Haynes Dodge Colt Owners Workshop Manual 0856964190, 9780856964190

Citation preview

DODGE 1977 thru 1978 Downsized models d 97.5 cu in (1.6 liter) 121.7 cu in (2.0 liter) n 155.9 cu in (2.6 liter)

Owners Workshop Manual

Digitized by the Internet Archive in

2009

http://www.archive.org/details/coltownersworkshOOhayn

Colt

Owners Workshop Manual by J H Haynes Member

and

of the Guild of Motoring Writers

A

J Jones

bsc. Eng. c. Eng.

Models covered: UK: Colt Lancer: Saloon and Estate; 1 200, 1 400, 600 cc and 600 GSR USA: Downsized Dodge Colt: Coupe, Sedan Hatchback and Station Wagon; 97-5 cu in (1600cc). 121 -7 cu in (2000 155-9 cu in (2600 cc) 1

1

Including Silent Shaft

Does not cover Dodge

ISBN

©

cc)

and Jet Valve engined models Colt Challenger

85696 419 Haynes Publishing Group 1979

No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder. All rights reserved.

Printed in England

HAYNES PUBLISHING GROUP SPARKFORD YEOVIL SOMERSET ENGLAND distributed in the

USA by

HAYNES PUBLICATIONS 861 LAWRENCE DRIVE NEWBURY PARK CALIFORNIA 91320 USA

INC

Acknowledgements Thanks are due to the Chrysler Corporation of the USA for the supply of technical information and certain illustrations; to Castrol Ltd for the lubrication data and the Champion Sparking Plug Company who supplied the illustrations showing the various spark plug conditions. The bodywork repair photographic sequence, used in this manual was presented by Lloyds Industries Limited who supply Turtle

Wax', Dupli-color

We

Holts',

and other Holts range products.

are also grateful for the assistance and co-operation of Four

Square Garages, Bournemouth. Last, but not least,

who

helped

in

the text and to

thanks are due to

all

those people at Sparkford

the production of this manual, to Robert lies for editing

Lee Saunders who planned the layout of each page.

About this manual Its

aims

/ts

arrangement The manual

numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on from the Section they are in, eg 5.1, 5.2, 5.3 etc. It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms of illustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in the Chapter: eg Fig. 6.4 is the 4th drawing/illustration in Chapter 6. Photographs are numbered (either individually or in related groups) the same as the Section or sub-section of the text where the operation they show is described. There is an alphabetical index at the back of the manual as well as a contents list at the front. References to the left' or right' of the vehicle are in the sense of a person in the driver's seat facing forwards. Whilst every care is taken to ensure that the information In this manual Is correct no liability can be accepted by the authors or publishers for loss, damage or Injury caused by any errors In, or omissions from, the Information given. Sections,

The aim of this Manual is to help you get the best value from your It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the Manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs the garage must charge to cover its labour and overheads. The Manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a step-by-step sequence so that even a novice can do the work. car.

is

divided

into

logical sub-division of the vehicle.

twelve Chapters, each covering a The Chapters are each divided into

Introduction to the Colt Lancer and Dodge Colt Lancer The models are manufactured in Japan by the Mitsubishi Motor Corporation and are sold in North America by the Chrysler Corporation and in the UK by the Colt Car Company. In North America the models are marketed as the Dodge Colt Lancer', or the Dodge Colt, this model being regarded as an extension to the original Dodge Colt range. The Lancer was introduced into the UK as a small engined saloon in 1 974 and since then the range has been extended to include the Hatchback and Estate versions and a wide range of engine capacities.

