Kelisa: Perodua

PERODUA
KELISA
EM
ENGINE MECHANICAL
TIMING BELT............................................. EM– 2 ENGINE TUNE-UP ...................................... EM-57
COMPONENTS .................................... EM– 2 ENGINE COOLANT ............................. EM–57
REMOVAL ............................................ EM– 2 RADIATOR CAP ................................... EM–57
INSPECTION ........................................ EM– 3 DRIVE BELT ......................................... EM–57
INSTALLATION ..................................... EM– 5 ENGINE OIL ......................................... EM–57
CYLINDER HEAD ...................................... EM– 8 SPARK PLUG ....................................... EM–57
COMPONENTS .................................... EM– 8 VALUE CLEARANCE ........................... EM–57
REMOVAL ............................................ EM– 9 IGNITION TIMING ................................ EM–57
DISASSEMBLY ..................................... EM–13 BATTERY .............................................. EM–57
INSPECTION ........................................ EM–15 CHARCOAL CANISTER ...................... EM–57
ASSEMBLY ........................................... EM–24 FUEL LINE & CONNECTION ............... EM–57
INSTALLATION ..................................... EM–25 COMPRESSION CHECK ..................... EM–57
CYLINDER BLOCK ................................... EM–34 CHECKING OF CO/HC CONCENTRATIONS .... EM– 59
COMPONENTS .................................... EM–34 CHECKING OF A/F CONTROL SYSTEM ... EM–59
DISASSEMBLY ..................................... EM–35 SERVICE SPECIFICATIONS ..................... EM–60
INSPECTION ........................................ EM–42 TIGHTENING TORQUE ............................. EM–61
ASSEMBLY ........................................... EM–49 SSTs .......................................................... EM–64
MEM00001-00000
NO. 9710-JE
EM(01-10) 1 29/11/2001, 2:32 PM

EM–2
TIMING BELT
COMPONENTS
(Refer to the “CYLINDER HEAD” section.)
REMOVAL
1. Loosen the all attaching bolts of the water pump pulley,
utilizing the tension of the drive belt.
2. Remove the V belt. (Refer to the CH section.)
3. Remove the water pump pulley.
MEM00002-00001
4. Remove the crankshaft pulley from the crankshaft, while

preventing the crankshaft pulley from being turned, using
the following SST given below.
SST: 09210-87701-000
[Reference]
• When the crankshaft pulley is removed during the in-
vehicle operation, use the SST 09213-87211-000. SST
MEM00003-00002
5. Remove the timing belt cover.

6 Rotate the crankshaft, until the mating mark of the cam-
Mating mark
shaft timing pulley is aligned with the mark of the cylinder
head cover.
CAUTION:
• Perform the engine turning operation at the crankshaft
side.
NOTE:
• Under this setting, ensure that the punched mark of
the crankshaft timing belt pulley is aligned with the MEM00004-00003
mating mark of the oil pump.

• With the mating marks aligned with each other, the
piston No. 1 is at the Top Dead Center under the com-
pression stroke.
Mating mark
MEM00005-00004
EM(01-10) 2 29/11/2001, 2:32 PM

EM–3
7. Remove the timing belt tensioner.
8. Remove the timing belt.
CAUTION:
• Do not try to pry the timing belt with a screwdriver or
the like during the removal or installation.
• Do not bend the belt at a sharp angle or turn the belt
inside out.
• Never turn the camshaft or crankshaft independently.
NOTE:
• Prior to the removal of the timing belt, put an arrow MEM00006-00005
mark indicating the normal rotating direction on the

belt, using a chalk or the like.
• If the timing belt is to be re-used, ensure that the print
line remains at the back side of the timing belt.
• If the print line above wears out, the mating marks
with the punched marks of the camshaft timing belt
pulley and the crankshaft timing belt pulley should be
put on the back side of the timing belt under a condi-
tion in which the piston No. 1 is set to the Top Dead
Center under the compression stroke.
MEM00007-00006
INSPECTION
Timing belt
If there are defects, as shown in the figures, check the fol-
lowing points and replace the timing belt, If necessary.
1. Premature separation
Check for proper installation.
Check the timing gear cover gaskets for damage and
check for correct installation.
MEM00008-00007
2. If the belt teeth are cracked or damaged, check to see if

the camshaft is seized.
MEM00009-00008
3. If there is noticeable wear or cracks on the belt face,

check to see if there are nicks on one side of the idler
pulley lock.
MEM00010-00009
EM(01-10) 3 29/11/2001, 2:32 PM

EM–4
4. If there is wear or damage on only one side of the belt,
check the pulley flange.
MEM00011-00010
Timing belt pulley (Crankshaft, Camshaft)

Visually inspect the timing belt pulleys for excessive wear.
Replace them if they exhibit any excessive wear.
(For the replacement procedure for the camshaft timing belt
pulley, refer to page “CYLINDER HEAD” section.)
MEM00012-00011
Timing belt tensioner

Turn the timing belt tensioner. Check to see if the bearing ex-
hibits locking or emits abnormal noise. Also, check the con-
tact surface with the belt for damage.
If any abnormality described above is present, replace the
relative parts.
MEM00013-00012
Timing belt cover

Ensure that the gasket exhibits no damage.
If the gasket is damaged, replace it with a new one.
Affix the gasket onto the cover, using an adhesive agent.
NOTE:
• Apply adhesive agent along the outer periphery of the
timing belt cover, as indicated in the illustration.
MEM00014-00013
Crankshaft timing belt pulley flange

Check the crankshaft timing belt pulley flange for bend,
damage and wear.
If necessary, replace the crankshaft timing belt pulley flange.
MEM00015-00014
EM(01-10) 4 29/11/2001, 2:32 PM

EM–5
INSTALLATION Pulley flanges
1. Install the crankshaft timing belt pulley with its flange at-
taching side facing toward the cylinder block.
2. Install the crankshaft timing belt pulley.
Crankshaft pulley
MEM00016-00015
3. Installation of timing belt

CAUTION:
• Do not try to pry the timing belt with a screwdriver or
the like.
• Do not bend the belt at a sharp angle or turn the belt
inside out.
• Perform the engine turning operation at the crankshaft
side.
• When the timing belt is reused, install the timing belt
in such a way that the direction of the arrow put dur-
ing the removal may match with the engine rotation di- MEM00017-00016
rection.
• Never turn the camshaft or crankshaft independently
before the timing belt installation is completed. Mating mark
(1) Rotate the crankshaft, until the mating mark of the

camshaft timing pulley aligns with the mark of the cyl-
inder head cover.
(2) Assemble the timing belt in such a way that the two
mating marks on the timing belt may be aligned with
the corresponding drilled marks on the crankshaft MEM00018-00017
timing belt pulley and mating mark of the camshaft
timing belt pulley.
NOTE:
• When the timing belt is reused, install the timing belt
in such a way that there exist teeth of the belt be-
tween the drilled marks of the crankshaft timing belt
pulley and the camshaft timing belt pulley.
Mating mark
MEM00019-00018
4. Adjustment of timing belt tension

(1) Install the timing belt tensioner temporarily.
NOTE:
• Make sure that the tensioner moves freely.
MEM00020-00019
EM(01-10) 5 29/11/2001, 2:33 PM

EM–6
(2) Tighten the crankshaft pulley bolt temporarily. Turn
the crankshaft two turns in the engine rotating direc-
tion. Ensure that the respective mating marks of the
camshaft timing belt pulley and the crankshaft timing
belt pulley are aligned properly.
NOTE:
• If the crankshaft should be turned in a reversed direc-
tion, redo the operation.
(3) Tighten the timing belt tensioner attaching bolt.

Tightening Torque: 39.0 ± 7.8 N·m MEM00021-00020
MEM00022-00021
(4) Checking of timing belt tension

When the midpoint of the belt at the tension side is
pushed 5 mm, ensure that the pushing force is 11.8 -
16.7 N.
Specified Pushing Force: 11.8 - 16.7 N 5 mm
11.8 - 16.7 N
(When belt is deflected 5 mm)
If the amount of deflection of the timing belt is devi-
ated, loosen the retaining bolt above of the timing
belt tensioner. Readjust the gap.
MEM00023-00022
5. Install the crankshaft timing belt pulley flange with its pro-
truding side facing toward the timing belt pulley. (Refer to
the page EM–5.)
6. Install the timing belt cover.
Tightening Torque: 5.5 ± 1.1 N·m
MEM00024-00023
7. Installation of crankshaft pulley set bolt

(1) Install the crankshaft pulley.
(2) Tighten the crankshaft pulley set bolt while pre-vent-
ing the crankshaft pulley from turning with the follow-
ing SST.
SST: 09210-87701-000
MEM00025-00024
EM(01-10) 6 29/11/2001, 2:33 PM

EM–7
8. Temporarily install the water pump pulley with the four
bolts.
9. Install the V-belt.
10. Adjust the V-belt tension.
(Refer to the CH section.)
11. Tighten the water pump pulley attaching bolts.
MEM00026-00025
EM(01-10) 7 29/11/2001, 2:33 PM

EM–8
CYLINDER HEAD
COMPONENTS
: Tightening torgue
Unit : N•m
5.5 ± 1.1 q
B
B w
8.0 ± 2.7 6.0 ± 1.8
B
!4 !6
e
!5
17.5 ± 3.0
12.5 ± 2.0
@0
!9 B r
!8 @1
!7
5.5 ± 1.1
@9 t
@5
@3 y
★ u
@6 @2
B B i
@7 o
B !0
19.0 ± 3.8 @8 !1
!2
#0
#1 !3
#2 8.0 ± 1.6 52.0 ± 5.0
#3 @4
39.0 ± 7.8
$3
$0
★
$1
#8 39.0 ± 5.0
#4
$2
$4
#6
#5 #7
54.0 ± 5.0
8.0 ± 1.6 25.0 ± 5.0
5.5 ± 1.1 #9
B
11.5 ± 2.3
q Ignition coil cover !6 Camshaft bearing cap No. 2 #1 Grommet

w Ignition coil !7 Snap ring #2 Injector
e Spark plug !8 Wave washer #3 Vibration insulator
r Cylinder head cover !9 Camshaft sub-gear #4 Timing belt cover
t Cylinder head cover gasket @0 Camshaft gear spring #5 Grommet
y Adjusting shim @1 Camshaft No. 1 #6 Timing belt tensioner
u Valve lifter @2 Camshaft No. 2 #7 Timing belt
i Valve spring retainer lock @3 Igniter unit #8 Plug
o Valve spring retainer @4 Cam angle sensor #9 Cam/crank angle sensor
!0 Valve spring @5 Intake manifold $0 Cylinder head
!1 Valve stem oil seal @6 Intake manifold gasket $1 Exhaust manifold gasket
!2 Valve seat @7 Pulsation damper $2 Exhaust manifold
!3 Valve @8 Fuel delivery pipe $3 Oil tube
!4 Oil control valve @9 Fuel inlet tube $4 Exhaust manifold heat insulator
!5 Camshaft bearing cap No. 1 #0 O-ring
MEM00027-00026
EM(01-10) 8 29/11/2001, 2:33 PM

EM–9
REMOVAL
1. Remove the V-belt, water pump pulley and alternator.
(Refer to the “TIMING BELT” section.)
2. Drain the engine coolant by removing the water pump
drain plug.
MEM00028-00027
3. Remove the timing belt.

