, apply engine oil to inner and
outer rotors.
After installation, run engine for a few minutes, and check
for leaks.

LC-44
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont'd)

=r= Washer
REGULATOR VALVE INSPECTION
1. Visually inspect components for wear and damage.
2. Check ol pressure regulator valve sliding surface and
valve sprng.
3. Coat regulator valve with engine ol and check that it falls
smoothly into the valve hole by its own weight.
lf damaged, replace regulator valve set or oil pump assembly.

Oll PRESSURE RELIEF VALVE INSPECTION


lnspect oil pressure relief valve for movement, cracks and
breaks by pushng the ball. lf replacement is necessary, remove
valve by pryng it out wth a screwdriver.
lnstall a new valve in place by tapping it.

,.- _

-G)
OIL PUMP INSPECTION
Using a feeler gauge, check the following clearance.
Unit mm (in}

Rotor tip clearance (i) Less than 0.12 (0.0047)

Outer rotor to body ciearance 0.15 - 0.21 (0.0059 - O.OOS3)


Side clearance (with gasket) (j) 0.05 - 0.12 (0.0020 - 0.0047}

lf it exceeds the lmit, replace gear set or entire oil pump


assembly.
SLC271

SLC724

LC-45
ENGINE LUBRICATION SVSTEM m
Oil Pressure Check
WARNING:
Be careful not to burn yourself, as the engine and oll may
be hot.
011 pressure check should be done In "Neutral" gear
positlon.

1. Warm up engine.
2. Stop engine and remove oil pressure switch.

Alternator
SLC483A

3. lnstall pressure gauge.


