ENGINE MECHANICAL

SECTION EM EM

CONTENTS
INTAKE MANIFOLD ...........................................EM-2 CYLINDER HEAD .............................................EM-11
Component Parts Location .............................EM-2 Component Parts Location ...........................EM-11
Removal and Installation of Intake Manifold ...EM-3 Removal and Installation of Cylinder Head
Removal and Installation of Air Horn Bolt .......EM-3 Assembly ......................................................EM-11
Inspection .......................................................EM-3 Cylinder Head Assembly ..............................EM-14
EXHAUST MANIFOLD .......................................EM-4 TIMING CHAIN .................................................EM-19
Component Parts Location .............................EM-4 Component Parts Location ...........................EM-19
Removal and Installation ................................EM-4 Removal .......................................................EM-19
OIL PAN AND OIL STRAINER ...........................EM-5 Installation ....................................................EM-22
Component Parts Location .............................EM-5 REMOVAL AND INSTALLATION OF
Removal and Installation ................................EM-5 ENGINE .............................................................EM-26
ROCKER COVER ...............................................EM-7 Removal .......................................................EM-26
Component Parts Location .............................EM-7 Installation ....................................................EM-28
Removal and Installation ................................EM-7 Inspection .....................................................EM-28
ROCKER ARM AND ROCKER SHAFT CYLINDER BLOCK ..........................................EM-29
ASSEMBLY .........................................................EM-8 Component Parts Location ...........................EM-29
Component Parts Location .............................EM-8 Disassembly .................................................EM-29
Removal and Installation ................................EM-8 Selective-Fit Service Parts ...........................EM-33
Disassembly and Assembly ...........................EM-9 Inspection After Disassembly .......................EM-33
Inspection .......................................................EM-9 Assembly ......................................................EM-46
INTAKE MANIFOLD
INTAKE MANIFOLD

Component Parts Location

EMM0392

EM-2
 INTAKE MANIFOLD

Removal and Installation of Intake Manifold

PREPARATION
• Drain engine coolant
• Oil level gauge
• Wiring, disconnecting lines, moving

Removal and Installation of Air Horn Bolt

REMOVAL
• Loosen bolts in the reverse of the order shown in the figure.

INSTALLATION
• Tighten bolts evenly in two steps in the order shown in the
figure.
: 1st: 9 - 10 N•m (0.9 - 1.1 kg-m, 6.6 - 7.4 ft-lb)
2nd: 18 - 21 N•m (1.8 - 2.2 kg-m, 13.3 - 15.5 ft-lb)

EMM0394

Inspection

CHECK INTAKE MANIFOLD DISTORTION.

• Check distortion of mounting surface in 6 directions using
straightedge and feeler gauge.
Limit: 0.2 mm (0.008 in.)

MASS AIR FLOW SENSOR

Refer to “Mass air flow sensor system” in EC section.

LPG INJECTOR HOLDER (LPG AND COMBINED USE)

Refer to “LPG injector system” and “LPG assistance injector system”
in EC section.

ELECTRIC THROTTLE CONTROL

Refer to “Throttle position sensor system” and “Throttle control motor
system” in EC section.

EM-3
 EXHAUST MANIFOLD
EXHAUST MANIFOLD

Component Parts Location

Exhaust manifold

6.4 - 7.5
Exhaust manifold gasket (0.65 - 0.76, 56 - 66)
(5)

Gasket

Exhaust connector
Yoke (*1)

27 - 31
(2.8 - 3.2, 20 - 23) (12)
*1 Exhaust
manifold side

: N m (kg-m, ft-lb) : Not reusable Nut (3) Exhaust manifold cover

: N m (kg-m, in-lb) 59 - 78 (6.0 - 8.0, 43 - 58) EMM0530

Removal and Installation

PREPARATION
• Disassemble exhaust front tube
• Exhaust manifold cover

REMOVAL AND INSTALLATION OF EXHAUST

MANIFOLD
1. Removal
• Loosen nuts in the reverse of the order shown in the figure.
2. Installation
• Install yoke with flat side facing exhaust manifold. (Refer to
“Component Parts Location.”)
• Tighten nuts in the numerical order shown in the figure.

EMM0397 INSPECTION
1. Exhaust manifold distortion
• Check distortion of mounting surface in 4 directions using
straightedge and feeler gauge.
Limit: 0.3 mm (0.012 in.)

EM-4
 OIL PAN AND OIL STRAINER
OIL PAN AND OIL STRAINER

Component Parts Location

Gasket Oil strainer

Bolt (2)
16 - 19
(1.6 - 1.9)
Washer
Bolt
16 - 19
(1.6 - 1.9)

Oil pan bolt (M6) (4)

6.3 - 8.3 (0.64 - 0.85)

Oil pan
Washer *1

Drain plug Oil pan side

Oil pan bolt (M8) (20) 54 - 59 (5.5 - 6.0)
: Liquid gasket 15.7 - 20.6 (1.6 - 2.1)
: Not reusable

: N m (kg-m, ft-lb) Bolt hole

EMM0522

Removal and Installation

PREPARATION
• Drain engine oil.

REMOVAL OF OIL PAN

• Loosen bolts in the reverse of the order shown in the figure.
• Use a seal cutter (SST).

EMM0400

EM-5
 OIL PAN AND OIL STRAINER

Removal and Installation (Cont’d)

INSTALLATION OF OIL PAN
• Apply a continuous bead of Three Bond 1207C to the positions
shown in the figure.
• Tighten bolts in the numerical order shown in the figure.

INSTALLATION OF OIL PAN DRAIN PLUG WASHER

• Install it with bending side facing oil pan. (Refer to “Component
Parts Location.”)
3.5 - 4.5 mm
(0.138 - 0.177 in.) dia.
EMM0531

EM-6
 ROCKER COVER
ROCKER COVER

Component Parts Location

To PCV valve
To air hose

Blow-by hose

Oil filler cap Blow-by hose

Rocker cover

1-3
(0.1 - 0.3, 9 - 26)
(15)
Washer

Washer tray

Gasket
: Not reusable

: N m (kg-m, in-lb) EMM0532

Removal and Installation

PREPARATION
• Move high-tension core
• Wiring, disconnecting lines, moving

REMOVAL AND INSTALLATION OF ROCKER COVER

1. Removal
• Loosen screws in the reverse of the order shown in the figure.
2. Installation
• Make sure that gasket is not missing from rocker cover
mounting groove.
• Tighten screws in the numerical order shown in the figure.
CAUTION:
• Tightening torque of the first screw may decrease after
tightening all screws. Retighten all screws.

EMM0403

EM-7
 ROCKER ARM AND ROCKER SHAFT ASSEMBLY
ROCKER ARM AND ROCKER SHAFT ASSEMBLY

Component Parts Location

16 - 22 (1.6 - 2.2, 12 - 16)

16 - 22 (1.6 - 2.2, 12 - 16)
Lock nut Spring washer
16 - 22 (1.6 - 2.2, 12 - 16)
(12) Rocker arm

Adjusting screw Rocker arm spring

Bolt hole
Spring washer
Rocker arm
bracket
Flat washer

Rocker arm and rocker shaft assembly

Rocker arm bracket

Rocker arm
Flat washer
Push rod (12)
Rocker arm
bracket

: Engine oil.
Crankshaft pulley side
: N m (kg-m, ft-lb)
EMM0533

CAUTION:
• Apply new engine oil to the parts marked in the figure
before installation.

Removal and Installation

PREPARATION
• Rocker cover
• Adjusting valve clearance (after installation)

REMOVAL AND INSTALLATION OF ROCKER ARM

AND ROCKER SHAFT ASSEMBLY
1. Removal
• Loosen lock nut, and then fully loosen valve clearance adjusting
screw.
• Loosen bolts evenly in several steps from outside to center.
• Carry each bracket with mounting bolts.
CAUTION:
• Hold aftermost No. 8 bracket to avoid dropping it when
carrying.

