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SECTION 1B

SOHC ENGINE MECANICAL

REPAIR INSTRUCTIONS

UNIT REPAIR



D102B701
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CYLINDER HEAD AND VALVE TRAIN COMPONENTS

(Typical Type Shown, Euro III Similar)
Tools Required



D102B702
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Disassembly Procedure

  1. Remove the cylinder head with the intake manifold and the exhaust manifold attached.
  2. Refer to "Cylinder Head and Gasket" in this section.


    D102B703
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    D102B704
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    D102B705
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  3. Remove the rocker arm shaft and rocker arm.


  4. D102B706
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  5. Remove the camshaft.
  6. Notice : Removing the camshaft, take extreme care to prevent any scratch, nick or damage.



    D102B707
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  7. Remove the valve keepers.


  8. D102B708
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  9. Remove the valves.


  10. D102B709
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  11. Remove the valve stem oil seals.
  12. Important : Do not reuse the removed oil seals. And the removed oil seals should be replaced by new one.



    D102B710
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  13. Remove the valve guide.
  14. Important : The removed valve guide should be replaced by new one of oversized. Do not reuse the removed valve guide.



D102B711
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Inspection/Measurement/Adjustment procedure

Abrasion of The Cam

  1. Measure the height of the cam using a micrometer, and replace the camshaft when the measured valve is less than the specified limit.
  2. Unit : mm (in.)
    Item
    Standard
    Limit
    Height of the cam
    IN
    35.156 (1.3841)
    35.124 (1.3828)
    EX
    34.814 (1.3706)
    34.789 (1.3696)


D102B712
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Measuring The Camshaft Bend

  1. Measure the bending of the camshaft using a dial gauge, and replace it when the measured value is over the specified limit.
  2. Unit : mm (in.)
    Item
    Limit
    Bending Limit
    0.03 (0.0012)


D102B713
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Abrasion of The Camshaft Journal

  1. Measure the outer diameter of each journal at the 4 different places (1).
  2. Using a bore gauge, measure the inner diameter of the cylinder head journal at the 4 places (The clearance of journal is measured by the difference between the outer diameter of camshaft journal and inner diameter of cylinder head journal part (2).
  3. Replace the camshaft (or cylinder head, if necessary) of which limit is over the specified limit.
  4. Unit : mm (in.)
    Item
    Standard
    Limit
    Journal clearance
    0.05 - 0.091 (0.0020 - 0.0036)
    0.15 (0.0059)


    D102B714
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    Unit : mm (in.)
    Item
    Outer diameter,camshaft journal
    Inner diameter, cylinder head journal part
    a
    Standard
    43.425 - 43.450 (1.7096-1.7106)
    43.500 - 43.516 (1.7126-1.7132)
    Limit
    43.375 (1.7077)
    43.525 (1.7136)
    b
    Standard
    43.625 - 43.650 (1.7175-1.7185)
    43.700 - 43.716 (1.7205-1.7211)
    Limit
    43.575 (1.7156)
    43.725 (1.7215)
    c
    Standard
    43.825 - 43.850 (1.7254-1.7264)
    43.900 - 43.916 (1.7283-1.7290)
    Limit
    43.775 (1.7234)
    43.925 (1.7293)
    d
    Standard
    44.025 - 44.050 (1.7333-1.7343)
    44.100 - 44.116 (1.7362-1.7369)
    Limit
    43.975 (1.7313)
    44.125 (1.7372)


D102B715
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Bending of The Rocker Arm Shaft

  1. Measure the bending of the rocker arm shaft by using the V block and dial gauge.
  2. Replace the rocker arm shaft of which bending is over the limit.
  3. Unit : mm (in.)
    Item
    Limit
    Bending Limit
    0.10 (0.0039)


D102B716
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Clearance Between The Rocker Arm and The Rocker Arm Shaft

  1. Measure the outer diameter of the rocker arm shaft using a micrometer (1).
  2. Measure the inner diameter of the rocker arm using a bore gauge (2).
  3. Replace the shaft or rocker arm (or both of them, if necessary) if the difference is over the limit between the outer diameter and the inner diameter.
  4. Unit : mm (in.)
    Item
    Standard
    Limit
    Clearance betweenthe rocker arm and the rocker arm shaft
    0.005-0.040 (0.0002-0.0016)
    0.06 (0.0024)


D102B717
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Clearance Between The Valve Stem and The Valve Guide

