100% found this document useful (3 votes)
11K views205 pagesToyota 4Y Engine Book
engine manual
Uploaded by
marjan43Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
100% found this document useful (3 votes)
11K views205 pagesToyota 4Y Engine Book
engine manual
Uploaded by
marjan43Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
/ 205
TOYOTA FORKLIFT
REPAIR MANUAL
TOYOTA MOTOR CORPORATION =
FOREWORD
This repair manual describes the description, construction, trouble shooting,
removal, disassembly, inspection and repair, assembly and installation of the various
components of the 4Y model engine equipped on the Toyota Forklift Trucks.
You are encouraged to become thoroughly familiar with this manual so as to make
the most of the outstanding performance and durability features of these vehicles
mounted with the 4Y engine and to perform the proper servicing to maintain them
in tip-top running condition.
| This repair manual contains the latest information available as of August 1986.
For any changes thereafter, you are asked to consult the Parts & Service News.
Toyota reserves the right to make changes in specifications and descriptions with-
out incurring any obligation and without previous notice.
TOYOTA MOTOR CORPORATION SECTION INDEX —
“STARTING SYSTEM _
_CHARGING SYSTEM _
-SSTLIST _
"SERVICE STANDARL GENERAL
Page
ENGINE VIEWS 2.0.0.0... 0. 0ccece eee eee eee eee ee 02
ENGINE PERFORMANCE CURVES 03
SPECIFICATIONS 05
ABBREVIATIONS . 06
TIPS FOR OPERATION .............00.00ee essere 06
STANDARD BOLT AND NUT TIGHTENING
TORQUES . 07 0-2
ENGINE VIEWS
AY Engine Exterior Views KAS426
~6- ENGINE PERFORMANCE CURVES
0-3
Engine horsepower
40}
30}
16.5/1800
a
4/2100
?
200/200
14 18 22
Engine speed (rom)
28
ww E
na €
a
2
10
egrn}
260
y
Fuel consumption ratio
180
(alps)
x10?
4Y Engine Performance Curves (11.75 ton)
~7-
KANT ~ ee ~ g
Z g
women cnesvonsunvesjons 2
ee £22 8 § 8 8 8
ee hE
28
68/1800
sarzaoo
NJ
70 12 18 cr
Engine speed (pm)
4Y Engine Performance Curves {2-3 ton)
semodossoy aui6ug 0-5
SPECIFICATIONS
[ 1 ton series 2,3 ton series
Engine model | ay -
Type Gesoling ©
Gyele a .
No, of oylinders and arrangement Indine 4 oylinders, longitudinal arrangement
Starting method Self-starting =
Combustion chamber type ‘Wedge type -
Valve mechanisin ~ OHV, Chain drive =
Bore x Stroke mmm fin.) | 97.0 x 86.0 (3.58 x 3.39) =
Total displacement 6 (eu:in} 2237 (138) +
Compression ratio 92 =
Compression pressure kg/cm? {psi)/rem 12.5 (178)/280 «
Rated horsepower PS/iom 45/2100 54/2400
Maximum torque kom (feibi/rm 16. (11ei/rom «
secede MEET tosh tem) | 200 (2000) | 195 (2300)
