Sect 2 Overhaul 1fs Engine Ce303

1FS RM.
book 1 ページ２０１３年９月２７日　金曜日　午後１２時４１分
2-1
ENGINE OVERHAUL
SST LIST .......................................................................... 2-2

ENGINE ACCESSORIES ............................................. 2-4 0
REMOVAL, INSPECTION AND INSTALLATION............ 2-4
1
CYLINDER HEAD .......................................................... 2-7
2
COMPONENTS ............................................................... 2-7
3
DISASSEMBLY, INSPECTION AND REASSEMBLY ... 2-11
TIMING GEAR............................................................... 2-18 4
COMPONENTS ............................................................. 2-18 5
DISASSEMBLY, INSPECTION AND REASSEMBLY ... 2-21 6
CYLINDER BLOCK ..................................................... 2-29 7
COMPONENTS ............................................................. 2-29
8
DISASSEMBLY, INSPECTION AND REASSEMBLY ... 2-33
9
ENGINE TUNE-UP ....................................................... 2-42
10
V BELT DEFLETION
INSPECTION AND ADJUSTMENT ........................... 2-42 11
VALVE CLEARANCE 12
INSPECTION AND ADJUSTMENT ........................... 2-43
IDLE SPEED INSPECTION........................................... 2-44 13
NO-LOAD MAXIMUM SPEED MEASUREMENT ......... 2-44 14
COMPRESSION INSPECTION ..................................... 2-44
1FS RM.book 2 ページ２０１３年９月２７日　金曜日　午後１２時４１分
2-2
SST LIST
Illustration Part No. Part Name
09032-76001-71
Oil pan seal cutter
(09032-00100)
09130-36770-71 Cylinder head union socket
09150-10170-71 Transmission bearing replacer
09201-76005-71
Valve stem oil seal replacer
(09201-58010)
09201-76006-71
Valve guide bush remover & replacer
(09201-60011)
09202-76002-71
Valve spring compressor
(09202-70020)
09213-76007-71
Crankshaft pulley and gear puller
(09213-60017)
09216-76001-71
Belt tension gauge
(09216-00020)
2-3
Illustration Part No. Part Name
09228-76004-71
Oil filter wrench
(09228-07501)
09370-20270-71 Drive pinion bearing replacer
09950-76014-71
Puller B set
(09950-40011)
09950-76019-71
Replacer B set
(09950-60020)
09950-76020-71
Handle set
(09950-70010)
09960-76001-71
Variable pin wrench set
(09960-10010)
09992-76001-71
Cylinder compression check gauge set
(09992-00024)
2-4
ENGINE ACCESSORIES
REMOVAL, INSPECTION AND INSTALLATION
T = N·m
T = 8 to 10 T = 15 to 21
T = 12 to 16
T = 7 to 11
4 10
T = 20 to 30
T = 9 to 16
T = 17 to 25
T = 29 to 43 T = 7 to 11
7
6
11
T = 13 to 23
T = 13 to 23
T = 17 to 25 T = 8 to 10
7
T = 17 to 25
12
3
T = 36 to 52
T = 15 to 27
T = 36 to 55
T = 47 to 69
1 T = 15 to 21
2-5
Removal and installation procedure

The installation procedure is the reverse of the removal procedure.
No. Item Removal Inspection Installation
1 Pulley, V-belt See page 2-42  
2 Alternator, adjusting bar
3 Water pump
Adapter (LPG or combination specification)
4
Air intake connector (gasoline specification)
5 Throttle body
6 Gauge guide bracket
7 Fuel filter, fuel pipe, fuel hose [Point 1]
8 Delivery pipe, injector
9 Oil filter [Point 2] [Point 4]
10 Ignition coil, spark plugs
11 Intake manifold [Point 3]
12 Exhaust manifold, insulator [Point 3]
Point operation
[Point 1]
Removal:
Remove fuel pressure of the fuel system according to the following
steps.
1. Put a cloth under the delivery pipe.
2. Cover the area around the union bolt with the cloth and loosen
the bolt slightly to remove fuel pressure.
3. Loosen the union bolt and drain the fuel inside the delivery
pipe into a pan.
WARNING:
• Use a cloth or take another measure to prevent spattering of
fuel.
• Never work near fire.
[Point 2]
Removal:
Remove the oil filter.
SST 09228-76004-71
(09228-07501)
SST
2-6
[Point 3]
Inspection:
Check the intake manifold for distortion.
Limit: 0.4 mm (0.016 in.)
Inspection:
Check the exhaust manifold for distortion.
Limit: 0.6 mm (0.024 in.)
[Point 4]
Installation:
Tighten the O-ring attached oil filter at the specified torque using
SST.
SST 09228-76004-71
(09228-07501)
T = 15.0 to 19.0 N·m
Caution:
• Coat a small amount of the engine oil on the O-ring.
SST
• Clean the fitting surface.
Inspection:
Limit: 0.6 mm (0.024 in.)
Inspection:
Limit: 0.6 mm (0.024 in.)
1FS RM.book
7 ページ
20
21
FC
43A
AZ COMPONENTS
43A
43D
CYLINDER HEAD
43A 30
30A
43A
20C
AZ
２０１３年９月２７日　金曜日　午後１２時４１分
20
43A
20B 20B
20A
20A
43D 43A
20B
43A
20A 45
20B
44 40
20A 45
44
45
44
45
44 AE
1104-206
1104-205 1104
1104
2-7
1FS RM.book
2-8
8 ページ
40
BG
49
41
AH
AZ
AD
BG
BI
BI
47A
47A
47
47 46
1302-091
1302-091
46
43A
44A
AN
AN FIG.1301
43 60 63
44
55 64
60A 63A
54 62
1302-174 1302-173
1302
1302
2-9
1302
AG
14
14
20C
22
22
22
22 20B
42
22
57
22C 22
22 56
20B 1302-091
45 22
20C 56
20
56
22A
1302-175
1701
1701-258
AD
BO
43
40
BV
AD
AN
BY
AN
AN
CA
BO
AN
72
AN
AN
2-10
1701
AR
AR AR
BP
AH
CX
BE
AQ 44
AQ
AQ
41
AQ
AF AF AQ
AQ AH
AF CX
BE
1701-259
2-11
DISASSEMBLY, INSPECTION AND REASSEMBLY

