Daihatsu CB Series Manual Download

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Summary of Contents for CB Series

Page 1: ...DAIHATSU MOTOR COgr LTD NO 9173 GE WWW PlanDeGraissage Org...

Page 2: ...WWW PlanDeGraissage Org...

Page 3: ...dure and servicing method of the Type CB 23 CB 61 and CB 80 engines which are mounted on the DAIHATSU CHARADE The contents and specifications in this manual may be partly revised without advance notic...

Page 4: ...WWW PlanDeGraissage Org...

Page 5: ...SECTION INDEX NAME WWW PlanDeGraissage Org...

Page 6: ...WWW PlanDeGraissage Org...

Page 7: ...TIONS 1 3 JACKING POINTS AND SUPPORTING POINTS OF SAFETY STANDS 1 5 SUPPORTING POINTS OF TWO POST LIFT 1 5 LOCATION OF ENGINE TYPE AND ENGINE NUMBER 1 6 ENGINE TYPE EMBOSSED POSITION 1 6 ENGINE NUMBER...

Page 8: ...e like is required the arrangement is made as follows Removal Procedure 3 With regard to the tightening torque specifications they are indicated in the Engine Components and Tightening Torque under SE...

Page 9: ...hibits 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...

Page 10: ...e temperature of the engine oil reaches at least 65 C 149 F These temperatures can be judged by observing a point where the cooling fan motor ceases its rotation NOTE When the idle speed is checked on...

Page 11: ...pporting point of garage jack Supporting point of safety stand Supporting points of safety stands Four supporting points are located at the right and left sides The supporting points have been strengt...

Page 12: ...block ENGINE NUMBER STAMPED POSITION 1 CB 23 and CB 61 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...

Page 13: ...d Center INtake Exhaust PR IPry Rating Society of the stroke Refers to intake system Refers to Exhaust system Representsstrengtfi of tires The larger the pry rating number the stronger the tire streng...

Page 14: ...of the exhaust emission control system are described in this manual in their abbreviated forms Abbreviat on Component name 1 BVSV B rnetal Vacuum Switching Valve 2 I C O Cho e opener 3 DP Dashrsot 4...

Page 15: ...87 x 25 04 92 202 9 50i5 5CO j j EEC EEC IN ECE EEC I I soec ficamns 315 600 I 5015 500 i 74 6 500 of 1 piston rings j 1 Valve timing j Nmirpm Australian 75 5i3 200 1specifications 1 ECE EEC i Nmirpm...

Page 16: ...r paper type Fiiter paper type Aisan kcgyo I Two aarrei type 28 1 10 32 j1 26 I 1 8 0 1 2 8 1 1 0 I Manufac urer Aisan kogyo Type I Two barrel type Throttle vaive disme er mm inchj 28 1 lo 32 I 26 Ven...

Page 17: ...Engine electr cal svstem Ba tery Tyoe I Voi age curent A i General speciiications 348 7L 55824L 1 34Bi71 5532CL I 3 B I 7L 55B24L Type ECE3 E E Cspec caims 55B24L 55324L j 55824L I Australian saec fic...

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Page 19: ...CTION 2 THE ENGINE PROPER ENGINESECTIONAL VIEWS 2 2 CB 23 2 2 CB 61 2 4 CB 80 2 6 ENGINE COMPONENTSAND TIGHTENINGTORQUE 2 8 CB 23 and CB 61 2 8 CB 80 2 9 MAINSERVICE SPECIFICATIONS 2 10 WWW PlanDeGrai...

Page 20: ...THE ENGINE PROPER ENGINE SECTIONAL VIEWS I Fig 2 1 WM 02002 WWW PlanDeGraissage Org...

Page 21: ...THE ENGINE PROPER WWW PlanDeGraissage Org...

Page 22: ...THE ENGINE PROPER WWW PlanDeGraissage Org...

Page 23: ...THE ENGINE PROPER WWW PlanDeGraissage Org...

Page 24: ...THE ENGINE PROPER WWW PlanDeGraissage Org...

Page 25: ...THE ENGINE PROPER Fig 2 6 WM 02007 WWW PlanDeGraissage Org...

Page 26: ...THE ENGINE PROPER ENGINE COMPONENTS AND TIGHTENING TORQUE CB 23 and CB 61 i I Fig 2 7 WM 02008 WWW PlanDeGraissage Org...

Page 27: ...THE ENGINE PROPER Q FRONT I F i g 2 8 WM 02009 WWW PlanDeGraissage Org...

Page 28: ...n2 Speciied value Ailowable init PSI 0 6 8 5 0 6 8 5 1 0 6 8 5 1I Raaiator leak check p essure 1 2 17 1 2 17 1 2 17 V belt deflection rnrnlkg incnilb 5 7 0 C 20 0 28122 1 Cooling wate I Total capacity...

Page 29: ...TYPECB ENGINE SECTION 3 ENGINE TUNE UP ENGINETUNE UP PROCEDURE 3 2 ENGINETUNE UP CB 23 and CB 611 3 6 ENGINE TUNE UP CB 801 3 1 9 WWW PlanDeGraissage Org...

Page 30: ...l and specific gravity Specified value Battery electrolyte specific gravity at electrolyte temperature of 20 C 1 27 to 1 29 34B 17L NOTE The vehicles mounted with a maintenance free battery should be...

Page 31: ...1 7 7 Checking ylinder head and manifolds for ka rn ft lb Specified value Cylinder head tightening torque Manifold tightening tightening condition toraue Exhaust rnan foid 1 0 1 6 1 0 1 6 4 0 5 0 tlg...

Page 32: ...i 0 4 0 5 gap mm inch 0 016 0 020 0 016 0 020 Dwell angle 1 58 66 j 58 66 I Checking and adjusting ignition timing Specified value CB 61 CE 80 Ignitiontiming BiDC Y Til lingBTDC 10 2 ndlin 3TDC 10 kZI...

Page 33: ...ecifications be sure to cut off the EGR operation NOTE Pull the choke button out as far as it wiil go and depress the accelerator pedal once or twice f Checking and adjusting dashpot Specified speed r...

Page 34: ...1 are sensed the reading can be read directly regardless of the number of cylinders 2 The power supply for the tachometer timing light and other instruments should be connected to the battery terminal...

Page 35: ...ater 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...

Page 36: ...anufac urer DEhSO 1 NGA 63SCH CHAMPICN CENSO NGK BOSCri CYAMPION ECE EEC WI6EXR U BPR5EY WR8DC RN 9YC W I 6 E X i l bii5E A l i R E v CR8DC 1Y C 2 0 E X C 1 ipRiEv ilR7DC RN YC spec rlcations W46EX U...

Page 37: ...spectively 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 3 5 0 r p m NOTE The compression pressure...

Page 38: ...m Daylight system equipped vehicle BTDC 5 f 2 1 000 4 50 rpm NOTE Upon completion of the ignition timing check be certain to install the clutch housing cover on the inspectionwindow 10 Adjustment 1 Th...

Page 39: ...n nected hose Acce erate the engine repeatedly Using 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...

Page 40: ...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 t...

Page 41: ...justing screw until the engine runs at 850 rpm Specified Idling Speed 850 50 rpm For Day Light Relay equippedvehicle 1000 50 rpm NOTE On those engines for ECE EEC Australian GCC and Singapore specific...

Page 42: ...ot conform to the specified value perform the icfle adjust ment described below Fia 3 17 WM 0x34 5 ldle limit cap installation lnstali the idle limit cap in the original position This applies to those...

Page 43: ...on pipe and the sampling pipe using heat resistant tape or the like If the idling speed dose not conform to the specified value adjust the idle speed by the throttle adjusting screw At this time if th...

