9
Make
SUre
there
is
proper
end
play
at
crankshaft
Crankshaft
end
play
0
05toO
15mm
0
OO20
to
0
0059
in
laJlk
h
end
play
J
EM486
Fig
EM
63
Checking
Crank
luJft
End
Play
10
Install
rear
oil
seal
using
suitable
drift
Fig
EM
64
n
talling
Rear
Oil
Seal
II
Install
rear
plate
12
Install
flywh
el
secwely
and
tighten
bolts
to
specified
torque
dl
Tightening
torque
Flywheel
and
drive
plate
A
14
engine
fixing
bolts
8
0
to
9
0
kg
m
58
to
65
ft
Ib
Drive
plate
A
15
engine
fixing
bolts
8
5
to
9
5
kg
m
61
to
69
ft
b
Fig
EM
65
n
talling
Flywheel
13
Rotate
engine
quarter
turn
and
install
piston
rod
assembly
using
Pis
Engine
Mechanical
ton
Ring
Compressor
EM03470000
EM497
Fig
EM
66
tolling
Platon
Rod
Assem
bly
Note
a
Insert
pistons
in
L
r
nding
cyl
inders
b
Apply
engine
oil
to
sliding
parts
c
Arrange
pistons
so
number
stamped
on
piston
head
faces
to
front
of
engine
d
Before
installing
piston
piston
rings
should
be
positioned
as
shown
in
Fig
EM
67
Second
ring
Oil
ring
lower
rail
EM49B
Fig
EM
67
Positioning
Piston
Ring
Gap
14
Apply
engine
oil
to
bearing
surfaces
dl
Tighte
ning
torque
Connecting
rod
cap
nuts
3
2
to
3
8
kg
m
23
to
27
ft
b
EM499
Fig
EM
68
Tightening
Connecting
Rod
Cap
Note
Am11
connecting
rods
and
connecting
rod
caps
so
cylinder
numben
face
in
same
direction
EM
14
I
S
Make
sure
there
exists
proper
end
play
at
connecting
rod
big
end
See
Fig
EM41
Big
end
play
0
1
to
0
2
mm
0
004
to
0
008
in
16
Insert
crank
sprocket
keys
in
keyways
of
crankshaft
Install
cam
shaft
and
crankshaft
sprockets
tempo
rarily
for
adjustment
of
tooth
height
by
using
adjusting
washers
Height
dif
Less1
h
l11
0
5
mm
0
020
in
Adjusting
washer
thickness
0
5
mm
10
020
in
EM500
Fig
EM
69
Adju
ting
Sprocket
Tooth
Height
17
Install
tinting
chain
and
cam
shaft
sprocket
with
their
markings
properly
aligned
See
Fig
EM
70
Then
set
No
I
piston
at
T
D
C
on
compression
stroke
See
Fig
EM
71
Oil
sprocket
teeth
and
chain
with
engine
oil
Match
mark
Key
groove
EM501
Fig
EM
70
Aligning
Markinga
Note
Make
sure
camshaft
sprocket
dowel
hole
and
crankshaft
sprocket
key
are
in
line
and
both
dowel
hole
and
key
are
located
downward
Engine
Mechanical
Main
bearing
undersize
Unit
mm
in
Main
bearing
undersi
ze
Crank
journal
diameter
Standard
size
49
943
to
49
964
1
9663
to
1
9671
0
25
0
0098
49701
to
49
714
1
9567
to
1
9572
Undersize
0
50
0
0197
49451
to
49
464
1
9469
to
1
9474
0
75
0
0295
49
201
to
49
214
1
9370
to
1
9376
Connecting
rod
bearing
undersize
Unit
mm
in
Connecting
rod
bearing
undersize
Crank
pin
diameter
Standard
size
44
954
to
44
974
1
7698
to
I
7706
0
08
0
0031
44
881
to
44
894
1
7670
to
1
7675
0
25
0
0098
44
711
to
44
724
1
7603
to
1
7608
Undersize
0
50
0
0197
44
461
to
44
474
1
7504
to
1
7509
0
75
0
0295
44
211
to
44
224
1
7406
to
I
7411
MISCELLANEOUS
COMPONENTS
Unit
mm
in
Max
tolerance
Runout
of
camshaft
0
1
0
004
0
15
0
0059
Runout
of
flywheel
EM
29
t
IGHTENING
TORQUE
Cylinder
head
bolt
Rocker
shaft
bracket
bolt
ain
bearing
cap
bolt
Flywheel
fixing
bolt
Drive
plate
fixing
bolt
Al4
AlS
Connecting
rod
cap
nut
Camshaft
sprocket
bolt
Locating
plate
bolt
Valve
rocker
adjusting
nut
Oil
strainer
bolt
Oil
pan
bolt
Oil
pan
drain
plug
Timing
chain
cover
bolt
Crank
pulley
bolt
Water
pump
bolt
Fuel
