This workshop manual contains essential information regarding the construction,
operation, adjustment procedure and servicing method of the Type
and
CB-80
The
contents and specifications in this manual may be partly revised without
advance notice and without incurring any obligation to us.
engines which are mounted on the DAIHATSU CHARADE.
CB-23,
CB-61
DAIHATSU MOTOR
CO.,
Published in June,
LTD.
1987
Page 4
Page 5
SECTION
INDEX
NAME
Page 6
Page 7
TYPE
CB
SECTION
1
GENERAL INFORMATION
HOW TO USE THIS WORKSHOP MANUAL
INSTRUCTIONS ON SERVICE OPERATIONS
JACKING POINTS AND SUPPORTING POINTS
OF SAFETY STANDS
SUPPORTING POINTS
LOCATION OF ENGINE TYPE AND
ENGINE NUMBER
ENGINE TYPE EMBOSSED POSITION
ENGINE NUMBER STAMPED POSITION
ABBREVIATION CODES
MAIN SPECIFICATIONS
.........................................
OF
TWO-POST
...............................................
........................................
.......................................
.........
.....
LIFT
.......
................
............
1-2
1-3
.
1-5
1-5
1-6
1
-6
1
-6
1
-7
1-9
WM-01001
Page 8
GENERAL
INFORMATION
HOW
[Articles
As regards general tools (those tools which are normally provided in a service shop), jacks and other
standard equipment, they are omitted in this workshop manual.
As for those Special Service
collective!y in the tables under SECTION 11 APPENDIX. Hence, please prepare them prior to the service
operation.
In respect to instruments, lubricants and so forth, be sure to use those designated by Daihatsu.
[Composition]
1.
2. In principle, each section is arranged in the foilowing crder. However, it should be noted
TO
USE
To
Be Prepared]
The component diagram is provided in the beginning of each section. Refer to this component d.iagram
whenever you want to assure the shape or the part name of each part during the installation operation
or the removal operation.
composition for the in-vehicle operation differs from this order.
However, instances where the removal or the installation is comparatively easy or no SST or the like is
required, the arrangement is made as follows:
THIS
WORKSHOP
Toois (SSTs) which are necessary for the service operations, they are posted
Removal Procedure
MANUAL
Inspection -~lnstallation Procedure
I
WM-C1002
that the
3.
With regard to the tightening torque specifications, they are indicated in the Engine Components and
Tightening Torque under SECTION 3-10. In addition, they are shown in the tables under SECTION 11
SERVICE SPECIFICATIONS.
However, as for those items where no specific tightening torque is mentioned, perform the operation
referring to the Tightening Torque for Main Components under SECTION
[Numerals]
As regards those numerals which are posted under "Inspection" and under sections other than SECTIOr'
11 SERVICE SPECIFICATIONS, those numerals from the specified values to the allowable limits a*
posted.As for those numerals which are posted under SECTION 11 SERVICE SPECIFICATIONS, those
numerals concerning the specified values and allowable limits are indicated separately.
[NOTE]
1.
"NOTES" posted in the main text clearly show those items which need particular attention or prohibited
items which must be avoided during the service operation.
2. Prior to the operation, make certain to take any necessary precautionary measures so as to prevent
personal injury during the
removal/installation of parts.
00.
WM-01003
WM-01004
'NM-01005
Page 9
GENERAL
INFORMATION
STRUCTIONS ON SERVICE OPERATIONS
1.
Make sure that only the specified bolts and nuts are used. Also, where specified, be sure to employ a
torque wrench to tighten bolts or nuts to specifications.
2.
When tightening or slackening bolts, be sure to progressively tighten or slacken them over several
stages, slightly at a time. This caution must be observed to prevent the tightened parts from being
distorted or damaged.
3.
Use only genuine parts for every replacement operation.
4.
For increased working efficiency and improved accuracy, utilize SSTs (Special Service Tools)
effectively.
5.
When both front and rear sections of the vehicle or only the rear section thereof is jacked up, make
certain to place chocks at the wheels correctly in order to assure safe operations.
6.
When the vehicle is jacked up, make sure to support the vehicle with safety stands positioned at the
specified jacking points.
7.
Before any repair work is made on the electrical system or the engine is removed or installed, first be
(-)
sure to disconnect the negative
8.
Disassembly
(1)
When complicated part are disassembled, put stamped marks or mate marks on suitable
non-functional sections of the parts in order that the said parts may be easily assembled in the
correct original positions.
(2)
Replacements of the cylinder block or crankshaft, etc. should be carried out after the engine
assembly has been removed from the vehicle.
9.
Checks to be performed during disassembly
Each time a part is removed, check conditions under which the part has been assembled. Also, check
to see if the part exhibits any evidence of distortion, breakage, wear or scores, etc.
10.
Arrangement of disassembled parts
Put disassembled parts in a good order. Moreover, divide disassembled parts into two groups: those
parts to be replaced and those parts which can be reused.
11.
Washing disassembled parts
As for those parts which can be reused, thoroughly clean or wash them. (except grease sealed
bearing)
12.
Inspection
Those parts which are to be reused must
13.
Those operations specified under "lnspection" are performed, in principle, in combination with the
checks and repairs.
;pecifications. However, in cases where otherwise specified in the main text, be sure to follow the given
instructions.
14.
Assembly of parts
Those satisfactory parts only should be assembled in accordance with the prescribed standards
specified adjustment values, tightening torque and so forth).
Furthermore, seal packing or grease should be applied, as required.
Furthermore, in respect to packings, gaskets, oil seals and similar items, be certain to install new parts.
15.
Adjustments and checking of service operations
Service operations must be carried out correctly by means of gauges or testers, if the use of these
instruments is required.
16.
Never smoke during the service operation. Also, be sure not to allow any fire to be brought near the
working bay.
17.
Under no circumstances should your hand touch with the front side and back sides, the installation
surfaces of each bearing insert. Also, be very careful not to
bearing surfaces with a cloth. Be certain to blow off them, using compressed air:
Protect your eyes with safety glasses during this cleaning.
It is, therefore, necessary to replace any part which does not conform to the
terminal of the battery.
becarefully inspected or measured, as required.
scratch the surfaces. Do not wipe
(e.g.
off
the
Page 10
GENERAL
18.
The warming-up state of the engine means a state in which the temperature of the cooling wati
reaches at least 75 -
(1
49
These temperatures can be judged
rotation.
NOTE:
When the idle speed is checked on Type
Hence, be sure to refer to the section under "Checking
INFORMATION
F).
85°C
(167
-
185
F)
and the temperature of the engine oil reaches at least
by
observing a point where the cooling fan motor ceases its
CB-80
engine, special warming-up procedure is required.
Idle Speed."
-
65°C
'uVM-01006
Page 11
GENERAL
INFORMATION
ACKING
I
Jacking point
Front side
Rear side
Supporting points
Four supporting points are located at the right and left sides. (The supporting points have been
strengthened by spot-welding reinforcements. Never support the vehicle at points other than
the specified points.)
POINTS AND SUPPORTING POINTS
...
Engine mounting center member (Place the jack below the member, exercising
care of the exhaust pipe.)
.....
Center
Engine mounting center rcember
of
rear floor cross member
\
of
safety
stands
OF
Rear floor
/
SAFETY STANDS
cross
member
Supporting point
@
of garage jack
Supporting point
of safety stand
I
SUPPORTING POINTS OF TWO-POST LIFT
-.n the supporting pads of a two-post lift with the supporting points of safety stands, as indicated in the
,,yure above.
\
Fig.
1-2
I
WR-01008
Page 12
GENERAL INFORMATION
LOCATION
OF
ENGINE
TYPE
AND
ENGINE NUMBER
ENGINE
The engine type is embossed on the power train side of the
cylinder block.
ENGINE
1. CB-23
The engine serial number is stamped on the cylinder head
at the front end section.
For the Australian specifications, the engine number is
s;amped also at the side of the embossed engine type.
2.
CB-80
The engine serial number is stamped on the cylinder head
at the rear end section
TYPE
EMBOSSED POSITION
NUMBER STAMPED POSITION
and
CB-61
Page 13
.BBREVIATION CODES
The
abbreviation codes that appear in this workshop manual stand for
the
following,
respectively.
Abbreviation
code
RH
LH
FR
R
R
STD StanDard
CIS Over Size
UiS
j
1
1
1
'
;
1
ATDC
BTDC
IN
Original
Right Hand
Left Hand
FRont
ReaR
Under Size
After Top
Dead Center
Top
Before
Dead Center
INtake
word
Meaning
Refers to rrght
Refers to left
,
Refers to front side.
Refers :o rear side.
When referring to automotive parts, "standard" represents those parts which have been
insta!led originally by the manufacturer and which i-iave standard dimensions.
I
In Icstances where fitting becomes too loose d~e :o wear
period of time or due to frequent
,
replaced with a part having larger dimensions, the other mating par: may be put into use
1
again. "Over sized" parts denote Pose parts having larger dirnensior,~ compared with
i
s:andard park.
1
In the same manner as with the "oversized" par:s. if fitting part (e.g. bush and bearing) is
!
replaced with a part having smaller bore dimensicns, the other mating part may be put into
i
use again. "Under sized" part denore those ?arts having smal!er dimensions compared
!
with standard pat%.
1
Refers to position of pision in cylinder where Psion is near but has passed over :he top of
/
the stroke.
1
Refers to position of piston in cylinder where pisicn is near but has not reached the top of
the stroke.
Refers to intake system.
s~de.
s~de.
removaliinstallat~o~ operations.
resulting
from use for a long
~f
fitting part (e.5. piston) is
EX
PR
S AE
API
SST
T
SIA
Ay;Assy
Wi
. .
i:
Mfl
A'T
Exhaust
I
Pry Rating
Society of
Automotive
Engineers
American
Petroleum
Institute
Speciai Serv~ce Tocl
Torque
Sub-Assembly
Assembly
With
Less Denotes that the following part is not attached.
Manual Transmission
/
Au:omatic Transmissian Refers to automarlc transm:ssion.
Refers to Exhaust system.
Represents
The larger the pry rating number, the stronger the tire strength.
For example, automotive oils are designated as SAE so and so number. These designation
,
numbers have been set forth by the Society of Automotive Engineers in the United States of
America (SAE). The larger the SAE number, the higher the oil viscosity. Conversely, the
I
smailer the SAE number, the lower the oil viscosity.
The standards set forth by the American Petroleum institute (abbreviated as AP!
/
Classification) have been employed to evaluate and classify properties of various oils.
Englne oils for gasoiine engines are classified as
1
diesel engines are classified as CC. CD and so on.
'
Refers to a tool designed tor a specific purpose.
'
Refers to tightening torque.
,
Refers to a component comprising more than two s~ngle parts which are welded, s:aked, or
i
studded
Refers to an
assembiy parts.
i Denotes that the foliowing part is attached.
Refers to
strengtfi of tires.
to
each other to form a single component.
assembied component compr~sing more than two sirgle pacs or sub-
maruai type transmissron.
SD,
SE and so on, whereas engine oils for
TC
W,'G
KC
1
Turbo Charger
1
I
Waste Sate Refers to exhaust by-pass.
i
Air Cieaner
Page 14
GENERAL
List of Abbreviated Component Names of Exhaust Emission Control System
INFORMATION
t.
The table below shows abbreviated component names of the exhaust emission control system. The
components of the exhaust emission control
system
are described
in
this manual in their abbreviated
forms.
-
Abbreviat~on Component
name
.
.
1
2
3
4
5
6
7
8
9
I
I
I
1
BVSV B~rnetal Vacuum
C/O
DP Dashrsot
vn/
VS
AD
TP Throttle Pos~trover
NSV Thermostat~c Vacuum Switch~ng Valve
EG
R
'
Cho~e opener
1
Vacuum Transmitt~ng Valve
Vacuum
1
I
Advance
Exhaust Gas Rec~rculation
Swltch
Switching
Valve
Page 15
GENERAL
INFORMATION
AIN
-
Item
Engine
SPECIFICATIONS
-
Type
Mountlng loca:ion
Cylinder No. and arrangement
Com~ust~on cham~er type
Valve mechanism
Bore x stroke rnm (inch)
Compression
Corpress~on sressure kg:cm2-rpm (psi-r2mj 12.5 - 350 (177 8 - 350)
I
/
Maximum
I
outpc:
I
I
1
I
Maxinum
1
torque
Engine dimensions
x
[Length
j
Service engine weight
'
1
piston rings
width x height] mrn (inch)
of
-
atio 9.5
SAE net
EEC
EEC DIN kwirpm
SAE net i Nmirpm
EEC
EEC
'IN
Com~ression ring
Oil
ring
j
1
/
Valve timing
!