4. Remove the camshaft timing belt pulley, using the SST to
prevent the turning of the camshaft.
SST: 09504-87501-000
MEM00029-00028
5. Remove the ignition coil from the cylinder head cover.
MEM00030-00031
6. Remove the oil control valve from the camshaft bearing

cap No. 1.
MEM00031-00030
7. Disconnect the vacuum hoses that are connected to the e t

intake manifold and cylinder head cover. w
8. Remove the surge tank stay from the cylinder head
cover.
9. Remove the cylinder head cover attaching bolts in the
sequence as indicated in the right figure. Remove the
cylinder head cover from the cylinder head.
q y r
MEM00032-00031
EM(01-10) 9 29/11/2001, 2:33 PM

EM–10
10. Removal of camshaft bearing cap No. 1 and camshaft
Camshaft center line
bearing cap No. 2. 10˚ - 20˚
(1) Using the hexagonal section of the camshaft No. 2,
set the mating marks of the camshaft gear sections
to the relationship as indicated in the right figure.
MEM00033-00032
(2) Loosen the oil pipe union bolt at the oil filter bracket
side.
(3) Remove the oil pipe cramp bolt from the cylinder
head.
(4) Remove the oil pipe union bolt with oil filter from the
camshaft bearing cap No. 1.
LEM00034-00033
(5) Remove the camshaft bearing cap No. 1 by removing

the bolts in a sequence, as indicated in the right w
figure. r
e
q
MEM00035-00034
(6) Secure the camshaft sub-gear to the gear section of

the camshaft No. 1, using a bolt (M5 size with a. Sub-gear
hold bolt
0.8 mm pitch).
MEM00036-00035
(7) Remove the camshaft bearing cap No. 2 by removing

!2 r
the bolts in a sequence, as indicated in the right
y i !0 w
figure.
u o !1 q e
t
MEM00037-00036
EM(01-10) 10 29/11/2001, 2:33 PM

EM–11
(9) Remove the camshaft No. 2 and camshaft No. 1 in this
sequence.
CAUTION:
• Be sure to hold the camshaft horizontally during the
removal, for the camshaft thrust clearance has be
come smaller. (Failure to observe this caution may
cause an undue force to be applied to the thrust
section, resulting in scores.)
MEM00038-00037
10. Remove the intake manifold from the cylinder head.
MEM00039-00038
11. Remove the intake manifold and gasket from the cylinder
head.
CAUTION:
• Never reuse the removed intake manifold gasket.
MEM00040-00039
12. Remove the fuel delivery pipe from the cylinder head.
13. Remove the injector from the cylinder head.
MEM00041-00040
14. Remove the oxygen sensor harness from the clamp.

15. Remove the exhaust manifold heat insulator from the
exhaust manifold.
16. Remove the oxygen sensor from the exhaust manifold.
CAUTION:
• Care must be exercised so that no oil, grease and
coolant may get to the oxygen sensor.
• Be very careful not to apply an undue force to the
lead wires.
MEM00042-00041
EM(11-20) 11 29/11/2001, 2:33 PM

EM–12
17. Remove the exhaust manifold and gasket from the
cylinder head.
CAUTION:
• Never reuse the removed exhaust manifold gasket.
MEM00043-00042
18. Remove the water inlet from the cylinder head.

19. Remove the thermostat from the cylinder head.
20. Remove the engine coolant temperature sensor.
MEM00044-00043
21. Remove the cam/crank angle sensor from the cylinder

head.
MEM00045-00044
22. Remove the cam angle sensor from the cylinder head.
MEM00046-00045
23. Remove the cylinder head attaching bolts in the se-

e t u w
quence as indicated in the right figure. Remove the cylin-
der head from the cylinder block.
24. Remove the cylinder head gasket from the cylinder
block.
CAUTION:
• Never reuse the cylinder head gasket.
q i y r
MEM00047-00046
EM(11-20) 12 29/11/2001, 2:33 PM

EM–13
DISASSEMBLY
Cylinder head
1. Remove the valve lifters from the cylinder head with the
adjusting shims installed on each valve lifter.
MEM00048-00047
2. Remove the valve spring retainer locks, using the follow-

ing SSTs given below.
SST: 09202-87002-000
09202-87002-0A0
MEM00049-00048
3. Remove the valve spring retainers, and valve springs.

4. Remove the valves from the cylinder head.
5. Remove the valve stem oil seals, using pliers or the like.
6. Remove the valve spring seats from the cylinder head.
MEM00050-00049
[Reference]
• When the SSTs specified above are employed, it is
SSTA
possible to perform replacements of the valve spring
retainers, valve spring retainer locks and valve springs
in the in-vehicle operation without removing the
cylinder head from the cylinder block.
WARNING:
• Make sure to protect your eyes with safety goggles
during this operation. SSTC SSTB
• Be very careful not to allow the spring, etc. to jump
MEM00051-00050
out.
CAUTION:
• When the valve spring retainer locks are removed, be
sure to perform this removal with each piston set to
the Top Dead Center, one cylinder at a time.
• Plug the oil return hole of the cylinder head with a
cloth or the like so that the valve spring retainer lock
may not be dropped inadvertently into the hole.
SST: 09202-87702-000 (SSTA)
09202-87202-000 (SSTB)
LEM00052-00051
09202-87201-000 (SSTC)
EM(11-20) 13 29/11/2001, 2:33 PM

EM–14
Camshaft No. 1
1. Secure the camshaft by clamping it in a vise.
CAUTION: SST
• Be very careful not to scratch the cam journal section.
2. Remove the sub-gear attaching bolt (which was used in

removing the camshaft from the cylinder head), using the
SST to prevent the camshaft from being turned.
SST: 09504-87501-000
MEM00027-00026
3. Using a snap ring expander, detach the shaft snap ring.

4. Remove the wave washer, camshaft sub-gear and cam-
shaft gear
MEM00028-00027
Camshaft No. 2
1. The camshaft No. 2 assembly cannot be disassembled,
for the DVVT controller and camshaft drive gear are of an
integral construction.
MEM00029-00028
EM(11-20) 14 29/11/2001, 2:33 PM

EM–15
INSPECTION
Cylinder head
NOTE:
• Clean the cylinder head by removing the remaining
gasket materials, carbon deposits, and so forth.
• Check the cylinder block for cracks, using a dye pen-
etration or like.
MEM00056-00055
1. Check of cylinder head for flatness

Using a precision straight edge and a feeler gauge,
check the gasket surfaces contacting the cylinder head
and manifolds for warpage.
Maximum Surface Warpage:
Cylinder Block Side: 0.10 mm
Intake Manifold Side: 0.10 mm
Exhaust Manifold Side: 0.10 mm
If surface warpage of the cylinder block side exceeds

the maximum limit, reface or replace the cylinder head.
If surface warpage of the intake manifold and/or exhaust
manifold side exceeds the maximum limit, replace the
cylinder head.
If the cylinder head surface warpage at the cylinder

block side exceeds the maximum warpage, reface the
cylinder head within the minimum thickness limit.
Cylinder Head Height Limit: 103 mm
MEM00057-00056
2. Check of camshaft oil clearance

NOTE:
• Prior to this oil clearance check, the camshaft should
be checked for bend in advance. (See page EM–16)
(1) Install the camshaft to the cylinder head.
(2) Place a plastigauge on each bearing.
MEM00058-00057
3. Install the bearing caps. Tighten them to the specified

q o
torque. u t e !1
y r w !2 !0
i
MEM00059-00058
EM(11-20) 15 29/11/2001, 2:33 PM

EM–16
(4) Remove the bearing caps and measure the oil
clearance.
Clearance:
Specified Value: 0.037 - 0.073 mm
NOTE:
• After completion of the check, remove the plastic
gauges. Wash the camshaft and bearing caps in
cleaning solvent.
(Reference) MEM00064-00063
Camshaft Journal Outer Diameter

Intake side, Exhaust side:
No. 1: 25.979 - 25.995 mm
No. 2: No. 3: No. 4: 22.979 - 22.995 mm
Camshaft bearing Cap Bore Diameter

Intake side, Exhaust side:
No. 1: 26.032 - 26.052 mm
No. 2: No. 3: No. 4: 23.032 - 23.052 mm
MEM00061-00060
3. Check of camshaft thrust clearance

Assemble the camshaft, referring to the assembling pro-
cedure of the camshaft in EM–28. Measure the thrust
clearance.
Specified Thrust Clearance:
Intake Side 0.04 - 0.10 mm
Exhaust Side 0.04 - 0.10 mm
MEM00062-00061
4. Check and grinding of valves

(1) Visually inspect the valve stem for seizure or
damage.
NOTE:
• If seizure or damage is found, replace the valve and
valve guide bush as a set.
• However, this replacement should be performed only
after the checks for the valve seat, valve stem and
valve guide bush have been finished.
• The valve guide bush hole must be used for refacing
the valve seat. Hence, if the valve guide bush hole MEM00063-00062
exhibits any roughness due to seizure, etc., rectify

the hole with an adjustable reamer.
(2) Visually inspect the valve head for melting or

damage.
If the valve head exhibits any melting or damage,
replace the valve.
If the roughness on the contact surface can be
corrected, grind the valve seat contact surface with a
valve refacer.
MEM00064-00063
EM(11-20) 16 29/11/2001, 2:34 PM

EM–17
(3) Grind the valves only enough to obtain a smooth con-
tact surface with the valve seat.
Valve Face Angle: 44.5°
NOTE:
• Make sure the valves are ground to the correct
valve face angle.
MEM00065-00064
(4) Visually inspect the valve stem end for abnormal

wear. If the valve stem end exhibits abnormal wear,
correct the stem end with a valve refacer. However,
this correction should be made within a limit of 0.2
mm from the standard length.
Reference:
Intake Valve: 79.4 mm
Exhaust Valve: 79.8 mm
MEM00066-00065
NOTE:
• Be very careful not to allow the valve to be overheated
during grinding.
MEM00067-00066
(5) Inspect the valve head for its stock thickness.

Minimum Stock Thickness:
Intake Valve: 1.0 ± 0.2 mm
Exhaust Valve: 1.0 ± 0.2 mm
If the stock thickness of the valve head is less than

the minimum stock thickness, replace it with a new
one.
MEM00068-00067
5. Check and cleaning of valve seats

(1) Using a 45-degree valve seat cutter, reface the
valve seats. Remove only enough metal stock to
clean the seats.
(2) Apply a thin film of red lead (or white lead) to the
valve seat.
(3) Let the valve drop by its own weight onto the
valve seat two or three times.
(4) Take out the valve.
MEM00069-00068
EM(11-20) 17 29/11/2001, 2:34 PM

EM–18
(5) Inspect the valve face and seat for the following
items.
1 Ensure that the valve seat contact surface of the
valve is continuous over the whole circumference.
If not, replace the valve.
2 Ensure that the valve contact surface of the valve
seat is continuous over the whole circumference.
If not, reface the valve seat.
MEM00070-00069
3 Measure the width of the contact surface of valve

seat.
Contact Surface of Valve Seat: 1.4 ± 0.5 mm
If not, reface the valve seat.
MEM00071-00070
6. Refacing of valve seat

(1) Using a 45-degree cutter, recondition the roughness
on the valve-to-valve seat contact surface, only
enough to obtain a smooth surface.
MEM00072-00071
(2) Using a 20-degree cutter, cut the valve seat in such a

way that the circumference of the surface refaced by
the 45-degree cutter may become the specified
value.
Specified Value: IN : 23.0 ± 0.1 mm
EX: 20.0 ± 0.1 mm
MEM00073-00072
(3) Using a 70-degree cutter, cut the valve seat in such a

way that the width of the surface refaced by the
45-degree cutter may become 1.4 mm.
MEM00074-00073
EM(11-20) 18 29/11/2001, 2:34 PM

EM–19
(4) Using the 45-degree cutter, remove burrs produced
during the refacing by the 20-degree and 70-degree
cutters.
M0EM00075-00074
7. Hand lapping of valves

