Toyota 2L Engine Mechanical

8/4/2019 Toyota 2L Engine Mechanical

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EM·'

EN'GINE MECHANICAIL

DIESEl ENlIGINE D'IAGINOSIS •.••• , .. , .. "., ,....

ID IESEL E LEGTRI>CAL. SYSTEM DIAGNOSIS •••••

EN.'GINE TUNE-UP ." , .. , .. " .. , .. , ".

COMPRESSION CH ECK .. " .•..••.. , ...• , •• " •••

TIM ING B,E l T " , .. , .. , .. , .. " ,.

C'ompol'1ents ••••...... " ....•.••.••.. , .. , ...

Removal of Timing Belt ..... ., ••..•.........

lnspectlon of Components ........•.. , .

lnstellatlun [If Timing Be-Hl " .. , .. , .. , .. "., .. ,.

·CYlIN DER HEAD· ••••••••..... " .. ,' •.•.• , ••.•• ,.

Components , .. , .. , , , , ".

Remov-al of Cylinder Head , .. , .. , .. , ...•..•.•

Disassembly of CyUnd{!r He-ad ..... ,." •• ,., ••

lnscecticn, Cieaning and Repaiir of Cylinder

Head Compcnents •.............. " ••.•...

Rep o laceme n1 of Camshaft 0 iI SeaI ....•••••••

Installation (If CyUnder Head " .•••. < • , , • , ••••

CYLIN DEA BLOCK , .. " .. "." •.

Co:rnpotlents ., •••.... , ..... " .. " .. " . , ... , ..••

DiSassembl'y 01 Cyminder Bllock

Page

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EM·19

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.EM'-.24

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EM·31

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EM-32

.EM-35

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EM~44

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lnspectionot Cylinder Bloc!k ." ......•.•• ,.... EM-55

lDis.assembly of Pilston and ConnectilllgRod Assembly , , ".,..... EM-56

Iinspection o r Piston and Connecting Rod

ASl:H3rmbly " .•.. , , , .. ,..... EM-·51

Re'p~acemenilt of Connectiing Rod Bush·ing .. ,.. EM-60

Inspection and R.epatr of Crankshaft ,..... IEM~61

~oritlg of CyUnden'i •• , •....... , ,....... EM-62

Rep,Walcement of Crankshaft Oil SoHalls ........• EM·63

A.ssembly of Platen and Connecting

Rod Assembly ., ..... , .... '.' .... , . .. a • • • • EM -64

InS1allatl em of eraIII

kshafi. P lstn nan dConnecting Rod Assemblly ., " ,. EM·6S

Assemb~y of Cylilru;ler Block .. , ,., .. ', .. , EM ·6:'1



EM-·2 ENG INE M ECHAIN ICAl - Diesel ErI_9illtl Dlagllosis

DIESEL ENGINE DI·AG'NOS.1IS

1. GENEHAL

Diesel engine problems are LJ5uaillycaused by the engine or fuel system. The injection pump is very rarely

the cause of 'fuel systemprdb~ems.

Before beginning Fuel system tests, ' first cheek tha t the eng ine compression, valve tilTling and othermajor svsterns are wi'lhin specttication:

The following fuel system dlaqnosls procedures are applicable to . Toyota 1C , 1C~T, 2C. L, 2L and .2L-Tengines equipped wIth 'the distributor tvpe injection pump-

2. PRELIM IN.ARY CHECKS

{a) Becfore perfofming fuel 'sys'hml checks, ·check, that the engine is in goo-d running condition. I'f

necessary. Hn3·1check the compression, ·timing and major components or systems.

(b) Checkthe air filter and clean or replace as n~@ded.

(d Check thai thereis swfficleh't fuel III th€! terrk.

(d) Check if the-fuel. is contaminated with ·gosollns or other fmeiign elements. O·nIIYgood-qu~lity diesel

ruel should be used. .

(e ) Bleed air from the system by pLlrnping the primjng; pump 30 - 40 limes.

tf} Check for water in the fuel Pliler and fuel tank and drain as necessary.

(gl If the engine will not crank or if it cranks slowly. first troubleshoot the electr ical system.



ENGINE MIECHANICAl- Di@sal Engine Dis_grrosis.

PRECAUTION

1. Tha basic trnubleshnotinq procedures for the diesel engin0 (valve clearance, compression, hearings,valves. pistons, etc.) are the same checks you would make fora qasoline engine.

2. The repair of aninjection pump require's considerable skill and use of a special test bench.

ENGINE WILL NOT CRANK

(IPossible C.ause) ~Check Procedure and.Conec1i.on Method)

LOOSE OR COR .ROOEDBATTERY CABLES

t--------i Check cables from batterv to starter and maken e ce ssa ry re oa i rs ,

Check alternatcr OU tput and the drive belt

R eUtlir a s tlI(!!·cess~ry.

D lS -C .HARG IE 'D BATTERY

\3. 1NOPERATNE STARTER \ r - - - - - - - - - - l Check for batterv voltage at starter terminals

30 and 50,If Okay .. see STARTING: SYSTEM, page {ST ~·15

or 16) for repair procedure.

EN.GINIE CRANKS SLQWL V-WILL NOT START

NOTE: Minimum urankinq speed: Cold M IT 100 rpmA/T 110 rpm

Hot 150 rpm

(Ched< Procedure ~.ndCorrection M~thQ(U

1. LOOSE 'OR C:OFl.RODED

BATTERY CABLES

1 2 . DISCHARGED BATTERY Refer to lternsj and 2 Of ENGINE WILL NOT

CRANK_

1 3 . IMPROPER EN GI N IE OIL Check engine oil,If improper visccsitv, drain arid refill with oil of

vi ;'lC·031ity rec 0 rnm e nd e d· by m ertu f~ctl.!i ' r i i : r~

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EM-4

ENGINE CRANKS NORMA.LLY BUT W~lL N,OT'START

(Passible Cause) (Check Procedure and Corr,ectro,n M,ethodl

1, NO fU EL TO NOZZLE 1-------1 Loosen any onelnjectton pipe unlon nut from itsI--------~------' nozzle holder:

Crank the eng,ine for a bou t 5 seconds while con-

firming that fuel is' bei,flg discharped from the pipe.lit 'fuel is co:rning .out, begin diagnosis from i'tem 4.

If not, b~gin trorn item 2,

2 ,. N O FUEL CUT saLENOID

OPERATION

I---------i With starter switch turned ON, checkfor tu¢1 cutsolenoid operation noise (eli,eking sound) while

repeatedly Gonn@Ctur1g and discnnnectlnq fuel cut

solenoid,

IT no noise, check if there are 1 2 volts 'to th esolenoid when the starter switch is 'ON,~f 12 volts are confirmed" ruel cut solenoid is faulty

and should 'be replaced, H not 1 2 volts, refer to

ElECTRICAL. D!AGNOSIS and mal~e necesservrepairs,

NO.c 'FUEL INTO tNJECTlON I I - _ _ ~ _ _ I P~sGonneGt ~nlet hoses 1. 0 fuel fllter :<)mdfeed cleen

PUlM P . fue ~fro rrr sap ara te cnn te irter d irec Uy into fue~pump.

If anq l l1e sta rts, ~Lth e r the fu e l fi Iter 0 r li n .e b etw e s 11

fuel tank and filter is clogged and should be repaired

accordingN·!'Fengine '"St:il~does not .stsrt ~riO fuel intake)" check fue l

llne between filter and PW'11p.

H normal, pump is faultvano should be replaced.

NOTE: W'hen feeding fuel directly into PUffilp •.

r<,eepcarrtalner at same level·as vehicle

fuel tank.

~.

,

1-------1 With the starter switch turned ON and the HI,ow plug

indicator light illuminated, check that there are 6 volts

appliad to the glow plug,

If not, refer 10 ELECnUCAL DIAGNOSIS and repair a s

n e c e s s a rv.

4. IN,OP'ERAT'IVE PRE-

HIEATING OPERATION

Check glow plug. for continuity,

If t10 eontrnuitv, a broken wlr.e is In{':llcalec1 and the.gkow plug should be, replaced.

FAULTY GLOW PlU G

O PE R.A T lO N .



Check for loose unions cr 'cracks.

If lie'aking, tighten to standard torque or, it necessary.replace pipe~s~.

6. FUEL LEAKAGE FROM

IN'J'ECTION P.P'E

Turn crankShaft clockwise to whare either No, 1 Or

NQ. 4- piston is at TOe and, after 'releasing cold

start advance system (LX), check plunger stroke

with SST .

5tafldard~

L 0.94- 1.06"mm

(0.0370 - 0.0417 h'l.)

2L wio ACSD 1.06 - 1.22 mrn(0.0417 - 0:0480 in.)

wI ACSD 0.82 - 0,98 mm

(0.032.3- 0.0386 in.]

2,L-T 0.75- 0.87 mm

(0,,0295 - 0.0343 in.)

If not at the standard indicated above, injection

pump is not .adju~tedproperly.

NOTE: If injection 'timing is off more than 10°,

it Gould indicate a slipped timing belt,

1. 1M PROPER INJ·ECTION

TIMING

l B . IMPROPER FAST IDLE -i Measure timer piston strokaanc fast idle lever

opernin~an,gl.e with injection pump tester.

a . FAULTY NOZZLE OR

NOZZL.E HOLDER

Check, ln lectron p,I'essure with r l "OZZ~ 'tester,

Standard plreSSLlirEi!;

t. . 2L (ex. rs Hongl Kong '& SingaporeL 2l- T

105 - 125 kglcrnz . .

(1.,4~3 ._ 'I r778 psi, 10,2.97 - l'2,258 kPa)

2L ~LSHong Kong & 'S~ngaporel145 - 16:8 kgjC:IT'!~

(2,062 -2.389 psi. 14,2.2.0 - 16.-475 kPa)

kf not within standard indicated above, nozzle

.adjustment is improper and pressure should be

readjusted,

If pressure cannc] be adjusted to standard,

. replace riOtzle holder sssembtv.

'EM-S



EM-6 EN G INE M ECHAN ICAl ~ Die sel'l Engine Di<lgnosirs

ROUGH IDLE WITH WARM ENGINE

(Possible Cause) jChe·cI{ Procedure and Correction Method)

1. IMPROPER ADJ USTMENT

OF ACCELERATOR CABl.EI----~_ With accelera tor pedal released. check 'that

adjr'llsti,ng lever is in contact with idle speed

.adjLJstitng screw. Also check i ' f , acoelerator cableor linkage IS catching on sornettnnq.

'I'Fnecesaerv, adjust so lever is ill contact with

screw, or make ether required repa irs ..

1 2 . ID L E R PM liD O lOWI

Check' if idII1l rpm is at standard bn~:HGated below-

St.andard idle rpm: 700 MIT (ex,. LXl

Sa o. M IT (LX) & 'A n

NOTE: If less than standard, idling would

normally be r·ough.

If not, adjust with idle speed 'i3idjustirng screw,

I

Check for Ieaksat the pump connections, pump

distributor head bo lts" no zz le holder a.nd

delivery valve,

Tlqhten a ny loose connections to specified

torque or replace parts as necessarv.

1 3 . FU EL L EA KA GE !I--------iI

R~fer to item 7 of ENGINE CRANKS

NORMAlLV BUT WILL NOT STA'RT, above,

4 . IM PR O PER IN J EC T IO Ii\l

T'MING

5. IMPROPI: ROPE RATION 0 F Wi til eng ln e ~d~ ijn g. 'Ioosen th e un ion nuts of theNOZZLE OR DELIVERY 1------1 injection pipe to each cvllnder in order. and check

VALVE i' f the idle speed changes. .

If no ehange, a faulty cylinder is indicated ..

Check according to foLlowing procedure.

Fau~tvNozzl.s Or Not!2le Holder'Check injection pressure with nozzle tester.Stand ard pre 55ure :

L" 2L (ex, lS Hong Kong'& Si_ngaporeL 2L·T

105 - 125 kg/em' .

(1,493- 1,778 psi" 10.297- 12,25& kPa,)

2L ItS Hong Kong & Singaporel

145 - 166 kg/l:an~

~2.,062- 2.389 psi. 1,4,220- 1£.475.I~Pa)

If pressure u s not wHhin standard indicated above,

nozzle is 'Faulty and inJect ion pressure should be

reedlusted.

Faultv 'Dei ivery Va l vs

If injection pressure is within standard, delivery

valve IS defective and should be replaced,



ENG.IN E M ECHANIICAL - Diesel Engine Diag rrosis

'6. N!O FUEL INTO IINJECTION 1------1 Refel' to item 3 of ENGINE CRANKS NORMALLY

PUMP BUT W'llL NOT 'START, above.

ENGIIINE SU DDENL Y STOPS

(Possfb le Cau 5e) (Check Proce dure and Correct ion Me tho d j

1. ENG,lINEWILL NOT RE-START

I----~---l Check toSE!1}f !!!ng,ine re-starts according to

prescribed procedure.If not. refer to ENG INE CRANKS NORMALLY BUT

, WilL NOT 5T A R T. above, and repalr ·as necessary_

1 2 . ROUGH IDLE 1--------1 IIFid le is n ot s.ta bIE fl,refer to ROUGH IDLE and repair'-------------- aocord:ing~.y.

~ __ ~~ __J

NOTE: No operation noise from the 'fuel cut

so leno·id rna v be· due to 100s e elec tr ica I

eormectlerrs, so check connectors before

prac eoedin 9 with fu rther repa irs,

Refer to ENGINE CRANKS NORMALLY BUT WilL

NOT START, above, end check accordinqlv.

3 MALFUNICTION OF FUEL

C UT SO LEN O ID

4. NO FUEL INTO INJECnON l.-__ -----::-----1

PUMP

R@fer to item 3 of ENGINE CRANKS NOHMA1L YBUT WILL NOT START, above:

LACK OF POWER

NOTE:

1. First cheelc that air eIea Iller lis Irrot Clogg ad all d eng ine not ave rheati ng.

2. Not ..appUcabh~~if customer desires outpu1 power 'higher than speelfled for that vehicle.

For accuracy. adjust with a chaasls dynamo.

lP'ossible Gause) (Check Procedure 'and Correctkm Method)

Witi:l.<Iccelel'ator fully depressed, check that

adluMingi lever is in contact with maxlmum spaed ,

01djus'l: ill gl S~r~w.If n ot, adjust accordi l1gry.

