engine identification overhaul procedures - general ...mitsugt.com/data/charadeoverhaul.pdf · 1.0l...

1.0L 3-CYL

1989 ENGINES Daihatsu - 1.0L 3-Cylinder

ENGINE IDENTIFICATION

The engine serial number is stamped on the exhaust manifold side of the engine block near the front of the cylinder head. The eight digit of the Vehicle Identification Number (VIN) identifies the engine.

REMOVAL & INSTALLATION

ENGINE

Removal

1. Disconnect battery cables, remove battery and battery carrier. Remove hood. Drain engine oil, transaxle oil and coolant. Disconnect accelerator cable at throttle body and remove retaining clamp. Disconnect clutch cable and speedometer cable at transaxle.

2. Mark and remove hoses from air cleaner. Remove air cleaner. Disconnect vent hose from valve cover. Mark and remove vacuum hoses from throttle body, brake booster, A/C fast idle and pressure Vacuum Switching Valve (VSV).

3. Disconnect ground cable at transaxle, engine and alternator. Disconnect wire clamp at ignitor. Disconnect wiring connector at ignitor, engine fuse block and cowl connector. Disconnect wiring at alternator and A/C compressor.

4. Cover fuel line at fuel filter with shop towel and carefully remove fuel line at fuel filter. Disconnect pressure sensor connector. Remove radiator and heater hoses.

5. Mark and remove vacuum hose between Bi-Metallic Vacuum Switching Valve (BVSV) and charcoal canister. Disconnect electrical connector at radiator fan motor. Remove radiator and A/C compressor drive belt.

6. Remove A/C compressor and lay aside. DO NOT disconnect hoses from compressor. Remove glove compartment door. Disconnect Electronic Control Unit (ECU) connector of engine harness. Remove engine harness clamps and pull engine harness toward the engine compartment.

7. Raise and support vehicle. Remove lower engine covers. Disconnect exhaust pipe at manifold. Disconnect exhaust pipe hangers and lower pipe. Remove stabilizer bar. Disconnect shift control rod at transaxle.

8. Disconnect lower arm at bracket and remove damper weight. See Fig. 1 . Pull axle shafts from transaxle. Disconnect front mount stopper and rear mount bracket at lower crossmember. See Fig. 2 .

NOTE: For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

WARNING: Fuel lines are under pressure. Use caution during removal to prevent personal injury.

1989 Daihatsu Charade CLS

1.0L 3-CYL' '1989 ENGINES Daihatsu - 1.0L 3-Cylinder



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Sábado, 01 de Marzo de 2008 El signo indica 10:49:30 p.m. © 2005 Mitchell Repair Information Company, LLC.

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Sábado, 01 de Marzo de 2008 El signo indica 10:49:36 p.m. Page 1 © 2005 Mitchell Repair Information Company, LLC.

Fig. 1: Disconnecting Lower Arm & Damper Weight Courtesy of DAIHATSU MOTOR CO., LTD.



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Fig. 2: Disconnecting Front Mount Stopper & Rear Mount Bracket Courtesy of DAIHATSU MOTOR CO., LTD.

9. Support engine with hoist. Remove engine mount rubber at upper right insulator and front mounting bracket bolts. Remove lower left insulator and rear mounting bolts. Remove front engine mount from cylinder head. Ensure all hoses and electrical connectors are removed. Remove engine.

Installation

1. To install, reverse removal procedure. Ensure front mount stopper is centered in engine lower mounting stopper during installation. Install new snap ring on axle shafts prior to installation.

2. Install new nut on stabilizer bar. Install new gasket on fuel line. Tighten bolts to specification. Adjust accelerator cable to obtain cable play of .120-.310" (3.05-7.87 mm). Adjust fluid levels.

CYLINDER HEAD & MANIFOLDS

CAUTION: Note direction and location of all vacuum hoses prior to REMOVAL. Hoses must be installed with painted areas installed in correct location.



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Removal

1. Disconnect negative battery cable. Drain coolant and engine oil. Remove timing belt. See TIMING BELT under CAMSHAFT. Mark hoses and remove oil cooler and throttle body hoses from throttle body.

2. Disconnect brake booster hose at upper intake manifold. On A/C equipped models, disconnect idle-up vacuum hose. Mark and disconnect vacuum hoses at intake manifold. Disconnect pressure sensor connector and retaining clamp.

3. Cover fuel line at fuel filter with shop towel and carefully remove fuel line at fuel filter. Mark and remove vacuum hose between Bi-Metallic Vacuum Switching Valve (BVSV), pressure regulator and charcoal canister.

4. Remove radiator hoses and heater hoses from inlet pipe and intake manifold. Remove EGR pipe. Disconnect idle-up VSV, EGR VSV, intake air temperature sensor, throttle body and cold start injector connectors.

5. Remove clamp located on rear of upper intake manifold. Disconnect fuel hose between cold start injector and fuel delivery pipe. Disconnect oil filler-to-upper intake manifold hose. Remove upper intake manifold and gasket.

6. Remove connector from injectors. Remove fuel hose at pressure regulator and fuel delivery pipe.

7. Remove fuel delivery pipe and insulators from intake manifold. Remove fuel injectors. Remove harness clamp at intake pipe.

8. Disconnect coolant temperature switch (A/C models only), cold start injector time switch and coolant temperature sender connectors. Disconnect radiator fan motor connector. Remove ground terminal at lower intake manifold. Remove oil cooler hose from lower intake manifold.

9. Remove lower intake manifold and gaskets. Mark spark plug wire location and remove. Disconnect Oxygen (O2) sensor and distributor connector. Remove exhaust pipe at exhaust manifold.

10. Remove exhaust manifold cover, support, O2 sensor and exhaust manifold. Remove distributor. Remove alternator bracket and valve cover. Loosen cylinder head bolts in 3 steps in proper sequence. See Fig. 3 . Remove head bolts and cylinder head.

WARNING: Fuel lines are under pressure. Use caution during removal to prevent personal injury.