pump
bolt
Spark
plug
Engine
mounting
securing
bolt
Engine
Mechanical
Unit
kg
iii
ft
lb
7
0
to
7
5
51
to
54
2
0t02
5
14to
18
5
0
to
6
0
36
to
43
8
0
to
9
0
58
to
65
8
0
to
9
0
58
to
65
8
5
to
9
5
61
to
69
3
2
to
3
8
23
to
27
4
0
to
4
8
29
to
35
0
5
to
0
8
3
6
to
5
8
1
6
to
2
2
12to
16
0
9
to
I
4
6
5
to
10
1
0
4
to
0
6
2
9
to
4
3
2
0
to
3
0
14
to
22
0
5
to
0
7
3
6
to
5
1
15to
20
l08
to
145
0
9
to
I
4
6
5
to
1O
l
0
9
to
I
4
6
5
to
10
1
1
5
to
2
0
11
to
14
1
9
to
2
5
14to
18
EM
30
2
Loosen
belt
then
remove
fan
blade
from
torque
coupling
and
torque
coupling
and
pulley
from
hub
Air
conditioning
system
equipped
models
only
4
Remove
pump
assembly
and
gas
ket
from
front
cover
C0051
Fig
CO
3
Removing
Water
Pump
INSTALLATION
1
Be
sure
to
clean
the
gasket
sur
faces
in
contact
with
pU
flP
and
front
cover
Always
use
new
gaskets
when
installing
pump
assembly
Be
sure
to
tighten
bolts
i
l
Tightening
torque
Water
pump
securing
bolts
0
9
to
1
4
kg
m
6
5
to
10
1
ft
Ib
2
Fill
cooling
system
and
check
for
leaks
at
pump
3
InstaD
fan
pulley
spacer
or
torque
coupling
and
fan
blade
and
tighten
attaching
bolts
securely
Install
belt
and
adjust
for
specified
tension
4
Operate
the
engine
at
fast
idle
and
re
Check
for
leaks
S
Install
fan
shroud
Note
Ensure
that
clearance
between
shroud
and
fan
even
at
any
place
DISASSEMBLY
Water
pump
should
not
be
disas
sembled
Cooling
System
INSPECTION
Inspect
pump
assembly
for
the
following
conditions
and
replace
if
necessary
I
Badly
rusted
or
corroded
body
assembly
and
vane
2
Excessive
end
play
or
roughness
of
bearings
in
operation
Note
If
excessive
mechanical
seal
squeak
occurs
when
engine
is
mn
ning
use
suitable
water
pump
seal
lubricant
to
prevent
squeak
ADJUSTMENT
Check
belt
deflection
between
alternator
and
fan
pulley
by
a
force
of
10
kg
22
Ib
Fan
belt
deflection
8
to
12
mm
0
31
to
0
47
in
If
adjustment
is
necessary
loosen
bolt
retaining
alternator
adjusting
bar
to
alternator
Move
alternator
toward
or
away
from
engine
until
the
correct
tension
is
obtained
TORQUE
COUPLING
The
torque
coupling
keeps
the
fan
speed
at
2
900
rpm
rated
or
below
to
conserve
horsepower
at
high
engine
speed
It
also
helps
reduce
fan
noise
to
a
minimum
during
high
speed
opera
tion
This
unit
is
filled
with
a
special
silicone
oil
used
as
a
fluid
coupling
which
controls
the
fan
speed
Silicone
oil
can
not
be
replenished
The
torque
coupling
is
installed
only
on
the
model
equipped
with
the
air
conditioning
system
In
this
case
use
7
x
350
mm
13
78
in
diam
eter
cooling
fan
CO
3
C0052
t
Wheel
2
Disc
3
Bearing
Fig
CO
4
Torque
Coupling
REMOVAL
Lousen
fan
belt
2
Remove
fan
blade
from
torque
coupling
3
Remove
torque
coupling
from
pulley
and
water
pump
hub
by
re
moving
securing
nuts
INSTALLATION
I
InstaD
the
torque
coupling
in
the
reverse
order
of
removal
2
Install
belt
and
adjust
belt
ten
sian
DISASSEMBLY
The
torque
coupling
is
so
designed
that
it
can
not
be
disassembled
INSPECTION
Inspect
torque
coupling
for
oil
leak
age
If
necessary
replace
REMOVAL
AND
INSTALLATION
I
Jack
up
the
car
Note
Apply
parking
brake
and
place
wheel
chocks
2
Remove
screws
securing
lower
shelter
of
catalytic
converter
Loosen
flange
bolt
connecting
catalytic
converter
to
front
and
rear
exhaust