(1) Perform hand lapping of the valves and valve seats,
using an abrasive compound.
(2) Clean the valves and valve seats after the hand lap-
ping of the valves.
MEM00076-00075
8. Check of valve recession

After the valve seat has been refaced, install the new
valve.
Measure the distance between the cylinder block attach-
ing surface of the cylinder head (attaching surface of the
cylinder head gasket) and the upper most section of the
valve.
Ensure that the distance does not exceed the following
specified value.
Specified Value: Intake Valve: 3.07 mm
Exhaust Value: 4.65 mm MEM00077-00076
If the recession exceeds the maximum limit, replace the

cylinder head.
9. Check of valve stem-to-valve guide bushing oil

clearance
(1) Using a caliper gauge, measure the inner diameter of
the valve guide at six points.
Record the measured values.
Reference:
Inner Diameter of the Valve Guide Bush: MEM00078-00077
IN, EX: 5.000 - 5.012 mm
(2) Using a micrometer, measure the diameter of the

valve stem at six points.
Record the measured values.
Reference:
Outer Diameter of the Valve Stem:
Intake: 4.975 - 4.990 mm
Exhaust: 4.965 - 4.980 mm
MEM00079-00078
EM(11-20) 19 29/11/2001, 2:34 PM

EM–20
(3) Calculation of oil clearance
Calculate the oil clearance of each valve according
to the following formula.
Oil clearance = Inner diameter of valve stem guide –
Outer diameter of valve stem
Specified Oil Clearance:

IN: 0.010 - 0.037 mm
EX: 0.020 - 0.047 mm
MEM00080-00079
10. Replacement of valve guide bush

(1) Drive out the valve guide bush from the combustion
chamber side, using a suitable tool.
NOTE:
• Be very careful not to tap the cylinder head.
REFERENCE:
• As for this suitable tool, determine it, whilereferring to
the inner diameter and outerdiameter of the valve
guide bush.
Valve Guide Bush Inner Diameter: MEM00081-00080
IN, EX: 9.727 - 9.738 mm

Valve Guide Bush Outer Diameter: IN: 13.5 ± 0.3 mm
IN, EX: 5.000 - 5.012 mm EX: 10.5 ± 0.3 mm
Cylinder head
(2) Drive a new valve guide bush into position, shown in

the right figure, using a suitable tool. MEM00082-00081
CAUTION:
• Be very careful not to give an excessive impact during
the installation. Failure to observe this caution will
result in valve guide bush cracks.
• Care must be exercised as to the shape of the valve
guide bush, for it differs between the intake side and
the exhaust side.
• The exhaust valve guide bush has a two-stage taper,
while the intake valve guide bush has a single-stage
taper. Intake Exhaust
MEM00083-00082
(3) Using an adjustable reamer, ream the valve guide
bush to remove any burr or the like.
NOTE:
• This reaming should be made only enough to remove
the burr or the like.
(4) Check of oil clearance

Ensure that the oil clearance meets the
specifications.
Specified Oil Clearance:
IN: 0.010 - 0.037
MEM00084-00083
EX: 0.020 - 0.047
EM(11-20) 20 29/11/2001, 2:34 PM

EM–21
11. Check of valve springs
(1) Check the valve spring for squareness, using a steel
Not the exceed 1.3 mm
square.
Maximum Squareness: 1.3 mm
If the squareness exceeds the maximum limit, replace

the valve spring.
MEM00057-00055
(2) Measure the valve spring for free length and spring
tension, using a spring tester.
Minimum Free Length: 37.1 mm
Minimum Tension/Installation Height:
123.17 ± 8.63 N/32.0 mm
MEM00058-00056
12. Check of valve lifter and cylinder head valve lifter bore oil
clearance
(1) Measure the outer diameter of the valve lifter.
Outer Diameter of Valve Lifter: 27.975 - 27.985 mm
(2) Measure the inner diameter of the cylinder head

valve lifter bore.
Bore Diameter: 28.000 - 28.021 mm
MEM00059-00057
(3) Calculate the oil clearance, based on the results of

the measurements (1) and (2). Check to see if the oil
clearance is within the specification.
If the oil clearance does not conform to the specifica-
tion, replace the valve lifter and/or cylinder head.
Specified Oil Clearance: 0.015 - 0.046 mm
MEM00060-00058
13. Check of manifold

Check the cylinder head attaching surface of the intake
manifold and exhaust manifold for warpage, using a
straight edge and a thickness gauge.
Maximum Warpage: 0.1 mm
MEM00061-00059
EM(21-31) 21 29/11/2001, 2:34 PM

EM–22
Camshaft
Camshaft
1. Check of gear
Visually inspect the teeth for wear.
2. Check of shaft
(1) Checking camshaft for runout
Support the camshaft at its both ends with V-shaped
blocks. Set a dial gauge to the mid-point of the
center journal section of the camshaft. Turn the cam
shaft one turn, making sure that the camshaft will not
move in the axial direction. Take a reading on the MEM00062-00060
dial gauge during the turning. Calculate the maxi

mum runout, i.e. the difference between the maxi
mum and minimum readings.
Maximum Runout: 0.03 mm
If the runout exceeds the maximum limit, replace the

camshaft.
MEM00000-00061
(2) Checking of cam lobe height

Measure the cam lobe height, using a micrometer.
Specified Cam Lobe Height: 40.25 mm
MEM00063-00062
(3) Inspection of oil seal contact surface

Inspect the oil seal contact surface for abnormal
wear.
Replace the camshaft if the contact surface exhibits
any abnormal wear.
MEM00064-00063
3. Check of DVVT actuator

(1) Clamp the hexagonal section for servicing of the
camshaft assembly No. 2 in a vice, etc.
MEM00065-00064
EM(21-31) 22 29/11/2001, 2:34 PM

EM–23
(2) Temporarily tighten the attaching bolt at the timing
belt pulley attaching bolt hole so as to plug the oil
Timing advance port
passage at the timing advance side.
MEM00066-00065
(3) Hold one of the two timing advance ports (in the
figure on the right) of the camshaft with your finger.
(4) Apply compressed air to the other timing advance
port, using an air tool.
CAUTION:
• Care must be exercised, for oil will splash.
MEM00067-00066
(5) At this time, ensure that the most retarded angle lock
of the actuator becomes unlocked and the actuator
can be moved by your hand without binding within a
range of approximately 30°.
NOTE:
• The actuator will be locked when it comes to the
most retarded angle position.
MEM00068-00067
(6) After completion of the check, lock the actuator at the

most retarded angle position. Then, remove the
timing pulley attaching bolt.
NOTE:
• After the bolt has been removed, be sure to wipe
off any residual sealing material lodged at the
screw hole of the camshaft. (Failure to perform
this operation may result in malfunction of the
DVVT after assembling.)
MEM00069-00068
EM(21-31) 23 29/11/2001, 2:34 PM

EM–24
Thermostat
For checking and replacement procedures, refer to the CO
section.
Engine coolant temperature sensor

For checking procedure, refer to the EF section.
Cam/crank angle sensor

For checking and replacement procedures, refer to the IG
section.
Cam angle sensor

section.
Spark plug
section.
MEM000070-00000
ASSEMBLY
Cylinder head
NOTE: Unleaded gasoline Leaded gasoline
• Thoroughly clean all parts to be assembled. Exhaust valve Intake valve Exhaust valve Intake valve
• Before installing the parts, apply new engine oil to all

sliding and rotating surfaces. E 4 I 4 E 6 I 6
• Replace all gaskets and oil seals with new ones.
CAUTION:
• It should be noted that the valves for unleaded gaso-
MEM00071-00069
line specifications differ from those for leaded gaso-
line specifications.
Identification marks:
EX: 11.2 ± 0.8
IN: 14.2 ± 0.8
Unleaded Gasoline: IN=14, EX=E4

Leaded Gasoline: IN=16, EX=E6
1. Install the valve spring seat

2. Installation of valve stem oil seal
(1) Apply engine oil to the inner surface of the metal ring
of the stem oil seal.
(2) Drive the valve stem oil seal into position.
NOTE: MEM00072-00070
• Make sure that the stem oil seals will not tilt against
the stem.
3. Dip the 30 to 40 mm long portion of the valve stem end
into engine oil.
4. Install the valve to the cylinder head.
NOTE:
• Care must be exercised as to the installing position.
Do not pull out the valve once it has been inserted.
• If the inserted valve should be pulled out, replace the
valve stem oil seal with a new one.
MEM00073-00071
EM(21-31) 24 29/11/2001, 2:34 PM

EM–25
5. Assembly of valve springs, valve spring retainers and
valve spring retainer locks
(1) Install the valve spring to the valve lifter inserting
hole.
(2) Install the valve spring retainer to the valve spring. In-
stall the valve spring retainer locks while compress-
ing the valve spring retainer, using the following SST.
SST: 09202-87002-000
09202-87002-0A0
MEM00074-00072
(3) After installing the valve spring retainer lock, lightly

tap the valve spring retainer with a plastic hammer or
the like so as to ensure that the valve spring retainer
locks are installed securely.
WARNING:
• During this operation, care must be exercised to
ensure that the valve spring retainer or retainer
locks may not jump out.
• Protect your eyes with safety goggles during this
operation.
• Never tap the hole into which the valve lifter is MEM00075-00073
inserted.
Camshaft No. 1
1. Set the SST to the two 6 mm dia. holes of the camshaft
sub gear using the following SST.
SST: 09504-87501-000
2. Turn the sub gear clockwise until the assembling auxil-

iary hole of the camshaft driven gear and also the teeth
of the sub-gear and driven gear are aligned with each
other. Install the sub gear retaining bolt (size: M5, pitch:
0.8 mm). MEM00076-00074
3. Install the camshaft rear springs, camshaft sub-gear and
wave washer. Secure the components, using a shaft
snap ring. SST
INSTALLATION MEM00077-00075
1. Clean the cylinder block upper gasket surface. Install the
cylinder head gasket, while aligning it with the pin ring
for locating use.
2. Temporarily install the crankshaft pulley bolt to the crank-
shaft.
3. Turn the crankshaft so that the crankshaft key groove
may come at the top position.
4. Install the cylinder head to the cylinder block.
NOTE:
• Care must be exercised to ensure that no damage
is made to the gasket surface of the cylinder head MEM000078-00000
with the cylinder block.
EM(21-31) 25 29/11/2001, 2:34 PM

EM–26
5. Coat each cylinder head bolt with a thin film of engine oil. r
y w u
Using these bolts, install the cylinder head to the cylinder
block. Tighten the bolts evenly over two or three stages,
following the sequence shown in the right figure.
NOTE:
• Failure to tighten the bolts evenly may cause cracks
and distortion of the cylinder head, even leading to
engine seizure. i q e t
• Make sure that all the bolts are tightened uniformly to MEM00078-00076
a constant level as well as that they are tightened

within the specified torque.
Jiggle valve
6. Installation of water inlet
(1) Install the thermostat to the water inlet, as shown in
the illustration.
(2) Apply soap water to the outer periphery of the
thermostat grommet.
(3) Install the water inlet to the cylinder head.
MEM00079-00077
7. Clean the threaded portion of the water temperature

sensor. Wind seal tape around the threaded portion.
Tighten the sensor to the cylinder head, using a long box
wrench.
MEM00080-00078
8. Clean the threaded portion of the radiator thermo control

switch. Wind seal tape around the threaded portion.
Tighten the switch to the water inlet.
MEM00081-00079
9. Install the cam/crank angle sensor to the cylinder head.

LEM00082-00080
EM(21-31) 26 29/11/2001, 2:34 PM

EM–27
10. Install the cam angle sensor to the cylinder head.
MEM00083-00081
11. Install the exhaust manifold to the cylinder head with a

new gasket interposed.
12. Install the heat insulator to the exhaust manifold.