CAUTION: DO NOT allow fuel to drip on alternator while removing fuel hose.

CAUTION: Cylinder head bolts must be loosened in proper sequence to prevent cylinder head warpage or cracking.



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Fig. 3: Cylinder Head Bolt Removal & Tightening SequenceCourtesy of DAIHATSU MOTOR CO., LTD.

Inspection

1. Measure cylinder head height, width between manifold areas and warpage. Cylinder head height or width must not be less than minimum specification after resurfacing. Resurfacing is required if warpage exceeds maximum specification. See CYLINDER HEAD & MANIFOLD WARPAGE SPECIFICATIONS table. Replace cylinder head if less than specification.

2. Check mating surfaces of upper and lower intake and exhaust manifolds for warpage. Replace if warpage exceeds specification. See CYLINDER HEAD & MANIFOLD WARPAGE SPECIFICATIONS table.

CYLINDER HEAD & MANIFOLD WARPAGE SPECIFICATIONS

Installation

1. Ensure mating surfaces and head bolt holes are clean and dry. Install head gasket. Rotate camshaft until key groove is positioned toward the top of cylinder head. See Fig. 4 .

2. Install cylinder head. Head bolts must be tightened in proper sequence. See Fig. 3 . Tighten head bolts in 3 steps to specification. See TORQUE SPECIFICATIONS table.

3. Pour ample amount of engine oil into camshaft chamber and distributor drive gear chamber of cylinder head. See Fig. 5 . Install new "O" ring on distributor and injectors prior to installation.

4. Coat injector "O" rings with silicone oil prior to installation. Tighten fuel delivery rail nuts in 3 steps to specification. Install and adjust timing belt. Reverse removal procedure for remaining components.

5. Tighten all bolts to specification. Install vacuum hose at upper intake manifold with painted end at intake manifold. Adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT under VALVES.

6. Fill fluid levels. Ensure oil filler cap is installed with "D" mark positioned so it can be seen from the front of the vehicle.

Application In. (mm)Cylinder Head

Maximum Warpage .004 (.10)Minimum Height 4.9488 (125.699)Minimum Width 6.2756 (159.400)

Intake & Exhaust Manifold: Maximum Warpage .004 (.10)

CAUTION: Camshaft key groove must be positioned toward the top of cylinder head to prevent valve interference with pistons during cylinder head installation.



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Fig. 4: Aligning Camshaft Key Groove Courtesy of DAIHATSU MOTOR CO., LTD.



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Fig. 5: Lubricating Camshaft & Distributor Drive Gear Chambers Courtesy of DAIHATSU MOTOR CO., LTD.



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TIMING BELT

Removal

1. Disconnect negative battery cable. Loosen accelerator cable lock nut and remove cable from throttle lever of throttle body and clamp.

2. Remove vent hose from valve cover. Remove air cleaner from throttle body. Mark location of all hoses on the air cleaner and remove. Remove air cleaner assembly.

3. Remove connector from alternator lead. On A/C equipped models, loosen idler pulley mounting nut. Loosen adjusting bolt and remove drive belt. On all models, remove alternator drive belt.

4. Remove right lower engine cover. Using a wooden block and jack, slightly apply pressure to oil pan to release pressure from front mounts. Remove front mount bracket-to-mount bolts. Remove front mount bracket-to-cylinder head bolts. Slightly lower jack and remove front mount bracket.

5. Hold water pump and remove water pump pulley bolts. Remove pulley. From left fenderwell, place socket on crankshaft pulley bolt and rotate engine to position No. 1 piston at TDC of compression stroke. Note that timing mark on flywheel is aligned with mating mark on bellhousing. See Fig. 6 .

Fig. 6: Aligning Timing Marks Courtesy of DAIHATSU MOTOR CO., LTD.

6. To ensure proper alignment, remove oil filler cap. Check that exhaust valve rocker on No. 1 cylinder is free. If rocker is not free, rotate crankshaft 360 degrees and align timing marks.

7. Using screwdriver inserted through bellhousing, hold ring gear and remove crankshaft pulley retaining bolt. Remove crankshaft pulley. Remove upper and lower timing belt covers.



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8. Remove flange located on the front of crankshaft belt pulley. See Fig. 7 . If timing belt is to be reused, mark direction of belt rotation.

9. Loosen idler pulley bolt and position pulley to the left as far as possible and tighten pulley bolt. Remove timing belt. Remove idler pulley and spring.

10. If belt pulleys require replacement, remove crankshaft belt pulley and flange. See Fig. 7 . For camshaft belt pulley removal, remove pulley retaining bolt. Pulley can be held by installing rod through pulley hole and rest against rib on cylinder head. Using Puller (SST 09213-87701-000), remove camshaft belt pulley.

Inspection

1. Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if damaged or contaminated.

2. Inspect idler pulley for smooth rotation. DO NOT wash idler pulley. Replace as necessary. Inspect idler pulley tension spring for damage.

3. Check tension spring free length and tension. Replace spring if not within specification. See PULLEY SPECIFICATIONS table. Inspect all belt pulleys for wear in belt areas. Measure diameter of crankshaft and camshaft belt pulleys. Replace belt pulley if not within specification. See PULLEY SPECIFICATIONS table.

PULLEY SPECIFICATIONS

Installation

1. Install camshaft belt pulley. Tighten retaining bolt to specification. Install crankshaft belt pulley and inner flange in proper direction. See Fig. 7 .

2. Install idler pulley and tension spring. Position pulley to the left as far as possible. Rotate camshaft and crankshaft to align mating marks. See Fig. 8 .

3. Install timing belt. If used belt is installed, ensure belt is installed in original direction of rotation. If new belt is installed, align line mark on back of belt with mating mark on each pulley.

CAUTION: If timing belt is to be reused, mark belt rotation prior to removal.