  1. Measure the outer diameter of the valve stem using a micrometer (1).
  2. Measure the inner diameter of the valve guide using a bore gauge (at least 1 place in the direction to valve length) (2).
  3. Measure the clearance between the valve stem and the valve guide.
  4. Unit : mm (in.)
    Item
    Standard
    Limit
    Valve stem outer diameter
    IN
    5.465 - 5.480 (0.2152-0.2157)
    -
    EX
    5.440 - 5.455 (0.2142-0.2148)
    -
    Valve guide inner diameter
    IN
    5.500 - 5.512 (0.2165-0.2170)
    5.53 (0.2177)
    EX
    5.500 - 5.512 (0.2165-0.2170)
    5.53 (0.2177)
    Clearance between stem and guide
    IN
    0.020 - 0.047 (0.0008-0.0019)
    0.07 (0.0028)
    EX
    0.045 - 0.072 (0.0018-0.0028)
    0.09 (0.0035)


    D102B718
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    D102B718
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  5. If a bore gauge is not available, measure the clearance using a dial gauge by moving the edge of the stem to the directions of (a), (b) (3).
  6. Replace the valve stem or valve guide, if the measured valve is over the limit.
  7. Unit : mm (in.)
    Item
    Limit
    Edge of the valve (a) ↔ (b) Clearance limit
    IN
    0.14 (0.0055)
    EX
    0.18 (0.0071)


D102B719
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Valve

  1. Remove all carbon from the valve.
  2. Check the valve or stem for abrasion, burn or bending, and replace as necessary.
  3. Abrasion of the valve edge.


  4. D102B720
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  5. Deviation to the rotating direction (2).
  6. Unit : mm (in.)
    Item
    Limit
    Deviation limit of valve head to the rotating direction
    0.08 (0.0031)


    D102B721
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  7. Checking the contact width (3).
  8. Unit : mm (in.)
    Item
    Limit
    Contact width on the surface of the valve seat
    IN
    1.46 - 1.66 (0.0575 - 0.0654)
    EX
    1.46 - 1.66 (0.0575 - 0.0654)


    D102B722
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  9. Valve seat repair (4).
  10. Important : Upon cutting, take care of the contact width. Finish the cutting with gradually reduced power for no cutting mark on the surface.



    D102B723
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  11. Valve lapping.
  12. a. Intake side.
    b. Exhaust side.


D102B724
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Cylinder Head

  1. Remove all carbon from the combustion chamber.
  2. Be sure not to make scratch on the intake and exhaust ports of the cylinder head, the combustion camber, and the head surface together with and the valve seats.
  3. Flatness of the cylinder head (1).


  4. D102B725
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    Notice : The deformation of the cylinder head surface may cause the loss of power due to the leakage of the compression.

    Unit : mm (in.)
    Item
    Limit
    Deformation limit of the cylinder head flatness
    0.05 (0.0020)


    D102B726
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  5. Deformation of the surface for manifold installation (2).
  6. Unit : mm (in.)
    Item
    Limit
    Limit of the manifold deformation
    0.10 (0.0039)


D102B727
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Valve Springs

  1. Weakened valve springs can be the cause of chatter, not be mentioned to possibility of reducing the power output due to gas leakage caused by decreased seating pressure.
  2. Free length of the valve spring (1).
  3. Replace the valve springs of which valve spring free length is less than than the limit.
  4. Unit : mm (in.)
    Item
    Standard
    Limit
    Valve spring free length
    54.45 (2.1437)
    53.40 (2.1024)


    D102B728A
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  5. Spring preload (2).
  6. Unit : mm (in.)
    Item
    Standard
    Limit
    Valve spring preload
    23.4-27.0 (0.9213-1.0630)
    22.0 (0.8661)
  7. Spring squareness (3).


  8. D102B729
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    Unit : mm (in.)
    Item
    Limit
    Valve spring squareness
    2.4 (0.0945)


D102B730
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Installation Procedure

  1. Make the valve guide hole using a valve guide reamer 09916-38210.


  2. D102B731
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  3. Install the valve guide.
  4. Important : Do not reuse the valve guide once disassembled, replace it with the new oversized valve guide.

    Unit : mm (in.)
    Valve guide oversize
    0.03 (0.0012)
    Valve guide protrusion
    14 (0.5512)


    D102B732
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  5. Repair the valve guide bore.


  6. D102B733
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  7. Install the new valve stem seals.
  8. Important : Do not reuse the disassembled oil seal and replace it with new one. When installing it, never tap or hit tool with a hammer or else. Install seal to guide only by pushing special tool with hand. Tapping or hitting tool may cause damage on seal.



    D102B734
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  9. Install the valves.
  10. Important : Before installing it, coat engine oil to the stem seals, valve guide bore and valve stem.



    D102B735
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  11. Install the valve springs and the spring retainers.


  12. D102B707
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  13. Install the valve keepers.
  14. Important : Coat engine oil to the valve stem oil seals, the valve guide hole, and the valve stem.



    D102B736A
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  15. Install the camshaft.
  16. Notice : Installing the camshaft, take extreme care to prevent any scratch, nick or damage.

