Page 369 of 513

ENGINE
MECHANICAL
o
Match
mark
Key
groove
Fig
EM
78
1
Setting
chain
12
Install
the
timing
chain
and
camshaft
sprocket
Camshaft
sprocket
tightening
torque
4
0
to
4
8
kg
m
29
to
35
ft
lb
Fig
EM
78
2
Chain
tensioner
installation
Fig
EM
7B
Cam
sprocket
gear
installation
Notes
a
Make
sure
that
the
camshaft
sprocket
dowel
hole
and
crankshaft
sprocket
key
are
in
line
and
both
the
dowel
hole
and
key
are
located
down
ward
b
Set
the
timing
chain
making
its
mating
marks
meet
with
those
of
crankshaft
sprocket
and
camshaft
sprocket
at
the
right
hand
side
13
Install
the
timing
chain
tensioner
and
tighten
the
tensioner
bolts
to
a
torque
of
0
6
to
0
8
kg
m
4
3
to
5
8
ft
lb
Check
the
tensioner
spindle
projection
Wear
limit
Spindle
projection
mm
in
15
0
591
Fig
EM
79
Checking
the
tension
spindle
projection
14
Install
the
crankshaft
oil
thrower
15
Install
the
new
oil
seal
to
the
front
cover
The
front
cover
oil
seal
should
be
replaced
when
the
front
cover
is
disassembled
16
Install
the
front
cover
applying
the
sealing
agent
to
both
surfaces
of
the
gasket
Tightening
torque
0
5
to
0
7
kg
m
3
6
to
5
1
ft
lb
EM
29
Page 370 of 513

ENGINE
17
Install
the
oil
strainer
and
the
oil
pan
using
the
gasket
Apply
sealing
agent
on
hath
surfaces
of
the
gasket
especially
on
the
front
and
rear
portions
of
the
oil
pan
Oil
pan
tightening
torque
0
4
to
0
6
kg
m
I
9
to
4
3
ft
lbJ
I
R
I
nvcrt
the
engine
and
install
the
cylinder
head
assembly
and
gasket
Cylinder
head
gasket
with
O
ring
Cylinder
block
side
Steel
sheet
D
QCO
0
0
i
O
1
nrr
11
I
Li
I
I
Vo
o
f
C
C
r
c
Sealing
agent
not
required
Cylinder
head
side
Joint
sheet
Remarks
Install
without
applying
sealing
agent
Be
careful
not
to
damage
the
push
rod
side
because
this
side
has
previously
been
provided
with
sealing
agent
Fig
EM
80
Cy
linder
head
installatjo
1
Note
Apply
sealing
agent
overall
the
cylinder
block
surface
Place
the
gasket
on
it
and
apply
sealing
agent
to
the
gasket
top
19
Tighten
the
cylinder
head
bolts
to
the
specified
torque
The
cylinder
head
uses
two
types
of
installation
bolt
one
is
for
the
center
right
side
and
the
other
is
for
all
other
positions
The
bolt
for
the
center
right
side
has
a
O
ring
j
I
Y
J
CYlinder
head
I
I
Cvlinderheadgasket
I
Cylinder
block
O
ring
To
be
inserted
into
hole
in
cylinder
block
T
mark
on
its
head
Tightening
torque
5
5
to
6
0
kg
m
40
to
43
ft
lb
fI
J
D
Bolt
number
Diameter
Identification
mark
CD
7
9
to
8
1
1
0
3111
to
0
3189
T
mark
Except
for
CD
8
87
to
9
03
o
not
marked
0
3492
to
0
3555
Fig
EM
8t
Head
bolt
segment
l
Fig
EM
82
Tightening
sequenc
EM
3D
Page 371 of 513

