rologo este manual de reparaciones explica...

ROLOGO

E s t e manual d e r e p a r a c i o n e s e x p l i c a 10s pun tos d e r e p a r a c i 6 n p a r a e l

motor modelo GM6-262 equipado en 10s Montacargas Toyota .

Le rogamos que u t i l i c e a 1 miiximo e s t e manual p a r a s u s e r v i c i o t 6 c n i c o .

E s t e manual d e r e p a r a c i o n e s c o n t i e n e l a inforrnaci6n rnbs r e c i e n t e

d i s p o n i b l e en sep t i embre d e 1 9 9 6 . En c u a n t o a cambios p o s t e r i o r e s ,

Toyota s e r e s e r v a e l de recho a r e a l i z a r t a l e s cambios e n l a s

e s p e c i f i c a c i o n e s y d e s c r i p c i o n e s s i n i n c u r r i r e n n inguna o b l i g a c i 6 n y

s i n p r e v i o a v i s o . TOYOTA MOTOR CORPORATION

This repair manual explains the repair points of the GM6-262 model

engine equipped on the Toyota Forklift Trucks.

Please make good use of this manual for your technical service.

This repair manual contains the latest information available as of

September 1996. For any changes thereafter, Toyota reserves the right

to make such changes in specifications and descriptions without

incurring any obligation and without previous notice.

TOYOTA MOTOR CORPORATION

Description Page # Date

1Added Service Manual Change History 2 8/31/13

2 Added SIB EN12-001 119 11/15/123 Added SIB EN13-001 123-124 8/31/13

Service Manual Change History

GENERALIDADES 0

PUESTA A PUNT0 DEL MOTOR 1

REVISION DEL MOTOR 2

SISTEMA DE COMBUSTIBLE 3

SISTEMA PCV 4

SISTEMA DE ENFRIAMIENTO 5

SISTEMA DE LUBRICACION 6

SISTEMA DE ENCENDIDO 7

SISTEMA DE ARRANQUE 8

SISTEMA DE CARGA 9

APENDICE 10

GENERAL 10 ENGINE TUNE-UP 0

ENGINE OVERHAUL FUEL SYSTEM PCV SYSTEM

COOLING SYSTEM LUBRICATION SYSTEM

IGNITION SYSTEM STARTING SYSTEM 10 CHARGING SYSTEM

APPENDIX

GEWERALIDADES

ESPECIFICACIONES .................................................. VISTAS EXTERIORES DEL MOTOR ...................................... COMO INTERPRETAR ESTE MANUAL ...................................

.... EXPLICACION SOBRE EL ALCANCE DE LOS TRABAJOS DE REPARACION

METODO DE EXPLICACION ...................................... TERMINOLOGIA IHPORTANTE ....................................... ABREVIATURAS. .................................................

INSTRUCCIONES SOBRE LA REPARACION ............................... .......... PARES DE APRETAHIENTO DE LOS PERNOS Y TUERCAS ESTANDAR

METODO DE IDENTIFICACION DEL TIP0 DE

RESISTENCIA DE LOS PERNOS ................................ ......................... TABLA DE LOS PARES DE APRETAMIENTO

GENERAL Page

................... ........................ SPECIFICATIONS .. 0-2

................................... ENGINE EXTERIOR VIEWS 0-3

HOW TO READ THIS MANUAL .................... ....... 0 -4

EXPLANATION RANGE OF REPAIR WORKS .............. 0 -4

........................................ EXPLANATION METHOD 0-4

SIGNAL WORD DEFINITIONS ................... .. ........ 0-5

ABBREVIATIONS ................... ... ......................... 0 -5

REPAIR INSTRUCTIONS ........................ .. .......... 0-5

STANDARD BOLT AND NUT TIGHTENING TORQUE .......................... 0-7

BOLT STRENGTH TYPE IDENTIFICATION METHOD ................................................ 0-7

................................. TIGHTENING TORQUE TABLE 0-8

ESPECIFICACIONES

Modelo del motor GM6-262 Tipo Gasolina Ciclos 4 No. de cilindros y disposicibn V6 90 grados Orden de encendido 1-6-5-4-3-2 ~Btodo de arranque Arrancador de cambio de pifibn Mecanismo valvular OHV, impulsi6n por cadena Tipo de cimara de combustibn Inclinada Calibre x carrera mm 101,60 x 86/39 Cilindrada cm' 4300 Relaci6n de compresibn 9,2 : 1 Potencia de rggimen kW(J1S PS)/rpm 67 (91)/2350 Par motor miximo N.m (kgSm)/rpm 294 00)/1200 Velocidad mixima estitica sin carga rpm Vea el manual de reparaciones

del modelo correspondiente Velocidad de marcha en vacio rpm Vea el manual de reparaciones (ralenti ) del modelo correspondiente Disposicibn de admisibn/escape Flujo transversal Dispositivo de recirculaci6n Tip0 cerrado de 10s gases de derivaci6n Tipo de la bomba de aceite Bomba de engranajes Tipo del filtro de aceite Filtro de papel

Sumidero de aceite 31 8

Capacidad de aceite de Sumidero de motor litros aceite t filtro 4,2

de aceite

SPECIFICATIONS

Gear pump

Paper filter

3.8 i1.001

4.2 (1.11)

Oil pump type

Oil filter type

Engine oil capacity ' IUS Oil pan

oil pan +oil filter

VISTAS EXTERXORES DEL UOTOB ENGINE EXTERIOR VIEWS 7----

COHO INTERPRETAR ESTE MANUAL

EXPLICACION SOBRE LOS PROCESOS DE LOS TNWLJOS DE REPARACION

Los t r a b a j o s d e r e p a r a c i 6 n e s t a n c l a s i f i c a d o s e n 4 p r o c e s o s . P r o c e s o 1 , B f i s q u e d a d e a v e r i a s e n e l m o n t a c a r g a s . P r o c e s o 2 .Remoci6n d e l v e h i c u l o e i n s t a l a c i 6 n . P r o c e s o 3 . D e s m o n t a j e y montaje/inspecci6n/ajuste. P r o c e s o 4 . T e r m i n a c i 6 n d e l a i n s p e c c i 6 n .

La i n s p e c c i 6 n d e este manua l a b a r c a e l p r o c e s o 3. En c u a n t o a 10s p r o c e s o s 1, 2 y 4 , c o n s u l t e e l manua l d e r e p a r a c i o n e s d e l mode lo c o r r e s p o n d i e n t e .

HgTODO DE EXPLICACION

1. P r o c e d i m i e n t o d e t r a b a j o (1) E l p r o c e d i m i e n t o d e t r a b a j o se d e s c r i b e e n l a f o r m a A o e n l a

f o r m a B como se i n d i c a a c o n t i n u a c i b n . Forma A: E x p l i c a c i 6 n d e c a d a e t a p a d e t r a b a j o c o n u n a i l u s t r a c i 6 n . Forma B: E x p l i c a c i 6 n d e l p r o c e d i m i e n t o d e t r a b a j o i n d i c a n d o 10s niimeros d e l a s e t a p a s e n u n a i l u s t r a c i 6 n , s e g u i d o d e l a e x p l i c a c i 6 n d e l a s p r e c a u c i o n e s y n o t a s r e s u m i d a s como p u n t o s d e t r a b a j o .

Ejemplo d e l a d a a c r i p c i b n e n e l t i p o B:

DESMONTAJE - INSPECCION - REMONTAJE Unidad d e l p a r d a a p r e t a m i e n t o T = N . m (kg-cm)

S i un l u g a r o una p a r t e no s a puede i n d i c a r d i r e c t a m e n t e , e l nombre d e l a p a r t e s e d e s c r i b e en uno d e 1 0 s l a d o s d e l a i l u a t r a c i b n .

Ejemplo: 1 T u b e r i a e

P r o c e d i m i e n t o d e deamonta je

1 S a q u e l a c u b i e r t a d e l e x t r e m o t r a s e r o . S e e x p l i c a d e s p u 6 s l

2 S a q u e e l e l s u j e t a d o r d e l a e s c o b i l l a . [ P u n t o 11 3 S a q u e e l r e g u l a d o r d e C I . [ P u n t o 21

P u n t o s d e t r a b a j o : E j e m p l o d e l p u n t 0 c l a v e p a r a e l t r a b a j o c o n u n a i l u s t r a c i 6 n / [ P u n t o 11 F' I n s p e c c i 6 n : I n s p e c c i o n e y r e p a r e l a s e s c o b i l l a s 1 Mida l a l o n g i t u d d e l a e s c o b i l l a .

E s t b n d a r : 1 0 , 5 mm L i m i t e : 1 , 5 mm

HOW TO READ THIS MANUAL

EXPLANATION RANGE OF REPAIR WORKS

Repair works are classified into 4 processes. Process 1. Troubleshooting on the truck. Process 2. Removal from the vehicle and installation. Process 3. Disassembly and assembly/inspectionladjustment. Process 4. Completion inspection. This manual inspection process 3. For processes 1, 2 and 4, please refer to the repair manual of the corresponding model.

EXPLANATION METHOD

1 . Operation procedure (1 I The operation procedure is described in either pattern A or pattern B below.

Pattern A: Explanation of each operation step with an illustration. Pattern B: Explanation of operation procedure by indicating step numbers In one illustration, followed by explsnstion of cautions and notes summarized as point operations.

Example of Description in Pattern 6 I -1 / DISASSEMBLY-INSPECTION-REASSEMBLY

Tightening torque unit T = N.m (kgf - cm) [ft -Ibfl

If a place or part cannot be indicated directry, the part name is described on either side of the illustration.

Example: 1 Piping

i I

Disassembly Procedure

1 Remove the rear end cover. ,' Operation explained later

2 Remove the brush holder. [Point 11

3 Remove the IC regulator. [Point 21

Point Operations Example of key point for operation with an illustration.

[Point 11 / Inspection: Inspect and repair the brushes.

1. Measure the brush length.

Standard: 10.5 rnrn (0.413 In) Llrnlt: 1 . 5 rnm (0.059 in)

2 . Cbmo i n t e r p r e t a r l a 8 f i g u r a e d e 10s componentes (Ejemplo) ( 1 ) La f i g u r a d e 1 0 s componentes u t i l i z a l a

i l u s t r a c i b n d e l c a t i l o g o d e p a r t e e p a r a e l 3201 modelo d e l v e h i c u l o . C o n e u l t e e l c a t t i l o g o NGmero d e l a p a r a comprobar e l nombre d e l a p a r t e . f i g u r a e n e l E l nGmero d e l a p a r t e s u p e r i o r d e r e c h a d e cada c a t i l o g o d e f i g u r a d e l o e componentee i n d i c a e l ndmero d e r e p u e e t o e l a f i g u r a e n e l c a t i l o g o d e r e p u e a t o e .

3 . P a r t e a o m i t i d a e e n e e t e manual ( 1 ) E s t e manual o m i t e l a d e a c r i p o i b n d e 10s t r a b a j o s s i g u i e n t e e , aunque

d e b e r d n r e a l i e a r s e e n e l t r a b a j o r e a l : 1 L impieea y l a v a d o d e l a a p a r t e e a a c a d a a , aeg6n eea n e c e e a r i o 2 I n a p e c c i b n v i s u a l ( d e a c r i t a p a r c i a l m e n t e ) 3 L e v a n t a m i e n t o c o n e l g a t 0 mecdnico y o t ro s m e d i o s

TERHINOLOGIA IWORTANTE

P r e c a u c i 6 n : E x p l i c a c i 6 n i m p o r t a n t e , que a i no t i e n e e n c u e n t a puede c a u s a r a c c i d e n t e s . Debe o b a e r v a r l a s i n f a l t a .

No t a : E x p l i c a c i b n i m p o r t a n t e , que a i no t i e n e en c u e n t a puede c a u s a r a c c i d e n t e s , o a a u n t o a que r e q u i e r e n a t e n c i b n e e p e c i a l d u r a n t e e l p r o c e d i m i e n t o d e t r a b a j o .

E s t i n d a r : Ea e l a l c a n c e p e r m i t i d o en l a i n s p e c c i 6 n o a j u s t e . L i m i t e : E l v a l o r mdximo o minimo tomado como c r i t e r i o en l a i n s p e c c i 6 n

o a j u a t e .

ABREVIATURAS

A b r e v i a t u r a S i g n i f i c a d o A b r e v i a t u r a S i g n i f i c a d o

APMS (BTDC) Antes pun to muerto PMS Punto muerto s u p e r i o r s u p e r i o r RIM Manual d e r e p a r a c i o n e s

DOHC Arbol de l e v a s s o b r e cu la ta rpm Revoluc ionea por minuto doble SST H e r r a m i e n t a e s p e c i a l d e

DPMS

EX IN MP O H V

Despuhs punto muerto s e r v i c i o superior s t . C a r r e r a a Escape STD E a t d n d a r

Admiai6n T = P a r d e a p r e t a m i e n t o

Grasa d e o b j e t i v o m G l t i p l e 'IS Vdlvu la s o b r e c u l a t a

O/S Sobretamaiio OPT. (OPC.) Opci6n PMI Punto muerto i n f e r i o r

INSTRUCCIONES SOBRE LA REPARACION

1 . TRABAJO CON SEGURIDAD ( 1 ) Use a i e m p r e e l e q u i p o d e p r o t e c c i 6 n c o r r e c t a m e n t e ( g o r r o , l e n t e s d e

s e g u r i d a d , g u a n t e a , z a p a t o a de e e g u r i d a d , e t c . ) . ( 2 ) P a r a e v i t a r quemadurae, no t o q u e e l r a d i a d o r , e l s i l e n c i a d o r , l a

t u b e r i a d e e s c a p e , e t c . , i n m e d i a t a m e n t e daapu6a d e p a r a r e l motor. ( 3 ) No co loque l a r o p a , l a 8 h e r r a m i e n t a s , e t c . , c e r c a d e l a e p a r t e s en

r o t a c i 6 n d u r a n t e e l t r a b a j o en e l motor . ( 4 ) Saque l a l l a v e d e e n c e n d i d o p a r a e v i t a r que e l motor a r r a n q u e

r e p e n t i n a m e n t e e x c e p t o cuando s e a n e c e s a r i o q u e e l motor e a t 6 e n marcha. D e s c o n e c t e e l c a b l e d e l a b a t e r i a d e l l a d o d e l t e r m i n a l d e l a b a t e r i a p a r a e v i t a r c o r t o c i r c u i t o s .

( 5 ) AsegGreae d e que ae u t i l i z a n l o 8 c a b l e s d e l a r e e i a t e n c i a c o r r e c t a p a r a l e v a n t a r m a t a r i a l e a pesados .

( 6 ) Despues de l e v a n t a r e l v e h i c u l o con e l g a t o mec8nic0, apoye e l v e h i c u l o en s o p o r t e s , e t c .

REPAIR INSTRUCTIONS

0-5

2. How to read components figures (1) The components figure uses the illustration

in the parts catalog for the vehicle model. (Example) Please refer to the catalog for checking the part name. The number at the right shoulder of each components figure indicates the Fig. number in the parts catalog. FIG number in parts catalog

3. (1 ) Matters This manual omitted omits in this description manual of the following E?3 jobs, but perform them in actual operation:

Cleaning and washing of removed parts as required 2 Visual inspection (partially described] 3 Jacking and lifting a

SIGNAL WORD DEFINITIONS

Caution: An important explanation item, negligence of which may cause an accident.

Note: An important explanation item, negligence of which may damage your vehicle. It also shows an item which requires special care in doing the repair work.

Standard: The permissible range in inspection or adjustment.

Limit: The maximum or minimum value of the criterion in inspection or adjustment.

ABBREVIATIONS

1 . SAFE OPERATION (1) Correctly wear protection tools (cap, safety, glasses, gloves, safety shoes, etc.) (2 ) Do not touch the radiator, muffler, exhaust pipe and other engine related parts immediately after

stopping the engine to prevent scalding. (3) Do not bring clothes, tools and others close to rotating parts during engine operation. (4) Remove the ignition key to prevent unexpected engine starting unless the engine operation is

necessary. Disconnect the battery cable from the negative terminal of the battery to prevent short circu~t.

( 5 ) Be sure to use wire ropes of the correct size for hoisting a heavy material. (6) After jacking up, always support the frame with stands, etc.

2. PREPARATION BEFORE DISASSEMBLY ( 1 ) Prepare general tools, SST, measuring tools, oils, greases, and non-reusable parts. 121 When disassembling a complicated assembly, put punch or matching marks at places not affect-

ing the function to facilitate reassembly operation.

Abbreviation ASSY ATDC BTDC

EX IN

01s OPT

2 . REPARACION ANTES DEL DESMOHTAJE ( 1 ) P r e p a r e l a e h e r r a m i e n t a s g e n e r a l e s , l a e SST, l a 8 h e r r a m i e n t a s de

medic ibn , e l a c e i t e y l a 8 p a r t e s d e s e c h a b l e s . ( 2 ) Cuando desmonte un c o n j u n t o compl icado , puneone o ponga marcaa de

a c o p l a m i e n t o en l u g a r e a que no a f e c t e n e l f u n c i o n a m i e n t o , p a r a f a c i l i t a r e l r e m o n t a j e .

Meaning

Assembly After top dead center Before top dead center Exhaust Intake Over size Option

Abbreviation OHV RIM rpm SST STD T = UIS

Meaning Over head valve Repalr manual Revolut~on per minute Special service tool Standard Tightening torque Under slze

3. CUIDADOS DURANTE EL DESMONTAJE (1 ) Cada vez que saque una parte,compruebe c6mo e s t a b a i n s t a l a d a

e s t a p a r t e y compruebe tamb ien l a p a r t e p o r s i e s t d deformada, t i e n e d e t e r i o r o s , aspereza y rayados .

( 2 ) Las p a r t e s desmontadas deberdn c o l o c a r s e en orden. D i s t i n g a l a s p a r t e s que va a recambiar de l a s que va a v o l v e r a u t i l i z a r .

( 3 ) Las p a r t e s que va a v o l v e r a u s a r deberdn l i m p i a r s e y l a v a r s e bien;

(4 ) E l desmontaje d e l equ ipo h i d r d u l i c o deberd r e a l i z a r s e en p a r - t i c u l a r en un l u g a r l i m p i o usando h e r r a m i e n t a s l i m p i a s .

4. INSPECCION Y MEDICION (1 ) La i n s p e c c i 6 n y m e d i c i 6 n d e t a l l a d a s deberen r e a l i z a r s e cuando

sea n e c e s a r i o p a r a l a s p a r t e s que va a v o l v e r a u s a r .

5 . INSTALACION (1 ) I n s t a l e l a s p a r t e s c o r r e c t a s s i g u i e n d o e l p r o c e d i m i e n t o c o r r e c t 0

y observando 10s s tandards determinados (pares de apre tamien to , v A l v u l a s de a jus te , e t c . ) .

(2 ) Use s iempre p a r t e s genuinas p a r a e l recambio de l a s p a r t e s e x i s t e n t e s .

(3 ) Recambie s iempre l a s j u n t a s herm6t i cas de a c e i t e , 10s a n i l l o s en "O", l a s j u n t a s de empaquetadura, 10s pasadores de chaveta, e t c . p o r nuevos.

(4) R e v i s t a con empaquetadura de s e l l a d o l a s j u n t a s de empaquetadura dependiendo de 10s lugares , r e v i s t a con a c e i t e 10s l u g a r e s de c o n t a c t 0 d e s l i z a n t e s , r e v i s t a con a c e i t e o g r a s a 10s l u g a r e s e s p e c i f i c a d o s , y r e v i s t a con g r a s a de o b j e t i v o m 6 l t i p l e 10s bordes de l a s j u n t a s hermet i cas de a c e i t e a n t e s d e l remonta je .

6 . AJUSTES Y FUNCIONAMIENTO (1 ) A j u s t e a 10s v a l o r e s s t a n d a r d de s e r v i c i o usando medidores y

probadores .

7. P a r t e s r e v e s t i d a s p rev iamente Las p a r t e a r e v e s t i d a s p r e v i a m e n t e son 10s pernos, t u e r c a s , e t c . que han s i d o r e v e s t i d o s con un adhes ivo de s e l l a d o en l a f i b r i c a .

( 1 ) No use p a r t e s r e v e s t i d a s p rev iamente en n inguno de 10s casos s i g u i e n t e s : 1 Cuando se saca una p a r t e r e v e s t i d a p rev iamente . 2 Cuando ae saca una p a r t e r e v e s t i d a p rev iamente como r e a u l t a d o de

una comprobac i6n d e l p a r de a p r e t a m i e n t o , e t c .

Nota: Compruebe e l p a r en e l l i m i t e i n f e r i o r d e l p a r de a p r e t a m i e n t o . S i se mueve, v u e l v a a a p r e t a r segGn e l p r o c e d i m i e n t o a i g u i e n t e :

3. CARE DURING DISASSEMBLY (1) Each time a part is removed, check the part for the installed state, deformation, damage, rough-

ening and scratching. (2) Disassembled parts must be arranged orderly. Distinguish the parts to be replaced from the parts

to be reused. (31 Parts to be reused must be cleaned and washed throughly. (4) Disassembly of hydraulic equipment must paticularlly be done in a clean place using clean tools.

4. INSPECTION AND MEASUREMENT (1 I Detailed inspection, measurement and judgement must be carried out as required for parts to

be reused.

5. INSTALLATION (1 I Install correct parts according to the correct procedure and observing the determined standards

(tightening torques, adjustment values, etc.1 (2) Always use genuine parts for replacement of existing parts. (31 Always replace oil seals. O-rings, gaskets, cotter pins, etc., with new ones. (4) Coat seal packing on gasket depending on the places, coat oil on the sliding contact places, coat

oil or grease at specified places, and coat MP grease on oil seal lips before reassembly.

6. ADJUSTMENTS AND OPERATION (1) Adjust to the service standard values by using gauges and testers.

7. PRECOATED PARTS Precoated parts mean bolts, nuts, etc., that have been coated with a seal lock adhesive at the factory.

(1) Do not use precoated pert in any of the following

1 When a precoated part is removed. 2 When a precoated part is removed as a result of g a s e s :

tightening torque check, etc.

Note: Check the torque with the lower limit of the tightening torque. I f I t moves, retlghten i t according to the following procedure.

(21 Recoating of precoated parts @ Clean off the old adhesive from the bolt, nut or

2 Dry with compressed air. 3 Apply the specified seal lock adhesive to the bolt 8 threads'

or nut threads.

( 2 ) R e v e s t i m i e n t o de l a s p a r t e s r e v e s t i d a s p r e v i a m e n t e 1 Q u i t e b i e n e l adhes ivo v i e j o d e l perno, l a t u e r c a o l a s

r o s c a s . 2 Seque con a i r e compr imido. 3 A p l i q u e a d h e s i v o de s e l l a d o e s p e c i f i c a d o a l a s r o s c a s d e l pe rno

o l a t u e r c a .

F i g . Agente de s e l l a d o

PARES DE APRETAUIBATO DB LOS PKRHOS X TUERCAS ESTANDAR

C6mo juzgar e l par de ap re t amien to de l o r pernos y l a 8 t u e r c a s e s t i nda r .

, Cbmo juogar e l par de ap re t amien to d e l perno o s t i n d a r . ~ v e r i g i i e e l tip0 d e l perno que burca consul tando l a l i r t a r i gu i en te . Luego, aver igbe e l par de a p r e t a 8 i e n t o buecando en l a t ab l a .

:. C6mo jusgar e l par de ap ra t amien to de l a t ue roa e r t i n d a r . E l pa r de a p r e t a m i e n t o do l a t u e r o a r e puede j u r g a r eab iendo e l t i p 0 d e l perno. (Vea e l punto a n t e r i o r ) .

HETODO DE IDENTIPICACIOH DBL TIP0 DB RESISTBHCIA DE LOS PERNOS

1. I d e n t i f i c a c i 6 n eegGn l a forma d e l 2. I d e n t i f i c a c i 6 n regGn e l perno nGnero de l a p a r t e

Porma y desc r ipc i6n

No. de l a cabers d e l perno

Perno de oabera hexagonal

Sin marca

Perno de Sin marca reborde hexagonal

Claee Perno d e cabeza hexagonal

4 = 4T 5 = 5T 6 = 6T NO. de l a p a r t e 7 1 7 1 91611-40625 8 = 8T

Perno de Doe l i n e a e en cabeza r e l i e v e 51 hexagonal

Longitud

Perno de Doe l i n e a r en reborde r e l i e v e 6 1 Perno f i j o hexagonal

Longitud (om) Diimetro (ma)

Claee

Diimetro

Perno do Tree l i n e a r en No. de 18 p a r t e cabeza r e l i e v e 7T 921 32-40614 hexagonal

Perno d e T r e s l i n e a s e n Clare

cabeza r e l i e v e 8T hexagonal

Diimetro

Perno eoldado 4T Longi tud

Sin marca 4T

Perno f i j o

Con ranura 6T

STANDARD BOLT AND NUT TIGHTENING TORQUE

How to judge tightening torque of a standard bolt or nut

1. How to judge tightening torque of a standard bolt. Find out the type of the bolt from the list below. Then, find the bolt tightening torque from the table.

2. How to judge tightening torque of a standard nut. The nut tightening torque can be judged from the bolt type. (See the item above.)

BOLT STRENGTH TYPE IDENTIFICATION METHOD

1 H e x a n 1 No mar, flange bolt I 4T I

1. ldentification by bolt shape

TWO protruding 1 I / Z:K 1 0 lines

Class 4 = 4T 5 = 5T 6 = 6T 7 = 7T 8 = 8T

4T

Hexagon head bolt

Three protruding 1 7T 1 / Ret 1 0 lines

Shape and class

@- Bolt head No.

No mark

Hexagon flange bolt

Welded bolt I I i IT i

2 , ldentification by part No.