Page 44: ...t idie speed Check 1 Warm up the engine Temperature of coolant 75 85 C 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 engi...

Page 45: ...k 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 re...

Page 46: ...this simple checking method of valve timing Timing mark Check mark Checking Procedure 1 Turn the crankshaft until the ignition mark on the flywheel is aligned with the ignition mark of the No 1 cylin...

Page 47: ...e sensed the reading can be read directly regardless of the number of cylinders 2 The power supply for the tachometer timing light and other instruments should be connected to the battery terminal 3 N...

Page 48: ...ecified 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 I...

Page 49: ...d Deflection of V Belt 7 5 8 5 0 3 0 35 inch With a force of 8 kg 18 Ib Applied Checking valve clearances 1 Warm up the engine Cooling water temperature 75 85 C 167 185 F 2 Check the valve clearances...

Page 50: ...aging the valves and piston Set the cut out section of each lifter to a position indicated in ihe figure SST 09248 87703 000 Insert the SST into between the camshaft and the valve lifter as shown in t...

Page 51: ...nosis code If any abnormality is detected perform the trouble shooting See the Troubie Shooting for Type CB 80 Engine Control System 3 Adjust the idle speed to 950250 rpm by means of the idle adjustin...

Page 52: ...idle speed adjustment i J 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...

Page 53: ...e 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...

Page 54: ...sting procedure above Connect the hose djus irg screw L I Fig 3 55 WM 93080 3 Dashpot function check a Keep the engine revcluticr speed at 3000 rpm for a short period of time Then release the throttle...

Page 55: ...T WATER PUMP 4 2 CRANKSHAFTOIL SEAL 4 7 CAMSHAFT CB 23 CB 61 ENGINES 4 8 CAMSHAFT CB 80 ENGINE 4 9 CAMSHAFT OIL SEAL CB 23 CB 61 ENGINES 4 10 CYLINDER HEAD GASKET CB 23 CB 61 ENGINES 4 1 1 CYLINDER HE...

Page 56: ...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 wate...

Page 57: ...to get to the belt for such matter would shorten the life of the belt Mark showing normal rotating direction I I Fig 4 5 WM 04007 _ Remove the water pump WM 34008 INSTALLATION 1 Install the water pum...

Page 58: ...lt never try to pry the 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...

Page 59: ...rks of the timing belt pulleys are aligned with the matins marks on the belt respec tively 4 Slacken the attaching Sclts of the tensioner which were tightened tern3orariiy in the previous step En sure...

Page 60: ...gine only 8 lnstall the intake oipe CB 67 engine only 9 lnstall the surge tank CB 61 engine only 10 lnstall the timing belt lower cover 11 lnstall the timing belt upper cover NM 04020 10 Align the ign...

Page 61: ...threaded holes provided in the side of the pulley 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 S...

Page 62: ...ection under Removal of Timing Belt Water Pump 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...

Page 63: ...stall each camshaft Searing cap as indicared in the right figure according to the embossed number and arrow at the back side of the camshaft bearing cars Tightening Torque 1 15 1 45 kg m 8 3 10 5 ft l...

Page 64: ...in the section under Removal of timing belt water 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...

Page 65: ...Pump As for the contents of these operations see the section under Timing Belt Water Pump CYLINDER HEAD GASKET CB 23 CBdl Engines MOVAL I After the operations up to the cylinder head cover removal in...

Page 66: ...moval 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 cylinder head cover 3 Remove the intake pipe 4...

Page 67: ...il pump NOTE Be sure to use new 0 ring 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 havin...

Page 68: ...n the illustration at the right denote the temporal tightening sequence for the s t d bolts Front direction mark represents stud boit of engine 9 Fig 4 39 WLI 04054 6 lnstall the stiffener plate 7 lns...

Page 69: ...NOF ENGINE 5 2 INTAKEAND EXHAUST SYSTEM 5 14 CB 23 AND CB 61 ENGINES 5 14 CB 80 ENGINE 5 19 TIMING BELT 5 24 CB 23 AND CB 61 ENGINES 5 24 CB 80 ENGINE 5 30 CYLINDER HEAD 5 39 CB 23 AND CB 61 ENGINES 5...

Page 70: ...eful not to scratch the body and hood WM 05003 Radiator water drain Dlua 3 Disconnect the negative terminal of the battery Detach the hold down clamp and remove the battery 4 Remove the battery carrie...

Page 71: ...Disconnect the speedometer cable 10 Disconnect the clutch cable 11 Disconnect the accelerator cable assembly 12 Disconnect the brake booster hose Disconnect the heater hose I I Fia 5 5 NM 05007 WWW P...

Page 72: ...tains 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 connecto...

Page 73: ...each injector 1 Fig 5 13 m u 5 0 i 6 I I Fin I 4 WM 05017 19 Disconnect the transmission related harness couplers CB 80 engine only 1 Starter harness 2 Transmission earth 3 Backup lamp harness 20 Rem...

Page 74: ...ORMATION 23 Drain the transmission oil 24 Disconnect the shift se1ec or shaft subassembly 25 Disconnect the exhaust front piqe Remove it from the manifold Fia 5 18 WM 5022 26 Remove the stabilizer bar...

Page 75: ...cted 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 L I Fia 5 22 WM 05026 30 is connection of engine m...

Page 76: ...09090 04810 000 Engine sling device NOTE When removing the engine perform final check to ensure that all removal parts have been removed 34 Remove the starter assembly from The transmission 35 Remove...

Page 77: ...sling device lnstall the engine mounting front insulator Tightening Torque 7 5 10 5 kg m 54 76 ft lb lnstall the engine mounting front stopper Tightening Torque 7 5 10 5 kg m 54 76 ft lb 5 lnstall th...

Page 78: ...38 11 Installation of stabilizer bar Tightening the suspension lower arm subassembly Tightening Torque 7 5 11 O kg rn 54 80 ft lb Tightening the stabilizer bracket Tightening Torque 4 0 6 0 kg rn 29 4...

Page 79: ...s for the parts given below 1 Alternator connector 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 Transmi...

Page 80: ...tall the positive terminal of the battery 30 lnstall the negative aterminal of the battery 31 lnstall the hold down clamp of he battery 32 lnstall the engine hood NOTE Apply rust preventive oil to the...

Page 81: ...j 0 14 1 Diesel engine Type CL 11 engine I 0 82 1 0 14 I 0 85 Diesel turbo engine Type CL 61 engine I I 0 14 Manual transmission 1 i 1 O O I Petrol engine I i 0 21 Type CB 23 engine 1Automatic transmi...

Page 82: ...d to cylinder head gasket aExhaust 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 0Turbocharger to ex...

Page 83: ...ay get into the turbocharger turbine Fig 5 46 WM 350 6 Remove the EGR pipe Swiss specifications only Remove the intake manifold assembly 3 Remove the hoses NOTE When removing the vacuum hoses put a ta...

Page 84: ...exhaust manifold 15 Remove the exhaust manifold to cylinder head gasket INSPECTION 1 Check the cylinder head attaching surface of the intake manifold for distortion Meas rethe distotion on the diagona...

Page 85: ...he exhaust manifold Tightening Torque 1 0 1 6 kg m 7 12 ft lb 3 lnstall the turbocharger to exhaust manifold gasket CB 61 engine only NOTE This gasket is a nonreusable part 4 lnstall the turbocharger...

Page 86: ...part 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 lnsta...

Page 87: ...delivery pipe Fuel cellvery pipe insulator aFuel injector Ay Intake man fold Intake man fold to cyl nder heaa gasket Turbocharger or1 inlet plpe SIA Exhaust man fold case Turbocharger to exhaustmanifo...

