SERVICE MANUAL

DAIHATSU

V116,V118,V119
TO INDEX

ENGINE MECHANICAL

CONTENTS
CYLINDER HEAD .............................. EM–02 INSPECTION OF PISTONS
COMPONENT ............................... EM–02 AND CONNECTING RODS ....... EM–48
REMOVAL PROCEDURE .............. EM–03 INSPECTION OF
DISASSEMBLY OF CYLINDER BLOCK .................... EM–55
CYLINDER HEAD ...................... EM–06 REPLACEMENT OF
INSPECTION ................................ EM–08 CYLINDER BLOCK .................... EM–55
ASSEMBLY OF BORING OF CYLINDER ............... EM–56
CYLINDER HEAD ...................... EM–15 INSPECTION AND
INSTALLATION OF REPAIRS OF CRANKSHAFT ...... EM–57
CYLINDER HEAD ...................... EM–17 REPAIR OF CYLINDER BLOCK .... EM–58
TIMING GEARS AND CAMSHAFT ... EM–23 INSPECTION OF VALVE LIFTERS
COMPONENT ............................... EM–23 AND VALVE LIFTER BORES ...... EM–61
REMOVAL OF TIMING GEARS REPLACEMENT OF CRANKSHAFT
AND CAMSHAFT ....................... EM–24 FRONT OIL SEAL ...................... EM–62
INSPECTION AND REPLACEMENT REPLACEMENT
OF TIMING GEARS AND REAR OIL SEAL ......................... EM–63
CAMSHAFT RELATED PARTS ... EM–31 INSPECTION AND REPAIR
INSTALLATION OF TIMING OF FLYWHEEL ........................... EM–64
GEARS AND CAMSHAFT .......... EM–32 ASSEMBLY OF PISTON AND
CYLINDER BLOCK ........................... EM–38 CONNECTING ROD .................. EM–65
COMPONENT ............................... EM–38 ASSEMBLY OF
DISASSEMBLY OF CYLINDER BLOCK .................... EM–67
CYLINDER BLOCK .................... EM–39 TIGHTENING TORQUE ..................... EM–75
SST (Special service tools) ............. EM–76
VEM00001-00000
EM–2
CYLINDER HEAD
COMPONENT

!7

T : 7.5 (0.76)

o
u
T : 25 (2.55)

t
i y
r q T : 49 ± 4.9 + 90˚ + 90˚
(5.0 ± 0.5 + 90˚ + 90˚)

!0- w
!1
!2
!3★
!4

!5
!0
!6
e★

T : Tightening Torque
Unit : N·m (kgf-m)
★ : Non-reusable parts

q Cylinder head bolt !0 Valve stem cap

w Cylinder head !1 Valve spring retainer lock
e Cylinder head gasket !2 Valve spring retainer
r Valve guide bush !3 Valve stem oil seal
t Valve rocker support !4 Compression spring (Inner)
y Valve rocker arm No. 1 !5 Compression spring (Outer)
u Compression spring !6 Valve
i Valve rocker arm No. 2 !7 Cylinder head cover
o Valve rocker shaft

VEM00002-00001
 EM–3
REMOVAL PROCEDURE 15. Slacken the three attaching bolts (two normal
1. Disconnect the battery ground cable terminal bolts and one hexagon bolt) and five nuts of
from the negative terminal of the battery. the intake manifold in the order shown in the
2. Drain the engine coolant. (Refer to MA sec- figure.
tion) 16. Remove the three attaching bolts and five nuts
3. Disconnect the front exhaust pipe from the ex- of the intake manifold while holding the intake
haust manifold. manifold by hand.
4. Disconnect the accelerator cable from the
venturi and remove the accelerator cable
bracket.
5. Remove the fuel inlet hose from the fuel inlet
pipe of the injection pump.
6. Remove the fuel inlet pipe bracket attaching
bolt.
7. Remove the fuel outlet hose at the fuel filter
side.
8. Remove the fuel filter bracket together with the
fuel inlet pipe from the intake manifold by re- VEM00005-00004
moving the two attaching bolts.
17. Disconnect the oil level gauge guide bracket
9. Remove the injection nozzle.
from the stud bolt.
(Refer to the injection nozzle removal proce-
18. Remove the intake manifold.
dure described in the section of the MA sec-
19. Remove the gasket from the cylinder head.
tion.)
10. Remove the accelerator cable bracket from
the intake manifold by removing two attaching
bolts.
11. Remove the blow-by gas hoses.
12. Disconnect the accelerator connecting rod.

VEM00006-00005

20. Remove the vacuum pipe from the engine.

21. Disconnect the connector which is connected
to the water temperature sender gauge.

VEM00003-00002

13. Loosen the venturi and flange attaching bolts

and nuts evenly.
14. Remove the venturi flange and two gaskets by
removing the two attaching bolts and nuts.

VEM00007-00006

VEM00004-00003
 EM–4
22. Loosen the attaching nuts of the water outlet 27. Loosen the exhaust manifold attaching bolts
housing evenly. and nuts evenly.
23. Remove the water outlet housing attaching
nuts.
24. Disconnect the water by-pass hose from the
water pump. Remove the water outlet assem-
bly with the by-pass hose.

VEM00011-00010

28. Remove the exhaust manifold, No.2 heat insu-

lator and gasket by removing its attaching
bolts and nuts.

VEM00008-00007

25. Remove the drive belt tension adjusting bar

attaching bolts which are connected to the
cylinder head.

VEM00012-00011

29. Loosen the cylinder head cover attaching nuts

and bolts.
30. Remove the cylinder head cover by removing
the attaching nuts and bolts.
VEM00009-00008

26. Remove the exhaust manifold heat insulator

by removing the attaching bolts and six spac-
ers.

VEM00013-00012

VEM00010-00009
 EM–5
31. Removal of rocker shaft assembly 32. Removal of cylinder head
(1) Loosen the valve clearance adjusting (1) Loosen the cylinder head bolts evenly
screw lock nuts and loosen the valve over two or three stages in the sequence
clearance adjusting screw. shown in the figure.
(2) Loosen the attaching bolts of the valve CAUTION:
rocker support evenly in the sequence • Failure to loose the bolts in the order
shown in the figure. shown may result in warpage or cracking
(3) Remove the attaching bolts of the valve of the cylinder head and cylinder block.
rocker support.
(4) Remove the valve rocker shaft assembly. (2) Remove the cylinder head bolts.
11 5 3
15 17 13
9 2
7
8
1 10
16
18
14
12
6
4

VEM00014-00013 VEM00017-00016

(5) Remove the valve stem caps. (3) Lift off the cylinder head and place the re-
NOTE: moved cylinder head on wooden pieces or
• Place the removed stem caps in the cor- the like so as to protect the cylinder head
rect order so that the attached positions from damage.
may be recognized. CAUTION:
• Never scratch the gasket surface of the
cylinder head and cylinder block.

NOTE:
• If any difficulty is encountered in separating
the cylinder head from the cylinder block,
pry out the cylinder head from the cylinder
block, using a screwdriver or the like as
shown in the figure.

33. Remove the cylinder head gasket.

VEM00015-00014

(6) Pull out the push rods.

NOTE:
• Place the removed push rods in the correct
order so that the attached position may be
recognized.

VEM00018-00017

VEM00016-00015
EM–6
DISASSEMBLY OF CYLINDER HEAD
1. Removal of valves
Remove the valve by removing the valve
spring retainer locks while compressing the
valve spring by a valve spring compressor.
WARNING:
• Protect your eyes by wearing safety gog-
gles.

NOTE:
• Compress the valve spring, using the fol- VEM00020-00019
lowing SST.
4. Cleaning upper surfaces of piston and cylin-
SST: 09202-87001-000
der block
(1) Remove the carbon deposit at the piston
• Place the removed parts in order and ac-
upper surfaces, using a gasket scraper.
cording to whether they are the intake or
(2) Remove any remaining portion of the cylin-
exhaust valve related parts.
der head gasket from the upper surface of
the cylinder block, using a gasket scraper.
09202-87001 Blow off any oil or coolant, etc. at the bolt
holes, using compressed air.
WARNING:
• Protect your eyes by wearing safety gog-
gles, when using compressed air.

NOTE:
• When blowing off oil, etc., use a cloth or
the like to prevent oil or coolant from
splashing

VEM00019-00018
VEM00021-00020
2. Remove the valve stem oil seals, using suit-
able pliers or the like.
CAUTION:
• Never reuse the removed oil seal.

3. Remove the valve spring seats.

“To be continued”
 EM–7
5. Cleaning of cylinder head combustion cham- (3) Cleaning of valve guide bushes
ber Clean the inside of all valve guide bushes,
(1) Remove carbon deposits at the combus- using a cloth or the like with kerosene or
tion chamber, using a wire brush. light oil.
CAUTION:
• Be very careful not to scratch the cylinder
head.

VEM00025-00024

7. Cleaning of valves
(1) Remove carbon deposit from the valve,
VEM00022-00021 using a gasket scraper.
6. Cleaning of cylinder head (2) Wash and clean the valve thoroughly with
(1) Remove any remaining portion of the gas- a wire brush, using kerosene or light oil.
kets from the cylinder head, using a gas-
ket scraper.
CAUTION:
• Be very careful not to scratch the cylinder
head.

VEM00026-00025

VEM00023-00022

(2) Wash the cylinder head with kerosene or

light oil with a soft brush.

VEM00024-00023
EM–8
INSPECTION
1. Ensure that no crack a exists on the cylinder
Seizure or
head, using a penetrant checker or other
damage
checking instrument.
2. Check that the warpage of the cylinder head
surface shown in the right figure is within the
specified value, using a straightedge and a
thickness gauge.
Specified maximum warpage
Cylinder block gasket surface:
0.2 mm VEM00028-00027
Intake manifold gasket surface:
(2) Visually inspect the valve head for melting
0.2 mm
or damage.
Exhaust manifold gasket surface:
If the valve head exhibits any melting or
0.2 mm
damage, replace the valve.
If the contact surface is rough, grind the
valve seat contact surface with a valve
refacer.

Melting or damage

VEM00029-00028

(3) Grind the valves only enough to obtain a

smooth contact surface with the valve
seat, while maintaining the specified
angle.
Specified valve face angle: 45.5°

VEM00027-00026

3. Inspection and grinding of valve

(1) Visually inspect that the valve stem for
seizure or damage.
• If seizure or damage is found, replace the
valve and valve guide bush as a set. 45.5˚
However, this replacement should be per-
formed only after checking the valve seat
and cylinder head for crack.
• The valve guide bush hole must be used VEM00030-00029

for refacing the valve seat. Hence, if the

valve guide bush hole exhibits roughness
due to seizure, etc., rectify the hole with an
adjustable reamer.

“To be continued”
 EM–9
(4) Valve head stock thickness
Ensure that the valve stock thickness be-
tween the position at the specified diame-
ter on the mushroom section of the valve
shown in the right figure and the lower sur-
face of valve is within the specified value.

Wear measurement at
tip-end of valve stem

Specified
Specified Specified
diameter
overall length minimum length
Measurement of valve
head stock thickness Intake valve 126.55 mm 126.15 mm
Exhaust valve 126.42 mm 125.92 mm
VEM00033-00032

4. Inspection of oil clearance between valve

Specified Standard Specified minimum
stock thickness
stems and valve guide bushes
diameter thickness
(1) Measure the bore diameter of each valve
Intake valve 43.9 mm 2.35 - 2.55 mm 2.0 mm
guide bush at a total of six points, as
Exhaust valve 37.0 mm 2.35 - 2.55 mm 2.0 mm shown in the right figure.
VEM00031-00030
Specified value
Intake valve : 9.01 - 9.03 mm
(5) Checking of valve tip end for wear
Exhaust valve: 9.01 - 9.03 mm
Ensure that no uneven wear exists on the
tip end of the valve.
If uneven wear exists, replace or correct
the uneven wear with a valve grinder, while
assuring that the overall length is within
the allowable limit.

Wear

VEM00034-00033

(2) Measure the external diameter of each

valve stem at a total of six points, as
shown in the right figure.
Specified value:
VEM00032-00031
Intake valve : 8.968 - 8.984 mm
Exhaust valve: 8.954 - 8.970 mm
(6) Overall length
Ensure that the valve overall length of
each valve is more than the specified mini-
mum overall length.

VEM00035-00034

“To be continued”
EM–10
(3) Calculate the clearance between the valve (3) Drive the valve guide bush into the cylin-
guide bush and the valve stem. Ensure der head from its upper surface, using the
that the clearance is within the specified following SST until the protruding amount
value. becomes the specified value.
Specified oil clearance SST: 09201-60011-000
Specified Specified
Specified protruding amount of valve guide
oil clearance maximum clearance bush
Intake 0.026 - 0.062 mm 0.10 mm Intake valve stem: 18.8 - 19.4 mm
Exhaust valve stem:
Exhaust 0.040 - 0.076 mm 0.12 mm
18.8 - 19.4 mm

If the oil clearance fails to meet the speci-

fied value, replace the valve and valve
stem guide with new ones.
VEM00036-00000

5. Replacement of valve guide bushes

(1) Drive off the valve guide bush from the
combustion chamber side, using the fol-
lowing SST in combination with a hydraulic
press.
SST: 09201-60011-000 VEM00039-00037

(4) Be sure to finish the inner diameter of the

valve guide bush in order to obtain the
specified oil clearance between the valve
stem and the guide bush, using a reamer.
Ream only enough to remove burrs made
during the installing procedure.
CAUTION:
• Do not ream the valve guide bush exces-
sively.