Hexagon head bolt 1

I

Part No 9161 1-40625

Length lmml

D~ameter lmml

Two protruding lines

iameter

6T

Pan N O

92132-40614

- D~nmeter lmml

iameter

Length M

TABLA DE U S PARES DE APRETAMIEETO Par eepeoificado

Clase Diimetro Paso Perno de Perno de cabeza hexagonal reborde hexagonal

0-8

TIGHTENING TORQUE TABLE

PUESTA A PUNT0 DEL MOTOR ENGINE TUNE-UP Page

INSPECCION DEL AGUA DE ENFRIAMIENTO .............. 1 - 2

INSPECCION DEL ACEITE DE MOTOR ................... 1- 2

INSPECCION DEL ELECTROLITO DE LA BATERIA ......... 1- 2

INSPECCION Y LIMPIEZA DEL FILTRO DE AIRE ......... 1-2

INSPECCION DEL SISTEMA DE AVISO DE TAPONAMIENTO .. 1 - 2

INSPECCION Y AJUSTE DE LA TENSION DE LA CORREA EN "VM ...................................... 1- 3

INSPECCION DE LAS BUJIAS DE ENCENDIDO ............ 1-4

INSPECCION Y AJUSTE DE LA DISTRIBUCION DE ENCENDIDO ................................... 1-4

INSPECCION Y AJUSTE DE LA VELOCIDAD DE MARCHA EN VACIO (RALENTI) ............................. 1-5

INSPECCION Y AJUSTE DEL AUMENTO DE MARCHA EN VACIO ...................................... 1-6

INSPECCION/AJUSTE DE LA VELOCIDAD MAXIMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIN CARGA 1-6

COOLING WATER INSPECTION .................. ... ... 1-2

ENGINE OIL INSPECTION ..................................... 1-2

BATTERY FLUID INSPECTION ............................. 1-2

AIR CLEANER INSPECTION .CLEANING .............. 1-2

CLOGGING WARNING SYSTEM INSPECTION .... 1-2

V BELT INSPECTION . ADJUSTMENT ................... 1-3

SPARK PLUG INSPECTION ................... ... ....... 1-4

IGNITION TIMING INSPECTION ADJUSTMENT .................................................. 1-4

IDLE SPEED 1NSPECTION.ADJUSTMENT ........... 1-5

IDLE UP INSPECTION . ADJUSTMENT .................. 1-6

NO-LOAD MAXIMUM SPEED ............................ INSPECTION .ADJUSTMENT 1-6

LOADED MAXIMUM SPEED MEASUREMENT ..... 1-7 MEDICION DE LA VELOCIDAD MAXIMA CON CARGA . . . . . . 1-7

INSPECCION DEL AGUA DE ENFRIAMIENTO 1. Inspecc ione e l n i v e l d e l agua d e e n f r i a m i e n t o .

Es tdnda r : E l n i v e l d e l agua d e e n f r i a m i e n t o debe rd estar e n t r e l a s marcas "FULL" ( l l e n o ) y "LOW" (ba jo ) .

2 . In specc ione l a concen t r ac i6n d e l LLC ( r e f r i g e r a n t e d e l a r g a v i d a l . Es tdnda r : 30% (50% p a r a zonas f r i a s ) o mas.

3 . Compruebe que no hay mezclados contaminantes t a l e s como aceite.

INSPECCION DEL ACEITE DE MOTOR 1. Inspeccione e l n ive l a c e i t e .

Estdndr: El n i v e l de a c e i t e deberd e s t a r e n t r e l a s l i n e a s "FULL"(1leno) y "LOWM(bajo) de l a v a r i l l a indicadora de n i v e l .

Sumidero de a c e i t e r t f i l t r o de a c e i t e : 4,2 l i t r o s Sumidern de a c e i t e : 3 , 8 l i t r o s

2. El a c e i t e debere e s t a r l i b r e de contaminantes pesados y t e n e r l a v i scos idad adecuada. El a c e i t e no debera contener r e f r i g e r a n t e n i a c e i t e l i g r o .

INSPECCION DEL FLUID0 DE LA BATERIA 1. Inspecc ione e l n i v e l d e l f l u i d o d e l a b a t e r l a .

Es tdnda r : Deberd e s t a r e n t r e l a s marcas "MAX" y "MIN" . 2 . I n specc ione l a gravedad e s p e c l f i c a d e cada e lemento .

Es tdnda r : 1 / 2 5 - 1 / 2 0 (a 20' C) Nota: S i e l f l u i d o d e l a b a t e r i a es i n s u f i c i e n t e , aiiada agua d e s t i l a d a .

INSPECCION/LIMPIEZA DEL FILTRO DE AIRE 1. Inspecc ione e l e lemento d e l f i l t r o d e a i r e p o r s i hay d e t e r i o r o ,

contaminaci6n o taponamiento . 2 . Limpie e l e lemento d e l f i l t r o d e a i r e con a i r e comprimido.

Nota : La p r e s i 6 n d e a i r e d e b e r i s e r d e 680 kPa (7 kgf/cm2) o menos.

3 . Limpie e l i n t e r i o r y e l e x t e r i o r d e l a c a j a d e l f i l t r o d e a i r e con un t r a p o d e t r a b a j o .

INSPECCION DEL SISTEMA DE AVISO DE TAPONAMIENTO 1. Inspecc ibn en e l v e h i c u l o

Gire l a l l a v e d e l i n t e r r u p t o r de encendido a "ON" y compruebe s i l a ldmpara d e a v i s o d e l f i l t r o d e a i r e que hay en e l p a n e l i n s t r u m e n t a l s e enc i ende . Compruebe tambi6n s i s e apaga cuando e l motor s e pone e n marcha.

COOLING WATER INSPECTION

1 . lnspect the cooling water level. ' FULL /l I Standard: The cooling water level shall be between the

I : FULL and LOW marks

; , 1 2. lnspect the LLC (Long Life Coolant) concentration.

! , \ Standard: 30% (50% for frigid zone) or more ' / , I I J 3. Check to see that no contaminant such as oil is mixed.

, ] ENGINE OIL INSPECTION

1, lnspect the oil level.

Standard: Shall ba between the full and low lines on the oil level gaga.

Oil pan + 011 filter: 4.2 1i1.11 US gal) Oil pan: 3.8 1 (1.00 US gall

1 1 2. The oil shall have appropriate viscosity without ex- ( I cessive contamination. Neither cooling water nor fuel

shall be mixed.

BATTERY FLUID INSPECTION

1, lnspect the battery fluid level.

Standard: Shell be between the MAX and MIN marks.

2, lnspect the specific gravity of each cell.

Standard: 1.25 - 1.28 (at 20°C ( 6 8 O F ) )

Note: If the battery fluid Is insufficient, add distilled water.

I \ I AIR CLEANER 1NSPECTION.CLEANING 1, lnspect the air cleaner element for damage, contamina-

tion and clogging.

2. Clean the air cleaner element with compressed air.

Note: The air pressure shall be 680 kPa (7 kgflcm21 I100 psi1 or less.

3. Clean the inside and outside of the air cleaner case by wiping with waste cloth.

CLOGGING WARNING SYSTEM INSPECTION

1 . ON-vehicle inspection Turn the key switch to ON and check if the air cleaner warning lamp on the instrument panel comes on. Also check if it goes out when the engine is started.

2. Inspecci6n individual Inspeccione la continuidad del interruptor de vacio cuando se aplica presibn negativa. Estdndar: Aprox. 7473 f 569 Pa (762 ). 58 mm H20, 56,O ). 4,3 mm Hg):

Habrd continuidad (no estarl abierta). Nota: Nunca aplique una presi6n negativa a 9807 Pa (1000 m H20, 72,O m Hg) a1 interruptor de vacio.

INSPECCION/AJUSTE DE LA CORREA EN "V" 1. Asegbrese de que el borde de la correa en "V" no alcanza la parte

inferior de la ranura de cada polea.

2. Inspeccione la flexi6n de la correa cuando el centro entre la bomba de agua y el alternador se empuja con una fuerza de aprox. 98 N (10 kgf . En la instalaci6n de la correa nueva:

7 - 9 m m En cada inspeccibn:

8 - 1 6 m m

Fig. posici6n de rnedici6n

Nota: Cuando se usa un medidor de tensiones: Aplique la SST (medidor de tensiones) entre la bomba de agua y el alternador y rnida la tensi6n. SST 09216-00021 A1 instalar la nueva correa: 392 - 588 N (40 - 60 kgf)

En cada inspecci6n: 294 - 392 N (30 - 40 kgf) Cuando recambie por una correa nueva, ajuste el valor central del alcance estdndar a1 instalar la correa nueva. Cuando vuelva a instalar una correa que se ha usado durante 5 minutos o m6s, ajuste el valor central del alcance estdndar en cada inspecci6n.

3. Ajuste de la flexi6n (1) Afloje el perno pasador A y el perno de inrnovilizaci6n B. (2) Ajuste la flexi6n. (3) Apriete 10s pernos en el orden de B y A. (4) Vuelva a medir la flexi6n.

, , i 2 , Individual insoection

1 Inspect the vecuum switch continuity when a negative pressure is applied.

Standard: Approx. 7473 + 569 Pa (762 + 58 m m HIO, 56.0 + 4.3 mmHg) f30.00 + 2.28 inHz0, 2.205 + 0.169 inHgl: Shall be continuous inot open).

Note: Never apply a negative pressure at 9807 Pa (1000 mmH20, 72.0 mmHgl (39.4 inH20, 2.83 inHgl to the

I I vacuum switch.

V BELT INSPECTION.ADJUSTMENT

- -- Mcastlrement & position

2 . lnspect the belt flexure when the center between the water pump and alternator is pushed with a force of approx. 98 N (10 kgf) I22 Ibfl.

Upon new belt installation: 7 - 9 mm (0.28 - 0.35 in)

A t each inspection: 8 - 16 mm (0.31 - 0.63 in1

Note: When e tension gage is used: Apply the SST (tension gaga) between the water pump and alternator and measure the tension. SST 09216-00021

Upon new belt insts\lation: 392 - 588 N (40 - 60 kgfl I88 - 132 Ibf l

A t each inspection: 294 - 392 N (30 - 40 kgfl [66 - 88 lbf l

When replacing with a new belt, adjust to the center value of the standard range upon new belt installation. When installing the belt that has been used for 5 minutes or more again, adjust to the center value of the standard range at each inspection.

Flexure adjustment (1 ) Loosen through boit A and lock boit 8. ( 2 ) Adjust the flexure. (3) Tighten bolts in the order of B and A. (4) Measure the flexure again.

Fig. Perno B Perno A

INSPECCION DE LA BUJIA DE ENCENDIDO 1. Inspeccione l a separaci6n.

~ s t b n d a r : 1 , 4 - 1 , 6 nun 2 . Ajuste o recambie s i no se s a t i s f a c e e l es tdndar .

-

I SPARK PLUG INSPECTION

1, Inspect the gap.

Standard: 1.4 - 1.6 mm (0.055 - 0.063 in)

2. Make adjustment or replacement if the standard is not satisfied.

INSPECCION/AJUSTE DE LA DISTRZBUCION DE ENCENDIDO I

I. Cal ien te e l motor. IGNITION TIMING INSPECTION - Temperatura d e l aqua de enfr iamiento: 8 0 ° C o mds ADJUSTMENT Temperatura d e l a c e i t e h idrdu l ico : 60° C o mds Nota: 1. Warm up the engine. Compruebe que l a vklvula de estrangulaoi6n esti totalmente a b i e r t a .

2 . Coloque un tac6metro y una luz de d i s t r i b u c i 6 n . Desconecte e l Cooling water temperature: 80°C (176°F) or more conector de inspeccibn y conecte e l cordbn de medici6n d e l tac6metro Hydraulic oil temperature: 60°C (140°F) or more en e l lado macho.

3. Compruebe l a d i s t r i b u c i 6 n de encendido. Note: (1) Desconecte e l conector de l a d i s t r i b u c i 6 n de encendido. Check to see that the choke valve is fully opened.

F i g . 2. Set a tachometer and timing light. Disconnect the Conector de d i s t r i b u c i 6 n de encendido inspection connector and connect the tachometer

measurement cord to the male side.

3. Ignition timing check. (1) Disconnect the ignition timing connector.

(2) Compruebe l a d i s t r i b u c i 6 n de encendido. Estandar: APMS 8 ' * 2 ' /ve loc idad de marcha en vacio

(3 ) S i no se s a t i s f a c e e l es tdndar , a f l o j e e l perno de sujeci6n d e l d i s t r i b u i d o r y g i r e e l d i s t r i b u i d o r para a j u s t a r .

( 4 ) Conecte e l conector de d i s t r i b u c i d n de encendido.

(2) Check the ignition timing.

Standard: BTDC 8' * 2'Iidla speed

(3) If the standard is not satisfied, loosen the distributor set bolt and rotate the distributor for adjustment.

(4) Connect the ignition timing connector.

INSPECCION/AJUSTE DE LA VELOCIDAD DE MARCHA EN VACIO (Motor de gasolina o gasolina GLP)

Nota: La velocidad de marcha en vacio se controla electrbnicamente.

1. Caliente el motor. Temperatura del agua de enfriamiento: 8 0 ° C o m6s Temperatura del aceite hidr6ulico: 60° C o m6s

2. Instale un tac6metro y un vacu6metro. (1) Desconecte el conector de inspecci6n y conecte el cordbn de

medici6n del tac6metro en el lado macho. (2) Desconecte la tuberia flexible de vacio e instale el vacu6metro.

3 . Inspecci6n y ajuste de la velocidad de marcha en vacio (ralenti) (1) Mida la velocidad de marcha en vacio. Estbndar: Vea el manual de reparaciones para cada modelo de

vehiculo. Ajuste el tornillo de ajuste de mezcla de tal manera que la presi6n negativa se estabiliza entonces a1 nivel m6s alto. Nota : Si la velocidad de marcha en vacio es alta, compruebe si el tornillo de ajuste de marcha en vacio est& empujando la palanca. Si empuja la palanca, afloje el tornillo. (2) Compruebe y ajuste la holgura entre el tornillo de ajuste de

marcha en vacio y la palanca. Est6ndar: 0 mm

Fig. Tornillo de ajuste de marcha en vacio Tornillo de ajuste de la mezcla

(Motor GLP) 1. Caliente el motor y conecte el tac6metro de la misma manera que en

el motor de gasolina o gasolina/ GLP. 2. Inspecci6n y ajuste de la velocidad de marcha en vacio.

(1) Ajuste la velocidad de marcha en vacio con el tornillo de ajuste de la obturaci6n. Estdndar: Vea el manual de reparaciones para cada modelo de

vehiculo. (2) Gire el tornillo de ajuste de marcha en vacio lentamente hacia

la derecha o hacia la izquierda y ajdstelo en la posici6n en que la velocidad sea la mdxima.

(3) Gire el tornillo de ajuste de la obturaci6n para alcanzar el valor est6ndar.

Nota: Repita las et.apas (2) y (3) hasta que el eatado indicado en la etapa (2) satisfaga el estindar.

(4) Gire el tornillo de ajuste de marcha en vacio hacia la izquierda hasta que la velocidad comience a descender, y vu6lvalo entOnCeS 4 5 O hacia la derecha a partir de esa posici6n.

Fig. Tornillo de ajuste de la obturaci6n Tornillo de ajuste de marcha en vacio

~ - -

IDLE SPEED INSPECTION . ADJUSTMENT

(Gasoline or GasolinelLPG Engine)

Note: The idle speed is controlled electronically.

1. Warm up the engine.

Cooling water temperature: 80°C 1176°F) or more Hydraulic oil temperature: 60°C (140°F) or more

2, Install a tachometer and vacuum gage. (1) Disconnect the inspection connector and connect the

tachometer measurement cord to the male side. (2) Disconnect the vacuum hose and install the vacuum

gage.

3, ldle speed inspection and adjustment. [ I ) Measure the idle speed.

Standard: Refer t o t h e repai r manua l for each vehicle model.

Adjust the mixrure adjusting screw so that the negative pressure then is stabilized at the highest level.

Note: If the idle speed is high, check if the idle adjusting screw is pushing the lever. I f it pushes the lever, loosen the screw.

(2) Check and adjust the clearance between the idle adjusting screw and the lever.

Standard: 0 m m (0 in)

(LPG Engine) 1. Warm up the engine and connect the tachometer in the

same as in the gasoline or gasoline1LPG engine.

2. ldle speed inspection and adjustment. (1) Adjust the idle speed with the throttle adjust screw

Standard: Refer t o t h e repai r manua l fo r each vehicle model.

(2) Turn the idle adjusting screw slowly clockwise or counterclockwise and set i t at the position where the speed is the highest.

(3) Turn the thrott le adjusting screw for the standard value.

Note: Repeat steps (21 and (31 unti l the state after step (21 satisfies the standard.

(41 Turn the idle adjusting screw counterclockwise until the speed starts to drop, and turn i t then by 45" clockwise from that position.

INSPECCION/AJUSTE DEL AUMENTO DE MARC= EN VACIO (Motor GLP) 1. Caliente el motor.

Temperatura del agua de enfriamiento: 80' C o mbs Temperatura del aceite hidrdulico: 60° C o mbs

2. Instale un tac6metro. 3. Compruebe la velocidad de aumento de marcha en vacio.

(1) Ponga en marcha el motor. Desconecte la tuberia flexible de vacio del lado del actuador de aumento de marcha en vacio y mida la velocidad despues de taponar la tuberla flexible.

Estbndar: Vea el manual de reparaciones para cada modelo de vehiculo.

(2) Si no se satisface el estdndar, realice el ajuste girando el tornillo de ajuste. Nota : Gire el tornillo de ajuste hacia la derecha pra aumentar la velocidad.

(3) Despues del ajuste, conecte la tuberia flexible de vacio.

Fig. Taponar Tornillo de ajuste

INSPECCION/AJUSTE DE LA VEWCIDAD MAXIMA SIN CAR- (Motor de gasolina o gasolina/GLP)

Nota: La velocidad mAxima se controla electr6nicamente.

1. Caliente el motor. Temperatura del agua de enfriamiento: 80° C o mbs Temperatura del aceite hidrdulico: 60" C o mbs

2. Instale un tac6metro. 3. Inspeccione la velocidad mbxima sin carga cuando se aprieta del todo

el pedal del acelerador. Estdndar: Vea el manual de reparaciones para cada modelo de

vehiculo.

IDLE UP INSPECTION * ADJUSTMENT

(LPG Engine)


Cooling water temparature: 80°C (176°F) or more Hydraulic oi l temparature: 60'C (140°F) or more

2. Install a tachometer

3. Check the idle-up speed. (1) Start the engine. Disconnect the vacuum hose from

the idle-up actuator and measure the speed after plugging the hose.

Standard: Refer to the repair manual for each vehicle model.

(2) If the standard is not satisfied, make adjustment by turning the adjusting screw.

Note: Turn the adjusting screw clockwise to increase speed.

(3) After adjustment, connect the vacuum hose.

NO-LOAD MAXIMUM SPEED INSPECTION - ADJUSTMENT

(Gasoline or GasolineILPG Engine)

Note: The maximum speed is controlled electronically.


Cooling water temperature: 80°C (176°F) or more Hydraulic oi l temperature: 60°C (140°F) or more

2. Install a tachometer.

3. Inspect the no - load m a x i m u m speed, when the accelerator pedal is fully depressed.

Standard: Refer t o the repair manual for each vehicle series.

(Motor GLP) 1. Caliente el motor.

Temperatura del agua de enfriamiento: 80° C o mas Temperatura del aceite hidriulico: 6 0 ° C o mas

2 . 1nstale un tac6metro. 3. Inspeccione y ajuste la velocidad mixima sin carga.

(1) Mida la velocidad cuando se aprieta del todo el pedal del acelerador. Estbndar: Vea el manual de reparaciones para cada modelo de

vehiculo. (2 ) Si no se satisface el estindar, ajuste la velocidad. (3) Saque el perno de sujeci6n del casquillo del regulador de aire.

Gire el casquillo del regulador de aire mientras fija el tornillo de ajuste para ajustar la velocidad.

Nota: Menos del estdndar: Gire el casquillo hacia la derecha. Mds del esthdar: Gire el casquillo hacia la izquierda. (4) Instale el perno de sujeci6n del casquillo del regulador de

aire.

Fig. Perno de sujecibn Casquillo

MEDICION DE LA VEUXIDAD MAXIMA CON CAR= Nota : La velocidad mdxima re controla electrbnicamente en el motor de gasolina o gasolina/GL&'.

(~otOr GLP) 1. Mientras el motor estd marchando a la velocidad mhxima, accione la

palanca de manipulacibn de materiales y mida la velocidad del motor en descompresi6n total. Compruebe que la disminuci6n de la velocidad (descenso de descompresi6n) esti dentro del alcance siguiente: Estandar: Vea el manual de reparaciones para cada modelo de

vehiculo. 2. Si no se satisface el estindar, gire el tornillo de ajuste para

a justar.

Fig. Tornillo de ajuste

(LPG Engine)


Cooling water temperature: 80°C (176°F) or more Hydraulic oil temperature: 60°C (140°F) or more

2. Install a tachometer.

3. Inspect and adjust the no-load maximum speed. (1) Measure the speed when the accelerator pedal is

fully depressed.

Standard: Refer to the repair manual for each vehicle series.

12) If the standard is not satisfied, adjust the speed. (3) Remove the air governor bushing lock bolt.

Turn the air governor bushing whi le f i x ing the adjusting screw to adjust the speed.

Note: Less than standard: Turn the bushing clockwise. More than the standard: Turn the bushing counter-

clockwise.

(4) Install the air governor bushing lock bolt.

LOADED MAXIMUM SPEED MEASUREMENT

Note: The maximum speed is controlled electronically i n the gasoline or gasoline1LPG engine.

(LPG Engine)

1. While the engine is running at the maximum speed, operate the material handling lever and measure the engine speed at full relief. Check that the decrease in the speed (relief down) is within the following range:

Standard: Refer t o the repair manual for each vehicle series.

2. If the standard is not satisfied, turn the adjusting screw for adjustment.

REVISION DEL MOTOR

COMPONENTES ................................... ACCESORIOS DEL MOTOR ..........................

REMOCION/INSTALACION ....................... CULATA DE CILINDROS .........................a.

REMOCION/INSTACACION ........................ PARTES DE LA CADENA DE DISTRIBUCION ...........

REMOCIONIINSTRWLCION ........................ BLOQUE DE CILINDROS ...........................

REMOCION/INSTALACION ........................

ENGINE OVERHAUL Page

.......................................................... COMPONENTS 2-2

ENGINE ACCESSORIES ............................................ 2-8

. ............................................ REMOVAL INSTALLATION 2-8

................... CYLINDER HEAD ............................ . 2-10

REMOVAL . INSTALLATION ....................... ............... .. 2-10

................... TIMING CHAIN PARTS .. ...................... 2-16

. ............................................... REMOVAL INSTALLATION 2-16

...................................................... CYLINDER BLOCK 2-22

. .................... REMOVAL INSTALLATION ........... .... 2-22

COMPONENTES COMPONENTS 1104

ACCESORIOS DEL MOTOR

Notti: Limpie siempre l a s p a r t e s sacadas an tes de l a inspecci6n e i n s t a l a c i b n .

T = N.m (kgf-cm)

P r o c e d i m i e n t o d e remoci6n

1 Saque 10s colgadores d e l motor.

2 Saque l a c o r r e a t ransmisora. [Punto 11

3 Saqua e l a l t e r n a d o r con e l soporte .

4 Saque l a polea d e l arb01 d e l cigtieiial.

5 Saque l a bomba de agua.

6 Ponga e l c i l i n d r o No. 4 en e l PMS de compresi6n. [Punto 2 1

7 Saque l a bobina de encendido d e l d i s t r i b u i d o r . (Vea l a pagina 7- 6

8 Saque e l espaciador y e l carburador.

9 Saque e l c o l e c t o r mti l t iple de escape. [Punto 31

P r o c e d i m i e n t o d e i n s t a l a c i 6 n

E l procedimiento de i n s t a l a c i 6 n e s e l inverso a 1 de remoci6n.

2-8

ENGINE ACCESSORIES

REMOVAL INSTALLATION

Note: Always clean the removed parts before inspection and installation.

T = N.m (kgf - cm) [h - lbfl I

L

1

I

Removal Procedure

1 Remove the engine hangers.

2 Remove the drive belt. IPoint 11

3 Remove the alternator Wlbracket.

4 Remove the crankshaft pulley.

5 Remove the water pump.

6 Set the No. 4 cylinder to compression TDC. [Point 21

7 Remove the ignition coil and distributor. (See page 7-6)

8 Remove the spacer and carburetor.

9 Remove the EX manifold. [Point 31

Installation Procedure

The installation procedure is the reverse of the removal procedure.

sheath

Text Box

Click here for information on Crankshaft Bolt Torque Procedure

Puntos de t r a b a j o

[Punto 11

Instalaci6n: Despues de l a instalaci6n, a jus te l a tensi6n de l a correa. (Vea l a p6gina 1-3)

[Punto 2 )

Remoci6n: Coloque e l c i l indro No.4 en e l PMS de compresi6n.

1. Alinee l a ranura del equilibrador de l drbol del cigiiefial y l a hoja de distr ibuci6n de l a cubierta delantera de l motor.

2. Compruebe que e l ro tor e s t a en l a posici6n No. 4 como s e muestra.

3. Si no es td en l a etapa 2 , g i r e e l arb01 del cigiiefial 360°.

[Punto 3 1

Inspeccibn: Inspeccione l a superficie de montaje de l colector miiltiple por s i hay cualquier deformaci6n.

Llmite: 0,25mm

Instalaci6n: Apriete l a tuerca del colector mGltiple comenzando con l a s dos tuercas centrales.

2-9

Point Operations

[Point 11

Installation: After installation, adjust the belt tension. (See page 1-3)

[Point 21

Removal: Set the No.4 cylinder to compression TDC.

1. Align the groove of the crankshaft balancer and the timing pointer on the engine front cover.

2. Check that the rotor is in a No. 4 position as shown.

3. If not facing in step 2, rotate the crankshaft by 360'.

[Point 31

Inspection: Inspect the manifold mounting face for any distortion.

Limit: 0.26 mm 10.010 in)

Installation: Tighten the manifold nut begining with the center two nuts.

CULATA DE CILINDROS

NOtaS: , Coloque las partes sacadas en orden para evitar instalar en

posiciones incorrectas. , Limpie siempre las partes sacadas antes de la inspeccibn e

instalaci6n. . Antes de instalar las partes, aplique aceite de motor nuevo a todas las superficies deslizantes y rotatorias.

T = N.m (kgf-cm)

Primero: T = 3 (30) Segundo: T = 12 (122) Final: T = 15 (153)

Primeror T = 30 (306) Segundor Perno corto + 55'

Perno medio + 65O Perno largo + 75O

Procedimiento de remoci6n

1 Siga las etapas 1 a 3 y 5 a 8 en la parte de Remoci6n/instalaci6n de accesorios del motor.

2 Saque el colector mclltiple de admisi6n. [Punto 11

3 Saque la cubierta de la culata de cilindros.

4 Saque 10s brazos del balancln de la vdlvula.

5 Saque las varillas de empuje de la vdlvula.

6 Saque el conjunto de la culata de cilindros. [Punto 21

7 Saque la valvula y 10s resortes de la vdlvula. [Punto 31

8 Saque la junta hermetica de aceite del vdstago de la vdlvula. [Punto 4 1

9 Saque el reten de gula del levantador de la valvula.

10 Saque 10s levantadores de las vdlvulas.

CYLINDER HEAD

REMOVAL INSTALLATION

Note: Keep the removed parts i n order t o prevent installation in incorrect positions. Always clean the removed parts before inspection and installation. Before installing the parts, apply new engine oi l t o all sliding and rotating surfaces.