Intake
r
Exhaust
j
Valve clearance
idling speed
Blow-by gas recirculating sysfem
Lubricating method
"Cption
'2General & Australian specifications mounted with manual transmission
'3ECE
*Vehicles mounted with automatic transmission
'5Norwegian specifications with automatic transmiss;on mounted model
Ba:tery
j
Alternator
!
j
Starter
Radio noise
&
EEC
specifications mounred with manual transmtssion
Tyoe
.
I
Voi:age, curent
Type ECE 3 EEC spec:,:caims
I
1
Caca:z
I
I
Type
Output V-A
Regulator
Type
Output
suppressing
i
:
~xcept for
b
EEC
Threaa M14 x 1.25 MI4 x 1.25
mrn :inch) (0.328 - OC3l)
General speciiications 348; 7L "55824L
Australian saec~fications
General speciiications
ECE
3
EEC
so%~:lcatons 36 (5bR) 36 1:5hR)
Australian soec:ficatrns
type
device Resistive cord
!
DENSO NGK BOSCH I C:dMFICH
/
ECE
!
H16EX-J
0.7 - 0.8
\/-A
,
:
,
'
I
:
3-Pqase aiterFlat:rg current cornmutating type
:
.
V-kw
'2?2-0.7. "12-0.8, &12-1
CB-23
DENS0
25W
/
!
NXil
6F19
0.8
-
J.J
-
2.G)
I
EIBOC:XY,:
0.7 - 0.a
(0.028 - 0.031)
N-l!YC
VBM-u
tf2Q;)M-lil
I
!
i
1
:.;.06
:@.%3
-
ib?:
-
-
1
55B24L
3381 7L
27 (5FR). "36 (5HR)
27 (5PR) 27 (5HR)
12-45. "12-50
Ccntact-po~ntless type
Magnet engaGing type
Checking battery electrolyte level and specific
gravity
Manual transmission
Automatic transmission
Specified value:
Engine oil capacity:
When
only
oil is
changed
oil
When
changed
and oii filter are
j
!
Specified value:
Radiator cap opening pressure:
0.75
-
1.05
kg/cm2
Specified value:
'
...-
Battery electrolyte specific gravity:
(1.7
(at electrolyte temperature of 20°C)
1.27
to
1.29 (34B-17L)
[NOTE]
The vehicles mounted with a maintenance-free
battery should
be
checked
3
9
3.0
-
2.3 psi)
3
9
3.0
by
a battery checker
40
3.1
I
Checking and cleaning air cleaner
I
Checking and adjusting spark plugs
I
Eng~ne
type
Manufac:urer
ECE & EEC
Except
for
ECE & EEC
Spark plug gap
mm
(inch)
I
....
Spark Plug Specifications
I
1
/
W$O
j
:
IY'E3.J
:
GEL44
0.7 - 0.8
/
(0,028 - 0.031)
CB-23
NGK
@.mi
EPEf
8PSF'
U-03
-Om
':~AMP~oN/
3mCti
IN-1:YC
SEX
WNeOcc
K';YC
0 7 - 0.8
(0.028 - 0.031
C3-61
CXC
j
NGK
W6Wl-U
'
1
)
ip~$
3xp
W563.U
;
m34
EKEd
XUj
sP62
0.i-11 &I-09
0~&~1~@J!2
-
00.
(26-80
BCSM
!WDN
W80C
fiN4C
wiyc
*RIFC
W80C
(x.qj
WmC
(0.028 - 0.031) 1 (0.035 - 0.03-
N.9vC
K9/
$:lYs
0.7 - 0 8
DENSO
IWBq:-
wxfiL
'
wm.~
~22~;~
0.9-1.0'
j
,
Page 31
3hecking resistive cords
I
I
..-
Specified value:
ENGINE
C3-61 CB-80
TUNE-UP
I
Cord No.1
Cord
Cord
Center cord
v
1
Checking and adjusting V-belt for deflection
[
... Specified deflection:
Cooling water capacity:
(including reserve tank capacity of
.
Checking 'ylinder
*
tightening condition toraue
head
and
manifolds for
Specified value:
. Cylinder head tightening torque
No.2
No.3
1
6.8 - 10.0
I
/
8.1 - 12.1 i 8.1 - 12.1
1
8.1-12.1
)
6.1 - 9.2
6.8
1
8.1-:2.1 7.0-10.3
6.1
&
Manifold tightening
-
100 1 3.2 - 4.8
,
4.6 - 7.0
-
9.2
1
5.1 - 7.7
0.6
liter)
mm/kg
ka-rn
(inch/lb)
(ft-lb)
I
Warming-up engine
(Cooling water temperature:
+
Checking valve clearances
v
75
to
80°C)
.
Cylinder head
tightening torque
-
Exhaust rnan~foid
tlghtening :oraue
Intake manifold tightening
l
tomue
Specified clearance:
....
(Clearance between cam and rocker arm)
-
(Wher, not)
[NOTE]
"HOT"
block temperature is above
vehicle has been warmed up completely.
denotes a period during which the engine
5.5 - 6.5 5.5 - 6.5 6.0 - 7.0
(40 - 47)
10-16 ' 1.0-16 4.0 - 5 0
1
(7-12)
1
.O
/
(7-12)
!
0.20 0.25 0.32
(0.0079)
-
1.6
1
(40 - 47) (43 - 51)
;
'
1
1
1
80°C
(7-12)
.O
(7-12) (29-36)
(0.0098) (0.0126)
'
-
1.6
(176°F)
(29 - 36)
:
1.7 - 2.5
rnm (inch)
after the
I
I
1
Page 32
ENGINE
Checking
Checking
TUNE-UP
compression pressure
i
and
adjusting
distributor
Item
\I
....
Minimum requirement
(350
rpn)
Difference between
cylinders
-...
Specified
Engine
value:
type
!
CB-23
/
1
CB-61
kg/cm2
1
CB-80
!
(pi
I
Checking
and
+
adjusting
ignition
(Except
timing
CB-80)
Dwell angle
....
Specified
Ignition timing
gap
mm
value:
(inch)
(.)
C3-23
0.4
(0.016
1
58
/
BiDC
-
0.5
-
0.020)
-
66
Y+Til~ling
I
1
CB-61
!
i
0.4
-
58
CB-61
BTDC
0.5
-
66
10"?2"ndlin~
(0.016 - 0.020)
j
I
3TDC
CE-80
10"kZIdling
Checking
idle
speed
I
i
....
Specified
[NOTE]
Make sure
as
headlamps
Automatic transmlsslon
(
)
Swedish
value:
that
no
additional
is
applied
/
850550
000
and
Norweg~an specifications.
electrical
to
the
engine.
/
-
50)
-
load
I
such
rom
-
I
Page 33
.easuring CO concentration
....
Specified value:
ENGINE
TUNE-UP
Not conformed to
specifications
4.
Adjusting idling speed
I+
Item
CO
concentration
NOTE:
For Swiss specifications, be sure to cut off the
....
Specified speed:
g1
Engine speed (rpm)
NOTE:
Pull the choke button out as far as it wiil go and
depress the accelerator pedal once or twice.
Engine type
CB-23 CB-61
/
1 2 0
5%
!
1 2 0.5%
/
2000 + 200 2600 2 200
EGR
(20-80
1
2 0.5%
operation.
f
Checking and adjusting dashpot
Checking choke opener for operation
(Except CB-80)
....
Specified speed:
I
General specifications
SWISS & Austral~an
specifications
Australian
spec~fications
1
LI
West German
;
1600 + 50 / 1600 + 50
1300F50
1
1300
1300250 /1600t100
!
,
300
I
rpm
1600
2
100
50 i ,600 2 100
I
I
Page 34
ENGINE
TUNE-UP
ENGINE TUNE-UP
Connecting Method of Instruments and Handling Instructions
1. Engine tachometer
(1)
In the case of a tachometer in which the pick-up is made from the primary circuit and there is
3-cylinder range, carry out the measurement using the 6-cylinder range. And multiply the reading
2.
This product is the actual revolutional speed of the 3-cylinder engine.
by
(2)
In the case of a tachometer in which the pulses flowing through the resistive cord of the cylinder
No.1 are sensed, the reading can be read directly regardless of
2.
The power supply for the tachometer, timing light and other instruments should be connected to the
battery terminal.
3. Never disconnect the battery terminals while the
(Failure to observe this caution will cause abnormal pulses to apply to ihe transistors, even leading to
damage of the transistors and other electronic meters, etc.)
4.
Care must be exercised to ensure that no water gets to each electric part during the cleaning.
5.
Make sure that the CO meter is adjusted and calibrated accurately before it is put into use.
)
Warming-up
(1
(2)
Zero-point adjustment
(3) Span adjustment
[CB-23
and
CB-611
the number of cylinders.
engine is running.
no
Page 35
Checking engine oil level
A
After the engine has warmed up, stop the engine.
few
minutes later, check the engine oil level using a level
gauge.
Ensure that the oil level is between the full level and the
low level.
c-
LI
ENGINE
IF->-
TUNE-UP
Engine Oil Capacity
Full level
Low
level
CB-23
2.7
1.7
,
CB-61
I
!
I
2.7
1.7
NOTE:
When the engine oil level is below the specified level,
replenish the specified oil to the full level.
(When the engine oil level is below the specified level,
check to see if oil leakage exists.)
2.
Checking cooling water level
Check the cooling water level at the reserve tank. Ensure
that the cooling water level is between
the
full level and
the low level.
NOTE:
When the cooling water level is below the specified level,
replenish the reserve tank with water to the full level.
If the cooling water level is below the low level, remove the
radiator cap and check the radiator cooling water for
correct level.
If the cooling water level is always below the specified
level, check the radiator cap and water leakage, using a
radiator cap tester.
Fig.
Fig.
3-1
3-2
011
level
WM-03007
f-
1
'NM-03008
CAUTION:
Never open the radiator cap when the engine is running or
when the cooling water is still hot.
Cooling
CB-23
CB-61
water capacity
Manual transmission-
I
equipped vehicle.
Automatic transmission-
equipped vehicle.
3.9
Q
1
(Including 0.6 Q for reserve tank)
1
(Including
(Including
0.5
0.6
3.5
Q
3.9
l
Q
for
Q
for
reserve tank)
reserve tank)
Page 36
ENGINE
3.
Checking air cleaner element
(1)
TUNE-UP
Visually inspect to see
if
the air cleaner element is
restricted, abnormally dirty or damaged.
NOTE:
Replace the air cleaner element, as required.
(2)
Clean
the element with compressed
Blow compressed air from the inside cr up side
air cleaner eiement.
4.
Checking spark plugs
(1)
Visually inspect the spark plugs for damage or cracks.
NOTE:
Replace the spark plug, as required.
(2)
Clean the spark plugs.
(3) Check and adjust the spark plug gaps.
air.
of
the
For petrol
I
Fig.
3-3
Fig.
3-4
engine
(CB-23)
For turbo
(CB-61)
vehicles
WM-030'0
WM-03011
I
I
1
1
Specified Spark Plug Gap
Ergme rype
Manufac:urer
ECE
&
EEC
spec~rlcations
ECE
specifica:ions
Soark
-,
~g
-
'
gas
EEC
nn
(~ncr)
DEhSO
WI6EXi-l bii5E.A-l i REv CR8DC -1
W46EX-d
i
07-08
IC
025 - 0
I
1
I
35%-L
03'1
I
Fig.
3-5
CE-23 CB-61
NGA
3P:cY '~V~NBDC IX.Y> N-'IYC
ca-:?
I:,
331
-
3
63SCH , CHAMPICN CENSO
YC
I
326,
07-08
(0 028 - 0 331)
WI 6EXR-U BPR5EY WR8DC RN-9YC
,,,,20EXC-
W46EX-U BP5EY W8DC
W~~~~-~
0;
110
328
03
-
O
031
1
,
r
13
ipRiEv
~pe~y
C3-90
332 - 3 0%)
NGK
BOSCri
ilR7DC
/
w7DC
(X
Y) 1 N-9YC
:X
"1
07-38
(0
028
wM-03012
CYAMPION
RN.,;
YC
'
N-1
IVC
-
0
031)
J
Page 37
Checking V-belt
(1)
Visually inspect to see if the V-belt exhibits damage,
cracks or wear.