EMM0405

EM-8
ROCKER ARM AND ROCKER SHAFT ASSEMBLY

Removal and Installation (Cont’d)

2. Installation
• Tighten bolts evenly in several steps from center to outer side in
this order.
CAUTION:
• Make sure that valve clearance adjusting screw is securely
inserted to push rod head.
• Perform installation with valve clearance adjusting screw
fully loosened so as not to be affected by valve spring
tension.
• Adjust valve clearance after installation.
EMM0406
Refer to “Inspection and adjustment of valve clearance” in
ET section.

INSTALLATION OF PUSH ROD

• Rotate push rod after inserting, and then make sure that push
rod tip is securely inserted into valve lifter sphere surface.

EMM0407

Disassembly and Assembly

DISASSEMBLY AND ASSEMBLY OF ROCKER ARM
AND ROCKER SHAFT ASSEMBLY
• Remove each part individually and avoid mixing.
• Install them to the original position.

INSTALLATION OF SPRING WASHER

• Install with each convex surface facing flat washer side. (Refer
to “Component Parts Location.”)

INSTALLATION OF ROCKER ARM

• Assemble rocker shaft with bolt hole side facing engine front
side and oil hole facing downward. (Refer to “Component Parts
Location.”)

Inspection
CHECKING FOR ROCKER SHAFT BEND
• Hold both ends of rocker shaft with V-blocks, and then set dial
indicator on the center.
• Rotate the rocker shaft in one direction by hand and read
indication on the dial indicator.
• Half of the reading is the rocker shaft bend.
Standard:
0.15 mm (0.0059 in.) or less
Limit:
0.3 mm (0.012 in.)
ECM0408

EM-9
ROCKER ARM AND ROCKER SHAFT ASSEMBLY

Inspection (Cont’d)
ROCKER ARM OIL CLEARANCE
1. Rocker shaft outer diameter
• Measure outer diameter around rocker arm mounting using a
micrometer.
Standard:
19.988 - 20.000 mm (0.7869 - 0.7874 in.) dia.

EMM0409

2. Rocker arm inner diameter

• Measure rocker arm shaft hole inner diameter using an inside
micrometer.
Standard:
20.020 - 20.038 mm (0.7882 - 0.7889 in.) dia.

EMM0410

3. How to calculate rocker arm oil clearance

• (Clearance)
= (Rocker arm inner diameter) - (Rocker shaft outer diameter)
Standard:
0.020 - 0.050 mm (0.0008 - 0.0020 in.)
Limit:
0.15 mm (0.0059 in.)
• Replace rocker arm and/or rocker shaft if outside the repair
limit. Refer to standards for the outer diameter and inner
diameter.

CHECKING PUSH ROD BEND

• Hold both ends of push rod with V-blocks, and then set dial
indicator on the center.
• Rotate push rod in one direction by hand and read indication on
the dial indicator.
• Half of the reading is the push rod bend.
Limit:
0.2 mm (0.008 in.)

EMM0411

EM-10
 CYLINDER HEAD
CYLINDER HEAD

Component Parts Location

Cylinder head bolt (26)

Refer to the direction.

Washer

Cylinder head auxiliary bolt Cylinder head assembly

6.4 - 7.5 (0.65 - 0.76, 56 - 66)

: Engine oil

: Not reusable Cylinder head gasket

: N m (kg-m, in-lb)
EMM0534

CAUTION:
• Apply new engine oil to the parts marked in the figure
before installation.

Removal and Installation of Cylinder Head

Assembly
PREPARATION
• Drain engine coolant
• Exhaust manifold
• Intake manifold
• High tension core
• Rocker cover
• Rocker arm and rocker shaft assembly
• Push rod
• Wiring, disconnecting lines, moving
• Alternator adjusting bar

EM-11
 CYLINDER HEAD

Removal and Installation of Cylinder Head

Assembly (Cont’d)
REMOVAL AND INSTALLATION OF CYLINDER
HEAD AUXILIARY BOLT
1. Removal
• Remove before loosening cylinder head bolt.
2. Installation
• Install after tightening cylinder head bolt.

EMM0413

REMOVAL AND INSTALLATION OF CYLINDER

HEAD BOLT
1. Removal
• Loosen bolts in the reverse of the order shown in the figure.
2. Installation
• Lubricate threads and seat surface of each cylinder head bolt
with new engine oil.
• Tighten bolts in the numerical order shown in the figure with the
following steps.
CAUTION:
• In step 3), loosen all bolts in the reverse of the order shown
in the figure.
1) Tighten to 29.4 N•m (3.0 kg-m, 22 ft-lb)
2) Tighten to 61.8 N•m (6.3 kg-m, 46 ft-lb).
3) Fully loosen to 0 N•m (0 kg-m, 0 in-lb).
4) Tighten to 29.4 N•m (3.0 kg-m, 22 ft-lb).
5) Tighten to 69° to 74°

EMM0414

Check tightening angle with an angle wrench (SST) or a protractor.

Do not simply estimate tightening angle.
• Tighten 64 - 74 N•m (6.5 - 7.5 kgf-m, 47 - 54 ft-lb) in step 5) if
checking tightening angle is difficult.
• Apply anticorrosive or engine oil after installation onto entire
head surfaces of cylinder head bolts (3, 5, 11, 13, 19, 21 in the
figure) that expose rocker cover exterior.

EMM0415

EM-12
 CYLINDER HEAD

Removal and Installation of Cylinder Head

Assembly (Cont’d)
INSTALLATION OF CYLINDER HEAD BOLT WASHER
• Washer installing direction is not specified if cylinder head bolt
angle-tightens in step 5).
• Install it in the direction shown in the figure if it does not angle-
tighten in step 5).

EMM0416

INSTALLATION OF CYLINDER HEAD GASKET

• After applying Three Bond 1207C to the position shown in the
figure, install cylinder head gasket.

EMM0417

EM-13
 CYLINDER HEAD

Cylinder Head Assembly

COMPONENT PARTS LOCATION

Valve collet 39 - 47
Spark plug Water connector (4.0 - 4.8, 29 - 35) (2)
Spring seat (LPG and combined use)
20 - 29
Rear engine slinger
Valve spring (outer) (2.0 - 3.0,
Plug (Gasoline)
14 - 22)
Valve spring (inner)

Valve oil seal

Spring seat (inner)
Spring seat (outer)

Valve guide

Thermal transmitter
15 - 20 (1.5 - 2.0, 11 - 14)
Cylinder head

Front engine slinger

Valve seat (INT)

39 - 47 (4.0 - 4.8, 29 - 35) (2)

: Liquid gasket
Valve seat (EXH)
Bulb (INT)
: Engine oil.
: Not reusable Bulb (EXH)
: N m (kg-m, ft-lb) EMM0535

CAUTION:
• Apply new engine oil to the parts marked in the figure
before installation.

DISASSEMBLY
1. Compress the valve spring with a valve spring compressor
(SST), and remove the valve collet with a magnetic driver.
2. Remove valve spring retainer.
3. Remove valve spring.
4. Push the valve stem toward the combustion chamber side and
remove valve.
• Check valve guide clearance before removal.
• Check the location, and store individually.

EMM0419

EM-14
 CYLINDER HEAD

Cylinder Head Assembly (Cont’d)

5. Remove valve oil seal using a valve oil seal puller (SST) when
removing.
6. Remove valve spring seats.
7. Refer to (EM section), “Valve seat contact inspection” when
removing valve seat.
8. Blow compressed air around spark plug and use a spark plug
wrench (commercial service tool) when removing spark plug.