VEM00037-00035

(2) Measure the valve guide bush inserting

hole of the cylinder head, using a caliper
gauge.
If the bore diameter is more than specified
value, replace the cylinder head.
Standard diameter:
Inner diameter of valve guide bush in-
serting hole: 14.00 - 14.018 mm
VEM00040-00038

VEM00038-00036
 EM–11
6. Valve seating check 7. Valve seat refacing
(1) Apply a thin film of Prussian blue (or white (1) Refacing procedure of valve seat
lead) to the valve seat. CAUTION:
(2) Insert the valve into the valve guide bush. • The refacing must be always performed
(3) Push the valve against the valve seat. while checking carefully the valve contact
CAUTION: position and contact width.
• Never turn the valve while it is being
pushed against the valve seat. q Using a 45-degree cutter, recondition
the roughness on the valve-to-valve
(4) Ensure that the valve-to-valve seat contact seat contact surface, only enough to
is made centering around the reference obtain a smooth surface.
line and that the contact width is within the w Using a 30-degree cutter, cut the valve
specified value over the entire circumfer- seat in such a way that the circumfer-
ence. ence of the surface refaced by the 45-
Reference line position from end surface of degree cutter may become 2.1 ± 0.1.
valve shown in right figure
Intake valve : 2.45 ± 0.1 mm q
Exhaust valve: 2.45 ± 0.1 mm 45˚
w
Reference 30˚
A line

Reference line Specified

width

VEM00043-00041

e Using a 65-degree cutter, cut the valve

seat in such a way that the circumfer-
VEM00041-00040 ence of the surface refaced by the 45-
Specified valve-to-valve seat contact width: degree cutter may become 2.1 ±
Intake valve : 1.89 - 2.89 mm 0.2 mm.
Exhaust valve: 2.05 - 2.45 mm r Using a 45-degree cutter, remove
burrs produced during the refacing by
If the valve-to-valve seat contact width and the 30-degree and 65-degree cutters.
reference line fail to meet the specification,
replace or repair the valve or repair valve w
q
seat. 65˚
45˚
Reference
line

Specified
width

VEM00044-00042

VEM00042-00039
EM–12
(2) Hand lapping of valve (3) Ensure that the tension of the valve spring
q Perform hand lapping of the valves is within the specified value when the
and valve seats, using abrasive com- valve spring is compressed to the speci-
pound. fied installed length.
w Clean the valve and valve seats after Specifications
the hand lapping of the valves. Installed height Minimum tension
e Check the valve seating condition
Inner spring 38.19 mm 135 N (13.8 kgf)
again.
Outer spring 41.69 mm 278 N (28.3 kgf)

If the installed tension fails to meet the

specified value, replace the valve spring
with a new one.

VEM00045-00043

8. Valve spring inspection

(1) Ensure that the free length of the valve
spring is within the specified value, using
vernier calipers.
Specified valve spring free length VEM00048-00046
Inner spring : 45.28 mm or more 9. Valve rocker shaft assembly inspection
Outer spring: 50.73 mm or more (1) Disassembly of valve rocker shaft
q Remove the hexagon screws which are
If the free length fails to meet the specified provided on both ends of the valve
value, replace the valve with a new one. rocker supports.
(2) Ensure that the squareness of the valve
spring is within the specified value, using
a steel square and a thickness gauge.
Maximum squareness: 2.0 mm

If the squareness fails to meet the speci-

fied value, replace the valve with a new
one.
Out-of squareness

VEM00049-00047

Free length

VEM00047-00045
 EM–13
w Pull out the valve rocker shaft w Measure the inside diameter of the
CAUTION: valve rocker arm, using an inner dial
• Be sure to place the disassembled parts in gauge.
order to identify the assembled position of Then, record the measured data.
each part. Standard diameter: 18.512 - 18.533 mm

e Measure the outer diameter of the

valve rocker shaft where the respective
valve rocker arm is fitted.
Standard diameter: 18.472 - 18.493 mm

VEM00050-00048

(2) Checking of valve rocker arm assembly

q Visually inspect that no remarkable
damage exists on the valve rocker
shaft, such as wear and deformation.
If a remarkable damage exists, replace VEM00052-00050

the valve rocker shaft with a new one. r Ensure that the valve rocker shaft-to-
w Check the stem cap contact surface of valve rocker arm oil clearance is within
the rocker arm for wear. the specified value by subtracting the
If the stem cap contact surface is measured valve rocker shaft outer di-
worn, replace the rocker arm with a ameter from the measured inner diam-
new one. eter of the valve rocker arm.
e Check the push rod contact surface of
Standard Maximum
the valve clearance adjusting screw. If Specified oil clearance oil clearance
the push rod contact surface of the value
0.019 - 0.061 mm 0.10 mm
valve clearance adjusting screw is
worn, replace the valve clearance ad- If the clearance fails to meet the speci-
justing screw with a new one. fied value, replace the valve rocker
shaft and arm.
VEM00053-00000

(4) Ensure that the free length of the compres-

sion spring is within the specified value,
using vernier calipers.
Specified compression spring free length:
28 mm

VEM00051-00049

(3) Inspection of valve rocker arm-to-shaft oil

clearance:
q Disassemble the valve rocker shaft as-
sembly and place the disassembled
valve rocker shaft-related parts in
order.
VEM00054-00051

“To be continued”
EM–14
(5) Inspection of thrust washer
q Ensure that there is no evidence of
seizure or other damage.
If any evidence exists, replace the
thrust washer with a new one.
w Ensure that the thickness of the thrust
washer is more than the specified
value.
If the measured value fails to meet the
specified value, replace the thrust
washer with a new one.
VEM00056-00053
Specified thickness: 2.0 mm
10. Inspection of push rods
(1) Ensure that the push rod exhibits no bend
that exceeds the specified value by mea-
suring the circle runout at the middle posi-
tion of the push rod, using a V-block in
combination with a dial gauge as shown in
the figure.
Specified maximum circle runout:
0.50 mm

Replace the push rod with a new one if the

VEM00055-00052 circle runout fails to meet the specification.
(6) Inspection of valve rocker support (2) Check that the tappet and valve rocker
Visually inspect the valve rocker support arm attaching parts for wear or damage.
for any score or other damage. If wear or damage exists, replace the push
If damage exists, replace the valve rocker rod with a new one.
support with a new one.
(7) Assembly of valve rocker shaft assembly
q Liberally apply engine oil to the sliding
part of the valve rocker shaft-related
parts.
w Install the valve rocker shaft into the
valve rocker support, which is provid-
ed with the valve rocker shaft attaching
hole, in such a direction that the oil slit
of the valve rocker shaft faces down-
ward.
VEM00057-00054
e Install the attaching screw of the valve
rocker shaft and tighten the screw to
the specified tightening torque.
Specified tightening torque: 7.5 N·m
(0.76 kgf-m)

r Install the valve rocker arms, thrust

washers, spring and valve rocker sup-
ports as shown.
t Install and tighten the lock screw of the
valve rocker shaft to the specified
tightening torque.
Specified tightening torque: 18.5 N·m
(1.89 kgf-m)

“To be continued”
 EM–15
11. Inspection of intake and exhaust manifolds
Ensure that no warpage exists on the cylinder
head attaching surface of the manifold in such
a direction as shown in the right figure, using
a precision straight edge and thickness
gauge.
Specified maximum warpage: 0.20 mm

Replace the manifold with a new one, if the

measuring warpage exceeds the specified
maximum warpage.
VEM00059-00056

r Degrease the tight plug attaching sur-

face of the cylinder head and tight
plugs, using washing solvent.
t Apply liquid sealer to the outer periph-
ery of the tight plugs.
y Install the tight plug into the cylinder
head to such a depth that the edge
surface of the tight plug is positioned
at the specified depth below, using a
suitable attachment.
VEM00058-00055 Specified depth: 0.2 - 0.8 mm
ASSEMBLY OF CYLINDER HEAD
CAUTION:
CAUTION: • Be sure to drive in the tight plug at right an-
• Prior to the installation, ensure that there is gles to the tight plug hole. Driving the tight
no excessive warpage at the cylinder block plug in a tilted state may cause water or oil
upper surface. leakage.
• Do not drive in the tight plug beyond the
1. Wash the all components with kerosene or specified extent.
light oil except rubber parts and sensors. Dry
them with compressed air. u Wipe off excessive liquid sealer from
WARNING: the tight plug driving position.
• Protect your eyes by wearing safety gog-
gles when using compressed air.

2. Replacement of tight plugs (only when it is

necessary)
(1) Removal of tight plug
q Make a hole by drilling at the middle of
the cylinder head plug.
w Make threads, using a tap.
e Screw-in the bolt to the thread made in
the middle of the tight plugs. VEM00060-00057

“To be continued”
EM–16
3. Replacement of stud bolts (3) Apply engine oil to a new oil seal lip.
(Only when it is necessary.) (4) Install the new oil seals on the valve guide
(1) Remove the stud bolts, using a stud bolt bush by pushing them down on the top of
remover. the valve guide bush by hand.
(5) Ensure that the oil seals are installed prop-
erly by turning them slightly.
If the oil seal can not be turned lightly,
push it to the valve guide bush side again
to seat it properly.
CAUTION:
• Do not turn the oil seal more than a half
turn.
• Replace the oil seal with a new one if the
oil seal can not be turned.
VEM00061-00058

(2) Clean the stud bolt holes of the cylinder

head with washing solvent and dry them
with compressed air.
WARNING:
• Be sure to protect your eyes by wearing
safety goggles, when using compressed
air.

(3) Install the stud bolts, using a stud bolt in-

staller. VEM00064-00061

(6) Install the valves into the cylinder block.

CAUTION:
• Do not remove the valve after the valve
end has been put once on the valve stem
oil seal. If the removal of the valve is re-
quired, be sure to replace the valve guide
bush oil seal with a new one.

VEM00062-00059

4. Installation of valves
(1) Apply engine oil to the valve spring seats
in order to affix the spring seats on the
cylinder block.
(2) Install the spring seat on the cylinder
head.
VEM00065-00062

VEM00063-00060
 EM–17
(7) Install the valve springs and spring retain-
er. Then, install the valve spring retainer
locks. While compressing the valve spring
using the following SST or a suitable
spring compressor.
SST: 09202-87001-000

09202-87001 Identification code

VEM00068-00065

w With each cylinder set at its top dead

center, using a dial gauge, measure
the protrusion amount of each piston’s
upper surface from the upper surface
of the cylinder block at two positions
VEM00066-00063 on each cylinder.
(8) Ensure that the valve retainer locks are in- CAUTION:
stalled properly by lightly tapping the • The measuring dial gauge must be at-
valve stem with a plastic hammer. tached perpendicular to the cylinder block
WARNING: gasket attaching surface.
• Protect your eyes by wearing safety gog-
gles.

e Select the correct cylinder head gas-

ket from the following table below,
VEM00067-00064 based on the highest value of the mea-
INSTALLATION OF CYLINDER HEAD sured piston protrusion amounts
1. Selection of cylinder head gasket among the eight points.
(1) If the cylinder head gasket only has been Maximum piston Head gasket
Selection mark
replaced, use a gasket of the same selec- protrusion value thickness
tion mark shown on the originally-installed 0.535 - 0.785 mm 1.5 1.5 mm
gasket. 0.785 - 0.885 mm 1.6 1.6 mm
(2) If the pistons, cylinder block, connecting
0.885 - 0.985 mm 1.7 1.7 mm
rods or crankshaft has been replaced, se-
lect the cylinder head gasket in the follow- VEM00069-00066

ing manner.
q Degrease the cylinder head gasket at-
taching surface of the cylinder block
with solvent.

“To be continued”
EM–18
2. Place the correct cylinder head gasket on the CAUTION:
cylinder block. • Do not apply the engine oil excessively.

(2) Install the cylinder head bolts to the cylin-

der head.
(3) Tighten the cylinder head bolts to the
specified tightening torque in the se-
quence shown in the figure.
Specified tightening torque:
49 ± 4.9 N·m (5.0 ± 0.5 kgf-m)
18 12 10 4 2 6 8 14 16

VEM00070-00067
Front
3. Place the cylinder head on the cylinder block.
CAUTION:
• Be very careful not to scratch the cylinder
head gasket attaching surface of the cylin-
der head during the installation.
• Ensure that the cylinder block attaching
15 13 7 5 1 3 9 11 17
hole of the cylinder head is dry before plac-
ing the cylinder block. Failure to observe VEM00073-00070

this caution may result in improper tighten- (4) Put an engine front side mark on the top
ing of the cylinder head bolts. surface of the cylinder head bolts as
VEM00071-00000 shown in the figure.
4. Checking of cylinder head bolt
(1) Ensure that no crack or other damage ex-
ists on the cylinder head bolt. Paint mark
If the bolt exhibits any damage, replace
the cylinder head bolt with a new one.
(2) Check the length of the cylinder head
bolts.
Ensure that the length of the cylinder head Front side of
bolt does not exceed the specified value. the engine
Specified value: 133 ± 0.5 mm
VEM00074-00071
If the length exceeds the specified value,
replace the cylinder head bolt with a new (5) Turn the cylinder head bolts 90 degrees in
one. the tightening direction in the sequence
shown in the figure.
Ensure that the paint mark provided on
each cylinder head bolt has been turned
90 degrees correctly.

VEM00072-00069

5. Tightening of cylinder head bolts

(1) Coat the threads and seating sections of
each cylinder head bolt with a small
VEM00075-00072
amount of engine oil.
“To be continued”
 EM–19
(6) Turn the cylinder head bolts 90 degrees (2) Ensure that the valve rocker support at-
further in the tightening direction in the se- taching holes are dry.
quence shown in the step above. If not, degrease the valve rocker support
Then, ensure that the paint mark provided attaching holes with washing solvent and
on each cylinder head bolt has been dry them with compressed air.
turned 90 degrees correctly from the pre- Failure to observe this procedure may
vious step. cause improper tightening torque.
WARNING:
• Protect your eyes by wearing safety gog-
Paint mark gles.

(3) Place the valve rocker shaft assembly on

the cylinder head.
(4) Install attaching bolts while aligning the
Rear side of rocker arm adjusting screws with the head
the engine section of the push rods.

VEM00076-00073

6. Installation of push rods

Insert the push rods in position.

VEM00079-00076

(5) Tighten the attaching bolts to the specified

tightening torque evenly in two or three
stages.
Specified tightening torque:
VEM00077-00074
25 N·m (2.25 kgf-m)
7. Install valve stem cap on the cylinder head.
(6) Apply engine oil to the sliding part of the
valve rocker shaft assembly.

VEM00078-00075

8. Installation of valve rocker shaft assembly

(1) Set the crankshaft in T.D.C. position by VEM00080-00077
aligning the T.D.C. mark provided on the
crankshaft pulley with one on the timing
gear case.

