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0% found this document useful (0 votes)
61 views130 pagesKIA Master 1000 Workshop Manual
KIA Master 1000
Uploaded by
ฉัตร มงคลCopyright
© © 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
/ 130
ic hr eer at
S-1000P-1300P
WORKSHOP MANUAL
Oe edt. meee WT O
Q
PRE-DELIVERY SEQUENCE GUIDES
AND
MAINTENANCE SCHEDULE 0
0-A, PRE-DELIVERY SEQUENCE GUIDES
Perform the following operations (checks, alignment, repleoachmats, adjustments, corrections, etc.) during the
pre-delivery inspection.
—_——__
UNDER HOOD — ENGINE OFF
Engine oll level Cheek battery cables for tightness
‘Steeriog gear housing olf Level Drive belt tension
brake & clutch master eylinder fluid level Carbaretor linkage, choke control and wide open
Windshield washer reservoir Muid Level
Rediator coolant level and specific gravity,
Mattery electrolyte level and state of charge
throttle position
Clean and check spark plug
UNDER HOOD — ENGINE OPERATING AND HOT
Cheek distributor dwell
Check inital ignition timing,
Allcmaior and regulator = operation
Carburetor ills speed adjustment
Foel, vacuum, coolant and hydraulic fines, Fittings,
connections and components for leake
Check air conditioner sight last A/C on (if equipped)
Compression promure
ON OUTSIDE
Latebet, Key and locks — operation
Hood, and door panels for fit, alignment and
operation o-6
Bumpers and mouldings — alignment O:6
‘Weatherstrips — adhesion and (it
‘Wheel bolt torque
‘Wheel caps ~ install
Headlight alignment — adjust if necessary
Brake & clutch peda fiee play :
Operation of all lights 0:6
Check upholatery aed internal finish
Front seat control — operation (manuaf or recljaings)
Seat lock latch — operation
‘Seat and shosider belts
Inside Jocks and door latch releases — operation
‘Windows and vents — operation and fit
(Cigar lighter — install and test
‘Set cock
Transmission oil level
Rear axle oll level
Fuel, coolant and hydraulic lines, fittings, connections
and components oa underside for leaks
Tite pressures and inspect tires
‘Steering linkage and connections
Ignition ewitch and steering lock — operation
Parking brake ~ operstian
Hom, windshithd wipers and washer ~ operation
Heater, defroster and ait conditioner ~ operation
Radio ~ operation and set push buttons
Brake operation
Clutch operation
Trantmission shift lever = operation
Accelerator pedal - operation:
Engise performance
‘Stecting control
Check for noise, squeaks and rattles
Speedometer, odorscter, fuel and temperature
auges und ammeter — operation
General performance and handling characterist
Remove seat protectors, windshield markings and ta
Wash car and check for leaks
Gass condition
Inspect for exterior and interior metal and paint
‘Check soft trim for sollage and excess sealer
Check tool kit, jack and owner's handbook, service
coapons and manufacturer's warranty booklet J
i
0
0-B. MAINTENANCE SCHEDULE
‘These maintenance services must be performed at the indicated intervals, following the procedures in this manual.
At first 1,000 km (600 mites)
Battery — Check electrolyte level and specific gravity.
Drive belt — Check for tension and wear. Adjust or replace if necessary.
Brake and clutch uid — Check fluid tovel. Replenish if necessary.
‘Check and adjast idle speed and idle mixture.
Intake and exhaust manifolds — Tighten.
Spark plugs — Inspect, clean, adjust and test. Replace if necessary.
Distributor breaker points — Check and adjust. Replace if necessary.
Check and adjust initial ignition timing and distributor mechanical and vacuum advances.
Engine oil — Change and check for oil leaks,
Fuel line and connections — Check for beaks
heck for deterioration, leaks and loose clamps of cooling system hoses. Repair and/or replace if
necessary
Clutch pedal — Check free play, Adjust if necessary.
Brake pedal — Check free play, Adjust if necessary.
Steering wheel free play — Check free play. Adjust if necessary.
Parking brake — Check and adjust if neceuary.
Transmission oil — Change.
Rear axle oil — Change,
Every 3,000 km (2,000 mites)
Carburetor air cleaner element — Clear. If vehicle is operated under dusty conditions, clean the air
cleaner clement every 1,500 km (1,000 miles)
Every 6,000 km (4,000 mites}
Battery — Check clectrolyte level and specific gravity.