NOTE:
Replace the V-belt, as required.
(2)
Measure the amount of belt deflection.
Specified Deflection of V-Belt:
5
-
7
mm (0.20 - 0.28 inch)
[With a force of
6.
Checking valve clearances
8
kg (17.64 Ib) Applied]
Warm up the engine.
Cooling water temperature: 75
Check and adjust the valve c!earances.
Specified Valve Clearance:
CB-23: 0.20 0.05
CB-61: 0.25
2
0.05
mm
mm
Both for Intake and Exhaust Valves
-
85°C (1
67
-
1 85
OF)
(0.0079 t 0.002 inch)
(0.0098 t 0.002 inch)
1
Fig.
3-6
ENGINE
TUNE-UP
'NM-GSCIG
I
NOTE:
Carry out the check and adjustment of valve clearances,
with the piston of the
No.1 cylinder set to the end of the
compression stroke or to the tops of the intake and
exhaust strokes, respectively. See the table at the right for
the adjustable valves for the respective positions of the
No.1 piston.
7.
Checking compression pressure
kg/cm2
(psi)
at
NOTE:
The compression pressure check should be performed
with all spark plugs removed. Also, be sure to keep both
the throttle valve and choke valve fully opened during the
check.
350 rpm
L
Fig.
3-7
When No.1 piston
to
end of
stroke
WPen
:ops
s:-okes
Fig.
3-8
compression
No 1 pls~on
of
irta~e
and
resoecbvely
IS
set
IS
set to
exhaust
i
/
1
0
-
-
0
WM-a3015
IN
1
0
1
-
EX~0~0
I
IN
1 - 0
EX'-
-
WU-02017
The measurement of compression pressure should be performed for a short period of time. Moreover, care must be
exercised to ensure that the measurement time for each
cylinder becomes equal.
If
the s~ecified pressure is not met, check to see if the
cylinder-to-piston clearance conforms
to the specification.
Also check the piston rings for wear.
Page 38
ENGINE
8.
Checking contact points
(1)
TUNE-UP
Check to see if the contact points exhibit the trace of
burning.
(2)
Check and adjust the gap of the contact points.
Specified Heel Gap:
-
0.5 mm (0.01
0.4
6
-
0.020 inch)
[Referential Information]
Specified Contact Point Gap:
-
0.5 mm (0.016 - 0.020 inch)
0.4
Specified Dwell Angle: 58"
9.
Checking ignition timing
(1)
Disconnect the vacuum hose from the vacuum advan-
-
66"
cer. Plug the disconnected vacuum hose.
a
Using
timing light, check ;he ignition timing while
idling the engine.
Specified Ignition Timing:
Manual transmission
+
BTDC 5"
2"/800 f 50 rpm
Automatic transmission
BTDC 5"
2'1850
f
50 rpm
f
Daylight system-equipped vehicle
5'
f
BTDC
2"/1,000 4 50 rpm
NOTE:
Upon completion of the ignition timing check, be certain to
install the clutch housing cover on the inspection window.
I
Fig.
3-1
0
WM-03020
1
10.
Adjustment
(1)
The ignition timing can be adjusted by slacken~ng the
retaining bolt of the distributor flange and then by
turning the distributor body.
NOTE:
When the distributor body is turned counterclockwise, the
ignition timing is advanced. Conversely, when the distributor body is turned clockwise, the ignition timing is retarded.
(2)
After the adjustment has been completed, reconnect
the auxiliary vacuum hose to the vacuum advancer.
Ensure that the engine revolution speed rises about
to
100
rpm. Also ensure that the engine is emitting
normal sound.
50
a
WM-OX22
I
Fig.
3-1
1
WN-03021
1
Page 39
(3)
Securely tighten the retaining bolt of the distributor.
Care must be exercised to ensure that the distributor
body dose not turn during this tightening operation.
Specified Tightening Torque:
1.5
-
2.2
kg-m
(1
11.
Checking ignition advance
(1)
Disconnect the vacuum hose and plug the disconnected hose.
Acce!erate the engine repeatedly. Using
0.8 - 15.9
ft-lb)
a timing light, check to see whether the governor
ignition advance is taking place.
NOTE:
Prior to starting this test, disconnect the vacuum hose.
Make sure to plug the disconnected hose.
V/M-03023
ENGINE
TUNE-UP
(2)
Apply a negative pressure to the vacuum advancer by
means of a
MityVac or by sucking the hose.
Ensure that the ignition mark moves in the ignition
advance direction.
(3)
Reconnect the vacuum hose in the original position.
Vacuum
controller
I
Fig.
3-1
CB-61
3
WM-03025
Page 40
ENGINE
TUNE-UP
12. Checking idle speed
Initial check and adjustment
Warming
(1) Precaution
up
engine and test
The following notes must be observed before or during the idle speed adjustment.
@
Warm uo the engine throughly
@
Do not perform the engine idling speed adjustment while the fan motor is functioning.
@
Never apply extra loads such as the headlamps, rear window defogger or the like during the
adjustment of the engine idle speed. (On the day light-equipped vehicle, keep the headlamps
glowing.)
@
Be sure to install the air cleaner element in place.
@
Be sure to disconnect the HIC (Hot Idle Compensator) hose and plug the disconnected hose.
@
Ensure that the choke valve opens fully.
@
Ensure that the exhaust system exhibits no gas leakage.
@
Ensure that the intake system exhibits no air leakage.
@
The idle limit cap can be removed by cutting it off with pliers or the like. (Except the ECE & EEC,
Australian, GCC, Singapore specifications) After the adjustment has been completed, be sure to
install a new cap. Make sure that it can rotate freely.
@
The shape of the idle limit cap for the ECE & EEC, Australian, GCC, Singapore specifications
differs from that of other specifications. Use the following SST to adjust the cap.
SST:
0
On those vehicles whose air cleaner is equipped with a vacuum motor, disconnect the vacuum
motor hose and plug the disconnected hose.
09243-00020
Installing test
equipment
(3)
Check and
adjustment of
idling
-
Installing idle limit cap
ECE
&
(Except
Australian,
Singapore Specifications)
ECC,
GCC,
and
WM-03026
WM-03027
,'
(2) Initial check and adjustment
@)
Warm up the engine, until the cooling water temperature becomes 75°C - 85°C
(As for a guide for this temperature, you may use a point when the fan motor stops running. Thb
idling should not be adjusted while the fan motor is operating.)
@
Warm up the
@
If the engine is equipped with a plastic idle limit cap, remove it.
@
Ensure that the choke valve opens fully.
(3)
Test equipment installation
Install an engine tachometer to the engine.
CO
meter.
(167
-
185°F).
Page 41
(4)
Check and adjustment of idle speed
Manual transmission-equipped vehicle
@
Back off the idling adjusting screw the specified
turns from the fully closed position.
Specified backing-off turn:
CB-23
CB-61
@
Start the engine. Turn the throttle adjusting
42/4
7
turns
turns
screw, until the engine runs at 850 rpm.
@
Screw in the idle adjusting
screw, until the
engine runs at 800 rpm.
i
Specified Idling Speed: 800
50 rpm
Automatic transmission-equipped vehicle
@
Back off the idle adjusting screw about 43% turns
from the fully-closed
@
Start the engine. Turn the throttle adjcisting
pos~tion.
screw, until the engine runs at 950 rprn.
@
Screw in the idle adjusting screw, until the
engine runs at 850 rpm.
+
Specified Idling Speed:
(For
Day-Light Relay-equipped vehicle:
+
1000
50 rpm)
850
50 rpm
NOTE:
On those engines for
Australian,
GCC
and
ECE
&
EEC
Singapore specifications, screw in the idle adjusting screw,
using a SST (09243-00020).
WM-03030
I
Fig.
3-14
ENGINE
TUNE-UP
WM-03029
J
Except
AS
(secondary air suction) system-equip-
ped vehicle
(As for the
AS
system-equipped vehicle, see the
next section.)
@
M-easure the
CO
concentration.
Specified CO concentration:
General specifications: 5-6%
ECE
&
EEC
@
If the
spec~fications:
CO
concentration does not conform to the
0.5
-
soecified values, turn the idle adjusting screw.
If
the engine rotates roughly, check to see if the
CO
concentration or engine revolution speed
drops excessively. Set these values to higher
points within the allowable ranges.
1.5
%
'NM-33C32
Fig.
3-15
'NM-W~I
I
Page 42
ENGINE TUNE-UP
AS
(secondary air suction) system-equipped
vehicle
(Australian, and West German specifications)
@
Measure the
(1)
Disconnect the hose between the air cleaner
and the air suction valve. Plug the disconnected hose.
(2)
Leave the engine idling for about
(3)
Check the
Specified
@
If the rneas~red concentration does not conform
to
the specified value. perform the icfle adjust-
ment described below.
Not
CO
CO
CO
to
exceed
concentration.
concentration.
Concentration:
1.0
%
10
minutes.
(5)
ldle limit cap installation
lnstali the idle limit cap in the original position. (This
applies to those engines equipped with a plastic idle
limit cap.)
(6)
Idle adjustment
@)
Back
off
the idle adjustins screw the specified
Specified idling speed:
Manual Transmission:
Automatic Transmission:
800
5
850 i 50
50
rpm
rpm
Fia.
1
Fig.
i
I
Fig.
3-17
3-1
3-19
8
Throttle
adjusting screw
\
Idle adjusting screw
I
WM-0x34
'NV-03035
Nt,l-OC036
1
1
I
i
I
@
Remove the air suction valve.
Fig.
3-20
CB-23
CB-61
1
WM-03037
Page 43
@
Insert the sampling pipe into the air suction pipe.
Plug the gap between the air suction pipe and the
sampling pipe, using heat-resistant,
@
Measure the
Specified
Swiss specifications:
Not to exceed 1.5
Australian specifications:
Not to exceed
West German specifications:
Not to exceed 1.5
CO
concentration.
CO
Concentration:
1.0
k
k
k
0.5
0.5
0.5
%
%
%
tape or the like.
ENGINE
TUNE-UP
@
If the idling speed dose not conform to the
specified value, adjust the idle speed
throttle adjusting screw.
At this time, if the engine rotates roughly, recheck
CO
the
engine revolutional speed is too low. Set the
concentration to 0.5 to 1.5%.
concentration and check to see if the
by
the
CO
I
Fig.
3-23
\
Idle
\
adjusting
\
screw
WM-03040
\
I
I
@
Reinstall the AS valve in the ori~inal position.
Fig.
3-25
CB-23
CB-61
1
WM-03042
Page 44
ENGINE
@
@
TUNE-UP
Ensure that the
Ensure that the engine revolution speed is within
the specified idle speed.
Specified idle speed:
Manual transmission-equipped vehicie:
800 + 50
Automatic transmission-equipped vehicle:
850 + 50
CO
concentration decreases.
rpm
rprn
I
Fig.
3-26
'NM-03043
I
13.
Checking fast
Check
(1)
Warm
(Temperature
(2)
Stop the engine and pull the choke button out as far as
it will go. Depress the accelerator pedal once or twice.
Restart the engine.
(3)
After starting the engine, ensure that :he choke opener
is functioning and that the fast idle adjusting lever
rests on the second stage of the fast idle cam
(4)
Check the engine revolution speed.
Specified Fast Idling Speed:
idie
speed
up
the engine.
of
coolant
CB-23: 1800 - 2200
CB-61: 2400 - 2800
75 - 85°C)
rpm
rprn
r
Fig.
Fast
3-27
idle
adjusting
Choke opener
screw
WM-03045
(5)
Ensure that the engine returns to its idling speed,
when the choke button is pushed back to the original
position.
NOTE:
The
operations described in the steps
a
be carried out for
short period of time.
Adjustment
The fast idling speed
can
be adjusted
idle adjusting screw.
(3)
and
(4)
by
turning the fast
should
I
I
Fig.
3-28
Choke apener
.Fast
idle
adjusting
lever
WM-03046
1
I
I
Page 45
ENGINE
TUNE-UP
Checking dashpot
(Dashpot-equipped vehicle only)
(1)
Touch revolution speed check
@
Start the engine. Disconnect the vacuum hose
from the diaphragm pioe
@
Open the throttle so that the throttle touch arm
@.
may be held separated from the diaphragm shaft
@.
Plug the diaphragm pioe by finger.