1 . 1M P 'ROPER _ ACCELERATORCABLE AIlJ U'STM ENT

Start engine, depress acceler:8Itar pedal to floorand check that no-load maxlrnum rpm is within

standard.I f n .o tt , 6 d1 j u ~ .t twith max , lmum sp~ed adjlustillg sc:rew.

2 _ INSUFFICIENT NO-LOAD

MAXIMUM RPM

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EM-8 ENGINE M ECHAN ICAL- Diese~ Eng,i l1e Diagnos. i :s

----,

3,. INTERCHANGED I- ~~(N10TE.: Ov-e:rflow screw is marked "OUT" andOVERFLOW SCRiEW lOUT) las an inner jet. They must l1Iot be interchanged.

A.ND INLET (NO MARK)

fiTTING

1 4 . FUEL LEAKAGE

6. IMp·FlOPER I.NJEGTIO!NI

TIMING

1. F,AULTV NOZZLE OR

NOZZLE HOLDER

I RMer··to item 3 of ROLJGIFIIDLE WITH WARM

ENGINE.

Disconnect inlet hose fro'rn fu~'l finer and feed

c lean h . J e l c lire c1 1Y lc m o th e pump.~f eng i rnE ! . cQnd· it ian imprQv i3$ ,. f U ' E : ! 1 filter , is c l' ogged

and should b~ repla.;:ed.

NOTE : When fe ed ~ng'fue I dilfefltl v i rsto PUll'!P,Ikeep container at same leve'l as vehicle ' fue!1

tank,

If no increase In 8r1ghlJt!l ccndstlon after replacing

fue~ftlter, check pfim~~'~lpump or perform otherneeessa r : ' f repa irs.

RHfer ·to item 7 of ENGINE. CRANtKS NORMAL LY

BUT W IL ,L NOT STAAT_

Re:rer tb item 9 o'f ENG~NE CRANKS NORMALLY

BUT WilL NOT srAfrt

EKe ESS ·IVE EX HAUST S MO K IE

NOTiE:

1 , CIheC'k th atill ii- r:~eaner is n01 c In99 ed..2. Check w.ith uustumer whetber aU consumption has beeneXGessiv:e.

(PO 55.tO l{l C a u s-e )

1. 1M PROPER IN J ECTION

T~MIIM.G

1 2 . CLOGGED ,FUEL FU.TER ~-----------i

I

'FlEif ief to item 7 o:f ENG INE CRANKs NORMALLY

BUT WilL. No.T START

NOTE : Black smoh:e zn d leates adva nee dtim i1119

while white smiokeindicates retarded tiMing.Adjus1ments should be made .accordingly.

Referc to item 5· of LACK Or- POWER.

NOTE: AI!;hi,gh rpm ~2rOOO- 3.0001, a clo99ledf i.lter' t8nds· to m ak e 1heex h ; ; 1 . 1 , 1 st smo ke white.



EN G IN IE . M EC HAN IU ::A L - Diese l Engin,e Diagnosls

1--_----1'[ Refer to item 9 ot ENGINE CRANKS NORMALLYBUT WILL NOT START.

3. FAULTV NOZZLE (lR

NOZZLE HO LDER

NOTE; Exc,essive exhaust smol"e ~s.often

eaused by noul,e pressm:e being 100 low.

EXCE.8,s,1VE FU IELCO NSUMiPTIO N

NOTE: Check whetherolutoh sUpPling. brakes grab.bingl, tires. 'w rongl size -or a , i i r filtef clogged.

(Check Pmceduni!and Correction Method)

Refer to item . : ? of R'OUG'H IDLE WrlH WARM

E N G I N E .

I "1. fU EL LE,AK AGEII

1 2 . mu: RPM TOO HU3H 1-------1 ,Af te1r sufficiently warm ing up eillgine, cheek that

L-_---------~- idle. rpm is as specified beJow.

Idh~ rpm: 700 MIT h~x. DO800 M!T (LX) & A/T

U'net, adjust wi-thidle speed adjusting screw,

r; .TN_·_OO.- .· .O~L.· ,.H-_AIG_.D .H...MAX~MUM RPM I I - - - - - ~ - - itart-engIne, depress a eea iera ro r peda l to f loorL . and Gh.~c.kthat no-load maximum rpm is within

sttlnciard,

Ne-load m axim um rpm :L, 2L {ex..lS Hong I(ong & , S j ,ngapC i IfE ! . Ausf ta lh !1

LV & LN56) & 2iL-T 4,900

2L (LS Hong Kong .& S o irig i;llpore, Auslra I iaLY & LN56) 4,500

Ilf not, 3u1uS1 with maximum spe.ed. adjusting screw,

Refer f o item 7 of EN.GIINEGHANKS NORMALLY

BUT WILL NOT .5TART. .4. IMPRO PER IN ,JEG TIO !N

TIMING

Rehw to item H nf ENGINE CRANKS NORMALLY

BUT WILL N . O · T START.5, FAULTV NOZZLE OR

NOZZLE HOLDER

E,NGINE NO ISEW HEN WARM

(Clanking, Nolse with Excessiv'e Vi bratlon)

'(Check Proeedureand CorrtllcUon Metho~l

CIl.~C k c o olla nt te rn p e r,1 lu re wit h coo 13nt

te m pe ra tu re -g a ug e --If not suff Id'~rrtl y wa rrn, the rmo stat is : fa uHy anoshould O!:lrep1lac,ed,

1. COOLANT lfEMPiERATU RE

TOO LOW

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EM-1I0

2, IM'P'ROPER 11~.uEC::TION

TIMING

J.. FAULTY NOZ·ZLE OR

NOZZLE HOLDER

NOTE (ex. w/ACSO):

Refer 10 i"tam 7 . o f ENGliNE CR AN KS N OR MA LLY

BUT WilL NOT START.

('Possible Cause)

BIN DING ACCELERATOR

UNKAGE

Refer to item 9 of ENGINE CRANKS NORMALLY

. BUT WILL NOT ST ART

ENGilNE WilL NOT RETURN TO ID'lE

Check. that idle adjusting kncb is returned.

iCheck Procedure and Correcti·o'!1 Method}

1------1 Operate (;!djl.l8ting lever on 'top of injection pump

and check. jf engltle retLJrI1S to ldle,

If 50, accelerator cable is . bindIng Of maladjusted

and should be repaired accordingly ..

If engine does not return 'to idle, injection pump i s "faulty ' and should be replaced,

ENG INE WI LL NOT SHUT OFF WI.TH KEY.

(Pos,sib1e C~use)

IMPROPER FUEL CUT

SOLENOm OPERATION

(Checl( Procedure and. Correc1ion Me1hod~

I------i Dlscorinect connector 011 top of fuel cut solenoid Elndcheck if engine stops;

If so, starter switch is i . f : ' luhy and should be !repairedas necessary or rep 1 aced. -~fellgil)9 does not stop, either 'F1JelCUl t solenoidis fa.ulty or there is interference by fOf ' la ign partlcles,R e,p al r as ne e€)ssa ry .



EM·"

DIESEL ELECTRI,CAL SYSTE.M DIAGNOSIS

ENGINE DOES NOT STAR.T GOLD

NOTE; 1. Ba'U;ery vo Itag e at lea st 1 2 V " Its ~·S"talrter swite hOFF.

,2. Engfne cranks normally.3. FU5ib~elink okay.

1. Sup.er G;ow System

Check if indicator light lights up with "Starter

Bwitch ON,Coolanl temp. at 20°.G (68°(=j: ,Approx. 2s,.;;cs.

YES

Starter sWi,tch OF F ,

Check for battery vQ!tage toterminal2 o'J pre-heatlnq 'timer with S!tarte'f

switch ON ,

Voltage NO"Voltage

Check that there I S OV betweenterminals 3 and g,

I I f ' t<l£uLty,repair glow p .~ug current

sensor,

If okaJY, 'timer is faulty and should

'b e re ;tlla eM ,

Check if voltane to terminal 2 ofpre-he·6ting timer is tsrrnlnated,

No Voltage Vo:ltagi3

Start the enginei:lm:J check if there is

vo I ta g~ stterrn insl 4, of prfl!~h m a t l · o g .

timer,I~fEl,Il'ty~ repair Ghar,gingsyslem as

F1ec.essary,

If ok",V, timer is faulty arid should t r i l l ·

rePI~?'~~.: .

Start13r switch OFF,

CONTINUED 'oN PAGE EM~ 12

Fuse Blownheck Fuse

(Se,e pag€! ST-2)

I Fus~ OK

INO

.Check 'for shan

circuit and repa~r

i 'f necess·.1lry,

Check indicator ~.6u'lb No Goodiight bulb.

Bulb. OK

R ep la ce bl,J~ b_

Check.. for battery voltag.e to terminal 7 of

pre- he.ating timer connector ~on wire har-

ness sjdeL

If okay, pre-heMing, timer is faulty andshould be .~~paln::d,

Pire ·, h ea t i ng · T iminer

lHt 1, UI, j , LX,.U

7 .~

I

..~TQo1>'l!~.

LH51,61,7l

1 D .

,

~ n s a \ STOO.~



l~

EM-12 ENG INE MECHANICAL - Dt@sel,Eleotric,al S'ystem Diagnosis

CON T~N U ED FHOM PAGE EM -l1

Places starter swltch a t ON and

check for vo!Jtage to glow p ~ L . J g

a few seconds later,

Thereafter, voltage should drop

about 1a.~------~--------~~

I Pre-heatinq Duration is Quite

1 D i" f: fe re n t T h an That Above

ex. LX ] L : X

1,0 -

. No Voltage

F-_--___l... ~-- , No Continuity r------~----~--------------~__Check glow plug for contlnultv. - Glow p~ug'faultyaind should be replaced_

Contlnuitv

No Voltag,e

at A H

-3D -ro HJ :);D ~o m-2.0 0 .20 4() (~r.'

" "J I J ~ m r .f I r: u I~ r ~ ~ : = :' '' :_ _ :I _ ~ f: _ 1_ - -- = .= r ~ n :l ~ :

Timer is faulty and should be replaeed,

Disc 0nnect water tempera tu re sensa r (le.Jt rearof €!1J9Iine)and check if pre-heatinq duration is

abo u t 1 5.0 se ep nds O f, if -C O rinector isdirectly groun(Jedr pre-haatinc duration ~s

about 3 seco nd s.

I f 0k av, wsts r tem pera ture sen sor I s . 'f au I ty a .nd

should be replaced.

If not. 'l~rner is' faulty and 'should be- replaced.A Her completion of pre-heating,

check for voltage at terminal8 1O l g a i r f ' 1 when starter .switeh is

placed-at ST.

Vo1 tageT

Starter switch OfF.

Place starter switch at ON and

check if current 'f low to . terrninat8 of tlmer ls.in accordance with

coolant temperature

Isee 9 fa ph a bovs) ;

I INo. 1/2 Voltage

Them.after

I

Timer is faulty and sncutc be. replaced.

Glow plug okay.

Check-for battery vol'tage at pos.itiv€' sl(Je of glow

p~ug current sensor (Int,ake manifold Side:),

If 0ka If j rep lace sense r.

If no veltaqe, No. lglow pilug r.eilay is faulty and

should be replaced.

(For component inspection, see pag:€'s ST-4 and

ST-5),

Check fQF battery v,oltag€i to plus side of resistor

{Inlal\e rnenlfold side;).If okay; replace resistor.

IF no voltage, No . .2 ,glow pl.og relay is hwlty

and should be replaced ..



ENGINE MECHANICAL.- Die,selEI~ctriGaJ System DlJ3gnosi$ EM-13

2.. Fuel Cut Solen'oid

W~Ul s ta r te r cSW i ·tci1 tu rned ON, ehec Ii; to Ii '

fuel cutsolsneld operation tlIois.!3'(di.ck~f1g

;Si0und ) wh i Ie repea ted IV GQ n n ac tln 9 a n d

disco ~ 1 flecti ng i fu e II cut soleno id,

No Noise

I - Fuse[Hown Check Tefr short cir.cuhCheck F u s: ~ \S e e p s·g e S T -2 JI---------------~... . c J ' ' , ' , '_

ano r e p : < : J . ir ~s n ecasse ry ,

Apply baUBfY voI.tQ .g .e (1 2 No!S '€ ' Check wire;;: h arn ess fromvotts] dir~Gt,ly to ~;:ole,no~dII-----------------~ fUSB A {S e e p ag !a S 'T -.2 }

and che.{>k for noise. to fuel CUlt solenoid.

No NOise

R ep l ac e fu el Gut soller!oj d.



EM··14

ENG ' N E TU_NE-UP

I.NSPECT OIL LEVEL

The oil1evel should be between the "L" and '''F'' marks 01 1

the level gauge_.

If low, ohecl< for le~l~og.e and add oil up to tile ~'F" marie

e:NGiNE MECHANICAL - Eng'ine Tune-up

Front,. Fir~t

EX IN IN EX

INSPECT AIR FILTER

{a~ Visual11v check that the air cleaner element IS not

excessively dirty r -damaged or oily,

(bl CI'ean the element witt1 compressed air,

First blow from the inside thoroughly, Then 'blow 6ffthe outside of the element.

~NSPECTION AND A'DJUSTMENT OF VALVECLEARANCES

NOTE; lnspect arid .a,djLJst the valve c learence after

engine i18Sreached normal operatiflg temperature.

1, REMOVE CytlN DER HEAD COVER. (See page EM -32)

2 . SET NO.1 CYLINDER TO TOC/COMPRESSiON

~a} Set the 'No, 1 cvllnder to TDC/compres.sion,

Align the groove on the pulley with thstiming pointer

by turninq the crarrkshaft clockwirse with a wrench,

(bJ Check that the rocker arms on the No, T cvlinder meloe ss a nd rocker arms on the N o_ '4·cylinder are ti,ght.

