04en R2 ENGINE Workshop Manual

R2 DIESEL ENGINE WORKSHOP MANUAL
R2 DIESEL ENGINE
WORKSHOP MANUAL
Ford Motor Company

FORD

General Information

General Information
Fundamental procedures 0-2

Symbols 0-2
Notices, cautions, and warnings 0-3
Jack and safety stand positions 0-5
Vehicle lift (2-support type) positions 0-6
Towing 0-7
Identification number locations 0-8
Units 0-8
Abbreviations 0-9
Electrical troubleshooting 0-10
- 0-1 -

General Information

GENERAL INFORMATION
FUNDAMENTAL PROCEDURES
Symbols
There are six primary symbols used to complement illustrations. These symbols indicate
the areas to apply such materials during service.
Symbol Meaning Type
New engine oil, gear oil, etc. as

Apply oil
appropriate
Apply brake fluid Only brake fluid
Apply automatic transmission

Only ATF
fluid (ATF)
Apply grease Appropriate grease
Apply sealant Appropriate sealant
Apply petroleum jelly Appropriate petroleum jelly
- 0-2 -

General Information

NOTICES, CAUTIONS, AND WARNINGS

As you read through the various procedures, you will encounter Notice, Cautions and Warnings.
Each one is there for a specific purpose. Notice give you added information that will assist you in
completing a particular procedure. Cautions prevent you from making an error that could damage
the vehicle. Warnings remind you to be especially careful in specific areas where carelessness can
cause personal injury.
The following items contain general procedures you should always follow when working on a
vehicle:
PROTECTION OF THE VEHICLE

• Always cover fenders, seats, and floor areas
before starting work.
A WORD ABOUT SAFETY

The following precautions must be followed when
jacking up the vehicle:
1. Block the wheels.
2. Use only the specified jacking positions.
3. Support the vehicle with safety stands.
Start the engine only after making certain the engine
compartment is clear of tools and people.
PREPARATION OF TOOLS AND MEASURING EQUIPMENT

• Be sure all necessary tools and measuring
equipment should be available before starting any
work.
SPECLAL SERVICE TOOLS (SST'S)

• Use special service tools when they are required.
- 0-3 -

General Information

REMOVAL OF PARTS
• Begin work only after first learning which parts and
subassemblies must be removed and
disassembled for replacement for repair.
DISASSEMBLY
• If the disassembly procedure is complex, requiring
many parts to be disassembled, all parts should be
disassembled in a way that will not affect their
performance or external appearance. Additionally,
these parts should be identified so that reassembly
can be done easily and efficiently.
INSPECTION OF PARTS
• When removed, each part should be carefully
inspected for malfunction, deformation, damage, or
other problems.
ARRANGEMENT OF PARTS
• All disassembled parts should be carefully
arranged for assembly.
Be separate or identify the parts to be replaced
form those that will be reused.
CLEANING PARTS FOR REUSE

• All parts to be reused should be carefully and
thoroughly cleaned according to the appropriate
method.
- 0-4 -

General Information

REASSEMBLY
Standard values, such as torques and certain adjust-
ments, must be strictly observed in the assembly of all
parts. When removed, the following parts should be
replaced with new ones:
1. Oil seals
2. O-rings
3. Cotter pins
4. Gaskets
5. Lock washers
DEPENDING ON LOCATION : 6. Nylon nuts
1. Sealant should be applied or new gaskets used.

2. Oil should be applied to the moving components of
parts.
3. Specified oil or grease should be applied at the
prescribed locations (such as oil seals) before
assembly.
ADJUSTMENT
• Use appropriate gauges and/or testers when making
adjustments.
RUBBER PARTS AND TUBING

• Prevent gasoline or oil from getting on rubber parts
or tubing.
JACK AND SAFETY STAND POSITIONS

• FRONT END
1. Jack position :
At the center of the rear crossmember
- 0-5 -

General Information

2. Safety stand positions :

On both sides of the body frame
• READ END
1. Jack position :
At the center of the rear crossmember
2. Safety stand positions :

On both sides of the body frame
VEHICLE LIFT (2-SUPPORT TYPE)

POSITIONS
1. Front end
(1) Side sills
2. Rear end
(1) Side sills
- 0-6 -

General Information

TOWING
1. Proper towing equipment is necessary to prevent damage to the vehicle.
Always observe laws and regulations applicable to vehicles in tow. As a general rule, towed
vehicles should be pulled with the driving wheels off the ground. If excessive damage or other
conditions prevent towing the vehicle with the driving wheels off the ground, use wheel dollies.
2. WITH MANUAL TRANSMISSION

If the transmission, rear axle, and steering system are not damaged, the vehicle may be towed
on all four wheels. If any of these components are damaged, use a towing dolly.
3. WITH AUTOMATIC TRANSMISSION

If excessive damage or other conditions prevent towing the vehicle with the driving wheels off
the ground, use a towing dolly. With all wheels on the ground, the vehicle may be towed only
forward. In this case, do not exceed 56km/h (35 mph)or a distance of 56 km (35 miles) or
transmission damage could result.
If towing speed will exceed 56 km/h (35 mph), or if towing distance will exceed 56 km (35 miles),
use one of these methods :
(1) Place the rear wheels on a dolly.
(2) Tow with the rear wheels off the ground.
(3) Disconnect the rear propeller shaft.
If the transmission or rear axle is inoperative, tow the vehicle with its rear wheels off the ground
or disconnect the rear propeller shaft.
CAUTION
• The power assist for the brakes and steering are inoperable while the engine is off.
• Do not use the hook loops under the front or rear of the vehicle for towing. These hook loops
are designed ONLY for transport tie down. If tie down hook loops are used for towing the
front or rear skirt and bumper will be damaged.
- 0-7 -

General Information

IDENTIFICATION NUMBER LOCATIONS
1. Engine model and number
2. Vehicle identification number (VIN)
UNITS
N·m (kg-m, or kg-cm, lb-ft or lb-in) Torque
rpm Revolutions per minute
A Ampere (s)
V Volt (s)
Ω Ohm (s) (resistance)
kPa (kg/cm², psi) Pressure (usually negative)
mmHg (inHg) Pressure (usually negative)
W Watt
liters (US qt, lmp qt) Volume
mm (in) Length
- 0-8 -

General Information

ABBREVIATIONS
ABDC After bottom dead center
A/C Air conditioner
ACC Accessories
ATX Automatic transaxle
ATDC After top dead center
ATF Automatic transaxle fluid
BAC Bypass air control
BBDC Before bottom dead center
BTDC Before top dead center
CPU Central processing unit
DRL Daytime running lights
EC-AT Electronically-controlled automatic transaxle
ECU Engine control unit
EGI Electronic gasoline injection
E/L Electrical load
EX Exhaust
GND Ground
HLA Hydraulic lash adjuster
IGN Ignition
IN Intake
INT Intermittent
ISC Idle speed control
LH Left hand
M Motor
MIL Malfunction indicator lamp
M/S Manual steering
MTX Manual transaxle
OD Overdrive
- 0-9 -

General Information

OFF Switch off
ON Switch on
PCV Positive crankcase ventilation
P/S Power steering
PRC Pressure regulator control
R/W Power window
RH Right hand
SOHC Single overhead camshaft
SST Special service tool
ST Start
SW Swtich
TDC Top dead center
TNS Tail number side
- 0-10 -

General Information

ELECTRICAL TROUBLESHOOTING
Electrical troubleshooting tools
• The test light, as shown in the figure, uses a 12V bulb.
The two lead wires should be connected to probes.
The test light is used for simple voltage checks and for
checking for short circuits.
CAUTION
When checking the control unit, never use a bulb
over 3.4W.
• The jumper wire is used for testing by shorting across

switch terminals and ground connections.
CAUTION
Do not attempt to connect the ohmmeter to any
circuit to which voltage is applied; this may burn or
otherwise damage the ohmmeter.
Electrical troubleshooting tester

1. Voltmeter
The DC voltmeter is used to measure of circuit
voltage. A voltmeter with a range of 15V or more is
used by connecting the positive (+) probe (red lead
wire) to the point where voltage is to be measured and
the negative (-) probe (block lead wire) to a body
ground.
2. Ohmmeter
The ohmmeter is used to measure the resistance
between two points in circuit and also to check for
continuity and diagnosis of short circuits.
CAUTION
Do not attempt to connect the ohmmeter to any
circuit to which voltage is applied; this may burn or
otherwise damage the ohmmeter.
- 0-11 -

General Information

3. Diagnosis Connector
Insert the probe into the service hole when connecting
a jumper wire to the diagnosis connector.
CAUTION
Do not insert the jumper wire probe into the
diagnosis connector terminal, which may damage
the terminal.
Battery Cable
• Insert the probe into the service hole when connecting
a jumper wire to the diagnosis connector.
Before disconnecting connectors or replacing
electrical parts, disconnect the negative battery cable.
Connectors
1. Removal of connector
Never pull on the siring harness when disconnecting
connectors.
Connectors can be removed by pressing or pulling the
lock lever as shown.
2. Locking of connector
When locking connectors, make sure to listen for a
click that will indicate they are securely locked.
- 0-12 -

General Information

3 Inspection
(1) When a tester is used to check for continuity or to
measure voltage, insert the tester probe from the
wire harness side.
(2) Check the terminals of waterproof connectors from

the connector side, as they cannot be accessed
from the wire harness side.
CAUTIONS
• Use fine wire to prevent damage to the terminal.
• Do not damage the terminal when inserting the
tester lead.
Terminals
1. Inspection
(1) Pull lightly on individual wires to check that they are
secured in the terminal.
2. Replacement of terminals
Use the appropriate tools to remove the terminal as
shown.
When installing the terminal, be sure to insert it until it
locks securely.
(1) Female
Insert a thin piece of metal from the terminal side of
the connector, and then, with the terminal locking
tab pressed down, pull the terminal out from the
connector.
(2) Male
Same as the female type.
- 0-13 -

General Information

Sensors, Switches, and Relays

• Handle sensors, switches, and relays carefully. Do not
drop them or strike them against other parts.
Wiring harness
• Two-color wires are indicated by a two-color code
symbol.
The first letter indicates the base color of the wire and
the second the color of the stripe.
CODE COLOR CODE COLOR
B Black O Orange
BR Brwon P Pink
G Green R Red
GY Gray V Violet
L Blue W White
LB Light Blue Y Yellow
LG Light Green - -
- 0-14 -

1. Engine Mechanical System

Engine Mechanical System

General Information 1-3
 Outline of construction 1-3
 Specifications 1-5
 Troubleshooting 1-6
Tune-up procedure 1-8

Inspection and adjustment 1-10
 Checking compression 1-10
 Adjustment of valve clearance 1-11
On-vehicle mentenance 1-12
 Timing belt 1-12
Removal 1-12
Inspection 1-13
Installation 1-14
 Cylinder head 1-16
Removal 1-16
Disassembly 1-17
Inspection 1-17
Assembly 1-17
Installation 1-19
 Valve seals 1-23
Replacement 1-23
Engine and transaxle assembly 1-25
 Removal & installation 1-25
 Engine disassembly 1-27
Disassembly related to engine auxiliary parts 1-27
Disassembly related to timing system 1-28
Disassembly related to Injection pump 1-31
- 1-1 -


Disassembly related to cylinder head 1-32

Disassembly related to lubrication system and flywheel 1-34
Disassembly related to piston and connecting rod 1-35
 Inspection and repair 1-36
Cylinder head 1-36
Cylinder Block 1-40
Connecting rods 1-42
Crankshaft 1-43
 Reassembly engine 1-46
Valves 1-46
Pistons and connecting rods 1-47
Crankshaft assembly 1-48
Rear cover assembly 1-51
Oil pump assembly 1-51
Oil strainer, oil baffle plate and oil pan 1-52
End plate, flywheel and clutch cover installation 1-52
Timing belt pulley installation 1-53
Cylinder head installation 1-54
Oil pressure switch and oil level gauge 1-55
Injection pump 1-56
Injection pipes 1-56
Water pump 1-56
Cooling fan bracket and thermostat assembly 1-57
Injection pump pulley 1-57
Timing belt tensioner and spring 1-58
Timing belt 1-58
Crankshaft pulley 1-59
Exhaust and intake manifold 1-59
Alternator 1-60
Valve clearance adjustment 1-60
Cylinder head cover 1-61
Engine mount 1-61
- 1-2 -


GENERAL INFORMATION
OUTLINE OF CONSTRUCTION
The new magma or R2 diesel engine, by using the latest technological advances, is an excellent
balance of output, fuel consumption, durability and quiet operation.
1. Aluminum alloy cylinder head
2. Direct-drive OHC
3. Timing belt
4. New tightening method for cylinder head bolts
5. Oil baffle plate for vibration reduction
- 1-3 -


Valve mechanism
By employing a direct-direct-drive OHC (overhead camshaft), the push rods, rocker arms,
rocker arm shafts, etc. used in the OHV (overhead valve) engine are not necessary. This has
resulted in reduced size and weight, decreased mechanical loss, and a great improvement of
high rotation efficiency.
Cylinder head bolt

1. The cylinder head bolt are tightend by means of the bolt torque-angle method.
When performing any service procedures related to the cylinder head, special care should be taken.
Refer to the main text for detailed information regarding the tightening method.
- 1-4 -


SPECIFICATIONS
ENGINE MODEL MAGMA or R2
Type 4 (In-line)
Number of cylinders 4
Valve system Direct drive, OHC
Displacement 2184 cc
Bore and stroke mm (in.) 86.0 X 94.0 (3.39 X 3.70)
Compression ratio 22.9 : 1
Compression pressure 30 kg/cm² (427 lb/in²) - 200 rpm
Open BTDC 10°

Intake
Close ABDC 42°
Valve timing
Open BBDC 57°
Exhaust
Close ATDC 11°
Intake 0.25 mm (0.098 in.)

Valve clearance (cold engine)
Exhaust 0.35 mm (0.138 in.)
Idling speed 750~800
Injection order 1-3-4-2
- 1-5 -


TROUBLESHOOTING GUIDE
Problem Possible Cause Action to be taken
Insufficient power Insufficient Improper valve clearance Adjust

compression
Compression leakage from valve Repair
seat (Grind the valve seat)
Seized valve stem Replace
Weak or broken valve spring Replace
Burned cylinder head gasket Replace
Cracked or distorted cylinder head Replace
Sticking, damaged, or worn piston

Replace
ring
Cracked or worn piston Replace
Malfunction of fuel system Refer to EC
Excessive oil Oil working up Worn or sticking piston ring or

Replace
consumption piston ring groove
Worn piston or cylinder Replace or repair
Oil working down Bad valve seal Replace
Worn valve stem or guide Replace
Refer to Lubrication
Oil leakage
system
Difficult starting Malfunction of Burned valve Replace
engine-related
Worn piston, piston ring, or cylinder Replace or repair
components
Burned cylinder head gasket Replace
Malfunction of electrical system Refer to EE
Abnormal Malfunction of Improper valve clearance Adjust

combustion engine related Sticking or burned valve Replace
components
Weak or broken valve spring Replace
Carbon accumulation in
Eliminate the carbon
combustion chamber
- 1-6 -


Poor idling Malfunction of Improper valve clearance Adjust
engine-related Poor valve to valve seat contact Repair or replace
components
Failure of cylinder head gasket Replace
Engine noise Crankshaft or Excessive main bearing oil

Replace or repair
bearing-related clearance
parts
Main bearing seized or
Replace
heat-damaged
Excessive crankshaft end play Replace or repair
Excessive connecting rod bearing

Replace or repair
oil clearance
Connecting rod bearing seized or

Replace
heat-damaged
Piston-related Worn cylinder Replace or repair

parts Worn piston or piston pin Replace
Seized piston Replace
Damaged piston ring Replace
Bent connecting rod Replace
Valves or related Excessive valve clearance Adjust

parts
Broken valve spring Replace
Excessive clearance between

Replace
valve stem and guide
Others Malfunction of water pump bearing Replace
Improper drive-belt tension Adjust
Malfunction of alternator bearing Replace
Exhaust gas leakage Repair
Malfunction of timing belt tensioner Replace
- 1-7 -


TUNE-UP PROCEDURE
Tune the engine according to the procedure described below.
1. Checking battery
(1) Check for corrosion on the terminals, or loose cable connections.
If a problem exists, clean the clamps and tighten firmly.
(2) Check the electrolyte level.
There is sufficient electrolyte if the level is
between the "UPPER LEVEL" and "LOWER
LEVEL" marks.
If the level is too lower, add distilled water up to
the "UPPER LEVEL" mark.
(3) Check the specific gravity.