The range was introduced to North America in 1977 with a minimum engine capacity of 1 600cc and the option of the silent shaft' engine. This engine incorporates two balancing shafts which cancel the inherent vibrations of a four cylinder engine and result in uncanny

smoothness. In

1978

USA. This

is

a further engine modification

was

the addition of a

improve combustion and

reduce exhaust emission.

jet valve, to

introduced into the

Contents Pago

Colt Lancer

1

600 Sport GSR

Colt Lancer Estate

Buying spare parts and vehicle identification numbers Buying spare parts

of obtaining the correct parts

Spare parts are available from many sources. Colt have many dealers throughout the UK and the USA, and other dealers, accessory stores and motor factors will also stock Colt spare parts.

take the

Our advice regarding spare part sources is as follows: Officially appointed vehicle main dealers - This is the best source of parts which are peculiar to your vehicle and are otherwise not generally available (eg complete cylinder heads, internal transmission component badges, interior trim etc). It is also the only place at which you should buy parts if your vehicle is still under warranty. To be sure

it will always be necessary to give the storeman your vehicle's engine and chassis number, and if possible, to

'old' part along for positive identification. Remember that parts are available on a factory exchange scheme - any parts returned should always be clean! It obviously makes good sense to go

many

straight to the specialists

on your vehicle

for this type of part, for they

are best equipped to supply you. Otfier dealers

good places maintenance

to

and auto accessory stores - These are often very buy materials and components needed for the

of your vehicle (eg

oil filters,

spark plugs, bulbs, fan belts,

Vehicle Identification Plate

Car 5

line

-Plymouth 21,41

&45

6-Dodge 21,41 & 45 7-Plymouth 24 8-Dodge 24

Price class

Body type

Engine displacement

L-Low 21-2 door M-Medium Coupe

K-97.5 CID

24-2 door H-High Hatchback P-Premium 41 —4 door

U-121.7CID

Sedan

Model year Transmission code

8-1978

(1600C.C.)

(2000C.C.)

F-155.9CID (2600C.C.)

45 -Station

49

states

—4 speed M/T 4-5 speed M/T 1

7 -Automatic

California

2-4 speed M/T 5-5 speed M/T 8-Automatic

Wagon

Canada

3-4 speed M/T 6-5 speed M/T 9— Automatic Vehicle Identification plate

Trim code

1— Low 2— Medium 3-High

6-Premium

orGT 7-Estate package

Sequence

number 00011

Buying spare parts and vehicle identification numbers

Vehicle identification

Torqueflite transmission

number

number

Gearbox

and greases, touch-up paint, filler paste etc). They also sell general accessories, usually have convenient opening hours, charge low/er prices and can often be found not far from home. - Good factors will stock of all of the more important components which wear out relatively quickly (eg clutch components, pistons, valves, exhaust systems, brake cylinders/pipes/hoses/seals/shoes and pads etc). Motor factors will often provide new or reconditioned components on a part exchange basis - this can save a considerable amount of money.

Body number location The body number compartment

number

Engine number

Body number

oils

Motor

serial

is

stamped on the bulkhead

inside the engine

(photo).

factors

Engine type and number The engine type 4G32 or 4G52 etc is cast on the left-hand side of the cylinder block, towards the bottom. The engine serial number is stamped onto the top face of the cylinder block on the right-hand side at the front (photo).

Gearbox serial number The gearbox serial number

Vehicle identification

numbers

gearbox case

is

stamped on the left-hand side

of the

(illustration C).

vehicle identification numbers contain 13 digits to a code shown in the illustration A. The number is located on a plate attached to the top left side of the instrument panel and visible through the

Automatic transmission serial number The torqueflite serial number is stamped on

windscreen

flange at the left-hand side (illustration D).

All

(illustration B).

to the

sump mounting

Use

of English

As this book has been written in England, it uses the appropriate English component names, phrases, and spelling. Some of these differ from those used in America. Normally, these cause no difficulty, but to make sure, a glossary is printed below. In ordering spare parts remember the parts list will probably use these words:

English

English

Aerial

Antenna

Accelerator Alternator Anti-roll bar Battery

Gas pedal

Layshaft (of gearbox) Leading shoe (of brake)

Generator (AC)

Locks

Energizer

Number

Bodywork

Sheet metal

Paraffin

Kerosene

Hood

Petrol

Gasoline Gas tank

Stabiliser or

Bonnet (engine cover) Boot lid Boot (luggage compartment) Bottom gear Bulkhead

Trunk Trunk

Cam

sway

bar

Catch Choke/venturi

plate

Petrol tank

lid

'Pinging'

'Pinking'

