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QUICK REFERENCE INDEX
NISSAN
STANZA
MODEL U12 SERIES
3
© 1989 NISSAN MOTOR CO.,LTD. Printed in Japan
Not to be reproduced in whole or in part without the prior written permission of Nissan Motor Company Ltd., Tokyo, Japan.FOREWORD
This manual contains maintenance and repair procedures for the 1990
NISSAN STANZA.
In order to assure your safety and the efficient functioning of the
vehicle, this manual should be read thoroughly. It is especially impor-
tant that the PRECAUTIONS in the GI section be completely under-
stood before starting any repair task.
All information in this manual is based on the latest product informa-
tion at the time of publication. The right is reserved to make changes in
specifications and methods at any time without notice.
IMPORTANT SAFETY NOTICE
The proper performance of service is essential for both the safety of the
technician and the efficient functioning of the vehicle.
‘The service methods in this Service Manual are described in such a
‘manner that the service may be performed safely and accurately.
Service varies with the procedures used, the skills of the technician and
the tools and parts available. Accordingly, anyone using service proce-
dures, tools or parts which are not specifically recommended by
NISSAN must first completely satisfy himself that neither his safety
nor the vehicle’s safety will be jeopardized by the service method
selected.
o> NISSAN MOTOR CO, LTD.
Overseas Service Department
Tokyo, JapanGENERAL INFORMATION
SECTION G l
CONTENTS
PRECAUTIONS ..ssessrnseneseo
HOW TO USE THIS MANUAL
HOW TO READ WIRING DIAGRAMS
HOW TO FOLLOW FLOW CHART IN
CONSULT CHECKING SYSTEM
Gl 2
Ges
G7
Gl-10
Gait4
IDENTIFICATION INFORMATION ..... Gi-16
LIFTING POINTS AND TOW TRUCK TOWING .. I-20
TIGHTENING TORQUE OF STANDARD BOLTS G23PRECAUTIONS
Observe the following precautions to ensure safe and proper
servicing. These precautions are not described in each individ-
ual section.
4. Do not operate the engine for an extended period of time
without proper exhaust ventilation.
Keep the work area well ventilated and free of any inflam-
mable materials. Special care should be taken when han-
dling any inflammable or poisonous materials, such as
gasoline, refrigerant gas, etc. When working in a pit or
other enclosed area, be sure to properly ventilate the area
before working with hazardous materials.
Do not smoke while working on the vehicle.
2. Before jacking up the vehicle, apply wheel chocks or other
tire blocks to the wheels to prevent the vehicle from
moving. After jacking up the vehicle, support the vehicle
weight with safety stands at the points designated for
proper lifting and towing before working on the vehicle.
‘These operations should be done on a level surface.
3. When removing a heavy component such as the engine or
transaxle/transmission, be careful not to lose your balance
and drop them, Also, do not allow them to strike adjacent
parts, especially the brake tubes and master cylinder.
Before starting repairs which do not require battery power,
always turn off the ignition switch, then disconnect the
ground cable from the battery to prevent accidental short
circuit.
To prevent serious burns, avoid contact with hot metal parts
such as the radiator, exhaust manifold, tail pipe and mut-
fler. Do not remove the radiator cap when the engine is hot.
GI-2Fender cover
PRECAUTIONS
6. Before servicing the vehicle, protect fenders, upholstery
and carpeting with appropriate covers
Take care that keys, buckles or buttons on your person do
not scratch the paint.
7. Clean all disassembled parts in the designated liquid or
solvent prior to inspection or assembly.
8. Replace oil seals, gaskets, packings, O-rings, locking
washers, cotter pins, self-locking nuts, etc. with new ones.
8. Replace inner and outer races of tapered roller bearings
and needle bearings as a set.
10. Arrange the disassembled parts in accordance with their
assembled locations and sequence.
11. Do not touch the terminals of electrical components which
use microcomputers (such as electronic control units. Static
electricity may damage internal electronic components.
42. After disconnecting vacuum or air hoses, attach a tag to
indicate the proper connection.
48. Use only the lubricants specified in MA section.
14. Use approved bonding agent, sealants or their equivalents
when required.
415. Use tools and recommended special tools where specified
for safe and efficient service repairs.
46. When repairing the fuel, oil, water, vacuum or exhaust
systems, check all affected lines for leaks.
17. Dispose of drained oil or the solvent used for cleaning parts
in an appropriate manner.
Precautions for E.F.I. or E.C.C.S. Engine
1. Before connecting or disconnecting E.F.l. or E.C.C.S. har-
ness connector to or from any E.F.I. or E.C.C.S. control unit,
be sure to turn the ignition switch to the "OFF" position and
disconnect the negative battery terminal.
Otherwise, there may be damage to contro! unit.
2. Before disconnecting pressurized fuel line from fuel pump
to injectors, be sure to release fuel pressure to eliminate
danger.
3. Be careful not to jar components such as control unit and
air flow meter.
GI-3PRECAUTIONS
Precautions for Catalyst
If a large amount of unburned fuel flows into the converter, the
converter temperature will be excessively high. To prevent this,
follow the procedure below:
1. Use unleaded gasoline only. Leaded gasoline will seriously
damage the catalytic converter.
2. When checking for ignition spark or measuring engine
compression, make tests quickly and only when necessary.
3. Do not run engine when the fuel tank level is low, otherwise
the engine may misfire causing damage to the converter.
4. Do not place the vehicle on inflammable material. Keep
inflammable material off the exhaust pipe.
Precautions for Fuel
Use unleaded gasoline with an octane rating of at least 87 AKI
(Anti-Knock Index) number (research octane number 91).
Gl-4HOW TO USE THIS MANUAL
1. AQUICK REFERENCE INDEX, a black tab (e.9. EM) is provided on the first page. You can quickly find
the first page of each section by mating It to the section's black tab
THE CONTENTS are listed on the first page of each section
THE TITLE is indicated on the upper portion of each page and shows the part or system,
THE PAGE NUMBER of each section consists of two letters which designate the particular section and
a number (e.g. “BR-5”).
THE LARGE ILLUSTRATIONS are exploded views (See below.) and contain tightening torques,
ubrication points and other information necessary to perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to
the appropriate PARTS CATALOG.
2 SON
“Example” pq retainer
9] 54-64 65-68, 40-47
s. co
—
“ toner shien —
. a | Yuu aainy-20, 12-10
seiner Wy >
foray
come
air bleedar
/ ® (7-0 (07-09,51-65)
outer shin tn ee-s2, 6-29
mo
Paton ea
Cylinder body
L pion ge FA: Ham
6. THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools,
11 - 14V or approximately 12V
Voltage: Approximately OV -+ Less than 1V
Cross reference of work symbols in the text and il-
lustrations
Illustrations are provided as visual aids for work proce-
dures. For example, symbol Bi indicated in the left upper
portion of each illustration corresponds with the symbol in
the flow chart for easy identification. More precisely, the
procedure under the “CHECK POWER SUPPLY" outlined
previously is indicated by an illustration
8
Symbols used in illustrations
‘Symbols included in illustrations refer to measurements or
procedures. Before diagnosing a problem, familiarize your-
self with each symbol.