T = N·m
T = 8 to 10
T = 36 to 52
4
T = 20 to 28
3 5
6
9
10
7 11
Disassembly and reassembly procedure

The reassembly procedure is the reverse of the disassembly procedure.
No. Item Disassembly Inspection Assembly
1 Remove the parts 1 to 8 and 10 to 12 on page 2-4. See page 2-5  
2 Cylinder head cover
3 Rocker shaft assembly [Point 1] [Point 2] [Point 16]
4 Valve stem cap [Point 3]
5 Valve push rod [Point 4] [Point 5]
6 Cylinder head bolt [Point 6] [Point 15]
7 Cylinder head assembly [Point 7] [Point 14]
8 Cylinder head gasket [Point 13]
9 Valve spring and valve [Point 8] [Point 9] [Point 12]
10 Valve stem oil seal [Point 11]
11 Valve guide bush [Point 10]  
2-12
Point operation
[Point 1]
Disassembly:
Loosen the support set bolts evenly in several steps in the order
shown to the left.
1 3 4 2
[Point 2]
Inspection:
Check the rocker arm for wear and damage on the contact area
with the valve stem cap.
If light damage is found, reface with an oil stone. If there is
significant wear or damage, replace it.
Inspection:
Move the rocker arm as shown and check the clearance between
the rocker arm and the shaft. If the clearance is too large,
disassemble and check the parts.
Inspection:
Check the oil clearance between the rocker arm and the rocker
shaft.
1. Measure the inside diameter of the rocker arm.
Standard: 18.500 to 18.521 mm (0.728 to 0.729 in.)
Limit: 18.60 mm (0.732 in.)
2. Measure the outside diameter of the rocker shaft.Measure the
gear shaft outside diameter.
Limit: 18.44 mm (0.726 in.)
3. Calculate the oil clearance.

Limit: 0.16 mm (0.006 in.)
If the limit is exceeded, replace the rocker arm or the rocker
shaft.
[Point 3]
Inspection:
Check the valve stem cap.
1. Measure the thickness of the valve stem cap.
2. If light damage is found in the contact areas with the rocker
arm, reface with an oil stone. If there is significant wear or
damage, replace the valve stem cap.
2-13
[Point 4]
Disassembly:
Sort the removed push rods carefully so they can be reassembled
in the correct order.
1 2 3 4 5 6 7 8
[Point 5]
Inspection:
Check the push rods for bend.
Measure the amount of bend per full turn of the push rod.
Bend = Dial gauge deflection / 2
Limit: 0.3 mm (0.012 in.)
1 7 9 15 17 14 12 6 4
[Point 6]
Disassembly:
Loosen the cylinder head bolts evenly in several steps in the order
shown to the left.
3 5 11 13 18 16 10 8 2
[Point 7]
Inspection:
Measure the cylinder head distortion using the straightedge and
thickness gauge.
1. Check the distortion along the four edges and along the
diagonal lines at the bottom of the cylinder head.
Limit: 0.15 mm (0.006 in.)
2. Check the distortion in the manifold fitting surface.
Limit: IN/EX 0.15 mm (0.006 in.)
If the limit is exceeded, reface or replace it.
2-14
Inspection:
Check the cylinder head for cracks.
Using the color check method (dye detection method), look for
cracks in the combustion chamber, intake port, exhaust port, and
the lower and upper cylinder head surfaces.
[Point 8]
Disassembly:
Keep the removed parts in cylinder groups.
SST SST 09202-76002-71
(09202-70020)
[Point 9]
Inspection:
Check the valve.
1. Measure the overall length of the valve.
Standard: IN 110.4 to 111.0 mm (4.346 to 4.370 in.)
EX 110.7 to 111.3 mm (4.358 to 4.382 in.)
Limit: IN 110.3 mm (4.343 in.)
EX 110.6 mm (4.354 in.)
Inspection:
Check the valve seat.
2. Coat a small amount of red lead on the valve face.
3. Insert the valve into the valve guide bushing, and push the
valve against the valve seat.
Do not turn the valve while it is being pushed.
4. Check that the contact width satisfies the standard for the
entire circumference.
EX 1.4 to 2.0 mm (0.055 to 0.079 in.)
If the standard is not satisfied, replace the valve or correct the
valve seat.
2-15
5. Correct the valve seat.

