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ENGINE MECHANICAL
SECTION EM EM
CONTENTS
PRECAUTIONS ......................................................... 1 Disassembly......................................................... 39
Parts Requiring Angular Tightening....................... 1 Inspection............................................................. 39
Liquid Gasket Application Procedure .................... 1 Assembly.............................................................. 45
PREPARATION ......................................................... 2
Special Service Tools ............................................ 2 TD
Commercial Service Tools..................................... 7
OUTER COMPONENT PARTS ............................... 49
COMPRESSION PRESSURE.................................. 51
KA
Measurement of Compression Pressure ............. 51
OUTER COMPONENT PARTS ................................. 9 OIL PAN................................................................... 52
COMPRESSION PRESSURE.................................. 10 Removal ............................................................... 52
Measurement of Compression Pressure ............. 10 Installation ............................................................ 52
OIL PAN................................................................... 11 CYLINDER HEAD.................................................... 53
Removal ............................................................... 11 Removal ............................................................... 54
Installation ............................................................ 12 Disassembly......................................................... 55
TIMING CHAIN ........................................................ 13 Inspection............................................................. 56
Removal ............................................................... 13 Assembly.............................................................. 62
Inspection............................................................. 17 Installation ............................................................ 63
Installation ............................................................ 17 OIL SEAL REPLACEMENT .................................... 67
OIL SEAL REPLACEMENT .................................... 22 ENGINE REMOVAL................................................. 69
Valve Oil Seal ...................................................... 22 Removal ............................................................... 70
Front Oil Seal....................................................... 22 Installation ............................................................ 70
Rear Oil Seal ....................................................... 23 ENGINE OVERHAUL .............................................. 71
CYLINDER HEAD.................................................... 24 Disassembly......................................................... 72
Removal ............................................................... 25 Inspection and Replacement ............................... 74
Disassembly......................................................... 27 Assembly.............................................................. 86
Inspection............................................................. 27
Assembly.............................................................. 33 KA
Installation ............................................................ 34
SERVICE DATA AND SPECIFICATIONS (SDS) ... 91
ENGINE REMOVAL................................................. 36
General Specifications ......................................... 91
Removal ............................................................... 37
Inspection and Adjustment .................................. 91
Installation ............................................................ 37
CYLINDER BLOCK ................................................. 38
TD
SERVICE DATA AND SPECIFICATIONS (SDS) ... 98
General Specifications ......................................... 98
Inspection and Adjustment .................................. 98
PRECAUTIONS
Parts Requiring Angular Tightening
q Use an angle wrench for the final tightening of the following
engine parts:
(1) Cylinder head bolts
(2) Connecting rod cap nuts for gasoline engines
q Do not use a torque value for final tightening.
q The torque value for these parts are for a preliminary step.
q Ensure thread and seat surfaces are clean and coated with
engine oil.
Liquid Gasket Application Procedure
a. Use a scraper to remove all traces of old liquid gasket
from mating surfaces and grooves. Also, completely
clean any oil from these areas.
b. Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
q For oil pan, be sure liquid gasket diameter is 3.5 to
4.5 mm (0.138 to 0.177 in) for gasoline engines.
q For areas except oil pan, be sure liquid gasket diam-
eter is 2.0 to 3.0 mm (0.079 to 0.118 in) for gasoline
SEM164F
engines and 2.5 to 3.5 mm (0.098 to 0.138 in) for
diesel engines.
c. Apply liquid gasket around the inner side of bolt holes
(unless otherwise specified).
d. Assembly should be done within 5 minutes after coating.
e. Wait at least 30 minutes before refilling engine oil and
engine coolant.
AEM080
EM-1
PREPARATION
Special Service Tools
*: Special tool or commercial equivalent
Tool number Engine application
Description
Tool name KA TD
ST0501S000* Disassembling and assem-
Engine stand assembly bling
V ST05011000
1
Engine stand
V ST05012000
2
X X
Base
NT042
KV10105001*
Engine attachment
X --
NT031
KV10106500*
Engine attachment
-- X
NT028
KV11103200*
Engine sub-attachment
-- X
NT246
KV10111200* Disassembling and assem-
Adapter bling valve components
-- X
NT687
EM-2
PREPARATION
Special Service Tools (Cont'd)
Tool number Engine application
Description
Tool name KA TD
KV101092S0* Disassembling and assem-
Valve spring compres- bling valve components
sor
V KV10109210
1
Compressor
X X
V2 KV10109220
Adapter
NT021
KV109B0010 Installing valve oil seal
Valve oil seal drift
X --
NT027
KV11105300 Installing valve oil seal
Valve oil seal drift
a: 20 (0.79) dia.