“To be continued”
 EM–20
9. Adjustment of valve clearance
Adjust the valve clearance to the specified
value specified below.
(Refer to the MA section for adjustment proce- r q u
dure.) y
Specified valve clearance (Cold)
Intake valve : 0.25 mm
i t
Exhaust valve: 0.40 mm w e

No. 1 cylinder: Top dead center at end of compression stroke

VEM00083-00080

(3) Install the heat insulator with the attaching

bolts temporarily.
(4) Tighten the attaching bolts to the specified
tightening torque in the sequence shown
in the figure.
No. 4 cylinder: Top dead center at end of compression stroke Specified tightening torque:
18.5 N·m (1.89 kgf-m)
VEM00081-00078

10. Installation of cylinder head cover

Tighten the cylinder head cover attaching w e
bolts and nuts evenly sequence shown in the
figure to the specified tightening torque. q
Tightening torque:
10.5 N·m (1.07 kgf-m)

5 2 4
VEM00084-00081

12. Installation of drive belt adjusting bar

(1) Install the drive belt adjusting bar with the
attaching bolts and tighten the cylinder
head side attaching bolt to the specified
6
3 1 tightening torque.
Specified tightening torque: 37.5 N·m
VEM00082-00079 (3.82 kgf-m)
11. Installation of exhaust manifold
(1) Install the new exhaust manifold gasket to (2) Install the alternator drive belt.
the cylinder head with the attaching nuts (3) Adjusting of alternator drive belt tension
and bolts. (Refer to the MA section for adjusting pro-
(2) Tighten the attaching bolts and nuts to the cedure.)
specified tightening torque evenly over
two or three stages in the sequence shown
in the figure.
Specified tightening torque:
47.5 N·m (4.84 kgf-m)

VEM00085-00082

“To be continued”
 EM–21
13. Installation of water outlet assembly 15. Install an engine oil level gauge to the oil level
(1) Install the water by-pass hose to the water gauge guide.
inlet and attach a new hose band. 16. Place the intake flange in such a direction that
(2) Install the water pump side new hose the arrow mark may face the intake manifold
band to the by-pass hose. side with a new gasket interposed.
(3) Connect the water by-pass hose to the 17. Install the venturi assembly to the cylinder
water pump. head on the intake flange with a new gasket
(4) Install the water outlet assembly with the interposed.
two attaching nuts with a new gasket inter- 18. Tighten the attaching bolts and nuts to the
posed. specified tightening torque evenly in two or
Tighten the nuts to the specified tightening three stages.
torque evenly over two or three stages. Specified tightening torque: 21.0 N·m
Specified tightening torque: 18.5 N·m (2.14 kgf-m)
(1.89 kgf-m)

(5) Attach a new hose band to the water

pump side.

VEM00088-00085

19. Install the fuel filter bracket with the attaching

bolts and tighten them to the specified tight-
ening torque.
VEM00086-00083 Specified tightening torque:
14. Installation of intake manifold 39.6 - 48.8 N·m (4.0 - 5.0 kgf-m)
(1) Install a new gasket to the intake manifold.
(2) Install the intake manifold with oil level 20. Install the fuel inlet pipe to the fuel filter with
gauge guide clamp to the cylinder head the union bolt with new gaskets interposed.
with the nuts, bolts and hexagon bolt. 21. Install the clamp bracket provided on the fuel
(3) Tighten the attaching nuts, bolts and hexa- inlet pipe to the injection pump bracket with
gon bolt to the specified tightening torque the attaching bolts.
evenly in two or three stages in the se-
quence shown in the figure.
Specified tightening torque: 18.5 N·m
(1.89 kgf-m)

7 4
6

1
3
VEM00089-00086
5 2 8

VEM00087-00084

“To be continued”
 EM–22
22. Installation of vacuum pipe

VEM00090-00087

23. Installation of injection nozzle, leakage pipe

and injection nozzle pipes
(Refer to the MA for the installation proce-
dure.)
24. Fill coolant.
(Refer to the MA section for refilling of
coolant.)
25. Check the engine oil level.
(Refer to the MA section for the oil level
checking method.)
26. Connect the battery ground cable terminal to
the negative terminal of the battery.
27. Start the engine. Ensure that no leakage of
engine oil or coolant exists.
28. Adjust the valve clearance.
(Refer to the MA section for the adjustment
procedure.)
29. Check and adjust the alternator drive belt ten-
sion.
(Refer to the MA section for the check and ad-
justing procedure.)
VEM00091-00000

“To be continued”
 EM–23
TIMING GEARS AND CAMSHAFT
COMPONENT

e q★

w
y
i

u★

!0
!2

t
!5 ★
!1

!3 ★

!4
!6
!7
@0
T : 294 (30)

@1
T : Tightening Torque
Unit : N·m (kgf-m) !9
★ : Non-reusable parts
!8 ★

q Timing gear case gasket !2 Thrust plate bolt

w Valve lifter guide set bolt !3 Timing gear cover gasket
e Timing gear case S/A !4 Timing gear cover S/A
r Idle gear shaft W/nozzle !5 Oil seal
t Injection pump drive gear !6 Crankshaft pulley
y Valve lifter !7 Oil pump pipe
u Camshaft bearing !8 Gasket
i Camshaft !9 Oil strainer
o Idle gear @0 Plate
!0 Idle gear thrust plate @1 Oil pan
!1 Crankshaft timing gear

VEM00092-00088
EM–24
REMOVAL OF TIMING GEARS AND 8. Remove the fan, fluid coupling (if equipped)
CAMSHAFT and water pump pulley by removing the at-
1. Disconnect the negative terminal of the bat- taching bolts.
tery ground cable from the negative terminal
of the battery.
2. Set the piston of the No.1 cylinder to the top
dead center at the end of the compression
stroke.

VEM00096-00092

9. Remove the heat insulator by removing the

three attaching bolts.
10. Loosen the exhaust manifold attaching bolts
and nuts evenly in the sequence shown in the
VEM00093-00089
figure.
3. Remove the front exhaust pipe. 11. Remove the exhaust manifold by removing the
4. Loosen the attaching bolts of the fan and nut and bolts.
water pump pulley. 12. Remove the exhaust manifold gasket.
5. Loosen the alternator attaching bolts and nut.
6. Remove the alternator drive belt.

VEM00097-00093

13. Remove the cylinder head cover by removing

VEM00094-00090
the attaching nut and bolts evenly.
7. Remove the alternator with alternator bracket
by removing its attaching bolts.

VEM00098-00094

VEM00095-00091
 EM–25
14. Loosen the valve clearance adjusting screw CAUTION:
lock nuts and loosen the adjusting screw. • Do not install the bolt with a tool or apply a
15. Loosen the valve rocker support attaching great force so that the valve lifter may not
bolts evenly over two or three stages in the se- be damaged.
quence shown in the figure.
16. Remove the valve rocker shaft assembly by 20. Ensure that the side wall section of the valve
removing the attaching bolts. lifter is visible from the lower side of the locat-
ing valve attaching holes.

VEM00099-00095

17. Pull out the push rods from the cylinder head. VEM00102-00098

NOTE: 21. Removal of crankshaft pulley

• Be sure to note the assembled position of (1) Remove the crankshaft pulley attaching
each push rod. bolt while preventing the crankshaft pulley
from turning, using suitable two bolts and
a bar or the following SST shown below.
SST: 09330-00021-000

VEM00100-00096

18. Remove the valve lifter locating bolts shown in

the figure.
VEM00103-00099

(2) Remove the crankshaft pulley from the

crankshaft, using the following SST, with
an adapter placed in between the SST
and the crankshaft, as shown in the figure.
SST: 09213-31021-000

Adapter

VEM00101-00097

19. Reinstall the upper side of the valve lifter lo-

cating bolts by hand, while aligning the bolt
holes with the long holes provided on the
valve lifter in order to hold the valve lifter at a
position higher than the cams of the camshaft. 09213-31021

VEM00104-00100
“To be continued”
 EM–26
22. Removal of timing gear cover
(1) Loosen the attaching bolts of the timing
gear cover evenly.
(2) Remove the attaching bolts of the timing
gear cover.
(3) Separate the timing gear cover from the
timing gear case by tapping the timing
gear cover lightly.
(4) Remove the timing gear cover.
(5) Remove the timing gear cover gasket.
(6) Remove the remaining timing gear cover
VEM00107-00103
gasket material from the timing gear cover
and timing gear case, using a gasket (2) Ensure that the backlash of each gear with
scraper. idle gear is within the specified value,
using a dial gauge, while holding the idler
gear.
Standard backlash value:
0.044 - 0.174 mm
Maximum allowable limit: 0.30 mm

Replace the gears as a set, if the backlash

exceeds the maximum allowable limit.

VEM00105-00101

23. Removal of injection pump drive gear from

timing gear cover
Remove the drive gear from the timing gear
cover while heating the timing gear cover to
approximately 60 °C, using a heater or the
like.
CAUTION:
VEM00108-00104
• Do not heat the driven gear cover beyond
the specified temperature. 25. Remove the vacuum pump.
(Refer to the VP section for the removal proce-
dure.)
26. Checking of idle gear thrust clearance
Ensure that the thrust clearance between the
idle gear and the idle gear thrust plate, using
a thickness gauge.
Standard thrust clearance:
0.06 - 0.17 mm
Maximum allowable limit: 0.30 mm

VEM00106-00102

24. Checking of gear backlash

(1) Install the injection pump drive gear to the
injection pump while aligning the toothless
section of the injection pump and injection
pump drive gear.

VEM00109-00105
“To be continued”
 EM–27
If the thrust clearance exceeds the maximum 29. Removal of camshaft timing gear and
allowable limit, replace the thrust plate, idle camshaft assembly
gear and/or idle gear shaft, respectively, ac- (1) Remove the two attaching bolts of the
cording to the standard side of each part. thrust plate.
Standard size of each part
Thrust plate : 4.4 - 6.6 mm
Idle gear : 23.93 - 24.00 mm
Idle gear shaft: 24.06 - 24.10 mm

B
A
C
VEM00113-00109

(2) Carefully remove the camshaft assembly

from the cylinder block.
CAUTION:
VEM00110-00106 • Do not scratch the camshaft bearing sur-
27. Removal of idle gear face during the removal.
Remove the idle gear by removing the two at-
taching bolts of the idle gear thrust plate.

VEM00114-00110

30. Removal of crankshaft timing gear

VEM00111-00107 Remove the crankshaft timing gear, using the
28. Removal of idle gear shaft following SST.
(1) Remove the union bolt of idle gear shaft oil SST: 09609-20010-000
pipe.
(2) Remove the idle gear shaft from the trans-
mission.

VEM00115-00111

VEM00112-00108
 EM–28
31. Replacement of camshaft timing gear Replace the camshaft with a new one,
(1) Inspection of camshaft if the cam lobe height is less than the
NOTE: minimum allowable cam lobe height.
• Inspect the camshaft before replacing the
camshaft.

q Visually inspect that the camshaft as-

sembly exhibits no discolor, excessive
wear, roughness on the cam surface
nor other damage that affects its oper-
ation.
If any damage exists, replace the dam-
aged part with a new one.
NOTE:
• The camshaft drive gear replacement
VEM00117-00113

should be performed only after confirming r Calculate each journal oil clearance,
that no damage is present on the based on the measurement results of
camshaft. the journal outer diameter and inner di-
ameter of the camshaft bearing.
w Ensure that the circle runout of the Ensure that the oil clearance is within
camshaft at the center journal is within the specified value.
the specified value, by measuring the Specified oil clearance:
circle runout, using a dial gauge, with 0.025 - 0.066 mm
the camshaft placed on the set of V- Maximum allowable limit: 0.10 mm
blocks as shown in the figure. Standard Journal diameter
Specified maximum circle runout: (From front side)
0.06 mm No.1: 53.459 - 53.475 mm
No.2: 53.209 - 53.225 mm
If the circle runout exceeds the maxi- No.3: 52.959 - 52.975 mm
mum limit, replace the camshaft. No.4: 52.709 - 52.725 mm
No.5: 52.459 - 52.475 mm

Replace the camshaft and/or camshaft

bearing with a new one, if the oil clear-
ance fails to meet the specified value.

VEM00116-00112

e Measure the cam height with a mi-

crometer. Ensure that the cam lobe
height is more than the specified mini-
mum height.
VEM00118-00114
Specified cam lobe height
Intake : 44.879 - 44.969 mm
Exhaust: 45.050 - 45.140 mm
Minimum allowable cam lobe height
Intake : 44.44 mm
Exhaust: 44.64 mm

“To be continued”
 EM–29
t Ensure that the thrust clearance be- w Separate the camshaft from the
tween the camshaft and the thrust camshaft timing gear, using a brass
plate is within the specified value, bar in combination with a hydraulic
using a thickness gauge. press as shown in the figure.
Specified thrust clearance: CAUTION:
0.06 - 0.13 mm • Do not damage the threaded section of the
Maximum allowable limit : 0.30 mm camshaft timing gear with a socket wrench.
• Be very careful not to damage or lose the
Replace the thrust plate and/or woodruff key.
camshaft, if the thrust clearance fails to • Be very careful not to drop the camshaft
meet the maximum allowable limit. and woodruff key.
<Reference>
Standard thickness of thrust plate: WARNING:
8.97 - 9.00 mm • Never drop the camshaft on your foot.

VEM00119-00115 VEM00121-00117

(2) Separation of camshaft from camshaft tim- (3) Inspection of camshaft thrust ring and
ing gear woodruff key
q Remove the camshaft timing gear at- Visually inspect that no remarkable dam-
taching bolt and plate washer, while age exists on the camshaft thrust ring and
preventing the camshaft timing gear woodruff key.
from turning, using the following SST or (4) Assembly of camshaft
the like. q Apply a small amount of lithium grease
SST: 09278-87201-000 to the thrust ring to keep it in position.
Then, attach the thrust ring to the
camshaft in such a direction that the oil
groove on the surface may face the
camshaft timing gear side.
w Attach the woodruff key to the
camshaft after applying a small
amount of MP grease to the woodruff
key to keep it in position.

VEM00120-00116

VEM00122-00118
EM–30
e Press the timing gear into the 32. Inspection of injection pump drive gear bear-
camshaft, using a hydraulic press as ing
shown in the figure. Ensure that the injection pump drive gear
CAUTION: bearing rotates smoothly without any binding.
• Ensure that the camshaft thrust ring is free Replace the injection drive gear bearing with
and not interfering with the camshaft or the a new one, if any binding or other damage ex-
camshaft timing gear during installation. ists.

