Daihatsu CB23-CB60-61-CB70-80 Engine Manual Daihatsu CB23-CB60-61-CB70-80 Engine Manual

DAIHATSU

MOTOR COgr

NO.9173-GE

LTD.

FOREWORD

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

SECTION

INDEX

NAME

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

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

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

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

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

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

.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

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

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

"ump ;ype

Oil

I

Oil filter

L~ori-

-mng

System

Super charger type

,edish and Norwegian specificat~ons.

type

Lubrrcaaon oil
capacity

Oil

cooler type

mrn (inch)

1

mole

1

When

I

1

When oil and oil filter are changed

kw/rpm

I

kw!rpm

I

j

Nmirpm

Nmirpm

General

specifica:ions
Australian

specifica:ions
ECE & EEC

soec~ficamns

1

specifications

Australian

1

specifications

1

ECE

1

specifications

I

!

Open

1

close
Ooen
Close
Intake
Exhaust

I

Manual !ransrnission

rpm

Automaric
transmission

is

cha,,sed

Engine type

&

EEC

kg

CB-23 CB-61

Petrol, 4-cycle

Front Front

3-cy~incer-ln-line. mounted transve!se!y 3cybr.de,-l~-i~ne, mccnted transverselv

Multi-spnere type

Belt-driven overhead camshaft aelt-driven overhead camshaf:

'

76 x 73 (2.99 x 2.87)

I

38!5.600 5015.500

38:5.600

,

,

i

1

(lb)

I

(

Fsll-flow filter type.filter paper tyae Full-flow filter type, filter paDer ;ype 'i~ull-flow filter type. filter paper type

Wateracled

315.600

75.5:3.200

75.5i3.200

75.5i3.200

566 x 530 x 636

(22.28

x

20.87 x 25.04)

92 (202.9)

2 2 2
1

:S0BTDC
5l0ABDC
5l0BBDC

19"ATDC

[Hot] 0.20 (0.0079)
[Hot] 0.20 (0.0079)

800

i

50 (-1000 ? 50)

850

F

50 ('1000 k 50)

Closed type

Fully-forced feed

Trochoid type Trochoid vpe Trochoid type

ty3e

method

3.2 3.2

2

7

3.0

(only

for trcplcal spec.j! Water-cooled type

-

!

i

i

I

i

1

1

1

I

I

!

I

1

I

I

/

1

1

i

I

i

1

I

'etrol, 4-cycle

3-cylinder-in-Ice,

Multi-sphere

76 x 73 (2.99 x 2.87) 76 x 73 (2.99 x 2.87)

72.0 - 350 (170.7 - 350) 10

8.0

type

i

I

I

!

50i5.5CO

5015.500

106:3,200

1 C613.200

106i3.500

x

52C x 632

563

x

(22.17

20.47 x 24.88)

96 (212)

1

:

1 "BTDC
4g0ABDC
49"SBDC

1 1 "ATDC

[Hot] 0.25 (0.0098)

0.25

[Hot]

800 + 50 ('1000 + 50)

(0.0098)

j

j

I

i

i

I

I

1

1

(22.68 x 22.56 x 24.57)

I

I

!

1

I

j

!

I

-

Closed type

Fully-forced feed rnerhod

2.7

3.0

1

!

Fully-forced feed method

I

I

I

j

i

.I

/

Turbocharger Turbocharger

CB-80

Pe!ro:. 4-cycle

Front

mclinted trarsversely

?en: roct type

Belt-driven (D3t!C)

7.8

5 - 200 (7A9.3 - 300)

74'6,500

-

74:6,500

i

3013.560

-

1301?,.500

576 x 573 x 624

105 (233.7)

1

23"BTCC
5l0ABDC
49"BBDC

1 PATCC
[Hot] 0.27 (0.0101)
[Hot] 0.32 (0.0126)

950 50

-

Closed type

3.3

2.7

3.1

Water-cooled type

-

GENERAL

INFORMATION

Item

Cooling method

!