Drive belt — Check for tension and wear, Adjust or replace if necessary.
Drake and clutch fluid — Check fluid level. Replenish if necessary,
Check and adjust idle speed and idle mixture,
Spark plugs — Inspect, clean, adjust and test. Replace if necessary.
Distributor breaker points — Check and adjust. Replace if necessary.
Check and adjust initial ignition timing and distributor mechanical and vacuum advances.
Engine oil — Change and check for oll leaks.
Fue! line and connections — Check for leaks.
‘Gheck fot deterioration, leaks and loose clamps of cooling system |.ws. Repair and/or replace if necessary.
‘Qutch pedal — Check free play, Adjust if necessary.
Brake..pedal — Check free play. Adjust if necessary.
Steering wheel free play — Check free play. Adjust if necessary,
Parking brake — Check and adjust if necessary.
Lights — Check operation of all kinds of lights and meters, replace as required.
Every 12,000km (8,000 miles}
Intake and exhaust manifolds — Tighten,
Engine off filter — Change.
Every 18,000 km (12,000 miles)
Carburetor linkage and choke mechanism — Check and if sticking, clean or correct,
Steering gear ofl — Check level. Replenish If necessary.
‘Cooling system hoses — Check for deterioration, leaks and loose clamps Repair and/or replace if
necessary.
Fuel filter — Change. Transmission of — Change
Rear ade oi) Change,
Brake lines and drum brake linings — Check, Adjust and/or replace if necesusry,
Every 36,000 km (24,000 mites}
Carburetor air cleaner dement — Change. Mf welucle is operated under dusty conditions,
leaner element every 18,000 km (12,000 miles)
Every 48,000 km (32,000 miles)
Lubricate (clean and repack) front wheel bearings.
Lubricate front suspension ball joints and idler arm.
Steering linkage ball joints — Check and replace i necessary.
Every tee years
Change piston cups of brake system.
Every tour years
Change brake hose and fuel howe.
GC, MAINTENANCE OPERATIONS
- UNDER HOOD —
O-C—1. Checking Engine Oil Level
Check the oil level dipstick ta be sure it indicates
the correct quantity of oil im the of pan (above the
L mark), Gn pre-delivery fill the oil until “F" mark
ii, Use only oll mocting speci
Fig. 0-2 Checking: stecring gear oil. level
3, Install the filler cap
0=1 Checking engine oi! level
0—C-2. Checking Steering Gear Oi Level
To check the oil level, remove the filler plig on
the top of the steering gear box and add lubricant
meeting specifications if necessary.
0-C-3. Checking Brake and Clutch Fluid Level
1. Remove the filler cap from the master cylinder. i
2. The Muid level should be kept at least 2/3 full in the Fig. 0-3 Make master cylinder
O:3
reservoir. Use only brake fluid meeting speciticatl 0
0-C-4, Checking Windshield Washer Fluld Level adequate level for the temperatures which may occur
Hall with wuter and solvent mecting specificatic in the area in which the car will be openuted. Refer
water can be used, but a good grade of wind to Pur. 3-B and check the specific gx
id washer solvent will help it clean better and
prevent freezing in cold weather, De not use radiate Note:
amtlfreece as thls will cause paint damage, Do not remow the mdalor cap when the coolant
temperature Is high or balling.
0-C-6. Checking Battery
Refer to Par, S A-I and check the battery for elec-
rolyte level and state of charge. Check the tightness
of the terminals to ensure good electrical connections,
‘ean the terminals and cou the terminals with grease
{0 relard corrosion and oxidant
Fig. 0-8 Checking lui tevel
0-C-5, Checking Radiator Coolont
The coolan ould dé full in the radiator and
within “Rall” and son the expansion tank
(se recommended inixtare of Long Life Coolant (0444
77) ay water to ke
nthe freeze protection at an
Fig. 0-7 Dattery
Q—C-7, Checking Drive Pulley Condition
Inspect pulley bell surface for deposits of must. if
fust present but can be removed easily with a doth
moistened with kerosene, rust is harmless and can
be ignored, If rust ¢ be so removed, remove
bell and polish pulley belt surfaces with fine sane
paper, Wipe or blow with compressed Install
belt and adjust the tension to specications.