MEM00084-00082
13. Install the oxygen sensor to the exhaust manifold.

CAUTION:
• Care must be exercised so that no oil, grease and
coolant may get to the oxygen sensor.
• Be very careful not to apply an undue force to thelead
wires.
14. Attach the oxygen sensor harness to the clamp.

MEM00085-00083
15. Install the injector to the cylinder head in such a way that
the connector faces toward the outside of the engine.
16. Apply lubrication oil to the O-ring of the injector.
17. Install the fuel delivery pipe to the cylinder head.
18. Turn the injector by your hand. Ensure that the injector
turns smoothly, although you may feel a certain resis-
tance.
MEM00086-00084
19. Install the intake manifold to the cylinder head with a new
gasket interposed.
MEM00087-00085
EM(21-31) 27 29/11/2001, 2:34 PM

EM–28
20. Install the spark plug to the cylinder head.
MEM00088-00086
21. Installation of camshaft

CAUTION:
• Be sure to hold the camshaft horizontally during the
installation, for the camshaft thrust clearance has be
come smaller. (Failure to observe this caution
causesan undue force to be applied to the thrust
section, resulting in scores.)
(1) Apply engine oil to the cam section and gear

section of the camshaft No. 1 and the journal section
of the cylinder head. MEM00089-00000
(2) Place the camshaft assembly No. 1 on the cylinder

Camshaft center line
head in such a way that the sub-gear retaining bolt
may face nearly upward.
(3) Turn the camshaft No. 1 so that the lower mating
mark of the mating marks at the back sides of the 10° - 20°
gears may come within a range of about 10 degree to
20 degree from the line connecting the centers of the
camshafts, as indicated in the right figure.
(4) Apply engine oil to the cam section and gear section
of the camshaft No. 2 and the journal section of the
MEM00090-00087
cylinder head.
Upper mating mark
Installation Upper mating mark
(5) Of the two mating marks at the back sides of the while rotating
camshaft driven gear and the camshaft drive gear, Lower mating mark
first align the upper marks each other. While the cam-
Camshaft
shaft drive gear is being turned on the camshaft center line
driven gear, install the camshaft No. 2.
Camshaft Camshaft No. 1
No. 2
MEM00091-00088
(6) While the camshaft No. 1 and camshaft No. 2 are in a Camshaft center line
set condition, ensure that the two mating marks at the 10° - 20°
back sides of the camshaft gears assume a relation-
ship as indicated in the right figure.
MEM00092-00089
EM(21-31) 28 29/11/2001, 2:35 PM

EM–29
22. Install the camshaft No. 2 bearing cap, as indicated in
q o
the right figure. Tighten the attaching bolts to the speci- t !1
u e
fied tightening torque in a sequence specified in the right
figure.
23. Remove the sub-gear retaining bolt of the camshaft No.

1.
y r w !2 !0
i
MEM00093-00090
24. Installation of camshaft No. 1 bearing cap

(1) Apply liquid gasket to those points on the camshaft
No. 1 bearing cap.
Liquid Gasket: Three bond 1207C or equivalent
MEM00094-00091
(2) Tighten the attaching bolts of the camshaft No. 1 r

bearing cap to the specified tightening torque in a
sequence specified in the right figure.
Tightening Torque: 12.5 ± 2.0 N·m w
q
t
MEM00095-00092
25. Press-fit the plug, using the following SST, so that the
plug may assume the position shown in the figure. 1 ± 1 mm
SST: 09237-87201-000
26. Apply engine oil to the lip surface of the type T oil seal. MEM00096-00093
Press the oil seal into the cylinder head, until you can get
a feeling of bottoming. For this installation, use the
following SST in combination with a M12 bolt (whose
nominal length is 80 to 90 mm).
SST: 09707-87302-000
SST
NOTE:
• If the oil seal is to be re-used, the press-fitting should
be made after applying silicone bond.
• After the bolt has been removed, check the condition
of the press-fitting by tapping the SST lightly with a MEM00097-00094
hammer.
EM(21-31) 29 29/11/2001, 2:35 PM

EM–30
27. Install the camshaft timing belt pulley to the camshaft.
Tighten the bolt to the specified torque, while using the
following SST to prevent the camshaft from being turned.
SST: 09504-87501-000
MEM00098-00095
28. Install the timing belt.

29. Adjustment of valve clearance
(1) Align the upper mating marks of the drive gear and
driven gear of the camshaft.
Upper mating marks
MEM00099-00096
(2) Using a thickness gauge, check the valve clearances

shown in the right figure.
MEM00100-00097
(3) After turning the crankshaft one turn, check the valve
clearances shown in the right figure.
MEM00101-00098
(4) If the clearance deviates from the specified value, re-

place the shim in the following procedure and adjust
it to the specified value.
NOTE:
• Record the position of the valve where the
clearance deviates from the specification, as well
as the their measurement results.
Specified Value : IN : 0.18 ± 0.05 mm (Cold)
EX : 0.25 ± 0.05 mm (Cold)
MEM00102-00000
EM(21-31) 30 29/11/2001, 2:35 PM

EM–31
(5) Turn the crankshaft so that the cam nose of the cylin-
der where the clearance deviates from the specifica-
tion points upward. Under this state, turn the valve
lifter so that its cut-out section faces inward.
Cut-out section
MEM00113-00099
(6) Turn the crankshaft so that the cam nose of the cylin-
der points downward and pushes down the valve
lifter.
MEM00104-00100
(7) Place the SST on the upper circumference of the SST

valve lifter from the inside of the cylinder head, as
shown in the right figure. Turn the crankshaft so that
the cam nose points approximately upward. In this
way, retain the valve lifter in a pushed-down state by
means of the SST.
SST: 09221-87208-000
MEM00105-00101
(8) Raise the shim from the cut-out section, using a SST
small-sized driver. Remove the shim toward the in-
side (spark plug side), using a magnet.
(9) Using a micrometer, measure the thickness of the

shim that has been removed.
Shim
(10) Select the shim, using the following formula given be-
low, so that the valve clearance becomes the speci-
fied value. MEM00106-00102
Intake Valve
(Thickness of shim to be selected)=(Thickness of
removed shim) + [(measured clearance) - 0.18
mm]
Exhaust Valve
(Thickness of shim to be selected)=(Thickness of
removed shim) + [(measured clearance) - 0.25
mm]
[Reference]
• As for a new shim, an identification number has been
written with inerasable ink. MEM00107-00103
EM(21-31) 31 29/11/2001, 2:35 PM

EM–32
No. Shim thickness (mm) No. Shim thickness (mm) No. Shim thickness (mm) No. Shim thickness (mm)
30 2.50 41 2.72 52 2.94 63 3.16
31 2.52 42 2.74 53 2.96 64 3.18
32 2.54 43 2.76 54 2.98 65 3.20
33 2.56 44 2.78 55 3.00 66 3.22
34 2.58 45 2.80 56 3.02 67 3.24
35 2.60 46 2.82 57 3.04 68 3.26
36 2.62 47 2.84 58 3.06 69 3.28
37 2.64 48 2.86 59 3.08 70 3.30
38 2.66 49 2.88 60 3.10
39 2.68 50 2.90 61 3.12
40 2.70 51 2.92 62 3.14
MEM00114-00000
(11) Set the selected shim to the valve lifter.

NOTE:
• Install the shim in such a way that the side bearing
the identification number faces downward.
MEM00109-00104
(12) Turn the crankshaft so that the cam nose faces down-
ward and pushes down the valve lifter. In this state, SST
remove the SST.
(13) Turn the crankshaft two or three turns. Check the
valve clearance. If it fails to meet the specification,
repeat the steps from (5) through (13).
MEM000110-00105
30. Install the oil pipe to the camshaft bearing cap No. 1.
NOTE:
• Be sure to interpose the gasket.
31. Install the oil pipe cramp bolt to the cylinder head.
32. Tighten the oil pipe union bolt at the oil filter bracket side
that has been loosened.
MEM00111-00106
EM(32-41) 32 29/11/2001, 2:35 PM

EM–33
33. Install the cylinder head cover to the cylinder head with
the gasket interposed, following the sequence shown in r w t
the right figure.
y q e
MEM00112-00107
34. Install the oil control valve to the camshaft bearing cap
No. 1.
NOTE:
• Be sure to completely remove any foreign matter that
may lodge at the installation hole or oil control valve.
• Apply engine oil to the O-ring section.
35. Install the timing belt. (Refer to the “TIMING BELT” MEM00113-00108
section.)
36. Install the timing belt cover. (Refer to the “TIMING BELT”
section.)
37. Install the crankshaft pulley.
38. Install the surge tank stay to the cylinder head cover.
39. Connect the vacuum hose to the cylinder head and in-
take manifold. MEM00114-00109
40. Install the ignition coil to the cylinder head cover.

EM(32-41) 33 29/11/2001, 2:35 PM

EM–34
CYLINDER BLOCK
COMPONENTS
e 21.0 ± 4.2
w
y q
t
12.5 ± 2.5
!1
!2
19.0 ± 3.8 !3 !4
!5 36.0 ± 6.0 !9
!0 !6
i o
!7
19.0 ± 3.8 44.0 ± 5.0

!8
@0
@1
@2
@3 @6
@4
@5
@7
59.0 ± 6.0
98.0 ± 10.0
@9
8.0 ± 1.6
@8
8.0 ± 1.6
24.0 ± 4.8
1 Cylinder block " Piston ring No. 1 - Key

2 Cylinder head gasket # Piston ring No. 2 . Spacer
3Rear end plate $ Oil ring / Crankshaft timing belt pulley
4Rear oil seal % Piston pin : Spacer
5 Rear oil seal retainer & Piston ; Crankshaft pulley
6 Water pump gasket ( Connecting rod < Crankshaft bearing
7 Water pump ) Connecting rod bearing = Crankshaft bearing cap
8 Front oil seal ~ Spacer > Oil strainer
9 Oil pump + Flywheel ? Oil pan
! Oil pump gasket , Crankshaft
MEM00119-00114
EM(32-41) 34 29/11/2001, 2:35 PM

EM–35
DISASSEMBLY
1. Drain the engine oil by removing the drain plug of the oil
pan.
2. Drain the engine coolant by removing the drain plug of
the water pump.
MEM00120-00115
3. Remove the timing belt. (For removal procedure, refer to

the “TIMING BELT” section.)
4. Remove the cylinder head. (For removal procedure, refer
to the “CYLINDER HEAD” section.)
5. Remove the pressure plate and clutch disc.
NOTE:
• Prevent the pressure plate from turning, using the fol-
lowing SST.
SST: 09210-87701-000
6. Remove the water pump.
MEM00121-00116
MEM00122-00117
7. Check of flywheel (drive plate) for runout

NOTE:
• If the runout does not conform to the specification,
confirm the tightening torque of the flywheel (drive
plate). Only in the case where the tightening torque
conforms to the specified value, replace the flywheel
(drive plate).
Specified Runout Limit: Less than 0.1 mm
MEM00123-00118
8. Loosen the attaching bolts of the flywheel (drive plate) in

the sequence as indicated in the right figure. Remove the
flywheel (drive plate).
MEM00124-00119
EM(32-41) 35 29/11/2001, 2:35 PM

EM–36
9. Remove the rear end plate.
10. Removal of oil pan
(1) Loosen the attaching bolts and nuts of the oil pan
over two or three stages. Pull out the bolts and nuts.
(2) Separate the oil pan from the cylinder block by driv-
ing the following SST into between the cylinder block
and the oil pan.
SST: 09032-00100-000
MEM00125-00120
11. Remove the oil strainer.

