
ENGINE 
MECHANICAL
Standard
mm 
in
Camshaft
sprocket
run 
out
Thrust 
deviation 
O 
OIS
0 
0006
Locating 
plate
thrust 
clearance 
0 
02 
to
0 
08
0 
0008 
to 
0 
003 
Wear 
limit
mm 
in
less 
than
0
0
0039
O
OS
0
0020
0 
1
0
0039
3
Check 
the
chain 
for
damage 
excessive
wear 
and
stretch 
at
its 
roller
links
Replace 
chain 
if
defective 
Flyw 
heel
I
Check 
the
clutch 
disc 
contact
surface 
of 
the
flywheel
for
damage 
and
wear
Repair 
or
replace 
if
necessary
2
Measure 
deviation 
of 
the
clutch 
disc 
contact 
surface
with 
a 
dial
gauge
If 
it
exceeds 
0 
2
mm 
0 
0079 
in
replace 
it
3
Check
tooth 
surfaces 
of 
the
ring 
gear 
for
flaw 
and
wear
Replace 
if
necessary
Note
Replace 
the
ring 
gear 
at
about 
180 
to
2000C 
356
to 
3920
Fl
ENGINE 
ASSEMBLY
PRECAUTION
CYLINDER 
HEAD
PRECAUTION 
CONTENTS
EM 
25
EM
25
Use
thoroughly 
cleaned
parts 
Particularly 
make
sure
that 
oil
holes 
are 
clear
of
foreign 
matter
2
When
installing 
sliding 
parts 
such 
as
bearings 
be
sure
to
apply 
engine 
oil
to 
them
3
Use 
new
packings 
and 
oil 
seals
4
Keep 
tools
and 
work 
benches 
clean
S
Keep 
the
necessary 
parts 
and 
tools 
near 
at 
hand
6 
Be 
sure 
to
follow
specified 
tightening 
torque 
and
orders
CYLINDER 
HEAD
Assembly 
of 
valve 
and 
valve
spring
Set 
the 
valve
spring 
seat 
in
position 
and 
fit 
the 
valve
guide 
with 
the
oil
lip 
seal
Assemble 
the
parts 
in 
order 
valve
spring 
spring
retainer
valve 
collet 
and
valve 
rocker
guide 
PISTON 
AND 
CONNECTING 
ROO
ASSEMBLING 
ENGINE 
EM 
25
EM 
26
I
I
11
00
I 
I
I
t
I
J
ftr
J
J
1
l
J
r
N
1
n
r
VI
I
I
C
I
L
I
Fig 
EM 
68 
Valve 
installation
Note 
Make
sure 
that 
the 
valve 
face 
is 
clear 
from
foreign
matters
PISTON 
AND
CONNECTING
ROD
Assemble
piston 
piston 
pin 
and
connecting 
rod
assorted
according 
to
cylinder 
number
for
every 
cylinder
EM 
25 

ENGINE 
MECHANICAL
3
Apply 
engine 
oil
to 
the 
main
bearing 
surfaces 
on
both 
sides 
of 
the
cylinder 
block 
and
cap
Install 
the 
crankshaft
4 
Install 
the 
main
bearing 
cap 
and
tighten 
the
bolts
with
specified 
torque
Tightening
torque
5 
0
to 
6
0
kg 
m 
36
to 
43
ft 
lb
Notes 
a
Arrange 
the
parts 
so 
that 
the 
arrow
mark 
on
the
bearing 
cap 
is 
faced 
toward 
the 
front 
of 
the
engine
b 
Prior 
to
tightening 
the
bearing 
cap 
bolts
place
the
bearing 
cap 
at 
a
proper 
position 
by
shifting
the 
crankshaft 
in 
the
axial 
direction
c
Tighten 
the
bearing 
cap 
bolts
gradually 
in
separating 
two 
to
three
stages 
and
outwardly 
from
the 
center 
beari
ng
d 
After
securing 
the
bearing 
cap 
bolts 
ascertain
that 
the 
crankshaft
can 
be
easily 
rotated
5 
Make 
sure
that 
the 
crankshaft 
end
play 
is
correct
Crankshaft 
end
play
0 
05
to 
0 
15
rom 
0 
0020 
to
0 
0059
in
Fig 
EM 
73
Crankshaft 
end
play 
check
EM 
27 
Fig 
EM 
73 
t
Applying 
adhesive
6 
Install 
the 
rear 
oil 
seal
7 
Install 
the
flywheel 
securely
using 
the
lock 
washers
and
tighten 
the 
bolts 
with
specified
torque
Tightening 
torque
6
5 
to 
7 
5
kg 
m 
47
to 
54
ft 
lb
Iii
Fig 
EM 
74
Flywheel 
installation
8 
Rotate 
the
engine 
a
quarter 
turn 
and 
install 
the
piston 
rod
assembly 