    Tighten
    Tighten the screw to 9-12 N•m (80-106 lb-in).



    D102B737A
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  17. Install the rocker arms and the rock arm shafts.
  18. Tighten
    Tighten the bolts to 9-12 N•m (80-106 lb-in).
    (Coat the Loctitte).



    D102B738A
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    Important : Rocker arm shafts for the intake valves and the exhaust valves are different and their directions of installation are different.



    D102B739A
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  19. Install the removed components to the cylinder head.
  20. Tighten
    Tighten the exhaust manifold nuts and bolts to 17-27 N•m (13-20 lb-ft) (a).



    D102B740A
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    Tighten
    Tighten the intake manifold heat shield bolts to 8-12 N•m (71-106 lb-in) (b).

    Tighten
    • Tighten the intake manifold nuts to 15-19 N•m (11-14 lb-ft) (c).
    • Tighten the intake manifold support bracket nut to 15-19 N•m (11-14 lb-ft) (d).

    Important : Before tightening the intake manifold nuts, first of all, tighten the intake manifold support bracket nut.



    D102B741A
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    Tighten
    • Tighten the distributor bolt to 9-12 N•m (80-106 lb-in) (e).
    (Coat the Loctitte)
    • Tighten the distributor nuts to 9-12 N•m (80-106 lb-in) (f).



    D102B742A
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    Tighten
    Tighten the bolts and the nut to 9-12 N•m (80-106 lb-in) (g).

    Tighten
    Tighten the bolt to 18-22 N•m (13-16 lb-ft) (h).



    D102B743
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    - Remove the engine and the transaxle. Refer to "Engine Assembly" in this section.
    - Remove the transaxle from the engine. Refer to Section 5B, Five-Speed Manual Transaxle.
    - Remove the fly wheel.
    - Install the engine overhaul stand KM 412 to the engine assembly as the figure.
    - Drain engine oil from the engine.
    - Remove the cylinder head. Refer to "Cylinder Head and Gasket" in this section.
    - Remove the oil pump from the cylinder block. Refer to "Oil Pump" in this section (In case of repairing the crankshaft unit).


D102B744
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ENGINE BLOCK COMPONENTS

Tools Required

09916-77310 Piston Compressor

Disassembly Procedure

  1. Remove the components attached around the engine block.


  2. D102B745
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    D102B746
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    D102B747
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    D102B748
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  3. Remove the oil pan and the oil pump pickup tube.


  4. D102B749
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  5. Remove the connecting rod bearing caps.


  6. D102B750
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  7. Remove the piston and the connecting rod.


  8. D102B751
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  9. Remove the piston oil rings, and the compression rings, then remove the connecting rod.
  10. a. Top compression ring (No.1).
    b. Second compression ring (No.2).
    c. Piston oil rings (No.3).
    d. Circlip.
    e. Piston pin.
    f. Piston.
    g. Connecting rod.
    h. Connecting rod bearing cap.


D102B752
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Inspection/Measurement/Adjustment Procedure

Cylinder

  1. Wipe out the cylinder wall and check any scratch or excess abrasion on it. Apply boring with oversize when such damage is over the limits.


  2. D102B753A
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    Unit : mm (in.)
    Item
    Limit
    Bore diameter of cylinder
    ∅68.570 (2.700)
    Taper
    0.10 (0.0039) and less
    Out of Round
    0.05 (0.002) and less

    Important : Specification of oversize shall be varied as 0.25, 0.50, 0.75 and 1.00, and the oversize should be same for cylinder, piston and rings upon boring and installing. The same oversize on the 3 cylinders should be maintained.



D102B754A
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Piston

  1. Clean piston with soft cloth and check any damage to determine whether to replace it.
  2. Unit : mm (in.)
    Outer diameter of piston oversize
    Standard
    Φ68.465 - Φ68.485 (2.6955 - 2.6963)
    Oversize 0.25
    Φ68.715 - Φ68.735 (2.7053 - 2.7061)
    Oversize 0.50
    Φ68.965 - Φ68.985 (2.7152 - 2.7160)


    D102B755A
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    Unit : mm (in.)
    Piston clearance
    0.025 - 0.045 (0.00098 - 0.00177)

    Important : Upon measuring of cylinder bore diameter and piston outer diameter, calculate the measured values both in the same directions of crankshaft and piston pin.