1st gear

Propeller shaft

Driveshaft

Firewall

Quarter light Retread Reverse Rocker cover

Quarter

Valve lifter or tappet Carburetor Latch

follower or tappet Carburettor

Motorway

Countershaft Primary shoe Latches Freeway, turnpike etc License plate

Valve cover Car-top carrier

Roof rack Saloon

Barrel

window

Recap Back-up

Sedan

Crownwheel

Snap-ring Lash Ring gear (of

Disc (brake)

Rotor/disk

Seized Side indicator lights Side light

Drop arm Drop head coupe

Pitman arm

Silencer

Frozen Side marker lights Parking light Muffler

Convertible

Spanner

Wrench

Dynamo

Generator (DC)

Sill

Earth (electrical) Engineer's blue

Ground

Estate car

Station

Exhaust manifold Fast back (Coupe)

Header Hard top

Tab washer

Fault finding/diagnosis

Trouble shooting

Tailgate

Circlip

Clearance

Float

Rocker panel panel (beneath doors) Split cotter (for valve spring cap) Lock (for valve spring retainer) Split pin Cotter pin Spindle arm Steering arm

Prussian blue

chamber

Float

wagon

Sump

bowl

Lash Coast

Free-play

Freewheel

Gudgeon

differential]

Piston pin or wrist pin

pin

Gearchange Gearbox

Hood Hot spot Interior light

Throw-out bearing

Van

lifter

High Tie-rod (or connecting rod)

Secondary shoe

Whole

drive line

Tire

Panel wagon/van Vise Lug nut

Vice

Wheel nut

Heat riser Turn signal Dome lamp

Indicator

Valve

Thrust bearing Top gear Trackrod (of steering)

shoe (of brake) Transmission Tyre

Axleshaft Parking brake Soft top

Handbrake

Liftgate

Tappet

Trailing

Shift

Transmission

Halfshaft

Oil pan Tang; lock

Windscreen

Windshield Fender

Wing/mudguard

Miscellaneous points An

seal'

is

'damper' haphazardly.

is

A

'oil

fitted to

components

a 'shock absorber',

lubricated by grease

it

damps

I

out bouncing, and absorbs shocks of

bump

impact. Both

names

are correct, and bqth are used

Note that British drum brakes are different from the Bendix type that is common in America, so different descriptive names result. The shoe end furthest from the hydraulic wheel cylinder is on a pivot; interconnection between the shoes as on Bendix brakes is most uncommon. Therefore the phrase 'Primary' or 'Secondary' shoe does not apply. A shoe is said to be 'Leading' or 'Trailing'. A Leading' shoe is one on which a point on the drum, as it rotates forward, reaches the shoe at the end worked by the hydraulic cylinder before the anchor end. The opposite is a Trailing' shoe, and this one has no self servo from the wrapping effect of the rotating drum.

Tools and working

facilities Tyre pressure gauge

Introduction

A selection of good tools is a fundamental requirement for anyone contemplating the maintenance and repair of a motor vehicle. For the owner who does not possess any, their purchase will prove a considerable expense, offsetting some of the savings made by doing-ityourself. However, provided that the tools purchased are of good quality, they will last for many years and prove an extremely worthwhile investment. To help the average owner to decide which tools are needed to carry out the various tasks detailed in this manual, we have compiled three lists of tools under the following headings: Maintenance and minor repair. Repair and overhaul, and Special. The newcomer to practical mechanics should start off with the Maintenance and minor repair tool kit and confine himself to the simpler jobs around the vehicle. Then, as his confidence and experience grows, he can undertake more difficult tasks, buying extra tools as, and when, they are needed. In this way, a Maintenance and minor repair Xoo\ kit can be built-up into a Repair and overhaul tool kit over a considerable period of time without any major cash outlays. The experienced do-ityourselfer will have a tool kit good enough for most repair and overhaul procedures and will add tools from the Special category when he feels the expense is justified by the amount of use to which these tools will be put. It is obviously not possible to cover the subject of tools fully here. For those who wish to learn more about tools and their use there is a book entitled How to Choose and Use Car Tools available from the publishers of this manual.