ENGINE
Fig 
EM 
75 
Piston 
and
connecting 
rod
assembly 
installation
Notes 
8
I 
nsert
the
pistons 
in 
the
corresponding 
cyl
inders
b
Apply 
engine 
oil 
to
parts 
as
requried
c
Arrange 
pistons 
so
that 
the 
F 
mark 
on 
the
piston 
is 
faced 
to
the 
front 
of 
the
engine
d 
Install
piston 
rings 
at 
180 
to 
each 
other
avoiding 
to 
fit 
them 
in 
the 
thrust 
and
piston
pin
axial 
directions
Fig 
EM 
76
Connecting 
rod
cap 
installation
Note
Arrange 
connecting 
rods 
and
connecting 
rod
caps
so 
that 
the
cylinder 
numbers 
are 
faced
toward 
the
same 
direction
EM 
28 
q
Install
the
connecting 
rod
cap
Tightening
torque
32 
to 
3 
8
kg 
m 
23 
I
to 
7 
S 
ft 
lb
10 
Make
sure 
that 
end
play 
of 
the
connecting 
rod
large
end 
is
correct
Big 
end
play
j
I
Fig 
EM 
77
Big 
end
play 
check
Big 
end 
end
play 
0 
2
to 
0
3
0
0079 
to 
0 
0118
11 
Install 
the 
camshaft 
and
crankshaft
sprockets
temporarily 
for
adjustment 
of 
the 
tooth
height 
by
using
adjusting 
washers
Height 
difference
mm 
in 
less 
than 
O 
S
0 
0197
Adjusting 
washer
thickness 
mm
in 
O 
IS 
0 
006
Fig 
EM 
78
Adjusting 
sprocket 
tooth
height 

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 

Water
pump
knocking
II 
Other 
mechanical
trouble
Sticked
valve
Seized
valve
seat
Excessively 
worn
cylinder 
and
piston 
ENGINE
MECHANICAL
Improper 
shaft 
end
play
Broken
impeller
Improper 
valve 
clearance
Insufficient 
clearance 
between
valve 
stem
and
guide
Weakened 
or 
broken 
valve
spring
Biting 
or
damage 
ofvalve
stem
Poor 
fuel
quality
Improper 
valve
clearance
Weakened 
valve
spring
Thin
valve 
head
edge
Narrow 
valve 
seat
Overheat
Over
speeding
Sticked
valve
guide
Shortage 
of
engine 
oil
Dirty
engine 
oil
Poor
oil
quality
Overheat
Wrong 
assembly 
of
piston 
with
connecting 
rod
Improper 
piston 
ring 
clearance
Dirty 
air
cleaner
Too
rich 
mixture
Engine 
over 
run
Slicked 
cho 
e 
valve
Over
choking
EM 
39 
Replace
Replace
Adjust
Clean 
stem 
or
ream 
the
guide
Replace
Replace 
or 
clean
Use
good 
fuel
Adjust
Replace
Replace 
valve
Reface
Repair 
or
replace
Drive 
under
proper 
speed
Repair
Add 
or
replace 
oil
Check 
oil 
level
on
daily 
basis
Clean 
crankcase
replace 
oil
and
re
place 
oil 
fIlter 
element
use
right 
oil
Repair 
or
replace
Repair 
or
replace
Adjust
Clean
periodically
Adjust
Drive
correctly
Clean 
and
adjust
Start 
in
correct
way 

