workshop manual - daihatsu 3 cyl 993cc efi

SERVICE SPECIFICATIONS

CB-41 CB-42

Pickup 4.4 i Coolant capacity

Van 4.6 I

Without oil filter 2.9 I Oil capacity

With oil filter 3.1 I

Intake 0.2 ± 0.05 mm/0.0078 ± 0.002 inch Valve clearances (HOT)

Exhaust 0.2 ± 0.05 mm/0.0078 ± 0.002 inch

CHAMPION NGK NIPPONDENSO

RN9YC BPR5EY W16EXR-U

Spark plug gap

0.7 - 0.8 mm (0.028 - 0.031 inch)

0.8 - 0.9 mm (0.031-0.035 inch)

0.7 - 0.8 mm (0.028-0.031 inch)

Ignition timing BTDC°/rpm 5 ±2/950 5±2/900

Idle speed rpm 950 ±50 900 ±50

CO concentration 1.5 % Not to exceed 0.2 % CO/HC concentrations

HC concentration Not to exceed 1000 ppm Not to exceed 100 ppm

STD LISMPa^kgf /cm 2)

Compression pressure Minimum 1.03 MPa (10.5 kgf/cm2)

350 rpm

Difference between cylinders 0.098 MPa(1.0kgf/cm2)

Camshaft 119.9 mm (4.270 inch) Timing belt pulley Wear limit (Minimum limit-)

Crankshaft 59.2 mm (2.331 inch)

Front STD 0.04 - 0.14 mm (0.0016 - 0.0055 inch)

Center STD 0.09 - 0.19 mm (0.0035 - 0.0075 inch)

Oil clearance

Rear STD 0.06 - 0.16 mm (0.0024 - 0.0063 inch)

Front 31.960 - 31.980 mm (1.2583 - 1.2591 inch)

Center 47.385 - 47.410 mm (1.8656 - 1.8665 inch)

Reference Journal diameter

Rear 48.415 - 48.440 mm (1.9061 - 1.9071 inch)

Intake Minimum limit 39.8 mm (1.5669 inch) Cam lobe height

Exhaust Minimum limit

39.8 mm (1.5669 inch)

Runout [Bend] 0.03 mm (0.0012 inch)

Camshaft

Uneven wear of camshaft journal Maximum limit 0.02 mm (0.0008 inch)

Cylinder block side

Intake manifold side

Flatness

Exhaust manifold side

0.1 mm

Intake

Cylinder head

Valve seat angel

Exhaust

45°

Intake 0.040 - 0.075 mm (0.0016 - 0.0030 inch) Valve guide bushes Oil clearance

Exhaust 0.045 - 0.080 mm (0.0018 - 0.0031 inch)

CB-41 CB-42

Contact width with valve seat 1.0 - 1.8 mm (0.0394 - 0.0709 inch)

Valve face angle 45.5°

Intake 0.9 -1.5 mm (0.035 - 0.059 inch) Valve stock thickness

Exhaust 1.2 -1.8 mm (0.047 - 0.071 inch)

Intake 6.945 - 6.960 mm (0.2734 - 0.2740 inch) Valve stem outer diameter

Exhaust 6.940 - 6.955 mm (0.2732 - 0.2738 inch)

Intake 101.65 mm (4.002 inch)

Valves

Overall length

Exhaust 101.65 mm (4.002 inch)

Free length 43.3 mm (1.7047 inch)

STD 29.9 kg

Vaive spring

Installed tension at 34.9 mm

Minimum limit 25.7 kg

Oil clearance between rocker arm and rocker shaft 0.016 - 0.09 mm (0.0006 - 0.0035 inch)

Valve rocker arm inner diameter 16.000 -16.018 mm (0.6299 - 0.6306 inch)

Valve rocker arm and valve rocker shaft

Vaive rocker shaft outer diameter 15.958 -15.984 mm (0.6283 - 0.6293 inch)

Valve rocker arm spring Minimum free length 33 mm (1.299 inch)

STD Cylinder block Flatness cylinder head gasket attaching surface

Maximum limit

0.1 mm (0.0039 inch)

STD 0.03 - 0.12 mm (0.0012 - 0.0047 inch) Oil clearance between piston-tc-cylinder

Maximum limit 0.12 mm (0.0047 inch)