Application SpecificationCamshaft Belt Pulley Diameter 4.720" (119.88 mm)Crankshaft Belt Pulley Diameter 2.335" (59.31 mm)Idler Pulley Tension Spring

Free Length 2.13" (54.1 mm)Spring Tension 3.66 lbs. @ 2.56"Spring Tension 1.66 kg @ 65.0 mm



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Fig. 7: Installing Crankshaft Pulley & Flanges Courtesy of DAIHATSU MOTOR CO., LTD.



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Fig. 8: Aligning Crankshaft & Camshaft Mating Marks Courtesy of DAIHATSU MOTOR CO., LTD.

4. Once belt is installed and all mating marks are aligned, loosen idler pulley bolt to allow spring tension on idler pulley. Temporarily tighten idler pulley bolt.

5. Temporarily install bolt in crankshaft and rotate crankshaft until No. 1 piston is at TDC. The "F" mark on the camshaft belt pulley should be toward the top when the No. 1 piston is at TDC.



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6. Loosen idler pulley bolt to allow spring tension against the timing belt. Tighten idler pulley bolt to 25-33 ft. lbs. (34-45 N.m). Ensure all timing marks are aligned. See Fig. 8 .

7. Install outer flange on crankshaft belt pulley with protruding side toward the crankshaft belt pulley. See Fig. 7 . To install remaining components, reverse removal procedure. Tighten bolts to specification. Ensure all drive belts are centered in pulleys.

Fig. 9: Exploded View of Cylinder Head & Components Courtesy of DAIHATSU MOTOR CO., LTD.

TIMING BELT INTERFERENCE VERIFICATION INFORMATION

TIMING BELT INTERFERENCE CAUTION

NOTE: CAMSHAFT DRIVE BELTS OR TIMING BELTS - The condition of camshaft drive belts should always be checked on vehicles which have more than 50,000 miles. Although some manufacturers DO NOT recommend replacement at a



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Crack Or Tears In Belt Surface Missing, Damaged, Cracked Or Rounded Teeth Oil Contamination Damaged Or Faulty Tensioners Incorrect Tension Adjustment

TIMING BELT INTERFERENCE CHECK MENU

TIMING BELT INTERFERENCE VERIFICATION (1)

CAMSHAFT

Removal

Remove rocker arm shaft assembly. See ROCKER ARM SHAFT ASSEMBLY . Using care not to damage camshaft, remove camshaft from rear of cylinder head. Using screwdriver, pry camshaft oil seal from cylinder head.

Inspection

1. Clean camshaft journals and cylinder head journal surfaces. Inspect journals and distributor drive gear for damage. Measure camshaft lobe height and runout. Replace camshaft if not within specification. See CAMSHAFT & CYLINDER HEAD SPECIFICATIONS table.

2. Measure cylinder head bores and camshaft journals to determine oil clearance. Replace worn components to obtain correct oil clearance. Replace if not within specification. See CAMSHAFT & CYLINDER HEAD SPECIFICATIONS table.

CAMSHAFT & CYLINDER HEAD SPECIFICATIONS

specified mileage, others require it at 60,000-100,000 miles. A camshaft drive belt failure may cause extensive damage to internal engine components on most engines, although some designs DO NOT allow piston-to-valve contact. These designs are often called "Free Wheeling". Many manufacturers changed their maintenance and warranty schedules in the mid-1980's to reflect timing belt inspection and/or replacement at 50,000- 60,000 miles. Most service interval schedules shown in this section reflect these changes. Belts or components should be inspected and replaced if any of the following conditions exist:

Application (1) Check For Possible DamageDaihatsu 1.0L (2) Yes(1) Damage to piston and/or valves caused by timing belt failure.(2) Check for possible damage to piston(s) or valve(s) if there has been a timing belt failure.

Application In. (mm)Camshaft Journal O.D.



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Installation

Using Seal Installer (SST 09515-87202-000), install oil seal in cylinder head. Coat seal lip with oil. Coat camshaft with oil and install. Install remaining components.

CAMSHAFT OIL SEAL

1. Remove timing belt and camshaft belt pulley. See TIMING BELT under CAMSHAFT . Using drift of Seal Remover/Installer (SST 09223-87702-000), place small hole in seal surface.

2. Install screw in seal surface. Using screwdriver, pry seal from cylinder head. Using Seal Installer (SST 09608-12010-000), install seal in cylinder head. Coat seal lip with oil. Install pulley and timing belt.

VALVE ARRANGEMENT

Firewall Side: All Intake valves.

Exhaust Manifold Side: All Exhaust valves.

ROCKER ARM SHAFT ASSEMBLY

Removal

1. Remove cylinder head. See CYLINDER HEAD & MANIFOLDS . Remove camshaft belt pulley from camshaft. See Fig. 9 .

2. Remove distributor housing and wave washer from rear of cylinder head. Loosen lock nut and adjusting screw on each rocker arm.

3. Using Rocker Shaft Puller (SST 09204-87701-000), remove rocker arm shaft while holding springs. See Fig. 10 . Mark components for location.

Front 1.2583-1.2591 (31.961-31.981)Center 1.8655-1.8665 (47.384-47.409)Rear 1.9061-1.9071 (48.415-48.440)

Camshaft Minimum Lobe Height 1.5669 (39.799)Camshaft Maximum Runout .0012 (.030)Camshaft Oil Clearance

Front .0016-.0055 (.041-.140)Center .0035-.0075 (.089-.191)Rear .0024-.0063 (.061-.160)

Cylinder Head Bore I.D.Front 1.2606-1.2616 (32.019-32.045)Center 1.8701-1.8711 (47.501-47.526)Rear 1.9094-1.9104 (48.499-48.524)

CAUTION: Remove rocker arms shafts while holding springs as they are under pressure. Mark all components for location for REASSEMBLY reference.



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Fig. 10: Removing Rocker Arms & Shafts Courtesy of DAIHATSU MOTOR CO., LTD.

