1

ENGINE
(DOHC)

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OUTLINE 1B— 2
STRUCTURAL VIEW 1B— 2
SPECIFICATIONS 1B— 3
TROUBLESHOOTING GUIDE 1B— 3
TUNE-UP PROCEDURE IB— 5
ON-VEHICLE INSPECTION 1B—10
COMPRESSION 1B—10
ON-VEHICLE MAINTENANCE 1B—11
TIMING BELT 1B—11
CYLINDER HEAD 1B—16
REMOVAL 1B—22
DISASSEMBLY 1B—24
AUXILIARY PARTS 1B—24
TIMING BELT 1B—26
CYLINDER HEAD 1B—28
CYLINDER BLOCK 1B—30
INSPECTION AND REPAIR 1B—34
ASSEMBLY 1B—48
CYLINDER BLOCK 1B—48
CYLINDER HEAD 1B—59
TIMING BELT 1B—64
AUXILIARY PARTS 1B—68
INSTALLATION 1B—73
TRANSAXLE ASSEMBLY 1B—73
ENGINE INSTALLATION 1B—74
76G01B-001
1 B OUTLINE

OUTLINE
STRUCTURAL VIEW

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4BG01A-002

1B—2
 TROUBLESHOOTING GUIDE 1 B

SPECIFICATIONS

Engine model FE DOHC

Item Leaded fuel Unleaded fuel
Type Gasoline, 4 cycle
Cylinder arrangement and number In line, 4 cylinders
Combustion chamber Pentroof
Valve system OHC, belt driven
Displacement cc (cu in) 1,998 (121.9)
Bore and stroke mm (in) 86.0 x 86.0 (3.39 x 3.39)
Compression ratio 10.0 : 1 9.2 : 1

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Compression pressure Standard 1,422 (14.5, 206)—290 1,373 (14.0, 199)—310
kPa (kg/cm 2 , psi)-rpm Minimum 996 (10.2, 144)—290 961 (9.8, 139)—310
Open BTDC 10° 10°
IN
Close ABDC 60° 55°
Valve timing
Open BBDC 60° 55°
EX
Close ATDC 10° 10°
IN 0; Maintenance-free
Valve clearance mm (in)
EX 0; Maintenance-free
Idle speed rpm 750 ± 50
Ignition timing BTDC 12° ± 1°
Firing order 1—3-- 4 - 2
76G01B-002

TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page

Difficult starting Malfunction of engine-related components

Burned valve Replace 1B—35
Worn piston, piston ring, or cylinder Replace or repair 1B—43
Failed cylinder head gasket Replace 1B—16
Malfunction of fuel system Refer to Section 4C
Malfunction of electrical system Refer to Section 5

Poor Idling Malfunction of engine-related components

Malfunction of HLA Replace 1B—60
Poor valve to valve seat contact Repair or replace 1B—37
Failed cylinder head gasket Replace 1B—16

Malfunction of fuel system Refer to Section 4C

Excessive oil Oil working up

consumption Worn piston ring groove or sticking piston ring Replace 1B-43
Worn piston or cylinder Replace or repair 1B-43

Oil working down

Worn valve seal Replace
Worn valve stem or guide Replace 1B-35

Oil leakage Refer to Section 2A

76G01B-003

1B—3
 TROUBLESHOOTING GUIDE1B

Problem Possible Cause Remedy Page

Insufficient power Insufficient compression

Malfunction of HLA Replace 1B—60
Compression leakage from valve seat Repair 1B—37
Seized valve stem Replace 1B—35
Weak or broken valve spring Replace 1B—38
Failed cylinder head gasket Replace 1B-16
Cracked or distorted cylinder head Replace 1B—34
Sticking, damaged, or worn piston ring Replace 1B—43
Cracked or worn piston Replace 1B—43

Malfunction of fuel system Refer to Section 4C

Others

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Slipping clutch Refer to Section 6
Dragging brakes Refer to Section 11
Wrong size tires Refer to Section 12
Abnormal Malfunction of engine-related components
combustion Malfunction of HLA Replace 1B-60
Sticking or burned valve Replace 1B-35
Weak or broken valve spring Replace 1B—38
Carbon accumulation in combustion chamber Eliminate carbon
Malfunction of fuel system Refer to Section 4C
Engine noise Crankshaft or bearing related parts
Excessive main bearing oil clearance Replace or repair 1B-51
Main bearing seized or heat-damaged Replace 1B—51
Excessive crankshaft end play Replace or repair 1B—52
Excessive connecting rod bearing oil clearance Replace or repair 1B—53
Connecting rod bearing seized or heat-damaged Replace 1B—53
Piston related parts
Worn cylinder Replace or repair 1B—41
Worn piston or piston pin Replace 1B-44
Seized piston Replace 1B—43
Damaged piston ring Replace 1B—43
Bent connecting rod Replace 1B-44

Valves or timing related parts

Malfunction of H L A * Replace 1B-60
Broken valve spring Replace 1B—38
Excessive valve guide clearance Replace 1B—35
Malfunction of timing belt tensioner Replace 1B—47
Malfunction of cooling system Refer to Section 3A
Malfunction of fuel system Refer to Section 4C

Others
Malfunction of water pump bearing Replace
Improper drive belt tension Adjust 1B— 6
Malfunction of alternator bearing Replace
Exhaust gas leakage Repair 1B—34

* Tappet noise may occur if the engine is not operated for an extended period of time. The noise should stop after the
engine has reached normal operating temperature.
76G01B-004

1B—4
 TUNE-UP PROCEDURE 1 B

TUNE-UP PROCEDURE
Tune the engine according to the procedures
described below.

Battery
1. Check for corrosion on the terminals, or loose ca-
ble connections.
If necessary, clean the clamps and tighten firmly.
2. Check that the electrolyte level is between the UP-
PER and LOWER marks.
Add distilled water if necessary.

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76G01A-102

3. Check the specific gravity by using a hydrometer.

If the specific gravity reading is 1.200 or less,
recharge the battery. (Refer to Section 5.)

76G01A-103

Air Cleaner Element

Visually check the air cleaner element for excessive
dirt, damage, or oil. Clean or replace if necessary.

Caution
When cleaning the air cleaner element, blow
dust off from the inside completely first, then
blow from the outside.

76G01B-005

Engine Oil
Check the engine oil level and condition with the oil
level gauge.
Add oil, or change it, if necessary.

4BG01A-010

1B—5
1B TUNE-UP PROCEDURE1B

Coolant Level (Cold engine)

1. Check that the coolant level is near the radiator inlet
port.
2. Check that the level in the coolant reservoir is be-
tween the FULL and LOW marks.
Add coolant if necessary.

Warning
a) Never remove the radiator cap while the en-
gine is hot.
b) Wrap a thick cloth around the cap and care-
fully remove it.

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86U01X-008

Drive Belt
1. Check that the drive belt is positioned in the pul-
ley groove.
2. Check the drive belt for wear, cracks, or fraying.
Replace if necessary.
3. Check the drive belt tension by using the tension
gauge.

Standard belt tension N (kg, lb)

Belt New Used
Alternator 589-785 (60-80, 132-176) 491-687 (50-70, 110-154)
P/S 687-883 (70-90,154-198) 589-785 (60-80.132-176)
76G01B-006 A/C 687-883 (70-90,154-198) 589-785 (60-80,132-176)

4. Check the drive belt deflection by applying moder-

ate pressure (98 N, 10 kg, 22 lb) midway between
the pulleys.

(1) Alternator belt deflection

New : 6—8 mm (0.24—0.31 in)
Used: 7—9 mm (0.27—0.35 in)

If necessary, loosen the alternator mounting

bolts and adjust the belt deflection by turning
the adjusting bolt.
76G01B-007

Tightening torque
A d j u s t i n g bolt
® : 31—46 Nm (3.2—4.7 m-kg, 23—34 ft-lb)
(§): 37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb)

(2) P/S belt deflection

New : 8—10 mm (0.31—0.39 in)
Used: 9—11 mm (0.35—0.43 in)

If necessary, loosen the idler pulley lock bolt

and adjust the belt deflection by turning the ad-
justing bolt.

Tightening torque of lock bolt:

76G01B-008 37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)

1B—6
 TUNE-UP PROCEDURE 1 B

(3) A/C belt deflection

New : 7—9 mm (0.27—0.35 in)
Used: 8—10 mm (0.31—0.39 in)

If necessary, loosen the A/C mounting bolts

and adjust the belt deflection by turning the ad-
justing bolt.

Tightening torque
(A): 37—52 N m (3.8—5.3 m-kg, 27—38 ft-lb)
(§): 37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb)

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76G01A-009

(4) P/S and A/C belt deflection

New : 7—9 mm (0.27—0.35 in)
Used: 8—10 mm (0.31—0.39 in)

If necessary, adjust the belt deflection using the

same procedure as used for the A/C belt
deflection.

76G01A-010

Spark Plug
Wear and adhesion
of carbon Check the following points. Clean or replace if
necessary.
Burnt 1. Damaged insulation
2. Worn electrodes
Damage and
deterioration
3. Carbon deposits
4. Damaged gasket
5. Burnt spark insulator
Damage 6. Plug gap

Plug gap:
0.7—0.8 mm (0.028—0.031 in)

76G01B-118

Distributor Cap
Check the following points. Replace if necessary.
1. Cracks or carbon deposits
2. Burnt or corroded terminals
3. Worn distributor center contact

| © © AU

76G01B-008

1B—7
 TUNE-UP PROCEDURE1B

High-Tension Lead
Check the following points. Clean or replace if
necessary.
1. Damaged lead
2. Carbon deposits

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86U01X-014

Hydraulic Lash Adjuster (HLA)

Note
i^rrr ' / Tappet noise may occur if the engine is not
operated for an extended period of time. The
noise should stop after the engine has
reached normal operating temperature.