tube
Catalytic
converter
assembly
can
then
be
taken
out
3
Installation
i
in
the
reverse
se
quence
of
removal
CAUTION
a
Be
careful
not
to
damage
catalytic
co
when
handliilg
b
Never
wet
catalyzer
with
water
oil
etc
t
J
Tightening
torque
Catalyti
converter
bolts
2
6
to
3
4
kg
m
19
to
25
ft
lb
Emission
Control
System
EC075A
EC076A
Fig
EC
103
Removing
Catalytic
Converter
INSPECTION
PrelimInary
In
pectlon
Vi
ually
check
condition
of
all
component
parts
including
hose
tubes
and
wires
replace
if
necessary
Refer
to
Air
Injection
System
for
inspection
EC
34
Catalytic
converter
Whether
catalytic
converter
is
nor
mal
or
not
can
e
checked
by
ob
serving
variation
in
CO
percentage
The
checking
procedure
is
as
follows
Apply
parking
brake
Shift
gears
into
Neutral
for
manual
transmis
sion
and
N
or
P
for
automatic
transmission
position
I
Adjust
engine
idling
speed
and
CO
percentage
Refer
to
Adjusting
Carburetor
Idle
RPM
and
Mixture
Ratio
for
adjustment
2
Race
engine
1
500
to
2
000
rpm
two
or
three
times
under
no
load
and
make
sure
that
specified
CO
percent
age
obtained
3
Remove
cap
and
connect
air
hose
to
air
check
valve
If
idling
speed
increases
readjust
it
to
specified
speed
with
throttle
adjusting
screw
4
Warm
up
engine
for
about
four
minutes
at
2
000
pm
under
no
load
S
Measure
Ci
percentage
at
idling
speed
After
stepAhas
been
complet
ed
wait
for
one
minute
before
making
CO
percentage
measurement
6
If
CO
percentage
measured
in
step
5
is
less
than
0
3
the
catalytic
converter
is
normaL
7
If
CO
percentage
measured
in
step
5
is
over
0
3
recheck
AJ
S
and
1
replace
air
check
valVe
The
perform
inspection
steps
4
and
S
8
If
CO
percentage
is
still
over
0
3
in
step
7
catalyt
iC
converter
i
mal
functioning
Replace
catalytic
con
verter
2
Inspect
silldered
conneetibn
of
armature
lead
and
commutator
If
loose
connection
is
found
solder
it
using
resin
flux
3
Armature
test
for
ground
Using
a
circuit
tester
place
one
test
probe
onto
armature
core
or
shaft
and
other
onto
each
commutator
bar
If
tester
shows
continuity
armature
is
grounded
and
must
be
replaced
L
L
I
EE022
F
EE
17
Teating
Armature
for
Ground
4
Check
armature
for
short
by
plac
ing
it
on
armature
tester
growler
with
a
piece
of
iron
over
arma
t
ure
core
rotating
armature
If
the
plate
vibrates
armature
is
shorted
jeBel
EE023
Fig
EE
18
Testing
Armature
or
Short
5
Check
armature
for
continuity
by
placing
probes
of
tester
on
two
seg
ments
side
by
side
If
tester
shows
no
continuity
the
circuit
is
open
OVERRUNNING
CLUTCH
ASSEMBLY
Inspect
pinion
assembly
and
screw
sleeve
or
reduction
gear
Screw
sleeve
must
slide
freely
along
armature
shaft
splines
or
pinion
gear
shaft
must
slide
freely
through
reduction
gear
If
dam
age
is
found
or
resistance
except
nor
mal
resistance
due
to
spring
felt
when
sliding
it
must
be
repaired
Inspect
pinion
teeth
If
excessive
rubbing
is
found
on
teeth
replace
Flywheel
ring
gear
also
must
be
inspected
Engine
Electrical
System
@
ll
EE278
Fig
EE
19
Overrunning
Clutch
Assembly
1
Pinion
gear
2
Reduction
gear
EE617
Fig
EE
20
Pinion
and
Reduction
Gear
Overrunni11C
Clutch
AS5em
bly
BRUSH
HOLDER
TEST
FOR
GROUND
Using
a
circuit
tester
place
one
test
probe
onto
negative
side
of
brush
holder
and
another