'If not. turn the ctanlrsh:aft one revolution (360°) and align

th€ mark as above,

3 _ .NSPECT AND AOJ UST VAL VE. CLEARANCE

(a) Measl~re only those valves indicated by arrows.

Valve clearance a-lot):

lntake 0.25 mrn (0.'009-8in.l

Exhaust 0.36 mm lO.O'l42 in.!



ENGINE MECHANICAL- Engine Tune-LIp EM·15

Second

EM01 05

\'/I

Ii

I

• Using a feeler ~auge, measure the valve clearance

between tha v~lve stem 'and rocker arm, Loosen

the lock nut and turn the adjusting screw to set theproper cleeranee,

Hold ths adjusting screw in position and tighten

the lock nut.

• Recheck the valve clearance, The feeler ,gauge

shou Id 8 1 ide with a very s~ight drag.

(b) Turn the crankshaft one revolution (3600) and ,align

the tirn iilg marks as above.

,Adj u s t a n lv the va IV8:S i r'ldic ated by arrows.

4. INST.A.LL CYLI NDER HEAOCOVER (See paiSe EM·49)

INSPECTI 0 NAND ,ADJ USTM ENli OFINJ.ECTI:ONTtMING

1. INSTALL PLUNGER STROK.E MEASURING TOOL (SST: I

AND DIAL INDICAiOH

~a) 'Remove the di5trib~tive. head bolt.

(b) lnstall SST· and the dial indicator to the distributive

head plug hole.

SST 09-275-54010

.2 . S.ET N'O. 11OR NO.4 CYlilN PER TO46

D

BT'DC/COMPRESSION'

3. RELEASE COLD STARING SYSTEM

(a) Usi FIg a screwdrlver, tu rn the co Id sta rting Iever

counterclockwise about 20D as shown.

(b) Put a.metal pilate 8.5 - 10 mm (0,3.35 -0.394 in.!

thick between the Gold starting lever ami thermo wax

plunger,



EM-'6 ENG!INE MECH.ANIICAL _- Engille Tuns-up

4. 1NSPECTAND ADJUST INJIECTION TIMING

(a l Set the dl.~1gauge a t z ero mm (0 ln.l.

~bl' Recheck to see' that the d lal Hauge rsmai nsat zero

mrn (0 in.], whl, le rotating, the cr,ankshaft pu l l, ey s li gh t-ly to the left and I[,g hi.

(c) Slowly rotate the crartkshatt pulley until No. 'i " or No.4 cylinder iset TDC/comf:Jn lSsion.

{d)' Me,asur,etile plun'ger stroke.

Plu ng er stroke:

L 0..94 - 1..06 rnrn jO.,0370 - 0..0.417 inJ2l w/o ACSID 1.06 - 1.22 mm

(0.0417 - 0.0480 inJ

wI A.CSD 0.B2 - 0.,98·mm

(0 0.0 .32 3 - 0 ..0 38 6 in.)2L- T 0.75 - 0.87 ! 1 1 1 i 1 1 (0..0295 - 0.0343 in.)

te,) Loosen the: foul' injectlion PIpe union nuts and fuelinlet pipe union nut at the injection pump side.

(f) l.oe 59n the fo ur injection PtJ IIIP mount ing bolts andtwo nuts.

'(g ) A d ju st the p lu ng e r stroke by sl.ig'htlv tilting file injeG·-

tlon pump body.

If the stroksis less than .specifigati·on, tiltthe pump towardengine.

If 9 mater than spec i fie atlon 'I i ~tthe pump away fro men,gine.

(h) Tig htsn 'the injection pump mmmting bolts and nuts.

TO'r .Ql Ie :

"801'5. 185 1<9-cm (13 ft-.b, 18 N'm)

Nuts 210 .Ieg-'em (15ft-lb, 21 Nom)

Recheck the plunqer stroke',

Tighten th e linjection pipe union nuts and fuel inllEltpipe unlo n nut.

Torque:

Injection pipe 250 k'g=cm{1a ft-Ib" 2,5N·mlInh~tp;pe 23(i~.g~om

(17ft-lb.

23N'm~

•

5. R'EMOVE METAL PLATE FROM COLD STARTINGLEVER ' .

6. REMOVE SST AND DIAL IN,o!'CATOR

ta l Remove SST and the d'ial indica tor .

SST 09275-54010

(b) Install the distribution heac bolt with a new gasket

Torque the bolts.

Torque: 170 kg-em ~12 'ft-lb,,17 N'ml

7. ,S,TART ENGINE AND CHECK FOR 'LEAKS



ENGINE; MECHANICAL ~ Engrn~ Tune-up

ldls SpeedtAdjusting ScrewI

INSPECTION AND ADJUSTMENT OF

IDLE AND MAXIMUM SPEEDS

1. mNITiAL CONDITIONS:

{a ) .Ai r clea 1 1 e r installed

(b~ En 'g~ne C dolant norma I ope ra ti 1 1 1 9 te rn p era tu re

(c) Aecessorles switched off

{d} Transmission in neutral

2 INSPECT AND ADJ UST IIDLE SPEED

~a ) C nBC k t ha t the illd j ust in 9 1la ve r to UG has ·t he idle speedacljlist ing screw when th e accelerator ped E l i is

released.

If not, adjust the accelerator linl~~~e,

(b) In is ta II a tac hamate, to !~~eng ine,

{d Start the engine,

( c O Check the ii'dIe speed.

Idie .speed': '']QO rp m MIT (ex. LX)

,800 rpm M)T (D O & . Ali

(·e) Adjust the idi,e.speed,

• D iscon nect 'th e a c cs l fi rater I i nkage .

• Loosen 'the lock nut 0 f the .idle speed 8 dj UIsting

screw.

• Adjust the idle speed by turning the IDLE SPE'ED

ADJUSTING SCREW.

• Secu re Iy tig hten the lee k 1 1 lit.

• Carmsct the accelerator lifukag.e.

• Afte.r adjustment, adjust the accsler ator linkage_

3., I:NSPECT A.ND ADJUST MAXIMUM S.PEED

~a} Check that 'the adjusting lever touches the maximum

speed adIl.iIs.ting screw when the accelerator pedal isdepressed all the way.

If not, adju;;:t the stop. bolt of the accelerator pedal.



EM-1B ENGINE. MECHANICAL - Engine Tune-up

{b} Insta II 9, ta Ghometer to the. 'eng ine.

( c . ) Start the engine,

(d) Depress the accelerator peda l a ll the way_

(e) Check the maxlmum speed.

M~.ximum speed:

k, 2L lex. LS Hong Kong & . Singap(H€!; Australia

lY& .

lN56)&

2L-T 4,900rpm

2L l.lS Hongi Kong & Singapore, Australia

l Y & LN56} 4,:500 rpm

m Adjust the maximum speed.

• Disconnect the accelerator linkage-

• Usill.9 SST, loosen 'the lock nut of the maximum

speed apjusting screw.

SST09275-54020

• Acljust the maximum speed by the MAXIMUMSPEE D ADJUST IN G SC REW _

NOTE: Ad h . J st at ielile speed. T h&n , r a l i see ngine speedand recheck the maximum soeed.

• Using SST, securely ti.ghten the lock nut.

SST09275-54020

• Connect thE! accelerator l inkage.

• A iter adjustment, adjust the stop bolt aT tha

accelerator pedal.

CH Eel< AND .ADJU STM ENT OFi NTAKEAIR VOL.UMe (LS, tX71 MIT)

1 , . INITIAL. CONmTIO'NS;

(a) Air cleaner installed

{bl Eng ine coolant normal operating temperature.

h . : : } Accessories switched off

(d} Transmissicn in neutral

{e) 900 meters or less above sea level,(f) intake air volume valve fully closed,

2. CHI;,CK AIND ADJUST INTAKE A.R VOLUME

o(a) Install a.vacuum g8u 'g ,e to the lntaks mani'folct

(b) S ta rt the eng ine.

(c ) Check the lntake rnarnfuld vacuum.

Vacuum: 11[} - 150 rnmHg

(4.33 - 5.91 i n. ,Hg • . 1,4.1 - :20.0 kPa)

(d). Adjust the' vacuum by kH;l~en~ngile lock nut 'and

turniflH theiNT AKE A,~RCONST'RfCTOR ADJUSTING

SCREW.

Intake Air Constrictor _

Adjusting s<;n~w. ,rV\acuum- -r-l~../ I , }IGauge~ ~'

~""



ENG IN,EM ECHli\N ICAL- Compression Chack

NOTE~ If there is lack of power; excessive oil or fuel con-

surnptlen, measure the~ylillder compresslcn pressure.

1. WARM UP ENGINE

.2, DISC01NNECT fUEL cur SOLENOID WIIRE

CO 'NN IE :CTOR

3, REMOVE FOU RG LOW PLUGS

(S@epa~geEM-21l

CAUTION: Make· sure tth~ load win:! is notgumnded.

4. IINST A.Ll aSTTO GLOW PLUG MOUNTI NG 1010.E

SST 09992-00023

.5 . M.EASURE CYUN.oIE R COMPRESSION iPRESSU RE

fa} Conn:eGt a comprassjcn gauge (SSTj to SST.

SST 09.992-00023

~b) While cranki ! " l o g t h(5 en9 ins with thesta rtsr, meat ure

the comp're 's6idrJ pressure.

NOlE: A. lways . us€ a fully charged bat tery so tha t atleast

2 : S.o rpm ea rr he re a G hed,

(c) RepElatste.p.s (al and (b) tor each cvlinder.

Compressicm prassure:

==-"-r L. ,2l-T 30.0 ikglcm2~427 psl, 2,942 kPa) ~~

zt, ~2,Okg!o.m'l (455 psi, 3,138 kPa)

Minim um pre s;sUl'e

'20.0 ~g/Gm'~ (284 pS'i , 1 . .,961 klPa)

Differenc €I D€ftwtl en eae h ·cyIinder:

LEtSS "lila n 5.0 kg! 0 rri~ (7" ps'j, 490 'lePa)

~d) IF the ·cylind~r corrrpresslorr in one Or more cylindar~

is low, pour a Iunall~ amount of engine oi~ inlo UIe

:cyi inder 1 h rou g h t h fl 9 I( lw pi ug h ola a nd repea'tstep:;;'

( 0 ; 1 ) and~b). for the ~:iylinder wIth ~ow compression.

• Hadd~liIg oil helps :thE;!co.mp res qion,. Ci1;;lf'lGOS are~hat ttl€ piston rirrqs end/or cYlin~eF bore are wornOr dam[llg~,L . . .

II! If pressure stays low, a "'alive may be stid·dng O

.$.~Etfingimprop~r~v, orttrere may be ieak:gl9€l' past

the gasket.



'EM-20 EN,GlNE MECHANICAL ,~ Tirnlnq Belt

TIMrNG BELTNOTE: If ropiacing the timing belt before the timing belt

warning light comes o!il,(I~ght comes on after 100, 000km of driving}, besure to reset the< tim.in'g belt counter of

, -

the speedometer to zero,

COMPONENTS

L FTiming Belt' Cover

Gasket

Sc raw G ro rnmet

Glow P'lug,

Connec,tor

!Fan

Drive Belt

N o_ 2 . I dle r P ull ey

Timing Belt Guide

,

r r : : : , kc , : 9 _m (ft.lb. N'ml \ . hp!,}Gified toreve Timing, Belt

l l ~ ~ ~ - = = ~ = = = = ~ ~ ~_~ ~ ~ ~ ~ ~ ~ _ _~~~'~~4

3. REMOVE CRANKSHAFT PU LLEY

(a) Using, SST, remove the mount bolt,

SST 09213-54-01 2 . and 09330-00020

R'EMOV A I L . 0 F TI M ING BELT

1" REMOVE DR 'IV i! BEL T 'S;

2. IREMOVEWATER PUMP PULLEY

(See S o tep' 3 on pag as; CO~4)



ENGINE MEOHAN ICAL- Timing Be~t EM-21

(b) Using SST, remove the pulley.

SST 09213-60.017

4, REMOVE TIIMING BELT COVER

Remove the twelve holts and bsh eave t" with the two

g.aske'ts,

5... REfi./10VE TIMING BELT GU IDE

6; REMOVE C URR'I:NT SEN SORAN D FOU A . GLOW

PLUGS

tao) Hem ove the fa u r 5crew gmmmats .•

(b} Remove the four glow P~Mgconnecting nuts.

~G } [futa pa (UrI. ix; LN)]Remo r\!! e . th e nu t, pi a te wa rsher, ! I n s u Ia torss and c tlr-rent sensor.

(dJ Removt:) theg 10w plug connactcr,

~el Hflmove t h i e to II J r gl'ow plug s ..

7. SET NO.1 CYUNDEH TO TDe/COMPRESSION

Usin g . .a crankshat t pulleV mount bQlt,aHgfll 'Ule TDC f fi< 11 r

of the earns n aft tim ing pu'l iey with the top end. 'of the

:cyliirldier head.

:?"

1<"'01-1' /



E N G lN E MECHA'N~CAl - -nmin'g Bel t

~ e , .REMOVE TIMING BELT

NOTE: If reusing the timing belt, draw a direction arrow

on the belt On direction Of eng ine revolution), 'and placernatchmarks 011the puil.eys and timillg bslt, .

fa) U:;:;ing needle-nosed pliers, remove the tensionS . p f H 1 g "

~b) Loosen the two NQ. 1 idler pu~IBy mount bolts.

tc} IRemove th€ timing belt.

9,. REM OVE NO . 1 IO lE 'R PU lLEV

'Remave the two mount bolts, plate washers: and idlerpulley,

10. REMOVE CAMSHAFT TtMI NG PU LLEV

Using SST, remove' the mount bolt.

SST 09278-54011



EN.GINEM.ECHANIICAl ~. Timing Belt ! : .M-

'-, I 'I t '", r- ',.

, : . , . < : : ~ 'f~ " . . '~, -

(j" ~

S$T

111. RIEMOVE iNS~;CTION· PU.MP DmVE. PULLEY

{a~ Us i( 1 9 SST, remov.e 'the m 0 u tH nut.