1. Check for tappet noise. If noise exists, check the

following points.
(1) Engine oil condition and level
(2) Engine oil pressure (Refer to Section 2A)
49 0 1 8 7 2 8 0
76G01B-011

2. If the noise does not stop, check for movement of

each HLA by pushing it during disassembly.
3. If the HLA moves, replace the HLA. (Refer to page
1B—60.)

76G01B-012

Ignition Timing
1. Warm up the engine and run it at idle.
2. Turn all electric loads OFF.
3. Connect a timing light tester.
4. Disconnect the vacuum hose from the vacuum
control, and plug the hose.
5. Check that the ignition timing mark (yellow) on the
crankshaft pulley and the timing mark on the tim-
ing belt cover are aligned.

Ignition timing: 12° ± 1° BTDC

(at idle speed)

76G01B-008

1B—8
 TUNE-UP PROCEDURE 1 B

6. If necessary, adjust the ignition timing by turning

the distributor.

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Idle Speed
1. Ground the test connector to the vehicle with a
jumper wire.
2. Connect a tachometer to the engine.
3. Check the idle speed.

Idle speed: 750 ± 50 rpm

4. If necessary, remove the blind cap from the throt-

tle body and adjust by turning the air adjust screw.
5. Install the blind cap and disconnect the jumper wire
from the test connector.

Idle Mixture
1. Connect an exhaust gas analyzer to the vehicle.
2. Measure the CO and HC concentration.

CO concentration: 1.5 ± 0.5%

HC concentration: Less than 1,000 ppm

76G01B-015

3. If necessary, remove the blind cap from the air flow

meter and adjust by turning the bypass air adjust
screw with SST.
4. Install the blind cap to the air flow meter and dis-
connect the jumper wire from the test connector.

76G01B-016

1B—9
1 B ON-VEHICLE INSPECTION

ON-VEHICLE INSPECTION
If the engine exhibits low power, poor fuel economy,
or poor idle, check the following points.
1. Ignition system (Refer to Section 5)
2. Compression
3. Fuel system (Refer to Section 4C)

COMPRESSION
1. Check that the battery is fully charged. Recharge
if necessary.

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76G01B-017

2. Warm up the engine to the normal operating tem-

perature.
3. Turn it off for about 10 minutes to allow the exhaust
manifold to cool.
4. Remove all spark plugs.
5. Disconnect the primary wire connector from the
ignition coil.

6. Connect a compression gauge to No.1 spark plug

hole.
7. Fully depress the accelerator pedal and crank the
86U01X-020 engine.
8. Note the maximum gauge reading.
9. Check each cylinder.

Standard compression:
1,422 kPa (14.5 kg/cm 2 , 206 psi)—290 rpm
Leaded fuel
1,373 kPa (14.0 kg/cm 2 ,199 psi)—310 rpm
... Unleaded fuel
Compression limit:
996 kPa (10.2 kg/cm2, 144 psi)—290 rpm
Leaded fuel
961 kPa (9.8 kg/cm2, 139 psi)—310 rpm
... Unleaded fuel
76G01B-018

Possible Cause
If compression is low, pour heavy oil into the cylinder and turn the crankshaft several times
Check compression once more

»
Yes 1. Worn piston or piston rings
Is compression increased?
2. Worn cylinder wall
No
1. Defective cylinder head gasket
2. Distorted cylinder head
Yes
Is compression in adjacent cylinder low?
1. Improper valve seating
No 2. Valve sticking in guide
3. Defective cylinder head gasket

86U01X-022

1B—10
 ON-VEHICLE MAINTENANCE (TIMING BELT) 1 B

ON-VEHICLE MAINTENANCE
TIMING BELT
Removal
1. Disconnect the negative battery cable.
2. Remove in the sequence shown in the figure referring to the removal note for specially marked parts.
76G01A-108

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76G01B-020

1. Center cover 7. Upper timing belt cover

2. High-tension lead and spark plug 8. Lower timing belt cover
3. Engine side cover 9. Baffle plate
4. Drive belt 10. Timing belt tensioner
5. Crankshaft pulley 11. Timing belt tensioner spring
6. Engine mount bracket 12. Timing belt

1B—11
 ON-VEHICLE MAINTENANCE (TIMING BELT)1B

Removal note
Timing belt tensioner
1. Turn the crankshaft to align the mating marks of
the camshaft pulleys.

Note
For intake side camshaft pulley, align " I "
mark.
For exhaust side camshaft pulley, align " E "
mark.

2. Remove the tensioner.

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76G01B-021

Timing belt
Mark the timing belt rotation for proper reinstallation
if it is reused.

Caution
Be careful not to allow oil, grease, or water
on the belt.

86U01X-024

Inspection
Inspect the following parts. (Refer to page 1B—46,
47.)
1. Timing belt
2. Timing belt tensioner and spring
3. Timing belt idler pulley
4. Timing belt pulley
5. Camshaft pulley

76G01B-022

1B—12
 1BON-VEHICLE MAINTENANCE (TIMING BELT)

Installation
Install in the reverse order of removal referring to the installation note.

Torque Specifications 76G01A-109

8—12 N m (80—120 cm-kg, 69—104 In-lb)

Installation note
Timing belt
1. Check that the mark on the timing belt pulley is
aligned with the mating mark.
2. Check that the mating mark of the camshaft pul-
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leys are aligned with the seal plate mating marks.

Note
For intake side camshaft pulley, align " I "
mark.
For exhaust side camshaft pulley, align " E "
mark.

76G01B-026

1B—13
1 B ON-VEHICLE MAINTENANCE (TIMING BELT)

3. Install the timing belt tensioner and spring. Tem-

porarily secure it with the spring fully extended.

Caution
Do not damage the pulleys when securing the
tensioner pulley.

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76G01B-024

4. Install the timing belt so that there is no looseness

at the tension side, and at the two camshaft pulleys.

Caution
a) If the timing belt is being reused, it must be
reinstalled to rotate in the original direction.
b) Check that there is no oil, grease, or dirt on
the timing belt.

76G01B-025

5. Loosen the tensioner lock bolt.

6. Turn the crankshaft twice in the direction of rota-
tion, and align the mating marks.
7. Check that the timing marks are correctly aligned.
If not aligned, remove the timing belt tensioner and
timing belt, and repeat steps 1—6.

69G01B-027

8. Turn the crankshaft to align the " S " mark of the

right side camshaft pulley with seal plate mating
mark.
Tighten the timing belt tensioner lock bolt.

Tightening torque:
37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb)

76G01B-026

1B—14
ON-VEHICLE MAINTENANCE (TIMING BELT) 1 B

10. Check the timing belt deflection. If the deflection

is not correct, repeat the adjustment from step 5
above.

Timing belt deflection: 7.5—8.5 mm

(0.30—0.33 in) /98 N (10 kg, 22 lb)

Caution
Be sure not to apply tension other than that
of the tensioner spring.

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76G01B-027

Drive belt
Install each drive belt, and check the belt deflection.
(Refer to page 1B—6.)

76G01B-028

Spark plug
1. Apply anti-seize compound or molybdenum-based
lubricant to the spark plug threads.
2. Install the spark plugs.

Tightening torque:
15—23 N m (1.5—2.3 m-kg, 11—17 ft-lb)

79G01C-021

Steps After Installation

Perform the necessary engine adjustment. (Refer to
TUNE-UP PROCEDURE.)

86U01X-029

1B—15
1 B ON-VEHICLE MAINTENANCE (CYLINDER HEAD)

CYLINDER HEAD
Removal
Warning: Release the fuel pressure. (Refer to Section 4C.)
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the sequence shown in the figure referring to the removal note for specially marked parts.

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76G01B-034

1B—16
 1BON-VEHICLE MAINTENANCE (CYLINDER HEAD)

1. Center cover 13. Exhaust manifold insulator

2. High-tension lead and spark plug 14. Exhaust pipe
3. Accelerator cable 15. Exhaust manifold
4. Air intake pipe assembly 16. Intake manifold bracket
5. Fuel hose 17. Intake manifold assembly
6. Upper radiator hose 18. Distributor
7. Heater hose 19. Engine mount stay
8. Brake vacuum hose 20. Upper timing belt cover
9. Canister hose (Unleaded fuel) 21. Timing belt tensioner spring
10. Engine harness connector and ground 22. Timing belt
11. EGR pipe (Unleaded fuel) 23. Cylinder head cover
12. A/C compressor and bracket 24. Cylinder head and gasket

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76G01B-030

Removal note
Fuel hose

Warning
a) Cover the hose with a rag because fuel will
spray out when disconnecting.
b) Keep sparks and open flame away from the
fuel area.

Plug the disconnected hoses to avoid fuel leakage.

86U01X-032

Timing belt
1. Before removing the timing belt, turn the crankshaft
to align the mating marks of the camshaft pulleys
with the seal plate timing mark.

Note
For intake side camshaft pulley, align " I "
mark.
For exhaust side camshaft pulley, align " E "
mark.

76G01B-031

2. Loosen the timing belt tensioner lock bolt.

3. Shift the tensioner outward as far as possible, then
temporarily tighten it.

76G01B-034

1B—17
1 B ON-VEHICLE MAINTENANCE (CYLINDER HEAD)

4. Remove the timing belt and secure it out of the way

to prevent damage during removal and installation
of the cylinder head.

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69G01B-037

Cylinder head bolt

CP ® (9) (I) Loosen the cylinder head bolts in two or three steps
in the order shown in the figure.
m a j

q Jo o ph£j

@ ® (D

76G01A-111

Disassembly of Cylinder Head

Refer to page 1B—28.

Inspection of Cylinder Head

Refer to page 1B—34.

Assembly of Cylinder Head

Refer to page 1B—59.