STD 76.00 - 76.03 mm (2.9921 - 2.9933 inch)

O/S 0.25 76.25 - 76.28 mm (3.0020 - 3.0031 inch)

Cylinder

Cylinder bore diameter (When over size piston is used)

O/S 0.50 76.50 - 76.53 mm (3.0118 - 3.0130 inch)

No. 1 0.03 - 0.07 mm (0.0012 - 0.0028 inch) Piston ring groove-to-piston ring side clearance

No. 2 0.02 - 0.06 mm (0.0008 - 0.0024 inch)

No. 1 1.47 -1.49 mm (0.0579 - 0.0587 inch) Piston ring thickness

No. 2 1.47 -1.49 mm (0.0579 - 0.0587 inch)

No. 1 0.20 - 0.70 mm (0.008 - 0.028 inch)

No. 2 0.20 - 0.70 mm (0.008 - 0.028 inch)

Piston, piston pin and piston rings

Piston ring end gap

Oil 0.20 -1.10 mm (0.008 - 0.043 inch)

Piston-to-piston pin oil clearance Maximum limit 0.03 mm (0.0012 inch) Piston, piston pin and piston rings

Piston pin-to-connecting rod interference fit 0.012 - 0.019 mm (0.0005 - 0.0019 inch)

Big end thrust clearance 0.150 - 0.30 mm (0.0059 - 0.0118 inch)

Maximum bend 0.05 mm (0.0020 inch)

Connecting rod

Maximum twist 0.05 mm (0.0020 inch)

Crankshaft bend 0.06 mm (0.0024 inch)

Uneven wear of main journal and crankpin journal 0.01 mm (0.0004 inch)

Main and crankpin journal oil clearance 0.020 - 0.070 mm (0.0008 - 0.0027 inch)

Crankshaft

Crankshaft thrust clearance 0.02 - 0.30 mm (0.0008 - 0.0118 inch)

CB-41 CB-42

Balance shaft thrust clearance 0.03 - 0.20 mm (0.0012 - 0.0078 inch) Balance shaft

Balance shaft bearing oil clearance 0.025 - 0.1 mm (0.0010 - 0.0039 inch)

Camshaft timing belt pulley outer diameter Minimum limit

119.9 mm (4.270 inch) Timing belt pulley

Crankshaft timing belt pulley outer diameter Minimum limit

59.2 mm (2.331 inch)

Fly wheel Run out Maximum limit 0.10 mm (0.0039 inch)

Crankshaft main journal bearing

Bearing center thickness Replacement STD bearing Undersize 0.25 bearing Undersize 0.50 bearing

1.986 - 2.006 mm (0.0782 - 0.0790 inch) 2.111 -2.131 mm (0.0831 - 0.0839 inch) 2.236 - 2.256 mm (0.0880 - 0.0888 inch)

Crankpin journal bearing (Connecting rod bearing)

Bearing center thickness Replacement STD bearing Undersize 0.25 bearing Undersize 0.50 bearing

1.486 -1.506 mm (0.0585 - 0.0593 inch) 1.611 -1.631 mm (0.0634 - 0.0642 inch) 1.736 -1.756 mm (0.0683 - 0.0691 inch)

Crankshaft thrust bearing

Bearing center thickness STD Oversize 0.25 bearing Oversize 0.50 bearing

1.940 - 1.990 mm (0.0764 - 0.0783 inch) 2.065 - 2.115 mm (0.0813 - 0.0833 inch) 2.190 - 2.240 mm (0.0862 - 0.0882 inch)

PEM00079O0000

TIGHTENING TORQUE

Tightening torque Tightening components

N-m kgf-m ft-lb

Cylinder head x Spark plug 14.7 - 21.6 1.5-2.2 10.8 - 15.9 Cylinder head x Cylinder block 53.9 - 63.7 5.5 - 6.5 39.8 - 42.0

Cylinder head cover x Cylinder head M8 7.8 -11.8 0.8- 1.2 5.8 - 8.7

M6 2.9 - 4.9 0.3 - 0.5 2.2 - 3.6

Timing belt cover 2.0 - 3.9 0.2 - 0.4 1.4-2.9

Crankshaft bearing cap x Cylinder block 53.0 - 64.7 5.4 - 6.6 39.1 - 47.7

Cylinder block x Oil pan 3.9 - 6.9 0.4 - 0.7 2.9 - 5.1 Cylinder block x Balance shaft thrust plate 9.8 -14.7 1.0-1.5 7.2 -10.8