Fig. O-8 Alternator palley and wotcr pomp pulley
0-—C-B. Checking Alternator Drive Belt Tension
UW is important to keep drive belt at the proper ten:
sion nut only to minimize nolse and prolong service
= life of the belt, but atm to protect the com
Fig. 0-6 Level marke o expansion tank being driven. If any helt is broken, glazed. or worn,
O24 0
replace it with a new belt, Use only the specified
type of belt. If belt is stretched so that it cannot
be tightened sufficiently, install a new bell. Refer
to Par, 1-E-27 and adjust the drive belt tension.
aaa
Fig, 0-8 Checking belt tension
0-C-9. Checking Carburetor Linkage
Inspect the throttle linkage for proper installation.
Remove the air cleaner, and with the accelerator full
depressed, observe the position of the carburetor
throttle valve. They should be vertical (wide open
position), Check accelerator for sticking ar binding
and for full return and sufficient height to fully open
throttle. Examine the choke control for free opera-
tion, Operate the choke valve manually to make sure
that it moves freely.
Fig, 0-10 Accelerator linkage
0-C-10. Checking and Adjusting Spark Plug
Refer to Par. $—-B—2 and check the spark plug.
O—C—11, Checking and Adjusting Dwell Angle
Refer to Par. $—C-3 and check the dwell angle and
adjust if necessary
0-C-12, Checking and Adjusting Ignition Timing
Refer to Par, S-C-2 and check the ignition timing
and adjust if necessary.
0-C-13. Adjusting Idle Speed
Refer to Par. 4—A-—4 and 4A—A—4, and adjust the
o:s
idle speed.
0-C—14. Checking Cooling System Hosts and Lines
Inspect the cooling system hoses for evident of crack-
ing, checking or extreme weathering. Replace cracked
hoses. Check for leaking or porous hoses and tighten
‘or replace. Make sure all supporting brackets for
hoses are in place and that the hoses are properly
installed in the brackets. Inspect the radiator cor
and tanks for seepage or leaks. Check all fittings
to see that they are tight and in good condition.
Examine the hoses at the fittings for cuts or weak-
ness. Replace the hose in questionable condition.
0-C-15. Checking Fuel Lines and Filter
‘With the engine off, examine the fuel line connections
for wetness or washed or stained areas that might
indicate a fuel leak. Start the cagine and observe all
the connections for fuel seepage. Tighten or replace
fuel Hines as necessary.
0-C-16. Checking Air Conditioner
Gean the sight glass before checking fer a proper
charge of refrigerant. Then, observe the sight glass
for bubbles with the engine running at |,500rpm, and
the A/C controls set at maximum cooling. Bubbles in
the sight glass indicate an undercharge of refrigerant
If am undercharge of refrigerant is found, check the
system for leaks. Repair any leaks and charge the
system with the proper amount of refrigerant—12. No
bubbles in the sight glass indicate either a full charge
of refrigerant or a complete loss of refrigerant. While
observing the sight glass, cycle the magnetic clutch
off and on, with the engine running at 1,500 rpm.
During the time the cluteh is off, bubbles will appear
if refrigerant is in the system and will disappear when
the clutch is on. If no bubbles appear during the
on and off cycle of the magnetic clutch, there is no
refrigerant in the system. If there is no refrigerant
in the system, it will be necessary to leak test, repair
‘a8 required, and charge the system, Under conditions
of extremely high temperatures, occasional foam or
bubbles may appear in the sight glass.
0-C-17. Checking Compression Pressure
Refer to Par. 1A.
— ON OUTSIDE —
0-G-18, Checking Latches, Keys and Locks
Check for ease of operation of locks, latches and
keys on doors, glove compartment andjor console,
tiunk Nid and hood. Adjust, correct and lubricate
meeting specifications.
2-C-19. Checking Hood and Door Panel
Check fit and alignment, Adjust as required.
2+C-20. Checking Bumper and Moulding
check condition, fit and alignment; adjust as required,
1-C-21, Checking Weatherstrip
Sheck fit and retention and correct as required 0-C--22 Checking Wheel Bolt Torque
Wheel bolts should be inspected and tightened to
specifications at pre-delivery. Loose wheel bolts may
cause shimmy and vibration
0-C-23. Checking Wheet Cop
Check for cortect type of cap and install, Center
the tire stem carefully in opening provided. Caution
should be exercised when installing mot to distort cap.
Use rubber mallet on outer perimeter.
0—C—24, Checking Headlight Aiming
heck and adjust the headlight aiming
- ON INSIDE -
0-C-25. Checking Clutch Pedal Free Travel
Refer to Par. 6—A and check the free travel of the
dutch pedal; adjust if necessary.