76G01B-032

1B—18
 1BON-VEHICLE MAINTENANCE (CYLINDER HEAD)

Installation
Install in the reverse order of removal referring to the installation note.

Note
a) Position the hose clamp in the original location on the hose.
b) Squeeze the clamp lightly with large pliers to ensure a good fit.

Torque Specifications

8—12 N-m (80—120 cm-kg, 69—104 —11 N-m (80—110 cm-kg, 69—95 In-lb)

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4—6 N-m (40—60 cm-kg, 35—52 in

15—23 N-m (1.5—2.3 m-kg, 11—17 ft-lb)

7—10 N-m (70—100 cm-kg,

61—87 In-lb)

37—52 N-m (3.8—5.3 m-kg.

27—38 ft-lb)
~ t / — - -19—30 N-m (1.9—3.1 m-kg,
g ^ 1 4 - 2 2 ft-lb)
80—86 N-m
(8.2—8.8 m-kj,
59—64 ft-lb)

\34—44 N-m (3.5—4.5 m-kg,

' 25—33 ft-lb)

19—30 N-m (1.9—3.1 m-kg,

14—22 ft-lb)
1 9 - 3 0 N-m
(1.9—3.1 m-kg,
14—22 ft-lb)

37—52 N-m (3.8—5.3 m-kg,

27—38 ft-lb)

76G01A-112

1B—19
1 B ON-VEHICLE MAINTENANCE (CYLINDER HEAD)

Installation note
Cylinder head
1. Thoroughly remove all dirt and oil from the top of
the cylinder block with a rag.
2. Place a new cylinder head gasket in position.

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86U01X-035

3. Set the cylinder head in place.

® © © (D ® 4. Apply engine oil to the bolt threads and seat faces.
5. Tighten the cylinder head bolts in two or three steps
in the order shown in the figure.

Tightening torque:
80—86 N m (8.2—8.8 m-kg, 59—64 ft-lb)

86U01X-036

Cylinder head cover

1. Apply silicon sealant to the shaded area as shown
in the figure.
2. Install the cylinder head cover and gasket.

Tightening torque:
4—6 N-m (40—60 cm-kg, 35—52 in-lb)

76G01B-033

Timing belt
1. Align the mating marks of the camshaft pulleys with
the seal plate timing mark.

Note
For intake side camshaft pulley, align " I "
mark.
For exhaust side camshaft pulley, align " E "
mark.

2. Install the timing belt. (Refer to TIMING BELT of

ON-VEHICLE MAINTENANCE.)

76G01B-034

1B—20
 ON-VEHICLE MAINTENANCE (CYLINDER HEAD) 1 B

Distributor
1. Apply engine oil to the O-ring, and position it on
the distributor.
2. Apply engine oil to the blade.
3. Install the distributor.
4. Loosely tighten the distributor mounting bolt.

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76G01A-035

Engine harness connector

Install the engine harness connectors.
1. IG coil
2. Heat gauge unit
3. Speed sensor
4. P/S switch
5. Engine ground
6. Water tempera-
ture sensor
7. Water thermo
switch
8. Crank angle
sensor
9. Oxygen sensor
10. Linear solenoid
11. Solenoid valve
(idle speed
control)
12. Throttle position
sensor
13. Injection harness

76G01B-035

Steps After Installation

1. Fill the radiator with the specified amount and type
of coolant.
2. Perform the necessary engine adjustments. (Re-
fer to TUNE-UP PROCEDURE.)

86U01X-041

1B-21
1 B REMOVAL

REMOVAL
Warning: Release the fuel pressure. (Refer to Section 4C.)
1. Disconnect the negative battery cable.
2. Drain the engine oil and coolant.
3. Remove in the sequence shown in the figure referring to the removal note for specially marked parts.

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76G01B-036

1B—22
 REMOVAL 1 B

1. Battery and battery carrier 12. Canister hose (Unleaded 21. Front wheel
2. Air cleaner assembly fuel) 22. Tie-rod end
3. High-tension lead 13. Heater hose 23. Stabilizer control rod
4. Accelerator cable 14. Transaxle harness 24. Lower arm bushing
5. Fuel hose 15. Speedometer cable 25. Driveshaft
6. Radiator hose 16. Clutch release cylinder 26. Change rod
7. Radiator harness 17. Drive belt 27. Extension bar
8. Radiator and electric fan 18. A/C compressor and 28. Exhaust pipe
9. EGI harness bracket 29. Engine mount
10. Engine harness 19. P/S oil pump 30. Engine and transaxle
11. Brake vacuum hose 20. Engine side cover 31. Transaxle
76G01B-037

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Removal Note
Fuel hose

Warning
a) Cover the hose with a rag because fuel will
spray out when disconnecting.
b) Keep sparks and open flame away from the
fuel area.

Plug the disconnected hoses to avoid fuel leakage.

76G01A-11£

P/S pump, A/C compressor

Remove the P/S pump and A/C compressor with the
hoses still connected to them, secure the pump and
compressor as shown in the figure.

67U01X-029

Driveshaft
Remove the driveshafts. (Refer to Section 9.) Slide
the SST into the transaxle.

86U01X-060

1B—23
1 B DISASSEMBLY (AUXILIARY PARTS)

DISASSEMBLY
1. Remove in the sequence shown in the figure referring to the disassembly note for specially marked
parts.
2. Code all identical parts (such as pistons, piston rings, connecting rods, and valve springs) so that
they can be reinstalled in the cylinder from which they were removed.
3. Clean the parts with steam, blow off any remaining water with compressed air.

Note
Care should be taken during the disassembly of any part or system to study its order of
assembly. Any deformation, wear, or damage should also be noted.

AUXILIARY PARTS

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76G01A-119

1B—24
 DISASSEMBLY (AUXILIARY PARTS) 1 B

1. Oil level gauge 11. Center cover

2. P/S oil pump bracket 12. Distributor and high-tension lead
3. EGR pipe(Unleaded fuel) 13. Spark plug
4. Exhaust manifold insulator 14. Thermostat and thermostat cover
5. Exhaust manifold assembly 15. Intake manifold bracket
6. Coolant inlet pipe and bypass pipe 16. Intake manifold assembly
7. Engine hanger 17. Oil filter
8. Alternator 18. Oil cooler
9. Alternator strap and bracket 19. Oil pressure switch
10. Engine mount bracket 76G01B-039

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Disassembly Note
Engine hanger
Remove the exhaust manifold; then connect the SST
to the engine.
49 0107 680A
Irf^Ys'^
,v,, I
' ir > \

49 G 0 3 0 D05A

76G01A-120

69G01X-000

1B—25
1 B DISASSEMBLY (TIMING BELT)

TIMING BELT

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69G01B-072

1. Crankshaft pulley 6. Timing belt idler pulley

2. Upper timing belt cover 7. Timing belt
3. Lower timing belt cover 8. Camshaft pulley
4. Baffle plate 9. Timing belt pulley
5. Timing belt tensioner and spring

1B—26
 DISASSEMBLY (TIMING BELT) 1 B

Disassembly Note
Crankshaft pulley
1. Set the SST against the flywheel.
2. Remove the crankshaft pulley.

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76G01A-121

Timing belt
Mark the 1. Loosen the tensioner lock bolt, and remove the ten-
direction of sioner spring.
rotation 2. Mark the timing belt rotation for proper reinstalla-
tion if it is reused.
3. Remove the timing belt.

Caution
Be careful not to allow oil or grease on the
belt.

76G01B-119

Camshaft pulley
Remove the pulley lock bolt using a screw driver to
prevent the camshaft from turning.

76G01A-123

1B—27
1 B DISASSEMBLY (CYLINDER HEAD)

CYLINDER HEAD

76G01B-040
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1. Cylinder head cover 9. Valve keeper
2. Seal plate 10. Upper spring seat
3. Camshaft cap 11. Outer valve spring
4. Camshaft 12. Inner valve spring
5. Hydraulic lash adjuster 13. Lower spring seat
6. Cylinder head bolt 14. Valve
7. Cylinder head 15. Valve seal
8. Cylinder head gasket

1B—28
 DISASSEMBLY (CYLINDER HEAD) 1 B

Disassembly Note
Camshaft
Before removing the camshaft, clean the bearings
and journals, and measure the following points.
1. Camshaft end play. (Refer to page 1B—41.)
2. Camshaft journal oil clearance. (Refer to page
1B—40.)

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76G01B-041

Hydraulic lash adjuster (HLA)

Remove the HLA from the cylinder head.

Note
Mark each HLA so that they can be reinstalled
in the position from which they were removed.

76G01B-042

Cylinder head bolt

Loosen the cylinder head bolts in two or three steps
in the order shown in the figure.

86U01X-068

Valve
Remove the valves from the cylinder head with the
SST.

86U01X-069

1B—29
1 B DISASSEMBLY (CYLINDER BLOCK)

CYLINDER BLOCK-I

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76G01B-043

1. Clutch cover 6. Oil strainer

2. Clutch disc 7. Rear cover
3. Flywheel 8. Water pump assembly
4. End plate 9. Oil pump assembly
5. Oil pan 10. Oil jet

1B—30
 DISASSEMBLY (CYLINDER BLOCK) 1 B

Disassembly Note
Clutch cover and flywheel
Remove the clutch cover and flywheel with the SST.