4. Start engine and warm it up to normal operating tempera-
ture.
5. Check oil pressure with engine running under no-load.
ST25051001
Approximate discharge pressure
Engine rpm
kPa (bar, kg/cm2, psi)
ldle speed More than 59 (0.59, 0.6, 9)
~~~~~~~~~~~---,~~~~~
363 - 520
3,000
(3.63 - 5.20, 3. 7 - 5.3, 53 - 75)
SLC926

6. lnstall oil pressure switch.


Oil pressure switch:
~: 10-16 Nm
(1.0 - 1.6 kg-m, 7 - 12 ft-lb)

LC-43
ENGINE LUBRICATION SYSTEM

Oil Pump

Pump body

tJ : Nm lkg-m. ftlb)

SLC905

Do not dlsassemble inner rotor and drive gear.


Always replace gaskets wlth new ones.
When lnstalllng oil pump, apply engine oll to inner and
outer rotors.
After installatlon, run engine for a few minutes, and check
for leaks.

LC-44
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont'd)
......... Washer REGULATOR VALVE INSPECTION
Spring/
1. Visually inspect components for wear and damage.
Regulator7 2. Check oil pressure regulator valve sliding surface and
valve J valve spring.
1
3. Coat regulator valve with engine ol and check that it falls
smoothly into the valve hole by its own weight.
lf damaged, replace regulator valve set or oil pump assembly.

. . . _@l SLC295

{@
I=~
OIL PRESSURE RELIEF VALVE INSPECTION
lnspect oil pressure relief valve for movement, cracks and

tf 1f .
breaks by pushing the ball. lf replacement is necessary, remove
valve by prying it out with a screwdriver.
lnstall a new valve in place by tapping it.

SLC275

OIL PUMP INSPECTION


Using a feeler gauge, check the following clearance.
Unit: mm (iil)

Rotor tip clearance Less than 0.12 (0.0047)


Outer rotor to body clearance @ 0.15 - 0.21 (0.0059 - 0.0083)
Side clearance (with gasket) @ 0.05 - 0.12 (0.0020- 0.0047}
lf it exceeds the limit, replace gear set or entire oll pump
assembly.

SLC724

LC-45
ENGINE COOLING SYSTEM

Cooling Circuit

Radiator

Carburetor
Water pump

lntake
manifold
Cylinder block

Water passage
Cylinder head in cylinder head Therrnostat housing

L
1

_ . Thermostat: open
SLC929

WARNING:
To avoid serious personal injury, never remove radiator cap
quickty when englne is hot. Sudden release of coollng system
pressure is very dangerous.
H lt is necessaryto remove radlator cap when radlator is hot,
wrap cap with a cloth and turn cap slowly counterclockwlseto
the first stop. After all pressure in the coollng system Is
released, turn cap passlng the stop and remove lt.

LC-46
ENGINE COOLING SYSTEM m
Cooling System lnspection
Refer to MA section.

Water Pump

L ._
~: Nm (kg-m, fHb)

__
,,,,_,,, ,,, _.
L.~.
~ 5.1 6.5
(0.52 0.66, 3.8 4.8)
,, .. SLC484A

CAUTION:
When removing water pump assembly, be careful not to get
coolant on tlming belt.
Water pump cannot be dlsassembled and should be re-
placed as a unlt.
To avold deformlng timlng cover, make sure there is
adequate clearance between cover and hose clamp.
After lnstalllng water pump, connect hose and clamp se-
curely, then check for leaks uslng radiator cap tester.

___ . . . . . INSPECTION
1. Check for badly rusted or corroded body assembly and
vane.
2. Check for rough operation due to excessive end play.

LC-47
ENGINE COOLING SYSTEM

Thermostat

l e

To heater unit

Air vent hole

U-~ll
A s., -e.s
A 5.1-1.5 10.52 0.66,
3.8 4.8)
(0.52 0.66,

housing
\
- Thermostat

Gasket t)

Water outlet housng ~ : Nm (kg-m, ftlb) SlC378


------- ....--
After installatlon, run englne for a few minutes, and check
for leaks.
Be careful not to spill coolant over engine compartment.
Place a rag to absorb coolant.

INSPECTION
1. Check valve seating condition at ordinary temperatures. lt

--------
should seat tightly.
2. Check valve opening temperature and maximum valve lift.
Frgd type Standard type Tropical type
Valve opening temperature
88 (190) 82 (180) 76.5 (170)
C (F)
Max. valve lift 8/100 8/95 8/90
mm/C (in/F) (0.31/212) (0.311203) (0.31/194)
SLC343

3. Then check if valve ctoses at SC (9F) below valve opening