Radiator type

I

Cooling
System j Coolant capacity

Air Filter paper type
cleaner

Fuel

Ewne
elecricai

sys:em

'Plunger stroke: 0.87

1

:Iter

I

!

i

Water ~ump type

j

Thermostat :ype

Type -,.ter pacer type Ftiter aaper vpe

:

/

Numoer 1 1 1

I

Fcei tank I

F-el plpe mater:al Rubber ano steel tuce
Fuel pump type

I

1

Fuel filter type

1

1

Carburetor

Fuel injection oevice

Injection

pump

!

i

Inlection
nozzle or ' Nozzle type

,

Injector

i

I

i

1

ignition
System

1

Capaclty Llter I 40 40
Location

Manufac:urer Aisan kogyo
Type
Throttle vaive
Venturi diameter mm (inch)
Choke vaive type

Type

injection

Piunger diameter mm (incl)
Cam lift mm (inch)
Type of self-aiigner

I

Type of inlectlon t:ming regula:ing

/

cevice

/

Type cf nozz!e retainer

disme?er

timing

:

I

1njec:ion pressure

'

'Joltage

'

Type Battery ignit~on type

I

1

Ipnit~on timing STDC 5'42911cling

'

Firing c?rc'er

Ds:nbutcr type Convenrional ?joe

;

I

CEr~bl;:or I

5

O.C3

Breaker type Contacr-po~nt type

)

PeCmucecl

!

i:mlng atiacc:ng

'

mecnac~m ! Vacuum type

mrn (0.035 i 0.0012 inch)

Engine type

-1

I

~lanual

!

:ransm~ssion
Autcmatic

1

transmission

mm (inchj

kg;cm2 (Psi)

/

Cectnfcga,

(26-23 ca-6: ca-80

]

Water cooled, e!ectromotor type / Water coo!ed. elec:romotor type Water cooled, elec:romotor

1

Corxgatan

,

[Including 0.6 for reserve tank] , [Including 0 6 for reserve tank] , [Including

!

1

[Inc!uding 0.6 for reserve tank]

/

Centrii~gal

1

1

I

I

Moun:ed underneath rear seat flwr / Mounted urderneath rear seat :loor . Mounted uncernea:h rear seat floor

I

/

1

I

I

Manual

I

!

/

qp

tcrced circulation ; iarmgatlcr type forced c!rculatbn

3.5 3.9 4.0

3.9

ty-.

"V

belt-ciiver: type . Cenlrlfugai

Wax

pellet type

-.

A

-

3

1

Diaphra~rn type

~aper type

Filter

Two-barrel type

28 (1 .lo), 32

18 (0.71). 25 (0.98)

Vpe.

(I

.26)

butterfly-shaped vake

-

-

-

-

1

-

-

!

-

!

i

J

I

yw

0°;750 rpm. 10.5":2.800 rpm

0":-100 mmHg. 1l0!-320 rnmhg

-

-

12 [Negative ground]

:

-2-3

i

I

!

Corm~atlon type forced circulat~on

I

I

:

I

Manual type, butterfty-shaped valve

!

1

!

I

i

/

!

/

O0ff5o rpm. 13.Y13.000 rprn

00:-60 mm~s, 10°/-450 mmHg

- -

:vpe.

'V'

be!t-dr~ven type

Wax

pelle: type

Sieei tube Steel tube

E1ec;rcmotor type E!ectromc:or type

Fiiter paper type

Aisan kcgyo

Two-aarrei type

28 (1.10). 32 j1.26)

18(0.1,28110

Centrifugal type.

I

!

I

!

I

I

-

-

-

-

-

-

-

I

1

I

1

With cushion rubber type

/

E!ec:ronic controlled throttle type

-

12 [hegative ground]

Ba~ery ignition type

9T3C 1O042"Idling

1-2-3 1-2-3
Conventional type
Contact-polnt type

j

12V [Negative grounc]

{

I

Full-trans~storized type

Elec:ron~c tlmlng aovarce
Eiectronic timing advance

0.6

for reserve tank]

"V"

belt-criven type

Wax

pellet type

Fiiter paper type

-

-

-

-

-

Electronic

type

-

-

-

-

-

-

2.55 (18 4)

Battery ignition type
BTDC 1O0+2":ldling

-

i

type

/

WM-01014

GENERAL

INFORMATION

-

Item

Manufacturer

!