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76G01B-044

Oil pan
1. Remove the oil pan mounting bolts.
2. Install the bolt ©from the mounting bolt or 10 mm
(0.39 in) bolts in the specified bolt holes ©(both
sides).
3. Screw in the bolts gradually and alternately to re-
move the oil pan.
Bolt hole
Caution
Oil pan • ,„ a) Do not pry the oil pan to prevent damaging
the contact surface.
b) Do not damage or scratch the contact sur-
Cylinder block face when removing the oil sealant.
76G01B-045

4. Remove the oil pan.

1B—31
1 B DISASSEMBLY (CYLINDER BLOCK)

CYLINDER BLOCK-II

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76G01B-046

1. Connecting rod cap 7. Main bearing cap

2. Connecting rod bearing 8. Crankshaft
3. Connecting rod and piston 9. Pilot bearing
4. Clip 10. Main bearing
5. Piston pin 11. Cylinder block
6. Piston ring

Disassembly Note
Connecting rod and cap
Before removing the connecting rod, clean the bear-
ing, connecting rod, and crank pin, and measure the
following points.
1. Connecting rod side clearance. (Refer to page
1B—53.)
2. Crankpin oil clearance. (Refer to page 1B—53.)

76G01B-047

1B—32
 DISASSEMBLY (CYLINDER BLOCK) 1 B

Main bearing cap

Before removing the main bearing caps, clean the
bearings, main journals, and caps, and measure the
following points.
1. Crankshaft end play. (Refer to page 1B—52.)
2. Main journal oil clearance. (Refer to page 1B—51.)

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76G01B-048

Pilot bearing
Remove the pilot bearing from the crankshaft with the
SST

76G01B-049

Piston and connecting rod

1. Before disassembling the piston and connecting
rod, check the oscillation torque as shown in the
figure.
If the large end does not drop by its own weight,
replace the piston or the piston pin.

79G01C-050

2. Remove the piston pin with the SST.

76G01B-050

1 B—33
1 B INSPECTION AND REPAIR

INSPECTION AND REPAIR

1. Clean all parts, taking care to remove any gasket fragments, dirt, oil or grease, carbon, moisture
residue, or other foreign materials.
2. Inspect and repair must be performed in the order specified.

Caution
Be careful not to damage the joints or friction surfaces of aluminum alloy components (such
as the cylinder head or pistons).
86U01X-077

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Cylinder Head
1. Inspect the cylinder head for damage, cracks, and
leakage of water or oil. Replace if necessary.
2. Measure the cylinder head distortion in the six
directions shown in the figure.

Distortion: 0.15 mm (0.006 in) max.

79G01C-106

3. If the cylinder head distortion exceeds specifica-

tion, grind the cylinder head surface.
If the cylinder head height is not within specifica-
tion, replace it.

Height:
133.95—134.05 mm (5.274—5.278 in)
Grinding limit: 0.20 mm (0.008 in) max.

Note
Before grinding the cylinder head, first check
the following. Replace if necessary.
• Sinking of valve seat
76G01B-051 • Damage of manifold contact surface
• Camshaft oil clearance and end play

4. Measure the manifold contact surface distortion in

the six directions shown in the figure.

Distortion: 0.15 mm (0.006 in) max.

5. If distortion exceeds specification grind the surface

or replace the cylinder head.

79G01C-053

1B-34
 INSPECTION AND REPAIR 1 B

Valve and Valve Guide

1. Inspect each valve for the following. Replace or
Stem tip resurface if necessary.
(1) Damaged or bent stem
(2) Roughness or damage to face
(3) Damage or uneven wear of stem tip
2. Check the valve head margin thickness. Replace
if necessary

Margin thickness
Valve face
Margin i IN : 0.85 mm (0.033 in) min.
angle
thickness - EX: 0.9 mm (0.035 in) min.
f 45°

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76G01B-120

3. Measure the valve length.

Length
IN : 103.18 mm (4.0622 in)
EX: 103.94 mm (4.0921 in)

76G01B-052

4. Measure the valve stem diameter.

Diameter
IN : 5.970—5.985 mm (0.2350—0.2356 in)
EX: 5.965—5.980 mm (0.2348—0.2354 in)

76G01B-053

5. Measure the valve guide inner diameter.

Inner diameter
IN : 6.01—6.03 mm (0.2366—0.2374 in)
EX: 6.01—6.03 mm (0.2366—0.2374 in)

76G01B-121
1B-35
1 B INSPECTION AND REPAIR

6. Measure the valve stem to guide clearance by sub-

tract the outer diameter of the valve stem from the
-Valve stem inner diameter of the corresponding valve guide.

Clearance
Valve guide IN : 0.025—0.060 mm (0.0010—0.0024 in)
EX: 0.030—0.065 mm (0.0012—0.0026 in)
Clearance Maximum: 0.20 mm (0.0079 in)

7. If the clearance exceeds the maximum, replace the

\ I/ valve and/or valve guide.

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76G01B-122

8. Check that the valve guide projection height

(dimension A in the figure). Replace if necessary.

Height: 11.4—11.9 mm (0.449—0.469 in)

76G01B-054

Replacement of valve guide

Note
Although the shapes of the intake and exhaust
valve guides are different.

76G01B-123

Removal
1. Gradually heat the cylinder head in water to ap-
prox. 90°C (194°F).

86U01X-083

1B-36
 INSPECTION AND REPAIR 1 B

2. Remove the valve guide from the side opposite the

combustion chamber with the SST.

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86U01X-084

Installation
1. Gradually heat the cylinder head in water to ap-
prox. 90°C (194°F).
2. Tap the valve guide in from the side opposite the
combustion chamber with the SST until the projec-
tion height is as specified.

76G01B-124

Valve Seat
1. Inspect the contact surface of the valve seat and
- d
valve face for the following.
(1) Roughness
(2) Damage
O") ( o o 2. If necessary, resurface the valve seat with a 45°
valve seat cutter and/or resurface the valve face.

/ y ^ X ' / i — l / o \ 1| 1

86U01X-087

3. Apply a thin coat of prussian blue to the valve face.

4. Check the valve seating by rotating the valve
against the seat.
(1) If blue does not appear 360° around the valve
face, replace the valve.
(2) If blue does not appear 360° around the valve
seat, resurface the seat.

69G01A-101

1B—37
 INSPECTION AND REPAIR1B

5. Check the seat contact width.

Width: 1.2—1.6 mm (0.047—0.063 in)

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76G01A-128

6. Check that the valve seating position is at the cen-

ter of the valve face.
(1) If the seating position is too high, correct the
valve seat with a 60° cutter and a 45° cutter.
(2) If the seating position is too low, correct the
7 5 valve seat with a 35° (IN) or 15° (EX) cutter
L 75° /\ and a 45° cutter.
60° 60
7. Seat the valve to the valve seat with a lapping
35°>\
450 V compound.
'%50
EX IN

86U01X-088

8. Check the sinking of the valve seat.

Measure protruding length (dimension L) of each
valve stem.
Dimension L: 36.8 mm (1.449 in)
(1) If L is as below, it can be used as it is.
36.8—37.6 mm (1.449—1.480 in)
(2) If L is as below, insert a spacer between the
spring seat and cylinder head to adjust.
37.6—38.3 mm (1.480—1.508 in)
(3) If L is more than as below, replace the cylin-
76G01B-055 der head.

38.3 mm (1.508 in) or more

Valve Spring
1. Inspect each valve spring for cracks or damage.
2. Check the free length and angle. Replace if
necessary.

Free length
Outer Standard: 39.1 mm (1.539 in)
Minimum: 38.7 mm (1.524 in)
Inner Standard: 38.0 mm (1.496 in)
Minimum: 37.7 mm (1.484 in)

76G01B-059

1B-38
 INSPECTION AND REPAIR 1 B

Angle
Outer: 1.4 mm (0.055 in) max.
-Angle limit Inner: 1.3 mm (0.051 in) max.

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76G01B-057

Camshaft
1. Set the front and rear journals on V-blocks.
Check the camshaft runout. Replace if necessary.

Runout: 0.03 mm (0.0012 in) max.

86U01X-092

2. Check the cam for wear or damage. Replace if

necessary.
3. Check the cam lobe height at the two points as
shown in the figure.

Height:
45.055 mm (1.7738 in) Leaded fuel
45.052 mm (1.7737 in) Unleaded fuel
Minimum:
44.855 mm (1.7659 in) Leaded fuel
44.852 mm (1.7658 in) Unleaded fuel

76G01B-058

4. Measure wear of the journals in X and Y directions

at the two points as shown in the figure.

Diameter:
29.940—29.965 mm (1.1787—1.1797 in)
Out-of-round: 0.05 mm (0.002 in) max.

76G01B-059

1B-39
1 B INSPECTION AND REPAIR
5. Measure the oil clearance of the camshaft and
camshaft caps.
(1) Remove any oil or dirt from the journals and
bearing surface.
(2) Set the camshaft onto the cylinder head.
(3) Position plasti-gauge on top of the journals in
the axial direction.

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76G01B-060

(4) Place the camshaft caps according the cap

number and arrow, and tighten them in the or-
der shown in the figure.

Tightening torque:
18—26 N-m (1.8—2.7 m-kg, 13—20 ft-lb)

76G01B-061

(5) Loosen the camshaft cap bolts in the order

shown in the figure.

76G01B-062

(6) Measure the oil clearance at each cap.

Oil clearance:
0.035—0.085 mm (0.0014—0.0033 in)
Maximum: 0.15 mm (0.0059 in)

(7) If the oil clearance exceeds the maximum, re-

place the camshaft and/ or the cylinder head.

76G01B-063

1B—40
 INSPECTION AND REPAIR 1 B

6. Measure the camshaft end play. If it exceeds the

maximum, replace the camshaft and/or the cylin-
der head.

End play:
0.08—0.10 mm (0.003—0.004 in)
Maximum: 0.20 mm (0.008 in)

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76G01B-125

Hydraulic Lash Adjuster (HLA)

1. Check the HLA face for wear or damage.
2. Hold the HLA between your fingers and press it.
If the HLA moves, replace it.

Caution
Do not disassemble the HLA.

76G01B-064

Cylinder Block
1. Check the cylinder block. Repair or replace if
necessary.
(1) Leakage damage
(2) Cracks
(3) Scoring of wall
2. Measure the distortion of the top surface of the cyl-
inder block in the six directions as shown in the
figure.