D102B756
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Piston ring

  1. Remove carbon and make the groove clean before inserting the ring, and measure the clearance between ring and ring land with thickness gauge. If the measured exceeds the limit, replace the piston (1).
  2. Unit : mm (in.)
    Ring clearance in the groove
    Piston ring
    Standard
    Limit
    Compression ring
    0.02 - 0.06 (0.00079-0.0024)
    0.10 (0.0039)
    Second compression ring
    0.02 - 0.06 (0.00079-0.0024)
    0.10 (0.0039)
    Piston oil ring
    0.06 - 0.10 (0.0024-0.0039)
    -


    D102B757
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  3. To measure the end gap, insert the piston ring into the cylinder bore with the piston, locating it at the lowest part of the bore, then use a filler gauge to measure the gap. If the gap measured exceeds the limit, replace the ring (2).
  4. Unit : mm (in.)
    Piston ring gap
    Piston ring
    Standard
    Limit
    Compression ring
    0.15 - 0.30 (0.0059-0.0120)
    0.70 (0.0280)
    Second compression
    0.10 - 0.30 (0.0039-0.0120)
    0.70 (0.0280)
    Piston oil ring
    0.20 - 0.70 (0.0079-0.0280)
    1.80 (0.0709)


D102B758
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Piston Pin

  1. Measure the clearance between piston pin and piston boss part, and if the measured exceeds the standard, replace the piston pin (1).
  2. Unit : mm (in.)
    Item
    Standard
    Outer diameter of piston pin
    15.995 - 16.000 (0.6297 - 0.6299)
    Inner diameter of piston boss
    16.006 - 16.014 (0.6302 - 0.6305)
    Piston pin clearance
    0.006 - 0.019 (0.0002 - 0.0007)


D102B759
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Connecting rods

  1. Check the big end of each connecting rod for thrust clearance, with the rod fitted and connected to the crank pin in the normal manner. If the measured clearance is found to exceed the limit or any damage is found on the thrust surface of both ends, the responsible connecting rod or the crankshaft must be replaced (1).
  2. Unit : mm (in.)
    Connecting rod big end thrust clearance
    Standard
    Limit
    0.10-0.20 (0.0039-0.0079)
    0.35 (0.0138)
  3. Check the bending and the twist of connecting rod with the connecting rod aligner, and if the limit is exceeded, replace it.


  4. D102B760
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    Unit : mm (in.)
    Item
    Limit
    Bending (a)
    0.05 (0.0020) (in case of 100mm (3.937 in.))
    Twist (b)
    0.10 (0.0039) (in case of 100mm (3.937 in.))
  5. Bearing clearance (3).
  6. a. Plastigauge


    D102B761A
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    b. Connecting rod bearing.
    c. Bearing cap.

    Tighten
    Tighten the connecting rod bearing cap nuts to 31-35 N•m (23-25 lb-ft).



    D102B762
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    Unit : mm (in.)
    Bearing oil clearance
    Standard
    Limit
    0.020 - 0.040 (0.00079 - 0.00157)
    0.065 (0.00256)
    Unit : mm (in.)
    Bearing size
    Size
    Standard
    Outer diameter of crank pin
    37.982 - 38.000 (1.4954 - 1.4961)


D102B763
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Crankshaft

  1. Remove the engine block.
  2. Remove the crankshaft rear oil seal housing.
  3. Remove the crankshaft bearing cap.
  4. After removing the crankshaft, remove the upper bearing.


  5. D102B764
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  6. Crankshaft runout.
  7. Unit : mm (in.)
    Limit on runout
    0.03 (0.0012)

    Important : To measure runout, turn crankshaft once to be matched with dial gauge on the journal part, and read and take 1/2 value of the maximum gauge.



    D102B765
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  8. Crankshaft thrust play
  9. Unit : mm (in.)
    Crankshaft thrust play
    Standard
    Limit
    0.11 - 0.31 (0.0043 - 0.0122)
    0.4 (0.0157)


    D102B766
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  10. Out of round and taper (uneven wear) of journal.
  11. Unit : mm (in.)
    Limit on out of round and taper
    0.01 (0.00039)


    D102B767A
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  12. Crankshaft bearing oil clearance (4).
  13. a. Plastigauge.
    b. Crankshaft bearing.
    c. Bearing cap.


    D102B768
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    Tighten
    Tighten the crankshaft bearing cap bolt to 55-60 N•m (41-44 lb-ft).

    Unit : mm (in.)
    Oil clearance for crankshaft bearings
    Standard
    Limit
    0.020 - 0.040 (0.00079 - 0.00157)
    0.065 (0.00256)


    D102B769
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    Unit : mm (in.)
    Item
    Standard
    Outer diameter of crankshaft journal
    43.982 - 44.000 (1.7316 - 1.7323)


D102B770
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Flywheel

  1. Inspect it for damage, crack and abnormal wear at the ring gear part, or at the contacting surface to the clutch plate. Replace the flywheel if necessary.
  2. Measure runout of the flywheel using block and dial gauge, and replace it if runout exceeds the limit (1).
  3. Unit : mm (in.)
    Limit on runout
    0.2 (0.0079)


D102B771
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Engine block

  1. Measure 6 different places using thickness gauge and straight scale in the same method as for the cylinder head (1).
  2. Polish and repair it, if the distortion, bent or twist exceeds the limit. If polishing needs more than 0.15mm (0.0059 in.), replace it with new one.
  3. Important : Pay attention to the flatness on the surface between combustion chambers.