T = N.m (kaf - cm) Lft -Ibfl

1:T. 30 13061 122.11

7 Midlurn length bolt + 65' Long length bolt + 15'

Removal Procedure

1 Follow steps 1 to 3 and 5 to 8 in the Engine Accessories Removal . linstailation section

2 Remove the IN manifold. [Point 11

3 Remove the cylinder head cover.

4 Remove the valve rocker arms.

5 Remove the valve push rods.

6 Remove the cylinder head ASSY. [Point 21

7 Remove the valve and valve springs. [Point 31

8 Remove the valve stem oil seal. [Point 41

9 Remove the valve lifter guide retainer.

10 Remove the valve lifters.

Procedimiento de instalaci6n

El procedimiento de instalaci6n es el inverso a1 de remoci6n.

Puntos de trabajo

[Punto 11

InspecciBn: Inspeccione la superficie de mntaje del colector mClltiple por si hay cualquier delormaci6n.

Limite: 0,25 nun

Instalaci6n: Instale el colector mdltiple.

1. Aplique sellador a1 lado de la culata de cilindros de las nuevas juntas de empaquetaduras del colector mdltiple.

2. Instdlelas en las culatas de cilindros.

Fig. Sellador

3. Aplique sellador a las partes delantera y trasera del bloque de cilindros.

Fig. Sellador

4 . Cubra con Locktite 10s pernos de sujecidn del colector m6ltiple y aprietelos en el orden ilustrado en 3 etapas. (Vea la pagina 2- 10)

2-1 1



Point Operations

[Point 11

Inspection: Inspect the manifold mounting face for any distortion.

Limit: 0.25 m m (0.010 in)

Installation: Install the manifold.

1. Apply a sealant to cylinder head side of new manifold gaskets.

2. Install them to the cylinder heads.

3. Apply a sealant t o the f ront and rear parts of the cylinder block.

4. Coat locktite on the manifold set bolts and tighten them in the illustrated order in 3 steps. (See page 2-10)

Remocibn: A f l o j e 10s pe rnos d e l a c u l a t a en e l orden i l u s t r a d o en 2 6 3 e t a p a s .

In specc i6n : In specc ione l a c u l a t a d e c i l i n d r o s p o r s i e s t 6 deformada.

L imi t e S u p e r f i c i e d e montaje d e l c o l e c t o r m b l t i p l e :

0125 mm S u p e r f i c i e d e monta je de l a c u l a t a d e c i l i n d r o s :

0 , l O mm

In specc ibn : In specc ione l a c u l a t a d e c i l i n d r o s p o r s i t i e n e g r i e t a s . Use comprobacibn d e c o l o r ( d e t e c c i b n d e l a s g r i e t a s mediante c o l o r ) e i n specc ione l a c6mara d e combusti6nl l a s lumbreras d e e n t r a d a y d e s a l i d a , l a s u p e r f i c i e s u p e r i o r d e l a c u l a t a y tambien l a i n f e r i o r .

1 n s t a l a c i b n : C u b r a con L o c k t i t e 10s pe rnos d e l a c u l a t a d e c i l i n d r o s y usando l a SST, a p r i b t e l o s en e l o rden i l u s t r a d o en 2 e t a p a s . (vea l a p6gina 2-10)

[Point 21

Removal: Loosen the head bolts in the illustrated order in 2 to 3 steos.

Inspection: lnspect the cylinder head for any distortion.

Limit: Manifold mounting surface:

0.25 mm (0.010 in) Cylinder head mounting surface:

0.10 mm (0.004 in)

Inspection: Inspect the cylinder head for any crack. Use color check (crack detection method by coloring) and inspect the combustion chamber, IN ports, EX ports, head upper surface and head lower surface.

Installation: Coat locktite on the cylinder head bolts and using SST, tighten them i n the illustrated order in 2 steps. (See page 2-10)

SST 5-36660

[Punto 31

Remoci6n/instalacibn: SST 5-5892

Inspecci6n: Inspeccione la holgura de aceite entre la guia de la v6lvula y el vdstago de la vdlvula.

1. Mida el didmetro interior de la guia de la v6lvula en las posiciones ilustradas.

2. Mida el didmetro del vdstago de la vSlvula en las posiciones ilustradas.

3. Calcule la holgura de aceite.

EstBndar: 0,025 - 0,069 mm Limite:

IN (admisi6n) 0,094 mm EX (salida) 0,119 mm

4 . Si se excede el limite, rectifique la guia y ajuste la holgura de aceite para que este dentro del estandar usando un vastago de la v6lvula O/S .

2-13

SST J-36660

[Point 31

Removal . Installation: SST J-5892

Inspection: Inspect the oil clearance between the valve guide and valve stem.

1. Measure the va lve gu ide ins ide d iameter at the illustrated positions.

2. Measure the valve stem diameter at the illustrated ~osi t ions.

3. Calculate the oil clearance.

Standard: 0.025 - 0.069 mm (0.0010 - 0.0027 in)

Limit: IN 0.094 mm (0.0037 in) EX 0.119 mm (0.0047 in)

4. If the limits is exceeded, ream the guide and adjust the oi l clearance to within the standard by using an 01s valve stem.

Inspecci6n: Inspeccione el asiento de cada vdlvula.

1. Aplique una capa delgada de minio en la superficie de la vdlvula e inserte la vdlvula en la guia. No gire la vdlvula durante la inserci6n.

2. Vea que la anchura de contacto estd dentro del estdndar todo alrededor.

Estdndar : IN (admisibn) 1,02 - 1,65 mm EX (salida) 1,65 - 2,49 mm

3. Si no se satisface el estdndar, recambie la vdlvula o corrija el asiento de la vdlvula.

4. Use una fresa de asientos de vdlvula para rectificar el asiento de la vdlvula y mida el dngulo del asiento y la anchura de contacto.

Angulo del asiento de la vdlvula: 46O

Use una fresa con punta de carburo cementado para el lado de salida. Compruebe la posici6n de contacto de la vdlvula y la anchura de contacto constantemente durante el corte con la fresa. Gradualmente disminuya la fuerza a1 final para evitar que el acabado quede escalonado.

Fig. Desviaci6n

Inspecci6n: Mida la longitud libre del resorte de la v8lvula.

Estdndar: 52;0 mm

Inspecci6n: Usando la SST, mida la tensibn del resorte. SST 5-9666

Estdndar : Cerrado: A 43 mm 338 - 374 N (34,5 - 38,l kgf)

Abierto: A 32 nun 832 - 903 N (84,8 - 92,l kgf)

Remontaje: Despu6s de la instalacibn, mida la altura instalado.

Estdndar: 42,9 - 43,4 mm Si no se satisface el estdndar, recambie el vdstago de la vdlvula, el resorte y la tapa del resorte de la vdlvula como un conjunto.

2-14

Inspection: Inspect each valve seat.

1. Apply a th in coat of red lead on the valve face and insert the valve into the guide. Do not rotate the valve during insertion.

2. See that the contact width is within the standard all around.

Standard: I N 1.02 - 1.65 rnrn ( 0.040 - 0.065 in) EX 1.65 - 2.49 rnm ( 0.065 - 0.098 in)

3. If the standard is not satisfied, either replace the valve or correct the valve seat.

4. Use a valve seat cutter to reface the valve seat and measure the seat angle and the contact width.

Valve seat angle: 46'

Use a cutter with cemented carbide tip for the EX side. Check the valve contact posit ion and contact width constantly during cutting. Gradually release the force near the end of cutting to prevent stepped finish.

Inspection: Measure the free length of valve spring.

Standard: 52.0 rnrn (2.05 in)

Inspection: Using SST, measure the spring tension.

SST J-9666

Standard: Closed: at 43 rnm (1.69 in) 338 - 374 N (34.5 - 38.1 kgf) 176.1 - 84.0 lbfl Open: at 32 mm 11.26 in) 832 - 903 N (84.8 - 92.1 kgf) f187.0 - 203.1 Ibfl

Reassembly: Af ter instal lat ion, measure the instal led height.

Standard: 42.9 - 43.4 mm (1.69 -. 1.71 in)

If the standard is not satisfied, replace the valve stem, spring and valve spring cap as a set.

[Punto 41

Remoci6n: Usando a l i c a t e s , saque l a junta hermetica de a c e i t e d e l vastago de l a valvula .

1 n s t a l a c i 6 n : I n s t a l e una junta hermetica de a c e i t e d e l vastago de l a valvula nueva.

1. Saque e l r e s o r t e expansor f u e r a de l a junta hermbtica de a c e i t e d e l vastago de l a vhlvula nueva.

2. Aplique grasa MP a 1 borde de l a junta hermbtica de a c e i t e . I ' ) 3 . Usando l a SST, i n s t a l e l a junta hermbtica de a c e i t e d e l vastago de

l a va lvu la .

SST 09201-58010

4 . Vuelva a i n s t a l a r e l r e s o r t e expansor.

[Point 4 I

Removal: Using pliers, remove the valve stem oil seal.

Installation: Install new valve stem oil seal.

1. Remove the expander spring from a new valve stem oil seal.

2. Apply MP grease to the oil seal lip.

3. Using SST, install the valve stem oil seal.

SST 09201-58010

4. Reinstall the expander spring.

PARTES DE WI CADENh DE DISTRIBUCION

Notas : Coloque las partes sacadas en orden para evitar instalar en posiciones incorrectas. Limpie siempre las partes sacadas antes de la inspecci6n e instalaci6n.

* Antes de instalar las partes, aplique aceite de motor nuevo a todas las superficies deslizantes y rotatorias.

1 Accesorios del motor

2 partes de la culata del cilindro

7 Holgura de empuje del arb01 de levas

TIMING CHAIN PARTS

REMOVAL. INSTALLATION

Note: Keep the removed parts In order to prevent installation in Incorrect positions. Always clean the removed parts before inspection and installation. Before installing the parts, apply new engine oil to all sliding and rotating surfaces.

T = N.m (kgf - c m ) [fl -Ibfl

1 Engine accessorins 2 Cylinder head parts 7 Camshah lhrust Clearance L T . 25 (255) 118.41

Procedimiento de remoci6n Nota:

Como l a c u b i e r t a de lan te ra d e l motor no s e puede volver a usar , recambie l a junta hermetica de a c e i t e de lan te ra d e l drbol d e l cigiiefial s i n desmontarla d e l motor.

Siga l a s e tapas 1 a 7 en l a p a r t e de Accesorios d e l motor. (Vea l a pdgina 2-8) Siga l a s e tapas 2 a 5, 9 y 10 en l a s p a r t e de l a Culata de c i l i n d r o s . (Vea l a pdgina 2-10) Saque e l sumidero de a c e i t e . [Punto 11 Saque e l contrapeso d e l drbol d e l cigiiefial. [Punto 21 Saque l a junta hermetica de a c e i t e de lan te ra d e l drbol d e l ciglieilal. [Punto 31 Saque l a cub ie r ta de lan te ra d e l motor. Mida l a holgura de empuje d e l drbol de levas . [Punto 41 Saque l a rueda dentada de d i s t r i b u c i 6 n d e l drbol de levas y l a cadena . [Punto 51 Saque l a rueda dentada d e l drbol d e l cigiieilal. [Punto 61 Saque e l engranaje d e l drbol de levas y e l drbol de levas . [Punto 71 Saque e l drbol d e l contrapeso. [Punto 81 Saque e l engranaje d e l drbol d e l contrapeso. [Punto 91

Procedimiento de i n s t a l a c i 6 n E l procedimiento de i n s t a l a c i 6 n e s e l inverso a 1 de remoci6n.

2-17

Removal Procedure

Note: Since the engine front cover is not reusable, replace the crankshaft front oil seal without disassembly from the engine.

1 Follow steps 1 to 7 in the Engine Accessories section. (See page 2-8)

2 Follow steps 2 to 5.9 end 10 in the Cylinder Head section. (See page 2-10)

3 Remove the oil pan. [Point 11

4 Remove the crankshaft balancer. [Point 21

5 Remove the crankshaft front oil seal. [Point 31

6 Remove the engine front cover.

7 Measure the camshaft thrust clearance. [Point 41

8 Remove the camshaft timing sprocket and chain. [Point 51

9 Remove the crankshaft sprocket. [Point 61

10 Remove the camshaft gear and camshaft. [Point 71

11 Remove the balance shaft. [Point 81

12 Remove the balance shaft gear. [Point 91



Puntos de trabajo

[Punto 11

Instalaci6n: Instale el sumidero de aceite mediante el procedimiento siguiente.

1. Aplique sellador a la cubierta delantera, a la uni6n del bloque de cilindros y a1 cdrter en la junta herm4tica de aceite trasera como se muestra en la ilustraci6n.

Fig. Sellador

2. Instale el sumidero de aceite con una junta de empaquetadura nueva y apriete con la mano 10s pernos y tuercas.

3. Inspeccione la alineaci6n del sumidero de aceite y el bloque de cilindros en las tres posiciones ilustradas.

Estdndar: 0,3 mm o menos

4. Apriete 10s pernos y las tuercas en el orden ilustrado.

5 . Vuelva a inspeccionar la alineaci6n del sumidero de aceite y el bloque de cilindros.

EstBndar: 0,3 mm o menos

Si se excede el estandar, repita las etapas 2, 3 y 4 hasta que la holgura se encuentre dentro del estandar.

Fig. 0,3 m o menos

[Punto 21

Remoci6n1 Usando la SST, saque el contrapeso del drbol del cigueiial . SST 3-14420-C

Instalacibn: Usando un martillo de cobre, instale el contrapeso del Brbol del ciguefial.

[Punto 31

Remoci6n: Usando la SST', saque la junta hermetica de aceite delantera del drbol del ciguefial.

SST 09308-00010

2-18

Point Operations

[Point 11

Installation: Install the oil pan according to the following procedure.

1. Apply sealant to the front cover to block joint and rear oil seal housing as shown in the illustration.

2. Install the oi l pan w i th a new gasket and manually tighten the bolts and nuts.

3. Inspect the oil pan end cylinder block for alignment at three illustrated positions.

Standard: 0.3 mm 10.01 in) or less

4. Tighten the bolts and nuts in the illustrated order.

5. Reinspect the oil pan and cylinder block for alignment.

Standard: 0.3 mm 10.01 in) or less

If the standard is exceeded, repeat steps 2.3 and 4 until the clearance is with in the standard.

[Point 21

Removal: Using SST, remove the crankshaft balancer.

SST J - 14420 - C Installation: Using a copper hammer, install the crankshaft

balancer.

[Point 31

Removal: Using SST, remove the crankshaft front o i l seal.

SST 09308 - 00010

Instalaci6n:Instale una junta hermetica de aceite delantera del drbol del cigilefial nueva.

1. Aplique grasa MP a1 borde de la junta hermetica de aceite nueva. 2 . Usando la SST, instale la junta hermetica de aceite.

SST 09316- 60011

Inspecci6n: Mida la holgura de empuje del drbol de levas. EstBndar:

0 , 0 2 5 - 0 , 2 2 9 mm

[Punto 51 Remoci6n/instalaci6n: Compruebe las marcas de alineaci6n. Fig. Marcas de alineacibn

Remoci6n: Usando la SST, saque la rueda dentada del drbol del cigilefial .

SST 09950-40010 09950-60010

Instalaci6n:Usando la SST, instale la rueda dentada del drbol del cigiienal.

SST 09316- 60011

2-19

Installation: Install a new crankshaft front oil seal.

1. Apply MP grease to a new oil seal lip.

2. Using SST, install the oil seal.

SST 09316 - 6001 1

[Point 41

Inspection: Measure the camshaft thrust clearance.

Standard: 0.025 - 0.229 mm (0.001 - 0.009 in)

[Point 51

Removal . Installation: Check the alignment marks.

[Point 61

Removal: Using SST, remove the crankshaft sprocket.

SST 09950 - 40010 09950 - 60010

Installation: Using SST, install the crankshaft sprocket.

SST 09316 - 6001 1

[Punto 71

Remoci6n/instalaci6n: Compruebe l a s marcas de a l ineac i6n .

F ig . Marcas de a l ineac i6n

Remoci6n/instalaci6n: Usando t r e s pernos de s e r v i c i o , haga e l t r a b a j o de remoci6n e i n s t a l a c i 6 n teniendo cuidado de no d e t e r i o r a r 10s c o j f n e t e s d e l Brbol de levas .

Perno de s e r v i c i o : 5 /16

F ig . Pernos de s e r v i c i o

Inspecci6n: Inspeccione e l Brbol de levas por s i t i e n e descentramiento.

Limite: 0,038 mm

Inspecci6n: Mida e l diBmetro e x t e r i o r de l muR6n d e l Brbol de levas .

Remoci6n: Usando un rnar t i l lo con cabeza de p l a s t i c o , saque e l drbol d e l contrapeso.

[Point 71

Removal. Installation: Check the alignment marks.

Removal . Installation: Using three service bolts, operare carefully to prevent damage to the camshaft bearings.

Inspection: Inspect the camshaft for runout.

Limit: 0.038 mm (0.0015 In)

Inspection: Measure the camshaft journal outside diameter.

Standard: 47.440 - 47.490 mm (1.868 - 1.870 in1

Removal: Using a plastic faced hammer, remove the balance shah.

1 n s t a l a c i b n : U s a n d o l a SST, i n s t a l e e l d r b o l d e l c o n t r a p e s o .

SST 09370- 20270- 71

I n s p e c c i 6 n : I n s p e c c i o n e l a h o l g u r a d e a c e i t e d e l a p a r t e t r a s e r a d e l d r b o l d e l c o n t r a p e s o .

1. Mida e l d i d m e t r o e x t e r i o r d e l mun6n t r a s e r o d e l d r b o l d e l c o n t r a p e s o .

E s t d n d a r : 3 8 , 0 8 4 - 3 8 , 1 0 0 mm

2 . Mida e l d i d m e t r o i n t e r i o r d e l c o j i n e t e d e l d r b o l d e l c o n t r a p e s o .

3 . C a l c u l e l a h o l g u r a d e a c e i t e .

E s t d n d a r : 0 , 0 2 5 - 0 , 0 9 1 nun

S i se e x c e d e e l l i m i t e , r e c a m b i e e l c o j i n e t e t r a s e r o . (Vea l a p d g i n a 2- 32)

[Punto 91

I n s t a l a c i 6 n : Usando l a SST, a p r i e t e e l p e r n o a1 p a r ( t o r q u e ) e s p e c i f i c a d o c o n u n a v u e l t a a d i c i o n a l de 35 g r a d o s .

2-21

Installation: Using SST, install the balance shaft.

SST 09370 - 20270 - 71

Inspection: Inspect the balance shaft rear oil clearance.

1. Measure t h e balance shaft rear journal ou t s ide diameter.

Standard: 38.084 - 38.100 mm (1.499 - 1.500 in)

2. Measure the balance shaft bearing inside diameter.


Standard: 0.025 - 0.091 mm (0.001 - 0.004 in)

If the limit is exceeded, replace the rear bearing. (See page 2-32)

[Point 91

Installation: Using SST, tighten the bolt to specified torque plus an additional turn of 35 degrees.

BLOQUE DE CILINDROS

Notas : Coloque las partes sacadas en orden para evitar instalar en posiciones incorrectas.

* Limpie siempre las partes sacadas antes de la inspecci6n e instalaci6n. Antes de instalar las partes, aplique aceite de motor nuevo a todas las superficies deslizantes y rotatorias.

1 Accesorios del motor

2 Partes de la culata del cilindro

3 Partes de la cadena de distribuci6n

2-22

CYLINDER BLOCK

REMOVAL - INSTALLATION

Note: keep the removed parts in order to prevent installation in incorrect positions. Always clean the removed parts before inspection and installation. Before installing the parts, apply new engine oil to all sliding and rotating surfaces.

T = N.m (kgf - c m ) Ift - lbfl

1 Engine accessories 2 Cylinder head pans

I T - 106 110711 177.51

3 Timing chain parts


1 Siga las etapas 1 a 8 de la parte de Accesorios del motor. (Vea la pdgina 2-8)

2 Siga las etapas 2 a 6, 9 y 10 de la parte de la Culata de cilindros. (Vea la pdgina 2-10)

3 Siga las etapas 3, 4, 6, 8 y 9 de la parte de las Partes de la cadena de distribuci6n. (Vea la pagina 2-16)

4 Saque la bomba de aceite.

5 Saque la junta herm4tica de aceite trasera del drbol del cigtieiial y el ret4n. [Punto 11

6 Saque la tapa del cojinete de la biela. [Punto 21

7 Saque la biela con el pist6n. [Punto 31

8 Saque el pist6n. [Punto 41

9 Saque la tapa del cojinete del arb01 del cigtiefial. [Punto 51

10 Saque el drbol del cigtieiial. [Punto 61

11 Inspeccione el bloque de cilindros. [Punto 7 )

12. Saque el cojinete del drbol del contrapeso y el cojinete del drbol de levas. [Punto 81

Procedimiento de instalaci6n El procedimiento de instalacidn es el inverso a1 de remoci6n.

Puntos de trabajo

[Punto 11

Remoci6n: Usando un destornillador, saque la junta hermetica de aceite.

Instalaci6n:Instale una junta hermetica de aceite nueva.

1. Aplique grasa MP a1 borde de la junta hermetica de aceite nueva. 2. Usando la SST, instale la junta hermetica de aceite.

Cuando el reten esta montado

SST 5-35621

Cuando el reten no estA montado

SST 09950-60020 09950-70010

Removal Procedure

1 Follow step 1 to 8 in the Engine Accessories section. (See page 2-8)

2 Follow step 2 to 6.9 and 10 in the cylinder Head section. (See page 2-10)

3 Follow step 3.4, 6, 8 and 9 i n the Timing Chain Parts section. (See page 2-16)

4 Remove the oil pump.

5 Remove the crankshaft rear oil seal and retainer. [Point 11

6 Remove the connecting rod bearing cap. [Point 21

7 Remove the connecting rod W / piston. [Point 31

8 Remove the piston. IPoint 41

9 Remove the crankshaft bearing cap. IPoint 51

10 Remove the crankshaft. IPoint 61

1 1 Inspect the cylinder brock. [Point 71

12 Remove the balance shaft bearing and camshaft bearing. [Point 81



Point Operations

IPoint 11

Removal: Using a screwdriver, remove the oil seal.

Installation: Install new oil seal.

1. Apply MP grease to a new oil seal lip

2. Using SST, install the oi l seal. While the retainer is assembled

SST J -35621

When the retainer is disassembled

SST 09950 - 60020 09950 - 70010

[ P u n t o 2 1

Remoci6n: Ponga e l ndmero d e l c i l i n d r o sobre l a c u l a t a d e l p i s t 6 n .

Fig. No. d e l c i l i n d r o

Inspecci6n: Mida l a holgura de empuje de cada b i e l a .

Estbndar: 0,152 - 0,432 mm

Remoci6n: Punzone e l No. d e l c i l i n d r o en l a b i e l a y en l a t a p a d e l c o j i n e t e .


Ins ta lac i6n : I n s t a l e l a t a p a d e l c o j i n e t e de l a b i e l a .

1. Alinee l a s marcas de acoplamiento y e l No. d e l c i l i n d r o e i n s t a l e l a t a p a d e l c o j i n e t e .


2. Vsando l a SST, a p r i e t e l a s tuercas a 1 par ( t o r q u e ) espec i f icado mas una v u e l t a ad ic iona l de 70 grados.

SST 5-36660

2-24

[Point 21

Removal: Put the cylinder No, on the piston head.

Inspection: Measure the th rus t clearance of each connecting rod.

Standard: 0.152 - 0.432 mm 10.006 - 0.017 in)

Removal: Punch the cylinder No, on the connecting rod and bearing cap.

Installation: Install the connecting rod bearing cap.

1. Align the match marks and cylinder No. and install the bearing cap.

2. Using SST, tighten the nuts to specified torque plus an additional turn of 70 degrees.

SST J - 36660

Inspecci6n: Mida la holgura de aceite de cada cojinete de la biela.

Est6ndar: 0,025 - 0,076 mm

[Punto 31

Remocibn: Coloque la SST sobre 10s pernos antes de la remoci6n para evitar qua se deteriore el calibre del cilindro.

SST 5-5239

Remontaje: Instale la biela seg6n el procedimiento siguiente:

1. Quite el aceite y las materias extrailas que haya en la cara trasera del cojinete y cubra con aceite de motor la superficie interior del co jinete.

2. Instale el cojinete alineando el trinquete del cojinete con las ranuras de la biela y la tapa.

3. Instale la SST en 10s pernos de la tapa del cojinete.

SST 5-5239

Inspection: Measure the oil clearance of each connecting rod bearing.

Standard: 0.025 - 0.076 mm (0,001 - 0.003 in)

[Point 3 1

Removal: Fit SST on bolts before removal to prevent the cylinder bore from being damaged.

SST J - 5239

Reassembly: Install the connecting rod according to the following procedure:

1. Remove the oil and foreign matters from the real face of the bearing and coat engine oil on the inner face if the bearing.

2. lnstall the bearing by aligning the bearing pawl wi th grooves in the connecting rod and cap.

I I J

( 1 3. Install SST on the bearing cap bolts.

1 ssTA / SST J -5239

4, lnstall SST after checking the piston ring gap position. (See page 2-27]

4. Instale la SST despu6s de comprobar la posici6n de la separaci6n del segment0 del pistbn. (Vea la pagina 2-27)

SST 5-8037

SST J - 8037

5. Col6quelos en el cilindro correspondiente.

6. Usando el mango de un martillo, golpee suavemente el pist6n para que entre en el cilindro. A1 mismo tiempo, guie la biela para que entre en el pasador del drbol del ciguenal.

[Punto 41

Remoci6n: SST 5-24086-C

Inspecci6n: Inspeccione la dimensi6n de acoplamiento de la circunferencia del pasador del pist6n y la holgura de aceite.

1. Mida el didmetro exterior del pasador del pist6n.

EstAndar : 23,545 - 23,548 INII

2. Mida el diAmetro del orificio en la biela.

3 . Calcule la dimensi6n de acoplamiento de interferencia,

EstAndar : 0,0203 - 0,0406 VJI Interferencia

Si el valor calculado es inferior a1 estdndar, recambie el pasador del pistbn y la biela como un conjunto.

4. Mida el didmetro del orificio del pasador del pistbn.

5. Calcule la holgura de aceite

Si se excede el limite, recambie el pist6n y el pasador del pist6n como un conjunto.

2-26

5. Place them in the matching cylinder.

6. Using a hammer handle, lightly tap the piston down into the cylinder. At the same time, guide the connecting rod to the crank shaft pin.