Distortion: 0.15 mm (0.006 in) max.

86U01X-100

3. If the distortion exceeds the maximum, repair by

grinding, or replace the cylinder block.

Grinding limit: 0.20 mm (0.008 in) max.

86U01X-101

1B—41
 INSPECTION AND REPAIR1B

4. Measure the cylinder bore in directions X and Y

at three levels in each cylinder as shown.

Cylinder bore mm (in)

o ^ ^ o -A-
Size Bore
( 7 / T \ V
Standard 86.000-86.019 (3.3858-3.3866)
B- 0.25 (0.010) oversize 8 6 . 2 5 0 - 8 6 . 2 6 9 (3.3957—3.3964)
0.50 (0.020) oversize 86.500—86.519 (3.4055-3.4062)
- c -

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79G01C-070

(1) If the difference between the measurement A

and C exceeds the maximum taper, rebore the
cylinder to oversize.

Taper: 0.019 mm (0.0007 in) max.

1- B

79G01C-071

(2) If the difference between the measurement X

and Y exceeds the maximum out-of-round, re-
bore the cylinder to oversize.

Out-of-round: 0.019 mm (0.0007 in) max.

Caution
The boring size should be based on the size
of an oversize piston and be the same for all
cylinders.

79G01C-072

5. If the upper part of the cylinder wall shows uneven

wear, remove the ridge with a ridge reamer.

86U01X-101

1B—42
 INSPECTION AND REPAIR 1 B

Piston
1. Inspect the outer circumferences of all pistons for
seizure or scoring. Replace if necessary.
2. Measure the outer diameter of each piston at a right
angle (90°) to the piston pin, 18 mm (0.709 in)
Oil ring below the oil ring land lower edge.
groove
Piston diameter mm (in)
18mm I J U v .
(0.709 in)*"! ^ Size Diameter
Standard 85.944—85.964 (3.3836—3.3844)
0.25 (0.010) oversize 8 6 . 1 9 4 - 8 6 . 2 1 4 (3.3935-3.3942)
0.50 (0.020) oversize 8 6 . 4 4 4 - 8 6 . 4 6 4 (3.4033-3.4041)

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79G01C-073

3. Check the piston to cylinder clearance.

Clearance:
0.036—0.075 mm (0.0014—0.0030 in)
Maximum: 0.15 mm (0.0059 in)

4. If the clearance exceeds the maximum, replace the

piston or rebore the cylinders to fit oversize pistons.

Caution
If the piston is replaced, replace the piston
rings also.
r Clearance
76G01A-130

Piston and Piston Ring

1. Measure the piston ring to ring land clearance
around the entire circumference using a new pis-
ton ring.

Clearance (Top and Second):

0.03—0.07 mm (0.001—0.003 in)
Maximum: 0.15 mm (0.006 in)

2. If the clearance exceeds the maximum, replace the

piston.

69G01A-125

Inspect the piston rings for damage, abnormal

HV JT\ wear, or breakage. Replace if necessary.
Insert the piston ring into the cylinder by hand and
101 push it to the bottom of the ring travel in using the
piston.

v A v
n ^ - n
iXXi ^ ^ P i s t o n ring

86U01X-101

1B—43
1 B INSPECTION AND REPAIR

5. Measure each piston ring end gap with a feeler

gauge. Replace if necessary.

End gap
Top : 0.20—0.35 mm (0.008—0.014 in)
Second: 0.15—0.30 mm (0.006—0.012 in)
Oil rail : 0.20—0.70 mm (0.008—0.028 in)
Maximum: 1.0 mm (0.039 in)

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76G01B-065

Piston and Piston Pin

%
1. Measure the piston pin hole diameter in X and Y
directions at four points.

Diameter:
21.988—21.998 mm (0.8657—0.8661 in)

-X

@H
C / v M
76G01B-066

2. Measure the piston pin diameter.

Diameter:
21.987—21.993 mm (0.8656—0.8659 in)

3. Determine the piston pin to piston clearance by

subtracting the two figures.

Clearance:
-0.005—0.011 mm (-0.0002—0.0004 in)

4. If the clearance exceeds the specification, replace

the piston and/or piston pin.
76G01B-067

Connecting Rod
1. Measure the connecting rod small end bore.

Diameter:
22.003—22.014 mm (0.8663—0.8667 in)

2. Check the clearance between the small end bore

and piston pin.

Clearance:
0.010—0.027 mm (0.0004—0.0011 in)

76G01B-063

1B—44
 INSPECTION AND REPAIR 1 B

3. Check each connecting rod for bending or twist-

ing. Repair or replace if necessary.

Bend: 0.06 mm (0.0024 in) max.

Twist: 0.06 mm (0.0024 in) max.

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86U01X-108

Crankshaft
1. Check the journals and pins for damage, scoring,
or oil hole clogging.
2. Set the crankshaft on V-blocks.
3. Check the crankshaft runout at the center journal.
Replace if necessary.

Runout: 0.03 mm (0.0012 in) max.

86U01X-109

4. Measure each journal diameter in X and Y direc-

tions at two points.

Main journal
Diameter:
59.937—59.955 mm (2.3597—2.3604 in)
Out-of-round: 0.05 mm (0.0020 in) max.

Crankpin journal
Diameter:
50.940—50.955 mm (2.0055—2.0061 in)
Out-of-round: 0.05 mm (0.0020 in) max.

76G01A-131

5. If the diameter is less than the minimum, grind the

Crankpin journals to match undersize bearings.

Undersize bearing: 0.25 mm (0.010 in),

0.50 mm (0.020 in), 0.75 mm (0.030 in)
Main journal diameter undersize mm (in)
Bearing size Journal diameter
0.25 (0 010) No 1,2,4,5 59.693-59.711 (2.3501-2.3508)
undersize No 3 5 9 . 6 8 7 - 5 9 . 7 0 5 (2.3499-2.3506)
0.50 (0.020) No.1,2,4,5 5 9 . 4 4 3 - 5 9 . 4 6 1 (2.3403—2.3410)
Main journal undersize No.3 5 9 . 4 3 7 - 5 9 . 4 5 5 (2.3400—2.3407)
0.75 (0 030) NO.1,2,4,5 5 9 . 1 9 3 - 5 9 . 2 1 1 (2.3304-2.3311)
69G01A-101 undersize No.3 5 9 . 1 8 7 - 5 9 . 2 0 5 (2.3302-2.3309)

1B—45
 INSPECTION AND REPAIR1B

Crankpin journal diameter undersize mm (in)

Bearing size Journal diameter
Rolled fillet 0.25 (0.010) undersize 5 0 . 6 9 0 - 5 0 . 7 0 5 (1.9957—1.9963)
0.50 (0.020) undersize 50.440—50.455 (1.9858-1.9864)
0.75 (0.030) undersize 5 0 . 1 9 0 - 5 0 . 2 0 5 (1.9760-1.9766)

Caution
Do not grind the rolled fillet area.

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76G01A-133

Main Bearing and Connecting Rod Bearing

Check the main bearings and the connecting rod
bearings for peeling, scoring, or other damage.

79G01C-077

Oil Jet
1. Check that the oil passage is not clogged.
2. Check that the check ball is not stuck.

76G01B-069

Timing Belt
1. Replace the timing belt if there is any oil or grease
on it.
2. Check the timing belt for damage, wear, peeling,
cracks, or hardening. Replace if necessary.

86U01X-101

1B—46
 INSPECTION AND REPAIR 1 B

Caution
a) Never forcefully twist, turn inside out, or
bend the timing belt.
b) Be careful not to allow oil or grease on the
belt.

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86U01X-114

Timing Belt Tensioner and Idler Pulley

Check the timing belt tensioner and idler pulley for
smooth rotation and abnormal noise. Replace if
necessary.

Caution
Do not clean the tensioner with cleaning
fluids. If necessary, use a soft rag to wipe it
clean, and avoid scratching it.

86U01X-115

Timing Belt Tensioner Spring

Check the free length of the tensioner spring. Replace
if necessary.

Free length: 53.3 mm (2.098 in)

76G01B-126

Timing Belt Pulley and Camshaft Pulley

Inspect the pulley teeth for wear, deformation, or other
damage. Replace if necessary.

Caution
Do not clean the pulley with cleaning fluids.
If necessary, use a rag to wipe it clean.

Timing Belt Cover (lower and upper)

Inspect the timing belt covers for damage or cracks.
Replace if necessary.

86U01X-101

1B—47
1 B ASSEMBLY (CYLINDER BLOCK)

ASSEMBLY
1. Clean all parts before reinstallation.
2. Apply new engine oil to all sliding and rotating parts.
3. Replace plain bearings if they are peeling, burned, or otherwise damaged.
4. Tighten all bolts and nuts to the specified torques.

Caution
Do not reuse gaskets or oil seals.

CYLINDER BLOCK—I
Torque Specifications

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69G01A-139

1B—48
 ASSEMBLY (CYLINDER BLOCK) 1 B

Connecting Rod
1. Align the identification mark to the cap of large end
of connecting rod and F mark on the piston as
shown in the figure.
2. Apply a coat of engine oil to the circumference of
each piston pin and to the small end of each con-
necting rod.

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76G01B-070

3. Set a clip into the clip groove in one side of the

piston.

76G01B-071

4. Insert the piston pin into the piston and connect-

ing rod from the opposite side of the piston with
the SST .
5. Tap the piston pin in until it touchs the clip. Install
the other clip into the groove in the piston.
6. Check the oscillation torque of the connecting rod.
(Refer to page 1B—33.)

Piston Ring
1. Install the three-piece oil rings on the pistons.
(1) Apply engine oil to the oil ring spacer and rails.
(2) Install the oil ring spacer so that the opening
faces upward.
(3) Install the upper rail and lower rail.