@
Release the throttle valve. Measure the engine
revolution speed at
arm begins to contact the diaphragm shaft. If this
engine speed falls within the following range. it
indicates that the system is functioning properly.
Touch Revolution Speed:
(2)
Adjustment
@)
Turn the adjusting screw @ so that the specified
revolution speed is obtained.
@
Upon completion of the adjustment, reconnect the
vacuum hose. Ensure that the engine revolution
speed drops to the idle speed.
a
time when the throttle touch
1200
-
1400
rpm
@)
@
I
Fig.
3-29
I
WM-03047
(3)
Dashpot function check
@
Keep the engine revolution speed at
2500
rpm for
a short period of time. Then, release the throttle
valve.
@
Measure the time required for the engine to drop
its engine revolution speed from the touch revolution speed to the idle revolution speed.
Specified Time Required:
(4)
If the measured time does not conform to'the specified
value, check the
VTV
the
15.
Checking choke opener
and replace them as required.
dashpot for air tightness. Also check
0.5
-
5.0
seconds
(Choke opener-equipped vehicle only)
While the engine is idling, disconnect the vacuum hose
connected to the choke opener. If the link functions
way as described in the table below, it represents that the
choke opener is functioning properiy.
Cooling
temperature
29°C
If the link will not move, check the
opener. Replace them, as
water
or above
When
hose is reconnected. link moves.
(Negative pressure is applied.)
BVSV,
TVSV
req~ired.
or choke
ir: :he
1
Fig.
L
Fig.
3-30
3-31
WM-03048
J
flM-C305G
Page 46
ENGINE
TUNE-UP
REFERENTIAL INFORMATION
Simple Checking Method
of
Valve Timing
The valve timing can be checked easily at a time when the
piston of the
No.1 cylinder is set to the top dead center at
the end of the compression stroke for the purpose of
checking and adjusting valve ciearances. The following is
the procedure for this simple checking method of valve
timing.
Checking Procedure
1. Turn the crankshaft, until the ignition mark on the
flywheel is aligned with the ignition mark of the
cylinder.
2.
When the operation described in the step 1 has been
made, check to see whether the check mark on the
timing belt cover is lined up with the timing mark on
the camshaft pulley, as indicated in the illustration at
the right.
When these marks are aligned to each other, the valve
I
timing is correct.
No.1
,
\
Timing
Check
mark
mark
Page 47
ENGINE
TUNE-UP
4GINE
CONNECTING METHOD
1.
Engine tachometer
(1) In the case of a tachometer in which the pick-up is made from the primary circuit and there is no
(2) In the case of a tachometer in which the pulses flowing through the resistive cord of the cylinder
2.
The power supply for the tachometer, timing light and other instruments should be connected to the
battery terminal.
3.
Never disconnect the battery terminals whiie the engine is running.
(Failure to observe this caution will cause abnorma! pulses to apply to the transistors, even leading to
damage of the transistors and other electronic meters, etc.)
4.
Care must be exercised to ensure that no water gets to each electric ?art during the cleaning.
5.
Make sure that the
(1)
(2) Zero-point adjustment
(3)
TUNE-UP
3-cylinder range, carry out the measurement using the 6-cylinder range. And multiply the reading
2.
This product is the actual revolutional speed of the 3-cylinder engine.
by
No.1 are sensed, the reading can be read directly regardless of the number of cylinders.
Warming-up
Span adjustment
[CB-801
OF
INSTRUMENTS AND HANDLING INSTRUCTIONS
CO
meter is adjusted and calibrated accurately before it is put into use.
Page 48
ENGINE
TUNE-UP
Checking engine oil level
After the engine has warmed up, stop the engine. A few
011
minutes later, check the engine
gauge.
Ensure that the oil level is between the full
low level.
Engine Oil Capacity:
Full level
Low level
NOTE:
When the engine oil level is below the specified level,
replenish the specified oil to the full level.
(When the engine oil level is below the specified level,
check to see if oil leakage exists.)
2.
Checking cooling water level
Check the cooling water level at the reserve tank. Ensure
that the cooling water level is between the full level and
the
!ow level.
NOTE:
When the cooling water level is below the specified level,
replenish the reserve tank with water to the full level.
If the cooling water level is below the low level, remove the
radiator cap and check the radiator cooling water for
correct level.
If the cooling water level is always below the specified
level, check the radiator cap and water leakage, using a
radiator cap tester.
2.7
1.7
level using a level
eve1 and the
Fig.
C
3-32
LI
Correct
011
level
-
WM-03052
CAUTION:
Never open the radiator cap when the engine is running or
is
when the cooling water
Cooling water capacity:
3.
Checking air cleaner element
(1)
Visually Inspect to see if the air cleaner element is
restricted, abnormally dirty or damaged.
NOTE:
Replace the air cleaner element, as required.
(2)
Clean the element with compressed air.
Blow compressed air from the upper of the air cleaner
eiement.
still hot.
4.0
Q
(Including
0.6 Q for reserve tank)
I
Fig. 3-34
wM-03C54
I
Fig.
3-35
WM-03055
Page 49
ENGINE
TUNE-UP
Checking
(1)
Visually inspect the spark plugs for damage
spark
plugs
NOTE:
Replace the spark plug, as required.
(2)
Clean the spark plugs.
(3)
Check and adjustment of the spark plug gaps.
Specified Spark Plug Gap:
0.9 - 1.0
(4)
If the spark plug is burnt excessively, replace it with a
mm
(0.035
replacement plug.
-
Manufacturer
ECE & EEC
'xcept
specifications
ECE
&
EEC
specifications
-
0.039
inch)
or
cracks.
I
Fig.
3-36
DENS0
W22ETR-L W20ETR-L
W22ET-L W2OET-i
Spark
plug
gap
SVM-a3056
1
Checking
(1) Visually inspect to see
V-belt
if
the V-belt exhibits damage,
cracks or wear.
NOTE:
Replace the V-belt, as required.
(2)
Measure the amount of belt deflection.
Specified Deflection of V-Belt
7.5
-
8.5 (0.3 - 0.35
[With a force of
inch)
8
kg (18 Ib) Applied]
Checking valve clearances
(1)
Warm
Cooling water temperature: 75
(2)
Check the valve clearances.
up
the engine.
-
85°C
(1
67
-
185°F)
Specified Valve Clearance:
Intake valve:
0.27 5 0.05
mm
(0.0106 5 0.002
inch)
Exhaust valve:
0.32 2 0.05
Carry oc;t the checking of valve clearances, with the piston
mm
(0.0126
2
0.002
inch)
of
the No.1 cylinder set to the end of the compression stroke or
to ihe tops of the intake and exhaust strokes, respectively.
See the table at the right for the adjustable valves for the
respective
pcsitions
of
the No. 1 piston.
L
Fig.
3-37
I
Fig.
3-38
b'i'hen
No.1
piston is set
to enc
of
coflpression
stroke
When
No.
1
pistcn
tops
oi
intake
and
srrokes, respectiveiy
is
set
to
exhaust
IN
G
EX
'o'o!
I,:
IN
1
,
;EXi
'NM-03058
1
>NV-~3059
I
,
'
,
O.
13j
I
3
I
Page 50
ENGINE
C3)
TUNE-UP
If the valve clearances do not conform to the specified
values, replace the adjusting shims, following the
procedure given below.
@
Turn the crankshaft so that the cam lobe of the
cylinder to be adjusted assumes nearly the upright
position of the valve.
NOTE:
When the valve clearances are adjusted, make sure that
the piston of the cylinder to be adjusted is not at its top
dead center.
(If
the SST is used when the piston is at its top dead
center, the valves may interfere with the piston, thus
damaging the valves and piston.)
@
Set the cut-out section of each lifter to a position
indicated in ihe figure.
SST: 09248-87703-000
l
Fig. 3-39
:
WM-~XO~:
1
@
Insert the SST into between the camshaft and the
valve lifter, as shown in the figure.
In this way, push down the two lifters.
@
Using a mini-sized nose piier or ihe like, raise the
adjusting shim through the cut-cut section
lifter.
of
the
1
Fig.
1
...
Fiq.
3-40
.,
3-41
WM-03062
.
..
.
J
1
I
WM-03063
@
Select a suitable shim.
Thickcess
of
shim to
be
Thickness of removed shim + measured valve
clearance
-
specified valve clearance
[Reference]
Adjusting shim is available
range from 2.500 to 3.300
mm
selected
in
41
mm
=
different kinds within
in increments of 0.02
WM-020%
Page 51
@
Place the selected shim in the lifter.
The shim should be placed in such a direction that
the surface marked by inerasable ink faces toward
the lifter side.
ENGINE
Face surface marked
by
inerasable ink
toward lifter side.
TUNE-UP
@
Remove the SST.
@ Ensure that the valve clearances have been ad-
justed within the specifications.
NOTE:
See the section under "Checking valve clearances."
@ Install the cylinder head cover.
7.
Checking ignition timing
(1)
Warm up the engine.
(2)
Short the terminal
Read the outputted diagnosis code. If any abnormality
is detected, perform the trouble shooting. (See the
"Troubie Shooting for Type
System.
")
T.
CB-80
WMG3068
Engine Control
I
Fig.
I
I
Fig.
3-43
3-44
Sho
clrc
WM-03066
'NM-01067
Earth terminal
1
I
J
1
I
(3)
Adjust the idle speed to
9502
50
rpm by means of the
idle adjusting screw of. the throttle body.
(4)
While the engine is idling, check the ignition timing,
using a timing light. Ensure that the ignition timing is
correct, using the ignition timing mark on the flywheel
and the indicator.
Reference
1
Ignition timing:
0°+2"
BTDCl950
550
rpm
Fig.
3-45
I
Idle adjusting screw
)I
I
Page 52
ENGINE
(5)
TUNE-UP
Adjustment
If
the ignition mark fails to align with the indicator,
slacken the attaching
bolts of the distributor. Adjust
the ignition timing by turning the distributor body.
NOTE:
When the distributor body is turned counterclockwise, the
ignition timing is advanced. Conversely, when the distributor body is turned clockwise, the ignition timing is retarded.
I
Fia.
3-48
(6)
Securely tighten the attaching bolts of
the
distributor.
NOTE:
Care must be exercised to ensure that the distributor body
will not
(7)
8.
Checking idle speed
turn during this tightening operation.
Tightening Torque: 1.5
-
2.2
kg-m
Detach the short pin at the terminal
(1 1
T.
-
16 ft-lb)
I
Fig.
3-49
NOTE:
The following notes must be observed before or during the idle speed adjustment.
(iJ
Warm up the engine thoroughly. (Warm up the engine for about another 15 minutes after the cooling
fan has started its operation.)
@
Do not perform the engine idle speed adjustment while
@
Never apply extra loads such as the headlamps or the like during the adjustment of the engine idle
the
fan motor is functioning.
speed. (As for the day-light-equipped vehicles, disconnect the day-light relay connector.)
@
Be sure to install the air cleaner element in place.
@
Ensure that the exhaust system exhibits no gas leakage.
@
Ensure that the intake system exhibits no air leakage.
WM-03072
~~-03073
WM-030-
1
I
(1)
Check and adjustment of idle speed
@
Install a tachometer and a CO meter.
@
Turn the bypass screw of the throttle body so that
the engine idle speed becomes
(When the bypass screw
idle speed drops. Conversely, when the bypass
screw is turned counterclockwise, the idle speed
rises.)
Specified
Idle Speed: 950250
950k50
is
turned clockwise, the
rpm.
rpm
Page 53
@
Measure the CO concentration, as follows:
A/F
Adjust the
concentration becomes 1 t0.5%.
Specified
After completion of the adjustment, check to see if the
engine idle speed conforms to the specifications. If the
idle speed
the operations
NOTE:
Under no circumstances should the adjustment of the
adjuster be performed without a CO meter.
(This engine is equipped with the diagnosis function.
Therefore, if the
CO meter, it may cause an erroneous diagnosis code.)
CO
fails to conform to the specifications, repeat
NF
adjuster screw so that the
Concentration: 0.5 - 1.5
@
and
0.
adjuster should be adjusted without a
%
CO
AIF
Fig.
3-51
ENGINE
TUNE-UP
WM-03076
Checking
(I)
Checking of touch revolution speed
@)
@
@
@
(2) Adjustment of
@
dashpot
Warm up the engine.
Disconnect the vacuum hose from the diaphragm
pipe.
Raise the engine revolution speed to about 2500
rpm. Plug the disconnected diaphragm pipe by
your finger.