b: 14.6 (0.575) dia.
c: 13.3 (0.524) dia. -- X
d: 8.5 (0.335) dia.
e: 17.5 (0.689)
f: 4.5 (0.177)
NT602 Unit: mm (in)
KV11105400* Installing valve guide
Valve guide drift
a: 20 (0.79) dia. -- X
b: 12.2 (0.480) dia.
c: 16 (0.63)
NT637 Unit: mm (in)
EM03470000* Installing piston assembly
Piston ring compressor into cylinder bore
X X
NT044
ST16610001* Removing crankshaft pilot
Pilot bushing puller bushing
X X
NT045
KV10111100 Removing oil pan
Seal cutter
X X
NT046
EM-3
PREPARATION
Special Service Tools (Cont'd)
Tool number Engine application
Description
Tool name KA TD
WS39930000* Pressing the tube of liquid
Tube presser gasket
X X
NT052
KV10107902* Disassembling valve oil
Valve oil seal puller seal
V KV10116100
1
Valve oil seal puller
-- X
adapter
NT605
KV10110300 Disassembling and assem-
Piston pin press stand bling piston with connect-
assembly ing rod
V KV10110310
1
Cap
V KV10110330
2
Spacer
V ST13030020
3 X --
Press stand
V4 ST13030030
Spring
V5 KV10110340
Drift
V KV10110320
6
Center shaft NT036
KV10112100 Tightening bolts for bearing
Angle wrench cap, cylinder head, etc.
X X
NT014
EG15060000
Compression gauge
and adapter
X --
NT238
EM-4
PREPARATION
Special Service Tools (Cont'd)
Tool number Engine application
Description
Tool name KA TD
1
V ED19601000 Checking compression
Compression gauge pressure
2
V ED19600600
Compression gauge
adapter (for glow
plug hole)
3
V ED19600700
Compression gauge -- X
adapter (for injector
hole)
4
V ED19600800
Compression gauge
adapter (Useless)
NT625
KV10106001* Removing oil filter
Oil filter wrench
-- X
NT690
KV10105800*
Chain stopper
X --
NT010
1
V KV11101110 Removing valve seat
Valve seat remover
2
V KV11103610
Adapter (Intake)
3
V KV11103620
Adapter (Exhaust)
-- X
NT251A
1
V ST15243000 Installing valve seat
Valve seat drift
2
V KV11103810
Adapter (Intake)
3
V KV11103820
Adapter (Exhaust) -- X
NT252A
EM-5
PREPARATION
Special Service Tools (Cont'd)
Tool number Engine application
Description
Tool name KA TD
1
V KV11104010 Removing and
Cylinder liner tool installing cylinder
2
V KV11104110 liner
Adapter for remov-
ing
3
V KV11104030
Adapter for installing
-- X
NT681A
KV111033S0 Preventing crankshaft from
Engine stopper rotating
V KV11103310
1
a: 3 (0.12)
Stopper plate
b: 6.4 (0.252)
V2 KV10105630
c: 2.8 (0.110) -- X
Stopper gear d: 6.6 (0.260)
e: 119 (4.69)
f: 12 (0.47)
g: 18 (0.71)
NT616
Unit: mm (in)
KV111045S0 Removing cam bushing or
Cam bushing replacer installing cam bushing
set
V KV11104510
1
Replacer bar
V KV11104520
2
-- X
Guide plate
V KV11104530
3
Adapter
(1st bushing)
V4 ST15243000
NT610
Drift
KV10109300* Preventing drive gear from
Pulley holder rotating
-- X
a: 68 mm (2.68 in)
NT628 b: 8 mm (0.31 in) dia.