Page 88: ...move the fuel pipe for cold start injector use NOTE When removing the pipe the fuel will be discharged Hence be sure to get a cloth ready to receive the fuel 4 Remove the throttle body 5 Remove the ai...

Page 89: ...ge 9 3 13 Remove the exhaust manifold Semove the exhaust manifold to cylinder head gasket INSPECTION 1 Check the surge tank and cylinder head attaching sur faces of the intake manifold for distortion...

Page 90: ...tall the exhaust manifold Tightening Torque 4 0 5 0 kg m 29 36 ft lb 3 lnstall the turbocharger assembly NOTE For handling instructions on the turbocharger assembly prior to its assembly see page 9 3...

Page 91: ...WM 05090 10 lnstall the fuel delivery pipe 11 lnstall the air surge tank assembly Tightening Torque 3 5 4 5 kg m 25 32 ft lb 12 lnstall the throttle body lnstall the fuel pipe for cold start injector...

Page 92: ...ENGINE MECHANICALS TIMING BELT CB 23 AND CB 61 ENGINES COMPONENTS OF TIMING BELT WWW PlanDeGraissage Org...

Page 93: ...tors 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...

Page 94: ...of back surface cracks at canvas i I 1 3 Wear i t canvas and tooth missing 4 Abnormal wear at side surface of belt I I I Rubber exposed due to wear I I Replace the belt in the following cases even if...

Page 95: ...belt pulley Wear limit of timing belt pulley mm inches Crankshaft timing belt pulley II 59 2 2 331 Camshaft timing belt pulley i 119 8 4 717 he wear exceeds the wear limit replace the timing belt pul...

Page 96: ...actice 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 wit...

Page 97: ...ead 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...

Page 98: ...S OF TIMING BELT Timing belt tensioner SIA Timing belt idler SiA No 1 Timing belt idler S A No 2 Crankshafttiming belt pulley flange Timing belt Crankshafttiming belt pulley Crankshafttiming belt pull...

Page 99: ...th 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 rotate...

Page 100: ...he bolts 17 Remove the camshaft timing belt pulley intake ex haust When removing the attaching bolt of the camshaft timing belt pulley prevent the rotation of the camshaft by holding the hexagonal sec...

Page 101: ...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 belt 3 Case where most...

Page 102: ...ear of the timing belt pulley exceeds the minimum limit above replace the timing belt pulley I I Fig 5 107 WM 05124 2 Check the belt contact surface of the timing belt pulley for scratches etc 5 Check...

Page 103: ...F mark at the end surface oi the crankshaft timing belt pulley facing toward your side insert the pulley into the crankshaft aligning with the key groove 4 lnstallation of timing belt idler subassembl...

Page 104: ...ith the belt installed the rotation should be made at the crankshaft sidc If the belt is reused install the belt in such a way that the belt is turned in the same directior indicated by the arrow mark...

Page 105: ...pulley I I Fig 5 118 WM 05126 6 Turn the crankshaft about two turns in the normal rotating direction until the mating mark on the cylinder head is aligned with the recessed timing mark on the camshaft...

Page 106: ...ad cover 12 Install the surge tank bracket 13 lnstall the surge tank cover 14 lnstall the oil filler cap 15 lnstall the resistive cords 16 lnstall the crankshaft pulley Tightening Torque 9 0 10 0 kg m...

Page 107: ...cover Oil seal Cylinder head Ay Valve spring retainer lock Distributor 0Valve spring retainer Distributor housing Compressionspring for valve Wave washer Valve Valve rocker shaft Valve spring seat Va...

Page 108: ...Slacken all adjusting screws of the valve rocker arm Pull out the vaive rocker shaft using the following SST SST 09204 87701 000 NOTE Perform this operation while holding the compression spring by han...

Page 109: ...ow them by compressed air Do not use a cloth or the like to wipe the parts Remove the cylinder head from the SST INSPECTION 1 Checking of cylinder head 1 Check the cylinder head for cracks damage and...

Page 110: ...conform to the specifications or the contact surface exhibits rough ness correct the cylinder head or replace it as required 3 Refacing valve seats Reface the valves using a valve seat cutter NOTE If...

Page 111: ...0 degree cutter cut the valve seat in I 1 such a way that the circumference of the surface refaced by the 45 degree cutter may becomes 32 mm 1 26 inches 32 mm 1 26 inch r 9 Fig 5 138 WM 5157 Using a 6...

Page 112: ...nch NOTE If the recession exceeds the maximum limit replace the cylinder head 2 Checking of valves 1 Checking valve stems Visually inspect the valve stem for seizure or damage If the valve exhibits da...

Page 113: ...e be sure to check the oil clearance with the valve guide bush I I Minimum Limit NOTE If the stock thickness of the valve head is less than the 3 Checking of valve guide bush to valve stem oil clearan...

Page 114: ...e guide bush NOTE When replacing the valve guide bush replace also the valve as a set However if the bushes with rings replacement part have been already installed as valve guide bushes replace the cy...

Page 115: ...til the snap ring contacts the cylinder head using the following SST SST 09201 87201 000 NOTE After the valve guide bush has been driven into position remove any burr or the like using an adjustable r...

Page 116: ...nd the outer diameter of the valve rocker arm installation section of the valve rocker shaft Fig 5 158 WM 05179 If the oil clearance does not meet the specifications replace the parts with new ones as...

Page 117: ...ocks Set a dial gauge to the mid point of the center journal section of the camshaft Turn the camshaft one turn making sure that the camshaft will not move in the axial direction Take a reading on the...

Page 118: ...he cylinder head WM 05185 Specified Dimensions Front Checking of wave washer Check the wave washer for flattened condition or damage Center j Rear 31 960 31 980 mm Outer diameter of camshaft journal s...

Page 119: ...4 lnstall the compression springs for the valves 5 lnstall the valve spring retainers 6 lnstallation of valve spring retainer locks Insert the valve rocker shaft into position lnstall the valve sprin...

Page 120: ...rms compression springs and valve rocker shaft attaching hoies of the cylinder head Then install these parts I I Fig 5 169 hM C5194 Exhacst side mm inch Fia 5 171 wM 05196 I I Fig 5 170 WM 05195 10 ln...

Page 121: ...as been mounted on the vehicle warm up the engine fully Readjust the valve clearances to the specifications for hot operation Reference L 1 Fig 5 174 WM 05200 Camshaft positio Installation of cylinder...

Page 122: ...Fill about 30 cc of engine oil in the distributor housing 3 Insert the distributor proper into he distributor housing in such a way that the solit line of the distributor proper may be aligned with t...

Page 123: ...arts DistributorAy Valve lifter Cylinder head Ay Valve spring retainer lock Cylinder head gasket Valve spring retainer Camshaft bearing cap I Compress on spring Oil seal Valve Camshaft Valve stem otl...

Page 124: ...e camshaft about 30 degrees counterclockwise so that the tappet may be orought under a non compressed state 2 Pull out the camshaft bearing cap bolts NOTE Be sure to alternately slacken the camshaft b...

Page 125: ...asket surface Maximum Limit 0 10 mm 0 039 inch Distortion of intake manifold attaching surface Maximum Limit 0 10 mm 0 039 inch Distortion of exhaust manifold attaching surface Maximum Limit 0 10 mm 0...

Page 126: ...tter Using a 70 degree cutter cut the valve seat in such a way that the width of the surface refaced by the 45 degree cutter may becomes 1 4t0 2 mm 0 055k0 008 inches I 1 Fig 5 187 WM 05218 Using the...

Page 127: ...by the 45 degree cutter may becomes 25 0 k 0 1 mm 0 98 k 0 004 inches Using a 70 degree cutter cut the valve seat in such a way that the width of the surface refaced by the 45 degree cutter may becom...