temperature.

LC-48
ENGINE COOLING SYSTEM

,,,,,, ,, ,,,,,,,,._,,, _
Radlator
----- -----------

Thermoswitch

~-j-~~--r-~-
A 5(0.5 10- 1.0
Nm
kg-m, -
~ ~ ~
"-:,_

as - u
> ~
. <,
f)) e::::?~
~~

,,, ,,,.,,, _ SLC48SA

CAUTION:
When filling radlator wlth coolant, refer to MA section.

Thermoswitch
INSPECTION
1. Drain about one liter of coolant.
2. Remove thermoswitch.
3. Check thermoswitch for proper operation.
Operating temperature:
OFF --. ON 87 93C (189 - 199F)

SLC463

LC-49
RADIATOR FAN MOTOR ELECTRICAL CIRCUIT ro
Trouble Dlagnoses- Radiator Fan Motor

RAD!ATOR IGNITION SWITCH


FAN ON or START

IJ
RELAY
(Aefer to "Power supply
routing" ln EL section.l

L. BATTERY

, - w/~
(v a fusble
G)

fir;il@
e

....o link-30A}

J
........
'O
e
ll ,,
u,lt
a1-' zffi
o
o
....mL. (Re ferS.Mto. .J.last page
l_ <Fo ldout page>. J 1111111 l I I I I
....o
'~
W/G f C5 =3-W/G -- ..
UP ..
lEng :\ne room
harnessl ~ ~ <~:;~essl FUSE BLOCK
(Refer to "Power supply
rout1ng" in EL section.)

IO..J
l
"''
ll<

THERMO- RADIATOR BODY


SWITCH FAN GROUND
MOTOR
SLC523AI

LC-50
RADIATOR FAN MOTOR ELECTRICAL CIRCUIT m
Trouble Dlagnoses - Radiator Fan Motor (Cont'd)
~~-IIIDlllt---,~~~. . . . . .I SYMPTOM:
~ l?.J ~ Even though the engine coolant Is hot, the radlator fan motor
~ does not rotate.

Radiator Thls check-should be perlormed alter englne Is wa...;.ed up J


tan hamess sufficiently.
connector ......... .. ,,, '" ........-,.----

CHECK POWER SUPPLY. ~ 1) Turn ignition switch "OFF".


1) Turn gntion switch "ON". 2) Disconnect radiator fan re-
SLC524A 2) Disconnect radiator fan har- lay.
ness connector. (il 3) Check voltage between

u
3) Check voltage between G) terminal @ and ground.
and ground. Battery voltage should
..... Battery ~oltage should e~ist. 1 exist.

O.K.
lf N.G., check harness


Radiator tan continuity between bat-
motor harness
CHECK GROUND CIRCUIT. tery $ pole and termnal
connector !~ @.
1} Turn gnition switch "OFF",
2) Disconnect radiator fan mo- liJ 4) Check harness continuity
tor harness connector. between radator tan re-
3) Check harness continuity lay terminal and radi-
...._ SLC52SA
,,,___

between @ and ground . ator fan motor harness


connector terminal G) .
1~
~ L. __ c_o_n_tl-nu_i_ty_s_h..,.o_u_ld_e_xi_s_t.
lf N.G., repair harness. __ __. Continuity should exist.

Radialor
0.K. __ ,,,,,----.----
lf N.G., repair harness.

O.K.
tan relay
hamess Replace radiator tan mot~r wthjl 1) Turn gnition switch "ON".

__
connector
a new one.
..... . .... .........,,,,,, -
,,,,
2) Check voltage between ter-
minal and ground .
Battery voltage should exlst.
lf N.G .. check following
SLC526A parts:
Harness contlnuty be-
tween fuse and terminal

Fuse

Radiator
tan motor
hamess
connector

SLC527AI

Radiator fan relay


harness connector

~ l I
L ~
LC-51
RADIATOR FAN MOTOR ELECTRICAL CIRCUIT m
Trouble Diagnoses - Radiator Fan Motor (Cont'd)
11
f .,---,
r
II
Turn igntion switch "OFF".
Check continuity between
terminal and ground.
. Contlnulty should exlst.

_1~1
Raditor tan
relay harness

l
lf N.G., check the following
oonnector
parts:
Thermoswitch
Harness continuity be-
SLC529A tween (D and thermo-
switch terminal

l
Harness contnuity be-
tween thermoswitch terrni- 1
. na~ and body g~ound j

r=
I
.E~----.I
vnt1Ck radiator fan relay. lf
[ N.G., replace with a new one. I

LC-52
CD
ENGINE LUBRICATION SYSTEM

LubricationCircuit

Note: .... : Oil gallerv in cvinder block

<;:::J : on passage
+--: By-pass passage

--i
Oil pump 1

1 1
,~_!.:::=-,
~ -..--~elief!~

Man bearing .Cvlinder head ol gallery


Oil strainer

Crankshatt
CD 17: Valve lifter Camshatt bracket
CD20: Hydraulic valve
L_ litter

Oil leed hose Camshaft journal

[- Connecting rod

~.mlobe
(J;ston and cylinder wall

SLC609A

LC-53
ENGINE LUBRICATION SYSTEM CD

011 Pressure Check


WARNING:
Ol pressure switch
Be careful not to burn yourself, as the englne and oil may