EMM0420

INSPECTION
1. Cylinder head distortion
• Remove oil, scale, gasket, sealant, and carbon deposits from
surface of cylinder head using a scraper.
CAUTION:
• Do not allow gasket fragments to enter oil or engine
coolant passages.
• Check flatness of cylinder head lower surface. Measure
distortion in 6 directions shown in the figure, at several
points in each direction.
Limit: 0.2 mm (0.008 in.)
EMM0421

2. Bulb Dimensions
• Measure dimensions at the points shown in the figure using a
micrometer.
Standard Unit: mm (in.)
Intake Exhaust
a :118.15 (4.65) 118.8 (4.677)
b :3.1 - 3.5 (0.122 - 0.138) 3.1 - 3.5 (0.122 - 0.138)
c :1.15 - 1.45 (0.0453 - 0.0571) 1.35 - 1.65 (0.0531 - 0.0650)
D (diameter) :47.0 - 47.2 (1.850 - 1.8583) 38.0 - 38.2 (1.496 - 1.504)
d (diameter) :7.965 - 7.980 (0.3136 - 0.3142) 7.945 - 7.960 (0.3128 - 0.3134)
α (degree) :45°15’ - 45°45’ 45°15’ - 45°45’

EMM0422

EMM0423

• Valve face is corrected using valve surface grinder.

EM-15
 CYLINDER HEAD

Cylinder Head Assembly (Cont’d)

• Stem edge surface is corrected using oilstone.
• Keep corrections to a minimum due to surface reduction.
Replace if outside the repair limit.

EMM0424

CORRECTION REPAIR LIMIT

Face correction length:
Intake valve:
0.5 mm (0.020 in.) or less
Exhaust valve:
0.5 mm (0.020 in.) or less
Stem edge surface correction length:
Intake valve:
0.2 mm (0.008 in.)
Exhaust valve:
EMM0425 0.2 mm (0.008 in.)

3. Valve guide clearance

• Check before removing the valve guide.
• Make sure the valve stem diameter is within the standard.
Refer to “Valve direction inspection” (previous page).
• Push the valve out toward the combustion chamber. Measure
runout while pushing the stem edge surface toward the dial
indicator.
• 1/2 of the dial indicator reading is the valve guide clearance.
Standard:
Intake:
0.020 - 0.053 mm (0.0008 - 0.0021 in.)
EMM0426
Exhaust:
0.040 - 0.073 mm (0.0016 - 0.0029 in.)
Repair limit:
Intake:
0.1 mm (0.004 in.)
Exhaust:
0.1 mm (0.004 in.)
• Replace cylinder head if it exceeds the limit.

4. Valve seat contact

• This inspection must be done after ensuring that the
dimensions of the valve guide and the valve are within the
standard.
• Check valve contact by applying red lead to valve seat contact
surface.
• Make sure that contact surfaces are connected all around.
• Reseat the valve and check again if seating condition is not
correct. Replace cylinder head if seating condition cannot be
corrected by reseating.

EMM0427

EM-16
 CYLINDER HEAD

Cylinder Head Assembly (Cont’d)

5. Valve spring squareness
• Set the valve spring against a square. Rotate the spring and
record the maximum gap between spring upper end and the
square.
Limit:
1.9 mm (0.075 in.) (Inner)
2.1 mm (0.083 in.) (Outer)

EMM0428

6. Free length and compression load of valve spring

• Check with a valve spring tester.
Standard mm (in)
Inner Outer
Free length mm (in.):
42.72 (1.6819) 48.02 (1.8905)
Length at installation mm (in.):
35.0 (1.378) 40.0 (1.57)
Load at installation N (kg, lb):
105 - 115 219 - 240
(10.7 - 11.7, 23.6 - 25.8) (22.3 - 24.4, 49.2 - 53.8)
EMM0429
Valve opening length mm (in.):
24.7 (0.972) 29.7 (1.169)
Valve opening load N (kg, lb):
292 - 319 584 - 638
(29.8 - 32.5, 65.7 - 71.7) (59.6 - 65.1, 131.4 - 143.5)
Identification paint:
Green Green

ASSEMBLY
1. Install valve spring seats.
• Install valve spring seat (outer) with rounded side facing
upward.
2. Install valve oil seals.
• Install valve oil seal to the dimensions specified in the figure
using a valve oil seal drift (SST).

EMM0430

EM-17
 CYLINDER HEAD

Cylinder Head Assembly (Cont’d)

3. Install valves.
• Apply engine oil to valve stem.
4. Install valve springs.
• Face the narrower pitch side of valve spring (with identification
paint mark) toward cylinder head.
5. Install valve spring retainers.
6. Compress the valve spring with a valve spring compressor
(SST), and install the valve collet with a magnetic driver.
• Tap valve stem tip with a plastic hammer to ensure a proper fit
after installing valve collet.
EMM0431
7. Install water connector (gasoline) or plug (LPG or combined
use).
• Apply Three Bond 1386B or equivalent to the threads, and then
connect the connector.
8. Install spark plug if it is removed.

EMM0432

EM-18
 TIMING CHAIN
TIMING CHAIN

Component Parts Location

Camshaft sprocket

Distributor driver gear (*1)

Distributor cap
Washer (with flat side facing
sprocket side)
Distributor
132 - 142
9.3 - 11 (13.5 - 14.5, 98 - 105)
(0.95 - 1.1, 82 - 95)

O-ring
Chain tensioner
6.4 - 7.5
(0.65 - 0.76, 56 - 66)
(2)
O-ring

Spring Key for

Front cover
crankshaft
sprocket
Sleeve
Key for cone
16 - 21 (1.6 - 2.1, 12 - 15) bushing
(8)
Timing chain

Chain guide
Crankshaft pulley
6.4 - 7.5 (0.65 - 0.76, 56 - 66) (2)

Cone bushing
Crankshaft Crankshaft sprocket *1
pulley (*2)
Oil pump driver spacer Camshaft sprocket side
O-ring (*1)

Stamp line
Oil seal *2 O-ring installing groove
Crankshaft pulley bolt 16 - 21 (1.6 - 2.1, 12 - 15)
181 - 191 (18.5 - 19.5, 134 - 141)
16 - 21 (1.6 - 2.1, 12 - 15) (4) Crankshaft pulley
R washer
: Engine oil.

: N m (kg-m, ft-lb) : Liquid gasket

: N m (kg-m, in-lb) : Not reusable EMM0536

CAUTION:
• Apply new engine oil to the parts marked in the figure prior
to installation.

Removal
1. Remove the following parts. (Refer to the appropriate section for
each preparation.)
• Engine drive belt
• Water pump pulley
• Oil pan
• Rocker cover
• Rocker arm
• Rocker shaft assembly
• Push rod
• Cylinder head

EM-19
 TIMING CHAIN

Removal (Cont’d)
2. Make sure that No. 1 cylinder is at TDC on its compression
stroke with the following procedure:
1) Rotate the crankshaft pulley clockwise (as viewed from the
front) and align orange notch with the timing indicator
(protrusion) on the front cover.
2) Make sure that distributor rotor is facing the direction (front side)
as shown in the figure.
• Turn crankshaft pulley 360 degrees in the direction shown
in the figure if the rotor is facing rear side.
3. Remove distributor.
4. Remove crankshaft pulley with the following procedure.
1) Remove starter motor.
2) Secure crankshaft by installing a ring gear stopper (SST) to
starter mounting hole.
• Use approximately 10 mm (0.39 in.) spacer between plate
and stopper.
3) Loosen crankshaft pulley bolts, and then remove crankshaft
pulley washer.
4) Screw crankshaft bolt by hand until it stops, and then rotate it 2
or 3 turns back.
5) Position a pulley puller (SST) to crankshaft pulley with M8 bolts
(2).
6) Set puller bolt to a pulley puller, and then tighten it until it
contacts with crankshaft pulley bolt.
7) Tighten M8 bolts (2) temporarily installed.
8) Tighten puller bolt approximately 2 turns after feeling that
EMM0437
sticking of crankshaft pulley is released.
9) Remove the pulley puller, place it to front surface of crankshaft
pulley, and tap it with a hammer. Release sticking of cone
bushing.
10) Remove cone bushing using long-nose pliers.
11) Remove crankshaft pulley.
12) Remove key for cone bushing.