0-C-26, Checking Brake Pedal Free Travel
Refer to Par. 11-A-I and check the free travel of
the brake pedal.
0—C-27. Checking Lights and Indicator
Check for proper operation of switches and bright-
ness of lights, including operation of oll pressure,
alternator warning lights and high beam indicator light.
Check detent action and retum of turn signal lever
by makeing full left and right tums during road test.
Check operation of emergency flasher system
0-C-28. Checking Front Seat Cantrol
Check lever for ease of operation. Test freeness of
seat movement on track and for solld engagement on
both sides with fever released
Check operation of seat in all adjustable positions.
Seat should operate smoothly without binding, and
it should lock in any selected position
0-C-29, Checking Seat and Shoulder Belts
Check belt anchor for secure fil. Check automatic
retractors, if wed, for full extension, retraction and
retention of belt, Check buckle and clasp for proper
retention, release, and length adjustment
0—C-30, Checking Windows and Vents
Check for ewse of operation.
= ON HOIST -
0-C-31. Checking Transmission Oil Level
1, Clean dirt and grease from the area around the
filler plug, and remove the filler plug.
2. The oil level should be maintained at the bottom
of the filler plug. If additional oil is required, use
sonly the specified type.
Fig, 0-11 Piller plug and drain plug
0-C~32, Checking Rear Axle Oil Level
1. Qean dirt and grease from the area around the
filler plug, and remove the filler plug.
2. The oll level should be maintained at the bottom
of the filler plug. I additional ial is required, use
only the specified type.
Fig. 0-12 Filler plug plug
0-C-33, Checking Tires
Inspect the tire treads; and remove all stones, nails,
wass, or other objects that may be wedged in the
tread. Check for holes or cuts that may permit air
leakage from the tire, and make the necessary repairs.
Inspect the tire side walls for cuts, beuises, and other
damage. If internal damage is suspocted, remove the
tire from the wheel for further insepetion and repair
or ‘replacement. Check the tre valve for air leaks,
and replace the valve if necessary. Replace any mis-
sing valve caps, The tires should be checked frequ.
ently to be sure that the air pressures agree with
those specified for the ties and vehicle model,
—C-34, Checking Steering Linkage and Connections
Check for looseness at the tie-rods ends, Looseness
can affect the toe.in readings and adjustment. Check
the front suspension ball joints and mountings for
looseness. Check the brake caliper attaching bolts,
Torque all loose nuts and bolts to specifications. Be
sure all cotter pins are correctly installed, Check ‘the
Steering gear mountings and all stecring linkage con-
nections for looseness. Torque all loase mountings
0:6 0
‘to specifications,
— ROAD TEST —
0-C-35, Checking Steering Lock
1. Turn the key to the LOCK position and remove
the key from the
Fig, O=13 Steering tock
2. Turn the steering wheel slightly left or right until
it snaps into the lock detent.
3. Check to see if the steering wheel is locked in
both directions.
Q-—C—36. Checking Parking Brake
Check the operation of the parking brake. With the
vehicle on a hoist and the parking brake fully released,
‘the cable should not have any slack, Also, the rear
brakes should mot drag when the wheels are turned.
W cither of the above conditions cxist, adjust as
required
Fig. 0-14 Adjusting parking ‘brake
(0-C—37, Checking Horn
‘Check pad-blow hom to be sure horn blow at all
pad contact positions,
0-C-38. Checking Wipers and Washers
Check for proper operation, including wiper sweep
and park. Adjust if required. Check washer operation
and adjust nozzles as required.
0-C—39, Checking Heater and Air Conditioner
Check the following items: leaks, sufficient heat,
blower operation, temperature contro! operation, op-
ération of defroster, operation of air conditioner con
o:7
trols and air conditioning temperatures. Adjust and
correct as necessary.
0-C-40. Checking Radio
Cheek type und location specified, and install using
installation instructions, Set push buttons for local
stations and check operation of controls.
0—C_41, Cheeking Brake Operation
Depress foot brake pedal to assure good pedal height
before road testing. Check and correct, if required,
the following conditions: pull in either direction,
harshness or noise, excess pedal effort, or spongy feel
and operation of the brake warning light (if equipped).
Avoid sudden hard. stops — make dow, gradual stops.
0-C-42. Checking Transmission Shift Lever
Check und adjust, if necessary, for smooth crossover
action.
0-C—43, Checking Steering Control
Check stecring wheel retwm from both directions.