VEM00123-00119 VEM00126-00121

r Install the attaching bolt with the plate 33. Replacement of injection pump drive gear
washer interposed and tighten the bolt bearing
to the specified torque while prevent- (1) Removal of injection pump drive gear
ing the camshaft timing gear from turn- bearing
ing, using the following SST. Remove the injection pump drive gear
SST: 09278-87201-000 bearing, using a suitable bearing puller or
Specified tightening torque: 37.5 N·m the following SST in combination with an
(3.82 kgf-m) adapter whose outer diameter is about
19.5 mm or less.
SST: 09950-20017-000
Universal puller

VEM00124-00120

(4) Ensure that the thrust clearance between

the thrust washer and the camshaft is with-
in the specified value, using a thickness VEM00127-00122

gauge.
Standard clearance: 0.06 - 0.13 mm
Specified maximum clearance: 0.30 mm
VEM00125-00000
 EM–31
(2) Installation of injection pump drive gear INSPECTION AND REPLACEMENT OF
bearing TIMING GEARS AND CAMSHAFT
Install the injection pump drive gear bear-
ing, using a hydraulic press in combina-
RELATED PARTS
tion with an adapter whose inner diameter 1. Inspection of oil clearance between idle gear
is about 20.5 mm and whose depth is and idle gear shaft
more than 1 mm from the end of the injec- (1) Measure the inner diameter of the idle
tion pump drive gear. gear, using an inner dial gauge or a cylin-
CAUTION: der gauge.
• Be sure to compress the inner race of the Reference
bearing during the installation. Idle gear inner diameter:
Do not compress the outer race of the 44.974 - 45.000 mm
bearing during the installation.

NOTE:
• The assembled position of the bearing
outer surface is lower than the bearing at-
taching shaft outer surface of the injection
drive gear.

VEM00129-00124

(2) Measure the idle gear shaft outer diame-

ter, using a micrometer.
Reference
Idle gear shaft diameter:
44.935 - 44.955 mm

VEM00128-00123 (3) Calculate the oil clearance by subtracting

the measured idle gear shaft outer diame-
ter from the measured idle gear inner di-
ameter.
Specified maximum oil clearance:
0.18 mm
Reference
Standard oil clearance:
0.019 - 0.065 mm

Replace the idle gear and idle gear shaft

with new ones, if the clearance is more
than the specified value.

VEM00130-00125
EM–32
2. Replacement of crankshaft front oil seal
(1) Off-vehicle replacement
q Drive out the crankshaft oil seal from
behind the timing gear cover, using a
pin punch or the like.

09308-10010

VEM00300-00240

w Apply a small amount of engine oil to a

new oil seal.
e Press in the new oil seal to the timing
gear cover, until the oil seal surface
VEM00131-00126 becomes flush with the timing gear
w Apply a small amount of engine oil to cover surface, using the following SST
the lip section of a new oil seal. and a hammer.
e Press in the new oil seal to the timing SST: 09635-20010-000
gear cover, until the oil seal surface
becomes flush with the timing gear 3. Checking/replacement of injection pump gear
cover surface, using the following SST thrust bearing
or the like. Ensure that no damage such as seizer or the
SST: 09517-87702-000 crack are not existing on the inner surface of
the injection pump thrust bearing.
CAUTION: If damage are existing, replace the injection
• Do not push the inner lip section of the oil pump gear thrust bering with injection pump
seal during the installation. drive gear as a set.
• Be sure to press the outer periphery of the (Refer to the LU section for replacement of in-
oil seal during the installation. jection pump gear thrust bearing.)
• Do not tilt the oil seal against the timing VEM00133-00000

gear cover during the installation. INSTALLATION OF TIMING GEARS AND

• Be very careful not to interfere the SST
CAMSHAFT
with the timing gear cover.
1. Installation of crankshaft timing gear
(1) Check to see if the woodruff key groove on
the crankshaft faces upward.
If not, turn the crankshaft, until the
woodruff key groove faces upward.

VEM00132-00127

(2) In-vehicle replacement

q Remove the crankshaft oil seal, using
the following SST.
SST: 09308-10010-000 VEM00134-00128

“To be continued”
 EM–33
(2) Apply a small amount of lithium grease to
the woodruff keys in order to keep them in
positions, if necessary.
(3) Attach the woodruff keys to the crankshaft.
(4) Install the crankshaft timing gear to the
crankshaft with the “1” stamped mark of
the crankshaft timing gear facing forward,
while aligning the crankshaft woodruff key
with the recessed section of the timing
gear.
VEM00137-00131

3. Install the two camshaft attaching bolts and

tighten them to the specified tightening
torque.
Specified tightening torque: 18.5 N·m
(1.89 kgf-m)

VEM00135-00129

(5) If any difficulty is encountered in installing

the timing gear, tap the timing gear gradu-
ally, using the following SST in combina-
tion with a hammer.
SST: 09506-87303-000
VEM00138-00132

4. Install the idle gear shaft temporarily and tight-

en the union bolt by hand.
5. Installation of injection pump drive gear

09506-87303

VEM00136-00130

2. Installation of camshaft timing gear and

camshaft assembly
(1) Liberally apply engine oil to the camshaft,
timing gear and thrust ring.
VEM00139-00133
(2) Install the camshaft to the cylinder block
carefully while preventing the camshaft
from interfering with the camshaft bear-
ings.
NOTE:
• Be very careful not to allow the thrust bear-
ing to interfere with the cylinder block.

“To be continued”
EM–34
6. Installation of idle gear
(1) Liberally apply engine oil to each gear and
the idle shaft.
(2) Install the idle gear to the idle gear shaft
while aligning the “0”, “1” and “2” marks
provided on the camshaft timing gear, in-
jection pump drive gear and crankshaft
timing gear with the corresponding mark
on the idle gear, respectively, as shown in
the figure.
VEM00141-00135

9. Installation of injection pump drive gear

(1) Apply engine oil to the drive gear spline,
bearing and injection pump spline.
(2) Install the injection pump drive gear to the
injection pump while aligning the toothless
part on the injection pump drive gear and
injection pump spline slightly.

VEM00301-00285

7. Tighten the union bolt to the specified tighten-

ing torque.
Specified tightening torque: 11.0 N·m
(1.12 kgf-m)

VEM00142-00136

10. Install the injection pump drive gear to the in-

jection pump properly, while aligning the mark
“0” provided on the injection pump drive gear
with the mating mark on the idle gear, as
shown in the figure step 6.

VEM00140-00134

8. Apply a small amount of engine oil to the

threaded section of the attaching bolts.
Install the idle gear attaching bolts with the
thrust plate interposed. Tighten the attaching
bolts evenly to the specified tightening torque.
Specified tightening torque:
47.5 N·m (4.84 kgf-m)

VEM00143-00137

“To be continued”
 EM–35
11. Installation of vacuum pump (2) Pack the multi-purpose lithium soap
based-grease into the timing gear cover.

15. Install the warmed gear cover with a new gas-

ket interposed with the eighteen bolts as
shown in the figure.
CAUTION:
• Be sure to install the gear cover attaching
bolts at the correct position.
• Be sure to wipe off the timing gear cover
completely.
• Be very careful not to scratch the lip sec-
VEM00144-00138
tion of the crankshaft oil seal.
12. Check the timing gear backlash.
Maximum allowable limit: 0.30 mm 16. Tighten the attaching bolts to the specified
Reference value tightening torque evenly in two or three
Standard backlash: 0.047 - 0.173 mm stages.
Tightening torque
Bolts A, B & C: 21 N·m (2.14 kgf-m)
Bolt D: 44 N·m (4.49 kgf-m)
C C C B
C A A B

C
B
C
D
VEM00145-00139

13. Ensure that the thrust clearance of the idle C B

C C D
gear is within the specified value, using a C
thickness gauge. VEM00147-00141
(Refer to page EM–26)
Maximum allowable limit: 0.30 mm
Reference value
Standard backlash: 0.06 - 0.17 mm

VEM00146-00140

14. Installation of timing gear cover

(1) Gradually heat the injection pump drive
bearing attaching part of the timing gear
cover to approximately 60 °C with a heater
or a drier.

“To be continued”
 EM–36
17. Installation of crankshaft pulley
(1) Install the crankshaft pulley to the crank- Bottom
shaft, while aligning the woodruff key
groove on the crankshaft pulley with the
woodruff key on the crankshaft.
NOTE: B
• If any difficulty is encountered in installing A
the crankshaft pulley, tap the crankshaft
pulley with a plastic hammer.
Top
CAUTION:
VEM00149-00143
• At this time, tap the inside of the crankshaft
pulley, if necessary. Do not tap the outer (3) Tighten the attaching bolts to the specified
periphery from the damper. tightening torque.
Tightening torque
(2) Apply a small amount of engine oil to the Bolt A: 37.5 N·m (3.82 kgf-m)
threads and seating section of the crank- Bolt B: 7.5 N·m (0.76 kgf-m)
shaft attaching bolt.
(3) Install and tighten the crankshaft attaching (4) Ensure that the valve lifter moves smoothly
bolt to the specified tightening torque, in an up- and-down direction and that the
while preventing the crankshaft pulley from lifter will not rotate.
turning, using a suitable bar or the follow- Bottom
ing SST.
SST: 09330-00021-000
Tightening torque: 294 N·m (30 kgf-m)

Top
VEM00150-00144

19. Install the valve rocker shaft assembly.

(Refer to the cylinder head section for the in-
stallation procedure of the valve rocker shaft
VEM00148-00142
assembly described in this manual.)
18. Releasing valve lifters from holding position 20. Adjust the valve clearances.
(1) Remove the valve lifter holding bolts A to (Refer to the MA section for adjustment proce-
release the valve lifter shown in the figure. dure.)
(2) Install the valve lifter setting bolts while
No. 1 cylinder: Top dead center at end of compression stroke
aligning the cutout section on the valve
lifter with the bolt holes with a new gasket
interposed.
CAUTION:
• Be very careful not to allow the bolts to in-
terfere with the valve lifters during the in-
stallation of the bolts.
• Ensure that the long hole provided on the No. 4 cylinder: Top dead center at end of compression stroke
valve lifters is aligned with the lower side
bolt heads. VEM00151-00145

“To be continued”
 EM–37
21. Installation of cylinder head cover. 24. Installation of alternator
Tighten the cylinder head cover attaching (1) Apply a small amount of engine oil to the
bolts and nuts evenly sequence shown in the threaded section of the alternator bracket
figure to the specified tightening torque. attaching bolts.
Tightening torque: 10.5 N·m (1.07 kgf-m) (2) Install the alternator with bracket by at-
taching the bolts. Tighten the attaching
bolts evenly over two or three stages to the
2 4 specified tightening torque.
5
Tightening torque: 98 N·m (10.0 kgf-m)

25. Install the alternator drive belt and adjust the

alternator drive belt tension.
(Refer to the MA section.)
6 26. Install the front exhaust pipe with a new gas-
3 1
ket interposed.
27. Ensure that the engine oil level is within the
VEM00302-00286
specified value.
22. Install the exhaust manifold and heat insulator. (Refer to the inspection of the oil level de-
(Refer to the cylinder head section for the in- scribed in the MA section in this manual.)
stallation procedure of the exhaust manifold 28. Ensure that the injection timing is correct.
assembly described in this manual). (Refer to the inspection of the injection timing
described in the MA section in this manual.)
29. Fill coolant.
(Refer to the MA section.)
30. Connect the battery ground cable terminal to
the negative terminal of the battery.
31. Start the engine and warm up the engine thor-
oughly.
32. Perform the engine tune-up.

Apply the
VEM00152-00146
liquid gasket

23. Installation of fan, fluid coupling (if equipped)

and water pump pulley
(Refer to the section for the cooling system in-
stallation procedure of the water pump assem-
bly described in this manual.)

VEM00154-00148

VEM00153-00147
EM–38
CYLINDER BLOCK
COMPONENT

q
w
e

r
t

y
u
★!3
T: 68.6 ± 4.9 + 90°
i (7.0 ± 0.5 + 90°)
!2 T: 160 (16.3)
o ★!1

!6

!5

!4
T: 18.5 (1.89)
!0

!8

@0

!7

!9
T: 200 (20.4)

★ : Non-reusable parts

q Piston ring No. 1 !1 Gasket

w Piston ring No. 2 !2 Rear oil seal retainer
e Oil ring !3 Oil seal
r Piston !4 Rear end plate
t Piston pin !5 Fly wheel
y Snap ring !6 Bearing
u Connecting rod
i Connecting rod cap
o Connecting rod bearing
!0 Cylinder block

VEM00155-00149
 EM–39
DISASSEMBLY OF CYLINDER BLOCK (6) Removal of water outlet
1. Disconnect the battery ground cable terminal q Displace the hose band of the water
from the negative terminal of the battery. by-pass hose which is attached on the
2. Drain the coolant. water pump side.
3. Drain the engine oil. w Remove the water outlet attaching nuts
4. Remove the engine from the vehicle and evenly.
place it on an engine bench. e Remove the water outlet and discon-
5. Remove the clutch cover and clutch disc by nect the water by-pass hose from the
removing its attaching bolts evenly. water pump.
6. Remove the flywheel by removing the attach-
ing bolts evenly.
7. Remove the rear end plate.
8. Install the cylinder block to a suitable engine
overhaul stand.
9. Removal of cylinder head
Perform the following procedure given below
when removing the cylinder head alone. If the
cylinder head overhauling is required, follow
the procedure described in the cylinder head
section. VEM00158-00152
(1) Loosen the alternator drive belt adjusting
(7) Removal of fuel filter
bolts and nut.
q Remove the fuel hose band at the in-
jection pump side.
w Disconnect the fuel hose at the injec-
tion pump side.
e Remove the fuel inlet pipe clamp bolt
at the injection pump bracket side.
r Remove the fuel filter with bracket by
removing the two attaching bolts.

VEM00156-00150

(2) Remove the drive belt.

(3) Remove the alternator with alternator
bracket by removing the attaching bolts.
(4) Loosen the cooling fan and cooling fan
pulley attaching bolts evenly.
(5) Remove the cooling fan, fluid coupling (if
equipped) and cooling fan pulley. VEM00159-00153

VEM00157-00151
EM–40
(8) Removal of injection pipes (13) Remove the cylinder head cover by re-
q Remove the No.3 and No.4 injection moving the attaching bolts and nuts after
pipe clamps. loosening them evenly.
w Remove the No.3 and No.4 injection
pipes by disconnecting the union nuts.
e Remove the No.1 and No.2 injection
pipe clamps.
r Remove the No.1 and No.2 injection
pipes by disconnecting the union nuts.