Release the throttle valve. Measure the engine
revolution speed at a time when the throttle touch
arm begins to contact the diaphragm shaft.
Specified Touch Revolution Speed:
t
1600
If this engine speed drops within the following
duration of time, it indicates that the system is
functioning properly.
Specified
Stop the engine. Slacken the lock nut of the
dashpot adjusting screw.
100 rpm
Time:.
touch revolution speed
0.5
-
5
@ Start the engine.
@
Keep the engine revolution speed at about 2500
rpm. Plug the diaphragm pipe of the
finger.
@
Release the throttle valve.
adj~sting screw so that the touch revolution speed
may become the specified value.
Seconds
Adjust the
dashpot by
dashpot
I
Fig.
I
I
I
Fig.
I
1
Fig.
3-52
3-53
3-54
/
/
/
Adjusting screw
/~djustin~ screw
WM-03077
WM-03078
WM-03079
1
I
I
I
I
I
Page 54
ENGINE
@
@
@
@
TUNE-UP
Stop the engine. Tighten the lock nut of the
adjusting screw.
Start the engine. Check the dashpot touch revolution speed.
If
the touch revolution speed fails to conform to the
specifications, repeat the adjusting procedure
above.
Connect the hose.
(3)
Dashpot function check
a
Keep the engine revcluticr! speed
a
short period of time. Then, release the throttle
valve.
@
Measure the time required for the engine to drop
its engine
tion speed
Specified
revoiution speed from the touch revolu-
to the idle revolution speed.
Time Required:
at
3000
rpm for
0.5 - 5.0 seconds
L
Fig.
Fig.
3-55
3-56
/
/'~djus:irg
screw
WM-93080
I
Page 55
TYPE
CB
ZNGlNZ
SECTION
4
IN-VEHICLE SERVICE
INSTRUCTIONS ON SERVICE OPERATIONS
TIMING BELT & WATER PUMP
CRANKSHAFT OIL SEAL
CAMSHAFT [CB-23 &.CB-61 ENGINES]
CAMSHAFT [CB-80 ENGINE]
CAMSHAFT OIL SEAL
This section only describes the removal/installation procedure for those parts which can be
removed/installed while the engine is still mounted on the vehicle. As for the overhaul or inspection for
the removed parts, see the section under "Engine Overhaul."
With regard to those operations for the timing belt, camshaft, crankshaft oil seal, camshaft oil seal
cylinder head gasket, previous to the operations, make sure to set the piston No.1 to the top dead
center under the
NOTE:
The top dead center under the compression stroke of the cylinder No.1 can be confirmed
the oil filler cap and observing the top mark of the camshaft.
com~ression stroke.
by
removing
and
TIMING
BELT
&
WATER
PUMP
REMOVAL
1.
Drain engine coolant.
2.
Remove the air cleaner and hose. (CB-61 & CB-80
engines only)
3.
Remove the engine mounting bracket. Prior to this operation, support the oil pan with a jack.
NOTE:
Be very careful not to deform the oil pan.
Extreme care must be exercised not to damage the oil
drain plug.
The deformation of the oil pan will cause engine seizure.
4.
Remove the V-belt.
5.
Remove the water pump pulley.
6.
Remove the crankshaft pulley.
When the crankshaft pulley is slackened, lock the ring
gear, using a screwdriver or the like.
(On Type CB-80 engine, the space is very limited for this
operation. Hence, it is advisable to use a screwdriver
a
whose end is bent at
right angle for this operation.)
I
Fig.
I
Fig.
4-1
4-2
WM-04003
WM-04004
I
1
7.
Remove the bracket (surge tank & cylinder head cover).
(CB-80 engine only)
8. Remove the resistive cords. (CB-80 engine only)
9.
Remove the cylinder head cover. (CB-80 engine only)
10. Remove the timing belt upper cover.
11. Remove the timing belt lower cover.
12. Remove the timing belt tensioner.
Before the timing belt tensioner is removed, align the
punch marks of the crankshaft and camshaft
tim~ng belt
pulleys with the indicator marks, respectively. thus setting
the piston
No.1 to the top dead center under the com-
pression stroke.
(CB-23 & CB-61
I
Fig.
4-3
engines)
WM-04005
1
Page 57
IN-VEHICLE SERVICE
13.
Remove the crankshaft timing belt pulley flange.
14.
Remove the timing belt.
Prior to the timing belt removal, put a mark which shows
the normal rotating direction at the back surface of the
t~ming belt, using chalk or the like.
NOTE:
@
When removing the timing belt, never use a tool such
as a screwdriver.
@
Make sure not to bend the belt sharply to form a small
radius. Such practice will cut the belt cord.
@
Never permit oils or water to get to the belt, for such
of
matter would shorten the life
-,
_
-
Remove the water pump.
the belt.
INSTALLATION
1.
Install the water pump.
NOTE:
Be sure to replace the gasket with a new one.
2.
1ns:allation of timing belt tensioner
(1
)
With the timing belt tensioner set to the lowest position.
bolt
temporarily tighten the attaching
bolts in case of
CB-80
engine) of the timing belt
tensioner.
be
(This tightening must
made to such an extent that
the tensioner can not be moved when the tension
spring is attached.)
(two
attaching
I
Fig.
4-5
(CB-23 & CB-61
Fig.
4-6
engines)
Mark showing
normal rotating
direction
WM-04007
WM-34008
WM-04009
I
Page 58
IN-VEHICLE
(2)
Install the tension spring. Ensure that the tension
spring are positively hooked at its both ends and will
not be detached.
SERVICE
~(CB-80 engine)
3.
Install the timing belt.
NOTE:
@
Make sure not to bend the belt sharply to form a small
radius. Such practice will cut the belt cord.
@
Never permit oils or water to get to the belt, for such
matter would shorten the life of the belt.
@
When installing the belt, never try to
screwdriver or the like.
@
When turning the engine with the belt installed, the
rotation should be made at the crankshaft side.
@
If the belt is reused, install the belt
the belt is turned in the same direction as indicated by
the arrow mark which was put at the belt's back
surface during the belt removal.
pry
the belt with a
in
such a way that
I
Fig.
4-7
(CB-80 engine)
WM-a010
I
(1)
Ensure that the mating marks
of
the crankshaft and
camshaft timing belt pulleys are aligned with the
indicator marks, respectively.
Fiq.
4-8
I
(CB-23
1
Fig.
4-9
&
C8-61 engines)
WM-04011
WM-04012
I
I
Page 59
IN-VEHICLE SERVICE
(CB-80
(2)
Engine only)
lns:all the timing belt in such a way that the part
number of the timing belt can be seen properly, as
viewed toward the cylinder head side,
and comes
between the timing marks of the camshaft pulley. Also,
make sure that the three mating marks at the back
surface of the belt are aiigned with the mating marks
on the camshaft and crankshaft timing
belt pulleys,
respectively. Ensure that the belt is not slackened.
especially at the tension side (exhaust side) of the
belt.
NOTE:
If the three mating marks at the back surface
erased, the belt should be installed in such
belt
is not slackened at the tension side (exhaust side).
(3)
Ensure that the mating marks
of
the timing belt pulleys
of
the belt are
a
way that the
are aligned with the matins marks on the belt, respectively.
(4)
Slacken the attaching Sclts of the tensioner which
were tightened
tern3orariiy in the previous step. En-
sure that the timing belt tension is provided by the
tension spring.
I
Fig.
4-10
.
,.,
',VM-O~O:S
I
I
Fig.
4-1
1
(5)
Turn the crankshaft slightly in the ncrmal rotating
I
direction (clockwise), thus applying tensicn to the
timing belt between the intake camshaft timing belt
puiley
and
the exhaust camshaft timing belt pulley and
between the exhaust camshaft timing belt pulley and
the crankshaft timing belt pulley.
L
Fig.
4-1
2
(6)
Tighten the timing beit tensioner temporarily.
(7)
Turn the crankshaft abocr two turns in the normal rotating directicn, until the mating mark on the
cylinder head is aligned wirh the recessed timing mark on the camshaft.
NOTE:
if
Never make a reverse turn, even
it is the slightest
one,
during this operation.
WM-04014
WM-04015
1
Page 60
IN-VEHICLE
(8)
Ensure that the tension spring force is being applied to the tensioner, by slackening the bolts of tt
timing belt tensioner.
(9)
Tighten the bolts of the timing belt tensioner
Tightening Torque:
(CB-23 & CB-61
(CB-80
M6
SERVICE
1.9 - 3.1
engine)
MI0
bolt
bolt
engines)
kg-m
(14
3.0
-
0.6 - 0.9
4.5
-
22 ft-lb)
kg-m
kg-m
(5
(22
-
-
7
33
ft-lb)
WM-04017
ft-lb)
(10)
Align the ignition timing marks at the flywheel by
turning the crankshaft
or?e :urn.
Push the belt between the camshaft timing belt pulleys
with a force of 3 kg
(6.6
Ib). Check to see if the
deflection meets the specification.
Specified Deflection: About 5
(with a force
4.
lnstall the crankshaft timing belt pulley flange.
nm
of
3
(0.1
97
inch)
kg
(6.6 Ib) applied)
NOTE:
Be sure to install the crankshaft timing belt pulley flange in
the correct direction.
Fig. 4-13
I
Fig. 4-14
.
WM-040-8
Deflection amount:
WM-04018A
5.
lnstall the cylinder head cover.
6.
lnstall the resistive cords.
7.
lnstall the air cleaner assemoly.
8.
lnstall the intake oipe.
9.
lnstall the surge tank.
10.
lnstall the timing belt lower cover.
11.
lnstall the timing belt upper cover.
12.
lnstall the crankshaft pulley.
(CB-67
(CB-61
(CB-23 & CB-61
(CB-23 & CB-61
(CB-23
engine only)
engine only)
engine only)
engines)
When the crankshaft pulley is tightened, lock the ring
gear, using a screwdriver or the like.
(On Type
CB-80
operation. Hence, it is advisable to use
engine, the space is very limited for this
a
screwdriver
whose end is bent at a right angle for this operation.)
Tightening Torque:
9.0
-
10.0
kg-m (65
-
72
engines)
'NM-04020
ft-lb)
Fig.
4-15
Fig. 4-1
6
WM-04021
Page 61
IN-VEHICLE
SERVICE
lnstall the cylinder head cover.
14. lnstall the bracket (surge tank
(CB-80
&
cylinder head cover). (CB-80 engine only)
engine only)
15. lnstall the water pump pulley.
16. lnstall the V-belt.
17.
lnstall the engine mounting bracket. Remove the jack supporting the oil pan.
18.
Install the air cleaner and hose.
19.
Fill cooling water.
CRANKSHAW
OIL
SEAL
(C8-61
&
CB-80
engines only)
REMOVAL
1.
After the operations up to the timing belt removal in the
&
section under "Removal of Timing Belt
have been completed, proceed to this operation of
"Crankshaft Oil Seal Removal."
L.
Remove the crankshaft timing belt pulley.
NOTE:
If
any difficulty should be encountered in removing the
crankshaft timing belt pulley, screw-in bolts into the
threaded holes provided in the side of the pulley.
Water Pump"
I
Fig.
4-17
wM-04023
1
3.
Remove the crankshaft timing belt pulley flange
4. Remove the woodruff key.
5.
Removal of crankshaft oil seal
Remove the oil seal, using the following SST.
SST:
(1)
With the oil seal remover & repiacer @ placed against
the oil
09223-87702-000
seai, drive a drift into the oil seal so as to make
a hole.
(2) Thread a tapping screw into the thus-produced hoie in
the oil seal.
(3)
Screw the puller @ so as to remove the oil seal.
INSTALLATION
1.
lnstall the new crankshaft oil seal.
SST:
(1) Apply engine oil to the lip section of the oil seal.
(2)
Place the oil seal remover & replacer
seal.
(3)
Place the crankshaft attaching bolt (2) against the
remover
seal into position by turning the crankshaft attaching
bolt
09223-87702-000
&
replacer
@.
@)
against the oil
@.
Then, proceed to install the oil
Fig.
4-1
8
Oil
seal
Crankshaft attaching
bolt
@
Fig.
4-19
remover
WM-04024
&
WM-04025
Page 62
IN-VEHICLE SERVICE
2. Install the woodruff key.
3.
Install the crankshaft timing oelt pulley flange.
NOTE:
Ensure that the flanges are installed only in the correct
direction.
4.