KV11103000* Removing drive gear
Injection pump drive
gear puller
-- X
NT676
EM-6
PREPARATION
Commercial Service Tools
Engine application
Tool name Description
KA TD
Pulley holder Holding camshaft pulley
while tightening or loosen-
ing camshaft bolt
X --
NT035
Valve seat cutter set Finishing valve seat dimen-
sions
X X
NT048
Piston ring expander Removing and installing
piston ring
X X
NT030
Valve guide reamer Reaming valve guide inner
V or hole for oversize
1
valve guide V
2
Diameter (Intake/Exhaust)
KA24E
d1: 7.000 - 7.018
(0.2756 - 0.2763)/
8.000 - 8.018
(0.3150 - 0.3157)
d2: 11.175 - 11.196
(0.4400 - 0.4408)/ X X
12.175 - 12.196
(0.4793 - 0.4802)
NT016 NA20S and Z24S
d1: 8.000 - 8.018
(0.3150 - 0.3157)
d2: 12.175 - 12.196
(0.4793 - 0.4802)
QD32 and TD27
d1: 8.000 - 8.015
(0.3150 - 0.3156)
d2: --
Unit: mm (in)
Valve guide drift Removing and installing
valve guide
Diameter (Intake/Exhaust)
KA24E
a: 10.5 (0.413)/11.5 (0.453)
b: 6.6 (0.260)/7.6 (0.299) X X
NA20S
a: 11.5 (0.453)
b: 6.5 (0.256)
NT015 Z24S, QD32 and TD25
a: 11.5 (0.453)
b: 7.6 (0.299)
Unit: mm (in)
EM-7
PREPARATION
Commercial Service Tools (Cont'd)
Engine application
Tool name Description
KA TD
Rear oil seal drift Installing rear oil seal
a: 98 (3.86) dia.
b: 86 (3.39) dia.
c: 15.9 (0.626) dia. X --
d: 33 (1.30)
e: 14.5 (0.571)
f: 10.5 (0.413)
NT608 Unit: mm (in)
EM-8
OUTER COMPONENT PARTS KA
SEM811F
EM-9
COMPRESSION PRESSURE KA
Measurement of Compression Pressure
1. Warm up engine.
2. Turn ignition switch OFF.
3. Release fuel pressure.
Refer to EC section (``Fuel Pressure Release'', ``BASIC SER-
VICE PROCEDURE'').
4. Remove all spark plugs.
5. Disconnect distributor center cable.
6. Attach a compression tester to No. 1 cylinder.
7. Depress accelerator pedal fully to keep throttle valve wide
open.
8. Crank engine and record highest gauge indication.
9. Repeat the measurement on each cylinder.
q Always use a fully-charged battery to obtain specified
engine speed.
Compression pressure:
kPa (bar, kg/cm2, psi)/rpm
Standard
SEM113B 1,324 (13.24, 13.5, 192)/300
Minimum
981 (9.8, 10, 142)/300
Difference limit between cylinders
98 (0.98, 1.0, 14)/300
10. If compression in one or more cylinders is low:
a. Pour a small amount of engine oil into cylinders through
spark plug holes.
b. Retest compression.
q If adding oil helps compression, piston rings may be
worn or damaged. If so, replace piston rings after check-
ing piston.
q If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve seat.
(Refer to SDS.) If valve or valve seat is damaged
excessively, replace them.
q If compression stays low in two cylinders that are next
to each other:
a. The cylinder head gasket may be leaking, or
b. Both cylinders may have valve component damage.
Inspect and repair as necessary.
EM-10
OIL PAN KA
SEM566F
Removal
1. Raise vehicle and support it with safety stands.
2. Remove engine under cover.
3. Drain engine oil.
4. Remove front final drive together with differential mounting
member. Refer to PD section (``Removal and Installation'',
``Front final drive'') -- 4WD models only.
5. Remove front suspension member bolt (RH & LH).
SEM600F
6. Remove oil pan bolts.
SEM567F
7. Remove oil pan.
a. Insert Tool between cylinder block and oil pan.
q Be careful not to damage aluminum mating surface.
q Do not insert screwdriver, or oil pan flange will be dam-
aged.
b. Slide Tool by tapping on the side of the Tool with a hammer.
8. Pull out oil pan from front side.
SEM365EA
EM-11
OIL PAN KA
Installation
1. Use a scraper to remove old liquid gasket from mating sur-
face of oil pan.
q Also remove traces of liquid gasket from mating surface
of cylinder block.
SEM568F
2. Apply a continuous bead of liquid gasket to mating surface
of oil pan.
q Use Genuine Liquid Gasket or equivalent.
q Apply to groove on mating surface.
q Allow 7 mm (0.28 in) clearance around bolt hole.
SEM569F
SEM015E
q Be sure liquid gasket diameter is 3.5 to 4.5 mm (0.138 to
0.177 in).
q Attaching should be done within 5 minutes after coating.
SEM086E
3. Install oil pan.
q Tighten oil pan bolts in numerical order.
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