Test for steering effort required and inconsistent
effort in different directions. If the steering is ex-
cxptionally stiff, check the steering effort with a scale
‘on the rim of the steering wheel and with pitman
arm disconnected, The effort required to rotate the
steering wheel should mot exceed the specifications.
Cheek for harshness, noise, wander or free play,
O-C—44, Testing Running Condition
Check speedometer, odometer, fuel and temperature
gauges, all warning and convenience lights, and_all
special optional equipment for proper operation, Tost
windshield washers and wipers, Operate all heater,
defroster, ventilating, and air conditioning (if equip
ped) controls, Repair or adjust all malfunctions noted
during road test, After road te rs
O-C-4B. After Testing on Road
Perform the following:
Remove seat protectors, windshield markings and tapes.
Wash the vehicle. Inspect the inlerior and exterior
metal damage, Check for soft trim sollage and ex-
cess sealer. Inspect the interior bright metal trim for
alignment and retention, If necessary, locate and
secure loose screws or clips, Verify information on
ownercard in glove compartment with warranty book
let, Be sure Owner's Handbook and Warranty Booklet
are in glove box, ‘These final operations are among
the most vitally important procedures in pre-delivery
service. All of them affect the uppearance of the
vehicle, which of course, is the first thing that will
come 10 the customer's attention, The through checks
and testsyou have given the vehicle in the stalls and
on the road, and the careful adjustments you have
made will be wasted if the vehicle is not delivered
to the new owner in a spatlessly shining condition,
‘This is the final evidence that every step has been
taken to deliver a quality product in perfect conditions, )
0_D, LUBRICANT SPECIFICATIONS
‘Typical specifications
Engine oll
Above 30°C (Above 85°F).
1S me BOPC (60 BSP version
1D ~ 15% 32 ~ 60°F). SAE 20
18 ~ 10°C (0 ~ 32°F), onentaeSAE 10W
10 ~ 15°C (15 ~ 60°F). AE 200.
20
AE. SW-20 of SAE SW-30
SAE LOW-30
Below -18°C (Below 0° FD.
=18 ~ 30°C ( 0 ~ 85°F).
~ 40% ( 0 ~ 100°F).
~ 50°C (0 = 10°F).
=10 ~ 40°C (15 ~ 10°F).
10 ~ 50°C (15 ~ 12°F)...
‘Transmission of
Above -18°C (0°)...
Below —18°C((0"P).
Steeting lubrication
Rear axte ail
J
Brake & clutch Maid ‘ire eS
Shock mbsor Cat 17 ~ 20/30°C
ee ASTM. Gy 7.5 mingSO°C
Wer arm N.LGL No, 2 (Lithivin grease)
Lower ball joints
No, 2 (Molybdenum disulfied grease)
Wheel bearing
No. 2 (Whoel bearing grease os fihiuim presse) ENGINE
1—A. CHECKING COMPRESSION PRESSURE...| ;
1—B, ENGINE REMOVAL.
1-C. ENGINE DISASSEMBL
. Inspecting and
Seat. 26
1-D-9, Checking Contact between
Valve and Valve Seat... 26
1-D-10. Checking Valve Seat Sinking...... |: 7
1—D-11. Inspection of Rocker Arm and
Shaft...
1-D-12, Cylinder Block Inspection,
1-D-—13. Inspecting Cylinder Bore,
1=D—I4. Piston Inspection.
1-D-15. Piston Clearance. .
1—D-16. Piston Ring Groove Inspection... :
1-D-17, Checking Piston Ring End
woos
=~ 1-D-18. oS Piston Pin Fit.
1—D-19. Replacing Small End Bush
1-D-20. Connecting Rod Bearing.
wows
1-D-21. Checking Connecting Rod
Bearing Clearance, =
1—D-22, Checking Connecting Rod 1
Side Play sens =
1-23. Checking Connecting Rod
Alignment.
1-D~24, Checking
Crankpin....
1-D-25. Checking Crankshaft
Alignment..
1-D-26. Main Bearing.
L-D_27. Checking Main Bearing
Clearance...
1—D—28. Checking Crankshaft End Pla
1-D-29. Camshaft Inspection. ...
1-D-30. Checking Camshaft Run-Ou
1-D-31. Checking Camshaft Bearing
‘Clearance.
1-D-32. Checking,
1-D-33. Checking Timing mn for
Stretch...