EM-20
 TIMING CHAIN

Removal (Cont’d)
5. Remove front cover bolt in the reverse of the order on EM
section, and then remove front cover using a seal cutter (SST).
CAUTION:
• Be careful not to damage mounting surface.

6. Remove key for cone bushing.

7. Remove oil pump drive spacer.
8. Remove crankshaft sprocket.
9. Remove key for crankshaft sprocket.
10. Lift and remove front seal on front cover using a screwdriver if it
needs to be replaced.
11. Remove O-ring of crankshaft pulley washer.
CAUTION:
• Do not reuse O-ring.

12. Remove camshaft sprocket bolt.

• Insert a screwdriver wrapped in a shop cloth to the hole on
camshaft sprocket, secure camshaft sprocket by attaching the
tip of screwdriver to camshaft locating plate bolt, and then
loosen the bolt.

EMM0439

13. Remove chain tensioner and chain guide.

CAUTION:
• Hold the sleeve with a finger to prevent it from popping out
when removing.

14. Remove distributor drive gear.

15. Remove camshaft sprocket and crankshaft sprocket together
with timing chain.

EM-21
 TIMING CHAIN

Removal (Cont’d)

EMM0438

Installation
NOTE:
• Installing condition and matching mark location of each part are
shown in the figure.
1. Install the key for crankshaft sprocket after making sure that
crankshaft key groove and camshaft key point straight up.

EMM0440

EM-22
 TIMING CHAIN

Installation (Cont’d)
2. Install camshaft sprocket and crankshaft sprocket aligning with
matching mark on timing chain.
• Insert each sprocket to the shaft in turn and in several steps.

EMM0441

• Move camshaft into cylinder block when inserting camshaft

sprocket. Hold camshaft by temporarily tightening bolts, tap it
using a plastic hammer, and then fully insert camshaft sprocket.
NOTE:
• Key for distributor drive gear to camshaft.

3. The distributor drive gear is not visible if camshaft sprocket

insertion is insufficient.
• Install so that indication stamp mark side is facing camshaft
sprocket side. (Refer to “Component Parts Location.”)
EMM0442
4. Install camshaft sprocket bolt.
• Install washer with flat side facing camshaft sprocket side.
(Refer to “Component Parts Location.”)
• Secure camshaft sprocket in the same procedure as removal,
and tighten bolts.
5. Install chain guide and chain tensioner.
• Install chain tensioner sleeve with the arrow on sliding portion
facing chain rotating direction (up).
6. Install oil pump drive spacer to crankshaft.
7. Install key for cone bushing.

EMM0443

8. Install front oil seal to front cover when replacing front oil seal.
• Install with the arrow facing outside.
• Press oil seal in until it is flush with the end surface of front
cover using an oil seal drift (SST) or 78 mm (3.07 in.) dia. drift.
CAUTION:
• Make sure that the circumference of oil seal is not
damaged and there is no burr.

EMM0444

EM-23
 TIMING CHAIN

Installation (Cont’d)
9. Install front cover.
• Remove oil, scale, and sealant completely from flange surface
and water hole.
• Apply a continuous bead of Three Bond 1207C to the positions
shown in the figure.
CAUTION:
• Do not apply liquid gasket to inlet/outlet side groove of oil
pump inlet/outlet. (2 at mark)
NOTE:
EMM0445 • Grooves at mark prevent liquid gasket from spreading into oil
pump inlet/outlet when installing.

• Install O-rings (2).

CAUTION:
• Be careful to avoid dropping or dislocating O-ring when
installing front cover to cylinder block.

• Do not reuse O-ring.

• Refer to the figure for location and tightening order of bolts.
A: M8 X Length under head: 35 mm (1.38 in.) (4)
B: M8 X Length under head: 65mm (2.56 in.) (8)
C: M8 X Length under head: 80mm (3.15 in.) (1)

EMM0446

10. Insert a crankshaft pulley guide (SST) to crankshaft, and then

install crankshaft pulley.
CAUTION:
• Front oil seal may be damaged if crankshaft pulley is
installed directly. Always use crankshaft pulley guide.

11. Install cone bushing.

12. Apply engine oil to O-ring, and then install O-ring to the O-ring
groove on crankshaft pulley washer. (Refer to “Component
Parts Location.”)
CAUTION:
• Do not reuse O-ring.

13. Install crankshaft pulley washer, and then tighten crankshaft

pulley bolt using a ring gear stopper (SST) following the
procedures above.

EM-24
 TIMING CHAIN

Installation (Cont’d)

EMM0447

14. Install distributor.

• Check TDC on compression stroke with matching mark on
crankshaft pulley.
• Insert distributor shaft to front cover aligning distributor shaft
matching mark (circle stamp mark) with unit side matching mark
(short stamp line).
NOTE:
• Matching mark on shaft is aligned with unit side matching mark
(long stamp line) by engagement of helical gear after inserting.

EMM0448

15. Reinstall removed parts in the reverse order of removal.

EM-25
 REMOVAL AND INSTALLATION OF ENGINE
REMOVAL AND INSTALLATION OF ENGINE

CAUTION:
• Always pay attention to safety.
• Do not remove engine until exhaust system and engine
coolant has completely cooled down.
• Support the vehicle at the specified lift points.
• Refer to appropriate sections for operation procedures for
components other than engine.

Mount bracket
77 - 98
(7.9 - 10.0, 57 - 72) (2) 77 - 98 (7.9 - 10.0, 57 - 72)

77 - 98 (7.9 - 10.0, 57 - 72)

22 - 28 (2.2 - 2.9,
16 - 21)
Mount bracket
Insulator

77 - 98 (7.9 - 10.0, 57 - 72) (4)

Heat insulator

77 - 98 (7.9 - 10.0, 57 - 72) (4) Insulator

77 - 98 (7.9 - 10.0, 57 - 72) (2)

: N m (kg-m, ft-lb)
EMM0537

Removal
[OPERATION DESCRIPTION]
• Remove transmission, and remove engine by pulling up.

[PREPARATION WORK]
1. Release the fuel pressure. Refer to EC section, “Release of fuel
pressure.”
2. Remove radiator drain plug and drain engine coolant.
3. Remove the following parts.
• Engine hood
• Undercover
• Engine cover
• Battery
• Radiator, shroud, and radiator hose
• Engine drive belt
• Cooling fan
4. Disconnect accelerator cable from throttle drum and move it out
of position.

EM-26
REMOVAL AND INSTALLATION OF ENGINE

Removal (Cont’d)
[LEFT SIDE OF ENGINE ROOM]
5. Remove air duct and air cleaner case.
6. Disconnect heated oxygen sensor harness connector and
ground (between exhaust manifold cover and body).
7. Disconnect water hose. Plug the hose immediately to prevent
engine coolant from draining.
CAUTION:
• Levelly secure reservoir tank. Tilting may cause oil leakage.

[RIGHT SIDE OF ENGINE ROOM]

8. Disconnect vacuum hose (for brake booster and for differential
lock) on engine side.
9. Remove fuel hose.
CAUTION:
• After disconnecting hoses, plug them immediately to
prevent fuel from draining.

10. Disconnect all harness connectors on engine side, and then

move harnesses to body side.
11. Disconnect water hose from body side clamp, and then move it
to engine side.
12. Remove starter motor.

[UNDER VEHICLE]
13. Remove exhaust front tube.
14. Disconnect A/T oil cooler piping from oil pan.
15. Remove U-joint.
16. Remove transmission.

[REMOVAL]
17. Engage chain block hook in front/rear engine slingers and
support.
CAUTION:
• Be careful not to contact hook and chain with body and
piping when engaging hook in slingers.

18. Remove engine mount insulator LH/RH nuts.

19. Pull up and remove engine by adjusting the position carefully.
CAUTION:
• Make sure that all wires and piping were disconnected
while removing.
• Be careful not to contact with body side parts.