VEM00163-00157

(14) Loosen the lock nuts of the valve clear-

ance adjusting screws.
(15) Loosen the valve clearance adjusting
screws.
(16) Loosen the valve rocker support attaching
VEM00160-00154 bolts evenly in the sequence as shown.
(9) Remove the blow-by gas hose from the (17) Remove the valve rocker shaft assembly
cylinder head and venturi. by removing the attaching bolts.
(10) Remove the accelerator connecting rod
from the venturi and injection pump.

VEM00164-00158

(18) Pull out the push rods.

VEM00161-00155 NOTE:
(11) Displace the leakage hose clamp at the • Be sure to place the push rod in order so
leakage pipe side. that each assembled position of the push
(12) Disconnect the leakage hose from the rods may be known.
leakage pipe.

VEM00165-00159

VEM00162-00156
 EM–41
(19) Loosen the cylinder head bolts gradually 12. Removal of relief valve
and evenly in the sequence shown. Remove the plug, gasket, spring and relief
(20) Remove the cylinder head from the cylin- valve from the oil filter bracket.
der block. 13. Remove the oil filter bracket and gasket by re-
NOTE: moving the attaching bolts evenly.
• Do not make scratches on the cylinder NOTE:
head, piston and cylinder block surface • Place a container under the oil filter brack-
during the removal. et.

(20) Remove the cylinder block gasket.

VEM00168-00162

14. Remove the oil cooler cover with oil cooler by

VEM00166-00160 removing the seven attaching bolts, three nuts
10. Remove the timing gears and camshaft-relat- and hexagon bolt evenly.
ed parts. NOTE:
(Refer to the removal procedure for the timing • Place a container under the oil cooler.
gears and camshaft.)
11. Loosen the oil filter, using an oil filter wrench 15. Remove the gasket.
and remove the oil filter.
NOTE:
• Place a container under the oil filter.

VEM00169-00163

16. Remove the water pump and gasket by re-

moving the attaching bolts.
VEM00167-00161

VEM00170-00164
 EM–42
17. Removal of oil pan 18. Removal of oil strainer and outlet pipe
(1) Remove the side cover and gasket by re- (1) Remove the oil strainer by removing the at-
moving the four attaching bolts evenly. taching two bolts and nuts.
(2) Remove the gasket for the oil strainer.
(3) Remove the union bolt and two nuts.
(4) Remove the oil pipe and three gaskets.

VEM00171-00165

(2) Slacken the seventeen bolts and seven

nuts evenly.
(3) Remove the bolts and nuts. VEM00173-00167

(4) Separate the oil pan from the cylinder 19. Removal of injection pump
block. (1) Ensure that the mating marks between the
Use the following SST in combination with injection pump flange and the timing gear
a hammer with the blade section of the case are aligned with each other.
SST inserted into between the cylinder If not, put a new mating mark with oily
block and the oil pan. paint or the like for reinstallation.
SST: 09032-00100-000 (2) Remove the injection pump by removing
the two nuts for the injection pump and the
CAUTION: two bolts attaching the injection pump at-
• Do not insert the blade section of the SST taching bracket to the cylinder block.
into between the timing gear case side and
the rear oil seal retainer side.
• Be very careful not to damage the oil pan
flange.

VEM00174-00168

VEM00172-00166
 EM–43
20. Removal of oil pump
(1) Loosen the attaching bolts of the oil pump
evenly.
(2) Remove the eight attaching bolts of the oil
pump.
(3) Separate the oil pump from the cylinder
block by tapping the oil pump lightly from
the cylinder block side.
(4) Remove the oil pump from the cylinder
block.
(5) Remove the oil pump gasket from the
VEM00177-00171
cylinder block.
If the thrust clearance fails to meet the specifi-
cation, replace the connecting rod and/or
crankshaft with new ones, based on the stan-
A B dard width of the connecting rod and length of
B
crankpin journal as follows.
C Standard width of connecting rod:
C C
35.73 - 35.80 mm
Standard length of crankpin journal:
36.00 - 36.05 mm
C C

VEM00175-00169

21. Removal of oil seal retainer

(1) Loosen the attaching bolts of the rear oil
seal retainer.
(2) Remove the rear oil seal retainer attaching
bolts.
(3) Separate the oil seal retainer from the
cylinder head by tapping the oil seal re-
tainer lightly.
VEM00178-00172
(4) Remove the oil seal retainer and gasket.
23. Checking of connecting rod bearing oil clear-
ance
(1) Put a mating mark on the connecting rod
and connecting rod cap for correct re-
assembling.

VEM00176-00170

22. Checking of thrust clearance of connecting

rod big end
Ensure that the thrust clearance of the con-
necting rod big end does not exceed the max-
VEM00179-00173
imum allowable limit, using a dial gauge.
Maximum allowable limit: 0.40 mm
Reference
Standard thrust clearance:
0.20 - 0.320 mm

“To be continued”
EM–44
(2) Loosen and remove the connecting rod r Remove the bearing cap by removing
cap attaching bolts evenly. the bearing cap attaching nuts after
(3) Lightly tap the connecting rod cap attach- loosening them evenly.
ing bolts to separate the connecting rod t Ensure that the oil clearance does not
from the connecting rod cap, using a plas- exceed the maximum allowable limit
tic hammer or the like. by measuring the widest point of the
(4) Remove the connecting rod cap and con- Plastigage.
necting rod cap bearing. Maximum allowable limit: 0.15 mm
Reference
Standard oil clearance:
Front mark 0.03 - 0.07 mm

If the clearance exceeds the maximum

limit, replace the connecting rod bear-
ing which is suited for the size of the
Front crankpin journal to be reconditioned.
(Refer to the page EM–58.)

VEM00180-00174

(5) Checking of connecting rod oil clearance

q Place a strip of Plastigage across the
crankpin journal.
w Install the connecting rod cap bearing
to the connecting rod cap bearing.
NOTE:
• Be sure to degrease the surfaces between
the connecting rod bearing cap and the
connecting rod bearing. VEM00182-00176

24. Removal of pistons

e Install the attaching nuts and tighten (1) Remove carbon ridge existing on the
the nuts by the specified tightening upper section of the cylinder, using a suit-
method. able ridge reamer.
(2) Cover the threaded section of the connect-
ing rod cap attaching bolts to prevent the
crankpin journal from being damaged.

VEM00181-00175

VEM00183-00177
 EM–45
(3) Remove the piston with connecting rod by
pushing the connecting rod to the piston
side.
CAUTION:
• Never push the connecting rod bearing
section of the connecting rod.
• Be very careful not to damage the connect-
ing rod and piston during the removal.
• Keep the connecting rod assembly with the
cap and bearings as a set.
• Arrange the removed piston assemblies in
VEM00185-00179
order, corresponding with the cylinder
number. 26. Checking of crankshaft main journal oil clear-
ance
(1) Loosen the main bearing cap bolts over
two or three stages in the numerical se-
quence shown in the figure.
(2) Remove the crankshaft bearing caps,
bearing and thrust washers (only for No.3
journal).
NOTE:
• Remove the crankshaft bearing caps by
prying the crankshaft bearing cap back and
forth, utilizing the cap bolts as shown in the
VEM00184-00178 right figure.
25. Checking of crankshaft thrust clearance • Keep the lower bearing fitted to the crank-
Ensure that the crankshaft thrust clearance is shaft bearing cap side.
within the maximum allowable limit, using a • Do not touch the surface of the crankshaft
dial gauge. bearing.
Maximum allowable limit: 0.40 mm
Reference
Standard thrust clearance:
0.040 - 0.250 mm

If the thrust clearance exceeds the allowable

limit, replace the thrust washers or the crank-
shaft by comparing the thickness of the used
thrust washer with the standard thickness of
the thrust washer.
Thrust washer thickness
VEM00186-00180
STD size : 2.430 - 2.480 mm
O/S 0.125: 2.493 - 2.543 mm
O/S 0.250: 2.555 - 2.605 mm

“To be continued”
EM–46
(3) Lift off the crankshaft. (7) Install the main bearings to the cylinder
NOTE: block and crankshaft main bearing caps.
• Be very careful not to allow the bearings to CAUTION:
be mixed with the bearings of the other • Do not touch both front and rear surfaces
cylinders. of the bearing by bare hand. It may cause
• Remove the thrust washer provided at bearing seizure.
No.3 journal section during removal.
• Keep the upper bearing fitted to the cylin-
der block.
• Do not touch the bearing surface of the
crankshaft.

VEM00189-00183

(8) Support both ends of the crankshaft with

“V” blocks.
(9) Ensure that the crankshaft runout is within
the specified value.
VEM00187-00181 Maximum allowable limit: 0.08 mm
(4) Degrease the main journals of the crank-
shaft, bearings and crankshaft bearing Replace the crankshaft with a new one, if
cap, using washing solvent. the runout exceeds the maximum allow-
(5) Dry them with compressed air. able limit.
WARNING:
• Protect your eyes by wearing safety gog-
gles when using compressed air.

(6) Check the main journals and bearings for

pitting or nicks.
If the main journals are damaged, replace
or regrind the crankshaft.
(See the assembling procedure for the
cylinder block.)
If the main journal bearings are damaged,
VEM00190-00184
replace the main journal bearings.
(See the assembling procedure for the (10) Place the crankshaft on the cylinder block.
cylinder block.)

VEM00191-00185

VEM00188-00182
 EM–47
(11) Place a strip of plastigage across each (Refer to the assembling procedure of the
crankshaft main journal. cylinder block for the finishing diameter of
the crankpin journal.)
Plastigage

VEM00192-00186

(12) Install the crankshaft main bearing caps. VEM00194-00188

(13) Install the crankshaft main bearing cap 27. Lift off the crankshaft from the cylinder block.
bolts. 28. Remove the crankshaft bearing from the cylin-
(14) Tighten the crankshaft main bearing bolts der block and crankshaft bearing cap.
sequence in the figure to the specified CAUTION:
tightening torque. • Do not touch the front and rear surface of
Tightening torque: 200 N·m (20.4 kgf-m) the crankshaft bearing during removal.
i r w y !0
• Place the removed parts in order.

u e q t o

VEM00193-00187

(15) Remove the crankshaft main bearing cap. VEM00195-00189

(Refer to the bearing cap removal proce- 29. Removal of valve lifters
dure on page EM–46.) (1) Remove the bolts which support the valve
(16) Ensure that the oil clearance is less than lifters.
the maximum allowable limit by measuring (2) Remove the valve lifters by lifting them,
the widest point of the Plastigage. using a piece of wire or the like, or push
Maximum allowable limit up the lifter by a rod from the cylinder
No.1, 2, 4, 5: 0.15 mm head side.
No.3 : 0.20 mm
Reference
Standard oil clearance
No.1, 2, 4, 5: 0.030 - 0.074 mm
No.3 : 0.060 - 0.104 mm

If the clearance exceeds the maximum

limit, replace the crankshaft bearing with a
new one or recondition the crankshaft
main journal outer diameter according to a
suitable undersized bearing.
VEM00196-00190

“To be continued”
 EM–48
30. Oil pressure switch
Remove the oil pressure switch, using a box
wrench having a hexagonal hole.

VEM00199-00193

2. Inspection of fit between piston and piston pin

Ensure that no movement is felt when you try
VEM00197-00191 to move the piston on the piston pin in an up-
INSPECTION OF PISTONS AND and-down or a right-and- left direction.
If movement is felt, replace the piston and pis-
CONNECTING RODS
ton pin as a set.
1. Inspection of fit between piston pin and con- VEM00200-00194
necting rod bush
3. Removal of piston rings
(1) Ensure that no movement is felt when you
NOTE:
try to move the piston pin in the connect-
• Arrange the removed piston rings in order
ing rod bush in an up-and-down or a right-
so that their installation position may be
and-left direction.
known readily.
If movement is felt, check the clearance
• Do not expand the piston ring unnecessari-
between the piston pin and the connecting
ly beyond the required extent.
rod bush.
(1) Remove the compression rings, using a
piston ring expander.
(2) Remove the oil ring and expander by
hand.

VEM00198-00192

(2) Ensure that the piston pin can be moved in

the connecting rod bush smoothly when
the piston pin is moved in a right-and-left
direction. VEM00201-00195
NOTE:
• When the piston pin is moved back and
forth in the connecting rod bush, you may
encounter hard movement. However, if the
piston pin moves smoothly without any
binding, this fitting of the piston pin is nor-
mal.

“To be continued”
 EM–49
4. Inspection of connecting rod bolts (2) Wash and clean the piston, piston pin, pis-
(1) Ensure that the connecting rod bolt ex- ton rings and connecting rod by washing
hibits no damage. solvent and a soft brush.
(2) Ensure that the length of the connecting CAUTION:
rod bolt does not exceed the specified • Do not scratch the piston during cleaning.
length.
Specified length: 64.5 - 65.0 mm

5. Disassembly of piston and connecting rod as-

sembly
(Perform only when it is necessary.)
(1) Remove the piston pin snap rings, using
snap ring pliers.

VEM00204-00198

(3) Checking of piston diameter and piston-to-

cylinder clearance.
q Measure the piston outer diameter at a
point 12 mm from the piston lower sur-
face at right angles to the piston pin.
Reference
Standard size of piston (At 20 °C)
VEM00202-00196 Mark 1 : 101.76 - 101.77 mm
(2) Gradually heat the piston to approximately Mark 2 : 101.77 - 101.78 mm
60°C. Mark 3 : 101.78 - 101.79 mm
(3) Tap out the piston pin using the following O/S 0.50: 102.26 - 102.29 mm
SST or a brass bar in combination with a O/S 0.75: 102.52 - 102.53 mm
hammer as shown. O/S 1.00: 102.78 - 102.79 mm
SST: 09221-46010-000

CAUTION:
• Keep the piston and piston pin together as
a set.

09221-46010

VEM00205-00199

VEM00203-00197

6. Inspection of pistons, piston pins, piston rings

and connecting rods
(1) Remove carbon deposits from the piston
top surface and piston ring grooves, using
a scraper, a broken piston ring or the like.
CAUTION:
• Do not scratch the piston during cleaning.