12. Remove the oil strainer gasket from the oil pump.
13. Remove the oil pump from the cylinder block.
(For the disassembly and inspection of the oil pump, re-
fer to the LU section.)
14. Remove the oil pump gasket from the cylinder block.
15. Remove the rear oil seal retainer.
MEM00126-00121
16. Measurement of connecting rod thrust clearance

Measure the thrust clearance between the connecting
rod and the crankshaft, using a thickness gauge.
Thrust Clearance:
Maximum Limit: 0.3 mm
NOTE:
• The thrust clearance should be measured while the
connecting rod is being pushed against either side of
the crankshaft in the axial direction. Measure the MEM00126-00122
thrust clearance at the opposite side.
If the clearance exceeds the specified value, replace the

connecting rod or the crankshaft, or both of them, refer-
ring to the width of the big end of the connecting rod in
the thrust direction and the side width of the crankpin
journal.
[Reference]
Width of big end of connecting rod in thrust direction Side width of crankpin journal
19.80 - 19.85 mm 20.00 - 20.05 mm
Connecting rod Crankshaft
MEM00128-00123
EM(32-41) 36 29/11/2001, 2:35 PM

EM–37
17. Loosen the connecting rod bearing cap nuts evenly over
two or three stages. Then, remove the nut.
18. Remove the connecting rod bearing cap.
MEM00129-00124
19. Measure the oil clearance between the crankpin journal

and the connecting rod bearing cap.
(For the tightening method of the connecting rod cap
nuts, refer to page EM–53.)
Oil Clearance:
STD: 0.020 - 0.044 mm
NOTE:
• If the oil clearance does not conform to the specifica-
tion, measure the crankshaft pin journal and connect- MEM00130-00125
ing rod big end bore, following the procedure given. If

both meet the specifications, replace the bearing ac-
A B
cording to the classification.
Measurement of crankpin diameter

1. Measure the crankpin diameter of the crankshaft in four
directions for each crankshaft pin, 90 degrees spaced,
at those points indicated in the right figure. 4 12 4 12 4 12
2. The greatest value among the measured diameters is re-
garded as the crankpin journal diameter.
Specified Crankpin Journal Diameter: MEM00131-00126
39.076 - 40.000 mm
Measurement of connecting rod big end bore diameter

1. Perform measurement at the two points indicated in the
figure.
2. The smaller value among the measured diameters is re- A B
garded as the connecting rod big end bore diameter.
Specified Connecting Rod Big End Bore:
43.000 - 43.024 mm 4 4
CAUTION: MEM00132-00127
• If the classification that has been determined by the
measured value differs from the code attached to the
part, be sure to carefully select the bearing.
• Since undersized bearings are available, the crank pin
journals of a crankshaft which will not meet the speci-
fication can be machined according to the undersized
bearing. In this case, perform machining of the crank
pin journals, referring to the table below.
• When some parts only are replaced, the replacement
should be done only when the classification matches
with each other. MEM00133-00000
EM(32-41) 37 29/11/2001, 2:35 PM

EM–38
Crankpin code No.
Crankpin code No. Crankpin diameter (mm)
1 39.976 - 39.984
2 39.985 - 39.992
3 39.993 - 40.000
No. 1 crankpin code No.

MEM00134-00128
Connecting rod big end bore code No. Connecting rod

Front mark
Connecting rod big Connecting rod big end bore diameter
end bore code No. (mm)
4 43.000 - 43.008
5 43.009 - 43.016
6 43.017 - 43.024
Connecting rod big end

bore code No.
MEM00135-00129
Connecting rod bearing Connecting rod bearing

code No. selection
Connecting rod Connecting rod Crankshaft Crankpin
bearing code No. bearing center code No.
(Identification color) thickness (mm) Connecting
rod 1 2 3
1 1.486 - 1.490
Connecting 4 3 2 1
2 1.491 - 1.494 rod big end 5 4 3 2
bore code No.
3 1.495 - 1.498
6 5 4 3
4 1.499 - 1.502
5 1.503 - 1.506 MEM00136-00000
Specified crankpin diameter

Kind of bearing Crankpin diameter (mm)
U/S 0.25 39.726 - 39.750
U/S 0.50 39.476 - 39.500
MEM00137-00000
EM(32-41) 38 29/11/2001, 2:35 PM

EM–39
20. Removal of piston
(1) Cover each connecting rod bolt with a short piece of
hose to protect the crankpin journal from damage.
(2) Push out the piston and connecting rod assembly
and the upper bearing through the top of the cylinder
block.
NOTE:
• Arrange the removed pistons and connecting rods so
that their installation positions may be identified
readily.
• Care should be exercised so as not to damage the MEM00138-00131
bearings.
21. Checking procedure of crankshaft thrust clearance

NOTE:
• Measure the thrust clearance, using a dial gauge.
Thrust Clearance:
If the thrust clearance exceeds the specified value, mea-

sure the width of the crankshaft thrust washer contact MEM00139-00132
surface. If the measure value is less than 22.63 mm, re-
place the thrust washer with a standard thrust washer or
a suitable oversize thrust washer. If the measured value
exceeds 22.63 mm, replace the crankshaft and thrust
washer.
[Reference]
• The oversize thrust washer comes in two thicknesses
of 0.125 mm and 0.25 mm. However, this figure repre-
sents the amount of oversize for each thrust washer.
MEM00140-00133
22. Removal of crankshaft

(1) Gradually loosen the main bearing cap bolts over
three stages in the numerical sequence shown in the
figure. Remove the bearing cap bolts.
MEM00141-00134
(2) With the main bearing cap bolts inserted into the bolt
holes of the main bearing cap, wiggle the bearing
cap back and forth. Remove the bearing cap to-
gether with the lower bearing.
NOTE:
• Keep the lower bearing fitted to the main bearing cap.
Arrange the removed main bearing caps in order.
MEM00142-00135
EM(32-41) 39 29/11/2001, 2:35 PM

EM–40
(3) Lift off the crankshaft.
(4) Remove the upper bearing.
NOTE:
• Be very careful not to allow the main bearings to be
mixed with the bearings of other cylinders.
• Remove the thrust washer.
MEM00142-00135
23. Measure the oil clearance between the crank journal and
the crankshaft bearing cap.
NOTE:
• For the tightening method of the crankshaft bearing
cap, refer to page EM–53)
Oil Clearance:
STD: 0.004 - 0.028 mm
NOTE:
• If the oil clearance is greater than maximum limit, MEM000143-00136
measure the crank journals, cylinder block crank jour-

nal bore diameters and crankshaft bearing center
thickness, following the procedure given below.
Replace any part which will not conform to the specifi-
cations.
As an alternative method, when undersized bearings
are available as replacement parts, machine the crank
journal in such a way that the following formula given
below may be satisfied.
Measured cylinder block crank journal bore diameter
– (Measured crank journal diameter + Undersized
bearing center thickness to be used ✕ 2) = 0.004 -
0.028 mm
Measurement of crank journal diameter

1. Measure the crank journal diameter of the crankshaft in
four directions for each crank journal, 90 degrees
spaced, at those points indicated in the right figure.
2. The greatest value among the measured diameters is re- 10 10 10 10
6 6 6 6
garded as the crank journal diameter.
Specified Crank Journal Diameter:
45.976 - 46.000 mm MEM00144-00137
Measurement of cylinder block crank journal bore

diameter
1. Perform the measurement at the two points shown in the
figure.
2. The smaller value among the measured diameters is re-
garded as the cylinder block crank journal bore diam-
eter.
Specified Cylinder Block Crank Journal Bore Diam-
eter:
50.000 - 50.024 mm 4 4 5 5 5 5 4 4
MEM00145-00138
EM(32-41) 40 29/11/2001, 2:35 PM

EM–41
CAUTION:
• If the classification that has been determined by the
measured value differs from the code attached to the
part, be sure to carefully select the bearing.
• Since undersized bearings are available, the crank
journals of a crankshaft which will not meet the speci-
fication can be machined according to the undersized
journals, referring to the table below.
• When some parts only are replaced, the replacement
should be done only when the classification matches
witch each other.
Crank journal code No.
Crank journal code No. Crank journal diameter (mm)
1 45.976 - 45.984
2 45.985 - 45.992
3 45.993 - 46.000
No. 4 crank journal code No.
MEM00147-00139
Cylinder block crank journal bore code No.

No. 1 cylinder
Cylinder block crank Cylinder block crank journal bore block crank journal
journal bore code No. diameter (mm) bore code No.
4 50.000 - 50.008
No. 2
5 50.009 - 50.016
No. 3
6 50.017 - 50.024
No. 4
MEM00148-00140
Crankshaft bearing code No.

Crankshaft bearing Crankshaft bearing
code No. center thickness
(Identification color) (mm)
2 1.994 - 1.998
3 1.999 - 2.002
4 2.003 - 2.006
5 2.007 - 2.010
6 2.011 - 2.014
MEM00149-00141
Crankshaft bearing selection code No. Specified crank journal diameter

Crankshaft Crank journal Cylinder block crank
Kind of bearing Crank journal diameter (mm)
code No. journal bore diameter (mm)
Cylinder block 1 2 3 50.000 - 50.008 45.742 - 45.750
4 4 3 2 U/S 0.25 50.009 - 50.016 45.750 - 45.759
Cylinder block
5 5 4 3 50.017 - 50.024 45.758 - 45.767
crank journal
bore code No. 50.000 - 50.008 45.492 - 45.500
6 6 5 4
U/S 0.50 50.009 - 50.016 45.500 - 45.509
50.017 - 50.024 45.508 - 45.517
MEM00150-00000
EM(32-41) 41 29/11/2001, 2:36 PM

EM–42
INSPECTION
Crank shaft
1. Check the main journals and bearings for pitting or
scratches.
If the main journals exhibits damage, repair or replace
the crankshaft.
If the main journal bearings are damaged, replace the
main journal bearings.
MEM00150-00142
2. Support the both ends of the crankshaft with a V-block.

Measure the crankshaft runout with a dial gauge at No. 3
journal.
Allowable Limit of Runout: 0.06 mm
NOTE:
• The allowable limit of bend is 0.03 mm
If the runout exceeds the allowable limit, replace the

crankshaft.
MEM00151-00143
Crankshaft bearing & Connecting rod bearing

Check the bearings for pitting or scratches.
If the bearings exhibits damage, replace the bearing.
MEM00152-00144
Cylinder block
1. Inspection of top surface of cylinder block
Using a precision straightedge and a thickness gauge,
check the surface contacting the cylinder head gasket
for warpage in the six directions as shown in the figure.
Maximum Warpage: 0.08 mm
If the warpage exceeds the allowable limit, replace the

cylinder block or reface the upper gasket surface of the
cylinder block, referring to the following cylinder block
height as a limit. MEM00153-00145
Cylinder Block Minimum Height: 235.8 mm

(Reference)
Cylinder Block Height:
STD: 235.9 - 236.1 mm
MEM00154-00146
EM(42-51) 42 29/11/2001, 2:36 PM

EM–43
2. Measurement of cylinder bores
(1) Measure the bore diameter of each cylinder at the six
points shown in the right figure. Ensure that the differ-
ence between the maximum and minimum bore di-
ameters of each cylinder is within 0.03 mm.
Specified Cylinder Bore Diameter:
72.000 - 72.030 mm
If the difference between the maximum and minimum

values exceeds 0.03 mm, perform boring and/or hon-
ing for the cylinder bore in accordance with the over- MEM00155-00147
sized piston.
3. Inspection of piston-to-cylinder bore clearance
13.5 mm
(1) Calculate the piston-to-cylinder bore clearance
based on the cylinder bore diameter and the piston
outer diameter that were measured in Step 2.
(2) Measurement of piston diameter
Measure the piston outer diameter horizontally at a
point 13 mm from the lower end of the piston at right
angles to the piston pin.
Specified Piston Outer Diameter: MEM00156-00148
71.965 - 71.995 mm
(3) Calculation of piston-to-cylinder bore clearance