EM-27
REMOVAL AND INSTALLATION OF ENGINE

Installation
Install in the reverse order of removal and note the following.
• Do not allow oil to get on the engine mount insulator. Be careful
not to damage the engine mount insulator.
• Securely insert positioning stopper pin into mating side hole.
• Make sure all mount insulators are seated properly, then tighten
mount bolts and nuts.

Inspection
• Check amount of engine coolant, oil and grease before starting
engine. Refill as necessary.
• Start engine and check for any unusual noise and vibration.
• Warm up engine, and then check engine coolant, oil and
grease, fuel, and exhaust gas for leakage.

EM-28
 CYLINDER BLOCK
CYLINDER BLOCK

Component Parts Location

Blot (6)
Flywheel
Flywheel housing 147 - 167 (15 - 17,
108 - 123)
Bolt (2)
Camshaft Vale lifter (12)
6.4 - 7.5
(0.65 - 0.76, 56 - 66)

Pilot bushing

Camshaft locating plate

Blot (4)
93 - 103
Rear oil seal (9.5 - 10.5,
Blot (6) 69 - 76)
Top ring 15.7 - 18.6 (1.6 - 1.9, 12 - 14)
Second ring Cylinder block Rear oil seal retainer

Camshaft bushing
Oil ring Crankshaft
Snap ring
Main bearing with thrust washer
Piston (No. 6 journal)

Piston pin
Connecting rod Main bearing cap
cap bolt
: Selective with proper
thickness.
Snap ring
: Engine oil.
Connecting rod
Main bearing : Not reusable
Connecting rod : Liquid gasket
bearing
Blot (14) : N m (kg-m, ft-lb)
Connecting rod cap
Connecting rod nut 162 - 172 : N m (kg-m, in-lb)
Refer to the direction. (16.5 - 17.5, 119 - 127)
EMM0538

CAUTION:
• Apply new engine oil to the parts marked in the figure prior
to installation.

Disassembly
1. Remove engine assembly from the vehicle.
(Refer to EM section, “Removal and Installation of Engine.”)
2. Keep the position using a hoist so as not to tilt engine.
3. Remove engine mount bracket.
4. Install engine assembly to engine stand (SST) with the following
procedure:

EM-29
 CYLINDER BLOCK

Disassembly (Cont’d)
1) Install engine sub-attachment (SST, A shown in the figure) to
engine mount bracket mounting hole on exhaust manifold side.
90425-09090 2) Install engine attachment (SST, B shown in the figure) to engine
A
sub-attachment.

77 - 98 (7.9 - 10.0, 57 - 72) Crankshaft

(4) pulley side
: N䍃m (kg-m, ft-lb) EMM0546

3) Hoist engine and mount it on engine stand (SST, C shown in the

figure).
• It is possible to set engine attachment and sub-attachment
to engine stand, and then install hoisting engine later.
5. Drain engine oil from oil pan drain plug.
6. Drain engine coolant from cylinder block drain plug.
(Refer to “Coolant Replacement” in CO section.)
7. Remove the following parts.
• Auxiliary brackets
• Exhaust manifold
• Thermostat housing
• Water pipe
• Intake manifold
• Distributor
• Rocker cover
• Rocker shaft assembly
• Cylinder assembly
• Oil pan
• Oil strainer
• Timing chain
• Oil filter and oil filter bracket

EMM0453

8. Remove flywheel.
• Secure crankshaft using a stopper plate (SST), and then
remove bolts.
CAUTION:
• Place a shop cloth on flywheel surface to prevent damage.
• Loosen bolts diagonally and remove them.

9. Remove flywheel housing.

10. Remove rear oil seal and retainer assembly.

EMM0454 NOTE:
• Oil seal is integrated with retainer.

EM-30
 CYLINDER BLOCK

Disassembly (Cont’d)
11. Remove valve lifter.
• Pull out from block upper surface with a finger and remove it.
• Remove camshaft with valve lifter in non-contact condition if
removal is difficult, and then remove valve lifter after tapping
from crankshaft side hole.
• Check the location, and store individually.

EMM0455

12. Remove camshaft.

• Pull camshaft straight out so as not to damage bushing.

EMM0456

13. Remove piston and connecting rod assembly.

1) Set crankshaft at removal piston assembly to BDC on
compression stroke.
2) Remove connecting rod cap and push piston and connecting
rod assembly out toward cylinder head side with handle of a
hammer.
• Before loosening connecting rod nuts, check connecting
rod side clearance. (Refer to EM section, “Inspection of
connecting rod side clearance.”)

EMM0457

3) Remove connecting rod bearing.

CAUTION:
• Check installation position of each part. Arrange removed
valves to prevent mixing them up.

14. Remove piston ring using piston ring expander (commercial

service tool).
CAUTION:
• Be careful not to damage piston.
• Do not expand piston rings excessively. It can damage
piston rings.
• Check piston ring side clearance before removing piston
ring. (Refer to EM section, “Inspection of piston ring side
clearance.”)

EMM0458

EM-31
 CYLINDER BLOCK

Disassembly (Cont’d)
15. Remove connecting rod from piston.
1) Remove snap ring using snap ring pliers.

EMM0459

2) Heat piston to between 60 and 70°C (140 and 158°F) using a

drier.

EMM0460

3) Push out piston pin from piston using a round bar with outer
diameter of approximately 20 mm (0.79 in.).
CAUTION:
• Do not remove connecting rod bolt from connecting rod.

EMM0523

16. Remove main bearing caps.

1) Loosen bolts in the reverse of the order shown in the figure.

EMM0462

EM-32
 CYLINDER BLOCK

Disassembly (Cont’d)
2) Remove main bearing cap while shaking it left/right using main
bearing bolts.
17. Remove crankshaft.
18. Remove main bearing from main bearing cap and cylinder
block.
CAUTION:
• Check installation position of each part. Arrange removed
parts to prevent mixing them up.
• Before loosening main bearing cap bolts, check crankshaft
side clearance.
EMM0463
(Refer to EM section, “Inspection of crankshaft side
clearance.”)

Selective-Fit Service Parts

SELECTION METHOD
Position Selective-fit service parts Item to be selected Selection method

Cylinder block to piston Piston and piston pin assembly Piston grade Piston grade = Cylinder bore grade (Bore
NOTE: Piston and piston pin are a (Piston outer diameter) inner diameter)
matched set. They make up one
part as an assembly.

• Identification grade stamped on each part shows the dimension

measured when it was new as a grade. It is not applicable when
it has been reused.
• When part is used or corrected, measure its dimension and
decide appropriate grade by referring to Selective-fit Service
Parts Table in this section.
• Refer to the direction specified in the text for details of
measurement method for each part, reusable standard, and
selection method for selective-fit service parts.

Inspection After Disassembly

CRANKSHAFT SIDE CLEARANCE
• Move crankshaft to front or rear and measure clearance
between thrust bearing (journal 6) and crank arm using a dial
indicator or a feeler gauge.
Standard:
0.05 - 0.17 mm (0.0020 - 0.0067 in.)
Repair limit:
0.30 mm (0.0118 in.)
• Replace main bearing (integrated with thrust bearing) of journal
6, and then measure clearance again if outside the repair limit.
EMM0464 • Replace crankshaft if it still exceeds the limit.

EM-33
 CYLINDER BLOCK

Inspection After Disassembly (Cont’d)

CONNECTING ROD SIDE CLEARANCE
• Measure connecting rod-to-crank arm side clearance using a
feeler gauge.
Standard:
0.20 - 0.35 mm (0.0079 - 0.0138 in.)
Repair limit:
0.40 mm (0.0157 in.)
• Replace connecting rod, and then measure clearance again if
outside the repair limit.
• Replace crankshaft if it still exceeds the limit.
EMM0465

PISTON-TO-PISTON PIN CLEARANCE

1. Piston pin hole diameter
• Measure inner diameter of piston pin hole using an inside
micrometer
Standard:
22.993 - 23.005 mm (0.9052 - 0.9057 in.) dia.