I

Type

Ignition / Spark

1

system / plug

1

i

1

!

!Glow

'

Engine
electr~cal
svstem

"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

.O

!

1

I

3-Pbase

1

I

1

I

1

/

Magnet engaging type

1

1

CS-61

NGK / BOSCH

3~5~

~v~cc(x.?

3KEY

wCC(X.q

;

01-0.a

i

IC.~

-

031

0.7 - 0.8

'

(0.028 - 0.03:

-

-

34Bi 71 "5532CL

55324L
3431 7L

27 (5HP:. "36 (5hR)

alternating

c0mmu:aiing iype

12-45

Contact-pointless type

12-0.8. ''i2-l .O

Resistive cord

current

CHAM?lCN

WYC

N.llYC

/

1

)

,

i

I

3BI

j

j

127 !5hR). "36 (5hR)

I

j

1

,

c-ner:

I

I

1

1

/

1

CB-80

DENS0

W20ETR-L

W20ET-L

M14x1.25

0.9

-

1.0

(0.035 - 0.039)

-

-

7L

"55B24L

55824L

-

36 (5HR),

,

-

3-hase il;e!natlng

csm?dal~g

Vpe

12-50
Cosia-winlea
kgrdt

12-0.8. '312-l.0

Resistive cord

$e

e~qtg

TYPE

CB

SECTION

THE

ENGINE SECTIONAL VIEWS

CB-23
CB-61
CB-80

ENGINE COMPONENTS AND

TIGHTENING TORQUE

CB-23
CB-80

MAIN SERVICE SPECIFICATIONS

ENGINE

..................................................................

.........................................................

.....................

and

CB-61

..............................................................

2

PROPER

...............................

;

.......................................

........................................

...............................................

. .

......................

2- 2
2- 2

2-

2-

2­2­2­2-

10

4

6

8

8

9

THE ENGINE PROPER

ENGINE SECTIONAL VIEWS

Fig.

2-1

I

WM-02002

THE

ENGINE

PROPER

THE

ENGINE

PROPER

THE

ENGINE

PROPER

THE

ENGINE

PROPER

.,.

THE

ENGINE

PROPER

Fig.

2-6

WM-02007

THE

ENGINE

ENGINE

PROPER

COMPONENTS

AND

TIGHTENING

.

TORQUE

CB-23

and

CB-61

i

Fig.

2-7

WM-02008

I

THE ENGINE PROPER

I

Fig.

2-8

Q

FRONT

WM-02009

THE

ENGINE

PROPER

MAIN SERVICE SPECIFICATIONS

Item Speciflea value
Eng:ne type
ialing speea rPm

i

General soecifications

'

-

:;nm)

kg'crn2

(PSI)

?6

2

ECE S EEC
Soec~iications

,

/D'

I

aus::a.tan. Swedish
and SWISS
spec:fications

:

Spec:iied value

,

;

Ailowable :knit

,

cyl~naers

1

Exnaus:

!

Total capacity

3il Dan capac:ty

(F

.evel)

Oil pan capacity

(L

:evel)

Speciied value

Ailowable .init

co

concentration

Corno:ess~on

pressure

k;:crnL.rpm

(psi-rpm) Difference between

'~aive ~lear- ! :nta~e
ance

[I-o:]