Maintenance and minor repair tooi f(it The

list should be considered as a minimum routine maintenance, servicing and minor repair opera-

tools given in this

requirement

if

We recommend the purchase of combinaspanners (ring one end, open-ended the other); although more expensive than open-ended ones, they do give the advantages of both types of spanner.

Grease gun (where applicable) can

Oil

Fine emery cloth (1 sheet) Wire brush (small)

Funnel (medium

size)

Repair and overhaul tool

kit

These tools are virtually essential for anyone undertaking any major repairs to a motor vehicle, and are additional to those given in the Maintenance and minor repair list. Included in this list is a comprehensive set of sockets. Although these are expensive they will be found invaluable as they are so versatile - particularly if various drives are included in the set. recommend the ^ in square-drive type, as this

We

can be used with most proprietary torque wrenches. If you cannot afford a socket set, even bought piecemeal, then inexpensive tubular box spanners are a useful alternative. The tools in this list will occasionally need to be supplemented by tools from the Special list.

Sockets (or box spanners) to cover range in previous Reversible ratchet drive (for use with sockets) Extension piece, 10 inch (for use with sockets) Universal joint (for use with sockets) Torque wrench (for use with sockets) 'Mole' wrench - 8 inch Ball pein hammer Soft-faced hammer, plastic or rubber Screwdriver - 6 in long x ^ in dia (flat blade) Screwdriver - 2 in long x ^ in square (flat blade) Screwdriver - l\in long x ^ in dia (cross blade! Screwdriver - 3 in long x \ in dia (electricians)

tions are to be undertaken.

Pliers

-

electricians side cutters

tion

Pliers

-

needle nosed

Pliers

-

circlip (internal

mm

Combination spanners -6,7,8,9, W, 1 1, & 12 Adjustable spanner - 9 inch Engine sumplgearbox/rear axle drain plug key (where applicable) Spark plug spanner (with rubber insert) Spark plug gap adjustment tool Set of feeler gauges Brake adjuster spanner (where applicable) Brake bleed nipple spanner Screwdriver - 4 in long x \ in dia (flat blade) Screwdriver - 4 in long x 4 in dia (cross blade) Combination pliers Hacksaw, junior Tyre

pump

-

6 inch

Cold chisel - \ inch Scriber (this can be

list

and external)

made by grinding

the

end of a broken hacksaw

blade)

Scraper (this can be made by flattening and sharpening one end of a piece of copper pipe) Centre punch Pin

punch

Hacksaw Valve grinding tool Steel rule/straight edge Allen keys Selection of files Wire brush (large) Axle-stands Jack (strong scissor or hydraulic type)

Tools and working Special tools The tools in this list are those which are not used regularly, are expensive to buy, or which need to be used in accordance with their manufacturers' instructions. Unless relatively difficult mechanical jobs are undertaken frequently, it will not be economic to buy many of these tools. Where this Is the case, you could consider clubbing together with friends (or a motorists' club) to make a joint purchase, or borrowing the tools against a deposit from a local garage or tool hire

facilities

(8 mm). This, together with a good range of twist drills, is virtually essential for fitting accessories such as wing mirrors and reversing lights.

Last, but not least,

contains only those tools and instruments freely available to the public, and not those special tools produced by the vehicle manufacturer specifically for its dealer network. You will find occasional references to these manufacturers' special tools in the text list

method of doing the job without the vehicle manufacturer's special tool is given. However, sometimes, there Is no alternative to using them. Where this is the case and the relevant tool cannot be bought or borrowed you will have to entrust the work to a franchlsed garage. of this manual. Generally, an alternative

Valve spring compressor Piston ring compressor Balljoint separator Universal hub/bearing puller Impact screwdriver

Micrometer and/or vernier gauge Carburettor flow balancing device (where applicable) Dial gauge Stroboscopic timing light

Dwell angle meter/tachometer Universal electrical multi-meter Cylinder compression gauge Lifting tackle

Trolleyjack

Light with extension lead

Buying tools For practically all tools, a tool factor is the best source since he will have a very comprehensive range compared with the average garage Having said that, accessory shops often offer excellent quality tools at discount prices, so it pays to shop around. Remember, you don't have to buy the most expensive items on the shelf, but It is always advisable to steer clear of the very cheap tools. There are plenty of good tools around at reasonable prices, so ask the proprietor or manager of the shop for advice before making a or accessory shop.

purchase.