Engine dimensions | S76xsI2x 707
(length x width x height) me tin) | (96.6 x 20,2 x 27.8) -
Service weight kg fib) | 134 (295) e
Number of piston rings Beam Reason ings <
. Open ag? BTDC | -
Intake valve timing
Close 40° ABDC =
~ | Open 54° BEDC -
Exhaust vatve timing =
Close & ATDC ~
intake 0 (Self adjusting) | «
Valve clearance - + - -
Exraust | , | =
Idle speed rom 850 # 60 -
No-load maximum governed speed rpm | 7300 # 60 2600 # 60
PCV system type Closed type + 0-6
ABBREVIATIONS
Abbreviation Abbreviation
{cociel Meaning code} Meaning
ASSY Assembly ois Oversize
ABDC After bottom dead center 3) OPT Option
ATDC After top dead center RH Right hand
BB0C Before bottom dead center cpm | Revolutions per minute
BTDC Before top dead center Sst Special service tool
BDC Bottom dead center sTo ‘Standard
EX Exhaust SUB-ASSY Sub-assembly
vA Integrated ignition assembly Ts Tightening torque
IN Intake us Undersize
LH Left hand
GENERAL RULES OF SERVICING WORK
PREPARATION BEFORE DISASSEMBLY
1. Prepare mechanic tools, necessary measuring instruments and SST before starting operation.
2. When disassembling a complicated assembly, put punch or matching marks at places not affecting
function to facilitate reassembly operation. When repairing an electrical system, start operation after
disconnecting the cable from the battery negative terminal.
INSPECTION DURING DISASSEMBLY
1. Each time a part is removed, check the part installed state, deformation, damage, roughening state
and seratching,
ORDERLY ARRANGEMENT OF DISASSEMBLED PARTS
1. Disassembled parts shall be arranged orderly, Distinguish the parts to be replaced from the parts to
be reused,
CLEANING OF DISASSEMBLED PARTS
1, Parts to be reusad shall be cleaned and washed thoroughly.
INSPECTION AND MEASUREMENT
1. Detaited inspection and measurement shail be carried out as required for parts to be reused.
INSTALLATION
1. Install good parts according to the correct procedure and observing the determined standards (tighten-
ing torques, adjustment values, etc.)
2. Always use genuine parts for replacement of existing parts.
3. Always use new packings, gaskets and cotter pins because they are not meant for reuse.
4. Coat seal packing on gaskets depending on the places, coat oil on the sliding contact places, coat oi
or grease at specified places, and coat MP grease on oil seal lips before reassembly.
ADJUSTMENTS AND OPERATION CHECK
1. Adjust to thé service standard values by using gages, a multimeter, etc.
—10- 0-7
STANDARD BOLT AND NUT TIGHTENING TORQUE JUDGEMENT
Standard bolt and nut tightening torques are not indicated; therefore tightening torque must be judged
as below:
1. Find out the type of the bolt from the tist below.
Then, find the bolt tightening torque frorn the table.
2. The nut tightening torque can be judged from the bolt type. (See the table.)
LIST OF BOLT TYPES AND STRENGTH
1. Sudging by pert 2. Judging by part No.
Shape and description Type Hexagon bolt
"Number in reief or | 2727 |] Semple number
| hallmark on the 91111-40610
Hexegon ea 6=6T o61¢
bolt prea ye7t
Standard T Length (mom): A
bottom
surface
I Diameter (mm): B
No mark. at
I Type
Hexagon T |
bolt |
{Collared No mark at CR Te
Hexagon
!
1
(Standora I Two relief lines on sr A
bottom the head
\
|
bottom)
surface) Y
Hexagon
at ‘ Two relief lines on er
‘clare
bottom) the head Stud bolt
i
Hexagon | Three relief lines on |p
bolt I the head Sample number
92132-40614
| L
Welded
we la Length om): A
Diameter (mm): B
! Type
Welding | No mark 4T 1 Ts
bolt Ll LUUUUUUY
Q aes
Stud
Stuc | Approximately 2mm
1 (0.08 in.)hollowon | 6T
either or both ends
a
BAHS28 BAHS25
-We 0-8
STANDARD BOLT TIGHTENING TORQUE
Precoated bolts (bolts and nuts coated
with seal lock agent on threaded parts)
1. Do not use precoated bolts in any of the fol:
lowing cases:
(1) When a precoated bolts is removed.
{2) When a precoated bolts is removed as
result of tightening check, etc. (When it
is loosened or tightened)
Note:
Check the torque with the lower limit of the
tightening torque. If it moves, retighten it,
according to the following procedure:
2, Method for reuse of precoated bolts
(1) Clean the bolt and threaded hole.