Measure the specific gravity by using a
hydrometer.
If the specific gravity reading is 1,200 or less,
recharge the battery.
Relation of specific gravity to recharging (at
solution temp. of 20°C [68°F]).
Electrolyte spec. grav. Recharging (%)

1.280 100
1.230 75
1.180 50
1.130 25
1.080 Almost no capacity
2. Checking air cleaner element

(1) Visually check that the element is not excessively
dirty. Clean or replace it if necessary.
NOTICE
When cleaning, first blow from the inside
completely, then blow dust off of the outside of
the air cleaner element.
- 1-8 -


3. Checking engine oil

Check the engine oil level, and for dirtiness, by using the
dipstick.
Add engine oil, or change it if necessary.
4. Checking engine coolant

While the coolant is cold, check whether the coolant level is
near the radiator inlet port, and whether the level in the
reserve tank is between the FULL and LOW marks. Add
coolant if the level is low.
5. Checking fuel filter

Drain the water from the fuel filter.
(1) Loosen the drain plug.
(2) Drain water until the drained fuel is pure.
(3) Securely tighten the drain plug.
(4) Do air-bleeding.
(5) Check the sediment or warning light is off and no fuel

leakage from fuel line.
CAUTION
If the water accumulate in the fuel filter is not drained at
proper times, damages to the major parts such as pump
priming plunger can be caused by water permeation in
the fuel filter.
6. Checking drive belt.

7. Checking valve clearance.
- 1-9 -


INSPECTION AND ADJUSTMENT

CHECKING DRIVE BELT
1. To check the belt tension, apply moderate pressure (10kg,
22lb) midway between the pulleys. Check the deflection, and
adjust it if necessary.
CAUTION
If the drive belt becomes worn, cracked, or frayed, it should
be replaced.
Deflection
Drive belt
New Used
1 Alternator 11~12 mm (0.44~0.47 in.) 12~14 mm (0.47~0.55 in.)
2 Air conditioner compressor 4~5 mm (0.16~0.20 in.) 5~6 mm (0.20~0.24in.)
CHECKING COMPRESSION
1. Warm up the engine thoroughly.
2. Stop the engine.
3. Remove all the fuel injection pipes, nozzles, washers and

corrugate washers.
4. Disconnect the fuel cut valve connector.
CAUTION
If this is not done, fuel will be injected from the injection pump
while cranking.
5. Connect a suitable cap to the fuel return pipe on the injection pump.
6. Install the compression gauge adapter (0K670 101 001) to the injection nozzle hole.
7. Connect a compression gauge to the compression gauge

adapter.
8. Crank the engine.
9. Check whether the gauge reading is above the limit.
Compression pressure kg/cm² (lg/in²)- rpm

Standard 30 (426) - 200
Limit 27 (384) - 200
- 1-10 -


ADJUSTMENT OF VALVE CLEARANCE

1. Remove the cylinder head cover.
2. Set the No.1 cylinder to compression TDC.
NOTICE
Turn the crankshaft so that the intake and exhaust cam
lobes face upward.
3. Measure the valve clearance of No.1 cylinder by using a

thickness gauge.
Standard valve clearances (engine cold condition):
- Intake: 0.20~0.30 mm (0.008~0.012.)

- Exhaust: 0.30~0.40 mm (0.012~0.016 in.)
4. Adjust the valve clearances by following the procedures

below if they are not within the standard.
(1) Face the intake cam straight upward.
(2) Move the tappet so that its notch is at the manifold side,
so that access to the adjusting disc is easy.
(3) Using the tappet holder (0K011 120 007), press the
tappet down to the position where the adjusting disc
becomes accessible.
(4) Using a small screw driver or similar tool, take out the
adjusting disc.
5. Select an appropriate disc depending on the valve clearance

measured. Install it and check the clearance again.
Example (Intake valve):
A. Thickness of original adjusting disc + (measured
clearance - standard clearance) = thickness of new
adjusting disc.
B. 4.00 + (0.30 - 0.25) = 4.05 mm
C. 0.157 + (0.012 - 0.010) = 0.159 in.
NOTICE
The number marked on the disc indicates its thickness.
Example: 3825 means 3.825 mm (0.1056 in.)
Adjusting discs are available in 37 different thickness within the
3.400-3.650 mm (0.134-0.144 in.), 4.350-4.600 mm (0.171-0.181
in.) range, at intervals of 0.050 mm (0.002 in.) and 3.700-4.275
mm (0.146-0.169 in.) range, at intervals of 0.25 mm (0.00984 in.)
6. Measure and adjust cylinder 2 to 4 in the same way.
- 1-11 -


ON-VEHICLE MENTENANCE
TIMING BELT
Removal
1. Disconnect the battery negative cable.
2. Drain engine coolant into a suitable container.
3. Then remove each part in numbered sequence shown in the figure.
CAUTIONS
• Wheels must be blocked.
• Be careful not to let oil or grease get on the removed parts.
• The timing belt, pulleys, and tensioner are not to be washed. If they are dirty, wipe them with rags.
• Replace the timing belt if there is moisture, oil, or grease on it.
• Be careful not to twist, crimp, or sharply bend the timing belt.
• Replace the timing belt after: 100,000 km (60,000 mile)
1. Radiator hose, upper 8. Crankshaft pulley

2. Cooling fan cover, upper 9. Timing belt cover, right
3. Cooling fan and pulley 10. Timing belt cover, left
4. Cooling fan cover, lower (Turn the crankshaft so that poston No. 1
5. Air conditioner drive belt (if equipped) cylinder at the top dead center)
6. Air conditioner drive belt tensioner and bracket 11. Timing belt tensioner and spring
(if equipped) 12. Timing belt
7. Alternator drive belt

- 1-12 -


1. Make sure that the timing marks of camshaft pulley timing

belt pulley and crankshaft pulley match to each timing TIMING MARK
mark Before removing the timing belt and timing belt

TIMING MARK
tensioner, align each timing mark.
Cautions
TIMING MARK
a) After removing the timing belt, don't rotate the
crankshaft pulley and camshaft pulley to prevent
damaging the valves.
b) If reusing the timing belt, draw a direction arrow on the

DIRECTION
timing belt to replace it in the same direction. ARROW
INSPECTION
Timing belt
1. Replace the belt if there is any oil, grease, or moisture on it.
DIRECTION
2. Check for damage, wear, peeling, cracks, or hardening. ARROW
Replace if necessary.
CAUTIONS
a) Never forcefully twist the timing belt, turn it inside out, or
bend it.
b) Be very careful not to allow oil, grease, or moisture to get
on the timing belt.
Timing belt tensioner

1. Check the rotation of the timing belt pulley, and check for
play or abnormal noise. Replace if necessary.
Cautions
a) Do not clean the timing belt tensioner with cleaning fluids.
b) If it is dirty, use a rag to wipe it clean, so as to avoid
scratching it.
Timing belt pulley, camshaft pulley and injection

pump pulley
1. Check the pulley teeth for damage, wear, deformation,
etc. Replace if necessary.
Cautions
• Do not wash the pulley. If it is dirty, use a rag to wipe it
clean, so as to avoid it being contaminates by oil etc.
- 1-13 -


INSTALLATION
1. Check to be sure that the timing marks of camshaft pulley
timing belt pulley and crankshaft pulley match to each TIMING MARK
timing mark.
TIMING MARK
TIMING MARK
2. Install the timing belt tensioner, lock bolt and spring in fully
loosened position, and then push timing belt tensioner left
as far as it will go and the temporarily tighten it.
3. Install the timing belt.

DIRECTION
ARROW
Teeth of timing belt : 164
CAUTION
The timing belt must always be reinstalled in the same
direction of previous rotation for continued durability.
4. Release the timing belt tensioner lock bolt to allow spring

pressure to bear on the timing belt.
5. Turn the crankshaft twice in the direction of rotation
(clockwise) to equalize tension on the timing belt.
CAUTIONS
Do not turn in reverse direction.
6. Tighten the timing belt tensioner lock bolt.
Tensioner lock bolt tightening torque:

31.4~46.1 N·m (3.2~4.7 kg·m, 23~34 lb·ft)
7. Re-check the timing marks on the crankshaft, injection

pump and camshaft pulley, and check the timing belt CHECKING
POINT
deflection when pressed with a force of 10 kg (22 lb)
Standard deflection: (under cold engine condition)
10.8~12.9 mm (0.43~0.51 in.)
- 1-14 -


8. Install the timing belt cover left with rubber seal.

TIMING BELT
9. Install the timing belt cover right with rubber seal. COVER, RIGHT
Timing belt covers tightening torque: TIMING BELT

COVER, LEFT
7.0~9.81 N·m (0.7~1.0 kg·m, 5~7 lb·ft)
10. Install the crankshaft pulley and the timing belt pulley
with the semi circular (wood-ruff) key, then tighten it to
the specified torque.
Crankshaft pulley tightening torque:
HEXAGON
22.5~32.3 N·m (2.3~3.3 kg·m, 17~24 lb·ft) WRENCH
CAUTION
Align the torsional damper to the knock pin on the timing
belt pulley, when installing.
11. Install the following parts.

(1) Air conditioner drive belt, tensioner and bracket.
(2) Cooling fan cover.
(3) Cooling fan pulley and cooling fan.
(4) Radiator hose, upper.
12 Install the air conditioner drive belt and air conditioner

compressor drive belt (if equipped).
13. Adjust each drive belt tension. ALTERNATOR
To check the belt tension, apply moderate pressure (10

kg, 22 lb) midway between the pulleys. Check the
deflection, and adjust it if necessary.
CAUTION
If the drive belt becomes worn, cracked, or frayed, it
should be replaced.
Deflection
Drive belt
New Used
1 Alternator 11~12 mm (0.44~0.47 in.) 12~14 mm (0. 47~0.55 in.)
2 Air conditioner compressor 4~5 mm (0.16~0.20 in.) 5~6 mm (0.20~0.24in.)
14 Fill the radiator with coolant.
- 1-15 -


CYLINDER HEAD
Removal
1. Disconnect the battery negative cable from the battery.
3. Then remove each part in the numbered sequence as shown in the figure.
4. Install in the reverse order of removal.
CAUTION
Wheels must be blocked during maintenance.
1. Timing belt (refer to page

1-12)
2. Intake duct
3. Vacuum hose
4. Alternator
5. Oil cooler hose
6. Exhaust pipe and bracket
7. Injection pipes
8. Fuel return pipe
9. Glow plug connector
10. Thermo unit gauge connector
11. Engine ground harness
12. Oil level gauge and pipe
13. Thermostat assembly
14. Camshaft pulley lock bolt
15. Camshaft pulley
16. Semi circular key
17. Seal plate bolt
18. Breather hose
19. Cylinder head cover
20. Cylinder head bolts
21. Cylinder head
22. Alternator bracket
23. Hot air duct
24. Exhaust manifold
25. Intake manifold

- 1-16 -


Camshaft pulley
1. Hold the camshaft with the wrench (29mm, 1.14 in.)
and loosen the camshaft pulley lock bolt.
CAUTIONS
• Before removing the camshaft pulley, turn the
crankshaft 45 clockwise, to prevent damage to the
valve.

• Don't damage the cylinder head edge with the
wrench.
2. Separate the camshaft pulley from the camshaft, using

the pulley puller (0K710 120 006)
Caution
• Do not hit the camshaft pulley with a hammer.
Disassembly
Refer to page 1-32
Inspection
Refer to page 1-36
Assembly
1. Install the valve seals.
(1) Apply engine oil to the valve guides.
(2) Using the valve seal pusher (0K011 120 002). Install
the valve seals.
CAUTION
• Be sure to use the special tool for installation. If it is not
installed correctly, the oil might work down.

- 1-17 -


2. Install the valves on to the cylinder head.

(1) Install the valve spring seat, lower.
(2) Insert the valve after applying grease (use a
molybdenum disulphide grease) to the valve stem.
(3) Install the valve spring and valve spring seat, upper.
(4) Using the valve spring lifter (0K993 120 001) and
pivot (0K993 120 004), press the valve spring. And
then install the spring retainer securely.
3. Install the tappets and adjusting discs.

(1) Install the tappet to the tappet hole, after applying
engine oil to the tappets.
(2) Install the adjusting discs.
4. Install camshaft as follows:

(1) Apply a coat of engine oil to the camshaft and the
cylinder head journal.
(2) Apply a coat of sealant to the places shown in the
figure.
(3) Set the camshaft and camshaft cap in position, and
loosely tighten the cap nuts.
(4) Insert the oil seal onto the camshaft after applying a
coating of engine oil to the lip.
(5) Insert the seal cap in position after applying a coating
of sealant to the seal cap.
(6) Tighten the camshaft cap nuts to the specified torque.
Camshaft cap tightening torque:

20.6~26.4 N·m (2.1~2.7 kg·m, 15~22 lb·ft)
CAUTION
• Tighten the left and right camshaft cap nuts alternately,
as shown in the figure, two or three times each.

- 1-18 -


5. Install the following parts to the cylinder head

(1) Engine hanger
(2) Glow plugs and connector
(3) Injection nozzles
(4) Intake manifold
(5) Exhaust manifold
(6) Hot air duct
(7) Alternator bracket
INSTALLATION
1. With a rag thoroughly remove all dirt and grease from the
top of the cylinder block.
2. Place the cylinder head gasket in position.
Caution
Use a new cylinder head gasket.
3. Remove any dirt and grease from the bottom surface of
the cylinder head.
4. Place the cylinder head in position.
5. Measure the length of the cylinder head bolt below the

head. If the measured value is within the limit, apply a
coating of engine oil to the threaded part and install.
Length of cylinder head out bolt below head
- Standard length: 112.7~113.3 mm (4.437~4.460 in.)
- Limit: 114.5 mm (4.508 in.)
CAUTION
If the length of the bolt below the head exceeds the limit,
it must be replaced with a new one.
6. Tighten the cylinder head bolts to a tightening torque of 3

kg·m (21.7 lb·ft), tightening them in the order shown in the
figure.
7. Make paint marks on the bolt heads, as shown in the figure.