Note
a) The upper rail and lower rail are the same.
b)Each rail can be installed with either face
upward.

69G01A-144

1B—49
1 B ASSEMBLY (CYLINDER BLOCK)

2. Check that both rails are expanded by the spacer

tangs as shown in the figure by checking that both
Spacer tang
rails turn smoothly in both directions.
Upper rail

Oil ring
spacer ends Lower rail

Piston

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69G01A-145

3. Install the second ring to the piston first, then in-

stall the top ring. Use a piston ring expander.

Caution
The rings must be installed with the " R "
marks facing upward.

4. Apply a liberal amount of clean engine oil to the

second and top piston rings.

86U01X-121

5. Position the opening of each ring as shown in the

figure.
Oil ring —
upper rail /
N. ^ Top ring

Oil ring I ^_t 3 0

° L^Pistion
spacer I T Pin

Oil ring j / Second ring

lower rail N.

69G01A-147

Crankshaft
1. Before installing the crankshaft, inspect the main
bearing oil clearances as described.

Note
The bearing with thrust shoulders is the cen-
ter bearing in the cylinder block.

86U01X-136

1B—50
 ASSEMBLY (CYLINDER BLOCK) 1 B

Oil clearance inspection

(1) Remove any foreign material and oil from the
journals and bearings.
(2) Install the upper main bearings in the cylinder
block.
(3) Set the crankshaft into the cylinder block.
(4) Position the plasti-gauge on top of the journals
in the axial direction.

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86U01X-122

(5) Install the main bearing caps along with the

lower main bearings according to the cap num-
ber and mark.
(6) Tighten the caps in two or three steps in the
order in the figure.

Tightening torque:
82—88 Nm (8.4—9.0 m-kg, 61—65 ft-lb)

Caution
Do not rotate the crankshaft when measuring
the oil clearances.

86U01X-123

(7) Remove the main bearing caps, and measure

the plasti-gauge at each journal at the widest
point for the smallest clearance, and at the nar-
rowest point for the largest clearance.
If the oil clearance exceeds specification, grind
the crankshaft and use undersize main bear-
ings. (Refer to page 1B—45.)

Oil clearance
No. 1, 2, 4, 5:
0.025—0.043 mm (0.0010—0.0017 in)
No. 3:
0.031—0.049 mm (0.0012—0.0019 in)
Maximum: 0.08 mm (0.0031 in)
Apply a liberal amount of engine oil to the main
bearings and main journals.
Install the crankshaft and the main bearing caps
according to the cap number and ^ mark.

86U01X-125

1B—51
1 B ASSEMBLY (CYLINDER BLOCK)

4. Inspect the crankshaft end play.

End play:
0.08—0.18 mm (0.0031—0.0071 mm)
Maximum: 0.30 mm (0.012 in)

5. If the end play exceeds specification, grind the

crankshaft and use undersize center main bearing.

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76G01A-074

Center main bearing width

Standard:
27.94—27.99 mm (1.1000—1.1020 in)
0.25 mm (0.010 in) undersize:
28.04—28.09 mm (1.1040—1.1059 in)
0.50 mm (0.020 in) undersize:
28.12—28.17 mm (1.1071—1.1091 in)
0.75 mm (0.030 in) undersize:
28.20—28.25 mm (1.1102—1.1122 in)

Note
Wider thrust width is available only in under-
size center main bearing.
86U01X-216

Pilot Bearing
1. Apply engine oil to the outer circumference of the
bearing.
2. Set a piece of pipe (outer diameter 30—34 mm,
1.18—1.34 in) against the outer race of the bear-
ing, then tap it evenly into the crankshaft.
3. Lubricate the bearing with grease.

76G01 B-075

Piston and Connecting Rod Assembly

1. Apply a liberal amount of clean engine oil to the
cylinder walls, piston, and rings.
2. Check the piston rings for the end gap alignment.
3. Insert each piston assembly into the cylinder block
with the F mark facing the front of the engine. Use
a piston installer tool (commercially available).

76G01A-136

1B—52
 ASSEMBLY (CYLINDER BLOCK) 1 B

Connecting Rod Cap

1. Check the connecting rod bearing clearances us-
ing the same procedure as used for the main bear-
ing oil clearance.

Connecting rod cap tightening torque:

69—73 Nm (7.0—7.4 m-kg, 51—54 ft-lb)

Oil clearance:
0.027—0.067 mm (0.0011—0.0026 in)
Maximum: 0.10 mm (0.0039 in)

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76G01B-076

Caution
Align the alignment marks on the cap and on
the connecting rod when installing the con-
necting rod cap.

2. If the oil clearance exceeds specification grind the

crankshaft and use undersize bearings. (Refer to
page 1B—46.)

76G01B-077

3. Check the side clearance of each connecting rod

without the cap installed.

Side clearance:
0.110—0.262 mm (0.004—0.0103 in)
Maximum: 0.30 mm (0.012 in)

If the clearance exceeds the maximum, replace the

connecting rod.

69G01B-139

4. Apply a liberal amount of engine oil to the crank-

pin journal and connecting rod bearing.
5. Install the connecting rod cap with the alignment
marks aligned.

Tightening torque:
69—73 Nm (7.0—7.4 m-kg, 51—54 ft-lb)

76G01B-078

1B—53
1 B ASSEMBLY (CYLINDER BLOCK)

CYLINDER BLOCK—II
Torque Specifications

19—25 N m
(1.9—2.6 m-kg, 1 4 - 1 9 ft-lb)

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7—12 N'm
(70—120 cm-kg,
61—104 in-lb)

69G01A-166

Rear Cover
1. Apply engine oil to the rear cover, oil seal and oil
seal lip.
2. Press the oil seal into the rear cover.

4BG01A-158

1B—54
 ASSEMBLY (CYLINDER BLOCK) 1 B

3. Install the rear cover and a new gasket.

Tightening torque:
8—12 N-m (80—120 cm-kg, 69—104 in-lb)

cardiagn.com
86U01X-131

4. Cut away the portion of the gasket that projects out

from the rear cover assembly toward the oil pan
side.

Caution
Do not scratch the rear cover assembly.

86U01X-132

End Plate
Install the end plate.

Tightening torque:
19—30 Nm (1.9—3.1 m-kg, 14—22 ft-lb)

4BG01A-160

Oil Pump
1. Apply engine oil to a new oil pump oil seal and the
oil pump body.
2. Press the oil seal into the oil pump body.

79G01C-085

1B—55
1 B ASSEMBLY (CYLINDER BLOCK)

3. Apply engine oil to the oil seal lip.

4. Remove any dirt or other material from the con-
tact surfaces.
5. Apply a continuos bead of silicon sealant to the
contact surface of the oil pump.

Caution
Do not allow any sealant to get into the oil
hole.

cardiagn.com
86U01X-133

6. Install a new O-ring into the pump body.

7. Install the oil pump.

Tightening torque
(A): 19—25 N m
(1.9—2.6 m-kg, 14—19 ft-lb)
(§): 37—52 N m
(3.8—5.3 m-kg, 27—38 ft-lb)

8. Remove any sealant which has been squeezed

out.

76G01A-137

Oil Jet
Install the oil jet as shown in the figure.

Tightening torque: 12—18 Nm

(1.2—1.8 m-kg, 104—156 in-lb)

Caution
The shapes of the No.1, 3 cylinders jet valves
and No.2, 4 jet valves are different.

76G01B-079

Oil Strainer
Install the oil strainer and a new gasket.

Tightening torque:
8—12 Nm (80—120 cm-kg, 69—104 in-lb)

86U01X-136

1B—56
 ASSEMBLY (CYLINDER BLOCK) 1 B

Oil Pan
1. Apply a continuous bead of silicon sealant to the
oil pan around inside of the bolt holes and over-
lap the ends.
2. Install the oil pan.

Tightening torque:
7—12 Nm (70—120 cm-kg, 61—104 in-lb)

Caution
Oil pan projection and recession from the end
of the cylinder block must not be more than

cardiagn.com
1.5 mm (0.06 in).
76G01 B-080

Flywheel
1. Remove any old sealant from the bolts and bolt
holes. If old sealant can not be removed from the
bolt, replace it.
2. Apply sealant to the bolt threads.

76G01B-081

3. Install, and tighten the flywheel with the SST.

Tightening torque:
96—103 N m (9.8—10.5 m-kg, 71—76 ft-lb)

76G01B-082

Clutch Disc and Clutch Cover

Install the clutch disc and clutch cover using the SST.
(Refer to Section 6.)

Tightening torque:
22—32 N m (2.2—3.3 m-kg, 16—24 ft-lb)

76G01 B-083

1B—57
1 B ASSEMBLY (CYLINDER BLOCK)

Water Pump
1. Remove all dirt, grease, and other material from
the water pump mounting surface.
2. Place a new O-ring in position.

Caution
Do not reuse the original O-ring.

cardiagn.com
86U01X-142

3. Install the water pump.

Tightening torque:
19—25 Nm (1.9—2.6 m-kg, 14—19 ft-lb)

7BU01B-103

1B-58
 ASSEMBLY (CYLINDER BLOCK) 1 B

CYLINDER HEAD
Torque Specifications

4—6 N m
(40—60 cm-kg, 35—52 In-lb)

18—26 N-m

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(1.8—2.7 m-kg,
13—20 ft-lb)

8—12 N m
(80—120 cm-kg, 69—104 in-lb)

69G01B-152

Valve Seal
1. Apply engine oil to the inside of the new valve seal.
2. Install the valve seal onto the valve guide with the
49 G 0 1 2 0 0 2 SST

76G01 B-083

1B—59
1 B ASSEMBLY (CYLINDER HEAD)

Valve and Valve Spring

Valve spring
1. Install the lower spring seat.
2. Install the valve.

3. Install the valve springs and the upper spring seat.

®>® Note
Install the outer and inner valve spring with
the closer pitch toward the cylinder head.