[Point 41

Removal: SST J - 24086 - C

Inspection: Inspect the p i s ton p i n in ter ference f i t dimension and oil clearance.

1. Measure the piston pin outside diameter.

Standard: 23.545 - 23.548 m m (0.9270 - 0.9271 in)

2. Measure diameter of the hole at the connecting rod.

3. Calculate the interference fit dimension.

Standard: 0.0203 - 0.0406 m m (0.0008 - 0.0016 in)

Interference

If the calculated valve is less than the standard, replace the piston pin and connecting rod as a set.

4. Measure the piston pin hole diameter.


Limit: 0.025 m m (0.001 in)

If the limit is exceeded, replace the piston and piston pin as a set.

Remocibn: Use l a h e r r a m i e n t a d e segmentos d e l p i u t 6 n p a r a s a c a r 10s segmentos d e compres i6n No. 1 y No. 2, y s a q u e manualmente e l segmento d e a c e i t e y e l r a i l l a t e r a l .

I n s p e c c i 6 n : Mida l a s e p a r a c i 6 n d e 10s ex t r emos d e l segmento d e l p i s t 6 n

1. I n s t a l e e l segmento d e l p i s t 6 n e n e l c a l i b r e d e l c i l i n d r o .

2. Usando un p i s t 6 n , g u i e e l segmento d e l p i s t 6 n e n e l c a l i b r e d e l c i l i n d r o h a s t a que e l segmento e s t 6 me t ido a unos 38 nun.

3 . Usando un c a l i b r a d o r d e e s p e s o r , mida l a s e p a r a c i 6 n d e l ex t r emo d e l segmento d e l p i s t 6 n .

L i m i t e : Segmento d e compres i6n 0,889 mm Segmento d e a c e i t e 1 , 651 mm

In specc i6n : Mida l a h o l g u r a e n t r e e l segmento d e l p i s t 6 n y l a r a n u r a d e l segmento.

L i m i t e : Segmento d e compres ibn 0,1067 mm Segmento d e a c e i t e 0,2032 nun

I n s t a l a c i 6 n : U s e una h e r r a m i e n t a d e segmentos d e l p i s t 6 n p a r a i n s t a l a r 10s segmentos d e compres i6n No. 1 y No. 2 con l a marca s u p e r i o r c o l o c a d a h a c i a a r r i b a e i n s t a l e manualmente e l segmento d e l p i s t 6 n y 10s r a i l e s l a t e r a l e s e n l a p o s i c i 6 n i l u s t r a d a .

A: S e p a r a c i 6 n d e l segmento d e compres i6n No. 1 8 : S e p a r a c i 6 n d e l segmento d e compres ibn No. 2 C: S e p a r a c i 6 n d e l r a i l d e l segmento d e a c e i t e D : Sepa rac i6n d e l e s p a c i a d o r d e l segmento d e a c e i t e

Despu6s d e l a i n s t a l a c i 6 n f compruebe l a h o l g u r a e n t r e e l segmento d e l p i s t 6 n y l a r a n u r a d e l segmento.

F i g . Marca s u p e r i o r

2-27

I 1 Removal: Use a piston ring tool for removing the No.1

I I

Inspection: Measure the piston ring end gaps.

1, Install the piston ring into the cylinder bore.

I b 4 7 , , , , , , , , 2 Using a piston, guide the piston ring into the cylinder , . .... , I bore until ring is down about 38 mm (1.50 in) berow

ring travel.

3. Using a feller gauge, measur the piston ring end gap.

Limit: Compression ring Oil ring

0.889 mm (0.035 In) 1.651 mm (0.065 in)

Inspection: Measure the clearance between the piston ring and ring groove.

Limit: Compression ring Oil ring

0.1067 0.2032 mm mm (0.004 (0.008 in) In)

Installation: Use a piston ring tool for installing the No.1 and No.2 compression rings with the upper mark on facing upward and manually install the oil ring and side rails in the illustrated position.

A: No.1 compression ring gap B: No.2 compression ring gap C: Oil ring rail gap D: Oil ring spacer gap

After installation, check the clearance between the piston ring and ring groove.

In specc i6n : In specc ione l a ho lgu ra d e l p i s t 6 n .

1. Mida e l d iSmetro e x t e r i o r d e l p i s t 6 n . Mida a 64 mm desde l a p a r t e s u p e r i o r d e l p i s t 6 n en d i r e c c i 6 n v e r t i c a l a 1 pasador d e l p i s t b n .

2 . Mida e l c a l i b r e d e l c i l i n d r o

Es tdnda r : 101,6187 - 101,643 INV

3 . C a l c u l e l a ho lgu ra d e l p i s t 6 n .

L imi t e : 0 ,061 mm

4. S i s e excede e l l l m i t e , r e c t i f i q u e e l c i l i n d r o d e nuevo y s e l e c c i o n e un p i s t 6 n O/S.

Fig . P a r t e d e l a n t e r a R a d i a l Empu j e

In s t a l ac i6n :Monte e l p i s t 6 n y l a b i e l a .

La d i r e c c i b n d e l a b i e l a es d i f e r e n t e e n t r e e l c i l i n d r o No. 1, 3 6 5 y e l c i l i n d r o No. 2 , 4 6 6 . Acople l a marca d e l a n t e r a d e l p i s t 6 n y l a marca d e l pun to d e l a b i e l a como s e i l u s t r a .

F i g . Marca d e l a n t e r a

Marca d e pun t0

2-28

Inspection: Inspect the piston clearance.

1. Measure the piston outside diameter. Measure at 64 mm (2.5 in) from the top of the piston in the direction vertical to the piston pin.

2. Measure the cylinder bore.

Standard: 101.6187 - 101.643 mm (4.0007 - 4.0017 in)

I I 3. Calculate the piston clearance. -- -

Radial Limit: 0.061 mm (0.0024 in) Front

4. If the limit is exceeded, bore the cylinder again and select as O/S piston.

Thrust

Front mark (

Installation: Assemble the piston and connecting rod.

The connecting rod direction is different between cylinder No.1, 3 or 5 and cylinder No. 2, 4 or 6. Match the piston front mark and the connecting rod dot mark as illustrated.

Usando l a SST, monte e l p i s t 6 n y l a b i e l a .

SST 5-24086-C

[Punto 51

Remoci6n: A f l o j e 10s p e r n o s d e m o n t a j e d e l a t a p a d e l c o j i n e t e e n 2 6 3 e t a p a s e n e l o r d e n i l u s t r a d o .

I n s p e c c i 6 n : Mida l a h o l g u r a d e empuje.

E s t d n d a r : 0 ,051 - 0 , 2 0 3 nun

S i se e x c e d e e l limite, r e c a m b i e e l c o j i n e t e d e l d r b o l d e l c i g l l e R a l No. 4 o e l a r b 0 1 d e l c i g u e i l a l .

I n s p e c c i 6 n : Mida l a h o l g u r a d e a c e i t e . No g i r e e l d r b o l d e l c ig i ie f ta l d u r a n t e l a m e d i c i b n .

E s t d n d a r N O . 1

0 , 0 2 5 - 0 , 0 3 8 nun No. 2 y No. 3

0 , 0 2 5 - 0,064 mm N O . 4

0 ,064 - 0 , 0 8 9 nun

S i se e x c e d e e l e s t d n d a r , r e c a m b i e e l c o j i n e t e d e l d r b o l d e l c i g i l e f i a l .

N O . 1 - NO. 3 U/S: 0 , 0 3 mm U/S: 0 , 2 5 mm

NO. 4 U/S: 0 , 0 3 nun U/S: 0 , 0 5 m m U/S: 0 , 2 5 mm U/S: 0 , 5 1 mm

2-29

Using SST, assemble the piston and connecting rod.

SST J - 24086 - C

[Point 51

Removal: Loosen the crankshaft bearing cap mounting bolts in 2 to 3 steps in the illustrated order.

Inspection: Measure the thrust clearance.

Standard: 0.051 - 0.203 mm (0.002 - 0.008 in)

If the limit is exceeded, replace the No.4 crankshaft bearing or crankshaft.

Inspection: Measure the oil clearance. Do not rotate the crankshaft during measurement.

Standard No.1

0.025 - 0.038 mm (0.0010 - 0.0015 in) No.2 and No.3

0.025 - 0.064 mm (0.0010 - 0.0025 In1

If the standard is exceeded, replace the crankshaft bearing.

No.? - No.3 UIS: 0.03 mm (0.001 in1 UIS: 0.25 mm (0.010 in)

N0.4 UIS: 0.03 mm (0.001 in) UIS: 0.05 mm (0.002 in) UIS: 0.25 mm (0.010 in) UIS: 0.51 mm (0.020 in)

I n s t a l a c i 6 n : I n s t a l e l a s t a p a s d e l c o j i n e t e d e l d r b o i d e l c igi ie i ' ia l s e g b n e l p r o c e d i m i e n t o s i g u i e n t e :

1. S a q u e e l a c e i t e y c u a l q u i e r r n a t e r i a ex t ra i ' i a q u e h a y a en l a s u p e r f i c i e t r a s e r a d e c a d a c o j i n e t e , y c u b r a c o n a c e i t e d e m o t o r l a s u p e r f i c i e i n t e r i o r d e l c o j i n e t e .

2 . I n s t a l e e l c o j i n e t e a c o p l a n d o l a r a n u r a d e l a t a p a d e l c o j i n e t e y l a p r o y e c c i 6 n d e l c o j i n e t e .

3 . Compruebe l a m a r c a d e l a n t e r a y e l No. d e l a t a p a e n l a t a p a d e l c o j i n e t e e n e l momento d e l a i n s t a l a c i 6 n .

4 . A p r i e t e 10s p e r n o s e n 2 6 3 e t a p a s e n e l o r d e n i l u s t r a d o .

5. Despubs d e l a i n s t a l a c i 6 n , compruebe q u e e l d r b o l d e l c igue i ' i a l g i r a s u a v e m e n t e .

I n s p e c c i 6 n : I n s p e c c i o n e e l d r b o l d e l c i g u e i t a l p o r s i h a y d e s c e n t r a m i e n t o .

Lirni te:O, 025 nun

S i s e e x c e d e e l llrnite, recarnb ie e l d r b o l d e l c ig i i e i ' i a l .

I n s p e c c i 6 n : I n s p e c c i o n e e l d r b o l d e l c igi ie i ' ia l p o r s i h a y d e s g a s t e .

1. Mida e l d i d m e t r o e x t e r i o r d e c a d a muii6n.

E s t d n d a r : NO. 1

62 ,199 - 6 2 , 2 1 7 nun No. 2 y No. 3

6 2 , 1 9 2 - 6 2 , 2 1 5 nun No. 4

6 2 , 1 8 0 - 62 ,202 nun

2 . Mida e n l a s c u a t r o p o s i c i o n e s i l u s t r a d a s y c a l c u l e l a e x c e n t r i c i d a d y l a c o n i c i d a d .

L i m i t e E x c e n t r i c i d a d : 0 , 0 2 5 mm C o n i c i d a d : 0 , 0 2 5 mm

1. Remove oil and foreign matters fully from the rear face of each bearing, and coat engine oil on the inner face of the bearing.

2-30

2. Install the bearing by matching the bearing cap groove and the bearing protrusion.

I\

Check the front mark and cap No, on the bearing cap at the time of installation.

Installation: Install the crankshaft bearing caps according to the following procedure:

I I

I I [Point 61

Tighten the bolts in 2 to 3 steps i n the illustrated order.

After installation check the crankshaft is rotated smoothlv.

Inspection: lnspect the crankshaft for runout.

Limit: 0.025 mm (0.0010 in)

If the limit is exceeded, replace the crankshaft.

I \ k 1. Measure the outside diameter at each journal.

I

Standard: No.1

62.199 - 62.217 mm (2.4488 - 2.4495 in) No.2 and No.3

62.192 - 62.215 mm (2.4485 - 2.4494 in) No.4

62.180 - 62.202 mm (2.4480 - 2.4489 in)

I

2. Measure at four illustrated positions and calculate the ellipticity and taper.

I I Inspection: Inspect the crankshaft for wear.

Limit Ellipticity: 0.025 mm (0.0010 in) Taper: 0.025 mm (0.0010 in)

3. Mida el didmetro exterior del pasador del drbol del cigilenal.

4. Mida en las cuatro posiciones ilustradas y calcule la excentricidad y conicidad.

Limite Excentricidad: 0,025 mm Conicidad: 0,025 mm

5. Si se excede el limite en la etapa 2 o en la 4 anteriores, rectifique el drbol del cigiieiial y use un cojinete U/S o recambie el 6rbol del cigilenal.

Tipos de cojinetes Cojinete de la biela

U/S: 0,025 mm Cojinete del drbol del cigilenal NO. 1 - NO. 4

U/S: 0,025 mm U/S: 0,254 mm

No. 5 U/S: 0,025 mm U/S: 0,635 mm

Inspecci6n: Inspeccione la superficie superior del bloque de cilindros por si hay deformaci6n.

Limite: 0, 051 mm

3. Measure the crankshaft pin outside diameter.

Standard: 53.310 - 53.335 m m (2.0988 - 2.0998 in1

4. Measure at four illustrated positions and calculate the ellipicity and taper.

Limit Ellipticity: 0.025 m m (0.0010 in1 Taper: 0.025 m m (0.0010 in)

5. if the limit is exceeded in step 2 or step 4 above, grind the crankshaft and either use an U/S bearing or replace the crankshaft.

Bearing types Connecting rod bearing

UIS: 0.025 m m (0.001 in) Crankshaft bearing

No.1 - No.4 U/S: 0.025 m m (0.001 in1 UIS: 0.254 m m (0.010 in)

No.5 U/S: 0.025 m m (0.001 in) UIS: 0.635 m m (0.025 in1

Inspection: sidtortion. inspect the cylinder biock upper surface for

Limit: 0.051 m m (0.002 in)

If the limit is exceeded or if an excessive streaks are found on the upper surface, replace the cylinder block.

Si se excede el limite o si hay rayados excesivos en la superficie superior, recambie el bloque de cilindros.

I n s p e c c i 6 n : Mida e l c a l i b r e d e l c i l i n d r o e n l a s seis p o s i c i o n e s i l u s t r a d a s , y c a l c u l e l a e x c e n t r i c i d a d y c o n i c i d a d .

L i m i t e : E x c e n t r i c i d a d 0 , 0 5 1 mm C o n i c i d a d 0 , 0 2 5 mm

S i s e - e x c e d e c u a l q u i e r l i m i t e , t o r n e e e l c i l i n d r o y u s e u n p i s t 6 n O/S o r e c a m b i e e l b l o q u e e l c i l i n d r o s .

V a l o r d e l p i s t 6 n O/S O/S: 0 , 7 6 mm

R a d i a l ~ i g . P a r t e d e l a n t e r a

Empu je

R e m o c i 6 n / i n s t a l a c i 6 n : Recambie 10s coj ine tes d e l B r b o l d e l e v a s segirn e l p r o c e d i m i e n t o s i g u i e n t e .

1. G o l p e e s u a v e m e n t e e l t a p 6 n t r a s e r o p o r e l i n t e r i o r d e l m o t o r .

2 . Usando l a SST, r e c a m b i e e l c o j i n e t e .

SST 09950- 60010 09950- 70010

, A n t e s d e i n s t a l a r un c o j i n e t e nuevo , a p l i q u e a c e i t e d e m o t o r n u e v o a l a s u p e r f i c i e e x t e r i o r . . Los o r i f i c i o s d e a c e i t e d e l c o j i n e t e y d e l b l o q u e d e c i l i n d r o s d e b e n es tar a l i n e a d o s a n t e s d e l a i n s t a l a c i b n .

3 . A p l i q u e s e l l a d o r a 1 t a p 6 n t rasero n u e v o .

4 . Usando l a SST, i n s t a l e e l t a p 6 n t r a s e r o a u n a p r o f u n d i d a d d e 0 - 0 , 8 mm.

SST 09950-60010 09950- 70010

R e m o c i 6 n / i n s t a l a c i 6 n : Recambie el c o j i n e t e t r a s e r o d e l d r b o l d e l c o n t r a p e s o s i g u i e n d o e l mismo p r o c e d i m i e n t o q u e e l d e l c o j i n e t e d e l d r b o l d e l e v a s .

Inspection: Measure the cylinder bore at six illustrated positions, and calculate the ellipticity and taper.

Limit: Ellipticity 0.051 mrn (0.0020 in) Taper 0.025 mm (0.0010 Inl

If any limit is exceeded, either bore the cylinder and use an O/S piston or replace the cylinder block.

Piston O / S valve OIS: 0.76 mm (0.030 in)

[Point 81

Removal . Installation: Replace the camshaft bearings to the following procedure.

1. Tap out the rear plug from the inside of the engine

2. Using SST, replace the bearing.

SST 09950 - 60010 09950 - 70010

Befor installing new bearing, apply new engine oil to outer serface. The oil holes of the bearing and cylinder block must be aligned before installation.

3. Apply sealant to new rear plug.

4. Using SST, install the rear plug to 0 - 0.8 mm (0 - 0.03 in) deep.

SST 09950 - 60010 09950 - 70010

Removal . Installation: Replace the balance shaft rear bearing in s a m e procedure a s camshaft bearing.

SST 09950 - 60010 09950 - 70010

SST 09950- 60010 09950- 70010

818- DE COMEUBTIBLE

Pdgina

ANTES DE TRABAJAR EN EL SISTEMA DE COMBUSTIBLE . . . . . . . . . . 3-2

INSPECCION EN EL VEHICULO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

BOMBA DE COMBUSTIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBUWDOR 3-6

FUEL SYSTEM Page

........... BEFORE HANDLING THE FUEL SYSTEM 3-2

ON-VEHICLE INSPECTION .................................. 3-2

...................................................... FUEL PUMP 3-5

CARBURETOR .......................... .. ..................... 3-6

ANTES DE TRABAJAR EN EL SISTEMA DE COMBUSTIBLE

Notas: . Desconecte e l t e r m i n a l nega t ivo d e l a b a t e r l a a n t e s de t r a b a j a r en e l sistema de combustible. . Mantenga e l fuego a l e j a d o . . Tenga cuidado para que l a s p a r t e s d e cuero o caucho no l a s toque l a gaso l ina .

, Disponga l a s p a r t e s componentes correc tamente para e v i t a r confus iones . . Mantenga e l t a l l e r d e t r a b a j o l impio y l impie cada p a r t e si e s t b s u c i a . No p ie rda n i confunda 10s s u j e t a d o r e s n i 10s r e s o r t e s .

INSPECCION EN EL VEHICUU)

MOTOR EN ESTADO FRIO

1. Saque e l conector d e a i r e d e admisibn fue ra d e l carburador .

2 . Inspeccione e l s i s t ema d e l a e s t r angu lac i6n autom6tica. ( 1 ) Mida l a r e s i s t e n c i a e n t r e e l t e r m i n a l d e l a caja d e l a bobina y

t i e r r a (masa) d e c a r r o c e r i a con un probador d e c i r c u i t o s .

Estbndar: 17 - 19 P (20°C)

( 2 ) Inmediatamante despues d e a r r a n c a r e l motor, compruebe que l a v6lvula de e s t r a n g u l a c i 6 n comienza a a b r i r s e y que s e c a l i e n t a l a c a j a d e l a bobina.

3 . Inspeccione e l s i s t ema d e l r u p t o r de l a es t rangulac ibn. (1) Ponga e n marcha e l motor . Desconecte l a t u b e r i a f l e x i b l e d e

v a c i o d e l r u p t o r d e l a e s t r a n g u l a c i 6 n y compruebe que s e mueve l a v h l v u l a d e e s t r a n g u l a c i b n h a c i a e l l a d o d e c e r r a r .

(2 ) Vuelva a c o n e c t a r l a t u b e r i a f l e x i b l e d e v a c l o a 1 r u p t o r d e l a e s t r a n g u l a c i 6 n y compruebe que l a v h l v u l a d e e s t r a n g u l a c i 6 n s e mueve h a c i a e l l a d o d e a b r i r d e n t r o d e l t iempo e s p e c i f i c a d o despubs d e v o l v e r a c o n e c t a r l a t u b e r i a f l e x i b l e .

Estbndar: 1 - 5 segundos

Fig. 1 - 5 segundos

4 . Inspeccione e l s i s t ema d e l r u p t o r de l a leva de marcha en v a c l o rapids. ( 1 ) Desconecte l a t u b e r l a f l e x i b l e d e vacfo d e l l ado d e l r u p t o r d e l a

leva d e marcha en vac io rbp ida .

F ig . FICB Desconectar

3-2

BEFORE HANDLING THE FUEL SYSTEM

Notes: Disconnect the battery negative terminal before handling the fuels system. Keep fire away. Do not let leather or rubber parts be smeared with gasoline. Arrange component parts with proper sorting to prevent confusion. Keep the workshop clean and clean each part if dirty. Do not lose or confuse clips and springs.

ON-VEHICLE INSPECTION

COLD ENGINE STATE

1 . Remove intake air connector from carburetor.

2, lnspect automatic choke system. (1) Measure the resistance between the coil housing

terminal and body ground with a circuit tester.

Standard: 17 - 19 fl (20°C1 (6E°F1

( 2 ) Soon after the engine starts, check that the choke valve begins to open and the coil hous~ng is heated.

3. lnspect the choke breaker system. (1) Start the engine. Disconnect the vacuum hose from

the choke breaker and check that the choke valve moves to close side.

(2) Reconnect the vacuum hose to the choke breaker and check that the choke valve moves to open side within the specified time after reconnecting the hose.

Standard: 1 - 5 seconds

4. lnspect the fast idle cam breaker system. (1) Disconnect the vacuum hose from the fast idle cam

breaker.

( 2 ) Ponga e n marcha e l motor, y vue lva c o n e c t a r l a t u b e r i a f l e x i b l e d e v a c i o . Compruebe que no s e mueve e l r u p t o r d e l a e s t r a n g u l a c i 6 n .

Fig . Reconectar

MOTOR EN ESTADO CALIENTE

5 . Compruebe e l s i s tema d e l r u p t o r de l a leva de marcha en vac lo rapids. ( 1 1 C a l i e n t e e l motor a l a t empera tu ra d e funcionarniento normal y

oa re lo . c - - - - - ( 2 ) Desconecte l a t u b e r i a f l e x i b l e d e vac io d e l l ado d e l r u p t o r d e l a

leva d e marcha en v a c i o r i p i d a .

F ig . Desconectar

( 3 ) A j s t e l a leva d e marcha en v a c i o r i p ida . Mientras s u j e t a l a o J u r a c i b n l i ge ramen te a b i e r t a , empuje l a v i l v u l a d e e s t r angu lac ibn para c e r r a r l a .

( 4 ) Su j6 te l a ce r r ada a 1 s o l t a r l a va lvu la de obturac ibn.

( 5 ) Ponga en marcha e l motor. (6) Vuelva a c o n e c t a r l a t u b e r i a f l e x i b l e d e v a c i o , y compruebe que

l a a r t i c u l a c i 6 n d e l a e s t r a n g u l a c i 6 n s e mueve y que s e puede s o l t a r l a l e v a d e marcha e n v a c i o r d p i d a a l a c u a r t a muesca.

Fig. Leva de marcha en v a c i o r i p i d a Reconectar

6 . Inspeccione l a vblvula d e e s t r angu lac ibn . Compruebe que l a v a l v u l a d e e s t r a n g u l a c i 6 n e s t b to ta lmente a b i e r t a .

F ig . Totalmente a b i e r t a

Start the engine, and reconnect the vacuum hose. Check that the choke breaker does not move.

FlCB I HOT ENGINE STATE

5. Check the fast idle cam breaker system. ( 1 Warm up the engine to normal operating temperature

and stop the engine. ( 2 ) Disconnect the vacuum hose from the fast idle cam

breaker.

13) Set the fast idle cam. While holding the throttle slightly open, push the choke valve closed.

(4) Hold it closed as you release the throttle valve.

I Fast idle cam I Start the engine. Reconnect the vacuum hose, and check that the choke linkage moves and that the fast idle cam is released to the 4th step.

I I

Fully opened 1 6. Inspect the choke valve Check that the choke valve is fully opened

7 . Inspeccione la bomba de aceleraci6n. Abra rdpidamente la vdlvula de obturaci6n, y compruebe que la gasolina sale por la boquilla de aceleracibn.

8. Instale el conector del aire de admisi6n. 9. Compruebe y ajuste la velocidad de marcha en vaclo. (Vea la p6gina

1-5) 10. Inspeccione y ajuste la velocidad mdxima sin carga y la velocidad

maxima con carga. (Vea la pdgina 1-6)

INSPECCION DE VSV Vea que A y B no estdn conectados cuando el motor estd frlo, y que estdn conectados cuando el motor estd caliente. Nota: EstAn conectados cuando la temperature del aqua de enfriamiento alcanza 40°C.

INSPECCION DE GET Vea que el aire fluye de A a B per0 no de B a A .

7. lnspect the acceleration pump. Quick ly open the th ro t t l e valve, and check tha t gasoline spurts out from the acceleration nozzle.

8 . Install the intake air connector

9. Check and adjust the idle speed. (See page 1-5)

10. lnspect and adjust the no-load maximum speed and loaded maximum speed. (See page 1-6)

BVSV INSPECTION

See that A and B are not connected while the engine is cold, and are connected when the engine is hot.

Note: They are connec ted w h e n t h e coo l ing w a t e r temperature rises t o 40°C (104°F).

GET INSPECTION

See that air flows from A to B but not from B to A

BOMBA DE COMBUSTIBLE FUEL PUMP

REMOCION DE LA BOMBA DE COMBUSTIBLE 1 Desconecte l a s t u b e r i a s r i g i d a s de l a bomba de combust ible. 2 Desconecte e l conector de l a bomba de combust ib le . 3 Saque e l con jun to de l a bomba de combust ible.

INSTALACION DE LA BOMBA DE COMBUSTIBLE El procedimiento de i n s t a l a c i 6 n es e l i nve rso a 1 de remoci6n.

FUEL PUMP REMOVAL

1 Disconnect the fuel pump piping.

2 Disconnect the fuel pump connecter.

3 Remove the fuel pump ASSY.

FUEL PUMP INSTALLATION


CARBURADOR

D I A G W ESQUEHATICO

1 Embolo de la bomba de aceleracibn 7 Valvula de aguja 2 Boquilla de aceleracibn 8 Vilvula de obturacibn primaria 3 vilvula de estrangulacibn 9 Tornillo de ajuste de mezcla de 4 Boquilla principal primaria rnarcha en vacio (ralenti) 5 Vilvula solenoide de corte de 10 Surtidor de lenta primario

combustible 11 Surtidor principal primario 6 Pistbn de potencia 12 ~ilvula de potencia

CARBURETOR

SCHEMATIC DIAGRAM

1 Acceleration Pump Plunger 2 Acceleration Nozzle 3 Chokevalve 4 Primary Main Nozzle 6 Fuel Cut Solenoid Valve 6 Power Piston .