8. With the paint marks as a reference point, turn the cylinder
head bolts another 90° (90°~105°) in the tightening
direction, turning them in the order shown in the figure.
9. Then tighten them once again 90° (90°~150°) more in the
tightening order shown in the figure.
CAUTION
Be absolutely sure that the bolts are tightened in the
order shown in the figure.
- 1-19 -


10. Install the following parts to the camshaft as shown in the

figure.
(1) Seal plate attaching bolts (2)
(2) Semi circular (woodruff) key
(3) Camshaft pulley
(4) Camshaft pulley lock bolt
Camshaft pulley tightening torque:
55.0~64.7 N·m (5.6~6.6 kg·m, 41~48 lb·ft)
NOTICE
Hold the camshaft with a wrench (29 mm, 1.4 in.), then
tighten the camshaft pulley lock bolt.
11. Align the timing mark of the camshaft pulley with the
timing mark on the seal plate.
12. Return the timing belt pulley so that the timing mark of the
timing belt pulley aligns with the knock pin.
13. Turn the injection pump pulley until timing marks align,
then affix it by using two affixing bolts (35~40 mm,
1.38~1.57 in.).
14. Install the timing belt tensioner and spring in fully

loosened position. Position the tensioner all the way to
the water pump side, and then tighten the lock nut
temporarily.
15. Install the timing belt.
CAUTION
The front timing belt must always be reinstalled in the
same direction of rotation for continued durability.
16. Release the timing belt tensioner lock belt to allow spring
pressure on the belt.
(clockwise) to equalize tension on the belt.
CAUTION
Do not turn in reverse direction.
- 1-20 -


18. Tighten the tensioner lock bolt.

Tensioner lock bolt tightening torque:
31.3~46.1 N·m (3.2~4.7 kg·m, 23~34 lb·ft)
19. Recheck the timing marks on each pulley.
20. Check the timing belt deflection, when pressed with a

force of 10 kg (22 lb).
Standard deflection (under engine condition):
10.8~12.9 mm (0.425~0.508 in.)
CAUTION
If the deflection isn't within specification, repeat the
procedure from 11.
21. Install the timing belt cover, left and timing belt cover,
right.
Timing belt cover tightening torque:
7.0~9.8 N·m (0.7~1.0 kg·m, 5~7 lb·ft)
22. Install the crankshaft pulley and the timing belt pulley with
the semi circular (woodruff) key, then tighten the hexagon
bolts (6 mm) to specified torque.
Crankshaft pulley tightening torque:
22.5~32.3 N·m (2.3~3.3 kg·m, 17~25 lb·ft)
CAUTION
Align the torsional damper to the knock pin on the timing
belt pulley, when installing.
23. Install thermostat parts.

(1) Air conditioner drive belt, tensioner and bracket.
(2) Thermostat assembly
(3) Cooling fan cover
(4) Cooling fan and pulley
(5) Radiator hose, upper
- 1-21 -


(6) Oil level gauge and pipe

(7) Leak pipe
(8) Injection pipes
(9) Engine ground
(10) Thermo unit gauge connector
(11) Glow plug connector
(12) Exhaust pipe

(13) Exhaust pipe bracket
(14) Air intake hose
(15) Alternator
(16) Vacuum pump oil hoses
24. Install the drive belts and adjust deflections. To check the
belt tension, apply moderate pressure (10 kg, 22 lb)
midway between the pulleys. Check the deflection, and
tighten if necessary.
Deflection
Drive belt
New Used
11~12 mm 12~14 mm
1 Alternator
(0.44~0.47 in.) (0. 47~0.55 in.)
2 Air conditioner 4~5 mm 5~6 mm
compressor (0.16~0.20 in.) (0.20~0.24in.)
- 1-22 -


Valve seals
Replacement
1. Remove the cylinder head cover.
2. Referring to the Timing Belt section of ON-VEHICLE
MAINTENANCE, remove the camshaft pulley.
3. Remove the camshaft cap. (The nuts should be gradually
loosened, in the order shown in the figure).
4. Remove the camshaft and oil seal.
5. Remove the valve seals as follows:

(1) Remove the tappets and adjusting discs.
(2) Move the piston of the valve seal to be replaced to
approximately top dead center.
(3) As shown in the figure, remove the spring retainers
and the valve spring by using the valve spring
compressor and pivot.
Caution
Plug the oil return hole with a rag in order to prevent the
spring retainers from falling into the oil pan.
(4) After removing the spring seat lower, use the valve
seal remover and remove by working it to the left and
right.
6. Install the valve seal as follows:

(1) Apply a coat of engine oil to the inside surface of the
new valve seal.
(2) Install the valve seal by using the valve seal pusher.
(3) Install the spring seats, valve springs and spring
retainers by using the valve spring compressor and
pivot. After removing the spring seat lower, use the
valve seal remover and remove by working it to the left
and right.
7. Move the No.1 piston to the top dead center, and then
rotate the crankshaft approximately 45°.
Caution
If not done, the valves may be damaged by the pistons
when tightening the camshaft cap nuts.
8. Install the tappets and adjusting discs after first applying a
coating of engine oil.

- 1-23 -


9. Install the camshaft as follows:

(1) Apply a coat of engine oil to the camshaft and the
journal.
(2) Apply a coat of sealant to the seal cap, and then install
it.
(3) Set the camshaft and camshaft cap in position, and
loosely tighten the cap nuts.
NOTICE
Set the camshaft so that the key groove faces directly
upward.
(4) Insert the oil seal after first applying a coating of
engine oil to the lip.
(5) Tighten the camshaft cap nuts to the specified torque.

19.6~26.4 N·m (2.0~2.7 kg·m, 15~20 lb·ft)
CAUTION
Tighten the left and right camshaft cap nuts alternately,
as shown in the figure, two or three times each.
10.Referring to the Timing Belt section of ON-VEHICLE

MAINTENANCE, install the camshaft pulley, and the
timing belt.
11.Make the adjustment of the valve clearances, and then
install the cylinder head cover.

- 1-24 -


ENGINE AND TRANSAXLE ASSEMBLY

REMOVAL & INSTALLATION
1. Disconnect the battery negative cable from the battery.
3. Then remove each part in the numbered sequence shown in the figure.
4. Installation is in reverse order of removal.
COMPONENTS
1. Alternator 9. Radiator hose, lower 15. Starter motor

2. Heater hose 10. Air conditioner drive belt 16. Fuel inlet hose
3. Radiator sub tank (if equipped) 17. Fuel return hose
4. Radiator hose, upper 11. Air conditioner compressor 18. Battery ground wire
5. Cooling fan cover, upper (if equipped) 19. Starter motor
6. Cooling fan 12. Engine ground harness 20. Engine mount
7. Cooling fan 13. Engine harness connectors
8. Cooling fan drive belt 14.Accelerator cable
- 1-25 -


Cooling fan assembly

1. After removing the cooling fan V-belt, loosen the cooling
fan attaching nuts by using a suitable wrench and screw
driver as shown in the figure.
Accelerator cable
1. After install the cable to the injection pump, adjust the
play to specified amount.
Standard accelerator cable play:

1~3 mm (0.04~0.12 in.)
- 1-26 -


ENGINE DISASSEMBLY
DISASSEMBLY
1. Each part when removed should be carefully inspected, for deformation, damage and other
problems.
2. All disassembled parts should be carefully arranged for reassembly. Be sure the separate or
otherwise identify the parts to be replaced from those that will be reused.
3. If the disassembly procedure is complex, requiring many parts are to be disassembled, all parts
should be disassembled in a way that will not affect their performance or external appearance so
that correct reassembly can be performed efficiently.
4. Remove each part in the numbered sequence shown in the figure. Important points on the
disassembly are shown after the structural view.
Disassembly related to engine auxiliary parts
1. Engine mount, left and right

2. Alternator and drive belt
3. Alternator bracket
4. Oil cooler and oil filter assembly
5. Hot air duct
6. Exhaust manifold and gasket
7. Intake manifold and gasket
Engine stand and engine hanger

1. After removing the engine mount (left and right) install
the engine onto the engine hanger (0K710 101 002) 0K130 990 007
attached to the engine stand (0K130 990 007).
0K710 101 002
- 1-27 -


TIMING SYSTEM
COMPONENTS AND COMPONENTS LOCATION
1. Torsional damper 8. Injection pump pulley

2. Crankshaft pulley 2. Camshaft pulley
3.Timing belt cover, right 10. Timing belt pulley
4.Timing belt cover, left 11. Thermostat assembly with pipe
5. Cylinder head cover 12. Cooling fan bracket
6.Timing belt tensioner and spring 13. Seal plate
7.Timing belt 14. Water pump with alternator strap

- 1-28 -


Timing belt
1. Draw a direction arrow in direction of engine revolution
on the timing belt, if the timing belt is to be reused.
2. Loosen the timing belt tensioner lock bolt, push it left as

far as it will go, then temporarily tighten the timing
tensioner lock bolt.
3. Turn the crankshaft about 45 from the timing mark

which is marked on the oil pump housing.
NOTICE
This prevents the pistons and valves from contacting
one another.
Injection pump pulley

1. Put two bolts of M8 x 1.25 x 35~40 mm size into the
arms of the injection pump pulley and affix them in the
thread hole of the injection pump bracket.
NOTICE
This is to prevent the injection pulley from turning while
loosening the injection pulley lock bolt.
2. Loosen the injection pump pulley lock bolt.
3. Using the pulley puller (0K710 120 006), Separate the

injection pump pulley from the injection pump shaft.
0K710 120 006

- 1-29 -


Camshaft pulley
1. Hold the camshaft with a wrench (29 mm, 1.1 in.) and
loosen the camshaft pulley lock bolt.
CAUTIONS
• Don't damage the edge of the cylinder head with
the wrench.
• If damaged, engine oil may leak.
2. Separate the camshaft pulley from the camshaft by

referring the procedure of the injection pump pulley
described above.
Timing belt pulley

Remove the timing belt pulley.
CAUTION 0K590 111 001
Set the ring gear brake (0K590 111 001) securely,

before loosening the lock bolt.
- 1-30 -


Disassembly related to Injection pump
1. injection pipes 3. Oil gauge

2. Injection pump & bracket 4. Pressure switch
Removal and installation

1. Remove or disconnect the following parts.
(1) Battery negative cable
(2) Accelerator control cable
(3) Cold start control cable.
(4) Fuel cut valve harness connector
(5) Injection pipes
(6) Fuel hoses and vacuum hose.
NOTICE：
As to the details of injection pump removal and
installation, refer to page 4-11.
- 1-31 -


Disassembly related to cylinder head

1.Cylinder head bolts 9. Spring retainers
2. Cylinder head assembly and gasket 10. Spring
3. Injection nozzles and leak pipe 11. Valve spring
4. Glow plug connector and glow plug 12. Valve
5. Camshaft caps 13. Spring seat, low
6. Camshaft 14. Spring seat
7. Camshaft oil seal and seal cap 15. Valve guide and clip
8.Tappet and adjusting disc 16. Combustion chamber insert and ball

Cylinder head bolt

1. Loosen the cylinder head bolts in the numbered order
shown in the figure. Loosen a little at a time, in order.
2. Remove the cylinder head by tapping the cylinder head
with a plastic hammer.
- 1-32 -


Camshaft cap
1. Loosen the camshaft cap nuts in the numbered order
shown in the figure. Loosen a little at a time, in order.
Adjusting disc and tappet

1. Remove the adjusting discs and tappets with a set.
CAUTION
• All adjusting discs and tappets should be disassembled
in a way so that correct reassembly can be performed
efficiently.
Valve spring
1. Remove the valves, spring seats and spring retainers
from the cylinder head by using the valve spring lifter
(0K993 120 001) and pivot (0K993 120 004).
NOTICES
• Disassemble the valve guide after completion of
checking and corrections.
• The procedure is described on page 10C-39.
Valve seal
1. After removing the spring seats (lower), remove the valve
seals by using the valve seal remover (0K993 120 006) to
grasp and work them out.
NOTICE
• The valve seal remover (0K993 120 006) cannot grasp
the valve seals unless the spring seats (lower) have
been removed.
Combustion chamber insert

1. Remove the combustion chamber inserts from the bottom
surface of the cylinder head by using a suitable mandrel.
- 1-33 -


Disassembly related to lubrication system and flywheel

COMPONENTS
1. Clutch cover 6. Oil strainer and gasket

2. Clutch disc 7. Oil battle plate
3. Flywheel 8. Rear cover assembly and gasket
4. End plate 9. Oil pump assembly
5. Oil pan
DISASSEMBLY
1. Connect the ring gear brake (0K590 111 001) to the
flywheel securely. Remove the clutch cover, clutch disc
and flywheel.

- 1-34 -


Disassembly related to piston and connecting rod

COMPONENTS
1. Connecting rod bearing caps 7. Main bearing caps, main bearings, and trust bearings
2. Connecting rod bearings 8. Crankshaft
3. Connecting rods and pistons 9. Main bearing and trust bearings
4. Pistons rings 10. Pilot bearings
5. Snap rings 11. Oil jets
6. Pistons pins 12. Cylinder block

DISASSEMBLY
Pilot bearing
1. Using the needle bearing puller (0K410 111 012), remove
the pilot bearing from the crankshaft end.

- 1-35 -


Inspection and repair

Cylinder head
1. Inspection and repair of cylinder head.
(1) Inspect for water leakage, fuel leakage, damage, and
cracks. If a problem is found, replace the part.
(2) Measure cylinder head for distortion in the six
directions shown in the figure.
Distortion limit: 0.10 mm (0.004 in.)
(3) If cylinder head distortion exceeds the limit, replace

the cylinder head.
CAUTIONS
• Do not attempt to repair a cylinder head by milling or
grinding.
• Handle the cylinder head carefully, taking special care
not to damage its lower surface.
(4) Measure the manifold contact surface distortion.

If the distortion exceeds the limit, grind the surface,
or replace the cylinder head.
Distortion limit: 0.20 mm (0.008 in.) max.
(5) Measure the oil clearance of the camshaft.

A. Remove the tappet and adjusting disc from the
cylinder head, and separate them by cylinder.
B. Clean away oil or dirt from the camshaft or cylinder
head journal.
C. Set a platinum gauge on the camshaft journal (in
the axial direction of the journal).
D. Set the camshaft cap, and tighten to the specified
torque.
19.6~26.4 N·m (2.0~2.7 kg·m, 15~20 lb·ft)
CAUTIONS
• When installing the camshaft cap, note the correct
order and arrow marks.
• When tightening the camshaft cap nut, do so evenly
and in the order shown in the engine assembly
section.

- 1-36 -


E. Remove the camshaft cap and measure the oil

clearance.
- Standard oil clearance: 0.025~0.066 mm
(0.0098~0.0260 in.)
- Limit: 0.1 mm (0.0039 in.)
F. If the oil clearance exceeds the limit, replace the
cylinder head or camshaft with a new one.
(6) Measure the end play of the camshaft.

If the end play exceeds the limit, replace the
camshaft or the cylinder head.
- Standard camshaft end play: 0.02~0.15 mm

(0.00079~0.00591 in.)
- Limit: 0.2 mm (0.0079 in.)
(7) Measure the amount that the combustion chamber

insert has receded.
A. Clean the lower side so that the surface of the
combustion chamber insert won't be scarred.
B. Measure by using a dial gauge.
Limits:
- Receded amount: 0.04 mm (0.0016 in.)
- Projection amount: 0.05 mm (0.0020 in.)
C. If either limit is exceeded, replace the insert or the
cylinder head.
2. Checking and repair of valve seats.

(1) Use a thickness gauge, as shown in the figure, to
measure the receded amount from the cylinder head
surface.
If the receded amount is 1.55~2.55 mm (0.061~0.100
in.), use an equivalent washer at the valve spring seat.
If the receded amount is 2.55 mm (0.100 in.) or more,
replace the cylinder head.
Standard amount of valve recession:
- Intake & exhaust: 0.75~1.05 mm (0.030~0.041 in.)
(2) Check the surface which contacts the valve face for
roughness or damage. If necessary, use a valve seat
cutter or valve seat grinder to repair to the specified
shape.
NOTICES
• To check the contact width, apply a thin coating of red
lead to the valve seat, and press the valve against the
valve seat. Be sure not to turn the valve when doing so.

- 1-37 -


• When grinding the valve seat, use a 15°, 45° or 60°
valve seat cutter or valve seat grinder to grind away
the roughness and/or scars (to the minimum limit) of
the seat surface, always checking the contact which
and contact position while grinding.
Standard valve seat contact width:
1.7~2.3 mm (0.067~0.09 in.)
(3) Seat the valve.

To seat the valve, apply a thin coating of engine oil
mixed with a small amount of compound to the seat
surface, and then lightly tap while turning the valve.
CAUTIONS
• When seating the valve, be careful not to let
compound adhere to the valve stem.
• The valve contact position in relation to the valve seat
must be at the center of the circumference, and the
contact width must be the standard value.
• Check to be sure that the amount of valve recession
is within the specification.
3. Inspection and repair of valves.