ENGINE
MECHANICAL
20
Install
the
push
rods
21
Install
the
rocker
shaft
assembly
and
tighten
the
rocker
shaft
bracket
bolts
to
the
specified
torque
Tightening
torque
2
0
to
2
5
kg
m
15
to
18
ft
Ib
Note
Tightening
operation
should
be
made
gradually
in
separating
two
or
three
stages
and
outwardly
from
the
center
bracket
Fig
EM
B
RockeT
shaft
installation
22
Install
the
intake
and
exhaust
manifolds
Tightening
torque
0
9
to
I
4
kg
m
6
5
to
10
ft
lb
Fig
EM
B4
Installation
of
intake
and
exhaust
manifolds
23
Adjust
valve
clearance
with
the
specified
di
mensions
Fig
EM
85
Valve
clearance
adjustment
Intake
at
cold
rom
in
0
35
0
0138
Exhaust
at
cold
rom
in
0
35
0
0138
24
Install
the
rocker
cover
and
carburetor
assembly
25
Install
the
water
pump
and
thermostat
Tightening
torque
0
9
to
I
4
kg
m
6
5
to
10
ft
lb
26
Install
the
crankshaft
pulley
Tighten
the
crank
pulley
bolt
to
the
specified
torque
Tightening
torque
15
to
16
kg
m
109
to
116
ft
lb
Tightening
tOI
q
e
15
JP
16
g
m
10l
to
11
ft
Ib
Fig
EM
B6
CTankshaft
pulky
installation
EM
31
Page 372 of 513
ENGINE
27
Install
the
oil
pump
with
oil
filter
28
Install
the
alternator
fan
and
fan
belt
29
Install
the
fuel
pump
30
Install
the
distributor
assembly
Fig
EM
B7
Timing
maTk
Fig
EM
SS
Distributor
installation
EM
32
Notes
3
Set
the
No
1
piston
to
its
top
dead
center
of
the
compression
stroke
b
Before
installation
return
the
distributor
rotor
approximately
60
degrees
from
its
regular
posi
tion
Insert
the
assembly
meshing
the
distributor
drive
gear
and
driven
gear
After
installation
the
distributor
rotor
should
come
into
contact
with
the
mark
on
the
rotor
cap
fitting
as
shown
in
the
Figure
31
Install
the
spark
plugs
and
connect
the
distributor
to
plug
high
tension
lead
wire
32
Install
the
fuel
hoses
and
tubes
33
Install
the
clutch
cover
assembly
34
Install
the
engine
stingers
and
crankcase
ventilation
hose
35
Dismount
the
engine
from
the
working
stand
Install
the
engine
mountings
Page 373 of 513
ENGINE
MECHANICAL
SERVICE
DATA
AND
SPECIFICATIONS
GENERAL
SPECIFICATION
Cylinder
arrangement
4
in
line
Displacement
cc
cu
in
mm
in
1
171
71
5
73
x
70
2
874
x
2
756
Bore
and
stroke
Valve
arrangemen
t
Over
head
valve
Firing
order
I
3
4
2
Engine
idle
rpm
800
Manual
transmission
650in
D
Automatic
transmission
Compression
ratio
8
5
Oil
pressure
Hot
at
2
000
rpm
kgfcm2
Ibfsq
in
3
0
to
3
5
43
to
50
TIGHTENING
TORQUE
Unit
kg
m
ft
lb
Cylinder
head
bolts
Flywheel
bolts
5
5
to
6
0
40
to
43
3
2
to
3
8
23
to
28
6
5
to
7
5
47
to
54
5
0
to
6
0
36
to
43
4
0
to
4
8
29
to
35
0
4
to
0
6
2
9
to
4
3
l
l
to
I
7
8
0
to
12
0
9
to
I
4
6
5
to
10
15
to
16
108
to
116
Connecting
rod
nuts
Main
bearing
cap
bolts
Camshaft
gear
bolts
Oil
pan
bolts
Oil
pump
bolts
Oil
strainer
bolts
Crank
pulley
bolts
EM
33
Page 374 of 513
ENGINE
SPECIFICATION
a
Valve
mechanism
Valve
clearance
Hot
Intake
mm
in
Exhaust
0
35
0
0138
0
35
0
0138
Valve
clearance
Cold
Intake
Exhaust
mm
in
0
25
0
0098
0
25
0
0098
Valve
head
diameter
mm
in
Intake
35
1
378
29
1
142
Exhaust
Valve
stem
diameter
mm
in
Intake
7
970
to
7
985
0
3138
to
0
3144
7
945
to
7
960
0
3128
to
0
3134
Exhaust
Valve
length
mm
in
Intake
Exhaust
102
35
to
102
65
4
030
to
4
041
102
35
to
102
65
4
030
to
4
041
Valve
spring
assembled
height
111m
kg
in
lb
8
5
0
3346
46
5
1
831
30
2
58
5
1
I99
129
38
7
23
9
1
524
52
7
5
0
Valve
lift
mm
in
Valve
spring
free
length
mm
in
Valve
spring
loaded
length
mm
kg
in
lb
Valve
spring
effective
turns
Valve
guide
length
111m
in
4
100
0
1614
26
4
1
031
1
53
2
087
Valve
spring
wire
diameter
mm
in
V
alve
sp
g
coil
diameter
inm
L
Valve
guide
height
from
head
surface
111m
in
18
0
709
Valve
guide
inner
diameter
mm
in
Intake
8
015
to
8
000
0
3156
to
0
3150
Exhaust
8
015
to
8
000
0
3156
to
0
3150
EM
34
Page 375 of 513