onto
positive
side
If
tester
shows
continuity
brush
hold
er
is
shorted
to
ground
Replace
brush
holder
EE025
Fig
EE
21
Testing
Brush
for
Ground
BEARING
METAL
Non
reduction
gear
type
spect
bearing
metal
for
wear
or
side
play
If
the
clearance
between
bearing
metal
and
armature
shaft
is
more
than
0
2
mm
0
008
in
replace
metal
EE
8
BAI
L
BEARING
Reduction
gear
type
Holding
outer
race
with
finger
rotate
bearing
to
see
if
there
is
any
play
or
bind
If
necessary
replace
bearing
MAGNETic
SWITCH
ASSEMBLY
I
Using
a
circuit
tester
check
con
tinuity
between
S
terminal
of
mag
netic
switch
and
switch
body
metal
If
continuity
does
not
exist
shunt
coil
is
opened
Replace
switch
assembly
2
In
the
same
manner
as
above
check
continuity
between
terminals
S
and
M
If
continuity
does
not
exist
series
coil
is
opened
Replace
switch
assembly
ASSEMBLY
Reassemble
starting
motor
in
re
verse
sequence
of
disassembly
When
assembling
be
sure
to
apply
grease
to
gear
case
and
rear
cover
bearing
metal
and
apply
oil
lightly
to
pinion
TEST
PERFORMANCE
TEST
Starter
motor
should
be
subjected
to
a
no
load
test
whenever
it
has
been
overhauled
to
ensure
that
its
perfo
rmance
will
be
satisfactory
when
installed
on
engine
Starter
motor
should
also
be
subjected
to
the
test
when
the
cause
of
abnormal
operation
is
to
be
determined
A
brief
outline
of
the
test
is
given
below
No
loadtest
Connect
starting
motor
in
series
willi
specified
12
volts
battery
and
an
ammeter
capable
of
indicating
1
000
amperes
Specified
current
draw
and
rev6lu
tion
in
this
test
are
shown
in
Sp
ci
Cications
REMOVAL
It
is
much
easier
to
remove
engine
and
transmission
as
a
single
unit
than
to
remove
alone
After
removal
engine
can
be
separated
from
the
transmission
assembly
WARNING
a
Place
wheel
chocks
in
fronl
of
front
wheels
and
in
rear
of
rear
wheels
b
Be
sure
to
hoist
engine
in
a
safe
manner
c
You
should
not
remove
engine
until
exhaust
system
has
com
pletely
cooled
off
Otherwise
you
may
burn
your
self
and
or
fire
may
break
out
in
fuel
line
Note
Fender
coven
should
be
used
to
protect
car
body
1
Disconnect
battery
ground
cable
from
battery
terminal
and
fusible
link
at
wire
connector
2
Remove
hood
as
follows
CAUTION
Have
an
assistant
help
you
so
as
to
prevent
damage
to
body
I
Mark
hood
hinge
locations
on
hood
to
facilitate
reinstallation
2
Support
hood
by
ltand
and
re
move
bolts
securing
it
to
hood
hinge
being
careful
not
to
let
hood
slip
when
bolts
are
removed
See
Fig
ER
2
3
Remove
hood
from
hood
hinge
f
Il
I
BF133A
Fig
ER
2
Removing
Hood
Remove
under
cover
Drain
radiator
coolant
and
engine
3
4
oil
5
Disconnect
upper
and
lower
hoses
from
radiator
and
disconnect
oil
cooler
hoses
automatic
transmission
only
6
Remove
four
bolts
securing
radia
Engine
Removal
Installation
tor
to
body
and
detach
radiator
after
removing
radiator
shroud
7
Remove
air
cleaner
assembly
from
carburetor
as
follows
1
Remove
fresh
air
duct
from
air
cleaner
2
Remove
hot
air
duct
from
air
cleaner
3
Loosen
air
cleaner
band
bolt
4
Disconnect
air
cleaner
to
air
pump
hose
at
air
cleaner
5
Disconnect
air
cleaner
ta
rocker
cover
hose
at
rocker
cover
6
Disconnect
air
cleaner
to
A
B
valve
hose
at
air
cleaner
7
Disconnect
air
cleaner
to
related
vacuum
hoses