Inspection

1. Inspect rocker arms and shafts for damage. Replace wave washer if flattened condition exists. 2. Measure rocker arm inside diameter and shaft outer diameter to determine oil clearance. Measure free

length of rocker arm compression springs. Replace all components to obtain correct oil clearance or if not within specification. See ROCKER ARMS & SHAFT SPECIFICATIONS table.

ROCKER ARMS & SHAFT SPECIFICATIONS

Note that shafts are different lengths.

Application In. (mm)Arm-to-Shaft Oil Clearance

New Components .0006-.0024 (.015-.061)Used Components (Max.) .004 (.10)

Rocker Arm I.D. .6299-.6306 (15.999-16.017)Rocker Arm Shaft O.D. .6283-.6293 (15.958-15.984)



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Installation

1. To install, reverse removal procedure. Install components in original location. Ensure proper length rocker arm shaft is installed in correct location.

2. Intake rocker arm shaft is 11.004" (279.50 mm) long while the exhaust rocker arm shaft is 11.201" (284.51 mm). Install new "O" ring on distributor housing. Tighten all bolts to specification.

VALVES

1. Disassemble cylinder head. Measure valve stem diameter. Replace valves not within specification. See VALVES SPECIFICATIONS table.

2. Measure valve margin. Replace valves if valve margin is not within specification. See VALVE MARGIN SPECIFICATIONS table. Remeasure valve margin after grinding valves.

VALVE MARGIN SPECIFICATIONS

VALVE GUIDE

Inspection

Measure valve stem-to-guide clearance. Replace valves and valve guides as a set if not within specification. See VALVE SPECIFICATIONS table.

Removal & Installation

1. On exhaust valve guides, use a brass bar and tap on valve guide to aid in removal. On all valve guides, use Valve Guide Remover/Installer (SST 09201-87201-000) and drive valve guide out toward the combustion chamber side of the cylinder head.

2. Using valve guide remover/installer, install valve guide until snap ring contacts the cylinder head. Ream guide to obtain correct oil clearance.

VALVE SEAT & VALVE RECESSION GRINDING

1. Grind valve seats to proper seat angle. Check valve seat width after grinding. Adjust seat width to specification. See VALVES SPECIFICATIONS table.

2. After valve seats have been refaced, install new valve. Using depth micrometer, measure distance between gasket area of cylinder head and upper area of valve. See Fig. 11 . This distance is referred to as the valve recession. Replace cylinder head if valve recession exceeds maximum specification. See

Rocker Arm Spring Free Length 1.3 (33)

Application In. (mm)Exhaust .039 (.99)Intake .032 (.81)

NOTE: If valve guide contains a snap ring or locating ring, cylinder head must be replaced.



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VALVE RECESSION SPECIFICATIONS table.

VALVE RECESSION SPECIFICATIONS

Fig. 11: Measuring Valve Recession

VALVE STEM OIL SEALS

Using Valve Stem Oil Seal Remover (SST 09201-87704-000), remove oil seals. Coat seals with oil. Using Valve Stem Oil Seal Installer (SST 09201-87703-000), drive valve stem oil seal in valve guide.

VALVE SPRINGS INSPECTION

Measure free length of valve springs. Check spring tension at specified height. Replace springs if not within specification. See VALVE SPRINGS table. Check valve spring for squareness. Replace spring if out-of-square exceeds .059" (1.49 mm).

VALVE CLEARANCE ADJUSTMENT

Application In. (mm)Exhaust .110 (2.79)Intake .074 (1.88)

NOTE: Valve clearance adjustment should be performed with coolant temperature



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1. Remove valve cover. From left fenderwell, place socket on crankshaft pulley bolt and rotate engine to position No. 1 piston at TDC of compression stroke. Note that timing mark on flywheel is aligned with mating mark on bellhousing. See Fig. 6 .

2. Ensure valves on No. 1 cylinder are free and valves are closed. Adjust valves in proper sequence. See VALVE ADJUSTMENT SEQUENCE table. Adjust valves to proper clearance depending on temperature. See VALVE CLEARANCE SPECIFICATIONS table.

3. Rotate crankshaft 360 degrees and adjust remaining valves while valves on No. 1 cylinder are open. Install valve cover and gasket. Tighten bolts to specification.

VALVE ADJUSTMENT SEQUENCE

VALVE CLEARANCE SPECIFICATIONS

above 176°F (80°C) and oil temperature above 140°F (60°C). If engine is rebuilt, readjust valves once correct temperature is obtained.

Application CylinderNo. 1 Cylinder Valves Closed

Exhaust Valve 1 & 2Intake Valve 1 & 3

No. 1 Cylinder Valves OpenExhaust Valve 3Intake Valve 2

Application In. (mm)Engine Cold .004-.008 (.10-.20)Engine Hot .006-.010 (.15-.25)



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Fig. 12: Exploded View of Cylinder Block Courtesy of DAIHATSU MOTOR CO., LTD.

CYLINDER BLOCK CLEANING & INSPECTION

1. Inspect cylinder block for cracks, warpage, bore diameter, taper, out-of-round and deck height. Replace or repair cylinder block if not within specification. See CYLINDER BLOCK SPECIFICATIONS table.

2. Inspect balance shaft bearings. See BALANCE SHAFT BEARINGS .

CYLINDER BLOCK SPECIFICATIONS Application In. (mm)Bore Diameter 2.992-2.993 (75.99-76.02)Bore Out-Of-Round .004 (.10)



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BALANCE SHAFT & GEAR COVER

Removal

1. Remove timing belt and crankshaft belt pulley. See TIMING BELT . Remove balance shaft gear cover and gasket. Note bolt location.

2. Measure deflection of oil pump drive chain at the center point between the sprockets. Replace sprockets and drive chain if deflection exceeds .275" (6.99 mm).

3. Remove oil pump sprocket from the oil pump. Note direction of sprocket installation. Remove balance weight from balance shaft. Remove oil pump drive sprocket and chain. Check thrust clearance of balance shaft prior to removal.

4. Attach dial indicator to front of cylinder block with stem resting on balance shaft. Check thrust clearance of balance shaft. Thrust clearance should be within .001-.008" (.03-.20 mm).