SST 0.9278-5401 1

{b } Using SST, remove the. pump drive pulley.

SST 09213-5.00'1 7

/I

i

12. REMOVIE;: NO. : 2 . IDLER IPULLE¥

R€irnci.v:€!.thG rnourtt boltarrd No. . 2idl~r pulley.

i,.

13.. REMOVE CRANKSHAFT TIMING PULL.IEY

Us}ng SST, ftlrIlOV€ ·the. tr~I~:st\aft timh~g puHey_

SST 09213-6Q017

/"". / ' - - - . ~---SST , .. ' .... -------

.... /~-- . . . .

. .~ I

",,: ~ ~~ I ....

!



ENGINE MECHANICAL - Timit"l:g Belt

INSPECTIONI OF COMPONENTS

1. INSPECT TIMING BEt T

CAUTION:1. Do not bend, twist 01' turn the belt lnslde out,

2. Do not allow the belt to come into GO ntact with

oil, water or steam.

3. Do not utUi2e belt tension when installing orremovin.9 the set bolt of the camsbart timing

p'ulley.

'If there are defects as. shown ln the: figures, check ·the

followif-lg paints and replace the timing belt " if necessarv.

{a) Premature parting

• Check fer proper lnstallatlon .

• Check 'the ,timing GOVer gasket for damage , endcheck Fer correct instsilatlon.

~b~ If tile belt teethare crackeo o r d~ma.ged, check to

see if the camshaft, water pump 0 1 1 " pil pum.p is

lcclesd.

~ ' C l If thi5re is notlceabte wear or cracks em the. belt face.

G.h~ck to see i f there are nicks Oil 'one side O f the idlerpu'lley lock;

{ e I ) If there is wear QI delma'ge on only one side of the

belt, check the beH guide '(Ind the alignment or eachpuHey,



1~39,7-4D,7 min

EM! 133

~e} If th €rclllis no ticea ble weaf 0n the belt teeth, check the-

timing cover .gaske!t for dam.age and check for cor-reetgaskst irrstallatic«, Check for foreign rnatertals

On the: pulley teeth,

.2.. ~NSPECT IOLER P'UILlEYS

Check "the tllrlnung smoothness; of 'the 'liming ben kH~rlPu~leys_

Ilf neeessa r y , replac~ fh e id lor puHI!i'y,

3. INSP'ECT TENSION SPRI.NG

( < ; ) ) Check th~ 'fr,ee length - O f 'the spring,

Free leng th:

39.7 - 40. '1 rum ~1.563 - 1.80.2 in.}

(Ib Check the te nslen of the spring ,a'~ the spec if iMinstalled lenglh_

I I nstall edr re n slo n :4·.0 1(9 (8.,B lb. 39 N) at 52 mm (2.05 in.)

If not .5pee ifi ed , rep l see the s'p ring,_

INSTALLATIO N 0 F TI MilNG BElTISee p,age E,M~20)

1. IINSTA,iLL CRANKSHAFT' 111MIN G PULIlI:Y

(a) A I tg r ! th e tim if lg pu IIe y set key wirth the key 9 roo ve 'O f

theUm:ing pullay.

(b) U!;iing SST i'lnd a ti l amm er, d ri;ve in timing pull ey .

SST 09214~.60010

2. INSTALL N'(};2 IlllERPUL'LEY

Torque.: 4000'I.(g~(lm (29 ft"lb,3JJ N·rnl



EM·26 ENGJNE MECHANICAt - Timil1Q Belt

[M0131

F,M01t9

3" l'NISTAlL INJ ECTION PUMP DR'IVE PULLEY

( G I ) Align the drive pulley setlkey with the key groove o f

the drive pulley.

(b,) Using, SST, Install the drlvs puHey with the mount

nut, Torque tile mount nut

Torque: 650 l<gl~cm(47ft-lb. 64 N·m)

SST 09278~54<OT 1

CAUTION: Do n01 use an im,pact wrench,

- -- -

I;MClr3B l

4, INSoTALL C,AMSHAFTTIIMING PULl.EY

{aj Align the timing pul'ley knock pin with the pin hole af

tha timillg pulley,

(b) Using SST; Install the timing pulley witn the mount

bolt and ptete washer. Torque the mount bolt.

Torque: 1.000 kg-em (72 it-lb. 98 N·m)

SST 09278-54011

5. liNSTALl NO" 'I IDLER PULLEY

~a} Tarnporari lv install th e idler p~!lley with th-e two

mount bolts 'and plate washers.

(b) Sw~ngthe idler pulley toward the lett,

6. SET' NO. 1 CVUN DiER TO TDe/COM PRESSION

Aligllthe t~mbng a nd drive puiIBYiJ. at each position.

CAUnON: The engi,neshould be Gold.



ENGIN E M ECHAN ICAL - Timing Belt

7. I NST ALL TIM ING BE:LT

If using new timing be'li:

.(_s) Install the tirrHri_g belt tothe camshaft timing p'l,Jiney.

CAllIT'ION: Be sure the ti:ming belt iss~curely

mesihed and. flot loos€!:.

Ib} Align the IDimingmarks of the pump drive Plllieyandell pump body. .

(c) InstaH the trming belt to tl,e pump drivl~ pullav.

C_At:lTION: Be sure the timing belt is securelv

meshed and not loose.

(d) lil$tal~ the timing belt to Ul~ No . .2 idler pu.lleyarrd

cran ksh a'ftti m ing. p'.uHey.

CAUTION,: Be' sure the belt is, not twisted air tOO

tight.

If reu'sing timh~.g 'beR;

AJ~gn 'Ul€ points rnerked d;ui'lng removal and installthe tim-

Lng belt with the' arrow po.jnting ~nthe directicn o·fengin.erevolution,

EM~112 13MB1 '16



B. IINSTAU. TENSION SIPR1NG

CAU'TION; LOo~a\!!1I 1 ; rha mount bolts to whe,re the tim"

ing beh idme pulliey llightly moves wi1h tension spring

fon~e.

EM-28 ENG INEMECHAN ICAl - Tlrnlnq Beli

1O.TORQUE NO. 1 ~DLE.R PULLI:Y MOUNT BOLTS

Tor'que: 195 I(g~cm (1,4 f1-lb, 19 N'm)

_1 CAUTION: WhUe 1ightenill'lg the mount bol1s. do notmove the idlrer pulley bracket.

9. CH EeK. POSITION OF TI MING A.IND DRIVE PU LlEVS

~a.) Place a crankshaft puUey mount bolt on the crank-

shaft.

(b} Usl ! ' 1 r 9 1 a w rene 1 " 1 , tum the cranks haft pu'lley mcuot

bolt 2 revclutions from TDe to TDe.

CAU1iI.ON. : Always turn the crankshaft clockwise.

(c) C hac k th at eae h pulley a 1 . 1 9ns wit h ibe marks,

If the marKS do not align, ramovs the timing belt enc

reinstall it



ENGINE IMECHANIICAl.- T!rn~r'I lg Belt EM-29

/

11. INSTALL FOUR GLOW PLUGS AND CU RIFIENTSENSOR

(.a} linstall and torque the fourg low plugs_

Torque: 13-0 kg~cm (,9 it-Ib, 13, N·m)

(b ) P li3Jc~ thl;! g .IDW piugcQllnectot on 'the glow plugis,

(c} [E,urope (LH, LX. LNnIn-stall th e c urrent sensor with the lnsulatores, platewasher. and nut

~d) Insta II the' fO ;U f g!ow p~u9 co nnect ing fHJtS.

(e) InstaHtile fourscrew grommets,

12. INST A.LL TIMI:ING IBELT GUmE

AI igrl the set k.eyon th e 0ranks haft wilt h the keygrDovs 0f

the belt 9u~dean d s I r i d e it itl,

j

13. INSTALL. TIMING BELT COVER

{a l Ins tall the gas kets 'to the. bel t (lOVB.L

{b) lnstall the belt cover with the twelve bol,s,

14.. INST ALL CRANKSHAFT PUlLiEY

~a l A l.ign th e pUlley sat key w it h .t he l~ ~Yg iro bv e of the-

pullev,

{bl' L J ; E i 1 i g SST and a 11[:1nrner, drive in th€i pl..Ill,ey,

SST 09223,-63010



(el U$.ing SST, install the mount bott arid torque it .

Torque: L400 kg~cm 1101ft~lb. 137 N·mi

SST 092l3~5"40 12 and 093-30-00'Cl20.

15;. 'INSTALL WATER 'PUMP PULLEY

(See step 4D!1 pa g,e CO- G,)

ENGINE. MECHAN~CAL - Tirning, Be'lt

-- -/"

"L" ~----

Ale Compressor Ptlll~y

P', B ...~ater Pump Pulley

I "'-t..\.

b£"'-..-1~6s~"mpp",!"~,-\{ _ _ w'"

AlternatorPLl~le.V' CfElnksh~ft Pulley 81;.1":)I,i;

16. ~NSTALL DRIVE BELTS

Driv-e belt defloGtioll t i l t 10 kg (22. lb, 9.8 N) mrn {in.)

Used

-..,_..__ - '. I I

---------12:~ cenditlcnPo 5 itic n '-.."--~ ___

New

( Watl!l"r pump- "I". Alte rn a to r .'

7-10 10-14

(0,2.8 - 0,39) [0.3.9 - 0.551-+------1

'13 - '17 17- 23

{C ).51 - 0 ,67 ) (0 .,6,7 - 0.91)- - - I - - - - - - - - - - - ~

8-10 10-14{O.31 - O.3m (0 ..39 - OJ;!5)

A

c

{ C ranksha ft- \

;" A i C compressor ...

(C,·anks. l .1af t- "1

" PS pump ,.'

NOTE. ;• . . N ®w bett" refers. to a bel l. w hich has ne:ver be en IIse d.

• "Used belt" refers to a Qelt which has been used 0[1 a

running eng ihefor 5 minutea or mere.



ENG tNE MECHANICAL- Cylinder Head EM-31

CYLINDER HEAD

COMPONEiNTS

Heat Insul;:'!tor

Exhaust Manifold

II..