Page 128: ...If the valve stem exhibits abnormal wear correct the stem end with a valve refacer However make sure that the valve has the following minimum valve overall lerigth given below Minimum Valve Overall L...

Page 129: ...valve guide bush If the valve to valve seat contact surface exh bitsany damage gr nd the surface w th a valve refacer Valve Face Angle 45 5 Fig 5 200 WM 0523 Stock th ckness Gr nd ng surface 45 5 O I...

Page 130: ...ure the inner diameter of the installation hole of the valve guide bush of the cylinder head Specified Inner Diameter 11 05 mm dia 0 45 inch dia 1 I Fig 5 203 WM 05235 I I Fig 5 204 WM 05237 NOTE If t...

Page 131: ...ss using a I I Fig 5 208 WM 05242 I 1 square Maximum limit 1 6 mm 0 063 inch I I Fia 5 209 wM 05243 2 Using a spring tester measure the free length Also measure the spring tension with the spring comp...

Page 132: ...valve lifter New part 29 975 29 985 mm 1 1801 1 I 805 inches 2 Checking cam lobe height Measure the cam lobe height Minimum limit Intake valve 39 4 mm 1 55 inches Exhaust valve 39 0 mm 1 53 inches 7 C...

Page 133: ...ash the valves and cylinder head using a cleaning solvent Blow them with compressed air WM 05254 INSTALLATION Install the cylinder head to the SST 09219 87703 000 Install the valve spring seats Instal...

Page 134: ...is installed securely NOTE During this check care must be exercised to ensure that the valve spring retainer or lock retainer may not be jumped out 7 Installation of valve lifters Apply engine oil to...

Page 135: ...aps Apply engine oil to the inside of each camshaft Searing cap Then evenly tighten the camshaft bearing caps to the specified torque Tightening Torque 1 15 1 45 kg m 8 3 10 5 ft lb NOTE Make sure tha...

Page 136: ...r oil remains in the attaching holes of the cylinder head bolts ld Installation of d stributor assembly 1 Remove he distr butor caD Tilt the rotor as indicated In the right figure 2 While turning the...

Page 137: ...piston Water inlet Flywheel Dust seal Rear end plate Water pump Ay Oil seal retainer with oil seal Dust seal Gasket Oil pan Balance shaft rear cover Baiance shaft gear cover Balance shaft rear cover g...

Page 138: ...oil pump outlet pipe 17 Removal of balance shaft 1 Align the stamped mark on the crank shaft gear with the stamped mark on the balance shaft drive gear I Align stamped marks with each other 2 Remove t...

Page 139: ...scratchthe front surface or back surface of the bearings Never touch the front surface or back surface of the bearings by hands 20 Removal of connecting rod with piston 1 If the uoper part of the cyli...

Page 140: ...tions may be known readily L Fig 5 239 I WM 05279 Fiq 5 240 29 Removal of crankshaft Remove the crankshaft by lifting it vertically so that no scratch may be made to the crankshaft journals and the cr...

Page 141: ...easure the bore diameter of each cylinder The measilrement should be made at six points Ensure that the difference between the maximum and minimum bore diameters of each cylinder is within 0 1 mm 0 03...

Page 142: ...re it with the attaching screw Place the piston on the fitting piece aligning the cut out sections 09221 25018 000 Install the longer lever into the piston hole Press off the piston pin using a press...

Page 143: ...learance mm inch I CB i nE 61 1I CB 80 engine Compressron rlng 1 0 03 0 12 0 05 0 12 No 1 0 0012 0 0047 0 0002 0 0047 Compression ring 0 02 0 12 0 0 2 0 1 2 NO2 0 3008 0 0047 0 0008 0 0047 If the meas...

Page 144: ...lace the piston and piston pin as a set I I I Fig 5 254 WM 05298 10 Checking piston ring end gap After the cylinder has been checked or reconditioned insert the piston ring into the cylinder bore down...

Page 145: ...1 0 5 34 f 7 1 I Fig 5 257 WM 05301 Install the plastigage on the crankpin journal Tighten the bearing cap lo the specified torque Tightening Torque kg m ft lb I I Fig 5 258 WM 35302 Remove the beari...

Page 146: ...Crankpin journal diameter Engine type NOTE The thrust clearance should be measured while the con necting rod being pushed against either side of the crankshaft in the axial direction Measure the clear...

Page 147: ...bearing journals and crank pin journals Measure the outer diameter at four points of each of the main bearing journals and crankpin journals This measurement should be conducted over the entire perip...

Page 148: ...ovided Lower bearing bearing cap side No groove is provided wv 05309 Install the crankshaft in the cylinder block NOTE Be careful not to scratch the crankshaft and bearing Do not apply engine oil to t...

Page 149: ...aring is available WM 05313 UIS 0 25 i 41 734 41 742 j 1 6430 1 6434 1 5 Checking crankshaft thrust clearance a Install the bearings in the cylinder block and main bearing caps Do not touch the front...

Page 150: ...0 02 to 0 30 Required thrust washer thickness D Thrust washer size Standard O S 0 125 O S 0 25 In this case use a O S 0 125 mm thrust washer However if the minimum value of D exceeds 2 240 mm 0 0882...

Page 151: ...forward end of the balance shaft at the balance shaft gear side measure the thrust clearance of the balance shaft Thrust clearance 0 03 0 20 mm 0 0012 0 0079 inch If the thrust clearance exceeds the...

Page 152: ...rs of the front and rear bearing journals of the balance shaft The measurement should be performed at the mid point of each of the front and rear journals in the two directions 90 degrees apart from e...

Page 153: ...diameter Balance shaft bearing I Front i Rear Install the balance shaft bearing using the following SST Repair standard i 44 925 44 975 1 769 1 77i SST 09215 87701 000 33 925 33 975 1 336 1 338 NOTE B...

Page 154: ...1 WM 05334 Fig 5 282 WM 05335 7 Checking of flywheel 1 Checking flywheel for runout Tighten the flywheel to the specified torque Tightening Torque kg m ft lb NOTE Prior to the check be sure that the c...

Page 155: ...nce WM 05338 Install the cylinder block to the following SSTs SSTS 09219 87202 000 09219 87701 000 L I Fig 5 283 WM 05339 2 Installation of crankshaft upper bearings 1 Install the crankshaft upper bea...

Page 156: ...mark provided on each bearing cap faces toward the front side of the engine 3 Tighten the crankshaft bearing caps to the specified torque in the sequence indicated in the right figure NOTE i J After t...

Page 157: ...Apply engine oil to the rear oil seal contact section of the crankshaft and the lip section of the oil seal Then install the oil seal retainer in the cylinder block 10 Install the rear end plate Insta...

Page 158: ...iston pin a lnsert the small end of the connecting rod into the piston pin hole NOTE Align the front mark of the piston with the front mark of the connecting rod Press the piston pin by pressing the s...

Page 159: ...f the connecting rod upper bearing and crankpin journal WM 05358 3 Assemble the compression rings No 1 and No 2 in such a way that each end of the compression rings is 120 degrees apart from the end o...

Page 160: ...gine oil to the bearing surface 3 Install the connecting rod bearing cap with the front mark facing toward the front side of the engine Tightening Torque kg m fe lb NOTE a When tightening the connecti...

Page 161: ...nstall the balance weight to the balance shaft Insert the washer and tighten the bolt NOTE When tightening the bolt prevent the crankshaft from turning using the following SST at the flywheel side SST...

Page 162: ...zzle assembly so that the assembly may not be damaged Fig 5 310 WM 05371 19 Installation of oil pump drive sprocket and oil pump drive chain assembly 1 Install the oil pump drive chain to the oil pump...

Page 163: ...stud bolts at the cylinder block 4 Install the oil pan aligning with the stud bolts at the cylinder block 5 Tighten the oil pan boits and nuts in he sequence indicated in the right figure Tightening T...