EMM0466

2. Piston pin outer diameter

• Measure piston pin outer diameter using a micrometer.
Standard:
22.989 - 23.001 mm (0.9051 - 0.9055 in.) dia.
3. How to calculate piston-to-piston pin clearance
• (Piston pin clearance)
= (Piston pin hole diameter) - (Piston pin outer diameter)
Standard clearance at room temperature [20°C (68°F)]:
-0.001 to 0.009 mm (0 to 0.0004 in.)
• Replace piston and piston pin assembly if clearance exceeds
EMM0467
the standard.

PISTON RING SIDE CLEARANCE

• Measure piston ring-to-piston ring groove clearance using a
feeler gauge.
Standard:
Top ring 0.040 - 0.073 mm (0.0016 - 0.0029 in.)
Second ring 0.030 - 0.063 mm (0.0012 - 0.0025 in.)
Oil ring 0.065 - 0.135 mm (0.0026 - 0.0053 in.)
Repair limit:
Top ring 0.1 mm (0.004 in.)
Second ring 0.1 mm (0.004 in.)
EMM0468 Oil ring -
• Replace piston and/or piston ring assembly if outside the repair
limit.

EM-34
 CYLINDER BLOCK

Inspection After Disassembly (Cont’d)

PISTON RING END GAP
• Make sure cylinder bore inner diameter is within the standard.
(Refer to EM section, “Piston and Cylinder Bore Clearance.”)
• Press-fit piston rings in cylinder halfway using a piston, and
measure end gap.
Standard:
Top ring 0.30 - 0.45 mm (0.012 - 0.018 in.)
Second ring 0.30 - 0.45 mm (0.012 - 0.018 in.)
Oil ring 0.20 - 0.60 mm (0.008 - 0.024 in.)
Repair limit:
EMM0469 Top ring 1.5 mm (0.059 in.)
Second ring 1.5 mm (0.059 in.)
Oil ring -

CONNECTING ROD BEND AND TORSION

• Check connecting rod bend and torsion using a connecting rod
alignment tool.
Bend limit:
0.15 mm (0.0059 in.) [per 100 mm (3.9370 in.)]
Torsion limit:
0.30 mm (0.0118 in.) [per 100 mm (3.9370 in.)]

EMM0470

CONNECTING ROD LARGE END DIAMETER

• Install connecting rod cap without connecting rod bearing.
Tighten connecting rod nuts to the specified torque.
• Measure connecting rod large end diameter using an inside
micrometer.
Standard:
59.987 - 60.000 mm (2.3617 - 2.3622 in.) dia.

EMM0471

CONNECTING ROD BUSHING OIL CLEARANCE (AT

SMALL END)
1. Connecting rod small end inner diameter
• Measure inner diameter of connecting rod small end using an
inside micrometer.
Standard:
23.000 - 23.012 mm (0.9055 - 0.9060 in.) dia.

EMM0472

EM-35
 CYLINDER BLOCK

Inspection After Disassembly (Cont’d)

2. Piston pin outer diameter
• Measure piston pin outer diameter using a micrometer.
Standard:
22.989 - 23.001 mm (0.9051 - 0.9055 in.) dia.

EMM0473

3. How to calculate connecting rod bushing oil clearance

• (Connecting rod small end oil clearance)
= (Connecting rod small end inner diameter) - (Piston pin outer
diameter)
Standard:
0.005 - 0.017 mm (0.0002 - 0.0007 in.)
• Refer to standards for each part if clearance was not within the
standard. Replace connecting rod and/or piston and piston pin
assembly.
• Refer to EM section, “Piston Selective-fit Service Parts” if
reusing connecting rod and replacing piston and piston
assembly with new one. Select piston fitted to the bore grade of
cylinder block.
NOTE:
• Piston and piston pin are a matched set. They make up one part
as an assembly.

EMM0474

CYLINDER BLOCK UPPER SURFACE DISTORTION

• Completely remove old gasket on cylinder block surface using a
scraper. Also remove oil, water stains, and carbon deposits.
CAUTION:
• Do not allow gasket fragments to enter oil or engine
coolant passages.
• Check flatness of cylinder block upper surface. Measure
distortion in 4 directions shown in the figure, at several
points in each direction.
Repair limit:
0.1 mm (0.004 in.)

EMM0475

EM-36
 CYLINDER BLOCK

Inspection After Disassembly (Cont’d)

PISTON-TO-CYLINDER BORE CLEARANCE
1. Cylinder bore diameter
• Measure cylinder bore at 2 points (A and B) in 2 directions (X
and Y) using a bore gauge.
Cylinder bore inner diameter standard:
99.500 - 99.550 mm (3.9173 - 3.9193 in.) dia.
Wear limit:
0.2 mm (0.008 in.)
Out-of-round limit
(difference between measurements X and Y):
EMM0476 0.015 mm (0.0006 in.)
Taper limit (difference between measurements A and B):
0.01 mm (0.0004 in.)
• Hone or bore cylinder if outside the repair limit or cylinder inner
wall is found with damage and seizure.
• 0.5 (0.020) OS [0.5 mm (0.020 in.) oversize] and 1.0 (0.039) OS
[1.0 mm (0.039 in.) oversize] pistons are available for service.
Be sure to use the same oversize piston rings with piston
cylinder clearance size piston when using oversize piston.

EMM0477

2. Piston outer diameter

• Measure piston skirt outer diameter using a micrometer.
Measuring point:
20 mm (0.79 in.) up from piston bottom
Standard:
99.460 - 99.510 mm (3.9157 - 3.9177 in.) dia.

HOW TO CALCULATE PISTON-TO-CYLINDER BORE CLEARANCE

• (Clearance) =
(Cylinder bore inner diameter) - (Piston skirt outer diameter)
EMM0478 Standard clearance at room temperature [20°C (68°F)]:
0.030 - 0.050 mm (0.0012 - 0.0020 in.)
• Replace piston and piston pin assembly if clearance is outside
the standard.
3. Piston selective-fit service parts
• When using new cylinder block
1) Check cylinder bore grade number (1 to 5) stamped on cylinder
block upper surface and select piston from selective-fit service
parts table.
NOTE:
• Piston and piston pin are a matched set. They make up one part
as an assembly.

EMM0479

EM-37
 CYLINDER BLOCK

Inspection After Disassembly (Cont’d)

• When reusing cylinder block
1) Measure cylinder bore inner diameter.
2) Find grade number of the measured cylinder bore in “Cylinder
Bore Inner Diameter Selective-fit Service Parts Table,” and
select piston (grades 1 to 5) from selective-fit service parts
table.

Selective-fit service parts table Unit: mm (in.)

Grade
number 1 2 3 4 5
EMM0480
(stamping)

99.510 99.520 99.530 99.540 99.550

Cylinder bore (3.9117) (3.9181) (3.9185) (3.9189) (3.9193)
inner
diameter 99.500 99.510 99.520 99.530 99.540
(3.9173) (3.9177) (3.9181) (3.9185) (3.9189)
99.470 99.480 99.490 99.500 99.510
Piston outer (3.9161) (3.9165) (3.9169) (3.9173) (3.9177)
diameter 99.460 99.470 99.480 99.490 99.500
(3.9157) (3.9161) (3.9165) (3.9169) (3.9173)

CRANKSHAFT JOURNAL DIAMETER

• Measure the journal outer diameter using a micrometer.
Standard:
70.907 - 70.920 mm (2.7916 - 2.7921 in.) dia.