5. Replace thrust plate if clearance is not within specification. If thrust clearance is not within specification after replacing thrust plate, balance shaft must be replaced.

6. For balance shaft removal, align marks on balance shaft gear and crankshaft gear. See Fig. 13 . Remove balance shaft thrust plate retaining bolts. Remove balance shaft using care not to damage shaft during removal.

Fig. 13: Aligning Balance Shaft Gear & Crankshaft Gear Courtesy of DAIHATSU MOTOR CO., LTD.

Bore Taper .004 (.10)Deck Height 7.8957 (200.550)Warpage .004 (.10)Warpage Grind Limit .012 (.30)

NOTE: Oil pan removal may be required to allow gear cover removal as some oil pan bolts tighten into the gear cover.



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Disassembly

If thrust plate or gear requires replacement, press balance shaft gear from shaft using press and Balance Shaft Gear Anvil (SST 09214-87701-000) and Anvil (SST 09253-87202-000). Remove thrust plate.

Inspection

1. Clean all components and dry with compressed air. Inspect balance shaft, thrust plate, gear and key for scoring or cracks.

2. Measure and record O.D. of balance shaft journals. Balance shaft journals should be within specification. See BALANCE SHAFT JOURNAL SPECIFICATIONS table.

BALANCE SHAFT JOURNAL SPECIFICATIONS

3. Oil clearance between balance shaft journals and balance shaft bearings must be determined. Measure I.D. of balance shaft bearings at 2 locations 90 degrees apart and subtract O.D. of balance shaft journals.

4. The oil clearance must be within .001-.004" (.03-.10 mm). If oil clearance is not within specification, inspect balance shaft bearings. See BALANCE SHAFT BEARINGS . Replace components as necessary to obtain correct oil clearance.

Reassembly

Install thrust plate and key. Install gear on shaft with alignment mark away from the shaft. Press balance shaft gear on the shaft using press and Balance Shaft Gear Anvil (SST 09214-87701-000) and Anvil (SST 09253-87202-000) and Installer (SST 09506-87303-000).

Installation

1. Coat balance shaft journals, balance shaft bearings and thrust plate with oil. Install balance shaft and align marks on balance shaft gear and crankshaft gear. See Fig. 13 .

2. Install thrust plate bolts and tighten to specification. Install sprocket, drive chain and balance weight. Tighten bolt to specification. Install sprocket and drive chain on oil pump.

NOTE: Balance shaft journal-to-bearing oil clearance must be checked. This ensures proper bearing and shaft installation as bearings and balance shafts are available in an undersize.

Application In. (mm)Front 1.770-1.771 (44.96-44.98)Rear 1.337-1.338 (33.96-33.99)

CAUTION: Ensure key is installed and thrust plate is not binding after installing balance shaft gear.

CAUTION: Sprocket must be installed on the oil pump with the letters "CB OUTSIDE" stamped on the sprocket positioned toward the front of



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3. Tighten sprocket bolt to specification. If oil seal on balance shaft gear cover requires replacement, use screwdriver and remove seal from cover. Lubricate new seal with oil. Using Seal Installer (SST 09515-87202-000), install new seal in cover.

4. Install cover, new gasket and dust seals. Tighten bolts to specification. To install remaining components, reverse removal procedure.

BALANCE SHAFT BEARINGS

Inspection

1. Inspect bearings for damage or wear. Measure and record the I.D. of bearings at 2 places 90 degrees apart. Bearings should be within specification. See BALANCE SHAFT BEARING SPECIFICATIONS table.

BALANCE SHAFT BEARING SPECIFICATIONS

2. Subtract balance shaft journals O.D. from bearing measurements to determine oil clearance. Oil clearance must be within .001-.004" (.03-.10 mm). If oil clearance is not within specification, replace components as necessary to obtain correct oil clearance.

Removal & Installation

Using Bearing Remover/Installer, remove bearings. Using bearing remover/installer, install bearings with recessed area toward the outside of cylinder block. Ensure bearing oil hole aligns with oil hole of cylinder block.

OVERHAUL

PISTON & ROD ASSEMBLY

Removal

1. Remove cylinder head. See CYLINDER HEAD & MANIFOLDS . Remove oil pan. Ensure cylinder ridge is removed. Mark connecting rod and cap for cylinder identification.

the engine.

NOTE: Bearing I.D. and oil clearance between shaft and bearing must be checked. This ensures proper bearing and shaft INSTALLATION as bearings and balance shafts are available in an undersize.

Application In. (mm)Front 1.7717-1.7726 (45.000-45.024)Rear 1.3386-1.3396 (34.000-34.026)

CAUTION: Ensure balance shaft bearings are installed with recessed area toward the outside of cylinder block and oil hole aligns with that of cylinder block.



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2. Note direction of "Front" mark on piston and connecting rod. See Fig. 14 . Remove rod cap. Remove piston assembly.

Installation

1. Ensure piston ring end gap and side clearance are within specification. Install rings on piston with ring code marks toward top of piston. Lubricate piston, rings and cylinder bore with engine oil.

2. Properly space ring end gaps on piston. See Fig. 14 . Install piston and rod into cylinder bore. Ensure piston and connecting rod are installed with "Front" mark toward front of engine. See Fig. 14 .

3. Check bearing clearance using Plastigage method. Tighten rod cap nuts in 3 steps to specification. See TORQUE SPECIFICATIONS table. Ensure rod moves freely on crankshaft. Check connecting rod side play. Repair or replace connecting rod if not within specification.

Fig. 14: Aligning Piston Rings & Checking Piston Alignment Marks Courtesy of DAIHATSU MOTOR CO., LTD.

FITTING PISTONS

Measure cylinder bore and piston skirt diameter. Piston skirt diameter should be measured at 90 degree angle to piston pin. Measure at approximately .590" (14.98 mm) from lower end of the piston. Clearance between piston and cylinder bore must be within specification. See PISTONS, PINS & RINGS table.