r
Defective
connecting
rod
Defective 
crankshaft
bearing 
ENGINE
Shortage 
of
engine 
oil
Low 
oil
pressure
Poor
engine 
oil
quslity
Rough 
surface 
of 
crankshaft
Clogged 
oil
passage
Wear 
or
eccentricity 
of
bearing
Wrong 
assembly 
of
bearing
Loose
bearing
Incorrect
connecting 
rod
alignment
Shortage 
of
engine 
oil
Low 
oil
pressure
Poor
engine 
oil
quality
Wear
or 
out 
of
round 
of 
crankshaft
journal
Clogged 
oil
passage 
in 
crankshaft
Wear 
or
eccentricity 
of
bearing
Wrong 
assembly 
of
bearing
Not 
concentric
crankshaft 
or
bearing
EM
40 
Add 
or
replace 
oil
Check 
oil 
level 
on
daily 
basis
Correct
Use
right 
oil
Grind 
and
replace 
bearing
Clean
Replace
Repair
Replace
Repair 
or
replace
Add 
or
replace
Check 
oil 
level 
on
daily 
basis
Adjust
Use
right 
oil
Repair
Clean
Replace
Repair
Replace 

LUBRICATION 
CIRCUIT
Oil 
drawn
from 
the 
oil
pan 
through 
the 
inlet
screen 
and
tube
to 
the 
inlet 
side 
of 
the 
oil
pump 
is 
delivered
by 
th
oil
pump 
through 
the 
outlet
portion 
of 
the 
oil
pump 
and
the 
oil
gallery 
to 
the 
inlet
side 
of 
the 
full 
flow 
oil
filter
and 
to 
the
main 
oil
gallery
The 
main 
oil
gallery
supplies 
oil 
to 
the
crankshaft 
main
bearings 
and
drilled
passages 
in 
the 
crankshaft 
and
thus
oil 
is
fed
directly 
from 
the
main
bearings 
to 
the
connecting 
rod
bearings
Oil
injected 
from
jet 
holes
on
connecting 
rods
lubri
cates 
the
cylinder 
walls 
and
pistion 
pins
The 
oil
distributed 
from 
the 
main
gallery 
enters 
the
chain
teosioner 
and 
the
pad 
is 
held
against 
the
chain
by
oil
pressure 
and
spring 
The 
oil
also 
lubricates 
the
timing
chain
through 
the
jet 
hole
located
near 
the 
chain
Furthermore
lubricant 
is
supplied 
to 
each 
camshaft
bearing 
through 
each 
crankshaft 
main
bearing 
and
finally
to 
the 
011
gallery 
in 
the 
rocker
shaft
through 
the 
center
camshaft
bearing
The 
rocker
arm 
and 
valve
are 
lubricated
by 
the 
oil
through 
the 
oil
gallery 
in 
the
rockershaft
To 
this
oil
gallery 
lubricant
is
supplied 
through 
the
center
camshaft
bearing 
as 
shown
in
Figure 
EL 
I
OIL 
PUMP
Description
The 
oil
pump 
assembly 
is 
installed 
on 
the 
bottom 
of
the
cylinder 
block 
and 
driven
by 
the 
distributor
drive
shaft
assembly 
The 
oil
pump 
is 
of
a 
rotor
type 
The 
oil
pressure 
is
regulated 
by 
the
regulator 
valve 
camshaft
Removal
Engine 
in 
vehicle
Drain
engine 
oil
2 
Remove 
the 
frunt
stabilizer
3 
Remove 
the
splash 
shield
board
4 
Detach 
the 
oil
pump 
body 
together 
with 
drive
gear
spindle 
ENGINE
Fig 
EL 
2 
Removal
of 
oil
pump
Disassembly
Prior 
to
disassembling 
check 
to
determine 
that 
the
pump 
is
defective
Take
out 
a 
total 
of 
2 
bolts
securing 
the
pump 
cover
to 
the
pump 
body 
The
outer 
and 
inner
rotors 
and 
drive
shaft 
can
then 
be
disassembled
2
Applying 
a 
suitable 
wrench 
or
spanner 
loosen 
off 
the
regulator 
valve
Note 
a 
When
placing 
the 
valve 
in 
a 
vise 
use 
extreme
care 
not 
to 
distort 
the
pump 
body 
and 
cover 
in 
the
jaws
b 
Do
not
pull 
out 
the 
drive 
shaft
pin
securing 
the
driven 
shaft 
and 
inner 
rotor 
The 
shaft 
is
press
fitted 
to 
the 
rotor 
with 
the
pin 
calked
n
Trochoid
Fig 
EL 
Oil
pump
EL 
2 