ENGINE
MECHANICAL
Valve
guide
outer
diameter
mm
in
Intake
12
044
to
12
033
0
4737
to
0
4733
Exhaust
12
044
to
12
033
0
4737
to
0
4733
Valve
guide
to
stem
clearance
mm
in
Exhaust
O
oJ5
to
0
045
0
0006
to
0
0018
0
040
to
0
070
0
0016
to
0
0028
Intake
Valve
seat
width
Intake
Exhaust
mm
in
1
3
0
0512
1
8
0
0709
Valve
sea
tangle
Intake
450
Exhaust
450
Valve
seat
interference
fit
mm
in
Intake
0
064
to
0
096
0
0025
to
0
0038
Exhaust
0
064
to
0
096
0
0025
to
0
0038
Valve
guide
interference
fit
rom
in
Intake
Exhaust
0
022
to
0
044
0
0009
to
0
0017
0
022
to
0
044
0
0009
to
0
0017
b
Camshaft
and
timing
chain
Camshaft
lobe
lift
mm
in
mm
in
0
02
to
0
08
0
0008
to
0
0031
Camshaft
end
play
5
65
0
222
Camshaft
journal
diameter
mm
in
1st
43
783
to
43
796
I
7237
to
I
7242
2nd
43
283
to
43
296
1
7041
to
1
7046
3rd
42
783
to
42
796
1
6844
to
1
6849
4th
42
283
to
42
296
1
6647
to
1
6652
5th
41
208
to
41
221
1
6224
to
1
6229
Camshaft
bend
mm
in
0
015
0
0006
Camshaft
bearing
inner
diameter
mm
in
1st
43
843
to
43
833
I
7261
to
1
7257
EM
35
Page 376 of 513

2nd
lrd
4th
5th
c
Rocker
arm
lever
ratio
d
Connecting
rod
Center
distance
Bearing
thickness
Big
end
end
play
Connecting
rod
bearing
clearance
Connecting
rod
bend
e
Crankshaft
and
main
bearing
Journal
diameter
Journal
taper
and
out
of
round
Crankshaft
end
play
mm
in
mm
in
mm
in
mm
in
mm
in
mm
in
mm
in
mm
in
Maximum
service
limit
of
crankshaft
mm
in
end
play
Crank
pin
diameter
mm
in
Main
bearing
thickness
Crank
pin
taper
and
out
of
round
mm
in
mm
in
Main
bearing
clearance
mm
in
Maximum
seIVice
limit
of
main
bearing
clearance
mm
in
Crankshaft
bend
f
Piston
mm
in
ENGINE
43
333
to
43
323
l
7060
to
I
7050
42
846
to
42
836
1
6868
to
1
6865
42
333
to
42
323
1
6667
to
1
6663
41
268
to
41
258
1
6247
to
1
6243
142
12147
to
121
53
4
7812
to
4
7788
1
500
to
1
508
0
0591
to
0
0594
0
2
to
0
3
0
0079
to
0
0012
less
than
0
4
0
016
0
020
to
0
050
0
0008
to
0
0020
0
05
to
0
10
0
0020
to
0
0039
49
951
to
49
964
1
9666
to
1
9671
less
than
0
03
0
0012
0
05
to
0
15
0
0020
to
0
0059
0
3
0
0118
44
974
to
44
961
1
2706
1
177012
less
than
0
03
0
0012
1
835
to
1
827
0
0722
to
0
0719
0
020
to
0
062
0
0008
to
0
0024
0
15
0
0059
0
Gl5
to
0
05
0
0006
to
0
0020
EM
36