Clean the threaded hole when the bolt is
to be replaced
(2) Dry the cleaned parts thoroughly by air
blowing.
(3) Coat the specified seat lock agent on the
threaded part of the bolt.
Standard tightening torque gem (ft-/b)
b Diameter Pisch a San
yee andar eat wi
6 10 55 ( 4.0) 60 { 43)
8 1.25 130 ( 9.4) 145 (10.5)
30 1.25 260. 8.8) 290 (20.9)
aT 12 1.28 480 (34.7) 540, {39.0}
14 15 760 (54.9) 850 (61.4)
16 16 1,150 {83.0) _
6 10 65 (4.7) _
8 1.26 160 (11.6) -
10 1.25 330 (23.8) |
oT 12 1.28 600 (43.3) ~
14 1S 930 (67.1) _
| 16 15 4,400 (101.1) _
6 1.0 80 ( 5.8) 90 ( 6.5)
8 | 1.25 195 (14,1) 210 (16.2)
6T 10 | 1.25 400 (28.9) 440 (31.8)
12 | 1,25 730 (52.7) 810 (58.5)
44 15 1,100 (79.4) i 1,260 (90.3)
6 10 110 ( 7.9) 120 ( 8.7)
8 1,25 (260 (18.8) 290 (20.9)
10 1.25 530 (38.3) 590 (42.6)
uv 2 1.28 970 (70.0) 1,050 (75.8)
a4 15 1,500 (108.3) 1,700 (122.7)
i6 16 2,300 (166.1)
BAHS6
~12-
Seal locking eaterial
84460 ENGINE TUNE-UP
COOLANT INSPECTION .
ENGINE OIL INSPECTION...............-..2200005
BATTERY ELECTROLYTE LEVEL AND SPECIFIC
GRAVITY INSPECTION .
AIR CLEANER INSPECTION AND CLEANING ......
CLOGGING WARNING SYSTEM INSPECTION .......
V-BELT INSPECTION AND ADJUSTMENT ..........
IGNITION PLUG CLEANING AND GAP
INSPECTION & ADJUSTMENT ................05
IGNITION TIMING INSPECTION AND
ADJUSTMENT . 2.22.06. 0 2 eee eee cee eens
IDLE-UP SPEED INSPECTION AND ADJUSTMENT
IDLE SPEED INSPECTION AND ADJUSTMENT |.
NO-LOAD MAXIMUM GOVERNED SPEED
INSPECTION AND ADJUSTMENT
COMPRESSION PRESSURE INSPECTION ..
=13-
Page
12
12
1:3
13
1-4
15
15 1-2
COOLANT INSPECTION
1. Coolant Inspection
(See Section 5.)
Standard:
The coolant jevel in the radiator reservoir
tank shall be between the FULL and LOW
lines.
The LLC concentration shall be 30% (50% in
frigid zone) or more, and the coolant shall
not be contaminated with oil, etc.
ENGINE OIL INSPECTION
1, Engine Oil inspection
Standard
The oil level shall be between F and L on the
dipstick.
The oil shall not be heavily contaminated,
and the viscosity shall be proper.
Neither coolant nor light oi shall exist in the
engine oil.
BATTERY ELECTROLYTE LEVEL
AND SPECIFIC GRAVITY
Inspecting the Coolant
KAHS109
INSPECTION Inspecting the Engine Oil Luos09
1. Battery Electrolyte Level Inspection
Standard:
The electrolyte level shall be between
UPPER LEVEL and LOWER LEVEL.
The specific gravity shall be 1.28 (at 20°C).
Caution:
If the battery electrolyte is insufficient, add |
distilled water.
Inspecting the Battery Electrolyte Level Kausso4
AIR CLEANER INSPECTION AND
CLEANING
1, Air Cleaner Element Inspection and
Cleaning
(1) Check the air cleaner element for da-
mage, dirt and clogging.