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PISTON PIN REPLACEMENT

Removal

Note reference of arrow on top of piston and connecting rod "D" mark. See Fig. 14 . Using press and Piston Pin Remover/Installer (SST 09221-87703-000) and (SST 09221-25018-000), remove pin. See Fig. 15 .

Fig. 15: Removing Piston Pin Courtesy of DAIHATSU MOTOR CO., LTD.

Inspection

1. Inspect piston for cracks or damage in ring areas. Check ring side clearance. Replace piston if not within specification. See PISTONS, PINS & RINGS SPECIFICATIONS table.

2. Measure pin bore I.D. of the piston and the O.D. of the pin. Clearance between piston and pin must be within specification. Measure clearance between connecting rod and piston pin. Clearance must be within specification. See PISTONS, PINS & RINGS table.

3. Check connecting rod for bend or twist. Replace connecting rod if twist or bend exceeds .002" (.05 mm).

Installation

CAUTION: Ensure piston is installed with arrow and connecting rod "D" mark properly positioned. See Fig. 14 .



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Position piston on connecting rod. Ensure arrow on top of piston is installed in accordance with connecting rod "D" mark. See Fig. 14 . Lubricate all components with oil. To install, reverse removal procedure.

MAIN BEARINGS

Removal

1. Ensure connecting rod and main bearing caps are marked for location. Remove connecting rod caps and bearings. Note direction of arrow on main bearing caps.

2. Gradually loosen main bearing caps in 3 steps in proper sequence. See Fig. 16 . Remove main bearing caps. Ensure all components are placed in correct order.

3. Note alignment marks for balance shaft prior to removing crankshaft. See Fig. 13 . Remove crankshaft. Remove main bearings from cylinder block. Mark bearings for location.



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Fig. 16: Main Bearing Cap Bolt Removal & Tightening Sequence Courtesy of DAIHATSU MOTOR CO., LTD.

Inspection



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Inspect crankshaft for cracks, damaged gear or threads. Check crankshaft for runout, out-of-round and taper. Replace or repair crankshaft if not within specification. See CRANKSHAFT WEAR SPECIFICATIONS table. Measure journal diameters. Replace or repair crankshaft if not within specification.

CRANKSHAFT WEAR SPECIFICATIONS

Installation

1. Install upper main bearings in cylinder block. Ensure oil hole is aligned and bearing is properly seated. Lubricate bearings with engine oil. Install crankshaft in block. Ensure crankshaft gear is aligned with balance shaft. See Fig. 13 .

2. Lubricate thrust washer with oil and install in the No. 3 journal with oil groove side toward the crankshaft. Check oil clearance using Plastigage method.

3. Tighten bolts to specification in proper sequence using 2 steps. Remove main bearing caps. Clearance must be within specification. If oil clearance exceeds specification, replace bearings or crankshaft.

4. Ensure crankshaft rotates freely with all main bearing caps installed. Check crankshaft end play. See CRANKSHAFT END PLAY CHECK .

5. Install connecting rod caps and bearings. Tighten to specification. Ensure connecting rods move freely on crankshaft.

CONNECTING ROD BEARINGS

1. Ensure bearing cap and connecting rod are marked for location. Loosen connecting rod nuts evenly in 2 steps. Remove connecting rod cap and bearing.

2. Install replacement bearing. Check bearing clearance using Plastigage method. Tighten nuts to specification. Ensure connecting rod moves freely on crankshaft. Check connecting rod side clearance.

CRANKSHAFT END PLAY CHECK

If not within specification, inspect thrust washer and crankshaft. Thrust washer is available in different thickness. Replace components to obtain correct end play.

FRONT CRANKSHAFT OIL SEAL

Removal

Remove drive belts and crankshaft pulley. Using a small drift, place a small hole in the seal housing. Install

Application In. (mm)Out-of-Round .0004 (.010)Runout .0024 (.060)Taper .0004 (.010)

CAUTION: Main bearing caps must be installed in original location with arrow facing front of engine.



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screw in the seal housing. Using puller, pull seal from balance shaft gear cover.

Installation

Coat seal lips with engine oil and install. Install crankshaft pulley. Tighten bolt to specification.

REAR CRANKSHAFT OIL SEAL

1. Remove oil pan. See OIL PAN under ENGINE LUBRICATION. article. Remove flywheel bolts in a crisscross pattern. Remove flywheel. Remove oil seal retainer and gasket.

2. Pry oil seal from seal retainer. Note direction of seal lips. Ensure seal surfaces are free of burrs. Lubricate seal lips with engine oil. Using Seal Installer (SST 09515-87301-000), install oil seal in retainer.

3. Install gasket and seal retainer. Ensure oil seal retainer gasket does not extend into oil pan mounting area. Tighten all bolts. Install flywheel and tighten bolts in a crisscross pattern in 2 steps to specification. Install oil pan.

OIL PAN

Removal

1. Disconnect negative battery cable. Drain engine oil. Remove rear engine mount-to-cylinder block bolt. Raise and support vehicle. Remove right front lower engine cover.

2. Remove exhaust pipe hanger support. Disconnect exhaust pipe from exhaust manifold. Remove front stopper mount bolts and rear mount bracket bolts. See Fig. 2 . Remove front bolt from engine lower crossmember.

3. Remove clutch housing cover and exhaust pipe support brackets. Remove oil pan bolts, oil pan and gasket.

Installation

1. To install oil pan, apply silicone sealant along the center of balance shaft gear cover and oil seal retainer areas and at cylinder block areas. See Fig. 17 .

2. Apply silicone sealant at designated area of oil pan gasket. See Fig. 17 . Install oil pan. Tighten oil pan nuts and bolts at the sides and the ends first. Then tighten all bolts and nuts to specification in proper sequence. See Fig. 17 .



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Fig. 17: Installing Oil Pan Courtesy of DAIHATSU MOTOR CO., LTD.