Connecting rod x Connecting rod cap 23.5 - 30.4 2.4 - 3.1 17.4-22.4

Flywheel x Crank shaft 39.2 - 49.0 4.0 - 5.0 28.9 - 36.2 Crankshaft pulley x Crankshaft 88.3 - 98.0 9.0 - 10.0 65.1 - 72.0

Camshaft timing belt pulley x Camshaft 29.4-44.1 3.0 - 4.5 21.7-32.5

Timing belt tensioner x Balance gear cover 33.3-44.1 3.0 - 4.5 21.7-32.5

Cylinder block x Oil pump 14.7 - 21.6 1.5 - 2.2 10.8 -15.9

Water pump x Water pump pulley 5.9 - 8.8 0.6 - 0.9 4.3 - 6.5 Cylinder head x Intake manifold 14.7 - 21.6 1.5-2.2 10.8 - 15.9

Cylinder head x Exhaust manifold 14.7-21.6 1.5 - 2.2 10.8 - 15.9

Balance shaft gear cover x Cylinder block 9.8 - 15.7 1.0-1.6 7.2-11.6 Balance shaft weight x Balance shaft 29.4-44.1 3.0 - 4.5 21.7-32.5

Oxygen sensor x Exhaust manifold 29.4 - 39.2 3.0 - 4.0 21.7-28.9

Coolant temperature sensor x Cylinder head 24.5 - 34.3 2.5 - 3.5 18.1 -25.3

Intake air temperature sensor x Intake manifold 29.4 - 39.2 3.0 - 4.0 21.7-28.9

Coolant temperature sender x Intake manifold 9.8- 17.6 1.0-1.8 7.2 - 13.0

Delivery pipe x Intake manifold 14.7-21.6 1.5-2.2 10.8 - 15.9

HW-15

WIRE HARNESS CONNECTING TABLE ENGINE

Item Circuit Item Wire size & color Dim-Dip relay (2) A25 | A35 Dim-Dip resister (-) 0.5 L Headlight LH (Lo) A3 | A37 Dim-Dip resister (LH) 0.5 R-G Headlight RH (Lo) A4 i A38 Dim-Dip resister (RH) 0.5 R-B Meter (charge) D1 D2 IC alternator (L) 0.5 LW Back-up lamp SW G1 G2 Back-up lamp (+) 0.5 RY Oil pressure SW H1 H2 Meter (oil) 0.5 YW Meter (temp.) H3 H4 Water temp, sensor 0.5 YL J/B (Fuse, heater) K1 K2 Back-up lamp SW 0.85 LB J/B (Fuse, engine) L1 L2 Fuel cut solenoide 0.85 WR Connect to L1-L2 L1 L3 IC alternator (IG) 0.85 WR Connect to L1-L2 L6 Carburetor (outer vent V/V) 0.85 WR Connect to L1-L2 L1 L21 Water temp. SW (PXC) 0.85 WR PYC heater L22 L23 Water temp. SW(PXC) 0.85 LR Main fuse Ml M2 Starter (B) 3 WR J/B (Ignition ST) M3 M4 Starter (ST) 2 BY Main fuse N1 N2 IC alternator (B) 3 W J/B (Ignition SW (IG)) N3 N4 Ignition coil (B) Z BL Distributor (-) N5 N6 Ignition coil (-) 0.85 BR Connect to N5-N6 N5 N11 F/C amp. 0.5 BR Connect to N3-N4 N3 N20 Distributor (+) 1.25 BL Ignition coil (+) N22 N23 Condenser Z BW Ignition coil (-) N6 N24 Resister (+) 0.5 BR Connect to N5-N6 N5 N25 Resister (-) 0.5 BR Choke SW (-) 06 010 Water temp. SW (choke) 0.5 Y-B