1-D-34. Checking Timing Chain, Oil
Pump Drive Chain and
Sprocket.
1 -D--35. Checking
1—D-36, Checking Chain Guide Strip
and Vibration Damper.
1-E. ENGINE ASSEMBLY...
1—F, ENGINE INSTALLATION.
SPECIAL TOOLS.. 1
ENGINE
The engine is a four cycle, indine water cooled,
four cylinder overhead camshaft type
CL
Bore Wimn (2.76in}
‘Tene (2.87in)
Stroke ae (2$2in) | Témm (2.99in)
Compression ratio 92:1
Piston displacement Sc (60,1ow-in)) 1272ce (77.6cv-in)
1-A. CHECKING COMPRESSION PRESSURE
To check the compression pressure, proceed as follows:
1. Be sure the engine oll is at the proper level and
the battery is properly charged.
2. Warm up the engine to the normal operating tem-
perature,
3. Remove all the spark plugs.
4, Set the carburetor throttle valve in the wide open
position.
5. Place a compression gtuge in the ue vies hole.
Fig. 1-1 Checking compersslon presi
6, Crank the engine with the starting motor until the
pressure reaches a maximum value,
7, Repeal the test on the remaining cylinders in the
same manner
8. The indicated compression pressures are considered
normal if lowest reading cylinder is within 7S percent of
ihe highest.
If one or more cylinders reads low, test the com-
pression pressure again after pouring a small quantity
‘of oil into each cylinder.
I) If the compression pressure improves considerably.
the piston rings or cylinder bores are worn,
2) If the compression pressure does not improve, valves
are sticking or seating poorly.
3) If two adjacent cylinders indicate low compression
pressures and pouring oil on the pistons docs not
increase the compression, the cause may be the cylin-
det head gasket leak between cylinders, Engine oil
and/or coolant in the cylinders could result from
this prablem.
1—B. ENGINE REMOVAL
‘The procedures for removing the engine from the
vehicle for overhauling are as follows:
1. Remove the hood.
2. Remove the engine under cover.
3. Drain the engine coolant by opening the drain
cocks at the lower parts of the radiator and the left
rear of the cylinder block.
4, Drain the engine oil.
S, Remove the battery.
6, Remove the air cleaner.
7. Disconnect the accelerator cable and the choke
cable at the carburetor.
8. Disconnect the fuel pipe at the fuel pump outlet.
9. Disconnect the heater inlet hose at the intake
manifold.
10. Pull off the primary wire from the distributor
and the high tension cable from the ignition coil.
IL. Pull off the wire from the water temperature gauge
‘unit.
12. Disconnect the wires from the starting motor and
the oil pressure switch.
43, Disconnect the coupler for the reverse lamp switch,
14, Remove the starting motor,
15, Loosen the hose clamps, and disconaect the radi-
ator upper how from the radiator, and the radiator
lower hos at the lower part of the radiator,
16, Disconnect the expansion tank hase at the radiator.
17. Remove the radiator
18. Disconnect the heater outlet hose at the engine.
19, Remove the bolt that attaches the front exhaust
pipe clamp to the bracket on the clutch housing.
Remove three bolts that attach the front exhaust
pipe to the exhaust manifold.
20. Disconnect the wires from the altemator.
21. Remove the bolt that attaches the radiator lower
hose clip to the body.
22. Remove the cover plate from the clutch housing.
23, Support the transmission with a suitable jack
24. Remove the nuts and bolts supporting the trans
mission to the engine.
25, Install a suitable lifting sling to the engine hanger
brackets. Attach the sling to a hoist or other lifting
device and take up all slack,
26, Remove the right and left engine mounting brack-
chs,
27. Pull the engine forward until it clears the clutch
shaft, Then, carefully lift the engine from the vehicle, 1-C, ENGINE DISASSEMBLY
Engine overhaul should be done in the following order
after removing the engine from the vehicle.
If the engine repair stand is not available, take care
#0 a6 to sufficiently protect the engine and its parts
against damage,
1—€—1. Removing Altemator
1. Remove the alternator strap attaching bolt.
2. Remove the alternator mounting bolt and nut, and
remove the alternator and the “V" belt.
3. Mount the engine on the angina stand (49 0107
630A and 49 0324 005A).
1-C-2. Removing Distributor
1, Disconnect the high tension cables from each spark
plug,
2. Pull off the vacuum tube from the distributor.
3, Remove the distributor locking nut and remove
the distributor from the cylinder head.