(2) Use compressed air to clean the air
cleaner element,
Caution:
The air pressure shall be 7 kg/em? (99 psi)
or less. Cleaning the Air Cleaner Elernent
1
KaHstit 1. Air Cleaner Case Cleaning
(1) Clean the inner and outer surfaces of
the case with cloth
CLOGGING WARNING SYSTEM
INSPECTION
1. Inspection on vehicle
(1) Check that the air cleaner warning lamp
‘on the instrument panel comes on when
the key switch is set to ON, and that it
goes off when the engine starts.
2. Individual inspection
(1) Check current conduction when a nega-
tive pressure is applied to the vacuum
switch
Standard:
Approx. 50 mmHg or above:
Conduction
Approx. 35 mmHg or less:
No conduction
Ceution:
Do not apply a negative pressure exceeding
75 mmHg to the vacuum switch.
V-BELT INSPECTION AND
ADJUSTMENT
1. Vehelt Inspection
(1) Check that the belt is correctly installed.
(2) If squealing or slipping exists, check the
belt surface in contact with the pulley
for wear, damage and scratches, and the
pulley for surface defects.
(3) Push the center of the belt between the
alternator and water pump with a force
of 10kg (22 Ib) and measure the flexure.
Standard V belt flexure:
New belt canto) (0.26-0.35)
[Freese 9 eaten
Caution:
© Always measure the belt flexure at be-
‘tween the specified pulleys.
AIR CLEANER |
Warning Lemp
KAds2
Inspecting the Vacuum Switch KAHS125
aN Pushing force:
NS TOkg (22 Io)
/ | Straight edge
e
Cc
J Fexure
Inspecting the V-belt Flexure KAISI
~B- 14
© When replaced with @ new belt, adjust the
flexure to the central value of the stan:
dard range for the new belt.
© When inspecting a belt used for 5 minutes
‘or more, apply the standard for general
inspection,
© When reinstalling a belt used for S minutes
or more, adjust the flexure to the central
value of the standard range for general
inspection.
(4) When the belt tension gauge is available,
apply the gauge at the center between
the alternator and water pump to
measure the tension of the V-belt
SST 09216-00020
\Vebelt tension standard:
For new belt kg io) | 38-62 (84-137)
For general inspection
‘eo (iby | 90-50 (66-110)
2. Vebelt Flexure Adjustment
(1) Loosen fixing bolts A and B.
(2) Turn adjusting bolt C to adjust the
flexure.
(3) Tighten fixing bolts 8 and A in this
‘order.
(4) Check the belt tension {flexure or
tension)
IGNITION PLUG CLEANING,
AND GAP INSPECTION
& ADJUSTMENT
1. Gap Inspection and Adjustment
(1) Inspect the gap and adjust it if the stan-
dard is not satisfied
Standard: 0.7 - 0.8mm
(0.028 ~ 0.031 in.)
(See page 7-3)
ce
Adjusting the V+
Inspecting the Ignition Plug
~16=
iG0089 IGNITION TIMING INSPECTION
AND ADJUSTMENT
1. Engine warm up
Standard:
Coolant temperature: 75 ~ 85°C
Engine oil temperature: 70°C or more
Hydraulic oil temperature: 50°C or more
2. Tachometer and timing light installation
(1) Disconnect the test connector and con-
ect the tachometer measuring lead to
the black wire,
3. Idle speed inspection
Standard: 650 £50 rpm
4, Ignition timing inspection and adjustment
(1) Disconnect the vacuum hose from the
Distributor (IIA),
“Test conhector
(black wire)
Installing the Tschometer KASS
(2) Use the timing fight and inspect the
ignition timing,
Standard: 7° BTDC/650 mpm
(3) If the standard is not satisfied, loosen
the’ distributor set boit and turn the
distributor for adjustment to the stan:
dard value.