    Unit : mm (in.)
    Limit of cylinder distortion
    0.05 (0.0020)
    Standard flatness
    0.03 (0.0012)


    D102B772
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    Notice : The deformation of the cylinder head surface may cause the loss of power due to the leakage of the compression.

    Important : Measure the flatness of the cylinder head surface in the location of each 4 side and diagonal.



D102B773
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Installation Procedure

  1. Install the crankshaft thrust bearing and upper main bearing, then install the crankshaft to the crankshaft journal.
  2. a. Oil groove.


    D102B774
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    b. Bearing oil port.

    Important : Coat engine oil to the inner surface of bearing, or journal surface of crankshaft (crank pin side) when installing bearing.



    D102B775A
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  3. Install the crankshaft bearing cap with the lower crankshaft main bearing installed to the crankshaft journal.
  4. Tighten
    Tighten the bearing cap bolts to 50-60 N•m (36-44 lb-ft).



    D102B776A
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  5. Install the gasket and the crankshaft rear oil seal housing.
  6. Important : Do not reuse the removed gasket and replace it with new one.

    Tighten
    • Tighten the bolts to 9-12 N•m (80-106 lb-in).
    • Tighten the screws to 9-12 N•m (80-106 lb-in).
    (Coat the Loctitte)



    D102B777A
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  7. Install the oil pump with the gasket.
  8. (In case of the crankshaft unit repair)

    Important : Do not reuse the removed gasket and replace it with new one.

    Tighten
    Tighten the bolts to 9-12 N•m (80-106 lb-in).
    • Cut them with scraper, if the gasket edges are bulged.



    D102B778
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  9. Assemble the piston and the connecting rod.
  10. Important : There are assembling directions for the piston and the connecting rod. Direct the piston front mark (▶) (a) on the piston head toward the crankshaft pulley and toward the inlet manifold (b) on the connecting rod toward the exhaust manifold to assemble the piston and the connecting rod.



    D102B779
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  11. Install the compression ring and the oil ring to the piston.
  12. a. Opening of compression ring (No.1)
    b. Opening of compression ring (No.2)
    c. Opening of oil ring rail (upper rail)
    d. Opening of oil ring spacer


    D102B780
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    e. Opening of oil ring rail (lower rail)
    f. Mark
    g. Piston head


    D102B781
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  13. Install the piston and the connecting rod assembly.


  14. D102B782
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    D102B783A
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  15. Install the bearing cap with the lower bearing installed to crankshaft crank pin part.
  16. Tighten
    Tighten the bearing cap nuts to 31-35 N•m (23-25 lb-ft).



    D102B784A
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  17. Install the oil pump pickup tube and the oil pan.
  18. Tighten
    Tighten the oil pump pickup tube bolts to 9-12 N•m (80-106 lb-in).

    Tighten
    Tighten the nuts and bolts to 9-12 N•m (80-106 lb-in). (Coat the Loctitte)



    D102B785A
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  19. Install the components removed.
  20. Tighten
    Tighten the bolts to 35-41 N•m (25-30 lb-ft) (a).

    Tighten
    Tighten the bolts to 35-41 N•m (25-30 lb-ft) (b).



    D102B786A
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    Tighten
    • Tighten the generator lower bolts and the nut loosely to 18-28 N•m (13-21 lb-ft) (c).
    • Tighten the generator belt tension adjusting bolt to 18-28 N•m (13-21 lb-ft) (d).
    • Install the engine mount bracket (4).
    • Install the A/C compressor/power steering pump and the bracket with the bolts (5).

    Tighten
    • Tighten the bracket bolt to 18-22 N•m (13-16 lb-ft) (e).
    • Tighten the bracket bolts to 35-41 N•m (25-30 lb-ft) (f).
    • Install the power steering pump bracket with the bracket bolt/nut and the adjusting bolt (6).



    D102B787A
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    Tighten
    • Tighten the power steering rear bracket bolt to 18-22 N•m (13-16 lb-ft) (g).
    • Tighten the adjusting bolt and the power steering rear bracket nut to 20-24 N•m (15-18 lb-ft) (h).
    • Position the A/C compressor into the normal location.