“To be continued”
EM–50
w Measure the cylinder bore diameter at (4) Checking of piston ring side clearance
three positions in the axial and thrust q Checking of top ring side clearance
directions. q-1
Reference Install the top ring to the piston, using
Standard size of cylinder (At 20 °C) piston ring pliers, in such a direction
Mark 1 : 102.00 - 102.01 mm that the “T” stamped mark faces up-
Mark 2 : 102.01 - 102.02 mm ward.
Mark 3 : 102.02 - 102.03 mm
O/S 0.50: 102.50 - 102.53 mm
O/S 0.75: 102.75 - 102.79 mm
O/S 1.00: 103.00 - 103.03 mm

Thrust
direction
Crankshaft
axial
direction
15 mm
VEM00208-00201

Center

15 mm

VEM00206-00200

e Subtract the measured piston outer di-

ameter from the measured cylinder
bore diameter. Ensure that the piston-
to-cylinder clearance is within the max-
imum limit.
Maximum cylinder-to-piston clearance:
0.30 mm
Reference
Standard cylinder-to-piston clearance:
0.23 - 0.25 mm

If the measured clearance fails to meet

the specified value, replace the piston
with oversized piston and rebore the
cylinder. If required oversized piston is
not available as a spare part, replace
the pistons and cylinder with new
ones.
NOTE:
• Reboring must be performed for the four
cylinders at the same time.
VEM00207-00000

“To be continued”
 EM–51
q-2 (5) Checking of piston pin-to-piston pin bore
Measure the side clearance with a clearance
thickness gauge around the piston at q Ensure that the piston pin-to-piston pin
the lower side of the piston ring while bore clearance is within the specified
pushing the piston ring into the piston value by measuring the piston pin
ring groove of the piston. outer diameter and piston pin bore di-
Ensure that the measured side clear- ameter of the piston.
ance is within the specified value. Standard piston pin-to-piston pin bore
Piston ring side clearance clearance: –0.006 to +0.004 mm
No.1: 0.062 - 0.092 mm

w Checking of second and oil ring side

clearance
Ensure that the piston ring side clear-
ances are within the specified value,
using a thickness gauge, while insert-
ing the piston ring into the piston ring
groove of the piston.
Piston ring side clearance
No.2 : 0.04 - 0.08 mm VEM00210-00203
Oil ring: 0.03 - 0.07 mm
Perform the check using the following
method, if the piston clearance fails to
If the side clearance fails to meet the
meet the above specification.
specified value, replace the piston ring
w Ensure that the piston pin can not be
and/or the piston with a new one, by
installed into the piston by pushing it
comparing the used piston and piston
with your thumb when the piston tem-
rings with the standard thickness of the
perature is below 60 °C. Conversely,
piston ring groove of the piston and
ensure that the piston pin can be in-
the piston ring thickness.
stalled into the piston by pushing the
Standard width of piston ring groove of pis-
piston pin with your thumb when the
ton
piston temperature rises gradually to
No.1 : 2.47 - 2.49 mm
60 °C.
No.2 : 2.15 mm
If the piston pin can be installed with
Oil ring: 3.97 - 3.99 mm
your thumb into the piston below 60
Standard thickness of piston ring
°C, replace the piston and piston pin
No.1 : 3.63 - 3.87 mm
with new ones as a set.
No.2 : 4.18 - 4.42 mm
Oil ring: 4.35 mm

VEM00211-00204

VEM00209-00202
EM–52
(6) Inspection of piston ring end gap
q Liberally apply engine oil to the cylin-
der walls.
w Insert the piston ring into the cylinder
bore.
NOTE:
• Be very careful not to scratch the cylinder
wall.

e Using the piston, push down the piston

ring to a point 150 mm measured from
VEM00213-00206
the cylinder block upper surface.
r Ensure that the piston ring end gap is (8) Checking of connecting rod bush oil clear-
within the specified value, using a ance
thickness gauge. q Calculate the oil clearance between
Maximum piston ring end gap the piston pin and the connecting rod,
No.1 : 1.34 mm based on the measured results of the
No.2 : 1.44 mm connecting rod bush inner diameter
Oil ring: 1.49 mm and connecting rod attaching surface
of the piston pin outer diameter. Ensure
If the end gap exceeds the maximum that the oil clearance does not exceed
limit, replace the piston ring with a new the maximum limit.
one or rebore the cylinder bore to the Maximum allowable limit: 0.05 mm
suitable dimensions of oversized pis-
ton and piston rings. If the oil clearance exceeds the maxi-
Reference mum allowable limit, replace the con-
Standard piston ring end gap necting rod bush or piston by compar-
No.1 : 0.35 - 0.50 mm ing the measured bush diameter and
No.2 : 0.40 - 0.53 mm piston pin outer diameter with the stan-
Oil ring: 0.20 - 0.40 mm dard values specified below.
Reference
Standard oil clearance:
0.004 - 0.014 mm
Standard bush diameter:
No. 1: 32.009 - 32.014 mm
No. 2: 32.014 - 32.019 mm
Standard piston pin outer diameter:
150 mm
No. 1: 32.000 - 32.005 mm
(6 inches)
No. 2: 32.005 - 32.010 mm

VEM00212-00205

(7) Checking of connecting rod for bend and

twist
Ensure that no bend nor twist exists on the
connecting rod, using a connecting rod
aligner.
Allowable limit of bend:
0.05 mm per 100 mm
Allowable limit of twist:
VEM00214-00207
0.15 mm per 100 mm

If the bend or twist exceeds the maximum

limit, replace the connecting rod.
“To be continued”
 EM–53
(9) Replacement of connecting rod bush r Set the bush on the SST in such a way
q Press out the connecting rod bush, that the smaller hole of the bush may
using the following SST in combination come on the ball section of the follow-
with a hydraulic press. ing SST.
SST: 09222-58020-000 SST: 09222-04020-000
(Use 09222-04015-000, (Use 09222-04015-000,
09222-04020-000 and 09222-04015-000 inner parts of
09222-04025-000) above SST.)

t Apply engine oil to the press-fitting

surface of the bush.

VEM00215-00208

w Using a round file, lightly file off any

roughness from the small end of the
connecting rod. VEM00218-00211

y Press the bush into the connecting rod,

using the SST in combination with a
hydraulic press.
SST: 09222-58020-000
(Use 09222-04015-000,
09222-04025-000 and
09222-04020- 000 inner parts of
above SST.)

CAUTION:
• Be sure to align the oil holes of the bush
VEM00216-00209
with the oil holes of the connecting rod be-
e Using a file, chamfer off the bush at fore and during the assembly.
the side press-fitted into the connect-
ing rod. u Hone the connecting rod bush inner
surface to remove burrs or the like pro-
duced during the installation, using a
hole grinder.

VEM00217-00210

VEM00219-00212
EM–54
i Checking of piston pin fit at normal (2) Selection of connecting rod bearing
room temperature NOTE:
Ensure that the piston pin coated with • Selection of connecting rod bearing may
engine oil can be inserted into the con- not be necessary. However, the following
necting rod bush by pushing it with manner is described here only for your ref-
your thumb. erence.
If not, check the clearance between • The standard sized connecting rod bearing
the piston pin and the connecting rod is supplied with a new connecting rod as-
bush. sembly.
(Refer to the step 7)
If the clearance fails to meet the speci- q Measure the outer diameter of each
fied value, finish the inner diameter of crankpin journal.
the bush, using a hole grinder. w Select the connecting rod bearing,
based on the measured outer diameter
of the crankpin journal.
U/S bearing Crankpin journal diameter
STD 60.98 - 61.00 mm
U/S 0.25 60.74 - 60.75 mm
U/S 0.50 60.49 - 60.50 mm
U/S 1.00 59.99 - 60.00 mm

If the measured crankpin journal diam-

eter fails to meet the standard diame-
ter specified above, select a bearing a
VEM00220-00213
little larger than the actually measured
7. Replacement of connecting rod value.
(1) Ensure that the piston pin and connecting Then, perform the oil clearance check.
rod bush clearance is within the specified (Refer to page EM–52.)
value by measuring the inner diameter of If the oil clearance exceeds 0.15 mm,
the connecting rod bush and outer diame- regrind the crankpin journal for the
ter of the piston pin. standard diameter specified above.
Maximum piston pin-to-connecting rod Or replace the crankshaft with a new
clearance: 0.05 mm one, if the crankpin journal diameter is
less than the standard value of U/S
(Refer to page EM–52.) 1.00 connecting rod bearing.
If the clearance exceeds the maximum VEM00222-00000
limit, replace the piston pin with piston as
a set.

VEM00221-00214
 EM–55
INSPECTION OF CYLINDER BLOCK The piston to be employed for each cylinder must
1. Inspection of cylinder block have the same stamped mark as that of the cylin-
(1) Visually inspect that the sliding surfaces der.
exhibit no damage, such as cracks, Standard piston diameter
seizure, nicks, oil or coolant leakage or Mark “1”: 101.76 - 101.77 mm
roughness. Mark “2”: 101.77 - 101.78 mm
Replace the cylinder block, if damage ex- Mark “3”: 101.78 - 101.79 mm
ists and it can not be corrected. Standard piston-to-cylinder clearance:
(2) Ensure that there is no warpage which ex- 0.23 - 0.25 mm
ceeds the maximum limit on the top sur- Selection marks Fitting cord
face of the cylinder head. of bore (1, 2 or 3)
Maximum allowable warpage: 0.20 mm

(3) Measurement of cylinder bore

(Refer to the section “Inspection of piston
and connecting rods.”

Front mark
VEM00224-00216

1. Selection of crankshaft main journal bearings

(1) Measure each crankshaft main journal di-
ameter at two positions in two directions
as shown in the figure EM–58, using a mi-
crometer.
If the out-of-roundness or taper value is
VEM00223-00215 more than 0.02 mm, grind or replace the
REPLACEMENT OF CYLINDER BLOCK crankshaft.
VEM00225-00000

NOTE:
• The cylinder block is furnished along with
the pistons as a set.

Hence, make sure that each piston is installed in

the correct cylinder bore.
Reference:

Each cylinder bore size mark is stamped on the

cylinder block upper surface as shown in the fig-
ure.
Standard cylinder bore diameter
Mark “1”: 102.00 - 102.01 mm
Mark “2”: 102.01 - 102.02 mm
Mark “3”: 102.02 - 102.03 mm

“To be continued”
EM–56
(2) Select the suitable main journal bearings 1. Selection of cylinder bore to be bored
specified in the table below according to (1) Measure the cylinder bore diameter.
the measured results of the crankshaft (Refer to page EM–50 for measurement.)
main journal diameters. (2) Select the oversized piston to be used,
If the measured results of the crankshaft based on the measured results of the
main journal diameter fail to meet the stan- cylinder bore diameter.
dard diameter, regrind the crankshaft main Unit: mm
journals to a suitable undersized bearing. Piston size O/S 0.50 O/S 0.75 O/S 1.00
If measured results meet the standard Piston 102.260 - 102.510 - 102.760 -
value in the table below, select the bearing diameter 102.290 102.540 102.790
according to the stamped number on the Standard Standard Standard
lower surface of the cylinder block. Cylinder bore 102.500 - 102.75 - 103.000 -
diameter 102.530 102.78 103.030
Cylinder Bearing
Specified bearing outer diameter Piston-to-
block paint Standard 0.23 - 0.25
of crankshaft main journal cylinder
code color Maximum 0.30
clearance
No. 1, 2, 4, 5 69.98 - 70.00 mm
1 Yellow If it is necessary to use pistons whose di-
No. 3 69.95 - 69.97 mm
ameter exceeds the O/S 1.00 mm, replace
No. 1, 2, 4, 5 69.98 - 70.00 mm
2 Green the cylinder block.
No. 3 69.95 - 69.97 mm 2. Decide each oversized piston to be used for
No. 1, 2, 4, 5 69.74 - 69.75 mm each cylinder.
U/S 0.25 mm
No. 3 69.71 - 69.73 mm 3. Measurement of piston diameter
No. 1, 2, 4, 5 69.49 - 69.50 mm Measure the piston diameter at a point 42.83
U/S 0.50 mm mm from the piston head at right angles to the
No. 3 69.46 - 69.48 mm
piston pin hole center line, using a microme-
No. 1, 2, 4, 5 68.99 - 69.00 mm ter, horizontally with the top surface of the pis-
U/S 1.00 mm
No. 3 68.96 - 68.98 mm ton head.
4. Determine the cylinder bore diameter by cal-
culating the size of each cylinder to be bored
as follows.
D=A+B+C
A: Piston diameter
B: Piston-to-cylinder bore clearance
Yellow or
(0.23 - 0.25 mm)
green
1 or 2 C: Horning allowance (0.02 mm)
D: Finishing diameter

No. 1, 2, 3, 4, 5
5. Bore each cylinder to the desired diameter.
VEM00226-00217
6. Hone the cylinder, leaving allowance of 0.02
mm.
BORING OF CYLINDER

CAUTION:
• When the cylinder block is bored, all cylin-
ders should be bored at the same time.
• As for the piston rings, use oversized pis-
ton rings matching with the oversized pis-
A
tons which are to be used after boring.

VEM00227-00218

“To be continued”
 EM–57
INSPECTION AND REPAIRS OF
CRANKSHAFT
1. Visually inspect that there is no roughness on
the main and crankpin journals which will af-
fect its operation.
If any damage is found, regrind or replace the
crankshaft.
2. Inspect the crankshaft for runout.
Ensure that the crankshaft runout does not ex-
ceed the maximum circle runout, using a dial
gauge and “V”-shaped blocks. VEM00229-00220

Maximum circle runout: 0.08 mm 4. Checking oil pump drive gear for damage
(1) Visually check the oil pump drive gear for
damage. If any damage exists, replace
the oil pump drive gear with a new one.
(2) Replacement of oil pump drive gear
q Tap out the oil pump drive gear from
the crankshaft, using a chisel or the
like to provide a space between the oil
pump drive gear and the crankshaft,
the space just enough to install the fol-
lowing SST.
VEM00228-00219
SST: 09506-87303-000
3. Checking of main and crankpin journal diame-
w Install the SST and remove the oil
ters
pump drive gear.
(1) Main journals
e Install the oil pump drive gear by tap-
If the diameter fails to meet the specifica-
ping it, using the following SST in com-
tion, check the oil clearance.
bination with a hammer.
(Refer to page EM–47.)
Then, grind the crankshaft to the specified
dimension specified in the section of
“Replacement of cylinder block” or
“Replacement of crankshaft.”
(2) Crankpin journals
q Measure each crankpin journal diame-
ter at two positions in two directions
shown in the figure, using a microme-
ter.
09506-87303
If the out-of-roundness or taper value
exceeds 0.02 mm, grind it to the diam- VEM00230-00221

eter suitable for undersized bearing or

replace the crankshaft.
If the measured diameter fails to meet
the specification, check the oil clear-
ance.