(4) Tighten the set bolt and recheck the
ignition timing
T= 1.85 kom (18.4 ftb)
(5) After ignition timing adjustment, seal
the distributor set bolt by using the
sealing tape.
IDLE-UP INSPECTION AND
ADJUSTMENT
1, Engine warm up
Standard:
Coolant temperature: 75 ~ 85°C
Engine oil temperature: 70°C or more
Hydraulic oil temperature: 50°C or more
‘Tachometer installation (See above.)
3. Idle-up speed inspection and adjustment
(1) Start the engine, Disconnect the vacuum
hose @) from the idleup actuator
©) , andl measure the engine speed.
Standard:
Clutch model: 1350+ 25 rpm
Torque converter model:
1280 + 25 rpm
If the standard is not satisfied, turn the
adjusting screw @ for adjustment.
Caution:
Clockwise turn of the adjusting screw in- _gjusting the Idle-up Speed KAL209
creases the engine speed.
n
-W- 1-6
IDLING SPEED INSPECTION
AND ADJUSTMENT
1. Engine warm up
Standard:
Coolant temperature: 76 — 85°C
Engine oil temperature: 70°C or more
Hydrautic oil temperature: 50°C or more
2, Tachometer and vacuum gauge installation
(1) install the tachometer. (See page 1-5.)
(2) Remove the intake manifold plug @
and connect the vacuum gauge
3. Idle speed inspection and adjustment
(1) Start the engine. Alternately turn the
throttle adjusting screw C) and idle
adjusting screw @) to maximize and
stabilize the vacuum while maintaining
the specified idle speed
(2) When engine idle spead does not return
to the normal (preset) speed due to the
imterference or contact between the
idle-up adjusting screw and the idleup
actuator rod, loosen the idle-up adjusting
screw. (See page 15)
Standards:
Idle speed: 660 + 60 rpm
Vacuum: 400 mmHg
NO LOAD MAXIMUM GOVERNED!
SPEED INSPECTION AND AD-
JUSTMENT
(See page 3:34)
COMPRESSION PRESSURE
INSPECTION
Note: Measuring the Compression Pressure emai,
If output reduction, excessive oil consump-
tion or extremely bad fuel consumption
ratio is observed, measure the cylinder com-
pression pressure.
1. Engine warm up
Standard:
Coolant temperature: 78 —85°C
Engine oil temperature: 60°C or more
2. Remove of all ignition plugs
3. Distributor connector disconnection 4, Compression pressure measurement
Caution:
Run the starting motor to discharge foreign
matters from cylinders before the com-
Pression pressure measurement,
(1) Insert the compression gauge to the
ignition plug hole.
(2) Fully open the throttle,
(3) Crank the engine by the starting motor
and measure the compression pressure.
Standard: 12.5 kg/cm? (178 psi)
Limit: 8.0 kg/em* (128 psi)
Caution:
Always use 2 fully charged battery to keep
the engine speed at 250 rpm or above.
(4) Repeat steps (1) to (3) above for all
cylinders and inspect the pressure dif
ference.
Pressure difference limit:
1.0 kg/cm? (14 psi)
(5) If the compression pressure is below the
limit or if the compression pressure in
any cylinder is deviated beyond the
pressure difference limit, add engine oil
slightly through the ignition plug hole,
and repeat steps (1} 10 (3)
@ if the pressure rises after the oil ad-
dition, the piston rings and/or cy-
Tinder bore may be worn or damaged.
@_ If the pressure is still low after the oi
addition, valve seizure, valve contact
defect or pressure leak from the
gasket may be the reason.
5. Distributor connector reconnection
6. Ignition plug instatlation
T= 1.8 kom (13.0 ft-lb)
-19- ~20- ENGINE OVERHAUL
ENGINE SECTIONAL VIEWS............--200--005
CYLINDER HEAD ....