Subtract the measured piston outer diameter from the
measured cylinder bore diameter.
Piston-to-Cylinder Bore Clearance:
If the piston-to-cylinder bore clearance exceeds the

allowable limit, perform boring and/or honing for the
cylinder bore in accordance with the oversized pis-
ton.
4. Boring and honing of cylinder bore
NOTE:
• When the cylinder is bored, all cylinders should be
bored at the same time.
• As for piston and piston rings, use oversized piston
and piston rings.
(1) Determining cylinder finishing diameter

1 Measure the diameter of the oversized piston to
be used, using a micrometer.
2 Calculate the finishing dimension, as follows.
A: Piston diameter
B: Piston-to-cylinder bore clearance
C: Honing allowance 0.02 mm
D: Finishing diameter
D=A+B–C
EM(42-51) 43 29/11/2001, 2:36 PM

EM–44
(2) Hone the cylinder after the boring.
1 Bore the cylinder, leaving a honing allowance of
0.02 mm.
2 Hone the cylinder.
Honing Angle: 35° ± 5°
Surface Coarse Degree: 1 - 4Z
[Reference]
• The table below shows the cylinder bore diameter
when oversized pistons are used.
• However, after the diameter of the replacement piston MEM00157-00149
has been measured, perform the finishing in accor-

dance with the piston diameter.
(mm)
Kind Piston outer diameter Cylinder bore
STD 72.000 - 72.030 71.965 - 71.995
0.25 72.250 - 72.280 72.215 - 72.245
0.50 72.500 - 72.530 72.465 - 72.495
0.75 72.750 - 72.780 72.715 - 72.745
1.00 73.000 - 73.030 72.965 - 72.995
Piston & Connecting rod

CAUTION:
• The piston and piston pin are available only as a set
so that the oil clearance may become the specified
value. Therefore, if you replace a piston or a piston
pin, be sure to replace them as a set. Moreover, the
piston and piston pin should be handled at all times
as a set. Care must be exercised so that no piston nor
piston pin may be mixed with other ones.
MEM00158-00000
1. Inspection of fit between piston and piston pin

Try to move the piston back and forth on the piston pin.
Ifany movement is felt, inspect the piston and piston pin
clearance.
NOTE:
• When the piston is moved back and forth on the pis-
ton pin, you may encounter hard movement. However,
if the piston moves smoothly without any binding, this
fitting of the piston is normal.
MEM00159-00150
EM(42-51) 44 29/11/2001, 2:36 PM

EM–45
2. Measurement of oil clearance
NOTE:
• The oil clearance can be measured, following the pro-
cedure given below.
(1) When measuring oil clearance without disassem-

bling: Interpose the big end of the connecting rod
between V-block on a surface plate. Measure the
play while moving the piston, as indicated in the right
figure.
Piston Pin-to-piston Clearance: MEM00160-00151
STD: 0.005 - 0.011 mm

Limit: 0.05 mm
If the oil clearance does not conform to the specifica-

tion, replace the piston and piston pin. (There are no
replacement parts for the piston only nor the piston
pin only.)
(2) When measuring oil clearance after disassembling

(For disassembling procedure refer to the page EM–46.)
1 Measure the diameter of the whole circumference
at the positions A and B indicated in the right fig-
A B
ure. The minimum dimension should be the
piston pin hole diameter.
2 Measure the diameter of the whole circumference
at the positions A and B indicated in the right fig- 8 8
ure. The maximum dimension should be the pis- Unit: mm
ton pin outer diameter. MEM00161-00152

3 Calculate the oil clearance.
If the oil clearance does not conform to the speci-
fication, replace the piston and piston pin. (There
are no replacement parts for the piston only nor A B
the piston pin only.)
8 8
Unit: mm
MEM00162-00153
3. Removal of piston rings

NOTE:
• Arrange the removed piston rings in order so that their
installation positions may be known readily.
• Do not expand the piston ring unnecessarily beyond
the required extent.
(1) Remove the piston rings No. 1 and No. 2 using a pis-
ton ring expander.
(2) Remove the oil ring side rails by hand.
(3) Remove the oil ring expander by hand. MEM00163-00154
EM(42-51) 45 29/11/2001, 2:36 PM

EM–46
4. Inspection of piston ring groove side clearance
Measure the side clearances of the piston rings No. 1
and No. 2 over the entire periphery of each groove, us-
ing a thickness gauge.
The maximum measured value is regarded as the piston
ring side clearance.
Piston ring side clearance (mm)
Specified value Allowable limit
Compression ring No. 1 0.03 - 0.07 0.12
Compression ring No. 2 0.02 - 0.06 0.11 MEM00164-00155
Replace the piston ring and/or piston so that the piston

ring side clearance may become less than the allowable
limit.
NOTE:
• When replacing the piston rings, a set of piston rings
for one cylinder should be replaced.
5. Inspection of piston ring end gap

(1) Apply engine oil to the cylinder walls.
(2) Insert the piston rings into the cylinder bore.
(3) Using a piston, push down the piston ring to a point
45 mm from the cylinder block upper surface.
(4) Measure the piston ring end gap, using a thickness
gauge or a feeler gauge.
Piston ring end gap (mm)
Specified value Allowable limit Piston ring
MEM00165-00156
Oil ring (Side rail) 0.15 - 0.50 1.0
If the piston ring end gap exceeds the allowable limit, a

set of piston rings for one cylinder should be replaced.
6. Disassembly of piston and connecting rod

Use the following SSTs for the disassembling operation.
SST: 09221-87202-000
09221-87207-000
(1) Set the SST to the piston as shown in the right figure.
MEM00166-00157
EM(42-51) 46 29/11/2001, 2:36 PM

EM–47
NOTE:
• Prior to this operation, remove the spacer 09221-
87202-000 in advance.
(2) Install the connecting rod in the following SST as

NOTE:
• Be sure to insert the shorter SST into the base side.
SST: 09221-87207-000
(3) Press off the piston pin, using a hydraulic press. MEM00167-00158
7. Inspection of connecting rods

(1) Visually inspect the connecting rods for damage or
cracks.
(2) Check the connecting rod for bend and twist, using a
connecting rod aligner.
Maximum Bend: 0.05 mm
Maximum Twist: 0.05 mm
If the bend and/or twist is greater than the maximum

limit, replace the connecting rod assembly.
MEM00168-00159
8. Inspection of piston pin-to-connecting rod interference fit

(1) Measure the outer diameter of the piston pin contact-
ing with the connecting rod, using a micrometer.
Specified Piston Pin Diameter: 17.994 - 17.997 mm
MEM00169-00160
(2) Measure the inner diameter of the connecting rod,

using a bore dial gauge.
Specified Connecting Rod Inner Diameter:
17.953 - 17.979 mm
(3) Determine the interference fit by subtracting the outer

diameter of the piston pin from the inner diameter of
the connecting rod.
Interference Fit: 0.015 - 0.044 mm
If the interference fit does not conform to the specifi- MEM00170-00161
cation, replace the connecting rod or piston. (There

are no replacement parts for the piston pin only.)
9. Assembly of piston and connecting rod
Use the following SSTs for the assembling operation.
SST: 09221-87202-000
09221-87207-000
(1) Install the piston pin to the following SST in a way

SST: 09221-87202-000
MEM00171-00162
EM(42-51) 47 29/11/2001, 2:36 PM

EM–48
(2) Install the piston and connecting rod in the SST in a
way shown in the right figure. Insert the SST with the
piston pin installed into the piston pin hole.
NOTE:
• The piston and connecting rod should be assembled
in such a way that the piston front mark and connect-
ing rod front mark come in the same direction.
• Prior to this operation, install the spacer 09221-
87207-000 in advance.
(3) Press the piston pin into the piston and connecting MEM00172-00163
rod, using a hydraulic press.

(4) Remove the piston and connecting rod assembly
from the SST. Remove the SST from the piston pin.
Rear oil seal retainer

Replacement of rear oil seal
1. Removal of rear oil seal
Remove the rear oil seal from the rear oil seal retainer,
using a pin punch.
NOTE:
• Be very careful not to damage the oil seal retainer.
MEM00173-00164
2. Installation of rear oil seal

Drive a new rear oil seal into position, using the following
SST.
SST: 09608-87302-000
NOTE:
• Care must be exercised to ensure that the oil seal is
not driven in a tilted state.
MEM00174-00165
Oil pan
Visually inspect the oil pan for damage or cracks.
Replace the oil pan, as required.
MEM00175-00166
EM(42-51) 48 29/11/2001, 2:36 PM

EM–49
Flywheel
Inspect the flywheel for cracks or damage.
Inspect the ring gear for damage.
Replace the flywheel if it exhibits defects.
CAUTION:
• Never disassemble the flexible type flywheel by re-
moving the flex-plate from the flywheel subassembly.
If the flywheel has undergone disassembling, it would
cause breakage of the flywheel due to unbalanced fly-
wheel mass, while the engine is running.
• Never expose the flexible type flywheel to flame of a MEM00176-00167
burner, etc. If the flywheel is exposed to flame of a

burner, for example, at the time of replacement of the
ring gear, the quenched state of the flex-plate will be
weakened. This may lead to breakage during the en-
gine running.
Oil pressure switch

For checking and replacement procedure, refer to the LU
section.
Knocking sensor
For checking and replacement procedure, refer to the EF
section.
Oil filter
For checking and replacement procedure, refer to the LU
section.
MEM00177-00000
ASSEMBLY
NOTE:
• The cylinder block is furnished along with the pistons
as a set.
• Hence, make sure that each piston is installed in the
mated cylinder bore.
[Reference]
• Those numerals stamped at the positions as indicated
in the right figure are the piston selection code No. for
each cylinder.
MEM00178-00000
The table below indicates those sizes corresponding to

each selection code No.
Code Cylinder bore diameter Piston outer diameter
1 72.000–72.010 71.965–71.975
2 72.011–72.020 71.976–71.985
3 72.021–72.030 71.986–71.995
MEM00179-00168
EM(42-51) 49 29/11/2001, 2:36 PM

EM–50
[Reference]
• Select the crankshaft bearing, connecting rod bearing
and piston, as required, referring to the table on page
EM–38, EM–41, EM–49.
MEM00180-00000
1. Installation of crankshaft
(1) Install the crankshaft bearings to the cylinder block
and crankshaft bearing caps.
NOTE:
• Do not touch the front and back surfaces of each
bearing.
• Be sure to hold the bearing at its edge surfaces.
MEM00181-00169
(2) Lubricate the surface of each bearing with engine oil.