Care and maintenance of tools Having purchased

a

reasonable tool

kit.

It

is

necessary to keep the wipe off any

tools In a clean serviceable condition. After use, always

grease and metal particles using a clean, dry cloth, before putting the tools away. Never leave them lying around after they have been used. A simple tool rack on the garage or workshop wall, for items such as screwdrivers and pliers is a good idea. Store all normal spanners and sockets in a metal box. Any measuring instruments, gauges, meters, etc, must be carefully stored where they cannot be damaged dirt,

or

become

rusty.

Take a little care when tools are used. Hammer heads inevitably become marked and screwdrivers lose the keen edge on their blades

fom time

to time.

A

soon restore items

little

emery cloth good serviceable finish.

timely attention with

like this to a

or a

file will

Working

facilities Not to be forgotten when discussing tools, is the workshop Itself. If anything more than routine maintenance is to be carried out, some form of suitable working area becomes essential. It is appreciated that many an owner mechanic Is forced by circumstances to remove an engine or similar item, without the benefit of a garage or workshop. Having done this, any repairs should always be done under the cover of a roof. Wherever possible, any dismantling should be done on a clean flat

workbench or table at a suitable working height. Any workbench needs a vice: one with a jaw opening of 4 in (100 mm) is suitable for most jobs. As mentioned previously, some clean dry storage space is also required for tools, as well as the lubricants, cleaning fluids, touch-up paints and so on which become necessary. Another item which may be required, and which has a much more general usage, is an electric drill with a chuck capacity of at least ^ in

always keep and

clean, lint-free rags available,

a

supply of old newspapers and keep any working area as

try to

clean as possible.

Spanner jaw gap comparison table

specialist.

The following

9

Jaw gap

(In)

Jacking and towing Safety is paramount before venturing under a car to carry out any maintenance or overhaul work. Placing the jack in the wrong place or using the jack on the wrong surface (too soft) or even using a worn out jack, contribute to many unnecessary accidents a year. sort of

The jack supplied with the car is adequate for changing a wheel and that is about ail. Never get under the car using just this means to support it. It is worth the effort to install stands for every task no matter how small, that demands attention underneath the car and the illustrations A and B show the points at which a trolley jack should be situated to raise the car one corner at a time and then install a stand, at the positions shown in illustrations C, D or E. However, be very careful when using this method and do it gradually, so that the car is raised evenly. Jack up one corner and install the stand with the pin in the first hole (from the top). Let the car down onto the stand and remove the jack. Move to the opposite side of the car and repeat the

operation. Then, returning to the side

first

raised jack up the car until

the pin of the stand can be inserted into the second hole. Repeat this until the car is at the height required. This method may little tedious and take some time but if the car was raised one corner as high as required and the stand then installed, the angle of the car to the stand may be enough to topple it once the opposite side commences to be jacked. So slowly and carefully are the key words to this operation, and do not forget to chock the wheels still left on the ground.

operation

sound a

Towing When

towing another vehicle or when being towed always use the attachment points depicted in illustrations F and G. Attaching a tow rope to other parts of the vehicle may cause damage to that component or even an accident if it were to break off.

)

11

Jacking point (Rear)

Jacking point (Front)

Stand position (Rear

1

Attachment point when being towed

Stand position (Front)

Stand position (Rear

2)

Attachment point when towing

12

Recommended Component

Engine

(

1

Castrol Product

)

Transmission

(3)

Brake system

Castrol

GTX

Castrol Castrol

TQ

Castrol

Hypoy B

(2)

Manual Automatic Rear axle

lubricants

Hypoy B Dexron R

Castrol Girling Universal Brake and Clutch Fluid

(4)

Castrol

LM Grease

Steering gear

Castrol

Hypoy B

Handbrake cable

Castrol

LM

Castrol

GTX

Wheel bearings

(5)

Door and bonnet

locks, hinges

Clutch cable and linkages

Engine

Grease

oil

Note: The above are general recommendations only. Lubrication requirements vary between different operating requirements. doubt, consult the vehicle handbook or nearest Dealer.