7 Needle Valve 8 Primary Throttle Valve 9 Idle Mixture Adjusting Screw 10 Primary Slow Jet 11 Primary Main Jet 12 Power Valve

Procedimiento de remoci6n 1 Desconecte el conector de aire de admisi6n. 2 Desconecte el cable del acelerador. [Punto 11 3 Desconecte la tuberia rigida de combustible. 4 Desconecte 10s conectores y saque el interruptor de la obturaci6n

(lado de marcha en vacio) . 5 Desconecte la tuberia flexible de vacio. 6 Saque el carburador. Procedimiento de instalaci6n 1 El procedimiento de instalaci6n es el inverso a1 de remoci6n. 2 Despu6s de instalar el conjunto del carburador, realice la

inspecci6n y el ajuste de la manera siguiente: (1) Inspeccione y ajuste la velocidad de marcha en vaclo. (Vea la

pagina 1-5) (2) Inspeccione y ajuste la velocidad mhxima. (Vea la pigina 1-61

I I

Removal Procedure

1 Disconnect the intake air connector.

2 Disconnect the accelerator cable. [Point 11

3 Disconnect the fuel pipe.

4 Disconnect the connectors and remove the throttle switch (idle side)

5 Disconnect the vacuum hose.

6 Remove the carburetor.


1 The installation procedure is the reverse of the removal procedure.

2 After installing the carburetor ASSY, make inspection and adjustment as follows: (1) lnspect end adjust the idle speed. (See page 1-5.) (2) Inspect and adjust the maximum speed. (See page 1-6.)

Puntos de t r a b a j o [Punto 11 Instalaci6n:Despu6s de l a i n s t a l a c i 6 n compruebe e l juego d e l cab le d e l

ace le rador . 1. Compruebe l a velocidad de marcha en vacio y l a posici6n d e l t o r n i l l o

de a j u s t e de marcha en vacio. (Vea l a pdgina 1-5)

2. Su je te l a a r t i c u l a c i 6 n de l a obturaci6n d e l carburador en l a posici6n de a b i e r t o aproximadamente 1 /2 (30°) y g i r e e l i n t e r r u p t o r de l a l l a v e a "ON" (encendido) .

3. Vuelva lentamente l a a r t i c u l a c i b n de l a obturaci6n y vea que l a palanca d e l motor no s e mueve. S i l a palanca d e l motor s e mueve, aumente l a longi tud d e l cab le d e l ace le rador para r e a l i z a r e l a j u s t e . S i t i e n e una longi tud mayor que e l n i v e l requerido, l a respuesta de l a a r t i c u l a c i 6 n de l a obturaci6n a1 accionamiento d e l pedal e s l e n t a . (1) Afloje l a tuerca de seguridad d e l cable d e l ace le rador . ( 2 ) Ajuste l a longi tud d e l cab le d e l ace le rador . ( 3 ) Apriete l a tuerca de seguridad.

F ig . Tuerca de seguridad

Point Operations

[Point 11

Installation: After installation, check the accelerator cable play.

1. Check the idle speed and idle adjusting screw position. (See page 1-5)

2. Hold the carburetor throttle link at a position opened by about 112 (30') and t u r n the key switch to ON.

3. Return the throttle l ink slowly and see that the motor lever does not move. If the motor lever moves, increase the accelerator cable length for adjustment. If it is lengthened beyond the required level, the throttle l ink response to accelerator pedal operation becomes slow.

(1) Loosen the accelerator cable lock nu t . (2) Adjust the length of the accelerator cable. (3) Tighten the lock n u t .

DESMONTAJE/INSPECCION/REMONTAJE Nota : Como hay muchas partes similares, mantenga las partes desrnont8das en orden para cada aonjunto. Tenga cuidado que no se le pierdan o se confundan 10s sujetadores ni 10s resortes. Use la SST (juego de destornilladores del carburador). SST 09860-11011 Nunca desmonte las partes siguientes:

Tornillo de sujeci6n de la valvula de estrangulacibn Tornillo de sujeci6n de la valvula de obturacibn

* Brdzo de obturaci6n

10 Surtidor de lenta superior primario.

DISASSEMBLY .INSPECTION .REASSEMBLY

Note: As there are many simllar parts, keep the disassembled parts orderly for each ASSY. Do not let the clips and springs be confused or lost. Use SST (carburetor driver set). SST 09860-1 101 1 Never disassemble the following parts:

Choke valve set screw Throttle valve set screw Throttle arm

-. , I 1

10 Primary upper slow jet

Procedimionto de desmontaje 1 Saque e l i n t e r r u p t o r de l a obturacibn ( lado de aber tu ra t o t a l ) . 2 Saque e l brazo de l a bomba de ace le rac ibn y l a a r t i c u l a c i b n . [Punto

1 I 3 Desconecte l a a r t i c u l a c i b n de l rup tor de l a l e v a de marcha en vacio

r l p i d a . 4 Saque e l conjunto de l a bocina de a i r e . [Punto 21 5 Saque e l f l o t a d o r y l a valvula de aguja. [Punto 31 6 Saque e l Bmbolo de l a bomba de ace le rac ibn . 7 Saque l a junta de empaquetadura de l a bocina de a i r e . 8 Saque e l a s i e n t o de l a vAlvula de aguja. 9 Saque e l p i s tbn de potencia . [Punto 41 10 Saque e l s u r t i d o r de l e n t a super io r primario. 11 Saque e l c a r t e r de l a bobina. [Punto 51 12 Saque e l rup tor de l a estrangulaci6n. [Punto 61 13 Saque l a valvula solenoide de c o r t e de combustible. [Punto 71 1 4 Saque e l c a r t e r d e l termostato. 15 Saque l a a r t i c u l a c i 6 n d e l ruptor de l a l eva de marcha en vacio

rdpida. [Punto 81 16 Saque l a bola de retenci6n de l a bomba de ace le rac ibn . 17 Saque e l s u r t i d o r de l e n t a . 18 Saque l a velvula de po tenc ia . [Punto 91 19 Saque e l s u r t i d o r p r i n c i p a l . 20 Saque e l ven tur i pequeno. 21 Saque e l rup tor de l a leva de marcha en vacio r l p i d a . [Punto 101 22 Saque l a leva de marcha en vacio rapida. 2 3 Saque e l cuerpo d e l carburador. [Punto 111 Procedimien to d e r e m o n t a j e E l procedimiento de remontaje e s e l inverso a1 de desmontaje. Notas : Limpie cada una de l a s p a r t e s desmontadas a n t e s de l a inspeccibn. 1. Use un c e p i l l o suave para l a v a r y l impiar l a s p a r t e s fundidas. 2. Limpie 10s dep6si tos de carbon0 de alrededor de l a vAlvula de

obturaci6n. 3. Lave o t r a s p a r t e s . 4. Use a i r e comprimido para sop la r l a suciedad y l a s mater ias ex t ranas

de 10s pasos d e l s u r t i d o r y de combustible y desde l a p a r t e de contact0 d e s l i z a n t e . No use un cab le para l impiar e l s u r t i d o r , ya que podria deformarse e l o r i f i c i o .

1 Remove the throttle switch (full open side).

2 Remove the acceleration pump arm and link. [Point 11

3 Disconnect the fast idle cam breaker link.

4 Remove the air horn ASSY. IPoint 21

5 Remove the float and needle valve. [Point 31

6 Remove the acceleration pump plunger.

7 Remove the air horn gasket.

8 Remove the needle valve seat.

9 Remove the power piston. [Point 41

10 Remove the priman/ upper slow jet,

11 Remove the coil housing. [Point 51

12 Remove the choke breaker. [Point 61

13 Remove the fuel cut solenoid valve. [Point 71

14 Remove the thermostat housing.

15 Remove the fast idle cam breaker link. [Point 81

16 Remove the acceleration pump check ball.

17 Remove the slow jet.

18 Remove the power valve. [Point 91

19 Remove the main jet.

20 Remove the smoll venturi.

21 Remove the fast idle cam breaker. [Point 101

22 Remove the fast idle cam.

23 Remove the carburetor body. [Point 111

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

Note: Clean each of disassembled parts before Inspection. 1. Use a soft brush to wash and clean casting parts. 2. Clean carbon deposit from around the throttle valve. 3. Wash other parts. 4. Use compressed air to blow dirt and foreign matters from the jet and fuel passages and from the

sliding contact portion. Do not use a wire for cleaning the jet at it may deform the hole.

Puntos de t r a b a i o [Punto 11 Instalaci6n:Despu6s de l a ins ta lac i6n , doble e l su je tador en forma de 13

como s e muestra.

[Punto 21 I n s t a l a c i 6 n : I n s t a l e l a placa d e l n6mero y l a abrazadera d e l cab le como

s e muestra en l a i l u s t r a c i 6 n .

Fig. Placa d e l nhmero Abrazadera d e l cable

[Punto 31 Inspecci6n: Despues de i n s t a l a r l a vAlvula de aguja y e l f l o t a d o r ,

inspeccione y a j u s t e e l n i v e l d e l f l o t a d o r . 1. Ajuste e l n ive l super io r .

(1) Coloque l a bocina de a i r e boca abajo y mida l a holgura e n t r e e l extremo de l a punta d e l f l o t a d o r y e l cuerpo cuando e l f l o t a d o r cae por su propio peso. SST 09240-00014

Estdndar: 7,O mm Nota : Esta medida debera hacerse s i n co locar l a jun ta de empaquetadura aobre l a bocina de a i r e .

(2) S i no s e s a t i s f a c e e l es tandar , a j u s t e l a holgura doblando l a p a r t e A d e l borde d e l f l o t a d o r .

2 . Inspeccione e l n ive l i n f e r i o r . (1) Inspeccione l a holgura e n t r e e l embolo de aguja y e l borde d e l

f lo tador . SST 09240-00020

Estdndar: 0,9 - 1,l nun (2) S i no s e s a t i s f a c e e l es tdndar , a j u s t e l a holgura doblando l a

p a r t e B d e l borde d e l f l o t a d o r .

Point Operations

[Point 11

Installation: After installation, bend thefi-clip as shown.

[Point 21

Installation: Install the number plate and wire clamp as shown in the illustration.

[Point 31

Inspection: After installing the needle valve and float, inspect and adjust the float level.

1. Adjust the upper level. (1) Place the air horn upside down and measure the

clearance between the float tip end and body when the float falls by its own weight. SST 09240-00014

Standard: 7.0 mm (0.276 in)

Note: This measurement should be made wlthout a gaaket on the air horn.

(2) If the standard is not satisfied, adjust the clearance by bending the A portion of the float lip.

2. Inspect the lower level. (1) Inspect the clearance between the needle plunger

and float lip. SST 09240-00020

Standard: 0.9 - 1.1 mm 10.035 - 0.043 in)

(2) if the standard is not satisfied, adjust the clearance by bending the B portion of the float lip.

In specc ibn : Despues d e i n s p e c c i o n a r e l f l o t a d o r , i n v i e r t a l a boc ina d e a i r e y succ ione desde e l l a d o d e l a t u b e r l a d e admis ibn d e combus t ib l e . Compruebe que no hay f i l t r a c i o n e s n i e s c a p e s d e a i r e .

In specc i6n : In specc ione l a v d l v u l a d e agu ja p a r a v e r s u e s t a d o d e d e s l i z a m i e n t o .

F i g . Succibn

[Punto 41 In specc i6n : Despubs de i n s t a l a r e l p i s t 6 n d e p o t e n c i a , compruebe que s e

mueve suavemente.

[Punto 5 ) In specc i6n : Mida l a r e s i s t e n c i a e n t r e 10s t e r m i n a l e s .

Es tdnda r : 1 7 - 1 9 ( 2 0 ° C)

F i g . Ohmimet r o

I n s t a l a c i 6 n : I n s t a l e e l c d r t e r d e l a bob ina . 1. I n s t a l e l a j u n t a d e empaquetadura en l a c a j a d e l t e r m o s t a t o . 2. A l i n e e un r e s o r t e b i m e t d l i c o con un r e s o r t e d e c a b l e e i n s t a l e e l

c d r t e r d e l a bobina a l i n e a n d o l a pa l anca d e l a e s t r a n g u l a c i b n como s e mues t r a en l a i l u s t r a c i b n .

F i g . R e s o r t e d e c a b l e R e s o r t e b i m e t a l i c o Pa l anca d e e s t r a n g u l a c i b n

3 . Antes d e i n s t a l a r 10s t o r n i l l o s d e a j u s t e , co loque l a l e v a d e marcha e n v a c i o r d p i d a en l a p r imera e t a p a y c i e r r e t o t a l m e n t e l a v d l v u l a d e l a e s t r a n g u l a c i 6 n . Vea que l a v a l v u l a d e l a e s t r a n g u l a c i b n s e a b r e cuando e l c d r t e r d e l a bobina s e g i r a h a c i a l a d e r e c h a .

Inspection: After installing the float, reverse the air horn and suck from the fuel inlet pipe side. Check no air leakege.

Inspection: Inspect the needle valve for the sliding state

[Point 41

Inspection: After installing the power piston, check that it moves smoothly.

[Point 51

Inspection: Measure the resistance between terminals.

Standard: 17 - 19 R (20°C) (68°F)

Installation: Install the coil housing.

1, Install the gasket on the thermostat case.

2. Align a bimetal spring with the wire spring and install the coil housing by aligning the choke lever as shown in the illustration.

3. Before installing the set screws, set the fast idle cam at the first stage and fully close the choke valve. See that the choke valve is opened when the coil housing is turned clockwise.

4 . Alinee la linea central de la escala de la caja del termostato con la linea del carter de la bobina y apriete 10s tornillos de ajuste a1 par (torque) especif icado.

[Punto 61 Inspecci6n: Inspeccione el diafragma del ruptor de la estrangulaci6n. 1. Aplique una presi6n negativa a la cdmara del diafragma y compruebe

si se mueve la varilla. 2 . Elimine la presi6n negativa desde el estado indicado en la etapa 1,

y compruebe que la varilla vuelve rdpidamente.

Instalaci6n:Instale el collarin en la direcci6n ilustrada.

[Punto 71 Inspecci6n: Inspeccione la valvula solenoide de corte de combustible. 1. Conecte la vilvula solenoide a la bateria. Conbctela y desconkctela

y comp!.uebe si se escucha el sonido de funcionamiento (sonido de clic) .

2 . Recambie la vdlvula si no funciona normalmente.

Fig. Bateria

[Punto 81 Inspecci6n: Compruebe que se mueve suavemente la vdlvula de

estrangulaci6n.

4. Align the scale center line of the thermostat case with the coil housing line and torque the set screws.

[Point 61

Inspection: Inspect the choke breaker diaphragm.

1. Apply a negative pressure to the diaphragm chamber and check i f the rod moves.

2. Eliminate the negative pressure from the state in step 1, and check that the rod returns quickly.

Installation: Install the collar in the illustrated direction.

[Point 71

Inspection: Inspect the fuel cut solenoid valve.

1. Connect the solenoid valve to the battery. Set i t to ON and OFF and check i f the operating sound (clicking sound) is heard.

2. Re~lace the valve if it does not operate normally.

[Point 81

Inspection: Check the choke valve moves smoothly.

[Punto 91 Inspecci6n: Inspeccione la vdlvula de potencia. 1. Presione la vdlvula con un dedo y sople por el lado del surtidor.

Compruebe que fluye el aire. 2. Quite el dedo y sople por el lado del surtidor. Compruebe que no

fluye el aire.

Fig. Aire Aire

[Punto 101 Inspecci6n: Inspeccione el diafragma del ruptor de la leva de marcha en

vacio rdpida. 1. Aplique presibn negativa a la cdmara del diafragma y compruebe si se

mueve la varilla. 2. Elimine la presi6n negativa desde el estado indicado en la etapa 1,

y compruebe que la varilla vuelve rApidamente.

[Punto 111 Inspecci6n: Compruebe que la vdlvula de obturaci6n se mueve suavemente.

3-16

[Point 91

Inspection: lnspect the power valve.

1. Press the valve with a finger and blow the jet side. Check that air flows.

2. Release the finger and blow the jet side. Check that no air flows.

[Point 101

Inspection: Inspect the fast idle cam breaker diaphragm.

1. Apply a negative pressure to the diaphragm chamber and check if the rod moves.

2. Eliminate the negative pressure from the state in step 1; and check that the rod returns quickly.

[Point 111

Inspection: Check the throttle valve moves smoothly.

AJUSTE DEL CARBURADOR SST 09240-00014 SST 09240-00020 1. Compruebe el dngulo de abertura total de la vdlvula de obturaci6n.

Estdndar: 60° desde la horizontal

Fig. Totalmente abierta

2. Ajuste el cdrter de la bobina. (1) Alinee la linea del cdrter de la bobina con la llnea central del

cdrter del termostato. Nota : La vblvula de oetrangulaci6n queda totalmento cerrada cuando l a presi6n atmosZ6rica alcanea 30° C.

3. Compruebe y ajuste la marcha en vacio rdpida. (1) Coloque la palanca de marcha en vacio rdpida en la leva de

marcha en vacio rdpida. 1 Mientras sujeta la vdlvula de obturaci6n ligeramente

abierta, empuje la vdlvula de estrangulaci6n para que cierre.

2 Suj6tela cerrada a1 soltar la vdlvula de obturacidn. 3 Compruebe que la palanca de marcha en vacio rdpida estd en

la primera etapa de la leva de marcha en vacio rdpida como se muestra.

(2) Compruebe el dngulo de la vdlvula de obturaci6n primaria. Estdndar: 22,5O desde la horizontal (3) Ajuste girando el tornillo de ajuste de marcha en vacio rdpida.

Fig. Tornillo de ajuste de marcha en vacio rdpida

4. Compruebe y ajuste el descargador (vdlvula de seguridad). (1) Co:) la vdlvula de obturaci6n primaria totalmente abierta,

compruebe el dngulo de la vdlvula de estrangulaci6n. Estdndar: 15 - 19" desde la horizontal

Fig. Totalmente abierta

CARBURETOR ADJUSTMENT

SST 09240-0001 4 SST 09240-00020

1. Check the full opening angle of the throttle valve.

Standard: 60" from horizontal

2. Set the coil housing. (1) Align the line on coil housing with the center line on

the thermostat housing.

Note: The choke valve becomes fu l l y closed w h e n t h e atmospheric temperature reaches 30°C (86°F).

3. Check and adjust fast idle setting. (1) Set the fast idle lever on the fast idle cam. a While holding the throttle valve slightly opened,

push the choke valve closed. $ Hole it closed as you release the throttle valve. 3 Check that the fast idle lever is set on the 1st step

of the fast idle cam as shown.

(2) Check the primary throttle valve angle.

Standard: 22.5 " f rom horizontal.

(3) Adjust by turning the fast idle adjusting screw.

4. Check and adjust the unloader. (1) With the primary throttle valve fully opened, check

the choke valve angle.

Standard: 15 - l9 ' f rom horizontal

(2) S i no s e s a t i s f a c e e l e s t h d a r , a j u s t e doblando l a palanca d e l descargador.

Fig. Palanca d e l descargador

5. Compruebe y a j u s t e e l rup tor de l a leva de marcha en vacio rdpida. (1) Ajuste l a palanca de marcha en vacio rdpida en l a l eva de marcha

en vacio rdpida. 1 Mientras s u j e t a l a vdlvula de obturaci6n ligeramente

a b i e r t a , empuje l a valvula de estrangulacibn para que s e c i e r r e .

2 S u j e t e l a cerrada mientras s u e l t a l a valvula de obturaci6n. 3 Compruebe que l a palanca de marcha en vacio rdpida esta en

l a primera e tapa de l a leva de marcha en vacio rdpida como s e muestra.

(2) Aplique pres i6n negat iva a 1 ruptor de l a leva de marcha en vacio rSpida y d e j e l a .

(3) Compruebe que s e mueve l a a r t i c u l a c i b n de l a es t rangulac i6n t y que l a leva de marcha en vacio rapids pasa a l a c u a r t a e tapa .

( 4 ) S i no e s a s i , a j u s t e doblando l a palanca d e l rup tor de l a leva de marcha en vacio rSpida.

Fig. Palanca d e l rup tor de l a leva de marcha en vacio rdpida

6. Compruebe y a j u s t e e l ruptor de l a estrangulaci6n. (1) Coloque l a palanca de marcha en vacio r l p i d a en l a l eva de

marcha en vacio rdpida. ( 2 ) Aplique presi6n negat iva a1 rup tor de l a es t rangulac i6n . (3) Compruebe e l dngulo de aber tu ra de l a va lvu la de estrangulaci6n. Estandar: 27 - 31° desde l a hor izon ta l ( 4 ) S i no s e s a t i s f a c e e l es tdndar , a j u s t e girando e l t o r n i l l o de

a j u s t e d e l rup tor de l a estrangulaci6n.

Fig. Presi6n negat iva

(2) If the standard is not satisfied, adjust by bending the unloader lever.

5. Check and adjust the fast idle cam breaker. (1) Set the fast idle lever on the fast idle cam. a While holding the throttle valve slightly opened,

push the choke valve closed. @ Hold it closed as you release the throttle valve. @ Check that the fast idle lever is set on the 1st step

of the fast idle cam as shown.

(2) Apply negative pressure to the fast idle cam breaker and release it.

(3) Check that the choke linkage moves, and that the fast idle cam is released to the 4th step.

(4) If not, adjust by bending the fast idle cam breaker lever.

6. Check and adjust the choke breaker. (1) Set the fast idle lever on the fast idle cam. (2) Apply negative pressure to the choke breaker. (3) Check the choke valve opening angle.

Standard: 27 - 31" from horizontal

(4) If the standard is not satisfied, adjust by turning the choke breaker adjusting screw.

7. Compruebe y a j u s t e l a bomba de ace le rac ibn . (1) Aplique pres i6n negat iva a 1 rup tor de l a leva de marcha en vacio

rdpida . (2) Gire e l Arbol de l a obturaci6n y mida l a longi tud de l a c a r r e r a . Estdndar: 9,80 - 10,80 mm (3) S i no s e s a t i s f a c e e l estAndar, a j u s t e doblando l a a r t i c u l a c i 6 n

de conexi6n.

Fig. Presibn negat iva Ar t icu lac i6n de conexi6n

8. Ajuste previamente e l t o r n i l l o de a j u s t e de velocidad de marcha en vacio. (1) Aplique presi6n negat iva a 1 rup tor de l a leva de marcha en vacio

rdpida. ( 2 ) Compruebe e l Angulo de l a vdlvula de obturaci6n primaria . Estdndar: 7O desde l a hor izon ta l (3) S i no s e s a t i s f a c e e l es tdndar , a j u s t e girando e l t o r n i l l o de

a j u s t e de velocidad de marcha en vacio.

Fig. T o r n i l l o de a j u s t e de velocidad de marcha en vacio

9 . Ajuste previamente e l t o r n i l l o de a j u s t e de mezcla de marcha en vaclo. (1) S i s e saca e l t o r n i l l o de a j u s t e de mezcla de marcha en vacio,

a p r i e t e l o totalmente una vez y vuelvalo a a f l o j a r en l a cant idad s igu ien te :

Estdndar: Vuelva 11/4 de vue l ta desde l a posici6n de totalmente apretado .

Nota : Hdgalo con cuidado para no apretar demasiado el tornillo o deteriorar la rosca del tornillo.

Fig. Torn i l lo de a j u s t e de mezcla

10. Compruebe e l i n t e r r u p t o r de l a obturacibn ( lado totalmente a b i e r t o ) . (1) Mida l a aber tu ra de l a vAlvula de obturaci6n cuando e l

i n t e r r u p t o r de l a obturaci6n estA en "ON" (conexi6n). Estdndar: 57 - 60° desde l a hor izon ta l Nota: Aseg(lrese de que el hgulo de abertura total de la vdlvula de obturaci6n estd ajustado aorrectamente. (Vea la etapa 1)

(2) S i no s e s a t i s f a c e e l estAndar, a j u s t e girando e l t o r n i l l o de a j u s t e .

Fig. I n t e r r u p t o r de l a obturaci6n T o r n i l l o de a j u s t e

7. Check and adjust the acceleration pump. (1) Apply negative pressure to the fast idle cam breaker. (2) Rotate the throttle shaft and measure the length of

the stroke.

Standard: 9.80 - 10.80 mm (0.386 - 0.425 in)

(3) If the standard is not satisfied, adjust by bending the connecting link.

8. Preset the idle speed adjusting screw. (1) Apply negative pressure to the fast idle cam breaker. (2) Check the primary throttle valve angle.

Standard: 7' from horizontal

(3) If the standard is not satisfied, adjust by turning the idle speed adjusting screw.

9. Preset the idle mixture adjusting screw. (1) If the idle mixture adjusting screw is removed, fully

tighten it once and loosen i t by the following amount:

Standard: Return by 1114 turns from the fully tight- ened position.

Note: Carefully operate so as not to overtighten the screw or damage the screw thread.

10. Check the throttle switch (full open side). (1) Measure the throttle valve opening where the throttle

switch is turned ON.

Standard: 57 - 60" from horizontal

Note: Be sure that the throttle valve full opening angle is adjusted correctly. (See step 1.)

(2) If the standard is not satisfid, adjust by turning the adjusting screw.

SISTEMA PCV

PBgina

SISTEMA PCV ..................................................... 4-2

COMPONEN'IES ................................................... 4-2 VALWLA PCV ..................................................... 4-2

REMOCION ...................................................... 4-2 INSPECCION .................................................... 4-2

INSTALACION ................................................... 4-2

PCV SYSTEM Page

................... ........................ PCV SYSTEM .... 4-2 ................... .... ............... COMPONENTS .. .. 4-2

.......................................................... PCV VALVE 4-2 ........................... .......................... REMOVAL ... 4-2

......................................................... INSPECTION 4-2

......................... ................... INSTALLATION ..... 4-2

SISTEMA PCV COMPONENTES

PCV SYSTEM

COMPONENTS

VALWLA PCV REMOCION 1. Saque la tuberia flexible de la PCV 1. 2. Saque la vdlvula PCV 2 fuera de la cubierta de la culata de

cilindros.

INSPECCION 1. Inspeccione la vdlvula PCV.

(1) Sacuda la vdlvula con la mano. Es normal el oir un sonido de clic.

( 2 ) Recambie la vblvula PCV si no escucha ningdn clic. 2. Inspeccione la tuberia flexible de la PCV.

Inspeccione la tuberia flexible de la PCV por si hay dafios, grietas o deterioros. Recdmbiela si encuentra alguna anormalidad.