r Gasket

/ /r l

/ -

r-----·Seal Washer

\--- Cyrjnder Head Cover

~~~~;;~~;;~iitY----GaSke'l

• Gasketlntaka Manifold

'. C8i rnshaftOil Seal

Cams.h~ft 0 iISe<: ll R~ ta iner

U- i Eng ii i~.H~riger

,-2-.5-0-(-11-1,5~~

[~ Ift.~b" N - m n : T~ghteningtorque

• Non-reusable part



EM·32 ·ENG INE M ECHAN ICAL. - Cylinder Heac

4. REMOVE CYLINDER HEAD GOVIER

~al ' Remova the two b0!1ts heIdiIi9 tne head C,OVE!r" to the

belt cover.

{b·~ Remove the three cap nuts, seal wasne~s, head coverand.qasket,

6. IREMOVE TIM ING BELT(See steps 1 to 8 on p.i:I.yesEM-2.0 to 22)

6. REMOVE C.A.MSHA-FT TIM.NG PULL'EYb- ~- __ ~_-_~E ..... : : : : . . ( ) : . . = ' ' 1 9 - (See step '10 Oil 'P·age EM-221 '

7. DISCONNECT ACCELERATOR CONNE.CTING RODFRO M A C.C ELERA TO R L IN K

R I: M OV AL O .F CY L I N D ER. HEAD

1. IREMOVE FOUR INJECTION PIPESlSee step 1 on page HlI~7 i'

2. REMOVE FOUA INJECTION NO.ZZLES

(See steps 2, 3 on p·ages FU-7. :81

3. IREMOVE FUEL INLET P:IPEtSee step 10 on page FU-14)

8. HE.MOVE ~NTAKE MANU; :O<LO AND ILH E.NGI:NE

HA'NGER

Remove the six" bolts, tw o nuts. U-I engine hanger arrdin ta ke m an ifo Id a rH;i 'gB,s'ket

9. REMOVE WA T 'E R O U TliET ASSE.M'BLY

Removt5· the two bolts. wster out~et assembly and gjjJsket



ENGI NE M ECHIlI.NIC.AL - Cylind,er Head EM·33

10" REMQVERHENGIN ~ HANGER

11. REMOVE EXHAUST MANIFOLD

(.al Remove th e fQyr 00 tis a nd two he.a t ineul a t or s.

(b) R(;!move the slx bolts" 'twon uts, lWG plate VIi;;:l sJwrs

and exhaust man~fald,

12" REMOVE CAMSHAFT 01 L SEAL RET AIINl I :A

Remove the sb;:botts, retainer with oll seal and g~sket..

13.•. CHECK CAMSHAFT THRUST CLE:A.FI.ANCE·

~6} Loosen the valve clearance adjustLng screws,

{b) Usinge l d~a~'mdlcator, measure th e. thrust c lea ra nc e

w'l"~i.lemmt~f1g the camshaft back. and forth"

Standard clearance: O.O~5- 0.155 mm

~O.O:022 - o .omn in,)

lMaximun1cllearance: 0.3 mm (0.012 in.)

If tha thrust G~e~r6nceiisgreatert'harn maximum, replace

thl:) ca m sha ft and ! or be,l;Iring ,

'14. REMOVE VAIL ViE ROCKER SHAIFT A~SEM.BL v,CAMSHAFT AND BEARI NlGS, AN D CHECK

OAMSHAFT 01 L C L E A R A N C E

[s;} Grad ua IIy 1 1 6 osen and rem ove the ten bolts in ttl fee

pa s s e s a n d ~ nth e 11u m eri c a I' 0 rder sh own.

{b) Remove the rcu ;;:ke r shaft assemblyandoamshaft'with the three upper bj1Nlrin~s."

N01E~. Keep the upper beadn!;Jl:nsi@ftad wlththe caps.

~G } Clean each camshaft journal ' an d bea rit l'Q.

(d) Check each camshaf t journal and b,etJr:ing for pitting·;!!r.lld .seratches,

Ihhe. carnehaf't jo.umaland b : e a r ! F 1 l g are d?im.aged, gr ind or

r®P ~ G leel th e ca rns h aft~nd replace the bearl ng.



EM-34

{e } P!lacethe qarn.s'haf 't on the cyiinde~ head.

t'F}~ay a strip of Pli ' i ist igage across each journal.

(g) Install the valve rocker shaft assembly on the cylinderhead ,

(Ii) Iinstall and gradually .t'ighten the ten bolts in three-

passes in the sequence shown .Torque the bolts on the final pass.

Torque: 1,915kg~cm ~14 <ft~lb, 19 N'm)

NOTE~ Do not turn the camshaft.

(i) Hernove the racket shaft assembly with ' the threeupper bearing.

'~) Mea SUre th e IPI asti gag'9 ati ts widest point

Standard oil clearance: 0,.02,2 - 0.014 mm

(0.0009 - 0'.0029 ln.]

Maximum oil clearance: 0.1 mrn '10.004 ln.l

lfclearenca is tira8ter than maximum, replace .rhe bear inq ,

~Grlnd the camsha-ft 61'replace the 'camshaft a required"

(k) Completely remove the P~astlgagl5,

W Remove the camshaft and three lower bearings.

N O TE ; A rra nge the. bearings i n order.

15. REMOVE HALF CIRC'UL.AR PLUG

,-Vi,

1 ' " " C T i1I. ,~~.,

, t : ; i l. I

" I

' : . . . . . ~ . : : ' : - - . _ ,

16. REMOVE CYL'INOER HEAD

( . a ) Gradually IOOSEiI1 a nd remove th e e-i .ght@sn head bolts

ill Ltu'6fl passes anti ill th e numerical order shown,

CAUTION: Head warpage or cracking could result

from removing in Ineorrectorder.

1 3

mailto:e-i.ght@sn

mailto:e-i.ght@sn



EN G fN E MECH A N iC A L - C ylinder H ea d EM·35

3 ·4

[b} lift the cylinder head from the dowels on the cylinder

block and ' place the he13d ' on wooden blocks 01113

bench,

NOTE: If the cvllnder head is . difficult 'to lift off, pry witha screwdriver between the cylinder head and bl'otksaliences,

(ei Remove: the .cylil1der head gasket

CAUTIO,N: Bec,areful nat to damage, the cvrrndethead and blooksutface on thecyliltder and head

gasket sides.,

DJ'SASSEMBL V OF CYLlNDE.R H.EAD('See pag,e',t:M-31)

1. A EMO VE VA LVES

(a) Using SST. re-move the keBpets., is.pring r¢tailler .and

spring.

SST 09;202~43013

(b) RemQve the valve. oil &ea~and spr.ing se~t.

NOTE: An'1.'!ngehe dlsessembled part-sin order.

2 . . REMOVE eOM'B.US:TfON CHAM .BERS

Drive out the combustion oharnbers arrd/or shim.

NOTE: Arrange the disassembled parts in order.



EM~36 ENG'INE MECHANICAL - Cylinder Head

INSPECTION, ,CLEANING AND, REPAiROF CYL IN DER ' H EAD COMPONENTS

1. CLEAN TOP OF PISTONS AN,n TOP Of BLOCK

ta} T\Jrnt;he .crankshatt and brinq eaoh piston to top

dea d center ..Sera pe th e carbo n fro m th-e pis ton top.

(b) Remove ail g.asket mat~.ri ja:1from the top of the block

Blowcarbon and oil from the bolt ho,l-es.

CAUTION: Protect your e;{es when usiJ19 com-

EM0161. pressed air.._ ~ ~~

2. CLEAN COMBUSTION CHAMBER

Using a wire brush, remove all the carbon from the com-

bustion chambers.

CAUnON: Be carefiUllno1 to scratch the head gaskef

contact surface.

3, CL'EAN VALVE G'UtOES

Using a v'alveguide brush and 'solvent, dean all the valveg,uides; .

4. 'R EMOVI:G .o .,SK ET MATER~.A .L

Usingl a .ga,skBt scraper, remove all' gasket material from

the manifold and head surface.

CAUTION: Be careful nut to scratch thesurfaces.

5. CLEAN CYUN D'ER HEAD

Using a s-oft brush and solvent. cle-an 'the head,



ENG IN E M ECHAN ICAl - Cylind:er Head EM·37

6. INSP'ECT CYLINDER HEAD FOR FLATNESS

Using s precision straight edge and teeter galJ'ge, measure

the surfaces contacting the cylinder block arid manifolds

f or we rpa ge~

M~,xim.umwarpaUf;!.: 0.2 mrn (0..008, ln.!

I~fwarpa~ge is 9rester than maximum. n~pl2lce the cVlinderhead.

7. INSPECT CYU NIDER HEAD FOR CRACI(S

LJsing, a dye penetrant, check. the combustion chamber,

inu< i1keand .exhaust ports, head s,urhlce_· and the top o 'f the

head klr cracks.

If a crack is found. replace the, cylinder head ,

8, CLEAN VALVES

~ E 1 ) Using , i ; ! gaskett i ,crap\5I" chip any carbon from the

valve: head ..

~b) U S i ' r 1 g a wire brush, thoroughly clean the valve,

I~~I[M01?'1

~1O'72

"..,l.l1'1'3

~~--'~,."

)



ENGINE ME,CHAN ICAl - Cytill'loer Head

9. INSPECT VALVE, STEM AND GUIDE

la) US'lnga d~a~ind~cator, measure tl18 inside diameter of

the valve guide,

Guide inside di,ameter: 8·,51 - 8.53 mm

(0.3350 - 0.3358 in.)

OJ) Using, a micrometer, measure the diameter of 'the

valve stem.

Stem. diameler.~

Intake 8.473 - 8.489 mm. (0.3336 - 0.3342 in.)

'Exhaust 8.454- 8.47.0 1 1 1 m

(0.3328, - 0.3335 in,,)

(d Subtract .the valve stem measurement from the valve

9uid~ measurement,Standard stem oHclearance:

Intake 0.021 - 0.051 mm(0,,0008,- 0.0022 inJ

Exhaust 0.040 - 0.076 mm(0.0016 ~ 0.0030 in.!

M,a;dmum stem 0 ' 1 1 clearance,:

Intake 0.10 mm (0.00:39in.)

Exhaust 0.12 1ll!11 (0.0047 i,n.)

If the clearance is greater than the above values, re-place

the valve and guide,

10. I F "';U:CESSARY. REPLACE. VALVE GiUIDE

fa} Using SST, and a hammer, -drive out the vallve-guide.

SST 0920 t -6001 f

(b) Using dial in¢litator, measure the 'ValVI';! guide bote of

th e ty lin d e r M a'c L



ENGINE MECHANrCAIL- ()lintli3:r Head EM~39

{c) Select a new valvegllJide.

I -f the .v :a lve guide bore of the cylinder head is more thanHk(J"i8 mm ( 'b,551 9 ~nJ;machtne the bore to the follow-ing dimensions.

Aebored cylinder head bushing Daf.e dtmenslons:14..044 - 14.068 rnm m.5529 - 0.·55,39 in.)

(d} U8ing SSLand a hemmer, drive in Q new vallve;guid.e

to wh'€n~ there is. 16,3- 16,7 rnrn (0,642 ~ (1657

in J protl'uding f rom the: oylin d : er h € ia d ,

S ST c l9 .2 0 1 -6"0 0 ,'1

(e) U\:iing a sharp' R5 mm reamer; ream the valve guide

1 ' ' 0 obtein th B spedfied. c l s ara n c e b€tween' the Itaiv egll~ide. and new valv'L!l,

Stem oil elearanee:Intake 0.021 - 0 ..057 rnrn

(O .OOOB - 0 .002 2 in.)EXhaust 0.040 .~. 0.076 rnm

(0.'0016' - 0.003.0 in.]

1 " 1 " . I NSPECT AND GRIN 0 VALVES

(a ) Grlnd vtll_\jes cnlv enough to remove plts.and carbon.

Ma:J ,; .esu re the ' va lves are :g rouno to th e c orre ct vableface i:lng,le,

Valve face fli1'Iule: 44.So

(b) C heck ttl';:: [email protected] head m.arg~n,·

M lnlmurn m3rgih 1:hic!lit!rH;!SS:

Intake 0.9 mill (O,035 in.]

Exhaust 1.0 mm ~.O.039 in.)

If the va lve h ea d m i: l'rg ~ F i1l l iCknezs-s , is less tha n m in im u m ,r.~pIQt.,e<thevalve.

1 lL '994 - 1 ~t,O 1S(0.5509 - [U).619~ Use STD

Over 14.01 8(0,S519)

Use 01$ 0.05.. I



"

E.M-40 ENGINE MECHA N ICA L - Cylinder Head

lI

Length1 -

E f . , 2 2EO

(c} C heo k th III v iJ .lv e a ve ra 'll le n g t h.

S1andard overall length:In1ake 122.95 mm ~.4,8405 h1!JExhal(!st 122.75 mm (4·,,8327 in..)

Minimum overall lengl th:

Iintake 122.45 mm (4.8209·in,J~xhaust 12.2.25 mm 14.8130 jn.~

.' ,

- '1 \

'J

(d) r f the valvastern tip i s worn. rel~~d.ac:e the 'tip with

grinder or rep~acethe vaive,

CAUTION:. DO'not grind Qf1 more than the m,inimufT

,amO'IJll il t .

12. INSPECT AND C.LEAN VALVS SEATS

(a) US!Iig' a 45" cutter, resurface the valve seats. RemQvonly eMiJgh metal to clean the seats-

(b) Cheek the valve se.ating positlo.1],

Apply a thin coat of prussian blue {or white lead) tothe valve 'face. lnstall the valve, While applying lighpressure to the v.alve, rotate the viii~veagainst theseat .

(el Check the val ve f sea and seat to r the foUow iing:

• ~ 'f blue appears 3,60° around the valvatace, the

valve is concentric. If not, replace the valve..

• If blul!! appears 360n around the valve seat the

9uqde and seat EirIE:or ' l:~nlr ~c, I r no t, re~urf ace 'thes e a t

• Check 'that the seat contact is on the middle of thevalv~ f..acewith the foHowing width:1.2 - 1.6·mm jO.047 - 0.063 in.)

If not corre ct the valve seat as fo 110W 5:

~1) If the sea ti '19 i s too h~gh 0n the va Ive fMIl, use

30° and ' 1 $ < : > cutters to correct the 'ssat,



ENGINE MECHAN OC :AL - Gyander H e a : d E M - 4 1

(2) IfseatiAg ls too low on the valve face" use 65

and 45° cutters to correct the, seat.

(d) Hand-lap the valve' and valve ssat with abrasive compound.

13. INSPECT VALVE: SPR.INGS

~a) Using a steel square, measure the squarsness of thva~ve sprl n g ' 5 . ,

Maximum squersness: 2..0 mm (0.079 in.)