be hot.
Oil pressure check should be done in uNeutral" gear
position.
1. Checkol leve!.
2. Removeoil pressure switch.

SLC461

3. lnstaUpressure gauge.
4. Start engine and warm it up to normal operating tempera-
ture.
5. Checkoil pressure with engine running under no-load.
ST25051001
Approximate discharge pressure
Engine rpm
kPa (bar, kg/cm2, psi)
!die speed More than 59 (0.59, 0.6, 9)
2,000 294 (2.9, 3, 43)

SLC926
lf dffference Is extreme, check oll passage and oll pump for oll
leaks.
6. lnstall oil pressure switch with sealant.

011 Pump
REMOVAL AND INSTALLATION
1. Drain engine coolant and engine ol.
2. Remove upper radiator hose, drive belts, crank pulley,
timing belt covers, front engine mounting (CD20)bracket
and timing belt.
3. Remove exhaust front tube, timing belt pulley and rear
engine gusset (bar type), then remove oil pan.

SLC462A

~ 12 16 Nm
(1.2 1.6 kg.n,, 9 12 ftlb) l
f"l 4.
5.
Removeoil pump assernblywith oil strainer.
Reinstall any part removed. Refll engine oil and engine
coolant.
lnstall new oil pump gasket. (CD17)
Apply liquid gasket to oil pump. (CD20)
Apply liquid gasket to oil pan.
Apply llqud gasket to both ends of oil pan oil seals.
lnstall oil pan, fitting oil seals in the correct postion.

LC-54
ENGINE LUBRICATION SYSTEM CD

011 Pump (Cont'd}


DISASSEMBL Y AND ASSEMBL Y
When installing oil pump, apply engine oil to lnner and outer
___ gears.
,,_,_,_,,.,,,. , ,, ,,_,_, __ __....
CD17

@r::,os,U-UI -[ql 4.5

. :i o-
_.;g}
0

Oilpump-
bodY
.. 0
o r
G ., t ~
as"e~@
~)---- lnner gear

R""'ulator
v" valve O
, 0 uter
gear

~~'\j
Spring..~ Oil 1tr1iner

Aegulator

~p-p
valve set
w.. h..

~ 39.49
14.0. s.c, A 12. 1s 11.2. r.e. 9 -121
29 .36)
ttJJ : Nm (kg-m, ftlbl

r
SLC911

CD20

~ 3.7 S.O (0.38 - 0.51, 2.7 s.n ~- Cover

Oil pump body '


\ Regulator valve

Springt ~~-
/' <>~
~,-~w
o

Shiml ~

qw1o,~w
11 /':::
\
~
l~'-V''
~~

~-------_Washer
~
-~,
'->' ~tc!J 39 69 (4.0 1.0. 29 51} A : Nm (kg-m, ft-lb)

SLC559A
---- ..-----------'

LC-55
ENGINE LUBRICATION SYSTEM CD

OH Pump (Cont'd)
Apply liquid gasket when installing ol pump onto engine.

2.5.0.5

"i'rifSU
(0.098 0.020) dia.
(0.()98 0.020)
dla.
Unit:m~
SLC566A

INSPECTION - CD17
Using a feeler gauge, check the following clearances.
Unt: mm (in)

Body to outer gear clearance G) 0.11 - 0.20 (0.0043 - 0.0079)


lnner gear to crescent clearance (}) 0.12 - 0.23 (0.0047- 0.0091)
Outer gear to crescent clearance @ 0.21 - 0.32 (0.0083 - 0.0126)
Housing to inner gear clearance @ 0.05 - 0.09 (0.0020- 0.0035)
Housing to outer gear clearance @ 0.05 - 0.11 (0.0020- 0.0043)

lf lt exceeds the limlt, replace gear set or entire oll pump


assembly.

INSPECTION - CD20
Using a feeler gauge, check the following clearances.
Unt: mm (in)

Body to outer gear clearance G) 0.12 - 0.20 (0.0047 - 0.0079)


Outer gear to inner gear clearance
less than 0.18 (0.0071)
(})
Housing to inner gear clearance @ 0.05 - 0.09 (0.0020- 0.0035)
Housing to outer gear clearance @ 0.05 - 0.11 (0.0020 - 0.0043)
SLCS60A
lnner gear to housing clearance @ 0.05 - 0.09 (0.0020 - 0.0035)

@. lf it exceeds the limit, replace gear set or entlre oil pump


assembly.

...__ .. SLCS61Cj

LC-56
ENGINE LUBRICATION SYSTEM CD
011 Pump (Cont'd)

r. _ . . .-- . . _ SLC568A

REGULATOR VALVE INSPECTION


Sprlng -Washer 1. Visually inspect components for wear and damage.

Regulator valve 7
I
/
2. Check oil pressure regulator valve sliding surface and
valve spring.
1// 3. Coat regulator valve with engine oil and check that it falls
smoothly into the valve hole by its own weight.
lf damaged, replace regulator valve set or oll pump assembly.

SLC295

OIL PRESSURE RELIEF VALVE INSPECTION


lnspect oil pressure relief valve for movement, cracks and
breaks by pushlng the ball. lf replacement is necessary, remove
valve by prying it out with a sultable tool. lnstall a new valve in
place by tapping it.

SLC446

LC-57