75° (EX) 45° (1) Use a 45° valve seat cutter for refacing.
55° (IN) (2) If the contact position is deviated outside, use a 30° cutter
30°
and if the contact position is deviated inside, use a 55°
(IN), 75° (EX) cutter for refacing.
Use a cutter with a cemented carbide tip on the EX side.
Cut while constantly checking the valve contact position
and contact width.
Cut the face evenly without undulation by gradually
reducing the pressure toward the end of refacing.
Correct after checking the valve guide bushing.
(3) Perform valve lapping.

Use a compound for lapping. Use red lead for checking
uniform contact with the valve along the entire
circumference.
After checking, completely remove the compound.
Inspection:
2.0 mm Check the compression spring.
(0.079 in.) 6. Measure squareness at the upper end of the spring.
7. Measure the free length.

Standard: IN/EX 47.0 mm (1.850 in.)
[Point 10]
Inspection:
Check the oil clearance between the valve guide bushing and the
valve stem.
1. Measure the inside diameter of the valve guide bushing.
2. Measure the outside diameter of the valve stem.
EX 7.965 to 7.980 mm (0.3136 to 0.3142 in.)
2-16

EX 0.030 to 0.065 mm (0.0012 to 0.0026 in.)
Limit: IN 0.120 mm (0.0047 in.)
EX 0.125 mm (0.0049 in.)
If the limit is exceeded, replace the valve or the valve guide
bushing. Use a reamer to grind the inside diameter and bring
the oil clearance between the bushing and valve stem within
the standard according to need. Perform valve lapping after
replacement. (See page 2-15)
Disassembly/Reassembly:
Replace the valve guide bushing.
SST 09201-76006-71
(09201-60011)
SST
Inspection:
Measure the protruded portion of the valve guide bushing.
[Point 11]
Reassembly:
SST
SST Coat engine oil on the lips of new valve stem oil seals and on valve
stems.
SST 09201-76005-71
(09201-58010)
[Point 12]
Reassembly:
Assemble the valve spring and valve.
SST SST 09202-76002-71
(09202-70020)
2-17
Engine front [Point 13]

Reassembly:
Install the gasket in the correct direction.
[Point 14]
Guide Reassembly:
Assemble the cylinder head union using SST.
SST 09130-36770-71
Put the guide part located at the end of SST on the top surface
of the cylinder head for the correct direction of union assembly.
SST
Note:
• Before pressing the cylinder head union, apply a sealing
agent (THREEBOND TB1386B or equivalent) to the entire
circumference/length of the press fit area.
• Press until the spool of the union touches the head.
• The pipe should be directed downward at an angle up to 20°
from the rear side horizontal direction.
18 12 10 4 2 5 7 13 15 [Point 15]
Reassembly:
Tighten the cylinder head bolts according to the following
procedure. Follow the order specified in the left figure for each
step.
1. Tighten all bolts to the specified torque.
T = 62 to 68 N·m
2. Retighten at 90° ±10° (1st time).
3. Retighten at 90° ±10° (2nd time).
16 14 8 6 1 3 9 11 17 Caution:
Do not reuse the cylinder head bolt if the thread diameter
becomes 11.6 mm (0.457 in.) or less. Replace it with new one.
[Point 16]
Reassembly:
Tighten the support set bolts evenly in several steps in the order
shown to the left.
4 2 1 3
1FS RM.book
2-18
18 ページ
COMPONENTS
TIMING GEAR
45
46 23
FH
AA
AW
AU AU AU
AW AU
AA
46A AV AU
AV
AV
AW
AW
AV 41
1106-212
AW
AV
20
AV
AV
20A AW
1106-211
1106
1106
1FS RM.book
19 ページ
40
BG
49
41
AH
AZ
AD
BG
BI
BI
47A
47A
47
47 46
46
43A
44A
AN
AN FIG.1301
43 60 63
44
55 64
60A 63A
54 62
1302-174 1302-173
1302
1302
2-19
2-20
1302
AG
14
14
20C
22
22
22
22 20B
42
22
57
22C 22
22 56
20B
45 22
20C 56
20
56
22A
1302-175
2-21

T = N·m
T = 36 to 52
3
14
T = 209 to 271
6
T = 36 to 52
T = 61 to 77
T = 17 to 25
T = 17 to 25
13
7 6
12
T = 61 to 77
T = 36 to 52
10
11
T = 42 to 62
9 T = 15 to 21
2-22