Page 164: ...bolts of the water inlet pipe 27 lnstall the oil filter bracket 28 lnstall the oil cooler assembly aligning the mating mark of the oil cooler assembly with the mating mark of the oil filter bracket T...

Page 165: ...TYPECB SECTION 6 FUEL SYSTEM CARBURETOR 6 2 FUEL LINE CB 23 Engine 6 9 FUEL LINE CB 61 Engine 6 1 1 FUEL PUMP CB 61 Engine 6 13 FUEL PUMP CB 80 Engine 6 14 FUEL TANK 6 15 WWW PlanDeGraissage Org...

Page 166: ...set screw Check ball retainer I B C K spring 0 Steel ball 0 Choke wire clamp screw Slow jet Throttle return sprirg Pump discharge weight 0 Set screw Q Needle valve seat gasket Fast idle cam spring Nee...

Page 167: ...FUEL SYSTEM WWW PlanDeGraissage Org...

Page 168: ...FUEL SYSTEM C L CARBURETOR SCHEMATIC DIAGRAM CB 61 Engine WWW PlanDeGraissage Org...

Page 169: ...y 1 Check the body for cracks Check each hole for distric tion 2 Check the small venturi for restriction 3 Check the large venturi for looseness or excessive wear Air Horn 1 Check the air horn for dis...

Page 170: ...or smooth operation Solenoid Valve Check the solenoid valve connecting wire to the battery positive terminal for proper operation by grounding the body The needle valve should be pulled in Diaphragm C...

Page 171: ...ected section of the float and the air horn Specified Gap 8 0 mm 0 315 inch If the gap does not conform to the specification bend the section A in order that the specified gap may be obtained When the...

Page 172: ...sitive pressure of 0 2 kgicm2 2 8 psi If the ink moves it indicates that the secondary diaphragm is functioning normally Link Secondary diaphragm Fig 6 19 WM 0602 3 Checking of jet operation 1 With th...

Page 173: ...EM UEL LlNE COMPONENTS OF FUEL LlNE CB 23 Engine Q Fuel filter Fuel hose Filter to Pump Fuel hose For return Fuel pump Fuel hose Pumpto carburetor Hose Q Push rod 1 1 Fig 6 2 1 WM 06034 WWW PlanDeGrai...

Page 174: ...nsert a good push rod into the distributor housing 2 Turn the crankshaft two turns i e turn the camshaft one turn Measure the maximum amount as well as the minimum amount of protrusion between the dis...

Page 175: ...Fuel filter Fuel pressure control valve Fuel hose Value to carburetor Fuel hose Valveto tanic Fuel pipe No 1 Fuel hose Carburetorto filter WWW PlanDeGraissage Org...

Page 176: ...9268 87701 000 Fuel pressure gauge attachment SST 09283 87701 000 5 Disconnect the connector from the magnetic switch of the starter This step is taken to prevent the starter rotation 6 Turn the engin...

Page 177: ...FUEL SYSTEM JEL PUMP COMPONENTS OF FUEL LINE CB 61 Engine Fuel pump Ay Cushion rubber Fuel pump cover Fuel pump filter Gasket Bracket SIA I Fig 6 32 WM WWW PlanDeGraissage Org...

Page 178: ...FUEL SYSTEM COMPONENTS OF FUEL LINE CB 80 Engine WWW PlanDeGraissage Org...

Page 179: ...he grommet 4 Removal of fuel tank subinlet hose and breather hose 3 door model 1 Detach the clamp Disconnect the fuel tank subinlet hose 2 Detach the clamp Disconnect the breather hose 5 door model 1...

Page 180: ...Remove the four attaching bolts of the fuel tank 3 Take out the fuel tank assembly from the vehicle Fuel sender Fzei pump By wirh bracket Gauge AY Remove the fuel hose and pipe Remove the coupler and...

Page 181: ...and the fuel sender gauge assembly 2 Install the fuel hose and pipe 3 Install the fuel tank assembiy with the four bolts NOTE Prior to the installation of the fuel tank assembly be sure to route the...

Page 182: ...let hose Secure it with the clamp 2 Connect the hoses to both ends of the breather pipe Secure them with the clips 3 Install the breather pipe with one bolt 6 Installation of fuel sender gauge and fue...

Page 183: ...CATION SYSTEM OIL PUMP 7 2 COMPONENTSOF OIL PUMP 7 2 INSPECTION 7 3 ASSEMBLY 7 4 OIL COOLER 7 7 COMPONENTS OF OIL COOLER CB 611 7 7 COMPONENTSOF OIL COOLER CB 801 7 8 INSTALLATION 7 9 INSPECTION 7 9 W...

Page 184: ...shaft sprocket Oil pump drive sprocket Oil pump drive chain Ay aOil pump outlet pipe S A 0 ring Oil nozzle bracket CBSO engine only Oil nozzle Ay CB 80 engine only Oil pump rotor set Oil pump cover Oi...

Page 185: ...mm 0 0018 0 0033 inch Limit 0 10 mrn 0 0039 inch 4 Measurement of tip clearance Specified Clearance 0 15 mrn 0 0059 inch or less Limit 0 25 mm 0 0098 inch 5 Side clearance Specified Clearance 0 03 0...

Page 186: ...umerical order shown in the figure 2 Oil pump rotor set Assemble the rotor in such a way that the punched marks point toward the same direction facing toward you NOTE Coat each sliding part with engin...

Page 187: ...becomes harder to turn until it cannot be turned any longer I 1 Fig 7 12 Wbl 0701J i Fia 7 13 whl 07c 5 Fig 7 1 4 WM 07016 7 Attach the oil pump assembly onto the cylinder block Install the oil pump...

Page 188: ...engine only NOTE The oil nozzle assembly can be distorted very easily Hence care must be exercised to ensure that the oil nozzle assembly is interfered with no other parts Tightening Torque 3 0 3 5 kg...

Page 189: ...TIONSYSTEM DIL COOLER COMPONENTS OF OIL COOLER CB 611 Oil filter element Oil cooler set bolt Oil cooler hose Oil cooler hose Oil cooler Oil filter bracket aGasket I Fig 7 17 WM 07019 WWW PlanDeGraissa...

Page 190: ...IONSYSTEM aOil filter element 0 Oil cooler set bolt Oil cooler Oil cooler hose Turbo oil outlet pipe Non reusable parts aTurbo oil inlet pipe Onring Oil filter bracket 0 ring 0 Gasket WWW PlanDeGraiss...

Page 191: ...e 3 0 4 0 kg m 22 29 ft lb NOTE Fig 7 19 WM 07021 Inasmuch as the gap between the oil cooler and the set bolt is very narrow difficulty may be ecountered in install ing the set bolt In such case the a...

Page 192: ...WWW PlanDeGraissage Org...

Page 193: ...8 2 RADIATOR CAP 8 2 INSPECTION 8 2 THERMOSTAT 8 3 INSPECTION 8 3 RADIATOR THERMO CONTROL SWITCH 8 4 IN VEHICLE INSPECTION 8 4 UNIT INSPECTION 8 4 WATER PUMP 8 5 COMPONENTSOF WATER PUMP 8 5 DISASSEMB...

Page 194: ...the test 3 Checking of neck filler sectiori water filling port i J Distorted or dented seal surface Distorted edge section NOTE If the neck filler section is distorted the radiator cap can not be sea...

Page 195: ...2 Replace the thermostat if the valve remains open at normal temperature or is not very tight when fully closed I Specifications Except ECE EEC SpeCi i 80 5 83 5 fications i 8 mm or more at 95 C ECE 8...