1-€-3, Removing Thermostat
1. Remove the bolts attaching the thermostat cover
to the inlet manifold.
2. Remove the thermostat cover and gasket.
3, Remove the thermostat.
1-C-4, Removing Inlet Menifold and Carburetor
Assembly
|, Disconnect the vacuum tube (distributor ~ carbu-
retor) at the carburetor
2. Loosen the hosc band and disconnect the water
bypass hose (water pump inlet ~ inlet manifold) from
the inlet manifold.
3. Disconnect the water bypass hose (water bypass
pipe ~ thermostat case) from the thermostat case.
4. Disconnect the fuel’ hose (fuel pump ~ carburetor)
from the carburetor,
5, Remove the nuts attaching the inlet manifold to
the cylinder head and remove the inlet manifold and
carburetor assembly
4-C-5, Removing Fue! Pump
1, Remove the bolis attaching the fuel pump to the
cylinder block,
2. Remove the fuel pump, insulator and gaskets.
3. Loosen and remove the plug, and then remove
the fuel pump push rod from the cylinder block.
1-C-6, Removing Oil Filter
Remove the oil filter cartridge with a suitable wrench.
a
Fig, 1-2 Removing oll filter
1-C-=7. Removing Cooling Fan and Pulley
1, Remove the bolts that attach the cooling fan and
pulley to the water pump boss
2, Ramove the cooling fan and pulley.
1-£-8. Removing Water Pump:
1. Remove the nuts that attach the water pump to
the timing chain cover.
2. Remove the alternator strap.
3. Remove the water pump and gasket.
1-€-9, Removing Cylinder Head
ching bolts and remove the valve
rocker arm cover and gasket,
2. Remove two semicircular oil seals.
3. Install the ring goar brake (49 O118 271A) to the
Aywheel,
4. Remove the lock mut and washer and lide the
distributor drive gear and spacer off the camshaft.
$. Remove the bolt that attaches the cylinder head to
the timing chain cover.
OT
Fig. 1-3 Remoring bolt (head to chain cover)
6, Loosen the cylinder head bolts in the reverse order
of tightening. (See Fig. 1-68)
Note:
To avoid cylinder head distortion, loosen the bolts
a few turns at a time until they are all loose.
7. Remove the rocker arm assembly.
8. Pull the camshaft rearward and remove the camshaft
from the camshaft sprocket, Remove the camshaft
sprocket,
9. Remove the cylinder head and gasket,
Note:
‘When removing only the camshaft or the cylinder
head, the timing chain should be lifted upward to
prevent the slipper head of the chain tensioner from
flying out and causing a difficulty in adjusting the
timing chain. 1
4-C-10. Removing Valve and Valve Spring
| Remave the carbon inside the combustion chamber.
2. Use the valve spring lifter (49 0636 100A and 49
0136 2228) as shown in Fig. 14 and compress the
valve springs.
Fig. 14 Vales spring tifter
3, Remove the taper ileeves, upper spring seat, valve
springs and lower spring seut
4, Remove the valve
Note:
Piace the taper sleeves, upper spring seats, valve springs,
lower spring scats and valves in order in a suitable
ease for reassembling.
1-C-11, Removing Crankshaft Pulley
1, Install the ring gear brake (49 O118 271A) to the
flywheel
2, Remove the pulley bolt and pull the pulley off
the front end of the crankshaft.
1-12, Remaving Clutch Assembly
1, Install the fing gear brake (49 0118 271A).
2 Remove the bolts holding the clutch cover to the
Qywhedl and remove the clutch cover and pressure
Fig. 1 Removing clutch cover aisombly
3, Remove the bolts attaching the Aywheel to the
rear end of the crankehaft.
4, Remove the ring gear beake and flywheel
isd
1-C-13. Removing Oil Pan
1. Rotate the cylinder block upside down position
2. Remove the bolts that attach the oil pam to the
cylinder block.
3. Remove the oil pan and gasket.
1—C-14. Removing Timing Chain Cover
1. Remove the bolts that attach the timing chain
cover ta the cylinder block
2. Remove the chain cover and gaskets,
3. Remove the oil thrower {rom the crankshaft
41-C-15, Removing Chain Tensioner, Chain Guide
Strip and Vibration Damper
Remove the bolts and screws, and then remove the
chain tensioner, chain guide strip and vibration damper
1-C=16, Romoving Timing Chain, Oi1 Pump Drive
Chain and Sprockets
1, Remove the lock nut and washer attaching the oil
pump sprocket.