If in

Routine maintenance Maintenance

is

essential for ensuring safety and reliability as well

maximum performance and economy. Over

the years the need for periodical lubrication has been reduced considerably, but

as for obtaining

which are not lubricated though the intervals may be infrequent.

for those items

for

life

it

is still

essential,

even

Lubricate transmission linkage

Every 250 miles (400 km) or weekly

Check Check Check Check Check Check Check

Lubricate clutch cable

and inflate if necessary (photo) engine oil level and top-up if necessary (photos) battery electrolyte level and top-up if necessary (photo) windscreen washer fluid level and top-up if necessary coolant level and top-up if necessary (photo) brake fluid level and top-up if necessary (photo) operation of all lights, instruments and controls tyre pressure

Check exhaust system for leaks Check brake master cylinder operation Change tyres round Check rear brakes Check clutch pedal movement

Every

1

5

000 miles (24 000 km)

or annually

Lubricate distributor

Every 5000 miles (8000 km)

Change engine oil (photo) Check gearbox oil or automatic transmission Check rear axle oil Check steering gear oil Check brake fluid and hinges Check brake and coolant hoses Inspect brake disc pads Check fan belt tension (photo) Oil locks

Every 10

Renew

000

miles (16

oil filter

Lubricate handbrake

000 km)

fluid (photo)

Grease front wheel bearing Check thermal reaction bolts (if fitted) Check exhaust manifold bolts Check and adjust carburettor linkage

Renew Renew

fuel filter air

cleaner

Check heated

Renew Renew

air

intake operation

distributor points

(if

fitted)

and condenser

spark plugs Check ignition wiring

Check

distributor

cap and rotor

Clean crankcase ventilation jjorts Check evaporation control system (if fitted) Check secondary air system (if fitted) Check exhaust gas recirculation system (if fitted) Check antifreeze and renew if necessary Check all rubber and plastic components in the engine compartment

Check

tyre pressures (weekly)

Top up

if

Check

necessary (weekly)

Check brake

fluid

level (weekly)

Check coolant

Check battery (weekly)

(weekly)

Check fan

oil

Drain engine

belt tension

(6000 miles)

oil

(5000 miles)

Renew

Check gearbox

oil filter

(10

000

miles)

level (weekly)

oil level

(5000 miles)

Chapter

1

Engine

Big-end and main bearing shells - examination Camshaft and rocker arms - removal and dismantling Camshaft bearings - inspection Crankcase ventilation system - description Crankcase ventilation system - inspection Crankshaft - examination and renovation Crankshaft - removal Crankshaft pulley, clutch and flywheel - removal Cylinder block - assembly (engines without balance

15 5 17

33 34 14 9 6

24

shafts)

Cylinder block

- assembly (4G3 engine with balance

25

shafts)

Cylinder block - assembly

(4G5 engine with balance

shafts)

26

Cylinder block - dismantling Cylinder bores - examination and renovation Cylinder head - dismantling Cylinder head - refitting

8 16

Cylinder head - reassembly Cylinder head - removal (engine out of

car)

7

28 27 4

Decarbonising Engine assembly - completion Engine components, cleaning, examination - general note Engine components - examination Engine mountings - removal and refitting Engine reassembly - general note Engine - refitting Fault diagnosis - engine General description Oil pump - dismantling and reassembly Pistons - dismantling Piston rings - refitting

Removal

and gearbox Separating the engine from the gearbox Timing chain, sprockets and chain tensioner - examination and renovation Valves - adjustment Valves - examination and renovation Valves - removal

Specifications

4G3

Series

4G32

Type Number and arrangement

of cylinders

Valve and camshaft arrangement Total displacement

Bore

X

stroke

in

mm Compression

ratio

Valve timing Inlet opens BTDC Inlet

closes

ABDC BBDC

Exhaust opens Exhaust closes

Firing order

ATDC

...