TIMING GEAR & CAMSHAFT ...........-.-----++
CYLINDER BLOCK
=21-
21
Page
22
24
2-25
. 241 2-2
ENGINE SECTIONAL VIEWS
AY Engine Longitudinal Sectional View Laois,
~22- 4Y Engine Transverse Sectional View LAOLs
=23- 24
CYLINDER HEAD
COMPONENTS
Peres
7
10.
oe
(Cylinder head cover SUB-ASSY
Seal washer
Cytinder head cover gaskat
il filer cap SUB-ASSY
Gasket
Gylinder head SUB-ASSY
Intake valve guide bush
Exhaust valve guide bush
Shaft snap ring
Plug
Gasket
12
13.
14.
16.
16.
17,
18.
19,
20.
21
22.
Intake valve ceat
Exhoust valve seat
Ignition plug hote
Gasket
Cylinder head gasket
Gasket
Head rear plate
Valve rocker arm, No. 2
Saring
Valve rockerarm, No. 1
Volve push rod
23,
24.
28.
27.
28,
30.
31
32.
33,
Value lifter
Stud bott
Stud belt
Valve rocker shaft No. 1
Valve spring retainer tock
Valve spring retainer
Valve spring
Valve stern oil seal
Spring seat
Intake velve
Exhaust valve
Cylinder Head Components
~24—
KAJMS ‘Manifold Components
—25—
KAsM4 2-8
CYLINDER HEAD REMOVAL.
1. Fan, fan pulley and V-belt removal
(1} Loosen alternator fixing bolts (2 pes.)
and the adjusting bolt
(2) Fan
(3) Fan puliey
(4) Vebelt
2. Alternator removal
(1) Fixing bolts (2 pes.)
(2) Adjusting bolt
(3) Alternator
Removing the Alternator (2)
= 26~
Katia 3. Air cleaner connector disconnection
(1). Disconnect ventitation hose No. 3.
(2) Disconnect the connector to governor
hose.
(3) Remove set bolts {2 pos.), and remove
the air cleaner connector.
Disconnecting the Air Gleaner Connector KAJI1.23.
4. Carburetor removal
(1) Disconnect vacuum hoses (4 pes.)
Note:
Attach identification tags to the vacuum
hoses before disconnection.
(2) Disconnect the water hose.
(3) Disconnect the fuel piping,
(4) Remove set nuts (2 pes.), and remove
the carburetor.
5. Governor removal
(1) Disconnect ventilation hose No, 1
(2) Disconnect the water hose.
(2) Remove the air governor.
(4) Remove the heat insuletor and fuel
insulator plate,
Removing the Air Governor KASI1.36
-27- 2-8
6. Water outlet pipe removal
(1) Union bolt
(2) Set bolts (2 pes.}
(3) Water bypass hose disconnection
(4) Water outlet pipe
7. Ignition plug and tube removal
{1} Use an ignition plug wrench and remove
ignition plugs (4 pes.} and ignition plug
tubes (4 pes.)
8. Oil Jevel gauge set bolt removal
9. Fuel pipe and hose removal
{1) Disconnect the fuel pipe from the fuel
pump,
{2} Fuat pipe clamp set bolts (2 pes.)
(3) Fuel pipe and hose
ee S .
Flomoving the Oil Level Gauge Set Bolt
Disconnecting the Fuel Pipe and Hose
28
A320 10. Cylinder head cover removal
(1) Cap nuts (3 pes.)
(2) Seat washers (3 pes.)
(3) Cylinder head cover
(4) Gasket
11. Valve rocker shaft ASSY removal
(1) Evenly loosen three valve rocker shaft
set bolis and two nuts in the illustrated
‘order in several steps, and remove them.
(2) Remove the valve racker shaft ASSY.
Removing the Valve Rocker Shaft ASSY ewan?
42. Valve push rod removal
Caution:
Extracted push rods shail be arranged in the
order of cylinders.
13. Manifold removal
(1) Set nuts (8 pes.)
(2) Manifold
(3) Gasket
Removing the Manifold KANS-27 2-10
14, Water pump ASSY removal
(1) Water inlet hose disconnection
{2} Set bolts (4 pes.)