1 Pulley, V-belt, alternator See page 2-42  
2 Cylinder head assembly * See page 2-11  
3 Crankshaft pulley, bolt [Point 1] [Point 16]
4 Timing gear cover
5 Measure the idle gear backlash and thrust clearance. [Point 2]
6 Idle gear No.1, No.2 shafts [Point 3] [Point 15]
7 Oil pump ASSY
8 Valve lifter [Point 4] [Point 5]
9 Oil pan [Point 6] [Point 14]
10 Camshaft with timing gear [Point 7]
11 Camshaft timing gear [Point 8] [Point 13]
12 Crank shaft timing gear, crank position rotor [Point 9] [Point 12]
13 Timing gear case [Point 11]
14 Front oil seal [Point 10]
* When removing items other than the camshaft, it is not necessary to remove the cylinder head.
Point operation
[Point 1]
Disassembly:
Remove the crankshaft pulley.
SST
SST 09213-76007-71
(09213-60017)
[Point 2]
A Inspection:
Measure the backlash in positions A to D before removing and after
installing the gear.
Standard: 0.05 mm (0.0020 in.)
C Limit: 0.3 mm (0.012 in.)
B
Inspection:
Measure the thrust clearance of idle gear No.1 and No.2.
Standard: Idle gear No.1: 0.03 to 0.11 mm
(0.0012 to 0.0043 in.)
Idle gear No.2: 0.03 to 0.09 mm
(0.0012 to 0.0035 in.)
Limit: Idle gear No.1: 0.3 mm (0.012 in.)
Idle gear No.2: 0.5 mm (0.0020 in.)
If the limit is exceeded, replace each idle gear.
2-23
[Point 3]
Inspection:
Check the idle gear oil clearance.
1. Measure the inside diameter of the idle gear.
Standard: No.1: 50.000 to 50.025 mm
(1.968 to 1.969 in.)
No.2: 51.000 to 51.030 mm
(2.008 to 2.009 in.)
2. Measure the outside diameter of the idle gear shaft.

(1.967 to 1.968 in.)
No.2: 50.940 to 50.970 mm
(2.006 to 2.007 in.)
(0.0010 to 0.0030 in.)
No.2: 0.030 to 0.090 mm
(0.0012 to 0.0035 in.)
Limit: 0.3 mm (0.012 in.)
[Point 4]
Disassembly:
Sort the removed valve lifters carefully so they can be installed in
the correct order.
1 2 3 4 5 6 7 8
[Point 5]
Inspection:
Check the valve lifter oil clearance.
1. Measure the outside diameter of the valve lifter.
Standard: STD 22.170 to 22.190 mm
(0.8728 to 0.8736 in.)
O/S 22.220 to 22.235 mm
(0.8748 to 0.87539 in.)
2. Measure the inside diameter of the cylinder block bore.

Standard: 22.200 to 22.221 mm
(0.8740 to 0.8748 in.)
3. Calculate the oil clearance of valve lifter.
Limit: 0.1 mm (0.004 in.)
If the limit is exceeded, replace the valve lifter.
2-24
[Point 6]
Disassembly:
Do not deform the oil pan flange while working.
SST 09032-76001-71
(09032-00100)
Caution:
• Do not use the SST on the timing gear case side.
• Do not pry with a screwdriver, etc.
SST
[Point 7]
Inspection:
Measure the thrust clearance of the camshaft.
Limit: 0.3 mm (0.012 in.)
Inspection:
Measure the cam height.
EX 42.800 to 42.900 mm (1.685 to 1.689 in.)
Limit: IN 42.12 mm (1.658 in.)
EX 42.75 mm (1.683 in.)
Inspection:
Check the camshaft for bend.
Limit: 0.03 mm (0.0012 in.)
Inspection:
Check the camshaft bearing oil clearance.
1. Measure the countershaft journal outside diameter.
Standard: No.1 (front): 51.151 to 51.170 mm
(2.0138 to 2.0146 in.)
No.2 (center): 50.921 to 50.940 mm
(2.0048 to 2.0055 in.)
No.3 (rear): 50.751 to 50.770 mm
(1.9981 to 1.9988 in.)
2-25
2. Measure the camshaft bearing inside diameter.

(2.0157 to 2.0169 in.)
No.2 (center): 51.00 to 51.03 mm
(2.0079 to 2.0090 in.)
No.3 (rear): 50.80 to 50.83 mm
(2.0000 to 2.0012 in.)
(0.0012 to 0.0031 in.)
No.2 (center): 0.060 to 0.109 mm
(0.0024 to 0.0043 in.)
No.3 (rear): 0.030 to 0.079 mm
(0.0012 to 0.0031 in.)
Limit: 0.15 mm (0.006 in.)
If a serious streak or damage is found on the camshaft journal,
reface the camshaft journal.
[Point 8]
Disassembly:
Remove the camshaft timing gear set bolt.
SST 09960-76001-71
(09960-10010)
SST
Disassembly:
Socket Remove the timing gear from the camshaft using a press.
[Point 9]
Disassembly:
Remove the crank position rotor.
2-26
Disassembly:
Remove the key for crankshaft pulley and crank position rotor, and
SST remove the crankshaft timing gear using the SST.
SST 09950-76014-71
(09950-40011)
[Point 10]
Reassembly:
SST(2)
Drive in the oil seal using the SST until it becomes flush with the
timing gear cover surface.
SST(1)
SST (1) 09950-76019-71
(09950-60020)
SST (2) 09950-76020-71
(09950-70010)
Note:
Coat MP grease on the oil seal lips.
[Point 11]
FIPG Reassembly:
Coat the FIPG on the timing gear case seal.
FIPG: 08826-76001-71
(For handling the FIPG, see page 0-23)
[Point 12]
Reassembly:
Reassemble the crankshaft timing gear using the SST and install
the key for the crankshaft pulley and crank position rotor.
SST SST 09370-20270-71
2-27
Reassembly:
Install the crank position rotor.
[Point 13]
Reassembly:
Install the camshaft timing gear.
Oil groove
1. Assemble by setting the oil groove to the thrust plate side.
2. Install the camshaft timing gear set bolt.