of engine

21

29 13

20 32 23 31

35 1

11

10 22 2 3 19

30 18 12

Chapter

16

1

Engine

Valve clearances (hot)

0006 0010

Inlet

Exhaust

Ignition timing at idling

700±50

Crankcase ventilation system Lubrication

mm) mm)

BTDC

speed

speed rpm

Idling

(0-15 (0-25

in

in

13°±1°

5°±1°

5°+1°

800+50

700±50

700+50

Closed type

method

Forced feed

pump

type type Oil capacity

Gear type

Oil filter

Full flow, cartridge

Cooling method

Water

Oil

3-5

Trochoid type

4-2 USqt, 4

qt,

litres

Pistons and piston rings Piston

OD

in

(76-9 mm) (19 mm) (0-25 mm) (0-50 mm) (0-75 mm)

in

(100 mm)

0276

Piston pin hole ID

748

Piston oversizes

010 020 030 040

2-874

in

in in in

in

(73

mm)

Piston ring to ring groove clearance:

No No

to 00028 in (0 03 to 007 mm) 0008 to 00024 in (002 to 006 mm) 0010 to 00030 in (0025 to 0075 mm) 006 in (0-15 mm) 006 to 0014 in (0- 5 to 0-35 mm) 040 in (10 mm) 7481 toO-7483 in (19001 to 19007 mm)

001 2

1

2

Oil ring

Maximum

clearance

(all

rings)

- standard - maximum

Piston ring end clearance

.

.

.

.

.

.

.

Piston pin OD Piston pin to piston clearance

1

0004to00005in

Connecting rod bend

Lessthan00012

Large end play - standard

0004 to 001 in (0002 in (0-5 mm)

- maximum

Crankshaft bearing

oil

OD

Crankshaft bend Journal ovality Pin ovality

0-002 .,

0-01

.\.

Undersize dimension of journals 001 in (0-25 mm) undersize 002 in (0-50 mm) undersize

4G33 and 4G36

003

in

to

1

mm)

0-25

(0-25

(005

in

to 0-

00354in(-0-9mm)

75 mm)

1

mm) (56-735 (56-485

to

in

to

56-75 mm) 56-50 mm)

2 140 to 2 -2 146

in

(56-235

to

56-25 mm)

7612

1-76 18

in

to 44-

751 4 to 1-7520

in

(44-735 (44-485

to

75 mm) 44-50 mm)

1-741 5 to 1-7421

in

(44-235

to

44-25 mm)

to to

2-2342 2-2244

in

to

only:

(0-75

mm)

undersize

0005

Less than

0-008

Camshaft bend cam

0007

to

in

2-2337 2-2238

Flywheel run out - standard -maximum Height of

(003 mm)

in

only:

003 in (0-75 mm) undersize Undersize dimensions of crankpin: 001 in (0-25 mm) undersize 002 in (0-50 mm) undersize 4G33 and 4G36

to00013 mm)

0020in(0-50mm) 0030 in (0-75 mm) 2-2441 in (57 mm) -00256 in (-0-65 mm) Less then 0001 2 in (003 mm) Less than 00004 in (001 mm) Less than 0-0004 in (001 mm)

- standard - minimum

End play - standard - maximum

001

00006 to 00031 in (001 6 to 0078 mm 0006 to 0028 in (0 016 to 007 mm) 0010 in (0-25 mm)

clearance

Crankshaft bearing undersizes

Crankshaft journal

(0

in

(0-2

0-0008

Less than

lobe (intake) - standard

.

- wear limit (exhaust) - standard

-wear Camshaft end play - standard - maximum

limit

.

.

.

.

.

.

.

1

3

mm)

in

(0

02 mm)

(36-363 mm) (-0-05 mm) 1-4336 in (36-412 mm) -002 in (-0-05 mm) 0002 to 0-006 in (0-05 to 0-

1-4316

in

-002

in

0012

in

0-315

in (8

(0-3

mm)

Valves Valve stem OD: Intake - standard

in (0-

mm)

mm)

1

5

mm)

Chapter -wear

0-315

limit

Valve head thickness - standard

- minimum

.

.

.

,

Valve to guide clearance: lntal