CRANKSHAFT PIN DIAMETER

• Measure the pin outer diameter using a micrometer.
Standard:
56.913 - 56.926 mm (2.2407 - 2.2412 in.) dia.
EMM0481

OUT-OF-ROUND AND TAPER OF CRANKSHAFT

• Measure each journal and pin at 4 positions shown in the figure
using a micrometer.
• Out-of-round is indicated by the difference between dimensions
A and B measured at points 1 and 2.
• Taper is indicated by difference between dimensions 1 and 2
measured in directions A and B.
Repair limit:
0.06 mm (0.0024 in.) dia.
(both out-of-round and taper)
EMM0482

CRANKSHAFT BEND
• Set a pair of V-blocks on a level surface and support journals 1
and 7 of crankshaft.
• Set a dial indicator vertically onto journal 4.
• Rotate crankshaft and read indication on the indicator.
• Half of the reading is the bend.
Repair limit:
0.2 mm (0.008 in.)

EMM0483

EM-38
 CYLINDER BLOCK

Inspection After Disassembly (Cont’d)

CONNECTING ROD BEARING OIL CLEARANCE
1. Measuring method
• Install connecting rod bearing to connecting rod and connecting
rod cap. Tighten connecting rod nuts to the specified torque.
Measure connecting rod inner diameter using an inside
micrometer.
(Oil clearance)
= (Connecting rod bearing inner diameter)
- (Crankshaft pin outer diameter)
Standard:
EMM0484 0.027 - 0.061 mm (0.0011 - 0.0024 in.)
Repair limit:
0.09 mm (0.0035 in.)
• Replace connecting rod bearing and/or crankshaft according to
judgement from values measured at previous steps 11 and 15-
1) if connecting rod bearing oil clearance is outside the repair
limit.
2. Using plastigage
• Completely clean off oil and dust on crankshaft pins and
bearing surfaces.
• Cut a piece of plastigage slightly shorter than bearing width,
and place it in axial direction avoiding oil hole.
• Install connecting rod bearing to connecting rod cap. Tighten
connecting rod nuts to the specified torque.
CAUTION:
• Do not rotate crankshaft while plastigage is in place.

EMM0485
• Remove connecting rod cap and bearing. Measure width of the
plastigage using scale printed on its bag.
CAUTION:
• Follow the method outlined in “By measuring” if clearance
is standard and repair limit, and if clearance exceeds repair
limit, but remeasure if clearance is less than standard.

MAIN BEARING OIL CLEARANCE

1. Measuring method
• Install main bearing to cylinder block and bearing cap. Tighten
bearing cap bolts to the specified torque and measure main
bearing inner diameter.
(Oil clearance)
= (Main bearing inner diameter) - (Crankshaft journal outer
diameter)
Standard:
0.030 - 0.087 mm (0.0012- 0.0034 in.)
Repair limit:
EMM0486
0.09 mm (0.0035 in.)
• Replace undersized bearing upper and lower as a set if
standard size main bearing oil clearance is outside the
standard.
(Refer to EM section, “Using Undersized Bearing.”)

EM-39
 CYLINDER BLOCK

Inspection After Disassembly (Cont’d)

2. Using plastigage
• Completely clean off oil and dust on crankshaft journal and
bearing surfaces.
• Cut a piece of plastigage slightly shorter than bearing width,
and place it in axial direction avoiding oil hole.
• Tighten main bearing to the specified torque.
CAUTION:
• Do not rotate crankshaft while plastigage is in place.

• Remove bearing cap and bearing. Measure width of the

EMM0487
plastigage using scale printed on its bag.
CAUTION:
• Follow the method outlined in “By measuring” if clearance
is standard and repair limit, and if clearance exceeds repair
limit, but remeasure if clearance is less than standard.

3. Using undersized bearing

• Use undersized bearing if standard size main bearing oil
clearance is outside the standard.
• When using undersize bearing, install it, measure bearing inner
diameter, and grind journal to obtain specified oil clearance.

R3.0 +0.4 +0.016

-0 (0.00118 -0 ) (All pins) Main bearing undersize table Unit: mm (in.)
R2.5 +0.4
-0 (0.098
+0.016
-0 ) (All journals)
Size Thickness

STD 2.000 (0.0787)

US0.25 (0.0098) 2.125 (0.0837)
US0.50 (0.0197) 2.250 (0.0886)
US0.75 (0.0295) 2.375 (0.0935)
US1.00 (0.0394) 2.500 (0.0984)
Unit: mm (in.)
EMM0547
NOTE:
• Each tolerance is +0.008 to +0.012 (+0.0003 to +0.0005).
CAUTION:
• Be careful not to damage fillet-roll area when grinding
crankshaft journal in order to use undersize bearing.

MAIN BEARING CRUSH HEIGHT

• Tighten bearing cap to the specified torque with main bearing
installed. Remove bearing cap and make sure that the main
bearing edges protrude. (There must be crush height).

EMM0489

EM-40
 CYLINDER BLOCK

Inspection After Disassembly (Cont’d)

VALVE LIFTER OIL CLEARANCE
• Check sliding surfaces with camshaft and lifter bore for uneven
wear and damage.
• Replace valve lifter if necessary.
1. Valve lifter outer diameter
• Measure the valve lifter outer diameter using a micrometer. (A in
the figure)
Standard:
24.960 - 24.970 mm (0.9827 - 0.9831 in.) dia.
2. Valve lifter bore inner diameter
• Measure valve lifter bore inner diameter using a bore gauge. (B
in the figure)
Standard:
25.000 - 25.003 mm (0.9843 - 0.9844 in.) dia.
EMM0490
3. How to calculate valve lifter oil clearance
• (Clearance) = (Valve lifter bore inner diameter) - (Valve lifter
outer diameter)
Standard:
0.030 - 0.073 mm (0.0012 - 0.0029 in.)
Repair limit:
0.1 mm (0.004 in.)
• Refer to standards for each part and replace valve lifter and/or
cylinder block if clearance exceeds the repair limit.

VISUAL INSPECTION OF CAMSHAFT

• Check camshaft nose or journal for damage and uneven wear.
• Replace camshaft as necessary.

CHECKING FOR CAMSHAFT BEND

• Set a pair of V-blocks on a level surface and support journals (1
and 7) of camshaft.
• Set a dial indicator vertically onto center of journal 4.
• Rotate the camshaft in one direction by hand and read
indication on the dial indicator. (Half of the reading is the bend.)
Repair limit:
0.03 mm (0.0012 in.)

EMM0491

CAM NOSE HEIGHT

• Measure with a micrometer.
Standard (intake side):
42.126 - 42.376 mm (1.6585 - 1.6683 in.)
Standard (exhaust side):
42.126 - 42.376 mm (1.6585 - 1.6683 in.)

EMM0492

EM-41
 CYLINDER BLOCK

Inspection After Disassembly (Cont’d)

CAMSHAFT OIL CLEARANCE
1. Camshaft journal outer diameter
• Measure with a micrometer.
Standard:
Journal 1 50.721 - 50.740 mm (1.9969 - 1.9976 in.)
Journal 2 50.521 - 50.540 mm (1.9890 - 1.9898 in.)
Journal 3 50.321 - 50.340 mm (1.9811 - 1.9819 in.)
Journal 4 50.121 - 50.140 mm (1.9733 - 1.9740 in.)
Journal 5 49.921 - 49.940 mm (1.9654 - 1.9661 in.)
Journal 6 49.721 - 49.740 mm (1.9575 - 1.9583 in.)
EMM0493 Journal 7 49.521 - 49.540 mm (1.9496 - 1.9504 in.)

2. Camshaft bushing inner diameter

• Measure using a bore gauge.
Standard:
Journal 1 50.76 - 50.83 mm (1.9984 - 2.0012 in.)
Journal 2 50.56 - 50.63 mm (1.9905 - 1.9933 in.)
Journal 3 50.36 - 50.43 mm (1.9827 - 1.9854 in.)
Journal 4 50.16 - 50.23 mm (1.9748 - 1.9776 in.)
Journal 5 49.96 - 50.03 mm (1.9669 - 1.9697 in.)
Journal 6 49.76 - 49.83 mm (1.9591 - 1.9618 in.)
Journal 7 49.56 - 49.63 mm (1.9512 - 1.9539 in.)
EMM0494
3. How to calculate camshaft oil clearance
• Oil clearance = Camshaft bushing inner diameter - Camshaft
journal outer diameter
Standard:
0.020 - 0.109 mm (0.0008 - 0.0043 in.)
Repair limit:
0.15 mm (0.0059 in.)
• Refer to the standards if clearance exceeds the repair limit.
Replace camshaft and/or camshaft bushing.