GI-11HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES
Direction mark
connector wmbot| 4 direction mark is shown to clarity the side of connector
= (terminal side or harness side).
Direction marks are mainly used in the illustrations indicating
7 terminal inspection
D Single tine =
A connector Cirection Cat} AG = View from terminal side ... 7.8.
All connector symbols shown from the terminal side are
enclosed by a single line.
Example
‘View from terminal side
View from harness side ... H.
View from harness side Connector symbol
HEH] | © Allconnector symbols shown from the harness side are
enclosed by a double line.
Connector
GI-12HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES.
Key to symbols signifying measurements or procedures
‘Symbol ‘Symbol explanation Symbol Symbol explanation
Check atter disconnecting the
Connector to be measured
lg
Current should be measured with
an ammeter
‘Check after connecting the ||
‘connector to be measured
®
Procedure with CONSULT
Insert key into ignition switch,
@
Procedure without CONSULT
Tutn ignition switch to “OFF
AIC switeh is “OFF
t
sufficiently,
Voltage should be measured with a
voltmeter
Circuit resistance should be
measured with an ohmmeter.
GI-A13
v
lg
AI
postion
Tur igation switch 19 “ON”
postion AIC switch is “ON
Turn ignition switch to “START ergy || Fan switch is “ON®. (AL any post
postion SB | lon encept tor “OFF” positon)
Turn inion awicn wom “Ort | ape oes | a smene
"ACC position. ‘i | « th is “OFF
Turn ignition switch from "ACG" to 3 “Asay battery votage avecty to
"OFF" postion Gs) componente, uae eety
Turn ignition switch trom “OFF” to || re
"ON" postion LR | oe vai
jon switch rom “ON® to
OFF" postion &) Disconnect battery negalve cable
Do not start engine, oF check vas
‘nn engine stopped | WY | vesress brake pel
Start engine, or check with engine
running. 4 Release brake pedal.
‘Anply parting brake, wl | epress accelerator peda
Release parking brake ¥4 Release accelerator pedal
eck after engine is warmed U = Pin terminal check for SM4
Sutter oe || eer
type ECU, and A/T contro!
Unt connectors.
For details regarding the
‘terminal arrangement, reter
to the foldout page.CONSULT CHECKING SYSTEM
Outside View
Power ON switch Diagnostic connector
Power OFF switeh \ \ Voltage probe
Battery pack”
‘Touch serean
Funetion keys J Program card! \
\
System Application
‘syster|
Diagnostic mode
‘Work support
‘Self-diagnostic results
Data monitor
‘Active test
ECU pi
XT Appieabre
‘number
Gl-14CONSULT CHECKING SYSTEM
Function
Diagnostic mode Function
Ths mode enable a technician to eau
Werk support rome devices faster and more accurately
by towing the inlcations on CONSULT
Jser-dlagnostic reauts canbe read and
ovased que
Selt-diagnostic results
InputiOutput data in the control unit can be
Data monitor ye
Mode in which CONSULT drives some ac-
ators apart from the control units and
iso shifts some parameters in a specified
range.
Active test
ECU. part number IEC.U. part number can be read.
Checking Equipment
Too! name Description
NISSAN CONSULT kit
@ CONSULT unit |
and accessories
@ Program card
® Operation manuals
@® Binder
® Carrying case
© Thermal paper (Rolls)
When ordering the above equipment, contact your NISSAN distributor.
GI-A15,IDENTIFICATION INFORMATION
Model Variation
Destination | Grade Model Engine Transaxle
le FLUIWFEU RSSFSOA
FLUT2WAEU REAFO2A
Non-California —
FLUIZYFEU RSSFSOV
\oxe
FLUT2VAEU REAFOOV
FLUT2WFEV RSSFSOA
E
FLUT2WAEV REAFO2A
California KAZE,
FLUI2YFEV RSSFSOV
exe
FLUT2YAEV REAFOOV
FLUT2WFEN RSSFSOA
le
FLUT2WAEN REAFO2A
Canada
FLUT2YFEN RSSFSOV
loxe
FLUT2YAEN RESFOQV
Prefix and suffix designations
F : KA24E engine —
Ll.
Non-Calilornia
California
Canada
EFL.
S-speed manual transaxle
‘Automatic transaxle
E grade
GXE gradeJENTIFICATION INFORMATION
Identification Number
enssen cones | Vee
\ Vehicle identification number plate
|
VEHICLE IDENTIFICATION NUMBER ARRANGEMENT
v2
2
vnssawe 1 JT]
||
|
|
|
|
INI: Nissan passenger vehicle
Manufacture plant
Engine ype | 1: oppama
F 2 KARE engine || |
| Model year
Vehicle line — | L 1990 year model
Model change 0 8) — Check digit 08 oF x)
Body type Restraint system
1: Sedan S = Standard
P= Automatic
GI-17
sso1630IDENTIFICATION INFORMATION
Identification Number (Cont'd)
IDENTIFICATION PLATE
NISSAN MOTOR CO. LTO. JAPAN
A
1 ee
2 Vat enieaion uber (has umber
3
3 Bot enor code
aa i) 5 Trim color code
ava & Engine mes
2 Ente Stet
ae 8 Trance over
“a 9 Anlomoae
BR ADHERE SH wri
sciats
ENGINE SERIAL NUMBER
Front rhos2u
MANUAL TRANSAXLE NUMBER AUTOMATIC TRANSAXLE NUMBER
GI-18IDENTIFICATION INFORMATION
Dimensions
Unit: men (in)
‘Sedan
‘Overall length 4370 (178)
Overall width 1697 (66.8)
Overall height 1875 (54.1)
Front tread 1460 (87.5),
Rear tread 1440 (58.7)
Wheelbase 2525 (99.4)
Wheels and Tires
Road wheel Conventional 14x 50
Spare 18a"
16672
ot set mm (in) 40 (157)
Tire size Conventional P1a6/65R14 89H
Spare ‘T125:70018"1
T135/70016"2
"rE grade
"2: GXE grade
GI-19LIFTING POINTS AND TOW TRUCK TOWING
Garage Jack and Safety Stand
WARNING:
© Never get under the vehicle while it is supported only by the
jack. Always use safety stands to support the frame when
you have to get under the vehicle.
© Place wheel chocks at the front wheels when the rear
wheels are raised and place wheel chocks at the rear
wheels when the front wheels are raised.
‘CAUTION:
Place a wooden or rubber block between safety stand and
body when the supporting body is flat.
J Front towing hook
| Rear towing hook
FS ck poss Safety stand pons
[ \
/
ear towing nook -
\ Front towing hook Garage jack point-/ sai
GI-20LIFTING POINTS AND TOW TRUCK TOWING
2-pole Lift
WARNING:
When lifting the vehicle, open the lift arms as wide as possible
and ensure that the front and rear of the vehicle are well
balanced.