(1) Inspect each valve and replace any that show valve
stem wear, damage, bending, or dents.
(2) Inspect each valve for roughness or damage on its

faces. If the problem is slight, repair the valve with
valve refacer.
Standard valve stem diameter:
- Intake: 7.970~7.985 mm (0.3138~0.3144 in.)
- Exhaust: 7.965~7.980 mm (0.3136~0.3142 in.)
4. Inspection and repair of valve guides.

(1) Measure the difference between the inner diameter of
each valve guide and the diameter of the
corresponding stem. Replace the valve guide if the
gap exceeds the limit.
Gap limit: 0.10 mm (0.004 in.)
- 1-38 -


5. Replace of valve guide.

(1) Removal
Tap the valve guide to the side opposite the
combustion chamber using the valve guide remover
(0K710 120 011).
(2) Installation
Fit the clip onto the valve guide. Use the valve guide
installer to tap the valve guide in from the side
opposite the combustion chamber until the clip barely
contacts the cylinder head.
Cautions
• When the valve guide is replaced, check the gap
between the valve and valve guide once again.
• The valve seal should be installed after inspection
and repair of the valve seat.
• Don't misassemble the valve guides because intake
and exhaust valve guides have a different seat.
Intake valve guide ...... longer
Exhaust valve guide ... shorter
6. Inspection of valve spring

(1) Inspect each valve spring for cracks or other damage.
Replace it if necessary.
(2) Check each spring for free length and angle limit.
Replace it if necessary.
- Free length limit: 44.8 mm (1.764 in.)

- Angle limit: 1.58 mm (0.062 in.)
7. Checking the tappet and adjusting disc.

(1) Measure the outer diameter of the tappet; replace it if
the limit is exceeded.
(2) Measure the inner diameter of the tappet hole in the
cylinder head, calculate the difference (clearance)
between it and the outer diameter of the tappet; if this
clearance is the limit value or more, replace the
tappet or the cylinder head.
- 1-39 -


7. (3) Measure the adjust disc and tappet diameter.
- Standard tappet outer diameter:

34.96~34.97 mm (1.3763~1.3771 in.)
- Standard tappet hole:
34.99~35.01 mm (1.3776~1.3787 in.)
- Standard clearance:
0.02~0.06 mm (0.0008~0.0024 in.)
- Clearance limit: 0.10 mm (0.0040 in.)
Camshaft
1. Check the camshaft for wear or damage. Replace if
necessary.
Standard cam height:
- Intake: 44.85 mm (1.766 in.)
- Exhaust: 45.30 mm (1.783 in.)
Cam height limit:
- Intake: 44.45 mm (1.750 in.)
- Exhaust: 44.90 mm (1.768 in.)
2 Measure wear of the journal at the four places shown in

the figure in directions A and B, front and rear. Replace
the camshaft if necessary.
- Journal elliptical limit: 0.05 mm (0.002 in.)
- Standard journal diameters: 31.96~31.98 mm
(1.258~1.259 in.)
- Journal diameter limit: 31.86 mm (1.254 in.)
3. Check the camshaft deflection.
Camshaft deflection limit: 0.10 mm (0.0040 in.)
NOTICE
Install the front and rear journals on a V-block to make
the measurement.
Cylinder Block
1. Cylinder block inspection and repair
(1) Check each cylinder for damage and cracks. Replace if
necessary.
(2) Measure the distortion (degree of flatness) of the top
surface of the cylinder block in the six directions shown
in the figure.
Distortion limit : 0.10 mm (0.0040 in)

- 1-40 -


(3) If the distortion exceeds the limit, replace the cylinder Straight edge
block.
CAUTION
Don’t grind the surface of the cylinder block. If grinded,
the valves will hit the pistons.
Feel gauge
(4) Check the cylinder wall for scoring or signs of seizure. If a

problem exists, reboring or replacement is necessary.
(5) If the upper part of the cylinder wall shows uneven
wear, use a ridge reamer to repair.
(6) Measure the cylinder diameter at the six place shown
in the figure. Check the amount of wear.
The amount of wear is the difference between the
maximum and minimum diameters.
If the amount of wear exceeds the limit, the cylinder
must be re-bored.
- Standard cylinder bore : 86.00 mm (3.386 in.)
- Cylinder bore wear limit : 86.17 mm (3.392 in.)
- Difference between cylinder bores : 0.022 mm
(0.0009 in.)
CAUTION
The boring size should be based on the size of an
oversize piston.
Over-size pistons :
- 0.10 mm (0.0040 in)
- 0.50 mm (0.020 in.)
Pistons and piston rings

1. Inspect the piston outer circumferences of all pistons for
seizure or scoring. Replace if necessary.
2. Measure the outer diameter of each piston, and be sure
the clearance between the piston and cylinder is correct.
- Piston standard outer diameter: 85.942~85.968 mm
(3.3835~3.3846 in.)
- Piston and cylinder clearance limit: 0.15 mm (0.006 in.)
CAUTIONS
• Measure the piston outer diameter in the thrust direction, 19 mm (0.75 in) above the bottom of
piston.
• If the piston is replaced, replace the piston ring also.
Oversize piston rings : 0.10 mm (0.0040 in.), 0.50 mm (0.020 in.)

- 1-41 -


3. Inspect the piston rings for damage, abnormal wear, or

breakage. Replace if necessary.
4. Insert the piston ring into the cylinder by hand, and push it
in by using the piston.
5. Measure the ring opening clearance.
Opening clearance limit : 1.0 mm (0.039 in)
6. Measure the clearance of the piston and ring groove.
Clearance limit : 0.2 mm (0.008 in.)

Top ring : 0.2 mm (0.008 in.)
2nd ring : 0.15 mm (0.006 in.)
CAUTION
Measure the clearance around the entire
circumference of the ring groove.
Connecting rods
1. Check each connecting rod for bending or torsion.
- Connecting rod bending limit: 0.16 mm (0.006 in) per
100 mm (3.94 in)
- Connecting rod torsion limit: 0.16 mm (0.006 in) per

100 mm (3.94 in)
2. Connecting rod bushing inspection and repair.

(1) Measure the clearance between the outer diameter of
the piston pin and the inner diameter of the bushing.
If the clearance exceeds the limit, replace the
connecting rod bushing.
- Standard connecting rod bushing inner diameter :
25.01~25.03 mm (0.9846~0.9854 in.)
- Clearance limit : 0.05 mm (0.002 in.)

- 1-42 -


Crankshaft
1. Check around the journals and pins for damage, scoring,
and oil hole clogging.
2. Check the crankshaft defection and each diameter.
Replace if necessary.
Deflection limit : 0.05 mm (0.002 in.)
Standard journal diameters

- Main journal diameter: 59.97~59.96 mm
(2.360~2.361 in.)
- Crankshaft pin diameter : 50.94~50.955 mm
(2.0055~2.0061 in.)
- Rear housing oil seal sliding surface :
89.95~90.00 mm (3.541~3.543 in.)
Journal wear limit : 0.05 mm (0.002 in.)

Deflection limit : 0.05 mm (0.002 in.)
If the wear exceeds the limit, replace or grind the

crankshaft to agree with the undersize bearing.
- Undersize bearings :
0.25 mm (0.010 in.), 0.50 mm (0.020 in.), 0.75 mm
(0.0295 in.)
CAUTION
When grinding the journal or pin, pay attention to each
Fillet R dimension.
Main and connecting rod bearings

1. Check the main and connecting rod bearings
(1) Check the bearing inside surfaces for streaking,
flaking, pin holes, etc.; replace all bearings as a set if
there is a problem.
Timing belt
If there are problems, as shown in the figures, check the
following points and replace the timing belt if necessary.
1. Premature severance
(1) Check for proper installation.
(2) Check timing belt cover gaskets for damage and
installation.

- 1-43 -


2. If the belt teeth are cracked or damaged, replace the

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

replace the timing belt.
4. If there is wear or damage on only one side of the belt,

replace the timing belt.
5. If there is noticeable wear on the belt teeth, replace the

timing belt.
CAUTIONS
• Never forcefully twist the timing belt. Don’t turn it
inside out or bend it.
• Be careful not to allow oil, grease, or moisture on
the belt.

- 1-44 -


Timing belt tensioner

1. Check the rotation of the pulley, and check for play or
abnormal noise. Replace if necessary.
CAUTIONS
• Do not clean the tensioner with cleaning fluids.
• If it is dirty, use a rag to wipe it clean, so as to avoid
scratching it.
Timing belt pulley, camshaft pulley and

injection pump pulley
1. Inspect the each pulley teeth for wear, deformation or
other damage.
2. Replace the pulley in necessary.
CAUTION
Do not clean the pulley. If it is dirty, use a rag to wipe it
clean, so as to avoid it being contaminated by oil, etc.
Timing belt covers (left, right)

1. Inspect each timing belt cover for deformation or
cracks. Replace if necessary.
2. Inspect the gasket for deformation, cracks, or
hardening. Replace if necessary.

- 1-45 -


REASSEMBLY ENGINE
1. Be sure all parts are clean before reassembly.
2. Apply new engine oil to all sliding and turning parts.
3. Do not reuse gaskets or oil seals.
4. During reassembly, inspect all critical clearances, endplays, oil clearances and bends.
5. Tighten all bolts of critical parts to the specified torques.
6. Replace plain bearings if they are peeling, burned, or otherwise damaged.
Valves
1. Install the valve seals.
(1) Apply engine oil to the valve guides.
(2) Using the valve seal pusher (0K011 120 002), install
the valve seals.
CAUTION
Be sure to use the special tool for installation. If it is not
installed correctly, the oil might work down.
2. Install the valves on to the cylinder head.

(1) Install the spring seat, lower.
(2) Insert the valve after applying the molybdenum
disulphide grease to the valve stem.
(3) Install the valve spring the spring sea, upper.
(4) Using the valve spring lifter (0K993 120 001) and
pivot (0K993 120 004), press the valve spring. And
then install the spring retainer securely.
3. Install the tappets and adjusting discs.

(1) Install the tappet in the tappet hole, after applying
engine oil to the tappets.
(2) Install the adjusting discs.

- 1-46 -


Piston and connecting rod

1. Assemble the piston and connecting rod.
(1) Apply a coat of engine oil to the small end of the
connecting rod and all around the piston.
(2) Insert a snap ring into one of the piston pin holes in
the piston.
(3) Connect the piston and connecting rod by the piston
pin, and lock the snap ring so it won’t come out,
(When doing so, the piston should be heated to 50 ~
75°C)
2. Assembly of the piston rings

(1) Assemble the piston ring to the piston by using a piston
ring inserting tool (commercially available).
The order of assembly is : oil ring expander, oil ring,
second ring, top ring.
(2) Align the piston ring matching places, as shown in the
figure.
CAUTIONS
• Apply a liberal coat of engine oil during installation.
• The rings must be mounted so the Indicator mark face
upward.
• When assemble the top ring & oil ring for reuse. Do not
change the upward and downward of each ring.
3. Install the piston and connecting rod

(1) Fit the connecting rod bearing to the connecting rod,
and apply a coating of engine oil.
(2) After cleaning the inner surface of the cylinder, apply a
(3) Insert each piston and connecting rod into the cylinder
block using a piston insertion tool (commercially
available).
CAUTIONS
• The pistons must be inserted so that the “F” marks
face the front of the cylinder block.
• Apply a liberal coating of engine oil to the cylinder
walls, piston circumference, and rings.

- 1-47 -


Crankshaft assembly
1. Install the oil jets to the cylinder block.
- Oil jet tightening torque :
11.7 ~ 17.6 N·m (1.2 ~ 1.8 kg·m, 9 ~ 13 lb·ft)
2. Install the crankshaft.
(1) Install the main bearings.
CAUTIONS
• No oil, dirt, etc. should be on the back surface of the
bearings.
• Because width of the center main bearings are wider
than those of the others, there isn’t interchangeability
between the center main bearings and others.
(2) Check the oil clearance of the crankshaft and main

bearings with a plastic-gauge.
A. Remove any foreign material from the journal or
bearing.
B. Position the Plastic-gauge on top of the journal (in the
journal axial direction).
C. Set the main bearing cap in position, and tighten it to
the specified torque, and in the order shown in the
figure.
- Main bearing cap tightening torque :
82.4 ~ 88.2 N·m (8.4 ~ 9.0 kg·m, 61 ~ 65 lb·ft)
D. Remove the main bearing cap, and measure the oil

clearance.
- Standard oil clearance : 0.031 ~ 0.050 mm
(0.0012 ~ 0.0020 in)
- Oil clearance limit : 0.08 mm (0.0031 in)
E. If the oil clearance exceeds the limit, replace the main
bearings with new ones. And measure the oil
clearance again.
F. In case the oil clearance exceeds the limit even if the

main bearings are replaced, repair the crankshaft by
grinding and use undersize bearings.
CAUTIONS
• Position the Plastic-gauge horizontally on the
crankshaft, away from the oil hole.
• Do not rotate the crankshaft when measuring the oil
clearance.
• Install the main bearing cap according to the cap No.
and mark.

- 1-48 -


(3) After checking and correcting the oil clearance, apply

a coating of engine oil to the main bearing and main
journal, and then install the crankshaft.
(4) Apply a coat of engine oil to the thrust bearing, and
install to the center park of the main journal.
CAUTION
Install the thrust bearing so that the inner surface of the
oil groove faces toward the cylinder block side.
(5) With the main bearing cap in the set condition,

manually push the crankshaft toward the front, and
then, with it pulled toward the rear, tighten the bolt to
Main bearing cap tightening torque :
82.4~88.2 N·m (8.4~9.0 kg·m, 61~64 lb·ft)
(6) Measure the end play of the crankshaft, and confirm

that it is within the standard range. At this time, check
to be sure that the crankshaft can be lightly turned.
- Standard crankshaft end play: 0.04~0.28 mm
(0.0016~0.0111 in.)
- End play limit : 0.3 mm (0.0118 in.)
(7) If the end play is not within the standard range, select
another thrust bearing.
- Undersize thrust bearing width:
2.18 ~ 2.23 mm (0.0858 ~ 0.0878 in.)
- Undersize thrust bearing width:
2.18 ~ 2.23 mm (0.0858 ~ 0.0878 in.)
CAUTION
First replace the rear thrust bearings, if still not within
limit, replace the front thrust bearings also.
3. Use a piece of pipe to tap the pilot bearing onto the

crankshaft.
(1) Fit the connecting rod bearing to the connecting rod,
and apply a coating of engine oil.
(2) After cleaning the inner surface of the cylinder, apply a
(3) Insert each piston and connecting rod into the cylinder
block using a piston insertion tool (commercially
available).
- 1-49 -


CAUTIONS
• Apply a coating of engine oil to the outer
circumference of the Pilot bearing and the crankshaft.
• Set a piece of pipe against the outer race of the
bearing, and tap evenly.
• After installation, apply grease to the bearing.
4. Install each connecting rod cap as follows :

(1) Measure and adjust the connecting rod bearing and
crankshaft pin journal oil clearance by adjust the
crankshaft and main bearing oil clearance.
Connecting rod cap tightening torque :
68.6~73.5 N·m (7.0~7.5 kg·m, 51~54 lb·ft)
- Standard oil clearance:

0.03~0.06 mm (0.0012~0.0024 in.)
- Oil clearance limit: 0.08 mm (0.0031 in)
- Undersize connecting rod bearings:
0.25 mm (0.010 in.), 0.50 mm (0.020 in.), and
0.75 mm (0.030 in.)
(2) Check the end play of the connecting rod.

- Standard connecting rod end play: 0.11~0.26 mm
(0.0043~0.0102 in.)
- End play limit : 0.35 mm (0.014 in.)
CAUTION
• Measure the connecting rod end play before in stalling
the connecting rod cap.
(3) Install the connecting rod bearing cap, and tighten to

When doing so, apply a coating of engine oil to the
bolt threaded parts, nuts and bearing surfaces.
Connecting rod bearing cap tightening torque :
68.6~73.5 N·m (7.0~7.5 kg·m, 51~54 lb·ft)
CAUTIONS
• When installing the connecting rod cap, do so after
aligning the cap and connecting rod matching marks.
• Before installation, be absolutely sure to apply a
coating of engine oil to the bearing.