Cylinder head side

cardiagn.com
76G01B-084

4. Compress the valve spring with the SST; then in-

stall the valve keepers.
5. Tap the end of the valve stem lightly two or three
times with a plastic hammer to confirm that the
keepers are all fully seated.

86U01X-145

Hydraulic Lash Adjuster (HLA)

1. Apply engine oil to the sliding surface.

76G01B-085

2. Install the HLA in the position from which they were

removed.
3. Check for free movement.

76G01B-086

1B—60
 ASSEMBLY (CYLINDER HEAD) 1 B

Cylinder Head
1. Thoroughly remove all dirt, oil, or other material
from the top of the cylinder block.
2. Place the new cylinder head gasket in position.

cardiagn.com
86U01X-146

3. Install the cylinder head.

© ® d> ® 4. Apply engine oil to the bolt threads and seat faces.
5. Tighten the cylinder head bolts in two or three steps
in the order shown in the figure.

Tightening torque:
80—86 Nm (8.2—8.8 m-kg, 59—64 ft-lb)

® © ® © (D
86U01X-147

Camshaft
1. Apply a liberal amount of engine oil to the journals
and bearings.
2. Place the camshaft in position with the dowel pin
facing straight up.

86U01X-148

Camshaft Oil Seal

1. Apply liberal amount of clean engine oil to the cam-
shaft oil seal and cylinder head.
2. Install the camshaft oil seal.

76G01B-087

1B-61
1 B ASSEMBLY (CYLINDER HEAD)

Camshaft Cap
1. Apply liberal amount of clean engine oil to the cam
lobes and journals.
2. Apply silicon sealant to the front camshaft cap
surface.

cardiagn.com
76G01B-088

3. Position the camshaft caps according to the cap

number and mark.

4. Install the camshaft caps. Tighten the bolts in two

or three steps in the order shown in the figure.

Tightening torque:
18—26 Nm (1.8—2.7 m-kg, 13—20 ft-lb)

Seal Plate
Install the seal plate.

Tightening torque:
8—12 N m (80—120 cm-kg, 69—104 in-lb)

1B—62
 ASSEMBLY (CYLINDER HEAD) 1 B

Cylinder Head Cover

1. Apply silicon sealant to the shaded area shown in
the figure.
2. Install the cylinder head cover.

Tightening torque:
4—6 N m (40—60 cm-kg, 35—52 in-lb)

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76G01B-092

1B—63
1 B ASSEMBLY (TIMING BELT)

TIMING BELT
Torque Specifications

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47-65 N m
(4.8—6,6 m-kg,
35—49

7—10 N-m
(70—100 cm-kg,
61—87 in-ll'

167—167 N*m
( 1 6 . 0 - 1 7 . 0 m-kg,
116—123 tt-tti)

12—17 N m
(1.25—1.75 m-kg,
109—152 in-lbj

69G01B-160

1B—64
 ASSEMBLY (TIMING BELT) 1 B

Camshaft Pulley
1. Install the camshaft pulley on the camshaft with the
dowel pin fit into the hole at the I mark (intake side)
and E mark (exhanst side).

cardiagn.com
76G01B-127

2. Tighten the camshaft pulley lock bolt.

Tightening torque:
47—65 Nm (4.8—6.6 m-kg, 35—48 ft-lb)

76G01A-141

3. Align the mating mark on the camshaft pulleys with

the alignment mark on the seal plate.

Note
For intake side camshaft pulley, align " I "
mark.
For exhanst side camshaft pulley, align " E "
mark.

76G01B-094

Timing Belt Pulley

1. Reverse the direction of the SST (ring gear brake).
2. Install the crankshaft key.
3. Install the timing belt pulley on the crankshaft.

Tightening torque: 157—167 N m

(16.0—17.0 m-kg, 116—123 ft-lb)

4. Release the ring gear brake.

5. Align the timing belt pulley and the pump body
alignment marks.

86U01X-160

1B—65
1 B ASSEMBLY (TIMING BELT)

Timing Belt Idler Pulley

Install the timing belt idler pulley.

Tightening torque:
37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb)

Timing Belt Tensioner

1. Install the timing belt tensioner and tensioner
spring.
2. Tentatively secure the tensioner with the spring fully
extended.

cardiagn.com
69G01B-165

Timing Belt
1. Install the timing belt so that there is no looseness
at the tension side, and at the two camshaft pulleys.

Caution
a) If the timing belt is being reused, it must be
reinstalled to rotate in the original direction.
b) Check that there is no oil, grease, or dirt on
the timing belt.

76G01B-095

2. Loosen the tensioner lock bolt.

3. Turn the crankshaft twice in the direction of rotation.
4. Check that the mating marks are correctly aligned.
If not aligned, remove the timing belt and tension-
er, and repeat the above-mentioned procedure.

79G01C-097

5. Turn the crankshaft to align the S mark of the right

side camshaft pulley with seal plate mating mark.
6. Tighten the timing belt tensioner lock bolt.

Tightening torque:
37—52 N m (3.8—5.3 m-kg, 27—38 ft-lb)

76G01B-096

1B-66
 ASSEMBLY (TIMING BELT) 1 B

7. Check the timing belt deflection. If the deflection

is not correct, loosen the tensioner lock bolt and
repeat steps 3—5 above. Replace the tensioner
spring if necessary.

Belt deflection:
7.5—8.5 mm (0.30—0.33 in)
/ 98 N (10 kg, 22 lb)

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76G01B-097

Baffle Plate
Position the baffle plate on the timing belt pulley.

Timing Belt Cover

Install the lower timing belt cover, upper timing belt
cover, and new gaskets.
Tightening torque:
7—10 Nm (70—100 cm-kg, 61—87 in-lb)

86U01X-163

Crankshaft Pulley
Install the crankshaft pulley.

Tightening torque: 12—17 N-m

(1.25—1.75 m-kg, 109—152 in-lb)

69G01B-170

1B—67
 DISASSEMBLY (AUXILIARY PARTS)1B

AUXILIARY PARTS
Torque Specifications

37—63 N-m 19—30 N-m (1.9—3.1 m-kg, 14—22 ft-lb)

(3.8—6.4 m-kg, 27—46 ft-lb)

cardiagn.com
19—30 N-m
(1.9—3.1 m-kg,
1 4 - 2 2 ft-lb)

85—117 N-m
(8.7—11.9 m
63—86 ft-lb)
19—30 N-m 37—52 N-m
(1.9—3.1 m-kg '(If (3.8—5.3 m-kg,
14—22 ft-lb) | / 27—38 ft-lb)

19—25 N-m 19—30 N-m

(1.9—2.6 m-kg, (1.9—3.1 m-kg,
14—19 ft-lb) 14—22 ft-lb)

37—63 N-m
(3.8—6.4 m-kg,
27—46 ft-lb) 19—30 N-m
34—49 N-m (1.9—3.1 m-kg,
(3.5—5.0 m-kg, 14—22 ft-lb)
2 5 - 3 6 ft-lb)

34—44 N-m
(3.5—4.5 m-kg, 25—33 ft-lb)

19—30 N-m
(1.9—3.1 m-kg,
14—2 Z ft-lb)

86U01X-164

1B—68
 ASSEMBLY (AUXILIARY PARTS) 1 B

Oil Pressure Switch

Install the oil pressure switch.

Tightening torque: 12—18 N-m

(1.2—1.8 m-kg, 104—156 in-lb)

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76G01A-087

Oil Cooler
Install the oil cooler.

Tightening torque:
29—39 N-m (3.0—4.0 m-kg, 22—29 ft-lb)

Oil Filter
1. Apply a small amount of engine oil to the rubber
seal of the new filter.
2. Install the oil filter and tighten it by hand until the
rubber seal contacts the base.
3. Then tighten the filter 1 and 1/6 turn with a wrench.

76G01B-099

Intake Manifold Assembly

1. Place the new gasket in position.
2. Install the intake manifold assembly.
3. Tighten the nuts in two or three steps.

Tightening torque:
19—30 N-m (1.9—3.1 m-kg, 14—22 ft-lb)

86U01X-167

Intake Manifold Bracket

Install the intake manifold bracket.

Tightening torque:
19—30 N-m (1.9—3.1 m-kg, 14—22 ft-lb)

86U01X-168

1B-69
expert22 fl/ia http://rutracker.org
1 B ASSEMBLY (AUXILIARY PARTS)

Thermostat and Thermostat Cover

1. Install the thermostat into the cylinder head with
the jiggle pin at the top.
2. Position a new gasket with the printed side facing
the cylinder head.
3. Install the thermostat cover.

Tightening torque:
19—30 Nm (1.9—3.1 m-kg, 14—22 ft-lb)

cardiagn.com
86U01X-169

Spark Plug
1. Apply anti-seize compound or molybdenum-based
lubricant to the spark plug threads.
2. Install the spark plugs.

Tightening torque:
15—23 N m (1.5—2.3 m-kg, 11—17 ft-lb)

86U01X-219

Distributor
1. Apply engine oil to the O-ring, and position it on
the distributor.
2. Apply engine oil to the blade.
3. Install the distributor.
4. Loosely tighten the distributor mounting bolt.

High-Tension Lead
Install the high-tension leads.

Center Cover
Install the center cover.

Tightening torque:
8—12 Nm (80—120 cm-kg, 69—104 in-lb)

Engine Mount Bracket

1. Install the engine mount bracket.

Tightening torque:
85—117 N m (8.7—11.9 m-kg, 63—86 ft-lb)

2. Install the stay to the engine mount bracket.

Tightening torque:
37—52 N m (3.8—5.3 m-kg, 27—38 ft-lb)

1B—70
 ASSEMBLY (AUXILIARY PARTS) 1 B

Alternator
1. Install the alternator strap and bracket.