When setting the lift arm, do not
brake tubes and fuel lines.
llow the arm to contact the
—.. Tipo
Renan eter cca
{he sil from deforming. I the pad does rot have pantograph jack
the sit, prepare @ sutable atachment wih si points.
Tow Truck Towing
CAUTION:
© Allapplicable state or Provincial (in Canada) laws and local
laws regarding the towing operation must be obeyed.
@ Itis necessary to use proper towing equipment to avoid
possible damage to the vehicle during towing operation.
Towing is in accordance with Towing Procedure Manual at
dealer.
¢ When towing with the rear wheels on the ground, release
the parking brake and move the gearshift lever to neutral.
NISSAN recommends that vehicle be towed with the driving
(front) wheels off the ground as illustrated,
Gl-21LIFTING POINTS AND TOW TRUCK TOWING
Front
eros!
Tow Truck Towing (Cont'd)
TOWING AN AUTOMATIC TRANSAXLE MODEL WITH
FOUR WHEELS ON GROUND
Observe the following restricted towing speeds and distances.
Speed:
Below 50 km/h (30 MPH)
Distance:
Less than 65 km (40 miles)
CAUTION:
Never tow an automatic transaxle model from the rear (i.e.,
backward) with four wheels on the ground as this may cause
serious and expensive damage to the transaxle.
TOWING AN AUTOMATIC TRANSAXLE MODEL WITH
REAR WHEELS RAISED (With front wheels on ground)
Never tow an automatic transaxle model with rear wheels
raised (with front wheels on ground) as this may cause serious
and expensive damage to the transaxle. If it is necessary to tow
it with rear wheels raised, always use a towing dolly under the
front wheels.
TOWING POINT
Always pull the cable straight out from the vehicle. Never pull
‘on the hook at a sideways angle.
GI-22TIGHTENING TORQUE OF STANDARD BOLTS
on Tianering org (nou wbrican)
rade | sotsize | diameter | Pe" Heragon head bot Hexagon Range bot
mm Nm kg-m felb Nm kg-m fib
we [eo [ve | 1] owe [ae | 1 | om | as
ie fw | a |e | [so
we | 20
> [a |e | * [16 |
ws [=| 2s | «| | |
a | mo | 00
i [| ze | |» [a |
is | @ [a | | | se |
wie | x20
i | «| a | | | sr [a
wa [we [is | mw] ef | || as
we [eo 10) ea | oe [ee | ee |?
vp a | er | | | as |
we | eo
vp | esp we] arf
is) a | a | | «| 4 | as
rm | mo | 190
ie [ep |e | | se |
ims [np 7a | | | ee | e@
wie | 0 —
iw [ pre) | || ee
[owe [aos er feof ts | 8
we [eo [|e |e fe) ws is fo
is | | so) =) |e)
we | 20
| # | a | = | # | ae | 2
15 x | 60 | 4 yo | 74 | 8
| mo | 190
iw [ | es | we | | ef
vs [we | wo | | | wo | er
we | 20
vs | we] no) | er | eo |
wa [wep ss] reef we) eee fate] se
1. Special parts are excluded
2. This standard is applicable to bolts having the following
‘marks embossed on the bolt head.
* Nominal diameter
Grade Mark M6
a 4 || nomi ameter f bt esc (Unt
7 7 Mette screw threads
or °
GI-23MAINTENANCE
rs |
cron MLA.
CONTENTS
PERIODIC MAINTENANCE svnensnanninnnne Me 2
GENERAL MAINTENANCE ...... MA- 5
RECOMMENDED FLUIDS AND LUBRICAN MA- 7
ENGINE MAINTENANCE osc MA- 9
CHASSIS AND BODY MAINTENANCE antennae MAAS
SERVICE DATA AND SPECIFICATIONS (S.0.8.) «0. MA-22PERIODIC MAINTENANCE
‘Two different maintenance schedules are provided, and should be used, depending upon the conditions
in which the vehicle is mainly operated. After 60,000 miles (96,000 km) or 48 months, continue the periodic
maintenance at the same mileage/time intervals.
SCHEDULE 1
Follow Periodic Maintenance Schedule 1 if your driving habits frequently includes one or more of the
following driving conditions:
© Repeated short trips of less than 5 miles (8 km).
© Repeated short trips of less than 10 miles (16 km) with outside temperatures remaining below
freezing.
© Operating in hot weather in stop-and-go “rush hour” traffic.
© Extensive idling and/or low speed driving for long distances, such as police, taxi or door-to-door
delivery use.
© Driving in dusty conditions.
© Driving on rough, muddy, or salt spread roads.
© Towing a trailer, using a camper or a car-top carrier.
SCHEDULE 2
Follow Periodic Maintenance Schedule 2 if none of the driving conditions shown in Schedule 1 apply to
your driving habits.
MA-2PERIODIC MAINTENANCE
Schedule 1
“peujnbos axe sjeas9quy pue suwioy soueuaqU}eW 1010
yons uoped jou peau sumo ay, “uopesado a/0149A o|
“syquowi ZL 40 (uD 000'r2) Se1Ms 000'SL A1oAo yoodsul ‘syuoU By 40 (4 000'96)
st
“pesinbos oq
094 s8injoejnuew 10 A\UEIIEM Uo}
40} NYSSIN £q pepuewiUode: oO:
Iw 900'0 Azone ye 110 (joadsut ISN! you) eBueYo ‘speos Appnut 10 yBno4 Uo BulALp 40 “4914489 do}-1e9 e 40 sodueD
‘quan ue yons ul “paBGoj0 owooeg 1yBIW $10)
wat 1 1 1 1 1 1
at 1 7 1 1 1 1 1 oes ee
~ ‘sUIOf
risen f \ ' \ ' ' ' ea vowuedane oY
ut tee Soren 8
we visodere
rant 1 ' 1 ' 1 ' ' “zedormnaee 9
~ - jo axe
eu u p (7) 31ON 29S yen opewomne B renUEH
BLN ' ' ' ' ' ' ' |B swap ‘sosip ‘sped ayes
a 1 7 1 coc
Zaueuajujeu Apoq pue s/e8EUD
aan ry son weds
saree BOR GEL wom on
cw uo ou Y uo oY uw uy y uw ue Bw uy wow w ae Cay
ww Ue eee eee ae
oN we Taio outa
eve mows 2
7 z coo
a 4 rel
ca (2) 310N 995, JauwaIo 11
z a10N 5 weer
“eoueUa UIE WAa}SAS jO4jUOD UO!SS]Wz
v7 oe «ee ewe eH om 6 8 Sn
oe a) ao a © Oo) @ em oO © od a aw @ omx~un
96ed eous119H gg gz'igg From
@ @® ©
°
® ® ©
semsose
Front
@® @ ®Q
7 © 9
p~
® ®@ ®
semeose
> Fron
® ®
3 6)
° 2
®
semaose
es
a6 3®
Cotiecor
rw mee | ON ann
SeEMs96C
Tightening Procedure of each Part
INTAKE MANIFOLD
(): 16 - 21 Nem (1.6 + 2.1 kg-m, 12 - 15 ft-lb)
EXHAUST MANIFOLD
1): 16 - 21 Nem (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
INTAKE MANIFOLD COLLECTOR
1): 16 - 21 Nem (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
THROTTLE CHAMBER
©): Bolts should be tightened twice.