- 1-50 -


Rear cover assembly

1. Apply engine oil to the rear cover and the oil seal.
CAUTION
• Remember that when the engine oil is applied to the
cover and seal, it must also be applied to the oil seal lip.
2. Press the oil seal into the rear cover.
3. Install the rear cover assembly through the gasket.
Rear cover assembly tightening torque :

7.0 ~ 9.8 N·m (0.7 ~ 1.0 kg·m, 5 ~ 7 lb·ft)
Oil pump assembly

1. Install an O-ring applied with grease (lithium base, NLGI
No. 2) onto the oil pump assembly.
2. Install the oil pump assembly after applying sealant.

Oil pump assembly tightening torque
M8 (Smaller) bolts : 1.6 ~ 2.3 kg·m (12 ~ 17 lb·ft)
M10 (Bigger) bolts : 3.2 ~ 4.7 kg·m (23 ~ 34 lb·ft)
CAUTIONS
• Do not let sealant get into the oil hole.
• Apply engine oil to oil seal lip.
• Before applying the sealant, use a rag to thoroughly
clean away any dirt or grease from the contact
surfaces of the cylinder block and oil pump assembly.
• Apply the sealant continuously without any interruption
around the bead as shown in the figure.
• After installation, clean away any sealant which oozes
out.

- 1-51 -


Oil strainer, oil baffle plate and oil pan

1. Cut away the part of the gasket which projects out from the
rear cover assembly to the oil pan.
CAUTION
Do not scratch the rear cover assembly.
2. Before assembly
This method must be used to install the oil pan. Apply
sealant to the oil pan and oil baffle plate. It should be put
on continuously (thickness 2 ~ 4 mm, 0.08 ~ 0.16 in),
rimming the surface inside the bolt holes, and the end
should overlap.
CAUTION
Before application, remove with a rag any dirt or grease
from the contact surfaces. After the sealant is applied,
the pan and oil baffle plate must be secured within 30
minutes.
3. Install the oil baffle plate on cylinder block.

4. Install the oil strainer on the pump body and cylinder block
and tighten it to the specified torque.
Oil strainer tightening torque :
7.0 ~ 9.8 N·m (0.7 ~ 1.0 kg·m, 5 ~ 7 lb·ft)
5. Install oil pan on the cylinder block, tightening to the

specified torque.
Oil pan tightening torque :
7.0 ~ 9.8 N·m (0.7 ~ 1.0 kg·m, 5 ~ 7 lb·ft)
End plate, flywheel and clutch cover

installation
1. Install the end plate.
End plate tightening torque :

15.6 ~ 22.5 N·m (1.6 ~ 2.3 kg·m, 12 ~ 17 lb·ft)

- 1-52 -


2. Install the flywheel assembly, using the ring rear brake

(0K590 111 001).
Tightening torque :
176 ~ 186 N·m (18 ~ 19 kg·m, 130 ~ 137 lb·ft)
CAUTIONS
• Sealant must be applied to the lock bolt to prevent oil
leakage from the lock bolts.
• After installation do not remove the ring gear brake.
3. Install the clutch disc and clutch cover using the clutch disc
center tool (0K 130 160 010).
Clutch cover tightening torque :

21.5 ~ 32.7 N·m (2.2 ~ 3.3 kg·m, 16 ~ 24 lb·ft)
CAUTIONS
• Remover to insert the spring washer.
• Be careful to follow the clutch disc installation directions
exactly.
Timing belt pulley installation

1. Install the timing belt pulley with the semicircular
(Woodruff) key and tighten it to specified torque.
Timing belt pulley bolt tightening torque :

157 ~ 166 N·m (16 ~ 17 kg·m, 116 ~ 123 lb·ft)
2. Release the ring gear brake, turn the flywheel, move the
No. 1 piston to the top position, and then turn it
approximately 45 in the forward direction.
CAUTION
This is to prevent damage to the piston and valve when
the cylinder head is installed.

- 1-53 -


Cylinder head installation

1. Install the cylinder head.
(1) With a rag thoroughly remove all dirt and grease from
the top of the cylinder block.
(2) Place the cylinder head gasket in position.
CAUTION
Use a new cylinder head gasket.
(3) Remove any dirt or grease from the bottom surface of
the cylinder head.
(4) Place the cylinder head in position.
(5) Measure the length of the cylinder head bolt below the
head. If the measured value is within the limit, apply a
coating of engine oil to the threaded part and install.
Standard length of cylinder head bolt below head:

112.7 ~ 113.3 mm (4.437 ~ 4.460 in)
CAUTION
If the length of the bolt below the head exceeds the
limit, it must be replaced with a new one
(6) Tighten the cylinder head bolts to a tightening torque

of 3.0 kg-m (22 lbft) in the order shown in the figure.
(7) Make paint marks on the bolt beads, as shown in the
figure.
(8) With the paint marks as a reference point, turn the
cylinder head bolts another 90 (90 ~ 105) in the
tightening direction, turning them in the order shown in
the figure.
(9) Then tighten them once again 90 (90 ~ 105) more in

the tightening order shown in the figure.
CAUTION
Be absolutely sure to tighten all bolts in the order
shown in the figure.
2. Install the camshaft

(1) Apply a coat of engine oil to the camshaft and journal
park of the cylinder head.
(2) Set the seal cap, and then apply sealant to the places
shown in the figure.
(3) Set the camshaft and camshaft cap, and then loosely
tighten the camshaft cap bolt.
NOTICE
Set the camshaft so that the key groove faces directly
upward.
- 1-54 -


(4) Set the camshaft and camshaft cap, and then loosely
tighten the camshaft cap bolt.
(5) Tighten the camshaft cap nut to the specified torque.
For measurement of the oil clearance.
Camshaft cap tightening torque :

19.6 ~ 26.4 N·m (2.0 ~ 2.7 kg·m, 15 ~ 20 lb·ft)
CAUTIONS
• When tightening the camshaft cap nut, do so
evenly, and in the order shown in the figure.
• The adjustment of the valve clearance should be
made only after the camshaft pulley, injection
pump pulley and timing belt have been installed.
3. Install the glow plugs and injection nozzles.

(1) Install the glow plugs and glow plug connector.
Glow plug tightening torque :

14.7 ~ 19.6 N·m (1.5 ~ 2.0 kg·m, 11 ~ 15 lb·ft)
(2) Install the corrugated washers, copper gasket and

injection nozzles and leak pipe as shown in the figure.
CAUTIONS
• Be sure that the corrugated washer is in the
directional position shown in the figure.
• The corrugated washer and copper gasket must
be replaced with new ones each time the injection
nozzle is removed.
Oil pressure switch tightening torque :

11.7 ~ 17.6 N·m (1.2 ~ 1.8 kg·m, 9 ~ 13 lb·ft)
Oil pressure switch and oil level gauge

1. Install the oil pressure switch.
2. Install the oil level gauge.

- 1-55 -


Injection pump
Install the injection pump with the fuel feed pipe and injection
pump bracket.
1. Install the oil pressure switch.
2. Install the oil level gauge.
NOTICE
In case the injection pump bracket and the injection pump
are separated, injection timing adjustment is necessary
after installing the timing belt.
Injection pipe
1. Install the fuel injection pipes.
Fuel injection pipe tightening torque :

17.6 ~ 22.5 N·m (1.8 ~ 2.3 kg·m, 13 ~ 17 lb·ft)
CAUTION
Check to be sure that no dirt or other foreign material
has adhered to the pipe coupling.
2. Tighten the clip channels.
Water pump
1. Install the water pump trough the gasket and alternator
strap, and tighten it to specified torque.
Water pump tightening torque :
31.3 ~ 46.1 N·m (3.2 ~ 4.7 kg·m, 23 ~ 34 lb·ft)
CAUTION
Before installation, remove any dirt from the contact
surface. Use a new gasket.
Seal plate
1. Install the seal plate.
Seal plate tightening torque :
8.0 ~ 11.7 N·m (0.8 ~ 1.2 kg·m, 5.75 ~ 8.625 lb·ft)
CAUTION
Check to be sure that the seal plate sealing rubbers are
installed in position.
- 1-56 -


Cooling fan bracket and thermostat assembly

1. Install the cooling fan bracket.
Cooling fan bracket tightening torque :
31.3 ~ 46.1 N·m (3.2 ~ 4.7 kg·m, 23 ~ 34 lb·ft)
NOTICE
Because there are two lengths of cooling fan bracket
bolts, don’t misassemble.
2. Install the thermostat assembly through the new gasket.
Thermostat assembly tightening torque :

15.6 ~ 22.5 N·m (1.6 ~ 2.3 kg·m, 12 ~ 17 lb·ft)
3. Connect the bypass hose to the thermostat assembly.
Camshaft pulley
1. Connect the camshaft pulley onto the camshaft with the
semi circular (woodruff) key.
2. Hold the camshaft with a wrench (29 mm, 1.14 in), then
tighten the camshaft pulley lock bolt to the specified
torque.
Camshaft pulley tightening torque :

54.9 ~ 64.7 N·m (5.6 ~ 6.6 kg·m, 41 ~ 48 lb·ft)
CAUTION
• Check to be sure that the mark on the camshaft pulley
aligns with the mark on the seal plate.
• Don’t damage the cylinder head edge with the wrench.
Injection pump pulley

1. Install the injection pump pulley with the semi circular
(woodruff) key to the injection pump shaft.
2. Rotate the injection pump pulley until the timing mark on
the injection pump pulley aligns with the timing mark on
the seal plate.
3. Affix the injection pump pulley to the injection pump
bracket using the two bolts (35 ~ 40 mm), and tighten it to
specified torque.
Injection pump pulley tightening torque :

58.8 ~ 68.6 N·m (6.0 ~ 7.0 kg·m, 43 ~ 52 lb·ft)

- 1-57 -


Timing belt tensioner and spring

1. Install the timing belt tensioner and spring in a fully
loosened position.
2. Position the timing belt tensioner all the way to the water
pump side, and then tighten the lock nut temporarily.
Timing belt
1. Return the crankshaft about 45 to the timing mark which is
marked on the oil pump housing.
CAUTION
Check to be sure that the matching marks of the camshaft
pulley and the injection pump pulley align to the each
matching mark on the seal plate.
2. Install the timing belt
CAUTION
The timing belt must always be reinstalled in the same
direction of rotation for continued durability.
3. Remove the two affixing bolts from the injection pump
pulley.
4. Loosen the tensioner lock bolt so that tension is applied to

the timing bolt by the tensioner spring.

(clock-wise) to equalize tension on the timing belt.
CAUTION
Don’t rotate in reverse direction.
6. Tighten the timing belt tensioner lock bolt.
Timing belt tensioner tightening torque :

31.3 ~ 46.1 N·m (3.2 ~ 4.7 kg·m, 23 ~ 34 lb·ft)
7. Recheck the timing marks on the crankshaft, camshaft

pulley and injection pump pulley.
8. Check the timing belt tension.
Standard timing belt deflection :

10.8 ~ 12.9 mm / 10kg (0.43 ~ 0.51 in / 22 lb)
- 1-58 -


9. Install the left and right timing belt covers.
Timing belt cover tightening torque :

7.0 ~ 9.8 N·m (0.7 ~ 1.0 kg·m, 5 ~ 7 lb·ft)
Crankshaft pulley
1. Install the crankshaft pulley with the semi circular
(woodruff) key.
Crankshaft pulley tightening torque :

22.5 ~ 32.3 N·m (2.3 ~ 3.3 kg·m, 17 ~ 24 lb·ft)
Exhaust and intake manifold

1. Install the exhaust manifold, tighten it to the specified
torque.
Exhaust manifold tightening torque :

21.5 ~ 26.4 N·m (2.2 ~ 2.7 kg·m, 16 ~ 20 ft·lb)
2. Install the intake manifold and gasket, and tighten it to the

specified torque, then install the hot air duct to the
exhaust manifold.
Intake manifold tightening torque :

15.6 ~ 26.4 N·m (1.6 ~ 2.7 kg·m, 12 ~ 20 lb·ft)
Oil cooler and oil filler assembly

1. Apply a coating of engine oil to the shaded area in the
figure.
2. Install three new “O” rings, and apply a coating of engine
oil to them.
- 1-59 -


3. Install the oil cooler assembly, and tighten it to the
specified torque.
Oil cooler assembly tightening torque
- M10 (Bigger): 31.3 ~ 46.1 N·m
(3.2 ~ 4.7 kg·m, 23 ~ 34 lb·ft)
- M6 (Smaller): 7.0 ~ 9.8 N·m
(0.7 ~ 1.0 kg·m, 5 ~ 7 lb·ft)
4. Install the water hose with a new gasket.
Water hose tightening torque
- Bracket: 18.6 ~ 25.5 N·m
(1.9 ~ 2.6 kg·m, 14 ~ 19 lb·ft)
- Flange: 8.0 ~ 10.7 N·m
(0.8 ~ 1.1 kg·m, 5.8 ~ 8.0 lb·ft)
5. Install the oil filter.
CAUTIONS
• When the oil filler is installed apply a coating of engine
oil to the filter’s O-ring.
• After completely tightening the oil filter with one hand,
then use a wrench to tighten it 1/4 of a turn further.
• The wrench used to further tighten the filter in the step
above must be a band-type wrench which will not
damage the filter.
Alternator
1. Install the alternator bracket, and tighten it to the specified
torque.
Alternator bracket tightening torque :
31.3 ~ 46.1 N·m (3.2 ~ 4.7 kg·m, 23 ~ 34 lb·ft)
2. Install the alternator and drive belt.
Standard alternator drive belt deflection
New : 11 ~ 12 mm (0.44 ~ 0.47 in) / 10 kg (22 lb)
Used : 12 ~ 14 mm (0.47 ~ 0.55 in) / 10 kg (22 lb)
3. Connect the vacuum pump oil hoses.
Vacuum pum oil hose tightening torque :
11.7 ~ 17.6 N·m (1.2 ~ 1.8 kg·m, 9 ~ 13 lb·ft)
Valve clearance adjustment

Measure the valve clearance and adjust it, if necessary.
NOTICE:
- Refer to page 1-11.