    Tighten
    • Tighten the bolts to 18-22 N•m (13-16 lb-ft) (i).
    • Tighten the bolt to 20-24 N•m (15-18 lb-ft) (j).
    • Install the power steering/air conditioning belt.
    • Install the cylinder head with the intake manifold, the exhaust manifold, and distributor/adaptor attached. Refer to "Cylinder Head and Gasket" in this section.
    • Install the timing belt and components. Refer to "Timing Belt" in this section.
    • Install the clutch and the transaxle to the engine, then engine assembly to the engine compartment. Refer to "Engine Assembly" in this section.
    • Refill the engine crankcase with engine oil.
    • Refill the engine coolant system. Refer to Section 1D, Engine Cooling.
    • Bleed the power steering system as necessary. Refer to Section 6A, Power Steering System.
    • Refill the A/C refrigerant system as necessary. Refer to Section 7B, Manual control Heating, Ventilation, and Air Conditioning System.
    • Refill the transaxle oil as necessary.
    • Connect the negative battery cable.
    • Start the engine and operate all systems.
    • Operate the idle air control valve reset procedure as necessary.



    D102B788A
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SPECIFICATIONS

ENGINE SPECIFICATIONS

Application
Description
Unit
Standard
Limit
Camshaft
Cam Height :
Intake
mm(in.)
35.156 (1.3841)
35.124 (1.3828)
Exhaust
mm(in.)
34.814 (1.3706)
34.789 (1.3696)
Bending
mm(in.)
-
0.03 (0.0012) and less
Journal Clearance
mm(in.)
0.050 - 0.091 (0.0020 - 0.0036)
0.15 (0.0059)
Journal OD :
No. 1
mm(in.)
43.425 - 43.450 (1.7096 - 1.7106)
43.375 (1.7077)
No. 2
mm(in.)
43.625 - 43.650 (1.7175 - 1.7185)
43.575 (1.7156)
No. 3
mm(in.)
43.825 - 43.850 (1.7254 - 1.7264)
43.775 (1.7234)
No. 4
mm(in.)
44.025 - 44.050 (1.7333 - 1.7343)
43.975 (1.7313)
Cylinder Head
Journal ID :
No. 1
mm(in.)
43.500 - 43.516 (1.7126 - 1.7132)
43.525 (1.7136)
No. 2
mm(in.)
43.700 - 43.716 (1.7205 - 1.7211)
43.725 (1.7215)
No. 3
mm(in.)
43.900 - 43.916 (1.7283 - 1.7290)
43.925 (1.7293)
No. 4
mm(in.)
44.100 - 44.116 (1.7362 - 1.7369)
44.125 (1.7372)
Surfaces Flatness Deformation
mm(in.)
-
0.05 (0.002)
Manifolds Surfaces Deformation
mm(in.)
-
0.1 (0.0039)
Rocker Arm Shaft
Bending
mm(in.)
-
0.1 (0.0039)
Clearance
mm(in.)
0.005 - 0.040 (0.0002 - 0.0016)
0.06 (0.0024)
Valve
Deviation
mm(in.)
-
0.08 (0.0031)
Contact Width :
Intake
mm(in.)
1.46 - 1.66 (0.0575 - 0.0654)
-
Exhaust
mm(in.)
1.46 - 1.66 (0.0575 - 0.0654)
-
Valve Guide
Protrusion
mm(in.)