(3) Water pump ASSY
15, Cylinder head removal
(1) Evenly loosen 13 cylinder head bolts in
the illustrated order in several steps
(2} Remove the set bolts and remove the
rear engine hanger.
(3) Remove the cylinder head from the
cylinder block.
Caution:
Carefully prevent the cylinder head instatla-
tion surface from any damage.
CYLINDER HEAD DISASSEMBLY
1. Valve remaval
{1} Set the SST to the vaive to compress the
velve spring, and remove two retainer
locks,
SST 09202-43013
(2) Remove spring retainers, springs, seats,
valves and oil seals.
Caution:
Removed parts shall be arranged orderly for
each cylinders.
Kasse
Removing the Cylinder Head
eM2416
sst
|
i
| égé
om BE
=30
| 2-11
CYLINDER HEAD INSPECTION
AND CLEANING
1
Piston and cylinder block top surface cleaning
(2) Rotate the crankshaft to bring each
piston to the top dead center. Use a
gasket scraper and remove the carbon
deposit on top of the piston,
(2) Use the scraper and remove the gasket
adhering on the cylinder block top sur
face.
(3). Use an air gun to blow off oil and foreign
matters from bolt holes,
Caution
Use cloth to prevent splashing of oit
Cylinder head gasket removal
(1) Use the scraper and clean the cylinder
head bottom surface and manifold in-
stallation surface,
Caution:
Do not damage the cylinder head during
cleaning.
Cylinder head combustion chamber cleaning
(7) Use @ wire brush to remove the carbon.
from the combustion chambers
Caution:
Do not damage the surface to be in contact
with the head gasket
Valve guide bush cleaning
(1) Use a solvent and clean the inner surface
of the valve quide bush.
Cleaning the Cylinder Block M2532
Soe SS
9,
SE SOSO
a a
a SS Soe >
x 0,
a> 2. Ss =
TOS ASC
TV TV r
Sena waar
ez
‘Contact width
Correcting the Valve Seat (2) M0185
Intake 60°
Exhoust 65° .
45
S¢
Gohtact with
M2535
Correcting the Valve Seat (31
so Se
% 1G
Se S
S SRG
eMo1E6
Lapping the Vaive
—36—
ew2400 14. Valve spring inspection
(1) Use a straight edge and thickness gauge, Squareness —e}-=—
‘and measure the squareness at the top }
end of the valve spring,
Limit: 2.0 mm (0.079 in.)
Replace the vaive spring if the limit is
exceeded.
‘Measuring the Valve Spring Squareness M0988
(2) Use 2 vernier caliper and measure the
free length of the valve spring
Standard: 47.0 mm (1.85 in.)
Meaturing the Valve Spring Free Length ENog07
(3) Use a spring tester and measure the in-
stalled tension of the valve spring,
Standard: 28.8-35.2 kg (63.5~77.6 |b}
(When the installed length is
40.6 mm (1.598 in.)}
If the standard is not satisfied, replace
the valve spring,
Rieasuring the Valve Spring
Installed Tension - M0281
15, Valve rocker arm inspection
(1) Inspect the rocker arm for the wear and
damage of the surface in contact with
the valve stem,
(2) If slight surface defect is found, correct
with an oil stone. ff heavily worn or
damaged, replace the rocker arm,
Inspecting the Valve Rocker Arm (1) M2399
~37~ 2-18
(3) Move the rocker arm as illustrated, and
inspect the clearance with the rocker
arm shaft
Standard: Almost no looseness shall be
felt.
If any looseness is felt, disassemble the
rocker arm ASSY and inspect the oil
clearance.
Inspecting the Vaive Rocker Arm M2298
16. Rocker arm to rocker shaft oil clearance
{1) Use a caliper gauge and measure the
rocker arm inside diameter
Standard: 18,500 ~ 18.515 mm
(0.7283 — 0.7289 in.)