INSTALACION El procedimiento de instalaci6n es el inverso a1 de remoci6n

PCV VALVE

REMOVAL

1. Remove the PCV hose @.

2. Remove the PCV valve @from the cylinder head cover.

INSPECTION

1, lnspect the PCV valve. (1) Shake the PCV valve w i th a hand. It is normal i f

clicking sound is heard. (2) Replace the PCV valve if no clicking sound is heard.

2. lnspect the PCV hose. lnspect the PCV hose f o r damage, crack and deterioration. Replace it if any abnormality is found.

INSTALLATION


SISTEMA DE ENFRIRMIENTO

Pdgina

SISTEMA DE ENFRIAMIENTO ................................ 5-2 COMPONENTES ......................................... 5-2 INSPECCION DEL AGUA DE ENFRIAMIENM ................. 5-3 RECAMBIO DEL AGUA DE ENFRIAMIENTO ................... 5-4 INSPECCION DEL RADIADOR ............................. 5-5

BOMBA DE AGUA .......................................... 5-6 REMOCION/INSTALACION ................................ 5-6

TERMOSTATO ............................................. 5-7 REMOCION/INSTALACION ................................ 5-7

COOLING SYSTEM Page

COOLING SYSTEM ................... .. ..................... 5-2

COMPONENTS ..................................................... 5-2

COOLING WATER INSPECTION .............. ........... .. 5-3

COOLING WATER REPLACEMENT ........................... 5-4

....................... .... RADIATOR INSPECTION ....... 5-5

WATER PUMP ........................ ..................... . 5-6

REMOVAL-INSTALLATION .......................... ..... . 5-6

THERMOSTAT ..................................................... 5-7

SISTEMA DE ENPRIAMIENTO

COMPONENTES

5-2

COOLING SYSTEM

COMPONENTS

(GUARDAPOLVO)

V e a l a F i g . 6701

V e a l a F i g . 6701

INSPECCION DEL AGUA DE ENFRXAMIENM

1. Inspeccione el nivel del agua de enfriamiento. Comprucbe que el nivel del agua de enfriamiento se encuentra entre las marcas "FULL" (lleno) y "LOW" (bajo) del dep6sito de reserva del radiador.

2. Inspeccione la concentraci6n de LLC (refrigerante de larga vida). (1) Inspeccione la temperatura del agua de enfriamiento y la

gravedad especlfica.

Nota: Compruebe que la concentraci6n de LLC es 30% (50% en zonas frias) o Ids.

COOLING WATER INSPECTION

1. lnspect the cooling water level. Check to see that the cooling water level is between the FULL and LOW marks on the radiator reservoir tank.

2. lnspect the LLC (Long Life Coolant) concentration. (1 lnspect the cooling water temperature and the specific

gravity.

Note: Check that the LLC concentration is 30% (50% in frigid areal or more.

(2) Obtenga la concentraci6n de LLC consultando el grbfico.

Nota: Este grafico muestra la relaci6n entre la temperatura del agua do enfriamiento y la gravedad especifica cuando la8 concentraciones de LLC son 30, 40 y 50%. Si la temperatura del agua de enfriamiento ea de 55O C y la gravebd eapocifica 1,035, la aoncentraci6n de LLC so puede obtener do la manera siguiente: La intersecci6n de 55O C y la gravedad especifica de 1,035 eat& c a d en el centro entre la8 curvas de 30% y 40%. En otras palabras, la concentraci6n de LLC es aproximadamente del 35%.

3. Inspeccione la calidad del agua de enfriamiento. Compruebe que el agua de enfriamiento estd libre de aceite u otros contaminantes.

Fig. Gravedad especifica

Temperatura medida (OC)

1 50% (aprox. -3E°C) [Las cifras entre parentesis 2 40% (aprox. -26OC) representan aproxirnadamente 3 30% (aprox. -16OC) 10s puntos de congelaci6nl

RECAMBIO DEL AGUA DE ENTRUIMIENTO

1. Drene el.agua de enfriamiento. (1) Abra las llaves de drenaje del radiador y del motor para

drenar el agua de enfriamiento. (2) Drene el agua de enfriamiento del dep6sito de reserva.

2. Rellene con agua de enfriamiento. (1) Cierre las llaves de drenaje del radiador y del motor, y eche

el agua de enfriamiento (LLC) . (2) Inspeccione el nivel del agua de enfriamiento despubs de

calentar el motor.

Fig. Llave de drenaje

Nota: Cuando saque la tapa del radiador, tenga cuidado porque puede saltar vapor o agua caliente.

(3) Anada agua de enfriamiento.

(2) Obtain the LLC concentration by referring to the graph.

Note: This graph shows the relationships between the cooling water temperature end spaclfic gravity when the LLC concentrations are 30, 40 end 50%. I f the cooling water temperature is 55OC and the specific gravity Is 1.035, the LLC concentration can be obtained as follows: The Intersection of the 55OC and specific gravity of 1.035 ie almost in the center between the 30% and 40% curves. In other words, the LLC concentration is approx. 35%.

3, Inspect the cooling water quality. Check that the cooling water is free from oil or other con- taminants.

COOLING WATER REPLACEMENT

1. Drain cooling water. (1 I Open the drain cocks of the radiator and engine to

drain cooling water. (2) Drain cooling water from the reservoir tank.

2. Fill cooling water. ( 1 ) Close the drain cocks of the radiator and engine, and

fill the cooling water (LLCI. (2) lnspect the cooling water level after warming up the

engine.

Note: When removing the radiator cap, be careful as steam or hot water may jet out.

(3) Add cooling water.

INSPECCION DEL RADIADOR

1. Inspeccione visualmente la tapa del radiador. (1) Compruebe la empaquetadura por si tiene grietas y

deformaci6n. (2) Compruebe la vdlvula y el asiento de la vdlvula por si tiene

deformaci6n o dentados. (3) Compruebe que no hay dep6sitos de escamas del agua entre la

vdlvula y el asiento de la vdlvula.

2. Mida la presibn de abertura de la vdlvula de la tapa del radiador. Instale el probador de tapas en la tapa del radiador para medir la presi6n de abertura de la vdlvula.

Estdndar: 73,5 - 103/0 kPa (0,75 - 1/05 kgf/cm2) Llmite: 58,8 kPa (0,6 kgf/cm2)

3. Inspeccione la parte de la admisi6n del agua. (1) Compruebe que la superficie de sellado no tiene deformaciones

ni dentados. (2) Compruebe que la parte del extremo no estd deformada.

4 . Comprcebe que no hay filtraciones de agua del sistema del agua de enfriamiento. (1) Saque la tapa del radiador, eche agua de enfriamiento e

instale un probador. (2) Caliente el motor. (3) Pare el motor. Aplique una presi6n de 176 kPa (1,8 kgf/cm2) y

compruebe qua no hay filtraciones de aceite por ninguna parte.

precauciones : Rellene siempre con agua de enfriamiento. Limpie bien e l agua de l a s partes que va a inspeccionar. Cuando instale y quite e l probador, no deforme l a parte de l a boca de l a admisi6n de agua del radiador accionando l a bomba. Cuando aaque e l probador, hSgalo con cuidado para evitar escaldaree con e l agua caliente que pueda sal tar .

RADIATOR INSPECTION

1. Visually inspect the rediator cap. ( 1 ) Check the packing for no crack and deformation. (2) Check the valve and valve seat for no deformation or

dent. (3) Check there is no water scale deposit between the

valve and valve seat.

2. Measure the radiator cap valve opening pressure. Install a cap tester on the radiator cap for measuring the valve opening pressure.

Standard: 73.5 - 103.0 kPa (0.75 - 1.05 kgflcm2) 110.7 - 14.9 psil

Limit: 58.8 kPa (0.6 kgflcm21 18.5 psil

3, Inspect the neck fly portion (water inlet). ( 1 ) Check the seal face for no deformation or dent. (21 Check no deformation at the end portion.

Caution: Always fill coollng water. Wipe wate r suf f ic ient ly f r o m t h e por t ions t o be Inspected. When Installing and removing the tester, do not deform the neck fly portion o f the radiator by pump operation. When removing the taster, carefully operate to avoid scalding by jetting hot water.

4. Check no water leak from the cooling water system. (1 Remove the radiator cap, fill cooling water and install

a tester. (2) Warm up the engine. (3) Stop the engine. Apply a pressure of 176 kPa (1.8

iB%F--- kgflcm2) 125.6 psil and check no oil leak from any oortion.

EOMBA DE AGUA

REMOCION/INSTAIJLCION

1 Agua de enfriamiento


1 Drene el agua de enfriamiento. (Vea la p6gina 5- 4)

2 Desconecte la tuberia flexible inferior.

3 Saque la correa transmisora. (Vea la pagina 1-3)

4 Saque la bomba de agua. [Punto 1)

5 Saque la polea de la bomba de agua.


El procedimiento de instalaci6n es el inverso a1 de remocibn.

Puntos de trabajo

Inspecci6n: Compruebe cada parte para ver que no tiene grietas ni deterioros. Recambie si encuentra anormalidades.

Inspecci6n: Gire la polea y compruebe que no se agarrota ni tiene sonido anormal.

WATER PUMP

REMOVAL INSTALLATlON T = N m (kgf-cm) [ft-lbf]

1 Cooling water

Removal Procedure

1 Drain cooling water. (See page 5-4)

2 Disconnect the lower hose.

3 Remove the drive belt. (See page 1-3)

4 Remove the water pump. [Point 11

5 Remove the water pump pulley.



I Point Operations

Inspection: Check each part for no crack or damage. Replace it if abnormal.

Inspection: Rotate the pulley and check no sticking or abnormal sound.

THERMOSTAT

REMOVAL.lNSTALLATlON T = N,m (kgf-cml [ft-lbfl

1 Agua d e e n f r i a m i e n t o

P roced imien to d e remoci6n P roced imien to d e i n s t a l a c i 6 n

1 Drene e l agua de e n f r i a m i e n t o . E l p roced imien to d e i n s t a l a c i 6 n (Vea l a pdgina 5-41 es e l i n v e r s o a 1 d e remoci6n.

2 Desconecte l a t u b e r i a f l e x i b l e d e s a l i d a d e l agua .

3 Saque e l t e r m o s t a t o . [Punto 11

1 Cooling water

Punto d e t r a b a j o [Punto 11

In specc i6n : In specc ione e l t e r m o s t a t o .

1. Sumerja e l t e r m o s t a t o e n agua y c a l i e n t e l a gradualmente .

2 . Mida l a t empera tu ra cuando comienza a a b r i r s e l a v d l v u l a d e l t e r m o s t a t o .

Es tdnda r : 75,O - 78,g0 C

3. Mida 1 i l e l e v a c i 6 n d e l a v d l v u l a y l a t empera tu ra cuando l a v d l v u l a e s t d t o t a l m e n t e a b i e r t a .

Es tdnda r : E levac i6n d e l a vd lvu la : 8,12 mm Temperatura d e a b e r t u r a t o t a l : 88 ,g0 C

Removal Procedure Installation Procedure

1 Drain cooling water. (See page 5-4) The installation procedure is the reverse of the removal procedure.

2 Disconnect the water outlet pipe.

3 Remove the thermostat. [Point 11

Point Operations

[Point 11

Inspection: Inspect the thermostat.

1, Immerse the thermostat in water and heat it gradually.

2. Measure the temperature when the thermostat valve starts to open.

Standard: 75.0 - 78.S°C (167 - 174OF)

3. Measure the valve lift and temperature when the valve is fully opened.

Standard Valve lift: 8.12 mm (0.320 in) Full opening temperature: 88.S°C 1192°F1

SISTEMA DE LUBRICACION

Pag ina

INSPECCION DE LA PRESION DE ACEITE ..................... 6-2

RECAMBIO DEL ACEITE DE MOTOR/FILTRO DE ACEITE .......... 6-3

BOMBA DE ACEITE ........................................ 6-4 COMPONENTES ......................................... 6-4

REMOCION/INSTALACION ................................ 6-5

DESMONTAJE/INSPECCION/REMONTAJE ..................... 6-6

LUBRICATION SYSTEM Page

OIL PRESSURE INSPECTION ............................ 6-2

ENGINE OIL-OIL FILTER REPLACEMENT ............. 6-3

OIL PUMP ............................ .. ..................... 6-4 COMPONENTS ........................ ... ........................ 6-4 REMOVAL-INSTALLATION ................... .. ............. 6-5 DlSASSEMBLY.INSPECTION.REASSEMBLY .............. 6-6

INSPECCION DE LA PRESION DE ACEITE

1. Inspeccione el aceite de motor. (1) Inspeccione el nivel de aceite.

Estdndar: Deberd estar entre las lineas de lleno y bajo del medidor de nivel de aceite.

Sumidero de aceite: 4,2 litros Sumidero de aceite + filtro de aceite: 3,8 litros

(2) El aceite tendrd la viscosidad apropiada sin contaminaci6n excesiva ni mezcla de aqua de enfriamiento ni combustibles.

Nota: Compruebe el nivel de aceite despu6s de que hayan pasado a1 menos tres minutos de parar el motor.

2. Saque el interruptor de presibn de aceite e instale un man6metro de aceite en la boquilla.

3. Caliente el motor.

Temperatura del aqua de enfriamiento: 80° C o mds Temperatura del aceite hidrbulico: 60° C o mas

4. Mida la presi6n de aceite.

Estdndar A 1000 rpm: 41,4 kPa (0,4 kqf/cm2) A 2000 rpm: 124,l kPa (1,3 kqf/cm2)

5. Saque el man6metro de aceite e instale el interruptor de presi6n de aceite.

Nota: Cubra con agente adhesivo 2 6 3 roscas del interruptor de presi6n de aceite antes de la instalaci6n. Agente adhesivo: Three Bond Y1215 o epuivalente En el orificio de admisi6n de aceite del interruptor de presi6n de aceite jards debera haber agente de sellado.

6. Despues de instalar el interruptor de presi6n de aceite, ponqa en marcha el motor y compruebe que no hay filtraciones de aceite.

Adhesive

OIL PRESSURE INSPECTION

1, Inspect the engine oil. (1) Inspect the oil level.

Standard: Shall be between the full and l o w lines on the 011 level gage.

Oil pan: 4.2 e (1.11 Usgal) Oil pan + Oil filter: 3.8 .t (1.00 USgal)

(2) The oil shall have appropriate viscosity without excessive contamination or mixture of cooling water or fuel.

Note: Check the oil level after lapse of at least three minutes after stopplng the englne.

2. Remove the oil pressure switch and install an oil pressure gage to nipple.


Cooling water temperature: 80°C (176OF) or more Hydraulic oil temperature: 60°C (140°F) or more

4. Measure the oil pressure.

Standard A t 1000 rprn: 41.4 kPa (0.4 kgflcrn2) [6 psi1 At 2000 rpm: 124.1 kPa (1.3 kgflcm2) [ l a psi]

5. Remove the oil pressure gage and install the oil pressure switch.

Note: Coat adhesive agent on 2 to 3 threads of the oil pressure switch before Installation. Adhesive agent: Three Bond # 1215 or equivalent Never let the oil inlet hole of the oil pressure switch be smeared wi th the sealing agent.

6. After installing the oil pressure switch, start the engine and check no oil leak.

Fig. Adhesivo

RECAMS10 DEL ACEITE DE MOTOR/FILTRO DE ACEITE

1. Drene e l a c e i t e de motor. (1) Saque l a t apa de admisi6n de a c e i t e . (2) Saque e l tap6n de drena je de a c e i t e para drenar e l a c e i t e de

motor.

2. Usando una l l a v e de f i l t r o s , saque e l f i l t r o de a c e i t e .

Fig. Llave de drena je

3. I n s t a l e un f i l t r o de a c e i t e nuevo. (1) Cubra con una pequeRa cant idad de a c e i t e de motor e l a n i l l o

en "0" para e l f i l t r o de a c e i t e . ( 2 ) Enrosque manualmente e l f i l t r o de a c e i t e h a s t a que l a junta

de empaquetadura e n t r e en un contact0 l i g e r o con e l bloque de c i l i n d r o s .

(3) Vuelva a a p r e t a r e l f i l t r o una vue l ta m6s a p a r t i r de esa posici6n.

4 . Rellene con a c e i t e de motor. (1) Limpie l a s u p e r f i c i e de montaje d e l tap6n de drena je e

i n s t a l e e l tap6n de drenaje con l a junta de empaquetadura e n t r e e l l o s .

(2) Rellene con a c e i t e de motor.

Capacidad t o t a l de a c e i t e : 4,2 l i t r o s Capacidad d e l sumidero de a c e i t e : 3,8 l i t r o s

(3) I n s t a l e l a t apa de admisi6n de a c e i t e .

5 . Inspeccione e l n ive l de a c e i t e y si hay f i l t r a c i o n e s de a c e i t e . (1) Saque e l medidor de n ive l de a c e i t e y compruebe e l n i v e l de

a c e i t e . ( 2 ) Ponga en marcha e l motor y compruebe que no hay f i l t r a c i o n e s

de a c e i t e . (3) Saque e l medidor de n ive l de a c e i t e y compruebe una vez m6s

e l n i v e l de a c e i t e .

ENGINE OIL-OIL FILTER REPLACEMENT

1. Drain engine oil. (1) Remove the oil filler cap. (2) Remove the oil drain plug to drain engine oil.

2. Using a filter wrench, remove the oil filter.

3. Install a new oil filter. (1) Coat a small amount of engine oil on the O-ring for

the oil filter. (2) Manually screw in the oil filter until the gasket

comes into light contact with the cylinder block. (3) Retighten position. the filter in further one turn from that

4. Fill engine oil. (1) Clean the drain plug mounting face and install the drain

plug with the gasket in-between. (2) Fill engine oil.

Total oil capacity: 4.2 t (1.11 USgal) Oil pan capacity: 3.8 t (1.00 USgall

(3) Install the oil filler cap

5, Inspect the oil level and oil leak. (1) Extract the oil level gage end check the oil level. (2) Start the engine and check no oil leak. (3) Extract the oil level gaga and check the oil level again.

Note: Check the oil level again after lapse of at least 3 minutes after atopplng the engine.

Nota : Cornpruebe el nivel de aceite otra ver despuba de que hayan pasado a1 menos 3 minutos de parar el motor.

BOMBA DE ACEITE

COMPONENTES

OIL PUMP

COMPONENTS

Nota : Saque e l conjunto d e l motor fuera d e l vehiculo a n t e s de l a remoci6n/ instalaci6n de la bomba de a c e i t e , ya que e s imposible hacer lo en e l vehiculo porque e l sumidero de a c e i t e e a t & in tegrado con e l reforzador.

T = N.m (kgf-cm)

2 Motor de a c e i t e


1 Saque e l motor. (Vea e l manual de reparaciones correspondiente a cada modelo de vehiculo)

2 Drene e l a c e i t e de motor.

3 Saque e l sumidero de a c e i t e . (Vea l a pagina 2-17)

4 Saque l a bomba de a c e i t e .

Procedimiento de i n s t a l a c i 6 n

E l procedimiento de i n s t a l a c i 6 n e s e l inverso a 1 de remoci6n.

Note: Remove the engine ASSY from the vehicle before oil pump removal/installation since it is impossible on the vehicle because the oil pan is integrated with the stiffener.

T = N.m (kgf-cml lft-lbfl

Removal Procedure

1 Remove the engine. (Refer to the repair manual for each vehicle model.)

2 Drain engine oil.

3 Remove the oil pan. (See page 2-17.)

4 Remove the oil pump.


The installation procedure is the reverse of the removal procedure

D E ~ M ~ N T ~ / I N ~ P E C C I O N / R E M O N T A J E T = N . m (kgf-cm)

DISASSEMBLY .INSPECTION .REASSEMBLY T = N,m (kgf-cm) [ft-lbfl

Procedimiento de desmontaje

1 Saque l a c u b i e r t a de l a bomba.

2 Saque e l colador . [Punto 11

3 Saque e l pasador y l a vdlvula l imitadora de pres ibn .

Procedimiento de remontaje

El procedimiento de remontaje e s e l inverso a1 de desrnontaje.

Desmontaje: No saque l a bomba de a c e i t e si no e s absolutarnente necesario.

Desmontaje: F i j e l a bomba en un t o r n i l l o de banco para su remoci6n. Use siempre una placa de aluminio en l a p a r t e l a t e r a l d e l t o r n i l l o de banco. Trabaje con cuidado p a r a no d e t e r i o r a r l a t u b e r i a .

Remontaje: Usando l a SST, i n s t a l e un nuevo colador de a c e i t e en p a r a l e l o con e l sumidero de a c e i t e .

SST 5-21882


1 Remove the pump cover.

2 Remove the strainer. [Polnt 11

3 Remove the pin and relief valve.



[Point 11

Disassembly: Do not remove the oil pump unless it is abso- lutely necessary.

Disassembly: Fix the pump in a vise for removal. Always use aluminium plate on the vise side. Carefully operate so as not to damage a pipe.

Reassembly: Using SST, install a new oil strainer in parallel with the oil pan. SST J-21882

SISTEMA DE ENCENDIDO

P6gina

SISTEMA DE ENCENDIDO .................................... 7-2 COMPONENTES .......................................... 7-2 INSPECCION EN EL VEHICULO ............................ 7-3

DISTRIBUIDOR ............................................ 7-5 COMPONENTES .......................................... 7-5 REMOCION/INSTALACION ................................. 7-6 DESMONTAJE/INSPECCION/REMONTAJE ...................... 7-8

IGNITION SYSTEM

Page

IGNITION SYSTEM ............................................... 7-2

COMPONENTS ...................................................... 7-2

ON-VEHICLE INSPECTION ...................................... 7-3

DISTRIBUTOR ....................................................... 7-5

COMPONENTS ................... ................ . . . 7-5

REMOVAL.lNSTALLATlON ....................... ........ . 7-6

DISASSEMBLY . INSPECTION a REASSEMBLY .............. 7-8

SISTEMA DE ENCENDIDO

COMPONENTES

IGNITION SYSTEM

COMPONENTS

(EC SPEC) 7

INSPECCION EN EL VEHICULO

Inspecci6n del cord6n de alta tensi6n.

1. Desconecte el cordbn de alta tensibn.

Nota: No tire del cord6n de alta tenri6n sujet&ndolo por la parts del cord6n cuando lo desconecte.

2 . Inspeccione el cordbn de alta tensibn. ( 1 ) Mida la resistencia de cada cordbn.

Limite: 25 kL-2 o menos

( 2 ) Si se excede el limite, inspeccione el terminal y recarnbie segOn sea necesario.

3. Conecte el cordbn de alta tensibn.

Limpieza/inspqcci6n de la bujia de encendido.

1. Desconecte el cordbn de alta tensibn y saque la bujia de encendido.

2. Limpie e inspeccione la bujia de encendido. (1 ) Limpie la bujia de encendido con un limpiador de bujias de

encendido. (2 ) Inspeccione 10s electrodos, la rosca del tornillo y el

aislador de la bujia de encendido.

( 3 ) In jpeccione y a juste la separacibn del electrodo . ~stdndar: 1,4 - 1,6 mm (Tipo de bujia de encendido: AC DELCO 41-932)

Si se excede el estdndar, ajuste doblando el electrodo exterior.

3. Instale la bujia de encendido y conecte el cordbn de alta tensibn.

Inspecci6n de la bobina de encendido.

1. Desconecte el cordbn de alta tensi6n y 10s conectores. Nota : No tire de la parte del cord6n do alta tenrri6n para derrconectarlo.

7-3


High tension cord inspection.

1. Disconnect the high tension cord.

Note: Do not pul l the high tension cord by holding the cord portion for disconnection.

2. lnspect the high tension cord. (1) Measure the resistance of each cord.

Limit: 25 kSl or less

(2) If exceeding the limit, inspect the terminal and replace as required.

3. Connect the high tention cord.

Spark plug cleanlng~lnspection.

1. Disconnect the high tention cord and remove the spark plug.

2. Clean and inspect the spark plug. (1 ) Clean the spark plug with spark plug cleaner. (21 lnspect the electrodes, screw thread and insulator of

the spark plug.

(3) lnspect and adjust the electrode gap.

Standard: 1.4 - 1.6 mm (0.055 - 0.063 in1 (Spark plug type : AC DELCO 41-9321

If exceeding the standard, adjust by bending the outer electrode.

3, Installs the spark plug and connect the high tention cord.

Ignition coil Inspection.

1. Disconnect the high tention cord and connectors.

Note: Do not pul l the high tension cord by cord portion for disconnection.

2 . Inspeccione l a bobina de encendido.

Est6ndar : Inspecci6n 1 m R Inspecci6n 2 0 - 1 R Inspecci6n 3 m R : Anormalidad

3 . S i no s e s a t i s f a c e e l estAndar, recambie l a bobina de encendido.

4 . Vuelva a conectar e l cord6n de a l t a t ens i6n y 10s conectores .

Inspecci6n del distribuidor

1. Quite l a t apa a 1 d i s t r i b u i d o r ,

2 . Desconecte e l conector de l a bobina de toma.

3 . Inspeccione l a bobina de toma.

4 . S i no s e s a t i s f a c e e l es thndar , recambie l a bobina de toma.

5 . Vuelva a conectar e l conector de l a bobina de toma.

6 . I n s t a l e l a t apa de l d i s t r i b u i d o r .

2, lnspect the ignition coil.

Standard: Inspection 1 m R Inspection 2 0 - 1 R Inspection 3 - i2 : Abnormality

3. If the standard is not satisfied, replace the ignition coil.

4. Reconnect the high tension cord and connectors.

Distributor inspection

1. Remove the distributor cap from the distributor.

2. Disconnect the pick up coil connecter.

3. Inspect the pick up coil.

Standard: Inspection 1 - R Inspection 2 500 - 1500R

4. If the standard is not satisfied, replace the pick up coil.

5. Reconnect the pick up coil connecter.

6. Install the distributor cap.

DISTRIBUIDOR

COMPONENTES

DISTRIBUTOR

COMPONENTS

6 BW

'P: BV

I

T = N.m (kgf-cm)

2 A j u s t e e l c i l i n d r o No. 4


1 Saque l a t a p a d e l d i s t r i b u i d o r .

2 A j u s t e e l c i l i n d r o No. 4 a 1 PMS de compresibn. [Punto 11

3 Saque e l pe rno de s u j e c i 6 n d e l d i s t r i b u i d o r . [Punto 21

4 Saque e l d i s t r i b u i d o r . [Punto 31


El proced im ien to de i n s t a l a c i 6 n es e l i n v e r s o a 1 de remocibn.