Ist:
9-11 Nem (0.9 - 1.1 kg-m, 6.5 - 8.0 ft-lb)
ind:
18 - 22 Nem (1.8 - 2.2 kg-m, 13 - 16 ft-lb)
EM-7COMPRESSION PRESSURE
10.
surement of Compression Pressure
Warm up engine.
Turn ignition switch off
Disconnect fusible link for injectors.
Remove all spark plugs,
Disconnect distributor center cable.
Attach a compression tester to No. 1 cylinder.
Depress accelerator pedal fully to keep throttle valve wide
open.
Crank engine and record highest gauge indication.
Repeat the measurement on each cylinder as shown above.
Always use a fully-charged battery to obtain specified
engine revolution.
‘Compression pressurs
kPa (kg/cm’, psi)/rpm
Standard
1,206 (12.3, 175)/250
Minimum
1,010 (10.3, 146)/250
Ditterence limit between cylinders
98 (1.0, 14)/250
It cylinder compression in one or more cylinders is low,
pour a small amount of engine oil into cylinders through
spark plug holes and retest compression.
I adding oll helps compression, piston rings may be worn
or damaged. It so, replace piston rings after checking
piston.
If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve seat. (Refer
to S.D.S,) If valve or valve seat is damaged excessively,
replace them.
lt compression in any two adjacent cylinders is low and it
adding oll does not help compression, there is leakage past
the gasket surface. If so, replace cylinder head gasket.
EM-8OIL PAN
Removal
Remove the following parts:
Front exhaust tube
Front side gusset
Center member (2WD model)
Remove oil pan bolts.
3. Remove oil pan.
(1) Insert Too! between cylinder block and oil pan.
© Do not drive seal cutter into oll pump or rear oil se
retainer portion, or aluminum mating face will be dama
© Do not insert screwdriver, or oil pan flange will be d
formed,
(2) Slide Too! by tapping its side with a hammer, and remove
oil pan,
Installation
1. Before installing oil pan, remove all traces of liq
from mating surface using a scraper.
© Also remove traces of liquid gasket from mating surface of
cylinder block,
gasket
2. Apply a continuous bead of liquid gasket to mating surface
of oil pan.
© Use Genuine Liquid Gasket or equivOIL PAN
Cut here.
Liguia gasket
su.ce0s
7 mm (0.28 in)
toner
ie
Groove Bolt hole ey49008
Installation (Cont'd)
© Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.17 in)
wide.
3. Apply liquid gasket to inner sealing surface as shown in
figure
© Attaching should be done within 5 minutes after coating.
4, Install oil pan.
© Wait at least 30 minutes before refilling engine oll.
EM-10TIMING CHAIN
8
Timing chan
CCamshatt sprocket
©) 18-197
(2-16, 87 - "\y
‘chain tensioner. yo] yy
| ‘
Pitanad SN
ecw ite “4
ania e NT
Front ol ea!
Cranks
Pym: 70 PUY
era |
12-18), bef a ‘>
sn
Nem gn 2) seat a2. s2-1) — Lroman og sexe
CAUTION:
¢ After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
Removal
1. Place wheel chocks at both front and back of rear wheels.
2 safety stands under designated front supporting
points. Remove front right side wheel.
3. Remove dust cover and under cover.
4. Drain engine oil.
EM-11TIMING CHAIN
Removal (Cont'd)
5. Set No. 1 piston at T.D.C. on its compression stroke.
SeMsssc
Remove the alternator and compressor drive belts.
Remove the following parts.
Alternator and adjusting bar
Oil separator
Power steering pump pulley, pump stay and bracket.
Compressor and bracket.
Crankshaft pulley and oll pump drive boss.
@eeeer?
Remove oil pan. (Refer to OIL PAN.)
Remove oil strainer securing bolt.
10. Remove front cover securing bolts (cover to block and head
to cover).
SeMs67¢
11. Remove rocker cover.
42. Support engine with hoist or chain block.
18. Remove right-side engine mounting bracket and lower the
engine.
EM-12rck
TIMING CHAIN
Removal (Cont'd)
14, Remove front cover.
15. Remove the following parts:
© Chain tensioner
© Chain guides
© Timing chain and sprocket
Inspection
Check for cracks and excessive wear at roller links. Replace if
necessary.
Installation
1. Install crankshaft sprocket.
Make sure that mating marks of crankshaft sprocket face
engine front.
EM-13TIMING CHAIN
Installation (Cont'd)
2. Install camshaft sprocket.
3. Confirm that No. 1 piston is set at T.D.C. on its compression
stroke.
4, Install timing chain.
© Set timing chain by aligning its mating marks with those of
crankshaft sprocket and camshatt sprocket.
5. Tighten camshaft sprocket bolt.
6. Install chain guide and chain tensioner.
7. Apply liquid gasket to front cover.
EM-14TIMING CHAIN
Installation (Cont'd)
8. Install front cover.
‘© Be careful not to damage cylinder head gasket.
© Do not forget oil seal.
9. Install rubber plug onto cylinder head. (Refer to
“installation” of CYLINDER HEAD.)
10. Install oil pan. (Refer to OIL PAN.)
11. Install engine mounting.
42. Install any parts removed.
EM-15OIL SEAL REPLACEMENT
VALVE OIL SEAL
1. Remove rocker cover.
2, Remove rocker shaft assembly.
3. Remove valve spring and valve oil seal with Tool or a
suitable tool.
Piston concerned should be set at T.D.C. to prevent valve from
falling.
4, Apply engine oil to new valve oil seal and install it with Tool.
Before installing valve oil seal, install valve spring seat.
156-162
spring vst (ote 0638)
NT 2
[10 0.030)
Unit in seweace
OIL SEAL INSTALLING DIRECTION
Ensine gy | Engine
inne ouuige
outset tio ||| -Dus sa in
senrsa|
FRONT OIL SEAL
1. Remove crankshatt pulley.
2. Remove front oil seal.
Be careful not to damage crankshaft.
EM-16OIL SEAL REPLACEMENT
3. Apply engine oil to new oil seal and install it using a
suitable tool
REAR OIL SEAL
1. Remove transaxle,
2. Remove flywheel or drive plate.
3. Remove rear oil seal retainer.
4. Remove traces of liquid gasket using scraper.
5. Remove rear oil seal from retainer.
6. Apply engine oil to new oil seal and install it using a
suitable tool.
7. Apply liquid gasket to rear oil seal retainer.
EM-17CYLINDER HEAD
53.72)
ot
‘© For ylindr heed bolt tightening procedure,
refer to “Inealletion” of CYLINDER HEAD,
-Camshett
FD: neem kon, tea)
EM-18CYLINDER HEAD
CAUTION:
‘© When installing sliding parts such as rocker arms, camshaft
and oil seal, be sure to apply new engine oil on their sliding
surfaces.