“To be continued”
EM–58
(Refer to LU section for oil clearance Tight plug No. X.
check) (1) Make a suitable hole at the center of the
Then, if the oil clearance fails to meet tight plug.
the specification, grind the crankpin CAUTION:
journal to the specified dimension suit- • Do not damage the under side of the tight
able for the undersized bearing speci- plug.
fied below.
Bearing Bearing (2) Insert a suitable bar into the hole and pry
Specified outer diameter off the tight plug.
cap paint
of crankpin journal
code color 2. Installation of tight plugs No.1, 2, 3 and 4 and
1 Yellow 60.98 - 61.00 mm expansion plug
2 Green 60.98 - 61.00 mm
(1) Clean and degrease the tight plug attach-
ing surface of the cylinder block and tight
U/S 0.25 mm 60.74 - 60.75 mm
plugs.
U/S 0.50 mm 60.49 - 60.50 mm (2) Apply liquid sealer to the outer periphery
U/S 1.00 mm 59.99 - 60.00 mm of the tight plug.
NOTE: (3) Drive in the tight plug into the cylinder
• Bearing cap code refers to the number block, until the edge of the tight plug is
stamped on the connecting rod cap as positioned 0.2 - 0.8 mm deep from the
shown in the figure bellow. cylinder block surface by holding the
edge surface of the tight plug.
Moreover, the bearing paint color CAUTION:
refers to the paint color which is ap- • Be sure to drive in the tight plug at right an-
plied on the edge surface of the bear- gles to the tight plug hole. Driving the tight
ing for identification purpose. plug in a tilted state may cause water or oil
leakage.
• Do not drive in the tight plug beyond the
specified extent.

(4) Wipe off excessive liquid sealer from the

tight plug driving position.
VE00232-00000

3. Inspection and replacement of oil nozzle

(1) Remove the oil nozzle, using the following
Yellow or Green
1 or 2 SST as shown.
SST: 09219-56010-000
VEM00231-00222

REPAIR OF CYLINDER BLOCK

1. Replacement of tight plug (Replacement per-
formed only when it is necessary.)
Tight plug No.1, 2, 3, 4.
(1) Make a 9 mm hole at the center of the tight
plug. SST
CAUTION:
• Do not damage the under side of the tight
plug.
VEM00233-00223
(2) Make a 10 mm thread, using a tap.
(3) Screw in the 10 mm bolt to remove the
tight plug.

“To be continued”
 EM–59
(2) Ensure that the oil nozzle exhibits no dam- 4. Inspection and replacement of oil check valve
age, such as bend or clogging. subassembly.
If there is any damage that affects its oper- (1) Remove the oil check valve subassembly.
ation, replace the oil nozzle with a new
one.

VEM00236-00226

(2) Ensure that the check ball is functioning

VEM00234-00224 properly by pushing the check ball with a
(3) Installation of oil nozzle suitable wooden stick which may not
q Replace the O-ring of the oil nozzle scratch the check ball.
with a new one.
w Apply a small amount of engine oil to
the new O-ring.
e Align the pointed part of the oil nozzle
with the align mark on the cylinder
block.
r Tap the four oil nozzles into the cylin-
der block, using a brass bar and a
hammer as shown.
CAUTION:
• Be very careful not to damage the O-ring
VEM00237-00227
during the installation.
(3) Install the check valve to the cylinder
block with a new gasket interposed and
tighten it to the specified tightening torque.
Tightening torque: 35 N·m (3.57 kgf-m)

VEM00235-00225

VEM00238-00228
EM–60
5. Replacement of drain cock & cock nozzle
(Replacement performed only when it is nec-
essary.)
(1) Remove the drain cock plug.
(2) Remove the drain cock.

VEM00241-00231

6. Replacement of taper screw plugs

(Replacement performed only when it is nec-
essary.)
(1) Remove the taper screw plug.
VEM00239-00229 (2) Clean the taper screw plug attaching hole
(3) Ensure that no damage exists on the drain of the cylinder block.
cock and drain cock plug. (3) Apply liquid gasket to threaded portion of
If damage exists, replace the damaged the taper screw plug.
parts, as required. (4) Install and tighten the taper screw plug.

VEM00240-00230 VEM00242-00232

(4) Clean the drain cock attaching part of the 7. Replacement of camshaft bearings
cylinder block. (1) Drive off the tight plug provided at the rear
(5) Apply liquid gasket to the threaded por- end of the camshaft on the cylinder block,
tion of the drain cock. using a steel bar or the like.
(6) Install the drain cock to the cylinder block CAUTION:
and tighten it to the specified tightening • Be very careful not to damage the cylinder
torque. block.
Tightening torque: 50 - 90 N·m
(5.1 - 9.2 kgf-m)

(7) Install and tighten the drain cock plug.

Tightening torque: 20 - 30 N·m
(2.0 - 3.1 kgf-m)

VEM00243-00233

“To be continued”
 EM–61
(2) Remove the camshaft bearings, using the (7) Tap in the tight plug to such a depth that
following SST. the outer surface of the tight plug is posi-
SST: 09215-00100-000 tioned 0.2 - 0.8 mm from the chamfered
edge of the cylinder block.
NOTE:
• Be sure to use a correct size of attachment
for each bearing.
,,,
,,,
Attachment to be used:

,,
09224-87301-000

09215-00100
,,
,,,
VEM00245-00235

INSPECTION OF VALVE LIFTERS AND

VALVE LIFTER BORES
1. Inspection of valve lifter oil clearance
VEM00244-00234
(1) Visually inspect that no damage, such as
seizure, nicks and roughness, is present
(3) Check and wash the camshaft attaching
on the valve lifters.
surface of the cylinder block.
Replace the valve lifter if it exhibits any
(4) Install the camshaft bearings, using the
damage.
SST specified in the previous step.
(2) Ensure that the valve lifter roller turns
CAUTION:
smoothly without any binding.
• Be sure to align the oil hole of the bearing
with the hole of the cylinder block before
and during the installation.
• Ensure that the oil hole of the bearing is
aligned with the hole of the cylinder block
after the installation.
• Be very careful not to make burrs on the
bearing during the installation of the bear-
ing.

NOTE:
• Be sure to use a correct size of attachment VEM00246-00236

for each bearing.

Attachment to be used:
09224-87301-000

(5) Degrease the tight plug attaching surface

using washing solvent and dry it with com-
pressed air.
WARNING:
• Protect your eyes by wearing safety gog-
gles.

(6) Apply liquid sealer to the outer periphery

of the tight plug.

“To be continued”
EM–62
(3) Measure the valve lifter bore diameter, REPLACEMENT OF CRANKSHAFT
using a cylinder gauge. FRONT OIL SEAL
Reference 1. Off-vehicle operation
Standard diameter: (1) Tap out the oil seal from the timing gear
27.010 - 27.030 mm cover, using a pin punch or the like.
(4) Measure the valve lifter diameter, using a
micrometer.
Reference
Standard diameter:
26.955 - 26.975 mm

(5) Calculate the oil clearance by subtracting

the measured valve lifter outer diameter
from the measured valve lifter bore diame-
ter.
Maximum oil clearance: 0.10 mm VEM00248-00238

Reference (2) Clean the oil seal attaching surface of the

Standard oil clearance: timing gear cover.
0.035 - 0.075 mm (3) Apply engine oil to the lip section of the
new oil seal.
If the oil clearance is greater than the max- (4) Tap the crankshaft front oil seal into the
imum limit, replace the valve lifter and/or timing gear cover, using the following SST
cylinder block, based on the standard di- and a hammer, until the oil seal surface
ameter of the valve lifter and valve lifter becomes flush with the timing gear cover.
bore diameter of the cylinder block. SST: 09635-20010-000

CAUTION:
• Be very careful not to tilt the oil seal during
installation.

VEM00247-00237

09635-20010

VEM00249-00239
 EM–63
2. On-Vehicle operation REPLACEMENT OF CRANKSHAFT
CAUTION: REAR OIL SEAL
• Do not make scratches or the like on the 1. Off-vehicle operation
crankshaft journal section during operation. (1) Tap out the oil seal from the rear oil seal
• Do not tilt the oil seal during the installa- retainer, using a pin punch or the like.
tion.

(1) Cut off the oil seal lip.

(2) Pry out the oil seal, using a suitable lever
or a screwdriver or following SST.
SST: 09308-10010-000

VEM00252-00242

(2) Clean the oil seal attaching surface of the

rear oil seal retainer.
(3) Apply engine oil to the lip section of a new
09308-10010
oil seal.
(4) Tap the crankshaft rear oil seal into the
VEM00250-00240
rear oil seal retainer, using the following
(3) Clean the oil seal attaching surface or the SST and a hammer, until the oil seal sur-
oil seal retainer and crankshaft. face becomes flush with the rear oil seal
(4) Apply engine oil to the lip section of the retainer.
new oil seal. SST: 09223-63010-000
(5) Install the crankshaft front oil seal into the
timing gear cover, using the following SST CAUTION:
and a hammer, until the oil seal surface • Be very careful not to tilt the oil seal during
becomes flush with the timing gear cover installation.
outer surface.
SST: 09635-20010-000

09223-63010

09635-20010 VEM00253-00243

VEM00251-00241
EM–64
2. In-Vehicle operation INSPECTION AND REPAIR OF
CAUTION: FLYWHEEL
• Do not made scratches or the like on the 1. Inspection of flywheel
crankshaft journal section during operation. Inspection the flywheel for cracks or damage.
• Do not tilt the oil seal during the installa- Replace the flywheel with a new one, if it ex-
tion. hibits damages.
(1) Cut off the oil seal lip.
(2) Pry out the oil seal, using a suitable lever
or a screwdriver.

VEM00256-00246
Cut position
2. Inspection and replacement of input shaft
bearing
(1) Inspection of input shaft bearing
VEM00254-00244
Ensure that the bearing inner race rotates
(3) Clean the oil seal attaching surface of the smoothly without any binding while apply-
rear oil seal retainer and crankshaft. ing pressure in the radial directions.
(4) Apply engine oil to the lip section of the Replace the input shaft, if any binding is
new oil seal. found.
(5) Install the crankshaft rear oil seal into the
rear oil seal retainer, using the following
SST and a hammer, until oil seal surface
becomes flush with the timing gear cover
outer surface.
SST: 09223-63010-000

SST

VEM00257-00247

(2) Replacement of input shaft bearing

q Removal of input shaft bearing
Remove the input shaft bearing, using
the following SST.
SST: 09303-35011-000
VEM00255-00245

09303-35011

VEM00258-00248
 EM–65
w Install the input shaft bearing, using CAUTION:
the following SST. • Do not tap the ring gear using a hammer or
SST: 09304-12012-000 the like.
• Never cool the ring gear quickly using
water, a fan or the like.

e Allow the ring gear to cool naturally.

09304-12012

VEM00259-00249

3. Inspection and replacement of ring gear

(1) Inspect the ring gear for damage.
Replace the ring gear with a new one, if it
exhibits damage. VEM00262-00252

(2) Removal of ring gear ASSEMBLY OF PISTON AND

q Place the ring gear on an adequate CONNECTING ROD
wooden block.
1. Install a new snap ring on one side of the pis-
w Drive out the ring gear, using a chisel
ton pin hole.
in combination with a hammer.

VEM00263-00253
VEM00260-00250
2. Gradually heat the piston to about 60 °C,
(3) Installation of ring gear
using a heater.
q Place a new ring gear horizontally on
3. Assemble the piston and connecting rod by
the flywheel.
inserting the piston pin into the piston and
connecting rod with your thumb while aligning
the front marks on the piston and connecting
rod.

Fitting code
Front
mark

VEM00261-00251

w Using a gas burner, heat the ring gear Front

evenly, until the ring gear due to its mark
own weight fits onto the flywheel VEM00264-00254

“To be continued”
EM–66
4. Install a new snap ring to the other side of the 6. Installation of connecting rod bearings
pin hole of the piston securely, using snap ring (1) Install the connecting rod bearings on the
pliers. connecting rod and conncetiong rod cap,
5. Installation of piston rings making sure that your finger will not touch
(1) Install an oil ring expander and oil rings to the front and back surface of the bearings.
the groove in the piston by hand.
CAUTION:
• Do not expand the piston ring beyond a re-
quired extent.

NOTE:
• Be sure to locate the open end of the oil
ring at the opposite position of the oil ring
expander joint section.

(2) Install the No.1 and No.2 compression

VEM00267-00257
rings with the code mark facing upward,
using a piston ring expander. (2) Cut an appropriate vinyl hose to a suitable
CAUTION: length.
• Do not expand the piston ring beyond a re- (3) Fit the vinyl hose to each connecting rod
quired extent. bolt sections.

VEM00268-00258
VEM00265-00255

(3) Locate the piston ring end gap of each

piston as shown in figure.
Oil ring

Front
No. 1

No. 2
VEM00266-00256
 EM–67
ASSEMBLY OF CYLINDER BLOCK • Do not touch the front and back surfaces of
each bearing. Be sure to hold the bearing
CAUTION: at its edge surface during installation.
• Apply new engine oil to all sliding and ro-
tating surfaces of each part before assem-
bly.
• Replace all gaskets and oil seals with new
ones.

1. Thoroughly clean all parts to be reused and to

be assembled except gaskets and oil seals
with cleaning solvent and dry them with com-
pressed air.
WARNING: VEM00270-00260
• Protect your eyes by wearing safety gog-
(2) Installation of upper thrust washers
gles when using compressed air.
Install the upper thrust washers to the
No.3 main journal section of the cylinder
2. Installation of valve lifter
block in such a direction that the oil
(1) Install the valve lifters to the cylinder
grooves may face outward and that the
block.
claw of the thrust washers matches with
(2) Install the lower side bolts by hand shown
the recessed part provided on the crank-
in the figure while aligning the long hole of
shaft.
valve lifters with the bolt holes.
CAUTION:
• Never scratch the valve lifter during instal-
lation.