ENGINE LUBRICATION

Oil pressure is provided by a rotor-type pump driven by the balance shaft sprocket and chain. Pressure relief valve is located in the oil pump body. Oil cooler is used between oil filter and cylinder block. Relief valve is located in oil filter bracket.

CRANKCASE CAPACITY

Crankcase capacity is 3.3 qts. (3.1L) with filter replacement.

NORMAL OIL PRESSURE

Oil pressure at idle should be 4 psi (.3 kg/cm2 ) and 35-71 psi (2.5-5.0 kg/cm2 ) at 3000 RPM with engine at normal operating temperature.



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Fig. 18: Exploded View of Oil Pump AssemblyCourtesy of DAIHATSU MOTOR CO., LTD.

OIL PUMP

Removal

1. Remove oil pan. See OIL PAN under ENGINE LUBRICATION. Remove pump strainer from oil pump. Measure deflection of oil pump drive chain at the center point between the sprockets. Replace sprockets and drive chain if deflection exceeds .275" (6.99 mm).

2. Remove drive shaft sprocket from oil pump. See Fig. 18 . Note direction of sprocket installation. Remove oil pump and outlet pipe.

Disassembly & Inspection

1. Remove pump cover. Place identification marks on drive and driven rotor for reassembly reference. Remove pump components. See Fig. 18 . Inspect rotors, pump shaft and pump body for scoring or damage. Ensure relief valve slides freely in bore.

2. Measure I.D. of pump body shaft hole and drive rotor shaft O.D. and determine oil clearance. If not within specification, replace oil pump assembly. See OIL PUMP SPECIFICATIONS table.

3. Install rotors in pump body. Check rotor tip clearance and clearance between driven rotor and pump body. Replace rotor set or pump assembly if not within specification.

4. Place straightedge across pump body to check rotor side clearance. Check clearance between straightedge and both rotors. Replace parts as necessary if not within specification. See OIL PUMP SPECIFICATIONS table.

OIL PUMP SPECIFICATIONS

Reassembly

Coat all components with oil. Install rotors with stamped identification mark aligned. To reassemble, reverse disassembly procedure. Tighten pump cover bolts to specification.

Installation

1. Coat new "O" rings with oil and install. Install sprocket and drive chain on oil pump. 2. Drive shaft sprocket must be installed with the letters "CB OUTSIDE" stamped on the sprocket

positioned toward the front of the engine. To install, reverse removal procedure. Tighten bolts to specification.

Application In. (mm)Drive Rotor Shaft Oil Clearance .0018-.0039 (.046-.099)Driven Rotor-To-Pump Body .0039-.0118 (.099-.299)Rotor Side Clearance .0079 (.201)Rotor Tip Clearance .0098 (.248)

CAUTION: Drive shaft sprocket must be installed with the letters "CB OUTSIDE"



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OIL COOLER & OIL FILTER BRACKET

Removal

Drain engine oil and coolant. Remove oil filter. Remove hoses from oil cooler. Remove retaining bolt from center of oil cooler. Remove oil cooler. Remove oil filter bracket retaining bolts. Remove oil filter bracket. Remove relief valve from oil filter bracket.

Inspection

1. Inspect oil cooler and oil filter bracket for damage. Plug one hose connection of oil cooler. Blow air into remaining hose connection. Replace oil cooler if air passes from the oil cooler.

2. Inspect relief valve for scoring. Using screwdriver, press relief valve inward and note that valve moves freely. Replace valve if binding exists.

Installation

To install, reverse removal procedure. Install relief valve and oil filter bracket using a new gasket. Tighten relief valve and all bolts to specification.

Fig. 19: Exploded View of Water Pump Assembly Courtesy of DAIHATSU MOTOR CO., LTD.

WATER PUMP

stamped on the sprocket positioned toward the front of engine.



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Removal

1. Disconnect negative battery cable and drain coolant. Remove timing belt. See TIMING BELT under CAMSHAFT . Remove coolant inlet pipe.

2. Remove throttle body hose at water pump. Remove water pump retaining bolts. Remove water pump.

Disassembly

1. Remove cover from water pump. See Fig. 19 . Using press, Water Pump Overhaul Tool (SST 09236-00100-000) and Bearing Remover/Installer (SST 09238-87201-000), press pump pulley seat from water pump.

2. Using press, water pump overhaul tool and Seal Remover/Installer (SST 09237-87201-000), press pump bearing from pump housing.

3. Using press, water pump overhaul tool and bearing remover/installer, press rotor and seal set from pump bearing.

Reassembly

1. Press pump bearing into rotor and seal set so the bearing shaft is positioned .02" (.5 mm) from the end of rotor.

2. Using press, water pump overhaul tool and bearing remover/installer, press pump bearing in pump housing so rotor is recessed .0039-.0118" (.099-.299 mm) below pump housing surface.

3. Using press and bearing remover/installer, press pump pulley seat onto the bearing so end of bearing shaft is positioned .02" (.5 mm) from end of the pump pulley seat. Ensure pump rotates smoothly. Install cover and gasket.

Installation

To install, reverse removal procedure. Use new pump mounting gasket and "O" rings on coolant inlet pipe. Tighten bolts to specification.

ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

NOTE: For further information on cooling systems, see ENGINE COOLING article.