If .squareness is, greater than maximum" replacs the, valspring,

{b} Using Gali l~l 'en",measure the free length Df thie' valspring,

Free length: 47.98 mm (1.8890 ln.l

If not as specified, replace .the valve spring,

(c} U sing a sprl ngl la s te r, me as ure the te ns iQn of thvalve spring at 'the specified installed :Iength.

Installed tension:'29.2 kg {64.4 Ib, 286 INI at 39.3 mm (1.5.47 lin.)

If not as specified, replace the valve spring',

\'

. ~ V ' · ' ( ~ \1 \ 1 ] ' - - 1 , \

\ I I \ h ' , . . .~ " \ 1



ENG1NE MEeHAN ICAL - Cylinder Head

14. IN.sP'ECT VALVE ROCK;ER ARM AND SHAFT

{a} Check for rocker arrn-to-shatt clearance by movingeach rocker arm.

1'[movement is felt disassemble and check,

~b) Check that the reeker a'rm roller turns srnoothly,

{el Disassemble tha rocker arm assembly aashown inthe fi~ure,

NOTE: Anange the disassembled parts, irr order.

Valve Rocke~Shaft

I

Camshaft Bearing Cap

E){halist Val,\I,e (Protrusion)Rocker Arm /

Compression '.~_o._"."Spring - .; .~ \ d

l Ij.·' \ ) i_ '.' ." > ,.\ ... ", -

Valv\';!Rooker Support

Intake V~lveBooker ArmFront

(d) Using -8 micrometer, measure the diameter of the-

rocker arm sbart.

Shaft -tUameter:18.464 - 18.483 mm (O,.72S·9- 0.7217 in.)

~e} U~;in9dial indicater, measure the inside diameter ofthe rockerarm,

Roc'ker arm inside diameter;

18.500 - 18.5,21 rom (0'.7283 - 0.7292 ln.]

( f ) ' Subtract the rocker arm shaft measurement from therocker arm measurement,

Standard oil clearance: 0.017 - 0.,.0.57 mm(0:0007- 0..0'0.22In.l

Maximum on clearance; 0.,1mm (0.004 in.)

i ' fthe olea ra n ce is. greater than m ~ S 1 x im u r n , reple oe the

rocker arm and/or shaft.

(g) Assemble the !'Ock.er armassembly in reverse order

as described in step 14-(b).



ENIGTNE.MECHANICAL - Cylinder He:ad~ , j ~ ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ ~ ~ ~ - - - - - - - - - - ~ - - - - ~ ~ ~ ~ ~ ~ ·{ ~I

~ ~ ~ - • .. > : -•-:;-• • • .< - - . ~ 3 . , ' ' " ' '(;l\Wl91

1.6. INSPECT CAMSHAfT

{a d PlacG the camshaft on V-'b.locks and, uSing a dial

indicator, measure the cilrc.le runout at the centerjournal,

M;;l:ldmumcircle runnut: 0.1 mrn (0.039 ill.)

If the G ii rchil run Qut is g re.ater than m ax~mum, rapiaC~ theC'8I1il!3 1 1 , ; l ft.

~b} Using a rrucrernater, rneasurethe cam lobe he~ght

Min imUmc am lobe he~gt1t:

Intall!:e L. 2L 46.76 rnm U .8409, ln.l

.2l~T 46.2'9 mr:n (1.8224 ln.]

E;I(haust 47.2.5 mm (1.860.211'1,)

If the cam lobe height is less than rninlrnurn, I'GplaGe thecamshaft.

(0 ) Us~ng a micrometer, measure the journal di·amete·r.

JOl,.llrnaI d lame ter: 34.9&9 - ~34.985 rnm

(1.3767 .~.1.3774 in.~

If Ute' Q~lcl e . a ranee eve 1 " 1 when new t i G ' < : ; i rilngsate use.d,IS

grei!ter than spE;lcif~ed, regrind or r!;u.)laie the eamstratt,

16. IF NECESSA.RY, GRIND AND HONE CAMSHAFT

JOURNAL

Grind < 3 1 l ! d hone the [ournals to the undersiaed finisheddiameter,

~rls ta II new ]0 Urrl a il bea rin g s,

Bea.r~ng.size OJ/S 0.125, 0.250)

Journam finishe.d diameter:U/S 00.125 ·34.8·44·~.34.860 mm

~1.3718·~ 1.3724 inJ

U/SO.Z50 .34.719 -3.4.735 mm

~1,3669- 1.:3'675ln.l

17.INSpIECT I.NTAKE ANID EX.'HAUST MANIFOLDS

Usfng.~lpn·.eci;s~onstrai:glit ~dg'eandf'€teler g·aug:e,measure'thl~ ,smrac(;j-.scMtacting the cylinder head for -w.i;lrp~ge_

Maximum rTIJanifoldswarpage: 0.4 mm W.01G i in.)

If warpage is greater than maximum, repl.~cethe manifoldl .< .



EM-44 EN Gi,N E. MECHAN tCA L - Cylinder Head

/" --,

,

./'~-... ~~~.. !f J_ - c : : _ : s . : . ! S '

~

SST

Cu t Posit iQ ! ,, !

t t " t u

REPLACEMENT OIFCAMSHAFT OIL a,EAL

NOTE: There are two methods ot oil seal replacement.

RE'PLACE CAMSHAFT ou, SEAL

If c:amshaft oil seal retainer is removed 'from cylinderhead:

(a) Using a :screwdriver and hammer. qriveoutthe oils e a l

(b) Using SST and a hammer, drive- in anew oil seal untilits surface i.s flush with the 0 1 ' 1 seal retainer edge-

SST 092 '4~60010

(el ' App 1 '1MP 9 re a se to the oll. seal

If carruj,h:dto,ii'! sea I retal net' is lnsta Ued. to, cy Iinderhead:

{a} Using a knife, cut off the oil seal lip,

(b) Usingl a screwdriver .. pry out the oil seal,

CAUTION:, Be careful not to, d~m.age the cams haft.Tape, the scr,ewdrivel".

(c} Apply MP grease to a new oi'l seal.

!d) Usingl SST and a hammer. drive in the oil seal until its5 ,u r ia c :e is fIIush w~th o~1seal retainer edge-

SST09214~60010



ENG INE MECHANICAL _, Cylinder Head

,

,,,,

ASSE M l B LY OF -CV L liN D E .R HEAD

(-SeE!page EM·3'f~

NOTE:

'R Thowughly dean all parts. 10' be essernbled .

• Before im.talling the pans, apply n.ew engina oil t~ all

5 1 iding and retati fig surfaces •

• Replo;lce all ga$k~ts, O-rings and oil seals. with newparts,

11. INST.AlL SWIIRL COMIBUS.TION CHAM BERS

{a~ Align the 8w~rl combustion chamber knock pin with

tha G y l.illder haadn etch,

(Ib) LJshlg a piastk: hammer, drive inths swirl combustion

(lh~mber {with the sh~m}-

k: l Using a alial tndlcetor, check. the' swirll cornousncncharnbe« protruslcn,

Combustion chamber prctnrelen:0;01 - OJ]"? mm {O.OOU4 ~ 0'.0028 in.l

If the pfo,tmsIOT1 Is-not within specificetien, adjust it witnas . w ir I ecrnb ustio n cha mber' shl rn, .

Comblllst:io!1 chamber shim 'thkkness:(1.005mmiO;002cO ln.]

0.10 mm (0.003,9 il'l.J

0.15 mm W·.0059 lin,'1

0:-20 ru m (O.0079in.1

2 . INSTALL VAL VES

{ i ; I ~ ~ lnsert the: V.,I\I~ in th@ e,ylinder head valve guide.

Check t n e v a Ive $ a re. l n s ta Ue o in the correc t .0 rder,

(b) linstrrfll the valvE: spring S®1H and newouseal.

(a ) Iinstall th e sprin ,95 r a n d s p w i rl9 retalners 0r! th e va Ilie's.



EM-46

{d} US~llg SST. compress the valve. sprin"9filTld place the

two keepers around the valve stern.

SST 092.02A3013

IENG.NE MECHANICAL ~ Cylinder Head

, /J

;

Fronl

U pp er {e ;.;, N , o_ 1Cllmsrnaft Be:aring)

and LOW'€ r r Be-ari.ng

Uppmt Bearing{No.1 CamshaftBeari!1gl

(6 ) Using g l p~astrc hammer. ligbt'ly tap the stem to

assure proper fit.

I.N STA L L A T I ON OIF CV II N D ER HEAD,

~.see 'Il'S.g e 'EM<~ 1)

1. INSTALL CYUNDER HEA'D

' ( i f l ) Install a nsw cylinder head g a si< ;,e t a n d th e head onthe Gy~irider block.

{b) Apply a Ught coat QTeng~ne oi'l on th$ thr-Mds and

under the head of bolts.

!d Inst ,al l grapually and t ighten the 'eHghte'EHl head boasin three passes and, in ·nUJ sequence shown. Torque

the bolts on the final pass..

Torque: 1.200 kg-ern l87 H"lb. 1,18 N'm)

2. INSTALL CAMSHA'FT 'aEARIN GS. CAMSHAfT AN 'D

VA.LV!: HOCKER SHAFT ASSEMBLY

(a) Install the upper be'arings to the camshaft bearing

caps.

{b}lnstalll the fowBr bearings to 'the cvlinder head,

(c ) PI,ace the camshaft in the cylinder head,



ENGIIN E M E,CHA.N.ICAL- Cylinder Head EM-47

{d} Tum the crankshaft to lowerths pistons.

{e) Instal17the varlve rocker shatt ,assembly On the cylir]der

head,

{f ) Gn'~du;;iHy fnst!;ldl a nd 'llg hten HH;! : ten bolts in three

p i 3 sse sin the sequen ce shown,

Torque the bolts on the final pass.

Torque: 195 k91~orn (14 ·ft-Ib, 1i9 N.nil)

3·. INSTALL C.AMSH:AFT Oil SEAL AETAI NEFI

Install a newga,sk!!it and the. retairner withthe s~')ifbolts

To rq ue t h € 001:t8.

Torque: 18S Ie.g-em (13 ft-!Ib, 18 N"m)

4. INSTAill EXHAUST MANifOLD

( , id Install ~ fl,ew 9 a is ke:t and the exh a ust m anift;d!CI with

.the six bolts, two plate washers and nuts, TO~QlJe,he

bolts and nuts.

Torque: l, 2.L 400k9~Gm t2.9fH~b~39 N'rrd

2l ~T 530 I~g~C'.m (38 H·llb, :5.2N'm)

~q ) Install the twolnsulators with thefour bolts. Torque

th e bolts,

Torque :120 kg~G'm U l ft- Ib, 12 N -rn]

5. INSTALL RH ENGINIE HANGER

Torque: 380 !<g~CITl . ~27'ft~lb, 37 N'm~

I ,

i ,

, I

I EM(!'!.~~

6. INSTALL WAfER OUTLET ASSEMBLY

Instflilia new g8slket and ·ttle watter outlet assembly with

th e -tw 0 no tts , T orq ue th e b0 lts,

Torque: 195 kg-em ~'14U-lb,'.9 N'mt

7. INSTALL INTAKE MANIFOLD A.ND LH iENGINE

HANGER

Insta II ' r : ! IlfllW ga.sket, inta ke 01 ani to~d.and LHe ngine ha ngewit hthe '5 ,1 ,x bo It s' : an d 'tw o nuts,

Torque: 240 h::U-GITI (17 U-Ilb,. 24 N'~n)

B. CON'NIECT ACCELERATOR CONINfCTl'NG ROD

9. IN€iT ALLfOU R INJECTION NOZZLES

(See steps 3, 4 on page .FU-12J

10 ... INS.TAlL FUEL INLET PIPE~S.ee pa-ge FU~47)



11. INSTAL'L fOU F I: 'IN.JECTION P~PES

(See page FU~12~

12, INSTALL G.AMSHAFT l]M ING PULL~Y

(See' page EM-l6I

13. ~NSl'AlL TI'MINGBEL T(Se-e s,te'p,s ,6 to16 011 .pages' 'EM-261:J] 3Q)

E,~NG~NEMECHANICAL - Cylinder H~ad'

First

Second

[M0105

'14.. ADJUST VALVE CLEARA. I \UJ· .ES

{a) Set the No.1 cylinder to TDC/cromp'ress"ion,

Afig n th e groove 0r! th e p ulle y wh'h the- t~imin 9 po in te r

by 'ill! r'n i n9 the era n ks haft c Iockw i,se w~th it! wrench.

(b) Check thatthe rocker arms emthe No.1 cvlinder areleo 5eand rocker arms on the No..4 cylim:ler are tLg.ht,

'If not, tu rt"I th e m~nk$.h attone ravclut [0n '(3'60 d } ,8nd alig n

the mark as above.

(c ) Adj~s •. 0 n Iy th ose v·aJve .s: i lid icated by II rro WS,

Va'ive elearareea tCold);

~ntak,eO.27 rnm {O.0106 InJE,xhau~t 0.38 mrn (0.0150 in.}

I NOTE: AUerins;talling the cyiiinder head, warm up the

eng in ill and aqJu stthe v alv e ela aea IIc e.

• U ~~ r1 lga feeh~Tgaug : e , fTI'9cE1SUl"e' t~W!valv€: clesranca

betwe,en 'the vel ve stem Q n d ree ke r arm, to osen

the ~oGkt1lutsnd turn the .adjuMinig SQr~Wto set the

proper clearance. .Hoidthe adjusting 'screw In pcsltinn arid t~ghten

t h € .1ock nut.

.• Hecnec k the vo:j~\fe c~ara nee, T h efe·e!erQ aug e

shou1d slida with a\/ery s!i.ght drag.

(d) T urnthe crsnksh aft one revolution (350 Q}snd a Ilgn

the t~m~ngmarks as!;Ibave,Ad ju~ t "bn~v t he · v t: l. lv es1rldiG,~t~d by arrows.



'~E .N lC iUN EIMEC HAN UO AL -C ylinde r Head EM·49

15. liNSTALL. HALF C~RCULAH PLUG·

~.a} Ap ply se a I Pac k.ifig black ~Part No. 08 B2 (3 ~OdO80) or

equlvalent to the half circular plug.

(b) Install th e ~1.alfc l fC U lar plug to the cy lind III r n earL

1G. INIS1'ALL CVl.IN DER HEAD COVEIR

ta) Apply seel P?cKing ·black.(p~rt No. 08B.216~iOOO.80} oraqui.val1ent to the camSihaft oil saal retainer. cyli100er

head end ha~·fciin::ular plug .as shown,

(b,) insti!! II a 9 as ket to the Iiiead cover,

'{9} inst'll~1he head c:overwith the thre.e. ~n;l61washers and

cHip nuts.

{dO InstaU the remaining two timjrl9 ,gear cover mountbollts.

\'.



IEM·50 ENIGIINE MECHANICAL Cyliind.;lr Block

CYLINDER BLOCK

COMIPONENTS

PistonRing (No, 1Compressioni---'

PistonRing (Oil)~----Pistoil Ring (No, 2 Compression)

o--Piiston PinPiston .-------------=--r®Snap Ring ---------

- \p RodBushing

II-----~Conneding Rod

Crankshaft~OilJel

. , 1 0 i I Check Va,lve