‘© When tightening cylinder head bolts and rocker shaft bolts,
\d portions and seat surfaces of
[ox _ «Hydraulic valve lifters are installed in each rocker arm. If
hydraulic valve lifter is kept on its side, even when installed
Rocker arm with in rocker arm, there is a possibility of air entering it. After
Sinaia removal, always set rocker arm straight up, or when laying
wr it on its side, have it soak in new engine oil.
oi
sema7ee
Do not disassemble hydraulic valve lifter.
Attach tags to valve lifters so as not to mix them up.
Removal
1. Drain coolant from radiator.
2. Relieve fuel pressure to zero.
Refer to EF & EC section “FUEL INJECTION CONTROL SYSTEM
INSPECTION”.
3. Remove the following parts:
Exhaust manifold
Air duct
Intake manifold collector
Intake manifold stay
Disconnect hoses.
Vacuum gallery hoses, which are installed on intake man-
ifold.
Fuel tube hoses
Disconnect water hoses as shown in figure.
EM-19CYLINDER HEAD
Removal (Cont'd)
6. Remove intake manifold.
7. Remove rocker cover.
When removing rocker cover, do not knock rocker cover against
rocker arms.
] 8. Set No. 1 piston at T.0.C. on its compression stroke.
9. Loosen camshaft sprocket bolt.
‘© Support timing chain by using Tool as shown in figure.
10. Remove camshaft sprocket.CYLINDER HEAD
seMssoc
Removal (Cont'd)
11. Remove front cover tightening bolts to cylinder head.
12, Remove cylinder head.
© Head warpage or cracking could result from removing in
incorrect order.
© Cylinder head bolts should be loosened in two or three
steps.
ssembly
4. Remove rocker shaft assembly.
a. When loosening bolts, evenly loosen from outside in se-
quence.
b. Bolts should be loosened in two or three steps.
2. Remove camshatt.
¢ Before removing camshaft, measure camshaft end play.
(Refer to “inspection”.)
Remove valve components with Tool.
Remove valve oil seals. (Refer to OIL SEAL REPLACE-
MENT.)
EM-21CYLINDER HEAD
‘seuazac
Inspection
CYLINDER HEAD DISTORTION
Head surface flatness:
Less than 0.1 mm (0.004 in)
If beyond the specified limit, replace it or resurface it.
Resurfacing limit:
The resurfacing limit of cylinder head is determined by the
cylinder block resurfacing in an engin
Amount of cylinder head resurfacing is “A”.
Amount of cylinder block resurfacing is “B”.
The maximum limit is as follows
‘A + B = 0.2 mm (0.008 in)
After resurfacing cylinder head, check that camshaft rotates
freely by hand. If resistance is felt, cylinder head must be
replaced.
Nominal cylinder head height:
98.8 - 99.0 mm (3.890 - 3.898 in)
CAMSHAFT VISUAL CHECK
Check camshaft for scratches, seizure and wear.
CAMSHAFT RUNOUT
1. Measure camshaft runout at the center journal.
Runout (Total indicator reading):
0 - 0.02 mm (0 - 0.0008 in)
2. fit exceeds the limit, replace camshaft.
CAMSHAFT CAM HEIGHT
1. Measure camshaft cam height.
Standard cam height:
‘44,839 - 45.029 mm (1.7653 - 1.7728 in)
Cam wear limit:
0.2 mm (0.008 in)
2. if wear is beyond the limit, replace camshaft,
CAMSHAFT JOURNAL CLEARANCE
1. Install camshaft bracket and rocker shaft and tighten bolts
to the specified torque.
2, Measure inner diameter of camshaft bearing,
Standard inner diameter:
‘99,000 - 33.025 mm (1.2992 - 1.3002 in)
EM-22CYLINDER HEAD
\semazec
Isewaaze
Inspection (Cont'd)
3, Measure outer diameter of camshaft journal.
Standard outer diameter:
32,95 - 32.955 mm (1.2967 - 1.2978 in)
4, If clearance exceeds the limit, replace camshaft and/or
cylinder head.
Camshaft journal clearance:
Standard
0.045 - 0.090 mm (0.0018 - 0.0035 in)
Limit
0.12 mm (0.0047 in)
CAMSHAFT END PLAY
1. Install camshaft in cylinder head.
2. Measure camshaft end play.
‘Camshaft end play:
Standard
0.07 - 0.15 mm (0.0028 - 0.0059 in)
Limit
0.2 mm (0.008 in)
CAMSHAFT SPROCKET RUNOUT
4. Install sprocket on camshaft.
2. Measure camshaft sprocket runout.
Runout (Total indicator reading):
Limit 0.12 mm (0.0047 in)
3. If it exceeds the limit, replace camshaft sprocket
VALVE GUIDE CLEARANCE
1. Measure valve deflection in a right-angled direction with
camshaft. (Valve and valve guide mostly wear in this
direction.)
Valve deflection limit (Dial gauge reading):
0.15 mm (0.0059 in)
EM-23sem22s¢
CYLINDER HEAD
Inspection (Cont'd)
2. Ifit exceeds the limit, check valve to valve guide clearance.
a. Measure valve stem diameter and valve guide inner diam-
eter.
b. Check that clearance is within specification,
Valve to valve guide clearance:
Standard
0.020 - 0.053 mm
(0.0008 - 0.0021 in) (Intake)
0.040 - 0.070 mm
(0.0016 - 0.0028 in) (Exhaust)
Limit
0.1 mm
©. Itt exceeds the li
004 in)
, replace valve or valve guide.
VALVE GUIDE REPLACEMENT
1. To remove valve guide, heat cylinder head to 160 to 160°C
(302 to 320°F).
2. Drive out valve guide with a press [under a 20 KN (2 t, 2.2US
ton, 2.0 Imp ton) pressure] or hammer and a suitable tool.
3. Ream cylinder head vaive guide hole.
Valve guide hole diameter
(for service parts):
Intake
11.175 - 11.196 mm (0.4400 - 0.4408 in)
Exhaust
12.175 - 12.196 mm (0.4793 - 0.4802 in)
EM-24[Je
SeM795A
CYLINDER HEAD
Inspection (Cont'd)
4, Heat cylinder head to 150 to 160°C (302 to 320°F) and press
service valve guide onto cylinder head.
Projection “L":
14.9 - 15.1 mm (0.587 - 0.594 in)
5. Ream valve guide.
Finished size:
Intake
7.000 - 7.018 mm (0.2756 - 0.2763 in)
Exhaust
8,000 - 8.018 mm (0.3150 - 0.3157 in)
VALVE SEATS
Check vaive seats for any evidence of pitting at valve contact
surface, and reseat or replace if it has worn out excessively,
© Before repairing valve seats, check valve and valve guide
for wear. If they have worn, replace them. Then correct
valve seat.
© Cut with both hands to uniform the cutting surface.