Perform the timing belt tensioner installation and the
following operations described in the section under
stallation of Timing Belt
&
Water Pump." As for the
contents of these cperations, see the section under
&
"Timing Belt
CAMSHAm
Water Pump."
(CB-23 & CB-61
Engines)
REMOVAL
1.
After the operations up to the timing belt removal in the
&
section under "Removal of Timing Belt
have been completed, proceed to this operation of "Cam-
shaft Removal."
2.
Remove the surge tank. (CB-61 engine only)
3.
Remove the intake pipe. (CB-61 engine oniy)
4.
Remove the air cleaner assembly. (CB-23 engine only)
5.
Remove the resistive cords.
6.
Remove the cylinder head cover.
7.
Remove the distributor and distributor hcusing.
8.
Remove the camshaft timing belt pulley.
NOTE:
During the timing belt pulley removal, the rotation of the
camshaft can be prevented by inserting a screwdriver
the
through
opening of the pulley.
Water Pump"
"ln-
I
Fig.
Convex
4-20
Frange
pulley
+~p(lvl-040~6
1
9.
Slacken the attaching screws of the valve rocker arm
10.
Remove the camshaft.
INSTALLATION
Reverse the removal procedure to install the camshaft.
'NM-04028
Fig.
4-21
WM-3401-
Page 63
IN-VEHICLE SERVICE
AMSHAFT
(CB-80
Engine)
REMOVAL
1.
After the operations up to the timing belt removal in the
section under "Removal of Timing
have been completed, prcceed to this
Belt & Water Pump"
operation of "Cam-
shaft Removal."
2.
Remove the camshaft timing belt pulley.
NOTE:
The rotation of the camshaft can be prevented by securing
the hexagon section on the cylinder
No.1.
Do not remove the camshaft timing belt pulley by utilizing
the tension of the timing belt.
3.
Remove the distributor.
4.
Remove the camshaft bearing caps.
5.
Remove oil seal from camshaft.
6.
Remove the camshafts.
INSTALLATION
1.
Install the camshafts.
2.
Installation of camshaft bearing caps
Install each camshaft Searing cap as indicared in the right
figure, according
the back side of the camshaft bearing cars
Tightening Torque:
to the embossed number and arrow at
-
1.15
1.45 kg-m
(8.3
-
10.5 ft-lb)
I
Fig.
4-22
'XM-34020
I
3.
Install the new camshaft oil seal, using
SST.,
SST: 0961 8-87301 -000
Installation of
(I)
Remove the distributor cap. Tilt ;he rctor, as indicated
distrib~tor
in the right figure.
(2)
While turning the rotor. push and install the distributor
into the groove provided in the camshaft
to drive the
distributor.
NOTE:
Since the distributor is eccentric with the groove provided
in the camshaft, the installation can be performed in one
direction. Therefore, never install the distributor forcibly.
Failure to observe this note will lead to distributor damage.
Fig.
I
Fig.
I
Fig.
-
4-23
4-24
4-25
7-
-
WM-04030
1
5,~'?A-c,c03CA
1
I
\ni~-04031
Page 64
IN-VEHICLE SERVICE
5.
Install the camshaft timing belt pulley.
NOTE:
The rotation of the camshaft can be prevented by securing
the hexagon section on the cylinder
Tightening Torque: 3.0
6.
Perform the timing belt installation and the following
-
4.5
operations described in the section under "Installation of
&
Timing Belt
Water Pump." As for the contents of these
operations, see the section under "Timing Belt
Pump."
CAMSHAK
OIL
SEAL
No.1.
kg-m (22
-
33
ft-lb)
&
Water
1
Fig.
4-26
WM-Cc032
1
(CB-23 & CB-61
Engines)
REMOVAL
1.
After the operations
in the section under "Removal of timing
pump" have been completed, proceed to this operation of
"Camshaft Oil Seal Removal."
2.
Remove the camshaft timing belt pulley.
NOTE:
During the timing belt pulley removal, the rotation of the
camshaft can be prevented
through the opening of the pulley.
3.
Removal of camshaft oil seal
(1)
Make a hole on the oil seal, using the following SST.
SST: 09223-87702-000
(2)
Screw in the SST into the hole.
SST: 09223-87702-000
up
to the cylincfer head cover removal
belt & water
by
inserting a screwdriver
I
Fia.
L
Fig.
4-27
4-28
wM-04033
WM-04034
I
I
1
1
(3)
Pry off
the
oil seal with a screwdriver or the like.
NOTE:
Be careful not to damage the camshaft and cylinder head.
L
Fig.
I
I
Fig.
4-29
4-30
'AM-~035
WM-04036
1
1
1
Page 65
STALLATlON
1.
Installation of camshaft oil seal
With the
into position.
NOTE:
Be sure to use a new oil seal.
SST:
SST
placed against the oil seal, drive the oil seal
09608-1 201 0-000
IN-VEHICLE
SERVICE
L
Fig.
4-31
2.
Install the camshaft timing pulley.
Tightening Torque:
3.
Perform the timing belt tensioner installaticn and the following operations described in the section under
"Installation of Timing Belt
under "Timing Belt
3.0
-
4.5
&
Water Pump." As for the contents of these operations, see the section
&
Water Pump."
kg-m
(22
-
33
ft-lb)
Fig.
4-32
WM-04037
I
\NM-04038
CYLINDER
HEAD
GASKET
(CB-23 & CBdl
Engines)
..MOVAL
I.
After the operations up to the cylinder head cover removal in the section under "Camshaft Removal"
have been completed, proceed to this operation of "Cylinder Head Gasket Removal."
2.
Draine engine oil
3.
Disconnect the exhaust pipe.
4.
Remove the
5.
Disconnect the hoses.
6.
Remove the cylinder head assembly.
7.
Remove the cylinder head gasket.
EGR
pipe. (Specific area only)
INSTALLATION
Reverse the removai procedure io install the
sket.
NOTE:
to
Be sure
use a new gasket
oil
seal.
cylinder
head
Fig.
433
WM-04046
Page 66
IN-VEHICLE
SERVICE
CYLINDER HEAD GASKET
(CB-80 Engine)
REMOVAL
1.
After the operations up to the distributor removal in the
section under "Camshaft Removal" have been completed,
proceed to this operation of "Cylinder Head Gasket
Removal.
2.
Remove the surge tank cover.
3.
Remove the hoses.
4. Remove the connectors.
5.
Remove the surge tank stay.
6.
Disconnect the exhaust pipe.
7.
Remove the intake pipe.
8.
Remove the cylinder head assembly.
9.
Remove the cylinder head gasket.
INSTALLATION
Reverse the removal procedure to install the cylinder head
gasket.
"
WM-04047
INJECTOR
(CB-80
Engine)
REMOVAL
1.
Remove the surge tank cover.
2. Remove the bracket (surge tank
3.
Remove the intake pipe.
4.
Remove the hoses.
Union (for cold start injector)
The fuel line system is retained under a highly-pressurized
state. When the union is removed, place a cl'oth underneath.
Be sure to slowly remove the union so as to prevent the fuel
from splashing.
5.
Remove the connectors
6.
Remove the surge tank.
7. Remove the delivery pipe.
8.
Remove the insulator.
9.
Remove the injector.
@
cylinder head cover).
INSTALLATION
Reverse the removal procedure to install the injector.
NOTE:
Be sure to use
new
gaskets.
Page 67
/IL
PUMP
REMOVAL
1.
Remove the exhaust pipe.
2.
Remove the bracket (transmission @ exhaust pipe).
3.
Remove the engine mounting rear bracket No.2.
4.
Remove the engine mounting rear bracket No.1.
5.
Remove the engine lower mounting mernjer.
6.
Remove the stiffener plate.
7.
Remove the oil pan.
8. Remove the oil pan gasket.
9.
Remove the oil pump drive shaft sprocket.
10.
Remove the oil jet. (CB-80 engine only)
11.
Remove the oil pump.
INSTALLATION
1.
Install the oil pump.
NOTE:
Be sure to use new
"0"
ring
Fig. 4-35
IN-VEHICLE SERVICE
WM-04050
2.
Install the oil jet. (CB-80 engine only)
3.
Install the oil pump drive shaft sprocket.
NOTE:
Be sure to install the oil pump drive shaft sprocket with the
side having the
"CB
OUTSIDE" stamp facing to the
outside.
4.
Install the oil pan gasket.
@
Aoply the seater to the cylinder block, following the
procedure indicated in the illustration at the right.
Sealer to be used: Silicon Bond
@
Apply the sealer to the oil pan gasket a the oil pan
side, following the procedure indicated in the illustra-
tion at the right. Place the oil pan gasket on the
cylinder block.
I
,Fig.
4-37
'-mark
represents
stud
bolt.
WM-~52,
1
Fig. 4-38
WM-04053
I
Page 68
IN-VEHICLE SERVICE
5.
lnstall the oil pan.
Tighten the stud bolt sections temporarily. Then, tighten
the oil pan attaching bolts in the sequence as shown in
the illustration at the right.
Tightening
The numerals in
Torque:
(
the temporal tightening sequence for the
6.
lnstall the stiffener plate.
7.
lnstall the engine lower mounting member.
8.
lnstall the engine mounting rear bracket No.1.
9.
lnstall the engine mounting rear bracket No.2.
10. lnstall the bracket (transmission @ exhaust pipe).
11.
lnstall the exhaust pipe.
0.4
-
0.7
Kg-m
)
in the illustration at the right denote
(2.9 - 5.1 ft-lb)
st~d bolts.
WV-154355
Front
of engine
9
Fig.
4-39
direction
*
mark
represents stud
boit.
WLI-04054
Page 69
+
TYPE
CB
ENGINE
SECTION
5
ENGINE MECHANICALS
REMOVAL AND INSTALLATION OF ENGINE
INTAKE AND EXHAUST SYSTEM
This operation must be performed by at least two persons. Since the engine hood is quite heavy, be very
careful not to scratch the body and hood.
plug
I
Radiator
drain
water
Dlua
.
-
WM-05002
WM-05003
3.
Disconnect the negative @ terminal of the battery. Detach
the hold-down clamp and remove the battery.
4.
Remove the battery carrier stay.
5.
Remove the intercooler assembly.
6.
Remove the radiator.
7.
Remove the air cleaner assembly.
8.
Remove the blow-by hose.
(CB-61
(CB-80
engine only)
engine only)
I--
Fia.
Fia.
5-2
5-3
-
--,-I
-Engine
hood
I
WM-05004
WM-05005
I
Fig.
5-4
Radiator
drain
plug
wM-05006
,
Page 71
Disconnect the speedometer cable.
ENGINE
MECHANICALS
10.
Disconnect the clutch cable.
1
1.
Disconnect the accelerator cable assembly
I
Fia.
5-5
'NM-05007
I
12.
Disconnect
'
^
Disconnect the heater hose.
the
brake booster hose.
Page 72
ENGINE
15.
Disconnect the fuel pipe.
1)
MECHANICALS
Disconnect the fuel hose between the fuel filter and
the delivery pipe.
(CB-80
engine only)
SST: 09258-00030-000
NOTE:
Even when the engine is stopped, a fuel pressure of about
2.55
kg/cm2 (36.3 psi) is applied to the fuel line. Hence, be
sure to prevent the fuel from splashing, using a cloth or the
like.
SST
09258-00030-000
\
0
I
Fig.
2)
Disconnect the fuel return hose between the delivery
pipe and the fuel tank.
(CB-80
engine only)
5-10
WM-05012
NOTE:
When disconnecting the hose, be sure to prevent the fuel
from splashing, using a cloth.
16.
Disconnect the wire harness connector.
NOTE:
@
The foilowing explanation and illustrations for disconnecting the wire harness connector pertains to
Type CB-80 engine. For Type
CB-23
and
CB-61
engines, refer to the following sections before
starting the operation.
@
Care must be exercised as
to
the removal method of the connector. Some connectors can be
removed by pulling the lock section, while others can be removed by pushing the lock section.
[CB-231
While the engine proper is still mounted on the vehicle, disconnect each connector of the switches and
sensors. Make sure that the wire harnesses are left at the vehicle side when the engine proper is removed.
WM-05014
I
[CB-611
Disconnect the connector between the cowl wire harness and
the engine wire harness, as indicated in the right figure. After
the engine has been removed, disconnect each connector of
the switches and sensors at the engine proper.
NOTE:
When removing the engine, perform final check to ensure
that all connectors have been disconnected.
Fig.
5-1
CB-61.