mm

iu3r:caI.On oil
caDacrty

Float level mrn (inch)

~~~~~~~~~g

pressure

Raaiator leak check p'essure

1

:

!

i

C3-23 C@-61

'"'T80~ i 50 AT350 r 50

0.5 - 1.5

12 5250 (1 77.8:350)

10.5iJSO

(1

49

4350)

Within

1.5 (21.3)

0.20 (0.0079) 0.25 (0 0098)

0.20 (0.0679)

3.2 3.2

2.7

17

22 (0.87) 22 (0.87)

0.75 - 1.05 0.75 - 1.05

-

14.9)

(10.7

0.6

(8.5)

1.2 (1 7) 1.2 (17) 1.2 (1 7)

I

12.0:350 (1 70.7350)

10.5;350 : 1

I

I

I

'800 C 50

0.5 - 1 5 0.5 - 1 .5

J9

4i350)

Withir

1

5

(21.3)

0.25 iC.0098)

-.

:

:

*.7

(10.7

-

14.9)

0.6 (8.5)

I

C3-80

950

f.

50

i

1

10.5ilOO

(149

3;3CO)

'8.5i3~0 (121i300)

I

LVith~n

1

5 (21.3)

0.27 (0 0101)

0.32 (0.0126)

3.3

2.7

I

1.7

!

-

1

0.75 - 1.05

!

(10.7 - I4.9)

1

06 (8.5)

1

Remarks

'

I

'

i

I

I

Measured from :op

!

suHace of booy

/

1

I

V-belt deflection rnrnlkg (incnilb)

I

Cooling wate-

ca~acity

Anti-treezing
sclution filling
capac::~

Cistcbutor

Spark >lug

Icjnlticn timing

-1000

rpr

I

Total capacity

2

Reserve tank capacity

-

10°C (23%)

/

-20°C

'

i

-3S°C (50%)

1

Owe.; angle
Heel gap rnrn

Manuiacturer

I

:

Except

Spark plug gap

Manual STCC
transrn~ssicn

Automaric
t:ansm~ssion

5C

for cay-light spec:ficaiicn veh~c.es

(35%)

for

ESE d EEC

(AT)

(incn)

mrn [inch)

/

I

:

!

i

i

1

I

0.66 (M;T), 0.76

1 44

SENSO

6lEXR-J

N16i(-l

'

07-oa

:0.028 - 0.03:)

(CB-23

5-7:; 0

(C

20-0.28122.1)

3.5 (3.9)

0.6
(&T)

1 .OO

(Mn),

1.14

(m

(MIT).

1

.M

(&T

58" - 66"

0 4 - 0.5 (9.016 - 0.020)

NGK

2R5EZ.i

1

E%5Y

I

3PiU.L

0153

18-39

C.W13!81

S°F2"

860 5 50

3TCC

5"

850 C 50

and

Ca-6:

:pm

2

-pm
only)

1

#NP;CK"

I

/

2"

57/10

,

[C

1.11 0.75 [0 141

[0.21]

[0.30)]

80Si3

1

Hii2CC

0.7 - 0.8

(0.028 - 0.031)

C-AUPOY

%K::YC

I

1

0.4 - 0.5 (0.016 - 0.020)

/

CihSC

f,x3fi.,

wlrwu

[

GE{."

j

jilE.

G.!.13

l!F<

hGX

j

3X6i.:

j

PIE

pL~

/

9.23

/

tC22

3TDC

800 r 50

(0.20-0.28:221)

3.9

0.6

1.14 [0.21]

1.64 [0.30]
58" - 66"

1

BOSCH 1 CUUPON

'?i27ZC

\,vecc

lx:?

i

l,-,.-.-IX

j

.3.E1

0.7 - 0.8

i

(0.028 - 0.031)

10°12"

rpm

-

/i.ja.a

1

/

!

I

/

j

YIC

,+..c

(0.%3.33,?7.6)

4.0

0.6

0.77 [0.14]

1.14 [0.21]
1

68

[0.30]

-

-

DEKSO

L'f2?E.L

0.9 - 1

BTDC

.O

10"

rpm

(0.035 - 0.039)

950 i 50

,

Including

/

reserve tank

0.6

/

~lilng amoun

1'

IF

'

for reserve tank

:

I

1

!

WM-020-

for

TYPE

CB

ENGINE

SECTION

ENGINE

ENGINE TUNE-UP PROCEDURE

ENGINE TUNE-UP [CB-23
ENGINE TUNE-UP [CB-801

3

TUNE-UP

and

CB-611

...................................

........................

................

3-

3-

3-1

2

6
9

ENGINE

TUNE-UP

ENGINE TUNE-UP PROCEDURE

NOTE:

The operation enclosed

by

heavy lines is described in the main text.

r

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

,

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

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

.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

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

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)

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

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.

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

(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

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).

(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

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

@

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

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

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

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

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.

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

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

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%

@

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

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

@

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

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

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

&

[CB-23

CYLINDER HEAD GASKET

[CB-23 & CB-61 ENGINES]

CYLINDER HEAD GASKET [CB-80 ENGINE]

INJECTOR [CB-80 ENGINE]

OIL PUMP

CB-61 ENGINES]

..............................................................