Tightening torque:
37—63 Nm (3.8—6.4 m-kg, 27—46 ft-lb)

cardiagn.com
86U01X-171

Install the alternator.

Tightening torque
(g): 31—46 N-m
(3.2—4.7 m-kg, 23—34 ft-lb)
(§): 37—52 N-m
(3.8—5.3 m-kg, 27—38 ft-lb)

Install the alternator drive belt, and adjust the belt

deflection. (Refer to page 1B—6.)

76G01B-102

Coolant Inlet Pipe and Bypass Pipe

1. Install the coolant inlet pipe.

Tightening torque:
19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb)

2. Apply vegetable oil to the O-ring.

3. Install the coolant bypass pipe.

Tightening torque:
37—63 N-m (3.8—6.4 m-kg, 27—46 ft-lb)

Engine Hanger
Install the front and rear engine hangers.

Tightening torque:
19—30 N-m (1.9—3.1 m-kg, 14—22 ft-lb)

76G01A-092

1B—71
1 B ASSEMBLY (AUXILIARY PARTS)

Exhaust Manifold Assembly

1. Place the new gaskets in position with the ridge
facing the cylinder head.
2. Install the exhaust manifold assembly.
3. Tighten the nuts in two or three steps.

Tightening torque:
34—49 N m (3.5—5.0 m-kg, 25—36 ft-lb)

cardiagn.com
76G01B-105

Exhaust Manifold Insulator

Install the exhaust manifold insulator.

Tightening torque:
19—30 Nm (1.9—3.1 m-kg, 14—22 ft-lb)

EGR Pipe (Unleaded fuel)

Install the EGR pipe.

Tightening torque:
34—44 N-m (3.5—4.5 m-kg, 25—33 ft-lb)

76G01B-106

P/S Oil Pump Bracket

Install the P/S oil pump bracket.

Tightening torque:
37—63 N-m (3.8—6.4 m-kg, 27—46 ft-lb)

86U01X-178

1B—72
 INSTALLATION 1 B

INSTALLATION
TRANSAXLE ASSEMBLY
Assemble the transaxle to the engine in the sequence shown in the figure.

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76G01B-107

1. Transaxle 2. Starter

1B-73
1 B INSTALLATION

ENGINE INSTALLATION
Install the engine and transaxle assembly.

Warning: Be sure the vehicle is securely supported.

Torque Specifications

67—93 N m (6.8—9.5 m-kg, 49—69 ft-lb)

85—117 N m (8.7—11.9 m-kg, 63—86 ft-lb)

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8—11 N-m (80—110 cm-kg,
69—95 in-lb)

8-11 N-m
(80—110 cm-kg,
69—95 In-lb)
[;> )
16—27 N-m (1.6—2.8 m-kg,
12—20 ft-lb)

64—89 N-m (6.5—9.1 m-kg,

47—66 ft-lb)

37—63 N-m
(3.8—6.4 m-l 36—54 N-m (3.7—5.5 m-kg,
27—46 ft-ll 27—40 ft-lb)
37—52 N-m (3.8—5.3 m-kg -31—46 N-m (3.2—4.7 m-kg,
27—38 ft-lb) 23—34 ft-lb)
31—46 N-m
(3.2-4.7 m-kg, 5—7 N-m (50—70 cm-kg,
23—34 ft-lb) 43—61 in-lb)

-16—23 N-m (1.6—2.3 m-kg,

12—17 ft-lb)
39—59 N-m
(4.0—6.0 m-kg,
29—43 ft-lb) 9—13 N-m (90—130 cm-kg,
78—113 In-lb)

8—11 N-m
(80—110 cm-kg,
69—95 in-lb) 29—44 N-m (3.0—4.5 m-kg,
22—33 ft-lb)

31—46 N-m (3.2—4.7 m

23—34 ft-lb) ,68—118 N-m
19—25 N-m (1.9—2.6 m-kg, 14- .0—12.0 m-kg
65—87 ft-lb)
19—25 N-m (1.9—2.6 m
16—23 N-m (1.6—2.3 m-l
43-54 N-m (4.4—5.5 m-kg, 32-40 tl-lb)

8—11 N-m (80—110 cm-kg, 69—95 In-lb)

86U01X-180

1B—74
 INSTALLATION 1 B

Engine Mount
Install the engine mount.

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86U01X-181

Exhaust Pipe
1. Install the exhaust pipe.

Tightening torque
(A): 31—46 Nm
(3.2—4.7 m-kg, 23—34 ft-lb)
(§): 64—89 N-m
(6.5—9.1 m-kg, 47—66 ft-lb)

2. Tighten the bracket bolt.

Tightening torque:
19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb)

Extension Bar
Install the extension bar to the transaxle.

Tightening torque:
31—46 N-m (3.2—4.7 m-kg, 23—34 ft-lb)

Change Rod
Install the change rod to the transaxle.

Tightening torque:
16—23 Nm (1.6—2.3 m-kg, 12—17 ft-lb)

1B—75
1 B INSTALLATION

Driveshaft
1. Apply grease to the end of the driveshaft.
2. Install the driveshaft and a new clip.

Caution
a) When installing the driveshaft, be careful
not to damage the oil seal.
b) After installation, pull the front hub outward
to confirm that the driveshaft is securely
held by the clip.

cardiagn.com
86U01X-184

Lower Arm
Install the lower arm ball-joint to the knuckle; then tight-
en the lock nut.

Tightening torque:
43—54 Nm (4.4—5.5 m-kg, 32—40 ft-lb)

86U01X-185

Tie-Rod End
1. Install the tie-rod end to the knuckle.

Tightening torque:
29—44 Nm (3.0—4.5 m-kg, 22—33 ft-lb)

2. Install the cotter pin.

86U01X-186

Stabilizer Control Rod

Install and adjust the front stabilizer control rods.

Dimension A: 20.1 mm (0.79 in)

Tightening
16—23 Nm torque:
(1.6—2.3 m-kg, 12—17 ft-lb)

Install the front wheel.

Tightening torque:
88—118 Nm (9.0—12.0 m-kg, 65—87 ft-lb)

86U01X-180

1B—76
 INSTALLATION 1 B

P/S Oil Pump

1. Install the P/S oil pump.

Tightening torque:
31—46 N m (3.2—4.7 m-kg, 23—34 ft-lb)

2. Tighten the pulley lock nut.

Tightening torque:
39—59 Nm (4.0—6.0 m-kg, 29—43 ft-lb)

cardiagn.com
86U01X-18S

A/C Compressor
1. Install the A/C compressor strap to the P/S oil pump
bracket.

Tightening torque:
19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb)

2. Install the A/C compressor bracket.

Tightening torque:
37—63 N-m (3.8—6.4 m-kg, 27—46 ft-lb)

3. Install the A/C compressor.

4. Install the A/C compressor upper bracket.

Tightening torque:
37—63 N-m (3.8—6.4 m-kg, 27—46 ft-lb)

5. Tighten to the lock nut and mounting bolts.

Tightening torque:
37—52 N m (3.8—5.3 m-kg, 27—38 ft-lb)

86U01X-190

Drive Belt
Install the drive belt and adjust the belt deflection. (Re-
fer to page 1B—6.)

76G01B-109

1B—77
1 B INSTALLATION

Clutch Release Cylinder

1. Set the pipe bracket in position.

Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)

2. Install the clutch release cylinder.

Tightening torque:
19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb)

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76G01B-110

Speedometer Cable
Install the speedometer cable.

Brake Vacuum Hose

Connect the brake vacuum hose.

Canister Hose (Unleaded fuel)

Connect the canister hoses.

76G01B-111

1B-78
 INSTALLATION 1B
Connector Location
Install each harness as shown in the figure.

1. IG coil
2. Heat gauge unit
3. Speed sensor
10. Linear solenoid
11. Solenoid valve (idle speed control)
12. Throttle position sensor
76G01B-112
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4. P/S switch 13. Injection harness
5. Engine ground 14. Transmission harness
6. Water temperature sensor 15. Alternator
7. Water thermo switch 16. Oil pressure switch
8. Crank angle sensor 17. Starter
9. Oxygen sensor

1B-79
1 B INSTALLATION

Radiator
1. Install the radiator and cooling fan.

Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)

2. Connect the radiator harness.

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76G01B-113

3. Connect the upper and lower radiator hoses.

Note
a) Position the hose clamp in the original lo-
cation on the hose.
b) Squeeze the clamp lightly with large pliers
to ensure a good fit.

Heater Hose and Fuel Hose

Connect the heater hoses and the fuel hoses.

76G01B-114

High-Tension Lead
Connect the high-tension lead to the ignition coil.

Accelerator Cable
Install the accelerator cable.

76G01B-115

Battery and Battery Carrier

1. Install the battery carrier.
Tightening torque:
9—13 N-m (90—130 cm-kg, 78—113 in-lb)
2. Install the fuse box.
Tightening torque:
8—11 N m (80—110 cm-kg, 69—95 in-lb)

3. Install the battery tray and battery.

Tightening torque:
76G01A-148 5 _ 7 N m (50—70 cm-kg, 43—61 in-lb)

1B—80
 INSTALLATION 1 B

Air Cleaner Assembly

1. Install the air cleaner assembly.

Tightening torque:
16—27 N m (1.6—2.8 m-kg, 12—20 ft-lb)

2. Connect the air flow sensor connector and air in-

take pipe.

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Engine Oil
Add the specified amount and type of engine oil. (Re-
fer to Section 2A.)

Coolant
Close the drain plug, fill the radiator and reservoir tank
with the specified amount and type of coolant. (Re-
fer to Section 3A.)

76G01A-100

Check Engine Condition

1. Check for leaks.
2. Perform engine adjustments if necessary.
3. Perform a road test.
4. Recheck the oil and coolant levels.

86U01X-204

1B-81