HWO0033-OO0OO

HW-17

Item Circuit Item Wire size & color

Oil pressure SW (+) H4 H5 Meter combination (oil pressure) 0.5 W-Y Meter combination, (coolant temp.) H6 H7 (Coolant temp, sensor (+)) 0.5 Y-L Connect to H6-H7 H6 H8 A/C amp. (9) 0.5 Y-L J/B (Fuse: wiper) I1 | I2 Front wiper motor (+) 1.5 L-R Front wiper SW (+1) I3 I4 Front wiper motor (+1) 0.5 V-Y Front washer motor (-) I5 I6 Front wiper SW (washer) 0.5 L Front wiper SW (+2) I7 I8 Front wiper motor (+2) 0.5 L-B Connect to I1-I2 I1 I9 Front washer motor (+) 1.0 L-R Rear wiper SW (washer) I10 I11 Rear washer motor (-) 0.5 L-W Rear wiper SW (+) I12 I13 Rear wiper motor (-) 0.5 V-Y Connect to I1-I9 I1 I14 Rear wiper motor (+) 1.0 L-R Connect to I1-I9 I1 I15 Rear washer motor (+) 1.0 L-R J/B (Intermittent wiper relay: S) I16 I17 Front wiper motor (S) 0.5 L-W Connect to K5-K6 J J Connect to K36-K14 1.0 L-B J/B (Fuse: Deffoger (L)) K1 K2 Deffoger SW (+) 1.5 B-R Deffoger SW (-) K3 K4 Deffoger (+) 1.0 L J/B (Fuse: Heater (L)) K5 K6 Heater blower motor (+) 1.0 L-B Heater blower SW (Hi) K7 K8 Heater blower motor (-) 0.5 L-W Heater blower motor (-) K8 K9 Heater resister (Hi) 0.5 L-W Heater blower SW (Me) K10 K11 Heater resister (Me) 0.5 V-B Heater blower SW (Lo) K12 K13 Heater resister (Lo) 0.5 L J/B (Fuse: Heater (L)) K36 K14 A/C SW (B) 1.0 L-B A/C SW (-) K15 K16 Dual pressure SW (+) 1.0 V-Y Connect to K5-K6 K5 K17 Back lamp SW (+) 0.5 L-B Connect to K5-K6 K5 K18 Meter combination (+B) 0.5 L-B A/C amp. (4) K54 K21 Idle up VSV (-) 0.5 R A/C amp. (5) K55 K25 Compressor magnet clutch (+) 0.5 L-R A/Camp. (10) K60 K30 Water temp, gauge (7V) 0.5 Y Idle up VSV (+) K32 K33 A/C amp. (3) 1.0 L-B Connect to K12-K13 K12 K58 A/C amp. (8) 0.5 L Condenser fan relay (M-) K65 K69 Condenser cooling fan motor (-) 2.5 B A/C amp. (6) K56 K83 Fuse, A/C (L) 0.5 O J/B (Fuse: Engine (L)) L1 L2 Radiator cooling fan motor (+) 1.5 W-R Connect to L1-L2 L1 L7 Fuel pump relay (+B) 0.5 W-R J/B (Fuse: Engine No. 2) N34 L11 Alternator (IG) 0.5 W-R Connect to L1-L2 L1 L12 Dim-Dip relay (7) 0.5 W-R Main fuse (B) M1 M2 Starter (B) 4.0 W-L IG SW (ST) M3 M4 Starter (ST) 2.5 B-Y Connect to M3-M4 M3 M5 Fuel pump relay (ST) 2.5 B-Y Main fuse (L) N1 | N2 J/B (IG SW (B)) 4.0 j W Connect to N1-N2 N1 N3 IG SW (B) 4.0 W Connect to N11-N5 N11 N4 Fuel pump relay (IG pulse) 0.5 B-R Connect to N1-N2 N1 N6 Alternator (B) 4.0 W J/B (IG coil B) N17 N8 IG coil (B) 4.0 B A/C amp. (14) N11 N15 Ignition coil (-) 0.5 B-R IG SW (IG) N7 N15 J/B (IG SW (IG)) 4.0 B Connect to N7-N45 N7 N16 J/B (IG SW (IG)) 4.0 B IG SW (IG2) N30 N31 Fuse holder (Fuse: Engine No. 2) 4.0 W-L Meter combination (charge) 03 04 Alternator (L) 0.5 W-G Engine coolant temp. SW (B) O10 06 Choke SW (-) 0.5 Y-B Meter combination (choke) 07 08 Choke SW (+) 0.5 Y-R