...........................

...................................

.............

.............................

...............................

...............................

................................

...

.....

4-

2

4-

2

4-

7

4- 8
4-

9

4-10
4-1

1

4-12
4-12
4-13

IN-VEHICLE SERVICE

INSTRUCTIONS ON SERVICE OPERATIONS

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

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

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

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

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

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

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-

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

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

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

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.

/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

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

+

TYPE

CB

ENGINE

SECTION

5

ENGINE MECHANICALS

REMOVAL AND INSTALLATION OF ENGINE
INTAKE AND EXHAUST SYSTEM

CB-23 AND CB-61 ENGINES

.........

CB-80 ENGINE

TIMING BELT 5-24

CB-23 AND CB-61 ENGINES

CB-80 ENGINE

CYLINDER HEAD

CB-23

CB-80 ENGINE

CYLINDER BLOCK

AND

.......................................................

CB-61 ENGINES

.........................................

;

.....................................................

.................................................

....................................................

..............................................

.......................

...............................

...............................

...............................

...

5­5-14
5-14
5-19

5-24
5-30
5-39
5-39

5-55

5-69

2

ENGINE

MECHANICALS

REMOVAL AND INSTALLATION

OF

ENGINE

REMOVAL

1.

Drain the engine oil and cooling water.

Oil

aralr

I

Fig.

5-1

2.

Remove the engine hood.

NOTE:

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

,

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.

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

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

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

.

.

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

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

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

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

. 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

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

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)

Diesel engine (Type CL-11 engine)

Petrol engine

Manual transmission

i

Autorr,atic

/

Manual transmission

transmisson

(Type CB-23 engine) 1 Automatic transmission

I

Petrol turbo engine (Type CB-61 engine)

I

Petrol turbo engine (Type 03-80 engine)

I

Diesel engine (Type CL-11 engine)

I

/

Diesel turbo engine (Type CL-61 engine)

I

!

j

I

1

i

'

98%

concentration

23%

35%

I

Fig.

5-44

I

1

Radiator (litre)

j

I

I

!

I

I

I

1

i

I

i

is

0.66

used:)

I

Reserve tank (litre)

[Wit? heater]

0.1 4

0.75 0.14

0.75 0.1

0.77

0.82

0.85 Diesel turbo engine (Type CL-61 engine)
1 .OO

1.14

1.14

1.17

1.25

j

1

I

I

i

I

0.1

0.14

0.14

0.21

0.21

0.21

0.21

0.21

1.29 0.21

4
4

WM-0505

I

1

-35°C

:

Petrol engine

Manual

tra~srnission

(Type CB-23 engine) Automatic transmission
Petrol turbo engine (Type CB-61 engine)

/

i

Petrol turbo engine (Type CB-80 engine)
Diesel engine (Type CL-11 engine)

!

Diesel turbo engine (Type CL-61 engine)

I

1

1

I

1

50%

1.44

!

I

i

I

1.64

1.64

1.68

1.79

i

i

I

!

0.30

0.30

0.30

0.30

0.30

1.84 0.30

ENGINE MECHANICALS

INTAKE

CB-23

AND

AND

EXHAUST

CB-61 ENGINES

SYSTEM

COMPONENTS OF INTAKE AND EXHAUST

SYSTEM

@

(CB-23 engine only)

c

@

Hoses

@

Fuel pump (CB-23 engine only)

@

Carburetor Ay

@

EGR pipe (Specific area only)

@

Intake manifold Ay

@

Intake manifold-to-cylinder head gasket

a

Exhaust manifold heat insulator No.1

@

Turbocharger oil inlet (CB-61 engine only)

@

Air suction pipe (Specific area only)

@

Exhaust manifold case (CB-61 engine only)

0

Turbocharger-to-exhaust manifold gasket (CB-61 engine only)

0

Turbocharger oil outlet pipe

@

Turbocharger Ay (CB-61 engine only)

@

Turbocharger-to-exhaust manifold gasket (CB-61 engine only)