Page 196: ...ture reaches 92 PC the radiator thermo control switch starts to operate When the cooling water temperatures begins to drop the radiator thermo control switch continues to function until the cooling wa...

Page 197: ...ss off the water pump pulley using the following SSTs SST 09253 87202 000 SST 09238 87201 000 2 Remove the water pump bearing using the follow ng SST SST 09237 87201 000 3 Remove the rotor and seal se...

Page 198: ...its defects 3 Check the water inlet pipe 0 ring for deterioration or damage Replace the 0 ring that indicates defects ASSEMBLY 1 Press the bearing into water pump rotor using the following SST SST 092...

Page 199: ...t into the water pump pulley seat using the following SSTs SST 09238 87201 000 SST 09254 87201 000 5 After assembl ng make sure the rotor rotates smoothly with the water pump seat In the installed con...

Page 200: ...WWW PlanDeGraissage Org...

Page 201: ...BOCHARGER SYSTEM TURBOCHARGER 9 2 COMPONENTS OF TURBO CHARGER CB 61 CB 81 Engines 9 2 INSPECTION ON TURBOCHARGED RELATED OPERATION 9 3 INSPECTION 9 4 IN VEHICLE INSPECTION 9 4 TROUBLE SHOOTING 9 6 WWW...

Page 202: ...should be performedonly after the temperature of the turbocharger has dropped sufficiently Turbo oil inlet pipe Exhaust manifold heat insulator No 1 Exhaust manifold heat insulator No 2 Air cleaner ho...

Page 203: ...rger 3 When the intake system exhaust system or lubrication system is disassembled make sure that no dust or foreign particle be permitted to enter into the tur bocharger Furthermore ensure that the t...

Page 204: ...on bolt washer with a new part 2 Apply engine oil to the union bolt during the assembly Fig 46 WM 09007 Checking of Turbocharger 1 Check the blades of the turbine and compressor for any evidence of da...

Page 205: ...ontrolling the supercharging pressure Attach a three way joint between the VSV and the vacuum switch turbo indicator Measure the supercharging pressure using a pressure gauge Turbocharger pressure gau...

Page 206: ...supercharging pressure is specified Check carburetor secondary valve for value of 0 40 to 0 60 kg cmz 5 7 to 8 5 psi proper operation Yes Check the engine proper Check to see if exhaust gas is leaking...

Page 207: ...see if hose attaching clip of waste gate valve actuator is detached L 1 I 1 I 1 NO Yes Repair or replace 1 No Repair Check to see if excessive oil deposit exists in inlet pipe between air cleaner and...

Page 208: ...WWW PlanDeGraissage Org...

Page 209: ...STARTER 10 1 0 COMPONENTSOF STARTER CB 23 M T CB 61 Engine CB 80 Engine with General Specification 10 1 0 CB 23 EngineAIT CB 80 Engine with ECE EEC Specificatior 10 1 1 PERFORMANCETEST 10 1 2 DISASSE...

Page 210: ...ributor cover Breaker points kit Wire aStationary plate Washer Vacuum advancer Condenser I Screw and washer Governor spring Q Distributor cam Snap washer Governor weight Governor shaft Q Governor spri...

Page 211: ...mounting screw and conde nser from the distributor housing 2 Remove the E ring Turn and pull out the vacuum advancer Remove the breaker plate 1 Remove the two screws ground wire and plate washers 2 Pu...

Page 212: ...ce the housing kit as required I I I Fig 10 11 WM 1GQ12 3 Breaker plate Turn the breaker plate Ensure that it has a slight drag If strong resistance or sticking is felt replace the breaker plate 4 Gov...

Page 213: ...I I Fig 10 12 WM 0 13 I 1 Fig 10 13 WM 10013A ASSEMBLY CB 23 CB 611 1 lnstall the cam with governor weights 1 Install the screw 2 Pack the high temperature grease into the shaft 3 Push on the grease...

Page 214: ...ct surfaces of the points with a piece of cloth saturated in solvent 2 Loosely install the breaker points and one end of the lead wire with two screws 3 Using a feeler gauge set the heel gap and tight...

Page 215: ...S OF IGNITION SYSTEM T J Resistor bracket 9 Resister Ignitioncoil Coil resistive cord Spark plug resistive cord No 2 Spark plug resistive cord No 1 Spark plug resistive cord No 1 Spark plug I Clamp Cl...

Page 216: ...7 25 3 kQ 3 Insulator resistance measurement Measure the resistance between the terminal and the coil case Resistance Infinity positive positive positive I I Fig 10 21 WM 10021 4 Resistor resistance m...

Page 217: ...0033 Cord No 3 1 8 1 12 1 8 1 12 1 7 0 10 3 Central cord 1 6 1 9 2 j 6 7 9 2 5 1 7 7 Fig 10 28 WM 10032 Spark Plug Specifications CB 23 CB 6 le type i C3 80 DENSO NGK 1 BOSCH I CHAMPION DENS0 W16EXR U...

Page 218: ...General Specification Screw Starter drive housing Starter pinion drive lever Stop collar Snap ring Magnetic switch Starter clutch I Armature Bearing cover Lock plate Spring Cover Dust protector I Comm...

Page 219: ...CAL SYSTEM Bearing Armature Bearing Starter yoke Spring brush Brush holder Drive housing Magnetic starter switch Spring Bail 0Starter clutch Idle gear I Roller Retainer Starter drive housing WWW PlanD...

Page 220: ...right figure Ensure that the pinion moves outward If the pinion does not move replace the magnetic switch Fig 10 31 WM 10037 2 Perform the hold in test While still connected above and with the pinion...

Page 221: ...hat the ammeter registers the specified cur rent Specified Current Less Than 50 A at 1 1 V 5 Perform the no load performance CB 23 Engine M 1 Connect the battery and ammeter to the starter as shown in...

Page 222: ...out to unhook the plunger from the drive lever 2 Remove the end frame 1 Remove the bearing cover 2 Using a feeler gauge check the armature shaft thrust clearance between the lock plate and the end fra...

Page 223: ...ling out the pinion smoothen the shaft with an oil stone 5 Remove the starter clutch DISASSEMBLY CB 23 Engine A T1 Remove the field frame with armature from the magnetic switch 1 Disconnect the lead w...

Page 224: ...ure Coil 1 Ensure that the commutator is not grounded Using an ohmmeter ensure that no continuity exists between the commutator and the armature coil core If continuity exists replace the armature 2 C...

Page 225: ...pect the pinion gear and spline teeth lnspect the pinion gear and spline teeth for wear or damage If damaged replace the starter clutch Also inspect the flywheel ring gear for wear or damage 2 Check t...

Page 226: ...plunger Push in the plunger and release it Ensure that it returns quickly to its original position 2 Perform the pull in coil open circuit test Using an ohmmeter ensure that continuity exists between...

Page 227: ...ch body If no continuity exists replace the magnetic switch ASSEMBLY CB 23 Engine M T T and CB 61 CB 80 Engines NOTE Use high temperature grease to lubricate the bearings and sliding parts when assemb...

Page 228: ...l the brush in he brush holder lnstall the four brushes 4 lnstall the end frame 1 Apply grease to the end frame bushing 2 lnstall the end frame on the armature shaft and secure with two through bolts...

Page 229: ...brushes NOTE Make sure that the positive lead wires are not grounded 2 lnstall the end cover to the field frame 3 lnstall the steel ball into the clutch shaft hole Apply grease to the ball and spring...

Page 230: ...c switch 1 Place the felt seal on the armature shaft 2 Align the protrusion of the field frame with the magne tic switch Fig 10 78 WM 70086 3 Install the two through bolts 4 Connect the coil lead to t...