at
air
cleaner
8
Disconnect
accelerator
control
wire
from
carburetor
9
Disconnect
the
following
cables
wires
and
hoses
Wire
to
auto
choke
heater
Wire
to
throttle
opener
cut
solenoid
or
throttle
switch
Wire
to
fuel
cut
solenoid
Wire
to
vacuum
switching
valve
High
tension
cable
between
igni
tion
coil
and
distributor
Battery
cable
to
starter
motor
Wire
to
distributor
Wire
to
thermal
transmitter
Wire
to
alternator
Engine
ground
cable
oil
pressure
switch
and
engine
harness
No
2
See
Fig
ER
3
o
1
Ground
cable
2
Engine
harness
No
2
3
Oil
pressure
switch
Fig
ER
3
EA368
Disconnecting
Cable
and
Wire
Fuel
hose
at
fuel
pump
and
fuel
return
hose
at
connection
Air
pump
air
cleaner
hose
Carbon
canister
hoses
Heater
inlet
and
outlet
hoses
if
so
equipped
ER
3
Vacuum
hose
of
brake
booster
at
intake
manifold
Air
conditioner
equipped
model
10
Remove
compressor
belt
To
remove
loosen
idler
pulley
nut
and
adjusting
bolt
1
Remove
air
pump
2
Remove
compressor
retaining
bolts
and
move
compressor
toward
fender
to
facilitate
removal
of
engine
Nole
Never
discharge
gas
from
com
pressor
while
work
is
being
per
formed
II
Compressor
EA478
Fig
ER
4
Location
of
Air
Compressor
3
Disconnect
vacuum
hose
of
air
conditioner
from
connector
of
intake
manifold
4
Remove
F
i
C
D
actuator
from
bracket
II
Remove
clutch
operating
cylin
der
from
clutch
housing
manual
trans
mission
only
dJ
Tightening
torque
Clutch
operating
cylinder
E
A3
to
clutch
housing
3
1
to
4
1
kg
22
to
30
ft
lbl
Fig
ER
5
Removing
Clutch
Operating
Cylinder
CLUTCH
DISC
AND
COVER
REMOVAL
1
Remove
transmission
from
en
gine
Refer
to
Removal
Section
MT
2
Insert
Clutch
Aligning
Bar
ST20610000
4
speed
tranSmission
or
KV30100IOO
5
speed
transmission
into
clutch
disc
hub
until
it
will
no
longer
gd
It
is
important
to
support
weight
of
clutch
disc
in
the
steps
that
follow
ST20610000
4
peed
transmission
KV30100100
S
peed
transmission
S
cL194
Fig
CL
W
Supporting
Clutch
Assembly
Clutch
CLUTCH
UNIT
n
j
3
Loosen
bolts
attaching
clutch
cover
to
flywheel
one
turn
each
at
a
time
until
spring
pressure
is
released
Be
sure
to
turn
them
out
in
a
crisscross
fashion
4
Remove
clutch
disc
and
cover
assembly
INSPECTION
Wash
all
disassembled
parts
except
disc
assembly
in
suiiable
cleaning
sol
vent
to
remove
dirt
and
grease
before
making
inspection
and
adjustment
FI
1
and
pressure
plate
Check
friction
surface
of
flywheel
and
pressure
plate
for
scoring
or
roughness
Slight
roughness
may
be
smoothed
by
using
fine
emery
cloth
If
surface
is
deeply
scored
or
grooved
the
part
should
be
replaced
Clutch
disc
sembi
Inspect
clutch
disc
for
worn
or
oily
facings
loose
rivets
and
broken
or
loose
torsional
springs
CL
7
1
Clutch
disc
assembly
2
Clutch
cover
assembly
3
ReleaJe
bearing
4
Bearing
sleeve
S
Withdrawal
lever
6
Withdrawa11ever
ball
pin
7
Return
spring
CL370
Fig
CL
9
Clutch
Unit
I
If
facings
are
oily
disc
should
be
replaced
In
this
case
inspect
transmis
sion
front
cover
oil
seal
pilot
bushing
engine
rear
oil
seals
and
other
points
for
oil
leakage
2
The
disc
should
also
be
replaced
when
facings
are
worn
locally
or
worn
down
io
ihe
specified
limit
Wear
limit
of
facing
A
Les
than
0
3
mm
0
012
in
9111
I
A
M
m
C
L336
Fig
CL
ll
M
asur
ng
Clutch
Facing
Wear