14 (0.5512)
-
Oversize
mm(in.)
0.03 (0.0012)
-
Clearance :
Intake
mm(in.)
0.020 - 0.047 (0.0008 - 0.0019)
0.07 (0.0028)
Exhaust
mm(in.)
0.045 - 0.072 (0.0018 - 0.0028)
0.09 (0.0035)
Inner Diameter :
Intake
mm(in.)
5.500 - 5.512 (0.2165 - 0.2170)
5.53 (0.2177)
Exhaust
mm(in.)
5.500 - 5.512 (0.2165 - 0.2170)
5.53 (0.2177)
Valve Stem
Diameter :
Intake
mm(in.)
5.456 - 5.480 (0.2148 - 0.2157)
-
Exhaust
mm(in.)
5.440 - 5.455 (0.2142 - 0.2148)
-
Edge Clearance :
Intake
mm(in.)
-
0.14 (0.0055)
Exhaust
mm(in.)
-
0.18 (0.0071)
Edge Abrasion
mm(in.)
-
0.05 (0.002)
Valve Spring
Free Length
mm(in.)
54.45 (2.1437)
53.4 (2.1024)
Preload
mm(in.)
23.4 - 27.0(0.9213 - 1.0630)
22.0 (0.8661)
Squareness
mm(in.)
-
2.4 (0.0945)
Cylinder Bore
Diameter
mm(in.)
-
68.57 (2.7)
Taper (Maximum)
mm(in.)
-
0.1 (0.0039) and less
Out of Round
mm(in.)
-
0.05 (0.002) and less
Piston
Diameter :
Standard
mm(in.)
68.465 - 68.485 (2.6955 - 2.6963)
-
Oversize 0.25
mm(in.)
68.715 - 68.735 (2.7053 - 2.7061)
-
Oversize 0.50
mm(in.)
68.965 - 68.985 (2.7152 - 2.7160)
-
Clearance
mm(in.)
0.025 - 0.045 (0.00098-0.00177)
-
Piston Rings
Groove Clearance :
Top Ring
mm(in.)
0.02 - 0.06 (0.00079 - 0.0024)
0.1 (0.0039)
2nd Ring
mm(in.)
0.02 - 0.06 (0.00079 - 0.0024)
0.1 (0.0039)
Oil Ring
mm(in.)
0.06 - 0.15 (0.0024 - 0.0059)
-
End Gap
Top Ring
mm(in.)
0.15 - 0.30 (0.0059 - 0.0118)
0.7 (0.0275)
2nd Ring
mm(in.)
0.30 - 0.45 (0.012 - 0.018)
0.7 (0.0275)
Oil Ring
mm(in.)
0.20 - 0.70 (0.0079 - 0.0275)
1.8 (0.0709)
Piston Pin
Diameter
mm(in.)
15.995 - 16.000 (0.6297 - 0.6299)
-
Boss Inner Diameter
mm(in.)
16.006 - 16.014 (0.6302 - 0.6305)
-
Clearance
mm(in.)
0.006 - 0.019 (0.0002 - 0.0007)
-
Connecting Rod
Thrust Clearance
mm(in.)
0.1 - 0.25 (0.0039 - 0.010)
0.35 (0.0138)
Bending,100 mm (3.937 in.)
mm(in.)
-
0.05 (0.002)
Twist, 100 mm (3.937 in.)
mm(in.)
-
0.1 (0.0039)
Oil Clearance
mm(in.)
0.02 - 0.04 (0.00079-0.00157)
0.065 (0.00256)
Crankshaft
Runout
mm(in.)
-
0.03 (0.0012)
Thrust Play
mm(in.)
0.11 - 0.31 (0.0043 - 0.0122)
0.4 (0.0157)
Out of Round / Taper
mm(in.)
-
0.01 (0.00039)
Bearing Oil Clearance
mm(in.)
0.02 - 0.04 (0.00079-0.00157)
0.065 (0.00256)
Joural OD
mm(in.)
43.982 - 44.000 (1.7316 - 1.7323)
-
Flywheel
Surfaces Deviation
mm(in.)
-
0.2 (0.0079)
Engine Block
Head Surfaces Deformation
mm(in.)
-
0.05 (0.002)
Flatness
mm(in.)
-
0.03 (0.0012)
Oil Pump
Gap Between Oil Pump Body and Outer Rotor
mm(in.)
0.10 - 0.17 (0.0039 - 0.0067)
-
Outer Rotor Side Clearance
mm(in.)
0.065 - 0.115 (0.0026 - 0.0045)
-