Page 231: ...ock nut Alternator pulley Spacer collar Driveend frameAy Stud bolt Bearing Retainer plate Bush Alternator rotor Ay Bearing Bearing cover Rear end frame Rectifier Terminal insulator IC regulator Brush...

Page 232: ...ws of the IC regulator assembly 4 Remove the brush holder assembly and regulator assembly INSPECTION 1 1 C Regulator Diode Ensure that continuity exists between the terminal B and the terminal F F B C...

Page 233: ...ohmmeter Resistance Less than 1 2 5 Rotor Measure the resistance between the slip rings using an ohmmeter Resistance 2 9 Cl ASSEMBLY 1 Install the brush holder assembly together with he IC regulator i...

Page 234: ...o the alternator terminal B wire harness 2 Run the engine at 2000 rpm Regulating Voltage 13 9 15 1 25 C Current Less than 10 A 2 Load Performance Test I Run the engine at 2000 rpm 2 Turn on the headla...

Page 235: ...SECTION 11 INTAKE SYSTEM AIR CLEANER 11 2 SURGETANK CB 61 Engine 11 6 INTERCOOLER CB 80 Engine 11 7 WWW PlanDeGraissage Org...

Page 236: ...SYSTEM AIR CLEANER r COMPONENTS OF AIR CLEANER CB 23 Engine 0 A I cleaner cap Gasket Air cleaner filter element Grommet Air cleaner case Hot air ntake duct Atr cleaner hose No 1 Clamp WWW PlanDeGraiss...

Page 237: ...CB 80 Engines Air cleaner cap Air cleaner filter element Air cleaner hose No 1 Air cleaner case Air cleaner cap Air cleaner filter element Air cleaner hose No 1 Air cleaner case Fig 11 2 WM 11003 WWW...

Page 238: ...t must be made at earlier time than the intervals above Cool AirIHot Air Switching Adjustment System Check CB 23 Engine 1 Check the vacuum motor Ensure that the air control valve opens fully when a ne...

Page 239: ...all the air cleaner cap 5 Start the engine Run the engine at the idling speed 6 When the temperature inside the air cleaner case rises above about 30 C ensure that the air control valve is opened full...

Page 240: ...elief valve hose and blow your breath into the surge tank There should be no air continuity 3 Turbocharger Indicator Lamp Inspection Engine switch turned ON i Apply positive pressure of 0 15 kg cm2 2...

Page 241: ...TEM lTERCOOLER COMPONENTS OF INTERCOOLER CB 80 Engine 9 T T III I c alnlet cool alr No 1 lnlet cool alr No 2 Intercooler SIA Bracket Hose Hose Intake pipe Hose I Fig 11 11 WM 11012 11 7 WWW PlanDeGrai...

Page 242: ...ooler for air leakage Tightly seal the intake and discharge ports of the inter cooler using sealing tape or the like Submerge the intercooler into the water in a water tank This water should be heated...

Page 243: ...7 CHECKING OF SECONDARY AIR SUCTION SYSTEM 12 27 AIR SUCTION FILTER ELEMENT 12 28 EGR EXHAUST GAS RECIRDULATING SYSTEM 12 28 EGR SYSTEM CHECK 12 28 JNlT INSPECTION 12 29 CHOKEWARNING SYSTEM 12 30 CHEC...

Page 244: ...I 1Singapore specificaiions 1 C I Manual transmission a 3 i o j j I 1 Singapore specifications 1 j Automatic transmission 0 i I 0 I 1 1 I I I I I I 1 1 1 1 0 0 Manual transmission CL 61 All specifica...

Page 245: ...EMISSION CONTROL SYSTEM XHEMATIC VIEW OF EMISSIONCONTROL SYSTEMS General Specifications with CB 23Engine and Manual Transmission Distributor J Fig 12 1 WM 12003 12 3 WWW PlanDeGraissage Org...

Page 246: ...EMISSIONCONTROL SYSTEM General Specifications with CB 23 Engine and Automatic Transmission WWW PlanDeGraissage Org...

Page 247: ...EMISSIONCONTROL SYSTEM lstralian Specifications with CB 23 Engine and Automatic Transmission 1 I I Fig 12 3 WM 12005 WWW PlanDeGraissage Org...

Page 248: ...EMISSION CONTROL SYSTEM Australian Specifications with CB 23 Engine and Manual Transmission l I cleaner Charcoal canister Air suction valve Vacuum motor Fig 124 WM 12006 WWW PlanDeGraissage Org...

Page 249: ...EMISSION CONTROL SYSTEM E EEC Specificationswith CB 23 Engine and Manual Transmission I 1 Fig 12 5 wM 12007 WWW PlanDeGraissage Org...

Page 250: ...EMISSION CONTROL SYSTEM ECE EEC Specifications with CB 23 Engine and Automatic Transmission c L Temperature Vacuum motor Chokewarnlng WWW PlanDeGraissage Org...

Page 251: ...EMISSION CONTROL SYSTEM udi Arabian GCC Specifications with CB 23 Engine and Manual Transmission Vacuum sw tch To fuel tank Charcoal canlster 1 I Fig 12 7 WM 12009 WWW PlanDeGraissage Org...

Page 252: ...EMISSIONCONTROL SYSTEM Saudi Arabian Specifications with CB 23 Engine and Automatic Transmission t Vacuum transmitting valve To fuel tank WWW PlanDeGraissage Org...

Page 253: ...EMISSION CONTROL SYSTEM lgapore Specifications with CB 23 Engine and Manual Transmission Fig 12 9 WM 12011 WWW PlanDeGraissage Org...

Page 254: ...EMISSION CONTROL SYSTEM Singapore Specifications with CB 23 Engine and Automatic Transmission I Intake manifold Temperature Vacuum motor senslng valve WWW PlanDeGraissage Org...

Page 255: ...iOL SYSTEM vedish Specifications with CB 23Engine and Manual Transmission Power Intake rnan iold TP PO g k l d Bimetalvacuum switchingvalve transmitting valve Air filter Green Choke warning WWW PlanDe...

Page 256: ...EMISSIONCONTROL SYSTEM Swiss Specificationswith CB 23 Engine and Manual Transmission Vacuum swilch J Bimetal vacuum Temperature Vacuum motor Air suctionvalve choke warning WWW PlanDeGraissage Org...

Page 257: ...EMISSION CONTROL SYSTEM neral Specificationswith CB 61Engine I I Bimetal control valve vacuum switching valve Fig 12 13 WM 12015 WWW PlanDeGraissage Org...

Page 258: ...EMISSION CONTROL SYSTEM Australian Specificationswith CB 61 Engine control valve Fig 12 14 WM 12016 WWW PlanDeGraissage Org...

Page 259: ...EMISSION CONTROL SYSTEM E EEC and Singapore Specifications with C8 61 Engine 1 Air cleaner 1 Turbocharger indicztor lamp ECE EEC specificatiors only V I Fig 12 15 WM 12017 WWW PlanDeGraissage Org...

Page 260: ...EMISSION CONTROL SYSTEM Swedish Specifications with CB 61 Engine C Bimetal vacuum Air cleaner control valve Check valve J Fig 12 16 WM 12018 WWW PlanDeGraissage Org...

Page 261: ...EMISSION CONTROL SYSTEM est German Specifications with CB 61 Engine I 1 Air cleaner Vacuum control vaive Fuel pressure control valve Check valve WWW PlanDeGraissage Org...

Page 262: ...EMISSION CONTROL SYSTEM BLOW BY GAS RECIRCULATIONSYSTEM 4 Blow by Gas Recirculating System CB 23 Engine Check valve Ventilation hcse gases I I Fig 12 19 wM 12021 WWW PlanDeGraissage Org...

Page 263: ...EMISSION CONTROL SYSTEM Ventiiat cn nose WWW PlanDeGraissage Org...