1
2
/(\
WM-05015
Page 73
Disconnect the distributor-related harness couplers.
(CB-80 engine only)
1)
Injector time switch
2) Water temperature sensor
3)
Fan motor switch
4)
Thermostat sender tinit
5)
Distributor connector
6)
Ignition coil resistive cord
ENGINE MECHANICALS
18.
Disconnect the surge tank-related harness couplers.
(CB-80 engine only)
1)
Cold start injector
2) Coupler of each injector
19.
Disconnect the transmission-related harness couplers
(CB-80 engine only)
1
)
Starter harness
2) Transmission earth
3)
Backup lamp harness
20. Remove the surge tank cover. (CB-80 engine only)
Fig.
I
Fin
5-13
.%I4
6
1
I
m~u-~50i
WM-05017
21.
Disconnect the engine-related harness couplers. (CB-80 engine only)
1)
Thrott!e sensor
-
2) Pressure sensor
3)
Variable resistor
4)
Intake air temperature sensor
5)
Earth
6)
Oil pressure switch
7)
Alternator connector
I
Thrctle
senscr
Pressure sensor
To
cowle
wire
-
I
Fig.
5-16
WM-05019
I
Page 74
ENGINE MECHANICALS
22.
Jack up the vehicle. Support the vehicle with safety stands. Remove the wheels.
NOTE:
the
For
23.
Drain the transmission oil.
24.
Disconnect the shift & se1ec:or shaft subassembly.
supporting points, see
the
section under "GENERAL INFORMATION."
25.
Disconnect the exhaust front piqe. Remove it from the
manifold.
26.
Remove the stabilizer bar
27.
Remove the lower suspension brace.
(CB-61
and
engines only)
28.
Disconnect :he suspension lower arm subassembly.
CB-80
Fia.
I
Fig.
5-1
5-19
8
WM-~5022
WM-05023
I
.
.
Page 75
1.
Remove the front drive shaft.
SST:
09648-87201 -000
NOTE:
@
On Type
CB-23
and
CB-61
engines, no stopper is
provided at the inside of the inboard of the drive shaft.
It is, therefore, necessary to support the inboard joint
section by hands during the removal.
ENGINE
'
SST
MECHANICALS
@
On Type
CB-80
inserting a crowbar into between the projected section
of the drive bearing shaft and the drive shaft. Care
must be exercised not to deform the dust cover of the
drive shaft during the removal.
30.
is connection
Remove the bolts
engine, remove the front dr~ve shaft by
of engine mounting lower ieft bracket
at
the transmission side only.
I
Fig.
L
Fia.
5-21
5-22
WM-05025
WM-05026
L
I
31.
Disconnection of engine mounting rear No.1 bracket
Remove the
rear No.
Sling the engine, using
SST:
bolt attaching :he engine lower mounting member subassembly to the engine mounting
1
bracket.
the following SST.
09090-0481 0-000
(Engine sling device)
Fig.
L
Fig.
5-23
5-24
'NM-05027
-',
,'
ii
f1
WM-05029
Page 76
ENGINE MECHANICALS
33.
Removal of engine assembly
a
Remove the engine mounting front stopper.
@
Remove the engine mounting front insulator.
@
Remove the engine
SST.
SST:
09090-0481 0-000
NOTE:
When removing the engine, perform final check to ensure
that all removal parts have been removed.
by
iifting it, using the following
(Engine sling device)
34. Remove the starter assembly from
35. Remove the transmission assembly
The transmission.
from
assembly.
Install the engine assembly to the following SSTs.
36.
SSTS:
0921 9-87701 -000
0921 9-87202-000
the engine
I
Fig.
5-26 WM-05031
I
WM-05632
Page 77
STALLATION
1.
Remove the engine assembly from the SSTs.
2.
lnstall the transmission assembly to the engine assembly.
-
Tightening Torque: 5.0
3.
lnstall the starter assembly to the transmission.
4. lnstallaticn of engine assembly
@
Sling the engine, using the following
SST: 09090-0481 0-000 (Engine sling device)
@
lnstall the engine mounting front insulator.
Tightening Torque: 7.5
@
lnstall the engine mounting front stopper.
Tightening Torque: 7.5
7.0 kg-m (36 - 51 ft-lb)
SST.
-
10.5 kg-m (54 - 76 ft-lb)
-
10.5 kg-m (54
-
76
ft-lb)
Fia.
5-27
ENGINE MECHANICALS
WM-05033
5.
lnstall the engine mounting rear No.1 bracket.
Tightening Torque: 7.5
6.
lnstall the engine mounting lower left bracket.
Tightening Torque: 3.0
7.
Remove the
SST
(engine sling device) from the engine
-
10.5 kg-m (54
-
4.5 kg-m
assembly.
(22
-
76
-
33 ft-lb)
ft-lb)
L
Fig.
5-28
'N
'NM-05035
1
~~~5034
I
Fig.
5-30
WM-05036
Page 78
ENGINE
8.
lnstall the front drive shaft.
MECHANICALS
NOTE:
Install the front drive shaft to the differential case slowly,
being very careful not to damage the lip section of the oil
seal.
9.
Install the suspension lower arm s~bassembry.
Tightening Torqce:
7.5
-
10.5
kqrn
(54
-
76
10. tnstall the lower suspension brace. (CB-61 and
englnes oniy)
-
Tightening Torque: 4.0
11.
Installation of stabilizer bar
@
Tightening the suspension lower arm subassembly.
Tightening Torque:
@
Tightening the stabilizer bracket.
Tightening Torque: 4.0
7.5
5.5 kg-m
-
11
.O kg-rn
-
6.0
kg-rn
(29
(54
(29
-
40 ft-lb)
-
80
-
43 ft-lb)
ft-lbj
CB-80
ft-lb)
Fis.
Fia.
5-31
5-32
',v"u-;l.50.77
WM-05038
I
12.
Install the exhaust front pipe.
3.0
-
Tightening Torque:
5.0 kg-m
(22 - 36
ft-lb)
lnstail the shift & selector shat subassemoiy.
Tightening Torque:
1
.O
-
1.6
kg-m
(7
-
12
ft-lb)
NOTE:
After completion of the installation, make sure that the shift
&
selector shaft subassembly can be shifted smoothly into
each position. Also, be sure that it can be returned
smoothly in the selecting direction.
I
Fig.
5-33
WM-05039
I
Page 79
. Fill the transmission fluid.
Lubricant viscosity recommendation:
SAE
80W (oil equivalent
to
API
classification
GL-4)
ENGINE
MECHANICALS
4-speed manual I 5-speed manual
transmission transmission
Oil level flush with
Filler plug
Oil level 5 mm below
Filler plug
/
About
About 1.9 litres
2.0
litres
About 2.2 litres
i
I
About 2.1 litres
15. Tighten the wheels temporarily. Remove the safety stands.
Tighten the wheels securely.
Tightening Torque:
(65 - 87
ft-lb)
9.0
-
12.0
kg-m
16. Connect the harness connectors .for the parts given below.
) Alternator connector
1
2) Oil pressure switch
3)
Earth
4)
Intake air temperature sensor
5)
Variab!e resistor
6)
Pressure sensor
7) Throttle sensor
8) Backup lamp harness
9)
Transmission earth
10)
Starter harness
11) Coupler of each injector
12) Cold start injector
13) Ignition coil resistive cord
14) Distributor connector
15) Thermostat sender unit
16) Fan motor switch
17) Water temperature sensor
18) Injector time switch
I
Fig.
I
I
Fig.
Oil
5-36
5-37
WM-05042
WM-05043
I
J
17. Install the hose of the turbocharger waste gate valve.
(CB-80 engine only)
18. Install the fuel pipe.
19.
lnstall the heater hose.
20. Install the brake booster hose.
Fig.
5-38
WM-05045
Page 80
ENGINE MECHANICALS
21.
Connect the accelerator cable.
22.
Connect the clutch cable.
NOTE:
Apply
lever is attached to the clutch cable.
23.
Connect the speedometer cable.
MP
grease to the point where the clutch release
I
Fig.
I
5-39
WM-C~O~~
J
1
24.
lnstall the air cleaner assembly.
25.
lnstall the blow-by hose. (CB-61 engine only)
26.
lnstall the radiator.
27.
lnstall the intercooler assembly.
28.
lnstall the battery carrier stay.
29.
lnstall the positive @ terminal
a
30. lnstall the negative
terminal of the battery.
31. lnstall the hold-down clamp of
32.
lnstall the engine hood.
of
the battery.
:he battery.
NOTE:
Apply rust preventive oil to the bolt tightening sections.
(Reference)
Rust Preventive Oil
3M
make
Rust Fighter-I (Aerosol Type)
L
Fig.
--_
Fig.
5.40
5-41
Eng~ne
hood
=-=3
'NM-~5047
WM-05048
I
33.
Fill ;he engine oil.
API Classification:
Lubrication oil capacity:
Classification: API
CB23
SC-SF
CB61 and
2.7
SC,
SD, SE or SF
CB80 SD-SF
liter
I
Fig.
Fig.
5-42
5-43
,-
Correct
I
level
oil.,
I
m~~~~-~5~c9
I
WM-05050
1
Page 81
Fill the radiator tank and reserve tank with cooling water.
NOTE:
@)
After completion of the operation, make sure that no
leakage exists.
@
Put the coolant,
as
required.
ENGINE
MECHANICALS
Amount of coolant (When undiluted coolant with
-
10or !
-
20°C
Atmosphere temperature iconsentration
i
,
Petrol engine
;
I
1
1
i
1
CB-23
Petrol iurbo engine (Type CB-61 engine)
Petrol turbo engine (Type CB-80 engine)
(West German, Australian and Swiss specifications only)
Page 86
ENGINE
MECHANICALS
Install the turbocharger oil inlet. (CB-61 engine only)
9.
lnstall the exhaust manifold heat insulator No.1.
10.
Install the intake manifold-to-cylinc'er
he&
gasket.
11. lnstall the intake manifold.
1
.O
-
1.6
kg-m
Tightening Torque:
(7 - 12
NOTE:
This gasket is a nonreusable part.
ft-lb)
Ins:all the
EGR
pipe. (Swiss specifications only)
lnstall the carburetor assembly.
lnstall the fuel pump assembly. (On Type CB-61 engine,
install the bracket.)
NOTE:
This gasket is a nonreusable part.
lnstall the hoses.
NOTE:
Be sure to install the hoses correctly in accordance with
the tags
pl;t during the removal.
16. lnstall the intake pipe. (CB-61 engine only)
17. lnstall
the surge tank assembly. (CB-61 engine only)
I
Fig.
1
Fig.
5-62
5-63
I
WM-05~72
1
Fig.
5-64
wM-05073
Page 87
ENGINE MECHANICALS
3-80
ENGINE
COMPONENTS
I
OF
INTAKE AND EXHAUST SYSTEM
0
--a
0
'-1
@
@
0
Hoses
@
Throttle body
@
Fuel pipe (Cold start injector)
8
Air
surge tank
@
Fuel delivery pipe
@
Fuel cellvery pipe insulator
a
Fuel injector Ay
@
Intake man~fold
@
Intake man~fold-to-cyl~nder heaa gasket
@
Turbocharger or1 inlet plpe SIA
@
Exhaust man~fold case
@
Turbocharger-to-exhaust manifold gasket
@
Turbocharger oil outlet
@
Turbocharger Ay
@
Turbocharger-to-exhaust manlfold gasket
9
Exhaust man~fold
,Q
Exhaust man~fold-to-cyllnder head gasket
Ay
ppe
S/A
I
Fig.
5-65
(1
T
:
Tightening torque
Unit: kg-m
*
:
Non-reusable part
WM-05074
Page 88
ENGINE MECHANICALS
--
REMOVAL
1.
Remove the hoses.
NOTE:
When removing the vacuum hoses, put a tag on each
removed hose so that the hoses may be installed correctly
in the original position.
2.
Remove the surge tank cover.
3.
Remove the fuel pipe for cold start injector use.
NOTE:
When removing the pipe, the fuel will be discharged.
a
Hence, be sure to get
cloth ready to receive the fuel.
4.
Remove the throttle body
5.
Remove the air surge tank assembly.
6.
Remove ihe fuel delivery pipe.
7.
Remove the fuel delivery pipe insulator
8.
Remove the intake manifold
I
Fig.
5-68
L
Fig.
5-69 WM-05078
WM-0.5077
I
3
I
1
Fig.