ENGINE 
LUBRICATION 
SYSTEM
Inspection 
and
repair
Clean 
the 
disassembled
parts 
with
cleaning 
solvent 
and
inspect 
for 
defects
Inspect 
the 
drive 
rotor 
shaft 
for
excessive 
wear 
and
scores 
and 
check
the 
following 
clearances
Side
clearance 
between
Quter 
and
inner 
rotors 
0 
12 
mm 
0
0047 
in 
or 
below
Tip 
clearance 
0 
04 
to 
0 
I2mm
0 
0016
to 
0 
0047 
in
Clearance 
between 
outer
rotor 
and
body
0 
15 
to 
0
21 
rom 
0 
0059 
to 
0 
0083 
in
Adjusting 
regulator
Insert 
valve 
in 
the
body 
and 
measure 
the 
distance 
A
from 
the 
valve 
end 
to 
the
spring 
contacting 
face 
inside 
the
plug 
See
Figure 
EL
4
2 
The 
distance 
from 
the
spring 
contacting 
face 
inside
the 
valve 
to 
the 
valve 
end 
amounts 
to 
18 
mm
0 
7086 
in
3 
On
inspecting 
the 
above
dimensions 
determine 
the
thickness 
of
adjusting 
shim
Shim 
thickness 
A 
18
mm 
0
7086 
in
spring
length 
at
compression 
load 
3 
67
kg 
8 
091bs
Assembly
Assembling 
the 
oil
pump 
is 
the
reverse 
order 
of
disassembly
Note 
3
Be 
sure 
no 
traces 
of
grinding 
chips 
lint 
or 
dirt
remain
b 
Be
sure 
gasket 
is 
not 
turned
up 
and 
discon
tinued
OIL
PRESSURE
REGULATOR
VALVE
The 
oil
pressure 
regulator 
valve 
is 
not
adjustable 
At
the
released
position 
the
valve
permits 
oil
passing 
through
a
passage 
on 
the
pump 
cover 
to 
the 
inlet
side 
of 
the
pump
Measure 
the
regulator 
valve
spring 
dimension
to 
ensure
that 
the
spring 
is
provided 
with 
the 
correct 
tension 
e
Q
@
I
I 
Adjusting 
shim
2
Valve
spring
13 
I 
RegulatoT 
valve
Fig 
EL 
4
RegulatoT 
valve
Tightening 
torque
Oil
pump 
cover
bolts
kg 
m 
ft 
lb 
2 
0 
1 
45
Oil
pump 
mounting
bolts 
kg 
m
ft 
lb 
13 
to
1
5
9 
4to 
II
Cap 
nut
regulator
valve
kg 
m 
ft
lb 
4 
0 
to 
5 
0
29 
to 
36
Specifications
Oil
pressure 
at
idling
kgfcm2 
Ibfsq 
in 
0 
9 
to 
1
2
13 
to 
17
Regulator 
valve
spirng
Free
length 
mm 
in
Pressured
length 
mm 
in 
4349
l71
30
3 
I 
19
Regulator 
valve
opening
pressure 
kgfcm2 
lbfsq 
in 
3 
8 
to 
4 
2
54 
to 
60
OIL
FILTER
The
oil 
filter 
is 
of 
a
cartridge 
type 
The 
oil 
filter 
is
installed
or 
removed
using 
special 
tool
The 
filter 
element 
and 
the 
filter
body 
are 
caulked
together 
I 
t
must 
be
replaced 
with 
a
new 
one 
as 
an
assembly
When
installing 
the
oil 
filter 
fasten 
it 
to 
the 
oil
pump
EL 
3