NOTE:
• Never apply engine oil to the crankshaft bearing caps.
MEM00182-00170
(3) Install the crankshaft in the cylinder block.
MEM00183-00171
(4) Apply engine oil to the thrust washers. With the side
having the oil groove facing toward the crankshaft
side, insert each thrust washer between the crank-
shaft main journal No. 3 and the cylinder block.
MEM00184-00172
EM(42-51) 50 29/11/2001, 2:36 PM

EM–51
(5) Apply engine oil to the crankshaft main journal sec-
tions.
NOTE:
• Care must be exercised to ensure that no oil flows into
the bearing cap attaching bolt holes.
MEM00185-00173
(6) Install the crankshaft bearing caps with the arrow

marks facing toward the oil pump side and also in the
numerical sequence.
(7) Thinly apply engine oil to the crankshaft bearing cap
bolts. Tighten the bolts to the specified torque over
two or three stages in the sequence shown in the
right figure.
MEM00186-00174
2. Assembly and installation of piston

Identification Color:
Compression ring No. 1:
Black (Leaded), Orange (Unleaded)
Compression ring No. 2:
Yellow (Leaded, Unleaded)
Oil ring spacer:
Red (Leaded), Pink (Unleaded)
(1) Install the oil ring spacer expander in the oil ring
groove. MEM00187-00175
Ensure that the expander end may not line up with

the thrust direction nor with the axial direction.
NOTE:
• Do not expand the spacer expander to an extent that
is more than necessary.
(2) Fit the upper rail into position in such a manner that it
is wound up while pushing the edge section of the oil
ring spacer expander with your thumb.
MEM00188-00176
NOTE:
• Ensure that the rail end is deviated 90 degrees to the
left from the end of the oil ring spacer expander.
• Do not expand the rail to an extent that is more than
necessary.
MEM00189-00177
EM(42-51) 51 29/11/2001, 2:36 PM

EM–52
(3) Fit the lower rail into position in such a manner that it
is wound up.
NOTE:
• Ensure that the rail end is deviated 90 degrees to the
right from the end of the oil ring spacer expander.
• Do not expand the rail to an extent that is more than
necessary.
• Make sure that the oil ring can be rotated smoothly.
MEM00190-00178
(4) Install the compression ring No. 2 with the stamped

mark facing upward, using a piston ring expander.
NOTE:
• Do not expand the piston ring to an extent that is
more than necessary.
(5) Install the compression ring No. 1 with the stamped

mark facing upward, using a piston ring expander.
MEM00191-00179
(6) Position the piston rings so that each ring end may
come at the respective points as indicated in the
right figure.
NOTE:
• It is not necessarily required to follow strictly the right
figure. However, be sure that the ring end is not lined
up with the thrust direction. Also, each ring should be
deviated about 120 to 180 degrees from the adjacent
ring.
MEM00192-00180
(7) Install the connecting rod bearings on the connecting

rod and connecting rod cap, making sure that your
fingers will not touch the front and back surfaces of
the bearings.
MEM00193-00181
(8) Cut an appropriate vinyl hose to a suitable length. Fit

the vinyl hose to each connecting rod bolt sections.
MEM00194-00182
EM(52-64) 52 29/11/2001, 2:37 PM

EM–53
(9) Apply engine oil to the piston rings, piston pins, con-
necting rod bearings, cylinder walls and crankpin
journals.
NOTE:
• Apply a small amount of engine oil to each cylinder
bore.
• Apply a small amount of engine oil to each piston ring
section.
MEM00196-00184
(10) Compress the piston rings by means of the piston

ring compressor SST, making sure that the piston ring
ends will not move during the installation.
SST: 09217-87001-000
(11) Push the piston by hand into the cylinder bore with
the front mark facing toward the oil pump side.
NOTE:
• Be very careful to avoid damaging the connecting rod
bearings during the installation.
• Care must be exercised to ensure that the crankpin MEM00196-00184
journal is not scratched by the connecting rod.
(12) Push the piston with a suitable tool, until the connect-
ing rod reaches the crankpin journal.
(13) Apply engine oil to the bearing surface of each con-
necting rod bearing.
NOTE:
• Do not touch the bearing front surface.
(14) Remove the vinyl hoses which were attached to the

connecting rod bolt sections. MEM00197-00185
(15) Install the connecting rod cap with the front mark fac-
ing toward the oil pump side.
(16) Thinly apply engine oil to the connecting rod cap MEM00198-00186
attaching nuts. Tighten the nuts to the specified
torque evenly over two or three stages.
NOTE:
• Prevent the crankshaft from turning, using the follow-
ing SST.
SST: 09210-87701-000
(17) Perform the operations described in the steps (1)

through (16) for each cylinder.
MEM00199-00187
EM(52-64) 53 29/11/2001, 2:37 PM

EM–54
3. Installation of oil pump
(1) Turn the crankshaft, until the No. 1 cylinder is set to
the top dead center.
(2) Apply engine oil to the inner surface of the oil seal.
(3) Insert a new O-ring into the groove section of the
pump cover. Secure the O-ring by holding it at the
three projection sections at the cover side.
NOTE:
• Embossed marks having a 5 mm diameter have been
provided at the holding positions.
MEM00200-00188
(4) With the crankshaft’s two-flat sections for driving the

oil pump aligned with the oil pump, install the oil
pump to the cylinder block with a new gasket
interposed.
(5) Tighten the oil pump attaching bolt and nuts to the
specified torque.
MEM00201-00189
4. Installation of rear oil seal retainer

(1) Apply engine oil to the inner surface of the oil seal.
(2) Apply Three Bond 1207F or equivalent to the flange
surface in such a way that the sealing may be formed
without any discontinued spot, in a size equivalent to
a 3 mm to 4 mm diameter, following the procedure
given in the right figure.
MEM00202-00190
(3) With the rear oil seal retainer aligned with the knock
pin, install the rear oil seal retainer to the cylinder
block with a new gasket interposed.
(4) Tighten the attaching bolt to the specified torque.
MEM00203-00203
5. Install the oil pump strainer with a new gasket inter-

posed.
MEM00204-00192
EM(52-64) 54 29/11/2001, 2:37 PM

EM–55
6. Installation of oil pan
(1) Thoroughly remove any foreign matters (grease and
water, etc.) from both the oil pan attaching surface of
the cylinder block and the cylinder block attaching
surface of the oil pan.
(2) Apply Three Bond 1207F or equivalent to the flange
surface in such a way that the sealing may be formed
without any discontinued spot, in a size equivalent to
a 3 mm to 4 mm diameter, following the procedure
given in the right figure.
MEM00000-00193
7. Install the rear end plate.

MEM00221-00191
(3) Install the oil pan to the cylinder block.

(4) Tighten the oil pan attaching nuts and bolts to the
specified torque over two or three stages.
MEM00206-00194
8. Installation of flywheel (drive plate)

(1) Assemble the flywheel (drive plate), aligning it with
the knock pin of the crankshaft.
(2) Temporarily tighten the flywheel (drive plate) attach-
ing bolts to the following torque in the sequence indi-
cated in the next step.
Tightening Torque: 25 - 34 N·m
NOTE:
• Prevent the crankshaft from turning at the ring gear
section, using the following SST. MEM00207-00195
SST: 09210-87701-000
(3) Tighten the flywheel (drive plate) attaching bolts to
the specified torque in the sequence indicated in the
right figure.
NOTE:
• Prevent the crankshaft from turning at the ring gear
section, using the following SST.
SST: 09210-87701-000
MEM00208-00196
EM(52-64) 55 29/11/2001, 2:37 PM

EM–56
9. Check the flywheel runout. (For checking procedure, re-
fer to the page EM–35.)
10. Install the cylinder head. (For installation procedure, refer
to the “CYLINDER HEAD” section.)
11. Install the timing belt. (For installation procedure, refer to
the page EM–5.)
MEM00209-00197
EM(52-64) 56 29/11/2001, 2:37 PM

EM–57
ENGINE TUNE-UP
ENGINE COOLANT
Refer to the CO section.
RADIATOR CAP
Refer to the CO section.
DRIVE BELT
Refer to the CH section.
ENGINE OIL
Refer to the LU section.
SPARK PLUG
Refer to the IG section.
VALVE CLEARANCE
Refer to the EM–30.
IGNITION TIMING
Refer to the IG section.
BATTERY
Refer to the CH section.
CHARCOAL CANISTER
Refer to the EC section.
FUEL LINE & CONNECTION
Refer to the EC section.
MEM00210-00000
COMPRESSION CHECK Fuel pump relay

NOTE:
• After completion of the engine tune-up, if the engine
exhibits lack of power, excessive oil consumption or
poor fuel economy, measure the cylinder compression
pressure.
1. Warm up the engine thoroughly.

2. Turn OFF the ignition key switch.
3. Remove the fuel pump relay from the relay box.
MEM00211-00198
4. Remove the spark plug from the cylinder head. (For re-
moval procedure refer to the IG section.)
5. Measurement of cylinder compression pressure
NOTE:
• Perform the measurement in the shortest possible
time.
• Crank the engine for the same duration for each cylin-
der.
• Always use a fully charged battery so that at least a
revolution speed of 400 rpm is attained.
MEM00246-00245
EM(52-64) 57 29/11/2001, 2:37 PM

EM–58
(1) Insert a compression gauge into the spark plug hole.
(2) Depress the accelerator pedal fully.
(3) While cranking the engine, measure the compression
pressure.
Compression Pressure:
1579 - 1755 kPa at 400 rpm
Difference Between Cylinders:
147 kPa at 400 rpm
MEM00213-00200
(4) Repeat the step (1) through (3) for each cylinder.
(5) If the compression of one or more cylinders is low,
pour a small amount of engine oil into that cylinder
through the spark plug hole and repeat the steps (1)
through (3) for the cylinder with low compression.
• If adding oil helps the compression to improve,
chances are that the piston rings and/or cylinder
bores are worn or damaged.
• If the pressure remains low after the operation de-
scribed in the step (5) has been performed, the valve
may be sticking or seated improperly, or there may MEM00214-00201
be leakage past the gasket.
6. Install the spark plug to the cylinder head, (Refer to the

IG section.)
7. Install the fuel pump relay to the relay box.
MEM00215-00000
EM(52-64) 58 29/11/2001, 2:37 PM

EM–59
CHECKING OF CO/HC CONCENTRATIONS
Preparation to be made prior to check of CO/HC concentrations.
• Apply the parking brake fully.
• Check the ignition timing.
• Check the idle speed.
• Warm up the engine thoroughly. (continue engine warm-up for another 10 minutes after the fan motor
has started its operation.)
• All accessory switches are turned OFF.
• The air cleaner element is installed.
• All pipes and vacuum hose are connected.
• Ensure that the intake system exhibits no air leakage.
• Ensure that the exhaust system exhibits no gas leakage.
• On the automatic transmission vehicle, the shift lever is placed in the [N] or [P] range.
• On the manual transmission vehicle, the shift lever is placed in the neutral position.
• Position the steering wheel to straight-ahead direction.
• Prior to the use, be sure to prepare the CO/HC meter, following the instructions of the manufacturer.
NOTE:
• This check is only for determining whether or not the idle HC/CO emission complies with the speci-
fied values.
Specified Values:
CO less than: 0.5 %
HC less than: 400 ppm
If the CO/HC concentrations will not conform to the specified values, check the A/F control system
and/or replace the exhaust manifold.
MEM00216-00000
CHECKING OF A/F (Air/Fuel) CONTROL SYSTEM

NOTE:
• Since the A/F adjustment is performed by a computer, you are not able to perform this adjustment.
Your check ensures that the computer control is being properly performed. Your check is not for per-
forming the adjustment.
1. Connect the test terminal and the ground terminal with a jumper wire of the diagnosis connector.
2. While keeping the engine revolution speed at a speed in excess of 1200 rpm (aiming at a speed of
around 3000 rpm), measure the voltage between the terminal VF of the diagnosis connector and the
body.
3. Check that the measured value changes between 0 V and 5 V.
4. If the voltage described in Step 3 above is not obtained, it means that the computer control is not func-
tioning properly. Perform the check of EFI ECU, referring to the EF section.
MEM00217-00000
EM(52-64) 59 29/11/2001, 2:37 PM