ENGINE LUBRICATION SYSTEM CD

OH Cooler
CAUTION:
Remove any dust from oH seal surface.

o-~
. . - . . . - . , TI
toJ34.44 ~
' cceter ... ,

Oil cooer

<~ . . . (1.6 1.9, 12 14)


toJ : Nm (kg-m, ft-lb}
SLC464A

INSPECTION
1. Check on cooler element and housing for cracks.
2. Check coolant inlet of oil cooler for clogging by blowing
through it.
Replace it if necessary.

Ol cooler

SLC465A

LC-58
ENGINE COOLING SYSTEM CD

Cooling Clrcuit

Bottom by-pass

Oil cooler

L-_R_a_d_ia...
to_r_c_ap_~--=:: :;J Reservoir tank I
Radiator

Water nlet
----~ Cold start
device
~----~

Thermonat

Water pump
Oil cooler
Cylinder block
Heater unit
Cylinder head
~: By-pass passage
Water outlet

SLC407

LC-59
ENGINE COOLING SYSTEM CD

:.., ::-ll
fL I
ater Pump
~}
REMOVAL AND INSTALLATION
Drain engine coolant from radiator and cylinder block.
2W1:Remove upper radiator hose, timing belt covers, front
engine mounting bracket and timing belt.
3. Remove timing belt tensioner and idler and timing belt
lower back cover.

Dran plug (Radiator)

SMA343C

4. Aemove water pump.

5. lnstall water pump with a new gasket. (CD17)


lnstall water pump with liquid gasket. (CD20)

A 16 21 Nm (1.6 2.1 kg-m, 12. 15 ft..fb)


SLC468A

LC-60
ENGINE COOLING SVSTEM CD

.CD20
__
.............. ,_, ,

Water pump
_ Water Pump (Cont'd)

I Bolt h~
I j
2.50.5
~(0.098 0.020~2.5
. j dla. l ... I
0.5
(0.098 0.020)
:J.
~it: mm L, 1
dia~-:..:?.565A
CD20 ": Apply liquid sealant to the thread.

~/ ;;7J>
~/ e!? 1!.
~ M7: 16 20 Nm (1.6 - 2.0 kg-m, 12 14 fUb)
M8: 16 - 21 N,m (1.6 - 2.1 kg-m, 12 15 ftlb)
SLCS63A

INSPECTION
1. Check for badly rusted or corroded body assembly and
vane.
2. Check for rough operation dueto excesslve end play.

LC-61
ENGINE COOLING SYSTEM CD

Thermostat
REMOVAL AND INSTALLATION

: CD17 only

CD17: Use gasket ~


CD20: Use liquid gasket

From cold start oevice


From oil cooler ,.
'

'Gasket t!+

a o
----""""""'------

... ... ...0(0.. .,


(~-0980.020)~
d1a.
o

Unit: mm {inJ
o
_r 2.50,5
~o,
Bott hol~) ~O.S (0.0980.020) dla. scu hole~s0.5 (0.0980,020) dla.
J2.50.5
[qJ : Nm (kg-m. ftlb) ,.a., (0.0980.020) dia. ra, (0.0980.020) dla.
SLC610A

Use new gasket. (CD17)


Apply liquid gasket to water outlet, thermostat housing and
water inlet. (CD20)

lnstall thermostat with jiggle valve uppermost.


After installation, run englne for a few minutes, and check
for leaks.

SLC097

LC-62
ENGINE COOLING SYSTEM CD
Thermostat(Cont'd)
INSPECTION
1. Check for valve seating condition at ordinary temperaturas.
lt should seat tightly.
2. Check valve opening temperatura and maximum valve lift.

CD17 CD20
---
Valve opening temperature e (F) 82 (180) 88 (190)
Max. valve lift mm/"C (inf'F) 8/95 (0.31/203) 8/100 (0.31/212)

3. Then check if valve closes at SC (9F)below valve opening


'--~-------------' SLC343

temperature.

Radiator

.AA
~
\~4 5
(0.4 0.5, 2.9 3.6)

.. ~~
------"~~ ........,,..._____ -
-------
1

M-
Radator ....... - ~

c-"--
~ ....N~-
. ..,_..-_,.,., . --o#" ~ ~ [q4.5
-> ~ ~
. \ ... (0.4 0.5,

~~L(?~~Thermos;:h .
~.~ 2.9-3.6)

(q} 29 49
(3,.0 5.0, 22 36)

>
Lower hose

~ rRJ : Nm (kgm. ft-lb)


Models wlth alr condltloner SLC469A
-----------

LC-63
ENGINE COOLING SYSTEM CD

Radiator Fan Motor


OPERATION

Water temperature Fan motor operatioo


C (F) A/C OFF A/CON
Below 90 (194) OFF
ON
Above 90 (194} ON

THERMOSWITCH INSPECTION
Check thermoswitch for proper operation.
Operating temperature:
OFF ON 90C (194F)
ON OFF 83C (181F)

SLC463

LC-64
RADIATOR FAN MOTOR ELECTRICAL CIRCUIT CD

Wirlng Diagram
a.
:.::>

o
t
..... r-1
C} z Q)
e 'O
u o

'
(1)
e .... e
o {O Q)
1J
C\I
a. o r-i o o
::, LU Q) E .
o U
o ..I
..... 'O
......... e E OII
Q) Q) Q) (O

W/G
U'O
o o ....
E E Q)
C
r-i.,...,
ID O) ro~
ooe (l")I"<:f
...........
ID ...J Z
U'OCO>
OOIDL..J
00 EE
r-,
ro a.
G)

II(Y)"sl'....,+.10
""" """
O X II
...JIIOOZU.CW 00

To air conc t rcner- syst em ----------


SLC633A

LC-65