Application In. (mm)Displacement

Cubic Inches 61Liters 1.0

Fuel System Fuel InjectedHP @ RPM 53 @ 5200Torque: Ft. @ RPM 58 @ 3600



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VALVE & VALVE SPRING SPECIFICATIONS

VALVE SPECIFICATIONS

PISTON/PIN/RING SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

Compression Ratio 9.5:1Bore 2.99 (75.9)Stroke 2.87 (72.9)

Application In. (mm)Intake

Face Angle 45.5°Minimum Valve Margin .032 (.81)Seat Width .039-.071 (.99-1.8)Stem Clearance .0016-.0035 (.041-.089)Valve Spring Free Length 1.65-.1.71 (41.9-43.4)Spring Out-of-Square .059 (1.49)Pressure: Lbs @ In. (Kg @ mm), W/Valve Open 56.7 @ 1.37 (25.7 @ 34.8)

ExhaustFace Angle 45.5°Minimum Valve Margin .039 (.99)Seat Width .039-.071 (.99-1.8)Stem Clearance .0018-.0039 (.046-.099)Valve Spring Free Length 1.65-.1.71 (41.9-43.4)Spring Out-of-Square .059 (1.49)Pressure: Lbs @ In. (Kg @ mm), W/Valve Open 56.7 @ 1.37 (25.7 @ 34.8)

Application In. (mm)Piston Clearance .0012-.0047 (.030-.119)Pin-to-Piston Fit .0012 (.030)Pin-to-Rod Fit .0006-.0017 (.015-.043)Rings

Ring No. 1End Gap .0079-.0276 (.201-.701)Side Clearance .0012-.0047 (.030-.119)

Ring No. 2End Gap .079-.0276 (.201-.701)Side Clearance .0008-.0047 (.020-.119)

Oil RingEnd Gap .0079-.0433 (.201-1.099)Side Clearance .0004-.0012 (.010-.030)



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BEARING SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

CONNECTING ROD SPECIFICATIONS

CONNECTING ROD SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

Application In. (mm)Main Bearings

Journal Diameter 1.652-1.653 (41.96-41.99)Clearance .0008-.0028 (.020-.071)Thrust Bearing No. 3Crankshaft End Play .0033-.0069 (.085-.174)

Connecting Rod BearingsJournal Diam. 1.5731-1.5745 (39.957-39.992)Clearance .0008-.0028 (.020-.071)Side Play .006-.015 (.15-.38)

Application In. (mm)Side Play .006-.015 (.030-.119)Maximum Bend & Twist .002 (.05)

Application In. (mm)Maximum Cylinder Head Warp .004 (.10)Seat Angle 45 °Seat Width .039-.071 (.99-1.80)Valve Stem Oil Clearance

Intake .0016-.0035 (.041-.089)Exhaust .0018-.0039 (.046-.099)

Application In. (mm)Maximum Block Warp .004 (.10)Cyl. Bore Std. Diameter 2.992-2.993 (75.99-76.02)Maximum Taper .004 (.10)Maximum Out-of-Round .004 (.10)



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CAMSHAFT SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application In. (mm)Journal Diameter

Front Journal 1.2583-1.2591 (31.961-31.981)Center Journal 1.8655-1.8665 (47.384-47.409)Rear Journal 1.9061-1.9071 (48.415-48.440)

Oil ClearanceFront Journal .0016-.0055 (.041-.140)Center Journal .0035-.0075 (.089-.191)Rear Journal .0024-.0063 (.061-.160)

Bearing BoreFront Journal 1.2606-1.2616 (32.019-32.045)Center Journal 1.8701-1.8711 (47.501-47.526)Rear Journal 1.9094-1.9104 (48.499-48.524)

Runout .0012 (.030)Lobe Height 1.5669 (39.799)

Application Ft. Lbs. (N.m)A/C Compressor Mount Bolt 18 (24)A/C Idler Pulley Bolt 23-35 (31-47)Balance Weight Bolt 22-33 (30-45)Camshaft Pulley Bolt 22-33 (30-45)Connecting Rod Nut (1) 17-28 (23-38)Crankshaft Pulley Bolt 65-72 (88-98)Cylinder Head Bolt (2) 40-47 (54-64)Exhaust Manifold Bolt 11-16 (15-22)Exhaust Manifold Support Bolt 22-33 (30-45)Exhaust Pipe-to-Manifold Bolt 22-36 (30-49)Flywheel Bolt (1) 30-36 (41-49)Front Mount Bracket-to-Cylinder Head Bolt

10mm 22-33 (30-45)12mm 36-51 (49-69)

Front Mount Stopper Bolt 54-76 (73-103)Front Mount-to-Block Bolt 30-40 (41-54)Fuel Hose-to-Fuel Filter Bolt 25-33 (34-45)Intake Manifold

Lower Manifold Bolt 11-16 (15-22)



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Upper Manifold Nut 11-16 (15-22)Lower Arm Bolt 30-43 (41-58)Lower Left Engine Mount Bolt 22-33 (30-45)Main Bearing Cap Bolt

Step 1 18-25 (24-34)Step 2 39-48 (53-65)

Oil Cooler Bolt 18-25 (24-34)Oil Filter Bracket Relief Valve 36-51 (49-69)Oil Pump Sprocket Bolt 11-16 (15-22)Oxygen Sensor 22-29 (30-39)Rear Mount Bracket Bolt 54-76 (73-103)Stabilizer Bar Bracket Bolt 30-43 (41-58)Stabilizer Bar Nut 54-80 (73-109)Timing Belt Idler Pulley Bolt 25-33 (34-45)Water Pump Bolt 11-16 (15-22)

INCH Lbs. (N.m)Air Cleaner Bolt 84-144 (10-16)Balance Shaft Gear Cover Bolt 84-144 (10-16)Balance Shaft Thrust Plate Bolt 84-132 (10-15)Distributor Housing Bolt 36-60 (4-7)Exhaust Manifold Cover Bolt 48-84 (5-10)Fuel Delivery Pipe Nuts (1) 84-144 (10-16)Fuel Hose-to-Cold Start Injector Bolt 108-156 (12-17)Oil Filter Bracket Bolt 84-144 (10-16)Oil Pan Bolts & Nuts 36-60 (4-7)Oil Pump Cover Bolt 36-60 (4-7)Oil Pump Outlet Pipe Bolt 48-84 (5-10)Oil Pump-to-Block Bolt 84-144 (10-16)Timing Belt Cover Bolt 12-36 (1-4)Valve Cover Bolt 72-108 (8-12)Water Pump Pulley Bolt 48-84 (5-10)(1) Tighten to specification in 2-3 steps.(2) Tighten to specification in 3 steps. See Fig. 3 .



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