5-70
wM-05079
I
Page 89
Remove the turbocharger oil inlet pipe subassembly.
10. Remove the exhaust manifold case.
11.
Remove the turbocharger oil outlet pipe subassembly.
ENGINE MECHANICALS
12.
Remove the turbocharger assembly.
NOTE:
For the handling instructions on the removed turbocharger
assembly, see page 9-3.
13. Remove the exhaust manifold.
Semove the exhaust manifold-to-cylinder head gasket.
Fia.
5-72
'NM-0508i
I
INSPECTION
1.
Check the surge tank and cylinder head attaching surfaces of the intake manifold for distortion. Measure the
distortion on the diagonal lines.
Allowable Limit: 0.1 mm (0.0039 inch)
If the distortion exceeds the allowable limit, correct the
surface by grinding it. However, this grinding amount
should be limited to 0.3 mm (0.012 inch).
5-21
I
Fig.
Fig.
5-74
5-75
'NM-Ci5C83
wM-05OW
Page 90
ENGINE MECHANICALS
2.
Check the turbocharger. (See the section under "Turbocharger Check" (page 9-4).)
INSTALLATION
1.
lnstall the exhaust manifold-to-cylinder head gasket.
NOTE:
When installing a new gasket, install it with the projected
section facing toward the manifold side.
2.
lnstall the exhaust manifold.
4.0
-
5.0
Tightening Torque:
kg-m (29
-
36
ft-lb)
r
.Z
I
3.
lnstall the turbocharger assembly.
NOTE:
For handling instructions on the turbocharger assembly
prior to its assembly, see page
Tightening Torque:
4.
lnstall the turbocharger oil outlet pipe subassembly
2.5
9-3.
-
3.3
kg-m (18 - 24 ft-lb)
5.
lnstall the exhacst manifold case.
-
3.3
Tightening Torque: 2.5
6.
lnstall the turbocharger oil inlet pipe subassembly.
kg-m (18 - 24 ft-lb)
I
Fig.
5-79
I
WM-05089
Page 91
lnstall the intake manifold.
Tightening Torque:
NOTE:
The gasket
8.
lnstall the fuel delivery pipe insulator.
9.
lnstall the fuel injector.
is a nonreusable
1.7
-
2.5 kg-m
part.
(1
2
-
18
ft-lb)
ENGINE
Fig.
5-80 WM-05090
MECHANICALS
10.
lnstall the fuel delivery pipe.
11.
lnstall the air surge tank assembly.
Tightening Torque: 3.5
12.
lnstall the throttle body.
lnstall the fuel pipe (for cold start injector use)
14.
lnstall the hoses.
NOTE:
Be
sure to install the hoses correctly according to the tags
which were put during the removal.
-
4.5
kg-m (25 - 32
ft-lb)
Fig.
5-82
VTVh.
Sc
GJ.$Y
V~M-05~93
I
Fig.
5-83
9
wM-05094
I
Page 92
ENGINE MECHANICALS
TIMING BELT
CB-23 AND
COMPONENTS
CB-61
ENGINES
OF
TIMING BELT
Page 93
EMOVAL
I
.
Remove the V-belt.
2.
Remove the water pump ?ulley.
3.
Remove the crankshaft pulley.
When slackening the attaching
pulley, use the following
turning.
SST:
0921
0-87701
SST
-000
ENGINE MECHANICALS
bolt oi the crankshaft
to prevent the ring gear from
4.
Remove the timing belt upper cover.
5.
Remove the timing belt lower csver.
6.
Remove the crankshaft timing belt pulley flange.
7.
Remove the timing beit tensioner subassembly.
When removing
the piston
',he timing belt tensioner subassembly, set
No.1 to the top dead center under the compression stroke.
(Before removing the timing
belt tensioner. align the
punch marks of the crankshaft and camshaft timing belt
pulleys with the indicators,
respec~ively.)
NOTE:
After the timing belt tensioner has. been removed, under no
circumstances should the camshaft or the crankshaft be
rotated. If they should be rotated, the piston will interfere
with the valves, resulting in damage to these parts.
I
Fig.
5-85
W\,I-C
J
jO?G
8.
Remove the timing belt.
Pricr
to
the timing belt removal, put a mark which shows
the normal rotating direction at the back surface
liming belt, using chalk or the like.
NOTE:
While removing the timing belt, make sure not to bend the
to
belt sharply
When removing the timing belt, never use
form a small radius.
a
screwdriver or
the like.
9.
Remove the crankshaft timing belt pulley, as follows:
M8
Screw in
bolts. Remove [he crankshaft timing belt
pulley together with the bolts.
of
the
-
Fia.
I
Fig.
5-86
5-87
:EJM-~5097
Mark showing
normal
direction
.
rotating
..
wive,-;sosa
I
1
I
Fig.
5-88
WM-05099
I
Page 94
ENGINE
10.
Remove the camshaft timing belt pulley.
During the timing belt pulley removal, the rotation of the
camshaft can be prevented by inserting a screwdriver
through the opening of the pulley.
MECHANICALS
Fig.
5-89
INSPECTION
1.
Checking of timing belt
Check each section of the timing belt. Replace the belt which exhibits the following damage.
(2)
Cracks at tooth bottom and peeling off and
(1)
Cracks at rubber portion
i
(3)
Wear it canvas and tooth missing
of
back surface
cracks at canvas
I
(4)
Abnormal wear at side surface of belt
I
I
Rubber exposed
\
due
to
wear
Tooth
I I
missing
Core wire exposed
1
I
Replace the belt in the following cases, even if no external damage is observed.
(1)
Case where the timing belt has been continuously exposed to water owing to water leakage of the
water pump, etc.
(2)
Case where the rubber may have swollen because of a large amount of oil stuck on the timing
(3)
Case where most likely excessive force has been applied to the timing belt due to a camsha11
seizure
5-26
bc
WM-05101
Page 95
Checking of timing belt tensioner
Turn the tensioner. Check the bearing for a lock condition
and abnormal noise. Also check the belt contact surface
for damage.
ENGINE
MECHANICALS
I
Fig.
3.
Checking of timing belt pulley
Wear limit
Crankshaft
Camshaft
of
timing belt pulley
timing
timing
belt pulley
belt pulley
I
I
i
59.2
11
9.8
mm
(2.331)
(4.71
7)
(inches)
I
,he wear exceeds the wear limit, replace the timing belt
pully.
Fig.
4.
Checking of crankshaft timing belt pulley flange
Check the crankshaft timing belt pulley flange for deformation or damage.
5-90
5-91
'VIM-05102
WM-05103
1
1
I
Page 96
ENGINE MECHANICALS
INSTALLATION
1.
lnstall the camshaft timing belt pulley.
To prevent the rotation of the camshaft, apply
to the rib section of the cylinder head.
(Be sure not to turn the camshaft while the
pulley is being installed.)
2.
Install the crankshaft timing belt pulley.
3.
Install the timing belt tensioner subassembly.
Temporarily attach the timing belt tensioner.
The setting bolt of the timing belt tensioner should be
backed off about half a turn from the completely tightened
position.
lnstall the tension spring bracket and tension spring.
a metal
timing
rod
belt
-
Fia.
5-92
4.
lnstall the timing belt.
NOTE:
(iJ
Make sure not to bend the belt sharply to form a small radius. Such practice will cut the belt cord.
@
Never permit oils, greases or water to get to the belt.
@
When installing the belt, never try to pry the timing belt with a screwdriver or the like.
@
When turning the engine with the belt installed, the rotation should be made at the crankshaft side.
@
If
the belt is reused, install the belt in such a way that the belt is turned in the same direction as
indicated by the arrow mark which was put at the belt's back surface during the belt removal.
(1)
Ensure that the punch marks of the crankshaft and
camshaft timing belt
indicator marks, respectively.
(2)
Ensure :hat
the belt are aligned with the punch marks of the
camshaft and crankshaft timing belt pulleys, respectively. Also. be
pclleys are aligned with the
two
mating marks at the back surface .of
cenain that the belt is not slackened.
Fig.
5-93
WM-051 C6
WM-Cj;
37
I
I
Fig.
5-94
Line
up
stamped mark with Indicator
WM-05108
I
J
Page 97
3)
Turn the crankshaft two turns in the normal rotating
direction (clockwise), until the piston
tween the point
30"
before the top dead center and the
No.1 comes be-
top dead center.
NOTE:
Never make
a
reverse rotation when turning the crank-
shaft.
(4)
Tighten the
attaching
bolt of the
timing
belt tensioner.
NOTE:
Do not push the tensioner by your finger, etc. during this
operation.
Tightening Torque: 2.0
-
3.0
kg-m
(14
-
22 ft-lb)
Fig.
5-95
ENGINE
MECHANICALS
(5)
Turn the crankshaft, until the piston No.1 comes at the top dead center under the compression
stroke.
(6)
Ensure that the punch marks of the crankshaft and camshaft timing belt pulley are aligned with the
indicators, respectively.
At
th~s time, however, the two mating marks at the back surface of the timing belt are not aligned
with the punch marks,
5.
lnstall the crankshaft timing be!t pulley flange.
The crankshaft timing
resaectiveiy.
beit pulley flange should be in-
stalled only in the correct direction.
6.
lnstall the timing belt iower cover.
7.
lnstall the timing Selt upper cover.
8.
lnstall the crankshaft pulley.
9.
lnstall the water pump pulley.
10.
lnstall the V-belt.
Fig.
5-96
I
Fig.
5-97
I
Corvex sclrface sice
i\
/
7od
LVM-351
',VM-35
nac
io
1
'
1
2
I
5-29
L
Fig.
5-98
tamped
"F"
mark
'NM-05113
Page 98
ENGINE MECHANICALS
CB-80 ENGINE
COMPONENTS OF
TIMING BELT
Timing belt tensioner
@
Timing belt idler
@
Timing belt idler
@
Crankshaft timing belt pulley
@
Timing belt
@
Crankshaft timing belt pulley
Crankshaft timing belt pulley (Intake
SiA
S/A
SIA
No.1
No.2
flange
&
exhaust)
Page 99
1. Remove the V-belt.
2.
Remove the water pump pulley.
3.
Remove the crankshaft pulley.
When removing the attaching bolt of the crankshaft pulley,
SST
use the following
to prevent the ring gear from
turning.
SST:
09201
-87701
-000
ENGINE
MECHANICALS
4. Remove the resistive cord.
5.
Remove the oi! filler cap.
6.
Remove the surge tank cover.
7.
Remove the surge tank bracket.
8. Remove the cylinder head cover.
9.
Remove the timing belt upper cover.
7.
Remove the timing belt lower cover.
,-
I.
Remove the timing belt tensioner subassembly.
'ahen removing the timing belt tensioner subassembly, set
the piston
No.1 to the top dead center under the compression stroke.
(Before removing the timing belt tensioner, align the
punch marks of the crankshaft and camshaft timing belt
pulleys with the indicators, respectively.)
NOTE:
After the timing belt tensioner has been removed, under no
circumstances should the camshaft or the crankshaft
timing belt pulley be rotated. If they should be rotated, the
piston will interfere with the valves, resulting in damage to
these parts.
12.
Remove the timing belt idler subassembly No.1.
". Remove the timing belt idler subassembiy No.2. Remove
it, using a 10 mm hexagon wrench.
Fig. 5-100
I
I
Fig.
5-1
01
WM-05
1
WM-05116
5
I
1
14. Remove :he crankshaft timing belt pulley flange.
15.
Remove the timing belt.
Prior to the timing belt removal, put a mark which shows
the normal rotating direction at the back surface of the
timing belt, using chalk or the like.
NOTE:
@ While removing the timing belt, make sure not to bend
a
the belt sharply to form
a screwdriver or the like.
use
@
Never allow oils and water to get to the timing belt.
small radius. Moreover, never
I'
Fig. 5-102
I
Fig. 5-103
WM-05i
WM-05:
:
18
I
7
I
1
Page 100
ENGINE
16.
Remove the crankshaft timing belt pulley, as follows:
Screw in
MECHANICALS
M6
bolts. Remove the crankshaft timing belt
pulley together with the bolts.
17.
Remove the camshaft timing belt pulley (intake & exhaust).
When removing the attaching bolt of the camshaft timing
23
by
mm)
belt pulley, prevent the rotation of the camshaft
the hexagonal section (width across flats:
cylinder
No.1 with a spanner or the like.
holding
of the
L
Fig.
I
Fig.
5-104
5-105
WM-05;
WM-05120
I
i
9
1
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