REPLACING VALVE SEAT FOR SERVICE PARTS,
1. Bore out old seat until it collapses. The machine depth stop
should be set so that boring cannot continue beyond the
bottom face of the seat recess in cylinder head
2, Ream cylinder head recess.
Reaming bore for service valve seat
Oversize [0.5 mm (0.020 in)]:
Intake
36.500 - 36.516 mm (1.4370 - 1.4376 in)
Exhaust
42.500 - 42.516 mm (1.6732 - 1.6739 in)
Reaming should be done to the concentric circles to valve guide
center so that valve seat will have the correct fit.
EM-25CYLINDER HEAD
semosza
TT (Margin thickness)
Py
Inspection (Cont'd)
3. Heat cylinder head to 150 to 160°C (302 to 320°F).
4. Cutor grind valve seat using a suitable tool to the specified
dimensions as shown in S.0.S.
5. After cutting, lap valve seat with abrasive compound,
6. Check vaive seating condition.
Seat face angle ‘a’:
45 deg.
Contacting width “Ww”
Intake
4.6 - 1.7 mm (0.063 - 0.067 in)
Exhaust
4.7 - 24 mm (0.067 - 0.083 in)
VALVE DIMENSIONS
Check dimensions in each valve. For dimensions, refer to S.0.S.
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
le
EM-26CYLINDER HEAD
| IE Btonetme
semzaae
Inspection (Cont'd)
VALVE SPRING
Squareness
4. Measure “S" dimension
‘Out-of-square:
Outer
Intake
Less than 2.5 mm (0.098 in)
Exhaust
Less than 2.3 mm (0.091 in)
Inner
Intake
Less than 2.3 mm (0.091 in)
Exhaust
38 than 2.1 mm (0.083 in)
2. If it exceeds the limit, replace spring.
Pressure
Check valve spring pressure.
Pressure: N (kg, Ib) at height mm (in)
Standard
Outer
Intake
604.1 (61.6, 135.8) at 37.6 (1.480)
Exhaust
640.4 (65.3, 144.0) at 34.1 (1.343)
Inner
Intake
284.4 (29.0, 63.9) at 32.6 (1.283)
Exhaust
328.5 (83.5, 73.9) at 29.1 (1.146)
Limit
Outer
Intake
‘567.8 (57.9, 127.7) at 37.6 (1.480)
Exhaust
620.8 (69.3, 139.6) at 94.1 (1.349)
Inner
Intal
266.8 (27.2, 60.0) at 32.6 (1.283)
Exhaust
318.7 (82.5, 71.7) at 29.1 (1.146)
It it exceeds the limit, replace spring.
ROCKER SHAFT AND ROCKER ARM
1. Check rocker shafts for scratches, seizure and wear.
2. Check outer diameter of rocker shaft.
Diameter:
21.979 - 22.000 mm (0.8653 - 0.866;
EM-27CYLINDER HEAD
semasec
Wide piteh
Narrow piteh
Knock pin
semasec
semssac
Inspection (Cont'd)
3. Check inner diameter of rocker arm
Diameter:
22.012 - 22.029 mm (0.8666 - 0.9673 in)
Rocker arm to shaft clearance:
0.012 - 0.050 mm (0.0005 - 0.0020 in)
@ Keep rocker arm with hydraulic valve lifter standing to
prevent air from entering hydraulic valve liter when check-
ing.
Assembly
1. Install valve component parts.
Always use new valve oil seal. Refer to OIL SEAL RE-
PLACEMENT.
Before installing valve oil seal, install inner valve spring
seat.
Install outer valve spring (uneven pitch type) with its narrow
pitch side toward cylinder head side.
After installing valve component parts, use plastic hammer
to lightly tap valve stem tip to assure a proper fit.
2. Mount camshaft onto cylinder head, placing knock pin at
front end to top position,
Apply engine oil to camshaft when mounting onto cylinder
head.
3, Install camshaft brackets.
Front mark is punched on the camshaft bracket.
EM-28exhaurt
sewsr9c
cutout
toake
Front en
a semarac
semssoc
CYLINDER HEAD
Assembly (Cont'd)
4, Install rocker shaft with rocker arms.
‘© Install retainer with cutout facing direction shown in figure
at left.
5, Tighten bolts as shown in figure at lett.
EM-29CYLINDER HEAD
Installation
1
a
(2)
(5)
Set No. 1 piston at T.0.C. on its compression stroke as
follows:
Align mark on crankshaft pulley with “0” position and
confirm that distributor rotor head is set as shown in figure.
Confirm that knock pin on camshatt is set at the top.
Install cylinder head with new gasket and tighten cylinder
head bolts in numerical order.
Do not rotate crankshaft and camshaft separ
will hit piston heads.
Tightening procedure
Tighten all bolts to 29 N-m (3.0 kg-m, 22 ft-lb).
Tighten all bolts to 78 N-m (8.0 kg-m, 58 ft-lb).
Loosen all bolts completely.
Tighten all bolts to 29 N-m (3.0 kg-m, 22 ft-lb).
Turn all bolts 80 to 85 degrees clockwise with an angle
wrench, or if an angle wrench is not available, tighten all
bolts to 74 to 83 N-m (7.5 to 8.5 kg-m, 54 to 61 ft-lb).
ly, or valves
EM-30CYLINDER HEAD
3 mm (0.12 in) diameter
Wiquid gasket) seMoaTe.
Installation (Cont'd)
3. Set chain on camshaft sprocket by aligning each mating
mark. Then install camshaft sprocket to camshatt.
4, Tighten camshaft sprocket bolt.
5. Install rubber plugs as follows:
(1) Apply liquid gasket to rubber plugs.
¢ Rubber plugs should be replaced with new ones.
¢ Rubber plugs should be installed within 5 minutes of
applying liquid gasket.
Install rubber plugs, then move them with your fingers to
uniformly spread the gasket on cylinder head surface.
Rubber plugs should be installed flush with the surface.
Do not start the engine for 30 minutes after installing rocker
cover
Wipe clean excessive liquid gasket from cylinder head top
surta
EM-31CYLINDER HEAD
Semarec
SeMsasc
sensere
Installation (Cont'd)
6
a
.
2)
@)
(4)
“
Check hydraulic vaive liter.
Push hydraulic valve lifter forcefully with your finger.
Be sure to check it with rocker arm in its free position.
If vaive lifter moves more than 1 mm (0.04 in), air may be
inside of it.
Bleed air off by running engine at 1,000 rpm under no-load
for about 20 minutes.
If hydraulic vaive lifters are still noisy, replace them and
bleed air off again in the same manner as in step (3).
Install rocker cover.
Be sure to avoid interference between rocker cover and
rocker arm.
Tighten bolts as follows:
Tighten 2 bolts to 3 N-m (0.8 kg-m, 2.2 ft-lb) temporarily in
order shown in figure.
Then tighten all bolts to 7 to 10 N-m (0.7 to 1.0 kg-m, 6.1 to
7.2 ft-lb) in order shown in figure.
Install any parts removed.