I 260 t19•.261 I

.,}----. Gasket

---Ol Pari

Ikij~c.m ('fl-llb, N :m ) I : Specifled torque

• Non - reusobl e part



ENGINe MECHANICAL - Cyl!~r!der Block

_ _ _ - - - _ - - - - -

D ISASSEM tBl V OF CVLI NDER BLOCK

(Se€! page EM "50)

1. REMOVE FLYWHEl!:l OR DRIVE PLATE

2. REMOVE REAR -=N D IPU \ TE

Rerl10ve the two bctts, end pl-at"e iElno dust cover,

,3 , INSTAll ENGI.NE TO ENG INE STAND FORDISABSEI\II SL¥

4. REMOVE CYLIIN DER HEAD

JS,eesteps 1, 3 to 1, 1.2, 14 and 16 on pages.E.M-32 1035) .

:5, REMOVE D.IL P UM P

(See steps 1 1 to 7 on p@:9,esLU~4 and 5l

6. REMOVE R~AR OIL SEAL RET/tIN ER

Remove the four bo lt s, r et a :i ne l' and gasket,

7. CHECK CONlNE.CTIIN.6. ROD THRUST CLEARANCE

Using a dial indinator. measure the. thrust clearance whllemoving the rod back and forth,

Standard tht us tc:le.ara nee:: O.as .~ 0..:2 0 mm

~O.0031 - 0.0079 ln.l

Maximum thrust clearance: 0.3 rum (0.012 inJ

If the cleeranee is 9 r&8 ter than the maxlrnum, replace thecan nec:tiJng ro d Q nd/cr cran ks ha1lt"

8. REMQVE- CONN ECTING ROD CAPS WITH LOWER

BEARIING .AIN.D CHECK Oil C l i EARANCE

(a) Pia oe match marks 0n the rod a rid cap,

( I ; l . ) Rernove the. rod nuts-

[e) UghUy tap 'the rod bolts and lift off the caps l/IJittl thet;lH~ring.

NOTE:. Keep th.€ be~rirng ilriSerWai With th€·C.,p,

(d~ Co:v~rthe.rod bolts with Q short piece of hose to pro-

teet the crankshaft frorndamaqe.



ENG'INE MECHANICAL - :Cylinder Block

(e~ C·rea"each crank pin and beairing,

m Check e~ch crank pin and beating for pitting andscratches,

If the crank ·pinand bearing are dC!maged, grind or replace

the I;:rankshaft an·d replace the baaril1g,

',2 Dr 3

/h.~.

'\\\,

Brown., Bla·ck o r Blue

EMJ~t"\.

(g} la.y·a strip of Plro;llstig,a.geacross the crank pin.

(h) Install the ro d caps {See' pagr€! EM-67)

Torque: 600 k~-cm (43 ft~lb. 59 N·m)

NOTE~ Do not turn the crankshaft.

m Hernov~ the rod cap,

m Measun'l: the PI~i"st:i9age at lts widest point

Standard oil clearance: 00.036,- 0.064 mm(0.00014 .~ 0.0025 tn.l

Maximum oil: etearance: 0.1 mm ("0,,004 in.)

'If the cleaeance 1S gr,eater than maximum, rep1i;1ce the

b~arin9, Grind the crank pins or replace the crenksheft as

required ..

NOTE: There six different ·standard bearinqs, distin-

guished numertcally (1, 2 and 3} and by color (b-rown,

black and b~ue),

For 2 L~T e.ng.ine s, rep ~ace be a ri09 with one h 0 1 \ 1 ing l~he

'Samenumberas marked on 'the bearinqoap. Far Land 2L

engines f replace. wilh o ne having .. the eolor with corres-

ponds. to the number on tbe bearil1g cao, i. e., 1 withbrown. 2 with black, 3 with blue.

tid Completely remove the PI; ;H~t igag.@.



ENG IN E M ECH,ANICAL - Cylinder Block EM-53

9. PUSH OUT PISTON, AND COINNECTING RODASSEMBLY WITH UPP'ER BEARING

(a) Remove 1 3 1 1 the carbon from the piston ring, ridge,

(b} Cover the rod bolts, (See, page EM~!J1)

(d P ush o ut the piston and rod assembly with the bear-ilng through the top 'of the 'cvllncer block"

NOTE:

IIKeep the bearing inserted with the rod •

.. Arrange the piston and r o o assernblvln order,

10" CHECK CRANr(SHAFT THRUST CLEARANCE

Using a :di~a~lnoir.rator, measure the thrust clearance while

p ry~ng, th e cr~rrks h a 'l't be ck and fa nh wi tha screwd rivsr,

Standard thrust clearance: 0.04 - 0.25 mm~O.0016- 0.0098 i n . . , )

Maximum thrust clearance: 0.3 mm 10.012 in.)

If the clearance: is greater than maximum, replace 'ththrust washers as. a set,

11. REMOVE MAIN BEARliNiG CAlPS WITH LOW'ER

eElA.RI:NG AJ'lJO C'HECK' Oil CLEARANCE

{a} loosen rha bolts until the threads no longer mesh.

{b ~ G ra5ping' th e bot ts to g .e th er, pul] 0 ff b ea ri'n g c s p,

NOTE: Keep the bearing inserted with the caps,

(c l Lift out the crankshaft.

~d} C lea n each [ournal .and bt'!!Minid.

~e} Check eaph journal and bearinq for pining a ndscratch e$ :.

If the jou:mal and beari .ng are darn.!jged. grind Or replacethe crankshaft and replace the bearing"

MOUN T G P .AVI-\TT CO l' rG E O F TA,FJ:'I

L I B R A R Y



EM·54 ENGINE MECHANICAL- Cyli1nder Block

~.2. 0.r3~- '.' '. l .. ;

\ : & : . y.

o Br,QWfI. Bla~k or muc:

2 - ~Of Black.!, o r :3 lo r Slue)

Front ..

·0

NQ, 1

LowerO

'1

m P~ace thecrankshaft 011 the ovlinder block.

I ( g ' } Lay a strip of Plasti.gage across each journal.

(h) II'1I.st31~he bearing C?iP (Sas pa.g~ EM~B6}

Torque: 1,050 kg-em ·176n·llb, 103 N'm'

NOTE: Do I'O( turn the crankshaft.

m Remove the bearing cap.

0) M~asure the Plast,igage'at its widest point.

Standard oil cNe,arance; 0.034 - 0.065 mrn

to .O'D13 - Q.0026 in.lMa ximU'rn · o n clearance: 0.1 men (0.004 inJ

If the clearance is . grea,tel ' than maximum, reptaee the

bearing. Grind the journals or replace the crankshaft as

rsqulred.

NOTE; ~fuSing a standard bearing. replace with one hav-

ing 'the same number as marked on the' cylinder block Or

havin:g its correspondlnq color, i- e. , 1 o r brown, 2 or black,

3 or blue.

(k} Cornpletelv remove the Plasti,gage.

12. REMOVE CRANKSHAFT AN D UPPER MAl N

BEARINGS

(a) lin outthe-crankshaft.

(b) Remove the b6<i!r~ng from the 'cyllnder block,

NOTE: Arranqe the caps, besrlng,!j a n d , 'thrust )Nesh{:m~,n

o r d e L



E:NGINE: MI::CHANICAl - CylInder Block EM-55

' 1 1 " : 3 . . RI:MOV:I:. OIL CH ECK VALVES AN 0 01 L. JETS

I NSPEGTI ON OIF CY U N.DE R BLOCK

1 ,REMOVEGAS'KET MAl"E.RIAl

Usi n9 ag ssket SClCl per. remove all gasket meteria I 'From

the cylinder bloek surface.

2. ClEA.N CYLI N.DER BLOCK

Usi[ l 'g a soff brus h ,s nd .soIyent, cl aan th e b U ode

3. IINSPECT TOP OF cvu NDER BLOCK

LJSirl'g~1precislon .straight edge and fe~l~r gauge, rneasure,the surlacas contacting the cylinder head gaske.tfor war-

page ..

Maximum warRage~ 0.2 mOl (0.008 in.]

~fw;i'lrp,age I.S,~rea'terthan maximum, rep.~ace~M ~vlinder

o'iock,

4. ~NSPEC'r CVLilN DERS'

V is u a lly c he ck th e eyli n ds r fN \len i c 131s c ra te hes,

If deep scratehas t1n~present, rebore allfour Gylil id fWS ..

o--

EMH23



EN (nN E M ECH A N IC A L - Cylinder Block

E B : : D Thrust

.. .' Dir~c.lon

~ .\ A xia lDirection

~ A rL 15 mm.1---....1 1 0 _5 9 < , rd

E l ' \MiddJe

C j, 15 rnm~~'-----+T(0_5.9 ird

/I,

5.. INSPECT CVUNDER BORES

Using a cylinder gauge, measure the cylinder bore ·at posi-

tiorrs A , Band C in the thrust and axia', directions.

Sta.ndard diameter

CyHnder bo re rnrn (in.)P l st o rl s iz e

L 2l, 2L· T

90.000 - 90,030 9'2,000 - 9'2.030(3.543 3 ~. ; 3 . .5445) (3.6220 - 3_6232)

90.500 - 90.;53.0 I 92.500 - 92.530{3.56 30'- 3 , 1 3 6421 (~.tl'417 - 3.6429)

S'fD

DiS 0.50.

mm ~inJylinde·r- bore1----

L~-------F----

STI) so .z s ~J,&524)~ - - ~ - - - - - r - - - - -

Q/S 0.50 90_73 f3$720)- ~ ~

2 L . 2 L - T

92.23 (3.63111

9 <2 .7 3 ~3 -6 50 S .J

If the diameter is.g r€!.ater than maximum of the ST'D size,

rebore a~1four cylinders.

If the di:~meter is g :rea t€ ll " than rnaxirnurn of the O/S 0.50,

r e 'p l a .G o e l t h e cyl~inder block.. .

6 . R EMOVE; C Y U N D ER R ID G E

1 " 1 the wear i,s less than 0:.2 mm (OJ006 ln.), use a ridge

reamer to rrm.c'hin€l '~hE!piston ri,ng ridge at the fop of the

cylinder;

DISASSEMBLY Q'F P'ISTON ANDCO NN EC 'T IN G RO D A SSEM BLY

,. C H EC K F IT BETW EEN P'STON AND PtN

Try to move the pi$ton bauk and forth on 'the piston pin.

If any' movement is felt, replace the piston and pin.

2. REMOVE PISTON RINGS

Us.ing a piSt_O.il ring expander, removethe piston rings,

Keep the rings .separats for .Iillii'l.chcylinder.



ENG IN E M ECHAN U::A l -

3. DI:SCONNECT CONNECTING ROD FROMIPISTON

(6 ) Using needle-nose pli:€Js. remove the snap rinqs,

{b} Gr"O;Jdus.llyeat the platen to about. '<60- 70"'C ~.140 -158,on

\1\

E 1 V < 7 1 6 B I

(c} Usi ng a pia stic- faced hamm !1 l rand brass bar, HghtlytaP 0ut the piston Pln and remave the {JQnnectlnq

rod,

NOTE:

• Th€l piston and pin are a rnMened set.

• KeG !p the p iston , p in , .r in.gs end conneetlnq re d to ge the r

'For ee c h cy I l i f ! der .

INSPECTION 0 IF PISTONI A'N D CONNECTI NGROD ASSEMBLY

t. CLEAN I PISTON

{ E l i ) S.cr~pllicarbon fromthe piston top,

{b~ Using '0 gro ove olea r1lng too lor b roken ring, clean the

c -, ri ng 9move s;

\\1 , \ . (c) .USh19 solvent and brush, 1i.horough~y clean the ptstorr.I 'I CA UTIO'N: Do noli: use a wi're brush.EM2 '1 '!O



2. INSPECT P1STON DIAMETER A.ND CLEA.R.ANCE

( . a } Using a micrometer, measure the piston diameter at aright angle to tine piston pin hole center ~ i n G l 34 rnrn

{1:34 ird or 23 mrn {O.·9.,inJ below the skirt bottom

edge.

L 34 rnrn2L, 2l·T 23.· rnrn

Front ...

T Thrust~V [:lJir.et tnQn

[ " 2 ; A~ ia l .,,- Direction

ili

5mrn

{O .59....l l . . ) .Mijddh,

1. 5 rnrn- ~O,59ln.l

Standard d i : o ; l metar

O iS 00.50

P isto n . s i . z f . l Piston bore rnm ( ] ; P e d1--------

l 2L,2Vr-1----

8·9.955- 89.985 9 1.9400 - 9".970{3,541 5 - 3.542 7) ~3,61'97 - 3,82.09}

TD

90,455- SOABSI (3,5612 - 3.5624J

92.44(l" - 92,410

( .3,6 394 - $.6.iJ-0 5)

{iJ) Measure the cylinder bore diameter in the thrust

dlrsctions {See page EM-,56)ano subtract the· piston

diameter meesurernent hom the cylinder diameter.

Starul3fd· clearance:L 0.035 - 0.055 rom (O.0014 - 0.00:22 in.)

2L,2L- T 0.050 ~ 0.070 mm.(0.0020 - 0.0028 in.)Max.imumGle·arsnce: 0.14 mm lO ,OQSS in.)

, d ' * t . . . J t the clearance ~sgreater than maxlmum. replace the"'·'piston,: O T reb-ore E 1 1 1 four ey.li ilders and replace all four

pistons.

3. iNSPECT CLEAR.ANCE BETWEEN, P'ISTON RiING, LAN D

A.ND NEW PISTON RING

(a) Install the N.o. 1 ring to the piston s.nd, lIsing . a te ele r

.gauge, measure the No..1 ring clearance between the

ring Ia nd a nd new pi sto n ring w h e ti l the fill 9 is f~ts.h·

with the piston surface,

No. 1 ring clearance:

L 0.010 - 0.055 mm (0.0004 - 0.0022 in.)

2L, ·2L.-T 0.0.20 - 0.065 mm ~O.{)008 - 0.0026 in.~

~bl Using a feeier gauge, measure the No.2 a,nd oil r~t1g

clearances between the ri·!lg land" and new piston ri,ng.

No, 2 ring c:'eatance:0.040- 0.' 00 rnm(O.OO 16 :- 0.0039 in.'

Oil rJng olearanee: ..>

0.030 - 0.070 rnen (O "; (iO ·'2 ~ 0.0028 inJ

If not within specification. replace the piston.



ENGIIN E MECHANICAL - Cyl.inder 'B!1ock EM·59

4, INSP'ECT PISTON R lNG I END GAP

(a) Insert a piston rillg into the cylinder bore.

~b) Usiing O il piston, push the p ils* . r , _ r~ little beyolldthe bottom of the ding 'tr;a,·. ' . 1 ' ' :

{140. mm ~5.51 inJ frHr.%~·· : , ,surface of cylinder

blo ckl . "\i:~ _

'(d U Iii ing a ,' feel 'El f 9 a u ge , rn B a' s u ra th e' '$ 'jf d' g a p.

Piston ring €Ina gap mrr;, (in,

IPiston Irm.g

tem 2L.2L-T

N ', 0,30 -'0,5:7 0,35 - 0.62