Nota: Despues de instalar el distribuidor, inspeccione la distribuci6n do encendido. (Vea la pAgina 1-4)

7-6

REMOVAL.INSTALLATION T = N,m [kgf-cm) Ift-lbfl

4 3 T - 26 - 48 1265. 4891 119.2 - 35.41

2 Set the No.4 cylinder

Removal Procedure

1 Remove the distributor cap.

2 Set the No. 4 cylinder to compression TDC. [Point 11

3 Remove the distributor set bolt. [Point 21

4 Remove the distributor. [Point 31


The installetion procedure is the reverce of the removal procedure.

Note: After lnstalltng the distributor, Inspect the Ignition timing. (See page 1-41

sheath

Text Box

Click here for R & R procedures on PSI and Spectrum equipped engines.


[Punto 1 1

Remoci6n: Ajuste el cilindro No. 4 a1 PMS de compresi6n.

1. Alinee la ranura del equilibrador del 6rbol del ciglienal y la aguja de distribuci6n de la cubierta delantera del motor.

2. Compruebe que el rotor estd en la posici6n mostrada.

3. Si no est6 como en la etapa 2, gire el drbol del cigliefial 3 6 0 ° .

[Punto 21

Remoci6n: Ponga marca de posici6n del rotor y marcas de acoplamiento en el distribuidor y el motor.

Instalaci6n:Despu6s de comprobar la distribuci6n de encendido, apriete el perno de sujecibn de la abrazadera.

(Vea la p6gina 1-41

Fig.

Posici6n del rotor Marcas de acoplamiento

Remoci6n: Despues de sacar el distribuidor, no gire el hrbol del ciglieflal.

Instalaci6n:Instale el distribuidor siguiendo este procedimiento:

1. Ajuste el cilindro No. 4 a1 PMS de compresi6n. Tanto las v6lvulas de admisi6n como de escape deberdn estar cerradas cuando el cilindro No. 4 est6 en el PMS de compresi6n.

2 . Ajuste la parte con muescas de la bomba de aceite en la posici6n mostrada en la ilustraci6n.

3 . Gire el rotor unos 45' hacia la izquierda m6s a116 de la marca de posici6n del rotor puesta durante la remoci6n.

4. Inserte el distribuidor. Asegdrese que estdn alineadas tanto la marca de posici6n del rotor como las marcas de acoplamiento.

7-7

Point Operations

[Point 11

Removal: Set the No.4 cylinder to compression TDC.

1. Align the groove of the crankshaft balancer and the timing pointer on the engine front cover.

2. Check that the rotor is in the shown a position.

3. If not facing in step 2, rotate the crankshaft by 360".

[Point 21

Removal: Put a rotor position mark and match marks for distributor and engine.

Installation: After checking the ignition timing, tighten the clamp set bolt. (See page 1-41

[Point 31

Removal: After removing the distributor, do not rotate the crankshaft.

Installation: Insta l l the d i s t r i bu to r accord ing to the following procedure:

1. Set the No. 4 cylinder to the compression TDC. Both the IN and EX valves should be closed when the No. 4 cylinder is set to the compression TDC.

2. Set the oil pump notched portion at the position shown in the illustration.

3. Turn the rotor about 45'counterclockwise past the rotor position mark put during removal.

4, Insert the distributor. Make sure both rotor position mark and match marks are aligned.

Fig. Posici6n del rotor Marcas de acoplamiento


Procedimiento de desmontaje

1 Saque el m6dulo de control del distribuidor. [Punto 11

2 Saque el rotor.

3 Saque el pasador y el engranaje. [Punto 21

4 Saque el arbol. [Punto 31

5 Saque el ret4n y el protector. [Punto 41

6 Saque la bobina de toma.

7 Saque la clavija de toma.


El procedimiento de remontaje es inverso a1 de desmontaje.


1 Remove the distributor control module. [Point I]

2 Remove the rotor.

3 Remove the pin and gear. [Polnt 21

4 Remove the shaft. [Polnt 31

5 Remove the retaner end shield. [Point 41

6 Remove the pick up coil.

7 Remove the pick up pole.


The reassembly procedure is the reverce of the disassembly.

Puntos de trabajo

~ e m o n t a j e : Aplique grasa de s i l i c i o a 1 reverso d e l mbdulo de con t ro l d e l d i s t r i b u i d o r .

Fig. Grasa de s i l i c i o

[Punto 21

Point Operations

[Point 11

Reassembly: Apply silicone grease to the reverse of the distributor control module.

[Point 21

Disassembly: Use the drift pin or equivalent for removing the pin.

Desmontaje: Use un pasador perforador o algo equivalente para l a remoci6n d e l pasador.

Remontaje: Alinee l a muesca d e l Arb01 y l a marca d e l punto d e l engranaje cuando i n s t a l e e l engranaje.

NO!C~ DOI mark

Fig. Marcas de acoplamiento

Muesca

Reassembly: Align the shaft notch and the gear dot mark when installing the gear.

Inspecci6n: I n s e r t e e l drbol en e l c a r t e r , y confirme que g i r a suavemente s i n agar ro ta rse t a n t o hacia l a derecha como hacia l a i zqu ie rda . Recambie e l Arb01 o e l c a r t e r s i s e agar ro tan .

[Punto 41

Desmontaje: No desmonte s i no es absolutamente necesario.

Desmontaje: Use un d e s t o r n i l l a d o r para sacar e l p ro tec tor , y tenga cuidado de no rayar l a s p a r t e s de alrededor.

Inspection: Insert the shaft into the housing, and confirm that it rotates smoothly without stick in both clockwise and counterclockwise directions. Replace the shaft or housing if sticking.

[Point 41

Disassembly: Do not make disassembly unless it is absolute- ly nessesaly.

Disassembly: Use a screwdriver to remove the shield, and take care not to scratch the surrounding parts.

SISTEMA DE ARRANQUE

DIAGRAMA DEL CIRCUIT0

A la bateria A 1 interruptor de encendido

Terminal 30 Terminal 50

Terminal C

8-2

STARTING SYSTEM

CIRCUIT DIAGRAM

to Battery to Ignition switch

MOTOR DE ARRANQUE

COMPONENTES STARTING MOTOR

COMPONENTS

DESMONTAJE Y REMONTAJE DEL HOTOR DE ARRANQUE

8-4


Proced imiento de desmontaje

1 Desconecte e l cab le conductor d e l t e r m i n a l d e l i n t e r r u p t o r magn6tico.

2 Saque e l con junto d e l casco. [Punto 1 1

3 Saque l a armazbn d e l extremo.

4 Saque l a s escob i l l as . [Punto 21

5 Saque e l con junto d e l i nduc ido . IPun to 31

6 Saque e l c i r t e r f ue ra d e l i n t e r r u p t o r magn8tico. [Punto 4 1

7 Saque e l embrague. [Punto 51

8 Saque l a bo la de acero.

9 Saque e l engranaje in termedio .

10 Saque e l r e t 6 n y e l r o d i l l o .

11 Saque e l r e s o r t e de r e t o r n o .


E l p roced imiento de remontaje es e l i n v e r s o a 1 d e l desmontaje.


1 Disconnect the lead wire from the magnet switch terminal.

2 Remove the yoke ASSY. [Polnt 11

3 Remove the end frame.

4 Remove the brushes. [Point 21

5 Remove the armature ASSY. [Polnt 31

6 Remove the housing from the magnet switch. [Polnt 41

7 Remove the clutch. [Polnt 51

8 Remove the steel ball.

9 Remove the idle gear.

10 Remove the retainer and roller.

11 Remove the return spring.



P u n t o s d e t r a b a j o

~ n s p e c c i b n : tlaga l a p r ~ i e b a d e c o n t i n u i d a d d e l a bobina i n d u c t o r a . I n s p e c c i o n e l a c o n t i n u i d a d e n t r e e l c a b l e c o n d u c t o r y l a e s c o b i l l a d e l a bobina i n d u c t o r a . Rccainbie l a b o b i n a i n d u c t o r a s i no hay c o n t i n u i d a d .

I n s p e c c i b n : Haga l a p rueba d e conexibn a t i e r r a (masa) d e l a b o b i n a i n d u c t o r a . I n s p e c c i o n e e l a i s l a m i e n t o e n t r e e l e x t r e m o d e l a b o b i n a i n d u c t o r a y l a armazbn i n d u c t o r a . S i hay c o n t i n u i d a d , r e p a r e o recambie l a armazbn i n d u c t o r a .

Remontaje: Acople l a p a r t e s a l i e n t e d e l a armazbn i n d u c t o r a y l a p a r t e r e c o r t a d a d e l i n t e r r u p t o r d e l i n t e r r u p t o r magnht ico .

D e s n o n t a j e : Use un d e s t o r n i l l a d o r p a r a s a c a r e l r e s o r t e , y s a q u e l a e s c o b i l l a f u e r a d e l s u j e t a d o r d e l a e s c o b i l l a .

~ n s p e c c i b n : I n s p e c c i o n e l a l o n g i t u d d e l a e s c o b i l l a .

E s t i n d a r : 15,O mm Limi te : 10,O mm

S i e s i n f e r i o r a 1 limite, r e c a m b i e e l s u j e t a d o r d e l a e s c o b i l l a y l a armazbn i n d u c t o r a .

I n s p e c c i b n : I n s p e c c i o n e l a a s p e r e z a d e l a s u p e r f i c i e d e c o n t a c t 0 d e l a e s c o b i l l a , y c o r r l j a l a . A r r o l l e p a p e l d e l i j a a l r e d e d o r d e l conmutador p a r a c o r r e g i r l a .

Point Operations

[Point 11

Inspection: Perform field coil continuity test. lnspect continuity between the lead wire and field coil brush. Replace the field coil if continuity does not exist.

Inspection: Perform field coil grounding test. lnspect insulation between the field coil end and field frame. If continuity exists, replace the field frame.

Reassembly: Match the field frame protruded part and magnet switch cutout portion.

[Point 21

Disassembly: Use a screwdriver to pull the spring, and remove the brush from the brush holder.

Inspection: lnspect the brush length.

Standard: 15 rnrn (0.59 In1 Limit: 10 mm (0.39 in)

If less than the limit, replace the brush holder and field frame.

Inspection: lnspect roughening of the brush contact surface, and correct it. Wrap sandpaper around the commutator for correction.

I n s p e c c i b n : I n s p e c c i o n e l a c a r g a d e l r e s o r t e d e l a e s c o b i l l a .

EstCndar: 1 7 , 5 0 5 * 2 3 , 6 8 3 N (1 ,785 - 2 , 4 1 5 kgf)

l l e c a m b i e e l r e s o r t e d e l a e e c o b i l l a s i n o s e s a t i s f a c e e l e s t s n d a r .

Fig. Escobilla

I n s p e c c i b n : I n s p e c c i o n e e l a i s l a m i e n t o e n t r e 10s l a d o s p o s i t i v o y n e g a t i v o d e l s u j e t a d o r d e l a e s c o b i l l a . S i hay c o n t i n u i d a d , c o r r i j a o r e c a m b i e e l s u j e t a d o r d e l a e s c o b i l l a .

Remontaje: Use un d e s t o r n i l l a d o r p a r a s a c a r e l r e s o r t e d e l a e s c o b i l l a , y c o n e c t e l a e s c o b i l l a a 1 s u j e t a d o r .

I n s p e c c i b n : Haga l a p rueba d e c o n e x i 6 n a t i e r r a (masa) d e l a b o b i n a d e l induc ido . I n s p e c c i o n e e l a i s l a m i e n t o e n t r e e l conmutador y l a b o b i n a d e l i n d u c i d o . S i hay c o n t i n u i d a d , recambie e l i n d u c i d o .

I n s p e c c i b n : I n s p e c c i o n e l a c o n t i n u i d a d d e l a bobina d e l i n d u c i d o . I n s p e c c i o n e l a c o n t i n u i d a d e n t r e 10s segmentos d e l conmutador. I n s p e c c i o n e e n t r e c a d s p a r d e segmentos. Recambie e l i n d u c i d o s i n o hay c o n t i n u i d a d .

8-6

Inspection: lnspect the brush spring load.

Standard: 17.505 - 23.683N (1.785 - 2.415 kgfl

13.93 - 5.32 lbfl

Replace the brush spring if the standard is not satisfied.

Inspection: lnspect insulation between the positive and negative sides of the brush holder. If continuity exists, replace the brush holder.

Reassembly: Use a screwdriver to pull the brush spring, and connect the brush to the brush holder.

[Point 31

Inspection: Perform the armature coil grounding test. Inspect insulation between the commutator and armature coil. If continuity exists, replace the armature.

Inspection: lnspect the armature coil continuity. lnspect continuity between commutator segments. Inspect between every pair of segments. Replace the armature if no continuity exists.

I n s p e c c i b n : I n s p e c c i o n e l a bobina d e l i n d u c i d o por s i hay c o r t o c i r c u i t o . Use un probador d e i n d u c i d o s y g i r e e l i n d u c i d o m i e n t r a s a p l i c a un t r o z o d e h i e r r o p a r a l e l a m e n t e a 1 i n d u c i d o . Cornpruebe que e l t r o z o d e h i e r r o no e s a t r a i d o y q u e n o v i b r a .

k 1 Inspection: lnspect the armature coil for short circuit. Use an armature tester and rotate the armature while ao~lvina an iron ~ i e c e in ~arallel with the . . . - armature. Check that no attraction or vibration of the iron piece occurs.

I n s p e c c i b n : I n s p e c c i o n e e l conmutador.

1 . I n s p e c c i o n e e l d e s c e n t r a m i e n t o r a d i a l .

L l m i t e : 0 , 0 5 mm

2 . Mida e l d i i m e t r o e x t e r i o r .

E s t i n d a r : 30 mm L i m i t e : 29 mrn

3. I n s p e c c i o n e l a p rofundidad d e l r e c o r t e e n t r e segmentos.

E s t a n d a r : 0 , 5 - 0,8 INU L l m i t e : 0 , 2 mm

S i l a p r o f u n d i d a d d e l r e c o r t e es i n f e r i o r a 1 l imite, c o r r i j a l o con u n a h o j a d e s i e r r a p a r a metales.

I n s p e c c i b n : I n s p e c c i o n e y recambie e l c o j i n e t e .

1 . G i r e manualmente e l c o j i n e t e m i e n t r a s l o empuja h a c i a a d e n t r o . S i s i e n t e c u a l q u i e r r e s i s t e n c i a o a g a r r o t a m i e n t o , recambie e l c o j i n e t e .

I I

n I Inspection: Inspect the commutator.

I I

-1 2. Measure the outside diameter.

Standard: 30 mm (1.18 in) Limit: 29 mm 11.14 in)

I

-1 3. lnspect the depth of undercut between segments.

l I Standard: 0.5 - 0.8 rnrn 10.020 - 0.031 in) Limit: 0.2 mm (0.008 in)

If the undercut-depth is less than limit, correct it with a hacksaw blade.

Inspection: lnspect and replace the bearing.

1. Manually rotate the bearing while pushing it inward. If any resistance or sticking is felt, replace the bearing.

2. Saque e l c o j i n e t e . SST 09286-4601 1

3 . I n s t a l e u n c o j i n e t e nuevo .

[ P u n t o 4 1

I n s p e c c i b n : I n s p e c c i o n e e l i n t e r r u p t o r magn6t ico .

1 . I n s p e c c i o n e l a c o n t i n u i d a d e n t r e 10s t e r m i n a l e s 50 y C.

F i g . T e r m i n a l C

T e r m i n a l 50

2 . I n s p e c c i o n e l a c o n t i n u i d a d e n t r e e l t e r m i n a l 50 y e l c u e r p o d e l i n t e r r u p t o r .

F i g . Cuerpo d e l i n t e r r u p t o r

T e r m i n a l 50

I n s p e c c i 6 n : I n s p e c c i o n e e l e n g r a n a j e p o r si hay d e s g a s t e o d e t e r i o r o .

I n s p e c c i b n : S u j e t e e l embrague d e l motor d e a r r a n q u e , y compruebe q u e puede g i r a r suavemente h a c i a l a d e r e c h a y q u e se i n m o v i l i z a a 1 g i r a r l o h a c i a l a i z q u i e r d a .

F i g . L i b r e I n m o v i l i z a d o

8-8

2. Remove the bearing. SST 09286-4601 1

3. Install a new bearing.

[Point 41

Inspection: lnspect the magnet switch.

1. lnspect the continuity between terminals 50 and C.

2, Inspect the continuity between terminal 50 and switch body.

[Point 51

Inspection: lnspect the gear for wear end damage.

Inspection: Hold the starting motor clutch, and check that it can be rotated smoothly in the clockwise direction and is locked when rotated counterclockwise.

INSPECCION INDIVIDUAL DEL CONJUNTO DEL MOTOR DE ARRANQUE

Nota: C o m p l e t e l a i n s p e c c i 6 n e n 3 a 5 s e g u n d o s p a r a e v i t a r q u e s e queme l a bobina . 1 . Haga l a p r u e b a d e a t r a c c i b n .

( 1 ) D e s c o n e c t e e l c a b l e c o n d u c t o r d e l a bobina i n d u c t o r a d e l l a d o d e l t e r m i n a l C.

( 2 ) Conec te l a b a t e r i a corno s e i l u s t r a a 1 i n t e r r u p t o r magngt ico . Colnpruebe que s a l e e l e n g r a n a j e d e l piiibn d e l embrague. S i n o es a s i , r ecambie e l c o n j u n t o d e l i n t e r r u p t o r magngt ico .

F i g . T e r m i n a l 50 T e r m i n a l c ate ria

2 . L l e v e a c a b o l a p r u e b a d e s u j e c i b n . D e s c o n e c t e e l c a b l e n e g a t i v o d e l t e r m i n a l c e n e l e s t a d o d e l a p r u e b a d e a t r a c c i b n , y compruebe q u e permanece h a c i a a f u e r a e l e n g r a n a j e d e l piiibn. S i e l e n g r a n a j e d e l pi6611 v u e l v e a d e n t r o , r e c a m b i e e l c o n j u n t o d e l i n t e r r u p t o r magngt ico .

F i g . D e s c o n e c t a r B a t e r i a

3. L l e v e a c a b 0 l a p r u e b a d e r e t o r n o d e l e n g r a n a j e d e l piii6n. D e s c o n e c t e e l c a b l e n e g a t i v o d e l cuerpo d e l i n t e r r u p t o r e n e l e s t a d o d e l a p r u e b a d e a t r a c c i b n , y compruebe que v u e l v e e l e n g r a n a j e d e l piiibn. S i e l e n g r a n a j e d e l pifibn no v u e l v e , recambie e l c o n j u n t o d e l i n t e r r u p t o r magn6t ico .

F i g . D e s c o n e c t a r ate ria

4 . Haga l a p r u e b a s i n c a r g a . ( 1 ) C o n e c t e e l p r o b a d o r y l a b a t e r i a como s e i l u s t r a . ( 2 ) Compruebe q u e e l e n g r a n a j e d e l pifibn d e l motor d e a r r a n q u e s a l e y

qua se puede g i r a r suavemente s i n a g a r r o t a m i e n t o . Lea e l amper imet ro cuando s e e s t a b i l i z a l a i n d i c a c i b n d e l a a g u j a .

F i g .

T e r m i n a l 30

T e r m i n a l 50 ate ria

STARTING MOTOR ASSY INDIVIDUAL INSPECTION

Note: Complete Inspection in 3 to 5 seconds to prevent the coil from burning.

1. Perform the pull-in test. (1 ) Disconnect the field coil lead wire from terminal C. 12) Connect the battery as illustrated to the magnet

switch. Check that the clutch pinion gear comes out. If not, replace the magnet switch ASSY.

2. Perform the hold-in test. Disconnect the negative wire from terminal C in the pull- in test state, and check that the pinion gear stays out. If the pinion gear returns, replace the magnet switch ASSY.

3. Perform the pinion gear return test. Disconnect the negative wire from the switch body in the hold-in test state, and check that the pinion gear returns. If the pinion gear does not return, replace the magnet switch ASSY.

4. Perform the no-load test. (1) Connect the tester and battery as illustrated. (2) Check that the starting motor pinion gear comes out

and that it can be rotated smoothly without sticking. Read the ammeter when the pointer indication is stabilized.

Standard: 90 A or less (at 11.5 V)

SISTEMA DE CARGA

P 8 g i n a

SISTEMA DE CARGA .................................. 9 - 2

.......................... DIAGRAMA DEL C I R C U I T 0 9 - 2

....................... INSPECCION EN EL VEHICULO 9-2

ALTERNADOR ........................................ 9-3

..................................... COMPONENTES 9-3

........... DESMONTAJE Y REMONTAJE DEL ALTERNAWR 9-4

CHARGING SYSTEM Page

............................................ CHARGING SYSTEM 9-2

................................................ CIRCUIT DIAGRAM 9-2

ON-VEHICLE INSPECTION ........................ .... .... 9-2

ALTERNATOR ...................... ... ........................... 9-3 COMPONENTS ................................ .. .................. 9-3 DlSASSEMBLY.INSPECTION.REASSEMBLY .............. 9-4

SISTEMA DE CARGA

DIAGRAMA DEL CIRCUIT0

CHARGING SYSTEM

CIRCUIT DIAGRAM

Conjunto d e l a l t e r n a d o r

I n t e r r u p t o r d e e n c e n d i d o

LBmpara d e a v i s o

C ARG A B a t e r i a

INSPECCION EN EL VEHICUM

I . I n s p e c c i o n e l a g ravedad e s p e c i f i c a d e l e l e c t r 6 l i t o d e l a b a t e r i a .

2. I n s p e c c i o n e e l t e r m i n a l d e l a b a t e r i a e n c u a n t o a l a f l o j e d a d u o x i d a c i 6 n .

3. I n s p e c c i o n e l a c o n t i n u i d a d d e f u s i b l e s y e s l a b o n e s f u s i b l e s .

4. I n s p e c c i o n e y a j u s t e l a c o r r e a e n "V". (Vea l a p i g i n a 1-31

5. Compruebe que no s e e s c u c h a ningGn s o n i d o anormal d e l a l t e r n a d o r cuando e l motor e s t i e n marcha.

6. Lleve a cab0 l a prueba s i n c a r g a d e l s i s t e m a d e c a r g a . ( I n s p e c c i b n d e l a c o r r i e n t e r e g u l a d a y v o l t a j e )

( 1 ) Conecte e l amper imet ro y e l v o l t i m e t r o como se i l u s t r a , ( 2 ) Anote g r a d u a l m e n t e l a v e l o c i d a d d e l motor a 2,000 rpm y mida e l

v o l t a j e .

EstBndar: 1 4 , 2 - 1 4 , 8 V ( a 25OC)

( 3 ) Mida l a c o r r i e n t e e n e l e s t a d o ( 2 ) a n t e r i o r .

Nota: ~a c o r r i e n t e t e m p o r a l m e n t e excede 10 A despues d e poner e n marcha e l motor, p e r o e s t o e s normal.

E s l a b b n f u s i b l e D e s c o n e c t e e l c o n e c t o r . Usando un c a b l e adecuado , c o n e c t e e l c o n e c t o r d e l a b a t e r i a a1 t e r m i n a l .

Alternatar ASSY


1. lnspect the specific gravity of battery electrolyte.

Standard: 1.25 - 1.28 (at 20°C (68OF))

2. lnspect the battery terminal for loosening or rust.

3. lnspect the continuity of fuses and fusible links.

4. lnspect and adjust the V belt. (See page 1-3.)

5. Check that no abnormal sound is heard from the alternator while the engine is running.

6. Perform the charging system no-load test. (Inspection of regulated current and voltage)

(1) Connect the ammeter and voltmeter as illustrated. (2) Gradually raise the engine speed to 2,000 rpm and

measure the voltage.

Standard: 14.2 - 14.8 V (at 25°C (77'F)I

(31 Measure the current in the state (2) above.

Standard: 10 A or less

Note: The current temporarily exceeds 10 A after starting the engine, but it is not an abnormality.

ALTERNADOR COMPONENTES

ALTERNATOR

COMPONENTS

DESMONTAJE Y REMONTAJE DEL ALTERNADOR

P r o c e d i m i e n t o d e d e s m o n t a j e

1 Saque l a c u b i e r t a d e l e x t r e m o t r a s e r o .

2 Saque e l s u j e t a d o r d e l a e s c o b i l l a . [ P u n t o 1 1

3 Saque e l r e g u l a d o r d e IC ( C I ) . [ P u n t o 2 1

4 Saque e l s u j e t a d o r d e l r e c t i f i c a d o r . [ P u n t o 31

5 Saque l a p o l e a d e l a l t e r n a d o r . [ P u n t o 41

6 Saque l a armaz6n d e l e x t r e m o d e l r e c t i f i c a d o r . [ P u n t o 51

7 Saque e l r o t o r f u e r a d e l a a rmaz6n d e l e x t r e m o i m p u l s o r . [ P u n t o 6 1

8 S a q u e e l c o j i n e t e d e l r o t o r y l a c u b i e r t a d e l c o j i n e t e . [ P u n t o 71

9 S a q u e e l c o j i n e t e d e l a a rmaz6n d e l e x t r e m o i m p u l s o r y e l r e t e n d e l c o j i n e t e . [ P u n t o 81

P r o c e d i m i e n t o d e r e m o n t a j e

E l p r o c e d i m i e n t o d e r e m o n t a j e es e l i n v e r s o a 1 d e desmonta je .

DISASSEMBLY .INSPECTION .REASSEMBLY T = N,m (kgf-cml [ft-lbfl


1 Remove the rear end cover.

2 Remove the brush holder. [Point 11

3 Remove the IC regulator. [Point 21

4 Remove the rectifier holder. [Point 31

5 Remove the alternator pulley. [Point 41

6 Remove the rectifier end frame. [Point 61

7 Remove the rotor from the drive end frame. [Point 61

8 Remove the rotor bearing and bearing cover. [Point 71

9 Remove the drive end frame bearing and bearing retainer. [Point 81




[ Punto 1 I

Inspecc ibn: Inspecc ione y repa re l a s e s c o b i l l a s .

1. Idida l a l o n g i t u d de l a e s c o b i l l a .

~ s t & n d a r : 10,5 mm ~ i m i t e : 1,5 rnm

2 . Recambie l a s e s c o b i l l a s s i e s t i n desgastadas mas d e l l i m i t e .

3. Recambie l a s e s c o b i l l a s . Recambie arnbas e s c o b i l l a s a 1 mismo tiempo, y mantenga e l g rosor de l a so ldadura i n f e r i o r a 1,O mm.

( 1 ) Funda l a soldadura de cada su je tado r de l a e s c o b i l l a y saque l a e s c o b i l l a .

( 2 ) Acople e l r e s o r t e a 1 su je tado r de l a e s c o b i l l a , y sue lde la para qua l a l o n g i t u d de l a e s c o b i l l a sea de 10,5 mm.