EM-32ENGINE REMOVAL
O)y an “sy \teneeseann
TAN ~
Wh 4s-55 44-50, 92- ——
Meseo wn
UO] 49 - 55 4-56, 32-41)
I
[UE Pe, 0-09
Y
wo 100, 57-72)
nem fan. i)
sensnoe
EM-33ENGINE REMOVAL
WARNING:
a. Situate vehicle on a flat and solid surface
b. Do not remove engine until exhaust system has compl
cooled off.
Otherwise, you may burn yourself and/or fire may break out
in fuel fin
¢. For safety during subsequent steps, the tension of wires
should be slackened against the engine.
d. Before disconnecting fuel hose, release fuel pressure from
fuel line.
Refer to “Releasing Fuel Pressure” in section EF & EC.
Before removing front axle from transaxle, place safety
stands under designated front supporting points. Refer to
GI section for lifting points and towing.
{. Be sure to hoist engine and transaxle in a safe manner.
g. For engines not equipped with engine slingers, attach
Proper slingers and bolts described in PARTS CATALOG.
CAUTION:
‘© When lifting engine, be careful not to strike adjacent parts,
especially accelerator wire casing, brake lines, and brake
master cylinder.
ngine, always use engine slingers in a safe
shaft, be careful not to damage grease
seal of transaxl
Removal
Drain coolant.
Disconnect adjacent wires, harness, pipes and hoses.
Remove the following parts:
Drive belts
Power steering pump
ANC compressor
Alternator and adjusting bar
Drive shafts
Front exhaust tube
Lift up engine slightly with engine slingers and disconnect
or remove all engine mountings.
5. Support engine and transaxle assembly by placing suitable
jacks under oil pan and transaxle.
6. Lower engine and transaxle assembly
7. Remove engine from transaxle.
peecceeone
EM-34CYLINDER BLOCK
EM-35,CYLINDER BLOCK
isassembly
PISTON AND CRANKSHAFT
Place engine on a work stand.
Drain oil
Remove oil pan.
Remove water pump.
Remove cylinder head,
Remove timing chain.
eonens
Remove pistons.
When disassembling piston and connecting rod, remove
snap rings, then heat piston to 60 to 70°C (140 to 158°F) or
use piston pin press stand at room temperature.
Piston heater
semsr7a
Kv10110300:
on
8 Remove main bearing beam and crankshaft.
‘© Before removing main bearing beam, measure crankshaft
end play.
‘© Bolts should be loosened in two or three steps.
Inspection
PISTON AND PISTON PIN CLEARANCE
1. Measure inner diameter of piston pin hole dp".
‘Standard diameter “dp”:
20.987 - 20.999 mm (0.8263 - 0.8267 in)
semneoe
EM-36| ¢
a 4
g Tee hS
Micrometer
Ns.
Fete.
98
ox.
semzaoc
Piston:
seme2t8
Isemzsoc
|
CYLINDER BLOCK
Inspection (Cont'd)
2. Measure outer diameter of piston pin “Dp”
‘Standard diameter “Dp”:
20.989 - 21.001 mm (0.8263 - 0.8268 in)
3. Calculate interference fit of piston pin to piston.
dp = Dp = 0 0,004 mm (0 - 0.0002 in)
Ifit exceeds the above value, replace piston assembly with pin
PISTON RING SIDE CLEARANCE
Side clearance:
Top ring
0.04 - 0,08 mm (0.0016 - 0.0031 in)
2nd ring
0.03 - 0.07 mm (0.0012 - 0.0028 in)
Max. limit of side clearanct
0.1 mm (0.004 in)
It out of specification, replace piston and/or piston ring assem-
bly.
PISTON RING END GAP
End gap:
Top ring
0.28 - 0.43 mm (0.0110 - 0.0169 in)
2nd ring
0.45 - 0.60 mm (0.0177 - 0.0236 in)
(For rings punched with R or T.)
0.55 - 0.70 mm (0.0217 - 0.0276 in)
(For rings punched with N.)
Oil ring
0.20 - 0.60 mm (0.0079 - 0.0236 in)
Max. limit of ring gap:
0.5 mm (0.020 in)
tout of specification, replace piston ring. If gap still exceeds the
limit even with a new ring, rebore cylinder and use oversized
piston and piston rings.
Refer to §.0.S.
CONNECTING ROD BEND AND TORSION
Bend:
Limit 0.15 mm (0.0059 in)
per 100 mm (3.94 in) length
Torsion:
Limit 0.30 mm (0.0118 in)
per 100 mm (3.94 in) length
I it exceeds the limit, replace connecting rod assembly.
EM-37CYLINDER BLOCK
Inspection (Cont'd)
[ Weasaring poms CYLINDER BLOCK DISTORTION AND WEAR
1, Clean upper face of cylinder block and measure the distor-
tion.
Limit:
0.10 mm (0.0039 in)
2. If out of specification, resurface it.
ee ‘The resurfacing limit is determined by cylinder head resur-
Ls han 0.10 me (0.0030 In) facing in engine.
Amount of cylinder head resurfacing is “A’
Amount of cylinder block resurfacing is “B’
‘The maximum limit is as follows:
A + B = 0.2 mm (0.008 in)
Nominal cylinder block height
from crankshaft cent
246.95 - 247.05 mm (9.7224 - 9.7264 in)
3. If necessary, replace cylinder block.
PISTON-TO-BORE CLEARANCE
1. Using a bore gauge, measure cylinder bore for wear,
out-of-round and taper.
Standard inner diameter:
89.000 - 89.030 mm (3.5039 - 3.5051 in)
Limit:
0.2 mm (0.008 in)
Out-of-round (X - ¥) limit:
0.015 mm (0.0006 in)
Taper (A - B) limi
0.015 mm (0.0006 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder
block if necessary.
2. Check for scratches and seizure. If seizure is found, hone it.
we
© If both cylinder block and piston ar
ones, select piston of the same gradi
cylinder block upper surface.
replaced with new
umber punched on
sem2s7e
EM-38CYLINDER BLOCK
inspection (Cont'd)
3, Measure piston skirt diameter.
Piston diameter “A:
Refer to S.0.S.
Measuring point ‘‘a” (Distance from the top):
‘Approximately 52 mm (2.05 in)
4. Check that piston-to-bore clearance is witrin specification,
Piston-to-bore clearance “B”:
0.020 - 0.040 mm (0.0008 - 0.0016 in)
Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service. Reler to S.D.S.
6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter “A”
Rebored size calculation:
D=A+B-C
where,
D: Bored diameter
‘A: Piston diameter as measured
B: Piston-to-bore clearance
€: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps, and tighten to the specified
torque to prevent distortion of cylinder bores in final
assembly.
8. Cut cylinder bores.
© When any cylinder needs boring, all other cylinders must
also be bored.