- 1-60 -


Cylinder head cover

1. Apply sealant to the shaded area.
2. Install the cylinder head cover, and tighten it to the
specified torque.
Cylinder head cover tightening torque :
7.0 ~ 9.8 N·m (0.7 ~ 1.0 kg·m, 5 ~ 7 lb·ft)
3. Install the air breather hose.
4. Remove the engine from the engine hanger ( 49 G030
005).
Engine mount
1. Install the engine mount and tighten it to specified torque.
Engine mount tightening torque :

31.3 ~ 46.1 N·m (3.2 ~ 4.7 kg·m, 23 ~ 34 lb·ft)

- 1-61 -


- 1-62 -

2. Lubrication System

Lubrication System
OUTLINE OF CONSTRUCTION 2-2

FLOW CHART 2-2
SPECIFICATIONS 2-3
ENGINE OIL 2-4
TROUBLESHOOTING GUIDE 2-4
INSPECTION 2-5
OIL FILTER 2-6
OIL PAN 2-7
OIL PUMP ASSY 2-8
OIL COOLER 2-11
OIL JET 2-13

- 2-1 -


Lubrication System
OUTLINE OF CONSTRUCTION
1. The oil pump is the crescent type, and directly driven by the crankshaft also.
2. The oil bypass filter is equipped to eliminate carbon, etc. in the engine oil and improve efficiency.
3. The oil filter relief valve is equipped in the oil filter body, just as is within the oil filter, in order to
protect the engine if the oil filter becomes clogged, at which time oil pressure warning light
operate to warn the driver.
4. The water-cooled oil cooler is equipped.
5. The oil jets are provided to cool the pistons.
FLOW CHART
- 2-2 -


SPECIFICATIONS
LUBRICATING SYSTEM FORCE-FED TYPE
Type Crescent inner gear type

Oil pump Oil pressure control valve
8.0 kg/cm² (114 lb/in²)
opening pressure
Type Full-flow tpe, paper filter

Oil filter Oil filter relief valve opening
1.0 kg/cm² (14 lb/in²)
pressure
Oil bypass filter Type Full-flow type, paper filter
Oil cooler Type Water cooled type
Oil pressure control valve

4.5 kg/cm² (64 lb/in²)
opening
Oil filter relief valve opening

Oil filter body Different pressure 1.0 kg/cm² (14 lb/in²)
pressure
Oil cooler relief valve

Different pressure 2.0 kg/cm² (28 lb/in²)
opening pressure
Oil warning lamp activation pressure 0.3 kg/cm² (4.3 lb/in²)
Total oil capacity 6.4 liters (6.76 U.S. quarts, 5.63 lmp. quarts)
Oil pan capacity 5.0 liters (5.28 U.S. quarts, 4.40 lmp. quarts)
Oil filter capacity 0.4 liters (0.42 U.S. quarts, 0.35 lmp. quarts)
Oil bypass filter capacity 0.4 liters (0.42 U.S. quarts, 0.35 lmp. quarts)
Engine oil API sevice CC and CD
- 2-3 -


ENGINE OIL
RECOMMENDED SAE VISCOSITY NUMBERS
Temperature range anticipated before next oil change. °C (°F)

Oil leakage Loose drain plug Tighten or replace
Faulty seal at oil pan and cylinder block Repair
Damaged cylinder head cover Replace
Loose oil pump body bolt, cylinder head cover
Tighten
bolt, or oil pan bolt
Damaged front housing gasket, or cylinder head
Replace
gasket
Faulty oil seal (s) Replace
Loose oil filter Tighten
Loose or damaged oil pressure switch Tighten or replace
Oil pressure drop Oil leak As described above
Insufficient oil Add oil
Worn and/or damaged oil pump gear Replace
Worn plunger (inside oil pump) or weak spring Replace
Clogged oil strainer Clean it
Excessive lubrication clearance between main
Refer to Engine
bearing and connecting rod bearing
Warning lamp Oil pressure drop As described above
illuminates while Malfunction of oil pressure switch Repair
engine running
Problem in electrical system Repair
- 2-4 -


INSPECTION
Checking Oil Pressure
1. Disconnect the vacuum pump oil hose.
NOTICE
Let the engine oil drain into a suitable container.
2. As shown in the figure, install the oil pressure gauge

adaptor and the oil pressure gauge.
3. Start the engine and let it warm up thoroughly.
4. Maintain engine rpm at 3,000, and note the gauge
reading.
Oil pressure : 4.1 ~ 4.9 kg/cm² (58 ~ 70 lb/in²)
5. If the pressure does not come up to specified

pressure, check each part, and repair if necessary.
(Refer to the troubleshooting guide).
- 2-5 -


OIL FILTER
REPLACEMENT
1. Remove the oil bypass filter with a suitable wrench.
2. Use a clean rag to wipe off the mounting surface on the

engine.
3. Apply engine oil to the rubber seal on the new oil

bypass filter.
4. Install the oil bypass filter and tighten it fully by hand.
5. Tighten it a 2/3 turn farther with a suitable wrench,

preferably a band-type.
CAUTION
Avoid using a chain-type wrench, which may deform
the oil bypass filter.
Tightening torque :
19.6 ~ 24.5 N·m (2.0 ~ 2.5 kg·m, 14.5 ~ 18.1 lb·ft)
6. Start the engine and inspect for leaks around the oil bypass filter seal. Check the oil level and fill
to the F mark if necessary.
Oil bypass filter capacity : 0.40 liter (0.42 U.S. qt, 0.35 lmp·qt)

- 2-6 -


OIL PAN
REMOVAL
1. Insert a flat-tipped scraper between the oil pan and oil
baffle plate to separate them and remove the oil pan.
CAUTION
Do not insert a flat-tipped scraper between the oil
baffle plate and cylinder block.
2. Remove oil strainer from cylinder block and oil pump.
3. Remove oil baffle plate from the cylinder block.

NOTICE
Avoid damage to oil baffle plate.
INSTALLATION
1. Apply a coat of sealant of sealant to the oil pan installation
surface shown in the figure.
NOTICE
Before installation clean oil baffle plate and oil pan.
INSPECTION
1. Check the following points.
A. Cracks, deformation, damage. (At bolt locations)
B. Damaged drain plug threads.
2. Repair or replace if necessary.
- 2-7 -


OIL PUMP ASSY

1. Disconnect battery negative cable.
2. Drain coolant into a suitable container.
3. Remove each part in the numbered sequence shown in the figure.
COMPONENTS
1. Timing belt pulley 4. Oil baffle plate

2. Oil pan 5. Oil pimp
3. Oil strainer
Before installation
1. Apply a thin coating of grease to the O-ring, and attach it at
the position shown in the figure.
2. Apply a coat of sealant of sealant to the oil pump
installation surface shown in the figure.
NOTICE
Be careful not to let sealant get into the oil hole.
3. Coat the oil seal lip with engine oil, and then install the seal.
Taking care not to damage the lip.
- 2-8 -


Disassembly
Screws
1. Loosen the screws by a impact driver or like tool so that
the oil pump body is not damaged.
2. Remove each part in the numbered sequence shown in
the figure.
Reassembly
1. Assembly is in reverse order of disassembly.
COMPONENTS
- 2-9 -


INSTALLATION
Oil seal replacement
1. Removal
Remove the oil seal by using a screwdriver or similar tool to
pry it out.
2. Installation
Press in the oil seal by using a pipe or round rod with an
outer diameter of 45 mm (1.77 in).
CAUTION
Press the oil seal in until the front end is aligned with the
front end of the pump body.

INSPECTION
Check the following points. Repair or replace if necessary.
1. Distortion or damage to pump body or cover
2. Worn or damaged plunger
3. Weak or broken plunger spring
4. Measure gear clearances
Outer gear tooth tip and crescent clearance

limit : 0.35 mm (0.013 in.)
Inner gear tooth tip and crescent clearance
limit : 0.35 mm (0.013 in.)
5. Measure the side clearance.
Limit : 0.15 mm (0.006 in.)
6. Measure the body clearance.
Outer gear to pump body clearance limit :

0.20 m (0.008 in.)
- 2-10 -


OIL COOLER
COMPONENTS
1. Coolant hoses 4. Oil cooler and oil filter assembly attaching bolts
2. Oil cooler pipe and nuts
3. Vacuum pump oil hose 5. Oil cooler and oil filter assembly

1. Disconnect battery negative cable.
2. Drain coolant into a suitable container.
- 2-11 -


DISASSEMBLY & REASSEMBLY

1. Disassembly each part in the numbered sequence shown in the figure.
2. Assembly is in reverse order of disassembly.
CAUTION
O-rings must be replaced with new ones, and apply engine oil to the new O-rings.
1. Oil filter 4. Oil cooler relief valve

2. Oil cooler 5. O-ring
3. Plug

NOTICE:
‧ When installing the oil cooler, align the oil cooler
holes and the projections of the oil filter body.
- 2-12 -


OIL JET
Removal & Installation
1. Remove each part in the following order.
Oil pan
Oil jet valves
Oil jets
INSPECTION
1. Make sure that the oil presage is not clogged.
2. Check and ensure that the spring incorporated
in the oil jet valve is not stuck or damaged.
- 2-13 -

3. Cooling System

Cooling System
DESCRIPTION 3-2
STRUCTURAL VIEW 3-2
FLOW CHART 3-3
SPECIFICATION 3-4
TROUBLESHOOTING GUIDE 3-5
COOLANT 3-6
WATER PUMP 3-7
THERMOSTAT 3-8
RADIATOR 3-9
COOLING FAN BEARING ASSEMBLY 3-10

‐ 3-1 -

3. Cooling System

Cooling System
DESCRIPTION
STRUCTURAL VIEW
- 3-2 -

3. Cooling System

FLOW CHART

‐ 3-3 -

3. Cooling System

SPECIFICATION
COOLING METHOD WATER-COOLED
With heater 9.0 liters (9.5 U.S. qts, 7.9 lmp qts)
Coolant capacity
Without heater 8.5 liters (9.0 U.S. qts, 7.5 lmp qts)
Type Wax type (2 stage)
Opening temp. (main/sub) 88° ± 1.5°C / 80° ± 1.5°C

Thermostat Full-open temp. (main/sub) 100°C (100°C)
8.0 mm (0.31 in) / more 1.5 mm (0.86

Full-open lift (main/sub)
in)
Water pump Type Centrifugal, timing belt driven
Type Corrugated
Radiator
Cap valve opening pressure 0.9 ± 0.15 kg/cm² (12.8 ± 2.1 lb/in²)
Type Thermo-modulated
Cooling fan Number of blades 8
Outer diameter 380 mm (15.0 in.)
- 3-4 -

3. Cooling System

Damaged radiator core seam Replace
Leakage from radiator hose or heater hose Repair or replace
Leakage from water temperature switch Repair or replace
Malfunction of water seal (water pump) Replace
Water leakage Damaged or loose thermostat cover or gasket Repair or replace
Loose cylinder head bolt Tighten
Damaged cylinder head gasket Replace
Creaked cylinder block Replace
Creaked cylinder block Replace
Corrosion Impurities in coolant Clean
Water passage clogged Clean
Thermostat malfunction Replace
Radiator fins clogged Clean
Overheating Water pump malfunction Repair or replace
Insufficient coolant Add
Thermo-modulated cooling fan malfunction Replace
Radiator cap malfunction Replace

‐ 3-5 -

3. Cooling System

Coolant
INSPECTION
CHECKING COOLANT LEVEL
While the coolant is cold, check whether the coolant level
is near the radiator inlet port, and whether the level in the
coolant reservoir is between the FULL and LOW marks.
Add coolant if the level is low.
WARNING
When removing either the radiator cap or the tester,
loosen it slowly until the pressure in the radiator drops
to zero, and then remove it.
CHECKING COOLANT LEAKAGE

1. Connect the tester at the radiator inlet port.
2. Apply a pressure of 1.05 kg/cm² (15 lb/in²) to the tester.
3. Check whether the tester indicator shows a reduction of
pressure. If it does, there may be a coolant leak. Locate
the leak.
WARNING
When removing either the radiator cap or the tester,
loosen it slowly until the pressure in the radiator drops
to zero, and then remove it.
COOLANT REPLACEMENT
1. Drain the coolant by opening the radiator drain plug.
2. Close the plugs tightly.
3. After pouring anti-freeze into the radiator in accordance
with the table below, add soft water.
4. Start the engine, bleed the air from the coolant
passages, and then add more coolant.
Anti-freeze solution mixture percentage
Protection Anti-freeze Water
Above -16°C (3°F) 35% 65%
Above -26°C (-15°F) 45% 55%
Above -40°C (-40°F) 55% 45%

- 3-6 -

3. Cooling System

Water pump
COMPONENTS

1. Turn the crankshaft so that the No. 1 cylinder is at top dead center of compression.
‐ 3-7 -

3. Cooling System

Disassembly & Reassembly

Disassemble each part in the numbered sequence shown
in the figure.
Assembly is in reverse order of disassembly.
1. Water pump cover
2. Gasket
3. Water pump body
CAUTION
Don’t disassemble the water pump body. Replace it
with an assembly if necessary.
Thermostat
COMPONENTS
1. Radiator hose, upper 3.Gasket

2. Thermostat cover 4. Thermostat cover

1. After draining the coolant, remove the parts in the numbered order shown in the figure.
2. Installation is the reverse order of removal.
- 3-8 -

3. Cooling System

Radiator
COMPONENTS
Removal

Installation
RADIATOR CAP
‐ 3-9 -

3. Cooling System

INSPECTION
Check the following points. Repair or replace if
necessary.
1. Cracks, damage
2. Bent fins (Repair by using a screwdriver)
3. Distorted or bent radiator inlet
COOLING FAN BEARING ASSEMBLY

REMOVAL
1. Remove the drive belt from alternator.
2. Remove the thermo modulated fan and remove the fan
pulley from pulley boss.
3. Remove the cooling fan assembly form cylinder block.
CAUTION
Don’t disassemble the water pump body. Replace it
with an assembly if necessary.
INSTALLATION
1. Install the cooling fan assembly.
Tightening torque : 37 N·m (3.7 kg·m, 26.7 lb·ft)
2. Install the fan pulley and thermo modulated fan.
Tightening torque : 21.5 N·m (2.2 kg·m, 15.9 lb·ft)
3. Install the drive belt at alternator.

NOTICE
Adjust the drive belt tension with thumb pressure of
about 10 kg (22 lb).
- 3-10 -

3. Cooling System

DISASSEMBLY
1. Remove the pulley boss using the water pump boss
puller (0K 130 175 008) and a suitable mandrel.
2. Remove the bearing by using a suitable pipe (outer

diameter 20 mm) and press.
REASSEMBLY
1. Press in the shaft into the pulley boss until the shaft
protrudes 2.1 mm (0.083 in).
2. Place the bracket a shown in the figure and install the

bearing so that it is horizontal to the bracket.
3. Press the bearing into the bracket.
‐ 3-11 -

3. Cooling System

- 3-12 -

4. Fuel System

Fuel System

 Description and Operation 4-2
 Repair procedures
Fuel Delivery System 4-6

 Description 4-6
 Repair procedures 4-6
 Fuel Filter 4-6
Mechanical Injection Pump 4-8

 Description 4-8
 Inspection 4-9
 Removal 4-11
 Installation 4-12
 Fuel cut valve
Injection Nozzle 4-14

 Removal 4-14
 Installation 4-14
 Inspection 4-15
 Reassembly 4-16
Inspection 4-17
 Air cleaner 4-17
 Accelerator linkage 4-17
 Air-bleeding 4-17
- 4-1 -

4. Fuel System

General Information
DESCRIPTION AND OPERATION
- 4-2 -

4. Fuel System

SPECIFICATIONS
ITEM SPECIFICATION
Capacity 60 liters (15.5 U.S. Gallons)

Fuel tank
Position Right side
Type VE type
Injection timing BTDC 2°
Injection pump Turning direction Clock-wise
Idling speed 700 - 750 rpm
Driving type Timing belt
Nozzle type Throttle type
Injection nozzle Orifice Dia. x No 10mm (0.039 in) × 1
Injection pressure 135 kg/cm²
Air cleaner Filter paper element type
Fuel filter Carridge type with water-detector
875 - 925 rpm

Fast idling speed Setting speed (When the air-con, switch is open and the vacuum line is
connected)
- 4-3 -

4. Fuel System

TROUBLESHOOTING
Hard starting Clogged fuel filter Replace
Air in fuel filter Air-bleed
Faulty fuel cut valve Replace
Faulty injection timing Adjust
Air in injection timing Air-bleed
Trouble inside of injection pump Replace
Seized needle valve of injection nozzle Clean or replace
Fuel dripping from injection nozzle Replace
Faulty injection starting nozzle Adjust
Rough idling Clogged fuel filter Replace
Air in injection pump Air-bleed
Trouble inside of injection pump Replace
Faulty injection strating pressure Adjust
Disassemble and assemble or

Improper mounting to nozzle holder
replace
Leakage of gasket Replace
Crack of injection pipe Replace
Leaking from injection pipe joint Retighten or replace
Improper idling speed Adjust
Engine knocking Faulty injection timing Adjust
Low quality of fuel Replace
- 4-4 -