Bottom

B
A
VEM00271-00261

(3) Apply engine oil to the crankshaft bearing

Top and thrust washer surface.
VEM00269-00259
CAUTION:
• Do not touch the front and back surfaces of
3. Installation of crankshaft
each bearing.
(1) Install the crankshaft bearing to the cylin-
• Care must be exercised to ensure that no
der block and crankshaft bearing caps
oil flows into the bearing cap attaching bolt
while aligning the bearing claws with the
holes.
claw grooves of the cylinder block and
crankshaft bearing caps.
CAUTION:
• Ensure that the oil hole of the cylinder
block is aligned with the crankshaft bearing
hole.
• The size of bearing No.3 differs from other
bearings.

VEM00272-00262

“To be continued”
EM–68
(4) Place the crankshaft on the cylinder block i r w y !0
gradually.
(5) Apply engine oil to the crankshaft journal
and thrust washer surface.
CAUTION:
• Care must be exercised to ensure that no
oil flows into the bearing cap attaching bolt
holes.
u e q t o

VEM00275-00265

(10) Ensure that the crankshaft turns smoothly.

(11) Check the crankshaft thrust clearance.
(Refer to page EM–45)
VEM00276-00000

4. Installation of piston assembly

(1) Position the piston rings in such a way that
the open end of piston rings may come at
VEM00273-00263 the respective points as indicated in the
(6) Install the lower thrust washers of the No.3 figure. (Refer to page EM–66.)
main bearing cap with the oil groove fac- (2) Apply engine oil to the piston rings, piston
ing outward. pins, connecting rod bearings, cylinder
walls and crankpin journals.
(3) Compress the piston rings by means of a
piston ring compressor, making sure that
the piston ring ends will not move during
the installation.
(4) Insert the piston assembly into the cylinder
in such a direction that the front mark of
the piston may face forward.
(5) Push the piston into the cylinder bore,
using a wooden handle part of a hammer
or the like.
VEM00274-00264
CAUTION:
(7) Install the crankshaft main bearing caps in • Be very careful not to damage the connect-
the numerical sequence with the arrow ing rod bearings during installation.
marks facing the oil pump side. • Care must be exercised to ensure that the
(8) Thinly apply engine oil to the threaded crankpin journal is not scratched by the
section of the crankshaft main bearing cap connecting rod.
bolts.
(9) Tighten the crankshaft main bearing cap 09217-87001
bolts to the specified torque over two or Front
three stages in the sequence shown in the mark
right figure.
Tightening torque: 200 N·m (2.04 kgf-m)
Front

VEM00277-00266

“To be continued”
 EM–69
(6) Push the piston by hand gradually until the (13) Put the front mark on the connecting rod
connecting rod reaches the crankpin jour- cap nuts with paint or the like.
nal. (14) Furthermore, tighten the connecting rod
CAUTION: cap nuts 90 degrees (1/4 turn).
• Be very careful not to damage the crankpin (15) Ensure that the mark provided on the con-
journal and bearing surface during installa- necting rod cap nuts faces sideward.
tion.

(7) Apply engine oil to the bearing surface of Paint mark

each connecting rod bearing.
CAUTION:
• Do not touch the bearing surface.

(8) Remove the vinyl hoses which have been 90˚

attached to the connecting rod bolts.
(9) Install the connecting rod cap with the Front side
front mark facing toward the oil pump side.
VEM00280-00269

(16) Ensure that the crankshaft turns smoothly.

(17) Ensure that the connecting rod thrust
Front mark clearance is within the specified value.
(Refer to page EM–43.)
VEM00281-00000

5. Installation of rear oil seal retainer

Front (1) Install the rear oil seal retainer with a new
gasket interposed.
(2) Install the six attaching nuts of the rear oil
seal retainer and tighten them to the speci-
VEM00278-00267 fied torque evenly over two or three
(10) Thinly apply engine oil to the threaded stages.
section of the connecting rod cap nuts. Tightening torque: 18.5 N·m (1.89 kgf-m)
(11) Install the connecting rod cap nuts.
(12) Tightening of connecting rod cap bolts
Tighten the connecting rod cap nuts to the
specified torque evenly over two or three
stages.
Tightening torque: 68.6 ± 4.9 N·m
(7.0 ± 0.5 kgf-m)

If any one of the nuts does not meet the

specification, or is broken or deformed, re-
place the connecting rod bolts with new
VEM00282-00270
one.

VEM00279-00268
EM–70
6. Installation of oil pump 7. Installation of oil strainer and oil pipe
(1) Ensure that the knock pins are installed on (1) Install the oil strainer with the two nuts and
the cylinder block surface as shown. two bolts with new gaskets interposed.
Tighten the attaching bolts and nuts even-
ly to the specified tightening torque.
Tightening torque: 18.5 N·m (1.89 kgf-m)

(2) Install the oil pipe to the cylinder block

with new gaskets for pipe and union bolts
interposed. Tighten them evenly to the
specified tightening torque.
Tightening torque
Nuts: 18.5 N·m (1.89 kgf-m)
Union: 50 N·m (5.1 kgf-m)
VEM00283-00271

(2) Install the oil pump to the cylinder block

with a new gasket interposed.
(3) Install the oil pump attaching bolts and
tighten them evenly over two or three
stages to the specified tightening torque.
Tightening torque
Bolts A & B: 44 N·m (4.49 kgf-m)
C : 18.5 N·m (1.89 kgf-m)

NOTE:
• Be sure to install the correct length of bolts VEM00285-00273

to each specified position.

A B

B
C
C C

C C

VEM00284-00272
 EM–71
8. Installation of oil pan
(1) Clean the oil pan attaching surface of the
cylinder block and oil pan, using degrease
detergent or the like and dry them, using
washing solvent.
NOTE:
• Remove gasket materials thoroughly from
the oil pan and cylinder block before de-
greasing.

CAUTION:
• Do not use a solvent which will affect the
painted surface.

(2) Apply seal packing (FIPG) to the oil pan

as shown in the figure.
CAUTION:
• The cutout dimension of the seal packing
which is applied to the oil pan should be
about 4 mm.
• Do not apply seal packing beyond the
specified extent, especially around the oil
VEM00286-00274
passage to prevent the oil passage from
being blocked. 9. Installation of injection pump.
• Be sure to assemble the oil pan within fif- (1) Replace the O-ring with a new one.
teen minutes after the seal packing is ap- (2) Install the injection pump with bracket to
plied. the cylinder block by attaching the nuts
and bolts temporarily.
(3) Install the oil pan attaching bolts and nuts (3) Tighten the injection pump attaching nuts
and tighten them evenly to the specified to the specified tightening torque, while
tightening torque. aligning the mark on the injection pump
Tightening torque: 18.5 N·m (1.89 kgf-m) with that on the oil pump (timing gear
case).
(4) Wipe off excessive seal packing. Tightening torque: 18.5 N·m (1.89 kgf-m)

(4) Tighten the injection pump bracket attach-

ing bolts to the specified tightening torque.
Tightening torque: 18.5 N·m (1.89 kgf-m)

VEM00287-00275

“To be continued”
 EM–72
10. Install the oil cooler case with the attaching
bolts, nuts and hexagon bolt with a new gas-
ket interposed.
Tighten them to the specified tightening
torque.
Tightening torque: 21 N·m (21.4 kgf-m)

VEM00298-00283

15. Installation of oil pressure switch

(1) Clean the oil pressure switch attaching
hole of the cylinder block.
(2) Clean the threaded portion of the oil pres-
sure switch.
VEM00288-00276 (3) Apply liquid gasket to the threaded portion
11. Install the oil filter bracket with the attaching of the oil pressure switch as shown.
bolts with a new gasket interposed. (4) Install the oil pressure switch to the cylin-
NOTE: der block, using a long box wrench having
• Be sure to install the bolt having a correct a hexagonal hole.
length to each specified position.

Tighten the attaching bolts to the specified

tightening torque.
Tightening torque: 44 N·m (4.49 kgf-m)

VEM00299-00284

16. Installation of cylinder head

(Refer to the cylinder head section for installa-
tion.)
17. Installation of injection pipes
VEM00289-00277 (Refer to the MA section.)
12. Install of oil filter 18. Installation of water pump pully and fan
(Refer to the MA section for installation.) (Refer to the cylinder head section for installa-
13. Installation of timing gears and camshaft. tion.)
(Refer to the section of the timing gears and VEM00290-00000

camshaft.)
14. Installation of vacuum pump
(1) Replace the O-rings with new ones.
(2) Install the vacuum pump to the oil pump
(timing gear case) with attaching bolts.
Tighten them to the specified torque even-
ly.

“To be continued”
 EM–73
19. Install the rear end plate by installing its at-
taching bolts and secure the bolts.
Tightening torque: 18.5 N·m (1.89 kgf-m)

VEM00296-00282

21. Installation of clutch cover and clutch disc.

Install the clutch cover and clutch disc, while
VEM00294-00280 centering them by means of the following SST.
20. Installation of flywheel SST: 09301-20020-000
(1) Ensure that the flywheel attaching bolts
holes and attaching surface of the crank
shaft and flywheel are dry.
09301-20020
If not, degrease the attaching bolt hole
and attaching surface, using washing sol-
vent and dry them with compressed air.
WARNING:
• Protect your eyes by wearing safety gog-
gles when using compressed air.

(2) Apply engine oil to the threaded section of

VEM00291-00278
the attaching bolts.
(3) Install the flywheel with attaching bolts and 22. Tighten the clutch cover to the specified
tighten the attaching bolts to the specified torque.
tightening torque in the sequence as Tightening Torque: 14.7 - 24.5 N·m
shown in the figure. (1.5 - 2.5 kgf-m)
Tightening torque: 160 N·m(16.3 kgf-m)

VEM00292-00279

VEM00295-00281
23. Fill engine oil.
(4) Ensure that the runout of the flywheel is (Refer to MA section for refill of engine oil.)
within the specified value. 24. Adjust the tension of the drive belt.
Maximum runout: 0.2 mm (Refer to the MA section for adjustment.)
25. Remove the engine from the engine overhaul
bench and place it on an engine stand.
VEM00293-00000

“To be continued”
 EM–74
26. Install the engine to the vehicle properly.
27. Fill coolant.
28. Connect the battery ground cable to the nega-
tive terminal of the battery.
29. Perform the engine tune-up.
(Refer to the engine tune-up procedure.)
VEM00297-00000
 EM–75
TIGHTENING TORQUE
Components N·m kgf-m
Rocker shaft & Rocker support 7.5 0.76
Cylinder head & Cylinder block (Wet) 49 ± 4.9 + 90°+90° 5.0±0.5+90°+90°
Rocker arm adjusting screw 18.5 1.89
Cylinder head & Exhaust manifold 47.5 4.84
Exhaust manifold & Heat insulater 18.5 1.89
Cylinder head & Adjusting bar 37.5 3.82
Cylinder head & Water outlet housing 18.5 1.89
Cylinder head & Intake manifold 18.5 1.89
Intake manifold & Venturi 21 2.14
Intake manifold & Fuel filter bracket 39.6 - 48.8 4.0 - 5.0
Camshaft & Timing gear 37.5 3.75
Cylinder block & Cam thrust plate 18.5 1.89
Oil pipe No. 1 & Gear case 11 1.12
Idle gear shaft & Cylinder block (Wet) 47.5 4.84
Timing gear case & Timing gear cover Bolt: A 21 2.14
Timing gear case & Timing gear cover Bolt: B 44 4.49
Crankshaft & Crankshaft pully (Wet) 294 30
Valve filter set bolt Bottom side: 37.5 3.82
Valve filter set bolt Top side: 7.5 0.76
Cylinder block & Alternator bracket (Wet) 98 10
Cylinder block & Check valve 35 3.57
Cylinder block & Drain cock 50 - 90 5.1 - 9.2
Draincock & Drain cock plug 20 - 30 2.0 - 3.1
Cylinder block & Crankshaft main bearing cap (Wet) 200 20.4
Connecting rod & Connecting rod cap (Wet) 68.6 ± 4.9 + 90° 7.0±0.5+90°
Cylinder block & Rear oil seal retainer 18.5 1.89
Cylinder block & Timing gear case Bolt: A&B 44 4.49
Cylinder block & Timing gear case Bolt: C 18.5 1.89
Cylinder block & strainer 18.5 1.89
Cylinder block & Oil pipe Nuts: 18.5 1.89
Cylinder block & Oil pipe Union: 50 5.1
Cylinder block & Oil pan 18.5 1.89
Injection pump & Timing gear case 18.5 1.89
Cylinder block & Injection pump bracket 18.5 1.89
Cylinder block & Oil cooler case 21 2.14
Oil cooler case & Oil filter bracket 44 4.49
Cylinder block & Rear end plate 18.5 1.89
Crankshaft & Fylwheel (Wet) 160 16.3
VEM00303-00000
EM–76
SST (Special service tools)
Shape Part No. Part name Remarks
09202-87001-000 Remover & replacer, valve
cotter

09201-60011-000 Remover & replacer, valve

guide bush

09213-31021-000 Puller, crankshaft pully

09330-00021-000 Tool, companion flange

holding

09609-20010-000 Puller, steering wheel

09278-87201-000 Tool, timing belt pully

holding

09635-20010-000 Replacer, lower ball joint

dust cover

09308-10010-000 Puller, oil seal

09517-87702-000 Replace, oil seal

09506-87303-000 Replacer, differential drive

pinion bearing corn, front

09032-00100-000 Cutter, oil pan seal

 EM–77
Shape Part No. Part name Remarks
09221-46010-000 Remover & replacer,
piston pin

09222-58020-000 Remover & replacer,

connecting rod bush

09219-56010-000 Remover, piston cooler

09215-00100-000 Remover & replacer,

camshaft bearing

09223-63010-000 Replacer, crankshaft rear

oil seal

09303-35011-000 Puller, input shaft front

bearing

09304-12012-000 Replace, input shaft front

bearing

09217-87001-000 Guide, piston replaming

09224-87301-000 Attachment, camshaft

bearing remover &
replacer

VEM00304-000287

TO INDEX TO NEXT SECTION