ENGINE MECHANICAL 6A – 61
Valve Seat Insert Installation
1. Carefully place the attachment (1) (having a smaller
outside diameter than the valve seat insert) on the
valve seat insert (2).
Legend
(1) Attachment
(2) Valve Seat Insert
(3) Bench Press
NOTE: The smooth side of the attachment must contact
the valve seat insert.
2. Use a bench press (3) to gradually apply pressure
to the attachment and press the valve seat insert
into place.
Note: Do not apply an excessive amount of pressure
with the bench press. Damage to the valve seat insert
will result.
Valve Seat Insert Correction
1. Remove the carbon from the valve seat insert
surface.
2. Use a valve cutter (15°, 45° and 75° blades) to
minimize scratches and other rough areas. This will
bring the contact width back to the standard value.
Remove only the scratches and rough areas. Do
not cut away too much. Take care not to cut away
unblemished areas of the valve seat surface.
Valve Seat Angle: 45°NOTE: Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.
3. Apply abrasive compound to the valve seat insert
surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat
insert.
6. Check that the valve contract width is correct.
7. Check that the valve seat insert surface is in
contact with the entire circumference of the valve.
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ENGINE MECHANICAL 6A – 85
3. Measure the oil clearance between the connecting
rod and the crankshaft.
1) Remove the connecting rod cap nuts and the
rod caps.
Arrange the removed rod caps in the cylinder
number order.
2) Clean the rod bearings and the crankshaft pins.
3) Carefully check the rod bearings.
If even one bearing is found to be damaged or
badly worn, the entire bearing assembly must be
replaced as a set. Reinstall the bearings in their
original positions.
Apply plastigage to the crank pin.
4) Reinstall the rod caps to their original positions.
5) Tighten the cap nuts in 2 steps, using angular
tightening method as shown in the following
specifications.
1st step: 29 Nꞏm (3.0 kgꞏm/22 lb ft)
2nd step: 45°– 60°NOTE: Do not allow the crankshaft to rotate
6) Remove the rod caps.
7) Measure the smallest width of the plastigage
and determine the oil clearance. If the oil
clearance exceeds the limit, replace the rod
bearings as a set.
8) Clean the plastigage from the bearings and the
crankshaft pins
Standard: 0.022 – 0.042 mm (0.0009 – 0.0017 in)
Limit: 0.100 mm (0.0039 in)
REASSEMBLY
1. Connecting Rod
2. Piston
3. Piston Pin
1) Apply a coat of engine oil to the piston pin and
the piston pin hole.
4. Piston Pin Snap Ring
1) Try to insert the piston pin into the piston pin
hole with normal finger pressure.
2) Weight each piston and connecting rod
assembly.
3) Select piston and connecting rod combinations
so that the weight variation of the different four
assemblies is held within the specified limits.
Variance in weight after assembly: Less than 3g
(0.1058 oz)
NOTE: When changing piston/connecting rod
combinations, do not change the piston/piston pin
combination.
4) Attach the piston to the connecting rod with the
piston front mark (2) and the connecting rod
front mark (3) on the same side.
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6E–185 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Poor Fuel Economy Symptom
StepActionVa l u e ( s )Ye sNo
1DEFINITION:
Fuel economy, as measured by an actual road test, is
noticeably lower than expected. Also, economy is
noticeably lower than it was on this vehicle at one time,
as previously shown by an actual road test. (Larger than
standard tires will cause odometer readings to be
incorrect, and that may cause fuel economy to appear
poor when it is actually normal.)
Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2
Go to OBD
System
Check
21. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?
—Verify repairGo to Step 3
3Was a visual/physical check performed?
—Go to Step 4
Go to Visual/
Physical
Check
4Check owner’s driving habits.
Is the A/C “ON” full time (defroster mode “ON”)?
Are tires at the correct pressure?
Are excessively heavy loads being carried?
Is acceleration too much, too often?
Is engine oil correct?
Was a problem found?
—Go to Step 5Go to Step 6
5Review the items in Step 4 with the customer and
advise as necessary.
Is the action complete?
—System OK—
61. Visually/physically check: Vacuum hoses for splits,
kinks, and improper connections and routing as
shown on the “Vehicle Emission Control
Information” label.
2. If a problem is found, repair as necessary.
Was a repair required?
—Verify repairGo to Step 7
71. Remove and check the air filter element for dirt or for
restrictions. Refer to
Air Intake System.
2. Replace the air filter element if necessary.
Was a repair required?
—Verify repairGo to Step 8
81. Check for low engine coolant level. Refer to Engine
Cooling
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 9
91. Check for an incorrect or faulty engine thermostat.
Refer to
Engine Cooling.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 10
101. Check for low engine compression. Refer to Engine
Mechanical
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 11