@

Exhaust manifold Ay

@

Exhaust manifold-to-cylinder head gasket

S/A

(CB-61 engine only)

Fig.

5-45

T

:

Tightening torque

Unit:

kg-m

*

:

Non-reusable

part

1

WM-05053

ENGINE

MECHANICALS

EMOVAL

1.

Remove the surge tank assembly.

2.

Remove the intake pipe.

NOTE:

After the intake pipe has been removed, plug the opening
with adhesive tape so that no dust, etc. may get into the

turbocharger turbine.

3.

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.

4.

Remove the carburetor assembly.

5.

Remove the fuel pump assembly. (On Type
remove the bracket.)

(CB-61

(CB-61

engine only)

engine only)

CB-61

engine,

I

Fig.

I

Fia.

5-46

5-47

0

WM-350:

WM-05055

1

6.

Remove the

-

Remove the intake manifold assembly.

8.

Remove the exhaust manifcld heat insulator

9.

Remove the turbocharger oil inlet.

10.

Remove the air suction pipe. (West German, Australian

and Swiss specifications only)

EGR

pipe. (Swiss specifications only)

(CB-61

No.

1.

engine only)

ENGINE

MECHANICALS

Remove the exhaust manifold case. (CB-61 engine only)

Remove the
(CB-61

ttirbocharger oii outlet pipe siibassembly.

engine only)

Remove the turbocharger assembly. (CB-61 engine only)

NOTE:

For the handling instructions on the removed turbocharger
assembly, see page

9-3.

14. Remove the exhaust manifold.

15.

Remove the exhaust manifold-to-cylinder head gasket.

Fia.

5-53

WM-O5Mi

INSPECTION

1. Check the cylinder head attaching surface of the intake
manifold for distortion.
diagonal iines.

Allowable Limit (both intake and exhaust manifolds):

0.1

mm

(0.0039

If

the distortion exceeds the allowable limit, correct the

surface

by

grinding it. However, this grinding amount

should be limited to

Meas~re the distotion on the

inch)

0.3

mm (0.012 inch).

5-16

I

Fig.

5-55

.w~-05063

1

ENGINE MECHANICALS

Check the

3.

Check the BVSV and TVSV. (See the section under "Exhaust Emission Control System" (page 12-23).)

4. Check the turbocharger. (See the section under "Turbocharger Check" (page

EGR

valve. (See the section under "Exhaust Emission Control System'' (page 12-28).)

9-4))

5. Check the carburetor. (See the section under "Carburetor Check" (page 6-5).)

INSTALLATION

1.

lnstall the exhaust manifold-to-cylinder head gasket.

2.

lnstall the exhaust manifold.

Tightening Torque:

3.

lnstall the turbocharger-to-exhaust manifold gasket.
(CB-61 engine only)
NOTE:

This gasket is a nonreusable part.

1.0 - 1.6

kg-m

(7

-

12 ft-lb)

WMd5064

4. lnstall the turbocharger assembly. (CB-61 engine only)
NOTE:
For the handling instructions on the turbocharger assem­bly, see page

Tightening Torque:

5.

lnstall the turbocharger oil outlet pipe subassembly.

9-3.

2.5 - 3.3

kg-m

(18

-

24

ft-lb)

1

Fia.

5-57

.

.

WM-05066

6. lnstall the exhaust manifold case. (CB-61 engine only)
Tightening Torque:

7.

lnstall the air suction pipe.

3.0

-

4.0

kg-m

(22

-

29

ft-lb)

(West German, Australian and Swiss specifications only)

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

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

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

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

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

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

ENGINE MECHANICALS

TIMING BELT

CB-23 AND
COMPONENTS

CB-61

ENGINES

OF

TIMING BELT

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

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

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

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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

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Fig.

5-94

Line

up

stamped mark with Indicator

WM-05108

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J

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

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)

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

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Fig.

5-1

01

WM-05

1

WM-05116

5

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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

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7

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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

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