4. Fuel System

Faulty injection starting pressure Adjust
High fuel Consumption Faulty injection timing Adjust
High idling speed Adjust
Faulty injection starting pressure Adjust
Fuel drippingfrom injection nozzle Replace
Leakage of gasket Replace
Clogged fuel filter Replace
Clogged air cleaner Clean or replace
Poor acceleration Clogged air cleaner Clean or replace
Air in injection pump Air-bleed
Trouble inside of pump Replace
Crack of injection pipe Replace
Clogged fuel filter Replace
Excessive exhaust smoke Clogged air cleaner Clean or replace
Improper injection timing Adjust
Faulty injection nozzle Adjust or replace
- 4-5 -

4. Fuel System

FUEL DELIVERY SYSTEM

DESCRIPTION
Repair procedures
Fuel filter
Description
1. The fuel filter, installed between fuel tank and
injection pump. Plays important roles of filtering
foreign material and separating water in fuel system.
Removal
1. Disconnect the wiring coupler.
2. Remove the fuel filter with a suitable wrench.
- 4-6 -

4. Fuel System

Installation
1. Apply fuel onto the "O" ring.
2. Install the fuel filter and tighten it fully, by hand.
3. Make sure to connect the wiring coupler and fuel
hoses in the correct position after installation.
CAUTIONS
1) After installing the filter, bleed air from the fuel
filter.
2) Also confirm that there are no fuel leaks by
staring the engine.
Water-drain
1. Loosen the water drain plug drain water until the
pure fuel comes out.
2. Close the water drain plug.
3. Do air-bleeding.
Air-bleeding
1. Loosen the air vent plug.
2. Pump the fuel priming plunger in an up-and-down
motion about 7 times until the pure fuel comes out.
3. Securely tighten the air vent plug.
Water detector inspection

1. Remove the detector from the fuel filter.
2. Check the continuity of the lead wires (Attach circuit
tester to lead wires).
3. The detector is normal when continuity exists in the
down position and no continuity exists in the up
position.
- 4-7 -

4. Fuel System

Mechanical Injection Pump

Description
IMPORTANT SERVICE POINT
If the inside of the injection pump is disassembled for maintenance, be sure to properly use
the checking device such as the injection pump tester, and carefully inspect each
component.
CONSTRUCTION OF VE INJECTION PUMP
- 4-8 -

4. Fuel System

Idling speed checking

1. Warm up the engine to normal operation
temperature.
2. Attach a tachometer and check the range speed.
Idling speed : 700~750 rpm
If the idling speed is not within the specified range,

adjust the idling speed.
Idling speed adjusting

1. Confirm the accelerator cable deflection.
If the deflection is not within the standard range,
adjust it by turning accelerator cable lock nuts.
Standard deflection : 1.0~3.0 mm (0.04~0.12 in)
2. Loosen the lock nut of the idle adjusting bolt and

adjust the idling speed by turning the idle adjusting
bolt.
NOTICE
Idle speed will increase when the adjusting bolt is
turned clockwise and decrease when turned
counter-clockwise.
Injection timing checking

1. Align the timing mark (2° BTDC) on the crankshaft
pulley with the indicator pin by turning the crankshaft.
2. Disconnect the injection pipes from the injection
pump.
3. Remove the hydraulic head plug on the injection

pump.
4. Mount the measuring device into the plug hole on the

hydraulic head so the tip of the dial gauge pointer
touches the plunger end of the pump and dial gauge
indicates approx. 20. mm 90.08 in).
- 4-9 -

4. Fuel System

INDICATOR PIN 5. Turn the crankshaft pulley slowly counter-clockwise (in

reverse direction of engine rotation) until the timing
mark on the crankshaft pulley moves from the original
position (2° BTDC) to the counterclockwise side by
30°~50° and make sure the dial indicator pointer stops.
Set the dial gauge pointer on Zero (0).
NOTICE
SET ON ZERO (0)
When setting the dial indicator, confirm that the dial
indicator pointer does not deviate from the scale mark of
"0" by slightly turning the crankshaft to the right and left.
2° BTDC
6. Turn the crankshaft pulley clockwise (in direction of
1mm
engine rotation) to align the timing mark with the
indicator pin. If the dial gauge pointer indicates
1±0.2mm (0.04±0.008 in) when the timing mark is
aligned with the indicator pin, the injection timing is
correctly adjusted. If necessary, adjust the injection
timing.
Injection timing adjusting

1. Perform the checking procedure.
2. Loosen the injection pump attaching nuts and bolts.
ATTACHING NUT
3. Adjust the injection timing by moving the injection pump

until the cam lift becomes 1±0.02 mm (0.04±0.0008 in).
COUNTER-CLOCKWISE
4. Remove the service hole cap of the injection pump
pulley.
5. Align the arrow mark on the timing belt cover with the
matching mark on the injection pump pulley.
CLOCKWISE
Cam lift Injection timing Adjustment:

When it is more then 1±0.02mm : Advanced
Turn the injection pump clockwise (in direction of
engine rotation)
When it is less than 1±0.02mm : Retarded
Turn the injection pump (in counter-clockwise reverse
direction of engine rotation)
- 4-10 -

4. Fuel System

Cam lift checking

1. Perform the injection timing checking procedure (1~5).
2. Turn the crankshaft clockwise (in direction of engine
rotation) and read the maximum value which the dial
indicator pointer indicates.
Cam lift : 2.2 mm (0.08 in)
3. If the cam lift is less than the specified value there is

a problem with the cam disc or roller ass'y.
Removal
1. Remove or disconnect the following parts.
(5) Injection pipes
2. Remove the service hole cap of the injection pump

MATCHING MARK
pulley.
3. Align the arrow mark on the timing belt cover with the
matching mark on the injection pump pulley.
4. Affix the injection pump pulley with two bolts

AFFIXING BOLTS
(35~40mm).
5. Remove the pulley lock nut and spring washer.
6. Apply the matching marks on the injection pump

MATCHING
MARK flange and bracket for reinstallation.
- 4-11 -

4. Fuel System

7. Remove the injection pump attaching nuts and loosen

the attaching bolts more than three revolutions.
8. After disconnecting the injection pump and pulley by

using the pulley puller (0K710 120 006), remove the
injection pump.
CAUTION
1) Do not remove the two affixing bolts until the
injection pump is installed.
2) Be careful not to drop the semi circular (woodruff)
key.
Installation
1. Install the semi circular(woodruff) key on the injection
pump shaft groove.
NOTICE
Before installing the key on the pump shaft, lightly tap
the key groove with hammer to assure the key
installation.
2. Install the injection pump and align the matching

MATCHING
MARK marks on the injection pump flange and bracket. Then
tighten the two attaching bolts and two nuts.
Tightening torque :
Two nuts :
15.6~22.5 N·m (1.6~2.3 kg-m, 11.5~16.6 lb-ft)
Two nuts :
31.3~46.1 N·m (3.2~4.7 kg-m, 23.0~33.8 lb-ft)
3. Install the spring washer and lock nut and tighten it.
Tightening torque :
68.6~78.4 N·m (7~8 kg-m, 23.0~33.8 lb-ft)
4. Remove the affixing bolts.
- 4-12 -

4. Fuel System

5. Install the service hole cap of the injection pump

pulley.
CAUTION
After the installation, check the injection timing. If
the injection timing is incorrect, adjust it.
6.. Install the following parts.

(1) Injection pipes
CAUTION
Bleed air from the injection pump.
FUEL CUT VALVE

INSPECTION
1. The fuel cut valve is in a normal condition when the
engine runs smoothly and is stopped by
disconnecting the coupler.
2. Check the above function. If the engine does no stop
by disconnecting the coupler, the fuel cut valve is
faulty.
3. When the fuel cut valve is faulty, replace the parts
shown in figure is a complete set.
- 4-13 -

4. Fuel System

Injection Nozzle
Repair procedures
REMOVAL
Remove in the following order.
1. Injection pipes
2. Leak pipe lock nut
3. Leak pipe
4. Washer
5. Injection nozzle
6. Gasket
7. Corrugate gasket
COMPONENTS
The injection nozzle consists of the following parts.
1. Retaining ring
2. Nozzle body and needle valve
3. Distance piece
4. Pressure pin
5. Pressure spring
6. Shim
7. Nozzle holder
8. Washer
9. Nut
INSTALLATION
1. Install in reverse order of removal.
CAUTIONS
1) The gasket and corrugated gasket and not be
reused.
2) Tighten the injection nozzle on the cylinder head to
3) Face the red paint applied side to the injection
nozzle when installing the corrugate gasket.
Nozzle tightening torque :

58.8~68.6 N·m (6~7 kg-m, 42~52 lb-ft)
- 4-14 -

4. Fuel System

INSPECTION
Check the nozzles using diesel fuel at approximate
temperature of 20°C(68°F).
Injection starting pressure

1. Set the nozzle on the nozzle tester.
2. Bleed the air by pumping the nozzle tester handle
several times.
3. Slowly lower the nozzle tester handle and check the
value shown on the pressure gauge when injection is
started.
Injection start pressure : 135 kg/cm²
(1919.7 lb/in²)
If the injection start pressure is not within the

specified range, adjust it. Adjust the starting pressure
with the shim. The shim has 27 different thicknesses
for every 0.04 mm (0.0016in) from 0.50 mm
(0.0197in) to 1.54mm(0.0606 in). As 0.04 mm
(0.0016 in) is added, approx. 4.8 kg/cm² (16.16lb/in²)
of injection pressure increases.
Tightness of valve seat

1. Apply a pressure of 115 kg/cm² (1635.3 lb/in²), and
check for fuel leaks from the nozzle injection hole. If
fuel leaks, it is necessary to disassemble, wash and
recheck the injection nozzle or replace it.
- 4-15 -

4. Fuel System

Atomizing condition (Spray pattern)

1. Set the injection nozzle on the nozzle tester.
2. Bleed the air by operating the nozzle tester handle
several times.
3. Keeping the pressure gauge of the nozzle tester in
the nonfunctioning condition, quickly lower the handle
several times (lower the handle as quickly as
possible so that a pulsation whistling sound can be
heard) and check the atomizing condition.
(1) Fuel is atomized uniformly and properly.
(2) The injection angle and direction are normal. If the
atomizing condition is incorrect, it is necessary to
disassemble, wash and recheck the injection
nozzle, or to replace it.
Nozzle body and needle valve Checking

1. Check and ensure that the valve sat of the needle
valve and other parts are not damaged.
2. Make sure that the nozzle body is not damaged. Hold
the nozzle body upright and insert approximately two
thirds of the needle valve and see if the needle valve
drops to the valve seat by its own weight.
REASSEMBLY
Pay attention to the following matters when assembling
injection nozzle.
CAUTIONS
1) After assembling the injection nozzle, check the
injection starting pressure and atomizing condition.
2) Tighten the nozzle body on the nozzle holder to the
specified torque.
Nozzle tightening torque :

78.4~98.1 N·m (8~10 kg-m, 58~72 lb-ft)
- 4-16 -

4. Fuel System

INSPECTION
AIR CLEANER
Cleaning the element
1. To clean the element, blow out the dust with
compressed air.
ACCELERATOR LINKAGE
CHECING AND ADJUSTING
1. Inspect the cable deflection at the fuel injection pump. If
the deflection is not within 1~3mm (0.039~0.118 in),
adjust by nuts (A).
2. Depress the accelerator pedal to the floor, and confirm
that the control shaft is touched to the maximum stopper
bolt.
Adjust by bolt (B) if necessary.
AIR-BLEEDING
1. Bleed air from the fuel filter.
2. Pump the head of the fuel filter repeatedly until it
becomes hard (about 15 times).
- 4-17 -

4. Fuel System

- 4-18 -

Engine Electrical System

ENGINE ELECTRICAL SYSTEM

 Tightening torque 5-3
Charging System 5-4
 Alternator 5-4
 Components and Components Location 5-5
 Battery 5-10
 General Safety Information and Caution 5-10
Starting System 5-12
 Starter 5-12
 Components and Components Location 5-12
Preheating System 5-22
 Schematic Diagrams 5-22
 Quick start system (QSS) 5-23
 Engine electrical system EWD 5-27
- 5-1 -

5. Engine Electrical System

GENERAL INFORMATION
SPECIFICATIONS
Starting System
Engine type
Item
HW DIESEL
Type DIRECT
Output (kw) 2.0
Standard 18 (0.71)
Brush length
Starter Wear limit 11 (0.43)
Spring force N (kg, lb) 8.8 (0.9, 2.0)
Armature runout Standard 0.05 (0.002)
mm (in) limit 0.4 (0.016)
Charging System
Engine type
Item
DIESEL
Voltage (V) 12V, negative ground

Battery
Type and capacity (5 hour rate) 68AH
Type A.C
Output (V-A) 12~55
Alternator Regulator type (V) Transistorized (Built-in IC regulator)
Drive belt tension NEW 11~12 (0.43~0.47)
mm (in) / 98 (10 kg, 22 lb) Used 12~14 (0.47~0.55)
- 5-2 -


TIGHTENING TORQUE
Starting System
Engine type
Item
DIESEL
Starter motor bolts 37~54 (3.8~5.5, 28~40)
B-terminal nut 16~23 (1.6~2.3, 12~17)
- 5-3 -


CHARGING SYSTEM
ALTERNATOR
1. The alternator produces a 60amp output current and has internal electronic voltage regulator. It is
mounted on the front of the engine and is driven by the V-belt that drives the thermo modulated
fan.
2. There are three terminals on the alternator which connect it to the vehicle electrical system.
The "B", "L" and "R" terminals is on the back of the alternator.
3. Vacuum pump is mounted on the rear of the alternator.
- 5-4 -


The alternator has a self-diagnostic function to warn of the following problem in the charging
system.
If a problem arises, the alternator warning lamp illuminates.
1. S terminal circuit open
2. No voltage output
3. Field coil circuit open
4. B terminal circuit open
5. Voltage output too high
COMPONENTS
- 5-5 -


REPAIR PROCEDURES
INSPECTION
CAUTIONS
1. Be sure battery connections are not reversed, because
this will damage the rectifier.
2. Do not use high-voltage tester, such as a Megger,
because they will damage the rectifier.
3. Remember that battery voltage is always applied to the
alternator's B terminal.
4. Do not ground the L terminal while the engine is
running.
5. Do not start the engine while the coupler is
disconnected from the L and R terminals.
1. Make current and voltage connections as shown in the

figure.
2. Turn the ignition switch OFF.
3. Read the voltage between the L terminal and ground.
The alternator is bad if the reading is not 0V.
4. Turn the ignition switch ON and read the voltmeter. If
the reading is 0V, there is a malfunction of the alternator
rear bracket, and then read the voltmeter. If the voltage
is near the battery voltage, short circuit the F terminal
and the alternator rear bracket, and then read the
voltmeter. If the voltage is lower than the battery
voltage, there is a malfunction of the IC regulator.
Checking no-load adjustment voltage

1. Check to be sure that the battery is fully charged.
2. Connect an ammeter and voltmeter as shown in the
figure.
Be sure that the voltmeter reading is 0V.
3. Turn the ignition key to ON, and then check to sure that
the voltmeter reading is significantly lower than the
battery voltage. (1~3V).
If the voltmeter reading is significantly lower than the
battery voltage, there may be a malfunction in the
alternator.
4. Short circuit the terminals of the ammeter, and then
start the engine. After starting, discontinue the short
circuiting.
NOTICE：
Be careful, when starting the motor, that the current of
the starter doesn't flow to the ammeter.
- 5-6 -