SST 09960-76001-71
(09960-10010)
SST
[Point 14]
Reassembly:
Coat the FIPG on the oil pan seal.
FIPG: 08826-76001-71
(For handling the FIPG, see page 0-23)
R7
FIPG
R7
7 mm
(0.28 in.)
2-28
[Point 15]
Reassembly:
Check that the piston No. 1 is at TDC, and assemble by aligning
the punched marks on the idle gear and on each gear.
[Point 16]
Reassembly:
Reassemble the crankshaft pulley.
SST 09150-10170-71
SST
1FS RM.book
29 ページ
20
AO
43B 43A COMPONENTS
AH
AO
43B
43B
CYLINDER BLOCK
AH
43B 43C
20 AE
AE
43B AF
43D
43A 43B
AF
43B
43C
AE
EY 43C AJ
EY
AE AK
AE
AI
AI AE
AI
AI AI
AI
1105-299
1105-297
1105
1105
2-29
2-30
1105
1105-298
AD
AC
DM
1105
1105-300
30
30A
30
41
AA
CF
CF
1FS RM.book
31 ページ
31
31A
31A
31A
31A
31A
40
BH
BH
BF
BF
21B
34 21A CS
1301-216 1105-301
1105
1301
2-31
2-32
1301
32
21
20A
20 20B
20C
30
30A 10
30A 42A
30A 41 41A
30A
AD
42
AC
67
1301-217
2-33

T = N·m
4
T = 17 to 25
9
11
8
12
T = 20 to 30
13
11
T = 123 to 137
11
7
T = 15 to 21
T = 90 to 100 3

1 Cylinder head assembly See page 2-11  
2 Timing gear parts See page 2-21  
3 Oil strainer
4 Rear oil seal retainer with oil seal
5 Rear oil seal [Point 12]
6 Connecting rod thrust clearance [Point 1]
7 Connecting rod cap with bearing [Point 2] [Point 11]
8 Piston with connecting rod [Point 10]
9 Piston [Point 3] [Point 4] [Point 9]
10 Crankshaft thrust clearance [Point 5]
11 Crankshaft cap, bearing, thrust washer [Point 6] [Point 8]
12 Crankshaft [Point 7]
13 Oil regulator
Caution:
Do not confuse the parts of different cylinders during installation.
2-34
Point operation
[Point 1]
Inspection:
Measure the thrust clearance of the connecting rod.
Limit: 0.35 mm (0.0138 in.)
[Point 2]
Inspection:
Measure the oil clearance of the connecting rod bearing.Measure
using the plastigage, and tighten the connecting rod cap set nut to
specified torque.
Do not turn the crankshaft during measurement.
Limit: 0.1 mm (0.004 in.)
If the limit is exceeded, replace the bearing.If excessive scratching
or burning exists, grind the crankshaft and use an U/S bearing.
Bearing cap Bearing Crank pin

fitting code fitting code OD standard mm (in.)
1 1 54.98 to 55.00
2 2 (2.1646 to 2.1654)
54.74 to 54.75
0.25 mm (0.01 in.) U/S
Fitting code (2.1551 to 2.1555)
54.49 to 54.50
0.50 mm (0.02 in.) U/S
(2.1453 to 2.1457)
Front mark
54.24 to 54.25
Fitting code 0.75 mm (0.03 in.) U/S
(2.1354 to 2.1358)
53.99 to 54.00
1.00 mm (0.04 in.) U/S
(2.1256 to 2.1260)
[Point 3]
Disassembly:
Disassemble the piston and connecting rod.
1. Remove the piston ring and the oil ring.
2-35
2. Remove the snap ring, warm the piston to 60 °C (140 °F), and
Brass bar remove the piston pin from piston using the brass bar.
Keep the piston, the piston pins and the connecting rods
sorted by cylinder groups.
[Point 4]
Inspection:
Check the cylinder block.
1. Check the cylinder block for distortion in the upper surface.
Limit: 0.1 mm (0.004 in.)
Make sure that the cylinder wall is free of serious scratches.
2. Measure at six points shown at left.

Thrust
direction
Crank
axis
direction
15 mm
(0.59 in.)
Center
15 mm
(0.59 in.)
3. Measure the piston clearance.

(1) Measure the outside diameter of the piston.
Measured point: The point 13 mm (0.51 in.) from the
bottom of the piston (skirt) at right
angle to piston pin.
(3.9740 to 3.9751 in.)
13 mm
(0.51 in.)
Pin hole size fitting code A, B or C Piston size fitting Cylinder boremm Piston outside
code (in.) diametermm (in.)
Front mark
101.00 to 101.01 100.94 to 100.95
1
(3.9764 to 3.9768) (3.9740 to 3.9744)
101.01 to 101.02 100.95 to 100.96
2
(3.9768 to 3.9772) (3.9744 to 3.9748)
Piston size fitting
101.02 to 101.03 100.96 to 100.97
code 3
1, 2 or 3 (3.9772 to 3.9776) (3.9748 to 3.9752)
2-36
(2) Calculate the piston clearance from the cylinder inside