‘Measuring the Rocker Arm Inside Diameter EM2297,
{2) Use a micrometer and measure the
rocker shaft outside diameter.
Standard: 18.474 — 18.487 mm
(0.7273 ~ 0.7278 in.)
(3) Calculate the difference between the
rocker arm inside diameter and rocker
shaft outside diameter.
Standard: 0.013 — 0.041 mm
' (0.0005 — 0.0016 in.)
Limit: 0.08 mm (0.0031 in.)
If the limit fs exceeded, replace the Measuring the Rocker Sha Outside M2096
rocker arm and rocker shaft, Diameter
No, 2
(4) Assemble the valve rocker shaft ASSY No.1
1 Check the direction of the rocker {A
acm shatt rear end, assemble the Q
rocker arms and springs as illustrated,
and position them by using SSTs. Protrusion
SST 09270-71010
Front
With protrusion
Positioning the Rocker Arms M2295
~38~ 2-19
17. Push rod inspection
(1). Inspect the push rod runout
Runout fimit: 0.30 mm (0.0118 in.)
If the limit is exceeded, replace the push
rod.
(2) Inspect the push rod end ail hole clog
ging.
If clogged, clean with an air gun,
Inspecting the Push Rod M2536
18. Intake and exhaust manifold distortion in-
spection
(1) Use a straight edge and thickness gauge,
and measure the distortion of the in-
stallation surface to the cylinder head,
Limit: 0.40 mm (0.0167 in.)
If the limit is exceeded, regrind or re-
place the manifold ASSY.
eM2304 2-20
CYLINDER HEAD ASSEMBLY
Notes
© Thoroughly clean the parts to be assem:
bled.
© Coat engine oil on the sliding contact and
rotating surfaces.
Replace the gaskets and oil seals with new
parts,
1. Valve assembly
(1) Insert valve @) into the valve guide bush.
(2) install valve spring seat @) and oil seat
@ Coat engine ail on the valve stem
and oit sea fp,
(3) Install valve spring @ and spring re
rwiner ©. Upwars
wow: t
The paint mark on the spring shall face the
head.
Paint mark
Assembling te Valve () Eos 0476
(4) Use the SST to compress the valve
Spring, and install spring retainer lock est |
©. |
SST 09202-43013 2
(5) Tap the valve stem top fightly with a
plastic hammer to settle the spring,
alg
Assembling the Valve (2) em2a13,
CYLINDER HEAD INSTALLATION
1. Cylinder head installation
(1) Install a new gasket 10 the cylinder
block, paying attention to its direction,
(2) Install the cylinder head.
(3) Coat engine oil on cylinder head bolts.
Installing the Cylinder Head Gasket em2393
-40- (4) Evenly tighten 13 cylinder head bots in
the ilfustrated order in several steps,
T= 9.0 kg-m (65 ft-lb}
«Mi2}
T= 1.95 kam (14 ft-lb)
«is)
Push rod and vaive rocker shaft ASSY in-
stallation
(1) Install each push rod @) at its original
position before removat.
{2}, Use the SST ond positfon the push rods
as illustrated
SST 09270-71010
Caution:
Check that the push rod is surely in the lifter
push rod seat portion.
(3) Install the valve rocker shaft ASSY to
‘the cylinder head
(4) Evenly tighten 3 bolts and 2 nuts in the
illustrated order in several steps.
40 kg-mn (17 fttb}
Caution:
Keep the push rods from leaving the rocker
arm, and tighten the bolts and nuts.
Water pump ASSY installation
(1) Install a new gasket,
(2) Install the water pump ASSY.
(3) Tighten 4 set bolts.
T= 1.85 kg-m (13 ft-lb)
(4) Install the waterinlet hose,
2-21
Botts
eM2qi6
eM2302
Installing the Velve Rocker Shaft ASSY
EM2a17,
Instailing the Weter Pump ASSY