Page 264: ...ose 2 1 Disconnect the ventilation hose from he car5uretor s insulator 2 Ensure that the hose exhibits no cracks 3 Damage or restriction 4 Remove the oil filter cap Strongly blow from the carburetor s...

Page 265: ...k is pulled it represents a normal operation Next release the vacuum If the link returns quickly it indicates a normal function Cooling water temperature 10 C or below I 1 Fig 12 25 WM 12027 When hose...

Page 266: ...ow t Check the valve for air continuity during the check C 0 mark denote that vent contin ity exists J I N M L K 0 C 34 F or below C 3 C G 14 C 57OF or above C n C C 46 C 115 F or above G 1 66 C 5l0F...

Page 267: ...ashpot system is func ioning properly Speeified Time 2 0 4 0 seconds UNIT CHECK Dashpot With a MityVac connected apply a vacuum of 220 mm Hg to the dashpot If the shaft is pulled out it represents a n...

Page 268: ...TANK there should be continuity 2 While blowing breath strongly into the canister through the port C perform the continuity check of the cheek valves located at the ports A and B following the procedu...

Page 269: ...12040 SECONDARY AIR SUCTION SYSTEM AS SYSTEM Air suction valve Air cleaner 1 I I I Fig 12 37 WM 12041 CHECKING OF SECONDARY AIR SUCTION STEM 1 Disconnectthe hose between the air suction valve and the...

Page 270: ...NG SYSTEM To air cleaner Fig 12 41 WM 2045 EGR SYSTEM CHECK When engine is cold Temperature of cooling water is above 29 C 1 Connect a vacuum gauge between the modulator valve and the EGR valve 2 Star...

Page 271: ...1 Air tighteness check Apply a negative pressure of 400 mmHg to the diaphragm chamber using a MityVac If the pointer is steady It indicates that the EGR valve is satisfactory 2 Air continuity check If...

Page 272: ...tory 1 I Fig 12 47 WM 12051 CHOKE WARNING SYSTEM Range of switch ON I Fully opened Fully closed I Choke switch To water thermo switch 1 T O battery via 15 A fuse Warning lamp Fig 12 48 WM 12052 CHECK...

Page 273: ...nal and earth when water temperature exceed 70 C 45 F after engi e started FUEL CUT SYSTEM DURING DECELERATION I I Fig 12 50 WM 12054 Fig 12 51 WM 12055 When the intake manifold negative pressure exce...

Page 274: ...the vacuum switch to the atmosphere If the engine revolution speed rises it means that the system is functioning properly UNIT CHECK Solenoid Valve 1 Turn ON the engine switch 2 Repeat the connection...

Page 275: ...emission Fuel evaporative emission which is emitted from the float chamber is sucked by means of the charcoal canister while the engine is stopped With the engine switch turned OFF the outer vent open...

Page 276: ...e hose Charcoal Canister Check the charcoal canister for continuity between ports as follows 1 Plug the port 0by your finger 2 When you blow your breath into the canister through the port there should...

Page 277: ...hrottle opening is registered it means that he system is functioning properly SUB SIDE 1 Connect a vacuum gauge between the sub side of the distributor and the four way joint 2 If the vacuum gauge reg...

Page 278: ...sfac tory 2 Diaphragm Air Tightness Check If the pointer is stable when a negative pressure of 500 mmHg is applied the unit is satisfactory lgnition timing check 1 Disconnect the vacuum hose at the su...

Page 279: ...een 250 mmHg and 350 mmHg during the idling it means that the system is functioning properly 3 Increase the engine speed gradually If the negative pressure in proportionto the throttle opening is regi...

Page 280: ...stable when a negative pressure of 500 mmHg is applied it means that the air tightness is satisfactory L I Fig 12 66 WM 12072 CHECK AND ADJUSTMENT OF IGNITION TIMING r vacuum 1 1 Disconnect the vacuu...

Page 281: ...TYPECB SECTION 13 APPENDIX SST Special Service Tools 13 2 SERVICE SPECIFICATIONS 13 5 TIGHTENING TORQUE SPECIFICATIONS FOR MAIN PARTS 13 10 WWW PlanDeGraissage Org...

Page 282: ...ear axle bearing inner replacer 09219 87703 000 Cylinder head holder 09202 87702 000 Valve spring replacer 09201 87201 000 09090 04810 000 09618 87301 000 Transmission bearing replacer 09221 25018 000...

Page 283: ...87702 000 011 seal remover replacer I I 09204 87701 000 Qg J 1 09842 87704 000 a 1 09842 30040 000 I I Valve rocker shaft puller EFI computer check subharness EFI inspect on wire D I 09201 87703 000 V...

Page 284: ...pump bearing remover 1replacer Water pump seal set remover 1 replacer Water pump rotor puller 09254 87201 000 Water pump bearing receiver i 1 Front hub drive pinion bearing replacer set I I 1 Carburet...

Page 285: ...ified value Allowable limit 7 000 7 015 6 010 6 025 0 2755 0 2762 1 0 2366 0 2372 1 I 1 2 1 6 Intake Exhaust 0 04C 0 070 Intake 0 00157 0 0 275 Valve stem to bush 6 010 6 025 1 0 2366 0 2372 1 I 7 000...

Page 286: ...mit of 0 8 mm Spring tension as installed 1 25 7134 9 I 22 7134 9 40 4127 67 34 427 67 If tension drops below I 75 91109 j kglmm lblinch 56 711374 50 111 374 89lil 09 limit replace Specified value All...

Page 287: ...0 05 0 002 i I I I Out of roundness j I 1 0 7 0 039 i If limit is exceeced taper mrn inch 0 1 0 039 recondition WM 73010 PISTON PISTON PIN PISTON RINGS 0 05 0 002 J I CB 23 CB 61 engines C3 80 en ine...

Page 288: ...ce exceeds Thrust clearance mm inch 1 0 30 0 0118 1 OOM79 0087 0 30 0 0118 I limit replace thrust 3 COO79 0 0087 I washer as require0 Itern Thrust clearance mm inch CB 80 engine IteT I Remarks Specitl...

Page 289: ...aft timing pulley Outer mm inch diameter Crankshaft tim ng pulley outer mm inch diameter 0 10 0 0039 1 0 10 0 0039 mm inch j 0 10 0 0039 I Exhaust side 1 39 55 39 65 1 39 4 1 551 1 557 1 56 1 I 1 I I...

Page 290: ...other stress such as vibratory loads and so forth WM 13019 METHOD TO IDENTIFY STRENGTH DIVISION OF BOLTS 1 Identification Method by Checking Bolts Themselves WM 1 2 ldentification Method by Part Numb...

Page 291: ...78 56 3 7 0 9 0 51 65 1 1 75 i 7 48 54 1 6 0 8 5 43 61 5 Exampleof part number 13 1 5 1 10 17 73 6 i 8 0 12 0 58 88 0 6 0 9 4 3 6 5 1 5 2 2 1 1 16 9 1 m 7 0 0 0 0 lo 25 1 3 37 24 4 3 0 4 5 22 33 10 I...

Page 292: ...4 3 0 0 2 0 4 1 4 3 0 1 5 2 2 11 1 6 1 I Oil cooler x Oil filter bracket 3 0 4 0 22 29 j 3 0 4 0 22 29 1 Camshaft bearing cap x Cylinder head 1 1 15 1 45 8 3 10 5 i Camshaft timing belt pulley x Cams...

Page 293: ...10 5 54 76 Tightening component EGR pipe No 1 x EGR valve Swiss specifications only EGR pipe No 2 x EGR valve Swiss specifications only Englne mounting upper right insulator x Eng ne mountlng front b...

Page 294: ...WWW PlanDeGraissage Org...

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