EM–60
SERVICE SPECIFICATIONS
Type Petrol, 4 cycle
Cylinder No. 3-cylinder-in-line
Combustion chamber type Pent roof type
Valve mechanism DOHC, Directly driven by camshaft
Bore × stroke 72.0 mm × 81.0 mm
Total displacement 989 cc
Compression ratio 10.0 ± 0.3
Compression pressure 1363 - 1538 kPa (13.9 - 15.7 kg/cm2) at 400 rpm
Maximum output 43.0/6000 (kW/rpm)
Maximum torque 88.3/3600 (N·m/rpm)
Number of piston ring Compression ring 2
Oil ring 1
Valve timing Intake Open BTDC 58° ~ - 2°
Close ABCD 2° ~ 62°
Exhaust Open BBDC 44°
Close ATDC 6°
Valve clearance Intake (Cold) 0.18 ± 0.05 mm
Exhaust (Cold) 0.25 ± 0.05 mm
Idling speed STD 850 ± 50 rpm
AUS and tropical spec. 900 ± 50 rpm
Blow-by gas recirculating system Closed type
MEM00218-00000
EM(52-64) 60 29/11/2001, 2:37 PM

EM–61
Timing belt Belt tension (When the midpoint of the belt at the tension side is pushed 5 mm) 11.8 - 16.7 N·m
Camshaft Camshaft journal outer dia. (IN, EX) No.1 25.979 - 25.995 mm
No. 2, No.3, No. 4 22.979 - 22.995 mm
Camshaft bearing cap inner dia. (IN, EX) No. 1 26.032 - 26.052 mm
No. 2, No. 3, No. 4 23.032 - 23.052 mm
Oil clearance (IN, EX) No. 1 0.037 - 0.073 mm
No. 2, No. 3, No. 4 0.037 - 0.073 mm
Camshaft thrust clearance (IN, EX) 0.04 - 0.10 mm
Cam lobe height (IN, EX) 40.25 mm
Camshaft for runout 0.03 mm
Cylinder head Warpage Cylinder block side 0.1 mm
Intake manifold side 0.1 mm
Exhaust manifold side 0.1 mm
Cylinder head height 103.0 mm
Valve seat angle IN 45°
EX 45°
Valve lifter outer dia. 27.975 - 27.985 mm
Inner dia. of the cylinder head valve lifter bore 28.000 - 28.021 mm
Valve lifter oil clearance 0.015 - 0.046 mm
Valve Valve stem dia. IN 4.975 - 4.990 mm
EX 4.965 - 4.980 mm
Inner dia. of valve guide bush 5.000 - 5.012 mm
Valve stem oil clearance IN 0.010 - 0.037 mm
EX 0.020 - 0.047 mm
Valve length IN 79.4 mm
EX 79.8 mm
Valve face angle (IN, EX) 44.5°
Valve stock thickness (IN, EX) 1.0 ± 0.2 mm
Valve recession IN 3.0 mm
EX 3.0 mm
Width of the contact surface of valve seat 1.4 ± 0.5 mm
Valve stem oil seal installed position IN 14.2 ± 0.8 mm
EX 11.2 ± 0.8 mm
Valve spring Free length 37.1 mm
Valve spring for squareness 1.3 mm
Minimum fension/installation height 123.17 ± 8.63 N/32.0 mm
EM(52-64) 61 29/11/2001, 2:37 PM

EM–62
Cylinder block Surface contacting the cylinder head gasket for warpage 0.1 mm
Cylinder block height 235.9 - 236.1 mm
Cylinder bore dia. 72.000 - 72.030 mm
Piston outer dia. 71.965 - 71.995 mm
Piston-to-cylinder bore oil clearance 0.025 - 0.045 mm
Crankshaft thrust clearance 0.02 - 0.22 mm
Connecting rod thrust clearance 0.15 - 0.25 mm
Width of big end of connecting rod in thrust direction 19.80 - 19.85 mm
Side width of crankpin journal 20.00 - 20.05 mm
Connecting Connecting rod big end bore dia. 43.000 - 43.024 mm
rod
Crankpin dia. 39.076 - 40.000 mm
Oil clearance between the crankpin journal and the connecting rod cap 0.020 - 0.044 mm
Connecting rod for bend 0.05 mm
Connecting rod for twist 0.05 mm
Crankshaft Crankshaft main journal dia. 45.976 - 46.000 mm
Cylinder block main journal dia. 50.000 - 50.024 mm
Oil clearance between the crankshaft main journal and crankshaft bearing cap 0.004 - 0.028 mm
Crankshaft for runout 0.06 mm
Piston Piston pin outer dia. 17.994 - 17.997 mm
Piston pin hole of piston dia. 18.002 - 18.005 mm
Piston-to-piston pin oil clearance 0.005 - 0.011 mm
Connecting rod small end bore dia. 17.953 - 17.979 mm
Connecting rod-to-piston pin interference fit 0.015 - 0.044 mm
Piston ring groove side clearance No. 1 0.03 - 0.07 mm
No. 2 0.02 - 0.06 mm
Piston ring end gap No. 1 0.20 - 0.35 mm
No. 2 0.22 - 0.37 mm
Oil ring 0.15 - 0.50 mm
Flywheel Flywheel for runout 0.1 mm
MEM00219-00000
EM(52-64) 62 29/11/2001, 2:37 PM

EM–63
TIGHTENING TORQUE
Components N·m kgf-m Remarks
Cylinder head × Ignition coil 6.0 ± 1.8 0.6 ± 0.18
Cylinder head × Spark plug 17.5 ± 3.0 1.8 ± 0.3
Cylinder head × Cylinder head cover 5.5 ± 1.1 0.55 ± 0.11
Cylinder head × Fuel delivery pipe 19.0 ± 3.8 1.95 ± 0.39
Cylinder head × Intake manifold 19.0 ± 3.8 1.95 ± 0.39
Cylinder head × Exhaust manifold 25.0 ± 5.0 2.6 ± 0.5
Cylinder head × Water inlet 19.0 ± 3.8 1.95 ± 0.39
Cylinder head × Cam position sensor 8.0 ± 1.6 0.8 ± 0.16
Cylinder head × Water temperature sensor 24.0 ± 4.8 2.5 ± 0.5
Cylinder block × Cylinder head 54.0 ± 5.0 5.5 ± 0.5
Cylinder block × Timing belt cover 5.5 ± 1.1 0.55 ± 0.11
Cylinder block × Timing belt tensioner 39.0 ± 7.8 4.0 ± 0.8
Cylinder block × Rear oil seal retainer 12.5 ± 2.5 1.3 ± 0.26
Cylinder block × Rear end plate 21.0 ± 4.2 2.1 ± 0.42
Cylinder block × Oil pan 8.0 ± 1.6 0.8 ± 0.16
Cylinder block × Oil pump 19.0 ± 3.8 1.95 ± 0.39
Oil pump × Oil strainer 8.0 ± 1.6 0.8 ± 1.6
Oil pan drain plug 24.0 ± 4.8 2.5 ± 0.5
Camshaft cap No.1, No. 2 12.5 ± 2.0 1.3 ± 0.2
Surge tank stay × Cylinder head cover 9.0 ± 2.7 0.9 ± 0.27
Water pump pulley × Water pump 9.5 ± 1.9 0.95 ± 0.19
Camshaft timing belt pulley × Camshaft 98.0 ± 10.0 10.0 ± 1.0
Exhaust manifold × Heat insulator 11.5 ± 2.3 1.15 ± 0.23
Connecting rod cap nut 36.0 ± 6.0 3.7 ± 0.6
Crankshaft bearing cap bolt 59.0 ± 6.0 6.0 ± 0.6
Crankshaft pulley set bolt 98.0 ± 10.0 10.0 ± 1.0
25 - 34 2.5 - 3.5 Temporarily tightening
Crankshaft × Flywheel
44.0 ± 5.0 4.5 ± 0.5
Oil filter bracket × Cylinder block 19.0 ± 3.8 1.95 ± 0.39
Oil filter bracket × Oil pipe 39.0 ± 5.0 3.82 ± 0.49
Oil pipe × Camshaft bearing cap No. 1 52.0 ± 5.0 5.1 ± 0.49
Camshaft No. 2 nut 125 ± 7.0 12.3 ± 0.7
LEM00247-00000
EM(52-64) 63 29/11/2001, 2:37 PM

EM–64
SSTs
Shape Part number Part name Remarks
09210-87701-000 Fly wheel holder
09504-87501-000 Differential side bearing adjusting nut wrench
09202-87002-000 Valve cotter remover & replacer
09202-87002-0A0 Valve cotter attachment
09202-87702-000 Valve spring replacer
09202-87202-000 Valve sprig replacer body
09202-87201-000 Valve spring replacer pivot
09237-87201-000 Replacer
09707-87302-000 Spring bush remover & replacer
09221-87208-000 Exchange attachment shim
09032-00100-000 Oil pan seal cutter
09221-87207-000 Piston pin body remover & replacer
09221-87206-000 Piston pin remover & replacer
09608-87302-000 Axle hub & drive pinion bearing tool set
09217-87001-000 Piston replacing guide
MEM00220-00202
EM(52-64) 64 29/11/2001, 2:37 PM

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PERODUA

EM(01-10) 1 29/11/2001, 2:32 PM

4. Remove the crankshaft pulley from the crankshaft, while

5. Remove the timing belt cover.

mating mark of the oil pump.

EM(01-10) 2 29/11/2001, 2:32 PM

mark indicating the normal rotating direction on the

2. If the belt teeth are cracked or damaged, check to see if

3. If there is noticeable wear or cracks on the belt face,

EM(01-10) 3 29/11/2001, 2:32 PM

Timing belt pulley (Crankshaft, Camshaft)

Timing belt tensioner

Timing belt cover

Crankshaft timing belt pulley flange

EM(01-10) 4 29/11/2001, 2:32 PM

3. Installation of timing belt

(1) Rotate the crankshaft, until the mating mark of the

4. Adjustment of timing belt tension

EM(01-10) 5 29/11/2001, 2:33 PM

(3) Tighten the timing belt tensioner attaching bolt.

(4) Checking of timing belt tension

7. Installation of crankshaft pulley set bolt

EM(01-10) 6 29/11/2001, 2:33 PM

EM(01-10) 7 29/11/2001, 2:33 PM

q Ignition coil cover !6 Camshaft bearing cap No. 2 #1 Grommet

EM(01-10) 8 29/11/2001, 2:33 PM

3. Remove the timing belt.

5. Remove the ignition coil from the cylinder head cover.

6. Remove the oil control valve from the camshaft bearing

7. Disconnect the vacuum hoses that are connected to the e t

EM(01-10) 9 29/11/2001, 2:33 PM

(5) Remove the camshaft bearing cap No. 1 by removing

(6) Secure the camshaft sub-gear to the gear section of

(7) Remove the camshaft bearing cap No. 2 by removing

EM(01-10) 10 29/11/2001, 2:33 PM

10. Remove the intake manifold from the cylinder head.

14. Remove the oxygen sensor harness from the clamp.

EM(11-20) 11 29/11/2001, 2:33 PM

18. Remove the water inlet from the cylinder head.

21. Remove the cam/crank angle sensor from the cylinder

23. Remove the cylinder head attaching bolts in the se-

EM(11-20) 12 29/11/2001, 2:33 PM

2. Remove the valve spring retainer locks, using the follow-

3. Remove the valve spring retainers, and valve springs.

EM(11-20) 13 29/11/2001, 2:33 PM

2. Remove the sub-gear attaching bolt (which was used in

3. Using a snap ring expander, detach the shaft snap ring.

EM(11-20) 14 29/11/2001, 2:33 PM

1. Check of cylinder head for flatness

If surface warpage of the cylinder block side exceeds

If the cylinder head surface warpage at the cylinder

2. Check of camshaft oil clearance

3. Install the bearing caps. Tighten them to the specified

EM(11-20) 15 29/11/2001, 2:33 PM

Camshaft Journal Outer Diameter

Camshaft bearing Cap Bore Diameter

3. Check of camshaft thrust clearance

4. Check and grinding of valves