2. Remove the crankshaft sprocket, oil pump drive
4, Remove the timing chain and crankshaft sprocket,
5. Remove the key and spacer from the crankshaft,
1-C-17, Removing Oil Pump and Oil Strainer
1. Remove the connection bolt attaching the oil outlet
pipe to the cylinder block.
1-6 Removing connection bolt
2. Remove the bolts attaching the oil strainer to the
oil pump and remove the oil strainer and gasket.
3. Remove the bolts that attach the pump cover to
the cylinder block and remove the pump cove
4. Remave the pump shaft and rotors from the cylinder
black.
1-C~18, Removing Piston and Connecting Rod
1. Remove the bolts from each connecting rod and
remove the bearing caps.
2. Push the piston and connecting rod assembly out
of the cylinder block with the handle end of a ham-
mer until the piston rings are free from the cylinder
bore, Remove the piston and connecting rod assembly from the top of the block,
3. To separate the piston and connecting rod assem:
bly, remove the clips and remove the piston pin with
the piston pin remover (49 0221 061A).
If tightly, heat the piston with a pision heater.
Fig. 1-7 Piston components
1—G-19, Removing Crankshaft
1. Remove the bolts that attach the main bearing caps
to the cylinder block,
2. Remove the main bearing caps and thrust washers,
When removing the rear main bearing cap, use the
main bearing cop puller (49 022! 2708)
Fig. 1-8 Removing rear main bearing cap
3. Take out the off seal from the crankshaft rear end.
4. Remove the crankshaft from the cylinder block.
1—D. ENGINE INSPECTION AND REPAIR
1-D—1, Cylinder Head Inspection
Remove all carbon in the combustion chamber and
exhaust port
Be sure that the water passages are open, Inspect
the tapped openings. Repair or replace any damaged
threads or broken studs,
Check for cylinder head distortion by placing
straight edge on the cylinder head surfuce. Measure
the clearance between the straight edge and the
cylinder head surface with a filler gauge as shown
in. Fig. 1-9. If the distortion exceeds 0.15 mm (0.006
in), grind with a surface grinder.
Fig. 1-9 Checking cylinder head surface
1—D—2, Manifold Inspection
Qheck the intake and exhaust manifold for distortion.
To check, place the manifold on a surface plate and
check the clearance between the manifold and surface
plale with a filler gauge.
If excessive distortion is found, comect it by grinding,
1—D-3. Valve Spring Inipection
Examine the springs for corrosion or uny damage.
If It is severe, replace with new ones.
Measure the free length and the fitting pressure. Re-
place with new springs if the free length is decreased
under 381mm (1.539 in) on the outer spring and
36.7 mm {1.406 in) on the inner spring, or if the fitting
load is reduced under 16.6 kg (36,61b) on the outer
spring and 8.1 kg (17.918) on the inner spring 1
‘The specifications of the springs are as follows:
ai Taper sping
Free length | 36.8 mum
Fig length | 32.0 mm (1.260ind
9.3 kg (20!
an OEE ST
40.3 mm ( i
33.5 mm (1,319 ip)
Fitsing toad 19.8 bg (43.7 in)
. 1-11 Checking free length of valve spring
1-D-4, Valve Inspection
Remove all carbon from the valves, Visually inspect
1 valves for warpage, cracks or excessive burning
and replace if any of these conditions is found
Replace any worn, pitted or corroded valves that can
not be cleaned or refuced,
Measure the diameter of the valve stem at two or
three places along the length of the stem with a
micrometer, Replace if the stem diameter is less than
7.980 mm (0.3142 in} on the inlet valve and 7.975 mm
(0.3140 in) on the exhaust valve.
Fig. 1-12 Measuring diameter of vatve stem
1—D-5. Checking Valve Stem to Guide Clearance
The standard clearance between the valve stem and
guide is, under the condition of the guide being
fited with the cylinder head, 0.018 ~ 0.053 mm
{0.0007 ~ 6.0021 in} on the inlet side and 0.018
~ 0,058 mm (0.0007 ~ 0.0023 in) on the exhaust
side.
To check this clearance, place the valve in cach
guide, Check the clearance with a suitably mounted
dial indicator, or feel the clearance by moving the
stem back and forth. If the clearance is 0.20mm
{0.008 in) or more, replace the valve guide and valve.
1:5
Fig. 1-13 Checking