1 _ ' _ 0 . _ ' ' - + - 1 _ ( 0 _ ' 0 _ ' ' _ ' _ 8 _ " _ - _ 0 _ . _ . 0 _ 2 . _ 2 _ 4 _ ) 1 (9,0138 - ,O_0244}

O ,Z 'O - '0 .52 0.20. - 0.47(0.007 9 - 0_0.205) ( 0 , 0 0 7 9 ' - 0_01 85]

O .2

1.1 1 2 (0.044) 1,07 (0_042)

1,12 \0,0441,

0,20 - 0,5.2(0,0079- 0.0205)

I------~~---~--------c

1.3.0 (O.05·'-to,1

Max~mum NQ,2

Oil

If the gap exceeds the speclfiad maxlrnurn, re:plac€! the

piston ring.

If the gap· exceeds the specified maximum E!"IEtnwith ~

new piston Ir.ilflg,. rebore theevllnder a nd use 'an o/s pis tonring. .

5.. CHECK PISTON PIN FIT

At 60 - 70< !C n 40 - 158tlF) YDU should be able to push

the pin into the piston with your thumb,

If the pin can be installed at a normal temperature, replace

the piston and pin,

6. INSPECli CONN ECl"ING ROns

~,a)' Using a rod allqner, check. the Connecting rod allqri-

merit.

• C heck for bend,

Malx.imum bend:

0".05 mm (O.OOZO in.l per 100 mm (3.94 in.]

• Check for tw~st-

Maximum twist:0.15 rnm (0.0059 ln.l per 100 mrn (3,.'94 in.l

If the rod is bent 01 " twisted, replac€! the connectinq rod.



ENGINE MECHAN ICAL - Cy"lnder Blo 'c;:1<

t;M2'174"

3.

{b} M e a s _ w l ! 1 ' e thG oil ¢learaVlce b~1we,Bn the r o d bushing

and pistcn cln .

• Using an lnsJde dial indicator, measure the insidediameter of the rod bushing .

• Using 1 3 , micrometer, measure the diarrreter o,f thepiston pin.

e Subtract the, piston pin diameter hom the rod

bushing inside diameter.

Stam1ard on cle;~lifance: 0.004 ~ 0.012 mm{O.0002 - 0,00005 il1.~

Maximum oil clearance: 0'.05 mm (0.0020 in.)

If the oil ctaerance is greater than rnaxirrrum, replace therod bushing.

R EP lA C E,M EN T O F CON N EC TIN G HO DBUSH.ING

1 . R EMOVE RO D 'BU SH IN G

Using SST and a press. press out the bu.sh ing ,

SST 009222-4001 'I

2. I'NSTA,LL N.EW ROD BUSHING

ta} A.llg,11he oil IriOIBS Qf the bush ing and connecting red,

(b), Using SST and a press,' press in the bushing,

SST 09222-40011

HONE ROD BUSHING ,AND, CHECK PISTON P'tN FIT liNCON,NECTING ROD

is!) Using a pin hQle grinder, hone the bushif,g and checkthat the: oil claaranoa is wiJhrn standard speclfication,

Standard oil clearance: 0,004 - 0.0'1,2 mm

(0.0002- 0.0005 w n . 1

(.b) Check rhe pis.ton pin fit at normal room temperatura,

Coat the piston pill witl1 engijne oil and push it intothe roo with your thumb.



I:NG.INE MECHANICAL - Cylinder Block EM-61

I

-$-

INS,PECTION AND REPAIR OF CRANI{SHAFT

1., INSPECT CRANKSHAFT

(8 ) Placethe crankshaft on V-blocks.

~b) Using a dia~ indicator, I11S.1lSLlre- the circle runout atthe center jouma~, ' .

Maximum elrela runnut: 0 . 1 ' 1 mm (0.039 in.)

I f the circle runout is, gre-ater than maximum, replace thee ra n k sh aft

(c) Using a micrometer, measure th e diameter ,o f the

main Journal and crank pin,

Standard ,~iame1i:er'(Standard sized bearing I , :Ma,in j:ournal 61.986 - 62.000 mm

(2.440·3 - ,2.4409inJ

Crank pin L. 2l 52..988- 53.000 mm

(2.'0861 - 2.086:6 ln.)2L-T 5,4.968 ~. 56.000 mm

12.1649 - 2.1654 inJ

!d} Check the main journal and crank pin for taper andcut-e F~roul!d as shown,

Max.imurn taper and out-ef-reund:

0.02 mm (0.0008 ln.]

' If t il le oil cie'i;lrapce even when new bear-ing s sre used , !S

greater than specified, regrind or replace -,he cr~nk5haft.

2. GRIND AND HONE MAl N JO 'U !RNAL AN D-/OR CRAiN,KPIN

Grin,cIand hOIl€: the main journals and/or c.l 'ank puns to theundelrsiz!ild finished 'dlarneter.

Main jcurnal finish~d diiametet:

UI!80 ..25 61.736 - 61.750 mm

(2.4305- 2,,4311 ln.]

U/S, 0 ..50 61..386 - 61.500 r n m(2.4167 - 2.4213 ~ nJ

Cran!k pin frnished diameter:U/S 0.25 L, .2L, 52,738 - 52.750 mm

(2.0763 - 2.0768 in.)2L·T 54,738 = 54.750 mm

12.1550 - 2.'1555 ln.]

U/S 0.50 L, 2l 5,2.488 - 52.500 mm~2.06'65- 2.0669 in,)

2L-T ,54.48,8- 54.5,00 romt2..1452 - ~.1457 ln.l

Instal'l new rnaln jOLJma ,1 and/Or crank pin undersize bear-lnqs,



BORING OF CY·UNDERS

EM-t:i2 ENGI NE MECHANICAL ~. Cylinder Block

t 34 rnrn2L, zt.T 13 mrn

1. SELECT PISTON AND PISTON RING

Piston diameter:

Standardsi.ze L

2L, 2L- T

89.955 - 89.985 mm(:3.541·5 .~. 3.5421 in,)

91.940 - 91.970 rnm

(3.6197 - 3J:i,209 ln.l

90~455- 90.485 mm13.5612 - 3.5624 in.l92..440 - 92.470 mrnt3.6394 - 3.6405 illl.)

Oversize L

2L.2L-T

Aepl.aG~ '@IIthe pistons.

R·epia ce the pj s t o 1 1 rings with ones rna teh in 9 the pisto n

2. CALCULATE AMOUNT TO BOHE CYLIINDE:R

( a ) Us.ing;;;lirnictornater, measure the piston diameter a

" igd l tang l€ to the piston PhF l hole center line 34 rn{, .34 inJ or 23. mm W.91 in.) b.elow the skirt bottoedge ..

(bl Calculate the arnount each cylinder I,sto be rebcrsastcltows:

Size to be rebored = P +C - H

P '"""Pis.ton diameter

C =P~stonclearance

t, 0,035- 0.055:mrn(0.0014 - 0.002·2 in.)

.2L, 2L~T 0.050 >= 0.070 mrn

(0.0020 - 0.0028 ln.lH =Allowance for honlin·g

Less than 0.02 mill (0.0008 bd

3. eOR,EAND HONE cvu NDERS TO CALCliLATED

IlIMENSJONiS

Maximum honing: 0.02 mrn ( O . O O C H 3 . in.}

CAUTlONI: EXC;E!.ss honing will destroy the finish

roundness.



EN mN E M ECH A N ICAL- Cylinder Block EM·53

REPLACE M ENT OF CRAN KS HAFT 01L SEALS

Cl:.I'tPosition

~~

NOTE: There are two rnetnods 0" oil sea t replacement.

1. REPLACE CReANKSHAFT FRONT OIL SEAL

If nll pump body is removed from cylinder block:

(a) UIiing a screwdrlver and hammer; a r r i V e out tile oil

seal ,

{b} IJsin9c' SST and a hammer .. drive in a new ell seal.to

the de:pth of 0_5 mm (0,020 in,) from the oili pump

body edge,

SST OH214-600 10

Ie ) Apply MP gr4;:N;lseo the ail seal.

If oll pump body is, ,nstalledto cylinder block:

{a l Usingl a k nif e', Gut off the oil sea! lip.

(b) Using a .screwdriver, ~ : ) l F y put the ell seal.

CAUTION: Be carefut not to d.ama'ge the erarrkshatt,

Tape the serewdrlver,

(c~ Apply MP gl'-ease 'to a new oil seal.

(d) Using SST and a hammer, drive in the nil seal to a

depth 'of 0,5 mm (0,020 ln.l from the o i , l pump body

edge.

SST 0'921.4-60010

2. REPLACE CRANKS'HAFT REAR Oil SEAL

11 tear oil11sea l retainer is rarnoved frorn cylinde'r bku: :k. :

{a } Using a screwdriver and narnrner , drive out the oil

seaL



ENGINE MECHANICAL ~ Cylif1der Block

C\ :dP os i~ ipn

~:~

\.

\, EM 1" 16 B _

~bl Usilng SST and a hammer, drive in a new o il seal uilt~1its surface is Husb with the rear oil seal re ta in er e dg e,

SST 09223-63010

{ c l A pply M P 9reas'e' to tha oil-seal.

If rear nll seai retaii i1er is, instaUed to cyHnder bloe'I(:

(a) Using a knife, aut off the: oil seal, Hp.

(b) Using a screwdnvar. p l F Y out the oil seal,

CAUTtDN: 'Be careful not to damaqe the crankshaft ..

Tape ttle screwdriver.

~ C ; ) A pplY ' M P gr:ea s,e to a newoMse~L

(d) UsIng, SST a nd ,8 hammer , drive in the ,oil ! ; l o B E I ' I until its

sur face is fh,J.!;ihwith the rear oil seal retainer edge.

SST 09223'-630100

,ASS'EM BL Y 0 F PISTON A,N 0 ,CONN ECTI NG

ROiDASSEMBLY

1. ASSEMBLE PISTON,AND CONNECT'NG ROO

(a} lnstall 1 :1 new snap ring 01 1 one side of the pis.toll p~n

hole.

{b} 'GraduaHy heat the piston, 'to about 60 - JODe ('40 -

1 6 S : < > F ) ,



.EN.GINE. MEC!HANIC:A.L- Cylinder Block

F ro nt M awk

L,2L .2.L.T

Frofit Mar~ Front Mark

~

r .,. ", v

\\<M;l""282 EM~ 'lo·, J

·r

Ringr:nds

h:;} Ailgn the front marks of tlhe piston and COM9cting

rod, <lindpush in .th e piston pin W_ith y"Our thumb,

{d } Insta II a !'lew sn.ap r.~ngo n th e ot tl e r sjd e ()'~ the: phrton

pin hole.

2., INS,TAlL PISTON RINGiS

(a) U.sing , < ' 1 ring l;!)I;p·~nder, install thG: piston rings with

the. · j ; :Ode marks tacing u.pwEI'r{L

NOTE.: Wh€r1 rrHlsembling. the ell ring and expander coil,

Insure that the expander eoll jointIs at theepposite side ofthe ringl€lntl!il,

(b) Po s l t lo n the p isto n dn9550 tha t the dng end 9aps~.re,

as shown.

CA,UTIOINl: Do not align the· ,e'nd gaps.

INSTALL BEA.FUNGS

!rl!lsta II the beatri ngi nserts i~thl ~;rCIOnnacting rods .a nd rod

caps,



ENG i NE M EC .H AN IC A,L - Cyl ind,er Block

.0 I ~ \ _ ;- \.0.

q2. INSTALL MAIN BE ;A ,R INGS

Install the bearinq in the, cylinde'[ block and bearing, caps.

CAUTION: Install.the bearing wlith the oil hole in the

bloc.k.

3, IN,·STAll UPPER THRUST WASHERS

lnstall the thrust washes under the N C L 3 main b-Baringcapposition o f the tl~O Gk with ' th,e eilg,roQve:s facing outward,

4. PLACECRANKSHAFT ON CYLINDER BLOCK

5. INSTA,lL MAIN BEARING CAPS WITH LOWER

THRUST WASHEIRS

NOTE: EaChbearing cap Is numbered.

{al Install the thrust washers on the No. 3 bearing capwith the o'il ~roov-es facing outward.



ENGINE M ECHIANICAL- Cylind.rilr Block EM~6

Ex.No.3 Beari!llg G~p No, 3 Bel;lrin.gCap {b) lnatall the tH~arir)9 caps in their proper location.

(c) Apply a light coating of enqlne oil on the threads and

heads under of the cap holts,

{d} InsM11and ti.ghten the cap bolls tn two or threepasses, Sind in the sequence shown.

Torque: 1,050 kq-nm (76 ft-Ib, 103N'm)

{ej Check that the crankshaft turns smoothly.

(f ) Check the crankshaft thrust clearanee.

(Sa,a pagB EM~53)

6. INSTALL PISTON AND CON NECTING ROO

ASSEMBLY

{a) Cover 'th e ro d bolts withQ short pi~:cElOf hose to proted tha crankshaft kOf1l damage ' ,

(b} Us·ing a r~ng compressor, push the correcuv nurn-

bared piston and rod assernblv into each Gylinde

with the 'front merk of the piston fffcing forward,

7. IINSTALL C ON N E C T I N G ROD CAPS

(a) Match the numbered cap' with the numbered rod.

(b) Install the rod caps with the front mark facing for

ward.

W!0:150

F ro nt M ark

~I

~j- f\'.

' 1 1 ~ .

Front f\ilark- J I (1\

~I



k:.} Apply a ~~!;Intcoat of the engiif l lei oil on the threads andunder the rod nuts. .

(d} Install, ,Sindtighten the rod nuts altematatv in two orthree pa·5se~.

Torque: 600 I(g~(lm(43 fHb, 59 N'm)

(8 ) Check that the crankshaft turns smoothly.

m C hec k th e rod th w st ole a ra n ce ,(See page EM~5~)

EM~68 ENGJNE MECHANI,CAL - .cylinder Block

ASSEMBLY OF CYLINDER. BLOCK

(See page EM~50)

1. INSTALl R'EAROIL SEAL RETAINER

Install 8 new ga.sket and the retainer with· the four bolts,T orq u e: tile holts,

Terque :130 kg-em '(9f't-lb, 13 N·m)

2 . INS,TALL O IL 'PU M P'

(Se'l! s.teps ~ to 7 on pages IL.U-6,7)

3. INSTALL CYlIND,ER HEADISee ,steps 1 to 3, 5, 10 to 14 !;lInd 16on p'ages EM~4·

1(49)

4. REMOVE E.NGIINf STAND

5. IINST ALL REAR E.ND PLATE

l'nst!!}'11 a dust :seal and the end plate with the two bolts.

Torque the bolts.

Terque: 1120 keg-em (9 fl·lib" 12 N·,m)

6. INSTALL FL V'W HiE EL O R DRIVE P'LATE

Torque: 1,250 kg-em (90 f1~I.b,123 N·m)

Toyota 2L Engine Mechanical

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