REPLACEMENT OF CAMSHAFT BUSHING

1. Remove welch plug.

EMM0495

EM-42
 CYLINDER BLOCK

Inspection After Disassembly (Cont’d)

2. Pull out camshaft bushings from cylinder block using a bar
(SST).

EMM0496

3. Install camshaft bushings (journals 7 to 2).

• Install journals 7 to 2 in the order from cylinder block front side
holes.
• Install camshaft bushings with cutout facing frontward and
upward. (It is same as journal 1.)

EMM0497

• Align camshaft bushing notches with knock pin of a bar (SST)

when installing.

EMM0498

• Secure journals 4 to 2 wrapped in tape so as not to dislocate

bushings.

EMM0499

EM-43
 CYLINDER BLOCK

Inspection After Disassembly (Cont’d)

• Insert bar with bushings into cylinder block, and then install a
guide plate (SST).
• Tighten bolts with “TB” mark stamped on guide plate facing up.
• Press-fit until bar matching mark (stamp line) is in the same
position as guide plate edge surface A.

EMM0500

EMM0501

• Slide bar matching mark (stamp line) in order depending on

journal position.

EM-44
 CYLINDER BLOCK

Inspection After Disassembly (Cont’d)

EMM0502

• Make sure that oil holes in each journal and cylinder block oil
holes are aligned after installing each journal.
4. Install camshaft bushing (journal 1).
• Align journal oil hole with cylinder block oil hole.
• Press-fit until journal front end is 0.5 mm (0.02 in.) inside from
cylinder block front end surface using a drift (SST).
• Make sure that journal oil hole and cylinder block oil hole are
aligned after installing journal.

EMM0503

EMM0504

EM-45
 CYLINDER BLOCK

Inspection After Disassembly (Cont’d)

5. Check camshaft bushing inner diameter and make sure that it is
within the standard.

EMM0505

6. Install welch plug.

• Apply liquid gasket (Three Bond TB1303) to welch plug.
• Press-fit using a drift (commercial service tool).

EMM0506

CAMSHAFT END PLAY

• Install locating plate and camshaft gear to camshaft, and tighten
bolt to the specified torque.
• Measure clearance between locating plate and camshaft front
end surface using a feeler gauge.
Standard:
0.08 - 0.28 mm (0.0031 - 0.0110 in.)
Repair limit:
0.5 mm (0.020 in.)
• Replace locating plate and measure again if outside the repair
EMM0507 limit.
• Replace camshaft if it still exceeds the limit.

Assembly
1. Thoroughly clean engine coolant and oil passages in cylinder
block, as well as inside of crank case and cylinder bores using
compressed air.

EM-46
 CYLINDER BLOCK

Assembly (Cont’d)
2. Install main bearing.
1) Clean bearing mounting surfaces on cylinder block and main
bearing cap to remove any foreign material, dust, and oil.
2) Install main bearing in the correct direction.
• Install main bearing half with oil groove and oil hole to
cylinder block, and the half without oil groove and oil hole to
main bearing cap.
• Install integrated thrust bearing to journal 6.
• Apply engine oil to bearing surface (inside) and thrust
outside when installing bearing. Do not apply engine oil to
reverse side of bearing, but thoroughly clean it.
• Install by aligning main bearing detent with the notch.
• Make sure the oil holes in cylinder block and main bearing
are aligned.
3. Install crankshaft to cylinder block.
• Make sure that it turns smoothly by hand.

EMM0508

4. Install main bearing caps.

• Install it by aligning main bearing identification number with
journal position.
• Install so that upper identification number faces the front of
engine.
• Tap with a plastic hammer and install it.

EMM0509

5. Tighten main bearing cap bolts.

• Lubricate threads and seat surface of bolt with new engine oil.
• Tighten bolts evenly in several steps in the order shown in the
figure.
• Rotate crankshaft by hand and make sure it turns smoothly
after tightening.
6. Install piston to connecting rod.
1) Install snap ring in snap ring installation groove on rear side of
piston using snap ring pliers.
• Make sure snap ring is securely seated in the groove.
EMM0510

EM-47
 CYLINDER BLOCK

Assembly (Cont’d)
2) Install piston to connecting rod.
• Heat piston [to between 60 and 70°C (140 and 158°F)]
using a dryer so that piston pin can be easily inserted by
hand. Insert piston pin in piston and connecting rod from
front side of piston.
• Assemble so that front mark on position head, oil hole in
connecting rod, and cylinder No. stamped on connecting
rod are positioned as shown in the figure.
3) Install snap ring onto piston front side.
• Make sure that the connecting rod swings freely after
EMM0511
completing work.
7. Install piston rings with piston ring expander (commercial
service tool).
CAUTION:
• Be careful not to damage piston.

• Install top and second rings with stamp marks on end gaps
facing up.

EMM0512

• Install oil ring with ring end gap as shown in the figure.

EMM0513

• Position end gaps of each piston ring as shown in the figure.

EMM0514

EM-48
 CYLINDER BLOCK

Assembly (Cont’d)
8. Install connecting rod bearing to connecting rod and connecting
rod cap.
• Apply engine oil to bearing surface (inside) when installing
connecting rod bearing. Do not apply engine oil to reverse side
of bearing, but thoroughly clean it.
• Install connecting rod bearing by aligning the projection with
detent notch on connecting rod.

EMM0515

9. Install piston and connecting rod assembly to crankshaft.

• Set crankshaft pin at the installation position to BDC on
compression stroke.
• Apply engine oil to cylinder bore, piston, and crankshaft pin
sufficiently.
• Install connecting rod to cylinder position corresponding to
cylinder stamped on it.
• Install piston so that front mark on piston head faces toward
crankshaft pulley mounting side using a piston ring compressor
(commercial service tool).
EMM0516
CAUTION:
• Be careful not to damage crankshaft pin with connecting
rod large end by contact.
10. Install connecting rod cap.
• Be sure that cylinder on connecting rod and connecting rod cap
match.
11. Tighten connecting rod nut.
• Angle-tighten as described below.
1) Apply new engine oil to threads and seat surfaces of connecting
rod.
2) Tighten to 38 - 40 N•m (3.9 - 4.1 kg-m, 28 - 30 ft-lb).
3) Tighten 40 to 45° using an angle wrench (SST) or a protractor.
CAUTION:
EMM0517
• Do not just estimate tightening angle.
NOTE:
• Tighten to 67 to 71 N•m (6.8 to 7.2 kg-m, 49 to 52 ft-lb) if
checking tightening angle is difficult.
4) Rotate crankshaft and make sure it turns smoothly after all
cylinders are tightened.
12. Install camshaft.
• Apply engine oil to camshaft machining surface.
• Install camshaft straightly so as not to damage bushing.
13. Install locating plate.
• Install locating plate with its mark (concave mark) facing up.
14. Install valve lifter.
• Apply engine oil to valve lifter.
• Install them in their original positions.

EMM0518

EM-49
 CYLINDER BLOCK

Assembly (Cont’d)
15. Install rear oil seal and retainer assembly.
• Apply a continuous bead of Three Bond 1207C to the positions
shown in the figure.

EMM0519

16. Install flywheel housing.

17. Install flywheel.
• Secure crankshaft using a ring gear stopper (SST).
• Tighten bolts evenly in several steps in the order shown in the
figure.
18. Assemble other parts in reverse order of disassembly.

EMM0520

EM-50