Cylinder inside diameter fitting diameter measured in the inspection 2.
code 1 to 3
Limit: 0.15 mm (0.006 in.)
Inspection:
Check the piston and connecting rod.
4. Measure the gap between the piston ring and the ring groove
along the entire circumference of the piston.
(0.0007 to 0.0028 in.)
No.2: 0.020 to 0.060 mm
(0.0007 to 0.0024 in.)
Oil ring: 0.020 to 0.065 mm (0.0007 to 0.0026 in.)
5. Press down the piston ring with the piston until it reaches the
sliding parts of the ring, and measure the piston ring end gap.
(0.0098 to 0.0138 in.)
No.2: 0.63 to0.78 mm
(0.0248 to 0.0307 in.)
Oil ring: 0.10 to 0.40 mm (0.0039 to 0.0157 in.)
6. Measure the oil clearance of the connecting rod bushing.

(1) Measure the inside diameter of the bushing.
(1.2602 to 1.2606 in.)
(2) Measure the outside diameter of the piston pin.

(1.2598 to 1.2603 in.)
(3) Calculate the oil clearance.
Standard: - 0.004 to 0.020 mm
(- 0.0002 to 0.0007 in.)
Limit: 0.05 mm (0.0020 in.)
If the limit is exceeded, replace the connecting rod
assembly.
2-37
[Point 5]
Inspection:
Measure the thrust clearance of the crankshaft.
Limit: 0.3 mm (0.012 in.)
If the limit is exceeded, replace the thrust washer or the crankshaft.
Thrust washer thickness (reference)
STD: 2.43 to 2.48 mm (0.0957 to 0.0976 in.)
O/S: 0.125, 0.250 mm (0.0049, 0.0098 in.)
[Point 6]
3 7 9 5 1
Disassembly:
Loosen the cap set bolts evenly in several steps in the order shown
to the left.
Sort the removed cap, bearing and washer carefully so they can be
installed in the correct positions.
4 8 10 6 2
[Point 7]
Inspection:
Check the crankshaft.
1. Measure the oil clearance of the crankshaft using the
plastigage.
Do not turn the crankshaft during measurement.
Limit: 0.1 mm (0.004 in.)
If the limit is exceeded, replace the bearing.If excessive
scratching or burning exists, grind the crankshaft and use an
U/S bearing.
2-38
Fitting code B is journal No.1 to Selecting the bearing

No.5 from front Based on the appropriate fitting code given in the table below,
select the bearing to be used.
C (code of bearing to be selected) = A (bearing bore code) + B
(journal outside diameter code)
A B C
Upper bearing C C C
hasoil groove o o o Bearing
Bearing bore Journal diameter
Fitting d d d thickness
code Lower bearing e e e
does not have oil
78.000 to 78.006 73.994 to 1.982 to 1.985
1 (3.0709 to 0 74.000(2.9131 to 1 (0.0780 to
3.0711) 2.9134) 0.0781)
78.006 to 78.012 73.987 to 73.994 1.985 to 1.988
2 (3.0711 to 1 (2.9129 to 2 (0.0781 to
3.0713) 2.9131) 0.0783)
78.012 to 78.018 73.980 to 73.987 1.988 to 1.991
3 (3.0713 to 2 (2.9126 to 3 (0.0783 to
3.0716) 2.9129) 0.0784)
78.018 to 78.024 1.991 to 1.994
4 (3.0716 to 4 (0.0784 to
3.0718) 0.0785)
1.994 to 1.997
5 (0.0785 to
0.0786)
1.997 to 2.000
6 (0.0786 to
0.0787)
U/S bearing
Bearing type Journal diameter Bearing thickness
73.74 to 73.75 2.104 to 2.110
U/S 0.25
(2.9031 to 2.9035) (0.0828 to 0.0831)
73.49 to 73.50 2.229 to 2.235
U/S 0.50
(2.8933 to 2.8937) (0.0878 to 0.0880)
73.24 to 73.25 2.354 to 2.360
U/S 0.75
(2.8835 to 2.8839) (0.0927 to 0.0929)
72.99 to 73.00 2.479 to 2.485
U/S 1.00
(2.8736 to 2.8740) (0.0976 to 0.0978)
2. Check the crankshaft for bend.
Measure the amount of bend per full turn of the crankshaft.
Limit: 0.03 mm (0.0012 in.)
2-39
3. Check the crankshaft for wear.

(1) Measure the dimensions of the crankshaft journal as
shown.
(2.9126 to 2.9134 in.)
(2) Calculate ellipticity and taper.
Limit: Ellipticity:0.02 mm (0.0008 in.)
Taper: 0.02 mm (0.0008 in.)
If the standard is not met or if the limit is exceeded, or if a
serious streak or damage is found, reface the crankshaft
and replace the bearing with a U/S bearing.
<Reference>
Finished outside diameter of the crankshaft
Bearing type
journal mm (in.)
U/S 0.25 73.74 to 73.75 (2.9031 to 2.9035)
U/S 0.50 73.49 to 73.50 (2.8933 to 2.8937)
U/S 0.75 73.24 to 73.25 (2.8835 to 2.8839)
U/S 1.00 72.99 to 73.00 (2.8736 to 2.8740)
(3) Measure the dimensions of the crankshaft pin as shown.