5. Under no-load conditions, increase the alternator speed to 5,000rpm (engine speed of
2,000~2,500rpm)
6. Read the indication shown by the voltmeter and the ammeter.
Ammeter : 5A or less
Voltmeter (adjustment voltage) : 14.7 ± 0.3V (at 20°C (68°F))
Checking output
1. Check to be sure that the battery is fully charged.
2. Connect an ammeter and a voltmeter as shown in the
figure.
3. Connect the negative battery cable.
4. Start the engine.
5. Apply a load by turning on the head lights.
6. Gradually increase the engine speed and read the
output current.
If the voltage is higher than the battery voltage and there
is an output current, there is no problem.
REMOVAL
1. Disconnect negative battery cable.
2. Remove the B-terminal nut.
3. Remove the B-terminal lead.
4. Disconnect the alternator connector.
5. Remove the adjustment bolt.
6. Remove the alternator bolt.
7. Disconnect the drive belt from the alternator pulley.
8. Disconnect the oil hose and vacuum hose.
9. Remove the alternator from vehicle.
10.Install in the reverse order of removal.
11.Adjust the tension of the V-belt.
Deflection
- New belt : 11~12mm (0.43~0.47mm)
- Used belt : 12~14mm (0.47~0.55mm)
Tightening torque
- Bolt A : 19~26 N·m (1.9~2.6 kg·m, 14~18 lb·ft)
- Bolt B : 38~51 N·m (3.8~5.3 kg·m, 27~38 lb·ft)
CAUTION
Be sure the battery connection are not reversed,
this will damage the rectifier.
- 5-7 -


DISASSEMBLY
1. Loosen the attaching bolts and remove the vacuum
pump.
2. Remove the cap screws fit a flat-tipped (-) screw driver

between the front bracket and the stator core, and then
separate the stator core, and then separate the stator
and rotor by tapping the screwdriver with a rubber
hammer.
CAUTION
Be careful not to force the screwdriver too far in,
because the coil may become scratched.
3. Secure the rotor in vise and loosen the pulley nut.
CAUTION
Insert protective material in the jaws of the vise.
4. Use a soldering iron to disconnect the stator lead

wiring
CAUTION
Do not disconnecting quickly, using the soldering
iron no more than about 5 seconds, because the
rectifier may become damaged if the inside is
overheated.
- 5-8 -


5. Use a soldering iron to disconnect the brush

holder and IC regulator assembly from the
rectifier.
6. When the rotor is to attached to the rear

bracket, insert a wire through the hold in the
rear bracket so that the brusher are at the
specified position.
7. Insert a seal washer at each end of the front

bracket. Install in the reverse of removal.
- 5-9 -


BATTERY
GENERAL SAFETY INFORMATION AND CAUTION
INSPECTION
Terminal and cable
1. Check the tightness of the terminals to ensure good
electrical connections. Clean the terminals and coat
them with grease after tightening the terminal.
2. Inspect for corroded or frayed battery cables.
3. Check the rubber protector on the positive terminal
for proper coverage.
Electrolyte level
1. Check whether or not the electrolyte level lies
between the UPPER LEVEL and the LOWER
LEVEL lines.
2. If low, add distilled water until the UPPER LEVEL
line is reached. Do not overfill.
Specific gravity
1. Measure the specific gravity of each cell with a
hydrometer.
2. If the specific gravity reading is below standard,
recharge the battery.
Standard gravity: 1.280 (at 77°F (25°C))
3. If the hydrometer readings for the highest and

lowest cells vary 0.05 or more, replace battery.
Quick charging
1. Remove the battery from the vehicle and remove
the vent caps to perform a quick charge.
WARNING
• Before performing maintenance or recharging the
battery, turn off all accessories and stop the engine.
• The negative cable must be removed first and
installed last.
• Set the battery in water when quick charging prevent
overheating the battery.
- 5-10 -



DESCRIPTION
• The original equipment battery is a conventional, low-maintenance 12 volt 48-amp-hour-battery
(FE gasoline vehicle).
• The original equipment battery is a conventional low-maintenance 12 volt 68-amp-hour battery
(HW diesel vehicle).
WARNING
• Hydrogen and oxygen gases are produced during normal operation. This gas mixture can
explode if flames, sparks, or lighted tobacco are brought near the battery. When charging or
using a battery in an enclosed space always provide ventilation and shield your face and
protect your eyes.
• Keep batteries out of the reach of children. Batteries contain sulfuric acid. Avoid contact with
skin or eyes. A;sp, shield your eyes. Also, shield your eyes when working near the battery to
protect against possible splashing of the acid solution. In case of acid contact with skin,
eyes, or clothing, flush immediately with water for a period of 15minutes andget medical
attention. If acid is swallowed call a physician immediately.
- 5-11 -


Starting System
Starter
Components and Components Location
- 5-12 -


Repair procedures
1. “S” terminal 2. “B” terminal 3. Starter motor
Removal
1. Disconnect the negative battery cable.
2. Remove the upper starter motor bolts.
3. Raise the vehicle.
4. Disconnect the S-terminal connector at the magnetic switch.
5. Remove the B-terminal washer and nut.
6. Disconnect the B-terminal connector at the magnetic switch.
7. Remove the lower starter motor bolts.
8. Remove the starter motor.
- 5-13 -


INSTALLATION
1. Install the starter motor.
2. Install the lower starter motor bolts.
Tightening torque : 37~54N·m (3.8~5.5kg-m, 27~40lb-ft)
3. Connect the S-terminal connector at the starter solenoid.
4. Install the B-terminal from the starter solenoid and install

the B-terminal washer and nut.
Tightening torque : 16~23N·m (1.6~2.3kg-m, 12~17lb-ft)
5. Lower the vehicle.
6. Install the upper starter motor bolts.
Tightening torque : 37-54N·m (3.8~5.5kg-m, 27~40lb-ft)
7. Connect the negative battery cable.
DIASSEMBLY
1. Remove the nut from the magnetic switch M-terminal.
2. Remove the field wire from the magnetic switch
M-terminal.
3. Remove the magnetic switch screws and the solenoid.
4. Remove the rear housing.

5. Using radio pliers or a similar tool, raise the positive (+)
side brush spring and remove the brush.
6. Remove the brush holder assembly and the armature.
7. Remove the front cover, and remove the lever and
springs.
- 5-14 -


8. Separate the yoke and center bracket.
9. Remove the cover and pull out the snap ring and washer.
10. Remove the pinion, over-running clutch assembly and

reduction gear the center bracket.
INSPECTION
1. Magnetic switch
(1) Continuity (S terminal - M terminal)
Check for continuity between S and M terminals with
ohmmeter. Replace the magnetic switchif there is no
continuity.
(2) Continuity (S terminal - Body)

Check for continuity between the S terminal and the
body with ohmmeter. Replace the magnetic switch if
there is no continuity.
- 5-15 -


(3) Grounding
Check continuity between M and B terminals with an
ohmmeter. Replace the magnetic switch if there is
continuity.
2. Brush and brush holder

(1) Insulation
Check continuity between each insulated brush and
the place with an ohmmeter. Replace the brush
holder if there is continuity.
(2) Measure the force of the brush spring with spring balance.
Brush spring force : 8.8N (0.9kg, 20lb)
(3) Replace the spring if necessary.
3. Brush
If a brush is worn almost to or beyond the wear limit,
replace all of the brusher.
TYPE DIESEL ENGINE
Standard 18mm (0.709in)
Minimum 11mm (0.433in)
- 5-16 -


4. Field coil
(1) Check for continuity between M terminal wire and
brushes with an ohmmeter. Replace the yoke
assembly if there is no continuity.
(2) Check continuity between the M terminal wire and

yoke with a yoke assembly if there is continuity.

(3) Check if the field loose. Replace the yoke assembly
if necessary.

5. Armature
(1) Check continuity between the commutator and the
core with an ohmmeter. Replace the armature if there
continuity.

(2) Check continuity between the commutator and the
shaft with an ohmmeter. Replace the amature if
there is continuity.

(3) Place the armature on V-blocks and measure the
runout with a dial indicator.
If the runout is not within specification, repair it with
a lathe or replace the amature.
Runout : 0.05mm (0.002in.)
Maximum : 0.4mm (0.016in.)
(4) Replace the armature if the outer diameter of the

commutator is almost at or less than grind limit.

- 5-17 -


(5) If the commutator surface is dirty, wipe it with a
cloth; if it is rough, repair it lathe is dirty, with a cloth;
if it is rough, repair it with a lathe or fine sandpaper.
Engine DIESEL ENGINE
Grind limit 31mm (1.22in)
(6) Segment groove depth

If the depth of the mold between segment is almost
at or less than than minimum, replace the armature.
Depth : 0.5~0.8mm (0.02~0.03in)

Minimum : 0.2mm (0.008in.)
6. Gear
Wear and damage.
7. Bearing
Replace the bearing when it is noisy or does not rotate
smoothly.
8. Over-running clutch
(1) Replace the pinion when a worn pinion or damaged
pinion are found.
(2) If the pinion does not rotate in both directions when
rotating the pinion by hand, replace it.
NOTICE
Do not wash the over-running clutch is gas or
kerosening, this destroy the grease packing.
- 5-18 -


REASSEMBLY
Assemble in the reverse order of disassembly referring to the following points.
1. Measure the thrust gap by moving the pinion shaft axial
direction.
Adjust the play within the adjusting washer.
Standard play : Less than 0.5mm (0.02in)
2. Lever installation
Install the lever as shown in figure.
3. Rear bracket installation

Align the matching marks when assembling the rear
bracket.
3. When disassembling or assembling or assembling the

starter, grease each sliding part, gear and bearing.
(1) Armature shaft gear.

(2) Reduction gear.
(3) Ball bearing. (both ends armature)
(4) Bearing box of rear bracket.
(5) Snap ring of pinion shaft.
(6) Sleeve bearing, pinion lever sliding part, others.

- 5-19 -


Troubleshooting
SYMPTOM TROUBLESHOOTING
1 Will not crank - Starter motor does not operate
Step Inspection Action
1 Yes Check charging system

Check if engine cranks with fully charged battery
No Go to next step.
2 Check if battery voltage is applied at B terminal Yes Go to next step
No Check wire harness
3 Check if battery voltage is applied at S terminal • Check magnetic switch

when ignition switch in START position Yes • Check field coil
• Check armature
• Check park/neutral switch (ATX)

No • Check ignition switch
• Check wire harness
2 Will not crank - starter motor spins
1 Check if drive pinion is pulled out while cranking Remove starter and check flywheel ring
Yes
(Click heard when pulled out) gear teeth and starter drive pinion teeth
• Check magnetic switch

No
• Check field coil
- 5-20 -


3 Cranks slowly
1 Check if engine cranks normally with fully Yes Check charging system
charged battery No Go to next step
2 Check starter cable connection for looseness Yes Replace or replace connection
and corrosion
No Crank for starter (brush, armature, etc)
- 5-21 -


Preheating System
Schematic Diagrams

- 5-22 -


QUICK START SYSTEM (QSS)

SYSTEM OPERATION
The Quick Start System has three functions: Pre-heating, Chopping, and After-glow; as used in the
previous model. Each function operates as follows:
1. Pre-heating: After ignition switch is turned to ON position, current flows to glow plug for 7 sec.
2. Chopping: While engine switch is in START position, current flows to glow plug continuously.
3. After-glow (coolant temperature below 30°C (86°F):
(1) When engine switch is kept in ON position after pre-heating, current flows to glow plug continuously
for 15 sec.
(2) After engine has stared, current flows to glow plug continuously for 15 sec.
4. Indicator lamp: Indicator illuminates for 5 sec. after ignition is ON position.

- 5-23 -


Preliminary Checks
When troubleshooting, check below first.
1. Main fuse
2. Fuses
3. Connectors
4. Ground circuit
5. Wiring harness
Condition Cause
Glow plug relay does not close. 1. Faulty glow plug relay
2. Faulty control unit internal circuit
3. Poor contact or disconnection between control unit terminal
"L" and harness
4. Faulty START harness (open circuit at "F" terminal in control
unit
5. Poor contact or disconnection between glow plug relay
terminal and harness
6. Faulty glow plug
Glow lug relay does not open. 1. Faulty glow plug relay
Glow plug relay does not repeat ON and 1. Faulty poor contact of engine switch
OFF. 2. Poor contact or disconnection of starter harness
Glow plug relay does not repeat ON and 1. Faulty water temperature switch
OFF within 15 sec. after turning the engine 2. Faulty control unit internal circuit
switch ON. 3. Faulty glow plug relay
4. Poor contact or disconnection between control unit "C" and
water temperature switch
- 5-24 -


System normal state

1. When setting the ignition switch to ON.
A. When the engine coolant temperature is below 30°C - The glow plug relay continues about 7 seconds
and works on ON-OFF cycle. (15 seconds after ignition switch to ON).
B. When the engine coolant temperature is above 30°C - The glow plug relay continues about 7 seconds
and does not work on ON-OFF cycle.
2. When setting the ignition switch to START.

A. The glow plug relay starts work on ON-OFF cycle.
3. When turning the ignition switch from START to ON.

A. When the engine coolant temperature is below 30°C - The glow plug relay works on ON-OFF cycle for
15 seconds.
B. When the engine coolant temperature is above 30°C - The glow plug relay does not continue.
∴ The continuity of glow plug relay can be recognized by working sound "click".
- 5-25 -


REPAIR PROCEDURES
INSPECTION
Glow plug relay
1. As shown in the figure connect the battery and an ohmmeter
to the relay.
2. If the ohmmeter shows continuity when the battery is
connected, and no continuity when the battery is
disconnected, the relay is good.
3. Replace the relay if it fails this test.
Glow plug
1. Check the continuity between the positive terminal of the glow
plug and cylinder head with a circuit tester.
2. If there is no continuity, replace the glow plug.
REMOVAL
Glow plug
Remove in the following order:
1. Glow plug connector attaching nut.
2. Glow plug connector.
3. Glow plug.
INSTALLATION
Install the glow plug, reverse order of removal.
- 5-26 -

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R2 DIESEL ENGINE WORKSHOP MANUAL

Ford Motor Company

Fundamental procedures 0-2

Symbol Meaning Type

New engine oil, gear oil, etc. as

Apply brake fluid Only brake fluid

Apply automatic transmission

Apply grease Appropriate grease

Apply sealant Appropriate sealant

Apply petroleum jelly Appropriate petroleum jelly

NOTICES, CAUTIONS, AND WARNINGS

PROTECTION OF THE VEHICLE

A WORD ABOUT SAFETY

PREPARATION OF TOOLS AND MEASURING EQUIPMENT

SPECLAL SERVICE TOOLS (SST'S)

CLEANING PARTS FOR REUSE

1. Sealant should be applied or new gaskets used.

RUBBER PARTS AND TUBING

JACK AND SAFETY STAND POSITIONS

2. Safety stand positions :

2. Safety stand positions :

VEHICLE LIFT (2-SUPPORT TYPE)

2. WITH MANUAL TRANSMISSION

3. WITH AUTOMATIC TRANSMISSION

IDENTIFICATION NUMBER LOCATIONS

1. Engine model and number

2. Vehicle identification number (VIN)

rpm Revolutions per minute

Ω Ohm (s) (resistance)

kPa (kg/cm², psi) Pressure (usually negative)

mmHg (inHg) Pressure (usually negative)

liters (US qt, lmp qt) Volume

• The jumper wire is used for testing by shorting across

Electrical troubleshooting tester

(2) Check the terminals of waterproof connectors from

Sensors, Switches, and Relays

CODE COLOR CODE COLOR

LB Light Blue Y Yellow

Engine Mechanical System

Tune-up procedure 1-8

Disassembly related to cylinder head 1-32

Cylinder head bolt

ENGINE MODEL MAGMA or R2

Valve system Direct drive, OHC

Bore and stroke mm (in.) 86.0 X 94.0 (3.39 X 3.70)

Compression ratio 22.9 : 1

Compression pressure 30 kg/cm² (427 lb/in²) - 200 rpm

Open BTDC 10°

Intake 0.25 mm (0.098 in.)

Idling speed 750~800

Injection order 1-3-4-2

Insufficient power Insufficient Improper valve clearance Adjust

Weak or broken valve spring Replace

Burned cylinder head gasket Replace

Cracked or distorted cylinder head Replace

Sticking, damaged, or worn piston

Malfunction of fuel system Refer to EC

Excessive oil Oil working up Worn or sticking piston ring or

Oil working down Bad valve seal Replace