HW-20

item Circuit Item Wire size & coior

Fuel level sender (+) H2 H3 Meter combination (Fuel) 0.5 Y-G Oil pressure SW (+) H4 H5 Meter combination (oil pressure) 0.5 W-Y Meter combination (coolant temp.) H6 H7 Coolant temp, sender (+) 0.5 Y-L Connect to H6-H7 H6 H8 Thermistor (A/C) 0.5 Y-L J/B (Fuse: wiper) 11 12 Front wiper motor (+) 1.5 L-R Front wiper SW (+1) 13 14 Front wiper motor (+1) 0.5 V-Y Front washer motor (-) 15 16 Front wiper SW (Washer) 0.5 L Front wiper SW (+2) 17 18 Front wiper motor (+2) 0.5 L-B Connect to 11-12 11 19 Front washer motor (+) 1.0 L-R J/B (Intermittent wiper relay: S) 116 117 Front wiper motor (S) 0.5 L-W Connect to K5-K6 J J K36-K14 1.0 L-B J/B (Fuse: Heater (L)) K5 K6 Heater blower motor (+) 1.0 L-B Heater blower SW (Hi) K7 K8 Heater blower motor (-) 0.5 L-W Heater blower motor (-) K8 K9 Heater resister (Hi) 0.5 L-W Heater blower SW (Me) K10 K11 Heater resister (Me) 0.5 V-B Heater blower SW (Lo) K12 K13 Heater resister (Lo) 0.5 L J/B (Fuse: Heater (L)) K36 K14 A/C SW (B) 1.0 L-B A/C SW (-) K15 K16 Dual pressure SW (+) 1.0 V-Y Connect to K5-K6 K5 K17 Back lamp SW (+) 0.5 L-B Connect to K5-K6 K5 K18 Meter combination (+B) 0.5 L-B Connect to K12-K13 K12 K58 A/C amp. 0.5 L Connect to Z1-Z2 Z1 K61 A/C amp. 0.5 W-B A/C amp. K60 K70 Water temp gauge (7V) 0.5 Y J/B (Fuse: Engine (L)) L1 L2 Radiator cooling fan motor (+) 1.5 W-R Connect to L1-L2 L1 !_7 Fuel pump relay (+B) 0.5 W-R J/B (Fuse: Engine No. 2) N34 L11 Alternator (IG) 0.5 W-R Connect to L1-L2 L1 | L12 Dim-Dip relay (®) 0.5 W-R Main fuse (B) M1 M2 Starter (B) 4.0 W-L IG SW (ST) M3 M4 Starter (ST) 2.5 B-Y Connect to M3-M4 M3 M5 Fuel Dump relay (ST) 2.5 B-Y Main fuse (L) N1 N2 J/B (IG SW (B)) 4.0 W Connect to N1-N2 N1 N3 IG SW (B) 4.0 W Connect to B5-N20 N5 N4 Fuel pump relay (IG pulse) 0.5 B-R Connect to N1-N2 N1 N6 Alternator (B) 4.0 W J/B (IG coil (B)) N17 LJM8 IG coil (B) 4.0 B IGSW(IG) l N7 N15 J/B (IG SW (IG)) 4.0 B Connect to N7-N15 N7 N16 J/B (IG SW (IG)) 4.0 B IG coil (-) N5 N20 A/C amp. 0.5 B-R IG SW (IG2) N30 N31 Fuse holder (Fuse: Engine No. 2) 4.0 W-L Meter combination (charge) 03 04 Alternator (L) 0.5 W-G Engine coolant temp. SW (B) 010 06 Choke SW (-) 0.5 Y-B Meter combination (choke) 07 O8 Choke SW (+) 0.5 Y-R J/B (Fuse: ACC (L)) R1 R2 Cigarette lighter (+) L 1-° Connect to R1-R2 R1 R4 Radio (+) 0.5 ■ IG SW (ACC) R6 R7 J/B (IG SW (ACC)) 2.5 B-W Radio (speaker (+)) R13 R15 Speaker (+) 0.5 R-Y Radio (speaker (-)) R14 R16 Speaker (-) 0.5 B-Y Fuel pump relay (L) U7 U12 Fuel pump motor (+) 2.5 L Body earth (Front RH) Z1 Z2 Body earth (Front LH) 1.5 W-B Connect to 21-Z2 Z1 Z3 Meter combination (Earth) 0.5 W-B Connect to Z1-Z2 Z1 Z4 Courtesy SW (-) 0.5 W-B