(2.1646 to 2.1654 in.)
(4) Calculate ellipticity and taper.
Limit: Ellipticity:0.02 mm (0.0008 in.)
Taper: 0.02 mm (0.0008 in.)
If the standard is not met or if the limit is exceeded, or if a
serious streak or damage is found, reface the crankshaft
and replace the bearing with a U/S bearing.
<Reference>
Finished outside diameter of the crankshaft
Bearing type
pin mm (in.)
U/S 0.25 54.74 to 54.75 (2.1551 to 2.1555)
U/S 0.50 54.49 to 54.50 (2.1453 to 2.1457)
U/S 0.75 54.24 to 54.25 (2.1354 to 2.1358)
U/S 1.00 53.99 to 54.00 (2.1256 to 2.1260)
[Point 8]
Front mark
Reassembly:
Reassemble the bearing cap.
1. Install the thrust washer with the oil groove facing the
crankshaft side.
2. Install in the same place as before disassembly with reference
to the front mark.
Oil groove
2-40
3. Tighten evenly in several steps in the order as shown.

8 4 2 6 10
7 3 1 5 9
[Point 9]
Reassembly:
Reassemble the connecting rod.
1. Install the snap ring on one side.
2. Warm the piston to about 60 °C (140 °F).
3. Align the front marks on the piston and the connecting rod.
4. Install the piston pin.
5. Reinstall the snap ring.
Front mark
Reassembly:
Install the piston ring.
6. Install the oil ring expander.
7. Install the oil ring side rail using a piston ring tool.
Oil rings may be installed with either side facing upward.
8. Install the piston ring using the piston ring tool.Install the
Punched mark "2T" second ring with the punched mark "2T" facing up.
Second ring Oil ring 9. Position the ring joints as shown.
Front
mark
Oil ring Top ring

expander
2-41
Reassembly:
Install the bearing.
Prevent foreign matter, oil, etc., from adhering to the bearing
Lock groove surface which comes into contact with the connecting rod.
Coat the engine oil on the bearing bore.
Install the upper bearing by matching the connecting rod lock
groove.
Install the lower bearing by matching the bearing cap lock groove.
Oil groove
[Point 10]
Reassembly:
Reassemble the piston in the same cylinder from which it was
disassembled.
Coat the piston and connecting rod sliding parts with engine oil.
Install the piston with the front mark facing the front side.
Do not damage the cylinder inner surface or the crankshaft with the
connecting rod bolt.
[Point 11]
Reassembly:
Reassemble the connecting rod cap.
1. Install the bearing cap with the front mark facing the front side
of the engine.
2. Prevent foreign matter, oil, etc., from adhering to the back
surface of the bearing.
3. Coat the engine oil on the bearing bore.
Front mark 4. Tighten left and right bolts alternately in several steps.
[Point 12]
Reassembly:
Reassemble the rear oil seal.
SST(2) SST (1) 09950-76019-71
(09950-60020)
SST (2) 09950-76020-71
(09950-70010)
SST(1)
2-42
ENGINE TUNE-UP
Pressure 98 N
Straightedge
V BELT DEFLETION INSPECTION AND
ADJUSTMENT
1. Check the V belt deflection.
(1) Make sure that the belt is fitted correctly.
Deflection (2) Press the belt between the water pump and alternator
with a force of about 98 N and check the amount of
deflection.
New belts: 7 to 9 mm (0.27 to 0.35 in.)
Belts in use: 8 to 13 mm (0.31 to 0.51 in.)
Caution:
• Measure the amount of deflection between the specified
pulleys.
• When a new belt is fitted, adjust deflection to the median of
the standard for "new belts".
• When checking a belt that has been used for 5 minutes or
longer, check that the deflection is the median of the
standard for "belts in use".
• When reassembling a belt that has been used for 5 minutes
or longer, adjust the deflection to the median of the
standard for "belts in use".
• Standard tension when SST is used

SST 09216-76001-71
(09216-00020)
New belts: 520 to 760 N
Belts in use: 320 to 560 N
Note:
Fit the belt tension gauge hooks to the belt crests to measure
tension.
Alternator adjusting bolt 2. Adjust the V-belt deflection.

(1) Loosen the alternator adjusting bolt.
(2) Stretch the V-belt using a pry bar with the length of 300 to
400mm (11.81 to 15.75 in.), and tighten the alternator
adjustment bolt.
(3) Recheck the V-belt tension.
Caution:
Tension adjustment using a lever tends to cause variation
from one mechanic to another. It must be followed by
measurement of the deflection.
2-43
Timing gear cover scale VALVE CLEARANCE INSPECTION AND

(c) ADJUSTMENT
1. Inspect the valve clearance.
(1) Set cylinder No.1 to the TDC.
(a) Align the notch on the crank pulley with the scale
mark of the timing gear cover as shown.
(b) Rotate the crank pulley two turns and adjust the
scale in the same manner while observing the valve
behavior.
Notch on crank pulley
Note:
Discriminate the TDC according to the valve motion.
• Cylinder No.1 at compression TDC
When the valves function in the following order:
No.3 EX  No.1 IN  No.4 EX  No.3 IN
• Cylinder No.4 at compression TDC
When the valves function in the following order:
No.2 EX  No.4 IN  No.1 EX  No.2 IN
(2) Measure the valve clearance as shown.