FASTENER TIGHTENING SPECIFICATIONS

Application
N•m
Lb-Ft
Lb-In
Distributor Housing Bolts / Nuts
9 - 12
-
80 - 106
Exhaust Manifold Bolts / Nuts
17 - 27
13 - 20
-
Exhaust Manifold Heat Shield Bolts
8 - 12
-
71 - 106
Valve Adjusting Lock Nuts
15 - 20
11 - 15
-
Rocker Arm Shaft Bolts
9 - 12
-
80 - 106
Spark Plug
20 - 30
15 - 22
-
Cylinder Head Cover Hexagon Bolts
9 -12
-
80 - 106
Cylinder Head Bolts
85 - 90
63 - 66
-
A/C Compressor Mounting Bracket Bolts
35 - 45
25 - 33
-
A/C Compressor Mounting Upper Bolts
18 - 22
13 - 16
-
A/C Compressor Mounting Lower Bolts
20 - 24
15 - 18
-
Air Filter Snorkel Bolt
7 - 9
-
62 - 80
Air Filter Housing Nuts
5 - 7
-
44 - 62
Engine Mount Damping Block Bolts
45 - 55
33 - 41
-
Engine Mount Intermediate Bracket Upper Nuts
60 - 70
44 - 52
-
Engine Mount Intermediate Bracket Bolts
72 - 88
53 - 65
-
Engine Mount Brace Bracket Bolts
35 - 45
25 - 33
-
Engine Mount Brace Bracket Nuts
18 - 22
13 - 16
-
Engine Mount Upper Bracket Bolts
35 - 41
25 - 30
-
Engine Mount Lower Bracket Bolts
35 - 41
25 - 30
-
Engine Mount Reaction Rod-to-Engine Mount Bolts/Nuts
68 - 83
50 - 61
-
Engine Mount Reaction Rod-to-Body Bolts
68 - 83
50 - 61
-
Engine Mount Front Bracket-to-Engine Mount Bolt
35 - 41
25 - 30
-
Engine Mount Front Damping Bush Bolts (Crossmember Side)
45 - 55
33 - 41
-
Engine Mount Front Damping Bush Bolt (Crossmember Side)
35 - 41
25 - 30
-
Engine Mount Front Damping Bush Bolt/Nut (Bracket Side)
68 - 83
50 - 62
-
Oil Level Gauge Guide Tube Bolt
9 - 12
-
80 - 106
Oil Pressure Switch
12 - 16
-
106 - 140
Oil Pan Drain Plug
30 - 40
22 - 30
-
Oil Pan Bolts / Nuts
9 - 12
-
80 - 106
Oil Pump Strainer Bolt
9 - 12
-
80 - 106
Oil Pump Cover Bolts
9 - 12
-
80 - 106
Oil Filter
12 - 16
-
106 - 140
Oil Filter Stud
20 - 25
15 - 18
-
Camshaft Plate Screw
9 - 12
-
80 - 106
Camshaft Gear Bolt
50 - 60
36 - 44
-
Connecting Rod Bearing Cap Nuts
31 - 35
23 - 25
-
Crankshaft Rear Oil Seal Housing Bolts / Screws
9 - 12
-
80 - 106
Crankshaft Main Bearing Cap Bolts
55 - 60
41 - 44
-
Crankshaft Pulley Bolt
65 - 75
48 - 55
-
Clutch Housing Lower Plate Bolts
4 - 7
-
35 - 62
Timing Belt Rear Cover Bolts
9 - 12
-
80 - 106
Timing Belt Tensioner Bolt
15 - 23
11- 17
-
Timing Belt Front Upper Cover Bolts
9 - 12
-
80 - 106
Timing Belt Front Lower Cover Bolts
9 - 12
-
80 - 106
Power Steering Pump Bolt
20 - 24
15 - 18
-
Power Steering Pump Front Bracket Bolt
20 - 24
15 - 18
-
Power Steering Pump Rear Bracket Bolt
18 - 22
13 - 16
-
Power Steering Pump Rear Bracket Nut
20 - 24
15 - 18
-
Power Steering Pump Rear Bracket Adjust Bolt
20 - 24
15 - 18
-
Flywheel Bolts
40 - 45
30- 33
-
Intake Manifold Nuts
15 - 19
11 - 14
-
Intake Manifold Main Bracket Bolts (10M)
9 - 12
-
80 - 106
Intake Manifold Main Bracket Bolt (12M)
18 - 22
13 - 16
-
Intake Manifold Main Bracket Nuts
9 - 12
-
80 - 106
Intake Manifold Subsidiary Bracket Bolt
18 - 22
13 - 16
-
Intake Manifold Subsidiary Bracket Nut
15 - 19
11 - 14
-

SPECIAL TOOLS

SPECIAL TOOLS TABLE


D102B101
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09900-00410 Hexagon Wrench Set

D102B102
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DW130-040 Oil Filter Wrench

D102B103
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09915-64510 Compression Pressure Gauge

D102B104
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09915-67310 Vacuum Gauge

D102B105
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09915-77310 Oil Pressure Gauge

D102B106
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09916-14510 Valve Spring Compressor
09916-48210 Valve Spring Compressor Attachment

D102B107
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09916-34541 Reamer Handle

D102B108
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09916-37320 Valve Guide Reamer (5mm or 0.1969 in.)

D102B109
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09916-38210 Valve Guide Reamer (11mm or 0.4331 in.)

D102B110
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09916-44910 Valve Guide Remover

D102B111
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09916-58210 Valve Guide Installer

D102B112
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09916-77310 Piston Compressor

D102B113
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09917-68220 Camshaft Sprocket Holder

D102B114
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09917-88220 Valve Guide Installer Attachment

D102B115
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09918-08210 Vacuum Gauge Joint

D102B116
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09924-17810 Flywheel Holder

D102B117
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09927-56020 Crankshaft Pully Holder

D102B118
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DW 100-010 Fuel Pressure Gauge

D102B119
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DW 100-020 Spring Clamp Remover/Installer

D103B103
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DW 110-021 Engine Assembly Support Fixture

D102B120
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DW 110-030A Engine Valve Compressor

D102B121
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DW 110-041 Engine & Transaxle Assembly Support Remover/Installer

D102B122
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DW 110-050A Stud Bolt Remover/Installer

D102B123
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DW 150-020 Distributor Case Nut Remover/Installer

D102B124
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KM - 412 Engine Overhaul Stand


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