( 3 ) Co r te e l exceso d e l cab le conductor. ( 4 ) Cubra con p i n t u r a a i s l a n t e l a p a r t e soldada.

Rernontaje: Corn ruebe que e l guardapolvo d e l su je tado r de l a e s c o b i l l a est! i n s t a l a d o correctamente.

[ Punto 2 I

~ n s p e c c i b n : L leve a cab0 l a prueba de con t i nu idad d e l d iodo e n t r e 10s te rm ina les B y F d e l r egu lado r de I C . Pruebe carnbiando l a s po lar idades, y compruebe qua hay con t i nu idad en una d i r e c c i 6 n y no en l a o t ra .

1nspecci6n: Inspecc ione l a con t i nu idad d e l r e c t i f i c a d o r .

1. Inspecc ione e l 6nodo d e l r e c t i f i c a d o r . ( 1 ) Conecte una c l a v i j a de prueba d e l p robador de c i r c u i t o s a 1

t e r m i n a l p o s i t i v o (8) d e l r e c t i f i c a d o r y conec te l a o t r a c l a v i j a a cada t e r m i n a l d e l r e c t i f i c a d o r . L l e v e a cabo e s t a i n s p e c c i 6 n p a r a t o d o s 10s t e r m i n a l e s d e l r e c t i f i c a d o r .

( 2 ) R e a l i c e l a misma prueba que en ( 1 ) cambiando l a s po lar idades. ( 3 ) Compruebe que hay con t i nu idad en una d i r e c c i b n y no en l a o t r a .

Point Operations

[Point 11

Inspection: lnspect and repair the brushes

1. Measure the brush length.

Standard: 10.5 mm 10.413 In) Limit: 1.5 mm (0.059 In)

2. Replace the brushes if worn beyond the limit.

3. Replace the brushes. Replace both brushes at the same time, and keep the solder thickness within 1.0 mm (0.039 in).

(1) Melt the solder at each brush holder and remove the brush.

(2) Attach the spring to the brush holder, and perform sol- dering to make the brush length 10.5 mm (0.41 3 in).

(31 Cut off excessive lead wire. (4) Coat insulating paint on the soldered portion.

Reassembly: Check that the brush holder boot is installed correctly.

Inspection: Perform continuity test of the diode between IC regulator terminals B and F. Test by changing the polarities, end check that continuity exists in one direction and does not exist in the other direction.

Inspection: lnspect continuity of the rectifier.

1, lnsoect the anode of the rectifier. (1) Connect one probe of the circuit tester to the

positive (B) terminal of the rectifier and connect the other probe to each rectifier terminal. Perform this inspection for all rectifier terminals. Check continuity at Kn range of the circuit tester.

(2) Perform the same test as in (I) by changing the polarities.

(3) Check that continuity exists in one direction and does not exists in the other direction.

2 . Inspeccione el catodo del rectificador. (1 ) Conecte una clavija de prueba del probador de circuitos a1

terminal negativo (E) del rectificador y conecte la otra clavija a cada terminal del rectificador. Lleve a cab0 esta inspecci6n para todos 10s terminales del rectificador.

(2) Lleve a cab0 la misma prueba que en ( 1 ) cambiando las polaridades. (3) Compruebe que hay continuidad en una direccibn y no en la otra.

2. Inspect the cathode of the rectifier. (1) Connect one p robe o f the c i rcu i t tester t o the

negative (E) terminal of the rectifier and connect the other probe to each rectifier terminal. Perform this inspection for all rectifier terminals. Check continuity at k n range of the circuit tester.

(21 Perform the same test as in ( 1 ) by changing the polarities.

(3) Check that continuity exists in one direction and does not exists in the other direction.

[Punto 41 I I

[Polnt 41 Desmontaje: Coloque la parte de la polea del alternador en un tornillo de

banco, y saque la tuerca de sujeci6n. Use siempre protectores Disassembly: Set the pulley portion of the alternator in a metalicos en el tornillo de banco. vise, and remove the set nut. Always use

metal pads at the vise.

Desmontaje: ~espubs de sacar la tuerca de sujeci6n y el perno de sujecibn, sujete la armaz6n del extremo trasero y aplique una sacudida a1 extremo del grbol del rotor para separarlos. Coloque el conjunto sobre una plancha de madera a1 aplicar la sacudida.

~nspeccibn: Inspeccione el rotor en cuanto a la continuidad. Mida la resistencia entre 10s anillos de deslizamienlo.

Inspeccibn: Lleve a cab0 la prueba de conexibn a tierra (masa) del rotor. Compruebe el aislamiento entre el anillo dealizante y el rotor.

[Point 51

Disassembly: After removing the set nut and set bolt, hold the rear end frame and apply shock to the rotor shaft end for separation. Operate on a wooden floor when applying the shock.

Inspection: lnspect the rotor for continuity. Measure the resistance between slip rings.

Standard: 2.9 n or less

Inspection: Perform the rotor grounding test. Check insulation between the slip ring and rotor.

I n s p e c c i b n : I n s p e c c i o n e e l a n i l l o d e s l i z a n t e .

1 . S i e l a n i l l o d e s l i z a n t e e s t h d e t e r i o r a d o , c o r r i j a con p a p e l d e l i j a ( H 4 0 0 ) .

2 . Mida e l d i a m e t r o e x t e r i o r d e l a n i l l o d e s l i z a n t e .

~ s t h n d a r : 1 4 , 4 mnl ~ i m i t e : 14,Omm

S i e l d e s g a s t e e s s u p e r i o r a 1 l i m i t e , recambie e l r o t o r .

I n s p e c c i b n : I n s p e c c i o n e e l e s t a t o r e n c u a n t o a l a c o n t i n u i d a d . Compruebe l a c o n t i n u i d a d e n t r e 10s c o n d u c t o r e s d e l a bobina. S i no hay c o n t i n u i d a d , r e c a m b i e e l c o n j u n t o d e l a armazbn d e l ex t remo i m p u l s o r .

I n s ~ e c c i b n : L l e v e a cab0 l a p rueba d e conexi6n a t i e r r a (maea) d e l e s t a t o r . compruebe e l a i s l a m i e n t o e n t r e e l c o n d u c t o r d e l a bobina y l a armaz6n d e l ex t remo i m p u l s o r . S i hay c o n t i n u i d a d , r e c a m b i e e l c o n j u n t o d e l a armaz6n d e l ex t remo impulsor .

I n s p e c c i 6 n : I n s p e c c i o n e e l c o j i n e t e d e l r o to r p o r s i t i e n e d e t e r i o r o o e e a g a r r o t a a1 g i r a r . Recambie e l c o j i n e t e s i e n c u e n t r a c u a l q u i e r a n o r m a l i d a d .

Desmonta je : S a q u e e l c o j i n e t e d e l r o t o r . No l o s a q u e s i n o h a y a n o n n a l i d a d e s . Saque e l c o j i n e t e d e l r o to r y l a c u b i e r t a d e l c o j i n e t e . SST 09820-00021

9-7

Inspection: Inspect the slip ring.

1. If the slip ring is damaged, correct with sandpaper ( # 400).

2. Measure the slip ring outside diameter.

Standard: 14.4 rnm (0.567 in) Limit: 14.0 mm (0.551 In)

If worn beyond the limit, replace the rotor.

Inspection: lnspect the stator for continuity. Check continuity between coil leads. If continuity does not exist, replace the drive end frame ASSY.

Inspection: Perform the stator grounding test. Check insulation between the coil lead and drive end frame. lf continuity exists, replace the drive end frame ASSY.

[Point 71

Inspection: Inspect the rotor bearing for damage or sticking in rotation. Replace the beering if any abnormality is found.

Disassembly: Remove the rotor bearing. Do not remove it unless any abnormality is found. Remove the rotor bearing and bearing cover. SST 09820-00021

Remontaje: Instale el cojinete del rotor. 1. Coloque la cubierta del cojinete sobre el rotor e instale el

co jinete. SST 09820-00030

2. Instale la cubierta del cojinete. SST 09285-76010

[Punto 81 Inspecci6n: Recambie el cojinete de la armaz6n del extremo impulsor.

Inspeccione el cojinete de la armaz6n del extremo impulsor por si tiene desgaste o deterioro. Recambie el cojinete si encuentra cualquier anormalidad.

Desmontaje: Saque el cojinete de la armaz6n del extremo impulsor. No lo saque si no encuentra ninguna anormalidad. Saque el cojinete usando una llave tubular y una prensa despues de sacar el ret6n.

Remontaje: Instale el cojinete de la armaz6n del extremo impulsor y el reten del cojinete. SST 09950-60010

Reassembly: lnstall the rotor bearing.

1. Place the bearing cover on the rotor and install the bearing. SST 09820-00030

2, Install the bearing cover. SST 09285-76010

[Point 81

Inspection: Replace the drive end frame bearing. Inspect the drive end frame bearing for wear or damage. Replace the bearing if any abnormality is found.

Disassembly: Remove the drive end frame bearing. Do not remove i t unless any abnormality is found. Remove the bearing using a socket and press after removing the retainer.

Reassembly: Install the drive end frame bearing and bearing retainer. SST 09950-60010

LISTA DE LAS SST (HERRAMIENTAS ESPECIALES DE SERVICIO)

Ilustraci6n No. de la parte

09201-58010

Nombre de la parte Secci6n

Reinstaladora de la junta hennetica de aceite del vdstago de la vdlvula

Medidor de tensi6n de la correa

Juego de calibradores de ajuste del carburador

Juego de calibradores de alambre

Reinstaladora del con0 del cojinete del drbol de levas de la bomba de inyecci6n

Extractora del drbol estriado de la bomba de inyeccibn

Extractora de juntas h e d t i c a s de aceite

Reinstaladora del cojinete de la transferencia y la transmisi6n

Extractom del cojinete del alternador

Reinstaladora del cojinete del alternador

Juego de destornilladores del carburador

Juego de extractoras B

Juego de reinstaladoras

Ilustraci6n NO. de la parte Nombre de la parte Seccibn

Juego de reinstaladoras NO. 2

09950-70010 Juego de mangos

09370-20270-71 Reinstaladora del cojinete del pifl6n transmisor

Juego de guias del perno de la biela

Compresor de resortes de vllvulas

Compresor del sepmento del piet6n

Probadors de resortes de v&lvulas

Extractors del amortiguador de torsi6n universal

Instaladora de la tuberia de succi6n de aceite

Herramienta del pasador del pist6n

Inetaladore de la junta h e d t i c a principal trasera

Medidor del &ngulo/par (torque)

INFORMACION D E HERRAMIENTAS DE SERVICIO (J- )

Contacto: Para cualquier pregunta, pdngaee en contact0 con

un concesionario de General Motors.

SERVICE TOOL INFORMATION (J-@@@@-@) Contact: Please take contact with a dealer of General Motors for any inquiry.

LISTA DE ESTANDARES DE SERVICIO PUESTA A PUNT0 DEL MOTOR

SERVICE STANDARDS LIST

Capacidad de aceite litros Sumidero de aceite 3,8 Sumidero de aceite + 4.2

Gravedad especifica del electr6lito de la bateria ( A 20° C) Flexi6n de la correa en "V" (cuando se empuja con una fuerza de 98 N (10 kgf) nun

Tensi6n de la correa en "V" (Medida con el medidor de tensiones) nun

Separaci6n de la bujia de encendido nun

Distribuci6n de encendido (en marcha en vacio) Orden de encendido Velocidad de aumento de rnarcha en vacio

Velocidad rndxima sin carga

Descenso de velocidad del motor en compresi6n de basculaci6n rpm

REVISION DEL MOTOR Culata de cilindros Defonnaci6n de la suparficie inferiornun Deformaci6n de la superficie de montaje del oolector mbltiple nun Angulo del asiento de la vdlvula V6lvulas Holgura de aceite desde la guia de la vdlvula mm

Anchura de contacto del asiento de la vdlvula nun Angulo de la cara de contacto Resorts de la vllvula Longitud libre mm Longitud instalado nun Tensi6n del resorte

filtro de aceite Estbndar 1,25 - 1,28 Estado de instalacibn 7 - 9 inicial 8 - 16 En la inspecoi6n Estado de instalacibn 392 - 588 (40 - 60) inioial 294 - 392 (30 - 40) En la inspecci6n Estbndar 1.4 - 1.6

Consulte el manual de reparaciones para cada modelo de vehlculo Consulte el manual de reparaciones para cada modelo de vehiculo Consulte el manual de reparaoiones para cada modelo de vehiculo

Limite 0,lO Limite 0,25

Estdndar 4 6'

Estdndar 0,025 - 0,069 Limites IN 0,094

EX 0,119

Estdndar IN 1,02 - 1,65 EX 1,65 - 2,49

Limite 4 So

Estbndar 52,O Estdndar 42,9 - 43,4

N (kgf) Estdndar Cerrado a 338 - 374 43 mm 134,s - 38,l)

Abierto a 832 - 903 32 nun (84,8 - 92,l)

ENGINE TUNE-UP

ENGINE OVERHAUL

Oil clearance from valve guide

Valve seat contact width

Spring tention N (kgf) [Ibfl Standards

Closed at 43 mm 11.69 in1

Open at32 rnrn 11.26inl

338 - 374 (34.5 - 38.1) l76.1 - 84.01

832 - 903 (84.8 -92.1) 1187.0 - 203.71

C o l e c t o r m S l t i p l e d e a d m i s i b n y e s c a p e

Deformaci6n d e l a a u p e r f i c i e d e montaje d e Limit e l a c u l a t a de c i l i n d r o s m

Arbo l d e l c o n t r a p e s o

Diemetro d e l muh6n ( t r a s e r o ) m EstAndar

Holgura de a c e i t e d e l Arbol d e l con t r apeso Esthndar m

Arbo l d e l e v a s

Holgura d e empuje m Esthndar

Cant idad de e l evac i6n de l a l eva m EatAndar

Descentramiento m L M t e

DiAmetro d e l muh6n m Eat Andar

Bloque da c i l i n d r o s

Deformacibn d e l a s u p e r f i c i e s u p e r i o r m Llmite

C a l i b r e d e l c i l i n d r o m EstAndar d e l d ihmetro i n t e r i o r

LLmite d e e x c e n t r i c i d a d

Limite d e con ic idad

P i s t b n y segmen to d e l p i s t b n

Holgura d e l p i s t 6 n e n t r e e l c i l i n d r o y Limite e l p i a t 6 n nun

Didmetro e x t e r i o r d e l pasador d e l pist6nmm Esthndar

Holgura de a c e i t e e n t r e e l p i s t 6 n y e l Llmite pasador d e l p i s t 6 n m

Holgura d e l a ranura d e l segment0 a 1 Llmites segment0 d e l p i s t 6 n m

Holgura de l a uni6n d e l segment0 d e l Limites p i s t 6 n m

Holgura d e empuje m EstAndar

Holgura de a c e i t e d e l c o j i n e t e nun Estbndar

Acoplamiento d e l pasador d e l p i s t 6 n en Estdndar l a b i e l a m

Super io r 0,1067

Ace i t e 0,2032

Super io r 0,889

Ace i t e 1,651

0,025 - 0,076

0 ,0203 - 0,0406 I n t e r f e r e n c i a

Cam lift amount

Bearing oil clearance mm (in)

Piston pin fit in connecting rod mm (in)

Standard

Standard

0.025 - 0.076 ( 0.001 - 0.003 )

0.0203 - 0.0406 ( 0.0008 - 0.0016

Interference

Arbol del cigllefial

Descentramiento nun Limite 0,025 Holgura de aceite del mufi6n n'un Estbndar 0,051 - 0,203 Holgura de empuje nun Estdndar No. 1 0,025 - 0,038

NO. 2, No. 3 0,025 - 0,064 No. 4 0,064 - 0,089

Mufi6n nun Estdndar Di6metro No. 1 62,199 - 62,217 exterior NO. 2, NO. 3 62,192 - 62,215

No. 4 62,180 - 62,202 Limite de excentricidad 0,025

Llmite de conicidad 0,025 Pasador INTI Estbndar Didmetro exterior 53,310 - 53,335

Limite de 0,025 excentrioidad

Limite de conicidad 0,025

SISTEMA DE COMBUSTIBLE Carburador Resistencia del calentador de la Estdndar 17 - 19 estrangulaci( n (a 20° C) n Nivel del flotador nun Posici6n superior del 7tO

flotador Posicibn inferior del 0,9 - 1,l

f lotador Angulo de cierre total de la vdlvula de Estdndar 7' obturaci6n (marcha en vacio) Angulo de abertura total de la vdlvula Estdndar 6 0' de obturaci6n Angulo de abertura de marcha en vacio Estdndar 22,5O rdpida hbertura del descargador Estdndar 15 - 19' (con l a vdlvula de obturacidn tota lmente

a b l e r t a )

Abertura del ruptor de la estrangulaci6n Estdndar 27 - 31" Carrera de la bomba de aceleraci6n nun Estdndar 9,80 - 10,80 SISTEMA DE ENFRIAMIENTO Radiador

Presi6n de abertura de la vdlvula de la Estdndar 7 3 , s - 1 0 3 , 0 ( 0 , 7 5 - 1 , 0 5 ) tapa del radiador kPa (kgf-cm2) Limite 58,8 (0161

Termoatato Temperatura de comienzo de la aberturaeC Estlndar 75,O - 78,9 Temperatura totalmente abierto O C Estdndar 68,9 Elevacibn de la v6lvula nun Est6ndar 8,12

Journal oil clearance

FUEL SYSTEM

COOLING SYSTEM

Radiator

Radiator cap valve opening pressure kPa (kgf/cml) [psi]

Thermostat

Opening start temperature 'C (OF)

Full open temperature "C ( O F )

Valve lift m m (in)

Standard

Limit

73.5 - 103.0 (0.75 - 1.051 [10.7 - 14.91 58.8 (0.61 18.51

Standard

Standard

Standard

75.0 - 78.9 (167 -174) 88.9 (192)

8.12 (0.3201

SISTEMA DE ENCENDIDO D i s t r i b u i d o r

Res i s t enc i a E s t l n d a r Inapeccldn 1 (vea l a pdgina 7-4 en cuan to a l a i n specc i6n d e l d i s t r i b u i d o r ) n Inspeocldn 2

Bobin. d e e n a e n d i d o

Res i s t enc i a (Vea l a pdgina 7-3 en cuan to Estdndar Inspaccibn 1 a l a i n specc i6n de l a bobina d e

n Inspeocidn 2 encendido)

C o r d 6 n do .It. t e n s i 6 n

Res i s t enc i a

SISTEMA DE ARRANQUE Motor & a r r a n q u e

k Q Limite

V o l t a j e nominal d e regimen V

Potencia nominal d e regimen kW

C a r a c t e r i s t i c a s s i n carqa V o l t a j e V

C o r r i e n t e A

Velocidad rpm

Conmutador nun Descentramiento

Di&metro E s t l n d a r

e x t e r i o r Limite

Longitud de l a e s c o b i l l a m E s t l n d a r

L imi t e r

Carga d e l r e s o r t e de l a e s c o b i l l a Es t lnda r i n s t a l a d o N (kgf)

SISTEMA DE CARGA A l t e r n a d o r

Vo l t a j e d e regimen

Potencia de regimen

C a r a c t e r i s t i c a s s i n carga

v A

V o l t a j e V

C o r r i e n t e A

Longitud d e l s a l i e n t e de l a e s c o b i l l a nun Estdndar

L M t e

Didmetro e x t e r i o r d e l a n i l l o d e s l i z a n t e nun E s t l n d a r

Llmite

Res i s t enc i a d e l a bobina d e l r o t o r n EstAndar

10-7

IGNITION SYSTEM

STARTING SYSTEM

Distributor

No-load characteristics

Resistance

(Refer to 7-4 for Distributor inspection) n Ignition coil

Resistance

(Refer to 7-3 for Ignition coil inspection) fi

CHARGING SYSTEM

Standards

Standards

High tention cord

Alternater

Inspection 1

Resistance k fl

w

12

35

14.2 - 14.8

10 or less

10.5 (0.413)

1.5 10.059)

14.4 (0.567)

14.0 (0.551)

2.9 or less

Rated voltage V

Rated output A

Limit

No-load characteristics

Brush protrution length mm (in)

Slip ring outside diameter mm (in)

Rotor coil resistance n

Inspection 2

25 or less

Voltage V

Current A

Standard

Limit

Standard

Limit

Standard

500 - 1500

lnspection 1

lnspection 2

Inspection 3

w

0 - 1 - : Abnormality

Blcque de c i l i n d r o s x Culata de c i l i n d r o s Primero: 30 (3061

Segundo: Perno c o r t o t55'

Perno medio t65-

Perno l a r g o t75'

x Tape d e l c o j i n e t e d e l d rbo l d e l cigUefial 105 (1071)

PAR DE APRETAMIENTO Lugar a a p r e t a r Pa r ( t o rque ) de ap re t amien to N.m (kgf-cm)

x Cubier ta d e l a n t e r a d e l motor

x Placa de empuje d e l d rbo l de l evas

x Sumidero de a c e i t e

TIGHTENING TORQUE

x Bomba de a c e i t e x Reten de l a junta hermet ica d e a c e i t e t r a s e r a x Bomba de agua x Unidad d e l i n t e r r u p t o r de p re s i6n d e a c e i t e

B ie l a x Tapa d e l a b i e l a

Culata de c i l i n d r o s x Cubie r t a de l a c u l a t a de c i l i n d r o s

x Bujia de encendidc

x Colec to r m h l t i p l e d e admisi6n

x Colec to r m h l t i p l e de escape

x BVSV

Co lec to r m h l t i p l e de admisibn x C d r t e r de s a l i d a d e l agua

x D i s t r i b u i d o r

x Espaciador d e l carburador

Espaciador d e l ca rbu rador x Carburador

a r t e r de salidn del aqua x Salida del agua

x Trandso r de l a t v r a t u r a del apua

hnldero & acoite x Tap6n da druu je

Arb01 del cigtl&al x Polea del d r b l & leva.

Arb1 & leva. x Rue& dents& del Arb1 & levas

Arb01 del mntrapao x Engranaje dsl lrbol &l contrapao

12 (1221

12 (1221

Perno:25 (2551

Tuerca: 23 (235)

Nueva: 30 (306)

Usada: 20 (204)

Primero: 3 (30)

Segundo: 12 (1221

F i n a l : 15 (153)

35 - 65 (357 - 663) 17,2 - 31,9 (175 - 325) 31,2 - 46,8 (318 - 479)

Place to be tighatened

Cylinder block X Cylinder head

X Crankshaft bearing cap

X Engine front cover

X Camshaft thrust plate

X Oil pan

X Oil pump

X Rear oil seal retainer

X Water pump

X Oil pressure switch unit

Connecting rod X Connecting rod cap

Cylinder head X Cylinder head cover

X Spark plug

X IN manifold

X EX manifold

X BVSV

IN manifold X Water outlet housing

X Distributor

X Carburetor spacer

Carburetor spacer X Carburetor

Water outlet housing X Water outlet

X Water TEMP, sender

Oil pan X Drain plug

Crankshaft X Camshaft pully

Camshaft X Camshaft sprocket

Balance shaft X Balance shaft gear

Tightening torque N.m (kgf-cml Ift-lbfl

1st: 30 (306) L22.11

2nd: Short length bolt +55'

Midium length bolt t65'

Long length bolt t75'

105 (1071) 177.51

12 (122) (8.81

12 (122) 18.81

Bolt: 25 (255) 118.41

Nut: 23 (235) 117.01

90 (918) I66.41

15 (153) (11.11

25 - 40 (255 - 408) 118.4 - 29.51 15.7 - 23.5 (160 - 240) 111.6 - 33.21

27 (275) 119.91 + 70' 12 (122) [6.81

New: 30 1306) 122.11

Reused: 20 (204) [14.81

1st: 3 (301 12.21

2nd: 12 (122) (6.81

Final: 15 (153) 111.01

35 - 65 (357 - 663) 125.6 - 46.01 17.2 - 31.9 (175 - 325) [12.7 - 23.51 31.2 - 46.6 (318 - 479) [23.0 - 34.61 25.9 - 48.1 (259 - 491) 119.1 - 35.51 10.2 - 15.3 (104 - 156) [7.5 - 11.31 10.2 - 15.3 (104 - 156) (7.5 - 11.31 8.4 - 15.6 (86 - 159) 16.2 - 11.51

28.0 - 42.0 (286 - 428) 120.7 - 31.01 25 (255) 116.41

313.8 - 470.7 (3200 - 4800) 1231.5 - 347.31 28 (266) 120.71

20 (204) 114.61 t 35'

SERVICE INFORMATION BULLETIN Subject: Distributor Replacement on GM V6 Spectrum and PSI Equipped Engines Page 1 of 4 MODEL APPLICATION: 7FG(C)U35-80 GENERAL INFORMATION: The following pages show instructions for replacing the distributor on GM V6 engines which use the Spectrum or PSI fuel system. REPAIR INFORMATION: Please include these pages in repair manual CU4630 GM6-262 Engine, chapter 7 page 6.

Engine EN12-001 October 15, 2012 Distributor Replacement on GM V6 Spectrum and PSI Equipped Engines 7FG(C)U35-80

sheath

Text Box

Subject: Distributor Replacement on GM V6 Spectrum and PSI Equipped Engines Page 2 of 4

SERVICE INFORMATION BULLETIN Subject: 4.3L Crankshaft Bolt Torque Procedure Page 1 of 2 MODEL APPLICATION: 7FGU35-80 and 7FGCU35-70 GENERAL INFORMATION: Please see the procedure below for torqueing the crankshaft pulley bolt on the 4.3L engine. SERVICE INFORMATION: Step 1: Ensure crankshaft bolt threads are clean and dry so Loctite has a good surface to adhere to. Step 2: Ensure threads inside the nose of the crankshaft are clean and dry. Step 3: Apply a thin layer (a few drops) of engine oil on the back of the head of Crank Pulley Bolt before installing the crankshaft pulley.

Engine EN13-001 August 15, 2013 4.3L Crankshaft Bolt Torque Procedure 7FGU35-80 and 7FGCU35-70

Subject: 4.3L Crankshaft Bolt Torque Procedure Page 2 of 2 Step 4: Apply Red Loctite number 272, at a minimum of 35 mm long and 5 mm wide on the crank pulley bolt threads and apply a few drops down the internal threads of the crankshaft towards bottom of the hole.

Step 5: Install the crankshaft pulley and the bolt on the crankshaft.

• Secure flywheel and Torque crankshaft bolt to 305 ft/lbs.

Step 6: Mark the edge of the bolt to the crankshaft pulley using a paint marker to signify torque process complete. Step 7: It is recommended that the engine NOT be started for 24 hours to allow sufficent time for the loctite to cure and obtain maximum cure strength.

rologo este manual de reparaciones explica...

Documents