Cylinder No.1 at compression TDC
Standard: IN 0.11 to 0.21 mm
(0.0043 to 0.0083 in.) (when cool)
EX 0.25 to 0.35 mm
(0.0098 to 0.0138 in.) (when cool)
(3) Rotate the crank pulley in the forward direction to set
cylinder No.4 at TDC.
(4) Measure the valve clearance of the remaining valves.
Cylinder No.4 at compression TDC
2. Adjust the valve clearance.

(1) Loosen the lock nut, and turn the adjusting screw for the
adjustment.
StandardI: IN 0.16 mm
(0.0062 in.) (when cool)
EX 0.30 mm
(0.0118 in.) (when cool)
(2) Tighten the lock nut, and inspect the valve clearance
again.
2-44
IDLE SPEED INSPECTION

1. Warm up the engine.
Standard: Coolant temperature 75 to 85 °C
(167 to 185 °F) or more
2. Inspect the idle speed.
Standard idle speed: See repair manual for vehicle
model.
Note:
See the repair manual for the vehicle model for idle speed
measurement.
NO-LOAD MAXIMUM SPEED

MEASUREMENT
(167 to 185 °F) or more
2. Fully depress the accelerator pedal and measure the
maximum speed.
Standard no-load maximum speed:
See repair manual for vehicle model.
Note:
See the repair manual for the vehicle model for no-load
maximum speed measurement.
COMPRESSION INSPECTION
(167 to 185 °F) or more
2. Disconnect the battery negative terminal.
3. Prepare for a compression measurement and crank speed
measurement according to the compression measurement
instructions given in the repair manual for the vehicle model.
Wood 4. Remove the throttle body set nut, and insert a wood piece or
piece, the like between the throttle body and surge tank to maintain a
etc. clearance of 3 to 5 mm (0.12 to 0.20 in.).
Note:
3 to 5 mm
(0.12 to Maintain intake air.
0.20 in.)
5. Connect the battery negative terminal and measure the

compression pressure.
Note:
• Use a fully charged battery to maintain the crank speed of at
least 250 rpm.
• Run the starter to empty the cylinder before measuring the
compression.
(1) Install the compression gauge attachment to the spark
plug hole, and install the compression gauge.
SST 09992-76001-71
(09992-00024)
2-45
(2) Crank the engine with the starter and measure the
compression pressure.
Standard: 1550 kPa
Limit: 1100 kPa
(3) Measure all the four cylinders and check the pressure
difference.
Pressure difference limit between cylinders: 500 kPa
(4) If the compression pressure in any cylinder is below the
limit or the pressure difference between cylinders is
above the limit, add a small amount of engine oil from the
spark plug hole and repeat steps (1) to (3) above.
(a) If the pressure increases after adding the oil, the
piston ring and/or the cylinder wall may be worn or
damaged.
(b) If the pressure remains low after adding the oil, there
may be a valve seizure, poor valve contact or
pressure leakage from the gasket.
(5) Install the spark plug.
T = 15.0 to 21.0 N·m
(6) Install the ignition coil.
T = 8.0 to 10.0 N·m

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book 1 ページ ２０１３年９月２７日 金曜日 午後１２時４１分

SST LIST .......................................................................... 2-2

Illustration Part No. Part Name

09130-36770-71 Cylinder head union socket

09150-10170-71 Transmission bearing replacer

Illustration Part No. Part Name

09370-20270-71 Drive pinion bearing replacer

Removal and installation procedure

DISASSEMBLY, INSPECTION AND REASSEMBLY

Disassembly and reassembly procedure

3. Calculate the oil clearance.

5. Correct the valve seat.

(3) Perform valve lapping.

7. Measure the free length.

3. Calculate the oil clearance.

Engine front [Point 13]

DISASSEMBLY, INSPECTION AND REASSEMBLY

Disassembly and reassembly procedure

2. Measure the outside diameter of the idle gear shaft.

2. Measure the inside diameter of the cylinder block bore.

2. Measure the camshaft bearing inside diameter.

2. Install the camshaft timing gear set bolt.

DISASSEMBLY, INSPECTION AND REASSEMBLY

Disassembly and reassembly procedure

Bearing cap Bearing Crank pin

2. Measure at six points shown at left.

3. Measure the piston clearance.

(2) Calculate the piston clearance from the cylinder inside

6. Measure the oil clearance of the connecting rod bushing.

(2) Measure the outside diameter of the piston pin.

Fitting code B is journal No.1 to Selecting the bearing

3. Check the crankshaft for wear.

(3) Measure the dimensions of the crankshaft pin as shown.

3. Tighten evenly in several steps in the order as shown.

Second ring Oil ring 9. Position the ring joints as shown.

Oil ring Top ring

• Standard tension when SST is used

Alternator adjusting bolt 2. Adjust the V-belt deflection.

Timing gear cover scale VALVE CLEARANCE INSPECTION AND

(2) Measure the valve clearance as shown.

Cylinder No.4 at compression TDC

2. Adjust the valve clearance.

IDLE SPEED INSPECTION

NO-LOAD MAXIMUM SPEED

5. Connect the battery negative terminal and measure the

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book 1 ページ２０１３年９月２７日　金曜日　午後１２時４１分