‘© Do not cut too much out of cylinder bore ata time. Cut only
0.05 mm (0.0020 in) or so in diameter at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance,
10. Measure finished cylinder bore for out-of-round and taper.
‘© Measurement should be done after cylinder bore cools
down.
aan CRANKSHAFT
1. Check crankshaft main and pin journals for score, wear or
cracks,
2. With a micrometer, measure journals for taper and out-
of-round,
Out-of-round (X = ¥):
Main journal Less than 0.01 mm (0.0004 in)
Crank pin Less than 0.005 mm (0.0002 in)
Teper: A-8 Taper (A ~ B):
Outotround: x ¥ ‘Main journal Less than 0.01 mm (0.0004 in)
SSEMOI6A
Crank pin Less than 0.005 mm (0.0002 in)
EM-39CYLINDER BLOCK
Inspection (Cont'd)
3. Measure crankshaft runout.
Runout (Total indicator reading):
Less than 0.10 mm (0.0039 in)
BEARING CLEARANCE
Either of the following two methcds may be used, however,
method "A" gives more reliable results and is preferred.
Method A (Using bore gauge and micrometer)
Main bearing
4. Set main bearings in their proper positions on cylinder
block and main bearing cap.
2. Install main bearing cap to cylinder block.
Tighten all bolts in correct order in two or three stages. Refer to
“Assembly”.
3, Measure inner diameter "‘A” of each main bearing.
4, Measure outer diameter “Dm” of each crankshaft main
journal.
5. Calculate main bearing clearance.
Main bearing clearance = A - Dm
Standard:
0.020 - 0.047 mm (0.0008 - 0.0019 in)
Limit:
0.1 mm (0.004 in)
6. If it exceeds the limit, replace bearing
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshatt journal and use undersized bear-
ing
EM-40CYLINDER BLOCK
Inspection (Cont'd)
‘a. When grinding crankshatt journal, confirm that “L” dimen-
sion in fillet roll is more than the specitied limit.
““L: 01 mm (0.004 in)
Refer to $.0.S. for grinding crankshaft and available service
parts.
8. If crankshaft, is reused, measure main bearing clearance
and thickness of main bearing.
If crankshaft is replaced with a new one, it is necessary to
select thickness of main bearings as follows:
a. Grade number of each cylinder block main journal is
punched on the respective cylinder block.
b. Grade number of each crankshaft main journal is punched
on crankshaft.
Select main bearing with suitable thickness according to
the following table.
Main bearing grade number:
Main journal]
crankonat grace number] 5 1 2
journal grade number
0 1 2
1 2 3
2 2 3 4
For example:
Main journal grade number: 1
Crankshaft journal grace number: 2
Main bearing grade number = 1 + 2 = 3
EM-41CYLINDER BLOCK
semsora
sem26ic
Inspection (Cont'd)
Connecting rod bearing (Big end)
1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque.
3. Measure inner diameter “C'" of each bearing.
4, Measure outer diameter “Dp of each crankshaft pin jour-
nal
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C - Dp
Standard:
0.010 - 0.035 mm (0.0004 - 0.0014 in)
Limit:
0.09 mm (0.0035 in)
6. If it exceeds the limit, replace bearing,
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bear-
ing
Refer to step 7 of “BEARING CLEARANCE — Main
bearing”.
8. If crankshaft is replaced with a new one, select connecting
rod bearing according to the following table.
Connecting rod bearing grade number
a Connecting rod bearing
grade numb
0 0
1 1
2 2
Method B (Using plastigauge)
CAUTION:
© Do not turn crankshaft or connecting rod while plastigauge
Is being inserte
© When bearing clearance exceeds the specified limit, ensure
that the proper bearing has been installed. Then if exces-
sive bearing clearance exists, use a thicker main bearing or
undersized bearing so that the specified bearing clearance
is obtaine
EM-42CYLINDER BLOCK
Micrometer
sempoaa
Inspection (Cont'd)
‘CONNECTING ROD BUSHING CLEARANCE (Small end)
1, Measure inner diameter “C’’ of bushing.
2. Measure outer diameter “Dp” of piston pin.
3. Calculate connecting rod bearing clearance.
C-Dp
0.005 - 0.017 mm (0.0002 - 0.0007 in) (Standard)
0.023 mm (0.0009 in) (Limit)
If it exceeds the limit, replace connecting rod assembly
and/or piston set with pin.
REPLACEMENT OF CONNECTING ROD BUSHING (Small
end)
4. Drive in small end bushing until it is flush with end surface
of rod.
Be sure to align the oll holes.
2. After driving in small end bushing, ream the bushing so that
clearance between small end bushing and piston pin is
specified value.
Clearance betwee
.005
‘small end bushing and piston pin:
.017 mm (0.0002 - 0.0007 in)
FLYWHEEL/DRIVE PLATE RUNOUT
Runout (Total indicator reading):
Flywheel (M/T model)
Less than 0.1 mm (0.004 in)
Drive plate (A/T model)
Less than 0.1 mm (0.004 in)
Assembly
PISTON
4. Install new snap ring on one side of piston pin hole.
EM-43Front mark
Piston grade number
Cylinder number
semaeac
mrss
CYLINDER BLOCK
‘Assembly (Cont'd)
2. Heat piston to 60 to 70°C (140 to 158°F) and assemble piston,
piston pin, connecting rod and new snap ring.
‘© Align the direction of piston and connecting rod.
¢ Numbers stamped on connecting rod and cap correspond
to each cylinder.
© After assembly, make sure connecting rod swings
smoothly.
3. Set piston rings as shown.
CRANKSHAFT
1
Set main bearings in their proper positions on cylinder
block and main bearing beam.
Confirm that correct main bearings are used. Refer to
“Inspection” of this section.semiso8
SEwa70¢
CYLINDER BLOCK
Assembly (Cont'd)
2. Install crankshaft and main bearing beam and tighten bolts
to the specified torque
‘© Prior to tightening bearing cap bolts, place bearing cap in
its proper position by shifting crankshaft in the axial direc-
tion.
‘© Tighten bearing cap bolts gradually in two or three stages.
Start with center bearing and move outward sequentially.
'® After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.
3. Measure crankshaft end play.
Crankshaft end play:
Standard
0.05 - 0.18 mm (0.0020 - 0.0074 in)
Limit
0.3 mm (0.012 in)
if beyond the limit, replace bearing with a new one.
4. Install connecting rod bearings in connecting rods and
connecting rod caps.
© Confirm that correct bearings are used.
Refer to “Inspection”.
© Install bearings so that oil hole in connecting rod aligns
with oil hole of bearing
5. Install pistons with connecting rods.
a. Install them into corresponding cylinders with Tool.
Be careful not to scratch cylinder wall by connecting rod.
Arrange so that front mark on piston head faces toward
front of engine.
b. Install connecting rod bearing caps.
Tighten connecting rod bearing cap nuts to the specified
torque.
Connecting rod bearing nut:
(1) Tighten to 14 to 16 Nm
(1.4 to 1.6 kg-m, 10 to 12 ft-lb).
(2) Tighten bolts 60 to 65 degrees clockwise with an
angle wrench, or if an angle wrench is not
available, tighten them to 38 to 44 N-m (3.9 to 4.5,
kg-m, 26 to 33 ft-lb).
EM-45